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Mazda RX-8 2004 Service Highlights

Mazda rx-8 2004
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Table of Contents

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2004
Mazda
RX-8
Service
Highlights
FOREWORD
This Service Highlights is intended for use
by service training personnel of Authorized
Mazda Dealers.
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing.
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
GENERAL INFORMATION
ENGINE
SUSPENSION
DRIVELINE/AXLE
BRAKES
TRANSMISSION/TRANSAXLE
STEERING
HEATER, VENTILATION &
AIR CONDITIONING (HVAC)
RESTRAINTS
BODY & ACCESSORIES
© 2003 Mazda Motor Corporation
PRINTED IN U.S.A., MARCH 2003
Form No. 3378–1U–03C
Part No. 9999–95–102F–04
Title
Section
00
01
02
03
04
05
06
07
08
09

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Summary of Contents for Mazda RX-8 2004

  • Page 1 All the contents of this manual, including drawings and specifications, are the latest STEERING available at the time of printing. HEATER, VENTILATION & Mazda Motor Corporation reserves the right AIR CONDITIONING (HVAC) to alter the specifications and contents of this manual without obligation or advance RESTRAINTS notice.

  • Page 2: Table Of Contents

    New Model Concept "New four-door, four-passenger sports car" • The Mazda RX-8 is an entirely new concept in a state-of-the-art sports car, combining unique sports-car styling and excellent driving performance, together with the comfort and practicality of a four-door, four- passenger layout.

  • Page 3: Outline

    • A compact cabin supported by pronounced overfenders, lowers the visual center of gravity, emphasizing a sense of "stability". • A pared-down body shape and a boldly contoured form gives the Mazda RX-8 an aggressive appearance. Interior design • Modern, high-quality design —...
  • Page 4 GENERAL INFORMATION Engine - the "RENESIS" - a new-generation rotary engine • Engine — 13B-multi side port (MSP) (High power and Standard power), new-generation rotary engine has been adopted. — Side exhaust system has been adopted by transferring the exhaust ports from the rotor housing to the side 00–00 housing.
  • Page 5 GENERAL INFORMATION — Three injectors per rotor have been provided on the High power model (2 per rotor for Standard power). Together with the electronically controlled (drive-by-wire) throttle valves and the 32-bit powertrain control module (PCM), the injector arrangement has realized fine control of the air-fuel ratio and reduced response time.
  • Page 6 GENERAL INFORMATION Suspension and steering • Tire pressure monitoring system — The tire pressure monitoring system (TPMS) has been adopted to assist the driver in understanding the tire status to improve the safety. • Front suspension 00–00 — Newly developed, in-wheel type double-wishbone suspension has been adopted. —...
  • Page 7 Safety • Lightweight and highly rigid safe body structure developed uniquely for the Mazda RX-8 has achieved high international standards of crash safety. • Reinforcement with high strength has been installed on the area equivalent to the center pillar on the rear doors, realizing strength nearly equal to that of a center pillar of a standard sedan.

  • Page 8: How To Use This Manual

    *=0 to 9, X Check Digit N= 13B-Standard power Engine type 3= 13B-High power Body style 7= Coupe 1=Drv. & Pass.-A/B, Restraint system Side A/B, Curtain A/B Vehicle type FE= Mazda RX-8 World manufacturer identification JM1= Mazda/passenger car CHU0000S001 End Of Sie 00–00–7...

  • Page 9: Units

    GENERAL INFORMATION UNITS CHU000000002S01 Electrical current A (ampere) Electric power W (watt) Electric resistance 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 10: Sae Standard

    • In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations are now used in this manual. The table below lists the names and abbreviations that have been used in Mazda manuals up to now and their SAE equivalents. 00–00...

  • Page 12: Charging System

    ENGINE SECTION 01–00 Toc of SCT OUTLINE ....01-00 EXHAUST SYSTEM ..01-15 ON-BOARD DIAGNOSTIC ..01-02 EMISSION SYSTEM.
  • Page 13 OUTLINE ENGINE FEATURES CHU010002000S02 • A side intake and exhaust port system adopted • 2-piece apex seals adopted • Keystone shaped side seals adopted Improved power performance • Cut-off seal adopted • A lightweight flywheel adopted • Advanced front mid-ship layout adopted •...
  • Page 14 2004 Mazda RX-8 Service Highlights (3378-1U-03C) OUTLINE Specifications Item 13B-MSP 13B-MSP (Standard power) (High power) Primary port 3° Open Secondary port ATDC 12° Auxiliary port – 38° Primary port 60° 65° 01–00 Port timing Close Secondary port ABDC 45° 36°...
  • Page 15 2004 Mazda RX-8 Service Highlights (3378-1U-03C) OUTLINE Specifications Item 13B-MSP 13B-MSP (Standard power) (High power) PCV system Closed design CHARGING SYSTEM Voltage Battery Type and capacity 50D20L (40) , 55D23L (48) (A·h) (5 hour rate) 75D23L (52) , 75D26L (52) Out-put (V–A)
  • Page 16 ON-BOARD DIAGNOSTIC 01–02 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC OUTLINE . . . 01–02–1 On-board Device Control ... 01–02–7 Features......01–02–1 DLC-2 Outline .

  • Page 17: Diagnostic Test Mode

    ON-BOARD DIAGNOSTIC DIAGNOSTIC TEST MODE CHU010200102S02 • To meet OBD-II regulations, the following diagnostic test modes have been adopted. Diagnostic test mode Item Mode 01 Sending diagnostic data (PID data monitor/On-board system readiness test) Mode 02 Sending freeze frame data Mode 03 Sending emission-related malfunction code (DTC) Mode 04...

  • Page 18: Sending Freeze Frame Data

    ON-BOARD DIAGNOSTIC Meaning of fuel system loop status • The following information is displayed on the tester. — Feedback operating: HO2S being used for feedback is normal. — Feedback stops: ECT is lower than the determined feedback zone. — Feedback stops: Open loop due to driving condition. —...
  • Page 19 ON-BOARD DIAGNOSTIC Meaning of fuel system loop status • The following information is displayed on the tester. — Feedback operating: HO2S being used for feedback is normal. — Feedback stops: ECT is lower than the determined feedback zone. — Feedback stops: Open loop due to driving condition. —...
  • Page 20 ON-BOARD DIAGNOSTIC Memory DTC No. Condition Monitor item function × P0442 EVAP system leak detected (small leak) EVAP system × P0443 Purge solenoid valve circuit problem × P0446 EVAP system vent control circuit problem EVAP system × P0455 EVAP system leak detected (large leak) EVAP system ×...

  • Page 21: Sending Intermittent Monitoring System Test Results

    ON-BOARD DIAGNOSTIC Memory DTC No. Condition Monitor item function × P2136 TP sensor No.1/No.3 voltage correlation problem × P2138 APP sensor No.1/No.2 voltage correlation problem × P2195 Front HO2S signal stuck lean HO2S × P2196 Front HO2S signal stuck rich HO2S ×...

  • Page 22: On-Board Device Control

    2004 Mazda RX-8 Service Highlights (3378–1U–03C) ON-BOARD DIAGNOSTIC 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 determines that the system returned to normal or the problem was mistakenly detected, and deletes the pending code.
  • Page 23 2004 Mazda RX-8 Service Highlights (3378–1U–03C) ON-BOARD DIAGNOSTIC P0103 MAF sensor circuit high input • The PCM monitors the input voltage from the MAF sensor when the engine is running. If the input voltage is more than 5.0 V, the PCM determines that the MAF sensor circuit input voltage is high.
  • Page 24 2004 Mazda RX-8 Service Highlights (3378–1U–03C) ON-BOARD DIAGNOSTIC MONITORING CONDITION — Front HO2S heater monitor: Completed — Fuel system loop status: Closed loop fuel control — Engine speed: 2,000—3,500 rpm — LOAD: 30.0—50.0 % P0138 Rear HO2S circuit high voltage •...
  • Page 25 2004 Mazda RX-8 Service Highlights (3378–1U–03C) ON-BOARD DIAGNOSTIC P0410 AIR system problem • The PCM monitors the front HO2S output current when the AIR control is operating. If the output current is less than the specification, the PCM determines that there is an AIR system problem.
  • Page 26 ON-BOARD DIAGNOSTIC P0461 Fuel gauge sender unit circuit range/performance problem • The PCM monitors the fuel tank level difference before and after the PCM-calculated fuel consumption has reached more than 21 L {22.2 US qt, 18.5 Imp qt}. If the difference is less than 5 %, the PCM determines that there is a fuel gauge sender unit circuit range/performance problem.
  • Page 27 ON-BOARD DIAGNOSTIC P0662 SSV solenoid valve control circuit high • The PCM monitors the SSV solenoid valve control voltage when the PCM turns the SSV solenoid valve on. If the control voltage is more than 11.5 V, the PCM determines that the SSV solenoid valve control circuit voltage is high.
  • Page 28 ON-BOARD DIAGNOSTIC P2101 Drive-by-wire relay control circuit problem • The PCM monitors the input voltage from the drive-by-wire relay when the PCM turns the drive-by-wire relay on. If the input voltage is less than 5.0 V, the PCM determines that the drive-by-wire relay control circuit voltage is low.
  • Page 29 ON-BOARD DIAGNOSTIC P2196 Front HO2S signal stuck rich • The PCM monitors the front HO2S output current when the following conditions are met. If the average output current is less than 0.8 A for 25 s, the PCM determines that the front HO2S signal remains rich. MONITORING CONDITION —...

  • Page 30: Koeo/Koer Self-Test

    ON-BOARD DIAGNOSTIC P2407 EVAP system leak detection pump sense circuit intermittent/erratic problem • The PCM monitors the pump load current (EVAP line pressure) when the evaporative leak monitor is operating. If the change in pump load current is more than the specification while the PCM obtains the reference current value 28 times, the PCM determines that there is an EVAP system leak detection pump sense circuit intermittent/erratic problem.
  • Page 31 ON-BOARD DIAGNOSTIC Test condition DTC No. Condition KOEO KOER × × P0113 IAT sensor circuit high input × × P0117 ECT sensor circuit low input × × P0118 ECT sensor circuit high input × × P0122 TP sensor No.1 circuit low input ×...
  • Page 32 ON-BOARD DIAGNOSTIC Test condition DTC No. Condition KOEO KOER P0704 CPP switch input circuit problem — — P0850 Neutral switch input circuit problem — — × P1260 Immobilizer system problem — × × P1574 TP sensor output incongruent × × P1577 APP sensor output incongruent 01–02...

  • Page 33: Pid/Data Monitor And Record

    ON-BOARD DIAGNOSTIC PID/DATA MONITOR AND RECORD CHU010200102S05 • The PID/DATA monitor items are shown below. PID/DATA monitor item table —: Not applicable Item Definition Unit/Condition PCM terminal ACCS A/C relay control signal in PCM On/Off ACSW Input signal from A/C switch On/Off AIP RLY AIR pump relay control signal in PCM...
  • Page 34 ON-BOARD DIAGNOSTIC Item Definition Unit/Condition PCM terminal LOAD LOAD — LONGFT1 Long term fuel trim — Input voltage from MAF sensor MIL control signal in PCM On/Off — MIL_DIS Distance travelled while MIL is activated mile — 01–02 MOP_POS Metering oil pump control status —...

  • Page 35: Simulation Test

    ON-BOARD DIAGNOSTIC SIMULATION TEST CHU010200102S06 • The simulation items are shown below. Simulation item table ×: Applicable —: Not applicable Test condition Item Applicable component Unit/condition PCM terminal KOEO KOER × × ACCS A/C relay On/Off × × AIP RLY AIR pump relay On/Off ×...
  • Page 36 MECHANICAL 01–10 MECHANICAL MECHANICAL OUTLINE ... . 01–10–1 BALANCE WEIGHT, COUNTERWEIGHT (AT), Features......01–10–1 FLYWHEEL (MT) CONSTRUCTION .

  • Page 37: Engine Structural View

    MECHANICAL ENGINE STRUCTURAL VIEW CHU011001001S02 BHJ0110N002 End Of Sie 01–10–2...

  • Page 38: Engine Front Cover Construction

    MECHANICAL ENGINE FRONT COVER CONSTRUCTION CHU011010908S01 • The lightweight, aluminum alloy engine front cover includes a metering oil pump driven gear shaft, metering oil pump driven gear and oil cooler with a hydraulic pressure adjusted oil pressure control valve. An internal oil passage for a metering type oil pump has also been added.

  • Page 39: Rotor Housing Construction

    MECHANICAL ROTOR HOUSING CONSTRUCTION CHU011010908S02 • Based on the SIP (Sheetmetal Insert Process) production method utilizing special steel on the inner surface and casting aluminum around the steel circumference, the rotor housings employ the benefits of both the lightweight feature of aluminum together with the excellent strength of steel. By the addition of MCP (Micro Channel Porous) chromium plating to the inner trochoid surface, fine grooves have been made in the surface of the chromium plating for improved oil retention.

  • Page 40: Side Housing Outline

    MECHANICAL SIDE HOUSING OUTLINE CHU011010908S03 • With the adoption of a side intake and exhaust port system, the exhaust ports have been moved from the rotor housing to the side housing. • Intake and exhaust port overlap has been eliminated on the side intake and exhaust port system by way of independently set intake and exhaust port size configurations.
  • Page 41 MECHANICAL • On the front and rear housings are the installation bosses for the stationary gears that regulate the rotational movement of the rotors supporting the eccentric shaft. • On the front housing are the bosses for installing the oil pump and the oil strainer. •...

  • Page 42: Tension Bolt Construction

    MECHANICAL • The anti-wet port with a projection is located on the bottom edge of the primary port. With the anti-wet port, jet air from the jet air fuel mixing nozzle, located at the primary port outlet of the intake manifold, flows upward, and atomization is accelerated under low load when air intake velocity is slow.

  • Page 43: Stationary Gear Construction

    MECHANICAL STATIONARY GEAR CONSTRUCTION CHU011010908S06 • The special steel used for the stationary gear is processed with ion nitriding for improved strengthening against fatigue on the tooth surfaces. • The main bearing is pressed into the stationary gear. Rotation lock of this bearing is done with a screw for the high power and a rotation lock tab for the standard power.

  • Page 44: Eccentric Shaft Construction

    MECHANICAL ECCENTRIC SHAFT CONSTRUCTION CHU011011901S01 • The highly durable, forged carbon steel eccentric shaft is processed with induction hardening for improved wear resistance. • The oil passage supplying lubrication for each journal and the rotor cooling oil jet plugs, runs from the front end of the eccentric shaft to the rear main journal.

  • Page 45: Eccentric Shaft Bypass Valve Construction

    MECHANICAL ECCENTRIC SHAFT BYPASS VALVE CONSTRUCTION CHU011011901S02 • An eccentric shaft bypass valve has been adopted to shorten the engine warm up period. The eccentric shaft bypass valve allows engine oil in the oil passage to escape at cold-engine start, maintaining a pressure in the eccentric shaft that prohibits injection of rotor cooling engine oil from the oil jet plugs until the engine is warmed ROTOR ECCENTRIC SHAFT...

  • Page 46: Balance Weight, Counterweight (At), Flywheel (Mt) Construction

    MECHANICAL BALANCE WEIGHT, COUNTERWEIGHT (AT), FLYWHEEL (MT) CONSTRUCTION CHU011011901S04 • A balance weight and a counterweight (AT) have been installed to prevent dynamic unbalance. • For MT, a weight has been added to perimeter of the flywheel to obtain the same balancing effect as the counterweight on AT.

  • Page 47: Apex Seal Construction

    MECHANICAL APEX SEAL CONSTRUCTION CHU011011910S03 • The special iron cast apex seals have been electronic beam processed to improve abrasion resistance on the trochoid friction surface. • The apex seal is comprised of two parts including a side piece set on the sharp end of an apex seal. The apex seals maintain a gas seal while sweeping the trochoid surface by the combined force of the apex seal springs and centrifugal force of the rotor rotation.

  • Page 48: Side Seal Construction

    MECHANICAL SIDE SEAL CONSTRUCTION CHU011011910S04 • The iron sintering system side seals maintain a gas seal while sweeping the side housing by the force of the side seal springs. • With the adoption of keystone-shaped (bulged shape) side seals, scraping and removal of carbon that collects in the side seal grooves has been improved.

  • Page 49: Corner Seal Construction

    MECHANICAL CORNER SEAL CONSTRUCTION CHU011011910S05 • The special cast iron corner seals maintain a gas seal while sweeping the side housing by the force of the corner seal springs. In addition, the chrome plating on perimeter side of the corner seals has reduced wear on the rotor installation holes.

  • Page 50: Oil Seal Construction

    MECHANICAL OIL SEAL CONSTRUCTION CHU011011910S06 • To prevent the oil that is supplied to the inner rotor for cooling and for lubrication of the bearings from leaking into the combustion chambers from the side surfaces, two oil seals have been added to each side of the rotor. •...

  • Page 51: Cut-Off Seal Construction

    MECHANICAL CUT-OFF SEAL CONSTRUCTION CHU011011910S08 • The zero-overlap side exhaust port system has structurally reduced the mixing of exhaust gas in the intake air process. When the position of the rotor is at top dead center (TDC) of exhaust, the intake ports and exhaust ports are closed by the side surfaces of the rotor.

  • Page 52: Drive Belt Construction

    MECHANICAL DRIVE BELT CONSTRUCTION CHU011015800S01 • The V-ribbed drive belts are composed of two belts, one that drives the generator and the water pump, and another that drives the A/C compressor. Serviceability has been improved from this simple layout based on the motorization of the air pump and P/S pump that were formerly driven by drive belts.

  • Page 53: Engine Mount Outline

    MECHANICAL ENGINE MOUNT OUTLINE CHU011039000S01 • With the adoption of a naturally aspirated engine, an ideal engine layout (advanced front-midship layout) has been realized by the engine being positioned approximately 60 mm {2.36 in} further rearward and approximately 39 mm {1.54 in} further downward than the previous engine. This has been made possible by reducing the height the oil pan and placing intake air related parts at the front of the engine.
  • Page 54 LUBRICATION 01–11 LUBRICATION LUBRICATION SYSTEM OUTLINE ..01–11–1 OIL STRAINER CONSTRUCTION ..01–11–4 Features......01–11–1 OIL PUMP CONSTRUCTION.

  • Page 55: Lubrication

    LUBRICATION LUBRICATION SYSTEM FLOW CHART CHU011101008S03 OIL FILTER METERING OIL PUMP OIL PRESSURE REGULATOR VALVE OIL PAN OIL PUMP STRAINER OIL COOLER* OIL COOLER *: HIGH POWER CHU0111S002 End Of Sie OIL FILTER CONSTRUCTION CHU011101008S04 • A full-flow type oil filter, one with an outer diameter of 65 mm {2.56 in} (Denso*), or another with a diameter of 68 mm {2.68 in} (Tokyo Roki) have been adopted.

  • Page 56: Oil Pan Construction

    LUBRICATION 01–11 CHU0111S009 CHU0111S007 End Of Sie OIL PAN CONSTRUCTION CHU011110040S02 • A thin oil pan made of steel has been adopted to lower the engine height. • An oil baffle plate has been adopted inside the oil pan to stabilize engine oil slosh or aeration when the vehicle rolls and to prevent air suction in the oil strainer.

  • Page 57: Oil Strainer Construction

    LUBRICATION OIL STRAINER CONSTRUCTION CHU011101008S05 • A plastic oil strainer with a resin filter in the middle of the strainer has been adopted for weight reduction. EXTERNAL VIEW SEC. A-A' OIL STRAINER BODY FILTER OIL STRAINER BODY OIL INLET CHU0111S005 End Of Sie OIL PUMP CONSTRUCTION CHU011101008S06...

  • Page 58: Metering Oil Pump Construction/Operation

    LUBRICATION • An oil pressure regulator has been adopted on the rear side housing to release oil when the oil pressure is 538—638 kPa {5.5—6.5 kgf/cm 78.0—92.5 psi} or more. End Of Sie BELOW SPECIFIED VALUE 01–11 ABOVE SPECIFIED VALUE CHU0111S015 METERING OIL PUMP CONSTRUCTION/OPERATION CHU011101008S07...

  • Page 59: Operation

    LUBRICATION • Two oil nozzles are adopted on each rotor in order to improve lubrication in the side housing and side seal in accordance with the adoption of the side exhaust system. They are tilted toward the side housing to inject oil directly to the side housing.

  • Page 60: Cooling System

    COOLING SYSTEM 01–12 COOLING SYSTEM COOLING SYSTEM OUTLINE ..01–12–1 Operation ..... . . 01–12–4 Features.

  • Page 61: Cooling System Outline

    COOLING SYSTEM COOLING SYSTEM FLOW CHART CHU011201008S03 COOLANT RESERVE TANK HEATER THERMOSTAT ENGINE WATER PUMP RADIATOR CHU0112S001 End Of Sie 01–12–2...

  • Page 62: Cooling System Cap, Coolant Reserve Tank Construction

    COOLING SYSTEM COOLING SYSTEM CAP, COOLANT RESERVE TANK CONSTRUCTION CHU011201008S04 • A low-pressure type cap has been adopted for the cooling system cap. It is installed on the coolant reserve tank to improve serviceability when adding engine coolant and bleeding air. •...

  • Page 63: Radiator Construction

    COOLING SYSTEM RADIATOR CONSTRUCTION CHU011201008S05 • A corrugated fin type radiator has been adopted. • The radiator tanks are made of plastic and the core is made of aluminum for weight reduction. • The down-flow direction of water inside the radiator causes air to bleed from the cooling TANK system easier.

  • Page 64: Water Pump

    COOLING SYSTEM WATER PUMP CONSTRUCTION/OPERATION CHU011201008S07 Construction • The water pump is composed of a steel water pump pulley, a water pump body made of aluminum alloy, and the gasket. The spiral casing is built into the front cover for weight reduction. 01–12 SECTIONAL VIEW GASKET...
  • Page 66 INTAKE-AIR SYSTEM 01–13 INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM OUTLINE ..01–13–1 VARIABLE FRESH AIR DUCT (VFAD) Features......01–13–1 SOLENOID VALVE FUNCTION INTAKE-AIR SYSTEM STRUCTURAL (13B-MSP (HIGH POWER)) .

  • Page 67: Intake-Air System

    INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM STRUCTURAL VIEW CHU011300113S02 CHECK VALVE VDI ACTUATOR SSV SOLENOID SSV ACTUATOR VALVE INTAKE MANIFOLD VDI SOLENOID APV MOTOR VALVE (13B-MSP (HIGH POWER)) VFAD SOLENOID VALVE (13B-MSP (HIGH POWER)) THROTTLE BODY CHECK VALVE (13B-MSP (HIGH POWER)) RESONANCE CHAMBER VACUUM CHAMBER (13B-MSP (HIGH POWER)) FRESH-AIR DUCT...

  • Page 68: Intake-Air System Structural

    INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM DIAGRAM CHU011300113S03 TO CHARCOAL CANISTER CATCH TANK SOLENOID SOLENOID VFAD VALVE VALVE THROTTLE VALVE 01–13 SOLENOID VALVE TO METERING OIL NOZZLE TO FUEL TANK CHECK VALVE VACUUM CHAMBER VDI ACTUATOR TO REAR TO POWER PRIMARY/SECONDARY BRAKE UNIT VACUUM PORTS VFAD...

  • Page 69: Intake-Air System Hose Routing Diagram

    INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM HOSE ROUTING DIAGRAM CHU011300113S04 VDI ACTUATOR SSV ACTUATOR AIR SOLENOID INTAKE MANIFOLD VALVE METERING OIL NOZZLE EXTENSION MANIFOLD (UPPER) PURGE SOLENOID VALVE AIR PUMP METERING OIL NOZZLE VACUUM CHAMBER ONE-WAY CHECK VALVE SSV SOLENOID AIR CONTROL VALVE VALVE EXHAUST MANIFOLD VDI SOLENOID VALVE...

  • Page 70: Fresh-Air Duct Construction

    INTAKE-AIR SYSTEM FRESH-AIR DUCT CONSTRUCTION CHU011313200S02 • Composed of the fresh-air duct, VFAD actuator FRESH-AIR DUCT (13B-MSP (High Power)), and VFAD valve (13B- MSP (High Power)). End Of Sie 01–13 VFAD VALVE VFAD ACTUATOR (ILLUSTRATION SHOWS 13B-MSP (HIGH POWER)) CHU0113S004 AIR CLEANER FUNCTION CHU011313300S01 •...

  • Page 71: Throttle Body Function

    INTAKE-AIR SYSTEM THROTTLE BODY FUNCTION CHU011313640S01 • An electronic throttle valve has been adopted which opens and closes the throttle valve with the ACTUATOR actuator according to a signal from the PCM. It THROTTLE BODY enables precise intake air control at all engine speed ranges.

  • Page 72: Intake Manifold Construction

    INTAKE-AIR SYSTEM INTAKE MANIFOLD CONSTRUCTION CHU011313100S02 Construction • Composed of the SSV, VDI valve, APV (13B-MSP (High Power)), APV motor (13B-MSP (High Power)), jet air fuel mixing nozzles, and body. (13B-MSP (STANDARD POWER)) (13B-MSP (HIGH POWER)) 01–13 VDI VALVE APV MOTOR JET AIR FUEL MIXING NOZZLE CHU0113S009 End Of Sie...

  • Page 73: Sequential Dynamic Air Intake System (S-Dais) Structure

    INTAKE-AIR SYSTEM SEQUENTIAL DYNAMIC AIR INTAKE SYSTEM (S-DAIS) STRUCTURE CHU011300113S06 • The S-DAIS is composed of the SSV, VDI valve, and VFAD valve (13B-MSP (High Power)) which are opened and closed by intake manifold vacuum or BARO, and the APV (13B-MSP (High Power)) which is opened and closed by motor drive.

  • Page 74: Sequential Dynamic Air-Intake System (S-Dais) Operation

    INTAKE-AIR SYSTEM SEQUENTIAL DYNAMIC AIR-INTAKE SYSTEM (S-DAIS) OPERATION CHU011300113S07 Operation Outline • To increase intake air amount and combustion VFAD VALVE (13B-MSP (HIGH POWER)) efficiency, the S-DAIS controls the size of the intake ports and the air length in the intake pipes VFAD by opening or closing the SSV, VDI valve, APV ACTUATOR...
  • Page 75 INTAKE-AIR SYSTEM Medium-speed range • When the engine speed reaches the medium range, the SSV opens and intake air from the secondary port begins. Due to this, the intake air amount increases, improving torque at the engine medium-speed range. Medium-to-high-speed range •...

  • Page 76: Secondary Shutter Valve (Ssv) Solenoid Valve Function

    INTAKE-AIR SYSTEM High-speed range • When the engine speed reaches the high range, the VDI valve opens, and the actual length of the intake air in the pipe is shortened to efficiently provide dynamic air charging effect. 01–13 VDI VALVE VDI ACTUATOR : INTAKE AIR : EXHAUST AIR...

  • Page 77: Secondary Shutter Valve (Ssv) Actuator Function

    INTAKE-AIR SYSTEM SECONDARY SHUTTER VALVE (SSV) ACTUATOR FUNCTION CHU011320130S01 • Opens and closes the SSV. End Of Sie SECONDARY SHUTTER VALVE (SSV) ACTUATOR CONSTRUCTION/OPERATION CHU011320130S02 • A diaphragm design has been adopted. • Normally, the rod is pushed by the force of the spring, closing the SSV. When intake manifold vacuum is applied to the diaphragm chamber, the rod is pulled, opening the SSV.

  • Page 78: Variable Fresh Air Duct (Vfad) Actuator Construction/Operation (13B-Msp (High Power))

    INTAKE-AIR SYSTEM VARIABLE FRESH AIR DUCT (VFAD) ACTUATOR CONSTRUCTION/OPERATION (13B-MSP (HIGH POWER)) CHU011320130S04 • A diaphragm design has been adopted. • Normally, the rod is pushed by the force of the spring, opening the VFAD valve. When intake manifold vacuum is applied to the diaphragm chamber, the rod is pulled, closing the VFAD valve.

  • Page 79: Variable Dynamic Effect Intake-Air (Vdi) Actuator Construction/Operation

    INTAKE-AIR SYSTEM VARIABLE DYNAMIC EFFECT INTAKE-AIR (VDI) ACTUATOR CONSTRUCTION/OPERATION CHU011320130S06 • A diaphragm design has been adopted. • Normally, the rod is pushed by the force of the spring, closing the VDI valve. When intake manifold vacuum is applied to the diaphragm chamber, the rod is pulled, opening the VDI valve.

  • Page 80: Jet Air Fuel Mixing System Outline

    INTAKE-AIR SYSTEM CHECK VALVE CONSTRUCTION/OPERATION CHU011342910S02 • Composed of the main body and valve. • Air can only flow from the vacuum chamber to the intake manifold. End Of Sie VALVE 01–13 INTAKE VACUUM MANIFOLD CHAMBER SIDE SIDE AIR FLOW DIRECTION WHITE GREEN...

  • Page 81: Jet Air Fuel Mixing System Operation

    INTAKE-AIR SYSTEM JET AIR FUEL MIXING SYSTEM OPERATION CHU011300113S10 • The nozzle is installed on the primary port outlet of the intake manifold. BARO is fed to the nozzle from upstream of the throttle valve with the hose. • Under low load, jet air is injected from the nozzle due to the difference in pressure in the primary port and nozzle.

  • Page 82: Specification

    FUEL SYSTEM 01–14 FUEL SYSTEM FUEL SYSTEM OUTLINE ... . 01–14–1 Fuel Pump Unit ....01–14–6 Features.

  • Page 83: Fuel Tank Side

    FUEL SYSTEM FUEL SYSTEM STRUCTURAL VIEW CHU011401006S02 Engine Room Side QUICK RELEASE CONNECTOR FUEL INJECTOR (RS) QUICK RELEASE CONNECTOR FUEL PUMP RESISTOR FUEL INJECTOR (FS) MAIN FUSE BLOCK FUEL PUMP SPEED CHECK CONTROL RELAY CONNECTOR FUEL INJECTOR (FP2, RP2) (13B-MSP (HIGH POWER)) FUEL PUMP FUEL INJECTOR RELAY...

  • Page 84: Fuel System Diagram

    FUEL SYSTEM FUEL SYSTEM DIAGRAM CHU011401006S03 QUICK RELEASE CONNECTOR AIR FILTER QUICK RELEASE CONNECTOR 01–14 EVAP SYSTEM LEAK QUICK RELEASE DETECTION PUMP CONNECTOR QUICK RELEASE CONNECTOR FUEL PUMP RELAY FUEL PUMP RESISTOR FUEL PUMP FUEL PUMP FUEL TANK SPEED CONTROL UNIT RELAY FUEL INJECTOR (FP2, RP2)

  • Page 85: Nonreturn Valve Construction/Operation

    FUEL SYSTEM NONRETURN VALVE CONSTRUCTION/OPERATION CHU011442270S02 • A single valve type has been adopted. NONRETURN VALVE FUEL TANK VALVE POSITION DURING REFUELING FUEL FUEL TANK SIDE FUEL-FILLER PIPE NORMAL VALVE POSITION CHU0114S014 • The nonreturn valve cannot be removed because it is fixed to the fuel-filler pipe in the fuel tank. •...

  • Page 86: Fuel Pump Unit Function

    FUEL SYSTEM FUEL PUMP UNIT FUNCTION CHU011413350S03 • The fuel pump suctions fuel from the fuel tank and pumps it to the fuel distributor. 01–14 FUEL SUCTION PIPE BRACKET FUEL PUMP UNIT RELIEF VALVE FROM SUB-TANK DISCHARGE OUTLET PRESSURE REGULATOR JET PUMP TO INSIDE JET PUMP...

  • Page 87: Fuel Pump Unit Construction/Operation

    FUEL SYSTEM FUEL PUMP UNIT CONSTRUCTION/OPERATION CHU011413350S04 Fuel Pump Unit • Mainly consists of a fuel filter (high-pressure), pressure regulator, fuel pump, fuel reserve cup, fuel filter (low- pressure), and fuel pump (transfer). • A pressure regulator is built-in due to the adoption of a returnless fuel system. •...

  • Page 88: Pulsation Damper Function

    FUEL SYSTEM • New quick release connectors excluding those for the fuel suction pipe, fuel shut-off valve and rollover valve are fitted with a checker tab that prevents improper fit. This checker tab cannot be removed under normal conditions. When the quick release connector is properly connected to the fuel pipe, the lock is released and the checker tab comes off.

  • Page 89: Fuel Injector Function

    FUEL SYSTEM FUEL INJECTOR FUNCTION CHU011413250S01 • Injects fuel according to fuel injector control signals from the PCM. End Of Sie FUEL INJECTOR CONSTRUCTION/OPERATION CHU011413250S02 COIL SPRING NEEDLE VALVE CHU0114S004 Fuel Injector (FP1, RP1) • Installed on the intermediate housing at an angle of approx. 45° ° ° ° , and injects fuel near the intake port opening. •...

  • Page 90: Fuel Pump Speed Control Relay Function

    FUEL SYSTEM FUEL PUMP SPEED CONTROL RELAY FUNCTION CHU011413350S06 • Supplies power to the fuel pump according to control signals from the PCM. • For fuel pump speed control, refer to CONTROL SYSTEM, FUEL PUMP SPEED CONTROL. (See 01–40–23 FUEL PUMP CONTROL OUTLINE, 01–40–24 FUEL PUMP CONTROL BLOCK DIAGRAM, 01–40–24 FUEL PUMP CONTROL OPERATION.) 01–14 MAIN FUSE BLOCK...

  • Page 92: Exhaust System

    EXHAUST SYSTEM 01–15 EXHAUST SYSTEM EXHAUST SYSTEM OUTLINE ..01–15–1 EXHAUST SYSTEM STRUCTURAL Features......01–15–1 VIEW .
  • Page 94 EMISSION SYSTEM 01–16 EMISSION SYSTEM EMISSION SYSTEM OUTLINE ..01–16–1 EVAPORATIVE EMISSIONS (EVAP) Features......01–16–1 CONTROL SYSTEM OUTLINE .

  • Page 95: Emission System

    EMISSION SYSTEM EMISSION SYSTEM STRUCTURAL VIEW CHU011601007S02 VACUUM CHAMBER CATCH TANK AIR CONTROL VALVE PURGE SOLENOID VALVE AIR PUMP AIR SOLENOID VALVE VENTILATION HOSE QUICK RELEASE CONNECTOR CHU0116S001 CHARCOAL CANISTER FUEL SHUT-OFF VALVE ROLLOVER VALVE EVAP SYSTEM LEAK DETECTION PUMP EVAPORATIVE CHAMBER AIR FILTER CHU0116S002...

  • Page 96: Emission System Structural

    EMISSION SYSTEM CATALYTIC CONVERTER SYSTEM STRUCTURE CHU011620500S02 • The catalytic converter consists of a three-way catalyst and insulator. • A 3.01 L {3.18 US qt, 2.65 lmp qt} capacity catalytic converter with a three-way platinum-palladium-rhodium based catalyst has been adopted. System Diagram PRESILENCER 01–16...

  • Page 97: Secondary Air Injection (Air) Control Valve Function

    EMISSION SYSTEM System Diagram AIR SOLENOID VALVE VACUUM CHAMBER AIR PORT AIR PORT EXHAUST PORT EXHAUST PORT AIR CONTROL VALVE AIR PUMP CHU0116S004 End Of Sie SECONDARY AIR INJECTION (AIR) CONTROL VALVE FUNCTION CHU011613990S01 • Opens/closes the path of air sent from the AIR pump to the exhaust ports. End Of Sie SECONDARY AIR INJECTION (AIR) CONTROL VALVE CONSTRUCTION/OPERATION CHU011613990S02...

  • Page 98: Secondary Air Injection (Air) Solenoid Valve Function

    EMISSION SYSTEM • When the AIR solenoid valve is turned off, atmospheric air forms in the actuator and the valve is closed by spring force, thereby blocking the path. • The reed valve provided in the AIR control valve prevents reverse flow of exhaust gas and protects the AIR pump.

  • Page 99: Secondary Air Injection (Air) Pump Construction/Operation

    EMISSION SYSTEM SECONDARY AIR INJECTION (AIR) PUMP CONSTRUCTION/OPERATION CHU011613811S02 MOTOR FROM ATMOSPHERE TO AIR CONTROL VALVE : SECONDARY AIR FLOW CHU0116S007 • Mainly consists of a DC motor and fan. • When the AIR pump relay is turned on due to a PCM signal, the motor drives the pump fan to discharge secondary air.

  • Page 100: Positive Crankcase Ventilation (Pcv) System Structure

    EMISSION SYSTEM POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM STRUCTURE CHU011613890S02 • A ventilation hose to the oil filler pipe is provided to send blowby gas to the extension manifold (upper). The gas is then introduced into the intake port together with intake air and recombusted. System Diagram VENTILATION HOSE...

  • Page 101: Evaporative Emissions (Evap) Control System Structure

    EMISSION SYSTEM EVAPORATIVE EMISSIONS (EVAP) CONTROL SYSTEM STRUCTURE CHU011601074S02 • Consists of a purge solenoid valve, charcoal canister, catch tank, evaporative chamber, rollover valves, fuel shut-off valve, EVAP system leak detection pump, air filter, and fuel-filler cap. CHARCOAL CANISTER AIR FILTER FUEL SHUT-OFF VALVE EVAP SYSTEM LEAK ROLLOVER VALVE...

  • Page 102: Purge Solenoid Valve Construction/Operation

    EMISSION SYSTEM PURGE SOLENOID VALVE CONSTRUCTION/OPERATION CHU011618740S04 • Installed to the catch tank integrated with the extension manifold (upper). FROM CHARCOAL TO EXTENSION CANISTER MANIFOLD (UPPER) SOLENOID 01–16 COIL PLUNGER SPRING : FLOW OF EVAPORATIVE GAS CHU0116S012 • Mainly consists of a solenoid coil, spring, and a plunger. •...

  • Page 103: Catch Tank Construction/Operation

    EMISSION SYSTEM CATCH TANK CONSTRUCTION/OPERATION CHU011613978S02 • Integrated with the extension manifold (upper) and cannot be disassembled. EXTENSION MANIFOLD (UPPER) CATCH TANK PURGE SOLENOID VALVE SIDE CHARCOAL CANISTER SIDE CHU0116S014 • Evaporative gas between the purge solenoid valve and the charcoal canister is liquefied while being transferred to the extension manifold (upper) due to a decrease in temperature and other factors.

  • Page 104: Fuel Shut-Off Valve Construction/Operation

    EMISSION SYSTEM FUEL SHUT-OFF VALVE CONSTRUCTION/OPERATION CHU011642990S02 Construction • Since the shut-off valve is press-fit to the top of the fuel tank, it cannot be disassembled. • The shut-off valve mainly consists of a valve, float, spring, and by-pass valve. Operation •...

  • Page 105: Rollover Valve Construction/Operation

    EMISSION SYSTEM ROLLOVER VALVE CONSTRUCTION/OPERATION CHU011642720S02 • The rollover valves are welded in two locations in the evaporative gas path on the top of the fuel tank and cannot be removed/installed. OPEN CLOSE VALVE FUEL FLOAT LEVEL SPRING :EVAPORATIVE GAS FLOW CHU0116S021 •...

  • Page 106: Evap System Leak Detection Pump Description

    EMISSION SYSTEM EVAP SYSTEM LEAK DETECTION PUMP DESCRIPTION CHU011618743S01 Function • The internal pump pressurizes the emission system by pumping air to check clogging and leakage in the emission system. Structure • Orifice 01–16 — Has a 0.5 mm {0.02 in} hole •...

  • Page 107: Air Filter Description

    EMISSION SYSTEM Evaporative system monitor is operated When obtaining the reference current value • Air is sent from the pump to the orifice. Small leak and very small leak determination SOLENOID IS OFF AND PUMP IS OPERATED CHANGE OVER VALVE (CLOSED) ORIFICE EVAP SYSTEM LEAK...
  • Page 108 CHARGING SYSTEM 01–17 CHARGING SYSTEM CHARGING SYSTEM OUTLINE ..01–17–1 BATTERY CONSTRUCTION ..01–17–2 Features......01–17–1 GENERATOR CONSTRUCTION .
  • Page 109 CHARGING SYSTEM BATTERY CONSTRUCTION CHU011701008S03 • Air that passes through the battery duct when the vehicle is moving is used to cool the battery, improving reliability. End Of Sie BATTERY COVER BATTERY BATTERY FRONT BATTERY TRAY BATTERY DUCT INTAKE AIR CHU0117S002 GENERATOR CONSTRUCTION CHU011701008S04...

  • Page 110: Features

    IGNITION SYSTEM 01–18 IGNITION SYSTEM IGNITION SYSTEM OUTLINE..01–18–1 Construction ..... 01–18–2 Features.

  • Page 111: Ignition System

    IGNITION SYSTEM IGNITION COIL CONSTRUCTION/OPERATION CHU011801008S03 Construction • Distributorless ignition coils have been adopted, and two ignition coils are installed each on both the trailing and leading sides. By adopting the distributorless ignition coil, the distributor has been eliminated in order to simplify the parts of the ignition system, and also to prevent voltage reduction occurring between the parts improving firing efficiency.

  • Page 112: Spark Plug Construction

    IGNITION SYSTEM SPARK PLUG CONSTRUCTION CHU011801008S04 • Iridium-tipped spark plugs have been adopted on both trailing and leading sides to improve durability. • A center electrode with a thick insulator and extremely thin tip (diameter of 0.8 mm {0.03 in}) and small single- ground electrode have been adopted to stabilize firing under a thin fuel-air mixture.
  • Page 114 STARTING SYSTEM 01–19 STARTING SYSTEM STARTING SYSTEM OUTLINE ..01–19–1 STARTER INTERLOCK SWITCH (MT) Features......01–19–1 CONSTRUCTION/OPERATION .
  • Page 115 STARTING SYSTEM STARTER INTERLOCK SWITCH (MT) CONSTRUCTION/OPERATION CHU011918400S02 Construction • The starter interlock switch mechanism prevents vehicle surge when the engine is started, enhancing the safety. The engine cannot be started unless the clutch is depressed. • The mechanism is provided with a starter interlock switch on the circuit between the ignition switch and the starter.
  • Page 116 CRUISE CONTROL SYSTEM 01–20 CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM OUTLINE ......01–20–1 STRUCTURAL VIEW ....01–20–2 Component and function .
  • Page 117 CRUISE CONTROL SYSTEM End Of Sie CRUISE CONTROL SYSTEM STRUCTURAL VIEW CHU012001011S02 CRUISE CONTROL INDICATOR LIGHT CRUISE CONTROL MAIN INDICATOR LIGHT CRUISE CONTROL SWITCH TCM (AT) BRAKE SWITCH CPP SWITCH (MT) NEUTRAL SWITCH (MT) THROTTLE VALVE ACTUATOR (ILLUSTRATION SHOWS 13B-MSP (HIGH POWER)) CHU0120S001 End Of Sie 01–20–2...
  • Page 118 CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM BLOCK DIAGRAM CHU012001011S03 CRUISE CONTROL SWITCH THROTTLE BRAKE SWITCH VALVE ACTUATOR 01–20 ABS HU/CU, DSC HU/CU CRUISE CONTROL INDICATOR LIGHT TCM (AT) CRUISE CONTROL MAIN CPP SWITCH (MT) INDICATOR LIGHT NEUTRAL SWITCH (MT) CHU0120S002 End Of Sie 01–20–3...
  • Page 120 CONTROL SYSTEM 01–40 CONTROL SYSTEM ENGINE CONTROL SYSTEM FUEL PUMP SPEED CONTROL OUTLINE ......01–40–3 OUTLINE ......01–40–24 Features.
  • Page 121 CONTROL SYSTEM A/C Cut-off at Wide Throttle Valve ENGINE COOLANT TEMPERATURE (ECT) Opening Angle ....01–40–36 SENSOR CONSTRUCTION/ A/C Cut-off at Standing Start OPERATION .

  • Page 122: Control System

    CONTROL SYSTEM ENGINE CONTROL SYSTEM OUTLINE CHU014000140S01 Features • Drive-by-wire control adopted Improved driveability • Sequential dynamic air intake system (S-DAIS) adopted Improved engine torque and output • Controller area network (CAN) adopted Wiring harness simplification Specification 01–40 Item Specification Neutral switch (MT) ON/OFF CPP switch (MT)

  • Page 123: Engine Control System Structural View

    CONTROL SYSTEM ENGINE CONTROL SYSTEM STRUCTURAL VIEW CHU014000140S02 CRUISE CONTROL SWITCH INSTRUMENT CLUSTER FRONT HO2S FRONT HO2S HEATER TCM (AT) CRUISE CONTROL SWITCH REAR HO2S INDICATOR (MT) REAR HO2S HEATER LIGHT BRAKE SWITCH CRUISE CONTROL MAIN SENSOR INDICATOR LIGHT (MAIN/SUB) CONTROL UNIT SOLENOID VALVE...

  • Page 124: Engine Control System Diagram

    CONTROL SYSTEM ENGINE CONTROL SYSTEM DIAGRAM CHU014000140S03 AIR FILTER 01–40 EVAP SYSTEM LEAK DETECTION PUMP FUEL PUMP SPEED CONTROL RELAY FUEL PUMP APP SENSOR RESISTER (MAIN/SUB) FUEL PUMP FUEL PUMP FUEL TANK RELAY UNIT PURGE SOLENOID VALVE SOLENOID VALVE TP SENSOR (MAIN/SUB) SOLENOID VALVE MAF/IAT TO METERING...

  • Page 125: Engine Control System Wiring Diagram

    CONTROL SYSTEM ENGINE CONTROL SYSTEM WIRING DIAGRAM CHU014000140S04 FUEL PUMP RELAY STARTER RELAY START FUEL PUMP SPEED CONTROL RELAY MAIN RELAY FUEL PUMP RESISTOR FUEL INJECTOR (FP) IGNITION RELAY FUEL INJECTOR (FS) DRIVE-BY-WIRE RELAY FUEL INJECTOR (RP) FUEL INJECTOR (RS) CPP SWITCH * FUEL INJECTOR (FP2) * NEUTRAL SWITCH *...
  • Page 126 CONTROL SYSTEM ECT SENSOR VFAD SOLENOID VALVE * IAT SENSOR VDI SOLENOID VALVE 01–40 SSV SOLENOID VALVE MAF SENSOR PURGE SOLENOID VALVE BARO SENSOR AIR SOLENOID VALVE AIR PUMP RELAY AIR PUMP APP SENSOR NO.1 GENERATOR A/C AMPLIFIER NO.2 THROTTLE BODY A/C RELAY TP SENSOR NO.1...

  • Page 127: Engine Control System Block Diagram

    CONTROL SYSTEM ENGINE CONTROL SYSTEM BLOCK DIAGRAM CHU014000140S05 MAIN RELAY MAIN RELAY CONTROL NEUTRAL SWITCH (MT) DRIVE-BY-WIRE RELAY CPP SWITCH (MT) DRIVE-BY-WIRE RELAY CONTROL THROTTLE VALVE ACTUATOR SSV SWITCH APV POSITION SENSOR SSV SOLENOID VALVE DRIVE-BY-WIRE CONTROL (13B-MSP (HIGH POWER)) APV MOTOR ECT SENSOR (13B-MSP (HIGH POWER))

  • Page 128: Engine Control System Relation Chart

    CONTROL SYSTEM ENGINE CONTROL SYSTEM RELATION CHART CHU014000140S06 • Each control system and their related input and output parts are as follows. x: Applied 01–40 ITEM INPUT NEUTRAL SWITCH (MT) CPP SWITCH (MT) SSV SWITCH ECT SENSOR IAT SENSOR TP SENSOR APP SENSOR MAF SENSOR FRONT HO2S...

  • Page 129: Main Relay Control Outline

    CONTROL SYSTEM MAIN RELAY CONTROL OUTLINE CHU014000140S07 • When the ignition switch is turned to the ON position, the main relay turns on. • When the ignition switch is turned from on to off, the main relay turns on for a few minutes to activate the fully- closed throttle learning function of the drive-by-wire control, the ignition switch off function of the metering oil pump control, the after-cleaning function of the electrical fan control, and EVAP system leak detection function of the EVAP control system.

  • Page 130: Drive-By-Wire Control Block Diagram

    CONTROL SYSTEM DRIVE-BY-WIRE CONTROL BLOCK DIAGRAM CHU014000140S11 • The PCM calculates a throttle valve opening angle matching the engine operation conditions from the following input signals and sends a duty signal to the throttle valve actuator. NEUTRAL SWITCH 01–40 CPP SWITCH ECT SENSOR IAT SENSOR TP SENSOR...

  • Page 131: Drive-By-Wire Control Operation

    CONTROL SYSTEM DRIVE-BY-WIRE CONTROL OPERATION CHU014000140S12 Idle Speed Control • Controls the throttle valve opening angle so that it is close to the target idle speed calculated by the PCM. • The PCM calculates the target throttle opening angle by adding each type of correction to the basic duty value which is the basis of the throttle valve opening angle, and then sends a duty signal to the throttle valve actuator.

  • Page 132: Traction Control

    CONTROL SYSTEM Traction Control • The PCM calculates the target throttle valve opening angle by the torque up/down request signal from the DSC HU/CM and TCM and the engine speed. Cruise Control • Calculates the throttle valve opening angle based on the deviation of the actual vehicle speed from the set vehicle speed which was set with the cruise control switch and sends a duty signal to the throttle valve actuator.

  • Page 133: Vehicle Speed Limiter (At)

    CONTROL SYSTEM Cruise control function • The cruise control includes accelerating, coasting, resume, tap-down, tap-up and downshift functions (AT). Function List Function Contents • When any of the following conditions are met while driving in cruise control and when the RESUME/ Accelerating ACCEL switch is continuously pressed, the PCM gradually increases the set vehicle speed.

  • Page 134: Sequential Dynamic Air Intake System (S-Dais) Control Block Diagram

    CONTROL SYSTEM SEQUENTIAL DYNAMIC AIR INTAKE SYSTEM (S-DAIS) CONTROL BLOCK DIAGRAM CHU014000140S16 • The PCM determines the engine conditions based on each input signal and sends signals to the SSV solenoid valve, the APV motor (13B-MSP (High Power)), the VDI solenoid valve, and the VFAD solenoid valve (13B- MSP (High Power)).
  • Page 135 CONTROL SYSTEM VFAD solenoid valve (13B-MSP (High Power)) • At an engine speed of less than 5,500 rpm, the VFAD solenoid valve turns off and feeds intake manifold vacuum to the actuator (valve closes). • At an engine speed of Approx. 5,500 rpm or more, the VFAD solenoid valve turns on and feeds BARO to the actuator (valve opens).

  • Page 136: Fuel Injection Control Outline

    CONTROL SYSTEM FUEL INJECTION CONTROL OUTLINE CHU014000140S18 • The fuel injection control includes the following: — synchronized injection control, which performs fuel injection at the rotor intake stroke according to designated timing. — non-synchronized injection control, which performs fuel injection only when fuel injection conditions are met regardless of rotor intake stroke.

  • Page 137: Fuel Injection Control Block Diagram

    CONTROL SYSTEM FUEL INJECTION CONTROL BLOCK DIAGRAM CHU014000140S19 • The PCM determines the engine operation conditions based on input signals and operates the injectors to inject fuel with the optimum fuel injection timing and fuel injection time (fuel injection amount). CONTROL ITEM CALCULATED ITEM ECCENTRIC SHAFT POSITION...

  • Page 138: Fuel Injection Control Operation

    CONTROL SYSTEM FUEL INJECTION CONTROL OPERATION CHU014000140S20 Fuel Injection Timing • The PCM calculates the optimum fuel injection timing according to the engine operation conditions and operates the injectors. • The fuel injection timing is controlled at engine start and after engine start. •...

  • Page 139: Air/Fuel Ratio Control

    CONTROL SYSTEM Air/fuel Ratio Control • Controls the fuel injection amount so that the actual air/fuel ratio is close to the target air/fuel ratio, to boost purification of the catalytic converter. • air/fuel ratio feedback and target air/fuel ratio feedback are adopted for precise control of the air/fuel ratio. •...

  • Page 140: Fuel Injection Distribution Control

    CONTROL SYSTEM Fuel Injection Distribution Control • There are primary 1, secondary and primary 2 (13B-MSP (High Power)) injectors, and they independently control fuel injection amount and timing according to the amount of fuel demand from the engine. • The amount of fuel demand from the engine is determined by each correction of the charging efficiency and injection time after engine start.
  • Page 141 CONTROL SYSTEM Ineffective injection time — Ineffective injection time at engine start is determined according to the battery voltage and lengthens as the battery voltage becomes lower. Each type of correction — Includes the following corrections: Fast idle correction • Determines the correction amount when the secondary air injection system operates to rapidly heat the catalytic converter.

  • Page 142: Non-Synchronized Injection Control

    CONTROL SYSTEM Non-synchronized Injection Control • The non-synchronized injection control allows fuel injection when fuel injection conditions are met, regardless of the position of the eccentric shaft. • The non-synchronized injection control includes non-synchronized injection control at engine start, acceleration, idle, and fuel cut recovery. Control name Purpose Injection condition...

  • Page 143: Fuel Pump Control Block Diagram

    CONTROL SYSTEM FUEL PUMP CONTROL BLOCK DIAGRAM CHU014000140S22 • The PCM determines the engine starting condition based on each input signal and controls the fuel pump relay on/off. IGNITION SWITCH FUEL PUMP RELAY ECCENTRIC SHAFT POSITION SENSOR CHU0140S020 End Of Sie FUEL PUMP CONTROL OPERATION CHU014000140S23 Operation condition...

  • Page 144: Fuel Pump Speed Control Block Diagram

    CONTROL SYSTEM FUEL PUMP SPEED CONTROL BLOCK DIAGRAM CHU014000140S25 • The PCM compares the fuel injection amount with the required fuel amount based on input signals and controls the fuel pump speed control relay on/off. SSV SWITCH 01–40 ECT SENSOR IAT SENSOR TP SENSOR MAF SENSOR...

  • Page 145: Fuel Pump Speed Control Operation

    CONTROL SYSTEM FUEL PUMP SPEED CONTROL OPERATION CHU014000140S26 • Controls the fuel pump speed control relay according to the fuel amount required by the engine. • The required fuel amount is determined by the engine speed, battery positive voltage and the ECT. •...

  • Page 146: Electric Spark Advance Control Block Diagram

    CONTROL SYSTEM ELECTRIC SPARK ADVANCE CONTROL BLOCK DIAGRAM CHU014000140S28 • The PCM calculates the optimum ignition timing based on the engine conditions and sends an ignition signal to the ignition coils. NEUTRAL SWITCH 01–40 CPP SWITCH ECT SENSOR IAT SENSOR TP SENSOR IGNITION COIL (T/F) APP SENSOR...

  • Page 147: Electric Spark Advance Control Operation

    CONTROL SYSTEM ELECTRIC SPARK ADVANCE CONTROL OPERATION CHU014000140S29 Ignition Method • The PCM controls fixed ignition and regular ignition according to the engine operation conditions. Ignition Method Ignition timing Fixed ignition Ignition fixed at BTDC 5° Regular ignition Appropriate ignition for engine operation conditions based on input signals. COMBUSTION EXHAUST INTAKE...

  • Page 148: Secondary Air Injection (Air) Control Outline

    CONTROL SYSTEM ECT spark advance correction • Corrects other than during idling. • Stabilizes combustion by correction of ignition timing in consideration of friction loss when the engine is at a low temperature. • The correction amount is determined by the ECT and charging efficiency, and increases as the ECT decreases.

  • Page 149: Secondary Air Injection (Air) Control Block Diagram

    CONTROL SYSTEM SECONDARY AIR INJECTION (AIR) CONTROL BLOCK DIAGRAM CHU014000140S31 • The PCM determines the engine conditions based on input signals and sends an operation signal to the AIR solenoid valve and the AIR pump relay. AIR SOLENOID VALVE ECT SENSOR AIR PUMP RELAY IAT SENSOR CHU0140S025...

  • Page 150: Evaporative Purge Control Operation

    CONTROL SYSTEM EVAPORATIVE PURGE CONTROL OPERATION CHU014000140S35 Evaporative Purge Control Execution Condition • When the following conditions are met, the evaporative purge control sends a duty signal to the purge solenoid valve. — During fuel injection control feedback — Fuel system and MAF sensor are normal —...

  • Page 151: Metering Oil Pump Control Block Diagram

    CONTROL SYSTEM METERING OIL PUMP CONTROL BLOCK DIAGRAM CHU014000140S37 • The PCM calculates the optimum amount of oil delivery (stepping motor step number) by determining the engine operation conditions based on each input signal, and sends an operation signal to the stepping motor (inside the metering oil pump).

  • Page 152: Initial-Set Function

    CONTROL SYSTEM Initial-set Function • Reverses the stepping motor 60 steps at engine start, and detects the 0-step position. • The 0-step position becomes the reference for the regular drive function. ENGINE SPEED APPROX. 500 RPM INITIAL-SET REGULAR DRIVE FUNCTION FUNCTION 01–40 STEPPING...

  • Page 153: Regular Drive Function

    CONTROL SYSTEM Fail-safe for each control Control Fail-safe At engine start Regular control When the throttle Fuel injection control (pulse width at last opening angle exceeds 4.50 ms + ineffective injection time injection) 13%. Other 2.65 ms + ineffective injection time Leading side Ignition timing control (ignition timing) Fixed at 4.88°CA...

  • Page 154: Heated Oxygen Sensor (Ho2S) Heater Control Block Diagram

    CONTROL SYSTEM HEATED OXYGEN SENSOR (HO2S) HEATER CONTROL BLOCK DIAGRAM CHU014000140S40 • The PCM determines the engine conditions based on input signals and sends an operation signal to the front or rear HO2S. ECT SENSOR 01–40 IAT SENSOR MAF SENSOR FRONT HO2S HEATER BARO SENSOR REAR HO2S HEATER...

  • Page 155: A/C Cut-Off Control Block Diagram

    CONTROL SYSTEM A/C CUT-OFF CONTROL BLOCK DIAGRAM CHU014000140S43 • The PCM determines the engine conditions based on signals from the various input parts and sends an on/off control signal to the A/C relay. ECT SENSOR TP SENSOR A/C RELAY APP SENSOR VEHICLE SPEED SIGNAL (CAN SIGNAL) CHU0140S032...

  • Page 156: A/C Cut-Off At High Ect

    CONTROL SYSTEM A/C Cut-off at High ECT • When the ECT exceeds 110 °C {230°F} during the A/C operation, the A/C relay alternately turns on and off approx. every 10 s to protect the SWITCH engine and to prevent deterioration of the A/C function.

  • Page 157: Generator Control Outline

    CONTROL SYSTEM Operation Conditions Cooling fan motor Cooling fan relay Function Operation condition No.1 No.2 No.1 No.2/No.3 ECT: Less than 97°C {206.6°F} Stop ECT: 97°C {206.6°F} or more Low speed rotation • When all the following conditions are met: — ECT: 97°C {206.6°F} or more Low speed rotation —...

  • Page 158: Generator Control Block Diagram

    CONTROL SYSTEM GENERATOR CONTROL BLOCK DIAGRAM CHU014000140S49 • The PCM determines the engine operation and electrical load conditions based on input signals, and controls energization time of the generator field coil. GENERATOR (TERMINAL P: STATOR COIL) 01–40 BATTERY POSITIVE VOLTAGE ECCENTRIC SHAFT POSITION SENSOR ECT SENSOR...

  • Page 159: Control

    CONTROL SYSTEM Control • In order to maintain the optimum battery positive voltage, the PCM calculates the target generator current (target output current) and target excitation current according to the generator rotation speed at that time. • The generator rotation speed is calculated based on the ratio between the generator pulley and eccentric shaft pulley, and the engine speed.
  • Page 160 CONTROL SYSTEM Multiplex module ABS HU/ Keyless TPMS Steering Signal Instrument control TCM (AT) control control angle cluster DSC HU/ module module module sensor Engine coolant – – – – – temperature 01–40 – Engine torque – – – – –...

  • Page 161: Pcm Function

    CONTROL SYSTEM PCM FUNCTION CHU014018880S01 Function List • The control descriptions are as shown below. Function Description Main relay control Turns on the main relay according to requests from the controls, even when the ignition switch is off. Drive-by-wire control Controls the drive-by-wire actuator to obtain the optimum throttle valve opening angle according to the engine operation conditions.

  • Page 162: Pcm Construction/Operation

    CONTROL SYSTEM PCM CONSTRUCTION/OPERATION CHU014018880S02 • Located in front area of the engine compartment. • 122-pin connector (13B-MSP (High Power)) or 105-pin connector (13B-MSP (Standard Power)) is used for the PCM. 01–40 13B-MSP (HIGH POWER) CHU0140S079 • The fresh air induction duct has been installed to cool the PCM.

  • Page 163: Clutch Pedal Position (Cpp) Switch Function (Mt)

    CONTROL SYSTEM CLUTCH PEDAL POSITION (CPP) SWITCH FUNCTION (MT) CHU014018990S01 • This switch determines whether the engine is under a load condition (condition in which the engine output is transmitted to the powertrain) or under a no-load condition (condition in which the engine output is not transmitted to the powertrain).

  • Page 164: Secondary Shutter Valve (Ssv) Switch Construction/Operation

    CONTROL SYSTEM SECONDARY SHUTTER VALVE (SSV) SWITCH CONSTRUCTION/OPERATION CHU014018660S02 • The SSV switch is installed on the position close to the SSV actuator. • When the SSV is closed, the SSV switch contact closes (ON) and the PCM detects a voltage of 0 V.

  • Page 165: Engine Coolant Temperature (Ect) Sensor Function

    CONTROL SYSTEM APV Position Sensor Voltage Characteristics End Of Sie APPROX. 2.0 V APPROX. 1.5 V APPROX. 0.7 V FULL FULL APV OPENING ANGLE CLOSE OPEN CHU0140S046 ENGINE COOLANT TEMPERATURE (ECT) SENSOR FUNCTION CHU014018840S01 • Detects the ECT. End Of Sie ENGINE COOLANT TEMPERATURE (ECT) SENSOR CONSTRUCTION/OPERATION CHU014018840S02 •...

  • Page 166: Intake Air Temperature (Iat) Sensor Function

    CONTROL SYSTEM System Diagram End Of Sie ECT SENSOR 01–40 CHU0140S049 INTAKE AIR TEMPERATURE (IAT) SENSOR FUNCTION CHU014018840S03 • Detects the IAT. End Of Sie INTAKE AIR TEMPERATURE (IAT) SENSOR CONSTRUCTION/OPERATION CHU014018840S04 • Installed on the air hose. MAF/IAT SENSOR (ILLUSTRATION SHOWS 13B-MSP (HIGH POWER)) CHU0140S050 •...

  • Page 167: Throttle Position (Tp) Sensor Construction/Operation

    CONTROL SYSTEM THROTTLE POSITION (TP) SENSOR CONSTRUCTION/OPERATION CHU014018910S02 • The sensor is built into the throttle body and detects the throttle valve opening angle. VALVE BODY • The Hall element design has been adopted for the sensor. THROTTLE • A non contact type sensor has been adopted to VALVE improve durability.

  • Page 168: Accelerator Pedal Position (App) Sensor Construction/Operation

    CONTROL SYSTEM ACCELERATOR PEDAL POSITION (APP) SENSOR CONSTRUCTION/OPERATION CHU014041600S02 • The sensor is installed on the AP and detects how much the AP is depressed. • The Hall element design has been adopted on the sensor. • A non contact type sensor has been adopted to APP SENSOR improve durability.

  • Page 169: Front Heated Oxygen Sensor (Ho2S) Function

    CONTROL SYSTEM • Built into the intake air temperature IAT sensor. • Converts the mass intake airflow amount into a voltage. • When the heating element is placed in the air, the AIR THERMOMETER heat is dissipated by the air cooling the heating element.

  • Page 170: Rear Heated Oxygen Sensor (Ho2S) Function

    CONTROL SYSTEM REAR HEATED OXYGEN SENSOR (HO2S) FUNCTION CHU014018860S03 • Detects the oxygen concentration in the exhaust gas. • A heater has been adopted, allowing stable detection of the oxygen concentration even when the exhaust gas temperature is low. End Of Sie REAR HEATED OXYGEN SENSOR (HO2S) CONSTRUCTION/OPERATION CHU014018860S04 •...

  • Page 171: Barometric Pressure (Baro) Sensor Construction/Operation

    CONTROL SYSTEM BAROMETRIC PRESSURE (BARO) SENSOR CONSTRUCTION/OPERATION CHU014018210S02 • The BARO sensor is installed on the secondary BARO SENSOR air injection pump bracket. • The piezoelectric element is enclosed in the sensor and the electric potential difference changes as the BARO drops. The output voltage lowers as the BARO drops.

  • Page 172: Eccentric Shaft Position Sensor Function

    CONTROL SYSTEM KS Characteristic (When 1G applied) End Of Sie ± 26 8 01–40 HIGH FREQUENCY CHU0140S089 ECCENTRIC SHAFT POSITION SENSOR FUNCTION CHU014018221S01 • Detects the rotation pulse of the eccentric shaft position plate as an eccentric shaft angle signal. End Of Sie ECCENTRIC SHAFT POSITION SENSOR CONSTRUCTION/OPERATION CHU014018221S02...

  • Page 173: Metering Oil Pump Switch Function

    CONTROL SYSTEM METERING OIL PUMP SWITCH FUNCTION CHU014018990S04 • Detects the fully-open position of the stepping motor when the learning function of the metering oil pump is performed. • Turns on when the stepping motor is at step 52 or more. End Of Sie METERING OIL PUMP SWITCH CONSTRUCTION/OPERATION CHU014018660S04...
  • Page 174 SUSPENSION SECTION Toc of SCT OUTLINE ....02-00 FRONT SUSPENSION ..02-13 02–00 ON-BOARD DIAGNOSTIC ..02-02 REAR SUSPENSION .
  • Page 175 OUTLINE SUSPENSION SPECIFICATIONS CHU020001013S03 Suspension Specification Item Standard suspension Sport suspension Type Double-wishbone Spring type Coil spring Monotube type: High-pressure gas charged, cylindrical, double- Shock absorber type acting Type Torsion bar Stabilizer Diameter (mm {in}) 25.4 {1.00} 26.5 {1.04} Tire [Tolerance 2 {0.08} (mm {in})

  • Page 176: On-Board Diagnostic System Outline (Tire Pressure Monitoring System)

    2004 Mazda RX-8 Service Highlights (3378–1U–03C) ON-BOARD DIAGNOSTIC 02–02 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC SYSTEM ON-BOARD DIAGNOSTIC SYSTEM OUTLINE (TIRE PRESSURE PID/DATA MONITOR FUNCTION MONITORING SYSTEM) ... . 02–02–1 (TIRE PRESSURE MONITORING Block Diagram .
  • Page 177 2004 Mazda RX-8 Service Highlights (3378–1U–03C) ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC SYSTEM FUNCTION (TIRE PRESSURE MONITORING SYSTEM) CHU020237020S02 Malfunction Detection Function • The malfunction detection function detects malfunctions in the input/output signal system of the tire pressure monitoring system (TPMS) control module based on abnormal signals from the wheel units when the ignition switch is at the ON position or driving the vehicle.

  • Page 178: System)

    2004 Mazda RX-8 Service Highlights (3378–1U–03C) ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC SYSTEM PID/DATA MONITOR FUNCTION (TIRE PRESSURE MONITORING SYSTEM) CHU020237020S03 • This function allows access to certain data values, input signal, calculated values, and system status information. PID/DATA monitor table Operation/unit...

  • Page 179: On-Board Diagnostic System External Tester Communication Function

    2004 Mazda RX-8 Service Highlights (3378–1U–03C) ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC SYSTEM EXTERNAL TESTER COMMUNICATION FUNCTION (TIRE PRESSURE MONITORING SYSTEM) CHU020237020S04 External Tester Communication Function • The external tester communication function communicates diagnostic information (reading DTCs and reading input/output signal) by sending and receiving signals between the TPMS control module and an external tester.
  • Page 180 WHEEL AND TIRES 02–12 WHEEL AND TIRES WHEELS AND TIRES OUTLINE..02–12–1 WHEEL UNIT WHEELS AND TIRES CONSTRUCTION/OPERATION ..02–12–5 STRUCTURAL VIEW ....02–12–2 Construction .

  • Page 181: Wheel And Tires

    WHEEL AND TIRES WHEELS AND TIRES STRUCTURAL VIEW CHU021201014S02 STYLED SIDE OF WHEEL 16-INCH ALUMINUM ALLOY WHEEL 18-INCH ALUMINUM ALLOY WHEEL CROSS-SECTIONAL VIEW ADHESIVE-TYPE BALANCE WEIGHT KNOCK-TYPE BALANCE WEIGHT INNER OUTER CHU0212S007 End Of Sie PUNCTURE REPAIR KIT OUTLINE CHU021237100S01 •...

  • Page 182: Tire Pressure Monitoring System (Tpms) Outline

    2004 Mazda RX-8 Service Highlights (3378–1U–03C) WHEEL AND TIRES TIRE PRESSURE MONITORING SYSTEM (TPMS) OUTLINE CHU021237020S01 • The tire pressure monitoring system (TPMS) has been adopted to assist the driver in understanding the tire status. It alerts the driver with the TPMS warning light and buzzer if there is an excessive drop in air pressure or air pressure higher than a specified value is detected.

  • Page 183: Tire Pressure Monitoring System (Tpms) Wiring Diagram

    2004 Mazda RX-8 Service Highlights (3378–1U–03C) WHEEL AND TIRES TIRE PRESSURE MONITORING SYSTEM (TPMS) WIRING DIAGRAM CHU021237020S04 WHEEL UNIT NO.1 NO.2 NO.3 NO.4 RF SIGNAL TPMS CM DRIVER ANTENNA INSTRUMENT CLUSTER CAN_H IG SW CAN_L BATTERY DRIVER DRIVER CHU0202W001 End Of Sie...

  • Page 184: Operation

    WHEEL AND TIRES Operation • The wheel unit installed to each wheel sends data on air pressure, temperature and acceleration of each tire by means of RF signals. The TPMS control module receives these signals with a built-in antenna. • The TPMS control module monitors the air pressure of each tire based on the tire data sent from each wheel unit.

  • Page 185: Sensing Function

    WHEEL AND TIRES Sensing Function • The sensing function periodically monitors the following data and sends it to the TPMS control module. — Tire pressure — Tire temperature — Tire acceleration — Voltage of the built-in battery • Intervals of tire data monitoring and data transmission to the TPMS control module differ depending on the operational mode (varies according to vehicle conditions).
  • Page 186 WHEEL AND TIRES Function list • Recognizes whether received signals are from own wheel units. Identification code recognition function • Compares received tire pressure data with preset values in the TPMS control Tire pressure determination/warning module. If the pressure is determined to be too low or high, the module alerts function the driver via the TPMS warning light and buzzer.
  • Page 187 WHEEL AND TIRES Low-pressure determination • When tire pressure data sent from a wheel unit is lower than the detection value configured in the TPMS control module, the module determines that the tire for that wheel unit has low tire pressure. —...

  • Page 188: Controller Area Network (Can) Outline

    WHEEL AND TIRES High-pressure determination • When tire pressure data sent from the wheel unit exceeds the upper limit, the module determines that the tire for that wheel unit has high tire pressure. — If high tire pressure is determined when the ignition is on, the TPMS control module illuminates the TPMS warning light built into the instrument cluster and sounds the TPMS warning buzzer for 3 s to alert the driver.
  • Page 190 FRONT SUSPENSION 02–13 FRONT SUSPENSION FRONT SUSPENSION OUTLINE ..02–13–1 FRONT UPPER ARM FRONT SUSPENSION CONSTRUCTION ....02–13–3 STRUCTURAL VIEW .

  • Page 191: Front Suspension

    FRONT SUSPENSION DOUBLE WISHBONE FRONT SUSPENSION CONSTRUCTION CHU021301015S03 Improved roadholding • The heightened damper lever ratio has improved the efficiency of shock absorber operation. — Damper lever ratio: shock absorber stroke (B)/wheel vertical stroke (A) — The heightened damper lever ratio has made it possible to provide a damping force even during minute strokes.

  • Page 192: Front Shock Absorber Construction

    FRONT SUSPENSION FRONT SHOCK ABSORBER CONSTRUCTION CHU021334700S01 • The high-pressure gas-filled monotube shock absorber minimizes cavitation and provides stable damping force even during hard driving. — The large-diameter piston ensures superior response during minute strokes, providing consistent damping force and stroke feeling. —...

  • Page 193: Front Lower Arm Construction

    FRONT SUSPENSION FRONT LOWER ARM CONSTRUCTION CHU021334300S01 • The front lower arm is made of forged aluminum for rigidity and weight reduction. • As with the front upper arm, the zero-stopper-clearance bushings optimize control over changes in vehicle behavior. LOWER ARM BUSHING ZERO-STOPPER-CLEARANCE STRUCTURE FRONT LOWER ARM...

  • Page 194: Rear Suspension

    REAR SUSPENSION 02–14 REAR SUSPENSION REAR SUSPENSION OUTLINE ..02–14–1 Improved Roadholding ... . . 02–14–2 REAR SUSPENSION REAR SHOCK ABSORBER STRUCTURAL VIEW ....02–14–1 CONSTRUCTION .
  • Page 195 REAR SUSPENSION MULTI-LINK REAR SUSPENSION CONSTRUCTION CHU021401016S03 Optimized Link and Shock Absorber Layout Compliance toe control • The suspension system layout is such that the center axis line of the shock absorber intersects TOE-IN MOMENT to the outside and rear of the virtual kingpin axis. CENTER AXIS OF This layout ensures that the toe-in moment is SHOCK ABSORBER...
  • Page 196 REAR SUSPENSION REAR CROSSMEMBER CONSTRUCTION CHU021428400S01 • Adoption of a six-point rubber-mounting system rear crossmember ensures link support stiffness and isolates vibration improving riding comfort and reducing road noise. • Zero-stopper-clearance rubber bushings are installed at three points (the front, middle, and rear) of the crossmembers, six locations in total, so that they form a three-dimensional triangle.
  • Page 198 DRIVELINE/AXLE SECTION Toc of SCT OUTLINE ....03-00 DRIVE SHAFT ... . . 03-13 FRONT AXLE .
  • Page 199 OUTLINE DRIVELINE/AXLE SPECIFICATIONS CHU030001018S02 Item Specification Transmission type Front axle Bearing type Angular ball bearing Rear axle Bearing type Angular ball bearing Rear drive shaft Wheel side Bell joint Joint type Differential side Tripod joint Left side: 31.0 {1.22} (Maximum diameter) 27.0 {1.06} (Minimum diameter) Left side: 25.0 {0.98} Shaft diameter...

  • Page 200: Front Axle

    FRONT AXLE 03–11 FRONT AXLE FRONT AXLE OUTLINE ... . . 03–11–1 FRONT AXLE CROSS-SECTIONAL VIEW ......03–11–1 End of Toc FRONT AXLE OUTLINE CHU031104000S01...

  • Page 202: Rear Axle

    REAR AXLE 03–12 REAR AXLE REAR AXLE OUTLINE ....03–12–1 REAR AXLE CROSS-SECTIONAL VIEW ......03–12–1 End of Toc REAR AXLE OUTLINE CHU031205000S01...

  • Page 204: Drive Shaft

    DRIVE SHAFT 03–13 DRIVE SHAFT REAR DRIVE SHAFT OUTLINE ..03–13–1 REAR DRIVE SHAFT CROSS-SECTIONAL VIEW ..03–13–1 End of Toc REAR DRIVE SHAFT OUTLINE CHU031325600S01 •...
  • Page 206 DIFFERENTIAL 03–14 DIFFERENTIAL REAR DIFFERENTIAL OUTLINE ..03–14–1 SUPER-LSD OPERATION ... . 03–14–3 REAR DIFFERENTIAL Straight ahead driving ....03–14–3 CONSTRUCTION .

  • Page 207: Super-Lsd Outline

    DIFFERENTIAL SUPER-LSD OUTLINE CHU031427100S03 • The super-LSD is a torque-sensing type that provides improved driving stability due to the following characteristics: — Low torque bias ratio provides improved controllability (torque bias ratio: 2.0) — Creation of initial torque provides improved starting from a standstill and acceleration/deceleration response, and driving straight-ahead (initial torque: 49 N·m {5.0 kgf·m, 36 ft·lbf}) —...

  • Page 208: Super-Lsd Operation

    DIFFERENTIAL SUPER-LSD OPERATION CHU031427100S05 Straight ahead driving • When driving straight, the right and left side gears rotate at the same speed, and the pinion and side gears rotate together with the differential gear case. Input force from the ring gear is transmitted to the pinion gears via the gear case and to the drive shaft via the side gears.

  • Page 209: Differential Operation

    DIFFERENTIAL Differential operation • If the rotation speed between the right and left wheels becomes different (during normal driving), the pinion gears rotate together while revolving around the center axle of the drive shaft, thereby absorbing the difference in rotation speed. This mechanism serves as a differential. ROTATION OF PINION GEAR SLOW FAST...

  • Page 210: Limited-Slip Operation

    DIFFERENTIAL Limited-slip operation • If the differential encounters a condition requiring limited-slip control such as wheel spin, thrust force acts on the side gears due to the reaction force from the meshing of the pinion and side gears. This thrust force presses the side gears against the taper ring, generating friction between the side gear cone and the taper ring and reducing the torque of the slipping wheel.

  • Page 212: Propeller Shaft

    PROPELLER SHAFT 03–15 PROPELLER SHAFT STRUCTURE ..... . 03–15–1 End of Toc STRUCTURE CHU031525002S01 • A one-piece, double-jointed propeller shaft has been adopted for all models. For MT vehicles, a lightweight propeller shaft, with a carbon fiber-reinforced resin pipe*, has been adopted.

  • Page 214: Antilock Brake

    BRAKES SECTION Toc of SCT OUTLINE ....04-00 ANTILOCK BRAKE ON-BOARD DIAGNOSTIC ..04-02 SYSTEM....04-13 CONVENTIONAL BRAKE DYNAMIC STABILITY SYSTEM .
  • Page 215 OUTLINE BRAKE FEATURES CHU040001021S01 • Intrusion minimizing brake pedal adopted Improved safety • Electronic brakeforce distribution (EBD) control adopted • ABS adopted • Dynamic stability control (DSC) adopted • Large diameter front disc brakes adopted Improved braking force • Large diameter rear disc brakes adopted •...
  • Page 216 ON-BOARD DIAGNOSTIC 04–02 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC SYSTEM ON-BOARD DIAGNOSTIC SYSTEM ACTIVE OUTLINE (ABS, DYNAMIC STABILITY COMMAND MODES FUNCTION CONTROL) ..... . 04–02–1 (ABS, DYNAMIC STABILITY Block Diagram .

  • Page 217: On-Board Diagnostic

    ON-BOARD DIAGNOSTIC Block Diagram BRAKE DSC OFF SYSTEM INDICATOR WARNING LIGHT* WARNING LIGHT* LIGHT LIGHT ON-BOARD DIAGNOSTIC FUNCTION MALFUNCTION INDICATION FUNCTION MEMORY DLC-2 FUNCTION SERIAL COMMUNICATION WDS OR EQUIVALENT MALFUNCTION PID/DATA ACTIVE DETECTION MONITOR COMMAND FUNCTION FUNCTION FUNCTION INSPECTION FAIL-SAFE FUNCTION FUNCTION INPUT...

  • Page 218: Control

    ON-BOARD DIAGNOSTIC Memory Function • The memory function stores DTCs of malfunctions in input/output signal systems. With this function, once a DTC is stored it is not cleared after the ignition switch has been turned off (LOCK position), even if the malfunctioning signal system has returned to normal.
  • Page 219 ON-BOARD DIAGNOSTIC Fail-safe function DTC number Warning light illumination status Control status Malfunction Brake system WDS or location warning light (when equivalent ABS warning light ABS control EBD control parking brake is display released) C1095 Pump motor, motor Illuminated Not illuminated Control disabled Control enabled relay systems...
  • Page 220 ON-BOARD DIAGNOSTIC Fail-safe function number Warning light illumination status Control status Brake system Malfunction WDS or warning location equivale DSC OFF warning light (when indicator light control Control control control light parking light Display brake is released) C1148 ABS wheel- C1158 speed sensor/ Control...

  • Page 221: On-Board Diagnostic System Pid/Data Monitor Function (Abs, Dynamic Stability Control)

    ON-BOARD DIAGNOSTIC Fail-safe function number Warning light illumination status Control status Brake system Malfunction WDS or warning location equivale DSC OFF warning light (when indicator light control Control control control light parking light Display brake is released) Control Control Control Control illuminated enabled...

  • Page 222: Pid/Data Monitor Table (Vehicles With Dsc)

    ON-BOARD DIAGNOSTIC PID/DATA Monitor Table (Vehicles with DSC) Unit/Condition PID/data monitor item Input/output part (Tester display) ABS_LAMP ABS warning light On/Off ABS_VOLT Battery ABSLF_I LF inlet solenoid valve On/Off ABSLF_O LF outlet solenoid valve On/Off ABSLR_I LR inlet solenoid valve On/Off ABSLR_O LR outlet solenoid valve...

  • Page 223: Active Command Modes Table (Vehicles With Dsc)

    ON-BOARD DIAGNOSTIC Active Command Modes Table (Vehicles with DSC) Operation Command name Output part name Operation condition Combined sensor (lateral acceleration) initialization LATACCEL TRUE/FALSE start-up LF_DSC_V LF stability control valve LF_INLET LF inlet solenoid valve LF_OUTLET LF outlet solenoid valve LF_TC_VLV LF traction control valve LR_INLET...
  • Page 224 ON-BOARD DIAGNOSTIC Diagnostic function name Signal received Signal sent Malfunction detection function DTC verification signal Command signal to read selected Monitored data for requested monitor PID/data monitor function monitor item item Operation command signal for selected Active command modes function Input/output part name active command modes item End Of Sie...
  • Page 226 CONVENTIONAL BRAKE SYSTEM 04–11 CONVENTIONAL BRAKE SYSTEM CONVENTIONAL BRAKE SYSTEM MASTER CYLINDER OUTLINE ......04–11–1 CONSTRUCTION ....04–11–3 CONVENTIONAL BRAKE SYSTEM POWER BRAKE UNIT STRUCTURAL VIEW .
  • Page 227 CONVENTIONAL BRAKE SYSTEM INTRUSION-MINIMIZING BRAKE PEDAL FUNCTION CHU041143300S01 • An intrusion-minimizing brake pedal, which minimizes the amount of rearward pedal thrust in a frontal collision, has been adopted. Due to this, impact force to the lower body of the driver is softened. End Of Sie INTRUSION-MINIMIZING BRAKE PEDAL OPERATION CHU041143300S02...
  • Page 228 CONVENTIONAL BRAKE SYSTEM MASTER CYLINDER CONSTRUCTION CHU041143400S01 • A plunger-type master cylinder with a 22.22 mm {0.875 in} bore has been adopted, improving durability. Note • Plunger type: A system where the cups are fixed on the cylinder, and the piston slides through the inner perimeter of the cups.
  • Page 229 CONVENTIONAL BRAKE SYSTEM REAR BRAKE (DISC) CONSTRUCTION CHU041126980S01 • A large diameter, ventilated disc type rear brake with a 302 mm {11.9 in} diameter and 18 mm {0.71 in} thickness has been adopted for all models, improving braking force and fade resistance.

  • Page 230: Parking Brake System

    PARKING BRAKE SYSTEM 04–12 PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM OUTLINE ......04–12–1 STRUCTURAL VIEW ....04–12–1 End of Toc PARKING BRAKE SYSTEM OUTLINE CHU041201022S01...

  • Page 232: Antilock Brake System

    ANTILOCK BRAKE SYSTEM 04–13 ANTILOCK BRAKE SYSTEM ABS OUTLINE..... 04–13–1 EBD CONTROL OUTLINE ... . 04–13–8 ABS STRUCTURAL VIEW .

  • Page 233: Abs System Wiring Diagram

    ANTILOCK BRAKE SYSTEM ABS SYSTEM WIRING DIAGRAM CHU041343000S03 ABS/DSC 60 A ABS WARNING LIGHT BRAKE SYSTEM WARNING LIGHT ENGINE 15 A IG SW WHEEL- SPEED SENSOR CAN DRIVER BATTERY INSTRUMENT CLUSTER CAN_H CAN DRIVER CAN_L CAN DRIVER ABS HU/CM BRAKE SWITCH AUDIO UNIT, CAR-NAVIGATION UNIT, BRAKE LIGHT AUTO LEVELING CONTROL MODULE...

  • Page 234: Abs Hu/Cm Construction

    ANTILOCK BRAKE SYSTEM ABS HU/CM CONSTRUCTION CHU041343750S01 • A high reliability, reduced size and weight ABS HU/CM, integrating both the ABS HU and ABS CM, has been adopted. End Of Sie BHJ0413N002 ABS HU PART FUNCTION 04–13 CHU041343750S02 • The ABS HU adjusts the fluid pressure to the caliper pistons by controlling (on/off) each solenoid valve and pump motor according to signals from the ABS CM.
  • Page 235 ANTILOCK BRAKE SYSTEM Function Of Main Component Parts Part name Function • Adjusts the fluid pressure in each brake system according to ABS CM signals. Inlet solenoid valve • Adjusts the fluid pressure in each brake system according to ABS CM signals. Outlet solenoid valve •...

  • Page 236: Operating

    ANTILOCK BRAKE SYSTEM Solenoid valve operation table Inlet solenoid Outlet solenoid Pump motor, valve valve pump ON (closed) ON (open) Operating MASTER CYLINDER INLET SOLENOID VALVE 04–13 OUTLET SOLENOID VALVE PUMP RESERVE PUMP MOTOR CHU0413S007 Pressure maintain mode • During pressure maintain mode, both the inlet and outlet solenoid valves are closed. The path for the brake fluid being applied to the caliper piston is blocked and brake fluid pressure is maintained.

  • Page 237: Abs Cm Part Function

    ANTILOCK BRAKE SYSTEM ABS CM PART FUNCTION CHU041343750S04 • The ABS CM detects the vehicle wheel speeds based on the signals from the four ABS wheel- speed sensors. The CM calculates the rotation condition of each wheel from the relation between the detected vehicle wheel speed and the estimated (based on the detected speed) vehicle speed from there on.

  • Page 238: Abs Control Operation

    ANTILOCK BRAKE SYSTEM ABS CONTROL OPERATION CHU041343750S06 • When the ABS CM determines wheel slip conditions based on the signals from the ABS wheel-speed sensors during braking, the ABS CM operates the ABS HU inlet and outlet solenoid valves, reducing and maintaining brake fluid pressure in accordance with the wheel slip factors.

  • Page 239: Ebd Control Outline

    ANTILOCK BRAKE SYSTEM EBD CONTROL OUTLINE CHU041343750S07 • EBD control uses the ABS system to control brake fluid pressure distribution to the rear wheels so that they do not lock-up prior to the front wheels during braking, thereby preventing the loss of handling stability. Features •...

  • Page 240: Operating Condition Transition Diagram

    ANTILOCK BRAKE SYSTEM Operating Condition Transition Diagram HIGH VEHICLE SPEED WHEEL SPEED (REAR) WHEEL SPEED SPEED (FRONT) EBD INITIAL CONTROL VALUE ABS INITIAL CONTROL VALUE TIME REAR SOLENOID VALVE CONTROL PRESSURE REDUCTION 04–13 PRESSURE MAINTAINED PRESSURE INCREASE HIGH FRONT BRAKE FLUID PRESSURE BRAKE FLUID PRESSURE...

  • Page 241: Abs Wheel-Speed Sensor Function

    ANTILOCK BRAKE SYSTEM ABS WHEEL-SPEED SENSOR FUNCTION CHU041343720S01 • The ABS wheel-speed sensor, which has a magnetic pick-up, transmits the rotation condition of each wheel to the ABS HU/CM. End Of Sie ABS WHEEL-SPEED SENSOR CONSTRUCTION/OPERATION CHU041343720S02 Structure • The front ABS wheel-speed sensor and the front ABS sensor rotor are integrated with the front COIL wheel hub and installed on the steering knuckle.
  • Page 242 DYNAMIC STABILITY CONTROL 04–15 DYNAMIC STABILITY CONTROL DYNAMIC STABILITY CONTROL (DSC) Oversteer Tendency Suppression..04–15–15 OUTLINE ......04–15–1 Understeer Tendency Suppression.

  • Page 243: Dynamic Stability Control

    DYNAMIC STABILITY CONTROL DSC Operation Outline • The ABS prevents wheel lock-up during braking. The TCS detects drive wheel spin due to the accelerator pedal being pressed too hard or similar causes and controls engine speed to suppress wheel spin. With these systems, safety is assured when driving or stopping.

  • Page 244: Dynamic Stability Control (Dsc) Structural View

    DYNAMIC STABILITY CONTROL DYNAMIC STABILITY CONTROL (DSC) STRUCTURAL VIEW CHU041543000S02 BRAKE SYSTEM DSC INDICATOR LIGHT WARNING LIGHT REAR ABS WHEEL-SPEED SENSOR COMBINED SENSOR STEERING ANGLE SENSOR DSC OFF LIGHT ABS WARNING 04–15 LIGHT REAR ABS SENSOR ROTOR DSC OFF SWITCH DSC HU/CM BRAKE FLUID PRESSURE SENSOR...

  • Page 245: Dynamic Stability Control (Dsc) System Wiring Diagram

    DYNAMIC STABILITY CONTROL DYNAMIC STABILITY CONTROL (DSC) SYSTEM WIRING DIAGRAM CHU041543000S04 DSC 30A COMBINED SENSOR ABS/DSC 60A BRAKE FLUID PRESSURE ENGINE 15A SENSOR IG SW BRAKE SWITCH BATTERY ABS WARNING LIGHT BRAKE LIGHT BRAKE SYSTEM WARNING LIGHT DSC OFF LIGHT DSC OFF SWITCH INDICATOR LIGHT...

  • Page 246: Dsc Hu/Cm Construction

    DYNAMIC STABILITY CONTROL DSC HU/CM CONSTRUCTION CHU041543750S01 • A high reliability, reduced size and weight DSC HU/CM, integrating both the DSC HU and the DSC CM, has been adopted. End Of Sie BHJ0415N003 DSC HU PART FUNCTION 04–15 CHU041543750S02 • According to DSC CM signals, the DSC HU controls (on/off) each solenoid valve and the pump motor, adjusts fluid pressure in each caliper piston, and actuates each function (ABS, EBD (Electronic Brakeforce Distribution), TCS and DSC) of the DSC system.
  • Page 247 DYNAMIC STABILITY CONTROL Hydraulic Circuit Diagram MASTER CYLINDER BRAKE FLUID PRESSURE SENSOR DAMPER CHAMBER TRACTION SWITCH TRACTION SOLENOID SWITCH VALVE SOLENOID VALVE STABILITY PUMP CONTROL STABILITY MOTOR CONTROL SOLENOID VALVE SOLENOID RESERVE RESERVE VALVE PUMP INLET INLET INLET SOLENOID SOLENOID SOLENOID VALVE INLET...
  • Page 248 DYNAMIC STABILITY CONTROL Operation During normal braking • During normal braking, the solenoid valves are not energized and all of them are off. When the brake pedal is depressed, brake fluid pressure is transmitted from the master cylinder, through the traction switch and inlet solenoid valves, and then to the caliper piston.
  • Page 249 DYNAMIC STABILITY CONTROL During ABS and EBD control • During ABS and EBD control, when wheel lock-up is about to occur, the traction switch and stability control solenoid valves are not energized, and the inlet and outlet solenoid valves are energized and controlled in three pressure modes (increase, reduction or maintain), thereby adjusting brake fluid pressure.
  • Page 250 DYNAMIC STABILITY CONTROL During DSC control (suppress oversteer tendency) and TCS control • When a large oversteer tendency or driving wheel spin is determined, the traction switch and the stability control solenoid valves are energized, switching the hydraulic circuits. At the same time, the pump motor is actuated to operate the pump, thereby increasing pressure by supplying brake fluid pressure to the caliper piston of the outer front wheel or the slipping driving wheel.
  • Page 251 DYNAMIC STABILITY CONTROL During DSC control (to suppress understeer tendency) • When a large understeer tendency is determined, the traction switch and the stability control solenoid valves are energized, switching the hydraulic circuits. At the same time, the pump motor is actuated to operate the pump, supplying brake fluid pressure from the reservoir to the inner rear wheel cylinder.

  • Page 252: Dsc Cm Part Function

    DYNAMIC STABILITY CONTROL DSC CM PART FUNCTION CHU041543750S04 • The DSC CM makes calculations using signals input from each sensor, outputs a brake fluid pressure control signal to the DSC HU to actuate DSC system functions and outputs an engine output control signal to the PCM. •...

  • Page 253: Block Diagram

    DYNAMIC STABILITY CONTROL Block Diagram INPUT CM INTERNAL CALCULATION OUTPUT WHEEL-SPEED ABS WHEEL- CALCULATION SPEED SENSOR PUMP ESTIMATED VEHICLE MOTOR SPEED CALCULATION CONTROL AMOUNT FRONT SOLENOID VALVE BRAKE OPERATING BRAKE SWITCH CONDITION DETERMINATION REAR ENGINE SPEED ENGINE SPEED SOLENOID CALCULATION VALVE CONTROL AMOUNT...

  • Page 254: Tcs Control Outline

    DYNAMIC STABILITY CONTROL TCS CONTROL OUTLINE CHU041543750S07 • TCS control actuates torque reduction through throttle, fuel cut and ignition timing control, as well as using brake control to control traction. Note • Brake control: Brake fluid pressure from the hydraulic unit to the slipping driving wheel is increased, operating the brake and preventing drive wheel slip.

  • Page 255: Dsc Control Outline

    DYNAMIC STABILITY CONTROL DSC CONTROL OUTLINE CHU041543750S09 • While a vehicle normally turns safely in response to steering operation, there are instances when the limits of tire lateral grip is surpassed due to road surface conditions or vehicle speed, and the influence of evasive steering to avoid an accident or similar situations.

  • Page 256: Dsc Control Operation

    DYNAMIC STABILITY CONTROL DSC CONTROL OPERATION CHU041543750S10 • When the DSC HU/CM determines that the vehicle has a strong oversteer or understeer tendency, engine output is lowered and, at the same time, it suppresses the yaw moment by affecting the braking of the front or rear wheels to inhibit the oversteer or understeer tendency.

  • Page 257: Controller Area Network (Can) Outline

    DYNAMIC STABILITY CONTROL CONTROLLER AREA NETWORK (CAN) OUTLINE CHU041543000S05 • The DSC HU/CM sends and receives data to and from other modules via the CAN system. Refer to Section 09 for a detailed explanation of the CAN system. Data sent •...

  • Page 258: Combined Sensor Function

    DYNAMIC STABILITY CONTROL COMBINED SENSOR FUNCTION CHU041543770S01 • A combined sensor, which integrates the yaw rate and lateral-G sensors, has been adopted. • The combined sensor, located in the floor under the rear console, detects the vehicle yaw rate (vehicle turning angular speed) and lateral-G, and transmits them to the DSC HU/CM.

  • Page 259: Steering Angle Sensor Function

    DYNAMIC STABILITY CONTROL STEERING ANGLE SENSOR FUNCTION CHU041566120S01 • The steering angle sensor, located on the combination switch, detects the steering angle degree and the neutral position, and transmits these to the DSC HU/CM via CAN lines. Warning • The following circumstances will cause the stored initialization value of the steering angle sensor to be cleared.

  • Page 260: Dsc Off Switch, Dsc Off Light Function

    DYNAMIC STABILITY CONTROL DSC Indicator Light Operation Item DSC indicator light condition TCS, DSC not operating Not illuminated TCS operating Flashes (0.5 s intervals) DSC operating DSC INDICATOR LIGHT 04–15 CHU0415S013 End Of Sie DSC OFF SWITCH, DSC OFF LIGHT FUNCTION CHU041566410S01 •...

  • Page 262: On-Board Diagnostic

    TRANSMISSION/TRANSAXLE SECTION Toc of SCT OUTLINE ....05-00 AUTOMATIC TRANSMISSION 05-13 ON-BOARD DIAGNOSTIC ..05-02 AUTOMATIC TRANSMISSION CLUTCH ....05-10 SHIFT MECHANISM .

  • Page 263: Clutch

    OUTLINE End Of Sie TRANSMISSION/TRANSAXLE FEATURES CHU050001030S02 CLUTCH • The clutch cover set load has been increased. Increased torque • Torsional spring tension has been reduced to reduce NVH. transmission capacity • A ball-type synchromesh mechanism has been adopted. • A triple synchronizer mechanism has been adopted for 1GR, 2GR and 3GR. Improved operability •...

  • Page 264: Manual Transmission Specifications

    OUTLINE MANUAL TRANSMISSION SPECIFICATIONS CHU050001030S04 Item Specifications Transmission type Y16M-D Transmission control Floor-shift Shift assist Synchromesh 3.760 2.269 1.645 Gear ratio 1.187 1.000 0.843 Reverse 3.564 Grade API service GL-4 or GL-5 Viscosity All season SAE 75W-90 Capacity (L {US qt, lmp qt}) 1.75 {1.85, 1.54} 05–00 (approx.
  • Page 266 ON-BOARD DIAGNOSTIC 05–02 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC (OBD) MALFUNCTION INDICATION SYSTEM OUTLINE ....05–02–1 FUNCTION ..... . . 05–02–3 ON-BOARD DIAGNOSTIC (OBD) FAIL-SAFE FUNCTION .
  • Page 267 ON-BOARD DIAGNOSTIC MALFUNCTION DETECTION FUNCTION CHU050201026S03 Malfunction Detection Function • In the malfunction detection function, the TCM detects malfunctions in the automatic transmission while driving. • When vehicle driving conditions correspond with a preset malfunction detection condition, the TCM determines that the automatic transmission has a malfunction and stores the corresponding DTC.
  • Page 268 ON-BOARD DIAGNOSTIC AT warning Monitor Memory DTC No. Condition light item function illuminated × U0073 CAN bus off × U0100 TCM cannot receive any signals from PCM MIL: Malfunction Indicator Lamp DC: Drive Cycle CCM: Comprehensive Component Monitor End Of Sie MEMORY FUNCTION CHU050201026S04 •...
  • Page 269 ON-BOARD DIAGNOSTIC On-board diagnostic Detection condition Fail-safe function • Engine coolant temperature signal is used for shifting. Transmission fluid • Feedback control disabled • Vehicle speed is 20 km/h {12.4 mph} temperature (TFT) sensor • Torque reduction control P0713 circuit malfunction (open or more, and signal from TFT sensor Enabled disabled...
  • Page 270 ON-BOARD DIAGNOSTIC On-board diagnostic Detection condition Fail-safe function • TCM monitors the rotation ratio of the parking gear compared to reverse and high clutch drum when the following monitoring conditions are met. If the rotation ratio is 1.266 or less, or 1.824 or more, the TCM determines that there is malfunction.
  • Page 271 ON-BOARD DIAGNOSTIC On-board diagnostic Detection condition Fail-safe function • TCM monitors the rotation ratio of the parking gear compared to reverse and high clutch drum when the following monitoring conditions are met. If the rotation ratio is 0.568 or less, or 0.819 or more, the TCM determines that there is malfunction.
  • Page 272 ON-BOARD DIAGNOSTIC On-board diagnostic Detection condition Fail-safe function • Open or short circuit in shift solenoid Shift solenoid B circuit B signal system (when the TCM • Driving restricted to 3GR malfunction (open circuit/ monitors solenoid output voltage, • Stops operation of TCC P0763 Disabled short to ground or power...
  • Page 273 ON-BOARD DIAGNOSTIC PARAMETER IDENTIFICATION (PID) DATA MONITORING FUNCTION CHU050201026S07 • The PID mode allows access to certain data values, analog and digital input and output, calculations and system state information. Monitor Item Table Display on the Definition Unit/Condition tester terminal 24B_Duty Shift solenoid valve B (2-4 brake duty) BOO_TCM...
  • Page 274 ON-BOARD DIAGNOSTIC DLC-2 OUTLINE CHU050201026S09 • The DLC-2 located in the drive compartment is a standard service connector as defined by OBD-II regulations. DLC-2 CAN_L CAN_H GND2 GND1 CHU0502S002 Terminal Function GND1 Body ground terminal GND2 Serial communication ground terminal CAN_H Serial communication terminal (Hi) CAN_L...
  • Page 276 CLUTCH 05–10 CLUTCH CLUTCH OUTLINE ....05–10–1 CLUTCH RELEASE CYLINDER ..05–10–2 CLUTCH STRUCTURAL VIEW..05–10–1 STRUCTURE .
  • Page 277 CLUTCH CLUTCH MASTER CYLINDER CHU051001025S03 • The clutch master cylinder consists of a primary cup, spacer, piston, and a return spring. PRIMARY CUP RETURN SPRING PISTON SPACER CHU0510T004 End Of Sie CLUTCH RELEASE CYLINDER CHU051001025S04 STRUCTURE • The clutch release cylinder consists of a return spring, piston, push rod and a bleeder screw for bleeding air. PISTON RETURN SPRING PUSH ROD...
  • Page 278 MANUAL TRANSMISSION [Y16M-D] 05–11 MANUAL TRANSMISSION [Y16M-D] MANUAL TRANSMISSION SHIFT INTERLOCK MECHANISM OUTLINE ......05–11–1 OPERATION ..... . 05–11–7 MANUAL TRANSMISSION In Neutral Position.

  • Page 279: Manual Transmission [Y16M-D]

    MANUAL TRANSMISSION [Y16M-D] MANUAL TRANSMISSION POWER FLOW CHU051101025S03 CHU0511S102 05–11–2...

  • Page 280: Synchronizer Mechanism Outline

    MANUAL TRANSMISSION [Y16M-D] Reverse REVERSE GEAR REVERSE IDLER GEAR SEC. A-A COUNTER REVERSE GEAR CHU0511S103 05–11 End Of Sie SYNCHRONIZER MECHANISM OUTLINE CHU051101025S04 • A ball-type synchronizer mechanism is used in each gear. • The ball-type synchronizer mechanism consists of a coil-type synchronizer key spring, synchronizer key, and ball.

  • Page 281: Triple Synchronizer Mechanism Structure

    MANUAL TRANSMISSION [Y16M-D] TRIPLE SYNCHRONIZER MECHANISM STRUCTURE CHU051101025S05 Features • A triple synchronizer mechanism using more rings than double synchronizer mechanism is used for the first, second and third gears to improve synchromesh capacity by increasing a friction surface area. •...

  • Page 282: Triple Synchronizer Mechanism Operation

    MANUAL TRANSMISSION [Y16M-D] TRIPLE SYNCHRONIZER MECHANISM OPERATION CHU051101025S06 1. As the hub sleeve moves leftward (in the direction of the arrow), the synchronizer key presses HUB SLEEVE SYNCHRONIZER RING against the end of the synchronizer ring. As the hub sleeve continues moving leftward, the BALL synchronizer key presses onto the synchronizer ring.

  • Page 283: Control Rod Operation

    MANUAL TRANSMISSION [Y16M-D] CONTROL ROD OPERATION CHU051101025S07 5TH/REVERSE SHIFT FORK 1ST/2ND SHIFT FORK BUSHING BUSHING CONTROL ROD BUSHING 3RD/4TH SHIFT FORK CHU0511S109 • The control rod sliding section and the supports of each shift fork are equipped with a teflon bushing, which reduces sliding resistance during shifts and thus improves shift feeling.

  • Page 284: Shift Interlock Mechanism Operation

    MANUAL TRANSMISSION [Y16M-D] SHIFT INTERLOCK MECHANISM OPERATION CHU051101025S09 In Neutral Position INTERLOCK BLOCK INTERLOCK BLOCK MAIN SHIFT FORK SHAFT SECTION C SECTION A SECTION C SECTION A 05–11 SHIFT FORK SHAFT No.2 BALL SHIFT FORK SHAFT No.3 INTERLOCK BLOCK INTERLOCK BLOCK SECTION B CHU0511S110 05–11–7...

  • Page 285: In 1St, 2Nd, 3Rd, And 4Th Gear Positions Example: In 3Rd Gear Position

    MANUAL TRANSMISSION [Y16M-D] In 1st, 2nd, 3rd, and 4th Gear Positions Example: in 3rd gear position INTERLOCK BLOCK INTERLOCK BLOCK MAIN SHIFT FORK SHAFT SECTION C MAIN SHIFT FORK SHAFT SECTION A SECTION C SECTION A INTERLOCK BLOCK INTERLOCK BLOCK 3RD/4TH 3RD/4TH SHIFT FORK...

  • Page 286: In 5Th Gear Position

    MANUAL TRANSMISSION [Y16M-D] In 5th Gear Position INTERLOCK BLOCK MAIN SHIFT FORK INTERLOCK BLOCK SHAFT 5TH/REVERSE SHIFT FORK SECTION C MAIN SHIFT FORK SHAFT INTERLOCK SECTION A BLOCK SECTION C SECTION A INTERLOCK BLOCK 05–11 REVERSE SHIFT SHIFT FORK SHAFT ARM HEAD No.2 5TH SHIFT HEAD...

  • Page 287: In 6Th Gear Position

    MANUAL TRANSMISSION [Y16M-D] In 6th Gear Position MAIN SHIFT FORK INTERLOCK BLOCK INTERLOCK BLOCK SHAFT SECTION C MAIN SHIFT FORK SHAFT SECTION A SECTION C SECTION A LEVER INTERLOCK BLOCK SHIFT FORK SHAFT No.2 5TH SHIFT HEAD SHIFT FORK SHAFT BALL 5TH SHIFT HEAD 6TH SHIFT FORK...

  • Page 288: In Reverse Gear Position

    MANUAL TRANSMISSION [Y16M-D] In Reverse Gear Position MAIN SHIFT FORK SHAFT INTERLOCK BLOCK INTERLOCK BLOCK INTERLOCK BLOCK SECTION A SECTION C MAIN SHIFT FORK SHAFT SECTION C 5TH/REVERSE SECTION A SHIFT FORK INTERLOCK INTERLOCK BLOCK BLOCK 05–11 SHIFT FORK SHAFT No.2 SHIFT FORK BALL 6TH SHIFT FORK...

  • Page 289: Reverse Lockout Mechanism Construction/Operation

    MANUAL TRANSMISSION [Y16M-D] REVERSE LOCKOUT MECHANISM CONSTRUCTION/OPERATION CHU051101025S11 • With the adoption of the reverse lockout mechanism, which utilizes a guide plate, reliability has been assured. • A guide plate, attached to the extension housing, prevents accidental shifting into reverse when shifting from 5th to 6th gear by restricting the movement of the shift lever.
  • Page 290 MANUAL TRANSMISSION [Y16M-D] Without PPF — In order to suppress vibration to the vehicle body, rubber mounts are used to connect the differential to the frame. When accelerating rapidly, the front part of the differential lifts upward which causes a time lag in the actual engine torque being transmitted to the tires and direct drive feeling is lost.

  • Page 292: Automatic Transmission

    AUTOMATIC TRANSMISSION 05–13 AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION OIL PRESSURE SWITCH OUTLINE ......05–13–2 CONSTRUCTION/OPERATION ..05–13–31 Outline of operation .
  • Page 293 AUTOMATIC TRANSMISSION TCC engagement ....05–13–44 Descending hill....05–13–44 Determination of TCC inhibition .
  • Page 294 AUTOMATIC TRANSMISSION Electronic control system • The TCM sends signals that suit current driving conditions to the solenoids of the hydraulic control system, according to input signals from sensors and switches, and shifts gears. POWERTRAIN SYSTEM TIRE PROPELLER TORQUE CLUTCHES, PLANETARY DIFFERE- SHAFT...
  • Page 295 AUTOMATIC TRANSMISSION Operation Operation of of oil Shift pattern Transmission solenoid valve pressure switch Mode Gear position Shift Reverse 2.272 2.785 1.545 1.000 1.000 NOMAL 0.694 0.694 2.785 1.545 1.000 1.000 MANUAL 0.694 0.694 : Automatic shift according to set speed and throttle opening angle : Manual shift based on selector lever or steering shift switch operation : Consective shift by tapping selector lever or steering shift switch two times in the downshift direction...
  • Page 296 AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION CROSS-SECTIONAL VIEW CHU051301030S02 05–13 CHU0513S001 05–13–5...
  • Page 297 AUTOMATIC TRANSMISSION End Of Sie AUTOMATIC TRANSMISSION ELECTRONIC CONTROL SYSTEM STRUCTURAL VIEW CHU051301030S03 Outline Features • A stand-alone TCM, used exclusively for transmission control, performs various controls such as up and down- shifts, according to signals relayed from sensors and switches. •...
  • Page 298 AUTOMATIC TRANSMISSION Structure Structural view (ENGINE SPEED SIGNAL, THROTTLE OPENING SIGNAL) SPEEDOMETER 05–13 SELECTOR INDICATOR LIGHT AT WARNING LIGHT TURBINE SENSOR TR SWITCH TFT SENSOR SHIFT SOLENOID A CONTROL VALVE BODY SHIFT SOLENOID B TCC SOLENOID OIL PRESSURE SHIFT SOLENOID C SWITCH B SHIFT SOLENOID F PRESSURE CONTROL SOLENOID...
  • Page 299 AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION CONTROL SYSTEM WIRING DIAGRAM CHU051301030S04 TR SWITCH R POSITION POWER SUPPLY D RANGE N POSITION PRESSURE CONTROL SOLENOID VALVE P POSITION TCC SOLENOID VALVE SHIFT SOLENOID F BRAKE SWITCH SHIFT SOLENOID B M RANGE SWITCH SHIFT SOLENOID C UP SWITCH SELECTOR SHIFT SOLENOID A...
  • Page 300 AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION BLOCK DIAGRAM CHU051301030S05 INPUT SIGNAL OUTPUT SIGNAL PRESSURE CONTROL SOLENOID SHIFT SOLENOID A SHIFT SOLENOID B SHIFT SOLENOID C TURBINE SHIFT SOLENOID F SENSOR TCC SOLENOID TR SWITCH 05–13 AT CONTROL INSTRUMENT CLUSTER SYSTEM VEHICLE SPEED M RANGE SIGNAL SWITCH...
  • Page 301 AUTOMATIC TRANSMISSION Electronic Control Item and Contents Control Item Contents • Detects engine load and vehicle speed, and switches to optimum gear in accordance Shift control with preset shift program • Switches between high and low line pressure to suit engine load and vehicle speed, Line pressure control according to on/off pressure control valve solenoid •...
  • Page 302 AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION DEVICE RELATIONSHIP CHART CHU051301030S06 Control item Direct Line Component Shift electronic Feedback pressure control shift control control system control control Input Turbine sensor M range switch TFT sensor Oil pressure switch B Oil pressure switch C Oil pressure switch F Throttle opening signal Engine speed signal...
  • Page 303 AUTOMATIC TRANSMISSION POWERTRAIN OUTLINE CHU051301030S07 • In the powertrain system, hydraulic pressure is transmitted from the control valves to operate the clutches and brakes, and the planetary gear changes the gear ratio according to the vehicle driving condition. • To improve shift quality, a plate-type clutch pack 2-4 brake, which has optimum control at low oil temperatures and is unaffected by changes over time, is used.
  • Page 304 AUTOMATIC TRANSMISSION Power flow P position LOW AND REVERSE BRAKE LOW CLUTCH FRONT PLANETARY CARRIER REAR SUN GEAR FRONT PINION GEAR LOW ONE-WAY CLUTCH FRONT SUN GEAR INPUT SHAFT OUTPUT SHAFT 05–13 REAR INTERNAL GEAR HIGH CLUTCH REAR PINION GEAR FRONT INTERNAL GEAR REAR PLANETARY CARRIER...
  • Page 305 AUTOMATIC TRANSMISSION R position LOW AND REVERSE BRAKE LOW CLUTCH FRONT PLANETARY CARRIER REAR SUN GEAR FRONT PINION GEAR LOW ONE-WAY CLUTCH FRONT SUN GEAR INPUT SHAFT OUTPUT SHAFT REAR INTERNAL GEAR HIGH CLUTCH REAR PINION GEAR FRONT INTERNAL GEAR REAR PLANETARY CARRIER REVERSE CLUTCH IN RELATION TO PINION:...
  • Page 306 AUTOMATIC TRANSMISSION N position LOW AND REVERSE BRAKE LOW CLUTCH FRONT PLANETARY CARRIER REAR SUN GEAR FRONT PINION GEAR LOW ONE-WAY CLUTCH FRONT SUN GEAR INPUT SHAFT OUTPUT SHAFT 05–13 REAR INTERNAL GEAR HIGH CLUTCH REAR PINION GEAR FRONT INTERNAL GEAR REAR PLANETARY CARRIER REVERSE CLUTCH...
  • Page 307 AUTOMATIC TRANSMISSION D range 1GR LOW AND REVERSE BRAKE LOW CLUTCH FRONT PLANETARY CARRIER REAR SUN GEAR FRONT PINION GEAR LOW ONE-WAY CLUTCH FRONT SUN GEAR INPUT SHAFT OUTPUT SHAFT REAR INTERNAL GEAR HIGH CLUTCH REAR PINION GEAR FRONT INTERNAL GEAR REAR PLANETARY CARRIER REVERSE CLUTCH...
  • Page 308 AUTOMATIC TRANSMISSION M range 1GR LOW AND REVERSE BRAKE LOW CLUTCH FRONT PLANETARY CARRIER REAR SUN GEAR FRONT PINION GEAR LOW ONE-WAY CLUTCH FRONT SUN GEAR INPUT SHAFT OUTPUT SHAFT 05–13 REAR INTERNAL GEAR HIGH CLUTCH REAR PINION GEAR FRONT INTERNAL GEAR REAR PLANETARY CARRIER REVERSE CLUTCH...
  • Page 309 AUTOMATIC TRANSMISSION D, M range 2GR LOW AND REVERSE BRAKE LOW CLUTCH FRONT PLANETARY CARRIER REAR SUN GEAR FRONT PINION GEAR LOW ONE-WAY CLUTCH FRONT SUN GEAR INPUT SHAFT OUTPUT SHAFT REAR INTERNAL GEAR HIGH CLUTCH REAR PINION GEAR FRONT INTERNAL GEAR REAR PLANETARY CARRIER REVERSE CLUTCH...
  • Page 310 AUTOMATIC TRANSMISSION D, M range 3GR LOW AND REVERSE BRAKE LOW CLUTCH FRONT PLANETARY CARRIER REAR SUN GEAR FRONT PINION GEAR LOW ONE-WAY CLUTCH FRONT SUN GEAR INPUT SHAFT OUTPUT SHAFT 05–13 REAR INTERNAL GEAR HIGH CLUTCH REAR PINION GEAR FRONT INTERNAL GEAR REAR PLANETARY CARRIER...
  • Page 311 AUTOMATIC TRANSMISSION D, M range 4GR LOW AND REVERSE BRAKE LOW CLUTCH FRONT PLANETARY CARRIER REAR SUN GEAR FRONT PINION GEAR LOW ONE-WAY CLUTCH FRONT SUN GEAR INPUT SHAFT OUTPUT SHAFT REAR INTERNAL GEAR HIGH CLUTCH REAR PINION GEAR FRONT INTERNAL GEAR REAR PLANETARY CARRIER REVERSE CLUTCH...
  • Page 312 AUTOMATIC TRANSMISSION TORQUE CONVERTER OUTLINE CHU051319100S01 • The RC4A-EL type torque converter adopts a TCC mechanism. • The TCC mechanism mechanically engages the pump impeller and the turbine runner under certain conditions, and transmits the power, not through the fluid, but directly, preventing the slip loss of the torque converter.
  • Page 313 AUTOMATIC TRANSMISSION OIL PUMP CONSTRUCTION/OPERATION CHU051319220S02 • The oil pump, mounted behind the torque converter, is driven directly by the torque converter. • Inner and outer rotors are built into the pump housing in the oil pump. • The inner rotor is driven by the torque converter in the same rotational direction as the engine. •...
  • Page 314 AUTOMATIC TRANSMISSION CENTRIFUGAL BALANCE CLUTCH CONSTRUCTION/OPERATION CHU051301030S10 Construction • Centrifugal balance clutch chambers are installed opposite the clutch chambers in the low and high clutches. The centrifugal balance clutch chambers are constantly filled with ATF from an exclusive hydraulic passage of the oil pump.
  • Page 315 AUTOMATIC TRANSMISSION CENTRIFUGAL BALANCE CLUTCH CONVENTIONAL CLUTCH CHANGES ACCORDING TO ROTATION SPEED TWO FORCES OF CLUTCH DRUM ARE ELIMINATED CENTRIFUGAL CENTRIFUGAL CENTRIFUGAL HYDRAULIC HYDRAULIC HYDRAULIC PRESSURE PRESSURE PRESSURE OF PISTON OF PISTON OF BALANCE CHAMBER CHAMBER CHAMBER SPRING CLUTCH PISTON SPRING FORCE PRESSURE...
  • Page 316 AUTOMATIC TRANSMISSION CONTROL VALVE BODY STRUCTURAL VIEW CHU051321100S02 OIL STRAINER OIL PRESSURE SWITCH C OIL PRESSURE SHIFT SOLENOID F SWITCH B OIL PRESSURE SWITCH F PRESSURE CONTROL SOLENOID SHIFT SOLENOID C 05–13 LOWER CONTROL VALVE BODY TFT SENSOR TCC SOLENOID UPPER CONTROL VALVE SHIFT SOLENOID B BODY...
  • Page 317 AUTOMATIC TRANSMISSION TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR FUNCTION CHU051319010S01 • The TFT sensor detects the ATF temperature in the oil pan, and sends control signals to the TCM. The TCM controls the driving pattern selection and the torque converter clutch based on signals from the TFT sensor. TFT SENSOR CHU0513S040 End Of Sie...
  • Page 318 AUTOMATIC TRANSMISSION TURBINE SENSOR CONSTRUCTION/OPERATION CHU051319010S04 • The turbine sensor is a Hall element type. A 32-pulse signal is generated per rotation of the reverse and high clutch drum and the sensor sends this signal to the TCM. • The TCM detects the shift start and end timing according to the signal from turbine sensor, and performs detailed control, improving shift quality.
  • Page 319 AUTOMATIC TRANSMISSION SOLENOID VALVE FUNCTION CHU051321280S01 • All solenoid valves have superior responsiveness to hydraulic control. • The solenoids have the following functions. SHIFT SOLENOID F PRESSURE CONTROL SOLENOID SHIFT SOLENOID C SHIFT SOLENOID A TCC SOLENOID SHIFT SOLENOID B CHU0513S032 Function chart Solenoid...
  • Page 320 AUTOMATIC TRANSMISSION SOLENOID VALVE CONSTRUCTION/OPERATION CHU051321280S02 Construction • The construction of all solenoids is the same, but the polarity of the positive and negative terminals is different. OUTPUT PORT (SOLENOID PRESSURE) SUPPLY PORT (PILOT PRESSURE) DRAIN PORT ( ):NORMAL LOW CHU0513S033 Operation 05–13...
  • Page 321 AUTOMATIC TRANSMISSION • Energized (ON) or duty 100% — Solenoid pressure is supplied to the output port because the output port (solenoid OUTPUT PORT DE-ENERGIZED (OFF) (SOLENOID PRESSURE) pressure) and the supply port (pilot pressure) connect in the solenoid. End Of Sie DRAIN PORT ENERGIZED (ON) OUTPUT PORT...
  • Page 322 AUTOMATIC TRANSMISSION OIL PRESSURE SWITCH CONSTRUCTION/OPERATION CHU051321280S04 • While clutch or brake pressure is applied, the oil pressure switches turn on when the oil pressure reaches the operating pressure of the switch, and turn off when the oil pressure is below the operating pressure of the switch.
  • Page 323 AUTOMATIC TRANSMISSION Structure System diagram SELECTOR LEVER COMPONENT SENSOR TR SWITCH DOWN M RANGE SWITCH SWITCH SWITCH SHIFT SOLENOID F SHIFT SOLENOID B SHIFT SOLENOID C SHIFT SOLENOID A THROTTLE OPENING SIGNAL ENGINE VEHICLE SPEED TORQUE SIGNAL CRUISE CONTROL SIGNAL ENGINE UP/DOWN SIGNAL COOLANT...
  • Page 324 AUTOMATIC TRANSMISSION LINE PRESSURE CONTROL STRUCTURE CHU051318901S07 Features • With direct electronic shift control, clutch pressure is regulated by duty-cycle solenoids (shift solenoids A, B, C, F) and amplifier valves, and thus conventional continuously variable line pressure control does not occur. Instead, throttle opening angle, vehicle speed, ATF temperature, and TR switch signals drive on/off type pressure control solenoids, and switch line pressure to high or low pressure to suit engine load and vehicle speed.
  • Page 325 AUTOMATIC TRANSMISSION LINE PRESSURE CONTROL OPERATION CHU051318901S08 • Line pressure switches to high or low pressure in accordance with line pressure switching pre-programmed in the TCM. • If the pressure control solenoid valve is energized, line pressure switches to the low- HIGH pressure side;...
  • Page 326 AUTOMATIC TRANSMISSION DIRECT ELECTRONIC SHIFT CONTROL STRUCTURE CHU051318901S09 Features • According to signals from switches and sensors, direct electronic shift control drives the duty-cycle solenoid valves (shift solenoid valves A, B, C, F), regulates clutch pressure to suit engine load and vehicle speed, and electronically controls clutch pressure directly.
  • Page 327 AUTOMATIC TRANSMISSION DIRECT ELECTRONIC SHIFT CONTROL OPERATION CHU051318901S10 • In the previous system, line pressure passages are switched with a combination of on/off shift solenoids and shift valves to engage the clutch. In the new system, clutch pressure is regulated for each clutch and brake with a combination of duty cycle shift solenoids and amplifier valves.
  • Page 328 2004 Mazda RX-8 Service Highlights (3378–1U–03C) AUTOMATIC TRANSMISSION AT WARNING LIGHT FUNCTION CHU051319010S07 • The AT warning light illuminates to alert the driver of a malfunction in the automatic transmission. End Of Sie AT WARNING LIGHT CONSTRUCTION/OPERATION CHU051319010S08 • The AT warning light is built into the instrument cluster.
  • Page 329 2004 Mazda RX-8 Service Highlights (3378–1U–03C) AUTOMATIC TRANSMISSION Construction Selector indicator “M” light and gear position indicator light flash • When the driver’s shift operation is cancelled, the gear position indicator light and selector lever indicator “M” light flash twice.
  • Page 330 AUTOMATIC TRANSMISSION Structure System diagram SELECTOR INDICATOR LIGHT GEAR POSITION INDICATOR LIGHT INSTRUMENT CLUSTER AT WARNING LIGHT SELECTOR LEVER COMPONENT M RANGE SWITCH UP SWITCH DOWN SWITCH TR SWITCH STEERING SHIFT SWITCH UP SWITCH DOWN SWITCH 05–13 TFT SENSOR CHU0513S105 End Of Sie MANUAL MODE SHIFT CONTROL OPERATION CHU051301030S12...
  • Page 331 AUTOMATIC TRANSMISSION Condition Shift control Note • To assure drive stability, automatically In 4GR deceleration, speed goes below coast-down set downshifts from 4GR to 3GR. speed (deceleration down- shift) • To assure drive stability, automatically In 3GR deceleration, speed goes below coast-down set downshifts from 3GR to 2GR and 3GR to —...
  • Page 332 AUTOMATIC TRANSMISSION FEEDBACK CONTROL STRUCTURE CHU051301030S13 Features • During shift up with the accelerator pedal depressed, feedback control regulates the clutch pressure on the engagement and release sides, according to the throttle opening angle and vehicle speed. It also uses past gearshifts to optimize clutch pressure.
  • Page 333 AUTOMATIC TRANSMISSION FEEDBACK CONTROL OPERATION CHU051301030S14 Upshift clutch engagement pressure feedback • Clutch pressure (2) is learned so that gear shift time (1) becomes a predetermined target value, and thus changes in performance and changes in the transmission over time are minimized based on past gear shift results.
  • Page 334 AUTOMATIC TRANSMISSION TORQUE CONVERTER CLUTCH (TCC) CONTROL STRUCTURE CHU051301030S16 Features • The TCM selects the TCC schedule according to the gear selected by the transmission. Fifty Hz (20 ms cycle) on/off signals are relayed from the TCC schedule, VSS and throttle opening angle to the duty cycle TCC solenoid valve to control the TCC.
  • Page 335 AUTOMATIC TRANSMISSION TORQUE CONVERTER CLUTCH (TCC) OPERATION CHU051301030S17 TCC release • The TCM stops driving the TCC solenoid (OFF) when TCC release is determined. TCC engagement • When the TCM determines TCC engagement, the TCM gradually increases the duty ratio energizing the TCC solenoid, and gradually drains the oil pressure in the torque converter F chamber.
  • Page 336 AUTOMATIC TRANSMISSION LUBRICATION SYSTEM OUTLINE CHU051319900S01 • In the conventional system, the rear section is lubricated by ATF returning from the ATF oil cooler. In the new system, all parts are lubricated directly from the control valve. • With this construction, the system is unaffected by the ATF oil cooler, and thus a steady amount of RC4A-EL TYPE lubricant is supplied.
  • Page 337 AUTOMATIC TRANSMISSION COOLING SYSTEM OUTLINE CHU051319900S02 • A water-cooling type AT oil cooler is adopted and installed in the radiator. The oil cooler cools the ATF heated in the AT body. BHJ0513N045 End Of Sie POWER PLANT FRAME (PPF) FUNCTION CHU051319900S03 •...
  • Page 338 AUTOMATIC TRANSMISSION SHIFT MECHANISM 05–14 AUTOMATIC TRANSMISSION SHIFT MECHANISM AUTOMATIC TRANSMISSION SHIFT SELECTOR LEVER STRUCTURE..05–14–3 MECHANISM OUTLINE ... . 05–14–1 M Range Switch ....05–14–3 AUTOMATIC TRANSMISSION SHIFT Up Switch .

  • Page 339: Automatic Transmission Shift Mechanism

    AUTOMATIC TRANSMISSION SHIFT MECHANISM KEY INTERLOCK SYSTEM OPERATION CHU051409000S04 Positions other than P position (Key interlock is operating) • When the selector lever is in a position or range other than P position, the cable end is set at the IMPOSSIBLE TO SPRING TURN KEY TO...

  • Page 340: Operation

    AUTOMATIC TRANSMISSION SHIFT MECHANISM SELECTOR LEVER OUTLINE CHU051446010S01 • Operability has been improved due to the short stroke feature of the selector lever. • Shift position has been optimized by the reduction of space achieved between the frequently utilized N and D ranges.

  • Page 341: Up Switch

    AUTOMATIC TRANSMISSION SHIFT MECHANISM End Of Sie STEERING SHIFT SWITCH FUNCTION CHU051446010S03 • When an up-shift or down-shift operation is detected in M range, an up-shift or down-shift request signal is sent to the TCM. End Of Sie STEERING SHIFT SWITCH CONSTRUCTION/OPERATION CHU051446010S04 Construction •...

  • Page 342: Electric Power

    STEERING SECTION Toc of SCT OUTLINE ....06-00 ELECTRIC POWER ON-BOARD DIAGNOSTIC ..06-02 STEERING (EPS)..06-13 Toc of SCT 06–00 OUTLINE...
  • Page 344 ON-BOARD DIAGNOSTIC 06–02 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC SYSTEM PID/DATA MONITOR FUNCTION OUTLINE (ELECTRIC POWER (ELECTRIC POWER STEERING) ..06–02–3 STEERING) ..... . 06–02–1 ON-BOARD DIAGNOSTIC SYSTEM Block Diagram .
  • Page 345 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC SYSTEM FUNCTION (ELECTRIC POWER STEERING) CHU060201038S02 Malfunction Detection Function • The malfunction detection function detects malfunctions in the input/output signal system of the EPS control module when the ignition switch is at the ON position or driving the vehicle. •...
  • Page 346 ON-BOARD DIAGNOSTIC DTC TABLE Fail-safe function System malfunction location EPS warning light illumination Control status status Battery power supply B1318 Illuminated Control suspended EPS control module B1342 Illuminated Control suspended EPS system (neutral position B2141 Illuminated Control available setting not performed) Torque sensor B2278 Illuminated...
  • Page 347 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC SYSTEM EXTERNAL TESTER COMMUNICATION FUNCTION (ELECTRIC POWER STEERING) CHU060201038S05 Outline • The external tester communication function enables communication of diagnostic data (DTC read-outs, input/ output signal read-outs, and operation of input/output parts) between the EPS control module and an external tester.
  • Page 348 ON-BOARD DIAGNOSTIC DLC-2 CONSTRUCTION CHU060201038S06 • A DLC-2 connector conforming to ISO (International Organization for Standardization) standards has been added. • Shape and terminal arrangement as stipulated by the ISO 15031-3 (SAE J1962) international standard has been adopted for this connector. The connector has a 16-pin construction that includes the CAN_H, CAN_L, GND1, GND2 and B+ terminals.
  • Page 350 ELECTRIC POWER STEERING (EPS) 06–13 ELECTRIC POWER STEERING (EPS) ELECTRIC POWER STEERING (EPS) TORQUE SENSOR OUTLINE ......06–13–1 CONSTRUCTION/OPERATION .

  • Page 351: Electric Power Steering (Eps)

    ELECTRIC POWER STEERING (EPS) ELECTRIC POWER STEERING (EPS) STRUCTURAL VIEW CHU061301034S02 STEERING WHEEL EPS WARNING LIGHT INSTRUMENT CLUSTER EPS MOTOR STEERING SHAFT TORQUE SENSOR EPS CONTROL MODULE STEERING GEAR AND LINKAGE CHU0613S001 End Of Sie 06–13–2...

  • Page 352: Electric Power Steering (Eps) System Wiring Diagram

    ELECTRIC POWER STEERING (EPS) ELECTRIC POWER STEERING (EPS) SYSTEM WIRING DIAGRAM CHU061301034S03 EPS CONTROL MODULE NOISE IG SWITCH EPS 60 A FILTER POWER RELAY STEERING GEAR AND LINKAGE ENGINE 15 A EPS MOTOR BATTERY INSTRUMENT CLUSTER MOTOR DRIVER RELAY TORQUE SENSOR CAN DRIVER ABS HU/CM OR 06–13...

  • Page 353: Electric Power Steering (Eps) Construction/Operation

    ELECTRIC POWER STEERING (EPS) ELECTRIC POWER STEERING (EPS) CONSTRUCTION/OPERATION CHU061301034S04 Construction • The EPS (Electric Power Steering) consists mainly of manual steering and electric assist mechanisms, and a control system. — Manual steering mechanism: Consists of the steering wheel, steering shaft, steering gear and linkage. —...

  • Page 354: Steering Gear And Linkage

    ELECTRIC POWER STEERING (EPS) Function of Component Parts Part name Function • Detects the steering force signal and inputs it to the EPS control Torque sensor module. Steering gear and • Generates an assist force based on the control current from the linkage EPS motor EPS control module.

  • Page 355: Electric Power Steering (Eps) Motor Construction/Operation

    ELECTRIC POWER STEERING (EPS) ELECTRIC POWER STEERING (EPS) MOTOR CONSTRUCTION/OPERATION CHU061332960S02 Construction • The EPS motor is a direct current motor with a magnet fixed to the inner surface of the motor housing. • The main structural parts are the armature coil (inserted through the steering rack), brush (where energization occurs), magnet and the ball screw.

  • Page 356: Construction

    ELECTRIC POWER STEERING (EPS) TORQUE SENSOR CONSTRUCTION/OPERATION CHU061332960S03 Construction • The torque sensor, installed on the pinion shaft, detects the amount of road surface resistance (steering torque) and the steering direction, and inputs a corresponding signal to the EPS control module. Operation •...

  • Page 357: Construction

    ELECTRIC POWER STEERING (EPS) ELECTRIC POWER STEERING (EPS) CONTROL MODULE CONSTRUCTION/OPERATION CHU061367880S01 Construction • The EPS control module is located in the engine compartment, on the underside of the PCM. • The module calculates the proper assist current based on the steering force signal from the torque sensor installed on the steering gear and linkage, and the vehicle and engine speed signals from the PCM using CAN communication line, and then outputs the control current to the EPS motor.
  • Page 358 ELECTRIC POWER STEERING (EPS) Operation Motor current control • The proper assist current is calculated based on the steering force signal from the torque sensor, and the vehicle and engine speed signals from the PCM, and then the control current is output to the EPS motor. •...
  • Page 359 ELECTRIC POWER STEERING (EPS) System overheating prevention control • To prevent a malfunction of the system caused by overheating (due to motor over-speed or other factors), the steering mechanism turning limit and cumulative value of the motor current are detected and the current output to the EPS motor is controlled accordingly.

  • Page 360: Energy Absorbing System Construction/Operation

    ELECTRIC POWER STEERING (EPS) ENERGY ABSORBING SYSTEM CONSTRUCTION/OPERATION CHU061332010S01 Construction • Due to impact absorbing mechanisms at two points on the steering shaft, when a collision occurs, the steering shaft effectively absorbs the impact energy that would be transmitted to the driver, thereby reducing injury. Operation •...
  • Page 362 HEATER, VENTILATION & AIR CONDITIONING (HVAC) SECTION Toc of SCT OUTLINE ....07-00 CONTROL SYSTEM ..07-40 BASIC SYSTEM .
  • Page 363 OUTLINE Item Specification Type Multiflow (sub-cooling type) Radiated heat (kW {kcal/h}) 7.0 {6,020} Condenser Receiver/drier capacity (ml {cc, fl oz}) 190 {190, 6.42} Desiccant XH-9 Expansion valve Type External pressure equalizer Evaporator Type Double-tank drawn cup Temperature control Reheat full air mix type Control System Item Specification...
  • Page 364 BASIC SYSTEM 07–11 BASIC SYSTEM BASIC SYSTEM OUTLINE ... 07–11–1 Air Mix Door Operation ... . . 07–11–4 BASIC SYSTEM STRUCTURAL Airflow Mode Door Operation .

  • Page 365: Basic System

    BASIC SYSTEM BASIC SYSTEM FLOW DIAGRAM CHU071101040S03 VENTILATION SYSTEM SIDE SIDE DEFROSTER DEFROSTER DEMISTER DEMISTER FRESH RECIR- CULATE HEATER CORE AIR FILTER SIDE CENTER CENTER SIDE VENT VENT VENT VENT BLOWER MOTOR EVAPORATOR REAR FRONT FRONT REAR HEAT HEAT HEAT HEAT CHU0711S004 REFRIGERANT SYSTEM...

  • Page 366: Blower Unit Construction

    BASIC SYSTEM BLOWER UNIT CONSTRUCTION CHU071113988S01 • Composed of the following parts: — Blower motor — Air intake door — Air intake actuator — Air filter End Of Sie AIR INTAKE DOOR AIR INTAKE ACTUATOR AIR FILTER BLOWER MOTOR CHU0711S006 AIR FILTER FUNCTION CHU071113988S02 •...

  • Page 367: A/C Unit Construction/Operation

    BASIC SYSTEM A/C UNIT CONSTRUCTION/OPERATION CHU071161130S01 Construction • An A/C unit with integrated cooling and heater units has been adopted. — Evaporator — Heater core — Expansion valve — Air mix door — Airflow mode door — Evaporator temperature sensor —...

  • Page 368: Airflow Mode Door Operation

    BASIC SYSTEM Airflow Mode Door Operation • The airflow mode doors move to the VENT, BI-LEVEL, HEAT, HEAT/DEF, or DEFROSTER position, depending on the position of the airflow mode selector switch. As a result, the airflow mode changes. AIRFLOW MODE DOOR EVAPORATOR AIR MIX DOOR...

  • Page 369: A/C Compressor Construction

    BASIC SYSTEM A/C COMPRESSOR CONSTRUCTION CHU071161480S01 • Composed of the following parts: — A/C compressor body — Magnetic clutch End Of Sie MAGNETIC CLUTCH A/C COMPRESSOR BODY CHU0711S011 CONDENSER CONSTRUCTION CHU071161480S02 • A sub cool condenser has been adopted. It is a multi-flow condenser which is equipped with a sub cooling part and integrated with a receiver/drier.

  • Page 370: Refrigerant Lines Construction

    BASIC SYSTEM REFRIGERANT LINES CONSTRUCTION CHU071161460S01 • Aluminum alloy has been adopted for the pipes of the refrigerant lines and rubber (flexible hoses) has been adopted for the hoses. • A high-pressure charging valve is installed on cooler pipe No.2, and a low-pressure charging valve is installed on the cooler hose (LO).
  • Page 372 CONTROL SYSTEM 07–40 CONTROL SYSTEM CONTROL SYSTEM OUTLINE..07–40–1 CONSTRUCTION ....07–40–4 CONTROL SYSTEM STRUCTURAL AMBIENT TEMPERATURE SENSOR VIEW .

  • Page 373: Control System

    CONTROL SYSTEM CONTROL SYSTEM SYSTEM WIRING DIAGRAM CHU074001040S03 IG2 B+ ECT SENSOR A/C AMPLIFIER REFRIGERANT PRESSURE SWITCH AMBIENT TEMPERATURE SENSOR AIR MIX ACTUATOR EVAPORATOR TEMPERATURE SENSOR AIRFLOW MODE ACTUATOR BLOWER MOTOR BLOWER RELAY RESISTOR FAN SWITCH AIR INTAKE ACTUATOR REAR WINDOW DEFROSTER RELAY CLIMATE...

  • Page 374: Air Mix Actuator Construction

    CONTROL SYSTEM AIR MIX ACTUATOR CONSTRUCTION CHU074061480S02 • A potentiometer type, which allows minute and smooth changes of the door position, has been adopted. MAX COLD 90° MAX HOT COLD CHU0740S003 End Of Sie AIRFLOW MODE ACTUATOR CONSTRUCTION CHU074061480S03 • A potentiometer type, which allows minute and smooth changes of the door position, has been adopted. DEFROSTER 90°...

  • Page 375: Resistor Operation

    CONTROL SYSTEM RESISTOR OPERATION CHU074061480S05 • Changes the resistance value of the blower motor operation current based on fan switch operation to control the airflow volume. BLOWER BLOWER MOTOR RELAY RESISTOR A/C AMPLIFIER FAN SWITCH CHU0740S009 End Of Sie MAGNETIC CLUTCH CONSTRUCTION CHU074061480S06 •...

  • Page 376: Ambient Temperature Sensor Construction

    CONTROL SYSTEM AMBIENT TEMPERATURE SENSOR CONSTRUCTION CHU074061480S07 • A thermistor type has been adopted. KILOHM AMBIENT TEMPERATURE SENSOR °C {°F} {14} {32} {50} {68} {86} {104} {122} 07–40 TEMPERATURE CHU0740S012 End Of Sie EVAPORATOR TEMPERATURE SENSOR CONSTRUCTION CHU074061480S08 • A thermistor type has been adopted. KILOHM EVAPORATOR TEMPERATURE...

  • Page 377: Refrigerant Pressure Switch Construction

    CONTROL SYSTEM REFRIGERANT PRESSURE SWITCH CONSTRUCTION CHU074061480S09 • A triple-pressure type has been adopted. • The refrigerant pressure switch is composed of the high-pressure and low-pressure switches, which cut the A/ C signal to protect the refrigeration cycle if pressure in the refrigeration cycle is too high or too low; and the medium-pressure switch, which sends an cooling fan control signal according to the operation load of the cooling fan.

  • Page 378: A/C Amplifier Function

    CONTROL SYSTEM A/C AMPLIFIER FUNCTION CHU074061480S10 • Receives signals from the climate control unit and sends operation control signals to the actuators. • A/C amplifier has defroster control. AIR MIX ACTUATOR AIRFLOW TEMPERATURE CHANGES AIRFLOW MODE ACTUATOR CLIMATE A/C AMPLIFIER AIRFLOW MODE CHANGES CONTROL UNIT...
  • Page 380 RESTRAINTS SECTION Toc of SCT OUTLINE ....08-00 AIR BAG SYSTEM ..08-10 ON-BOARD DIAGNOSTIC ..08-02 SEAT BELT .
  • Page 382 ON-BOARD DIAGNOSTIC 08–02 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC FUNCTION Self-diagnostic Function ... . 08–02–1 OUTLINE ......08–02–1 PID/Data Monitoring Function .
  • Page 383 ON-BOARD DIAGNOSTIC DTC table Air bag system warning light System malfunction location Priority display Flashing pattern ranking SAS control module activation (deployment) B1231 control freeze SAS control module B1342 SAS control module (DTC 12 detection circuit  Continuously illuminated malfunction) Seat belt warning light circuit short to power B1426 supply...
  • Page 384 ON-BOARD DIAGNOSTIC Air bag system warning light System malfunction location Priority display Flashing pattern ranking Driver-side air bag module (inflator No.1) circuit B1932 resistance high Passenger-side air bag module (inflator No.1) B1933 circuit resistance high Driver-side air bag module (inflator No.1) circuit B1934 resistance low Passenger-side air bag module (inflator No.1)
  • Page 385 ON-BOARD DIAGNOSTIC Air bag system warning light System malfunction location Priority display Flashing pattern ranking Passenger-side air bag module (inflator No.2) B2235 circuit resistance low Crash zone sensor (communication error, internal B2296 circuit abnormal) Driver-side front buckle switch circuit short to B2434 ground Driver-side front buckle switch circuit resistance...
  • Page 386 ON-BOARD DIAGNOSTIC Air bag system warning light System malfunction location Priority display Flashing pattern ranking Poor connection of any SAS control module B2867 connectors Driver-side side air bag sensor (communication U2017 error) Passenger-side side air bag sensor U2018 (communication error) PID/Data Monitoring Function •...
  • Page 387 ON-BOARD DIAGNOSTIC PID name (definition) Unit/Condition Operation Condition (Reference) Terminal • Related wiring harness normal: NORMAL NORMAL/ • Related wiring harness circuit open: OPEN DS1_STAT OPEN/ • Related wiring harness short to ground: SHRT_GND (Driver-side air bag module SHRT_GND/ 1S, 1V •...
  • Page 388 ON-BOARD DIAGNOSTIC PID name (definition) Unit/Condition Operation Condition (Reference) Terminal • Related wiring harness normal: NORMAL NORMAL/ • Related wiring harness circuit open: OPEN OD_PSAB_ST OPEN/ • Related wiring harness short to ground: SHRT_GND (Passenger-side side air bag SHRT_GND/ 2I, 2L •...

  • Page 390: Air Bag System

    AIR BAG SYSTEM 08–10 AIR BAG SYSTEM AIR BAG SYSTEM OUTLINE ..08–10–1 Inflator Operation ....08–10–7 AIR BAG SYSTEM STRUCTURAL PASSENGER-SIDE AIR BAG MODULE VIEW .
  • Page 391 AIR BAG SYSTEM AIR BAG SYSTEM STRUCTURAL VIEW CHU081001046S02 AIR BAG SYSTEM WARNING LIGHT DRIVER-SIDE AIR BAG MODULE SEAT BELT WARNING LIGHT PASSENGER-SIDE AIR BAG MODULE CLOCK SPRING SAS CONTROL MODULE CURTAIN AIR BAG MODULE CRASH ZONE SENSOR PRE-TENSIONER SEAT BELT SIDE AIR BAG SENSOR SIDE AIR BAG MODULE DRIVER SEAT...
  • Page 392 AIR BAG SYSTEM AIR BAG SYSTEM WIRING DIAGRAM CHU081001046S03 CLOCK SPRING TWISTED PAIR SEAT TRACK INFLATOR POSITION NO.1 SENSOR DRIVER-SIDE AIR BAG MODULE POOR CONNECTION INFLATOR DETECTOR BAR NO.2 TWISTED PAIR CRASH ZONE INFLATOR SENSOR NO.1 PASSENGER-SIDE AIR BAG MODULE DLC-2 INFLATOR NO.2...

  • Page 393: Front Air Bag System (2-Step Deployment Control)

    AIR BAG SYSTEM SAS CONTROL MODULE CONSTRUCTION/OPERATION CHU081057030S03 Front Air Bag System (2-Step Deployment Control) 1. During a frontal or frontal offset collision, the crash sensors in the crash zone sensor and the SAS control module detect the impact. 2. The degree of impact detected by the crash sensors in the crash zone sensor is converted to an electric signal and sent to the SAS control module.
  • Page 394 AIR BAG SYSTEM Side air bag system 1. During a lateral collision to the vehicle, the crash sensors in the side air bag sensor and SAS control module detect the collision. 2. The degree of impact detected by the crash sensor in the side air bag sensor is converted to an electrical signal and sent to the SAS control module through the signal amplification circuit.

  • Page 395: Seat Position Matching Deployment Control

    AIR BAG SYSTEM Seat Position Matching Deployment Control • The SAS control module controls the air bag deployment operation pattern (deploying only inflator No.1 or both inflator No.1 and No.2) according to the seat track position of the driver’s seat. •...

  • Page 396: Seat Track Position Sensor Construction/Operation

    AIR BAG SYSTEM SEAT TRACK POSITION SENSOR CONSTRUCTION/OPERATION CHU081057030S04 • The seat track position sensor consists of a Hall element (semi-conductor) and a magnet. The sensor converts the effect of the magnetic flux (produced by the magnet) on the Hall element, into an electrical signal. •...

  • Page 397: Passenger-Side Air Bag Module Construction/Operation

    AIR BAG SYSTEM PASSENGER-SIDE AIR BAG MODULE CONSTRUCTION/OPERATION CHU081057050S02 Inflator Operation 1. The igniter built into the inflator begins to build up heat when the operation (deployment) signal is sent from the SAS control module. The inflation agent is ignited by the build up of heat in the igniter. 2.

  • Page 398: Side Air Bag Module Construction/Operation

    AIR BAG SYSTEM SIDE AIR BAG MODULE CONSTRUCTION/OPERATION CHU081000147S02 Construction • Side air bag modules are installed on the outboard sides of the front seat backs. • The side air bag module is composed of an inflator, module cover and air bag. •...

  • Page 399: Curtain Air Bag Module Construction/Operation

    AIR BAG SYSTEM CURTAIN AIR BAG MODULE CONSTRUCTION/OPERATION CHU081000171S02 Construction • The curtain air bag modules are equipped along the roof edge between the A and B pillars. • The curtain air bag module is composed of the inflator, pipe, bag cover, and air bag. •...

  • Page 400: Pre-Tensioner Seat Belt Function

    AIR BAG SYSTEM Inflator operation 1. The igniter built into the inflator begins to build up heat when the operation (deployment) signal is sent from the SAS control module. The inflation agent is ignited by the build up of heat in the igniter. 2.
  • Page 401 AIR BAG SYSTEM Operation Before Activation (Normal Condition) • The spool has a pinion on its end, which rotates with the spool when the belt webbing is retracted or withdrawn. • There is a ring gear around the pinion. Because the pinion does not engage with the ring gear during normal operation, the ring gear does not rotate even when the belt webbing is retracted or withdrawn.
  • Page 402 AIR BAG SYSTEM After Activation 1. Directly after the activation of the pre-tensioner seat belt system and the application of a load to the seat belt in the direction of withdrawal, the ELR lock mechanism operates and the pawl engages the housing gear. 2.

  • Page 404: Seat Belt

    SEAT BELT 08–11 SEAT BELT SEAT BELT OUTLINE ....08–11–1 SEAT BELT LOCK RELEASE SYSTEM Features......08–11–1 DIAGRAM .
  • Page 405 SEAT BELT SEAT BELT LOCK RELEASE STRUCTURAL VIEW CHU081157100S05 KEYLESS REAR DOOR CONTROL MODULE UPPER LATCH SWITCH LOCK RELEASE SOLENOID ACTUATOR WEIGHT CANCEL LEVER FRONT SEAT BELT DOOR SWITCH FRONT BUCKLE SWITCH REAR DOOR LOWER LATCH SWITCH CHU0811S002 End Of Sie SEAT BELT LOCK RELEASE SYSTEM DIAGRAM CHU081157100S06 KEYLESS CONTROL MODULE...
  • Page 406 SEAT BELT SEAT BELT LOCK RELEASE OPERATION CHU081157100S07 • When the seat belt lock release function is not operated, the weight is under a no-load condition. When a sudden shock is applied to the vehicle, the weight moves to push the actuator upward. The actuator engages with a lock gear and stops its rotation (ELR condition).
  • Page 407 SEAT BELT CHILD RESTRAINT SEAT ANCHOR CONSTRUCTION CHU081101046S01 • ISOFIX anchors for securing an ISOFIX child restraint seat, and tether strap anchors have been adopted. Caution • • • • Installation procedure varies with the type of child restraint seat. When installing a child restraint seat, be sure to follow the prescribed procedure for each type.
  • Page 408 BODY & ACCESSORIES SECTION Toc of SCT OUTLINE ....09-00 INTERIOR TRIM ... . 09-17 BODY PANELS .
  • Page 409 OUTLINE BODY AND ACCESSORIES FEATURES CHU090001034S02 • Pop-up type headlight cleaner adopted Design Improvement • Power window system adopted • Power outer mirror adopted • Power seat adopted Improved marketability • Power door lock system adopted • keyless entry system adopted •...

  • Page 410: Body Panels

    BODY PANELS 09–10 BODY PANELS BODY PANEL OUTLINE... . . 09–10–1 CABIN CONSTRUCTION ... . . 09–10–2 CRUSH ZONE CONSTRUCTION ..09–10–1 HOOD CONSTRUCTION .
  • Page 411 BODY PANELS • A high-tensile-strength plate that is highly effective in absorbing force has been adopted for CROSSMEMBER the large profile, straight-shaped rear side frame. REAR BUMPER Structural strength of the high-mount backbone REINFORCEMENT HIGH-MOUNT BACKBONE FRAME frame and the crossmember rear side frame has been reinforced in order to disperse an impact to the fuel tank area and thereby suppress deformation.
  • Page 412 BODY PANELS • Cabin distortion when driving has been suppressed due to the crossmembers, attached on each side of and crossing over the transmission tunnel. These also heighten the rigidity of the front seat supports and improve handling. CROSSMEMBER CHU0910S002 End Of Sie HOOD CONSTRUCTION CHU091056601S01...
  • Page 414 DOORS AND LIFTGATE 09–11 DOORS AND LIFTGATE DOOR OUTLINE ....09–11–1 DOOR CONSTRUCTION ... . . 09–11–1 Features.
  • Page 415 DOORS AND LIFTGATE • A large-sized release handle located inside the rear door jamb is used to open the rear door. Due to this, a mechanism that keeps the rear door from opening if the front is not opened first has been adopted, and accidental opening is prevented.
  • Page 416 DOORS AND LIFTGATE FRONT DOOR CONSTRUCTION CHU091158010S03 • The inner construction of the door, including the power window regulator, door speaker, door harness and other parts, have been integrated into a single door unit. • Due to the integrated door unit, weight reduction has been achieved for the whole door. •...
  • Page 418 GLASS/WINDOWS/MIRRORS 09–12 GLASS/WINDOWS/MIRRORS REAR WINDOW DEFROSTER SYSTEM OUTER MIRROR STRUCTURAL OUTLINE ......09–12–1 VIEW ......09–12–4 REAR WINDOW DEFROSTER SYSTEM POWER MIRROR SYSTEM WIRING STRUCTURAL VIEW .

  • Page 419: Glass/Windows/Mirrors

    GLASS/WINDOWS/MIRRORS REAR WINDOW DEFROSTER SYSTEM WIRING DIAGRAM CHU091263000S03 REAR WINDOW DEFROSTER RELAY CLIMATE CONTROL UNIT HEATED OUTER MIRROR FILAMENT REAR WINDOW DEFROSTER FILAMENT MICROCOMPUTER REAR WINDOW DEFROSTER REAR WINDOW DEFROSTER SWITCH INDICATOR LIGHT CHU0912S007 End Of Sie POWER WINDOW SYSTEM OUTLINE CHU091258000S01 •...

  • Page 420: Power Window System Wiring Diagram

    GLASS/WINDOWS/MIRRORS POWER WINDOW SYSTEM WIRING DIAGRAM CHU091258000S03 DRL CONTROL MODULE (VEHICLE WITH DRL SYSTEM) DELAYED POWER CONTROL MODULE (VEHICLE WITHOUT DRL SYSTEM) POWER-CUT SWITCH POWER WINDOW MAIN SWITCH CLOSE CLOSE OPEN MANUAL AUTO OPEN OPEN OPEN CLOSE RELAY RELAY 09–12 POWER WINDOW OPEN CLOSE...

  • Page 421: Power Mirror System Wiring Diagram

    GLASS/WINDOWS/MIRRORS OUTER MIRROR STRUCTURAL VIEW CHU091269100S02 POWER OUTER MIRROR POWER MIRROR SWITCH FILAMENT (HEATED OUTER MIRROR ) CHU0912S004 End Of Sie POWER MIRROR SYSTEM WIRING DIAGRAM CHU091269100S03 POWER OUTER MIRROR SWITCH RIGHT/ LEFT/ LEFT RIGHT DOWN DOWN RIGHT LEFT RIGHT LEFT SIDE SIDE...

  • Page 422: Rearview Mirror System Wiring Diagram

    GLASS/WINDOWS/MIRRORS REARVIEW MIRROR STRUCTURAL VIEW CHU091269220S02 MANUAL DAY/NIGHT MIRROR AUTO-DIMMING MIRROR CHU0912S006 End Of Sie REARVIEW MIRROR SYSTEM WIRING DIAGRAM CHU091269220S03 09–12 AT: TR SWITCH (R RANGE ) MT: BACK-UP LIGHT SWITCH BACK-UP LIGHT AUTO-DIMMING MIRROR CHU0912S201 End Of Sie 09–12–5...

  • Page 423: Auto-Dimmimg Mirror Construction/Operation

    GLASS/WINDOWS/MIRRORS AUTO-DIMMIMG MIRROR CONSTRUCTION/OPERATION CHU091269220S04 Function • The auto-dimming mirror automatically reduces glare from rear car headlights when the auto-dimming mirror on/off switch is turned on. • The auto-dimming mirror comes with an integrated HomeLink Wireless Control System, which enables the programming of the mirror for activation of garage doors, electric gates, and home lighting.
  • Page 424 SEATS 09–13 SEATS SEAT OUTLINE....09–13–1 POWER SEAT SYSTEM WIRING SEAT SPECIFICATION....09–13–1 DIAGRAM .
  • Page 425 SEATS POWER SEAT SYSTEM WIRING DIAGRAM CHU091357101S01 SLIDE SWITCH RECLINER SWITCH FRONT TILT SWITCH REAR TILT SWITCH POWER SEAT SWITCH DOWN FORWARD DOWN BACKWARD BACKWARD FORWARD FRONT TILT MOTOR REAR TILT MOTOR SLIDE MOTOR RECLINER MOTOR LUMBAR SUPPORT SWITCH BACKWARD FORWARD LUMBAR SUPPORT MOTOR CHU0913S102...
  • Page 426 SEATS POWER SEAT CONSTRUCTION/OPERATION CHU091357101S02 • The following motors are built into the seat: — Slide motor — Recliner motor — Front tilt motor — Rear tilt motor — Lumbar support motor • The slide, front tilt and rear tilt switches are all operated by use of a single switch knob. RECLINER OPERATION SLIDE OPERATION FRONT TILT OPERATION...

  • Page 428: Security And Locks

    SECURITY AND LOCKS 09–14 SECURITY AND LOCKS SECURITY AND LOCKS OUTLINE ..09–14–1 IMMOBILIZER SYSTEM OUTLINE ..09–14–10 Features......09–14–1 IMMOBILIZER SYSTEM STRUCTURAL POWER DOOR LOCK SYSTEM VIEW .
  • Page 429 SECURITY AND LOCKS POWER DOOR LOCK SYSTEM STRUCTURAL VIEW CHU091401090S02 KEYLESS CONTROL MODULE DOOR LOCK SWITCH REAR DOOR UPPER LATCH SWITCH DOOR KEY CYLINDER SWITCH FRONT DOOR LOCK ACTUATOR (BUILT-IN DOOR LOCK-LINK SWITCH) DOOR SWITCH REAR DOOR LOWER LATCH SWITCH CHU0914S207 End Of Sie 09–14–2...
  • Page 430 SECURITY AND LOCKS POWER DOOR LOCK SYSTEM WIRING DIAGRAM CHU091401090S03 INSTRUMENT CLUSTER DOOR SWITCH (LH) DOOR FRONT DOOR SWITCH (RH) LOCK ACTUATOR KEYLESS REAR DOOR REAR DOOR CONTROL MODULE UPPER LATCH LOWER LATCH SWITCH SWITCH DOOR LOCK SWITCH (DRIVER'S SIDE) DOOR LOCK SWITCH (PASSENGER'S SIDE) DOOR KEY CYLINDER SWITCH...
  • Page 431 SECURITY AND LOCKS KEYLESS ENTRY SYSTEM STRUCTURAL VIEW CHU091401090S05 FLASHER CONTROL KEYLESS TRUNK LID OPENER MODULE RECEIVER CANCEL SWITCH DOOR LOCK SWITCH HORN KEYLESS CONTROL MODULE TRUNK LID OPENER RELAY KEY REMINDER REAR DOOR SWITCH UPPER LATCH SWITCH TRANSMITTER HORN RELAY DOOR KEY CYLINDER SWITCH FRONT DOOR...
  • Page 432 SECURITY AND LOCKS KEYLESS ENTRY SYSTEM WIRING DIAGRAM CHU091401090S06 KEYLESS CONTROL MODULE INSTRUMENT CLUSTER DOOR HORN SWITCH (LH) RELAY HORN DOOR SWITCH (RH) REAR DOOR REAR DOOR UPPER LATCH LOWER LATCH SWITCH SWITCH FLASHER CONTROL MODULE KEY REMINDER HAZARD WARNING SWITCH SWITCH DOOR LOCK SWITCH...
  • Page 433 SECURITY AND LOCKS THEFT-DETERRENT SYSTEM STRUCTURAL VIEW CHU091450000S02 KEYLESS RECEIVER DOOR LOCK SWITCH HORN KEYLESS CONTROL MODULE FLASHER CONTROL MODULE KEY REMINDER SWITCH REAR DOOR UPPER LATCH SWITCH HOOD LATCH SWITCH TRANSMITTER HORN RELAY DOOR KEY CYLINDER SWITCH DOOR LOCK-LINK SWITCH DOOR SWITCH...
  • Page 434 SECURITY AND LOCKS THEFT-DETERRENT SYSTEM WIRING DIAGRAM CHU091450000S03 INSTRUMENT CLUSTER HORN DOOR RELAY SWITCH (LH) HORN DOOR SWITCH (RH) REAR DOOR REAR DOOR KEYLESS UPPER LATCH LOWER LATCH CONTROL MODULE INSTRUMENT SWITCH SWITCH CLUSTER KEY REMINDER (SECURITY LIGHT) SWITCH DOOR LOCK SWITCH FLASHER CONTROL (DRIVER'S SIDE) MODULE...
  • Page 435 SECURITY AND LOCKS THEFT-DETERRENT SYSTEM OPERATION CHU091450000S04 Item Action Confirmation Note • Hazard warning lights • With any door open, the doors will The theft-deterrent system can be armed by performing the following flash once. not lock with the transmitter and the operations: theft-deterrent system will not arm •...
  • Page 436 SECURITY AND LOCKS System flowchart Deactivated Hazard warning light: off Horn: off Ignition switch to ON position Ignition switch to LOCK position or key reminder switch on and key reminder switch off Initial Hazard warning light: off Horn: off Under all the following conditions, lock doors with transmitter, key or *door lock switch: All door closed Trunk lid closed...
  • Page 437 AND CLEARING OUTLINE”. • • • • Two or more key ID numbers must be registered for the engine to start. For key ID number registration, refer the Mazda RX-8 Workshop Manual (1772-1U-03C) Section 09-14, “IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY ADDITION AND CLEARING”.
  • Page 438 SECURITY AND LOCKS IMMOBILIZER SYSTEM STRUCTURAL VIEW CHU091467000S02 SECURITY LIGHT COIL KEY (TRANSPONDER) 09–14 KEYLESS STARTER CONTROL MODULE RELAY CHU0914S202 End Of Sie IMMOBILIZER SYSTEM WIRING DIAGRAM CHU091467000S03 INSTRUMENT CLUSTER SECURITY LIGHT IG1 B+ KEYLESS COIL CONTROL STARTER MODULE RELAY TX LINE STARTER RX LINE...
  • Page 439 SECURITY AND LOCKS Immobilizer System Release Operation The ignition switch is turned from the LOCK (ACC) to the ON (START) position. (Security light illuminates.) (1) The keyless control module sends data A* to the key (transponder) via the coil. (2) The key (transponder) calculates data B from received data A and sends its specific key ID number and data B to the keyless control module via the coil.
  • Page 440 SECURITY AND LOCKS ON-BOARD DIAGNOSTIC SYSTEM (IMMOBILIZER SYSTEM) MALFUNCTION DIAGNOSIS FUNCTION CHU091467000S05 • The immobilizer system is provided with a malfunction diagnosis function. • Malfunction diagnosis of the immobilizer system occurs automatically when the ignition switch is turned from the LOCK (ACC) to the ON (START) position. •...
  • Page 441 SECURITY AND LOCKS WDS or equivalent display Detected condition Security light flashing pattern Keyless control module The keyless control module cannot read key ID B1602 P1260 number data normally. B1601 P1260 Unregistered key detected. Communication error between the keyless control U2510 P1260 module and the PCM (no response)
  • Page 442 • When replacing any of the immobilizer system component parts, adding/erasing keys or performing other functions, refer to the following table. For repair procedures, refer to the Mazda RX-8 Workshop Manual (1772- 1U-03C) Section 09-14, “IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY ADDITION AND CLEARING”.
  • Page 443 The on-board diagnostic system is initiated by the key reminder switch, ignition switch and driver-side door switch, and the following operations can be verified. Refer to the Mazda RX-8 Workshop Manual for detailed procedures and descriptions regarding the operations.
  • Page 444 • When replacing the keyless control module for vehicles with the immobilizer system, initialization configuration according to the vehicle information and immobilizer system resetting are required. Refer to the Mazda RX-8 Workshop Manual for detailed procedures and descriptions regarding the operations.
  • Page 445 SUNROOF 09–15 SUNROOF SLIDING SUNROOF OUTLINE..09–15–1 SLIDING SUNROOF OPERATION ..09–15–2 SUNROOF SPECIFICATION ..09–15–1 SUNROOF UNIT SLIDING SUNROOF STRUCTURAL CONSTRUCTION/OPERATION .
  • Page 446 SUNROOF SLIDING SUNROOF SYSTEM WIRING DIAGRAM CHU091501049S04 SUNROOF MOTOR HALL IC 2 HALL SLIDE SWITCH CONTROL IC 1 OPEN MODULE CLOSE DOWN INPUT TILT SWITCH SENSOR CHU0915S102 End Of Sie SLIDING SUNROOF OPERATION CHU091501049S05 • The glass panel opens/closes using tilting and sliding operations. •...
  • Page 447 SUNROOF SUNROOF UNIT CONSTRUCTION/OPERATION CHU091569850S01 • Consists of a glass panel, frame and sunroof motor. • The drive cables inside the frame are engaged with the sunroof motor drive gear so that when the motor rotates the drive cables also move. •...
  • Page 448 SUNROOF SUNROOF MOTOR CONSTRUCTION CHU091569873S01 • The motor consists of gear and control parts. • A magnetic wheel is provided on the motor shaft. • Two Hall ICs are provided in the control part. • The control unit detects the rotation direction, speed and amount based on pulse signals from the two Hall ICs, and controls the position and static load of the glass panel accordingly.

  • Page 449: Interior Trim

    INTERIOR TRIM 09–17 INTERIOR TRIM INTERIOR TRIM OUTLINE ... 09–17–1 INTERIOR TRIM STRUCTURAL VIEW . . 09–17–1 End of Toc INTERIOR TRIM OUTLINE CHU091755000S01 • The center module with integrated audio and climate control units, is located at the center of the dashboard panel.
  • Page 451 LIGHTING SYSTEMS 09–18 LIGHTING SYSTEMS LIGHTING SYSTEMS OUTLINE ..09–18–1 Operation When Driving ... . 09–18–7 LIGHTING SYSTEMS AUTO LEVELING CONTROL MODULE SPECIFICATION ....09–18–1 FUNCTION .
  • Page 452 LIGHTING SYSTEMS Item Specifications 5 × 2 Map light bulb 10 × 1 Interior light bulb 5 × 2 Courtesy light bulb 5 × 1 Trunk compartment light bulb Interior light bulb capacity 1.7 × 1 Glove compartment light bulb 1.4 ×...
  • Page 453 LIGHTING SYSTEMS FRONT COMBINATION LIGHT CONSTRUCTION CHU091851060S01 • A headlight with built-in front turn light and parking light has been adopted for design improvement. • Projector type headlights have been adopted, and these have been incorporated, along with the front turn light and the parking light, into a single unit to reduce size.
  • Page 454 LIGHTING SYSTEMS DISCHARGE HEADLIGHT STRUCTURAL VIEW CHU091801052S02 DISCHARGE HEADLIGHT BULB HEADLIGHT DISCHARGE CONTROL MODULE SEC. A—A CHU0918S132 End Of Sie DISCHARGE HEADLIGHT OPERATION CHU091801052S03 1. A high voltage pulse (approx. 25,000 V) traveling from the discharge headlight control unit is applied between both discharge headlight bulb terminals, energizing the xenon gas in the bulb.
  • Page 455 Warning • Incorrect servicing of the discharge headlights could result in electrical shock. Before servicing the discharge headlights, always refer to the discharge headlight service warnings. (See Mazda RX-8 Workshop Manual (1772-1U-03C).) • Built into the headlight and installed on the headlight lower side.
  • Page 456 LIGHTING SYSTEMS HEADLIGHT AUTO LEVELING SYSTEM DIAGRAM CHU091801052S08 REAR AUTO FRONT AUTO LEVELING SENSOR LEVELING SENSOR ABS HU/CM INSTRUMENT AUTO LEVELING CONTROL MODULE CLUSTER DSC HU/CM HEADLIGHT LEVELING HEADLIGHT LEVELING ACTUATOR (RH) ACTUATOR (LH) CHU0918S112 End Of Sie 09–18–6...
  • Page 457 LIGHTING SYSTEMS HEADLIGHT AUTO LEVELING SYSTEM OPERATION CHU091801052S09 Varying Passenger and Cargo Conditions Operation 1. According to the fluctuation of the suspension, the auto leveling sensors installed in the front and rear of the vehicle send a signal to the auto leveling control module. 2.
  • Page 458 LIGHTING SYSTEMS AUTO LEVELING CONTROL MODULE FUNCTION CHU091801052S10 • In order to prevent blinding from oncoming traffic and to improve visibility, the auto leveling control module automatically controls the optical axis direction for optimal illumination based on signals input from the ABS (DSC) HU/CM and the auto leveling sensor.
  • Page 459 LIGHTING SYSTEMS Item Test condition Fail-safe function Indicator light Cancel condition ABS (DSC) HU/CM Vehicle speed of 180 km/h or more Fixes the optical Not illuminated Vehicle speed of detected axis angle at the less than 180 km/h position where detected vehicle speed of 180 km/h or more...
  • Page 460 LIGHTING SYSTEMS LICENSE PLATE LIGHT CONSTRUCTION CHU091851270S01 • Installed to the rear bumper with the connecting tabs. REAR BUMPER LICENSE PLATE LICENSE PLATE LIGHT LIGHT BULB SEC. A—A SEC. B—B CHU0918S135 End Of Sie DRL SYSTEM OUTLINE CHU091801056S01 • The DRL system automatically operates the low-beam headlights when the ignition switch is turned to the ON position.
  • Page 461 LIGHTING SYSTEMS DRL SYSTEM WIRING DIAGRAM CHU091801056S03 HEADLIGHT RELAY DRL CONTROL MODULE HEAD LL 15 A FUSE 15 A FUSE HEAD LR 15 A FUSE HEADLIGHT FRONT FOG RELAY 15 A FUSE FRONT FOG LIGHT ROOM DRL 1 RELAY 30 A FUSE HEADLIGHT HEADLIGHT (LH)
  • Page 462 LIGHTING SYSTEMS INTERIOR LIGHTING SYSTEM CONSTRUCTION CHU091851311S02 • The map light is located on the roof, towards the front. There are two types of map lights: one for vehicles with sunroofs and one for vehicles without. • The map, interior and courtesy lights settings are controlled by the interior light control system. ×: Equipped –: Not equipped Installation...
  • Page 463 LIGHTING SYSTEMS ROOM LIGHT CONTROL SYSTEM FUNCTION CHU091851311S03 • The interior light control system turns on, turns off, or dims the interior light when the interior light switch is in the DOOR position. INTERIOR COURTESY LIGHT LIGHT LIGHT KEYLESS SWITCH DOOR DOOR KEYLESS CONTROL MODULE...
  • Page 464 LIGHTING SYSTEMS Interior light Conditions before operation Operation Cancel condition Illuminat Brightne (Conditions which must be satisfied) condition (When any condition satisfied) ion time • Turn the ignition switch to the • Turn the ignition switch to the ON LOCK or ACC position. position.
  • Page 465 LIGHTING SYSTEMS IGNITION KEY ILLUMINATION FUNCTION CHU091851311S05 • The illumination time of the ignition key illumination is controlled by the microcomputer in the instrument cluster. • The ignition key illumination glows when the ignition switch is at the LOCK or ACC position and any door is open.
  • Page 467 WIPER/WASHER SYSTEM 09–19 WIPER/WASHER SYSTEM WIPER/WASHER SYSTEM OUTLINE . . 09–19–1 WINDSHIELD WASHER TANK WIPER/WASHER SYSTEM SPECIFICATION ....09–19–4 STRUCTURAL VIEW ....09–19–1 WASHER FLUID-LEVEL SENSOR WINDSHIELD WIPER SYSTEM FUNCTION .
  • Page 468 WIPER/WASHER SYSTEM WINDSHIELD WIPER SYSTEM OUTLINE CHU091901052S03 • The windshield wiper system has autostop function, one-touch function, and intermittent function with various timings. End Of Sie WINDSHIELD WIPER SYSTEM WIRING DIAGRAM CHU091901052S04 End Of Sie IG 1 WINDSHIELD WINDSHIELD ONE-TOUCH WIPER WIPER ONE-TOUCH...
  • Page 469 WIPER/WASHER SYSTEM Autostop Function • While the wipers are operating, the autostop switch remains on except when the wipers are in the park position. Current flows through the INT relay to the windshield wiper switch, windshield wiper motor, then to ground. Thus, the wipers continue to operate until they reach the park position even if the windshield wiper switch moves to the OFF position.
  • Page 470 WIPER/WASHER SYSTEM Intermittent Wiper Operation • When the windshield wiper switch moves to the INT position, the intermittent wiper (INT) relay turns on, and current flows through the INT relay to the windshield wiper switch, windshield wiper motor, then to ground. The wipers operate at low speed.
  • Page 471 WIPER/WASHER SYSTEM WASHER FLUID-LEVEL SENSOR FUNCTION CHU091967488S01 • Warn the driver that the washer fluid-level is low. WASHER FLUID-LEVEL INDICATOR LIGHT INSTRUMENT CLUSTER CHU0919S114 09–19 INSTRUMENT CLUSTER MICROCOMPUTER WASHER FLUID-LEVEL INDICATOR LIGHT WASHER FLUID-LEVEL SENSOR CHU0919S115 End Of Sie HEADLIGHT CLEANER SYSTEM OUTLINE CHU091901052S06 •...
  • Page 472 WIPER/WASHER SYSTEM HEADLIGHT CLEANER SYSTEM WIRING DIAGRAM CHU091901052S07 WINDSHIELD WIPER AND WASHER SWITCH WINDSHIELD WASHER SWITCH HEADLIGHT RELAY RELAY HEADLIGHT CLEANER RELAY HEADLIGHT HEADLIGHT HEADLIGHT WINDSHIELD CLEANER MOTOR SWITCH WASHER MOTOR HEADLIGHT CHU0919S108 End Of Sie 09–19–6...
  • Page 473 WIPER/WASHER SYSTEM HEADLIGHT CLEANER SYSTEM OPERATION CHU091901052S08 Auto-operation • If the windshield washer switch is turned on when the ignition and headlight switches are at the ON position, the headlight cleaner motor operates. • The headlight cleaner operates only one time for every five times the windshield washer switch is operated. •...
  • Page 474 WIPER/WASHER SYSTEM HEADLIGHT CLEANER ACTUATOR OPERATION CHU091901052S09 • The headlight cleaner nozzle is held retracted by a spring within the headlight cleaner actuator. • When fluid pressure rises due to the operation of the headlight cleaner motor, the piston in the headlight cleaner actuator is pushed, causing the nozzle to pop out of the front bumper and spray washer fluid.
  • Page 475 ENTERTAINMENT 09–20 ENTERTAINMENT ENTERTAINMENT OUTLINE ..09–20–2 CAR-NAVIGATION SYSTEM AUDIO SYSTEM STRUCTURAL SPECIFICATIONS ....09–20–16 VIEW ......09–20–2 Car-navigation Unit .

  • Page 476: Entertainment

    ENTERTAINMENT ENTERTAINMENT OUTLINE CHU092001066S01 • The center panel module installed with the audio unit and the audio switch, A/C switch, hazard warning switch and rear window defroster switch built into the center panel has been adopted. • The audio unit consists of the following parts: —...

  • Page 477: Audio System Block Diagram

    ENTERTAINMENT AUDIO SYSTEM BLOCK DIAGRAM CHU092001066S03 BOSE Specification Vehicles FRONT DOOR AUDIO ANTENNA INFORMATION SPEAKER AMPLIFIER UNIT DISPLAY CENTER PANEL FRONT TWEETER MODULE (RIGHT) (BUILT-IN AUDIO AUDIO UNIT) FRONT DOOR CONTROL SPEAKER (RIGHT) CIRCUIT CENTER SPEAKER FRONT DOOR MAIN SPEAKER (LEFT) BASE UNIT AUDIO AMPLIFIER...

  • Page 478: Audio System Specifications

    ENTERTAINMENT AUDIO SYSTEM SPECIFICATIONS CHU092001066S04 Audio Unit Specification Item BOSE Standard Rated voltage (kHz) 530—1620 Frequency band (MHz) 87.5—108.0 External type audio amplifier • Main amplifier Audio amplifier maximum — 25×3 25×4 output power — 12.75×2 • Front door speaker amplifier —...

  • Page 479: Terminal Layout And Signal

    ENTERTAINMENT Terminal Layout and Signal Audio unit Terminal Signal Left front speaker (+) B+ (Power back up) Left front speaker (–) Right front speaker (+) TNS (+) Right front speaker (–) Illumination (–) AudioPilot control Vehicle speed signal AMP. control UART 1 (car-navigation signal 1) TEL.

  • Page 480: Switch/Button Location

    ENTERTAINMENT Information display harness Terminal Signal LCD DRV (8 V) ACC (5 V) LCD CONT. RC LCD CONT. AC LCD CONT. CS LCD CONT. SCL LCD CONT. DATA — LCD CONT. INH Digital ground TNS (8V) Power ground — — —...

  • Page 481: Terminal Layout And Signal

    ENTERTAINMENT Switch/button Related system Switch/button Related system Preset button “6” Audio system A/C switch Air conditioner system SCAN (upper) button Audio system Rear window defroster switch Rear window SCAN (lower) button Audio system defroster system TUNE AUTO-M button Audio system REC/FRESH switch Air conditioner TEXT AUDIO CONT button...

  • Page 482: Auto Level Control (Alc)

    ENTERTAINMENT Auto Level Control (ALC) Function • Adjusts the audio volume so that the sound is balanced against wind and road noise while driving. Operation • The audio unit changes the volume automatically based on the vehicle speed signal sent from the ABS HU/CM (with ABS) or DSC HU/CM (with DSC).

  • Page 483: Audiopilot (Bose Specification Vehicle)

    ENTERTAINMENT AudioPilot (BOSE specification vehicle) Function • Measures the driving noise level inside the vehicle with a specialized microphone, and the main amplifier modifies the volume accordingly. Due to this, passengers can enjoy music with constant sufficient volume. Construction/Operation • A microphone is installed on the lower panel. •...
  • Page 484 ENTERTAINMENT Display function • When the self-diagnostic function is activated, the information display displays the DTC stored in the memory. • The DTC consists of the following codes and numbers: — Supplier code (indicates manufacturer) — Part number (indicates malfunctioning part) —...

  • Page 485: Diagnostic Assist Function

    ENTERTAINMENT Diagnostic Assist Function • The diagnostic assist function displays the operating condition of the following functions (components) and forces them to operate in order to examine whether they are malfunctioning or not. • For the start procedure of each mode, refer to the Service Section. •...

  • Page 486: Audio Amplifier Construction

    ENTERTAINMENT Audio amplifier (external) • The diagnostic assist function displays the output AUDIO AMPLIFIER OPERATING SIGNAL IS OUTPUT state of the audio amplifier operating signal to determine condition of the audio amplifier, base unit, and wiring harness between the base unit and audio amplifier.

  • Page 487: Front Door Speaker Amplifier

    ENTERTAINMENT Signal Terminal 8-pin connector Power GND Center speaker output (–) Center speaker output (+) — — — — Front Door Speaker Amplifier • Located in the front door trim. • A digital amplifier (switching amplifier) has been adopted. • On/off digital signals are amplified and output, allowing power conservation and lower heat generation. Due to this, a radiating plate (heat sink) is not required, and downsizing of the amplifier has been achieved.

  • Page 488: Audio Control Switch Outline

    ENTERTAINMENT ANTENNA CONSTRUCTION CHU092066939S01 Glass Antenna • A glass antenna with high noise resistance has been adopted inside the rear window glass. End Of Sie AUDIO CONTROL SWITCH OUTLINE CHU092000148S01 • A steering wheel remote control for the audio system, with simplified design for easy operation, has been adopted.

  • Page 489: Car-Navigation System Structural View

    ENTERTAINMENT CAR-NAVIGATION SYSTEM STRUCTURAL VIEW CHU092066000S02 CAR-NAVIGATION UNIT LCD UNIT AUDIO UNIT GPS ANTENNA FRONT TWEETER MAIN AMPLIFIER (BOSE) FRONT DOOR SPEAKER FRONT DOOR SPEAKER AMPLIFIER (BOSE) CAR-NAVIGATION CONTROL SWITCH BACK-UP LIGHT SWITCH (MT) 09–20 TR SWITCH (AT) DSC HU/CM (WITH DSC) OR ABS HU/CM (WITH ABS) CHU0920S100 End Of Sie...

  • Page 490: Car-Navigation System Specifications

    ENTERTAINMENT CAR-NAVIGATION SYSTEM BLOCK DIAGRAM CHU092066000S03 CAR-NAVIGATION UNIT VEHICLE SPEED SIGNAL ABS HU/CM (WITH ABS) OR DSC HU/CM (WITH DSC) R-RANGE TR SWITCH (AT) OR SIGNAL BACK-UP LIGHT SWITCH (MT) GPS ANTENNA PARKING BRAKE SWITCH RECEIVER PARKING BRAKE GYRO SIGNAL SENSOR LCD UNIT DVD DRIVER...

  • Page 491: Component Part And Function

    ENTERTAINMENT COMPONENT PART AND FUNCTION CHU092066000S05 Item Function • Reads the data (map, voice and other) from the DVD-ROM. Car-navigation unit • Calculates and displays the vehicle’s position from various signals. • Calculates the route to the destination. • Navigates the driver to the destination using the map screen and/or the voice. Note •...

  • Page 492: Terminal Layout And Signals

    ENTERTAINMENT Terminal Layout and Signals Signals Terminal 16-pin connector – PR front speaker input (-) Illumination (-) PR front speaker input (+) Vehicle speed signal PR front speaker output (-) Parking brake signal PR front speaker output (+) R-range signal Front speaker output (-) Front speaker output (+) Front speaker input (-)

  • Page 493: Gyro Sensor Function

    ENTERTAINMENT Signals Terminal 8-pin connector (for extended function) – 3G 3E 3C 3A Serial output – Serial input Power Reset 3F 3D 3B Signal Terminal 1-pin connector GPS antenna input End Of Sie GYRO SENSOR FUNCTION CHU092066902S03 • The gyro sensor is located in the navigation unit. The sensor converts yaw rate, which is one of the inputs used in calculating the vehicle’s direction of travel from the vehicle’s cornering angle, into electrical signals.

  • Page 494: Autonomous Navigation Operation

    ENTERTAINMENT • The pick-up sides are distorted by Coriolis force , which happens as a result of the turning arc and its effect on the center axis of the sensor pillar. Two piezoelectric pick-up sides convert the distortion amount into two electrical signals to indicate the exact yaw ratio.

  • Page 495: Gps (Global Positioning System) Navigation Operation

    ENTERTAINMENT GPS (GLOBAL POSITIONING SYSTEM) NAVIGATION OPERATION CHU092066902S07 Principles of Measurement • A vehicle's present position is defined as X , and Z , with the center of the earth being the point of reference. A GPS satellite sends its position (X , and Z ) and time T when it sends the signal.

  • Page 496: Map Matching Outline

    ENTERTAINMENT End Of Sie MAP MATCHING OUTLINE CHU092066902S08 • This function compares the route shape the vehicle is travelling to map data using the GPS satellite signals, and corrects the vehicle's position to the most appropriate road on the map data. MAP-MATCHED ROUTE ACTUAL INDICATED ROUTE...
  • Page 497 ENTERTAINMENT Cause (Condition) Driving condition Remarks (Solution etc.) • At a Y-shaped fork in the road where the roads separate gradually, the vehicle locator mark may be displayed on the wrong road. • If the vehicle makes continuous, large turns, for example on a loop structure, the vehicle locator mark may go off the road altogether.
  • Page 498 ENTERTAINMENT Cause (Condition) Driving condition Remarks (Solution etc.) • If there are parallel roads nearby, for example motorways and service roads, the vehicle locator mark may go off the road. • If driving in an area where roads are not available on the map, the vehicle locator mark may deviate from the correct position when the vehicle returns to the road.
  • Page 499 ENTERTAINMENT Cause (Condition) Driving condition Remarks (Solution etc.) • If driving on a new road not registered in the map data, the navigation system may incorrectly match the vehicle’s position with a nearby road and when the vehicle returns to a road available in the map data, the vehicle locator mark may be off the correct road.

  • Page 500: Lcd Unit Outline

    ENTERTAINMENT Cause (Condition) Driving condition Remarks (Solution etc.) • In locations such as cities where there are • Input with precision (A) of a lot of roads, if the setting accuracy is approx. 1 mm {0.039 in} on poor when the vehicle’s position is moved, the screen with a road the navigation system may be unable to displayed on the vehicle...

  • Page 501: Terminal Layout And Signal

    ENTERTAINMENT Terminal Layout and Signal Signal Terminal 24-pin connector Video (B) Video (G) Video (composite sync) Video (R) Video GND Video GND Shield GND Video input Monitor serial output 1 Shield GND Monitor serial output 2 — Control illumination — Parking brake signal Shield GND R-range signal...

  • Page 502: Car-Navigation Control Switch Outline

    ENTERTAINMENT CAR-NAVIGATION CONTROL SWITCH OUTLINE CHU092066921S01 • A remote control for the car-navigation system, with simplified design for easy operation, has been adopted. End Of Sie CAR-NAVIGATION CONTROL SWITCH CONSTRUCTION/OPERATION CHU092066921S02 Construction • The car-navigation control switch is located on the console. CAR-NAVIGATION CONTROL SWITCH CHU0920S114...
  • Page 503 ENTERTAINMENT End Of Sie NAVIGATION FUNCTION CHU092066000S06 Outline • A vehicle's position is measured by a hybrid method of autonomous navigation (using yaw-rate signals from the gyro sensor and vehicle speed signals from the DSC HU/CM (with DSC) or ABS HU/CM (with ABS) and GPS navigation (using signals from GPS satellites).
  • Page 504 ENTERTAINMENT Scroll map mode • The scroll map is displayed when operating the joystick on the current position map. • This map can be scrolled with the crosshair cursor. • By moving the crosshair cursor to a road and pressing [ENTER] button, the road name is displayed on the screen.

  • Page 505: Pop-Up Menu

    ENTERTAINMENT Pop-up Menu • Pop-up menu appears when pressing [ENTER] button. • The following items are displayed on the pop-up menu. The actual displayed items vary according to the selected map, guidance, and other factors. Note • Pop-up menu is not available on intersection zoom maps. •...
  • Page 506 ENTERTAINMENT Destination Setting Function Outline • The following instructions explain how destinations can be chosen and set. Note • A destination can be set to where the crosshair cursor indicates by selecting the Destination option of the scroll map mode pop-menu. Area Street Address...
  • Page 507 ENTERTAINMENT POI categories • When setting POI destination, the following categories can be selected. Data for categories according to the selected country will be displayed. CHU0920S128 09–20 Auto services Ski resort Auto repair Stadium/arena Automobile association Theater Gas station Tourist attraction Park &...
  • Page 508 ENTERTAINMENT Route Search Function Whole route search function • After setting a destination, the following route search methods can be used: Items Route search method • Selects a route according to the shortest distance. Shortest route setting • Selects a route that reduces use of motorways. Avoid motorway setting Detour function •...
  • Page 509 ENTERTAINMENT Contents Selected items Default Sets map screen color (daytime). Green, Beige, Black Beige Sets map screen color (nighttime). Green, Beige, Black Beige Sets map direction. North up, Head up North up Sets display of the vehicle position indicator on the map Center: The current vehicle position Center screen.
  • Page 510 ENTERTAINMENT Guidance Function • When using route guidance, the map displays and the system voice announces upcoming intersections, highway entrances/ exits, destination information, and passing via points. • The types of voice guidance are as follows: — Normal intersection guidance —...
  • Page 511 ENTERTAINMENT Multiple junction guidance • A multiple junction condition occurs when the distance from the first to the second turn point is less than or equal to 150 meters {492 feet}. • When the last guidance for the first turn point is announced, guidance for the second turn point is also provided. RIGHT TURN FOLLOWED BY LEFT TURN GUIDANCE EXAMPLE IN 300 METERS RIGHT TURN AHEAD,...
  • Page 512 ENTERTAINMENT Continuous highway junction guidance • A continuous highway junction condition occurs when the distance from the first to the second turn point is more than 500 meters {1640 feet} and less than or equal to 750 meters {2460 feet}. •...

  • Page 513: Intersection Distance Display

    ENTERTAINMENT Intersection Distance Display • When approaching the next guidance point, the distance to that point is counted down. • In case of a continuous or multiple junction, guidance point bars for the next two turns will be displayed. • In case of a continuous or multiple junction, after the first turn point is passed the following occurs: 1.

  • Page 514: Operation While Driving Display Function

    ENTERTAINMENT Operation While Driving Display Function Screen activation • The following operation while driving warning screen appears when the unit determines from the pulse of the speedometer sensor that the vehicle is moving. A6E8126T076 Activation condition • When driving and the following screens are displayed, operating the following buttons will activate the warning screen.
  • Page 515 POWER SYSTEMS 09–21 POWER SYSTEMS POWER SYSTEMS OUTLINE..09–21–1 POWER SYSTEMS STRUCTURAL VIEW ......09–21–1 End of Toc POWER SYSTEMS OUTLINE CHU092167730S01...
  • Page 517 INSTRUMENTATION/DRIVER INFO. 09–22 INSTRUMENTATION/DRIVER INFO. INSTRUMENT CLUSTER OUTLINE..09–22–1 SPEEDOMETER CONTROL INSTRUMENT CLUSTER CONSTRUCTION/OPERATION ..09–22–10 SPECIFICATIONS ....09–22–1 System Wiring Diagram .
  • Page 518 INSTRUMENTATION/DRIVER INFO. Item Specification Meter type Stepping motor type (rpm) 0—9,000 (13B-MSP (Standard Power)) Indication range 0—10,000 (13B-MSP (High Power)) (rpm) 7,500—9,000 (13B-MSP (Standard Power)) Red zone Tachometer 9,000—10,000 (13B-MSP (High Power)) Input signal communication system CAN system Input signal source Rated voltage DC 12 Meter type...

  • Page 519: Instrument Cluster Structural View

    INSTRUMENTATION/DRIVER INFO. End Of Sie INSTRUMENT CLUSTER STRUCTURAL VIEW CHU092255430S03 Meter And Gauge TRIPMETER TACHOMETER WATER SWITCH SPEED UNIT TEMPERATURE SELECTOR OIL PRESSURE GAUGE GAUGE FUEL GAUGE BRAKE ODOMETER/ TRIPMETER SPEEDOMETER CHU0922S009 Warning And Indicator Light 09–22 BRAKE CHU0922S001 X: Applied 09–22–3...
  • Page 520 INSTRUMENTATION/DRIVER INFO. Warning and indicator Input signal source CAN system Note light EPS warning light EPS control module — Washer fluid-level warning With washer fluid-level warning Washer fluid-level sensor — light system Tire pressure warning light TPMS control module — Fuel-level warning light Fuel gauge sender unit —...

  • Page 521: Instrument Cluster System Wiring Diagram

    INSTRUMENTATION/DRIVER INFO. INSTRUMENT CLUSTER SYSTEM WIRING DIAGRAM CHU092255430S04 FUEL GAUGE OIL PRESSURE WATER GAUGE TEMPERATURE TACHOMETER GAUGE TNS INDICATOR INSTRUMENT CLUSTER LIGHT ILLUMINATION DIMMER SWITCH ODOMETER/ SPEEDOMETER TRIPMETER CAN SYSTEM-RELATED MODULE MICROCOMPUTER SPEED UNIT SELECTOR DOOR SWITCH DOOR SWITCH (RR) (PASSENGER'S SIDE) IIGNITION KEY ILLUMINATION...

  • Page 522: Input/Output Check Mode Outline

    INSTRUMENTATION/DRIVER INFO. AIR BAG SYSTEM WARNING LIGHT SAS CONTROL MODULE TURN INDICATOR LIGHT(LH) FRONT TURN LIGHT (LH) TURN INDICATOR LIGHT (RH) SECURITY LIGHT FLASHER KEYLESS CONTROL CONTROL OIL LEVEL TURN MODULE MODULE WARNING LIGHT SWITCH DSC INDICATOR LIGHT DSC OFF LIGHT HAZARD REAR ABS WARNING...

  • Page 523: Input/Output Check Mode Operation

    INSTRUMENTATION/DRIVER INFO. INPUT/OUTPUT CHECK MODE OPERATION CHU092255430S06 Operation procedure • Refer to RX-8 Workshop Manual. Input circuit check • When the parts listed in the chart are operated and output a signal to the instrument cluster, the built in microcomputer judges the quality of the input circuit based on that signal. Check Check Parts sending input signal...

  • Page 524: Individual Circuit Check

    INSTRUMENTATION/DRIVER INFO. Individual circuit check • By operating the parts listed in the chart, the built in microcomputer judges the quality of the individual parts. Check Check Parts sending input signal Parts sending input signal code code Ignition key illumination Speedometer Fuel gauge Tachometer...

  • Page 525: Over-Revolution Warning Alarm Outline

    INSTRUMENTATION/DRIVER INFO. LIGHTS-ON REMINDER WARNING ALARM CONSTRUCTION/OPERATION CHU092255430S08 System Wiring Diagram RELAY INSTRUMENT LIGHT CLUSTER SWITCH BUZZER MICROCOMPUTER DOOR SWITCH (DRIVER'S SIDE) CHU0922S101 Operation • The buzzer in the instrument cluster sounds continuously when all the following three conditions are met: —...

  • Page 526: Speedometer Control Outline

    INSTRUMENTATION/DRIVER INFO. SPEEDOMETER CONTROL OUTLINE CHU092255430S11 • The vehicle speed signal is output from the ABS HU/CM or DSC HU/CM to the microcomputer in the instrument cluster. End Of Sie SPEEDOMETER CONTROL CONSTRUCTION/OPERATION CHU092255430S12 System Wiring Diagram IG1 B+ SPEEDOMETER INSTRUMENT CLUSTER MICROCOMPUTER...

  • Page 527: Fuel Gauge Control Outline

    INSTRUMENTATION/DRIVER INFO. FUEL GAUGE CONTROL OUTLINE CHU092255430S15 • The fuel level signal is output from the fuel gauge sender unit to the microcomputer in the instrument cluster. Fuel gauge variation caused by fluctuating fuel level when cornering or driving on a slope, is reduced by microcomputer control.

  • Page 528: Oil Pressure Gauge Control Outline

    INSTRUMENTATION/DRIVER INFO. OIL PRESSURE GAUGE CONTROL OUTLINE CHU092255430S19 • The oil pressure signal is output from the PCM to the microcomputer in the instrument cluster. End Of Sie OIL PRESSURE GAUGE CONTROL CONSTRUCTION/OPERATION CHU092255430S20 System Wiring Diagram IG1 B+ OIL PRESSURE GAUGE INSTRUMENT CLUSTER...
  • Page 529 INSTRUMENTATION/DRIVER INFO. Clock function • A clock is integrated. • Time can be adjusted with the buttons on the center panel module. CENTER PANEL MODULE TIME DISPLAY SET BUTTON CLOCK BUTTON CHU0922S007 End Of Sie HORN CONSTRUCTION CHU092266790S01 • A trumpet-type horn with spiral-shaped resonant pipes has been adopted. Horns are located symmetrically, one each on the right and left.
  • Page 531 CONTROL SYSTEM 09–40 CONTROL SYSTEM CONTROLLER AREA NETWORK (CAN) Twisted Pair ..... 09–40–2 SYSTEM OUTLINE ....09–40–1 Time Division Multiplex .
  • Page 532 CONTROL SYSTEM CAN SYSTEM DESCRIPTION CHU094055430S04 Mechanism of CAN System-Related Module • A CAN system-related module is composed of an electrical circuit, CPU, and input/output interface. • The size of the module has been reduced due to the elimination of the bulky, superfluous, input/output interface in the conventional type of electrical module.
  • Page 533 CONTROL SYSTEM Time Division Multiplex • For information exchange between electrical modules in a conventional system, a wire connection was necessary for each information signal. However, by sending different signals at varying times over one channel, it is possible to send a large amount of information via a small harness. •...
  • Page 534 CONTROL SYSTEM CAN Signal-Chart OUT: Output (sends signal) IN: Input (receives signal) Multiplex module ABS HU/ Keyless TPMS Steering Signal Instrument control TCM (AT) control control angle cluster DSC HU/ module module module sensor – – – – – – Immobilizer-related information –...
  • Page 535 CONTROL SYSTEM Multiplex module ABS HU/ Keyless TPMS Steering Signal Instrument control TCM (AT) control control angle cluster DSC HU/ module module module sensor ABS/ Brake system – – – EBD/ status ABS/ – Torque down request – – – –...
  • Page 536 CONTROL SYSTEM Block diagram WITH DSC STEERING KEYLESS CONTROL ANGLE CONTROL MODULE SENSOR MODULE INSTRUMENT CLUSTER WITH ABS ABS HU/CM TPMS TWISTED PAIR DLC-2 CONTROL MODULE : CAN_H : CAN_L WITH DSC DSC HU/CM CHU0940S002 Failure detection function • The failure detection function in each CAN system-related module detects malfunctions in input/output signals. •...
  • Page 537 CONTROL SYSTEM DTC table Malfunction location Module outputting DTC • PCM • TCM U0073 CAN system communication error • EPS control module • Keyless control module U0100 Communication error to PCM U0101 Communication error to TCM U0121 Communication error to ABS HU/CM U0155 Communication error to instrument cluster U0167...
  • Page 538 CONTROL SYSTEM Flowchart START Verify that DTCs are displayed for PCM, TCM, ABS HU/CM, DSC HU/CM, EPS control module, keyless control module, TPMS control module and instrument cluster. Are any DTCs display? Verify that PID/data monitor is displayed for instrument cluster. ABS_MSG TCM_MSG PCM_MSG...
  • Page 539 CONTROL SYSTEM 2. PID/data monitor information for the ABS HU/CM and instrument cluster can be verified using an SST (WDS or equivalent). Module PID name (definition) Condition Probable malfunction point PCM_MSG ABS HU/CM Not Present Communication error between ABS HU/CM and PCM (Missing message from the PCM) PCM_MSG Communication error between instrument cluster and...

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