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2006 SX4
Suzuki 2006 SX4 Manuals
Manuals and User Guides for Suzuki 2006 SX4. We have
2
Suzuki 2006 SX4 manuals available for free PDF download: Service Manual
Suzuki 2006 SX4 Service Manual (1556 pages)
Brand:
Suzuki
| Category:
Automobile
| Size: 60.82 MB
Table of Contents
Table of Contents
5
Precautions
8
Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System
8
General Precautions
10
Exhaust System
11
Warning for Wheel (with Tire) Removal
13
Precautions for Catalytic Converter
14
Precautions in Servicing 4WD Model
14
Precaution for CAN Communication System
15
Precautions for Electrical Circuit Service
15
Air Bag Warning
17
Air Bag System Service Warning
17
Fastener Caution
18
Suspension Caution
18
Wheels and Tires Caution
18
Brake Caution
18
Precautions for Installing Mobile Communication Equipment
15
Repair Instructions
19
Electrical Circuit Inspection Procedure
19
Intermittent and Poor Connection Inspection
21
Section 0 General Information
23
General Information
23
Maintenance and Lubrication
23
Differential
25
Rear Suspension
28
Engine Identification Number
29
Vehicle Identification Number
29
Fuel System
32
Engine Oil and Filter Change
35
Engine Coolant Change
36
Exhaust System Inspection
36
Spark Plug Replacement
36
Air Cleaner Filter Inspection
37
Air Cleaner Filter Replacement
37
Fuel Evaporative Emission Control System
37
Fuel Filter Replacement
37
Fuel Lines and Connections Inspection
37
Fuel Tank Inspection
37
Inspection
37
PCV Valve Inspection
37
Brake Discs and Pads (Front) Inspection
38
Brake Drums and Shoes (Rear) Inspection
38
Brake Fluid Replacement
38
Brake Hoses and Pipes Inspection
38
Brake Lever and Cable Inspection
38
Clutch Fluid Inspection
39
Tires Inspection
39
Wheel Bearing Inspection
39
Wheel Discs Inspection
39
Drive Shaft (Axle) Boots Inspection
40
Front Suspension
40
Steering System Inspection
40
Suspension System Inspection
40
Automatic Transaxle Fluid Cooler Hose
41
Automatic Transaxle Fluid Level Inspection
41
Automatic Transaxle Fluid Replacement
41
Inspection
41
Manual Transaxle Oil Inspection
41
Manual Transaxle Oil Replacement
41
Propeller Shaft (4WD) Inspection
41
Rear Deferential Oil Inspection (4WD)
41
Transfer Oil Inspection (4WD)
41
Transfer Oil Replacement (4WD)
41
Final Inspection for Maintenance Service
42
HVAC Air Filter (if Equipped) Inspection
42
HVAC Air Filter (if Equipped) Replacement
42
Specifications
43
Special Tools and Equipment
43
Recommended Fluids and Lubricants
43
Special Tool
43
Tightening Torque Specifications
43
Section 1 Engine
45
Precautions
50
Precautions for Engine
50
Engine General Information and Diagnosis
51
Precautions
51
Precautions on Engine Service
51
Precaution on On-Board Diagnostic (OBD) System
51
Precautions in Diagnosing Trouble
51
Precautions for DTC Troubleshooting
52
Precautions of ECM Circuit Inspection
52
Precautions of Electric Throttle Body System Calibration
52
Precaution on CAN Troubleshooting
53
General Description
55
Statement on Cleanliness and Care
55
Engine Diagnosis General Description
55
On-Board Diagnostic System Description
55
Data Link Connector (DLC)
58
Engine and Emission Control System Description
58
CAN Communication System Description
59
Air Intake System Description
61
Description of Electric Throttle Body System Calibration
61
Description of Electric Throttle Body System
61
Immobilizer Control System
62
Engine and Emission Control Input / Output Table
68
Schematic and Routing Diagram
69
Engine and Emission Control System Diagram
69
Component Location
71
Electronic Control System Components Location
71
Diagnostic Information and Procedures
72
Engine and Emission Control System Check
72
Malfunction Indicator Lamp (MIL) Check
75
DTC Check
75
DTC Clearance
76
Troubleshooting for Communication Error with Scan Tool Using CAN
76
DTC Table
82
Fail-Safe Table
86
For Vehicle Equipped with a
86
Scan Tool Data
88
Engine Basic Inspection
93
Visual Inspection
93
Engine Symptom Diagnosis
95
Malfunction Indicator Lamp Does Not Come on with Ignition Switch on and Engine Stop (but Engine Can be Started)
102
Malfunction Indicator Lamp Remains on after Engine Starts
104
DTC P0010: Camshaft Position Actuator Circuit (for Engine with VVT System)
105
DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / Retarded (for Engine with VVT System)
107
DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)
109
DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)
111
DTC P0101: Mass Air Flow Circuit Range / Performance
113
DTC P0102: Mass Air Flow Circuit Low Input
116
DTC P0103: Mass Air Flow Circuit High Input
117
DTC P0106: Manifold Absolute Pressure Range / Performance
119
DTC P0107: Manifold Absolute Pressure Circuit Low Input
120
DTC P0108: Manifold Absolute Pressure Circuit High Input
122
DTC P0111: Intake Air Temperature Circuit Range / Performance
124
DTC P0112: Intake Air Temperature Sensor Circuit Low
126
DTC P0113: Intake Air Temperature Sensor Circuit High
128
DTC P0116: Engine Coolant Temperature Circuit Range / Performance
130
DTC P0117: Engine Coolant Temperature Circuit Low
133
DTC P0118: Engine Coolant Temperature Circuit High
135
DTC P0122: Throttle Position Sensor (Main) Circuit Low
137
DTC P0123: Throttle Position Sensor (Main) Circuit High
139
DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)
142
DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)
145
DTC P0134: O2 Sensor (HO2S) Circuit no Activity Detected (Sensor-1)
146
DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)
148
DTC P0140: O2 Sensor (HO2S) Circuit no Activity Detected (Sensor-2)
151
DTC P0171 / P0172: Fuel System too Lean / Rich
153
DTC P0222: Throttle Position Sensor (Sub) Circuit Low
155
DTC P0223: Throttle Position Sensor (Sub) Circuit High
157
Dtc P0301, P0302, P0303, P0304
160
DTC P0327 / P0328: Knock Sensor Circuit Low / High
162
DTC P0335: Crankshaft Position (CKP) Sensor Circuit
164
DTC P0340: Camshaft Position (CMP) Sensor Circuit
166
DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected
169
DTC P0403: Exhaust Gas Recirculation Control Circuit
172
DTC P0420: Catalyst System Efficiency below Threshold
174
DTC P0443: Evaporative Emission System Purge Control Valve Circuit
176
DTC P0462 / P0463: Fuel Level Sensor Circuit Low / High
178
DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit
179
DTC P0481: Cooling Fan 2 (A/C Condenser Fan) Control Circuit
181
DTC P0500: Vehicle Speed Sensor (VSS) Malfunction
184
DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low
186
DTC P0533: A/C Refrigerant Pressure Sensor Circuit High
188
DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance
189
DTC P0616: Starter Relay Circuit Low
190
DTC P0617: Starter Relay Circuit High
191
DTC P1510: ECM Back-Up Power Supply Malfunction
193
DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance
194
DTC P2102: Throttle Actuator Control Motor Circuit Low
196
DTC P2103: Throttle Actuator Control Motor Circuit High
197
DTC P2111: Throttle Actuator Control System - Stuck Open
198
DTC P2119: Throttle Actuator Control Throttle Body Range / Performance
199
DTC P2122: Pedal Position Sensor (Main) Circuit Low Input
201
DTC P2123: Pedal Position Sensor (Main) Circuit High Input
203
DTC P2127: Pedal Position Sensor (Sub) Circuit Low Input
205
DTC P2128: Pedal Position Sensor (Sub) Circuit High Input
208
DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation
210
DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation
213
DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction
215
DTC U0073: Control Module Communication Bus off
216
DTC U0101: Lost Communication with TCM
216
DTC U0121: Lost Communication with ABS Control Module
216
DTC U0140: Lost Communication with Body Control Module
216
Troubleshooting for CAN-DTC
217
Inspection of ECM and Its Circuits
222
ECM Power and Ground Circuit Check
243
Fuel Injector Circuit Check
246
Fuel Pump and Its Circuit Check
248
Fuel Pressure Check
251
A/C Condenser Cooling Fan Control System Inspection
252
A/C System Circuits Check
255
Electric Load Signal Circuit Check
259
Radiator Cooling Fan Control System Check .1A-211
261
Repair Instructions
262
Idle Speed and IAC Throttle Valve Opening Inspection
262
Special Tools and Equipment
263
Special Tool
263
Aux. Emission Control Devices
264
Diagnostic Information and Procedures
264
EGR System Inspection (if Equipped)
264
Repair Instructions
264
EVAP Canister Purge Inspection
264
EVAP Canister Purge Valve and Its Circuit Inspection
264
Vacuum Passage Inspection
265
Vacuum Hose Inspection
266
EVAP Canister Purge Valve Inspection
266
EVAP Canister Inspection
267
EGR Valve Removal and Installation (if Equipped)
267
EGR Valve Inspection (if Equipped)
267
PCV Hose Inspection
268
PCV Valve Inspection
268
Special Tools and Equipment
268
Special Tool
268
Engine Electrical Devices
269
Repair Instructions
269
Engine Control Module (ECM) Removal and Installation
269
Manifold Absolute Pressure (MAP) Sensor Inspection (if Equipped)
270
Electric Throttle Body Assembly On-Vehicle Inspection
270
Electric Throttle Body System Calibration
273
Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection
273
Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation
273
Accelerator Pedal Position (APP) Sensor Assembly Inspection
274
Engine Coolant Temperature (ECT) Sensor Removal and Installation
275
Engine Coolant Temperature (ECT) Sensor Inspection
275
Heated Oxygen Sensor (HO2S-1 and HO2S-2) Heater On-Vehicle Inspection (if Equipped)
276
Heated Oxygen Sensor (HO2S-1 and HO2S-2) Removal and Installation (if Equipped)
276
Camshaft Position (CMP) Sensor Removal and Installation
277
Camshaft Position (CMP) Sensor Inspection
277
Crankshaft Position (CKP) Sensor Removal and Installation
278
Crankshaft Position (CKP) Sensor Inspection
279
Knock Sensor Removal and Installation
279
Main Relay, Fuel Pump Relay, Starting Motor Control Relay, Throttle Actuator Control Relay and Radiator Cooling Fan Relay Inspection
280
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection
280
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation
281
Intake Air Temperature (IAT) Sensor Inspection
281
Specifications
282
Tightening Torque Specifications
282
Engine Mechanical
283
General Description
283
Engine Construction Description
283
Camshaft Position Control (VVT Variable Valve Timing) System Description
285
Diagnostic Information and Procedures
287
Compression Check
287
Engine Vacuum Check
288
Valve Lash (Clearance) Inspection
289
Repair Instructions
292
Air Intake System Components
292
Air Cleaner Filter Removal and Installation
292
Air Cleaner Filter Inspection and Cleaning
292
Air Cleaner Assembly Removal and Installation
293
Cylinder Head Cover Removal and Installation
293
Throttle Body and Intake Manifold Components
295
Throttle Body On-Vehicle Inspection
296
Electric Throttle Body Assembly Removal and Installation
296
Throttle Body Cleaning
296
Intake Manifold Removal and Installation
297
Engine Mountings Components
298
Engine Assembly Removal and Installation
299
Timing Chain Cover Components
304
Timing Chain Cover Removal and Installation
305
Timing Chain Cover Inspection
307
Oil Control Valve Removal and Installation (for Engine with VVT)
308
Oil Control Valve Inspection (for Engine with VVT)
308
Timing Chain and Chain Tensioner Components
309
Timing Chain and Chain Tensioner Removal and Installation
309
Timing Chain and Chain Tensioner Inspection
313
Camshaft, Tappet and Shim Components
314
Camshaft, Tappet and Shim Removal and Installation
315
Camshaft, Tappet and Shim Inspection
318
Valves and Cylinder Head Components
321
Valves and Cylinder Head Removal and Installation
322
Valves and Cylinder Head Disassembly and Assembly
324
Valves and Valve Guides Inspection
327
Cylinder Head Inspection
329
Valve Spring Inspection
330
Pistons, Piston Rings, Connecting Rods and Cylinders Components
331
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation
331
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly
333
Cylinders, Pistons and Piston Rings Inspection
334
Piston Pins and Connecting Rods Inspection
336
Crank Pin and Connecting Rod Bearings Inspection
337
Main Bearings, Crankshaft and Cylinder Block Components
341
Main Bearings, Crankshaft and Cylinder Block Removal and Installation
342
Crankshaft Inspection
345
Main Bearings Inspection
347
Cylinder Block Inspection
352
Flywheel Inspection
352
Rear Oil Seal Inspection
352
Sensor Plate Inspection
352
Specifications
353
Tightening Torque Specifications
353
Special Tools and Equipment
355
Recommended Service Material
355
Special Tool
355
Engine Lubrication System
357
General Description
357
Engine Lubrication Description
357
Diagnostic Information and Procedures
358
Oil Pressure Check
358
Repair Instructions
359
Oil Pan and Oil Pump Strainer Components
359
Oil Pan and Oil Pump Strainer Removal and Installation
360
Oil Pan and Oil Pump Strainer Cleaning
361
Oil Pump Components
362
Oil Pump Removal and Installation
362
Oil Pump Disassembly and Reassembly
362
Oil Pump Inspection
363
Specifications
365
Tightening Torque Specifications
365
Special Tools and Equipment
365
Recommended Service Material
365
Special Tool
365
Engine Cooling System
366
General Description
366
Cooling System Description
366
Coolant Description
366
Schematic and Routing Diagram
367
Coolant Circulation
367
Diagnostic Information and Procedures
368
Engine Cooling Symptom Diagnosis
368
Repair Instructions
369
Cooling System Components
369
Coolant Level Check
370
Engine Cooling System Inspection and Cleaning
370
Cooling System Draining
370
Cooling System Flush and Refill
371
Cooling Water Pipes or Hoses Removal and Installation
371
Thermostat Removal and Installation
372
Thermostat Inspection
372
Radiator Cooling Fan Assembly On-Vehicle Inspection
373
Radiator Cooling Fan Relay Inspection
373
Radiator Cooling Fan Assembly Removal and Installation
373
Radiator Cooling Fan Disassembly and Reassembly
374
Radiator On-Vehicle Inspection and Cleaning
374
Radiator Removal and Installation
374
Water Pump / Generator Drive Belt Tension Inspection and Adjustment
375
Water Pump / Generator Drive Belt Removal and Installation
375
Water Pump Removal and Installation
376
Water Pump Inspection
377
Specifications
377
Tightening Torque Specifications
377
Special Tools and Equipment
377
Recommended Service Material
377
Fuel System
378
Precautions
378
Precautions on Fuel System Service
378
General Description
379
Fuel System Description
379
Fuel Delivery System Description
379
Fuel Pump Description
379
Schematic and Routing Diagram
380
Fuel Delivery System Diagram
380
Diagnostic Information and Procedures
380
Fuel Pressure Inspection
380
Fuel Cut Operation Inspection
381
Repair Instructions
382
Fuel System Components
382
Fuel Hose Disconnecting and Reconnecting
383
Fuel Pressure Relief Procedure
384
Fuel Leakage Check Procedure
385
Fuel Lines On-Vehicle Inspection
385
Fuel Pipe Removal and Installation
385
Fuel Injector On-Vehicle Inspection
386
Fuel Injector Removal and Installation
386
Fuel Injector Inspection
387
Fuel Filler Cap Inspection
389
Fuel Tank Inlet Valve Removal and Installation
389
Fuel Tank Inlet Valve Inspection
389
Fuel Tank Removal and Installation
390
Fuel Tank Inspection
391
Fuel Tank Purging Procedure
392
Fuel Pump On-Vehicle Inspection
392
Fuel Pump Assembly Removal and Installation
392
Main Fuel Level Sensor Removal and Installation
393
Fuel Pump Inspection
394
Specifications
394
Tightening Torque Specifications
394
Special Tools and Equipment
395
Special Tool
395
Ignition System
396
General Description
396
Ignition System Construction
396
Schematic and Routing Diagram
397
Ignition System Wiring Circuit Diagram
397
Component Location
398
Ignition System Components Location
398
Diagnostic Information and Procedures
399
Ignition System Symptom Diagnosis
399
Reference Waveform of Ignition System
399
Ignition System Check
399
Ignition Spark Test
399
Repair Instructions
401
High-Tension Cord Removal and Installation
401
High-Tension Cord Inspection
402
Spark Plug Removal and Installation
402
Spark Plug Inspection
402
Ignition Coil Assembly (Including Ignitor) Removal and Installation
403
Ignition Coil Assembly (Including Ignitor) Inspection
403
Ignition Timing Inspection
403
Special Tools and Equipment
405
Special Tool
405
Specifications
405
Tightening Torque Specifications
405
Diagnostic Information and Procedures
406
Cranking System Symptom Diagnosis
406
Cranking System Test
408
Schematic and Routing Diagram
406
Cranking System Circuit Diagram
406
Starting System
406
Repair Instructions
409
Starting Motor Dismounting and Remounting
409
Starting Motor Components
410
Starting Motor Inspection
411
Specifications
414
Cranking System Specifications
414
Tightening Torque Specifications
414
Special Tools and Equipment
414
Recommended Service Material
414
Charging System
415
General Description
415
Battery Description
415
Generator Description
417
Diagnostic Information and Procedures
418
Battery Inspection
418
Generator Symptom Diagnosis
418
Generator Test (Undercharged Battery Check)
419
Generator Test (Overcharged Battery Check)
420
Repair Instructions
420
Jump Starting in Case of Emergency
420
Battery Dismounting and Remounting
421
Water Pump / Generator Drive Belt Tension Inspection and Adjustment
421
Water Pump / Generator Drive Belt Removal and Installation
422
Generator Dismounting and Remounting
423
Generator Components
424
Generator Inspection
425
Specifications
427
Charging System Specifications
427
Tightening Torque Specifications
427
Exhaust System
428
General Description
428
Exhaust System Description
428
Diagnostic Information and Procedures
428
Exhaust System Check
428
Repair Instructions
429
Exhaust System Components
429
Exhaust Manifold Removal and Installation
430
Exhaust Pipe and Muffler Removal and Installation
431
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Suzuki 2006 SX4 Service Manual (1478 pages)
Brand:
Suzuki
| Category:
Automobile
| Size: 58.39 MB
Table of Contents
Table of Contents
5
Precautions
8
Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System
8
General Precautions
10
Exhaust System
11
Warning for Wheel (with Tire) Removal
13
Precautions in Servicing 4WD Model
14
Precautions for Catalytic Converter
15
Precautions for Installing Mobile Communication Equipment
15
Precaution for CAN Communication System
15
Precautions for Electrical Circuit Service
16
Air Bag Warning
18
Fastener Caution
18
Suspension Caution
18
Wheels and Tires Caution
18
Brake Caution
18
Repair Instructions
19
Electrical Circuit Inspection Procedure
19
Intermittent and Poor Connection Inspection
21
General Information
23
Maintenance and Lubrication
23
Differential
25
Rear Suspension
28
Engine Identification Number
29
Vehicle Identification Number
29
Fuel System
32
Section 1 Engine
39
Precautions
44
Precautions for Engine
44
Engine General Information and Diagnosis
45
Precautions
45
Precautions on Engine Service
45
Precaution on On-Board Diagnostic (OBD) System
45
Precautions in Diagnosing Trouble
45
Precautions for DTC Troubleshooting
46
Precautions of ECM Circuit Inspection
46
Precautions of Electric Throttle Body System Calibration
46
Precaution on CAN Troubleshooting
47
General Description
48
Statement on Cleanliness and Care
48
Engine Diagnosis General Description
49
On-Board Diagnostic System Description
49
DLC (Data Link Connector)
51
Engine and Emission Control System Description
51
CAN Communication System Description
52
Air Intake System Description
54
Description of Electric Throttle Body System
55
Description of Electric Throttle Body System Calibration
56
A/F Sensor Description
56
Electronic Control System Description
57
Engine and Emission Control Input / Output Table
62
Schematic and Routing Diagram
66
Engine and Emission Control System Diagram
66
Component Location
68
Electronic Control System Components Location
68
Diagnostic Information and Procedures
69
Engine and Emission Control System Check
69
Malfunction Indicator Lamp (MIL) Check
72
DTC Check
73
DTC Clearance
73
Troubleshooting for Communication Error with Scan Tool Using CAN
73
DTC Table
78
Fail-Safe Table
84
Scan Tool Data
86
Visual Inspection
91
Engine Basic Inspection
91
Engine Symptom Diagnosis
93
MIL Does Not Come on with Ignition Switch on and Engine Stop (but Engine Can be Started)
99
MIL Remains on after Engine Starts
101
DTC P0030: HO2S Heater Control Circuit (Sensor-1, Bank-1)
102
DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1, Bank-1)
103
DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2, Bank-1)
105
DTC P0101: Mass or Volume Air Flow Circuit Range / Performance
106
DTC P0102 / P0103: Mass or Volume Air Flow Circuit Low / High Input
108
DTC P0111: Intake Air Temperature Sensor 1 Circuit Range / Performance
110
DTC P0112 / P0113: Intake Air Temperature Sensor Circuit Low / High Input
110
DTC P0116: Engine Coolant Temperature Circuit Range / Performance
112
DTC P0117 / P0118: Engine Coolant Temperature Circuit Low / High
114
DTC P0122 / P0123: Throttle / Pedal Position Sensor / Switch "A" Circuit Low / High
115
DTC P0131 / P0132: O2 Sensor Circuit Low Voltage / High Voltage (Sensor-1, Bank-1)
118
DTC P0133: O2 Sensor Circuit Slow Response / Performance (Sensor-1, Bank-1)
119
DTC P0134: O2 Sensor Circuit no Activity Detected (Sensor-1, Bank-1)
121
DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2, Bank-1)
122
DTC P0140: O2 Sensor (HO2S) Circuit no Activity Detected (Sensor-2, Bank-1)
124
DTC P0171 / P0172: System too Lean / too Rich (Sensor-1, Bank-1)
125
DTC P0222 / P0223: Throttle Position Sensor (Sub) Circuit Low / High
127
DTC P0327 / P0328: Knock Sensor Circuit Low / High
131
DTC P0335: Crankshaft Position Sensor "A" Circuit
132
DTC P0340: Camshaft Position Sensor "A" Circuit
134
System Description
134
DTC P0420: Catalyst System Efficiency below Threshold (Bank-1)
136
DTC P0443: EVAP Emission System Purge Control Valve Circuit
138
DTC P0462 / P0463: Fuel Level Sensor Circuit Low / High
140
DTC P0480: Fan 1 Control Circuit
142
DTC P0481: Fan 2 Control Circuit
145
DTC P0500: Vehicle Speed Sensor
147
DTC P0504: Brake Switch "A"/"B" Correlation 1A-104
148
DTC P0532 / P0533: A/C Refrigerant Pressure Sensor Circuit Low / High
150
DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance
151
DTC P0616 / P0617: Starter Relay Circuit Low / High
152
DTC P0660 / P0662: Intake Manifold Tuning Valve Control Circuit Open / High
154
DTC P1510: ECM Back-Up Power Supply Malfunction
155
DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance
156
DTC P2102: Throttle Actuator Control Motor Circuit Low
157
DTC P2103: Throttle Actuator Control Motor Circuit High
159
DTC P2111: Throttle Actuator Control System - Stuck Open
159
DTC P2119: Throttle Actuator Control Throttle Body Range / Performance
160
DTC P2122 / P2123: Throttle / Pedal Position Sensor / Switch "D" Circuit Low / High
161
DTC P2127 / P2128: Throttle / Pedal Position Sensor / Switch "E" Circuit Low / High Input . 1A-119
163
DTC P2135: Throttle / Pedal Position Sensor / Switch "A" / "B" Voltage Correction
165
DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correction
166
DTC P2195 / P2196: O2 Sensor Signal Stuck Lean / Stuck Rich (Sensor-1, Bank-1)
167
DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Performance / Low / High
168
DTC U0073: Control Module Communication Bus off
169
DTC U0101: Lost Communication with TCM
169
DTC U0121: Lost Communication with ABS / ESP® Control Module
169
DTC U0140: Lost Communication with Body Control Module
169
Troubleshooting for CAN-DTC
169
Inspection of ECM and Its Circuits
174
ECM Power and Ground Circuit Check
192
Fuel Injector Circuit Check
195
Fuel Pump and Its Circuit Check
197
Fuel Pressure Check
200
A/C Condenser Cooling Fan Control System Inspection
202
A/C System Circuits Check
204
Electric Load Signal Circuit Check
207
Radiator Cooling Fan Low Speed Control
210
Radiator Cooling Fan High Speed Control System Check
211
System Check
211
Repair Instructions
212
Idle Speed and IAC Throttle Valve Opening Inspection
212
Special Tools and Equipment
213
Special Tool
213
Aux. Emission Control Devices
214
Diagnostic Information and Procedures
214
EVAP Canister Purge System Inspection
214
Repair Instructions
215
EVAP System Components
215
EVAP Canister Purge Inspection
215
EVAP Canister Purge Valve and Its Circuit Inspection
216
Vacuum Passage Inspection
217
Vacuum Hose and Purge Valve Chamber Inspection
217
EVAP Canister Purge Valve Inspection
217
EVAP Canister Removal and Installation
218
EVAP Canister Inspection
218
PCV Hose Inspection
218
PCV Valve Removal and Installation
218
PCV Valve Inspection
219
Specifications
219
Tightening Torque Specifications
219
Special Tools and Equipment
219
Recommended Service Material
219
Special Tool
219
Engine Electrical Devices
220
Repair Instructions
220
Engine Control Module (ECM) Removal and Installation
220
Electric Throttle Body Assembly On-Vehicle Inspection
221
Electric Throttle Body System Calibration
223
Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection
223
Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation
224
Accelerator Pedal Position (APP) Sensor Assembly Inspection
224
Engine Coolant Temperature (ECT) Sensor Removal and Installation
225
Engine Coolant Temperature (ECT) Sensor Inspection
225
Air Fuel Ratio (A/F) Sensor On-Vehicle Inspection
226
Heated Oxygen Sensor (HO2S) Heater On-Vehicle Inspection
226
Air Fuel Ratio (A/F) Sensor, Heated Oxygen Sensor (HO2S) Removal and Installation
226
Camshaft Position (CMP) Sensor Removal and Installation
227
Camshaft Position (CMP) Sensor Inspection
227
Crankshaft Position (CKP) Sensor Removal and Installation
227
Crankshaft Position (CKP) Sensor Inspection
228
Knock Sensor Removal and Installation
228
Engine and Emission Control System Relay Inspection
229
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection
229
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation
230
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection
230
IMT Valve Actuator Inspection
231
Specifications
231
Tightening Torque Specifications
231
Engine Mechanical
232
General Description
232
Engine Construction
232
IMT (Intake Manifold Tuning) System
233
Diagnostic Information and Procedures
234
Compression Check
234
Engine Vacuum Check
235
Valve Lash (Clearance) Inspection
235
Repair Instructions
238
Air Cleaner Components
238
Air Cleaner Assembly Removal and Installation
239
Air Cleaner Filter Removal and Installation
239
Air Cleaner Filter Inspection and Cleaning
239
Electric Throttle Body and Intake Manifold Components
240
Electric Throttle Body On-Vehicle Inspection
241
Electric Throttle Body Assembly Removal and Installation
241
Electric Throttle Body Cleaning
241
Intake Manifold Removal and Installation
242
IMT Valve Actuator Removal and Installation
243
Cylinder Head Cover Components
243
Cylinder Head Cover Removal and Installation
243
Engine Mountings Components
245
Engine Assembly Removal and Installation
246
Front Suspension
247
Timing Chain Cover Components
250
Timing Chain Cover Removal and Installation
250
Timing Chain Cover Cleaning and Inspection
253
2Nd Timing Chain and Chain Tensioner Components
253
2Nd Timing Chain and Chain Tensioner Removal and Installation
254
2Nd Timing Chain and Chain Tensioner Inspection
257
1St Timing Chain and Chain Tensioner Components
258
1St Timing Chain and Chain Tensioner Removal and Installation
258
1St Timing Chain and Chain Tensioner Inspection
260
Camshafts, Tappet and Shim Components
261
Camshafts, Tappet and Shim Removal and Installation
262
Camshaft, Tappet and Shim Inspection
263
Valves and Cylinder Head Components
266
Valves and Cylinder Head Removal and Installation
266
Valves and Cylinder Head Disassembly and Reassembly
268
Valves and Valve Guides Inspection
271
Cylinder Head Inspection
273
Valve Spring Inspection
274
Pistons, Piston Rings, Connecting Rods and Cylinders Components
275
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation
276
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Reassembly
277
Pistons, Piston Rings, Connecting Rods and Cylinders Inspection and Cleaning
279
Main Bearings, Crankshaft and Cylinder Block Components
286
Main Bearings, Crankshaft and Cylinder Block Removal and Installation
287
Main Bearings, Crankshaft and Cylinder Block Inspection
290
Special Tools and Equipment
298
Recommended Service Material
298
Engine Lubrication System
300
General Description
300
Engine Lubrication Description
300
Diagnostic Information and Procedures
301
Oil Pressure Check
301
Repair Instructions
302
Engine Oil and Filter Change
302
Oil Pan and Oil Pump Strainer Components
304
Oil Pan and Oil Pump Strainer Removal and Installation
305
Oil Pan and Oil Pump Strainer Cleaning
306
Oil Pump Components
307
Oil Pump Removal and Installation
308
Oil Pump Disassembly and Reassembly
309
Oil Pump Inspection
309
Specifications
310
Special Tools and Equipment
311
Recommended Service Material
311
Special Tool
311
Engine Cooling System
312
General Description
312
Cooling System
312
Coolant
312
Schematic and Routing Diagram
313
Coolant Circulation
313
Diagnostic Information and Procedures
314
Engine Cooling Symptom Diagnosis
314
Repair Instructions
315
Cooling System Components
315
Coolant Level Check
316
Engine Cooling System Inspection and Cleaning
316
Cooling System Draining
316
Cooling System Flush and Refill
317
Cooling Water Pipes or Hoses Removal and Installation
317
Thermostat Removal and Installation
318
Thermostat Inspection
318
Radiator Cooling Fan Assembly Inspection
319
Radiator Cooling Fan Relay Inspection
319
Radiator Cooling Fan Assembly Removal and Installation
319
Radiator Cooling Fan Disassembly and Reassembly
320
Radiator On-Vehicle Inspection and Cleaning
320
Radiator Removal and Installation
320
Water Pump Removal and Installation
321
Water Pump Inspection
321
Specifications
321
Tightening Torque Specifications
321
Precautions
322
Precautions on Fuel System Service
322
Fuel System
322
General Description
323
Fuel System
323
Fuel Delivery System
323
Fuel Pump
323
Schematic and Routing Diagram
324
Fuel Delivery System Diagram
324
Diagnostic Information and Procedures
324
Fuel Pressure Inspection
324
Fuel Cut Operation Inspection
325
Repair Instructions
326
Fuel System Components
326
Fuel Hose Disconnecting and Reconnecting
327
Fuel Pressure Relief Procedure
329
Fuel Leakage Check Procedure
329
Fuel Tank, Cap Gasket and Fuel Line Inspection
329
Fuel Pipe Removal and Installation
330
Fuel Injector On-Vehicle Inspection
330
Fuel Injector Removal and Installation
331
Fuel Injector Inspection
332
Fuel Filler Cap Inspection
333
Fuel Tank Inlet Valve Removal and Installation
334
Fuel Tank Inlet Valve Inspection
334
Fuel Tank Removal and Installation
334
Fuel Tank Inspection
337
Fuel Tank Purging Procedure
337
Fuel Pump On-Vehicle Inspection
337
Fuel Filter Replacement
338
Fuel Pump Assembly Removal and Installation
338
Main Fuel Level Sensor Removal and Installation
339
Fuel Pump Inspection
339
Specifications
340
Tightening Torque Specifications
340
Special Tools and Equipment
340
Special Tool
340
Ignition System
341
General Description
341
Ignition System Construction
341
Schematic and Routing Diagram
342
Ignition System Wiring Circuit Diagram
342
Component Location
343
Ignition System Components Location
343
Diagnostic Information and Procedures
343
Ignition System Check
343
Ignition System Symptom Diagnosis
345
Reference Waveform of Ignition System
345
Ignition Spark Test
345
Repair Instructions
346
Spark Plug Removal and Installation
346
Spark Plug Inspection
346
Ignition Coil Assembly (Including Ignitor)
346
Removal and Installation
346
Ignition Coil Assembly (Including Ignitor) Inspection
346
Ignition Timing Inspection
347
Specifications
348
Tightening Torque Specifications
348
Special Tools and Equipment
348
Special Tool
348
Starting System
349
Schematic and Routing Diagram
349
Cranking System Circuit Diagram
349
Diagnostic Information and Procedures
349
Cranking System Symptom Diagnosis
349
Cranking System Test
351
Repair Instructions
352
Starting Motor Unit Components
352
Starting Motor Dismounting and Remounting
352
Starting Motor Components
353
Starting Motor Inspection
354
Specifications
357
Tightening Torque Specifications
357
Special Tools and Equipment
357
Recommended Service Material
357
Charging System
358
General Description
358
Battery Description
358
Generator Description
359
Diagnostic Information and Procedures
361
Battery Inspection
361
Generator Symptom Diagnosis
361
Generator Test
362
Check)
362
Repair Instructions
363
Jump Starting in Case of Emergency
363
Battery Dismounting and Remounting
364
Water Pump and Generator Drive Belt On-Vehicle Inspection
365
Water Pump and Generator Drive Belt Removal and Installation
365
Generator Unit Components
366
Generator Dismounting and Remounting
367
Generator Components
368
Generator Inspection
369
Specifications
372
Charging System Specifications
372
Tightening Torque Specifications
372
General Description
373
Diagnostic Information and Procedures
373
Exhaust System Check
373
Exhaust System
373
Repair Instructions
374
Exhaust System Components
374
Exhaust Manifold Removal and Installation
375
Exhaust Pipe and Muffler Removal and Installation
376
Specifications
377
Tightening Torque Specifications
377
Section 2 Suspension
379
Precautions
381
Precautions on Suspension
381
Diagnostic Information and Procedures
382
Suspension, Wheels and Tires Symptom Diagnosis
382
Suspension General Diagnosis
382
Repair Instructions
384
Suspension System Inspection
384
Wheel Bearing Inspection
384
General Description
386
Front Suspension Construction
386
Front Wheel Alignment Construction
387
Front Suspension
386
Repair Instructions
387
Front Wheel Alignment Inspection and Adjustment
387
Front Strut Assembly Components
389
Front Strut Assembly Removal and Installation
390
Front Strut Assembly Disassembly and Reassembly
391
Front Strut Assembly Check
392
Front Wheel Hub and Steering Knuckle Components
393
Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation
393
Front Wheel Hub, Disc, Bolt and Bearing Check
398
Suspension Control Arm / Bushing Removal and Installation
398
Suspension Control Arm / Bushing Disassembly and Assembly
399
Suspension Control Arm / Steering Knuckle Check
400
Suspension Control Arm Bushing Check
400
Suspension Control Arm Joint Check
400
Front Suspension Frame, Stabilizer Bar And/Or Bushing Components
401
Front Suspension Frame, Stabilizer Bar And/Or Bushing Removal and Installation (2WD Model)
402
Front Suspension Frame, Stabilizer Bar And/Or Bushing Removal and Installation (4WD Model)
404
Front Suspension Frame Check
405
Front Stabilizer Bar, Bushing And/Or Joint Check
405
Front Suspension Fasteners Check
405
Specifications
407
Special Tools and Equipment
407
Recommended Service Material
407
Special Tool
407
Rear Suspension
408
Repair Instructions
408
Rear Suspension Components
408
Rear Shock Absorber Removal and Installation
409
Rear Shock Absorber Inspection
410
Rear Shock Absorber Bush Inspection
410
Rear Coil Spring Removal and Installation
411
Spring Upper Seat / Spring Lower Seat Inspection
412
Rear Axle Removal and Installation
413
Rear Axle and Coil Spring Inspection
414
Rear Axle Bush Inspection
414
Rear Wheel Disc, Bolt and Bearing Inspection
414
Rear Wheel Hub Assembly Removal and Installation
415
General Description
417
Tires Description
417
Wheels Description
418
Irregular And/Or Premature Wear Description
419
Wear Indicators Description
419
Radial Tire Waddle Description
419
Radial Tire Lead / Pull Description
420
Balancing Wheels Description
420
Wheels and Tires
417
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