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Mazda6
Workshop
Manual
FOREWORD
This manual contains on-vehicle service
and diagnosis for the Mazda6.
For proper repair and maintenance,
a thorough familiarization with this manual
is important, and it should always be kept
in a handy place for quick and easy
reference.
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing.
As modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Mazda dealers. This manual
should be kept up-to-date.
Mazda Motor Corporation reserves
the right to alter the specifications and
contents of this manual without obligation
or advance notice.
All rights reserved. No part of this book
may be reproduced or used in any form or
by any means, electronic or
mechanical—including photocopying and
recording and the use of any kind of
information storage and retrieval
system—without permission in writing.
Mazda Motor Corporation
HIROSHIMA, JAPAN
APPLICATION:
This manual is applicable to vehicles
beginning with the Vehicle Identification
Numbers (VIN), and related materials shown
on the following page.
CONTENTS
Title
General Information
Engine
Lubrication System
Cooling System
Fuel and Emission Control Systems
Engine Electrical System
Clutch
Manual Transaxle
Automatic Transaxle
Steering System
Braking System
Suspension
Body
Body Electrical System
Heater and Air Conditioner Systems
Technical Data
Special Tools
© 2002 Mazda Motor Corporation
PRINTED IN The Netherlands, MARCH 2002
1730–1E–02C
Section
GI
B
D
E
F
G
H
J
K
M
N
P
R
S
T
U
TD
ST

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Troubleshooting

   Also See for Mazda 2002 6

   Summary of Contents for Mazda 2002 6

  • 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: Supports) And Safety Stand 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 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 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 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 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: Valve Clearance

    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 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 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 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 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 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 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

    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 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 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 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 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 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 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 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 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: Engine Coolant

    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 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 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 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: Water Pump

    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 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

    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

    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 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

    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

    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

    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 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

    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 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

    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

    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

    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

    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

    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 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 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 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

    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 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 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 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 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 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

    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 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 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

    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

    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

    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 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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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 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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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 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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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 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 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

    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

    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

    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

    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 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

    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

    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 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

    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 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

    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 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 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 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 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 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 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 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 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 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 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 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 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 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

    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

    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 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 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 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

    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 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 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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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

    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 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

    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

    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

    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

    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...

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    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. —...

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    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...

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    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...

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    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)

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    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.

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    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.). •...

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    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...

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    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.

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    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 •...

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    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.

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    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).

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    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 –...

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    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. —...

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    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.

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    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.

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    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. —...

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