manualshive.com logo in svg

Mazda MX-6 1998, Workshop Manual

Get your hands on the Mazda MX-6 1998 Workshop Manual for free download. This comprehensive manual provides detailed instructions for maintaining and repairing your vehicle. Access it easily from manualshive.com to ensure you have the information you need to keep your Mazda running smoothly.

Share
Download
background image

ALPHABETICAL  INDEX

BACK-UP  LIGHT SWITCH

REMOVAL/INSTALLATION..........................0 9 -1 8 -5

BASE  INSTALLATION  ................................. 0 9 -1 2 -2 0
BASE  REMOVAL  ......................................... 0 9 -1 2 -2 0
BASIC  SYSTEM  STRUCTURAL VIEW  . . .   07-11-2
BATTERY INSPECTION  ............................... 01-17-1
BATTERY  R E C H A R G IN G ............................. 0 1 -1 7 -2
BATTERY  REMOVAL/INSTALLATION  . . . .   01-17-1
BEFORE  REPAIR  PROCEDURE  ................01-14-1
BLOWER  MOTOR  INSPECTION  ..............  0 7 -4 0 -7
BLOWER  MOTOR

REMOVAL/INSTALLATION.......................   0 7 -4 0 -7

BLOWER  RELAY

REMOVAL/INSTALLATION.....................   07-40-11

BLOWER  UNIT

DISASSEMBLY/ASSEMBLY......................  0 7 -1 1 -3

BLOWER  UNIT  REMOVAL/INSTALLATION  0 7 -1 1 -3  
BOOT  PANEL  DISASSEMBLY/ASSEMBLY  0 9 -1 7 -4
BOOT  PANEL REMOVAL/INSTALLATION  .  0 9 -1 7 -4
BRAKE  F L U ID ........................................... ..  04-11-2

BRAKE  PEDAL  INSPECTION  ................ ..  04-1 1 -4
BRAKE  PEDAL  REMOVAL/INSTALLATION  04 -1 1 -5
BRAKE  PIPE  INSPECTION  ................... ..  04-11-2
BRAKE  PIPE  REMOVAL/INSTALLATION .  04-11-3
BRAKE  SWITCH  IN S P E C T IO N .............. ..  04-11-6
BUCKLE  SWITCH  IN S P E C TIO N ............

08 -1 1 -3

c

C-PILLAR  TFÏÏM

REMOVAL/INSTALLATION................... .  0 9 -17-12

CAMSHAFT POSITION  SENSOR

INSPECTION  [FS]  ................................. 01-40A -16

CAMSHAFT POSITION  SENSOR

INSPECTION [KL]  ................................. 01-40B -17

CAMSHAFT POSITION  SENSOR

REMOVAL/INSTALLATION  [KL]  .......... 01-40B -17

CANISTER  DRAIN  CUT VALVE  (CDCV)

IN SPEC TIO N ........................................... ..  0 1 -1 6 -5

CATCH TANK  IN S P E C TIO N ................... ..  0 1 -1 6 -6
CENTER  LOWER  PANEL

REMOVAL/INSTALLATION................... ..  0 9 -1 7 -4

CENTER  PANEL

REMOVAL/INSTALLATION................... ..  0 9 -1 7 -5

CHARCOAL CANISTER  INSPECTION  . ..  0 1 -1 6 -5
CIGARETTE LIGHTER  INSPECTION  .. ..  0 9 -2 0 -9
CIGARETTE  LIGHTER

REMOVAL/INSTALLATION................... .  .  0 9 -2 0 -9

CLOCK SPRING A D JU S T M E N T ............ .  .  0 8 -1 0 -3
CLOCK SPRING  INSPECTION  .............. ..  0 8 -1 0 -4
CLOCK  SPRING

REMOVAL/INSTALLATION................... ..  0 8 -1 0 -5

CLUTCH  COVER  INSPECTION  ............ ..  0 5 -1 0 -9
CLUTCH  DISC  IN S P E C TIO N ................. .  0 5 -1 0 -1 0
CLUTCH  FLUID  IN S P E C TIO N ................ ..  05-10-1
CLUTCH  FLUID  R E P LA C E M E N T .......... ..  05-10-1
C LU TC ^M A S TE R   CYLINDER

DISASSEMBLY/ASSEMBLY................. ..  0 5 -1 0 -5

CLUTCH  MASTER  CYLINDER

REMOVAL/INSTALLATION................... ..  0 5 -1 0 -4

CLUTCH  PEDAL A D JU S TM E N T............ ..  0 5 -1 0 -2
CLUTCH  PEDAL

REMOVAL/INSTALLATION................... ..  0 5 -1 0 -3

CLUTCH  RELEASE  COLLAR

INSPECTIO N........................................... .  0 5 -1 0 -1 0

CLUTCH  RELEASE CYLINDER

DISASSEMBLY/ASSEMBLY........................0 5 -1 0 -6

CLUTCH  RELEASE CYLINDER

REMOVAL/INSTALLATION..........................0 5 -1 0 -6

CLUTCH  SWITCH  INSPECTION  [FS]  ..  0 1 -4 0 A -2 8  
CLUTCH  SWITCH  INSPECTION  [KL]  ..  0 1 -4 0 B -3 0  
CLUTCH  SWITCH

REMOVAL/INSTALLATION  [FS]  ........... 0 1 -4 0 A -2 9

CLUTCH  SWITCH

REMOVAL/INSTALLATION  [KL]  ........... 01-40B -31

CLUTCH  UNIT  REMOVAL/INSTALLATION  0 5 -1 0 -7  
CODE  WORD  INPUT PROCEDURE  . . . .   0 9 -1 4 -2 3
COIL  REMOVAL/INSTALLATION................0 9 -1 4 -1 7
COLUMN  COVER

REMOVAL/INSTALLATION..........................0 9 -1 7 -5

COMBINATION  SWITCH

DISASSEMBLY/ASSEMBLY........................0 9 -1 8 -6

COMBINATION  SWITCH

REMOVAL/INSTALLATION..........................0 9 -1 8 -5

COMPRESSION  INSPECTION  [ F S ]  

0 1 -1 0 A -4

COMPRESSION  INSPECTION  [ K L ]  

01-1 OB-5

CONDENSER  FAN  IN S P E C T IO N ..............  0 7 -4 0 -8
CONDENSER  FAN  RELAY

REMOVAL/INSTALLATION......................  07-40-11

CONDENSER  FAN

REMOVAL/INSTALLATION........................  0 7 -4 0 -8

CONDENSER  INSPECTION  ...................... 0 7 -1 1 -1 0
CONDENSER  REMOVAL/INSTALLATION 

0 7 -1 1 -9  

CONTROL SYSTEM  COMPONENT

LOCATION  [FS]  ......................................... 0 1 -4 0 A -2

CONTROL SYSTEM  COMPONENT 

LOCATION  [K L ]...........................................0 1 -4 0 B -2

CONTROL SYSTEM  STRUCTURAL VIEW  0 7 -4 0 -2  
CONTROL VALVE  BODY AND TERMOSTATIC 

OIL LEVEL CONTROL VALVE 

REMOVAL/INSTALLATION  [LA4A-EL]  0 5 -1 7 A -2 7  

CONTROL VALVE  BODY 

REMOVAL/INSTALLATION  [GF4A-EL]  .  0 5 -1 7 B -2 6

COOLING  FAN  MOTOR  INSPECTION  . . .   0 1 -1 2 -7  
COOLING  FAN  MOTOR

REMOVAL/INSTALLATION..........................0 1 -1 2 -7

COOLING  FAN  RELAY  INSPECTION  . . . .   0 1 -1 2 -8  
COOLING  SYSTEM  SERVICE  WARNINGS  01-12-1 
COOLING  UNIT

DISASSEMBLY/ASSEMBLY......................  0 7 -1 1 -5

COOLING  UNIT

REMOVAL/INSTALLATION........................  0 7 -1 1 -4

COWL GRILLE  REMOVAL/INSTALLATION  0 9 -1 6 -2

C P U   IN S P E C T IO N .............................................  0 9 - 4 0 - 1

CPU  REMOVAL/INSTALLATION................  09-40-1
CRANKSHAFT POSITION  SENSOR

INSPECTION  [FS]  ...................................0 1 -4 0 A -1 7

CRANKSHAFT POSITION  SENSOR

INSPECTION  [KL]  ...................................0 1 -4 0 B -1 9

CRANKSHAFT  POSITION  SENSOR

REPLACEMENT [F S ]...............................0 1 -4 0 A -1 7

CRANKSHAFT POSITION  SENSOR

REPLACEMENT [K L ]...............................0 1 -4 0 B -1 9

CRUISE ACTUATOR  INSPECTION  ............ 0 1 -2 0 -2
CRUISE ACTUATOR

REMOVAL/INSTALLATION..........................0 1-20-1

CRUISE  CONTROL  SWITCH

INSPECTION................................................. 0 1 -2 0 -4

CRUISE CONTROL SWITCH 

REMOVAL/INSTALLATION..........................0 1 -2 0 -4

A I-0 2

Summary of Contents for MX-6 1998

Page 1: ......

Page 2: ...hlights 3311 10 971 Engine W orkshop Manual FS 1582 10 971 Engine W orkshop Manual K L 1583 10 971 Manual Transaxle W orkshop Manual G 2 5 M R 1584 10 971 Autom atic Transaxle W orkshop Manual G F 4 A...

Page 3: ...11 Reassembly 00 00 12 Adjustments 00 00 12 Rubber Parts and Tubing 00 00 12 Hose C lam ps 00 00 12 Torque Formulas 00 00 12 V is e 00 00 13 Dynamometer 00 00 13 INSTALLATION OF RADIO SYSTEM 00 00 13...

Page 4: ...i e removal installation of parts jacking vehicle lifting cleaning of parts and visual inspection have been omitted Service Procedure Inspection adjustment Inspection and adjustment procedures are div...

Page 5: ...MOVAL Refer to UNDERCOVER INSTALLATION 3 Remove in the order indicated in the table 4 Install in the reverse order of removal Indicates reievant references that need to be followed during installation...

Page 6: ...tions 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...

Page 7: ...ICATOR LIGHT DOES NOT ILLUMINATE WHEN HOLD SWITCH IS TURNED ON or No 27 HOLD INDICATOR LIGHT ILLUMINATES WHEN HOLD SWITCH IS NOT TURNED ON Go to next step Repair or replace any defeciive parts Go to n...

Page 8: ...N 0 shiti o o 11 Engine stalls when vehicle about 10 run o Z Engine stalls on acceleration and while c ru isin g 1 3 0 o o o o 13 Poor acceieraiion insulliaent power surges while cruismg Hesitaies 0...

Page 9: ...4 0 P O W E R T R A IN C O N T R O L M O D U L E P C M IN S P E C T IO N Is term inal vo ltage O K Yes G o to step 3 No C arry out the stall test c r 0 5 1 7 M E C H A N IC A L S Y S T E M T E S T Sta...

Page 10: ...ounded up to 270 and 39 SAE STANDARDS W6UOOOWO3 In accordance with new regulations SAE Society of Automotive Engineers standard names and abbreviations are now used in this manual The table below list...

Page 11: ...PCM Powertrain Control Module Device that controls engine and powertrain ECM Engine Control Module Engine Modification EM Engine Modification Engine RPM Signal Engine Speed Input Signal Evaporative E...

Page 12: ...h Test Mode DTM Diagnostic Test Mode Diagnostic trouble codes depend on the diagnostic test mode Throttle Body TB Throttle Body Throttle Sensor TP Throttle Position Sensor Turbocharger TC Turbocharger...

Page 13: ...is complex requiring many parts to be disassembled all parts should be disassembled in a way that will not affect their performance or external appearance and identified so reassembly can be performe...

Page 14: ...should be applied to the moving components of parts Specified oil or grease should be applied at the prescribed locations such as oil seals before reassembly W 6 U 0 0 0 W A U Torque Formulas When usi...

Page 15: ...systems may be affected When the vehicle is to be equipped with a radio observe the following precautions 1 Install the antenna at the farthest point from control modules W 6 U 0 0 0 W 0 5 2 Install...

Page 16: ...insert the tester probe from the wiring harness side W6U000WB2 Check the terminals of waterproof connectors from the connector side since they cannot be accessed from the wiring harness side Caution...

Page 17: ...BLACK RED Fuse Replacement When replacing a fuse be sure to replace it with one of the same capacity If a fuse fails again the circuit probably has a short and the wiring should be checked Be sure the...

Page 18: ...his will damage the ohmmeter VOLTMETER POWER SOURCE LINE Ohmmeter The ohmmeter is used to measure the resistance between two points in a circuit and to check for continuity and short circuits JACKING...

Page 19: ...ls W 6 U 0 0 0 W 0 9 Caution Do not tow the vehicle backward with driving wheels on the ground This may cause internal damage to the transaxle WHEEL DOLLIES W6U000WBL Proper lifting and towing are nec...

Page 20: ...ok loops under the front and rear bumpers for towing They are designed ONLY for tying down the vehicle when it s being transported Using them for towing will damage the bumper Tiedown Hooks Front Rear...

Page 21: ...Ground CCS Pressure of 3 2 timing coasting clutch CDCV Canister drain cut valve CD1 Ignition 1 4 CD2 Ignition 2 5 CD3 Ignition 3 6 CID Cylinder identification CID Cylinder identification C ID Cylinde...

Page 22: ...nser fan circuit failed HGND Ground for California HI High HLUP TCC control HSS1 Shift solenoid A HSS2 Shift solenoid B HSS3 Shift solenoid C HSS5 3 2 timing solenoid valve HTR11 Heated oxygen sensor...

Page 23: ...r bag sensor SHIFT A Shift solenoid A SHIFT B Shift solenoid B SHIFT C Shift solenoid C SHORTFT1 Short fuel trim FS Short fuel trim RH KL SHORTFT2 Short fuel trim LH SIG Signal SIGRTN Ground SPRKADV S...

Page 24: ...m Ignition switch and steering lock Air bag system by using warning light Cruise set if equipped Shift lock system ATX only Starter interlock All lights including warning and indicator lights Sound wa...

Page 25: ...ing belt 1 0 Inspect for 60 000 miles 96 000 km 90 000 miles 144 000 km Replace every 105 000 miles 168 000 km Engine oil R R R R R R R R Oil filter R R R R R R R R Hoses and tubes for emission 1 I AI...

Page 26: ...Maintenance Item Maintenance Interval Number of months or miles kilometers whichever comes first Months 4 8 12 16 20 24 28 32 36 40 44 48 x 1000 Miles 5 10 15 20 25 30 35 40 45 50 55 60 Kilometers 8 1...

Page 27: ...ices be performed at the recommended time or mileage period to ensure long term reliability O For vehicle sold in California and Massachusetts For vehicle sold outside California and Massachusetts Sch...

Page 28: ...ar I I All chassis and body nuts and bolts I I I I Exhaust system heat shields I I All locks and hinges L L L L L L L L L L L L Washer fluid level I I I I I I I I I I I I Function of all lights I I I...

Page 29: ...1 01A 4 Key ON Engine OFF Self Test Procedure 01 01 A 4 Key ON Engine Running Self Test Procedure 01 01A 5 After Repair Procedure 01 01A 5 PID DATA Monitor and Record Procedure 01 01 A 5 Playback of S...

Page 30: ...pped A check of the inputs and outputs is made during operating conditions and at normal temperature The brake on off transaxle control and power steering pressure switch tests are part of the KOER se...

Page 31: ...t 1 Perform the necessary vehicle preparation and visual inspection Hook up the SST NGS tester to the vehicle V F H IC L E AND ENGINE S E l F C T IQ N I DIAGNOSTIC DATA LINK VIEW RECORDER AREAS DIGITA...

Page 32: ...RIGGER TO START W6U101WC6 9 Move the cursor to DIAGNOSTIC TEST MODE Press the trigger key to enter this selection D I A G N O S T I C T E S T M O D E S PID DATA MONITOR AND RECORD ACTIVE COMMAND MODES...

Page 33: ...FUNCTIONS and clear DTCs W6U101WCC 3 Perform Self Test to ensure customer s concern has been resolved PID DATA Monitor and Record Procedure 1 Perform the New generation star NGS tester hook up procedu...

Page 34: ...de from ALL ON to LOW FAN HIGH FAN and ALL OFF Return the mode to ALL ON 7 Press START Key 4 to run the fuel pump Press STOP Key 4 to turn off the fuel pump 8 To open and close certain actuators in th...

Page 35: ...y the VEHICLE i l SPEED speedometer and the tachometer Check the vehicle speed and engine speed during driving mode by using the NGS tester If the OBD II system check is not completed while the drive...

Page 36: ...O2 sensor heater P0171 Adaptive fuel control system System too lean ON 2 Fuel P0172 Adaptive fuel control system System too rich ON 2 Fuel P0230 Fuel pump Circuit malfunction OFF P0300 Ignition Random...

Page 37: ...s Incorrect 2GR ratio p 05 01A AUTOMATIC TRANSAXLE ON BOARD DIAGNOSIS LA4A EL P0733 SS1 SS2 or internal parts Incorrect 3GR ratio t r 05 01A AUTOMATIC TRANSAXLE ON BOARD DIAGNOSIS LA4A EL P0734 SS1 SS...

Page 38: ...CCM P1460 Wide open throttle air conditioning cutoff Circuit malfunction OFF P1464 Air conditioner A C Out of self test range OFF P1474 Fan control system Cooling fan control primary circuit malfunct...

Page 39: ...RANSAXLE ON BOARD DIAGNOSIS LA4A EL P1747 EPC solenoid EPC solenoid circuit failure shorted to ground or open TT 05 01A AUTOMATIC TRANSAXLE ON BOARD DIAGNOSIS LA4A EL P1751 SS1 SS1 circuit failure tr...

Page 40: ...or vehicle harness connector and battery negative post Is voltage greater than 10 5 volts Yes Power harness circuit from MAF sensor to battery negative post is okay Go to next step No Service open pow...

Page 41: ...NUITY Key off MAF sensor disconnected Breakout box installed PCM disconnected Measure resistance between PCM ground circuit at MAF sensor vehicle harness connector and Test Pin 36 at breakout box Is r...

Page 42: ...ime Check possible intermittent G oto ENGINE SYMPTOM TROUBLESHOOTING No 27 No MAF signal circuit or PCM ground circuit is open or shorted together in PCM REPLACE PCM REMOVE breakout box RECONNECT PCM...

Page 43: ...circuit but not in MAF sensor REMOVE Jumper Go to next step 2 RERUN SELF TEST WITH MAF SENSOR DISCONNECTED Key off Disconnect MAF sensor Disconnect PCM Inspect for damage or pushed out pins corrosion...

Page 44: ...ESS CIRCUITS Key off EGR boost sensor disconnected Disconnect PCM Inspect for damaged or pushed out pins corrosion loose wires Yes Go to next step etc Service as necessary Install breakout box Leave P...

Page 45: ...AT EGR BOOST SOLENOID Key off EGR boost solenoid disconnected Key on engine idling Measure voltage between power circuit and chassis ground at EGR boost solenoid vehicle harness connector Is EGR boos...

Page 46: ...Install vacuum pump at input port of EGR boost solenoid apply 27 33 kPa 203 254 mmHg 8 10 inHg of vacuum to EGR boost solenoid Disconnect vacuum line from barometric pressure to EGR boost sensor at Ba...

Page 47: ...dure COMPLETE OBD II Drive Mode Confirm repair by performing EGR portion of OBD II Drive Mode to check for DTCs 3 CHECK EGR BOOST SIGNAL CIRCUIT FOR SHORT TO GROUND Key off EGR boost sensor disconnect...

Page 48: ...fter Repair Procedure COMPLETE OBD II Drive Mode Confirm repair by performing EGR portion of OBD II Drive Mode to check for DTCs 3 CHECK EGR BOOST SENSOR SIGNAL CIRCUIT FOR SHORT TO POWER Key off EGR...

Page 49: ...sensor Disconnect TP sensor Key on engine off Measure voltage between constant voltage circuit and ground circuit at TP sensor vehicle harness connector Is voltage between 4 5 volts and 5 5 volts Yes...

Page 50: ...MPLETE Comprehensive Component Monitor Drive Mode No Go to next step 2 CHECK PCM VEHICLE HARNESS Still monitoring PID While obsering approprate PID perform the following Hold the vehicle harness close...

Page 51: ...Key off Disconnect suspected temperature sensor Disconnect PCM Inspect for damaged or pushed out pins corrosion loose wire etc Service as necessary Install breakout box Leave PCM Yes REMOVE breakout...

Page 52: ...age circuit and ground circuit at TP sensor vehicle harness connector Is voltage between 4 0 and 6 0 volts Yes Go to next step No KEY off RECONNECT all components REPAIR open in constant voltage circu...

Page 53: ...off TP sensor disconnected Key on engine off Measure voltage between constant voltage circuit and ground circuit at TP sensor vehicle harness connector Is voltage between 4 0 and 6 0 volts Yes TP sign...

Page 54: ...engine running and engine at operating temperature Activate KOER self test Is DTCs P1127 present during KOER self test Yes Go to DTC chart and service DTCs P1127 as necessary No Go to next step 2 HEA...

Page 55: ...OMPLETE OBD II Drive Mode RERUN OBD Test No Go to next step 6 CHECK RESISTANCE OF HEATED OXYGEN SENSOR SIGNAL CIRCUIT Key off Disconnect NGS tester Disconnect PCM Inspect both end of connect for bent...

Page 56: ...d proper assembly Note On some applications vehicle hoist may be required to access heated oxygen sensor harness Were any concerns found during visual inspection Yes SERVICE any concerns found in the...

Page 57: ...ND POWER CIRCUIT SHORTED TO HEATED OXYGEN SENSOR CASE Disconnect suspected sensor Measure the resistance between heated oxygen sensor heater ground at heated oxygen sensor connector and heated oxygen...

Page 58: ...cle harness connector H02S heater Front Test Pin 93 Heater ground H02S heater Rear Test Pin 95 Heater ground is resistance less than 4 0 ohms Yes Open or shorted or excessive resistance in heater circ...

Page 59: ...ET PCM to completely clear DTCs tr After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test No Continuous Memory DTCs P0136 Go to next step All others Go to step 3 2 CHECK FOR KOER DTCS P1137...

Page 60: ...completely clear DTCs o After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test 5 CHECK RESISTANCE OF HEATED OXYGEN SENSOR AND HEATED OXYGEN SENSOR GROUND CIRCUIT Key off Breakout box install...

Page 61: ...tely clear DTCs cr After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test No REPLACE PCM RECONNECT all components RESET PCM to completely clear DTCs tr After Repair Procedure COMPLETE OBD II...

Page 62: ...ow chart contains fuel system diagnosis and repair procedures Read following warnings before performing fuel system service Fuel vapor is hazardous It can easily ignite causing serious injury and dama...

Page 63: ...onnected Measure resistance between heated oxygen sensor ground terminal at heated oxygen sensor vehicle harness connector and ground Test Pin 91 at breakout box Is resistance reading less than 5 0 oh...

Page 64: ...Disconnect suspected heated oxygen sensor Inspect for damage or pushed out pins corrosion and loose wires Service as necessary NGS tester connected Access 02S11 PID Is reading 0 2 volt or less Yes Go...

Page 65: ...ear DTCs cr After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test 14 CHECK PRC SOLENOID VALVE HARNESS CIRCUIT RESISTANCE Key off PRC solenoid valve disconnected Disconnect PCM Inspect for d...

Page 66: ...nd PRC solenoid valve output vacuum port for blockage kinks or cracks Is vacuum line free of damage Yes Vacuum line is okay RECONNECT vacuum line Go to next step No Vacuum line is damaged SERVICE or R...

Page 67: ...COMPLETE OBD II Drive Mode RERUN OBD Test 21 CHECK PCM CONTROL OF PRC SOLENOID VALVE Key off Breakout box installed PCM connected Install digital multimeter between Test Pin 19 and Test Pin 71 of bre...

Page 68: ...vacuum hose at fuel pressure regulator and plug it Drive vehicle with heavy accelerations while observing fuel pressure gauge reading Does fuel pressure reading hold steady within 21 kPa 0 21 kgf cm2...

Page 69: ...0 CHECK SUPPLY FUEL LINE FOR RESTRICTIONS Key off Observe Warnings Cautions and Notes at beginning of this Pinpoint Test Disconnect supply fuel line at fuel rail and at fuel pump Inspect supply line f...

Page 70: ...Pin 71 97 at breakout box and power circuit pin at suspected fuel injector harness connector Measure resistance between fuel injector Test Pin s at breakout box and Fuel Injector Signal Pin at fuel in...

Page 71: ...dure COMPLETE OBD II Drive Mode RERUN OBD Test 38 INSPECT INDUCTION SYSTEM FOR AIR LEAKS Inspect following areas for signs of air leaks Inlet tube s from air cleaner to throttle body Gaskets which sea...

Page 72: ...to completely clear DTCs o After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test 41 ATTEMPT TO GENERATE DTC P1131 Key off Disconnect heated oxygen sensor Jumper heated oxygen sensor signal...

Page 73: ...rness or connector RESET PCM to completely clear DTCs xt After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test No Go to next step 44 TEST DRIVE WHILE MONITORING HEATED OXYGEN SENSOR PID FOR...

Page 74: ...breakout box and chassis ground With immobilizer system Test Pin 70 Without immobilizer system Test Pin 80 Is voltage less than 1 0 volt Yes Go to next step No SERVICE short to power REMOVE breakout...

Page 75: ...E REPAIR PROCEDURE D 01 14 AFTER REPAIR PROCEDURE STEP INSPECTION ACTION 1 CHECK POSSIBLE CAUSES TO MISFIRE Note Running out of fuel may turn on the MIL and possibly store Continuous Misfire DTC Has v...

Page 76: ...mber Test pin 1 75 3 74 2 101 4 100 No W 6 U 1 0 1 W D 2 Start engine Does test lamp emit dim glow while No light or bright light REPLACE PCM REMOVE breakout box COMPLETE OBD II Drive Mode RERUN OBD T...

Page 77: ...r DTCs tr After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test No Go to next step 13 CHECK PURGE SOLENOID VALVE This step will verify the mechanical integrity of purge solenoid valve Solen...

Page 78: ...ION ACTION 1 CHECK KNOCK SENSOR VOLTAGE Key off Disconnect PCM Inspect for damage or pushed out pins corrosion and loose wires Service as necessary Install breakout box Key on engine running Read DC v...

Page 79: ...Mode RERUN OBD Test No SERVICE short circuit RECONNECT all components RESET PCM to completely clear DTCs i t After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test 6 CHECK KNOCK SENSOR CIRC...

Page 80: ...olts Yes Go to next step No SERVICE open in CMP sensor power circuit RECONNECT all components RESET PCM to completely clear DTCs tr After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test 4 C...

Page 81: ...sensor disconnected Breakout box installed Measure resistance between Test Pin 85 and Test Pins 51 103 71 97 91 at breakout box Is each resistance greater than 500 ohms Yes Go to next step No REPLACE...

Page 82: ...step 3 CHECK CYLINDER COMPRESSION Check cylinder compression o 01 10A COMPRESSION INSPECTION FS Are cylinder compression readings within specification Yes Go to next step No SERVICE as necessary RESET...

Page 83: ...DTCs tr After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test CHECK POWER CIRCUIT TO EGR BOOST SOLENOID VALVE Key off EGR boost solenoid valve disconnected Key on engine off Measure voltage...

Page 84: ...R boost solenoid valve and apply 27 30 kPa 203 247 mmHg 8 10 inHg of vacuum Disconnect vacuum line from EGR boost solenoid valve to EGR boost sensor at sensor Inspect vacuum line for damage service as...

Page 85: ...mage Fuel can also irritate skin and eyes To prevent this always complete BEFORE REPAIR PROCEDURE and AFTER REPAIR PROCEDURE described in this manual xr 01 14 BEFORE REPAIR PROCEDURE D 01 14 AFTER REP...

Page 86: ...s can indicate that thermostat is not operating correctly or that engine coolant level is not filled to specifications Resulting in above normal operating temperatures Were any of following ECT sensor...

Page 87: ...210 310 kPa 2 2 3 1 kgf cm2 31 46 psi Yes Fuel pressure is okay REMOVE fuel pressure gauge Go to next step No Fuel pressure is out of specification Inspect Fuel Delivery System zr 01 14 FUEL INJECTOR...

Page 88: ...m with transaxle in NEU1 RAL Observe vacuum gauge needle rises while maintaining increased engine rpm Note On a non restricted exhaust system vacuum gauge needle will rise quickly to normal range as i...

Page 89: ...ack pressure at high engine rpm REPLACE exhaust manifold if unable to remove casting flash restriction RESET PCM to completely clear DTCs cr After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD...

Page 90: ...l can also irritate skin and eyes To prevent this always complete BEFORE REPAIR PROCEDURE and AFTER REPAIR PROCEDURE described in this manual tr 01 14 BEFORE REPAIR PROCEDURE o 01 14 AFTER REPAIR PROC...

Page 91: ...ECT all components RESET PCM to completely clear DTCs tr After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test No RECONNECT all components Go to next step 8 INSPECTION OF CHARCOAL CANISTER...

Page 92: ...mponents RESET PCM to completely clear DTCs tr After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test 13 CHECK FOR EVAPORATIVE EMISSION MONITOR SYSTEM Key off Disconnect vacuum hose from cha...

Page 93: ...detected Yes SERVICE or REPLACE fuel tank or sealing RECONNECT all components RESET PCM to completely clear DTCs o f After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test No RECONNECT all c...

Page 94: ...PCM to completely clear DTCs o After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test 3 CHECK CONTINUITY OF PURGE SOLENOID VALVE SIGNAL CIRCUIT Key off Purge solenoid valve disconnected Disc...

Page 95: ...ose tube Constant voltage circuit to FTP sensor open Fuel vapor storage canister vent restriction Damaged Canister Vent side filter Damaged Canister Drain Cut Valve CDCV Damaged PCM Warning Following...

Page 96: ...sphere venting port to canister drain cut valve CDCV most applications have CDCV directly attached to charcoal canister Check for kinks or bends in purge air inlet tube larger diameter hose between CD...

Page 97: ...V REPLACE CDCV RECONNECT all components RESET PCM completely clear DTCs t After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test No Go to next step 9 CHECK CDCV CIRCUIT FOR SHORT TO GROUND C...

Page 98: ...tank filler cap open or not open to atmosphere is 2 37 2 87 volts Access FTP V PID with NGS tester Is FTP V PID voltage less than 0 22 volt Yes FTP sensor voltage less than acceptable minimum Go to n...

Page 99: ...ll components RERUN OBD Test No SERVICE harness short between FTP signal circuit and FTP sensor ground or ground circuit REMOVE breakout box RECONNECT all components RESET PCM to completely clear DTCs...

Page 100: ...OR SHORT TO POWER CIRCUIT Key off FTP sensor disconnected Disconnect PCM Inspect for damaged or pushed out pins corrosion and loose wires Service as necessary Install breakout box Leave PCM disconnect...

Page 101: ...rected you here RESET PCM to completely clear DTCs tr After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test Is resistance greater that 10 000 ohms No SERVICE harness short between FTP signa...

Page 102: ...REPAIR PROCEDURE and AFTER REPAIR PROCEDURE described in this manual o 01 14 BEFORE REPAIR PROCEDURE cr 01 14 AFTER REPAIR PROCEDURE STEP INSPECTION ACTION 1 CHECK FOR OTHER CONTINUOUS MEMORY DTC Che...

Page 103: ...l components RESET PCM to completely clear DTCs COMPLETE OBD II Drive Mode tr After Repair Procedure RERUN OBD Test No RECONNECT all components Go to next step 8 INSPECTION OF CATCH TANK Remove catch...

Page 104: ...all components RESET PCM to completely clear DTCs er After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test 14 CHECK FTP SIGNAL CIRCUIT FOR SHORTS TO FTP SENSOR GROUND AND GROUND CIRCUIT Ke...

Page 105: ...components Go to next step 18 INSPECTION FUEL FILLER PIPE Remove fuel filler pipe Visually inspect for fuel filler pipe damage Is fault detected Yes REPLACE fuel filler pipe RECONNECT all components R...

Page 106: ...R PIPE Remove fuel filler pipe Visually inspect for fuel filler pipe damage Is fault detected Yes REPLACE fuel filler pipe RECONNECT all components RESET PCM to completely clear DTCs e r rAfter Repair...

Page 107: ...PID filled Yes Go to next step No INSPECT fuel tanks for leaks SERVICE as necessary EVALUATE fuel tank for overfilled condition greater than 75 ADD fuel tank for under filled condition less than 25 RE...

Page 108: ...circuit REMOVE breakout box RECONNECT all components RESET PCM to completely clear DTCs id After Repair Procedure COMPLETE OBD II Drive Mode RUN VSS Drive Mode to verify repair 2 CHECK VSS HARNESS CIR...

Page 109: ...rcuit pin and lead on IAC valve pin Is resistance between 6 0 and 13 0 ohms Yes Go to next step No REPLACE IAC valve assembly RECONNECT all components RERUN OBD Test 3 CHECK IAC VALVE FOR AN INTERNAL...

Page 110: ...o next step No SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN OBD Test 8 CHECK IAC VALVE SIGNAL CIRCUIT FOR SHORT TO GROUND Key off Breakout box installed PCM disconnected IA...

Page 111: ...bend a small section of harness from IAC to dash panel and from dash panel to PCM Do IAC or RPM PIDs suddenly change in value indicating fault Yes ISOLATE fault and SERVICE as necessary RECONNECT all...

Page 112: ...proximity to ignition components or wires Is wiring too close to ignition components or wires Yes REROUTE as necessary RERUN OBD Test No Engine compartment wire routing is okay Go to next step 3 CHEC...

Page 113: ...rness connector and inspect for damage pushed out or broken pins and broken wires Service as required Measure resistance across the clutch switch terminals with clutch pedal down Measure resistance ac...

Page 114: ...No COMPLETE self test using correct procedure 2 CHECK FOR CONSTANT VOLTAGE AT TP SENSOR Key off TP sensor disconnected Key on engine off Measure voltage between constant voltage and TP sensor ground...

Page 115: ...10 5 volts Yes Go to next step No SERVICE open in DLC power circuit RERUN OBD Test 8 CHECK DLC CHASSIS GROUND CONTINUITY Key off Measure resistance between chassis ground circuit cavity at DLC and cha...

Page 116: ...CIRCUIT CONTINUITY Key off Breakout box installed Leave PCM disconnected Measure resistance between Test Pin 16 at breakout box and BUS circuit at DLC is resistance less than 5 0 ohms Yes Go to next s...

Page 117: ...RUN OBD Test Access MAF V PID for fault indication while performing following Lightly tap on MAF sensor and wiggle harness connector to simulate road shock Does MAF V PID go below minimum 0 39 volts o...

Page 118: ...on loose wires etc Service as necessary NGS tester connected Install breakout box Connect PCM to breakout box Key on engine off Measure between Test Pin 88 and Test Pins 24 or 103 at breakout box Is v...

Page 119: ...YMPTOM TROUBLESHOOTING Measure voltage between Test Pin 88 at breakout box and battery negative post Is voltage between 0 34 and 1 96 volts at idle Yes MAF SIG to PCM is okay Go to next step No MAF se...

Page 120: ...N OBD Test 12 CHECK PCM GROUND CIRCUIT BETWEEN PCM AND MAF SENSOR GROUND FOR SHORT TO GROUND CIRCUITS Key off MAF sensor disconnected Breakout box installed PCM disconnected NGS tester disconnected fr...

Page 121: ...TP sensor Measure voltage between constant voltage circuit and TP sensor ground circuit at TP sensor vehicle harness connector Is voltage between 4 5 volts and 5 5 volts Yes There is sufficient const...

Page 122: ...IRCUIT VOLTAGE Key off TP sensor disconnected Key on engine off Measure voltage between constant voltage circuit and TP sensor ground circuit at TP sensor vehicle harness connector Is voltage between...

Page 123: ...F sensor and throttle body including air noise sounds while engine is running SERVICE as necessary If okay REPLACE TP sensor RERUN OBD Test No Go to next step 4 CHECK TP SENSOR SIGNAL LOW VERSUS THE E...

Page 124: ...ACTION 1 CHECK FOR TP CIRCUIT INTERMITTENT VOLTAGE INPUT Start engine and bring to idle Run engine up to 1 500 rpm for 5 seconds Key on engine running Access TP V PID for fault indication with NGS tes...

Page 125: ...lenoid valve connector Key on engine off Measure voltage between power circuit at PRC solenoid valve connector and chassis ground Is voltage greater than 10 5 volts Yes Go to next step No SERVICE open...

Page 126: ...etely clear DTCs tr After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test 3 CHECK EGR VALVE CONTROL SIGNAL CIRCUIT SHORT TO GROUND Key off EGR valve disconnected Disconnect PCM Inspect for...

Page 127: ...Perform continuous memory self test Are any continuous memory DTCs displayed Yes Go to appropriate DTC test No Go to next step 3 PERFORM KOEO SELF TEST Key off NGS tester connected Key on engine off P...

Page 128: ...ed Measure resistance between EGR boost solenoid valve circuit at EGR boost solenoid valve connector Test Pin 98 at breakout box Is resistance less than 5 0 ohms Yes Go to next step No SERVICE open ci...

Page 129: ...II Drive Mode to check for DTCs 14 CHECK EGR CONTROL SIGNAL CIRCUIT SHORT TO GROUND Key off EGR valve disconnected Disconnect PCM Measure resistance between following terminals EGR valve connector and...

Page 130: ...OID VALVE CIRCUIT FOR SHORT TO GROUND CIRCUIT Key off Purge solenoid valve disconnected Breakout box installed PCM disconnected Disconnect NGS tester from DLC Measure resistance between Test Pin 67 an...

Page 131: ...PLETE OBD II Drive Mode RERUN OBD Test 3 CHECK RESISTANCE OF CDCV CIRCUIT Key off Disconnect CDCV and PCM Inspect for damaged or pushed out pins corrosion and loose wires Service as necessary Install...

Page 132: ...rive Mode RERUN OBD Test No RETURN to the action to take column of pinpoint test step that directed you here KOEO KOER P1460 DTC Wide open throttle air conditioning cutoff circuit malfunction DESCRIPT...

Page 133: ...ester from DLC Breakout box installed PCM disconnected Measure resistance between Test Pin 69 at breakout box and chassis ground Is resistance greater than 10 000 ohms Yes Go to next step No SERVICE s...

Page 134: ...necessary REMOVE jumper wire RECONNECT all components RESET PCM completely clear DTCs tr After Repair Procedure START engine TURN A C to ON WAIT 15 seconds A C off Key off RERUN OBD Test No Go to next...

Page 135: ...at breakout box and chassis ground A C switch ON 0 V A C switch OFF 12 V Are voltages correct Yes Go to next step No Go to step 6 5 CHECK CONTINUITY OF A C RELAY CIRCUIT Key off Disconnect A C relay a...

Page 136: ...ONTROL SIGNAL CIRCUIT CYCLING Key on engine off Applicable fan relay disconnected NGS tester connected Access Output Test Mode Connect non powered test lamp between power circuit and cooling fan contr...

Page 137: ...ntrol circuit for short to ground REMOVE breakout box RECONNECT all components RERUN OBD Test 5 CHECK COOLING FAN CONTROL SIGNAL OR CONDENSER FAN CONTROL SIGNAL CIRCUIT RESISTANCE Key off Appropriate...

Page 138: ...epair Procedure COMPLETE OBD II Drive Mode RERUN OBD test while performing following lamp will turn off when fault detected indicating open or short to power Shake wiggle bend cooling fan control circ...

Page 139: ...is detected indicating an open or short to power Shake wiggle and bend the condenser fan control signal circuit between PCM and condenser fan relay Shake wiggle and bend power circuit to condenser fan...

Page 140: ...ect PCM Inspect for damaged or pushed out pins corrosion loose wires etc Repair as necessary Install breakout box Leave PCM disconnected Key on engine off Measure voltage between Test Pin 98 at breako...

Page 141: ...r connection or component malfunction REPAIR or REPLACE as necessary DTC P1506 Idle air control IAC system overpseed error DESCRIPTION DTC P1506 indicates self test has detected an IAC valve over spee...

Page 142: ...Is each resistance greater than 10 000 ohms Yes For Fast Idle Symptom currently present REPLACE PCM REMOVE breakout box RECONNECT all components RERUN OBD Test All others RECONNECT all components Go t...

Page 143: ...Battery IU L Ignition switch black white Is there open circuit Yes Repair wiring harness No Go to next step 6 CHECK WIRING HARNESS SHORT CIRCUIT Check for wiring harness short circuit with IU connect...

Page 144: ...ced and reprogramming system Possible Cause Unregistered key is used in step 3 of immobilizer system Transformation of key ID number stored in PCM reprogram procedure IU replacement STEP INSPECTION AC...

Page 145: ...onent malfunction REPAIR or REPLACE as necessary No Go to next step 2 CHECK PSP SWITCH OPERATION Key off Start engine and let idle in Park Neutral Install dwell tacho tester Disconnect PSP switch conn...

Page 146: ...s connector Does engine rpm decrease Yes Go to step No Go to next step 3 CHECK CONTINUITY OF PSP CIRCUIT Key off PSP switch disconnected Disconnect PCM Inspect for damage or pushed out pins corrosion...

Page 147: ...test Key off Disconnect brake switch Measure power input voltage between brake switch and chassis ground Is voltage greater than 10 volts Yes Go to next step No SERVICE open power circuit to brake sw...

Page 148: ...n Go to step 6 if brake light is always on 3 CHECK FOR BOO PID CYCLING Key on engine off Access BOO PID Apply and release brake pedal several times while viewing BOO PID Note If BOO PID is not accessi...

Page 149: ...HORT TO POWER IN PCM Key off Brake switch disconnected Key on Is brake light still on Yes Go to next step No REPLACE PCM RECONNECT brake switch RERUN OBD Test 8 CHECK FOR SHORT TO POWER CIRCUIT IN SHI...

Page 150: ...s jerks during acceleration cruising or deceleration Hesitation stumble Acceleration Momentary pause at beginning of acceleration or during acceleration Surges Acceleration cruise Momentary minor irre...

Page 151: ...c transaxle Upshift downshift enga concerns gement Automatic transaxle concerns not related to engine performance 29 Fuel fill issues Fuel tank does not fill smoothly 30 Fuel filling shut off issues F...

Page 152: ...aged drive belts X K improper engine coolant level C O X 3 Water and anti freeze mixture improperly s o X X x X X X X 3 TJ Malfunction of cooling system radiator hoses overflow system thermostat etc z...

Page 153: ...7C O X X Malfunction of knock sensor and related circuit 03 X x X X T5 T 3 Immobilizer system operation m A X Malfunction of FEPS circuit O X x X C U cr Malfunction of power steering pressure switch...

Page 154: ...system is under high pressure Warning Fuel line spills and leaks are dangerous Fuel can ignite and cause serious injuries or death and damage Fuel can also irritate skin and eyes To prevent this alway...

Page 155: ...100 A Main fuse Generator BTN 40 A BTN fuse ROOM fuse ROOM 15 A ROOM fuse PCM terminal EGI INJ 30 A Main relay Fuel injectors Generator EGR boost solenoid valve PRC solenoid valve EGR valve Idle air...

Page 156: ...ny other electrical accessories work Yes Go to next step No Check the charging system cr 01 17 GENERATOR INSPECTION 5 Note Following test should be performed on automatic transaxles only For manual tr...

Page 157: ...PAIR PROCEDURE o 01 14 AFTER REPAIR PROCEDURE STEP INSPECTION ACTION 1 Verify following Vacuum leaks Fuel quality i e proper octane contamination winter summer blend Loose bands on intake air system C...

Page 158: ...o pressure regulator Install vacuum gauge to intake manifold Start the engine Does fuel pressure gauge reading increase as vacuum gauge reading decreases and or does fuel pressure gauge reading decrea...

Page 159: ...s injuries or death and damage Fuel can also irritate skin and eyes To prevent this always complete BEFORE REPAIR PROCEDURE and AFTER REPAIR PROCEDURE described in this manual d 01 14 BEFORE REPAIR PR...

Page 160: ...intake air system No restriction of intake air system Proper sealing of intake manifold and components attached to intake manifold i e EGR valve IAC valve Ignition wiring Fuel quality such as proper...

Page 161: ...ion coil Open circuit between ignition coil and PCM 2 2 Check spark plug conditions Is spark plug wet converted with carbon or grayish white Yes If spark plug is wet or converted with carbon check for...

Page 162: ...urge solenoid and intake manifold from purge solenoid side Plug opening end of vacuum hose Start engine Is engine stall eliminated Yes Check if purge control solenoid sticks to open Check evaporative...

Page 163: ...sparks and flames away from fuel Fuel line spills and leaks are dangerous Fuel can ignite and cause serious injuries or death and damage Fuel can also irritate skin and eyes To prevent this always com...

Page 164: ...fuel shut off or accessory ignition switch alarm etc Fuel quality such as proper octane contamination winter summer blend No air leaks from intake air system Proper sealing of intake manifold and comp...

Page 165: ...t to ground in constant voltage circuit between TP sensor EGR boost sensor or fuel tank pressure FTP sensor and powertrain control module 23 Disconnect NGS tester Turn ignition switch on Check V termi...

Page 166: ...ndex to service any additional symptoms 6 SLOW RETURN TO IDLE DESCRIPTION Engine takes more time than normal to return to idle speed POSSIBLE CAUSE Malfunction of ECT sensor Thermostat stuck to open T...

Page 167: ...stem service 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 leaks are dangerous Fuel can ignite and ca...

Page 168: ...Is there any crack on high tension leads Yes Repair suspected high tension lead No Go to next step 9 Check spark plug conditions Is spark plug wet converted with carbon or grayish white Yes If spark p...

Page 169: ...condition improve Yes Replace EGR valve No Go to next step 19 Is engine compression correct Yes Check valve timing No Check for causes 2 0 Verify test results If okay return to diagnostic index to ser...

Page 170: ...nnecting IAC valve No Check following Circuit from idle air control valve to PCM for open and short Idle air control valve for sticking If okay go to next step 5 Disconnect vacuum hose between purge s...

Page 171: ...cleaner restriction Improper valve timing due to jumping out timing belt Intermittently open short in fuel pump circuit Fuel pump mechanical malfunction Fuel injector clogged Clutch slippage Warning F...

Page 172: ...conditions Is spark plug wet converted with carbon or grayish white Yes If spark plug is wet or converted with carbon check for fuel leak from fuel injector If spark plug is grayish white check for cl...

Page 173: ...heck cruise control system Is cruise control system okay No Repair or replace 15 Disconnect vacuum hose between purge solenoid valve and intake manifold from solenoid valve side Plug opening end of va...

Page 174: ...following warnings before performing fuel system service Fuel vapor is hazardous It can easily ignite causing serious injury and damage Always keep sparks and flames away from fuel Fuel line spills an...

Page 175: ...ed with carbon check for fuel leak from fuel injector If spark plug is grayish white check for clogged fuel injector No Install spark plugs on original cylinders Go to next step 8 Remove and shake PCV...

Page 176: ...ission control system No Go to next step 14 Visually inspect camshaft position CMP sensor and tooth of camshaft Is CMP sensor and tooth of camshaft okay Yes Go to next step No Replace malfunctioning p...

Page 177: ...Connect NGS tester to DLC Acrpss FCT PID Verify ECT PID is less than 116 C 240 8 F during driving Is ECT PID less than specification Yes Go to next step No Inspect cooling system for cause of overhea...

Page 178: ...BEFORE REPAIR PROCEDURE and AFTER REPAIR PROCEDURE described in this manual ay 01 14 BEFORE REPAIR PROCEDURE cp 01 14 AFTER REPAIR PROCEDURE STEP INSPECTION ACTION 1 Check following Contaminated air c...

Page 179: ...fuel line High Check pressure regulator for high pressure cause Check for clogged fuel return line 6 Remove and shake PCV valve Does PCV valve rattle Yes Go to next step No Replace PCV valve 7 Is ther...

Page 180: ...escribed in this manual or 01 14 BEFORE REPAIR PROCEDURE tr 01 14 AFTER REPAIR PROCEDURE STEP INSPECTION ACTION 1 Check following Vacuum lines for leaks or blockage Electrical connections Yes Go to ne...

Page 181: ...specification for 60 seconds when ignition switch is turned ON Fuel line pressure 210 260 kPa 2 1 2 6 kgf cm2 30 37 psi Yes Go to next step No Check pressure regulator for high pressure cause 8 Remove...

Page 182: ...Remove MIL bulb Is voltage correct on positive side of MIL bulb socket Specification More than 10 5 V Yes Go to next step No Repair open circuit in wiring harness between fuse block and MIL bulb socke...

Page 183: ...rmostat has opened Is thermostat opening voltage okay Thermostat operating voltage Approx 0 6 0 9 V Yes Engine coolant temperature and thermostat are okay Go to next step No Remove thermostat from eng...

Page 184: ...IBLE CAUSE Thermostat malfunction Malfunction of cooling fan system Malfunction of condenser fan system STEP INSPECTION ACTION 1 Is customer s any complaint Lack of Yes Check A1C and heater system pas...

Page 185: ...is manual zr 01 14 BEFORE REPAIR PROCEDURE cr 01 14 AFTER REPAIR PROCEDURE STEP INSPECTION ACTION 1 What color is smoke coming from exhaust system Blue Burning oil indicated Go to next step White Wate...

Page 186: ...clogged main fuel line High Check pressure regulator for high pressure cause Check for clogged fuel return line 7 Does fuel line pressure remain at specification for 60 seconds when ignition switch i...

Page 187: ...check for fuel leakage at fuel injector O ring pressure regulator and fuel line Service as necessary Install fuel pressure gauge between fuel filter and fuel delivery pipe Start engine and run at idl...

Page 188: ...present Yes Check following Engine oil level Drive belts No Go to next step 2 Is rumble or grind sound present Yes Check drive belt No Go to next step 3 Is rattle sound present Yes Check location of...

Page 189: ...ere continuity between connector terminal and ground Yes Short to ground Repair or replace wire harness No Check for short to ground at power steering pressure switch If switch is okay go to next step...

Page 190: ...on Read ACCS PID while disconnecting high pressure switch connector Note ACCS PID should read OFF when disconnecting connector If ACCS PID reading remains ON short to ground circuit may be present Do...

Page 191: ...TP sensor loosely installed STEP INSPECTION ACTION 1 Does A C turn off when A C switch is turned off Yes Go to next step No Go to flowchart 24 for A C ALWAYS ON A C COMPRESSOR RUNS CONTINUOUSLY 2 Ret...

Page 192: ...or exhaust smoke concerns present Yes Go to appropriate flow chart No Go to next step 2 Check following Electrical connections Vacuum lines Are all items okay Yes Go to next step No Service as necessa...

Page 193: ...for abrupt changes in PID values Are any PID values out of range or suddenly drop out and back into range Yes Possible wiring or component problem Check each wire for corrosion bent or loose terminal...

Page 194: ...ext step 2 Remove fuel filler pipe Make sure non return valve is installed properly Check non return valve operation Is non return valve okay Yes Check as followings Improper use of fuel nozzle Inadeq...

Page 195: ...tant voltage and ground circuits at TP sensor connector Is voltage between 4 0 and 6 0 volts Yes Replace EGR boost sensor No Go to step 6 6 Key off Disconnect TP sensor connector Install breakout box...

Page 196: ...pair open ground circuit 12 Key off Disconnect NGS tester from DLC Install breakout box Leave PCM disconnected Measure resistance between battery negative terminal and ground Test Pins 51 76 77 103 at...

Page 197: ...l system service 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 leaks are dangerous Fuel can ignite an...

Page 198: ...erous 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 described i...

Page 199: ...PAIR PROCEDURE STEP INSPECTION ACTION 1 Is air cleaner element tree of restrictions Yes Go to next step No Replace air cleaner element 2 Carry out spark test Is a strong blue spark visible at each cyl...

Page 200: ...rect Fuel line pressure 260 310 kPa 2 6 3 2 kgf cm2 37 46 psi at ignition switch ON Yes Check following PID MAF PID a 01 40A MASS AIR FLOW SENSOR INSPECTION FS ECT PID D 01 40A ENGINE COOLANT TEMPERAT...

Page 201: ...no load condition Headlight Cooling fan Blower motor A C switch and fan switch ON Note Excludes temporary idle speed drop immediately after the electrical loads are turned ON 6 If not as specified che...

Page 202: ...TER REPAIR PROCEDURE Refer to 01 14 BEFORE REPAIR PROCEDURE 01 14 AFTER REPAIR PROCEDURE 1 Disconnect the negative battery cable 2 Install a fuel pressure gauge between the fuel filter and the main fu...

Page 203: ...tion 2 as required Inspection 1 1 Connect the SSTs NGS tester to the DLC 2 Access the following PIDs ECT PID R efer to 0 1 4 0 A ENGINE CO O LANT TEM PER ATU RE SENSOR INSPECTION FS IAT PID Refer to 0...

Page 204: ...tic clutch is heard A C compressor starts to work 4 Fully open the throttle valve Check if the A C compressor magnetic clutch operation sound is heard A C compressor stops to work Then 3 6 seconds aft...

Page 205: ...inding resistance okay Yes Go to next step No Replace ignition coil 5 Are following parts okay CKP sensor and crankshaft pulley also check for a gap Specification 0 5 1 5 mm 0 020 0 059 In PCM termina...

Page 206: ...is heard check cooling fan relay and open circuit in wiring harnesses and connectors 8 Turn the A C switch and fan switch ON 9 Verify the cooling fan is operating 10 If fan does not operate check A C...

Page 207: ...Test Results Ignition Timing Control Inspection 01 01 B 180 Access Procedure 01 01B 6 A C Cut Off Control Inspection 01 01 B 180 OBD II Drive M o d e 01 01B 6 Spark Test 01 01B 181 Fuel Cut Control I...

Page 208: ...o detect certain faults not tested during other self test operations All self tests are menu driven in the NGS Tester Parameter Identification PID Access The PID mode allows access to certain data val...

Page 209: ...to SELECT NEW VEHICLE YEAR MODEL Press the trigger key to enter this selection POWERTRAIN CONTROL MODULE ABS ANTILOCK BRAKE SYSTEM SELECT ITEM AND PRESS TRIGGER TO START W 6 U 1 0 1 W K 5 NO VE HI LE...

Page 210: ...GS tester The brake pedal must be depressed and released after KOER Self Test is initiated If not performed DTC P1703 will be indicated on the NGS tester The steering wheel must be turned to the right...

Page 211: ...ew area 3 Select up to the four PIDs to review in the table format or two PIDs to review in the graph mode 4 Table format Scroll through the PID data while analyzing the information Look for sudden dr...

Page 212: ...GEN SENSOR TESTS Press trigger 7 Select MANUFACTURING SPECIFIC TEST ID Press trigger 8 Scroll up to the test number 41H and press trigger OBD II Drive Mode To complete the OBD II system check followin...

Page 213: ...oolant temperature sensor Circuit high input ON 1 CCM P0122 Throttle position sensor Circuit low input ON 1 CCM P0123 Throttle position sensor Circuit high input ON 1 CCM P0125 Engine coolant temperat...

Page 214: ...ncy below threshold ON 2 Catalyst P0442 Evaporative emission control system Leak detected Small leak ON 2 Purge P0443 Evaporative emission control system Purge solenoid valve circuit malfunction ON 2...

Page 215: ...GNOSIS GF4A EL P0760 Shift solenoid C Shift solenoid C circuit failure tr 05 01B AUTOMATIC TRANSAXLE ON BOARD DIAGNOSIS GF4A EL P1001 KOER aborted KOER not able to complete OFF P1100 Mass air flow sen...

Page 216: ...it malfunction OFF Other P1479 Fan control system Condenser fan control primary circuit malfunction OFF Other P1487 EGR boost solenoid valve Circuit malfunction OFF Other P1501 Vehicle speed sensor In...

Page 217: ...is not under 700 rpm go to ENGINE SYMPTOM TROUBLESHOOTING Run engine up 1500 rpm for 5 seconds then bring it back to idle Access MAF PID with NGS tester Is MAF PID less than specified value tr 01 40B...

Page 218: ...to next step 7 CHECK MAF SENSOR GROUND CIRCUIT CONTINUITY Key off MAF sensor disconnected Breakout box installed Disconnect PCM Disconnect NGS tester from DLC Measure resistance between ground circuit...

Page 219: ...r Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test 12 CHECK MAF SIGNAL CIRCUIT OUTPUT WITH NGS TESTER Key off MAF sensor connected Breakout box Installed PCM connected Key on engine running...

Page 220: ...F sensor Disconnect PCM Inspect for damage or pushed out pins corrosion loose wires etc Service as necessary Install breakout box Leave PCM disconnected Key on engine off Measure voltage between Test...

Page 221: ...s than 5 ohms Yes Go to next step No Service open in appropriate circuit EGR boost sensor harness circuit RESET PCM to completely clear DTCs tr After Repair Procedure COMPLETE OBD II Drive Mode Confir...

Page 222: ...d Measure solenoid resistance Is resistance between 30 and 70 ohms Yes Go to next step No REPLACE EGR boost solenoid RESET PCM to completely clear DTCs x t After Repair Procedure COMPLETE OBD II Drive...

Page 223: ...ox to ground and observe vacuum gauge Key off Was vacuum signal of 0 3 3 kPa 0 25 mmHg 0 1 InHg Indicated by vacuum gauge before Test Pins 98 and 51 were shorted and 27 33 kPa 203 254 mmHg 8 10 inHg a...

Page 224: ...r Procedure COMPLETE OBD II Drive Mode Confirm repair by performing EGR portion of OBD II drive mode to check for DTCs 3 CHECK EGR BOOST SIGNAL CIRCUIT FOR SHORT TO GROUND Key off EGR boost sensor dis...

Page 225: ...ear DTCs fp After Repair Procedure COMPLETE OBD II Drive Mode Confirm repair by performing EGR portion of OBD II drive mode to check for DTCs 3 CHECK EGR BOOST SIGNAL CIRCUIT FOR SHORT TO POWER Key of...

Page 226: ...rature sensor Disconnect TP sensor Key on engine off Measure voltage between constant voltage circuit and ground circuit at TP sensor vehicle harness connector Is voltage between 4 5 volts and 5 5 vol...

Page 227: ...DTCs P1112 and P1117 COMPLETE Comprehensive Component Monitor Drive Mode No Go to next step 2 CHECK PCM VEHICLE HARNESS Still monitoring PID While observing approprate PID perform following Hold vehi...

Page 228: ...off Disconnect suspected temperature sensor Disconnect PCM Inspect for damaged or pushed out pins corrosion loose wire etc Service as necessary Install breakout box leave PCM disconnected Measure res...

Page 229: ...cuit and ground circuit at TP sensor vehicle harness connector Is voltage between 4 0 and 6 0 volts Yes Go to next step No KEY off RECONNECT all components REPAIR open in constant voltage circuit 3 CH...

Page 230: ...Key off TP sensor disconnected Key on engine off Measure voltage between constant voltage circuit and ground circuit at TP sensor vehicle harness connector Is voltage between 4 0 and 6 0 volts Yes TP...

Page 231: ...EY ON ENGINE RUNNING KOER SELF TEST Key on engine running and engine at operating temperature Activate key on engine running KOER self test Is DTCs P1127 present during KOER self test Yes Go to DTC ch...

Page 232: ...1 Front LH Note Heated oxygen sensor displayed as 02S11 Front RH 02S12 Middle 02S21 Front LH or 02S13 Rear on NGS tester Is voltage greater than 1 50 volts Yes Heated oxygen sensor signal circuit is n...

Page 233: ...ectors Low battery positive voltage Cut or pulled wires Corrosion or poor mating terminals Disconnected wiring Damaged heated oxygen sensor heater Open heated oxygen sensor heater power circuit Damage...

Page 234: ...ir Procedure COMPLETE OBD II Drive Mode RERUN OBD Test 5 CHECK HEATED OXYGEN SENSOR HEATER RESISTANCE Key off Heated oxygen sensor disconnected Connect circuit tester to heated oxygen sensor ground ci...

Page 235: ...NNECT all components RESET PCM to completely clear DTCs tr After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test 8 CHECK FOR OPEN HEATED OXYGEN SENSOR HEATER GROUND HARNESS CIRCUIT Key off...

Page 236: ...as necessary RESET PCM to completely clear DTCs c r After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test No Continuous Memory DTCs P0136 Go to next step All others Go to step 3 2 CHECK FO...

Page 237: ...ower Test Pin 71 and 97 Constant voltage Test Pin 90 Is resistance greater than 10 000 ohms Yes Go to next step No SERVICE short circuit in harness REMOVE breakout box RECONNECT all components RESET P...

Page 238: ...ated oxygen sensor signal circuit at vehicle harness connector Key on Access heated oxygen sensor PID and Monitor 02S12 PID Is PID voltage greater than 1 5 volts Yes REPLACE heated oxygen sensor RECON...

Page 239: ...t Yes SERVICE as necessary RESET PCM to completely clear the DTCs tr After Repair Procedure COMPLETE a OBD II Drive Mode RERUN OBD Test No Continuous Memory DTCs P0156 Go to next step All others Go to...

Page 240: ...Pin 71 and 97 Constant voltage Test Pin 90 Is resistance greater than 10 000 ohms Yes Go to next step No SERVICE short circuit in harness REMOVE breakout box RECONNECT all components RESET PCM to comp...

Page 241: ...n sensor Rear disconnected Jumper power to heated oxygen sensor signal circuit at the vehicle harness connector Key on Access heated oxygen sensor PID and monitor 02S13 PID Is PID voltage greater than...

Page 242: ...ean for an overly lean condition Heated oxygen sensor voltage is greater than 0 45 volt Possible Cause Fuel System Induction System Excessive fuel pressure Air leaks after MAF sensor Leaking fuel inje...

Page 243: ...essary Key on engine off Access correct heated oxygen sensor PID 02S11 02S21 Note If spark occurs remove jumper and go to step 7 check fuse in heater circuit Jumper heated oxygen sensor signal circuit...

Page 244: ...Pin and Test Pins 23 24 51 76 77 103 and 91 at breakout box Is each resistance greater than 10 000 ohms Yes Go to next step No SERVICE short circuit REMOVE breakout box RECONNECT PCM and heated oxygen...

Page 245: ...SOR SIGNAL SHORTED TO HEATED OXYGEN SENSOR HEATER CIRCUIT IN SENSOR Key off Connect suspected heated oxygen sensor NGS tester connected Key on engine off Note heated oxygen sensor displayed as 02S11 F...

Page 246: ...OBD II Drive Mode RERUN OBD Test 15 CHECK PRC SOLENOID VALVE CIRCUIT FOR SHORTS TO POWER AND GROUND Key off PRC solenoid valve disconnected Breakout box installed PCM disconnected Disconnect NGS teste...

Page 247: ...e Is vacuum signal indicated by vacuum gauge Yes PRC solenoid valve is not stuck closed Go to next step No PRC solenoid valve is stuck closed REPLACE damaged PRC solenoid valve REMOVE vacuum gauge and...

Page 248: ...5 psi of highest reading after one minute Yes For Continuous DTCs P1130 P1150 P0171 P0172 P0174 and P0175 Go to step 31 For No Starts Go to step 32 For Fuel Control DTCs displayed with misfire DTCs G...

Page 249: ...d held vacuum pump to fuel pressure regulator Start engine and let run at idle Observe fuel pressure while applying vacuum Does fuel pressure change as vacuum changes Yes SERVICE vacuum system UNPLUG...

Page 250: ...CK ABILITY OF FUEL INJECTOR S TO DELIVER FUEL Pressure gauge installed Cycle key three times Monitor pressure gauge while cranking engine for at least five seconds Was there pressure drop greater than...

Page 251: ...ector harness Measure resistance between fuel injector Test Pin s refer to step 33 and Test Pin s 71 or 97 24 and 103 at breakout box Measure resistance between Fuel injector Test Pin s at breakout bo...

Page 252: ...stem Are there any sings of leaks or damage Yes SERVICE as necessary RESET PCM to completely clear DTCs tr After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test No CONTINUOUS DTCs P0171 P01...

Page 253: ...r RESET PCM to completely clear DTCs tr After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test 41 ATTEMPT TO GENERATE DTCS P1131 AND P1151 Key off Disconnect heated oxygen sensor Jumper heat...

Page 254: ...Service harness or connector RESET PCM to completely clear DTCs t After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test No Go to next step 44 TEST DRIVE WHILE MONITORING HEATED OXYGEN SENSO...

Page 255: ...connected Key on engine off Measure voltage between appropriate Test Pin at breakout box and chassis ground With immobilizer system Test Pin 70 Without Immobilizer system Test Pin 80 Is voltage less t...

Page 256: ...cribed in this manual o 01 14 BEFORE REPAIR PROCEDURE cr 01 14 AFTER REPAIR PROCEDURE STEP INSPECTION ACTION 1 CHECK POSSIBLE CAUSES TO MISFIRE Note Running out of fuel may turn on MIL and possibly st...

Page 257: ...ylinder Number Test pin 1 75 4 100 2 101 5 73 3 74 6 99 No W6U101WKQ Start engine Does test lamp emit dim glow while No light or bright light REPLACE PCM REMOVE breakout box COMPLETE OBD II Drive Mode...

Page 258: ...ar DTCs ty After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test No Go to next step 13 CHECK PURGE SOLENOID VALVE This step will verify mechanical integrity of purge solenoid valve Solenoid...

Page 259: ...ECTION ACTION 1 CHECK KNOCK SENSOR VOLTAGE Key off Disconnect PCM Inspect for damage or pushed out pins corrosion and loose wires Service as necessary Install breakout box Key on engine running Read D...

Page 260: ...ERUN OBD Test No Service short circuit Reconnect all components RESET PCM to completely clear DTCs ip After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test 6 CHECK KNOCK SENSOR CIRCUIT SHOR...

Page 261: ...Is voltage greater than 10 5 volts Yes Go to next step No SERVICE open in CMP sensor power circuit RECONNECT all components COMPLETE PCM RESET PCM to completely clear DTCs it After Repair Procedure CO...

Page 262: ...isconnected Breakout box installed Connect PCM to breakout box Measure resistance between Test Pin 85 and Test Pins 51 103 71 97 91 and 23 at breakout box Is each resistance greater than 500 ohms Yes...

Page 263: ...ere any air leaks Yes Air leaks located SERVICE source of air leak RESET PCM to completely clear DTCs tr After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test No Go to next step 3 CHECK CYL...

Page 264: ...ETE OBD II Drive Mode RERUN OBD Test No SERVICE short in EGR valve harness circuit REMOVE breakout box RECONNECT all components RESET PCM to completely clear DTCs cr After Repair Procedure COMPLETE OB...

Page 265: ...ost solenoid valve and apply 27 33 kPa 203 247 mmHg 8 10 InHg of vacuum Disconnect vacuum line from EGR boost sensor solenoid valve to EGR boost sensor at EGR boost sensor Inspect vacuum line for dama...

Page 266: ...To prevent this always complete BEFORE REPAIR PROCEDURE and AFTER REPAIR PROCEDURE described in this manual cr 01 14 BEFORE REPAIR PROCEDURE rr 01 14 AFTER REPAIR PROCEDURE STEP INSPECTION ACTION 1 CH...

Page 267: ...ECT sensor DTCs can indicate that thermostat is not operating correctly or that engine coolant level is not filled to specification Resulting in above normal operating temperatures Were any of followi...

Page 268: ...2 3 1 kgf cm2 31 46 psi Yes Fuel pressure Is okay REMOVE fuel pressure gauge Go to next step No Fuel pressure is out of specification Inspect Fuel Delivery System it 01 14 FUEL INJECTOR INSPECTION Fue...

Page 269: ...h transaxle in NEUTRAL Observe vacuum gauge needle rises while maintaining increased engine rpm Note On non restricted exhaust system vacuum gauge needle will rise quickly to normal range as increased...

Page 270: ...ressure at high engine rpm REPLACE exhaust manifold if unable to remove casting flash restriction RESET PCM to completely clear DTCs tr After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test...

Page 271: ...mage Fuel can also Irritate skin and eyes To prevent this always complete BEFORE REPAIR PROCEDURE and AFTER REPAIR PROCEDURE described in this manual cr 01 14 BEFORE REPAIR PROCEDURE kt 01 14 AFTER RE...

Page 272: ...RECONNECT all components RESET PCM to completely clear DTCs i t After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test No RECONNECT all components Go to next step 8 INSPECTION OF CHARCOAL CA...

Page 273: ...ll components RESET PCM to completely clear DTCs r r After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test 13 CHECK FOR EVAPORATIVE EMISSION MONITOR SYSTEM Key off Disconnect vacuum hose fr...

Page 274: ...CM to completely clear DTCs id After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test DTC P0443 Evaporative emission control system purge solenoid valve circuit malfunction DESCRIPTION DTC P...

Page 275: ...RVICE harness short circuit REMOVE breakout box RECONNECT all components VERIFY symptom no longer exists RESET PCM to completely clear DTCs tr After Repair Procedure COMPLETE OBD II Drive Mode RERUN O...

Page 276: ...EFORE REPAIR PROCEDURE v 01 14 AFTER REPAIR PROCEDURE STEP INSPECTION ACTION 1 CHECK FTP SENSOR Key on engine off Note FTP V PID should read between 2 50 and 2 70 volts Start engine If FTP V PID is eq...

Page 277: ...m to vacuum hose Does air flow No Go to next step 5 INSPECTION OF CHECK VALVE Remove and Inspect check valve for plugging Is the fault detected Yes REPLACE the check valve RECONNECT all components RES...

Page 278: ...PTOM TROUBLESHOOTING No 30 DTC P0452 Evaporative emission control system fuel tank pressure sensor circuit low input DESCRIPTION Diagnostic trouble code P0452 Indicates that Fuel Tank Pressure FTP sen...

Page 279: ...RTS TO FTP SENSOR GROUND AND GROUND CIRCUIT Key off FTP sensor disconnected Disconnect PCM Inspect for damaged or pushed out pins correction and loose wires Service as necessary Install breakout box L...

Page 280: ...OWER CIRCUIT Key off FTP sensor disconnected Disconnect PCM Inspect for damaged or pushed out pins corrosion and loose wires Service as necessary Install breakout box Leave PCM disconnected Key on eng...

Page 281: ...e COMPLETE OBD II Drive Mode RERUN OBD Test Measure resistance between Test Pin 62 and Test Pin 90 at breakout box Is resistance greater that 10 000 ohms No SERVICE harness short between FTP signal an...

Page 282: ...ORE REPAIR PROCEDURE and AFTER REPAIR PROCEDURE described in this manual c r 01 14 BEFORE REPAIR PROCEDURE cr 01 14 AFTER REPAIR PROCEDURE STEP INSPECTION ACTION 1 CHECK FOR OTHER CONTINUOUS MEMORY DT...

Page 283: ...all components RESET PCM to completely clear DTCs er After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test No RECONNECT ail components Go to next step 8 INSPECTION OF CATCH TANK Remove cat...

Page 284: ...all components RESET PCM to completely clear DTCs o After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test 14 CHECK FTP SIGNAL CIRCUIT FOR SHORTS TO FTP SENSOR GROUND AND GROUND CIRCUIT Key...

Page 285: ...l components Go to next step 18 INSPECTION FUEL FILLER PIPE Remove fuel filler pipe Visually inspect for fuel filler pipe damage Is fault detected Yes REPLACE fuel filler pipe RECONNECT all components...

Page 286: ...control valve RECONNECT all components RESET PCM to completely clear DTCs o After Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD Test No RECONNECT all components Go to next step 23 INSPECTION F...

Page 287: ...fuel gauge is between one quarter and three quarters filled but fuel level input PID indicates reading much higher or lower reading approximately 100 or 0 check fuel pump resistance Access fuel level...

Page 288: ...ircuit REMOVE breakout box RECONNECT all components RESET PCM to completely clear DTCs t r After Repair Procedure COMPLETE OBD II Drive Mode RUN VSS Drive mode to verify repair 2 CHECK VSS HARNESS CIR...

Page 289: ...e Due to diode In solenoid place DVOM lead on power circuit pin and lead on IAC valve pin Is resistance between 6 0 and 13 0 ohms Yes Go to next step No REPLACE IAC valve component RECONNECT all compo...

Page 290: ...to next step No SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN OBD Test 8 CHECK IAC VALVE SIGNAL CIRCUIT FOR SHORT TO GROUND Key off Breakout box installed PCM disconnected I...

Page 291: ...d bend small section of harness from IAC to dash panel and from dash panel to PCM Do IAC or RPM PIDs suddenly change in value indicating fault Yes ISOLATE fault and SERVICE as necessary RECONNECT all...

Page 292: ...ximity to ignition components or wires Is wiring too close to ignition components or wires Yes REROUTE as necessary RERUN OBD Test No Engine compartment wire routing is okay Go to next step 3 CHECK KE...

Page 293: ...nd Is voltage greater than 10 5 volts Yes Go to next step No SERVICE open power circuit to brake switch RECONNECT switch RESET PCM to completely clear DTCs ixrAfter Repair Procedure COMPLETE OBD II Dr...

Page 294: ...actuator cruise control module ABS TCS control module to isolate brake switch Key on engine off Is brake light still on Yes SERVICE short to power in brake light circuit RECONNECT PCM brake switch and...

Page 295: ...harness connector and inspect for damage pushed out or broken pins and broken wires Service as required Measure resistance across clutch switch terminals with clutch pedal down Measure resistance acr...

Page 296: ...used Yes Go to next step No COMPLETE self test using correct procedure 2 CHECK FOR CONSTANT VOLTAGE AT TP SENSOR Key off TP sensor disconnected Key on engine off Measure voltage between constant volta...

Page 297: ...s Yes Go to next step No SERVICE open in DLC power circuit RERUN OBD Test 8 CHECK DLC CHASSIS GROUND CONTINUITY Key off Measure resistance between chassis ground circuit cavity at DLC and chassis grou...

Page 298: ...UIT CONTINUITY Key off Breakout box installed Leave PCM disconnected Measure resistance between Test Pin 16 at breakout box and BUS circuit at DLC Is resistance less than 5 0 ohms Yes Go to next step...

Page 299: ...ified value tr 01 40B MASS AIR FLOW SENSOR INSPECTION KL Yes DISCONNECT and INSPECT MAF sensor connector If okay REPLACE MAF sensor RESET PCM to completely clear DTCs t r After Repair Procedure COMPLE...

Page 300: ...Disconnect PCM Inspect for damaged or pushed out pins corrosion loose wires etc Service as necessary NGS tester connected Install breakout box Connect PCM to breakout box Key on engine off Measure bet...

Page 301: ...Measure voltage between Test Pin 88 at breakout box and battery negative post Is voltage between 0 34 and 1 96 volts at idle Yes MAF signal circuit to PCM is okay Go to next step No MAF signal circuit...

Page 302: ...E OBD II Drive Mode RERUN OBD Test 12 CHECK PCM GROUND CIRCUIT BETWEEN PCM AND MAF SENSOR GROUND CIRCUIT FOR SHORT TO GROUND CIRCUITS Key off MAF sensor disconnected Breakout box installed PCM disconn...

Page 303: ...sor Measure voltage between constant voltage circuit and TP sensor ground circuit at TP sensor vehicle harness connector Is voltage between 4 5 volts and 5 5 volts Yes There is sufficient constant vol...

Page 304: ...TAGE Key off TP sensor disconnected Key on engine off Measure voltage between constant voltage circuit and TP sensor ground circuit at TP sensor vehicle harness connector Is voltage between 4 0 and 6...

Page 305: ...or and throttle body including air noise sounds while engine is running SERVICE as necessary if okay REPLACE TP sensor RERUN OBD Test No Go to next step 4 CHECK TP SENSOR SIGNAL LOW VERSUS ENGINE LOAD...

Page 306: ...ION 1 CHECK FOR TP CIRCUIT INTERMITTENT VOLTAGE INPUT Start engine and bring to Idle Run engine up to 1 500 rpm for 5 seconds Key on engine running Access TP V PID for fault indication with NGS tester...

Page 307: ...t temperature modeling which allows for upstream heaters being energized independent of downstream heaters Possible Cause Exhaust system too cool STEP INSPECTION ACTION 1 CHECK HEATED OXYGEN SENSOR HE...

Page 308: ...sconnect PCM Inspect for damaged or pushed out pins corrosion loose wires etc Service as necessary Install breakout box Leave PCM disconnected Key on engine off Measure voltage between Test Pin 19 PRC...

Page 309: ...sion loose wires etc Service as necessary Measure resistance between following terminals EGR valve connector and battery negative post Test Pin 68 Test Pin 72 Test Pin 46 Test Pin 56 Is each resistanc...

Page 310: ...ter Perform continuous memory self test Are any continuous memory DTCs displayed Yes Go to appropriate DTC test No Go to next step 3 PERFORM KOEO SELF TEST Key off NGS tester connected Key on engine o...

Page 311: ...ed Measure resistance between EGR boost solenoid valve circuit at EGR boost solenoid valve connector Test Pin 98 at breakout box Is resistance less than 5 0 ohms Yes Go to next step No SERVICE open ci...

Page 312: ...Drive Mode to check for DTCs 14 CHECK EGR CONTROL SIGNAL CIRCUIT SHORT TO GROUND Key off EGR valve disconnected Disconnect PCM Measure resistance between following terminals EGR valve connector and b...

Page 313: ...HORT TO GROUND CIRCUIT Key off Purge solenoid valve disconnected Breakout box installed PCM disconnected Disconnect NGS tester from DLC Measure resistance between Test Pin 67 and Test Pins 24 and 103...

Page 314: ...ure COMPLETE OBD II Drive Mode RERUN OBD Test 3 CHECK RESISTANCE OF CDCV CIRCUIT Key off Disconnect CDCV and PCM Inspect for damaged or pushed out pins corrosion and loose wires Service as necessary I...

Page 315: ...Mode RERUN OBD Test No RETURN to Action to Take column of Pinpoint Test Step that directed you here DTC P1460 Wide open throttle air conditioning cutoff circuit malfunction DESCRIPTION Key on engine o...

Page 316: ...om DLC Breakout box installed PCM disconnected Measure resistance between Test Pin 69 at breakout box and chassis ground Is resistance greater than 10 000 ohms Yes Go to next step No SERVICE short to...

Page 317: ...necessary REMOVE jumper wire RECONNECT all components RESET PCM completely clear DTCs w After Repair Procedure START engine TURN A C to ON WAIT 15 seconds A C off Key off RERUN OBD Test No Go to next...

Page 318: ...ge between Test Pin 41 at breakout box and chassis ground A C switch ON 0 V A C switch OFF 12 V Are voltages correct Yes Go to next step No Go to step 6 5 CHECK CONTINUITY OF A C RELAY CIRCUIT Key off...

Page 319: ...NTROL SIGNAL CIRCUIT CYCLING Key on engine off Applicable fan relay disconnected NGS tester connected Access Output Test Mode Connect non powered test lamp between power circuit and cooling fan contro...

Page 320: ...an circuit for short to ground REMOVE breakout box RECONNECT all components RERUN OBD Test 5 CHECK COOLING FAN CONTROL SIGNAL OR CONDENSER FAN CONTROL SIGNAL CIRCUIT RESISTANCE Key off Appropriate fan...

Page 321: ...r Repair Procedure COMPLETE OBD II Drive Mode RERUN OBD test while performing following lamp will turn off when fault detected indicating open or short to power Shake wiggle bend cooling fan control c...

Page 322: ...s detected indicating an open or short to power Shake wiggle and bend condenser fan circuit between PCM and cooling fan relay Shake wiggle and bend power circuit to condenser fan relay Lightly tap on...

Page 323: ...Disconnect PCM Inspect for damaged or pushed out pins corrosion loose wires etc Repair as necessary Install breakout box Leave PCM disconnected Key on engine off Measure voltage between Test Pin 98 at...

Page 324: ...r connection or component malfunction REPAIR or REPLACE as necessary DTC P1506 Idle air control IAC system overspeed error DESCRIPTION DTC P1506 indicates self test has detected an IAC system over spe...

Page 325: ...istance greater than 10 000 ohms Yes For Fast Idle Symptom currently present REPLACE PCM REMOVE breakout box RECONNECT all components RERUN OBD Test All others RECONNECT all components Go to next step...

Page 326: ...Battery IU L Ignition switch black white Is there open circuit Yes Repair wiring harness No Go to next step 6 CHECK WIRING HARNESS SHORT CIRCUIT Check for wiring harness short circuit with IU connecto...

Page 327: ...ed and reprogramming system Possible Cause Unregistered key is used in step 3 of immobilizer system Transformation of key ID number stored in PCM reprogram procedure IU replacement STEP INSPECTION ACT...

Page 328: ...ted to start more than three times under malfunction STEP INSPECTION ACTION 1 CHECK DTC P1624 PRESENT RESET PCM to completely clear DTCs t r After Repair Procedure RERUN OBD test Is P1624 still presen...

Page 329: ...Disconnect PCM Inspect for damaged or pushed out pins corrosion loose wires etc Service as necessary Install breakout box Leave PCM disconnected Measure resistance between Test Pin 31 at breakout box...

Page 330: ...n loose wires etc Service as necessary Install breakout box Leave PCM disconnected Measure resistance between Test Pin 31 at breakout box and PSP switch vehicle harness connector Is resistance less th...

Page 331: ...test Key off Disconnect brake switch Measure power circuit input voltage between brake switch and chassis ground Is voltage greater than 10 volts Yes Go to next step No SERVICE open power circuit to b...

Page 332: ...never on Go to step 6 if brake light Is always on 3 CHECK FOR PCM BOO PID CYCLING Key on engine off Access BOO PID Apply and release brake pedal several times while viewing BOO PID Note If BOO PID is...

Page 333: ...PCM Key off Brake switch disconnected Key on Is brake light still on Yes Go to next step No REPLACE PCM RECONNECT brake switch RERUN OBD Test 8 CHECK FOR SHORT TO POWER CIRCUIT IN SHIFT LOCK ACTUATOR...

Page 334: ...ucks jerks during acceleration cruising or deceleration Hesitation stumble Acceleration Momentary pause at beginning of acceleration or during acceleration Surges Acceleration cruise Momentary minor i...

Page 335: ...saxle Upshift downshift concerns engagement Automatic transaxle concerns not related to engine performance 29 Fuel refill Issues Fuel tank does not refill smoothly 30 Fuel refilling shut off issues Fu...

Page 336: ...ine stalls After start X X X X X X X X X X X X X X X X X X At idle X X X X X X X X X X X X X X X X X X 5 Cranks normally but will not start X X X X X X X X X X X X X X X X X 6 Slow return to idle X X...

Page 337: ...nock sensor and related circuit TJ X X X X O O Immobilizer system operation X Malfunction of FEPS circuit TO X X u cr Malfunction of power steering pressure switch and related circuit cr X x X X x X X...

Page 338: ...der high pressure Warning Fuel line spills and leaks 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 t...

Page 339: ...erator BTN 40 A BTN fuse ROOM fuse ROOM 15 A ROOM fuse PCM terminal EGI INJ 30 A Main relay Fuel injectors Generator EGR boost solenoid valve PRC solenoid valve EGR valve Idle air control valve Purge...

Page 340: ...any other electrical accessories work Yes Go to next step No Check charging system a 01 17 GENERATOR INSPECTION 5 Note Following test should be performed on automatic transaxles only For manual transa...

Page 341: ...EPAIR PROCEDURE o 01 14 AFTER REPAIR PROCEDURE STEP INSPECTION ACTION 1 Verify follows Vacuum leaks Fuel quality i e proper octane contamination winter summer blend Loose bands on intake air system Cr...

Page 342: ...hose to pressure regulator Install vacuum gauge to intake manifold Start engine Does fuel pressure gauge reading increase as vacuum gauge reading decreases and or does fuel pressure gauge reading dec...

Page 343: ...e stalled after approx 2 seconds since engine is started Yes Go to next step No Immobilizer system is okay 3 Is immobilizer unit connector securely connected to immobilizer unit Yes Go to next step No...

Page 344: ...e any DTCs displayed Yes DTC displayed Go to appropriate DTC test No If communication error message is displayed on NGS tester check following Open circuit between main relay and PCM using breakout bo...

Page 345: ...lter and fuel distributor Connect NGS tester to DLC In OUTPUT TEST MODE select ALL ON and press start Is fuel line pressure correct with ignition switch ON Fuel line pressure 260 310kPa 2 6 3 2 kgf cm...

Page 346: ...y to PCM Open PCM ground or vehicle body ground EGR valve malfunction Low engine compression Vacuum leak Poor fuel quality Air cleaner restriction Disconnect electrical connector disconnection Inadequ...

Page 347: ...ollowing External fuel shut off or accessory ignition switch alarm etc Fuel quality such as proper octane contamination winter summer blend No air leaks from intake air system Proper sealing of intake...

Page 348: ...o ground in constant voltage circuit between TP sensor EGR boost sensor or fuel tank pressure FTP sensor and powertrain control module 23 Disconnect NGS tester Turn ignition switch on Check terminal v...

Page 349: ...urn to diagnostic index to service any additional symptoms 6 SLOW RETURN TO IDLE DESCRIPTION Engine takes more time than normal to return to idle speed POSSIBLE CAUSE Malfunction of ECT sensor Thermos...

Page 350: ...system service 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 leaks are dangerous Fuel can ignite and...

Page 351: ...Is there any crack on high tension leads Yes Repair suspected high tension lead No Go to next step 9 Check spark plug conditions Is spark plug wet converted with carbon or grayish white Yes If spark p...

Page 352: ...g EGR valve housing Does engine condition improve Yes Replace EGR valve No Go to next step 19 Is engine compression correct Yes Check valve timing No Check for causes 20 Verify test results If okay re...

Page 353: ...valve Yes Go to next step No Check following Circuit from idle air control valve to PCM for open and short Idle air control valve for sticking If okay go to next step 5 Disconnect vacuum hose between...

Page 354: ...r cleaner restriction Improper valve timing due to jumping out timing belt Intermittently open short in fuel pump circuit Fuel pump mechanical malfunction Fuel injector clogged Clutch slippage Warning...

Page 355: ...CKP sensor and teeth of crankshaft pulley okay Yes Go to next step No Replace malfunctioning part 7 Measure gap between crankshaft position CKP sensor and teeth of crankshaft pulley Specification 0 5...

Page 356: ...with cruise control ON If other symptoms exist go to next step Check cruise control system Is cruise control system okay Yes Go to next step No Repair or replace 16 Disconnect vacuum hose between purg...

Page 357: ...gnite causing serious injury and damage Always keep sparks and flames away from fuel Fuel line spills and leaks are dangerous Fuel can ignite and cause serious injuries or death and damage Fuel can al...

Page 358: ...s wet or converted with carbon check for fuel leak from fuel injector If spark plug is grayish white check for clogged fuel injector No Install spark plugs on original cylinders Go to next step 9 Remo...

Page 359: ...follows Wrong connection of VRIS solenoid valves connectors Wrong routing of vacuum hoses Vacuum leaks from vacuum hoses VRIS actuator No 1 or No 2 stuck to open or close 16 Visually inspect camshaft...

Page 360: ...t NGS tester to DLC A r r o c c P O T P1I Verify ECT PID is less than 116 C 240 8 F during driving Is ECT PID less than specification Yes Go to next step No Inspect cooling system for cause of overhea...

Page 361: ...BEFORE REPAIR PROCEDURE and AFTER REPAIR PROCEDURE described in this manual cr 01 14 BEFORE REPAIR PROCEDURE cr 01 14 AFTER REPAIR PROCEDURE STEP INSPECTION ACTION 1 Check following Contaminated air c...

Page 362: ...est is failed POSSIBLE CAUSE Vacuum lines leaks or blockage Spark plug malfunction Erratic or no signal from camshaft position sensor PCV valve malfunction or incorrect valve installation Exhaust syst...

Page 363: ...Start engine and run it at idle Measure fuel line pressure at idle Is fuel line pressure correct at idle Fuel line pressure 210 260 kPa 2 1 2 6 kgf cm2 30 37 psi Yes Go to next step No Zero or low Ch...

Page 364: ...IL bulb Is voltage correct on positive side of MIL bulb socket Specification More than 10 5 V Yes Go to next step No Repair open circuit in wiring harness between fuse block and MIL bulb socket 5 Appl...

Page 365: ...r less thermostat has opened Is thermostat opening voltage okay Thermostat opening voltage Approx 0 6 0 9 V Yes Engine coolant temperature and thermostat are okay Go to next step No Remove thermostat...

Page 366: ...rmostat malfunction Malfunction of cooling fan system Malfunction of condenser fan system STEP INSPECTION ACTION 1 Is customer s any complaint Lack of passenger compartment heat Yes Check A C and heat...

Page 367: ...in this manual cr 01 14 BEFORE REPAIR PROCEDURE w 01 14 AFTER REPAIR PROCEDURE STEP INSPECTION ACTION 1 What color is smoke coming from exhaust system Blue Burning oil Indicated Go to next step White...

Page 368: ...r clogged main fuel line High Check pressure regulator for high pressure cause Check for clogged fuel return line 7 Does fuel line pressure remain at specification for 60 seconds when ignition switch...

Page 369: ...check for fuel leakage at fuel injector O ring pressure regulator and fuel line Sen ice as necessary Install fuel pressure gauge between fuel filter and fuel delivery pipe Start engine and run at idl...

Page 370: ...leaks Spark plug loose Intake air system leaks No Go to next step 5 Is rap or roar sound present Yes Check exhaust system for loose parts No Go to next step 6 Is knock sound present Yes Go to flow ch...

Page 371: ...C switch on Is there correct voltage at terminal of A C compressor magnet clutch connector Specification More than 10 5 V Yes Check for ground condition of A C compressor magnet clutch If ground condi...

Page 372: ...urn A C switch on Read ACCS PID while disconnecting high pressure switch connector Note ACCS PID should read OFF when disconnecting connector If ACCS PID reading remains ON short to ground circuit may...

Page 373: ...TP sensor loosely installed STEP INSPECTION ACTION 1 Does A C turn off when A C switch is turned off Yes Go to next step No Go to flowchart 24 for A C ALWAYS ON A C COMPRESSOR RUNS CONTINUOUSLY 2 Retr...

Page 374: ...ust smoke concern present Yes Go to appropriate flow chart No Go to next step 2 Check following Electrical connections Vacuum lines Are all items okay Yes Go to next step No Service as necessary Repea...

Page 375: ...k for abrupt changes in PID values Are any PID values out of range or suddenly drop out and back into range Yes Possible wiring or component problem Check each wire for corrosion bent or loose termina...

Page 376: ...n valve to the proper position If the non return valve does not operate properly Replace the non return valve 30 FUEL REFILLING SHUT OFF ISSUES DESCRIPTION Fuel refill does not shut off properly POSSI...

Page 377: ...d battery negative terminal Is voltage greater than 10 5 volts Yes Reconnect VRIS solenoid valve No 1 solenoid connector Go to next step No Repair open power circuit 6 Key OFF Leave TP sensor disconne...

Page 378: ...sensor connector and test pin 91 at breakout box Is resistance less than 5 0 ohms Yes Reconnect sensor connector Go to next step No Repair open ground circuit 13 Key OFF Disconnect NGS tester from DL...

Page 379: ...system service 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 leaks are dangerous Fuel can ignite and...

Page 380: ...rous 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 described in...

Page 381: ...TEP INSPECTION ACTION 1 Is air cleaner element free of clogs Yes Go to next step No Replace air cleaner element 2 Carry out spark test Is a strong blue spark visible at each cylinder Yes Go to next st...

Page 382: ...Fuel line pressure 260 310 kPa 2 6 3 2 kgf cm2 37 46 psi at ignition switch ON Yes Check following PID MAF PID vr 01 40B MASS AIR FLOW SENSOR INSPECTION KL ECT PID et 01 40B ENGINE COOLANT TEMPERATURE...

Page 383: ...ition Headlight Cooling fan Blower motor A C switch and fan switch ON Note Excludes temporary idle speed drop immediately after the electrical loads are turned ON 6 If not as specified check the relat...

Page 384: ...to 01 14 BEFORE REPAIR PROCEDURE 01 14 AFTER REPAIR PROCEDURE 1 Disconnect the negative battery cable 2 Install a fuel pressure gauge between the fuel filter and the main fuel hose Install clamps as...

Page 385: ...el pressure is not within the specification carry out either Inspection 1 or Inspection 2 as required Inspection 1 1 Connect the SSTs NGS tester to the DLC 2 Access the following PIDs ECTPID Refer to...

Page 386: ...stops to work Then 3 6 seconds after check if the operation sound of the A C compressor electromagnetic clutch is heard 5 Turn the A C switch and the fan switch OFF 6 If the operation sound is not hea...

Page 387: ...Specification 0 5 1 5 mm 0 020 0 059 in PCM terminal 21 22 voltage Specification Approx 1 5 V Yes Check for open or short in wiring harness and connectors of CKP sensor No Repair or replace Fuel Cut...

Page 388: ...operating 10 If fan does not operate check A C system Condenser fan relay 1 Verify that the A C switch and fan switch are off 2 Start the engine and let it idle 3 Verify that the condenser fan is not...

Page 389: ...ooting chart describe the possible cause with step numbers Use the troubleshooting hint as reference of further diagnostic procedures No Malfunction symptom 1 Set speed is not kept even when SET switc...

Page 390: ...e control switch malfunction Malfunction of Brake on off signal and related parts Malfunction in wiring harness between brake switch and cruise actuator Malfunction in wiring harness between STOP 15 A...

Page 391: ...r cable to accelerator pedal and cruise actuator link Are they securely and properly connected Yes Go to next step No Connect actuator cable securely and properly then go to step 37 10 Remove actuator...

Page 392: ...7 16 Inspect transaxle range switch tr 05 17A ELECTRICAL SYSTEM COMPONENT FS o 05 17B TRANSAXLE RANGE SWITCH INSPECTION KL Is it okay ________________________________ Yes Go to next step No Inspect po...

Page 393: ...cluster Inspect continuity between terminal 2B of instrument cluster 14 pin and terminal 2C of instrument cluster 14 pin Is there continuity Yes Repair wiring harness from cruise actuator to instrumen...

Page 394: ...terminal A cruise control switch position signal and B cruise control switch position signal of clock spring Is resistance at 228 to 252 i2 Yes Repair wiring harness from cruise actuator to clock spri...

Page 395: ...ring connected to TURN 10 A fuse or cruise control switch then go to step 37 No Replace cruise control switch then go to step 37 28 Measure voltage at terminal B brake on off signal and G brake on off...

Page 396: ...age 12 V Yes Go to next step No Repair wiring harness from STOP 15 A fuse to brake switch then go to step 37 W 6 U 1 0 1 W P G 32 Measure voltage at terminal C brake on off signal of brake switch conn...

Page 397: ...ensor connector of wiring harness and ground Is there continuity Yes Go to next step N f A 1 is P r w 1 3U101WPK No Repair wiring harness from vehicle speedometer sensor to ground then go to step 37 3...

Page 398: ...ument cluster and cruise actuator Combination meter base malfunction STEP INSPECTION ACTION Inspect METER 10 A fuse Is it okay METER 10 A FUSE W6U101WPL Yes Go to next step No Replace fuse then go to...

Page 399: ...wiring harness Is voltage 12 V Yes Repair wiring harness from instrument cluster to cruise actuator then go to step 7 No Go to next step 11 i 1 Ci iX L m 1J W 6 U 1 0 1 W P P Remove instrument cluster...

Page 400: ...vehicle operate normally Yes Troubleshooting completed No Reconfirm the symptoms of the trouble If the trouble persists go back to step 1 4 While driving at the set speed the speed can not be cancele...

Page 401: ...ch switch connector of wiring harness and ground while clutch pedal is depressed Is there continuity Yes Repair wiring harness from cruise actuator to clutch switch then go to step 13 No Go to next st...

Page 402: ...le range switch Inspect continuity between the following of transaxle range switch connector of wiring harness and ground KL B terminal FS 4 terminal Is there continuity Yes Inspect transaxle range sw...

Page 403: ...rouble persists go back to step 1 6 While driving at the set speed the set speed is canceled although the cancel operation has not been executed TROUBLESHOOTING HINTS Customer misunderstood the system...

Page 404: ...Oil Seal Installation N o te 01 10A 13 ENGINE REMOVAL INSTALLATION F S 01 10A 13 No 4 Engine Mount Bracket Installation Note 01 10A 14 ENGINE DISASSEMBLY ASSEMBLY F S 01 10A 15 ENGINE TUNE UP FS 01 10...

Page 405: ...turning the adjusting bolt C Refer to 01 1OA DRIVE BELT INSPECTION FS 3 Tighten mounting bolts A and nut B P S P S A C 44 60 A 4 4 6 2 32 44 GENERATOR A 19 25 1 9 2 6 14 18 B 38 51 3 8 5 3 28 38 A C...

Page 406: ...re positioned straight up 2 Remove the camshaft cap bolts as necessary Remove only one pair of cap bolts at a time Install the cap bolts before removing the next pair EX side No 1 2 3 cylinder adjustm...

Page 407: ...m Fuel Line Safety Procedures Leave the fuel pump relay removed Refer to 01 14 BEFORE REPAIR PROCEDURE 5 Remove the spark plugs 6 Disconnect the ignition coil connector 7 C onnect a com pression gauge...

Page 408: ...40A CRANKSHAFT POSITION SENSOR INSPECTION FS 8 Start the engine and 1 Inspect for the pulleys and drive belt for runout and contact 2 Verify the ignition timing Refer to 01 1 OA ENGINE TUNE UP FS Igni...

Page 409: ...tion on the belt for proper reinstallation 4 FAULTY 25 mm 1 0 in MIN I W6U110WAL W6U110WAH No 3 Engine Mount Rubber Removal Note 1 Suspend the engine by using the chain block 2 Remove the No 3 engine...

Page 410: ...seness at the idler side W6U110WAR 3 Turn the crankshaft clockwise twice and align the timing marks 4 Verify that all timing marks are correctly aligned If not aligned remove the timing belt and repea...

Page 411: ...ures Refer to 0 1 1 4 BEFORE REPAIR PROCEDURE 1 Rem ove the tim ing belt Refer to 0 1 1 0A TIM ING BELT REMOVAL INSTALLATION FS 2 Remove the front pipe Refer to 01 15 EXHAUST SYSTEM REMOVAL INSTALLATI...

Page 412: ...allation Note Camshaft or Removal Note tj Installation Note Camshaft Pulley Removal Note Hold the camshaft by using a wrench on the cast hexagon as shown and loosen the camshaft pulley lock bolt 3 Int...

Page 413: ...a of the cylinder head journal To avoid this the following procedure must be observed 1 Assemble camshaft onto the cylinder head facing the cam noses at No 1 and No 3 cylinders as shown CYLINDER W 6 U...

Page 414: ...der shown Tightening torque 11 3 14 2 N m 115 145 kgf cm 100 125 in lbf 7 Verify that the camshaft settles horizontally when two bearing cap bolts at No 3 journal are tightened 8 Apply clean engine oi...

Page 415: ...a rag Front Oil Seal Installation Note 1 Apply clean engine oil to the oil seal lip 2 Push the oil seal slightly in by hand 3 Tap the oil seal in evenly by using the SST and a hammer HAMMER 49 H010 40...

Page 416: ...he air cleaner 4 Remove the accelerator cable Refer to 01 13A ACCELERATOR CABLE INSPECTION ADJUSTMENT FS 5 Disconnect the fuel hose Refer to 01 14 BEFORE REPAIR PROCEDURE Refer to 01 14 AFTER REPAIR P...

Page 417: ...e mount bracket or Installation Note 8 Engine transaxle 1 No 5 engine mount rubber 2 Engine mount member 3 No 1 engine mount stay bracket 4 No 3 engine mount rubber 5 No 1 engine mount bolt and nut No...

Page 418: ...the oil filter Refer to 01 11 OIL FILTER Oil Filter Replacement 5 Remove the thermostat Refer to 01 12 THERMOSTAT REMOVAL INSTALLATION 6 Remove the ignition coil 7 Remove the generator 8 Disassemble i...

Page 419: ...tment 4 Connect a timing light to the high tension lead of the No 1 cylinder 5 Verify that the timing mark yellow is within the specification W6U110W24 6 If not as specified inspect the following Cams...

Page 420: ...AND RECORD and press the TRIGGER 2 Verify that the HDLMP status changes from OFF to ON when the headlight switch is turned to the passing position If it does not change inspect following harnesses con...

Page 421: ...tch are on 4 Steering wheel is fully turned 4 If not as specified with all load conditions inspect the idle air control valve 5 If not as specified with some load conditions inspect related input swit...

Page 422: ...PLACEMENT K L 01 10B 16 Rear Oil Seal Removal N ote 01 10B 16 Rear Oil Seal Installation N o te 01 10B 16 ENGINE REMOVAL INSTALLATION K L 01 10B 17 No 4 Engine Mount Bracket Installation Note 01 10B 1...

Page 423: ...BELT ADJUSTMENT KL 1 Loosen locknut A 2 Adjust the belt deflection or tension by turning the adjusting bolt B Refer to 01 1 OB DRIVE BELT INSPECTION KL 3 Tighten locknut A GENERATOR GENERATOR A C 3 2...

Page 424: ...9 If the valve clearance exceeds the standard replace the adjustment shim Refer to 01 10B VALVE CLEARANCE ADJUSTMENT KL 5 Install the cylinder head cover Refer to 01 10B CYLINDER HEAD GASKET REPLACEM...

Page 425: ...SST on the tappet by its notch 9 Tighten bolt B to secure the SST body 10 Tighten bolt C and press down the tappet W 6 U 1 1 0 W C 2 12 Select proper adjustment shim New adjustment shim Removed shim...

Page 426: ...49 H010 103 W 6 U 1 1 0 W 1 6 Compression ________________________________ kPa kgf cm2 psi rpm Standard 1 393 14 2 202 250 Minimum 971 9 9 141 250 Maximum difference between cylinders 196 kPa 2 0 kgf...

Page 427: ...e engine and 1 Inspect for the pulleys and drive belt for runout and contact 2 Verify the ignition timing Refer to 01 10B ENGINE TUNE UP KL Ignition Timing Adjustment N m kgf m ft lbf W 6 U 1 1 0 W C...

Page 428: ...lt holes are aligned otherwise the threads can be damaged 3 Remove the No 1 idler pulley Timing Belt Removal Note Caution When removing the bolt hold the tensioner so that the bolt holes are aligned o...

Page 429: ...one to reduce the timing belt resistance when the idler pulley is installed 1 Set the tensioner in place and hand tighten the tensioner upper bolt W 6 U 1 1 0 W C G 2 Turn the camshafts clockwise and...

Page 430: ...ng 6 Install the No 1 idler while applying the pressure on the timing belt No 1 IDLER W 6 U 1 1 0 W C L 7 Push the auto tensioner in the direction of the arrow and hand tighten the lower bolt Tighten...

Page 431: ...BEFORE REPAIR PROCEDURE Refer to 01 14 AFTER REPAIR PROCEDURE 6 Drain the engine coolant Refer to 01 12 ENGINE COOLANT REPLACEMENT 7 Remove in the order indicated in the table 8 Install in the reverse...

Page 432: ...hown and loosen the camshaft pulley lock bolt W 6 U 1 1 0 W C T Camshaft Removal Note Caution When the camshaft lobe is pressing on the tappet removing the camshaft cap can damage the cylinder head th...

Page 433: ...Gasket Installation Note Install the new cylinder head gaskets on the cylinder block R mark for RH L mark for LH W 6 U 1 1 0 W C Y Cylinder Head installation Note 1 Before installation measure the le...

Page 434: ...erwise excessive force will be applied to the thrust area causing burr on the thrust receiving area of the cylinder head journal To avoid this the following procedure must be observed t J J W 6 U 1 1...

Page 435: ...fy that the grooves on the cylinder head cover are free of oil water and other foreign material 2 Install the new cylinder head cover gasket into the cylinder head cover 3 Apply silicone sealant to th...

Page 436: ...ve the oil seal by using a screwdriver protected with a rag W 6 U 11 0 W D L W6U110WDK 1 Timing belt pulley 2 Key 3 Front oil seal a Removal Note T Installation Note Front Oil Seal Installation Note 1...

Page 437: ...ove the oil seal by using a screwdriver DRIVE PLATE REMOVAL INSTALLATION protected w h a rag GF4A EL 3 Remove in the order indicated in the table 4 Install in the reverse order of removal W6U110WDN Re...

Page 438: ...REPAIR PROCEDURE 6 Remove the front pipe Refer to 01 15 EXHAUST SYSTEM REMOVAL INSTALLATION 7 Remove the rods cables and pipes related to the transaxle 8 Remove the battery 9 Remove the P S oil pump w...

Page 439: ...NSAXLE REMOVAL INSTALLATION Refer to 05 17B TRANSAXLE REMOVAL INSTALLATION GF4A EL 2 Remove the intake air system 3 Remove the exhaust system 4 Remove the oil filter Refer to 01 11 OIL FILTER Oil Filt...

Page 440: ...eed Refer to Idle Speed Adjustment 4 Connect a timing light to the high tension lead of the No 1 cylinder 5 Verify that the timing mark yellow is within the specification W6U110W23 Specification BTDC...

Page 441: ...d terminals of the headlight signal circuit From battery to combination switch From combination switch to PCM 3 Connect the inductive pick up type tachometer to the high tension lead Note The inductiv...

Page 442: ...tions check related input switches harnesses and connectors Idle Mixture Inspection 1 Perform Engine Tune up Preparation 2 Verify that the idle speed and ignition timing are within the specification 3...

Page 443: ...ontinuous exposure with USED engine oil has caused skin cancer in laboratory mice Protect your skin by washing with soap and water immediately after this work 1 Position the vehicle on level ground 2...

Page 444: ...the oil pressure switch 3 Screw the SST into the oil pressure switch installation hole FS W 6 U 1 1 1 W A 2 KL W 6 U 1 1 1 W 0 4 5 Run the engine at the specified speed and note the gauge readings No...

Page 445: ...following instructions before removing the oil pan 1 Screw a oil pan bolt in a weld nut hole to make a small gap between the oil pan upper block and the oil pan FS WELD NUT W 6 U 1 1 1 W A 7 W 6 U 1 1...

Page 446: ...LUBRICATION SYSTEM Apply silicone sealant to the oil pan along the inside of the bolt holes and overlap the ends Thickness 02 0 3 0 mm 0 079 0 118 in W 6 U 1 1 1 W A B 01 11 4...

Page 447: ...calding coolant and steam may shoot out and cause serious injury It may also damage the engine and cooling system Turn off the engine and wait until it is cool Even then be very careful when removing...

Page 448: ...r port FS or into the engine up to the coolant filler port KL Filling pace 1 0 L 1 1 US qt 0 9 Imp qt min max W6U112W03 SPECIFIC COOLANT PROTECTION 14 32 50 68 86 104 122 140 158 176 194 COOLANT TEMPE...

Page 449: ...ngs and other components and cause leaks 4 Apply pressure to the radiator Pressure 123 kPa 1 25 kgf cm2 17 8 psi 5 Verify that the pressure is held If not inspect the system for coolant leakage RADIAT...

Page 450: ...move the oil pipe FS ATX 6 Remove in the order indicated in the table 7 Install in the reverse order of removal FS W 6 U 1 1 2 W 0 6 1 Cooling fan component d Installation Note 2 Radiator Cooling Fan...

Page 451: ...U 1 1 2 W A 7 1 Lower radiator hose 2 Thermostat cover 3 Thermostat xr Installation Note W 6 U 1 1 2 W 0 7 1 Water inlet pipe MTX Oil cooler ATX 2 Thermostat cover 3 Thermostat XT Installation Note T...

Page 452: ...2 W 0 8 W 6 U 1 1 2 W A H WATER PUMP REMOVAL INSTALLATION 1 Remove the timing belt Referto 01 1OA TIMING BELT REMOVAL INSTALLATION FS Referto 01 10B TIMING BELT REMOVAL INSTALLATION KL 2 Drain the en...

Page 453: ...the cooling fan motor operates smoothly at the standard current draw Item Engine FS KL Current A 6 0 9 0 5 If not as specified replace the cooling fan motor COOLING FAN MOTOR REMOVAL INSTALLATION 1 Re...

Page 454: ...d replace the cooling fan relay O O Continuity Step Terminal A B C D 1 O 0 2 B GND o O W 6 U 1 1 2 W A K 1 Disconnect the negative battery cable 2 Remove the cooling fan relay 3 Apply battery positive...

Page 455: ...01 13A 3 IDLE AIR CONTROL IAC VALVE INSPECTION FS 01 13A 3 ACCELERATOR PEDAL REMOVAL INSTALLATION F S 01 13A 3 Accelerator Cable Installation Note 01 13A 3 ACCELERATOR CABLE INSPECTION ADJUSTMENT FS 0...

Page 456: ...r to 01 12 ENGINE COOLANT REPLACEMENT 3 Remove in the order indicated in the table 4 Install in the reverse order of removal 5 Refill the engine coolant to radiator Refer to 01 12 COOLING SYSTEM SERVI...

Page 457: ...itch is OFF 2 Disconnect the IAC valve connector 3 Measure the resistance between the IAC valve terminal by using an ohmmeter Resistance 7 7 9 3 n 23 C 73 4 F ACCELERATOR PEDAL REMOVAL INSTALLATION FS...

Page 458: ...fication adjust the accelerator cable as follows 1 Move the white loocking tab A to the unlock position 2 Turn stopper B to the unlock position Note If stopper B will not unlock it may be necessary to...

Page 459: ...VALVE ACTUATOR No 2 INSPECTION KL 01 13B 4 VARIABLE RESONANCE INDUCTION SYSTEM VRIS CHECK VALVE ONE WAY INSPECTION K L 01 13B 4 VARIABLE RESONANCE INDUCTION SYSTEM VRIS SOLENOID VALVE No 1 No 2 INSPEC...

Page 460: ...0 12 ENGINE COOLANT REPLACEMENT 3 Remove in the order indicated in the table 4 Install in the reverse order of removal 5 Refill the engine coolant to radiator Refer to 01 12 COOLING SYSTEM SERVICE WAR...

Page 461: ...ntake manifold gasket make sure that the convex side of gasket is faced to the intake manifold side IDLE AIR CONTROL IAC VALVE INSPECTION KL 1 Verify that the ignition switch is OFF 2 Disconnect the I...

Page 462: ...ALVE ACTUATOR No 2 INSPECTION KL W 6 U 1 1 3 W 5 5 1 Disconnect the vacuum hose from the VRIS shutter valve actuator No 2 2 Connect the vacuum pump to the VRIS shutter valve actuator No 2 Vacuum kPa m...

Page 463: ...U 1 1 3 W B 9 3 If not as specified replace the necessary parts ACCELERATOR PEDAL REMOVAL INSTALLATION KL 1 Remove in the order indicated in the table 2 Install in the reverse order of removal W 6 U...

Page 464: ...ion adjust the accelerator cable as follows 1 Move the white locking tab A to the unlock position 2 Turn stopper B to the unlock position Note If stopper B will not unlock it may be necessary to caref...

Page 465: ...1 14 14 Volume Test K L 01 14 15 PRESSURE REGULATOR REMOVAL INSTALLATION 01 14 16 PRESSURE REGULATOR INSPECTION 01 14 16 PRC SOLENOID VALVE REMOVAL INSTALLATION 01 14 17 PRC SOLENOID VALVE INSPECTION...

Page 466: ...gative battery cable be sure all fuel connections clamps and fittings are secure Fuel pump will operate at full pressure anytime the cable is connected to the battery When the cable makes contact it i...

Page 467: ...he fuel from the fuel tank Refer to Fuel Drawing Note 4 Remove in the order indicated in the table 5 Install in the reverse order of removal 6 Complete the AFTER REPAIR PROCEDURE Refer to 01 14 AFTER...

Page 468: ...ner and disconnect the fuel pipe connector W 6 U 1 1 4 W A 8 3 Cover the disconnected connector and pipe to prevent them from scratched or contaminated with foreign material RETAINER W 6 U 1 1 4 W A 9...

Page 469: ...Install a new retainer onto the connector 2 Inspect that the inside of the pipe and the connector is free of foreign material and damage Clean if necessary taking care not to damage the sealing surfac...

Page 470: ...the fuel tank FUEL SHUT OFF VALVE INSPECTION Note The fuel shut off valve is located in the fuel tank Carry out the FUEL TANK INSPECTION Refer to 01 14 FUEL TANK INSPECTION NONRETURN VALVE INSPECTION...

Page 471: ...N Fuel Pump Continuity 1 Disconnect the fuel pump connector 2 Inspect continuity between fuel pump connector terminals A and D 3 If there is no continuity carry out the Fuel Pump Maximum Pressure Insp...

Page 472: ...si 8 Disconnect the negative battery cable and remove the jumper wire 9 If not as specified carry out the Fuel Line Hold Pressure Inspection 10 Complete the AFTER REPAIR PROCEDURE Refer to 01 14 AFTER...

Page 473: ...t as specified replace the fuel pump 12 Complete the AFTER REPAIR PROCEDURE Refer to 01 14 AFTER REPAIR PROCEDURE FUEL FILTER HIGH PRESSURE SIDE REMOVAL INSTALLATION W 6 U 1 1 4 W 0 8 1 Complete the B...

Page 474: ...6 U 1 1 4 W A N 1 Fuel Injector connector 2 Fuel hose 3 Pressure regulator FUEL INJECTOR INSULATOR O RING FUEL DISTRIBUTOR INTAKE MANIFOLD W 6 U 1 1 4 W A P FUEL INJECTOR REMOVAL INSTALLATION KL 1 Com...

Page 475: ...Pressure regulator 3 Verify that the fuel distributor is clean 4 Clean the fuel distributor with gasoline if necessary 5 Install the fuel injector squarely into the fuel distributor while turning it b...

Page 476: ...Injector No Right Bank a b 1 a c 5 a d 3 Left Bank d c 2 d b 4 d a 6 Resistance 12 16 2 20 C 68 F 3 If not as specified inspect continuity of the harness and Inspect for poor connection 4 If the harne...

Page 477: ...h and damage Always carry out the following procedure with the engine stopped 1 Complete the BEFORE REPAIR PROCEDURE Refer to 01 14 BEFORE REPAIR PROCEDURE 2 Disconnect the negative battery cable 3 Re...

Page 478: ...eate a danger of ignition or explosion 12 Connect the negative battery cable to operate the fuel pump and inspect for fuel leaks from fuel injector 13 Disconnect the negative battery cable and remove...

Page 479: ...isconnect the negative battery cable 3 Remove the fuel injectors and fuel distributor component 4 Connect the SST as shown in the figure Caution Connecting the wrong fuel pum p relay socket term inals...

Page 480: ...2 7 kgf cm2 30 38 psi KL 210 250 kPa 2 1 2 6 kgf cm2 30 36 psi 7 Disconnect the vacuum hose from the pressure regulator and measure the fuel line pressure Complete the BEFORE REPAIR PROCEDURE Refer to...

Page 481: ...1 Remove the PRC solenoid valve 2 Inspect airflow between each port under the following conditions W 6 U 1 1 4 W A Z Step W 6 U 1 1 4 W 1 S O O Continuity 0 0 Airflow Terminal O B B O GND Port o o o...

Page 482: ...cool before removing or installing the exhaust system 1 Disconnect the negative battery cable 2 Remove in the order indicated in the table 3 Install In the reverse order of removal 16 22 1 6 2 3 12 22...

Page 483: ...nd wait until they are cool before removing or installing the exhaust system 1 Disconnect the negative battery cable 2 Remove in the order indicated in the table 3 Install in the reverse order of remo...

Page 484: ...LVE CDCV INSPECTION 01 16 5 CATCH TANK INSPECTION 01 16 6 ROLLOVER VALVE INSPECTION 01 16 6 PURGE SOLENOID VALVE INSPECTION 01 16 6 EGR VALVE REMOVAL INSTALLATION F S 01 16 6 EGR VALVE REMOVAL INSTALL...

Page 485: ...M EMISSION SYSTEM ENGINE COMPARTMENT SIDE COMPONENT LOCATION KL W 6 U 1 1 6 W 0 A W 6 U 1 1 6 W N 0 1 Catch tank 2 Purge solenoid valve 3 EGR valve 4 EGR boost solenoid valve 5 EGR boost sensor 6 PCV...

Page 486: ...N m 90 130 kgf cm 79 112 in lbf W 6 U 1 1 6 W A 1 1 Evaporative gas check valve two way 2 Air filter 3 Canister drain cut valve CDCV 4 Pressure control valve 5 Fuel tank pressure sensor 6 Charcoal can...

Page 487: ...gure W 6 U 1 1 6 W A 4 4 Verify that there is airflow from port D when pressure of 0 98 kPa 7 4 mmHg 0 29 inHg is applied to port A 5 If there is no airflow replace the pressure control valve 6 Set th...

Page 488: ...into port C 3 Verify that there is no air leakage W 6 U 1 1 6 W 0 6 7 9 10 7 N m 80 110 kgf cm 69 5 95 4 In lbf 2 0 3 9 N m 20 40 kgf cm 18 34 In lb f 8 9 12 7 N m 90 130 kgf cm 79 112 in lb f A 7 9...

Page 489: ...ION Refer Two rollover valves are located in the fuel to 01 14 FUEL TANK INSPECTION tank PURGE SOLENOID VALVE INSPECTION 1 Remove the purge solenoid valve 2 Inspect airflow of the valve under the foll...

Page 490: ...ction 1 Crank the engine and listen for initialization noise clicks of the EGR valve by using a screwdriver or a soundscope Note EGR valve initialization is closing action of the valve observed before...

Page 491: ...0 Airflow Step Terminal Port A B A B c 1 r k J w 2 B GND r W 6 U 1 1 6 W A K 3 If not as specified replace the EGR boost solenoid valve PCV VALVE INSPECTION 1 Remove the PCV valve 2 Blow through the...

Page 492: ...6 Battery tray W 6 U 1 1 7 W 0 2 Test load chart Step Inspection Action 1 Measure open circuit voltage of battery Above 12 4 V Go to step 3 Below 12 4 V Go to next step 2 Quick charge for 30 minutes...

Page 493: ...rom the top and surrounding area of open battery cells Caution When disconnecting the battery remove the negative cable first and install it last to prevent damage to electrical components or the batt...

Page 494: ...STEM REMOVAL INSTALLATION FS 4 Remove in the order indicated in the table 5 Install in the reverse order of removal 6 Verify the drive belt deflection tension Refer to 01 10A DRIVE BELT INSPECTION FS...

Page 495: ...6 U 1 1 7 W 0 5 Standard voltage Terminal Ignition switch ON V Idle V 20 C 68 F FS KL FS KL B B 14 1 14 7 L Approx 1 13 2 13 8 S B 14 1 14 7 6 If not as specified disassemble and inspect the generato...

Page 496: ...in the table 4 Install in the reverse order of removal W 6 U 1 1 8 W 0 1 FS 7 9 10 7 N m 80 110 kgf cm 69 5 95 4 Inlbf W 6 U 1 1 8 W A 0 1 High tension lead o 01 18 HIGH TENSION LEAD REMOVAL INSTALLA...

Page 497: ...y using a 500 V mega tester Specification Above 10 Mft W 6 U 1 1 8 W A 6 KL W 6 U 1 1 8 W A 3 3 If not as specified replace the ignition coil Secondary Coil Winding 1 Disconnect the high tension leads...

Page 498: ...lation can damage the leads and cause power loss and negatively effect the electronic components SPARK PLUG INSPECTION KL W 6 U 1 1 8 W 0 4 Caution To protect the platinum electrode 1 Do not use a wir...

Page 499: ...01 13A INTAKE AIR SYSTEM REMOVAL INSTALLATION FS Refer to 01 13B INTAKE AIR SYSTEM REMOVAL INSTALLATION KL 3 Remove the transverse member 4 Remove the intake manifold bracket FS 5 Remove the fuel fil...

Page 500: ...ed inspect the wiring harness ignition switch starter interlock switch MTX and transaxle range switch ATX No Load Test 1 Verify that the battery is fully charged 2 Connect the starter battery voltmete...

Page 501: ...STARTING SYSTEM 3 If not as specified replace the starter interlock switch 01 19 3...

Page 502: ...e negative battery cable 2 Remove in the order indicated in the table 3 Install in the reverse order of removal 4 Adjust the actuator cable Refer to 01 20 ACTUATOR CABLE ADJUSTMENT W 6 U 1 2 0 W A 2 3...

Page 503: ...40 Q Cruise control switch RESUME ACCEL switch hold at on measure the resistance between terminals E and F Approx 910 n Other check for continuity between terminals E and F No F Cruise control switch...

Page 504: ...LATION 1 Remove the actuator cable cap from the cruise actuator by pushing the tab and rotating the actuator cable cap counterclockwise W 6 U 1 2 0 W 0 4 3 Remove the actuator cable from the cruise ac...

Page 505: ...ISE CONTROL SWITCH INSPECTION 1 Disconnect the negative battery cable 2 Remove the driver side air bag module Refer to 08 10 DRIVER SIDE AIR BAG MODULE REMOVAL INSTALLATION 3 Disconnect the cruise con...

Page 506: ...MPERATURE SENSOR INSPECTION FS 01 40A 20 Inspection of Output Voltage 01 40A 20 Inspection of Resistance 01 40A 20 INTAKE AIR TEMPERATURE SENSOR INSPECTION FS 01 40A 21 Inspection of Output Voltage 01...

Page 507: ...Except California 13 Heated oxygen sensor Rear Except California 14 Clutch switch 15 Neutral switch 16 Power steering pressure switch 17 Main relay 1 PCM 2 Intake air temperature sensor 3 Mass air flo...

Page 508: ...s replaced Keep Alive Memory KAM should be cleared by disconnecting the battery terminal to erase the information stored in the PCM on the original component POWERTRAIN CONTROL MODULE PCM INSPECTION F...

Page 509: ...ction according to diagnostic trouble code Diagnostic trouble code output is a part of serial communication Judgment by terminal voltage is not possible On board diagnostic system 16 Diagnostic troubl...

Page 510: ...t sensor Related harness Idle 35 Heated oxygen sensor Rear Heated oxygen sensor Rear Ignition switch ON Below 1 0 Heated oxygen sensor Rear Related harness Idle Engine cold Approx 0 After warm up 0 1...

Page 511: ...ttery Constant B PCM 55 terminal Battery harness connector 56 EGR valve 4 coil control EGR valve Ignition switch ON B EGR valve Related harness Idle Below 1 0 57 Knocking Knock sensor Ignition switch...

Page 512: ...itch ON B A C relay Related harness Idle A C operating Below 1 0 A C stops B 70 Fuel pump control with immobilizer Fuel pump relay Ignition switch ON B Fuel pump relay Related harness Cranking Below 1...

Page 513: ...hrottle position 0 3 0 7 Throttle position sensor Related harness Wide open throttle 3 4 5 3 90 Constant voltage Vref Throttle position sensor EGR boost sensor Fuel tank pressure sensor Ignition switc...

Page 514: ...tester to the data link connector BATTERY W 6 U 1 4 0 W A 3 2 Referring to the NGS tester instruction manual select the PID DATA MONITOR AND RECORD and press TRIGGER Note The PID DATA MONITOR AND REC...

Page 515: ...X DRIVECT Number of OBD II drive cycles completed X X DRLMP Daytime running lights ON OFF X X DTC CNT Total number of codes and pending codes stored X X ECT Engine coolant temperature F X X ECTV Engin...

Page 516: ...oltage V X X MIL Malfunction indicator lamp ON OFF X X MILF Malfunction indicator lamp Failed detected YES NO X X MISF Currently misfiring ON OFF X X 02S11 Heated oxygen sensor Front signal voltage V...

Page 517: ...me running lights ON ON For CANADA Others OFF DTC CNT Indicates total number of diagnostic trouble codes DTC stored in PCM Includes pending codes ECT After warm up Approx 85 C 185 F ECT V Engine coola...

Page 518: ...Approx 40 IACF IAC system failed YES Others NO IAT Indicates intake air temperature IATV Intake air temperature 20 C 68 F Approx 3 1 V INJ1F Fuel injector 1 circuit failed YES Others NO INJ2F Fuel in...

Page 519: ...OFF indicator light circuit failed YES Others NO TCS O D OFF switch pushed ON Others OFF TFT Idle After warm up Approx 70 C 150 F TFT V After warm up Approx 1 9 V TP V Closed throttle position 0 3 0 7...

Page 520: ...itive voltage Mass air flow sensor terminal C voltage Below 1 0 V W6U140W04 7 If the terminal voltage is correct and there is harness continuity replace the mass air flow sensor Refer to 01 13A INTAKE...

Page 521: ...n ohmmeter W 6 U 1 4 0 W 0 S Specification Approx 0 95 1 25 kft 3 If not as specified check related wiring harness If they are okay replace the camshaft position sensor Tightening torque 7 9 10 7 Nm 8...

Page 522: ...HAFT POSITION SENSOR REPLACEMENT FS W 6 U 1 4 0 W 0 9 1 Disconnect the negative battery cable Tightening torque 2 Disconnect the crankshaft position sensor 7 9 10 7 N m connector 80 100 kgfcm 69 5 95...

Page 523: ...t TP V on the NGS tester display and press START NGS tester measures and shows the voltage Specification Closed throttle position 0 3 0 7 V Wide open throttle 3 4 5 3 V Verify that the voltage increas...

Page 524: ...n At wide open throttle Throttle position sensor harness side connector terminal A voltage V PCM terminal 89 voltage V 4 5 4 7 3 5 4 4 4 7 4 8 3 6 4 5 4 8 4 9 3 7 4 6 4 9 5 0 3 7 4 8 5 0 5 1 3 8 4 9 5...

Page 525: ...ion Engine coolant temperature condition PCM terminal 38 voltage V 20 C 68 F Approx 3 1 After warm up Below 1 0 6 If not as specified check the related harness and engine coolant temperature sensor re...

Page 526: ...emperature condition PCM terminal 39 voltage V 20 C 68 F Approx 3 1 6 If not as specified check the related harness and intake air temperature sensor resistance 2 If the SSTs NGS tester are used check...

Page 527: ...up 0 1 0 9 Engine cold Below 0 5 Approx 0 Deceleration 0 0 5 Acceleration 0 5 1 0 W 6 U 1 4 0 W 1 4 2 If the SSTs NGS tester are used check in the following order 1 Connect the SSTs NGS tester to the...

Page 528: ...2 Connect the SST 104 Pin Breakout Box to the PCM as shown W 6 U 1 4 0 W 1 5 W 6 U 1 4 0 W A Q 3 Tighten the connector bolt Tightening torque 7 9 10 7 N m 80 100 kgf cm 69 5 95 4 in lbf Caution Do no...

Page 529: ...OL MODULE PCM REMOVAL INSTALLATION FS 2 Connect the SST 104 Pin Breakout Box to the PCM as shown W 6 U 1 4 0 W A U 3 Tighten the connector bolt Tightening torque 7 9 10 7 N m 80 100 kgf cm 69 5 95 4 i...

Page 530: ...Turn the ignition switch to ON Caution Do not apply a vacuum outside of the specified limits Doing so will damage the fuel tank pressure sensor 5 Apply pressure then a vacuum to the fuel tank pressure...

Page 531: ...wheel fully turned B Steering wheel straight ahead position Below 1 0 7 If not as specified check the related harness and power steering pressure switch continuity 2 If the SSTs NGS tester are used c...

Page 532: ...95 4 in lbf 4 Turn the ignition switch to ON 5 Measure the voltage at PCM terminal 64 Specification Condition PCM terminal 64 voltage V Other than neutral position and clutch pedal released B Neutral...

Page 533: ...T 104 Pin Breakout Box are used check in the following order 1 Remove the PCM Refer to 01 40A POWERTRAIN CONTROL MODULE PCM REMOVAL INSTALLATION FS 2 Connect the SST 104 Pin Breakout Box to the PCM as...

Page 534: ...ess and clutch switch continuity 6 If okay check the neutral switch Inspection of Continuity 1 Disconnect the clutch switch connector 2 Check continuity of the clutch switch by using an ohmmeter A 8 I...

Page 535: ...ON 5 Measure the voltage at PCM terminal 71 and 97 Specification__________________________________ Condition VPWR voltage V Ignition switch OFF Below 1 0 Ignition switch ON B 5 If not as specified che...

Page 536: ...SITION SENSOR ADJUSTMENT K L 01 40B 21 ENGINE COOLANT TEMPERATURE SENSOR INSPECTION KL 01 40B 22 Inspection of Output Voltage 01 40B 22 Inspection of Resistance 01 40B 23 INTAKE AIR TEMPERATURE SENSOR...

Page 537: ...H 13 Heated oxygen sensor Middle 14 Heated oxygen sensor Rear 15 Clutch switch 16 Neutral switch 17 Power steering pressure switch 18 Main relay 1 PCM 2 Intake temperature sensor 3 Mass air flow senso...

Page 538: ...component is replaced Keep Alive Memory KAM in the PCM should be cleared by disconnecting the battery terminal to erase the information stored on the original component KL W6U140W0C 4 Tighten the conn...

Page 539: ...0 Fan switch Related harness Fan switch ON at 3rd or higher Below 1 0 11 Torque reduction request Instrument cluster ABS TCS CM Ignition switch ON Approx 10 ABS TCS control module Related harness Idle...

Page 540: ...ming solenoid valve Related harness Solenoid valve ON B 29 O D OFF switch ATX O D OFF switch O D OFF switch released B O D OFF switch Related harness O D OFF switch depressed Below 1 0 30 31 Power ste...

Page 541: ...3 500 rpm Below 1 0 43 44 VRIS control VRIS solenoid valve No 2 Ignition switch ON B VRIS solenoid valve No 2 Related harness Idle Engine speed above 4 500 rpm Below 1 0 45 Cooling fan control Coolin...

Page 542: ...pressure 0 kPa 0 mmHg 0 inHg Barometric pressure Approx 2 5 Fuel tank pressure sensor Related harness 63 Fuel level Fuel gauge sender unit Full fuel Approx 6 Fuel level sender unit Related harness Low...

Page 543: ...switch ON B Fuel pump relay Related harness Cranking Below 1 0 Idle Below 1 0 81 Pressure control solenoid ATX Pressure control solenoid Idle Closed throttle position Approx 7 Pressure control soleno...

Page 544: ...nt LH Related harness sensor Front LH Idle Below 1 0 95 Heated oxygen sensor heater Middle Heated oxygen Ignition switch ON B Heated oxygen sensor Middle Related harness sensor Middle Idle Below 1 0 9...

Page 545: ...TRX2 TATCF AIRM EVAPVMA IMRC TCCA ARCF FANM IMRCF TCCMACT CCS FFFM IMTVF TRAC DPFEGR FPM INJ7F TRANRAT EGRC FTP B INJ8F TRD EGRCF HFCA KSV WACA EGRFO HTR11A LFCA WACF EGRFS HTR12A LFPF 4 x 4L EGRV HTR...

Page 546: ...r heater Middle ON OFF X X HTR12F Heated oxygen sensor heater Middle failed YES NO X X HTR21 Heated oxygen sensor heater Front LH ON OFF X X HTR21F Heated oxygen sensor heater Front LH failed YES NO X...

Page 547: ...H X X SPRKADV Ignition timing BTDC X X SS1 Shift solenoid A ON OFF X SS2 Shift solenoid B ON OFF X SS3 Shift solenoid C ON OFF X TCC Torque converter clutch solenoid valve duty value X TCS O D OFF swi...

Page 548: ...V After warm up Below 1 0 V EGR Indicates atmospheric pressure Except OBD II EGR monitor testing EGRBARO During OBD II EGR monitor testing OFF Others ON EGRCD1 IG switch ON OFF Idle OFF EGRCD2 IG swi...

Page 549: ...temperature IATV Intake air temperature 20 C 68 F Approx 3 1 V INJ1F Fuel injector 1 circuit failed YES Others NO INJ2F Fuel Injector 2 circuit failed YES Others NO INJ3F Fuel injector 3 circuit fail...

Page 550: ...ox 3 5 V TP MODE Closed throttle position C P Half throttle position P T Wide open throttle WOT TP V Closed throttle position 0 3 0 7 V Wide open throttle 3 4 5 3 V TP_MODE Closed throttle position C...

Page 551: ...ss air flow sensor terminal C voltage Below 1 0 V W6U140W0D 7 If the terminal voltage is correct and there is harness continuity replace the mass air flow sensor Refer to 01 13B INTAKE AIR SYSTEM REMO...

Page 552: ...t as specified check related wiring harness If they are okay replace the camshaft position sensor W6U140WM8 CAMSHAFT POSITION SENSOR REMOVAL INSTALLATION KL 1 Disconnect the battery negative cable 2 D...

Page 553: ...ous 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 REPAIR PROCEDURE Refer to 01 14B BEFORE REPAIR PROCED...

Page 554: ...at the crankshaft position sensor is installed correctly and securely 2 Measure the air gap between the crankshaft pulley projection and the crankshaft position sensor by using a feeler gauge Specific...

Page 555: ...is at the closed throttle position 5 Turn the ignition switch to ON 6 Measure the PCM terminal 89 voltage by using a voltmeter Specification Closed throttle position 0 3 1 0 V Wide open throttle 2 8...

Page 556: ...that the throttle valve is at the closed throttle position 5 Turn the ignition switch to ON 6 Rotate the throttle link by hand and adjust the PCM terminal 89 voltage to specification Specification At...

Page 557: ...le position sensor harness side connector terminal B voltage V TP V voltage V 4 5 4 7 3 5 4 4 4 7 4 8 3 6 4 5 4 8 4 9 3 7 4 6 4 9 5 0 3 7 4 8 5 0 5 1 3 8 4 9 5 1 5 3 4 0 5 0 5 3 5 4 4 1 5 1 5 4 5 5 4...

Page 558: ...ox are used check in the following order 1 Remove the PCM Refer to 01 40B POWERTRAIN CONTROL MODULE PCM REMOVAL INSTALLATION KL 2 Connect the SST 104 Pin Breakout Box to the PCM as shown W 6 U 14 0 W...

Page 559: ...ox are used check in the following order 1 Remove the PCM Refer to 01 40B POWERTRAIN CONTROL MODULE PCM REMOVAL INSTALLATION KL 2 Connect the SST 104 Pin Breakout Box to the PCM as shown W6U140WMS 3 T...

Page 560: ...oxygen sensor terminals C and D by using an ohmmeter COMPONENT SIDE CONNECTOR VIEW FROM TERMINAL SIDE MIDDLE FRONT RH C _C A 3 D 8 Specification Approx 6 Q 3 If not as specified replace the heated ox...

Page 561: ...oltage Ignition switch ON EGR boost sensor terminal B voltage Ground Below 1 0 V EGR boost sensor terminal C voltage Constant voltage 4 5 5 5 V 4 If terminal voltage is incorrect check the PCM 8 If te...

Page 562: ...elect the PID DATA MONITOR AND RECORD function on the NGS tester display and press TRIGGER 3 Select FTP V on the NGS tester display and press START The NGS tester measure and shows the voltage 4 Turn...

Page 563: ...KL 2 Connect the SST 104 Pin Breakout Box to the PCM as shown W 6 U 1 4 O W N 0 3 Tighten the connector bolt Tightening torque 7 9 10 7 N m 80 100 kgf cm 69 5 95 4 inlbf 4 Warm up the engine to normal...

Page 564: ...the ignition switch to ON 5 Measure the voltage at PCM terminal 64 Specification Condition PCM terminal 64 voltage V Other than neutral position and clutch pedal released B Neutral position or clutch...

Page 565: ...ox are used check in the following order 1 Remove the PCM Refer to 01 40B POWERTRAIN CONTROL MODULE PCM REMOVAL INSTALLATION KL Connect the SST 104 Pin Breakout Box to the PCM as shown 2 W6U140WN7 3 T...

Page 566: ...tch connector 2 Check continuity of the clutch switch by using an ohmmeter O O Continuity Condition Terminal C E Clutch pedal depressed 0 O Clutch pedal released W 6 U 1 4 0 W N 9 5 If not as specifie...

Page 567: ...f the SSTs NGS tester are used check in the following order 1 Connect the SSTs NGS tester to the data link connector W6U140WOX 2 Turn the ignition switch to ON 3 Select the PID DATA MONITOR AND RECORD...

Page 568: ...2 70 90 154 198 Used 491 686 50 70 110 154 491 686 50 70 110 154 Limit 392 40 88 294 30 66 P S New 589 784 60 80 132 176 540 686 55 70 121 154 Used 491 686 50 70 110 154 393 539 40 55 88 121 Limit 392...

Page 569: ...50 750 Idle mixture HC concentration within the regulation CO concentration within the regulation LUBRICATION SYSTEM Oil pressure kPa kgf cm2 psi 3000 rpm 393 490 4 0 5 0 57 71 334 490 3 4 5 0 49 71 O...

Page 570: ...ed current Reference A Engine speed rpm 1000 Terminal B current Approx 58 or below must not be 0 Approx 70 or below must not be 0 2000 Terminal B current Approx 77 or below must not be 0 Approx 90 or...

Page 571: ...3 A C switch and fan switch are tuned on 4 Steering wheel fully turned 5 Hot condition at the staring 6 Dark current is the constant flow of current present for the audio unit clock PCM etc when the i...

Page 572: ...X T G 0 3 3 1 0 7 A T P 0 0 5 2 0 4 X 49 G019 017 Oil seal installer KL 49 0187 280 Oil pressure gauge 49 G014 001 Oil filter wrench T G 0 1 9 0 1 7 X T 0 1 8 7 2 8 0 X T G 0 1 4 0 0 1 X 49 9200 145 R...

Page 573: ...hecker set KL T E 0 1 8 9 A 0 X 49 H018 001 Knock sensor Y wrench J T H 0 1 8 0 0 1 X 49 H 010103 Compression T H 0 1 0 1 0 3 X 49 H010 104 Adaptor T H 0 1 0 1 0 4 X 49 U014 001 Air pressure tester ft...

Page 574: ...it to 90 110 Nm 9 12 kgf m 66 86 ft lbf Suspension links removal installation Tighten any part of the suspension that uses rubber bushings only after the vehicle has been lowered and unloaded W 6 U 2...

Page 575: ...oil at specified levels spare tire jack and tools in designated position 02 W 6 U 2 1 1 W 0 1 7 Measure the height from the center of the wheel to the fender brim The difference between the left and r...

Page 576: ...nd the left toward the rear increases toe in Note Turning both tie rods one complete turn changes toe in by about 6 mm 0 24 in 0 36 4 Tighten the tie rod locknuts to the specified torque Tightening to...

Page 577: ...N TOE OUT DIRECTION TOE IN DIRECTION W 6U211W A3 Note Turning the adjusting cam bolt one graduation changes the toe in about 3 2 mm 0 13 in 0 18 4 Tighten the cam nut Tightening torque 87 116 N m 8 8...

Page 578: ...RONT STABILIZER REMOVAL INSTALLATION 02 13 6 Stabilizer Bushing and Bracket Installation Note 02 13 6 STABILIZER CONTROL LINK INSPECTION 02 13 6 TRANSVERSE MEMBER AND FRONT CROSSMEMBER REMOVAL INSTALL...

Page 579: ...oil spring by using the SSTs WHEN USING ENGINE STAND Coil Spring Installation Note 1 Temporarily install the coil spring upper spring seat rubber and upper spring seat and mounting rubber on the shock...

Page 580: ...elease it 2 Verify that the piston extends fully at a normal speed 5 Replace the shock absorber as necessary FRONT SHOCK ABSORBER DISPOSAL Warning The gas in the shock absorber is pressurized and coul...

Page 581: ...damper 4 Lower arm component 5 Dust boot y Removal Note e t Installation Note Dust Boot Installation Note Remove the dust boot by using a chisel being careful not to damage the ball joint and the arm...

Page 582: ...to the ball stud and measure the rotation torque by using a pull scale 3 Replace it if not within the specification Ball joint preload 1 0 4 9 N m 10 50 kgf cm 9 43 inlbf Pull scale reading 9 8 49 N 1...

Page 583: ...e stabilizer bushing 2 Align the bushing with the installation mark on the stabilizer bar 1 Stabilizer control link 2 Stabilizer bracket t r rInstallation Note 3 Stabilizer bushing c r Installation No...

Page 584: ...ll joint bolt 8 Crossmember and steering gear component w Removal Note 9 Steering gear and linkage 10 Front stabilizer tr FRONT STABILIZER REMOVAL INSTALLATION 11 Front lower arm 12 Front crossmember...

Page 585: ...RONT SUSPENSION Crossmember and Steering Gear Component Removal Note 1 Support the crossmember by using a jack and remove the bolts and nuts 2 Remove the crossmember and steering gear component 02 13...

Page 586: ...ying degrees of oil wetness may be noticed on the rear shock absorber If there is a thin oily film or sheen on the top of the shock absorber near the piston it may be a normal condition with no ride o...

Page 587: ...r seat spring by using a piece of cloth then set the SSTs 4 Compress the coil spring by using the SSTs 5 Install the shock absorber so that the lower end of the coil spring is seated on the step of th...

Page 588: ...W 0 4 1 Stabilizer control link 2 Stabilizer bushing and bracket o Installation Note 3 Protector 4 Rear stabilizer Stabilizer Bushing Installation Note Align the bushing with the installation mark on...

Page 589: ...5 27 39 63 93 6 4 9 5 47 68 19 25 1 9 2 6 14 18 1 Parking brake cable bracket 2 Trailing link 3 Cap 4 Nut cam plate adjusting cam bolt ty Removal Note or Installation Note 5 Rear lateral link 6 Front...

Page 590: ...djusting cam bolt Tighten the nut REAR CRO SSM EM B ER REM OVAL INSTALLATION W 6 U 2 1 4 W 0 7 1 Remove the rear stabilizer Refer to REAR STABILIZER REMOVAL INSTALLATION 2 Remove the front and rear la...

Page 591: ...Max 2 5 0 10 Steel Max 2 0 0 08 Aluminum Wheel imbalance 3 g oz Max 10 0 35 14 inch wheel Max 9 0 32 15 Inch wheel Temporary spare tire wheel Size 15x4T Offset mm in 45 1 77 Pitch circle diameter mm i...

Page 592: ...34 102 Stand Part of 49 T034 1A0 T T 0 3 4 1 0 2 X 49 T034 103 Part of 49T034 1A0 T T 0 3 4 1 0 3 X 49T034 104 Support L o 49 T034 1A0 T T 0 3 4 1 0 4 X 49 T034 105 Attachment T T 0 3 4 1 0 5 X 49 010...

Page 593: ...gfm 66 86 ft lbf Brake Line Disconnection Connection Caution Brake fluid will damage painted surfaces If brake fluid does get on a painted surface wipe it off immediately Tighten the brake pipe flare...

Page 594: ...ion N o te 03 11 4 Locknut Installation N o te 03 11 5 WHEEL HUB STEERING KNUCKLE PREINSPECTION Wheel Bearing Play Inspection 1 Position a dial indicator against the wheel hub Push and pull the wheel...

Page 595: ...It Removal Note o Installation Note 12 Dust cover 17 Removal Note tr Installation Note 13 Steering knuckle 14 Hub bolt cr Removal Note tr Installation Note 1 Locknut w Removal Note tr Installation Not...

Page 596: ...t Cover Removal Note Wheel Hub Component Removal Note 1 Remove the wheel hub component by using the SSTs 2 If the bearing inner race remains on the front wheel hub component grind a section of the bea...

Page 597: ...ion Note 1 Mark the new dust cover as the removed one W 6 U 3 1 1 W A F Oil Seal Installation Note 1 Apply grease to the new oil seal lip 2 Install the new oil seal flush with the knuckle by using the...

Page 598: ...FRONT AXLE Locknut Installation Note Install a new locknut and stake it as shown Tightening torque 236 318 N m 24 0 32 5 kgf m 174 235 ft lbf 03 0 5 mm 0 02 in OR MORE W 6 U 3 1 1 W A H 03 11 5...

Page 599: ...Wheel Bearing Play Inspection 03 12 3 WHEEL HUB BOLT REPLACEMENT 03 12 3 WHEEL HUB HUB SPINDLE REMOVAL INSTALLATION DISC BRAKE MODEL 03 12 4 WHEEL HUB HUB SPINDLE PREINSPECTION DRUM BRAKE MODEL W 6 U...

Page 600: ...TEERING KNUCKLE REMOVAL INSTALLATION Hub Bolt Removal Note X T 03 11 WHEEL HUB STEERING KNUCKLE REMOVAL INSTALLATION Hub Bolt Installation Note 7 Wheel hub component 8 Parking brake cable bracket 9 Cl...

Page 601: ...lation Note Note The ABS sensor rotor can be installed in either direction 1 Install a new rear ABS sensor rotor onto the wheel hub 2 Using a steel plate and the SST press the rotor until it is flush...

Page 602: ...9 Dust cover 10 ABS wheel speed sensor with ABS 11 Hub spindle 1 Hub Cap 2 Locknut c r WHEEL HUB HUB SPINDLE REMOVAL INSTALLATION DRUM BRAKE MODEL Locknut Removal Note c r WHEEL HUB HUB SPINDLE REMOVA...

Page 603: ...Boot Band Disassembly N ote 03 13 9 Clip Disassembly N ote 03 13 9 Snap Ring Disassembly N ote 03 13 9 Balls Inner Ring Cage Disassembly Note 03 13 9 Boot Disassembly N o te 03 13 9 ABS Sensor Rotor...

Page 604: ...Tie rod end ball joint cr 06 12 STEERING GEAR AND LINKAGE REMOVAL INSTALLATION Tie rod End Ball Joint Removal Note 3 Lower arm ball joint 4 Right drive shaft and axle sr Removal Note cr Installation...

Page 605: ...cing upward CLIP Joint Shaft Removal Note Install the SST into the transaxle to hold the side gears after the joint shaft is removed Right Drive Shaft and Axle Installation Note 1 Push the drive shaft...

Page 606: ...Dust Cover Disassembly Note W hile holding the joint shaft press out the dust cover by using the SST W 6 U 3 1 3 W A 8 Joint Shaft Disassembly Note Disassem ble the joint shaft by using the SST 49 H0...

Page 607: ...3 W A E r W 6 U 3 1 3 W A G Dust Cover Assembly Note 1 Mark the shaft as shown in the figure Length L 88 5 89 5 mm 3 49 3 52 in W 6 U 3 1 3 W A F DRIVE SHAFT PREINSPECTION 1 Inspect the dust boot on t...

Page 608: ...8 9 5 50 68 75 104 7 6 10 7 55 77 94 131 9 5 13 4 69 96 W 6 U 3 1 3 W A J 1 Splash shield 2 Locknut cr 03 11 WHEEL HUB STEERING KNUCKLE REMOVAL INSTALLATION Locknut Removal Note cr 03 11 WHEEL HUB STE...

Page 609: ...haft from the transaxle 1 Separate the left side drive shaft from the transaxle by prying with a bar inserted between the outer ring and the transaxle as shown in the figure 2 Install the SST into the...

Page 610: ...erse order of disassembly W 6 U 3 1 3 W A S 1 Boot band vr Disassembly Note tr Assembly Note 2 Clip p Disassembly Note tr Assembly Note 3 Outer ring d Assembly Note 4 Snap ring tr Disassembly Note tr...

Page 611: ...ing pliers W6U313WAV Balls Inner Ring Cage Disassembly Note Caution Mark with paint do not use a punch The component will be damaged 1 Mark the inner ring and cage 2 Turn the cage approximately 30 deg...

Page 612: ...me disengaged ABS Sensor Rotor Assembly Note Caution Verify the direction of the sensor rotor Set a new ABS sensor rotor on the drive shaft and press it on with the SST W 6 U 3 1 3 W A Z Outer Ring Cl...

Page 613: ...D TYPE DISASSEMBLY ASSEMBLY 1 Disassemble in the order indicated in the table 2 Assemble in the reverse order of disassembly DO NOT DISASSEMBLE 7 W 6 U 3 1 3 W 0 7 LEFTSIDE RIGHT SIDE W 6 U 3 1 3 W B...

Page 614: ...proper assembly 2 Remove the outer ring W 6 U 3 1 3 W B A W 6 U 3 1 3 W B 8 Snap Ring Tripod Joint Disassembly Note 1 Mark the shaft and tripod joint for proper assembly 2 Remove the snap ring by usin...

Page 615: ...Align the marks and install the tripod joint by using a bar and a hammer MARKS W6U313WBE 2 Install the new snap ring by using a snap ring pliers Outer Ring Assembly Note Note Use the specified grease...

Page 616: ...oot with the repair kit grease 5 Adjust clearance A by turning the adjusting bolt of the SST Clearance A 3 2 mm 0 13 in 6 Crimp the wheel side big boot band by using the SST Verify that clearance B is...

Page 617: ...m in 0 1 0 004 REAR AXLE Maximum wheel bearing play mm in 0 1 0 004 DRIVE SHAFT Shaft length Air in boot at atmospheric pressure mm in Right side 595 2 605 2 23 44 23 82 593 1 603 1 23 36 23 74 595 2...

Page 618: ...49 G033 105 Attachment Part of 49 G033 1A1 TG0331A1X TG033102X TG033105X 49 G033 106 Attachment Part of 49 G033 1A1 49 F027 0A1 Bearing installer set 49 F027 004 Attachment 080 Part of 49 F027 0A1 TG...

Page 619: ...03 Oil seal installer i TW027003X 49 H027 002 Bearing installer TH027002X 49 G017 5A0 Engine support v TG0175A0X 49 G030 455 Differential side i f gear holder TG030455X 49 G025 001 Sensor rotor i inst...

Page 620: ...1 7 ANTILOCK BRAKE SYSTEM AND TRACTION CONTROL SYSTEM SYMPTOM TROUBLESHOOTING 04 01 12 Diagnostic In d e x 04 01 12 Symptom Troubleshooting 04 01 14 FOREWORD Refer to 0 0 0 0 HOW TO USE THIS MANUAL Tr...

Page 621: ...minates when there is a problem in the electrical system Also past and present malfunctions are recorded in the ABS TCS CM This function can find malfunctions that do not occur during periodic inspect...

Page 622: ...the trigger key to enter this selection I 1998 VIN 10 W 1 9 9 7 VIN 10 V 1 9 9 6 VIN 10 T 1995 VIN 10 S 1 9 9 4 VIN 10 R SELECT ITEM AND PRESS TRIGGER TO START W 6 U 4 0 1 W 8 6 5 Move the cursor to...

Page 623: ...the appropriate DTC troubleshooting chart 13 After completion of repairs clear DTCs Clearing DTCs Procedure 1 Connect the SST NGS tester to the data link connector and select READ CLEAR DIAGNOSTIC TE...

Page 624: ...3 Diagnostic Trouble Code Table DTC Display on the NGS Diagnosis component B1318 BATTERY VOLTAGE LOW Battery voltage B1342 ECU DEFECTIVE ABS control module B1484 BRAKE PEDAL INPUT OPEN CIRCUIT Brake s...

Page 625: ...LF_WSPD Front left wheel speed sensor input MPH RF_WSPD Front right wheel speed sensor input MPH LR_WSPD Rear left wheel speed sensor input MPH RR_WSPD Rear right wheel speed sensor input MPH PART NO...

Page 626: ...hen engine is idling Yes Go to next step No Go to step 7 6 With IG SW OFF is resistance between D of ABS CM harness and secure ground less than 5 2 Yes Go to next step No Repair harness between D and...

Page 627: ...CM harness connector and secure ground less than 5 fi Yes Go to next step No Repair harness between A and joint box ground for open circuit 6 Connect the SST NGS Select ACTIVE COMMAND MODES Select PID...

Page 628: ...istance Less than 5 a Are they as specified Yes Go to step 2 of DTC 1222 chart No There is a short to ground Inspect short point and repair it as necessary 04 Models with TCS DTC C1222 ABS wheel speed...

Page 629: ...epair harness between C and ABS fuse 20 A for short to ground No Go to next step 4 Is resistance between C of ABS CM harness connector and ABS fuse 20 A less than 5 n Yes Replace ABS CM No Repair harn...

Page 630: ...s temporarily poor contact in wiring harness or connector Repair or replace as necessary C1119 Torque reduction engine condition signal line U2012 Torque reduction engine condition signal line DESCRIP...

Page 631: ...on Improper drive belt tension Poor connection in ABS CM harness Malfunction of ABS warning light harness Malfunction of instrument cluster print board ABS CM inoperative 3 When IG switch is turned to...

Page 632: ...hen driving with different size tires or when tire air pressure is low When TCS is activated TCS will not be canceled until TCS operation is completed even if the TCS OFF switch is depressed 10 When I...

Page 633: ...ect meter fuse If fuse is melted inspect for short to ground between ignition switch and fuse panel or fuse panel and warning light 2 Inspect harnesses of ABS warning light meter fuse and warning ligh...

Page 634: ...in instrument cluster Is it okay Yes Replace ABS CM No Replace instrument cluster print board Caution Recheck the diagnostic trouble code after repair completion Note The ABS warning light normally il...

Page 635: ...ere air in the brake system Yes Bleed the air No Go to next step 3 Is brake piping of ABS hydraulic unit okay Yes Inspect the following conventional brake parts Master cylinder Power brake unit Propor...

Page 636: ...fter repair com pletion Note The ABS warning light normally illuminates for 2 4 seconds after ignition switch is turned to ON If any symptoms have occurred in the past but are now okay malfunction of...

Page 637: ...tus of TCS OFF PID change when TCS OFF switch is operated Yes Go to next step No Repair or replace harness or TCS OFF switch 5 Perform PCM on board diagnostic inspection Is DTC displayed Yes Repair pr...

Page 638: ...be selected until the operation has been completed When wheel spinning occurs the TCS indicator light flashes It indicates that the TCS system is operating normally If flashing is observed too often...

Page 639: ...p the system is normal The TCS OFF light illuminates at key on engine off Start engine and inspect again If any symptoms have occurred in the past but are now okay malfunction of related harness could...

Page 640: ...h for the following lights ABS warning light TCS indicator light TCS OFF light Is everything okay Yes Go to next step No Repair or replace harness 3 Inspect the bulbs for the following lights ABS warn...

Page 641: ...w ipe it off im m ediately Tighten the brake pipe flare nut by using the SST 49 0259 770B Be sure to modify the brake pipe flare nut tightening torque to allow for use of a torque wrench SST combinati...

Page 642: ...1 4 FRONT CALIPER DISASSEMBLY ASSEMBLY 0 4 1 1 1 4 Piston Disassembly Note 0 4 1 1 1 4 Piston Seal Disassembly N o te 0 4 1 1 1 5 REAR BRAKE DISC ON VEHICLE INSPECTION 0 4 1 1 1 5 Disc Pad Thickness...

Page 643: ...SS116 DOT 3 W 6 U 4 1 1 W 2 4 1 Remove the brake fluid from the reservoir by using a suction pump 2 Fill the reservoir with clean brake fluid 3 Attach a vinyl tube to the farthest bleeder screw and pl...

Page 644: ...hten the flare nut by using the SST Verify that the hose can not come in contact with any other parts of vehicle Tightening torque 12 9 21 5 N m 130 220 kgf cm 113 190 in lbf W 6 U 4 1 1 W B R 3 Secur...

Page 645: ...he lock unit operates correctly Caution When the brake pedal height is adjusted a new brake switch must be used The new switch can be adjusted only once Pulling or pushing the tip of the new brake swi...

Page 646: ...1 Start the engine and verify that the distance from the floor panel to the pedal pad center is as specified when the pedal is depressed with a force of 589 N 60 kgf 132 Ibf W 6 U 4 1 1 W A 5 BRAKE P...

Page 647: ...ation Note 6 O rinc Master Cylinder Installation Note 1 Loosen the adjusting nut of the SST 2 Place the SST on the power brake unit and tighten the nut and washer W 6 U 4 1 1 W 0 6 Tightening torque 9...

Page 648: ...U 4 1 1 W A E Adjustment Clearance at B 1 Measure and record the height D1 of the gauge rod 2 Turn the adjusting nut until the SST body sets closely on the master cylinder Turn only enough for the bo...

Page 649: ...U 4 1 1 W A L MASTER CYLINDER DISASSEMBLY ASSEMBLY W 6 U 4 1 1 W 0 8 Caution If the master cylinder body is damaged replace the unit as an assembly When securing the master cylinder in a vise tighten...

Page 650: ...the engine stopped depress the pedal several times 2 With the pedal depressed start the engine 3 If the pedal moves down slightly im m ediately after the engine starts the unit is operating Step 2 1 S...

Page 651: ...475 500 mmHg 18 7 19 7 inHg the unit is operating 4 Start the engine 5 Depress the brake pedal with a force of 196 N 20 kgf 44 Ibf 6 With the brake pedal depressed stop the engine when the vacuum gaug...

Page 652: ...390 4 60 49 U043 005 MASTER CYLINDER PRESSURE kPa kgf cm psi W6U411WAU 4 If not within the specification replace the dual proportioning valve Fluid pressure W6U411WAT kPa kgf cm2 psi DUAL PROPORTIONIN...

Page 653: ...ate is removed from the vehicle then machined excessive runout may result Machine the disc plate which is installed on the vehicle W 6 U 4 1 1 W 1 2 Minimum 22 mm 0 87 in Minimum thickness after machi...

Page 654: ...7 Guide plate 8 Mounting support 9 Disc plate cr Removal Note D Installation Note Disc Plate Removal Note Mark the wheel hub bolt and disc plate for guide at installation before removal 2 Install the...

Page 655: ...PER DISASSEMBLY ASSEMBLY 1 Disassemble in the order indicated in the table 2 Assemble in the reverse order of removal W 6 U 4 1 1 W 1 5 49 0259 770B Nm kgfcm inlbf W6U411WB3 1 Dust seal 2 Piston tr Di...

Page 656: ...right and left wheels if either is less than the minimum thickness W 6 U 4 1 1 W B 7 W 6 U 4 1 1 W 1 6 Disc Plate Thickness Inspection 1 Measure the thickness of the disc plate Caution When it is nece...

Page 657: ...r 6 Spring 7 Disc pad t r Installation Note 8 Shim 9 Guide plate 10 Mounting support 11 Disc plate er FRONT BRAKE DISC REMOVAL INSTALLATION Disc Plate Removal Note cr FRONT BRAKE DISC REMOVAL INSTALLA...

Page 658: ...in the table 2 Install in the reverse order of removal N m kgf m ft lbf W 6 U 4 1 1 W B A 1 Parking brake cable clip 2 Screw plug 3 Lock bolt 4 Spring 5 Disc pad cr REAR BRAKE DISC REMOVAL INSTALLATIO...

Page 659: ...gear 4 Snap ring 5 Adjusting bolt 6 O ring 7 Connecting link 8 Piston seal tr CALIPER FRONT DISASSEMBLY ASSEMBLY Piston Seal Disassembly Note 9 Spring 10 Operating lever 11 Sleeve 12 Boot 13 Bleeder...

Page 660: ...t the remaining thickness of the lining Thickness 1 0 mm 0 04 in min 3 Replace both left and right brake shoes if either is at or less than the minimum thickness W 6 U 4 1 1 W B E Brake Drum inspectio...

Page 661: ...7 N m 100 150 kgfem 87 120 In lbf APPLY g TO SHADED AREA 49 0259 770B 177 235 18 0 24 0 131 173 N m kgf m ftlb f W 6 U 4 1 1 W B H 1 Hub cap 2 Screw 3 Brake drum pr Removal Note p Installation Note 4...

Page 662: ...f the drum brake 3 Install the brake drum and align the marks made before removal W 6 U 4 1 1 W B J WHEEL CYLINDER DISASSEMBLY ASSEMBLY Caution Replace the wheel cylinder assembly if a problem is foun...

Page 663: ...stroke by pulling the 6 8 notches parking brake lever with a force of 98 N 10 kgf 44 Ibf PARKING BRAKE ADJUSTMENT 1 Start the engine and depress the brake pedal several times 2 Stop the engine 3 Turn...

Page 664: ...insulator bolts 3 Remove in the order indicated in the table 4 Install in the reverse order of removal 5 Adjust the parking brake stroke N m kgf m ft lbf W 6 U 4 1 2 W A 1 5 Front cable and equalizer...

Page 665: ...3 Turn the ignition switch to OFF 4 On level ground jack up the vehicle and support it evenly on safety stands Shift the transaxle to neutral MTX or N range ATX 5 Release the parking brake 6 Rotate th...

Page 666: ...5 ABS hydraulic unit 6 Spring plate 7 Stud 8 Soft mount ABS Hydraulic Unit and ABS Control Module Removal Installation Note When removing installing the ABS hydraulic unit and ABS control module from...

Page 667: ...t the coils of the ABS CM over the valve bodies 4 Locate the ABS CM by placing the new bolts evenly against the housing and tightening them slightly by hands To aid alignment the housing may be presse...

Page 668: ...A Harness C fuse 20 A D System ground signal Ground point Continuity D ground point IG SW is at OFF Yes Harness to ground point E 3 TCS OFF light TCS OFF light Voltage E D IG SW is at ON B 1 Harness E...

Page 669: ...epressed IG SW is at ON B Harness AY brake sw when brake light normal Brake switch Y D When brake pedal released IG SW is at ON 0 V Z Power supply system Ignition switch Voltage Z D IG SW is at ON B H...

Page 670: ...l speed sensor and the sensor rotor Clearance 1 3 2 0 mm 0 0512 0 0787 in ABS WHEEL SPEED SENSOR CLEARANCE W6U413WAB W 6 U 4 1 3 W 0 5 Resistance Inspection 1 Disconnect the ABS wheel speed sensor con...

Page 671: ...LATION W 6 U 4 1 3 W 0 6 1 Remove the trunk compartment covering Refer to 09 17 TRUNK COMPARTMENT COVERING REMOVAL INSTALLATION 2 Remove in the order indicated in the table 3 Install in the reverse or...

Page 672: ...ne and follow the troubleshooting procedures W 6 U 4 1 4 W 0 1 4 Shift the transaxle to second MTX or D range ATX 5 Depress the accelerater pedal for 5 seconds and verify that the engine speed is held...

Page 673: ...move the TCS OFF switch 2 Measure the resistance between B and C of the connector Resistance W hen sw itch is pressed 100 or less W hen sw itch is released F E D C B A 3 If not within the specificatio...

Page 674: ...sure when master cylinder pressure is 5880 kPa 60 kgf cm2 850 psi kPa kgf cm2 psi 3830 39 550 295 3 43 4170 42 5 600 390 4 60 Front disc brake Minimum disc pad thickness mm in 2 0 0 08 Minimum disc pl...

Page 675: ...r out tool 49 0221 600C Disc brake expand tool 49 U043 005 Joint Part of 49 U043 0A0 T 0 2 0 8 7 0 1 A T 0 2 2 1 6 0 0 C T U 0 4 3 0 0 5 X 49 E043 003A Turning lock tool 49 B043 004 Socket wrench 49 U...

Page 676: ...01 A 31 Turbine Shaft Speed TSS Sensor Connector Component 05 01A 32 AUTOMATIC TRANSAXLE BASIC INSPECTION LA4A EL 05 01A 32 AUTOMATIC TRANSAXLE SYMPTOM TROUBLESHOOTING LA4A EL 05 01A 33 Diagnosis Ind...

Page 677: ...tr 01 01A ENGINE ON BOARD DIAGNOSIS FS N A P0117 Engine coolant temperature sensor Circuit low input e t 01 01A ENGINE ON BOARD DIAGNOSIS FS N A P0118 Engine coolant temperature sensor Circuit high i...

Page 678: ...A P0443 Evaporative emission control system Purge control valve circuit malfunction s t 01 01A ENGINE ON BOARD DIAGNOSIS FS N A P0446 Evaporative emission control system Vent control malfunction s t 0...

Page 679: ...function ON 2 CCM OFF P1001 KOER aborted KOER not able to complete cr 01 01A ENGINE ON BOARD DIAGNOSIS FS N A P1100 Mass air flow sensor Sensor intermittent p 01 01A ENGINE ON BOARD DIAGNOSIS FS N A P...

Page 680: ...60 Wide open throttle air conditioning cutoff Circuit malfunction cr 01 01A ENGINE ON BOARD DIAGNOSIS FS N A P1464 Air conditioner A C Demand out of self test range cr 01 01A ENGINE ON BOARD DIAGNOSIS...

Page 681: ...OFF P1746 EPC solenoid Open PCM output driver OFF 2 CCM FLASH P1747 EPC solenoid circuit failure shorted to ground or open ON 2 CCM OFF P1751 SS1 SS1 circuit failure OFF 2 CCM OFF P1756 SS2 SS2 elect...

Page 682: ...t mode o 01 01A ENGINE ON BOARD DIAGNOSIS FS Select SS1 and SS2 PIDs Cycle SS1 OFF ON by selecting stop start mode in output test mode ALL ON Set ALL OFF mode Cycle SS2 ON OFF by selecting STOP START...

Page 683: ...27 and 71 Between test pin 27 and 97 Between test pin 27 and 77 Between test pin 27 and 103 Between test pin 27 and 91 Between test pin 1 and 71 Between test pin 1 and 97 Between test pin 1 and 77 Bet...

Page 684: ...milliamps Yes Replace Solenoid Body Component Record and erase codes Rerun OBD tests Solenoid Tester Jack SS1 SS1A PWR SS2 SS2A PWR No W 6 U 5 0 1 W A O Connection should show infinite resistance no...

Page 685: ...Is voltage between 4 0 and 6 0 volts Yes VREF voltage is in range Reconnect TP sensor Go to next step No VREF voltage is out of range Reconnect transaxle connector Go to reference voltage test cr 01 4...

Page 686: ...rt to GND or TFT sensor ground circuit in TFT signal harness circuit Damaged powertrain control module PCM STEP INSPECTION ACTION BB1 CONTINUOUS MEMORY DTC P0712 VERIFY TFT SIGNAL VOLTAGE Connect NGS...

Page 687: ...circuits or the PCM Remove jumper wire Go to BC4 No The opposite condition could not be induced Remove jumper wire Go to next step BC2 CHECK CONTINUITY OF TFT SIGNAL AND TFT SENSOR GROUND CIRCUITS Ke...

Page 688: ...all components Clear DTCs and rerun self tests No Reconnect all components Unable to duplicate or identify fault at this time Intermittent poor connection or component malfunction Repair or repalace a...

Page 689: ...the voltage between 4 0 and 6 0 volts Yes VREF voltage is in range Reconnect the TP sensor Go to next step No VREF voltage is out of range Go to reference voltage test tr 01 40A POWERTRAIN CONTROL MOD...

Page 690: ...short or open If resistance was between 0 8K and 100K ohms perform the following test If transaxle is cold run transaxle to warm it up If transaxle is warm allow transaxle to cool Check TFT sensor re...

Page 691: ...TOMATIC TRANSAXLE SYMPTOM TROUBLESHOOTING LA4A EL Pinpoint test C P0741 P0743 DTC P1742 P1743 P1744 P1767 TCC control engagement error TCC solenoid circuit failure during self test TCC solenoid failed...

Page 692: ...nnector Disconnect PCM Inspect for damaged or pushed out pins corrosion loose wires etc Service as required Install breakout box leave PCM disconnected Refer to connector schematic and table of soleno...

Page 693: ...cation Set bench drive switch to bench mode Rotate gear select switch to ohms check position Connect ohmmeter negative lead to TCC jack and positive lead to VPWR jack on tester Record resistance Is re...

Page 694: ...lt ohm meter VOM positive test lead to TR signal circuit and negative test lead to the signal return SIG RTN of TR switch connector vehicle harness side Place VOM on 20 volt scale Key on engine off Is...

Page 695: ...e between TR and SRTN of the TR switch verify the switch resistance value in all gear positions xt 05 17A ELECTRICAL SYSTEM COMPONENTS LA4A EL MLP Tester Instruction TR switch resistance tests Are the...

Page 696: ...s operate properly and only in the proper gear positions Yes Service as required No Replace TR switch and adjust Erase DTCs and rerun OBD test Pinpoint test DA KOEO KOER DTC P1702 TR switch Intermitte...

Page 697: ...at the TR switch connector Is each resistance less than 5 0 ohms Yes Service as required No Repair or replace harness and or connector Pinpoint test E DTC P1747 P1746 Electronic pressure control EPC s...

Page 698: ...d or pushed out pins corrosion loose wires etc Install breakout box leave PCM disconnected Refer to connector schematic and table of the solenoid body ay Solenoid Body Connector Component Measure resi...

Page 699: ...tween BAT engine ground and appropriate jack with an ohmmeter or other low current tester less than 200 milliamps Yes Replace solenoid body component Record and erase DTCs Rerun OBD test Solenoid Test...

Page 700: ...lled PCM disconnected Measure resistance between PCM test pins 84 91 and test pins 71 97 at breakout box Measure resistance between PCM test pins 84 91 71 97 and test pins 77 103 at breakout box Is ea...

Page 701: ...function test Pinpoint test FA KOEO KOER DTC P1701 Turbine shaft speed TSS sensor intermittent DESCRIPTION DTC P1701 is not received during KOEO and KOER self test but are output during Continuous Mem...

Page 702: ...ms Yes Go to next step No Replace solenoid body component Record and erase diagnostic trouble codes DTCs Rerun OBD test G3 CHECK SOLENOID FOR SHORT TO GROUND Check for continuity between BAT engine gr...

Page 703: ...80 O D OFF switch not cycled during self test DESCRIPTION This Pinpoint test is intended to diagnose the following components Transaxle wiring harness O D OFF switch O D OFF indicator light PCM POSSIB...

Page 704: ...ce short circuit Remove breakout box Reconnect all components Rerun OBD test TB6 O D OFF INDICATOR LIGHT ALWAYS ON Key on engine off Cycle O D OFF switch Does O D OFF indicator light turn on and off Y...

Page 705: ...OFF Disconnect PCM Inspect for damaged or pushed out pins corrosion loose wires etc Service as necessary Install breakout box PCM disconnected Disconnect VSS Measure resistance between test pin 58 VS...

Page 706: ...record any continuous memory DTCs Address the DTCs in Section 5 powertrain diagnostic trouble code charts If no DTCs are generated testing is complete Solenoid Body Connector Component Vehicle harnes...

Page 707: ...AUTOMATIC TRANSAXLE FLUID ATF INSPECTION LA4A EL ATF Condition Inspection Are ATF color and odor normal Yes Go to next step No Repair or replace any defective parts 3 Perform the line pressure test cr...

Page 708: ...ft 18 Soft slipping 3 4 shift 19 Soft slipping 4 3 shift Automatic 2 0 Soft slipping 3 2 shift Automatic 2 1 Soft slipping 2 1 shift Automatic or kickdown 2 2 Harsh 1 2 shift 23 Harsh 2 3 shift 24 Har...

Page 709: ...sis Chart I Cont d Diagnostic trouble code Road test Line pressure test Stall test Inspection method Al F level and condition T J Selector lever CD Stall test 3 Line pressure test 3 Q O Road test O Po...

Page 710: ...ange o o o O o o 12 No first gear in 1 range First gear in D range okay c 0 o O o Q 13 No 1 2 shift o 0 o 0 o 14 No 2 3 shift 0 o 0 o o 15 No 3 4 shift o o o o o J 16 Soft slipping 1 2 shift o G o o 1...

Page 711: ...gear D range o O 12 No first gear in 1 range First gear in D range okay 13 No 1 2 shift 0 O 0 o 14 No 2 3 Shift 0 0 o 15 No 3 4 shift o o Q o 16 Shift concern Soft slipping 1 2 shift 0 S J o No o 17 S...

Page 712: ...l pump Do any of the following problems exist Bolts are not torqued to spec Gaskets are damaged Porosity cross leaks and or ball plug is missing or leaking or a plugged hole Pump support seal rings 3...

Page 713: ...4 Control valve body Do any of the following problems exist Bolts are not torqued to specification Gasket is damaged 1 2 shift valve SS1 main regulator valve low reverse modulator valve low reverse ac...

Page 714: ...m pinpoint tests BA BB BC BD BE BF and E cr 05 01A AUTOMATIC TRANSAXLE ON BOARD DIAGNOSIS LA4A EL Pinpoint Test No Go to next step 3 Improper pressure Is line pressure higher than normal cr 05 17A MEC...

Page 715: ...e only Do any of the following problems exist Seals or piston are damaged Wave spring is damaged Friction elements are damaged worn misassembled Return spring component is damaged worn or misassembled...

Page 716: ...gs 3 and 4 Forward or 6 and 7 Reverse are damaged Pump gear pocket is damaged Separator plate is damaged Yes Service as required No Go to next step 7 Forward clutch component Forward only Do any of th...

Page 717: ...ges Do any of the following problems exist Damaged Misadjusted Misassembled tr 05 18 SELECTOR LEVER REMOVAL INSTALLATION Yes Service as required No Go to step 10 4 Control valve body Do any of the fol...

Page 718: ...ry gearsets differential Are there any problems with the following Gear Teeth Carriers Splines Yes Service as required No The problem is fixed 6 SOME OR ALL SHIFTS MISSING TROUBLESHOOTING HINTS ATF Po...

Page 719: ...dometer sensor drive gear is damaged Yes Service as required No The problem is not in the automatic transaxle Go to engine symptom troubleshooting d 01 01A ENGINE SYMPTOM TROUBLESHOOTING FS 8 SHIFT CO...

Page 720: ...CONCERN FEEL SOFT SLIPPING TROUBLESHOOTING HINTS ATF Control valve body Powertrain control system Oil pump Internal or external shift linkages Oil filter and seal component Improper pressure STEP INS...

Page 721: ...plate gasket are damaged or missing Yes Service as required No Go to next step Oil pump Do any of the following problems exist Bolts are not torqued to specification Gaskets are damaged Porosity cros...

Page 722: ...STALLATION LA4A EL Yes Service as required No Go to next step Engine mounts Do any of the following problems exist Damaged Loose Missing cr 05 17A AUTOMATIC TRANSAXLE REMOVAL INSTALLATION LA4A EL Yes...

Page 723: ...L SYSTEM COMPONENT LA4A EL Yes Run OBD test Perform Pinpoint tests A and D it 05 01A AUTOMATIC TRANSAXLE ON BOARD DIAGNOSIS LA4A EL Pinpoint Test No Go to next step Internal or external shift linkages...

Page 724: ...ARD DIAGNOSIS LA4A EL No Go to next step 2 Internal or external shift linkage Do any of the following problems exist Damaged Misadjusted Misassembled tr 05 18 SELECTOR LEVER REMOVAL INSTALLATION Yes S...

Page 725: ...ued to specification Gaskets are damaged 1 2 shift valve 2 4 accumulator main regulator valve are stuck damaged or misassembled SS1 SS2 malfunction Pressure tap plate gasket are damaged Separator plat...

Page 726: ...assembled SS1 SS2 malfunction also no fourth Separator plates are damaged Pressure tap plate gasket leaks Hydraulic passages are damaged Yes Service as required No Go to next step 4 Oil pump Do any of...

Page 727: ...f the following problems exist Bolts are not torqued to specification Gasket leaks 3 4 Shift Valve main regulator valve are stuck damaged or misassembled SS1 SS2 malfunction Also no first gear Separat...

Page 728: ...es Service as required No Go to next step 3 2 4 band and servo component Do any of the following problems exist Piston seals or piston bore are damaged or missing Servo rod or rod bore is damaged 2 4...

Page 729: ...ssure tap plate gasket leaks Yes Service as required No Go to next step 3 Oil pump Do any of the following problems exist Bolts are not torqued to specification Gaskets are damaged Pump support seals...

Page 730: ...re tap plate gasket leaks Hydraulic passages are damaged Separator plates are damaged or orifice is blocked Yes Service as required No Go to next step 3 2 4 band and servo component Do any of the foll...

Page 731: ...plates are damaged or blocked Yes Service as required No Go to next step 3 2 4 band and servo component Do any of the following problems exist 2 4 band and or reverse clutch drum component are damage...

Page 732: ...r blocked Yes Service as required No Go to next step 3 Oil pump Do any of the following problems exist Bolts are not torqued to specification Gaskets are damaged Porosity cross leaks Pump support seal...

Page 733: ...1A AUTOMATIC TRANSAXLE ON BOARD DIAGNOSIS LA4A EL Pinpoint Test No Go to next step 2 Oil pump Do any of the following problems exist Gaskets are damaged Porosity cross leaks Pump support seals 3 and 4...

Page 734: ...ion Gasket leaks 2 4 accumulator valve 3 2 control valve also harsh 3 4 shift are stuck damaged or misassembled Separator plates are damaged Hydraulic passages are damaged Yes Service as required No G...

Page 735: ...stuck damaged or misassembled Separator plates are damaged Hydraulic passages are damaged Yes Service as required No Go to next step 3 Oil pump Do any of the following problems exist Bolts are not tor...

Page 736: ...ged or misassembled Hydraulic passages are damaged Separator plates are damaged or blocked Yes Service as required No Go to next step 3 Oil pump Do any of the following problems exist Bolts are not to...

Page 737: ...h valve are stuck damaged or misassembled Hydraulic passages are damaged Separator plates are damaged or blocked Yes Service as required No Go to next step 3 Oil pump Do any of the following problems...

Page 738: ...alve are stuck damaged misassembled Hydraulic passages are damaged Separator plates are damaged or blocked 3 2T CCS solenoid malfunction Yes Service as required No Go to next step 3 Oil pump Do any of...

Page 739: ...ing problems exist Leakage Internal damage Yes Perform torque converter test t r 05 17A MECHANICAL SYSTEM TEST LA4A EL Torque Converter Clutch Operation Test No Replace the torque converter component...

Page 740: ...t Vehicle wiring harness PCM Transaxle fluid temperature TFT sensor Throttle position TP sensor O D OFF switch tr 05 17A ELECTRICAL SYSTEM COMPONENT LA4A EL Yes Run OBD test If the problem is engine r...

Page 741: ...REMOVAL INSTALLATION t r 05 17A AUTOMATIC TRANSAXLE REMOVAL INSTALLATION LA4A EL Yes Service as required No Go to next step 3 Starter drive plate Do any of the following problems exist Damaged Misass...

Page 742: ...4 Control valve body Do any of the following problems exist Bolts are not torqued to specification Main regulator valve bypass clutch control valve converter regulator valve are stuck damaged or misa...

Page 743: ...tep 3 Oil pump Do any of the following problems exist Pump support seal rings 2 and 3 for the coast clutch circuit are or damaged missing Yes Service as required No Go to next step 4 Coasting clutch c...

Page 744: ...ired No The problem is not in the automatic transaxle Go to engine symptom troubleshooting tr 01 01A ENGINE SYMPTOM TROUBLESHOOTING FS 35 OTHER VEHICLE MOVEMENT WITH GEAR SELECTOR IN N POSITION TROUBL...

Page 745: ...5 17A AUTOMATIC TRANSAXLE FLUID ATF INSPECTION LA4A EL Yes Service as required No Go to next step Seals gaskets Differential seal speedometer seal pump main control cover servo cover split frange conv...

Page 746: ...l module i d 01 40A POWERTRAIN CONTROL MODULE PCM INSPECTION FS O D OFF indicator light signal Is terminal voltage okay Yes Go to next step No Replace powertrain control module w 01 40A POWERTRAIN CON...

Page 747: ...le Code N um ber chart in 0 1 0 1 B ENGINE ON BOARD DIAGNOSIS KL D TC s that are not directly related to Mazda vehicles ones not written in the W M m ay appear on the NGS tester screen Please ensure t...

Page 748: ...an r r 01 01B ENGINE ON BOARD DIAGNOSIS KL N A P0172 Adaptive fuel control system RH System too rich er 01 01B ENGINE ON BOARD DIAGNOSIS KL N A P0174 Adaptive fuel control system LH System too lean t...

Page 749: ...OSIS KL N A P0605 PCM Read only memory ROM test error X T 01 01B ENGINE ON BOARD DIAGNOSIS KL N A P0703 Brake switch Input malfunction X T 01 01B ENGINE ON BOARD DIAGNOSIS KL N A P0704 Clutch switch I...

Page 750: ...gen sensor heater Exhaust system too cool o 01 01B ENGINE ON BOARD DIAGNOSIS KL N A P1130 Upstream heated oxygen sensor Lack of H02S 11 switch adaptive fuel at limit tr 01 01B ENGINE ON BOARD DIAGNOSI...

Page 751: ...ntrol IAC system Underspeed error cr 01 01B ENGINE ON BOARD DIAGNOSIS KL N A P1602 Immobilizer system Communication error Immobilizer unit PCM o 01 01B ENGINE ON BOARD DIAGNOSIS KL N A P1603 Immobiliz...

Page 752: ...wertrain control module connector terminals 6 9 7 32 and corresponding connector terminals at the transaxle range switch Yes Go to next step No Repair or replace connectors and wiring then go to step...

Page 753: ...t negative battery cable Disconnect transaxle fluid temperature sensor and powertrain control module connectors Is there continuity between powertrain control module terminal 37 and I terminal at the...

Page 754: ...tery cable Disconnect input turbine speed sensor and powertrain control module connectors Is there continuity between powertrain control module connector terminals 84 23 and corresponding connector te...

Page 755: ...o to next step Below specification Go to step 6 4 Check line pressure in D range O D OFF SW OFF Is line pressure okay cr 05 17B MECHANICAL SYSTEM TEST GF4A EL Line Pressure Test Yes Go to next step No...

Page 756: ...RTRAIN CONTROL MODULE PCM INSPECTION KL Yes Go to step 8 No Above specification Go to next step Below specification Go to step 6 4 Check line pressure in D 2 range Is line pressure okay cr 05 17B MECH...

Page 757: ...TROL MODULE PCM INSPECTION KL Yes Go to step 8 No Above specification Go to next step Below specification Go to step 6 4 Check line pressure when solenoid connector is disconnected Solenoid connector...

Page 758: ...s than specification repair or replace any defective parts If ATF color is 3 or 4 replace ATF 3 Is diagnostic trouble code P0732 Gear 2 incorrect ratio indicated Yes Refer to flowchart for diagnostic...

Page 759: ...nspect operation of solenoid valve Disconnect negative battery cable Disconnect solenoid connector Is it operating okay irr 05 17B SOLENOID VALVE INSPECTION GF4A EL Yes Go to next step No Replace torq...

Page 760: ...ect solenoid connector and powertrain control module connectors Is there continuity between terminals Yes Go to next step No Repair or replace connectors and wiring then go to step 7 4 Check for a sho...

Page 761: ...nector and powertrain control module connector Is there continuity between terminals Yes Go to next step No Repair or replace connectors and wiring then go to step 7 4 Check for a short circuit betwee...

Page 762: ...nnect solenoid connector and powertrain control module connector Is there continuity between terminals Yes Go to next step No Repair or replace connectors and wiring then go to step 7 4 Check for a sh...

Page 763: ...ect solenoid connector and powertrain control module connector Is there continuity between terminals Yes Go to next step No Repair or replace connectors and wiring then go to step 7 4 Check for a shor...

Page 764: ...train control module Disconnect negative battery cable Disconnect solenoid connector and powertrain control module connector Is there continuity between terminals Yes Go to next step No Repair or repl...

Page 765: ...tery cable Disconnect solenoid connector and powertrain control module connector Is there continuity between terminals Yes Go to next step No Repair or replace connectors and wiring then go to step 7...

Page 766: ...17B O D OFF SWITCH INSPECTION GF4A EL Yes Go to next step No Replace O D OFF switch then go to step 6 o 05 17B O D OFF SWITCH REMOVAL INSTALLATION GF4A EL 5 After diagnostic trouble code has been cle...

Page 767: ...does not move in D 2 1 ranges or R position when idling on a flat paved road 6 Low maximum speed and poor acceleration Vehicle acceleration is poor at start Delayed acceleration when accelerator is de...

Page 768: ...No engine braking in 1 range and 2 range Second gear Engine speed drops to idle but vehicle coasts when accelerator pedal released during cruising at medium to high speeds Engine speed drops to idle b...

Page 769: ...D or N to R position range shift shock Excessive shift shock w hen upshifting and downshifting Excessive torque converter clutch TCC shift shock Noise at idle when vehicle stopped in all positions ran...

Page 770: ...n D 2 1 ranges and or in R position I I o 0 22 No engine braking in 1 range or 2 range Second gear I o o o 23 Transaxle overtieats O I o o o O Q o 24 Engine stalls when shifted to D 2 1 ranges and or...

Page 771: ...of pressure modifier valve Poor operation sticking Malfunction of pilot valve Poor operation sticking Malfunction of selector lever Parking mechanism not properly operation STEP INSPECTION ACTION 1 Wi...

Page 772: ...Adjust selector lever S 3 05 18 SELECTOR LEVER ADJUSTMENT 2 Check the voltage at the following terminal of the powertrain control module t r 01 40B POWERTRAIN CONTROL Yes Go to next step MODULE PCM I...

Page 773: ...tion The engine torque is not start The torque converter is malfunction STEP INSPECTION ACTION 1 Does vehicle creep in any range position Yes Go to next step No Inspect or adjust selector lever cr 05...

Page 774: ...el economy i t 01 01B ENGINE SYMPTOM TROUBLESHOOTING KL Does CIS system okay Yes Go to next step No Repair or replace any defective parts 3 Disconnect solenoid connector Does vehicle operate as follow...

Page 775: ...Selector lever adjustment incorrect T h e 3GR is fixed Operation in fail safe function Short or open circuit in wiring Poor connection of connector Malfunction of Input output signal system STEP INSPE...

Page 776: ...oltage at the following terminals of the powertrain control module tr 01 40B POWERTRAIN CONTROL MODULE PCM INSPECTION KL Throttle position sensor signal Input turbine speed sensor signal Vehicle speed...

Page 777: ...th indicator switch at ON does O D OFF indicator light indication correspond to O D OFF switch operation Yes Go to next step No Go to No 26 O D OFF INDICATOR LIGHT DOES NOT ILLUMINATE WHEN O D OFF SWI...

Page 778: ...NORMAL SHIFT 2 Check the voltage at the following terminal of the powertrain control module c r 01 40B POWERTRAIN CONTROL Yes Go to next step MODULE PCM INSPECTION KL Pressure control solenoid signal...

Page 779: ...ay Yes Go to next step No Repair or replace any defective parts 2 Check the voltage at the following terminals of the powertrain control module id 01 40B POWERTRAIN CONTROL MODULE PCM INSPECTION KL Th...

Page 780: ...2 Perform the stall test cr 05 17B MECHANICAL SYSTEM TEST GF4A EL Stall Test Is stall speed okay Yes Go to next step No Go to step 4 3 Check the voltage at the following terminals of the powertrain co...

Page 781: ...the stall test tr 05 17B MECHANICAL SYSTEM TEST GF4A EL Stall Test Is stall speed okay Yes Go to next step No Repair or replace any defective parts 2 Check the voltage at the following terminal of the...

Page 782: ...r replace any defective parts 3 Check duty of pressure control solenoid cr 05 17B SOLENOID VALVES INSPECTION GF4A EL Pressure Control Solenoid Output Duty Inspection Is duty okay Yes Overhaul control...

Page 783: ...RTRAIN CONTROL MODULE PCM INSPECTION KL Shift solenoid C signal Input turbine speed sensor signal Vehicle speedometer sensor signal Is terminal voltage okay Yes Overhaul control valve body and repair...

Page 784: ...e at the following terminal of the powertrain control module c r 01 40B POWERTRAIN CONTROL MODULE PCM INSPECTION KL Load no load distinction signal R position D 2 1 ranges signal TCC control solenoid...

Page 785: ...OFF indicator light Is O D OFF indicator light okay Yes Inspect for open circuit or disconnected connector in harness between the following Ignition switch and O D OFF indicator light O D OFF indicato...

Page 786: ...ng the procedure add brake fluid bleed the air and inspect for leakage after the procedure has been completed 2 If removing the clutch pipe remove it by using the SST 49 0259 770B If installing the cl...

Page 787: ...y hand until clutch resistance is felt and measure the pedal free play Pedal free play 1 0 3 0 mm 0 04 0 11 in Total pedal free play 5 0 14 0 mm 0 20 0 55 in W 6 U 5 10 W 0 4 11 8 16 6 Nm 120 170 k g...

Page 788: ...table 4 Install in the reverse order of removal 19 25 W 6 U 5 1 0 W A 2 1 Nut 2 Clutch switch connector 3 Clutch switch 4 Nut 5 E clip 6 Pin 7 Bushing 8 Nut 9 Push rod 10 Clevis 11 Pedal pad 12 Clutch...

Page 789: ...rder indicated in the table 2 Install in the reverse order of removal 49 0259 770B 1 Charcoal canister 2 Clip 3 Clutch pipe 4 Nut 5 Clutch master cylinder 6 Gasket 1 9 2 6 14 18 12 8 21 5 N m 130 220...

Page 790: ...W 6 U 5 10 W 0 7 D O W 6 U 5 10 W A 4 1 Joint 5 Spacer 2 Bushing 6 Primary cap 3 Snap ring 7 Return spring tr Disassembly Assembly Note 8 Master cylinder body 4 Piston and secondary cap Snap Ring Disa...

Page 791: ...lutch pipe Bolt 3 Clutch release cylinder CLUTCH RELEASE CYLINDER DISASSEMBLY ASSEMBLY 1 Disassemble in the order indicated in the table 2 Assemble in the reverse order of disassembly W 6 U 5 1 0 W 0...

Page 792: ...h disc t r Removal Note jt Installation Note 8 Pilot bearing r r Removal Note o Installation Note 9 Flywheel c r Removal Note cr Installation Note 1 Clutch release cylinder 2 Manual transaxle tr 05 15...

Page 793: ...pilot bearing Note FS 6 bolt KL 8 bolt Pilot Bearing Installation Note Install a new pilot bearing by using a SST Bearing installation depth 0 0 4 mm 0 0 015 in W 6 U 5 1 0 W A A Flywheel Removal Not...

Page 794: ...0 0236 in max 2 Measure the flatness of the pressure plate by using a straight edge and a feeler gauge Maximum clearance 0 5 mm 0 020 in W6U510W11 3 When checking the diaphragm spring fingers mount a...

Page 795: ...6 U 5 1 0 W A K CLUTCH RELEASE COLLAR INSPECTION W 6 U 5 1 0 W 1 3 Caution 2 If the collar sticks or has excessive resistance Cleaning the clutch release collar with replace it cleaning fluids or a s...

Page 796: ...TION 1 Install a dial gauge on the cylinder block 2 Measure the flywheel runout by using a dial indicator Replace the flywheel if runout is excessive Runout 0 2 mm 0 008 in max W 6 U 5 1 0 W 1 5 W 6 U...

Page 797: ...and the oil level plug Tightening torque 40 58 Nm 4 0 6 0 kgf m 29 43 ftlbf TRANSAXLE OIL REPLACEMENT 1 Remove the drain plug and washer 2 Drain the oil into a suitable container 3 Install a new wash...

Page 798: ...R SENSOR INSPECTION 1 Remove the vehicle speedometer sensor 2 Measure voltage between terminals of the vehicle speedometer sensor while the gear is turning Meter needle Action Moves slightly under 5 V...

Page 799: ...he order indicated in the table 8 Install in the reverse order of removal 9 Add the specified amount of the specified transaxle oil Refer to 05 15 TRANSAXLE OIL REPLACEMENT 10 Warm up the engine and t...

Page 800: ...Note 9 Stabilizer control link 10 Lower arm ball joint 11 Drive shaft zr 03 13 DRIVE SHAFT REMOVAL INSTALLATION 12 Joint shaft zr 03 13 JOINT SHAFT REMOVAL INSTALLATION 13 No 5 engine mount bolt 14 E...

Page 801: ...8 2 41 59 94 131 9 5 13 4 68 8 96 9 67 93 6 8 9 5 50 68 75 104 7 6 10 7 6 8 9 5 50 68 44 60 4 4 6 2 32 44 1 Neutral switch connector 2 Back up light switch connector 3 Speedometer sensor connector 4 S...

Page 802: ...Transaxle Removal Note 1 Loosen the SST 49 G017 5A0 and lean the engine toward the transaxle 2 Support the transaxle on a jack 3 Remove the transaxle mounting bolts 4 Remove the transaxle Transaxle I...

Page 803: ...MANUAL TRANSAXLE W 6 U 5 1 5 W A C 05 15 7...

Page 804: ...6 W 0 1 1 Remove the three way catalystic converter Refer to 01 13A EXHAUST SYSTEM REMOVAL INSTALLATION FS Refer to 01 13B EXHAUST SYSTEM REMOVAL INSTALLATION KL 2 Remove in the order indicated in the...

Page 805: ...le______ Insulator Transverse member Heat insulator Change control rod Bushing Bushing Nut Washer Nut_______________ Boot Retaining ring Spacer___________ Compression ring Upper ball seat Boot Lower b...

Page 806: ...OR REMOVAL INSTALLATION LA4A EL 05 17A 19 O D OFF INDICATOR LIGHT INSPECTION LA4A EL 05 17A 19 POWERTRAIN CONTROL MODULE INSPECTION LA4A EL 05 17A 19 POWERTRAIN CONTROL MODULE REMOVAL INSTALLATION LA4...

Page 807: ...the line pressure inspection port 3 Start the engine 4 W hile depressing the brake pedal move the shifter to each sector position and record line pressure at engine idle 5 C om pare pressure valves re...

Page 808: ...brake pedal with the left foot and then gradually depress the accelerator pedal with the right 4 When the engine speed no longer increases quickly read the engine speed and release the accelerator 5 S...

Page 809: ...ting in death or injury Always have another person in the vehicle with you to read the manual or devices while you drive Note Perform the OBD test Check for a code P0741 or P0743 Refer to the appropri...

Page 810: ...obtained The shift points must be as shown in the D range O D OFF switch OFF shift point 4 Drive the vehicle in fourth third and second gears and verify that kickdown occurs for 4 3 3 2 3 1 2 1 and th...

Page 811: ...8 36 17 22 Half throttle 2GR 3GR 61 77 38 48 NORMAL 3GR 4GR 105 132 65 82 TCC ON 4GR 118 145 73 90 Closed throttle position 4GR 3GR 37 43 23 27 D 3GR 1GR 8 14 5 9 4GR 3GR 148 158 92 98 Kickdown 3GR 2G...

Page 812: ...ondition Inspection One way of determining whether the transaxle should be disassembled is by noting 1 If the ATF is muddy or varnished 2 If the ATF smells strange or unusual ATF Condition Condition P...

Page 813: ...lutch or stuck valve WHEEL CHOCK W6U517WCW 7 Ensure that the ATF level is between max and min 3 Adjust the length of the thermistor probe measure to the same length as the dipstick and hold the probe...

Page 814: ...ansaxle tester at the solenoid body connector allows the separation of the vehicle electronics from the transaxle electronics Disconnecting the normal vehicle electronics will set additional DTCs and...

Page 815: ...ter perform the Pinpoint Tests as indicated in On Board Diagnostics Refer to 05 01A AUTOMATIC TRANSAXLE ON BOARD DIAGNOSIS LA4A EL based on the DTC which were displayed Perform repairs as indicated by...

Page 816: ...s shorted to BAT LED will remain OFF if an activated solenoid harness is shorted to ground or no continuity STATUS 1 2 3 4 O I ST T E bfsi ptf IfCTT o I 6r s e n irsnroni O F F irSET W 6 U 5 1 7 W A D...

Page 817: ...to REVERSE Did vehicle shift into REVERSE Was engagement harsh 2 Shift vehicle from REVERSE to PARK 4 Turn GEAR SELECT switch to 1 1 Depress EPC switch Line pressure should drop to idle pressure 2 Whi...

Page 818: ...e appropriate shift solenoids activate deactivate Torque converter clutch TCC engagement Does the torque converter engage Does the engine speed drop Did the TCC solenoid activate Note This test should...

Page 819: ...ester 3 Testing the TR switch 4 Testing the Park Neutral and backup circuits 5 Removing the transaxle tester and clearing DTCs Preliminary testing and diagnosis Before any diagnostic testing is carrie...

Page 820: ...ter a repair 3 Turn the test select switch to the TR MLP SENSOR TEST position SENSOR TEST TR MLP SENSOR S C TEST POSITION 0 W 6 U 5 1 7 W A Q 4 Plug the transaxle tester power supply plug into the cig...

Page 821: ...transaxle tester from the transaxle range TR switch connector W6U517WAU 2 Reinstall the emission harness Verify the connection by pulling up on the harness 3 Disconnect the transaxle tester power lea...

Page 822: ...D OFF SWITCH INSPECTION GF4A EL O D OFF SWITCH REMOVAL INSTALLATION LA4A EL W 6 U 5 1 7 W 4 2 Refer to 05 17B O D OFF SWITCH REMOVAL INSTALLATION GF4A EL VEHICLE SPEEDOMETER SENSOR INSPECTION LA4A EL...

Page 823: ...TAKE AIR SYSTEM REMOVAL INSTALLATION FS 11 Connect the negative battery cable W 6 U 5 1 7 W F A SOLENOID BODY REMOVAL INSTALLATION LA4A EL 1 Remove the control valve body Refer to 05 17A CONTROL VALVE...

Page 824: ...sh shield 10 Install the wheel and tire drivers sheets side 11 Connect the negative battery cable TRANSAXLE FLUID TEMPERATURE SENSOR REMOVAL INSTALLATION LA4A EL W 6 U 5 1 7 W 4 7 Note SOLENOID BODY R...

Page 825: ...in the reverse order of removal 10 Install the splash shield 11 Install the wheel and tire 12 Install the fresh air duct air cleaner component Refer to 01 13A INTAKE AIR SYSTEM REMOVAL INSTALLATION F...

Page 826: ...N m 80 110 kgf cm 69 5 95 4 in lb f 86 116 8 7 11 9 63 86 35 56 3 5 5 8 26 41 37 53 3 7 5 5 27 39 86 116 8 9 11 9 63 86 68 99 6 9 10 1 50 73 86 116 8 7 11 9 63 86 94 131 9 5 13 4 69 96 44 60 4 4 6 2...

Page 827: ...t 12 No 4 engine mount tr Removal Note 13 Transverse member 14 Vehicle speedometer sensor connector 15 Engine mounting member tr Installation Note 16 Tie rod end tr Removal Note d Installation Note 17...

Page 828: ...tie rod end dust boot Install the SST so that the sharp edges are between the dust boot and the tie rod 1 Remove the cotter pin and nut 2 Disconnect the tie rod end from the knuckle by using the SST...

Page 829: ...B 8 3 Remove the transaxle mounting bolts 4 Remove the transaxle Transaxle Installation Note Warning Do not allow the transaxle to fall from the jack Verify that the transaxle is securely supported b...

Page 830: ...ning torque 7 9 10 7 N m 80 110 kgf cm 69 5 95 4 in lbf W 6 U 5 1 7 W F B W 6 U 5 1 7 W B D Drive Shaft Installation Note Refer to 03 13 JOINT SHAFT REMOVAL INSTALLATION Clip Installation Note Lower A...

Page 831: ...permanent thread sealer This nut and washer will aid in the installation of the cover W 6 U 5 1 7 W 0 8 5 Remove the servo cover retaining ring and release the tension on the servo cover component sl...

Page 832: ...mponent ELECTRICAL CONNECTOR W 6 U 5 1 7 W C R 13 If the thermostatic oil level control valve must be removed remove the bolt and the bracket Pull the thermostatic oil level control valve straight out...

Page 833: ...he oil hose Refer to 05 17A OIL COOLER REMOVAL INSTALLATION LA4A EL 31 Connect the solenoid body connector 32 Connect the TR switch connector 33 Install the splash shild 34 Install the wheel and tire...

Page 834: ...case interface area refer to the following service procedure to replace the pump body seal Caution This procedure does not require complete teardown of the transaxle and should only be used for leak...

Page 835: ...bearing This bearing may be attached to the pump support or on the reverse clutch hub W 6 U 5 1 7 W C 2 11 Remove the pump support mounting bolts W 6 U 5 1 7 W C 3 12 Remove the pump support W 6 U 5...

Page 836: ...p support seals and the pump bore in the case 24 Lower the pump component into the case W 6 U 5 1 7 W C 6 15 Install the SST in the holes Use the bolt hole next to the TSS sensor hole and the bolt hol...

Page 837: ...ence shown 26 Install the turbine shaft speed TSS sensor and mounting bolt and tighten to 13 N m 1 3 kgf m 10 ft lbf 27 Install the pump drive shaft 28 Install the torque converter into the transaxle...

Page 838: ...LUID ATF REPLACEMENT LA4A EL 6 Connect the negative battery cable 7 Inspect for oil leakage from the oil pipes and oil hoses 8 Inspect the ATF level and condition Refer to 05 17A AUTOMATIC TRANSAXLE F...

Page 839: ...and slide the oil hose onto the oil pipe until it is fully seated as shown MARKS Note In order to prevent ATF leakage replace the hose When any damages are found inside or outside of the hose especia...

Page 840: ...nting Bolts Removal Note 1 Set the SST or equivalent against the drive plate 2 Remove the bolts and the drive plate Drive Plate Mounting Bolts Installation Note 1 Remove any old locking compound from...

Page 841: ...Resistance 05 17B 16 Inspection of O peration 05 17B 16 Inspection of Output D u ty 05 17B 16 SOLENOID VALVE REMOVAL INSTALLATION G F4A E L 05 17B 17 O D OFF INDICATOR LIGHT INSPECTION G F4A E L 05 1...

Page 842: ...e 5 Replace the SST 49 B019 901 to the 49 B019 902 W 6 U 5 1 7 W 1 4 Caution If the accelerator pedal is pressed for longer than 5 seconds while the brake pedal is depressed the transaxle could be dam...

Page 843: ...right 4 W hen the engine speed no longer increases quickly read the engine speed and release the accelerator pedal 5 Shift the selector to N position and let the engine idle for 1 minute or more to co...

Page 844: ...More than specification N D shift Insufficient line pressure Forward clutch slipping One way clutch 1 slipping One way clutch 2 slipping N R shift Insufficient line pressure Low and reverse brake sli...

Page 845: ...effect is felt in fourth and third gears 6 Drive the vehicle and verify that torque converter clutch operation is obtained in fourth gear only for NORMAL mode D range O D OFF switch ON 1 Shift the sel...

Page 846: ...1GR 2GR 36 40 22 25 3 650 2 257 SLOPE Half throttle 2GR 3GR 70 89 43 55 3 150 3 300 3GR 4GR 93 119 58 74 3 350 3 050 D TCC ON 4GR 133 140 82 87 3 400 3 550 Closed throttle position 4GR 1GR 11 17 7 10...

Page 847: ...hicle speed km h mph Turbine speed rpm 2 4GR 3GR 165 171 102 106 4 200 4 300 3GR 2GR 101 107 62 66 3 650 3 900 Vehicle with TCS Range Throttle condition Shift Vehicle speed km h mph Turbine speed rpm...

Page 848: ...ection One way of determining whether the transaxle should be disassembled is by noting 1 If the ATF is muddy or varnished 2 If the ATF smells strange or unusual ATF Condition Condition Possible cause...

Page 849: ...not warm the transaxle by performing stalls This will damage the torque converter 5 While depressing the brake pedal shift the selector lever to each range P 1 pausing momentarily in each range 6 Shif...

Page 850: ...ft lbf O D OFF SWITCH INSPECTION GF4A EL Inspection of Operation 1 Turn the ignition switch from OFF to ON 2 Verify that the O D OFF indicator is not illuminated Depress the O D OFF switch and verify...

Page 851: ...R DISASSEMBLY ASSEMBLY 9 Install the front console Refer to 09 17 FRONT CONSOLE REMOVAL INSTALLATION 10 Connect the negative battery cable TRANSAXLE RANGE SWITCH INSPECTION GF4A EL Inspection of Opera...

Page 852: ...nge switch 9 Rotate the manual shaft to converter housing side fully then return 2 notches to set the neutral position 10 Turn the transaxle range switch so that the N mark is in line with the flat st...

Page 853: ...spring pin and clip 13 Install the air cleaner component fresh air duct and resonance chamber Refer to 01 13B INTAKE AIR SYSTEM REMOVAL INSTALLATION KL 14 Connect the negative battery cable TRANSAXLE...

Page 854: ...st Refer to 05 17B MECHANICAL SYSTEM TEST GF4A EL Line Pressure Test INPUT TURBINE SPEED SENSOR INSPECTION GF4A EL 1 Disconnect the negative battery cable 2 Remove the resonance chamber fresh air duct...

Page 855: ...eed sensor connector 9 Install the fuel filter mounting nuts 10 Install the air cleaner component fresh air duct and resonance chamber Refer to 01 13B INTAKE AIR SYSTEM REMOVAL INSTALLATION KL 11 Conn...

Page 856: ...ctor 4 Measure the resistance between terminals A through G and a ground ATF temperature 4 0 160 C 40 320 F Terminal Solenoid valve Resistance 2 A Shift solenoid A 11 27 B Shift solenoid B 11 27 C Shi...

Page 857: ...8 N m 66 80 kgf cm 58 69 in lbf 5 Install the control valve body Refer to 05 17B CONTROL VALVE BODY REMOVAL INSTALLATION GF4A EL 6 Carry out the time lag test and line pressure test Refer to 05 17B M...

Page 858: ...NSTRUMENT CLUSTER REMOVAL INSTALLATION 9 Connect the negative battery cable POWERTRAIN CONTROL MODULE INSPECTION GF4A EL W6U517W29 Note For PID DATA Monitor and Record refer to 01 40B POWERTRAIN CONTR...

Page 859: ...Install in the reverse order of removal 10 Install the splash shield 11 Install the wheel and tire 12 Install the air cleaner component fresh air duct Refer to 01 13B INTAKE AIR SYSTEM REMOVAL INSTAL...

Page 860: ...N m 70 100 kgfcm 60 7 86 7 in lbf g 7 9 10 7 N m 80 110 kgfcm 69 5 95 4 in lbf 7 9 10 7 N m 80 110 kgfcm 69 5 95 4 In lbf 75 104 7 6 10 7 54 9 77 3 94 131 9 5 13 4 69 96 75 104 7 6 10 7 54 9 77 3 67...

Page 861: ...ting bolts_________________ Oil hose O 05 17B OIL COOLER REMOVAL INSTALLATION GF4A EL Breather hose c r Installation Note Lower arm sy Removal Note Ixr Installation Note Tie rod end cr Removal Note u...

Page 862: ...the ball joint dust boot 3 Pry the lower arm out of the knuckle W 6 U 5 1 7 W D Y Tie Rod End Removal Note Caution The sharp edges of the SST can slice the tie rod end dust boot Install the SST so tha...

Page 863: ...event damage to the body insert a rag into the gap between the fender and body when installing the SST 1 Support the engine by using the SST before removing the engine mounting member 2 Remove the eng...

Page 864: ...2 engine mount stud bolts through the engine mount member installation holes 3 Install the engine mount member bolts A and nuts A Tightening torque A 67 93 N m 6 8 9 5 kgf m 50 68 ftlbf 4 Loosely tigh...

Page 865: ...the oil seal 3 Hand tighten A bolts 4 Tighten the A B bolts to the specified torque Tightening torque 43 61 N m 4 3 6 3 kgf m 32 45 ft lbf Lower Arm Installation Note 1 Connect the lower arm to the kn...

Page 866: ...N GF4A EL 5 Using the SST and a hammer tap the new oil seal in evenly until the SST contacts the transaxle case 6 Coat the lip of the oil seal with ATF 0 5 0 5 mm 0 02 0 02 in W 6 U S 1 7 W E N CONTRO...

Page 867: ...lbf W 6 U 5 1 7 W E U 14 Install the radiator hose Refer to 01 12 RADIATOR REMOVAL INSTALLATION 15 Install the oil cooler hose Refer to 05 17B OIL COOLER REMOVAL INSTALLATION GF4A EL 16 Install the s...

Page 868: ...GF4A EL 10 Carry out the line pressure test Refer to 05 17B MECHANICAL SYSTEM TEST GF4A EL Line Pressure Test 11 Carry out the road test Refer to 05 17B ROAD TEST GF4A EL N m kgf m ft lbf W 6 U 5 1 7...

Page 869: ...t MARK CONTROL VALVE BODY COVER i S W 6 U 5 1 7 W E Y 2 Aligen the marks and slide the oil hose onto oil pipe until it is full seated as shown Oil Hose Installation Note Oil cooler side 1 Position the...

Page 870: ...moval Note cr Installation Note Backing plate Drive Plate Mounting Bolts Removal Note 1 Set the SST or equivalent against the drive plate 2 Remove the bolts and the drive plate Drive plate Adapter Dri...

Page 871: ...emove the interlock cable and lock unit 2 With the slider pin protrusion dimension A as specified below verify that the interlock cable moves freely in the lock unit W 6 U 5 1 8 W 0 1 3 If not as spec...

Page 872: ...all the front console Refer to 09 17 FRONT CONSOLE REMOVAL INSTALLATION 11 Verify correct operation of the selector lever Refer to 05 18 SELECTOR LEVER INSPECTION HEAVY GAUGE WIRE W 6 U 5 1 8 W A 6 5...

Page 873: ...order of removal 10 Install the SAS unit braket Refer to 08 10 SAS UNIT BRAKET REMOVAL INSTALLATION 11 Install the heater unit Refer to 07 11 HEATER UNIT REMOVAL INSTALLATION 12 Install the front con...

Page 874: ...lock Cable Installation Note 1 Verify that the ignition switch is in LOCK position and shift the selector lever in P position 2 Install the lock unit Tightening torque 4 3 6 2 N m 43 63 kgfcm 38 54 in...

Page 875: ...to P position KL or D range FS 4 Connect the set button 5 Slide the lock cover and lock the set button W 6 U 5 1 8 W A K Selector Cable Installation Note 1 Shift the selector lever and manual shaft to...

Page 876: ...n each range W 6 U 5 1 8 W A M SELECTOR LEVER DISASSEMBLY ASSEMBLY W 6 U 5 1 8 W 0 6 1 Disassemble in the order indicated in the table 2 Assemble in the reverse orde of disassembly W 6 U 5 1 8 W A N 5...

Page 877: ...2 Align the alignment screws in the slider with the holes in the indicator panel Install heavy gauge wire to hold the slider W 6 U 5 1 8 W A Q 3 Temporarily install the indicator panel to the selecto...

Page 878: ...ANUAL TRANSAXLE Transaxle type G25M R Grade API service GL 4 or GL 5 Oil Viscosity All season SAE 75W 90 Above 10 C 50 F SAE 80W 90 Capacity L US qt Imp qt 2 7 2 9 2 4 AUTOMATIC TRANSAXLE Transaxle ty...

Page 879: ...0 1044 0 1090 Turbine shaft speed sensor TSS C l 12 22 Input turbine speed sensor C i ATF temperature 40 160 X 40 320 F 235 604 Shift solenoid No 1 SS1 12 22 Shift solenoid No 2 SS2 12 22 TCC 12 5 19...

Page 880: ...re guage T B 0 1 9 9 0 2 X T B 0 1 9 9 0 3 X T 8 0 1 9 9 0 1 X 49 UN01 086 MLPS alignment tool LA4A EL nJ 49 UN01 071 Transaxle tester LA4A EL o 49 UN01 089 Transaxle diagnostic harness LA4A EL T U N...

Page 881: ...T U N 1 1 1 0 1 X T E 0 1 1 1 A O X T E 0 1 1 1 0 3 X 49 E011 104 Collar Part of 49 E011 1AO a 49 E011 105 Stopper Part of 49E011 1AO 49 UN01 100 Oil pump removal bolts T E 0 1 1 1 0 4 X 49 8501 631A...

Page 882: ...el is removed tighten it to 89 117 N m 9 0 12 0 kgf m 66 86 ft lbf Power steering components removal installation If any power steering fluid line has been disconnected anytime during the procedure ad...

Page 883: ...UMP REMOVAL INSTALLATION 06 12 11 Nut Removal Installation Note 06 12 12 POWER STEERING OIL PUMP DISASSEMBLY ASSEMBLY 06 12 13 Oil Pump Disassembly N o te 06 12 15 Shaft And Bearing Disassembly Note 0...

Page 884: ...e valve is left closed for more than 5 seconds the fluid temperature will increase excessively and adversely affect the oil pump 5 Close the gauge valve completely Increase the engine speed to 1 000 1...

Page 885: ...verify that the play is within the specification Play 0 30 mm 0 1 18 in 2 If the play exceeds the specification either the steering joints are worn or the backlash of the steering gear is excessive Co...

Page 886: ...e or connectors 3 Function of oil pump and steering gear N m kgf m tt lbf W 6 U 6 1 2 W A 7 STEERING WHEEL AND COLUMN REMOVAL INSTALLATION W 6 U 6 1 2 W 0 4 1 Remove in the order indicated in the tabl...

Page 887: ...position 3 After installation lightly tap the lower bracket at the point shown by using a hammer to verify correct installation STEERING SHAFT COMPONENT DISASSEMBLY ASSEMBLY W 6 U 6 1 2 W 0 5 1 Steeri...

Page 888: ...ponent as necessary 1 Column bearing rotates smoothly and there is no damage 2 Steering shaft length is within the specification W 6 U 6 1 2 W 0 6 3 Tilt operation 1 Verify that the adjusting lever mo...

Page 889: ...m 70 100 kgfcm 60 8 86 7 in lbf 18 26 1 8 2 7 14 19 6 87 9 80 N m 70 100 kgfcm 60 8 86 7 in lbf jj 2 31 44 3 2 4 5 24 32 DD 64 89 6 5 9 1 47 65 94 131 9 5 13 4 69 96 N m kgf m ft lbf W 6 U 6 1 2 W B 1...

Page 890: ...pulling it from the right side Mounting Bracket Nut And Bolt Installation Note 1 Loosely tighten nuts 4 and 3 2 Tighten the mounting bracket nuts and bolts to the specified torque in the order shown B...

Page 891: ...e 2 Assemble in the reverse order of removal W 6 U 6 1 2 W A L 9 Boot 10 Tie rod 11 Locknut adjusting cover 12 Adjusting cover tr Assembly Note 13 Spring 14 Pressure pad 15 Steering gear component 1 O...

Page 892: ...lbf 49 0180 510B STEERING GEAR AND LINKAGE INSPECTION Tie rod End Inspection 1 Inspect the tie rod end for damage and boot cracks Replace it as necessary 2 Inspect the ball joint for looseness Replac...

Page 893: ...indicated in the table 3 Install in the reverse order of removal 4 Adjust the drive belt Referto 01 10A DRIVE BELT ADJUSTMENT FS Referto 01 10B DRIVE BELT ADJUSTMENT KL FS ENGINE N m kgf m ft lbf W 6...

Page 894: ...in lbf 1 Locknut 2 Idler puiley and bearing 3 Adjusting bolt 4 Drive belt 5 Nut d Removal Installation Note 6 Pulley 7 Pump bracket 8 PSP switch connector 9 Pressure pipe 10 Return hose 11 Power stee...

Page 895: ...irs are necessary 1 Disassemble in the order indicated in the table 2 Assemble in the reverse order of disassembly N m kgf m ft lbf W 6 U 6 1 2 W B 2 10 Cam ring er Assembly Note 11 Backup ring 12 Rot...

Page 896: ...t 5 O ring 6 Connector 7 O ring 8 Control valve 9 Spring 10 Rear Pump body e7 Assembly Note 11 Gasket 12 Pin 13 Cam ring nr Assembly Note 14 Rotor 15 Blade cr Assembly Note 16 Side plate 17 O ring 18...

Page 897: ...ng Disassembly Note Disassemble the shaft and bearing by using a press Blade Assembly Note Place the blades in the rotor with the rounded edges contacting the cam Oil Seal Assembly Note Tap the oil se...

Page 898: ...STEERING WHEEL Steering wheel play mm in 0 30 0 1 2 Steering wheel effort N m kgf cm in lbf 7 8 80 69 max STEERING SHAFT AND JOINT Shaft length mm in 516 4 20 33 POWER STEERING SYSTEM Type ATF M III o...

Page 899: ...t r r r r r snr T 1 2 3 2 6 7 0 A 49 1232 670A T1232673X 49 H002 671 49 0180 510B Preload attachment T 0 1 8 0 5 1 0 B 49 G032 3A4 Adapter set T G 0 3 2 3 A 4 X gauge adapter w ga h T H 0 0 2 6 7 1 X...

Page 900: ...terminal and for any damage If the connection is poor reconnect them or repair or replace the appropriate parts if necessary Troubleshooting hint lists inspection part step according to malfunction U...

Page 901: ...hen go to step 4 2 K 2 I o O 2 A 2 L 2 J 2 H 2 F 2 D 2 B W6U701WA0 Measure voltage at terminal 2J GND signal of heater control unit 10 pin connector is voltage 0 V Yes Replace heater control unit then...

Page 902: ...heater control unit and air mix actuator Malfunction In air mix actuator s actuator control signal circuit Malfunction in wiring harness between heater control unit and air mix actuator Malfunction in...

Page 903: ...it 10 pin connector and air mix actuator connector Check if there is no continuity between the following terminals and ground Terminal 2D 10 pin heater control unit terminal F air mix actuator Is ther...

Page 904: ...rol unit terminal F air mix actuator Is there continuity Yes Go to next step 2 K 21 ro O 2 A 2 L 2 J 2 h 2 F 2 D 2B G X C H F D No Repair wiring harness between heater control unit and air mix actuato...

Page 905: ...repairs to customer No Reconfirm malfunction symptoms then repeat from step 1 if malfunction reoccurs No cool air TROUBLESHOOTING HINTS Malfunction in A C switch indicator light circuit Heater contro...

Page 906: ...nt system performance test o 07 10 REFRIGERANT SYSTEM PERFORMANCE TEST Is operation normal Yes Reconfirm malfunction symptoms No Go to next step Inspect drive belt t e r01 10 DRIVE BELT INSPECTION Is...

Page 907: ...nal 1F 14 pin heater control unit Is there continuity Yes Go to next step 10 1M 1K X 1E 1C 1A 1N 1L 1J 11H 1F 1D 1B No B Repair wiring harness between refrigerant pressure switch LO and heater control...

Page 908: ...efrigerant pressure switch LO Is there continuity Yes Go to next step No Repair wiring harness between refrigerant pressure switch HI and LO then go to step 25 REFRIGERANT PRESSURE SWITCH HI CONNECTOR...

Page 909: ...0 Inspect Input signal parts power steering pressure switch engine coolant temperature sensor crankshaft position sensor throttle position sensor A C switch and refrigerant pressure switches excluding...

Page 910: ...nt compressor oil A C compressor malfunction STEP INSPECTION ACTION 1 Perform refrigerant system performance test w 07 10 REFRIGERANT SYSTEM PERFORMANCE TEST Is operation okay Yes Operation is normal...

Page 911: ...p 13 Remove A C compressor and drain compressor oil d 07 11 A C COMPRESSOR REMOVAL INSTALLATION Check charged compressor oil amount Refill specified compressor oil amount into A C compressor After com...

Page 912: ...ls at closed Yes Turn dial to open position then go to step 10 position No Go to next step 4 Is vent clogged Yes Remove obstruction then go to step 10 No Go to next step 5 Is duct in dashboard properl...

Page 913: ...epair wiring harness between A C 10 A fuse and air intake actuator then go to step 7 A IR IN T A K E A C T U A T O R W 6 U 7 0 1 W A R Remove air intake actuator Turn ignition switch to ON Set fan swi...

Page 914: ...uator malfunction Malfunction in heater control unit s each signal circuit Malfunction in wiring harness between heater control unit and airflow mode actuator Malfunction in heater unit s each door ci...

Page 915: ...tinuities 1 0 1 M 1K r 1E 1C 1 A 1N 1L 1J 1 1 H 1 F 1D 1B H E A T E R C O N T R O L U N IT 1 4 P IN C O N N E C T O R 2 K 2 I m 2 A 2 L 2J 2 H 2 F 2 D 2 B I G X C A J H F D B H E A T E R C O N T R O L...

Page 916: ...heat A poisonous gas may be generated if the refrigerant gas contacts fire or heat such as from cigarettes and heaters When carrying out any operation that can cause refrigerant leakage extinguish or...

Page 917: ...ature is in the shaded zone W 6 U 7 1 0 W 0 4 C fF 10 50 O 9 48 8 46 7 45 W 6 43 cccr 5 41 L UL U h CL L Z 2 2 0 2 5 3 0 3 5 4 0 C O K 6 8 7 7 8 6 9 5 1 0 4 T AMBIENT TEMPERATURE W 6 U 7 1 0 W A 2 12...

Page 918: ...he manifold gauge are a t 101 kPa 760 mmHg 29 9 inHg Close each valve of the manifold gauge W 6 U 7 1 0 W A 5 10 Stop the vacuum pump and wait for 5 minutes 11 Check the high and low pressure side rea...

Page 919: ...l fragments and liquid refrigerant that can seriously injure you Therefore do not open the high pressure side valve while the engine is running 17 Open the low pressure side valve of the manifold gaug...

Page 920: ...ten the joint and check for leaks again If there is still a leak at the same joint discharge the refrigerant and then repair the joint Repeat the charging procedure from step 7 If there are no leaks a...

Page 921: ...1 7 Airflow Mode Main Link Installation Note 07 11 7 HEATER CORE INSPECTION 07 11 7 REAR DUCT REMOVAL INSTALLATION 07 11 8 REAR HEAT DUCT REMOVAL INSTALLATION 07 11 8 A C COMPRESSOR REMOVAL INSTALLATI...

Page 922: ...1 1 W A O 8 Rear heat duct CANADA only 9 A C compressor 10 Condenser 11 Orifice tube 12 Accumulator tank 13 Heater hose 14 Refrigerant lines 1 Blower unit 2 Cooling unit 3 Evaporator 4 Heater unit 5 A...

Page 923: ...rse order of removal W 6 U 7 1 1 W 0 2 1 Connector 2 Nut 3 Blower unit W 6 U 7 1 1 W A 1 BLOWER UNIT DISASSEMBLY ASSEMBLY 1 Disassemble in the order indicated in the table 2 Assemble in the reverse or...

Page 924: ...lator tank Refer to 07 11 ACCUMULATOR TANK REMOVAL INSTALLATION 4 Disconnect cooler pipe No 5 Refer to 07 11 REFRIGERANT LINES REMOVAL INSTALLATION 5 Remove in the order indicated in the table Do not...

Page 925: ...to straighten them DISASSEMBLY ASSEMBLY 2 Check for cracks damage and oil leakage If any are found replace the evaporator HEATER UNIT REMOVAL INSTALLATION W 6 U 7 1 1 W 0 7 1 Disconnect the negative b...

Page 926: ...the reverse order of disassembly W 6 U 7 1 1 W A 6 9 Polyurethane protector 10 Seal 11 Cover 12 Case 13 Heater core 14 Air mix door 15 Case 16 Airflow mode door 1 Airflow mode actuator 2 Airflow mode...

Page 927: ...ghtly and rotate it in the direction of the arrow then set the projections of each airflow mode sub link into the grooves of the airflow mode main link 4 Rotate airflow mode main link and verify that...

Page 928: ...ant from the system 2 Disconnect the negative battery cable 3 Remove the under cover 4 Remove the drive belt Caution If moisture or foreign material enters the refrigeration cycle cooling ability will...

Page 929: ...e or foreign material enters the refrigeration cycle cooling ability will be lowered and abnormal noise will occur Always immediately plug all open fittings after removing any refrigeration cycle part...

Page 930: ...on cycle cooling ability will be lowered and abnormal noise will occur Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out o...

Page 931: ...efer to 09 18 HEADLIGHT REMOVAL INSTALLATION 6 Remove the radiator grille and splash shield then remove cooler pipe No 3 7 Remove the accumulator tank then remove cooler pipe No 5 Refer to 07 11 ACCUM...

Page 932: ...ooler pipe No 5 oy Refrigerant Lines Removal Note ty Refrigerant Lines Installation Note 6 Cooler hose HI iy Refrigerant Lines Removal Note ty Refrigerant Lines Installation Note 7 Cooler hose LO gy R...

Page 933: ...07 40 9 A C Compressor Pulley Removal Note 07 40 9 MAGNETIC CLUTCH ADJUSTMENT 07 40 10 MAGNETIC CLUTCH INSPECTION 07 40 10 CONDENSER FAN RELAY REMOVAL INSTALLATION 07 40 11 A C RELAY BLOWER RELAY AND...

Page 934: ...CONTROL SYSTEM CONTROL SYSTEM STRUCTURAL VIEW W6U740WA0 07 40 2...

Page 935: ...r control unit 11 Swing louver 12 A C relay 13 Blower relay 14 Condenser fan relay 15 Resistor 1 Magnetic clutch 2 Condenser fan 3 Air intake actuator 4 Air mix actuator 5 Airflow mode actuator 6 Blow...

Page 936: ...W6U740WAA AIR INTAKE ACTUATOR INSPECTION 1 Remove the air intake actuator 2 Connect battery positive voltage to terminal B and ground to terminal D or H of the air intake actuator 3 Verify that the ai...

Page 937: ...voltage to terminal D and ground to terminal H and battery positive voltage to terminal H and ground to terminal D of the air mix actuator 3 Verify that the air mix actuator operates as shown below HO...

Page 938: ...2 Connect battery positive voltage to terminal B and ground to terminal D and battery positive voltage to terminal D and ground to terminal B of the airflow mode actuator 3 Verify that the airflow mod...

Page 939: ...in the table 4 Install In the reverse order of removal W 6 U 7 4 0 W A N W6U740W14 1 Connector 2 Screw 3 Blower motor BLOWER MOTOR INSPECTION 1 Remove the under cover 2 Disconnect the blower motor con...

Page 940: ...nect battery positive voltage to terminal A and ground to terminal B of the condenser fan and verify its operation W 6 U 7 4 0 W A 8 3 If not as specified replace the condenser fan RESISTOR REMOVAL IN...

Page 941: ...resistor MAGNETIC CLUTCH DISASSEMBLY ASSEMBLY 1 Disassemble in the order indicated in the table 2 Assemble in the reverse order of disassembly 3 Adjust the magnetic clutch clearance Refer to 07 40 MAG...

Page 942: ...oint B and C on the pressure plate surface by repeating the above steps 2 through 4 0 35 0 65 mm 0 014 0 025 in W 6 U 7 4 0 W 0 3 W 6 U 7 4 0 W A 4 If not within the specification remove the pressure...

Page 943: ...the relay 2 Check for continuity between the relay terminals by using an ohmmeter O O Continuity Step Terminal B F A E 1 O O 2 B GND 0 O W 6 U 7 4 D W B 3 T 7 7 W 6 U 7 4 0 W 2 5 E X A F B W 6 U 7 4 0...

Page 944: ...material enters the refrigeration cycle cooling ability will be lowered and abnormal noise will occur Always immediately plug all open fittings after removing any refrigeration cycle parts to keep mo...

Page 945: ...A S 5 If not as specified replace the refrigerant pressure switch MPa kgf cm2 psl W 6 U 7 4 0 W A Q LO 0 118 1 20 17 1 4 CONTINUITY NO CONTINUITY 0 149 0 167 1 51 1 71 21 5 24 3 MPa kgf cm2 psl W 6 U...

Page 946: ...ht control SW 1C Common power source Airflow mode actuator Moving to VENT 0 5 Airflow mode actuator Moving to DEFROSTER 10 5 1D TNS TNS relay Headlight switch at TNS position B TNS relay Headlight swi...

Page 947: ...mode actuator Moving to VENT 10 6 Airflow mode actuator Moving to DEFROSTER 0 7 2I Motor drive Airflow mode actuator Moving to DEFROSTER 10 6 Airflow mode actuator Moving to VENT 0 7 2J GND GND Const...

Page 948: ...ositive voltage to terminal B and ground to terminal A of the swing louver 3 Verify that the swing louver operates as indicated below Swing louver switch position Swing louver Off Stopped On Operation...

Page 949: ...cified replace the cooler hose HI 2 Start the engine 3 Turn the fan switch and A C switch on 4 Verify the high pressure side reading of the manifold gauge 5 Check for leaks from the pressure relief va...

Page 950: ...V A C 07 50 1 07 HVAC W6U750W01 Item Specification Refrigerant Type R 134a Regular amount 9 oz 750 26 5 Lube oil Type SP 20 A C compressor Sealed volume ml cc fl oz 240 240 8 11 Magnetic clutch clear...

Page 951: ...Troubleshooting 08 01 A 1 0 08 01 A 1 0 08 01 A 1 0 08 01 A 1 0 FOREWORD Use the following flowchart to verify the cause of the trouble Flowchart W6U801W01 START Turn ignition switch to ON Does air b...

Page 952: ...on 2 A W6U801WA2 SAS unit 3 X L W6U801WA3 Battery 6 JWUX W6U801WA4 Driver side air bag module 7 W6U801WA5 Passenger side air bag module Continuously flashes Deployment authorization standby code see b...

Page 953: ...itch to LOCK Disconnect negative battery cable and wait for more than 1 minute to allow the backup power supply of SAS unit to deplete its stored power Remove rear console tr 09 17 REAR CONSOLE REMOVA...

Page 954: ...Warning Handling the SAS unit improperly can accidently deploy the air bag modules which may cause serious injury Read AIR BAG SYSTEM SERVICE WARNINGS before handling the SAS unit cr 08 10 AIR BAG SY...

Page 955: ...DITION Resistance detected between terminals M 0 of SAS unit is other than 2 C X POSSIBLE CAUSE Driver side air bag module malfunction Clock spring malfunction Malfunction in wiring harness between SA...

Page 956: ...gative battery cable and wait for more than 1 minute to allow backup power supply of SAS unit to deplete its stored power Disconnect clock spring connector Is clock spring connector pin okay Yes Go to...

Page 957: ...ear console zr 09 17 REAR CONSOLE REMOVAL INSTALLATION Remove driver side side wall Disconnect SAS unit connector Inspect wiring harness between terminal 0 of SAS unit connector and terminal A of cloc...

Page 958: ...VICE WARNINGS Turn ignition switch to LOCK Disconnect negative battery cable and wait for more than 1 minute to allow backup power supply of SAS unit to deplete its stored power Remove glove compartme...

Page 959: ...N Remove driver side side wall Disconnect SAS unit connector Inspect wiring harness between terminal K of SAS unit connector and terminal A of passenger side air bag module connector and between termi...

Page 960: ...inal S of SAS unit connector 21 pin and ground terminal X of SAS unit connector 21 pin and ground 5 Simultaneous poor contact in wiring harness between METER 10 A fuse and SAS unit ENGINE 10 A fuse an...

Page 961: ...late No 1 of instrument cluster Is there continuity Yes Go to next step No Replace print plate No 1 then go to step 10 Turn ignition switch to LOCK Disconnect negative battery cable and wait for more...

Page 962: ...s illuminated TROUBLESHOOTING HINTS Malfunction in air bag system warning light circuit A ir bag system warning light remains illuminated SAS unit malfunction Malfunction in short bar between terminal...

Page 963: ...pin Insert insulative material between terminals Q and S of SAS unit connector 21 pin so short bar cannot operate Check for continuity between terminal Q at SAS unit connector 21 pin of wiring harness...

Page 964: ...s turned to ON belt is fastened Symptom Troubleshooting Seat belt warning light and buzzer do not operate TROUBLESHOOTING HINTS Malfunction in seat belt warning light and buzzer input signal circuit S...

Page 965: ...uster power supply circuit Seat belt warning light does not illuminate Malfunction in wiring harness between METER 10 A fuse and instrument cluster STEP INSPECTION ACTION Are other warning lights illu...

Page 966: ...CTION ACTION Is ROOM 15 A fuse okay Yes Go to next step No Replace fuse after repairing wiring harness Has seat belt warning buzzer sounded for 4 to 8 seconds since turning ignition switch to ON Yes S...

Page 967: ...nition switch is turned to ON belt fastened TROUBLESHOOTING HINTS Malfunction in seat belt warning buzzer input signal circuit Warning buzzer sounds for 4 to 8 seconds when seat belt is fastened CPU m...

Page 968: ...y repairing an air bag system wiring harness can accidently deploy the air bag module which may cause serious injury If a problem is found in the system wiring replace the wiring harness Do not try to...

Page 969: ...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 resu...

Page 970: ...ed power 3 Remove the glove compartment 4 Remove in the order indicated in the table 5 Install in the reverse order of removal 6 Turn the ignition switch to ON 7 Verify that the air bag system warning...

Page 971: ...3 Check for continuity between the clock spring terminals W 6 U 8 1 0 W 0 5 Continuity Step Terminal 1A 1B 2A 2B 2C 2D 3A 3B 3C 4A 4B 4C 1 2 0 3 0 4 pi vj 5 O 6 W 6 U 8 1 0 W A E VEHICLE SIDE SB 3C 4...

Page 972: ...the SAS unit Refer to 08 10 AIR BAG SYSTEM SERVICE WARNINGS 1 Turn the ignition switch to LOCK 2 Disconnect the negative battery cable and wait for more than 1 minute to allow the backup power supply...

Page 973: ...val 6 9 11 7 N m 70 120 kgfcm 61 104 In lbf W 6 U 8 1 0 W A J 1 Nut 2 SAS unit bracket AIR BAG MODULES DEPLOYMENT AUTHORIZATION PROCEDURES 1 Install a new SAS unit Verify that the air bag system warni...

Page 974: ...ter to the passenger side air bag module as shown _ PASSENGER SIDE AIR BAG MODULE CONNECTOR SEE V A W 49 D 0 6 6 002 WSIJ810W 10 6 Connect the SST Deploym ent Tool to the SST Harness Adapter 7 Connect...

Page 975: ...eployment Tool to the driver side air bag module as shown W 6 U 8 1 0 W A Q 5 Stack three tires on top of the tire with the attached air bag module Make sure the tire on top of the stack has a wheel A...

Page 976: ...t of the module is facing up 3 Tie the air bag module to the tire wheel with the front of the module facing up Wrap the wire through the wheel and around the air bag module bolt at least four times W...

Page 977: ...fter deployment W 6 U 8 1 0 W 1 1 Warning A deployed air bag module may contain deposits of sodium hydroxide a caustic byproduct of the gas generated combustion If this substance gets into your eyes o...

Page 978: ...clip to positive battery terminal and black clip to negative battery terminal On Off 2 Connect connectors A and B of SST Deployment Tool Off On 3 Press activation switch On Off 2 If not as specified d...

Page 979: ...SPECTION 08 11 4 SEAT BELT ALR INSPECTION 08 11 4 FRONT SEAT BELT REMOVAL INSTALLATION Caution Do not disassemble the retractor The emergency locking retractor ELR has a spring that will unwind if the...

Page 980: ...0 2 3 9 7 8 3 9 8 0 2 9 57 N m kgf m ftlb f W 6 U 8 1 1W A 1 Bolt Rear seat belt REAR CENTER SEAT BELT REMOVAL INSTALLATION Caution Do not disassemble the retractor The emergency locking retractor EL...

Page 981: ...the reverse order of removal 1 Boit 2 Front buckle BUCKLE SWITCH INSPECTION 1 Disconnect the negative battery cable 2 Disconnect the driver side buckle switch connector 3 Check for continuity between...

Page 982: ...fy that the retractor locks at approximately 30 inclination W 6 U 8 1 1 W A 7 W 6 U 8 1 1 W A 8 3 Remove the retractor 4 Hold the retractor as it would be installed 7 If not as specified replace the s...

Page 983: ...SERVICE TOOLS 08 60 SERVICE TOOLS 08 RESTRAINTS S S T 08 60 1 08 RESTRAINTS SST 08 60 1...

Page 984: ...NG AUDIO 09 01N TROUBLESHOOTING INSTRUMENTATION DRIVER INFO 09 01P BODY PANELS 09 10 DOORS AND LIFTGATE 09 11 GLASS WINDOWS MIRRORS 09 12 SEATS 09 13 SECURITY AND LOCKS 09 14 SLIDING SUNROOF 09 15 EXT...

Page 985: ...be operated by power window subswitches when power cut switch is at OFF Symptom Troubleshooting 1 Power windows do not operate TROUBLESHOOTING HINTS Malfunction in power window main switch power suppl...

Page 986: ...wer window regulator Malfunction in power window regulator operation circuit Power window at driver s door does not operate Driver s side power window regulator malfunction STEP INSPECTION ACTION 1 In...

Page 987: ...w subswitches but cannot be operated by power window main switch TROUBLESHOOTING HINTS Malfunction in power window main switch power supply circuit Power windows do not operate Power window main switc...

Page 988: ...harness between ROOM 15 A fuse and CPU Malfunction in wiring harness between CPU and ground Malfunction in rear window defroster relay power supply circuit 0 Rear window defroster does not function M...

Page 989: ...U from joint box Measure voltage at terminal 1J at joint box Is voltage B Yes Go to next step No Repair wiring harness between ROOM 15 A fuse and CPU W 6 U 9 0 1 W B 1 Check for continuity between ter...

Page 990: ...itch No Go to next step Disconnect rear window defroster switch connector Check for continuity between terminal C at rear window defroster switch connector of wiring harness and ground Is there contin...

Page 991: ...p No Replace rear window defroster relay 10 Install rear window defroster relay and CPU Measure voltage at terminal 3F USA or 4J CANADA at CPU connector and terminal D at rear window defroster relay o...

Page 992: ...piller trim Is filament installed to body ground securely Yes Repair filament No Repair wiring harness between filament and ground 09 2 Rear window defroster does not continuously operate for 15 minut...

Page 993: ...RMATION and thoroughly read and understand the basic flow of troubleshooting to properly perform the procedures POWER OUTSIDE MIRROR SYMPTOM TROUBLESHOOTING W 6 U 9 0 1 W 1 2 Diagnostic Index No Sympt...

Page 994: ...er outside mirror switch malfunction STEP INSPECTION ACTION Is RADIO 15 A fuse okay RADIO 15 A FUSE W 6 U 9 0 1 W C 0 Yes Go to next step No Replace fuse after repairing wiring harness Remove power ou...

Page 995: ...necting power outside mirror switch connector Turn ignition switch to ACC Turn power outside mirror switch to left side position and turn it to left or to down position Measure voltage at terminal F a...

Page 996: ...cting power outside mirror switch connector Turn ignition switch to ACC Turn power outside mirror switch to right side position and turn it to left or to down position Measure voltage at terminal F at...

Page 997: ...nt of driver s seat does not move up or down Other functions operate normally 4 Rear of driver s seat does not move up or down Other functions operate normally Symptom Troubleshooting 1 Power seat doe...

Page 998: ...SEAT DISASSEMBLY ASSEMBLY 3 Front of driver s seat does not move up or down Other functions operate normally TROUBLESHOOTING HINTS Malfunction in front tilt motor circuit Power seat does not move up...

Page 999: ...n d e x 09 01 E 8 Symptom Troubleshooting 09 01E 9 FOREWORD W 6 U 9 0 1 W 2 1 When there is malfunction in power door lock system without keyless entry system perform troubleshooting No 4 7 according...

Page 1000: ...the vehicle Make sure the ignition key is in the LOCK position or removed Does the keyless entry system work If works explain correct system operations or how to operate to the customer Yes No 3 Confi...

Page 1001: ...cular area such as being near TV towers power plants power lines or factories Yes Attempt to lock or unlock doors with transmitter in non interference area If system operates Area of operation is bad...

Page 1002: ...k system does not operate Go to next step If buzzer sounds one time but trunk lid does not unlock Go to step 11 If buzzer sounds two times Go to step 14 of symptom troubleshooting No 1 10 Operate inne...

Page 1003: ...nit and CPU to activate the power door lock and trunk lid opener systems without the transmitter OBD function 2 monitors a keyless entry demand signal sent from the transmitter and used inside the key...

Page 1004: ...TROUBLESHOOTING POWER DOOR LOCK SYSTEM On board Diagnostic Function 2 Before performing troubleshooting conduct the following procedure Go to next page w6U9oiwe2 09 01E 6...

Page 1005: ...TROUBLESHOOTING POWER DOOR LOCK SYSTEM From previous page Go to next page W 6 U 9 0 1 W H 3 09 01E 7...

Page 1006: ...1 On board diagnostic function 1 and or 2 inoperative 2 On board diagnostic function 1 inoperative Door lock and or trunk lid opener systems do not lock or unlock in on board diagnostic function 1 3...

Page 1007: ...tall CPU to joint box securely Confirm on board diagnostic function 1 activation Turn ignition switch off Open driver s side door only Make sure that passenger s side and rear doors are closed Check c...

Page 1008: ...terminal 1C or 1J Make sure that driver s side door is open Connect volt meter between CPU connector terminal 20 and ground Perform following procedures within 30 seconds Repeat following four times...

Page 1009: ...2A 2P 2N 2 2J 2H 2F 20 2B W 6 U 9 0 1 W E 4 Yes Go to next step No Visually check for bents or other damage to CPU connector terminals If terminals are okay replace CPU Turn ignition switch to ON Con...

Page 1010: ...ring lock Repeat following three times Push driver s side door switch Release driver s side door switch Measure voltage at keyless unit connector terminal E 5 V during performing the above procedures...

Page 1011: ...e door switch Release driver s side door switch Measure voltage at keyless unit connector terminal E 5 V during performing the above procedures 0 V until on board diagnostic activate verification buzz...

Page 1012: ...minal E 5 V 0 V during on board diagnostic activate verification buzzer sounds 5 V 3 5 V 3 seconds later after buzzer sounded 5 V 1 7 V 6 and 9 seconds later after buzzer sounded Are voltages okay W 6...

Page 1013: ...buzzer sounds 3 5 V after 3 seconds after buzzer sounded 1 7 V after 6 seconds after buzzer sounded 1 7 V after 9 seconds after buzzer sounded If voltage is okay replace CPU If voltage is not okay rep...

Page 1014: ...f buzzer sounds three times on all three tests go to step 5 For different number of buzzer sounds go to next step 2 Visually inspect transmitter battery Are following items okay Transmitter battery in...

Page 1015: ...oor lock timer unit 2 power supply ground circuit Power door lock system does not function D LOCK 30 A fuse malfunction Malfunction in wiring harness between D LOCK 30 A fuse and door lock timer unit...

Page 1016: ...rminal C at door lock timer unit 1 connector and terminal C at door lock timer unit 2 connector Is there continuity Yes Check for open or short circuit between terminal D at door lock timer unit 1 and...

Page 1017: ...lly peel off passenger s side door screen Check for continuity between terminal A at passenger s side door lock actuator connector and terminal G at door lock timer unit 1 connector Is there continuit...

Page 1018: ...EP INSPECTION ACTION Note If driver s side door lock system does not unlock with transmitter only replace CPU Remove driver s side side panel Remove lower panel Is voltage at door lock timer unit 2 co...

Page 1019: ...Malfunction in wiring harnessbetween door lock timer unit 2 and trunk lid opener switch Malfunction in wiring harnessbetween trunk lid opener switch and ground Malfunction in trunk lid lock actuator...

Page 1020: ...TCH INSPECTION Is trunk lid opener switch okay Yes Go to next step No Replace trunk lid opener switch Check for continuity between terminal B at trunk lid opener switch connector and ground Is there c...

Page 1021: ...uator 8 Door lock monitor inoperative TROUBLESHOOTING HINTS CPU malfunction Horn system malfunction Open circuit between CPU connector terminal 2A and horn relay Note Horn sounds once as a part of doo...

Page 1022: ...nal M Repair or replace the wiring harness if necessary 1 Turn the ignition switch to START for 2 seconds then back to ON 2 Wait for 2 minutes 3 Verify the security light condition and read the DTC if...

Page 1023: ...ential malfunctions Malfunctions 01 02 03 11 21 24 30 P1602 P1603 P1604 P1621 P1622 P1623 P1624 Open circuit IU PCM 3 3 IU Ground 3 3 IU Coil 1 1 3 1 IU Battery Engine runs normally and no DTC is indi...

Page 1024: ...STEP INSPECTION ACTION Go to ID number input procedure id 09 14 IMMOBILIZER SYSTEM REPROGRAM PROCEDURE Key Replacement or Addition DTC 02 ID number format error voltage range freguency POSSIBLE CAUSE...

Page 1025: ...tween immobilizer unit and coil STEP INSPECTION ACTION Is connector of coil or immobilizer unit connected securely Yes Go to next step No Connect connector securely Check for continuity between termin...

Page 1026: ...bilizer unit and PCM connectors connected properly Yes Go to next step No Connect connectors properly Disconnect immobilizer unit and PCM unit connectors Connect SST to PCM connector Connect one probe...

Page 1027: ...communication error POSSIBLE CAUSE Defective immobilizer unit Defective PCM STEP INSPECTION ACTION Replace immobilizer unit and reprogram immobilizer system pr 09 14 IMMOBILIZER SYSTEM REPROGRAM PROCE...

Page 1028: ...ot performed correctly after replacing PCM STEP INSPECTION ACTION 1 CHECK DTC PRESENT RESET PCM to completely clear DTCs trAfter Repair Procedure RERUN OBD test Is same DTC present after cranking Yes...

Page 1029: ...NG PROCEDURE PCM Replacement DTC P1623 Code word or key ID number write read error in PCM DESCRIPTION PCM internal EEPROM damaged Possible Cause PCM internal EEPROM damaged STEP INSPECTION ACTION 1 CH...

Page 1030: ...icle is armed 2 Security light does not flash at 0 3 second interval when any door is opened without using transmitter after vehicle is armed 3 Horn does not sound but other warnings headlight and tur...

Page 1031: ...less entry system Power door lock one touch system Trunk lid unlocked with trunk lid opener switch Yes Go to next step No Go to symptom troubleshooting of power door lock system cr 09 01E FOREWORD Rem...

Page 1032: ...light switch connector Inspect trunk compartment light switch tr 09 18 TRUNK COMPARTMENT LIGHT SWITCH INSPECTION Is trunk compartment light switch okay Yes Go to next step No Replace trunk lid lock t...

Page 1033: ...tep No Go to symptom troubleshooting No 1 Remove driver s side front scuff plate Remove driver s side front side trim Remove nut fixed in joint box and remove CPU from joint box Open any door Check fo...

Page 1034: ...front scuff plate Remove driver s side front side trim Remove nut fixed in joint box Measure voltage at terminal 2A at CPU connector with horn switch OFF Is voltage B Yes Replace CPU c r 09 40 CPU RE...

Page 1035: ...e CPU o 09 40 CPU REMOVAUINSTALLATION No Repair wiring harness between flasher unit and CPU 1 r 20 2U 2K 21 2G 2E 2C 2A 2 i 21 2J 2H 2F 20 28 W 6 U 9 0 1 W J 5 6 Alarm does not stop when door is unloc...

Page 1036: ...tage 5 V TRUNK KEY CYLINDER SWITCH CONNECTOR A W 6 U 9 0 1 W J 7 Yes Go to step 3 No Go to next step Remove driver s side front scuff plate Remove driver s side front side trim Remove nut fixed in joi...

Page 1037: ...uzzer operate okay Yes Replace CPU No Go to symptom troubleshooting of instrumentation driver info tr 09 01P FOREWORD 10 Alarm does not continue for 2 5 minutes TROUBLESHOOTING HINTS Malfunction in th...

Page 1038: ...of does not move Symptom Troubleshooting 1 Sliding sunroof does not move TROUBLESHOOTING HINTS Sliding sunroof does not move SUNROOF 15 A fuse malfunction Malfunctionin wiring harness between SUNROOF...

Page 1039: ...Turn ignition switch to ON Measure voltage at terminal 1C of sunroof control module connector of wiring harness Is voltage B Yes Go to next step No Repair wiring harness between SUNROOF 15 A fuse and...

Page 1040: ...oof control module connector of wiring harness Is there continuity Yes Go to next step No Repair wiring harness between sunroof motor and sunroof control module W6U901WL9 Remove sunroof motor Inspect...

Page 1041: ...uminate 10 Taillights do not illuminate 11 Parking lights do not illuminate Symptom Troubleshooting 1 Headlight auto light off does not operate TROUBLESHOOTING HINTS Malfunction in headlight auto ligh...

Page 1042: ...e voltage at terminal 4K at CPU connector D of wiring harness Is voltage B Yes Go to next step t a No Repair wiring harness between headlight high relay and CPU n 4M 4K 4E 4C 4A 4N 4L 4 j 4 H 4F 4D 4B...

Page 1043: ...M IK 1J 11 1H 16 1F IE 1D 1C 1B No Go to next step f t W 6 U 9 0 1 W M 4 10 Remove column cover Inspect ignition switch tr 09 21 IGNITION SWITCH INSPECTION Is ignition switch okay Yes Repair wiring ha...

Page 1044: ...switch Malfunction in wiring harness between headlight and CPU Malfunction in wiring harness between headlight relay and CPU Malfunction in wiring harness between headlight and headlight high relay W...

Page 1045: ...f plate Remove driver s side front side trim Turn headlight switch to OFF Measure voltage at terminal 4E at CPU connector D of wiring harness Is voltage B Yes Go to next step 3 No Repair wiring harnes...

Page 1046: ...tor Is voltage B Yes Go to next step E X A F B No Repair wiring harness between headlight and headliqht high relay W 6 U 9 0 1 W M D 10 Install CPU in joint box Measure voltage at terminal 4K at CPU c...

Page 1047: ...t CPU connector D of wiring harness Is voltage 0 V Yes Replace CPU s t 09 40 CPU REMOVAL INSTALLATION t s No Repair wiring harness between light switch headlight switch and CPU 4M 4 k 4E 4C 4A 4N 4 4...

Page 1048: ...step No Repair wiring harness between headlight and light switch headlight switch 16 Remove column cover Inspect light switch headlight switch c r 09 18 LIGHT SWITCH INSPECTION Is light switch headlig...

Page 1049: ...L Yes Go to next step No Go to step 5 Remove column cover Inspect light switch headlight switch jt 09 18 LIGHT SWITCH INSPECTION Is light switch headlight switch okay Yes Go to next step No Replace li...

Page 1050: ...n Light switch headlight switch malfunction Headlight bulb malfunction Headlight high relay malfunction Malfunction in wiring harness between headlight and headlight high relay Malfunction in wiring h...

Page 1051: ...r s side front side trim Measure voltage at terminal 4K at CPU connector D of wiring harness Is voltage B Yes Replace CPU tr 09 18 CPU REMOVAL INSTALLATION Go to next step No Repair wiring harness bet...

Page 1052: ...fuse and CPU STEP INSPECTION ACTION Is METER 10 A fuse okay METER 10 A FUSE W 6 U 9 0 1 W M U Yes Go to next step No Replace fuse after repairing wiring harness Remove rear console o 09 17 REAR CONSOL...

Page 1053: ...TS Malfunction in headlight input signal circuit Daytime running lights do not turn off Parking brake switch malfunction Malfunction in headlight operation circuit Daytime running lights do not turn o...

Page 1054: ...G HINTS Malfunction in headlight input signal circuit Daytime running lights do not illuminate Ignition switch malfunction Malfunction in headlight operation circuit 0 Daytime running lights do not il...

Page 1055: ...ircuit T N S do not illuminate CPU malfunction Light switch headlight switch malfunction Malfunction in wiring harness between CPU and light switch headlight switch STEP IPECTION ACTION Is TAIL 15 Afu...

Page 1056: ...ir wiring harness between TNS relay and CPU Set headlight switch to OFR Measure voltage at terminal 4M at CPU connector D of wiring harness Is voltage 0 V Yes Replace CPU tr 09 40 CPU REMOVAL INSTALLA...

Page 1057: ...LIGHT SWITCH INSPECTION Is light switch headlight switch okay Yes Replace CPU rr 09 40 CPU REMOVAL INSTALLATION No Replace light switch headlight switch n r 09 18 LIGHT SWITCH REMOVAL INSTALLATION 9...

Page 1058: ...rear combination light STEP INSPECTION ACTION Inspect brake light taillight bulb Is bulb okay Yes Go to next step No Replace brake light taillight bulb Partially peel off trunk side trim vr 09 17 TRUN...

Page 1059: ...ove front combination light Connect front combination light connector Turn headlight switch to first position Measure voltage at terminal A at front combination light connector of wiring harness Is vo...

Page 1060: ...interior light switch is at ON interior light illuminates 3 When interior light switch is at DOOR interior lighting control system does not operate properly 4 Vanity mirror illumination does not turn...

Page 1061: ...ior light connector of wiring harness Is voltage B W 6 U 9 0 1 W N 7 Yes No Go to next step Repair wiring harness between ROOM 15 A fuse and interior light Inspect interior light zr 09 18 INTERIOR LIG...

Page 1062: ...e voltage at terminal 1F at joint box Is voltage B W 6 U 9 0 1 W N 1 Yes Go to step 3 No Go to step 2 Inspect interior light cr 09 18 INTERIOR LIGHT INSPECTION Is interior light okay Yes Repair wiring...

Page 1063: ...keyless unit cr 09 14 KEYLESS UNIT INSPECTION No Replace CPU cr 09 40 CPU REMOVAL7INSTALLATION Vanity mirror illumination does not turn on TROUBLESHOOTING HINTS Malfunction in vanity mirror illuminati...

Page 1064: ...mination bulb sr 09 18 VANITY MIRROR ILLUMINATION REMOVAL INSTALLATION 4 Open vanity mirror cover Measure voltage at terminal B at vanity mirror illumination connector of wiring harness Is voltage B Y...

Page 1065: ...1 W 5 2 Diagnostic Index Use the chart below to verify the symptoms of the trouble in order to diagnose the appropriate area No M alfunction Symptom 1 Turn and hazard warning functions do not operate...

Page 1066: ...hazard warning switch and ground Malfunction in turn and hazard warning functions operation circuit T u rn signal and hazard warning lights do not illuminate Light switch turn switch malfunction Flas...

Page 1067: ...step No Replace flasher unit o 09 18 FLASHER UNIT REMOVAL INSTALLATION Remove column cover Remove light switch turn switch without disconnecting connectors Turn ignition switch to ON Measure voltage a...

Page 1068: ...Turn ignition switch to LOCK Go to next step No Repair wiring harness between light switch turn switch and flasher unit W 6 U 9 0 1 W P 5 Measure voltage at terminal A at hazard warning switch connec...

Page 1069: ...y Yes Go to next step TURN 10 A FUSE W 6 U 9 0 1 W P 7 No Replace fuse after repairing wiring harness 2 Remove column cover Remove light switch turn switch without disconnecting connectors Turn igniti...

Page 1070: ...h Malfunction in wiring harness between hazard warning switch and ground STEP INSPECTION ACTION Is HAZARD 15 A fuse okay HAZARD 15 A FUSE W6U901WP9 Yes Go to next step No Replace fuse after repairing...

Page 1071: ...tion circuit Left or right turn signal light does not illuminate Hazard warning lights illuminate Light switch turn switch malfunction Flasher unit malfunction Malfunction in wiring harness between tu...

Page 1072: ...unction Malfunction in wiring harness between brake switch and brake lights STEP INSPECTION ACTION Is STOP 15 A fuse okay STOP 15 AFUSE W 6 U 9 0 1 W P D Yes Go to next step No Replace fuse after repa...

Page 1073: ...brake light and ground STEP INSPECTION ACTION Partially peel off trunk side trim vr 09 17 TRUNK SIDE TRIM REMOVAL INSTALLATION Remove rear combination light Inspect brake light bulb Is brake light bul...

Page 1074: ...ring harness between high mount brake light and ground STEP INSPECTION ACTION 1 Remove high mount brake light bulb o 09 18 HIGH MOUNT BRAKE LIGHT BULB REMOVAL INSTALLATION Inspect high mount brake lig...

Page 1075: ...nsaxle range switch tr 05 17A ELECTRICAL SYSTEM COMPONENT LA4A EL tr 05 17B TRANSAXLE RANGE SWITCH INSPECTION GF4A EL Is transaxle range switch okay Yes Go to step 5 No Replace transaxle range switch...

Page 1076: ...lace back up light bulb tr 09 18 REAR COMBINATION LIGHT REMOVAL INSTALLATION Is it a MTX vehicle Yes Go to step 3 No Go to step 4 Turn ignition switch to ON Move shift lever knob to reverse position M...

Page 1077: ...ate normally 3 High speed wiper operation is not possible Other functions operate normally 4 Wipers continue operation after windshield wiper and washer switch is turned to OFF 5 Intermittent wiper op...

Page 1078: ...operate Windshield wiper and washer switch malfunction STEP INSPECTION ACTION Is WIPER 20 A fuse okay WIPER 20 A FUSE W6U901WQ0 Yes Go to next step No Replace fuse after repairing wiring harness Remov...

Page 1079: ...windshield wiper and washer switch ground circuit Intermittent wiper operation is not possible Windshield wiper and washer switch malfunction Malfunction in wiring harness between windshield wiper and...

Page 1080: ...alfunction in windshield wiper motor operation circuit Autostop operation does not work Windshield wiper motor malfunction STEP INSPECTION Turn ignition switch to ON Measure voltage at terminal F at w...

Page 1081: ...g windshield wiper and washer switch connector Turn ignition switch to ON Turn windshield washer switch on Measure voltage at terminal G at windshield wiper and washer switch connector of wiring harne...

Page 1082: ...rument cluster input signal circuit Washer fluid level warning light does not illuminate Instrument cluster malfunction Malfunction of wiring harness between instrument cluster and washer fluid level...

Page 1083: ...vel sensor okay Yes Go to next step No Replace washer fluid level sensor Check for continuity between terminal B at washer fluid level sensor connector of wiring harness and ground Is there continuity...

Page 1084: ...er antenna does not operate Symptom Troubleshooting 1 No speakers operate in all cases Radio and CD modes TROUBLESHOOTING HINTS Malfunction in audio unit power supply ground circuit No speakers operat...

Page 1085: ...tor still connected remove audio unit t r 09 20 AUDIO UNIT REMOVAL Turn ignition switch to ACC Measure voltage at terminal 1A at audio unit connector of wiring harness Is voltage B Yes Go to next step...

Page 1086: ...ound Connect audio unit connector Turn ignition switch to ACC Measure voltage at terminal 1J at audio unit connector of wiring harness Is voltage B Yes Go to next step No Replace audio unit tr 09 20 A...

Page 1087: ...ithout BOSE speaker Audio unit malfunction Speaker malfunction Malfunction in wiring harness between audio unit and speaker Some speakers do not operate Equipped with BOSE speaker Audio unit malfuncti...

Page 1088: ...1J11H 1F 1D A tu X 2A 2 H 2 F 2B 1 A I B I t1 W 6 U 9 0 1 W S 7 Yes Replace audio unit cr 09 20 AUDIO UNIT INSTALLATION No Repair wiring harness between audio unit and speaker With connector still co...

Page 1089: ...1E 1C 1A 1N 1L 1j 1H 1F 1D Y W U Q M K I Q C i EEEE iEEEEF Z X V N I J H D B W 6 U 9 0 1 W S 9 Yes Go to next step No Repair wiring harness between audio unit and audio amplifier Check for continuity...

Page 1090: ...STALLATION 5 Equipped with manual antenna Inspect manual antenna tr 09 20 MANUAL ANTENNA INSPECTION Is manual antenna normal Equipped with power antenna Inspect power antenna cr 09 20 POWER ANTENNA IN...

Page 1091: ...Are all speakers poor in sound quality Yes Go to next step No Go to step 4 Remove audio unit tr 09 20 AUDIO UNIT REMOVAL Check for continuity between terminal 3A at audio unit connector of wiring harn...

Page 1092: ...pump noise Ignition noise Generator noise Windshield wiper motor noise Windshield washer motor noise Power window regulator noise Cooling fan motor noise Condenser fan motor noise Brake switch noise...

Page 1093: ...on Windshield washer motor noise Noise occurs when windshield washer is operated Power window regulator noise Noise occurs when power window is operated Cooling fan motor noise Noise occurs when cooli...

Page 1094: ...NTS Malfunction in audio unit power supply circuit CD cannot be unloaded Audio unit malfunction STEP INSPECTION ACTION Is CD loaded properly Yes Go to malfunction symptom No 10 No Replace audio unit x...

Page 1095: ...ng harness between audio unit and power antenna Malfunction in wiring harness between power antenna and ground STEP INSPECTION ACTION Turn ignition switch to ACC Verify that power switch is on Turn ov...

Page 1096: ...NTENNA REMOVAL INSTALLATION No Repair wiring harness between power antenna and ground With connector still connected remove audio unit o 09 20 AUDIO UNIT REMOVAL Turn ignition switch to ACC Verify tha...

Page 1097: ...correct 8 All warning lights do not illuminate with ignition switch at ON engine stopped 9 Generator warning light does not illuminate with ignition switch at ON engine running 10 Brake system warning...

Page 1098: ...and instrument cluster Malfunction in wiring harness between ROOM 15 A fuse and instrument cluster Malfunction in wiring harness between instrument cluster and ground STEP INSPECTION ACTION Is METER...

Page 1099: ...instrument cluster Turn ignition switch to LOCK Check for continuity between terminal 2B at instrument cluster 14 pin connector of wiring harness and ground Is there continuity Yes Go to next step No...

Page 1100: ...I i l 4A W 6 U 9 0 1 W U 6 Yes Go to next step No Replace print plate o 09 22 INSTRUMENT CLUSTER DISASSEMBLY ASSEMBLY Check for continuity between terminal 2B 14 pin at print plate and print plate con...

Page 1101: ...ition switch to ON and LOCK 3 times Turn ignition switch to ON Push odometer tripmeter switch 3 times r W 6 U 9 0 1 W U 8 Select DTC 12 by pushing odometer tripmeter switch Does speedometer needle mov...

Page 1102: ...r Disconnector print plate connector Check for continuity between terminal 2D 14 pin at print plate and print plate connector 4G 8 pin terminal Is there continuity Yes Go to next step No Replace print...

Page 1103: ...t Display unit assembly malfunction STEP INSPECTION ACTION Turn ignition switch to LOCK Disconnect negative battery cable After 30 seconds or more reconnect negative battery cable Turn ignition switch...

Page 1104: ...le Turn ignition switch to ON and LOCK 3 times Turn ignition switch to ON Push odometer tripmeter switch 3 times r W 6 U 9 0 1 W U G Select DTC 13 by pushing odometer tripmeter switch Does tachometer...

Page 1105: ...LY ASSEMBLY Remove rear console Set SST to PCM Measure voltage at terminal 48 of PCM when ignition switch ON Is voltage above 10 V Yes Repair wiring harness between instrument cluster and PCM No Go to...

Page 1106: ...egative battery cable Turn ignition switch to ON and LOCK 3 times Turn ignition switch to ON Push odometer tripmeter switch 3 times W 6 U 9 0 1 W U M Select DTC 13 by pushing odometer tripmeter switch...

Page 1107: ...30 seconds or more reconnect negative battery cable Turn ignition switch to ON and LOCK 3 times Turn ignition switch to ON Push odometer tripmeter switch 3 times r W 6 U 9 0 1 W U P Select DTC 23 by p...

Page 1108: ...tor Check for continuity between terminal 2E 14 pin at print plate and print plate connector 4F 8 pin terminal Is there continuity Yes Go to next step No Replace print plate cr 09 22 INSTRUMENT CLUSTE...

Page 1109: ...re reconnect negative battery cable Turn ignition switch to ON and LOCK 3 times Turn ignition switch to ON Push odometer tripmeter switch 3 times W 6 U 9 0 1 W U V Select DTC 25 by pushing odometer tr...

Page 1110: ...heck for continuity between terminal 2H 14 pin at print plate and print plate connector 4D 8 pin terminal Is there continuity Yes Go to next step No Replace print plate D 09 22 INSTRUMENT CLUSTER DISA...

Page 1111: ...between METER 10 A fuse and instrument cluster STEP INSPECTION ACTION Is METER 10 A fuse okay Yes Go to next step No Replace fuse after repairing wiring harness Remove meter hood Remove instrument clu...

Page 1112: ...B of generator connector Turn ignition switch to ON Does generator warning light illuminate Yes Replace generator No Go to next step 2 Turn ignition switch to LOCK Remove meter hood Remove instrument...

Page 1113: ...ter and CPU STEP INSPECTION ACTION Remove driver s side front scuff plate Remove driver s side front side trim Remove nut fixed in joint box and remove CPU from joint box Connect ground to terminal 1D...

Page 1114: ...pin connector of wiring harness and ground Is there continuity W 6 U 9 0 1W V 9 Yes Go to next step No Repair wiring harness between instrument cluster and CPU Remove brake system warning light bulb...

Page 1115: ...ck for continuity between terminal 3H at instrument cluster 14 pin connector of wiring harness and ground Is there continuity 3H Iff III I I I I I I I I I I I I I I I W 6 U 9 0 1W V B Yes Go to next s...

Page 1116: ...Disconnect negative battery cable After 30 seconds or more reconnect negative battery cable Turn ignition switch to ON and LOCK 3 times Turn ignition switch to ON Push odometer tripmeter switch 3 tim...

Page 1117: ...r unit Disconnect print plate connector Check for continuity between terminal 2E 14 pin at print plate and print plate connector 4F 8 pin terminal Is there continuity Yes Replace display unit assembly...

Page 1118: ...TEP INSPECTION ACTION Turn ignition switch to LOCK Disconnect negative battery cable After 30 seconds or more reconnect negative battery cable Turn ignition switch to ON and LOCK 3 times Turn ignition...

Page 1119: ...for continuity between terminal 2E 14 pin at print plate and print plate connector 4F 8 pin terminal Is there continuity W 6 U 9 0 1 W V K Yes Replace display unit assembly cr 09 22 INSTRUMENT CLUSTE...

Page 1120: ...een terminal A at oil pressure switch and ground Is there continuity W6U901WVQ Yes Go to step 3 No Go to next step Stop engine Remove meter hood Remove instrument cluster Check for continuity between...

Page 1121: ...Malfunction in door ajar warning light operation circuit Door ajar warning light does not illuminate CPU malfunction Door ajar warning light bulb malfunction Print plate malfunction Malfunction in wi...

Page 1122: ...at joint box 16 pin and ground Is there continuity iTj 11111 i i n Yes Replace CPU No Go to next step U i I 5 1 r m I W6U901WW Remove door switch Inspect door switch a 09 18 DOOR SWITCH INSPECTION Is...

Page 1123: ...in joint box and remove CPU from joint box Check for continuity between terminal 1E at instrument cluster 12 pin connector of wiring harness and terminal 1H at joint box 16 pin Is there continuity 1H...

Page 1124: ...nut fixed in joint box and remove CPU from joint box Turn ignition switch to ON Does door ajar warning light illuminate Yes Go to step 4 No Go to next step Turn ignition switch to LOCK Open any door...

Page 1125: ...cluster and CPU Malfunction in wiring harness between instrument cluster and brake fluid level sensor STEP INSPECTION ACTION Remove driver s side front scuff plate Remove driver s side front side trim...

Page 1126: ...y W 6 U 9 0 1 W W 6 Yes Repair wiring harness between instrument cluster and CPU No Go to next step Disconnect brake fluid level sensor connector Check for continuity between terminal 3L at instrument...

Page 1127: ...Is there continuity Yes Replace brake fluid level sensor No Repair wiring harness between brake fluid level sensor and ground Even if ignition key is left in steering lock key reminder warning buzzer...

Page 1128: ...1J at joint box 16 pin Is voltage B Yes Go to next step No Repair wiring harness between ROOM 15 A fuse and CPU Check for continuity between terminal 1G at joint box 16 pin and ground Is there contin...

Page 1129: ...eminder switch connector Is voltage B Yes Repair wiring harness between key reminder switch and CPU J U No Replace steering lock W 6 U 9 0 1 W W F Open any door Check for continuity between terminal 1...

Page 1130: ...NTS Malfunction in key reminder warning buzzer input signal circuit Q Key reminder warning buzzer still sounds Key reminder switch malfunction CPU malfunction STEP INSPECTION ACTION 1 Remove column co...

Page 1131: ...LLATION 09 10 6 FUEL FILLER LID ADJUSTMENT 1 Measure the gap and height between the fuel filler lid and the body Clearance Standard mm in Minimum mm in Maximum mm in a 3 5 0 14 2 5 0 10 4 5 0 17 b 0 5...

Page 1132: ...2 Tighten the hood installation bolts Height Turn the stop rubber to adjust the height of the hood HOOD REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Pull out the windshield washer pi...

Page 1133: ...ht side o Left side O Increase Right side o Left side o Decrease Right side 0 Left side o W 6 U 9 1 0 W A 6 3 Hand tighten the trunk lid striker installation bolts 4 If not as specified loosen the tru...

Page 1134: ...D ADJUSTMENT W 6 U 9 1 0 W 0 6 1 Connector 2 Bolt 3 Trunk lid 4 Balance spring w Removal note 5 Nut 6 Trunk lid hinge Balance Spring Removal Note Caution The balance springs are under high tension 1 C...

Page 1135: ...the negative battery cable 2 Remove the rear combination light Refer to 09 18 REAR COMBINATION LIGHT REMOVAL INSTALLATION 3 Remove in the order indicated in the table 4 Install in the reverse order o...

Page 1136: ...10 FRONT BUMPER REMOVAL INSTALLATION 4 Remove the front fender seal plate 5 Remove in the order indicated in the table 6 Install in the reverse order of removal 7 Adjust the headlight aiming Refer to...

Page 1137: ...0 0 20 3 0 0 14 7 0 0 25 b 10 0 0 40 8 0 0 32 12 0 0 47 c 5 0 0 20 4 0 0 16 6 0 0 23 d 0 0 1 5 0 05 1 5 0 05 e 0 0 1 0 0 03 0 5 0 01 f 4 5 0 18 3 5 0 14 5 5 0 21 W 6 U 9 1 1 W 0 1 3 Hand tighten the...

Page 1138: ...Pull the green pin out until it stops 4 Disconnect the connector Connector Installation Note 1 Install the rubber boot to the connector 2 Connect the connector 3 Push the green pin in until it stops f...

Page 1139: ...asure the gap and height between the rear door and body Clearance Nominate mm in Minimum mm in Maximum mm in a 4 5 0 18 3 5 0 14 5 5 0 21 b 0 0 1 0 0 03 0 5 0 01 c 0 0 0 5 0 01 1 0 0 03 d 0 0 1 5 0 05...

Page 1140: ...ker 8 9 12 7 N m 90 130 kgfcm 79 112 Inlb f 20 30 2 2 3 1 16 22 Nm kgfm ftlbf W 6 U 9 1 1 W A 5 Connector Removal Note 1 Remove the rubber boot from the connector 2 Pull out the green pin out until it...

Page 1141: ...1 W 0 8 1 Remove the rear door trim Refer to 09 17 REAR 4 Install in the reverse order of removal DOOR TRIM REMOVAL INSTALLATION 2 Disengage the clips by using a fastener remover 3 Remove the rear doo...

Page 1142: ...12 13 FILAMENT INSPECTION 09 12 15 FILAMENT REPAIR 09 12 15 REAR WINDOW DEFROSTER SWITCH REMOVAL INSTALLATION 09 12 15 REAR WINDOW DEFROSTER SWITCH INSPECTION 09 12 16 REAR WINDOW DEFROSTER RELAY REM...

Page 1143: ...W REGULATOR INSPECTION 1 Disconnect the negative battery cable 2 Remove the front door trim Refer to 09 17 FRONT DOOR TRIM REMOVAL INSTALLATION 3 Partially peel off the front door screen 4 Disconnect...

Page 1144: ...Remove the regulator handle Refer to 09 12 REGULATOR HANDLE REMOVAL Refer to 09 12 REGULATOR HANDLE INSTALLATION 2 Remove the front door glass Refer to 09 12 FRONT DOOR GLASS AND GUIDE REMOVAL INSTAL...

Page 1145: ...e negative battery cable 2 Remove the rear door glass Refer to 09 12 REAR DOOR GLASS AND GUIDE REMOVAL INSTALLATION 3 Disconnect the negative battery cable 4 Remove in the order indicated in the table...

Page 1146: ...POWER WINDOW MAIN SWITCH REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Remove the driver s side front door trim Refer to 09 17 FRONT DOOR TRIM REMOVAL INSTALLATION 3 Remove in the or...

Page 1147: ...minal F O O Continuity Power cut switch Switch position Terminal A B C D F H i J K L On Off p p p p W vJ Driver Manual close p n ps p p L Auto open Manual open pv a w T p vJ V vJ Passenger Close Pi p...

Page 1148: ...9 1 2 W 1 1 1 Disconnect the negative battery cable 2 Remove the passenger s side front door trim or rear door trim Refer to 09 17 FRONT DOOR TRIM REMOVAL INSTALLATION Refer to 09 17 REAR DOOR TRIM RE...

Page 1149: ...continuity between the power window subswitch terminals by using an ohmmeter ________________________________ O O Continuity Switch position Close Off Open Terminal O o o o O o o O O W 6 U 9 1 2 W A...

Page 1150: ...protective tape along the edge of the headliner to protect it from damage 5 Apply protective tape along the edge of the body to protect it from damage Note The rear window molding is a replacement par...

Page 1151: ...by using a razor knife PROTECTIVE TAPE 7 Make a hole through the sealant from the inside of the vehicle by using an awl 8 Pass the SST piano wire through the hole 9 Wind each end of the wire around ba...

Page 1152: ...e lower edge and moving upward and inward being careful to not pull out the corners C 6 Install the side and lower starting from the upper edge and moving downward and inward being careful to not pull...

Page 1153: ...ly protective tape along the edge of the body to protect it from damage 6 Remove the sunvisor and apply protective tape along the edge of the headliner to protect it from damage 7 Apply protective tap...

Page 1154: ...windows and leave them open until the sealant has hardened 1 Cut away the old sealant by using a razor knife so that 1 2 mm 0 04 0 07 in thickness of a sealant remains around the circumference of the...

Page 1155: ...along both the upper and sides are 7 3 mm 0 29 in m m in W 6 U 9 1 2 W B 9 14 Use a scraper to smooth away any sealant that oozes out Add more sealant to any points of poor contact Adjust the sealant...

Page 1156: ...t is faulty Repair the filament FILAMENT REPAIR 1 Use white gasoline to clean around the damaged section of the filament 2 Attach tape above and below the damaged section of the filament W 6 U 9 1 2 W...

Page 1157: ...move the rear window defroster relay W 6 U 9 1 2 W B H REAR WINDOW DEFROSTER RELAY INSPECTION 1 Remove the rear window defroster relay 2 Inspect for continuity between the rear window defroster relay...

Page 1158: ...WER OUTSIDE MIRROR DOOR SCREEN N m kgf cm in lbf W 6 U 9 1 2 W B M 7 Install in the reverse order of removal MANUAL OUTSIDE MIRROR REMOVAL INSTALLATION 1 Remove the inner garnish 2 Remove the nuts and...

Page 1159: ...to secure it MANUAL OUTSIDE MIRROR GLASS REMOVAL Refer to 09 12 POWER OUTSIDE MIRROR GLASS REMOVAL W 6 U 9 1 2 W 2 9 W 6 U 9 1 2 W 3 0 MANUAL OUTSIDE MIRROR GLASS INSTALLATION Refer to 09 12 POWER OU...

Page 1160: ...E C H F D B W 6 U 9 1 2 W B U 3 If not as specified replace the power outside mirror switch W 6 U 9 1 2 W B T REARVIEW MIRROR REMOVAL 1 Insert a flathead screwdriver between the mirror and the base 2...

Page 1161: ...a free of dirt and grease and do not touch the surface or the primer may not properly bond to the surface of the glass 3 Apply primer to the glass and the base Use only glass primer on the glass and b...

Page 1162: ...INSPECTION 09 13 5 FRONT TILT MOTOR INSPECTION 09 13 6 REAR TILT MOTOR INSPECTION 09 13 6 POWER SEAT SWITCH INSPECTION 09 13 6 FRONT SEAT REMOVAL INSTALLATION 1 Disconnect the negative battery cable...

Page 1163: ...mbly W 6 U 9 1 3 W A 1 1 Headrest 2 Power seat switch knob 3 Recliner lever 4 Cap 5 Knuckle cover 6 Front cover 7 Seat back trim 8 Seat back pad 9 Seat back frame 10 Pole guide 11 Seat cushion trim 12...

Page 1164: ...e in the reverse order of disassembly W 6 U 9 1 3 W A 2 1 Headrest 2 Recliner lever 3 Cap 4 Knuckle cover 5 Seat back trim 6 Seat back pad 7 Seat back frame 8 Pole guide 9 Seat cushion trim 10 Seat cu...

Page 1165: ...L INSTALLATION W 6 U 9 1 3 W 0 3 1 Remove in the order indicated in the table 2 Install in the reverse order of removal W 6 U 9 1 3 W A 3 3 Rear seat back hinge 4 Rear seat back 1 Rear seat cushion 2...

Page 1166: ...ck catch knob 5 Rear seat back trim 6 Rear seat back pad 7 Rear seat back frame SLIDE MOTOR INSPECTION 1 Remove the front seat Refer to 09 13 FRONT SEAT REMOVAL INSTALLATION 2 Disconnect the slide mot...

Page 1167: ...nnector and check operation of the seat when battery positive voltage is applied to the terminals as shown Connection Seat operation B GND A B Up B A Down W 6 U 9 1 3 W 0 7 W 6 U 9 1 3 W A 7 3 If not...

Page 1168: ...SEATS 4A 4 If not as specified replace the power seat switch 2A 2B t 4B 3A 1C 1A 1F W6U913WA9 09 13 7...

Page 1169: ...14 10 KEYLESS UNIT INSPECTION 09 14 11 Terminal Voltage List Reference 09 14 11 KEYLESS UNIT REMOVAL INSTALLATION 09 14 11 TRANSMITTER ID CODE CHANGE 09 14 12 HOOD SWITCH INSPECTION 09 14 13 TRUNK KE...

Page 1170: ...le 7 D o o r ke y c y lin d e r W6U914WA0 FRONT DOOR LOCK ACTUATOR INSPECTION Note The front door lock actuator is built in the front door lock 1 Disconnect the negative battery cable 2 Remove the fr...

Page 1171: ...ove the striker horizontally or vertically W 6 U 9 1 4 W 0 3 3 Tighten the front door lock striker installation screws W 6 U 9 1 4 W A 2 FRONT DOOR LOCK STRIKER REMOVAL INSTALLATION W 6 U 9 1 4 W 0 4...

Page 1172: ...re e n 4 R e a r d o o r lo ck 5 O u te r h a n d le REAR DOOR LOCK ACTUATOR INSPECTION Note The rear door lock actuator is built in the rear door lock 1 Disconnect the negative battery cable 2 Remov...

Page 1173: ...REMOVAL INSTALLATION 1 Remove the screws 2 Remove the rear door lock striker W6U914W08 3 Install in the reverse order of removal 4 Adjust the rear door lock striker Refer to 09 14 REAR DOOR LOCK STRI...

Page 1174: ...meter C o n tin u ity O W V O R e sista n ce Switch position Terminal A B Lock O V Ay O R Neutral Unlock O O R 9 5 0 10 50 2 W 6 U 9 1 4 W B K W6U914W10 A B 4 If not as specified replace the door lock...

Page 1175: ...lated wiring harnesses 4 If the parts and wiring harnesses are okay but the system still does not work properly replace the door lock timer unit 1 Terminal Voltage List Reference G ___ c E 7 1 c A H F...

Page 1176: ...rly replace the door lock timer unit 2 Terminal Voltage List Reference 6 E C A H F D B W 6 U 9 1 4 W A D Terminal Signal Connection Test condition Voltage V Continuity Inspection area A N o t u se d B...

Page 1177: ...er of removal 6 Adjust the hood lock Refer to 09 14 HOOD LOCK ADJUSTMENT W 6 U 9 1 4 W 1 5 N m kgf cm in lbf W 6 U 9 1 4 W A E 1 N u t A 2 B olt 3 H o o d lo ck 4 N u t B 5 H o o d re le a s e ca b le...

Page 1178: ...tton If the transmitter is malfunctioning the battery cannot be properly inspected 1 Remove the transmitter cover 2 Connect the positive lead of the voltmeter to the positive terminal of the transmitt...

Page 1179: ...5 A fu s e C o n s ta n t B R O O M 15 A fu s e B K e y le s s u n it g ro u n d G N D C o n s ta n t c h e c k fo r c o n tin u ity to g ro u n d Yes G N D C N o t u se d D N o t u se d E D o o r lo...

Page 1180: ...In order to prevent this the ID codes for all three transmitters must be reprogrammed when reprogramming an ID code Also when one or two transmitters are used the ID code must be programmed three time...

Page 1181: ...tor 4 Check for continuity between the trunk key cylinder switch terminals by using an ohmmeter O O C o n tin u ity Switch position Terminal A B N e u tra l U n lo c k O O S L A B W 6 U 9 1 4 W 2 3 W...

Page 1182: ...EMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Disassemble the pocket Refer to 09 17 FRONT DOOR TRIM DISASSEMBLY ASSEMBLY 3 Remove in the order indicated in the table 4 Install in the r...

Page 1183: ...the trunk lid striker IMMOBILIZER SYSTEM SERVICE CAUTION Caution When an immobilizer system component such as the PCM immobilizer unit coil or the key has failed it must be accurately determined acco...

Page 1184: ...isconnect the immobilizer unit connector before checking for continuity at terminal C 5 If not specified inspect the parts listed under Inspection area and the related wiring harnesses 6 If the parts...

Page 1185: ...all keys she he has to the dealer This is because the previously programmed key IDs are erased when reprogramming the key IDs into the immobilizer unit and PCM If customer has only one valid key when...

Page 1186: ...y one or no valid key code word is required Note If no specific time interval is given step should be performed within 30 seconds of the previous step 1 Cut new transponder equipped key s 2 Using key...

Page 1187: ...y 3 back to ON Observe illumination of security light in instrument panel 2 Turn key 3 to LOCK Observe security light goes out Note Operate next two steps within 30 seconds of step 5 2 6 Remove key 1...

Page 1188: ...ment of the IMMOBILIZER SYSTEM REPROGRAM PROCEDURE When customer has brought at least one valid key code word is required VALID KEY KEY 1 VALID OR NEW KEYS 3 KEY 2 KEY 3 W 6 U 9 1 4 W B 4 Note If no s...

Page 1189: ...umination for 1 2 seconds 1 Turn key 2 to LOCK and remove from steering lock 5 Using key 1 start engine Observe security light illumination for 1 2 seconds and engine continues to run 1 Turn key 1 to...

Page 1190: ...in instrument panel 1 Turn key 1 to LOCK Observe security light blinks once repeatedly 4 Using key 2 turn ignition switch to ON Observe security light illuminates and then goes out 1 Turn key 2 to LO...

Page 1191: ...step 2 for rest of six digits 3 When code word is registered correctly in the PCM The security light stops flashing and illuminates 4 As soon as the security light stops flashing and illuminates the f...

Page 1192: ...tch is turned to LOCK and ON while the security light is off SECURITY LIGHT IGNITION SWITCH INCORRECT W 6 U 9 1 4 W B A The unmatch cord word to the immobilizer unit is input Code Word Input Error Rec...

Page 1193: ...ALLATION 09 15 7 SUNROOF SWITCH INSPECTION 09 15 7 SUNROOF CONTROL MODULE INSPECTION 09 15 8 Terminal Voltage List Reference 09 15 8 SUNROOF CONTROL MODULE REMOVAL INSTALLATION 09 15 9 SUNROOF UNIT RE...

Page 1194: ...R REMOVAL 7 Slide the guide backward and remove it from the sunroof frame W 6 U 9 1 5 W A 4 8 Remove the drive unit from the guide 9 Remove the deflector Refer to 09 15 DEFLECTOR REMOVAL INSTALLATION...

Page 1195: ...TOR INSTALLATION 7 Slide the drip rail guide forward and install it to the sunroof frame 8 Push the drip rail guide downward to engage pins A and B to the guide W 6 U 9 1 5 W A 9 9 Slide the sunshade...

Page 1196: ...drain hose from the clips 3 Pull the front drain hose into the room side 4 Remove the front drain hose CLIP CLIP CLIP W 6 U 9 1 5 W 0 5 CLIP SEC A A SEC B B SEC C C SEC D D W 6 U 9 1 5 W A D FRONT DRA...

Page 1197: ...se inserting area 2 Insert one end of the rear drain hose into the sunroof frame set the hose along the clips and insert the rear drain hose joint into the rear pillar inner hole W 6 U 9 1 5 W 0 7 3 I...

Page 1198: ...OOF MOTOR REMOVAL 2 Apply battery positive voltage to the sunroof motor terminals and check the operation of the motor Connection Motor operation B GND E F Open Tilt down turn right F E Close Tilt up...

Page 1199: ...iner Refer to 09 17 HEADLINER REMOVAL INSTALLATION SUNROOF SWITCH REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Disengage the clip A by using a tape wrapped flathead screwdriver as sh...

Page 1200: ...o p e n in g tiltin g d o w n 0 S u n ro o f s w itc h S u n ro o f m o to r S u n ro o f c lo s in g tiltin g up B 2 A S lid e o p e n S u n ro o f sw itc h Ig n itio n s w itc h a t O N S lid e o p...

Page 1201: ...negative battery cable 5 Install in the reverse order of removal 2 Remove the headliner Refer to 09 17 HEADLINER REMOVAL INSTALLATION 3 Slide the sunroof control module and disengage hooks from the s...

Page 1202: ...09 16 5 ROOF MOLDING REMOVAL 09 16 6 ROOF MOLDING INSTALLATION 09 16 6 AIRDAM SKIRT REMOVAL INSTALLATION 09 16 7 EXTRACTOR CHAMBER REMOVAL INSTALLATION 1 Remove the rear bumper Refer to 09 10 REAR BUM...

Page 1203: ...cowl grille to disengage clips A from the body W 6 U 9 1 6 W 0 5 REAR FINISHER REMOVAL INSTALLATION 1 Remove the screws and bolts and nuts 2 Pull the rear finisher to disengage clips A and pins B from...

Page 1204: ...50 0 1 97 D 35 0 1 38 Distance from vehicle front end mm in Nominate mm in A 1600 62 99 208 5 8 21 B 2000 78 74 212 1 8 35 C 2500 98 43 216 9 8 54 D 2600 102 36 218 0 8 58 E 2900 114 17 220 7 8 69 F...

Page 1205: ...a height 3 mm 0 12 in between the glass and the body 3 0 12 CARTRIDGE 3 0 12 REPAIR SEALANT m m in W 6 U 9 1 6 W A D 9 Reshape the repair sealant as shown if necessary W 6 U 9 1 6 W A E Caution Once t...

Page 1206: ...power outside mirror Refer to 09 12 MANUAL OUTSIDE MIRROR REMOVAL INSTALLATION Refer to 09 12 POWER OUTSIDE MIRROR REMOVAL INSTALLATION 2 Remove the front door glass Refer to 09 12 FRONT DOOR GLASS A...

Page 1207: ...om the adhesion surface of the body 3 Apply repair sealant as shown 1040 1080 40 95 42 51 690 730 27 2 28 7 350 390 13 8 15 3 35 1 4 VEHICLE FORWARD 35 1 4 30 1 2 20 0 8 APPLY SEALANT IN MODERATE IN T...

Page 1208: ...EXTERIOR TRIM AIRDAM SKIRT REMOVAL INSTALLATION W 6 U 9 1 6 W 1 7 1 Remove the bolts 3 Install in the reverse order of removal 2 Remove the airdam skirt W6U916WAI 09 16 7...

Page 1209: ...ION 09 17 8 VENTILATOR GRILLE REMOVAL INSTALLATION 09 17 8 Left S id e 09 17 8 Right Side 09 17 8 UNDER COVER REMOVAL INSTALLATION 09 17 8 FRONT DOOR TRIM REMOVAL INSTALLATION 09 17 9 FRONT DOOR TRIM...

Page 1210: ...Remove the side wall Refer to 09 17 SIDE WALL REMOVAL INSTALLATION 7 Remove the front side trim Refer to 09 17 FRONT SIDE TRIM REMOVAL INSTALLATION 8 Remove the under cover 9 Remove the lower panel Re...

Page 1211: ...UNIT REMOVAL INSTALLATION 3 Remove the audio unit Refer to 09 20 AUDIO UNIT REMOVAL INSTALLATION 4 Disassemble in the order indicated in the table 5 Assemble in the reverse order of disassembly W 6 U...

Page 1212: ...la te 4 B o o t 5 P a n e l CENTER LOWER PANEL REMOVAL INSTALLATION 1 Remove the rear console Refer to 09 17 REAR CONSOLE REMOVAL INSTALLATION 2 Remove the glove compartment 3 Remove the under cover...

Page 1213: ...disengage clips A and pins B from the dashboard COLUMN COVER REMOVAL INSTALLATION 1 Remove the screws to remove the column cover SCREW W 6 U 9 1 7 W A 6 W 6 U 9 1 7 W 0 7 2 Install in the reverse ord...

Page 1214: ...dicated in the table 2 Assemble in the reverse order of disassembly W 6 U 9 1 7 W 1 0 1 S c re w A 2 R e a r c o n s o le lid 3 S c re w B 4 R e a r c o n s o le lid in n e r 5 R e a r c o n s o le li...

Page 1215: ...LLATION 1 Disconnect the negative battery cable 2 Remove the driver s side side panel 3 Remove the lower panel 4 Remove the screws 5 Pull the meter hood to disengage clips A from the dashboard 6 Disco...

Page 1216: ...2 Remove the lower panel 3 Remove the meter hood 4 Push up clip A from the backside of the dashboard to remove the ventilator grille VENTILATOR GRILLE W 6 U 9 1 7 W A G 5 Install in the reverse order...

Page 1217: ...body 9 Pull the front door trim upward to disengage hooks B from the body 10 Disconnect the trunk lid opener switch connector 11 Disconnect the connector if equipped with a power window W 6 U 9 1 7 W...

Page 1218: ...6 Pull the rear door trim to disengage clips A from the body 7 Pull the rear door trim upward to disengage hooks B from the body 8 Disconnect the connector if equipped with a power window CLIP HOOK 4...

Page 1219: ...everse order of removal B PILLAR UPPER TRIM REMOVAL INSTALLATION W 6 U 9 1 7 W 2 3 1 Remove the upper anchor of the front seat belt 6 Install in the reverse order of removal Refer to 08 11 FRONT SEAT...

Page 1220: ...6 U 9 1 7 W 2 5 1 Disconnect the negative battery cable 2 Remove the rear side seat Refer to 09 13 REAR SEAT REMOVAL INSTALLATION 3 Remove the high mount brake light 4 Remove the fasteners 5 Push up c...

Page 1221: ...the body FRONT SIDE TRIM REMOVAL INSTALLATION W 6 U 9 1 7 W 2 8 1 Remove the front scuff plate 4 Install in the reverse order of removal 2 Remove the fasteners 3 Slide the front side trim to disengag...

Page 1222: ...1 Disconnect the negative battery cable 2 Remove the interior light Refer to 09 18 INTERIOR LIGHT REMOVAL INSTALLATION 3 Remove the sunroof switch Refer to 09 15 SUNROOF SWITCH REMOVAL INSTALLATION 4...

Page 1223: ...t Refer to 09 13 FRONT SEAT REMOVAMNSTALLATION 3 Remove the rear seat cushion 4 Remove the dashboard Refer to 09 17 DASHBOARD REMOVAMNSTALLATION 5 Remove the B pillar lower trim Refer to 09 17 B PILLA...

Page 1224: ...18 9 FLASHER UNIT REMOVAL INSTALLATION 09 18 9 FLASHER UNIT INSPECTIO N 09 18 10 Terminal Voltage List Reference 09 18 10 INTERIOR LIGHT REMOVAL INSTALLATION 09 18 10 Lens Removal Note 09 18 11 INTERI...

Page 1225: ...er of removal 5 Adjust the headlight aiming Refer to 09 18 HEADLIGHT ADJUSTMENT W 6 U 9 1 8 W A 1 HEADLIGHT BULB REMOVAL INSTALLATION W 6 U 9 1 8 W 0 3 Caution A halogen bulb generates extremely high...

Page 1226: ...ight bulb W 6 U 9 1 8 W A 3 REAR COMBINATION LIGHT REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Partially peel off the trunk compartment covering Refer to 09 17 TRUNK COMPARTMENT COV...

Page 1227: ...e high mount brake light 3 Remove the socket to remove the high mount brake light bulb W 6 U 9 1 8 W 0 7 SOCKET W 6 U 9 1 8 W A 6 LICENSE PLATE LIGHT REMOVAUINSTALLATION 1 Disconnect the negative batt...

Page 1228: ...O O Other W 6 U 9 1 8 W B 4 W 6 U 9 1 8 W 1 0 A B W 6 U 9 1 8 W A A 3 If not as specified replace the back up light switch COMBINATION SWITCH REMOVAL INSTALLATION 1 Disconnect the negative battery ca...

Page 1229: ...W 6 U 9 1 8 W 1 2 1 Cancel cam 2 Spring 3 Light switch 4 Windshield wiper and washer switch W 6 U 9 1 8 W A C LIGHT SWITCH REMOVAL INSTALLATION W 6 U 9 1 8 W 1 3 1 Disconnect the negative battery cab...

Page 1230: ...ontinuity Switch position Terminal 2C 2A 2B Left O O Off Right 0 0 2C LEFT RIGHT W 6 U 9 1 8 W B 6 n n 2F 2E 2D 2C 2B 2A I _________ I 2A 2B W 6 U 9 1 8 W A F 3 If not as specified replace the light s...

Page 1231: ...LATION W 6 U 9 1 8 W 1 7 Canada Only 5 Install in the reverse order of removal 1 Disconnect the negative battery cable 2 Remove the nuts to move the main fuse block to the side 3 Disconnect the connec...

Page 1232: ...place the headlight relay TNS RELAY INSPECTION 1 Disconnect the negative battery cable 2 Remove the TNS relay 3 Check for continuity between the TNS relay terminals by using an ohmmeter O Q Continuity...

Page 1233: ...on B Turn switch Other 0 E Turn signal flasher RH Turn signal light RH Ignition switch at ON and turn signal light RH flashes Alternates 0 and B Turn signal light RH Other 0 F Turn switch on off LH T...

Page 1234: ...erminals by using an ohmmeter 1 Lens tr Removal Note 2 Interior light bulb vr Installation Note 3 Screw 4 Connector 5 Housing Lens Removal Note 1 Insert a tape wrapped flathead screwdriver as shown in...

Page 1235: ...ole W6U918W25 4 Remove the vanity mirror illumination bulb 5 Install in the reverse order of removal 3 Twist the flathead screwdriver to remove the lens VANITY M IRRO R ILLUM INATIO N INSPECTIO N 1 Re...

Page 1236: ...h position Terminal A Body GND Pressed Released O O W 6 U 9 1 8 W 2 8 W6U918WBD 3 If not as specified TR U N K C O M PA R TM EN T LIG HT SW ITCH INSPECTIO N 1 Disconnect the trunk compartment light sw...

Page 1237: ...TION W 6 U 9 1 8 W 3 0 1 Disconnect the negative battery cable 4 Install in the reverse order of removal 2 Remove the meter hood Refer to 09 17 METER HOOD REMOVAL INSTALLATION 3 Press the hooks of the...

Page 1238: ...onnection Test condition Voltage V Continuity Inspection area A Not used B TNS Light switch Headlight switch at first or second position B Light switch TAIL 15 A fuse Other 0 C Illumination Each illum...

Page 1239: ...NDSHIELD WASHER NOZZLE ADJUSTMENT 09 19 7 WINDSHIELD WASHER NOZZLE REMOVAL 09 19 7 WINDSHIELD WASHER NOZZLE INSTALLATION 09 19 7 WINDSHIELD WASHER PIPE REMOVAL INSTALLATION 09 19 8 WINDSHIELD WIPER AR...

Page 1240: ...d wiper link WINDSHIELD WIPER MOTOR REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Remove the windshield wiper arm and blade Refer to 09 19 WINDSHIELD WIPER ARM AND BLADE REMOVAL INSTA...

Page 1241: ...l E and battery positive voltage to the following terminals of the windshield wiper motor Verify that the windshield wiper motor operates as indicated below Terminal Operation A High C Low W 6 U 9 1 9...

Page 1242: ...lbf W 6 U 9 1 9 W A A WINDSHIELD WASHER MOTOR REMOVAL INSTALLATION W 6 U 9 1 9 W 0 7 1 Disconnect the negative battery cable 2 Partially peel off the right side mud guard 3 Remove the windshield wash...

Page 1243: ...tery cable 2 Partially peel off the right side mud guard 3 Remove the windshield washer tank 4 Remove in the order indicated in the table 5 Install in the reverse order of removal W 6 U 9 1 9 W 0 9 Wa...

Page 1244: ...INDSHIELD W IPER AND W ASHER SWITCH CO NNECTOR W 6 U 9 1 9 1 A G W IN D S H IE LD W IPER A N D W ASHER SW ITCH INSPECTIO N 1 Remove the column cover 2 Remove the windshield wiper and washer switch 3 I...

Page 1245: ...tor 2 Disconnect the windshield washer pipe from the windshield washer nozzle 3 Remove the windshield washer nozzle by using a 10 mm 0 4 in deep socket wrench from underneath the bonnet WINDSHIELD WAS...

Page 1246: ...REMOVAL INSTALLATION 1 Partially peel off the right side mud guard 2 Remove in the order indicated in the table 3 Install in the reverse order of removal W 6 U 9 1 9 W 1 6 1 Clip 2 Joint pipe 3 Winds...

Page 1247: ...09 20 9 Socket Removal Note 09 20 9 DOOR SPEAKER REMOVAL INSTALLATION Caution When removing or installing a door speaker touching the radio cone paper could cause poor sound quality When removing or...

Page 1248: ...inal A B Standard type O V V O Ri BOSE type O v O R W 6 U 9 2 0 W 0 4 3 Touch the leads of an ohmmeter to the rear speaker terminals and verify that the speaker clicks Range x 1 Cl 4 If not as specifi...

Page 1249: ...the negative battery cable 2 Remove the rear console Refer to 09 17 REAR CONSOLE REMOVAL INSTALLATION 3 Remove the audio unit Refer to 09 20 AUDIO UNIT REMOVAL 4 Remove in the order indicated in the t...

Page 1250: ...ct the rear antenna feeder 6 Remove in the order Indicated in the table 7 Install in the reverse order of removal W 6 U 9 2 0 W A 9 1 Clip Rear antenna feeder REAR ANTENNA FEEDER INSPECTION 1 Remove t...

Page 1251: ...tment covering from passenger s side Refer to 09 17 TRUNK COMPARTMENT COVERING REMOVAL INSTALLATION 2 Disconnect the rear antenna feeder 3 Verify that there is no continuity between manual antenna ter...

Page 1252: ...ut according to the specified torque value 1 Disconnect the negative battery cable 2 Turn over the trunk compartment covering from passenger s side Refer to 09 17 TRUNK COMPARTMENT COVERING REMOVAL IN...

Page 1253: ...e the power antenna or the antenna mast 1 Use snap ring pliers to remove the mounting nut W 6 U 9 2 0 W 1 4 2 Turn the ignition switch to ON or ACC 3 Turn the audio unit radio switch on 4 Pull out the...

Page 1254: ...n the order indicated in the table 4 Install in the reverse order of removal W 6 U 9 2 0 W A M W 6 U 9 2 0 W 1 6 1 Bolt 2 Connector 3 Audio amplifier AUDIO UNIT REMOVAL 1 Disconnect the negative batte...

Page 1255: ...E LIGHTER INSPECTION 1 Remove the socket Refer to 09 20 CIGARETTE LIGHTER REMOVAL INSTALLATION 2 Verify the bimetals in the socket are not warped 3 Check if the backs of the bimetals can be seen from...

Page 1256: ...Remove the main fuse block cover the MAIN fuse 3 Remove the main fuse block mounting nuts 5 Install in the reverse order of removal ROOM FUSE INSTALLATION Note When the ROOM fuse is burnt or removed...

Page 1257: ...1 W A 3 5 If not as specified replace the ignition switch W 6 U 9 2 1 W A 2 KEY REMINDER SWITCH INSPECTION 1 Disconnect the negative battery cable 2 Remove the column cover 3 Disconnect the key remin...

Page 1258: ...R UNIT INSTALLATION 09 22 7 WATER TEMPERATURE SENDER UNIT INSPECTION 09 22 7 HORN REMOVAL INSTALLATION 09 22 8 HORN RELAY INSPECTION 09 22 8 INSTRUMENT CLUSTER REMOVAL INSTALLATION 1 Disconnect the ne...

Page 1259: ...temperature gauge 26 LCD Operating Order 1 Turn the ignition switch to LOCK 2 Disconnect the negative battery cable 3 Reconnect the negative battery cable after 30 seconds or more 4 Cycle the ignitio...

Page 1260: ...o the speedometer INSPECTION INDICATION SITUATION ACTION Wait for 2 seconds after selecting DTC 12 No indication Speedometer needle move full scale and then indicated 60 mph Speedometer is okay Other...

Page 1261: ...0 i n z i i U L _ I n m U ___ 1 1 ___ W 6 U 9 2 2 W B 8 The LCD indication range is 27 32 Go to next step Other than above stated Replace the display unit assembly 3 Set up the SST Fuel Thermometer Ch...

Page 1262: ...6 U 9 2 2 W B E The LCD indication range is 86 92 Go to next step Other than above stated Replace the display unit assembly 3 Set up the SST Fuel Thermometer Checker resistance to 120 C l 1o r 1 U _ J...

Page 1263: ...cluster Refer to 09 22 INSTRUMENT CLUSTER REMOVAL INSTALLATION 4 Turn the socket counterclockwise to remove the bulb as shown in the figure 5 Install in the reverse order of removal FUEL GAUGE SENDER...

Page 1264: ...W 6 U 9 2 2 W A 4 W 6 U 9 2 2 W 0 7 WATER TEMPERATURE SENDER UNIT REMOVAL 1 Disconnect the negative battery cable 2 Disconnect the water temperature sender unit connector 3 Remove the water temperatur...

Page 1265: ...Refer to 09 18 HEADLIGHT REMOVAL INSTALLATION 3 Disconnect the horn connector 4 Remove the bolt 5 Remove the horn BOLT W6U922WA7 CONNECTOR HORN HORN RELAY INSPECTION 1 Remove the horn relay 2 Check f...

Page 1266: ...NSPECTION 1 Remove the driver s side front scuff plate 2 Remove the driver s side front side trim 3 Remove the nut fixed in the joint box 4 Follow the appropriate procedure referring to the terminal v...

Page 1267: ...spection area 1A Trunk lid open closed Trunk compartment light Trunk compartment light switch Trunk lid open 0 ROOM 15 A fuse Trunk compartment light Trunk compartment light switch Trunk lid closed B...

Page 1268: ...eck for continuity to ground No 10 Seat belt buckled unbuckled Seat belt warning light Buckle switch Ignition switch at ON Driver s side seat belt buckled B METER 10 A fuse Instrument cluster Buckle s...

Page 1269: ...ch Headlight switch at 2nd position 0 Light switch Headlight switch at OFF or 1st position 5 3C Hood open closed Hood switch Hood open 0 Hood switch Hood closed 5 3D Not used 3F Rear window defroster...

Page 1270: ...ht switch Dimmer switch at LO 5 4J Rear window defroster relay operation Rear window defroster relay Ignition switch at ON Rear window defroster switch on 0 DEFOG 40 A circuit breaker Rear window defr...

Page 1271: ...llumination 3 4 x 3 1 4X 1 INSTRUMENTATION DRIVER INFO ABS warning light 1 4 x 1 Air bag system warning light 1 4 x 1 Brake system warning light 1 4 X 1 Cruise set indicator light 1 4 x 1 Door ajar wa...

Page 1272: ...lu T 0 3 0 5 8 7 0 A 49 T088 OAO New generation star tester set T T 0 8 8 O A O X 49 0839 285 Fuel and thermometer checker T 0 8 3 9 2 8 5 X 49 G050 1AO Sealant remover 49 T088 010E Program card 49 U...

Page 1273: ...ACTUATOR INSPECTION 07 40 5 AIR MIX ACTUATOR REMOVAL INSTALLATION 07 40 5 AIRDAM SKIRT REMOVAL INSTALLATION 09 16 7 AIRFLOW MODE ACTUATOR INSPECTION 07 40 6 AIRFLOW MODE ACTUATOR REMOVAL INSTALLATION...

Page 1274: ...LATION 05 10 3 CLUTCH RELEASE COLLAR INSPECTION 05 10 10 CLUTCH RELEASE CYLINDER DISASSEMBLY ASSEMBLY 05 10 6 CLUTCH RELEASE CYLINDER REMOVAL INSTALLATION 05 10 6 CLUTCH SWITCH INSPECTION FS 01 40A 28...

Page 1275: ...ENGINE COMPARTMENT SIDE C O M PO N EN T LOCATION K L 0 1 1 6 2 EMISSIONSYSTEM FUELTANKSIDE COMPONENT REMOVAL INSTALLATION 01 16 3 ENGINECOOLANTLEAKAGE INSPECTION 01 12 3 ENGINECOOLANTLEVEL INSPECTION...

Page 1276: ...0 2 1 3 4 FRONT M ANUAL W IN D O W REGULATOR R EM O V AL IN S TA LLA TIO N 0 9 1 2 3 FRONT OIL SEAL REPLACEM EN T FS 0 1 1 0 A 1 2 FRONT OIL SEAL REPLACEM EN T KL 0 1 1 0 B 1 5 FRO NT POW ER W IN D O...

Page 1277: ...CEDURE 09 14 17 IMMOBILIZER SYSTEM SERVICE CAUTION 0 9 1 4 1 5 IMMOBILIZER UNIT INSPECTION 09 14 16 IMMOBILIZER UNIT REMOVAL INSTALLATION 09 14 16 INDICATOR PANEL ADJUSTMENT 05 18 2 INPUT TURBINE SPEE...

Page 1278: ...NSPECTION 0 9 2 2 7 OIL PUMP BODY SEAL REM OVAL INSTALLATION LA4A EL 0 5 1 7 A 2 9 OIL SEAL DIFFERENTIAL R E P LA C E M E N T 0 5 1 5 2 OIL SEAL REM OVAL INSTALLATION G F4A EL 0 5 1 7 B 2 6 OIL SEALS...

Page 1279: ...M O V AL IN S TA LLA TIO N 0 9 1 0 5 REAR CALIPER D IS A S S E M B LY AS S E M B LY 0 4 1 1 1 8 REAR CENTER SEAT BELT R EM O V AL IN S TA LLA TIO N 0 8 1 1 2 REAR COM BINATION LIGHT R EM O V AL IN S T...

Page 1280: ...N 0 5 1 8 3 SELECTO R LEVER D IS A S S E M B LY AS S E M B LY 0 5 1 8 6 SELECTO R LEVER INSPECTION 0 5 1 8 1 SHIFT MECHANISM R EM O V AL IN S TA LLA TIO N 0 5 1 6 1 SIDE PANEL REM OVAL INSTALLATION 0...

Page 1281: ...S P E C T IO N 0 9 1 4 1 4 T R U N K LID LOCK AND OPENER R E M O V AL IN S TA LLA TIO N 0 9 1 4 1 3 TR U N K LID O PENER SW ITCH IN S P E C T IO N 0 9 1 4 1 4 T R U N K LID OPENER SW ITCH R E M O V AL...

Page 1282: ...M O V AL IN S TA LLA TIO N 0 9 1 9 4 W IN D SH IELD W ASHER NOZZLE A D JU STM EN T 0 9 1 9 7 W IN D SH IELD W ASHER NOZZLE IN S T A LLA T IO N 0 9 1 9 7 W IN D SH IELD W ASHER NOZZLE REM OVAL 0 9 1 9...

Reviews:

No comments

Related manuals for MX-6 1998

Kargo Master 40131 Installation Manual preview
40131
Brand: Kargo Master Pages: 5
Bestop 54822 Installation Instructions Manual preview
54822
Brand: Bestop Pages: 11
Whispbar K455W Fitting Instructions Manual preview
K455W
Brand: Whispbar Pages: 14
Vauxhall 2014 Insignia VXR SuperSport Specifications preview
2014 Insignia VXR SuperSport
Brand: Vauxhall Pages: 56
Mobile Create MCM3 Instruction Manual preview
MCM3
Brand: Mobile Create Pages: 15
BrandMotion 1009-6503 Installation Instructions Manual preview
1009-6503
Brand: BrandMotion Pages: 8
Ironton 44596 Owner'S Manual preview
44596
Brand: Ironton Pages: 7
Audi Q3 2015 - 2019 Technical Service Bulletin preview
Q3 2015 - 2019
Brand: Audi Pages: 12
Paccar PACCHARGE AC20 Installation Manual preview
PACCHARGE AC20
Brand: Paccar Pages: 63
WABCO TP19039 Manual preview
TP19039
Brand: WABCO Pages: 34
Vauxhall 2013 Ampera Infotainment Manual preview
2013 Ampera
Brand: Vauxhall Pages: 95
Westin 32-1660 Instructions preview
32-1660
Brand: Westin Pages: 3
Smappee EVB-1332-BL-E Installation Manual preview
EVB-1332-BL-E
Brand: Smappee Pages: 28
Easee Base 1-Way User Manual / Installation Manual preview
Base 1-Way
Brand: Easee Pages: 21
QA1 MU1RCA Install Instructions preview
MU1RCA
Brand: QA1 Pages: 4
Kia RIO 2005 General Information Manual preview
RIO 2005
Brand: Kia Pages: 25
AEV AEV30348AC User Manual preview
AEV30348AC
Brand: AEV Pages: 16
LAS 10637 Operating Instructions Manual preview
10637
Brand: LAS Pages: 9

Brands by name

Popular brands

Load more brands