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GRAND VITARA
Suzuki GRAND VITARA User Manual
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9A-75
Wirin
g Systems:
"B-5"
Front
Motor
2
BLU/YEL
BLU/WHT
Rear end
door lock
motor
BW
BR
BY
BY
"B-5"
"B-5"
Front
Motor
"B-5"
Rear
Motor (R)
"B-5"
Rear
Motor (L)
BCM
G08
L09
3
BR
BLU/RED
BLU/RED
5
G08
L09
19
6
12
L42
O01
BLU/RED
BLU/RED
BLU/RED
BLU/RED
BLU/RED
BLU/RED
11
BLU/YEL
BLU/YEL
BLU/YEL
BLU/YEL
4
12
L07
J01
BLU/YEL
BLU/YEL
10or5
L13
J16
BR
BR
BY
BLU/RED
BLU/RED
6
BR
BY
BLU/RED
BLU/RED
19or14
BLU/YEL
BLU/YEL
12
L31
J09
BLU/YEL
BLU/YEL
10
L37
J21
"B-5"
Front
Motor
9
8
7
BLU/WHT
BLU/WHT
BLU/WHT
Rear end
door lock
motor
BW
BR
B
BB
"B-5"
"B-5"
Front
Motor
"B-5"
Rear
Motor (R)
"B-5"
Rear
Motor (L)
3
BR
BLU/RED
BLU/RED
5
G08
L09
19
6
12
L42
O01
BLU/RED
BLU/RED
BLU/RED
BLU/RED
BLU/RED
BLU/RED
11
BLU
BLU
BLU
4
12
L07
J01
2
BLU/YEL
BLU/YEL
BLU/YEL
10or5
L13
J16
BR
BR
BY
BLU/RED
BLU/RED
6
BR
BY
BLU/RED
BLU/RED
19or14
BLU/BLK
BLU/BLK
BLU/BLK
2
G72
L27
G08
L09
12
L31
J09
BLU/YEL
BLU/YEL
10
L37
J21
BB
B
J/C
G76
J/C
RHD
LHD
2-Action
1-Action
A
B
C
D
IF EQPD
"B-7"
Steering
switch
(Horn)
"B-7"
Horn relay
B
17
E78
G05
"D-1"
Headlight
LO relay
RB
B
"D-1"
Diode #1
RB
13
E74
G36
RED/BLU
BLU
BLU
BLU
BLU
RED/BLU
16
G31
G32
15
G08
L09
G72
L27
A
B
9
7
A
B
G72
L27
G08
L09
A
B
D
7
9
A
B
C
I5JB0A910996-
04
1407
1409
Table of Contents
Table of Contents
5
Precautions
7
Air Bag Locations
8
Precautions
8
Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System
8
Diagnosis, Servicing and Handling
9
General Precautions
11
Precaution in Servicing Full-Time 4WD Vehicle
14
Precautions for Catalytic Converter
15
Precaution for CAN Communication System
16
Precautions for Electrical Circuit Service
16
Precautions for Installing Mobile Communication Equipment
18
Air Bag Warning
18
Discharge Headlight Warning
18
A/C System Caution
18
Fastener Caution
18
Suspension Caution
19
Wheels and Tires Caution
19
Brakes Caution and Note
19
Differential Gear Oil Note
19
Repair Instructions
19
Electrical Circuit Inspection Procedure
19
Intermittent and Poor Connection Inspection
22
General Information
23
General Information
24
General Description
24
Abbreviations
24
Symbols
25
Wire Color Symbols
26
Fastener Information
26
General Information
27
Vehicle Lifting Points
28
Engine Supporting Points
30
Vehicle Identification Number
30
Engine Identification Number
30
Transmission Identification Number
30
Component Location
31
Warning, Caution and Information Label Location
31
Maintenance and Lubrication
33
Precautions
33
Precautions for Maintenance and Lubrication
33
Scheduled Maintenance
33
Maintenance Schedule under Normal Driving Conditions
33
Maintenance Recommended under Severe Driving Conditions
34
Repair Instructions
36
Engine Accessory Drive Belt Inspection
36
Engine Accessory Drive Belt Replacement
36
Valve Lash (Clearance) Inspection
36
Engine Oil and Filter Change
37
Engine Coolant Change
38
Exhaust System Inspection
39
Spark Plugs Replacement
39
Air Cleaner Filter Inspection
39
Air Cleaner Filter Replacement
39
Fuel Lines and Connections Inspection
39
Fuel Filter Replacement
39
Fuel Tank Inspection
39
Crankcase Ventilation Hoses and Connections Inspection (Vehicle Without A/F Sensor)
39
PCV Valve Inspection
39
Fuel Evaporative Emission Control System Inspection
40
Brake Discs and Pads Inspection
40
Brake Drums and Shoes Inspection
40
Brake Hoses and Pipes Inspection
40
Brake Fluid Change
40
Parking Brake Lever and Cable Inspection
41
Clutch Fluid Inspection
41
Tire / Wheel Inspection and Rotation
41
Wheel Discs Inspection
42
Wheel Bearing Inspection
42
Suspension System Inspection
42
Steering System Inspection
42
Propeller Shafts and Drive Shafts Inspection
43
Manual Transmission Oil Inspection
43
Manual Transmission Oil Change
43
Automatic Transmission Fluid Inspection
43
Automatic Transmission Fluid Change
44
Automatic Transmission Fluid Cooler Hose Inspection
44
Transfer Oil Inspection (if Equipped)
44
Differential Oil Inspection
44
Transfer (if Equipped) and Differential Oil Change
44
Power Steering (P/S) System Inspection
45
All Hinges, Latches and Locks Inspection
45
HVAC Air Filter Inspection (if Equipped)
45
HVAC Air Filter Replacement (if Equipped)
45
Final Inspection for Maintenance Service
45
Specifications
47
Tightening Torque Specifications
47
Special Tools and Equipment
47
Recommended Fluids and Lubricants
47
Special Tool
47
Engine
49
Precautions
55
Precautions for Engine
55
Engine General Information and Diagnosis
56
Precautions
56
Precautions on Engine Service
56
Precautions in Diagnosing Trouble
56
Precautions for DTC Troubleshooting
57
Precautions of ECM Circuit Inspection
57
Precautions of Electric Throttle Body System Calibration
57
General Description
57
Statement on Cleanliness and Care
57
Engine Diagnosis General Description
58
On-Board Diagnostic System Description
58
Engine and Emission Control System Description
61
CAN Communication System Description
61
Air Intake System Description
64
Description of Electric Throttle Body System
65
Description of Electric Throttle Body System Calibration
66
Generator Control System Description
66
A/F Sensor Description
67
Electronic Control System Description
68
Engine and Emission Control Input / Output Table
76
Schematic and Routing Diagram
77
Engine and Emission Control System Diagram
77
Component Location
78
Electronic Control System Components Location
78
Diagnostic Information and Procedures
80
Engine and Emission Control System Check
80
Malfunction Indicator Lamp (MIL) Check
83
DTC Check
83
DTC Clearance
84
DTC Table
85
Fail-Safe Table
91
Scan Tool Data
92
Visual Inspection
98
Engine Basic Inspection
99
Engine Symptom Diagnosis
103
Malfunction Indicator Lamp Does Not Come on with Ignition Switch on and Engine Stop (but Engine Can be Started)
112
Wiring Diagram
112
Malfunction Indicator Lamp Remains on after Engine Starts
114
DTC P0010: Camshaft Position Actuator Circuit (for M16 Engine)
115
DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / -Retarded (for M16 Engine)
117
DTC P0030: HO2S Heater Control Circuit (Sensor-1)
119
DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)
120
DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)
124
DTC P0101: Mass Air Flow Circuit Range / Performance
127
DTC P0102: Mass Air Flow Circuit Low Input
130
DTC P0103: Mass Air Flow Circuit High Input
132
DTC P0106: Manifold Absolute Pressure Range / Performance
134
DTC P0107: Manifold Absolute Pressure Circuit Low Input
135
DTC P0108: Manifold Absolute Pressure Circuit High Input
137
DTC P0111: Intake Air Temperature Circuit Range / Performance
139
DTC P0112: Intake Air Temperature Sensor Circuit Low
142
DTC P0113: Intake Air Temperature Sensor Circuit High
144
DTC P0116: Engine Coolant Temperature Circuit Range / Performance
146
DTC P0117: Engine Coolant Temperature Circuit Low
149
DTC P0118: Engine Coolant Temperature Circuit High
150
DTC P0122: Throttle Position Sensor (Main) Circuit Low
153
DTC P0123: Throttle Position Sensor (Main) Circuit High
156
DTC P0131 / P0132 / P0134: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage / no Activity Detected (Sensor-1)
159
DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)
160
DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)
162
DTC P0140: O2 Sensor (HO2S) Circuit no Activity Detected (Sensor-2)
165
DTC P0171 / P0172 / P2195 / P2196: Fuel System too Lean / Rich / Stuck Lean / Stuck Rich
166
DTC P0222: Throttle Position Sensor (Sub) Circuit Low
170
DTC P0223: Throttle Position Sensor (Sub) Circuit High
173
DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected
176
DTC P0327 / P0328: Knock Sensor Circuit Low / High
178
DTC P0335: Crankshaft Position (CKP) Sensor Circuit (for J20 Engine)
180
Dtc Confirmation Procedure
180
DTC P0335: Crankshaft Position (CKP) Sensor Circuit (for M16 Engine)
182
DTC P0340: Camshaft Position (CMP) Sensor Circuit
185
DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected
188
DTC P0403: Exhaust Gas Recirculation Control Circuit
191
DTC P0420: Catalyst System Efficiency below Threshold
193
DTC P0443: Evaporative Emission System Purge Control Valve Circuit
195
DTC P0462: Fuel Level Sensor Circuit Low
197
DTC P0463: Fuel Level Sensor Circuit High
199
DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit
201
DTC P0500: Vehicle Speed Sensor (VSS) Malfunction
205
DTC P0504: Brake Switch "A"/"B" Correlation (for J20 Engine)
207
DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low
209
DTC P0533: A/C Refrigerant Pressure Sensor Circuit High
211
DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance
212
DTC P0616: Starter Relay Circuit Low
213
DTC P0617: Starter Relay Circuit High
215
DTC P0620: Generator Control Circuit
216
DTC P0625 / P0626: Generator Field Terminal Circuit Low / High
218
DTC P0660: Intake Manifold Tuning Valve Control Circuit / Open (for J20 Engine)
220
DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High
222
DTC P1510: ECM Back-Up Power Supply Malfunction
224
DTC P1603: TCM Trouble Code Detected (for J20 Engine)
225
DTC P1674: CAN Communication (Bus off Error)
226
DTC P1676: CAN Communication (Reception Error for TCM (for A/T Model))
231
DTC P1678: CAN Communication (Reception Error for BCM)
235
DTC P1685: CAN Communication (Reception Error for ABS Control Module)
239
DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance
242
DTC P2102: Throttle Actuator Control Motor Circuit Low
244
DTC P2103: Throttle Actuator Control Motor Circuit High
246
DTC P2111: Throttle Actuator Control System - Stuck Open
247
DTC P2119: Throttle Actuator Control Throttle Body Range / Performance
248
DTC P2122: Pedal Position Sensor (Main) Circuit Low Input
250
DTC P2123: Pedal Position Sensor (Main) Circuit High Input
253
DTC P2127: Pedal Position Sensor (Sub) Circuit Low Input
255
DTC P2128: Pedal Position Sensor (Sub) Circuit High Input
257
DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation
260
DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation
263
DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction
265
Inspection of ECM and Its Circuits
267
ECM Power and Ground Circuit Check
289
Fuel Injector Circuit Check
293
Fuel Pump and Its Circuit Check
295
Fuel Pressure Check
298
A/C System Circuits Check
300
Electric Load Signal Circuit Check
303
Radiator Cooling Fan Low Speed Control System Check
305
Troubleshooting
305
Radiator Cooling Fan High Speed Control System Check
308
Repair Instructions
310
Idle Speed and IAC Throttle Valve Opening Inspection
310
Special Tools and Equipment
311
Special Tool
311
Aux. Emission Control Devices
312
Diagnostic Information and Procedures
312
EGR System Inspection
312
Repair Instructions
312
EVAP Canister Purge Inspection
312
EVAP Canister Purge Valve and Its Circuit Inspection
313
Vacuum Passage Inspection
313
Vacuum Hose and Purge Valve Chamber Inspection
314
EVAP Canister Purge Valve Inspection
314
EVAP Canister Inspection
315
EGR Valve Removal and Installation
315
EGR Valve Inspection
315
PCV Hose Inspection
315
PCV Valve Removal and Installation
316
PCV Valve Inspection
316
Specifications
317
Tightening Torque Specifications
317
Special Tools and Equipment
317
Recommended Service Material
317
Special Tool
317
Engine Electrical Devices
318
Repair Instructions
318
Engine Control Module (ECM) Removal and Installation
318
Manifold Absolute Pressure (MAP) Sensor Inspection
318
Electric Throttle Body Assembly On-Vehicle Inspection
319
Electric Throttle Body System Calibration
321
Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection
322
Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation
322
Accelerator Pedal Position (APP) Sensor Assembly Inspection
323
Engine Coolant Temperature (ECT) Sensor Removal and Installation
323
Engine Coolant Temperature (ECT) Sensor Inspection
324
Air Fuel Ratio (A/F) Sensor On-Vehicle Inspection
324
Heated Oxygen Sensor (HO2S-2) Heater On-Vehicle Inspection
325
Air Fuel Ratio (A/F) Sensor, Heated Oxygen Sensor (HO2S-2) Removal and Installation
325
Camshaft Position (CMP) Sensor Removal and Installation
325
Camshaft Position (CMP) Sensor Inspection
326
Crankshaft Position (CKP) Sensor Removal and Installation
326
Crankshaft Position (CKP) Sensor Inspection
327
Knock Sensor Removal and Installation
328
Control Relay Inspection
329
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection
330
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation
330
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection
331
Vacuum Tank Assembly Inspection (for J20 Engine)
331
Electric Load Current Sensor On-Vehicle Inspection (for J20 Engine)
333
Electric Load Current Sensor Removal and Installation (for J20 Engine)
333
Specifications
334
Engine Mechanical
335
For M16A Engine with VVT
335
General Description
335
Engine Construction Description
335
Camshaft Position Control (VVT Variable Valve Timing) System Description
336
Diagnostic Information and Procedures
338
Compression Check
338
Engine Vacuum Check
339
Valve Lash (Clearance) Inspection
340
Repair Instructions
342
Air Cleaner Filter Removal and Installation
342
Air Cleaner Filter Inspection and Cleaning
343
Cylinder Head Cover Removal and Installation
343
Throttle Body and Intake Manifold Components
345
Throttle Body On-Vehicle Inspection
345
Electric Throttle Body Assembly Removal and Installation
346
Throttle Body Cleaning
346
Intake Manifold Removal and Installation
347
Engine Mountings Components
348
Engine Assembly Removal and Installation
348
Timing Chain Cover Components
352
Timing Chain Cover Removal and Installation
353
Timing Chain Cover Inspection
355
Oil Control Valve Removal and Installation
355
Oil Control Valve Inspection
356
Timing Chain and Chain Tensioner Components
357
Timing Chain and Chain Tensioner Removal and Installation
357
Timing Chain and Chain Tensioner Inspection
360
Camshaft, Tappet and Shim Components
361
Camshaft, Tappet and Shim Removal and Installation
361
Camshaft, Tappet and Shim Inspection
364
Valves and Cylinder Head Components
367
Valves and Cylinder Head Removal and Installation
368
Valves and Cylinder Head Disassembly and Assembly
369
Valves and Valve Guides Inspection
372
Cylinder Head Inspection
374
Valve Spring Inspection
375
Pistons, Piston Rings, Connecting Rods and Cylinders Components
376
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation
376
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly
378
Cylinders, Pistons and Piston Rings Inspection
379
Piston Pins and Connecting Rods Inspection
381
Crank Pin and Connecting Rod Bearings Inspection
382
Main Bearings, Crankshaft and Cylinder Block Components
386
Main Bearings, Crankshaft and Cylinder Block Removal and Installation
387
Crankshaft Inspection
390
Main Bearings Inspection
391
Sensor Plate Inspection
395
Rear Oil Seal Inspection
395
Flywheel Inspection
396
Cylinder Block Inspection
396
Specifications
397
Tightening Torque Specifications
397
Special Tools and Equipment
398
Recommended Service Material
398
Special Tool
398
For J20 Engine
400
General Description
400
Engine Construction Description
400
Air Cleaner Element Introduction
402
IMT (Intake Manifold Tuning) System
402
Diagnostic Information and Procedures
404
Compression Check
404
Engine Vacuum Check
405
Valve Lash (Clearance) Inspection
406
Repair Instructions
409
Air Cleaner Assembly Removal and Installation
409
Air Cleaner Filter Removal and Installation
409
Air Cleaner Filter Inspection and Cleaning
409
Throttle Body and Intake Manifold Components
410
Throttle Body On-Vehicle Inspection
410
Electric Throttle Body Assembly Removal and Installation
410
Throttle Body Cleaning
411
Intake Manifold Removal and Installation
411
Cylinder Head Cover Removal and Installation
412
Engine Mountings Components
414
Engine Assembly Removal and Installation
415
Timing Chain Cover Components
418
Timing Chain Cover Removal and Installation
418
Timing Chain Cover Cleaning and Inspection
421
2Nd Timing Chain and Chain Tensioner Components
421
Tightening Torque
421
2Nd Timing Chain and Chain Tensioner Removal and Installation
422
2Nd Timing Chain and Chain Tensioner Inspection
424
1St Timing Chain and Chain Tensioner Components
425
Camshaft Sprocket
425
1St Timing Chain and Chain Tensioner Removal and Installation
426
1St Timing Chain and Chain Tensioner Inspection
428
Camshafts, Tappet and Shim Components
429
Camshafts, Tappet and Shim Removal and Installation
429
Camshaft, Tappet and Shim Inspection
431
Valves and Cylinder Head Components
433
Valves and Cylinder Head Removal and Installation
433
Valves and Cylinder Head Disassembly and Assembly
435
Valves and Valve Guides Inspection
438
Cylinder Head Inspection
440
Valve Spring Inspection
441
Pistons, Piston Rings, Connecting Rods and Cylinders Components
442
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation
442
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly
443
Pistons, Piston Rings, Connecting Rods and Cylinders Inspection and Cleaning
446
Main Bearings, Crankshaft and Cylinder Block Components
452
Main Bearings, Crankshaft and Cylinder Block Removal and Installation
453
Main Bearings, Crankshaft and Cylinder Block Inspection
456
Specifications
463
Tightening Torque Specifications
463
Special Tools and Equipment
464
Recommended Service Material
464
Special Tool
464
Engine Lubrication System
467
For M16A Engine with VVT
467
General Description
467
Engine Lubrication Description
467
Diagnostic Information and Procedures
469
Oil Pressure Check
469
Repair Instructions
470
Oil Pan and Oil Pump Strainer Components
470
Oil Pan and Oil Pump Strainer Removal and Installation
471
Oil Pan and Oil Pump Strainer Cleaning
472
Oil Pump Components
473
Oil Pump Removal and Installation
473
Oil Pump Disassembly and Reassembly
473
Oil Pump Inspection
474
Specifications
476
Tightening Torque Specifications
476
Special Tools and Equipment
476
Recommended Service Material
476
Special Tool
476
For J20 Engine
477
General Description
477
Engine Lubrication Description
477
Diagnostic Information and Procedures
479
Oil Pressure Check
479
Repair Instructions
480
Oil Pan and Oil Pump Strainer Components
480
Oil Pan and Oil Pump Strainer Removal and Installation
481
Oil Pan and Oil Pump Strainer Cleaning
482
Oil Pump Components
482
Oil Pump Removal and Installation
483
Oil Pump Disassembly and Assembly
483
Oil Pump Inspection
484
Special Tools and Equipment
486
Recommended Service Material
486
Special Tool
486
Engine Cooling System
487
General Description
487
Cooling System Description
487
Coolant Description
487
Schematic and Routing Diagram
488
Coolant Circulation
488
Diagnostic Information and Procedures
489
Engine Cooling Symptom Diagnosis
489
Repair Instructions
490
Cooling System Components
490
Coolant Level Check
492
Engine Cooling System Inspection and Cleaning
492
Cooling System Draining
493
Cooling System Flush and Refill
493
Cooling Water Pipes or Hoses Removal and Installation
494
Thermostat Removal and Installation
494
Thermostat Removal and Installation
495
Thermostat Inspection
495
Radiator Cooling Fan Motor On-Vehicle
496
Inspection
496
Radiator Cooling Fan Relay Inspection
496
Radiator Cooling Fan Assembly Removal and Installation
497
Radiator On-Vehicle Inspection and Cleaning
497
Radiator Removal and Installation
498
Water Pump Removal and Installation
498
Water Pump Removal and Installation
499
Water Pump Inspection
500
Specifications
500
Tightening Torque Specifications
500
Special Tools and Equipment
500
Recommended Service Material
500
Fuel System
501
Precautions
501
Precautions on Fuel System Service
501
General Description
501
Fuel System Description
501
Fuel Delivery System Description
501
Fuel Pump Description
502
Schematic and Routing Diagram
502
Fuel Delivery System Diagram
502
Diagnostic Information and Procedures
503
Fuel Pressure Inspection
503
Fuel Cut Operation Inspection
504
Repair Instructions
505
Fuel System Components
505
Fuel Hose Disconnecting and Reconnecting
508
Fuel Pressure Relief Procedure
510
Fuel Leakage Check Procedure
510
Fuel Lines On-Vehicle Inspection
511
Fuel Pipe Removal and Installation
511
Fuel Injector Removal and Installation
512
Fuel Injector Inspection
513
Fuel Pressure Regulator Removal and Installation
515
Fuel Pressure Regulator Inspection
515
Fuel Filler Cap Inspection
516
Fuel Tank Inlet Valve Removal and Installation
516
Fuel Tank Inlet Valve Inspection
517
Fuel Tank Removal and Installation
517
Fuel Tank Inspection
519
Fuel Tank Purging Procedure
519
Fuel Pump On-Vehicle Inspection
519
Fuel Pump Assembly Removal and Installation
520
Main Fuel Level Sensor Removal and Installation
521
Fuel Pump Inspection
521
Sub Fuel Level Sensor Removal and Installation
521
Sub Fuel Level Sensor Inspection
522
Specifications
522
Tightening Torque Specifications
522
Special Tools and Equipment
523
Recommended Service Material
523
Special Tool
523
Ignition System
524
General Description
524
Ignition System Construction
524
Component Location
526
Ignition System Components Location
526
Diagnostic Information and Procedures
527
Ignition System Symptom Diagnosis
527
Reference Waveform of Ignition System
527
Ignition System Check
527
Ignition Spark Test
527
Repair Instructions
530
High-Tension Cord Inspection
530
Spark Plug Removal and Installation
530
Spark Plug Inspection
531
Ignition Coil Assembly (Including Ignitor) Removal and Installation
531
Ignition Coil Assembly (Including Ignitor) Inspection
532
Ignition Timing Inspection
532
Specifications
534
Tightening Torque Specifications
534
Special Tools and Equipment
534
Starting System
535
Precautions
535
Cranking System Note
535
General Description
535
Cranking Circuit Introduction
535
Starting Motor Circuit Description
535
Diagnostic Information and Procedures
536
Cranking System Symptom Diagnosis
536
Starting Motor Performance Test
537
Repair Instructions
539
Starting Motor Dismounting and Remounting
539
Starting Motor Components
540
Starting Motor Inspection
541
Specifications
544
Starting Motor Specifications
544
Tightening Torque Specifications
544
Special Tools and Equipment
544
Recommended Service Material
544
Charging System
545
General Description
545
Battery Description
545
Generator Description
546
Diagnostic Information and Procedures
547
Battery Inspection
547
Generator Symptom Diagnosis
548
Generator Test (Undercharged Battery Check)
548
Generator Test (Overcharged Battery Check)
549
Repair Instructions
550
Jump Starting in Case of Emergency
550
Battery Dismounting and Remounting
551
Water Pump and Generator Drive Belt Removal and Installation (for M16 Engine)
551
Water Pump and Generator Drive Belt Tension Inspection and Adjustment (for M16 Engine)
552
Water Pump and Generator Drive Belt On-Vehicle Inspection (for J20 Engine)
553
Water Pump and Generator Drive Belt Removal and Installation (for J20 Engine)
554
Generator Dismounting and Remounting
555
Generator Components
556
Generator Inspection
557
Specifications
560
Charging System Specifications
560
Tightening Torque Specifications
560
Exhaust System
561
General Description
561
Exhaust System Description
561
Diagnostic Information and Procedures
561
Exhaust System Check
561
Repair Instructions
561
Exhaust System Components
561
Exhaust Manifold Removal and Installation (for M16 Engine Model)
564
Exhaust Manifold Removal and Installation (for J20 Engine Model)
564
Exhaust Pipe and Muffler Removal and Installation
565
Specifications
566
Tightening Torque Specifications
566
Suspension
567
Precautions
569
Precautions on Suspension
569
Suspension General Diagnosis
570
Diagnostic Information and Procedures
570
Suspension, Wheels and Tires Symptom Diagnosis
570
Specifications
572
Wheel Alignment Specifications
572
Front Suspension
573
General Description
573
Front Suspension Construction
573
Front Wheel Alignment Construction
574
Repair Instructions
574
Front Wheel Alignment Inspection and Adjustment
574
Front Strut Assembly Components
576
Front Strut Assembly Removal and Installation
577
Front Strut Assembly Disassembly and Assembly
579
Front Strut Assembly Check
580
Front Wheel Hub Assembly and Steering Knuckle Components
581
Front Wheel Hub Assembly Removal and Installation
581
Steering Knuckle Removal and Installation
583
Front Wheel Hub, Disc, Nut and Bearing Check
584
Suspension Control Arm Removal and Installation
585
Suspension Control Arm / Bushing Disassembly and Assembly
587
Suspension Control Arm / Steering Knuckle Check
588
Suspension Control Arm Bushing Check
588
Suspension Control Arm Joint Check
588
Front Suspension Frame, Stabilizer Bar And/Or Bushings Components
589
Front Suspension Frame, Stabilizer Bar And/Or Bushings Removal and Installation
590
Front Suspension Frame Check
594
Front Stabilizer Bar, Bushing And/Or Joint Check
594
Special Tools and Equipment
596
Recommended Service Material
596
Special Tool
596
Rear Suspension
597
General Description
597
Rear Suspension Construction
597
Rear Wheel Alignment Construction
598
Repair Instructions
598
Rear Wheel Alignment Inspection and Adjustment
598
Rear Shock Absorber and Rear Coil Spring Components
600
Rear Shock Absorber Removal and Installation
601
Shock Absorber Check
602
Rear Coil Spring and Bump Stopper Removal and Installation
602
Rear Coil Spring Check
604
Rod and Arm Components
605
Control Rod Removal and Installation
606
Control Rod / Bushing Disassembly and Assembly
608
Control Rod Check
608
Trailing Rod Removal and Installation
609
Trailing Rod / Bushing Disassembly and Assembly
610
Trailing Rod Check
611
Lower Arm Removal and Installation
611
Lower Arm / Bushing Disassembly and Assembly
612
Lower Arm Check
613
Upper Arm Removal and Installation
613
Upper Arm / Bushing Disassembly and Assembly
615
Upper Arm Check
615
Rear Suspension Frame Components
616
Rear Suspension Frame Removal and Installation
617
Rear Suspension Frame / Bushing Disassembly and Assembly
619
Rear Suspension Frame, Bushing and Pad Check
620
Rear Wheel Hub Assembly and Rear Suspension Knuckle Components
620
Rear Wheel Hub Assembly Removal and Installation
621
Rear Wheel Hub Assembly, Wheel Bearing and Wheel Stud Inspection
623
Rear Wheel Disc, Nut and Bearing Check
623
Rear Suspension Knuckle Removal and Installation
624
Rear Suspension Knuckle Check
627
Rear Suspension Fasteners Check
627
Special Tools and Equipment
629
Recommended Service Material
629
Wheels and Tires
630
General Description
630
Tires Description
630
Wheels Description
631
Irregular And/Or Premature Wear Description
631
Wear Indicators Description
632
Radial Tire Waddle Description
632
Radial Tire Lead / Pull Description
633
Balancing Wheels Description
633
Repair Instructions
634
General Balance Procedures
634
Tire Rotation
634
Wheel Removal and Installation
635
Tire Mounting and Dismounting
635
Tire Repair
635
Specifications
636
Wheels and Tires Specifications
636
Tightening Torque Specifications
636
Driveline / Axle
637
Precautions
640
Precautions for Driveline / Axle
640
Drive Shaft / Axle
641
Front
641
General Description
641
Front Drive Shaft Construction
641
Diagnostic Information and Procedures
641
Front Drive Shaft Symptom Diagnosis
641
Repair Instructions
642
Front Drive Shaft Boot and Joint Check
642
Front Drive Shaft Components
642
Front Drive Shaft Assembly Removal and Installation
643
Front Drive Shaft Disassembly and Assembly
643
Specifications
646
Tightening Torque Specifications
646
Special Tools and Equipment
646
Recommended Service Material
646
Special Tool
646
Rear
647
General Description
647
Rear Drive Shaft Construction
647
Repair Instructions
647
Rear Drive Shaft Components
647
Rear Drive Shaft Assembly Removal and Installation
648
Rear Drive Shaft Disassembly and Assembly
648
Specifications
649
Tightening Torque Specifications
649
Special Tools and Equipment
649
Recommended Service Material
649
Special Tool
649
Differential
650
Front
650
General Description
650
Front Differential Construction
650
Diagnostic Information and Procedures
650
Front Differential Symptom Diagnosis
650
Repair Instructions
651
Front Differential Oil Change
651
Front Differential Unit Components
652
Front Differential Dismounting and Remounting
652
Front Differential Components
653
Front Differential Assembly Disassembly and Reassembly
654
Front Differential Inspection
666
Specifications
667
Tightening Torque Specifications
667
Special Tools and Equipment
667
Recommended Service Material
667
Special Tool
667
Rear
670
General Description
670
Rear Differential Construction
670
Diagnostic Information and Procedures
670
Rear Differential Symptom Diagnosis
670
Repair Instructions
670
Rear Differential Oil Change
670
Rear Differential Unit Components
670
Rear Differential Dismounting and Remounting
671
Rear Differential Components
672
Rear Differential Assembly Disassembly and Reassembly
673
Special Tools and Equipment
686
Recommended Service Material
686
Special Tool
686
Transfer
689
Motor-Shift Type
689
Precautions
689
Transfer Warning
689
Precautions in Diagnosing Trouble
689
General Description
689
Transfer Description
689
Transfer Shift Control System Components
690
4WD Control System Description
691
Function of 4WD Control System Component
693
4WD Control System Operation
693
4WD Control System Wiring Circuit Diagram
699
Module
700
Module
701
CAN Communication System Description
701
Diagnostic Information and Procedures
702
4WD Control System Check
702
Transfer Position Indicator Operation Check
705
4WD Control System Operation Inspection
705
Visual Inspection
706
DTC Check
707
DTC Clearance
708
DTC Table
708
Fail-Safe Table
709
Scan Tool Data
710
Scan Tool Data Definitions
710
4WD Control Symptom Diagnosis
711
Transfer Position Indicator Does Not Come on at Ignition Switch on but Engine Stops
712
Transfer Position Indicator Remains on Steady at Ignition Switch
714
DTC C1213: Transfer Switch Circuit Open
715
DTC C1214: Transfer Switch Circuit Short
716
DTC C1223 / C1235: Transfer Shift Actuator Motor Position Switch 1 Circuit Open / Transfer Shift Actuator Motor Position Switch 2 Circuit Open
718
DTC C1224 / C1236: Transfer Shift Actuator Motor Position Switch 1 Circuit Short / Transfer Shift Actuator Motor Position Switch 2 Circuit Short
720
DTC C1227: 4L/N Switch Circuit Open
722
DTC C1228: 4L/N Switch Circuit Short
723
DTC C1230: Transfer Actuator Circuit Malfunction
725
DTC C1237: Center Differential Lock Switch Circuit Open
726
DTC C1238: Center Differential Lock Switch Circuit Short
728
DTC C1240: 4WD Control Module Power Supply Circuit Malfunction
729
DTC C1243: Internal Circuit Malfunction of 4WD Control Module
730
DTC C1246: Clutch Pedal Position (CPP) Switch Circuit Short
731
DTC U1101: Lost Communication with TCM
736
DTC U1121: Lost Communication with ABS Hydraulic Unit / Control Module
738
Inspection of 4WD Control Module and Its Circuits
739
Repair Instructions
742
Transfer Oil Level Check
742
Transfer Oil Change
742
Transfer Oil Seal Removal and Installation
743
Transfer Switch Removal and Installation
743
Installation
743
Transfer Assembly Dismounting and Remounting
745
Transfer Assembly Components
746
Transfer Assembly Disassembly and Reassembly
747
Transfer Assembly Inspection
755
Input Gear Assembly, Counter Gear Assembly, Front Output Shaft Assembly and Rear Output Shaft Assembly Components
757
Input Gear Assembly Disassembly and Reassembly
758
Counter Gear Assembly Disassembly and Reassembly
759
Front Output Shaft Assembly Disassembly and Reassembly
759
Rear Output Shaft Assembly Disassembly and Reassembly
760
Non-Shift Type (Transfer Without Shift Actuator)
763
Precautions
763
Transfer Warning
763
General Description
763
Transfer Construction
763
Diagnostic Information and Procedures
764
Transfer Symptom Diagnosis
764
Repair Instructions
765
Transfer Oil Change
765
Transfer Oil Level Check
765
Transfer Oil Seal Removal and Installation
765
Transfer Assembly Dismounting and
765
Transfer Assembly Components
766
Transfer Assembly Disassembly and Reassembly
768
Input Gear Assembly Disassembly and Reassembly
774
Front Output Shaft Assembly Disassembly and Reassembly
774
Rear Output Shaft Assembly Disassembly and Reassembly
774
Specifications
775
Tightening Torque Specifications
775
Special Tools and Equipment
775
Recommended Service Material
775
Special Tool
775
Propeller Shafts
776
Precautions
776
Propeller Shaft Caution
776
General Description
776
Propeller Shaft Construction
776
Diagnostic Information and Procedures
777
Propeller Shaft Symptom Diagnosis
777
Brakes
783
Precautions
785
Precautions for Brakes
785
Brake Control System and Diagnosis
786
General Description
786
Brakes Construction
786
Front Brake Hose / Pipe Construction
787
Rear Brake Hose / Pipe Construction
788
Master Cylinder Assembly Construction
788
Booster Assembly Construction
789
Diagnostic Information and Procedures
789
Brake Diagnosis Note
789
Brakes Symptom Diagnosis
790
Repair Instructions
792
Excessive Pedal Travel Check
792
Brake Pedal Play Check
792
Brake Fluid Level Check
792
Air Bleeding of Brake System
793
Brake Pedal Free Height Adjustment
794
Brake Light Switch Adjustment
794
Brake Flexible Hose and Pipe Check
794
Master Cylinder Check
794
Flushing Brake Hydraulic System
795
Booster Operation Check
795
Front Brake Hose / Pipe Removal and Installation
796
Rear Brake Hose / Pipe Removal and Installation
796
Master Cylinder Components
797
Master Cylinder Reservoir Removal and Installation
798
Master Cylinder Assembly Removal and Installation
799
Master Cylinder Assembly Inspection
800
Brake Booster Components
801
Brake Booster Removal and Installation
802
Booster Push Rod Clevis Adjustment
802
Special Tool
803
Front Brakes
804
General Description
804
Front Disc Brake Caliper Assembly Construction
804
Repair Instructions
805
Front Disc Brake Components
805
Front Disc Brake Pad On-Vehicle Check
806
Front Disc Brake Pad Removal and Installation
806
Front Brake Disc and Pad Inspection
807
Front Disc Brake Caliper Removal and Installation
808
Front Disc Brake Caliper Disassembly and Assembly
809
Front Disc Brake Caliper Inspection
810
Front Brake Disc Removal and Installation
811
Front Brake Disc Inspection
811
Specifications
812
Tightening Torque Specifications
812
Special Tools and Equipment
812
Recommended Service Material
812
Rear Brakes
813
General Description
813
Rear Drum Brake Assembly Construction
813
Repair Instructions
814
Rear Drum Brake Assembly Components
814
Rear Brake Drum Removal and Installation
815
Rear Brake Drum and Shoe Inspection
816
Rear Brake Shoe On-Vehicle Check
816
Rear Brake Shoe Removal and Installation
817
Rear Brake Shoe Inspection
818
Wheel Cylinder Removal and Installation
818
Wheel Cylinder Inspection
819
Rear Brake Back Plate Removal and Installation
819
Parking Brake
822
Component Location
822
Parking Brake Cable Location
822
Repair Instructions
824
Parking Brake Check and Adjustment
824
Parking Brake Lever Removal and Installation
825
Parking Brake Cable Removal and Installation
825
Specifications
826
Tightening Torque Specifications
826
Abs
827
Precautions
827
Precautions in Diagnosing Troubles
827
General Description
827
ABS Description
827
ABS Hydraulic Unit / Control Module Assembly Description
828
CAN Communication System Description
828
Schematic and Routing Diagram
829
ABS Schematic
829
ABS Wiring Circuit Diagram
830
Component Location
832
ABS Components Location
832
Diagnostic Information and Procedures
833
ABS Check
833
ABS Warning Lamp Check
835
EBD Warning Lamp (Brake Warning Lamp) Check
835
DTC Check
835
DTC Table
836
DTC Clearance
836
Scan Tool Data
836
Ignition Switch
837
ABS Warning Lamp Comes on Steady
839
EBD Warning Lamp (Brake Warning Lamp) Comes on Steady
842
Serial Data Link Circuit Check
843
DTC C1015: G Sensor Circuit
845
DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right-Rear / Left-Rear Wheel Speed Sensor Circuit or Encoder
846
DTC C1057: Power Source Circuit
849
DTC C1061: ABS Pump Motor And/Or Motor Driver Circuit
850
DTC C1063: Solenoid Valve Power Supply Driver Circuit
851
DTC C1071: ABS Control Module
852
DTC U1073: Control Module Communication Bus off
853
DTC U1100: Lost Communication with ECM (Reception Error)
855
Repair Instructions
856
ABS Hydraulic Unit Operation Check
856
ABS Hydraulic Unit / Control Module Assembly Components
857
ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection
857
ABS Hydraulic Unit / Control Module Assembly Removal and Installation
858
Front Wheel Speed Sensor On-Vehicle Inspection
860
Front Wheel Speed Sensor Removal and Installation
861
Front Wheel Speed Sensor Inspection
862
Rear Wheel Speed Sensor On-Vehicle Inspection
862
Rear Wheel Speed Sensor Removal and Installation
862
Rear Wheel Speed Sensor Inspection
863
Front Wheel Encoder On-Vehicle Inspection
863
Front Wheel Encoder Removal and Installation
863
Rear Wheel Encoder On-Vehicle Inspection
863
Rear Wheel Encoder Removal and Installation
863
Specifications
864
Tightening Torque Specifications
864
Special Tools and Equipment
864
Special Tool
864
Transmission / Transaxle
865
Precautions
868
Automatic Transmission/Transaxle
869
General Service Procedure Information
869
General Description
871
Automatic Transmission Description
871
Clutch / Brake Functions of Automatic Transmission
873
Table of A/T System Component Operation
874
CAN Communication System Description
875
Electronic Shift Control Input / Output Table
876
Brake Interlock System Description
879
A/T Diagnosis General Description
879
On-Board Diagnostic System Description
879
Schematic and Routing Diagram
881
Automatic Gear Shift Table
881
Bearing and Race Installation Diagram
884
Component Location
885
Electronic Shift Control System Components Location
885
Diagnostic Information and Procedures
886
A/T System Check
886
Malfunction Indicator Lamp (MIL) Check
888
Diagnosis Connector)
888
POWER" Lamp Operation Check
888
DTC Table
889
DTC Check
890
DTC Clearance
891
Fail Safe Table
892
Scan Tool Data
894
Visual Inspection
897
A/T Basic Check
897
Road Test
898
Manual Road Test
899
Stall Test
900
Time Lag Test
901
Line Pressure Test
901
Engine Brake Test
903
P" Range Test
903
A/T Symptom Diagnosis
904
No Gear Shift to 4Th Gear
911
No Lock-Up Occurs
912
Transmission Warning Light Circuit Check - Light Does Not Come "ON" at Ignition Switch on (Vehicle Is Equipped with Engine Diagnosis Connector)
913
Transmission Warning Light Circuit Check - Light Remains "ON" at Ignition Switch on (Vehicle Is Equipped with Engine Diagnosis Connector)
913
DTC P0705 Transmission Range Sensor Circuit Malfunction
914
DTC P0707 Transmission Range Sensor Circuit Low
916
DTC P0712 Transmission Fluid Temperature Sensor "A" Circuit Low
918
DTC P0713 Transmission Fluid Temperature Sensor "A" Circuit High
919
DTC P0717 Input / Turbine Speed Sensor Circuit no Signal
920
DTC P0722 Output Speed Sensor Circuit no Signal
921
DTC P0741 / P0742 TCC Circuit Performance or Stuck off / TCC Circuit Stuck
922
DTC P0751 / P0752 Shift Solenoid-A Performance or Stuck off / Shift Solenoid-A Stuck
923
DTC P0756 / P0757 Shift Solenoid-B Performance or Stuck off / Shift Solenoid-B Stuck
924
DTC P0962 Pressure Control Solenoid "A" Control Circuit Low
925
DTC P0963 Pressure Control Solenoid "A" Control Circuit High
926
DTC P0973 / P0976 Shift Solenoid "A" Control Circuit Low / Shift Solenoid "B" Control Circuit Low
927
DTC P0974 / P0977 Shift Solenoid "A" Control Circuit High / Shift Solenoid "B" Control Circuit High
929
DTC P1702 Internal Control Module Memory Check Sum Error
930
DTC P1703 CAN Invalid Data - TCM
930
DTC P1723 Range Select Switch Malfunction
931
DTC P1774: CAN Communication Bus off
932
DTC P1777: TCM Lost Communication with ECM (Reception Error)
934
DTC P1778: TCM Lost Communication with BCM (Reception Error)
935
DTC P1874 4L Switch Circuit Malfunction (Short)
936
DTC P1875 4L Switch Circuit Malfunction (Open)
937
DTC P1878 Torque Converter Clutch Shudder
939
DTC P2763 Torque Converter Clutch (TCC) Circuit High
939
DTC P2764 Torque Converter Clutch (TCC) Circuit Low
941
Inspection of TCM and Its Circuits
942
TCM Power and Ground Circuit Check
946
Repair Instructions
948
A/T Fluid Level Check
948
A/T Fluid Change
949
Manual Selector Assembly Components
949
Manual Selector Assembly Removal and Installation
950
Select Lever Knob Installation
950
Manual Selector Assembly Inspection
950
3" Position Switch Inspection
950
Select Cable Component
951
Select Cable Adjustment
951
Transmission Range Sensor Removal and Installation
952
Transmission Range Sensor Inspection and Adjustment
952
Key Interlock Cable Removal and Installation
953
Brake and Key Interlock System Inspection
955
Mode Select Switch Inspection
956
Input Shaft Speed Sensor Removal and Installation
956
Input Shaft Speed Sensor Inspection
956
Output Shaft Speed Sensor Removal and Installation
957
Output Shaft Speed Sensor Inspection
957
Oil Cooler Hose and Pipes Removal and Installation
958
Solenoid Valves
959
Removal and Installation
961
Solenoid Valves
961
Transmission Fluid Temperature Sensor Removal and Installation
961
Transmission Fluid Temperature Sensor Inspection
962
Transmission Control Module (TCM) Removal and Installation
963
A/T Relay Inspection
963
Automatic Transmission Unit Components
964
Automatic Transmission Assembly Dismounting and Remounting
965
Automatic Transmission Unit Disassembly
966
Oil Pump Components
971
Oil Pump Disassembly and Assembly
972
Oil Pump Inspection
972
Overdrive (Planetary Gear Side) Components
974
Overdrive (Planetary Gear Side) Disassembly and Assembly
974
Overdrive (Planetary Gear Side) Inspection
976
Overdrive (Case Side) Components
977
Overdrive (Case Side) Disassembly and Assembly
978
Overdrive (Case Side) Inspection
979
Forward Clutch Components
980
Forward Clutch Disassembly and Assembly
980
Forward Clutch Inspection
982
Direct Clutch Components
983
Direct Clutch Disassembly and Assembly
983
Direct Clutch Inspection
985
Center Support Components
986
Center Support Disassembly and Assembly
987
Center Support Inspection
990
Planetary Gears and Output Shaft Components
991
Planetary Gears and Output Shaft Disassembly and Assembly
992
Planetary Gears and Output Shaft Inspection
993
Valve Body Assembly Components
994
Automatic Transmission Unit Assembly
994
Special Tools and Equipment
1004
Recommended Service Material
1004
Special Tool
1004
Manual Transmission/Transaxle
1006
General Description
1006
Manual Transmission Construction
1006
Diagnostic Information and Procedures
1007
Manual Transmission Symptom Diagnosis
1007
Repair Instructions
1008
Manual Transmission Assembly Components
1008
Gear Shift Control Lever Rear Case Assembly Components
1010
Gear Shift Lever Front Case Assembly Components
1011
Gear Shift Shaft and Fork Components
1012
Input Shaft Assembly, Output Shaft Assembly and Countershaft Assembly Components
1013
Manual Transmission Oil Change
1014
Transmission Shift Control Lever Removal and Installation
1015
Transmission Shift Control Lever Inspection
1015
Back up Light Switch Removal and Installation
1016
Back up Light Switch Inspection
1016
Gear Shift Control Lever Rear Case Assembly Removal and Installation
1016
Gear Shift Control Lever Rear Case Assembly Disassembly and Reassembly
1017
Gear Shift Control Lever Rear Case Assembly Inspection
1017
Gear Shift Lever Front Case Assembly Removal and Installation
1017
Gear Shift Lever Front Case Assembly Disassembly and Reassembly
1018
Gear Shift Lever Front Case Assembly Inspection
1019
Engine Rear Mounting Replacement
1019
Manual Transmission Assembly Dismounting and Remounting
1019
Manual Transmission Unit Disassembly
1022
Manual Transmission Unit Reassembly
1023
Locating Spring Inspection
1026
Input Shaft Disassembly
1026
Input Shaft Inspection
1027
Input Shaft Reassembly
1028
Countershaft Disassembly and Assembly
1030
Countershaft and Reverse Idle Gear Inspection
1033
Output Shaft Disassembly and Assembly
1034
Output Shaft Inspection
1034
Manual Transmission Front Case Disassembly and Assembly
1035
Manual Transmission Adapter Case Disassembly and Assembly
1035
Special Tools and Equipment
1037
Recommended Service Material
1037
Special Tool
1037
Clutch
1039
Clutch (Hydraulic Type) Construction
1039
Component Location
1040
Clutch Fluid Pipe and Hose Location
1040
Diagnostic Information and Procedures
1040
Clutch (Hydraulic Type) Symptom Diagnosis
1040
Clutch Pedal Height Inspection
1041
Clutch Pedal Free Travel Check
1041
Clutch Fluid Inspection
1041
Repair Instructions
1042
Clutch Pedal Position (CPP) Switch Removal and Installation
1042
Clutch Pedal Position (CPP) Switch Inspection and Adjustment
1042
Clutch Fluid Pipe and Hose Removal and
1042
Clutch Fluid Pipe and Hose Inspection
1043
Clutch Master Cylinder Removal and Installation
1043
Clutch Master Cylinder Inspection
1044
Clutch Operating Cylinder Assembly Removal and Installation
1044
Clutch Cover, Clutch Disc and Flywheel Components
1045
Clutch Cover, Clutch Disc and Flywheel Removal and Installation
1046
Clutch Cover, Clutch Disc and Flywheel Inspection
1047
Specifications
1048
Tightening Torque Specifications
1048
Special Tools and Equipment
1048
Recommended Service Material
1048
Special Tool
1048
Steering
1049
Precautions
1051
Precautions for Steering
1051
Steering General Diagnosis
1052
Diagnostic Information and Procedures
1052
Steering Symptom Diagnosis
1052
Steering Wheel and Column
1053
Precautions
1053
Service Precautions of Air Bag Steering Wheel and Column
1053
Handling and Storage of Air Bag Steering Wheel and Column
1053
Disposal of Air Bag Steering Wheel and Column
1053
General Description
1053
Steering Wheel and Column Construction
1053
Diagnostic Information and Procedures
1055
Air Bag Steering Wheel and Column Symptom Diagnosis
1055
Air Bag Steering Wheel and Column Inspection and Repair Required after Accident
1055
Diagnosis and Servicing of Air Bag Steering
1055
Wheel and Column
1055
Repair Instructions
1055
Checking Steering Column for Accident
1055
Damage
1055
Steering Wheel Removal and Installation
1056
Contact Coil Cable Assembly Removal and Installation
1057
Contact Coil Cable Assembly Inspection
1059
Centering Contact Coil Cable Assembly
1059
Steering Column Assembly Removal and Installation
1059
Steering Column Assembly Inspection
1062
Ignition Switch Cylinder Assembly Removal and Installation (Without Keyless Start System)
1062
Steering Lock Assembly (Ignition Switch) Removal and Installation
1063
Adjustable Steering Column Release Lever Inspection
1063
Steering Upper Shaft Assembly Removal and Installation
1063
Steering Upper Shaft Assembly Inspection
1064
Steering Lower Shaft Assembly Removal and Installation
1065
Specifications
1066
Tightening Torque Specifications
1066
Special Tools and Equipment
1066
Special Tool
1066
Power Assisted Steering System
1067
Precautions
1067
P/S System Note
1067
General Description
1067
P/S System Construction
1067
Steering Gear Case Construction
1068
P/S Pump Construction
1068
Schematic and Routing Diagram
1069
P/S Fluid Flow Diagram
1069
Diagnostic Information and Procedures
1069
P/S System Symptom Diagnosis
1069
Steering Wheel Check
1070
Steering Force Check
1071
Steering Wheel Recovery Check
1071
Idle up System Check
1071
Hydraulic Pressure in P/S Circuit Check
1071
Repair Instructions
1073
P/S Fluid Change
1073
P/S Fluid Level Check
1073
P/S Fluid Leakage Check
1074
P/S System Air Bleeding Procedure
1074
P/S Pump and A/C Compressor
1075
Adjustment for M16 Engine Model
1075
P/S Pump and A/C Compressor (if Equipped) Drive Belt Removal and Installation for M16 Engine Model
1075
P/S Pump and A/C Compressor (if Equipped) Drive Belt Removal and Installation for J20 Engine Model
1076
Steering Rack Boot Check
1076
Tie-Rod End Boot Check
1076
Tie-Rod End Removal and Installation
1076
Tie-Rod End Ball Joint Inspection
1077
P/S Gear Case Assembly Components
1078
P/S Gear Case Assembly Removal and Installation
1079
Steering Gear Case Mount Bushing Removal and Installation
1080
Steering Gear Case Mount Bushing Inspection
1080
Installation
1080
P/S Pump Removal and Installation for M16
1084
Engine Model
1084
P/S Pump Removal and Installation for J20
1084
Model
1084
P/S Pump Assembly Components for J20
1086
Engine Model
1086
P/S Pump Disassembly and Assembly for
1086
Hvac
1091
Model
1092
Precautions
1094
Precautions for HVAC
1094
Heater and Ventilation
1095
General Description
1095
Heater and Ventilation Construction
1095
Body Ventilation Construction
1096
On-Board Diagnostic System Description
1096
HVAC Control System Description (for Vehicle Without a
1097
Schematic and Routing Diagram
1097
Heater and Ventilation Wiring Circuit Diagram
1097
Electronic Control Input / Output Table (for Vehicle Without a
1097
Electronic Components Location for Heater (for Vehicle Without a
1098
Diagnostic Information and Procedures
1099
Heater and Ventilation System Check
1099
Visual Inspection
1099
DTC Check
1099
DTC Clearance
1101
DTC Table
1101
Fail-Safe Table
1101
Scan Tool Data
1101
Heater and Ventilation Symptom Diagnosis
1102
Repair Instructions
1103
Blower Unit and Heater Unit Components
1103
HVAC Unit Removal and Installation
1103
Vehicle Without a
1103
HVAC Air Filter Removal and Installation
1103
HVAC Air Filter Inspection
1103
Blower Motor Removal and Installation
1103
Blower Motor Inspection
1103
Blower Motor Controller Removal and
1104
Blower Motor Controller Inspection
1104
Blower Motor Relay Inspection
1104
Heater Core Removal and Installation
1105
HVAC Control Module Removal and Installation
1105
HVAC Control Module and Its Circuits
1105
Air Flow Control Actuator Removal and
1105
Air Flow Control Actuator Inspection
1105
Temperature Control Actuator Removal and Installation
1106
Temperature Control Actuator Inspection
1106
Air Intake Control Actuator Removal and
1107
Air Intake Control Actuator Inspection
1107
Actuator Linkage Inspection
1107
Center Ventilation Louver Removal and
1108
Side Ventilation Louver Removal and
1108
Rear Duct Components
1109
Rear Duct Removal and Installation
1109
Air Conditioning System
1110
A/C System Caution
1110
Precautions on Servicing A/C System
1110
Precautions in Diagnosing Trouble
1110
Precautions on Handling Refrigerant HFC-134A
1110
Precautions on Servicing Refrigerant Line
1111
Precautions on Refrigerant Recovery
1112
Precautions on Refrigerant Charge
1112
Precautions on Replenishing Compressor Oil
1112
Precautions on Servicing Compressor Assembly
1113
General Description
1113
AUTO A/C System Description
1113
HVAC Control System Description
1113
Auto A/C Electronic Control Input / Output Table
1114
HVAC Control Module Operation Description
1114
A/C Refrigerant Type Description
1114
Sub-Cool A/C System Description
1115
A/C Evaporator Temperature Sensor
1116
On-Board Diagnostic System Description
1116
Component Location
1118
Major Components of A/C System
1118
A/C Control System Components Location
1119
Diagnostic Information and Procedures
1120
Air Conditioning System Check
1120
DTC Check
1121
DTC Clearance
1123
DTC Table
1123
Fail-Safe Table
1126
Scan Tool Data
1127
Visual Inspection
1129
A/C System Performance Inspection
1129
A/C System Symptom Diagnosis
1135
Abnormal Noise Diagnosis
1137
Abnormal Noise Symptom Diagnosis of A/C System
1137
DTC B1502: Inside Air Temperature Sensor And/Or Its Circuit Malfunction
1139
DTC B1503: A/C Evaporator Air Temperature Sensor And/Or Its Circuit Malfunction
1140
DTC B1504: Sunload Sensor And/Or Its Circuit Malfunction
1142
DTC B1511: Temperature Control Actuator (Position Sensor) And/Or Its Circuit Malfunction
1143
DTC B1512: Air Flow Control Actuator (Position Sensor) And/Or Its Circuit Malfunction
1146
DTC B1514: Air Flow Control Actuator And/Or Its Circuit Malfunction
1151
DTC B1520: Temperature Selector And/Or Its Circuit Malfunction
1153
DTC B1521: Blower Speed Selector And/Or Its Circuit Malfunction
1154
DTC B1530: Air Intake Control Actuator (Position Sensor) And/Or Its Circuit Malfunction
1154
DTC B1531: Air Intake Control Actuator And/Or Its Circuit Malfunction
1157
DTC B1546: A/C Refrigerant Pressure Malfunction
1159
DTC B1551: Serial Communication Circuit Malfunction
1160
DTC B1552: Serial Communication Circuit Malfunction
1162
DTC B1553: CAN Communication Circuit Malfunction
1162
DTC B1556: Camshaft Position (CMP) Sensor And/Or Its Circuit Malfunction
1163
DTC B1557: Wheel Speed Sensor And/Or Its Circuit Malfunction
1163
DTC B1561: Engine Coolant Temperature Sensor And/Or Its Circuit Malfunction
1163
DTC B1562: Outside Air Temperature Sensor And/Or Its Circuit Malfunction
1164
DTC B1563: A/C Refrigerant Pressure Sensor And/Or Its Circuit Malfunction
1164
HVAC Control Module and Its Circuits Inspection
1164
A/C System Inspection at ECM
1167
Operation Procedure for Charging A/C with Refrigerant
1168
A/C Condenser Assembly On-Vehicle Inspection
1172
A/C Condenser Assembly Removal and Installation
1172
Desiccant Removal and Installation
1173
HVAC Air Filter Removal and Installation
1174
HVAC Air Filter Inspection
1174
HVAC Unit Components
1175
HVAC Unit Removal and Installation
1176
A/C Evaporator Removal and Installation
1177
A/C Evaporator Inspection
1177
A/C Evaporator Temperature Sensor Removal and Installation
1177
A/C Evaporator Temperature Sensor Inspection
1177
Expansion Valve On-Vehicle Inspection
1178
Expansion Valve Removal and Installation
1178
A/C Refrigerant Pressure Sensor and Its Circuit Inspection
1178
A/C Refrigerant Pressure Sensor Removal and Installation
1179
Sunload Sensor Removal and Installation
1179
Sunload Sensor Inspection
1180
Inside Air Temperature Sensor Removal and Installation
1180
Inside Air Temperature Sensor Inspection
1180
Outside Air Temperature Sensor Removal and Installation
1180
Outside Air Temperature Sensor Inspection
1180
Air Flow Control Actuator Removal and Installation
1180
Air Flow Control Actuator Inspection
1180
Air Intake Control Actuator Removal and Installation
1181
Air Intake Control Actuator Inspection
1181
Temperature Control Actuator Removal and Installation
1181
Temperature Control Actuator Inspection
1181
HVAC Control Module Removal and Installation
1181
A/C Compressor Drive Belt Inspection and Adjustment
1181
A/C Compressor Drive Belt Removal and Installation
1181
A/C Compressor Relay Inspection
1181
Compressor Assembly On-Vehicle Inspection
1182
Compressor Assembly Removal and Installation for M16 Engine Model
1182
Compressor Assembly Removal and Installation for J20 Engine Model
1183
Magnet Clutch Components for M16 Engine Model
1184
Magnet Clutch Components for J20 Engine Model
1185
Magnet Clutch Operating Check for M16 Engine Model
1185
Magnet Clutch Operating Check for J20 Engine Model
1185
M16 Engine Model
1190
Thermal Switch Removal and Installation for M16 Engine Model
1190
Relief Valve On-Vehicle Inspection for M16
1190
Engine Model
1190
Relief Valve On-Vehicle Inspection for J20
1190
Special Tools and Equipment
1192
Recommended Service Material
1192
Special Tool
1192
Restraint
1193
Precautions
1195
Precautions on Restraint
1195
Seat Belts
1196
Precautions on Service and Diagnosis of Seat Belt
1196
General Description
1196
Seat Belt Construction
1196
Diagnostic Information and Procedures
1197
Repair and Inspection Required after Accident
1197
Repair Instructions
1198
Front Seat Belt Components
1198
Front Seat Belt Removal and Installation
1199
Front Seat Belt Inspection
1199
Rear Seat Belt Components
1201
Rear Seat Belt Removal and Installation
1202
Rear Seat Belt Inspection
1202
Tightening Torque Specifications
1202
Air Bag System
1203
Precautions on Service and Diagnosis of Air Bag System
1203
Precautions on Handling and Storage of Air Bag System Components
1203
Precautions on Disposal of Air Bag and Seat Belt Pretensioner
1207
General Description
1207
Air Bag System Construction
1207
Air Bag System Input / Output Table
1208
Schematic and Routing Diagram
1209
Air Bag System Wiring Circuit Diagram
1209
Component Location
1213
Air Bag System Components, Wiring and Connectors Location
1213
Diagnostic Information and Procedures
1214
Air Bag Diagnostic System Check
1214
Air Bag Diagnostic System Check Flow
1214
DTC Check
1215
DTC Clearance
1219
Scan Tool Data
1220
AIR BAG" Warning Lamp Comes on Steady
1221
AIR BAG" Warning Lamp Flashes
1225
AIR BAG" Warning Lamp Cannot Indicate Flashing Pattern of DTC (if Equipped with "AIR BAG" Monitor Coupler)
1226
DTC B1013: SDM Fault
1227
DTC B1016: Power Source Voltage High
1227
DTC B1017: Power Source Voltage Low
1229
DTC B1021: Air Bag Module Deployed
1231
DTC B1031: Driver Air Bag Initiator Circuit Resistance High
1232
DTC B1032: Driver Air Bag Initiator Circuit Resistance Low
1236
DTC B1033: Driver Air Bag Initiator Circuit Short to Ground
1239
DTC B1034: Driver Air Bag Initiator Circuit Short to Power Circuit
1242
DTC B1041: Passenger Air Bag Initiator Circuit Resistance High
1245
DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low
1248
DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground
1251
DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circuit
1254
DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance High
1257
DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circuit Resistance Low .8B-58
1260
DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground
1263
DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power Circuit
1266
DTC B1073 / B1077: Driver / Passenger Forward-Sensor Circuit Short to Ground
1269
DTC B1074 / B1078: Driver / Passenger Forward-Sensor Circuit Short to Power Circuit or Open
1271
DTC B1086 / B1096: Left / Right Side-Sensor Performance Problem
1273
DTC B1087 / B1097: Left / Right Side-Sensor Communication Error
1273
DTC B1321 / B1325: Left / Right Side-Air Bag Initiator Circuit Resistance High
1275
DTC B1322 / B1326: Left / Right Side-Air Bag Initiator Circuit Resistance Low
1279
DTC B1323 / B1327: Left / Right Side-Air Bag Initiator Circuit Short to Ground
1282
DTC B1324 / B1328: Left / Right Side-Air Bag Initiator Circuit Short to Power Circuit
1285
DTC B1331 / B1335: Left / Right Side Curtain-Air Bag Initiator Circuit Resistance High
1287
DTC B1332 / B1336: Left / Right Side Curtain-Air Bag Initiator Circuit Resistance Low
1290
DTC B1333 / B1337: Left / Right Side Curtain-Air Bag Initiator Circuit Short to Ground
1292
DTC B1334 / B1338: Left / Right Side Curtain-Air Bag Initiator Circuit Short to Power Circuit
1294
Inspection of Intermittent and Poor Connections
1295
Repair and Inspection Required after Accident
1296
Repair Instructions
1299
Disabling Air Bag System
1299
Enabling Air Bag System
1300
SDM Removal and Installation
1300
SDM Inspection
1301
Driver Air Bag (Inflator) Module Removal and Installation
1302
Driver Air Bag (Inflator) Module Inspection
1303
Passenger Air Bag (Inflator) Module Removal and Installation
1303
Passenger Air Bag (Inflator) Module Inspection
1305
Side-Air Bag (Inflator) Module Removal and Installation
1305
Side-Air Bag (Inflator) Inspection
1307
Side Curtain-Air Bag (Inflator) Module Removal and Installation
1307
Side Curtain-Air Bag (Inflator) Module Inspection
1309
Forward-Sensor Removal and Installation
1309
Forward-Sensor Inspection
1310
Side-Sensor Removal and Installation
1310
Side-Sensor Inspection
1311
Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal
1312
Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal
1322
Recommended Service Material
1324
Special Tool
1324
Body, Cab and Accessories
1327
Precautions
1333
Precautions on Body, Cab and Accessories
1333
Precautions for Body Service
1333
Fastener Caution for Body Service
1333
Cautions in Body Electrical System Servicing
1333
Precautions for Wiring System
1333
Wiring Systems
1334
General Description
1335
Wire / Connector Color Symbols
1335
Symbols and Marks
1336
How to Read Connector Layout Diagram
1338
How to Read Connector Codes and Terminal Nos
1339
How to Read Ground Point
1342
How to Read Power Supply Diagram
1343
Fuse Number
1343
How to Read System Circuit Diagram
1344
Engine Compartment
1346
B: A/C Compressor Wire / E: Main Harness, Front Height Sensor Wire (RHD)
1351
B: A/C Compressor Wire / E: Main Harness, Front Height Sensor Wire (LHD)
1353
Instrument Panel
1355
E: Main Harness, Controller Wire (RHD)
1355
E: Main Harness, Controller Wire (LHD)
1356
B: A/C Wire / F: Console Wire / G: Instrument Panel Harness / Q: A/B Wire (RHD)
1357
B: A/C Wire / F: Console Wire / G: Instrument Panel Harness / Q: A/B Wire (LHD)
1358
Door, Roof
1360
J: Front and Rear Door Wire, Rear Door Joint Wire / K: Roof Wire (RHD, 5Dr)
1360
J: Front and Rear Door Wire, Rear Door Joint Wire / K: Roof Wire (LHD, 5Dr)
1361
L: Floor Harness, Rear Height Sensor Wire / R: Fuel Pump Wire (RHD, 5Dr)
1364
L: Floor Harness, Rear Height Sensor Wire / R: Fuel Pump Wire (LHD, 5Dr)
1365
L: Floor Harness, Luggage Compartment Light Wire, Rear Height Sensor Wire / R: Fuel Pump Wire (RHD, 3Dr)
1367
L: Floor Harness, Luggage Compartment Light Wire, Rear Height Sensor Wire / R: Fuel Pump Wire (LHD, 3Dr)
1368
O: Rear End Door Harness
1370
Ground (Earth) Point
1371
Power Supply Diagram
1372
Fuses and the Protected Parts
1376
Fuses in Battery Fuse Box, Fuse Box No.1
1376
Fuse Box No.2 (in Power Integration No.1, Power Integration No.2), Relay Box
1377
Junction Block (J/B) Connector / Fuse Layout
1380
Fuse Side
1380
Junction Block Inner Circuit (Overview)
1381
Junction Block Inner Circuit (Detail)
1382
System Circuit Diagram
1386
A-1 Cranking System Circuit Diagram
1387
A-2 Charging System Circuit Diagram
1388
Ignition System Circuit Diagram (M16A)
1389
Ignition System Circuit Diagram (J20A)
1390
A-4 Cooling System Circuit Diagram
1391
Engine and A/C Control System Circuit Diagram (M16A)
1392
Engine and A/C Control System Circuit Diagram (J20A)
1397
A-6 A/T Control System Circuit Diagram
1402
A-7 Immobilizer System Circuit Diagram
1404
A-8 Body Control System Circuit Diagram
1405
A-10 4WD Control System Circuit Diagram
1410
B-1 Windshield Wiper and Washer Circuit Diagram
1412
B-2 Rear Wiper and Washer Circuit Diagram
1413
B-3 Rear Defogger Circuit Diagram
1414
B-4 Power Window Circuit Diagram
1415
B-5 Power Door Lock Circuit Diagram
1417
B-6 Power Mirror Circuit Diagram
1419
B-7 Horn Circuit Diagram
1420
B-8 Seat Heater Circuit Diagram
1421
B-9 Smart Key System Circuit Diagram
1422
B-10 Sliding Roof Circuit Diagram
1423
B-11 Headlight Cleaner Circuit Diagram
1424
C-1 Combination Meter Circuit Diagram
1425
Headlight System Circuit Diagram (One Bulb Type)
1427
Headlight System Circuit Diagram (with Projector Light)
1428
Headlight System Circuit Diagram (with Discharge Bulb)
1429
D-2 Position, Tail and Licence Plate Light System Circuit Diagram
1430
D-3 Front Fog Light System Circuit Diagram
1431
D-4 Illumination Light System Circuit Diagram
1432
D-5 Interior Light System Circuit Diagram
1433
D-6 Turn Signal and Hazard Warning Light System Circuit Diagram
1434
D-7 Brake Light System Circuit Diagram
1436
D-8 Back-Up Light System Circuit Diagram
1437
Headlight Beam Leveling System Circuit Diagram (Manual Leveling)
1438
Headlight Beam Leveling System Circuit Diagram (Auto Leveling)
1439
D-10 Rear Fog Light Circuit Diagram
1440
E-2 Auto A/C System Circuit Diagram
1441
Air-Bag System Circuit Diagram
1443
Air-Bag System Circuit Diagram
1444
F-2 Anti-Lock Brake System Circuit Diagram
1446
G-1 Audio System Circuit Diagram
1448
G-2 Multi Information Display / Accessory Socket System Circuit Diagram
1449
G-4 Navigation System Circuit Diagram
1450
List of Connectors
1451
Lighting Systems
1463
Precautions for Discharge Headlight Service (if Equipped)
1463
Precautions in Diagnosing Troubles (Vehicle Equipped with Auto Leveling Headlight System)
1463
General Description
1464
Discharge Headlight Description (if Equipped)
1464
Auto Leveling Headlight System Description (if Equipped)
1465
Auto-On Headlight System Description (if Equipped)
1467
System Description (if Equipped)
1468
Schematic and Routing Diagram
1468
Headlight Auto Leveling System Wiring Circuit Diagram
1468
Component Location
1469
Lighting System Components Location
1469
Interior Light System Location
1470
Diagnostic Information and Procedures
1470
Self-Diagnosis Function for Auto Leveling Headlight System
1470
Headlight Leveling Warning Light Check
1470
Headlight Symptom Diagnosis (Vehicle Equipped with Discharge Headlight)
1471
Headlight Symptom Diagnosis (Vehicle Not Equipped with Discharge Headlight)
1471
Auto-On Headlight System Symptom Diagnosis (if Equipped)
1472
DRL System Symptom Diagnosis (if Equipped)
1472
Headlight Auto Leveling System Symptom Diagnosis (if Equipped)
1473
Headlight Manual Leveling System Symptom Diagnosis (if Equipped)
1473
Turn Signal and Hazard Warning Light Symptom Diagnosis
1473
Clearance, Tail and License Plate Light Symptom Diagnosis
1474
Back-Up Light Symptom Diagnosis
1474
Stop (Brake) Lamp Symptom Diagnosis
1475
Front Fog Light (if Equipped) Symptom Diagnosis
1475
Rear Fog Light Symptom Diagnosis (if Equipped)
1475
Illumination Cancel System Symptom Diagnosis (if Equipped)
1475
Interior Light Symptom Diagnosis
1476
Auto-On Headlight Operation Inspection (if Equipped)
1476
DRL Operation Inspection (if Equipped)
1476
Inspection of Headlight Leveling Control Module and Its Circuit (Vehicle Equipped with Auto Leveling Headlight System)
1477
Repair Instructions
1479
Headlight Housing Removal and Installation
1479
Headlight Bulb Replacement
1479
Ballast Removal and Installation
1480
Igniter Removal and Installation
1481
Headlight Aiming Adjustment with Screen
1481
Headlight Switch (in Lighting Switch) Removal and Installation
1483
Headlight Switch (in Lighting Switch) Inspection
1483
Hazard Warning Switch Removal and Installation
1484
Hazard Warning Switch Inspection
1484
Stop (Brake) Lamp Switch Inspection
1484
Turn Signal Light Switch (in Lighting Switch) Removal and Installation
1485
Turn Signal Light Switch (in Lighting Switch) Inspection
1485
Turn Signal and Hazard Warning Relay Removal and Installation
1485
Turn Signal and Hazard Warning Relay Inspection
1485
License Lamp Assembly Removal and Installation
1486
Front Fog Light Assembly Removal and Installation (if Equipped)
1486
Front Fog Light Bulb Replacement (if Equipped)
1486
Front Fog Light Switch Inspection (if Equipped)
1487
Front Fog Light Relay Inspection (if Equipped)
1487
Front Fog Light Aiming Adjustment with Screen (if Equipped)
1487
Headlight Manual Leveling Switch (if Equipped) Inspection
1488
Headlight Leveling Actuator Inspection (if Equipped)
1489
Rear Fog Light Switch Inspection (if Equipped)
1489
Height Sensor Removal and Installation (if Equipped)
1490
Height Sensor and Its Circuit Inspection (if Equipped)
1491
Leveling Control Module Removal and Installation (if Equipped)
1491
Initialization of Auto Leveling Headlight System
1491
Illumination Cancel Switch (if Equipped) Inspection
1492
Auto-On Headlight Sensor Inspection (if Equipped)
1493
Tightening Torque Specifications
1493
Instrumentation / Driver Info. / Horn
1494
Precautions in Diagnosing Troubles for Combination Meter
1494
General Description
1494
CAN Communication Data of Combination Meter
1494
Schematic and Routing Diagram
1495
Combination Meter Circuit Diagram
1495
Component Location
1496
Audio System Component Location
1496
Diagnostic Information and Procedures
1497
Speedometer Symptom Diagnosis
1497
Tacho Meter Symptom Diagnosis
1497
Engine Coolant Temperature (ECT) Meter
1497
Fuel Meter Symptom Diagnosis
1497
Low Fuel Warning Light Symptom Diagnosis
1498
Oil Pressure Warning Light Symptom Diagnosis
1498
Brake and Parking Brake Warning Light Symptom Diagnosis
1499
Seat Belt Reminder Light Symptom Diagnosis (if Equipped)
1499
Illumination Indicator Symptom Diagnosis
1500
Headlight Auto Leveling Indicator Symptom Diagnosis (if Equipped)
1500
A/T Power Mode Indicator Symptom Diagnosis (A/T Model Only)
1500
A/T Shift Position Indicator (A/T Model Only) Symptom Diagnosis
1501
Charge Warning Light Symptom Diagnosis
1501
Main Beam (High Beam) Indicator Symptom Diagnosis
1501
Warning Buzzer Circuit Symptom Diagnosis
1502
Cigarette Lighter Symptom Diagnosis (if Equipped)
1502
Horn Symptom Diagnosis
1502
Information Display Symptom Diagnosis (if Equipped)
1503
Clock Symptom Diagnosis (if Equipped)
1503
Audio System Symptom Diagnosis (if Equipped)
1504
Remote Audio Control Switch Symptom Diagnosis (if Equipped)
1505
Navigation Symptom Diagnosis (if Equipped)
1505
Repair Instructions
1505
Ignition Switch Removal and Installation
1505
Ignition Switch Inspection
1506
Combination Meter Removal and Installation
1506
Fuel Level Sensor Removal and Installation
1506
Fuel Level Sensor Inspection
1507
Oil Pressure Switch Removal and Installation
1507
Oil Pressure Switch Inspection
1508
Engine Coolant Temperature (ECT) Sensor Inspection
1508
Brake Fluid Level Switch Inspection
1508
Parking Brake Switch Inspection
1508
Door Switch (Front / Rear / Rear End Door) Inspection
1509
Outside Air Temperature Sensor Removal and Installation (if Equipped)
1509
Outside Air Temperature Sensor Inspection (if Equipped)
1509
Instrument Panel Removal and Installation
1509
Information Display (Clock) Removal and Installation
1511
Audio Unit Removal and Installation
1511
Front Speaker Removal and Installation
1512
Rear Speaker Removal and Installation (5 Door Model)
1512
Rear Speaker Removal and Installation (3 Door Model)
1512
GPS Antenna Removal and Installation (if Equipped)
1513
Horn Removal and Installation
1513
Horn Inspection
1513
Horn Relay Inspection
1513
Antenna Base Removal and Installation
1514
Remote Audio Control Switch Removal and Installation
1514
Remote Audio Control Switch Inspection
1515
Tightening Torque Specifications
1515
Wipers / Washers
1516
Diagnostic Information and Procedures
1516
Front Wiper and Washer Symptom Diagnosis
1516
Rear Wiper and Washer Symptom Diagnosis (if Equipped)
1516
Headlight Washer Symptom Diagnosis (if Equipped)
1517
Headlight Washer Operation Inspection
1517
Inspection of Headlight Washer Control Module and Its Circuit
1518
Repair Instructions
1519
Wipers and Washers Components
1519
Washer Tank and Washer Pump Removal and Installation
1520
Washer Pump Inspection
1520
Windshield Wiper Removal and Installation
1521
Windshield Wiper Motor Inspection
1522
Rear Wiper Removal and Installation (if Equipped)
1523
Rear Wiper Motor Inspection (if Equipped)
1524
Windshield Wiper and Washer Switch Removal and Installation
1525
Windshield Wiper and Washer Switch Inspection
1526
Rear Wiper and Washer Switch Removal and Installation
1527
Rear Wiper and Washer Switch Inspection
1527
Rear Wiper Relay Removal and Installation
1527
Rear Wiper Relay Inspection
1528
Headlight Washer Switch Inspection (if Equipped)
1528
Headlight Washer Pump Removal and Installation (if Equipped)
1528
Headlight Washer Nozzle Removal and Installation (if Equipped)
1528
Tightening Torque Specifications
1529
Glass / Windows / Mirrors
1530
General Description
1530
Rear End Door Window Defogger System Description
1530
Windshield Construction
1530
Rear Quarter Window Construction
1531
Diagnostic Information and Procedures
1532
Rear End Door Window Defogger Symptom Diagnosis
1532
Power Window Control System Symptom Diagnosis
1533
Power Door Mirror Control System Symptom Diagnosis (if Equipped)
1533
Door Mirror Heater Symptom Diagnosis (if Equipped)
1533
Repair Instructions
1534
Windshield Removal and Installation
1534
Rear Quarter Window Removal and Installation
1537
Front Door Window Components
1542
Front Door Glass Removal and Installation
1543
Front Door Window Regulator Removal and Installation
1544
Front Door Window Regulator Inspection
1544
Rear Door Window Components
1545
Rear Door Glass Removal and Installation
1545
Rear Door Window Regulator Removal and Installation
1546
Rear Door Window Regulator Inspection
1547
Rear End Door Window Components
1547
Rear End Door Glass Removal and Installation
1548
Rear End Door Window Defogger Relay Inspection
1548
Rear End Door Window Defogger Wire Inspection
1549
Rear End Door Window Defogger Wire Repair
1549
Power Window Main Switch Inspection
1549
Power Window Sub Switch Inspection
1551
Door Mirror Components
1551
Door Mirror Removal and Installation
1552
Power Door Mirror Switch Inspection (if Equipped)
1552
Power Door Mirror Actuator Inspection (if Equipped)
1552
Door Mirror Heater Inspection (if Equipped)
1552
Door Mirror Heater Relay Inspection (if Equipped)
1553
Special Tools and Equipment
1553
Recommended Service Material
1553
Security and Locks
1554
General Description
1554
Key Coding Construction
1554
Component Location
1554
Power Door Lock and Keyless Entry System Component Location
1554
Diagnostic Information and Procedures
1555
Power Door Lock System Symptom Diagnosis
1555
Power Door Lock System Operation Inspection
1555
Keyless Entry System Symptom Diagnosis (if Equipped)
1556
Keyless Entry System Operation Inspection
1557
Door Lock Function of Keyless Start System Symptom Diagnosis (if Equipped)
1557
Repair Instructions
1557
Front Door Lock Assembly Components
1557
Front Door Lock Assembly Removal and Installation
1558
Front Door Lock Assembly Inspection
1559
Power Door Lock Switch Inspection
1560
Door Key Cylinder Switch Inspection
1560
Power Door Lock Actuator Inspection (if Equipped)
1560
Rear Door Lock Assembly Components
1562
Rear Door Lock Assembly Removal and Installation
1563
Rear Door Lock Assembly Inspection
1563
Rear End Door Lock Assembly Components
1564
Rear End Door Lock Assembly Removal and Installation
1564
Rear End Door Lock Assembly Inspection
1565
Replacement of Transmitter Battery
1565
Programming Transmitter Code for Keyless Entry System (Vehicle Without Keyless Start System)
1566
Keyless Entry Receiver Removal and Installation
1566
Keyless Entry Receiver and Its Circuit Inspection
1567
Tightening Torque Specifications
1568
Special Tools and Equipment
1568
Recommended Service Material
1568
Seats
1569
Diagnostic Information and Procedures
1569
Front Seat Heater Symptom Diagnosis (if Equipped)
1569
Repair Instructions
1569
Front Seat Components
1569
Front Seat Removal and Installation
1570
Front Seat Heater Switch (Driver and Passenger Side) Inspection (if Equipped)
1570
Front Seat Heater Wire Inspection (if Equipped)
1570
Rear Seat Components
1571
Rear Seat Removal and Installation
1571
Tightening Torque Specifications
1571
Interior Trim
1572
Repair Instructions
1572
Floor Carpet Removal and Installation
1572
Head Lining Removal and Installation
1572
Console Box Components
1575
Sun Roof / T-Top / Convertible Top
1576
General Description
1576
Power Sliding (Sun) Roof System Description
1576
Diagnostic Information and Procedures
1576
Power Sliding (Sun) Roof System Symptom Diagnosis
1576
Repair Instructions
1576
Sliding (Sun) Roof Glass Components
1576
Sliding (Sun) Roof Glass Removal and Installation
1577
Sliding (Sun) Roof Glass Adjustment
1577
Sliding (Sun) Roof Switch Inspection
1577
Sliding (Sun) Roof Motor Removal and Installation
1578
Sliding (Sun) Roof System Circuit and Motor Inspection
1578
Sliding (Sun) Roof Assembly Components
1579
Sliding (Sun) Roof Assembly Removal and Installation
1580
Sliding (Sun) Roof Assembly Disassembly and Reassembly
1581
Hood / Fenders / Doors
1582
Repair Instructions
1582
Hood Removal and Installation
1582
Hood Inspection and Adjustment
1582
Front Fender Components
1583
Front Fender Removal and Installation
1583
Front Door Assembly Components
1584
Front Door Assembly Removal and Installation
1585
Rear Door Assembly Components
1586
Rear Door Assembly Removal and Installation
1586
Rear End Door Assembly Components
1587
Rear End Door Assembly Removal and Installation
1588
Tightening Torque Specifications
1589
Special Tools and Equipment
1589
Recommended Service Material
1589
Body Structure
1590
Repair Instructions
1590
Front Bumper Components
1590
Rear Bumper Components
1591
Cowl Top Components
1592
Body Dimensions
1593
Panel Clearance
1603
Paint / Coatings
1605
General Description
1605
Anti-Corrosion Treatment Construction
1605
Plastic Parts Finishing
1606
Component Location
1606
Sealant Application Areas
1606
Under Coating Application Areas
1616
Anti-Corrosion Compound Application Area
1620
Exterior Trim
1622
Repair Instructions
1622
Control Systems
1625
Precautions
1627
Precautions for Control Systems
1627
Cruise Control System
1628
General Description
1628
Cruise Control System Construction
1628
Components and Functions of Cruise Control System
1629
Cancel Conditions of Cruise Control System
1630
Input / Output Diagram
1630
Schematic and Routing Diagram
1631
Cruise Control System Wiring Diagram
1631
Diagnostic Information and Procedures
1632
Cruise Control System Symptom Diagnosis
1632
Inspection of Cruise Control System Circuit
1633
Repair Instructions
1635
Cruise Control Switch Removal and Installation
1635
Cruise Control Switch Inspection
1635
CPP Switch (for Cruise Control) Removal and Installation
1635
Clutch Pedal Position (CPP) Switch (for Cruise Control) Inspection and Adjustment
1636
Stop (Brake) Lamp Switch Removal and Installation
1636
Stop (Brake) Lamp Switch Inspection
1636
ECM Removal and Installation
1636
Tightening Torque Specifications
1636
Body Electrical Control System
1637
Precautions in Diagnosing Trouble
1637
General Description
1637
BCM General Description
1637
CAN Communication for BCM
1637
Schematic and Routing Diagram
1638
Connector Layout Diagram of BCM
1640
Component Location
1641
BCM and Related System Component Location
1641
Diagnostic Information and Procedures
1642
BCM Self-Diagnosis Function
1642
Body Electrical Control System Check
1644
Scan Tool Data
1646
DTC Check
1648
DTC Clearance
1649
BCM Power Circuit and Ground Circuit Check
1650
DTC B1133 (DTC No. 1133): Battery Voltage too High
1651
Dtc B1141 / Dtc B1142 / Dtc B1143
1652
Temperature (Ambient Temp.) Sensor
1653
DTC B1150 (No. 1150): Air Bag Communication Circuit Malfunction
1653
DTC B1157 (No. 1157) Air Bag Deployment Signal Input
1655
DTC B1170 (No. 1170): EEPROM Access Error
1655
DTC U1073 (No. 1073): Control Module Communication Bus off
1656
DTC U1100 (No. 1100): Lost Communication with ECM
1659
DTC U1101 (No. 1101): Lost Communication with TCM
1661
DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module
1663
Inspection of BCM and Its Circuits
1665
Repair Instructions
1671
BCM Removal and Installation
1671
Outside Air Temperature Sensor Removal and Installation
1671
Outside Air Temperature Sensor Inspection
1672
Special Tools and Equipment
1672
Special Tool
1672
Immobilizer Control System
1673
Precautions
1673
Precautions in Diagnosing Troubles
1673
Precaution in Replacing ECM
1673
Precautions in Handling Immobilizer Control System
1673
General Description
1674
Immobilizer Control System Introduction
1674
Immobilizer Control System Components Location
1674
On-Board Diagnostic System Description (Self-Diagnosis Function)
1675
Schematic and Routing Diagram
1676
Immobilizer Control System Wiring Circuit Diagram
1676
Diagnostic Information and Procedures
1677
Immobilizer Control System Check
1677
Diagnostic Trouble Code (DTC) Check
1678
Diagnostic Trouble Code (DTC) Clearance
1678
Diagnostic Trouble Code (DTC) Table
1678
Scan Tool Data
1679
Immobilizer Indicator Lamp Does Not Come on with Ignition Switch on and Engine Stop
1680
Immobilizer Indicator Lamp Remains on after Engine Start
1681
DTC P1614: Transponder Response Error
1681
DTC P1615: Steering Lock Unit Communication Error (for Vehicle with Keyless Start System)
1682
DTC P1616: Unregistered Keyless Start Control Module (for Vehicle with Keyless Start System)
1685
DTC P1618: Keyless Start Control Module CAN Communication Error (for Vehicle with Keyless Start System)
1685
DTC P1621: Immobilizer Communication Line Error
1687
DTC P1622: EEPROM Error
1690
DTC P1623: Unregistered Transponder
1690
DTC P1625: Immobilizer Antenna Error
1691
DTC P1636: Immobilizer Information Registration Failure
1692
DTC P1638: Immobilizer Information Mismatched
1693
Inspection of Immobilizer Control Module (ICM) and Its Circuit
1694
Repair Instructions
1696
Immobilizer Control Module (ICM) Removal and Installation
1696
Registration of the Ignition Key
1696
Procedure after ECM Replacement
1696
Special Tools and Equipment
1697
Special Tool
1697
Keyless Start System
1698
General Description
1698
Keyless Start System Description
1698
Parts and Functions
1699
Keyless Engine Start Function
1700
Door Lock Function of Keyless Start System
1701
Operation Area of Remote Controller
1702
Alarm Function
1703
CAN Communication of Keyless Start System
1703
Schematic and Routing Diagram
1704
Keyless Start System Electric Wiring Circuit Diagram
1704
Diagnostic Information and Procedures
1705
Precautions in Diagnosing Troubles
1705
Self-Diagnosis Function
1705
Keyless Start System Diagnosis Introduction
1705
Keyless Start System Check
1705
Customer Questionnaire (Example)
1706
Key Indicator Lamp Check
1707
DTC Check
1707
DTC Table
1708
DTC Clearance
1709
Keyless Start System Symptom Diagnosis
1709
Keyless Start System Operation Inspection
1710
Door Lock Operation (Keyless Start System)
1711
Inspection of Keyless Start Control Module and Its Circuits
1711
No DTC Detection after Performing DTC Check
1716
Key Indicator Lamp Circuit Check (Key Indicator Lamp Doesn't Light When Ignition Knob Switch Is Pushed.)
1718
Keyless Start Control Module Power and Ground Circuit Check
1719
DTC No. 11: Communication Error with Steering Lock Unit
1720
DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction
1722
DTC No. 21 / No. 22: Internal Error of Keyless Start Control Module (EEPROM Reading Error) / (EEPROM Writing Error)
1722
DTC No. 31: Lost Communication with BCM
1723
DTC No. 33: Control Module Communication Bus off
1725
DTC No. 51 / No. 52 / No. 53: Driver Side / Passenger Side / Rear End Door Request Switch Failure
1727
Repair Instructions
1729
Antennas and Request Switches Removal and Installation
1729
Front Door (Driver and Passenger Side) Rear End Door Request Switch Inspection
1730
Steering Lock Unit Removal and Installation
1730
Steering Lock Unit Inspection
1730
Front Door Lock Switch Inspection
1730
Keyless Start Control Module Removal and Installation
1731
Remote Controller Inspection
1731
Replacement of Remote Controller Battery
1731
Registration Procedure for Remote Controller ID Code
1732
Other manuals for Suzuki GRAND VITARA
Service Manual
518 pages
Manual
184 pages
Brochure
5 pages
4
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Suzuki GRAND VITARA Specifications
General
Brand
Suzuki
Model
GRAND VITARA
Category
Automobile
Language
English
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