M11 SM print ready file.pdf

2009CHERYA3 SedanService Manual

FOREWORDThis manual contains on-vehicle serviceand diagnosis procedures for the Chery A3Sedan.

A thorough familiarization with this manualis important for proper repair andmaintenance. It should always be kept in ahandy place for quick and easy reference.

The contents of this manual, includingdrawings and specifications, are the latestavailable at the time of printing. Asmodifications affecting repair ormaintenance occur, relevant informationsupplementary to this volume will be madeavailable at Chery dealers. This manualshould be kept up-to-date.

Chery Automobile Company, Ltd. reserves theright to alter the specifications andcontents of this manual without obligationor advance notice.

All rights reserved. No part of this bookmay be reproduced or used in any form orby any means, electronic or mechanical—including photocopying and recording and theuse of any kind of information storage andretrieval system—without permission inwriting.NOTE:

This A3 Sedan service manual only applies to thefollowing engines and transaxles:• 1.6L with M/T• 1.8L with M/T

Chery Automobile Company, Ltd.Wuhu, Anhui Province, CHINA

CONTENTS

Title Section

GENERAL INFORMATION 01

ENGINE 02

ELECTRONIC ENGINE CONTROLS 03

FUEL DELIVERY 04

STARTING & CHARGING 05

COOLING 06

EXHAUST 07

TRANSAXLE 08

DRIVELINE & AXLE 09

SUSPENSION 10

STEERING 11

BRAKES 12

HEATING & AIR CONDITIONING 13

RESTRAINTS 14

BODY & ACCESSORIES 15

WIRING 16

ALPHABETICAL INDEX AI

© 2009 Chery Automobile Co., Ltd.PRINTED AUGUST, 2009

01

GENERAL INFORMATION

01CONTENTS

pageService Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

Vehicle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9

Electrical Circuit Diagnosis Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-15

Electrical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-20

SERVICE INFORMATION

HOW TO USE THIS MANUAL 01-2Topics 01-2Service Procedures 01-2Diagnostic Procedures 01-2Specifications 01-2

VEHICLE SERVICE PREPARATION 01-3Preparation For Vehicle Service 01-3Tools and Testing Equipment 01-3Special Tools 01-4Disconnection of the Negative Battery
Cable 01-4
Chery Automobile Co., Ltd.

PROPER SERVICE PRACTICES 01-5Removal of Parts 01-5Component Disassembly 01-5Inspection of Parts 01-5Arrangement of Parts 01-6Cleaning of Parts 01-6Component Reassembly 01-6Adjustments 01-7Rubber Parts and Rubber Tubing 01-7Hose Clamps 01-8Vise 01-8Dynamometer 01-8

01–1

HOW TO USE THIS MANUALTopicsThis manual contains procedures for performing all required service operations.

The procedures are divided into three basic operations:• Removal/Installation• Disassembly/Assembly• Inspection

Service ProceduresMost repair procedures begin with an illustration. It identifies the components, shows how the parts fit together anddescribes visual part inspection. Removal & Installation procedures have written instructions.

Service procedures include the following elements:• Detailed removal & installation instructions• Integrated torque specifications• Integrated illustrations• Component specifications

Diagnostic ProceduresThe diagnostic procedures are grouped into the following:

Diagnostic Trouble Codes (DTC)

• DTCs are important hints for repairing malfunctions that are difficult to simulate. Perform the specific DTC diag-nostic inspection to quickly and accurately diagnose the malfunction.

Diagnostic Symptoms

• Symptom troubleshooting quickly determines the location of the malfunction according to symptom type.

SpecificationsThis manual contains specifications that are divided into the following groups:• Torque specifications• Clearance specifications• Capacity specifications

01–2 Chery Automobile Co., Ltd.

01

VEHICLE SERVICE PREPARATIONPreparation For Vehicle Service• Always be sure to cover fenders, seats and floor

areas before starting work.

Tools and Testing Equipment• Be sure that all necessary tools and measuring

equipment are available before starting any work.• Inspect the vehicle and reference any needed ser-

vice information before starting any work.

BESM010004

BESM010005

01–3

VEHICLE SERVICE PREPARATION

Special Tools• Use special tools when they are required.

Disconnection of the Negative Battery Cable• Before beginning any work, turn the ignition switch

to LOCK, disconnect the negative battery cable andthen wait two minutes to allow the backup supplyof the air bag diagnostic monitor unit to deplete itsstored power. Disconnecting the battery cabledeletes the memories of the clock, audio andDTCs, etc. Therefore, it is necessary to verify thosememories before disconnecting the cable.

BESM010006T

VISM010001

01–4

01

PROPER SERVICE PRACTICESRemoval of Parts• While correcting a problem, also try to determine its

cause. Begin work only after first learning whichparts and subassemblies must be removed and dis-assembled for replacement or repair. After removingthe part, plug all holes and ports to prevent foreignmaterial from entering.

Component Disassembly• If the disassembly procedure is complex, requiring

many parts to be disassembled, make sure that allparts are disassembled in a way that will not affecttheir performance or external appearance. Identifyeach part so reassembly can be performed easilyand efficiently.

Inspection of Parts• When removed, inspect each part for possible mal-

function, deformation, damage or other problems.

BESM010007

BESM010008

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01–5

PROPER SERVICE PRACTICES

Arrangement of Parts• All disassembled parts should be carefully arranged

for reassembly.• Be sure to separate or otherwise identify the parts

to be replaced from those that will be reused.

Cleaning of Parts• Carefully and thoroughly clean all parts to be

reused.

WARNING!

Using compressed air can cause dirt and other particles to fly out causing injury to the eyes. Wear protectiveeyewear whenever using compressed air.

Component Reassembly• Standard values, such as torques and certain

adjustments, must be strictly observed in the reas-sembly of all parts. If removed, replace these partswith new ones:

− Oil seals− Gaskets− O-rings− Lock washers− Cotter pins− Nylon nuts

BESM010010

BESM010011

BESM010012

01–6


01

Depending on location:• Apply sealant and gaskets, or both, to specified

locations. When sealant is applied, install partsbefore sealant hardens to prevent leaks.

• Apply oil to the moving components of parts.• Apply specified oil or grease at the prescribed loca-

tions (such as oil seals) before reassembly.

Adjustments• Use suitable gauges and testers when making

adjustments.

Rubber Parts and Rubber Tubing• Prevent gasoline or oil from getting on rubber parts

or tubing.

CAUTION:Exposing rubber components to gasoline or oil can deteriorate the rubber components.

BESM010013

BESM010014

BESM010015

01–7


Hose Clamps• When reinstalling, position the hose clamp in the

original location on the hose and squeeze theclamp lightly with large pliers to ensure a good fit.

Vise• When using a vise, put protective plates in the

jaws of the vise to prevent damage to parts.

Dynamometer• When test-running a vehicle on a dynamometer:

− Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle.− Connect an exhaust gas ventilation unit.

WARNING!

Exhaust gases can injure or kill. They contain carbon monoxide (CO), which is colorless and odorless. Breathingit can make you unconscious and can eventually poison you.

− Cool the exhaust pipes with a fan.− Keep the area around the vehicle uncluttered.− Monitor the engine coolant temperature gauge.

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01–8

VEHICLE INFORMATION

01

VEHICLE IDENTIFICATION NUMBER(VIN) 01-10VIN Location 01-10VIN Identification Codes 01-11

INTERNATIONAL SYMBOLS 01-13
International Symbols 01-13

FASTENER USAGE 01-14Fastener Usage 01-14

01–9

VEHICLE IDENTIFICATION NUMBER (VIN)VIN Location

The VIN is printed on a plastic tag attached to the top left corner of the upper instrument panel. The VIN is alsofound on the vehicle certification (VC) label.

Vehicle Identification Number (VIN) Tag LocationVISM010002


VEHICLE IDENTIFICATION NUMBER (VIN)

01

VIN Identification CodesThe vehicle identification number (VIN) is a 17-digitcombination of letters and numbers.

NUMBERDESIGNATION DEFINITION

1 World Manufacturer Identifier

2 Brand Of The Vehicle

3 Vehicle Chassis Type

4 Transmission Type

5 Engine Type

6 Restraint System

7 Check Digit

8 Model Year

9 Assembly Plant

10 Production Sequence Number

• Digits #1, #2, #3 The first 3 vehicle identification number (VIN) positions are the world manufacturer identifier:− �LVV� represents Chery Automobile Co., Ltd.

• Digit #4 The fourth digit of the VIN code represents the brand of the vehicle:− The brand �Chery� is represented by the letter �D�.

• Digit #5 The fifth digit of the VIN code represents the body configuration of the vehicle:− �A� represents three compartments, five-door, and 4X2.− �B� represents two compartments, five-door, and 4X2.− �C� represents three compartments, four-door, two-lid, and 4X2.− �D� represents two compartments, five-door, and 4X4.

• Digit #6 The sixth digit of VIN code represents the type of transmission:− �1� represents manual transmission.− �2� represents automatic transmission.

• Digit #7 The seventh digit of VIN code represents the type of engine:− �1� represents electronically controlled gasoline engines 1.5L - 2.0L (excluding 2.0L) series.− �2� represents engines smaller than 1.5L (excluding 1.5L).− �4� represents 2.0L - 2.5L engines (excluding 2.5L).

BESM010002

01–11

VEHICLE IDENTIFICATION NUMBER (VIN)

• Digit #8 The eighth digit of VIN code represents the Restraint System:− �A� represents manual safety belts.− �B� represents manual safety belts plus air bags in the front row.

• Digit #9 The ninth digit of VIN code is the check digit:− It is to check accuracy of VIN record, and is made out through computation after confirming the other six-

teen digits of VIN• Digit #10 The tenth VIN position represents the model year code:

− �5� represents the year 2005• Digit #11 The eleventh VIN position represents the assembly plant code:

− �D� represents the �Chery Automobile Co., Ltd.�• Digits #12, #13, #14, #15, #16, #17 The last six VIN positions represent the production sequence number.

− This represents the actual production number of the vehicle.


01

INTERNATIONAL SYMBOLSInternational SymbolsThe graphic symbols illustrated in the following International Control and Display Symbols chart are used to identifyvarious instrument controls. The symbols correspond to the controls and displays that are located on the instrumentpanel.

1 - High Beam

2 - Fog Lamps

3 - Headlamp, Parking Lamps, Panel Lamps

4 - Turn Signals

5 - Hazard Warning

6 - Windshield Washer

7 - Windshield Wiper

8 - Windshield Wiper and Washer

9 - Windshield Defroster

10 - Blower Motor Fan

11 - Rear Window Defroster

13 - Rear Window Washer

14 - Fuel

15 - Engine Coolant Temperature

16 - Battery Charging Condition

17 - Engine Oil

18 - Seat Belt

19 - Brake Failure

20 - Parking Brake

21 - Hood

22 - Trunk

23 - Horn

12 - Rear Window Wiper 24 - Lighter

BESM01000301–13Chery Automobile Co., Ltd.

FASTENER USAGEFastener UsageWARNING!

Use of an incorrect fastener may result in component damage. Failure to follow these instructions may result inpersonal injury or death.

Fasteners and torque specification references in this Service Manual are identified in metric format.

During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly.If the fastener is not salvageable, a fastener of equivalent specification must be used.


ELECTRICAL CIRCUIT DIAGNOSIS INFORMATION

01

DIAGNOSING AN ELECTRICALFAILURE 01-16Performing Efficient Electrical Circuit
Diagnosis and Troubleshooting 01-16

Electrical Circuit Failure Simulation Tests 01-16Precautions For Handling Control Modulesand Electrical Components 01-18How To Check Electrical Connectors 01-19

01–15

DIAGNOSING AN ELECTRICAL FAILUREPerforming Efficient Electrical Circuit Diagnosis and Troubleshooting

STEP DESCRIPTION

Step 1 Obtain detailed information about the conditions and the environment when the electricalincident occurred.

Step 2Operate the affected system, road test the vehicle if necessary.Verify the parameter of the incident.If the problem cannot be duplicated, refer to “Electrical Failure Simulation Tests”.

Step 3

Gather the proper diagnosis material together including:• Electrical Power Supply Routing Diagram• System Operation Descriptions• Applicable Service Manual Sections• Check for any Service Bulletins• Identify where to begin diagnosis based upon your knowledge of the system operation

and the customer comments.

Step 4Inspect the system for mechanical binding, loose connectors or wiring damage.Determine which circuits and components are involved and diagnose using the ElectricalPower Supply Routing Diagram and Harness Layouts.

Step 5 Repair the circuit or replace the component as necessary.

Step 6Operate the system in all modes. Verify the system functions properly under all conditions.Confirm you have not inadvertently created an additional new incident during yourdiagnosis or repair steps.

Electrical Circuit Failure Simulation TestsOften the symptom is not present when the vehicle is brought in for service. If possible, re-create the conditionspresent at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The following illustratestests to simulate the conditions/environment under which the owner experiences an electrical incident.

The tests are broken into the seven following topics:• Vehicle Vibration Test• Heat Sensitive Test• Freezing Test• Water Intrusion Test• Electrical Load Test• Cold or Hot Start Up Test• Voltage Drop Test

NOTE :Always get a thorough description of the incident from the customer. It is important for simulating the conditions ofthe problem.


DIAGNOSING AN ELECTRICAL FAILURE

01

Vehicle Vibration TestThe problem may occur or become worse while driving on a rough road or when the engine is vibrating (idle with A/Con). In such a case, check for a vibration related condition. Refer to the following vehicle areas:

Connectors & Harness

• Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gentlyshake each connector and harness while monitoring the system for the incident you are trying to duplicate. Thistest may indicate a loose or poor electrical connection.

NOTE :Connectors can be exposed to moisture. It is possible for a thin film of corrosion to form on the connector terminals.A visual inspection may not reveal this without disconnecting the connector. If the problem occurs intermittently, per-haps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the terminals on relatedconnectors in the system.

Sensors & Relays

• Gently apply a slight vibration to sensors and relays in the system you are inspecting. This test may indicate aloose or poorly mounted sensor or relay.

Engine Compartment

• There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the thingsto check for are:

− Connectors not fully seated.− Wiring harness not long enough and is being stressed due to engine vibrations or rocking.− Wires laying across brackets or moving components.− Loose, dirty or corroded ground wires.− Wires routed too close to hot components.

• To inspect components under the hood, start by verifying the integrity of the ground connections (See GroundInspection described later). First, verify that the system is properly grounded. Then check for any loose connec-tions by gently shaking the wiring or components as previously explained. Using the wiring diagrams, inspectthe wiring for continuity.

Behind The Instrument Panel

• An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehiclevibration can aggravate a harness which is routed along a bracket or near a mounting screw.

• An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides)during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage orpinching.

Heat Sensitivity TestThe customer’s concern may occur during hot weather or after the vehicle has sat for a short time. In such cases youwill want to check for a heat sensitive condition.

To determine if an electrical component is heat sensitive, heat the component with a heat gun or equivalent.

CAUTION:Do not heat components above 60 °C (140 °F).

If the incident occurs while heat testing the component, replace or properly insulate the component as needed.

Freezing TestThe customer may indicate the incident goes away after the vehicle warms up (winter time). The cause could berelated to water freezing somewhere in the wiring/electrical system. There are two methods to check for this:• The first method is to arrange for the owner to leave the vehicle overnight. Make sure it will get cold enough to

demonstrate the complaint. Leave the vehicle parked outside overnight. In the morning, do a quick and thor-ough diagnosis of those electrical components which could be affected.

• The second method is to put the suspect component into a freezer long enough for any water to freeze. Rein-stall the part into the vehicle and check for the reoccurrence of the incident. If it occurs, repair or replace thecomponent as needed.

01–17Chery Automobile Co., Ltd.


Water Intrusion TestThe incident may occur only during high humidity or in rainy/snowy weather. In such cases the incident could becaused by water intrusion on an electrical part. This can be simulated by soaking the car or running it through a carwash.

Electrical Load TestThe incident may be electrical load sensitive. Perform diagnosis with all accessories (including A/C, rear windowdefogger, radio, fog lamps) turned on.

Cold or Hot Starting TestOn some occasions an electrical incident may occur only when the vehicle is started cold, or it may occur when thevehicle is restarted hot shortly after being turned off. In these cases you may have to keep the vehicle overnight tomake a proper diagnosis.

Voltage Drop TestVoltage drop tests are often used to find components or circuits which have excessive resistance. A voltage drop ina circuit is caused by a resistance in the circuit during operation.• Check the circuit using a Digital Multimeter (DMM).• When measuring resistance with a DMM, remember that contact by a single strand of wire will give a reading

of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand of wire is not ableto carry the current. The single strand will have a high resistance to the current. This will be indicated as aslight voltage drop.

• Unwanted resistance can be caused by the following:− Undersized wiring (single strand example)− Corrosion on switch contacts− Loose wire connections or splices.

Precautions For Handling Control Modules and Electrical Components• Never reverse polarity of battery terminals.• Only install components specified for the vehicle.• Before replacing the control module, check the input and output and functions of the components.• When disconnecting components:

− Do not apply excessive force when disconnecting a connector.− If a connector is installed by tightening bolts, loosen mounting bolt, then remove it by hand.

• When connecting components:− Before installing a connector, make sure the terminal is not bent or damaged, and then correctly connect it.− When installing a connector by tightening bolts, tighten the mounting bolt until the painted area of the con-

nector becomes even with the surface.• Do not apply excessive shock to the control module by dropping or hitting it.• Be careful to prevent condensation in the control module due to rapid temperature changes and do not let

water or rain get on it. If water is found in the control unit, dry it fully and then install it in the vehicle.• Be careful not to let oil get on the control module connector.• Avoid cleaning the control module with volatile oil.



01

• When using a DMM, be careful not to let the test probes touch each other causing a short circuit. Prevent thepower transistor in the control module from beingshorted to damaging battery voltage.

• When checking input and output signals of the con-trol module, use the specified test adapter (if appli-cable).

How To Check Electrical ConnectorsMany electrical problems are caused by faulty electricalconnections or wiring. It is also possible for a stickingcomponent or relay to cause a problem. Before con-demning a component or wiring assembly, alwayscheck the electrical connectors for good continuity.

How To Probe Connectors• Connector damage and an intermittent connection

can result from improperly probing the connectorduring circuit checks.

• The probe of a DMM may not correctly fit the con-nector cavity. To correctly probe the connector, fol-low the procedures below using a “T” pin. For thebest contact grasp the “T” pin using an alligatorclip.

Probing From Harness Side• If the connector has a rear cover connector,

remove the rear cover before probing the terminal.• Do not probe waterproof connectors from the har-

ness side. Damage to the seal between the wireand connector may result.

Probing From Terminal Side• Female Terminal:

− Do not insert any object into the female connector, that is bigger than the male terminal.• Male Terminal:

− Carefully probe the contact surface of each terminal using a “T” pin. Do not bend terminal.

How To Check Proper Contact Spring Tension Of Terminal• An enlarged contact spring of a terminal may create intermittent signals in the circuit.• If an intermittent open circuit occurs, follow the procedure below to inspect for open wires and enlarged contact

spring of female terminal.− Use a male terminal which matches the female terminal.− Disconnect the suspected faulty connector and hold it terminal side up.− While holding the wire of the male terminal, attempt to insert the male terminal into the female terminal.− While moving the connector, check whether the male terminal can be easily inserted or not.

NOTE :If the male terminal can be easily inserted into the female terminal, replace the female terminal.

LTSMD030028

01–19

ELECTRICAL INFORMATION

HOW TO READ ELECTRICALSCHEMATICS 01-21Connector Symbols 01-21Option Splices 01-22
Electrical Schematic - Example 01-23
01–20

HOW TO LOCATE ELECTRICALSCHEMATICS IN THE SERVICEMANUAL 01-25Electrical Schematic Index 01-25


01

HOW TO READ ELECTRICAL SCHEMATICSConnector Symbols• Connector symbols shown from the terminal side

are enclosed by a single line and followed by thedirection mark.

• Connector symbols shown from the harness sideare enclosed by a double line and followed by thedirection mark.

• Most of the connector symbols in the wiring dia-grams are shown from the terminal side.

• In wiring diagrams, male terminals are shown inblack and female terminals are shown in white.

NOTE :Connector guides for male terminals are shown in blackand female terminals in white in wiring diagrams.

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01–21

HOW TO READ ELECTRICAL SCHEMATICS

Option Splices

• Option splices are shown with solid diamond-shaped boxes with identification numbers inside.BESMW010002T



01

Electrical Schematic - Example

BESMW010001T



Below is a list of the symbols and their definitions that are used in the wiring diagrams.

NUMBER ITEM DESCRIPTION

1 Power source This represents the condition when the system receivesbattery positive voltage.

2 Fuse The single line represents that this is a fuse.

3 Current rating This represents the current rating of the fuse.

4 Fuse location This represents the location of the fuse in the PowerFuse Box or Front Fuse and Relay Box.

5 Connectors This represents connector E-101 is female andconnector C-101 is male.

6 Terminal number This represents the terminal number of a connector.

7 Component name This represents the name of a component.

8 Connector numberThis represents the connector number.The letter represents which harness the connector islocated in.

9 Splice The shaded circle represents that the splice is alwayson the vehicle.

10 Optional splice The open circle represents that the splice is optionaldepending on vehicle application.

11 Option abbreviation This represents that the circuit is optional depending onvehicle application.

12 Ground (GND)This represents the ground connection (See GroundDistribution in Section 16 Wiring).Ground connector number has no view face.

13 Page crossing

This arrow represents that the circuit continues to anadjacent page.The �A� corresponds with the �A� on the adjoining pageof the electrical schematic.

14 Data link This represents that the system branches to anothersystem identified by cell data code.

15 Option description This represents a description of the option abbreviationused on the page.

16 Connector viewsThis represents the connector information.This component side is described by the connectorsymbols.

17 Connector color

This shows a code for the color of the connector:B = BlackW = WhiteR = RedG = GreenL = BlueY = YellowBR = BrownO = OrangeGR = Gray

18 Shielded line The line enclosed by broken line circle representsshielded wire.

19 Light-emitting diodes As an illumination tool, in the circuit and instrumentcluster.


01

HOW TO LOCATE ELECTRICAL SCHEMATICS IN THESERVICE MANUAL

Electrical Schematic IndexThe following table shows where to locate a specific electrical schematic for a vehicle component or system. Theelectrical schematics are found throughout the service manual and are easily identified by their components or vehi-cle systems.

NOTE :Some service manual chapters DO NOT contain electrical schematics, and will be identified as None in the Com-ponent/Vehicle System column.

SERVICE MANUAL CHAPTER COMPONENT / VEHICLE SYSTEM

01 - General Information • None

02 - Engine • None

03 - Electronic Engine Controls

• Engine Control Module (ECM)• Engine Coolant Temperature Sensor• Knock Sensor• Upstream Oxygen Sensor• Downstream Oxygen Sensor• Crankshaft Position Sensor• Camshaft Position Sensor• Ignition Coil• Canister Control Valve• Front Fuse and Relay Box• A/C Compressor• Immobilizer• Fuel Injectors• Manifold Absolute Pressure Sensor (1.6L Only)• Air Flow Sensor (1.8L Only)• Accelerator Pedal Position Sensor• Vehicle Speed Sensor• Throttle Pedal Position Sensor• Power Steering Switch• Clutch Pedal Switch (if equipped)• Electronic Throttle Control Actuator

04 - Fuel Delivery • Fuel Injectors• Fuel Level Sensor and Fuel Pump

05 - Starting & Charging

• Starter Motor• Ignition Switch• Clutch Pedal Switch (if equipped)• Generator

06 - Cooling System • Cooling Fan


HOW TO LOCATE ELECTRICAL SCHEMATICS IN THE SERVICE MANUAL


07 - Exhaust • None

08 - Transaxle & Transfer Case • Manual Transaxle Assembly• Backup Lamp Switch

09 - Driveline & Axle • None

10 - Suspension • None

11 - Steering

• Power Steering Switch• Electronic Power Steering (EPS) Control Unit• Steering Torque Sensor• EPS Motor

12 - Brakes

• Antilock Brake System (ABS) Module• Wheel Speed Sensors• Brake Switch• Parking Brake Switch• Brake Fluid Level Switch

13 - Heating & Air Conditioning

• Automatic Temperature Control System• Blower Motor• In-Car Temperature Sensor• Outside Temperature Sensor• A/C Compressor• Refrigerant Pressure Switch

14 - Restraints

• Airbag Module• Seat Belt Buckle Switch• Front Crash Sensors• Driver Airbag• Passenger Airbag



01


15 - Body & Accessories

• Windshield Wiper Motor• Windshield Washer Motor• Rear Window Defroster• Power Door Locks• Power Windows• Power Mirrors• Radio• Interior Lights• Exterior Lights• Oil Pressure Switch• Warning Buzzer• Front Body Control Module (FBCM)• Rear Body Control Module (RBCM)• Instrument Cluster• Driver Information Center• Key Switch• Power Outlet• Data Link Connector• Immobilizer• Horn

16 - Wiring

• Power Distribution• Front Fuse and Relay Box• Power Fuse Box• Ignition Switch• Ground Distribution

Abbreviation List

TERM ABBREVIATION

Antilock Brake System ABS

Accelerator Sensor AES

Accelerator Pedal Position Sensor APS

Automatic Temperature Control ATC

Body Control Module BCM

Brake Pressure Sensor BPS

Camshaft Position Sensor CMP Sensor

Clutch Pedal Position Switch CPP Switch

Crankshaft Position Sensor CKP Sensor

Data Link Connector DLC

Diagnostic Trouble Code DTC

Engine Control Module ECM

Engine Coolant Temperature ECT

Engine Speed RPM

Evaporative Emission EVAP

Evaporative Emission Canister EVAP Canister

Evaporative Emission System EVAP System

Exhaust Gas Recirculation Valve EGR Valve

Electronic Power Steering EPS



TERM ABBREVIATION

Electronic Stability Program ESP

Front Left Wheel Speed Sensor FLS

Front Right Wheel Speed Sensor FRS

Rear Left Wheel Speed Sensor RLS

Rear Right Wheel Speed Sensor RRS

Ground GND

Heated Oxygen Sensor O2S

Idle Air Control IAC

Intake Air Temperature IAT

Ignition IGN

Ignition Control IC

Injector INJ

Input Shaft Speed Sensor ISS Sensor

Knock Sensor KS

Manifold Absolute Pressure MAP

Mass Air Flow MAF

Oil Pressure Switch OPS

Output Shaft Speed Sensor OSS Sensor

Positive Crankcase Ventilation Valve PCV Valve

Power Supply PWR

SRS Airbag Control System SRC

Throttle Position Sensor TPS

Transmission Control Module TCM

Turbine Speed Sensor TSS

Vehicle Identification Number VIN

Electronic Pedal Control EPC

Vehicle Speed Sensor VSS


ENGINE

02CONTENTS

page1.6L & 1.8L Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-1

1.6L & 1.8L ENGINE MECHANICAL

GENERAL INFORMATION 02-3Description 02-3Operation 02-3Specifications 02-3Special Tools 02-7Lubrication System 02-10

DIAGNOSIS & TESTING 02-13Engine Performance Diagnostics 02-13Engine Mechanical Diagnostics 02-14Cylinder Compression Pressure Test 02-15Cylinder Head Gasket Test 02-15

ON-VEHICLE SERVICE 02-16

Accessory Drive Belt - WithConventional Power Steering 02-16

Removal & Installation 02-16

Accessory Drive Belt - With ElectronicPower Steering 02-17


Air Cleaner Element 02-18Removal & Installation 02-18

Air Cleaner Housing 02-18Removal & Installation 02-18

Cylinder Head Cover 02-19Removal & Installation 02-19

Camshaft 02-20Removal & Installation 02-20

Cylinder Head 02-23Removal & Installation 02-23

Front Crankshaft Oil Seal 02-25Removal & Installation 02-25

Rear Crankshaft Oil Seal 02-26Removal & Installation 02-26

Engine Mounts 02-28Left Mount - Removal & Installation 02-28Right Mount - Removal & Installation 02-29Rear Mount - Removal & Installation 02-30

Engine Assembly 02-30Removal & Installation 02-30

Engine Timing Belt 02-38Removal & Installation 02-38

Intake Manifold 02-42Removal & Installation 02-42

Exhaust Manifold 02-44Removal & Installation 02-44

Idler Pulley 02-46Removal & Installation 02-46

Oil Filter 02-46Removal & Installation 02-46

Oil Pan 02-47Removal & Installation 02-47

Oil Pump 02-48Removal & Installation 02-48

Oil Strainer 02-49Removal & Installation 02-49

02


ENGINE UNIT REPAIR 02-50

Engine Block 02-50Specifications 02-50Disassembly 02-50Inspection 02-52Assembly 02-52

Pistons 02-53Specifications 02-53Disassembly 02-54Inspection 02-55Assembly 02-57

Connecting Rods 02-58Specifications 02-58Disassembly 02-58Inspection 02-59Assembly 02-59

Crankshaft 02-60Specifications 02-60Disassembly 02-60Inspection 02-61Assembly 02-62

CYLINDER HEAD UNIT REPAIR 02-63

Cylinder Head 02-63Specifications 02-63Disassembly 02-63Inspection 02-65Assembly 02-65

Camshaft 02-66Specifications 02-66Disassembly 02-67Inspection 02-67Assembly 02-69

Valve & Valve Guides 02-70Specifications 02-70Disassembly 02-70Inspection 02-72Assembly 02-73

Valve Springs 02-73Specifications 02-73Disassembly 02-74Inspection 02-75Assembly 02-75


GENERAL INFORMATIONDescriptionThe 1.6L & 1.8L in-line four cylinder engines have the following features:• Dual overhead camshafts• Four valves per cylinder• Aluminum cylinder head• Aluminum cylinder block (1.6L Engine)• Cast iron cylinder block (1.8L Engine)

OperationThe 1.6L & 1.8L engines utilize 4 valve-per-cylinders and a dual overhead camshaft design. The engines use anindividual coil ignition system. The 1.6L engine uses an aluminum cylinder block, and the 1.8L engine is made of castiron The bearing caps are integrated into the lower cylinder block assembly. An aluminum oil pan bolts to the bottomof the lower cylinder block. The camshafts are mounted in the cylinder head and act against valve tappets to openand close the valves. The camshafts are driven off the front of the cylinder head by one timing belt. The belt is drivenby a sprocket that is located on the crankshaft. The piston assembly is an aluminum piston with a cast iron con-necting rod.

The aluminum cylinder head contains dual overhead camshafts with 4 valve-per-cylinder construction. The valves arearranged in two in-line banks. The cylinder head incorporates powdered metal valve guides and seats. The cylinderhead is sealed to the block using a multi-layer steel head gasket and retaining bolts.

Specifications

1.6L Engine Specifications

DESCRIPTION SPECIFICATION

Type In-Line OHV, DOHC

Number of Cylinders 4

Compression Ratio 10.5:1

Compression Pressure 10 - 15 Bar

Maximum Compression Pressure Variation Between Cylinders 25%

Stroke 77.5 mm

Bore 81 mm

Displacement 1597 cc

Firing Order 1-3-4-2

1.8L Engine Specifications


Type In-Line OHV, DOHC

Number of Cylinders 4

Compression Ratio 10.5:1

Compression Pressure 10 - 15 Bar

Maximum Compression Pressure Variation Between Cylinders 25%

Stroke 89.5 mm

Bore 81 mm

Displacement 1845 cc

Firing Order 1-3-4-2

02


Mechanical Specifications

Description ITEM STANDARD LIMIT

Engine Oil Pressure

Lower Idle Speed (800 ±50 r/min) 1.2 - 1.5 bar -

High Idle Speed (2000r/min) 3.2 - 3.5 bar -

High Speed (4000 r/min) 3.7 ± 0.5 bar -

Engine Block Clearance

Surface Distortion - 0.15 mm

Inner Diameter 81.000 - 81.010 mm -

Out-Of-Round - Less than 0.008 mm

Taper - Less than 0.01 mm

Piston Ring GrooveClearance

First Ring 0.04 - 0.08 mm -

Second Ring 0.0251 - 0.01 mm -

Piston Ring End GapClearance

First Ring 0.2 - 0.4 mm 0.8 mm

Second Ring 0.4 - 0.6 mm 1.0 mm

Piston To Piston PinClearance - 0.002 - 0.013 mm -

Piston Diameter - 80.946 - 80.964 mm -

Ring Groove ClearanceFirst Ring 0.04 - 0.08 mm -

Second Ring 0.01 - 0.0251 mm -

Connecting Rod RadialClearance - 0.016 - 0.051 mm -

Connecting Rod AxialClearance - 0.002 - 0.013 mm -

Diameter Of CrankshaftMain Journals - 53.981 - 54 mm -

Diameter Of CrankshaftRod Journals - 47.884 - 47.9 mm -

Out-Of-Round MaximumOf Crankshaft MainJournals

- - Less than 0.008 mm

Axial Clearance OfCrankshaft - 0.07 - 0.265 mm -

Radial Clearance OfCrankshaft - 0.0035 - 0.034 mm -

Coaxality Crankshaft MainJournal - - Less than 0.005 mm

Thrust Washer Thickness - 2.4 - 2.405 mm -

Oil Clearance OfCrankshaft Rod And MainJournals

- 0.022 mm 0.058 mm

Cylinder Head Flatness - - Less than 0.04 mm

Intake Valve Deflection - - Less than 0.02 mm

Exhaust Valve Deflection - - Less than 0.04 mm

Spring Height - 47.7 mm -

Spring Height At 620Newtons Of Pressure - 32.0 mm -

Intake Cam Lobe Height - 37.15 mm -

GENERAL INFORMATION


Description ITEM STANDARD LIMIT

Exhaust Cam Lobe Height - 37.05 mm -

Camshaft Journal #1 OuterDiameter - 31.934 - 31.95 mm -

Camshaft Journal #2, #3,#4, #5, Outer Diameter - 23.947 - 23.96 mm -

Camshaft Cam Bearing #1Inner Diameter - 32 - 32.025 mm -

Camshaft Cam Bearing#2, #3, #4, #5, InnerDiameter

- 24 - 24.021 mm -

Camshaft Journal #1Clearance - 0.05 - 0.091 mm -

Camshaft Journal #2, #3,#4, #5 Clearance - 0.04 - 0.074 mm -

Intake Camshaft AxialClearance - 0.15 - 0.20 mm -

Exhaust Camshaft AxialClearance - 0.15 - 0.20 mm -

Intake Valve GuideClearance - 0.012 - 0.043 mm -

Exhaust Valve GuideClearance - 0.032 - 0.063 mm -

Valve Outer DiameterIntake Valve 5.98 ± 0.008 mm -

Exhaust Valve 5.96 ± 0.008 mm -

Valve Guide InnerDiameter

Intake Valve 5.4 ± 0.1 mm -


Fringe Thickness On TopOf Valve

Intake Valve 0.3 ± 0.15 mm -


Valve Tilt AngleIntake Valve 65 ° -

Exhaust Valve 68 ° -

Valve HeightIntake Valve 107.998 mm -

Exhaust Valve 106.318 mm -

Torque Specifications

CAUTION:When torquing a fastener in two steps, DO NOT use a torque wrench for the second step.

DESCRIPTION TORQUE (N·m)

Accessory Drive Belt Tensioner Pulley Bolt 35

Camshaft Bearing Cap Bolts 11

Clutch Pressure Plate Bolts 25

Connecting Rod Cap Bolts 1st Step: Tighten the bolt to 25 N·m2nd Step: Tighten the bolt an additional 90°

Crankshaft Holder 28

Crankshaft Main Bearing Cap Bolts 1st Step: Tighten the bolt to 45 N·m2nd Step: Tighten the bolt an additional 180°

GENERAL INFORMATION

02



Crankshaft Timing Belt Pulley Bolt 1st Step: Tighten the bolt to 130 N·m2nd Step: Tighten the bolt an additional 65°

Crankshaft Vibration Damper Bolts 25

Cylinder Head Cover Bolts 11

Cylinder Head Bolts1st Step: Tighten the bolt to 40 ± 5 N·m

2nd Step: Tighten the bolt an additional 90 ± 5°3rd Step: Tighten the bolt an additional 90 ± 5°

Dipstick Bracket Bolts 11

Engine Left Mount Bolt 120

Engine Right Mount Bolt 120

Engine Rear Mount Bolt 120

Engine To Transaxle Bolts 80

Exhaust Manifold Nuts 25

Exhaust Manifold Heat Shield Bolts 15

Exhaust Camshaft Timing Belt Pulley Bolt 120

Flywheel Bolts 75

Fuel Rail Bracket Bolts 11

Idler Pulley Bolt 40

Intake Camshaft Timing Belt Pulley Bolt 120

Intake Manifold Bolts 10

Intake Manifold Nuts 11

Intake Manifold Bracket Bolts 25

Lower Idler Pulley Bolt 45

Lower Cylinder Block Bolts 23

Oil Filter 25

Oil Pan Bolts 18

Oil Drain Plug 40

Oil Strainer Bolts 18

Oil Pump Bolts 11(Apply with Loctite 5910 Thread-Locker)

Rear Timing Cover Bolts 7

Timing Belt Upper Cover Bolts 11

Timing Belt Lower Cover Bolts 11

Timing Belt Tensioner Assembly 27

Timing Belt Tensioner Pulley Bolt 30

Throttle Body Bolts 11

Upper Idler Pulley Bolt 45

GENERAL INFORMATION


Special Tools

Right Engine Mount Bolt RemoverCH-20001

Camshaft Seal InstallerCH-20002

Crankshaft HolderCH-20003

Valve Spring Compressor AdaptorCH-20004

Rear Crankshaft Oil Seal InstallerCH-20005

GENERAL INFORMATION

02


Rear Crankshaft Oil Seal GuideCH-20006

Front Crankshaft Seal InstallerCH-20007

Front Crankshaft Seal GuideCH-20008

Camshaft HolderCH-20010

Valve Seal InstallerCH-20011

GENERAL INFORMATION


Valve Stem Seal Installer GuideCH-20012

Valve Seal RemoverCH-20013

Valve Keeper InstallerCH-20017

Valve Spring CompressorCH-20018

Crankshaft Belt Pulley FixtureCH-20019

GENERAL INFORMATION

02


Engine Hoist

Flywheel FixtureCH-20043

Oil Filter RemoverCH-10003

Lubrication SystemThe engine lubrication system operates as follows:• Oil is drawn into the oil pump through the oil pump strainer tube in the sump of the oil pan.• Oil is pumped through the oil filter on the cylinder block.• Oil enters the main oil gallery where it is distributed to the crankshaft main journals and to the cylinder head.• From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate the con-

necting rod bearings. Controlled leakage through the crankshaft main bearings and connecting rod bearings isslung radially outward to cool and lubricate the cylinder walls as well as the entire connecting rod, piston andpiston ring assembly.

• The engine lubrication system is a full-flow filtration, pressure feed type. The oil pump body is mounted to theengine block. The pump inner rotor is driven by the crankshaft.

Engine Oil Pressure

Lower Idle Speed (800 ± 50 RPM) 1.2 - 1.5 bar

High Idle Speed (2000 RPM) 3.2 - 3.5 bar

High Speed (4000 RPM) 3.7 ± 0.5 bar

GENERAL INFORMATION


Engine Oil Flow Diagram

1 – Oil Pump Strainer

2 – Baffle Plate

3 – Oil Pan

4 – Oil Pump

5 – Turbocharger Inlet Oil Passage (if equipped)

6 – To Cylinder Head

7 – Oil Return Passage

8 – To Front Bearing Cap

9 – To Middle Bearing Cap

10 – Oil Dipstick

11 – To Crankcase

12 – Crankcase Pipe

13 – Oil Filter Bracket

14 – Oil Pressure Switch

15 – Oil Cooler

16 – Oil Filter

GENERAL INFORMATION

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Engine Lubrication System Exploded View

1 - Oil Dipstick

2 - Oil Dipstick Bolt

3 - Oil Dipstick Bracket

4 - Oil Dipstick Guide

5 - Crankshaft Rear Oil Seal

6 - O-Ring

7 - Oil Filter Bracket Cushion

8 - Oil Filter Bracket

9 - Pressure-Relief Plunger

10 - Flange Bolt

11 - Flange Bolt

12 - Oil Cooler

13 - Oil Filter Connector

14 - Oil Filter

15 - Dowel Pin

16 - Oil Pan Bolt

17 - Oil Pan Bolt

18 - Oil Pan Bolt

19 - Oil Pan

20 - O-Ring

21 - O-Ring

22 - Oil Pump Strainer Bolt

23 - Oil Pump Strainer

24 - Baffle Plate

25 - O-Ring

26 - O-Ring

27 - Crankshaft Front Oil Seal

28 - Oil Pump Bolt

29 - Oil Pump Assembly

30 - Oil Pump Assembly Gasket

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DIAGNOSIS & TESTINGEngine Performance Diagnostics

CONDITION POSSIBLE CAUSE CORRECTION

ENGINE DOES NOT START

1. Weak battery.2. Corroded or loose batteryconnections.3. Faulty starter.4. Faulty coil(s) or control unit.5. Incorrect spark plug gap.6. Contamination in fuel system.7. Faulty fuel pump.8. Incorrect timing.

1. Test battery. Charge or replace ifnecessary.2. Clean and tighten battery connections.Apply a coat of light mineral grease toterminals.3. Test starting system. Check for codes.(Refer to Appropriate Diagnostic Information)4. Test and replace as needed. (Refer toAppropriate Diagnostic Information)5. Set gap.6. Clean system and replace fuel filter.7. Test fuel pump and replace as needed.(Refer to Appropriate Diagnostic Information)8. Check for a skipped timing belt.

ENGINE STALLS OR IDLESROUGH

1. Idle speed too low.2. Incorrect fuel mixture.3. Intake manifold leakage.4. Faulty ignition coil(s).

1. Test minimum air flow. (Refer toAppropriate Diagnostic Information)2. (Refer to Appropriate DiagnosticInformation)3. Inspect intake manifold, manifold gasket,and vacuum hoses.4. Test and replace if necessary. (Refer toAppropriate Diagnostic Information)

ENGINE LOSS OF POWER

1. Dirty or incorrectly gappedspark plugs.2. Contamination in fuel system.3. Faulty fuel pump.4. Incorrect valve timing.5. Leaking cylinder head gasket.6. Low compression.7. Burned, warped, excessiveclearance or pitted valves.8. Plugged or restricted exhaustsystem.9. Faulty ignition coil(s).10. Burned spark plugs.

1. Clean spark plugs and set gap.2. Clean system and replace fuel filter.3. Test and replace if necessary. (Refer toAppropriate Diagnostic Information)4. Correct valve timing.5. Replace cylinder head gasket.6. Test compression of each cylinder.7. Replace valves.8. Perform exhaust restriction test. Installnew parts.9. Test and replace if necessary. (Refer toAppropriate Diagnostic Information)10. Replace spark plugs.

ENGINE MISS ONACCELERATION

1. Dirty or incorrectly gappedspark plugs.2. Contamination in fuel system.3. Burned, warped, or pittedvalves.4. Faulty ignition coil(s).

1. Clean spark plugs and set gap.2. Clean fuel system and replace fuel filter.3. Replace valves.4. Test and replace if necessary. (Refer toAppropriate Diagnostic Information)

ENGINE MISS AT HIGH SPEED

1. Dirty or incorrect spark pluggap.2. Faulty ignition coil(s).3. Dirty fuel injector(s).4. Contamination in fuel system.

1. Clean spark plugs and set gap.2. Test and replace if necessary. (Refer toAppropriate Diagnostic Information)3. Test and replace if necessary. (Refer toAppropriate Diagnostic Information)4. Clean system and replace fuel filter.

DIAGNOSIS & TESTING

02


Engine Mechanical Diagnostics


VALVE TRAIN NOISE

1. High or low oil level in crankcase.2. Thin or diluted oil.3. Thick oil.4. Low oil pressure.5. Worn cam lobe.6. Worn valve guides.7. Excessive runout of valve seatson valve faces.

1. Check and correct engine oillevel.2. Change oil to correct viscosity.3. Change engine oil and filter.4. Check and correct engine oillevel.5. Install new camshaft.6. Replace cylinder head.7. Grind valve seats and replacevalves.

CONNECTING ROD NOISE

1. Insufficient oil supply.2. Low oil pressure.3. Thin or diluted oil.4. Excessive bearing clearance.5. Connecting rod journal out-of-round.6. Connecting rod out-of-round.7. Misaligned connecting rods.

1. Check engine oil level.2. Check engine oil level. Inspect oilpump relief valve and spring.3. Change oil to correct viscosity.4. Measure bearings for correctclearance. Repair if necessary.5. Replace crankshaft or grindsurface.6. Replace connecting rod.7. Replace bent connecting rods.

MAIN BEARING NOISE

1. Insufficient oil supply.2. Low oil pressure.3. Thin or diluted oil.4. Excessive bearing clearance.5. Excessive end play.6. Crankshaft journal out-of-round orworn.7. Loose flywheel or torqueconverter.

1. Check engine oil level.2. Check engine oil level. Inspect oilpump.3. Change oil to correct viscosity.4. Measure bearings for correctclearance. Repair if necessary.5. Check thrust bearing for wear onflanges.6. Replace crankshaft or grindjournals.7. Tighten to correct torque.

OIL PRESSURE DROP

1. Low oil level.2. Faulty oil pressure sending unit.3. Low oil pressure.4. Clogged oil filter.5. Thin or diluted oil.6. Excessive bearing clearance.

1. Check engine oil level.2. Install new sending unit.3. Check sending unit and mainbearing oil clearance.4. Install new oil filter.5. Change oil to correct viscosity.6. Measure bearings for correctclearance.

OIL LEAKS

1. Misaligned or deterioratedgaskets.2. Loose fastener, broken or porousmetal part.3. Misaligned or deteriorated cup orthreaded plug.

1. Replace gasket.2. Tighten, repair or replace the part.3. Replace if necessary.

OIL CONSUMPTION OR SPARKPLUGS FOULED

1. PCV system malfunction.2. Worn, scuffed or broken rings.3. Carbon in oil ring slots.4. Rings fitted too tightly in grooves.5. Worn valve guide(s).6. Valve stem seal(s) worn ordamaged.

1. Check system and repair ifnecessary.2. Hone cylinder bores. Install newrings.3. Install new rings.4. Remove rings and check grooves.If groove is not proper width, replacepiston.5. Replace cylinder head.6. Replace seal(s).

DIAGNOSIS & TESTING


Cylinder Compression Pressure Test• The result of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions.• Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise

the indicated compression pressures may not be valid for diagnostic purposes.− Check engine oil level and add oil if necessary.− Disconnect the spark plug wires.− Remove all spark plugs from engine (as spark plugs are being removed, check electrodes for abnormal

firing indicators fouled, hot, oily, etc.).− Record cylinder number of each spark plug for future reference.− Disconnect fuel injector electrical connectors.− Be sure throttle blade is fully open during the compression check.− Insert compression pressure adaptor or the equivalent into each spark plug hole in cylinder head.− Crank engine until maximum pressure is reached on gauge. Record each cylinder pressure.− Compression should not be less than 1000 kPa and not vary more than 25 percent from cylinder to cylinder.− If one or more cylinders have abnormally low compression pressures, repeat the compression test.− If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could

indicate the existence of a problem in the cylinder in question.

NOTE :The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engineshould not be disassembled to determine the cause of low compression unless some malfunction is present.

Cylinder Head Gasket Test• A cylinder head gasket leak can be located between adjacent cylinders, between a cylinder and the adjacent

water jacket or from an oil passage to the exterior of the engine.• Possible indications of the cylinder head gasket leaking between adjacent cylinders are:

− Loss of engine power− Engine misfiring− Poor fuel economy

• Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:− Engine overheating− Loss of coolant− Excessive steam (white smoke) emitting from exhaust− Coolant foaming

DIAGNOSIS & TESTING

02


ON-VEHICLE SERVICE

Accessory Drive Belt - With Conventional Power Steering

Removal & Installation

WARNING!

Inspect the drive belt only when the engine is stopped.

1. While using a suitable tool and securely holding the hexagonal portion of the drive belt tensioner, rotate thepulley counterclockwise to loosen the drive belt.

WARNING!

Avoid placing hands near the drive belt tensioner while it is being held.

1 - Drive Belt

2 - Generator Bolt

3 - Tensioner Pulley Bolt

4 - Tensioner

5 - Compressor

6 - Generator

7 - Idler Pulley

8 - Generator Bracket

9 - Generator Bracket Bolt

10 - Generator Bracket Bolts

11 - Power Steering Pump Bolt



14 - Power Steering Pump Bracket

15 - Power Steering Pump Bracket Bolts

16 - Power Steering Pump

17 - Idler Pulley

18 - Compressor Bolts

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2. Remove the drive belt.3. If replacing the accessory drive belt tensioner,

remove the accessory drive belt tensioner pulleybolt (1).(Tighten: Accessory drive belt tensioner pulley boltto 35 N·m)

4. Installation is in the reverse order of removal.

Accessory Drive Belt - With Electronic Power Steering

Removal & InstallationWARNING!

Inspect the drive belt only when the engine is stopped.

1. While using a suitable tool and securely holding the hexagonal portion of the drive belt tensioner, rotate thepulley counterclockwise to loosen the drive belt.

WARNING!


2. Remove the drive belt.3. If replacing the accessory drive belt tensioner,

remove the accessory drive belt tensioner pulleybolt (1).(Tighten: Accessory drive belt tensioner pulley boltto 35 N·m)


ON-VEHICLE SERVICE

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02


Air Cleaner Element

Removal & Installation1. Remove the air cleaner case side bolts (1) and

remove the air cleaner upper case.2. Remove the air cleaner element.3. Install a new air cleaner element.4. Installation is in the reverse order of removal.

Installation Notes:

• If necessary, clean the inside of the air cleanerhousing before installing new air cleaner element.

Air Cleaner Housing

Removal & Installation1. Disconnect the negative battery cable.2. Disconnect the air flow sensor electrical connector

(1) (1.8L engine only).

3. Loosen the clamps (1) between the air intake hoseand the air cleaner.

ON-VEHICLE SERVICE

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4. Remove the bolts (1) securing the air cleanerhousing to its base.

5. Remove the air cleaner housing.6. Installation is in the reverse order of removal.

Cylinder Head Cover

Removal & Installation1. Disconnect the negative battery cable.2. Use compressed air to blow dirt and debris off the

cylinder head cover prior to removal.3. Disconnect the camshaft position sensor electrical

connector.4. Remove the camshaft position sensor (2) and set it

aside.5. Remove the spark plug wires (3) and set them

aside.6. Remove the PCV hose (1) from cylinder head

cover.

ON-VEHICLE SERVICE

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02


7. Remove the cylinder head cover bolts (1).(Tighten: Cylinder head cover bolts to 11 N·m)

8. Remove the cylinder head cover (2) from the cylin-der head.

9. Remove the cylinder head cover gasket (3).10. Installation is in the reverse order of removal.

Camshaft


NOTE :The following special tools are required to perform the repair procedure:• CH-20002 - Camshaft seal installer• CH-20010 - Camshaft holder

1. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).2. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).3. Remove the cylinder head cover (See Cylinder Head Cover Removal & Installation in Section 02 Engine).4. Remove the intake or exhaust camshaft timing belt pulleys.

(Tighten: Camshaft timing belt pulley bolt to 120 N·m)

ON-VEHICLE SERVICE

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5. Remove the rear timing cover of the timing pulley.(Tighten: Rear timing cover bolts to 7 N·m)

6. Remove the camshaft bearing cap bolts.(Tighten: Camshaft bearing cap bolts to 11 N·m)NOTE: Equally loosen camshaft bearing cap boltsin several steps.

7. Remove the camshaft bearing caps and placethem in proper order.NOTE: The camshaft bearing caps are marked foridentification.

8. Remove the camshafts and then remove the camshaft seals.9. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

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02


Installation Notes:

• Use special tool CH-20010 (1), to install the camshaft holder to hold the camshafts in place.

NOTE :The camshaft holder will prevent the camshafts fromrotating in either direction.

• Use special tool CH-20002 (1), to install the camshaft seal.• Install the intake and exhaust camshaft bearing

caps in the proper order.• Slowly tighten bolts to the specified torque.

• Follow the torque sequence as shown.

ON-VEHICLE SERVICE

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Cylinder Head


NOTE :Replacement cylinder head comes complete with valves, seals, springs, retainers, keepers, and camshafts.

1. Remove engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).2. Remove the cylinder head cover (See Cylinder Head Cover Removal & Installation in Section 02 Engine).3. Remove the camshafts (See Camshaft Removal & Installation in Section 02 Engine).4. Remove intake manifold (See Intake Manifold Removal & Installation in Section 02 Engine).5. Remove exhaust manifold (See Exhaust Manifold Removal & Installation in Section 02 Engine).6. Remove water pipe and thermostat assembly.

1 - Rocker Arm

2 - Hydraulic Tappet

3 - Valve Keeper

4 - Valve Spring Upper Retainer

5 - Valve Spring

6 - Valve Oil Seal

7 - Valve Spring Lower Retainer

8 - Valve

ON-VEHICLE SERVICE

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02


7. Remove the cylinder head bolts in the ordershown.

8. Remove cylinder head gasket.9. Installation is in the reverse order of removal.

Installation Notes:

• Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are notdamaged.

• The cylinder head bolts should not be reused. The new bolts should be examined before use. If the bolts arestretched, the bolts should be replaced.

• Position the new cylinder head gasket on the engine block with the part number facing up. Ensure gasket isseated over the locating dowels in the block.

• Before installing the bolts, the threads should be lightly coated with engine oil.

ON-VEHICLE SERVICE

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• Install the cylinder head bolts in the order shown.• Torque the cylinder head bolts in the following

three step sequence:− 1st Step: Tighten the bolt to 40 ± 5 N·m− 2nd Step: Tighten the bolt an additional

90 ± 5°− 3rd Step: Tighten the bolt an additional

90 ± 5°

Front Crankshaft Oil Seal


NOTE :The following special tools are required to perform the repair procedure:

• CH-20007 - Front crankshaft seal installer• CH-20008 - Front crankshaft seal guide• CH-20019 - Crankshaft belt pulley fixture

1. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).2. Remove the crankshaft vibration damper bolts (1).

(Tighten: Crankshaft vibration damper bolts to25 N·m)

3. Remove the engine timing belt (See Engine TimingBelt Removal & Installation in Section 02 Engine).

ON-VEHICLE SERVICE

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4. Remove the crankshaft timing belt pulley bolt (2)from the crankshaft.(Tighten: Crankshaft timing belt pulley bolt to 130N·m and an additional 65°)

5. Remove the key-way from the crankshaft.6. Use an appropriate tool and remove the front

crankshaft oil seal (1).

CAUTION:Be careful not to damage the front cover sealsurface while removing the seal.


Installation Notes:

• Use the front crankshaft seal installer CH-20008 (1), to install the new seal.• Lubricate the new front seal with engine oil prior to

assembly.

Rear Crankshaft Oil Seal


NOTE :The following special tools are required to perform the repair procedure:• CH-20005 - Rear crankshaft oil seal installer• CH-20006 - Rear crankshaft oil seal guide• CH-20043 - Flywheel fixture

1. Remove the transaxle assembly (See Transaxle Assembly Removal & Installation in Section 08 Transmission).2. Using special tool CH-20043 (1), hold the flywheel.

ON-VEHICLE SERVICE

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3. Remove clutch pressure plate retaining bolts (1)and then remove the clutch pressure plate.(Tighten: Clutch pressure plate bolts to 25 N·m)

4. Remove the engine flywheel mounting bolts (1),and then remove the flywheel.(Tighten: Flywheel mounting bolts to 75 N·m)

5. Remove the rear oil seal using a suitable tool.6. Installation is in the reverse order of removal.

Installation Notes:

• When installing seal, lubricate seal guide with cleanengine oil.

• Position the seal over the rear crankshaft sealguide.

• Use special tool CH-20005 (2) and CH-20006 (1),to install the rear crankshaft oil seal.

• Ensure that the lip of the seal is facing toward thecrankcase during installation.

ON-VEHICLE SERVICE

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02


Engine Mounts

Left Mount - Removal & Installation

NOTE :The following special tools are required to perform the repair procedure:• Engine Hoist

1. Disconnect the positive and negative battery cables.2. Remove the battery (See Battery Removal & Installation in Section 05 Starting & Charging).3. Remove the front fuse and relay box.4. Remove the battery tray retaining bolts (1).

5. Remove the left transaxle mount bolts (2) and theleft transaxle mount bracket bolts (1).(Tighten: Left transaxle mount bolt to 120 N·m)


ON-VEHICLE SERVICE

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Right Mount - Removal & Installation


1. Disconnect the negative battery cable.2. Disconnect the coolant level sensor electrical connector.3. Remove the coolant reservoir retaining bolts (1)

and the hose clamps (2) then set it aside.

4. Remove the vapor canister retaining bolts (1) andset the canister aside.

5. Remove the right engine mount bolts (1) and theright engine mount bracket bolts (2).(Tighten: Right engine mount bolts to 120 N·m)


ON-VEHICLE SERVICE

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02


Rear Mount - Removal & Installation


1. Remove the rear engine mount retaining bolts (2)and the rear engine mount bracket bolts (1).(Tighten: Rear engine mount bolt to 120 N·m)


Engine Assembly


NOTE :The following special tools are required to perform the repair procedure:• CH-20001 - Right engine mount bolt remover• Engine hoist

NOTE :The engine is removed with the transaxle as an assembly.

1. Remove the vehicle hood.2. Remove the battery, battery hold downs, and battery tray (See Battery Removal & Installation in Section 05

Starting & Charging).3. Loosen the clamps (1) between the air intake hose

and the air cleaner, then remove the air inlet hose.NOTE: For 1.8L engine, disconnect the air flowsensor electrical connector.

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4. Remove the retaining bolts (1) and remove the aircleaner and air cleaner housing assembly.

5. Remove the power fuse box (1) and set it aside.6. Remove the front fuse and relay box (2).

7. Remove the front air intake hose retaining bolt (1)and take off the front air intake hose (2).

8. Evacuate the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating and Air Condition-ing).

9. Drain the cooling system (See Cooling SystemDraining and Filling in Section 06 Cooling).

10. Remove the coolant reservoir retaining bolts (1)and the hose clamps (2).

11. Remove the coolant reservoir.

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02



13. Remove the coolant fan & radiator assembly (See Coolant Fan & Radiator Assembly Removal & Installation inSection 06 Cooling).

14. Remove the starter motor wiring.15. Remove the negative battery cable from the engine.16. Relieve the fuel pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).17. Disconnect and remove the fuel line at the fuel rail.18. Remove the ground cable bolt from the cylinder head.19. Disconnect and remove the following electrical connectors:

Coolant temperature sensorCoolant level sensorCamshaft position sensorIgnition coilFour fuel injectorsIntake manifold air pressure sensor (1.6L engine only)Air flow sensor (1.8L engine only)Carbon canister solenoid valveThrottle body controlA/C compressorOil pressure sensorPower steering pump pressure switchGenerator

20. Remove the pipe from the canister control valve.21. Disconnect the heater hoses (1) on the vehicle.22. Remove the vacuum line from the brake booster

(2).23. Remove the dipstick.

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24. Remove the transaxle shift cable (1).

25. Remove the shift cable clamp (1) from the shiftcable bracket.

26. Remove the shift cable bracket retaining bolts (1).

27. Remove the coolant pipe bracket retaining bolts(1).

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28. Disconnect the hydraulic line (1) from the hydraulicclutch cylinder and position it aside.

CAUTION:While hoses are disconnected, plug all openings to prevent foreign material from enteringthem.

29. Remove the hydraulic line clamp (1).

30. Remove the A/C compressor line bolt (1) from theA/C compressor.(Tighten: A/C compressor line bolts to 20 N·m)NOTE: After removing the A/C lines, plug the A/Clines to prevent any debris from entering the A/Csystem.

31. If equipped with conventional power steering,re-move the high pressure line (1) and low pressureline (2) from the power steering pump (drain fluidfrom lines).(Tighten: High pressure line to power steeringpump 40 ± 5 N·m)(Tighten: Low pressure line to power steering pump40 ± 5 N·m)

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32. Remove the exhaust manifold heat shield bolts (1)and then remove heat shield.(Tighten: Exhaust manifold heat shield bolts to15 N·m)

33. Disconnect the upstream and downstream oxygen sensor connectors.34. Remove the catalytic converter to exhaust manifold

bolts (1).

35. Raise the vehicle.36. Remove the front axle shaft (See Front Axle Shaft Removal & Installation in Section 09 Driveline & Axle).37. Drain the engine oil.38. Lower the vehicle and install engine lift chain hangers.39. Remove the rear engine mount bolts (2) and the

rear engine mount bracket bolt (1).(Tighten: rear engine mount bolt to 120 N·m)

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40. Remove the left transaxle mount bolts (2) and theleft transaxle mount bracket bolts (1).(Tighten: Left transaxle mount bolt to 120 N·m)

41. Remove the right engine mount bolts (1) and theright engine mount bracket bolts (2).(Tighten: Right engine mount bolt to 120 N·m)

42. Verify all components between the engine and vehicle are disconnected.43. Remove the front sub-frame (See Front Sub-frame Removal & Installation in Section 10 Suspension).44. Hoist the engine from vehicle.

CAUTION:Verify all electrical connectors are disconnected prior to engine/transaxle removal.45. Separate engine and transaxle.46. Remove the accessory drive belt (1) and the idle

pulley (See Accessory Drive Belt Removal & Instal-lation in Section 02 Engine).

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47. Remove the generator (1) from the bracket (SeeGenerator Removal & Installation in Section 05Starting & Charging).

48. Remove the A/C compressor (2) (See A/C Com-pressor Removal & Installation in Section 13 Heat-ing and Air Conditioning).

49. If equipped with conventional power steering,remove the power steering pump (1) with the linesattached, set aside and secure with wire (SeePower Steering Pump Removal & Installation inSection 11 Steering).


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02


Engine Timing Belt


NOTE :The following special tools are required to perform the repair procedure:• CH-20001 - Right engine mount bolt remover• CH-20003 - Crankshaft holder• CH-20010 - Camshaft holder• Engine hoist

1. Disconnect the negative battery cable.2. Disconnect the coolant level sensor electrical connector.3. Release the coolant system pressure.

WARNING!

Never remove the pressure relief cap under any conditions while the engine is operating or hot. Failure to followthese instructions could result in personal injury or damage to the cooling system or engine. To avoid havingscalding hot coolant or steam blow out of the cooling system, use extreme care when removing the pressurerelief cap. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn itslowly one turn (counterclockwise). Step back while the pressure is released from the cooling system. When youare certain all the pressure has been released, (with a cloth) turn and remove the pressure relief cap. Failure tofollow these instructions may result in serious personal injury.

1 - Timing Belt Upper Cover Bolts

2 - Timing Belt Upper Cover

3 - Timing Belt Upper Cover Gasket

4 - Timing Belt

5 - Timing Belt Pulley

6 - Camshaft Timing Belt Pulley Bolts

7 - Camshaft Timing Belt Pulleys

8 - Timing Belt Rear Cover Bolts

9 - Timing Belt Rear Cover

10 - Idler Pulley

11 - Tensioner Pulley

12 - Tensioner Pulley Bolt

13 - Timing Belt Lower Cover

14 - Timing Belt Lower Cover Bolts

15 - Timing Belt Upper Cover Bolts

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4. Drain the cooling system (See Cooling SystemDraining and Filling in Section 06 Cooling).

5. Remove the coolant reservoir retaining bolts (1)and the hose clamps (2).

6. Remove the coolant reservoir.


8. Attach an engine hoist and support the engine using an engine hoist.9. Using special tool CH-20001, remove the right

engine mount bolts (1) and bracket bolts (2).

10. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).11. Remove the crankshaft vibration damper bolts (1).

(Tighten: Crankshaft vibration damper bolts to25 N·m)

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12. Remove the timing belt upper cover (1) and timingbelt lower cover (2).(Tighten: Timing belt upper cover bolts to11 N·m)(Tighten: Timing belt lower cover bolts to11 N·m)

13. Remove the cylinder head cover (See Cylinder Head Cover Removal & Installation in Section 02 Engine).14. Remove the plug in the cylinder block.15. Using special tool CH-20003 (1), install the crank-

shaft holder into the cylinder block and rotate thecrankshaft until the crankshaft tool completelyholds the crankshaft in place.(Tighten: Crankshaft holder to 28 N·m)NOTE: The crankshaft holder will prevent thecrankshaft from rotating in either direction.

16. Using special tool CH-20010 (1), install the cam-shaft holder to hold the camshafts in place.NOTE: The camshaft holder will prevent the cam-shafts from rotating in either direction.

CAUTION: Rotating the camshafts or crankshaft with timing components loosened or removed can causeserious damage to the valves or pistons.

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17. Loosen the bolt of the timing belt tensioner pulley(1), remove the pulley.(Tighten: Timing belt tensioner pulley bolt to30 N·m)

18. Remove the timing belt (3).19. Installation is in the reverse order of removal.

Installation Notes:

• Install the timing belt and rotate the tensioner pul-ley with an Allen wrench in order to apply tensionto the belt and align the finger pointer of the ten-sioner to the middle of the U-slot opening. Tightenthe tensioner pulley bolt (1) to 30 N·m, then tightenthe intake and exhaust camshaft pulley bolts (2) &(4) to 120 N·m.

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02


Intake Manifold


1. Disconnect the negative battery cable.2. Drain the engine coolant.

WARNING!

Never remove the pressure relief cap under any conditions while the engine is operating or hot. Failure to followthese instructions could result in personal injury or damage to the cooling system or engine. To avoid havingscalding hot coolant or steam blow out of the cooling system, use extreme care when removing the pressurerelief cap. Wait until the engine is cool, then wrap a thick cloth around the pressure relief cap and turn it slowlyone turn (counterclockwise). Step back while the pressure is released from the cooling system. When you arecertain all the pressure has been released, (with a cloth) turn and remove the pressure relief cap. Failure tofollow these instructions may result in serious personal injury.

1 - Fuel Rail Bolts

2 - Fuel Rail

3 - Electronic Throttle Control Actuator Bolts

4 - Electronic Throttle Control Actuator

5 - Electronic Throttle Control Actuator Gasket

6 - Air Intake Pressure Temperature Sensor Bolt

7 - Air Intake Pressure Temperature Sensor

8 - Intake Manifold Bolt

9 - Intake Manifold

10 - Intake Manifold Support Bracket

11 - Intake Manifold Gasket

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3. Disconnect the four fuel injector electrical connec-tors (1).

4. Disconnect the throttle body control electrical con-nector (2).

5. Disconnect the air pressure sensor electrical con-nector (1) (1.6L engine only).

6. Remove MAP sensor (2) from intake manifold.

7. Disconnect the air flow sensor electrical connector(1) (1.8L engine only).

8. Loosen the clamp between the air intake hose and the air cleaner.9. Loosen the clamp between the air intake hose and the throttle body and then remove the intake pipe.

10. Loosen the clamp on the PCV hose and then disconnect the PCV hose.

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11. Remove the fuel rail bracket bolts (1).(Tighten: Fuel rail bracket bolts to 11 N·m)

12. Remove the fuel rail with 4 fuel injectors and setaside.

13. Remove the screws securing the vacuum valve bracket to the intake manifold.14. Set aside the vacuum valve and pipe.15. Disconnect intake manifold electrical harness, and vacuum hose.16. Remove the bolts (2) & (3) securing the engine oil

dipstick to intake manifold. Remove the dipstick.(Tighten: Dipstick bracket bolts to 11 N·m)

17. Disconnect the oil pressure switch connector (4).18. Remove the nuts (1) securing the intake manifold

to cylinder head.(Tighten: Intake manifold nuts to 11 N·m)

NOTE: Replace a new intake manifold gasket.19. Installation is in the reverse order of removal.

Installation Notes:

• Clean all surfaces of manifold and cylinder head.• Install new O-rings on the fuel injectors.

Exhaust Manifold

Removal & Installation1. Remove the engine cover.2. Remove the bolts (1) attaching the exhaust mani-

fold heat shield.(Tighten: Exhaust manifold heat shield bolts to15 N·m)

3. Remove the exhaust manifold heat shield.

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4. Remove the three bolts (1) securing the exhaustmanifold to the catalytic converter assembly.

5. Disconnect the catalytic converter assembly fromthe manifold.

6. Remove the exhaust manifold nuts (1).(Tighten: Exhaust manifold nuts to 25 N·m)

7. Remove and discard manifold gasket (1).


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Installation Notes:

• Clean all surfaces of manifold and cylinder head.

Idler Pulley

Removal & Installation1. While using a suitable tool and securely holding the hexagonal portion of the drive belt tensioner, rotate the

pulley counterclockwise to loosen the drive belt.

WARNING!


2. Remove the drive belt.

Upper Accessory Drive Belt Idler Pulley (1)

• Remove the bolt and the upper accessory drivebelt idler pulley.

(Tighten: Upper idler pulley bolt to 45 N·m)

Lower Accessory Drive Belt Idler Pulley (2)

• Remove the bolt and the lower accessory drive beltidler pulley.

(Tighten: Lower idler pulley bolt to 45 N·m)


Oil Filter


NOTE :The following special tools are required to perform the repair procedure:• CH-10003 - Oil filter remover

CAUTION:When servicing the oil filter, avoid deforming the filter by installing the special tool against thebase of the filter.1. Using special tool CH-10003 oil filter remover,

remove the oil filter (1).(Tighten: Oil filter to 25 N·m)


Installation Notes:

• Clean all surfaces, and verify the oil filter does not leak.

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Oil Pan

Removal & Installation1. Remove the oil dipstick.2. Raise the vehicle on hoist.3. Remove the oil pan drain plug and drain the

engine oil.(Tighten: Oil pan drain plug to 40 N·m)

NOTE :Do not pry on cylinder block to remove oil pan.

4. Remove oil pan bolts (1).(Tighten: Oil pan bolts to 18 N·m)

5. Using a putty knife, loosen seal around oil pan.6. Remove the oil pan.7. Installation is in the reverse order of removal.

Installation Notes:

• Oil pan sealing surfaces must be free of grease or oil.• Install the four oil pan corner bolts in the sequence shown (1-2-3-4).• Install the remaining oil pan bolts.• Torque all the oil pan bolts to the proper

specification.

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Oil Pump

Removal & Installation1. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).2. Remove the crankshaft vibration damper retaining

bolts (1).(Tighten: Crankshaft vibration damper bolts to25 N·m)

3. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).4. Remove the crankshaft timing belt pulley bolt (2)

from the crankshaft.(Tighten: Crankshaft timing belt pulley bolt to 130N·m and an additional 65°)

5. Remove the key-way from the crankshaft.6. Use an appropriate tool and remove the front

crankshaft oil seal (1).

7. Remove the four oil pump bolts (1).(Tighten: Oil pump bolts to 11 N·m)

8. Remove the oil pump (2) using a suitable tool.9. Remove the oil pump gasket (3).


Installation Notes:

• Before installing, prime the new oil pump. Fill the oil pump with engine oil and rotate the oil pump.• Replace the oil pump gasket.

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Oil Strainer

Removal & Installation1. Raise the vehicle on hoist.2. Remove the oil pan (See Oil Pan Removal & Installation in Section 02 Engine).3. Remove the oil strainer retaining bolts (1).

(Tighten: Oil strainer bolts to 18 N·m)

4. Carefully remove the oil strainer.5. Installation is in the reverse order of removal.

Installation Notes:

• Install new O-rings on the oil strainer pipe.

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ENGINE UNIT REPAIR

Engine Block

Specifications



Connecting Rod Cap Bolts 1st Step: Tighten the bolt to 25 N·m2nd Step: Tighten the bolt an additional 90°

Main Bearing Cap Bolts 1st Step: Tighten the bolt to 45 N·m2nd Step: Tighten the bolt an additional 180°


Clearance Specifications


Surface Distortion Limit 0.15 mm

Inner Diameter Standard 81 mm

Out-Of-Round Less than 0.008 mm

Taper Less than 0.01 mm

Disassembly1. Remove the oil pan and then remove oil baffle.2. Remove the oil strainer.

3. For each connecting rod / piston assembly to be removed, rotate the crankshaft to the bottom dead center posi-tion for each cylinder.

NOTE :Before removing the connecting rod / piston assembly, check the connecting rod side clearance.

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4. Remove the connecting rod retaining bolts.

5. Remove the connecting rod bearing cap.

6. Using a hammer handle or similar tool, push theconnecting rod / piston assembly (1) out throughthe top of the cylinder block.

7. Remove the connecting rod bearings (See Con-necting Rod Removal & Installation in Section 02Engine).

CAUTION: When removing the connecting rod side bearings, note the installation position. Keep them inthe correct order.

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Inspection

NOTE :All measurements should be taken with the engine block at room temperature, 21°C.

Engine Block

• Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking.• Examine block and cylinder bores for cracks or fractures.• Check block deck surfaces for flatness. Deck surface must be within service limit of 0.050 mm.

Cylinder Bore

• The cylinder walls should be checked for out-of-round and taper with cylinder indicator or equivalent. If the cyl-inder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted.

• Measure the cylinder bore at three levels in directions X and Y. Top measurement should be 10 mm down andbottom measurement should be 10 mm up frombottom of bore.

CYLINDER BORE

All Cylinders 81.000 - 81.010 mm

Assembly

NOTE :Cleanliness is extremely important during the engine assembly procedure. Any foreign material, including any mate-rial created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can causeengine failure.

NOTE :Assemble all components in their original position.

1. Install the pistons to the connecting rods.2. Using a piston ring expander, install the piston rings.3. Assemble all components in the reverse order of disassembly.

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Pistons

Specifications

Clearance Specifications - Pistons


Surface Distortion Limit 0.15 mm

Inner Diameter Standard 81 mm

Out-Of-Round Less than 0.008 mm

Taper Less than 0.01 mm

Clearance Specifications - Piston Ring Groove


First Ring 0.04 - 0.08 mm

Second Ring 0.0251 - 0.01 mm

Clearance Specifications - Piston Ring End Gap

DESCRIPTION SPECIFICATION LIMIT



Clearance Specifications - Piston to Piston Pin


Piston To Piston Pin 0.002 - 0.013 mm

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02


Disassembly• Piston Ring Removal

− Using a suitable ring expander, remove upperand intermediate piston rings.

− Remove the upper oil ring side rail, lower oilring side rail and then oil ring expander frompiston.

− Clean ring grooves of any carbon deposits.

CAUTION:Before removing the piston rings (1), check thepiston ring side clearance. Be careful to markthe location of the piston rings if they are tobe reused.

• Piston Pin Snap Ring Removal− Using snap ring pliers, remove the snap ring

(1).− Heat the pistons if necessary.

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• Piston Pin Removal− Push out the piston pin with a suitable tool.

• Connecting Rod & Piston Disassembly− Remove the piston from the connecting rod.

Inspection• Check the piston diameter.

PISTON DIAMETER

All Pistons 80.946 - 80.964 mm

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• Check the inner diameter of each cylinder bore(See Cylinder Bore Inspection in Section 02Engine).

CYLINDER BORE

All Cylinders 81.000 - 81.010 mm

Check piston ring to groove side clearance:• Clean the ring slot using a suitable tool.• Measure piston ring to groove side clearance.

RING GROOVE CLEARANCE

First Ring 0.04 - 0.08 mm

Second Ring 0.01 - 0.0251 mm

Check piston ring end gap clearance:• Wipe the cylinder bore clean.• Insert ring and push down with piston to ensure it

is square in the bore.• The ring end gap measurement must be made with

the ring positioned at least 13 mm from bottom ofcylinder bore and below the bottom of the oil ringtravel where the cylinder bore has minimal wear.

• Check the ring end gap with feeler gauge.

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RING END GAP CLEARANCE



• Check the diameter of the piston pin bore.• Check the outer diameter of the piston pin.

• Check the inner diameter of connecting rod (small end).

PISTON PIN CLEARANCE

Piston and Piston Pin 0.002 - 0.013 mm

Assembly1. Install the piston to the connecting rod. Assemble the components in their original positions.2. Using a piston ring expander, install the piston rings. Assemble the components in their original positions.3. Assemble all components in the reverse order of disassembly.

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Connecting Rods

Specifications



Connecting Rod Bolts1st Step: Tighten bolts to 25 N·m

2nd Step: Tighten the connecting rod bolts an additional90°



Connecting Rod Radial Clearance 0.016 - 0.051 mm

Connecting Rod Axial Clearance 0.002 - 0.013 mm

Disassembly1. Remove the connecting rod cap bolts.2. Remove the connecting rod bearing cap.

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3. Using a hammer handle or similar tool, push the piston and connecting rod assembly (1) out through the cylinderhead side of the engine block.

NOTE: Before removing the piston and connecting rod assembly, check the connecting rod side clearance.4. Remove the connecting rod bearings.

CAUTION:When removing the connecting rod side bearings, note the installation position. Keep them inthe correct order.

Inspection• Check the radial clearance of connecting rod bearing.

CONNECTING ROD RADIAL CLEARANCE

Radial Clearance 0.016 - 0.051 mm

Assembly

NOTE :The rod bolts should not be reused.

1. Before installing the NEW rod bolts, the threads and under the bolt head should be oiled with clean engine oil.2. Install each bolt finger tight, then alternately tighten each bolt to assemble the cap properly.3. Tighten the connecting rod bolts using the two step

torque-turn method:• 1st Step: Tighten bolts to 25 N·m• 2nd Step: Tighten the connecting rod bolts an addi-

tional 90°

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4. Using a feeler gauge check connecting rod side clearance.• Check axial clearance of connecting rod.

Crankshaft

Specifications



Main Bearing Cap Bolts 1st Step: Tighten the bolt to 45 N·m2nd Step: Tighten the bolt an additional 180°




Diameter of Crankshaft Main Journals 53.981 - 54 mm

Diameter of Crankshaft Rod Journals 47.884 - 47.9 mm

Out-of-Round Maximum of Crankshaft Main Journals 0.008 mm

Axial Clearance of Crankshaft 0.07 - 0.265 mm

Radial Clearance of Crankshaft 0.0035 - 0.034 mm

Coaxality Crankshaft Main Journal 0.05 mm

Thrust Washer Thickness 2.4 - 2.405 mm

Disassembly1. Remove the front crankshaft oil seal (See Front Crankshaft Oil Seal Removal & Installation in Section 02

Engine).2. Remove the rear crankshaft oil seal (See Rear Crankshaft Oil Seal Removal & Installation in Section 02 Engine).3. Remove the pistons with connecting rod assemblies.

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4. Remove the lower cylinder block bolts in thesequence shown.NOTE: Before loosening the lower cylinder blockbolts, measure the crankshaft side clearance.

5. Remove the lower cylinder block.6. Remove the crankshaft.7. Remove the main bearings and thrust bearings from the cylinder block and lower cylinder block.

NOTE: If reusing the bearings, identify and number the bearings so that they are assembled in the same positionand direction.

InspectionInspect the crankshaft rod and main journals for the fol-lowing:• The crankshaft main journals should be checked for

excessive wear, roundness and scoring.• Main journal limits of roundness should be held to

0.008 mm.• Rod journal limits of roundness should be held to

0.005 mm.• DO NOT nick crank pin or bearing fillets.

CAUTION:DO NOT nick crank journals or bearing fillets.

Check the axial clearance after installation:• Standard axial clearance should be 0.07 mm.• Limits of axial clearance should be held to 0.265

mm.

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Check oil clearance of crankshaft main and rod jour-nals:• Clean the journal and bearing.• Install the crankshaft.• Cut the plastic-gauge to the same width as the

bearing, and then put it onto the crankshaft journalto make it parallel with the central line of the crank-shaft.

• Install the main bearing cap carefully, and tightenthe bolts to the specified torque.

• Remove the main bearing cap.• Measure the oil clearance with the plastic-gauge.

− Standard oil clearance of crankshaft rod andmain journals should be 0.022 mm

− Limits of oil clearance of crankshaft rod andmain journals should be 0.058 mm

Assembly1. Install the main bearings and thrust bearings to the upper cylinder block and lower cylinder block.

NOTE: Identify and number the bearings, if reusing them, so that they are assembled in the same position anddirection.

2. Assemble the crankshaft and main bearings in the reverse order of disassembly.

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CYLINDER HEAD UNIT REPAIR

Cylinder Head

Specifications



Cylinder Head Bolts1st Step: Tighten the bolt to 40 ± 5 N·m

2nd Step: Tighten the bolt an additional 90 ± 5°3rd Step: Tighten the bolt an additional 90 ± 5°

Cylinder Head Cover Bolts 11



Cylinder Head Flatness 0.04 mm

Intake Valve Deflection 0.02 mm

Exhaust Valve Deflection 0.04 mm

Spring Height 47.7 mm

Disassembly

NOTE :The following special tools are required to perform the repair procedure:• CH-20010 - Camshaft Holder• CH-20011 - Valve seal installer• CH-20012 - Valve stem seal installer guide• CH-20013 - Valve seal remover• CH-20017 - Valve keeper installer• CH-20018 - Valve spring compressor

NOTE :Replacement cylinder head comes complete with valves, seals, springs, retainers, keepers, tappets, and camshafts.

1. Remove camshafts (See Camshaft Removal & Installation in Section 02 Engine).2. Remove the hydraulic tappet assembly (1).

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3. Using the special tool CH-20018 (1), compress thevalve spring.

4. Remove the valve keeper (1), valve spring retainer(2) and valve spring (3).

5. Push the valve stem from the cylinder head andremove the valve (4).

6. Using special tool CH-20013 (1), remove the valveoil seal.

7. Remove the valve guide if necessary.8. Remove the spark plugs.


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InspectionInspect the cylinder head for the following:• Cylinder head must be flat within 0.04 mm.• Inspect camshaft bearing journals for scoring.• Remove carbon and varnish deposits from inside of

valve guides with a valve guide cleaner.• Verify the valve tappets move freely in their bores,

and that they have been rotating.• Check the valve guide height.

Assembly1. Install new valve guide if necessary.2. Install new valve seat if necessary.3. Using special tool CH-20011 (1) and CH-20012 (2),

install the new valve oil seal.

4. Install the valves into the cylinder head (larger diameter on intake side).5. Install the valve springs.6. Install the valve spring retainers.


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02


7. Using a valve spring compressor CH-20018 (1),compress the valve springs.

8. Install the valve keepers.

9. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.10. Install valve tappets in the head.11. Install the camshafts.

Installation Notes:

• Coat the valve oil seal with engine oil.

Camshaft

Specifications

Camshaft Specifications


Intake Cam Lobe Height 37.15 mm

Exhaust Cam Lobe Height 37.05 mm

Journal #1 Outer Diameter 31.934 - 31.95 mm

Journal #2, #3, #4, #5, Outer Diameter 23.947 - 23.96 mm

Cam Bearing #1 Inner Diameter 32 - 32.025 mm

Cam Bearing #2, #3, #4, #5, Inner Diameter 24 - 24.021 mm

Journal #1 Clearance 0.05 - 0.091 mm

Journal #2, #3, #4, #5 Clearance 0.04 - 0.074 mm

Intake Camshaft Axial Clearance 0.15 - 0.20 mm

Exhaust Camshaft Axial Clearance 0.15 - 0.20 mm


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Disassembly1. Remove the camshaft bearing caps bolts.

NOTE: Equally loosen camshaft bearing cap boltsin several steps.

2. Remove the camshaft bearing caps and place them in proper order.NOTE: The camshaft bearing caps are marked for identification.

3. Remove the camshafts and then remove the camshaft seals.

InspectionInspect the camshaft for the following:• Measure the camshaft cam lobe height.• If wear is beyond the limit, replace the camshaft.

CAMSHAFT CAM LOBE HEIGHT

Intake Cam Lobe Height 37.15 mm

Exhaust Cam Lobe Height 37.05 mm


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• Measure the outer diameter of the camshaftjournal.

OUTER DIAMETER OF CAMSHAFT JOURNAL

Journal #1 Outer Diameter 31.934 - 31.95 mm

Journal #2, #3, #4, #5, Outer Diameter 23.947 - 23.96 mm

• Measure the inner diameter of the camshaftbearing.

INNER DIAMETER OF CAMSHAFT BEARING

Cam Bearing #1 Inner Diameter 32 - 32.025 mm

Cam Bearing #2, #3, #4, #5, Inner Diameter 24 - 24.021 mm

• Calculation of camshaft journal clearance

Journal clearance = (inner diameter of camshaft bearing) - (outer diameter of camshaft journal)

CAMSHAFT JOURNAL CLEARANCE

Journal #1 Clearance 0.05 - 0.091 mm

Journal #2, #3, #4, #5 Clearance 0.04 - 0.074 mm


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• Measure the axial clearance of camshaft.

CAMSHAFT AXIAL CLEARANCE

Intake Camshaft 0.15 - 0.20 mm

Exhaust Camshaft 0.15 - 0.20 mm

Assembly1. Using special tool CH-20010 (1), install the cam-

shaft holder to hold the camshafts in place.

NOTE :The camshaft holder will prevent the camshafts fromrotating in either direction.


Installation Notes:

• Install the intake and exhaust camshaft bearingcaps in the proper order.

• Slowly tighten bolts to the specified torque.• Follow the torque sequence as shown.


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Valve & Valve Guides

Specifications

Valve & Valve Guide Specifications


Intake Valve Deflection 0.02 mm

Exhaust Valve Deflection 0.04 mm

Intake Valve Guide Clearance 0.012 - 0.043 mm

Exhaust Valve Guide Clearance 0.032 - 0.063 mm

Disassembly

NOTE :The following special tools are required to perform the repair procedure:• CH-20011 - Valve seal installer• CH-20012 - Valve stem seal installer guide• CH-20013 - Valve seal remover• CH-20017 - Valve keeper installer• CH-20018 - Valve spring compressor

1. Using the special tool CH-20018 (1), compress thevalve springs.


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2. Remove the valve keeper (1), valve spring retainer(2) and valve spring (3).

3. Remove valves (4) from the cylinder head.


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Inspection

ITEM SPECIFICATION (mm)

Valve Outer DiameterIntake Valve 5.98 ± 0.008

Exhaust Valve 5.96 ± 0.008

Valve Guide Inner DiameterIntake Valve 5.4 ± 0.1


Fringe Thickness On Top Of ValveIntake Valve 0.3 ± 0.15


Valve Tilt AngleIntake Valve 65 °

Exhaust Valve 68 °

Valve HeightIntake Valve 107.998

Exhaust Valve 106.318

Inspect the valves for the following:• Clean all valves thoroughly and discard burned, warped and cracked valves.• Check valve seats and valve faces for damage.• When reconditioning valves follow the specifications outlined for both intake and exhaust valves.• Measure valve deflection.

VALVE DEFLECTION LIMIT (DIAL GAUGE READING)

Intake 0.02 mm

Exhaust 0.04 mm


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• If it exceeds the limit, check valve to valve guide clearance.− Measure valve stem diameter and valve guide inner diameter.− Check that clearance is within specification.− If it exceeds the limit, replace valve or valve

guide.

VALVE TO VALVE GUIDE CLEARANCE STANDARD

Intake 0.012 - 0.043 mm

Exhaust 0.032 - 0.063 mm

Assembly1. Install the valves into the cylinder head (larger diameter on intake side).2. Install the valve springs.3. Install the valve spring retainers.4. Using valve spring compressor CH-20018 (1), com-

press the valve springs.5. Install the valve keepers.

6. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.

Valve Springs

Specifications

Valve Spring Specifications


Spring Free Length 47.7 mm

Spring Height At 620 Newtons Of Pressure 32.0 mm


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Disassembly

NOTE :The following special tools are required to perform the repair procedure:• CH-20011 - Valve seal installer• CH-20012 - Valve stem seal installer guide• CH-20013 - Valve seal remover• CH-20017 - Valve keeper installer• CH-20018 - Valve spring compressor

1. Using the special tool CH-20018 (1), compress thevalve springs.

2. Remove the valve keeper (1), valve spring retainer(2).

3. Remove the valve springs (3) from the cylinderhead.


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InspectionInspect the valve springs for the following:• Whenever valves have been removed for inspec-

tion, reconditioning or replacement, valve springsshould be tested for correct load.

• Discard the springs that do not meet specifications.• The following specifications apply to both intake

and exhaust valve springs.

VALVE SPRING LENGTH/HEIGHT

Spring Free Length 47.7 mm

Spring Height At 620 Newtons Of Pressure 32.0 mm

If it is not within specifications, replace the valve spring.

Assembly1. Install the valve springs.2. Install the valve spring retainers.3. Using a valve spring compressor CH-20018 (1),

compress the valve springs.4. Install the valve keepers.

5. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.


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ELECTRONIC ENGINE CONTROLS

03CONTENTS

page1.6L & 1.8L Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-1

Engine Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-200

Ignition Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-222

Evaporative Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-230

1.6L & 1.8L ENGINE CONTROLS

GENERAL INFORMATION 03-3Description 03-3Operation 03-3Specifications 03-4Special Tools 03-4Electrical Schematics 03-7ECM Connector Pin-Out Table 03-18

DIAGNOSIS & TESTING 03-20Diagnostic Help 03-20Intermittent DTC Troubleshooting 03-20Ground Inspection 03-20Electronic Throttle Control ActuatorSelf-Learning Operation Introduction 03-20Diagnostic Trouble Code (DTC) List 03-21

Power Supply and Ground Circuit Test 03-25Power Supply And Ground Circuit 03-25

Diagnostic Trouble Code (DTC) Tests 03-33P0102 - Mass Or Volume Air FlowCircuit Low Input - 1.8L 03-33P0103 - Mass Or Volume Air FlowCircuit High Input - 1.8L 03-39P0105 - Manifold Absolute Pressure/Barometric Pressure Circuit, P0106 -Manifold Absolute Pressure OrBarometric Pressure Range/Performance - 1.6L 03-44P0107 - Manifold Absolute Pressure OrBarometric Pressure Low Input, P0108- Manifold Absolute Pressure OrBarometric Pressure High Input- 1.6L 03-49P0112 - Intake Air Temperature CircuitLow Input 03-54P0113 - Intake Air Temperature CircuitHigh Input 03-59

P0016 - Camshaft Position-CrankshaftPosition Correlation Error 03-65P0117 - Engine Coolant TemperatureCircuit Low Input 03-74P0118 - Engine Coolant TemperatureCircuit High Input 03-78P0122 - Throttle Position Sensor ACircuit Low Input, P0123 - ThrottlePosition Sensor A Circuit High Input 03-83P0031 - O2 Sensor 1 Heater ControlCircuit Low, P0032 - O2 Sensor 1Heater Control Circuit High 03-88P0132 - O2 Sensor Circuit 1 HighVoltage 03-93P0171 - Fuel Trim System Too Lean 03-97P0172 - Fuel Trim System Too Rich 03-110P0201 - Cylinder 1 - Injector Circuit,P0202 - Cylinder 2 - Injector Circuit,P0203 - Cylinder 3 - Injector Circuit,P0204 - Cylinder 4 - Injector Circuit 03-122P0221 - Throttle Position Sensor BPerformance 03-130P0321 - Distributor Engine SpeedIn-Phase Circuit Performance 03-137P0324 - Knock Control System Error,P0327 - Knock Sensor 1 Circuit LowInput, P0327 - Knock Sensor 1 CircuitHigh Input 03-142P0340 - Camshaft Position SensorCircuit, P0341 - Camshaft PositionSensor Performance, P0342 - CamshaftPosition Sensor Circuit Low Input,P0343 - Camshaft Position SensorCircuit High Input 03-146P0444 - Evaporative Emission SystemPurge Control Valve Circuit Open 03-152P0506 - Idle Control System RPMLower Than Expected 03-156

03


P0562 - System Voltage Low Voltage,P0563 - System Voltage High Voltage 03-158P0604 - Internal Controller ModuleRandom Access Memory (RAM) Error,P0605 - Internal Controller ModuleROM Test Error, P0606 - ECMProcessor 03-163P0602 - Control Module ECMProgramming Error 03-165P0645 - A/C Clutch Relay Circuit 03-167P1545 - Throttle Position ControlPerformance 03-170P2138 - Pedal Position SensorPerformance 03-177U1000 - High Speed CAN Defective 03-185


Engine Coolant Temperature Sensor 03-191Description 03-191Operation 03-191Removal & Installation 03-191

Knock Sensor 03-192Description 03-192Operation 03-192Removal & Installation 03-192

Oxygen Sensor 03-192Description 03-192Operation 03-192Removal & Installation 03-192

Crankshaft Position Sensor 03-193Description 03-193Operation 03-193Removal & Installation 03-193

Camshaft Position Sensor 03-194Description 03-194Operation 03-194Removal & Installation 03-194

Manifold Absolute Pressure Sensor -1.6L 03-195

Description 03-195Operation 03-195Removal & Installation 03-195

Air Flow Sensor - 1.8L 03-196Description 03-196Operation 03-196Removal & Installation 03-196

Accelerator Pedal Position Sensor 03-196Description 03-196Operation 03-196Removal & Installation 03-196

Electronic Throttle Control Actuator 03-197Description 03-197Operation 03-197Removal & Installation 03-197

Engine Control Module (ECM) 03-198Description 03-198Operation 03-198Removal & Installation 03-198


GENERAL INFORMATIONDescriptionThe Engine Control Module (ECM) controls the engine management system. The ECM can adjust for varying drivingconditions and modify fuel and ignition requirements as needed to maintain optimum performance and economy.

The following are the input and output components monitored by the ECM.

ECM Inputs

• Brake Switch Sensor• A/C Pressure Sensor• Camshaft Position (CMP) Sensor• Crankshaft Position (CKP) Sensor• Engine Coolant Temperature (ECT) Sensor• Manifold Absolute Pressure (MAP) Sensor (1.6L)• Air Flow Sensor (1.8L)• Electric Throttle Control Actuator• Power Steering Switch• Accelerator Pedal Position (APP) Sensor• Knock Sensor• Upstream Oxygen Sensor• Downstream Oxygen Sensor• Clutch Pedal Switch• Immobilizer• CAN Bus

ECM Outputs

• Canister Control Valve• Fuel Injectors• Fuel Pump Relay• Electronic Throttle Control Actuator• Ignition Coil• A/C Compressor• Cooling Fan• Oxygen Sensor Heater (Upstream & Downstream)• CAN Bus

OperationThe ECM is a pre-programmed, microprocessor-based digital computer. It regulates ignition timing, air-fuel ratio,emission control devices, charging system, certain transmission features, speed control, air conditioning compressorclutch engagement and idle speed. The ECM can adapt its programming to meet changing operating conditions.

The ECM monitors components and circuits and tests them in various ways depending on the hardware, function,and type of signal. For example, analog inputs such as throttle position or engine coolant temperature are typicallychecked for opens, shorts and out-of-range values. This type of monitoring is carried out continuously. Some digitalinputs like vehicle speed or crankshaft position rely on rationality checks - checking to see if the input value makessense at the current engine operating conditions. These types of tests may require monitoring several componentsand can only be carried out under appropriate test conditions.

03


Specifications



Engine Coolant Temperature (ECT) Sensor 20

Knock Sensor 20

Oxygen Sensors 45

Crankshaft Position (CKP) Sensor 10

Camshaft Position (CMP) Sensor 7

Air Flow Sensor Bolts 5

Engine Control Module (ECM) Bolts 6

Accelerator Pedal Position (APP) Sensor 11

Electronic Throttle Control Actuator 10

Manifold Absolute Pressure (MAP) Sensor 6

Special Tools

Diagnostic Scan ToolX-431

Engine AnalyzerKES-200

GENERAL INFORMATION


Digital MultimeterFluke 15B & 17B

Compression Gauge

Fuel Pressure Gauge

GENERAL INFORMATION

03


Hardware RequirementsThe hardware configuration of X-431 is as follows:

Diagnostic Scan Tool Configuration

ITEM NAME Function

1 X-431 Main Unit

To DisplayOperationalButtons, TestResults, HelpInformation, etc.

2 Mini-Printer To Print TestResults. (Optional)

3 CF Card

To StoreDiagnosticSoftware andData

4 USB Cable

To Connect CFCard Reader/Writer andComputer

5 CF CardReader/Writer

To Read or WriteData On The CFCard

6 Mitsubishi-12+16Pin Connector

To DiagnoseMitsubishiElectronic ControlSystems OnChery M11 & M12Series

7 Fiat-3 PinConnector

To DiagnoseVehicles WithFiat-3 PinDiagnosticConnector

ITEM NAME Function

8 Smart OBDII-16Pin Connector

To DiagnoseOther Systems OfVehicle WithOBDII-16 PinDiagnosticConnector

9 Power Cord

To Connect AC100 - 240 V Outletand PowerAdapter

10 Cigarette LighterCable

To Get PowerFrom VehicleCigarette Lighter

11 Battery CableW/Two Clips

To Get PowerFrom VehicleBattery

12 Power Adapter

To Convert 100 -240 V AC PowerInto 12 V DCPower

13 Main Cable

To Connect TheDiagnosticConnector andSmartbox

14 Smartbox To PerformVehicle Diagnosis

GENERAL INFORMATION

BESM03000303–6 Chery Automobile Co., Ltd.

Electrical Schematics

Electronic Engine Controls (Page 1 of 11)

GENERAL INFORMATION

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GENERAL INFORMATION

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GENERAL INFORMATION

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GENERAL INFORMATION

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GENERAL INFORMATION

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GENERAL INFORMATION

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ECM Connector Pin-Out TableECM PIN-OUT TABLE

PIN CIRCUIT IDENTIFICATION PIN CIRCUIT IDENTIFICATION

1 - 42 Intake Air Temperature Sensor

2 Ignition Coil 2 43 -

3 GND (Ignition) 44 Switched Supply Voltage

4 - 45 Switched Supply Voltage

5 Ignition Coil 1 46 Canister Control Valve

6 Injector 2 47 Injector 4

7 Injector 3 48 Upstream Oxygen Sensor Heating(With EOBD)

8 - 49 -

9 - 50 Fan Relay Control

10 - 51 GND (Signal)

11 EPC Lamp 52 -

12 Continuous Supply Voltage 53 GND (Signal)

13 Ignition Switch 54 Electronic Throttle Control Actuator(Position Sensor)

14 EMS Relay (Main Relay) 55 Downstream Oxygen Sensor

15 Crankshaft Position Sensor 56 -

16 Accelerator Position Sensor 57 A/C Stand By

17 Sensor (GND) 58 Brake Switch

18 Upstream Oxygen Sensor 59 Vehicle Speed Sensor

19 Knock Sensor 1 60 A/C Middle Pressure Switch

20 Knock Sensor 2 61 GND (Power)

21 Brake Switch 62 CAN-H

22 - 63 Switched Supply Voltage

23 - 64 Electric Throttle Control Actuator




27 Injector 1 68 Fan Relay Control 2

28 Downstream Oxygen SensorHeating (With EOBD) 69 Air Compressor Relay

29 - 70 Fuel Pump Relay

30 - 71 Diagnostic Link K

31 - 72 -

32 Regulated Sensor Supply 2 73 Regulated Sensor Supply 1

33 Regulated Sensor Supply 1 74 Clutch Pedal Switch

34 Crankshaft Position Sensor 75 -

GENERAL INFORMATION



35 Sensor (GND) 76 Power Steering Switch

36 Sensor (GND) 77 -

37Manifold Absolute Pressure Sensor

(With 1.6L Engine) 78 Sensor (GND)Air Flow Sensor (With 1.8L Engine)

38 Electronic Throttle Control Actuator(Position Sensor) 79 Camshaft Position Sensor

39 Engine Coolant Temperature Sensor 80 GND (Power)

40 Accelerator Pedal Position Sensor 81 CAN-L

41 -

GENERAL INFORMATION

03


DIAGNOSIS & TESTINGDiagnostic Help1. The X-431 scan tool connects to the Data Link Connector (DLC) and communicates with the vehicle electronic

modules through the data network.2. Confirm that the malfunction is current and carry-out the diagnostic tests and repair procedures.3. If the Diagnostic Trouble Code (DTC) cannot be deleted, it is a current fault.4. Use only a digital multimeter to perform voltage readings on electronic systems.5. Refer to any Technical Bulletins that may apply to the failure.6. Visually inspect the related wiring harness.7. Inspect and clean all Engine Control Module (ECM) grounds that are related to the most current DTC.8. If numerous trouble codes were set, use a wiring schematic and look for any common ground circuits or voltage

supply circuits that may apply to the DTC.

Intermittent DTC TroubleshootingIf the failure is intermittent perform the following:• Check for loose connectors.• Look for any chafed, pierced, pinched, or partially broken wires.• Monitor the scan tool data relative to this circuit.• Wiggle the related wiring harness and connectors while looking for an interrupted signal on the affected circuit.• If possible, try to duplicate the conditions under which the DTC set.• Look for the data to change or for the DTC to reset during the wiggle test.• Look for broken, bent, pushed out or corroded terminals.• Inspect the sensor and mounting area for any condition that would result in an incorrect signal, such as dam-

age, or foreign material.• A data recorder, and/or oscilloscope should be used to help diagnose intermittent conditions.• Remove the Engine Control Module (ECM) from the troubled vehicle and install in a new vehicle and test. If

the DTC cannot be deleted, the ECM is malfunctioning. If the DTC can be deleted, return the ECM to the origi-nal vehicle.

Ground InspectionGround connections are very important to the proper operation of electrical and electronic circuits. Ground connec-tions are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwantedresistance. This added resistance can alter the way a circuit works.

Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drasticallyaffect an electronically controlled circuit. A poor or corroded ground can effect the circuit. Perform the following wheninspecting a ground connection:

1. Remove the ground bolt or screw.2. Inspect all mating surface for tarnish, dirt, rust, etc.3. Clean as required to assure good contact.4. Reinstall bolt or screw securely.5. Inspect for �add-on� accessories which may be interfering with the ground circuit.6. If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires

are clean, securely fastened and providing a good ground path. If multiple wires are crimped to one eyelet, makesure no excess wire insulation has been crimped creating a bad ground.

Electronic Throttle Control Actuator Self-Learning Operation Introduction

Electronic Pedal Control (EPC) Lamp Control StrategyThe EPC lamp will light when the ignition switch is turned to the ON position and the engine is not running. After theengine is started, the EPC lamp will go off if there is no EPC DTCs that exist in the ECM. If the internal EPC self-check failed, the EPC lamp will continue to light.

Electronic Throttle Control Actuator Self-Learning Condition• Engine stopped and the ignition switch on.• Vehicle speed is 0 km/h.


• The Engine Coolant Temperature (ECT) is between 5.25 °C and 100.5 °C.• The intake air temperature is more than 5.25 °C.• The accelerator pedal fully released.• Battery voltage is more than 12 V.

Electronic Throttle Control Actuator Self-Learning Operating ProcedureTurn ignition switch on for 10 seconds, then turn the ignition switch off. During the procedure, don’t operate any othercomponents.

Self-Learning ComponentsSelf-Learning should be performed on these components under the following conditions:• After replacing the ECM.• After disconnecting and reconnecting the ECM.• After replacing the Accelerator Pedal or Electronic Throttle Control Actuator.

Self-Learning Operating ProcedureTurn the ignition switch on for 10 seconds, then turn the ignition switch off. During the procedure, don’t operate anyother components.

Self-Learning ConditionThe self-learning condition is known as the �Electronic Throttle Control Actuator Self-Learning Condition�.

CAUTION:Make sure that the Electronic Throttle Control Actuator self-learning procedure lasts for at least 10seconds according to the Electronic Throttle Control Actuator self-learning condition. If the self-learning procedure fails, the engine cannot be started, or the EPC lamp will be lit. If this conditionoccurs, the self-learning procedure should be performed again after the DTCs have been erased inECM.

Diagnostic Trouble Code (DTC) List

DTC DTC DEFINITION

P000A �A� Camshaft Position Slow Response

P000B �B� Camshaft Position Slow Response

P0010 �A� Camshaft Position Actuator Circuit/Open

P0011 �A� Camshaft Position - Timing Over - Advanced or System Performance

P0012 �A� Camshaft Position - Timing Over - Retarded

P0013 �B� Camshaft Position - Actual Circuit/Open

P0014 �B� Camshaft Position - Timing Over - Advanced or System Performance

P0015 �B� Camshaft Position - Timing Over - Retarded

P0016 Crankshaft - Camshaft Position Correlation

P0030 O2 Sensor Heater Control Circuit (Bank 1 Sensor 1)

P0031 O2 Sensor Heater Control Circuit (Bank 1 Sensor 1) Low

P0032 O2 Senor Heater Control Circuit (Bank 1 Sensor 1) High

P0036 O2 Senor Heater Control Circuit (Bank 1 Sensor 2)

P0037 O2 Senor Heater Control Circuit (Bank 1 Sensor 2) Low

P0038 O2 Senor Heater Control Circuit (Bank 1 Sensor 2) High

P0053 O2 Senor Heater Resistance (Bank 1 Sensor 1)

P0054 O2 Senor Heater Resistance (Bank 1 Sensor 2)

P0101 Mass or Volume Air Flow Circuit Range/Performance (1.8L)

P0102 Mass or Volume Air Flow Circuit Low Input (1.8L)

DIAGNOSIS & TESTING

03


DTC DTC DEFINITION

P0103 Mass or Volume Air Flow Circuit High Input (1.8L)

P0105 Manifold Absolute Pressure or Barometric Pressure Circuit (1.6L)

P0106 Manifold Absolute Pressure or Barometric Pressure Range/Performance(1.6L)

P0107 Manifold Absolute Pressure or Barometric Pressure Low Input (1.6L)

P0108 Manifold Absolute Pressure or Barometric Pressure High Input (1.6L)

P0112 Intake Air Temperature Circuit Low Input

P0113 Intake Air Temperature Circuit High Input

P0116 Engine Coolant Temperature Circuit Range/Performance

P0117 Engine Coolant Temperature Circuit Low Input

P0118 Engine Coolant Temperature Circuit High Input

P0121 Throttle/Pedal Position Sensor A Circuit Range/Performance

P0122 Throttle/Pedal Position Sensor A Circuit Low Input

P0123 Throttle/Pedal Position Sensor A Circuit High Input

P0130 O2 Sensor Circuit Bank 1 - Sensor 1 Malfunction

P0131 O2 Sensor Circuit Bank 1 - Sensor 1 Low Voltage

P0132 O2 Sensor Circuit Bank 1 - Sensor 1 High Voltage

P0133 O2 Sensor Circuit Bank 1 - Sensor 1 Slow Response

P0134 O2 Sensor Circuit Bank 1 - Sensor 1 No Activity Detected

P0136 O2 Sensor Circuit Bank 1 - Sensor 2 Malfunction

P0137 O2 Sensor Circuit Bank 1 - Sensor 2 Low Voltage

P0138 O2 Sensor Circuit Bank 1 - Sensor 2 High Voltage

P0140 O2 Sensor Circuit Bank 1 - Sensor 2 No Activity Detected

P0170 Fuel Trim, Bank 1 Malfunction

P0171 Fuel Trim, Bank 1 System too Lean

P0172 Fuel Trim, Bank 1 too Rich

P0201 Cylinder 1 - Injector Circuit




P0219 Engine Overspeed Condition

P0221 Throttle/Pedal Position Sensor/Switch B Range/Performance

P0222 Throttle/Pedal Position Sensor/Switch B Low Input

P0223 Throttle/Pedal Position Sensor/Switch B High Input

P0261 Cylinder 1 - Injector Circuit Low

P0262 Cylinder 1 - Injector Circuit High







P0300 Random/Multiple Cylinder Misfire Detected

P0301 Cylinder 1 Misfire Detected

DIAGNOSIS & TESTING


DTC DTC DEFINITION




P0318 Rough Road Sensor �A� Signal Circuit

P0321 Ignition/Distributor Engine Speed Input Circuit Range/Performance

P0322 Ignition/Distributor Engine Speed Input Circuit No Signal

P0324 Knock Control System Error

P0327 Knock Sensor 1 Circuit Low Input

P0328 Knock Sensor 1 Circuit High Input

P0340 Camshaft Position Sensor Circuit

P0341 Camshaft Position Sensor Circuit Range/Performance

P0342 Camshaft Position Sensor Circuit Low Input

P0343 Camshaft Position Sensor Circuit High Input

P0420 Catalyst System, Bank 1 Efficiency Below Threshold

P0444 Evaporative Emission System Purge Control Valve Circuit Open

P0458 Evaporative Emission System Purge Control Valve Circuit Low

P0459 Evaporative Emission System Purge Control Valve Circuit High

P0480 Cooling Fan 1 Control Circuit

P0481 Cooling Fan 2 Control Circuit

P0501 Vehicle Speed Sensor Range/Performance

P0506 Idle Control System RPM Lower than Expected

P0507 Idle Control System RPM High than Expected

P0508 Idle Air Control System Circuit Low

P0509 Idle Air Control System Circuit High

P0511 Idle Air Control Circuit

P0532 A/C Refrigerant Pressure Sensor Circuit Low Input

P0533 A/C Refrigerant Pressure Sensor Circuit High Input

P0537 A/C Evaporator Temperature Sensor Circuit Low

P0538 A/C Evaporator Temperature Sensor Circuit High

P0560 System Voltage Malfunction

P0562 System Voltage Low Voltage

P0563 System Voltage High Voltage

P0571 Brake Switch �A� Circuit

P0602 Control Module Programming Error

P0604 Internal Control Module Random Access Memory (RAM) Error

P0605 Internal Control Module ROM Test Error

P0606 ECM Processor

P0627 Fuel Pump �A� Control Circuit/Open

P0628 Fuel Pump �A� Control Circuit Low

P0629 Fuel Pump �A� Control Circuit High

P0645 A/C Clutch Relay Circuit

P0646 A/C Clutch Relay Control Circuit Low

P0647 A/C Clutch Relay Control Circuit High

DIAGNOSIS & TESTING

03


DTC DTC DEFINITION

P0650 Malfunction Indicator Lamp Control Circuit

P0688 EMC/ECM Power Relay Sense Circuit Open

P0691 Cooling Fan 1 Control Circuit Low

P0692 Cooling Fan 1 Control Circuit High

P0693 Cooling Fan 2 Control Circuit Low

P0694 Cooling Fan 2 Control Circuit High

P0700 Transmission Control System Malfunction

P0704 Clutch Switch Input Circuit

P1336 Engine Torque Control Adaptation at Limit

P1545 Throttle Position Control Malfunction

P1558 Throttle Actuator Electrical Malfunction

P1559 Idle Speed Control Throttle Position Adaptation Malfunction

P1564 Idle Speed Control Throttle Position Low Voltage during Adaptation

P1565 Idle Speed Control Throttle Position Lower Limit not Attained

P1568 Idle Speed Control Throttle Position Mechanical Malfunction

P1579 Idle Speed Control Throttle Position Adaptation not Started

P1604 Internal Control Module Driver Error

P1610 Manufacture Controlled Computer and Auxiliary Outputs






P2106 Throttle Actuator Control System Forced Limited Power

P2122 Throttle/Pedal Position Sensor/Switch D Circuit Low Input

P2123 Throttle/Pedal Position Sensor/Switch D Circuit High Input

P2127 Throttle/Pedal Position Sensor/Switch E Circuit Low Input

P2128 Throttle/Pedal Position Sensor/Switch E Circuit High Input

P2138 Accelerator Pedal Position Sensor Signal Correlation Error

P2177 System Too Lean Off Idle

P2178 System Too Rich Off Idle

P2187 System Too Lean At Idle

P2188 System Too Rich At Idle

P2195 O2 Sensor Signal Stuck Lean; Bank 1 Sensor 1

P2196 O2 Sensor Signal Stuck Rich; Bank 1 Sensor 1

P2270 O2 Sensor Signal Stuck Lean; Bank 1 Sensor 2

P2271 O2 Sensor Signal Stuck Rich; Bank 1 Sensor 2

U0001 High Speed CAN Defective

U0101 Lost Communication with ECM

U0104 Lost Communication with Cruise Control Module

U0121 Lost Communication with Anti-Lock Brake System (ABS) Control Module

U0155 Lost Communication with Instrument Panel Cluster Control Module

U0415 Invalid Data Received from ABS Control Module

DIAGNOSIS & TESTING


Power Supply and Ground Circuit Test

Power Supply And Ground Circuit

DIAGNOSIS & TESTING

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03


Check reference values between ECM terminals and ground under the following conditions:

ECM TERMINAL NO. ITEM CONDITION DATA (DC VOLTAGE)

12 Continuous SupplyVoltage - Voltage (11 - 14 V)

13 Ignition SwitchIgnition switch: ON Voltage (11 - 14 V)

Ignition switch: OFF Approximately 0 V

14 EMS Relay (Main Relay)

Ignition switch: OFFMore than a few seconds

after turning ignition switchOFF

Voltage (11 - 14 V)

44Switched Supply Voltage

(SSV) Ignition switch: ON Voltage (11 - 14 V)45

63

DIAGNOSIS & TESTING


DIAGNOSIS & TESTING

VISMW030004T

03




3 GND (IGN) Ignition switch: ON Approximately 0 V

51 GND (Signal) Ignition switch: ON Approximately 0 V

53 GND (Signal) Ignition switch: ON Approximately 0 V

61 GND (Power) Ignition switch: ON Approximately 0 V

80 GND (Power) Ignition switch: ON Approximately 0 V

Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Start the engine and warm it to normal operating temperature.• With the scan tool, select view data stream.• If the data stream is not detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the data stream is detected, the condition is intermittent (See Diagnostic Help and Intermittent DTC Trouble-

shooting in Section 03 Electronic Engine Controls for more information).

DIAGNOSIS & TESTING


Diagnostic Procedure

1. PRELIMINARY INSPECTION

• Attempt to start the engine.

Is engine running?

Yes >> • Go to step 8.

No >> • Go to step 2.

2. CHECK ECM POWER SUPPLY CIRCUIT - (1)

• Turn ignition switch off and then on.• Check voltage between ECM terminal 13 and

ground with a digital multimeter.• Battery voltage should exist.

Is the check result normal?



3. DETECT MALFUNCTIONING PART

• Check the following:− Fuse FB1 (5A)− Ignition relay R5− Front fuse and relay box connector K & E− Harness between ECM and fuse− Ground connection A-201− Open or short in ignition relay supply circuit or ground circuit


Yes >> • Go to the next step.

No >> • Repair or replace malfunctioning part(s).


• Check the voltage between ECM terminal 12 and ground with a digital multimeter.• Battery voltage should exist.



No >> • Check and repair the following:− Fuse FB18 (7.5A)− Front fuse and relay box connector K9− Harness open or short between ECM connector E-001 terminal 12 and battery

DIAGNOSIS & TESTING

LTSMD030061

03


5. CHECK GROUND CONNECTIONS

• Turn ignition switch off.• Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine

Controls).• Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Layout -

Engine Room Harness in Section 16 Wiring).

Are the ground connections OK?


No >> • Repair or replace ground connections.

6. CHECK ECM GROUND CIRCUIT FOR AN OPEN OR SHORT

• Disconnect the ECM harness connector (1).• Check harness continuity between ECM termi-

nals 3, 51, 53, 61, 80 and ground (refer towiring diagram for circuit information).

• Continuity should exist.• Check harness for a short to power.



No >> • Go to the next step.


• Check the harness for an open or short between ECM terminals 3, 51, 53, 61, 80 and ground.



No >> • Repair the circuit for an open or short to power in harness or connectors.

DIAGNOSIS & TESTING

VISMD030014



• Turn ignition switch on and then off.• Check voltage between ECM terminals 44, 45,

63 and ground with a digital multimeter.− Turn the ignition switch on, battery voltage

should exist.− Turn the ignition switch off, battery voltage will

exist for a few seconds, then drop to approxi-mately 0 V.


Yes >> • Check the starting system.


9. CHECK EMS RELAY (R2) SUPPLY VOLTAGE

• Turn ignition switch off. Wait for at least 10seconds.

• Check voltage between ECM terminal 14 andground with a digital multimeter.

• Battery voltage should exist.





• Disconnect the ECM harness connector.• Disconnect the ECM power supply circuit connector K in front fuse and relay box harness connector.• Check harness continuity between ECM terminals 44, 45, 63 and front fuse and relay box terminal K11

(refer to wiring diagram for circuit information).• Check harness for a short to ground or short to power.



No >> • Repair the circuit for an open or short in harness or connectors.

DIAGNOSIS & TESTING

LTSMD030062

LTSMD030063

03


11. CHECK EMS RELAY (R2) CIRCUIT

• Disconnect the ECM harness connector.• Disconnect the ECM power supply circuit connector K in front fuse and relay box harness connector.• Check harness continuity between ECM terminal 14 and front fuse and relay box terminal K10 (refer to

wiring diagram for circuit information).• Continuity should exist.• Check EMS relay R2.• Check harness for a short to ground or short to power.



No >> • Repair or replace the malfunctioning components.

12. CHECK FUSE

• Disconnect fuse SB2 (30A), fuse FB12 (20A), fuse FB18 (7.5A) in the front fuse and relay box.• Check the fuses for an open.



No >> • Replace the damaged components.

13. CHECK FRONT FUSE AND RELAY BOX

• Check front fuse and relay box for damage.


Yes >> • Replace the ECM.

NOTE :The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 ElectronicEngine Controls).

No >> • Replace the front fuse and relay box.

DIAGNOSIS & TESTING


Diagnostic Trouble Code (DTC) Tests

P0102 - Mass Or Volume Air Flow Circuit Low Input - 1.8L

DIAGNOSIS & TESTING

VISMW030018T

03



ECM TERMINAL NO. ITEM CONDITION DATA (AVERAGE DCVOLTAGE)

17 Sensor (GND) Engine: RunningECT: 78 °CIdle: 795 RPMIAT: 36 °CIAT signal: 1.88 V

Approximately 0 V

33 Regulated sensor supply 1 5 V

37 Air flow sensorApproximately 322 kg/h

Approximately 1.39 V

On Board Diagnostic Logic

• Self-diagnosis detection logic.

DTC NO. DTC DEFINITION DTC DETECTIONCONDITION

DTC SETCONDITION POSSIBLE CAUSE

P0102Mass or Volume AirFlow (MAF) circuitlow input

Ignition switch on orengine is running

ECM detected thatthe input signal is

out of theacceptable range.

• MAF sensor• Intake air leaks• Harness orconnectors• ECM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on.• With the scan tool, record and erase stored DTCs in the ECM.• Start the engine and warm it to normal operating temperature.• With the scan tool, select view DTCs in the ECM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-

bleshooting in Section 03 Electronic Engine Controls for more information).

DIAGNOSIS & TESTING



1. CHECK INTAKE SYSTEM

• Check the following components for proper connections.− Air duct− Vacuum hoses− Intake air passage between air duct and manifold.



No >> • Reconnect the connectors or replace the malfunctioning part.

2. CHECK MAF SENSOR POWER SUPPLY CIRCUIT

• Disconnect MAF sensor harness connector (1).

• Turn ignition switch on.• Check voltage between terminal 2 and ground in

the MAF sensor electrical connector E-009 with adigital multimeter.





DIAGNOSIS & TESTING

VISMD030005

LTSMD030041

03



• Check the following parts:− EMS relay R2− Front fuse and relay box K− Fuse SB2 (30A), fuse FB12 (20A), fuse FB18 (7.5A)− Harness for an open or short between MAF sensor and fuse

• Repair or replace any malfunctioning part.• With X-431, view DTCs in ECM.

Is DTC P0102 still present?


No >> • The system is now operating properly at this time.

4. CHECK MAF SENSOR REFERENCE VOLTAGE

• Check voltage between MAF sensor terminal 4 andground in the MAF sensor electrical connectorE-009 with a digital multimeter.

• 5 V should exist.



No >> • Repair or replace the circuit for an openor short in harness or connectors.

• If circuit is normal, go to the next step.

5. CHECK THE MAF SENSOR GROUND CIRCUIT FOR AN OPEN OR SHORT

• Turn ignition switch off.• Disconnect the ECM harness connector.• Check harness continuity between MAF sensor terminal 3 and ECM terminal 17.• Continuity should exist.• Check harness for a short to ground.



No >> • Repair or replace circuit for an open or short in harness or connectors.

6. CHECK THE MAF SENSOR OUTPUT SIGNAL CIRCUIT FOR AN OPEN OR SHORT

• Check harness continuity between MAF sensor terminal 5 and ECM terminal 37.• Continuity should exist.• Check harness for a short to ground.



No >> • Repair or replace the circuit for an open or short to ground in harness or connectors.

DIAGNOSIS & TESTING

LTSMD030042


7. CHECK THE MAF SENSOR SIGNAL

• Install all removed parts.• Start engine.• Check MAF sensor signal with X-431.

MAF SENSOR SIGNAL - WITH THE X-431 SCAN TOOL

TERMINALNO. ITEM CONDITION

DATA(AVERAGE

DCVOLTAGE)

37 Air flowsensor

• Engine isrunning• ECT: 78 °C• Idle: 795RPM• IAT: 36 °C• IAT signal:1.88 V

Approximately322 kg/h

Approximately1.39 V

• If without the X-431, check voltage between MAF sensor terminal 5 and ground with a digital multimeter.

MAF SENSOR SIGNAL - WITHOUT THE X-431 SCAN TOOL


DATA(AVERAGE

DCVOLTAGE)

37 Air flowsensor

• Engine isrunning• ECT: 78 °C• Idle: 795RPM• IAT: 36 °C• IAT signal:1.88 V

Approximately1.39 V

• If the signal voltage is out of specification, proceed to the following.• Check the following for the cause of uneven air flow through the MAF sensor:

− Crushed air ducts− Air cleaner seal− Clogged air cleaner element

• If any components are malfunctioning, repair or replace them.• If the components are OK, clean the MAF sensor, then check the signal of the MAF sensor.

Is the MAF signal normal?


No >> • Replace MAF sensor.

DIAGNOSIS & TESTING

03


8. CHECK DTC

• With the X-431 scan tool, read ECM DTCs.• Refer to �DTC Confirmation Procedure�.




No >> • The system is now operating properly.

DIAGNOSIS & TESTING


P0103 - Mass Or Volume Air Flow Circuit High Input - 1.8L

DIAGNOSIS & TESTING

VISMW030018T

03




17 Sensor (GND)Ignition switch: ON

Approximately 0 V

33 Regulated Sensor supply1 5 V

37 Air flow sensor

Engine: RunningWarm-up condition: 78 °CIdle: 795 RPMIAT: 36 °CIAT signal voltage: 1.88 V

Approximately 322 kg/hor approximately 1.39 V

Engine: RunningWarm-up condition: 52 °CIdle: 910 RPMIAT: 30 °CIAT signal voltage: 2.17 V

Approximately 420 kg/hor approximately 1.52 V





P0103Mass or Volume AirFlow (MAF) circuit

high input

Ignition switch on orengine is running

ECM detected thatthe input signal isout of theacceptable range.

• MAF sensor• Harness orconnectors• ECM



DIAGNOSIS & TESTING



1. CHECK INTAKE SYSTEM

• Check the following components for proper connections.− Air cleaner− Intake air duct



No >> • Clean or replace the components.

2. CHECK THE SENSOR POWER SUPPLY CIRCUIT

• Disconnect the MAF sensor harness connectorE-009 (1).

• Turn ignition switch on.• Check voltage between MAF sensor terminal 4 and

ground in the MAF sensor connector E-009 with adigital multimeter (refer to wiring diagram for circuitinformation).





DIAGNOSIS & TESTING

VISMD030005

LTSMD030042

03



• Check harness for short to power between the air flow sensor and ECM.



No >> • Repair or replace the circuit for a short to power in harness or connectors.

4. CHECK THE MAF SENSOR GROUND CIRCUIT FOR A SHORT

• Turn ignition switch off.• Disconnect the ECM harness connector.• Check harness continuity between MAF sensor terminal 3 and ECM terminal 17.• Continuity should exist.• Check harness for a short to power.




5. CHECK THE MAF SENSOR OUTPUT SIGNAL CIRCUIT

• Check harness continuity between the MAF sensor terminal 5 and ECM terminal 37.• Continuity should exist.• Check harness for short to power.




DIAGNOSIS & TESTING


6. CHECK THE MAF SENSOR

• Install all removed parts.• Start engine.• Check MAF signal in data stream with X-431.

MAF SENSOR SIGNAL - WITH THE X-431 SCAN TOOL


DATA(AVERAGE

DCVOLTAGE)

37Air

flowsensor

• Engine isrunning• Warm-upcondition:78 °C• Idle: 795RPM• IAT: 36 °C• IAT signalvoltage:1.88 V

Approximately322 kg/h

Approximately1.39 V

• If without X-431, check voltage between MAF sensor terminal 5 and ground with a digital multimeter.

MAF SENSOR SIGNAL - WITHOUT THE X-431 SCAN TOOL


DATA(AVERAGE

DCVOLTAGE)

37Air

flowsensor

• Engine isrunning• Warm-upcondition:78 °C• Idle: 795RPM• IAT: 36 °C• IAT signal:1.88 V

Approximately1.39 V

Is the signal voltage of the MAF normal?


No >> • Replace the MAF sensor.

7. CHECK DTC

• With the X-431 scan tool, read ECM DTCs.• See DTC Confirmation Procedure.





DIAGNOSIS & TESTING

03


P0105 - Manifold Absolute Pressure/Barometric Pressure CircuitP0106 - Manifold Absolute Pressure Or Barometric Pressure Range/Performance - 1.6L

DIAGNOSIS & TESTING

VISMW030009T



ECM TERMINALNO. ITEM CONDITION DATA (DC

VOLTAGE)

17 Sensor (GND)

Engine: Running

- Approximately 0 V

33 Regulated sensorsupply 1 - Approximately 5 V

37Manifold AbsolutePressure (MAP)

sensor

Engine running: IdlePress acceleratorpedal slowly

Approximately 1.3 V

Press acceleratorpedal quickly

Up to approximately4 V (instantaneous)





P0105Manifold absolute

pressure/barometricpressure circuit

Ignition switch on orafter engine start

Signal output is outof acceptable rangefor a few secondscontinuously.

• MAP sensor• Harness orconnectors• ECM

P0106

Manifold absolutepressure or

barometric pressurerange/performance




DIAGNOSIS & TESTING

03




• Turn ignition switch off.• Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Con-

trols).• Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information -

Engine Control Harness in Section 16 Wiring).




2. CHECK THE MAP SENSOR POWER SUPPLY

• Disconnect MAP sensor harness connector (1).

• Turn ignition switch on.• Check supply voltage between terminal 1 and 3 in

MAP sensor connector E-033 terminal side.• 5 V should exist.




DIAGNOSIS & TESTING

LTSMD030076

VISMD030010


3. CHECK THE MAP SENSOR POWER SUPPLY CIRCUIT FOR AN OPEN OR SHORT

• Check supply voltage between terminal 3 andground in the MAP sensor connector E-033 with adigital multimeter.

• Approximately 5 V should exist.



No >> • Repair or replace the circuit for an openor short to ground or short to power inharness or connectors.


4. CHECK THE MAP SENSOR GROUND CIRCUIT FOR AN OPEN

• Turn ignition switch off.• Disconnect the ECM sensor harness connector E-001.• Check harness continuity between terminal 1 in MAP sensor connector E-033 and terminal 17 in ECM connec-

tor E-001.• Continuity should exist.



No >> • Repair or replace the circuit for an open in harness or connectors.

5. CHECK THE MAP SENSOR OUTPUT SIGNAL CIRCUIT FOR AN OPEN OR HIGH RESISTANCE

• Check harness continuity between MAP sensor terminal 4 and ECM terminal 37.• Continuity should exist.



No >> • Repair or replace the circuit for an open or high resistance in harness or connectors.

DIAGNOSIS & TESTING

LTSMD030057

03


6. CHECK THE MAP SENSOR SIGNAL

• Check sensor signal between sensor terminal 4 and ground with a digital multimeter.

MAP SENSOR OUTPUT SIGNAL

MAPSENSOR

TERMINALNO.

ITEM CONDITION DATA (DCVOLTAGE)

4 MAPsensor

Engine:Running

Enginerunning: IdlePressacceleratorpedal slowly

Approximately1.3 V

Pressacceleratorpedal quickly

Up toapproximately

4 V(instantaneous)




7. CHECK OR REPLACE THE MAP SENSOR

• Check the sensor as follows:− Remove the sensor mounting bolt.− Remove the sensor.− Visually check the sensor for blockage or damage, and clean the pressure port of the sensor.


Yes >> • Replace the MAP sensor with a known good MAP sensor.• Select view DTC on the X-431 screen.

− If DTC P0105 or P0106 is not present, the system is OK.− If DTC P0105 or P0106 is present, go to step 8.

No >> • Clean or replace the MAP sensor.

8. CHECK DTC


Is DTC P0105 or P0106 still present?




DIAGNOSIS & TESTING


P0107 - Manifold Absolute Pressure Or Barometric Pressure Low InputP0108 - Manifold Absolute Pressure Or Barometric Pressure High Input- 1.6L

DIAGNOSIS & TESTING

VISMW030009T

03




VOLTAGE)

17 Sensor (GND)

Ignition switch: ON

- Approximately 0 V



sensor

Engine running: Idle Approximately 1.3 V

Engine running:2000 RPM Approximately 1.5 V





P0107

Manifold AbsolutePressure orBarometric Pressurelow input


Signal output isbelow minimumacceptable range fora few secondscontinuously.


P0108

Manifold AbsolutePressure orBarometric Pressurehigh input

Signal output isabove maximumacceptable range fora few secondscontinuously.




DIAGNOSIS & TESTING









No >> • Repair or replace ground harness or connections.

2. CHECK MAP SENSOR POWER SUPPLY

• Disconnect MAP sensor harness connector (1).

• Turn ignition switch on.• Check supply voltage between terminal 1 and ter-

minal 3 in MAP sensor connector E-033.• 5 V should exist.




DIAGNOSIS & TESTING

LTSMD030076

VISMD030010

03


3. CHECK THE MAP SENSOR POWER SUPPLY CIRCUIT FOR AN OPEN OR SHORT

• Check supply voltage between sensor terminal 3and ground in the MAP sensor connector E-033with a digital multimeter.




No >> • Repair or replace the circuit for an openor short to ground or short to power inharness or connectors.


4. CHECK THE MAP SENSOR GROUND CIRCUIT FOR AN OPEN OR SHORT

• Turn ignition switch off.• Disconnect the ECM harness connector E-001.• Check harness continuity between MAP sensor terminal 1 and ECM terminal 17.• Continuity should exist.



No >> • Repair or replace the circuit for an open or high resistance or short to power in harness or connec-tors.

5. CHECK THE MAP SENSOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT

• Check harness continuity between MAP sensor terminal 4 and ECM connector E-001, terminal 37.• Continuity should exist.• Check harness for a short to ground or short to power.



No >> • Repair or replace the circuit for an open or short to ground or short to power in harness or connec-tors.

DIAGNOSIS & TESTING

LTSMD030057


6. CHECK THE MAP SENSOR SIGNAL

• Check sensor signal between sensor terminal 4 and ground with a digital multimeter.

MAP SENSOR OUTPUT SIGNAL

MAPTERMINAL

NO.ITEM CONDITION DATA (DC

VOLTAGE)

4 MAPsensor

Engine:Running

• Enginerunning: Idle• Pressacceleratorpedal slowly

Approximately1.3 V

• Pressacceleratorpedal quickly

Up toapproximately

4 V(Instantaneous)




7. CHECK AND REPLACE THE MAP SENSOR

• Check the sensor as follows:− Remove the sensor mounting bolt.− Remove the sensor.− Visually check the sensor for blockage or damage, and clean the pressure port of the sensor.


Yes >> • Replace the MAP sensor with a known good MAP sensor.• Select view DTC on the X-431 screen.

− If DTC P0107 or P0108 is not present, the system is OK.− If DTC P0107 or P0108 is present, go to step 8.

No >> • Clean or replace the MAP sensor.

8. CHECK DTC






DIAGNOSIS & TESTING

03


P0112 - Intake Air Temperature Circuit Low Input

DIAGNOSIS & TESTING

VISMW030018T


DIAGNOSIS & TESTING

VISMW030009T

03




VOLTAGE)

17 Sensor (GND) Ignition switch: ON 0 V

42Intake Air

Temperature (IAT)sensor

Ignition switch: ON IAT: 36 °C Approximately 1.88V





P0112Intake air

temperature circuitlow input


When output signalis wrong or out ofacceptable range.

• IAT sensor• Harness orconnectors• ECM











DIAGNOSIS & TESTING


2. CHECK THE IAT SENSOR SIGNAL CIRCUIT

• Disconnect IAT sensor (For 1.6L engine: IAT sensoris built-into MAP sensor) harness connector E-033(1).

• Turn ignition switch on.• Check reference voltage between IAT sensor termi-

nal 2 and ground in the IAT sensor electrical con-nector E-003 with a digital multimeter.


• Disconnect IAT sensor (For 1.8L engine: IAT sensoris built-into MAF sensor) harness connector E-009(1).

• Turn ignition switch on.• Check reference voltage between IAT sensor termi-

nal 1 and ground in the IAT sensor electrical con-nector E-009 with a digital multimeter.



Yes >> • Go to Step 4.


DIAGNOSIS & TESTING

LTSMD030076

VISMD030011

VISMD030005

LTSMD030031

03



• Turn ignition switch off.• Disconnect the ECM harness connector.• Check the harness for a short to ground between IAT connector terminal 2 and ECM connector E-001, terminal

42.



No >> • Repair circuit for a short to ground in harness or connectors.

4. CHECK THE IAT SENSOR

• Connect IAT sensor connector.• Connect the ECM harness connector.• Turn ignition switch on.• Check the IAT signal under the following conditions:

− For 1.6L engine (IAT sensor is built-into MAP sensor): Check signal between terminal 2 and ground in MAPsensor connector E-033.

− For 1.8L engine (IAT sensor is built-into MAF sensor): Check signal between terminal 1 and ground in MAFsensor connector E-009.

IAT SENSOR OUTPUT SIGNAL REFERENCE DATA

IAT SENSORTERMINAL NO. ITEM CONDITION DATA (DC

VOLTAGE)

1 (For 1.8L engine)IAT sensor Ignition switch: ON IAT: 36 °C 1.88 V

2 (For 1.6L engine)



No >> • Replace the IAT sensor.

5. CHECK DTC






DIAGNOSIS & TESTING


P0113 - Intake Air Temperature Circuit High Input

DIAGNOSIS & TESTING

VISMW030018T

03


DIAGNOSIS & TESTING

VISMW030009T




VOLTAGE)

17 Sensor (GND) Ignition switch: ON 0 V

42Intake Air

Temperature (IAT)sensor

Ignition switch: ON IAT: 36 °C Approximately1.88 V





P0113Intake airtemperature circuithigh input


Output signal iswrong or out ofacceptable range.

• IAT sensor• Harness orconnectors• ECM











DIAGNOSIS & TESTING

03


2. CHECK THE IAT SENSOR SIGNAL CIRCUIT

• Disconnect IAT sensor (For 1.6L engine: IAT sensoris built-into MAP sensor) harness connector E-033(1).

• Turn ignition switch on.• Check supply voltage between IAT sensor terminal

2 and ground in the IAT sensor electrical connectorE-033 with a digital multimeter.


• Disconnect IAT sensor (For 1.8L engine: IAT sensoris built-into MAF sensor) harness connector E-009(1).

• Turn ignition switch on.• Check supply voltage between IAT sensor terminal

1 and ground in the IAT sensor electrical connectorE-009 with a digital multimeter.




No >> • Repair circuit for an open or short topower in harness or connectors.


DIAGNOSIS & TESTING

LTSMD030076

VISMD030011

LTSMD030075

LTSMD030031


3. CHECK THE IAT SENSOR GROUND CIRCUIT FOR OPEN OR SHORT

• Turn ignition switch off.• Disconnect the ECM harness connector.• Check harness continuity between the following terminals:

− For 1.6L engine, check continuity between IAT sensor terminal 1 and ECM terminal 17.

CHECK SENSOR GROUND CIRCUIT - 1.6L

IAT SENSORCONNECTOR TERMINAL

ECM CONNECTORTERMINAL

1 17

• Check harness continuity between the following terminals:− For 1.8L engine, check continuity between IAT sensor terminal 3 and ECM terminal 17.

CHECK SENSOR GROUND CIRCUIT - 1.8L

IAT SENSORCONNECTOR TERMINAL

ECM CONNECTORTERMINAL

3 17

• Refer to wiring diagram for circuit information.• Continuity should exist.• Check harness for a short to power.



No >> • Repair or replace the circuit for an open or short to power in harness or connectors.

DIAGNOSIS & TESTING

03


4. CHECK THE IAT SENSOR

• Connect IAT sensor connector.• Connect the ECM harness connector.• Turn ignition switch on.• Check the IAT signal under the following conditions:

− For 1.6L engine (IAT sensor is built-into MAP sensor): Check signal between terminal 2 and ground in MAPsensor connector E-033.

− For 1.8L engine (IAT sensor is built-into MAF sensor): Check signal between terminal 1 and ground in MAFsensor connector E-009.

IAT SENSOR OUTPUT SIGNAL REFERENCE DATA

IAT SENSORTERMINAL NO. ITEM CONDITION DATA (DC

VOLTAGE)

1 (For 1.8L engine)IAT sensor Ignition switch: ON IAT: 36 °C 1.88 V

2 (For 1.6L engine)



No >> • Replace the IAT sensor.

5. CHECK DTC






DIAGNOSIS & TESTING


P0016 - Camshaft Position-Crankshaft Position Correlation Error

DIAGNOSIS & TESTING

VISMW030014T

03


DIAGNOSIS & TESTING

VISMW030006T




15 Crankshaft Position (CKP)sensor

• Ignition switch: ON• Engine: Not cranking Approximately 3 V

34

79 Camshaft Position (CMP)sensor

• Ignition switch: ON• Engine: Not cranking Approximately 10 V





P0016Camshaft position-Crankshaft position

correlation errorEngine is running

ECM detected thatthe CMP sensor isout of phase with

CKP sensor.

• CMP sensor• CKP sensor• Harness orconnectors• Camshaft signalplate• Crankshaft signalplate• Timingmisalignment• ECM











DIAGNOSIS & TESTING

03


2. CHECK THE CMP SENSOR POWER SUPPLY CIRCUIT FOR AN OPEN OR SHORT

• Disconnect CMP sensor connector (1).

• Turn ignition switch on.• Check supply voltage between terminal 3 and

ground in CMP sensor connector E-007 terminalside with a digital multimeter.






• Check the following:− Front fuse and relay box K− Fuse SB2, fuse FB12, and fuse FB18− Harness for an open or short between CMP sensor and fuse

• Repair or replace malfunctioning part as necessary.• With the X-431 scan tool, read ECM DTCs.• Refer to �DTC Confirmation Procedure�.



No >> • The system is now operating correctly at this time.

4. CHECK THE CMP SENSOR GROUND CIRCUIT FOR AN OPEN OR SHORT

• Turn ignition switch off.• Check harness continuity between CMP sensor terminal 1 and ground.• Continuity should exist.



No >> • Repair or replace the circuit for an open or short.

DIAGNOSIS & TESTING

VISMD030001

LTSMD030044


5. CHECK THE CMP SENSOR INPUT SIGNAL CIRCUIT FOR AN OPEN OR SHORT

• Turn ignition switch on.• Check voltage between terminal 2 and ground in CMP sensor connector E-007 terminal side.• 11 V should exist.



No >> • Repair or replace circuit for an open or short to power or short to ground in harness or connectors.• If circuit is normal, go to the next step.

6. CHECK CMP SENSOR SIGNAL

• Turn ignition switch off.• Connect CMP sensor connector.• Check the CMP output signal between terminal 2 and ground in CMP sensor connector E-007 harness side,

with the engine running.• Approximately 6 V square wave signal should exist.

CMP SENSOR SIGNAL OUTPUT

WITH ENGINE ANALYZER(KES-200)

CMP SENSOR SIGNAL

Is the CMP output signal normal?



DIAGNOSIS & TESTING

03


7. CHECK CMP SENSOR

• Remove the CMP sensor (1).• Inspect and clean the CMP sensor and mounting

area for any condition that would result in an incor-rect signal, such as damage, foreign material, orexcessive movement.

• Perform the following to check the resistance of the CMP sensor:

CMP SENSOR RESISTANCE

TERMINAL NO. RESISTANCE � (25 °C)

1 & 2

Except 0 or �1 & 3

2 & 3

• Remove the CMP sensor (1).• Inspect and clean the CMP sensor and mounting area for any condition that would result in an incorrect signal,

such as damage, foreign material, or excessive movement.


Yes >> • Replace the CMP sensor with a known good CMP sensor.• Monitor the CMP sensor signal on the KES-200 screen.

− If the CMP sensor signals were normal, the system is OK.− If the CMP sensor signals were still irregular or missing, go to step 10.

No >> • Replace CMP sensor.

DIAGNOSIS & TESTING

BESM030016


8. CHECK CKP SENSOR SIGNAL WAVE

• Check signal between terminal 1 and ground, termi-nal 2 and ground in CKP sensor (1) connectorE-006 harness side, with the engine running.

CKP SENSOR SIGNAL OUTPUT

WITH ENGINE ANALYZER(KES-200)

CKP SENSOR SIGNAL

Is the CKP output signal normal?



DIAGNOSIS & TESTING

VISMD030004

03


9. CHECK CKP SENSOR

• Remove the CKP sensor (1).• Inspect and clean the CKP sensor and mounting

area for any condition that would result in an incor-rect signal, such as damage, foreign material, orexcessive movement.

• Perform the following to check the resistance of the CKP sensor:

CKP SENSOR RESISTANCE


1 & 2 Approximately 1000 �


Yes >> • Replace the CKP sensor with a known good CKP sensor.• Monitor the CKP sensor signal on the KES-200 screen.

− If the CKP sensor signals were normal, the system is OK.− If the CKP sensor signals were still irregular or missing, go to step 11.

No >> • Replace CKP sensor.

DIAGNOSIS & TESTING

BESM030025


10. CHECK THE CAMSHAFT AND CAMSHAFT SIGNAL PLATE

• Remove the cylinder head cover and timing belt cover (See Timing Belt Removal & Installation in Section02 Engine).

• Check the installed clearance (See CMP Sensor Removal & Installation in Section 03 Electronic EngineControls).

NOTE :0.8 - 1.2 mm should exist.

• Check the camshaft and camshaft signal plate for any condition that would result in an incorrect signal,such as damage, become flexible, foreign material when rotate the camshaft.

Were any problems found?

Yes >> • Remove debris and clean the signal plate of camshaft rear end or replace camshaft.• Reinstall the CMP sensor.


11. CHECK THE CRANKSHAFT AND CRANKSHAFT SIGNAL PLATE

• Check the installed clearance (See Crankshaft Position Sensor Removal & Installation in Section 03 Elec-tronic Engine Controls).


• Check the crankshaft and camshaft signal plate for any condition that would result in an incorrect signal,such as damage, become flexible, foreign material when rotate the camshaft.


Yes >> • Remove debris and clean the signal plate of crankshaft rear end or replace crankshaft.• Reinstall the CKP sensor.


12. CHECK THE TIMING

• Check for timing misalignment.

Is the timing misaligned?

Yes >> • Align the engine timing belt (See Timing Belt Removal & Installation in Section 02 Engine).


13. CHECK DTC






DIAGNOSIS & TESTING

03


P0117 - Engine Coolant Temperature Circuit Low Input

DIAGNOSIS & TESTING

VISMW030008T




VOLTAGE)

17 Sensor (GND)

Ignition switch: ON

- Approximately 0 V

39Engine Coolant

Temperature (ECT)sensor

ECT: 59 °C 1.89 V

ECT: 78 °C 1.25 V

ECT: 90 °C 0.94 V





P0117Engine coolanttemperature circuitlow input



• ECT sensor• Harness orconnectors• ECM



NOTE :• Before performing this DTC diagnostic procedure, verify that the Engine coolant temperature is normal.









DIAGNOSIS & TESTING

03


2. CHECK THE ENGINE ECT SENSOR SIGNAL CIRCUIT FOR A SHORT

• Disconnect ECT sensor harness connector (1).

• Turn ignition switch on.• Check ECT sensor reference voltage between sen-

sor terminal 2 and ground in the sensor electricalconnector E-019 with a digital multimeter.

• 4.5 - 4.9 V should exist.





• Turn ignition switch off.• Disconnect the ECM harness connector.• Check the harness for a short to ground between the ECT sensor connector terminal 2 and ECM connector

E-001, terminal 39.




No >> • Repair or replace the circuit for a short in harness or connectors.

DIAGNOSIS & TESTING

BESM030019

LTSMD030032


4. CHECK ECT SENSOR

• Check the resistance between the ECT sensor terminal 1 and 2.

ECT RESISTANCE REFERENCE DATA

ECT °C RESISTANCE K�

-10 °C 8.62 - 10.28

20 °C 2.37 - 2.63

80 °C 0.299 - 0.345

• Connect ECT sensor connector.• Connect the ECM harness connector.• Turn ignition switch on.• Check sensor output signal.

ECT SENSOR OUTPUT SIGNAL REFERENCE DATA

ECT TERMINALNO. ITEM CONDITION DATA (DC

VOLTAGE)

17 Sensor (GND)

Ignition switch: ON

- Approximately 0 V

39 ECT sensor

ECT: 59 °C 1.89 V

ECT: 78 °C 1.25 V

ECT: 90 °C 0.94 V



No >> • Replace ECT sensor.

5. CHECK DTC






DIAGNOSIS & TESTING

03


P0118 - Engine Coolant Temperature Circuit High Input

DIAGNOSIS & TESTING

VISMW030008T




VOLTAGE)

17 Sensor (GND)

Ignition switch: ON

- Approximately 0 V

39Engine Coolant

Temperature (ECT)sensor

Engine coolanttemperature: 59 °C

Approximately1.89 V


Approximately1.25 V


Approximately0.94 V





P0118Engine coolant

temperature circuithigh input



• ECT sensor• Harness orconnectors• ECM



NOTE :• Before performing this DTC diagnostic procedure, verify that the engine coolant temperature is normal.

DIAGNOSIS & TESTING

03










2. CHECK ECT SENSOR SIGNAL CIRCUIT FOR A SHORT

• Disconnect the ECT sensor harness connector (1).

• Turn ignition switch on.• Check the ECT sensor reference voltage between

sensor terminal 2 and ground in the sensor electri-cal connector E-019 with a digital multimeter.




No >> • Repair or replace the harness for anopen or short to power between ECTconnector terminal 2 and ECM connec-tor E-001, terminal 39.

• If harness is normal, replace the ECM.


DIAGNOSIS & TESTING

BESM030019

LTSMD030032


3. CHECK ECT SENSOR GROUND CIRCUIT FOR OPEN OR SHORT TO POWER

• Turn ignition switch off.• Check harness continuity between the following terminals (see wiring diagram for circuit information).• Continuity should exist.• Check harness for a short to power.

SENSOR GROUND CIRCUIT

ECTSENSOR

TERMINAL

ECMTERMINAL CONTINUITY

1 17 Yes




DIAGNOSIS & TESTING

03


4. CHECK ECT SENSOR

• Check resistance between ECT sensor terminal 1 and 2.

ECT RESISTANCE REFERENCE DATA

ECT °C RESISTANCE K�

-10 °C 8.62 - 10.28

20 °C 2.37 - 2.63

80 °C 0.299 - 0.345

• Connect ECT sensor connector.• Connect the ECM harness connector.• Turn ignition switch on.• Check sensor output signal.

ECT SENSOR OUTPUT SIGNAL REFERENCE DATA

ECT TERMINALNO. ITEM CONDITION DATA (DC

VOLTAGE)

17 Sensor (GND)

Ignition switch: ON

- Approximately 0 V

39 ECT sensor

ECT: 59 °C 1.89 V

ECT: 78 °C 1.25 V

ECT: 90 °C 0.94 V



No >> • Replace ECT sensor.

5. CHECK DTC






DIAGNOSIS & TESTING


P0122 - Throttle Position Sensor A Circuit Low InputP0123 - Throttle Position Sensor A Circuit High Input

DIAGNOSIS & TESTING

VISMW030005T

03




VOLTAGE)

32 Regulated sensorsupply 2

Ignition switch: ON

- Approximately 5 V

38Electronic throttlecontrol actuator

(Position Sensor)

Engine stoppedAccelerator pedal:Fully released

4.24 V

Engine stoppedAccelerator pedal:Fully depressed

0.72 V

54 Electronic throttlecontrol actuator


0.74 V


4.62 V

64 Motor 4

-

12 or 0 V65 Motor 3

66 Motor 20 or 12 V

67 Motor 1

73 Regulated sensorsupply Approximately 5 V

78 Sensor (GND) Approximately 0 V





P0122Throttle position

sensor A circuit lowinput



• TPS ormisalignment• Harness orconnectors• ECM

P0123Throttle position

sensor A circuit highinput


• TPS ormisalignment• Harness orconnectors• ECM



DIAGNOSIS & TESTING










2. CHECK THE TPS POWER SUPPLY CIRCUIT

• Disconnect TPS harness connector (1).

• Turn ignition switch on.• Check throttle position sensor supply voltage

between sensor terminal 3 and ground in the sen-sor electrical connector E-027 with a digital multim-eter.




No >> • Repair circuit for an open or short toground or short to power in harness orconnectors.

• If the circuit is normal, go to the nextstep.

DIAGNOSIS & TESTING

VISMD030006

LTSMD030035

03


3. CHECK TPS SIGNAL CIRCUIT FOR AN OPEN OR SHORT

• Turn ignition switch off.• Disconnect the ECM harness connector.• Check harness continuity between the following terminals (see wiring diagram for circuit information):• Continuity should exist.

TPS SIGNAL CIRCUIT

TPS TERMINAL ECM TERMINAL

6 54

5 38

• Check harness for short to power or short to ground.





• Check the harness for an open, a short to ground or a short to power between TPS connector terminal 2 andECM connector E-001, terminal 78



No >> • Repair or replace harness or connectors.

5. CHECK THE TPS RESISTANCE

• Check resistance between TPS terminal 2 and 3.• 2 k� ± 20 % (20 °C) should exist.• Check resistance between TPS terminal 2 and 6 with a digital multimeter.• Slowly open the throttle, the TPS resistance value should change in a linear movement with the throttle as it

opens.



No >> • Replace the TPS.• Perform the TPS self-learning procedure.

DIAGNOSIS & TESTING


6. CHECK THE TPS

• Turn ignition switch off.• Connect the ECM harness connector.• Connect TPS connector.• Turn ignition switch on.• Check voltage between the TPS terminal 3 and ground under the following conditions:

TPS OUTPUT SIGNAL

TERMINAL NO. ITEM CONDITION DATA (DCVOLTAGE)


Ignition switch: ON

- Approximately 5 V

38Electronic throttlecontrol actuator

(Position Sensor)


4.24 V


0.72 V



0.74 V


4.62 V

64 Motor 4

-

12 V or 0 V65 Motor 3

66 Motor 20 V or 12 V

67 Motor 1

73 Regulated sensorsupply Approximately 5 V




No >> • Replace the TPS.• Perform the TPS self-learning.

7. CHECK DTC






DIAGNOSIS & TESTING

03


P0031 - O2 Sensor 1 Heater Control Circuit LowP0032 - O2 Sensor 1 Heater Control Circuit High

DIAGNOSIS & TESTING

VISMW030015T




18 Upstream oxygen sensor

Engine is runningWarm-up conditionKeep the engine speed2000 RPM

Approximately 0.1 V - 0.9V (change 5 - 8 times in10 seconds periodically)

28 Downstream oxygensensor heating - -

36 Sensor (GND) Warm-up conditionIdle speed Approximately 0 V

48 Upstream oxygen sensorheating - -

55 Downstream oxygensensor

Engine is runningWarm-up conditionKeep the engine speed2000 RPM

Approximately 100 mV



DTC NO. DTC DEFINITION DTC DETECTIONCONDITION POSSIBLE CAUSE

P0031 O2 sensor 1 heatercontrol circuit low

Engine is running

• Oxygen sensor• Harness or connectors• ECM

P0032 O2 sensor 1 heatercontrol circuit high

• Oxygen sensor• Harness or connectors• ECM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on.• With the scan tool, record and erase stored DTCs in the ECM.• Start the engine and warm it to normal operating temperature.• Turn ignition switch off and wait at least 10 seconds.• Start the engine and keep the engine speed 2000 RPM for at least 1 minute.• Let engine idle for 2 minutes.• With the scan tool, select view DTCs in the ECM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


DIAGNOSIS & TESTING

03










2. CHECK OXYGEN SENSOR HEATER POWER SUPPLY CIRCUIT

• Disconnect oxygen sensor (1) harness connectorE-004.

• Turn ignition switch on.• Check supply voltage between oxygen sensor ter-

minal 2 and ground in the oxygen sensor electricalconnector E-004 with a digital multimeter.



Yes >> • Go to Step 4.



• Check the following:− Front fuse and relay box K− Fuse SB2, fuse FB10, fuse FB18− Harness for an open or short between oxygen sensor and fuse

• Repair or replace any malfunctioning part.• With X-431, select view DTC.



No >> • The system is normal now.

DIAGNOSIS & TESTING

BESM030017

LTSMD030029


4. CHECK THE OXYGEN SENSOR HEATER CONTROL CIRCUIT FOR AN OPEN OR SHORT

• Turn ignition switch off.• Disconnect the ECM connector.• Check harness continuity between ECM terminal and oxygen sensor terminal (refer to wiring diagram for circuit

information).• Continuity should exist.

OXYGEN SENSOR HEATER CONTROL CIRCUIT

COMPONENT TERMINAL

ECM 48

Upstream Oxygen Sensor 1

• Check harness for a short to ground or short to power.



No >> • Repair or replace the circuit for an open or short to ground or short to power in harness or connec-tors.

5. CHECK THE OXYGEN SENSOR HEATER

• Check resistance between oxygen sensor terminals.

OXYGEN SENSOR HEATER

TERMINAL NO. RESISTANCE

1 & 2 (including wire andconnector) Approximately 2.5 - 4.9 �

• Check resistance between oxygen sensor terminals.

CHECK OXYGEN SENSOR

TERMINAL NO. RESISTANCE

1 & 3 and 1 & 4

� � (Continuityshould not exist)

4 & 1 and 4 & 2

DIAGNOSIS & TESTING

03




No >> • Replace the oxygen sensor.

6. CHECK DTC






DIAGNOSIS & TESTING


P0132 - O2 Sensor Circuit 1 High Voltage

DIAGNOSIS & TESTING

VISMW030015T

03




18 Upstream oxygen sensor Engine is runningWarm-up condition

Approximately 0.1 V - 0.9V (change 5 - 8 times in10 seconds periodically)

28 Downstream oxygensensor heating - -

36 Sensor (GND) Warm-up conditionIdle Approximately 0 V

48 Upstream oxygen sensorheating - -

55 Downstream oxygensensor

Engine is runningWarm-up condition Approximately 100 mV




P0132 O2 sensor 1 (upstream)circuit high voltage Engine is running

• Fuel quality• Oxygen sensor 1(upstream)• Harness or connectors• ECM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on.• With the scan tool, record and erase stored DTCs in the ECM.• Start the engine and warm it to normal operating temperature.• Turn ignition switch off and wait at least 10 seconds.• Start engine and keep the engine speed 2000 RPM for at least 1 minute.• Let engine idle for 2 minutes.• With the scan tool, select view DTCs in the ECM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-










DIAGNOSIS & TESTING


2. CHECK THE OXYGEN SENSOR GROUND CIRCUIT

• Disconnect oxygen sensor harness connector (1).

• Disconnect the ECM harness connector.• Check harness continuity between ECM terminal 18 and oxygen sensor terminal 4 (refer to wiring diagram for

circuit information).• Continuity should exist.• Check the harness for an open and a short to power supply circuit.



No >> • Repair circuit for an open or short to power in harness or connectors.

3. CHECK OXYGEN SENSOR INPUT SIGNAL CIRCUIT FOR AN OPEN OR SHORT

• Check the harness continuity between ECM terminal and oxygen sensor terminal as follows (refer to wiring dia-gram for circuit information).

• Continuity should exist.

OXYGEN SENSOR SIGNAL CIRCUIT

COMPONENT TERMINAL

ECM 18

Upstream Oxygen Sensor 4

Check the harness for a short to power supply circuit.




DIAGNOSIS & TESTING

BESM030017

03


4. CHECK OXYGEN SENSOR

• Connect oxygen sensor connector.• Connect the ECM harness connector.• If using the X-431, reference data stream value.• If not using the X-431, perform the following:

− Start engine and warm it up to normal operating temperature 350 °C.− Turn ignition switch off.− Start engine and keep the engine speed between 3,500 RPM and 4,000 RPM for at least 1 minute.− Let engine idle for 1 minute.− Connect the digital multimeter probes between ECM terminal 4 and ground.

OXYGEN SENSOR OUTPUT SIGNAL

CHECK ITEM CHECK CONTENT NORMALVALUE

Oxygensensor

• Warm-upcondition• Becomelean whiledecelerate

Deceleratefrom

approximately4,000 RPMsuddenly

Below 100mV

• Warm-upcondition• Becomerich whileaccelerate

Acceleratesuddenly

Approximately600 - 900 mV

• Warm-upcondition• Check withoxygensensor signal

Idle 100 - 900 mV

Approximately2500 RPM

Approximately600 - 900 mV



No >> • Replace oxygen sensor.

5. CHECK DTC






DIAGNOSIS & TESTING


P0171 - Fuel Trim System Too Lean

DIAGNOSIS & TESTING

VISMW030018T

03


DIAGNOSIS & TESTING

VISMW030009T


DIAGNOSIS & TESTING

VISMW030011T

03


DIAGNOSIS & TESTING

VISMW030012T


DIAGNOSIS & TESTING

VISMW030013T

03




6 Injector 2Engine is runningIdleWarm-up conditionAccelerate suddenly

Voltage: 11-14 V7 Injector 3

27 Injector 1

47 Injector 4

ECM TERMINALNO. ITEM CONDITION DATA (AVERAGE

DC VOLTAGE)

17 Sensor (GND) - 0 V

33 Regulated sensorsupply 1 Ignition switch: ON Approximately 5 V


sensor (1.6L)

Engine running: IdlePress accelerator pedal slowly Approximately 1.3 V

Engine running: 2000 RPM Approximately 1.5 V

Press accelerator pedal quickly Up to Approximately4 V (Instantaneous)

ECM TERMINAL NO. ITEM CONDITION DATA

37 MAF sensor (1.8L)

Engine is runningIAT: 36 °CIdle: 795 RPMECT: 78 °CIAT signal voltage: 1.88 V

Approximately 322 kg/hApproximately 1.39 V



DTC NO. DTCDEFINITION

DTCDETECTIONCONDITION


P0171 Fuel trim systemtoo lean

Engine isrunning

The amount ofmixture ratiocompensation istoo large (Themixture ratio istoo lean).

• Intake air leaks• MAP sensor• MAF sensor• Fuel injector• Exhaust gas leaks• Incorrect fuel pressure• Lack of fuel• Incorrect PCV hose connection• Upstream O2 sensor• ECM

DIAGNOSIS & TESTING


DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on.• With the scan tool, record and erase stored DTCs in the ECM.• Start engine and warm it to normal operating temperature, then select view DTC and data stream.• If DTC is detected, go to �Diagnostic Procedure�.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help in Section 03 - Electronic

Engine Controls).


1. CHECK EXHAUST GAS LEAK

• Start engine and run it at idle.• Listen for any exhaust gas leaks before the three way catalyst.



No >> • Repair the leak as necessary.

2. CHECK FOR INTAKE AIR LEAK

• Turn ignition switch on.• Listen for intake air leak after the MAF sensor.• Check PCV hose connector.



No >> • Repair or replace as necessary.

3. CHECK ECM CONTROL SIGNAL IN DATA STREAM

• With X-431, select view data stream.

INJECTOR REFERENCE DATA

MONITOR ITEM CONDITION DATA

Injector pulse

Engine Temp: Warm-up78 °CTransaxle Position: NAir Conditioner: OffEngine load: No load

Idle Approximately 2.5 ms




DIAGNOSIS & TESTING

03


4. CHECK UPSTREAM O2 SENSOR SIGNAL CIRCUIT

• Turn ignition switch off.• Disconnect upstream O2 sensor 1 harness connec-

tor (1).

• Disconnect the ECM harness connector.• Check the harness continuity between the following terminals (refer to wiring diagram for circuit information).• Continuity should exist.

OXYGEN SENSOR CIRCUIT

COMPONENT ECM TERMINAL OXYGEN SENSOR TERMINAL

TERMINAL36 3

18 4

• Check harness for a short to ground.



No >> • Repair or replace the circuit for an open or short to ground in harness or connectors.

5. CHECK THE MAP OR MAF SENSOR SIGNAL

• For the 1.6L engine, check MAP signal in data stream.

1.6L MAP SIGNAL DATA


VOLTAGE)


sensorEngine: Running


Approximately 1.3 V



Up to Approximately4 V (instantaneous)

DIAGNOSIS & TESTING

BESM030017


• For the 1.8L engine, check MAF signal in data stream.

1.8L MAF SIGNAL DATA


37 MAF sensor

Engine is runningWarm-up condition: 78 °CIdle: 795 RPMIAT: 36 °CIAT signal voltage: 1.88 V



Ye >> • Go to the next step.

No >> • Check connectors for rusted terminals or loose connectors in the MAP or MAF sensor circuit orground.

6. CHECK FUEL PRESSURE

• Release the fuel system pressure (See FuelPressure Relief Procedure in Section 04 FuelDelivery).

• Install fuel pressure gauge (2) and check thefuel pressure (See Fuel Pressure Test in Sec-tion 04 Fuel Delivery).

• Observe the following fuel pressures when testing:

FUEL PRESSURES

Key On 400 kPa (4.0 bar)

Key Off 380 kPa (3.8 bar) in 10 minutes

Engine Idle 400 - 420 kPa (4.0 - 4.2 bar)

DIAGNOSIS & TESTING

BESM030020

03






• Check the following:− Fuel lines− Fuel pump and circuit− Fuel pressure regulator− Fuel filter for clogging


Yes >> • If using the X-431, go to the next step.• If not using the X-431, go to step 9.

No >> • Repair or replace the malfunctioning part.

8. PERFORM ACTIVE TEST FUNCTION

• Start engine.• Select �ACTIVE TEST� menu.• Perform injector active test.• Make sure that each test produces a momentary drop in engine speed.




9. CHECK FUNCTION OF INJECTOR

• Listen to each injector for an operating sound.• Operating sound should exist.




DIAGNOSIS & TESTING


10. CHECK INJECTOR POWER SUPPLY CIRCUIT AND CONTROL CIRCUIT

• Turn ignition switch off.• Disconnect the injector harness connectors (1).

• Turn ignition switch on.• Check injector supply voltage between sensor

terminal and ground in the injector harnessconnector with a digital multimeter.


• Turn ignition switch off• Disconnect the ECM harness connector.• Check harness continuity between the following terminals (see wiring diagram for circuit information).• Continuity should exist.

FUEL INJECTOR CIRCUIT

INJECTOR NO. ECMTERMINAL

INJECTORTERMINAL

1 27 2

2 6 2

3 7 2

4 47 2

• Check harness for a short to power.



No >> • Repair or replace circuit for an open or short to power in harness or connectors.

DIAGNOSIS & TESTING

BESM040006

LTSMD030024

03


11. CHECK INJECTOR RESISTANCE

• Disconnect the injector harness connectors.• Check harness continuity between the following terminals (see wiring diagram for circuit information).

FUEL INJECTOR RESISTANCE

INJECTORNO.

INJECTORTERMINAL

RESISTANCE(APPROXIMATELY)

� (20 °C)

1 1 & 2

11 - 16

2 1 & 2

3 1 & 2

4 1 & 2



No >> • Replace injector.• Go to step 13.

12. CHECK INJECTOR

WARNING!

Confirm that the engine is cooled down and there are no fire hazards near the vehicle.

• Remove fuel delivery rail with injectors (See Fuel Injector Rail Removal & Installation in Section 04 FuelDelivery).

NOTE :Be careful not to drop the fuel injectors when removing the fuel delivery rail.

• Keep fuel hose and all injectors connected to injector rail.• Disconnect all ignition coil harness connectors.• Prepare pans or saucers under each injector.• Crank engine for approximately 3 seconds.• Fuel should be sprayed evenly from each injector.•



No >> • Clean any injector that sprays unevenly or replace any injector that does not spray fuel.

DIAGNOSIS & TESTING


13. CHECK DTC






DIAGNOSIS & TESTING

03


P0172 - Fuel Trim System Too Rich

DIAGNOSIS & TESTING

VISMW030018T


DIAGNOSIS & TESTING

VISMW030009T


DIAGNOSIS & TESTING

VISMW030011T

03


DIAGNOSIS & TESTING

VISMW030012T


DIAGNOSIS & TESTING

VISMW030013T




6 Injector 2Engine is runningIdleWarm-up conditionAccelerate suddenly

Voltage: 11-14 V7 Injector 3

27 Injector 1

47 Injector 4


DC VOLTAGE)

17 Sensor (GND) - 0 V

33 Regulated sensorsupply 1 Ignition switch: ON Approximately 5 V


sensor (1.6L)

Engine running: IdlePress accelerator pedal slowly Approximately 1.3 V

Engine running: 2000 RPM Approximately 1.5 V

Press accelerator pedal quickly Up to Approximately4 V (instantaneous)


37 MAF sensor (1.8L)

Engine is runningIAT: 36 °CIdle: 795 RPMECT: 78 °CIAT signal: 1.88 V




DTC NO. DTCDEFINITION

DTCDETECTIONCONDITION

DTC SET CONDITION POSSIBLE CAUSE

P0172Fuel trim

system toorich

Engine isrunning

The amount of mixture ratiocompensation is too large(The mixture ratio is too rich).

• MAP sensor• MAF sensor• Fuel injector• Exhaust gas leaks• Incorrect fuel pressure• Upstream O2 sensor• ECM



DIAGNOSIS & TESTING

03



1. CHECK EXHAUST GAS LEAK

• Start engine and run it at idle.• Listen for any exhaust gas leaks before the three way catalyst.



No >> • Repair the leak as necessary.

2. CHECK ECM CONTROL SIGNAL IN DATA STREAM

• With X-431, select view data stream.


MONITOR ITEM CONDITION DATA

Injector pulse

Engine Temp: Warm-up78 °CTransaxle Position: NAir Conditioner: OffEngine load: No load

Idle Approximately 2.5 ms




3. CHECK UPSTREAM O2 SENSOR SIGNAL CIRCUIT

• Turn ignition switch off.• Disconnect upstream O2 sensor harness connector

(1).

• Disconnect the ECM harness connector.• Check harness continuity between the following terminals (refer to wiring diagram for circuit information).• Continuity should exist.

OXYGEN SENSOR CIRCUIT

COMPONENT ECM OXYGEN SENSOR

TERMINAL36 3

18 4

DIAGNOSIS & TESTING

BESM030017


• Check harness for short to power.



No >> • Repair or replace circuit for an open or short to power in harness or connectors.

4. CHECK FUEL PRESSURE

• Release the fuel system pressure (See FuelPressure Relief Procedure in Section 04 FuelDelivery).

• Install fuel pressure gauge (2) and check thefuel pressure (See Fuel Pressure Test in Sec-tion 04 Fuel Delivery).

• Observe the following fuel pressures when testing:

FUEL PRESSURES


Key Off 380 kPa (3.8 bar) in 10 minutes

Engine Idle 400 - 420 kPa (4.0 - 4.2 bar)




DIAGNOSIS & TESTING

BESM030020

03



• Check the following:− Fuel pump and circuit− Fuel pressure regulator



No >> • Repair or replace as necessary.

6. CHECK THE MAP OR MAF SENSOR SIGNAL

• Turn ignition switch off.• Install all previously removed parts.• For 1.6L engine, check MAP signal.

1.6L MAP DATA


VOLTAGE)


sensorEngine: Running


Approximately 1.3 V



Up to Approximately4 V (instantaneous)

• For 1.8L engine, check MAF signal in data stream.

1.8L MAF DATA


37 MAF sensor

Engine is runningIAT: 36 °CIdle: 795 RPMWarm-up condition: 78 °CIAT signal voltage: 1.88 V




No >> • Check connectors for damaged or MAP signal circuit for short to power circuit.

DIAGNOSIS & TESTING








• Listen to each injector for operating sound.• Operating sound should exist.




9. CHECK INJECTOR CONTROL CIRCUIT

• Turn ignition switch off.• Disconnect the injector harness connectors (1).

• Disconnect the ECM harness connector.• Check harness for short to ground between following terminals (refer to wiring diagram for circuit information).• Continuity should not exist.

FUEL INJECTOR CIRCUITS

INJECTOR NO. ECMTERMINAL

INJECTORTERMINAL

1 27 2

2 6 2

3 7 2

4 47 2

DIAGNOSIS & TESTING

BESM040006

03




No >> • Repair circuit for a short to ground in harness or connectors.

10. CHECK INJECTOR RESISTANCE

• Disconnect the injector harness connectors.• Check harness continuity between the following terminals (refer to wiring diagram for circuit information).


INJECTORNO.

INJECTORTERMINAL


� (20 °C)

1 1 & 2

11 - 162 1 & 2

3 1 & 2

4 1 & 2



No >> • Replace injector.• Go to step 12.

11. CHECK INJECTORS

WARNING!

Confirm that the engine is cooled down and there are no fire hazards near the vehicle.

• Remove fuel delivery rail with injectors (See Fuel Injector Rail Removal & Installation in Section 04 FuelDelivery).

NOTE :Be careful not to drop the fuel injectors when removing the fuel delivery rail.

• Keep fuel hose and all injectors connected to injector rail.• Disconnect all injector harness connectors.• Disconnect all ignition coil harness connectors.• Prepare pans or saucers under each injector.• Crank engine for approximately 3 seconds.• Make sure fuel does not drip from injectors.



No >> • Replace any injectors from which fuel is dripping. Always replace O-ring with new one.

DIAGNOSIS & TESTING


12. CHECK DTC






DIAGNOSIS & TESTING

03


P0201 - Cylinder 1 - Injector CircuitP0202 - Cylinder 2 - Injector CircuitP0203 - Cylinder 3 - Injector CircuitP0204 - Cylinder 4 - Injector Circuit

DIAGNOSIS & TESTING

VISMW030011T


DIAGNOSIS & TESTING

VISMW030012T

03


DIAGNOSIS & TESTING

VISMW030013T




6 Injector 2Engine is runningWarm-up conditionIdleAccelerate suddenly

Voltage: 11 - 14 V7 Injector 3

27 Injector 1

47 Injector 4





Engine is running• Injector• Harness or connectors• ECM






DIAGNOSIS & TESTING

03










2. PRELIMINARY INSPECTION


Is any cylinder firing?









• Listen to each injector for operating sound.• Operating sound should exist.




DIAGNOSIS & TESTING


5. CHECK INJECTOR POWER SUPPLY CIRCUIT FOR OPEN OR SHORT

• Turn ignition switch off.• Disconnect the injector harness connector (1).

• Turn ignition switch on.• Check injector supply voltage between sensor ter-

minal and ground in the electrical connector with adigital multimeter.






• Check the following:− Front fuse and relay box K− Fuse FB2, fuse FB12, fuse FB18− Harness for an open or short to ground between injector and fuse


Yes >> • With X-431, check the system, If OK, go to the next step.

No >> • Repair or replace malfunctioning parts.

DIAGNOSIS & TESTING

BESM040006

LTSMD030024

03


7. CHECK INJECTOR CONTROL CIRCUITS FOR OPEN

• Check injector control circuit voltage.• 3.6 V should exist.





• Turn ignition switch off.• Disconnect the ECM harness connector.• Check harness continuity between the following terminals (see wiring diagram for circuit information).• Continuity should exist.

CHECK INJECTOR CIRCUIT

INJECTOR NO ECMTERMINAL

INJECTORTERMINAL

1 27 2

2 6 2

3 7 2

4 47 2



No >> • Repair circuit for an open in harness or connectors.

DIAGNOSIS & TESTING


9. CHECK INJECTOR

• Refer to wiring diagram for circuit information.


INJECTORNO.

INJECTORTERMINAL


� (20 °C)

1 1 & 2

11 - 162 1 & 2

3 1 & 2

4 1 & 2

• Check sensor signal output.• Connect the ECM harness connector.• Connect injector connector.• Refer to wiring diagram for circuit information.


TERMINAL NO. INJECTOR NO CONDITION DATA (AVERAGE DCVOLTAGE)

6 2 • Engine is running• Warm-up condition• Idle• Accelerate suddenly

Voltage: 11 - 14 V7 3

27 1

47 4



No >> • Replace injector.

10. CHECK DTC


Is DTC P0201, P0202, P0203 or P0204 still present?




DIAGNOSIS & TESTING

03


P0221 - Throttle Position Sensor B Performance

DIAGNOSIS & TESTING

VISMW030005T


DIAGNOSIS & TESTING

VISMW030010T

03




VOLTAGE)


Ignition switch: ON

- Approximately 5 V

38Electronic throttlecontrol actuator(position sensor)


4.24 V


0.72 V



0.74 V


4.62 V

64 Motor 4

-



67 Motor 1

73 Regulated sensorsupply 2 Approximately 5 V






P0221Throttle PositionSensor (TPS) B

performance


Rationally incorrectvoltage is sent toECM compared withthe signals fromTPS1 and TPS2.

• Electric throttlecontrol actuator(TPS1 and TPS2)• Harness orconnectors• Accelerator pedalposition sensor 2• ECM



DIAGNOSIS & TESTING










2. CHECK THE TPS POWER SUPPLY CIRCUIT

• Disconnect the TPS connector (1).

• Turn ignition switch on.• Check supply voltage between TPS terminal 3 and

ground in the sensor electrical connector E-027with a digital multimeter.





3. CHECK TPS POWER SUPPLY CIRCUIT

• Turn ignition switch off.• Disconnect the ECM harness connector.• Check harness continuity between TPS terminal 3 and ECM terminal 32 (refer to wiring diagram for circuit infor-

mation).• Continuity should exist.



No >> • Repair or replace circuit for an open.• If the circuit is normal, go to the next step.

DIAGNOSIS & TESTING

VISMD030006

LTSMD030035

03



• Check harness for short to power and short to ground, between the following terminals:

TPS POWER SUPPLY

ECM TERMINAL TPS / APPS TERMINAL

32 or 73 TPS terminal 3

32 or 73 APP sensor terminal 3

33 APP sensor terminal 6



No >> • Repair circuit for a short to ground or short to power in harness or connectors.

5. CHECK THE APP SENSOR

• Connect all harness connectors disconnected.• Turn ignition switch on.• Check voltage between ECM terminals 16 (APP sensor 1 (APPS1) signal), 40 (APP sensor 2 (APPS2) signal)

and ground under the following conditions:

APP SENSOR SIGNAL

ECMTERMINAL

NO.

APPSENSOR

TERMINALITEM CONDITION DATA (DC

VOLTAGE)

16APP

sensorterminal 4

AcceleratorPedal

PositionSensor

Ignitionswitch:

ON

EnginestoppedAcceleratorpedal:Fullyreleased

0.72 -0.74 V

EnginestoppedAcceleratorpedal:Fullydepressed

3.95 V

40APP

sensorterminal 1

AcceleratorPedal

PositionSensor


0.36 -0.37 V


1.97 V



No >> • Replace the Accelerator Pedal Assembly (See Accelerator Pedal Position Sensor Removal & Installa-tion in Section 03 Electronic Engine Controls).

• Perform accelerator pedal position learning.• Perform throttle valve position learning.

DIAGNOSIS & TESTING

03


6. CHECK THE TPS SIGNAL CIRCUIT FOR AN OPEN OR SHORT

• Turn ignition switch off.• Disconnect the ECM harness connector.• Check harness continuity between the electronic throttle control actuator terminal 5 and ECM terminal 38 (refer

to wiring diagram for circuit information).• Continuity should exist.• Check harness for a short to power and short to ground.



No >> • Repair circuit for an open or short to power or short to ground in harness or connectors.

7. CHECK TPS GROUND CIRCUIT FOR AN OPEN

• Check harness continuity between the electronic throttle control actuator terminal 2 and ECM terminal 78 (referto wiring diagram for circuit information).

• Continuity should exist.• Check harness for short to power.



No >> • Repair circuit for an open or short to power in harness or connectors.

DIAGNOSIS & TESTING

03


8. CHECK TPS

• Connect all harness connectors that have been disconnected.• Turn ignition switch on.• Check voltage between TPS terminals 6 (TPS1) and ground, terminal 5 (TPS2) and ground under the following

conditions:

TPS TERMINAL

TPSTERMINAL

NO.ITEM CONDITION

VOLTAGE(DC

VOLTAGE)

5

ThrottlePositionSensor

2(TPS2)

Ignitionswitch:ON


4.24 V


0.72 V

6

ThrottlePositionSensor

1(TPS1)


0.74 V


4.62 V



No >> • Replace electronic throttle control actuator, and perform throttle valve position learning.

9. CHECK DTC






DIAGNOSIS & TESTING


P0321 - Distributor Engine Speed In-Phase Circuit Performance

DIAGNOSIS & TESTING

VISMW030006T




15 Crankshaft Position (CKP)sensor

Ignition switch: ONEngine: Not cranking 3 V

34





P0321Distributor enginespeed in-phase

circuit performanceEngine is running


• CKP sensor• Crankshaft signalplate• Harness orconnectors• ECM



DIAGNOSIS & TESTING










2. CHECK THE CKP SENSOR REFERENCE VOLTAGE CIRCUIT

• Disconnect CKP sensor harness connector (1).

• Turn ignition switch on.• Check CKP sensor supply voltage between sensor

connector E-006, terminal 1 and ground, terminal 2and ground in the sensor electrical connector witha digital multimeter.






• Check the harness for an open or short between CKP sensor and ECM.




No >> • Repair or replace the circuit for an open or short in harness or connectors.

DIAGNOSIS & TESTING

VISMD030004

LTSMD030048

03


4. CHECK CKP SENSOR SIGNAL

• Connect the ECM harness connector.• Connect CKP sensor connector.• Check sensor output signal when engine is running.

CKP SENSOR OUTPUT SIGNAL

WITH ENGINE ANALYZER (KES-200)

CKP SENSOR SIGNAL

Is the CKP output signal normal?



5. CHECK CKP SENSOR

• Check the sensor as follows:− Remove the sensor mounting bolt.− Remove the sensor.− Visually check the sensor for any damage.

• Check the sensor resistance as shown in the following table:


TERMINAL NO.RESISTANCE

(APPROXIMATELY) �(20 °C)

1 & 2 Approximately 860 �

DIAGNOSIS & TESTING



Yes >> • Replace the CKP sensor with a known good CKP sensor.• Monitor the CKP sensor signal on the KES-200 screen.

− If the CKP sensor signals were normal, the system is OK.− If the CKP sensor signals were still irregular or missing, go to step 6.

No >> • Replace or clean the CKP sensor.

6. CHECK CKP SENSOR INSTALLED CLEARANCE

• Check the installed clearance (See Crankshaft Position Sensor Removal & Installation in Section 03 ElectronicEngine Controls).




No >> • Reinstall CKP sensor.

7. CHECK GEAR TEETH

• Visually check for any chipped signal plate gear teeth.



No >> • Replace the signal plate.

8. CHECK DTC






DIAGNOSIS & TESTING

03


P0324 - Knock Control System ErrorP0327 - Knock Sensor 1 Circuit Low InputP0327 - Knock Sensor 1 Circuit High Input

DIAGNOSIS & TESTING

VISMW030007T

03




19 Knock sensor 1Test Method 1: Knock atcylinder with rubberhammerTest Method 2: Knock atsensor slightly

Output signal voltageshould exist.

20 Knock sensor 2



DTC NO. DTC DEFINITION DTC SET CONDITION POSSIBLE CAUSE

P0324 Knock control systemerror

ECM detected that theinput signal is out of the

acceptable range.

• Knock sensor• Harness or connectors• ECM

P0327 Knock sensor 1 circuit lowinput

ECM detected that theinput signal is low

condition.

P0328 Knock sensor 1 circuithigh input

ECM detected that theinput signal is high

condition.











DIAGNOSIS & TESTING


2. CHECK THE KNOCK SENSOR RESISTANCE

• Disconnect knock sensor harness connector.• Check resistance between knock sensor connector E-017, terminal 1 and terminal 2.• The resistance should be above 1 M�.



No >> • Replace the knock sensor.

3. CHECK THE KNOCK SENSOR OUTPUT SIGNAL CIRCUIT

• Disconnect the ECM harness connector.• Check harness continuity between sensor connector E-017, terminal 1 and ECM terminal 19, sensor terminal 2

and ECM terminal 20 with a digital multimeter.• Continuity should exist.

KNOCK SENSOR CIRCUIT

ECM TERMINAL KNOCK SENSORTERMINAL

19 1

20 2

• Check harness for a short to ground and short to power.



No >> • Repair or replace the circuit for an open or short in harness or connectors.

DIAGNOSIS & TESTING


4. CHECK KNOCK SENSOR SIGNAL

• Check knock sensor (1) output signal as shown intable.

• Set digital multimeter on voltage range.

KNOCK SENSOR OUTPUT SIGNAL

KNOCK SENSORTERMINAL NO. TEST METHOD

1 - 2

• Method 1: Knock atcylinder with rubberhammer

• Method 2: Knock atsensor slightly

• Output signal voltage should exist.



No >> • Replace the knock sensor.

5. CHECK DTC


Is DTC P0324, P0327, P0328 still present?




DIAGNOSIS & TESTING

BESM030018

03


P0340 - Camshaft Position Sensor CircuitP0341 - Camshaft Position Sensor PerformanceP0342 - Camshaft Position Sensor Circuit Low InputP0343 - Camshaft Position Sensor Circuit High Input

DIAGNOSIS & TESTING

VISMW030014T




79 Camshaft Position (CMP)sensor

Ignition switch: ONEngine: Not cranking 11 V





P0340 Camshaft Position(CMP) sensor circuit

Engine is running


• CMP sensor• Camshaft• Harness orconnectors (Thesensor circuit is openor shorted)• ECM

P0341Camshaft Position

(CMP) sensorperformance


(CMP) sensor circuitlow input


(CMP) sensor circuithigh input



DIAGNOSIS & TESTING

03










2. CHECK CMP SENSOR POWER SUPPLY CIRCUIT FOR OPEN OR SHORT

• Disconnect CMP sensor harness connector (1).

• Turn ignition switch on.• Check CMP sensor supply voltage between sensor

connector E-007, terminal 3 and ground in the sen-sor electrical connector with a digital multimeter.






• Check the following:− Front fuse and relay box K− Fuse SB2, fuse FB12, fuse FB18− Harness for open or short between CMP sensor and fuse



No >> • Repair or replace the malfunctioning part(s).

DIAGNOSIS & TESTING

VISMD030001

LTSMD030044


4. CHECK CMP SENSOR GROUND CIRCUIT FOR AN OPEN OR SHORT

• Turn ignition switch off.• Check harness continuity between CMP sensor terminal 1 and ground.• Continuity should exist.• Check harness for short to power.




5. CHECK CMP SENSOR INPUT SIGNAL CIRCUIT FOR AN OPEN OR SHORT TO POWER

• Turn ignition switch on.• Check voltage between CMP sensor terminal 2 and ground.• 10 V should exist.



No >> • Repair or replace the open circuit or short to power in harness or connectors.• If circuit is normal, go to the next step.

6. CHECK CMP SENSOR SIGNAL

• Connect CMP sensor connector.• Check signal voltage between CMP sensor terminal 2 and ground when engine is running.• Approximately 6 V square wave signal should exist.

CKP SENSOR SIGNAL

WITH ENGINE ANALYZER (KES-200)

CMP SENSOR SIGNAL

Is the CMP output signal normal?



DIAGNOSIS & TESTING

03


7. CHECK CKP SENSOR

• Check the sensor as follows:− Remove the sensor mounting bolt.− Remove the sensor.− Visually check the sensor for any damage.

• Check the sensor resistance as shown in the following table:



1 - 2

Except 0 or �1 - 3

2 - 3


Yes >> • Replace the CMP sensor with a known good CMP sensor.• Monitor the CMP sensor signal on the KES-200 screen.

− If the CMP sensor signals are normal, the system is OK.− If the CMP sensor signals are still irregular or missing, go to step 8.

No >> • Replace CMP sensor.

8. CHECK CMP SENSOR INSTALLED CLEARANCE

• Check the installed clearance (See Camshaft Position (CMP) Sensor Removal & Installation in Section 03 Elec-tronic Engine Controls).

• 0.8 - 1.2 mm should exist.



No >> • Reinstall CMP sensor.

DIAGNOSIS & TESTING


9. CHECK CAMSHAFT

• Check the following:− Accumulation of debris on the signal plate at the rear of the camshaft.− Chipped signal plate teeth at the rear of the camshaft.



No >> • Remove debris and clean the signal plate at the rear of the camshaft or replace camshaft.

10. CHECK DTC






DIAGNOSIS & TESTING

03


P0444 - Evaporative Emission System Purge Control Valve Circuit Open

DIAGNOSIS & TESTING

VISMW030022T



ECM TERMINAL NO. ITEM CONDITION X-431 DATA STREAM

46 Canister control valve Engine running 0 % - 99.9 %





P0444

Evaporative (EVAP)emission system

purge control valvecircuit open

Engine is running

ECM detected thatthe improper voltagesignal is sent toECM.

• EVAP canistercontrol• Harness orconnectors• ECM











2. CHECK EVAP CANISTER CONTROL VALVE ACTION

• Start engine and warm it up to the normal operating temperature then select view DTC.• Touch the EVAP canister valve body, raise engine speed up to 2,000 RPM.• With the X-431 scan tool, use the �ACTIVE TEST� function of the EVAP canister valve, touch the EVAP canis-

ter valve body, perform the action test.• The EVAP canister valve should have a slight vibration.




DIAGNOSIS & TESTING

03


3. CHECK EVAP CANISTER CONTROL VALVE POWER SUPPLY CIRCUIT

• Disconnect EVAP canister control valve (1) harnessconnector.

• Turn ignition switch on.• Check supply voltage between EVAP canister con-

trol valve terminal 1 and ground with a digital multi-meter.






• Check the following:− Front fuse and relay box K− Fuse SB2, fuse FB12, fuse FB18− Harness for an open or short between EVAP canister control valve and fuse



No >> • Repair or replace malfunctioning parts.

5. CHECK EVAP CANISTER CONTROL VALVE CONTROL CIRCUIT FOR AN OPEN

• Check voltage between EVAP canister control valve terminal 2 and ground with a digital multimeter.• Approximately 3.6 V should exist.



No >> • Repair or replace circuit for an open in harness or connectors.• If harness is normal, replace and match ECM.

DIAGNOSIS & TESTING

VISMD030007

LTSMD030046


6. CHECK EVAP CANISTER CONTROL VALVE

• Turn ignition switch off.• Remove EVAP canister control valve.• Check the resistance as shown in the following table:

EVAP CANISTER CONTROL VALVE


1 & 2 Approximately 26

• Check air passage continuity and operation when applying 12 V current supply voltage between terminals 1 and2.

• The air passage should be opened.



No >> • Replace EVAP canister control valve.

7. CHECK DTC






DIAGNOSIS & TESTING


P0506 - Idle Control System RPM Lower Than Expected


• Self-diagnosis detection logic.• If DTC P0506 is displayed with other DTC, first perform the trouble diagnosis for the other DTC.



P0506Idle control system

RPM lower thanexpected

• Engine is running• With the engineidling, the brakeapplied, engine runtime below acalibrated minimumvalue, and no VSS,MAF/MAP, ECT,TPS, ETC,Crankshaft Positionsensor, fuel system,or injector DTCspresent.

ECM detected thatthe idle speed is

less than theacceptable range.

• Electric throttlecontrol actuator• Intake air leak• ECM



DIAGNOSIS & TESTING



1. CHECK INTAKE AIR LEAK

• Start the engine and let it idle.• Listen for an intake air leak after the mass air flow sensor.



No >> • Repair the air leak as necessary.

2. CHECK THE ELECTRONIC THROTTLE CONTROL ACTUATOR

• Check the electronic throttle open degree.• Check the electronic throttle clearance.



No >> • Clean or replace as necessary.

3. CHECK DTC






DIAGNOSIS & TESTING

03


P0562 - System Voltage Low VoltageP0563 - System Voltage High Voltage

DIAGNOSIS & TESTING

VISMW030003T

03


DIAGNOSIS & TESTING

VISMW030004T






P0562 System voltage lowvoltage

Ignition switch on

ECM detected thatthe battery voltageis excessive low.

• Charge system• Harness orconnector• Battery• ECM

P0563 System voltage highvoltage

ECM detected thatthe battery voltageis excessive high.

• Charge system• ECM



NOTE :• Inspect the vehicle for aftermarket accessories that may exceed the Generator System output.• Inspect the fuses. If an open fuse is found, use the wiring schematics as a guide and inspect the wiring and

connectors for damage.

DIAGNOSIS & TESTING










2. CHECK ECM POWER SUPPLY

• Check ECM supply between terminal 12 andground in the ECM electrical connector E-001, har-ness side.

Is the voltage between 9 - 17 V?


NOTE :The ECM must be matched to the vehicle Immobilizer(See ECM Removal & Installation in Section 03 Elec-tronic Engine Controls).

No >> • If the voltage is less than 9 V, go to step 3.• If the voltage is more than 17 V, go to step 6.

3. CHECK SYSTEM VOLTAGE

• Connect the ECM harness connector.• Start the engine, raise the speed over 1000 RPM.• Measure the charging system voltage with the voltmeter at battery positive and negative.

Is the voltage less than 9 V?

Yes >> • Check the charging system.


4. CHECK THE BATTERY

• Start the engine, raise the speed over 1000 RPM for a few minutes.• Turn ignition switch off.• Measure the voltage drop with the voltmeter at battery positive and negative while cranking the engine.• Battery voltage should be more than approximate 9 V.



No >> • Charge or replace the battery.

DIAGNOSIS & TESTING

LTSMD030063

03


5. CHECK ECM POWER SUPPLY CIRCUIT

• Measure the resistance between ECM terminal 12 and battery positive terminal.• Continuity should exist.



No >> • Check fuse.• Inspect the harness.• Check all related components.


• Start the engine and raise the engine speed over 1000 RPM.• Measure the charge voltage with the voltmeter at battery positive and negative.

Is the voltage more than 17 V?

Yes >> • Replace the AC generator.


7. CHECK DTC


Is DTC P0562, P0563 still present?




DIAGNOSIS & TESTING


P0604 - Internal Controller Module Random Access Memory (RAM) ErrorP0605 - Internal Controller Module ROM Test ErrorP0606 - ECM Processor




P0604Internal Controller ModuleRandom Access Memory

(RAM) Error ECM detected an internalfailure. • ECM

P0605 Internal Controller ModuleROM Test Error

P0606 ECM Processor



DIAGNOSIS & TESTING

03



1. CHECK DTC

• Perform DTC confirmation procedure.

Is DTC P0604, P0605 or P0606 present?


No >> • The conditions that caused this code to set are not present at this time (See Diagnostic Help inSection 03 Electronic Engine Controls).

2. CHECK ECM POWER SUPPLY AND GROUND

• Check the ECM supply voltage circuit, ground circuit open, high resistance or short circuits existing.



No >> • Repair or replace the circuit for open or short in harness and connectors.

3. CHECK DTC



Yes >> • The system is now operating properly.

No >> • Replace the ECM.


DIAGNOSIS & TESTING


P0602 - Control Module ECM Programming Error



DTC NO. DTC DEFINITION POSSIBLE CAUSE

P0602 Control module programming error • ECM



DIAGNOSIS & TESTING

03



1. CHECK DTC


Is DTC P0602 present?



2. CHECK ECM POWER SUPPLY AND GROUND

• Check the ECM supply voltage circuit, ground circuit open, high resistance or short circuits existing.



No >> • Repair circuit for an open or short in harness and connectors.

3. MATCH ECM

• With X-431 scan tool, match the ECM before replacing the ECM. and view the DTC with X-431.• With X-431 scan tool view the DTCs


Yes >> • Go to the next step.• Refer to any Technical Bulletins that have been issued.


4. CHECK DTC






DIAGNOSIS & TESTING


P0645 - A/C Clutch Relay Circuit

DIAGNOSIS & TESTING

VISMW030019T

03




DC VOLTAGE)

69 Air compressor relay

• Ignition switch on or after engine start.• If IAT is above 140.3 °C, A/C will be shutoff.• If ECT is above 140.3 °C, A/C will be shutoff. If ECT is below 111.8 °C, A/C will beresume.• If engine speed is above 6520 RPM orbelow 520 RPM, A/C will be shut off.• If A/C high pressure is above 20 bar, A/Cwill be shut off. If A/C high pressure isbelow 19.5 bar, A/C will be resume.• If evaporator temperature is below 1.5 °C,A/C will be shut off. If evaporatortemperature is above 4.5 °C, A/C will beresume.• If system voltage is below 8.04 V, A/C willbe shut off. If evaporator temperature isabove 10.01 V, A/C will be resume.

0 V or 12 V





P0645 A/C compressorrelay circuit Engine is running


• Fuse• A/C compressorrelay• Harness orconnectors• ECM



DIAGNOSIS & TESTING




• Turn ignition switch off.• Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine

Controls).• Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information -





2. CHECK A/C COMPRESSOR RELAY CONTROL CIRCUIT POWER SUPPLY CIRCUIT FOR OPEN

• Turn ignition switch on.• Turn A/C switch off.• Check A/C compressor relay control circuit

supply voltage between ECM terminal 69 andground in the ECM electrical connector E-001with a digital multimeter.






• Check the following:− Body fuse and relay box K, E− Fuse FB1, FB18, SB2− A/C compressor relay, ignition relay, EMS relay− Harness for an open or short



No >> • Repair or replace malfunctioning part(s).

4. CHECK DTC






DIAGNOSIS & TESTING

LTSMD030065

03


P1545 - Throttle Position Control Performance

DIAGNOSIS & TESTING

VISMW030005T


DIAGNOSIS & TESTING

VISMW030010T

03




VOLTAGE)


Ignition switch: ON

- Approximately 5 V



4.24 V


0.72 V



0.74 V


4.62 V

64 Motor 4

-



67 Motor 1

73 Regulated sensorsupply 2 Approximately 5 V






P1545 Throttle positioncontrol performance

Ignition switch on orafter engine start.

Rationally incorrectvoltage is sent toECM compared withthe signals fromTPS1 and TPS2.

• Electric throttlecontrol actuator(TPS1 and TPS2)• Harness orconnectors• Accelerator pedalposition sensor 2• ECM



DIAGNOSIS & TESTING










2. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT - (1)

• Disconnect TPS harness connector (1).

• Turn ignition switch on.• Check supply voltage between sensor terminal 3

and ground in the TPS electrical connector E-027with a digital multimeter.





3. CHECK TPS POWER SUPPLY CIRCUIT - (2)

• Turn ignition switch off.• Disconnect the ECM harness connector.• Check harness continuity between TPS terminal 3 and ECM terminal 32 (refer to wiring diagram for circuit infor-

mation).• Continuity should exist.



No >> • Repair or replace the open circuit.

DIAGNOSIS & TESTING

VISMD030006

LTSMD030035

03


4. CHECK TPS POWER SUPPLY CIRCUIT - (3)

• Check harness for a short to power and short to ground, between following terminals:

TPS POWER SUPPLY CIRCUIT

ECM TERMINAL TPS TERMINAL

32 or 73 TPS terminal 3

32 or 73 APP sensor terminal 3

33 APP sensor terminal 6



No >> • Repair or replace short to ground or short to power in harness or connectors.

5. CHECK THE APP SENSOR

• Connect all harness connectors that have been disconnected.• Turn ignition switch on.• Install a digital multimeter to the APP sensor as shown in the following:

APP SENSOR CIRCUIT

ECM TERMINAL APPS TERMINAL

16 APP sensor terminal4

40 APP sensor terminal1

• Check voltage between ECM terminals 16 (APP sensor 1 signal), 40 (APP sensor 2 signal) and ground underthe following conditions:

APP SENSOR REFERENCE DATA

TERMINAL NO. ITEM CONDITION DATA (DCVOLTAGE)

16 Accelerator PedalPosition Sensor

Ignition switch: ON


0.72 - 0.74 V


3.95 V

40 Accelerator PedalPosition Sensor


0.36 - 0.37 V


1.97 V

DIAGNOSIS & TESTING




No >> • Replace the Accelerator Pedal Assembly (See Accelerator Pedal Position Sensor Removal & Installa-tion in Section 03 Electronic Engine Controls).


6. CHECK THE TPS SIGNAL CIRCUIT FOR AN OPEN OR SHORT

• Turn ignition switch off.• Disconnect the ECM harness connector.• Check harness continuity between electronic throttle control actuator terminal 5 and ECM terminal 38, electronic

throttle control actuator terminal 6 and ECM terminal 54 (refer to wiring diagram for circuit information).• Continuity should exist.• Check harness for short to power or short to ground.



No >> • Repair or replace the open circuit or short to power or short to ground in harness or connectors.

7. CHECK THE TPS GROUND CIRCUIT FOR AN OPEN OR SHORT

• Check harness continuity between the electronic throttle control actuator terminal 2 and ECM terminal 78 (referto wiring diagram for circuit information).

• Continuity should exist.• Check harness for a short to power and short to ground.




DIAGNOSIS & TESTING

03


8. CHECK TPS

• Connect all harness connectors disconnected.• Turn ignition switch on.• Check voltage between ECM terminals 54 (TPS 1 signal), 38 (TPS 2 signal) and ground under the follow-

ing conditions:

TPS REFERENCE DATA

TPSTERMINAL

NO.ITEM CONDITION VOLT (DC

VOLTAGE)

5

Electronicthrottlecontrol

actuator(TPS2)

Ignitionswitch:ON


4.24 V


0.72 V

6


actuator(TPS1)


0.74 V


4.62 V



No >> • Replace the electronic throttle control actuator, and perform throttle valve position learning.

9. CHECK DTC

• With the X-431 scan tool, read ECM DTCs.• See DTC Confirmation Procedure.





DIAGNOSIS & TESTING


P2138 - Pedal Position Sensor Performance

DIAGNOSIS & TESTING

VISMW030010T

03


DIAGNOSIS & TESTING

VISMW030005T




VOLTAGE)

16Accelerator PedalPosition Sensor 1

(APPS1)

Ignition switch: ON


0.72 - 0.74 V


3.95 V



35 Sensor (GND) - Approximately 0 V

36 Sensor (GND) - Approximately 0 V

40Accelerator PedalPosition Sensor 2

(APPS2)


0.36 - 0.37 V


1.97 V






P2138Accelerator pedalposition sensor

performance


Rationally incorrectvoltage is sent toECM compared withthe signals fromAPPS1 and APPS2.

• Accelerator pedalposition sensor 1and 2• Harness orconnectors• Electric throttlecontrol actuator(TPS1 and TPS2)• ECM



DIAGNOSIS & TESTING

03










2. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 (APPS1) POWER SUPPLY CIRCUIT

• Disconnect APPS1 harness connector C-301 (1).

• Turn ignition switch on.• Check supply voltage between sensor terminal 6

and ground in the APPS1 electrical connector witha digital multimeter.





DIAGNOSIS & TESTING

VISMD030008

LTSMD030053



• Check the following:− Harness connectors E-102, C-102, C-109, C-401− Harness for an open or short between APPS1 and ECM− Refer to wiring diagram for circuit information.




No >> • Repair or replace the open or short circuit in harness or connectors.

4. CHECK ACCELERATOR PEDAL POSITION SENSOR 2 (APPS2) POWER SUPPLY CIRCUIT

• Check supply voltage between APPS2 terminal 3and ground in the sensor electrical connectorC-301 with a digital multimeter (refer to wiring dia-gram for circuit information).






• Check the following:− Harness connectors E-102, C-102, C-109, C-401− Harness for open or short between APPS2 and ECM− Refer to wiring diagram for circuit information.




No >> • Repair or replace the open or short circuit in harness or connectors.

DIAGNOSIS & TESTING

LTSMD030066

03



• Check harness for short to power and short to ground between the following terminals:

TPS POWER SUPPLY CIRCUIT

ECM TERMINAL TPS TERMINAL

32 or 73 3



No >> • Repair circuit for short to ground or short to power in harness or connectors.

7. CHECK THE TPS

• Connect all harness connectors disconnected.• Turn ignition switch on.• Check voltage between ECM terminals 54 (TP sensor 1 (TPS1) signal), 38 (TP sensor 2 (TPS2) signal)

and ground under the following conditions:

TPS REFERENCE DATA

TPSTERMINAL

NO.ITEM CONDITION VOLT (DC

VOLTAGE)

5


actuator(TPS2)

Ignitionswitch:ON


4.24 V


0.72 V

6


actuator(TPS1)


0.74 V


4.62 V



No >> • Repair or replace the TPS circuits for a short or open.• If the TPS circuits are normal, replace the electronic throttle control actuator. Perform throttle valve

position self-learning.

DIAGNOSIS & TESTING


8. CHECK THE APPS GROUND CIRCUIT FOR AN OPEN OR SHORT

• Turn ignition switch off.• Disconnect the ECM harness connector.• Check harness continuity between APPS2 terminal 2 and ECM terminal 35, APPS1 terminal 5 and ECM

terminal 36 (refer to wiring diagram for circuit information).• Continuity should exist.• Check harness for a short to power.



No >> • Repair or replace the open circuit or short to power in harness or connectors.

9. CHECK APPS SIGNAL CIRCUIT FOR AN OPEN OR SHORT

• Check harness continuity between APPS1 terminal 4 and ECM terminal 16, APPS2 terminal 1 and ECMterminal 40 (refer to wiring diagram for circuit information).

• Continuity should exist.• Check harness for a short to power or short to ground.




10. CHECK APP SENSOR

• Connect all harness connectors that have been disconnected.• Turn ignition switch on.• Check voltage between ECM terminals 16 (APP sensor 1 signal), 40 (APP sensor 2 signal) and ground

under the following conditions:

APP SENSOR REFERENCE DATA

TERMINAL NO. ITEM CONDITION VOLT (DCVOLTAGE)

16Accelerator pedalposition sensor 1

(APPS1)

Ignition switch: ON


0.72 - 0.74 V


3.95 V

40Accelerator pedalposition sensor 2

(APPS2)


0.36 - 0.37 V


1.97 V



No >> • Replace the Accelerator Pedal Assembly (See Accelerator Pedal Position Sensor Removal & Instal-lation in Section 03 Electronic Engine Controls).


DIAGNOSIS & TESTING

03


11. CHECK DTC






DIAGNOSIS & TESTING


U1000 - High Speed CAN Defective

DIAGNOSIS & TESTING

VISMW030021T

03






U0001 High speed CANdefective

With ignition switchon

The circuit iscontinuouslymonitored.

• ECM• FBCM• ABS module• Restraints controlmodule• Unified metercontrol unit• EPS control unit• CAN Bus harnessor connectors

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on.• With the scan tool, record and erase stored DTCs in the ECM.• Cycle ignition switch several times then select view DTC and data stream.• With the scan tool, select view DTCs in the ECM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


NOTE :• Ensure that the battery is fully charged.• Before performing any DTC diagnostic procedures, verify the ECM power and ground circuits are properly con-

nected.• Before performing this diagnostic procedure, repair all other ECM DTCs first.

DIAGNOSIS & TESTING










2. CHECK DTC

• Turn ignition switch on.• With the scan tool, select view ECM DTCs and data stream.

Is CAN DTC U0001 present?



3. CHECK OTHER MODULE CAN DTCS

• With the X-431 scan tool, attempt to enter all the other CAN communication modules such as FBCM, ABSmodule, Restraints control module, Unified meter control unit, EPS control unit.

• Read CAN DTCs.

Were other modules DTCs found?

Yes >> • If all of the other modules have the CAN DTC �High speed CAN Communication�, go to the nextstep.

• If all of the other modules have the CAN DTC about �Lost communication with ECM�, and haven’tthe �High speed CAN Communication�, replace the ECM.


No >> • Go to step 8.• Replace the ECM.


DIAGNOSIS & TESTING

03


4. CHECK CAN BUS LINE TERMINAL RESISTANCE IN ECM

• Turn ignition switch off.• Disconnect the negative battery cable.• Disconnect the ECM harness connector.• Check resistance between ECM connector terminal 62 and terminal 81.

CAN TERMINAL RESISTANCE

ECM TERMINAL(CAN-H)

ECMTERMINAL

(CAN-L)RESISTANCE �

62 81 123.3 �





• The problem caused by the ECM is an internal error.

5. CHECK CAN BUS LINE TOTAL RESISTANCE

• Turn ignition switch off.• Connect all disconnected modules.• Check CAN Bus line total resistance between DLC terminal 14 and 6.

CAN TERMINAL RESISTANCE

DLC TERMINAL(CAN-H)

DLC TERMINAL(CAN-L) RESISTANCE

6 14 60 �




DIAGNOSIS & TESTING


6. CHECK THE CAN BUS LINE

• Disconnect all other module connectors with CAN Bus lines.• Check harness continuity between the following terminals:

CAN-H CONTINUITY

CANNETWORK

DLCTERMINAL TERMINAL CONTINUITY

CAN-H 6 Ground No

• Check harness continuity between the following terminals:

CAN-L CONTINUITY

CANNETWORK

DLCTERMINAL TERMINAL CONTINUITY

CAN-L 14 Ground No

• Check the harness for an open or short to power.



No >> • Repair or replace the CAN Bus line for an open or short.

DIAGNOSIS & TESTING

03


7. CHECK THE CAN BUS LINE

• Connect all other disconnected CAN Bus modules connectors.• Disconnect CAN Bus module one by one.• Connect the negative battery cable.• Turn ignition switch on.• Check CAN Bus voltage between the following terminals after disconnecting CAN Bus modules one at a time.

− CAN-H: Voltage should be more than 2.5 V.− CAN-L: Voltage should be less than 2.5 V.

CAN BUS LINE VOLTAGE

DLC TERMINAL TERMINAL

6 (CAN-H)

Ground

14 (CAN-L)

Is the check result normal and DTC U0001 not present?

Yes >> • Replace the disconnected module.• The problem is caused by an internal error in the disconnected module.


8. CHECK ECM ELECTRICAL CONNECTOR

• Inspect the ECM electrical connector pins for proper fit or any chafed, pierced, pinched, or partially brokenwires.

• With the X-431 scan tool, read ECM DTCs.

Is the check result normal and CAN DTC U0001 not present?

Yes >> • The system is now operating properly.• Reassemble the vehicle and road test to verify the customers complaint is repaired.



• The problem caused by the ECM is an internal error.

DIAGNOSIS & TESTING


ON-VEHICLE SERVICE

Engine Coolant Temperature Sensor

DescriptionThe Engine Coolant Temperature (ECT) sensor threads into the coolant outlet connector. The ECT is a negativethermal coefficient sensor.

OperationThe ECT provides an input to the Engine Control Module (ECM). As temperature increases, resistance of the sensordecreases. As coolant temperature varies, the ECT sensor resistance changes resulting in a different voltage valueat the ECT sensor signal circuit. The ECM uses the input to control air-fuel mixture, timing, and radiator fan on/offtimes.

Removal & Installation1. Disconnect and isolate the negative battery cable.2. Release the coolant system pressure.

WARNING!

Never remove the pressure relief cap under any conditions while the engine is operating or hot. Failure to followthese instructions could result in personal injury or damage to the cooling system or engine. To avoid havingscalding hot coolant or steam blow out of the cooling system, use extreme care when removing the pressurerelief cap. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn itslowly one turn (counterclockwise). Step back while the pressure is released from the cooling system. When youare certain all the pressure has been released, (with a cloth) turn and remove the pressure relief cap. Failure tofollow these instructions may result in serious personal injury.

3. Disconnect the coolant temperature sensor electri-cal connector.

CAUTION:Remove the coolant temperature sensor whenthe engine is cold.4. Remove the engine coolant temperature sensor

(1).(Tighten: Engine coolant temperature sensor to 20N·m)

5. Discard the O-ring.6. Installation is in the reverse order of removal.

LTSM030035

03


Installation Notes:

• After installing the coolant temperature sensor, check and adjust the coolant level.

Knock Sensor

DescriptionThe knock sensor is attached to the cylinder block. The knock sensor is designed to detect engine vibration that iscaused by detonation.

OperationKnock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to theECM while the engine operates. As the intensity of the crystal’s vibration increases, the knock sensor output voltagealso increases.

When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the Engine Control Module(ECM). In response, the ECM retards ignition timing for all cylinders by a specified amount.

The ECM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specifiedvalue, knock retard is allowed.

Removal & Installation1. Disconnect and isolate the negative battery cable.2. Disconnect the knock sensor electrical connector.3. Remove the knock sensor retaining bolt (1) and

remove the knock sensor.(Tighten: Knock sensor retaining bolt to 20 N·m)


Oxygen Sensor

DescriptionThis oxygen sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1 volt in richerconditions to 0 volt in leaner conditions. This vehicle is equipped with two oxygen sensors (upstream oxygen sensor& downstream oxygen sensor). The oxygen sensors are located before and after the three way catalyst.

OperationThe oxygen sensor has a much longer switching time between rich and lean than the air flow sensor. The oxygenstorage capacity of the three way catalyst (manifold) causes the longer switching time. The oxygen senses the oxy-gen content in the exhaust flow and outputs a voltage between 0 and 1.0 volt. Lean of stoichiometric, air/fuel ratio ofapproximately 14.7:1, the oxygen sensor generates a voltage between 0 and 0.45 volt. Rich of stoichiometric, theoxygen sensor generates a voltage between 0.45 and 1.0 volt.

The oxygen sensor senses the oxygen content in the exhaust flow and outputs a voltage between 0 and 1.0 volt.Lean of stoichiometric, air/fuel ratio of approximately 14.7:1, the oxygen sensor generates a voltage between 0 and0.45 volt. Rich of stoichiometric, the oxygen sensor generates a voltage between 0.45 and 1.0 volt.

Removal & Installation1. Disconnect and isolate the negative battery cable.2. Disconnect the oxygen sensor electrical connector.

ON-VEHICLE SERVICE

BESM030018


CAUTION:Remove the oxygen sensor when the exhaust pipe is cold.3. Remove the upstream oxygen sensor (1) and

downstream oxygen sensor (2).(Tighten: Oxygen sensor to 45 N·m)


Crankshaft Position Sensor

DescriptionThe Crankshaft Position (CKP) sensor is located on the flywheel shell facing the gear teeth of the signal plate. Itdetects the fluctuation of the engine revolution. The sensor consists of a permanent magnet and Induction coil.

OperationWhen the engine is running, the high and low parts of the teeth cause the gap with the sensor to change. Thechanging gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltagefrom the sensor changes. The Engine Control Module (ECM) receives the voltage signal and detects the fluctuationof the engine revolution.

Removal & Installation1. Disconnect and isolate the negative battery cable.2. Disconnect the CKP sensor electrical connector.3. Remove the CKP sensor retaining bolt (1) and

remove the CKP sensor.(Tighten: Crankshaft position sensor retaining boltto 10 N·m)


ON-VEHICLE SERVICE

BESM030017

LTSM030036

03


Camshaft Position Sensor

DescriptionThe Camshaft Position (CMP) sensor senses the protrusion of the intake valve cam sprocket to identify a particularcylinder. The CMP sensor senses the piston position. When the Crankshaft Position (CKP) sensor becomes inoper-ative, the CMP sensor provides various controls of engine parts instead, utilizing timing of cylinder identification sig-nals. The sensor consists of a permanent magnet and Hall IC.

OperationWhen the engine is running, the high and low parts of the teeth cause the gap with the sensor to change. Thechanging gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltagefrom the sensor changes. The Engine Control Module (ECM) detects the voltage signal and identify piston positionand cylinder timing.

Removal & Installation1. Disconnect the negative battery cable.2. Disconnect the CMP sensor electrical connector.3. Remove the CMP sensor retaining bolt (1).

(Tighten: Camshaft position sensor retaining bolt to7 N·m)

4. Pull the CMP sensor up and remove from the cyl-inder head cover.


ON-VEHICLE SERVICE

BESM030016


Manifold Absolute Pressure Sensor - 1.6L

DescriptionThe Manifold Absolute Pressure (MAP) sensor, is mounted to the front of the engine.

OperationThe MAP sensor monitors the pressure in the intake manifold. The pressure in the manifold moves a diaphragmconnected to resistors which alter their resistance values. The output voltage of the MAP sensor signals the ECMabout the pressure in the intake manifold.

Removal & Installation1. Disconnect the negative battery cable.2. Disconnect the MAP sensor electrical connector.3. Remove the MAP sensor mounting bolt (1).

(Tighten: MAP sensor mounting bolt to 6 N·m)4. Remove the MAP sensor.5. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

LTSM030037

03


Air Flow Sensor - 1.8L

DescriptionThe air flow sensor is placed in the stream of intake air. The air flow sensor measures the intake flow rate by mea-suring a part of the entire intake flow. The air flow sensor converts the amount of air drawn into the engine into avoltage signal. The Engine Control Module (ECM) needs to know intake air volume to calculate engine load. This isnecessary to determine how much fuel to supply to the engine.

OperationThe air flow sensor controls the temperature of the hot wire to a certain amount. The heat generated by the hot wireis reduced as the intake air flows around it. The more air,the greater the heat loss. Therefore, the electric currentsupplied to the hot wire is changed to maintain the temperature of the hot wire as air flow increases. The ECMdetects the air flow by means of this current change.

Removal & Installation1. Disconnect the negative battery cable.2. Disconnect the air flow sensor electrical connector.3. For 1.8L engine, remove the air flow sensor retain-

ing bolts (1).(Tighten: Air flow sensor retaining bolts to 5 N·m)

4. Pull sensor up and remove it.5. Installation is in the reverse order of removal.

Accelerator Pedal Position Sensor

DescriptionThe Accelerator Pedal Position (APP) sensor is located inside the accelerator pedal. The accelerator pedal positionsensor can not be serviced by itself. The accelerator pedal must be replaced as a unit.

OperationThe accelerator pedal position (APP) sensor works according to the Hall principal. the sensor is integrated into thepedal lever axis. It consists of a shaft with a ring magnet. This rotates in a printed circuit board with a stator in thefixed Hall elements. This produces a change in the voltage. The accelerator pedal position sensor is supplied with 5volts from the Engine Control Module (ECM). The information regarding accelerator position is supplied to the ECMby means of two voltages.

Removal & Installation1. Disconnect the negative battery cable.2. Remove the instrument panel lower trim panel (See Instrument Panel Removal & Installation in Section 15 Body

& Accessories).

ON-VEHICLE SERVICE

VISM020007


3. Disconnect the APP sensor electrical connector (2).4. Remove the three APP sensor mounting bolts (1).

(Tighten: APP sensor mounting bolts to 11 N·m)5. Remove the APP sensor with the pedal.6. Installation is in the reverse order of removal.

Electronic Throttle Control Actuator

DescriptionThe throttle body is located on the intake manifold. It controls air into the intake manifold.

The electronic throttle control actuator consists of the throttle control motor, throttle position sensor, etc. The throttlecontrol motor is operated by the ECM and it opens and closes the throttle valve. The throttle position sensor detectsthe throttle valve position.

OperationFiltered air from the air cleaner enters the intake manifold through the throttle body. A throttle valve (plate) is used tosupply air for idle and driving conditions. The throttle position sensor is part the throttle body. The throttle positionsensor signal is used by the ECM to determine throttle position. The ECM controls the electronic throttle control tometer air into the engine. This regulates engine power. The vehicle is in sense a “Drive by Wire” system.

Removal & Installation1. Disconnect the negative battery cable.2. Remove the intake air hose.3. Disconnect the electronic throttle control actuator

connector.4. Remove two pipes on electronic throttle control

actuator.5. Remove four electronic throttle control actuator

mounting bolts.(Tighten: Electronic throttle control actuator bolts to10 N·m)

6. Remove the throttle control actuator carefully.7. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

LTSM030038

BESM030022

03


Engine Control Module (ECM)

DescriptionThe Engine Control Module (ECM) for this model is serviced only as a complete unit.

OperationThe ECM is a pre-programmed, microprocessor-based digital computer. It regulates ignition timing, air-fuel ratio,emission control devices, charging system, certain transmission features, speed control, air conditioning compressorclutch engagement and idle speed. The ECM can adapt its programming to meet changing operating conditions.

Removal & Installation1. Disconnect he negative battery cable.2. Remove the scuff plate (See scuff plate Removal & Installation in Section 15 Body).3. Set the front passenger floor mat aside.4. Remove the ECM cover retaining bolts (1).

(Tighten: ECM cover bolts to 10 N·m)5. Remove the ECM cover.

6. Disconnect the ECM electrical connector.

ON-VEHICLE SERVICE

VISM030001


7. Remove the ECM retaining bolts (1).(Tighten: ECM retaining bolts to 6 N·m)

8. Remove the ECM.

9. Installation is in the reverse order of removal.• Perform the following to match the ECM to the Immobilizer:

− With the X-431 scan tool, choose M11 or M12 series.− Choose �immobilize�.− Choose �input code�.− Input the safety code.− Click the small keyboard.− Click �OK�.− Choose �Immobilizer adapt�.− Choose �read Immobilizer to ECM� immediately.− Click �OK�.

ON-VEHICLE SERVICE

VISM030006

03


ENGINE SYMPTOM DIAGNOSIS

Symptom Diagnostic Tests 03-201General Troubleshooting Checks 03-201Visual Inspection 03-201Diagnostic Help 03-201Symptom Diagnostic Test List 03-201Engine Cranks Normal But Will NotStart 03-202Engine Will Not Crank 03-204

Hard Start / Long Crank / Erratic Start /Erratic Crank 03-206Fast Idle 03-209Lack / Loss Of Power 03-210Back Fires 03-213Engine Poor Driveability 03-215Low Idle / Stalls During Deceleration 03-219Idle Speed Slow Return To Normal Idle 03-221


Symptom Diagnostic Tests

General Troubleshooting Checks• Confirm the engine trouble light is working properly.• Confirm that there are no DTCs recorded with the X-431 Scan Tool.• Confirm that the customer’s complaint is current, and the conditions that are causing the failure are present.

Visual Inspection• Check the fuel system for any fuel leakage.• Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses.• Check the intake air pipe for being jammed, leaking, or damaged.• Check the ignition system for any broken or aging spark plug wires and verify the engine firing order is correct.• Check the engine ground cable and verify a clean and tight connection.• Check the sensors and actuators electrical connectors and verify good contact and tight connection.

NOTE :Repair any of the above conditions first before continuing with symptom diagnostics.

Diagnostic Help• Confirm there are no current engine DTCs.• Confirm that the failure exists and the customer complaint can be verified.• Inspect the engine following the above steps and verify all engine features are operating properly.• While servicing the vehicle, verify the service record, vehicle maintenance, engine compression pressures,

mechanical ignition timing and fuel conditions.• If replacing the Engine Control Module (ECM), carry out the validation test. If the failure no longer exists, the

failure is in the ECM; if the failure still exists, reinstall the original ECM and repeat the diagnostic test.

Symptom Diagnostic Test List

SYMPTOM DEFINITION

Engine Cranks Normal But Will Not Start

Engine Will Not Crank

Hard Start / Long Crank Time

Fast Idle

Lack / Loss Of Power

Back Fires

Engine Poor Driveability

Low Idle / Stalls During Deceleration

Idle Speed Slow Return To Normal Idle

ELECTRONIC ENGINE CONTROLS - ENGINE SYMPTOM DIAGNOSIS

03


Engine Cranks Normal But Will Not StartThe following conditions apply to this symptom:• The engine cranks at normal speed.• The engine will not start.• The battery is fully charged.

1. PRELIMINARY CHECKS

CAUTION:Extended cranking because of a No Start can load the exhaust system with raw fuel, damaging thecatalytic converter after the engine starts.• Carry out the following preliminary checks:

− Fuel quality− Electrical connections− Intake air tube integrity− Fuses and relays



No >> • Repair as necessary.• Verify the symptom no longer exists.

2. CHECK DTC

• Turn the ignition switch on.• With the scan tool X-431, select view DTC.

Are there any DTCs present?

Yes >> • Check for cause (See Diagnostic Trouble Code (DTC) Index).


3. TRY TO START THE ENGINE WITH THE THROTTLE CLOSED


Does the engine start now with the throttle closed?

Yes >> • Verify the symptom no longer exists.




4. CHECK EXHAUST SYSTEM

• Inspect the vehicles exhaust system for restriction.

Is there a restriction in the exhaust system?

Yes >> • Repair as necessary.


5. CHECK ENGINE CYLINDER COMPRESSION

• Perform a compression test on the engine.

Is engine compression correct?

Yes >> • Verify test results. If OK, see Diagnostic Test List to repair any additional symptoms.

No >> • Check for cause.


03


Engine Will Not CrankThe following conditions apply to this symptom:• The engine will not crank.


• Carry out the following preliminary vehicle inspection:− Fuel quality− Battery connections− Starter relay connections− Manual transmission clutch fully depressed− Engine immobilizer activated− Fuses/Fuse links



No >> • Repair as necessary• Verify the symptom no longer exists.

2. LISTEN FOR STARTER RELAY CLICKING


Is a clicking sound heard from the starter relay when the ignition key is turned to START?



3. CHECK STARTING SYSTEM

• Check the starter, starter ground, starter relay cable to starter and battery.

Is a fault indicated?



4. CHECK OPERATION OF OTHER ELECTRICAL ACCESSORIES

• Check all accessories.

Do any other electrical accessories work?


No >> • Check the charging system.



5. CHECK DTC

• Turn the ignition switch on.• With the scan tool X-431, read the DTC.


Yes >> • Check for cause.


6. CHECK STARTING SYSTEM PRIMARY CIRCUITS

• Check the starting system primary circuits as follows:− Starter relay− Ignition switch

Are components/systems OK?

Yes >> • Ensure customer’s concern has been resolved.

No >> • Repair as necessary.


03


Hard Start / Long Crank / Erratic Start / Erratic CrankThe following conditions apply to this symptom:• The engine cranks for an extended period of time.• The engine starts hard during a long cranking time.


• Confirm that the correct starting procedure was used by the customer before proceeding with diagnosis.• Carry out the following preliminary checks:

− Vacuum leaks− Fuel quality (concerns such as correct octane, contamination, winter/summer blend)− Intake air system (tubes)− Air cleaner (restrictions)− Battery condition and starter current draw.

Are all checks OK?



2. CHECK ECM DTC

• With scan tool X-431, select view DTC and data stream in ECM.


Yes >> • Check for cause of DTC (See Diagnostic Trouble Code (DTC) List in Section 03 Electronic EngineControls).


3. CHECK SECONDARY IGNITION SYSTEM

• Perform the following to test the secondary ignition system:− Disconnect the injector fuse.− Remove any of the 4 spark plugs.− Connect the spark plug to spark plug wire.− Ground the spark plug on the cylinder block.− Crank the engine to test the secondary ignition system with the spark plugs removed.

Is a strong blue spark visible at each spark plug while cranking the engine?


No >> • Check Camshaft Position (CMP) sensor signal at ECM.• If CMP sensor is OK, check the following:

− Crankshaft Position (CKP) sensor malfunction− Faulty spark plug wires− Faulty spark plugs



4. CHECK FUEL SYSTEM PRESSURE

• Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).• Check fuel system pressure (See Fuel Pressure Test in Section 04 Fuel Delivery).

Is fuel pressure correct?


No >> • If the fuel pressure is greater than 400 kPa (4.0 Bar):− Install a new fuel pressure regulator.

• If the fuel pressure is less than 400 kPa (4.0 Bar):− Check the fuel supply system for restrictions or leaks.− If no problems, repair or replace fuel filter, pressure regulator or fuel pump assembly.


• Check the exhaust system for restrictions.




6. CHECK ENGINE OVERHEATING

• Is the engine overheating (hot start concern only)?

For hot start concerns, does engine appear to be overheating?

Yes >> • Repair the engine cooling system.


7. CHECK POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM

• Remove the PCV valve and shake it.

Does PCV valve rattle?


No >> • Replace the PCV valve.


03


8. CHECK EVAPORATIVE EMISSIONS (EVAP) SYSTEM

• Disconnect the canister control valve (1) hose.• Place a stiff piece of paper over the hose end and

start the engine.

Does vacuum hold the paper?

Yes >> • Check for a vacuum leak in EVAP sys-tem (refer to EVAP system) and refer toEVAP control circuit relative DTC.


9. CHECK INTAKE AIR SYSTEM

• Check for MAP/MAF sensor.

Is there any contamination?

Yes >> • Install a new MAF/IAT or MAP/IAT sensor.

No >> • See Diagnostic Help for additional information.


VISMD030007


Fast IdleThe following conditions apply to this symptom:• The engine idles at a higher than recommended speed.

1. VERIFY ENGINE OPERATES AT NORMAL OPERATING TEMPERATURE

• Check the engine operating temperature.

Does the engine appear to be either overheating or not reaching normal operating temperature?

Yes >> • Repair the engine cooling system.



• Carry out the following preliminary checks:− Vacuum leaks− Throttle plate and linkage− Intake air tube (leaks)− Correct sealing of intake manifold and components attached to intake air tube

Are all checks OK?



3. CHECK ECM DTC

• Turn the ignition switch on.• With the scan tool X-431, select view DTC and data stream in ECM.


Yes >> • Check for causes. See Diagnostic Trouble Code (DTC) index — Engine Control Module (ECM).



03


Lack / Loss Of PowerThe following conditions apply to this symptom:• The engine has poor performance.• The engine has poor acceleration.


• Verify symptom is reported under normal driving conditions without excessive engine/vehicle load conditions.• Carry out the following preliminary checks:

− Fuel quality− Vacuum lines (check for damage and correct routing)− Intake air system (check for damaged tubes and dirty air filter)− Vehicle wiring (disconnected, corroded/damaged)− Throttle linkage− Radiator (obstructed)− Transaxle

NOTE :Be aware of the over RPM limiting functions of the ECM.

Are all checks OK?



2. CHECK ECM DTC

• Turn ignition switch on.• With the scan tool X-431, read the DTC.

Do any DTC displayed on the scan tool?

Yes >> • Check for causes. See Diagnostic Trouble Code (DTC) index — Engine Control Module (ECM).






No >> • If the fuel pressure is greater than 400 kPa (4 Bar):− Install a new fuel pressure regulator.

• If the fuel pressure is less than 400 kPa (4 Bar):− Check fuel supply system for restriction or leak.− If no problems, repair or replace fuel filter, pressure regulator or fuel pump assembly.








− Crankshaft Position (CKP) sensor malfunction− Spark plug wires− Spark plugs

5. CHECK INTAKE AIR SYSTEM

• Check for MAP/MAF sensor.

Is there any contamination?

Yes >> • Clean or replace the sensor.







7. CHECK BASE ENGINE CONCERNS

• Check for base engine concerns (such as improper compression, worn camshaft/valve train, gasket leaks).




8. CHECK AUTOMATIC/MANUAL TRANSAXLE OPERATION

• Check the operation of the transaxle.

Is the transaxle operation normal?




03


9. CHECK FOR BRAKE SYSTEM CONCERNS

• Check the operation of the brakes.




10. ADDITIONAL CHECKS

• Check the following for possible additional causes:− Customer driving habits (such as excessive loads or over RPM limiting functions enabled).− Clutch.− Charging system.− Ignition base timing (if not previously checked).

• If the base timing is not correct, align the engine timing belt (See Engine Timing Belt Removal & Instal-lation in 02 Engine).

Are all checks OK?

Yes >> • See Diagnostic Help for additional information.




Back FiresThe following conditions apply to this symptom:• The engine will back fire when operated.• The engine back fire occurs at all operating parameters.


• Carry out the following preliminary checks:− Vacuum lines (check for damage and correct routing).− Spark plug wire routing (correct firing order).

Are all checks OK?


No >> • Repair as necessary. Verify symptom no longer exists.

2. CHECK ECM DTC

• Turn the ignition switch on.• With the scan tool X-431, select view DTC and stream data in ECM.


Yes >> • Check for causes.• See Diagnosis trouble code (DTC) index— Engine Control Module (ECM).








4. CHECK FUEL QUALITY

• Check fuel quality (concerns such as correct octane, contamination).

Is the fuel quality OK?




03


5. CHECK KNOCK SENSOR

• Check knock sensor.




6. CHECK TIMING

• Check for the timing misalignment.



No >> • Align the engine timing belt (See Engine Timing Belt Removal & Installation in 02 Engine).







8. CHECK FOR BASE ENGINE CONCERNS

• Check for base engine concerns (such as improper cylinder compression, worn camshaft/valve train, gasketleaks).






Engine Poor DriveabilityThe following conditions apply to this symptom:• Engine stalls/quits, engine runs rough, misses, buck/jerk, hesitation/stumble acceleration, surges, rolling idle.• Engine stops unexpectedly at beginning of acceleration or during acceleration.• Engine stops unexpectedly while cruising.• Engine speed fluctuates during acceleration.• Engine misses during acceleration.• Vehicle bucks/jerks during acceleration, cruising or deceleration.• Momentary pause during acceleration.• Momentary minor loss in engine output.


NOTE :Be aware of the over RPM limiting functions of the ECM.• Carry out the following preliminary checks:

− Fuel quality− Vacuum lines (check for damage and correct routing)− Intake air system (check for damaged tubes and dirty air filter)− Vehicle wiring (disconnected, corroded/damaged)− Throttle linkage.− Radiator (obstructed)− Transaxle

Are all checks OK?


No >> • Repair as necessary. Verify symptom no longer exists.

2. CHECK FOR STALL AT IDLE

• Check for engine stall at idle.

NOTE :Confirm that proper vehicle maintenance has been performed before continuing with engine diagnosis.• Inspect the following components:

− Clean the injectors− Fuel filter− Intake air filter− Throttle body− Spark plugs− Spark plug wires

Does the engine now stall at idle?




03


3. CHECK FOR ROUGH IDLE

• Check for engine rough idle.


− Clean the carbon deposit on intake and exhaust valves− Valve stem− Spark plugs− Throttle body− Spark plugs and combustion chamber

Does the engine idle rough?



4. CHECK ECM DTC





5. CHECK THE ELECTRONIC THROTTLE CONTROL (ETC) ACTUATOR

• Start engine and let idle.• While checking for RPM drop or engine stall, disconnect ETC actuator connector.

Did RPM drop or engine stall when the ETC connector was disconnected?

Yes >> • Connect ETC actuator connector.• Go to the next step.





















9. CHECK PCV SYSTEM

• Check the Positive Crankcase Ventilation (PCV) system.• Remove PCV valve and shake it.

Is PCV valve normal?



10. CHECK EVAPORATIVE EMISSIONS (EVAP) SYSTEM

• Disconnect the canister control valve (1) hose.• Place a stiff piece of paper over the hose end,

start engine.

Does vacuum hold the paper?

Yes >> • Check for a vacuum leak in EVAP system (refer to EVAP system) and refer to EVAP control circuitrelative DTC.



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03


11. CHECK ENGINE CYLINDER COMPRESSION

• Check engine cylinder compression.• Compression should not be less than 1,000 kPa, and not vary more than 25 percent from cylinder to cylin-

der.

Is engine compression correct?



12. ADDITIONAL CHECKS

• Check the following for possible additional causes:− Driveline− Transaxle− Charging system− A/C system (for surge with A/C on)

Are the checks OK?

Yes >> • See Diagnostic Help for additional information.




Low Idle / Stalls During DecelerationThe following conditions apply to this symptom:• Engine stops unexpectedly at beginning of deceleration or recovery from deceleration.


• Carry out the following preliminary checks:− Vacuum lines (routing, leaks)− Intake air tubes− Wiring connections

Are all checks OK?



2. CHECK FOR ROUGH OR STALL AT IDLE

• Check for rough idle or stall at idle.


− Clean the carbon deposit on intake and exhaust valves− Valve stem− Spark plugs and combustion chamber

Does the engine idle rough?



3. CHECK ECM DTC





4. CHECK THE ELECTRONIC THROTTLE CONTROL (ETC) ACTUATOR

• Start engine and let idle.• Disconnect ETC actuator connector and check for RPM drop or engine stall.

Did RPM drop or engine stall when the ETC connector was disconnected?

Yes >> • Connect ETC actuator connector.• Go to the next step.



03


5. CHECK CLUTCH OPERATION CONDITION.

• Check clutch operation condition.

Is the transaxle clutch operation normal?



6. CHECK A/C SYSTEM OPERATION

• Start engine.• Cycle A/C switch from on to off (verify A/C clutch engages condition).• Check the A/C system operation.

Does the A/C system operate normally?









8. CHECK FOR BASE ENGINE CONCERNS

• Check for base engine concerns (such as improper compression, worn camshaft/valve train, gasket leaks).






Idle Speed Slow Return To Normal IdleThe following conditions apply to this symptom:• Slow return to idle.


• Carry out the following preliminary checks:− Vacuum leaks− Intake air system− Throttle body

Are all checks OK?



2. CHECK ECM DTC





3. CHECK PCV VALVE

• Remove Positive Crankcase Ventilation (PCV) valve and shake it.

Does PCV valve rattle?

Yes >> • Install PCV valve, go to the next step.


4. CHECK PCV SYSTEM

• Start engine and bring to normal operating temperature. Disconnect crankcase ventilation hose from PCV valve.Place a stiff piece of paper over the hose. Wait 1 minute.

Does vacuum hold paper in place?

Yes >> • Verify test results. If OK, see diagnostic index to repair any additional symptom.

No >> • Check for vacuum leaks, obstructions in the PCV system, oil cap, PCV valve, rocker cover bolttorque/gasket leak. Repair as necessary.


03


IGNITION CONTROL

GENERAL INFORMATION 03-223Description 03-223Operation 03-223Specifications 03-223Special Tools 03-224Electrical Schematics 03-225


Ignition Coil 03-227Description 03-227

Operation 03-227Removal & Installation 03-227

Spark Plug Wire 03-228Removal & Installation 03-228

Spark Plug 03-229Removal & Installation 03-229


GENERAL INFORMATIONDescriptionThe electronic ignition system consists of the following components:• Engine Control Module (ECM)• Ignition Coil• Spark Plugs• Spark Plug Wires• Camshaft Position Sensor• Crankshaft Position Sensor

OperationThe ignition coil is split and each side supplies voltage to two cylinders. When the ignition coil discharges, two sparkplugs fire at the same time. The coil is controlled by the Engine Control Module (ECM) based on inputs from theCrankshaft Position Sensor and the Camshaft Position Sensor.

The ignition coil consists of a primary and secondary coil. The primary coil is powered on one side, and on the otherside is connected to the ECM. The secondary coil connects to two spark plugs, they form a loop and provide ahigh-voltage output.

Specifications



Spark Plugs 30

Ignition Coil Bolts 6

Spark Plug Specifications

DESCRIPTION Gap (mm)

FR7DTC 0.7 - 1.1

03


Special Tools



GENERAL INFORMATION



Ignition Control System (Page 1 of 2)

GENERAL INFORMATION

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03


Ignition Control System (Page 2 of 2)

GENERAL INFORMATION

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ON-VEHICLE SERVICE

Ignition Coil

DescriptionThe ignition coil consists of primary and secondary groups of wire. The primary wire is located on one end of the coil.One end of the wire is connected to power and the other end is connected to the Engine Control Module (ECM). Thesecondary coil connects two spark plugs. They form a loop and provide high-voltage output.

OperationWhen the primary wire is connected to power, current will flow causing a strong magnetic field to form. When theprimary wire is disconnected, the magnetic field will collapse into the secondary wire causing very high voltage out-put.

Removal & Installation1. Disconnect the negative battery cable.2. Disconnect the ignition coil electrical connector.3. Twist the spark plug wires from the ignition coil and

remove the four spark plug wires (1).

NOTE :Mark the sequence number when removing the spark plug wires from ignition coil.

4. Remove the 4 ignition coil retaining bolts (1).(Tighten: Ignition coil retaining bolts to 6 N·m)

5. Remove the ignition coil.6. Installation is in the reverse order of removal.

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03


Spark Plug Wire

Removal & Installation1. Disconnect the negative battery cable.2. Twist the spark plug wire (1) from the ignition coil

and remove the spark plug wire.

3. Remove the PCV hose (2).4. Twist the spark plug wire (1) from the spark plug.

5. Remove the spark plug wire (1).

CYLINDERNUMBER 1 2 3 4

Part Number A11-3707130HA A11-3707140HA A11-3707150HA A11-3707160HA

L (mm) 405 275 165 125

Resistance (K�) 6.99-12.08 5.32-9.59 3.92-7.48 3.4-6.71


ON-VEHICLE SERVICE

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BESM030013


Spark Plug

Removal & Installation1. Disconnect the negative battery cable.2. Remove the PCV hose (1).3. Twist the spark plug wire (2) from spark plug then

pull the spark plug wire straight up.

4. Remove the spark plug.(Tighten: Spark plugs to 30 N·m)

5. Inspect the spark plug condition.6. Installation is in the reverse order of removal.

Installation Notes:

• Verify the proper spark plug gap before installingthe spark plugs.

− Spark plug gap (A) : 0.7 - 1.1 mm

ON-VEHICLE SERVICE

LTSM030039

BESM030011

03


EVAPORATIVE EMISSIONS

GENERAL INFORMATION 03-231Description 03-231Operation 03-231Electrical Schematics 03-232Specifications 03-233Special Tools 03-233


Canister Control Valve 03-234Description 03-234

Operation 03-234Removal & Installation 03-234

Vapor Canister 03-235Description 03-235Operation 03-235Diagnosis & Testing 03-235Removal & Installation 03-235


GENERAL INFORMATIONDescriptionThe evaporation control system prevents the emission of fuel tank vapors into the atmosphere. When fuel evaporatesin the fuel tank, the vapors pass through vent hoses or tubes to an activated carbon filled evaporative canister. Thecanister temporarily holds the vapors. The Engine Control Module (ECM) allows intake manifold vacuum to drawvapors into the combustion chambers during certain operating conditions.

Operation

The ECM will only energize the solenoid when the engine is at operating temperature, but will de-energize it duringperiods of deceleration. When de-energized, no vapors are purged. The pulse-width modulated canister control valvemodulates the fuel vapor purge rate from the vapor canister and fuel tank to the engine intake manifold.

1 - Fuel Tank

2 - Fuel Vapor

3 - Canister

4 - Intake Air

5 - Hose

6 - Canister Control Valve

7 - Throttle Valve

8 - Air Filter Assembly

9 - To Engine

10 - Intake Air

BESM030026

03



Canister Control Valve (Page 1 of 1)

GENERAL INFORMATION

VISMW030022T


Specifications



Vapor Canister Bolts 10

Special Tools



GENERAL INFORMATION

03


ON-VEHICLE SERVICE

Canister Control Valve

DescriptionThis vehicle uses a pulse-width modulated canister control valve. The canister control valve regulates the rate ofvapor flow from the vapor canister to the throttle body. The Engine Control Module (ECM) controls the frequency atwhich the canister control valve operates in order to accommodate the vapor volume for each cylinder.

OperationThe canister control valve is installed near the engine air filter. The Engine Control Module (ECM) controls the open-ing and closing of the canister control valve. When the ECM relay is energized, the canister control valve switchesfrom closed to open.

Removal & Installation1. Disconnect the negative battery cable.2. Disconnect the canister control valve electrical con-

nector.3. Disconnect the lines (1) from canister control valve.

4. Remove canister control valve (1) from the bracket.VISM030005

BESM030014



Vapor Canister

DescriptionThe vapor canister is located on the RH-side of the core support and (beside the generator) is filled with activatedcarbon granules.

OperationThis vehicle uses a vapor canister filled with activated carbon granules. Fuel tank vapors are vented into the canisterwhere they are absorbed by the activated carbon granules. The canister temporarily holds the fuel vapors until intakemanifold vacuum draws them into the cylinder chamber. The Engine Control Module (ECM) purges the canisterthrough the pulse-width modulated canister control valve. The ECM purges the canister at predetermined intervalsand engine conditions.

Diagnosis & Testing1. Disconnect the intake air hose and plug the intake air hole.2. Apply air pressure into the fuel stream intake hose. Verify the air can flow freely through the hose.3. Make sure the vapor canister is not be plugged or leaking.

Removal & Installation1. Disconnect and isolate the negative battery cable.2. Disconnect the coolant level sensor electrical connector.3. Remove the coolant reservoir retaining bolts (1)

and hose clamps (2) then set it aside.(Tighten: Coolant reservoir bolts to 10 N·m)

4. Remove two hoses at the vapor canister.5. Remove vapor canister retaining bolts (1).

(Tighten: Vapor canister retaining bolts to 10 N·m)6. Remove the vapor canister.7. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

VISM030003

VISM030002

03


FUEL DELIVERY

04CONTENTS

pageFuel Delivery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-1

FUEL DELIVERY SYSTEM


DIAGNOSIS & TESTING 04-10Fuel Pressure Test 04-10


Fuel Pressure Relief Procedure 04-12Fuel Pressure Relief Procedure 04-12

Fuel Pump 04-12Description 04-12Operation 04-12Removal & Installation 04-12Fuel Pump Inspection 04-14

Fuel Filter 04-15Description 04-15Operation 04-15Removal & Installation 04-15

Fuel Injector Rail 04-16Description 04-16Operation 04-16Removal & Installation 04-16

Fuel Injector 04-17Description 04-17Operation 04-17Removal & Installation 04-17Fuel Injector Inspection 04-18

Fuel Tank 04-19Description 04-19Operation 04-19Removal & Installation 04-19

04


GENERAL INFORMATIONDescriptionThe fuel system consists of a fuel tank with a reservoir, fuel pump, fuel filter, fuel delivery line, fuel rail, fuel rail pulsedamper and fuel injectors. The Engine Control Module (ECM) controls the fuel system based on signal inputs. Theimmobilizer module signals the ECM to activate the fuel system. If the ECM does not receive the proper signal fromthe immobilizer module, the ECM will not allow the fuel system to operate.• The ACTECO engine utilizes a returnless fuel delivery system.

WARNING!

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-relatedcomponent. Highly flammable mixtures are always present and may be ignited. Failure to follow these instruc-tions may result in serious personal injury.


1 - Fuel Tank

2 - Fuel Filter

3 - Fuel Rail And Fuel Injector

4 - EVAP Canister

5 - Intake Manifold

6 - EVAP Canister Purge Solenoid

GENERAL INFORMATION

VISM040007

04


OperationThe fuel delivery system is enabled when it reaches the following conditions:• Turn the ignition switch ON (engine off), the fuel delivery system is enabled for 3-6 seconds.• The Engine Control Module (ECM) receives a Crankshaft Position (CKP) sensor signal.

The fuel injectors are a solenoid-operated valve that meter fuel flow to each cylinder. The fuel injectors are openedand closed constantly during engine operation. The amount of fuel is controlled by the length of time the fuel injectoris held open. The fuel injectors are powered by a 12 V source and are controlled through the ground side of thecircuit by the ECM.

The fuel pump operation is defined in the fuel system control strategy and is controlled by the ECM.

Specifications



Fuel Rail Bracket Bolt 11

Fuel Filter Mounting Bolt 2

Fuel Pressure Specifications

DESCRIPTION PRESSURE

Fuel Pressure at Fuel Rail - Key On 400 kPa (4.0 bar)

Fuel Pressure at Fuel Rail - Engine Idle 400 kPa (4.0 bar) - 420 kPa (4.2 bar)

Fuel Pressure at Fuel Rail - Key Off 380 kPa (3.8 bar) after 10 minutes

GENERAL INFORMATION


Special Tools


Fuel Pressure Gauge

Fuel Pump RemoverCH-20032

Service Jack

GENERAL INFORMATION

04



Fuel Delivery System (Page 1 of 4)

GENERAL INFORMATION

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GENERAL INFORMATION

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04



GENERAL INFORMATION

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GENERAL INFORMATION

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04


DIAGNOSIS & TESTINGFuel Pressure TestWARNING!

Fuel in the fuel system remains under high pressure, even when the engine is not running. Before servicing ordisconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved toprevent accidental spraying of fuel (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery). Failure tofollow these instructions may result in serious personal injury.

Perform the following procedure to test for proper fuel pressure:

WARNING!

Wrap towels around fuel lines to catch any gasoline spillage.

1. Remove the protective cap and connect the fuel pressure gauge (2) to the fuel rail service test port pressurefitting (1) on the fuel rail (3).

2. Start and warm the engine and note pressure gauge reading. Fuel pressure should be 420 kPa (4.2 bar) at idle.3. If engine runs, but pressure is below 420 kPa (4.2 bar), check for a kinked fuel supply line somewhere between

the fuel rail (3) and the fuel pump. If the line is not kinked, replace the fuel pump (See Fuel Pump Removal &Installation in Section 04 Fuel Delivery).

4. If operating pressure is above 420 kPa (4.2 bar), the electric fuel pump is OK, but fuel pressure regulator isdefective. Replace the fuel pressure regulator (See Fuel Pump Removal & Installation in Section 04 FuelDelivery).NOTE: The fuel pressure regulator is integrated into the fuel pump assembly and is not serviced separately.

5. Install the protective cap to the service test port pressure fitting (1) on the fuel rail.

BESM030020


Observe the following fuel pressures when testing:

FUEL PRESSURE


Key Off 380 kPa (3.8 bar) after 10 minutes

Engine Idle 400-420 kPa (4.0 - 4.2 bar)

Fuel System Troubleshooting Chart

CONDITION POSSIBLE CAUSES CORRECTION

No Start/Hard Start/Start and Stall

· Contaminated fuel· Low fuel pressure· Restricted fuel filter· Fuel pump relay inoperative· Restricted or leaking fuel lines· Open fuel tank meter check valve

· Drain, flush and refill fuel system.· Check fuel pump pressure.· Replace fuel filter· Test fuel pump relay.· Inspect/Replace necessary fuelline(s), perform fuel system airpurge.· Inspect/Replace necessary.

Stalls Under Aggressive Maneuvers/Loss Of Fuel Pressure

· Restricted or damaged fuel filter· Contaminated fuel· Damaged fuel tank

· Replace fuel filter.· Drain, flush and refill fuel system.· Replace fuel tank.

Cannot Refill Fuel Tank/ExcessivePressure in Fuel Tank When Cap isRemoved

· Sticking or damaged fuel tankfill/vent valve, hose or lines.

· Inspect, repair vent hose and lines,replace fuel tank.

DIAGNOSIS & TESTING

04


ON-VEHICLE SERVICE

Fuel Pressure Relief Procedure

Fuel Pressure Relief ProcedureWARNING!

Fuel in the fuel system remains under high pressure, even when the engine is not running. Before servicing ordisconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved toprevent accidental spraying of fuel. Failure to follow these instructions may result in serious personal injury.

Perform the following procedure to relieve fuel pressure from the fuel system:

1. Remove the cover of the front fuse and relay box.2. Identify and remove the fuel pump relay from the front fuse and relay box.3. Start and run engine until it stalls.4. Attempt to restart engine until it will no longer run.5. Turn the ignition key to OFF position.

NOTE :Replace the fuel pump relay when the fuel system service is complete.

Fuel Pump

DescriptionThe fuel pump assembly contains the fuel pump motor, fuel level sensor and fuel pressure regulator.

OperationThe Engine Control Module (ECM) activates the fuel pump relay for several seconds after the ignition switch isturned ON. When the relay is activated, it provides voltage to the fuel pump. When the ECM receives an enginespeed signal from the Crankshaft Position (CKP) sensor, the ECM will again energize the fuel pump relay. If theengine speed signal is not received when the ignition switch is ON, the ECM will de-energize the fuel pump relay.


Release the fuel system pressure before servicing any fuel system components. Service vehicles in well venti-lated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personalinjury or death.

1. Release the fuel system pressure (See Fuel Pressure Relief Procedure In Section 04 Fuel Delivery).2. Remove the negative battery cable.3. Remove the rear seat cushion (See Rear Seat Removal & Installation in Section 15 Body & Accessories).


4. Using a screwdriver, remove the fuel pump cover(1).

5. Disconnect the fuel pump electrical connector.6. Disconnect the fuel lines (1).

7. Using special tool CH-20032, remove the fuel pump mounting cover.8. Pull the fuel pump up and out of the fuel tank.

WARNING!

• Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow theseinstructions may result in serious personal injury.• Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type whenworking on or near any fuel-related component. Highly flammable mixtures are always present and may beignited. Failure to follow these instructions may result in serious personal injury.• When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage.Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instruc-tions may result in serious personal injury.

NOTE :Make sure not to spill fuel inside of vehicle.

9. Tip the fuel pump on its side and drain the fuel from the fuel pump and remove the fuel pump from vehicle.10. Cover the fuel pump hole in the fuel tank to keep any debris from entering the fuel system.11. Remove and discard the seal from the fuel tank.12. Installation is in the reverse order of removal.

Installation Notes:

• Install a new seal on the fuel pump sealing surface.• Turn the ignition switch to ON (without starting the engine) to apply fuel pressure to the fuel system, then

check the fuel line connections for fuel leaks.• Start the engine and let it idle and check for fuel leaks at the fuel line connections.

ON-VEHICLE SERVICE

VISM040002

VISM040001

04


Fuel Pump Inspection

NOTE :The fuel pump must be removed before performing the following inspection procedure.

CAUTION:These tests must be completed within 10 seconds to prevent the coil from burning out.

WARNING!

Keep the fuel pump as far away from the battery as possible. Always switch the voltage on and off on the battery side, not on the fuel pump side.

1. Check the fuel pump resistance: Use the following table to test fuel pump resistance. Connect a digital multimeter to terminals 2 and 3. If the result is not as specified, replace the fuel pump.

2. Check the fuel pump operation: Use the following table to test fuel pump operation. Apply battery voltage to terminals 2 and 3. Check that the pump operates within 10 seconds. If the pump does not operate, replace the fuel pump.

MEASURINGCONDITION SPECIFICATION INSPECTION DIAGRAM

Digital MultimeterPositive (+) toterminal – 2Digital MultimeterNegative (-) toterminal – 3

< 130 �

Battery positive (+)to terminal – 2Battery negative (-)to terminal – 3

8 - 16 V

ON-VEHICLE SERVICE


Fuel Filter

DescriptionThe fuel filter consists of a housing with an integrated filter element.

OperationThe fuel flows through the filter from the outside to the inside. As a result, any impurities are trapped inside the filter.



1. Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).2. Disconnect the negative battery cable.3. Remove the fuel filter mounting screw (1).

4. Remove the fuel lines.5. Remove the fuel filter.6. Installation is in the reverse order of removal.

Installation Notes:

• Verify there are no leaks at the fuel line connections of the fuel filter.

ON-VEHICLE SERVICE

VISM040003

04


Fuel Injector Rail

DescriptionThe fuel rail is used to mount the fuel injectors to the engine and is itself mounted to the intake manifold.

OperationThe fuel rail supplies the necessary fuel to each individual fuel injector and is located above the intake manifold andfuel injectors.



1. Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).2. Turn the ignition switch off.3. Disconnect the negative battery cable.4. Disconnect the electrical connectors (1) from the

fuel injectors.5. Remove the fuel line (2) from the fuel rail.6. Remove the two fuel rail bracket bolts (3) that

mount the fuel rail (4) to the intake manifold.(Tighten: Fuel rail bracket bolts to 11 N·m)

ON-VEHICLE SERVICE

VISM040006


7. Remove the fuel rail with the four fuel injectors (1).


Installation Notes:

• Install a new seal on the fuel injector sealing surfaces.

Fuel Injector

DescriptionThe fuel injectors are positioned in the intake manifold with the nozzle ends directly above the intake valve port.

OperationInjector operation is controlled by a ground path provided for each injector by the Engine Control Module (ECM).Injector on-time (pulse-width) is variable, and is determined by the ECM. Based on the engine operating conditions,the ECM will control injector pulse-width operation to obtain optimum performance.



1. Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).2. Disconnect the negative battery cable.3. Remove the ground cable on the cylinder head.

ON-VEHICLE SERVICE

BESM04000504


4. Disconnect the electrical connectors (1) from thefuel injectors.

5. Remove the fuel line (2) from the fuel rail.6. Remove the two fuel rail bracket bolts (3) that

mount the fuel rail (4) to the intake manifold.(Tighten: Fuel rail bracket bolts to 11 N·m)

7. Remove the fuel rail with the four fuel injectors.8. Remove the clip holding the fuel injector to the fuel rail.9. Remove the four fuel injectors (1) from the fuel rail.


Installation Notes:

• Install new seals on the fuel injector sealing surfaces.

Fuel Injector Inspection1. Remove the fuel injector electrical connector.2. Use a digital multimeter to measure the resistance between the two fuel injector pins (fuel injector side).

SPECIFICATION TEMPERATURE

11 - 16 � 20 °C

ON-VEHICLE SERVICE

VISM040006

BESM040005


Fuel Tank

DescriptionThe fuel tank is constructed of a plastic composite material. The fuel tank stores fuel and the fuel pump module ismounted in the fuel tank.

OperationThe fuel tank stores fuel and the fuel pump delivers fuel from the tank to the fuel injectors.



1. Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).2. Remove the negative battery cable.3. Remove the rear seat cushion (See Rear Seat Removal & Installation in Section 15 Body & Accessories).4. Remove the fuel pump (See Fuel Pump Removal & Installation in Section 04 Fuel Delivery).5. Drain the fuel from the tank.6. Disconnect the vapor canister line (1).7. Disconnect the fuel line (2).

8. Raise and support the vehicle.9. Remove the muffler (See Muffler Removal & Installation in Section 07 Exhaust).

10. Remove the fuel tank protector.

CAUTION:There may be fuel in the fill tube. Remove hose carefully to reduce fuel splash.11. Disconnect the fuel tank from the rubber fill hose

(2).12. Disconnect the fuel tank vapor hose (1).

ON-VEHICLE SERVICE

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04


13. Using a service jack, support the fuel tank.14. Remove the four bolts (1) from the fuel tank straps.

15. Remove the fuel tank from the vehicle.16. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

VISM040005


STARTING & CHARGING

05CONTENTS

pageStarting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1

Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-10

STARTING SYSTEM


DIAGNOSIS AND TESTING 05-5Starter Motor Bench Test 05-5Starter Solenoid Test 05-5


Battery 05-6Description 05-6Operation 05-6


Positive Battery Cable 05-7Removal & Installation 05-7

Negative Battery Cable 05-7Removal & Installation 05-7

Battery Hold Down 05-7Removal & Installation 05-7

Battery Tray 05-8Removal & Installation 05-8

Starter Motor Assembly 05-8Description 05-8Operation 05-9Removal & Installation 05-9

05


GENERAL INFORMATIONDescription

The starting system consists of the following components:• Starter motor (including an integral starter solenoid)• Battery• Battery cables• Ignition switch and key lock cylinder• Wire harnesses and connections• Start relay and fuse• Charge fuse

OperationThe battery, starting, and charging systems operate in conjunction with one another, and must be tested as a com-plete system. For correct operation of starting/charging systems, all components used in these three systems mustperform within specifications. When attempting to diagnose any of these systems, it is important to keep their inter-dependency in mind. These components form two separate circuits, a high amperage circuit that feeds the startermotor up to 150 A, and a control circuit that operates on less than 20 A.

LTSM050007T


Specifications



Starter Mounting Bolt 30

Starter Solenoid Nut 13

Special Tools


GENERAL INFORMATION

05



Starting System (Page 1 of 1)

GENERAL INFORMATION

VISMW050001T


DIAGNOSIS AND TESTINGStarter Motor Bench TestCorrect starter motor operation can be confirmed byperforming the following free-running bench test. Thistest can only be performed with the starter motorremoved from the vehicle.

1. Remove the starter motor from the vehicle (SeeStarter Motor Removal & Installation in Section 05Starting and Charging).

2. Mount the starter motor securely in a soft-jawedbench vise. The vise jaws should be clamped onthe mounting flange of the starter motor (neverclamp on the starter motor by the field frame).

3. Connect a suitable volt-ampere tester and a 12 Vbattery to the starter motor in series, and set theammeter to the 100 A scale.

4. Install a jumper wire from the solenoid terminal to the solenoid battery terminal. The starter motor should oper-ate. If the starter motor fails to operate, replace the faulty starter motor assembly.

5. Adjust the carbon pile load of the tester to obtain the free running test voltage.6. Note the reading on the ammeter and compare this reading to the free-running test maximum amperage draw.7. If the ammeter reading exceeds the maximum amperage draw specification, replace the faulty starter motor

assembly.

Starter Solenoid TestThis test can only be performed with the starter motor removed from the vehicle.

1. Remove the starter motor from the vehicle (SeeStarter Motor Removal & Installation in Section 05Starting and Charging).

2. Disconnect the wire from the solenoid field coil ter-minal.

3. Check the solenoid for continuity between the sole-noid terminal and the solenoid field coil terminalwith a continuity tester. There should be continuity.If there is continuity, go to Step 4. If not, replacethe faulty starter motor assembly.

4. Using a continuity tester, check for continuitybetween the solenoid terminal and the solenoidcase. There should be continuity. If not, replace thefaulty starter motor assembly.

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VISM050007

05


ON-VEHICLE SERVICE

Battery

DescriptionThis vehicle is equipped with a single 12 V battery. All of the battery system components are located within theengine compartment of the vehicle. The battery system for this vehicle contains the following components:• Battery - The battery provides a reliable means of storing a renewable source of electrical energy within the

vehicle.• Battery Cables - The battery cables connect the positive and negative charged battery terminal posts to the

vehicle electrical system.• Battery Hold Down - The battery hold down hardware secures the battery in the battery tray.• Battery Tray - The battery tray provides a secure mounting location in the vehicle for the battery and an anchor

point for the battery hold down hardware.

OperationThe battery is designed to store electrical energy in a chemical form. When an electrical load is applied to the ter-minals of the battery, an electrochemical reaction occurs. This reaction causes the battery to discharge electricalcurrent from its terminals. As the battery discharges, a gradual chemical change takes place within each cell. Thesulfuric acid in the electrolyte combines with the plate materials, causing both plates to slowly change to lead sulfate.At the same time, oxygen from the positive plate material combines with hydrogen from the sulfuric acid, causing theelectrolyte to become mainly water. The chemical changes within the battery are caused by the movement of excessor free electrons between the positive and negative plate groups. This movement of electrons produces a flow ofelectrical current through the load device attached to the battery terminals.

Removal & Installation1. Disconnect the negative and positive battery cables

retaining nuts (1).

2. Remove the battery hold down retaining nuts (1).

3. Remove the battery.4. Installation is in the reverse order of removal.

VISM050002

VISM050001


Positive Battery Cable

Removal & Installation1. Disconnect the negative battery cable.2. Disconnect the positive battery cable.3. Remove the battery cable from the B+ terminal of the generator.4. Remove the battery cable from the B+ terminal of the starter motor.5. One at a time, trace the battery cable retaining push pins, fasteners and routing clips until the cables are free

from the vehicle.6. Remove the battery cable from the engine compartment.7. Installation is in the reverse order of removal.

Negative Battery Cable

Removal & Installation1. Disconnect the negative battery cable.2. Remove the bolts securing the negative cable to the body ground and the transaxle.3. One at a time, trace the battery cable retaining push pins, fasteners and routing clips until the cables are free

from the vehicle.4. Remove the battery cable from the engine compartment.5. Installation is in the reverse order of removal.

Battery Hold Down

Removal & Installation1. Disconnect the negative battery cable.2. Disconnect the positive battery cable.3. Remove the battery hold down retaining nuts (1).

4. Remove the battery hold down.5. Installation is in the reverse order of removal.

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05


Battery Tray

Removal & Installation1. Disconnect the negative and positive battery cables

retaining nuts (1).

2. Remove the battery hold down retaining nuts (1).

3. Remove the battery.4. Remove the bolts (1) connecting the battery tray to

car body.

5. Lift the battery tray out of the engine compartment and remove from the vehicle.6. Installation is in the reverse order of removal.

Starter Motor Assembly

DescriptionThe starter motor is located on the side of the engine, and mounted to the transaxle housing with two bolts. Thestarter motor incorporates several features to create a reliable, efficient, compact, lightweight and powerful unit. Theelectric motor of the starter features electromagnetic field coils wound around pole shoes, and brushes that contactthe motor commutator.

ON-VEHICLE SERVICE

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OperationThe starter motor is equipped with a planetary gear reduction system. The planetary gear reduction system consistsof a gear that is integral to the output end of the electric motor armature shaft that is in continual engagement witha larger gear that is splined to the input end of the starter pinion gear shaft. This feature makes it possible to reducethe dimensions of the starter and at the same time, it allows higher armature rotational speed and delivers increasedtorque through the starter pinion gear to the starter ring gear.

Removal & Installation1. Disconnect the negative battery cable.2. Disconnect the electrical connector from the starter.3. Remove the bolts connecting the engine oil dipstick to the cylinder block and intake manifold.4. Remove the engine oil dipstick.

NOTE: After removing the engine oil dipstick, you should immediately plug the hole in the cylinder block in orderto prevent any debris from entering the engine.

5. Remove the engine intake manifold (See Intake Manifold Removal & Installation in Section 02 Engine).6. Remove the starter solenoid nut (1) from the

starter.(Tighten: Starter solenoid nut to 10 N·m)

7. Remove the two starter mounting bolts (1) connect-ing the starter and transaxle.(Tighten: Starter mounting bolts to 30 N·m)

8. Remove the starter from the engine.9. Installation is in the reverse order of removal.

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05


CHARGING SYSTEM


DIAGNOSIS & TESTING 05-13Generator Noise 05-13


Generator 05-14Removal & Installation 05-14Generator Inspection 05-14



The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the generator fails for anyreason, the entire assembly must be replaced. The generator produces DC voltage.

OperationAs the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into thewindings of the stator coil.

The Y-type stator winding connections deliver the induced AC current to three positive and three negative diodes forrectification. From the diodes, rectified DC current is delivered to the vehicle’s electrical system through the gener-ator, battery, and ground terminals.

Specifications



Generator Cable Nut 13

Generator Mounting Bolt 30

Special Tools


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05



Charging System (Page 1 of 1)

GENERAL INFORMATION

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DIAGNOSIS & TESTINGGenerator NoiseNoise emitted from the generator may be caused by the following:• Worn, loose or defective bearings• Loose or defective drive pulley• Incorrect, worn, damaged or misadjusted drive belt• Loose mounting bolts• Misaligned drive pulley• Defective stator• Damaged internal fins

05


ON-VEHICLE SERVICE

Generator

Removal & Installation1. Disconnect the negative battery cable.2. Disconnect the generator electrical connector.3. Remove the engine drive belt (See Drive Belt Removal & Installation in Section 02 Engine).4. Remove the generator cable nut (1) connecting the

positive cable to the generator.(Tighten: Generator cable nut to 10 N·m)

5. Remove two generator mounting bolts (1).(Tighten: Generator mounting bolts to 30 N·m)

6. Remove the generator from the engine.7. Installation is in the reverse order of removal.

Generator Inspection1. Start the engine.

NOTE: If the battery warning lamp lights, there may be a problem with the charging system.2. With the engine running, check the output voltage of the generator with a digital multimeter (note the voltage).3. If the voltage is between 14.1v - 14.7v, the generator is good.

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COOLING

06CONTENTS

pageCooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06-1

COOLING SYSTEM


DIAGNOSIS AND TESTING 06-7Cooling System Pressure Test 06-7Cooling System Concentration Test 06-7


Cooling System Draining and Filling 06-8Cooling System Draining Procedure 06-8Cooling System Filling Procedure 06-8

Thermostat 06-9Description 06-9Operation 06-9Removal & Installation 06-9

Thermostat Inspection 06-10

Coolant Pump 06-10Removal & Installation 06-10Coolant Pump Inspection 06-11

Radiator 06-11Description 06-11Operation 06-11Removal & Installation 06-11

Cooling Fan 06-13Description 06-13Operation 06-13Removal & Installation 06-13Cooling Fan Inspection 06-14

Coolant Level Sensor 06-15Description 06-15Operation 06-15Removal & Installation 06-15

06


GENERAL INFORMATIONDescriptionThe cooling system regulates engine operating temperature. It allows the engine to reach normal operating temper-ature as quickly as possible, maintains normal operating temperature and prevents overheating.

The cooling system also provides a means of heating the passenger compartment. The cooling system is pressurizedand uses a centrifugal water pump to circulate coolant throughout the system.

The cooling system consists of the following components:• Radiator• Coolant• Coolant pump• Electric cooling fans• Electric cooling fans control module• Thermostat• Coolant reservoir• Hoses and clamps• Coolant temperature sensor• Coolant level sensor• Heater core

OperationThe primary purpose of a cooling system is to maintain engine temperature in a range that will provide satisfactoryengine performance and emission levels under all expected driving conditions. It also provides hot coolant for heaterperformance. It does this by transferring heat from engine metal to coolant, moving this heated coolant to the radi-ator, and then transferring this heat to the ambient air.

Specifications



Coolant Pump Mounting Bolt 15

Radiator Support Mounting Bolt 5

Coolant Fan Mounting Bolt 5

Thermostat Mounting Bolt 15

Fluid Specifications

DESCRIPTION CAPACITY (L)

Cooling System 7.0


Special Tools

Cooling System Pressure Tester

GENERAL INFORMATION

06



Cooling System (Page 1 of 3)

GENERAL INFORMATION

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GENERAL INFORMATION

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06



GENERAL INFORMATION

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DIAGNOSIS AND TESTINGCooling System Pressure TestWARNING!

Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure reliefcap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam andhot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions mayresult in serious personal injury.

CAUTION:Do not pressurize the cooling system beyond the maximum pressure listed in the specificationstable in this section, or cooling system components can be damaged.1. Turn the engine off.2. Check the engine coolant level. Adjust the coolant level as necessary.3. Attach the pressure tester to the coolant recovery reservoir. Install a pressure test pump to the quick-connect

fitting of the test adapter.4. Pressurize the engine cooling system. Observe the gauge reading for approximately 2 minutes. Pressure should

not drop during this time. If the pressure drops within this time, inspect for leaks and repair as necessary.5. If no leaks are found and the pressure drops, the pressure relief cap may be leaking. Install a new pressure

relief cap and retest the system.6. If no leaks are found after a new pressure relief cap is installed, and the pressure drops, the leak may be inter-

nal to the radiator transmission cooler (if equipped). Inspect the coolant for transmission fluid and the transmis-sion fluid for coolant. Repair as necessary.

7. If there is no contamination of the coolant or transmission fluid, the leak may be internal to the engine. Inspectthe coolant for engine oil and the engine oil for coolant.

8. Release the system pressure by loosening the pressure relief cap. Check the coolant level and adjust as nec-essary.

Cooling System Concentration Test

CAUTION:Do not mix types of coolant, corrosion protection will be severely reduced.

Coolant concentration should be checked when any additional coolant is added to the cooling system or after a cool-ant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion whenmixed to a freeze point of -37 °C to -46 °C. The use of a hydrometer or a refractometer can be used to test coolantconcentration.

06


ON-VEHICLE SERVICE

Cooling System Draining and Filling

Cooling System Draining ProcedureWARNING!

Never remove the pressure relief cap, under any conditions, while the engine is operating or hot. Failure to fol-low these instructions could result in personal injury or damage to the cooling system or engine. To avoid hav-ing scalding hot coolant or steam blow out of the cooling system, use extreme care when removing the pressurerelief cap. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn itslowly one turn (counterclockwise). Step back while the pressure is released from the cooling system. When youare certain all the pressure has been released, (with a cloth) turn and remove the pressure relief cap. Failure tofollow these instructions may result in serious personal injury.

Perform the following procedure when draining the cooling system:

1. DO NOT remove the pressure cap first with the engine hot.2. With the engine cold, remove the pressure cap.3. Raise and support the vehicle on a hoist and locate the radiator drain plug.4. Attach one end of a hose to the drain plug (1). Put

the other end into a clean container. Remove thedrain plug (1) and drain the coolant from the radi-ator.

5. After the coolant is empty, install the radiator drainplug.

Cooling System Filling Procedure

CAUTION:Failure to purge air from the cooling system can result in an overheating condition and severeengine damage.

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Perform the following procedure when filling the cooling system:

1. Fill the system using the proper mixture of anti-freeze/coolant and water. Fill the coolant recoveryreservoir to the �MAX� line and install the pressurecap.

2. With the heater control in the HEAT position, start and operate the engine with coolant recovery reservoir capinstalled.

3. Add coolant to the coolant recovery reservoir as necessary. Only add coolant to the coolant recovery reservoirwhen the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion.

Thermostat

DescriptionA pellet-type thermostat controls the operating temperature of the engine by controlling the amount of coolant flow tothe radiator. On all engines the thermostat begins to close below 90 °C. Above this temperature, coolant is allowedto flow to the radiator. This provides quick engine warm up and overall temperature control.

OperationThe wax pellet is located in a sealed container at the spring end of the thermostat. When heated, the pellet expands,overcoming closing spring tension and coolant pump pressure to force the thermostat to open.



1. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).

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06


2. Remove the thermostat mounting bolts (1).(Tighten: Thermostat mounting bolts to 15 N·m)

3. Remove the thermostat and gasket.4. Installation is in the reverse order of removal.

Installation Notes:

• Verify the cooling system is filled to proper specifications.

Thermostat Inspection1. Inspect the sealing surface of the thermostat (the

seat should be tight at room temperature).2. Inspect the opening temperature and maximum

stroke of the thermostat.• Opening temperature of the thermostat is 87 ± 2 °C• Maximum stroke of the thermostat is 8 mm• Full opening temperature of the thermostat is 104 °C3. Verify the thermostat closes 5 °C lower than the

opening temperature.4. If the thermostat fails any of the inspection steps,

replace the thermostat.

Coolant Pump



1. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).2. Remove the timing belt (See Timing Belt Removal & Installation in Section 02 Engine).

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3. Remove the coolant pump mounting bolts (1).(Tighten: Coolant pump mounting bolts to 15 N·m)

4. Remove the coolant pump (1) and gasket.


Installation Notes:


Coolant Pump InspectionCheck coolant seal of the coolant pump for coolant leak; if coolant pump bearing is loose, replace the assembly.

Radiator

DescriptionThe radiator is a cross-flow type (horizontal tubes) with design features that provide greater strength, as well assufficient heat transfer capabilities to keep the engine coolant within operating temperatures.

OperationThe radiator functions as a heat exchanger, using air flow across the exterior of the radiator tubes. Heat from thecoolant is then transferred from the radiator into the moving air.



1. Disconnect the negative battery cable.2. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).

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06


3. Disconnect the radiator coolant upper hose (2) andcoolant return hose (1) from the radiator.

4. Disconnect the radiator lower hose (1) from theradiator.

5. Disconnect the cooling fan electrical connectors.6. Remove the cooling fan (See Cooling Fan Removal & Installation in Section 06 Cooling).7. Remove the grille (See Grille Removal & Installation in Section 15 Body & Accessories).8. Remove the two radiator mounting bolts (1).

.

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9. Remove the radiator from the engine compartment.10. Installation is in the reverse order of removal.

Installation Notes:


Cooling Fan

DescriptionThe radiator cooling fans are dual-speed electric motor driven fans. The radiator fan assembly includes two electricmotors, two five-blade fans, and a support shroud that is attached to the radiator. The radiator fans are serviced asan assembly.

OperationThe radiator cooling fan operation is controlled by the Engine Control Module (ECM) and the fan relays, with inputsfrom the following:• Engine coolant temperature• A/C signal

Inspect the cooling fan for proper low speed and high speed operation:• The low speed fan should be switched on at 98 °C and switched off at 94 °C.• The high speed fan should be switched on at 105 °C and switched off at 101 °C.• If the water temperature is greater than 101 °C after the fan is switched off, the fan will continue to operate for

1 minute.• If the water temperature is greater than 94 °C after the fan is switched off, the fan will continue to operate for

0.5 minute.• If the water temperature is less than 85 °C after the fan is switched off, the fan will stop operating.



1. Disconnect the negative battery cable.2. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).3. Disconnect the radiator coolant upper hose (2) and

coolant return hose (1) from the radiator.

4. Disconnect the cooling fan electrical connectors.

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06


5. Remove the cooling fans mounting bolts (1) to theradiator.(Tighten: Cooling fans mounting bolts to 5 N·m)

6. Remove the radiator fan from the engine compartment.7. Installation is in the reverse order of removal.

Installation Notes:


Cooling Fan Inspection1. Using the following table, apply battery voltage to the specified connector terminals.2. Verify that the fan motor operates smoothly when voltage is applied.3. If the test results are not as specified, replace the fan motor.

MEASURINGCONDITION OPERATION INSPECTION DIAGRAM


Turns smoothly withhigh speed


Turns smoothly withlow speed

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Coolant Level Sensor

DescriptionThe coolant level sensor is located in the coolant reservoir. The coolant level sensor monitors the coolant level incoolant reservoir.

OperationWhen the coolant level is lower than the �MIN� level in the coolant reservoir, the coolant level sensor sends a signalto instrument cluster to illuminate the coolant temperature warning light and let the driver know the coolant level islow.

Removal & Installation1. Disconnect the negative battery cable.2. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).

WARNING!

Never remove the pressure relief cap under any conditions while the engine is operating or hot. Failure to followthese instructions could result in personal injury or damage to the cooling system or engine. To avoid havingscalding hot coolant or steam blow out of the cooling system, use extreme care when removing the pressurerelief cap. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn itslowly one turn (counterclockwise). Step back while the pressure is released from the cooling system. When youare certain all the pressure has been released, (with a cloth) turn and remove the pressure relief cap. Failure tofollow these instructions may result in series personal injury.

3. Disconnect the coolant level sensor electrical con-nector.

4. Remove the coolant reservoir hose clamp (2).5. Remove the coolant reservoir retaining bolts (1).

(Tighten: Coolant reservoir bolts to 10 N·m)6. Remove the coolant reservoir with the coolant level

sensor.7. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

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06


EXHAUST

07CONTENTS

pageExhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-1

EXHAUST SYSTEM

GENERAL INFORMATION 07-2Description 07-2Operation 07-2Specifications 07-3

DIAGNOSIS AND TESTING 07-4Exhaust System Diagnostic Chart 07-4


Exhaust Pipe Assembly 07-5Removal & Installation 07-5

Muffler 07-5Removal & Installation 07-5

Catalytic Converter 07-6Description 07-6Operation 07-6Removal & Installation 07-7

07



The exhaust system contains the following components:• Catalytic converter assembly• Muffler assembly• Exhaust brackets with isolators• Heated oxygen sensors mounted to the exhaust pipes• Tailpipe assembly

The exhaust system provides an exit for exhaust gases and reduces engine noise by moving exhaust gases throughthe catalytic converter, a muffler inlet pipe and a muffler. Rubber exhaust hanger insulators attach the exhaust systemto the mounting hooks.

WARNING!

Exhaust gases contain carbon monoxide which can be harmful to your health and are potentially lethal. Exhaustsystem leaks should be repaired immediately. Never operate the engine in enclosed areas. Failure to followthese instructions may result in personal injury or death.

OperationIn order to reduce vehicle emissions released by the engine, the catalytic converter is required to perform in all oper-ating conditions. This reduction is especially beneficial during the cold start and warm up phases of operation. It isduring these phases when a majority of the tailpipe emissions occur on today’s cars because the catalytic converterhas not yet reached its operating temperature. The exhaust system channels exhaust gases from the engine andaway from the vehicle.

Exhaust System

1 - Rear Muffler Assembly

2 - Middle Muffler Assembly

3 - Front Muffler Assembly

4 - Main Catalytic Converter Assembly

5 - Pre-Catalytic Converter Assembly

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Specifications



Exhaust Manifold Flange Bolts 50

Catalytic Converter Mounting Nuts 50

Muffler Nuts 50

GENERAL INFORMATION

07


DIAGNOSIS AND TESTINGExhaust System Diagnostic Chart


Excessive Exhaust Noise

· Leaks at pipe joints.· Burned or blown out muffler.· Burned or rusted-out exhaust pipe.· Exhaust pipe leaking at manifoldflange.· Exhaust manifold cracked orbroken.· Leak between exhaust manifoldand cylinder head.· Restriction in muffler or tailpipe.· Exhaust system contacting body orchassis.

· Tighten clamps to specified torqueat leaking joints.· Replace muffler assembly.· Replace exhaust pipe.· Tighten manifold flange bolts.· Replace exhaust manifold.· Tighten exhaust manifold tocylinder head stud nuts or bolts.· Remove restriction, if possible, andthen replace muffler or tailpipe, asnecessary.· Re-align exhaust system to clearsurrounding components.

Leaking Exhaust Gases · Leaks at pipe joints. · Tighten/replace clamps at leakingjoints.


ON-VEHICLE SERVICE

Exhaust Pipe Assembly


The normal operating temperature of the exhaust system is very high. Therefore, never work around, or attemptto service any part of the exhaust system until it has cooled. Special care should be taken when working nearthe catalytic converter. The temperature of the converter rises to a high level after a short period of engine oper-ation.

1. Raise and support the vehicle.2. Remove the catalytic converter to exhaust manifold

flange bolts (1).(Tighten: Exhaust manifold flange bolts to 50 N·m)

3. Remove the two oxygen sensors (1) & (2).

4. Remove all the support isolators.5. Remove the exhaust pipe assembly.

Muffler


The normal operating temperature of the exhaust system is very high. Therefore, never work around, or attemptto service any part of the exhaust system until it has cooled. Special care should be taken when working nearthe catalytic converter. The temperature of the converter rises to a high level after a short period of engine oper-ation.

1. Raise and support the vehicle.

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2. Remove the muffler mounting bolts (1) and gas-kets.(Tighten: Muffler mounting bolts to 50 N·m)

3. Remove the support isolators.4. Remove the muffler.5. Clean the ends of the pipes and the muffler to assure proper mating of all parts. Discard broken or worn isola-

tors, rusted or overused clamps, supports, and attaching parts.6. Installation is in the reverse order of removal.

Catalytic Converter

DescriptionThe catalytic converter is attached to the exhaust manifold using fasteners and a gasket for sealing.

The catalytic converter plays a major role in the emission control system by operating as a gas reactor. Its catalyticfunction is to speed the heat-producing chemical reaction of components in the exhaust gases in order to reduce airpollutants.

OperationCatalyst operation is dependent on its ability to store and release the oxygen needed to complete the emissions-reducing chemical reactions. As a catalyst deteriorates, its ability to store oxygen is reduced. Since the catalyst’sability to store oxygen is somewhat related to proper operation, oxygen storage can be used as an indicator of cat-alyst performance.

CAUTION:Unleaded gasoline must be used in order to avoid damaging the catalyst core.

CAUTION:Do not allow the engine to operate above 1200 RPM in Neutral for more than 5 minutes. This mayresult in excessive exhaust system/floor pan temperatures because of the lack of air movementunder the vehicle.

ON-VEHICLE SERVICE

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The normal operating temperature of the exhaust system is very high. Therefore, never work around or attemptto service any part of the exhaust system until it has cooled. Special care should be taken when working nearthe catalytic converter. The temperature of the converter rises to a high level after a short period of engine oper-ating time.

1. Raise and support the vehicle.2. Disconnect the negative battery cable.3. Remove the catalytic converter mounting bolts (1)

& (2) and gaskets.(Tighten: Catalytic converter mounting bolts to50 N·m)

4. Remove the catalytic converter.5. Clean ends of the pipes to assure mating of all parts. Discard broken or worn isolators, rusted or overused

clamps, supports, and attaching parts.6. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

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07


TRANSAXLE

08CONTENTS

page5-Speed Manual Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-1

Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-33

Clutch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-39

5-SPEED MANUAL TRANSAXLE

GENERAL INFORMATION 08-2Description 08-2Operation 08-2Specifications 08-5Special Tools 08-6

DIAGNOSIS & TESTING 08-8Abnormal Transaxle Noise 08-8Symptom Diagnostics 08-8


Manual Transaxle 08-9Removal & Installation 08-9

Gear Selector & Shifter Assembly 08-14Removal & Installation 08-14

TRANSAXLE UNIT REPAIR 08-18

Transaxle 08-18Specifications 08-18Disassembly 08-18Assembly 08-23

Input Shaft 08-24Specifications 08-24Disassembly 08-24Inspection 08-25Assembly 08-26

Output Shaft 08-27Disassembly 08-27Inspection 08-28Assembly 08-28

Idler Gear 08-29Disassembly 08-29Assembly 08-29

Reverse Shift Fork 08-30Disassembly 08-30

1st-2nd Shift Fork 08-30Disassembly 08-30

3rd, 4th, 5th & Reverse Fork Shaft 08-31Disassembly 08-31

08


GENERAL INFORMATIONDescriptionThe QR519MHA five-speed transaxle is a constant-mesh manual transaxle that is synchronized in all gear ranges,including reverse.

The transaxle consists of three major sub-assemblies:• Input shaft• Output shaft• Differential assembly

The transaxle shift system consists of the following components:• Mechanical shift cover• Shift rails• Shift forks• Shift cables

OperationThe following are the details of the manual transaxle:

NeutralEngine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. Since no synchro-nizers are engaged on either the input or output shafts, power is not transmitted to the output shafts, power is nottransmitted to the output shaft and the differential does not turn.

1st GearEngine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft firstgear is integral to the input shaft, and is in constant mesh with the intermediate shaft first speed gear. Because ofthis constant mesh, the output shaft first speed gear freewheels until first gear is selected. As the gearshift lever ismoved to the first gear position, the 1-2 fork moves the 1-2 synchronizer sleeve towards first gear on the outputshaft. The synchronizer sleeve engages the first gear clutch teeth, engaging the gear to the output shaft, and allow-ing power to transmit through the output shaft to the differential.

QR519MH External View

1 – End Cover-Rear

2 – Transaxle Housing Assembly

3 – Clutch Slave Cylinder

4 – Clutch Housing Assembly

5 – Gearshift Mechanism

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2nd GearEngine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaftsecond gear is integral to the input shaft, and is in constant mesh with the output shaft second speed gear. Becauseof this constant mesh, the output shaft second speed gear freewheels until second gear is selected. As the gearshiftlever is moved to the second gear position, the 1-2 fork moves the 1-2 synchronizer sleeve towards second gear onthe output shaft. The synchronizer sleeve engages the second gear clutch teeth, engaging the gear to the outputshaft, and allowing power to transmit through the output shaft to the differential.

3rd GearEngine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft thirdspeed gear is in constant mesh with the output shaft 3-4 cluster gear which is fixed to the output shaft. Because ofthis constant mesh, the input shaft third speed gear freewheels until third gear is selected. As the gearshift lever ismoved to the third gear position, the 3-4 fork moves the 3-4 synchronizer sleeve towards third gear on the inputshaft. The synchronizer sleeve engages the third gear clutch teeth, engaging the gear to the input shaft, and allowingpower to transmit through the output shaft to the differential.

4th GearEngine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft fourthspeed gear is in constant mesh with the output shaft 3-4 cluster gear which is fixed to the output shaft. Because ofthis constant mesh, the input shaft fourth speed gear freewheels until fourth gear is selected. As the gearshift leveris moved to the fourth gear position, the 3-4 fork moves the 3-4 synchronizer sleeve towards fourth gear on the inputshaft. The synchronizer sleeve engages the fourth gear clutch teeth, engaging the gear to the input shaft, and allow-ing power to transmit through the output shaft to the differential.

5th GearEngine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft fifthspeed gear is pressed on to the input shaft, and is in constant mesh with the output shaft fifth speed gear. Becauseof this constant mesh, the output shaft fifth speed gear freewheels until fifth gear is selected. As the gearshift leveris moved to the fifth gear position, the 5-R fork moves the 5-R synchronizer sleeve towards the output shaft fifthspeed gear. The synchronizer sleeve engages the fifth gear clutch teeth, engaging the gear to the input shaft, andallowing power to transmit through the output shaft to the differential.

Reverse GearEngine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaftreverse gear integral to the input shaft, and is in constant mesh with the reverse idler gear. The reverse idler gear,which reverses the rotation of the output shaft, is in constant mesh with the output shaft reverse gear. Because ofthis constant mesh, the output shaft reverse gear freewheels until reverse gear is selected. As the gearshift lever ismoved to the reverse gear position, the 5-R fork moves the 5-R synchronizer sleeve towards the output shaft reversegear. The synchronizer sleeve engages the reverse gear clutch teeth, engaging the gear to the output shaft, andallowing power to transmit through the output shaft to the differential.

GENERAL INFORMATION

08


Transaxle Identification NumberThe transaxle serial number can be found on a metaltag (1) fastened to the transaxle case on the clutchhousing. The third row data is transaxle serial number.

1 – Output Shaft

2 – Input Shaft

3 – 5th Gear Synchronizer

4 – 5th Driving Gear


6 – 3rd & 4th Gear Synchronizer

7 – 3rd Driving Gear

8 – 2nd Driving Gear

9 – Reverse Driving Gear

10 – 1st Driving Gear

11 – Idler Gear Shaft

12 – Clutch

13 – Crankshaft

14 – Idler Gear

15 – Differential Driving Gear

16 – 1st Driven Gear

17 – Axle Shaft

18 – Differential Side Gear

19 – Pinion Gear

20 – Differential Case

21 – Differential Driven Gear

22 – 1st & 2nd Gear Synchronizer

23 – 2nd Driven Gear

24 – 3rd Driven Gear

25 – 4th Driven Gear


GENERAL INFORMATION

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Specifications



Differential Driven Gear Bolt 120 - 130

Drain Plug 30 - 35

Transaxle External Housing-to-Case Bolt 22 - 26

Fork Shaft Seat 45 - 50

End Cover Bolt 18 - 23

Reverse Idler Shaft-to-Case Bolt 45 - 50

Reverse Fork Mechanism Bolt 22 - 26

Backup Lamp Switch Assembly 18 - 23

Bearing Retainer Bolt 15 - 20

5th Gear-to-Input Shaft Bolt 140 - 150

Release Bearing-to-Case Bolt 22 - 26

Gear Shift Mechanism Assembly Bolt 22 - 26

Reverse Lock Mechanism Bolt 15 - 22

Engine To Transaxle Bolt 78 - 80

Gear Ratio Specifications

GEAR RATIO

1st 3.546

2nd 2.048

3rd 1.346

4th 0.972

5th 0.816

Reverse 3.333

Final Drive Ratio 4.2

lubrication Specifications

DESCRIPTION ITEM

Transaxle Fluid Quantity 2.1 L

Fluid Type API 75W-90 GL-4

GENERAL INFORMATION

08


Special Tools

Bearing RemoverCH-10001


Clutch Pressure Plate InstallerCH-20014

Spline SpannerCH-30001

GENERAL INFORMATION


Differential Seal InstallerCH-30002

Gear RemoverCH-30003

Bearing DetacherMB-998801

Gear FixtureCH-30004

GENERAL INFORMATION

08


DIAGNOSIS & TESTINGAbnormal Transaxle NoiseTransaxle noise is most often a result of worn or damaged components. Chipped, broken gear or synchronizer teeth,and worn bearings all cause noise.

Inspect the following:• Insufficient lubrication• Incorrect lubricant• Miss-assembled or damaged internal components• Improper operation

Symptom Diagnostics

Hard Shifting• Hard shifting may be caused by a mis-adjusted crossover cable. If hard shifting is accompanied by gear clash,

synchronizer clutch and stop rings or gear teeth may be worn or damaged.

Slips Out Of Gear• Transaxle disengagement may be caused by misaligned or damaged shift components, or worn teeth on the

drive gears or synchronizer components. Incorrect assembly also causes gear disengagement.

Low Lubricant Level• Insufficient transaxle lubricant is usually the result of leaks, or inaccurate fluid level check or refill method. Vehi-

cle must be level to accurately check fluid level. Leakage is evident by the presence of fluid around the leakpoint. If leakage is not evident, the condition is probably the result of an under fill.

• If air-powered lubrication equipment is used to fill a transaxle, be sure the equipment is properly calibrated.Equipment out of calibration can lead to an under fill condition.

Clutch Problems• Worn, damaged, or misaligned clutch components can cause difficult shifting, gear clash, and noise.• A worn or damaged clutch disc, pressure plate, or a faulty slave cylinder can cause hard shifting and gear

clash.

Abnormal Noise• Transaxle noise is most often a result of worn or damaged components. Chipped, broken gear or synchronizer

teeth, and worn bearings all cause noise.

Inspect the following:

− Insufficient lubrication− Incorrect lubricant− Improperly assembled or damaged internal components


ON-VEHICLE SERVICE

Manual Transaxle

Removal & Installation1. Raise and support the vehicle.2. Disconnect the negative battery cable.3. Loosen the clamps (1) between the air intake hose

and the air cleaner and remove the air intake hose.

4. Disconnect the air flow sensor electrical connector (1.8L engine).5. Remove the retaining bolts (1) and remove the air

cleaner and air cleaner housing assembly.

6. Remove the power fuse box (1) and set it aside.7. Remove the front fuse and relay box (2).

VISM020001

VISM020004

VISM080015

08


8. Remove the front air intake hose retaining bolt (1)and take off the front air intake hose (2).

9. Remove the battery and battery tray (See Battery Removal & Installation in Section 05 Starting & Charging).10. Disconnect the hydraulic line (1) from the hydraulic

clutch cylinder and position it aside.

CAUTION: While hoses are disconnected, plug all openings to prevent foreign material from enteringthem.

11. Remove the hydraulic line clamp (1).

ON-VEHICLE SERVICE

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VISM080038


12. Remove the two shift cables (1) from the transaxle.


14. Remove the shift cable bracket retaining bolts (1).

15. Disconnect the electrical connector for the backuplamp switch (1) and remove the ground cable (2).

ON-VEHICLE SERVICE

BESM080051

VISM080026

VISM080025

VISM080039

08


16. Disconnect the crankshaft sensor connect.17. Remove the intake manifold (See Intake Manifold Removal & Installation in Section 02 Engine).18. Remove the coolant pipe bracket retaining bolts(1).

19. Remove the starter motor (See Starter Removal & Installation in Section 05 Starting & Charging).20. Support the engine using an engine support fixture or suitable jack.21. Remove the left transaxle mount bolts (2) and

bracket bolts (1).

22. Raise the vehicle.23. Remove the engine undercover and splash shields.24. Remove the drain screw plug (1) and drain the

transaxle fluid.

25. Remove both front axle shafts (See Front Axle Shaft Removal & Installation in Section 09 Driveline & Axle).

ON-VEHICLE SERVICE

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VISM080012


26. Disconnect the rear transaxle mount bolts (2) andthe rear transaxle mount bracket bolts (1).

27. Remove the front sub-frame assembly (See Front Sub-frame Removal & Installation in Section 10 Suspension).

28. Remove the engine to transaxle bolts (1).(Tighten: Engine to transaxle bolts to 78 - 80 N·m)

29. Separate the transaxle from the engine and remove it from the vehicle.

WARNING!

Support the transaxle with a suitable jack while removing the transaxle.


Installation Notes:

• When installing the transaxle, be careful to avoid interference between the transaxle input shaft and the clutch.• After installation, remove the filling hole bolt (1) and fill the transaxle fluid until it bleeding from the filling hole.

ON-VEHICLE SERVICE

VISM020003

VISM080002

VISM080011

08


Gear Selector & Shifter Assembly


1 – Gear Selection & Shift Shaft

2 – Top Base For 5th-Reverse Return Spring

3 – Pin Shaft – Reverse Lock Mechanism

4 – Torsion Spring – Reverse Lock Mechanism

5 – Reverse Lock Plate

6 – Reverse Lock Mechanism Bolts

7 – Reverse Lock Plate Bracket

8 – 5th-Reverse Return Spring

9 – Bottom Base For 5th-Reverse Return Spring

10 – 5th-Reverse Return Spring Retainer

11 – Linear Bearing

12 – Gear Selection & Shift Mechanism Housing

13 – Air Duct

14 – Air Duct Cap

15 – Selector Lever Assembly

16 – Spring Pin

17 – Boot Gear Selection & Shift Shaft

18 – Oil Seal Gear Selection & Shift Shaft

19 – Sleeve – Selector Lever Nut

20 – Nut

21 – Slide Block – Selector Lever

22 – Large Gasket – Selector Lever

23 – Small Gasket – Selector Lever

24 – Selector Lever Assembly

25 – Boot Selector Lever

26 – Selector Lever Bracket Assembly

27 – Selector Lever Bracket Bolt

28 – Interlock Plate

29 – Shift Finger

30 – Spring Pin

31 – Split Baffle Ring 1st-2nd Return Spring Assembly

32 – Bottom Base For 1st-2nd Return Spring

33 – 1st-2nd Return Spring

34 – Top Base For 1st-2nd Return Spring

ON-VEHICLE SERVICE

BESM080027


1. Disconnect the negative battery cable.2. Remove the power fuse box (1).3. Remove the front fuse and relay box (2).

4. Remove the battery and battery tray (See Battery Removal & Installation in Section 05 Starting & Charging).5. Remove the air cleaner housing assembly.6. Raise and support the vehicle.7. Remove the two shift cables (1) from the transaxle.


ON-VEHICLE SERVICE

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VISM080026

08


9. Remove the gearshift knob.10. Remove the gearshift boot from the lower console.

11. Apply the parking brake (apply parking brake han-dle to clear lower console upon removal).

12. Remove the lower console (See Lower Console Removal & Installation in Section 15 Body).13. Remove the crossover cable and the selector cable

(1) from the gearshift mechanism.

14. Remove the four bolts (1) and then remove thegearshift mechanism from the bracket.

ON-VEHICLE SERVICE

VISM080017

VISM080018

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15. Remove the selector cable clamp (1) and bracketretaining bolts (2).

16. Remove the gear selector & shifter assembly.17. Installation is in the reverse order of removal.

NOTE :Selector cable can be adjusted with the adjustment bolt (1).

ON-VEHICLE SERVICE

VISM080006

LTSM080180

08


TRANSAXLE UNIT REPAIR

Transaxle

Specifications



Differential Driven Gear Bolt 120 - 130

Drain Plug 30 - 35

Fork Shaft Seat 45 - 50

End Cover Bolt 18 - 23

Reverse Idler Shaft-to-Case Bolt 45 - 50

Reverse Fork Mechanism Bolt 22 - 26

Backup Lamp Switch Assembly 18 - 23

Bearing Retainer Bolt 15 - 20

5th Gear-to-Input Shaft Bolt 140 - 150

Release Bearing-to-Case Bolt 22 - 26

Gear Shift Mechanism Assembly Bolt 22 - 26

Reverse Lock Mechanism Bolt 15 - 22

Disassembly1. Place the transaxle on bench.2. Remove the fluid drain plug (1) and drain the trans-

axle fluid.(Tighten: Drain plug to 30 - 35 N·m)

3. Disconnect the hydraulic release bearing seat andthe quick coupler (1) for the release bearing.

4. Remove the two release bearing bolts (2) and thenthe release bearing.(Tighten: Release bearing bolts to 22 - 26 N·m)

VISM080012

BESM080001


5. Remove the shift finger locating base.6. Remove the eight end cover retaining bolts (1) and

then the end cover.(Tighten: End cover retaining bolts to 18 - 23 N·m)

7. Remove the reverse synchronizer ring (1).

8. Place the shift fork in the 5th gear position to lockthe gear train. Remove the 5th driven gear retain-ing bolt (1).NOTE: Engage the 5th gear and put a thin copperbar (or any other low-hardness metal bar) betweenthe 5th driving and driven gears, and then use atorque wrench to remove the nut for the 5th drivengear.

9. Remove the 5th driving gear retaining bolt (1).


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BESM080003

BESM080004

BESM080005

08


10. Remove the elastic lock pin (1) with the punch andthen remove the 5th & reverse shift fork.

11. Remove the 5th driving and driven gears.

12. Remove the needle roller bearing.

13. Remove the bearing retainer bolts (1) and thenremove the bearing retainer.


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BESM080007

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BESM080009


14. Remove the snap ring (1) from the rear outputshaft bearing.

15. Remove the snap ring from the rear input shaft bearing.16. Remove the gearshift mechanism assembly bolts

(1) from the transaxle housing.(Tighten: Gearshift mechanism assembly bolts to22 - 26 N·m)

17. Remove the backup lamp switch (1).

18. Remove the gearshift finger locating bolt (1).


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BESM080011

VISM080024

VISM080008

08


19. Remove the three retaining bolts as shown:1. 5th/Reverse shift fork locating base2. 1st/2nd shift fork locating base3. 3rd/4th shift fork locating base

20. Remove the idler gear shaft retaining bolt (1).

21. Remove the transaxle housing bolts (1).

22. Remove the clutch housing bolts (1).


BESM080012

VISM080009

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BESM080013


23. Use a copper bar to tap the input and output shaftsand then remove the transaxle housing along withthe 5th collar.

24. Remove the reverse idler gear assembly (1).25. Remove the reverse shift fork mechanism bolts (2)

and remove the reverse shift fork.

26. Remove the retainer ring (1).

27. Grasp the input shaft assembly, output shaft assembly, 1st-2nd shift fork, 3rd-4th shift fork and 5th-reverse forkshaft together and remove.

28. Remove the differential assembly.

Assembly1. Assemble the transaxle in the reverse order of disassembly.


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08


Input Shaft

Specifications


SYNCHRONIZER RING VALUE OF A WEARING LIMIT

1st-2nd Gear 1.10 - 1.17 mm 0.05 mm

3rd-4th Gear 1.35 - 1.90 mm 0.05 mm

5th Gear 1.10 - 1.17 mm 0.05 mm

Disassembly

NOTE :The following special tools are required to perform the repair procedure:• MB-998801 - Bearing Detacher

1 – Front Input Shaft Bearing

2 – Input Shaft

3 – 3rd-5th Needle Roller Bearing

4 – 3rd Driving Gear

5 – 3rd-4th Synchronizer Cone

6 – Synchronizer Ring 3rd-4th Synchronizer

7 – Steel Ring Spring For 3rd-4th Synchronizer

8 – Guide Block For 3rd-4th Synchronizer

9 – Gear Hub For 3rd-4th Synchronizer

10 – Gear Sleeve For 3rd-4th Synchronizer

11 – Steel Ring Spring For 3rd-4th Synchronizer

12 – 4th Gear Needle Roller Bearing


14 – 3rd-4th Synchronizer Cone


BESM080015


1. Using special tool MB-998801 (1), remove the 4thgear collar.

2. Using special tool MB-998801 (1), Remove the 4thdriving gear.

3. Remove 4th gear needle roller bearing.4. Remove 3rd-4th synchronizer assembly.5. Using special tool MB-998801, Remove the 3rd

driving gear.6. Remove the input shaft bearing from the front end

of input shaft.

Inspection1. Clean all components.2. Inspect the input shaft for the following:

Any damage, abnormal wear or lockup of the needle roller bearings.Any damage or wear of the spline.Gears for correct fit and assembly.Smooth rotation of gears.Any loose components or noise.

3. Inspect the 3rd and 4th driving gears for the follow-ing:

€ Any damage or wear on tooth surfaces ofhelical gear and clutch gear.

€ Any damage, wear or coarsening on thesynchronizer’sconical surface.

€ Any damage or wear on the inner-diameter,and rear surfaces.

4. Inspect the gear sleeve and gear hub of the 3rd-4th synchronizer:€ Assemble the gear sleeve and gear hub together and check whether they can slide smoothly or whether

theyare locked up as shown.

€ Inspect for any damage in the front and rear of the gear sleeve’s inner surface.


LTSM080038

BESM080016

BESM080017

08


front

5. Inspect for any damage or wear on the gear toothsurfaces of the synchronizer ring, whether there isany damage or wear on the inner-diameter surfaceof the synchronizer’s conical portion, and inspectthe threads for any damage.

6. Press the synchronizer rings onto their respectivegears’ conical surfaces and check the values ofclearance �A�. The standard values of �A� are asshown in the following table:

SYNCHRONIZER RING CLEARANCE

SYNCHRONIZER RING VALUE OF �A� WEARING LIMIT

1st-2nd Gear 1.10 - 1.17 mm 0.05 mm

3rd-4th Gear 1.35 - 1.90 mm 0.05 mm

5th Gear 1.10 - 1.17 mm 0.05 mm

Assembly1. Assemble the transaxle in the reverse order of disassembly.


BESM080018

BESM080019


Output Shaft

Disassembly

1. Using special tool MB-998801, remove the rear output shaft bearing and the 4th driven gear.2. Remove the 3rd-4th driven collar.3. Using special tool MB-998801 (2), remove the 3rd

driven gear (1), 2nd driven gear, take out 1st-2ndsynchronizer cone ring, out synchronizer ring, innersynchronizer ring and 2nd needle roller bearing.

1 – Front Bearing Inner Race for Output Shaft

2 – Output Shaft

3 – 1st-2nd Needle Roller Bearing

4 – 1st Driven Gear

5 – 1st-2nd Synchronizer Cone Ring

6 – 1st-2nd Synchronizer Ring (Outer)

7 – 1st-2nd Synchronizer Ring (Inner)

8 – Guide Block for 1st-2nd Synchronizer

9 – Gear Hub - 1st-2nd Synchronizer

10 – Gear Sleeve - 1st-2nd Synchronizer

11 – 1st-2nd Needle Roller Bearing

12 – 1st-2nd Synchronizer Cone Ring

13 – 2nd Driven Gear

14 – 3rd Driven Gear

15 – 3rd-4th Driven Shaft Sleeve



BESM080020

LTSM080065

08


4. Use snap-ring pliers to remove the snap ring (1) for1st-2nd synchronizer gear hub as shown.

5. Using special tool MB-998801 (1), remove the 1st-2nd synchronizer assembly and take out the 1stdriven gear and 1st needle roller bearing.

6. Using special tool MB-998801 (1), Remove thefront output shaft inner bearing from the front endof output shaft.

Inspection1. Clean all components.2. Inspect the following components for wear:

€ Output shaft€ Needle roller bearing€ 1st driven gear€

2nd driven gear€1st-2nd synchronizer gear sleeve and hub€Outer synchronizer ring, inner synchronizer ring and synchronizer cone ring€

Damage on the tooth surfaces and conical surfaces

Assembly1. Assemble is in the reverse order of disassemble.


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PZSM080040

PZSM080039


€€€

Idler Gear

Disassembly

1. Remove the reverse shift arm bracket retainingbolts (1) and the reverse shift arm (3) then removethe idle gear shaft (2).

2. Separate the reverse idle gear from idle gear shaftand take off the idle gear gasket.

Assembly1. Assemble is in the reverse order of disassemble.

1 – Idler Gear Shaft

2 – Reverse Idler Gear

3 – Idler Gear Gasket


VISM080042

PZSM080015

PZSM010008

08


Reverse Shift Fork

Disassembly1. Remove the reverse shift arm bracket retaining

bolts (1) and the reverse shift arm assembly (2) .

1st-2nd Shift Fork

Disassembly1. Separate the 1st-2nd shift fork from the shift fork

assembly.

2. Use a suitable tool to remove the shift fork springpin from the shift fork and the shift fork shaft.


VISM010008

VISM020016

VISM020015


3. Remove the shift fork shaft (1) from the shift fork(2).

3rd, 4th, 5th & Reverse Fork Shaft

Disassembly1. Separate the 3rd, 4th, 5th & reverse shift fork from

the shift fork assembly.


VISM010011

VISM020016

08


2. Remove the spring pins (2) & (3) from the 3rd-4th shift fork shaft (1).3. Remove the split baffle ring (5).4. Separate the 3rd-4th shift fork shaft (1) and 3rd-4th shift fork (4).5. Separate the reverse shaft (6).6. Remove the interlock pin (7) and spring pin (10)7. Separate the 5th-reverse shift fork shaft (8) from 5th-reverse shift fork (9).

1 – 3rd-4th Shift Fork Shaft

2 – Spring Pin

3 – Spring Pin

4 – 3rd-4th Shift Fork

5 – Split Baffle Ring

6 – Reverse Shaft

7 – Interlock Pin

8 – 5th-Reverse Shift Fork Shaft

9 – 5th-Reverse Shift Fork

10 – Spring Pin for Fork Shaft


BESM080026


DIFFERENTIAL


DIFFERENTIAL UNIT REPAIR 08-36

Differential Carrier 08-36Removal & Installation 08-36Disassembly 08-36Inspection 08-37Assembly 08-38

08


GENERAL INFORMATIONDescriptionThe differential includes the differential side gears and the shaft mounted differential pinion gears. Direct contactbetween the gears and the differential case is prevented by the differential side gear thrust washers installed underthe gears. The differential pinion shaft is held in position by a differential pinion shaft lock pin that extends throughthe end of the differential pinion shaft and the differential case.

The differential assembly consists of the following components:• Differential case (part of the final drive carrier)• 2 pinion gears supported by a pinion shaft• 2 side gears supported by the differential case and half shafts

OperationThe differential operates through the gear mesh with the ring gear bolted to the differential case. The engine poweris transmitted to the axle shafts through the pinion mate and side gears. The side gears are connected to the axleshafts.

1 – Front/Rear Differential Bearing

2 – Final Drive Driven Gear

3 – Differential Housing

4 – Bolts - Final Drive Driven Gear and Differential Housing

5 – Driving Gear - Odometer

6 – Spherical Washer Planetary Gear

7 – Planetary Gear Shaft

8 – Adjusting Washer - Side Gear

9 – Spring Pin - Planetary Gear

10 – Side Gear

11 – Planetary Gear

BESM080028


Specifications


Clearance between side gear and planetary gear 0.025 - 0.150 mm

Adjusting washer 0.93 - 1.00 mm

Special Tools

Differential Seal InstallerCH-30002

GENERAL INFORMATION

08


DIFFERENTIAL UNIT REPAIR

Differential Carrier

Removal & Installation1. Remove the input shaft assembly, output shaft assembly, 1st-2nd shift fork, 3rd-4th shift fork and 5th-reverse fork

shaft together as a unit (See Transaxle Assembly Unit Repair in Section 08 Transaxle).2. Remove the differential assembly.

Disassembly

1 – Front/Rear Differential Bearing

2 – Final Drive Driven Gear

3 – Differential Housing

4 – Bolts - Final Drive Driven Gear and Differential Housing

5 – Driving Gear - Odometer

6 – Spherical Washer Planetary Gear

7 – Planetary Gear Shaft

8 – Adjusting Washer - Side Gear

9 – Spring Pin - Planetary Gear

10 – Side Gear

11 – Planetary Gear

BESM080028


1. Fixing the differential on the table vice.2. Remove the drive gear bolts (1).

3. Tap the drive gear off the differential case assembly using a suitable tool.4. Remove the pinion mate shaft use suitable tool.

5. Turn the pinion mate gear, then remove the pinion mate gear, pinion mate thrust washer, side gear and side gearthrust washer from the differential case.

Inspection1. Clean all components.2. Inspect the following components for wear:

€ Ring gear€ Adjusting washers€ Side gears€

Spherical washers€Planetary gears€Planetary gear shaft


LTSM080117

LTSM080112

08


€€€

AssemblyInstallation of the adjusting washers, side gears, spherical washers, planetary gears and the planetary gear shaft:• Install the adjusting washers respectively on the backs of the side gears and put the side gears in place within

the differential.

NOTE :The adjusting washer for any new side gear have an appropriate thickness (0.93 - 1.00 mm).• Engage two planetary gears with side gears behind the spherical washers on the backs of the planetary gears

(rotate the gears for proper alignment).• Insert the planetary gear shaft.• Measure the clearances between side gear and planetary gear.

NOTE :Standard value: 0.025 - 0.150 mm

DIFFERENTIAL SIDE GEAR CLEARANCE

Standard 0.025 - 0.150 mm

Adjusting Washer 0.93 - 1.00 mm

• If any measured clearance is not within specifications, select and install the appropriate adjusting washer(s) andthen measure the clearances again.

NOTE :Adjust the side clearance equally on both sides.


BESM080032


CLUTCH SYSTEM


CLUTCH ASSEMBLY SERVICE 08-42

Clutch and Pressure Plate 08-42Removal & Installation 08-42

Clutch Master Cylinder 08-43Description 08-43Operation 08-43Removal & Installation 08-44

Clutch Slave Cylinder 08-46Removal & Installation 08-46

Bleeding Hydraulic Clutch 08-46Operation 08-46

08



The hydraulic clutch system consists of a clutch master cylinder (2), slave cylinder (3), and an interconnectinghydraulic fluid line. Hydraulic fluid is supplied by the clutch system via the clutch master cylinder reservoir (1).

OperationThe clutch hydraulic system is responsible for engaging and disengaging the clutch. Depressing the clutch pedaldevelops fluid pressure in the clutch master cylinder. This pressure is transmitted to the integral release bearingwhich is in contact with the pressure plate diaphragm spring. As additional force is applied, the bearing depresses thediaphragm spring fingers inward on the fulcrums. The action moves the pressure plate rearward, relieving clampingforce on the clutch disc.

VISM080044


Specifications



Slave Cylinder Bolt 17

Clutch Pressure Plate Bolt 25

Flywheel Bolts 75

Special Tools


Clutch Pressure Plate InstallerCH-20014

GENERAL INFORMATION

08


CLUTCH ASSEMBLY SERVICE

Clutch and Pressure Plate

Removal & Installation1. Remove the transaxle assembly (See Transaxle Assembly Removal & Installation in Section 08 Transaxle).2. Using special tool CH-20043 (1), hold the flywheel.

3. Make the mark (1) before remove the clutch pres-sure plate.

4. Remove the clutch pressure plate bolts (1).(Tighten: Clutch pressure plate bolts to 25 N·m)

5. Remove the modular clutch assembly.

LTSM080145

PZSM010005

BESM080046


6. Remove the flywheel-to-crankshaft bolts (1) andremove the flywheel (if necessary for resurfacing).(Tighten: Flywheel-to-crankshaft bolts to 75 N·m)


Clutch Master Cylinder

DescriptionThe clutch master cylinder mounts to the clutch pedaland consists of a piston and cylinder housing, an actu-ating push rod, and an interconnecting hydraulic tube.Fluid is supplied to the clutch master cylinder via thebrake fluid reservoir.

OperationWhen the clutch pedal is depressed, the push rod moves the piston in the master cylinder, displacing fluid throughthe hydraulic line and into the release bearing. As the release bearing extend it is forced into the fingers of the clutchdiaphragm springs. As the fingers move, they release the clamping pressure on the clutch disc between the clutchpressure plate and the flywheel. The clutch becomes disengaged as this pressure is released. When the clutch pedalis released, the system hydraulic pressure is released. This allows the force of the clutch diaphragm springs to returnthemselves to their original position, re-clamping the clutch disc between the flywheel and the clutch pressure plate.Also, the release bearing is forced to return, which reverses the movement of the hydraulic system and returns thepedal to its original position against the up stop.


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VISM010009

08


Removal & Installation1. Remove air cleaner housing assembly retaining

bolts (1) and remove the air cleaner housingassembly.

2. Disconnect hydraulic supply tube to clutch mastercylinder (1). To completely drain clutch master cyl-inder and tubing.

3. Disconnect hydraulic tube (1) and drain fluid intosuitable container.

4. Remove instrument panel lower trim panel (1) (SeeInstrument Panel Removal & Installation In Section15 Body & Accessories).


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VISM010010

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VISM150144


5. Disconnect clutch master cylinder push-rod (1)from clutch pedal.

6. Remove hydraulic tube from rail retainer.7. Release master cylinder by rotating to disengage from pedal bracket assembly.

CAUTION:Use care when removing clutch master cylinder from engine compartment. Aggressive handlingcan result in a damaged hydraulic tube and improper clutch release operation upon reassembly.

CAUTION:Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash itoff immediately with water.8. Remove the master cylinder assembly (1) from the

mounting position and carefully maneuver thehydraulic pipe from the engine compartment.



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VISM010010

08


Clutch Slave Cylinder


NOTE :To prevent the drainage of the clutch master cylinder assembly when replacing the slave cylinder, it is necessary tomake sure brake master cylinder fluid level is full and reservoir cap is installed tightly.

1. Remove the transaxle assembly (See Transaxle Assembly Removal & Installation in Section 08 Transaxle).2. Disconnect the hydraulic release bearing seat and

the quick coupler (1) for the release bearing.3. Remove the two release bearing bolts (2) and then

the release bearing.(Tighten: Release bearing bolts to 22 - 26 N·m)


Bleeding Hydraulic Clutch

Operation1. Verify fluid level in brake master cylinder. Top off

with DOT 4 brake fluid as necessary. Leave capoff.

2. Raise the vehicle on hoist.3. Remove the bleed port protective cap and install a

suitable size and length of clear hose to monitorand divert fluid into a suitable container.

4. Loosen the bleed port (1) by wrench.

5. Actuate the clutch pedal until the brake master cylinder fluid drains from the bleed port.


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VISM080023

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6. Depress the clutch pedal, screw down the bleed port.7. From driver’s seat, actuate the clutch pedal until the hydraulic bleed circuit has the pressure.8. Depress the clutch pedal, loosen the bleed port and bleeding the brake master cylinder fluid.9. Repeat the step 6 to step 8 for several times until make sure that there is no air in hydraulic bleed circuit.

NOTE :Do not allow clutch master cylinder to run dry while fluid exits bleed port.

10. Close the hydraulic bleed circuit, remove the drain hose and replace the dust cap on bleed port.11. Top off the brake master cylinder fluid level with DOT 4 brake fluid as necessary.

CAUTION:Make sure the brake master cylinder fluid in bleeding process is always full.


08


DRIVELINE & AXLE

09CONTENTS

pageFront Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-1

Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-8

FRONT AXLE


DIAGNOSIS & TESTING 09-4Vehicle Inspection 09-4Noise Or Vibration On Turns 09-4Clunking Noise During Acceleration 09-4

Shudder Or Vibration During Acceleration 09-4Vibration At Highway Speeds 09-4


Front Hub and Bearing 09-5Removal & Installation 09-5

Front Axle Shaft 09-5Removal & Installation 09-5

09



This vehicle is equipped with an unequal length half shaft system consisting of short left and long right half shafts.The half shafts consist of a fixed Constant Velocity (CV) joint at the outboard end connected by a solid shaft to aplunging CV joint on the inboard end. The inner CV joint has a splined end and is attached to the transaxle and isretained with a snap ring. The outer joint has a splined connection to the wheel hub and is retained with a lock nut.

OperationThe front axle transmits torque from the transaxle to the wheels. In order to allow vertical and horizontal movementof the wheels, the axle shafts have plunging CV joints on the inboard ends of the axle shafts.

1 - Left Brake Rotor

2 - Left Strut Assembly

3 - Left Front Axle Shaft

4 - Right Front Axle Shaft

5 - Steering Gear

6 - Right Strut Assembly

7 - Right Brake Rotor

VISM090001


Specifications



Axle Shaft Hub Nut 270

Brake Caliper Adapter To Steering Knuckle Bolts 85 ± 5

Brake Caliper To Adapter Bolts 22 ± 1

Dust Shield Bolts 8 ± 1

Steering Knuckle to Strut Assembly Bolt 120 ± 10

Wheel Mounting Nuts 110

GENERAL INFORMATION

09


DIAGNOSIS & TESTINGVehicle InspectionInspect the following for leaks or damage:• Check for grease in the vicinity of the inboard tripod joint and outboard CV joint.• Check the inner or outer joint seal boot or seal boot clamp for damage.

Noise Or Vibration On TurnsA clicking noise or a vibration in turns could be caused by one of the following conditions:• Damaged outer CV joint or damaged CV seal boot or seal boot clamps.• Damaged inner CV joint or damaged CV seal boot or seal boot clamps.• Noise may also be caused by another component of the vehicle coming in contact with the half shafts.

NOTE :If the CV seal boot is damaged, this will result in the loss and/or contamination of the joint grease, resulting in inad-equate lubrication of the joint.

Clunking Noise During AccelerationThis noise may be a result of one of the following conditions:• A torn seal boot on the inner or outer joint of the half shaft assembly.• A loose or missing clamp on the inner or outer joint of the half shaft assembly.• A damaged or worn half shaft CV joint.

Shudder Or Vibration During AccelerationThis problem could be a result of:• A worn or damaged half shaft inner tripod joint.• Improper wheel alignment.

Vibration At Highway SpeedsThis problem could be a result of:• Foreign material (mud, etc.) packed on the backside of the wheel(s).• Out of balance tires or wheels.• Improper tire or wheel runout.


ON-VEHICLE SERVICE

Front Hub and Bearing

Removal & Installation1. Raise and support the vehicle.2. Remove the wheel mounting nuts and then remove the wheel.

(Tighten: Wheel mounting nuts to 110 N·m)3. Remove the front axle hub nut (1) from the front

knuckle.(Tighten: Front axle hub nut to 270 N·m)

4. Remove the front brake rotor (See Front Brake Rotor Removal & Installation in Section 12 Brakes).5. Using the bearing puller, remove the wheel hub

bearing from the front knuckle.


Front Axle Shaft

Removal & Installation1. Raise and support the vehicle.2. Remove the wheel mounting nuts and the tire and wheel assembly.

(Tighten: Wheel mounting nuts to 110 N·m)

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LTSM090003

09


3. Remove the front wheel speed sensor (1).

4. Remove the front axle hub nut (1) from the frontknuckle.(Tighten: Front axle hub nut to 270 N·m)

5. Remove the front brake caliper (See Front Brake Caliper Removal & Installation in Section 12 Brake).6. Remove the two bolts (1) connecting the steering

knuckle to the front strut assembly.(Tighten: Steering knuckle to front strut mountingbolts to 120 ± 10 N·m)

ON-VEHICLE SERVICE

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LTSM090006

VISM100023


CAUTION:When removing the front axle shaft, do not subject the constant velocity joint to an excessiveangle. Also, be careful not to excessively extend the slide joint.7. Remove the front axle one end from the steering knuckle.8. Remove the front axle shaft other end from the transaxle.9. Pull out the front axle shaft.


Installation Notes:

• Move the CV joint up/down, left/right, and in axial direction, check for any rough movement or significant loose-ness.

• Check the CV seal boot for cracks or other damage, and for grease leakage.• If damaged, disassemble axle shaft to verify damage, and repair or replace as necessary.• After installing the front axle shaft, check the front wheel alignment (See Alignment in Section 10 Suspension).

ON-VEHICLE SERVICE

09


REAR AXLE


DIAGNOSIS & TESTING 09-10Vehicle Inspection 09-10

Vibration At Highway Speeds 09-10


Rear Hub and Bearing 09-11Removal & Installation 09-11


GENERAL INFORMATIONDescriptionThe rear axle utilizes an independent design. This suspension system incorporates a separate wheel knuckle foreach wheel and allows the wheels to react to road imperfections independent of each other. This independent actionoffers improved isolation from the effects of jounce and rebound.

The rear axle consists of the following components:• Wheel hub• Wheel studs• Wheel bearing• Knuckle

OperationThe rear axle utilizes a sealed wheel bearing housed in the rear knuckle assembly.

Specifications



Brake Caliper Adapter To Rear Knuckle Bolts 85

Brake Caliper To Adapter Bolts 22

Rear Axle Hub Nut 230

Wheel Mounting Nuts 110

1 - Rear Knuckle Assembly

2 - Rear Backing Plate

3 - Rear Knuckle Assembly Mounting Nuts

4 - Rear Hub and Bearing Assembly

5 - Rear Brake Rotor

6 - Rear Brake Caliper Bolts

7 - Rear Brake Caliper Assembly

8 - Hub, Rotor and Caliper Assembly

LTSM120002

09


DIAGNOSIS & TESTINGVehicle InspectionInspect the rear axle for the following:• Check the rear axle for loose bearings.• Check the rear axle hub for any damage or excessive runout.• Check the rear bearing for runout.• Check for any noise from the rear bearing while driving the vehicle.

Vibration At Highway SpeedsThis problem could be a result of:• Foreign material (mud, etc.) packed on the backside of the wheel(s).• Out of balance tires or wheels.• Improper tire or wheel runout.


ON-VEHICLE SERVICE

Rear Hub and Bearing

Removal & Installation1. Raise and support the vehicle.2. Remove the wheel mounting nuts and the wheel assembly.

(Tighten: Wheel mounting nuts to 110 N·m)3. Remove the rear brake rotor (See Rear Brake Rotor Removal & Installation in Section 12 Brakes).4. Remove the rear hub and bearing (1).

5. Installation is in the reverse order of the removal.VISM120010

09


SUSPENSION

10CONTENTS

pageFront Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25

Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35

Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43

FRONT SUSPENSION


DIAGNOSIS & TESTING 10-5Vehicle Suspension Troubleshooting Chart 10-5


Front Steering Knuckle 10-6Description 10-6Operation 10-6Removal & Installation 10-6

Front Lower Control Arm 10-8Description 10-8Operation 10-8Removal & Installation 10-8Inspection 10-9

Front Stabilizer Bar Link 10-10Removal & Installation 10-10

Front Stabilizer Bar 10-11Removal & Installation 10-11

Front Strut Assembly 10-12Description 10-12Operation 10-14Diagnosis & Testing 10-14Removal & Installation 10-14

Front Coil Spring 10-15Description 10-15Operation 10-15Removal & Installation 10-15

Sub-Frame Assembly 10-16Removal & Installation 10-16

UNIT REPAIR 10-21

Front Strut 10-21Disassembly 10-21Inspection 10-22Dispose Notices 10-22Assembly 10-23

10


GENERAL INFORMATIONDescriptionThe suspension system incorporates a strut assembly that takes the place of the upper control arm and upper balljoint. The strut carries out the function of a shock absorber and is encompassed by a coil spring. The strut and springassembly supports the weight of the vehicle and is also the pivot point for the steering knuckle. This system uses alower control arm and ball joint for the lower pivot point of the steering knuckle.

1 - Front Strut Assembly

2 - Front Stabilizer Bar Link

3 - Front Stabilizer Bar

4 - Front Sub-Frame

5 - Front Lower Control Arm

6 - Front Steering Knuckle

7 - Front Hub And Bearing

VISM100020


WARNING!

Do not remove the strut rod nut while the strut assembly is installed in the vehicle, or before the coil spring iscompressed with a spring compressor. The spring is held under high pressure and must be compressed beforethe strut rod nut can be removed.

CAUTION:At no time when servicing a vehicle can a sheet metal screw, bolt, or other metal fastener beinstalled in the shock tower to replace the original plastic clip. It may come in contact with thestrut or coil spring.

CAUTION:Wheel bearing damage will result if the vehicle is rolled or the weight of the vehicle is allowed tobe supported by the tires for any length of time with the axle hub nut loose.

OperationThe front suspension utilizes a Macpherson strut system. This suspension system incorporates a strut assembly thattakes the place of the upper arm and ball joint. The strut performs the function of a shock absorber and is encom-passed by a coil spring.

Specifications



Sub-Frame Mounting Bolt 110 ± 10

Dust Shield Bolt 60 ± 5

Lower Ball Joint Nut 120 ± 10

Lower Control Arm Front Pivot Bolt 120 ± 10

Lower Control Arm Rear Pivot Bolt 120 ± 10

Wheel Speed Sensor Bolt 10 ± 1

Stabilizer Bar Mounting Bracket Bolt 20 ± 2

Stabilizer Bar Link Nut 50 ± 5

Steering Knuckle to Strut Assembly Bolt 120 ± 10

Strut Clevis To Steering Knuckle Nut 110 ± 10

Front Strut to Strut Tower Nut 30 ± 3

Front Strut to Steering Knuckle Bolt 110 ± 10

Front Axle Shaft Nut 270 ± 20

Inner Tie Rod Adjuster Jam Nut 35 ± 3

Outer Tie Rod End to Steering Knuckle Nut 35 ± 3

Wheel Mounting Nut 110

GENERAL INFORMATION

10


Special Tools

Ball Joint SeparatorCH-10002

GENERAL INFORMATION


DIAGNOSIS & TESTINGVehicle Suspension Troubleshooting Chart


Front End Whine On Turns· Defective wheel bearing.· Incorrect wheel alignment.· Low power steering fluid level.

· Replace wheel bearing.· Check and reset wheel alignment.· Fill power steering fluid reservoir toproper level and check for leaks(make sure all air is bled from thesystem).

Road Wander

· Incorrect tire pressure.· Incorrect front or rear wheelToe-in.· Worn wheel bearings.· Worn control arm bushings.· Excessive friction in strut upperbearing.

· Inflate tires to recommendedpressure.· Correct front or rear wheel Toe-in.· Replace wheel bearing.· Replace control arm.· Replace strut bearing.

Lateral Pull

· Unequal tire pressure.· Incorrect front wheel camber.· Wheel braking.· Excessive cross-caster.

· Inflate all tires to recommendedpressure.· Check and reset front wheelcamber.· Correct braking condition causinglateral pull.· Check wheel alignment and adjustif necessary.

10


ON-VEHICLE SERVICE

Front Steering Knuckle

DescriptionThe steering knuckle is a single casting with legs machined for attachment to the front strut assembly on the top andsteering linkage on the trailing leading end. The steering knuckle also has two machined, drilled legs on the endcasting to support and align the front disc brake caliper adapter.

OperationThe steering knuckle supports the hub and bearing. The front suspension steering knuckle is not a repairable com-ponent of the front suspension. It must be replaced if found to be damaged in any way. If it is determined that thesteering knuckle is bent when servicing the vehicle, no attempt should be made to straighten the steering knuckle.


NOTE :The following special tools are required to perform the repair procedure:• CH-10002 - Ball Joint Separator

1. Raise and support the vehicle.2. Remove the wheel mounting nuts, then the wheel assembly.

(Tighten: Wheel mounting nuts to 110 N·m)3. While a helper applies the brakes to keep the hub

from rotating, remove the front axle shaft nut.(Tighten: Axle shaft hub nut to 270 ± 20 N·m)

4. Access and remove the Front Brake Rotor (See Front Brake Rotor Remove & Installation in Section 12 Brakes).VISM100022


5. Remove the wheel speed sensor mounting bolt (1)and set it aside.(Tighten: Wheel speed sensor mounting bolt to 10± 1 N·m)

6. Remove the wheel speed sensor.

7. Remove the lower ball joint mounting nut (1)attaching the lower control arm to the knuckle.(Tighten: Lower ball joint mounting nut to120 ± 10 N·m)

8. Remove the nut (1) attaching the outer tie rod endto the steering knuckle.(Tighten: Outer tie rod end to the steering knucklenut to 35 ± 3 N·m)

9. Using the special tool CH-10002, remove the outertie rod end from the steering knuckle.

ON-VEHICLE SERVICE

VISM110003

VISM080029

LTSM110034

10


10. While holding the bolt heads stationary, remove thetwo nuts (1) from the bolts attaching the strutassembly to the steering knuckle.(Tighten: Strut assembly to steering knuckle boltsto 120 ± 10 N·m)

NOTE :Do not allow the half shaft to hang by the inner C/V joint, it must be supported to keep the joint from separatingduring this operation.

11. Pull the knuckle off the half shaft outer C/V joint splines and remove the knuckle from the vehicle.12. Remove the screws fastening the shield to the knuckle. Remove the shield.13. Using the suitable tool, slide the hub and bearing out of the knuckle.14. Installation is in the reverse order of removal.

Front Lower Control Arm

DescriptionThe lower control arm is located between the steering knuckle and the vehicle sub-frame. The lower control arm usesa lower ball joint on the outer end and two sub-frame mounts on the inner end.

OperationThe front lower control arm supports the steering knuckle. The lower control arm controls the vehicle steering bymaintaining the proper wheel alignment through all driving conditions.


NOTE :Inspect the lower control arm for signs of damage from contact with the ground or road debris. If the lower controlarm shows any sign of damage, look for distortion. Do not attempt to repair or straighten a broken or bent lowercontrol arm. If damaged, the lower control arm is serviced only as a complete component.

1. Raise and support the vehicle.2. Remove the wheel mounting nuts and the wheel assembly.

(Tighten: Wheel mounting nuts to 110 N·m)3. Remove the lower ball joint nut (1) from the steer-

ing knuckle, then separate the lower control armball joint from the steering knuckle.(Tighten: Lower ball joint nut to 120 ± 10 N·m)

ON-VEHICLE SERVICE

VISM100023

VISM080029


4. Remove the lower control arm rear pivot bolt (1).(Tighten: Lower control arm rear pivot bolt to120 ± 10 N·m)

5. Remove the lower control arm front pivot bolt (1).(Tighten: Lower control arm front pivot bolt to120 ± 10 N·m)

6. Remove the lower control arm from the sub-frame.7. Installation is in the reverse order of removal.

Inspection1. Check for smooth rotation.2. Inspect ball stud for damage.3. Inspect dust cover for damage or grease leak.4. inspect for play in ball joint, if found defective,

replace the ball joint.

ON-VEHICLE SERVICE

LTSM100055

LTSM100057

VISM100026

10


Front Stabilizer Bar Link


(Tighten: Wheel mounting nuts to 110 N·m)3. Remove the nut (1) connecting the front stabilizer

bar link to the front strut mounting bracket on frontstrut.(Tighten: Front stabilizer link to front strut mountingbracket nut to 50 ± 5 N·m)

4. Remove the bolt (1) connecting the front stabilizerbar link to the front stabilizer bar.(Tighten: Front stabilizer link and the front stabilizerbar nut to 50 ± 5 N·m)


Installation Notes:

• After installation, each bolt must be tightened to the required tightening torque.

ON-VEHICLE SERVICE

LTSM100010

VISM100025


Front Stabilizer Bar


(Tighten: Wheel mounting nuts to 110 N·m)3. Remove the front stabilizer bar link (See Front Stabilizer Bar Link Removal & Installation in Section 10 Suspen-

sion).4. Lower the sub-frame. (See Sub-frame Removal & Installation in Section 10 Suspension).5. Remove the left and right stabilizer bar mounting

bracket to sub-frame bolts (1).(Tighten: Front stabilizer bar mounting bracket boltsto 20 ± 2 N·m)

6. Remove the front stabilizer bar mounting brackets and the rubber bushings.7. Remove the front stabilizer bar.8. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

VISM100004

10


Front Strut Assembly

DescriptionA Macpherson type design strut assembly is used in place of the traditional front suspension upper control arm andupper ball joint. The bottom of the strut mounts directly to the steering knuckle using two attaching bolts and nutsgoing through the strut clevis bracket and steering knuckle. The top of the strut mounts directly to the strut tower ofthe vehicle using the three threaded studs on the strut assembly’s upper mount.

ON-VEHICLE SERVICE


1 - Mounting Nut

2 - Upper Mount

3 - Pivot Bearing

4 - Bearing and Upper Spring Seat

5 - Upper Spring Isolator

6 - Cushion Pad

7 - Plastic Cover

8 - Cushion

9 - Coil Spring

10 - Strut

ON-VEHICLE SERVICE

BESM100012

10


OperationThe strut assembly cushions the ride of the vehicle, controlling vibration, jounce and rebound of the suspension. Thecoil spring controls ride quality and maintains proper ride height. The spring isolators isolate the coil spring at the topand bottom from coming into metal-to-metal contact with the upper mounting seat and the strut. The strut dampensjounce and rebound motions of the coil spring and suspension.

Diagnosis & TestingBefore removing the front strut, perform the following to test the front strut functionality:• Adjust the tire pressure to all tires to proper specifications.• Push and shake the front of the vehicle three or four times with identical force every time• During the pushing and recoiling, the resistance and recoil times of the vehicle should be equal.• If the strut (shock absorber) functions properly, the vehicle will recoil several times and then stop recoiling after

the pushing force is removed.


CAUTION:At no time when servicing a vehicle can a sheet metal screw, bolt or other metal fastener beinstalled into the strut tower to take the place of an original plastic clip. Also, do not drill holes inthe front strut tower for the installation of any metal fasteners.1. Open the engine hood.2. Raise and support the vehicle.3. Remove the wheel mounting nuts and the wheel assembly.

(Tighten: Wheel mounting nuts to 110 N·m)4. Remove the strut-to-tower nuts (1) attaching the

strut assembly upper mount to the strut tower.(Tighten: Strut-to-tower nuts to 30 ± 3 N·m)

5. Remove the nut (1) from the front stabilizer bar linkbracket on the front strut.(Tighten: Front stabilizer bar link bracket nut to50 ± 5 N·m)

ON-VEHICLE SERVICE

BESM100024

LTSM100010


6. Remove the strut to the steering knuckle bolts (1).(Tighten: Strut to steering knuckle bolts to120 ± 10 N·m)

7. Remove the strut assembly from the vehicle.8. Installation is in the reverse order of removal.

Installation Notes:

• After installation, each bolt must be tightened to the required tightening torque.• Four-wheel alignment inspection is required after the installation.

Front Coil Spring

DescriptionA coil-over front strut assembly supports each front coil spring. The top of the strut assembly mounts to the struttower.

OperationCoil springs are designed to store energy and subsequently release it and to absorb shock and maintain a forcebetween contacting surfaces. Coil springs are rated for specific vehicle applications.

NOTE :Each component is serviced by removing the strut assembly from the vehicle and disassembling it. Coil springs arerated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service.If a coil spring requires replacement, be sure that it is replaced with a spring meeting the correct load rating for thevehicle and its specific options.


CAUTION:At no time when servicing a vehicle can a sheet metal screw, bolt or other metal fastener beinstalled into the strut tower to take the place of an original plastic clip. Also, do not drill holes intothe front strut tower for the installation of any metal fasteners into the strut tower area indicated.1. Remove the front strut assembly (See Front Strut Removal & Installation in Section 10 Suspension).

WARNING!

Do not remove the strut rod nut before the coil spring is properly compressed. The coil spring is held underpressure. The coil spring must be compressed, removing spring tension from the upper mount and bearing,before the strut rod nut is removed.

ON-VEHICLE SERVICE

VISM100023

10


2. Position the strut assembly in the strut coil springcompressor following the manufacturer’s instruc-tions and set the lower and upper hooks of thecompressor on the coil spring.

3. Compress the coil spring until all coil spring tensionis removed from the upper mount and bearing.

4. Once the spring is sufficiently compressed, install the strut nut wrench on the strut rod nut.5. Install a deep socket on the end of the strut rod.6. While holding the strut rod, remove the nut using

the strut nut wrench.(Tighten: Strut rod nut to 110 ± 10 N·m)

7. Remove the lower spring isolator from the strut seat.8. Remove the dust shield and jounce bumper.9. Remove the upper mounting bracket.

10. Remove the upper spring seat and isolator.11. Release the tension from the coil spring by backing off the compressor drive completely. Release the compressor

hooks and remove the coil spring.12. Assembly is in the reverse order of disassembly.

Sub-Frame Assembly


Before removing the sub-frame assembly, properly support the engine and transaxle assembly.

1. Raise and support the vehicle.2. Remove the wheel mounting nuts and the tire and wheel assemblies from both sides.

(Tighten: Wheel mounting nuts to 110 N·m)3. Support the engine using an engine support fixture or suitable jack.4. Remove the engine undercover and splash shields.

ON-VEHICLE SERVICE

LTSM100014

LTSM100015

10


5. Remove the intermediate shaft coupling bolt (1).(Tighten: Intermediate shaft coupling bolt to30 ± 3 N·m)

6. Remove the exhaust pipe assembly mounting bolts(1).(Tighten: Exhaust pipe assembly mounting bolts to25 ± 3 N·m)

7. Remove the exhaust pipe assembly (See Exhaust Pipe Removal & Installation in Section 07 Exhaust).8. Remove the wheel speed sensor (1) and set it

aside.(Tighten: Vehicle speed sensor bolts to10 ± 1 N·m)

ON-VEHICLE SERVICE

VISM110005

VISM110016

VISM110003


9. Remove the lower control arm ball joint retainingbolts (1).(Tighten: Lower control arm bolt to 120 ± 10 N·m)

10. On each side of the steering gear, remove the nut(1) attaching the outer tie rod end to the steeringknuckle.(Tighten: Outer tie rod end nut to 35 ± 3 N·m)

NOTE :Using special tool CH-10002, separate the outer tie rod ends from both steering knuckles.

11. Remove the left and right front stabilizer bar links (See Front Stabilizer Bar Link Removal & Installation in Section10 Suspension).

12. Remove the rear transaxle mount bolts (2) and therear transaxle mount bracket bolts (1).(Tighten: Rear transaxle mount bolts to90 ± 5 N·m)

ON-VEHICLE SERVICE

VISM010003

LTSM110034

VISM020003

10


13. Remove the high pressure and low pressure lines(1) from the steering gear.(Tighten: High pressure line to steering gear50 ± 5 N·m)(Tighten: Low pressure line to steering gear50 ± 5 N·m)

14. Remove the power steering lines from the sub-frame.

NOTE :Before removing the front suspension sub-frame from the vehicle, the location of the sub-frame must be marked onthe body of the vehicle. Do this so the sub-frame can be relocated, upon reinstallation, against the body of vehicle inthe same location as before removal. If the front suspension sub-frame is not reinstalled in exactly the same locationas before removal, the preset front wheel alignment settings (caster and camber) may be lost.

15. Use a jack to support the front sub-frame assembly.

ON-VEHICLE SERVICE

LTSM110007


16. Remove the front sub-frame retaining bolts (1) ofeach side.(Tighten: Front sub-frame bolts to 110 ± 10 N·m)

17. Lower the jack with the front sub-frame.18. Remove the steering gear mounting bolts (1).

(Tighten: Steering gear mounting bolts to120 ± 10 N·m)

19. Separate the steering gear.20. Separate the front lower control arm and the front stabilizer bar from sub-frame assembly.21. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

VISM100001

VISM110011

10


UNIT REPAIR

Front Strut

Disassembly

NOTE :The strut assembly must be removed from the vehicle for it to be disassembled and assembled. For the disassemblyand assembly of the strut assembly, use a strut spring compressor, or the equivalent, to compress the coil spring.Follow the manufacturer’s instructions closely.

1. Remove the front strut assembly (See Front Strut Removal & Installation in Section 10 Suspension).2. If both struts are being serviced at the same time, mark both the coil springs and strut assemblies according to

which side of the vehicle the strut is being removed from.

WARNING!

Do not remove the strut rod nut before the coil spring is properly compressed. The coil spring is held underpressure. The coil spring must be compressed, removing spring tension from the upper mount and bearing,before the strut rod nut is removed.

3. If the spring compressor fixture is unable to attachto a workbench, attach the spring compressor to abench vise.

4. Position the strut assembly in the strut coil springcompressor following the manufacturer’s instruc-tions and set the lower and upper hooks of thecompressor on the coil spring.

5. Loosen the spring compressor, then attach theclamps between the top and bottom of the spring.

6. Compress the coil spring until all coil spring tension is removed from the upper mount and bearing.

CAUTION:Never use impact or high speed tools to remove the strut rod nut. Damage to the strut internalbearings can occur.

LTSM100013

LTSM100014


7. Once the spring is sufficiently compressed, installthe strut nut wrench on the strut rod nut.

8. Install a deep socket on the end of the strut rod.While holding the strut rod, remove the nut usingthe strut nut wrench.(Tighten: Strut rod nut to 110 ± 10 N·m)

9. Remove the lower spring isolator from the strut seat.10. Remove the dust shield and jounce bumper.11. Remove the upper mounting bracket.12. Remove the upper spring seat and isolator.13. Release the tension from the coil spring by backing off the compressor drive completely. Release the compressor

hooks and remove the coil spring.

InspectionInspect the strut assembly for damage and evidence of fluid running from the upper end of the fluid reservoir (actualleakage will be a stream of fluid running down the side of the reservoir tube and dripping off lower end of unit).

Inspect the strut assembly components for the following and replace if necessary:• Inspect the dust shield for cracks and tears.• Check the upper mount for cracks and distortion

and its retaining studs for any sign of damage.• Check the bearing and upper spring seat for any

binding.• Inspect the upper and lower spring isolators for

material deterioration and distortion.• Inspect the coil spring for any sign of damage to

the coating.

Dispose Notices

NOTE :Follow the procedure below to properly dispose of the strut assembly.• Pull the strut rod to extend the strut rod out as far as possible.

UNIT REPAIR

LTSM100015

LTSM100011

10


• Drill a hole to discharge the gas in the strut assembly cylinder (Drill a hole in the cylinder body according tothe figure to discharge the gas).

Assembly1. Replace all necessary parts prior to reassembly:

1. Cushion Pad 2. Dust Boot 3. Cushion Block 4. Upper Spring Seat 5. Upper Spring Mount

2. Mount the new strut assembly into the fixture.

3. Insert the coil spring into the spring compressor.4. Compress the coil spring to a distance of ≤120 mm

between the two clamps.

UNIT REPAIR

LTSM100012

LTSM100016

LTSM100017

LTSM100018


5. Ensure the cushion stopper mark (1) is in line withthe mark on the strut .

6. Install the cushion block and pull the piston rod to the bottom.7. Align the coil spring on the bottom spring holder (1)

(the end of the spring should be indexed in thespring pocket).

8. Install the upper spring holder with the index posi-tion of 180° angle between the punched hole andthe spring strut mounting position (1).

9. Install the upper spacer and bearing.10. Install the strut rod nut to the strut rod.

UNIT REPAIR

LTSM100019

LTSM100020

LTSM100021

10


REAR SUSPENSION


DIAGNOSIS & TESTING 10-28Vehicle Inspection 10-28Vibration At High Speed 10-28


Rear Lower Control Arm 10-29Removal & Installation 10-29

Rear Upper Control Arm 10-30Removal & Installation 10-30

Rear Guide Bar 10-30Removal & Installation 10-30

Rear Trailing Arm 10-31Removal & Installation 10-31

Rear Shock Absorber 10-32Description 10-32Operation 10-32Removal & Installation 10-32Inspection 10-33

Rear Coil Spring 10-33Description 10-33Operation 10-33Removal & Installation 10-33

Rear Stabilizer Bar 10-33Removal & Installation 10-33

Rear Stabilizer Bar Link 10-34Removal & Installation 10-34



WARNING!

Only frame contact or wheel lift hoisting equipment can be used on this vehicle. It cannot be hoisted usingequipment designed to lift a vehicle by the rear axle. If this type of hoisting equipment is used, damage to rearsuspension components will occur.

1 - Rear Shock Absorber

2 - Rear Coil Spring

3 - Rear Sub-Frame

4 - Rear Stabilizer Bar Assembly

5 - Rear Lower Control Arm

6 - Rear Guide Bar

7 - Rear Knuckle

8 - Rear Upper Control Arm

9 - Rear Trailing Arm Bracket

10 - Rear Trailing Arm

11 - Rear Stabilizer Bar Link

VISM100002

10


CAUTION:If a rear suspension component becomes bent, damaged or fails, no attempt should be made tostraighten or repair it. Always replace it with a new component.

OperationThe rear suspension utilizes an independent multi-link arm design. This suspension system allows the wheels toreact to road imperfections independent of each other. This independent action offers improved isolation from theeffects of jounce and rebound.

Specifications



Parking Brake Cable Mounting Bolt 10 ± 1

Rear Lower Control Arm Mounting Bolt 90 ± 5

Rear Shock Absorber Lower Mounting Bolt 200 ± 10

Rear Shock Absorber Upper Mounting Nut 35 ± 3

Rear Trailing Arm Mounting Bolt 90 ± 5

Rear Upper Control Arm to The Rear Sub-Frame Bolt 150 ± 10

Rear Upper Control Arm to The Rear Knuckle Bolt 200 ± 10

Rear Guide Bar to The Rear Sub-Frame Bolt 90 ± 5

Rear Guide Bar to The Rear Knuckle Bolt 200 ± 10

Rear Trailing Arm to The Knuckle Bolt 90 ± 5

Rear Trailing Arm to The Trailing Arm Bracket Bolt 90 ± 5

Rear Trailing Arm Bracket to Body Bolt 50 ± 5

Rear Stabilizer Bar Mounting Bracket Bolt 20 ± 2

Rear Stabilizer Bar Link Bolt 50 ± 5

GENERAL INFORMATION


DIAGNOSIS & TESTINGVehicle InspectionInspect the rear axle for the following:• Check the rear axle for loose bearings.• Check the rear axle hub for any damage or excessive runout.

Vibration At High SpeedThis problem could be a result of:• Foreign material (mud, etc.) packed on the backside of the wheel(s).• Out of balance tires or wheels.• Improper tire or wheel runout.

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ON-VEHICLE SERVICE

Rear Lower Control Arm


(Tighten: Wheel mounting nuts to 110 N·m)3. Use a jack to support the lower control arm.4. Remove the rear shock absorber lower mounting

bolt (1).(Tighten: Rear shock absorber lower mounting boltto 200 ± 20 N·m)

5. Remove the rear lower control arm to the rearsteering knuckle retaining bolt (1).(Tighten: Rear lower control arm mounting bolts to90 ± 5 N·m)

6. Lower the jack and remove the rear coil spring.7. Remove the rear lower control arm to the rear sub-

frame mounting bolts (1).(Tighten: Rear lower control arm mounting bolts to90 ± 5 N·m)

8. Remove the rear lower control arm.9. Installation is in the reverse order of removal.

VISM100009

VISM010005

VISM010004


Installation Notes:

• After installing the rear lower control arm, check and adjust the alignment.

Rear Upper Control Arm


(Tighten: Wheel mounting nuts to 110 N·m)3. Remove the rear upper control arm to the rear sub-

frame bolt (1).(Tighten: Rear upper control arm to the rear sub-frame bolt to 150 ± 10 N·m)

4. Remove the rear upper control arm to the steeringknuckle nut (1).(Tighten: Rear upper control arm to the rear sub-frame nut to 200 ± 10 N·m)

5. Remove the rear upper control arm.


Installation Notes:

• After installing the rear upper control arm, check and adjust the alignment.

Rear Guide Bar



ON-VEHICLE SERVICE

VISM100011

VISM100016

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3. Remove the rear guide bar to the rear sub-framebolt (1).(Tighten: Rear guide bar to rear sub-frame bolt to90 ± 5 N·m)

4. Remove the rear guide bar to the rear knuckle bolt(2).(Tighten: Rear guide bar to rear knuckle bolt to200 ± 10 N·m)

5. Remove the rear guide bar.6. Installation is in the reverse order of removal.

Rear Trailing Arm


(Tighten: Wheel mounting nuts to 110 N·m)3. Remove the trailing arm mounting bracket bolts (1).

(Tighten: Trailing arm to the trailing arm mountingbracket bolt to 50 ± 5 N·m)

4. Remove the trailing arm to the rear knuckle bolt(1).(Tighten: Trailing arm to rear knuckle bolt to90 ± 5 N·m)

ON-VEHICLE SERVICE

VISM100013

VISM100005

VISM100006


5. Remove the parking brake cable mounting bolt (1).(Tighten: Parking brake cable mounting bolt to10 ± 1 N·m)

6. Remove the parking brake cable clamp on the rear trailing arm.7. Remove the rear stabilizer bar link to trailing arm bolt.

(Tighten: Rear stabilizer bar link to trailing arm bolt to 50 ± 5 N·m)8. Remove the trailing arm and trailing arm bracket assembly.9. Separate the trailing arm and the trailing arm bracket.

(Tighten: Trailing arm to trailing arm bracket bolt to 90 ± 5 N·m)10. Installation is in the reverse order of removal.

Rear Shock Absorber

DescriptionThe lower shock absorber assembly mounts to the rear knuckle. The upper shock absorber assembly mounts to thebody.

OperationThe shock absorber assembly cushions the ride of the vehicle, controls vibration, jounce and rebound of the sus-pension. The shock absorber dampens jounce and rebound motions of the coil spring and suspension.

Removal & Installation1. Remove the luggage compartment floor mat.2. Remove the rear shock absorber upper mounting

nut.(Tighten: Rear shock absorber upper mounting nutto 35 ± 3 N·m)

ON-VEHICLE SERVICE

VISM100024

VISM100019

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3. Raise and support the vehicle.4. Remove the rear shock absorber to rear knuckle

lower mounting bolt (1).(Tighten: Rear shock absorber to rear knucklelower mounting bolt to 200 ± 10 N·m)

5. Remove the rear shock absorber.6. Installation is in the reverse order of removal.

Inspection1. Inspect shock absorber for oil leakage, replace it if necessary. Then inspect the damping force of the shock

absorber, and replace it if not conform to specification.

Rear Coil Spring

DescriptionThe rear coil spring is located between the vehicle body and the rear lower control arm assembly.

OperationCoil springs are designed to store energy and subsequently release it and to absorb shock and maintain a forcebetween contacting surfaces. Coil springs are rated for specific vehicle applications.


(Tighten: Wheel mounting nuts to 110 N·m)3. Remove the rear shock absorber (See Rear Shock Absorber Removal & Installation in Section 10 Suspension).4. Use a jack to support the rear lower control arm.5. Remove the rear lower control to the rear steering

knuckle retaining bolts (1).(Tighten: Rear lower control arm to rear knucklebolt to 90 ± 5 N·m)

6. Lower the jack and remove the rear coil spring.7. Installation is in the reverse order of removal.

Rear Stabilizer Bar

Removal & Installation1. Raise and support the vehicle.

ON-VEHICLE SERVICE

VISM100009

VISM010005


2. Remove the rear stabilizer bar to rear stabilizer barlink bolt (1).(Tighten: Rear stabilizer bar to rear stabilizer barlink bolt to 50 ± 5 N·m)

3. Remove the rear stabilizer bar mounting bracket torear sub-frame mounting bolts (1).(Tighten: Rear stabilizer bar mounting bracket torear sub-frame mounting bolts to 20 ± 2 N·m)

4. Remove the rear stabilizer bar.5. Installation is in the reverse order of removal.

Rear Stabilizer Bar Link


(Tighten: Wheel mounting nuts to 110 N·m)3. Remove the rear stabilizer bar link to rear stabilizer

bar bolt (2).(Tighten: Rear stabilizer bar link to rear stabilizerbar bolt to 50 ± 5 N·m)

4. Remove the rear stabilizer bar to trailing arm bolt(1).(Tighten: Rear stabilizer bar to trailing arm bolt to50 ± 5 N·m)

5. Remove the rear stabilizer bar link.6. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

VISM100014

VISM100008

VISM100007

10


ALIGNMENT

GENERAL INFORMATION 10-36Description 10-36Operation 10-36Pre-Wheel Alignment Inspection 10-36Wheel Alignment Setup 10-37Specifications 10-38

DIAGNOSIS & TESTING 10-39Vehicle Inspection 10-39Tire Wear 10-39Tire Wear Chart 10-39

Alignment Troubleshooting Chart 10-40


Front Wheel Alignment 10-41Front-axle Toe-in Adjustment 10-41Front Wheel Alignment Specifications 10-41

Rear Wheel Alignment 10-42Rear-axle Camber Adjustment 10-42Rear-axle Toe-in Adjustment 10-42


GENERAL INFORMATIONDescriptionVehicle wheel alignment is the positioning of all interrelated front and rear suspension angles. These angles affect thehandling and steering of the vehicle when it is in motion. Proper wheel alignment is essential for efficient steering,good directional stability, and proper tire wear.

The method of checking a vehicle’s front and rear wheel alignment varies depending on the manufacturer and typeof equipment used. The manufacturer’s instructions should always be followed to ensure accuracy of the alignment.On this vehicle, the suspension angles that can be adjusted are as follows:

Front-axle

• Camber• Toe-in• Caster

Rear-axle

• Camber• Toe-in

Check the wheel alignment and make all wheel alignment adjustments with the vehicle standing at its proper curbheight specification. Curb height is the normal riding height of the vehicle. It is measured from a certain point on thevehicle to the ground or a designated area while the vehicle is sitting on a flat, level surface.

Operation

Curb Height MeasurementThe wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb heightspecification.• Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack.• The tires are to be inflated to the recommended pressure.• All tires are to be the same size as standard equipment.• Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load.• Vehicle height is not adjustable.• If the measurement is not within specifications, inspect the vehicle for bent or weak suspension components.• Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for

a match.• Once removed from the vehicle, compare the coil spring height to a new or known good coil spring. The

heights should vary if the suspect spring is weak.

NOTE :Prior to reading the curb height measurement, the front and rear of the vehicle must be jounced to settle the sus-pension. Induce jounce by pushing down on the center of the bumper (fascia), using care not to damage the vehicle,moving the vehicle up and down, gradually increasing the suspension travel with each stroke. Release the bumper atthe bottom of each stroke, repeating this action several times. Perform this to both front and rear suspensions anequal amount of times.

Pre-Wheel Alignment InspectionBefore any attempt is made to change or correct the wheel alignment, the following inspection and necessary cor-rections must be made to the vehicle to ensure proper alignment.

1. Verify the fuel tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the curb height ofthe vehicle and the alignment specifications.

2. The passenger and luggage compartments of the vehicle should be free of any load that is not factory equip-ment.

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3. Check the tires on the vehicle. The tires are to beinflated to the recommended air pressure. All tiresmust be the same size and in good condition withapproximately the same tread wear.

4. Check the front tire and wheel assemblies for excessive radial runout.5. Inspect all suspension component fasteners for looseness and proper torque.6. Inspect all ball joints and all steering linkage for looseness and any sign of wear or damage.7. Inspect the rubber bushings on all the suspension components for signs of wear or deterioration. If any bushings

show signs of wear or deterioration, they should be replaced prior to aligning the vehicle.8. Check vehicle curb height.

Wheel Alignment Setup1. Position the vehicle on an alignment rack.

2. Install all required alignment equipment on the vehicle, per the alignment equipment manufacturer’s instructions.On this vehicle, a four-wheel alignment is recommended.

3. Read the vehicle’s current front and rear alignment settings. Compare the vehicle’s current alignment settings tothe vehicle specifications for camber, caster and toe-in.

NOTE :Prior to reading the vehicle’s alignment readouts, the front and rear of vehicle should be jounced. Induce jounce (rearfirst, then front) by grasping the center of the bumper and jouncing each end of vehicle an equal number of times.The bumper should always be released when vehicle is at the bottom of the jounce cycle.

GENERAL INFORMATION

LTSM100027

LTSM110026

10


Specifications



Camber Adjustment Bolt 110 ± 10

Inner Tie Rod Adjuster Jam Nut 35 ± 3

Rear Lower Control Arm Eccentric Cam Bolt 120 ± 10

Rear Upper Control Arm Eccentric Cam Bolt 150 ± 10


Front-axle Alignment Specifications

ALIGNMENT ANGLE PREFERRED SETTING ACCEPTABLE RANGE

Camber -24’ -4’ to -44’

Caster +3°57’ +4°27’ to +3°27’

Toe-Individual 0° +10’ to -10’

Rear-axle Alignment Specifications


Camber -20’ 0° to -40’

Toe-Individual -7’ +3’ to -17’

GENERAL INFORMATION


DIAGNOSIS & TESTINGVehicle InspectionInspect the following for damage:• Inspect the tires.• Inspect the rims.

Replace any tire or rim that is found to be damaged.

Tire WearInspect the following for accurate tire wear:• Check the depth of tire remaining tread.• Standard tire: not less than 1.6 mm.• Snow tire: 50% tire tread.

If the tread is below the specifications, the tire should be replaced.

Tire Wear Chart

1 Condition:(1) RapidWear At

Shoulders

(2) RapidWear AtCenter

(3) CrackedTreads

(4) WearOn One

Side

(5)Feathered

Edge

(6) BaldSpots

(7)Scalloped

Wear

2 Effect: (1) Excessive Tire Wear (3) TireDamage

(4) VehiclePulls

(2)ExcessiveTire Wear

(6) PoorTraction

(7)ExcessiveTire Wear

3 Cause:

(8) UnderInflation OrLack OfRotation

(9) OverInflation OrLack OfRotation

(10) UnderInflation OrExcessiveSpeed

(11)ExcessiveCamber

(12)IncorrectToe-in

(13)UnbalancedWheel

(15) LackOf Rotation/ Tires Worn/ Alignment/Suspension

4Correction:

(16) Adjust Tire PressureTo Specifications / RotateTires

(16)ReplaceTire

(17) AdjustCamber ToSpecifications

(18) AdjustToe-In ToSpecifications

(19)BalanceWheels

(20) RotateTires /ReplaceTires /CheckAlignment /Suspension

BESM100022


Alignment Troubleshooting Chart

CONDITION POSSIBLE CAUSES CORRECTIONS

Early Tire Wearing · Incorrect tire pressure.· Incorrect wheel alignment.

· Adjust the tire pressure.· Check the wheel alignment andthen adjust.

Tire Noise · Incorrect tire pressure.· Tire wearing.

· Adjust the tire pressure.· Check the wheel alignment andthen adjust.

Road Noise Or Vehicle BodyVibration

· Incorrect tire pressure.· Unbalanced tire.· Deformation of rim or tire.· Tire wearing.

· Adjust the tire pressure.· Check the wheel alignment andthen adjust.· Repair or install new suspensioncomponent if necessary.

Up-Down Vibration Of The SteeringWheel

· Loose wheel nut or axle.· Unbalanced tire.· Crack or wearing of enginemounting rubber.· Crack or wearing of transmissionbracket rubber.

· Fasten wheel nut.· Check the wheel alignment andthen adjust.· Repair or install new suspensioncomponent if necessary.· Repair or install new engine ortransmission mounting rubber ifnecessary.

Circular Vibration Of The SteeringWheel

· Loose wheel nut or axle.· Unbalanced tire.· Deficient tire pressure.· Damage or wearing of front wheelbearing.· Failure of steering system.

· Fasten wheel nut.· Adjust the tire pressure.· Check the wheel alignment andthen adjust.· Repair or install new suspensioncomponent if necessary.

Steering Wheel Deflecting To SingleSide

· Incorrect tire pressure.· Excessive tire wearing.· Failure of steering system.· Failure of suspension system.

· Adjust the tire pressure.· Check steering system.· Check the wheel alignment andthen adjust.· Repair or install new suspensioncomponent if necessary.

Unstable Driving· Loose wheel nut.· Failure of steering system.· Failure of suspension system.


Heavy Steering Wheel

· Incorrect tire pressure.· Failure of steering system.· Failure of suspension system.· Incorrect wheel alignment.


Bad Alignment Return Of SteeringWheel

· Incorrect tire pressure.· Failure of steering system.· Failure of suspension system.


DIAGNOSIS & TESTING

10


ON-VEHICLE SERVICE

Front Wheel Alignment

Front-axle Toe-in Adjustment

CAUTION:Do not twist the inner tie rod steering gear boot (bellows) while turning the inner tie rod duringfront toe-in adjustment. It may be necessary to remove the clamp where the boot meets the innertie rod.1. Loosen the tie rod adjusting jam nut (1).

(Tighten: Tie rod adjusting jam nut to 35 ± 3 N·m)2. Grasp the inner tie rod shaft and adjust the tie rod

end until the front toe-in is set to specifications.

3. Make sure the inner tie rod steering gear boot is not twisted. If removed, reinstall the clamp where the bootmeets the inner tie rod.

4. Remove the alignment equipment.5. Lower vehicle and jounce the front and rear of the vehicle.

Front Wheel Alignment Specifications

NOTE :The front-axle camber cannot be adjusted.

FRONT WHEEL ALIGNMENT


Camber -24’ -4’ to -44’

Caster +3°57’ +4°27’ to +3°27’

Toe-Individual 0° +10’ to -10’

VISM100021


Rear Wheel Alignment

Rear-axle Camber Adjustment1. While holding the rear lower control arm eccentric

cam bolt (1) stationary, loosen the rear lower con-trol arm eccentric cam bolt.

2. Rotate the eccentric cam bolt left or right until therear wheel toe-in for that rear wheel is set to theproper specification.

3. While holding the rear eccentric cam bolt station-ary, tighten the rear eccentric cam bolt to the spec-ified torque.(Tighten: Rear lower control arm eccentric cam boltto 90 ± 5 N·m)

Rear-axle Toe-in Adjustment1. While holding the rear upper control arm eccentric

cam bolt (1) stationary, loosen the rear upper con-trol arm eccentric cam bolt.

2. Rotate the rear upper control arm eccentric cambolt left or right until the rear wheel camber for thatrear wheel is set to the proper specification.

3. While holding the rear upper control arm eccentriccam bolt stationary, tighten the rear upper controlarm eccentric cam bolt to specified torque.(Tighten: Rear upper control arm eccentric cambolt to 150 ± 10 N·m)

REAR WHEEL ALIGNMENT


Camber -20’ 0° to -40’

Toe-Individual -7’ +3’ to -17’

ON-VEHICLE SERVICE

VISM100012

VISM100011

10


WHEELS AND TIRES


DIAGNOSIS & TESTING 10-45Vehicle Inspection 10-45Tire and Wheel Vibration 10-45Tire Wear Patterns 10-45Wheel Out-Of-Round Inspection 10-45


Tire Replacement & Repair 10-46Description 10-46

Replacement Procedure 10-46Repair Procedure 10-46

Wheel Assembly 10-47Description 10-47Removal & Installation 10-47

Wheel Balance 10-47Description 10-47Wheel Balance Procedure 10-48

Tire Rotation 10-48Description 10-48Non-Directional Tires 10-49Directional Tires 10-49


GENERAL INFORMATIONDescriptionTires are designed and engineered for each specific vehicle. They provide the best overall performance for normaloperation. The ride and handling characteristics match the vehicle’s requirements. With proper care they will giveexcellent reliability, traction, skid resistance, and tread life.

OperationDriving habits have more effect on tire life than any other factor. Careful drivers obtain, in most cases, greater mile-age than drivers whose habits result in severe tire wear and usage. A few of the driving habits which will shorten thelife of any tire are:• Rapid acceleration• Severe application of brakes• High-speed driving• Taking turns at excessive speeds• Striking curbs and other obstacles• Operating vehicle with over or under inflated tire pressures

Specifications




Tire Pressure Specifications

DESCRIPTION STANDARD COLD INFLATION PRESSURE (kPa)

Front Wheel 220

Rear Wheel 200

Spare Wheel 250

Rim Out-Of-Round Specifications

DESCRIPTION MAXIMUM RUN-OUT (mm)

Aluminum Rim 3

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DIAGNOSIS & TESTINGVehicle InspectionVisual inspection of the vehicle is recommended prior to road testing or performing any other procedure. Raise thevehicle on a suitable hoist.

Inspect the following:• Inspect tires and wheels for damage, mud packing and unusual wear; correct if necessary.• Check and adjust tire air pressure to the pressure listed on the label attached to the driver’s door opening.

Tire and Wheel VibrationTire and wheel imbalance, runout and force variation can cause vehicles to exhibit steering wheel vibration.

NOTE :Balance equipment must be calibrated and maintained per equipment manufacturer’s specifications.

Tire Wear PatternsTire wear patterns can be traced to the following tire conditions:• Under inflation will cause wear on the shoulders of tire.• Over inflation will cause wear at the center of tire.• Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the

other.• Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread.

NOTE :Tread wear indicators are molded into the bottom of the tread grooves. When tread depth is 1.6 mm, the tread wearindicators will appear as a band. Tire replacement is necessary when indicators appear in two or more grooves or iflocalized balding occurs.

Wheel Out-Of-Round Inspection• Raise vehicle and securely support it.• Attach a dial indicator on the edge of rim and measure its unevenness.• Replace the rim if necessary.

NOTE :On both edges of the rim, the maximum allowed average value of the unevenness should not exceed the following:

MAXIMUM RIM OUT-OF-ROUND

Aluminum Rim 3 mm


ON-VEHICLE SERVICE

Tire Replacement & Repair

DescriptionTires are designed and engineered for each specific vehicle. They provide the best overall performance for normaloperation. The ride and handling characteristics match the vehicle’s requirements. With proper care they will giveexcellent reliability, traction, skid resistance, and tread life.

WARNING!

Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure.In order to maintain the speed capability of the vehicle, replacement tires must have speed ratings equal to orhigher than those fitted to the vehicle as original equipment. If tires with lower speed ratings are fitted, the vehi-cle’s handling may be affected and the speed capability of the vehicle may be lowered to the maximum speedcapability of the replacement tires. To avoid an accident resulting in severe or fatal injury, consult the tire man-ufacturer in regards to maximum speed ratings.

Replacement ProcedureNote the following guidelines when replacing a tire:• It is recommended that tires equivalent to the original equipment tires be used when replacement is needed.• Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle.• The use of tires smaller than the minimum tire size approved for the vehicle can result in tire overloading and

failure.• Use tires that have the approved load rating for the vehicle and never overload them.• Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure and

loss of vehicle control.• The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and

steering travel, interference with vehicle components may cause tire damage.

Perform the following when replacing a tire:

1. Raise and support the vehicle.2. Remove the wheel mounting nuts and the wheel assembly.3. Deflate the tire completely before removing the tire from the wheel.4. Use lubrication such as a mild soap solution when dismounting or mounting tire.5. Replace the tire with a tire approved for the vehicle.6. Use tools free of burrs or sharp edges which could damage the tire or wheel rim.7. Before mounting the tire on the wheel, make sure all rust is removed from the rim bead and repaint if necessary.8. Balance the wheel assembly.9. Install the wheel assembly and install the wheel mounting nuts.


Repair ProcedureNote the following guidelines when performing a tire repair:• For proper repairing, a radial tire must be removed from the wheel.• Repairs should only be made if the defect, or puncture, is in the tread area.• The tire should be replaced if the puncture is located in the sidewall.

Perform the following when repairing a tire:

1. Raise and support the vehicle.2. Remove the wheel mounting nuts and the wheel assembly.3. Deflate the tire completely before removing the tire from the wheel.4. Use lubrication such as a mild soap solution when dismounting or mounting tire.5. Repair the tire only if the defect, or puncture, is in the tread area.6. Use tools free of burrs or sharp edges which could damage the tire or wheel rim.7. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary.

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8. Install the wheel assembly and install the wheel mounting nuts.(Tighten: Wheel mounting nuts to 110 N·m)

Wheel Assembly

DescriptionOriginal equipment wheels are designed for operation up to the specified maximum vehicle capacity.

Inspect wheels for the following:• Dents or cracks• Damaged wheel bolt holes• Air leaks from any area or surface of the rim• Excessive run out

NOTE :Do not attempt to repair a wheel by hammering, heating or welding.

NOTE :The wheel nuts are designed for specific applications. Do not use replacement fasteners with a different design orlesser quality.

Removal & Installation1. Raise and support the vehicle.2. If the vehicle is equipped with wheel center caps that cover the wheel nuts, remove the cap with an appropriate

removal tool utilizing the notch located between the wheel and the outer edge of the cap.NOTE: Use care not to damage the finish on the wheel.

3. Remove the wheel mounting nuts (2) with the suit-able tool and remove the wheel assembly (1).(Tighten: Wheel mounting nuts to 110 N·m)


Wheel Balance

DescriptionBalance the wheel assembly if necessary following the wheel balancer manufacturer’s instructions.• Road test the vehicle for at least 5 miles.• If the vibration persists, continue with Diagnosis & Testing procedure.

NOTE :• Balance equipment must be calibrated and maintained per equipment manufacturer’s specifications.• Wheel weight must fit the rim.

ON-VEHICLE SERVICE

VISM100031


Wheel Balance Procedure1. Raise and support the vehicle.2. Remove the wheel mounting nuts and the wheel

assembly.3. Perform a dynamic balance test.

NOTE :A wheel requiring 5g or less of weight per side is con-sidered to be within the proper specifications for awheel balance.

4. Install the appropriate wheel weights on the inner(2) and outer (1) edges of the rim until the wheel isbalanced within specifications.

NOTE :Not more than one wheel weight can be attached toeach side of the wheel, with its maximum weight notexceeding 40g.

CAUTION:Use caution not to damage wheel weights dur-ing tire and wheel installation.5. Install the wheel assembly and install the wheel

mounting nuts.(Tighten: Wheel mounting nuts to 110 N·m)

Tire Rotation

DescriptionTires on the front and rear operate at different loads and perform different steering, driving, and braking functions.For these reasons they wear at unequal rates and tend to develop irregular wear patterns. These effects can bereduced by rotating the tires at regular intervals.

The benefits of tire rotation are:• Increase tread life• Maintain traction levels• A smooth, quiet ride

ON-VEHICLE SERVICE

BESM100020

10


Non-Directional Tires

The suggested method of tire rotation is shown. Other rotation methods can be used, but they will not provide all thetire longevity benefits.

NOTE :Only the four-tire rotation method may be used if the vehicle is equipped with a compact or temporary spare tire.

1. Raise and support the vehicle.2. Remove the wheel mounting nuts and the wheel assembly.3. Rotate the tire to the desired location.

CAUTION:Use caution not to damage wheel weights during tire and wheel installation.4. Install the wheel assembly and install the wheel mounting nuts.


Directional TiresSome vehicles may be fitted with special high-performance tires having a directional tread pattern. These tires aredesigned to improve traction on wet pavement. To obtain the full benefits of this design, the tires must be installed sothat they rotate in the correct direction. This is indicated by arrows on the tire sidewalls. When being installed, extracare is needed to ensure that this direction of rotation is maintained.

1. Remove the wheel mounting nuts and the wheel assembly.2. Rotate the tire to the desired location.

CAUTION:Use caution not to damage wheel weights during tire and wheel installation.3. Install the wheel assembly and install the wheel mounting nuts.


ON-VEHICLE SERVICE

BESM100021

10


STEERING

11CONTENTS

pageSteering System - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Steering Column - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8

Steering Gear - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20

Steering System - Electronic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-29

Steering Column - Electronic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-34

Steering Gear - Electronic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45

Electronic Power Steering Electrical Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-55

Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-69

STEERING SYSTEM - HYDRAULIC POWER STEERING

GENERAL INFORMATION 11-2Description 11-2Operation 11-3Special Tools 11-3Specifications 11-3

DIAGNOSIS & TESTING 11-4Power Steering Troubleshooting Chart 11-4

Fluid Troubleshooting Chart 11-5


Power Steering Filling and Flushing 11-6Filling 11-6Flushing 11-6Inspection 11-7 11


GENERAL INFORMATIONDescriptionThe steering system uses a power steering pump which is a constant flow rate and displacement vane type pump.The pump reservoir supplies fluid to the pump body. The pump is connected to the steering gear assembly by thepressure and return hoses. The steering gear used is a rack and pinion type gear.

1 - Power Steering Fluid Reservoir

2 - Power Steering Fluid Return Hose

3 - Power Steering Wheel

4 - Power Steering Column

5 - Power Steering Gear Assembly

6 - Power Steering Fluid Pressure Hose

7 - Power Steering Pump

VISM110009


OperationTurning of the steering wheel is converted into linear travel through the meshing of the helical pinion teeth with therack teeth within the steering gear. The lateral travel pushes and pulls the tie rods to change the direction of thevehicle’s front wheels.

Power assist steering is provided by a belt driven rotary pump. It directs fluid through power steering fluid hoses tothe power steering gear where it is used to assist the driver’s turning effort.

Manual steering control of the vehicle can be maintained if power steering assist is lost. However, under this condi-tion, steering effort is significantly increased.

WARNING!

Power steering fluid, engine components and the exhaust system may be extremely hot if the engine has beenrunning. Do not start the engine with any loose or disconnected hoses. Do not allow hoses to touch the hotexhaust manifold or catalyst. Fluid level should be checked with the engine off to prevent personal injury frommoving parts.

Special Tools

Steering Wheel Puller


Specifications



Power Steering Fluid (ATF III) 1.2

GENERAL INFORMATION

11


DIAGNOSIS & TESTINGPower Steering Troubleshooting ChartReview this troubleshooting chart any time a power steering system problem is present. This chart will help deter-mine if the power steering pump or power steering gear is functioning properly.


Steering Wheel Is Loose

· Steering wheel retaining bolt loose.· Check steering wheel retaining bolttorque and tighten to specifications ifnecessary.

· Loose steering column toinstrument panel fasteners.

· Check steering column toinstrument panel fastener torque andtighten to specifications if necessary.

Steering Catches, Surges Or SticksIn Certain Positions Or Is Difficult ToTurn

· Low power steering fluid level.

· Check fluid level and fill to properlevel if necessary. Check for leaks.Make sure all air is bled fromsystem.

· Tire(s) not properly inflated. · Check and inflate tires to thespecified pressure.

· Loose or slipping power steering/accessory drive belt.

· Verify belt tension. Replace beltauto-tensioner and belt if necessary.

· Lack of lubrication in steering gearouter tie rod end(s). · Check the outlet tie rod ends.

Steering Wheel Does Not Return ToCenter Position


· Improper front wheel alignment. · Check and adjust wheel alignmentif necessary.

Excessive Steering Wheel KickbackFrom Road Inputs

· Air in power steering fluid.

· Inspect for excessive air bubbles influid (fluid will appear foamy andlighter in color). Inspect hoses forleaks and replace if necessary.Bleed air from fluid.

· Power steering gear loose oncradle/Sub-frame.

· Inspect gear mounting bolts.Replace if necessary and tighten tospecifications.

· Steering column, coupling orintermediate shaft worn or loose.

· Rotate steering wheel back-and-forth while inspecting intermediateshaft going into steering gear. Lookfor excessive free-play. Retighten ifloose bolt is found. Replace steeringcolumn, coupling or intermediateshaft if necessary.

· Power steering pump flow is toolow.

· Perform Power Steering Flow andPressure Test. Look for low or erraticflow or pressure. Replace powersteering pump if necessary.


Fluid Troubleshooting Chart

NOTE :Extremely cold temperatures may cause power steering fluid aeration. The air should work its way out of the systemas the fluid warms.


Low Fluid Level With Visible Leak

· Loose power steering hose fittingsor connections.

· Check torque on all tube nuts (atgear and pump). Inspect clamps atall rubber hose connections forcorrect position, damage andtension. Tighten tube nuts tospecifications as required.Reposition or replace clamps athose connections. Clean joints andreinspect for leaks.

· Damaged or missing O-ring atpower steering hose tube nuts.

· Remove tube nut and inspectO-ring. If damaged or missing,replace O-ring. Clean joints andreinspect for leaks.

· Power steering line or hose failure.

· Clean fluid from around suspectareas. Run vehicle and inspect forleaks. Look inside reservoir to see ifair is being ingested. Replace hosesif necessary.

· Power steering component leaking(reservoir, pump or gear).

· Clean fluid from around suspectareas. Run vehicle and inspect forleaks. Look inside reservoir to see ifair is being ingested. Replace powersteering component if necessary.

Aerated Fluid

· Low power steering fluid level.

· Check fluid level and fill to properlevel if necessary. Check for leaks.Make sure all air is bled fromsystem.

· Air leak at power steering supplyhose, reservoir or pump.

· Inspect components. Place a handvacuum pump with reservoir andverify that system can sustainvacuum. System should not losemore than 1 psi in 2 minutes (makesure vacuum pump is sealed well tothe reservoir). Replace steeringcomponent if necessary.

DIAGNOSIS & TESTING

11


ON-VEHICLE SERVICE

Power Steering Filling and Flushing

Filling1. Fill the power steering fluid reservoir to the proper level and let the fluid settle for at least two minutes.2. Start the engine and let it run for a few seconds, then turn the engine off.3. Add fluid if necessary.4. Repeat the above procedure until the fluid level remains constant after running the engine.5. When the steering fluid temperature is relatively high, the steering fluid level will approach to the “MAX” position.6. When the steering fluid cools down, the steering fluid level may approach to the “MIN” position.

NOTE :If the fluid is extremely foamy or milky looking, allow the vehicle to stand a few minutes and repeat the procedure.

Flushing1. Raise and support the vehicle.2. Siphon out the contaminated power steering fluid from the power steering liquid reservoir.3. Remove the power steering fluid return hose from the power steering liquid reservoir.4. Insert the power steering fluid return hose into a container for the discharged power steering fluid.5. Start the engine and idle.6. Fill the power steering fluid reservoir.7. When the return hose discharges clean power steering fluid, stop the engine and install the return hose.8. Slowly turn the steering wheel several times to the right and left, lightly contacting the wheel stops at each turn.

NOTE :Approximately 1.2L of power steering fluid should be needed to fully flush the power steering reservoir.


Inspection1. If the power steering fluid level is low, inspect the entire power steering system for potential leaks.

CAUTION:DO NOT operate the vehicle with foamy steering fluid for an extended period. This may causepump damage.2. Perform the following to inspect the power steering fluid reservoir level:

• Park the vehicle on a level surface.• Start the engine.• Turn the steering wheel several times to heat the power steering fluid to 50 - 60°C.• With the engine running, turn the steering wheel left and right to the wheel stops and repeat this several

times.• Check the power steering fluid reservoir to see whether there is foam or milky fluid present. Check the

fluid level difference between engine off (2)and engine running (1). If the fluid level varia-tion exceeds 5 mm, air is in the system andshould be removed.

ON-VEHICLE SERVICE

LTSM110030

11


STEERING COLUMN - HYDRAULIC POWER STEERING


DIAGNOSIS & TESTING 11-11Vehicle Inspection 11-11Loose Steering / Vehicle Leads / DriftsTroubleshooting Chart 11-11


Steering Wheel 11-12Removal & Installation 11-12Inspection - Hydraulic System 11-12

Steering Column Shroud 11-14Removal & Installation 11-14

Steering Column Shaft 11-16Removal & Installation 11-16


GENERAL INFORMATIONDescriptionThe steering column has been designed so that the wiring, switches, shrouds and steering wheel can be servicedwithout removing the steering column from the vehicle.

OperationThe steering column is the mechanical linkage between the steering wheel and the steering gear. The steering col-umn shaft connects the steering column to the steering gear. The tilt function of the steering column is controlled bya mechanical lever on the underside of the steering column, which uses a cam to lock and unlock the steering col-umn.

1 - Steering Wheel Lock Nut

2 - Steering Wheel

3 - Driver Airbag

4 - Spiral Cable

5 - Steering Column

6 - Adjust Handle

VISM110010

11


Specifications



Steering Wheel Lock Nut 35 ± 5

Special Tools


GENERAL INFORMATION


DIAGNOSIS & TESTINGVehicle InspectionThere is some noise in all power steering systems. One of the most common is a hissing sound. Hiss is a highfrequency noise similar to that of a water tap being closed slowly. The noise is present in all valves that have a highvelocity fluid passing through an orifice. There is no relationship between this noise and steering performance. Thehissing sound is commonly heard during the following operations:• Evident at a standstill• At park with the engine running• With the engine at idle and the steering wheel in the full lock position

Loose Steering / Vehicle Leads / Drifts Troubleshooting Chart


Excessive Play In Steering Wheel

· Worn or loose suspension orsteering components.· Worn or loose wheel bearings.· Steering gear mounting.· Gear out of adjustment.· Worn or loose steering coupler.

· Repair if necessary.· Repair if necessary.· Tighten gear mounting bolts tospecification.· Adjust gear to specification.· Repair if necessary.

Vehicle Pulls To One Side DuringBraking

· Tire pressure.· Air in brake hydraulics system.· Worn brake components.

· Adjust tire pressure.· Bleed brake system.· Repair if necessary.

Vehicle Leads Or Drifts FromStraight Ahead Direction OnUncrowned Road.

· Tire pressure.· Radial tire lead.· Brakes dragging.· Wheel alignment.· Weak or broken spring.· Loose or worn steering/suspensioncomponents.

· Adjust tire pressure.· Rotate front tires side-to-side.· Repair if necessary.· Align vehicle.· Replace spring.· Repair if necessary.

11


ON-VEHICLE SERVICE

Steering Wheel


Before servicing the steering column, the airbag system must be disarmed. Failure to do so may result in acci-dental deployment of the airbag and possible personal injury (See Airbag System Disarming Procedure in Sec-tion 14 Restraints).

NOTE :To help maintain alignment of the spiral cable connector during reassembly, apply a small piece of tape to the spiralcable and the steering column to keep them in alignment.

1. Set the front wheels to straight-ahead position.2. Disconnect the negative battery cable.3. Remove the driver airbag (See Driver Airbag Removal & Installation in Section 14 Restraints).4. Disconnect the spiral cable electrical connector.5. Remove the steering wheel lock nut (1).

(Tighten: Steering wheel lock nut to 35 ± 5 N·m)

6. Using the steering wheel puller, remove the steering wheel.7. Installation is in the reverse order of removal.

Installation Notes:

• The spiral cable could be damaged if installed in an improper position.• Do not rotate the spiral cable quickly or beyond the limit of turns (this can cause the cable to break).• Verify the airbag system is operating properly after the repair is complete.

Inspection - Hydraulic System1. Steering Wheel Free-Play Inspection

• Set the front wheels to straight-ahead position with the engine idling (hydraulic system is working).

VISM110013


• Slightly turn steering wheel to the right and left, and before the wheels begin turning, measure the freeplay of steering wheel.Maximum Limit: 40 mm.

• If the free play exceeds the limit value, inspect the gap between the steering shaft joint and the steeringlinkage, repair or replace the related parts as necessary. If the free play still exceeds the limit value, turnthe steering wheel to the right position with the engine off. Apply 5 N·m of load to the steering wheel andinspect the free-play again.(Standard value: Less than 15 mm steering wheel free play with the engine off)

• If free play exceeds standard value, remove steering gear housing and inspect the gross torque of piniongear.

2. Static Steering Force Inspection• Park the vehicle on a level surface, and turn the steering wheel to the straight-ahead position. Start the

engine, adjust engine speed to 1000 ± 100 RPM.

CAUTION:After adjusting the engine speed, return it back to standard idle speed.

• Connect a spring scale to the outer circle of steering wheel. Measure the steering force required whenturning the steering wheel leftward and rightward (within 1.5 circles) at straight-ahead position. If obvioussteering force fluctuation exists, inspect the steering force as necessary.

− Standard steering force: Less than 34 N·m− Fluctuation tolerance: Less than 5.9 N·m

• If the measured force exceeds the standard value, see the trouble shooting section for inspection andadjustment.

3. Steering Wheel Return to Center InspectionNOTE: This test shall be performed during a road test. The following procedures should be performed during theroad teat:

• Make smooth turns and sharp turns. Check the driving �sense� to ensure there is no difference between the leftand right turns in terms of steering force and the steering wheel returning to center.

• When the vehicle speed is between 20 to 30 km/h turn the steering wheel 90° for 1 or 2 seconds and releasethe steering wheel. If the steering wheel returnsover 70°, the steering wheel return function can beconsidered good.

NOTE :When rapidly turning the steering wheel, there will be a sense of “heavy”, however, this does not indicate a problemwith the steering system (this is due to insufficient steering fluid supplied to the steering fluid pump during idlespeed).

ON-VEHICLE SERVICE

LTSM110025

LTSM110029

11


Steering Column Shroud




1. Disconnect the negative battery cable.2. Remove the driver airbag (See Driver Airbag Removal & Installation in Section 14 Restraints).3. Remove the steering wheel lock nut (1).


ON-VEHICLE SERVICE

VISM110013


4. Using the steering wheel puller, remove the steering wheel.5. Remove 4 retaining bolts (1).

(Tighten: Steering column shroud bolts to10 ± 1 N·m)

6. Press the steering column shroud clamp (1).

7. Remove the steering column shroud.8. Installation is in the reverse order of removal.

Installation Notes:

• The spiral cable could be damaged if installed in an improper position.• Do not rotate the spiral cable quickly or beyond the limit of turns (this can cause the cable to break).• Verify the airbag system is operating properly after the repair is complete.

ON-VEHICLE SERVICE

VISM110017

VISM080028

11


Steering Column Shaft



1. Set the front wheels to straight-ahead position.2. Disconnect the negative battery cable.3. Remove the driver airbag (See Driver Airbag Removal & Installation in Section 14 Restraints).4. Disconnect the spiral cable electrical connector.5. Remove the steering wheel lock nut (1).


6. Using the steering wheel puller, remove the steering wheel.7. Remove the steering column shroud (See Steering Column Shroud Removal & Installation in Section 11 Steer-

ing)8. Remove the lower console side panel retaining

bolts (1).

ON-VEHICLE SERVICE

VISM110013

VISM080027


9. Remove the instrument panel lower shroud retain-ing bolts (1) and remove the lower shroud.

10. Disconnect the multi-function switch and the wiperand washer switch electrical connector.

11. Remove the spiral cable retaining bolts (1) and remove the spiral cable assembly with the switch.12. Disconnect the ignition switch electrical connector.

ON-VEHICLE SERVICE

VISM150144

VISM110004

11


13. Remove the intermediate shaft coupling bolt (1).(Tighten: Intermediate shaft coupling bolt to 30 ± 3N·m)

14. Remove the steering column upper retaining bolts(1).(Tighten: Steering column upper retaining bolts to22 ± 1 N·m)

ON-VEHICLE SERVICE

VISM110005

VISM110001


15. Remove the steering column lower retaining bolts(1).(Tighten: Steering column lower retaining bolts to25 ± 3 N·m)

16. Remove the steering column.17. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

VISM110002

11


STEERING GEAR - HYDRAULIC POWER STEERING


DIAGNOSIS & TESTING 11-22Binding and Sticking TroubleshootingChart 11-22

Insufficient Assist/Poor Return To CenterTroubleshooting Chart 11-22


Steering Gear 11-23Removal & Installation 11-23

Tie Rod 11-28Removal & Installation 11-28


GENERAL INFORMATIONDescriptionThe steering gear used is the rack-and-pinion type with power assist. It is mounted on the front suspension sub-frame. The outer ends of the outer tie rods attach to the front steering knuckles.

NOTE :The power steering gear should not be serviced or adjusted. If a steering gear malfunction or steering gear leakoccurs, the complete steering gear assembly should be replaced.

OperationThe steering wheel turns the pinion. The rack is a long flat bar with teeth on one side. The rack teeth mesh with theteeth on the pinion. Rotation of the pinion moves the rack from left to right and right to left. The tie rod then causesthe wheels to turn to the left or right.

Specifications



Front Sub-Frame and Vehicle Body Connection 110 ± 10

Heat Shield Bolt 10 ±1

Intermediate Shaft Coupling Bolt 30 ± 3

Lower Control Arm Pinch Bolt 120 ± 10

Lower Control Arm Front Mounting Bolt 120 ± 10

Lower Control Arm Rear Mounting Bolt 120 ± 10

Power Steering Hose Routing Clamp Bolt 10 ± 1

Power Steering Pressure Line to Steering Gear 50 ± 5

Power Steering Return Line to Steering Gear 50 ± 5

Pressure/Return Hose Routing Clamp Screws toSub-Frame 10 ± 1

Rear Sub-Frame and Vehicle Body Connection 120 ± 10

Rear Transaxle Mount Bolt 90 ± 5

Steering Gear Mounting Bolt 120 ± 10

Tie Rod End Nut 35 ± 3

Tie Rod Jam Nut 35 ± 3


Special Tools



DIAGNOSIS & TESTINGBinding and Sticking Troubleshooting Chart


Difficult To Turn Steering Wheel,Sticks Or Binds

· Low fluid level.· Tire pressure.· Steering component.· Loose belt.· Low pump pressure.· Column shaft coupler binding.· Steering gear worn or out ofadjustment.· Ball joints binding.· Belt routing.

· Fill to proper level.· Adjust tire pressure.· Inspect and lube.· Adjust or replace.· Pressure test and replace ifnecessary.· Replace coupler.· Repair or replace gear.· Inspect and repair if necessary.· Verify belt routing is correct.

Insufficient Assist/Poor Return To Center Troubleshooting Chart


Hard Turning Or MomentaryIncrease In Turning Effort

· Tire pressure.· Low fluid level.· Loose belt.· Lack of lubrication.· Low pump pressure or flow.· Internal gear leak.· Belt routing.

· Adjust tire pressure.· Fill to proper level.· Adjust or replace.· Inspect and lubricate steering andsuspension components.· Pressure and flow test and repair ifnecessary.· Pressure and flow test, and repairif necessary.· Verify belt routing is correct.


· Tire pressure.· Wheel alignment.· Lack of lubrication.· High friction in steering gear.· Ball joints binding.

· Adjust tire pressure.· Align front end.· Inspect and lubricate steering andsuspension components.· Test and adjust if necessary.· Inspect and repair if necessary.

11


ON-VEHICLE SERVICE

Steering Gear




1. Siphon out as much power steering fluid as possible from the reservoir.2. Disconnect the negative battery cable.3. Position the front wheels of vehicle in the straight-ahead position, turn the ignition switch off, and lock the steer-

ing wheel.4. Remove the lower console side panel retaining

bolts (1).

5. Reposition the floor carpeting to access the intermediate shaft coupling at the base of the steering column.6. Remove the instrument panel lower shroud retain-

ing bolts (1) and remove the lower shroud.

7. Reposition the floor carpeting to access the intermediate shaft coupling at the base of the steering column.

VISM080027

VISM150144



9. Use a service jack to support the engine.10. Raise and support the vehicle.11. Remove both front wheel mounting nuts and the wheel assemblies.

(Tighten: Wheel mounting nuts to 110 N·m)12. Remove the exhaust pipe assembly mounting bolts

(1).(Tighten: Exhaust pipe assembly mounting bolts to25 ± 3 N·m)

13. Remove the exhaust pipe assembly (See Exhaust Pipe Assembly Removal & Installation in Section 07 Exhaust).

ON-VEHICLE SERVICE

VISM110005

VISM110016

11


14. Remove the wheel speed sensor (1) and set aside.(Tighten: Wheel speed sensor bolts to 10 ± 1 N·m)

15. Remove the lower control arm pinch bolts (1).(Tighten: Lower control arm pinch bolt to120 ± 10 N·m)


NOTE :Using special tool CH-10002, separate the outer tie rod ends from both steering knuckles.

ON-VEHICLE SERVICE

VISM110003

VISM080029

LTSM110034


17. Remove the rear transaxle mount bolts (2) and therear transaxle mount bracket bolts (1).(Tighten: Rear transaxle mount bolts to90 ± 5 N·m)

18. Remove the high pressure and low pressure lines(1) from the steering gear.(Tighten: High pressure line to steering gear50 ± 5 N·m)(Tighten: Low pressure line to steering gear50 ± 5 N·m)

19. Remove the power steering lines from the sub-frame.

NOTE :Before removing the front suspension sub-frame from the vehicle, the location of the sub-frame must be marked onthe body of the vehicle. Do this so the sub-frame can be relocated, upon reinstallation, against the body of vehicle inthe same location as before removal. If the front suspension sub-frame is not reinstalled in exactly the same locationas before removal, the preset front wheel alignment settings (caster and camber) may be lost.

20. Use a service jack to support the front sub-frame assembly.

ON-VEHICLE SERVICE

VISM020003

LTSM110007

11


21. Remove the front sub-frame retaining bolts (1) oneach side.(Tighten: Front sub-frame bolts to 110 ± 10 N·m)

22. Lower the service jack with the front sub-frame.23. Remove the steering gear mounting bolts (1).

(Tighten: Steering gear mounting bolts to120 ± 10 N·m)

24. Separate the steering gear.25. Installation is in the reverse order of removal.

Installation Notes:

• After installing the new steering gear, perform a front end alignment procedure to reset the toe-in (See FrontWheel Alignment in Section 10 Suspension).

ON-VEHICLE SERVICE

VISM100001

VISM110011


Tie Rod




(Tighten: Wheel mounting nuts to 110 N·m)3. Loosen the tie rod jam nut (1).

(Tighten: Tie rod jam nut to 35 ± 3 N·m)

4. Remove the nut (1) attaching the outer tie rod endto the steering knuckle.(Tighten: Outer tie rod end nut to 35 ± 3 N·m)

5. Using special tool CH-10002, separate the outer tierod end from the steering knuckle.

6. Remove the outer tie rod end from the steering rack.

NOTE :When removing the outer tie rod end, count the number of revolutions when removing. This will aid in installation,getting the toe setting close to where it needs to be when setting the final toe-in wheel alignment.


Installation Notes:

• After installing the new tie rod end, perform a front end alignment procedure to reset the toe-in (See FrontWheel Alignment in Section 10 Suspension).

ON-VEHICLE SERVICE

VISM100021

LTSM110034

11


STEERING SYSTEM - ELECTRONIC POWER STEERING


DIAGNOSIS & TESTING 11-32Binding & Sticking Troubleshooting Chart 11-32Insufficient Assist/Poor Return to CenterTroubleshooting Chart 11-33


GENERAL INFORMATIONDescriptionThe Electronic Power Steering (EPS) system provides power steering assist to the driver by replacing the conven-tional hydraulic valve system with an electric motor coupled to the steering shaft. The motor is controlled by the EPScontrol unit that senses the steering effort through the use of a torque sensor mounted between the steering columnshaft and the steering gear. Steering assist is provided in proportion to the steering input effort and vehicle speed.

The EPS system consists of these major components:• Steering Wheel (1)• Steering Column (2)• EPS Motor (3)• Steering Clutch• EPS Module (4)• Steering Torque Sensor• Wheel Speed Sensor• Steering Direction Sensor• Steering Gear Assembly (5)

VISM110006

11


OperationThe vehicle speed, which is sent by the Engine Control Module (ECM) over the CAN bus, provides the necessaryvehicle speed information to the electronic power steering system to determine the amount or level of power assist.As vehicle speed increases, the amount of power assist provided by the system is reduced to improve and enhanceroad feel at the steering wheel. If the vehicle speed is missing or out of range, the Electronic Power Steering (EPS)control unit defaults to a reduced level of assist. If the vehicle speed returns to the correct in-range values, the EPScontrol unit adjusts the steering assist level accordingly.

The EPS control unit manages the electronic power steering system. The power steering control unit receives vehiclespeed information from the ECM via the CAN bus, the unit also receives information from the steering shaft torquesensor to determine the amount of assist that is needed. At lower speeds, the control unit will provide greater assist.At higher speeds, the control unit will provide less assist. The power steering control unit is part of the steeringcolumn and is not serviceable separately.

Specifications




Special Tools



GENERAL INFORMATION


DIAGNOSIS & TESTINGBinding & Sticking Troubleshooting Chart




· Loose Steering Column toInstrument Panel Fasteners.






· Power steering gear loose oncradle/Sub-frame.




11


Insufficient Assist/Poor Return to Center Troubleshooting ChartReview this troubleshooting chart any time an electronic power steering system problem is present. This chart willhelp determine if the power steering pump or power steering gear is functioning properly.


Steering Has No Power Assist

· Loose electrical connector. · Verify the wiring connectors arecorrectly connected.

· Open system fuse. · Replace the fuse.

· Relay damaged. · Replace the relay.

· EPS control unit or electronicpower steering motor damaged.

· Replace the EPS control unit orelectronic power steering motor.

Steering Power Assist Is DifferentWhen Turning to Right and Left

· Steering torque sensor outputvoltage has deviation

· Adjust the steering torque sensorpositionoutput voltage is 2.5 V ± 0.05 V.

· Control unit or electronic powersteering motor damage


Steering Wheel Turns When Started · Control unit or steering torquesensor damage

· Replace the EPS control unit orsteering torque sensor.

Hard Steering Effort

· Battery voltage low. · Charge battery.

· Electronic power steering motordamaged.

· Replace the electronic powersteering motor.

· Front tire pressure low. · Fill the tires to proper pressurespecifications.

Steering Is Noisy



· Lower steering shaft or steeringgear worn.

· Replace the lower power steeringshaft or replace the steering gear.

· Lower steering shaft to steeringcolumn loose.

· Tighten the retaining bolt tospecifications.

DIAGNOSIS & TESTING


STEERING COLUMN - ELECTRONIC POWER STEERING


DIAGNOSIS & TESTING 11-37Vehicle Inspection 11-37Loose Steering / Vehicle Leads / DriftsTroubleshooting Chart 11-37Insufficient Assist/Poor Return to CenterTroubleshooting Chart 11-38


Steering Wheel 11-39Removal & Installation 11-39

Steering Column Shroud 11-40Removal & Installation 11-40

Steering Column Shaft 11-41Removal & Installation 11-41

11


GENERAL INFORMATIONDescriptionThe steering column has been designed so that the wiring, switches, shrouds and steering wheel can be servicedwithout removing the steering column from the vehicle.

OperationThe steering column is a mechanical/electronic intelligent linkage between the steering wheel and the steering gear.The steering column shaft then connects the steering column to the steering gear. The tilt function of the steeringcolumn is controlled by a mechanical lever on the underside of the steering column, which uses a cam to lock andunlock the steering column. The electronic power steering motor is controlled by the Electronic Power Steering (EPS)control unit.

1 - Steering Wheel

2 - Steering Wheel Lock Nut

3 - Driver Airbag

4 - Spiral Cable

5 - Steering Column Shaft

6 - Electronic Power Steering Module

7 - Electronic Power Steering Motor

VISM110012


Specifications




Special Tools


GENERAL INFORMATION

11


DIAGNOSIS & TESTINGVehicle InspectionThe Electronic Power Steering (EPS) system requires a 12-volt feed for system operation. The EPS control unit isactivated when power is applied to the ignition/run input. After activation, the EPS control unit monitors the CAN busto determine vehicle speed.

Inspect the following components for electronic power steering concerns:• Fuse or ignition switch• Electronic power steering motor• Electronic power steering unit

Loose Steering / Vehicle Leads / Drifts Troubleshooting Chart


Excessive Play In Steering Wheel

· Worn or loose suspension orsteering components.· Worn or loose wheel bearings.· Worn or loose steering gearmounting.· Gear out of adjustment.· Worn or loose steering coupler.

· Repair if necessary.· Repair if necessary.· Tighten gear mounting bolts tospecification.· Adjust gear to specification.· Repair if necessary.

Vehicle Pulls To One Side DuringBraking

· Tire pressure.· Worn brake components.

· Adjust tire pressure.· Bleed brake system.· Repair if necessary.

Vehicle Leads Or Drifts FromStraight Ahead Direction OnUncrowned Road.

· Tire pressure.· Radial tire lead.· Brakes dragging.· Wheel alignment.· Weak or broken spring.· Loose or worn steering/suspensioncomponents.

· Adjust tire pressure.· Rotate front tires side-to-side.· Repair if necessary.· Align vehicle.· Replace spring.· Repair if necessary.






















Steering Is Noisy







DIAGNOSIS & TESTING

11


ON-VEHICLE SERVICE

Steering Wheel




1. Set the front wheels to straight-ahead position.2. Disconnect the negative battery cable.3. Remove the driver side airbag (See Driver Airbag Removal & Installation in Section 14 Restraints).4. Disconnect the spiral cable electrical connector.5. Remove the steering wheel lock nut (1).


6. Using the steering wheel puller, remove the steering wheel.7. Installation is in the reverse order of removal.

Installation Notes:

• The spiral cable could be damaged if installed in an improper position.• Do not rotate the spiral cable quickly or beyond the limit of turns (this can cause the cable to snap).• Verify the airbag system is operating properly after the repair is complete.

VISM110013


Steering Column Shroud




1. Disconnect the negative battery cable.2. Remove the driver side airbag (See Driver Airbag Removal & Installation in Section 14 Restraints).3. Remove the steering wheel lock nut.

(Tighten: Steering wheel lock nut to 40 N·m)4. Using the steering wheel puller, remove the steering wheel.5. Remove the four retaining bolts (1).

(Tighten: Steering column shroud screws to10 ± 1 N·m)

6. Remove the steering column shroud.7. Installation is in the reverse order of removal.

Installation Notes:

• The spiral cable could be damaged if installed in an improper position.• Do not rotate the spiral cable quickly or beyond the limit of turns (this can cause the cable to snap).• Verify the airbag system is operating properly after the repair is complete.

ON-VEHICLE SERVICE

VISM110017

11


Steering Column Shaft

Removal & Installation1. Set the front wheels to straight-ahead position.2. Disconnect the negative battery cable.3. Remove the driver side airbag (See Driver Airbag Removal & Installation in Section 14 Restraints).4. Disconnect the spiral cable electrical connector.5. Remove the steering wheel lock nut (1).


6. Remove the steering column shroud (See Steering Column Shroud Removal & Installation in Section 11 Steer-ing).

7. Using the steering wheel puller, remove the steering wheel.8. Remove the lower console side panel retaining

bolts (1).


ON-VEHICLE SERVICE

VISM110013

VISM080027

VISM150144


10. Disconnect the multi-function switch and the wiperand washer switch electrical connector.

11. Remove the spiral cable retaining bolts (1) andremove the spiral cable assembly with the switch.

12. Disconnect the ignition switch electrical connector.13. Remove the intermediate shaft coupling bolt (1).

(Tighten: Intermediate shaft coupling bolt to30 ± 3 N·m)

ON-VEHICLE SERVICE

VISM110004

VISM110005

11


14. Remove the steering column upper retaining bolts(1).(Tighten: Steering column upper retaining bolts to21 ± 1 N·m)

15. Remove the steering column lower retaining bolts(1).(Tighten: Steering column lower retaining bolts to25 ± 3 N·m)Remove the steering column.


ON-VEHICLE SERVICE

VISM010006

VISM110008


Installation Notes

• Hold the electronic power steering column in a fixed position (2) & (3) when installing the electronic powersteering column.

CAUTION:Do not hold position (1) when removing orinstalling the electronic power steeringcolumn.

ON-VEHICLE SERVICE

VISM110021

11


STEERING GEAR - ELECTRONIC POWER STEERING


DIAGNOSIS & TESTING 11-48Binding & Sticking Troubleshooting Chart 11-48

Insufficient Assist/Poor Return to CenterTroubleshooting Chart 11-49


Electronic Power Steering Gear 11-50Removal & Installation 11-50

Tie Rod 11-54Removal & Installation 11-54


GENERAL INFORMATIONDescriptionThe steering gear used is the rack-and-pinion type with power assist. It is mounted on the front suspension sub-frame. The outer ends of the outer tie rods attach to the front knuckles.

OperationThe steering wheel turns the pinion. The rack is a long flat bar with teeth on one side. The rack teeth mesh with theteeth on the pinion. Rotation of the pinion moves the rack from left to right and right to left. The tie rod then causesthe wheels to turn to the left or right.

Specifications



Front Sub-Frame and Vehicle Body Connection 110 ± 10

Heat Shield Bolt 10 ± 1

Intermediate Shaft Coupling Bolt 30 ± 3

Lower Control Arm Pinch Bolt 120 ± 10

Lower Control Arm Front Mounting Bolt 120 ± 10

Lower Control Arm Rear Mounting Bolt 120 ± 10


Power Steering Pressure Line To Steering Gear 50 ± 5

Power Steering Return Line To Steering Gear 50 ± 5

Pressure/Return Hose Routing Clamp Screws ToSub-frame 10 ± 1

Rear Sub-Frame And Vehicle Body Connection 120 ± 10

Rear Transaxle Mount Bolt 90 ± 5

Steering Gear Mounting Bolt 120 ± 10

Tie Rod End Nut 35 ± 3

Tie Rod Jam Nut 35 ± 3


Special Tools


11



Steering System (Page 1 of 1)

GENERAL INFORMATION

VISMW110004T


DIAGNOSIS & TESTINGBinding & Sticking Troubleshooting Chart




· Loose steering column toinstrument panel fasteners.






· Power steering gear loose oncradle/sub-frame.




11






















Steering Is Noisy







DIAGNOSIS & TESTING


ON-VEHICLE SERVICE

Electronic Power Steering Gear




1. Disconnect the negative battery cable.2. Position the front wheels of vehicle in the straight-ahead position and turn the ignition switch lock and lock the

steering wheel.3. Remove the lower console side panel retaining

bolts (1).


VISM080027

VISM150144

11



6. Reposition the floor carpeting to access the intermediate shaft coupling at the base of the steering column.7. Use a service jack to support the engine.8. Raise and support the vehicle.9. Remove the wheel mounting nuts and the tire and wheel assemblies from both sides.

(Tighten: Wheel mounting nuts to 110 N·m)10. Remove the exhaust pipe assembly mounting bolts

(1).(Tighten: Exhaust pipe assembly mounting bolts to25 ± 3 N·m)

11. Remove the exhaust pipe assembly (See Exhaust Pipe Assembly Removal & Installation in Section 07 Exhaust).

ON-VEHICLE SERVICE

VISM110005

VISM110016


12. Remove the wheel speed sensor (1).(Tighten: Wheel speed sensor bolts to 10 ± 1 N·m)

13. Remove the lower control arm pinch bolts (1).(Tighten: Lower control arm pinch bolt to120 ± 10 N·m)


NOTE :Using special tool CH-10002, separate the outer tie rodends from both steering knuckles.

ON-VEHICLE SERVICE

VISM110003

VISM080029

LTSM110034

11


15. Remove the rear transaxle mount bolts (2) and thetransaxle mount bracket bolts (1).(Tighten: Rear transaxle mount bolts to90 ± 5 N·m)

16. Use a service jack to support the front sub-frameassembly.

17. Remove the front sub-frame retaining bolts (1).(Tighten: Front sub-frame bolts to 110 ± 10 N·m)

18. Lower the service jack with the front sub-frame.

19. Remove the steering gear mounting bolts (1).(Tighten: Steering gear mounting bolts to120 ± 10 N·m)

20. Remove the steering gear.21. Installation is in the reverse order of removal.

Installation Notes:

• After installing the new steering gear, perform afront end alignment procedure to reset the toe-in(See Front Wheel Alignment in Section 10Suspension).

ON-VEHICLE SERVICE

VISM020003

VISM100001

VISM110011


Tie Rod




(Tighten: Wheel mounting nuts to 110 N·m)3. Loosen the tie rod jam nut (1).

(Tighten: Tie rod jam nut to 35 ± 3 N·m)

4. Remove the nut (1) attaching the outer tie rod endto the steering knuckle.(Tighten: Outer tie rod end nut to 35 ± 3 N·m)

5. Using special tool CH-10002, separate the outer tierod end from the steering knuckle.

6. Remove the outer tie rod end from the steering rack.

NOTE :When removing the outer tie rod end, count the number of revolutions when removing. This will aid in installation,getting the toe setting close to where it needs to be when setting the final toe-in wheel alignment.


Installation Notes:

• After installing the new tie rod end, perform a front end alignment procedure to reset the toe-in (See FrontWheel Alignment in Section 10 Suspension).

ON-VEHICLE SERVICE

VISM100021

LTSM110034

11


ELECTRONIC POWER STEERING ELECTRICALDIAGNOSTICS

GENERAL INFORMATION 11-56Description 11-56Operation 11-56Electrical Schematics 11-57EPS Control Module Pin-Out Table 11-58

DIAGNOSIS & TESTING 11-59Diagnostic Help 11-59Intermittent DTC Troubleshooting 11-59Ground Inspection 11-59Electronic Power Steering (EPS) SystemMaintenance Specification 11-59Diagnostic Tools 11-6011-60

Symptom Diagnostic List 11-60EPS Symptoms 11-60

Diagnostic Trouble Code (DTC) List 11-61EPS Control Module DTC List 11-61

Diagnostic Trouble Code (DTC) Tests 11-62C1323 - ECU Is Faulted, C1324 -Module Configuration Failure, C1325 -Flash Programming Malfunction, U1027- Missing ECU Message 11-62C1901 - Battery Voltage Low, C1902 -Battery Voltage High 11-64


GENERAL INFORMATIONDescriptionThe Electronic Power Steering (EPS) control unit manages the electronic steering system. The EPS control unitreceives vehicle speed information from the Engine Control Module (ECM) via the CAN bus, the EPS control unitalso receives information from the steering shaft torque sensor to determine the amount of assist that is needed. Atlower speeds, the EPS control unit will provide greater assist. At higher speeds, the EPS control unit will provide lessassist. The power steering control unit is part of the steering column and is not serviced separately.

OperationThe Electronic Power Steering (EPS) control unit is self-monitoring and has the capability of setting DTCs. If a faultoccurs in the system, the EPS control unit will set a DTC. Depending on the DTC set, the EPS control unit will enterinto a safe mode and will provide a set amount of assist to the steering system.

11



Electronic Power Steering System (Page 1 of 1)

GENERAL INFORMATION

VISMW110004T


EPS Control Module Pin-Out Table

PIN CIRCUIT IDENTIFICATION

1 IGN

2 CAN-H

3 CAN-L

4 -

5 -

6 GND

7 -

8 -

9 -

10 -

B Continuous Supply Voltage (Motor)

G GND

GENERAL INFORMATION

11


DIAGNOSIS & TESTINGDiagnostic Help1. The X-431 scan tool connects to the Data Link Connector (DLC) and communicates with the Electronic Power

Steering (EPS) control unit through the data network.2. Confirm that the malfunction is current and carry-out the diagnostic tests and repair procedures.3. If the Diagnostic Trouble Code (DTC) cannot be deleted, it is a current fault.4. Use a digital multimeter to perform voltage readings on electronic systems.5. Refer to Technical Bulletins that have been issued.6. Visually inspect the related wiring harness.7. Inspect and clean all EPS control unit grounds that are related to the most current DTC.8. If numerous trouble codes were set, use a wiring schematic and look for any common ground circuits or voltage



age, or foreign material.• A data recorder, and/or oscilloscope should be used to help diagnose intermittent conditions.• Remove the EPS from the troubled vehicle and install in a new vehicle and test. If the DTC cannot be deleted,

the EPS control unit is malfunctioning. If the DTC can be deleted, return the EPS control unit to the originalvehicle.





Electronic Power Steering (EPS) System Maintenance SpecificationThe Electronic Power Steering (EPS) system is a highly accurate and high-powered steering system.

In order to ensure all of the capability and enhance the service life of the steering system, the following guidelinesshould be followed:

1. Keep the battery in good condition: If the battery voltage is low, it will cause hard steering effort.2. All electrical connectors should be properly connected: Proper connector connections will keep moisture and

heat away from the terminals.3. The harness of the EPS system should be routed independently: To ensure the voltage supply capability, the

EPS system harness should be separate from the other electronic control system harnesses.


4. The EPS control unit should not be placed in a wet or a high temperature environment.5. When the steering wheel is at the maximum steering angle, and the steering gear reaches the end of its travel,

electrical current reaches the maximum. The EPS control unit and the EPS actuator will heat quickly under thiscondition. When turning the steering wheel, pay attention not to turn it to the maximum position. When this con-dition cannot be avoided, the maximum time that the steering should be held to the maximum is 3 seconds.Damage to steering components could occur if the time is exceeded.

Diagnostic Tools• Diagnostic Scan Tool X-431• Digital Multimeter• Jumper Wire

Symptom Diagnostic List

EPS SymptomsReview this troubleshooting chart any time an electronic power steering system problem is present. This chart willhelp determine if the power steering pump or power steering gear is functioning properly.











· Control unit or electrical powersteering motor damage









Steering Is Noisy







DIAGNOSIS & TESTING

11



EPS Control Module DTC List

DTC DTC DEFINITION

C1300 Steering Shaft Torque Sensor Malfunction

C1301 Steering Angle Sensor Signal Error

C1302 Steering Angle Sensor Not Trimmed

C1323 ECM Is Faulted

C1324 Module Configuration Failure

C1325 Flash Programming Malfunction

C1350 Electronic Power Steering Motor Malfunction

C1901 Battery Voltage Low

C1902 Battery Voltage High

U1027 Missing ECU Message

U1000 Bus Off Fault

DIAGNOSIS & TESTING



C1323 - ECU Is FaultedC1324 - Module Configuration FailureC1325 - Flash Programming MalfunctionU1027 - Missing ECU Message




C1323 ECU is faulted

Electronic Power Steering(EPS) control unit

detected an internal failureEPS control unit

C1324 Module configurationfailure

C1325 Flash programmingmalfunction

U1027 Missing ECU Message

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the EPS control unit.• Start the engine and warm it to normal operating temperature.• With the scan tool, select view DTC and data stream on the EPS control unit.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-

bleshooting in Section 11 Steering for more information).

DIAGNOSIS & TESTING

11



1. CHECK DTC


Is DTC C1323, C1324, C1325 or U1027 present?


No >> • The conditions that caused this code to set are not present at this time (See Diagnostic Help formore information).

2. CHECK THE EPS CONTROL MODULE POWER SUPPLY AND GROUND CIRCUITS

• Check the EPS control unit voltage supply circuit and ground circuits for an open, high resistance or a shortedcondition.



No >> • Repair the circuit if necessary.

3. CHECK DTC

• With the X-431 scan tool, read EPS control unit DTCs.• Refer to �DTC Confirmation Procedure�.

Is DTC C1323, C1323, C1325 or U1027 still present?

Yes >> • Replace the EPS control unit.


DIAGNOSIS & TESTING


C1901 - Battery Voltage LowC1902 - Battery Voltage High

DIAGNOSIS & TESTING

VISMW110001T

11


DIAGNOSIS & TESTING

VISMW110002T




DTC N0. DTC DEFINITION DTC DETECTIONCONDITION


C1902 Battery voltage high

Ignition switch: ON

Electronic PowerSteering (EPS)control unit detectedthat the batteryvoltage is excessivehigh.

• Charging system• EPS control unit

C1901 Battery voltage low

Electronic PowerSteering (EPS)control unit detectedthat the batteryvoltage is excessivelow.

• Battery• Charging system• Harness is open orshorted• EPS control unit

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the EPS control unit.• Start the engine and warm it to normal operating temperature.• With the scan tool, select view DTC and data stream on the EPS control unit.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-

bleshooting in Section 11 Steering for more information).


connectors for damage.• Troubleshoot any Engine Control Module (ECM) charging/cranking DTCs before proceeding.



• Turn the ignition switch off.• Loosen and retighten ground connectors B-203 and C-202 (See Ground Inspection in Section 11 Steering).• Inspect the ground connection C-202 position (See Vehicle Wiring Harness Information - Main Harness in Sec-

tion 16 Wiring).• Inspect the ground connection B-203 position (See Vehicle Wiring Harness Information - Body Harness in Sec-

tion 16 Wiring).



No >> • Repair the ground connections if necessary.

DIAGNOSIS & TESTING

11


2. CHECK EPS ACTUATOR POWER SUPPLY

• Disconnect the EPS actuator electrical connectorC-008.

• Turn the ignition switch on.• Start the engine.

• Check the EPS actuator power supply circuitbetween terminal 1 in the EPS actuator electricalconnector C-008 terminal side and ground.


Yes >> • Replace and program the EPS controlunit.

No >> • If the voltage is less than 9 V, go tostep 3.

• If the voltage is more than 17 V, go tostep 6.


• Connect the EPS actuator electrical connector.• Start the engine, raise the engine speed to over 1000 RPM.• Measure the charging system voltage with a multimeter at the battery positive and negative terminals.




DIAGNOSIS & TESTING

VISMD110001

VISMD110002


4. CHECK BATTERY

• Maintain the engine speed over 1000 RPM for a few minutes.• Turn the ignition switch off.• Measure the voltage drop with a multimeter between the battery positive and negative terminals while cranking

the engine.• Battery voltage should be more than approximately 9 V.




5. CHECK EPS ACTUATOR SUPPLY CIRCUIT

• Measure the resistance between the EPS actuator electrical connector terminal 1 and battery positive.• Continuity should exist.



No >> • Check fuse.• Check the harness.• Check correlative components.


• Start the engine and raise the engine speed to over 1000 RPM.• Measure the charging voltage with a multimeter at the battery positive and negative terminals.

Is the voltage greater than 17 V?

Yes >> • Replace the generator.


7. CHECK DTC

• With the X-431 scan tool, read EPS control unit DTCs.• Refer to �DTC Confirmation Procedure�.

Is DTC C1901 or DTC C1902 still present?

Yes >> • Replace the EPS control unit.


DIAGNOSIS & TESTING

11


POWER STEERING PUMP


DIAGNOSIS & TESTING 11-71Steering System Noise TroubleshootingChart 11-71Insufficient Assist / Poor Return To CenterTroubleshooting Chart 11-71


Power Steering Pump 11-72Removal & Installation 11-72

Power Steering Fluid Reservoir 11-73Removal & Installation 11-73

Power Steering Pressure and ReturnHoses 11-73



GENERAL INFORMATIONDescriptionThe power steering pump uses hydraulic pressure to operate the power steering gear. The power steering pump isa belt driven droop-flow type power steering pump.

OperationThe power steering pump is mounted to the engine and driven by the engine accessory drive belt. Power steeringfluid enters the pump from the reservoir. The power steering fluid is then trapped between the pump vanes andmoved to the high-pressure side of the pump creating a flow of fluid. The restriction of this flow by the steering gearcreates the pressure that provides the steering assist.

Specifications




Power Steering Pressure Line To Steering Gear 50 ± 5

Power Steering Return Line To Steering Gear 50 ± 5

Power Steering Pressure Line To Power Steering Pump 40 ± 5

Power Steering Return Line To Power Steering Pump 40 ± 5

Power Steering Pump Mounting Bolt 23 ± 2

Pressure/Return Hose Routing Clamp Bolt To Sub-frame 10 ± 1

Power Steering Pump Reservoir Line To Power SteeringPump 10 ± 1



Power Steering Fluid (ATF III) 1.2

11


DIAGNOSIS & TESTINGSteering System Noise Troubleshooting Chart


Hiss Or Whistle Sound WhenTurning Steering Wheel

· Steering intermediate shaft to dashpanel seal.· Noisy valve in power steering gear.

· Check and repair seal at dashpanel.· Replace steering gear.

Rattle Or Clunk

· Gear mounting bolts loose.· Loose or damaged suspensioncomponents.· Loose or damaged steeringlinkage.· Internal gear noise.· Pressure hose in contact withother components.

· Tighten bolts to specification.· Inspect and repair suspension.· Inspect and repair steering linkage.· Replace gear.· Reposition hose.

Chirp Or Squeal · Loose belt.· Belt routing.

· Adjust or replace.· Verify belt routing is correct.

Whine Or Growl

· Low fluid level.· Pressure hose in contact withother components.· Internal pump noise.· Air in the system.

· Fill to proper level.· Reposition hose.· Replace pump.· Perform pump initial operation.

Sucking Air Sound

· Loose return line clamp.· O-ring missing or damaged onhose fitting.· Low fluid level.· Air leak between pump andreservoir.

· Replace clamp.· Replace O-ring.· Fill to proper level.· Repair if necessary.

Scrubbing Or Knocking · Wrong tire size.· Wrong gear.

· Verify tire size.· Verify gear.

Insufficient Assist / Poor Return To Center Troubleshooting Chart


Hard Turning Or MomentaryIncrease In Turning Effort

· Tire pressure.· Low fluid level.· Loose belt.· Lack of lubrication.· Low pump pressure or flow.· Internal gear leak.· Belt routing.

· Adjust tire pressure.· Fill to proper level.· Adjust or replace.· Inspect and lubricate steering andsuspension components.· Pressure and flow test and repair ifnecessary.· Pressure and flow test, and repairif necessary.· Verify belt routing is correct.

Steering Wheel Does Not Want ToReturn To Center Position

· Tire pressure.· Wheel alignment.· Lack of lubrication.· High friction in steering gear.· Ball joints binding.

· Adjust tire pressure.· Align front end.· Inspect and lubricate steering andsuspension components.· Test and adjust if necessary.· Inspect and repair if necessary.


ON-VEHICLE SERVICE

Power Steering Pump

Removal & Installation1. Siphon as much fluid as possible from the power steering fluid reservoir.2. Remove the drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).3. Remove the high pressure line (1) and low pres-

sure line (2) from the power steering pump (drainfluid from lines).(Tighten: High pressure line to power steeringpump 40 ± 5 N·m)(Tighten: Low pressure line to power steering pump40 ± 5 N·m)

4. Remove the three power steering pump mountingbolts (1).(Tighten: Power steering pump mounting bolts to23 ± 2 N·m)

5. Remove the power steering pump.6. Installation is in the reverse order of removal.

BESM110011

LTSM110045

11


Power Steering Fluid Reservoir

Removal & Installation1. Siphon as much fluid as possible from the power steering fluid reservoir.2. Remove the hose clamps securing the return hose and the supply hose to the fluid reservoir fitting.3. Slide the hose off the end of the reservoir fitting.4. Remove the reservoir mounting bolts (1) then

remove power steering fluid reservoir.(Tighten: Power steering fluid reservoir bolts to10 ± 1 N·m)


Power Steering Pressure and Return Hoses

Removal & Installation1. Siphon as much fluid as possible from the power steering fluid reservoir.2. Remove the hose clamps securing the return hose and the supply hose to the fluid reservoir fitting.3. Remove the high pressure line (1) and low pres-

sure line (2) from the power steering pump (drainfluid from lines).(Tighten: High pressure line to power steeringpump 40 ± 5 N·m)(Tighten: Low pressure line to power steering pump40 ± 5 N·m)

ON-VEHICLE SERVICE

VISM110007

BESM110011


4. Remove the high pressure and low pressure lines(1) from the steering gear (drain fluid from lines).(Tighten: High pressure line to power steering gear50 ± 5 N·m)(Tighten: Low pressure line to power steering gear50 ± 5 N·m)

5. Remove the pressure and return hoses mounting bracket bolts.(Tighten: Power steering lines routing clamp bolts to 10 ± 1 N·m)

6. Remove the pressure and return hoses.7. Installation is in the reverse order of the removal.

ON-VEHICLE SERVICE

LTSM110007

11


BRAKES

12CONTENTS

pageBase Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

Antilock Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32

Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-87

BASE BRAKES


DIAGNOSIS & TESTING 12-8Diagnostic Help 12-8Brake Noise 12-9Braking Concerns 12-9


Brake Bleeding Procedure 12-10Brake Bleeding Information 12-10Brake Bleeding Procedure 12-10Manual Bleeding 12-11Pressure Bleeding 12-11

Master Cylinder 12-12Description 12-12Operation 12-12Removal & Installation 12-12

Power Brake Booster 12-13Description 12-13Operation 12-13Removal & Installation 12-13

Front Brake Caliper 12-15Description 12-15Operation 12-16Removal & Installation 12-16

Rear Brake Caliper 12-17Description 12-17Operation 12-17Removal & Installation 12-17

Front Brake Rotor 12-17Removal & Installation 12-17Inspection 12-18

Rear Brake Rotor 12-19Removal & Installation 12-19Inspection 12-20

Front Brake Pads 12-21Removal & Installation 12-21Inspection 12-22

Rear Brake Pads 12-22Removal & Installation 12-22Inspection 12-23

Brake Pedal 12-24Removal & Installation 12-24

Rear Brake Backing Plate 12-25Removal & Installation 12-25

UNIT REPAIR 12-26

Front Brake Caliper 12-26Disassembly 12-26Inspection 12-27Assembly 12-28

Rear Brake Caliper 12-29Disassembly 12-29Inspection 12-30Assembly 12-31

12



Base Brakes

The base brake system consists of the following components:• Power brake booster (1)• Master cylinder (2)• Brake pedal (3)• Disc brakes (front) (4)• Parking brake (5)• Brake tubes and hoses (6)• Disc brakes (rear) (7)

VISM120001


Front Disc Brake

The front disc brake assembly consists of the following major components:• Caliper• Caliper adapter bracket• Brake pads• Rotor

1 - Front Brake Rotor

2 - Front Wheel Hub Assembly

3 - Dust Board Bolt

4 - Dust Board

5 - Brake Caliper Assembly

6 - Front Wheel Knuckle

7 - Front Wheel Knuckle Bearing

GENERAL INFORMATION

VISM120002

12


Rear Disc Brake

The rear disc brake assembly consists of the following major components:• Caliper• Caliper adapter bracket• Brake pads• Rotor• Parking brake shoes

1 - Rear Brake Caliper Assembly

2 - Parking Brake Bracket

3 - Rear Parking Brake Assembly

4 - Rear Bearing

5 - Rear Brake Rotor

6 - Rear Axle Nut

7 - Rear Steering Knuckle Assembly

GENERAL INFORMATION

VISM120003


CAUTION:• Use DOT 4 brake fluid or equivalent from a tightly sealed container. Do not use petroleum-based

fluids, which would cause seal damage in the brake system.• Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash

it off immediately with water.• Never use gasoline, kerosene, alcohol, motor oil, transmission fluid or any fluid containing min-

eral oil to clean system components. These fluids damage rubber cups and seals.• During service procedures, grease or any other foreign material must be kept off the caliper

assembly, brake linings, brake rotor and external surfaces of the hub.• When handling the brake rotor and caliper, be careful to avoid damaging the brake rotor and

caliper, and scratching or nicking the brake shoe lining.

OperationApplying the brake pedal uses lever action to push a rod into the brake booster, which through the use of vacuum,boosts the force of the rod and then transmits this force into the master cylinder. This produces hydraulic pressure inthe master cylinder. On vehicles not equipped with an Antilock Brake System (ABS), the hydraulic pressure is trans-mitted by brake fluid through the brake tubes to the individual brake calipers or wheel cylinders. On vehiclesequipped with ABS, the hydraulic pressure is transmitted by brake fluid through the brake tubes to the ABS HydraulicControl Unit (HCU), which then distributes that pressure to the individual brake calipers and wheel cylinders. Thebrake calipers use hydraulic pressure to apply the brake pads. The application of the brake pads or shoes will causethe rotation of the wheels to slow or stop depending on how much brake pressure is applied. The parking brakescarry out the same function except that they are mechanically actuated by a cable that connects only to the rearbrakes.

Specifications



Axle Shaft Hub Nut 270 ± 20

Brake Disc Mounting Bolt 8 ± 1

Brake Flex Hose Fitting – Front Caliper 17 ± 1

Brake Pedal/Booster Mounting Nut 22 ± 1

Brake Tube Nut 10 ± 1

Disc Brake Caliper Adapter Bracket (To Knuckle) - Front 85 ± 5

Disc Brake Caliper Adapter Bracket (To Support) - Rear 85 ± 5

Disc Brake Caliper Guide Pin Bolt - Front 22 ± 1

Disc Brake Caliper Guide Pin Bolt - Rear 22 ± 1

Disc Brake Caliper Bleeder Bolt 10 ± 1

Fluid Reservoir Mounting Bolt 11 ± 2

Master Cylinder Mounting Nut 25 ± 2

Parking Brake Lever Mounting Nut 30 ± 5

Rear Hub and Bearing Nut 230 ± 10

Rear Dust Shield to Rear Knuckle Bolt 63 ± 1


GENERAL INFORMATION

12


Rotor Specifications

BRAKE ROTOR ROTORTHICKNESS

MINIMUM ROTORTHICKNESS

ROTORTHICKNESSVARIATION

ROTOR RUNOUT

Front Rotor 25 mm 23 mm 0.005 mm 0.025 mm

Rear Rotor 10 mm 7 mm 0.015 mm 0.025 mm

Special Tools

Dial Indicator


GENERAL INFORMATION



Brake System (Page 1 of 1)

GENERAL INFORMATION

VISMW120011T

12


DIAGNOSIS & TESTINGDiagnostic HelpBrake diagnosis involves determining if the concern is related to a mechanical, hydraulic, electrical or vacuum oper-ated component.

NOTE :The brake reservoir fluid level will decrease in proportion to normal lining wear.

NOTE :Brake fluid tends to darken over time. This is normal and should not be mistaken for contamination.

NOTE :Before starting repairs which do not require battery power:• Turn off ignition switch.• Disconnect the negative battery terminal.

Preliminary Brake Check:• Check the condition of the tires and wheels. Damaged wheels and worn, damaged or under inflated tires can

cause a pull, shudder, vibration and a condition similar to brake grab.• If a complaint was based on noise while braking, check the suspension components. Jounce the front and the

rear of vehicle and listen for anything that might be caused by a loose, worn or damaged suspension or steer-ing component.

• Inspect the brake fluid level and condition.1. If the fluid level is abnormally low, look for any evidence of leaks at the calipers, brake lines, master cyl-inder and at the Antilock Brake System (ABS) Hydraulic Control Unit (HCU).2. If the fluid appears to be contaminated, drain a sample to examine.

• The system will have to be flushed if the fluid is separated into layers, or contains a substance other thanbrake fluid. The system seals, cups, hoses, master cylinder and HCU will also have to be replaced after flush-ing. Use clean brake fluid to flush the system.

• Check the parking brake operation. Verify free movement and full release of the cables and the lever. Also noteif the vehicle was being operated with the parking brake partially applied.

• Check the brake pedal operation. Verify that the pedal does not bind and has adequate free play. If the pedallacks free play, check the pedal and the power booster for looseness or for a binding condition. DO NOT roadtest the vehicle until the condition is located and corrected.

• Check the vacuum booster check valve and vacuum supply hose.• If the preliminary checks appear to be OK, road test the vehicle.

Diagnosing Intermittent DTCsWhen diagnosing intermittent DTCs observe the following guide lines:• �Changing� components is not the recommended method to diagnosis an intermittent DTC.• An intermittent DTC is usually caused by chafed, pierced, pinched, or partially broken wires.

There are three ways to isolate an intermittent fault:• Perform a self-check to confirm if the DTC is repeatable.• Allow the engine to reach normal operating temperature.• Drive the vehicle and road test on specific road surfaces to allow any loose components to vibrate to verify the

intermittent faults.• Monitor the scan tool data relative to the circuit in question and wiggle test the wiring and connectors. Look for

the data to change or for the DTC to reset during the wiggle test.


Brake Noise


Disc Brake Chirp · Excessive brake rotor runout.· Small metal particles

· Diagnose and correct asnecessary.

Disc Brake Rattle Or Clunk

· Broken or missing spring clips.· Caliper guide pin bolts loose.· Missing abutment shims.· Small metal particles

· Replace brake pads· Tighten guide pin bolts.· Replace missing abutment shims.

Disc Brake Squeak At Low Speed(While Applying Light Brake PedalEffort)

· Brake shoe linings. · Replace brake pads.

Scraping Or Whirring · ABS wheel speed sensor hittingtone wheel.

· Inspect, correct or replace faultycomponent(s).

Braking Concerns


Excessive Pedal Effort

· Obstruction of brake pedal.· Low power brake booster assist.· Glazed brake linings.· Brake pad lining transfer to brakerotor.

· Inspect, remove or moveobstruction.· Refer to Power Brake Booster inthis section.· Resurface or replace brake rotorsas necessary. Replace brake pads.· Resurface or replace brake rotorsas necessary. Replace brake pads.

Excessive Pedal Effort (Hard Pedal— Cannot Skid Wheels)

· Power brake booster runout(vacuum assist).

· Check booster vacuum hose andengine tune for adequate vacuumsupply.

Excessive Pedal Travel (VehicleStops OK) · Air in brake lines. · Bleed brakes.

Pedal Pulsates/Surges DuringBraking

· Disc brake rotor has excessivethickness variation.

· Isolate condition as rear or front.Resurface or replace brake rotors asnecessary.

Pedal Is Spongy · Air in brake lines. · Bleed brakes.

Vehicle Pulls To Right Or Left OnBraking

· Frozen brake caliper piston.· Contaminated brake pad/shoelining (most likely front lining).· Pinched brake lines.· Leaking piston seal.· Suspension problem.

· Replace frozen piston or caliper.Bleed brakes.· Inspect and clean, or replacepads/shoes. Repair source ofcontamination.· Replace pinched line.· Replace piston seal or brakecaliper.· See the Suspension section.

Parking Brake—Excessive HandleTravel · Rear brakes out of adjustment. · Adjust rear parking brake shoes on

vehicles with rear disc brakes.

DIAGNOSIS & TESTING

12


ON-VEHICLE SERVICE

Brake Bleeding Procedure

Brake Bleeding InformationWARNING!

When bleeding the brake system, wear safety glasses. A clear bleed tube must be attached to the bleederscrews and submerged in a clear container filled partially with clean brake fluid. Direct the flow of brake fluidaway from yourself and the painted surfaces of the vehicle. Brake fluid at high pressure may come out of thebleeder screws when opened.

CAUTION:Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matterfrom dropping into the master cylinder reservoir. Use brake fluid or an equivalent from a fresh,tightly sealed container. Brake fluid must conform to DOT 4 specifications.

NOTE :During the brake bleeding procedure, be sure the brake fluid level remains close to the �MAX� level in the mastercylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add brake fluid asrequired.

NOTE :Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding process. This willonly increase the amount of air in the system and make additional bleeding necessary. Do not allow the mastercylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air intothe brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit sequence forbleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulicsystem.

Brake Bleeding ProcedureThe following wheel circuit sequence for bleeding the brake hydraulic system should be used to ensure adequateremoval of all trapped air from the hydraulic system:• Left rear wheel• Right front wheel• Right rear wheel• Left front wheel


Manual Bleeding

NOTE :To bleed the brakes manually, the aid of a helper will be required.

Attach a clear plastic hose to the bleeder screw andfeed the hose into a clear jar containing enough freshbrake fluid to submerge the end of the hose.

1. Turn the ignition switch off.2. Have a helper pump the brake pedal three or four times and hold it in the down position.3. With the pedal in the down position, open the bleeder screw at least one full turn.4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the

brake pedal.5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times).6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor

the fluid level in the master cylinder reservoir to make sure it does not go dry.7. Check and adjust brake fluid level to the �MAX� mark.8. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be

trapped in the system. Re-bleed the brakes as necessary.9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct.

Pressure Bleeding

NOTE :Follow pressure bleeder manufacturer’s instructions for use of pressure bleeding equipment.

Attach the pressure bleeding equipment to the mastercylinder.


1. Turn the ignition switch off.2. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid.3. After approximately 120-240 ml of fluid have been bled through the brake circuit and an air-free flow is main-

tained in the clear plastic hose and jar, close the bleeder screw.4. Repeat this procedure at all the remaining bleeder screws.5. Check and adjust brake fluid level to the �MAX� mark on the reservoir.6. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be


ON-VEHICLE SERVICE

BESM120001

BESM120001

12


Master Cylinder

DescriptionThe master cylinder body is an anodized aluminum casting. It has a machined bore to accept the master cylinderpistons and also has threaded ports with seats for hydraulic brake tube connections. The master cylinder has thebrake fluid reservoir mounted on top of it and supplies brake fluid to the master cylinder as required. The brake fluidreservoir also feeds the clutch hydraulic circuit. The reservoir is made of clear plastic and it houses the brake fluidlevel switch.

OperationWhen the brake pedal is pressed, the master cylinder pistons apply brake pressure through the chassis brake tubesto each brake assembly. The brake fluid reservoir supplies the brake hydraulic system with the necessary fluid tooperate properly.


CAUTION:The vacuum in the power brake booster must be pumped down before removing the master cyl-inder to avoid damaging the master cylinder and to prevent the booster from sucking in any con-tamination. This can be done by pumping the brake pedal while the engine is not running until afirm brake pedal is achieved.1. Turn the ignition switch off.2. Siphon out as much brake fluid as possible from the master cylinder.3. With the engine off, pump the brake pedal 4-5 strokes until the pedal feel is firm.4. Disconnect the negative battery cable.5. Disconnect the brake fluid level switch electrical connector at the brake fluid reservoir.6. Disconnect the brake tubes (1) at the master cylin-

der outlet ports. Install plugs at all of the openbrake tube outlets on the master cylinder.(Tighten: Brake tube nuts to 10 ± 1 N·m)

7. Remove the clamps (1) and remove the clutchactuator hose off the reservoir port.

ON-VEHICLE SERVICE

VISM120020

VISM120006


8. Clean the area around where the master cylinder attaches to the power brake booster using a suitable brakecleaner such as Brake Parts Cleaner or an equivalent.

9. Remove the two nuts (1) attaching the master cyl-inder to the power brake booster.(Tighten: Master cylinder mounting nuts to25 ± 2 N·m)

10. Slide the master cylinder straight out of the power brake booster.11. Installation is in the reverse order of removal.

NOTE :After installation, bleed the master cylinder or bleed the whole brake system as necessary.

Power Brake Booster

DescriptionThe power brake booster is mounted to the engine compartment side of the dash panel. The master cylinder isbolted to the front of the booster.

OperationA vacuum line connects the check valve to engine source vacuum. The booster input rod extends through the dashpanel and connects to the brake pedal.


CAUTION:The vacuum in the power brake booster must be pumped down before removing the master cyl-inder to avoid damaging the master cylinder and to prevent the booster from sucking in any con-tamination. This can be done by pumping the brake pedal while the engine is not running until afirm brake pedal is achieved.1. Remove the master cylinder (See Master Cylinder Removal & Installation in Section 12 Brakes).2. Disconnect the vacuum hose (1) from the check

valve on the power brake booster.

ON-VEHICLE SERVICE

VISM120013

VISM120021

12


3. Remove the spring-type cotter pin (2) and clevispin (1) from the brake booster rod (3).

4. Remove the nuts (2) attaching the power brakebooster to the dash panel.(Tighten: Brake pedal/Power brake booster mount-ing nuts to 25 N·m)

5. Slide the power brake booster (1) forward until itsmounting studs clear the dash panel, then removeit through the engine compartment.


ON-VEHICLE SERVICE

BESM120009

VISM120014


Front Brake Caliper

Description

1 - Locating Guide Rod

2 - Dust Cap

3 - Brake Gasket

4 - Brake Lining Assembly

5 - Lining Damper

6 - Brake Caliper Bracket

7 - Brake Caliper Body

8 - Bleeding Screw

9 - Dust Cover

10 - Connecting Bolt Of Brake Caliper Body

11 - Piston Dust Cap

12 - Piston

13 - Piston Seal

14 - Brake Caliper Bracket Bolt

The calipers are a single piston type. The calipers are free to slide laterally on the anchor, this allows continuouscompensation for lining wear. The calipers are directly bolted to the wheel hub with mounting bolts. The disc brakerotor dust shield is mounted to the hub.

ON-VEHICLE SERVICE

LTSM120007

12


OperationWhen the brakes are applied, fluid pressure is exerted against the caliper piston. The fluid pressure is exertedequally and in all directions. This means pressure exerted against the caliper piston and within the caliper bores willbe equal. Fluid pressure applied to the pistons is transmitted directly to the inboard brake pad. This forces the padlining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bores forcesthe caliper to slide inward on the slide pins. This action brings the outboard brake pad lining into contact with theouter surface of the disc brake rotor.

Removal & Installation1. Using a brake pedal holding tool, depress the brake pedal past its first 25 mm of travel and hold it in this posi-

tion. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid todrain out of the master cylinder reservoir when the lines are opened.

2. Raise the vehicle.3. Remove the wheel mounting nuts and the tire and wheel assembly.

(Tighten: Wheel mounting nuts to 110 N·m)4. Using a large C-clamp (2), push the caliper piston

to an adequate depth to remove the brake caliper(1) from the brake disc.

5. Remove the front brake hose (2) from the frontbrake caliper.(Tighten: Front caliper brake hose to 17 ± 1 N·m)

6. Remove the front caliper guide pin bolts (3).(Tighten: Front caliper guide pin bolts to 22 ± 1N·m)

7. Slide the front brake caliper (1) from the disc brakeadapter bracket and remove.

8. Remove the disc brake adapter bolts (1) andremove the brake adapter bracket.(Tighten: Disc brake adapter bolts to 85 ± 5 N·m)

ON-VEHICLE SERVICE

LTSM120009

VISM120023

VISM120024



Installation Notes:

• Completely retract the caliper piston back into the bore of the caliper.• After installation bleed the caliper as necessary.

Rear Brake Caliper

DescriptionThe rear disc brakes consist of fixed single piston style calipers and solid rotors. The rear caliper is mounted to therear wheel hub. The calipers are directly bolted to the wheel hub with mounting bolts. The disc brake rotor dust shieldis mounted to the hub. The disc brake rotor has a built in drum used for the parking brakes. The parking brake shoesare mounted to the wheel hub.

OperationWhen the brakes are applied, fluid pressure is exerted against the caliper piston. The fluid pressure is exertedequally and in all directions. This means pressure exerted against the caliper piston and within the caliper bores willbe equal. Fluid pressure applied to the pistons is transmitted directly to the inboard brake pad. This forces the padlining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bores forcesthe caliper to slide inward on the slide pins. This action brings the outboard brake pad lining into contact with theouter surface of the disc brake rotor.

Removal & Installation1. Using a brake pedal holding tool, depress the brake pedal past its first 25 mm of travel and hold it in this posi-

tion. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid todrain out of the master cylinder reservoir when the lines are opened.

2. Raise the vehicle.3. Remove the wheel mounting nuts and the tire and wheel assembly.

(Tighten: Wheel mounting nuts to 110 N·m)4. Remove the banjo bolt (1) connecting the brake

hose to the rear brake caliper (2).(Tighten: Rear caliper banjo bolt to 17 ± 1 N·m)

5. Remove the rear caliper guide pin bolt (3).(Tighten: Rear caliper guide pin bolts to 22 ± 1N·m)

6. Remove rear brake caliper adapter mounting bolts(4).(Tighten: Rear brake caliper adapter mounting boltsto 85 ± 5 N·m)

7. Slide the rear brake caliper (2) from the disc brakeadapter bracket and brake pads and remove.


Installation Notes:

• Completely retract the caliper piston back into the bore of the caliper.• After installation bleed the caliper as necessary.

Front Brake Rotor



ON-VEHICLE SERVICE

VISM120015

12


3. Remove the front brake rotor locating bolt (1).(Tighten: Front brake rotor locating bolt to 8 ± 1N·m)

4. Remove front caliper (2) and adapter (1) together(See Front Caliper Removal & Installation in Sec-tion 12 Brakes).

5. Slide the front brake rotor (3) off the hub and bear-ing.


InspectionExcessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This increases guide pinsleeve wear due to the tendency of the caliper to follow the rotor wobble.

Braking Surface InspectionLight braking surface scoring and wear is acceptable. If heavy scoring or warping is evident, the rotor must be resur-faced or replaced. Excessive wear and scoring of the rotor can cause improper lining contact on the rotor’s brakingsurface. If the ridges on the rotor are not removed before new brake linings are installed, improper wear of the shoeswill result. Some discoloration or wear of the rotor surface is normal and does not require resurfacing when liningsare replaced. If cracks or burned spots are evident, the rotor must be replaced.

Rotor Minimum ThicknessMeasure the rotor thickness (1) at the center of thebrake pad contact surface. Replace the rotor (2) if it isworn below minimum thickness or if machining the rotorwill cause its thickness to fall below specifications.

CAUTION:Do not machine the rotor if it will cause the rotor to fall below minimum thickness.

ON-VEHICLE SERVICE

VISM120028

VISM120026

BESM120004


Rotor Runout1. Install standard wheel mounting nuts, flat side to rotor, on all the wheel bolts (2). Progressively tighten the bolts

in a crisscross pattern to 110 N·m.2. Mount a dial indicator (1), with wheel, or equiva-

lent, to the knuckle. Position the dial indicatorwheel to contact the rotor braking surface approxi-mately 10 mm from the outer edge of the rotor.

3. Slowly rotate the brake rotor (3) checking lateralrunout, marking the low and high spots. Recordthese measurements.

4. Check and record the runout on the opposite sideof the rotor in the same fashion, marking the lowand high spots.

5. Compare runout measurement to specification.6. If runout is in excess of specifications, check the

lateral runout of the hub face.




ROTOR RUNOUT

Front Rotor 25 mm 23 mm 0.005 mm 0.025 mm

Rear Brake Rotor


(Tighten: Wheel mounting nuts to 110 N·m)3. Remove the rear brake rotor locating bolt (1).

(Tighten: Rear brake rotor locating bolt to 8 ± 1N·m)

4. Remove rear caliper (1) and adapter (2) together(See Rear Caliper Removal & Installation in Sec-tion 12 Brakes).

5. Slide the rear brake rotor (3) off the hub and bear-ing.

ON-VEHICLE SERVICE

VISM120016

VISM120029

VISM120017

12



InspectionExcessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This increases guide pinsleeve wear due to the tendency of the caliper to follow the rotor wobble.

Braking Surface InspectionLight braking surface scoring and wear is acceptable. If heavy scoring or warping is evident, the rotor must be resur-faced or replaced. Excessive wear and scoring of the rotor can cause improper lining contact on the rotor’s brakingsurface. If the ridges on the rotor are not removed before new brake linings are installed, improper wear of the shoeswill result. Some discoloration or wear of the rotor surface is normal and does not require resurfacing when liningsare replaced. If cracks or burned spots are evident, the rotor must be replaced.

Rotor Minimum ThicknessMeasure the rotor thickness (1) at the center of thebrake pad contact surface. Replace the rotor (2) if it isworn below minimum thickness or if machining the rotorwill cause its thickness to fall below specifications.

CAUTION:Do not machine the rotor if it will cause the rotor to fall below minimum thickness.

Rotor Runout1. Install standard wheel mounting nuts, flat side to rotor, on all the wheel bolts (2). Progressively tighten the bolts

in a crisscross pattern to 110 N·m.2. Mount a dial indicator (1), with wheel, or equiva-

lent, to the knuckle. Position the dial indicatorwheel to contact the rotor braking surface approxi-mately 10 mm from the outer edge of the rotor.

3. Slowly rotate the brake rotor (3) checking lateralrunout, marking the low and high spots. Recordthese measurements.

4. Check and record the runout on the opposite sideof the rotor in the same fashion, marking the lowand high spots.

5. Compare runout measurement to specification.6. If runout is in excess of specifications, check the

lateral runout of the hub face.




ROTOR RUNOUT

Rear Rotor 10 mm 7 mm 0.015 mm 0.03 mm

ON-VEHICLE SERVICE

BESM120004

VISM120016


Front Brake Pads



NOTE :In some cases, it may be necessary to retract the cal-iper piston in its bore a small amount in order to pro-vide sufficient clearance between the pads and therotor.

3. Remove the front caliper guide pin bolts (1).(Tighten: Front caliper guide pin bolts to 22 ± 1N·m)

4. Remove the disc brake caliper (2) from the discbrake adapter bracket and hang it out of the wayusing wire. Use care not to over extend the brakehose when doing this.

5. Remove the inboard brake pad from the caliper adapter bracket.6. Remove the outboard brake pad from the caliper by prying the brake pad retaining clip over the raised area on

the caliper. Slide the brake pad off of the brake caliper.7. Installation is in the reverse order of removal.

Installation Notes:

• Before installing brake pads, completely retract the caliper piston back into the bore of the caliper.• After installation and before moving the vehicle, pump the brake pedal several times to set the pads to the

brake rotor.• Check and adjust the brake fluid level in the reservoir as necessary.• Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the

brake pads.• After installation and before moving the vehicle, pump the brake pedal several times to set the pads to the

brake rotor.

ON-VEHICLE SERVICE

VISM120032

12


InspectionVisually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration. Check the clear-ance between the tips of the wear indicators (if equipped) on the pads and the brake rotors. If a visual inspectiondoes not adequately determine the condition of the lining, a physical check will be necessary. To check the amountof lining wear, remove the disc brake pads from the vehicle. Measure the brake pad minimum thickness. Brake padsmust be replaced when usable material on a brake pad lining measured at its thinnest point measures one millimeteror less. Replace both disc brake pads (inboard and outboard) at each caliper. It is also necessary to replace the padson the opposite side of the vehicle as well as the pads failing inspection to maintain proper braking characteristics.If the brake pad assemblies do not require replacement, be sure to reinstall the brake pads in the original positionfrom which they were removed.

New Brake Pad Thickness Minimum Brake Pad Thickness

11 mm 1.5 mm

Check the front brake pad thickness.

Rear Brake Pads



NOTE :In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide suf-ficient clearance between the pads and the rotor.

3. Remove the lower rear caliper guide pin bolt (2).(Tighten: Rear caliper guide pin bolt to 22 ± 1 N·m)CAUTION:When moving rear brake caliperupward, use extreme care not to damage oroverextend the flex hose.

4. Rotate the caliper (1) upward hinging off the upperguide pin bolt. Rotate the caliper upward justenough to allow brake pad removal.

ON-VEHICLE SERVICE

LTSM120033

VISM120018


5. Slide the rear brake pads off of the brake caliperadapter.

InspectionVisually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration. Check the clear-ance between the tips of the wear indicators (if equipped) on the pads and the brake rotors. If a visual inspectiondoes not adequately determine the condition of the lining, a physical check will be necessary. To check the amountof lining wear, remove the disc brake pads from the vehicle. Measure the brake pad minimum thickness. Brake padsmust be replaced when usable material on a brake pad lining measured at its thinnest point measures one millimeteror less. Replace both disc brake pads (inboard and outboard) at each caliper. It is also necessary to replace the padson the opposite side of the vehicle as well as the pads failing inspection to maintain proper braking characteristics.If the brake pad assemblies do not require replacement, be sure to reinstall the brake pads in the original positionfrom which they were removed.

New Brake Pad Thickness Minimum Brake Pad Thickness

10.2 mm 1.5 mm

Check the rear brake pad thickness.

ON-VEHICLE SERVICE

LTSM120018

LTSM120033

12


Brake Pedal

Removal & Installation1. Disconnect the negative battery cable.2. Remove the instrument panel lower shroud retain-

ing bolts (1) and remove the instrument panellower shroud.

3. Disconnect the stop lamp switch electrical connector.4. Remove the spring-type cotter pin (2) and clevis

pin (1) from the brake booster rod (3).

5. Remove the nuts (3) attaching the brake pedal (1)and power brake booster to the dash panel.(Tighten: Brake pedal/Power brake booster mount-ing nuts to 25 ± 5 N·m)

6. Remove the retaining nut (2) attaching the brakepedal (1) to the dash panel.(Tighten: Brake pedal/Power brake booster mount-ing nut to 25 ± 5 N·m)

7. Remove the brake pedal (1).8. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

VISM150144

BESM120009

VISM120025


Rear Brake Backing Plate


(Tighten: Wheel mounting nuts to 110 N·m)3. Remove the rear brake caliper (See Rear Brake

Caliper Removal & Installation in Section 12Brake).

4. Remove rear brake rotor (See Rear Brake RotorRemoval & Installation in Section 12 Brakes).

5. Remove the rear hub as show direction.

6. Remove four bolts (1) that mount rear brake back-ing plate to trailing link.(Tighten: Rear brake backing plate bolts to 63 ± 1N·m)

7. Remove the rear brake backing plate assembly.


ON-VEHICLE SERVICE

VISM120030

VISM080035

12


UNIT REPAIR

Front Brake Caliper

DisassemblyBefore disassembling the brake caliper, clean andinspect it.

WARNING!

• Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personalinjury could result from such a practice.

• Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do notuse high pressure.

1. Place a wooden block (1) in the caliper.2. Apply low pressure compressed air to the caliper

fluid inlet port in short spurts to force the pistonout.

3. Remove the piston from the caliper.

4. Remove the dust boot from the piston and discardit.

CAUTION:Do not use a screwdriver or other metal toolfor seal removal. Using such tools can scratchthe bore or leave burrs on the seal grooveedges.

VISM120033

VISM080034

LTSM120010


5. Using a soft tool such as a plastic trim stick (1),work the piston seal (2) out of its groove in caliperpiston bore. Discard the used seal.

6. Clean the piston bore and drilled passage wayswith alcohol or a suitable solvent. Wipe it dry usingonly a lint-free cloth.

Inspection1. Inspect both the piston and bore for scoring or pitting. Bores that show light scratches or corrosion can usually

be cleared of the light scratches or corrosion using crocus cloth.2. Remove deposits on the piston using a soft brass wire brush or a rough shop towel. Do not clean piston with a

polishing or emery cloth because this will damage the chrome-plated surface. Replace the piston if the chromeplated surface is damaged. If the piston is jammed or if the cylinder bores are scored or rusted, replace thecomplete brake caliper. Remove small, light rust spots in the cylinder bore with a polishing cloth. Remove heavyrust spots in front of the groove for the piston seal using fine-grit emery paper (grit size 380 to 500).

3. Inspect the caliper guide sleeves for smooth oper-ation. Repair and grease caliper sleeves asnecessary.

UNIT REPAIR

BESM120003

VISM120035

VISM120033

12


Assembly

NOTE :• Always have clean hands when assembling a brake caliper.• Always use fresh, clean brake fluid when assembling a brake caliper.• Never use an old piston seal.• Bleed the brakes as necessary.

Perform the following procedure to assemble the brake caliper:

1. Lubricate the caliper piston, piston seals and pistonbore with clean brake fluid.

2. Install the new piston seal into the seal groove.

NOTE :Verify seal is fully seated into seal groove and nottwisted.

3. Install the new dust boot on the caliper piston andseat the dust boot lip into the piston groove.

4. Stretch the dust boot rearward to straighten theboot folds, then move the boot forward until thefold snaps into place.

5. Install the piston into the caliper bore and press thepiston down to the bottom of the caliper bore byhand or with the handle of a hammer as showdirection.NOTE: Apply a small amount of air pressure intothe caliper to help during assembly.

CAUTION:When assembling, the force applied to the piston to seat it in the bore, must be applied uniformlyto avoid cocking and binding of the piston.6. Install the new caliper bleed screw.7. Install the caliper (See Front Brake Caliper Removal & Installation in Section 12 Brakes).

UNIT REPAIR

LTSM120014

LTSM120015

LTSM120016


Rear Brake Caliper

DisassemblyBefore disassembling the brake caliper, clean andinspect it.

WARNING!

• Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personalinjury could result from such a practice.

• Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do notuse high pressure.

1. Place a wooden block (1) in the caliper.2. Apply low pressure compressed air to the caliper

fluid inlet in short spurts to force the piston out.3. Remove the piston from the caliper.

4. Remove the dust boot from the piston and discardit.

UNIT REPAIR

VISM120035

VISM080034

LTSM120010

12


CAUTION:Do not use a screwdriver or other metal tool for seal removal. Using such tools can scratch thebore or leave burrs on the seal groove edges.5. Using a soft tool such as a plastic trim stick (1),

work the piston seal (2) out of its groove in caliperpiston bore. Discard the used seal.

6. Clean the piston bore and drilled passage wayswith alcohol or a suitable solvent. Wipe it dry usingonly a lint-free cloth.

Inspection1. Inspect both the piston and bore for scoring or pitting. Bores that show light scratches or corrosion can usually

be cleared of the light scratches or corrosion using crocus cloth.2. Remove deposits on the piston using a soft brass wire brush or a rough shop towel. Do not clean piston with a

polishing or emery cloth because this will damage the chrome-plated surface. Replace the piston if the chromeplated surface is damaged. If the piston is jammed or if the cylinder bores are scored or rusted, replace thecomplete brake caliper. Remove small, light rust spots in the cylinder bore with a polishing cloth. Remove heavyrust spots in front of the groove for the piston seal using fine-grit emery paper (grit size 380 to 500).

3. Inspect the caliper seal rings. Repair the seal ringsas necessary.

UNIT REPAIR

BESM120003

VISM010012

VISM120034


Assembly

NOTE :• Always have clean hands when assembling a brake caliper.• Always use fresh, clean brake fluid when assembling a brake caliper.• Never use an old piston seal.• Bleed the brakes as necessary.

Perform the following procedure to assemble the brake caliper:

1. Lubricate the caliper piston, piston seals and pistonbore with clean brake fluid.

2. Install the new piston seal into the seal groove.

NOTE :Verify seal is fully seated into seal groove and nottwisted.

3. Install the new dust boot on the caliper piston andseat the dust boot lip into the piston groove.

4. Stretch the dust boot rearward to straighten theboot folds, then move the boot forward until thefold snaps into place.

5. Install the piston into the caliper bore and press thepiston down to the bottom of the caliper bore byhand or with the handle of a hammer.NOTE: Apply a small amount of air pressure intothe caliper to help during assembly.

CAUTION:When assembling, the force applied to the piston to seat it in the bore must be applied uniformlyto avoid cocking and binding of the piston.6. Install the new caliper bleed screw.7. Install the caliper (See Front Brake Caliper Removal & Installation in Section 12 Brakes).

UNIT REPAIR

LTSM120014

LTSM120015

LTSM120016

12


ANTILOCK BRAKES

GENERAL INFORMATION 12-33Description 12-33Operation 12-34Specifications 12-34Special Tools 12-35Electrical Schematics 12-36Antilock Brake System (ABS) ModuleConnector Pin-Out Table 12-39

DIAGNOSIS & TESTING 12-40

Diagnostic Help 12-40Diagnostic Help 12-40Ground Inspection 12-40Diagnostic Tools 12-40

Diagnostic Trouble Code (DTC) List 12-41Antilock Brake System DTC List 12-41

Diagnostic Trouble Code (DTC) Tests 12-430X403A0A - Rear Right Wheel SpeedSensor-Signal Erratic 12-430X403A06 - Rear Right Wheel SpeedSensor Open 12-470X40310A - Front Left Wheel SpeedSensor-Signal Erratic 12-510X40340A - Front Right Wheel SpeedSensor-Signal Erratic 12-550X40370A - Rear Left Wheel SpeedSensor-Signal Erratic 12-590X403106 - Front Left Wheel SpeedSensor Open 12-63

0X403406 - Front Right Wheel SpeedSensor Open 12-670X403706 - Rear Left Wheel SpeedSensor Open 12-710X900001 - 12 Volt System SupplyVoltage - Above Maximum Threshold,0X900002 - 12 Volt System SupplyVoltage - Below Minimum Threshold 12-750Xf00003 - Control Module-ComponentInternal Failure 12-80


Antilock Brake System (ABS) BleedingProcedure 12-81

ABS Bleeding Information 12-81ABS Bleeding Instructions 12-81Manual Bleeding Instructions 12-82Pressure Bleeding Instructions 12-82

Antilock Brake System (ABS) HydraulicControl Module 12-83


Yaw Rate Sensor 12-84Removal & Installation 12-84

Front Wheel Speed Sensor 12-85Removal & Installation 12-85

Rear Wheel Speed Sensor 12-86Removal & Installation 12-86



This Antilock Brake System (ABS) uses components of the base brake system, but also features the following com-ponents:• Hydraulic Control Unit (HCU) and Antilock Brake System (ABS) Module• Wheel Speed Sensors (wheel speed sensor) - Four sensors (one sensor at each wheel making it a four-chan-

nel system)

The purpose of the ABS is to prevent wheel lockup under braking conditions on virtually any type of road surface.Antilock braking is desirable because a vehicle that is stopped without locking the wheels retains directional stabilityand some steering capability. This allows the driver to retain greater control of the vehicle during braking.

LTSM120040

12


Operation

ABS Braking

• ABS operation is activated when the ABS hydraulic control module senses a wheel lock-up condition. If a wheellock-up is detected during a brake application, the brake system enters the ABS mode. During ABS braking,hydraulic pressure in the four wheel circuits is modulated to prevent any wheel from locking. Each wheel circuitis designed with a set of electric solenoids to allow modulation. The system can build and release pressure ateach wheel, depending on signals generated by the wheel speed sensors at each wheel and received at theABS hydraulic control module.

• There are a few performance characteristics of the ABS that may at first seem abnormal, but in fact are nor-mal. These characteristics are described below.

− If the electrical system malfunctions, the Fail-Safe function is activated, the ABS becomes inoperative andthe ABS warning lamp turns on.

− During ABS operation, the brake pedal may vibrate lightly and a mechanical noise may be heard. This isnormal.

− Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel, orsnow-covered (fresh, deep snow) roads.

Specifications



ABS Mounting Bolt (To Bracket) 10 ± 1

ABS Mounting Bracket Bolt (To Frame) 20 ± 2

ABS Mounting Bracket Screw And Nut (To Frame) 20 ± 2

ABS Wheel Speed Sensor Head Mounting Bolt - Rear 10 ± 1

Brake Tube Nut 15 ± 3


GENERAL INFORMATION


Special Tools



CAN BUS : Diagnostic Connector

GENERAL INFORMATION

12



Antilock Brake System (Page 1 of 3)

GENERAL INFORMATION

VISMW120013T



GENERAL INFORMATION

VISMW120014T

12



GENERAL INFORMATION

VISMW120015T


Antilock Brake System (ABS) Module Connector Pin-Out Table

PIN CIRCUITIDENTIFICATION PIN CIRCUIT

IDENTIFICATION

1 Continuous SupplyVoltage (Motor) 20 -

2 - 21 -

3 Front Wheel SpeedSensor RH + 22 -

4 Front Wheel SpeedSensor RH - 23 -

5 CAN-H 24 -

6 CAN-L 25 Continuous Supply Voltage

7 Continuous SupplyVoltage 26 -

8 - 27 Front Wheel SpeedSensor LH -

9 - 28 Front Wheel SpeedSensor LH +

10 Rear Wheel SpeedSensor RH - 29 ESP Switch Input

11 Rear Wheel SpeedSensor RH + 30 -

12 - 31 ESP Switch Output

13 GND (Power) 32 -

14 - 33 Ignition Switch

15 - 34 -

16 - 35 Rear Wheel Speed SensorLH -

17 - 36 Rear Wheel Speed SensorLH +

18 - 37 -

19 - 38 GND (Motor)

GENERAL INFORMATION

12


DIAGNOSIS & TESTING

Diagnostic Help

Diagnostic Help1. The X-431 scan tool connects to the Data Link Connector (DLC) and communicates with the vehicle electronic

modules through the class two serial data circuit.2. Confirm that the malfunction is current and carry-out the diagnostic tests and repair procedures.3. If the Diagnostic Trouble Code (DTC) cannot be deleted, it is a current fault.4. Use a digital multimeter to perform voltage readings on electronic systems.5. Refer to any Technical Bulletins that may apply to the failure.6. Visually inspect the related wiring harness.7. Perform a voltage drop test on the related circuits between the suspected component and the ABS module.8. Inspect and clean all ECM, ABS, engine, and chassis grounds that are related to the most current DTC.9. If numerous trouble codes were set, use a wiring schematic and look for any common ground circuits or voltage

supply circuits that may apply to the DTC.10. For any wheel speed sensor DTCs, inspect for dirt/metal debris.11. Use the scan tool to perform a System Test if one applies to the failed component.


age or foreign material.• A data recorder, and/or oscilloscope should be used to help diagnose intermittent conditions.• Remove the ABS module from the troubled vehicle and install in a new vehicle and test. If the DTC can not be

deleted, the ABS module is malfunctioning. If the DTC can be deleted, return the ABS module to the originalvehicle.


Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drasticallyaffect an electronically controlled circuit. A poor or corroded ground can affect the circuit.

Perform the following when inspecting a ground connection:

1. Remove the ground bolt or screw.2. Inspect all mating surfaces for tarnish, dirt, rust, etc.3. Clean as required to assure good contact.4. Reinstall bolt or screw securely.5. Inspect for �add-on� accessories which may be interfering with the ground circuit.6. If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires





Antilock Brake System DTC List

DTC DTC DEFINITION

0x402006 ABS Pump Motor Control- Open/Shorted To Gnd

0x403102 Front Left Wheel Speed Sensor - Below Minimum Threshold

0x403104 Front Left Wheel Speed Sensor - No Signal

0x403105 Front Left Wheel Speed Sensor - Shorted To Gnd

0x403106 Front Left Wheel Speed Sensor - Open

0x403108 Front Left Wheel Speed Sensor - Invalid Signal

0x40310A Front Left Wheel Speed Sensor - Signal Erratic

0x403402 Front Right Wheel Speed Sensor - Below Minimum Threshold

0x403404 Front Right Wheel Speed Sensor - No Signal

0x403405 Front Right Wheel Speed Sensor - Shorted To Gnd

0x403406 Front Right Wheel Speed Sensor - Open

0x403408 Front Right Wheel Speed Sensor - Shorted To Gnd

0x40340A Front Right Wheel Speed Sensor - Signal Erratic

0x403702 Rear Left Wheel Speed Sensor - Below Minimum Threshold

0x403704 Rear Left Wheel Speed Sensor - No Signal

0x403705 Rear Left Wheel Speed Sensor - Shorted To Gnd

0x403706 Rear Left Wheel Speed Sensor - Open

0x403708 Rear Left Wheel Speed Sensor - Invalid Signal

0x40370A Rear Left Wheel Speed Sensor - Signal Erratic

0x403A02 Rear Right Wheel Speed Sensor - Below Minimum Threshold

0x403A04 Rear Right Wheel Speed Sensor - No Signal

0x403A05 Rear Right Wheel Speed Sensor - Shorted To Gnd

0x403A06 Rear Right Wheel Speed Sensor - Open

0x403A08 Rear Right Wheel Speed Sensor - Invalid Signal

0x403A0A Rear Right Wheel Speed Sensor - Signal Erratic

0x404008 Brake Pedal Switch - Invalid Signal

0x404401 Brake Pressure Sensor Principle - Above Maximum Threshold

0x40440A Brake Pressure Sensor Principle - Signal Erratic

0x40440B Brake Pressure Sensor Principle - Step Error

0x40440C Brake Pressure Sensor Principle - Signal Implausible

0x404507 Brake Pressure Sensor Reference - Open/Shorted To +

0x404606 Brake Pressure Sensor Principle/Reference - Open/Shorted To Ground

0x40460D Brake Pressure Sensor Principle/Reference - Missing Calibration

0x405101 Steering Wheel Position Sensor - Above Maximum Threshold

0x40510B Steering Wheel Position Sensor - Step Error

0x40510D Steering Wheel Position Sensor - Missing Calibration

0x406101 Lateral Acceleration Sensor - Above Maximum Threshold

0x406103 Lateral Acceleration Sensor - Component Internal Failure

0x40610B Lateral Acceleration Sensor - Step Error

0x40610C Lateral Acceleration Sensor - Signal Implausible

DIAGNOSIS & TESTING

12


DTC DTC DEFINITION

0x40610D Lateral Acceleration Sensor - Above Maximum Threshold

0x406301 Yaw Rate Sensor - Signal Amplitude Maximum

0x406303 Yaw Rate Sensor - Component Internal Failure

0x40630B Yaw Rate Sensor - Step Error

0x40630C Yaw Rate Sensor - Signal Implausible +N246+N259

0x40630D Yaw Rate Sensor - Above Maximum Threshold

0x406903 Yaw Rate Sensor - Inertial Sensor Cluster Failure

0x40780F Tire Diameter - Incorrect Assembly

0x40890C TC/VSC Disable Switch - Signal Implausible

0x500001 High Power Ground Feed - Above Maximum Threshold

0x50020E Solenoids - Component or System Over Temperature

0x500500 TC Brake Intervention Temporarily Disabled

0x5E0600 Only For Development

0x5E700 Only For Development

0x900001 12 Volt System Supply Voltage - Above Maximum Threshold

0x900002 12 Volt System Supply Voltage - Below Minimum Threshold

0xC00100 High Speed CAN Communication Bus

0xC10000 Lost Communication With ECM/PCM

0xC10100 Lost Communication With TCM

0xC12300 Lost Communication With Yaw Rate Sensor Module

0xC12600 Lost Communication With Steering Angle Sensor

0xC14000 Lost Communication With Body Control Module

0xC15500 Lost Communication With Instrument Panel Cluster (IPC) Control

0xC40100 Invalid Data Received From ECM/PCM

0xC40200 Invalid Data Received From TCM

0xC42200 Invalid Data Received From Body Control Module

0xC42800 Invalid Data Received From Steering Angle Sensor Module

0xC42300 Invalid Data Received From Instrument Panel Cluster (IPC) Control

0xD0000 Invalid Data Received From Yaw Rate Sensor Module

0xE00102 Sensor Cluster - Below Minimum Threshold

0xE0010C Sensor Cluster - Signal Implausible

0xE20000 Car Configuration Sent By FBCM3 Message Is Invalid

0xF00003 Control Module - Component Internal Failure

0xF00100 Control Module Improper Shut Down

0xF00606 Control Module Input Power �Fail safe Relay� - Open/Shorted To Ground

0xF00706 Control Module Input Power �Pump� - Open/Shorted To Ground

0xF00905 Control Module Ground Pump Motor Supply - Open/Shorted To Ground

0xC16400 Lost Communication With A/C Control Module

DIAGNOSIS & TESTING



0X403A0A - Rear Right Wheel Speed Sensor-Signal Erratic

DIAGNOSIS & TESTING

VISMW120007T

12






0X403A0ARear right wheel

speed sensor signalerratic

With the vehiclespeed above 40km/h (25 mph)

When the RearRight Wheel SpeedSensor input signalto the Antilock BrakeSystem (ABS)module isintermittentlymissing whilevehicle speed isabove 40 km/h (25mph), or erraticwheel speed signalduring acceleration,or sensed wheelspeed is differentfrom other wheels.

• RR wheel speedsensor• Harness is open orshorted• Bearing clearance• ABS module

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on.• With the scan tool, record and erase stored DTCs in the ABS module.• Start engine and warm it to normal operating temperature.• Turn ignition switch off and wait for a few seconds.• Start the engine. With the scan tool connected to the DLC, drive the vehicle over 40 km/h (25 mph).

NOTE :Vehicle must be driven above 40 km/h (25 mph) for fault setting conditions to be met.

NOTE :If a wheel speed sensor open or short DTC is present, it must be repaired before continuing.• With the scan tool select: View ABS Data Stream and DTC.• If DTC is detected, the DTC condition is current. Go to Diagnostic Procedure - Step 1.• If DTC is not detected, the DTC condition is intermittent (See Diagnostic Help in Section 12 Brakes for more

information on intermittent DTC troubleshooting).• Erase all codes and test drive the vehicle to verify the repair is complete.• This DTC must be active for the results of this test to be valid.

DIAGNOSIS & TESTING



1. CHECK ABS MODULE DTC

• With the scan tool select: View ABS Data Stream.• With an assistant driving the vehicle, check the following data stream list items while driving the vehicle over 40

km/h (25 mph).− Front Left Wheel Speed.− Front Right Wheel Speed.− Rear Left Wheel Speed.− Rear Right Wheel Speed.

• With the scan tool, read active DTCs in the ABS module.

Is DTC 0X403A0A present and the Rear Right Wheel Speed signal normal?


No >> • See Diagnostic Help in Section 12 Brakes for more information on intermittent DTC troubleshooting.

2. CHECK AND ADJUST TIRE PRESSURE

• Turn ignition switch off.• Check and adjust the tire pressure in the Rear Right tire (Check for a slow leak).• Check and adjust all other tire pressures.• Inspect for mismatched tires on the vehicle.

Is the RR tire improperly inflated or mismatched tires on the vehicle?

Yes >> • Repair Rear Right tire as necessary.


3. CHECK CLEARANCE BETWEEN RR WHEEL SPEED SENSOR AND SENSOR RING

• Inspect the wheel speed sensor and sensor ring for the following conditions that would result in an incorrectsignal:

− Damaged sensor− Loose sensor− Foreign material

• Check the clearance between RR wheel speed sensor and sensor ring.• 1 - 2 mm should exist.



No >> • Clean/replace the wheel speed sensor or sensor ring.• Reinstall the sensor and adjust the clearance as necessary.

DIAGNOSIS & TESTING

12


4. CHECK RR WHEEL BEARING FOR EXCESSIVE RUNOUT OR CLEARANCE

• Inspect the RR wheel bearing for excessive runout or clearance before replacing the wheel bearing assembly.• Replace the RR wheel bearing assembly (See Rear Hub and Bearing Removal & Installation in Section 09

Driveline & Axle).

WARNING!

To avoid personal injury or death, verify vehicle braking before road testing.

• Connect the module and sensor connectors.• Road test the vehicle over 40 km/h (25 mph).

NOTE :Vehicle must be driven above 40 km/h (25 mph) for fault setting conditions to be met.• With the X-431 scan tool, read ABS DTCs.

Did DTC - 0X403A0A reset?

Yes >> • Replace the ABS module (See ABS Module Removal & Installation in Section 12 Brakes).

No >> • The system is now operating properly.• Reassemble the vehicle and road test to verify the customers complaint is repaired.

DIAGNOSIS & TESTING


0X403A06 - Rear Right Wheel Speed Sensor Open

DIAGNOSIS & TESTING

VISMW120006T

12






0X403A06 Rear right wheelspeed sensor open

Ignition switch: ONVehicle: Running

ABS moduledetected that theRear Right WheelSpeed Sensor inputsignal to ABSmodule is open.

• RR wheel speedsensor• Harness is open• ABS module


NOTE :Vehicle must be driven above 40 km/h (25 mph) for fault setting conditions to be met.• With the scan tool select: View ABS Data Stream and DTC.• If DTC is detected, the DTC condition is current. Go to Diagnostic Procedure - Step 1.• If DTC is not detected, the DTC condition is intermittent (See Diagnostic Help in Section 12 Brakes for more

information on intermittent DTC troubleshooting).• Erase all codes and test drive the vehicle to verify the repair is complete.






Is DTC 0X403A06 present and the Rear Right Wheel Speed signal normal?


No >> • See Diagnostic Help in Section 12 Brakes for more information.

DIAGNOSIS & TESTING


2. CHECK THE RR SENSOR REFERENCE SIGNAL CIRCUIT

• Turn ignition switch off.• Disconnect the sensor (1) connector .

• Turn ignition switch on.• Check reference voltage between terminal 2 and

ground in sensor connector B-022 with a digitalmultimeter.

Is approximately 11 V present?


No >> • Repair or replace the open circuit inconnector or harness.

3. CHECK THE RR SENSOR RESISTANCE

• Check sensor resistance between sensor connectorB-022, terminal 1 & 2.

Is the check result between 700 - 1500 ohms?


No >> • Replace the RR sensor.

DIAGNOSIS & TESTING

VISM120012

VISMD120003

VISMD120005

12


4. CHECK THE RR SENSOR GROUND CIRCUIT

• Turn ignition switch off.• Disconnect ABS module connector.

• Check continuity between terminal 10 in ABS mod-ule connector B-015 and terminal 1 in RR wheelspeed sensor B-022.





5. CHECK DTC

• With the X-431 scan tool, read ABS module DTCs.• Refer to �DTC Confirmation Procedure�.

Is DTC 0X403A06 present?

Yes >> • Replace ABS module

No >> • The system is now operating properly.• Erase all codes and test drive the vehicle to verify the repair is complete.

DIAGNOSIS & TESTING

VISMD120008


0X40310A - Front Left Wheel Speed Sensor-Signal Erratic

DIAGNOSIS & TESTING

VISMW120004T

12






0X40310AFront left wheel

speed sensor signalerratic


When the Front LeftWheel SpeedSensor input signalto the Antilock BrakeSystem (ABS)module isintermittentlymissing whilevehicle speed isabove 40 km/h (25mph), or erraticwheel speed signalduring acceleration,or sensed wheelspeed is differentfrom other wheels.

• FL wheel speedsensor• Harness is open orshorted• Bearing clearance• ABS module



NOTE :If a wheel speed sensor open or short DTC is present, it must be repaired• With the scan tool select: View ABS Data Stream and DTC.• If DTC is detected, the DTC condition is current. Go to Diagnostic Procedure - Step 1.• If DTC is not detected, the DTC condition is intermittent (See Diagnostic Help in Section 12 Brakes for more


DIAGNOSIS & TESTING







Is DTC 0X40310A present and the Front Left Wheel Speed signal normal?




• Turn ignition switch off.• Check and adjust the tire pressure in the left front tire (check for a slow leak).• Check and adjust all other tire pressures.• Inspect for mismatched tires on the vehicle.

Is the FL tire improperly inflated or mismatched tires on the vehicle?

Yes >> • Repair Front Left tire as necessary.


3. CHECK CLEARANCE BETWEEN FL WHEEL SPEED SENSOR AND SENSOR RING



• Check the clearance between FL wheel speed sensor and sensor ring.• 1 - 2 mm should exist.




DIAGNOSIS & TESTING

12


4. CHECK FL WHEEL BEARING FOR EXCESSIVE RUNOUT OR CLEARANCE

• Inspect the FL wheel bearing for excessive runout or clearance before replacing the wheel bearing assembly.• Replace the FL wheel bearing assembly (See Rear Hub and Bearing Removal & Installation in Section 09

Driveline & Axle).

WARNING!




Is DTC - 0X40310A still present?



DIAGNOSIS & TESTING


0X40340A - Front Right Wheel Speed Sensor-Signal Erratic

DIAGNOSIS & TESTING

VISMW120005T

12






0X40340AFront right wheelspeed sensor signalerratic


When the FrontRight Wheel SpeedSensor input signalto the Antilock BrakeSystem (ABS)module isintermittentlymissing whilevehicle speed isabove 40 km/h (25mph), or erraticwheel speed signalduring acceleration,or sensed wheelspeed is differentfrom other wheels.

• FR wheel speedsensor• Harness is open orshorted• Bearing clearance• ABS module





DIAGNOSIS & TESTING







Is DTC 0X40340A present and the Front Right Wheel Speed signal normal?




• Turn ignition switch off.• Check and adjust the tire pressure in the front right tire (check for a slow leak).• Check and adjust all other tire pressures.• Inspect for mismatched tires on the vehicle.

Is the FR tire improperly inflated or mismatched tires on the vehicle?

Yes >> • Repair Front Right tire as necessary.


3. CHECK CLEARANCE BETWEEN FR WHEEL SPEED SENSOR AND SENSOR RING



• Check the clearance between FR wheel speed sensor and sensor ring.• 1 - 2 mm should exist.




DIAGNOSIS & TESTING

12


4. CHECK FR WHEEL BEARING FOR EXCESSIVE RUNOUT OR CLEARANCE

• Inspect the FR wheel bearing for excessive runout or clearance before replacing the wheel bearing assembly.• Replace the FR wheel bearing assembly (See Rear Hub and Bearing Removal & Installation in Section 09

Driveline & Axle).

WARNING!




Is DTC - 0X40340A still present?



DIAGNOSIS & TESTING


0X40370A - Rear Left Wheel Speed Sensor-Signal Erratic

DIAGNOSIS & TESTING

VISMW120006T

12






0X40370ARear left wheelspeed sensor signalerratic


When the Rear LeftWheel SpeedSensor input signalto the Antilock BrakeSystem (ABS)module isintermittentlymissing whilevehicle speed isabove 40 km/h (25mph), or erraticwheel speed signalduring acceleration,or sensed wheelspeed is differentfrom other wheels.

• RL wheel speedsensor• Harness is open orshorted• Bearing clearance• ABS module





DIAGNOSIS & TESTING







Is DTC 0X40370A present and the Front Left Wheel Speed signal normal?




• Turn ignition switch off.• Check and adjust the tire pressure in the rear left tire (check for a slow leak).• Check and adjust all other tire pressures.• Inspect for mismatched tires on the vehicle.

Is the RL tire improperly inflated or mismatched tires on the vehicle?

Yes >> • Repair Rear Left tire as necessary.


3. CHECK CLEARANCE BETWEEN RL WHEEL SPEED SENSOR AND SENSOR RING



• Check the clearance between RL wheel speed sensor and sensor ring.• 1 - 2 mm should exist.




DIAGNOSIS & TESTING

12


4. CHECK RL WHEEL BEARING FOR EXCESSIVE RUNOUT OR CLEARANCE

• Inspect the RL wheel bearing for excessive runout or clearance before replacing the wheel bearing assembly.• Replace the RL wheel bearing assembly (See Rear Hub and Bearing Removal & Installation in Section 09

Driveline & Axle).

WARNING!




Is DTC 0X40370A still present?



DIAGNOSIS & TESTING


0X403106 - Front Left Wheel Speed Sensor Open

DIAGNOSIS & TESTING

VISMW120004T

12






0X403106 Front left wheelspeed sensor open

• Ignition switch:ON• Vehicle: Running

ABS moduledetected that theLeft Front WheelSpeed Sensor inputsignal to ABSmodule is open.

• FL wheel speedsensor• Harness is open orshorted• ABS module









Is DTC 0X403106 present and the Front Left Wheel Speed signal normal?


No >> • Refer to Diagnostic Help for an intermittent fault.

DIAGNOSIS & TESTING


2. CHECK FL SENSOR REFERENCE SIGNAL CIRCUIT

• Turn ignition switch off.• Disconnect the sensor (1) connector.

• Turn ignition switch on.• Measure reference voltage between terminal 2 and





3. CHECK FL SENSOR RESISTANCE

• Check sensor resistance between sensor connectorterminal 1 & 2.



No >> • Replace the FL sensor.

DIAGNOSIS & TESTING

VISMD120001

VISMD120003

VISMD120005

12


4. CHECK FL SENSOR GROUND CIRCUIT

• Turn ignition switch off.• Disconnect ABS module connector.

• Check continuity between terminal 28 in ABS mod-ule connector B-015 and terminal 1 in FL wheelspeed sensor B-011.





5. CHECK DTC


Is DTC 0X403106 still present?



DIAGNOSIS & TESTING

VISMD120004


0X403406 - Front Right Wheel Speed Sensor Open

DIAGNOSIS & TESTING

VISMW120005T

12






0X403406 Front Right wheelspeed sensor open


ABS moduledetected that theFront Right WheelSpeed Sensor inputsignal to ABSmodule is open.

• FL wheel speedsensor• Harness is open• ABS module









Is DTC 0X403406 present and the Front Right Wheel Speed signal normal?



DIAGNOSIS & TESTING


2. CHECK FR SENSOR REFERENCE SIGNAL CIRCUIT

• Turn ignition switch off.• Disconnect the sensor (1) connector.






3. CHECK FR SENSOR RESISTANCE

• Check sensor resistance between sensor terminal 1& 2.



No >> • Replace the FR sensor.

DIAGNOSIS & TESTING

VISMD120001

VISMD120003

VISMD120005

12


4. CHECK FR SENSOR GROUND CIRCUIT

• Turn ignition switch off.• Disconnect ABS module connector.• Check continuity between terminal 4 in ABS module

connector B-015 and terminal 1 in FL wheel speedsensor B-020.





5. CHECK DTC


Is DTC 0X403406 present?



DIAGNOSIS & TESTING

VISMD120006


0X403706 - Rear Left Wheel Speed Sensor Open

DIAGNOSIS & TESTING

VISMW120006T

12






0X403706 Rear left wheelspeed sensor open


ABS moduledetected that theRear Left WheelSpeed Sensor inputsignal to ABSmodule is open.

• RL wheel speedsensor• Harness is open• ABS module









Is DTC 0X403706 present and the Rear Left Wheel Speed signal normal?



DIAGNOSIS & TESTING


2. CHECK THE RL SENSOR REFERENCE SIGNAL CIRCUIT

• Turn ignition switch off.• Disconnect the sensor (1) connector .





No >> • Repair or replace open circuit in con-nector or harness.

3. CHECK THE RL SENSOR RESISTANCE

• Check sensor resistance between sensor terminal 1& 2.



No >> • Replace the RL sensor.

DIAGNOSIS & TESTING

VISM120012

VISMD120003

VISMD120005

12


4. CHECK THE RL SENSOR GROUND CIRCUIT

• Turn ignition switch off.• Disconnect ABS module connector.• Check continuity between terminal 35 in ABS mod-

ule connector B-015 and terminal 1 in RL wheelspeed sensor B-021.





5. CHECK DTC


Is DTC 0X403706 present?

Yes >> • Replace ABS module.


DIAGNOSIS & TESTING

VISMD120007


0X900001 - 12 Volt System Supply Voltage - Above Maximum Threshold0X900002 - 12 Volt System Supply Voltage - Below Minimum Threshold

DIAGNOSIS & TESTING

VISMW120002T

12


DIAGNOSIS & TESTING

VISMW120003T






0X900001

12 volt systemsupply voltage-

above maximumthreshold

Ignition switch: ON

ABS moduledetected that thebattery voltage isexcessively high.

• Charge system• ABS module

0X900002

12 volt systemsupply voltage-below minimum

threshold

ABS moduledetected that thebattery voltage isexcessively low.

• Charge system• Harness is open orshorted• Battery• ABS module

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on.• With the scan tool, record and erase stored DTCs in the ABS module.• Start engine and warm it to normal operating temperature.• With the scan tool connected to the DLC, drive the vehicle over 40 km/h (25 mph).• With the scan tool select: View ABS Data Stream and DTC.• If DTC is detected, the DTC condition is current. Go to Diagnostic Procedure - Step 1.• If DTC is not detected, the DTC condition is intermittent (See Diagnostic Help in Section 12 Brakes for more


NOTE :Inspect the vehicle for aftermarket accessories that may exceed the Generator System output.

NOTE :Inspect the fuses. If an open fuse is found, use the wiring schematics as a guide and inspect the wiring and con-nectors for damage.



• Turn ignition switch off.• Loosen and retighten ground connections B-201 and B-202 (See Diagnosis & Testing Ground Inspection in Sec-

tion 12 Brakes).• Inspect the ground connections B-201 and B-202 position (See Vehicle Wiring Harness Information Body Har-

ness in Section 16 Wiring).



No >> • Repair or replace the ground connections.

DIAGNOSIS & TESTING

12


2. CHECK ABS MODULE POWER SUPPLY

• Turn ignition switch off.• Disconnect ABS module electrical connector.• Turn ignition switch on.• Start engine.

• Check ABS module power supply between terminal7, 25, 33 and terminal 13, 38 in the ABS moduleelectrical connector B-015 terminal side.


Yes >> • Replace the ABS module.




• Connect ABS module connector.• Start the engine, raise the engine speed over 1000 rpm.• Measure the charging voltage with a digital multimeter at battery positive and negative.





• Start the engine, raise the engine speed over 1000 rpm for a few minutes.• Turn ignition switch off.• Measure the voltage drop with the voltmeter at battery positive and negative while crank engine.• Battery voltage should be more than approximately 9 V.




5. CHECK ABS MODULE POWER SUPPLY CIRCUIT

• Measure continuity between ABS module terminal 25 and battery positive.• Continuity should exist.



No >> • Check fuse.• Check the harness.• Check correlative components.

DIAGNOSIS & TESTING

VISMD120009



• Start the engine, raise the engine speed over 1000 rpm.• Measure the charging voltage with a digital voltmeter at the battery positive and negative terminals.




7. CHECK DTC


Is DTC 0X900001 or DTC 0X900002 present?



DIAGNOSIS & TESTING

12


0Xf00003 - Control Module-Component Internal Failure




0XF00003 Control module-component internal failure

ABS module detected aninternal failure. ABS module

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on.• With the scan tool, record and erase stored DTCs in the ABS module.• Start engine and warm it to normal operating temperature.• With the scan tool connected to the DLC, drive the vehicle over 40 km/h (25 mph).• With the scan tool select: View ABS Data Stream and DTC.• If DTC is detected, the DTC condition is current. Go to Diagnostic Procedure - Step 1.• If DTC is not detected, the DTC condition is intermittent (See Diagnostic Help in Section 12 Brakes for more



1. CHECK DTC


Is DTC 0XF00003 present?


No >> • The conditions that caused this code to set are not present at this time.• See Diagnostic Help in Section 12 Brakes for more information

2. CHECK ABS MODULE POWER SUPPLY AND GROUND CIRCUIT

• Check the ABS module supply voltage circuit and ground circuit for an open or high resistance or short.



No >> • Repair or replace the circuit for an open, high resistance or short in harness and connectors.

3. CHECK DTC


Is DTC 0XF00003 still present?



DIAGNOSIS & TESTING


ON-VEHICLE SERVICE

Antilock Brake System (ABS) Bleeding Procedure

ABS Bleeding InformationWARNING!

When bleeding the brake system, wear safety glasses. A clear bleed tube must be attached to the bleederscrews and submerged in a clear container filled partially with clean brake fluid. Direct the flow of brake fluidaway from yourself and the painted surfaces of the vehicle. Brake fluid at high pressure may come out of thebleeder screws when opened.

CAUTION:Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matterfrom dropping into the master cylinder reservoir. Use brake fluid or an equivalent from a fresh,tightly sealed container. Brake fluid must conform to DOT 4 specifications.

NOTE :During the brake bleeding procedure, be sure the brake fluid level remains close to the �MAX� level in the mastercylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add brake fluid asrequired.

NOTE :Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding process. This willonly increase the amount of air in the system and make additional bleeding necessary. Do not allow the mastercylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air intothe brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit sequence forbleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulicsystem.

ABS Bleeding InstructionsWhen bleeding the ABS system, the following bleeding sequence must be followed to ensure complete and adequatebleeding:1. Make sure all hydraulic fluid lines are installed and properly torqued.2. Connect the X-431 scan tool to the Data Link Connector.3. Using the scan tool, check to make sure the ABS module does not have any fault codes stored. If it does,

clear them.4. Bleed the base brake system (See Manuel Brake Bleeding In Section 12 Brakes).

NOTE :Pressure bleeding is recommended to bleed the base brake system to ensure all air is removed from the brakesystem.5. Using the scan tool, access ABS bleeding. Follow the instructions displayed. When finished, disconnect the

scan tool and proceed.6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent

emptying, causing air to enter the hydraulic system.7. Fill the master cylinder fluid reservoir to the �MAX� level.8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel

spongy.

12


Manual Bleeding Instructions

NOTE :To bleed the brakes manually, the aid of a helper will be required.


1. Turn the ignition switch off.2. Have a helper pump the brake pedal three or four times and hold it in the down position.3. With the pedal in the down position, open the bleeder screw at least one full turn.4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the

brake pedal.5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times).6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor

the fluid level in the master cylinder reservoir to make sure it does not go dry.7. Check and adjust brake fluid level to the �MAX� mark.8. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be


Pressure Bleeding Instructions

NOTE :Follow pressure bleeder manufacturer’s instructions for use of pressure bleeding equipment.

Attach the pressure bleeding equipment to the MasterCylinder.


1. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid.2. After approximately 120-240 ml of fluid have been bled through the brake circuit and an air-free flow is main-

tained in the clear plastic hose and jar, close the bleeder screw.3. Repeat this procedure at all the remaining bleeder screws.4. Check and adjust brake fluid level to the �MAX� mark on the reservoir.5. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be


ON-VEHICLE SERVICE

BESM120001

BESM120001


Antilock Brake System (ABS) Hydraulic Control Module


NOTE :The following special tools are required to perform the repair procedure:• Diagnostic Scan Tool X-431

NOTE :The ABS hydraulic control module is comprised of the Hydraulic Control Unit (HCU) and the Electronic Control Unit(ECU). These are serviced as a complete unit and cannot be serviced separately.

1. Turn the ignition switch off.2. Disconnect the negative battery cable.3. Using a brake pedal holding tool, depress the brake pedal past its first 25 mm of travel and hold it in this posi-

tion. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid todrain out of the master cylinder reservoir while the lines are disconnected.

4. Disconnect the ABS hydraulic control module elec-trical connector (2).

5. Remove the brake tubes (1) at the hydraulic con-trol unit.(Tighten: Brake tube nuts to 15 ± 3 N·m)

6. Remove the mounting bolts (3) attaching the ABShydraulic control module mounting bracket to vehi-cle.(Tighten: ABS mounting bracket bolts to 20 ± 2N·m)

7. Position the brake tubes as necessary without bending them.8. Remove the ABS hydraulic control module from vehicle.9. Remove the ABS mounting bolts and mounting bracket as necessary.

(Tighten: ABS mounting bolts to 10 ± 1 N·m)10. Installation is in the reverse order of removal.

Installation Notes:

• After installation connect the X-431 scan tool to initialize the ABS hydraulic control module and bleed the brakesystem (See Antilock Brake System (ABS) Bleeding Procedure in Section 12 Brakes).

ON-VEHICLE SERVICE

VISM120022

12


Yaw Rate Sensor

Removal & Installation1. Disconnect the negative battery cable.2. Move the passage seat to the furthest front end.3. Disconnect the yaw rate sensor electrical connec-

tor (1).4. Remove the yaw rate sensor retaining bolt (2).

(Tighten: Yaw rate sensor bolt to 15 ± 3 N·m)5. Remove the yaw rate sensor.6. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

VISM120005


Front Wheel Speed Sensor

Removal & Installation1. Disconnect the negative battery cable.2. Raise and support the vehicle.3. Remove the wheel mounting nuts and the tire and wheel assembly.

(Tighten: Wheel mounting nuts to 110 N·m)4. Remove the front wheel speed sensor retaining

bolt.(Tighten: Front wheel speed sensor retaining boltto 10 ± 1 N·m)

5. Remove the front wheel speed sensor (1).6. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

VISM110003

12


Rear Wheel Speed Sensor

Removal & Installation1. Disconnect the negative battery cable.2. Raise and support the vehicle.3. Remove the wheel mounting nuts and the tire and wheel assembly.

(Tighten: Wheel mounting nuts to 110 N·m)4. Remove the rear wheel speed sensor mounting

bolt (1).(Tighten: Rear wheel speed sensor mounting boltsto 10 ± 1 N·m)

5. Remove the rear wheel speed sensor (1).6. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

VISM120012

VISM080033


PARKING BRAKE


DIAGNOSIS & TESTING 12-90Parking Brake Warning Light 12-90Parking Brake Operation 12-90Parking Brake Adjustment 12-90


Parking Brake Lever 12-92Removal & Installation 12-92

Parking Brake Cable 12-92Removal & Installation 12-92

Parking Brake Shoes 12-94Removal & Installation 12-94

12


GENERAL INFORMATIONDescriptionThe parking brakes consist of the following components:• Hand-operated parking brake lever• Parking brake cables (one each side)• Parking brake controls

OperationAll vehicles are equipped with a center-mounted, hand-operated parking brake lever mounted between the frontseats. A tensioner is built into the equalizer mounted on the end of the lever’s output cable. There is an individualparking brake cable for each rear wheel that joins a parking brake cable equalizer, attached to the parking brakelever, to the rear parking brakes. The parking brake cables are made of flexible steel cable.

Specifications



Parking Brake Cable Routing Clamp Bolt 10 ± 1

Parking Brake Cable Bracket Bolts 10 ± 1

Parking Brake Lever Nut 30 ± 5


Special Tools

Brake Measuring Gauge



Parking Brake System (Page 1 of 1)

GENERAL INFORMATION

VISMW120012T

12


DIAGNOSIS & TESTINGParking Brake Warning LightThe parking brake switch is part of the circuit for the red warning lamp in the dash panel. The switch will cause thelamp to illuminate only when the parking brakes are applied. If the lamp remains on after parking brake is released,the switch or circuit is faulty.

Parking Brake OperationThe leading cause of improper parking brake operation, is excessive clearance between the parking brake shoes andthe shoe braking surface. Excessive clearance is a result of lining and/or drum wear, drum surface machined over-size.

In most cases, the actual cause of an improperly functioning parking brake (too loose/too tight/won’t hold), can betraced to a parking brake component.

Inspect the following when diagnosing a parking brake problem:• Brake shoe wear• Drum surface (in rear rotor) machined oversize• Front cable not secured to lever• Rear cable not attached to actuator• Rear cable seized• Parking brake lever not seated• Parking brake lever bind

Parking Brake AdjustmentAdjust the parking brake only if the parking brake lever can be pulled up more than 3 notches without having anadequate solid braking effect.

NOTE :Excessive parking brake lever travel (sometimes described as a loose lever or too loose condition) could be theresult of worn brake shoes, improper brake shoe adjustment, or improperly assembled brake parts. A too-loose con-dition can also be caused by inoperative or improperly assembled parking brake components. Always confirm that theparking brake components are assembled properly. Perform the following procedure to adjust the parking brake:

1. Verify the parking brake lever is in the released (down) position.2. Raise and support the vehicle.3. Remove the wheel mounting nuts and the rear tire and wheel assemblies.4. Using the access hole (1) in the rotor, use a suitable tool to adjust the brake shoes.

VISM120019


5. Adjust the parking brake shoes by turning theadjuster (1).

6. Reach inside the vehicle and fully apply and release the parking brake.7. With the parking brake lever in the fully applied (up) position, attempt to rotate the rear rotors by hand (to ensure

that the parking brake shoes are working properly).8. With the parking brake lever in the released (down) position, attempt to rotate the rear rotors by hand (to ensure

that the parking brake shoes are not dragging).9. Install both rear tire and wheel assemblies and the wheel mounting nuts.

(Tighten: Wheel mounting nuts to 110 N·m)10. Lower the vehicle.

DIAGNOSIS & TESTING

VISM120027

12


ON-VEHICLE SERVICE

Parking Brake Lever

Removal & Installation1. Disconnect the negative battery cable.2. Block the tire and wheel assemblies so the vehicle does not move once the vehicle parking brake lever is

released.3. Remove the center console (See Center Console Removal & Installation in Section 15 Body & Accessories).4. Release and lower the parking brake lever.5. Loosen the adjusting nut on the lever’s output

cable, taking tension off parking brake cables.6. Back the nut off until it is flush with the end of the

output cable.7. Remove the screws connecting the rear air outlet

and bracket.8. Remove the bolts connecting the bracket and floor

plate and remove the bracket.9. Remove the parking brake cables (1) from the

parking brake cable equalizer (2).

10. Disconnect the electrical connector from the park-ing brake switch.

11. Remove the bolts (1) attaching the parking brakelever to the vehicle.(Tighten: Parking brake lever nuts to 30 ± 5 N·m)

12. Remove the parking brake assembly (2).13. Installation is in the reverse order of removal.

Installation Notes:

• After installation, adjust the parking brake cable as necessary (See Parking Brake Adjustment in Section 12Brakes).

Parking Brake Cable

Removal & Installation1. Block the tire and wheel assemblies so the vehicle does not move once the vehicle parking brake lever is

released.2. Remove the center console (See Center console Removal & Installation in Section 15 Body & Accessories).3. Release and lower the parking brake lever.4. Loosen the adjusting nut on the lever’s output cable taking tension off the parking brake cables. Back the nut off

until it is flush with the end of the output cable.5. Remove the screws connecting the rear air outlet and bracket.6. Remove the bolts connecting bracket and floor plate and remove the bracket.

BESM120011

BESM120012


7. Remove the parking brake cables (1) from the parking brake cable equalizer (2).8. Fold the rear carpeting forward to expose the park-

ing brake cables at the end of the rear floor.9. Remove the bolts connecting the parking brake

cable bracket and floor plate, and remove thecable from the bracket.(Tighten: Parking brake cable bracket bolts to10 ± 1 N·m)

10. Raise and support the vehicle.11. Remove the rear wheel mounting nuts and both rear tire and wheel assemblies.

(Tighten: Wheel mounting nuts to 110 N·m)12. Access and remove the parking brake shoes (See Parking Brake Shoes Removal & Installation in Section 12

Brakes).13. Pull the parking brake cable bracket (1) from the

support plate and parking brake cable clamp (2)from the rear trailing arm.

14. Remove the parking brake cable from the rear trail-ing arm (1).

15. Remove the parking brake cable with sealinggrommet through the hole in the floor pan of thevehicle.


Installation Notes:

• After installation, adjust the parking brake cable as necessary (See Parking Brake Adjustment in Section 12Brakes).

ON-VEHICLE SERVICE

BESM120011

VISM080032

VISM100024

12


Parking Brake Shoes

Removal & Installation1. Raise and support the vehicle.2. Remove the rear wheel mounting nuts and both rear tire and wheel assemblies.

(Tighten: Wheel mounting nuts to 110 N·m)3. Access and remove rear brake rotor (See Rear

Brake Rotor Removal & Installation in Section 12Brakes).

4. Turn the brake shoe adjuster wheel until theadjuster is at shortest length.

5. Remove the brake shoe hold-down springs (2) andpins (3). Rotate the pins 90° to disengage.

6. Remove the parking brake cable from the arm onthe rear parking brake shoe.

7. Remove the brake shoes (5), adjuster (6) andlower return spring (4) as an assembly from thesupport plate.

8. Remove the lower return spring (4) and adjuster(6) from the shoes (5).

9. Remove the upper return spring (1).10. Remove the parking brake shoes.


ON-VEHICLE SERVICE

LTSM120037

VISM080030


Installation Notes:

• Perform the following to measure and adjust parking brake shoes:1. Using a brake measuring gauge or equivalent, measure the inside diameter of parking brake drum (1).2. Place the brake measuring gauge over theparking brake shoes at their widest point.

3. Using the adjuster wheel, adjust the parking brake shoes until the linings on both parking brake shoes justtouch the jaws on the brake measuring gauge.

• After installation, adjust the parking brake cable asnecessary (See Parking Brake Adjustment in Sec-tion 12 Brakes).

ON-VEHICLE SERVICE

BESM120024

LTSM120039

12


HEATING & AIR CONDITIONING

13CONTENTS

pageManual/Automatic Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

System Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14

Air Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26

System Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-32

MANUAL/AUTOMATIC TEMPERATURE CONTROL


DIAGNOSIS & TESTING 13-10A/C System Performance 13-10Heater Performance 13-12


Manual/Automatic Temperature ControlModule 13-13


13



1 - Condenser

2 - A/C Compressor

3 - Accumulator

4 - Suction Line

5 - Liquid Line

6 - Evaporator Assembly

7 - HVAC Control Panel

VISM130002


Operation

Specifications



All General Service Screws 2

Evaporator House Bolt 9 ± 1

Expansion Valve Bolt 7.5 ± 1

Pipeline Stent 4

Refrigerant Lines To A/C Accumulator 6

Condenser Bolt 6

Refrigerant Lines To A/C Compressor Bolt 30

Refrigerant Lines 10

Refrigerant Lines To A/C Evaporator Bolt 25

GENERAL INFORMATION

VISM130001T 13


A/C Pressure Specifications

AMBIENT TEMPERATURE A/C HIGH SIDE PRESSURE A/C LOW SIDE PRESSURE

15.5 °C8.4 - 11.9 kgf/cm2

120 - 170 psi1.9 - 2.1 kgf/cm2

28 - 31 psi

21.1 °C10.5 - 17.5 kgf/cm2

150 - 250 psi1.9 - 2.1 kgf/cm2

28 - 31 psi

26.6 °C12.6 - 19.3 kgf/cm2

180 - 275 psi1.9 - 2.1 kgf/cm2

28 - 31 psi

32.2 °C14.0 - 21.8 kgf/cm2

200 - 310 psi1.9 - 2.1 kgf/cm2

28 - 31 psi

37.7 °C16.1 - 23 kgf/cm2

230 - 330 psi1.9 - 2.4 kgf/cm2

28 - 35 psi

43.3 °C18.9 - 25.3 kgf/cm2

270 - 360 psi1.9 - 2.6 kgf/cm2

28 - 38 psi

AMBIENTTEMPERATURE Engine Speed A/C HIGH SIDE

PRESSUREA/C LOW SIDE

PRESSURE

35 °C Idle Speed 1.4 - 1.8 MPa 0.26 - 0.33 MPa

30 °C Idle Speed 1.3 - 1.8 MPa 0.26 - 0.33 MPa

A/C Refrigerant Charge Specifications

DESCRIPTION CAPACITY (g)

R-134a Refrigerant 625 ± 10

Special Tools


GENERAL INFORMATION



Climate Control System (Page 1 of 5)

GENERAL INFORMATION

VISMW130001T

13



GENERAL INFORMATION

VISMW130002T



GENERAL INFORMATION

VISMW130003T

13



GENERAL INFORMATION

VISMW130004T



GENERAL INFORMATION

VISMW130005T

13


DIAGNOSIS & TESTINGA/C System PerformanceThe ambient air temperature must be a minimum of 21 °C for this test:

1. Connect a manifold gauge set.2. Set the A/C Heater mode control switch knob in the Panel position, the temperature control knob in the full cool

position, the A/C button in the On position, and the blower motor switch knob in the highest speed position.3. Start the engine and hold the idle at 1,300 RPM with the compressor clutch engaged.4. The engine should be at operating temperature. The doors and windows must be open.5. Insert a thermometer in the driver side center A/C (panel) outlet. Operate the engine for five minutes.6. The compressor clutch may cycle, depending upon the ambient temperature and humidity.7. With the compressor clutch engaged, record the discharge air temperature and the compressor discharge pres-

sure.8. Compare the discharge air temperature to the performance temperature and pressure chart.

NOTE :The discharge air temperatures will be lower if the humidity is less than the percentages shown.

TEMPERATURE AND PRESSURE

Ambient AirTemperature andHumidity

21 °C( 80% humidity)





Air Temperatureat Center PanelOutlet

10 - 13 °C 14 - 17 °C 15 - 18 °C 17 - 20 °C 14 - 17 °C

Evaporator InletPressure atCharge Port

310 - 350 kPa 360 - 420 kPa 375 - 438 kPa 420 - 480 kPa 360 - 420 kPa

CompressorDischargePressure

1337 - 1377 kPa 1390 - 1550 kPa 1450 - 1590 kPa 1550 - 1698 kPa 1390 - 1550 kPa


A/C System Troubleshooting Chart


Rapid Compressor ClutchCycling (ten or more cycles perminute)

· Low refrigerant system charge.· Test the A/C system for leaks. Repair,evacuate and charge the refrigerant system,if necessary.

Equal Pressures, But TheCompressor Clutch Does NotEngage

· No refrigerant in the refrigerantsystem.· Faulty A/C compressor clutchcoil.· Faulty A/C pressuretransducer.· Faulty HVAC control panel.

· Test the A/C system for leaks. Repair,evacuate and charge the A/C, if necessary.· Test the compressor clutch coil andreplace, if necessary.· Test the A/C high pressure transducer andreplace, if necessary.· Test the HVAC control panel and replace, ifnecessary.

Normal Pressures, But A/CPerformance Test AirTemperatures At Center PanelOutlet Are Too High

· Excessive refrigerant oil insystem.· Blend door inoperative orsealing improperly.· Blend door actuator faulty orinoperative.

· Recover the refrigerant from the refrigerantsystem and inspect the refrigerant oilcontent. Restore the refrigerant oil to theproper level, if necessary.· Inspect the blend door for proper operationand sealing and correct, if necessary.· Replace if faulty.

The Low Side Pressure IsNormal Or Slightly Low, And TheHigh Side Pressure Is Too Low

· Low refrigerant system charge.· Refrigerant flow through theaccumulator is restricted.· Refrigerant flow through theevaporator is restricted.· Faulty compressor.

· Test the refrigerant system for leaks.Repair, evacuate and charge the refrigerantsystem, if necessary.· Replace the restricted accumulator, ifnecessary.· Replace the restricted evaporator coil, ifnecessary.· Replace the compressor, if necessary.

The Low Side Pressure IsNormal Or Slightly High, AndThe High Side Pressure Is TooHigh

· Condenser air flow restricted.· Inoperative cooling fan.· Refrigerant systemovercharged.· Air in the refrigerant system.· Engine overheating.

· Check the condenser for damaged fins,foreign objects obstructing air flow throughthe condenser fins, and/or missing orimproperly installed air seals. Clean, repair,or replace components as required.· Test the cooling fan and replace, ifnecessary.· Recover the refrigerant from the refrigerantsystem. Charge the refrigerant system to theproper level, if necessary.· Test the refrigerant system for leaks.Repair, evacuate and charge the refrigerantsystem, if necessary.· Test the cooling system and repair asnecessary.

The Low Side Pressure Is TooHigh, And The High SidePressure Is Too Low

· Accessory drive belt slipping.· Faulty compressor.

· Inspect the accessory drive belt conditionand tension. Tighten or replace theaccessory drive belt, if necessary.· Replace the compressor, if necessary.

The Low Side Pressure Is TooLow, And The High SidePressure Is Too High.

· Restricted refrigerant flowthrough the refrigerant lines.· Restricted refrigerant flowthrough the A/C accumulator.· Restricted refrigerant flowthrough the condenser.

· Inspect the refrigerant lines for kinks, tightbends or improper routing. Correct therouting or replace the refrigerant line, ifnecessary.· Replace the accumulator if restricted.· Replace the restricted condenser, ifnecessary.

DIAGNOSIS & TESTING

13


Heater PerformanceEngine coolant is delivered to the heater core through heater hoses. With the engine idling at normal operating tem-perature, set the temperature control knob in the full hot position, the mode control switch knob in the floor heatposition, and the blower motor switch knob in the highest speed position. Using a test thermometer, check the tem-perature of the air being discharged at the HVAC housing floor outlets. Compare the test thermometer reading to theheater performance chart.

HEATER PERFORMANCE

Ambient AirTemperature 15.5 °C (60 °F) 21.1 °C (70 °F) 26.6 °C (80 °F) 32.2 °C (90 °F)

Minimum AirTemperature at FloorOutlet

62.2 °C (144 °F) 63.8 °C (147 °F) 65.5 °C (150 °F) 67.2 °C (153 °F)

Both of the heater hoses should be hot to the touch. The coolant return heater hose should be slightly cooler thanthe coolant supply heater hose. If the return hose is much cooler than the supply hose, locate and repair the enginecoolant flow obstruction in the cooling system.

Obstructed Coolant FlowPossible locations or causes of obstructed coolant flow:• Pinched or kinked heater hoses.• Improper heater hose routing.• Plugged heater hoses or supply and return ports at the cooling system connections.• A plugged heater core.

Mechanical ProblemsPossible locations or causes of insufficient heat:• An obstructed cowl air intake.• Obstructed heater system outlets.• A blend door not functioning properly.• An air-bound system.

Temperature ControlIf the heater outlet air temperature cannot be adjusted with the temperature control knob(s) on the HVAC controlpanel, the following could require service:• The HVAC control panel.• The blend door actuator(s).• The wire harness circuits for the HVAC control panel or the blend door actuator(s).• The blend door(s).• Improper engine coolant temperature.

DIAGNOSIS & TESTING


ON-VEHICLE SERVICE

Manual/Automatic Temperature Control Module

Removal & Installation1. Disconnect the negative battery cable.2. Remove the lower console (See Lower Console Removal & Installation in Section 15 Body & Accessories).3. Remove the center control panel bezel retaining

screws (1).

4. Disconnect the Manual/Automatic TemperatureControl module connectors (1).

5. Remove the Manual/Automatic Temperature Control module.6. Installation is in the reverse order of removal.

VISM150001

VISM130018

13


SYSTEM CONTROLS


DIAGNOSIS & TESTING 13-20Mechanical Problems 13-20Temperature Control 13-20


Blend Door Actuator 13-21Removal & Installation 13-21

Mode Door Actuator 13-22Removal & Installation 13-22

Defrost Door Actuator 13-22Removal & Installation 13-22

Recirculation Door Actuator 13-23Removal & Installation 13-23

Blower Control Module 13-24Removal & Installation 13-24

Inside Temperature Sensor 13-25Removal & Installation 13-25


GENERAL INFORMATIONDescriptionThis vehicle is equipped with a common Heating, Ventilation and Air Conditioning (HVAC) housing assembly. Thesystem combines air conditioning, heating, and ventilating capabilities in a single unit housing mounted under theinstrument panel. The driver can choose the following functions from the HVAC control panel:• The inside temperature• The speed of the blower• Five different modes of operation• A/C compressor clutch operation• Recirculation door position

NOTE :To maintain the performance level of the HVAC system, the engine cooling system must be properly maintained. Anyobstructions in front of the radiator or A/C condenser will reduce the performance of the A/C and engine coolingsystems.

Operation

1 Temperature Control Dial

2 A/C Control Switch

3 Blower Speed Control Dial

4 Recirculation Control Switch

5 Mode Control Dial

6 Rear Window DefoggerSwitch

VISM130019

13


TEMPERATURE CONTROL DIAL• The Temperature Control Dial increases or decreases the interior set temperature.

RECIRCULATION CONTROL SWITCH• When the Recirculation Control Switch is ON, the Recirculation switch indicator light turns ON, and the air inlet

is set to Recirculation.• When the Recirculation switch is turned OFF, the air inlet is set to fresh. The Recirculation mode can be re-en-

tered by pressing the Recirculation switch again.• The Recirculation switch does not operate when the HVAC system is in the Defrost Mode.

DEFROSTER SWITCH• The Defroster Switch causes the air outlet doors to move to the defrost position. Also, when the Defroster

Switch is selected, outside air is drawn into the cabin and the A/C compressor is energized.

REAR WINDOW DEFOGGER SWITCH• The Rear Window Defogger Switch is used to energize the rear window defogger grid.

A/C CONTROL SWITCH• The A/C Control Switch is used to manually energize the A/C compressor.

MODE CONTROL DIAL• The Mode Control Dial is used to change the air discharge direction.

BLOWER SPEED CONTROL DIAL• The Blower Speed Control Dial will control the ON and OFF function of the blower motor, and manually control

the four blower speeds.

GENERAL INFORMATION


Air Discharge

Air Flow Discharge

1. Panel Mode

Air is directed from theoutlets in the instrumentpanel. Each of these outletscan be individually adjustedto direct the flow of air.

2. Bi-Level Mode

Air is directed from both theinstrument panel outlets,floor outlets and defrost. Aslight amount of air is alsodirected through the sidewindow demister outlets.

3. Floor Mode

Air is directed from the flooroutlets. A slight amount of airis directed through thedefrost and side windowdemister outlets.

4. Mix Mode

Air is directed from the floor,defrost and side windowdemister outlets. This modeworks best in cold or snowyconditions.

5. Defrost Mode

Air is directed from thewindshield and side windowdemister outlets. Use thissetting when necessary todefrost your windshield andside windows.

GENERAL INFORMATION

LTSM130012

13


Air Distribution Doors

1 - Recirculation Door 2 - Defogger Door 3 - Blend Door 4 - Mode Door

GENERAL INFORMATION

VISM130003


Specifications



All General Service Screw 2

Blend Door Actuator Screw 2

Mode Door Actuator Screw 2

Defrost Door Actuator Screw 2

Recirculation Door Actuator Screw 2

Special Tools


GENERAL INFORMATION

13


DIAGNOSIS & TESTINGMechanical ProblemsPossible locations or causes of insufficient heat:• An obstructed cowl air intake.• Obstructed heater system outlets.• A blend door not functioning properly.• An air-bound system.

Temperature ControlIf the heater outlet air temperature cannot be adjusted with the temperature control knob(s) on the HVAC controlpanel, the following could require service:• The HVAC control panel.• The blend door actuator(s).• The wire harness circuits for the HVAC control panel or the blend door actuator(s).• The blend door(s).• Improper engine coolant temperature.


ON-VEHICLE SERVICE

Blend Door Actuator

Removal & Installation1. Remove the instrument panel (See Instrument Panel Removal & Installation in Section 15 Body & Accessories).2. Remove the HVAC housing assembly (See HVAC Housing Assembly Removal & Installation in Section 13 Heat-

ing & Air Conditioning).3. Remove the rod connected to the blend door actuator.4. Disconnect the blend door actuator electrical connector.5. Remove the screws (1) connecting the blend door

actuator to the bracket.(Tighten: Blend door actuator screws to 2 N·m)


Installation & Inspection:

• Turn the ignition switch to the ACC position.• Start the engine and turn on the air conditioner.• Set the air conditioner temperature adjusting knob to HOTTEST or COLDEST.• Close the air conditioner panel until the motor stops.• Adjust the mixing damper manually to HOTTEST or COLDEST position according to the status.• Adjust the rod to the proper position to connect to the actuator.

VISM130009

13


Mode Door Actuator


ing & Air Conditioning).3. Disconnect the mode door actuator electrical connector.4. Remove the screws (1) connecting the mode door

actuator to the bracket.(Tighten: Mode door actuator screws to 2 N·m)

5. Remove the mode door actuator.6. Installation is in the reverse order of removal.

Installation & Inspection:

• Turn the ignition switch to the ACC position.• Start the engine and turn on the air conditioner.• Close the air conditioner panel until the motor stops.• Adjust the rod to the proper position to connect to the actuator.

Defrost Door Actuator


ing & Air Conditioning).3. Disconnect the defrost door actuator electrical connector.

ON-VEHICLE SERVICE

VISM130010


4. Remove the screws (1) connecting the defrost dooractuator to the bracket.(Tighten: Defrost door actuator screws to 2 N·m)

5. Remove the defrost door actuator.6. Installation is in the reverse order of removal.

Recirculation Door Actuator


ing & Air Conditioning).3. Remove the rod connected to the recirculation door actuator.4. Remove the screws (1) connecting the recirculation

door actuator to the bracket.(Tighten: Recirculation door actuator screws to 2N·m)


ON-VEHICLE SERVICE

VISM130011

VISM130020

13


Blower Control Module


The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior toservicing the blower motor resistor, wait five minutes to allow the blower motor resistors to cool before per-forming diagnosis or service. Failure to take this precaution can result in possible personal injury.

CAUTION:Do not operate the blower motor with the blower motor resistor removed from the circuit. Failure totake this precaution can result in vehicle damage.1. Disconnect the negative battery cable.2. Remove the instrument panel (See Instrument Panel Removal & Installation in Section 15 Body & Accessories).3. Remove the HVAC Housing assembly (See HVAC Housing Assembly Removal & Installation in Section 13 Heat-

ing & Air Conditioning).4. Disconnect the blower control module electrical connector.5. Remove the screw (1) attaching the blower motor

module to the evaporator housing.

6. Remove the blower control module.7. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

VISM130006


Inside Temperature Sensor

Removal & Installation1. Remove the HVAC Housing assembly (See HVAC Housing Assembly Removal & Installation in Section 13 Heat-

ing & Air Conditioning).2. Remove the instrument panel (See Instrument Panel Removal & Installation in Section 15 Body & Accessories).3. Remove the left lower trim panel assembly of the

instrument panel retaining bolts (1).

4. Remove the inside temperature sensor (1) on theleft lower panel.

5. Disconnect the inside temperature sensor electrical connector.6. Remove the inside temperature sensor from the HVAC housing assembly.7. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

VISM150144

VISM130025

13


AIR DISTRIBUTION


DIAGNOSIS & TESTING 13-29Blower Motor Electrical Troubleshooting 13-29Blower Motor Noise 13-29Blower Motor Vibration 13-29


HVAC Housing Assembly 13-30Removal & Installation 13-30

Blower Motor 13-31Description 13-31Operation 13-31Removal & Installation 13-31


GENERAL INFORMATIONDescriptionAll models are equipped with a common Heating, Ventilation and Air Conditioning (HVAC) housing assembly thatcombines A/C and heating capabilities into a single unit mounted within the passenger compartment. The HVAChousing assembly consists of three separate housings:• HVAC housing — The HVAC housing is mounted to the dash panel behind the instrument panel and contains

the A/C evaporator. The HVAC housing has mounting provisions for the air inlet housing, blower motor and theair distribution housing.

• Air distribution housing — The air distribution housing is mounted to the rear of the HVAC housing and con-tains the heater core, blend-air and mode-air doors and door linkage.

• Air inlet housing — The air inlet housing is mounted to the passenger side end of the HVAC housing. The airinlet housing contains the recirculation-air door and actuator.

OperationThe A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an A/C evaporator to cool anddehumidify the incoming air prior to blending it with the heated air. A temperature control determines the discharge airtemperature by operating the temperature control cable, which moves the blend-air door. This allows an almostimmediate control of the output air temperature of the system. The mode door cable operates the mode-air doorswhich direct the flow of the conditioned air out the various air outlets, depending on the mode selected. Whenequipped with A/C, the recirculation door actuator operates the recirculation-air door which closes off the fresh airintake and recirculates the air already inside the vehicle. The electric recirculation door actuator and the blower motorare connected to the vehicle electrical system by the instrument panel wire harness. The blower motor controls thevelocity of air flowing through the HVAC housing assembly by spinning the blower wheel within the HVAC housing atthe selected speed by use of the blower motor resistor, which is located in the dash panel in the engine compart-ment.

The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-airand mode-air doors. The air inlet housing must be removed from HVAC housing and disassembled for service of therecirculation-air door. The HVAC housing must be removed from the vehicle and disassembled for service of the A/Cevaporator.

Specifications



All General Service Screw 2

Evaporator House Bolt 9 ± 1

Expansion Valve Bolt 7.5 ± 1

Pipeline Stent 4

Refrigerant Lines To A/C Accumulator 6

Condenser Bolt 6

Refrigerant Lines To A/C Compressor Bolt 30

Refrigerant Lines 10

Refrigerant Lines To A/C Evaporator Bolt 25

13


Special Tools


GENERAL INFORMATION


DIAGNOSIS & TESTINGBlower Motor Electrical TroubleshootingTo determine if an open condition exists within the blower motor circuit wiring, it is necessary to disconnect the neg-ative battery cable and check for continuity within the blower motor circuits using an ohmmeter.

Possible causes of an inoperative blower motor include the following:• Open fuse• Inoperative blower motor switch• Inoperative blower motor• Inoperative blower motor circuit wiring or wiring harness electrical connectors

Blower Motor NoiseTo determine if the blower motor is the source of the noise, simply switch the blower motor from Off to On. To verifythat the blower motor is the source of the noise, unplug the blower motor wire harness connector and operate theheater-A/C system. If the noise goes away, possible causes include:• Foreign material on fresh air inlet screen• Foreign material in blower wheel• Foreign material in HVAC housing• Incorrect blower motor mounting• Deformed or damaged blower wheel• Worn blower motor bearings or brushes

Blower Motor VibrationPossible causes of a blower motor vibration include:• Incorrect blower motor mounting• Foreign material in blower wheel• Deformed or damaged blower wheel• Worn blower motor bearings

13


ON-VEHICLE SERVICE

HVAC Housing Assembly

Removal & Installation1. Evacuate the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating and Air Condition-

ing).2. Disconnect heater core hoses (1).

3. Remove the instrument panel (See Instrument Panel Removal & Installation in Section 15 Body).4. Remove the HVAC housing assembly retaining

nuts (1) in the engine compartment.

5. Remove the HVAC housing assembly retaining bolt(1) from the instrument panel.(Tighten: Evaporator assembly retaining bolt to 25± 2 N·m)

6. Disconnect the electrical connector (2).

7. Remove the HVAC housing assembly.8. Installation is in the reverse order of removal.

VISM130024

VISM130008

VISM130016


Installation Notes:

• Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the refriger-ant line fittings.

• Use only the specified O-rings as they are made of a special material for the R-134a system.• Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.• Recharge the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating and Air Condition-

ing).

Blower Motor

DescriptionThe blower motor is mounted in the HVAC housing. The following are blower motor functions:• The blower motor will operate whenever the ignition switch is in the ON position and the blower motor control

is in any position except Off.• The blower motor can be accessed for service from underneath the instrument panel.• The blower motor and blower motor wheel are factory balanced as an assembly and cannot be adjusted or

repaired and must be replaced if found inoperative or damaged.

OperationThe blower motor is used to control the velocity of air moving through the HVAC housing by spinning the blowerwheel within the HVAC air inlet housing at the selected speed. The blower motor is a 12-volt, direct current (DC)motor mounted within a plastic housing with an integral wire harness connector. The blower wheel is secured to theblower motor shaft and is positioned within the air inlet housing on the passenger side of the HVAC housing.


NOTE :The blower motor is located on the bottom of the HVAC housing. The blower motor can be removed from the vehiclewithout having to remove the HVAC housing.

1. Disconnect the blower motor electrical connector(1).

2. Remove the mounting bolts (2) for the blowermotor.

3. Pull out the blower motor.4. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

VISM130005

13


SYSTEM PLUMBING


DIAGNOSIS & TESTING 13-35A/C Compressor Noise Testing 13-35Refrigerant System Leaks 13-35Refrigerant System Empty 13-36Refrigerant System Low 13-36


A/C System Evacuation and Recharge 13-37Connecting Refrigerant Recovery/Recycling Station 13-37A/C System Evacuation 13-38A/C System Recharge 13-38

Compressor 13-39Description 13-39Operation 13-39Removal & Installation 13-39

Evaporator 13-41Description 13-41Operation 13-41Removal & Installation 13-41

Condenser 13-41Description 13-41Operation 13-41Removal & Installation 13-42

Accumulator 13-42Description 13-42Operation 13-42Removal & Installation 13-43

Liquid Line 13-43Description 13-43Operation 13-43Removal & Installation 13-43

Suction Line 13-45Description 13-45Removal & Installation 13-45

Heater Core 13-47Removal & Installation 13-47


GENERAL INFORMATIONDescriptionThe A/C refrigerant lines and pipes are used to carry the refrigerant between the various A/C system components.

Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire A/C system and canreduce the flow of refrigerant within the system.

OperationHigh pressure is produced in a refrigerant system when the A/C compressor is operating. Extreme care must beexercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a goodpractice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition andproperly routed. Depending on vehicle, model and market application, refrigerant lines are connected to each other orother A/C system components with block-type or quick-connect type fittings. To ensure the integrity of the refrigerantsystem, O-rings and/or gaskets may be used to seal the refrigerant system connections. The refrigerant lines andhoses cannot be repaired and must be replaced if leaking or damaged.

WARNING!

The A/C system contains refrigerant under high pressure. Repairs should only be performed by qualified servicepersonnel. Serious or fatal injury may result from improper service procedures.If an accidental A/C system discharge occurs, ventilate the work area before resuming service. Large amounts ofrefrigerant released in a closed work area will displace the oxygen and cause suffocation and serious or fatalinjury.

CAUTION:• Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12 equipment or

parts on an R-134a A/C system. These refrigerants are not compatible and damage to the A/Csystem will result.

• Do NOT run the engine while using a vacuum pump on the A/C system or with a vacuum presentwithin the A/C system. Failure to follow this caution will result in serious A/C compressor dam-age.

• Do not overcharge the refrigerant system. Overcharging will cause excessive compressor headpressure and can cause compressor noise and A/C system failure.

Specifications



A/C Compressor Bracket Bolt 40

A/C Compressor Line Bolt 20

A/C Refrigerant Charge Specifications

DESCRIPTION CAPACITY (g)

R-134a Refrigerant 625 ± 10

13


A/C Oil Specifications

DESCRIPTION ML

Compressor 150

Condenser 30

Evaporator 30

Accumulator 20

Special Tools

Refrigerant Recovery/Recycling Station

GENERAL INFORMATION


DIAGNOSIS & TESTINGA/C Compressor Noise TestingWhen investigating an A/C system related noise, you must first know the conditions under which the noise occurs.These conditions include: weather, vehicle speed, transaxle in gear or neutral, engine speed, engine temperature,and any other special conditions. Noises that develop during A/C operation can often be misleading. For example:what sounds like a failed bearing, may be caused by loose bolts, nuts, mounting brackets or a loose compressorassembly.

NOTE :The A/C compressor must be replaced if any unusual noise is heard from the compressor itself.

NOTE :Drive belts are speed sensitive. At different engine speeds and depending upon drive belt tension, drive belts candevelop noises that are mistaken for an A/C compressor noise. Improper drive belt tension can cause a misleadingnoise when the compressor is operating at maximum displacement, which may not occur when the compressor is atminimum displacement.

1. Select a quiet area for testing.2. Duplicate the complaint conditions as much as possible.3. Turn the A/C system On and Off several times to clearly identify any compressor noise.4. Listen to the A/C compressor while it is operating at maximum and minimum displacement.5. Probe the A/C compressor with an engine stethoscope or a long screwdriver with the handle held to your ear to

better localize the source of the noise.6. To duplicate high-ambient temperature conditions (high head pressure), restrict the air flow through the A/C con-

denser. Install a manifold gauge set or a scan tool to be certain that the discharge pressure does not exceed2600 kPa.

7. Check the condition of the accessory drive belt.NOTE: The A/C compressor must be replaced if the drive hub is broken or if the compressor shaft does notrotate smoothly.

8. Check the compressor hub and pulley and bearing assembly. Be certain that the hub and pulley are properlyaligned and that the pulley bearing is mounted securely to the A/C compressor. .

9. Check the refrigerant system plumbing for incorrect routing, rubbing or interference, which can cause unusualnoises. Also check the refrigerant lines and hoses for kinks or sharp bends that will restrict refrigerant flow, whichcan cause noises.

10. Loosen all of the compressor mounting hardware and retighten.CAUTION:Do NOT run the engine with a vacuum pump in operation or with a vacuum present within theA/C system. Failure to follow this caution will result in serious A/C compressor damage.

11. If the noise is from opening and closing of the high pressure relief valve, recover, evacuate and recharge therefrigerant system, If the high pressure relief valve still does not seat properly, replace the A/C compressor.

12. If the noise is from liquid refrigerant slugging in the A/C suction line, replace the A/C accumulator and check therefrigerant oil level and the refrigerant system charge.

13. If a slugging condition still exists after replacing the A/C accumulator, then replace the A/C compressor.

Refrigerant System LeaksWARNING!

R-134a service equipment or vehicle A/C system should not be pressure tested or leak tested with compressedair. Mixture of air and R-134a can be combustible at elevated pressures. These mixtures are potentially danger-ous and may result in fire or explosion causing property damage, personal injury or death. Avoid breathing A/Crefrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved serviceequipment meeting SAE requirements to discharge an R-134a system. If accidental system discharge occurs,ventilate work area before resuming service.

13


NOTE :If the A/C refrigerant system charge is empty or low, a leak in the A/C system is likely. Visually inspect all A/C lines,fittings and components for an oily residue. Oil residue can be an indicator of an A/C system leak location.

NOTE :The only way to correctly determine if the refrigerant system is fully charged with R-134a is to completely evacuateand recharge the A/C system.

Refrigerant System Empty1. Evacuate the refrigerant system to the lowest degree of vacuum possible . Determine if the system holds a vac-

uum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level,proceed to STEP 2.

2. Prepare and dispense 0.3 kilograms of R-134a refrigerant into the evacuated refrigerant system and proceed toSTEP 1 of the System Low procedure.

Refrigerant System Low1. Position the vehicle in a wind-free work area. This will aid in detecting small leaks.2. Operate the heating-A/C system with the engine at idle under the following conditions for at least 5 minutes:

Doors or windows openTransaxle in Park or Neutral with the parking brake set (depending on application)HVAC control panel set to outside airFull coolPanel modeHigh blower

€ A/C compressor engaged3. Shut the vehicle off and wait 2 - 7 minutes. Then use an electronic leak detector that is designed to detect

R-134a refrigerant and search for leaks. Fittings, lines or components that appear to be oily usually indicate arefrigerant leak. To inspect the A/C evaporator for leaks, insert the leak detector probe into the drain tube open-ing or an air outlet. A dye for R-134a is available to aid in leak detection. Use only approved refrigerant dye.

CAUTION:A leak detector only designed for R-12 refrigerant will not detect leaks in an R-134a refrigerant sys-tem.

DIAGNOSIS & TESTING


ON-VEHICLE SERVICE

A/C System Evacuation and Recharge

Connecting Refrigerant Recovery/Recycling Station

WARNING!

The A/C system is under high pressure, use caution when working on the A/C system.

VISM130026

13


1. Connect the refrigerant recovery/recycling stationto the vehicles high and low side A/C lineconnectors.NOTE: The refrigerant recovery/recycling stationblue connector (1) is connected to the A/C low sidefitting and the Red connector (2) is connected tothe A/C high side fitting.

A/C System Evacuation

CAUTION:Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/Csystem. Failure to follow this caution will result in serious A/C compressor damage.

NOTE :Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil is very difficultto remove and will cause a reliability problem with the A/C compressor.

If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled.Moisture and air mixed with the refrigerant will raise the compressor high pressure above acceptable operating lev-els. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at nearroom temperature when exposed to vacuum. To evacuate the refrigerant system:

NOTE :When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed.This will reduce the amount of effort required to make the connection.

1. With the engine OFF, connect a suitable refrigerant recovery/recycling station, refrigerant recovery machine or amanifold gauge set with vacuum pump and refrigerant recovery equipment. Do not operate the engine with avacuum on the A/C system.

2. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimumof 45 minutes prior to charge to eliminate all moisture in system. When the suction gauge reads to the lowestdegree of vacuum possible for 30 minutes, close all valves and turn off vacuum pump. If the system fails toreach specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant systemmaintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and dischargevalves. Then allow the system to evacuate an additional 10 minutes.

3. Close all valves. Turn off and disconnect the vacuum pump.4. Charge the refrigerant system.

A/C System RechargeAfter all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerantcharge can be injected into the system.

CAUTION:A small amount of refrigerant oil is removed from the A/C system each time the refrigerant systemis recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost dur-ing the recovery process.1. Evacuate the refrigerant system (See A/C System Evacuation And Recharge In Section 13 Heating & Air Con-

ditioning).2. A manifold gauge set and an R-134a refrigerant recovery/recycling/refrigerant recovery/recycling station that

meets SAE standard J2210 should be connected to the refrigerant system.3. Open both the suction and discharge valves, then open the charge valve to allow the refrigerant to flow into the

system.

ON-VEHICLE SERVICE

VISM130027


4. When the transfer of refrigerant has stopped, close both the suction and discharge valves.5. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle

and set the heating-A/C system controls so that the A/C compressor is operating and the blower motor is runningat its lowest speed setting. Run the engine at a steady high idle (approx. 2000 RPM).

6. Open the low-pressure valve to allow the remaining refrigerant to transfer to the refrigerant system.

WARNING!

Take care not to open the discharge (high pressure) valve at this time. Failure to follow this warning could resultin possible personal injury or death.

7. Disconnect the refrigerant recovery/recycling station and manifold gauge set from the refrigerant system serviceports.

8. Reinstall the caps onto the refrigerant system service ports.

Compressor

DescriptionThe A/C system uses a 7-piston incline-disk compressor. The compressor is a variable displacement compressor.The variable displacement compressor has a swash plate that rotates to reciprocate pistons, which compress refrig-erant. The variable displacement compressor changes the swash plate angle to change the refrigerant displacement.The variable displacement compressor manages displacement by controlling refrigerant differential pressure beforeand after a throttle at the discharge side; achieving precise cooling capability in accordance with the cabin environ-ment and driving conditions.

CAUTION:Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/Csystem. Failure to follow this caution will result in serious A/C compressor damage.

NOTE :The compressor drive hub and the pulley and bearing assembly cannot be serviced separately from the A/C com-pressor. In the event of drive hub or pulley and bearing assembly damage or failure, the A/C compressor, drive huband pulley and bearing must be replaced as an assembly.

OperationThe A/C compressor is controlled by the Engine Control Module (ECM), depending on engine application. The ECMcalculates compressor displacement required by A/C system load and demand by monitoring vehicle speed, A/C highside pressure, engine speed, evaporator temperature, accelerator pedal position, ambient temperature and A/C-heater request signals. The ECM then sends a pulse width modulated signal to the A/C compressor control solenoidto increase or decrease refrigerant flow through an orifice located within the compressor housing. The amount ofrefrigerant allowed to pass through the orifice in the compressor determines the head pressure which controls theangle of the swash plate, which in turn, determines the amount of compressor displacement. When there is nodemand for A/C, the swashplate is adjusted to nearly a zero degree angle, which removes compressor torque dragfrom the engine.

NOTE :The A/C compressor cannot be repaired and it must be replaced if found inoperative or damaged. If an internal fail-ure of the A/C compressor has occurred, the A/C accumulator and the A/C liquid line must also be replaced.


Review safety precautions and warnings in this group before performing this procedure. Failure to follow thewarnings and cautions could result in possible personal injury or death.

ON-VEHICLE SERVICE

13


CAUTION:The A/C accumulator and the A/C liquid line must be replaced if an internal failure of the A/C com-pressor has occurred. Failure to replace the A/C accumulator and the A/C liquid line can causeserious damage to the replacement A/C compressor.

NOTE :When replacing multiple A/C system components, determine how much oil should be removed from the new A/Ccompressor.

NOTE :Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failureto replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.

1. Evacuate the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Conditioning).2. Disconnect the A/C compressor electrical connector.3. Remove the engine drive belt (See Drive Belt Removal & Installation in Section 02 Engine).4. Remove the A/C compressor line bolt (1) from the

A/C compressor.(Tighten: A/C compressor line bolts to 20 N·m)NOTE: After removing the A/C lines, plug the A/Clines to prevent any debris from entering the A/Csystem.

5. Remove the A/C compressor mounting bolts (1).6. Remove the A/C compressor assembly.


Installation Notes:


• Use only the specified O-rings as they are made of a special material for the R-134a system.• Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.• Recharge the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Condition-

ing).

ON-VEHICLE SERVICE

VISM130017

VISM130004


Evaporator

DescriptionThe evaporator coil is located in the HVAC housing, under the instrument panel. The evaporator coil is positioned inthe HVAC housing so that all air that enters the housing must pass over the fins of the evaporator before it is dis-tributed through the system ducts and outlets. However, air passing over the evaporator coil fins will only be condi-tioned when the compressor is engaged and circulating refrigerant through the evaporator coil tubes.

OperationRefrigerant enters the evaporator from the orifice tube as a low-temperature, low-pressure liquid. As air flows overthe fins of the evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by therefrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gasbefore it leaves the evaporator. The evaporator core housing directs airflow from the blower motor through the evap-orator core and heater core. All airflow from the blower motor passes through the evaporator core. The airflow is thendirected through or around the heater core by the temperature blend door(s).

Removal & Installation1. Evacuate the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Conditioning).2. Remove the instrument panel (See Instrument Panel Removal & Installation in Section 15 Body & Accessories).3. Remove the HVAC housing assembly (See HVAC Housing Assembly Removal & Installation in Section 13 Heat-

ing & Air Conditioning).4. Remove the screws on the lid of the evaporator

core assembly, and then remove the evaporatorcore assembly (1).


Installation Notes:



ing).

Condenser

DescriptionThe condenser is located in the air flow in front of the engine cooling radiator. The condenser transforms the refrig-erant from a gas into a liquid. It is attached to the vehicle with bolts and the A/C lines with fittings.

OperationWhen the refrigerant gas releases its heat, it condenses. When the refrigerant leaves the condenser, it has becomea high-pressure liquid refrigerant. The volume of air flowing over the condenser fins is critical to the proper coolingperformance of the air conditioning system. Therefore, it is important that there are no objects placed in front of theradiator grille openings in the front of the vehicle or foreign material on the condenser fins that might obstruct proper

ON-VEHICLE SERVICE

VISM130021

13


air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or condenserservice.

Removal & Installation1. Disconnect the negative battery cable.2. Evacuate the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Conditioning).3. Remove the front bumper (See Front Bumper Removal & Installation in section 15 Body & Accessories).4. Remove the nut (3) that secures the A/C high-pres-

sure line to the A/C condenser. Remove and dis-card the O-ring seal and gasket.NOTE: After removing the A/C lines, plug the A/Clines to prevent any debris from entering the A/Csystem.

5. Remove the nut (2) that secures the A/C low-pres-sure line to the A/C condenser. Remove and dis-card the O-ring seal and gasket.

6. Remove the condenser mounting bolts (1).

7. Remove the condenser from the engine compartment.8. Installation is in the reverse order of removal.

Installation Notes:



ing).

Accumulator

DescriptionThe accumulator is connected directly to the evaporator outlet and stores excess liquid refrigerant. Accumulators areused on systems that use an orifice tube to meter refrigerants into the evaporator.

OperationThe primary function of the accumulator is to isolate the compressor from any damaging liquid refrigerant. The accu-mulator removes debris and moisture from the air conditioning system.

Removal & Installation1. Disconnect the negative battery cable.

ON-VEHICLE SERVICE

VISM130015


2. Evacuate the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Conditioning).3. Remove the nuts (2) connect the suction lines to

accumulator.4. Remove the accumulator mounting bolts (1).

5. Remove the accumulator. Remove and discard the O-ring seals and gaskets.NOTE: After removing the A/C lines, plug the A/C lines to prevent any debris from entering the A/C system.


Installation Notes:



ing).

Liquid Line

DescriptionThe A/C liquid line connects the A/C condenser to the A/C accumulator and the A/C accumulator to the A/C evap-orator.

OperationThe high pressure A/C liquid line is the refrigerant line that carries refrigerant from the A/C condenser to the A/Caccumulator. Air conditioning hoses are designed to control liquid and gas at high pressures and temperatures. Thehoses are usually flexible and manufactured with special metal fittings at the ends to prevent leaks and provide asure seal and connection between components.

Removal & Installation1. Disconnect and isolate the negative battery cable.2. Evacuate the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Conditioning).

ON-VEHICLE SERVICE

VISM130014

13


3. Remove the bolt (2) that secures the A/C liquid andsuction line assembly to the A/C expansion valve.

4. Remove the two retaining clamps (1) for the refrig-erant lines..

5. Remove the nut (1) connecting the liquid line to thecondenser.

6. Remove the A/C liquid line assembly from the A/C evaporator to compressor and remove and discard the seals.7. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports.8. Remove the A/C liquid line assembly from accumulator to condenser and from accumulator to evaporator.9. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

VISM130013

VISM130023


Installation Notes:



ing).

Suction Line

DescriptionThe A/C suction line connects the A/C evaporator to the A/C compressor and the A/C compressor to the A/C con-denser.

Removal & Installation1. Disconnect the negative battery cable.2. Evacuate the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Conditioning).3. Remove the bolt (2) that secures the A/C liquid and

suction line assembly to the A/C expansion valve.4. Remove the two retaining clamps (1) for the refrig-

erant lines.

5. Remove the bolt (1) connecting the suction line tothe A/C compressor.

ON-VEHICLE SERVICE

VISM130013

VISM130017

13


6. Remove the nut (1) connecting the suction line tothe condenser.

7. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports.8. Remove the A/C suction line assembly from evaporator to compressor.9. Installation is in the reverse order of removal.

Installation Notes:



ing).

ON-VEHICLE SERVICE

VISM130022


Heater Core

Removal & Installation1. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).2. Evacuate the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Conditioning).3. Remove the HVAC housing assembly (See HVAC Housing Removal & Installation in Section 13 Heating & Air

Conditioning).4. Remove the heater core retaining screws (1).

5. Remove the heater core.6. Installation is in the reverse order of removal.

Installation Notes:


ON-VEHICLE SERVICE

VISM130007

13


RESTRAINTS

14CONTENTS

pageAirbag System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

Seat Belt System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-41

AIRBAG SYSTEM

GENERAL INFORMATION 14-2Description 14-2Operation 14-3Specifications 14-3Special Tools 14-4Electrical Schematics 14-6Restraints Control Module ConnectorPin-Out Table 14-9

DIAGNOSIS & TESTING 14-10Diagnostic Help 14-10Intermittent DTC Troubleshooting 14-10Ground Inspection 14-10Diagnostic Tools 14-10

Diagnostic Trouble Code (DTC) List 14-11Restraints Control Module DTC List 14-11

Diagnostic Trouble Code (DTC) Tests 14-15B1102 - Battery Voltage Low 14-15B1322 - WCS ECU Defect 14-20

B1346 - Driver Airbag Resistance TooHigh Or Open (1St Stage) 14-22B1352 - Passenger Airbag ResistanceToo High Or Open (1St Stage) 14-28B1361 - Pretensioner Front-DriverResistance Too High, B1363 -Pretensioner Front-Driver ResistanceCircuit Short To Ground 14-33


Airbag System Disarming Procedure 14-38Description 14-38

Driver Side Airbag 14-38Removal & Installation 14-38

Front Passenger Side Airbag 14-39Removal & Installation 14-39

Restraints Control Module (RCM) 14-40Removal & Installation 14-40

14



Available occupant restraints for this vehicle include both active and passive types. Active restraints are those whichrequire the vehicle occupants to take some action to employ, such as fastening a seat belt; while passive restraintsrequire no action by the vehicle occupants to be employed.

1 - Driver Side Airbag

2 - Steering Wheel

3 - Spiral Cable

4 - Restraints Control Module Electrical Harness

5 - Front Passenger Side Airbag

6 - Restraints Control Module

VISM140001


Active Restraints

• Front Seat Belts• Rear Seat Belts

Passive Restraints

• Driver Airbag• Passenger Airbag• Seat Belt Tensioner

Operation

Active RestraintsThe primary passenger restraints are the seat belts. Seat belts are referred to as an active restraint because thevehicle occupants are required to physically fasten and properly adjust these restraints in order to benefit from them.

Passive RestraintsThe passive restraints are referred to as a supplemental restraint system because they were designed and areintended to enhance the protection for the occupants of the vehicle only when used in conjunction with the seat belts.They are referred to as passive restraints because the vehicle occupants are not required to do anything to makethem operate; however, the vehicle occupants must be wearing their seat belts in order to obtain the maximum safetybenefit from the supplemental restraint system.

The supplemental restraint system electrical circuits are continuously monitored and controlled by a microprocessorand software contained within the Restraints Control Module (RCM). An airbag indicator in the Instrument Clusterilluminates for about seven seconds as a bulb test each time the ignition switch is turned to the ON or START posi-tions. Following the bulb test, the airbag indicator is turned ON or OFF by the RCM to indicate the status of thesupplemental restraint system. If the airbag indicator comes ON at any time other than during the bulb test, it indi-cates that there is a problem in the supplemental restraint system electrical circuits. Such a problem may causeairbags not to deploy when required, or to deploy when not required.

Deployment of the supplemental restraints depends upon the angle and severity of an impact. When an impact issevere enough, the microprocessor in the RCM signals the inflator of the appropriate airbag units to deploy theirairbag cushions. The front seat belt tensioners are provided with a deployment signal by the RCM in conjunction withthe front airbags.

Specifications



Driver Side Airbag Mounting Bolt 10

Restraints Control Module Mounting Nut 10

Front Passenger Side Airbag Mounting Bolt 10

GENERAL INFORMATION

14


Special Tools



General Airbag Special Load Tool - Resistor Harness(For Driver’s and Passenger’s (Front) Airbag)

GENERAL INFORMATION


General Airbag Special Load Tool - Dummy Resistor

General Airbag Special Load Tool - Resistor Harness(For Seat Belt Pre-tensioner)

GENERAL INFORMATION

14



Restraint System (Page 1 of 3)

GENERAL INFORMATION

VISMW140013T



GENERAL INFORMATION

VISMW140014T



GENERAL INFORMATION

VISMW140015T

14


Restraints Control Module Connector Pin-Out Table

PIN CIRCUIT IDENTIFICATION PIN CIRCUITIDENTIFICATION

1 GND 43 -

2 - 44 -

3 Driver Airbag Hi 45 -

4 Driver Airbag Lo 46 -

5 Front Passenger Airbag Hi 47 -

6 Front Passenger Airbag Lo 48 -

7 - 49 -

8 - 50 -

9 - 51 -

10 - 52 -

11 - 53 -

12 - 54 -

13 - 55 -

14 - 56 -

15 CAN-Hi 57 -

16 CAN-Lo 58 -

17 - 59 -

18 - 60 -

19 - 61 -

20 - 62 -

21 - 63 -

22 - 64 -

23 - 65 -

24 - 66 -

25 Ignition-Switch 67 -

26 - 68 -

27 - 69 -

28 - 70 -

29 - 71 -

30 - 72 -

31 - 73 -

32 - 74 -

33 - 75 -

34 - 76 -

35 - 77 -

36 - 78 -

37 Driver Seat Belt Pre-tensioner Lo 79 -

38 Driver Seat Belt Pre-tensioner Hi 80 -

39 Front Passenger Seat Belt Pre-tensioner Hi 81 -

40 Front Passenger Seat Belt Pre-tensioner Lo 82 -

41 - 83 -

42 - 84 -

GENERAL INFORMATION

14



modules through the data network.2. Confirm that the malfunction is current and carry-out the diagnostic tests and repair procedures.3. If the Diagnostic Trouble Code (DTC) cannot be deleted, it is a current fault.4. Use only a digital multimeter to perform voltage readings on electronic systems.5. Refer to any Technical Bulletins that may apply to the failure.6. Visually inspect the related wiring harness.7. Inspect and clean all Restraints Control Module (RCM) grounds that are related to the most current DTC.8. If numerous trouble codes were set, use a wiring schematic and look for any common ground circuits or voltage



age, or foreign material.• A data recorder, and/or oscilloscope should be used to help diagnose intermittent conditions.• Remove the Restraints Control Module (RCM) from the troubled vehicle and install in a new vehicle and test. If

the DTC cannot be deleted, the RCM is malfunctioning. If the DTC can be deleted, return the RCM to the origi-nal vehicle.


Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drasticallyaffect an electronically controlled circuit. A poor or corroded ground can affect the circuit. Perform the following wheninspecting a ground connection:



Diagnostic Tools

Diagnostic Scan Tool X-431Read the following when connecting the X-431 scan tool:• Connect the scan tool to the Data Link Connector (DLC) for communication with the vehicle.• The DLC is located on the driver side compartment under the steering column (it is attached to the instrument

panel and accessible from the driver seat).• The DLC is rectangular in design and capable of accommodating up to 16 terminals.• The electrical connector has keying features to allow easy connection.


Airbag Special Load ToolUse the airbag special load tool to diagnose airbag system faults:• The airbag special load tool simulates airbag system components.

NOTE :Using the airbag special load tool will help prevent other airbag DTCs from being set while troubleshooting the sys-tem.

Digital MultimeterRead the following when using the digital multimeter:• Use a multimeter to troubleshoot electrical problems and wiring systems.• Use a multimeter for basic fault finding and bench testing.• Use a multimeter to measure voltage, current and resistance.


Restraints Control Module DTC List

DTC DTC DEFINITION

B1101 Battery Voltage High

B1102 Battery Voltage Low

B1321 WCS Short To Battery Or No Response

B1322 WCS ECU Defect

B1323 WCS Sensor Defect

B1324 WCS Communication Error

B1325 WCS Wrong ID

B1326 FIS-Driver Short To Ground

B1327 FIS-Driver Short To Battery

B1328 FIS-Driver Defect

B1329 FIS-Driver Communication Error

B1330 FIS-Driver Wrong ID

B1331 FIS-Passenger Short To Ground

B1332 FIS-Passenger Short To Battery

B1333 FIS-Passenger Defect

B1334 FIS-Passenger Communication Error

B1335 FIS-Passenger Wrong ID

B1336 FIS-Center Short To Ground

B1337 FIS-Center Short To Battery

B1338 FIS-Center Defect

B1339 FIS-Center Communication Error

B1340 FIS-Center Wrong ID

B1346 Driver Airbag Resistance Too High (1st Stage)

B1347 Driver Airbag Resistance Too Low (1st Stage)

B1348 Driver Airbag Resistance Circuit Short To Ground (1st Stage)

B1349 Driver Airbag Resistance Circuit Short To Battery (1st Stage)

B1352 Passenger Airbag Resistance Too High (1st Stage)

B1353 Passenger Airbag Resistance Too Low (1st Stage)

B1354 Passenger Airbag Resistance Circuit Short To Ground (1st Stage)

DIAGNOSIS & TESTING

14


DTC DTC DEFINITION

B1355 Passenger Airbag Resistance Circuit Short To Battery (1st Stage)

B1356 Rear Airbag Resistance Too Low

B1357 Rear Airbag Resistance Too High

B1358 Rear Airbag Resistance Circuit Short To Ground

B1359 Rear Airbag Resistance Circuit Short To Battery

B1361 Pretensioner Front-Driver Resistance Too High

B1362 Pretensioner Front-Driver Resistance Too Low

B1363 Pretensioner Front-Driver Resistance Circuit Short To Ground

B1364 Pretensioner Front-Driver Resistance Circuit Short To Battery

B1367 Pretensioner Front-Passenger Resistance Too High

B1368 Pretensioner Front-Passenger Resistance Too Low

B1369 Pretensioner Front-Passenger Resistance Circuit Short To Ground

B1370 Pretensioner Front-Passenger Resistance Circuit Short To Battery

B1371 STPS-Driver Instability

B1372 STPS-Passenger Instability

B1378 Side Airbag Front - Driver Resistance Too High

B1379 Side Airbag Front - Driver Resistance Too Low

B1380 Side Airbag Front - Driver Resistance Circuit Short To Ground

B1381 Side Airbag Front - Driver Resistance Circuit Short To Battery

B1382 Side Airbag Front - Passenger Resistance Too High

B1383 Side Airbag Front - Passenger Resistance Too Low

B1384 Side Airbag Front - Passenger Resistance Circuit Short To Ground

B1385 Side Airbag Front - Passenger Resistance Circuit Short To Battery

B1387 STPS-Driver Short Or Short To Ground

B1388 STPS-Driver Open Or Short To Battery

B1389 STPS-Driver Defect

B1390 STPS-Passenger Short Or Short To Ground

B1391 STPS-Passenger Open Or Short To Battery

B1392 STPS-Passenger Defect

B1395 Firing Loops Interconnection Fault

B1400 SIS Front-Driver Defect

B1401 SIS Front-Driver Circuit Short To Ground

B1402 SIS Front-Driver Circuit Short To Battery

B1403 SIS Front-Passenger Defect

B1404 SIS Front-Passenger Circuit Short To Ground

B1405 SIS Front-Passenger Circuit Short To Battery

B1409 SIS Front-Driver Communication Error

B1410 SIS Front-Passenger Communication Error

B1412 SIS Rear-Driver Communication Error

B1413 SIS Rear-Passenger Communication Error

B1414 SIS Front-Driver Wrong ID

B1415 SIS Front-Passenger Wrong ID

B1416 SIS Rear-Driver Wrong ID

DIAGNOSIS & TESTING


DTC DTC DEFINITION

B1417 SIS Rear-Passenger Wrong ID

B1418 SIS Rear-Driver Defect

B1419 SIS Rear-Passenger Defect

B1451 SIS Rear-Driver Circuit Short To Ground

B1452 SIS Rear-Driver Circuit Short To Battery

B1454 SIS Rear-Passenger Circuit Short To Ground

B1455 SIS Rear-Passenger Circuit Short To Battery

B1473 Inflatable Curtain Airbag-Driver Resistance Too High

B1474 Inflatable Curtain Airbag-Driver Resistance Too Low

B1475 Inflatable Curtain Airbag-Driver Resistance Circuit Short To Ground

B1476 Inflatable Curtain Airbag-Driver Resistance Circuit Short To Battery

B1477 Inflatable Curtain Airbag-Passenger Resistance Too High

B1478 Inflatable Curtain Airbag-Passenger Resistance Too Low

B1479 Inflatable Curtain Airbag-Passenger Resistance Circuit Short To Ground

B1480 Inflatable Curtain Airbag-Passenger Resistance Circuit Short To Battery

B1481 2nd Stage Driver Airbag Resistance Too High

B1482 2nd Stage Driver Airbag Resistance Too Low

B1483 2nd Stage Driver Airbag Resistance Circuit Short To Ground

B1484 2nd Stage Driver Airbag Resistance Circuit Short To Battery

B1485 2nd Stage Passenger Airbag Resistance Too High

B1486 2nd Stage Passenger Airbag Resistance Too Low

B1487 2nd Stage Passenger Airbag Resistance Circuit Short To Ground

B1488 2nd Stage Passenger Airbag Resistance Circuit Short To Battery

B1511 Buckle Switch Driver Open Or Short To Battery

B1512 Buckle Switch Driver Short Or Short To Ground

B1513 Buckle Switch Passenger Open Or Short To Battery

B1514 Buckle Switch Passenger Short Or Short To Ground

B1515 Buckle Switch Driver Defect

B1516 Buckle Switch Passenger Defect

B1517 Buckle Switch Driver Instability

B1518 Buckle Switch Passenger Instability

B1527 Passenger Airbag On/Off Switch Open Or Short To Battery

B1528 Passenger Airbag On/Off Switch Short Or Short To Ground

B1529 Passenger Airbag On/Off Switch Defect

B1530 Passenger Airbag On/Off Switch Instability

B1620 Internal Fault - Replace ECU

B1650 Crash Record In 1st Stage Only (Frontal - Replace ECU)

B1651 Crash Record In Driver Side Airbag (Replace ECU)

B1652 Crash Record In Passenger Side Airbag (Replace ECU)

B1657 Crash Record In Belt Pretensioner Only

B1658 Belt Pretensioner 6 Times Deployment

B1659 Rear Crash Detected

B1670 Crash Recorded In Fault Stage (Frontal - Replace ECU)

DIAGNOSIS & TESTING

14


DTC DTC DEFINITION

B1676 Crash Output Short To Ground

B1677 Crash Output Short To Battery

B1701 Buckle Pretensioner - Driver Resistance Too High

B1702 Buckle Pretensioner - Driver Resistance Too Low

B1703 Buckle Pretensioner - Driver Resistance Circuit Short To Ground

B1704 Buckle Pretensioner - Driver Resistance Circuit Short To Battery

B1706 Buckle Pretensioner - Passenger Resistance Too High

B1707 Buckle Pretensioner - Passenger Resistance Too Low

B1708 Buckle Pretensioner - Passenger Resistance Circuit Short To Ground

B1709 Buckle Pretensioner - Passenger Resistance Circuit Short To Battery

B1738 PPS Front - Driver Wrong ID

B1739 PPS Front - Driver Defect

B1740 PPS Front - Driver Short To Ground

B1741 PPS Front - Driver Short To Battery

B1742 PPS Front - Driver Communication Error

B1743 PPS Front - Driver Environment Fail

B1744 PPS Front - Passenger Wrong ID

B1745 PPS Front - Passenger Defect

B1746 PPS Front - Passenger Short To Ground

B1747 PPS Front - Passenger Short To Battery

B1748 PPS Front - Passenger Communication Error

B1749 PPS Front - Passenger Environment Fail

B1750 PPS Rear - Driver Wrong ID

B1751 PPS Rear - Driver Defect

B1752 PPS Rear - Driver Short To Ground

B1753 PPS Rear - Driver Short To Battery

B1754 PPS Rear - Driver Communication Error

B1755 PPS Rear - Driver Environment Fail

B1756 PPS Rear - Passenger Wrong ID

B1757 PPS Rear - Passenger Defect

B1758 PPS Rear - Passenger Short To Ground

B1759 PPS Rear - Passenger Short To Battery

B1760 PPS Rear - Passenger Communication Error

B1761 PPS Rear - Passenger Environment Fail

B2500 Warning Lamp

B2502 Passenger Airbag Telltale Lamp

B2505 Passenger Airbag Off Warning Lamp Failure

B2660 CAN Bus Off

B2661 CAN Communication Error - Network Management

B2662 CAN Communication Error - BCM

B2663 CAN Communication Error - ICM

DIAGNOSIS & TESTING



B1102 - Battery Voltage Low

DIAGNOSIS & TESTING

VISMW140002T

14


DIAGNOSIS & TESTING

VISMW140003T


NOTE :The Restraints Control Module (RCM) ground pin must be connected to the vehicle chassis in the immediate locationof the RCM mounting area.





B1102 Battery voltage low Ignition switch: ON

Restraints ControlModule (RCM)detected that thebattery voltage isexcessively low.

• Battery• Charging system• Harness is open orshorted• Restraints ControlModule (RCM)

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn the ignition switch on.• With the scan tool, record and erase stored DTCs in the Restraints Control Module (RCM).• Turn ignition switch off, and then turn the ignition switch on.• With the scan tool, select view DTC and data stream in the RCM.• If the DTC is detected, the DTC condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-

bleshooting in Section 14 Restraints for more information).

NOTE :• Troubleshoot any Engine Control Module (ECM) charging/cranking DTCs before proceeding.• If the warning lamp goes out immediately after the warning lamp flashed for 6 - 7 seconds, this indicates that the

system is OK.• If the warning lamp is on for 6 - 7 seconds continuously, then goes out, or the warning lamp is on continuously,

this indicates that there are history DTCs in the system. Use the Scan Tool to erase the DTCs.• If any other condition occurs, use the Scan Tool to erase the history DTCs first, then check the warning lamp. If

the warning lamp does not go out immediately after the warning lamp flashes for 6 - 7 seconds when using theScan Tool, erase the history DTCs first.

• In the course of troubleshooting the airbag system, make sure the system power supply is shut off, and wait twominutes for the system capacitor to discharge.

• The following tools are required to perform the following test:• X-431 Scan Tool• Airbag Special Load Tool• Digital Multimeter• The squib circuit connectors integrate a �shorting� spring (which prevents the airbag from deploying unintentionally

due to static electricity by shorting the positive wire to the negative wire in the squib circuit when the connectorsare disconnected). Therefore, if the airbag electrical connector or spiral cable electrical connector is damaged orimproperly connected, the shorting spring may not be released when the electrical connector is connected.

DIAGNOSIS & TESTING

14




• Turn ignition switch off.• Disconnect the negative battery cable.• Loosen and retighten ground screws on the body (See Ground Inspection in Section 14 Restraints for more

information).• Inspect the ground connection C-203 position (See Vehicle Wiring Harness Information - Main Harness in Sec-

tion 16 Wiring).

Is the ground connection OK?


No >> • Repair or replace ground connection.

2. CHECK RESTRAINTS CONTROL MODULE (RCM) POWER SUPPLY

• Turn ignition switch off.• Disconnect the Restraints Control Module (RCM)

electrical connector (1).

• Turn ignition switch on• Check voltage between terminal 1 and terminal 25 in the RCM electrical connector C-036 terminal side.

RESTRAINTSCONTROL

MODULE (RCM)CONNECTOR

TERMINAL

VOLTAGE

1 & 25 Less than 9 V



No >> • Replace the RCM.

DIAGNOSIS & TESTING

LTSM140006



• Start the engine, raise the engine speed to above 1000 rpm.• Measure the charging system voltage with a digital multimeter at the battery positive and negative terminals.





• Maintain engine speed above 1000 rpm for a few minutes.• Turn the ignition switch off.• Measure the voltage drop with a digital multimeter at the battery positive and negative terminals while cranking

the engine.• Battery voltage should be more than approximately 9.0 V.




5. CHECK RESTRAINTS CONTROL MODULE (RCM) SUPPLY CIRCUIT

• Turn the ignition switch off.• Disconnect the battery positive terminal.• Measure continuity between the RCM connector terminal 25 and the battery positive terminal.• Continuity should exist.



No >> • Check fuse.• Check the electrical harness for an open or high resistance.

6. CHECK DTC

• With the X-431 scan tool, read RCM DTCs.• Refer to �DTC Confirmation Procedure�.

Is DTC B1102 still present?

Yes >> • Replace the RCM.


DIAGNOSIS & TESTING

14


B1322 - WCS ECU Defect





B1322 WCS ECU defect Ignition switch: ON

Restraints ControlModule (RCM)

detected an internalfailure.

RCM










DIAGNOSIS & TESTING



1. CHECK DTC


Is DTC B1322 present?


No >> • The conditions that caused this code to set are not present at this time (See Diagnosis & TestingDiagnostic Help in Section 14 Restraints).

2. CHECK RESTRAINTS CONTROL MODULE (RCM) POWER SUPPLY AND GROUND CIRCUIT

• Check the RCM voltage supply and ground circuits for an open, high resistance or short circuits.



No >> • Replace the circuit for open or shorts as necessary.

3. CHECK DTC

• With the X-431 scan tool, read RCM DTCs.• Refer to �DTC Confirmation Procedure�.


Yes >> • Replace the Restraints Control Module (RCM).


DIAGNOSIS & TESTING

14


B1346 - Driver Airbag Resistance Too High Or Open (1St Stage)

DIAGNOSIS & TESTING

VISMW140006T



WARNING!

After installing the Restraints Control Module (RCM), make sure all of the connectors are firm, and all of theharness are normal. The resistance between the RCM shell and body is less than 100 m�.





B1346Driver airbag

resistance too highor open (1st stage)

Ignition switch: ON

Restraints ControlModule (RCM)detected that theresistance of RCMconnector terminalsis out of thespecification range.

• Spiral cable• Driver airbag• Driver airbagconnector• Harness is openbetween spiral cableand RCM• RCM










DIAGNOSIS & TESTING

14



1. CHECK DRIVER AIRBAG

• Turn the ignition switch off.• Disconnect the negative battery cable.

WARNING!

To avoid serious or fatal injury, turn ignition switch off, disconnect the negative battery cable and wait two min-utes before proceeding.

• Disconnect driver airbag electrical connector C-037.

NOTE :Check connectors - Clean and repair as necessary.• Connect the airbag special load tool (connect special tool dummy resistor to special tool resistor harness) to

the spiral cable side of the vehicle harness (in place of the driver airbag).

WARNING!

To avoid serious or fatal injury, the driver airbag should not be checked with a multimeter.

NOTE :If the airbag special load tool is not available, connect a known good driver airbag.• Connect the negative battery cable.

WARNING!

To avoid serious or fatal injury, reconnect the battery, then turn ignition switch on.

• Turn the ignition switch on.• With the scan tool, erase the DTC memory.• Turn ignition switch off, and wait a few seconds, then turn ignition switch on.• With the scan tool, read the RCM DTCs



No >> • Replace the driver airbag (See Driver Airbag Removal & Installation in Section 14 Restraints).• Reassemble the vehicle and road test to verify the customers complaint is repaired.

DIAGNOSIS & TESTING


2. CHECK DRIVER AIRBAG CONTROL CIRCUITS

• Disconnect the airbag special load tool (or disconnect the known good driver airbag).

WARNING!

To avoid serious or fatal injury, turn the ignition switch off, disconnect the negative battery cable and wait twominutes before proceeding.

• Disconnect the RCM connectors C-036 (1).

• Disconnect the spiral cable connector C-033.

NOTE :Check connectors - Clean and repair as necessary.

• Check harness continuity of the driver airbag circuit between the RCM electrical connector terminal 4 andthe spiral cable electrical connector terminal 11.

SPIRALCABLE

TERMINAL

RCMTERMINAL CONTINUITY

11 4 Yes

• Check harness continuity of the driver airbag circuit between the RCM electrical connector terminal 3 andthe spiral cable electrical connector terminal 12.

DIAGNOSIS & TESTING

LTSM140006

14


SPIRALCABLE

TERMINAL

RCMTERMINAL CONTINUITY

12 3 Yes




No >> • Replace the cable.

3. CHECK DRIVER AIRBAG CONTROL CIRCUITS

WARNING!


• Check harness continuity of the driver airbag circuit between the driver airbag electrical connector terminal 1and the spiral cable electrical connector terminal 11.

SPIRALCABLE

TERMINAL

DRIVERAIRBAG

TERMINALCONTINUITY

11 1 Yes

DIAGNOSIS & TESTING


• Check harness continuity of the driver airbag circuit between the RCM electrical connector terminal 2 and thespiral cable electrical connector terminal 12.

SPIRALCABLE

TERMINAL

DRIVERAIRBAG

TERMINALCONTINUITY

12 2 Yes





4. CHECK CONNECTORS

NOTE :Diagnose and repair all active codes before diagnosing stored codes (See Restraints Control Module DTC List inSection 14 Restraints).• With the scan tool, record and erase all RCM DTCs.• Using the electrical schematic as a guide, inspect the following:

− Inspect the wiring and connectors of the related airbag system wiring and connectors.− Look for any chafed, pierced, pinched, or partially broken wires.− Look for broken, bent, pushed out or corroded terminals.− Verify that there is good pin to terminal contact in the related connectors.


Yes >> • Replace as necessary.


5. CHECK DTC

• Reconnect all disconnected components and harness connectors.• With the X-431 scan tool, read RCM DTCs.• Refer to �DTC Confirmation Procedure�.

Is the DTC B1346 still present?



DIAGNOSIS & TESTING

14


B1352 - Passenger Airbag Resistance Too High Or Open (1St Stage)

DIAGNOSIS & TESTING

VISMW140007T



WARNING!

After the Restraints Control Module (RCM) is installed, make sure all of the connectors are firm, and all of theharnesses are normal. The resistance between the RCM shell and body is less than 100 m�.

On Board Diagnosis Logic




B1352Passenger airbag

resistance too highor open (1st stage)

Ignition switch: ON

Restraints ControlModule (RCM)detected that theresistance of RCMconnector terminalsis out of thespecification range.

• Passenger airbag• Spiral cable• Passenger airbagconnector• Harness is openbetween passengerairbag and RCM• RCM










DIAGNOSIS & TESTING

14



1. CHECK THE PASSENGER AIRBAG


WARNING!


• Disconnect passenger airbag electrical connector C-038.


the spiral cable side of the vehicle harness (in place of the passenger airbag).• Connect the negative battery cable.

WARNING!

To avoid serious or fatal injury, the passenger airbag should not be checked by a multimeter.

NOTE :If the airbag special load tool is not available, connect a known good passenger airbag.

WARNING!


• Turn the ignition switch on.• With the scan tool, erase the DTC memory.• Turn ignition switch off, and wait a few seconds, then turn ignition switch on.• With the scan tool, read the active RCM DTCs



No >> • Replace the passenger airbag (See Passenger Airbag Removal & Installation in Section 14Restraints).

• Reassemble the vehicle and road test to verify the customers complaint is repaired.

DIAGNOSIS & TESTING


2. CHECK THE PASSENGER AIRBAG CONTROL CIRCUITS

• Disconnect the negative battery cable.

WARNING!


• Disconnect the airbag special load tool (or disconnect the known good passenger airbag).

• Disconnect the RCM connectors (1).


• Check harness continuity of the passenger airbag circuit between the RCM electrical connector terminal 5 andpassenger airbag electrical connector terminal 1.

FRONTPASSENGER

AIRBAGCONNECTOR

C-038TERMINAL

RCMCONNECTOR

C-036TERMINAL

CONTINUITY

1 5 Yes

• Check harness continuity of the passenger airbag circuit between the RCM electrical connector terminal 6 andpassenger airbag electrical connector terminal 2.

FRONTPASSENGER

AIRBAGCONNECTOR

C-038TERMINAL

RCMCONNECTOR

C-036TERMINAL

CONTINUITY

2 6 Yes

DIAGNOSIS & TESTING

LTSM140006

14





No >> • Replace the cables.

3. CHECK CONNECTORS

NOTE :Diagnose and repair all active codes before diagnosing stored codes (See Restraints Control Module DTC List inSection 14 Restraints).• With the scan tool, record and erase all RCM DTCs.• Using the electrical schematic as a guide, inspect the following:

− Inspect the wiring and connectors of the related airbag system.− Look for any chafed, pierced, pinched, or partially broken wires.− Look for broken, bent, pushed out or corroded terminals.− Verify that there is good pin to terminal contact in the related connectors.




4. CHECK DTC





DIAGNOSIS & TESTING


B1361 - Pretensioner Front-Driver Resistance Too HighB1363 - Pretensioner Front-Driver Resistance Circuit Short To Ground

DIAGNOSIS & TESTING

VISMW140004T

14



WARNING!

After installing the Restraints Control Module (RCM), make sure all of the connectors are firm, and all of theharness are normal. The resistance between the RCM shell and body is less than 100 m�.





B1361Pretensionerfront-driver

resistance too high

Ignition switch: ON

Restraints ControlModule (RCM)detected that theharness of driverseat beltpretensioner isopen.

• Harness orconnector• Harness openbetween driver seatbelt pretensioner andRCM• RCM

B1363

Pretensionerfront-driver

resistance circuitshort to ground

Restraints ControlModule (RCM)detected that theharness of driverseat beltpretensioner short toground.

• Harness orconnector• Harness short toground betweendriver seat beltpretensioner andRCM• RCM








• The following tools are required to perform the following test:• X-431 Scan Tool• Airbag Special Load Tool

DIAGNOSIS & TESTING


• Digital Multimeter• The squib circuit connectors integrate a �shorting� spring (which prevents the airbag from deploying unintentionally



1. CHECK DRIVER SEAT BELT PRETENSIONER


WARNING!


• Disconnect driver seat belt pretensioner connector B-024.


driver seat belt pretensioner connector B-024 of the vehicle harness (in place of the driver seat belt preten-sioner).

WARNING!

To avoid serious or fatal injury, the driver seat belt pretensioner should not be checked with a multimeter.

NOTE :If the airbag special load tool is not available, connect a known good driver seat belt pretensioner.• Connect the negative battery cable.

WARNING!


• Turn the ignition switch on.• With the scan tool, erase the DTC memory.• Turn ignition switch off, and wait a few seconds, then turn ignition switch on.• With the scan tool, read the RCM DTCs

Is DTC B1361 or B1363 present?


No >> • Replace the driver seat belt pretensioner (See Driver Seat Belt Pretensioner Removal & Installationin Section 14 Restraints).

• Reassemble the vehicle and road test to verify the customers complaint is repaired.

DIAGNOSIS & TESTING

14


2. CHECK DRIVER SEAT BELT PRETENSIONER CONTROL CIRCUITS

• Disconnect the airbag special load tool (or disconnect the known good driver seat belt pretensioner).

WARNING!


• Disconnect the RCM connectors J-001 (1).


• Check harness continuity between the RCM electrical connector terminal 37 and the driver seat belt pre-tensioner electrical connector B-024, terminal 2.


DRIVER SEATBELT

PRETENSIONERCONNECTOR

TERMINAL

RCMCONNECTOR

TERMINALCONTINUITY

2 37 Yes

• Check harness continuity between the RCM electrical connector terminal 38 and the driver seat belt pre-tensioner electrical connector terminal 1.


DIAGNOSIS & TESTING

LTSM140006


DRIVER SEATBELT

PRETENSIONERCONNECTOR

TERMINAL

RCMCONNECTOR

TERMINALCONTINUITY

1 38 Yes

• Check harness continuity between the driver seat belt pretensioner electrical connector terminal 1 andground.

• Check harness continuity between the driver seat belt pretensioner electrical connector terminal 2 andground.

• Continuity should not exist.




3. CHECK CONNECTORS

NOTE :Diagnose and repair all active codes before diagnosing stored codes (See Restraints Control Module DTC List inSection 14 Restraints).

• With the scan tool, record and erase all RCM DTCs.• Using the electrical schematic as a guide, inspect the following:

− Inspect the wiring and connectors of the related airbag system wiring and connectors.− Look for any chafed, pierced, pinched, or partially broken wires.− Look for broken, bent, pushed out or corroded terminals.− Verify that there is good pin to terminal contact in the related connectors.




4. CHECK DTC


Is the DTC B1361 or B1363 still present?



DIAGNOSIS & TESTING

14


ON-VEHICLE SERVICE

Airbag System Disarming Procedure

DescriptionWARNING!

The steering column contains the driver’s airbag. The airbag system is a sensitive, complex electro-mechanicalunit. Before attempting to diagnose, remove or install the airbag system components, you must first disconnectand isolate the negative battery (ground) cable. Then wait two minutes for the system capacitor to discharge.Failure to do so could result in accidental deployment of the airbag and possible personal injury. The fasteners,screws, and bolts, originally used for the airbag components, have special coatings and are specificallydesigned for the airbag system. They must never be replaced with any substitutes. Anytime a new fastener isneeded, replace with the correct fasteners provided in the service package or fasteners listed in the parts books.

1. Turn the ignition off.2. Disconnect and isolate the negative battery cable.3. Wait two minutes for the system capacitor to discharge.4. The airbag system can now be serviced safely.

Driver Side Airbag


WARNING!

Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system orcomponent service. Failure to do so may result in accidental airbag development, serious or fatal injury (SeeAirbag System Disarming Procedure in Section 14 Restraints).

2. Remove two driver side airbag retaining bolts (1).(Tighten: Driver side airbag retaining bolts to 10N·m)

3. Take out the driver side airbag and disconnect the airbag squib electrical connector.4. Installation is in the reverse order of removal.

VISM140006

14


Front Passenger Side Airbag


WARNING!


2. Remove the glove box mounting bolts (1).

3. Remove the front passenger side airbag mountingbolts (1).

4. Disconnect the front passenger side airbag squib electrical connector.5. Remove the front passenger side airbag from the vehicle.6. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

VISM150015

VISM140007


Restraints Control Module (RCM)


WARNING!


2. Remove the lower console (See Lower Console Removal & Installation in Section 15 Body & Accessories).3. Disconnect the Restraints Control Module (RCM) electrical connector.4. Remove the RCM retaining bolts (1).

(Tighten: RCM retaining bolts to 10 N·m)

5. Remove the RCM from the vehicle.6. Installation is in the reverse order of the removal.

ON-VEHICLE SERVICE

VISM140002

14


SEAT BELT SYSTEM



Front Seat Belt and Pre-Tensioner 14-43Removal & Installation 14-43

Adjustable Shoulder Belt Anchor 14-45Removal & Installation 14-45

Rear Seat Belt and Tensioner 14-46Removal & Installation 14-46


GENERAL INFORMATIONDescriptionThe primary passenger restraints are the seat belts. Seat belts are referred to as an active restraint because thevehicle occupants are required to physically fasten and properly adjust these restraints in order to benefit from them.

OperationThe passive restraints are referred to as a supplemental restraint system because they were designed and areintended to enhance the protection for the occupants of the vehicle only when used in conjunction with the seat belts.

Specifications



Adjustable Shoulder Belt Anchor Bolt 50

Front Seat Belt Buckle Retaining Bolt 50

Front Seat Belt Pre-Tensioner Lower Retaining Bolt 50

Front Seat Belt Upper Turning Loop Retaining Bolt 50

Rear Seat Belt Pre-Tensioner Upper Retaining Bolt 50

Rear Seat Belt Pre-Tensioner Lower Retaining Bolt 50

Special Tools


14


ON-VEHICLE SERVICE

Front Seat Belt and Pre-Tensioner

Removal & Installation1. Disconnect the negative battery cable.2. Remove the seat belt lower mounting bolt (1).

3. Remove the seat belt upper mounting bolt (1).LTSM150076

LTSM150077


4. Remove the B-pillar retaining screw (1).5. Use plastic stick to remove the B-pillar lower trim

panel.

6. Remove the front seat belt pre-tensioner retainingbolts (1).(Tighten: Front seatbelt retaining bolts to 50 N·m)

7. Remove the front seat belt and pre-tensioner.8. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

VISM150005

VISM140005

14


Adjustable Shoulder Belt Anchor

Removal & Installation1. Remove the B-pillar retaining screw (1).

2. Use a plastic stick to remove the B-pillar lower trim panel.3. Remove the two bolts (1) and then remove the

adjustable shoulder belt anchor.(Tighten: Adjustable shoulder belt anchor bolts to50 N·m)

4. Installation is in the reverse order of the removal.

ON-VEHICLE SERVICE

VISM150005

BESM140006


Rear Seat Belt and Tensioner

Removal & Installation1. Remove the rear seat.2. Remove the rear seat belt mounting bolts (1).

(Tighten: Rear seat belt mounting bolts to 50 N·m)

3. Remove the C-pillar (See C-Pillar Removal & Installation in Section 15 Body & Accessories).4. Remove the tensioner mounting bolts (1).

5. Remove the tensioner.6. Installation is in the reverse order of the removal.

ON-VEHICLE SERVICE

VISM140004

VISM140003

14


BODY & ACCESSORIES

15CONTENTS

pageBody Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

Body Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-236

BODY INTERIOR

AUDIO SYSTEM 15-4Description 15-4Operation 15-4Electrical Schematics 15-5

CD Player 15-7Removal & Installation 15-7

Antenna 15-8Removal & Installation 15-8

BODY INTERIOR TRIM 15-9

A-Pillar Trim Panel 15-9Removal & Installation 15-9

B-Pillar Trim Panel 15-10Removal & Installation 15-10

C-Pillar Trim Panel 15-11Removal & Installation 15-11

Passenger Grab Handle 15-11Removal & Installation 15-11

Scuff Plate 15-12Removal & Installation 15-12

Pedal Pad 15-12Removal & Installation 15-12

Sun Visor - LH 15-13Removal & Installation 15-13

Sun Visor - RH 15-13Removal & Installation 15-13

Headliner 15-14Removal & Installation 15-14

CAN VEHICLE COMMUNICATIONS 15-15Description 15-15Operation 15-15Electrical Schematics 15-16

CHIME 15-18Description 15-18Operation 15-18Electrical Schematics 15-19

DOOR LOCKS 15-26Description 15-26Operation 15-26Electrical Schematics 15-27

Power Lock Switch 15-31Removal & Installation 15-31

Power Lock Motor 15-32Removal & Installation 15-32Door Lock Assembly Inspection 15-38

FRONT BODY CONTROL MODULE -FRONT BCM 15-39Description 15-39Operation 15-39Electrical Schematics 15-41Front Body Control Module ConnectorPin-Out Table 15-50

DIAGNOSIS & TESTING 15-52Diagnostic Help 15-52Ground Inspection 15-52Diagnostic Tools 15-52

Diagnostic Trouble Code (DTC) List 15-53Front Body Control Module DTC List 15-53

Diagnostic Trouble Code (DTC) Tests 15-55B1001 - Left Turn Lights Control CircuitLow Current 15-55B1004 - Right Turn Lights ControlCircuit Low Current 15-60B1045 - Front Fog Lights Control CircuitOpen 15-65B1047 - Front Fog Lights Control CircuitHigh 15-70

15


B1063 - Parking Lights Control CircuitOpen 15-74B1064 - Parking Lights Control CircuitLow Voltage 15-80B1320 - Central Lock Control CircuitLow Current 15-85B1353 - FL Window Down ControlCircuit Low Current 15-91B1385 - Horn Control Circuit Open 15-96B1386 - Horn Control Circuit LowVoltage 15-101B1400 - Front Power Supply VoltageLow, B1401 - Front Power SupplyVoltage High 15-105B2311 - Boot Lid Release ControlCircuit Open 15-110U1000 - CAN Bus Off-Transmit Error 15-115


Front Body Control Module (FBCM) 15-120Removal & Installation 15-120

REAR BODY CONTROL MODULE -REAR BCM 15-121Description 15-121Operation 15-121Electrical Schematics 15-122Rear Body Control Module ConnectorPin-Out Table 15-124


Diagnostic Trouble Code (DTC) List 15-126Rear Body Control Module DTC List 15-126

Diagnostic Trouble Code (DTC) Tests 15-127B1048 - Rear Fog Lights Control CircuitOpen 15-127B1362 - RL Window Up Control CircuitLow Current 15-131


Rear Body Control Module (RBCM) 15-135Removal & Installation 15-135

INSTRUMENT PANEL 15-136

Instrument Panel 15-136Removal & Installation 15-136

Lower Console 15-139Removal & Installation 15-139

INSTRUMENT CLUSTER 15-143Description 15-143

Operation 15-144Specifications 15-144Special Tools 15-145Electrical Schematics 15-146Instrument Cluster Module ConnectorPin-Out Table 15-151

DIAGNOSIS & TESTING 15-152Clearing Service Monitor Lamp 15-152Diagnostic Help 15-152Intermittent DTC Troubleshooting 15-152Ground Inspection 15-152Diagnostic Tools 15-153

Diagnostic Trouble Code (DTC) List 15-153Instrument Cluster DTC List 15-153

Diagnostic Trouble Code (DTC) Tests 15-154B1701 - Fuel Gauge Sender-G OpenOr Short Circuit To Power 15-154B1702 - Fuel Gauge Sender-G ShortCircuit To Earth 15-158B1705 - Vehicle Power Supply TooLarge, B1706 - Vehicle Power SupplyToo Small 15-162B1723 - EEPROM Checksum Error 15-167U0073 - ICM Communication Bus Off 15-168


Instrument Cluster 15-174Removal & Installation 15-174

Driver Information Center 15-175Removal & Installation 15-175

INTERIOR LAMPS 15-176Description 15-176Operation 15-176Electrical Schematics 15-177

Front Courtesy/Dome Lamp Assembly 15-182Removal & Installation 15-182

Rear Room Lamp 15-182Removal & Installation 15-182

Keyhole Lamp 15-183Removal & Installation 15-183

POWER OUTLET 15-184Description 15-184Operation 15-184Electrical Schematics 15-185

Power Outlet 15-186Removal & Installation 15-186

POWER WINDOWS 15-187Description 15-187Operation 15-187


Electrical Schematics 15-188

Power Window Switch 15-192Removal & Installation 15-192

Power Window Motor 15-193Removal & Installation 15-193Power Window Motor Inspection 15-200

SEATS 15-201

General Information 15-201Description 15-201Operation 15-201

Front Seat 15-201Removal & Installation 15-201

Rear Seat 15-203Removal & Installation 15-203

IMMOBILIZER 15-205Description 15-205Operation 15-205Electrical Schematics 15-206Immobilizer Module Connector Pin-OutTable 15-207


Diagnostic Trouble Code (DTC) List 15-209Immobilizer Module DTC List 15-209

Diagnostic Trouble Code (DTC) Tests 15-210B1000 - ECU Defect, Internal Errors 15-210B3042 - W-Line Short Circuit ToGround, B3043 - W-Line Short CircuitTo Battery 15-214B3050 - Relay External Line ShortCircuit To Ground Or Open Circuit,Relay External Line Malfunction, B3053- Relay External Line Short Circuit ToBattery 15-218B3055 - No Transponder Modulation OrNo Transponder, B3056 - NoTransponder Fixed Code Programmed 15-223B3060 - Unprogrammed TransponderFixed Code Received, B3061 -Disturbed Or No Challenge/ResponseTransponder Communication, B3077 -Read-Only Transponder Detected 15-228


Immobilizer 15-233Removal & Installation 15-233

Remote Keyless Entry (RKE)Inoperative 15-234

No Response From Remote KeylessEntry (RKE) Transmitter 15-234

BODY AND ACCESSORIES - BODY INTERIOR

15


AUDIO SYSTEMDescriptionThe audio system consists of the following components:• Audio unit• Front speakers: two on left and right front door• Front tweeters: two on left and right front door• Rear Speakers: two on left and right rear door• Antenna (audio)

The audio system is standard factory-installed equipment. The system uses an ignition switched source of batterycurrent so that the system will operate when the ignition switch is in the LOCK/ACC/ON positions. The radio will alsooperate for up to one hour with the ignition switch in the OFF position.

OperationWith audio system on, radio signals are received by the window antenna, the audio unit then sends audio signals tofront speakers, rear speakers and front tweeters.



Audio System (Page 1 of 2)

AUDIO SYSTEM

VISMW150029T

15


Audio System (Page 2 of 2)

AUDIO SYSTEM

VISMW150030T


CD Player

Removal & Installation1. Disconnect the negative battery cable.2. Open the instrument panel storage compartment and remove the upper radio bezel bolts.3. Remove the lower console (See Lower Console Removal & Installation in Section 15 Body & Accessories).4. Remove the radio bezel bolts (1).

5. Remove the CD player mounting bolts (1).(Tighten: CD player mounting bolts to 8 ± 1 N·m)

6. Disconnect the radio electrical connector.7. Remove the radio.8. Installation is in the reverse order of removal.

AUDIO SYSTEM

VISM150001

VISM150002

15


Antenna

Removal & Installation1. Disconnect the negative battery cable.2. Remove the headliner (See Headliner Removal & Installation in Section 15 Body & Accessories).3. Disconnect the antenna connectors (1).4. Remove the antenna mounting nut (2)

.5. Remove the antenna (1).

6. Remove the antenna cable.7. Installation is in the reverse order of removal.

AUDIO SYSTEM

VISM150168

VISM150003


BODY INTERIOR TRIM

A-Pillar Trim Panel

Removal & Installation1. Remove the A-pillar retaining screw (1).2. Using a plastic trim stick, remove the A-pillar trim

panel.


Installation Notes:

• The A-pillar trim panel clips should be installed to allow the trim panel a tight fit between the roof and theweatherstrip.

VISM150004

15


B-Pillar Trim Panel

Removal & Installation1. Remove the seatbelt mounting bolts.2. Remove the B-pillar retaining screw (1).

3. Using a plastic trim stick, remove the B-pillar lower trim panel.4. Using a plastic trim stick, remove the B-pillar upper trim panel.5. Installation is in the reverse order of removal.

BODY INTERIOR TRIM

VISM150005


C-Pillar Trim Panel

Removal & Installation1. Remove the C-pillar retaining screw (1).2. Using a plastic trim stick, remove the C-pillar trim

panel.


Passenger Grab Handle

Removal & Installation1. Loosen the grab handle trim cover.2. Remove the two grab handle bolts (1).3. Remove the passenger grab handle.4. Installation is in the reverse order of removal.

BODY INTERIOR TRIM

VISM150006

BESM150128

15


Scuff Plate

Removal & Installation1. Grasp the scuff plate and gently pull it away to

release the retaining clips.2. Using a plastic trim stick, remove the scuff plate

from the front door sill.


Pedal Pad

Removal & Installation1. Remove the cover for the pedal pad bolts.2. Remove the pedal pad bolts (1).

(Tighten: Pedal pad bolts to 8 ± 1 N·m)

3. Remove the pedal pad for the left foot.4. Installation is in the reverse order of removal.

BODY INTERIOR TRIM

BESM150124

VISM150007


Sun Visor - LH

Removal & Installation1. Disconnect the sun visor from the retaining clip.2. Remove the retaining screws (1) on the sun visor

hinge.3. Remove the sun visor assembly.4. Installation is in the reverse order of removal.

Installation Notes:

• Do not overtighten the sun visor mounting screw.Tighten the sun visor mounting screw at the sunvisor hinge just enough to allow for free movementof the sun visor.

Sun Visor - RH

Removal & Installation1. Disconnect the sun visor from the retaining clip.2. Remove the retaining screws on the sun visor hinge.

NOTE :Over tightening the sun visor retainer screws could prevent the sun visor from working properly.

3. Remove the sun visor assembly.

NOTE :The sun visor hinge could seize-up preventing the sun visor from working properly.


Installation Notes:

• Do not overtighten the sun visor mounting screw. Tighten the sun visor mounting screw at the sun visor hingejust enough to allow for free movement of the sun visor.

BODY INTERIOR TRIM

VISM150008

15


Headliner

Removal & Installation1. Remove the passenger grab handle (See Passenger Grab Handle Removal & Installation in Section 15 Body &

Accessories).2. Remove the two rear grab handles (See Passenger Grab Handle Removal & Installation in Section 15 Body &

Accessories).3. Remove the front courtesy lamp (See Front Courtesy Lamp Removal & Installation in Section 15 Body & Acces-

sories).4. Remove the rear room lamp (See Rear Room Lamp Removal & Installation in Section 15 Body & Accessories).5. Remove the A/B/C pillar trim panel (See A/B/C Pillar Trim Panel Removal & Installation in Section 15 Body &

Accessories.)6. Remove the left and right sun visors (See Sun Visor Removal & Installation in Section 15 Body & Accessories.)7. Using a trim stick, remove the eye glass storage

compartment from the overhead console (1).

8. Remove all the retaining clips.9. Remove the headliner.


Installation Notes:

• The front edge of the headliner should fit tight to the roof and not interfere with the view of the front wind-shield.

• The headliner corners should fit tight to the roof and not be visible outside the car.• The headliner should fit tight with the weatherstrip around the door openings and the luggage compartment.• The headliner should fit tight to the roof around the arcs of the upper trim panels (A, B, and C pillars) with a

clearance less than 0.2 mm.

BODY INTERIOR TRIM

VISM150166


CAN VEHICLE COMMUNICATIONSDescriptionController Area Network (CAN) communication is a multiplex communication system. The CAN system allows thevehicles electronic components and electronic modules to transmit and receive data. The following electronic com-ponents are located on the CAN network:• Engine Control Module (ECM)• Instrument Cluster (IC)• Antilock Brake System (ABS) Hydraulic Control Module• Yaw Rate Sensor• Front Body Control Module (FBCM)• Spiral Cable• Electronic Power Steering Actuator (if equipped)• Restraints Control Module• HVAC Conditioner Control Unit

OperationThe CAN network uses a twisted pair of circuits to transmit data (+) and data (-). The data (+) and the data (-)circuits are each regulated to approximately 2.5 volts during neutral or rested network traffic. As bus messages aresent on the data (+) circuit, voltage is increased by approximately 1.0 volt. Inversely, the data (-) circuit is reduced byapproximately 1.0 volt when a bus message is sent. Multiple bus messages can be sent over the CAN circuits allow-ing multiple modules to communicate with each other.

15



CAN Vehicle Communications (Page 1 of 2)

CAN VEHICLE COMMUNICATIONS

VISMW150025T


CAN Vehicle Communications (Page 2 of 2)

CAN VEHICLE COMMUNICATIONS

VISMW150026T

15


CHIMEDescriptionThe chime is located in the Instrument Cluster (IC). The chime warning system is an audible notification to the driver.The chime warning system is designed to alert the driver of a vehicle problem or condition.

OperationThe Instrument Cluster (IC) uses hard wired inputs from various sensors and switches to activate the chime. Thesensors and switches are located throughout the vehicle. The following conditions will cause the chime to operate:• Turn signal on• Hazard warning flashers on• Seat belt unbuckled• Low fuel level• Low oil pressure• Low brake fluid• Doors unlocked• Charging system fault• Engine performance fault• Airbag system fault• Low coolant level• EPC fault• Immobilizer fault• Engine overheating



Chime (Page 1 of 7)

CHIME

VISMW150031T

15


Chime (Page 2 of 7)

CHIME

VISMW150032T


Chime (Page 3 of 7)

CHIME

XLSMW150025T

15


Chime (Page 4 of 7)

CHIME

XLSMW150026T


Chime (Page 5 of 7)

CHIME

XLSMW150027T

15


Chime (Page 6 of 7)

CHIME

XLSMW150028T


Chime (Page 7 of 7)

CHIME

VISMW150037T

15


DOOR LOCKSDescriptionThe power door locks allow the doors to be locked or unlocked electronically. The power door lock switch is locatedon the left front door trim panel. The power door locks can also be operated by the Remote Keyless Entry (RKE)transmitter.

OperationThe power lock system receives non-switched battery current, so that the power locks remain operational, regardlessof the ignition switch position.



Power Door Lock System (Page 1 of 4)

DOOR LOCKS

VISMW150039T

15



DOOR LOCKS

VISMW150040T



DOOR LOCKS

VISMW150041T

15



DOOR LOCKS

VISMW150042T


Power Lock Switch

Removal & Installation1. Disconnect the negative battery cable.2. Using a trim stick, remove the power lock switch

assembly (1) on the left front door.

3. Disconnect the power lock switch electrical connec-tor (1).

4. Remove the retaining screws and remove the power lock switch assembly.5. Installation is in the reverse order of removal.

DOOR LOCKS

VISM150009

VISM15001015


Power Lock Motor

Removal & Installation1. Turn the ignition switch off.2. Using a trim stick, remove the power lock switch



DOOR LOCKS

VISM150009

VISM150010


4. Using a trim stick, pry up the inside door handlepanel (1).

5. Remove the retaining bolt (1) from the inside doorhandle panel.(Tighten: Door retaining bolts to 7 ± 1 N·m)

DOOR LOCKS

VISM150084

VISM150156

15


6. Remove the retaining bolt (1) from the door handlepanel.(Tighten: Door retaining bolts to 7 ± 1 N·m)

CAUTION: While servicing the door panels, care should be taken to maintain a clean work environment.7. Using a trim stick, remove the step lamp cover (1).

DOOR LOCKS

VISM150087

VISM150085


8. Remove the step lamp bracket (1).

9. Disconnect the step lamp connector (1).

DOOR LOCKS

VISM150151

VISM150086

15


10. Using a trim stick, remove the inside cover (1) forthe mirror bolts from the door trim panel.

11. Using a screwdriver, remove the door trim panelupper retaining screw (1).

12. Using a screwdriver, remove the door trim panellower four retaining screws (1).

13. Remove the door trim panel and disconnect the speaker electrical connector.

DOOR LOCKS

VISM150167

VISM150155

VISM150152


14. Loosen the inside door handle control cable (1).

15. Remove the protective film from the front door.16. Disconnect the power lock motor electrical connector.17. Remove the power lock retaining bolts (1).

(Tighten: Power lock motor retaining bolts to 8 ± 1N·m)

18. Remove the retaining bolt (2) connecting the win-dow glass guide rail and the door.(Tighten: Glass guide rail and door connecting boltto 7 ± 1 N·m)

19. Remove the door lock switch bracket retainingbolts (1).

20. Remove the door handle control cable retainingscrews (2).

21. Disconnect the door lock motor connecting rod to the door outside handle.

DOOR LOCKS

VISM150153

VISM150011

VISM150154

15


22. Remove the power lock motor.

23. Disconnect the power lock motor electric connectors.24. Installation is in the reverse order of removal.

Door Lock Assembly Inspection1. Using the following table, apply battery voltage to the specified connector terminals.2. Verify that the door lock assembly locks and unlocks when voltage is applied to the specific terminals.3. If the test results are not as specified, replace the motor.

MEASURING CONDITION OPERATION

Battery positive (+) to terminal – 1Battery negative (-) to terminal – 2 Lock

Battery positive (+) to terminal – 2Battery negative (-) to terminal – 1 Unlock

DOOR LOCKS

VISM150012


FRONT BODY CONTROL MODULE - FRONT BCMDescriptionThe Front Body Control Module (FBCM) is located behind the left lower trim panel. The FBCM controls many elec-trical components and systems for the vehicle electrical system. The FBCM is the primary hub that controls functionssuch as internal and external lighting, power windows and power door locks.

OperationThe Front Body Control Module (FBCM) uses hard wired inputs from various sensors and switches. The sensors andswitches are located throughout the vehicle.

The following components are inputs to the FBCM:• Key switch• Rear window defogger switch• Hazard lamp switch• Front power window switches• Power door lock switches• Door ajar switches• Front fog lamp switch• Backup lamp switch• Trunk lid open switch• Backlight switch• Horn switch• Lighting and turn signal switch• Outside mirror switch• Engine hood switch• Trunk lamp switch and trunk release solenoid• Trunk lid open switch• Wiper and washer switch

The following components are outputs from the BCM:• Key lamp• High/low beam relay• Rear defogger grid• Front combination lamps• Rear combination lamps• Courtesy lamps• Turn signal lamps• Security lamp• Step lamps• Front power window motor• Power door lock motor• Washer motor• Wiper motor

15


FUSE NO. AMPERAGERATING FUNCTION

1 30 A Front PowerWindow

2 10 A Not Used

3 10 A Left ParkingLamps

4 7.5 A IP Lamps

5 5 A Right ParkingLamps

6 15 A Lock

FUSE NO. AMPERAGERATING FUNCTION

7 25 A Wiper andWasher

8 10 A Interior Lamps

9 10 A Horn

10 15 A Front FogLamps

11 25 A Defogger

12 15 A Turn Signal andWarning Lamps

FRONT BODY CONTROL MODULE - FRONT BCM

VISM150138



Front Body Control Module (Page 1 of 9)


VISMW150100T

15




VISMW150101T




VISMW150102T

15




VISMW150103T




VISMW150104T

15




VISMW150105T




VISMW150106T

15




VISMW150107T




VISMW150108T

15


Front Body Control Module Connector Pin-Out Table


1 Park Lamp Input 50 CAN-H

2 Front Wiper Input 51 LIN

3 Auto Light Input 52 LIN

4 Rear Right Door Ajar Input 53 Window Rear Right Down Input

5 - 54 Window Rear Left Down Input

6 Hazard Input 55 Window Rear Right Up Input

7 Washer Input 56 Window Rear Left Up Input

8 High Bean Input 57 Window Front Right Down Input

9 Turns Input 58 Window Front Left Down Input

10 Wiper INC/DEC Input 59 Window Front Right Up Input

11 - 60 Window Front Left Up Input

12 - 61 -

13 - 62 -

14 - 63 IGN Input

15 Lamp SW Output 64 Hood Ajar

16 - 65 -

17 Wiper Park Input 66 Dome Lights Output

18 Front Wiper Input 67 SEC IND Output

19 Boot Ajar Input 68 Right Turn Output

20 Rear Left Door Ajar Input 69 Left Turn Output

21 Reverse Input 70 Fog Out Notel

22 Horn Input 71 Fog Out Notel

23 - 72 Defroster Out 1

24 Low Beam Output 73 -

25 High Beam Output 74 Mirror Defrost Output

26 Key Lamp Output 75 -

27 - 76 Unlock Output

28 - 77 Lock Output

29 - 78 Boot Release Output

30 Rear Defrost Input 79 Washer Output

31 - 80 Wiper Low Output

32 - 81 Wiper High Output

33 CAN-L 82 SEC LED PWR

34 LIN (IISU) 83 Battery Saver Output

35 LIN (IISU) 84 Horn Output

36 Lock Input 85 Window FL Up Output

37 Unlock Input 86 Window FL Down Output

38 Passenger Door Ajar Input 87 Siren Output

39 Driver Door Ajar Input 88 Window FR Up Output

40 Rear Fog Input 89 Window FR Down Output

41 Front Fog Input 90 Radio (reserved)

42 Key Input 91 Radio Fuse (reserved)




43 - 92 Trunk Light (10A) Fuse

44 Low Beam Input 93 Trunk Light (10A)

45 - 94 Park Lamp Output

46 Boot REL Input 95 IP Illum Output

47 ACC Input 96 Park Lamp Output

48 Tamper Input B Continuous Supply Voltage

49 - G GND (Power)


15



modules through the class two serial data circuit.2. Confirm that the malfunction is current and carry-out the diagnostic tests and repair procedures.3. If the DTC cannot be deleted, it is a current fault.4. Use a digital multimeter to perform voltage readings on electronic systems.5. Refer to Technical Bulletins that have been issued.6. Visually inspect the related wiring electrical harness.7. Inspect and clean all FBCM grounds that are related to the DTC.8. If numerous trouble codes were set, use a wiring schematic and look for any common ground circuits or voltage


Intermittent DTC TroubleshootingIf the failure is intermittent perform the following:• Check for loose connectors.• Look for any chafed, pierced, pinched, or partially broken wires.• Monitor the scan tool data relative to this circuit.• Wiggle the related wiring electrical harness and connectors while looking for an interrupted signal on the

affected circuit.• If possible, try to duplicate the conditions under which the DTC set.• Look for the data to change or for the DTC to reset during the wiggle test.• Look for broken, bent, pushed out or corroded terminals.• Inspect the sensor and mounting area for any condition that would result in an incorrect signal, such as dam-

age or foreign material.• A data recorder, and/or oscilloscope should be used to help diagnose intermittent conditions.• Remove the FBCM module from the troubled vehicle and install in a new vehicle and test. If the DTC cannot

be deleted, the FBCM module is malfunctioning. If the DTC can be deleted, return the FBCM module to theoriginal vehicle.








Front Body Control Module DTC List

DTC DTC DEFINITION

B1001 Left Turn Lights Control Circuit Low Current

B1002 Left Turn Lights Control Circuit Short to Ground

B1004 Right Turn Lights Control Circuit Low Current

B1005 Right Turn Lights Control Circuit Short to Ground

B1045 Front Fog Lights Control Circuit Open

B1046 Front Fog Lights Control Circuit Low Voltage

B1047 Front Fog Lights Control Circuit High Voltage

B1063 Parking Lights Control Circuit Open

B1064 Parking Lights Control Circuit Low Voltage

B1065 Parking Lights Control Circuit High Voltage

B1102 Dome Light Control Circuit Low Voltage

B1103 Dome Light Control Circuit High Voltage

B1319 Central Lock Control Circuit Stuck On

B1320 Central Lock Control Circuit Low Current

B1321 Central Lock Control Circuit High Current

B1322 Central Lock Control Circuit Stuck On

B1323 Central Lock Control Circuit Low Current

B1324 Central Lock Control Circuit High Current

B1350 FL Window Up Control Circuit Low Current

B1351 FL Window Up Control Circuit Stuck On

B1353 FL Window Down Control Circuit Low Current

B1354 FL Window Down Control Circuit Stuck On

B1356 FR Window Up Control Circuit Low Current

B1357 FR Window Up Control Circuit Stuck On

B1359 FR Window Down Control Circuit Low Current

B1360 FR Window Down Control Circuit Stuck On

B1373 Front Wiper Control Circuit Open

B1374 Front Wiper Control Circuit Low Voltage

B1375 Front Wiper Control Circuit High Voltage

B1376 Front Wiper Hi Control Open

B1377 Front Wiper Hi Control Low Voltage

B1378 Front Wiper Hi Control High Voltage

B1382 Front Washer Control Circuit Open

B1383 Front Washer Control Circuit Low Voltage

B1385 Horn Control Circuit Open

B1386 Horn Control Circuit Low Voltage

B1384 Front Washer Control Circuit High Voltage

B1385 Horn Control Circuit Open

B1386 Horn Control Circuit Low Voltage

B1387 Horn Control Circuit High Voltage

DIAGNOSIS & TESTING

15


DTC DTC DEFINITION

B1388 Rear Defroster Control Circuit Open

B1389 Rear Defroster Control Circuit Low Voltage

B1390 Rear Defroster Control Circuit High Voltage

B1391 Front Defroster Control Circuit Open

B1392 Front Defroster Control Circuit Low Voltage

B1393 Front Defroster Control Circuit High Voltage

B1395 Nozzle Control Circuit Low Voltage

B1396 Nozzle Control Circuit High Voltage

B1400 Front Power Supply Voltage Low

B1401 Front Power Supply Voltage High

B1402 Front Battery Saver Output Circuit Low Voltage

B1403 Front Battery Saver Output Circuit High Voltage

B1773 Cruise Control Switch Input Circuit Low Voltage

B1774 Cruise Control Switch Input Circuit High Voltage

B1808 Lost Communication With Anti Theft Siren Module (ATSM)

B1809 Lost Communication With Anti Theft Siren Module (CLM)

B2311 Boot Lid Release Control Circuit Open

B2312 Boot Lid Release Control Circuit High Voltage

B2313 Boot Lid Circuit Low Voltage

B2314 Front Wiper Park Switch Circuit No Signal

B2316 Window Module Left Voltage

B2318 Window Module Right Voltage

B2319 Window Module Left Motor

B2320 Window Module Right Motor

B2321 Key Lock Control Circuit Low Voltage

B2322 Key Lock Control Circuit High Voltage

B2323 Window Module Left Thermo

B2324 Window Module Right Thermo

U1000 CAN Bus Off Transmit Error

U1020 Lost Communication With Anti-Lock Brake System (ABS) Control Module

U1021 Lost Communication With Body Control Module �B�

U1022 Lost Communication With Instrument Panel Cluster (IPC) Control Module

U1023 Lost Communication With �Door Window Motor A� (Left)

U1024 Lost Communication With �Door Window Motor B� (Right)

U1025 Lost Communication With Rain Sensing Module

U1026 CAN Communication Bus Fault - Receive Error

U0156 Lost Communication With Supplementary Cluster

DIAGNOSIS & TESTING



B1001 - Left Turn Lights Control Circuit Low Current

DIAGNOSIS & TESTING

VISMW150079T

15


Check reference values between FBCM terminals and ground under the following conditions:

FBCM TERMINAL NO. ITEM CONDITION DATA (AVERAGE DCVOLTAGE)

69 Left Turn OutIgnition switch: ONTurn LH turn signal lightswitch on

0 V or 12 V intermittent





B1001Left turn lights

control circuit lowcurrent

Ignition switch: ONWith left turn lightsactivated.

When the FrontBody ControlModule (FBCM)detects the RH turnsignal lamp controlcircuit opencondition.

• Front or rear LHturn lamps• Harness orconnectors• LH turn lamp fuse• FBCM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the FBCM.• Turn the left turn signal light on.• With X-431 select view active DTCs and data stream in the FBCM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-

bleshooting in Section 15 Body & Accessories for more information).

DIAGNOSIS & TESTING



1. CHECK TURN LAMP FUSE IN FRONT BODY CONTROL MODULE (FBCM)

• Turn ignition switch off.• Check turn lamp fuse (1-1) (15A) in FBCM.



No >> • Replace the fuse.

2. CHECK THE LH TURN SIGNAL BULBS

• Turn LH turn signal switch off.• Disconnect front LH turn signal lamp (2) connector.

DIAGNOSIS & TESTING

VISMD150045

VISMD150060

15


• Disconnect rear LH turn signal lamp connector (3).• Remove and inspect the LH turn signal bulbs.

LIGHT BULB POWER RATINGS

1 Rear Fog Lamp 12 V (21 W)

2 Reverse Lamp 12 V (21 W)

3 Turning Lamp 12 V (21 W)

4 Stop Lamp 12 V (18 W)

5 Rear Parking Lamp 12 V (5 W)

Are the front LH and rear LH turn signal bulbs OK?


No >> • Replace the LH turn signal bulbs.

3. CHECK THE LH TURN SIGNAL LAMPS SUPPLY CIRCUIT POWER SUPPLY

• Turn ignition switch on.• Turn the LH turn signal lamp on.• Check voltage between the front LH turn signal lamp harness connector A-021, terminal 2 and ground.

FRONT TURN SIGNALLAMP TERMINAL

GROUND

2

DIAGNOSIS & TESTING

VISM150104


• Check voltage between the rear LH turn signal lamp harness connector B-004, terminal 4 and ground.

REAR TURN SIGNALLAMP TERMINAL

GROUND

4

• Refer to Wiring Diagram.• 12 V should intermittently exist.



No >> • Repair or replace circuit for an open in harness or connectors between FBCM and LH turn signallamp.

4. CHECK THE LH TURN SIGNAL LAMPS GROUND CIRCUIT

• Turn ignition switch off.• Disconnect the LH turn signal lamps connectors.• Check resistance between the front LH turn signal lamp harness connector A-021, terminal 1 and ground.• Check resistance between the rear LH turn signal lamp harness connector B-004, terminal 8 and ground.• Continuity should exists.



No >> • Repair or replace ground circuit for an open or high resistance in harness or connectors.

5. CHECK DTC

• With the X-431 scan tool, read FBCM DTCs.• Refer to �DTC Confirmation Procedure�.

Is the DTC B1001 present?

Yes >> • Replace FBCM.


DIAGNOSIS & TESTING

15


B1004 - Right Turn Lights Control Circuit Low Current

DIAGNOSIS & TESTING

VISMW150078T




68 Right Turn OutIgnition switch: ONTurn RH turn signal lightswitch on

0 V or 12 V intermittent





B1004Right turn lights


Ignition switch: ONWith right turn lightsactivated

The Front BodyControl Module(FBCM) detects theRH turn signal lightscontrol circuit opencondition.

• Front or rear RHturn light• Harness orconnectors• RH turn lamp fuse• FBCM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the FBCM.• Turn the RH turn signal light on.• With X-431 select view active DTCs and data stream in the FBCM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


DIAGNOSIS & TESTING

15



1. CHECK TURN LAMP FUSE IN FRONT BODY CONTROL MODULE (FBCM)

• Turn ignition switch off.• Check turn lamp fuse (1-1) (15A) in FBCM.




2. CHECK RH TURN SIGNAL BULBS

• Turn RH turn signal switch off.• Disconnect front RH turn signal lamp (2) connector.

DIAGNOSIS & TESTING

VISMD150045

VISMD150060


• Disconnect rear RH turn signal lamps harness con-nectors (3).

• Remove and inspect the RH turn signal bulbs.







Is the front RH and rear LH turn signal bulbs OK?


No >> • Replace the RH turn signal bulbs.

3. CHECK THE RH TURN SIGNAL LAMPS POWER SUPPLY

• Turn ignition switch on.• Turn the RH turn signal light on.• Check voltage between the front RH turn signal lamp harness connector A-022 , terminal 2 and ground.

FRONT RH TURNSIGNAL LAMP

TERMINAL

GROUND

2

DIAGNOSIS & TESTING

VISM150104

15


• Check voltage between the rear RH turn signal lamp harness connector B-005, terminal 4 and ground.

REAR TURN SIGNALLAMP TERMINAL

GROUND

4

• Refer to Wiring Diagram.• 12 V should intermittently exists.



No >> • Repair or replace supply circuit for an open in harness or connectors between FBCM and RH turnsignal lamp.

4. CHECK THE LH TURN SIGNAL LAMPS GROUND CIRCUIT.

• Turn ignition switch off.• Disconnect the LH turn signal lamps connectors.• Check resistance between the front RH turn signal lamp harness connector A-022, terminal 1 and ground.• Check resistance between the rear RH turn signal lamp harness connector B-005, terminal 8 and ground.• Continuity should exists.



No >> • Repair or replace ground circuit for an open or high resistance in harness or connectors.

5. CHECK DTC





DIAGNOSIS & TESTING


B1045 - Front Fog Lights Control Circuit Open

DIAGNOSIS & TESTING

VISMW150076T

15




70 Fog Out (1) NotelIgnition switch: ONThe front lamp switchshould be on PARKposition or the headlightswitch on LOW position.With the front fog lampsactivated.

12 V

71 Fog Out (2) Notel





B1045 Front fog lightscontrol circuit open

Ignition switch: ONThe headlampswitch should be onPARK position or onLOW positionWith the front foglights activated

When the FrontBody ControlModule (FBCM)detects the front foglights control circuitopen condition.

• Front fog bulbs• Harness orconnectors• FBCM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the FBCM.• Turn the front parking lights on or turn the headlight switch on LOW position.• Turn front fog lamp switch on.• With X-431 select view active DTCs and data stream in the FBCM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


NOTE :If DTC B1047 also exists, perform DTC B1047 diagnostic procedure first.

DIAGNOSIS & TESTING



1. CHECK THE FRONT FOG LAMP FUSE IN FBCM

• Turn ignition switch off.• Check front fog lamp fuse (1-3) (15A) in FBCM.



No >> • Replace the damaged fuse.

2. CHECK FRONT FOG BULBS

• Turn the front fog lamps switch off.• Disconnect the front fog lamps (1) connector.• Remove and inspect the front fog lamp bulbs.

Are the two front fog lamp bulbs OK?


No >> • Replace the two damaged front foglamp bulbs.

DIAGNOSIS & TESTING

VISMD150045

VISMD150060

15


3. CHECK FRONT FOG LAMPS POWER SUPPLY

• Turn ignition switch on.• Turn the front parking lights on or turn the headlight switch to the LOW position.• Turn front fog lamp switch on.• Check voltage between the front lamp harness connector A-003 or A-004, terminal 2 and ground.

FRONT FOGTERMINAL TERMINAL VOLTAGE

2 Ground 12 V

• Refer to Wiring Diagram.• 12 V should exist.




4. CHECK FRONT FOG LAMPS SUPPLY CIRCUIT

• Turn ignition switch off.• Disconnect FBCM connectors B-026.• Check harness continuity between terminal 70 or 71 in FBCM connector B-026 terminal side and terminal 2 in

front fog lamp LH connector A-003 or RH connector A-004 terminal side.

FBCM TERMINAL FRONT FOG TERMINAL

70 or 71 2




No >> • Repair or replace the circuit for an open in harness or connectors between FBCM and front foglamps.

• Repair or replace front fuse and relay box C, E.

DIAGNOSIS & TESTING


5. CHECK FRONT FOG LAMPS GROUND CIRCUIT

• Check front fog lamp ground circuits for an open between front fog lamp LH connector A-003, terminal 1 andground.

• Check front fog lamp ground circuits for an open between front fog lamp LH connector A-003, terminal 1 andground.




No >> • Repair or replace the ground circuit for an open in harness or connectors.

6. CHECK DTC





DIAGNOSIS & TESTING

15


B1047 - Front Fog Lights Control Circuit High

DIAGNOSIS & TESTING

VISMW150076T




70 Fog Out (1) NotelIgnition switch: ONThe front lamp switchshould be on PARKposition or the headlightswitch on LOW position.With the front fog lightsactivated.

12 V

71 Fog Out (2) Notel





B1047Front fog lightscontrol circuit highvoltage

Turn ignition switchon

When the FrontBody ControlModule (FBCM)detects the front foglights control circuithigh condition.

• Harness orconnectors• FBCM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the FBCM.• Try to turn on or depress other components switch one by one.• With X-431 select view active DTCs and data stream in the FBCM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


NOTE :If DTC B1045 also exists, perform DTC B1047 diagnostic procedure first. Repairing DTC B1047 first, will correct DTCB1045.

DIAGNOSIS & TESTING

15



1. CHECK FRONT FOG LAMPS SUPPLY VOLTAGE

• Turn ignition switch off.• Disconnect front fog lamp harness connectors (1).

• Turn ignition switch on.• Turn front fog lamp switch off.• Disconnect the front fog lamps connector.• Check voltage between the front fog lamp harness connector A-003 or A-004, terminal 2 and ground.

FRONT FOGTERMINAL TERMINAL VOLTAGE

2 Ground Not exist

• Refer to Wiring Diagram.• Voltage should not exist.




DIAGNOSIS & TESTING

VISMD150060


2. CHECK THE FRONT FOG LAMPS SUPPLY CIRCUIT FOR A SHORT TO POWER CIRCUIT

• Turn all related components off.• Disconnect FBCM connectors.• Check continuity between front fog lamp supply circuits and related components supply circuits.• Continuity should not exist.• Also check the front fog lamp supply circuits for a short to power.• Continuity should also not exist.



No >> • Repair or replace circuit for a short in harness or connectors.

3. CHECK DTC





DIAGNOSIS & TESTING

15


B1063 - Parking Lights Control Circuit Open

DIAGNOSIS & TESTING

VISMW150075T




94 Park Light 2 Out Turn ignition switch on.The lamp switch shouldbe on PARK position.

12 V96 Park Light 1 Out





B1063 Parking lightscontrol circuit open

Ignition switch: ONThe lamp switchshould be on PARKposition.

When the FrontBody ControlModule (FBCM)detects the parkinglights control circuitopen condition.

• Parking lampbulbs• Harness orconnectors• FBCM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the Front Body Control Module

(FBCM).• Turn light switch on PARK position.• With X-431 select view active DTCs and data stream in the FBCM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


NOTE :If DTC B1065 also exists, perform this DTC diagnostic procedure first.

DIAGNOSIS & TESTING

15



1. CHECK THE PARKING LAMPS

• Turn parking lights switch off.• Disconnect the front parking lamps connector (3).• Remove and inspect the parking lamp bulbs.


1 Low Beam Lamp 12 V (55 W)

2 High Beam Lamp 12 V (55 W)

3 Front Parking Lamp 12 V (5 W)

• Disconnect the rear parking lamps connector (5).• Remove and inspect the parking lamp bulbs.







Are the parking lamp bulbs OK?


No >> • Replace the damaged parking lamp bulbs.

DIAGNOSIS & TESTING

VISM150102

VISM150104


2. CHECK PARKING LAMPS POWER SUPPLY

• Turn ignition switch on.• Turn the parking lamps on.• Check voltage between the front LH combination lamp connector A-001, terminal 6 and ground or between the

front RH combination lamp connector A-002, terminal 6 and ground.

FRONT LH PARKINGLAMPS TERMINAL

GROUND

6

• Check voltage between the rear LH combination lamp connector B-004, terminal 3 and ground or between therear RH combination lamp connector B-005, terminal 3 and ground.

REAR LH PARKINGLAMPS TERMINAL

GROUND

3





DIAGNOSIS & TESTING

15


3. CHECK THE PARKING LAMPS SUPPLY CIRCUIT

• Turn ignition switch off.• Disconnect FBCM connectors.

• Check continuity between FBCM connector B-027, terminal 94 or 96 and front parking lamps connector A-001or A-002, terminal 6.

FBCM B-027 TERMINAL FRONT PARKINGLAMPS TERMINAL

94

6

96




No >> • Repair or replace the circuit for an open in harness or connectors between FBCM and parkinglamps.

4. CHECK THE PARKING LAMPS GROUND CIRCUIT

• Check continuity between front parking lamps connector A-001 or A-002, terminal 4 and ground.• Check continuity between rear parking lamps connector B-004 or B-005, terminal 8 and ground.• Continuity should exist.



No >> • Repair or replace ground circuit for an open in harness or connectors.

DIAGNOSIS & TESTING

VISMD150032


5. CHECK DTC

• Connect all disconnected connectors.• With the X-431 scan tool, read FBCM DTCs.• Refer to �DTC Confirmation Procedure�.


Yes >> • Replace FBCM in accordance with the service information.


DIAGNOSIS & TESTING

15


B1064 - Parking Lights Control Circuit Low Voltage

DIAGNOSIS & TESTING

VISMW150075T




94 Park Light 2 Out Ignition switch: ONThe lamp switch shouldbe on PARK position.

12 V96 Park Light 1 Out





B1064Parking lights

control circuit lowvoltage

Ignition switch: ONThe lamp switchshould be on PARKposition.

When The FrontBody ControlModule (FBCM)detects the parkinglights control circuitlow voltagecondition.

• Parking bulbs• Harness orconnectors• FBCM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the FBCM.• Turn light switch on PARK position.• With X-431 select view active DTCs and data stream in the FBCM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


DIAGNOSIS & TESTING

15



1. CHECK THE PARKING LAMPS

• Turn parking lights switch off.• Disconnect the front parking lamps connector (3).• Remove and inspect the parking bulbs.




3 Front Parking Lamp 12 V (5 W)

• Disconnect the rear parking lamps connector (5).• Remove and inspect the parking bulbs.







Are the parking lamp bulbs OK?


No >> • Replace the damaged parking lamp bulbs.

DIAGNOSIS & TESTING

VISM150102

VISM150104


2. CHECK THE PARKING LAMPS POWER SUPPLY

• Turn ignition switch on.• Turn the parking lamps on.• Check voltage between the LH combination lamp connector A-001, terminal 6 and ground or between the RH

combination lamp connector A-002, terminal 6 and ground.

FRONT PARKING LAMPSTERMINAL

GROUND

6

• Refer to Wiring Diagram.• 12 V should exists.




DIAGNOSIS & TESTING

15


3. CHECK THE PARKING LAMPS CONTROL CIRCUIT

• Turn ignition switch off.• Disconnect FBCM connectors.

• Check resistance between the LH combination lamp connector A-001, terminal 6 and ground or between theRH combination lamp connector A-002, terminal 6 and ground.

FRONT PARKING LAMPSTERMINAL TERMINAL

6 Ground

• Continuity should not exists.



No >> • Repair circuit for a short to ground in harness or connectors between FBCM and parking lamps.• Repair circuit for a short to ground in front fuse and relay box E, L.

4. CHECK DTC



Yes >> • Replace and program FBCM in accordance with the service information.


DIAGNOSIS & TESTING

VISMD150032


B1320 - Central Lock Control Circuit Low Current

DIAGNOSIS & TESTING

VISMW150082T

15


DIAGNOSIS & TESTING

VISMW150083T




76 Unlock Out With the door lock orunlock switch activated 12 V

77 Lock Out





B1320 Central lock controlcircuit low current

With the door lockswitch activated

When the FrontBody ControlModule (FBCM)detects the lockcontrol circuit lowcondition.

• Door lock actuator• Harness orconnectors• FBCM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the FBCM.• Operate the lock and unlock switch several times.• With X-431 select view active DTCs and data stream in the FBCM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


DIAGNOSIS & TESTING

15



1. CHECK CENTRAL LOCK FUSE IN FBCM

• Turn ignition switch off.• Check central lock fuse (2-1) (15A) in FBCM.




DIAGNOSIS & TESTING

VISMD150045


2. CHECK CENTRAL LOCK ACTUATOR POWER SUPPLY

• Disconnect central lock actuator harness connectorD-006.

• Turn ignition switch on.

• Check voltage between the central lock actuator harness connector D-006 , G-006 , I-003 or H-003 terminal 1and ground while operating the left front power window switch in the up position.

CENTRAL LOCKACTUATOR TERMINAL

GROUND

1




No >> • Repair or replace the lock control circuit between FBCM connector B-026, terminal 77 and door lockactuator connectors for open or high resistance.

DIAGNOSIS & TESTING

VISM150012

15


3. CHECK CENTRAL LOCK ACTUATOR RETURN CIRCUIT

• Check voltage between central lock actuator harness connector D-006 , G-006 , I-003 or H-003, terminal 1 andterminal 2 while operating the left front power window switch in the up position.

CENTRAL LOCKACTUATOR

CONNECTOR TERMINAL

CENTRAL LOCKACTUATOR

CONNECTOR TERMINAL

1 2




No >> • Repair or Replace the lock return circuit between FBCM connector B-026, terminal 76 and door lockactuator connectors for open or high resistance.

4. CHECK CENTRAL LOCK ACTUATORS

• Remove and check FR, FL, RL and RR central lock actuators.

Are all the central lock actuators OK?


No >> • Replace all the central lock actuators.

5. CHECK DTC





DIAGNOSIS & TESTING


B1353 - FL Window Down Control Circuit Low Current

DIAGNOSIS & TESTING

VISMW150084T

15




85 WIN FL Up Out With the FL window downswitch activated. 12 V

86 WIN FL Down Out





B1353FL window downcontrol circuit low

current

With the FL windowdown switch

activated.

When the FrontBody ControlModule (FBCM)detects the FLwindow downcontrol circuit lowcondition.

• FL power windowmotor• Harness orconnectors• FBCM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the FBCM.• Operate the left front power window switch up and down several times.• With X-431 select view active DTCs and data stream in the FBCM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


DIAGNOSIS & TESTING



1. CHECK FRONT LH POWER WINDOW MOTOR FUSE IN FBCM

• Turn ignition switch off.• Check front power window motor fuse (2-6) (30A) in FBCM.




DIAGNOSIS & TESTING

VISMD150045

15


2. CHECK FRONT LH POWER WINDOW MOTOR POWER SUPPLY

• Disconnect front LH power window motor harnessconnector D-002.

• Turn ignition switch on.

• Check voltage between front LH power window motor harness connector D-002, terminal 1 and ground whileoperating the left front power window switch in the down position.

FRONT LH POWERWINDOW MOTOR

TERMINAL

GROUND

1

• 12 V should exists.



No >> • Repair or replace the circuit between FBCM connector B-027, terminal 86 and front LH power win-dow motor connectors D-002, terminal 1 for open or high resistance.

3. CHECK FRONT LH POWER WINDOW MOTOR

• Remove and check front LH power window motor.

Is the window motor normal?


No >> • Replace all the front LH power window motor.

DIAGNOSIS & TESTING

VISM150092


4. CHECK DTC





DIAGNOSIS & TESTING

15


B1385 - Horn Control Circuit Open

DIAGNOSIS & TESTING

VISMW150080T




84 Horn Out Ignition switch: OnWith the horn activated 12 V





B1385 Horn control circuitopen

Turn ignition switchonWith the hornactivated

When the FrontBody ControlModule (FBCM)detects the horncontrol circuit opencondition.

• Horn• Harness orconnectors• FBCM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the FBCM.• Press horn switch.• With X-431 select view active DTCs and data stream in the FBCM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


DIAGNOSIS & TESTING

15



1. CHECK HORN FUSE IN FBCM

• Turn ignition switch off.• Check horn fuse (1-4) (10A) in FBCM.




DIAGNOSIS & TESTING

VISMD150045


2. CHECK HORN POWER SUPPLY

• Disconnect horn connector A-006 or A-005 (1).• Turn ignition switch on.

• Check voltage between the horn connector A-006, terminal 1 and ground or A-005, terminal 1 and ground whenpress the horn switch.

HORN TERMINAL

GROUND

1





3. CHECK HORN GROUND CIRCUIT

• Check horn ground circuit for open.• Continuity should exist.



No >> • Repair or replace ground circuit.

DIAGNOSIS & TESTING

VISMD150058

15


4. CHECK HORN CONTROL CIRCUIT

• Turn ignition switch off.• Disconnect FBCM connectors.• Check harness continuity between FBCM connector terminal 84 and horn connector terminal 1.

FBCM TERMINAL HORN TERMINAL

84 1

• Continuity should exists.



No >> • Repair or replace circuit for an open in harness or connectors between FBCM and horns.• Repair or replace front fuse and relay box.

5. CHECK HORNS

• Remove and inspect the horns.

Are the two horns OK?


No >> • Replace the two horns.

6. CHECK DTC





DIAGNOSIS & TESTING


B1386 - Horn Control Circuit Low Voltage

DIAGNOSIS & TESTING

VISMW150080T

15




84 Horn Out Turn ignition switch onWith the horn activated. 12 V





B1386 Horn control circuitlow voltage

• Turn ignitionswitch on• With the hornactivated.

When the FrontBody ControlModule (FBCM)detects the horncontrol circuit lowvoltage condition.

• Horn• Harness orconnectors• FBCM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the FBCM.• Press horn switch.• With X-431 select view active DTCs and data stream in the FBCM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


DIAGNOSIS & TESTING




• Turn ignition switch off.• Disconnect horn connector A-006 or A-005 (1).• Turn ignition switch on.

• Check voltage between the horn connector A-006, terminal 1 and ground or A-005, terminal 1 and ground whenpress the horn switch.

HORN TERMINAL

GROUND

1

• Refer to Wiring Diagram.• 12 V should exists.




DIAGNOSIS & TESTING

VISMD150058

15



• Turn ignition switch off.• Disconnect FBCM connector B-026.• Check resistance between the horn connector A-006, terminal 1 and ground or horn harness connector A-005,

terminal 1 and ground.

HORN TERMINAL

GROUND

1

• Refer to Wiring Diagram.• Continuity should not exists.



No >> • Repair circuit for a short to ground in harness or connectors between FBCM and horns.• Repair or replace front fuse and relay box.

3. CHECK HORNS

• Remove and inspect the horns.

Are the two horns OK?


No >> • Replace the damaged horns.

4. CHECK DTC



Yes >> • Replace FBCM in accordance with the service information.


DIAGNOSIS & TESTING


B1400 - Front Power Supply Voltage LowB1401 - Front Power Supply Voltage High

DIAGNOSIS & TESTING

VISMW150073T

15


DIAGNOSIS & TESTING

VISMW150074T






B1400 Front power supplyvoltage low

Turn ignition switchon

When the FrontBody ControlModule (FBCM)detects that thebattery voltage is tolow.

• Battery• Harness• Charging system• FBCM

B1401 Front power supplyvoltage high

When the FrontBody ControlModule (FBCM)detects that thebattery voltage is tohigh.

• Charging system• FBCM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on.• With the scan tool, record and erase stored DTCs in the FBCM.• Start engine and warm it to normal operating temperature, then select view DTC and data stream.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


NOTE :• Inspect the vehicle for aftermarket accessories that may exceed the Generator System output.• Inspect the fuses. If a burned fuse is found, use the wiring schematics as a guide and inspect the wiring and

connectors for a short.• Troubleshoot any Engine Control Module (ECM) charging/cranking DTCs before proceeding.



• Turn the ignition switch off.• Loosen and retighten ground connectors B-204 (See Ground Inspection in Section 15 Body & Accessories).• Inspect the ground connection B-204 position (See Vehicle Wiring Harness Information - Body Harness in Sec-

tion 16 Wiring).




DIAGNOSIS & TESTING

15


2. CHECK FRONT BODY CONTROL MODULE (FBCM) POWER SUPPLY

• Turn ignition switch off.• Disconnect FBCM electrical connector.

• Turn ignition switch on.• Check FBCM power supply between terminal 11,

47, 63 and terminal G in the FBCM electrical con-nector terminal side.






• Start the engine, raise the engine speed over 1000 rpm for a few minutes.• Turn ignition switch off.• Measure the voltage drop with the voltmeter at the battery positive and negative terminals while cranking the

engine.• Battery voltage should more than approximately 9 V.





• Start the engine, raise the engine speed over 1000 rpm.• Measure the charging voltage with a digital multimeter at the battery positive and negative terminals.




DIAGNOSIS & TESTING

VISMD150032

VISMD150031


5. CHECK FBCM SUPPLY CIRCUIT

• Disconnect the battery positive cable.• Measure the resistance between FBCM terminal 11 and battery positive.• Continuity should exist.



No >> • Check fuse.• Check the harness for an open or short to ground or high resistance.• Check related components.


• Start the engine, raise the engine speed over 1000 rpm.• Measure the charging voltage with a digital multimeter at the battery positive and negative terminals.




7. CHECK DTC





DIAGNOSIS & TESTING

15


B2311 - Boot Lid Release Control Circuit Open

DIAGNOSIS & TESTING

VISMW150088T

15




78 Boot Release Out With the release switchactivated. 12 V





B2311 Boot lid releasecontrol circuit open

With the releaseswitch activated.

When the FrontBody ControlModule (FBCM)detects the trunkrelease solenoidcontrol circuit opencondition.

• Trunk releasesolenoid• Harness orconnectors• FBCM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the FBCM.• Press the trunk release switch.• With X-431 select view active DTCs and data stream in the FBCM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


DIAGNOSIS & TESTING

15



1. CHECK TRUNK RELEASE SOLENOID FUSE IN FBCM

• Turn ignition switch off.• Check trunk release solenoid fuse (2-1) (15A) in FBCM.




DIAGNOSIS & TESTING

VISMD150045


2. CHECK TRUNK RELEASE SOLENOID POWER SUPPLY

• Open the trunk lid.• Disconnect trunk release solenoid harness connec-

tor B-401 (1).

• Close the trunk lid release latch.• Turn ignition switch on.• Check voltage between the trunk release solenoid harness connector B-401, terminal 2 and ground while press

the trunk release switch.

TRUNKRELEASESOLENOID

CONNECTORTERMINAL

TERMINAL VOLTAGE

2 Ground 12 V





3. CHECK TRUNK RELEASE SOLENOID GROUND CIRCUIT

• Check the trunk release solenoid ground circuit for an open.



No >> • Repair or replace the ground circuit.

DIAGNOSIS & TESTING

VISM150127

15


4. CHECK TRUNK RELEASE SOLENOID

• Remove and inspect the release solenoid.

Is the trunk release solenoid OK?


No >> • Replace the trunk release solenoid.

5. CHECK TRUNK RELEASE SOLENOID SUPPLY CIRCUIT

• Turn ignition switch off.• Disconnect FBCM connectors.• Check harness continuity between FBCM connector B-026, terminal 78 and trunk release solenoid connector

B-401, terminal 2.

FBCM TERMINAL TRUNK RELEASESOLENOID TERMINAL

78 2

• Continuity should exists.



No >> • Repair or replace open circuit in harness or connectors between FBCM and the trunk release sole-noid.

6. CHECK DTC





DIAGNOSIS & TESTING


U1000 - CAN Bus Off-Transmit Error

DIAGNOSIS & TESTING

VISMW150111T

15






U1000 CAN bus off-transmit error


The Body ControlModule (BCM) lostcommunication overthe CAN BUScircuit. The circuit iscontinuouslymonitored.

• ECM• FBCM• ABS module• EPS control unit• Restraints controlmodule• Unified metercontrol unit• CAN-Bus Harnessor connectors

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the FBCM.• Start engine and warm it to normal operating temperature, then select view DTC and data stream.• With X-431 select view active DTCs and data stream in the FBCM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


NOTE :• Ensure that the battery is fully charged.• Before performing the diagnostic procedure, settle all other FBCM DTCs first.• Before performing any DTC diagnostic procedures, verify the FBCM power and ground circuits are properly con-

nected.



• Turn the ignition switch off.• Loosen and retighten ground connectors B-204 (See Ground Inspection in Section 15 Body & Accessories).• Inspect the ground connection B-204 position (See Vehicle Wiring Harness Information - Body Harness in Sec-

tion 16 Wiring).




2. CHECK DTC

• Turn ignition switch on.• With the scan tool, select view FBCM DTCs and data stream.

Is CAN DTC U1000 present?


No >> • The conditions that caused this code to set are not present at this time (See Diagnostic Help inSection 15 Body & Accessories).

DIAGNOSIS & TESTING


3. CHECK OTHER MODULE DTC

• With the scan tool X-431, attempt to enter all the other CAN communication modules such as ECM, ABS mod-ule, Restraints control module, Unified meter control unit, EPS control unit.

• Read CAN DTCs.


Yes >> • If all of the other modules have the CAN DTC �High speed CAN Communication�, Go to the nextstep.

• If all of the other modules have the DTC about �Lost communication with BCM�, and not have the�CAN Bus off-Transmit Error�, Replace FBCM.


4. CHECK CAN-BUS LINE TOTAL RESISTANCE

• Turn ignition switch off.• Check CAN-Bus line total resistance between DLC terminal 14 and 6.

CAN-H CAN-L RESISTANCE

6 14 60 �




DIAGNOSIS & TESTING

15


5. CHECK CAN-BUS LINE

• Disconnect all other module connectors with CAN-Bus lines.• Check harness continuity between the following terminals.

CAN-H CIRCUIT CONTINUITY

CAN DLCTERMINAL TERMINAL CONTINUITY

CAN-H 6 Ground No

• Check harness continuity between the following terminals.

CAN-L CIRCUIT CONTINUITY


CAN-L 14 Ground No



No >> • Repair or replace CAN-Bus line.

DIAGNOSIS & TESTING


6. CHECK CAN-BUS LINE

• Connect all other disconnected CAN-Bus modules connectors.• Disconnect CAN-Bus modules one by one.• Connect battery negative.• Turn ignition switch on.• Check CAN-Bus voltage between the following terminals after one CAN-Bus module has been disconnected.

− CAN-H: Voltage should be more than 2.5 V.− CAN-L: Voltage should be less than 2.5 V.

CAN CIRCUIT VOLTAGE

DLC TERMINAL GROUND

6 (CAN-H)

Ground

14 (CAN-L)


Yes >> • Replace the disconnected module.• The problem caused by the disconnected module internal error.


7. CHECK BCM ELECTRICAL CONNECTOR

• Inspect the BCM electrical connector pins for proper fit or any chafed, pierced, pinched, or partially brokenwires.

• With the X-431 scan tool, read BCM DTCs.



No >> • Replace FBCM.• The problem caused by FBCM internal error.

DIAGNOSIS & TESTING

15


ON-VEHICLE SERVICE

Front Body Control Module (FBCM)

Removal & Installation1. Disconnect the negative battery cable.2. Remove the left lower trim panel assembly of the instrument panel (See Instrument Panel Removal & Installation

in Section 15 Body & Accessories).3. Remove the retaining bolts (1).

4. Disconnect the FBCM electrical connector.5. Remove the FBCM.6. Installation is in the reverse order of removal.

VISM150032


REAR BODY CONTROL MODULE - REAR BCMDescriptionThe Rear Body Control Module (RBCM) is located in the trunk. It controls the parking sonar, rear fog lamp, and rearpower window motor.

OperationThe Rear Body Control Module (RBCM) is through the LIN to connect with the Front Body Control Module (FBCM).

The following components are inputs to the BCM:• Parking sonar• Rear fog lamp switch• Rear power window switch

The following components are outputs from the BCM:• Rear fog lamp• Rear power window motor

15



Rear Body Control Module (Page 1 of 2)

REAR BODY CONTROL MODULE - REAR BCM

VISMW150109T


Rear Body Control Module (Page 2 of 2)


VISMW150110T

15


Rear Body Control Module Connector Pin-Out Table

PIN CIRCUIT IDENTIFICATION

1 -

2 Window RR Up Output

3 Window RR Down Output

4 GND

5 GND

6 Window RL Up Output

7 Window RL Down Output

8 -

9 -

10 -

11 Continuous Supply Voltage

12 Rear Fog Output

13 -

14 Reverse Radar Sensor Right

15 Reverse Radar Sensor Left

16 -

17 -

18 -

19 -

20 -

21 -

22 LIN (IISU)

23 GND (Sensor)

24 -

25 -

26 -

27 -

28 -

29 -

30 -

31 LIN (IISU)




modules through the class two serial data circuit.2. Confirm that the malfunction is current and carry-out the diagnostic tests and repair procedures.3. If the DTC cannot be deleted, it is a current fault.4. Use a digital multimeter to perform voltage readings on electronic systems.5. Refer to Technical Bulletins that issued.6. Visually inspect the related wiring electrical harness.7. Inspect and clean all RBCM grounds that are related to the DTC.8. If numerous trouble codes were set, use a wiring schematic and look for any common ground circuits or voltage


Intermittent DTC TroubleshootingIf the failure is intermittent perform the following:• Check for loose connectors.• Look for any chafed, pierced, pinched, or partially broken wires.• Monitor the scan tool data relative to this circuit.• Wiggle the related wiring electrical harness and connectors while looking for an interrupted signal on the


age or foreign material.• A data recorder, and/or oscilloscope should be used to help diagnose intermittent conditions.• Remove the RBCM module from the troubled vehicle and install in a new vehicle and test. If the DTC cannot

be deleted, the RBCM module is malfunctioning. If the DTC can be deleted, return the RBCM module to theoriginal vehicle.






15



Rear Body Control Module DTC List

DTC DTC DEFINITION

B1048 Rear Fog Lights Control Circuit Open

B1049 Rear Fog Lights Control Circuit Low Voltage

B1050 Rear Fog Lights Control Circuit High Voltage

B1362 RL Window Up Control Circuit Low Current

B1363 RL Window Up Control Circuit Stuck On

B1365 RL Window Down Control Circuit Low Current

B1366 RL Window Down Control Circuit Stuck On

B1368 RR Window Up Control Circuit Low Current

B1369 RR Window Up Control Circuit Stuck On

B1371 RR Window Up Control Circuit Low Current

B1372 RR Window Up Control Circuit Stuck On

DIAGNOSIS & TESTING



B1048 - Rear Fog Lights Control Circuit Open

DIAGNOSIS & TESTING

VISMW150077T

15


Check reference values between RBCM terminals and ground under the following conditions:

RBCM TERMINAL NO. ITEM CONDITION DATA (AVERAGE DCVOLTAGE)

12 Rear Fog Output

Ignition switch: ONThe rear lamp switchshould be on PARKposition or the headlightswitch on LOW position.With the rear fog lightsactivated.

12 V





B1048 Rear fog lightscontrol circuit open

Ignition switch: ONThe headlampswitch should be onPARK position or onLOW positionWith the rear foglights activated

The Rear BodyControl Module(RBCM) detects therear fog lightscontrol circuit opencondition.

• Rear fog lampbulbs• Harness orconnectors• RBCM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the RBCM.• Turn the headlamp switch on PARK position or on LOW position.• Turn rear fog lamp switch on.• With X-431 select view active DTCs and data stream in the RBCM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


NOTE :If DTC B1050 also exists, perform this DTC B1050 diagnostic procedure first.

DIAGNOSIS & TESTING



1. CHECK REAR FOG LAMP BULBS

• Turn rear fog lamp switch off.• Disconnect the rear fog lamps connector (1).• Remove and inspect the rear fog lamp bulbs.







Are the two rear fog lamp bulbs OK?


No >> • Replace the two rear fog bulbs.

2. CHECK REAR FOG LAMPS POWER SUPPLY

• Turn ignition switch on.• Turn the headlamp switch on PARK position or on LOW position.• Turn the rear fog lamp switch on.• Check voltage between the rear lamp harness connector B-004 or B-005, terminal 6 and ground.

REAR FOG TERMINAL

GROUND

6

DIAGNOSIS & TESTING

VISM150104

15






3. CHECK THE REAR FOG LAMPS POWER SUPPLY CIRCUIT

• Turn ignition switch off.• Check harness continuity between FBCM connector B-028, terminal 12 and rear fog lamp connector B-004 or

B-005, terminal 6.

RBCMTERMINAL

REAR FOGTERMINAL CONTINUITY

12 6 Yes




No >> • Repair or replace open circuit in harness or connectors between RBCM and rear fog lamps.

4. CHECK REAR FOG LAMPS GROUND CIRCUIT

• Check rear fog lamp ground circuits for an open between rear fog lamp LH connector B-004, terminal 8 andground.

• Check rear fog lamp ground circuits for an open between rear fog lamp RH connector A-005, terminal 8 andground.



No >> • Repair or replace the ground circuit or ground connection in harness or connectors.

5. CHECK DTC

• With the X-431 scan tool, read RBCM DTCs.• Refer to �DTC Confirmation Procedure�.


Yes >> • Replace RBCM.


DIAGNOSIS & TESTING


B1362 - RL Window Up Control Circuit Low Current

DIAGNOSIS & TESTING

VISMW150086T

15


Check reference values between Rear Body Control Module (RBCM) terminals and ground under the following con-ditions:

RBCM TERMINAL NO. ITEM CONDITION DATA (AVERAGE DCVOLTAGE)

6 WIN RL Down Out With the RL window upswitch activated. 12 V

7 WIN RL Up Out





B1362RL window up


With the RL windowup switch activated.

The Rear BodyControl Module(RBCM) detects theRL window upcontrol circuit lowcondition.

• RL power windowmotor• Harness orconnectors• RBCM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the RBCM.• Operate the left rear power window switch up and down several times.• With X-431 select view active DTCs and data stream in the RBCM.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


DIAGNOSIS & TESTING



1. CHECK REAR LH POWER WINDOW MOTOR POWER SUPPLY

• Turn ignition switch off.• Disconnect rear LH power window motor harness

connector I-001.• Turn ignition switch on.

• Check voltage between rear LH power window motor harness connector I-001, terminal 1 and ground whileoperating the left rear power window switch in the up position.

REAR LH POWERWINDOW MOTOR

TERMINAL

GROUND

1




No >> • Repair or replace circuit between RBCM connector B-028, terminal 6 and rear LH power windowmotor connectors I-001, terminal 1 for open or high resistance.

2. CHECK REAR LH POWER WINDOW MOTOR

• Remove and check rear LH power window motor.

Is the window motor normal?


No >> • Replace the rear LH power window motor.

DIAGNOSIS & TESTING

VISM150092

15


3. CHECK DTC

• With the X-431 scan tool, read RBCM DTCs.• Refer to �DTC Confirmation Procedure�.


Yes >> • Replace RBCM.


DIAGNOSIS & TESTING


ON-VEHICLE SERVICE

Rear Body Control Module (RBCM)

Removal & Installation1. Disconnect the negative battery cable.2. Remove the left floor mat in the luggage compartment.3. Remove the RBCM retaining bolts (1).

4. Disconnect the RBCM electrical connector.5. Remove the RBCM.6. Installation is in the reverse order of removal.

VISM150031

15


INSTRUMENT PANEL

Instrument Panel

Removal & Installation1. Disconnect the negative battery cable.2. Remove the instrument cluster (See Instrument Cluster Removal & Installation in Section 15 Body & Accesso-

ries).3. Remove the driver airbag (See Driver Airbag Removal & Installation in Section 14 Restraints).4. Remove the steering wheel (See Steering Wheel Removal & Installation in Section 11 Steering).5. Remove the driver information center (See Driver Information Center Removal & Installation in Section 15 Body

& Accessories).6. Remove the lower console (See Lower Console Removal & Installation in Section 15 Body & Accessories).7. Remove the CD player (See CD Player Removal & Installation in Section 15 Body & Accessories).8. Remove the HVAC control panel (See HVAC Control Panel Removal & Installation in Section 13 HVAC).9. Remove the A-pillar panel (See A-Pillar Panel Removal & Installation in Section 15 Body & Accessories).

10. Remove the main harness connecting with the body harness front door harness, the front end modules harness,the engine control harness and the air conditioning harness connectors.

11. Remove the shroud retaining screws (1) to removethe shroud.

12. Disconnect the spiral cable connector and remove the spiral cable.VISM110017


13. Remove the wiper switch and high beam switchretaining screws (1).

14. Remove the left lower trim panel assembly of theinstrument panel retaining bolts (1).

15. Remove the glove box assembly mounting bolts(1).

16. Disconnect the passenger airbag electrical connector.

INSTRUMENT PANEL

VISM110004

VISM150144

VISM150015

15


17. Remove the left blanking cover assembly andremove the retaining bolts (1).(Tighten: Left retaining bolts to 11 ± 1 N·m)

18. Remove the right blanking cover assembly andremove the retaining bolts (1).(Tighten: Right retaining bolts to 11 ± 1 N·m)

INSTRUMENT PANEL

VISM150018

VISM150019


19. Remove the lower retaining bolts (1) and theground cable.(Tighten: Lower retaining bolts to 11 ± 1 N·m)(Tighten: Ground cable bolts to 8 ± 1 N·m)

20. Remove the instrument panel assembly.21. Installation is in the reverse order of removal.

Lower Console

Removal & Installation1. Remove the lower console panel retaining screws.2. Remove the left and right console panel (1).

3. Remove the mounting screws (1) connecting theinstrument panel bracket.

INSTRUMENT PANEL

VISM150020

VISM150021

VISM150143

15


4. Remove the screws (1) connecting the lower con-sole and the center bezel.

5. Remove the shifter boot (1).

INSTRUMENT PANEL

VISM150027

VISM150022


6. Remove the bolts (1) connecting the lower consoleand the gearshift base.(Tighten: Lower console and gearshift base bolts to8 ± 1 N·m)

7. Using a trim stick, remove the parking brake levelshield (1).

INSTRUMENT PANEL

VISM150025

VISM150024

15


8. Remove the ashtray and remove the bolts (1) asshown.(Tighten: Lower console bolts to 8 ± 1 N·m)

9. Remove the lower console and disconnect thepower outlet.


INSTRUMENT PANEL

VISM150023

VISM150026


INSTRUMENT CLUSTERDescriptionThe Instrument Cluster (IC) is located in the instrument panel directly in front of the driver. The IC is used to informthe driver of specific vehicle information. The IC uses indicator lamps and gauges to warn the driver of potentiallycritical operating conditions.

The IC indicator lights are listed below:• EPS Warning Light (1)• Airbag Light (2)• Charging System Light (3)• Oil Pressure Light (4)• Tachometer (5)• Speedometer (6)• Malfunction Indicator Light (7)• Anti-Lock Warning Light (ABS) (8)• Left Turn Light (9)• Immobilizer Light (10)• High Beam Indicator Light (11)• Brake System Warning Light (12)• Right Turn Light (13)

VISM15013115


• Seat Belt Reminder Light (14)• Fuel Gauge (15)• Temperature Gauge (16)• Temperature Warning light (17)• Low Fuel Warning Light (18)• Electronic Throttle Control Indicator Light (19)• Odometer/Trip Odometer (20)• Parking Brake System Warning Light (21)• Parking Light (22)• Door Open Warning Display (23)• ESP Warning Light (24)• Maintenance Indicator Light (25)

The driver information center lights are listed below:• Front Fog Light Indicator Light (1)• Trunk Lid Open Warning Display (2)• Outside Temperature Display (3)• Rear Fog Light Indicator Light (4)

OperationThe Instrument Cluster (IC) uses hard wired inputs from various sensors and switches. The sensors and switches arelocated throughout the vehicle. The IC displays the following gauges:• Speedometer - The IC displays the vehicle speed as determined by the Engine Control Module (ECM) indicat-

ing the vehicle speed.• Tachometer - The IC displays the engine speed as determined by the Engine Control Module (ECM) indicating

engine speed.• Temperature Gauge - The IC displays the engine coolant temperature as determined by the Engine Control

Module (ECM) indicating engine coolant temperature.• Fuel Gauge - The IC displays the amount of fuel in the fuel tank as determined by the fuel level sensor.

Specifications



Instrument Cluster Bezel Fasteners 2

Instrument Cluster Fasteners 9

INSTRUMENT CLUSTER

VISM150134


Special Tools



INSTRUMENT CLUSTER

15



Instrument Cluster (Page 1 of 4)

INSTRUMENT CLUSTER

VISMW150089T



INSTRUMENT CLUSTER

VISMW150090T

15



INSTRUMENT CLUSTER

VISMW150091T



INSTRUMENT CLUSTER

VISMW150092T

15


Driver Information Center (Page 1 of 1)

INSTRUMENT CLUSTER

VISMW150010T


Instrument Cluster Module Connector Pin-Out Table


IDENTIFICATION

1 - 17 -

2 Coolant Lever Sensor 18 Parking Brake Switch

3 GND (Power) 19 Seat Belt Buckle SwitchLH

4 - 20 -

5 GND (Sensor) 21 Fuel Level Input

6 - 22 -

7 Speed Output 23 -

8 Reserve 24 -

9 Oil Pressure Switch 25 -

10 - 26 Brake Fluid Level Input

11 Continuous SupplyVoltage 27 Vehicle Speed Input

12 Illumination Lamp 28 -

13 Ignition Switch 29 CAN-L

14 - 30 CAN-H

15 - 31 -

16 Charge 32 -

INSTRUMENT CLUSTER

15


DIAGNOSIS & TESTINGClearing Service Monitor LampPerform the following to clear the service monitor lamp:

1. Turn the ignition switch off.2. Press down and hold the Mode switch.3. Turn the ignition switch on.4. Release the Mode switch.5. Touch the Mode switch and the Clock switch simultaneously in 30 seconds with a touch time less than 2 sec-

onds to clear the mileage maintenance identification.

Diagnostic Help1. The X-431 scan tool connects to the Data Link Connector (DLC) and communicates with the vehicle electronic

modules through the data network.2. Confirm that the malfunction is current and carry-out the diagnostic tests and repair procedures.3. If the DTC can not be deleted, it is a current fault.4. Use a digital multimeter to perform voltage readings on electronic systems.5. Refer to any Technical Bulletins that may apply to the failure.6. Visually inspect the related wiring harness.7. Inspect and clean all Instrument Cluster (IC) grounds that are related to the most current DTC.8. If numerous trouble codes were set, use a wiring schematic and look for any common ground circuits or voltage



age or foreign material.• A data recorder, and/or oscilloscope should be used to help diagnose intermittent conditions.• Remove the Instrument Cluster (IC) from the troubled vehicle and install in a new vehicle and test. If the DTC

cannot be deleted, the IC is malfunctioning. If the DTC can be deleted, return the IC to the original vehicle.








Instrument Cluster DTC List

DTC DTC DEFINITION

B1701 Fuel Gauge Sender-G Open/Short Circuit To Power

B1702 Fuel Gauge Sender-G Short Circuit To Earth

B1705 Vehicle Voltage Terminal 30 Power Supply Too Large

B1706 Vehicle Voltage Terminal 30 Power Supply Too Small

B1708 LED EPC In Fault

B1709 LED ABS In Fault

B1710 LED Air Bag In Fault

B1712 LED ESP In Fault

B1713 LED Brake Failure In Fault

B1714 LED Engine Check In Fault

B1723 EEPROM Checksum Error

U0073 ICM Communication Bus Off

U0100 Lost Communication With EMS

U0101 Lost Communication With TCM

U0121 Lost Communication With BSM

U0127 Lost Communication With TPM

U0131 Lost Communication With EPS

U0140 Lost Communication With FBCM

U0151 Lost Communication With ABM

DIAGNOSIS & TESTING

15



B1701 - Fuel Gauge Sender-G Open Or Short Circuit To Power

DIAGNOSIS & TESTING

VISMW150006T






B1701

Fuel gaugesender-G open or

short circuit topower

Ignition switch: ON

The InstrumentCluster (IC) moduledetects the fuelsensor circuit openor shorted to voltagecondition.

• Fuel level sensor• Harness orconnectors• Instrument cluster

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on.• With the scan tool, record and erase stored DTCs in the Instrument cluster (IC).• Start engine and warm it to normal operating temperature, then select view DTC and data stream.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


NOTE :• Ensure that the battery is fully charged.• Before performing any DTC diagnostic procedures, verify the IC power and ground circuits are properly connected.


1. CHECK DTC

•• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the IC.• Turn ignition switch off, and wait a few seconds, then turn ignition switch on.• With the scan tool, view active DTCs in the IC module.



No >> • The condition that caused the DTC is currently not present. Monitor the scan tool data relative tothis circuit while wiggle test the wiring and connectors and look for if the DTC reset.

DIAGNOSIS & TESTING

15


2. CHECK FUEL LEVEL SENSOR REFERENCE VOLTAGE

• Turn ignition switch off.• Disconnect the fuel level sensor and fuel pump assembly electrical connector.• Turn ignition switch on.

• Check if the fuel level sensor reference voltage ispresent between the fuel level sensor connectorB-032, pin 1 and ground.

• The voltage (less than 1 V) should exist.

Is the reference voltage normal?



3. CHECK FUEL LEVEL SENSOR CIRCUIT FOR OPEN AND SHORT TO POWER

• Turn ignition switch off.• Disconnect the IC module connector.• Check harness continuity between the following terminals:

FUEL LEVELSENSOR

TERMINALIC TERMINAL

1 21

• Refer to Wiring Diagram.• Continuity should exist.• Check harness for short to power.



No >> • Repair or replace the fuel level sensor supply circuit as necessary.• Check harness connector C-101, B-101, terminal 13 between IC connector C-001, terminal 21 and

fuel level sensor connector B-032, terminal 1.

DIAGNOSIS & TESTING

VISMD150022


4. CHECK FUEL LEVEL SENSOR GROUND CIRCUIT

• Using a 12 V test light connected to battery (+), probe fuel level sensor ground circuit.

Does the test light illuminate brightly?

Yes >> • Connect a jumper wire between the fuel level sensor connector B-032 pin 1 and pin 2, go to thenext step.

No >> • Repair or replace the fuel level sensor ground circuit for an open.

5. CHECK FUEL LEVEL METER INDICATE

• Turn the ignition switch off.• Connect the IC connector.• Turn ignition switch on.• With the scan tool, view active DTCs and data stream in the IC.• Check the fuel meter indicate full or if the DTC B1701 is not currently present.




6. CHECK FUEL LEVEL SENSOR RESISTANCE

• Check the fuel level sensor as follows:

FUEL LEVEL SENSOR REFERENCE DATA

FUEL GAUGE POINTERPOSITION POINTER DEPART (°) SENDER RESISTANCE

(�) POINTER TOLERANCE

EMPTY 0 283 ± 3°

RESERVE 11.25 189 ± 3°

1/4 22.5 137 ± 3°

1/2 45 89 ± 3°

3/4 67.5 62 ± 3°

FULL 90 40 ± 3°



No >> • Replace the fuel level sensor.

7. CHECK DTC

• With the X-431 scan tool, read IC DTCs.• Refer to �DTC Confirmation Procedure�.


Yes >> • Replace the IC.


DIAGNOSIS & TESTING

15


B1702 - Fuel Gauge Sender-G Short Circuit To Earth

DIAGNOSIS & TESTING

VISMW150006T






B1702Fuel gauge

sender-G shortcircuit to earth

Ignition switch: ON

The InstrumentCluster (IC) moduledetects the fuelsensor shorted toground condition.

• Fuel level sensor• Harness orconnectors• Instrument cluster

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on.• With the scan tool, record and erase stored DTCs in the Instrument Cluster (IC).• Start engine and warm it to normal operating temperature, then select view DTC and data stream.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-


NOTE :• Ensure that the battery is fully charged.• Before performing any DTC diagnostic procedures, verify the IC power and ground circuits are properly connected.


1. CHECK DTC

• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the IC.• Turn ignition switch off, and wait a few seconds, then turn ignition switch on.• With the scan tool, view active DTCs in the IC.



No >> • The condition that caused the DTC is currently not present. See Diagnostic Help for more informa-tion.

2. CHECK FUEL LEVEL SENSOR REFERENCE VOLTAGE

• Turn ignition switch off.• Disconnect the fuel level sensor and fuel pump assembly electrical connector.

• Turn ignition switch on.• Check if the fuel level sensor reference voltage is

present between the fuel level sensor connectorB-032, pin 1 and ground.

• The voltage (less than 1 V) should exist.

Is the reference voltage normal?



DIAGNOSIS & TESTING

VISMD150022

15


3. CHECK FUEL LEVEL SENSOR CIRCUIT FOR A SHORT TO GROUND

• Turn ignition switch off.• Disconnect the IC connector.• Check harness for a short to ground as follows:

FUEL LEVEL SENSORTERMINAL GROUND

1 Ground

• Refer to wiring diagram.



No >> • Repair or replace the fuel level sensor supply circuit as necessary.• Check harness connector C-101, B-101, terminal 13 between IC connector C-001, terminal 21 and

fuel level sensor connector B-032, terminal 1.

4. CHECK FUEL LEVEL METER INDICATE

• Turn ignition switch off.• Connect the IC connector.• Turn ignition switch on.• With the scan tool, view active DTCs and data stream in the IC.• Check the fuel meter indicate low or the DTC B1702 is not currently present.




DIAGNOSIS & TESTING


5. CHECK FUEL LEVEL SENSOR RESISTANCE

• Turn ignition switch off.• Check the fuel level sensor as follows:

FUEL LEVEL SENSOR REFERENCE DATA

FUEL GAUGE POINTERPOSITION POINTER DEPART (°) SENDER RESISTANCE

(�) POINTER TOLERANCE

EMPTY 0 283 ± 3°

RESERVE 11.25 189 ± 3°

1/4 22.5 137 ± 3°

1/2 45 89 ± 3°

3/4 67.5 62 ± 3°

FULL 90 40 ± 3°



No >> • Replace the fuel level sensor.

6. CHECK DTC





DIAGNOSIS & TESTING

15


B1705 - Vehicle Power Supply Too LargeB1706 - Vehicle Power Supply Too Small

DIAGNOSIS & TESTING

VISMW150004T


DIAGNOSIS & TESTING

VISMW150005T

15






B1705Vehicle voltage

terminal 30 powersupply too large

Ignition switch: ON

Instrument Cluster(IC) detected thatthe battery voltageis excessive high.

• Charging system• Instrument cluster

B1706Vehicle voltage

terminal 30 powersupply too small

Instrument Cluster(IC) detected thatthe battery voltageis excessive low.

• Battery• Harness is open orshorted• Charging system• Instrument cluster




connectors for damage.• Troubleshoot any Engine Control Module (ECM) charging/cranking DTCs before proceeding.• The following tools are required to perform the following test:• X-431 Scan Tool• Digital Multimeter• Jumper Wire



• Turn ignition switch off.• Loosen and retighten ground screws on the body (See Ground Inspection in Section 15 Body & Accessories).• Inspect ground connections C-201 and C-202 positions (See Vehicle Wiring Harness Information - Main Har-





DIAGNOSIS & TESTING


2. CHECK INSTRUMENT CLUSTER (IC) POWER SUPPLY

• Turn ignition switch off.• Disconnect IC electrical connector.• Turn ignition switch on.

• Check power supply between IC terminal 11, 13and terminal 3, 5 in the IC electrical connectorC-001 terminal side.











• Start the engine, raise the engine speed over 1000 rpm for a few minutes.• Turn ignition switch off.• Measure the voltage drop with a digital voltmeter at the battery positive and negative terminals while cranking

the engine.• Battery voltage should more than approximately 9 V.




5. CHECK INSTRUMENT CLUSTER (IC) SUPPLY CIRCUIT

• Disconnect the battery positive cable.• Measure the continuity between IC terminal 11, 13 and battery positive.• Continuity should exist.



No >> • Check fuse.• Check circuit for an open or short to ground.• Check related components.

DIAGNOSIS & TESTING

VISMD150055

15







7. CHECK DTC



Yes >> • Replace IC.


DIAGNOSIS & TESTING


B1723 - EEPROM Checksum Error




B1723 EEPROM checksum error Instrument Cluster (IC)detected an internal failure Instrument cluster




1. CHECK DTC





2. CHECK INSTRUMENT CLUSTER (IC) POWER SUPPLY AND GROUND

• Check the IC supply voltage circuit, ground circuit open, high resistance or short circuits existing.



No >> • Repair circuit for open or short in harness and connectors.

3. CHECK DTC




No >> • Replace and program IC.

DIAGNOSIS & TESTING

15


U0073 - ICM Communication Bus Off

DIAGNOSIS & TESTING

VISMW150164T






U0073 ICM communicationbus off


The InstrumentCluster (IC) lostcommunication overthe CAN-Bus circuit,and the CAN-Buscircuit iscontinuouslymonitored.

• CAN-Bus harnessor connectors• ECM• FBCM• ABS Module• Restraints ControlModule• Unified MeterControl Unit• EPS Control Unit



NOTE :• Ensure that the battery is fully charged.• Before performing any DTC diagnostic procedures, verify the IC power and ground circuits are properly connected.• Before performing the diagnostic procedure, settle all other IC DTCs first.



• Turn ignition switch off.• Loosen and retighten ground screws on the body (See Ground Inspection in Section 15 Body & Accessories).• Inspect ground connections C-201 and C-202 positions (See Vehicle Wiring Harness Information - Main Har-





2. CHECK DTC

• Turn ignition switch on.• With the scan tool, select view IC DTCs and data stream.

Is DTC U0073 present?



DIAGNOSIS & TESTING

15


3. CHECK OTHER MODULE DTC

• With the scan tool X-431, attempt to enter all the other CAN communication modules such as ECM, ABS mod-ule, Restraints Control Module, Body Control Module (BCM), EPS control unit.

• Read CAN DTCs.


Yes >> • If all of the other modules have the CAN DTC �High Speed CAN Communication�, go to the nextstep.

• If all of the other modules have the DTC about �Lost communication with ICM�, and not have the�High Speed CAN Communication�, Replace IC.


4. CHECK CAN-BUS LINE TERMINAL RESISTANCE IN IC

• Turn ignition switch off.• Disconnect the battery negative cable.• Disconnect IC connector.• Check the resistance between IC connector 29 and 30.

CAN BUS CIRCUIT RESISTANCE

CAN-H CAN-L RESISTANCE �

30 29 123.6 �



No >> • Replace IC.• The problem was caused by IC internal error.

DIAGNOSIS & TESTING


5. CHECK CAN BUS LINE TOTAL RESISTANCE

• Turn ignition switch off.• Check CAN-Bus line total resistance between DLC terminal 14 and 6.

CAN BUS CIRCUIT RESISTANCE

CAN-H CAN-L RESISTANCE

6 14 60 �




6. CHECK CAN BUS LINE

• Disconnect all other with CAN-Bus lines modules connectors.• Check harness continuity between the following CAN-H terminals.

CAN BUS CIRCUIT CONTINUITY


CAN-H 6 Ground No

DIAGNOSIS & TESTING

15


• Check harness continuity between the following CAN-L terminals.

CAN BUS CIRCUIT CONTINUITY


CAN-L 14 Ground No

• Also check harness for an open and short to power.



No >> • Repair or replace CAN-Bus line.

7. CHECK CAN BUS LINE

• Connect all other disconnected CAN-Bus modules connectors.• Disconnect CAN-Bus modules one by one.• Connect battery negative.• Turn ignition switch on.• Check CAN-Bus voltage between the following terminals after one CAN-Bus module has been discon-

nected.− CAN-H: Voltage should be more than 2.5 V.− CAN-L: Voltage should be less than 2.5 V.

CAN BUS LINE VOLTAGE

DLC TERMINAL TERMINAL

6 (CAN-H)

Ground

14 (CAN-L)


Yes >> • Replace the disconnected module.• The problem was caused by the disconnected module internal error.


DIAGNOSIS & TESTING


8. CHECK THE IC ELECTRICAL CONNECTOR

• Inspect the IC electrical connector pins for proper fit or any chafed, pierced, pinched, or partially broken wires.• With the X-431 scan tool, read IC DTCs.



No >> • Replace the IC.• The problem was caused by the IC internal error.

DIAGNOSIS & TESTING

15


ON-VEHICLE SERVICE

Instrument Cluster

Removal & Installation1. Disconnect the negative battery cable.2. Remove the two instrument cluster cover retaining

screws (1).

3. Remove the instrument cluster cover (1).

4. Remove the four retaining bolts (1) around thecluster.

VISM150165

VISM150016

VISM150017


5. Disconnect the instrument cluster electrical connec-tor (1).

6. Remove the instrument cluster.7. Installation is in the reverse order of removal.

Driver Information Center

Removal & Installation1. Remove the center bezel.2. Remove the driver information center retaining

screws (1).

3. Remove the driver information center and then disconnect the sun sensor.4. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

VISM150164

VISM150135

15


INTERIOR LAMPSDescriptionThe interior lamps are controlled by the Front Body Control Module (FBCM). Interior lamps consist of the following:• Keyhole Lamp• Front Courtesy Lamp• Rear Room Lamp• Front Step Lamp• Backlight Adjusting Switch• Instrument Cluster• Headlamp Aiming Switch• Driver Information Center• Combination Lamp Switch• Hazard Switch• ESP Switch• Trunk Lid Open Switch• Console Power Socket (Illumination)• Audio Unit• Door Mirror Remote Control Switch• Main Power Window And Door Lock/Unlock Switch• Front Power Window Switch• Rear Power Window Switch• Glove Box Lamp

OperationThe Front Body Control Module (FBCM) receives switch inputs and controls voltage output to the interior lamps. Thesupply voltage is transmitted from the fuse box to the lamps.



Interior Lamps (Page 1 of 5)

INTERIOR LAMPS

VISMW150065T

15



INTERIOR LAMPS

VISMW150066T



INTERIOR LAMPS

VISMW150067T

15



INTERIOR LAMPS

VISMW150068T



INTERIOR LAMPS

VISMW150069T

15


Front Courtesy/Dome Lamp Assembly

Removal & Installation1. Disconnect the negative battery cable.2. Using an appropriate tool, remove the lamp hous-

ing.3. Remove the retaining screws and disconnect the

electrical connector.4. Remove the front courtesy/dome lamp assembly.5. Installation is in the reverse order of removal.

Rear Room Lamp

Removal & Installation1. Disconnect the negative battery cable.2. Using screw driver, separate the rear interior room

lamp from the headliner.

3. Disconnect the electrical connector.4. Remove the rear room lamp.5. Installation is in the reverse order of removal.

INTERIOR LAMPS

VISM150028

VISM150029


Keyhole Lamp

Removal & Installation1. Disconnect the negative battery cable.2. Turn off the ignition switch.3. Remove the steering column shroud retaining

screws (1).

4. Disconnect the keyhole lamp electrical connector.5. Remove the keyhole lamp.6. Installation is in the reverse order of removal.

INTERIOR LAMPS

VISM110017

15


POWER OUTLETDescriptionThere are two 12 volt electrical outlets. One is under the center console which is used for the cigarette lighter. Theother is located on the right trim panel, near the front passenger area.

CAUTION:This power outlet is designed for 12V (120W) only. Do not use any type of accessory above thisvoltage.

OperationThe power outlets are powered when the ignition switch is in the ACC/ON position.



Power Outlet (Page 1 of 1)

POWER OUTLET

VISMW150024T

15


Power Outlet

Removal & Installation1. Disconnect the negative battery cable.2. Using an appropriate tool, pry the power outlet (1)

out of the trim panel.3. Disconnect the power outlet electrical connector.4. Installation is in the reverse order of removal.

POWER OUTLET

VISM150030


POWER WINDOWSDescriptionThe power window system allows each of the door windows to be raised and lowered electrically by actuating aswitch on each door trim panel. The driver�s window switch allows the driver to lock out the individual rear windowswitches from operation. The power window system includes the power window switches on the driver’s door trimpanel, passenger door and rear doors, and the power window motors.

OperationThe front and rear power window motors are permanent magnet type. A battery positive and negative connection toeither of the two motor terminals will cause the motor to rotate in one direction. Reversing current through thesesame two connections will cause the motor to rotate in the opposite direction. Each individual motor is groundedthrough their respective switch.

15



Power Window System (Page 1 of 4)

POWER WINDOWS

VISMW150044T



POWER WINDOWS

VISMW150045T

15



POWER WINDOWS

VISMW150046T



POWER WINDOWS

VISMW150047T

15


Power Window Switch

Removal & Installation1. Disconnect the negative battery cable.2. Using a trim stick, remove the power window

switch assembly (1) on the left front door.

3. Disconnect the power window switch electrical con-nector (1).

4. Remove the retaining screws and remove the power window switch assembly.5. Installation is in the reverse order of removal.

POWER WINDOWS

VISM150009

VISM150010


Power Window Motor

Removal & Installation1. Turn off the ignition switch.2. Using a trim stick, remove the power lock switch



POWER WINDOWS

VISM150009

VISM15001015



5. Remove the retaining bolt (1) in the inside doorhandle panel.(Tighten: Door retaining bolts to 7 ± 1 N·m)

POWER WINDOWS

VISM150084

VISM150156


6. Remove the retaining bolt (1) in the door handlepanel.(Tighten: Door retaining bolts to 7 ± 1 N·m)


POWER WINDOWS

VISM150087

VISM150085

15




10. Using a screwdriver, remove the door trim panellower three retaining screws (1).

POWER WINDOWS

VISM150151

VISM150086

VISM150152


11. Using a trim stick, remove the triangular panel (1).


13. Remove the door trim panel and disconnect the speaker electrical connector.14. Loosen the inside door handle control cable (1).

15. Remove the protective film from the front door.16. Disconnect the power lock motor electrical connector.

POWER WINDOWS

VISM150167

VISM150155

VISM150153

15


17. Remove the retaining bolts (1).(Tighten: Power lock motor retaining bolts to 8 ± 1N·m)




21. Remove the inside door glass weatherstrip (3).

POWER WINDOWS

VISM150011

VISM150157


22. Lower the glass to a proper position, remove thepower window motor retaining bolts (1).

23. Remove the window glass.24. Disconnect the connector of the window motor.25. Remove the guide rail mounting bolts (3).26. Remove the window regulator retaining nuts (2) on

the inner door panel.(Tighten: Window regulator retaining nuts to9 ± 1 N·m)

27. Remove the window regulator and guide railassembly.


POWER WINDOWS

VISM150091

VISM150092

15


Power Window Motor Inspection1. Using the following table, apply battery voltage to the specified connector terminals.2. Verify that the motor operates smoothly when voltage is applied in each direction.3. If the test results are not as specified, replace the motor.

MEASURINGCONDITION

OPERATIONALDIRECTION INSPECTION DIAGRAM


Down


Up

POWER WINDOWS


SEATS

General Information

DescriptionThe power seat switches are on the outboard side of the seat near the floor. The power seat system is capable ofallowing a user to adjust the power seat to the desired driving position.

OperationUse the switch to move the seat up, down, forward, rearward, or to tilt the seat. The power seat can be adjusted tocontrol eight different seating positions.

Front Seat

Removal & Installation1. Move the seat to the furthest front end, and remove the protection cover of guide rail.2. Move seat to the furthest back end, and remove the protection cover of guide rail.3. Remove the mounting bolts at the front end of the

guide rail (1).

VISM150033 15


4. Remove the mounting bolts at the back end of theguide rail (1).

5. The removal & installation of right front seat is similar to the left front seat.6. Installation is in the reverse order of removal.

SEATS

VISM150034


Rear Seat

Removal & Installation1. Remove the rear seat cushion (1).

2. Remove the left and right side cushions (1).

3. Pull the seat release upward to fold the rear seat.

SEATS

VISM150163

VISM150162

15


4. Open the trunk lid.5. Remove the seats mounting bolts (1).

6. Remove the seats retaining clips (1).

7. Remove the rear seats.8. Installation is in the reverse order of removal.

SEATS

VISM150160

VISM150161


IMMOBILIZERDescriptionThe vehicle security system uses a Vehicle Security Module (VSM) as an anti-theft device that prevents the enginefrom starting if an incorrect key is inserted into the ignition switch.

OperationWhen an incorrect key is inserted into the ignition switch, the vehicle security system senses the incorrect key andsends a signal to the VSM. The Engine Control Module (ECM) receives the signal from VSM via the R-line. The ECMthen disables the engine from starting.

15



Immobilizer (Page 1 of 1)

IMMOBILIZER

VISMW150012T


Immobilizer Module Connector Pin-Out Table


IDENTIFICATION

1 Continuous SupplyVoltage 7 Diagnostic Link K

2 GND 8 W-Line

3 - 9 Coil (GND)

4 Ignition Switch 10 Coil (ANT B)

5 R-Line 11 Coil (ANT A)

6 - - -

IMMOBILIZER

15



modules through the class two serial data circuit.2. Confirm that the malfunction is current and carry-out the diagnostic tests and repair procedures.3. If the DTC cannot be deleted, it is a current fault.4. Use a digital multimeter to perform voltage readings on electronic systems.5. Refer to any Technical Bulletins that issued.6. Visually inspect the related wiring electrical harness.7. Inspect and clean all Immobilizer grounds that are related to the DTC.8. If numerous trouble codes were set, use a wiring schematic and look for any common ground circuits or voltage


Intermittent DTC TroubleshootingIf the failure is intermittent, perform the following:• Check for loose connectors.• Look for any chafed, pierced, pinched, or partially broken wires.• Monitor the scan tool data relative to this circuit.• Wiggle the related wiring electrical harness and connectors while looking for an interrupted signal on the


age or foreign material.• A data recorder, and/or oscilloscope should be used to help diagnose intermittent conditions.








Immobilizer Module DTC List

DTC DTC DEFINITION

B1000 ECU Defect, Internal Errors

B3040 Communication Error On W-Line, ECM Doesn’t Answer On Challenge OrResponse Requests

B3042 W-Line Short Circuit To Ground

B3043 W-Line Short Circuit To Battery

B3045 DWA Line Short Circuit To Ground Or Open Circuit, DWA Line Malfunction

B3048 DWA Line Short Circuit To Battery

B3050 Relay External Line Short Circuit To Ground Or Open Circuit, RelayExternal Line Malfunction

B3053 Relay External Line Short Circuit To Battery

B3055 No Transponder Modulation Or No Transponder

B3056 No Transponder Fix Code Programmed

B3057 No Security Code Programmed

B3060 Unprogrammed Transponder Fix Code Received

B3061 Disturbed Or No Challenge / Response Transponder Communication

B3077 Read-Only Transponder Detected

DIAGNOSIS & TESTING

15



B1000 - ECU Defect, Internal Errors

DIAGNOSIS & TESTING

VISMW150012T





B1000 ECU defect, internalErrors

Immobilizer detects aninternal failure. Immobilizer

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in the Immobilizer.• Try to start the engine.• Turn ignition switch off, and wait a few seconds, then turn ignition switch on.• With the scan tool, view DTCs in the Immobilizer.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-



1. CHECK DTC





2. CHECK IMMOBILIZER POWER SUPPLY AND GROUND

• Check the Immobilizer supply voltage circuit, ground circuit open, high resistance or short circuits existing.



No >> • Repair circuit for open or short in harness and connectors.

DIAGNOSIS & TESTING

15


3. CHECK IMMOBILIZER COIL

• Turn ignition switch off.• Disconnect the Immobilizer electrical connector

C-026 (1).

• Check the resistance between the Immobilizer coil connector C-026, pin 9 and pin 11.

IMMOBILIZERCOIL

TERMINAL

IMMOBILIZERCOIL

TERMINALRESISTANCE

9 11 5 - 20 ohms

• The resistance should be 5 to 20 ohms.• Check the resistance between the Immobilizer coil connector C-026, pin 9 and pin 10.• Check the resistance between the Immobilizer coil connector C-026, pin 11 and pin 10.

IMMOBILIZERCOIL

TERMINAL

IMMOBILIZERCOIL

TERMINALCONTINUITY

9 10

Not

11 10



No >> • Replace the Immobilizer coil.

DIAGNOSIS & TESTING

LTSMD150019


4. CHECK DTC

• With the X-431 scan tool, read the Immobilizer DTCs.• Refer to �DTC Confirmation Procedure�.


Yes >> • Replace and program the Immobilizer.• Refer to DTC B3077 Diagnostic Procedure.


DIAGNOSIS & TESTING

15


B3042 - W-Line Short Circuit To GroundB3043 - W-Line Short Circuit To Battery

Immobilizer

DIAGNOSIS & TESTING

VISMW150012T






B3042 W-line short circuitto ground

Ignition switch: ON

The Immobilizerdetects a shortground condition onthe W-Line for atleast 3 seconds.

• Harness orconnectors• Immobilizer• ECM

B3043 W-Line short circuitto battery

The Immobilizerdetects a shortbattery condition onthe W-Line for atleast 3 seconds.

• Harness orconnectors• Immobilizer• ECM

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in Immobilizer.• Try to start the engine.• Turn ignition switch off, and wait a few seconds, then turn the ignition switch on.• With the scan tool, view active DTCs in the Immobilizer.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-




• Turn ignition switch off.• Loosen and retighten ground screws on the body (See Ground Inspection in Section 15 Body & Accessories).• Inspect ground connection C-204 position (See Vehicle Wiring Harness Layout - Main Harness in Section 16

Wiring).




2. CHECK IMMOBILIZER DTC

• With the scan tool, view DTCs in the Immobilizer. Refer to DTC confirmation procedure.

Is the warning light flashing and DTC B3042 or B3043 present?



DIAGNOSIS & TESTING

15


3. CHECK IMMOBILIZER AND ECM COMMUNICATION CIRCUIT

• Turn ignition switch off.• Disconnect the Engine Control Module (ECM) elec-

trical connector E-001 (1).

• Disconnect the Immobilizer electrical connectorC-025, C-026 (1).

• For DTC B3042, check the resistance of K-Line between the Immobilizer connector C-025, pin 8 and ground.

IMMOBILIZERTERMINAL TERMINAL RESULT

8 GroundContinuityshould not

exist

DIAGNOSIS & TESTING

VISMD150056

LTSMD150019


• For DTC B3043, turn ignition switch on, check voltage between the Immobilizer connector C-025, pin 8 andground.

IMMOBILIZERTERMINAL TERMINAL RESULT

8 Ground 12 V should notexist



No >> • Repair the circuits fault as necessary.

4. REPLACE AND PROGRAM THE IMMOBILIZER

• Replace and program the Immobilizer with the X-431.• Reconnect all disconnected electrical harness connectors.• With the X-431 scan tool, view the DTCs in the Immobilizer.

Is DTC B3042 or B3043 present again?


No >> • The system is now operating properly.• The DTC caused by Immobilizer.

5. REPLACE AND PROGRAM THE ECM

• With the X-431 scan tool, view the DTCs in the ECM.• Refer to �DTC Confirmation Procedure�.

Is DTC B3042 or B3043 still present?

Yes >> • Replace and program ECM.


DIAGNOSIS & TESTING

15


B3050 - Relay External Line Short Circuit To Ground Or Open Circuit, Relay ExternalLine MalfunctionB3053 - Relay External Line Short Circuit To Battery

DIAGNOSIS & TESTING

VISMW150012T






B3050

Relay external lineshort circuit toground or open

circuit, relay externalline malfunction


The Immobilizerdetects a shortground condition onthe relay externalline for at least 3seconds.

• Harness orconnectors• Immobilizer

B3053Relay external line

short circuit tobattery

With the ignitionswitch on

The Immobilizerdetects a short tobattery condition onthe relay externalline.

• Harness orconnectors• Immobilizer

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn ignition switch on, with the scan tool, view and erase stored DTCs in Immobilizer.• Try to start the engine.• Turn ignition switch off, and wait a few seconds, then turn ignition switch on.• With the scan tool, view active DTCs in the Immobilizer.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-





Wiring).






Is DTC B3050 or B3053 present?



DIAGNOSIS & TESTING

15


3. CHECK IMMOBILIZER POWER SUPPLY


C-025 (1).

• Turn ignition switch on.• Check voltage between the Immobilizer connector C-025, pin 4, 1 and ground.

IMMOBILIZERTERMINAL GROUND VOLTAGE

1

Ground 12 V shouldexist

4


Yes >> • Replace and program the Immobilizer. Refer to DTC B3077 Diagnostic Procedure.

No >> • For DTC B3050, go to the next step.• For DTC B3053, go to the step 5.

DIAGNOSIS & TESTING

LTSMD150019


4. CHECK IMMOBILIZER POWER SUPPLY CIRCUIT

• Turn ignition switch off.• Disconnect the negative battery cable.• Disconnect the body fuse and relay box electrical connector A.• Refer to Wiring Diagram.• Continuity should exist.• Check harness continuity between the following terminals:

Front Fuse and Relay Box

FRONT FUSEAND RELAY

BOXTERMINAL

IMMOBILIZERTERMINAL CONTINUITY

C6 1 Yes

• Check harness continuity between the following terminals:

Body Fuse Box

BODY FUSEBOX

TERMINAL


C20 4 Yes

• Check harness for short to ground.• Continuity between Immobilizer power supply and ground should not exist.


Yes >> • Go to the step 6.

No >> • Check fuse 9 (15A).• Repair or replace the open or high resistance circuit or short to ground in harness or connectors.

DIAGNOSIS & TESTING

15


5. CHECK IMMOBILIZER POWER SUPPLY CIRCUIT

• Turn ignition switch off.• Disconnect the negative battery cable.• Disconnect the body fuse and relay box electrical connector A.• Check the resistance between Immobilizer ignition switch circuit terminal 4 and Immobilizer power supply circuit

terminal 1.

IMMOBILIZERTERMINAL


1 4 No

• Check resistance between Immobilizer ignition switch circuit and other power circuits.• Refer to Wiring Diagram.


Yes >> • Go to the step 7.

No >> • Repair or replace short to power circuits in harness or connectors.


• Check fuse 15 (7.5A), fuse SB7 (30A).• Check body fuse box, front fuse and relay box.• Check harness connector B-103, C-103, terminal 11.• Harness between battery and body fuse box, harness between battery and front fuse and relay box.



No >> • Repair or replace damaged components.

7. REPLACE AND PROGRAM THE IMMOBILIZER

• With the X-431 scan tool, view the DTCs in the Immobilizer.• Refer to �DTC Confirmation Procedure�.

Is DTC B3050 or B3053 still present?

Yes >> • Replace and program Immobilizer.


DIAGNOSIS & TESTING


B3055 - No Transponder Modulation Or No TransponderB3056 - No Transponder Fixed Code Programmed

DIAGNOSIS & TESTING

VISMW150012T

15






B3055No transponder

modulation or notransponder

Ignition switch: ON

The Immobilizerdetects notransponder or notranspondermodulationcondition.

• Transponder• Harness orconnectors• Immobilizer

B3056No transponder

fixed codeprogrammed

The Immobilizerdetects that thetransponder is notprogrammed.

• Transponder• Harness orconnectors• Immobilizer

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn the ignition switch on, with the scan tool, view and erase stored DTCs in Immobilizer.• Try to start the engine.• Turn ignition switch off, and wait a few seconds, then turn the ignition switch on.• With the scan tool, view active DTCs in the Immobilizer.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-





Wiring).









DIAGNOSIS & TESTING




C-026 (1).


IMMOBILIZER COILTERMINAL


9 11

Is the resistance range from 5 to 20 ohms?




• Check the resistance between the Immobilizer coil connector C-026, pin 9 and pin 10.• Check the resistance between the Immobilizer coil connector C-026, pin 11 and pin 10.

IMMOBILIZERCOIL

TERMINAL

IMMOBILIZERCOIL

TERMINALCONTINUITY

9 10

Not

11 10

DIAGNOSIS & TESTING

LTSMD150019

15


• Continuity should not exist.




5. REPLACE AND PROGRAM TRANSPONDER

• Reconnect the Immobilizer electrical connectorC-026.

• Replace the chip (1) with a new one.

• Turn ignition switch on and perform the following:− With the X-431 scan tool, choose M11 series.− Choose �immobilize�.− Choose �input code�.− Input the safety code.− Click the small keyboard.− Click �OK�.− Choose �Immobilizer adapt�.− Choose �Key learning� immediately.− Click �OK�.

• Try to start the engine.

Is the warning light flashing and DTC B3055present?


No >> • No problem found at this time.• This concern may have been caused by

the transponder.• Erase all codes before returning the

vehicle to the customer.

DIAGNOSIS & TESTING

VISMD150018

VISMD150019T

VISMD150020T


6. REPLACE AND PROGRAM IMMOBILIZER

• Using the wiring schematic as a guide, inspect the related wiring and connectors of the Immobilizer.• Verify that there is good terminal contact in the related connectors.• Try to start the engine.• With the X-431 scan tool, view active DTCs in Immobilizer.

Is the warning light flashing and DTC B3055 or B3056 still present?

Yes >> • Replace and match the Immobilizer (This concern may have been caused by Immobilizer internalfault). Refer to DTC B3077 Diagnostic Procedure.

No >> • No problem found at this time.• This concern may have been caused by a loose or corroded terminal or connector.• Erase all codes before returning the vehicle to the customer.

DIAGNOSIS & TESTING

15


B3060 - Unprogrammed Transponder Fixed Code ReceivedB3061 - Disturbed Or No Challenge/Response Transponder CommunicationB3077 - Read-Only Transponder Detected

DIAGNOSIS & TESTING

VISMW150012T






B3060Unprogrammed

transponder fixedcode received

With the ignitionswitch on

The Immobilizerdetects the receivedunprogrammedtranspondercondition.

• Transponder• Harness orconnectors• Immobilizer• ECM

B3061

Disturbed or nochallenge/response

transpondercommunication

The Immobilizerdetects the receivedunprogrammedtranspondercondition.

B3077Read-only

transponderdetected

The Immobilizerdetects a read-onlytranspondercondition.

DTC Confirmation Procedure:Before performing the following procedure, confirm that battery voltage is more than 12 V.• Turn ignition switch off.• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.• Turn the ignition switch on, with the scan tool, view and erase stored DTCs in Immobilizer.• Try to start the engine.• Turn the ignition switch off, and wait a few seconds, then turn the ignition switch on.• With the scan tool, view active DTCs in the Immobilizer.• If the DTC is detected, the condition is current. Go to Diagnostic Procedure - Step 1.• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-





Wiring).




DIAGNOSIS & TESTING

15




Is DTC B3060, B3061 or B3077 present?

Yes >> • For DTC B3060, go to step 5.• For DTC B3061, go to the next step.• For DTC B3077, go to step 6.

No >> • The condition that caused the DTC is currently not present. Monitor the scan tool data relative tothis circuit while wiggle test the wiring and connectors and look for if the DTC reset.

− Using the wiring schematic as a guide, inspect the related wiring and connectors of the Immobilizer.− Verify that there is good terminal contact in the related connectors.

3. CHECK THE IMMOBILIZER COIL


C-026 (1).




9 11

Is the resistance range from 5 to 20 ohms?



DIAGNOSIS & TESTING

LTSMD150019



• Check the resistance between the Immobilizer coil connector C-026, pin 9 and pin 10.• Check the resistance between the Immobilizer coil connector C-026, pin 11 and pin 10.

IMMOBILIZERCOIL

TERMINAL

IMMOBILIZERCOIL

TERMINALCONTINUITY

9 10

Not

11 10




5. PROGRAM THE TRANSPONDER

• Using the X-431 scan tool, program the vehicle security system.

• Turn ignition switch on and perform the following:− With the X-431 scan tool, choose M11 series.− Choose �immobilize�.− Choose �input code�.− Input the safety code.− Click the small keyboard.− Click �OK�.− Choose �Immobilizer adapt�.− Choose �Key learning� immediately.− Click �OK�.

• Try to start the engine.• With the X-431 scan tool, view active DTCs in Immobilizer.



No >> • No problem found at this time.• This concern may have been caused by the not programmed transponder.• Erase all codes before returning the vehicle to the customer.

DIAGNOSIS & TESTING

VISMD150019T

15


6. REPLACE AND PROGRAM THE TRANSPONDER

• Replace the chip (1) with a new one.

• Turn ignition switch on.• Repeat step 5.• Try to start the engine.• With the X-431 scan tool, view DTCs in Immobi-

lizer.


Yes >> • Replace and program the Immobilizer(See Immobilizer Removal & Installationin Chapter 15 Body & Accessories).

• Go to the next step.

No >> • No problem found at this time.• This concern may have been caused by

the transponder fault.• Erase all codes before returning the vehicle to the customer.

7. VERIFY NEW IMMOBILIZER

• Try to start the engine.• With the X-431 scan tool, view active DTCs in the Immobilizer.



No >> • No problem found at this time.• This concern may have been caused by the Immobilizer fault.• Erase all codes before returning the vehicle to the customer.

8. REPLACE AND MATCH ECM

• Using the wiring schematic as a guide, inspect the related wiring and connectors of the ECM.• Verify that there is good terminal contact in the related connectors.• Try to start the engine.• With the X-431 scan tool, view active DTCs in Immobilizer.

Is DTC B3060, B3061 or B3077 still present?

Yes >> • Replace the ECM and match the ECM to the Immobilizer (See Electronic Control Module Removal& Installation in Section 03 Electronic Engine Controls) (This concern may have been caused by anECM internal fault).

No >> • No problem found at this time.

DIAGNOSIS & TESTING

VISMD150018

VISMD150019T


ON-VEHICLE SERVICE

Immobilizer

Removal & Installation1. Remove the instrument panel (See Instrument Panel Removal & Installation in Section 15 Body & Accessory)2. Remove the retaining bolt (1) on the steering

column.

3. Disconnect the Immobilizer harness.4. Installation is in the reverse order of removal.

• Perform the following to match the Immobilizer to the ECM:− With the X-431 scan tool, choose M11 series.− Choose �immobilize�.− Choose �input code�.− Input the safety code.− Click the small keyboard.− Click �OK�.− Choose �Immobilizer adapt�.− Choose �read EMS to Immobilizer� immediately.− Click �OK�.

NOTE :If replacing the ECM with a new one, choose �read Immobilizer to EMS � immediately.

VISM150035

15


Remote Keyless Entry (RKE) Inoperative

No Response From Remote Keyless Entry (RKE) Transmitter

1. CHECK BATTERY

• Check battery of the RKE transmitter.

Is the battery voltage of the RKE transmitter normal?


No >> • This concern has been caused by the transmitter battery.• Go to step 4.

2. CHECK THE IGNITION LOCK CYLINDER CONDITION

• Check the ignition lock cylinder for proper operation.



No >> • Repair or replace the ignition lock cylinder key switch.

3. PERFORM THE RKE TRANSMITTER MATCH PROCEDURE

• Close all the doors.• Insert the ignition key into the ignition switch which has lost synchronization in LOCK position.• Press any button on the RKE transmitter within 5 seconds.• Pull the ignition key out of the ignition switch.• Try to operate the RKE transmitter.

Does the RKE transmitter operate properly?

Yes >> • Erase all codes before returning the vehicle to the customer.


ON-VEHICLE SERVICE


4. PERFORM THE RKE TRANSMITTER MATCH WITH THE X-431

• Replace the RKE transmitter.• Connect the X-431 scan tool to the Data Link Connector (DLC), press the POWER key to start the X-431 (use

the most current software available).

• Turn ignition switch on.− Enter the Diagnostic Program.− Select Chery main program.− Select diagnostic version.− Enter download program.− Select M11 series, and then select ISU.− Select �Remoter Match�.

• Press the lock button on the RKE transmitter for less than 2 seconds.• Remove the key from the ignition switch.• Try to operate the RKE transmitter.

Does the RKE transmitter operate properly?

Yes >> • Erase all codes before returning the vehicle to the customer.• The concern was caused by the RKE transmitter.

No >> • Replace the FBCM (See FBCM Removal & Installation in Section 15 Body & Accessories).• Refer to the RKE transmitter match procedure with X-431 as the description.• Perform match between the RKE transmitter and FBCM with the X-431.

ON-VEHICLE SERVICE

LTSMD150020T

15


BODY EXTERIOR

BODY DIMENSIONS 15-238Description 15-238

Frame 15-239Body Frame Dimensions (Units: mm) 15-239

Front View 15-240Body Front Dimensions 15-240

Rear View 15-243Body Rear Dimensions 15-243

Side View 15-246Body Side Dimensions (Units: mm) 15-246

Engine Compartment 15-251Engine Compartment Dimensions(Units: mm) 15-251

Windshield 15-252Windshield Dimensions (Units: mm) 15-252

Body Openings 15-253Body Opening Dimensions 15-253

BUMPERS 15-255

Front Bumper 15-255Removal & Installation 15-255

Rear Bumper 15-256Removal & Installation 15-256

DOORS 15-258

Front Door 15-258Removal & Installation 15-258Disassembly 15-260Assembly 15-269Power Window System Inspection 15-269Replacing Front Door Hinge 15-269

Rear Door 15-269Removal & Installation 15-269Disassembly 15-270Assembly 15-274Replacing Rear Door Hinge 15-274

EXTERIOR LAMPS 15-275Description 15-275Operation 15-275Specification 15-275Electrical Schematics 15-276

Front Combination Lamp Assembly 15-290Removal & Installation 15-290

Rear Combination Lamp Assembly 15-291Removal & Installation 15-291

Headlamp 15-292Removal & Installation 15-292

Front Fog Lamp 15-292Removal & Installation 15-292

Backup/Stop/Rear Position/Rear TurnSignal/Rear Fog Lamp 15-293


High Mounted Stop Lamp 15-294Removal & Installation 15-294

Turn Signal Lamp 15-295Removal & Installation 15-295

License Plate Lamp 15-295Removal & Installation 15-295

FENDER 15-296

Front Fender 15-296Removal & Installation 15-296

FUEL DOOR 15-298

Fuel Door 15-298Removal & Installation 15-298

GRILLE 15-299

Grille 15-299Removal & Installation 15-299

HOOD 15-300

Hood 15-300Removal & Installation 15-300

Hood Release Cable 15-301Removal & Installation 15-301

HORN 15-302Description 15-302Operation 15-302Electrical Schematics 15-303

Horn 15-304Removal & Installation 15-304

MIRRORS 15-305Description 15-305Operation 15-305Electrical Schematics 15-306

Outside Mirror 15-310Removal & Installation 15-310

PAINT 15-311

Paint Codes 15-311Specification 15-311


PARKING SONAR 15-312Description 15-312Operation 15-312Electrical Schematics 15-313

Sonar Sensor 15-315Removal & Installation 15-315

Sonar Alarm 15-315Removal & Installation 15-315

RADIATOR SUPPORT 15-316

Radiator Support 15-316Removal & Installation 15-316

STATIONARY GLASS 15-317Description 15-317Electrical Schematics 15-318

Front Windshield 15-319Removal 15-319Installation 15-319

Rear Window 15-321Removal 15-321Installation 15-322

TRUNK LID 15-324Description 15-324Operation 15-324Electrical Schematics 15-325

Trunk Lid 15-327Removal & Installation 15-327

Power Trunk Lid Release 15-328Removal & Installation 15-328

WIPERS AND WASHERS 15-330Description 15-330Operation 15-330Electrical Schematics 15-331

Wiper Motor 15-333Removal & Installation 15-333

Wiper Arm 15-333Removal & Installation 15-333

Wiper Linkage 15-334Removal & Installation 15-334

Washer Bottle 15-334Removal & Installation 15-334

Washer Pump 15-335Removal & Installation 15-335

Wiper Switch 15-335Removal & Installation 15-335

BODY AND ACCESSORIES - BODY EXTERIOR

15


BODY DIMENSIONSDescription• All measurements should be made from the bare metal, remove trim and bumper covers as necessary.• Repair the badly damaged areas before taking measurements for underbody alignment.• Monitor the upper body structure for excessive stress or movement while making any corrections to the under-

body structure.• Remove all the necessary glass to prevent breakage.• All dimensions are shown in millimeters (mm).

Frame

Body Frame Dimensions (Units: mm)

VISM150036


Front View

Body Front Dimensions

The clearance between the front hood and the air inletgrille at A-1: 7 ± 0.9 mm.

1 - Front Hood 2 - Air Inlet Grille

BODY DIMENSIONS

VISM150037

VISM150038

15


The clearance between the front bumper and the fronthood at A-2: 6 ± 1 mm.

The clearance between the headlamp and the fronthood at A-3: 5 ± 1 mm.

The clearance between the front hood and the frontwindshield at A-4: 13 ± 1 mm.

1 - Front Hood 2 - Front Bumper

1 - Headlamp 2 - Front Hood

1 - Front Hood 2 - Front Windshield

BODY DIMENSIONS

VISM150039

VISM150040

VISM150041


The clearance between the headlamp and the frontbumper at A-5: 2.5 ± 0.7 mm.

The clearance between the front window and the roofat A-6: 3.2 ± 1 mm.

The clearance between the front hood and the frontbumper at A-7: 4 ± 1 mm.

1 - Headlamp 2 - Front Bumper

1 - Front Window 2 - Roof

1 - Front Hood 2 - Front Bumper

BODY DIMENSIONS

VISM150042

VISM150043

VISM150044

15


The clearance between the front bumper and the airinlet grille at A-8: 2.7 ± 1 mm.

Rear View

Body Rear Dimensions

1 - Front Bumper 2 - Air Inlet Grille

BODY DIMENSIONS

VISM150045

VISM150046


The clearance between the rear bumper and middleluggage compartment cover at B-1: 5 ± 1.3 mm

The clearance between the rear window and the lug-gage compartment cover at B-2: 7.3 ± 1.9 mm

The clearance between the rear window and the roof atB-3: 3.5 ± 0.9 mm

1 - Luggage CompartmentCover 2 - Rear Bumper

1 - Rear Window 2 - Luggage CompartmentCover

1 - Rear Window 2 - Roof

BODY DIMENSIONS

VISM150047

VISM150048

VISM150049

15


The clearance between the taillamp and the luggagecompartment cover at B-4: 2.5 ± 1 mm

The clearance between the taillamp and the rearbumper at B-5: 4 ± 1 mm

The clearance between the luggage compartment coverand the rear bumper at B-6: 6 ± 1.5 mm

1 - Taillamp 2 - Luggage CompartmentCover

1 - Taillamp 2 - Rear Bumper

1 - Luggage CompartmentCover 2 - Rear Bumper

BODY DIMENSIONS

VISM150050

VISM150051

VISM150052


The clearance between the rear fender and the lug-gage compartment cover at B-7: 4 ± 1 mm

Side View

Body Side Dimensions (Units: mm)

The clearance between the front door and the frontfender at C-1: 4 ± 0.7 mm

1 - Rear Fender 2 - Luggage CompartmentCover

1 - Front Fender 2 - Front Door

BODY DIMENSIONS

VISM150053

VISM150054

VISM150055

15


The clearance between the front fender and A pillar atC-2: 4 ± 0.7 mm

The clearance between upper front door and upper reardoor at C-3: 4 ± 0.7 mm

The clearance between middle front door and middlerear door at C-4: 4 ± 0.7 mm

1 - Front Fender 2 - A Pillar

1 - Front Door 2 - Rear Door

1 - Front Door 2 - Rear Door

BODY DIMENSIONS

VISM150056

VISM150057

VISM150058


The clearance between the front fender and the frontdoor at C-5: 6 ± 1.1 mm

The clearance between the rear door and the rearfender at C-6: 4 ± 0.7 mm

The clearance between the fuel door and the rearfender at C-7: 3 ± 0.8 mm

1 - Roof 2 - Front Door

1 - Rear Door 2 - Rear Fender

1 - Fuel Door 2 - Rear Fender

BODY DIMENSIONS

VISM150059

VISM150060

VISM150061

15


The clearance between the taillamp and the rear fenderat C-8: 1.5 ± 0.8 mm

The clearance between the rear bumper and the rearfender at C-9: 0.5 + 0.7 mm, 0.5 - 0.5 mm.

The clearance between the front bumper and the frontfender at C-10: 0.5 + 0.7 mm, 0.5 - 0.5 mm.

1 - Taillamp 2 - Rear Fender

1 - Rear Bumper 2 - Rear Fender

1 - Front Bumper 2 - Front Fender

BODY DIMENSIONS

VISM150062

VISM150063

VISM150064


The clearance between the rear door and upper rearfender at C-11: 6 ± 1.1 mm.

The clearance between the rear fender and the sidepanel at C-12: 6.6 ± 1.5 mm.

The clearance between the side panel and the frontdoor at C-13: 6 ± 1.5 mm.

1 - Rear Door 2 - Rear Fender

1 - Side Panel 2 - Rear Fender

1 - Side Panel 2 - Front Door

BODY DIMENSIONS

VISM150065

VISM150066

VISM150067

15


The clearance between the front fender and the sidepanel at C-14: 6 ± 1.5 mm.

Engine Compartment

Engine Compartment Dimensions (Units: mm)

1 - Front Fender 2 - Side Panel

BODY DIMENSIONS

VISM150068

VISM150069


Windshield

Windshield Dimensions (Units: mm)

BODY DIMENSIONS

VISM150070

15


Body Openings

Body Opening Dimensions

MARK NAME

ABJoint Place of FrontWindshield Lower CrossBeam and Front Fender

BC Joint Place of Top Cover andSide Panel

MARK NAME

CD Joint Place of Top Cover andSide Panel (on Rear Fender)

EFJoint Place of RearWindshield Cross Beam andSide Panel (on Rear Fender)

BODY DIMENSIONS

VISM150070

VISM150071


MARK NAME

AB Mounting hole for the lockcolumn of the rear door

CD Mounting hole for the upperhinge of the rear door

EF Mounting hole for the lowerhinge of the rear door

MARK NAME

GH Mounting hole for the upperhinge of the front door

IJ Mounting hole for the lowerhinge of the front door

VISM15007215


BUMPERS

Front Bumper

Removal & Installation1. Open the engine hood.2. Remove the upper bumper six retaining bolts (1).

3. Remove the grille from the vehicle.

4. Raise and support the vehicle.5. Remove the lower retaining bolts (1) (left and

right).(Tighten: Lower retaining bolts to 9 ± 1 N·m)

6. Remove the bottom connecting bolts.(Tighten: Bottom connecting bolts to 11 ± 1 N·m)

7. Disconnect the front fog lamp (left and right) and turn-signal lamp (left and right).

BUMPERS

VISM150073

VISM150074

VISM150075


8. Lower the vehicle and then remove the frontbumper.


Rear Bumper

Removal & Installation1. Remove the dust shield connecting bolts (1) (left

and right).(Tighten: Dust shield connecting bolts to5 ± 0.5 N·m)

2. Remove the trunk lid inner panel retaining screws(1).

BUMPERS

VISM150077

VISM150078

VISM150079

15


3. Raise the vehicle and remove the bottom connect-ing clamps (1).

4. Lower the vehicle and remove the rear bumper.5. Disconnect the parking sonar and the plate lamp.6. Using a screwdriver, remove the parking sonar (1).


BUMPERS

VISM150080

VISM150081


DOORS

Front Door

Removal & Installation1. Turn off the ignition switch.2. Disconnect the inner electrical harness connector

(1) on the front door.

3. Remove the retaining bolts (1) connecting the doorand the A pillar.(Tighten: Retaining bolt to 63 ± 5 N·m)

4. Remove the front bumper (See Front Bumper Removal & Installation in Section 15 Body & Accessories).5. Remove the bolts connecting the fender and the dust shield.

VISM150095

VISM150136

15


6. Remove the bolt (1) connecting the fender and theupper A pillar.(Tighten: Connecting bolt to 11 ± 1 N·m)

7. Remove the bolt (1) connecting the fender apronand the lower A pillar.(Tighten: Connecting bolt to 11 ± 1 N·m)

8. Remove the bolts (1) on the fender apron.

9. Remove the bolts (1) connecting the fender to thebody.

10. Remove the fender.

DOORS

VISM150096

VISM150097

VISM150098

VISM150099


11. Remove the front door mounting bolts (1).(Tighten: Front door mounting bolts to36 ± 4 N·m)


Installation Notes:

• Adjust the door in left, right and vertical directions.

Disassembly1. Remove the outside mirror inner trim strip to the front door.2. Remove the mounting nuts (1), and remove the

outside mirror electrical connector.(Tighten: Outside mirror mounting nuts to 7 ± 1N·m)

3. Remove the outside mirror.4. Turn off the ignition switch.

DOORS

VISM150100

VISM150090

15


5. Using a trim stick, remove the power lock switchassembly (1) on the left front door.


DOORS

VISM150009

VISM150010



8. Remove the retaining bolt (1) in the inside doorhandle panel.(Tighten: Door retaining bolts to 7 ± 1 N·m)

DOORS

VISM150084

VISM150156

15


9. Remove the retaining bolt (1) in the door handlepanel.(Tighten: Door retaining bolts to 7 ± 1 N·m)


DOORS

VISM150087

VISM150085




13. Using a screwdriver, remove the door trim panellower three retaining screws (1).

DOORS

VISM150151

VISM150086

VISM150152

15


14. Using a trim stick, remove the inside cover (1) forthe mirror bolts from the door trim panel.


16. Remove the door trim panel and disconnect the speaker electrical connector.17. Loosen the inside door handle control cable (1).

18. Remove the protective film from the front door.

DOORS

VISM150167

VISM150155

VISM150153


19. Remove the speaker screws (1) and disconnectthe speaker electrical connector.

20. Remove the speaker.21. Remove the door lock switch bracket retaining

bolts (1).22. Remove the door handle control cable retaining

screws (2).23. Remove the inside door glass weatherstrip (3).

DOORS

VISM150089

VISM150157

15


24. Lower the glass to a proper position, remove thepower window motor retaining bolts (1).

25. Remove the window glass.26. Disconnect the connector of the window motor.27. Remove the guide rail mounting bolts (3).28. Remove the window regulator retaining nuts (2) on

the inner door panel.(Tighten: Window regulator retaining nuts to 9 ± 1N·m)

29. Remove the window regulator and guide railassembly.

DOORS

VISM150091

VISM150092


30. Remove the power lock motor retaining bolts (1).(Tighten: Power lock motor retaining bolts to 8 ± 1N·m)


32. Disconnect the door lock motor connecting rod to the door outside handle.33. Remove the power door lock motor.

34. Remove the side turn signal lamp (1) and discon-nect the connector.

35. Remove the manual door lock switch bracket retaining bolts and then remove the door lock switch bracket.(Tighten: Door lock switch bracket retaining bolts to 7 ± 1 N·m)

DOORS

VISM150011

VISM150012

VISM150093

15


36. Remove the front door outside handle retainingbolts (1).(Tighten: Front door outside handle retaining boltsto 7 ± 1 N·m)

37. Remove the power door lock motor connectors andtie rods.

Assembly1. Assembly is in the reverse order of disassembly.

Power Window System Inspection1. After installing the power window system, it should

be checked. The time for the glass to travel fromthe lowest position to the highest position should be about 7 seconds. If the time is too long, recheck the oper-ation of the power window system.

2. Check the power window motor working condition.3. Check the window channel for any abrasive debris that could effect the window operation.4. Check the window regulator and guide rails for any condition that could effect window operation.

Replacing Front Door Hinge1. Remove the front fender to gain access to the door hinge (See Fender Removal & Installation in Section 15

Body & Accessories).2. Support the door.3. Remove the retaining bolts from the upper and lower hinges, and then remove the hinges.

Rear Door

Removal & Installation1. Turn off the ignition switch.2. Disconnect the inner electrical harness connector

(1) on the rear door.

DOORS

VISM150094

VISM150117


3. Remove the retaining bolt (1) connecting the door and the B pillar.(Tighten: Retaining bolt to 63 ± 5 N·m)

4. Remove the four rear door mounting bolts (1).(Tighten: Rear door mounting bolts to 36 ± 4 N·m)


Installation Notes:

• Adjust the door in left, right and vertical directions.

Disassembly1. Using a screwdriver, remove the door trim panel and door connecting screws.2. Using a trim stick, remove the door lock switch.3. Remove the power window switch (1) and discon-

nect the electrical connector.

4. Using a trim stick, remove the inner door handle panel.

DOORS

VISM150118

VISM150119

VISM150108

15


5. Remove the retaining bolt (1) in the inside handlepanel.(Tighten: Retaining bolt to 7 ± 1 N·m)

6. Remove the retaining bolt (1) connecting the trimpanel and the door in the power window switch.(Tighten: Retaining bolt to 7 ± 1 N·m)

7. Remove the rear door trim panel retaining screws(1).

8. Loosen the inside door handle control cable (1)and then remove the inner door handle.

DOORS

VISM150109

VISM150110

VISM150158

VISM150153


9. Remove the door trim panel.CAUTION: While servicing the door panels, care should be taken to maintain a clean work environment.

10. Remove the protective film from the rear door.11. Remove the speaker screws and disconnect the speaker electrical connector.12. Remove the speaker.13. Remove the rear door inner and outside weatherstrip.14. Remove the glass run.15. Remove the bolts (1) connecting the inner handle

and the rear door.(Tighten: Inner handle retaining bolts to 7 ± 1 N·m)

16. Remove the bolts connecting the outside handleand the rear door (1).(Tighten: Outside handle retaining bolts to 8 ± 1N·m)

17. Remove the rear door outside handle and doorlock connecting rod (1).

DOORS

VISM150111

VISM150112

VISM150113

15




20. Remove the inside door glass weatherstrip (3).

21. Remove the rear door outside handle.22. Lower the glass to a proper position, remove the

retaining bolts (1).23. Remove the window glass.24. Disconnect the connector of the window regulator.25. Remove the window regulator retaining nuts (2).

(Tighten: Window regulator retaining nuts to 9 ± 1N·m)

26. Remove the rear door lock bracket retaining bolts(3).

27. Remove the window regulator assembly and guiderail.

DOORS

VISM150157

VISM150115

VISM150114


28. Remove the power lock motor retaining bolts (1).(Tighten: Power lock motor retaining bolts to 8 ± 1N·m)


30. Remove the power lock motor and disconnect theharness.

Assembly1. Assembly is in the reverse order of disassembly.

Replacing Rear Door Hinge1. Remove the door check bolts.2. Support the door.3. Remove the retaining bolts from the upper and lower hinges, and then remove the hinges.

DOORS

VISM150011

VISM150116

15


EXTERIOR LAMPSDescriptionThe exterior lamps consist of the following:• Headlamps• Turn Signal Lamps• Fog Lamps• Stop Lamps• Backup Lamps• Position Lamps

Operation• Headlamps: With the light switch in the 2nd position, the Front Body Control Module (FBCM) receives input

requesting head lamp operation. The FBCM then supplies power to the head lamps.• Turn Signal Lamps: When the turn signal switch is in LH or RH position with the ignition switch in ON position,

the FBCM detects the RH or LH turn signal request. The FBCM supplies power to the respective turn signallamp.

• Hazard Lamps: When the hazard switch is in ON position, the FBCM detects the hazard switch signal. TheFBCM outputs the flasher signal (right and left). The FBCM then activates the hazard indicator and audiblebuzzer.

• Fog Lamps: When the front/rear fog lamp switch is in ON position and also the light switch is in the 1st or 2ndposition. The FBCM/RBCM receives input requesting fog lamp operation. The FBCM/RBCM then supplies powerto the fog lamps.

• Stop Lamps: When the brake pedal is applied, the stop lamp switch sends the signal to the RBCM. The RBCMthen supplies power to the stop lamps.

• Backup Lamps: When the FBCM receives the signal from the backup lamp switch. The FBCM then sends asignal to the RBCM, then the RBCM supplies power to the backup lamp.

Specification

Torque Specification

DESCRIPTION N·m

Front Combination Lamp Fixing Bolts 8 ± 1

Rear Combination Lamp Fixing Bolts 8 ± 1



Headlamp Aiming System (Page 1 of 3)

EXTERIOR LAMPS

VISMW150049T

15



EXTERIOR LAMPS

VISMW150050T



EXTERIOR LAMPS

VISMW150051T

15


Parking, License Plate and Tail Lamps (Page 1 of 2)

EXTERIOR LAMPS

VISMW150053T


Parking, License Plate and Tail Lamps (Page 2 of 2)

EXTERIOR LAMPS

VISMW150054T

15


Fog Lamps (Page 1 of 3)

EXTERIOR LAMPS

VISMW150055T



EXTERIOR LAMPS

VISMW150056T

15



EXTERIOR LAMPS

VISMW150057T


Turn Signal and Hazard Warning Lamps (Page 1 of 3)

EXTERIOR LAMPS

VISMW150058T

15



EXTERIOR LAMPS

VISMW150059T



EXTERIOR LAMPS

VISMW150060T

15


Stop Lamps (Page 1 of 1)

EXTERIOR LAMPS

VISMW150052T


Backup Lamp (Page 1 of 2)

EXTERIOR LAMPS

VISMW150061T

15


Backup Lamp (Page 1 of 2)

EXTERIOR LAMPS

VISMW150062T


Front Combination Lamp Assembly

Removal & Installation1. Open the engine hood.2. Remove the front bumper (See Front Bumper Removal & Installation in Section 15 Body & Accessories).3. Disconnect the front combination lamp assembly electrical connector.4. Remove the three fixing bolts (1) of headlamp

assembly.

5. Remove the headlamp assembly carefully.




3 Front PositionLamp 12 V (5 W)

EXTERIOR LAMPS

VISM150101

VISM150102

15


Rear Combination Lamp Assembly

Removal & Installation1. Open the trunk lid.2. Remove the trunk lid floor mat.3. Removal the four rear combination lamp retaining

nuts (1).

4. Disconnect the rear combination lamp electrical connectors.5. Pull out the rear combination lamp assembly

carefully.



2 Backup Lamp 12 V (21 W)

3 Rear Turn SignalLamp 12 V (21 W)


5 Rear PositionLamp 12 V (5 W)

EXTERIOR LAMPS

VISM150103

VISM150104


Headlamp

Removal & Installation1. Remove the front combination lamp assembly (See Front Combination Lamp Assembly Removal & Installation in

Section 15 Body & Accessories).2. Remove the headlamp bulb cover.3. Disconnect the headlamp bulb electrical connector

(1).

4. Remove the headlamp bulb clip.5. Carefully remove the bulb for the headlamp.6. Replace the bulb.7. Installation is in the reverse order of removal.

Front Fog Lamp

Removal & Installation1. Disconnect the negative battery cable.2. Remove the front bumper (See Front bumper Removal & Installation in Section 15 Body & Accessories).3. Remove the front fog lamp retaining screws (1).

EXTERIOR LAMPS

VISM150145

VISM150105

15


4. Replace the bulb (1).5. Installation is in the reverse order of removal.

Backup/Stop/Rear Position/Rear Turn Signal/Rear Fog Lamp

Removal & Installation1. Open the trunk lid door.2. Remove the trunk lid floor mat.3. Remove the bulbs for backup/stop/rear position/

rear turn signal/rear fog lamps by hand.

4. Replace the bulb.5. Installation is in the reverse order of removal.

EXTERIOR LAMPS

VISM150146

VISM150147


High Mounted Stop Lamp

Removal & Installation1. Disconnect the negative battery cable.2. Remove the rear seat.3. Remove the rear seatbelt.4. Remove the rear parcel shelf finisher.

5. Remove the high mounted stop lamp mountingscrews (1).

6. Remove the high mounted stop lamp.7. Replace the bulb.8. Installation is in the reverse order of removal.

EXTERIOR LAMPS

VISM150142

VISM150140

15


Turn Signal Lamp

Removal & Installation1. Disconnect the negative battery cable.2. Remove the front bumper (See Front bumper Removal & Installation in Section 15 Body & Accessories).3. Remove the front turn signal lamp retaining screws

(1).

4. Remove the side turn signal lamp (1).

5. Disconnect the side turn signal lamp electrical connector.6. Replace the bulb.7. Installation is in the reverse order of removal.

License Plate Lamp

Removal & Installation1. Using plastic trim stick, remove the license plate

lamp (1).2. Replace the bulb.3. Installation is in the reverse order of removal.

EXTERIOR LAMPS

VISM150148

VISM150093

VISM150141


FENDER

Front Fender

Removal & Installation1. Remove the front bumper (See Front Bumper Removal & Installation in Section 15 Body & Accessories).2. Remove the bolts connecting the fender and the dust shield.3. Remove the bolt (1) connecting the fender and the

upper A pillar.(Tighten: Connecting bolt to 11 ± 1 N·m)

4. Remove the bolt (1) connecting the fender apronand the lower A pillar.(Tighten: Connecting bolt to 11 ± 1 N·m)

5. Remove the bolts (1) on the fender apron.

VISM150096

VISM150097

VISM150098

15


6. Remove the bolts (1) connecting the fender to thebody.


FENDER

VISM150099


FUEL DOOR

Fuel Door

Removal & Installation1. Open the fuel door.2. Remove the two fuel door retaining bolts (1).3. Remove the fuel door.4. Installation is in the reverse order of removal.

VISM150106

15


GRILLE

Grille

Removal & Installation1. Open the engine hood.2. Remove the grille from the vehicle.

3. Installation is in the reverse order of removal.VISM150074


HOOD

Hood

Removal & Installation1. Remove the retaining clips with a screwdriver, and

remove the under hood heat shield (1).

2. Loosen the windshield washer hose, and thenremove the spray nozzle clip (1) to remove thespray nozzle.

VISM150120

VISM150121

15


3. Remove the retaining bolts (two each side) and setthe hood aside.


Hood Release Cable

Removal & Installation1. Remove the left lower trim panel on the instrument panel.2. Remove the left fender inner lining (See Fender Removal & Installation in Section 15 Body & Accessories).3. Remove the hood lock bolts (1) and remove the

hood control cable.(Tighten: Hood lock bolts to 9 ± 1 N·m)


HOOD

BESM150133

VISM150123


HORNDescriptionA dual note electric horn system is installed on this vehicle. The horn system features electromagnetic horns. Thehorn system includes the following components:• Horn - The horns are located under the headlamp in the front bumper.• Horn Switch - The horn switch is located under the driver airbag.

OperationThe horn system operates on battery current received through a fuse in the Front Body Control Module (FBCM). Thehorn system circuit is designed so that the system will remain operational, regardless of the ignition switch position.

15



Horn (Page 1 of 1)

HORN

VISMW150017T


Horn

Removal & Installation1. Disconnect the negative battery cable.2. Disconnect the horn electrical connectors.3. Remove the horn retaining bolts (1) and remove

the horns.


HORN

VISM150124

15


MIRRORSDescriptionThe mirrors are controlled by a single switch assembly located on the driver’s door trim panel. A three-position switchselects the right or left power mirror for adjustment. A momentary joystick directional switch allows the driver to adjustthe selected power mirror in the Up & Down or Right & Left directions. The heated mirror system is controlled byFront Body Control Module (FBCM). When there is water vapor on the mirrors, the heated mirrors will eliminate thewater vapor.

OperationUse the mirror select switch, located on the driver’s door trim panel, to adjust the view obtained in the outside mir-rors. Rotate the joystick for Left or Right mirror selection. Select a mirror and press the joystick that correspond withthe direction that you want the mirror to move.



Power Mirrors (Page 1 of 2)

MIRRORS

VISMW150020T

15


Power Mirrors (Page 2 of 2)

MIRRORS

VISMW150021T


Heated Mirrors (Page 1 of 2)

MIRRORS

VISMW150022T

15


Heated Mirrors (Page 2 of 2)

MIRRORS

VISMW150023T


Outside Mirror

Removal & Installation1. Disconnect the negative battery cable.2. Remove the outside mirror inner trim strip to the front door.3. Remove the mounting nuts (1), and remove the

outside mirror electrical harness.(Tighten: Rear view mirror mounting nuts to 7 ± 1N·m)

4. Remove the outside mirror.


Installation Notes:

• If replacing the side view mirror lens, remove the lens and replace it before reinstalling the mirror.

MIRRORS

VISM150090

15


PAINT

Paint Codes

Specification

NO COLOR ITEM CODE

1 Nasdaq Silver KH

2 Wolfsburg Gray GF

3 Aegean Blue HU

4 Magic Black CB

5 Chery White BK


PARKING SONARDescriptionWhen the transaxle selector lever is in the �R� position, a stationary object will be detected by the rear sonar sensorcausing the sonar buzzer to sound a tone. As the vehicle moves closer to the object, the rate of the tone willincrease. When the object is very close to the vehicle, the tone will sound continuously.

OperationWith power and ground supplied, transaxle gear selector lever in �R� position, the rear sonar sensor will detect obsta-cles within 1.5 m of the rear sonar sensors. The sensor signal inputs are transmitted to the Rear Body Control Mod-ule (RBCM) and the Front Body Control Module (FBCM). The RBCM and the FBCM communicate this signal to theinstrument cluster via CAN communication to activate the buzzer. The vehicle operator is notified of obstacles by avaried rate of tone from the sonar buzzer depending on the distance of the obstacle being sensed.

15



Parking Sonar (Page 1 of 2)

PARKING SONAR

VISMW150027T


Parking Sonar (Page 2 of 2)

PARKING SONAR

VISMW150028T

15


Sonar Sensor

Removal & Installation1. Disconnect the negative battery cable.2. Using a screwdriver, carefully remove the sonar

sensor (1) from the bumper.

3. Disconnect the sonar sensor electrical connector.4. Installation is in the reverse order of removal.

Sonar Alarm


NOTE :The sonar alarm is located at the instrument cluster.

1. Remove the instrument cluster (See Instrument Cluster Removal & Installation in Section 15 Body & Accesso-ries).


PARKING SONAR

VISM150081


RADIATOR SUPPORT

Radiator Support

Removal & Installation1. Remove the radiator support retaining bolts (1) (on

each side).2. Remove the radiator support.3. Installation is in the reverse order of removal.

VISM150129

15


STATIONARY GLASSDescriptionThe stationary glass is comprised of the following:• Front Windshield• Rear Window• Rear Window Defogger



Rear Window Defogger (Page 1 of 1)

STATIONARY GLASS

XLSMW150001T

15


Front Windshield

Removal1. Remove the wiper arms and the lower trim panel from the windshield (See Wiper Arm Removal & Installation in

Section 15 Body & Accessories).2. Using piano wire, insert the piano wire between the

body and the glass. Attach wooden blocks to bothends of the piano wire.

CAUTION:To prevent vehicle paint damage, use adhesivetape on painted surfaces during windshieldremoval. Place a plastic cover between thepiano wire and the instrument panel to preventthe instrument panel from being scuffed whenremoving the glass.

3. Pull the piano wire around the glass, and cut offthe bonding agent to remove the glass.

NOTE :Leave as much bonding agent as possible on the bodywhen removing the bonding portion of the glass.

Installation1. Remove the rough portions on the body with a knife and clean the cut bonding agent with a rag soaked with

cleaning solvent.

CAUTION:Even if the entire bonding agent has been cleared, you should also clean the body surface. Do nottouch the glass surface after cleaning.2. Remove the stopper with a knife.3. Clear the bonding agent adhered to the glass with a scraper and clean the glass with glass cleaner.

NOTE :Do not touch the glass after cleaning.

STATIONARY GLASS

BESM150013

BESM150014


4. Replace the clamping piece if necessary:• Remove the stopper with a knife• Remove the old clamping piece• Replace with a new clamping piece

5. Position the glass:• Place the glass in the proper position• Make reference marks on the glass and the

body• Remove the glass

6. Clean the contact surface of the glass:• Clear any residue around the peripheral con-

tact face of the glass with glass cleaner

NOTE :Do not touch the glass surface after cleaning.

7. Install the water resistance piece:• Install the water resistance piece using double face adhesive tape as shown in the figure.

8. Apply a layer of primer M on the contact surface ofthe body and apply a layer of primer M on the con-tact face of the body with a brush.

NOTE :Allow the primer coat to dry for a minimum of 3 minutes. Do not apply the primer to the bonding agent. Do not savethe opened primer M for later use.

9. Apply a layer of primer G on the contact surface of the glass:• Apply a layer of primer G on the edges and the contact surface of the glass with a brush or sponge.• Wipe the excess primer off with a clean rag before it dries.

NOTE :Allow the primer coat to dry for a minimum of 3 minutes. Do not apply the primer to the bonding agent. Do not savethe opened primer G for later use.

10. Mixing the bonding agent:• Clean a mixing board and a scraper completely with solvent.• Thoroughly mix 500 grams of host crystal with 75 grams of hardener on a mixing board with a scraper.

NOTE :Make sure that the molding be installed before the bonding agent has cured.

1 - Primer M 2 - Primer M 3 - Primer M

STATIONARY GLASS

BESM150015

BESM150016

15


11. Applying the bonding agent:• Cut off the pot tip and fill the bonding agent

into the pot.• Place the pot into the sealant gun.• Apply the bonding agent on the glass as

shown in the figure.

12. Installing the glass:

CAUTION:Verify that the water resistant piece is adhered to the panel of the body as shown in the figure.13. To install the glass, align the reference marks on

the glass and the body and then lightly press theglass into the body opening.

14. Apply the bonding agent on the edges of the glasswith a scraper.

15. Remove any excessive or over flown bondingagent with a scraper.

16. Clamp the glass until the bonding agent has hard-ened.

17. Check for water leakage:• Perform the leakage test after the hardening

period.• Seal any leaks with the proper sealant.

18. Install the upper molding of the windshield:• Install the upper windshield molding on the body and tap it lightly to fasten it.• Install the outer windshield molding.

Rear Window

Removal1. Lay the seat back down and remove the coat track.2. Remove the lower molding.3. Remove the double face adhesive tape at both

ends of the molding with a scraper as shown in thefigure.

4. Rear window removal:• Using piano wire, insert the piano wire between the body and the glass.• Attach wooden blocks to both ends of the piano wire.• Pull the piano wire through between the body and the glass from inside of the vehicle.• Pull the piano wire along the bonding agent to cut it off.

STATIONARY GLASS

BESM150017

BESM150018

BESM150019


CAUTION:Do not let the piano wire damage the two stoppers.

• Remove the rear window.

Installation1. Place the rear window molding around the glass and fit it manually.2. Remove the rough portions on the body with a knife and clean the cut bonding agent with a rag soaked with

cleaning solvent.

CAUTION:Even if the entire bonding agent has been cleared, you should also clean the body surface. Do nottouch the glass surface after cleaning.3. Remove the stopper with a knife.4. Clean the removed rear window:

• Clean any bonding agent adhered to the glass with a scraper.• Remove the stopper with a knife.• Clean the glass with glass cleaner.

NOTE :Do not touch the glass after cleaning

5. Position the glass:• Place the glass in the proper position• Make reference marks on the glass and the body• Remove the glass

6. Clean the contact surface of the glass:• Clear any residue around the peripheral contact face of the glass with glass cleaner.

NOTE :Do not touch the glass surface after cleaning.

7. Apply a layer of primer M on the contact surface of the body with a brush.

NOTE :Allow the primer coat to dry for a minimum of 3 minutes. Do not apply the primer to the bonding agent. Do not savethe opened primer M for later use.

8. Apply a layer of primer G on the contact surface of the glass:• Apply a layer of primer G on the edges and the contact surface of the glass with a brush or sponge.• Wipe the excess primer off with a clean rag before it dries.

NOTE :Allow the primer coat to dry for a minimum of 3 minutes. Do not apply the primer to the bonding agent. Do not savethe opened primer G for later use.

9. Mixing the bonding agent:• Clean a mixing board and a scraper completely with solvent.• Thoroughly mix 500 grams of host crystal with 75 grams of hardener on a mixing board with a scraper.

NOTE :Make sure that the molding be installed within the application period of the bonding agent, and the bonding agentshould be mixed within 5 minutes.

STATIONARY GLASS

15


10. Applying the bonding agent:• Cut off the pot tip and fill the bonding agent

into the pot.• Place the pot into the sealant gun.• Apply the bonding agent on the glass as

shown in the figure.

11. Installing the glass:

CAUTION:Verify that the water resistant piece is adhered to the panel of the body as shown in the figure.12. To install the glass, align the reference marks on

the glass and the body and then lightly press theglass into the body opening.

13. Apply the bonding agent on the edges of the glasswith a scraper.

14. Remove any excessive or over flown bondingagent with a scraper.

15. Clamp the glass until the bonding agent has hard-ened.

16. Check for water leakage:• Perform the leakage test after the hardening

period.• Seal any leaks with the proper sealant.

17. Install the rear window molding:• Install the rear window outer lower molding on the body and tap it lightly to fasten it.• Connect the leads of the rear window defroster.

STATIONARY GLASS

BESM150017

BESM150018


TRUNK LIDDescriptionThe trunk lid is located at the back of the vehicle.

OperationThe trunk lid can be opened with the key, remote key FOB or by using the trunk lid release button on the left lowertrim panel.

15



Trunk Lid (Page 1 of 2)

TRUNK LID

VISMW150013T


Trunk Lid (Page 2 of 2)

TRUNK LID

VISMW150014T

15


Trunk Lid

Removal & Installation1. Disconnect the negative battery cable.2. Remove the retaining clips with a screwdriver, and

remove the under trunk shield (1).NOTE: Trunk shield has 13 clips.

3. Disconnect the electrical connector (1) of the trunklid release.

4. Remove the retaining bolts (1) of the lock actuator.(Tighten: Lock actuator retaining bolts to9 ± 1 N·m)

TRUNK LID

VISM150122

VISM150127

VISM150125


5. Remove the luggage compartment lock retainingbolt (1).(Tighten: Luggage compartment lock retaining boltto 9 ± 1 N·m)

6. Remove the trunk lid stay bar clips (2).7. Remove the four bolts (1) (two at left and right) to

detach the luggage compartment door.(Tighten: Luggage compartment door bolts to10 ± 1 N·m)

8. Remove the luggage compartment wheel house trim assembly and the floor mat.9. Remove the weatherstrip of the rear luggage compartment.

10. Lift the luggage compartment floor mat up to remove the spare tire.11. Installation is in the reverse order of removal.

Power Trunk Lid Release

Removal & Installation1. Disconnect the negative battery cable.2. Disconnect the negative battery cable.3. Remove the retaining clips with a screwdriver, and

remove the under trunk shield.NOTE: Trunk shield has 13 clips.

TRUNK LID

VISM150126

VISM150128

VISM150122

15


4. Disconnect the electrical connector (1) of the trunklid release.

5. Remove the retaining bolts of the lock actuator.(Tighten: Lock actuator retaining bolts to9 ± 1 N·m)

6. Remove the luggage compartment lock.(Tighten: Luggage compartment lock retaining boltsto 9 ± 1 N·m)


Installation Notes:

• Adjust the luggage compartment lock to maintain a clearance of 5 ± 0.5 mm between the luggage compartmentcover and the rear side enclosure.

TRUNK LID

VISM150127

VISM150125

VISM150126


WIPERS AND WASHERSDescriptionThe wiper system operates the front and rear wipers. The windshield wiper system includes the following compo-nents:• Wiper and Washer Switch• Wiper Motor• Wiper Arm• Wiper Link• Washer Bottle• Washer Motor

OperationThe wiper system is controlled by the wiper and washer switch. The wiper and washer system operate with theignition switch is in the ON position. All wiper and washer functions are controlled by rotating the control knob on theend of the control stalk to the MIST, OFF, INT, LO or HI wiper positions.

15



Wiper and Washer System (Page 1 of 2)

WIPERS AND WASHERS

VISMW150015T


Wiper and Washer System (Page 2 of 2)

WIPERS AND WASHERS

VISMW150016T

15


Wiper Motor

Removal & Installation1. Remove the protection caps from the left and right wiper arms.2. Remove the retaining nuts (1) from the wiper arms.3. Remove the two wiper arms.

4. Remove the lower trim panel of front windscreen.5. Remove the fixing bolts of linking mechanism.6. Disconnect the motor (1), remove the linking mech-

anism retaining bolts (2).


Wiper Arm

Removal & Installation1. Remove the protection cap of the fixing nuts from

the wiper arm.2. Remove the retaining nuts (1) from the wiper arm.3. Remove the wiper arm.4. Installation is in the reverse order of removal.

WIPERS AND WASHERS

VISM150137

VISM150130

VISM150137


Wiper Linkage

Removal & Installation1. Remove the left lower trim panel from the front windshield.2. Disconnect the motor electrical connector (1).3. Remove the wiper linkage retaining bolts (2).4. Installation is in the reverse order of removal.

Washer Bottle

Removal & Installation1. Remove the front bumper (See Front Bumper Removal & Installation in Section 15 Body & Accessories).2. Disconnect the washer hose and the washer pump

(2) electrical connector.3. Remove the retaining bolts (1) to remove the

washer bottle.4. Installation is in the reverse order of removal.

WIPERS AND WASHERS

VISM150130

VISM150139

15


Washer Pump

Removal & Installation1. Remove the front bumper (See Front Bumper Removal & Installation in Section 15 Body & Accessories).2. Disconnect the negative battery cable.3. Disconnect the washer hose and the washer pump

(2) electrical connector.4. Remove the washer pump assembly.5. Remove the retaining bolts (1) as shown to remove

the washer bottle if need.6. Installation is in the reverse order of removal.

Wiper Switch

Removal & Installation1. Disconnect the negative battery cable.2. Remove the steering wheel.3. Disconnect the wiper switch electrical connector.4. Remove the wiper switch retaining screws (1).


WIPERS AND WASHERS

VISM150139

VISM150132


6WIRING

16CONTENTS

pageWiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

Vehicle Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-12

Vehicle Ground Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-25

Vehicle Fuse Box Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-34

Vehicle Wiring Harness Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-41

WIRING INFORMATION

GENERAL INFORMATION 16-2Description 16-2Electrical Schematics 16-2International Symbols 16-3

ELECTRICAL TROUBLESHOOTING 16-5Troubleshooting Wiring Problems 16-5Testing For Voltage 16-5Testing For Continuity 16-5Testing For A Short To Ground 16-5Intermittent and Poor Connections 16-5

ELECTRICAL TROUBLESHOOTINGTOOLS 16-6Jumper Wires 16-6

Voltmeter 16-6Ohmmeter 16-7

ELECTRICAL REPAIR 16-8Wire Repair 16-8Fuse Replacement 16-8

ELECTRICAL COMPONENTS 16-9Battery Cable 16-9Sensors, Switches, and Relays 16-9Connectors 16-9

16


GENERAL INFORMATIONDescriptionThe wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harnessrouting and retention, connector pin-out information and location views for the various wiring harness components,splices and grounds.

Electrical SchematicsThe electrical schematics are grouped into individual service manual chapters. If a component is most likely found ina particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, theEngine Control Module (ECM) is most likely to be found in Chapter 03 (Electronic Engine Controls), so it is shownthere complete. It can, however, be shown partially in another group if it contains some associated wiring.

Chery electrical schematics are designed to provide information regarding the vehicles wiring content. In order toeffectively use the wiring diagrams to diagnose and repair Chery vehicles, it is important to understand the followingfeatures and characteristics:• Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the

ground (B-) side of the circuit is placed near the bottom of the page.• All switches, components, and modules are shown in the at rest position with the doors closed and the key

removed from the ignition.• Components are shown with a solid line around the component.• It is important to realize that no attempt is made on the diagrams to represent components and wiring as they

appear on the vehicle. For example, a short piece of wire is treated the same as a long one.• Switches and other components are shown as simply as possible, with regard to function only.


International SymbolsInternational symbols are used throughout the wiring diagrams. These symbols are consistent with those being usedaround the world.

GENERAL INFORMATION

BESMW010001T

16


Below is a list of the symbols and their definitions that are used in the wiring diagrams.

NUMBER ITEM DESCRIPTION

1 Power source This represents the condition when the system receivesbattery positive voltage.

2 Fuse The single line represents that this is a fuse.

3 Current rating This represents the current rating of the fuse.

4 Fuse location This represents the location of the fuse in the PowerFuse Box or Front Fuse and Relay Box.

5 Connectors This represents connector E-101 is female andconnector C-101 is male.

6 Terminal number This represents the terminal number of a connector.

7 Component name This represents the name of a component.

8 Connector numberThis represents the connector number.The letter represents which harness the connector islocated in.

9 Splice The shaded circle represents that the splice is alwayson the vehicle.

10 Optional splice The open circle represents that the splice is optionaldepending on vehicle application.

11 Option abbreviation This represents that the circuit is optional depending onvehicle application.

12 Ground (GND)This represents the ground connection (See GroundDistribution in Section 16 Wiring).Ground connector number has no view face.

13 Page crossing

This arrow represents that the circuit continues to anadjacent page.The �A� corresponds with the �A� on the adjoining pageof the electrical schematic.

14 Data link This represents that the system branches to anothersystem identified by cell data code.

15 Option description This represents a description of the option abbreviationused on the page.

16 Connector viewsThis represents the connector information.This component side is described by the connectorsymbols.

17 Connector color

This shows a code for the color of the connector:B = BlackW = WhiteR = RedG = GreenL = BlueY = YellowBR = BrownO = OrangeGR = Gray

18 Shielded line The line enclosed by broken line circle representsshielded wire.

19 Light-emitting diodes As an illumination tool, in the circuit and instrumentcluster.

GENERAL INFORMATION


ELECTRICAL TROUBLESHOOTINGTroubleshooting Wiring ProblemsWhen troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed andexplained below. Always check for non-factory equipped components added to the vehicle before doing any diagno-sis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of theproblem.

Perform the following when troubleshooting a wiring problem:

1. Verify the problem.2. Verify any related symptoms (do this by performing operational checks on components that are in the same

circuit).3. Analyze the symptoms (use the wiring diagrams to determine what the circuit is doing, where the problem most

likely is occurring and where the diagnosis will continue).4. Isolate the problem area.5. Repair the problem area.6. Verify the proper operation (for this step, check for proper operation of all items on the repaired circuit).

Testing For Voltage1. Connect the ground lead of a voltmeter to a known good ground.2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON

to check voltage. Refer to the appropriate test procedure.

Testing For Continuity1. Remove the fuse for the circuit being checked or, disconnect the battery.2. Connect one lead of the ohmmeter to one side of the circuit being tested.3. Connect the other lead to the other end of the circuit being tested (low or no resistance means good continuity).

Testing For A Short To Ground1. Remove the fuse and disconnect all items involved with the fuse.2. Connect a test light or a voltmeter across the terminals of the fuse.3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test

light.4. If the voltmeter registers voltage or the test light glows, there is a short to ground in that general area of the

wiring harness.

Intermittent and Poor ConnectionsMost intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for asticking component or relay to cause a problem. Before condemning a component or wiring assembly, check thefollowing items:• Connectors are fully seated• Spread terminals, or terminal push out• Terminals in the wiring assembly are fully seated into the connector/component and locked into position• Dirt or corrosion on the terminals (any amount of corrosion or dirt could cause an intermittent problem)• Damaged connector/component casing exposing the item to dirt or moisture• Wire insulation that has rubbed through causing a short to ground• Some or all of the wiring strands broken inside of the insulation• Wiring broken inside of the insulation

16


ELECTRICAL TROUBLESHOOTING TOOLSJumper Wires• A jumper wire is used to create a temporary circuit.

Connect the jumper wire between the terminals ofa circuit to bypass a switch.

CAUTION:Do not connect a jumper wire from the powersource line to a body ground. This may causeburning or other damage to wiring harnessesor electronic components.

Voltmeter• The DC voltmeter is used to measure circuit volt-

age. A voltmeter with a range of 15 V or more isused by connecting the positive (+) probe (red leadwire) to the point where voltage will be measuredand the negative (-) probe (black lead wire) to abody ground.

BESM010026

BESM010027T


Ohmmeter• The ohmmeter is used to measure the resistance

between two points in a circuit and to check forcontinuity and short circuits.

CAUTION:Do not connect the ohmmeter to any circuitwhere voltage is applied. This will damage theohmmeter.

ELECTRICAL TROUBLESHOOTING TOOLS

BESM010028

16


ELECTRICAL REPAIRWire Repair

NOTE :When splicing a wire it is important that the correct gage be used.

1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced.2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long

enough to cover and seal the entire repair area.3. Place the strands of wire overlapping each other inside of the splice clip.4. Using a crimping tool, crimp the splice clip and wires together.

NOTE :Do not use acid core solder when making wiring repairs.

5. Solder the connection together using a soldering iron and rosin core type solder only.6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly

sealed and sealant comes out of both ends of the tubing.

Fuse Replacement• When replacing a fuse, be sure to replace it with

one of the same capacity. If a fuse fails again, thecircuit probably has a short and the wiring shouldbe checked.

• Be sure the negative battery terminal is discon-nected before replacing a main fuse.

• When replacing a pullout fuse, use the fuse puller.

BESM010025


ELECTRICAL COMPONENTSBattery Cable• Before disconnecting connectors or removing elec-

trical parts, disconnect the battery cables (1).

Sensors, Switches, and Relays• Handle sensors, switches and relays carefully. Do

not drop them or strike them against other objects.

Connectors

Disconnecting Connectors• When disconnecting 2 connectors, grasp the con-

nectors, not the wires.

VISM050002

BESM010024

BESM010018

16


• Connectors can be disconnected by pressingor pulling the lock lever as shown.

Locking Connector• When locking connectors, listen for a click indicat-

ing they are securely locked.

Connector Terminals• Pull lightly on individual wires to check that they

are secured in the terminal.

ELECTRICAL COMPONENTS

BESM010019

BESM010020

BESM010023


Connector/Terminal Replacement• Use the appropriate tools to remove a terminal as

shown. While installing a terminal, be sure to insertit until it locks securely.

• Insert a thin piece of metal from the terminal sideof the connector and with the terminal locking tabpressed down, pull the terminal out from theconnector.

ELECTRICAL COMPONENTS

BESM010029

16


VEHICLE POWER DISTRIBUTION

GENERAL INFORMATION 16-13Description 16-13Operation 16-13

ELECTRICAL SCHEMATICS 16-14Electrical Schematics 16-14


GENERAL INFORMATIONDescriptionThe power distribution system is designed to provide safe, reliable, centralized and convenient access to the distri-bution of the electrical power required to operate all vehicle electrical and electronic systems.

The following components are used for power distribution:• Battery• Power Fuse Box• Front Fuse and Relay Box• Body Fuse Box• Ignition Switch• Fuses• Circuit Breakers• Relays

OperationThe power distribution system operates all electrical and electronic engine, transaxle, chassis, safety, comfort andconvenience systems.

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ELECTRICAL SCHEMATICSElectrical SchematicsThe power distribution electrical schematics include all wiring information detailed on the power side of all vehiclecircuits. This is helpful when attempting to troubleshoot a specific electrical failure, and shows connector pin-out infor-mation and splices.

Power Distribution (Page 1 of 11)

VISMW160020T



ELECTRICAL SCHEMATICS

VISMW160021T

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VISMW160022T




VISMW160023T

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VISMW160024T




VISMW160026T

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VISMW160027T




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VISMW160029T




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VISMW160031T


VEHICLE GROUND DISTRIBUTION


ELECTRICAL SCHEMATICS 16-27Electrical Schematics 16-27

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GENERAL INFORMATIONDescriptionThe ground distribution system is designed to provide centralized and convenient ground locations for the entire vehi-cle electrical system.

OperationThe ground distribution system provides a grounding path for all electrical and electronic engine, chassis, safety,comfort and convenience systems.


ELECTRICAL SCHEMATICSElectrical SchematicsThe ground distribution electrical schematics include all wiring information detailed on the ground side of all vehiclecircuits. This is helpful when attempting to troubleshoot a specific electrical failure, and shows connector pin-out infor-mation and splices.

Ground Distribution (Page 1 of 7)

VISMW160040T

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VISMW160041T




VISMW160042T

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VISMW160045T




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VEHICLE FUSE BOX INFORMATION


Power Fuse Box 16-35Description 16-35Operation 16-35Overview 16-36

Front Fuse and Relay Box 16-37Description 16-37Operation 16-37Overview 16-38

Body Fuse Box 16-39Description 16-39Operation 16-39Overview 16-40


GENERAL INFORMATIONDescriptionFuses are used to protect the vehicle wiring. Fuses are sized and located to protect the wire they are connected to.If a component suddenly draws enough current to blow the fuse, the fuse is there to protect the wiring harness fromdamage.

The vehicle fuses are located in the following locations:• Power Fuse Box• Front Fuse and Relay Box• Body Fuse Box

OperationWhen replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fusewith a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse con-tinues to blow, it indicates a problem in the circuit that must be corrected.

Power Fuse Box

DescriptionAll of the electrical current distributed throughout the vehicle is directed through the power fuse box. The power fusebox houses six maxi-type bolt in fuses. The power fuse box is located on top of the battery, mounted to the batteryhold down bracket.

OperationAll of the electrical current from the battery and the generator output enters the power fuse box. The positive cableand eyelet are secured with a nut to the power fuse box B(+) terminal stud located on one end of the power fuse boxhousing. The power fuse box terminal stud cover is unlatched and opened to access the fuses.

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Overview

Power Fuse Box

GENERAL INFORMATION

VISMW160003T



DescriptionThe front fuse and relay box houses many of the fuses and relays for the vehicles electrical system. The front fuseand relay box is located on the left side of the engine compartment just in front of the battery. The front fuse andrelay box cannot be serviced, it must be replaced as a unit.

OperationAll of the circuits entering and leaving the front fuse and relay box do so through connectors. There are severalseparate wiring harness connectors that connect to the front fuse and relay box.

GENERAL INFORMATION

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Overview


GENERAL INFORMATION

VISMW160001T


Body Fuse Box

DescriptionThe body fuse box houses many of the fuses for the vehicles electrical system. The body fuse box is located on theleft front side of the interior under the instrument panel, and mounted on the cross beam of the instrument panel. Thebody fuse box cannot be serviced, it must be replaced as a unit.

OperationAll of the circuits entering and leaving the body fuse box, do so through connectors. There are several separatewiring harness connectors that connect to the body fuse box.

GENERAL INFORMATION

16


Overview

Body Fuse Box

GENERAL INFORMATION

VISMW160004T


VEHICLE WIRING HARNESS INFORMATION

GENERAL INFORMATION 16-42Description 16-42Operation 16-42How To Read Harness Layout Diagrams 16-42

VEHICLE HARNESS ROUTING MAPS 16-43Vehicle Harness Layout 16-43Front End Module Harness 16-44Engine Control Harness 16-46

Main Harness 16-48Body Harness 16-51Front Door LH Harness 16-54Front Door RH Harness 16-56Rear Door LH Harness 16-58Rear Door RH Harness 16-60Roof Harness 16-62Air Conditioner Harness 16-63Tail Harness 16-64

16


GENERAL INFORMATIONDescriptionThis section provides illustrations identifying component and ground locations in the vehicle.

To help locate all electrical components on the drawings, the following harness layouts use a map style grid:• Front End Module Harness• Engine Control Harness• Main Harness• Body Harness• Front Door LH Harness• Front Door RH Harness• Rear Door LH Harness• Rear Door RH Harness• Roof Harness• Air Conditioner Harness• Tail Harness

OperationUse the wiring harness diagrams in each harness section for component and ground identification. Refer to theappropriate index for the specific vehicle harness.

How To Read Harness Layout Diagrams1. Find the desired connector number on the connector list.2. Find the grid reference.3. On the drawing, find the crossing of the grid reference column letter and row number.4. Find the connector number in the crossing zone.5. Follow the line (if used) to the connector.


VEHICLE HARNESS ROUTING MAPSVehicle Harness Layout

Vehicle Harness Layout (Page 1 of 1)

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Front End Module Harness

VEHICLE HARNESS ROUTING MAPS

VISMW160012T


A-001 B/10 Front Combination Lamp LH C4

A-002 B/10 Front Combination Lamp RH E1

A-003 B/2 Fog Lamp LH B3

A-004 B/2 Fog Lamp RH C1

A-005 GR/2 Horn 1 B4

A-006 GR/2 Horn 2 B4

A-007 B/2 Outside Temperature Sensor C3

A-008 GR/2 Front Washer Motor D1

A-009 B/2 Engine Hood Switch C2

A-010 B/6 Cooling Fan Control Module C3

A-011 B/4 Cooling Fan Control Module C4

A-012 B/2 Cooling Fan Motor LH C3

A-013 B/2 Cooling Fan Motor RH C3

A-017 W/13 Front Fuse and Relay Box (E) D4

A-018 W/20 Front Fuse and Relay Box (P) D4

A-020 B/2 Front Wheel Speed Sensor RH E3

A-021 B/2 Front Turn Signal Lamp LH B4

A-022 B/2 Front Turn Signal Lamp RH C1

A-023 B/3 Front Combination Lamp LH(Headlamp Adjusting Motor) C4

A-024 B/3 Front Combination Lamp RH(Headlamp Adjusting Motor) D1

A-100 B/15 To B-100 D4

A-201 - Ground C5

A-202 - Ground C5

A-203 - Ground E1

A-204 - Ground E2


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Engine Control Harness


VISMW160015T


E-001 B/81 ECM E4

E-003 B/4 A/C Pressure Switch F3

E-004 W-O/4 Upstream Oxygen Sensor E3

E-005 W-O/4 Downstream Oxygen Sensor E3

E-006 B/3 Crankshaft Position Sensor D5

E-007 B/3 Camshaft Position Sensor E4

E-008 B/3 Generator D2

E-009 B/5 Air Flow Sensor D3

E-010 B/2 Fuel Injector No. 1 E2



E-013 B/2 Fuel Injector No. 4 D2

E-014 GR/1 Power Steering Switch D2

E-015 B/2 A/C Compressor C1

E-016 W/1 Oil Pressure Switch C2

E-017 B/3 Knock Sensor C2

E-018 B/1 Starter Motor D3

E-019 B/2 Engine Coolant Temperature Sensor D4

E-020 B/4 Ignition Coil D4

E-021 B/2 Backup Lamp Switch D4

E-022 B/2 Canister Control Valve D4

E-024 B/2 Coolant Level Sensor E2

E-027 B/6 Electronic Throttle Control Actuator D3

E-029 W/11 Front Fuse and Relay Box (J) D5

E-030 W/18 Front Fuse and Relay Box (K) D5

E-033 B/4 Manifold Absolute Pressure Sensor D2

E-100 W/26 To C-100 F3

E-201 - Ground E3

E-202 - Ground E3

E-203 - Ground D3


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Main Harness


VISMW160006T


C-001 L/32 Instrument Cluster B1

C-002 W/6 Ignition Switch C2

C-003 W/4 Key Switch C2

C-004 W/16 Driver Information Center D1

C-005 Y/4 Brake Switch C2

C-006 B/6 Multi-Function Switch C2

C-007 B/10 Wiper and Washer Switch C2

C-008 W/10 Electrical Power Steering Actuator B2

C-012 L/6 Hazard Switch D2

C-014 W/2 Front Power Socket RH D5

C-015 W/3 Console Power Socket(For Cigarette Lighter) D4

C-016 B/6 Yaw Rate Sensor E5

C-017 B/2 Glove Box Lamp F2

C-019 W/3 Dimmer Control Switch B2

C-020 W/6 Trunk Lid Opener Switch D2

C-022 B/16 Data Link Connector B3

C-023 B/6 Headlamp Aiming Switch B2

C-024 B/2 Clutch Pedal Switch B2

C-025 B/8 Immobilizer C2

C-029 Y/6 ESP Switch D2

C-031 B/16 Audio D2

C-033 Y/14 Spiral Cable B2

C-035 W/1 Parking Brake Switch D4

C-036 B/25 Restraints Control Module D3

C-037 L/2 Driver Airbag Module C2

C-038 L/2 Front Passenger Airbag Module F1

C-039 B/10 Outside Mirror Remote Control Module B2

C-040 G/32 FBCM (Front Body Control Module) B2

C-041 L/32 FBCM (Front Body Control Module) B2

C-042 B/10 Combination Lamp Switch B2

C-043 W/18 Body Fuse Box (A) B2

C-044 W/4 Body Fuse Box (B) B2

C-045 W/22 Body Fuse Box (D) B2

C-046 BR/3 Body Fuse Box (D) B2

C-100 W/26 To C-100 G2

C-101 W/32 To B-101 A3

C-102 W/26 To B-102 B3

C-103 W/15 To B-103 B3

C-104 B/26 To B-104 G2

C-105 W/15 To B-105 F2

C-106 W/8 To D-103 A3

C-107 W/14 To D-101 A3

C-108 B/6 To C-401 C2

C-109 W/15 To N-100 F2


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C-201 - Ground C3

C-202 - Ground C3

C-203 - Ground C3

C-204 - Ground C3

C-301 B/6 Accelerator Pedal Position Sensor C2

C-401 B/6 To C-109 C2



Body Harness


VISMW160013T

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B-001 B/1 FBCM (Front Body Control Module) D4

B-002 B/1 FBCM (Front Body Control Module) D4

B-003 B/4 Front Wiper Motor C3

B-004 B/8 Rear Combination Lamp LH G2

B-005 B/8 Rear Combination Lamp RH F1

B-007 W/2 Seat Belt Buckle Switch E4

B-008 W/2 License Plate Lamp F2

B-009 B/1 Rear Window Defogger F2

B-010 B/1 Rear Window Defogger E1

B-011 B/2 Front Left Wheel Speed Sensor C4

B-012 L/2 Electronic Power Steering Actuator D4

B-013 B/2 Siren D4

B-014 B/2 Brake Fluid Level Switch C4

B-015 B/38 ABS Hydraulic Control Module C4

B-016 W/2 High Mounted Stop Lamp F2

B-017 W/22 Front Fuse and Relay Box (G) C4

B-018 L/19 Front Fuse and Relay Box (L) C4

B-019 G/2 Front Fuse and Relay Box (A) B4

B-020 W/8 Front Fuse and Relay Box (C) C4

B-021 B/2 Rear Left Wheel Speed Sensor F3

B-022 B/2 Rear Right Wheel Speed Sensor E3

B-023 B/48 Restraints Control Module C4

B-024 Y/2 Driver Seat Belt Pre-Tensioner E4

B-025 Y/2 Passenger Seat Belt Pre-Tensioner C3

B-026 W/20 FBCM (Front Body Control Module) C4

B-027 W/12 FBCM (Front Body Control Module) C4

B-028 B/18 RBCM (Rear Body Control Module) G2

B-029 B/13 RBCM (Rear Body Control Module) G2

B-031 /1 Power Fuse Box (3) C4

B-032 B/4 Fuel Level Sensor and Fuel Pump E3

B-033 G/1 Trunk Lamp G2

B-034 G/1 Trunk Lamp G2

B-035 W/2 Rear Parking Sonar LH G2

B-036 W/2 Rear Parking Sonar RH F1

B-037 W/2 Rear Room Lamp LH E2

B-038 W/2 Rear RoomLamp RH D1




B-100 B/15 To A-100 C5

B-101 W/26 To C-101 D4

B-102 W/26 To C-102 D4

B-103 W/15 To C-103 D4

B-104 B/26 To C-104 B3



B-105 W/15 To C-105 B3

B-107 W/22 To G-100 B3

B-108 W/12 To D-102 D4

B-109 W/12 To F-100 D4

B-110 W/6 To B-301 G2

B-111 W/14 To I-100 E4

B-112 W/14 To H-100 C3

B-201 - Ground C5

B-202 - Ground C5

B-203 - Ground C5

B-204 - Ground C5

B-205 - Ground E4

B-206 - Ground E4

B-207 - Ground F2

B-208 - Ground G2

B-209 - Ground E1

B-210 - Ground C3

B-211 - Ground E2


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Front Door LH Harness


VISMW160008T


D-001 Y/16 Main Power Window and Door Lock/Unlock Switch

D-002 GR/2 Front Power Window Motor LH

D-003 W/6 Outside Mirror LH

D-004 B/2 Front Speaker LH

D-005 W/2 Step Lamp LH

D-006 B/2 Front Door Lock Assembly LH

D-007 GR/4 Front Door Lock Assembly LH

D-008 B/4 Front Door Lock Assembly LH

D-009 W/2 Security Lamp

D-010 W/2 Turn Signal Lamp LH

D-101 W/14 To C-107

D-102 W/12 To B-108

D-103 W/8 To C-106


16


Front Door RH Harness


VISMW160009T


G-001 B/10 Front Power Window Switch RH

G-002 GR/2 Front Power Window Motor RH

G-003 W/6 Outside Mirror RH

G-004 B/2 Front Speaker RH

G-005 W/2 Step Lamp RH

G-006 B/2 Front Door Lock Assembly RH

G-007 GR/4 Front Door Lock Assembly RH

G-008 B/4 Front Door Lock Assembly RH

G-009 W/2 Turn Signal Lamp RH

G-100 W/12 To B-107


16


Rear Door LH Harness


VISMW160010T


I-001 GR/2 Rear Power Window Motor LH

I-002 B/10 Rear Power Window Switch LH

I-003 B/2 Rear Door Lock Assembly LH

I-004 GR/4 Rear Door Lock Assembly LH

I-005 B/2 Rear Speaker LH

I-100 W/14 To B-111


16


Rear Door RH Harness


VISMW160011T


H-001 GR/2 Rear Power Window Motor RH

H-002 B/10 Rear Power Window Switch RH

H-003 B/2 Rear Door Lock Assembly RH

H-004 GR/4 Rear Door Lock Assembly RH

H-005 B/2 Rear Speaker RH

H-100 W/14 To B-112


16


Roof Harness

F-002 W/6 Front Courtesy/Dome Lamp Assembly

F-005 W/3 Optical Sensor

F-100 W/12 To B-109


VISMW160014T


Air Conditioner Harness

N-001 B/20 Automatic Temperature Control (ATC) Module

N-002 B/16 Automatic Temperature Control (ATC) Module

N-003 W-Y/2 Blower Motor

N-004 B/6 Recirculation Door Actuator

N-005 W/6 Blend Door Actuator

N-006 B/6 Mode Door Actuator

N-008 W/2 Inside Temperature Sensor

N-009 W/4 Sun Sensor

N-017 B/3 Blower Control Module

N-018 Y/6 Defrost Door Actuator

N-100 W/15 To C-109


VISMW160016T

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Tail Harness

B-301 W/6 To B-110

B-401 W/3 Trunk Lamp Switch and Trunk Release Solenoid


VISMW160005T


AA-Pillar Trim Panel, Body Interior . . . . . . . . . . . . . . . . . 15-9A/C System Evacuation and Recharge,

System Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . 13-37Accelerator Pedal Position Sensor,

1.6L & 1.8L Engine Controls . . . . . . . . . . . . . . . . . 3-196Accessory Drive Belt - With Conventional

Power Steering, 1.6L & 1.8L Engine Mechanical . . . . . 2-16Accessory Drive Belt - With Electronic

Power Steering , 1.6L & 1.8L Engine Mechanical . . . . 2-17Accumulator, System Plumbing . . . . . . . . . . . . . . . . . 13-42Adjustable Shoulder Belt Anchor, Seat Belt System . . . . 14-45Air Cleaner Element, 1.6L & 1.8L Engine Mechanical . . . 2-18Air Cleaner Housing, 1.6L & 1.8L Engine Mechanical . . . 2-18Air Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26Air Flow Sensor - 1.8L, 1.6L & 1.8L Engine Controls . . 3-196Airbag System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1Airbag System Disarming Procedure, Airbag System . . . 14-38Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35Antenna, Body Interior . . . . . . . . . . . . . . . . . . . . . . . . 15-8Antilock Brake System (ABS) Bleeding

Procedure, Antilock Brakes . . . . . . . . . . . . . . . . . . . 12-81Antilock Brake System (ABS) Hydraulic

Control Module, Antilock Brakes . . . . . . . . . . . . . . . 12-83Antilock Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32Audio System, Body Interior . . . . . . . . . . . . . . . . . . . . 15-4

BB-Pillar Trim Panel, Body Interior . . . . . . . . . . . . . . . . 15-10Backup/Stop/Rear Position/Rear Turn Signal/Rear

Fog Lamp, Body Exterior . . . . . . . . . . . . . . . . . . . 15-292Base Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1Battery Hold Down, Starting System . . . . . . . . . . . . . . . 5-7Battery Tray, Starting System . . . . . . . . . . . . . . . . . . . . 5-8Battery, Starting System . . . . . . . . . . . . . . . . . . . . . . . . 5-6Bleeding Hydraulic Clutch, Clutch System . . . . . . . . . . . 8-46Blend Door Actuator, System Controls . . . . . . . . . . . . 13-21Blower Control Module, System Controls . . . . . . . . . . 13-24Blower Motor, Air Distribution . . . . . . . . . . . . . . . . . . 13-31Body Dimensions, Body Exterior . . . . . . . . . . . . . . . . 15-238Body Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-236Body Fuse Box, Vehicle Fuse Box Information . . . . . . . 16-39Body Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1Body Interior Trim, Body Interior . . . . . . . . . . . . . . . . . 15-9Body Openings, Body Exterior . . . . . . . . . . . . . . . . . 15-252Brake Bleeding Procedure, Base Brakes . . . . . . . . . . . 12-10Brake Pedal, Base Brakes . . . . . . . . . . . . . . . . . . . . . 12-24Bumpers, Body Exterior . . . . . . . . . . . . . . . . . . . . . 15-254

CC-Pillar Trim Panel, Body Interior . . . . . . . . . . . . . . . . 15-11Camshaft Position Sensor,

1.6L & 1.8L Engine Controls . . . . . . . . . . . . . . . . . 3-194Camshaft, 1.6L & 1.8L Engine Mechanical . . . . . . 2-20, 2-66CAN Vehicle Communications, Body Interior . . . . . . . . 15-15Canister Control Valve, Evaporative Emissions . . . . . . . 3-234Catalytic Converter, Exhaust System . . . . . . . . . . . . . . . . 7-6CD Player, Body Interior . . . . . . . . . . . . . . . . . . . . . . . 15-7Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10Chime, Body Interior . . . . . . . . . . . . . . . . . . . . . . . . 15-18Clutch and Pressure Plate, Clutch System . . . . . . . . . . . 8-42Clutch Assembly Service, Clutch System . . . . . . . . . . . . 8-42Clutch Master Cylinder, Clutch System . . . . . . . . . . . . . 8-43Clutch Slave Cylinder, Clutch System . . . . . . . . . . . . . . 8-46Clutch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39Compressor, System Plumbing . . . . . . . . . . . . . . . . . 13-39Condenser, System Plumbing . . . . . . . . . . . . . . . . . . 13-41Connecting Rods, 1.6L & 1.8L Engine Mechanical . . . . . 2-58Coolant Level Sensor, Cooling System . . . . . . . . . . . . . 6-15Coolant Pump, Cooling System . . . . . . . . . . . . . . . . . . 6-10Cooling Fan, Cooling System . . . . . . . . . . . . . . . . . . . 6-13Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1Cooling System Draining and Filling, Cooling System . . . . 6-8Crankshaft Position Sensor,

1.6L & 1.8L Engine Controls . . . . . . . . . . . . . . . . . 3-193Crankshaft, 1.6L & 1.8L Engine Mechanical . . . . . . . . . 2-60Cylinder Head Cover, 1.6L & 1.8L Engine Mechanical . . . 2-19Cylinder Head Unit Repair,

1.6L & 1.8L Engine Mechanical . . . . . . . . . . . . . . . . 2-63Cylinder Head, 1.6L & 1.8L Engine Mechanical . . . 2-23, 2-63

DDefrost Door Actuator, System Controls . . . . . . . . . . . 13-22Diagnosing An Electrical Failure,

Electrical Circuit Diagnosis Information . . . . . . . . . . . 1-16Diagnosis & Testing, 1.6L & 1.8L Engine Controls . . . . . 3-20Diagnosis & Testing, 1.6L & 1.8L Engine Mechanical . . . 2-13Diagnosis & Testing, 5-Speed Manual Transaxle . . . . . . . 8-8Diagnosis & Testing, Air Distribution . . . . . . . . . . . . . 13-29Diagnosis & Testing, Airbag System . . . . . . . . . . . . . . 14-10Diagnosis & Testing, Alignment . . . . . . . . . . . . . . . . . 10-39Diagnosis & Testing, Antilock Brakes . . . . . . . . . . . . . 12-40Diagnosis & Testing, Base Brakes . . . . . . . . . . . . . . . . 12-8Diagnosis & Testing,

Body Interior . . . . . . . . . . . 15-125, 15-152, 15-208, 15-52Diagnosis & Testing, Charging System . . . . . . . . . . . . . 5-13

INDEX

AI

AI-1

Diagnosis & Testing, Electronic PowerSteering Electrical Diagnostics . . . . . . . . . . . . . . . . 11-59

Diagnosis & Testing, Front Axle . . . . . . . . . . . . . . . . . . 9-4Diagnosis & Testing, Front Suspension . . . . . . . . . . . . . 10-5Diagnosis & Testing, Fuel Delivery System . . . . . . . . . . 4-10Diagnosis & Testing, Manual/Automatic

Temperature Control . . . . . . . . . . . . . . . . . . . . . . . 13-10Diagnosis & Testing, Parking Brake . . . . . . . . . . . . . . 12-90Diagnosis & Testing, Power Steering Pump . . . . . . . . . 11-71Diagnosis & Testing, Rear Axle . . . . . . . . . . . . . . . . . . 9-10Diagnosis & Testing, Rear Suspension . . . . . . . . . . . . 10-28Diagnosis & Testing, Steering Column - Electronic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-37Diagnosis & Testing, Steering Column - Hydraulic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11Diagnosis & Testing, Steering Gear - Electronic Power

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-48Diagnosis & Testing, Steering Gear - Hydraulic Power

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22Diagnosis & Testing, Steering System - Electronic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32Diagnosis & Testing, Steering System - Hydraulic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4Diagnosis & Testing, System Controls . . . . . . . . . . . . 13-20Diagnosis & Testing, System Plumbing . . . . . . . . . . . . 13-35Diagnosis & Testing, Wheels and Tires . . . . . . . . . . . . 10-45Diagnosis and Testing, Cooling System . . . . . . . . . . . . . 6-7Diagnosis and Testing, Exhaust System . . . . . . . . . . . . . 7-4Diagnosis and Testing, Starting System . . . . . . . . . . . . . 5-5Diagnostic Help, Antilock Brakes . . . . . . . . . . . . . . . . 12-40Diagnostic Trouble Code (DTC) List, Airbag System . . . 14-11Diagnostic Trouble Code (DTC) List, Antilock Brakes . . . 12-41Diagnostic Trouble Code (DTC) List, Body Interior . . . 15-126,

15-153, 15-209, 15-53Diagnostic Trouble Code (DTC) List, Electronic Power

Steering Electrical Diagnostics . . . . . . . . . . . . . . . . 11-61Diagnostic Trouble Code (DTC) Tests,

1.6L & 1.8L Engine Controls . . . . . . . . . . . . . . . . . . 3-33Diagnostic Trouble Code (DTC) Tests, Airbag System . . 14-15Diagnostic Trouble Code (DTC) Tests, Antilock Brakes . . 12-43Diagnostic Trouble Code (DTC) Tests,

Body Interior . . . . . . . . . . . 15-127, 15-154, 15-210, 15-55Diagnostic Trouble Code (DTC) Tests, Electronic Power

Steering Electrical Diagnostics . . . . . . . . . . . . . . . . 11-62Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33Differential Carrier, Differential . . . . . . . . . . . . . . . . . . . 8-36Differential Unit Repair, Differential . . . . . . . . . . . . . . . . 8-36Door Locks, Body Interior . . . . . . . . . . . . . . . . . . . . . 15-26Doors, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . 15-257

Driver Information Center, Body Interior . . . . . . . . . . 15-175Driver Side Airbag, Airbag System . . . . . . . . . . . . . . . 14-38

EElectrical Circuit Diagnosis Information . . . . . . . . . . . . . 1-15Electrical Components, Wiring Information . . . . . . . . . . 16-9Electrical Information . . . . . . . . . . . . . . . . . . . . . . . . . 1-20Electrical Repair, Wiring Information . . . . . . . . . . . . . . . 16-8Electrical Schematics, Vehicle Ground Distribution . . . . 16-27Electrical Schematics, Vehicle Power Distribution . . . . . 16-14Electrical Troubleshooting Tools, Wiring Information . . . . 16-6Electrical Troubleshooting, Wiring Information . . . . . . . . 16-5Electronic Power Steering Electrical Diagnostics . . . . . . 11-55Electronic Power Steering Gear, Steering

Gear - Electronic Power Steering . . . . . . . . . . . . . . 11-50Electronic Throttle Control Actuator, 1.6L & 1.8L

Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 3-197Engine Assembly, 1.6L & 1.8L Engine Mechanical . . . . . 2-30Engine Block, 1.6L & 1.8L Engine Mechanical . . . . . . . . 2-50Engine Compartment, Body Exterior . . . . . . . . . . . . . 15-250Engine Control Module (ECM), 1.6L & 1.8L

Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 3-198Engine Coolant Temperature Sensor, 1.6L & 1.8L

Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 3-191Engine Mounts, 1.6L & 1.8L Engine Mechanical . . . . . . 2-28Engine Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . 3-200Engine Timing Belt, 1.6L & 1.8L Engine Mechanical . . . . 2-38Engine Unit Repair, 1.6L & 1.8L Engine Mechanical . . . . 2-50Evaporative Emissions . . . . . . . . . . . . . . . . . . . . . . . 3-230Evaporator, System Plumbing . . . . . . . . . . . . . . . . . . 13-41Exhaust Manifold, 1.6L & 1.8L Engine Mechanical . . . . . 2-44Exhaust Pipe Assembly, Exhaust System . . . . . . . . . . . . 7-5Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1Exterior Lamps, Body Exterior . . . . . . . . . . . . . . . . . 15-274

FFastener Usage, Vehicle Information . . . . . . . . . . . . . . . 1-14Fender, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . 15-295Frame, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . 15-238Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1Front Axle Shaft, Front Axle . . . . . . . . . . . . . . . . . . . . . 9-5Front Body Control Module (FBCM), Body Interior . . . 15-120Front Body Control Module - Front BCM,

Body Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-39Front Brake Caliper, Base Brakes . . . . . . . . . . . 12-15, 12-26Front Brake Pads, Base Brakes . . . . . . . . . . . . . . . . . 12-21Front Brake Rotor, Base Brakes . . . . . . . . . . . . . . . . . 12-17Front Bumper, Body Exterior . . . . . . . . . . . . . . . . . . 15-254

INDEX

AI-2

Front Coil Spring, Front Suspension . . . . . . . . . . . . . . 10-15Front Combination Lamp Assembly, Body Exterior . . . 15-289Front Courtesy/Dome Lamp Assembly, Body Interior . . 15-182Front Crankshaft Oil Seal, 1.6L & 1.8L Engine

Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25Front Door, Body Exterior . . . . . . . . . . . . . . . . . . . . 15-257Front Fender, Body Exterior . . . . . . . . . . . . . . . . . . . 15-295Front Fog Lamp, Body Exterior . . . . . . . . . . . . . . . . 15-291Front Fuse and Relay Box, Vehicle Fuse

Box Information . . . . . . . . . . . . . . . . . . . . . . . . . . 16-37Front Hub and Bearing, Front Axle . . . . . . . . . . . . . . . . 9-5Front Lower Control Arm, Front Suspension . . . . . . . . . 10-8Front Passenger Side Airbag, Airbag System . . . . . . . . 14-39Front Seat Belt and Pre-Tensioner, Seat Belt System . . . 14-43Front Seat, Body Interior . . . . . . . . . . . . . . . . . . . . . 15-201Front Stabilizer Bar Link, Front Suspension . . . . . . . . . 10-10Front Stabilizer Bar, Front Suspension . . . . . . . . . . . . . 10-11Front Steering Knuckle, Front Suspension . . . . . . . . . . . 10-6Front Strut Assembly, Front Suspension . . . . . . . . . . . 10-12Front Strut, Front Suspension . . . . . . . . . . . . . . . . . . 10-21Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1Front View, Body Exterior . . . . . . . . . . . . . . . . . . . . 15-239Front Wheel Alignment, Alignment . . . . . . . . . . . . . . . 10-41Front Wheel Speed Sensor, Antilock Brakes . . . . . . . . . 12-85Front Windshield, Body Exterior . . . . . . . . . . . . . . . . 15-318Fuel Delivery System . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Fuel Door, Body Exterior . . . . . . . . . . . . . . . . . . . . . 15-297Fuel Door, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . .297Fuel Filter, Fuel Delivery System . . . . . . . . . . . . . . . . . 4-15Fuel Injector Rail, Fuel Delivery System . . . . . . . . . . . . 4-16Fuel Injector, Fuel Delivery System . . . . . . . . . . . . . . . . 4-17Fuel Pressure Relief Procedure, Fuel Delivery System . . . 4-12Fuel Pump, Fuel Delivery System . . . . . . . . . . . . . . . . . 4-12Fuel Tank, Fuel Delivery System . . . . . . . . . . . . . . . . . 4-19

GGear Selector & Shifter Assembly, 5-Speed

Manual Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14General Information, 1.6L & 1.8L Engine Controls . . . . . . 3-3General Information, 1.6L & 1.8L Engine Mechanical . . . . 2-3General Information, 5-Speed Manual Transaxle . . . . . . . . 8-2General Information, Air Distribution . . . . . . . . . . . . . . 13-27General Information, Airbag System . . . . . . . . . . . . . . . 14-2General Information, Alignment . . . . . . . . . . . . . . . . . 10-36General Information, Antilock Brakes . . . . . . . . . . . . . 12-33

General Information, Base Brakes . . . . . . . . . . . . . . . . 12-2General Information, Body Interior . . . . . . . . . . . . . . 15-201General Information, Charging System . . . . . . . . . . . . . 5-11General Information, Clutch System . . . . . . . . . . . . . . . 8-40General Information, Cooling System . . . . . . . . . . . . . . . 6-2General Information, Differential . . . . . . . . . . . . . . . . . . 8-34General Information, Electronic Power

Steering Electrical Diagnostics . . . . . . . . . . . . . . . . 11-56General Information, Evaporative Emissions . . . . . . . . . 3-231General Information, Exhaust System . . . . . . . . . . . . . . . 7-2General Information, Front Axle . . . . . . . . . . . . . . . . . . . 9-2General Information, Front Suspension . . . . . . . . . . . . . 10-2General Information, Fuel Delivery System . . . . . . . . . . . 4-2General Information, Ignition Control . . . . . . . . . . . . . 3-223General Information, Manual/Automatic

Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . 13-2General Information, Parking Brake . . . . . . . . . . . . . . 12-88General Information, Power Steering Pump . . . . . . . . . 11-70General Information, Rear Axle . . . . . . . . . . . . . . . . . . . 9-9General Information, Rear Suspension . . . . . . . . . . . . 10-26General Information, Seat Belt System . . . . . . . . . . . . 14-42General Information, Starting System . . . . . . . . . . . . . . . 5-2General Information, Steering Column - Electronic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35General Information, Steering Column - Hydraulic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9General Information, Steering Gear - Electronic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-46General Information, Steering Gear - Hydraulic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21General Information, Steering System - Electronic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30General Information, Steering System - Hydraulic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2General Information, System Controls . . . . . . . . . . . . . 13-15General Information, System Plumbing . . . . . . . . . . . . 13-33General Information, Vehicle Fuse Box Information . . . . 16-35General Information, Vehicle Ground Distribution . . . . . 16-26General Information, Vehicle Power Distribution . . . . . . 16-13General Information, Vehicle Wiring Harness

Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-42General Information, Wheels and Tires . . . . . . . . . . . . 10-44General Information, Wiring Information . . . . . . . . . . . . 16-2Generator, Charging System . . . . . . . . . . . . . . . . . . . . 5-14Grille, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . . 15-298Grille, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . .298

INDEX

AI

AI-3

HHeadlamp, Body Exterior . . . . . . . . . . . . . . . . . . . . . 15-291Headliner, Body Interior . . . . . . . . . . . . . . . . . . . . . . 15-14Heater Core, System Plumbing . . . . . . . . . . . . . . . . . 13-47High Mounted Stop Lamp, Body Exterior . . . . . . . . . . 15-293Hood Release Cable, Body Exterior . . . . . . . . . . . . . . 15-300Hood, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . . 15-299Hood, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . .299Horn, Body Exterior . . . . . . . . . . . . . . . . . . 15-301, 15-303How To Locate Electrical Schematics In

The Service Manual, Electrical Information . . . . . . . . . 1-25How To Read Electrical Schematics,

Electrical Information . . . . . . . . . . . . . . . . . . . . . . . 1-21How To Use This Manual, Service Information . . . . . . . . 1-2HVAC Housing Assembly, Air Distribution . . . . . . . . . . 13-30

IIdler Gear, 5-Speed Manual Transaxle . . . . . . . . . . . . . . 8-29Idler Pulley, 1.6L & 1.8L Engine Mechanical . . . . . . . . . 2-46Ignition Coil, Ignition Control . . . . . . . . . . . . . . . . . . . 3-227Ignition Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-222Immobilizer, Body Interior . . . . . . . . . . . . . . 15-205, 15-233Input Shaft, 5-Speed Manual Transaxle . . . . . . . . . . . . . 8-24Inside Temperature Sensor, System Controls . . . . . . . . 13-25Instrument Cluster, Body Interior . . . . . . . . . 15-143, 15-174Instrument Panel, Body Interior . . . . . . . . . . . . . . . . 15-136Instrument Panel, Body Interior . . . . . . . . . . . . . . . . . . .136Intake Manifold, 1.6L & 1.8L Engine Mechanical . . . . . . 2-42Interior Lamps, Body Interior . . . . . . . . . . . . . . . . . . 15-176International Symbols, Vehicle Information . . . . . . . . . . 1-13

KKeyhole Lamp, Body Interior . . . . . . . . . . . . . . . . . . 15-183Knock Sensor, 1.6L & 1.8L Engine Controls . . . . . . . . 3-192

LLicense Plate Lamp, Body Exterior . . . . . . . . . . . . . . 15-294Liquid Line, System Plumbing . . . . . . . . . . . . . . . . . . 13-43Lower Console, Body Interior . . . . . . . . . . . . . . . . . . 15-139

MManifold Absolute Pressure Sensor - 1.6L, 1.6L & 1.8L

Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 3-195Manual Transaxle, 5-Speed Manual Transaxle . . . . . . . . . 8-9Manual/Automatic Temperature Control . . . . . . . . . . . . . 13-1Manual/Automatic Temperature Control Module,

Manual/Automatic Temperature Control . . . . . . . . . . . 13-13

Master Cylinder, Base Brakes . . . . . . . . . . . . . . . . . . 12-12Mirrors, Body Exterior . . . . . . . . . . . . . . . . . . . . . . 15-304Mode Door Actuator, System Controls . . . . . . . . . . . . 13-22Muffler, Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . 7-5

NNegative Battery Cable, Starting System . . . . . . . . . . . . . 5-7

OOil Filter, 1.6L & 1.8L Engine Mechanical . . . . . . . . . . . 2-46Oil Pan, 1.6L & 1.8L Engine Mechanical . . . . . . . . . . . . 2-47Oil Pump, 1.6L & 1.8L Engine Mechanical . . . . . . . . . . 2-48Oil Strainer, 1.6L & 1.8L Engine Mechanical . . . . . . . . . 2-49On-Vehicle Service, 1.6L & 1.8L Engine Controls . . . . . 3-191On-Vehicle Service, 1.6L & 1.8L Engine Mechanical . . . . 2-16On-Vehicle Service, 5-Speed Manual Transaxle . . . . . . . . 8-9On-Vehicle Service, Air Distribution . . . . . . . . . . . . . . 13-30On-Vehicle Service, Airbag System . . . . . . . . . . . . . . . 14-38On-Vehicle Service, Alignment . . . . . . . . . . . . . . . . . . 10-41On-Vehicle Service, Antilock Brakes . . . . . . . . . . . . . . 12-81On-Vehicle Service, Base Brakes . . . . . . . . . . . . . . . . 12-10On-Vehicle Service, Body Interior . . . 15-120, 15-135, 15-174,

15-233On-Vehicle Service, Charging System . . . . . . . . . . . . . . 5-14On-Vehicle Service, Cooling System . . . . . . . . . . . . . . . . 6-8On-Vehicle Service, Evaporative Emissions . . . . . . . . . . 3-234On-Vehicle Service, Exhaust System . . . . . . . . . . . . . . . . 7-5On-Vehicle Service, Front Axle . . . . . . . . . . . . . . . . . . . 9-5On-Vehicle Service, Front Suspension . . . . . . . . . . . . . . 10-6On-Vehicle Service, Fuel Delivery System . . . . . . . . . . . 4-12On-Vehicle Service, Ignition Control . . . . . . . . . . . . . . 3-227On-Vehicle Service, Manual/Automatic

Temperature Control . . . . . . . . . . . . . . . . . . . . . . . 13-13On-Vehicle Service, Parking Brake . . . . . . . . . . . . . . . 12-92On-Vehicle Service, Power Steering Pump . . . . . . . . . . 11-72On-Vehicle Service, Rear Axle . . . . . . . . . . . . . . . . . . . 9-11On-Vehicle Service, Rear Suspension . . . . . . . . . . . . . 10-29On-Vehicle Service, Seat Belt System . . . . . . . . . . . . . 14-43On-Vehicle Service, Starting System . . . . . . . . . . . . . . . . 5-6On-Vehicle Service, Steering Column - Electronic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-39On-Vehicle Service, Steering Column - Hydraulic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12On-Vehicle Service, Steering Gear - Electronic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-50On-Vehicle Service, Steering Gear - Hydraulic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23

INDEX

AI-4

On-Vehicle Service, Steering System - HydraulicPower Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

On-Vehicle Service, System Controls . . . . . . . . . . . . . 13-21On-Vehicle Service, System Plumbing . . . . . . . . . . . . . 13-37On-Vehicle Service, Wheels and Tires . . . . . . . . . . . . . 10-46Output Shaft, 5-Speed Manual Transaxle . . . . . . . . . . . . 8-27Outside Mirror, Body Exterior . . . . . . . . . . . . . . . . . . 15-309Oxygen Sensor, 1.6L & 1.8L Engine Controls . . . . . . . 3-192

PPaint Codes, Body Exterior . . . . . . . . . . . . . . . . . . . 15-310Paint, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . . 15-310Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-87Parking Brake Cable, Parking Brake . . . . . . . . . . . . . . 12-92Parking Brake Lever, Parking Brake . . . . . . . . . . . . . . 12-92Parking Brake Shoes, Parking Brake . . . . . . . . . . . . . . 12-94Parking Sonar, Body Exterior . . . . . . . . . . . . . . . . . . 15-311Passenger Grab Handle, Body Interior . . . . . . . . . . . . 15-11Pedal Pad, Body Interior . . . . . . . . . . . . . . . . . . . . . . 15-12Pistons, 1.6L & 1.8L Engine Mechanical . . . . . . . . . . . . 2-53Positive Battery Cable, Starting System . . . . . . . . . . . . . 5-7Power Brake Booster, Base Brakes . . . . . . . . . . . . . . . 12-13Power Fuse Box, Vehicle Fuse Box Information . . . . . . 16-35Power Lock Motor, Body Interior . . . . . . . . . . . . . . . . 15-32Power Lock Switch, Body Interior . . . . . . . . . . . . . . . 15-31Power Outlet, Body Interior . . . . . . . . . . . . . 15-184, 15-186Power Steering Filling and Flushing, Steering

System - Hydraulic Power Steering . . . . . . . . . . . . . . 11-6Power Steering Fluid Reservoir,

Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . 11-73Power Steering Pressure and Return Hoses,

Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . 11-73Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . 11-69Power Steering Pump, Power Steering Pump . . . . . . . 11-72Power Supply and Ground Circuit Test,

1.6L & 1.8L Engine Controls . . . . . . . . . . . . . . . . . . 3-25Power Trunk Lid Release, Body Exterior . . . . . . . . . . 15-327Power Window Motor, Body Interior . . . . . . . . . . . . . 15-193Power Window Switch, Body Interior . . . . . . . . . . . . 15-192Power Windows, Body Interior . . . . . . . . . . . . . . . . . 15-187Proper Service Practices, Service Information . . . . . . . . . 1-5

RRadiator Support, Body Exterior . . . . . . . . . . . . . . . . 15-315Radiator Support, Body Exterior . . . . . . . . . . . . . . . . . . .315Radiator, Cooling System . . . . . . . . . . . . . . . . . . . . . . 6-11Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8Rear Body Control Module (RBCM), Body Interior . . . 15-135

Rear Body Control Module -Rear BCM, Body Interior . . . . . . . . . . . . . . . . . . . 15-121

Rear Brake Backing Plate, Base Brakes . . . . . . . . . . . . 12-25Rear Brake Caliper, Base Brakes . . . . . . . . . . . 12-17, 12-29Rear Brake Pads, Base Brakes . . . . . . . . . . . . . . . . . . 12-22Rear Brake Rotor, Base Brakes . . . . . . . . . . . . . . . . . 12-19Rear Bumper, Body Exterior . . . . . . . . . . . . . . . . . . 15-255Rear Coil Spring, Rear Suspension . . . . . . . . . . . . . . . 10-33Rear Combination Lamp Assembly, Body Exterior . . . . 15-290Rear Crankshaft Oil Seal, 1.6L & 1.8L

Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . 2-26Rear Door, Body Exterior . . . . . . . . . . . . . . . . . . . . 15-268Rear Guide Bar, Rear Suspension . . . . . . . . . . . . . . . 10-30Rear Hub and Bearing, Rear Axle . . . . . . . . . . . . . . . . 9-11Rear Lower Control Arm, Rear Suspension . . . . . . . . . 10-29Rear Room Lamp, Body Interior . . . . . . . . . . . . . . . 15-182Rear Seat Belt and Tensioner, Seat Belt System . . . . . . 14-46Rear Seat, Body Interior . . . . . . . . . . . . . . . . . . . . . 15-203Rear Shock Absorber, Rear Suspension . . . . . . . . . . . 10-32Rear Stabilizer Bar Link, Rear Suspension . . . . . . . . . . 10-34Rear Stabilizer Bar, Rear Suspension . . . . . . . . . . . . . 10-33Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25Rear Trailing Arm, Rear Suspension . . . . . . . . . . . . . . 10-31Rear Upper Control Arm, Rear Suspension . . . . . . . . . 10-30Rear View, Body Exterior . . . . . . . . . . . . . . . . . . . . 15-242Rear Wheel Alignment, Alignment . . . . . . . . . . . . . . . 10-42Rear Wheel Speed Sensor, Antilock Brakes . . . . . . . . . 12-86Rear Window, Body Exterior . . . . . . . . . . . . . . . . . . 15-320Recirculation Door Actuator, System Controls . . . . . . . 13-23Remote Keyless Entry (RKE) Inoperative,

Body Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-234Restraints Control Module (RCM), Airbag System . . . . . 14-40Reverse Shift Fork, 5-Speed Manual Transaxle . . . . . . . . 8-30

SScuff Plate, Body Interior . . . . . . . . . . . . . . . . . . . . . 15-12Seat Belt System . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-41Seats, Body Interior . . . . . . . . . . . . . . . . . . . . . . . . 15-201Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Side View, Body Exterior . . . . . . . . . . . . . . . . . . . . . 15-245Sonar Alarm, Body Exterior . . . . . . . . . . . . . . . . . . . 15-314Sonar Sensor, Body Exterior . . . . . . . . . . . . . . . . . . 15-314Spark Plug Wire, Ignition Control . . . . . . . . . . . . . . . . 3-228Spark Plug, Ignition Control . . . . . . . . . . . . . . . . . . . 3-229Starter Motor Assembly, Starting System . . . . . . . . . . . . 5-8Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Stationary Glass, Body Exterior . . . . . . . . . . . . . . . . 15-316

INDEX

AI

AI-5

Steering Column - Electronic Power Steering . . . . . . . . 11-34Steering Column - Hydraulic Power Steering . . . . . . . . . 11-8Steering Column Shaft, Steering Column - Electronic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-41Steering Column Shaft, Steering Column - Hydraulic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16Steering Column Shroud, Steering Column - Electronic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40Steering Column Shroud, Steering Column - Hydraulic

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14Steering Gear - Electronic Power Steering . . . . . . . . . . 11-45Steering Gear - Hydraulic Power Steering . . . . . . . . . . 11-20Steering Gear, Steering Gear - Hydraulic Power

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23Steering System - Electronic Power Steering . . . . . . . . 11-29Steering System - Hydraulic Power Steering . . . . . . . . . 11-1Steering Wheel, Steering Column - Electronic Power

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-39Steering Wheel, Steering Column - Hydraulic Power

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12Sub-Frame Assembly, Front Suspension . . . . . . . . . . . 10-16Suction Line, System Plumbing . . . . . . . . . . . . . . . . . 13-45Sun Visor - LH, Body Interior . . . . . . . . . . . . . . . . . . 15-13Sun Visor - RH, Body Interior . . . . . . . . . . . . . . . . . . 15-13Symptom Diagnostic List, Electronic Power Steering

Electrical Diagnostics . . . . . . . . . . . . . . . . . . . . . . . 11-60Symptom Diagnostic Tests, Engine Symptom

Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-201System Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14System Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . 13-32

TThermostat, Cooling System . . . . . . . . . . . . . . . . . . . . . 6-9Tie Rod, Steering Gear - Electronic Power Steering . . . 11-54Tie Rod, Steering Gear - Hydraulic Power Steering . . . . 11-28Tire Replacement & Repair, Wheels and Tires . . . . . . . 10-46Tire Rotation, Wheels and Tires . . . . . . . . . . . . . . . . . 10-48Transaxle Unit Repair, 5-Speed Manual Transaxle . . . . . . 8-18Transaxle, 5-Speed Manual Transaxle . . . . . . . . . . . . . . 8-18

Trunk Lid, Body Exterior . . . . . . . . . . . . . . . 15-323, 15-326Turn Signal Lamp, Body Exterior . . . . . . . . . . . . . . . 15-294

UUnit Repair, Base Brakes . . . . . . . . . . . . . . . . . . . . . 12-26Unit Repair, Front Suspension . . . . . . . . . . . . . . . . . . 10-21

VValve & Valve Guides, 1.6L & 1.8L Engine Mechanical . . 2-70Valve Springs, 1.6L & 1.8L Engine Mechanical . . . . . . . 2-73Vapor Canister, Evaporative Emissions . . . . . . . . . . . . 3-235Vehicle Fuse Box Information . . . . . . . . . . . . . . . . . . 16-34Vehicle Ground Distribution . . . . . . . . . . . . . . . . . . . . 16-25Vehicle Harness Routing Maps, Vehicle Wiring

Harness Information . . . . . . . . . . . . . . . . . . . . . . . 16-43Vehicle Identification Number (VIN), Vehicle

Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10Vehicle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9Vehicle Power Distribution . . . . . . . . . . . . . . . . . . . . 16-12Vehicle Service Preparation, Service Information . . . . . . . 1-3Vehicle Wiring Harness Information . . . . . . . . . . . . . . 16-41

WWasher Bottle, Body Exterior . . . . . . . . . . . . . . . . . . 15-333Washer Pump, Body Exterior . . . . . . . . . . . . . . . . . . 15-334Wheel Assembly, Wheels and Tires . . . . . . . . . . . . . . 10-47Wheel Balance, Wheels and Tires . . . . . . . . . . . . . . . . 10-47Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43Windshield, Body Exterior . . . . . . . . . . . . . . . . . . . . 15-251Wiper Arm, Body Exterior . . . . . . . . . . . . . . . . . . . . 15-332Wiper Linkage, Body Exterior . . . . . . . . . . . . . . . . . . 15-333Wiper Motor, Body Exterior . . . . . . . . . . . . . . . . . . . 15-332Wiper Switch, Body Exterior . . . . . . . . . . . . . . . . . . 15-334Wipers and Washers, Body Exterior . . . . . . . . . . . . . 15-329Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

YYaw Rate Sensor, Antilock Brakes . . . . . . . . . . . . . . . 12-84

INDEX

AI-6

Documents

M11 SM print ready file.pdf