Name: Suzuki Grand Vitara 2005
Brand: Suzuki
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7B-75 Air Conditioning System:

Magnet Clutch Components for M16 Engine Model

S5JB0A7206044

(b)

(a)

I5JB0A720060-01

1. Armature plate bolt 5. Shim(s) 9. Thermal switch

2. Armature plate 6. Magnet clutch coil : 15 N⋅m (1.5 kgf-m, 11.0 lb-ft)

3. Circlip 7. Compressor body assembly : 4.9 N⋅m (0.49 kgf-m, 4.0 lb-ft)

4. Magnet clutch 8. Magnet clutch coil bolt : Do not reuse.

Table of Contents5
Precautions7
Air Bag Locations8
Precautions8
Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System8
Diagnosis, Servicing and Handling9
General Precautions11
Precaution in Servicing Full-Time 4WD Vehicle14
Precautions for Catalytic Converter15
Precaution for CAN Communication System16
Precautions for Electrical Circuit Service16
Precautions for Installing Mobile Communication Equipment18
Air Bag Warning18
Discharge Headlight Warning18
A/C System Caution18
Fastener Caution18
Suspension Caution19
Wheels and Tires Caution19
Brakes Caution and Note19
Differential Gear Oil Note19
Repair Instructions19
Electrical Circuit Inspection Procedure19
Intermittent and Poor Connection Inspection22
General Information23
General Information24
General Description24
Abbreviations24
Symbols25
Wire Color Symbols26
Fastener Information26
General Information27
Vehicle Lifting Points28
Engine Supporting Points30
Vehicle Identification Number30
Engine Identification Number30
Transmission Identification Number30
Component Location31
Warning, Caution and Information Label Location31
Maintenance and Lubrication33
Precautions33
Precautions for Maintenance and Lubrication33
Scheduled Maintenance33
Maintenance Schedule under Normal Driving Conditions33
Maintenance Recommended under Severe Driving Conditions34
Repair Instructions36
Engine Accessory Drive Belt Inspection36
Engine Accessory Drive Belt Replacement36
Valve Lash (Clearance) Inspection36
Engine Oil and Filter Change37
Engine Coolant Change38
Exhaust System Inspection39
Spark Plugs Replacement39
Air Cleaner Filter Inspection39
Air Cleaner Filter Replacement39
Fuel Lines and Connections Inspection39
Fuel Filter Replacement39
Fuel Tank Inspection39
Crankcase Ventilation Hoses and Connections Inspection (Vehicle Without A/F Sensor)39
PCV Valve Inspection39
Fuel Evaporative Emission Control System Inspection40
Brake Discs and Pads Inspection40
Brake Drums and Shoes Inspection40
Brake Hoses and Pipes Inspection40
Brake Fluid Change40
Parking Brake Lever and Cable Inspection41
Clutch Fluid Inspection41
Tire / Wheel Inspection and Rotation41
Wheel Discs Inspection42
Wheel Bearing Inspection42
Suspension System Inspection42
Steering System Inspection42
Propeller Shafts and Drive Shafts Inspection43
Manual Transmission Oil Inspection43
Manual Transmission Oil Change43
Automatic Transmission Fluid Inspection43
Automatic Transmission Fluid Change44
Automatic Transmission Fluid Cooler Hose Inspection44
Transfer Oil Inspection (if Equipped)44
Differential Oil Inspection44
Transfer (if Equipped) and Differential Oil Change44
Power Steering (P/S) System Inspection45
All Hinges, Latches and Locks Inspection45
HVAC Air Filter Inspection (if Equipped)45
HVAC Air Filter Replacement (if Equipped)45
Final Inspection for Maintenance Service45
Specifications47
Tightening Torque Specifications47
Special Tools and Equipment47
Recommended Fluids and Lubricants47
Special Tool47
Engine49
Precautions55
Precautions for Engine55
Engine General Information and Diagnosis56
Precautions56
Precautions on Engine Service56
Precautions in Diagnosing Trouble56
Precautions for DTC Troubleshooting57
Precautions of ECM Circuit Inspection57
Precautions of Electric Throttle Body System Calibration57
General Description57
Statement on Cleanliness and Care57
Engine Diagnosis General Description58
On-Board Diagnostic System Description58
Engine and Emission Control System Description61
CAN Communication System Description61
Air Intake System Description64
Description of Electric Throttle Body System65
Description of Electric Throttle Body System Calibration66
Generator Control System Description66
A/F Sensor Description67
Electronic Control System Description68
Engine and Emission Control Input / Output Table76
Schematic and Routing Diagram77
Engine and Emission Control System Diagram77
Component Location78
Electronic Control System Components Location78
Diagnostic Information and Procedures80
Engine and Emission Control System Check80
Malfunction Indicator Lamp (MIL) Check83
DTC Check83
DTC Clearance84
DTC Table85
Fail-Safe Table91
Scan Tool Data92
Visual Inspection98
Engine Basic Inspection99
Engine Symptom Diagnosis103
Malfunction Indicator Lamp Does Not Come on with Ignition Switch on and Engine Stop (but Engine Can be Started)112
Wiring Diagram112
Malfunction Indicator Lamp Remains on after Engine Starts114
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 / Performance127
DTC P0102: Mass Air Flow Circuit Low Input130
DTC P0103: Mass Air Flow Circuit High Input132
DTC P0106: Manifold Absolute Pressure Range / Performance134
DTC P0107: Manifold Absolute Pressure Circuit Low Input135
DTC P0108: Manifold Absolute Pressure Circuit High Input137
DTC P0111: Intake Air Temperature Circuit Range / Performance139
DTC P0112: Intake Air Temperature Sensor Circuit Low142
DTC P0113: Intake Air Temperature Sensor Circuit High144
DTC P0116: Engine Coolant Temperature Circuit Range / Performance146
DTC P0117: Engine Coolant Temperature Circuit Low149
DTC P0118: Engine Coolant Temperature Circuit High150
DTC P0122: Throttle Position Sensor (Main) Circuit Low153
DTC P0123: Throttle Position Sensor (Main) Circuit High156
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 Rich166
DTC P0222: Throttle Position Sensor (Sub) Circuit Low170
DTC P0223: Throttle Position Sensor (Sub) Circuit High173
DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected176
DTC P0327 / P0328: Knock Sensor Circuit Low / High178
DTC P0335: Crankshaft Position (CKP) Sensor Circuit (for J20 Engine)180
Dtc Confirmation Procedure180
DTC P0335: Crankshaft Position (CKP) Sensor Circuit (for M16 Engine)182
DTC P0340: Camshaft Position (CMP) Sensor Circuit185
DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected188
DTC P0403: Exhaust Gas Recirculation Control Circuit191
DTC P0420: Catalyst System Efficiency below Threshold193
DTC P0443: Evaporative Emission System Purge Control Valve Circuit195
DTC P0462: Fuel Level Sensor Circuit Low197
DTC P0463: Fuel Level Sensor Circuit High199
DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit201
DTC P0500: Vehicle Speed Sensor (VSS) Malfunction205
DTC P0504: Brake Switch "A"/"B" Correlation (for J20 Engine)207
DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low209
DTC P0533: A/C Refrigerant Pressure Sensor Circuit High211
DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance212
DTC P0616: Starter Relay Circuit Low213
DTC P0617: Starter Relay Circuit High215
DTC P0620: Generator Control Circuit216
DTC P0625 / P0626: Generator Field Terminal Circuit Low / High218
DTC P0660: Intake Manifold Tuning Valve Control Circuit / Open (for J20 Engine)220
DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High222
DTC P1510: ECM Back-Up Power Supply Malfunction224
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 / Performance242
DTC P2102: Throttle Actuator Control Motor Circuit Low244
DTC P2103: Throttle Actuator Control Motor Circuit High246
DTC P2111: Throttle Actuator Control System - Stuck Open247
DTC P2119: Throttle Actuator Control Throttle Body Range / Performance248
DTC P2122: Pedal Position Sensor (Main) Circuit Low Input250
DTC P2123: Pedal Position Sensor (Main) Circuit High Input253
DTC P2127: Pedal Position Sensor (Sub) Circuit Low Input255
DTC P2128: Pedal Position Sensor (Sub) Circuit High Input257
DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation260
DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation263
DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction265
Inspection of ECM and Its Circuits267
ECM Power and Ground Circuit Check289
Fuel Injector Circuit Check293
Fuel Pump and Its Circuit Check295
Fuel Pressure Check298
A/C System Circuits Check300
Electric Load Signal Circuit Check303
Radiator Cooling Fan Low Speed Control System Check305
Troubleshooting305
Radiator Cooling Fan High Speed Control System Check308
Repair Instructions310
Idle Speed and IAC Throttle Valve Opening Inspection310
Special Tools and Equipment311
Special Tool311
Aux. Emission Control Devices312
Diagnostic Information and Procedures312
EGR System Inspection312
Repair Instructions312
EVAP Canister Purge Inspection312
EVAP Canister Purge Valve and Its Circuit Inspection313
Vacuum Passage Inspection313
Vacuum Hose and Purge Valve Chamber Inspection314
EVAP Canister Purge Valve Inspection314
EVAP Canister Inspection315
EGR Valve Removal and Installation315
EGR Valve Inspection315
PCV Hose Inspection315
PCV Valve Removal and Installation316
PCV Valve Inspection316
Specifications317
Tightening Torque Specifications317
Special Tools and Equipment317
Recommended Service Material317
Special Tool317
Engine Electrical Devices318
Repair Instructions318
Engine Control Module (ECM) Removal and Installation318
Manifold Absolute Pressure (MAP) Sensor Inspection318
Electric Throttle Body Assembly On-Vehicle Inspection319
Electric Throttle Body System Calibration321
Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection322
Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation322
Accelerator Pedal Position (APP) Sensor Assembly Inspection323
Engine Coolant Temperature (ECT) Sensor Removal and Installation323
Engine Coolant Temperature (ECT) Sensor Inspection324
Air Fuel Ratio (A/F) Sensor On-Vehicle Inspection324
Heated Oxygen Sensor (HO2S-2) Heater On-Vehicle Inspection325
Air Fuel Ratio (A/F) Sensor, Heated Oxygen Sensor (HO2S-2) Removal and Installation325
Camshaft Position (CMP) Sensor Removal and Installation325
Camshaft Position (CMP) Sensor Inspection326
Crankshaft Position (CKP) Sensor Removal and Installation326
Crankshaft Position (CKP) Sensor Inspection327
Knock Sensor Removal and Installation328
Control Relay Inspection329
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection330
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation330
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection331
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
Specifications334
Engine Mechanical335
For M16A Engine with VVT335
General Description335
Engine Construction Description335
Camshaft Position Control (VVT Variable Valve Timing) System Description336
Diagnostic Information and Procedures338
Compression Check338
Engine Vacuum Check339
Valve Lash (Clearance) Inspection340
Repair Instructions342
Air Cleaner Filter Removal and Installation342
Air Cleaner Filter Inspection and Cleaning343
Cylinder Head Cover Removal and Installation343
Throttle Body and Intake Manifold Components345
Throttle Body On-Vehicle Inspection345
Electric Throttle Body Assembly Removal and Installation346
Throttle Body Cleaning346
Intake Manifold Removal and Installation347
Engine Mountings Components348
Engine Assembly Removal and Installation348
Timing Chain Cover Components352
Timing Chain Cover Removal and Installation353
Timing Chain Cover Inspection355
Oil Control Valve Removal and Installation355
Oil Control Valve Inspection356
Timing Chain and Chain Tensioner Components357
Timing Chain and Chain Tensioner Removal and Installation357
Timing Chain and Chain Tensioner Inspection360
Camshaft, Tappet and Shim Components361
Camshaft, Tappet and Shim Removal and Installation361
Camshaft, Tappet and Shim Inspection364
Valves and Cylinder Head Components367
Valves and Cylinder Head Removal and Installation368
Valves and Cylinder Head Disassembly and Assembly369
Valves and Valve Guides Inspection372
Cylinder Head Inspection374
Valve Spring Inspection375
Pistons, Piston Rings, Connecting Rods and Cylinders Components376
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation376
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly378
Cylinders, Pistons and Piston Rings Inspection379
Piston Pins and Connecting Rods Inspection381
Crank Pin and Connecting Rod Bearings Inspection382
Main Bearings, Crankshaft and Cylinder Block Components386
Main Bearings, Crankshaft and Cylinder Block Removal and Installation387
Crankshaft Inspection390
Main Bearings Inspection391
Sensor Plate Inspection395
Rear Oil Seal Inspection395
Flywheel Inspection396
Cylinder Block Inspection396
Specifications397
Tightening Torque Specifications397
Special Tools and Equipment398
Recommended Service Material398
Special Tool398
For J20 Engine400
General Description400
Engine Construction Description400
Air Cleaner Element Introduction402
IMT (Intake Manifold Tuning) System402
Diagnostic Information and Procedures404
Compression Check404
Engine Vacuum Check405
Valve Lash (Clearance) Inspection406
Repair Instructions409
Air Cleaner Assembly Removal and Installation409
Air Cleaner Filter Removal and Installation409
Air Cleaner Filter Inspection and Cleaning409
Throttle Body and Intake Manifold Components410
Throttle Body On-Vehicle Inspection410
Electric Throttle Body Assembly Removal and Installation410
Throttle Body Cleaning411
Intake Manifold Removal and Installation411
Cylinder Head Cover Removal and Installation412
Engine Mountings Components414
Engine Assembly Removal and Installation415
Timing Chain Cover Components418
Timing Chain Cover Removal and Installation418
Timing Chain Cover Cleaning and Inspection421
2Nd Timing Chain and Chain Tensioner Components421
Tightening Torque421
2Nd Timing Chain and Chain Tensioner Removal and Installation422
2Nd Timing Chain and Chain Tensioner Inspection424
1St Timing Chain and Chain Tensioner Components425
Camshaft Sprocket425
1St Timing Chain and Chain Tensioner Removal and Installation426
1St Timing Chain and Chain Tensioner Inspection428
Camshafts, Tappet and Shim Components429
Camshafts, Tappet and Shim Removal and Installation429
Camshaft, Tappet and Shim Inspection431
Valves and Cylinder Head Components433
Valves and Cylinder Head Removal and Installation433
Valves and Cylinder Head Disassembly and Assembly435
Valves and Valve Guides Inspection438
Cylinder Head Inspection440
Valve Spring Inspection441
Pistons, Piston Rings, Connecting Rods and Cylinders Components442
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation442
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly443
Pistons, Piston Rings, Connecting Rods and Cylinders Inspection and Cleaning446
Main Bearings, Crankshaft and Cylinder Block Components452
Main Bearings, Crankshaft and Cylinder Block Removal and Installation453
Main Bearings, Crankshaft and Cylinder Block Inspection456
Specifications463
Tightening Torque Specifications463
Special Tools and Equipment464
Recommended Service Material464
Special Tool464
Engine Lubrication System467
For M16A Engine with VVT467
General Description467
Engine Lubrication Description467
Diagnostic Information and Procedures469
Oil Pressure Check469
Repair Instructions470
Oil Pan and Oil Pump Strainer Components470
Oil Pan and Oil Pump Strainer Removal and Installation471
Oil Pan and Oil Pump Strainer Cleaning472
Oil Pump Components473
Oil Pump Removal and Installation473
Oil Pump Disassembly and Reassembly473
Oil Pump Inspection474
Specifications476
Tightening Torque Specifications476
Special Tools and Equipment476
Recommended Service Material476
Special Tool476
For J20 Engine477
General Description477
Engine Lubrication Description477
Diagnostic Information and Procedures479
Oil Pressure Check479
Repair Instructions480
Oil Pan and Oil Pump Strainer Components480
Oil Pan and Oil Pump Strainer Removal and Installation481
Oil Pan and Oil Pump Strainer Cleaning482
Oil Pump Components482
Oil Pump Removal and Installation483
Oil Pump Disassembly and Assembly483
Oil Pump Inspection484
Special Tools and Equipment486
Recommended Service Material486
Special Tool486
Engine Cooling System487
General Description487
Cooling System Description487
Coolant Description487
Schematic and Routing Diagram488
Coolant Circulation488
Diagnostic Information and Procedures489
Engine Cooling Symptom Diagnosis489
Repair Instructions490
Cooling System Components490
Coolant Level Check492
Engine Cooling System Inspection and Cleaning492
Cooling System Draining493
Cooling System Flush and Refill493
Cooling Water Pipes or Hoses Removal and Installation494
Thermostat Removal and Installation494
Thermostat Removal and Installation495
Thermostat Inspection495
Radiator Cooling Fan Motor On-Vehicle496
Inspection496
Radiator Cooling Fan Relay Inspection496
Radiator Cooling Fan Assembly Removal and Installation497
Radiator On-Vehicle Inspection and Cleaning497
Radiator Removal and Installation498
Water Pump Removal and Installation498
Water Pump Removal and Installation499
Water Pump Inspection500
Specifications500
Tightening Torque Specifications500
Special Tools and Equipment500
Recommended Service Material500
Fuel System501
Precautions501
Precautions on Fuel System Service501
General Description501
Fuel System Description501
Fuel Delivery System Description501
Fuel Pump Description502
Schematic and Routing Diagram502
Fuel Delivery System Diagram502
Diagnostic Information and Procedures503
Fuel Pressure Inspection503
Fuel Cut Operation Inspection504
Repair Instructions505
Fuel System Components505
Fuel Hose Disconnecting and Reconnecting508
Fuel Pressure Relief Procedure510
Fuel Leakage Check Procedure510
Fuel Lines On-Vehicle Inspection511
Fuel Pipe Removal and Installation511
Fuel Injector Removal and Installation512
Fuel Injector Inspection513
Fuel Pressure Regulator Removal and Installation515
Fuel Pressure Regulator Inspection515
Fuel Filler Cap Inspection516
Fuel Tank Inlet Valve Removal and Installation516
Fuel Tank Inlet Valve Inspection517
Fuel Tank Removal and Installation517
Fuel Tank Inspection519
Fuel Tank Purging Procedure519
Fuel Pump On-Vehicle Inspection519
Fuel Pump Assembly Removal and Installation520
Main Fuel Level Sensor Removal and Installation521
Fuel Pump Inspection521
Sub Fuel Level Sensor Removal and Installation521
Sub Fuel Level Sensor Inspection522
Specifications522
Tightening Torque Specifications522
Special Tools and Equipment523
Recommended Service Material523
Special Tool523
Ignition System524
General Description524
Ignition System Construction524
Component Location526
Ignition System Components Location526
Diagnostic Information and Procedures527
Ignition System Symptom Diagnosis527
Reference Waveform of Ignition System527
Ignition System Check527
Ignition Spark Test527
Repair Instructions530
High-Tension Cord Inspection530
Spark Plug Removal and Installation530
Spark Plug Inspection531
Ignition Coil Assembly (Including Ignitor) Removal and Installation531
Ignition Coil Assembly (Including Ignitor) Inspection532
Ignition Timing Inspection532
Specifications534
Tightening Torque Specifications534
Special Tools and Equipment534
Starting System535
Precautions535
Cranking System Note535
General Description535
Cranking Circuit Introduction535
Starting Motor Circuit Description535
Diagnostic Information and Procedures536
Cranking System Symptom Diagnosis536
Starting Motor Performance Test537
Repair Instructions539
Starting Motor Dismounting and Remounting539
Starting Motor Components540
Starting Motor Inspection541
Specifications544
Starting Motor Specifications544
Tightening Torque Specifications544
Special Tools and Equipment544
Recommended Service Material544
Charging System545
General Description545
Battery Description545
Generator Description546
Diagnostic Information and Procedures547
Battery Inspection547
Generator Symptom Diagnosis548
Generator Test (Undercharged Battery Check)548
Generator Test (Overcharged Battery Check)549
Repair Instructions550
Jump Starting in Case of Emergency550
Battery Dismounting and Remounting551
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 Remounting555
Generator Components556
Generator Inspection557
Specifications560
Charging System Specifications560
Tightening Torque Specifications560
Exhaust System561
General Description561
Exhaust System Description561
Diagnostic Information and Procedures561
Exhaust System Check561
Repair Instructions561
Exhaust System Components561
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 Installation565
Specifications566
Tightening Torque Specifications566
Suspension567
Precautions569
Precautions on Suspension569
Suspension General Diagnosis570
Diagnostic Information and Procedures570
Suspension, Wheels and Tires Symptom Diagnosis570
Specifications572
Wheel Alignment Specifications572
Front Suspension573
General Description573
Front Suspension Construction573
Front Wheel Alignment Construction574
Repair Instructions574
Front Wheel Alignment Inspection and Adjustment574
Front Strut Assembly Components576
Front Strut Assembly Removal and Installation577
Front Strut Assembly Disassembly and Assembly579
Front Strut Assembly Check580
Front Wheel Hub Assembly and Steering Knuckle Components581
Front Wheel Hub Assembly Removal and Installation581
Steering Knuckle Removal and Installation583
Front Wheel Hub, Disc, Nut and Bearing Check584
Suspension Control Arm Removal and Installation585
Suspension Control Arm / Bushing Disassembly and Assembly587
Suspension Control Arm / Steering Knuckle Check588
Suspension Control Arm Bushing Check588
Suspension Control Arm Joint Check588
Front Suspension Frame, Stabilizer Bar And/Or Bushings Components589
Front Suspension Frame, Stabilizer Bar And/Or Bushings Removal and Installation590
Front Suspension Frame Check594
Front Stabilizer Bar, Bushing And/Or Joint Check594
Special Tools and Equipment596
Recommended Service Material596
Special Tool596
Rear Suspension597
General Description597
Rear Suspension Construction597
Rear Wheel Alignment Construction598
Repair Instructions598
Rear Wheel Alignment Inspection and Adjustment598
Rear Shock Absorber and Rear Coil Spring Components600
Rear Shock Absorber Removal and Installation601
Shock Absorber Check602
Rear Coil Spring and Bump Stopper Removal and Installation602
Rear Coil Spring Check604
Rod and Arm Components605
Control Rod Removal and Installation606
Control Rod / Bushing Disassembly and Assembly608
Control Rod Check608
Trailing Rod Removal and Installation609
Trailing Rod / Bushing Disassembly and Assembly610
Trailing Rod Check611
Lower Arm Removal and Installation611
Lower Arm / Bushing Disassembly and Assembly612
Lower Arm Check613
Upper Arm Removal and Installation613
Upper Arm / Bushing Disassembly and Assembly615
Upper Arm Check615
Rear Suspension Frame Components616
Rear Suspension Frame Removal and Installation617
Rear Suspension Frame / Bushing Disassembly and Assembly619
Rear Suspension Frame, Bushing and Pad Check620
Rear Wheel Hub Assembly and Rear Suspension Knuckle Components620
Rear Wheel Hub Assembly Removal and Installation621
Rear Wheel Hub Assembly, Wheel Bearing and Wheel Stud Inspection623
Rear Wheel Disc, Nut and Bearing Check623
Rear Suspension Knuckle Removal and Installation624
Rear Suspension Knuckle Check627
Rear Suspension Fasteners Check627
Special Tools and Equipment629
Recommended Service Material629
Wheels and Tires630
General Description630
Tires Description630
Wheels Description631
Irregular And/Or Premature Wear Description631
Wear Indicators Description632
Radial Tire Waddle Description632
Radial Tire Lead / Pull Description633
Balancing Wheels Description633
Repair Instructions634
General Balance Procedures634
Tire Rotation634
Wheel Removal and Installation635
Tire Mounting and Dismounting635
Tire Repair635
Specifications636
Wheels and Tires Specifications636
Tightening Torque Specifications636
Driveline / Axle637
Precautions640
Precautions for Driveline / Axle640
Drive Shaft / Axle641
Front641
General Description641
Front Drive Shaft Construction641
Diagnostic Information and Procedures641
Front Drive Shaft Symptom Diagnosis641
Repair Instructions642
Front Drive Shaft Boot and Joint Check642
Front Drive Shaft Components642
Front Drive Shaft Assembly Removal and Installation643
Front Drive Shaft Disassembly and Assembly643
Specifications646
Tightening Torque Specifications646
Special Tools and Equipment646
Recommended Service Material646
Special Tool646
Rear647
General Description647
Rear Drive Shaft Construction647
Repair Instructions647
Rear Drive Shaft Components647
Rear Drive Shaft Assembly Removal and Installation648
Rear Drive Shaft Disassembly and Assembly648
Specifications649
Tightening Torque Specifications649
Special Tools and Equipment649
Recommended Service Material649
Special Tool649
Differential650
Front650
General Description650
Front Differential Construction650
Diagnostic Information and Procedures650
Front Differential Symptom Diagnosis650
Repair Instructions651
Front Differential Oil Change651
Front Differential Unit Components652
Front Differential Dismounting and Remounting652
Front Differential Components653
Front Differential Assembly Disassembly and Reassembly654
Front Differential Inspection666
Specifications667
Tightening Torque Specifications667
Special Tools and Equipment667
Recommended Service Material667
Special Tool667
Rear670
General Description670
Rear Differential Construction670
Diagnostic Information and Procedures670
Rear Differential Symptom Diagnosis670
Repair Instructions670
Rear Differential Oil Change670
Rear Differential Unit Components670
Rear Differential Dismounting and Remounting671
Rear Differential Components672
Rear Differential Assembly Disassembly and Reassembly673
Special Tools and Equipment686
Recommended Service Material686
Special Tool686
Transfer689
Motor-Shift Type689
Precautions689
Transfer Warning689
Precautions in Diagnosing Trouble689
General Description689
Transfer Description689
Transfer Shift Control System Components690
4WD Control System Description691
Function of 4WD Control System Component693
4WD Control System Operation693
4WD Control System Wiring Circuit Diagram699
Module700
Module701
CAN Communication System Description701
Diagnostic Information and Procedures702
4WD Control System Check702
Transfer Position Indicator Operation Check705
4WD Control System Operation Inspection705
Visual Inspection706
DTC Check707
DTC Clearance708
DTC Table708
Fail-Safe Table709
Scan Tool Data710
Scan Tool Data Definitions710
4WD Control Symptom Diagnosis711
Transfer Position Indicator Does Not Come on at Ignition Switch on but Engine Stops712
Transfer Position Indicator Remains on Steady at Ignition Switch714
DTC C1213: Transfer Switch Circuit Open715
DTC C1214: Transfer Switch Circuit Short716
DTC C1223 / C1235: Transfer Shift Actuator Motor Position Switch 1 Circuit Open / Transfer Shift Actuator Motor Position Switch 2 Circuit Open718
DTC C1224 / C1236: Transfer Shift Actuator Motor Position Switch 1 Circuit Short / Transfer Shift Actuator Motor Position Switch 2 Circuit Short720
DTC C1227: 4L/N Switch Circuit Open722
DTC C1228: 4L/N Switch Circuit Short723
DTC C1230: Transfer Actuator Circuit Malfunction725
DTC C1237: Center Differential Lock Switch Circuit Open726
DTC C1238: Center Differential Lock Switch Circuit Short728
DTC C1240: 4WD Control Module Power Supply Circuit Malfunction729
DTC C1243: Internal Circuit Malfunction of 4WD Control Module730
DTC C1246: Clutch Pedal Position (CPP) Switch Circuit Short731
DTC U1101: Lost Communication with TCM736
DTC U1121: Lost Communication with ABS Hydraulic Unit / Control Module738
Inspection of 4WD Control Module and Its Circuits739
Repair Instructions742
Transfer Oil Level Check742
Transfer Oil Change742
Transfer Oil Seal Removal and Installation743
Transfer Switch Removal and Installation743
Installation743
Transfer Assembly Dismounting and Remounting745
Transfer Assembly Components746
Transfer Assembly Disassembly and Reassembly747
Transfer Assembly Inspection755
Input Gear Assembly, Counter Gear Assembly, Front Output Shaft Assembly and Rear Output Shaft Assembly Components757
Input Gear Assembly Disassembly and Reassembly758
Counter Gear Assembly Disassembly and Reassembly759
Front Output Shaft Assembly Disassembly and Reassembly759
Rear Output Shaft Assembly Disassembly and Reassembly760
Non-Shift Type (Transfer Without Shift Actuator)763
Precautions763
Transfer Warning763
General Description763
Transfer Construction763
Diagnostic Information and Procedures764
Transfer Symptom Diagnosis764
Repair Instructions765
Transfer Oil Change765
Transfer Oil Level Check765
Transfer Oil Seal Removal and Installation765
Transfer Assembly Dismounting and765
Transfer Assembly Components766
Transfer Assembly Disassembly and Reassembly768
Input Gear Assembly Disassembly and Reassembly774
Front Output Shaft Assembly Disassembly and Reassembly774
Rear Output Shaft Assembly Disassembly and Reassembly774
Specifications775
Tightening Torque Specifications775
Special Tools and Equipment775
Recommended Service Material775
Special Tool775
Propeller Shafts776
Precautions776
Propeller Shaft Caution776
General Description776
Propeller Shaft Construction776
Diagnostic Information and Procedures777
Propeller Shaft Symptom Diagnosis777
Brakes783
Precautions785
Precautions for Brakes785
Brake Control System and Diagnosis786
General Description786
Brakes Construction786
Front Brake Hose / Pipe Construction787
Rear Brake Hose / Pipe Construction788
Master Cylinder Assembly Construction788
Booster Assembly Construction789
Diagnostic Information and Procedures789
Brake Diagnosis Note789
Brakes Symptom Diagnosis790
Repair Instructions792
Excessive Pedal Travel Check792
Brake Pedal Play Check792
Brake Fluid Level Check792
Air Bleeding of Brake System793
Brake Pedal Free Height Adjustment794
Brake Light Switch Adjustment794
Brake Flexible Hose and Pipe Check794
Master Cylinder Check794
Flushing Brake Hydraulic System795
Booster Operation Check795
Front Brake Hose / Pipe Removal and Installation796
Rear Brake Hose / Pipe Removal and Installation796
Master Cylinder Components797
Master Cylinder Reservoir Removal and Installation798
Master Cylinder Assembly Removal and Installation799
Master Cylinder Assembly Inspection800
Brake Booster Components801
Brake Booster Removal and Installation802
Booster Push Rod Clevis Adjustment802
Special Tool803
Front Brakes804
General Description804
Front Disc Brake Caliper Assembly Construction804
Repair Instructions805
Front Disc Brake Components805
Front Disc Brake Pad On-Vehicle Check806
Front Disc Brake Pad Removal and Installation806
Front Brake Disc and Pad Inspection807
Front Disc Brake Caliper Removal and Installation808
Front Disc Brake Caliper Disassembly and Assembly809
Front Disc Brake Caliper Inspection810
Front Brake Disc Removal and Installation811
Front Brake Disc Inspection811
Specifications812
Tightening Torque Specifications812
Special Tools and Equipment812
Recommended Service Material812
Rear Brakes813
General Description813
Rear Drum Brake Assembly Construction813
Repair Instructions814
Rear Drum Brake Assembly Components814
Rear Brake Drum Removal and Installation815
Rear Brake Drum and Shoe Inspection816
Rear Brake Shoe On-Vehicle Check816
Rear Brake Shoe Removal and Installation817
Rear Brake Shoe Inspection818
Wheel Cylinder Removal and Installation818
Wheel Cylinder Inspection819
Rear Brake Back Plate Removal and Installation819
Parking Brake822
Component Location822
Parking Brake Cable Location822
Repair Instructions824
Parking Brake Check and Adjustment824
Parking Brake Lever Removal and Installation825
Parking Brake Cable Removal and Installation825
Specifications826
Tightening Torque Specifications826
Abs827
Precautions827
Precautions in Diagnosing Troubles827
General Description827
ABS Description827
ABS Hydraulic Unit / Control Module Assembly Description828
CAN Communication System Description828
Schematic and Routing Diagram829
ABS Schematic829
ABS Wiring Circuit Diagram830
Component Location832
ABS Components Location832
Diagnostic Information and Procedures833
ABS Check833
ABS Warning Lamp Check835
EBD Warning Lamp (Brake Warning Lamp) Check835
DTC Check835
DTC Table836
DTC Clearance836
Scan Tool Data836
Ignition Switch837
ABS Warning Lamp Comes on Steady839
EBD Warning Lamp (Brake Warning Lamp) Comes on Steady842
Serial Data Link Circuit Check843
DTC C1015: G Sensor Circuit845
DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right-Rear / Left-Rear Wheel Speed Sensor Circuit or Encoder846
DTC C1057: Power Source Circuit849
DTC C1061: ABS Pump Motor And/Or Motor Driver Circuit850
DTC C1063: Solenoid Valve Power Supply Driver Circuit851
DTC C1071: ABS Control Module852
DTC U1073: Control Module Communication Bus off853
DTC U1100: Lost Communication with ECM (Reception Error)855
Repair Instructions856
ABS Hydraulic Unit Operation Check856
ABS Hydraulic Unit / Control Module Assembly Components857
ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection857
ABS Hydraulic Unit / Control Module Assembly Removal and Installation858
Front Wheel Speed Sensor On-Vehicle Inspection860
Front Wheel Speed Sensor Removal and Installation861
Front Wheel Speed Sensor Inspection862
Rear Wheel Speed Sensor On-Vehicle Inspection862
Rear Wheel Speed Sensor Removal and Installation862
Rear Wheel Speed Sensor Inspection863
Front Wheel Encoder On-Vehicle Inspection863
Front Wheel Encoder Removal and Installation863
Rear Wheel Encoder On-Vehicle Inspection863
Rear Wheel Encoder Removal and Installation863
Specifications864
Tightening Torque Specifications864
Special Tools and Equipment864
Special Tool864
Transmission / Transaxle865
Precautions868
Automatic Transmission/Transaxle869
General Service Procedure Information869
General Description871
Automatic Transmission Description871
Clutch / Brake Functions of Automatic Transmission873
Table of A/T System Component Operation874
CAN Communication System Description875
Electronic Shift Control Input / Output Table876
Brake Interlock System Description879
A/T Diagnosis General Description879
On-Board Diagnostic System Description879
Schematic and Routing Diagram881
Automatic Gear Shift Table881
Bearing and Race Installation Diagram884
Component Location885
Electronic Shift Control System Components Location885
Diagnostic Information and Procedures886
A/T System Check886
Malfunction Indicator Lamp (MIL) Check888
Diagnosis Connector)888
POWER" Lamp Operation Check888
DTC Table889
DTC Check890
DTC Clearance891
Fail Safe Table892
Scan Tool Data894
Visual Inspection897
A/T Basic Check897
Road Test898
Manual Road Test899
Stall Test900
Time Lag Test901
Line Pressure Test901
Engine Brake Test903
P" Range Test903
A/T Symptom Diagnosis904
No Gear Shift to 4Th Gear911
No Lock-Up Occurs912
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 Malfunction914
DTC P0707 Transmission Range Sensor Circuit Low916
DTC P0712 Transmission Fluid Temperature Sensor "A" Circuit Low918
DTC P0713 Transmission Fluid Temperature Sensor "A" Circuit High919
DTC P0717 Input / Turbine Speed Sensor Circuit no Signal920
DTC P0722 Output Speed Sensor Circuit no Signal921
DTC P0741 / P0742 TCC Circuit Performance or Stuck off / TCC Circuit Stuck922
DTC P0751 / P0752 Shift Solenoid-A Performance or Stuck off / Shift Solenoid-A Stuck923
DTC P0756 / P0757 Shift Solenoid-B Performance or Stuck off / Shift Solenoid-B Stuck924
DTC P0962 Pressure Control Solenoid "A" Control Circuit Low925
DTC P0963 Pressure Control Solenoid "A" Control Circuit High926
DTC P0973 / P0976 Shift Solenoid "A" Control Circuit Low / Shift Solenoid "B" Control Circuit Low927
DTC P0974 / P0977 Shift Solenoid "A" Control Circuit High / Shift Solenoid "B" Control Circuit High929
DTC P1702 Internal Control Module Memory Check Sum Error930
DTC P1703 CAN Invalid Data - TCM930
DTC P1723 Range Select Switch Malfunction931
DTC P1774: CAN Communication Bus off932
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 Shudder939
DTC P2763 Torque Converter Clutch (TCC) Circuit High939
DTC P2764 Torque Converter Clutch (TCC) Circuit Low941
Inspection of TCM and Its Circuits942
TCM Power and Ground Circuit Check946
Repair Instructions948
A/T Fluid Level Check948
A/T Fluid Change949
Manual Selector Assembly Components949
Manual Selector Assembly Removal and Installation950
Select Lever Knob Installation950
Manual Selector Assembly Inspection950
3" Position Switch Inspection950
Select Cable Component951
Select Cable Adjustment951
Transmission Range Sensor Removal and Installation952
Transmission Range Sensor Inspection and Adjustment952
Key Interlock Cable Removal and Installation953
Brake and Key Interlock System Inspection955
Mode Select Switch Inspection956
Input Shaft Speed Sensor Removal and Installation956
Input Shaft Speed Sensor Inspection956
Output Shaft Speed Sensor Removal and Installation957
Output Shaft Speed Sensor Inspection957
Oil Cooler Hose and Pipes Removal and Installation958
Solenoid Valves959
Removal and Installation961
Solenoid Valves961
Transmission Fluid Temperature Sensor Removal and Installation961
Transmission Fluid Temperature Sensor Inspection962
Transmission Control Module (TCM) Removal and Installation963
A/T Relay Inspection963
Automatic Transmission Unit Components964
Automatic Transmission Assembly Dismounting and Remounting965
Automatic Transmission Unit Disassembly966
Oil Pump Components971
Oil Pump Disassembly and Assembly972
Oil Pump Inspection972
Overdrive (Planetary Gear Side) Components974
Overdrive (Planetary Gear Side) Disassembly and Assembly974
Overdrive (Planetary Gear Side) Inspection976
Overdrive (Case Side) Components977
Overdrive (Case Side) Disassembly and Assembly978
Overdrive (Case Side) Inspection979
Forward Clutch Components980
Forward Clutch Disassembly and Assembly980
Forward Clutch Inspection982
Direct Clutch Components983
Direct Clutch Disassembly and Assembly983
Direct Clutch Inspection985
Center Support Components986
Center Support Disassembly and Assembly987
Center Support Inspection990
Planetary Gears and Output Shaft Components991
Planetary Gears and Output Shaft Disassembly and Assembly992
Planetary Gears and Output Shaft Inspection993
Valve Body Assembly Components994
Automatic Transmission Unit Assembly994
Special Tools and Equipment1004
Recommended Service Material1004
Special Tool1004
Manual Transmission/Transaxle1006
General Description1006
Manual Transmission Construction1006
Diagnostic Information and Procedures1007
Manual Transmission Symptom Diagnosis1007
Repair Instructions1008
Manual Transmission Assembly Components1008
Gear Shift Control Lever Rear Case Assembly Components1010
Gear Shift Lever Front Case Assembly Components1011
Gear Shift Shaft and Fork Components1012
Input Shaft Assembly, Output Shaft Assembly and Countershaft Assembly Components1013
Manual Transmission Oil Change1014
Transmission Shift Control Lever Removal and Installation1015
Transmission Shift Control Lever Inspection1015
Back up Light Switch Removal and Installation1016
Back up Light Switch Inspection1016
Gear Shift Control Lever Rear Case Assembly Removal and Installation1016
Gear Shift Control Lever Rear Case Assembly Disassembly and Reassembly1017
Gear Shift Control Lever Rear Case Assembly Inspection1017
Gear Shift Lever Front Case Assembly Removal and Installation1017
Gear Shift Lever Front Case Assembly Disassembly and Reassembly1018
Gear Shift Lever Front Case Assembly Inspection1019
Engine Rear Mounting Replacement1019
Manual Transmission Assembly Dismounting and Remounting1019
Manual Transmission Unit Disassembly1022
Manual Transmission Unit Reassembly1023
Locating Spring Inspection1026
Input Shaft Disassembly1026
Input Shaft Inspection1027
Input Shaft Reassembly1028
Countershaft Disassembly and Assembly1030
Countershaft and Reverse Idle Gear Inspection1033
Output Shaft Disassembly and Assembly1034
Output Shaft Inspection1034
Manual Transmission Front Case Disassembly and Assembly1035
Manual Transmission Adapter Case Disassembly and Assembly1035
Special Tools and Equipment1037
Recommended Service Material1037
Special Tool1037
Clutch1039
Clutch (Hydraulic Type) Construction1039
Component Location1040
Clutch Fluid Pipe and Hose Location1040
Diagnostic Information and Procedures1040
Clutch (Hydraulic Type) Symptom Diagnosis1040
Clutch Pedal Height Inspection1041
Clutch Pedal Free Travel Check1041
Clutch Fluid Inspection1041
Repair Instructions1042
Clutch Pedal Position (CPP) Switch Removal and Installation1042
Clutch Pedal Position (CPP) Switch Inspection and Adjustment1042
Clutch Fluid Pipe and Hose Removal and1042
Clutch Fluid Pipe and Hose Inspection1043
Clutch Master Cylinder Removal and Installation1043
Clutch Master Cylinder Inspection1044
Clutch Operating Cylinder Assembly Removal and Installation1044
Clutch Cover, Clutch Disc and Flywheel Components1045
Clutch Cover, Clutch Disc and Flywheel Removal and Installation1046
Clutch Cover, Clutch Disc and Flywheel Inspection1047
Specifications1048
Tightening Torque Specifications1048
Special Tools and Equipment1048
Recommended Service Material1048
Special Tool1048
Steering1049
Precautions1051
Precautions for Steering1051
Steering General Diagnosis1052
Diagnostic Information and Procedures1052
Steering Symptom Diagnosis1052
Steering Wheel and Column1053
Precautions1053
Service Precautions of Air Bag Steering Wheel and Column1053
Handling and Storage of Air Bag Steering Wheel and Column1053
Disposal of Air Bag Steering Wheel and Column1053
General Description1053
Steering Wheel and Column Construction1053
Diagnostic Information and Procedures1055
Air Bag Steering Wheel and Column Symptom Diagnosis1055
Air Bag Steering Wheel and Column Inspection and Repair Required after Accident1055
Diagnosis and Servicing of Air Bag Steering1055
Wheel and Column1055
Repair Instructions1055
Checking Steering Column for Accident1055
Damage1055
Steering Wheel Removal and Installation1056
Contact Coil Cable Assembly Removal and Installation1057
Contact Coil Cable Assembly Inspection1059
Centering Contact Coil Cable Assembly1059
Steering Column Assembly Removal and Installation1059
Steering Column Assembly Inspection1062
Ignition Switch Cylinder Assembly Removal and Installation (Without Keyless Start System)1062
Steering Lock Assembly (Ignition Switch) Removal and Installation1063
Adjustable Steering Column Release Lever Inspection1063
Steering Upper Shaft Assembly Removal and Installation1063
Steering Upper Shaft Assembly Inspection1064
Steering Lower Shaft Assembly Removal and Installation1065
Specifications1066
Tightening Torque Specifications1066
Special Tools and Equipment1066
Special Tool1066
Power Assisted Steering System1067
Precautions1067
P/S System Note1067
General Description1067
P/S System Construction1067
Steering Gear Case Construction1068
P/S Pump Construction1068
Schematic and Routing Diagram1069
P/S Fluid Flow Diagram1069
Diagnostic Information and Procedures1069
P/S System Symptom Diagnosis1069
Steering Wheel Check1070
Steering Force Check1071
Steering Wheel Recovery Check1071
Idle up System Check1071
Hydraulic Pressure in P/S Circuit Check1071
Repair Instructions1073
P/S Fluid Change1073
P/S Fluid Level Check1073
P/S Fluid Leakage Check1074
P/S System Air Bleeding Procedure1074
P/S Pump and A/C Compressor1075
Adjustment for M16 Engine Model1075
P/S Pump and A/C Compressor (if Equipped) Drive Belt Removal and Installation for M16 Engine Model1075
P/S Pump and A/C Compressor (if Equipped) Drive Belt Removal and Installation for J20 Engine Model1076
Steering Rack Boot Check1076
Tie-Rod End Boot Check1076
Tie-Rod End Removal and Installation1076
Tie-Rod End Ball Joint Inspection1077
P/S Gear Case Assembly Components1078
P/S Gear Case Assembly Removal and Installation1079
Steering Gear Case Mount Bushing Removal and Installation1080
Steering Gear Case Mount Bushing Inspection1080
Installation1080
P/S Pump Removal and Installation for M161084
Engine Model1084
P/S Pump Removal and Installation for J201084
Model1084
P/S Pump Assembly Components for J201086
Engine Model1086
P/S Pump Disassembly and Assembly for1086
Hvac1091
Model1092
Precautions1094
Precautions for HVAC1094
Heater and Ventilation1095
General Description1095
Heater and Ventilation Construction1095
Body Ventilation Construction1096
On-Board Diagnostic System Description1096
HVAC Control System Description (for Vehicle Without a1097
Schematic and Routing Diagram1097
Heater and Ventilation Wiring Circuit Diagram1097
Electronic Control Input / Output Table (for Vehicle Without a1097
Electronic Components Location for Heater (for Vehicle Without a1098
Diagnostic Information and Procedures1099
Heater and Ventilation System Check1099
Visual Inspection1099
DTC Check1099
DTC Clearance1101
DTC Table1101
Fail-Safe Table1101
Scan Tool Data1101
Heater and Ventilation Symptom Diagnosis1102
Repair Instructions1103
Blower Unit and Heater Unit Components1103
HVAC Unit Removal and Installation1103
Vehicle Without a1103
HVAC Air Filter Removal and Installation1103
HVAC Air Filter Inspection1103
Blower Motor Removal and Installation1103
Blower Motor Inspection1103
Blower Motor Controller Removal and1104
Blower Motor Controller Inspection1104
Blower Motor Relay Inspection1104
Heater Core Removal and Installation1105
HVAC Control Module Removal and Installation1105
HVAC Control Module and Its Circuits1105
Air Flow Control Actuator Removal and1105
Air Flow Control Actuator Inspection1105
Temperature Control Actuator Removal and Installation1106
Temperature Control Actuator Inspection1106
Air Intake Control Actuator Removal and1107
Air Intake Control Actuator Inspection1107
Actuator Linkage Inspection1107
Center Ventilation Louver Removal and1108
Side Ventilation Louver Removal and1108
Rear Duct Components1109
Rear Duct Removal and Installation1109
Air Conditioning System1110
A/C System Caution1110
Precautions on Servicing A/C System1110
Precautions in Diagnosing Trouble1110
Precautions on Handling Refrigerant HFC-134A1110
Precautions on Servicing Refrigerant Line1111
Precautions on Refrigerant Recovery1112
Precautions on Refrigerant Charge1112
Precautions on Replenishing Compressor Oil1112
Precautions on Servicing Compressor Assembly1113
General Description1113
AUTO A/C System Description1113
HVAC Control System Description1113
Auto A/C Electronic Control Input / Output Table1114
HVAC Control Module Operation Description1114
A/C Refrigerant Type Description1114
Sub-Cool A/C System Description1115
A/C Evaporator Temperature Sensor1116
On-Board Diagnostic System Description1116
Component Location1118
Major Components of A/C System1118
A/C Control System Components Location1119
Diagnostic Information and Procedures1120
Air Conditioning System Check1120
DTC Check1121
DTC Clearance1123
DTC Table1123
Fail-Safe Table1126
Scan Tool Data1127
Visual Inspection1129
A/C System Performance Inspection1129
A/C System Symptom Diagnosis1135
Abnormal Noise Diagnosis1137
Abnormal Noise Symptom Diagnosis of A/C System1137
DTC B1502: Inside Air Temperature Sensor And/Or Its Circuit Malfunction1139
DTC B1503: A/C Evaporator Air Temperature Sensor And/Or Its Circuit Malfunction1140
DTC B1504: Sunload Sensor And/Or Its Circuit Malfunction1142
DTC B1511: Temperature Control Actuator (Position Sensor) And/Or Its Circuit Malfunction1143
DTC B1512: Air Flow Control Actuator (Position Sensor) And/Or Its Circuit Malfunction1146
DTC B1514: Air Flow Control Actuator And/Or Its Circuit Malfunction1151
DTC B1520: Temperature Selector And/Or Its Circuit Malfunction1153
DTC B1521: Blower Speed Selector And/Or Its Circuit Malfunction1154
DTC B1530: Air Intake Control Actuator (Position Sensor) And/Or Its Circuit Malfunction1154
DTC B1531: Air Intake Control Actuator And/Or Its Circuit Malfunction1157
DTC B1546: A/C Refrigerant Pressure Malfunction1159
DTC B1551: Serial Communication Circuit Malfunction1160
DTC B1552: Serial Communication Circuit Malfunction1162
DTC B1553: CAN Communication Circuit Malfunction1162
DTC B1556: Camshaft Position (CMP) Sensor And/Or Its Circuit Malfunction1163
DTC B1557: Wheel Speed Sensor And/Or Its Circuit Malfunction1163
DTC B1561: Engine Coolant Temperature Sensor And/Or Its Circuit Malfunction1163
DTC B1562: Outside Air Temperature Sensor And/Or Its Circuit Malfunction1164
DTC B1563: A/C Refrigerant Pressure Sensor And/Or Its Circuit Malfunction1164
HVAC Control Module and Its Circuits Inspection1164
A/C System Inspection at ECM1167
Operation Procedure for Charging A/C with Refrigerant1168
A/C Condenser Assembly On-Vehicle Inspection1172
A/C Condenser Assembly Removal and Installation1172
Desiccant Removal and Installation1173
HVAC Air Filter Removal and Installation1174
HVAC Air Filter Inspection1174
HVAC Unit Components1175
HVAC Unit Removal and Installation1176
A/C Evaporator Removal and Installation1177
A/C Evaporator Inspection1177
A/C Evaporator Temperature Sensor Removal and Installation1177
A/C Evaporator Temperature Sensor Inspection1177
Expansion Valve On-Vehicle Inspection1178
Expansion Valve Removal and Installation1178
A/C Refrigerant Pressure Sensor and Its Circuit Inspection1178
A/C Refrigerant Pressure Sensor Removal and Installation1179
Sunload Sensor Removal and Installation1179
Sunload Sensor Inspection1180
Inside Air Temperature Sensor Removal and Installation1180
Inside Air Temperature Sensor Inspection1180
Outside Air Temperature Sensor Removal and Installation1180
Outside Air Temperature Sensor Inspection1180
Air Flow Control Actuator Removal and Installation1180
Air Flow Control Actuator Inspection1180
Air Intake Control Actuator Removal and Installation1181
Air Intake Control Actuator Inspection1181
Temperature Control Actuator Removal and Installation1181
Temperature Control Actuator Inspection1181
HVAC Control Module Removal and Installation1181
A/C Compressor Drive Belt Inspection and Adjustment1181
A/C Compressor Drive Belt Removal and Installation1181
A/C Compressor Relay Inspection1181
Compressor Assembly On-Vehicle Inspection1182
Compressor Assembly Removal and Installation for M16 Engine Model1182
Compressor Assembly Removal and Installation for J20 Engine Model1183
Magnet Clutch Components for M16 Engine Model1184
Magnet Clutch Components for J20 Engine Model1185
Magnet Clutch Operating Check for M16 Engine Model1185
Magnet Clutch Operating Check for J20 Engine Model1185
M16 Engine Model1190
Thermal Switch Removal and Installation for M16 Engine Model1190
Relief Valve On-Vehicle Inspection for M161190
Engine Model1190
Relief Valve On-Vehicle Inspection for J201190
Special Tools and Equipment1192
Recommended Service Material1192
Special Tool1192
Restraint1193
Precautions1195
Precautions on Restraint1195
Seat Belts1196
Precautions on Service and Diagnosis of Seat Belt1196
General Description1196
Seat Belt Construction1196
Diagnostic Information and Procedures1197
Repair and Inspection Required after Accident1197
Repair Instructions1198
Front Seat Belt Components1198
Front Seat Belt Removal and Installation1199
Front Seat Belt Inspection1199
Rear Seat Belt Components1201
Rear Seat Belt Removal and Installation1202
Rear Seat Belt Inspection1202
Tightening Torque Specifications1202
Air Bag System1203
Precautions on Service and Diagnosis of Air Bag System1203
Precautions on Handling and Storage of Air Bag System Components1203
Precautions on Disposal of Air Bag and Seat Belt Pretensioner1207
General Description1207
Air Bag System Construction1207
Air Bag System Input / Output Table1208
Schematic and Routing Diagram1209
Air Bag System Wiring Circuit Diagram1209
Component Location1213
Air Bag System Components, Wiring and Connectors Location1213
Diagnostic Information and Procedures1214
Air Bag Diagnostic System Check1214
Air Bag Diagnostic System Check Flow1214
DTC Check1215
DTC Clearance1219
Scan Tool Data1220
AIR BAG" Warning Lamp Comes on Steady1221
AIR BAG" Warning Lamp Flashes1225
AIR BAG" Warning Lamp Cannot Indicate Flashing Pattern of DTC (if Equipped with "AIR BAG" Monitor Coupler)1226
DTC B1013: SDM Fault1227
DTC B1016: Power Source Voltage High1227
DTC B1017: Power Source Voltage Low1229
DTC B1021: Air Bag Module Deployed1231
DTC B1031: Driver Air Bag Initiator Circuit Resistance High1232
DTC B1032: Driver Air Bag Initiator Circuit Resistance Low1236
DTC B1033: Driver Air Bag Initiator Circuit Short to Ground1239
DTC B1034: Driver Air Bag Initiator Circuit Short to Power Circuit1242
DTC B1041: Passenger Air Bag Initiator Circuit Resistance High1245
DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low1248
DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground1251
DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circuit1254
DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance High1257
DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circuit Resistance Low .8B-581260
DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground1263
DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power Circuit1266
DTC B1073 / B1077: Driver / Passenger Forward-Sensor Circuit Short to Ground1269
DTC B1074 / B1078: Driver / Passenger Forward-Sensor Circuit Short to Power Circuit or Open1271
DTC B1086 / B1096: Left / Right Side-Sensor Performance Problem1273
DTC B1087 / B1097: Left / Right Side-Sensor Communication Error1273
DTC B1321 / B1325: Left / Right Side-Air Bag Initiator Circuit Resistance High1275
DTC B1322 / B1326: Left / Right Side-Air Bag Initiator Circuit Resistance Low1279
DTC B1323 / B1327: Left / Right Side-Air Bag Initiator Circuit Short to Ground1282
DTC B1324 / B1328: Left / Right Side-Air Bag Initiator Circuit Short to Power Circuit1285
DTC B1331 / B1335: Left / Right Side Curtain-Air Bag Initiator Circuit Resistance High1287
DTC B1332 / B1336: Left / Right Side Curtain-Air Bag Initiator Circuit Resistance Low1290
DTC B1333 / B1337: Left / Right Side Curtain-Air Bag Initiator Circuit Short to Ground1292
DTC B1334 / B1338: Left / Right Side Curtain-Air Bag Initiator Circuit Short to Power Circuit1294
Inspection of Intermittent and Poor Connections1295
Repair and Inspection Required after Accident1296
Repair Instructions1299
Disabling Air Bag System1299
Enabling Air Bag System1300
SDM Removal and Installation1300
SDM Inspection1301
Driver Air Bag (Inflator) Module Removal and Installation1302
Driver Air Bag (Inflator) Module Inspection1303
Passenger Air Bag (Inflator) Module Removal and Installation1303
Passenger Air Bag (Inflator) Module Inspection1305
Side-Air Bag (Inflator) Module Removal and Installation1305
Side-Air Bag (Inflator) Inspection1307
Side Curtain-Air Bag (Inflator) Module Removal and Installation1307
Side Curtain-Air Bag (Inflator) Module Inspection1309
Forward-Sensor Removal and Installation1309
Forward-Sensor Inspection1310
Side-Sensor Removal and Installation1310
Side-Sensor Inspection1311
Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal1312
Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal1322
Recommended Service Material1324
Special Tool1324
Body, Cab and Accessories1327
Precautions1333
Precautions on Body, Cab and Accessories1333
Precautions for Body Service1333
Fastener Caution for Body Service1333
Cautions in Body Electrical System Servicing1333
Precautions for Wiring System1333
Wiring Systems1334
General Description1335
Wire / Connector Color Symbols1335
Symbols and Marks1336
How to Read Connector Layout Diagram1338
How to Read Connector Codes and Terminal Nos1339
How to Read Ground Point1342
How to Read Power Supply Diagram1343
Fuse Number1343
How to Read System Circuit Diagram1344
Engine Compartment1346
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 Panel1355
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, Roof1360
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 Harness1370
Ground (Earth) Point1371
Power Supply Diagram1372
Fuses and the Protected Parts1376
Fuses in Battery Fuse Box, Fuse Box No.11376
Fuse Box No.2 (in Power Integration No.1, Power Integration No.2), Relay Box1377
Junction Block (J/B) Connector / Fuse Layout1380
Fuse Side1380
Junction Block Inner Circuit (Overview)1381
Junction Block Inner Circuit (Detail)1382
System Circuit Diagram1386
A-1 Cranking System Circuit Diagram1387
A-2 Charging System Circuit Diagram1388
Ignition System Circuit Diagram (M16A)1389
Ignition System Circuit Diagram (J20A)1390
A-4 Cooling System Circuit Diagram1391
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 Diagram1402
A-7 Immobilizer System Circuit Diagram1404
A-8 Body Control System Circuit Diagram1405
A-10 4WD Control System Circuit Diagram1410
B-1 Windshield Wiper and Washer Circuit Diagram1412
B-2 Rear Wiper and Washer Circuit Diagram1413
B-3 Rear Defogger Circuit Diagram1414
B-4 Power Window Circuit Diagram1415
B-5 Power Door Lock Circuit Diagram1417
B-6 Power Mirror Circuit Diagram1419
B-7 Horn Circuit Diagram1420
B-8 Seat Heater Circuit Diagram1421
B-9 Smart Key System Circuit Diagram1422
B-10 Sliding Roof Circuit Diagram1423
B-11 Headlight Cleaner Circuit Diagram1424
C-1 Combination Meter Circuit Diagram1425
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 Diagram1430
D-3 Front Fog Light System Circuit Diagram1431
D-4 Illumination Light System Circuit Diagram1432
D-5 Interior Light System Circuit Diagram1433
D-6 Turn Signal and Hazard Warning Light System Circuit Diagram1434
D-7 Brake Light System Circuit Diagram1436
D-8 Back-Up Light System Circuit Diagram1437
Headlight Beam Leveling System Circuit Diagram (Manual Leveling)1438
Headlight Beam Leveling System Circuit Diagram (Auto Leveling)1439
D-10 Rear Fog Light Circuit Diagram1440
E-2 Auto A/C System Circuit Diagram1441
Air-Bag System Circuit Diagram1443
Air-Bag System Circuit Diagram1444
F-2 Anti-Lock Brake System Circuit Diagram1446
G-1 Audio System Circuit Diagram1448
G-2 Multi Information Display / Accessory Socket System Circuit Diagram1449
G-4 Navigation System Circuit Diagram1450
List of Connectors1451
Lighting Systems1463
Precautions for Discharge Headlight Service (if Equipped)1463
Precautions in Diagnosing Troubles (Vehicle Equipped with Auto Leveling Headlight System)1463
General Description1464
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 Diagram1468
Headlight Auto Leveling System Wiring Circuit Diagram1468
Component Location1469
Lighting System Components Location1469
Interior Light System Location1470
Diagnostic Information and Procedures1470
Self-Diagnosis Function for Auto Leveling Headlight System1470
Headlight Leveling Warning Light Check1470
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 Diagnosis1473
Clearance, Tail and License Plate Light Symptom Diagnosis1474
Back-Up Light Symptom Diagnosis1474
Stop (Brake) Lamp Symptom Diagnosis1475
Front Fog Light (if Equipped) Symptom Diagnosis1475
Rear Fog Light Symptom Diagnosis (if Equipped)1475
Illumination Cancel System Symptom Diagnosis (if Equipped)1475
Interior Light Symptom Diagnosis1476
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 Instructions1479
Headlight Housing Removal and Installation1479
Headlight Bulb Replacement1479
Ballast Removal and Installation1480
Igniter Removal and Installation1481
Headlight Aiming Adjustment with Screen1481
Headlight Switch (in Lighting Switch) Removal and Installation1483
Headlight Switch (in Lighting Switch) Inspection1483
Hazard Warning Switch Removal and Installation1484
Hazard Warning Switch Inspection1484
Stop (Brake) Lamp Switch Inspection1484
Turn Signal Light Switch (in Lighting Switch) Removal and Installation1485
Turn Signal Light Switch (in Lighting Switch) Inspection1485
Turn Signal and Hazard Warning Relay Removal and Installation1485
Turn Signal and Hazard Warning Relay Inspection1485
License Lamp Assembly Removal and Installation1486
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) Inspection1488
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 System1491
Illumination Cancel Switch (if Equipped) Inspection1492
Auto-On Headlight Sensor Inspection (if Equipped)1493
Tightening Torque Specifications1493
Instrumentation / Driver Info. / Horn1494
Precautions in Diagnosing Troubles for Combination Meter1494
General Description1494
CAN Communication Data of Combination Meter1494
Schematic and Routing Diagram1495
Combination Meter Circuit Diagram1495
Component Location1496
Audio System Component Location1496
Diagnostic Information and Procedures1497
Speedometer Symptom Diagnosis1497
Tacho Meter Symptom Diagnosis1497
Engine Coolant Temperature (ECT) Meter1497
Fuel Meter Symptom Diagnosis1497
Low Fuel Warning Light Symptom Diagnosis1498
Oil Pressure Warning Light Symptom Diagnosis1498
Brake and Parking Brake Warning Light Symptom Diagnosis1499
Seat Belt Reminder Light Symptom Diagnosis (if Equipped)1499
Illumination Indicator Symptom Diagnosis1500
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 Diagnosis1501
Charge Warning Light Symptom Diagnosis1501
Main Beam (High Beam) Indicator Symptom Diagnosis1501
Warning Buzzer Circuit Symptom Diagnosis1502
Cigarette Lighter Symptom Diagnosis (if Equipped)1502
Horn Symptom Diagnosis1502
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 Instructions1505
Ignition Switch Removal and Installation1505
Ignition Switch Inspection1506
Combination Meter Removal and Installation1506
Fuel Level Sensor Removal and Installation1506
Fuel Level Sensor Inspection1507
Oil Pressure Switch Removal and Installation1507
Oil Pressure Switch Inspection1508
Engine Coolant Temperature (ECT) Sensor Inspection1508
Brake Fluid Level Switch Inspection1508
Parking Brake Switch Inspection1508
Door Switch (Front / Rear / Rear End Door) Inspection1509
Outside Air Temperature Sensor Removal and Installation (if Equipped)1509
Outside Air Temperature Sensor Inspection (if Equipped)1509
Instrument Panel Removal and Installation1509
Information Display (Clock) Removal and Installation1511
Audio Unit Removal and Installation1511
Front Speaker Removal and Installation1512
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 Installation1513
Horn Inspection1513
Horn Relay Inspection1513
Antenna Base Removal and Installation1514
Remote Audio Control Switch Removal and Installation1514
Remote Audio Control Switch Inspection1515
Tightening Torque Specifications1515
Wipers / Washers1516
Diagnostic Information and Procedures1516
Front Wiper and Washer Symptom Diagnosis1516
Rear Wiper and Washer Symptom Diagnosis (if Equipped)1516
Headlight Washer Symptom Diagnosis (if Equipped)1517
Headlight Washer Operation Inspection1517
Inspection of Headlight Washer Control Module and Its Circuit1518
Repair Instructions1519
Wipers and Washers Components1519
Washer Tank and Washer Pump Removal and Installation1520
Washer Pump Inspection1520
Windshield Wiper Removal and Installation1521
Windshield Wiper Motor Inspection1522
Rear Wiper Removal and Installation (if Equipped)1523
Rear Wiper Motor Inspection (if Equipped)1524
Windshield Wiper and Washer Switch Removal and Installation1525
Windshield Wiper and Washer Switch Inspection1526
Rear Wiper and Washer Switch Removal and Installation1527
Rear Wiper and Washer Switch Inspection1527
Rear Wiper Relay Removal and Installation1527
Rear Wiper Relay Inspection1528
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 Specifications1529
Glass / Windows / Mirrors1530
General Description1530
Rear End Door Window Defogger System Description1530
Windshield Construction1530
Rear Quarter Window Construction1531
Diagnostic Information and Procedures1532
Rear End Door Window Defogger Symptom Diagnosis1532
Power Window Control System Symptom Diagnosis1533
Power Door Mirror Control System Symptom Diagnosis (if Equipped)1533
Door Mirror Heater Symptom Diagnosis (if Equipped)1533
Repair Instructions1534
Windshield Removal and Installation1534
Rear Quarter Window Removal and Installation1537
Front Door Window Components1542
Front Door Glass Removal and Installation1543
Front Door Window Regulator Removal and Installation1544
Front Door Window Regulator Inspection1544
Rear Door Window Components1545
Rear Door Glass Removal and Installation1545
Rear Door Window Regulator Removal and Installation1546
Rear Door Window Regulator Inspection1547
Rear End Door Window Components1547
Rear End Door Glass Removal and Installation1548
Rear End Door Window Defogger Relay Inspection1548
Rear End Door Window Defogger Wire Inspection1549
Rear End Door Window Defogger Wire Repair1549
Power Window Main Switch Inspection1549
Power Window Sub Switch Inspection1551
Door Mirror Components1551
Door Mirror Removal and Installation1552
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 Equipment1553
Recommended Service Material1553
Security and Locks1554
General Description1554
Key Coding Construction1554
Component Location1554
Power Door Lock and Keyless Entry System Component Location1554
Diagnostic Information and Procedures1555
Power Door Lock System Symptom Diagnosis1555
Power Door Lock System Operation Inspection1555
Keyless Entry System Symptom Diagnosis (if Equipped)1556
Keyless Entry System Operation Inspection1557
Door Lock Function of Keyless Start System Symptom Diagnosis (if Equipped)1557
Repair Instructions1557
Front Door Lock Assembly Components1557
Front Door Lock Assembly Removal and Installation1558
Front Door Lock Assembly Inspection1559
Power Door Lock Switch Inspection1560
Door Key Cylinder Switch Inspection1560
Power Door Lock Actuator Inspection (if Equipped)1560
Rear Door Lock Assembly Components1562
Rear Door Lock Assembly Removal and Installation1563
Rear Door Lock Assembly Inspection1563
Rear End Door Lock Assembly Components1564
Rear End Door Lock Assembly Removal and Installation1564
Rear End Door Lock Assembly Inspection1565
Replacement of Transmitter Battery1565
Programming Transmitter Code for Keyless Entry System (Vehicle Without Keyless Start System)1566
Keyless Entry Receiver Removal and Installation1566
Keyless Entry Receiver and Its Circuit Inspection1567
Tightening Torque Specifications1568
Special Tools and Equipment1568
Recommended Service Material1568
Seats1569
Diagnostic Information and Procedures1569
Front Seat Heater Symptom Diagnosis (if Equipped)1569
Repair Instructions1569
Front Seat Components1569
Front Seat Removal and Installation1570
Front Seat Heater Switch (Driver and Passenger Side) Inspection (if Equipped)1570
Front Seat Heater Wire Inspection (if Equipped)1570
Rear Seat Components1571
Rear Seat Removal and Installation1571
Tightening Torque Specifications1571
Interior Trim1572
Repair Instructions1572
Floor Carpet Removal and Installation1572
Head Lining Removal and Installation1572
Console Box Components1575
Sun Roof / T-Top / Convertible Top1576
General Description1576
Power Sliding (Sun) Roof System Description1576
Diagnostic Information and Procedures1576
Power Sliding (Sun) Roof System Symptom Diagnosis1576
Repair Instructions1576
Sliding (Sun) Roof Glass Components1576
Sliding (Sun) Roof Glass Removal and Installation1577
Sliding (Sun) Roof Glass Adjustment1577
Sliding (Sun) Roof Switch Inspection1577
Sliding (Sun) Roof Motor Removal and Installation1578
Sliding (Sun) Roof System Circuit and Motor Inspection1578
Sliding (Sun) Roof Assembly Components1579
Sliding (Sun) Roof Assembly Removal and Installation1580
Sliding (Sun) Roof Assembly Disassembly and Reassembly1581
Hood / Fenders / Doors1582
Repair Instructions1582
Hood Removal and Installation1582
Hood Inspection and Adjustment1582
Front Fender Components1583
Front Fender Removal and Installation1583
Front Door Assembly Components1584
Front Door Assembly Removal and Installation1585
Rear Door Assembly Components1586
Rear Door Assembly Removal and Installation1586
Rear End Door Assembly Components1587
Rear End Door Assembly Removal and Installation1588
Tightening Torque Specifications1589
Special Tools and Equipment1589
Recommended Service Material1589
Body Structure1590
Repair Instructions1590
Front Bumper Components1590
Rear Bumper Components1591
Cowl Top Components1592
Body Dimensions1593
Panel Clearance1603
Paint / Coatings1605
General Description1605
Anti-Corrosion Treatment Construction1605
Plastic Parts Finishing1606
Component Location1606
Sealant Application Areas1606
Under Coating Application Areas1616
Anti-Corrosion Compound Application Area1620
Exterior Trim1622
Repair Instructions1622
Control Systems1625
Precautions1627
Precautions for Control Systems1627
Cruise Control System1628
General Description1628
Cruise Control System Construction1628
Components and Functions of Cruise Control System1629
Cancel Conditions of Cruise Control System1630
Input / Output Diagram1630
Schematic and Routing Diagram1631
Cruise Control System Wiring Diagram1631
Diagnostic Information and Procedures1632
Cruise Control System Symptom Diagnosis1632
Inspection of Cruise Control System Circuit1633
Repair Instructions1635
Cruise Control Switch Removal and Installation1635
Cruise Control Switch Inspection1635
CPP Switch (for Cruise Control) Removal and Installation1635
Clutch Pedal Position (CPP) Switch (for Cruise Control) Inspection and Adjustment1636
Stop (Brake) Lamp Switch Removal and Installation1636
Stop (Brake) Lamp Switch Inspection1636
ECM Removal and Installation1636
Tightening Torque Specifications1636
Body Electrical Control System1637
Precautions in Diagnosing Trouble1637
General Description1637
BCM General Description1637
CAN Communication for BCM1637
Schematic and Routing Diagram1638
Connector Layout Diagram of BCM1640
Component Location1641
BCM and Related System Component Location1641
Diagnostic Information and Procedures1642
BCM Self-Diagnosis Function1642
Body Electrical Control System Check1644
Scan Tool Data1646
DTC Check1648
DTC Clearance1649
BCM Power Circuit and Ground Circuit Check1650
DTC B1133 (DTC No. 1133): Battery Voltage too High1651
Dtc B1141 / Dtc B1142 / Dtc B11431652
Temperature (Ambient Temp.) Sensor1653
DTC B1150 (No. 1150): Air Bag Communication Circuit Malfunction1653
DTC B1157 (No. 1157) Air Bag Deployment Signal Input1655
DTC B1170 (No. 1170): EEPROM Access Error1655
DTC U1073 (No. 1073): Control Module Communication Bus off1656
DTC U1100 (No. 1100): Lost Communication with ECM1659
DTC U1101 (No. 1101): Lost Communication with TCM1661
DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module1663
Inspection of BCM and Its Circuits1665
Repair Instructions1671
BCM Removal and Installation1671
Outside Air Temperature Sensor Removal and Installation1671
Outside Air Temperature Sensor Inspection1672
Special Tools and Equipment1672
Special Tool1672
Immobilizer Control System1673
Precautions1673
Precautions in Diagnosing Troubles1673
Precaution in Replacing ECM1673
Precautions in Handling Immobilizer Control System1673
General Description1674
Immobilizer Control System Introduction1674
Immobilizer Control System Components Location1674
On-Board Diagnostic System Description (Self-Diagnosis Function)1675
Schematic and Routing Diagram1676
Immobilizer Control System Wiring Circuit Diagram1676
Diagnostic Information and Procedures1677
Immobilizer Control System Check1677
Diagnostic Trouble Code (DTC) Check1678
Diagnostic Trouble Code (DTC) Clearance1678
Diagnostic Trouble Code (DTC) Table1678
Scan Tool Data1679
Immobilizer Indicator Lamp Does Not Come on with Ignition Switch on and Engine Stop1680
Immobilizer Indicator Lamp Remains on after Engine Start1681
DTC P1614: Transponder Response Error1681
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 Error1687
DTC P1622: EEPROM Error1690
DTC P1623: Unregistered Transponder1690
DTC P1625: Immobilizer Antenna Error1691
DTC P1636: Immobilizer Information Registration Failure1692
DTC P1638: Immobilizer Information Mismatched1693
Inspection of Immobilizer Control Module (ICM) and Its Circuit1694
Repair Instructions1696
Immobilizer Control Module (ICM) Removal and Installation1696
Registration of the Ignition Key1696
Procedure after ECM Replacement1696
Special Tools and Equipment1697
Special Tool1697
Keyless Start System1698
General Description1698
Keyless Start System Description1698
Parts and Functions1699
Keyless Engine Start Function1700
Door Lock Function of Keyless Start System1701
Operation Area of Remote Controller1702
Alarm Function1703
CAN Communication of Keyless Start System1703
Schematic and Routing Diagram1704
Keyless Start System Electric Wiring Circuit Diagram1704
Diagnostic Information and Procedures1705
Precautions in Diagnosing Troubles1705
Self-Diagnosis Function1705
Keyless Start System Diagnosis Introduction1705
Keyless Start System Check1705
Customer Questionnaire (Example)1706
Key Indicator Lamp Check1707
DTC Check1707
DTC Table1708
DTC Clearance1709
Keyless Start System Symptom Diagnosis1709
Keyless Start System Operation Inspection1710
Door Lock Operation (Keyless Start System)1711
Inspection of Keyless Start Control Module and Its Circuits1711
No DTC Detection after Performing DTC Check1716
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 Check1719
DTC No. 11: Communication Error with Steering Lock Unit1720
DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction1722
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 BCM1723
DTC No. 33: Control Module Communication Bus off1725
DTC No. 51 / No. 52 / No. 53: Driver Side / Passenger Side / Rear End Door Request Switch Failure1727
Repair Instructions1729
Antennas and Request Switches Removal and Installation1729
Front Door (Driver and Passenger Side) Rear End Door Request Switch Inspection1730
Steering Lock Unit Removal and Installation1730
Steering Lock Unit Inspection1730
Front Door Lock Switch Inspection1730
Keyless Start Control Module Removal and Installation1731
Remote Controller Inspection1731
Replacement of Remote Controller Battery1731
Registration Procedure for Remote Controller ID Code1732

Suzuki Grand Vitara 2005 Owner's Manual

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Suzuki Grand Vitara 2005 Specifications

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Brand	Suzuki
Model	Grand Vitara 2005
Category	Automobile
Language	English