Page 1 As modifications affecting repair or Steering System maintenance occur, relevant information supplementary to this volume will be made Braking System available at Mazda dealers. This manual should be kept up-to-date. Suspension Mazda Motor Corporation reserves Body the right to alter the specifications and...
Page 2 VEHICLE IDENTIFICATION NUMBERS (VIN) U.K. specs. JMZ GG12820# 100001— JMZ GG14320# 100001— JMZ GG14820# 100001— JMZ GG12F20# 100001— JMZ GG12F50# 100001— JMZ GG14F20# 100001— JMZ GG14F50# 100001— European (L.H.D.) specs. JMZ GG1232✻ ✻ ✻ ✻ # 100001— JMZ GG1282✻ ✻ ✻ ✻ # 100001—...
Page 3 The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and Mazda Motor Corporation reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation.
Page 4: Table Of Contents
G ENERAL INFORMATION HOW TO USE THIS MANUAL ......GI-2 INSTALLATION OF RADIO SYSTEM ....GI-17 RANGE OF TOPICS...........GI-2 INSTALLATION OF RADIO SYSTEM ..... GI-17 SERVICE PROCEDURE ........GI-2 ELECTRICAL SYSTEM........GI-18 SYMBOLS............GI-4 ELECTRICAL PARTS ........GI-18 ADVISORY MESSAGES ........GI-4 CONNECTORS..........GI-18 TROUBLESHOOTING PROCEDURE....GI-5 ELECTRICAL TROUBLESHOOTING UNITS ..............GI-11...
Page 5: How To Use This Manual
HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL RANGE OF TOPICS A6E201000001W01 • This manual contains procedures for performing all required service operations. The procedures are divided into the following five basic operations: — Removal/Installation — Disassembly/Assembly — Replacement —...
Page 6 HOW TO USE THIS MANUAL Repair procedure 1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together and describes visual part inspection. However, only removal/installation procedures that need to be performed methodically have written instructions. 2.
Page 7: Symbols
HOW TO USE THIS MANUAL SYMBOLS A6E201000001W03 • There are eight symbols indicating oil, grease, fluids, sealant, and SST or equivalent use. These symbols show application points or use of these materials during service. Symbol Meaning Kind New appropriate Apply oil engine oil or gear New appropriate Apply brake fluid...
Page 8: Troubleshooting Procedure
HOW TO USE THIS MANUAL TROUBLESHOOTING PROCEDURE A6E201000001W05 Basic flow of troubleshooting XME2010002 DTC troubleshooting flow (on-board diagnostic) • Diagnostic trouble codes (DTCs) are important hints for repairing malfunctions that are difficult to simulate. Perform the specific DTC diagnostic inspection to quickly and accurately diagnose the malfunction. •...
Page 9 HOW TO USE THIS MANUAL Procedures for Use Using the basic inspection (section K) • Perform the basic inspection procedure before symptom troubleshooting. • Perform each step in the order shown. • The reference column lists the location of the detailed procedure for each basic inspection. •...
Page 10 HOW TO USE THIS MANUAL Using the DTC troubleshooting flow • DTC troubleshooting flow shows diagnostic procedures, inspection methods, and proper action to take for each DTC. XME2010004 GI–7...
Page 11 HOW TO USE THIS MANUAL Using the diagnosis index • The symptoms of the malfunctions are listed in the diagnostic index for symptom troubleshooting. • The exact malfunction symptoms can be selected by following the index. XME2010006 GI–8...
Page 12 HOW TO USE THIS MANUAL Using the quick diagnosis chart • The chart lists the relation between the symptom and the cause of the malfunction. • The chart is effective in quickly narrowing down the relation between symptom and cause of the malfunction. It also specifies the area of the common cause when multiple malfunction symptoms occur.
Page 13 HOW TO USE THIS MANUAL Using the symptom troubleshooting • Symptom troubleshooting shows diagnostic procedures, inspection methods, and proper action to take for each trouble symptom. XME2010007 End Of Sie GI–10...
Page 14: Units
UNITS UNITS UNITS A6E201200002W01 Electrical current A (ampere) Electric power W (watt) Electric resistance Ω (ohm) Electric voltage V (volt) mm (millimeter) Length in (inch) kPa (kilo pascal) Negative pressure mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal) kgf/cm (kilogram force per square Positive pressure...
Page 15: Fundamental Procedures
FUNDAMENTAL PROCEDURES FUNDAMENTAL PROCEDURES PROTECTION OF VEHICLE A6E201400004W01 • Always be sure to cover fenders, seats and floor areas before starting work. X3U000WAG End Of Sie PREPARATION OF TOOLS AND MEASURING EQUIPMENT A6E201400004W02 • Be sure that all necessary tools and measuring equipment are available before starting any work.
Page 16: Disconnection Of The Negative Battery Cable
FUNDAMENTAL PROCEDURES 5. If no dye leakage is found, allow the engine to run for another 30 minutes or drive the vehicle then reinspect. 6. Find where the oil is leaking from, then make necessary repairs. Note • To determine whether it is necessary to replace the oil after adding the fluorescent dye, refer to the fluorescent dye instruction manual.
Page 17: Inspection During Removal, Disassembly
FUNDAMENTAL PROCEDURES INSPECTION DURING REMOVAL, DISASSEMBLY A6E201400004W08 • When removed, each part should be carefully inspected for malfunction, deformation, damage, and other problems. X3U000WAM End Of Sie ARRANGEMENT OF PARTS A6E201400004W09 • All disassembled parts should be carefully arranged for reassembly. •...
Page 18: Adjustment
FUNDAMENTAL PROCEDURES • If removed, these parts should be replaced with new ones: — Oil seals — Gaskets — O-rings — Lockwashers — Cotter pins — Nylon nuts • Depending on location: — Sealant and gaskets, or both, should be applied to specified locations. When sealant is applied, parts should be installed before sealant hardens to prevent leakage.
Page 19: Hose Clamps
FUNDAMENTAL PROCEDURES HOSE CLAMPS A6E201400004W14 • When reinstalling, position the hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit. WGIWXX0035J End Of Sie TORQUE FORMULAS A6E201400004W19 • When using a torque wrench-SST or equivalent combination, the written torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench.
Page 20: Dynamometer
• Some Ford SST or equivalent are used as SSTs necessary for engine repair. Note that these SSTs are marked with Ford SST numbers. • Note that a Ford SST number is written together with a corresponding Mazda SST number as shown below. Example (section ST)
Page 21: Electrical System
ELECTRICAL SYSTEM ELECTRICAL SYSTEM ELECTRICAL PARTS A6E201700006W01 Battery cable • Before disconnecting connectors or removing electrical parts, disconnect the negative battery cable. WGIWXX0007E Wiring Harness • To remove the wiring harness from the clip in the engine room, pry up the hook of the clip using a flathead screwdriver.
Page 22 ELECTRICAL SYSTEM • Connectors can be disconnected by pressing or pulling the lock lever as shown. WGIWXX0042E Locking connector • When locking connectors, listen for a click indicating they are securely locked. X3U000WB1 Inspection • When a tester is used to inspect for continuity or measuring voltage, insert the tester probe from the wiring harness side.
Page 23 ELECTRICAL SYSTEM Terminals Inspection • Pull lightly on individual wires to verify that they are secured in the terminal. X3U000WB4 Replacement • Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it until it locks securely. •...
Page 24 ELECTRICAL SYSTEM Fuse Replacement • When replacing a fuse, be sure to replace it with one of the same capacity. If a fuse fails again, the circuit probably has a short and the wiring should be inspected. • Be sure the negative battery terminal is disconnected before replacing a main fuse.
Page 25: Electrical Troubleshooting Tools
ELECTRICAL SYSTEM Vehicle-harness-side connector Direction of view is from the harness side. * : Part names are shown only when there are multiple connector drawings. WGIWXX0101E Other Because vehicle-harness-side connectors, such as the DLC 2, have to be viewed from the terminal side, the direction of view is from the terminal side.
Page 26: Precautions Before Welding
ELECTRICAL SYSTEM Voltmeter • The DC voltmeter is used to measure circuit voltage. A voltmeter with a range of 15 V or more is used by connecting the positive (+) probe (red lead wire) to the point where voltage will be measured and the negative (-) probe (black lead wire) to a body ground.
Page 27: Jacking Positions ,Vehicle Lift (2 Supports),Safety Stands (Rigid Rack) Positions
JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS), SAFETY STANDS (RIGID RACK) POSITIONS JACKING POSITIONS ,VEHICLE LIFT (2 SUPPORTS), SAFETY STANDS (RIGID RACK) POSITIONS JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) AND SAFETY STAND (RIGID RACK) POSITIONS A6E202200019W01 Jacking Positions Warning • Improperly jacking a vehicle is dangerous. The vehicle can slip off the jack and cause serious injury.
Page 28 JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS), SAFETY STANDS (RIGID RACK) POSITIONS Jacking positions, vehicle lift (2 supports) and safety stand (rigid rack) positions view A6E2021W001 End Of Sie GI–25...
Page 29: Towing
TOWING TOWING TOWING A6E202400009W01 • Proper lifting and towing are necessary to prevent damage to the vehicle. Government and local laws must be followed. • A towed vehicle should have its front wheels off the ground. If excessive damage or other conditions prevent this, use wheel dollies.
Page 30 TOWING FRONT 1. Remove the towing eyelet and the lug wrench from the trunk. 2. Wrap a screwdriver or similar tool with a soft cloth to prevent damage to the painted bumper and open the cap located on the front bumper, below the left headlight. Caution •...
Page 31: Identification Number Locations
IDENTIFICATION NUMBER LOCATIONS IDENTIFICATION NUMBER LOCATIONS VEHICLE IDENTIFICATION NUMBER(VIN) A6E202600010W01 A6E2026W004 End Of Sie ENGINE IDENTIFICATION NUMBER A6E202600010W02 A6E2026W001 End Of Sie GI–28...
Page 32 NEW STANDARDS NEW STANDARDS NEW STANDARDS A6E202800020W01 • Following is a comparison of the previous standard and the new standard. New Standard Previous Standard Remark Abbrevi- Abbrevi- Name Name ation ation Accelerator Pedal — Accelerator Pedal Air Cleaner — Air Cleaner Air Conditioning —...
Page 33: New Standards
NEW STANDARDS New Standard Previous Standard Remark Abbrevi- Abbrevi- Name Name ation ation — Output Speed Sensor — Vehicle Speed Sensor 1 Oxidation Catalytic Converter — Catalytic Converter Oxygen Sensor — Oxygen Sensor Park/Neutral Position — Park/Neutral Range — PCM Control Relay —...
Page 34: Abbreviations
ABBREVIATIONS ABBREVIATIONS ABBREVIATIONS A6E203000011W01 Overdrive Air conditioner Oil control valve Antilock brake system Switch off Accessories Switch on Automatic locking retractor Power steering Automatic transaxle fluid P/W CM Power window control module Automatic transaxle PATS Passive anti-theft system Controller area network Positive crankcase ventilation Control module Parameter identification...
Page 35: Pre-Delivery Inspection
PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION ❏Seat belt warning system PRE-DELIVERY INSPECTION ❏Door locks, including childproof door locks A6E203200012W01 PRE-DELIVERY INSPECTION TABLE ❏Power door lock EXTERIOR ❏Power windows (if equipped) • INSPECT and ADJUST, if necessary, the ❏Horn, wipers, and washers following items to specification: ❏Wiper blades performance ❏Glass, exterior bright metal and paint for damage Clean the wiper blades and windshield, if necessary...
Page 36: Scheduled Maintenance
• To ensure efficient operation of the engine and all systems related to emission control, the ignition and fuel systems must be serviced regularly. It is strongly recommended that all servicing related to these systems be done by an authorized Mazda Dealer. • After the described period, continue to follow the described maintenance at the recommended intervals.
Page 37 • To ensure efficient operation of the engine and all systems related to emission control, the ignition and fuel systems must be serviced regularly. It is strongly recommended that all servicing related to these systems be done by an authorized Mazda Dealer. • After the described period, continue to follow the described maintenance at the recommended intervals.
Page 38 • To ensure efficient operation of the engine and all systems related to emission control, the ignition and fuel systems must be serviced regularly. It is strongly recommended that all servicing related to these systems be done by an authorized Mazda Dealer. • After the described period, continue to follow the described maintenance at the recommended intervals.
Page 39 SCHEDULED MAINTENANCE Maintenance Interval (Number of months or km (miles), whichever comes first) Months Maintenance Item ×1000 km 90 100 110 120 130 140 150 160 ×1000 miles 6.25 12.5 18.75 31.25 37.5 43.75 56.25 62.5 68.75 81.25 87.5 93.75 ENGINE Drive belts Engine oil...
Page 40 • The ignition and fuel systems are highly important to the emission control system and to efficient engine operation. All inspections and adjustments must be made by an Authorized Mazda Dealer. • After the prescribed period, continue to follow the described maintenance at the recommended intervals.
Page 41 SCHEDULED MAINTENANCE Maintenance Interval (Number of months or km (miles), whichever comes first) Months ×1000 km Maintenance Item 90 100 110 120 130 140 150 160 ×1000 miles CHASSIS AND BODY Brake lines, hoses and connections Brake fluid Parking brake Power brake unit and hoses Disc brakes Power steering fluid, lines, hoses and...
Page 42 SCHEDULED MAINTENANCE Scheduled Maintenance Service (Specific Work Required) For Europe (L.H.D. U.K.) Maintenance Item Specific Work Required ENGINE Engine valve clearance Measure clearance. Inspect for wear, cracks and fraying, and check tension. Drive belts Replace drive belt. Engine timing belt Replace engine timing belt.
Page 43 SCHEDULED MAINTENANCE Maintenance Item Specific Work Required Steering operation & linkages Check steering wheel free play, hard steering, and operation noise. Check linkages, boots and ball joints condtion. Check grease or gear oil. Check fluid level and lines for improper attachment, leakage, cracks, Power steering fluid &...
Page 44 E NGINE LOCATION INDEX ..........B-2 MECHANICAL LOCATION INDEX ...... B-2 DRIVE BELT ............B-3 DRIVE BELT INSPECTION ......... B-3 DRIVE BELT REPLACEMENT ......B-3 DRIVE BELT AUTO TENSIONER INSPECTION ............B-4 VALVE CLEARANCE..........B-4 VALVE CLEARANCE INSPECTION....B-4 VALVE CLEARANCE ADJUSTMENT ....B-5 COMPRESSION PRESSURE ........
Page 45: Location Index
LOCATION INDEX LOCATION INDEX MECHANICAL LOCATION INDEX A6E220001002W01 A6E2200W300 Drive belt Front oil seal (See B–3 DRIVE BELT INSPECTION) (See B–21 FRONT OIL SEAL REPLACEMENT) (See B–3 DRIVE BELT REPLACEMENT) Rear oil seal (See B–4 DRIVE BELT AUTO TENSIONER (See B–25 REAR OIL SEAL REPLACEMENT) INSPECTION)
Page 46: Drive Belt
DRIVE BELT End Of Sie DRIVE BELT DRIVE BELT INSPECTION A6E221015800W01 Note • Front and water pump drive belt deflection/tension inspection is not necessary because of the use of the front drive belt auto tensioner. Front Drive Belt 1. Verify that the drive belt auto tensioner indicator mark does not exceeds the limit.
Page 47: Drive Belt Auto Tensioner Inspection
DRIVE BELT, VALVE CLEARANCE DRIVE BELT AUTO TENSIONER INSPECTION A6E221015980W01 1. Remove the drive belt. (See B–3 DRIVE BELT REPLACEMENT.) 2. Verify that the drive belt auto tensioner moves smoothly in the operational direction. • Replace the drive belt auto tensioner if necessary.
Page 48: Valve Clearance Adjustment
VALVE CLEARANCE 16. Install the tire (RH). End Of Sie VALVE CLEARANCE ADJUSTMENT A6E221212111W02 1. Disconnect the negative battery cable. 2. Remove the tire (RH). 3. Remove the splash shield (RH). 4. Remove the spark plugs. (See G–10 SPARK PLUG REMOVAL/INSTALLATION.) 5.
Page 49 VALVE CLEARANCE 16. Loosen the timing chain. (1) Using a suitable screwdriver or equivalent tool, unlock the chain tensioner ratchet. (2) Turn the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen the timing chain. (3) Placing the suitable bolt (M6 X 1.0 length 25mm—35mm {0.99in—1.37in}) at the engine front cover upper blind plug, secure the chain guide at the position where the...
Page 50 VALVE CLEARANCE New adjustment shim = Removed shim thickness + Measured valve clearance - Standard valve clearance (IN: 0.25 mm {0.0098 in}, EX: 0.30 mm {0.0118 in}) Standard [Engine cold] IN: 0.22—0.28 mm {0.0087—0.0110 in} (0.25±0.03 mm {0.0098±0.0011 in}) EX: 0.27—0.33 mm {0.0106—0.0130 in} (0.30±0.03 mm {0.0118±0.0011 in}) 23.
Page 51 VALVE CLEARANCE 29. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown. 30. Tighten the exhaust camshaft sprocket lock bolt. N·m {kgf·m, ft·lbf} Bolt type Tigtining torque} Bolt and washer — {7.1—7.6, 50.9—55.3} assembly Washer based —...
Page 52: Compression Pressure
COMPRESSION PRESSURE COMPRESSION PRESSURE COMPRESSION INSPECTION A6E221402000W01 Warning • Hot engines and oil can cause severe burns. Be careful not to burn yourself during removal/ installation of each component. 1. Verify that the battery is fully charged. • Recharge it if necessary. (See G–4 BATTERY INSPECTION.) 2.
Page 53: Timing Chain
COMPRESSION PRESSURE, TIMING CHAIN kPa {kgf/cm , psi} [rpm] Engine type Item Standard 1,430 {14.5819, 207.404} [290] Minimum 1,000 {10.197, 145.00} [290] Maximum difference 196.1 {1.999, 28.44} between cylinders 11. Disconnect the compression gauge. 12. Install the spark plugs. (See G–10 SPARK PLUG REMOVAL/INSTALLATION.) 13.
Page 54 TIMING CHAIN AME2215W001 Cylinder head cover Front oil seal (See B–17 Cylinder Head Cover Installation Note) (See B–13 Engine Front Cover Removal Note) (See B–15 Front Oil Seal Installation Note) Crankshaft pulley lock bolt (See B–12 Crankshaft Pulley Lock Bolt Removal Chain tensioner Note) (See...
Page 55 TIMING CHAIN Crankshaft Pulley Lock Bolt Removal Note 1. Remove the cylinder block lower blind plug. 2. Install the SST. 3. Turn the crankshaft clockwise the crankshaft is in the No.1 cylinder TDC position. AME2212W004 4. Hold the crankshaft pully by using the SSTs. AME2215W002 Chain Tensioner Removal Note 1.
Page 56 TIMING CHAIN Oil Pump Sprocket Removal Note 1. Hold the oil pump sprocket by using the SST. AME2215W005 Engine Front Cover Removal Note 1. Remove the oil seal using a screwdriver as shown. AME2215W006 Oil Pump Sprocket Installation Note 1. Hold the oil pump sprocket by using the SST. AME2215W005 B–13...
Page 57 TIMING CHAIN Timing Chain Installation Note 1. Install the SST to the camshaft as shown. European countries AME2212W010 Except European countries 2. Install the timing chain. 3. Remove the retaining wire or paper clip from the auto tensioner to apply tension to the timing chain.
Page 58 TIMING CHAIN 2. Install the cylinder head cover bolts in the order as shown. Bolt No. Tightening torque 1—18 8.0—11.5 N·m {81.6—117.2 kgf·cm, 70.9—101.7 in·lbf} 19—22 40—55 N·m {4.1—5.6 kgf·m, 29.7—40.5 ft·lbf} AME2215W008 Front Oil Seal Installation Note 1. Apply clean engine oil to the oil seal. 2.
Page 59 TIMING CHAIN No.3 Engine Mount Rubber and No.3 Engine Joint Bracket Installation Note 1. Tighten the stud bolt of the No.3 engine mount bracket. Tightening torque: 7.0—13 N·m {71.4—132.5 kgf·cm, 62.0—115.0 in·lbf} 2. Install the No.3 engine mount rubber hand- tighten.
Page 60 TIMING CHAIN 2. Install the M6 x 1.0 bolt in by hand. 3. Turn the crankshaft clockwise the crankshaft is in the No.1 cylinder TDC position. AME2215W013 4. Hold the crankshaft pully by using the SST. 5. Tighten the crankshaft pulley lock bolt using the following two steps.
Page 61: Cylinder Head Gasket
TIMING CHAIN, CYLINDER HEAD GASKET 3. Tighten the bolts in the order shown. Tightening torque: 8.0—11.5 N·m {81.6—122.3 kgf·cm, 70.9— 106.2 in·lbf} AME2215W015 End Of Sie CYLINDER HEAD GASKET CYLINDER HEAD GASKET REPLACEMENT A6E221810271W01 Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
Page 62 CYLINDER HEAD GASKET AME2218W002 Camshaft Cylinder head (See B–19 Camshaft Removal Note) (See B–20 Cylinder Head Removal Note) (See B–21 Camshaft Installation Note) (See B–20 Cylinder Head Installation Note) Oil control valve (OCV) (L3) Cylinder head gasket Camshaft Removal Note Note •...
Page 63 CYLINDER HEAD GASKET 1. Loosen the camshaft cap bolts in several passes in the order shown. AME2212W008 Cylinder Head Removal Note 1. Loosen the cylinder head bolts in several passes in the order shown. AME2218W003 Cylinder Head Installation Note 1. Measure the length of each cylinder head bolt. •...
Page 64: Front Oil Seal
CYLINDER HEAD GASKET, FRONT OIL SEAL Camshaft Installation Note 1. Set the cam position of the No.1 cylinder at the top dead center (TDC) and install the camshaft. 2. Temporarily tighten the camshaft bearing caps in two or three even movements. 3.
Page 65 FRONT OIL SEAL Crankshaft Pulley Lock Bolt Removal Note 1. Remove the cylinder block lower blind plug. 2. Install the SST. 3. Turn the crankshaft clockwise the crankshaft is in the No.1 cylinder TDC position. AME2212W004 4. Hold the crankshaft pulley by using the SSTs. AME2215W002 Front Oil Seal Removal Note 1.
Page 66 FRONT OIL SEAL Front Oil Seal Installation Note 1. Apply clean engine oil to the oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a hammer. AME2215W009 AME2215W010 Crankshaft Pulley Lock Bolt Installation Note...
Page 67 FRONT OIL SEAL 2. Install the M6 x 1.0 bolt in by hand. 3. Turn the crankshaft clockwise the crankshaft is in the No.1 cylinder TDC position. AME2215W013 4. Hold the crankshaft pulley by using the SSTs. 5. Tighten the crankshaft pulley lock bolt in the order shown using the following two steps.
Page 68: Rear Oil Seal
REAR OIL SEAL REAR OIL SEAL REAR OIL SEAL REPLACEMENT A6E222211399W01 1. Remove the flywheel. (MTX) (See H–11 CLUTCH UNIT REMOVAL/INSTALLATION) 2. Remove the drive plate. (ATX) (See K–43 DRIVE PLATE REMOVAL/INSTALLATION) 3. Remove in the order indicated in the table. 4.
Page 69: Engine
ENGINE ENGINE ENGINE REMOVAL/INSTALLATION A6E222401001W01 Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injures or death and damage.
Page 70 ENGINE AME2213W001 No.4 Engine mount bracket and No.4 Engine mount No.1 Engine mount rubber rubber (See B–28 No.1 Engine Mount Rubber Removal (See B–28 No.4 Engine Mount Bracket and No.4 Note) Engine Mount Rubber Removal Note) (See B–31 No.1 Engine Mount Rubber Installation (See B–30 No.4 Engine Mount Bracket and No.4 Note)
Page 71 ENGINE No.1 Engine Mount Rubber Removal Note 1. Suspend the engine using the SSTs. 2. Remove the through bolt A on the No.1 engine mount bracket side. AME2215W004 3. Loosen the through bolt B on the chassis side until approximately three pitches are showing. Note •...
Page 72 ENGINE 2. Remove the SST. AME2215W004 3. Secure the engine and the transaxle using a hoist. AME2213W004 4. No.4 engine mount bracket and engine mount rubber together in one piece. AME2213W005 No.3 Engine Joint Bracket Installation Note 1. Tighten the No.3 engine mount bracket stud bolt. Tightening torque: 7.0—13 N·m {71.4—132.5 kgf·cm, 62.0—115.0 in·lbf}...
Page 73 ENGINE 2. Tighten the No.3 engine joint bracket bolt and nut in the order shown. AME2213W010 No.4 Engine Mount Bracket and No.4 Engine Mount Rubber Installation Note 1. Tighten the No.4 engine mount bracket and No.4 engine mount rubber bolt and nut in the order as shown.
Page 74: Engine Disassembly/Assembly
ENGINE No.1 Engine Mount Bracket Installation Note 1. Tighten No.1 engine mount bracket bolt A. Tightening torque: 93.1—116.6 N·m {9.50—11.88 kgf·m, 68.72— 85.92 ft·lbf} 2. Tighten No.1 engine mount bracket bolt B. Tightening torque: 93.1—116.6 N·m {9.50—11.88 kgf·m, 68.72— 85.92 ft·lbf} AME2213W008 No.1 Engine Mount Rubber Installation Note 1.
Page 75: Variable Valve Timing
VARIABLE VALVE TIMING VARIABLE VALVE TIMING VARIABLE VALVE TIMING ACTUATOR INSPECTION A6E222500142W01 Caution • Variable valve timing actuator can not be disassembled it is a precision unit. 1. Disconnect the negative battery cable. 2. Remove the plug hole plate. 3. Remove the high-tension lead. 4.
Page 76: Oil Control Valve (Ocv
VARIABLE VALVE TIMING, OIL CONTROL VALVE (OCV) Variable Valve Timing Actuator Removal Note 1. Set a wrench or equivalent tool at the hexagonal part of the camshaft to prevent rotation. 2. Loosen the variable valve timing actuator tightening bolts. Variable Valve Timing Actuator Installation Note 1.
Page 77 OIL CONTROL VALVE (OCV) Spool Valve Operation Inspection 1. Disconnect the negative battery cable. 2. Remove the oil control valve. 3. Verify that the spool valve in the oil control valve is in the maximum valve timing retard position as indicated in the figure.
Page 78 L UBRICATION SYSTEM LOCATION INDEX ..........D-2 LOCATION INDEX..........D-2 OIL PRESSURE INSPECTION ......D-3 OIL PRESSURE INSPECTION......D-3 ENGINE OIL ............D-4 ENGINE OIL INSPECTION........D-4 ENGINE OIL REPLACEMENT......D-4 OIL FILTER.............D-6 OIL FILTER REPLACEMENT ......D-6 OIL COOLER ............D-7 OIL COOLER REMOVAL/INSTALLATION ..D-7 OIL PAN..............D-8 OIL PAN REMOVAL/INSTALLATION....D-8 OIL PUMP .............D-10 OIL PUMP REMOVAL/INSTALLATION.....D-10 D–1...
Page 79: Location Index
LOCATION INDEX LOCATION INDEX LOCATION INDEX A6E330001002W01 AME3300W001 Oil filter Oil pan (See D–6 OIL FILTER REPLACEMENT) (See D–8 OIL PAN REMOVAL/INSTALLATION) Oil pump Oil cooler LF and L3 engine models) (See D–10 OIL PUMP REMOVAL/INSTALLATION) (See D–7 OIL COOLER REMOVAL/ INSTALLATION) End Of Sie D–2...
Page 80: Oil Pressure Inspection
OIL PRESSURE INSPECTION OIL PRESSURE INSPECTION OIL PRESSURE INSPECTION A6E331001003W01 Warning • Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil. •...
Page 81: Engine Oil
ENGINE OIL ENGINE OIL ENGINE OIL INSPECTION A6E331214001W01 1. Position the vehicle on level ground. 2. Warm up the engine to normal operating temperature. 3. Stop the engine and wait for 5 min. 4. Remove the dipstick. 5. Verify that the oil level is between the F and L marks on the dipstick and check the engine oil condition. •...
Page 82 5W-20 20W-40, 15W-40, 20W-50, 15W-50, 5W-20, 5W-30 Remarks Mazda genuine Dexelia oil e.g. — — 8. Refit the oil filler cap. 9. Start the engine and inspect for oil leakage. • If the oil leaks, specify the faulty part and repair or replace it.
Page 83: Oil Filter
OIL FILTER OIL FILTER OIL FILTER REPLACEMENT A6E331414300W01 Warning • Continuous 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. • Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the engine oil have cooled.
Page 84 OIL FILTER D – 6 L UBRICATION SYSTEM OIL FILTER Spin-on Type 1. Remove the under cover. 2. Remove the oil filter using a commercially available, cap-type oil filter wrench (diameter-76 mm {3.0 in}, 15 sided). 3. Use a clean rag to wipe off the mounting surface. 4.
Page 85: Oil Cooler
OIL COOLER D L UBRICATION SYSTEM OIL COOLER OIL COOLER REMOVAL/INSTALLATION A6E331819900W01 LF, L3 1. Remove the under cover. 2. Drain the engine coolant. (See E–4 ENGINE COOLANT REPLACEMENT.) 3. Remove the oil filter cover, and drain the engine oil into a container. (See D–6 OIL FILTER REPLACEMENT.) 4.
Page 86: Oil Pan
OIL PAN OIL PAN OIL PAN REMOVAL/INSTALLATION A6E332010040W01 Warning • Hot engine and engine oil can cause severe burns. Turn off the engine and wait until it and the engine oil have cooled. 1. Disconnect the negative battery cable. 2. Remove the under cover. 3.
Page 87 OIL PAN Oil Pan Installation Note 1. Use a square ruler to unite the oil pan and the cylinder block junction side on the engine front cover side. AME3320W002 2. Apply silicone sealant to the oil pressure switch threads as shown. AME3320W003 3.
Page 88: Oil Pump
OIL PUMP OIL PUMP OIL PUMP REMOVAL/INSTALLATION A6E332214100W01 1. Disconnect the negative battery cable. 2. Drain the engine oil. (See D–4 ENGINE OIL REPLACEMENT.) 3. Remove the oil pan. (See D–8 OIL PAN REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5.
Page 89 OIL PUMP Oil Pump Sprocket Removal / Installation Note 1. Install the SST to the oil pump sprocket to stop the oil pump from turn in. AME3322W002 End Of Sie D–11...
Page 90 C OOLING SYSTEM LOCATION INDEX ..........E-2 LOCATION INDEX..........E-2 COOLING SYSTEM SERVICE WARNINGS ..E-3 COOLING SYSTEM SERVICE WARNINGS ..E-3 ENGINE COOLANT..........E-3 ENGINE COOLANT LEVEL INSPECTION..E-3 ENGINE COOLANT PROTECTION INSPECTION......E-3 ENGINE COOLANT REPLACEMENT ....E-4 ENGINE COOLANT LEAKAGE INSPECTION ..E-4 RADIATOR CAP.............
Page 91: Location Index
LOCATION INDEX LOCATION INDEX LOCATION INDEX A6E360001002W01 AME3602N001 Radiator Water pump (See E–6 RADIATOR REMOVAL/INSTALLATION) (See E–8 WATER PUMP REMOVAL/ INSTALLATION) Radiator cap (See E–5 RADIATOR CAP INSPECTION) Cooling fan (See E–9 COOLING FAN REMOVAL/ Thermostat INSTALLATION) (See E–7 THERMOSTAT REMOVAL/ INSTALLATION) Cooling fan motor (See...
Page 92: Cooling System Service Warnings
COOLING SYSTEM SERVICE WARNINGS, ENGINE COOLANT COOLING SYSTEM SERVICE WARNINGS COOLING SYSTEM SERVICE WARNINGS A6E361001004W01 Warning • Never remove the radiator cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding coolant and steam may shoot out and cause serious injury.
Page 93: Engine Coolant Replacement
ENGINE COOLANT ENGINE COOLANT REPLACEMENT A6E361215001W03 Warning • Drain the engine coolant while the engine is cold, otherwise it may burn you and cause serious injury. 1. Remove the radiator cap. AME3612W001 2. Remove the radiator drain plug. 3. Drain the coolant into a container. 4.
Page 94: Radiator Cap
ENGINE COOLANT, RADIATOR CAP the pressure escapes. • When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it. 1. Inspect the coolant level. 2. Remove the radiator cap. 3.
Page 95: Radiator
RADIATOR End Of Sie RADIATOR RADIATOR REMOVAL/INSTALLATION A6E361615200W01 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (See E–4 ENGINE COOLANT REPLACEMENT.) 3. Remove the cooling fan. (See E–9 COOLING FAN REMOVAL/INSTALLATION.) 4. Remove the oil hose. (ATX) 5.
Page 96: Thermostat
THERMOSTAT THERMOSTAT THERMOSTAT REMOVAL/INSTALLATION A6E361815171W01 1. Remove the plug hole plate. 2. Disconnect the negative battery cable. 3. Drain the engine coolant. (See E–3 COOLING SYSTEM SERVICE WARNINGS.) 4. Remove the drive belt. (See B–3 DRIVE BELT REPLACEMENT.) 5. Remove the washer tank. 6.
Page 97: Thermostat Inspection
THERMOSTAT, WATER PUMP THERMOSTAT INSPECTION A6E361815171W02 1. Inspect the thermostat for the following. • Closed valve in room temperature • Opening temperature and lift of the valve — If not as specified, replace the thermostat. Initial-opening temperature 80.0—84.0 {176—183.2} (°C {°F}) Full-open temperature 97 {206.6} (°C {°F})
Page 98: Fan Motor
FAN MOTOR FAN MOTOR COOLING FAN REMOVAL/INSTALLATION A6E362215025W01 1. Disconnect the negative battery cable. 2. Remove the shroud panel. (See S–119 SHROUD PANEL REMOVAL/INSTALLATION.) 3. Remove the A/C pipe stay. 4. Remove the ATX pipe stay (ATX). 5. Remove in the order indicated in the table. 6.
Page 99: Cooling Fan Motor Removal/Installation
FAN MOTOR COOLING FAN MOTOR REMOVAL/INSTALLATION A6E362215025W02 1. Remove the cooling fan. (See E–9 COOLING FAN REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. AME3621W002 Cooling fan motor No.2 Cooling fan No.2 Cooling fan motor No.1 Cooling fan No.1 End Of Sie...
Page 100: Cooling Fan Motor Inspection
FAN MOTOR COOLING FAN MOTOR INSPECTION A6E362215025W03 1. Verify that the battery is fully charged. 2. Connect battery positive voltage and an ammeter to the fan motor connector. 3. Verify that the fan motor operates smoothly at the standard current draw. •...
Page 101 F UEL AND EMISSION CONTROL SYSTEMS LOCATION INDEX ..........F-3 EXHAUST SYSTEM INTAKE-AIR SYSTEM ......... F-3 REMOVAL/INSTALLATION ......F-35 EMISSION SYSTEM ..........F-38 FUEL SYSTEM ............ F-4 EMISSION SYSTEM..........F-6 CHARCOAL CANISTER INSPECTION ..... F-38 EVAPORATIVE GAS CHECK VALVE CONTROL SYSTEM..........F-7 (ONE-WAY) INSPECTION (L.H.D.) ....
Page 102 OBD DRIVE MODE..........F-64 DTC P2503............F-177 DIAGNOSTIC MONITORING TEST RESULTS. F-65 DTC P2504............F-178 DTC CONFIRMATION PROCEDURE ....F-66 TROUBLESHOOTING........F-181 KOEO/KOER SELF-TEST ......... F-66 ENGINE SYMPTOM TROUBLESHOOTING ... F-181 AFTER REPAIR PROCEDURE ......F-66 QUICK DIAGNOSTIC CHART ......F-182 DTC TABLE ............
Page 103: Location Index
LOCATION INDEX LOCATION INDEX INTAKE-AIR SYSTEM A6E390013000W01 A6E3910W018 Air cleaner VTCS shutter valve actuator (See F–10 INTAKE-AIR SYSTEM REMOVAL/ (See F–15 VARIABLE TUMBLE CONTROL INSTALLATION) SYSTEM (VTCS) SHUTTER VALVE ACTUATOR INSPECTION) IAC valve (See F–13 IDLE AIR CONTROL (IAC) VALVE VAD Check valve (one-way) (L3) INSPECTION) (See...
Page 104: Fuel System
LOCATION INDEX End Of Sie FUEL SYSTEM A6E390001006W01 Engine Room Side A6E3912W015 F–4...
Page 105 LOCATION INDEX Fuel tank side A6E3912W045 Fuel tank Fuel injector (See F–18 FUEL TANK REMOVAL/INSTALLATION) (See F–28 FUEL INJECTOR REMOVAL/ (See F–19 FUEL TANK INSPECTION) INSTALLATION) (See F–31 FUEL INJECTOR INSPECTION) Nonreturn valve (See F–20 NONRETURN VALVE INSPECTION) Pulsation damper (See F–34 PULSATION DAMPER REMOVAL/ Fuel pump unit...
Page 106: Emission System
LOCATION INDEX EMISSION SYSTEM A6E390001074W01 Engine room side A6E3916W017 EGR valve PCV valve (See F–39 EGR VALVE REMOVAL/INSTALLATION) (See F–41 PCV VALVE INSPECTION) (See F–40 EGR VALVE INSPECTION) Purge solenoid valve (See F–41 THREE-WAY CATALYTIC CONVERTER (See F–38 PURGE SOLENOID VALVE REMOVAL/ (TWC) INSPECTION) INSTALLATION)
Page 107: Control System
LOCATION INDEX CONTROL SYSTEM A6E390001074W02 A6E3940W500 MAF/IAT sensor Knock sensor (See F–50 INTAKE AIR TEMPERATURE (IAT) (See F–56 KNOCK SENSOR INSPECTION) SENSOR INSPECTION) (See F–56 KNOCK SENSOR REMOVAL/ (See F–51 MASS AIR FLOW (MAF) SENSOR INSTALLATION) INSPECTION) Heated oxygen sensor TP sensor (See F–56 HEATED OXYGEN SENSOR (HO2S)
Page 108: Engine Tune-Up
ENGINE TUNE-UP End Of Sie ENGINE TUNE-UP IGNITION TIMING INSPECTION A6E390802000W01 Note • Ignition timing is not adjustable. • Ignition timing verification requires WDS or equivalent. 1. Turn off the electrical loads. 2. Warm up the engine as follows. (1) Start the engine. (2) Maintain the engine speed at approx.
Page 109: Idle Mixture Inspection
ENGINE TUNE-UP Idle speed (LF engine ATX model) Condition Engine speed (rpm)* No load 650—750 650—750 Electrical loads* P/S ON 650—750 A/C ON and refrigerant 650—750 pressure switch (middle) OFF A/C ON and refrigerant 700—800 pressure switch (middle) ON Idle speed (L3 engine model) Condition Engine speed (rpm)* No load...
Page 110: Intake-Air System
INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM A6E391020030W01 A6E3910W034 End Of Sie INTAKE-AIR SYSTEM REMOVAL/INSTALLATION A6E391013000W01 Warning • When the engine and intake-air system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the intake-air system. •...
Page 111 INTAKE-AIR SYSTEM 4. Complete the “AFTER REPAIR PROCEDURE”. (See F–17 AFTER REPAIR PROCEDURE.) 5—7 {51—71, 45—61} 0.55—0.85 {5.6—8.6, 4.9—7.5} 2.5—3.4 {26—34, 23—30} 20—30 {204—305, 177—265 } 2.5—3.4 {26—34, 23—30} 8.0—11.5 8.0—11.5 {82—117, 71—101} {82—117, 71—101} L8, LF ENGINE MODELS 0.8—1.0 {8.2—10.0, 7.1—8.8} RUBBER MOUNT (ENGINE SIDE)
Page 112: Variable Air Duct (Vad) Shutter Valve Inspection (L3
INTAKE-AIR SYSTEM Resonance Chamber Removal Note 1. Remove the front mudguard (LH) before removing the resonance chamber. Vacuum Hose (Purge Solenoid Valve) Installation Note 1. Fit the vacuum hose (purge solenoid valve) onto the respective fittings, and install clamps as shown.
Page 113: Variable Air Duct (Vad) Control Solenoid Valve Inspection (L3
INTAKE-AIR SYSTEM VARIABLE AIR DUCT (VAD) CONTROL SOLENOID VALVE INSPECTION (L3) A6E391013000W03 1. Remove the VAD control solenoid valve. (See F–10 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 2. Inspect airflow between the ports under the following conditions. • If not as specified, replace the VAD control solenoid valve.
Page 114: Variable Intake-Air System (Vis) Shutter Valve Actuator Inspection (L3
INTAKE-AIR SYSTEM 2. Disconnect the IAC valve connector. 3. Measure the resistance between the IAC valve terminals using an ohmmeter. • If not as specified, replace the IAC valve. (See F–10 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) • If as specified but the Operation Test is failed, carry out the “Circuit Open/Short Inspection”. Specification Ambient temperature (°C {°F}) Resistance (ohms)
Page 115: Variable Tumble Control System (Vtcs) Shutter Valve Actuator Inspection
INTAKE-AIR SYSTEM Circuit Open/Short Inspection 1. Disconnect the PCM connector. (See F–43 PCM REMOVAL/INSTALLATION.) 2. Inspect the following wiring harness for open or short (continuity check). Open circuit • If there is no continuity, the circuit is open. Repair or replace the harness. —...
Page 116: Accelerator Pedal Removal/Installation
INTAKE-AIR SYSTEM 2. Inspect the following wiring harness for open or short (continuity check). Open circuit • If there is no continuity, the circuit is open. Repair or replace the harness. — Variable tumble control solenoid valve terminal B (harness-side) and PCM terminal —...
Page 117: Fuel System
FUEL SYSTEM FUEL SYSTEM BEFORE REPAIR PROCEDURE A6E391201006W01 Warning • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage.
Page 118: Fuel Tank Removal/Installation
FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION A6E391242110W01 Warning • Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. •...
Page 119: Fuel Tank Inspection
FUEL SYSTEM Breather Hose Installation Note 1. Fit the breather hose onto the respective fittings, and install clamps as shown. A6E3912W038 Joint Hose Installation Note 1. Fit the joint hose onto the respective fittings, and install clamps as shown. A6E3912W034 End Of Sie FUEL TANK INSPECTION A6E391242110W02...
Page 120: Nonreturn Valve Inspection
FUEL SYSTEM 8. Turn the fuel tank upside-down and apply pressure of –2.0 kPa {–15 mmHg, –0.6 inHg} to port A. (1) Plug port C and verify there is no vacuum from port B. • If there is vacuum, replace the fuel tank. A6E3912W046 End Of Sie NONRETURN VALVE INSPECTION...
Page 121 FUEL SYSTEM Note • The stopper may be removed from the quick connector. Take care not to loose it. Reinstall it to the quick release connector before reconnecting the fuel line. A6E3912W001 • The locking coupler has two internal locking tabs which retain the pulsation damper pipe.
Page 122: Fuel Pump Unit Removal/Installation
FUEL SYSTEM 13. Complete the “BEFORE REPAIR PROCEDURE”. (See F–17 BEFORE REPAIR PROCEDURE) 14. Disconnect the SST. Note • A checker tab is integrated with quick release connector for new plastic fuel hoses. The checker tab will be released from the quick release connector after it is completely engaged with the fuel pipe. 15.
Page 123 FUEL SYSTEM Plastic Fuel Hose Removal Note Caution • The quick release connector may be damaged if the tab is bent excessively. Do not expand the tab over the stopper. 1. Disconnect the quick release connector. (1) Push the tab on the locking coupler 90 degrees until it stops. (2) Pull the fuel hose straight back.
Page 124: Fuel Pump Unit Disassembly/Assembly
FUEL SYSTEM Fuel Pump Unit Installation Note 1. Verify that the fuel tank mark is aligened with the fuel pump mark as shown. A6E3912W026 Plastic Fuel Hose Installation Note Note • A checker tab is integrated with quick release connector for new plastic fuel hoses. The checker tab will be released from the quick release connector after it is completely engaged with the fuel pipe.
Page 125 FUEL SYSTEM F – 2 4 FUEL AND EMISSION CONTROL SYSTEMS FUEL SYSTEM 2. Assemble in the reverse order of disassembly. Packing Fuel pump unit Fuel gauge sender unit A6E3912W025 Except for European (L.H.D. U.K.) Specs. Caution • Do not touch the fuel pump discharge pipe unless it is necessary. If servicing is needed, be careful not to damage the pipe with tools or other objects, or by applying lateral stress.
Page 126 FUEL SYSTEM Note • The disassembly/assembly procedure differs depending on whether the nylon tube NYLON TUBE between the fuel filter (high-pressure) and fuel pump is equipped or not, or if the fuel filter (high-pressure) and fuel pump are FUEL PUMP replaced as a single unit or replaced separately.
Page 127 FUEL SYSTEM Type B; With nylon tube, replaced separately (2WD) DISASSEMBLY ASSEMBLY HOLDING HOLDING COVER SET PLATE COVER SEAL RUBBER FUEL PUMP SPACER FUEL PUMP SPRING SPRING FUEL FILTER (HIGH-PRESSURE) FUEL FILTER (HIGH-PRESSURE) RESERVE CUP RESERVE CUP FUEL GAUGE SENDER UNIT FUEL GAUGE SENDER UNIT C6E114ZL4016 Type B;...
Page 128 FUEL SYSTEM Type C; Without nylon tube (2WD) DISASSEMBLY/ASSEMBLY DISASSEMBLY HOLDING COVER SEAL RUBBER FUEL PUMP SPACER ASSEMBLY SPRING FUEL FILTER (HIGH-PRESSURE) RESERVE CUP FUEL GAUGE SENDER UNIT C6E114ZL4017 Type C; Without nylon tube (4WD) DISASSEMBLY/ASSEMBLY DISASSEMBLY HOLDING COVER SEAL RUBBER ASSEMBLY FUEL PUMP SPACER...
Page 129 FUEL SYSTEM Disassembly 1. Remove the fuel gauge sender unit. FUEL PUMP UNIT FUEL GAUGE SENDER UNIT C6E114ZL4002 2. Disconnect the fuel pump connector. FUEL PUMP CONNECTOR C6E114ZL4014 3. Remove the arm part of the set plate. SET PLATE FUEL FILTER (HIGH-PRESSURE) C6E114ZL4003 F–24–5...
Page 130 FUEL SYSTEM Note • The disassembly procedure differs depending on whether the nylon tube NYLON TUBE between the fuel filter (high-pressure) and fuel pump is equipped or not. FUEL PUMP • Perform Step 4 (type A, B). • Go to Step 5 (type C). FUEL FILTER (HIGH-PRESSURE) C6E114ZL4026...
Page 131 FUEL SYSTEM Caution • Do not pull out the fuel hose located between the pressure regulator and reserve cup (2WD) or between the pressure regulator and transfer jet pump FUEL HOSE (4WD). Do not forcedly rotate or bend it, or it could damage the sealing of the fuel hose (press fit area), or cause pipe breakage or splitting.
Page 132 FUEL SYSTEM Note • Perform Step 14 (4WD). • Go to Step 15 (2WD). 14. Remove the O-ring from the transfer jet pump and replace with a new one (4WD). PRESSURE REGULATOR TRANSFER JET PUMP O-RING C6E114ZL4035 Note • The disassembly procedure differs depending on whether the nylon tube NYLON TUBE between the fuel filter (high-pressure) and...
Page 133 FUEL SYSTEM Caution • When removing the nylon tube, do not use a cutter knife or similar object. Otherwise, the fuel pump discharge pipe could be damaged, or fuel leakage may occur. 18. Remove the nylon tube from the fuel pump discharge pipe using pliers.
Page 134 FUEL SYSTEM Assembly Note • The assembly procedure differs depending on whether the fuel filter (high-pressure) and fuel pump are replaced as a single unit or replaced separately. • Perform Step 1 (type B, C). • Go to Step 7 (type A). Type B, C Caution •...
Page 135 FUEL SYSTEM 5. Engage the snap fit tab and lower case, and verify that they are properly engaged. 6. Verify that the O-ring is seated in the upright FUEL FILTER position without twisting. (HIGH- PRESSURE) LOWER CASE SNAP FIT TAB FUEL FILTER (LOW-PRESSURE) C6E114ZL4009 Type A, B, C...
Page 136 FUEL SYSTEM Note • Perform Step 14 (2WD). • Go to Step 15 (4WD). 14. Install the pressure regulator to the fuel filter (high-pressure) (2WD). Note • Perform Step 15 (4WD). • Go to Step 16 (2WD). 15. Install the transfer jet pump to the reserve cup and pressure regulator to the fuel filter (high-pressure) together at the same time (4WD).
Page 137 FUEL SYSTEM Caution • Do not grasp the pipe located on the upper surface of the set plate. The pipe may be damaged causing fuel leakage. 19. Perform the following procedure to install the set plate to the reserve cup. (1) Position the fuel gauge sender unit installation side of the reserve cup outward.
Page 138 FUEL SYSTEM 20. Install the fuel gauge sender unit. 21. Perform the following procedure to connect the fuel gauge sender unit connector, routing the wiring harness in the proper position. FUEL PUMP UNIT FUEL GAUGE SENDER UNIT C6E114ZL4002 (1) Install the wiring harness to the reserve cup CONNECTOR-SIDE clip.
Page 139 FUEL SYSTEM (2) Remove the fuel pump connector wiring harness from the right side of the fuel gauge FUEL PUMP sender unit connector. CONNECTOR (3) Connect the connector. 23. Press the set plate to expand/contract the fuel pump unit, and inspect it for the following: •...
Page 140: Fuel Pump Unit Inspection
FUEL SYSTEM F F UEL AND EMISSION CONTROL SYSTEMS FUEL SYSTEM FUEL PUMP UNIT INSPECTION A6E391213350W03 Caution • It is normal to hear the fuel pump operating when the ignition switch is turned to the ON position. Note • To improve startability, the fuel pump control operates the fuel pump unit when the ignition switch is turned to the ON position.
Page 141 FUEL SYSTEM Fuel Pump Hold Pressure Inspection Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. Caution • Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector.
Page 142 FUEL SYSTEM 5. Cover the disconnected quick release connector with vinyl sheet or the like to prevent it from being scratched or contaminated with foreign material. A6E3912W021 6. Turn the lever 90 degrees against the hose of the SST to plug the SST outlet. 7.
Page 143: Fuel Injector Removal/Installation
FUEL SYSTEM End Of Sie FUEL INJECTOR REMOVAL/INSTALLATION A6E391213250W01 Caution • Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.
Page 144 FUEL SYSTEM • The locking coupler has two internal locking tabs which retain the fuel pipe. Be sure that the tab on the locking coupler is rotated until it stops to release two internal locking tabs. A6E3912W002 2. Cover the disconnected quick release connector and fuel pipe with vinyl sheets or the like to prevent them from being scratched or contaminated with foreign material.
Page 145 FUEL SYSTEM (2) Pull the clip parallel to the injector groove, and remove it from the injector. (3) Discard the clip. A6E3912W042 Fuel Injector Installation Note 1. Lightly lubricate the injector groove and O-ring. 2. Pre-attach a new clip in the injector groove. Note •...
Page 146: Fuel Injector Inspection
FUEL SYSTEM (4) Lightly pull and push the quick release connector a few times by hand and verify that it can move 2.0—3.0 mm {0.08—0.11 in} and it is connected securely. • If quick release connector does not move at all, verify that O-ring is not damaged and slipped, and reconnect the quick release connector.
Page 147 FUEL SYSTEM — No.2 cylinder fuel injector terminal A (harness-side) and power supply. — No.3 cylinder fuel injector terminal A (harness-side) and power supply. — No.4 cylinder fuel injector terminal A (harness-side) and power supply. Fuel Leakage Inspection Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage.
Page 148 FUEL SYSTEM Volume Inspection Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. Note • If there is an after market fuel injector tester, perform the following test. •...
Page 149: Pressure Regulator Inspection
FUEL SYSTEM PRESSURE REGULATOR INSPECTION A6E391213280W01 Note • Due to the adoption of the mechanical returnless fuel system, the pressure regulator cannot be inspected separately. 1. Perform “FUEL LINE PRESSURE INSPECTION”. (See F–20 FUEL LINE PRESSURE INSPECTION.) End Of Sie PULSATION DAMPER REMOVAL/INSTALLATION A6E391220180W01 1.
Page 150: Exhaust System
EXHAUST SYSTEM EXHAUST SYSTEM EXHAUST SYSTEM INSPECTION A6E391440000W01 1. Start the engine and inspect each exhaust system component for exhaust gas leakage. • If leakage is found, repair or replace as necessary. End Of Sie EXHAUST SYSTEM REMOVAL/INSTALLATION A6E391440000W02 Warning •...
Page 151 EXHAUST SYSTEM A6E3914W002 F–36...
Page 152 EXHAUST SYSTEM Main silencer Exhaust manifold gasket Middle pipe Exhaust manifold insulator (lower) HO2S (front) (See F–37 HO2S Removal Note) Exhaust manifold insulator (upper) HO2S (rear) Bracket (See F–37 HO2S Removal Note) Exhaust manifold (See F–37 Exhaust Manifold Installation Note) HO2S Removal Note 1.
Page 153: Emission System
EMISSION SYSTEM EMISSION SYSTEM CHARCOAL CANISTER INSPECTION A6E391613970W01 1. Remove the charcoal canister. 2. Plug the atmosphere side port and purge solenoid valve side port of the charcoal canister. 3. Blow air into the charcoal canister from the fuel tank side port and verify that there is no air leakage. •...
Page 154: Purge Solenoid Valve Inspection
EMISSION SYSTEM PURGE SOLENOID VALVE INSPECTION A6E391618740W02 Airflow Inspection Note • Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the purge solenoid valve. (See F–38 PURGE SOLENOID VALVE REMOVAL/INSTALLATION.) 3. Inspect airflow between the ports under the following conditions. •...
Page 155: Egr Valve Inspection
EMISSION SYSTEM EGR VALVE INSPECTION A6E391620300W02 Operation Test 1. Carry out the “EGR Control Inspection”. (See F–233 EGR Control System Inspection.) • If not as specified, perform the further inspection for the EGR valve. Resistance Inspection Note • Perform the following test only when directed. 1.
Page 156: Pcv Valve Inspection
EMISSION SYSTEM PCV VALVE INSPECTION A6E391613890W01 1. Disconnect the negative battery cable. 2. Remove the intake maniforld.(see F–10 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 3. Remove the PCV valve. 4. Blow through the valve and verify that air flows as specified. • If not as specified, replace the PCV valve. Specification Condition Airflow...
Page 157 EMISSION SYSTEM Upstream HO2S graph line example A6E3916W021 Downstream HO2S graph line example 1 Equation RATIO = 30 inversions (upstream HO2S inversions) ÷ 5 inversions (downstream HO2S inversions) = 6.0 (good WU-TWC) A6E3916W012 Downstream HO2S graph line example 2 A6E3916W014 Downstream HO2S graph line example 3 Equation RATIO = 30 inversions (upstream HO2S...
Page 158: Control System
CONTROL SYSTEM CONTROL SYSTEM PCM REMOVAL/INSTALLATION A6E394018880W01 Note • For replace the PCM, Setup the WDS and perform the PCM configuration. (See F–50 PCM CONFIGURATION.) 1. Disconnect the negative battery cable. 2. For R.H.D, perform the following procedures. (1) Remove the front side trim (left-side). (2) Partially peel back the flower covering.
Page 159 CONTROL SYSTEM European (L.H.D.) specs. A6E3940W001 PCM cover PCM connector Set Nut/bolt Removal Note 1. Using a chisel and a hammer, cut a groove on the head of the set nut/bolt so that a screwdriver can be inserted. 2. Loose the set nut/bolt using an impact screwdriver or pliers.
Page 160: Pcm Inspection
CONTROL SYSTEM PCM INSPECTION A6E394018880W02 Using SST (WDS or Equivakent) Note • PIDs for the following parts are not available on this model. Go to the appropriate part inspection page. — CMP sensor (See F–55 CAMSHAFT POSITION (CMP) SENSOR INSPECTION.) —...
Page 161 CONTROL SYSTEM Monitor item Unit/ Condition/Specification Action (Definition) Condition (Reference) terminal No load: 700 rpm E/L operating: 700 rpm P/S operating: 750 rpm Inspect following PIDs: IAT, RPM, A/C ON: 750 rpm MAP, ECT, MAF, TP, INGEAR, LF MTX and L3 MTX ACSW, TR, PSP, ALTT V.
Page 162 CONTROL SYSTEM Monitor item Unit/ Condition/Specification Action (Definition) Condition (Reference) terminal FDPDTC Perform applicable DTC (Pending code caused — — troubleshooting. — FFD storage) (See F–67 DTC TABLE) Ignition switch ON: OFF Inspect following PIDs: RPM. FP (Fuel pump relay) ON/OFF Idle: ON Inspect fuel pump relay.
Page 163 CONTROL SYSTEM Monitor item Unit/ Condition/Specification Action (Definition) Condition (Reference) terminal Inspect knock sensor. KNOCKR (Knocking Ignition switch ON: 0 DEG ANGLE (See F–56 KNOCK SENSOR 2P, 2S retard) Idle: 0 DEG INSPECTION) Inspect MAF sensor. Ignition switch ON: 0% LOAD (Engine load) (See F–51 MASS AIR FLOW (MAF)
Page 164 CONTROL SYSTEM F – 4 8 F UEL AND EMISSION CONTROL SYSTEMS CONTROL SYSTEM PCM INSPECTION A6E394018880W02A Monitor item Unit/ Condition/Specification Action (Definition) Condition (Reference) terminal Perform applicable DTC SHRTFT1 (Short term Idle (after warm up): approx.–30— troubleshooting. — fuel trim) (See F–67 DTC TABLE)
Page 165 CONTROL SYSTEM Without Using the SST Caution • The PCM terminal voltages vary with change in measuring conditions and vehicle conditions. Always carry out a total inspection of the input systems, output systems, and PCM to determine the cause of trouble. Otherwise, a wrong diagnosis will be made. 1.
Page 166 CONTROL SYSTEM Voltage Terminal Signal Connected to Test condition Action ECT 20 °C • Inspect ECT sensor 3.04— {68 °F} 3.14 (See F–53 ENGINE COOLANT Ignition switch TEMPERATURE ECT sensor ECT 60 °C (ECT) SENSOR 1.29— {140 °F} INSPECTION) 1.39 •...
Page 167 CONTROL SYSTEM Voltage Terminal Signal Connected to Test condition Action • Inspect PSP switch Steering wheel at straight (See F–58 POWER ahead position STEERING PRESSURE (PSP) SWITCH PSP switch Idle INSPECTION) While turning • Inspect power Below 1.0 steering wheel steering system •...
Page 168 CONTROL SYSTEM Voltage Terminal Signal Connected to Test condition Action MAF/IAT sensor, HO2S (Front, Rear), • Inspect related Sensor GND ECT sensor, Under any condition Below 1.0 harness TP sensor, MAP sensor, TFT sensor, TR switch • Inspect VSS sensor (See J–5 VEHICLE •...
Page 169 CONTROL SYSTEM Voltage Terminal Signal Connected to Test condition Action Instrument cluster, Because this terminal is for CAN, good/no • Inspect related ABS HU/CM, CAN (+) good judgment by terminal voltage is not ABS/TCS HU/CM, harness possible. DSC HU/CM — —...
Page 170 CONTROL SYSTEM Voltage Terminal Signal Connected to Test condition Action • Inspect shift solenoid Detects TCC operation Shift solenoid E Shift solenoid E • Inspect related control Others Below 1.0 harness Below 1.0 • Inspect HOLD switch HOLD switch Ignition switch •...
Page 171 CONTROL SYSTEM Voltage Terminal Signal Connected to Test condition Action ECT below 100 °C {212 °F} • Inspect cooling fan relay A/C operating Cooling fan control Cooling fan relay Idling • Inspect related and refrigerant Below 1.0 harness pressure switch (middle) ON •...
Page 172 CONTROL SYSTEM Voltage Terminal Signal Connected to Test condition Action • Inspect VIS solenoid Engine speed: above 4,500 rpm valve (See F–14 VARIABLE INTAKE-AIR SYSTEM VIS control VIS control (VIS) CONTROL solenoid valve Engine speed: below 4,500 rpm Below 1.0 SOLENOID VALVE INSPECTION (L3))
Page 173 CONTROL SYSTEM Voltage Terminal Signal Connected to Test condition Action • Inspect fuel injector No.3 • Inspect using the wave profile. (See F–31 FUEL Fuel injection (#3) Fuel injector No.3 (See F–48–10 Inspection Using An INJECTOR Oscilloscope (Reference).) INSPECTION) • Inspect related harness : MTX models : ATX models...
Page 174 CONTROL SYSTEM Generator field coil control signal PCM terminals • 1AD(+)—1C(–) Oscilloscope setting • 0.5 V/DIV (Y), 1 ms/DIV (X), DC range Vehicle condition • Idle after warm up (engine speed approx. 650 rpm [MTX] or 700 rpm [ATX], no load, P/S off, A/C off) A6A3940W006 CKP sensor signal...
Page 175 CONTROL SYSTEM CMP sensor signal L3 engine (+) PCM terminals • 2J(+)—2H(–) Oscilloscope setting • 1 V/DIV (Y), 10 ms/DIV (X), DC range Vehicle condition • Idle after warm up (engine speed approx. 650 rpm [MTX] or 700 rpm [ATX], no load, P/S off, A/C off) A6A3940W012 LF, L8 engine (+)
Page 176 CONTROL SYSTEM Input/turbine speed sensor signal PCM terminals • 3G(+)—2AC(–) Oscilloscope setting • 500 mV/DIV (Y), 1 ms/DIV (X), DC range Vehicle condition • Idle after warm up (engine speed approx. 650 rpm [MTX] or 700 rpm [ATX], no load, P/S off, A/C off) A6A3940W016 Pressure control solenoid signal...
Page 177 CONTROL SYSTEM IAC signal PCM terminals • 4G(+)—1C(–) Oscilloscope setting • 2 V/DIV (Y), 0.4 ms/DIV (X), DC range Vehicle condition • Idle after warm up (engine speed approx. 650 rpm [MTX] or 700 rpm [ATX], no load, P/S off, A/C off) A6A3940W020 (–)
Page 178 CONTROL SYSTEM F F UEL AND EMISSION CONTROL SYSTEMS CONTROL SYSTEM Fuel injection control PCM terminals • Fuel Injection No.1: 4Z(+)—1C(–) • Fuel Injection No.1: 4W(+)—1C(–) • Fuel Injection No.1: 4AD(+)—1C(–) • Fuel Injection No.1: 4AA(+)—1C(–) Oscilloscope setting • 4 V/DIV (Y), 10 ms/DIV (X), DC range Vehicle condition •...
Page 179: Pcm Configuration
CONTROL SYSTEM PCM CONFIGURATION A6E394018880W03 1. Connect the WDS to DLC-2. 2. Set up the WDS (including the vehicle recognition.) 3. Select “Module programming.” 4. Select “Programmable module installation.” 5. Select “PCM” and perform procedures according to directions on the WDS screen. DLC-2 Note •...
Page 180: Mass Air Flow (Maf) Sensor Inspection
CONTROL SYSTEM MASS AIR FLOW (MAF) SENSOR INSPECTION A6E394013210W01 Voltage Inspection Note • Perform the following inspection only when directed. 1. Visually inspect for the following on the MAF sensor. • Damage • Cracks • Terminal bends • Terminal rust —...
Page 181: Manifold Absolute Pressure (Map) Sensor Inspection
CONTROL SYSTEM Circuit Open/Short Inspection 1. Disconnect the PCM connector. (See F–43 PCM REMOVAL/INSTALLATION.) 2. Inspect the following wiring harnesses for open or short. (Continuity check) Open circuit • If there is no continuity, the circuit is open. Repair or replace the harness. —...
Page 182: Engine Coolant Temperature (Ect) Sensor Removal/Installation
CONTROL SYSTEM ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION A6E394018840W01 Warning • When the engine is hot, it can badly burn. Turn off the engine and wait until it is cool before removing the ECT sensor. 1. Drain the engine coolant. (See E–3 COOLING SYSTEM SERVICE WARNINGS.) 2.
Page 183: Crankshaft Position (Ckp) Sensor Inspection
CONTROL SYSTEM — ECT sensor terminal B (harness-side) and power supply End Of Sie CRANKSHAFT POSITION (CKP) SENSOR INSPECTION A6E394018230W01 Note • Perform the following inspection only when directed. Resistance Inspection 1. Disconnect the CKP sensor connector. 2. Measure the resistance between CKP sensor terminals A and B using an ohmmeter. •...
Page 184: Camshaft Position (Cmp) Sensor Inspection
CONTROL SYSTEM (2) Remove the cylinder block lower blind plug and install the SST. (3) Turn the crankshaft pulley to the clockwise until it stops. 2. Install the CKP sensor to the CKP sensor installer. 3. Fit the forked part of the CKP sensor installer with the ninth tooth (counting counterclockwise from the empty space) of the pulse wheel.
Page 185: Knock Sensor Inspection
CONTROL SYSTEM KNOCK SENSOR INSPECTION A6E394018921W01 Note • Perform the following test only when directed. Resistance Inspection 1. Turn the ignition switch to LOCK. 2. Disconnect the knock sensor connector. 3. Measure the resistance between the knock sensor terminals A and B using an ohmmeter. •...
Page 186 CONTROL SYSTEM 3. Connect the voltmeter test leads to the following HO2S terminals: • HO2S (front and rear) — (+) lead—terminal A — (–) lead—terminal B 4. With the vehicle stopped, run the engine at 3,000 rpm until the voltmeter moves between 0.5 and 0.7 V.
Page 187: Power Steering Pressure (Psp) Switch Inspection
CONTROL SYSTEM Circuit Open/Short Inspection (Heater) 1. Disconnect the PCM connector. (See F–43 PCM REMOVAL/INSTALLATION.) 2. Inspect the following wiring harnesses for open or short. (Continuity check) Open circuit • If there is no continuity, the circuit is open. Repair or replace the harness.
Page 188: Clutch Switch Inspection
CONTROL SYSTEM CLUTCH SWITCH INSPECTION A6E394018660W01 Note • Perform the following inspection only when directed. Continuity Inspection 1. Verify that the clutch switch is installed properly. 2. Disconnect the negative battery cable. 3. Remove the clutch switch. 4. Inspect for continuity between the clutch switch terminals using an ohmmeter.
Page 189: Barometric Pressure (Baro) Sensor Inspection
CONTROL SYSTEM Circuit Open/Short Inspection 1. Disconnect the PCM connector. (See F–43 PCM REMOVAL/INSTALLATION.) 2. Inspect the following harness for open or short. (Continuity check) Open circuit • Neutral switch terminal B (harness-side) and PCM terminal 1W (harness-side) • Neutral switch terminal A (harness-side) and body GND Short circuit •...
Page 190: On-Board Diagnostic
ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC FOREWORD A6E397018881W01 • When the customer reports a vehicle malfunction, check the malfunction indicator lamp (MIL) indication and diagnostic trouble code (DTC), then diagnose the malfunction according to following flowchart. — If a DTC exists, diagnose the applicable DTC inspection. (See F–67 DTC TABLE.) —...
Page 191: Obd Pending Trouble Codes
ON-BOARD DIAGNOSTIC OBD PENDING TROUBLE CODES A6E397018881W02 • These appear when a problem is detected in a monitored system. 2 Drive Cycle Type • The code for a failed system is stored in the PCM memory in the first drive cycle. If the problem is not found in the second drive cycle, the PCM judges that the system returned to normal or the problem was mistakenly detected, and deletes the pending code.
Page 192 ON-BOARD DIAGNOSTIC Pending Trouble Code Access Procedure 1. Perform the necessary vehicle preparation and visual inspection. 2. Connect WDS or equivalent to the vehicle DLC-2 16-pin connector located as shown in the figure. 3. Retrieve PENDING TROUBLE CODES by WDS or equivalent.
Page 193: Obd Drive Mode
ON-BOARD DIAGNOSTIC OBD DRIVE MODE A6E397018881W09 • Performing the Drive Mode inspects the OBD system for proper operation. The Drive Mode must be performed to ensure that no additional DTCs are present. • During Drive Mode, the following systems are inspected: —...
Page 194: Diagnostic Monitoring Test Results
ON-BOARD DIAGNOSTIC For MTX Shift Vehicle Speed Time Zone Position km/h {mph} Sec. Neutral 0 {0} T1: Above 455 40—50 {25—32} T2: Above 30 65—75 {41—47} 60—75 {38—46} T3: Above 20 75—100 {47—62} 50—75 {31—46} T4: Above 120 75—100 {47—62} A6E3970W004 For ATX Vehicle Speed...
Page 195: Dtc Confirmation Procedure
ON-BOARD DIAGNOSTIC DTC CONFIRMATION PROCEDURE A6E397018881W11 STEP INSPECTION ACTION RECORD CONTINUOUS MEMORY DTC AND Yes Record all stored DTCs (Continuous Memory DTC) and Freeze Frame Data on repair order, then go to next step. FREEZE FRAME DATA • Turn ignition key to ON (Engine OFF). Go to next step.
Page 196: Dtc Table
ON-BOARD DIAGNOSTIC DTC TABLE A6E397018881W14 DTC table ×: Applicable —: Not applicable Memory DTC No. Condition Monitor item Page function CMP actuator circuit × P0010 (See F–70 DTC P0010) malfunction × P0011 CMP timing over-advanced (See F–72 DTC P0011) × P0012 CMP timing over-retarded (See...
Page 197 ON-BOARD DIAGNOSTIC Memory DTC No. Condition Monitor item Page function Evaporative emission control × P0443 system purge control valve (See F–138 DTC P0443) circuit malfunction Fan relay control circuit × P0480 Other (See F–140 DTC P0480) malfunction Vehicle speed sensor (VSS) ×...
Page 198 ON-BOARD DIAGNOSTIC Memory DTC No. Condition Monitor item Page function P0757 Shift solenoid B stuck ON (See K–53 DTC TABLE) Shift solenoid B malfunction P0758 (See K–53 DTC TABLE) (electrical) P0761 Shift solenoid C stuck OFF (See K–53 DTC TABLE) P0762 Shift solenoid C stuck ON (See...
Page 199: Dtc P0010
ON-BOARD DIAGNOSTIC DTC P0010 A6E397001084W01 DTC P0010 CMP actuator circuit • PCM monitors OCV voltage. If PCM detects OCV control voltage (calculated from OCV) is above or below the threshold voltage (calculated from battery positive voltage), PCM determines that OCV circuit has malfunction.
Page 200 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION CLASSIFY MALFUNCTION AT POWER Yes Malfunction at control circuit. Go to next step. SUPPLY CIRCUIT OR CONTROL CIRCUIT • Turn ignition key to ON (Engine OFF). Malfunction at power supply circuit. • Measure voltage between OCV terminal B Repair or replace harness for open circuit, then go to Step (harness-side) and body GND.
Page 201: Dtc P0011
ON-BOARD DIAGNOSTIC DTC P0011 A6E397001084W02 DTC P0011 CMP - Timing over-advanced • Actual valve timing is over-advanced by 30 deg. from target valve timing when the OCV is controlled in the maximum valve timing retard condition. Diagnostic support note • This is a continuous monitor (CCM). DETECTION •...
Page 202: Dtc P0012
ON-BOARD DIAGNOSTIC DTC P0012 A6E397001084W03 DTC P0012 CMP - Timing over-retarded • Actual valve timing is over-retarded by 5 deg. from target valve timing for 5 s when the OCV system control is within feed-back range. Diagnostic support note • This is a continuous monitor (CCM). DETECTION •...
Page 203: Dtc P0031
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0012 Yes Replace PCM, then go to next step. (See F–43 PCM REMOVAL/INSTALLATION.) COMPLETED • Make sure to reconnect all disconnected Go to next step. connectors. • Clear DTC from PCM memory using WDS or equivalent.
Page 204 ON-BOARD DIAGNOSTIC DTC P0031 Front HO2S heater circuit low input Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN...
Page 205: Dtc P0032
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT CONTROL CIRCUIT OF FRONT HO2S Yes Repair or replace harness for short to ground, then go to Step 8. HEATER FOR SHORT TO GROUND • Inspect continuity between front HO2S terminal Go to next step. D (harness-side) and body ground.
Page 206 ON-BOARD DIAGNOSTIC DTC P0032 Front HO2S heater circuit high input Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN...
Page 207: Dtc P0037
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0032 Yes Replace PCM, then go to next step. (See F–43 PCM REMOVAL/INSTALLATION.) COMPLETED • Make sure to reconnect all disconnected Go to next step. connectors. • Clear DTC from PCM memory using WDS or equivalent.
Page 208 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) INSPECT POOR CONNECTION OF REAR HO2S Yes Repair or replace terminal, then go to Step 8.
Page 209: Dtc P0038
ON-BOARD DIAGNOSTIC DTC P0038 A6E397001084W07 DTC P0038 Rear HO2S heater circuit high input • PCM monitors rear HO2S heater control signal at PCM terminal 4D. If PCM turns rear HO2S heater on but rear HO2S heater circuit has high voltage, PCM determines that rear HO2S heater circuit has malfunction. Diagnostic support note •...
Page 210: Dtc P0101
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT PCM TERMINAL Yes Repair terminal, then go to Step 6. • Disconnect PCM connector. Go to next step. • Inspect for bent terminals. • Is there any malfunctions? INSPECT REAR HO2S HEATER CONTROL Yes Repair or replace harness for shot to power circuit, then go to next step.
Page 211 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY CURRENT INPUT SIGNAL STATUS-IS Yes Make sure that throttle position sensor resistance changes smoothly while gradually opening throttle valve. CONCERN INTERMITTENT OR CONSTANT • If not, replace throttle position sensor and go to Step 7. •...
Page 212: Dtc P0102
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0101 Yes Replace PCM, then go to next step. (See F–43 PCM REMOVAL/INSTALLATION.) COMPLETED • Make sure to reconnect all disconnected Go to next step. connectors. • Turn ignition key to ON (Engine OFF). •...
Page 213 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) INSPECT POOR CONNECTION OF MAF Yes Repair or replace terminals, then go to Step 7.
Page 214: Dtc P0103
ON-BOARD DIAGNOSTIC DTC P0103 A6E397001084W10 DTC P0103 MAF circuit high input • PCM monitors input voltage from MAF sensor when engine running. If input voltage at PCM terminal 1P is above 4.9 V, PCM determines that MAF circuit has malfunction. Diagnostic support note •...
Page 215: Dtc P0107
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT MAF SIGNAL CIRCUIT FOR SHORT Yes Go to next step. TO POWER CIRCUIT Repair or replace suspected harness, then go to Step 6. • Turn ignition key to ON (Engine OFF). • Measure voltage between MAF/IAT sensor terminal C (harness-side) and body ground.
Page 216 ON-BOARD DIAGNOSTIC DTC P0107 MAP sensor circuit low input Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN...
Page 217: Dtc P0108
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT MAP SENSOR SIGNAL AND Yes Repair or replace suspected harness, then go to next step. GROUND CIRCUIT FOR SHORT EACH OTHER Go to next step. • Check continuity between MAP sensor terminals D and A (harness-side). •...
Page 218 ON-BOARD DIAGNOSTIC DTC P0108 MAP sensor circuit high input Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN...
Page 219: Dtc P0111
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY MAP SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace suspected harness, then go to Step 8. SHORT TO CONSTANT VOLTAGE CIRCUIT Go to next step. • Inspect for continuity between MAP sensor terminal D and C (harness-side). •...
Page 220: Dtc P0112
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF PCM Yes Repair or replace terminal, then go to Step 6. CONNECTOR Go to next step. • Disconnect PCM connector. • Inspect for poor connection (damaged, pulled- out pins, corrosion, etc.). •...
Page 221: Dtc P0113
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) INSPECT IAT SENSOR TERMINAL Yes Repair or replace terminal, then go to Step 6.
Page 222 ON-BOARD DIAGNOSTIC DTC P0113 IAT circuit high input Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN...
Page 223: Dtc P0117
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF PCM Yes Repair or replace terminal, then go to Step 9. CONNECTOR Go to next step. • Turn ignition key to OFF. • Disconnect PCM connector. • Inspect PCM terminals 2E and 2H (harness- side) for tightness using feeler tool.
Page 224 ON-BOARD DIAGNOSTIC DTC P0117 ECT circuit low input Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN...
Page 225: Dtc P0118
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0117 Yes Replace PCM, then go to next step. (See F–43 PCM REMOVAL/INSTALLATION.) COMPLETED • Make sure to reconnect all disconnected Go to next step. connectors. • Clear DTC from PCM memory using WDS or equivalent.
Page 226 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) INSPECT POOR CONNECTION OF ECT Yes Repair or replace terminal, then go to Step 8.
Page 227: Dtc P0121
ON-BOARD DIAGNOSTIC DTC P0121 A6E397001084W18 DTC P0121 Throttle position stuck close (lower than expected)/open (higher than expected) • If PCM detects that throttle valve opening angle is below 12.5% for 5 s after following conditions are met, PCM determines that TP is stuck closed: MONITORING CONDITION —...
Page 228 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY CURRENT INPUT SIGNAL STATUS - IS Yes Intermittent concern exists. Go to INTERMITTENT CONCERNS troubleshooting procedure. CONCERN INTERMITTENT OR CONSTANT • Drive the vehicle and read MAF PID. Inspect Mass airflow sensor and related circuits and •...
Page 229: Dtc P0122
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT PCM TERMINALS FOR ELECTRICAL Yes Repair terminal, then go to next step. CORROSION Go to next step. • Disconnect PCM connector. • Inspect for electrical corrosion on PCM and PCM connector male and female terminals. •...
Page 230 ON-BOARD DIAGNOSTIC DTC P0122 TP circuit low input Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN...
Page 231: Dtc P0123
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TP SIGNAL CIRCUIT FOR OPEN Yes Go to next step. CIRCUIT Repair or replace suspected harness, then go to Step 7. • Turn ignition key to OFF. • Inspect continuity between TP sensor terminal B (harness-side) and PCM terminal 2A.
Page 232 ON-BOARD DIAGNOSTIC DTC P0123 TP circuit high input Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN...
Page 233: Dtc P0125
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT PCM CONNECTOR Yes Repair terminal, then go to Step 9. • Disconnect PCM connector. Go to Step 9. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.). • Is there any malfunction? VERIFY TP SIGNAL CIRCUIT FOR SHORT TO Yes Repair or replace suspected harness, then go to next step.
Page 234: Dtc P0131, P0132
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT ECT SENSOR Yes Go to next step. • Inspect ECT sensor. Replace ECT sensor, then go to Step 7. (See F–53 ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION.) • Is it okay? INSPECT POOR CONNECTION OF PCM Yes Repair or replace terminal, then go to next step.
Page 235 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY RELATED SERVICE INFORMATION Yes Perform repair or diagnosis according to available Service Information. AVAILABILITY • If vehicle is not repaired, go to next step. • Check for related Service Information availability. Go to next step. •...
Page 236 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT FUEL LINE FROM FUEL PUMP TO Yes Replace suspected fuel line, then go to Step 19. FUEL DELIVERY PUMP Inspect fuel filters for following: • Visually inspect fuel line for any leakage. • Restriction or clogging at fuel filter (high-pressure side). •...
Page 237: Dtc P0133
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0131 or Yes Replace PCM, then go to next step. (See F–43 PCM REMOVAL/INSTALLATION.) P0132 COMPLETED • Make sure to reconnect all disconnected Go to next step. connectors. • Turn ignition key to ON (Engine OFF). •...
Page 238 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY RELATED PENDING AND STORED Yes Go to DTC P0443 troubleshooting procedures, then go to Step 13. DTCS • Turn ignition key to OFF, then ON (Engine Go to next step. OFF). • Verify pending and /or stored DTCs using WDS or equivalent.
Page 239: Dtc P0134
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT SEALING OF ENGINE COOLANT Yes Air gets in from poor sealing on head gasket or other areas between combustion chamber and engine coolant PASSAGE passage. Repair or replace faulty parts, then go to next step. Warning •...
Page 240 ON-BOARD DIAGNOSTIC DTC P0134 Front HO2S circuit no activity detected Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN...
Page 241: Dtc P0138
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT GAS LEAKAGE FROM EXHAUST Yes Repair or replace any faulty exhaust parts, then go to Step SYSTEM • Visually check if any gas leakage is found • Inspect the following harnesses for open or short to between exhaust manifold and front HO2S.
Page 242 ON-BOARD DIAGNOSTIC DTC P0138 Rear HO2S circuit high input Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME DATA on repair order, then go to • Has FREEZE FRAME DATA been recorded? next step.
Page 243: Dtc P0140
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0138 Yes Replace PCM, then go to next step. (See F–43 PCM REMOVAL/INSTALLATION.) COMPLETED • Make sure to reconnect all disconnected Go to next step. connectors. • Turn ignition key to ON (Engine OFF). •...
Page 244 ON-BOARD DIAGNOSTIC DTC P0140 Rear HO2S circuit no activity detected Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN...
Page 245: Dtc P0171
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT GAS LEAKAGE FROM EXHAUST Yes Repair or replace any faulty exhaust parts, then go to Step SYSTEM • Visually check if any gas leakage is found • Inspect the following harnesses for open or short to between exhaust pipe and rear HO2S.
Page 246 ON-BOARD DIAGNOSTIC DTC P0171 Fuel trim system too lean • Misfire • Front HO2S deterioration • Front HO2S heater malfunction • Pressure regulator malfunction • Fuel pump malfunction • Fuel filter clogged or restricted POSSIBLE • Fuel leakage on fuel line from fuel delivery pipe and fuel pump CAUSE •...
Page 247 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT MAF PID Yes Go to next step. • Start engine. Replace Mass air flow sensor, then go to Step 18. • Access MAF PID using WDS or equivalent. • Verify that MAF PID changes quickly according to race engine RPM.
Page 248: Dtc P0172
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT VARIABLE VALVE TIMING CONTROL Yes Go to next step. SYSTEM OPERATION Repair or replace malfunctioning part according to variable valve timing control system inspection results, then go to Note Step 18. • The following test should be performed for variable valve timing control system.
Page 249 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY RELATED PENDING CODE OR Yes Go to appropriate DTC troubleshooting procedures. STORED DTCS If drive ability concern is present, go to Step 8. • Turn ignition key to OFF, then ON (Engine If not, go to next step. OFF).
Page 250: Dtc P0300
ON-BOARD DIAGNOSTIC DTC P0300 A6E397001085W01 DTC P0300 Random misfire detection • PCM monitors CKP sensor input signal interval time. PCM calculates change of interval time for each cylinder. If change of interval time exceeds preprogrammed criteria, PCM detects misfire in the corresponding cylinder.
Page 251 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY CURRENT INPUT SIGNAL STATUS Yes Inspect suspected circuit and/or part according to inspection results. UNDER TROUBLE CONDITION • Inspect same PIDs as in Step 4 while (See F–45 PCM INSPECTION.) Then go to Step 22. simulating FREEZE FRAME DATA condition.
Page 252 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT FUEL LINE FROM FUEL PUMP TO Yes Replace suspected fuel line, then go to Step 22. FUEL DELIVERY PIPE Inspect fuel filters for following: • Visually inspect for fuel leakage in fuel line for •...
Page 253 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT SEALING OF ENGINE COOLANT Yes Air gets in from poor sealing on head gasket or other areas between combustion chamber and engine coolant PASSAGE passage. Repair or replace faulty parts, then go to next step.
Page 254 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME DATA on repair order, then go to • Has FREEZE FRAME DATA been recorded? next step. VERIFY RELATED SERVICE INFORMATION Yes Perform repair or diagnosis according to available Service Information.
Page 255: Dtc P0327
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT SEALING OF ENGINE COOLANT Yes Air gets in from poor sealing on head gasket or other areas between combustion chamber and engine coolant PASSAGE passage. Repair or replace faulty parts, then go to Step 12. Warning Go to next step.
Page 256 ON-BOARD DIAGNOSTIC DTC P0327 Knock sensor circuit low input Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN...
Page 257: Dtc P0328
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT FOR SHORT CIRCUITS Yes Repair or replace suspected harness, then go to Step 8. • Inspect continuity between knock sensor Go to next step. female terminals A and B (harness-side). • Is there continuity? INSPECT PCM CONNECTOR TERMINAL Yes Repair terminal, then go to Step 8.
Page 258 ON-BOARD DIAGNOSTIC DTC P0328 Knock sensor circuit high input Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN...
Page 259: Dtc P0335
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0328 Yes Replace PCM, then go to next step. (See F–43 PCM REMOVAL/INSTALLATION.) COMPLETED • Make sure to connect all disconnected Go to next step. connectors. • Clear DTC from PCM memory using WDS or equivalent.
Page 260 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME DATA on repair order, then go to • Has FREEZE FRAME DATA been recorded? next step. VERIFY RELATED SERVICE INFORMATION Yes Perform repair or diagnosis according to available Service Information.
Page 261: Dtc P0340
CONTROL SYSTEM STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0335 Yes Replace PCM, then go to next step. (See F–43 PCM REMOVAL/INSTALLATION.) COMPLETED • Make sure to reconnect all disconnected Go to next step. connectors. • Turn ignition key to ON (Engine OFF). •...
Page 262 ON-BOARD DIAGNOSTIC F – 1 3 2 F UEL AND EMISSION CONTROL SYSTEMS ON-BOARD DIAGNOSTIC DTC P0340 Camshaft position (CMP) sensor circuit malfunction Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next s RECORDED tep.
Page 263 ON-BOARD DIAGNOSTIC F F UEL AND EMISSION CONTROL SYSTEMS ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT CMP CIRCUIT FOR SHORT TO Yes Repair or replace suspected harness, then go to Step 15. GROUND Go to next step. • Inspect continuity between following terminal and body ground: —...
Page 264: Dtc P0403
CONTROL SYSTEM STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0340 Yes Replace PCM, then go to next step. (See F–43 PCM REMOVAL/INSTALLATION.) COMPLETED • Make sure to reconnect all disconnected Go to next step. connectors. • Turn ignition key to ON (Engine OFF). •...
Page 265 ON-BOARD DIAGNOSTIC DTC P0403 EGR valve (stepper motor) circuit malfunction • EGR valve malfunction • Connector or terminal malfunction • Short to power circuit in wiring between EGR valve terminal E and PCM terminal 4E • Short to power circuit in wiring between EGR valve terminal A and PCM terminal 4H •...
Page 266 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POWER CIRCUIT FOR OPEN Yes Go to next step. CIRCUIT Repair or replace harness for open circuit then go to Step • Turn ignition key to ON (Engine OFF). • Measure voltage following terminal and body ground.
Page 267: Dtc P0420
ON-BOARD DIAGNOSTIC DTC P0420 A6E397001086W02 DTC P0420 Catalyst system efficiency below threshold • PCM compares number of front HO2S and rear HO2S inversions for a predetermined time. PCM monitors number of inversions rear side performs while front side inverts for a specified number of times when the following monitoring conditions are met.
Page 268: Dtc P0443
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0420 Yes Replace PCM, then go to next step. (See F–43 PCM REMOVAL/INSTALLATION.) OR P0431 COMPLETED • Make sure to reconnect all disconnected Go to next step. connectors. • Turn ignition key to ON (Engine OFF). •...
Page 269 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) CLASSIFY OPEN CIRCUIT OR SHORT TO Yes Go to Step 4.
Page 270: Dtc P0480
ON-BOARD DIAGNOSTIC End Of Sie DTC P0480 A6E397001086W04 DTC P0480 Fan relay control circuit malfunction • PCM monitors cooling fan relay No.2 control signal at PCM terminal 4L. if PCM detects cooling fan relay DETECTION No.2 control signal does not change coolant temperature above 100 °C {212 °F}, PCM determines that CONDITION cooling fan relay No.2 control has malfunction.
Page 271 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT COOLING FAN RELAY NO.2 POWER Yes Go to next step. CIRCUIT FOR OPEN Replace or replace harness for open, then go to Step 9. • Turn ignition switch to ON (Engine OFF). • Measure voltage between cooling fan relay No.2 terminal E (harness side) and body ground.
Page 272: Dtc P0500
ON-BOARD DIAGNOSTIC DTC P0500 A6E397001087W01 DTC P0500 Vehicle speed sensor (VSS) circuit malfunction (MTX vehicles without ABS) • Vehicle speed signal does not input after following conditions are met: — Gear is in other than neutral position — Load is above 40% —...
Page 273 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY CURRENT INPUT SIGNAL STATUS-IS Yes Go to intermittent concern troubleshooting procedure. (See F–227 INTERMITTENT CONCERN CONCERN INTERMITTENT OR CONSTANT • Connect WDS or equivalent to DLC-2. TROUBLESHOOTING.) • Start engine. Go to next step. •...
Page 274: Dtc P0505
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0500 Yes Replace PCM, then go to next step. (See F–43 PCM REMOVAL/INSTALLATION.) COMPLETED • Make sure to reconnect all disconnected Go to next step. connectors. • Turn ignition key to ON (Engine OFF). •...
Page 275: Dtc P0506
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT GENERATOR CONTROL CIRCUIT Yes Go to next step. MALFUNCTION Repair short to power circuit in generator control circuit, • Apply electrical load. then go to Step 9. • Is engine speed increased? INSPECT AIR CLEANER ELEMENT Yes Clean or replace air cleaner element, then go to Step 9.
Page 276 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY RELATED PENDING OR STORED Yes Repair applicable DTCs. (See F–67 DTC TABLE.) DTCS • Turn ignition key to OFF, then ON (Engine Go to next step. OFF). • Verify pending code or stored DTCs using WDS or equivalent.
Page 277: Dtc P0507
ON-BOARD DIAGNOSTIC DTC P0507 A6E397001087W04 DTC P0507 Idle control system RPM higher than expected • Actual idle speed is higher than expected by 200 rpm for 14 s, when brake pedal is depressed (brake switch is on) and steering wheel is held straight ahead (power steering pressure switch is off). Note •...
Page 278: Dtc P0511
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0507 Yes Replace PCM, then go to next step. (See F–43 PCM REMOVAL/INSTALLATION.) COMPLETED • Make sure to reconnect all disconnected Go to next step. connectors. • Start engine. • Clear DTC from PCM memory using WDS or equivalent.
Page 279 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) INSPECT POOR CONNECTION OF IAC VALVE Yes Repair or replace terminal, then go to Step 8.
Page 280: Dtc P0550
ON-BOARD DIAGNOSTIC DTC P0550 A6E397001087W06 DTC P0550 PSP switch circuit malfunction • PCM monitors PSP switch signal at PCM terminal 1Z. If input voltage is low (switch stays on) for 1 minute when VSS is above 60 km/h {37.3 mph} and ECT is above 60 °C {140 °F}, PCM determines that PSP switch circuit has malfunction.
Page 281 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT PSP SWITCH Yes Go to next step. • Perform PSP switch inspection. Replace PSP switch, then go to Step 8. (See F–58 POWER STEERING PRESSURE (PSP) SWITCH INSPECTION.) • Is PSP switch okay? INSPECT PSP SWITCH SIGNAL CIRCUIT FOR Yes Repair or replace harness for short to ground, then go to Step 8.
Page 282: Dtc P0602
ON-BOARD DIAGNOSTIC DTC P0602 A6E397001088W01 DTC P0602 PCM programming error • No configuration data in PCM DETECTION Note • If “PCM CONFIGURATION” is successful, the PCM stored DTC P0602 and illuminates the MIL CONDITION (System i s normal) Clear the DTC P0602 using WDS or equivalent after “PCM CONFIGURATION”. •...
Page 283: Dtc P0661
ON-BOARD DIAGNOSTIC End Of Sie DTC P0661 A6E397001088W03 DTC P0661 Variable intake-air system (VIS) contol solenoid valve circuit low input • PCM monitors VIS control solenoid valve control signal at PCM terminal 4R. If PCM turns VIS control DETECTION solenoid valve off but voltage at PCM terminal 4R still remains low, PCM determines that VIS control CONDITION solenoid valve circuit has malfunction.
Page 284: Dtc P0662
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT VIS CONTROL SOLENOID VALVE Yes Repair or replace harness for short to ground, then go to Step 8. CONTROL CIRCUIT FOR SHORT TO GROUND • Inspect continuity between VIS control Go to next step. solenoid valve terminal A (harness-side) and body ground.
Page 285 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) INSPECT VIS CONTROL SOLENOID VALVE Yes Repair or replace terminal, then go to Step 6.
Page 286: Dtc P0703
ON-BOARD DIAGNOSTIC DTC P0703 A6E397001089W01 DTC P0703 Brake switch input malfunction • PCM monitors changes in input voltage from brake switch. If PCM does not detect PCM terminal 1K voltage changes while alternately accelerating and decelerating 8 times, PCM determines that neutral switch circuit has malfunction.
Page 287 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT BRAKE SWITCH CONNECTOR FOR Yes Repair or replace terminal, then go to Step 14. POOR CONNECTION Go to next step. • Turn ignition switch to OFF. • Disconnect brake switch connector. • Inspect for poor connection (damaged/pulled- out terminals, corrosion, etc.).
Page 288: Dtc P0704
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0703 Yes Replace PCM, then go to next step. (See F–43 PCM REMOVAL/INSTALLATION.) COMPLETED • Make sure to reconnect all disconnected Go to next step. connectors. • Clear DTC from memory using WDS or equivalent.
Page 289 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME DATA on repair order, then go to • Has FREEZE FRAME DATA been recorded? next step. VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service information.
Page 290: Dtc P0850
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT CLUTCH SWITCH SIGNAL CIRCUIT Yes Repair or replace harness for short to ground, then go to Step 14. FOR SHORT TO GROUND • Inspect continuity between clutch switch Go to Next step. terminal B and ground. •...
Page 291 ON-BOARD DIAGNOSTIC DTC P0850 Neutral switch circuit malfunction Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME DATA on repair order, then go to • Has FREEZE FRAME DATA been recorded? next step.
Page 292: Dtc P1410
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT NEUTRAL SWITCH GROUND Yes Go to next step. CIRCUIT FOR OPEN CIRCUIT Repair or replace neutral switch power circuit for open, then • Inspect continuity between neutral switch Go to Step 14. terminal A and ground. •...
Page 293 ON-BOARD DIAGNOSTIC DTC P1410 Variable air duct (VAD) control system circuit malfunction • VAD solenoid valve malfunction. • Connector or terminal malfunction. • Short to ground in wiring between VAD solenoid valve terminal B and PCM terminal 4C POSSIBLE • Open circuit in wiring between main relay and VAD solenoid valve terminal A CAUSE •...
Page 294: Dtc P1562
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF PCM Yes Repair terminals, then go to Step 11. CONNECTOR Go to next step. • Disconnect PCM connector. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.). • Are there any malfunctions? INSPECT CONTROL CIRCUIT FOR SHORT TO Yes Repair or replace harness for short to ground, then go to Step 11.
Page 295 ON-BOARD DIAGNOSTIC DTC P1562 PCM +BB (back-up battery) voltage low Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN...
Page 296: Dtc P2006
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY AFTER REPAIR PROCEDURE Yes Go to applicable DTC troubleshooting. • Perform “After Repair Procedure”. (See F–67 DTC TABLE.) (See F–66 AFTER REPAIR PROCEDURE.) Troubleshooting completed. • Is there any DTC present? End Of Sie DTC P2006 A6E397001083W03 DTC P2006...
Page 297 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION CLASSIFY INTERMITTENT CONCERN OR Yes Go to next step. CONTINUOUS CONCERN Intermittent concern exists. Go to INTERMITTENT • Clear DTC from PCM memory using WDS or CONCERN TROUBLESHOOTING procedure. equipment. (See F–227 INTERMITTENT CONCERN • Drive vehicle under following conditions: TROUBLESHOOTING.) —...
Page 298: Dtc P2009
ON-BOARD DIAGNOSTIC DTC P2009 A6E397001083W04 DTC P2009 Variable tumble control solenoid valve circuit low input • PCM monitors variable tumble control solenoid valve control signal at PCM terminal 4T. If PCM turns variable tumble control solenoid valve off but voltage at PCM terminal 4T still remains low, PCM determines that VTCS solenoid valve circuit has malfunction.
Page 299 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT VARIABLE TUMBLE CONTROL Yes Go to next step. SOLENOID VALVE POWER SUPPLY CIRCUIT Repair or replace harness for open, then go to Step 8. FOR OPEN CIRCUIT • Disconnect variable tumble control solenoid valve connector. •...
Page 300: Dtc P2010
ON-BOARD DIAGNOSTIC DTC P2010 A6E397001083W05 DTC P2010 Variable tumble control solenoid valve circuit high input • PCM monitors variable tumble control solenoid valve control signal at PCM terminal 4T. If PCM turns variable tumble control solenoid valve on but voltage at PCM terminal 4T still remains high, PCM determines that variable tumble control solenoid valve circuit has malfunction.
Page 301 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT PCM CONNECTOR FOR POOR Yes Repair terminal, then go to Step 6. CONNECTION Go to next step. • Turn ignition key to OFF. • Disconnect PCM connector. • Inspect for poor connection at PCM terminal 4T.
Page 302: Dtc P2228
ON-BOARD DIAGNOSTIC DTC P2228 A6E397001083W06 DTC P2228 BARO sensor circuit low input • PCM monitors input voltage from BARO sensor. If input voltage at PCM terminal 1G is below 0.35 V, PCM determines that BARO sensor circuit has malfunction. Diagnostic support note •...
Page 303 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT BARO SENSOR MALFUNCTiON Yes Go to next step. • Perform BARO sensor inspection. Replace BARO sensor, then go to Step 8. (See F–60 BAROMETRIC PRESSURE (BARO) SENSOR INSPECTION.) • Is BARO sensor okay? INSPECT POWER SUPPLY CIRCUIT VOLTAGE Yes Go to next step.
Page 304: Dtc P2229
ON-BOARD DIAGNOSTIC DTC P2229 A6E397001083W07 DTC P2229 BARO sensor circuit high input • PCM monitors input voltage from BARO sensor. If input voltage at PCM terminal 1G is above 4.92 V, PCM determines that BARO sensor circuit has malfunction. Diagnostic support note •...
Page 305 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT BARO SENSOR MALFUNCTiON Yes Go to next step. • Perform BARO sensor inspection. Replace BARO sensor, then go to Step 8. (See F–60 BAROMETRIC PRESSURE (BARO) SENSOR INSPECTION.) • Is BARO sensor okay? VERIFY BARO SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace short to power harness, then go to Step SHORT TO REFERENCE VOLTAGE CIRCUIT •...
Page 306: Dtc P2502
ON-BOARD DIAGNOSTIC DTC P2502 A6E397001083W08 DTC P2502 Generator terminal B circuit open • PCM judges generator output voltage is above 17 V or battery voltage is below 11 V during engine DETECTION CONDITION running. • Open circuit between generator terminal B and battery positive terminal •...
Page 307: Dtc P2503
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P2502 Yes Replace PCM, then go to next step. (See F–43 PCM REMOVAL/INSTALLATION.) COMPLETED • Make sure to reconnect all connectors. Go to next step. • Clear DTC from memory using WDS or equivalent.
Page 308: Dtc P2504
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF PCM Yes Repair terminals, then go to Step 9. CONNECTOR Go to next step. • Turn ignition key to OFF. • Disconnect PCM connector. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.).
Page 309 ON-BOARD DIAGNOSTIC DTC P2504 Battery overcharge Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. Intermittent concern exists. Go to INTERMITTENT (See F–66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F–227 INTERMITTENT CONCERN •...
Page 310 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT GENERATOR CONTROL TERMINAL Yes Repair or replace generator, then go to Step 7. FOR SHORT TO POWER Go to next step. • Measure resistance between generator terminal D (part-side) and body ground. • Is voltage B+? VERIFY TROUBLESHOOTING OF DTC P2504 Yes Replace PCM, then go to next step.
Page 311: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING ENGINE SYMPTOM TROUBLESHOOTING A6E398018881W01 • Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart. Diagnostic Index TROUBLESHOOTING ITEM DESCRIPTION Melting of main or other fuses — MIL illuminates MIL is illuminated incorrectly. Will not crank Starter does not work.
Page 312: Quick Diagnostic Chart
TROUBLESHOOTING QUICK DIAGNOSTIC CHART A6E398018881W02 A6E3980W001 F–182...
Page 313 TROUBLESHOOTING A6E3980W002 F–183...
Page 314 TROUBLESHOOTING A6E3980W003 F–184...
Page 315 TROUBLESHOOTING A6E3980W004 End Of Sie F–185...
Page 316: No.1 Melting Of Main Or Other Fuses
TROUBLESHOOTING NO.1 MELTING OF MAIN OR OTHER FUSES A6E398018881W03 MELTING OF MAIN OR OTHER FUSES [TROUBLESHOOTING HINTS] Inspect condition of fuse. Damaged fuse Related wiring harness • IG KEY2 fuse MAIN • AD FAN fuse • FAN fuse • PCM ENG +B •...
Page 317: No.3 Will Not Crank
TROUBLESHOOTING Diagnostic procedure STEP INSPECTION RESULTS ACTION Connect WDS or equivalent to DLC-2. DTC is displayed: • Go to appropriate DTC test. Retrieve any DTC. Are there DTC displayed? No DTC is displayed: • Inspect instrument cluster operation. See Section T. Verify test results.
Page 318 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Is there continuity between PCM terminal 4I and Go to next step. starter relay with clutch pedal depressed (MTX Repair replace wiring harness. with starter interlock system), P or N position (ATX)? Inspect following: Go to next step. •...
Page 319: No.4 Hard To Start/Long Crank/Erratic Start/Erratic Crank
TROUBLESHOOTING NO.4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK A6E398018881W06 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK • Starter cranks engine at normal speed but engine requires excessive cranking time before starting. DESCRIPTION • Battery is in normal condition. • Spark leakage from high-tension leads •...
Page 320 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Visually inspect CKP sensor and teeth of Go to next step. crankshaft pulley. Replace malfunctioning parts. Are CKP sensor and teeth of crankshaft pulley okay? Measure gap between CKP sensor and teeth of Go to next step. crankshaft pulley.
Page 321: No.5 Engine Stalls-After Start/At Idle
TROUBLESHOOTING NO.5 ENGINE STALLS-AFTER START/AT IDLE A6E398018881W07 ENGINE STALLS—AFTER START/AT IDLE • Engine stops unexpectedly. DESCRIPTION • A/C system operation is improper • Air leakage from intake-air system parts • Purge solenoid valve malfunction • Improper operation of IAC valve •...
Page 322 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Does security light illuminate? Go to next step. Inspect instrument cluster and wiring harness. Connect WDS or equivalent to DLC-2 and Go to appropriate DTC test. retrieve DTC. Go to next step. Are any of following DTCs displayed? B1213, B1342, B1600, B1602, B1681, B2103, B2431 Is there continuity between PCM GND terminals...
Page 323 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Connect WDS or equivalent to DLC-2. Go to next step. Access RPM PID. Inspect for following:. Is RPM PID indicating engine speed during • Open or short circuit in CKP sensor engine cranking? • Open or short circuit between CKP sensor and PCM terminal 2C or 2D •...
Page 324 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Note Go to next step. • Following test is for stall concerns with A/ If A/C is always on, go to symptom troubleshooting C on. If other symptoms exist, go to next "No.24 A/C is always on or A/C compressor runs step.
Page 325: No.6 Cranks Normally But Will Not Start
TROUBLESHOOTING NO.6 CRANKS NORMALLY BUT WILL NOT START A6E398018881W08 CRANKS NORMALLY BUT WILL NOT START • Starter cranks engine at normal speed but engine will not run. • Refer to symptom troubleshooting "No.5 Engine stalls" if this symptom appears after engine stall. DESCRIPTION •...
Page 326 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Is coil connector securely connected to coil? Go to next step. Connect coil connector securely. Return to Step 2. Does security light illuminate? Go to next step. Inspect instrument cluster and wiring harness. Connect WDS equivalent to DLC-2 and retrieve Go to appropriate DTC test.
Page 327 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Will engine start and run smoothly at part Inspect IAC valve and wiring harness. throttle? Go to next step. Connect WDS or equivalent to DLC-2. Go to next step. Access RPM PID. Inspect for following: Is RPM PID indicating engine speed when •...
Page 328: No.7 Slow Return To Idle
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Is air leakage felt or heard at intake-air system Repair or replace. components while racing engine to higher Go to next step. speed? Inspect engine condition while tapping EGR Replace EGR valve. valve housing. Go to next step. Is engine condition improved? Note Go to next step.
Page 329: No.8 Engine Runs Rough/Rolling Idle
TROUBLESHOOTING NO.8 ENGINE RUNS ROUGH/ROLLING IDLE A6E398018881W10 ENGINE RUNS ROUGH/ROLLING IDLE • Engine speed fluctuates between specified idle speed and lower speed and engine shakes DESCRIPTION excessively. • Idle speed is too slow and engine shakes excessively. • Air leakage from intake-air system parts •...
Page 330 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Connect WDS or equivalent to DLC-2. DTC is displayed: Retrieve any continuous memory, KOEO and Go to appropriate DTC test. KOER. No DTC is displayed: Are there any DTCs displayed? Go to next step. Is engine overheating? Go to symptom troubleshooting "No.17 Cooling system concerns - Overheating".
Page 331: No.9 Fast Idle/Runs On
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Connect WDS or equivalent to DLC-2. Go to next step. Start the engine and run it at idle. Inspect and repair or replace faulty HO2S, harness, Access O2S11 PID. connector or terminal, then go to next step. Is O2S11 PID okay? •...
Page 332: No.10 Low Idle/Stalls During Deceleration
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Connect WDS or equivalent to DLC-2. DTC is displayed: Retrieve any continuous memory DTCs. Go to appropriate DTC test. Are there any DTCs displayed? No DTC is displayed: Go to next step. Connect WDS or equivalent to DLC-2. Go to next step.
Page 333 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Disconnect vacuum hose between purge Inspect evaporative emission control system. solenoid valve and intake manifold from purge Go to next step. solenoid valve side. Plug opening end of vacuum hose. Drive vehicle. Does engine condition improve? Connect WDS or equivalent to DLC-2.
Page 334: No.11 Engine Stalls/Quits, Engine Runs Rough, Misses, Buck/Jerk, Hesitation/Stumble, Surges
TROUBLESHOOTING NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE, SURGES A6E398018881W13 ENGINE STALLS/QUITS — ACCELERATION/CRUISE ENGINE RUNS ROUGH — ACCELERATION/CRUISE MISSES — ACCELERATION/CRUISE BUCK/JERK — ACCELERATION/CRUISE/DECELERATION HESITATION/STUMBLE — ACCELERATION SURGES — ACCELERATION/CRUISE • Engine stops unexpectedly at beginning of acceleration or during acceleration. •...
Page 335 TROUBLESHOOTING Diagnostic procedure STEP INSPECTION RESULTS ACTION Verify for following: Go to next step. • Vacuum connection Service as necessary. • Air cleaner element Repeat Step 1. • No air leakage from intake-air system • No restriction of intake-air system •...
Page 336 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Install fuel pressure gauge between fuel pipe Go to next step. and fuel distributor. Zero or low: Connect jumper wire between F/P terminal at Inspect for clogged fuel line. DLC-2 in engine compartment and GND. If okay, replace fuel pump unit.
Page 337: No.12 Lack/Loss Of Power-Acceleration/Cruise
TROUBLESHOOTING NO.12 LACK/LOSS OF POWER-ACCELERATION/CRUISE A6E398018881W14 LACK/LOSS OF POWER — ACCELERATION/CRUISE DESCRIPTION Performance is poor under load (e.g., power down when climbing hills). • Improper A/C system operation • Erratic signal or no signal from CMP sensor • Air leakage from intake-air system parts •...
Page 338 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Connect WDS or equivalent to DLC-2. DTC is displayed: Retrieve any continuous memory, KOEO and Go to appropriate DTC test. KOER DTCs. No DTC is displayed: If engine stall condition exists, retrieve Go to next step. continuous memory and KOEO DTCs.
Page 339 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Note Go to next step. • Following test is for engine stalling with A/ If A/C is always on, go to symptom troubleshooting C on concern. If other symptoms exist, go "No.24 A/C is always on or A/C compressor runs to next step.
Page 340: No.13 Knocking/Pinging-Acceleration/Cruise
TROUBLESHOOTING NO.13 KNOCKING/PINGING-ACCELERATION/CRUISE A6E398018881W15 KNOCKING/PINGING - ACCELERATION/CRUISE Sound is produced when air/fuel mixture is ignited by something other than spark plug (e.g., hot spot in DESCRIPTION combustion chamber). • Engine overheating due to cooling system malfunction • ECT sensor malfunction •...
Page 341: No.14 Poor Fuel Economy
TROUBLESHOOTING NO.14 POOR FUEL ECONOMY A6E398018881W16 POOR FUEL ECONOMY DESCRIPTION Fuel economy is unsatisfactory. • Contaminated air cleaner element • VIS malfunction (if equipped) • Engine cooling system malfunction • Improper ATF level (ATX) • Weak spark • Poor fuel quality •...
Page 342 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Is strong blue spark visible at each disconnected Inspect for following: • Spark plugs malfunction high-tension lead while cranking engine? • CMP sensor is improperly installed. • Trigger wheel damage on camshaft • Open or short circuit on CMP sensor •...
Page 343: No.15 Emission Compliance
TROUBLESHOOTING NO.15 EMISSION COMPLIANCE A6E398018881W17 EMISSION COMPLIANCE DESCRIPTION Fails emissions test. • Vacuum lines leakage or blockage • Cooling system malfunction • Spark plug malfunction • Leakage from intake manifold • Erratic or no signal from CMP sensor • Inadequate fuel pressure •...
Page 344: No.16 High Oil Consumption/Leakage
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Is strong blue spark visible at each disconnected Inspect for following: • Spark plugs malfunction high-tension lead while cranking engine? • Improperly installed CMP sensor • Damage of trigger wheel on camshaft • Open or short circuit on CMP sensor •...
Page 345: No.17 Cooling System Concerns-Overheating
TROUBLESHOOTING NO.17 COOLING SYSTEM CONCERNS-OVERHEATING A6E398018881W19 COOLING SYSTEM CONCERNS -OVERHEATING DESCRIPTION Engine runs at higher than normal temperature/overheats. • Improper coolant level • Blown fuses • Coolant leakage • Excessive A/C system pressure • A/C system operation is improper • Improper water/anti-freeze mixture •...
Page 346: No.18 Cooling System Concerns-Runs Cold
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Cool down the engine. Engine coolant temperature and thermostat are okay, Remove thermostat and inspect operation. inspect engine block for leakage or blockage. (See E–7 THERMOSTAT REMOVAL/ Access ECT PID. INSTALLATION.) Inspect for both ECT PID and temperature gauge (See E–8 THERMOSTAT INSPECTION.)
Page 347: No.19 Exhaust Smoke
TROUBLESHOOTING NO.19 EXHAUST SMOKE A6E398018881W21 EXHAUST SMOKE DESCRIPTION Blue, black, or white smoke from exhaust system Blue smoke (Burning oil): • PCV valve malfunction • Engine internal oil leakage White smoke (Water in combustion): • Cooling system malfunction (coolant loss) •...
Page 348: No.20 Fuel Odor
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Install fuel pressure gauge between fuel pipe Go to next step. and fuel distributor. Zero or low: Start engine and run it at idle. • Inspect for clogged fuel line. Measure fuel line pressure at idle. •...
Page 349: No.21 Engine Noise
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Connect WDS or equivalent to DLC-2. DTC is displayed: Retrieve any continuous memory, KOEO and Go to appropriate DTC test. KOER DTCs. No DTC is displayed: Are there any DTCs displayed? Inspect charcoal canister for fuel saturation. If excess amount of liquid fuel is present, replace charcoal canister.
Page 350: No.22 Vibration Concerns (Engine
TROUBLESHOOTING NO.22 VIBRATION CONCERNS (ENGINE) A6E398018881W24 VIBRATION CONCERNS (ENGINE) • Vibration from under hood or driveline DESCRIPTION • Loose attaching bolts or worn parts POSSIBLE CAUSE • Components malfunction such as worn parts Diagnostic procedure STEP INSPECTION RESULTS ACTION Inspect following components for loose attaching Inspect following systems: •...
Page 351: No.24 A/C Is Always On Or A/Ccompressor Runs Continuously
TROUBLESHOOTING End Of Sie NO.24 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY A6E398018881W26 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY. DESCRIPTION A/C compressor magnetic clutch does not disengage. • Stuck engagement A/C compressor magnetic clutch • A/C relay is stuck closed. •...
Page 352: No.26 Exhaust Sulphur Smell
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Connect WDS or equivalent to DLC-2. DTC is displayed: Retrieve any continuous memory, KOEO and Go to appropriate DTC test. KOER DTCs. No DTC is displayed: Are there any DTCs displayed? Inspect TP sensor for proper adjustment. Verify test results.
Page 353: No.27 Constant Voltage
TROUBLESHOOTING End Of Sie NO.27 CONSTANT VOLTAGE A6E398018881W29 CONSTANT VOLTAGE DESCRIPTION Incorrect constant voltage • Constant voltage circuit malfunction POSSIBLE CAUSE Note • TP sensor uses constant voltage. Diagnostic procedure STEP INSPECTION RESULTS ACTION Disconnect TP sensor connector where constant Go to Step 13.
Page 354 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Are DTCs present for two or more sensors Go to next step. connected to PCM terminal 2H? Repair open GND circuit to sensor where constant Sensor connected to PCM terminal 2H: voltage circuit inspection failed. •...
Page 355: No.28 Spark Plug Condition
TROUBLESHOOTING NO.28 SPARK PLUG CONDITION A6E398018881W30 SPARK PLUG CONDITION DESCRIPTION Incorrect spark plug condition Note • Inspecting spark plugs condition can determine whether problem is related to a specific cylinder possibly all cylinders. Wet/carbon stuck on specific plug: • Spark—Weak, not visible •...
Page 356 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Carry out fuel line pressure inspection. Inspect fuel injector for following: • Open or short in injector Is fuel line pressure correct? • Leakage • Injection volume Zero or low: Inspect fuel pump circuit. Inspect for fuel pump relief valve open. Inspect for fuel leakage inside pressure regulator.
Page 357: Intermittent Concern Troubleshooting
TROUBLESHOOTING INTERMITTENT CONCERN TROUBLESHOOTING A6E398018881W31 Vibration Method 1. If malfunction occurs or becomes worse while driving on a rough road or when engine is vibrating, perform the steps below. Note • There are several reasons vehicle or engine vibration could cause an electrical malfunction. Some of the things to check for are: —...
Page 358 TROUBLESHOOTING Inspection Method for Sensors 1. Connect WDS or equivalent to DLC-2. 2. Turn ignition switch to ON position (Engine OFF). Note • If engine starts and runs, perform the following steps at idle. 3. Access PIDs for the switch you are inspecting. 4.
Page 359: Engine Control System Operation Inspection
TROUBLESHOOTING ENGINE CONTROL SYSTEM OPERATION INSPECTION A6E398018881W32 Main Relay Operation Inspection 1. Verify that the main relay clicks when the ignition switch is turned to ON position and off. • If there is no operation sound, inspect the following. — Main relay (See T–24 RELAY INSPECTION.) —...
Page 360 TROUBLESHOOTING 7. Verify that the engine speed is within the specification under each load condition. • If not as specified specific load condition, inspect the following. — A/C switch and related harness (See U–47 CLIMATE CONTROL UNIT INSPECTION.) — Fan switch and related harness (See U–47 CLIMATE CONTROL UNIT INSPECTION.)
Page 361 TROUBLESHOOTING Variable Tumble Control System (VTCS) Operation Inspection 1. Connect the WDS or equivalent to the DLC-2. 2. Access ECT PID. 3. Verify that ECT PID is between 63°C {145°F} and 67°C {152°F}. 4. Start the engine. 5. Inspect rod operation under the following condition. Rod operation 3,750 rpm Engine speed...
Page 362 TROUBLESHOOTING Fuel Pump Operation Inspection 1. Connect WDS or equivalent to the DLC-2. 2. Remove the fuel-filler cap. 3. Turn the ignition switch to ON position. 4. Turn the fuel pump relay from off to on using the FP PID and inspect if the operation sound is heard. •...
Page 363 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Are following item okay? Inspect for open or short in wiring harness and • CKP sensor and crankshaft pulley connector of CKP sensor. • PCM terminal 1A/1B voltage Repair or replace malfunctioning parts, then go to Step Specification Approx.
Page 364 TROUBLESHOOTING A/C Cut-off Control System Inspection 1. Start the engine. 2. Turn the A/C switch and fan switch on. 3. Verify that the A/C compressor magnetic clutch actuates. • If it does not actuate, go to symptom troubleshooting “No.23 A/C does not work sufficiently“. 4.
Page 365 TROUBLESHOOTING 4. Inspect if the operation sound is heard from the cooling fan relay. • If the operation sound is heard, inspect the wiring harness, connectors and cooling fan motor. • If the operation sound is not heard, inspect cooling fan relay and open circuit wiring harness and connectors.
Page 366 TROUBLESHOOTING • If the cooling fan is not operating and condenser fan is operating, inspect for following: — Short to GND circuit between PCM terminal 4F and transfer relay — Transfer relay stuck ON position — Short to GND circuit between PCM terminal 4B and cooling fan relay No.3 —...
Page 367 TROUBLESHOOTING L8, LF (Intensely hot area) engine models Cooling fan system operation (at idle) Cooling fan Cooling fan Cooling fan Cooling fan Cooling fan Cooling fan Engine condition relay No.2 relay No.4 relay No.1 relay No.3 motor No.1 motor No.2 Engine coolant temperature below 100°C {212°F} Engine coolant temperature above...
Page 368 TROUBLESHOOTING 3. Inspect the operation sound is heard from cooling fan relay No.1 and cooling fan relay No.4. — If the operation sound is not heard from cooling fan relay No.4, inspect cooling fan relay No.4 and open circuit between PCM 4F and cooling fan relay No.4 wiring harnesses and connectors. —...
Page 369 TROUBLESHOOTING Variable Valve Timing Control System Operation Inspection When idling cannot be continued 1. Remove the oil control valve (OCV) and verify that the spool valve is at maximum retard position. 2. If the spool valve is stuck in advance direction, replace the oil control valve (OCV). 3.
Page 370 E NGINE ELECTRICAL SYSTEM LOCATION INDEX ..........G-2 LOCATION INDEX..........G-2 CHARGING SYSTEM..........G-3 BATTERY REMOVAL/INSTALLATION ....G-3 BATTERY INSPECTION........G-4 BATTERY RECHARGING ........G-5 GENERATOR REMOVAL/INSTALLATION ..G-6 GENERATOR INSPECTION ......G-7 IGNITION SYSTEM ..........G-8 IGNITION COIL REMOVAL/INSTALLATION..G-8 IGNITION COIL INSPECTION......
Page 371: Location Index
LOCATION INDEX LOCATION INDEX LOCATION INDEX A6E470001002W01 AME4700W001 Battery Ignition coil (See G–3 BATTERY REMOVAL/INSTALLATION) (See G–9 IGNITION COIL INSPECTION) (See G–4 BATTERY INSPECTION) Spark plug (See G–5 BATTERY RECHARGING) (See G–10 SPARK PLUG REMOVAL/ Generator INSTALLATION) (See G–6 GENERATOR REMOVAL/ (See G–10–1 SPARK PLUG INSPECTION)
Page 372: Charging System
CHARGING SYSTEM CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION A6E471018520W01 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. Negative battery cable Battery cable Battery clamp Battery Battery tray A6E4710W002 End Of Sie G–3...
Page 373: Battery Inspection
CHARGING SYSTEM BATTERY INSPECTION A6E471018520W02 Battery 1. Inspect the battery in the following procedure. Step Inspection Result Action More than Go to 12.4 V Step 3. Measure open circuit voltage of battery. Less than Go to 12.4 V next step. More than Go to 12.4 V...
Page 374: Battery Recharging
CHARGING SYSTEM BATTERY RECHARGING A6E471018520W03 Warning • Keep any flammable away from the battery, otherwise evaporated gas of the battery fluid may catch fire, and cause serious injury or death. Caution • When removing the battery, disconnect the negative battery cable first and install it last to prevent damage to electrical components or the battery.
Page 375: Generator Removal/Installation
CHARGING SYSTEM GENERATOR REMOVAL/INSTALLATION A6E471018300W01 Warning • When the battery cables are connected, touching the vehicle body with generator terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components. Always disconnect the battery negative cables before performing the following operation. Caution •...
Page 376: Generator Inspection
CHARGING SYSTEM GENERATOR INSPECTION A6E471018300W02 Generator Warning Light 1. Verify that the battery is fully charged. • Charge if necessary. 2. Verify that the drive belt deflection/tension is correct. (See B–3 DRIVE BELT INSPECTION.) • If not as specified, replace the drive belt. 3.
Page 377: Ignition System
CHARGING SYSTEM , IGNITION SYSTEM Standard current (Reference) Measuring conditions Room temperature: 20 °C {68 °F} Voltage: 13.5 V Engine hot Engine Terminal B current (A) speed (rpm) 1,000 0*—80 2,000 0*—90 * : Must not be 0 A End Of Sie IGNITION SYSTEM IGNITION COIL REMOVAL/INSTALLATION A6E471218110W01...
Page 378: Ignition Coil Inspection
IGNITION SYSTEM IGNITION COIL INSPECTION Primary Coil Winding 1. Remove the ignition coil. 2. Measure the resistance between the following lead holes using an ohmmeter. • A and B, B and C — If not specified, replace the ignition coil. Specification 0.49—0.57 ohms [20°C {68°F}] A6E4712W003...
Page 379: Spark Plug Removal/Installation
IGNITION SYSTEM Insulation Resistance of Case 1. Disconnect the high-tension lead. 2. Disconnect the ignition coil connector. 3. Measure the insulation resistance between the following terminals and ignition coil case using an ohmmeter. • Terminal B and ignition coil case. —...
Page 380: Spark Plug Inspection
IGNITION SYSTEM G– 1 0 E NGINE ELECTRICAL SYSTEM IGNITION SYSTEM SPARK PLUG REMOVAL/INSTALLATION A6E471218110W03A 6. Install the plug hole plate. Caution • If the plug hole plate interferes with metal clips and the accelerator cable, the cable could be damaged, so when installing follow the procedure below.
Page 381: Starting System
STARTING SYSTEM G E NGINE ELECTRICAL SYSTEM STARTING SYSTEM STARTER REMOVAL/INSTALLATION A6E471418400W01 Warning • When the battery cables are connected, touching the vehicle body with starter terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components. Always disconnect the battery negative cables before performing the following operation.
Page 382: Starter Inspection
STARTING SYSTEM STARTER INSPECTION A6E471418400W02 On-vehicle Inspection 1. Verify that the battery is fully charged. 2. Crank the engine and verify that the starter rotates smoothly without any noise. • If not, inspect the following. — Remove the starter and inspect the magnetic switch and the starter. —...
Page 383 C LUTCH LOCATION INDEX ..........H-2 CLUTCH LOCATION INDEX .......H-2 GENERAL PROCEDURES ........H-3 PRECAUTION (CLUTCH)........H-3 CLUTCH FLUID ............H-4 CLUTCH FLUID INSPECTION ......H-4 CLUTCH FLUID REPLACEMENT .......H-4 CLUTCH PEDAL ............H-5 CLUTCH PEDAL ADJUSTMENT......H-5 CLUTCH PEDAL REMOVAL/INSTALLATION..H-6 CLUTCH MASTER CYLINDER ......H-7 CLUTCH MASTER CYLINDER REMOVAL/ INSTALLATION..........H-7 CLUTCH MASTER CYLINDER DISASSEMBLY/ ASSEMBLY............H-8...
Page 384: Location Index
LOCATION INDEX LOCATION INDEX CLUTCH LOCATION INDEX A6E490001036W01 A6E4900W001 Clutch pedal Clutch release cylinder (See H–5 CLUTCH PEDAL ADJUSTMENT) (See H–9 CLUTCH RELEASE CYLINDER (See H–6 CLUTCH PEDAL REMOVAL/ REMOVAL/INSTALLATION) INSTALLATION) (See H–10 CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY) Clutch master cylinder (See H–7 CLUTCH MASTER CYLINDER Clutch unit...
Page 385: General Procedures
LOCATION INDEX, GENERAL PROCEDURES Clutch disc (See H–14 CLUTCH DISC INSPECTION) Clutch release collar (See H–14 CLUTCH RELEASE COLLAR INSPECTION) Flywheel (See H–15 FLYWHEEL INSPECTION) Clutch fluid (See H–4 CLUTCH FLUID INSPECTION) (See H–4 CLUTCH FLUID REPLACEMENT) End Of Sie GENERAL PROCEDURES PRECAUTION (CLUTCH) A6E491016003W01...
Page 386: Clutch Fluid
CLUTCH FLUID CLUTCH FLUID CLUTCH FLUID INSPECTION A6E491216010W01 Note • A common reservoir is used for the clutch and brake system fluid. • The fluid in the reservoir must be maintained between the MIN/MAX level during replacement. End Of Sie CLUTCH FLUID REPLACEMENT A6E491216010W02 Caution...
Page 387: Clutch Pedal
CLUTCH PEDAL CLUTCH PEDAL CLUTCH PEDAL ADJUSTMENT A6E491441030W01 Clutch Pedal Height 1. Measure the distance from the upper surface of the pedal pad to the carpet. • If not as specified, adjust the pedal height by turning adjustment bolt B and locknut A. Pedal height(with carpet) L.H.D.: 216—222 mm {8.50—8.74 in} R.H.D.: 229—235 mm {9.02—9.25 in}...
Page 388: Clutch Pedal Adjustment
CLUTCH PEDAL 6. Hold the pedal when the gear noise stops (clutch pedal disengagement point). 7. Measure distance A (the distance from the clutch pedal disengagement point to the fully depressed position) and the pedal stroke. 8. Verify that they are within specification. •...
Page 389: Clutch Master Cylinder
CLUTCH PEDAL, CLUTCH MASTER CYLINDER Pedal pad Clutch pedal (See H–7 Clutch Pedal Installation Note) Clutch Pedal Installation Note 1. After installation, adjust the pedal height and free play. (See H–5 CLUTCH PEDAL ADJUSTMENT.) End Of Sie CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION A6E491641990W01 1.
Page 390: Clutch Master Cylinder Disassembly/Assembly
CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY A6E491641990W02 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. A6E4916W002 Clip Piston and secondary cap component Hose Spacer Joint Primary cap Bushing Return spring Snap ring Clutch master cylinder body (See...
Page 391: Clutch Release Cylinder
CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION A6E491841920W01 1. Remove the under cover. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. A6E4918W001 Clutch pipe Clutch release cylinder Bolt End Of Sie H–9...
Page 392: Clutch Release Cylinder Disassembly/Assembly
CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY A6E491841920W02 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. A6E4918W002 Boot Bleeder cap Push rod Bleeder screw Piston and cap Release cylinder body Return spring End Of Sie H–10...
Page 393: Clutch Unit
CLUTCH UNIT CLUTCH UNIT CLUTCH UNIT REMOVAL/INSTALLATION A6E492016000W01 1. Remove in the order indicated in the table. 2. Install in the reverse order oremoval. A6E4920W001 Clutch release cylinder Clutch cover (See H–12 Clutch Cover and Disc Removal Note) Manual transaxle (See H–13 Clutch Cover Installation Note)
Page 394 CLUTCH UNIT Clutch Cover and Disc Removal Note 1. Install the SSTs. 2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released. 3. Remove the clutch cover and disc. A6E4920W002 Flywheel Removal Note 1.
Page 395: Clutch Cover Inspection
CLUTCH UNIT Clutch Disc Installation Note 1. Hold the clutch disc position using the SST. A6E4920W005 Clutch Cover Installation Note 1. Install the SSTs. 2. Tighten the bolts evenly and gradually in a crisscross pattern. Tightening torque 18.6—25.5 N·m {1.9—2.6 kgf·m, 14—19 ft·lbf} A6E4920W006 End Of Sie CLUTCH COVER INSPECTION...
Page 396: Clutch Disc Inspection
CLUTCH UNIT 4. Rotate the flywheel and check for misaligned diaphragm spring fingers. • If not as specified, replace the clutch cover. Misalignment 0.6 mm {0.024 in} max. XME4920W012 End Of Sie CLUTCH DISC INSPECTION A6E492016460W01 1. Using vernier calipers, measure the thickness of the lining at a rivet head on both sides.
Page 397: Flywheel
FLYWHEEL FLYWHEEL FLYWHEEL INSPECTION A6E492211500W01 1. Install a dial gauge on the cylinder block. 2. Measure the flywheel runout using a dial indicator. • If the runout is excessive, replace the flywheel. Runout 0.1 mm {0.004 in} max. XME4922W001 End Of Sie H–15...
Page 398 M ANUAL TRANSAXLE LOCATION INDEX ..........J-2 MANUAL TRANSAXLE LOCATION INDEX ..J-2 MANUAL TRANSAXLE.......... J-3 TRANSAXLE OIL INSPECTION ......J-3 TRANSAXLE OIL REPLACEMENT ..... J-3 OIL SEAL (DIFFERENTIAL) REPLACEMENT ..J-4 VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION ......J-4 VEHICLE SPEEDOMETER SENSOR INSPECTION ............
Page 399: Location Index
LOCATION INDEX LOCATION INDEX MANUAL TRANSAXLE LOCATION INDEX A6E510001036W01 A6E5100W001 Oil seal (differential) Manual transaxle (See J–4 OIL SEAL (DIFFERENTIAL) (See J–5 MANUAL TRANSAXLE REMOVAL/ REPLACEMENT) INSTALLATION) Vehicle speedometer sensor Shift mechanism (See J–4 VEHICLE SPEEDOMETER SENSOR (See J–9 SHIFT MECHANISM REMOVAL/ REMOVAL/INSTALLATION) INSTALLATION) (See...
Page 400: Manual Transaxle
MANUAL TRANSAXLE MANUAL TRANSAXLE TRANSAXLE OIL INSPECTION A6E511227001W01 1. Park the vehicle on level ground. 2. Remove the oil level plug and washer. 3. Verify that the oil is near the brim of the plug port. • If the oil level is lower than the low level, add the specified amount and type of oil through the oil level plug hole.
Page 401: Oil Seal (Differential) Replacement
MANUAL TRANSAXLE OIL SEAL (DIFFERENTIAL) REPLACEMENT A6E511219240W01 1. On level ground, jack up the vehicle and support it evenly on safety stands. 2. Drain the oil from the transaxle. 3. Remove the front wheels and splash shields. 4. Separate the drive shaft and joint shaft from the transaxle. (See M–17 DRIVE SHAFT REMOVAL/ INSTALLATION.) (See M–12 JOINT SHAFT...
Page 402: Vehicle Speedometer Sensor Inspection
MANUAL TRANSAXLE VEHICLE SPEEDOMETER SENSOR INSPECTION A6E511217400W02 Without ABS 1. Remove the vehicle speedometer sensor. 2. Measure voltage (AC range) between terminals of the vehicle speedometer sensor while the gear is turning. Meter needle Action Moves slightly under Repair wiring harness between 5 V (AC range) instrument cluster and vehicle speedometer sensor.
Page 403 MANUAL TRANSAXLE A6E5112W012 sensor connector Harness bracket Vehicle speedometer sensor connector Back-up light switch connector (GCC specs.) Neutral switch connector J–6...
Page 404 MANUAL TRANSAXLE Selector cable Joint shaft (See M–12 JOINT SHAFT REMOVAL/ Shift cable INSTALLATION.) Selector cable bracket No.1 engine mount Clutch release cylinder (See J–7 No.1 Engine Mount Bracket Removal Starter Note) (See J–8 No.1 Engine Mount and No.4 Engine Endplate cover Mount Bracket Installation Note)
Page 405 MANUAL TRANSAXLE Manual Transaxle Installation Note 1. Set the transaxle on a jack and lift into place. 2. Install the transaxle mounting bolts. 3. Tighten the SST (49 E017 5A0)so that the engine is located at the specified position. A6E5112W004 No.1 Engine Mount and No.4 Engine Mount Bracket Installation Note 1.
Page 406: Shift Mechanism
SHIFT MECHANISM SHIFT MECHANISM SHIFT MECHANISM REMOVAL/INSTALLATION A6E511446010W01 1. Remove the battery, battery tray and battery bracket. 2. Remove the air cleaner component. (See F–10 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 3. Remove the dashboard compleat. (See S–82 DASHBOARD REMOVAL/INSTALLATION.) 4. Remove the SAS control module. (See T–124 SAS UNIT REMOVAL/INSTALLATION.)
Page 407 SHIFT MECHANISM Select Cable Installation Note 1. Remove the center console. 2. Make sure that the shift lever (transaxle side) is in neutral. 3. Unlock the lock pice of the select cable (shift lever side) in the order shown in the figure. 4.
Page 408 A UTOMATIC TRANSAXLE LOCATION INDEX ..........K-4 SELECTOR LEVER AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION ......K-46-3 LOCATION INDEX..........K-4 SELECTOR LEVER AUTOMATIC TRANSAXLE........K-6 DISASSEMBLY/ASSEMBLY ......K-51 MECHANICAL SYSTEM TEST ......K-6 ON-BOARD DIAGNOSTIC ........K-52 ROAD TEST ............K-9 FOREWORD............K-52 AUTOMATIC TRANSAXLE FLUID (ATF) AUTOMATIC TRANSAXLE ON-BOARD INSPECTION ..........
Page 409 NO.7 NO SHIFTING.........K-120 NO.8 DOES NOT SHIFT TO FOURTH GEAR (4GR) ..........K-120 NO.9 ABNORMAL SHIFTING......K-122 NO.10 FREQUENT SHIFTING ......K-122 NO.11 SHIFT POINT IS HIGH OR LOW ..K-122 NO.12 TORQUE CONVERTER CLUTCH (TCC) NON-OPERATION ..... K-123 NO.13 NO KICKDOWN........K-123 NO.14 ENGINE FLARES UP OR SLIPS WHEN UPSHIFTING OR DOWNSHIFTING ..........K-124...
Page 410 K–3...
Page 411: Location Index
LOCATION INDEX LOCATION INDEX AUTOMATIC TRANSAXLE LOCATION INDEX A6E560001074W01 A6E5600W001 K–4...
Page 412 LOCATION INDEX HOLD switch Automatic transaxle (See K–13 HOLD SWITCH INSPECTION) (See K–29 AUTOMATIC TRANSAXLE REMOVAL/ (See K–14 HOLD SWITCH REMOVAL/ INSTALLATION) INSTALLATION) Oil seal Transaxle range (TR) switch (See K–33 OIL SEAL REPLACEMENT) (See K–14 TRANSAXLE RANGE (TR) SWITCH Control valve body INSPECTION) (See...
Page 413: Automatic Transaxle
AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE MECHANICAL SYSTEM TEST A6E561401030W01 Mechanical System Test Preparation 1. Engage the parking brake and use wheel chocks at the front and rear of the wheels. 2. Inspect the engine coolant. (See E–3 ENGINE COOLANT LEVEL INSPECTION.) 3.
Page 414 AUTOMATIC TRANSAXLE 15. Remove the SSTs. 16. Install a new square head plug in the inspection port. Tightening torque 5.0—9.8 N·m {50—100 kgf·cm, 44—86 in·lbf} Evaluation of line pressure test Line pressure Possible cause Worn oil pump Oil leaking from oil pump, control valve body, and/or transaxle case Pressure regulator valve sticking Low pressure in all ranges Pressure control solenoid malfunction...
Page 415 AUTOMATIC TRANSAXLE Evaluation of stall test Condition Possible cause Worm oil pump Oil leaking from oil pump, control valve, and/ or transaxle case In all forward ranges and R Insufficient position line pressure Pressure regulator valve sticking Pressure control solenoid malfunction Pressure modulator valve sticking Forward clutch slippage In forward ranges...
Page 416: Road Test
AUTOMATIC TRANSAXLE ROAD TEST A6E561401030W02 Warning • When performing a road test, be aware of other vehicles, people, impediments, etc. to avoid an accident. Note • When the legal speed limit must be exceeded, use a chassis dynamomenter instead of performing a road test.
Page 417 AUTOMATIC TRANSAXLE 8. Accelerate the vehicle at half throttle and WOT, and verify that 4→3, 3→2, and 2→3 shift can be obtained. The shift points must be as shown in the table below. • If not as specified, inspect the PCM and ATX. (See K–113 SYMPTOM TROUBLESHOOTING ITEM TABLE.) 9.
Page 418 AUTOMATIC TRANSAXLE 7. Accelerate the vehicle in 2GR at half throttle and WOT, and verify that 2GR is held. • If not as specified, inspect the PCM and ATX. (See K–113 SYMPTOM TROUBLESHOOTING ITEM TABLE.) 8. Decelerate the vehicle and verify that engine braking effect is felt. •...
Page 419: Automatic Transaxle Fluid (Atf) Inspection
AUTOMATIC TRANSAXLE P Position Test 1. Shift into P position on a gentle slope. Release the brake and verify that the vehicle does not roll. End Of Sie AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION A6E561401030W03 Automatic Transaxle Fluid (ATF) Condition Inspection 1.
Page 420: Automatic Transaxle Fluid (Atf) Replacement
AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT A6E561401030W04 Warning • When the transaxle and ATF are hot, they can badly burn you. Turn off the engine and wait until they are cool before changing the ATF. 1. Remove the oil dipstick. 2.
Page 421: Hold Switch Removal/Installation
AUTOMATIC TRANSAXLE Continuity Inspection of 1. Disconnect the negative battery cable. 2. Remove the console. 3. Disconnect the HOLD switch connector. 4. Inspect continuity at the HOLD switch. • If the switch is okay, inspect the wiring harness. (HOLD switch—PCM, HOLD switch—Body ground) •...
Page 422: Transaxle Range (Tr) Switch Removal/Installation
AUTOMATIC TRANSAXLE 3. Disconnect the TR switch connector. A6E5614W008 4. Inspect for continuity at the TR switch. • If not as specified, adjust the TR switch and go to Step 4. 5. Reinspect for continuity at TR switch. • If not as specified, replace the TR switch. (See K–15 TRANSAXLE RANGE (TR) SWITCH...
Page 423 AUTOMATIC TRANSAXLE 7. Remove the manual shaft lever. 8. Remove the TR switch. A6E5614W012 9. Rotate the manual shaft to the converter housing side fully, then return 2 notches to set the N position. A6E5614W013 10. Turn the protrusion at resistance between the terminals B and C become 750 ohms.
Page 424 AUTOMATIC TRANSAXLE 13. Inspect the resistance between the terminals B and C. • If not as specified, readjust the TR switch. (See K–18 TRANSAXLE RANGE (TR) SWITCH ADJUSTMENT.) Resistance 750 ohms 14. Tighten the TR switch mounting bolts. Tightening torque A6E5614W010 8—11 N·m {82—112 kgf·cm, 71—97 in·lbf} Caution...
Page 425: Transaxle Range (Tr) Switch Adjustment
AUTOMATIC TRANSAXLE 20. Connect the selector cable. 21. Inspect for continuity at the TR switch. (See K–14 TRANSAXLE RANGE (TR) SWITCH INSPECTION.) • If not as specified, readjust the TR switch. (See K–18 TRANSAXLE RANGE (TR) SWITCH ADJUSTMENT.) 22. Connect the TR switch connector. 23.
Page 426: Transaxle Fluid Temperature (Tft) Sensor Inspection
AUTOMATIC TRANSAXLE 6. Loosen the TR switch mounting bolts. A6E5614W020 7. Measure the resistance between the terminals B and C. 8. Adjust the switch to the point as follow. Resistance standard value 750 ohms 9. Tighten the TR switch mounting bolts. Tightening torque 8—11 N·m {82—112 kgf·cm, 71—97 in·lbf} A6E5614W010...
Page 427 AUTOMATIC TRANSAXLE 3. Disconnect the transaxle connector. A6E5614W021 4. Measure the resistance between the terminals E and H. • If it is out of specification, perform the off- vehicle inspection of TFT sensor. (See K–21 TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR REMOVAL/INSTALLATION.) ATF temperature (°C {°F}) Resistance (kilohm)
Page 428: Transaxle Fluid Temperature (Tft) Sensor Removal/Installation
AUTOMATIC TRANSAXLE 5. Measure resistance between the terminals of the TFT sensor. • If not as specified, replace the TFT sensor. (See K–21 TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR REMOVAL/ INSTALLATION.) ATF temperature (°C {°F}) Resistance (kilohm) -20 {-4} 236—324 0 {32} 84.3—110 20 {68} 33.5—42.0...
Page 429 AUTOMATIC TRANSAXLE 3. Disconnect the cord assembly connector. A6E5614W026 4. Verify that there is no continuity between cord assembly terminal and ground. • If as continuity, inspect the cord assembly. • If the cord assembly is okay, inspect the oil pressure switch.
Page 430: Oil Pressure Switch Removal/Installation
AUTOMATIC TRANSAXLE Off-vehicle inspection 1. Remove the oil pressure switch. 2. Apply air pressure at 400—440 kPa {4.1—4.4kgf/cm ,58—63psi} 3. Inspect continuity the between oil pressure switch terminal and screw part. • If not as continuity, replace the oil pressure switch.
Page 431: Input/Turbine Speed Sensor Removal/Installation
AUTOMATIC TRANSAXLE 5. Measure resistance between the terminals of the input/turbine speed sensor. • If not as specified, replace the input/turbine speed sensor. Resistance 250—600 ohms (ATF temperature: –40—160 °C {–40—320 °F}) 6. Connect the input/turbine speed sensor connector. 7. Install the air cleaner component. (See F–10 A6E5614W031 INTAKE-AIR SYSTEM REMOVAL/...
Page 432 AUTOMATIC TRANSAXLE 6. Inspect wave profile. • PCM terminal: 3C (+) - 1D (-) • Oscilloscope setting: 1 V/DIV (Y), 2.5 ms/DIV (X), DC range • Vehicle condition: drive the vehicle with 32 km/h{20 mph} — If wave profile or voltage are out of specifications, carry out the “Open Circuit Inspection”...
Page 433: Vehicle Speedometer Sensor (Vss) Removal/Installation
AUTOMATIC TRANSAXLE VEHICLE SPEEDOMETER SENSOR (VSS) REMOVAL/INSTALLATION A6E561401030W06 Caution • Water or foreign objects entering the connector can cause a poor connection or corrosion. Be sure not to drop water or foreign objects on the connector when disconnecting it. • If foreign materials are stuck to the VSS, disturbance by magnetic flux can cause sensor output to be abnormal and thereby negatively affect control.
Page 434 AUTOMATIC TRANSAXLE 4. Measure the resistance between the following terminals. • If not as specified, inspect the ground, then perform the operating inspection. ATF temperature: –40—150 °C {–40—302 °F} Resistance Terminal Solenoid valve (ohm) A—GND Shift solenoid A 1.0—4.2 C—GND Shift solenoid B 1.0—4.2 G—GND...
Page 435: Solenoid Valve Removal/Installation
AUTOMATIC TRANSAXLE Pressure control solenoid Resistance 2.4—7.3 ohms (ATF temperature: –40—150 °C {–40—302 °F}) A6E5614W041 Shift solenoid A, B, C Resistance 1.0—4.2 ohms (ATF temperature: –40—150 °C {–40—302 °F}) A6E5614W042 Shift solenoid D, E Resistance 10.9—26.2 ohms (ATF temperature: –40—150 °C {–40—302 °F}) A6E5614W043 End Of Sie...
Page 436: Pcm Inspection
AUTOMATIC TRANSAXLE 6. Install the solenoid valve in the control valve body. Tightening torque 7.8—10.8 N·m {80—110 kgf·cm, 70—95.4 in·lbf} 7. Install the control valve body. (See K–34 CONTROL VALVE BODY REMOVAL.) 8. Install the under cover. 9. Connect the negative battery cable. 10.
Page 437 AUTOMATIC TRANSAXLE A6E5614W046 sensor connector Oil pressure switch connector (for ATX) Input/turbin speed sensor connector Oil pressure switch connector (for oil filter) K–30...
Page 438 AUTOMATIC TRANSAXLE TR switch connector Drive shaft (See M–17 DRIVE SHAFT REMOVAL/ Transaxle connector INSTALLATION) VSS connector Joint shaft Oil dipstick and filler tube (See M–12 JOINT SHAFT REMOVAL/ Harness bracket INSTALLATION) Oil hose No.1 engine mount (See K–31 No.1 Engine Mount Bracket Removal Selector cable Note) Transaxle mounting bolt (upper side)
Page 439 AUTOMATIC TRANSAXLE 4. Remove the transaxle. A6E5614W051 Transaxle Installation Note 1. Set the transaxle on a jack and lift it. 2. Install the transaxle mounting bolts. Tightening torque 37.3—52 N·m {3.8—5.3 kgf·m, 28—38 ft·lbf} A6E5614W052 Torque Converter Nuts Removal Note 1.
Page 440: Oil Seal Replacement
AUTOMATIC TRANSAXLE Torque Converter Nuts Installation Note 1. Hold the cankshaft pulley to prevent drive plate from rotating. Caution • Loosely and equally tighten the torque converter nuts, then further tighten them to the specified tightening torque. A6E5614W091 2. Tighten the torque converter mounting nuts. Tightening torque 34.3—60.8 N·m {3.5—6.2 kgf·m, 25—45 ft·lbf} A6E5614W092...
Page 441: Control Valve Body Removal
AUTOMATIC TRANSAXLE • The oil seal is easily damaged by the sharp edges of the drive shaft splines. Do not let the splines contact the oil seal. 2. Remove the drive shaft. (See M–17 DRIVE SHAFT REMOVAL/INSTALLATION.) 3. Remove the oil seal. 4.
Page 442: Control Valve Body Installation
AUTOMATIC TRANSAXLE 10. Remove the accumulators and accumulator springs. A6E5614W059 End Of Sie CONTROL VALVE BODY INSTALLATION A6E561421100W02 On-Vehicle Installation Caution • Be sure to align the parking rod and the manual valve. A6E5614W060 1. Install the accumulator springs and accumulators into the transaxle case.
Page 443: Oil Cooler Flushing
AUTOMATIC TRANSAXLE 2. Install the control valve body component. Tightening torque 7.8—10.8 N·m {80—110 kgf·cm, 70—95 in·lbf} Bolt length (measured from below the head) B: 40 mm {1.575 in} No mark: 70 mm {2.756 in} 3. Install the oil strainer. 4.
Page 444 AUTOMATIC TRANSAXLE 1. Remove the two oil cooler line hoses and apply air pressure of 196 kPa {2.0 kgf/cm , 28 psi} from the return hose (pipe) side. Caution • Power flushing should be performed very carefully when removing the accumulated debris from the fluid baffle, otherwise the debris cannot be removed or the problem becomes even worse.
Page 445 AUTOMATIC TRANSAXLE Power Flushing Repair procedure 1. Before power flushing, inspect the hoses/lines and clamps. Power flushing must begin with back flushing followed by forward flushing to quickly dislodge the restriction. If back flushing is not performed before forward flushing, the restriction could further reduce the ATF flow through the internal mesh type baffle of the cooler and flushing will not be effective or possible.
Page 446: Oil Cooler Removal/Installation
AUTOMATIC TRANSAXLE OIL COOLER REMOVAL/INSTALLATION A6E561419900W02 1. Disconnect the negative battery cable. 2. Drain the ATF into a container. (See K–13 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT.) 3. Remove the radiator. (See E–6 RADIATOR REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5.
Page 447 AUTOMATIC TRANSAXLE WITHOUT OIL COOLER A6E5614W080 Oil hose O-ring (See K–40 Oil Pipe, Hose Clamp, Oil Hose Radiator (in tank oil cooler) Installation Note.) (See K–40 Radiator (In Tank Oil Cooler) Installation Hose clamp Note.) (See K–40 Oil Pipe, Hose Clamp, Oil Hose Installation Note.) Connector bolt...
Page 448: Oil Cooler Disassembly/Assembly
AUTOMATIC TRANSAXLE 2. Align the marks, and slide the oil hose onto the oil pipe until it is fully seated as shown. Note • If reusing the hose, install the new hose clamp exactly on the mark left by the previous hose camp.Then apply force to the hose clamp in the direction of the arrow in order to fit the clamp in the place.
Page 449 AUTOMATIC TRANSAXLE Radiator Outer Tank (In Tank Oil Cooler) Removal Note 1. Inspect the height of the header tabs. 2. Insert the end of a medium tip screwdriver between the end of the header tab and the outer tank. Note •...
Page 450: Drive Plate Removal/Installation
AUTOMATIC TRANSAXLE 4. Squeeze the header tabs down in order as shown against the lip of radiator outer tank base with locking-type pliers while rotating the pliers toward the tank. A6E5614W076 5. Verify the height of the header tabs is same as the height before removal.
Page 451 AUTOMATIC TRANSAXLE Drive Plate Mounting Bolts Removal Note 1. Set the SST or equivalent against the drive plate. 2. Remove the bolts and the drive plate. A6E5614W079 Drive Plate Installation Note Caution • If the bolts are reused, remove the oil sealant from the bolt threads. Tightening a bolt that has old sealant on it can cause thread damage.
Page 452: Automatic Transaxle Shift Mechanism
AUTOMATIC TRANSAXLE SHIFT MECHANISM AUTOMATIC TRANSAXLE SHIFT MECHANISM SHIFT-LOCK INSPECTION A6E561630000W01 1. Turn the ignition switch to ON position. 2. Verify that the selector lever is in P position. 3. Depress the brake pedal and verify that the selector lever can be shifted from P position. •...
Page 453: Interlock Cable Adjustment
AUTOMATIC TRANSAXLE SHIFT MECHANISM End Of Sie INTERLOCK CABLE ADJUSTMENT BHE051409000W03 1. Turn the ignition switch to ON position (engine OFF). 2. Pull up the lock piece of the interlock cable to release the lock. A6E5616W010 3. Remove the clip of the selector lever base plate, then remove the interlock cable from the U- groove.
Page 454 AUTOMATIC TRANSAXLE SHIFT MECHANISM AUTOMATIC TRANSAXLE K – 4 6 8. Push the snap pin (or a φ1.5 round bar or AUTOMATIC TRANSAXLE SHIFT MECHANISM INTERLOCK CABLE ADJUSTMENT BHE051409000W03A LOCK UNIT INTERLOCK simular.) into hole A by fully pushing the slider pin CABLE 9.
Page 455: Selector Lever Inspection
AUTOMATIC TRANSAXLE SHIFT MECHANISM 18. Press the interlock cable lock piece in until it is locked. LOCK PIECE Caution • Applying a load to the interlock cable while pressing the lock piece in can affect the lock unit operation. INTERLOCK CABLE UNLOCK LOCK A6E5616W012...
Page 456: Selector Cable Adjustment
AUTOMATIC TRANSAXLE SHIFT MECHANISM SELECTOR CABLE ADJUSTMENT A6E561646102W02 1. Remove the center console. 2. Shift the selector lever to P position. 3. Unlock the lock piece of the selector cable (selector lever side) in the order shown in the figure. 4.
Page 457 AUTOMATIC TRANSAXLE SHIFT MECHANISM AUTOMATIC TRANSAXLE SHIFT MECHANISM K A UTOMATIC TRANSAXLE 1. Install in the reverse order of removal. A6E5616W005 Column cover(with key interlock) Selector cable (See K–48 Selector Cable Removal Note.) Clip(with key interlock) (See K–48 Selector Cable Installation Note.) Clip(with key interlock) Selector lever...
Page 458 AUTOMATIC TRANSAXLE SHIFT MECHANISM Selector Cable Removal Note 1. Remove the clip. 2. Remove the selector cable. A6E5616W006 Selector Cable Installation Note 1. Install the selector cable to the selector lever certainly. 2. Install the selector cable to the bracket certainly. Note •...
Page 459 AUTOMATIC TRANSAXLE SHIFT MECHANISM Caution • Bending the selector cable in the manner shown in the figure will damage the cable and it may become loose when shifted. When installing the selector cable, hold it straight. Note • Install the selector lever to the manual shaft lever with the spring side of the selector cable end facing the front of the vehicle.
Page 460 AUTOMATIC TRANSAXLE SHIFT MECHANISM 9. Pull the slider pin outward until it contacts the MARKING brake pedal stopper rubber and rotate the slider SLIDER PIN pin to lock. 10. Verify that the shift the selector lever in P position. MARKING STOPPER RUBBER BHE0514W011...
Page 461 AUTOMATIC TRANSAXLE SHIFT MECHANISM AUTOMATIC TRANSAXLE SHIFT MECHANISM K – 5 0 A UTOMATIC TRANSAXLE SELECTOR LEVER REMOVAL/INSTALLATION Interlock Cable Installation Note A6E561646102W03B 15. Connect the brake switch connector with the brake pedal released. Caution • The clearance between the brake switch and the brake pedal is automatically adjusted to the correct amount when the brake switch connector is connected after the brake switch has been properly installed.
Page 462: Selector Lever Disassembly/Assembly
AUTOMATIC TRANSAXLE SHIFT MECHANISM AUTOMATIC TRANSAXLE SHIFT MECHANISM K A UTOMATIC TRANSAXLE SELECTOR LEVER DISASSEMBLY/ASSEMBLY A6E561646102W04 1. Disassemble in the order shown in the figure. 2. Assemble in the reverse order of disassembly. A6E5616W015 Connector Indicator panel (See K–51 Connector Disassembly Note.) Selector illumination light Selector lever knob component...
Page 463: On-Board Diagnostic
ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC FOREWORD A6E567001030W01 • When the customer reports a vehicle malfunction, check the malfunction indicator lamp (MIL), HOLD indicator light flashing, and PCM memory for diagnostic trouble code (DTC), then diagnose the malfunction according to following flowchart. —...
Page 464 ON-BOARD DIAGNOSTIC 9. Drive the vehicle in D range and shift gears between 1st and 4th (TCC operation) gear. 10. Gradually slow down and stop the vehicle. 11. Make sure that the repaired DTC does not recur. End Of Sie DTC TABLE A6E567001030W04 HOLD...
Page 465: Dtc P0500
ON-BOARD DIAGNOSTIC HOLD indicator Monitor Memory DTC No. Condition Page light item function flashes VSS circuit malfunction (MTX) (See F–67 DTC TABLE) P0500 (See K–55 DTC × VSS circuit malfunction (ATX) P0500) P0505 Idle control system malfunction (See F–67 DTC TABLE) P0506 Idle control system RPM lower than expected...
Page 466 ON-BOARD DIAGNOSTIC HOLD indicator Monitor Memory DTC No. Condition Page light item function flashes (See K–95 DTC × P0762 Shift solenoid C stuck ON P0762) (See K–96 DTC × P0763 Shift solenoid C malfunction (electrical) P0763) (See K–99 DTC × P0766 Shift solenoid D stuck OFF P0766)
Page 467 ON-BOARD DIAGNOSTIC DTC P0500 Vehicle speed sensor (VSS) circuit malfunction Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME PID DATA on repair order, then • Has FREEZE FRAME PID DATA been go to next step.
Page 468: Dtc P0706
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT PCM CONNECTOR FOR POOR Yes Go to next step. CONNECTION Repair or replace pin or connector, then go to Step 10. • Disconnect PCM connector. • Check for poor connection (damaged/pulled- out terminals, corrosion, etc.). •...
Page 469: Dtc P0707
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME PID DATA on repair order, then • Has FREEZE FRAME PID DATA been go to next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair AVAILABILITY...
Page 470 ON-BOARD DIAGNOSTIC DTC P0707 Transaxle range (TR) switch circuit low input Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME PID DATA on repair order, then • Has FREEZE FRAME PID DATA been go to next step.
Page 471: Dtc P0708
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT TR SWITCH SIGNAL CIRCUIT FOR Yes Repair or replace harness for short to ground, then Go to SHORT TO GROUND step 7. • Turn ignition key to OFF. Go to next step. • Disconnect PCM connector •...
Page 472 ON-BOARD DIAGNOSTIC DTC P0708 Transaxle range (TR) switch circuit high input Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME PID DATA on repair order, then • Has FREEZE FRAME PID DATA been go to next step.
Page 473 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT TR SWITCH Yes Go to next step. • Turn ignition key to OFF. Adjust TR switch, then go to Step 9. • Disconnect TR switch connector. (See K–18 TRANSAXLE RANGE (TR) SWITCH • Inspect for resistance between TR switch ADJUSTMENT.) terminals B and C (part-side).
Page 474: Dtc P0711
ON-BOARD DIAGNOSTIC DTC P0711 A6E567001030W09 DTC P0711 Transaxle fluid temperature (TFT) sensor circuit range/performance (stuck) • When all conditions below are satisfied. — When 180 seconds have passed after engine is started, vehicle is driven for 150 seconds or more at vehicle speed between 25 –...
Page 475: Dtc P0712
ON-BOARD DIAGNOSTIC End Of Sie DTC P0712 A6E567001030W10 DTC P0712 Transaxle fluid temperature (TFT) sensor circuit malfunction (short to ground) • If PCM detects either of following conditions for 150 seconds or more, PCM determines that TFT sensor circuit has a malfunction. —...
Page 476: Dtc P0713
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY CURRENT INPUT SIGNAL STATUS Yes Go to intermittent concern troubleshooting procedure. • Turn ignition key to OFF. (See F–227 INTERMITTENT CONCERN • Connect breakout box to PCM. TROUBLESHOOTING.) • Turn ignition key to ON (engine OFF). Go to next step.
Page 477 ON-BOARD DIAGNOSTIC DTC P0713 Transaxle fluid temperature (TFT) sensor circuit malfunction (open circuit) • TFT sensor malfunction • Open circuit between TFT sensor terminal A and ATX connector terminal E • Open circuit between TFT sensor terminal B and ATX connector terminal H POSSIBLE •...
Page 478 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT TFT SENSOR CIRCUIT Yes Go to next step. • Turn ignition key to ON (engine OFF). Go to Step 8. • Measure the voltage at PCM terminal 3D when connect between ATX connector terminals E and H (vehicle harness-side) using jumper wire.
Page 479: Dtc P0715
ON-BOARD DIAGNOSTIC DTC P0715 A6E567001030W12 DTC P0715 Input/turbine speed sensor circuit malfunction • When all conditions below satisfied and 0.7 second or more have passed. — D, S or L range of TR switch input. — Driving vehicle with vehicle speed 40 km/h {25 mph} or above. —...
Page 480 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY CURRENT INPUT SIGNAL STATUS Yes Go to intermittent concern troubleshooting procedure. • Turn ignition key to OFF. (See F–227 INTERMITTENT CONCERN • Start engine. TROUBLESHOOTING.) • Measure frequency of input/turbine speed Go to next step. sensor using a oscilloscope.
Page 481: Dtc P0731
ON-BOARD DIAGNOSTIC DTC P0731 A6E567001030W13 DTC P0731 Gear 1 incorrect (Incorrect Gear Ratio Detected) • PCM monitors revolution ratio of forward clutch drum revolution to differential gear case revolution when the following monitoring conditions are met. If revolution ratio is below 2.157, PCM determines that there is malfunction.
Page 482: Dtc P0732
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT STALL SPEED Yes Go to next step. • Measure stall speed in D range. Replace automatic transaxle, then go to Step8. (See K–7 Stall Test.) (See K–29 AUTOMATIC TRANSAXLE REMOVAL/ Specification INSTALLATION.) 2,000—2,600 rpm •...
Page 483 ON-BOARD DIAGNOSTIC DTC P0732 Gear 2 incorrect (Incorrect Gear Ratio Detected) • ATF level low • Deteriorated ATF • Shift solenoids A, B or C stuck • Pressure control solenoid stuck • Line pressure low POSSIBLE • 2-4 brake band slipping CAUSE •...
Page 484: Dtc P0733
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY REPAIR OF DTC P0732 Yes Replace PCM, then go to next step. • Make sure to reconnect all disconnected Go to next step. connectors. • Clear DTC using WDS or equivalent. • Start engine. •...
Page 485 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION CHECK ATF LEVEL Yes Go to next step. • Start engine. Adjust ATF level, then go to Step 8. • Warm up ATX. • Is ATF level within specification? (See K–12 AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION.) INSPECTION SHIFT SOLENOID VALVE A AND Yes Go to next step.
Page 486: Dtc P0734
ON-BOARD DIAGNOSTIC DTC P0734 A6E567001030W16 DTC P0734 Gear 4 incorrect (Incorrect Gear Ratio Detected) • PCM monitors revolution ratio of forward clutch drum revolution to differential gear case revolution when the following monitoring conditions are met. If revolution ratio is below 0.6 or above 1.249, PCM determines that there is malfunction.
Page 487 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT LINE PRESSURE Yes Go to next step. • Start engine. All ranges: Replace oil pump, then go to Step 8. • Measure line pressures. Any ranges: Replace control valve body, then go to Step 8. Specification (See K–34 CONTROL VALVE BODY...
Page 488: Dtc P0741
ON-BOARD DIAGNOSTIC DTC P0741 A6E567001030W17 DTC P0741 Torque converter clutch (TCC) stuck OFF • When all conditions below satisfied. — ATF temperature 20 °C {68 °F} or above. — Driving in 4GR at D range. — Engine run. — Turbine speed within 225—4,988 rpm. —...
Page 489: Dtc P0742
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION CHECK OPERATION OF EACH VALVE AND Yes Replace ATX, then go to next step EACH SPRING (See ATX Workshop Manual FN4A-EL (9999-95-FN4A- • Turn ignition key to OFF. 99).) • Remove control valve body. Repair or replace shift valve and return spring, then go to •...
Page 490 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair AVAILABILITY information. • Check for related Service Bulletins availability. • If vehicle is not repaired, go to next step. • Is any related repair information available? Go to next step.
Page 491: Dtc P0745
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY AFTER REPAIR PROCEDURE Yes Go to applicable DTC inspection. • Perform “After Repair Procedure”. Troubleshooting completed. (See K–52 AFTER REPAIR PROCEDURE.) • Are any DTCs present? End Of Sie DTC P0745 A6E567001030W19 DTC P0745 Pressure control solenoid malfunction •...
Page 492 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair AVAILABILITY information. • Check for related Service Bulletins availability. • If vehicle is not repaired, go to next step. • Is any related repair information available? Go to next step.
Page 493: Dtc P0751
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0745 Yes Replace PCM, then go to next step. COMPLETED (See F–43 PCM REMOVAL/INSTALLATION.) • Make sure to reconnect all disconnected No concern is detected. Go to next step. connectors. • Clear DTC from memory using WDS or equivalent.
Page 494: Dtc P0752
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT LINE PRESSURE Yes Go to next step. • Start engine. • All ranges: Replace oil pump or control valve body, then • Measure line pressure. go to Step 7. Specification • Any ranges: Replace ATX, then go to Step 7. Idle: 330—470 kPa {3.4—4.7 kgf/cm , 49—66 (See...
Page 495 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME PID DATA on repair order, then • Has FREEZE FRAME PID DATA been go to next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair AVAILABILITY...
Page 496: Dtc P0753
ON-BOARD DIAGNOSTIC DTC P0753 A6E567001030W22 DTC P0753 Shift solenoid A malfunction (electrical) • If PCM detects either of following conditions, PCM determines that shift solenoid A circuit has a malfunction: — Shift solenoid A voltage is stuck at B+ after engine start. —...
Page 497 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME PID DATA on repair order, then • Has FREEZE FRAME PID DATA been go to next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair AVAILABILITY...
Page 498: Dtc P0756
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0753 Yes Replace PCM, then go to next step. COMPLETED (See F–43 PCM REMOVAL/INSTALLATION.) • Make sure to reconnect all disconnected No concern is detected. Go to next step. connectors. • Clear DTC from memory using WDS or equivalent.
Page 499 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT LINE PRESSURE Yes Go to next step. • Start engine. • All ranges: Replace oil pump or control valve body, then • Measure line pressure. go to Step 7. Specification • Any ranges: Replace ATX, then go to Step 7. Idle: 330—470 kPa {3.4—4.7 kgf/cm , 49—66 (See...
Page 500: Dtc P0757
ON-BOARD DIAGNOSTIC DTC P0757 A6E567001030W24 DTC P0757 Shift solenoid B stuck ON • When either of DTC P0731 and P0733 are not generated, and both the following conditions are satisfied. — When all conditions below satisfied while driving in 2GR. •...
Page 501: Dtc P0758
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT LINE PRESSURE Yes Go to next step. • Start engine. • All ranges: Replace oil pump or control valve body, then • Measure line pressure. go to Step 7. Specification • Any ranges: Replace ATX, then go to Step 7. Idle: 330—470 kPa {3.4—4.7 kgf/cm , 49—66 (See...
Page 502 ON-BOARD DIAGNOSTIC DTC P0758 Shift solenoid B malfunction (electrical) • Shift solenoid B malfunction • Short to ground between ATX connector terminal C and PCM terminal 4AC • Short to power between ATX connector terminal C and PCM terminal 4AC •...
Page 503 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT RESISTANCE Yes Go to Step 7. • Inspect resistance between ATX connector Go to next step. terminal C (transaxle case side) and body ground. • Is resistance within 1.0—4.2 ohms? (See K–26 Resistance Inspection (On-Vehicle Inspection).) INSPECT SHIFT SOLENOID B CONNECTOR Yes Go to next step.
Page 504: Dtc P0761
ON-BOARD DIAGNOSTIC DTC P0761 A6E567001030W26 DTC P0761 Shift solenoid C stuck OFF • When either of DTC P0733 and P0734 are not generated, and both the following conditions are satisfied. — When all conditions below satisfied while driving in 1GR. •...
Page 505 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT LINE PRESSURE Yes Go to next step. • Start engine. • All ranges: Replace oil pump or control valve body, then • Measure line pressure. go to Step 7. Specification • Any ranges: Replace ATX, then go to Step 7. Idle: 330—470 kPa {3.4—4.7 kgf/cm , 49—66 (See...
Page 506: Dtc P0762
ON-BOARD DIAGNOSTIC DTC P0762 A6E567001030W27 DTC P0762 Shift solenoid C stuck ON • When either of DTC P0731 and P0732 are not generated, and both the following conditions are satisfied. — When all conditions below satisfied while driving in 3GR. •...
Page 507: Dtc P0763
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT LINE PRESSURE Yes Go to next step. • Start engine. • All ranges: Replace oil pump or control valve body, then • Measure line pressure. go to Step 7. Specification • Any ranges: Replace ATX, then go to Step 7. Idle: 330—470 kPa {3.4—4.7 kgf/cm , 49—66 (See...
Page 508 ON-BOARD DIAGNOSTIC DTC P0763 Shift solenoid C malfunction (electrical) Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME PID DATA on repair order, then • Has FREEZE FRAME PID DATA been go to next step.
Page 509 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT SHIFT SOLENOID C CONNECTOR Yes Go to next step. FOR POOR CONNECTION Repair or replace connector and/or terminal, then go to • Disconnect shift solenoid C connector. Step 11. • Check for poor connection (damaged/pulled- out terminals, corrosion, etc.).
Page 510: Dtc P0766
ON-BOARD DIAGNOSTIC DTC P0766 A6E567001030W29 DTC P0766 Shift solenoid D stuck OFF • When any of DTC P0731, P0732, and P0733 not output (correct judgment), and all conditions below are satisfied. — ATF temperature 20 °C {68 °F} or above. —...
Page 511: Dtc P0767
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION CHECK OPERATION OF EACH VALVE AND Yes Replace ATX, then go to next step. EACH SPRING (See K–29 AUTOMATIC TRANSAXLE REMOVAL/ • Turn ignition key to OFF. INSTALLATION.) • Remove control valve body. (See ATX Workshop Manual FN4A-EL (9999-95-FN4A- •...
Page 512 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME PID DATA on repair order, then • Has FREEZE FRAME PID DATA been go to next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair AVAILABILITY...
Page 513: Dtc P0768
ON-BOARD DIAGNOSTIC DTC P0768 A6E567001030W31 DTC P0768 Shift solenoid D malfunction (electrical) • If PCM detects either of following conditions while driving in 4GR at D range, PCM determines that shift solenoid D circuit has a malfunction: — Shift solenoid D voltage is stuck at B+ after engine start. —...
Page 514 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair AVAILABILITY information. • Check for related Service Bulletins availability. • If vehicle is not repaired, go to next step. • Is any related repair information available? Go to next step.
Page 515: Dtc P0771
ON-BOARD DIAGNOSTIC DTC P0771 A6E567001030W32 DTC P0771 Shift solenoid E stuck OFF • When any of P0731, P0732, and P0734 are not generated, and all conditions below are satisfied. — ATF temperature 20 °C {68 °F} or above. — Driving in 4GR at D range. —...
Page 516: Dtc P0772
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION CHECK OPERATION OF EACH VALVE AND Yes Replace ATX, then go to next step. EACH SPRING (See K–29 AUTOMATIC TRANSAXLE REMOVAL/ • Turn ignition key to OFF. INSTALLATION.) • Remove control valve body. (See ATX Workshop Manual FN4A-EL (9999-95-FN4A- •...
Page 517 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME PID DATA on repair order, then • Has FREEZE FRAME PID DATA been go to next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair AVAILABILITY...
Page 518: Dtc P0773
ON-BOARD DIAGNOSTIC DTC P0773 A6E567001030W34 DTC P0773 Shift solenoid E malfunction (electrical) • If PCM detects either of following conditions while driving in 4GR at D range with TCC operation, PCM determines that shift solenoid E circuit has a malfunction: —...
Page 519 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT ATX CONNECTOR FOR POOR Yes Go to next step. CONNECTION Repair or replace connector and/or terminals, then go to • Turn ignition key to OFF. Step 11. • Disconnect ATX connector. • Check for poor connection (damaged/pulled- out terminals, corrosion, etc.).
Page 520: Dtc P0841
ON-BOARD DIAGNOSTIC DTC P0841 A6E567001030W35 DTC P0841 Oil pressure switch circuit malfunction • When each of DTC P0731, P0732, P0733 and P0734 are not generated and 10 seconds or more passed. — When all conditions below satisfied while driving in 1GR, 2GR or 3GR. •...
Page 521: Pid/Data Monitor Inspection
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT OIL PRESSURE SWITCH Yes Go to next step. CONNECTOR FOR POOR CONNECTION Repair or replace connector and/or terminal, then go to • Disconnect shift oil pressure switch connector. Step 7. • Check for poor connection (damaged/pulled- out terminals, corrosion, etc.).
Page 522 ON-BOARD DIAGNOSTIC PID/DATA MONITOR AND RECORD function table Monitor item Unit/ Condition/Specification Action (Definition) Condition terminal 1GR: 1 Inspect following PIDs: SSA/SS1, SSB/ 3P, 3S, 2GR: 2 SS2, SSC/SS3, SSD/SS4, SSE/SS5 GEAR — 3Y, 4Y, 3GR: 3 4AB, 4AC 4GR: 4 Inspect following PIDs: LINEDES inHg Indicates target line pressure...
Page 523: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING FOREWORD A6E568001030W01 • Refer to Section GI and thoroughly read and understand the basic flow of troubleshooting in order to properly perform the procedures. End Of Sie BASIC INSPECTION A6E568001030W02 STEP INSPECTION ACTION Perform the mechanical system test. Yes Go to next step.
Page 524: Symptom Troubleshooting Item Table
TROUBLESHOOTING SYMPTOM TROUBLESHOOTING ITEM TABLE A6E568001030W03 • Use the chart below to verify the symptoms of the trouble in order to diagnose the appropriate area. TROUBLESHOOTING ITEM DESCRIPTION PAGE Vehicle does not move in D, S, L Vehicle does not move when AP depressed. (See K–117 NO.1 VEHICLE ranges, or in R position DOES NOT MOVE IN D, S, L...
Page 525 TROUBLESHOOTING TROUBLESHOOTING ITEM DESCRIPTION PAGE Excessive shift shock is given when Excessive shift shock is felt when (See K–127 NO.18 upshifting and downshifting depressing accelerator pedal to accelerate EXCESSIVE SHIFT SHOCK IS at upshifting. FELT WHEN UPSHIFTING During cruising, excessive shift shock is felt DOWNSHIFTING.) when depressing accelerator pedal at downshifting.
Page 526 TROUBLESHOOTING QUICK DIAGNOSIS CHART A6E568001030W04 A6E5680W001 K–115...
Page 527 TROUBLESHOOTING A6E5680W002 End Of Sie K–116...
Page 528 TROUBLESHOOTING NO.1 VEHICLE DOES NOT MOVE IN D, S, L RANGES, OR IN R POSITION A6E568001030W05 Vehicle does not move in D, S, L ranges, or in R position • Vehicle does not move when AP depressed. DESCRIPTION • If the vehicle does not move in D, S, L ranges or R position, basically, the malfunction is in the ATX. (Vehicle will move even with a malfunction in the PCM.) Since a malfunction is in the sensor circuit or output circuit is the cause of the malfunction in the ATX, inspect the sensors, output circuit, and the related harnesses.
Page 529 TROUBLESHOOTING STEP INSPECTION ACTION Disconnect PCM. Yes Go to next step. Is resistance between ground terminal at PCM Repair open ground circuit. connector and body ground less than 5.0 Reconnect PCM. ohms? Check LPS PID value using WDS or equivalent. Yes Overhaul control valve body and repair or replace any Is LPS PID value okay? defective parts.
Page 530 TROUBLESHOOTING STEP INSPECTION ACTION Check the value at the following PID using the Yes Go to next step. WDS or equivalent. Repair or replace any defective parts. (See F–45 PCM INSPECTION.) • TP Is PID value okay? Disconnect PCM. Yes Go to next step. Is resistance between ground terminal at PCM Repair open ground circuit.
Page 531 TROUBLESHOOTING STEP INSPECTION ACTION Disconnect solenoid connector. Yes Go to next step. Does vehicle operate as follows? Overhaul control valve body and repair or replace any defective parts. If problem remains, overhaul transaxle and D, S ranges: 3GR (fixed) L range: 1GR (fixed) repair or replace any defective parts.
Page 532 TROUBLESHOOTING • Basically, TCC does not operate when fail-safe is operating. Verify the DTCs first. If the TCC operates when driving at high speeds only, malfunction (improper adjustment) is in the HOLD switch circuit or TR switch circuit. Caution • If the TCC is stuck, inspect it. In addition, inspect the oil cooler for foreign particles which may have mixed in with the ATF.
Page 533 TROUBLESHOOTING NO.9 ABNORMAL SHIFTING A6E568001030W13 Abnormal shifting • Shift incorrectly (incorrect shift pattern). DESCRIPTION • There is a malfunction in the signal circuit which controls shifting (TP sensor, input/turbine speed sensor, vehicle speed sensor), the control valve is stuck, the accumulator (forward or servo apply) is stuck, or the clutch circuit is stuck.
Page 534 TROUBLESHOOTING NO.12 TORQUE CONVERTER CLUTCH (TCC) NON-OPERATION A6E568001030W16 Torque converter clutch (TCC) non-operation • TCC does not operate when vehicle reaches TCC operation range. DESCRIPTION • Basically, the TCC does not operate when the fail-safe is operating. Verify the DTC first. Caution •...
Page 535 TROUBLESHOOTING End Of Sie NO.14 ENGINE FLARES UP OR SLIPS WHEN UPSHIFTING OR DOWNSHIFTING A6E568001030W18 Engine flares up or slips when upshifting or downshifting • When accelerator pedal is depressed for driveway, engine speed increases but vehicle speed increases DESCRIPTION slowly.
Page 536 TROUBLESHOOTING NO.16 JUDDER UPON TORQUE CONVERTER CLUTCH (TCC) OPERATION A6E568001030W20 Judder upon torque converter clutch (TCC) operation • Vehicle jolts when TCC is engaged. DESCRIPTION • Poor TCC engagement due to either slippage because the TCC is stuck or the line pressure is low Caution •...
Page 537 TROUBLESHOOTING NO.17 EXCESSIVE SHIFT SHOCK FROM N TO D OR N TO R POSITION/RANGE A6E568001030W21 Excessive shift shock from N to D or N to R position/range • Strong shock felt when shifting from N to D or N to R position/range. DESCRIPTION •...
Page 538 TROUBLESHOOTING End Of Sie NO.18 EXCESSIVE SHIFT SHOCK IS FELT WHEN UPSHIFTING AND DOWNSHIFTING A6E568001030W22 Excessive shift shock is felt when upshifting and downshifting • Excessive shift shock felt when depressing accelerator pedal to accelerate at upshifting. During DESCRIPTION cruising, excessive shift shock is felt when depressing accelerator pedal at downshifting. •...
Page 539 TROUBLESHOOTING NO.20 NOISE OCCURS AT IDLE WHEN VEHICLE IS STOPPED IN ALL POSITIONS/RANGES A6E568001030W24 Noise occurs at idle when vehicle is stopped in all positions/ranges • Transaxle noisy in all positions and ranges when vehicle is idling. DESCRIPTION • The malfunction is in the oil pump which causes a high-pitched noise to be emitted from the transaxle at idle.
Page 540 TROUBLESHOOTING NO.22 NO ENGINE BRAKING IN HOLD MODE A6E568001030W26 No engine braking in hold mode • Engine speed drops to idle but vehicle coasts when accelerator pedal is released during cruising at medium to high speeds. DESCRIPTION • Engine speed drops to idle but vehicle coasts when accelerator pedal is released when in L range at low vehicle speed.
Page 541 TROUBLESHOOTING STEP INSPECTION ACTION • Disconnect PCM. Yes Go to next step. • Is resistance between ground terminal at Repair open ground circuit. PCM connector and body ground less than Reconnect PCM. 5.0 ohms? • Check LPS PID value. Yes Overhaul control valve body and repair or replace any •...
Page 542 TROUBLESHOOTING Diagnostic procedure STEP INSPECTION ACTION • Are other indicator lights illuminated with Yes Inspect meter fuse. ignition switch is at ON? Go to next step. • Check the HOLD switch Yes Go to next step. (See K–13 HOLD SWITCH INSPECTION.) Repair or replace any defective parts.
Page 543: Front And Rear Axles
FRONT AND REAR AXLES LOCATION INDEX ..........M-2 FRONT AXLE/DRIVE SHAFT LOCATION INDEX........... M-2 REAR AXLE LOCATION INDEX......M-3 GENERAL PROCEDURES ........M-3 PRECAUTION (FRONT AND REAR AXLE) ..M-3 FRONT AXLE ............M-4 WHEEL HUB, STEERING KNUCKLE PRE-INSPECTION........... M-4 WHEEL HUB BOLT REPLACEMENT ....
Page 544: Location Index
LOCATION INDEX LOCATION INDEX FRONT AXLE/DRIVE SHAFT LOCATION INDEX A6E630004000W01 A6E0612W106 Hub bolt Drive shaft (See M–4 WHEEL HUB BOLT REPLACEMENT) (See M–16 DRIVE SHAFT PRE-INSPECTION) (See M–17 DRIVE SHAFT REMOVAL/ Wheel hub, steering knuckle INSTALLATION) (See M–4 WHEEL HUB, STEERING KNUCKLE (See M–19 DRIVE SHAFT (ATX) DISASSEMBLY/ PRE-INSPECTION)
Page 545: Rear Axle Location Index
LOCATION INDEX, GENERAL PROCEDURES REAR AXLE LOCATION INDEX A6E630005000W01 A6E0312W016 Wheel hub, hub spindle (See M–9 WHEEL HUB, HUB SPINDLE PRE- INSPECTION) (See M–10 WHEEL HUB, HUB SPINDLE REMOVAL/INSTALLATION) End Of Sie GENERAL PROCEDURES PRECAUTION (FRONT AND REAR AXLE) A6E631001018W01 Wheel and Tire Removal/Installation 1.
Page 546: Front Axle
FRONT AXLE FRONT AXLE WHEEL HUB, STEERING KNUCKLE PRE-INSPECTION A6E631204000W01 Wheel Bearing Play Inspection 1. Position a dial indicator against the wheel hub. 2. Push and pull the wheel hub by hand in the axial direction and measure the wheel bearing play. Maximum wheel bearing play 0.05 mm {0.002 in} 3.
Page 547: Wheel Hub, Steering Knuckle Removal/Installation
FRONT AXLE WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION A6E631204000W02 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while the vehicle is being serviced.
Page 548 FRONT AXLE Locknut Removal Note 1. Knock the crimped portion of the locknut outward using a small chisel and a hammer. 2. Lock the hub by applying the brakes. 3. Remove the locknut. A6E6321W001 Wheel Hub Component Removal Note 1. Remove the wheel hub component using the SSTs.
Page 549 FRONT AXLE Dust Cover Removal Note Note • The dust cover does not need to be removed unless it is being replaced. 1. Mark the dust cover and steering knuckle for proper installation. A6E0311W018 2. Remove the dust cover using a chisel. A6E0311W019 Hub Bolt Removal Note Note...
Page 550 FRONT AXLE Dust Cover Installation Note 1. Mark the new dust cover in the same way as the removed one. 2. Align the marks of the new dust cover and the knuckle. A6E0312W010 3. Install the new dust cover using the SSTs. A6E0312W011 Wheel Bearing Installation Note 1.
Page 551: Rear Axle
FRONT AXLE, REAR AXLE Locknut Installation Note 1. Install a new locknut and stake it as shown. A6E0312W015 End Of Sie REAR AXLE WHEEL HUB, HUB SPINDLE PRE-INSPECTION A6E631405000W01 Wheel Bearing Play Inspection 1. Position a dial indicator against the wheel hub. 2.
Page 552: Wheel Hub, Hub Spindle Removal/Installation
REAR AXLE WHEEL HUB, HUB SPINDLE REMOVAL/INSTALLATION A6E631405000W02 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (body side) and fix it to an appropriate place where the sensor will not be pulled by mistake while the vehicle is being serviced.
Page 553 REAR AXLE ABS Sensor Rotor Removal Note Note • The sensor rotor does not need to be removed unless it is being replaced. 1. Remove the sensor rotor using a chisel. A6E6314W001 ABS Sensor Rotor Installation Note Caution • Position the SST so that marking B faces the bottom. 1.
Page 554: Drive Shaft
DRIVE SHAFT DRIVE SHAFT JOINT SHAFT PRE-INSPECTION A6E631625700W01 1. Verify that the joint shaft is not twisted or cracked. • Replace it as necessary. 2. Turn the joint shaft by hand and verify that the bearing rotates smoothly and freely. •...
Page 555 DRIVE SHAFT Tie-rod end ball joint Disk plate (See N–11 Tie-rod End Ball Joint Removal Note) (See P–20 Disc Plate Removal Note) bolt Wheel hub, steering knuckle and drive shaft (See M–13 Wheel Hub, Steering Knuckle and Drive Lower arm (front, rear) ball joint Shaft Removal Note) (See...
Page 556: Joint Shaft Disassembly/Assembly
DRIVE SHAFT Clip Installation Note 1. Install a new clip onto the joint shaft with the opening facing upward. Ensure that the diameter of the clip does not exceed the specification on installation. 2. After installation, measure the outer diameter. If it exceeds the specification, repeat Step 1 using a new clip.
Page 557 DRIVE SHAFT Bearing Disassembly Note 1. Remove the bearing using the SSTs. A6E0313W053 Dust Seal (Right) Assembly Note 1. Apply grease to the new dust seal lip. 2. Install the new right side dust seal using the SSTs. A6E0313W028 Bearing Assembly Note 1.
Page 558: Drive Shaft Pre-Inspection
DRIVE SHAFT Dust Seal (Left) Assembly Note 1. Apply grease to the new dust seal lip. 2. Install the new left side dust seal using a steel plate and the SSTs. A6E0313W030 Joint Shaft Assembly Note 1. Assemble the joint shaft using a press and the SST.
Page 559: Drive Shaft Removal/Installation
DRIVE SHAFT DRIVE SHAFT REMOVAL/INSTALLATION A6E631625500W02 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while the vehicle is being serviced.
Page 560 DRIVE SHAFT Drive Shaft Removal Note 1. Install a spare nut onto the drive shaft so that the nut is flush with the end of the drive shaft. 2. Tap the nut with a copper hammer to loosen the drive shaft from the front wheel hub. 3.
Page 561: Drive Shaft (Atx) Disassembly/Assembly
DRIVE SHAFT Drive Shaft Installation Note Caution • The sharp edges of the drive shaft can slice or puncture the oil seal. Be careful when installing the drive shaft to the transaxle. • The oil seals are damaged easily if this procedure is not done correctly.
Page 562 DRIVE SHAFT Boot Band (Wheel Side) Disassembly Note Note • The boot band does not need to be removed unless it is being replaced. 1. Remove the boot clamp with end clamp pliers as shown and discard the clamp. A6E6316W004 Boot Band (Transaxle Side) Disassembly Note 1.
Page 563 DRIVE SHAFT Boot Disassembly Note Note • The wheel side boot does not need to be removed unless replacing it or the ball joint and shaft component. • Do not strip the tape until the boot is assembled. 1. Wrap the shaft splines with tape. 2.
Page 564 DRIVE SHAFT ABS Sensor Rotor (With ABS) Assembly Note 1. Set a new ABS sensor rotor on the drive shaft and press it on using the SSTs. A6E0313W050 Boot Assembly Note Note • The wheel side and transaxle side boots are different. 1.
Page 565 DRIVE SHAFT 4. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped screwdriver. Caution • Do not let grease leak. • Do not damage the boot. 5. Verify that the drive shaft length is within the standard.
Page 566: Drive Shaft (Mtx) Disassembly/Assembly
DRIVE SHAFT 6. Crimp the wheel side big boot band using the SST. 7. Verify that clearance B is within the specification. • If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot again. •...
Page 567 DRIVE SHAFT Boot band (wheel side) Inner Ring (See M–20 Boot Band (Wheel Side) Disassembly (See M–25 Balls, Inner Ring, Cage Disassembly Note) Note) (See M–23 Boot Band (Wheel Side) Assembly (See M–26 Cage, Inner Ring, Balls, Snap Ring Note) Assembly Note) Boot band (transaxle side)
Page 568 DRIVE SHAFT Dynamic Damper Assembly Note 1. Install the dynamic damper as shown in the figure. Standard length 334.7—340.7 mm {13.2—13.4 in} 2. Install the new boot band onto the dynamic damper. A6E6316W006 Boot Assembly Note Note • The wheel side and transaxle side boots are different. 1.
Page 569 DRIVE SHAFT Standard length mm {in} Left side Right side 677.7—687.7 L8, LF {26.69—27.07} 628.6—638.6 {24.75—25.14} 676.6—686.6 {26.64—27.03} 6. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped screwdriver. Caution •...
Page 570 S TEERING SYSTEM LOCATION INDEX ..........N-2 STEERING LOCATION INDEX ......N-2 GENERAL PROCEDURES ........N-3 PRECAUTION (STEERING)........N-3 ENGINE SPEED SENSING POWER STEERING............N-3 AIR BLEEDING ............N-3 POWER STEERING FLUID INSPECTION..N-4 STEERING WHEEL AND COLUMN INSPECTION ............N-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION ......N-7 STEERING SHAFT INSPECTION .......N-9 STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION ......N-10 STEERING GEAR AND LINKAGE...
Page 571: Location Index
LOCATION INDEX LOCATION INDEX STEERING LOCATION INDEX A6E660001036W01 A6E0610W010 Power steering fluid Steering gear and linkage (See N–4 POWER STEERING FLUID (See N–10 STEERING GEAR AND LINKAGE INSPECTION) REMOVAL/INSTALLATION) (See N–12 STEERING GEAR AND LINKAGE Steering wheel and column DISASSEMBLY) (See N–6 STEERING WHEEL AND COLUMN (See...
Page 572: General Procedures
GENERAL PROCEDURES , ENGINE SPEED SENSING POWER STEERING GENERAL PROCEDURES PRECAUTION (STEERING) A6E661001036W01 Wheels and Tires Removal/Installation 1. The removal and installation procedures for the wheels and tires are not mentioned in this section. When a wheel is removed, tighten it to 88—118 N·m {9.0—12.0 kgf·m, 65.0—87.0 ft·lbf}.
Page 573: Power Steering Fluid Inspection
ENGINE SPEED SENSING POWER STEERING POWER STEERING FLUID INSPECTION A6E661432040W01 Fluid Level Inspection 1. Inspect the power steering fluid level. • Add fluid to the specified level as necessary. Fluid specification ® ATF M-III or equivalent (e.g. Dexron Fluid Leakage Inspection 1.
Page 574 ENGINE SPEED SENSING POWER STEERING 6. Close the gauge valve completely. 7. Increase the engine speed to 1,000—1,500 rpm and measure the fluid pressure generated by the oil pump. • If the pressure is not within the specification, repair or replace the oil pump component. Caution •...
Page 575: Steering Wheel And Column Inspection
ENGINE SPEED SENSING POWER STEERING STEERING WHEEL AND COLUMN INSPECTION A6E661432010W01 Steering Wheel Play Inspection 1. With the wheels in the straight-ahead position, gently turn the steering wheel to the left and right and verify that the play is within the specification. •...
Page 576: Steering Wheel And Column Removal/Installation
ENGINE SPEED SENSING POWER STEERING STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION A6E661432010W02 Warning • Handling the air bag module improperly can accidentally deploy the air bag module, which may seriously injure you. Read AIR BAG SYSTEM WARNINGS before handling the air bag module. (See T–117 SERVICE WARNINGS.) 1.
Page 577 ENGINE SPEED SENSING POWER STEERING Steering Wheel Removal Note Caution • Do not try to remove the steering wheel by hitting the shaft with a hammer. The column will collapse. 1. Set the vehicle in the straight-ahead position. 2. Remove the steering wheel using a suitable puller. Steering Lock Mounting Bolts Removal Note 1.
Page 578: Steering Shaft Inspection
ENGINE SPEED SENSING POWER STEERING STEERING SHAFT INSPECTION A6E661432100W01 1. Inspect the following. (1) Column bearing for damage (2) Steering shaft length • Replace the steering shaft component as necessary. Length 211.6 mm {8.3 in} A6E0612W022 2. Inspect the tilt and telescope operation (1) Verify that the adjusting lever moves smoothly from unlock position to lock position.
Page 579: Steering Gear And Linkage Removal/Installation
ENGINE SPEED SENSING POWER STEERING STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION A6E661432960W01 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.
Page 580 ENGINE SPEED SENSING POWER STEERING Bolt (Intermediate Shaft) Removal Note 1. Mark the pinion shaft and gear housing for proper installation. A6E0612W084 Tie-rod End Ball Joint Removal Note 1. Remove the tie rod-nut. 2. Separate the tie-rod end from the steering knuckle using the SSTs.
Page 581: Steering Gear And Linkage Disassembly
ENGINE SPEED SENSING POWER STEERING Steering Gear and Linkage Installation Note 1. Loosely tighten bolts. 2. Tighten the mounting bracket bolts to the specified torque in the order shown. Tightening torque 74.4—104.8 N·m {7.6—10.6 kgf·m, 55—77 ft·lbf} 3. Tighten the crossmember installation nuts. (L.H.D.) Tightening torque Nut: 119.6—154.8 N·m {12.2—15.7 kgf·m, 89—114 ft·lbf}...
Page 582 ENGINE SPEED SENSING POWER STEERING Oil pipe Seal ring Tie-rod end Pinion shaft Locknut Valve housing component Boot clamp Upper bearing (See N–15 Upper Bearing, Oil Seal Disassembly Boot band Note) Boot Oil seal Tie rod (See N–15 Upper Bearing, Oil Seal Disassembly (See N–13 Tie Rod Disassembly Note)
Page 583 ENGINE SPEED SENSING POWER STEERING Adjusting Cover Disassembly Note 1. Remove the adjusting cover. A6E0612W033 Pinion Shaft and Housing Component Disassembly Note 1. Hold the pinion shaft as shown, and pull out the pinion shaft and housing component. A6E0612W038 Pinion Shaft Component Disassembly Note Note •...
Page 584 ENGINE SPEED SENSING POWER STEERING Upper Bearing, Oil Seal Disassembly Note 1. Set the SST as shown. 2. Using a press, remove the oil seal and upper bearing without applying pressure to the edge of the valve housing. A6E0612W035 Holder Disassembly Note 1.
Page 585: Steering Gear And Linkage Inspection
ENGINE SPEED SENSING POWER STEERING STEERING GEAR AND LINKAGE INSPECTION A6E661432960W03 Rack Inspection 1. Inspect the rack for cracking, damage, and tooth wear. Replace it as necessary. 2. Measure the runout of the rack. Runout Near point A: 0.15 mm {0.006 in} max. Near point B: 0.20 mm {0.008 in} max.
Page 586 ENGINE SPEED SENSING POWER STEERING 1. Assemble in the order indicated in the table. A6E0612W044 Gear housing Control valve Mounting rubber Seal ring (See N–18 Mounting Rubber Assembly Note) (See N–20 Seal Ring Assembly Note) Oil seal Snap ring (See N–18 Oil Seal, Inner Guide Assembly Note) O-ring...
Page 587 ENGINE SPEED SENSING POWER STEERING Mounting Rubber Assembly Note 1. Apply soapy water to the rubber part of the mounting rubber. 2. Press the mounting rubber until the mounting rubber end comes out completely from the gear housing using the SSTs and a press. A6E0612W087 3.
Page 588 ENGINE SPEED SENSING POWER STEERING 5. Using the SST, place the oil seal and inner guide at the edge of the steering rack’s pinion, and remove the SST. A6E0612W049 6. After installing the steering rack to the gear housing, press the oil seal and inner guide using the SSTs until the force required suddenly increases.
Page 589 ENGINE SPEED SENSING POWER STEERING Oil Seal Assembly Note 1. Apply grease to a new oil seal. 2. Press in the new oil seal using the SSTs. A6E0612W036 Upper Bearing Assembly Note 1. Apply grease to a new upper bearing. 2.
Page 590 ENGINE SPEED SENSING POWER STEERING 5. Measure the pinion torque using the SST and a pull scale. Standard Center of rack ±90° 0.8—1.2 N·m {8.2—12.2 kgf·cm, 5.8—8.8 in·lbf} [Pull scale reading 8—12 N {0.9—1.2 kgf, 1.8—2.6 lbf}] Except center of rack ±90° Less than 1.6 N·m {16.3 kgf·cm, 11.8 in·lbf} A6E0612W042...
Page 591: Power Steering Oil Pump Removal/Installation
ENGINE SPEED SENSING POWER STEERING POWER STEERING OIL PUMP REMOVAL/INSTALLATION A6E661432650W01 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. A6E0612W092 Drive belt Suction hose Pressure switch connector Power steering oil pump Pressure pipe End Of Sie POWER STEERING OIL PUMP DISASSEMBLY/ASSEMBLY...
Page 592 ENGINE SPEED SENSING POWER STEERING A6E0612W068 Power steering oil pump component O-ring (See N–24 Power Steering Oil Pump Component Clip Disassembly Note) Cam ring Pressure switch component (See N–25 Cam Ring Assembly Note) Connector Rotor O-rings Vane Control valve (See N–25 Vane Assembly Note) Spring...
Page 593 ENGINE SPEED SENSING POWER STEERING Power Steering Oil Pump Component Disassembly Note 1. Secure the power pressure oil pump using the SST. Caution • Use the SST to prevent damage to the pump when securing it in a vise. A6E0612W070 Clip Disassembly Note 1.
Page 594 ENGINE SPEED SENSING POWER STEERING Oil Seal Assembly Note 1. Install the oil seal in the front pump body using the SST and plastic hammer. A6J6612W100 Vane Assembly Note 1. Place the vanes in the rotor with the rounded edges contacting the cam. A6E6316W013 Cam Ring Assembly Note 1.
Page 595 B RAKING SYSTEM LOCATION INDEX ..........P-3 REAR ABS WHEEL-SPEED SENSOR CONVENTIONAL BRAKE LOCATION INDEX ... P-3 REMOVAL/INSTALLATION ......P-34 PARKING BRAKE LOCATION INDEX ....P-4 DYNAMIC STABILITY CONTROL ....... P-35 ABS/TCS LOCATION INDEX ......P-4 DSC SYSTEM INSPECTION......P-35 DSC LOCATION INDEX ........
Page 596 DTC C1507, C1508..........P-91 NO.3 THERE IS A MALFUNCTION IN DTC C1510, C1511, C1512, C1513 ....P-92 THE SYSTEM EVEN THOUGH ABS DTC C1953, C1954..........P-92 WARNING LIGHT, BRAKE SYSTEM DTC C1955, C1956..........P-93 WARNING LIGHT, DSC INDICATOR DTC U2021 ............P-96 LIGHT AND DSC OFF LIGHT DO TROUBLESHOOTING NOT ILLUMINATE ........P-120 (ABS/TCS/DYNAMIC STABILITY CONTROL) .
Page 597: Location Index
LOCATION INDEX LOCATION INDEX CONVENTIONAL BRAKE LOCATION INDEX A6E690001015W01 A6E6900W001 Brake pedal Dual proportioning valve (without ABS) (SeeP–7 BRAKE PEDAL INSPECTION) (SeeP–16 DUAL PROPORTIONING VALVE (SeeP–9 BRAKE PEDAL REMOVAL/ INSPECTION (WITHOUT ABS)) INSTALLATION) (SeeP–16 DUAL PROPORTIONING VALVE (SeeP–8 BRAKE SWITCH INSPECTION) REPLACEMENT (WITHOUT ABS))
Page 598: Parking Brake Location Index
LOCATION INDEX PARKING BRAKE LOCATION INDEX A6E690001015W02 A6E6900W005 Parking bake lever (SeeP–26–1 PARKING BRAKE (LEVER TYPE) INSPECTION) (SeeP–26–1 PARKING BRAKE (LEVER TYPE) ADJUSTMENT) (SeeP–26–2 PARKING BRAKE (LEVER TYPE) REMOVAL/INSTALLATION) End Of Sie ABS/TCS LOCATION INDEX A6E690001015W03 A6E6900W003 ABS (ABS/TCS) HU/CM Front ABS wheel-speed sensor (SeeP–27 ABS (ABS/TCS) HU/CM SYSTEM (SeeP–32 FRONT ABS WHEEL-SPEED SENSOR...
Page 599: Dsc Location Index
LOCATION INDEX Rear ABS wheel-speed sensor L.H.D. (SeeP–34 REAR ABS WHEEL-SPEED SENSOR R.H.D. REMOVAL/INSTALLATION) TCS OFF switch (SeeP–31 TCS (DSC) OFF SWITCH REMOVAL/ INSTALLATION) (SeeP–32 TCS (DSC) OFF SWITCH INSPECTION) End Of Sie DSC LOCATION INDEX A6E690001015W04 A6E6900W004 DSC HU/CM DSC OFF switch (SeeP–40 DSC HU/CM INSPECTION)
Page 600: General Procedures
GENERAL PROCEDURES, CONVENTIONAL BRAKE SYSTEM GENERAL PROCEDURES PRECAUTION (BRAKES) A6E691001020W01 Wheels and Tires Removal/Installation 1. The removal and installation procedures for the wheels and tires are not mentioned in this section. When a wheel is removed, tighten it to 88—118 N·m {9.0—12.0 kgf·m, 65.0—87.0 ft·lbf}. Brake Lines Disconnection/Connection Caution •...
Page 601: Vacuum Hose Check Valve Inspection
CONVENTIONAL BRAKE SYSTEM 4. A second person should loosen the bleeder screw, drain out the fluid and close the screw using the SST. Tightening torque Front:6.9—9.8 N·m {71—99 kgf·cm, 62—86 in·lbf} Rear:5.9—8.8 N·m {61—89 mgf·cm, 53—77 in·lbf} 5. Repeat steps 3 and 4 until no air bubbles are seen.
Page 602: Brake Switch Inspection
CONVENTIONAL BRAKE SYSTEM 1. Loosen locknut B and turn the bolt A until it does not contact the pedal. 2. Loosen locknut D and turn rod C to adjust the height. 3. Tighten the bolt with locknut B . Tightening torque 9.8—14.7 N·m {100—149 kgf·cm, 116—130 in·lbf} 4.
Page 603 CONVENTIONAL BRAKE SYSTEM 3. Inspect for continuity between the brake switch connector terminals. • If not as specified, replace the brake switch. A6E6912W034 A6E6912W033 End Of Sie BRAKE PEDAL REMOVAL/INSTALLATION A6E691243300W02 Caution • The clearance between the brake switch and the brake pedal is automatically adjusted to the correct amount when the brake switch connector is connected after the brake switch has been properly installed.
Page 604: Master Cylinder Removal/Installation
CONVENTIONAL BRAKE SYSTEM MASTER CYLINDER REMOVAL/INSTALLATION A6E691243400W01 1. Remove in the order indicated in the table. R.H.D. A6E6912W028 L.H.D. A6E6912W018 Brake fluid level sensor connector Brake pipe Hose (MTX) Master cylinder (See P–11 Master Cylinder Installation Note O-ring 2. Install in the reverse order of removal. P–10...
Page 605 CONVENTIONAL BRAKE SYSTEM Master Cylinder Installation Note Caution • Always install the gasket of the power brake unit push rod before performing measurement inspections or adjustments. 1. Install the SST to the power brake unit as shown, and tighten within the specified torque. Tightening torque 9.8—16.0 N·m {100—163 kgf·cm, 87—141 in·lbf}...
Page 606: Fluid Level Sensor Inspection
CONVENTIONAL BRAKE SYSTEM 6. Install the master cylinder to the power brake unit. Caution • If after installing the master cylinder, air does not bleed properly from the brake lines even after performing air bleeding, brake drag occurs or other characteristics are present, it is possible that the master cylinder piston is jammed against the power brake unit.
Page 607 CONVENTIONAL BRAKE SYSTEM Reservoir Stop pin and O-ring (with ABS) (See P–13 Stop Pin and O-ring (with ABS) Joint bushing Assembly Note) Snap ring Stop screw and O-ring (without ABS) Piston guide (SeeP–13 Stop Screw and O-ring (without ABS) Assembly Note) Stopper Secondary piston...
Page 608: Power Brake Unit Removal/Installation
CONVENTIONAL BRAKE SYSTEM POWER BRAKE UNIT REMOVAL/INSTALLATION A6E691243800W02 1. Remove the master cylinder. (See P–10 MASTER CYLINDER REMOVAL/INSTALLATION.) 2. Remove the wiper arm. (See T–57 WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.) 3. Remove the cowl grille. (See S–50 COWL GRILLE REMOVAL/INSTALLATION.) 4.
Page 609 CONVENTIONAL BRAKE SYSTEM Power Brake Unit Function Check (Inspection Using The Testers) 1. Connect the SSTs, vacuum gauge, and pedal depression force gauge as shown in the figure to bleed the air from SSTs and brake line. (Bleed the air from SSTs using a air bleed valve A.) A6E6912W005 Checking for vacuum loss (unloaded condition) 1.
Page 610: Dual Proportioning Valve
CONVENTIONAL BRAKE SYSTEM DUAL PROPORTIONING VALVE INSPECTION (WITHOUT ABS) A6E691243900W01 1. Connect the SSTs to the brake pipes as shown in the figure. 2. Bleed the air from the brake system. 3. Measure the fluid pressure of the master cylinder and the rear brake.
Page 611 CONVENTIONAL BRAKE SYSTEM Dual Proportioning Valve Installation Note 1. Install the dual proportioning valve so that the R mark faces the left side of the vehicle. A6E6912W045 End Of Sie FRONT BRAKE (DISC) INSPECTION A6E691233980W01 Brake Judder Repair Hint Description 1.
Page 612 CONVENTIONAL BRAKE SYSTEM Inspection and repair procedure A6E6912W008 Lateral runout inspection 1. To secure the disc plate and the hub, tighten the hub nuts upside down or insert a washer (thickness 10 mm {0.39 in}, inner diameter more than 12 mm {0.47 in}) between the hub bolt and the hub nut. Note •...
Page 613 CONVENTIONAL BRAKE SYSTEM Thickness variation inspection 1. Clean the disc plate-to-pad friction surface using a brake cleaner. 2. Measure the points indicated in the illustration using a caliper (micrometer). 3. Subtract the minimum value from the maximum, and if the result is not within specification, machine the disc plate using a lathe.
Page 614 CONVENTIONAL BRAKE SYSTEM FRONT BRAKE (DISC) REMOVAL/INSTALLATION A6E691233980W02 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not drag.
Page 615 CONVENTIONAL BRAKE SYSTEM Disc Pad Installation Note 1. Push the piston fully inward using the SST. 2. Install the disc pad. 49 0221 600C A6E6912W038 End Of Sie DISC PAD (FRONT) REPLACEMENT A6E691233630W01 1. Remove in the order indicated in the table. 2.
Page 616: Caliper (Front) Disassembly/Assembly
CONVENTIONAL BRAKE SYSTEM End Of Sie CALIPER (FRONT) DISASSEMBLY/ASSEMBLY A6E691233990W01 1. Disassemble in the order indicated in the table. Dust seal Piston (See P–22 Piston Disassembly Note) Piston seal (See P–22 Piston Seal Disassembly Note) Bleeder cap Bleeder screw (See P–23 Bleeder Screw Assembly Note) Caliper body...
Page 617: Rear Brake (Disc) Inspection
CONVENTIONAL BRAKE SYSTEM Bleeder Screw Assembly Note 1. Assemble the bleeder screw to the caliper using the SST. Tightening torque 6.9—9.8 N·m {71—99 kgf·cm, 62—86 in·lbf} A6E6912W049 End Of Sie REAR BRAKE (DISC) INSPECTION A6E691226980W01 Brake Judder Repair Hint 1. (See P–17 FRONT BRAKE (DISC) INSPECTION.) Disc Plate Thickness Inspection...
Page 618: Rear Brake (Disc) Removal/Installation
CONVENTIONAL BRAKE SYSTEM REAR BRAKE (DISC) REMOVAL/INSTALLATION A6E691226980W02 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation, depress the pedal several times, rotate the wheel by hand, and verify that the brake does not drag.
Page 619: Disc Pad (Rear) Replacement
CONVENTIONAL BRAKE SYSTEM Disc Pad Installation Note 1. Push the piston fully inward using the SST. 2. Install the disc pads. 49 FA18 602 A6E6912W039 End Of Sie DISC PAD (REAR) REPLACEMENT A6E691226630W01 1. Remove in the order indicated in the table. 2.
Page 620: Caliper (Rear) Disassembly/Assembly
CONVENTIONAL BRAKE SYSTEM CALIPER (REAR) DISASSEMBLY/ASSEMBLY A6A691226990W01 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 37.3—49.0 N·m {3.81—4.99 kgf·m, 27.6—36.1 ft·lbf} 5.9—8.8 {61—89, 53—77} BRAKE FLUID BRAKE FLUID RUBBER GREASE *49 0259 770B N·m {kgf·cm, in·lbf} A6A6912W303 Piston...
Page 621: Parking Brake System
PARKING BRAKE SYSTEM P – 2 6 B RAKING SYSTEM PARKING BRAKE SYSTEM PARKING BRAKE (LEVER TYPE) INSPECTION A6E691444000W01 1. Pull the parking brake lever a few times. 2. Depress the brake pedal a few times. 3. Inspect the parking brake stroke by pulling the parking brake lever with a force of 98 N {10 kgf, 22 lbf}. Stroke 3—6 notches End Of Sie...
Page 622: Parking Brake (Lever Type) Removal/Installation
PARKING BRAKE SYSTEM PARKING BRAKE (LEVER TYPE) REMOVAL/INSTALLATION A6E691444000W03 1. Remove the center console. (See S–86 2. Remove the rear seat cushion (4SD) or rear seat (5HB) . (See S–110 REAR SEAT REMOVAL/ INSTALLATION.) 3. Remove the exhaust pipe bracket. 4.
Page 623: Abs/Tcs
ABS/TCS P B RAKING SYSTEM ABS/TCS ABS (ABS/TCS) HU/CM SYSTEM INSPECTION A6E692143780W01 System Inspection Preparation 1. Verify that the battery is fully charged. With the ignition switch on, verify that the ABS and BRAKE system warning lights goes out after 2.4 seconds. 2.
Page 624: Abs (Abs/Tcs) Hu/Cm Removal/Installation
ABS/TCS ABS (ABS/TCS) HU/CM REMOVAL/INSTALLATION A6E692143700W01 Caution • When replacing the ABS (ABS/TCS) HU/CM, configuration procedure must be done before removing the ABS (ABS/TCS) HU/CM. If configuration is not completed before removing the ABS (ABS/TCS) HU/CM, TCS will not work properly (with TCS model). •...
Page 625: Abs (Abs/Tcs) Or Dsc Hu/Cm Configuration
ABS/TCS Connector Removal Note 1. Pull the lock lever up and make it unlock. 2. Remove the connector. A6E6916W006 ABS HU/CM Removal/Installation Note 1. When removing/installing the ABS HU/CM from/to the vehicle, attach a strip of protective tape on the ABS HU/ CM connector to prevent brake fluid from entering.
Page 626 ABS/TCS Terminal Voltage Table (Reference) (Engine is idling, and connector is connected unless otherwise indicated.) A6E6921W001 Terminal Signal Connected to Test condition Voltage (V) Action Vehicle is stopped 0 (AC) • Inspect by using the wave profile. RR wheel-speed RR wheel-speed sensor (See P–31 Inspection Using An...
Page 627: Tcs (Dsc) Off Switch Removal/Installation
ABS/TCS Terminal Signal Connected to Test condition Voltage (V) Action Brake pedal is 10—14 depressed • Inspect related harness Brake switch Brake switch Brake pedal is Below 0.5 released • Inspect related harness Power supply Ignition switch — Power supply Battery —...
Page 628: Tcs (Dsc) Off Switch Inspection
ABS/TCS TCS (DSC) OFF SWITCH INSPECTION A6E692167650W03 1. Remove the TCS OFF switch. 2. Inspect for continuity between the TCS OFF switch terminals using an ohmmeter. A6E6921W010 A6E6921W009 • If not within the specification, replace the TCS OFF switch. End Of Sie FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION A6E692143720W01 1.
Page 629: Front/Rear Abs Wheel-Speed Sensor Inspection
ABS/TCS End Of Sie FRONT/REAR ABS WHEEL-SPEED SENSOR INSPECTION A6E692143720W02 Visual Inspection 1. Remove the wheel and tire, and inspect the sensor for looseness and damage. Replace the sensor if necessary. Clearance Inspection 1. Inspect the clearance between the wheel-speed sensor and the sensor rotor.
Page 630: Rear Abs Wheel-Speed Sensor Removal/Installation
ABS/TCS REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION A6E692143710W01 1. Remove the tire house trim.S–91 TIRE HOUSE TRIM REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. A6E6916W002 Connector Rear ABS wheel-speed sensor Bolt End Of Sie P–34...
Page 631: Dynamic Stability Control
DYNAMIC STABILITY CONTROL DYNAMIC STABILITY CONTROL DSC SYSTEM INSPECTION A6E692067650W01 Preparation 1. Verify that the battery is fully charged. 2. With ignition switch on, verify that the ABS warning light goes out after 2.4 seconds. 3. Turn the ignition switch off. 4.
Page 632 DYNAMIC STABILITY CONTROL Pressure reduction Wheels Command name LF_TC_VLV RF_TC_VLV LF_DSC_V RF_DSC_V ABS_POWER LF_INLET LF_OUTLET LR_INLET LR_OUTLET RF_INLET RF_OUTLET RR_INLET RR_OUTLET PMP_MOTOR Note • To protect the DSC HU/CM, the solenoid valve used for simulations and the ABS motor stay on for 10 seconds each time they are switched on.
Page 633 DYNAMIC STABILITY CONTROL Pressure retention Wheels Inhibition of understeer tendency Inhibition of oversteer tendency Command name control control LF_TC_VLV RF_TC_VLV LF_DSC_V RF_DSC_V ABS_POWER LF_INLET LF_OUTLET LR_INLET LR_OUTLET RF_INLET RF_OUTLET RR_INLET RR_OUTLET PMP_MOTOR Note • To protect the DSC HU/CM, the solenoid valve used for simulations and the ABS motor stay on for 10 seconds each time they are switched on.
Page 634: Dsc Hu/Cm Removal/Installation
DYNAMIC STABILITY CONTROL DSC HU/CM REMOVAL/INSTALLATION A6E692067650W03 Caution • When replacing the DSC HU/CM, configuration procedure must be done before removing the DSC HU/CM. If configuration is not completed before removing the DSC HU/CM, DTC B2477 will be detected. • Do not drop the DSC HU/CM. Replace it if it is subjected to an impact. 1.
Page 635 DYNAMIC STABILITY CONTROL Connector Removal Note 1. Rotate the lock lever 40° to the direction A, then push the lock lever to the direction B. Caution • After rotated the lever 40° , do not push the lock lever to the direction C. The lock lever will be damaged.
Page 636: Dsc Hu/Cm Inspection
DYNAMIC STABILITY CONTROL DSC HU/CM INSPECTION A6E692067650W04 1. Remove the battery and battery bracket. 2. Disconnect the DSC HU/CM connector. 3. Connect the SST (49 G066 004) to the DSC HU/CM connector and harness side connector. 4. Inspect voltage referring the table below. Terminal Voltage Table (reference value) (Ignition switch is at ON, and connector is connected unless indicated otherwise.) A6E6920W009...
Page 637 DYNAMIC STABILITY CONTROL Terminal Signal Connected to Test condition Voltage (V) Action • Inspect related harness Combine Combine sensor — 3.5—5.0 • Inspect combine sensor sensor Vehicle is stopped 2.3—2.7 Fluctuation Right cornering between • Inspect related harness Yaw rate Combine 2.5—4.62 •...
Page 638: Combine Sensor Removal/Installation
DYNAMIC STABILITY CONTROL Wheel speed • DSC HU/CM terminal: RF : M ( + ) — I ( - ) RR : K ( + ) — H ( - ) LF : F ( + ) — J ( - ) LR : Q ( + ) —...
Page 639: Combine Sensor Inspection
DYNAMIC STABILITY CONTROL COMBINE SENSOR INSPECTION A6E692067650W06 Caution • Be careful and do not allow the lateral-G sensor to fall. If by chance it is subjected to strong impact, replace it. 1. Connect the connector. 2. Turn ignition switch on, verify the voltage between terminals B and E under the following conditions.
Page 640: Combine Sensor Initialization Procedure
DYNAMIC STABILITY CONTROL 2) Measure voltage at output terminal D and ground terminal E when the yaw rate sensor is rotated left and right. Caution • Be careful when turning the yaw rate sensor rotation position while it is in a reversed state because the rotation direction and voltage will be reversed.
Page 641 ON-BOARD DIAGNOSTIC (ABS/TCS) ON-BOARD DIAGNOSTIC (ABS/TCS) ABS (ABS/TCS) SYSTEM WIRING DIAGRAM A6E697567650W01 A6E6921T001 IG switch Cruise actuator SUS 15 A fuse TCS OFF switch ABS 60 A fuse DLC-2 Meter CAN-H ABS warning light CAN-L Brake system warning light ABS Wheel-speed sensor TCS OFF light Battery TCS indicator light...
Page 642: On-Board Diagnostic (Abs/Tcs
ON-BOARD DIAGNOSTIC (ABS/TCS) End Of Sie ABS (ABS/TCS) ON-BOARD DIAGNOSIS A6E697567650W02 On-Board Diagnostic (OBD) Test Description • The OBD test inspects the integrity and function of the ABS (ABS/TCS) and outputs the results when requested by the specific tests. • On-board diagnostic test also: —...
Page 643 ON-BOARD DIAGNOSTIC (ABS/TCS) Active Command Modes Procedure Note • When driving, the ABS motor and each valve forcibly turn ABS_VOLT on, and then each command on. ABS_VOLT regulates the power supply for the ABS motor and 8 valves. 1. Connect WDS or equivalent to the vehicle DLC-2 16-pin connector.
Page 644 ON-BOARD DIAGNOSTIC (ABS/TCS) WDS or Diagnosis system component Page equiva- lent C1246 Right rear pressure reduction solenoid valve (See P–63 DTC C1194, C1198, C1210, C1214, C1242, C1246, C1250, C1254) C1250 Left rear pressure retention solenoid valve (See P–63 DTC C1194, C1198, C1210, C1214, C1242, C1246, C1250, C1254) C1254...
Page 645 ON-BOARD DIAGNOSTIC (ABS/TCS) ABS (ABS/ PID Name Unit/Condition Condition/Specification Action TCS) HU/CM/ (Definition) CM terminal • During ABS or EBD Internal fault of ABS (ABS/ control: ON/OFF TCS) HU/CM. Replace ABS ABSLR_O (solenoid valve is (ABS/TCS) HU/CM. (Left rear ABS pressure activated/deactivated) (See P–28 ABS (ABS/TCS)
Page 646: Dtc B1318
ON-BOARD DIAGNOSTIC (ABS/TCS) ABS (ABS/ PID Name Unit/Condition Condition/Specification Action TCS) HU/CM/ (Definition) CM terminal • Vehicle is stopped: 0 KPH Inspect wheel-speed RF_WSPD {0 MPH} sensor/sensor rotor. (Right front wheel-speed KPH or MPH D, G • Vehicle is driving: sensor input) Indicates vehicle speed •...
Page 647 ON-BOARD DIAGNOSTIC (ABS/TCS) Diagnostic procedure STEP INSPECTION ACTION INSPECT BATTERY VOLTAGE Yes Make sure that battery terminal connection is okay. • Is battery terminal voltage okay? Go to next step. Charge or replace battery, then go to Step 6. INSPECT BATTERY GRAVITY Yes Go to next step.
Page 648: Dtc B1342
ON-BOARD DIAGNOSTIC (ABS/TCS) End Of Sie DTC B1342 A6E697567650W04 Caution • When attaching the tester lead to the ABS (ABS/TCS) HU/CM harness connector, the SST (49 G066 001) must be used. (See P–29 ABS (ABS/TCS) HU/CM INSPECTION.) B1342 ABS (ABS/TCS) HU/CM DETECTION The on-board diagnostic function detects control module malfunction.
Page 649 ON-BOARD DIAGNOSTIC (ABS/TCS) Diagnostic procedure STEP INSPECTION ACTION VERIFY OTHER DTC HAS BEEN RECORDED Yes Go to applicable DTC inspection. • If any of DTC C1186 and/or C1266 has also Go to next step. been stored? INSPECT ABS FUSE CONDITION Yes Go to next step.
Page 650 ON-BOARD DIAGNOSTIC (ABS/TCS) STEP INSPECTION ACTION VERIFY PUMP MOTOR OPERATION Yes Go to next step. • Turn ignition key to OFF. Repair ABS (ABS/TCS) HU/CM, then go to next step. • Remove SST (adapter harness) and connect all disconnected connectors. •...
Page 651 ON-BOARD DIAGNOSTIC (ABS/TCS) Diagnostic procedure STEP INSPECTION ACTION CHECK FOR CAN FOR DTCs Yes Follow inspection procedures for CAN system. • If any of DTC U1900 and/or U2516 has also T–144 DTC U0073, U1900, U2516 been stored? Go to next step. CHECK FOR PCM FOR DTCs Yes Follow inspection procedures for engine control system.
Page 652 ON-BOARD DIAGNOSTIC (ABS/TCS) End Of Sie DTC C1145, C1155, C1165, C1175 A6E697567650W10 Caution • When attaching the tester lead to the ABS (ABS/TCS) HU/CM harness connector, the SST (49 G066 001) must be used. (See P–29 ABS (ABS/TCS) HU/CM INSPECTION.) C1145 RF wheel-speed sensor C1155...
Page 653 ON-BOARD DIAGNOSTIC (ABS/TCS) P–57...
Page 654 ON-BOARD DIAGNOSTIC (ABS/TCS) Diagnostic procedure STEP INSPECTION ACTION INSPECT WHEEL-SPEED SENSOR CIRCUIT Yes Go to next step. FOR OPEN CIRCUIT Go to Step 3. • Turn ignition key to OFF. • Disconnect ABS (ABS/TCS) HU/CM connector. • Measure resistance between suspected sensor terminals of ABS (ABS/TCS) HU/CM connector (harness side).
Page 655 ON-BOARD DIAGNOSTIC (ABS/TCS) DTC C1148, C1158, C1168, C1178, C1233, C1234, C1235, C1236 A6E697567650W11 Caution • When attaching the tester lead to the ABS (ABS/TCS) HU/CM harness connector, the SST (49 G066 001) must be used. (See P–29 ABS (ABS/TCS) HU/CM INSPECTION.) C1148, C1234 RF wheel-speed sensor/sensor rotor...
Page 656 ON-BOARD DIAGNOSTIC (ABS/TCS) Diagnostic procedure STEP INSPECTION ACTION VERIFY OTHER DTC HAS BEEN RECORDED Yes Go to applicable DTC inspection. • Have DTCs related to solenoid valve, pump Go to next step. motor, or pump motor relay been stored? P–60...
Page 657 ON-BOARD DIAGNOSTIC (ABS/TCS) STEP INSPECTION ACTION VERIFY IF CURRENT CONCERNED INPUT Yes Go to Step 8. SIGNAL STATUS IS INTERMITTENT OR If there is a difference in speed of four wheels: Go to next CONSTANT step. • Turn ignition key to OFF. If any wheel speed is 0 km/h {0 mph}: Go to Step 4.
Page 658 ON-BOARD DIAGNOSTIC (ABS/TCS) STEP INSPECTION ACTION INSPECT ABS (ABS/TCS) HU/CM Yes Go to next step. OPERATION Replace ABS (ABS/TCS) HU/CM, then go to next step. • Perform ABS (ABS/TCS) HU/CM system inspection. (See P–27 ABS (ABS/TCS) HU/CM SYSTEM INSPECTION) • Is it okay? VERIFY TROUBLESHOOTING COMPLETED Yes Replace ABS (ABS/TCS) HU/CM, then go to next step.
Page 659 ON-BOARD DIAGNOSTIC (ABS/TCS) Diagnostic procedure STEP INSPECTION ACTION INSPECT ABS FUSE CONDITION Yes Go to next step. • Is ABS fuse (60 A) okay? Replace fuse, then go to Step 4. INSPECT FAIL-SAFE RELAY POWER Yes Go to next step. SUPPLY CIRCUIT FOR OPEN CIRCUIT Repair or replace harness for open circuit between battery •...
Page 660: Dtc C1414
ON-BOARD DIAGNOSTIC (ABS/TCS) End Of Sie DTC C1414 A6E697567650W14 C1414 ABS (ABS/TCS) HU/CM mismatched installation • Detection of situation where vehicle-type or drive system input signal and ABS (ABS/TCS) HU/CM DETECTION CONDITION information remains incongruent through CAN information. POSSIBLE • Mismatched installation of ABS (ABS/TCS) HU/CM CAUSE Diagnostic procedure STEP...
Page 661: Dtc U2021
ON-BOARD DIAGNOSTIC (ABS/TCS) Diagnostic procedure STEP INSPECTION ACTION VERIFY OTHER DTC HAS BEEN RECORDED Yes Go to applicable DTC inspection. • Has any ABS wheel-speed sensor, sensor Go to next step. rotor, solenoid valve, pump motor, or motor relay related DTC been output? INSPECT ABS (ABS/TCS) HU/CM Yes Go to next step.
Page 662 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DSC SYSTEM WIRING DIAGRAM A6E697367650W01 A6E6920T005 IG switch Meter SUS 15A fuse ABS warning light ABS 60 A fuse Brake system warning light P–66...
Page 663: Dtc B1342
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DSC OFF light Wheel-speed sensor DSC indicator light Combine sensor CAN driver Steering angle sensor Battery Brake switch Cruise actuator Brake light DSC OFF switch Back-up light switch (MTX only) DLC-2 Back-up light CAN-H Audio unit, Wiper and washer switch, Car-navegation unit, Auto leveling control unit CAN-L End Of Sie...
Page 664 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) WDS or Diagnosis system component Page equiva- lent C1234 Right front wheel-speed sensor/sensor rotor (See P–83 DTC C1148, C1158, C1168, C1178, C1233, C1234, C1235, C1236) C1235 Right rear wheel-speed sensor/sensor rotor (See P–83 DTC C1148, C1158, C1168, C1178, C1233, C1234, C1235, C1236) C1236...
Page 665 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) WDS or Diagnosis system component Page equiva- lent U2516 Can communication (See T–144 DTC U0073, U1900, U2516 PID/DATA Monitor Table ABS/TCS HU/ PID Name Unit/Condition Condition/Specification Action CM or DSC HU/ (Definition) CM terminal • Engine is stopped: 0 RPM •...
Page 666 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) ABS/TCS HU/ PID Name Unit/Condition Condition/Specification Action CM or DSC HU/ (Definition) CM terminal • ABS warning light is Inspect ABS warning light. ABS_LAMP illuminated: ON (ABS warning light driver ON/OFF — • ABS warning light is not output state) illuminated: OFF •...
Page 667 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) ABS/TCS HU/ PID Name Unit/Condition Condition/Specification Action CM or DSC HU/ (Definition) CM terminal • Motor relay is activated: Inspect DSC HU/CM. ABSPMPRLY (See P–40 DSC HU/CM ON/OFF — • Motor relay is deactivated: (Motor relay output state) INSPECTION •...
Page 668 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Active Command Modes Table Command Name Definition Operation Note RF_DSC_V Stability control solenoid valve (RF-LR) ON/OFF LF_DSC_V Stability control solenoid valve (LF-RR) ON/OFF ABS_POWER Fail-safe relay ON/OFF LR_OUTLET Left rear ABS pressure reduction solenoid valve ON/OFF LR_INLET Left rear ABS pressure retention solenoid valve...
Page 669 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION ACTION INSPECT BATTERY VOLTAGE Yes Make sure that battery terminal connection is okay. • Is battery terminal voltage okay? Go to next step. Charge or replace battery, then go to Step 6. INSPECT BATTERY GRAVITY Yes Go to next step.
Page 670 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) End Of Sie DTC B1342 A6E697367650W04 Caution • When attaching the tester lead to the DSC HU/CM connector the SST (49 G066 004) must be used. B1342 DSC HU/CM DETECTION The on-board diagnostic function detects control module malfunction. CONDITION POSSIBLE •...
Page 671 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION ACTION INSPECT DSC HU/CM TO BRAKE SWITCH Yes Go to next step. FOR OPEN CIRCUIT Repair or replace harness for open circuit between DSC • Turn ignition key to OFF. HU/CM and brake switch, then go to next step. •...
Page 672 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DTC B1627 A6E697367650W06 Caution • When attaching the tester lead to the DSC HU/CM connector the SST (49 G066 004) must be used. B1627 Reverse signal • Reverse signal is input for 10 seconds or more while driving at a vehicle speed of DETECTION CONDITION 65 km/h {40.3 mph}.
Page 673 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION ACTION CHECK TR SWITCH FOR DTCs (ATX) Yes Follow inspection procedures for TR switch. • Turn ignition key to OFF. Go to step 4. • Connect WDS or equivalent to DLC-2. •...
Page 674 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION ACTION VERIFY OTHER DTC HAS BEEN RECORDED Yes Go to applicable DTC inspection. • If any of DTC C1186 and/or C1266 has also Go to next step. been stored? INSPECT ABS FUSE CONDITION Yes Go to next step.
Page 675: Dtc C1119
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) STEP INSPECTION ACTION VERIFY PUMP MOTOR OPERATION Yes Go to next step. • Turn ignition key to OFF. Repair DSC HU/CM, then go to next step. • Remove SST (adapter harness) and connect all disconnected connectors. •...
Page 676: Dtc C1125
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION ACTION CHECK FOR PCM FOR DTCs Yes Follow inspection procedures for engine control system. • Turn ignition key to OFF. Go to next step. • Connect WDS or equivalent to DLC-2 •...
Page 677: Dtc C1145, C1155, C1165, C1175
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DTC C1140 A6E697367650W11 C1140 DSC HU/CM (pump) DETECTION Right front and left rear wheels, or left front and right rear wheel-lock is detected during DSC operation. CONDITION POSSIBLE Stuck pump motor in DSC HU/CM CAUSE Diagnostic procedure STEP INSPECTION...
Page 678 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION ACTION INSPECT WHEEL-SPEED SENSOR CIRCUIT Yes Go to next step. FOR OPEN CIRCUIT Go to Step 3. • Turn ignition key to OFF. • Disconnect DSC HU/CM connector. • Measure resistance between suspected sensor terminals of DSC HU/CM connector (harness side).
Page 679 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) STEP INSPECTION ACTION INSPECT WHEEL-SPEED SENSOR CIRCUIT Yes Repair or replace harness for short to ground circuit between DSC HU/CM and wheel-speed sensor(s), then go FOR SHORT TO GROUND • Turn ignition key to OFF. to Step 5.
Page 680 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION ACTION VERIFY OTHER DTC HAS BEEN RECORDED Yes Go to applicable DTC inspection. • Have DTCs related to solenoid valve, pump Go to next step. motor, or pump motor relay been stored? P–84...
Page 681 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) STEP INSPECTION ACTION VERIFY IF CURRENT CONCERNED INPUT Yes Go to Step 8. SIGNAL STATUS IS INTERMITTENT OR If there is a difference in speed of four wheels, go to next CONSTANT step. • Turn ignition key to OFF. If any wheel speed is 0 km/h {0 mph}, go to Step 4.
Page 682 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) STEP INSPECTION ACTION INSPECT DSC HU/CM OPERATION Yes Go to next step. • Perform DSC HU/CM system inspection. Replace DSC HU/CM, then go to next step. • See P–35 DSC SYSTEM INSPECTION • Is it okay? VERIFY TROUBLESHOOTING COMPLETED Yes Replace DSC HU/CM, then go to next step.
Page 683 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION ACTION INSPECT ABS FUSE CONDITION Yes Go to next step. • Is ABS fuse (60 A) okay? Replace fuse, then go to Step 4. INSPECT FAIL-SAFE RELAY POWER Yes Go to next step. SUPPLY CIRCUIT FOR OPEN CIRCUIT Repair or replace harness for open circuit between battery •...
Page 684 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) STEP INSPECTION ACTION VERIFY TROUBLESHOOTING COMPLETED Yes Replace DSC HU/CM, then go to next step. • Clear DTC from memory. Go to next step. (See P–46 Clearing DTCs Procedures) • Start engine and drive vehicle at 10 km/h {6.2 mph} or above.
Page 685 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) C1280, C1730, C1951, C1952, C1959 Combine sensor • C1280: — Yaw rate sensor part 0-point correction value is 3 or more, or 2 or less. — Output voltage value from yaw rate sensor part remains absolutely unchanged. —...
Page 686 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION ACTION INSPECT COMBINE SENSOR POWER Yes Go to next step. SUPPLY CIRCUIT FOR OPEN CIRCUIT Repair or replace harness for open circuit between yaw rate • Turn ignition key to ON (engine OFF). sensor terminal C and ignition switch, then go to Step 8.
Page 687 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) End Of Sie DTC C1414 A6E697367650W16 C1414 DSC HU/CM mismatched installation • Detection of situation where vehicle-type or drive system input signal and DSC HU/CM information DETECTION CONDITION remains incongruent through CAN information POSSIBLE • Mismatched installation of DSC HU/CM CAUSE Diagnostic procedure STEP...
Page 688 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DTC C1510, C1511, C1512, C1513 A6E697367650W21 C1510 RF solenoid valve, motor or RF wheel-speed sensor/sensor rotor C1511 LF solenoid valve, motor or LF wheel-speed sensor/sensor rotor C1512 RR solenoid valve, motor or RR wheel-speed sensor/sensor rotor C1513 LR solenoid valve, motor or LR wheel-speed sensor/sensor rotor •...
Page 689: Dtc C1955, C1956
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DTC C1955, C1956 A6E697367650W19 Caution • When attaching the tester lead to the DSC HU/CM connector the SST (49 G066 004) must be used. C1955, C1956 Steering angle sensor • C1955: — Output voltages from steering angle sensors 1 and 2 are not at 1 V or less, or not at 3.25 V or more.
Page 690 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION ACTION INSPECT STEERING ANGLE SENSOR Yes Go to next step. POWER SUPPLY CIRCUIT FOR OPEN Repair or replace harness for open circuit between steering CIRCUIT angle sensor terminal A and ignition switch, then go to Step •...
Page 691 ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) STEP INSPECTION ACTION INSPECT STEERING ANGLE SENSOR Yes Go to next step. SIGNAL CIRCUIT FOR OPEN CIRCUIT Repair or replace harness for open circuit between DSC • Inspect continuity between DSC HU/CM HU/CM terminal and steering angle sensor terminal, then go terminal (harness side) and steering angle to Step 7.
Page 692: Dtc U2021
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DTC U2021 A6E697367650W22 Note • To warm up the engine completely, idle the engine and wait for more than 5 minutes. U2021 Engine coolant temperature • After engine is warmed up, engine coolant temperature is 0 °C {32 °F} or less, and TCS operation is DETECTION CONDITION inhibited by PCM.
Page 693: Troubleshooting (Abs/Tcs/Dynamic Stability Control
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) SYSTEM WIRING DIAGRAM A6E699067650W01 ABS (ABS/TCS) A6E6921T001 IG switch Cruise actuator SUS 15 A fuse TCS OFF switch ABS 60 A fuse DLC-2 Meter CAN-H ABS warning light CAN-L Brake system warning light ABS Wheel-speed sensor TCS OFF light Battery...
Page 694 TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) A6E6920T005 IG switch DSC OFF light SUS 15A fuse DSC indicator light ABS 60 A fuse CAN driver Meter Battery ABS warning light Cruise actuator Brake system warning light DSC OFF switch P–98...
Page 695: Precaution
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) DLC-2 Brake switch CAN-H Brake light CAN-L Back-up light switch (MTX only) Wheel-speed sensor Back-up light Combine sensor Audio unit, Wiper and washer switch, Car-navegation unit, Auto leveling control unit Steering angle sensor End Of Sie FOREWORD A6E699067650W02 •...
Page 696 TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) Warning lights that may Cases in which the light may Conditions in which the ABS, EBD, TCS and DSC illuminate and/or flash illuminate light will go out control All the following lights When the engine coolant When engine is started and ABS: Cuts control.
Page 697 TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) Vehicle with DSC 1. The ABS warning light and/or BRAKE system warning light and/or DSC indicator light and/or TSC OFF light illuminate even when the system is normal. Warning lights that may Cases in which the light may Conditions in which the ABS, EBD, TCS and DSC illuminate and/or flash...
Page 698 TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) (2) Malfunction in hydraulic system • Symptom in hydraulic system malfunction are similar to those in a conventional brake malfunction. However, it is necessary to determine if the malfunction is in a DSC component or the conventional brake system.
Page 699 TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) 4. Shake each connector or wire harness a bit vertically and horizontally while monitoring the PID. • If PID value is unstable, check for poor connection. YDE6980W002 Inspection method for sensors 1. Connect WDS or equivalent to DLC-2. 2.
Page 700: Symptom Troubleshooting
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) SYMPTOM TROUBLESHOOTING A6E699067650W04 • Verify the symptoms, and perform troubleshooting according to the appropriate number. Vehicles with ABS/TCS Symptom ABS warning light, BRAKE system warning light, TCS OFF light do not illuminate with ignition switch on. Neither ABS warning light nor BRAKE system warning light illuminate with ignition switch on.
Page 701 TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) Vehicle with ABS/TCS A6E6980W002 P–105...
Page 702 TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) Vehicle with DSC A6E6980W100 End Of Sie P–106...
Page 703: No.1 Abs Warning Light, Brake System Warning Light, Tcs Off Light Do Not Illuminate With Ignition Switch On
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.1 ABS WARNING LIGHT, BRAKE SYSTEM WARNING LIGHT, TCS OFF LIGHT DO NOT ILLUMINATE WITH IGNITION SWITCH ON A6E699067650W05 Vehicle with ABS/TCS ABS warning light, BRAKE system warning light, TCS OFF light do not illuminate with ignition switch [TROUBLESHOOTING HINTS] •...
Page 704: No.2 Neither Abs Warning Light Nor Brake System Warning Light Illuminate With Ignition Switch On
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.2 NEITHER ABS WARNING LIGHT NOR BRAKE SYSTEM WARNING LIGHT ILLUMINATE WITH IGNITION SWITCH ON A6E699067650W06 Neither ABS warning light nor BRAKE system warning light illuminate with ignition switch [TROUBLESHOOTING HINTS] • Malfunction of instrument cluster or ABS/TCS HU/CM •...
Page 705: No.3 Abs Warning Light Does Not Illuminate With Ignition Switch On
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.3 ABS WARNING LIGHT DOES NOT ILLUMINATE WITH IGNITION SWITCH ON A6E699067650W07 ABS warning light does not illuminate with ignition switch on. [TROUBLESHOOTING HINTS] • Malfunction of instrument cluster or ABS/TCS HU/CM Diagnostic procedure STEP INSPECTION ACTION COMFIRM DTC U1900 USING WDS OR Yes Go to next step.
Page 706: No.5 Tcs Off Light, Tcs Indicator Light Do Not Illuminate With Ignition Switch On
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.5 TCS OFF LIGHT, TCS INDICATOR LIGHT DO NOT ILLUMINATE WITH IGNITION SWITCH ON A6E699067650W09 TCS OFF light , TCS indicator light do not illuminate with ignition switch on. [TROUBLESHOOTING HINTS] • Malfunction of instrument cluster or ABS/TCS HU/CM •...
Page 707: Light Stay On More Than
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) STEP INSPECTION ACTION • When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while doing the inspection to discover whether poor contact points are the cause of any intermittent malfunction. If there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly and undamaged.
Page 708 TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) STEP INSPECTION ACTION INSPECT PID/DATA IN ABS/TCS HU/CM Yes Go to Step 7. Inspect the following items using WDS or Go to next step. equivalent PID/DATA monitor function. • ABS_LAMP (ABS warning light) • BRAKE_ LAMP (BRAKE system warning light) •...
Page 709: No.7 Abs Warning Light Stays On More Than 4 Seconds With Ignition Switch On
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) STEP INSPECTION ACTION End Of Sie NO.7 ABS WARNING LIGHT STAYS ON MORE THAN 4 SECONDS WITH IGNITION SWITCH ON A6E699067650W11 ABS warning light stays on more than 4 seconds with ignition switch on. [TROUBLESHOOTING HINTS] •...
Page 710: No.8 Brake System Warning Light Stays On More Than 4 Seconds With Ignition Switch On
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) STEP INSPECTION ACTION INSPECT WIRING HARNESS BETWEEN ABS/ Yes Repair wiring harness between ABS/TCS HU/CM and data TCS HU/CM AND DLC-2 (DATA LINK link connector. CONNECTOR-2) FOR SHORT TO GROUND Replace ABS/TCS HU/CM (communication circuit Is there continuity between SST connector malfunction is ABS/TCS HU/CM).
Page 711 TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) STEP INSPECTION ACTION INSPECT PID/DATA IN ABS/TCS HU/CM Yes Connect ABS/TCS HU/CM connector terminal X securely, then go to next step. Inspect (BRAKE system warning light) using WDS or equivalent PID/DATA monitor function. Go to step 6. Is BRAKE_LAMP on after more than 4 seconds with ignition switch on? VERIFY WHETHER MALFUNCTION IS IN...
Page 712: No.9 Tcs Off Light Stays On More Than 4 Seconds With Ignition Switch On
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.9 TCS OFF LIGHT STAYS ON MORE THAN 4 SECONDS WITH IGNITION SWITCH ON A6E699067650W13 BRAKE system warning light stays on more than 4 seconds with ignition switch on. (Parking brake is released.) [TROUBLESHOOTING HINTS] • Warning light circuit open or shorted to ground in ABS/TCS HU/CM INSPECT WIRING HARNESS BETWEEN ABS/ Yes If a communication error message is displayed even after inspecting according to procedures displayed on WDS or...
Page 713: No.10 Tcs Does Not Work Correctly
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.10 TCS DOES NOT WORK CORRECTLY A6E699067650W14 TCS does not work correctly. [TROUBLESHOOTING HINTS] • There is difference in size or air pressure between the front and rear tires. • There is malfunction in the engine control system. •...
Page 714 TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION ACTION CHECK FOR DTCS IN DSC HU/CM Yes Perform inspection using appropriate DTC. • Check the DTC for the DSC ON-BOARD Go to next step. DIAGNOSTIC SYSTEM. • Have DTCs been recorded in memory? CHECK TO SEE WHETHER MALFUNCTION Yes Go to next step.
Page 715: No.2 Any Of The Following
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.2 ANY OF THE FOLLOWING LIGHTS STAY ON: (ABS WARNING LIGHT, BRAKE SYSTEM WARNING LIGHT, DSC INDICATOR LIGHT AND/OR OFF LIGHT) A6E699067650W17 Any of the following lights stay on: (ABS warning light, BRAKE system warning light, DSC indicator light and/or DSC OFF light) [TROUBLESHOOTING HINTS] •...
Page 716: No.3 There Is A Malfunction In
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.3 THERE IS A MALFUNCTION IN THE SYSTEM EVEN THOUGH ABS WARNING LIGHT, BRAKE SYSTEM WARNING LIGHT, DSC INDICATOR LIGHT AND DSC OFF LIGHT DO NOT ILLUMINATE A6E699067650W18 There is a malfunction in the system even though ABS warning light, BRAKE system warning light, DSC indicator light and DSC OFF light do not illuminate.
Page 717: No.5 Dsc*2 Operates
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.5 DSC OPERATES FREQUENTLY/DSC DOES NOT WORK CORRECTLY : DSC INDICATOR LIGHT GOES ON AND OFF WHILE DSC OPERATES A6E699067650W20 DSC (*2) operates frequently. /DSC does not work correctly. (*2): DSC indicator light goes on and off while DSC operates. [TROUBLESHOOTING HINTS] •...
Page 718 SUSPENSION LOCATION INDEX ..........R-2 TRAILING LINK FRONT SUSPENSION LOCATION INDEX..R-2 REMOVAL/INSTALLATION ......R-35 REAR SUSPENSION LOCATION INDEX ...R-3 REAR CROSSMEMBER GENERAL PROCEDURES ........R-4 REMOVAL/INSTALLATION ......R-37 PRECAUTION (SUSPENSION) ......R-4 WHEEL ALIGNMENT..........R-4 WHEEL ALIGNMENT PRE-INSPECTION...R-4 FRONT WHEEL ALIGNMENT......R-5 REAR WHEEL ALIGNMENT .......R-6 WHEEL AND TIRE ..........R-7 WHEEL BALANCE ADJUSTMENT (ALUMINUM ALLOY WHEEL) ......R-7 FRONT SUSPENSION ...........R-9...
Page 719: Location Index
LOCATION INDEX LOCATION INDEX FRONT SUSPENSION LOCATION INDEX A6E740001015W01 A6E7414W033 Front shock absorber and coil spring Front lower arm (rear) (See R–9 FRONT SHOCK ABSORBER AND (See R–19 FRONT LOWER ARM (REAR) SPRING REMOVAL/INSTALLATION) REMOVAL/INSTALLATION) (See R–21 FRONT LOWER ARM (REAR) Front shock absorber INSPECTION) (See...
Page 720: Rear Suspension Location Index
LOCATION INDEX REAR SUSPENSION LOCATION INDEX A6E740001016W01 A6E7416W016 Rear shock absorber Rear lateral link (SeeR–28 REAR SHOCK ABSORBER REMOVAL/ (SeeR–33 REAR LATERAL LINK REMOVAL/ INSTALLATION) INSTALLATION) (See R–28 REAR SHOCK ABSORBER Trailing link INSPECTION) (SeeR–35 TRAILING LINK REMOVAL/ (See R–28 REAR SHOCK ABSORBER DISPOSAL) INSTALLATION) Rear coil spring...
Page 721: General Procedures
GENERAL PROCEDURES , WHEEL ALIGNMENT GENERAL PROCEDURES PRECAUTION (SUSPENSION) A6E741001013W01 Wheels and Tires Removal/Installation 1. When a wheel is installed, tighten it to 88—118 N·m {9.0—12.0 kgf·m, 65.0—87.0 ft·lbf}. Suspension Links Removal/Installation 1. Tighten any part of the suspension that uses rubber bushings only after the vehicle has been lowered and unloaded.
Page 722: Front Wheel Alignment
WHEEL ALIGNMENT, WHEEL AND TIRE FRONT WHEEL ALIGNMENT A6E741201015W01 Specification (Unloaded)* Normal Fuel gauge indication Item Empty Full (mm {in}) Tire: 2±4 {0.08±0.16}, Rim inner: 1±3 {0.04±0.12} Total toe-in (degree) 0°11′±0°22′ 18 inch wheel: 36°±3° Inner Except for above: 39°±3° Maximum steering angle 18 inch wheel: 30°±3°...
Page 723: Rear Wheel Alignment
WHEEL ALIGNMENT REAR WHEEL ALIGNMENT A6E741201016W01 Specification (Unloaded)* Normal Fuel gauge indication Item Empty Full (mm {in}) Tire: 2±4 {0.08±0.16}, Rim inner: 1±3 {0.04±0.12} Total toe-in (degree) 0°11′±0°22′ –1°05′±1° –1°07′±1° –1°09′±1° –1°11′±1° –1°13′±1° Camber angle* Thrust angle (degree) 0°±0°48′ Elevated Fuel gauge indication Item Empty...
Page 724: Wheel And Tire
WHEEL ALIGNMENT, WHEEL AND TIRE 2. Adjust the toe-in turning the adjusting link. Specification Total Toe-in: 2±4 mm {0.08±0.16 in} Note • Toe change amount: 0°43′ / one rotation A6E7412W005 3. Tighten the locknut. Tightening torque 68.6—98.1 N·m {7.0—10.0 kgf·m, 50.6—72.3 ft·lbf} A6E7412W004 End Of Sie WHEEL AND TIRE...
Page 725 WHEEL AND TIRE 6. If attaching 2 balance weights, position them so that each is on either side of the position indicated by the wheel balancer. Caution • Do not attach weight balances in a row. • Do not overlap the balance weights. •...
Page 726: Front Suspension
FRONT SUSPENSION FRONT SUSPENSION FRONT SHOCK ABSORBER AND SPRING REMOVAL/INSTALLATION A6E741404910W01 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.
Page 727 FRONT SUSPENSION Bolt (Front Shock Absorber Lower Side) Removal Note 1. Support the knuckle with a jack to prevent from falling. Piston Rod Nut Removal Note Warning • Removing the piston rod nut is dangerous. The shock absorber and spring could fly off under tremendous pressure and cause serious injury or death.
Page 728 FRONT SUSPENSION 4. Compress the coil spring using the SSTs. 5. Install the shock absorber so that the lower end of the coil spring is seated on the step of the lower spring seat. 6. Make sure that the marks on the shock absorber and dust boot are aligned.
Page 729: Front Shock Absorber Inspection
FRONT SUSPENSION Damper Fork Installation Note 1. Align the gap of the damper fork with the projections of the damper. 2. Tighten the bolt. A6E7414W005 End Of Sie FRONT SHOCK ABSORBER INSPECTION A6E741434700W01 1. Remove the front shock absorber from the vehicle. 2.
Page 730: Front Upper Arm Removal/Installation
FRONT SUSPENSION FRONT UPPER ARM REMOVAL/INSTALLATION A6E741434200W01 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.
Page 731: Front Upper Arm Inspection
FRONT SUSPENSION 2. Separate the ball joint from the knuckle using the SST. A6E7414W006 Bolt (Front Upper Arm) Removal Note 1. Remove the nuts (3 locations) from the upper part of the front shock absorber. 2. Pull the front shock absorber and coil spring out of the way, towards the outer side of the vehicle.
Page 732: Front Lower Arm (Front) Removal/Installation
FRONT SUSPENSION End Of Sie FRONT LOWER ARM (FRONT) REMOVAL/INSTALLATION A6E741434300W01 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. A6E7414W018 Front lower arm (front) ball joint Front lower arm (front) bushing (inner side) (See R–16 Front Lower Arm (Front) Ball Joint (See...
Page 733 FRONT SUSPENSION Front Lower Arm (Front) Ball Joint Removal Note 1. Separate the ball joint from the knuckle using the SSTs. A6E7414W030 Front Lower Arm (Front) Bushing (Inner Side) Removal Note 1. Press the bushing (inner side) out using the SSTs.
Page 734 FRONT SUSPENSION 2. Press the bushing in to the marking using the SSTs. A6E7414W012 3. Verify that clearance distance A—B is 8.75 mm— 10.75 mm {0.3445 in—0.4232 in}. A6E7414W003 Front Lower Arm (Front) Bushing (Inner Side) Installation Note 1. Mark the new bushing as shown in the figure. A6E7414W013 2.
Page 735: Front Lower Arm (Front) Inspection
FRONT SUSPENSION 3. Verify that clearance distance A—B is 12.75 mm—14.75 mm {0.5020 in—0.5807 in}. A6E7414W007 Clip Installation Note 1. Wipe the grease off the ball stud. 2. Fill the inside of the new dust boot with grease. 3. Install the boot on the ball joint. 4.
Page 736: Front Lower Arm (Rear) Removal/Installation
FRONT SUSPENSION FRONT LOWER ARM (REAR) REMOVAL/INSTALLATION A6E741434300W02 1. Remove the under cover. 2. Remove the splash shield. 3. Remove the steering gear and linkage installation bolts, and pipe component installation bolts from the front crossmember, then suspend the steering gear and linkage with a cable. Tightening torque •...
Page 737 FRONT SUSPENSION Crossmember Bracket Removal Note Warning • Removing the crossmember is dangerous. The crossmember component could fall and cause serious injury or death. Verify that the jack securely supports the crossmember component before removing the crossmember bracket. 1. Support the crossmember component with a jack and remove the nuts.
Page 738: Front Lower Arm (Rear) Inspection
FRONT SUSPENSION 2. Press the bushing in to the marking using the SSTs. A6E7414W027 3. Verify that clearance distance A—B is 23.75 mm—25.75 mm {0.936 in—1.013 in}. A6E7414W028 Clip Installation Note 1. Wipe the grease off the ball stud. 2. Fill the inside of the new dust boot with grease. 3.
Page 739: Front Stabilizer Removal/Installation
FRONT SUSPENSION FRONT STABILIZER REMOVAL/INSTALLATION 1. Remove the front crossmember component. (See R–23 FRONT CROSSMEMBER REMOVAL/ INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. Adjust the headlight zeroset. (See T–31 HEADLIGHT ZEROSET.) 5.
Page 740: Stabilizer Control Link Inspection
FRONT SUSPENSION STABILIZER CONTROL LINK INSPECTION A6E741434150W01 1. Remove the stabilizer control link from the vehicle. 2. Inspect for bending and damage. 3. Measure the ball joint starting torque. (1) Rock the ball joint stud side to side 10 times. (2) Rotate the ball joint stud 10 times.
Page 741 FRONT SUSPENSION A6E7414W100 Nut (stabilizer control link) Crossmember component Front lower arm (front) ball joint Stabilizer bracket and bushing (See R–16 Front Lower Arm (Front) Ball Joint Front Stabilizer Removal Note) Front lower arm (front) Front lower arm (rear) ball joint Front lower arm (rear) (See R–19 Front Lower Arm (Rear) Ball Joint...
Page 742 FRONT SUSPENSION No.1 Engine Mount Center Bolt Removal Note 1. Suspend the engine using the SST. 2. Remove the No.1 engine mount center bolt. A6E7414W016 Crossmember Bracket Removal Note Warning • Removing the crossmember is dangerous. The crossmember component could fall and cause serious injury or death.
Page 743 FRONT SUSPENSION Front Crossmember Bushing Installation Note 1. Set the bushings as shown in the figure. A6E7414W041 2. Install the bushing onto the crossmember using the SSTs. A6E7414W042 End Of Sie R–26...
Page 744: Transverse Member Removal/Installation
FRONT SUSPENSION TRANSVERSE MEMBER REMOVAL/INSTALLATION A6E741434890W01 1. Remove in the order indicated in the table. Transverse member and transverse cover Transverse cover (European (L.H.D. U.K.) specs.) (See R–27 Transverse Cover Installation Note) Transverse member 2. Install in the reverse order of removal. A6E7414W037 Transverse Cover Installation Note 1.
Page 745: Rear Suspension
REAR SUSPENSION REAR SUSPENSION REAR SHOCK ABSORBER REMOVAL/INSTALLATION A6E741628700W01 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.
Page 746: Rear Coil Spring Removal/Installation
REAR SUSPENSION REAR COIL SPRING REMOVAL/INSTALLATION A6E741628011W01 1. Remove the rear auto leveling sensor. (See T–32 REAR AUTO LEVELING SENSOR REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. Adjust the headlight zeroset. (See T–31 HEADLIGHT ZEROSET.)
Page 747: Rear Lower Arm Removal/Installation
REAR SUSPENSION Bound Stopper (Body Side) Removal/Installation Note 1. Remove or/and install the bound stopper (body side) using the extension bar. Rear Coil Spring Installation Note 1. Install the coil spring so that the distinguisher mark is located on under side. 2.
Page 748: Rear Upper Arm Removal/Installation
REAR SUSPENSION REAR UPPER ARM REMOVAL/INSTALLATION A6E741628210W01 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.
Page 749 REAR SUSPENSION Bolt (Rear Shock Absorber Lower Side) Removal Note 1. Support the trailing link with a jack. A6E7416W005 Bolt (Rear Upper Arm) Removal Note 1. Loosen the bolts on the inner and outer side of the lateral link. Rear Upper Arm Bushing Removal Note 1.
Page 750: Rear Lateral Link Removal/Installation
REAR SUSPENSION 3. Verify that clearance distance A—B is 14.0 mm— 16.0 mm {0.56 in-0.62 in}. A6E7416W013 End Of Sie REAR LATERAL LINK REMOVAL/INSTALLATION A6E741628600W01 1. Remove the rear lateral link. 93.1—126.4 {9.50—12.88, 68.67—93.22} REAR LATERAL LINK 93.1—126.4 {9.50—12.88, 68.67—93.22} N·m {kgf·m, ft·lbf} B6U0214W015 Caution...
Page 751: Rear Stabilizer Removal/Installation
REAR SUSPENSION End Of Sie REAR STABILIZER REMOVAL/INSTALLATION A6E741628100W01 1. Remove the rear auto leveling sensor. (See T–32 REAR AUTO LEVELING SENSOR REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4.
Page 752: Stabilizer Control Link Inspection
REAR SUSPENSION STABILIZER CONTROL LINK INSPECTION A6E741634150W01 1. Remove the stabilizer control link from the vehicle. 2. Inspect for bending and damage. 3. Measure the ball joint starting torque. (1) Rock the ball joint stud side to side 10 times. (2) Rotate the ball joint stud 10 times.
Page 753 REAR SUSPENSION A6E7416W018 ABS wheel-speed sensor Bolt (rear shock absorber lower side) Parking brake cable Bolt (trailing link front side) (See R–37 Bolt (Trailing Link Front Side) Removal Calliper component Note) (See R–37 Caliper Component Removal Note) (See R–37 Bolt (Trailing Link Front Side) Installation Disc plate Note) Spindle and hub component...
Page 754 REAR SUSPENSION Caliper Component Removal Note 1. Suspend the caliper aside with cable. Bolt (Trailing Link Front Side) Removal Note 1. Support the trailing link with a jack. Caution • Removing the trailing link is dangerous. The trailing link could fall and cause serious injury or death.
Page 755 REAR SUSPENSION A6E7416W020 Spindle and hub component ABS wheel-speed sensor (See M–10 WHEEL HUB, HUB SPINDLE Parking brake cable REMOVAL/INSTALLATION) Caliper component Bolt (stabilizer control link) (See R–39 Caliper Component Removal Note) Rear coil spring Disc plate (See R–29 REAR COIL SPRING REMOVAL/ INSTALLATION) R–38...
Page 756 REAR SUSPENSION Rear lower arm Trailing link (See R–30 REAR LOWER ARM REMOVAL/ Rear lateral link INSTALLATION) Rear upper arm Bolt (rear shock absorber lower side) Rear stabilizer Bolt (trailing link front side) Rear crossmember (See R–39 Bolt (Trailing Link Front Side) Removal Rear crossmember Bushing Note) (See...
Page 757 REAR SUSPENSION Rear Crossmember Bushing Installation Note 1. Set the bushings as shown in the figure. A6E7416W021 2. Tap the bushing onto the rear crossmember using the SSTs. A6E7416W002 Bolt (Trailing Link Front Side) Installation Note 1. Support the trailing link with a jack. 2.
Page 758 B ODY LOCATION INDEX ..........S-4 POWER DOOR LOCK SYSTEM ......S-30 EXTERIOR............S-4 FRONT DOOR LOCK ACTUATOR INTERIOR............S-6 INSPECTION ..........S-30 DOOR ..............S-9 REAR DOOR LOCK ACTUATOR BONNET ............... S-10 INSPECTION ..........S-32 BONNET REMOVAL/INSTALLATION ....S-10 TRUNK LID LOCK ACTUATOR BONNET ADJUSTMENT........
Page 759 MOLDING ............. S-55 GLOVE COMPARTMENT FRONT BELTLINE MOLDING REMOVAL ..S-55 REMOVAL/INSTALLATION ......S-85 CONSOLE REMOVAL/INSTALLATION.....S-86 FRONT BELTLINE MOLDING CONSOLE DISASSEMBLY/ASSEMBLY ...S-86 INSTALLATION..........S-55 TRIM..............S-87 REAR BELTLINE MOLDING REMOVAL... S-56 A-PILLAR TRIM REMOVAL .......S-87 REAR BELTLINE MOLDING A-PILLAR TRIM INSTALLATION .......S-87 INSTALLATION..........
Page 760 SEAT..............S-105 FRONT SEAT REMOVAL/INSTALLATION ..S-105 FRONT SEAT DISASSEMBLY/ASSEMBLY ... S-106 REAR SEAT REMOVAL/INSTALLATION ..S-110 REAR SEAT DISASSEMBLY/ASSEMBLY ..S-112 REMOTE HANDLE LEVER REMOVAL/INSTALLATION......S-114 SEAT BACK STRIKER REMOVAL/INSTALLATION......S-115 POWER SEAT SWITCH INSPECTION ... S-115 FRONT TILT MOTOR INSPECTION ....S-116 REAR TILT MOTOR INSPECTION ....
Page 761: Location Index
LOCATION INDEX LOCATION INDEX EXTERIOR A6E770001086W01 Front A6E7700W001 Shroud panel Glass panel (See S–119 SHROUD PANEL REMOVAL/ (See S–74 GLASS PANEL REMOVAL/ INSTALLATION) INSTALLATION) (See S–75 GLASS PANEL ADJUSTMENT) Radiator grille (See S–50 RADIATOR GRILLE REMOVAL/ Sunroof unit INSTALLATION) (See S–76 SUNROOF UNIT REMOVAL/ INSTALLATION) Front bumper...
Page 762 LOCATION INDEX Rear A6E7700W002 Rear spoiler Side protector (See S–54 REAR SPOILER REMOVAL/ (See S–52 SIDE PROTECTOR REMOVAL) INSTALLATION) (See S–53 SIDE PROTECTOR INSTALLATION) Rear window glass Front beltline molding (See S–68 REAR WINDOW GLASS REMOVAL) (See S–55 FRONT BELTLINE MOLDING (See S–70 REAR WINDOW GLASS REMOVAL)
Page 763: Interior
LOCATION INDEX INTERIOR A6E770001086W02 Front A6E7700W003 A-pillar trim Lower panel (See S–87 A-PILLAR TRIM REMOVAL) (See S–84 LOWER PANEL REMOVAL/ (See S–87 A-PILLAR TRIM INSTALLATION) INSTALLATION) Dashboard Column cover (See S–82 DASHBOARD REMOVAL/ (See S–84 COLUMN COVER REMOVAL/ INSTALLATION) INSTALLATION) (See S–83 DASHBOARD DISASSEMBLY/ Console...
Page 764 LOCATION INDEX Recliner motor Seat warmer unit (See S–116 RECLINER MOTOR INSPECTION) (See S–118 SEAT WARMER UNIT INSPECTION) Power seat switch (See S–115 POWER SEAT SWITCH INSPECTION) Rear A6E7700W004 Rearview mirror Headliner (See S–61 REARVIEW MIRROR REMOVAL) (See S–96 HEADLINER REMOVAL/ (See S–61 REARVIEW MIRROR INSTALLATION)
Page 765 LOCATION INDEX Rear door trim Rear scuff plate (See S–90 REAR DOOR TRIM REMOVAL/ (See S–89 REAR SCUFF PLATE REMOVAL/ INSTALLATION) INSTALLATION) C-pillar trim Front floor covering (See S–89 C-PILLAR TRIM REMOVAL/ (See S–99 FRONT FLOOR COVERING REMOVAL/ INSTALLATION) INSTALLATION) Rear buckle Child restraint seat anchor (See...
Page 766: Door
LOCATION INDEX DOOR A6E770001086W03 A6E7700WH01 Front door Front outer handle (See S–15 FRONT DOOR REMOVAL/ (See S–21 FRONT OUTER HANDLE REMOVAL/ INSTALLATION) INSTALLATION) (See S–16 DOOR ADJUSTMENT) Rear outer handle Rear door (See S–21 FRONT OUTER HANDLE REMOVAL/ (See S–15 REAR DOOR REMOVAL/ INSTALLATION) INSTALLATION) Front door key cylinder...
Page 767: Bonnet
BONNET BONNET BONNET REMOVAL/INSTALLATION A6E771001084W01 Warning • Removing the bonnet without supporting can be dangerous. The bonnet may fall and injure you. Always perform the following procedure with at least another person. 1. Disconnect the windshield washer hose. 2. To remove the bonnet hinge, remove the front fender panel.
Page 768 BONNET 4. Verify that the gap between the bonnet and the body is within the specification. Clearance a: 2.5—4.5 mm {0.08—0.17 in} A6E7710W004 Height Adjustment 1. Turn the stop rubber to adjust the height of the bonnet. A6E7710W006 A6E7710W003 2. Verify that the height between the bonnet and the body is within the specification.
Page 769: Front Fender Panel
FRONT FENDER PANEL FRONT FENDER PANEL FRONT FENDER PANEL REMOVAL/INSTALLATION A6E771252110W01 1. Disconnect the negative battery cable. 2. Remove the front side turn light. 3. Remove the fender molding. (See S–50 COWL GRILLE REMOVAL/INSTALLATION.) 4. Remove the front bumper. (See S–47 FRONT BUMPER REMOVAL/INSTALLATION.) 5.
Page 770: Door
DOOR DOOR FRONT DOOR STRUCTURAL VIEW A6E771458010W01 A6E7714W001 Front door Protector Front door hinge Outer handle Checker Front door key cylinder Front door latch and lock actuator Front door glass Front door unit Glass run channel Hole cover Front door weatherstrip A Power window motor Front door lower weatherstrip Power window regulator...
Page 771: Rear Door Structural View
DOOR REAR DOOR STRUCTURAL VIEW A6E771472010W01 A6E7714W002 Rear door Outer handle Rear door hinge Rear door glass Checker Quarter window glass Rear door latch and lock actuator Glass run channel Rear door unit Glass guide Hole cover Quarter window molding Power window motor Rear door weatherstrip A Regulator handle...
Page 772: Front Door Removal/Installation
DOOR FRONT DOOR REMOVAL/INSTALLATION A6E771458010W02 1. Disconnect the negative battery cable. 2. To remove the front door hinge, remove the front fender panel. 3. To remove the checker, remove the door speaker. 4. Remove in the order indicated in the table. Connector (See S–15 Connector Removal...
Page 773: Door Adjustment
DOOR End Of Sie DOOR ADJUSTMENT A6E771458010W03 1. Measure the gap and height between the front or rear door and the body. 2. If not as specified, loosen the front or rear door hinge installation bolts or the door lock striker installation screws, and reposition the door.
Page 774: Rear Door Glass Removal/Installation
DOOR 5. Remove the screws. 6. Insert your hand in hole of the front door unit, and lift out the front door glass. 7. Install in the reverse order of removal. A6E7714W003 End Of Sie REAR DOOR GLASS REMOVAL/INSTALLATION A6E771472510W01 1.
Page 775: Front Door Unit Removal/Installation
DOOR FRONT DOOR UNIT REMOVAL/INSTALLATION A6E771458971W01 1. Remove the front door glass. 2. Remove the inner handle. 3. Remove the front door speaker. 4. Disconnect the power window motor connector, front door lock actuator connector, power outside mirror connector. 5. Remove the door harness from the front door unit. 6.
Page 776: Front Door Latch And Lock Actuator Removal/Installation
DOOR 10. For power window system-equipped vehicles, remove the power window motor and power window regulator from the door unit. For manual window system-equipped vehicles, remove the regulator handle and manual window regulator. 11. Install in the reverse order of removal. A6E7714W017 End Of Sie FRONT DOOR LATCH AND LOCK ACTUATOR REMOVAL/INSTALLATION...
Page 777: Front Door Key Cylinder Removal/Installation
DOOR FRONT DOOR KEY CYLINDER REMOVAL/INSTALLATION A6E771458310W03 1. Remove the front door unit. 2. Remove the cover, then remove the bolt. A6E7714W027 3. For protector-equipped vehicles, pull out the protector tab from the latch and remove the protector. 4. Disconnect the rod. 5.
Page 778: Front Outer Handle Removal/Installation
DOOR FRONT OUTER HANDLE REMOVAL/INSTALLATION A6E771458410W01 1. Remove the front door glass. 2. Detach the outer handle and front door latch rod. 3. For protector-equipped vehicles, refer to key cylinder removal/installation to remove the protector. 4. Remove the bolts. A6E7714W004 5.
Page 779: Inner Handle Removal/Installation
DOOR INNER HANDLE REMOVAL/INSTALLATION A6E771458330W01 1. Remove the front door trim. 2. Using a flathead screwdriver, press and hold the hook in the direction indicated by arrow (1), and pull the shaft in the direction indicated by arrow (2), remove the shaft. 3.
Page 780: Power Window System
POWER WINDOW SYSTEM POWER WINDOW SYSTEM INITIAL SETTING A6E771666350W01 Note • A driver side window will not fully close automatically under following the conditions: — The battery has been disconnected during vehicle maintenance or for other reasons. — The power window main switch connector, or driver-side power window motor connector has been disconnected.
Page 781: Door Glass Position Change Procedure
POWER WINDOW SYSTEM DOOR GLASS POSITION CHANGE PROCEDURE A6E771666350W03 Note • After performing the following procedure, verify that the two-step down function operates normally and the door glass position has changed. If the two-step down function does not operate or the door glass position has not changed, the procedure was not performed properly.
Page 782: Power Window Switch Removal/Installation
POWER WINDOW SYSTEM POWER WINDOW SWITCH REMOVAL/INSTALLATION A6E771666350W04 1. Disconnect the negative battery cable. 2. Remove the front door trim or rear door trim. 3. Remove the screws, then the power window switch. 4. Install in the reverse order of removal. A6E7716W003 End Of Sie S–25...
Page 783: Power Window Main Switch Inspection
POWER WINDOW SYSTEM POWER WINDOW MAIN SWITCH INSPECTION A6E771666350W05 Driver’s side 1. Remove the driver-side front door trim. 2. Connect the power window main switch connector. 3. Measure the voltage at the power window main switch terminals as indicated below. 4.
Page 784 POWER WINDOW SYSTEM Except driver’s side 1. Turn the power-cut switch to UNLOCK. 2. Inspect for continuity between the power window main switch terminals using an ohmmeter. • If not as specified, replace the power window main switch. A6E7716W009 End Of Sie S–27...
Page 785: Power Window Regulator Removal/Installation
POWER WINDOW SYSTEM POWER WINDOW SUBSWITCH INSPECTION A6E771666370W01 1. Inspect for continuity between the power window subswitch terminals. • If not as specified, replace the power window subswitch. A6E7716W011 A6E7716W013 End Of Sie POWER WINDOW REGULATOR REMOVAL/INSTALLATION A6E771658560W01 1. Disconnect the negative battery cable. 2.
Page 786: Power Window Motor Removal/Installation
POWER WINDOW SYSTEM 7. Remove the power window regulator from the speaker installation hole. 8. Install in the reverse order of removal. A6E7716W007 End Of Sie POWER WINDOW MOTOR REMOVAL/INSTALLATION A6E771659560W01 1. Disconnect the negative battery cable. 2. Remove the front door trim or rear door trim. 3.
Page 787: Power Door Lock System
POWER WINDOW SYSTEM, POWER DOOR LOCK SYSTEM Except Driver's Side 1. Apply battery positive voltage to the power window motor terminals and inspect the operation of the power window motor. • If not as specified, replace the power window motor. Terminal Motor operation DOWN...
Page 788 POWER DOOR LOCK SYSTEM Door Lock-link Switch 1. Disconnect the front door lock actuator connector. 2. Inspect for continuity between the door lock-link switch terminals using an ohmmeter. • If not as specified, replace the front door lock actuator. A6E7718W008 A6E7718W012 Door Key Cylinder Switch 1.
Page 789: Rear Door Lock Actuator Inspection
POWER DOOR LOCK SYSTEM REAR DOOR LOCK ACTUATOR INSPECTION A6E771872310W01 Door Lock Actuator 1. Disconnect the front door lock actuator connector. 2. Apply battery positive voltage to the front door lock actuator terminals and inspect the operation of the front door lock actuator. •...
Page 790: Liftgate Lock Actuator Inspection
POWER DOOR LOCK SYSTEM LIFTGATE LOCK ACTUATOR INSPECTION A6E771862310W01 1. Disconnect the liftgate lock actuator connector. 2. Apply battery positive voltage to the liftgate lock actuator terminals and inspect the operation of the liftgate lock actuator. • If not as specified, replace the liftgate lock. Connection Actuator operation Lock...
Page 791: Door Lock Timer Unit Inspection
POWER DOOR LOCK SYSTEM DOOR LOCK TIMER UNIT INSPECTION A6E771867830W02 1. Measure the voltage at the door lock timer unit terminals (other than terminal 1E and 2W) as indicated below. • If not as specified, inspect the parts listed under “Action.” 2.
Page 792 POWER DOOR LOCK SYSTEM Voltage (V)/ Terminal Signal Connected to Test condition Action Continuity • Inspect key reminder Key reminder switch at on switch reminder Key reminder switch • Inspect related Other Below 1.0 switch harness • Inspect cargo Lliftgate is open (cargo Below 1.0 compartment light switch is on) compartment light...
Page 793: Door Lock Timer Unit Id Code Change
POWER DOOR LOCK SYSTEM End Of Sie DOOR LOCK TIMER UNIT ID CODE CHANGE A6E771801097W01 Note • When programming the ID code into a door lock timer unit, verify that other transmitters are not being operated in the vicinity. START Remove key from steering lock.
Page 794: Transmitter Battery Replacement
POWER DOOR LOCK SYSTEM TRANSMITTER BATTERY REPLACEMENT A6E771800110W01 1. Insert a small screwdriver into the slot and gently pry open the transmitter. A6E7718W001 2. Press the portion of the battery indicated by A and remove the battery. 3. Install a new battery (CR2025) into the front portion of the holder with the positive pole (+) facing up.
Page 795: Transmitter Battery Inspection
POWER DOOR LOCK SYSTEM TRANSMITTER BATTERY INSPECTION A6E771800110W02 Caution • Since the battery voltage does not drop fully if the button is pushed for only 4 seconds or less, it can not be properly examined to see whether it is good or bad. Always push the button for 5 seconds.
Page 796: Trunk Lid
TRUNK LID TRUNK LID TRUNK LID REMOVAL/INSTALLATION A6E772052610W01 Warning • Removing the stay damper without supporting the trunk lid can be dangerous. The trunk lid may fall and injure you. Open the trunk lid fully and support it before removing the stay damper. 1.
Page 797: Trunk Lid Disassembly/Assembly
TRUNK LID 6. Remove the nuts, then remove the trunk lid. 7. Remove the bolts, then remove the trunk lid hinge. 8. Install in the reverse order of removal. 9. Adjust the trunk lid. (See S–41 TRUNK LID ADJUSTMENT.) A6E7720W007 End Of Sie TRUNK LID DISASSEMBLY/ASSEMBLY A6E772052610W02...
Page 798: Trunk Lid Adjustment
TRUNK LID TRUNK LID ADJUSTMENT A6E772052610W03 1. Measure the gap and height between the front door and the body. 2. If not as specified, loosen the door hinge installation bolts or the door lock striker installation screws, and reposition the door. Clearance a: 2.5—4.5 mm {0.10—0.18 in} b: -1.0—1.0 mm {-0.04—0.04 in}...
Page 799: Liftgate
LIFTGATE LIFTGATE LIFTGATE REMOVAL/INSTALLATION A6E772262010W01 Warning • Removing the stay damper without supporting the liftgate can be dangerous. The liftgate may fall and injure you. Open the liftgate fully and support it before removing the stay damper. 1. Disconnect the negative battery cable. 2.
Page 800 LIFTGATE 9. To remove the stay damper, remove the bolt B. A6E7722W001 10. Install in the reverse order of removal. End Of Sie S–43...
Page 801: Liftgate Disassembly/Assembly
LIFTGATE LIFTGATE DISASSEMBLY/ASSEMBLY A6E772262010W02 1. Disconnect the negative battery cable. 2. Remove the liftgate lower trim. 3. To remove the liftgate outer handle and liftgate key cylinder, remove the rear finisher. 4. To remove the stud ball, separate the stud ball and the stay damper. 5.
Page 802: Liftgate Adjustment
LIFTGATE LIFTGATE ADJUSTMENT A6E772262010W03 1. Measure the gap and height between the liftgate and the body. 2. If not as specified, loosen the liftgate hinge installation bolts or the liftgate striker installation screws, and reposition the liftgate. Clearance a: 3.0—7.0 mm {0.12—0.28 in} b: -1.0—3.4 mm {-0.04—013 in} c: 2.8—5.2 mm {0.11—0.24 in} d: -1.2—1.2 mm {0.05—0.05 in}...
Page 803: Fuel-Filler Lid And Opener
FUEL-FILLER LID AND OPENER FUEL-FILLER LID AND OPENER FUEL-FILLER LID AND OPENER REMOVAL/INSTALLATION A6E772456890W01 1. To remove the fuel-filler lid opener, remove the left side trunk side trim (4SD) or trunk side lower trim (5HB). 2. To remove the fuel-filler lid opener cable, perform the following and turn over the floor covering. (1) Remove the driver-side front seat.
Page 804: Bumper
BUMPER BUMPER FRONT BUMPER REMOVAL/INSTALLATION A6E772650031W01 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. Screw A Fastener A Screw B Bolt Fastener B Front bumper (See S–47 Front Bumper Removal Note) (See S–48 Front Bumper Installation Note) 3.
Page 805: Front Bumper Disassembly/Assembly
BUMPER Front Bumper Installation Note 1. Spread the front bumper ends (wheel arches) apart. 2. Attach the front bumper to the body. 3. Press the front bumper connection portion into the body to engage with the bumper slider. End Of Sie FRONT BUMPER DISASSEMBLY/ASSEMBLY A6E772650031W02 1.
Page 806: Rear Bumper Removal/Installation
BUMPER REAR BUMPER REMOVAL/INSTALLATION A6E772650221W01 1. Disconnect the negative battery cable. 2. Remove the rear combination light. 3. Remove in the order indicated in the table. Screw A Screw B Screw C Fastener A Bolt A Fastener B Rear bumper (See S–49 Rear Bumper Removal Note)
Page 807: Exterior Attachment
BUMPER, EXTERIOR ATTACHMENT Refractor Removal Note 1. Lift the refractor up in the direction of the arrow, then unhook it from the rear bumper. A6E7726W002 End Of Sie EXTERIOR ATTACHMENT RADIATOR GRILLE REMOVAL/INSTALLATION A6E772850710W01 1. Remove the screws. 2. Press clip A in the direction of the arrow, pll the radiator grille outward and remove from the front bumper.
Page 808: Front Flap Removal/Installation
EXTERIOR ATTACHMENT FRONT FLAP REMOVAL/INSTALLATION A6E772851840W01 1. Remove the screws and fastner. 2. Remove the front flap. 3. Install in the reverse order of removal. A6E7728W011 End Of Sie REAR FLAP REMOVAL/INSTALLATION A6E772851940W01 1. Remove the screws. 2. Remove the rear flap. 3.
Page 809: Rear Door Garnish Installation
EXTERIOR ATTACHMENT REAR DOOR GARNISH INSTALLATION A6E772850030W02 Note • Double-sided adhesive tape has already been attached to the new rear door garnish. Warning • Using a razor with bare hands can cause injury. Always wear gloves when using a razor. 1.
Page 810: Side Protector Installation
EXTERIOR ATTACHMENT SIDE PROTECTOR INSTALLATION A6E772850680W02 1. Remove the adhesive remaining on the side protector (if it will be reused) and the body using a razor. 2. Remove any grease or dirt from the adhesion surface of the side protector (if it will be reused) and the body. 3.
Page 811: Rear Finisher Removal/Installation
EXTERIOR ATTACHMENT REAR FINISHER REMOVAL/INSTALLATION A6E772850850W01 1. Remove the trunk lid trim (4SD). 2. Remove the liftgate lower trim (5HB). 3. Remove the nuts. 4. Pull the rear finisher toward you, then disengage clip A from the body. 5. Install in the reverse order of removal. A6E7728W002 End Of Sie REAR SPOILER REMOVAL/INSTALLATION...
Page 812: Molding
MOLDING MOLDING FRONT BELTLINE MOLDING REMOVAL A6E773050640W01 Note • When removing the front beltline molding, the clip may be damaged. If the clip is damaged, replace it with a new one. 1. Pull the A section upward and remove the clip. 2.
Page 813: Rear Beltline Molding Removal
MOLDING REAR BELTLINE MOLDING REMOVAL A6E773050660W01 Note • When removing the rear beltline molding, the clip may be damaged. If the clip is damaged, replace it with a new one. 1. Pull the A section upward and remove the clip. 2.
Page 814: Roof Molding Removal
MOLDING ROOF MOLDING REMOVAL A6E773050620W01 1. Detach the clips which secure A and B sections of roof molding, using a screwdriver or equivalent tool. 2. While pulling the roof molding up, detach the fit for the T stat of the A section and the roof molding and then remove the roof molding.
Page 815: Outside Mirror
OUTSIDE MIRROR OUTSIDE MIRROR POWER OUTSIDE MIRROR REMOVAL/INSTALLATION A6E773269110W01 1. Disconnect the negative battery cable. 2. Remove the inner garnish. 3. Remove the front door trim. 4. Disconnect the power outside mirror connector. 5. Remove the screws and the mirror retention clips. 6.
Page 816 OUTSIDE MIRROR Cover Disassembly Note 1. Pull off the mirror holder tab with a screwdriver and press the mirror cover tab downward. A6E7732W004 Outside Mirror Glass Assembly Note 1. Press the mirror into the base so that the pin does not dislodge.
Page 817 OUTSIDE MIRROR Mirror Garnish Removal 1. Remove the mirror glass from the outside mirror. (See S–59 Mirror Glass Removal.) MIRROR GARNISH 2. Pinch the clip ends using pincers and detach the clips by pushing them forward. 3. Grasp the upper side of the mirror garnish and remove it by pulling it in the direction of the arrow.
Page 818: Power Outside Mirror Inspection
OUTSIDE MIRROR S – 6 0 B ODY OUTSIDE MIRROR POWER OUTSIDE MIRROR INSPECTION A6E773269110W03 1. Disconnect the power outside mirror connector. 2. Apply battery positive voltage to the power outside mirror terminals and inspect the operation of the power outside mirror. •...
Page 819 OUTSIDE MIRROR THIS PAGE IS INTENTIONALLY LEFT BLANK End Of Sie S–60–2...
Page 820: Rearview Mirror
REARVIEW MIRROR REARVIEW MIRROR REARVIEW MIRROR REMOVAL A6E773469220W01 1. Insert a screwdriver between the mirror and the base. 2. Push the base pin down to remove the rearview mirror. A6E7734W001 End Of Sie REARVIEW MIRROR INSTALLATION A6E773469220W02 1. Install the rearview mirror onto the base. A6E7734W002 End Of Sie BASE REMOVAL...
Page 821: Base Installation
REARVIEW MIRROR BASE INSTALLATION A6E773469240W02 1. Cut away all of the original sealant using a razor. 2. Clean and degrease the ceramic coating on the glass and the base. 3. Apply primer to the bonding area of the glass and the base. Caution •...
Page 822: Rear Window Defroster
REAR WINDOW DEFROSTER REAR WINDOW DEFROSTER FILAMENT REPAIR A6E773663930W01 1. Use isopropyl alcohol to clean around the damaged section of the filament. 2. Attach tape above and below the damaged section of the filament. 3. Using a small brush or marking pen, repair the filament with silver paint or equivalent.
Page 823: Window Glass
WINDOW GLASS WINDOW GLASS WINDSHIELD REMOVAL A6E773863900W01 1. Remove the rearview mirror. 2. Remove the cowl grille. 3. Remove the headliner. 4. Apply protective tape along the edge of the body to protect it from damage. 5. Apply protective tape to the dashboard to protect it from damage. 6.
Page 824: Windshield Installation
WINDOW GLASS 2. Pass the SST (piano wire) through the hole. Warning • Using a SST (piano wire) with bare hands can cause injury. Always wear gloves when using a SST (piano wire). 3. Wind each end of the SST (piano wire) around a bar.
Page 825 WINDOW GLASS 4. If installing reused glass, install pins at the ceramic void on the upper part of the windshield. 5. If installing reused glass, align the front windshield molding marking and the center of the upper section of the windshield, then install the molding to the winshield.
Page 826: Quarter Window Glass Removal/Installation
WINDOW GLASS 9. Verify that the gap of the A pillar part as shown the figure. A6E7738W003 10. Keeping the measurement of the molding lip gap within specification, press completely along the perimeter of the glass. 11. Install the seaming welt. 12.
Page 827: Rear Window Glass Removal
WINDOW GLASS REAR WINDOW GLASS REMOVAL A6E773863931W01 1. For the 4SD, remove the following parts: (1) Remove the headliner. (2) Remove the rear package trim. 2. For the 5HB, remove the following parts. (1) Remove the rear wiper arm and blade. (2) Remove the liftgate lower trim.
Page 828 WINDOW GLASS Reusing Glass Note • Before removing the rear window glass from the body, mark the position of the glass by affixing tape to the glass and body panel. 1. Make a hole through the sealant, avoiding pins, from the inside of the vehicle using an awl. A6E7738W010 2.
Page 829: Rear Window Glass Installation
WINDOW GLASS 4. Working with another person, saw through the sealant around the edge of the glass. 5. Remove the rear window glass. 6. Remove the pins from the glass. 7. Remove the rear window molding from the glass. A6E7738W021 End Of Sie REAR WINDOW GLASS INSTALLATION A6E773863931W02...
Page 830 WINDOW GLASS 5. Use only glass primer on the glass, and body primer on the body and the molding. Allow it to dry for approximately 30 minutes. Caution • Keep the area free of dirt and grease, and do not touch the surface or the primer may not properly bond to the surface of the glass and body, which may cause leaks to occur.
Page 831 WINDOW GLASS 6. Apply urethane to the area of the glass surface as shown in the figure. A6E7738W020 7. Set the position of the front windshield glass and insert a pin into the body. Install the glass. A6E7738W018 8. Verify that the gap of the upper part is 7.3 mm {0.29 in} and the A pillar part is 6.8 mm {0.27 in}.
Page 832 WINDOW GLASS 9. Keeping the measurement of the molding lip gap within specification, press completely along the perimeter of the glass. 10. For the 4SD, install the following parts: (1) Install the headliner. (2) Install the rear package trim. 11. For the 5HB, install the following points. (1) Install the rear wiper motor.
Page 833: Sliding Sunroof
SLIDING SUNROOF SLIDING SUNROOF DEFLECTOR REMOVAL/INSTALLATION A6E774069880W01 1. Fully open the glass panel. 2. Remove the headliner. 3. Remove the screws. 4. Disengage the hooks. (1) Press the rear end of each hook. (2) After sliding the hooks rearward, press them upward. 5.
Page 834: Glass Panel Adjustment
SLIDING SUNROOF End Of Sie GLASS PANEL ADJUSTMENT A6E774069810W02 1. Fully close the glass panel. 2. Measure the gap and height between the glass panel and body. 3. If not as specified, loosen the glass panel installation screws and reposition the glass panel. Clearance a: -0.8—1.2 mm {-0.032—0.047 in} b: 0 mm {0 in}...
Page 835: Rear Drain Hose Removal
SLIDING SUNROOF End Of Sie REAR DRAIN HOSE REMOVAL A6E774069922W01 1. Remove the headliner. 2. Remove the trunk side trim. (4SD) 3. Remove the trunk side upper trim and trunk side trim. (5HB) 4. Disconnect the rear drain hose from the sunroof frame. 5.
Page 836: Sunroof Unit Disassembly/Assembly
SLIDING SUNROOF 6. Remove the bolt B and nuts, and then remove the sunroof unit. 7. Install in the reverse order of removal. 8. Adjust the glass panel. (See S–75 GLASS PANEL ADJUSTMENT.) A6E7740W005 End Of Sie SUNROOF UNIT DISASSEMBLY/ASSEMBLY A6E774069850W02 1.
Page 837 SLIDING SUNROOF Slider Disassembly Note 1. Remove the screw. 2. Slide the slider rearward, and remove it from the sunroof frame. A6E7740W012 Guide Disassembly Note 1. Slide the guide rearward, and remove it from the sunroof frame. A6E7740W013 Decoration Link Assembly Note 1.
Page 838: Sunroof Motor Removal
SLIDING SUNROOF SUNROOF MOTOR REMOVAL A6E774069870W01 1. Disconnect the negative battery cable. 2. Remove the headliner. 3. Disconnect the connector. 4. Remove the screws, and then remove the sunroof motor. A6E7740W002 End Of Sie SUNROOF MOTOR INSTALLATION A6E774069870W02 1. Connect the sunroof motor connector. 2.
Page 839: Sunroof Relay Inspection
SLIDING SUNROOF Limit Switch 1. Remove the headliner. (See S–96 HEADLINER REMOVAL/INSTALLATION.) 2. Verify the glass panel position. 3. Disconnect the connector. 4. Inspect for continuity between the sunroof motor terminals using an ohmmeter. • If not as specified, replace the sunroof motor. A6E7740W021 A6E7740W020 End Of Sie...
Page 840: Sunroof Switch Removal/Installation
SLIDING SUNROOF Voltage (V)/ Terminal Signal Connected to Test condition Action Continuity • Inspect sunroof switch Sunroof is fully opening. (See S–81 SUNROOF Slide open Sunroof switch SWITCH INSPECTION) Other • Inspect related harness Sunroof relay Under any condition: inspect •...
Page 841: Dashboard And Console
DASHBOARD AND CONSOLE DASHBOARD AND CONSOLE DASHBOARD REMOVAL/INSTALLATION A6E774255100W01 1. Disconnect the negative battery cable. 2. Remove the glove compartment. 3. Remove the console. 4. Remove the meter hood. 5. Remove the instrument cluster. 6. Remove the column cover. 7. Remove the lower panel. 8.
Page 842: Dashboard Disassembly/Assembly
DASHBOARD AND CONSOLE DASHBOARD DISASSEMBLY/ASSEMBLY A6E774255100W02 1. Remove the passenger-side air bag module. 2. Remove the ventilator grilles. 3. Remove the audio unit. 4. Remove the climate control unit. 5. Disassemble in the order indicated in the table. 6. Assemble in the reverse order of disassembly. A6E7742W003 Dashboard harness Damper...
Page 843: Column Cover Removal/Installation
DASHBOARD AND CONSOLE COLUMN COVER REMOVAL/INSTALLATION A6E774260200W01 1. Detach the fit of the upper column cover from the meter hood rubber. 2. Remove the upper column cover. 3. Remove the ignition key illumination. 4. Remove the screws. 5. Remove the lower column cover. 6.
Page 844: Center Box Removal/Installation
DASHBOARD AND CONSOLE CENTER BOX REMOVAL/INSTALLATION A6E774264030W01 1. Disconnect the negative battery cable. 2. Remove the center panel module. 3. Remove the screws. 4. Pull the center box forward, then disengage the tabs 5. Disconnect the LDC unit connector. 6. Install in the reverse order of removal. A6E7742W012 End Of Sie GLOVE COMPARTMENT REMOVAL/INSTALLATION...
Page 845: Console Removal/Installation
DASHBOARD AND CONSOLE CONSOLE REMOVAL/INSTALLATION A6E774264270W01 Applied VIN (assumed): JMZ GG12✻✻✻# 100001—190206 JMZ GG14✻✻✻# 100001—190206 JMZ GY19✻✻✻# 100001—137241 JMZ GY89✻✻✻# 100001—137241 1. For MT vehicle, remove the shift lever knob. 2. Slightly bend back the cradle. (with car-navigation system) 3. Remove the cup holder panel using a tape- wrapped screwdriver.
Page 846 DASHBOARD AND CONSOLE DASHBOARD AND CONSOLE S – 8 6 B ODY CONSOLE DISASSEMBLY/ASSEMBLY A6E774264270W02 1. Disassemble in the order indicated in the table. Console lid (only large console box) Rear ashtray case Bracket Console Console cover Box storage Lock No.1 Inner console lid Lid core Lock No.2...
Page 847: Trim
TRIM S B ODY TRIM A-PILLAR TRIM REMOVAL A6E774468160W01 1. Turn the seaming welt over. 2. Disengage clips A using a fastener remover. 3. Pull the A-pillar trim, then disengage clip B (1). 4. Pull the A-pillar trim upward, then disengage clip B from the A-pillar trim (2).
Page 848: B-Pillar Lower Trim Removal/Installation
TRIM B-PILLAR LOWER TRIM REMOVAL/INSTALLATION A6E774468220W01 1. Remove the front scuff plate. 2. Remove the rear scuff plate. 3. Pull the area marked A, then remove one side of the B-pillar lower trim. 4. Pull the B-pillar lower trim, then remove the pin from the body.
Page 849: Front Scuff Plate Removal/Installation
TRIM FRONT SCUFF PLATE REMOVAL/INSTALLATION A6E774468710W01 1. Pull the front scuff plate upward, then disengage clips B, pins C, D and hooks E from the body, and remove the front scuff plate. 2. Install in the reverse order of removal. A6E7744W017 End Of Sie REAR SCUFF PLATE REMOVAL/INSTALLATION...
Page 850: Front Door Trim Removal/Installation
TRIM FRONT DOOR TRIM REMOVAL/INSTALLATION A6E774468420W01 1. Disconnect the negative battery cable. 2. Open the cap using a small screwdriver, then remove the screw. 3. Remove the inner handle cover. 4. Remove the inner garnish. A6E7744W009 5. Remove the cover, then remove screw A. 6.
Page 851: Tire House Trim Removal/Installation
TRIM 7. Pull the rear door trim upward, then disengage hooks B from the rear door. 8. Disconnect the power window subswitch connector if equipped. 9. Remove the rear door trim. 10. Remove the switch panel from the rear door trim. 11.
Page 852: Rear Package Trim Removal/Installation
TRIM REAR PACKAGE TRIM REMOVAL/INSTALLATION A6E774468320W01 1. Remove the high-mount brake light. 2. Fold the rear seat back. 3. Remove the fasteners. 4. Pull the rear package trim upward, then disengage the clips from the body. 5. Disengage the hooks, then remove the rear package trim.
Page 853: Trunk Side Upper Trim Removal/Installation
TRIM TRUNK SIDE UPPER TRIM REMOVAL/INSTALLATION A6E774468860W02 1. Disconnect the negative battery cable. (LH only) 2. Remove the tire house trim. 3. Remove the rear seat remote lever. 4. Remove the screw. 5. Pull the trunk side upper trim toward you, then disengage clips A from the body.
Page 854: Liftgate Upper Trim Removal/Installation
TRIM 1. Pull the trunk end trim upward, then disengage clips A, pins B, and hooks. 2. Remove the trunk end trim. 3. Install in the reverse order of removal. A6E7744W013 End Of Sie LIFTGATE UPPER TRIM REMOVAL/INSTALLATION A6E774468930W01 1. Pull the liftgate upper trim toward you, then disengage clips A, and pin B from the body.
Page 855: Liftgate Lower Trim Removal/Installation
TRIM 3. Pull the liftgate side trim toward you, then disengage clips A, pin B and the strap hanger from the body and pin B, hook C, D from the liftgate lower trim. 4. Remove the liftgate side trim. 5. Remove the hanger strap from the liftgate side trim.
Page 856: Headliner
HEADLINER HEADLINER HEADLINER REMOVAL/INSTALLATION A6E774668030W01 1. Disconnect the negative battery cable. 2. Turn the seaming welt and weatherstrip over. 3. Remove the sunroof seaming welt. (vehicles with sunroof only) 4. Remove the A-pillar trims. 5. Remove the B-pillar upper trims. 6.
Page 857: Shock Absorbing Pad Removal/Installation
HEADLINER SHOCK ABSORBING PAD REMOVAL/INSTALLATION A6E774668H10W01 1. Remove the headliner. 2. Remove the fastener, then remove the shock absorbing pad. 3. Install in the reverse order of removal. A6E7746W003 End Of Sie ASSIST HANDLE REMOVAL/INSTALLATION A6E774669440W01 1. Insert a screwdriver into the assist handle notch and remove the assist handle cover.
Page 858: Sunvisor Removal/Installation
HEADLINER SUNVISOR REMOVAL/INSTALLATION A6E774669270W01 1. Remove the screws, then the sunvisor. A6E7746W005 2. Disengage the center adapter (sunvisor stopper) from the body using a fastener remover. 3. Install in the reverse order of removal. YTA7746W103 End Of Sie S–98...
Page 859: Floor Covering
FLOOR COVERING FLOOR COVERING FRONT FLOOR COVERING REMOVAL/INSTALLATION A6E774868670W01 1. Disconnect the negative battery cable. 2. Remove the front seats. (See S–105 FRONT SEAT REMOVAL/INSTALLATION.) 3. Remove the rear seat. 4. Remove the front scuff plates. 5. Remove the rear scuff plates. 6.
Page 860: Seat Belt
SEAT BELT SEAT BELT FRONT SEAT BELT REMOVAL/INSTALLATION A6E775057630W01 Warning • Handling the front seat belt (pre-tensioner seat belt) improperly can accidentally deploy the pre- tensioner, which may seriously injure you. Read SERVICE WARNINGS before handling the front seat belt. (See T–117 SERVICE WARNINGS.) Warning...
Page 861 SEAT BELT REAR SIDE SEAT BELT REMOVAL/INSTALLATION A6E775057730W01 Caution • The ELR has a spring that will unwind if the retractor's cover is removed. The spring cannot be rewound by hand. If this occurs, the ELR will not work properly. Therefore, do not disassemble the retractor.
Page 862: Front Buckle Removal/Installation
SEAT BELT 1. Remove the rear scuff plate. 2. Remove the tire house trim. 3. Remove the trunk side upper trim. 4. Remove the C-pillar trims. 5. Remove the bolts. 6. Remove the rear center seat belt. 7. Install in the reverse order of removal. A6E7750W004 End Of Sie FRONT BUCKLE REMOVAL/INSTALLATION...
Page 863 SEAT BELT SEAT BELT INSPECTION A6E775057000W01 Belt 1. Confirm that the seat belt is installed correctly. 2. Inspect the seat belt for damage and deformation of metal parts. • If any damage is found, replace as necessary. 1. Verify that the belt can be pulled out smoothly, and that it moves smoothly when wound.
Page 864: Buckle Switch Inspection
SEAT BELT BUCKLE SWITCH INSPECTION A6E775057620W02 Driver's Seat 1. Disconnect the negative battery cable. 2. Disconnect the buckle switch connector. 3. Inspect for continuity between the buckle switch terminals using an ohmmeter. • If not as specified, replace the front buckle. A6E7750W009 A6E7750W010 End Of Sie...
Page 865: Seat
SEAT SEAT FRONT SEAT REMOVAL/INSTALLATION A6E775257100W01 Warning • Handling the front seat (side air bag) improperly can accidentally deploy the side air bag, which may seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling the front seat. (See T–117 SERVICE WARNINGS.) 1.
Page 866: Front Seat Disassembly/Assembly
SEAT FRONT SEAT DISASSEMBLY/ASSEMBLY A6E775257100W02 Warning • Handling the front seat (side air bag) improperly can accidentally deploy the side air bag, which may seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling the front seat. (See T–117 SERVICE WARNINGS.) 1.
Page 867 SEAT Driver's Seat (Power Seat) A6E7752W027 Headrest Front buckle Lumber support lever Pole guide (See S–109 Lumber support lever disassembly Seat back trim note.) Seat warmer unit (European (L.H.D.) specs. only) Slider and lifter switch knob Seat back pad Recliner switch knob Seat back frame Side cover Seat cushion trim...
Page 868 SEAT Passenger's Seat Warning • Do not disassemble the seat cushion. Doing so will necessitate reassembly which may damage or press the occupancy sensor. This will cause the misoperation of the air bag system, which may seriously injure you. A6E7752W003 Headrest Seat warmer unit (European (L.H.D.) specs.
Page 869 SEAT Lumber support lever disassembly note 1. Remove the pin from the lumber support lever installation part with rag. A6E7752W018 Recliner dial disassembly note 1. Remove the pin from the recliner dial installation part with rag. A6E7752W019 Side cover disassembly note 1.
Page 870: Rear Seat Removal/Installation
SEAT End Of Sie REAR SEAT REMOVAL/INSTALLATION A6E775257200W01 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. A6E7752W006 Rear seat cushion Rear seat back Rear side seat S–110...
Page 871 SEAT 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. A6E7752W012 Remote wire Rear seat (See S–111 Remote wire removal note.) (See S–112 Rear seat removal note.) Remote wire removal note 1. Turn over the trunk floor mat. 2.
Page 872 SEAT Rear seat removal note 1. Remove the front hinge installation bolts. 2. Lift the rear seat cushion, then remove the rear hinge installation bolts. A6E7752W013 End Of Sie REAR SEAT DISASSEMBLY/ASSEMBLY A6E775257200W02 1. Disassemble in the order indicated in the table. 2.
Page 873 SEAT Armrest pad Seat back pad Pole guide Seat back frame Seat back trim 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. A6E7752W015 Headrest Cup holder Hinge cover Armrest hinge Seat cushion trim Armrest trim Seat cushion pad Armrest pad...
Page 874: Remote Handle Lever Removal/Installation
SEAT End Of Sie REMOTE HANDLE LEVER REMOVAL/INSTALLATION A6E775200166W01 1. To remove the remote wire, remove the trunk side trim. 2. Remove in the order indicated in the table. Remote handle lever Remote wire Remote catch 3. Install in the reverse order of removal. A6E7752W005 1.
Page 875: Seat Back Striker Removal/Installation
SEAT SEAT BACK STRIKER REMOVAL/INSTALLATION A6E775262361W01 1. Remove the tire house trim. 2. Remove the trunk side upper trim and trunk side lower trim. 3. Remove the bolts. 4. Remove the seat back striker. 5. Install in the reverse order of removal. A6E7752W016 End Of Sie POWER SEAT SWITCH INSPECTION...
Page 876: Front Tilt Motor Inspection
SEAT End Of Sie FRONT TILT MOTOR INSPECTION A6E775288650W01 1. Disconnect the front tilt motor connector. 2. Inspect the front tilt motor operation when B+ is applied to the terminals as shown. • If not as specified, replace the seat cushion frame.
Page 877: Seat Warmer Switch Removal/Installation
SEAT SEAT WARMER SWITCH REMOVAL/INSTALLATION A6E775259000W01 1. Disconnect the negative battery cable. 2. Remove the brake boots panel. (See S–86 CONSOLE REMOVAL/INSTALLATION 3. Remove in the order indicated in the table. Seat warmer switch (See S–117 Seat Warmer Switch Removal Note.) Connector 4.
Page 878: Seat Warmer Unit Inspection
SEAT SEAT WARMER UNIT INSPECTION A6E775259000W03 1. Remove the front seat. (See S–105 FRONT SEAT REMOVAL/INSTALLATION.) 2. Remove the seat cushion trim. 3. While inspecting for continuity between the terminals A and B of the connector, use a dryer to warm the thermostat of the seat warmer unit on seat cushion.
Page 879: Body Shell
BODY SHELL BODY SHELL SHROUD PANEL REMOVAL/INSTALLATION A6E775453140W01 1. Remove the bonnet. (See S–10 BONNET REMOVAL/INSTALLATION.) 2. Remove the front bumper. (See S–47 FRONT BUMPER REMOVAL/INSTALLATION.) 3. Remove the front combination light. (See T–26 FRONT COMBINATION LIGHT REMOVAL/INSTALLATION.) 4. Remove the front bumper reinforcement. (See S–48 BUMPER REINFORCEMENT REMOVAL/ INSTALLATION.) 5.
Page 880: Troubleshooting [Power Window System
TROUBLESHOOTING [POWER WINDOW SYSTEM] TROUBLESHOOTING [POWER WINDOW SYSTEM] INTERMITTENT CONCERN TROUBLESHOOTING A6E778058000W01 Vibration Method • If malfunction occurs or becomes worse while driving on a rough road or when engine is vibrating, perform the steps below. Note • There are several reasons why vehicle or engine vibration could cause an electrical malfunction. Some of the things to check for: —...
Page 881: Basic Power Window System Inspection
TROUBLESHOOTING [POWER WINDOW SYSTEM] BASIC POWER WINDOW SYSTEM INSPECTION A6E778058000W03 Manual Mode Function Inspection STEP INSPECTION ACTION • Turn ignition switch to ON position. Yes Go to next step. • Do all windows go up and down in manual • Inspect the following items: mode using power window main switch? —...
Page 882 TROUBLESHOOTING [POWER WINDOW SYSTEM] Automatic Window Return Function Inspection STEP INSPECTION ACTION • Turn ignition switch to ON position. Yes Go to Step 1 of NO. 3 DRIVER-SIDE FRONT WINDOW • Lower driver-side front window completely. REVERSES EVEN THOUGH THE GLASS DOES NOT •...
Page 883: No. 1 Driver-Side Front Window Does Not Go Up And Down In Automatic Mode
TROUBLESHOOTING [POWER WINDOW SYSTEM] STEP INSPECTION ACTION • Close all doors. Yes Replace power window main switch, then go to two-step • Turn ignition switch to ON position. down function inspection. • Push/pull power window main switch for • IG OFF timer function is normal. driver-side front window after approximately •...
Page 884 TROUBLESHOOTING [POWER WINDOW SYSTEM] Diagnostic procedure STEP INSPECTION ACTION INSPECT WHETHER POWER WINDOW MAIN Yes Recheck malfunction symptoms. SWITCH ENTERS FAIL-SAFE MODE OR NOT Go to next step. (Power window main switch may enter fail- • Did driver-side front window go up or down in safe mode.) automatic mode? VERIFY WHETHER MALFUNCTION IS IN...
Page 885 TROUBLESHOOTING [POWER WINDOW SYSTEM] STEP INSPECTION ACTION VERIFY WHETHER MALFUNCTION IS IN Yes Replace power window main switch. (malfunction in power window main switch automatic mode control), then go to POWER WINDOW MAIN SWITCH OR Step 11. ELSEWHERE • Turn ignition switch to ON position. Go to next step.
Page 886: No. 2 Driver-Side Front Window Does Not Reverse, Even When Encountering A Foreign Object In Its Path
TROUBLESHOOTING [POWER WINDOW SYSTEM] NO. 2 DRIVER-SIDE FRONT WINDOW DOES NOT REVERSE, EVEN WHEN ENCOUNTERING A FOREIGN OBJECT IN ITS PATH A6E778058000W06 Driver-side front window does not reverse, even when encountering a foreign object in its path. • Automatic window return range did not reset after battery disconnect: Step 2 POSSIBLE CAUSE Diagnostic procedure...
Page 887 TROUBLESHOOTING [POWER WINDOW SYSTEM] NO. 3 DRIVER-SIDE FRONT WINDOW REVERSES EVEN THOUGH THE GLASS DOES NOT ENCOUNTER A FOREIGN OBJECT WHILE IT IS GOING UP IN AUTOMATIC MODE A6E778058000W07 Driver-side front window reverses even though the glass does not encounter a foreign object while it is going up in automatic mode.
Page 888: Troubleshooting [Keyless Entry System
TROUBLESHOOTING [KEYLESS ENTRY SYSTEM] TROUBLESHOOTING [KEYLESS ENTRY SYSTEM] FOREWORD A6E778269000W01 • Go to troubleshooting after identifying the specific malfunction by doing a keyless entry system preliminary inspection. Flowchart A6E7782W002 End Of Sie S–128...
Page 889: Keyless Entry System Check Sheet
TROUBLESHOOTING [KEYLESS ENTRY SYSTEM] KEYLESS ENTRY SYSTEM CHECK SHEET A6E778269000W02 • Use the sheet below as a customer interview sheet when accepting a vehicle for service. • If the symptom is “Power door lock system does not operate with transmitter at all,” find out how the customer uses the keyless entry system by following the check sheet below.
Page 890: On-Board Diagnostic Function
TROUBLESHOOTING [KEYLESS ENTRY SYSTEM] STEP INSPECTION ACTION • Did customer use keyless entry system in Yes Attempt to lock/unlock doors with transmitter in particular area, such as being near TV non-interference area. towers, power plants, power lines, or If system operates: factories? •...
Page 891: Troubleshooting Index
TROUBLESHOOTING [KEYLESS ENTRY SYSTEM] TROUBLESHOOTING INDEX A6E778269000W05 TROUBLESHOOTING ITEM DESCRIPTION PAGE • Malfunction in hazard warning light system One or more on-board (See S–131 NO. 1 ONE OR diagnostic functions inoperative. (except vehicle with theft-deterrent system), or MORE ON-BOARD DIAGNOSTIC door lock linkage system, driver’s door key FUNCTIONS INOPERATIVE)
Page 892 TROUBLESHOOTING [KEYLESS ENTRY SYSTEM] STEP INSPECTION ACTION CHECK TO SEE WHETHER MALFUNCTION Yes Recheck malfunction symptoms, then repeat from Step 1 if IS IN DOOR LOCK ACTUATOR, DOOR LOCK malfunction reoccurs. TIMER UNIT GROUND CIRCUIT OR • Inspect door lock timer unit connector. ELSEWHERE •...
Page 893: No. 3 Transmitter Id Code Cannot Be Reprogrammed
TROUBLESHOOTING [KEYLESS ENTRY SYSTEM] STEP INSPECTION ACTION CHECK TO SEE WHETHER MALFUNCTION Yes Repair malfunctioning wiring harness, then go to Step 8. IS IN WIRING HARNESS (SHORT TO B+ Go to next step. BETWEEN FUSE BLOCK AND DOOR LOCK TIMER UNIT, OR BETWEEN DOOR LOCK TIMER UNIT AND GROUND) OR ELSEWHERE •...
Page 894 TROUBLESHOOTING [KEYLESS ENTRY SYSTEM] STEP INSPECTION ACTION INSPECT TRANSMITTER BATTERY Yes Go to next step. • Inspect transmitter battery. Replace transmitter battery, then go to Step 8. • Is battery voltage normal? INSPECT DOOR LOCK TIMER UNIT Yes Go to next step. BRACKET INSTALLATION Install bracket securely, then go back to Step 6 of keyless •...
Page 895 B ODY ELECTRICAL SYSTEM LOCATION INDEX ..........T-5 COMBINATION SWITCH POWER SYSTEM..........T-5 REMOVAL/INSTALLATION ......T-37 EXTERIOR LIGHTING SYSTEM ......T-6 COMBINATION SWITCH INTERIOR LIGHTING SYSTEM ......T-9 DISASSEMBLY/ASSEMBLY ......T-38 WIPER AND WASHER SYSTEM ...... T-10 STEERING ANGLE SENSOR WARNING AND INDICATOR SYSTEM.....
Page 896 PANEL LIGHT CONTROL SWITCH HEADLIGHT CLEANER SWITCH INSPECTION ..........T-54 REMOVAL/INSTALLATION ......T-71 WIPER AND WASHER......... T-56 HEADLIGHT CLEANER SWITCH WINDSHIELD WIPER MOTOR INSPECTION ..........T-71 REMOVAL/INSTALLATION ......T-56 WARNING AND INDICATOR SYSTEM ....T-72 WINDSHIELD WIPER MOTOR INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY ......
Page 897 NOISE FILTER DTC U0073, U1900, U2516 ......T-144 REMOVAL/INSTALLATION......T-104 ON-BOARD DIAGNOSTIC NOISE FILTER INSPECTION ......T-105 [DISCHARGE HEADLIGHT] ......T-146 CONDENSER FOREWORD............ T-146 REMOVAL/INSTALLATION......T-106 DTC TABLE ..........T-146-1 CENTER ROOF ANTENNA PID/DATA MONITOR TABLE .......T-146-1 REMOVAL/INSTALLATION......T-107 DTC B2386 ........... T-146-2 CENTER ROOF ANTENNA DTC B2387 ...........
Page 898 DTC 03:ER01........... T-170 NO.1 WHILE VEHICLE IS IN REVERSE, DTC 03:ER02........... T-170 VEHICLE LOCATOR MARK DTC 03:ER07........... T-171 GOES FORWARD........T-229 DTC 00:ER01........... T-171 NO.2 IN NAVIGATION MODE, DTC 00:ER03........... T-172 VEHICLE LOCATOR MARK SKIPS..... T-229 DTC 00:ER04........... T-172 NO.3 EVEN WHEN HEADLIGHT SWITCH IS DTC 05:ER01...........
Page 899: Location Index
LOCATION INDEX LOCATION INDEX POWER SYSTEM A6E810001072W01 A6E8110W124 Key reminder switch Main fuse (See T–21 KEY REMINDER SWITCH REMOVAL/ (See T–19 MAIN FUSE REMOVAL/INSTALLATION) INSTALLATION) Fuse block (See T–21 KEY REMINDER SWITCH (See T–20 FUSE BLOCK REMOVAL/ INSPECTION) INSTALLATION) Cigarette lighter Ignition switch (See T–21 CIGARETTE LIGHTER REMOVAL/...
Page 900 LOCATION INDEX Cooling fan relay No.3 Headlight relay (See T–24 RELAY INSPECTION) (See T–24 RELAY INSPECTION) Stater relay TNS relay (See T–24 RELAY INSPECTION) (See T–24 RELAY INSPECTION) Cooling fan relay No.4 Cooling fan relay No.1 (See T–24 RELAY INSPECTION) (See T–24 RELAY INSPECTION)
Page 901 LOCATION INDEX Discharge headlight control unit Front combination light (See T–25 DISCHARGE HEADLIGHT SERVICE (See T–25 DISCHARGE HEADLIGHT SERVICE WARNINGS) WARNINGS) (See T–30 DISCHARGE HEADLIGHT CONTROL (See T–26 FRONT COMBINATION LIGHT UNIT REMOVAL/INSTALLATION) REMOVAL/INSTALLATION) (See T–30 AUTO LEVELING CONTROL UNIT (See T–26 HEADLIGHT AIMING)
Page 902 LOCATION INDEX Flasher unit (See T–44 FLASHER UNIT REMOVAL/ INSTALLATION) (See T–44 FLASHER UNIT INSPECTION) Running light unit (See T–45 RUNNING LIGHT UNIT REMOVAL/ INSTALLATION) (See T–46 RUNNING LIGHT UNIT INSPECTION) A6E8112W162 License plate light Rear combination light (See T–37 LICENSE PLATE LIGHT REMOVAL/ (See T–35 REAR COMBINATION LIGHT INSTALLATION)
Page 903 LOCATION INDEX INTERIOR LIGHTING SYSTEM A6E810001052W02 A6E8114W130 Courtesy light Front map light (See T–51 COURTESY LIGHT BULB REMOVAL/ (See T–48 FRONT MAP LIGHT REMOVAL/ INSTALLATION) INSTALLATION) (See T–48 FRONT MAP LIGHT INSPECTION) Door switch (See T–52 DOOR SWITCH REMOVAL/ Rear map light INSTALLATION) (See T–49 REAR MAP LIGHT REMOVAL/...
Page 904: Wiper And Washer System
LOCATION INDEX End Of Sie WIPER AND WASHER SYSTEM A6E810001052W03 A6E8116T101 Windshield washer nozzle Windshield wiper arm and blade (See T–60 WINDSHIELD WASHER NOZZLE (See T–57 WINDSHIELD WIPER ARM AND REMOVAL/INSTALLATION) BLADE REMOVAL/INSTALLATION) (See T–60 WINDSHIELD WASHER NOZZLE (See T–58 WINDSHIELD WIPER ARM AND CLEANING) BLADE ADJUSTMENT)
Page 905 LOCATION INDEX Rear washer motor (5HB) (See T–61 REAR WASHER MOTOR REMOVAL/ INSTALLATION) (See T–61 REAR WASHER MOTOR INSPECTION) Washer fluid-level sensor (5HB) (See T–59 WASHER FLUID-LEVEL SENSOR REMOVAL/INSTALLATION) (See T–60 WASHER FLUID-LEVEL SENSOR INSPECTION) Windshield washer hose (See T–61 WINDSHIELD WASHER HOSE REMOVAL/INSTALLATION) Rear washer hose (5HB) (See...
Page 906: Warning And Indicator System
LOCATION INDEX WARNING AND INDICATOR SYSTEM A6E810001067W01 A6E8118W012 Instrument cluster Fuel gauge sender unit (See T–72 INSTRUMENT CLUSTER REMOVAL/ (See T–83 FUEL GAUGE SENDER UNIT INSTALLATION) INSPECTION) (See T–73 INSTRUMENT CLUSTER Oil pressure switch DISASSEMBLY/ASSEMBLY) (See T–84 OIL PRESSURE SWITCH (See T–73 INSTRUMENT CLUSTER INSPECTION)
Page 907: Theft-Deterrent System
LOCATION INDEX THEFT-DETERRENT SYSTEM A6E810050000W01 A6E8120W007 Theft-deterrent control module Intruder sensor (Vehicle with sliding sunroof) (See T–86 THEFT-DETERRENT CONTROL (See T–89 INTRUDER SENSOR REMOVAL/ MODULE REMOVAL/INSTALLATION) INSTALLATION) (See T–86 THEFT-DETERRENT CONTROL Intruder sensor (Vehicle without sliding sunroof) MODULE INSPECTION) (See T–89 INTRUDER SENSOR REMOVAL/ Bonnet switch INSTALLATION)
Page 908: Immobilizer System
LOCATION INDEX IMMOBILIZER SYSTEM A6E810067000W01 A6E8122W004 Coil (See T–90 COIL REMOVAL/INSTALLATION) (See T–90 IMMOBILIZER SYSTEM REPROGRAM PROCEDURE) Key (transponder) (See T–90 IMMOBILIZER SYSTEM REPROGRAM PROCEDURE) End Of Sie T–14...
Page 909: Audio And Navigation System
LOCATION INDEX AUDIO AND NAVIGATION SYSTEM A6E810001066W01 Audio System A6E8124W044 Audio unit Center roof antenna (See T–93 ANTI-THEFT SYSTEM) (See T–107 CENTER ROOF ANTENNA REMOVAL/ (See T–96 CENTER PANEL MODULE REMOVAL/ INSTALLATION) INSTALLATION) (See T–107 CENTER ROOF ANTENNA (See T–97 CENTER PANEL MODULE INSPECTION) DISASSEMBLY/ASSEMBLY) Glass antenna...
Page 910 LOCATION INDEX Car-navigation System A6E8124W045 Car-navigation unit Front door speaker (See T–98 CAR-NAVIGATION UNIT REMOVAL/ (See T–101 FRONT DOOR SPEAKER REMOVAL/ INSTALLATION) INSTALLATION) (See T–101 FRONT DOOR SPEAKER Car-navigation unit INSPECTION) (See T–98 CAR-NAVIGATION UNIT REMOVAL/ INSTALLATION) Tweeter (See T–103 TWEETER REMOVAL/INSTALLATION) GPS antenna (See...
Page 911: Cruise Control System
LOCATION INDEX CRUISE CONTROL SYSTEM A6E810001011W01 A6E8128W017 Cruise actuator Cruise control switch (See T–110 CRUISE ACTUATOR REMOVAL/ (See T–115 CRUISE CONTROL SWITCH INSTALLATION) REMOVAL/INSTALLATION) (See T–110 CRUISE ACTUATOR INSPECTION) (See T–116 CRUISE CONTROL SWITCH INSPECTION) Actuator cable (See T–112 ACTUATOR CABLE REMOVAL) (See T–114 ACTUATOR CABLE...
Page 912: Air Bag System
LOCATION INDEX AIR BAG SYSTEM A6E810001046W01 A6E8130W049 Driver-side air bag module Pre-tensioner seat belt (See T–120 DRIVER-SIDE AIR BAG MODULE (See T–127 AIR BAG MODULE AND PRE- REMOVAL/INSTALLATION) TENSIONER SEAT BELT DEPLOYMENT (See T–127 AIR BAG MODULE AND PRE- PROCEDURES) TENSIONER SEAT BELT DEPLOYMENT SAS unit PROCEDURES)
Page 913: Power System
POWER SYSTEM POWER SYSTEM FUSE SERVICE CAUTION A6E811066000W01 Caution • Determine and correct the cause of the burnt fuse before replacing it with the specified type. If the fuse is replaced before doing this, it may burn again. End Of Sie MAIN FUSE REMOVAL/INSTALLATION A6E811066761W01 1.
Page 914: Fuse Block Removal/Installation
POWER SYSTEM FUSE BLOCK REMOVAL/INSTALLATION A6E811066730W01 1. Disconnect the negative battery cable. 2. Remove the left-side front side trim. (See S–88 FRONT SIDE TRIM REMOVAL/INSTALLATION) 3. Remove in the order indicated in the table. Connector Bolt Fuse block 4. Install in the reverse order of removal. A6E8110W107 End Of Sie IGNITION SWITCH REMOVAL/INSTALLATION...
Page 915: Key Reminder Switch Removal/Installation
POWER SYSTEM KEY REMINDER SWITCH REMOVAL/INSTALLATION A6E811066152W01 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Disconnect the key reminder switch connector. 4. Remove the key reminder switch. 5. Install in the reverse order of removal. A6E8110W102 End Of Sie KEY REMINDER SWITCH INSPECTION A6E811066152W02...
Page 916: Cigarette Lighter Inspection
POWER SYSTEM Socket Removal Note 1. Insert a tape-wrapped screwdriver into the socket hole, then press against the ring protrusion to lift the socket toward you. A6E8110W104 2. As shown in the figure, lift out the socket until the ring protrusion locks into the lower socket hole. 3.
Page 917: Relay Location
POWER SYSTEM RELAY LOCATION A6E811067730W01 A6E8110T102 Main relay Cooling fan relay No.2 Headlight relay Horn relay TNS relay Cooling fan relay No.3 Cooling fan relay No.1 Stater relay Headlight cleaner relay Cooling fan relay No.4 Front fog light relay Woofer relay Fuel pump relay Rear window defroster relay Blower relay...
Page 918: Relay Inspection
POWER SYSTEM RELAY INSPECTION A6E811067730W02 Relay Type Terminal type Parts name • Main relay • Fuel pump relay • Stater relay • TNS relay • Front fog light relay • Rear fog light relay • Horn relay • Headlight cleaner relay •...
Page 919 POWER SYSTEM, EXTERIOR LIGHTING SYSTEM Type C 1. Remove the relay. 2. Inspect for continuity between the relay terminals using an ohmmeter. • If not as specified, replace the relay. A6E8110W126 A6E8110W122 End Of Sie EXTERIOR LIGHTING SYSTEM DISCHARGE HEADLIGHT SERVICE WARNINGS A6E811251060W01 Discharge headlight bulb service warnings •...
Page 920 EXTERIOR LIGHTING SYSTEM FRONT COMBINATION LIGHT REMOVAL/INSTALLATION A6E811251060W02 Caution • Incorrect servicing of the discharge headlights could result in electrical shock. Before servicing the discharge headlights, always refer to the “Discharge headlight service warnings.” (See T–25 DISCHARGE HEADLIGHT SERVICE WARNINGS) Note •...
Page 921 EXTERIOR LIGHTING SYSTEM 6. Set the headlights 3 m {10 ft} from the wall. 7. While adjusting one headlight, mask the other. 8. Start the engine to charge the battery. 9. Turn on the lower-beam headlight. 10. Set the headlight leveling switch to 0 position. 11.
Page 922 EXTERIOR LIGHTING SYSTEM 5. Set the headlights 3 m {10 ft} from the wall. 6. While adjusting one headlight, mask the other. 7. Start the engine to charge the battery. 8. Turn on the high-beam headlights. 9. Set the headlight leveling switch to 0 position. A6E8112W157 10.
Page 923 EXTERIOR LIGHTING SYSTEM Discharge type Caution • Incorrect servicing of the discharge headlights could result in electrical shock. Before servicing the discharge headlights, always refer to the “Discharge headlight service warnings.” (See T–25 DISCHARGE HEADLIGHT SERVICE WARNINGS) 1. Disconnect the negative battery cable. 2.
Page 924: T-26 Front Combination Light
EXTERIOR LIGHTING SYSTEM DISCHARGE HEADLIGHT CONTROL UNIT REMOVAL/INSTALLATION A6E811251030W03 Caution • Incorrect servicing of the discharge headlight control unit could result in electrical shock. Before servicing the discharge headlight control unit, always refer to the “Discharge headlight service warnings.” (See T–25 DISCHARGE HEADLIGHT SERVICE WARNINGS) •...
Page 925 EXTERIOR LIGHTING SYSTEM HEADLIGHT ZEROSET A6E811251030W05 Note • When the configuration is not set for the auto leveling control unit, headlight zeroset cannot be executed. 1. Adjust the tire air pressure to the specification. 2. Position the unloaded vehicle on a flat, level surface. 3.
Page 926: Front Auto Leveling Sensor
EXTERIOR LIGHTING SYSTEM FRONT AUTO LEVELING SENSOR REMOVAL/INSTALLATION A6E811251030W06 1. Disconnect the negative battery cable. 2. Jack up the vehicle and remove the wheel and tire. 3. Remove in the order indicated in the table. Connector Bolt Bracket Front auto leveling sensor 4.
Page 927: Parking Light Bulb Removal/Installation
EXTERIOR LIGHTING SYSTEM PARKING LIGHT BULB REMOVAL/INSTALLATION A6E811251040W01 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. Cover Socket Parking light bulb 3. Install in the reverse order of removal. A6E8112W109 End Of Sie FRONT TURN LIGHT REMOVAL/INSTALLATION A6E811251050W01 1.
Page 928: Front Fog Light Aiming
EXTERIOR LIGHTING SYSTEM FRONT FOG LIGHT AIMING A6E811251680W01 1. Adjust the tire air pressure to the specification. 2. Position the unloaded vehicle on a flat, level surface. 3. Seat one person in the driver’s seat. 4. Position the vehicle 3 m {10 ft} in front of a white screen.
Page 929: Rear Combination Light Removal/Installation
EXTERIOR LIGHTING SYSTEM REAR COMBINATION LIGHT REMOVAL/INSTALLATION A6E811251150W01 1. Disconnect the negative battery cable. 2. Remove the trunk side trim. (See S–92 TRUNK SIDE TRIM REMOVAL/INSTALLATION) 3. Remove in the order indicated in the table. Connector Bolt Rear combination light Socket Rear turn light bulb Brake light/taillight bulb...
Page 930: High-Mount Brake Light Removal/Installation
EXTERIOR LIGHTING SYSTEM 2. Pleace the bracket in the proper position as shown in the figure and press it to the trunk lid (liftgate) to attach. A6E8112W121 End Of Sie HIGH-MOUNT BRAKE LIGHT REMOVAL/INSTALLATION A6E811251580W01 In-vehicle-type 1. Disconnect the negative battery cable. 2.
Page 931: License Plate Light Removal/Installation
EXTERIOR LIGHTING SYSTEM High-mount brake light removal note 1. Tie a string to the end of the connector of the high-mount brake light beforehand so that the connector can be passed easily through the rear spoiler during installation. A6E8112W116 1. Disconnect the negative battery cable. 2.
Page 932: Combination Switch Disassembly/Assembly
EXTERIOR LIGHTING SYSTEM 6. Remove in the order indicated in the table. Connector Screw Combination switch 7. Install in the reverse order of removal. A6E8112W102 End Of Sie COMBINATION SWITCH DISASSEMBLY/ASSEMBLY A6E811266120W02 Caution • For vehicles with DSC, the clock spring is generally not to be removed from the combination switch as may result in a malfunction of the steering angle sensor.
Page 933: Steering Angle Sensor Inspection
EXTERIOR LIGHTING SYSTEM STEERING ANGLE SENSOR INSPECTION A6E811266120W03 With DSC 1. Remove the column cover. (See S–84 COLUMN COVER REMOVAL/INSTALLATION) 2. Disconnect the steering angle sensor connector. 3. Connect battery positive voltage to terminal A and ground to terminal F of the steering angle sensor. 4.
Page 934 EXTERIOR LIGHTING SYSTEM LIGHT SWITCH INSPECTION A6E811266121W02 Light switch LH side 1. Remove the light switch. (See T–39 LIGHT SWITCH REMOVAL/INSTALLATION) 2. Inspect for continuity between the light switch terminals using an ohmmeter. • If not as specified, replace the light switch. Headlight switch A6E8112W129 A6E8112W144...
Page 935: Hazard Warning Switch Inspection
EXTERIOR LIGHTING SYSTEM Light switch RH side 1. Remove the light switch. (See T–39 LIGHT SWITCH REMOVAL/INSTALLATION) 2. Inspect for continuity between the light switch terminals using an ohmmeter. • If not as specified, replace the light switch. Headlight switch A6E8112W131 A6E8112W146 Turn switch...
Page 936 EXTERIOR LIGHTING SYSTEM FRONT AND REAR FOG LIGHT SWITCH INSPECTION A6E811266402W01 Light switch LH side 1. Remove the light switch. (See T–39 LIGHT SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the light switch terminals using an ohmmeter. • If not as specified, replace the light switch. A6E8112W140 A6E8112W148 Light switch RH side...
Page 937: Headlight Leveling Switch Removal/Installation
EXTERIOR LIGHTING SYSTEM HEADLIGHT LEVELING SWITCH REMOVAL/INSTALLATION A6E811251030W08 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. Headlight leveling switch (See T–43 Headlight Leveling Switch Removal Note) Connector 3. Install in the reverse order of removal. A6E8112W138 Headlight Leveling Switch Removal Note 1.
Page 938: Back-Up Light Switch Inspection
EXTERIOR LIGHTING SYSTEM BACK-UP LIGHT SWITCH INSPECTION A6E811217640W02 1. Disconnect the back-up light switch connector. 2. Inspect for continuity between the back-up light switch terminals using an ohmmeter. • If not as specified, replace the back-up light switch. A6E8112W153 A6E8112W128 End Of Sie FLASHER UNIT REMOVAL/INSTALLATION A6E811266830W01...
Page 939 EXTERIOR LIGHTING SYSTEM Terminal Voltage List (Reference) A6E8112W154 Voltage (V)/ Terminal Signal Connected to Test condition Action Continuity • Inspect HAZARD 10 A HAZARD 10 A Power supply Under any condition fuse fuse • Inspect related harness Turn signal light (LH) flashes Alternates •...
Page 940 EXTERIOR LIGHTING SYSTEM RUNNING LIGHT UNIT INSPECTION A6E811266731W02 1. Connect the connector to the running light unit. 2. Connect the negative battery cable. 3. Measure the voltage at the running light unit using voltmeter. • When inspecting terminal D, H or P for continuity, disconnect the running light unit connector. 4.
Page 941 EXTERIOR LIGHTING SYSTEM Voltage (V)/ Terminal Signal Connected to Test condition Action Continuity • Inspect front and rear Front and rear fog light switch at OFF position: inspect for continuity fog light switch (See T– to ground Front fog light Front and rear 42 FRONT AND REAR on/off...
Page 942: Front Map Light
INTERIOR LIGHTING SYSTEM INTERIOR LIGHTING SYSTEM FRONT MAP LIGHT REMOVAL/INSTALLATION A6E811451310W01 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. Front map light (See T–48 Front Map Light Removal Note) Connector Socket Map light bulb 3.
Page 943: Rear Map Light
INTERIOR LIGHTING SYSTEM REAR MAP LIGHT REMOVAL/INSTALLATION A6E811451311W01 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. Rear map light (See T–49 Rear Map Light Removal Note) Connector Socket Rear map light bulb 3. Install in the reverse order of removal. A6E8114W104 Rear Map Light Removal Note 1.
Page 944 INTERIOR LIGHTING SYSTEM CARGO COMPARTMENT LIGHT REMOVAL/INSTALLATION A6E811451441W01 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. Cargo compartment light Connector Lens Cargo compartment light bulb 3. Install in the reverse order of removal. A6E8114W101 End Of Sie CARGO COMPARTMENT LIGHT INSPECTION...
Page 945 INTERIOR LIGHTING SYSTEM INTERIOR LIGHTING SYSTEM T – 5 0 B ODY ELECTRICAL SYSTEM VANITY MIRROR ILLUMINATION REMOVAL/INSTALLATION A6E811469270W01 Applied VIN (assumed): JMZ GG12***# 202316— JM7 GG32***# 128767— JMZ GG14***# 202316— JM7 GG42***# 128767— JMZ GY19***# 146118— JM7 GG34***# 128767— JMZ GY89***# 146118—...
Page 946: Trunk Compartment Light Bulb
INTERIOR LIGHTING SYSTEM TRUNK COMPARTMENT LIGHT BULB REMOVAL/INSTALLATION A6E811451440W01 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. Lens Trunk compartment light bulb 3. Install in the reverse order of removal. A6E8114W112 End Of Sie TRUNK COMPARTMENT LIGHT SWITCH INSPECTION A6E811451440W02 1.
Page 947: Ashtray Illumination Bulb
INTERIOR LIGHTING SYSTEM DOOR SWITCH REMOVAL/INSTALLATION A6E811466540W01 Front 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. Screw Door switch Connector 3. Install in the reverse order of removal. A6E8114W108 Rear 1. Disconnect the negative battery cable. 2.
Page 948: Glove Compartment Light Bulb
INTERIOR LIGHTING SYSTEM End Of Sie IGNITION KEY ILLUMINATION BULB REMOVAL/INSTALLATION A6E811460231W01 1. Disconnect the negative battery cable. 2. Remove the column cover. (See S–84 COLUMN COVER REMOVAL/INSTALLATION) 3. Remove the ignition key illumination bulb. 4. Install in the reverse order of removal. A6E8114W129 End Of Sie GLOVE COMPARTMENT LIGHT BULB REMOVAL/INSTALLATION...
Page 949 INTERIOR LIGHTING SYSTEM PANEL LIGHT CONTROL SWITCH INSPECTION A6E811466600W02 1. Connect the connector to the panel light control switch. 2. Connect the negative battery cable. 3. Measure the voltage at the panel light control switch using voltmeter. • When inspecting terminal B for continuity, disconnect the panel light control switch connector. 4.
Page 950 INTERIOR LIGHTING SYSTEM Terminal C inspection 1. Measure the wave pattern of the terminal C on the panel light control switch using an oscilloscope. 2. Set the headlight switch to either the TNS or headlight position. 3. Set the panel light control switch to the brightest position.
Page 951 WIPER AND WASHER WIPER AND WASHER WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION A6E811667340W01 1. Disconnect the negative battery cable. 2. Remove the windshield wiper arm and blade. (See T–57 WINDSHIELD WIPER ARM AND BLADE REMOVAL/ INSTALLATION.) 3. Remove the cowl grille. (See S–50 COWL GRILLE REMOVAL/INSTALLATION.) 4.
Page 952 WIPER AND WASHER R.H.D. 1. Disconnect the windshield wiper motor connector. 2. Connect battery positive voltage to terminal B or A and ground to terminal D, and inspect the operation of the windshield wiper motor as indicated below. Terminal Operation High 3.
Page 953 WIPER AND WASHER WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT A6E811667320W02 1. Operate the windshield wiper motor to set the wipers in the park position. 2. Set the windshield wiper arms height as shown. A6E8116W107 End Of Sie WASHER TANK REMOVAL/INSTALLATION A6E811667481W01 1.
Page 954 WIPER AND WASHER WINDSHIELD WASHER MOTOR REMOVAL/INSTALLATION A6E811676670W01 1. Disconnect the negative battery cable. 2. Remove the washer tank. (See T–58 WASHER TANK REMOVAL/INSTALLATION) 3. Remove in the order indicated in the table. Windshield washer motor Grommet 4. Install in the reverse order of removal. A6E8116W123 End Of Sie WINDSHIELD WASHER MOTOR INSPECTION...
Page 955 WIPER AND WASHER WASHER FLUID-LEVEL SENSOR INSPECTION A6E811676670W04 1. Disconnect the negative battery cable. 2. Remove the washer tank. (See T–58 WASHER TANK REMOVAL/INSTALLATION) 3. Insoect for continuity between the washer fluid- level sensor terminals using an ohmmeter. 4. Verify that the windshield washer motor operates. •...
Page 956: Windshield Washer Hose
WIPER AND WASHER WINDSHIELD WASHER HOSE REMOVAL/INSTALLATION A6E811650601W01 1. Remove the bonnet insulator. 2. Partially peel off the right side mud guard. 3. Remove in the order indicated in the table. Clip Joint pipe Windshield washer hose 4. Install in the reverse order of removal. A6E8116W126 End Of Sie REAR WASHER MOTOR REMOVAL/INSTALLATION...
Page 957 WIPER AND WASHER REAR WIPER MOTOR REMOVAL/INSTALLATION A6E811667450W01 1. Disconnect the negative battery cable. 2. Remove the rear wiper arm and blade. (See T–63 REAR WIPER ARM AND BLADE REMOVAL/ INSTALLATION.) 3. Remove the liftgate lower trim. (See S–95 LIFTGATE LOWER TRIM REMOVAL/INSTALLATION) 4.
Page 958 WIPER AND WASHER 7. Verify that the rear wiper stops in the park position. • If not as specified, replace the rear wiper motor. A6E8116W119 A6E8116W133 End Of Sie REAR WIPER ARM AND BLADE REMOVAL/INSTALLATION A6E811667420W01 1. Remove in the order indicated in the table. Rear wiper arm (See T–63 Rear Wiper Arm Installation...
Page 959 WIPER AND WASHER REAR WIPER ARM AND BLADE ADJUSTMENT A6E811667420W02 1. Operate the rear wiper motor to set the wiper in the park position. 2. Set the rear wiper arm onto the ceramics end line. A6E8116W109 End Of Sie REAR WASHER NOZZLE REMOVAL/INSTALLATION A6E811667511W01 1.
Page 960 WIPER AND WASHER REAR WASHER HOSE REMOVAL/INSTALLATION A6E811667470W01 1. Disconnect the negative battery cable. 2. Remove the washer tank. (See T–58 WASHER TANK REMOVAL/INSTALLATION) 3. Partially peel off the right side mud guard. 4. Remove rear washer hose No.1 from the clips. 5.
Page 961: Rear Wiper Motor
WIPER AND WASHER INTERMITTENT REAR WIPER RELAY REMOVAL/INSTALLATION A6E811666810W01 1. Disconnect the negative battery cable. 2. Remove the trunk side trim. (See S–92 TRUNK SIDE TRIM REMOVAL/INSTALLATION) 3. Remove in the order indicated in the table. Connector Bolt Interittent rear wiper relay 4.
Page 962 WIPER AND WASHER Voltage (V)/ Terminal Signal Connected to Test condition Action Continuity Rear wiper • Inspect R. WIP 10 A switch at INT fuse position • Inspect wiper and • Rear wiper Rear wiper Ignition switch at washer switch (See T–...
Page 963 WIPER AND WASHER WIPER AND WASHER SWITCH INSPECTION A6E811666122W02 Windshield Wiper And Washer Switch Without vehicle-speed sensing type wipers 1. Remove the wiper and washer switch. (See T–67 WIPER AND WASHER SWITCH REMOVAL/INSTALLATION) 2. Inspect for continuity between the wiper and washer switch terminals using an ohmmeter.
Page 964 WIPER AND WASHER 4. Inspect whether the vehicle speed signal to the wiper and washer switch terminal N (D) is input correctly using an oscilloscope. • Connect the oscilloscope probes to the wiper and washer switch terminal N (D) (+) and terminal M (C) (-). •...
Page 965: T-71 Headlight Cleaner Hose
WIPER AND WASHER HEADLIGHT CLEANER MOTOR INSPECTION A6E811651030W02 1. Disconnect the negative battery cable. 2. Remove the washer tank. (See T–58 WASHER TANK REMOVAL/INSTALLATION) 3. Connect battery positive voltage to terminal D and ground to terminal C of the motor. 4.
Page 966 WIPER AND WASHER HEADLIGHT CLEANER HOSE REMOVAL/INSTALLATION A6E811651030W06 1. Remove the front bumper. (See S–47 FRONT BUMPER REMOVAL/INSTALLATION) 2. Remove in the order indicated in the table. Clip Headlight cleaner hose Check valve 3. Install in the reverse order of removal. A6E8116W118 End Of Sie HEADLIGHT CLEANER SWITCH REMOVAL/INSTALLATION...
Page 967 WARNING AND INDICATOR SYSTEM WARNING AND INDICATOR SYSTEM INSTRUMENT CLUSTER REMOVAL/INSTALLATION A6E811855430W01 Caution • When replacing the instrument cluster, the configuration procedure must be performed before removing the instrument cluster. If the configuration procedure is not performed before removing the instrument cluster, it is possible that the instrument cluster will not operate normally. 1.
Page 968 WARNING AND INDICATOR SYSTEM INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY A6E811855430W03 Caution • If the instrument cluster is dropped or the print plate is damaged, the system will not work properly and it may be the cause of trouble or malfunctions. 1. Disassemble in the order indicated in the table. Lens Case Meter unit...
Page 969 WARNING AND INDICATOR SYSTEM Tachometer Using the input/output check mode 1. Inspect the tachometer by setting it in the input/output check mode DTC 13. Using the SSTs (WDS or equivalent) Caution • If the engine speed exceeds the allowable range, the engine could be damaged. Therefore, when inspecting the tachometer, do not allow the engine speed to exceed the allowable range indication on the tachometer.
Page 970 WARNING AND INDICATOR SYSTEM INSTRUMENT CLUSTER INPUT/OUTPUT CHECK MODE A6E811855430W06 Note • In this mode, it is possible to check the items in the following chart. Diagnostic Trouble Code Chart Checked item Related item Buckle switch Buckle switch • Ignition key illumination •...
Page 971 WARNING AND INDICATOR SYSTEM Operating Order A6E8118W009 T–76...
Page 972 WARNING AND INDICATOR SYSTEM Checking Order Note • When inspecting more than two DTCs, perform the inspection by following the priority order of inspection indicated in the chart below. Priority order IG switch Check code of inspection position 01, 04, 08, 12, 13, 14, 16, 18, 23, 25, 26 LOCK Inspection of Diagnostic Trouble Codes DTC 01 Buckle switch on/off signal...
Page 973 WARNING AND INDICATOR SYSTEM DTC 04 Door switch on/off signal Diagnostic procedure STEP INSPECTION INDICATION ACTION Open driver-side door. (Door switch Close driver-side door, then go to next step. on.) Measure voltage at instrument cluster terminal 1J. Is voltage 0 V? •...
Page 974 WARNING AND INDICATOR SYSTEM STEP INSPECTION INDICATION ACTION Close all doors. (Door switch off.) Measure voltage at instrument cluster terminals 1I and Is voltage B+? • If as specified, replace instrument cluster. • If not as specified, inspect following parts. —...
Page 975 WARNING AND INDICATOR SYSTEM DTC 13 Operation signal to tachometer INSPECTION INDICATION SITUATION ACTION Wait for 2 seconds after selecting DTC 13. Tachometer needle moves Tachometer is okay. full scale then returns to 3000 rpm. Other than stated above. Replace instrument cluster.
Page 976 WARNING AND INDICATOR SYSTEM DTC 22 Fuel level signal Diagnostic procedure STEP INSPECTION INDICATION ACTION Select DTC 22 with fuel gauge Go to next step. sender unit connector disconnected. Other than stated Replace instrument cluster. above. Connect between instrument cluster Go to next step.
Page 977 WARNING AND INDICATOR SYSTEM DTC 23 Operation signal to fuel gauge INSPECTION INDICATION SITUATION ACTION Wait for 2 seconds after selecting DTC 23. Fuel gauge indicates in Fuel gauge is okay. following order for every 2 seconds. • F→1/2→E→F (fixed) Other than stated above.
Page 978 WARNING AND INDICATOR SYSTEM STEP INSPECTION INDICATION ACTION Remove key from steering lock (Key Measure voltage at instrument cluster terminal 2B. reminder switch off.) Is voltage 0 V? • If as specified, replace instrument cluster. • If not as specified, inspect following parts. —...
Page 979 WARNING AND INDICATOR SYSTEM OIL PRESSURE SWITCH INSPECTION A6E811818500W01 1. Verify that the oil pressure warning light illuminates when the ignition switch is at ON position. 2. Verify that the oil pressure warning light goes off when the engine is started. •...
Page 980: Theft-Deterrent System
THEFT-DETERRENT SYSTEM THEFT-DETERRENT SYSTEM BONNET SWITCH INSPECTION A6E812001084W01 Note • Bonnet switch has a built-in bonnet lock. 1. Open the bonnet. 2. Disconnect the negative battery cable. 3. Remove the radiator grille. 4. Disconnect the bonnet switch connector. 5. Check the continuity between the bonnet switch terminals A and B using an ohmmeter.
Page 981: Theft-Deterrent Control Module Removal/Installation
THEFT-DETERRENT SYSTEM THEFT-DETERRENT CONTROL MODULE REMOVAL/INSTALLATION A6E812067790W01 1. Disconnect the negative battery cable. 2. Remove the center panel module. (See T–96 CENTER PANEL MODULE REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. Screw Connector Theft-deterrent control module 4. Install in the reverse order of removal. A6E8120W001 End Of Sie THEFT-DETERRENT CONTROL MODULE INSPECTION...
Page 982: Theft-Deterrent Siren
THEFT-DETERRENT SYSTEM Voltage (V)/ Terminal Signal Connected to Test condition Action continuity Alternates Theft-deterrent system between alarm: Active below 1.0 Theft-deterrent siren Theft-deterrent • Inspect related harness and B+ on/off siren Theft-deterrent system alarm: Other • Theft-deterrent • Inspect door lock timer system recognition unit signal output...
Page 983 THEFT-DETERRENT SYSTEM Voltage (V)/ Terminal Signal Connected to Test condition Action continuity • Inspect passenger’s or Passenger’s and rear door lock-link switch rear door lock-link switch locked: inspect for (See S–30 FRONT • Passenger’s continuity to ground DOOR LOCK door lock-link ACTUATOR Lock/unlock switch...
Page 984 THEFT-DETERRENT SYSTEM INTRUDER SENSOR REMOVAL/INSTALLATION A6E812000172W01 1. Disconnect the negative battery cable. 2. Remove the headliner. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. WITHOUT SLIDING SUNROOF WITH SLIDING SUNROOF A6E8120W005 Connector Intruder sensor Screw...
Page 985: Immobilizer System
IMMOBILIZER SYSTEM IMMOBILIZER SYSTEM COIL REMOVAL/INSTALLATION A6E812267004W01 Note • Do not remove the coil unless you are replacing it. • When only the coil is replaced, the immobilizer system reprogram procedure is not necessary. 1. Disconnect the negative battery cable. 2.
Page 986 IMMOBILIZER SYSTEM Note • If no specific time interval is given, each step should be performed within 30 seconds of the previous step. 1. Cut new transponder-equipped key(s). 2. Using key 1, turn ignition switch to ON position. (1) Observe illumination of security light in instrument cluster. (2) After the security light turns off (after approx.
Page 987 IMMOBILIZER SYSTEM Key Replacement Note • Perform this procedure to erase a previously registered key code and register a new key. • If a new key code is registered by following this procedure, the engine will not start using the previously registered keys.
Page 988 • After reading out the outcode, do not turn ignition switch from LOCK to ON position 5 times, otherwise the outcode value will be changed. 4. Access the Mazda official website to obtain the incode that corresponds to the outcode. Refer to Service Information Ref. No. A001/02 for details of this procedure.
Page 989: Audio And Navigation System
AUDIO AND NAVIGATION SYSTEM T B ODY ELECTRICAL SYSTEM AUDIO AND NAVIGATION SYSTEM ANTI-THEFT SYSTEM A6E812466900W01 Alarm Conditions • If the anti-theft system protection has been activated, any one of the following conditions will trigger the system: — Disconnected battery cable —...
Page 990 AUDIO AND NAVIGATION SYSTEM 6. With the code number displayed, press the AUTO-M button, then simultaneously press channel button 6 for approximately 2 seconds. “CODE” will be displayed for approximately 5 seconds. After it disappears, the code number is set. 7.
Page 991 AUDIO AND NAVIGATION SYSTEM 5. With the code number displayed, press the AUTO-M button, then simultaneously press channel button 6 for approximately 2 seconds. “CODE” will be displayed for approximately 5 seconds. After it disappears, the code number is canceled. 6.
Page 992: Center Panel Module Removal/Installation
AUDIO AND NAVIGATION SYSTEM CENTER PANEL MODULE REMOVAL/INSTALLATION A6E812466900W02 1. Cancel the anti-theft operation. (with anti-theft system) (See T–93 ANTI-THEFT SYSTEM.) 2. Disconnect the negative battery cable. 3. Remove the glove compartment. 4. Remove the rear console. 5. Remove in the order indicated in the table. Dial (manual A/C only) Screw (manual A/C only) Screw...
Page 993: Center Panel Module Disassembly/Assembly
AUDIO AND NAVIGATION SYSTEM CENTER PANEL MODULE DISASSEMBLY/ASSEMBLY A6E812466900W03 Caution • Before disassembling the center panel module, spread a cloth on the floor to put the disassembled parts on. This protects the surface of the panel from scratches or dirt. 1.
Page 994: Car-Navigation Unit
AUDIO AND NAVIGATION SYSTEM CAR-NAVIGATION UNIT REMOVAL/INSTALLATION A6E812466902W01 1. Disconnect the negative battery cable. 2. Remove the glove compartment. 3. Remove in the order indicated in the table. Bolt Car-navigation unit (See T–98 Car-navigation Unit Installation Note) Connector 4. Install in the reverse order of removal. A6E8124W015 Car-navigation Unit Installation Note 1.
Page 995: Audio Control Switch Removal/Installation
AUDIO AND NAVIGATION SYSTEM 2. While pressing down the unit behind the LCD unit, pull the LCD unit out from the dashboard. A6E8124W018 End Of Sie AUDIO CONTROL SWITCH REMOVAL/INSTALLATION A6E812400148W01 Note • The audio control switch and the cruise control switch use a common connector. 1.
Page 996: Audio Control Switch Inspection
AUDIO AND NAVIGATION SYSTEM AUDIO CONTROL SWITCH INSPECTION A6E812400148W02 1. Disconnect the negative battery cable. 2. Remove the driver-side air bag module. (See T–120 DRIVER-SIDE AIR BAG MODULE REMOVAL/ INSTALLATION.) 3. Disconnect the audio control switch connector. 4. Measure the resistance and inspect for continuity between the cruise control switch terminals using an ohmmeter.
Page 997: Front Door Speaker Removal/Installation
AUDIO AND NAVIGATION SYSTEM FRONT DOOR SPEAKER REMOVAL/INSTALLATION A6E812466960W01 1. Disconnect the negative battery cable. 2. Remove the front door trim. 3. Remove in the order indicated in the table. Screw Connector Front door speaker (See T–101 Front Door Speaker Installation Note) 4.
Page 998: Rear Door Speaker
AUDIO AND NAVIGATION SYSTEM REAR DOOR SPEAKER REMOVAL/INSTALLATION A6E812466964W01 1. Disconnect the negative battery cable. 2. Remove the rear door trim. 3. Remove in the order indicated in the table. Screw Connector Rear door speaker (See T–102 Rear Door Speaker Installation Note) 4.
Page 999: Tweeter Removal/Installation
AUDIO AND NAVIGATION SYSTEM TWEETER REMOVAL/INSTALLATION A6E812468966W01 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. Inner garnish Connector Screw Cover Tweeter 3. Install in the reverse order of removal. A6E8124W004 End Of Sie TWEETER INSPECTION A6E812468966W02 1.
Page 1000: Woofer Inspection
AUDIO AND NAVIGATION SYSTEM 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. Temporary spare tire cover Wing bolt Connector Woofer 3. Install in the reverse order of removal. A6E8124W006 End Of Sie WOOFER INSPECTION A6E812466967W02 1.

Mazda 2002 6 Workshop Manual

G Eneral Information

How to Use this Manual

Units

Fundamental Procedures

Installation of Radio System

Electrical System

Jacking Positions ,Vehicle Lift (2 Supports),Safety Stands (Rigid Rack) Positions

Towing

Identification Number Locations

New Standards

Abbreviations

Pre-Delivery Inspection

Scheduled Maintenance

E Ngine

Location Index

Drive Belt

Valve Clearance

Compression Pressure

Timing Chain

Cylinder Head Gasket

Front Oil Seal

Rear Oil Seal

Engine

Variable Valve Timing

Oil Control Valve (Ocv) Removal/Installation

L Ubrication System

C Ooling System

Location Index

Engine Coolant Protection Inspection

Cooling System Service Warnings

Radiator Cap

Radiator

Thermostat

Water Pump

Fan Motor

F Uel and Emission Control Systems

Location Index

Engine Tune-Up

Intake-Air System

Fuel System

Exhaust System

Emission System

Control System

On-Board Diagnostic

Troubleshooting

E Ngine Electrical System

Location Index

Charging System

Ignition System

Starting System

Quick Links

Chapters

Troubleshooting

Related Manuals for Mazda 2002 6

Summary of Contents for Mazda 2002 6