2004 forester service manual quick reference index body section

2004 FORESTER SERVICE MANUAL

BODY SECTION

This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.

This manual includes the procedures for maintenance, disassembling, reassembling, inspection and adjustment of components and diagnostics for guidance of experienced mechanics.

Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition.

When replacement of parts during repair work is needed, be sure to use

SUBARU genuine parts.

QUICK REFERENCE INDEX

HVAC SYSTEM

(HEATER, VENTILATOR AND A/C)

HVAC SYSTEM (AUTO A/C)

(DIAGNOSTIC)

AIRBAG SYSTEM

AC

AC

AB

AB AIRBAG SYSTEM (DIAGNOSTIC)

SEAT BELT SYSTEM SB

LI LIGHTING SYSTEM

WIPER AND WASHER SYSTEM WW

ET ENTERTAINMENT

COMMUNICATION SYSTEM COM

GW GLASS/WINDOW/MIRROR

BODY STRUCTURE BS

IDI INSTRUMENTATION/DRIVER INFO

SEAT SE

SECURITY AND LOCK SL

SUNROOF/T-TOP/CONVERTIBLE TOP

(SUNROOF)

SR

EXTERIOR/INTERIOR TRIM EI

EXTERIOR BODY PANEL EB

All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval.

FUJI HEAVY INDUSTRIES LTD.

G8080GE7

2004 FORESTER SERVICE MANUAL

BODY SECTION

QUICK REFERENCE INDEX

CRUISE CONTROL SYSTEM


(DIAGNOSTIC)


(DIAGNOSTIC)


(DIAGNOSTIC)

IMMOBILIZER (DIAGNOSTIC)

CC

CC(H4SO)

CC(H4DOTC)

CC(H4DOTC 2.5)

IM

G8080GE7

HVAC SYSTEM

(HEATER, VENTILATOR AND A/C)

AC

Page

1.

General Description ....................................................................................2

2.

Refrigerant Pressure with Manifold Gauge Set.........................................25

3.

Refrigerant Recovery Procedure...............................................................26

4.

Refrigerant Charging Procedure ...............................................................27

5.

Refrigerant Leak Check ............................................................................30

6.

Compressor Oil .........................................................................................31

7.

Blower Motor Unit Assembly .....................................................................32

8.

Blower Resistor (Manual A/C Model) ........................................................33

9.

Heater Core...............................................................................................34

10.

Control Unit ...............................................................................................35

11.

Compressor...............................................................................................36

12.

Condenser.................................................................................................37

13.

Condenser (Sub Fan)................................................................................38

14.

Heater Cooling Unit...................................................................................39

15.

Evaporator.................................................................................................40

16.

Hose and Tube..........................................................................................41

17.

Relay and Fuse .........................................................................................42

18.

Pressure Switch (Triple Pressure Switch) .................................................43

19.

Ambient Sensor (Auto A/C Model) ............................................................44

20.

Sunload Sensor (Auto A/C Model) ............................................................45

21.

Air Vent Grille ............................................................................................46

22.

Heater Duct ...............................................................................................47

23.

Heater Vent Duct.......................................................................................48

24.

Heater Cock Solenoid Valve .....................................................................49

25.

General Diagnostics ..................................................................................50

General Description

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

1. General Description

A: SPECIFICATION

1. HEATER SYSTEM

Item Specifications

Heating capacity

Air flow rate

Max air flow rate

Heater core size

(height

×length×width)

Type

Blower motor

Fan type and size

(diameter

×width)

2. A/C SYSTEM

• AUTO A/C MODEL

5.0 kW (4,300 kcal/h,

17,062 BTU/h) or more

280 m

3

(9,888 cu ft)/h

480 m

3

(16,951 cu ft)/h

134.1

×224.3×32 mm

(5.28

×8.83×1.26 in)

Auto A/C (Brushless motor)

230 W or less

Manual A/C (Cylinder motor)

260 W or less

Sirocco fan type

150

×75 mm (5.91×2.95 in)

Condition

• Mode selector switch: HEAT

• Temperature control switch: FULL HOT

• Temperature difference between hot water and inlet air: 65

°C (149°F)

• Hot water flow rate: 3602 (95.1 US gal, 79.2

Imp gal)/h

Heat mode (FRESH), FULL HOT at 12.5 V

• Temperature control switch: FULL COLD

• Blower fan speed: 4th position

• Mode selector lever: RECIRC

—

12.5 V

12.5 V

—

Type of air conditioner

Cooling capacity

Refrigerant

Compressor

Magnet clutch

Condenser

Receiver drier

Expansion valve

Evaporator

Blower fan

Item

Type

Discharge

Max. permissible speed

Type

Power consumption

Type of belt

Pulley dia. (effective dia.)

Pulley ratio

Type

Core face area

Core thickness

Radiation area

Effective inner capacity

Type

Type

Dimensions (W

×H×T)

Fan type

Outer diameter

×width

Power consumption

Specifications

Reheat air-mix type

5.1 kW

(4,386 kcal/h, 17,403 BTU/h)

HFC-134a (CH

2

FCF

3

)

[0.6

±0.05 kg (1.32±0.11 lb)]

Vane rotary, fix volume (DKV-14G)

140 cm

3

(8.54 cu in)/rev

7,000 rpm

Dry, single-disc type

38 W (DC 12 V-25

°C)

V-belt 4 PK

125 mm (4.92 in)

1.064

Corrugated fin (Sub cool type)

0.234 m

2

(2.52 sq ft)

16 mm (0.63 in)

5.6 m

2

(62.28 sq ft)

220 cm

3

(13.42 cu in)

External equalizing

Single tank

176.5

×266×60 mm

(6.95

×10.47×2.36 in)

Sirocco fan

150

×75 mm (5.91×2.95 in)

230 W or less at 12.5 V

AC-2

Condenser fan (Sub fan)

Radiator fan (Main fan)

Item



Motor type

Power consumption

Fan outer diameter

Motor type

Power consumption

Idling speed (A/C ON)

Triple switch

(Pressure switch)

Low-pressure switch operating pressure

High-pressure switch operating pressure

Fan outer diameter

MPFI model

ON

→ OFF

OFF

→ ON

ON

→ OFF

OFF

→ ON

Middle pressure switch operating pressure

ON

→ OFF

OFF

→ ON

Specifications

Magnet

2.5 L turbo model and turbo AT model for EC and

EK:

120 W at 12 V

Other model than above:

70 W at 12 V

320 mm (12.6 in)

Magnet


EK:

120 W at 12 V


70 W at 12 V

320 mm (12.6 in)

800

±100 rpm

177

±25 kPa

(1.80

±0.25 kg/cm 2

, 25.60

±3.56 psi)

206

±30 kPa

(2.10

±0.31 kg/cm

2

, 29.86

±4.41 psi)

2,940

±200 kPa

(29.98

±2.03 kg/cm

2

, 426.32

±28.87 psi)

590

±200 kPa

(6.02

±2.03 kg/cm 2

, 85.6

±28.87 psi)

1370

±120 kPa

(13.97

±1.22 kg/cm 2

, 198.65

±17.35 psi)

1,770

±100 kPa

(18.05

±1.02 kg/cm

2

, 256.81

±14.50 psi)

3.0

0.3

ON

Thermo control amplifier working temperature

(Evaporator outlet air)

OFF

• MANUAL A/C MODEL

Type of air conditioner

Cooling capacity

Refrigerant

Compressor

Item

Magnet clutch

Type

Discharge

Max. permissible speed

Type

Power consumption

Type of belt

Pulley dia. (effective dia.)

Pulley ratio

AC-00082

Specifications

Reheat air-mix type

5.1 kW (4,386 kcal/h, 17,403 BTU/h)

HFC-134a (CH

2

FCF

3

)

[600

±50 g (1.32±0.11 lb)]

Vane rotary, fix volume (DKV-14G)

140 cm

3

(8.54 cu in)/rev

7,000 rpm

Dry, single-disc type

38 W (DC12 V — 25

°C)

V-belt 4 PK

125 mm (4.92 in)

1.064

AC-3



Item

Condenser

Receiver drier

Expansion valve

Evaporator

Blower fan

Condenser fan (Sub fan)

Radiator fan (Main fan)

Type

Core face area

Core thickness

Radiation area

Effective inner capacity

Type

Type

Dimensions (W

×H×T)

Fan type

Outer diameter

×width

Power consumption

Motor type

Power consumption

Fan outer diameter

Motor type

Power consumption

Idling speed (A/C ON)

Triple switch

(Pressure switch)

Low-pressure switch operating pressure

Fan outer diameter

MPFI model

ON

→ OFF

OFF

→ ON

High-pressure switch operating pressure

ON

→ OFF

OFF

→ ON

Middle pressure switch operating pressure

ON

→ OFF

OFF

→ ON

Specifications

Corrugated fin (Sub cool type)

0.234 m

2

(2.52 sq ft)

16 mm (0.63 in)

5.6 m

2

(6.26 sq ft)

220 cm

3

(13.42 cu in)

External equalizing

Single tank

176.5

×266×60 mm

(6.95

×10.47×2.36 in)

Sirocco fan

150

×75 mm (5.91×2.95 in)

260 W or less at 12.5 V

Magnet


EK:

120 W at 12 V


70 W at 12 V

320 mm (12.6 in)

Magnet


EK:

120 W at 12 V


70 W at 12 V

320 mm (12.6 in)

800

±100 rpm

177

±25 kPa

(1.80

±0.25 kg/cm

2

, 25.60

±3.56 psi)

206

±30 kPa

(2.10

±0.31 kg/cm 2

, 29.86

±4.41 psi)

2,940

±200 kPa

(29.98

±2.03 kg/cm 2

, 426.32

±28.87 psi)

590

±200 kPa

(6.02

±2.03 kg/cm

2

, 85.6

±28.87 psi)

1,370

±120 kPa

(13.97

±1.22 kg/cm

2

, 198.65

±17.35 psi)

1,770

±100 kPa

(18.05

±1.02 kg/cm 2

, 256.81

±14.50 psi)

3.0

0.3

ON

Thermo control amplifier working temperature

(Evaporator outlet air)

OFF

AC-00082

AC-4

B: COMPONENT

1. HEATER COOLING UNIT

• LHD MODEL WITH AUTO A/C



T

(17)

(6)

(7)

(21)

(19)

(19)

(18)

(22)

(20)

(23)

(15)

(13)

T

(4)

(3)

(5)

(16)

(1) Evaporator cover

(2) Mode actuator

(3) Mode main lever

(4) Vent door lever

(5) Foot door lever

(6) Mode actuator link

(7) Defroster lever

(8) Foot duct

(9) Lower case

(2)

(14)

(10)

(10) Heater core

(11) Drain hose

(12) Mix actuator

(13) Mix door lever

(14) Foot door lever (B)

(15) Upper case

(16) Aspirator

(17) Packing

(18) Cooling unit pipe

(9)

(12)

(1)

(8)

T

(11)

AC-00358

(19) O-ring

(20) Expansion valve

(21) Evaporator

(22) Evaporator lining

(23) Evaporator sensor

Tightening torque: N·m (kgf-m, ft-lb)

T: 7.5 (0.76, 5.5)

AC-5



• RHD MODEL WITH AUTO A/C

T

(22)

(18)

(21)

(20)

(20)

(24)

(23)

(19)

(15)

(6)

(7)

(4)

(3)

(5)

(2)

(14)

(13)

T

(17)

(9)

(12)

(16)


(2) Mode actuator

(3) Mode main lever

(4) Vent door lever

(5) Foot door lever (A)


(7) Defroster lever

(8) Foot duct

(9) Lower case

(1)

(8)

T

(10)

(11)

(10) Heater core

(11) Drain hose

(12) Mix actuator

(13) Mix door lever

(14) Foot door lever (B)

(15) Upper case

(16) Aspirator hose

(17) Aspirator

(18) Packing

AC-00001


(20) O-ring


(22) Evaporator




T: 7.5 (0.76, 5.5)

AC-6

• LHD MODEL WITH MANUAL A/C



T

(14)

(18)

(16)

(16)

(15)

(19)

(17)

(20)

(13)

(5)

(6)

(11)

T

(3)

(2)

(4)

(12)


(2) Mode main lever

(3) Vent door lever

(4) Foot door lever


(6) Defroster lever

(7) Foot duct

(8) Lower case

(9)

(9) Heater core

(10) Drain hose

(11) Mix actuator lever

(12) Foot door lever

(13) Upper case

(14) Packing


(16) O-ring

(8)

(1)

(7)

T

(10)

AC-00359


(18) Evaporator




T: 7.5 (0.76, 5.5)

AC-7



• RHD MODEL WITH MANUAL A/C

T

(20)

(16)

(19)

(18)

(18)

(22)

(21)

(17)

(15)

(6)

(7)

(4)

(3)

(5)

(2)

(14)

(9)

(13)

(12)

T


(2) Side rod

(3) Mode actuator lever

(4) Vent door lever

(5) Foot door lever


(7) Defroster lever

(8) Foot duct

(9) Lower case

(1)

(8)

T

(10)

(11)

(10) Heater core

(11) Drain hose

(12) Mix actuator rod

(13) Mix actuator lever

(14) Foot door lever

(15) Upper case

(16) Packing


(18) O-ring

AC-00084


(20) Evaporator




T: 7.5 (0.76, 5.5)

AC-8

2. BLOWER MOTOR UNIT

• LHD MODEL WITH AUTO A/C



(4)

(6)

(7)

(2)

(3)

(1)

(5)

(8)

(1) Upper case

(2) Air inlet select actuator

(3) Air inlet select link

(4) Link lever

(5) Filter cover

(6) Cover

(7) Lower case

(8) Blower motor ASSY

AC-00334

AC-9



• RHD MODEL WITH AUTO A/C

(4)

(3)

(2)

(1)

(5)

(6)

(7)

(8)

(1) Upper case



(4) Link lever

(5) Filter cover

(6) Cover

(7) Lower case


AC-00332

AC-10




(4)

(7)

(8)

(2)

(3)

(1)

(6)

(5)

(9)

(1) Upper case



(4) Link rod

(5) Filter cover

(6) Blower resistor

(7) Cover

(8) Lower case


AC-00209

AC-11




(4)

(3)

(2)

(1)

(5)

(7)

(8)

(6)

(9)

(1) Upper case


(3) Air inlet select lever


(5) Filter cover

(6) Blower resister

(7) Cover

(8) Lower case


AC-00085

AC-12

3. CONTROL UNIT

• AUTO A/C MODEL



(1) Panel

(2) Control dial

(3) Switch

(7)

(6)

(5)

(4)

(1)

(4) Control case (front)

(5) Bulb

(6) Control unit circuit

(2)

(7) Control case (rear)

(3)

AC-00210

AC-13




(11)

(9)

(10)

(2)

(8)

(1) Panel

(2) Temperature control dial

(3) Fan dial

(4) Mode control dial

(1)

(5) A/C switch

(6) Air inlet select switch

(7) Rear defogger switch

(8) Switch circuit board

(4)

(3)

(7)

(5)

(6)

AC-00211

(9) Mode control cable

(10) Temperature control cable

(11) Bulb

AC-14




(9)

(11)

(10)

(2)

(8)

(1)

(6)

(5)

(7)

(3)

(4)

(1) Panel

(2) Mode control dial

(3) Fan dial


(5) A/C switch

(6) Rear defogger switch

(7) Air inlet select switch

(8) Switch circuit board

(9) Mode control cable

(10) Temperature control cable

(11) Bulb

AC-00333

AC-15



4. AIR CONDITIONING UNIT

• LHD MODEL

(5)

T2

(6)

(1)

(6)

(6)

(3)

T2

(6)

(2)

T1

(7)

(4)

(6)

T1

(1) Condenser

(2) High-pressure hose

(3) Low-pressure hose

(4) Pipe

(5) Compressor

(6) O-ring

(7) Triple pressure switch

(6)

AC-00866


T1: 7.4 (0.75, 5.4)

T2: 15 (1.5, 10.8)

AC-16



• RHD MODEL

T1

(1)

(6)

(6)

(5)

T2

(6)

(3)

T2

(2)

T1

(7)

(6)

(4)

(6)

(1) Condenser

(2) High-pressure hose

(3) Low-pressure hose

(4) Pipe

(5) Compressor

(6) O-ring

(7) Triple pressure switch

AC-00243


T1: 7.4 (0.75, 5.4)

T2: 15 (1.5, 10.8)

AC-17



5. COMPRESSOR

T5

(4)

T5

T5

(5)

(8)

(1)

(4)

(5)

(6)

T3

T2

(1)

T1

(2)

(7)

(3)

Idler pulley bracket

(2) Idler pulley adjuster

(3) Idler pulley

Compressor bracket

Compressor

V-belt

(6)

T4

T4

AC-00335

(7) Compressor belt cover (Non-turbo model)

(8) Compressor stay


T1: 4.0 (0.40, 2.95)

T2: 22.6 (2.3, 16.6)

T3: 23.0 (2.35, 17.0)

T4: 28.9 (2.95, 21.3)

T5: 35 (3.6, 26)

AC-18

6. HEATER DUCT



(5)

(3)

(4)

(1)

(2)

(6)

(1) Front defroster nozzle

(2) Side defroster duct (LH)

(3) Side defroster duct (RH)

(4) Side ventilation duct (LH)

(5) Side ventilation duct (RH)

(6) Rear heater duct

AC-00212

AC-19



C: CAUTION

1. HFC-134a A/C SYSTEM

• The cooling system components for the HFC-

134a system such as the refrigerant and compressor oil are different from the old conventional HFC-

12 system components and they are incompatible with each other.

• Vehicles with the HFC-134a system can be identified by the label (A) attached to the vehicle.

Before maintenance, check which A/C system is installed in the vehicle.

(A)

4. HANDLING OF REFRIGERANT

• The refrigerant boils at approx.

−30°C (−22°F).

When handling it, be sure to wear safety goggles and protective gloves. Direct contact of the refrigerant with skin may cause frostbite.

If the refrigerant gets into your eye, avoid rubbing your eyes with your hands. Wash your eye with plenty of water, and receive medical treatment from an eye doctor.

• Do not heat a service can. If a service can is directly heated, or put into boiling water, the inside pressure will become extremely high. This may cause the can to explode. If a service can must be warmed up, use hot water in 40

°C (104°F) max.

• Do not drop or impact a service can. (Observe the precautions and operation procedure described on the refrigerant can.)

• When the engine is running, do not open the high-pressure valve of the manifold gauge. The high-pressure gas will back-flow resulting in an explosion of the can.

• Provide good ventilation and do not work in a closed area.

• In order to prevent global warming, avoid releasing HFC-134a into the atmosphere. Using a refrigerant recovery system, discharge and reuse it.

AC-00006

2. COMPRESSOR OIL

• HFC-134a compressor oil has no compatibility with that for R12 system.

• Use only the manufacturer-authorized compressor oil for the HFC-134a system; only use

ZXL200PG.

• Do not mix multiple compressor oils.

If HFC-12 compressor oil is used in a HFC-134a A/

C system, the compressor may become stuck due to poor lubrication, or the refrigerant may leak due to swelling of rubber parts.

On the other hand, if HFC-134a compressor oil is used in a HFC-12 A/C system, the durability of the

A/C system will be lowered.

• HFC-134a compressor oil is very hygroscopic.

When replacing or installing/removing A/C parts, immediately isolate the oil from the atmosphere using a plug or tape. In order to avoid moisture, store the oil in a container with its cap securely closed.

3. REFRIGERANT

• The HFC-12 refrigerant cannot be used in the

HFC-134a A/C system. The HFC-134a refrigerant, also, cannot be used in the HFC-12 A/C system.

• If an incorrect or no refrigerant is used, poor lubrication will result and the compressor itself may be damaged.

(A)

(C) (D)

(B)

(F)

(E)

AC-00007

(A) Goggles

(B) Gloves

(C) Avoid open flame

(D) No direct heat on container

(E) Do not discharge

(F) Loosen

AC-20



5. O-RING CONNECTIONS

• Use new O-rings.

• In order to keep the O-rings free of lint which will cause a refrigerant gas leak, perform operations without gloves and shop cloths.

• Apply the compressor oil to the O-rings to avoid sticking, then install them.

• Use a torque wrench to tighten the O-ring fittings:

Over-tightening will damage the O-ring and tube end distortion.

• If the operation is interrupted before completing a pipe connection, recap the tubes, components, and fittings with a plug or tape to prevent foreign matters from entering.

• Use compressor oil specified in the service manual to lubricate the O-rings.

Apply the oil to the top and sides of the O-rings before installation.

Apply compressor oil to the bead of tube.

(A) Seal

• Visually check the surfaces and mating surfaces of O-rings, threads, and connecting points. If a failure is found, replace the applicable parts.

• Install the O-rings at right angle to the tube beards.

(A)

(B)

(C)

(A)

(D)

AC-00008

AC-00010

• After tightening, use a clean cloth to remove excess compressor oil from the connections and any oil which may have run on the vehicle body or other parts.

• If any leakage is suspected after tightening, do not retighten the connections, disconnect the connections, remove the O-rings, and check the Orings, threads, and connections.

D: PREPARATION TOOL

CAUTION:

When working on vehicles with the HFC-134a system, only use HFC-134a specified tools and parts. Do not mix with CFC-12 tools and parts. If

HFC-134a and CFC-12 refrigerant or compressor oil is mixed, poor lubrication will result and the compressor itself may be destroyed.

In order to help prevent mixing HFC-134a and

CFC-12 parts and liquid, the tool and screw type and the type of service valves used are different. The gas leak detectors for the HFC-134a and CFC-12 systems must also not be interchanged.

(C)

Tool & screw type

Valve type

HFC-134a

Millimeter size

Quick joint type

CFC-12

Inch size

Screw-in type

AC-00009

(A) O-ring

(B) OK

(C) NG

(D) Bead

AC-21



Illustration Tools and Equipment

Wrench

Various WRENCHES will be required to service any A/C system. A 7 to

40 N·m (0.7 to 4.1 kgf-m, 5 to 30 ft-lb) torque wrench and various crowfoot wrenches will be needed. Open end or flare nut wrenches will be needed for back-up on the tube and hose fittings.

AC-00213

Applicator bottle

A small APPLICATOR BOTTLE is recommended to apply refrigerant oil to the various parts. They can be available at a hardware or drug store.

AC-00012

Manifold gauge set

A MANIFOLD GAUGE SET (with hoses) can be available at from either a refrigerant supplier or an automotive equipment supplier.

AC-00013

Refrigerant recovery system

A REFRIGERANT RECOVERY SYSTEM is used for the recovery and reuse of A/C system refrigerant after contaminants and moisture have been removed from the refrigerant.

AC-00014

AC-22

Illustration



Tools and Equipment

Syringe

A graduated plastic SYRINGE will be needed to add oil back into the system. The syringe can be available at a pharmacy or a drug store.

AC-00015

Vacuum pump

A VACUUM PUMP (in good working condition) is necessary, and can be available at either a refrigerant supplier or an automotive equipment supplier.

AC-00016

Can tap

A CAN TAP for the 397 g (14 oz) can is available at an automotive equipment supplier.

AC-00017

Thermometer

Pocket THERMOMETERS are available at either a industrial hardware store or a refrigerant suppliers.

AC-00018

AC-23



Illustration Tools and Equipment

Electronic leak detector

An ELECTRONIC LEAK DETECTOR can be available at either a specialty tool supplier or an A/C equipment supplier.

AC-00019

Weight scale

A WEIGHT SCALE such as an electronic charging scale or a bathroom scale with digital display will be needed, if a 13.6 kg (30 lb) refrigerant container is used.

AC-00020

AC-24

Refrigerant Pressure with Manifold Gauge Set


2. Refrigerant Pressure with Manifold Gauge Set

A: OPERATION

1) Place the vehicle in the shade and draftless condition.

2) Connect the manifold gauge set.

3) Open the front windows and close all doors.

4) Open the hood.

5) Increase the engine speed to 1,500 rpm.

6) Turn ON the A/C switch.

7) Turn the temperature control dial to MAX COOL.

8) Set the air inlet select switch to RECIRC position.

9) Turn the fan dial to HI.

10) Read the gauge.

Standard:

Low pressure: 127 — 196 kPa (1.3 — 2.0 kg/cm

2

, 18 — 28 psi)

High pressure: 1,471 — 1, 667 kPa (15 — 17 kg/cm

2

, 213 — 242 psi)

Ambient temperature: 30 — 35

°

C (86 — 95

°

F)

B: INSPECTION

Symptom

High-pressure side is unusually high.

High-pressure side is unusually low.

Probable cause

• Defective condenser fan motor

• Clogged condenser fin

• Too much refrigerant

• Air inside the system

• Defective receiver dryer

Repair order

• Replace the fan motor.

• Clean the condenser fin.

• Discharge refrigerant.

• Replace the receiver dryer.

• After reevacuating the receiver dryer, charge appropriate amount of refrigerant.

• Replace the compressor.

• Check for leaks.

• Replace the expansion valve.

• Fully evacuate the expansion valve.

Low-pressure side is unusually high.

Low-pressure side is unusually low.

• Defective compressor

• Not enough refrigerant

• Clogged expansion valve

• Expansion valve frozen temporarily by moisture

• Defective compressor

• Defective expansion valve

• Too much refrigerant

• Not enough refrigerant

• Clogged expansion valve

• Expansion valve frozen temporarily by moisture

• Saturated receiver dryer

• Replace the compressor.


• Discharge refrigerant.

• Check for leaks.


• Replace the receiver dryer.

AC-25

Refrigerant Recovery Procedure


3. Refrigerant Recovery Procedure

A: OPERATION

CAUTION:

• During operation, be sure to wear safety goggles and protective gloves.

• Connect the refrigerant recovery system with the manifold gauge set to discharge the refrigerant from the A/C system and reuse it.

• When reusing the discharged refrigerant, keep service cans on hand. Because the discharge rate with the recovery system is approx. 90%, service cans are necessary to charge the refrigerant.

• Follow the detailed operation procedure described in the operation manual attached to the refrigerant recovery system.

1) Perform the compressor oil return operation.

<Ref. to AC-31, OPERATION, Compressor Oil.>

2) Stop the engine.

3) Make sure the valves on low-/high-pressure sides of manifold gauge set are fully closed.

4) Install the low-/high-pressure hoses to the service ports on the low-/high-pressure sides of the vehicle respectively.

(1) (2)

(3)

(1)

L H

(3)

AC-00147

(1) Low-pressure service port

(2) High-pressure service port

(3) Close

5) Connect the center hose to the refrigerant recovery system.

6) Follow the operation manual to activate the refrigerant recovery system.

(4)

(2)

(5)

(6)

(1)

L: Low-pressure gauge

H: High-pressure gauge

(1) Low-pressure valve

(2) Vacuum pump valve

(3) High-pressure valve

(4) For low-pressure

(5) For vacuum pump

(6) For high-pressure

(2)

(3)

AC-00146

AC-26

Refrigerant Charging Procedure


4. Refrigerant Charging Procedure

A: OPERATION

CAUTION:

• During operation, be sure to wear safety goggles and protective gloves.

• If air is mixed in refrigeration cycle, poor cooling may result, and also if moisture is mixed in refrigeration cycle, clogging (freezing) or rust may result.

Before charging the refrigerant, evacuate the system using vacuum pump to remove air and moisture in the system. Moisture can be evaporated and removed easily even at normal temperature, if the system is evacuated using vacuum pump.

1) Close all valves of manifold gauge.

2) Install the low-/high-pressure hoses to corresponding service ports on vehicle.

(1) (2)

(3)

L H

(1)

(4)

(2)

(5)

(6)

(3)

AC-00147

(1) Low-pressure service port

(2) High-pressure service port

(3) Close

CAUTION:

Be sure that the hoses are securely connected.

3) Connect the center hose of manifold gauge with vacuum pump.

4) Activate the vacuum pump and then open the valves on low-/high-pressure sides.

(1)

L: Low-pressure gauge

H: High-pressure gauge

(1) Low-pressure valve

(2) Vacuum pump valve

(3) High-pressure valve

(4) For low-pressure

(5) For vacuum pump

(6) For high-pressure

(2)

(3)

AC-00146

(2)

(1)

AC-00148

(1) Vacuum pump

(2) Open

CAUTION:

Be sure to evacuate the system using vacuum pump.

5) After at least 5 minutes of evacuation, if the lowpressure gauge reading shows 100.0 kPa (750 mmHg, 29.5 inHg) or higher, close the valves on center hose to stop the vacuum pump.

AC-27



6) Leave it at least 5 to 10 minutes after closing the valves on low-/high-pressure sides, and then check the low-pressure gauge reading for any changes.

When the gauge reading changes, this is a sign of leakage. Check the pipe or hose connector points, and repair if necessary. Repeat the procedure from

1) after repairing the faulty part.

7) If there are no leaks, further evacuate the system 20 to 30 minutes.

8) Close all valves and stop the vacuum pump.

9) Following the can tap operation manual instructions, install it to refrigerant can.

13) Loosen the center hose connection on manifold gauge (if applicable, press a purge valve on manifold gauge) only for a couple of seconds to allow the air in the center hose to escape by the refrigerant.

(1)

(2)

AC-00216

14) Make sure that the high-pressure valve of manifold gauge is closed, and then open the low-pressure side valve only to charge the refrigerant.

AC-00214

(1) Tap valve

(2) To center manifold hose

10) Disconnect the vacuum pump from center hose, and connect the hose to tap valve.

11) When a 13.6 kg (30 lb) refrigerant container is used, measure the refrigerant amount in use using a weighting scale before connecting to center hose.

(1)

(2)

AC-00215

(1) Refrigerant container (HFC-134a)

(2) Weighting scale

12) Open the valve on HFC-134a source.

(1)

(2)

AC-00217

(1) Open

(2) Close

CAUTION:

Do not open the high-pressure valve. Be sure to open the low-pressure valve.

15) Close the low-pressure valve when the lowpressure gauge reading reaches 200 kPa (1,500 mmHg, 59.1 inHg).

16) Using a leak tester, check the system for refrigerant leaks.

17) After confirming that there are no leaks with the leak test, charge the required amount of refrigerant.

18) If the HFC-134a source is empty, close the lowpressure valve and then close the valve on can tap before replacing the empty source. Restart charging operation after replacing the HFC-134a source with a new one and purging.

19) Close the low-pressure valve if the charge rate of refrigerant becomes worse.

20) Confirm that both the low-/high-pressure valves are closed. Start the engine with A/C switch

OFF.

21) Quickly repeat A/C switch ON-OFF cycles a few times to prevent initial compressor damage.

AC-28



22) Set up the vehicle to the following status:

• A/C switch ON

• Engine running at 1,500 rpm

• Blower speed setting to “HI”

• Temperature setting to “MAX COOL”

• Air inlet setting to “RECIRC”

• Window open

23) Open the low-pressure valve and charge the specified amount of refrigerant.

24) Close all valves and disconnect the hoses from service port after charging the refrigerant.

25) Install the cap to service port.

AC-29

Refrigerant Leak Check


5. Refrigerant Leak Check

A: INSPECTION

1) Operate the A/C system for approx. 10 minutes, and confirm that the high-pressure side shows at least 690 kPa (7.03 kg/cm

2

, 100 psi). Then stop the engine to start the leak test.

2) Starting from the connection between the highpressure pipe and evaporator, check the system for leaks along the high-pressure side through the compressor. The following items must be checked thoroughly.

3) Check the joint and seam between the pressure switch (triple pressure switch) and high-pressure pipe.

4) Check the connections between the condenser and pipes, and welded joints on the condenser.

The leak tester may detect the oil on the condenser fins as a leak.

5) Check the joint between the compressor and hoses.

6) Check the machined area of compressor and other joints on the compressor.

7) Check the compressor shaft seal at the area near the center of compressor clutch pulley.

Some shaft seals show a slight amount of leakage about 28 g (1.0 oz) per year. This is not a problem.

8) Starting from the connection between the lowpressure pipe and evaporator, check the system for leakage along the low-pressure side through the compressor. The following items must be checked thoroughly.

• Connection between two parts

• Connection between the pipe and plate

CAUTION:

Carefully check the external surface of hoses and tubes at approx. 25 mm (0.98 in) per second.

(A)

AC-00036

(A) Flexible hose

10) Disconnect the drain hose from the heater case, and check the hose end for at least 10 seconds.

After the test is finished, reconnect the drain hose.

11) Turn the ignition switch to ON, and run the blower at high speed for 1 minute. Stop the blower to check the ventilation grille on the instrument panel. While moving the tester closer to the grille, run the blower for 1 or 2 seconds, then stop it. Check the grille at that point for at least 10 seconds.

AC-00037

12) Check the valve in the service port.

13) Visually check the rubber seal in the service port cap.

AC-00035

9) Visually check the rubber area of the flexible hose for cracks.

Check the entire length of the flexible hose, especially the connection with the metal hose end.

AC-00038

AC-30

Replacement parts

Evaporator

Condenser

Hose

Receiver dryer

Compressor Oil


6. Compressor Oil

A: OPERATION

NOTE:

Before making repairs, conduct the oil return operation to return the compressor oil in circulation with the refrigerant to the compressor.

1) Increase the engine speed to 1,500 rpm.


3) Turn the temperature control dial to MAX COOL.

4) Set the air inlet select switch to RECIRC position.

5) Turn the fan dial to HI.

6) Leave in this condition for 10 minutes.

B: REPLACEMENT

NOTE:

• If a component is replaced, add an appropriate amount of compressor oil (same as the amount of remaining oil in removed component).

• When replacing the compressor, the new compressor will already have the specified amount of oil in it. Install the new compressor after removing the same amount of oil that is remaining in the compressor removed.

Amount of oil replenishment

Approx. 50 cm

3

(1.7 US fl oz, 1.8 Imp fl oz)

Approx. 30 cm

3


Approx. 10 cm

3


Approx. 10 cm

3


AC-31

Blower Motor Unit Assembly


7. Blower Motor Unit Assembly

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Remove the glove box. <Ref. to EI-37, REMOV-

AL, Glove Box.>

3) Loosen the nut to remove the support beam stay.

B: INSTALLATION

Install in the reverse order of removal.

Tightening torque:

Refer to COMPONENT in General Descrip-

tion. <Ref. to AC-5, HEATER COOLING UNIT,

COMPONENT, General Description.> <Ref. to

AC-9, BLOWER MOTOR UNIT, COMPONENT,

General Description.>

C: INSPECTION

Inspection of Auto A/C Brush-less Motor

Operation

Connect the motor connector terminal 1 from the battery to the positive (+) lead and terminal 2 and 5 at the same time to the negative (

−) lead. Make sure the motor runs smoothly.

AC-00218

4) Disconnect the connectors of blower motor and intake actuator resistor.

1

2

5

5 2 1

AC-00244

AC-00219

5) Loosen the bolt and nut to remove blower motor unit assembly.

AC-00220

AC-32

Blower Resistor (Manual A/C Model)


8. Blower Resistor (Manual A/C

Model)

A: REMOVAL


AL, Glove Box.>

2) Disconnect the blower resistor connector.

3) Remove the two screws to remove blower resistor.

B: INSTALLATION


C: INSPECTION

AC-00221

0.4

0.7

1.5

1

4

2 3

6

MO H MH ML L

2 1 4 6 3

AC-00245

Measure the blower resistor resistance.

Terminal No.

3 and 6

3 and 4

2 and 1

Standard

Approx. 0.4

Ω

Approx. 1.1

Ω

Approx. 2.6

Ω

If NG, replace the blower resistor.

AC-33

Heater Core


6) Remove the screws to remove lower case.

9. Heater Core

A: REMOVAL

1) Remove the heater cooling unit. <Ref. to AC-39,

REMOVAL, Heater Cooling Unit.>

2) Remove the screws to remove the heater core pipe cover (RHD model).

AC-00046

7) Remove the heater core.

AC-00042

3) Remove the screws to remove mode actuator.

B: INSTALLATION


AC-00047

AC-00043

4) Remove the screws to remove foot duct.

AC-00044

5) Remove the screws to remove evaporator cover.

AC-00867

AC-34

10.Control Unit

Control Unit


A: REMOVAL


2) In case of manual A/C, remove the mode cable and air-mix cable from links of heater unit.

3) Remove the console front cover.

6) Insert the flat tip screwdriver to the position (A) and release the claw with pulling out the lower portion of center console panel.

CAUTION:

Do not insert the flat tip screwdriver into any portion except for indicated in the figure.The instrument panel may be damaged.

(A) (A)

(A)

(A)

(A)

(A)

(A)

EI-00726

(A) Hook

4) Apply the thick protective tape (A) to instrument panel pad to protect the surface of it.

NOTE:

Also apply the protective tape to the deep inside portion between center console panel and instrument panel pad.

EI-00732

(A) Inserting position of flat tip screwdriver

7) Remove the four screws on rear side of center console panel, and then remove the control unit.

B: INSTALLATION


(A)

5) Loosen the screws.

(C)

(B)

(A)

(A) Screw

(B) Clip

(C) Claw

EI-00731

(C)

(A)

EI-00728

AC-35

Compressor


11.Compressor

A: INSPECTION

1. MAGNETIC CLUTCH CLEARANCE

1) Check the clearance of the entire circumference around the drive plate and pulley.

Standard:

0.3 — 0.6 mm (0.0118 — 0.0236 in)

2. MAGNETIC CLUTCH OPERATION

1) Disconnect the compressor connector.

2) Connect the battery positive (+) terminal to the

No. 3 terminal of the compressor connector.

9) Remove the bolts to remove compressor bracket.

3) Make sure the magnet clutch engages.

If NG, replace the compressor.

B: REMOVAL

AC-00048

1) Perform the compressor oil return operation.

<Ref. to AC-31, OPERATION, Compressor Oil.>

2) Turn the A/C switch OFF and stop the engine.

3) Using the refrigerant recovery system, discharge

refrigerant. <Ref. to AC-26, OPERATION, Refrigerant Recovery Procedure.>


5) Remove the V-belt. <Ref. to ME(H4SO)-43, RE-

MOVAL, V-belt.> <Ref. to ME(H4DOTC)-52, RE-

MOVAL, V-belt.>

6) Remove the generator. <Ref. to SC(H4SO)-15,

REMOVAL, Generator.>

7) Remove the low-pressure hose and high-pressure hose.

AC-00049

8) Disconnect the compressor harness from body harness.

AC-36

AC-00336

10) Remove the bolts and then separate compressor and bracket.

AC-00051

C: INSTALLATION

1) Install in the reverse order of removal.

2) Replace the O-rings on low-/high-pressure hoses with new ones, then apply compressor oil.

3) When replacing compressor, adjust amount of

compressor oil. <Ref. to AC-31, OPERATION,

Compressor Oil.>

4) Charge refrigerant. <Ref. to AC-27, OPERA-

TION, Refrigerant Charging Procedure.>



tion. <Ref. to AC-16, AIR CONDITIONING

UNIT, COMPONENT, General Description.>

<Ref. to AC-18, COMPRESSOR, COMPO-

NENT, General Description.>

12.Condenser

A: REMOVAL

1) Using the refrigerant recovery system, discharge

refrigerant. <Ref. to AC-26, OPERATION, Refrigerant Recovery Procedure.>


3) Disconnect the pressure hose and pipe from condenser.

Condenser


B: INSTALLATION


CAUTION:

Replace the O-rings on hoses or pipes with new ones, and then apply compressor oil. Confirm that lower guide of condenser has been fitted into holes on radiator panel.

4) Remove the radiator bracket (A).

AC-00246

(A)

AC-00053

5) Remove the two bolts. While lifting the condenser, pull it out through the space between radiator and radiator panel.

AC-00092




Refer to COMPONENT in General Description.

<Ref. to AC-16, AIR CONDITIONING UNIT,

COMPONENT, General Description.>

<Ref. to CO(H4SO)-7, RADIATOR AND RADI-

ATOR FAN, COMPONENT, General Description.>

C: INSPECTION

1) Check that no dust or insects are found on the condenser fins. Air-blow or flush fins with water as needed.

2) Check that no oil leaks from condenser. If a failure is found, replace the condenser with a new one.

AC-00091

CAUTION:

Be careful not to damage the radiator fins and condenser fins. If a damaged fin is found, repair it using a thin screwdriver.

If the condenser is replaced, add appropriate amount of compressor oil to the compressor.

<Ref. to AC-31, REPLACEMENT, Compressor

Oil.>

AC-37

Condenser (Sub Fan)


13.Condenser (Sub Fan)

A: REMOVAL

<Ref. to CO(H4SO)-35, REMOVAL, Radiator Main

Fan and Fan Motor.>

B: INSTALLATION

<Ref. to CO(H4SO)-37, INSTALLATION, Radiator

Main Fan and Fan Motor.>

AC-38

Heater Cooling Unit


14.Heater Cooling Unit

A: REMOVAL


2) Using the refrigerant recovery system, dis-

charge refrigerant. <Ref. to AC-26, OPERATION,

Refrigerant Recovery Procedure.>

3) Drain the engine coolant from radiator.

4) Remove the bolt securing expansion valve and pipe in engine compartment. Release the heater hose clamps in engine compartment to remove the hoses.

AC-00870

5) Remove the instrument panel. <Ref. to EI-40,

REMOVAL, Instrument Panel Assembly.>

6) Remove the support beam.

7) Remove the blower motor unit assembly. <Ref.

to AC-32, REMOVAL, Blower Motor Unit Assembly.>

8) Disconnect the servo motor connectors.

9) Remove the bolt and nuts to remove the heater and cooling unit.

AC-00055

B: INSTALLATION






tion. <Ref. to AC-5, HEATER COOLING UNIT,


AC-39

Evaporator


15.Evaporator

A: REMOVAL

1) Perform the refrigerant recovery operation, and

then disconnect the toe board area A/C pipe. <Ref.

to AC-26, OPERATION, Refrigerant Recovery Procedure.>

2) Remove the glove box.

3) Remove blower motor unit assembly. <Ref. to

AC-32, REMOVAL, Blower Motor Unit Assembly.>

4) Loosen the screws and remove evaporator cover.

AC-00867

5) Remove the A/C pipes in unit.

6) Rotate the upper part of evaporator tilt toward the front vehicle and the lower part tilt toward the interior, respectively. Then pull out the heater case to the left side.

7) Remove the two bolts to remove expansion valve.

AC-00868

CAUTION:

If the evaporator is replaced, add appropriate

amount of compressor oil to evaporator. <Ref. to AC-31, REPLACEMENT, Compressor Oil.>

B: INSTALLATION


NOTE:

Replace the O-ring for A/C pipe with a new one, and then apply compressor oil.

AC-40

16.Hose and Tube

A: REMOVAL

CAUTION:

• When disconnecting/connecting hoses, do not apply excessive force to them. Confirm that no torsion and excessive tension exists after installing.

• Seal the disconnected hose with a plug or vinyl tape to prevent foreign matters from entering.


2) Using the refrigerant recovery system, dis-

charge refrigerant. <Ref. to AC-26, OPERATION,

Refrigerant Recovery Procedure.>

3) Remove the evaporator unit mounting bolt (A).

4) Remove the low-pressure hose attaching bolts

(B).

5) Disconnect the low-pressure hose from evaporator unit.

6) Disconnect the low-pressure hose from compressor.

7) Remove the low-pressure hose from vehicle.

8) Remove the high-pressure hose attaching bolts

(C).

9) Disconnect the high-pressure hose from compressor.

10) Disconnect the high-pressure hose from condenser.

11) Remove the high-pressure hose from vehicle.

12) Remove the high-pressure tube attaching bolt

(D).

13) Remove the high-pressure tube from vehicle.

Hose and Tube


B: INSTALLATION

CAUTION:

• When disconnecting/connecting hoses, do not apply an excessive force to them. Confirm that no torsion and excessive tension exists after installing.

• Seal the disconnected hose with a plug or vinyl tape to prevent foreign matters from entering.

• Replace the o-rings for hoses and pipes with new ones, and then apply compressor oil.






tion. <Ref. to AC-16, AIR CONDITIONING

UNIT, COMPONENT, General Description.>

C: INSPECTION

NOTE:

Check the hoses for cracks, damage and expansion. If any failure is found, replace them with new ones.

(A)

(B)

(D)

(C)

AC-00869

AC-41

Relay and Fuse


17.Relay and Fuse

A: LOCATION

B: INSPECTION

4

1

2

5

3

(2)

(3)

(4)

(1)

(5)

(6)

(7)

(1) Main fuse box (M/B)

(2) Main fan relay

(3) Sub fan relay

(4) A/C relay

(5) Fan mode relay

(6) Main fan fuse

(7) Sub fan fuse

AC-00834

3

1

4

5

2

AC-00093

(1) — (2) Continuity exists.

(3) — (4) Continuity exists.

(3) — (5) No continuity.

While applying battery voltage between the terminals (1) and (2), check continuity between the terminals (3) and (5).

If no continuity exists, replace the relay with a new one.

AC-42

Pressure Switch (Triple Pressure Switch)


18.Pressure Switch (Triple Pressure Switch)

A: INSPECTION

1) Connect the manifold gauge to the service valve on the high-pressure side.

2) Remove the pressure switch harness connector.

Using a circuit tester, inspect the ON-OFF operation of the pressure switch.

High and low pressure switch

Middle pressure switch

3

1

2

4

AC-00248

Terminal

No.

1 and 2

3 and 4

Operation

Standard kPa (kg/cm

2

, psi)

Turns OFF.

Pressure increases up to 2,940

±200 (30.0±2, 427±28).

Pressure decreases down to 177

±25 (1.8±0.3, 26±4).

Pressure increases up to 206

±30 (2.1±0.3, 30±4).

Turns ON.

Pressure decreases down to 2,350

±200 (24±2, 341±28).

Turns OFF.

Pressure decreases down to 1,370

±120 (14±1, 199±14).

Turns ON.

Pressure increases up to 1,770

±100 (18±1, 256±14).

AC-43

Ambient Sensor (Auto A/C Model)


19.Ambient Sensor (Auto A/C

Model)

A: REMOVAL

1) Open the front hood.


3) Disconnect the ambient sensor connector.

4) Remove the ambient sensor from radiator lower panel.

AC-00125

B: INSTALLATION


C: INSPECTION

<Ref. to AC-32, AMBIENT SENSOR, Diagnostic

Procedure for Sensors.>

AC-44

Sunload Sensor (Auto A/C Model)


20.Sunload Sensor (Auto A/C

Model)

A: REMOVAL


2) Disconnect the sunload sensor connector.

AC-00126

CAUTION:

Be careful not to damage the sensors and interior trims when removing them.

B: INSTALLATION


C: INSPECTION

<Ref. to AC-39, SUNLOAD SENSOR, Diagnostic

Procedure for Sensors.>

AC-45

Air Vent Grille


21.Air Vent Grille

A: REMOVAL

1. CENTER GRILLE


2) Remove the center console panel. <Ref. to EI-

40, REMOVAL, Instrument Panel Assembly.>

3) Loosen the two screws to remove the center air vent grille.

AC-00060

2. SIDE GRILLE

Remove the side vent grille by prying four points.

AC-00249

B: INSTALLATION


C: INSPECTION

1) Check that the direction and amount of air can be adjusted smoothly.

2) Check that the adjustment can be kept in each position.

AC-46

Heater Duct


22.Heater Duct

A: REMOVAL

1) Remove the front seat. <Ref. to SE-6, REMOV-

AL, Front Seat.>

2) Remove the front side sill cover.

3) Pull off the floor mat, remove the cover, and then remove the heater duct.

B: INSTALLATION


AC-47

Heater Vent Duct


23.Heater Vent Duct

A: REMOVAL

1) Remove the instrument panel. <Ref. to EI-40, REMOVAL, Instrument Panel Assembly.>

2) Remove the screws.

3) Remove the heater vent duct.

B: INSTALLATION


AC-00224

AC-48

Heater Cock Solenoid Valve


24.Heater Cock Solenoid Valve

A: REMOVAL

1) Drain the engine coolant.

<Ref. to CO(H4SO)-19, DRAINING OF ENGINE

COOLANT, REPLACEMENT, Engine Coolant.>

2) Remove the battery.

3) Remove the two bolts and disconnect harness connector, and move the washer tank forward.

C: INSPECTION

1) Remove the heater cock solenoid valve. <Ref. to

AC-49, REMOVAL, Heater Cock Solenoid Valve.>

2) Connect the positive terminal of battery to No. 1 terminal of heater cock solenoid valve, and the ground terminal to No. 2 terminal. Check that the heater cock solenoid valve opens and closes normally.

2 1

WW-00011

4) Disconnect the harness connector (A) of the heater cock solenoid valve.

5) Remove the two bolts to remove the heater cock solenoid from the bracket.

AC-00888

If any failure is found, replace the heater cock solenoid valve.

(A)

AC-00886

6) Pull out the heater cock solenoid. Loosen the hose clamp and disconnect the two heater hoses.

B: INSTALLATION


AC-00887

AC-49

General Diagnostics


25.General Diagnostics

A: INSPECTION

Symptom

Blower motor

Compressor

Condenser fan

Cold air not emitted.

Warm air not emitted.

Does not run.

Noise

Does not run.

Noise

Does not run.

Noise

Repair order

Fuse

Blower motor relay

Wiring harness

Blower motor

Blower motor resistor (Manual A/C model)

Blower switch

Blower motor

Refrigerant

Fuse

A/C relay

Wiring harness

Magnet clutch

Compressor

Pressure switch

A/C switch

Blower switch

V-Belt

Magnet clutch

Compressor

Fuse

Sub fan relay

Wiring harness

Condenser fan motor

Refrigerant

V-Belt

Magnet clutch

Compressor

Pressure switch

Blower fan relay, Blower motor

A/C switch

Blower switch

Wiring harness

Heater duct

Heater vent duct

Control unit

Expansion valve

Evaporator

Air mix actuator (Auto A/C), Temperature control cable (Manual

A/C)

Engine coolant

Aspirator hose

Blower switch


A/C)

Heater core

Heater cock solenoid valve (Non-turbo model for EC/EK)

AC-50

Symptom

Temperature of air from vents does not change.

Unable to switch blow vents.

Unable to switch suction vents.



Repair order

Wiring harness


A/C)

Temperature adjustment switch

Wiring harness

Mode actuator (Auto A/C), Mode control cable (Manual A/C)

Mode switch

Wiring harness

FRESH/RECIRC actuator

Air inlet select switch

AC-51



AC-52

HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)

AC

Page

1.

Basic Diagnostics Procedure ......................................................................2

2.


3.

Electrical Component Location ...................................................................5

4.

Auto A/C Control Module I/O Signal............................................................7

5.

Diagnostic Chart for Self-Diagnosis ............................................................9

6.

Diagnostics for A/C System Malfunction ...................................................12

7.

Diagnostic Procedure for Actuators ..........................................................21

8.

Diagnostic Procedure for Sensors ............................................................32

9.

General Diagnostic Table..........................................................................41

Basic Diagnostics Procedure

HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)

1. Basic Diagnostics Procedure

A: PROCEDURE

1

2

3

4

Step

START INSPECTIONS.

1) Perform the pre-inspection. <Ref. to AC-3,

INSPECTION, General Description.>

2) Perform the self-diagnosis. <Ref. to AC-9,

OPERATION, Diagnostic Chart for Self-Diagnosis.>

Does the self-diagnosis operate?

Check Yes

Go to step 2.

No

<Ref. to AC-12, A/

C OR SELF-DIAG-

NOSIS SYS-

TEMS DO NOT

OPERATE, Diagnostics for A/C

System Malfunction.>

Go to step 3.

IDENTIFY MALFUNCTION PART.

Identify the malfunction part with self-diagnosis.

Can the malfunction part be identified?

Repair the malfunction part in accordance with each diagnostic chart.

Go to step 4.

CHECK COMPARTMENT TEMPERATURE.


2) Turn the temperature control dial at maximum cool position.

3) Check the compartment temperature change.

Does the compartment temperature change?

CHECK A/C SYSTEM RESPONSE.

Change the temperature setting, and check the response of A/C system.

Does the A/C system respond quickly?

A/C system is normal.

<Ref. to AC-16,

COMPARTMENT

TEMPERATURE

DOES NOT

CHANGE, OR A/C

SYSTEM DOES

NOT RESPOND

PROMPTLY.,

Diagnostics for A/

C System Malfunction.>

<Ref. to AC-16,

COMPARTMENT

TEMPERATURE

DOES NOT

CHANGE, OR A/C

SYSTEM DOES

NOT RESPOND

PROMPTLY.,

Diagnostics for A/

C System Malfunction.>

AC-2




A: CAUTION

1) Never connect the battery in reverse polarity.

Auto A/C control module may be destroyed instantly.

2) Do not disconnect the battery terminals while the engine is running.

A large counter electromotive force will be generated in the generator, and this voltage may damage electronic parts such as auto A/C control module, etc.

3) Before disconnecting the connectors of each sensor and the auto A/C control module, be sure to turn off the ignition switch.

Auto A/C control module may be damaged.

4) Every A/C-related part is a precision part. Do not drop them.

5) Airbag system wiring harness is routed near the

A/C control panel (auto A/C control module) and junction box.

CAUTION:

• For airbag system, yellow-colored wiring harness and connectors are all used. Do not use the electrical test equipment on these circuits.

• Be careful not to damage the airbag system wiring harness when servicing the A/C control panel (auto A/C control module) and junction box.

B: INSPECTION

Before performing the diagnosis, check the following items which might affect A/C system problems.

1. BATTERY

1) Measure battery voltage and specific gravity of electrolyte.

Standard voltage: 12 V

Specific gravity: More than 1.260

2) Check the condition of the fuses for A/C system power supply and other fuses.

3) Check the condition of harness and harness connector connections.

2. ASPIRATOR HOSE

1) Turn the ignition switch to ON, and press the A/

C switch.

2) Turn the temperature control dial at maximum hot position.

3) Press the defroster switch.

4) Turn the fan speed control dial to 4th position.

5) Approach a strip of paper (b) in front of the in-vehicle sensor suction port (a) located in the instrument lower cover, and check that air is being sucked into the port by seeing the paper moving towards port.

NOTE:

Be careful not to let the paper get sucked into port.

(a)

(a)

(b)

AC-00094

6) If the paper does not move at all, remove the in-

strument panel lower cover <Ref. to EI-40, RE-

MOVAL, Instrument Panel Assembly.> and check

for improper connection of the aspirator hose (a), in-vehicle sensor and heater unit, and repair them if necessary.

(a)

AC-00065

3. A/C LINE

Check the connection for A/C line (A) and lower side high-pressure pipe.

(A)

AC-00096

4. CONTROL LINKAGE

1) Check the state of mode door linkage.

2) Check the state of air mix door linkage.

3) Check the state of intake door linkage.

AC-3



5. CONTROL SWITCHES

Start and warm-up the engine completely.

1) Inspection using switches

No.

Point to check Switch operation

1 Fan speed control dial Turn the fan speed control dial clockwise.

2 AUTO switch

3 Defroster switch

4

FRESH/RECIRC switch

5 Mode control dial

1) Press the AUTO switch.

2) Turn the temperature control dial to the left fully, and set maximum cool position.

3) Turn the temperature control dial to the right slowly, and change the setting from maximum cool position to maximum hot position gradually.

4) Turn the temperature control dial to the right fully, and set maximum hot position.

Press the defroster switch.

Press the FRESH/RECIRC switch.

Press the mode control dial.

Judgment standard

Fan speed changes 1st

→ 2nd → 3rd → 4th as dial turn.

• Outlet air temperature: COOL

• Fan speed: 4th

• Outlet opening: VENT

• Inlet opening: RECIRC

• Compressor: AUTO

• Outlet air temperature: COOL

→ HOT

• Fan speed: AUTO

• Outlet opening: AUTO

• Inlet opening: AUTO


• Outlet air temperature: HOT

• Fan speed: 4th

• Outlet opening: HEAT

• Inlet opening: FRESH


• Outlet air temperature: AUTO

• Fan speed: AUTO

• Outlet opening: DEF

• Inlet opening: FRESH

• Compressor: ON

Inlet opening switches RECIRC

→ FRESH or

FRESH

→ RECIRC each time pressing the switch.

Outlet opening switches VENT

→ BI-LEVEL

→ HEAT → DEF/HEAT each time dialing clockwise.

2) Compressor operation inspection

No.

Point to check

1 Compressor

Switch operation

1) A/C switch is turned to ON.

2) Turn the fan speed control clockwise.

3) Inspection of illumination control

No.

Point to check

1 Illumination

Switch operation

1) Turn the lighting switch to ON.

2) Press the OFF switch one second or more.

Judgment standard

Compressor: ON

Judgment standard

Illumination comes on.

Illumination dimming is cancelled.

AC-4

Electrical Component Location


3. Electrical Component Location

A: LOCATION

1. ENGINE COMPARTMENT

(1)

(2)

(2)

(3)

(1)

(3)

(4)

(1) A/C compressor

(2) A/C relay

(3) Pressure switch

AC-5

(4) Ambient sensor

AC-00097

Electrical Component Location


2. PASSENGER COMPARTMENT

(3)

(6)

(2)

(4)

(1)

(7)

(5)

(3)

(7)

(6)

(4)

(5)

(1)

(1) Mode door actuator

(2) In-vehicle sensor

(3) Sunload sensor

(4) Intake door actuator

(5) Blower motor


AC-6

(7) Air mix door actuator

AC-00098

Auto A/C Control Module I/O Signal


4. Auto A/C Control Module I/O Signal

A: ELECTRICAL SPECIFICATION

10

20

9

19

8

18

7

17

6

16

5

15

4

14

3

13

2

12

1

11

To B: i49

8

16

7

15

6

14

5

13

4

12

3

11

2

10

1

9

To A: i48

AC-00099

Terminal No.

B9

B8

B7

B6

B5

B4

B3

B2

B1

B20

B19

B18

B17

B16

B15

B13

B12

B11

A7

A5

A4

A1

A16

Content Measuring condition

Mode door actuator power supply

Air mix door actuator power supply

IGN power supply

Battery power supply

Sunload sensor

Changes outlet from VENT to DEF.

Changes outlet from DEF to VENT.

Changes air mix door from COOL to HOT.

Changes air mix door from HOT to COOL.

Ignition switch: ON

Ignition switch: OFF, ACC, ON

Ignition switch: ON and under normal sunload

(without sunload: 5 V)

Evaporator sensor

Air mix door actuator P.B.R. signal

Intake door actuator signal

Ignition switch: ON

Air mix door: COOL position

Air mix door: HOT position

Air inlet: FRESH (other positions: 12 V)

Air inlet: MIX (other positions: 12 V)

Air inlet: RECIRC (other positions: 12 V)

A/C: ON (A/C OFF: 0 V)

*3

A/C ON signal

Blower motor control

Blower fan ON signal

Engine coolant temperature sensor

In-vehicle sensor

Ground

When blower fan running (when blower fan not running: 12 V)

When the engine coolant is at 49

°C (120°F)

—

When there is continuity to chassis ground

Air mix door actuator P.B.R. reference voltage Ignition switch: ON

Mode door actuator position detection signal Outlet

BI-LEVEL, DEF

VENT, HEAT, DEF/HEAT

HEAT, DEF/HEAT, DEF

Mode door actuator position detection signal Outlet

VENT, BI-LEVEL

Ignition switch: ON, light switch: ON

Illumination power supply

Ignition switch: ON, light switch: OFF

Sensor ground When there is continuity to chassis ground

Specified value

*2

*1

Battery voltage

Battery voltage

3 V

5 V or less

0.5 V

4.5 V

0 V

0 V

0 V

8 — 10 V

*3

0 V

8.9 V

—

0

Ω

5 V

5 V

0 V

5 V

0 V

Battery voltage

0 V

0

Ω

AC-7

Auto A/C Control Module I/O Signal


Terminal No.

Content Measuring condition

Specified value

A14

Combination meter (ambient temperature signal)

*3 *3

A13

A12

Mode door actuator position detection signal

Mode door actuator position detection signal

Outlet

Outlet

VENT, BI-LEVEL, HEAT

DEF/HEAT, DEF

VENT, DEF/HEAT

BI-LEVEL, HEAT, DEF

5 V

0 V

5 V

0 V

A10

A9

A/C cutout signal

Illumination ground

A/C: ON

Pressure switch operated

When there is continuity to chassis ground

Battery voltage

0 V

0

Ω

*1: Battery voltage is indicated when motor running, 0 V or battery voltage pulse signal is output when motor stops.

*2: Battery voltage is indicated when motor running, 0 V is indicated when motor stops.

*3: Voltage can not be measured because of pulse signal.

B: WIRING DIAGRAM:

<Ref. to WI-58, WIRING DIAGRAM, Air Conditioning System.>

AC-8

Diagnostic Chart for Self-Diagnosis


5. Diagnostic Chart for Self-Diagnosis

A: OPERATION

(3)

(4)

(5)

(2)

(7)

(1)


(2) OFF/BRIGHT switch

(3) AUTO switch

(9)

(4) A/C switch

(5) Defroster switch

(6) Air flow control switch

(8)

(6)

AC-00250

(7) Rear window defogger switch

(8) FRESH/RECIRC switch

(9) Fan speed control dial

:

(2)

(1)

DEF

(3)

+

A / C

OFF

(4)

(5)

(6)

AUTO

FRESH / RECIRC

FRESH / RECIRC

A / C

AUTO

(7)

A / C

A / C

FRESH / RECIRC

(9)

AUTO

(1) Normal Operation

(2) Switch

(3) IG OFF

→ ON with pressing

(4) Self-Diagnosis Mode

(5) LED Display Check

(8)

AUTO

FRESH / RECIRC A / C

(10)

AUTO

AC-00242

(6) After the LED display (Approx. 20 sec.)

(7) Sensor Check (Sequential Operation)

(8) Sensor Check (Phased Operation)

(9) Output Equipment Operation

(Sequential Operation)

(10) Output Equipment Operation

(Phased Operation)

AC-9



1

2

3

4

5

Step

SELECT CONTROL PANEL TO SELF-DIAG-

NOSIS MODE.

1) Turn the ignition switch to OFF.

2) Start the engine while pressing defroster switch and A/C switch.

Check

Does the self-diagnosis mode operate?

NOTE:

Self-diagnosis can also be performed with the ignition switch ON, but start the engine because telling the magnet clutch operation is difficult.

3) The LED in A/C control panel blinks.

CHECK LED ILLUMINATION.

Make sure that three LED blink in turn on A/C control panel (5 patterns are repeated 2 times).

Do all LED blink?

CHECK SENSORS MALFUNCTION.

1) After completing the LED check or when

AUTO switch is pressed, the A/C switch LED illuminates, and then the sensor check is started.

2) Check the input signal of each sensor in turn. If there are any trouble for each sensor,

DEF, MODE and fan speed LEDs are blinked.

Also check for each sensor is possible respectively every time AUTO switch is pressed. (At this time, the AUTO switch LED illuminates.)

3) If there is no trouble, DEF, MODE and fan speed LEDs are turned off.

Does each DEF, MODE and fan speed LED turn off?

NOTE:

Rear window defogger LED illuminates in case of stored malfunction but does not illuminate in case of present malfunction.

CHECK OPERATION OF EACH ACTUATOR,

COMPRESSOR AND FAN MOTOR.

1) Press the FRESH/RECIRC switch

(FRESH/RECIRC switch LED illuminates at this time.).

2) Refer to OPERATING MODE TABLE to check the operation of each actuator, compres-

sor and fan motor. <Ref. to AC-11, OPERAT-

ING MODE TABLE, OPERATION, Diagnostic

Chart for Self-Diagnosis.>

Also check for each step is possible respectively every time AUTO switch pressed. (At this time, the AUTO switch LED illuminates.)

Does each actuator, compressor and fan motor operate according to operating mode table?

CHECK POOR CONTACT.

Check the auto A/C control module connector for poor contact.

Is there a poor contact in connector?

Yes

Go to step 2.

Go to step 3.

Go to step 4.

No

<Ref. to AC-12, A/

C OR SELF-DIAG-

NOSIS SYS-

TEMS DO NOT

OPERATE, Diagnostics for A/C

System Malfunction.>

Go to step 5.

Confirm the combination of illuminating LEDs by using Sensor

Check Table, and identify the malfunctioning sensor before repairing.

<Ref. to AC-11,

SENSOR CHECK

TABLE, OPERA-

TION, Diagnostic

Chart for Self-

Diagnosis.>

Press the OFF switch or turn the ignition switch to

OFF and finish the self-diagnosis mode.

Refer to each diagnostics chart for actuator, compressor and fan motor, and repair the malfunctioning part as necessary.

<Ref. to AC-12,

Diagnostics for A/

C System Mal-

function.> <Ref. to

AC-21, Diagnostic

Procedure for

Actuators.>

Replace the auto

A/C control module.

Repair the connector.

AC-10



1. SENSOR CHECK TABLE

NOTE:

When the sunload sensor is checked indoors or in the shade, open circuit might be indicated. Always check the sunload sensor at a place where sun shines directly on it.

Diagnostic steps

1

2

3

4

5

Checked sensor

In-vehicle sensor

Ambient sensor

Evaporator sensor

Sunload sensor*1

Air mix door actuator P.B.R.

6

Combination meter communication (Ambient sensor)

When all parts are in good condition

Open circuit

DEF LED

Turn off

MODE/FAN

LED

VENT

LED blinks

BI-LEVEL

LED blinks

HEAT

LED blinks

DEF/HEAT

LED blinks

Fan speed

1st

LED blinks

Fan speed

2nd

LED blinks

Short circuit

DEF LED

Illuminate

Turn off

MODE/FAN

LED

VENT

LED blinks

BI-LEVEL

LED blinks

HEAT

LED blinks

DEF/HEAT

LED blinks

Fan speed

1st

LED blinks

Fan speed

2nd

LED blinks

Present malfunction

Stored malfunction

REAR WINDOW

DEFOGGER LED

Turn off Illuminate

*1: Only present malfunction is indicated for open circuit of sunload sensor. (However, stored malfunction can be indicated for short circuit of sunload sensor.)

2. OPERATING MODE TABLE

Step

Illuminating LED

Fan speed

Mode actuator

Intake actuator

Air mix door actuator

Compressor

(magnet clutch)

1

VENT

LED

LO

VENT

FRESH

FULL

COOL

(0%)

OFF

2

BI-LEVEL

VENT

LO

VENT

RECIRC

FULL

COOL

(0%)

3

HEAT LED

ML

VENT

RECIRC

FULL

COOL

(0%)

4

DEF/HEAT

LED

ML

BI-LEVEL

FRESH

5

Fan speed

1st LED

ML

HEAT

FRESH

MEDIUM

(50%)

MEDIUM

(50%)

6

Fan speed

2nd LED

MH

HEAT

FRESH

7

Fan speed

3rd LED

MH

DEF/HEAT

FRESH

8

Fan speed

4th LED

HI

DEF

FRESH

FULL HOT

(100%)

FULL HOT

(100%)

FULL HOT

(100%)

ON ON ON ON ON ON ON

AC-11

Diagnostics for A/C System Malfunction


6. Diagnostics for A/C System Malfunction

A: A/C OR SELF-DIAGNOSIS SYSTEMS DO NOT OPERATE

TROUBLE SYMPTOM:

• Switch LEDs are faulty and switches do not operate.

• Self-diagnosis system does not operate.

WIRING DIAGRAM:

IGNITION

SWITCH

F/B NO.17

SBF-4 SBF-1

BATTERY

M/B NO.2

B201 : LHD B202 : RHD i40 : LHD i41 : RHD

A: i48

B: i49 AUTO A/C CONTROL MODULE

A: i48

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

B: i49

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

LHD : LHD MODEL

RHD : RHD MODEL

E

B201

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

B202

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

AC-00149

AC-12

1

2

3

4

5

6



Step

CHECK FUSE.


2) Remove the fuse No. 17 from fuse & relay box.

3) Check the condition of fuse.

Check

CHECK FUSE.


2) Remove the fuse No. 2 from main fuse box.


Is the fuse blown-out?

Is the fuse blown-out?

Yes No

Replace the fuse.

Go to step 2.

Replace the fuse.

Go to step 3.

CHECK AUTO A/C CONTROL MODULE

POWER CIRCUIT.

1) Pull out the auto A/C control module connector.

2) Measure the voltage between auto A/C control module connector terminal and chassis ground after turning the ignition switch to OFF position.

Connector & terminal

(i49) No. 4 (+) — Chassis ground (

−

):

Is the voltage more than 10 V? Go to step 4.

Check open or short circuit in harness between auto

A/C control module and fuse.


POWER CIRCUIT.

Measure the voltage between auto A/C control module connector terminal and chassis ground after turning the ignition switch to ON position.



−

):


Go to step 6.


GROUND CIRCUIT.

Measure the resistance in harness between auto A/C control module and chassis ground.


(i49) No. 11 — Chassis ground:

Is the resistance less than 1

Ω?


Check poor contact in auto A/C control module connector.

Is there poor contact in connector?


Check open or short circuit in harness between auto

A/C control module and fuse.

Repair the harness for ground line.

Replace the auto

A/C control module.

AC-13



B: BLOWER FAN DOES NOT ROTATE.


• Blower motor does not rotate.

• Blower motor does not change.

WIRING DIAGRAM:

SBF-3 SBF-1

BLOWER

MOTOR RELAY

B50

2

1

3

4

F/B NO.1

F/B NO.2

F/B NO.17

B201

LHD

3

18 i40

LHD

IGNITION

SWITCH

SBF-4

BATTERY

BLOWER MOTOR

1

2

5

B87

B202

22 i41

LHD : LHD MODEL

RHD : RHD MODEL

A: i48 B: i49 AUTO A/C CONTROL MODULE

E

B50

1 2

3 4

B202

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

B87

1 2 3 4 5 6

B201

A: i48

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

B: i49

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

AC-00150

AC-14

1

2

3

4

5



Step Check

CHECK FUSE.

1) Remove the fuse No. 1, 2 and 17 from fuse

& relay box.


Is any fuse blown-out?

Yes No

Replace the fuse.

Go to step 2.

CHECK POWER SUPPLY FOR BLOWER

MOTOR.

1) Turn the ignition switch to ON.

2) Turn the fan speed control dial clockwise.

3) Measure the voltage between blower motor and chassis ground.


(B87) No. 1 (+) — Chassis ground (

−

):

Is the voltage more than 8 V (at normal temperature)?

Go to step 3.

Go to step 4.

CHECK BLOWER MOTOR RELAY.


2) Remove the blower motor relay.

3) Connect the battery positive (+) terminal to terminal No. 1 of blower motor relay, and negative (

−) terminal to terminal No. 3.

4) Measure the resistance between terminals

No. 2 and 4.

Terminals

No. 2 — No. 4:


Ω?

CHECK BLOWER MOTOR.

1) Disconnect the connector from blower motor.

2) Connect the battery positive (+) terminal to terminal No. 1 of blower motor connector, and negative (

−) terminal to terminal No. 2 and No.

5.

3) Make sure the blower motor runs.

Does the blower motor run?




Go to step 5.


Repair the open circuit of blower motor power supply line harness.

Replace the blower motor relay.

Replace the blower motor.

Replace the auto

A/C control module.

AC-15



C: COMPARTMENT TEMPERATURE DOES NOT CHANGE, OR A/C SYSTEM

DOES NOT RESPOND PROMPTLY.


• Compartment temperature is not changed. (No cool air is discharged.)

• A/C system does not respond quickly.

WIRING DIAGRAM:

• LHD model

IGNITION

SWITCH

BATTERY

A/C RELAY HOLDER

SUB FAN FUSE

MAIN FAN FUSE

FAN RELAY

FAN MODE RELAY

FAN RELAY

A/C RELAY

PRESSURE SWITCH

1

2

4

3

18

17

15

19

16

28

25

27

29

26

COMPRESSOR

F79

MAGNET

CLUTCH

1

F24

F27

3

4

1

2

9

5

7

8

6

31

34

32

30

33

F/B NO.17

F/B NO.18

F2

B100

A: B134 C:

B136

B: B135 D: B137

ECM

A: i48

SBF-4

F45

B62

ET

ET

B: i49

B202 i41

AUTO A/C

CONTROL MODULE

SBF-1

ET

F17 MAIN FAN MOTOR

2

1

M


1

2

M

TA

F16 SUB FAN MOTOR

2

1

M

F16

SUB FAN MOTOR

1

2

M

E

*

4

*

5

*

6

* 1

* 2

*

3

TB

: TURBO MODEL : B33

NON-TURBO MODEL : A9





: TURBO MODEL : C30

NON-TURBO MODEL : B11

: TURBO MODEL : D17

NON-TURBO MODEL : C11


NON-TURBO MODEL : D13

: TURBO MODEL

NA : NON-TURBO MODEL

ET

TA

ET

TA

: EXCEPT NON-TURBO

AT MODEL

: TURBO AT MODEL

F16 :

TA

F17 :

TA

1 2

F16 :

ET

F17 :

ET

2 1

F79

3

1

2

4

F2

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20

F27

1 2

3 4

5 6 7

8

9

10

11

15 16 17

18

12 13 14 19

20

21

22 23 24

25 26 27

28

29

30

31

32 33 34

35

36

A: B134 :

NA

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

24 25 26 27 28 29 30 31 32 33 34 35

F24

1

1

8

26

9

27

B: B135 : NA

1

8

2

9

20 21

3

10 11 12 13 14 15

22 23 24 25

4 5 6 7

16 17 18 19

26 27 28

C: B136 :

NA

1 2

7 8

3

9

18 19 20

10

4 5 6

11 12 13 14 15 16 17

21 22 23 24 25 26

D: B137 :

NA

1

5

14

2

6

15

3 4

7 8 9 10 11

16 17 18

12 13

19 20

B: B135 :

TB

C: B136 :

TB

8

1

28

9

20 21

2 3 4

10 11 12 13 14 15

22 23 24 25

29 30 31 32 33

5 6 7

16 17 18 19

26 27

34 35 28

1

29 30

2

7 8 9 10

17 18 19 20 21

3 4

11 12 13 14 15

22 23 24 25

16

26 27

31 32

5 6

33 34 35

D: B137 :

TB

2

10

3

18 19 20 21

4

22 23

28 29

5 6 7

11 12 13 14 15 16 17

24 25

30 31

F45

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16

B202

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

A: i48

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

B: i49

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

AC-00882

AC-16



• RHD model

A/C RELAY HOLDER

SUB FAN FUSE

MAIN FAN FUSE

FAN RELAY

FAN MODE RELAY

FAN RELAY

A/C RELAY

PRESSURE SWITCH

4

3

1

2

18

17

15

19

16

28

25

27

29

26

COMPRESSOR

F79

MAGNET

CLUTCH

1

F24

F27

3

4

1

2

9

5

7

8

6

31

34

32

30

33

F/B NO.17

F/B NO.18

IGNITION

SWITCH

SBF-4 SBF-1

BATTERY

F2

B100

A: B134 C:

B136

B: B135 D: B137

ECM

B201 i40

A: i48

ET

ET

B: i49

AUTO A/C

CONTROL MODULE

B202 i41

E

ET


2

1

M

F17

MAIN FAN MOTOR

1

2

M

TA

F16

SUB FAN MOTOR

2

1

M

F16 SUB FAN MOTOR

1

2

M

*

3

*

4

*

1

*

2

*

5

* 6

TB







: TURBO MODEL : C30

NON-TURBO MODEL : B11


NON-TURBO MODEL : C11


NON-TURBO MODEL : D13

: TURBO MODEL

NA : NON-TURBO MODEL

ET

TA

ET : EXCEPT NON-TURBO

AT MODEL

TA : TURBO AT MODEL

F16

:

TA

F17

:

TA

1 2

F16

:

ET

F17

:

ET

2 1

F79

3

1

2

4

F2

1 2 3 4 5

11 12

6 7 8 9 10

13 14 15 16 17 18 19 20 21 22

F27

1 2

3 4

5 6 7

8

9

10

11

12 13 14

15 16 17

18

19

20

21

25 26 27

22 23 24

28

29

30

31

32 33 34

35

36

A: B134 :

NA

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

24 25 26 27 28 29 30 31 32 33 34 35

F24

1

1

8

5 6 7

11 12 13 14 15

18 19 20 21

26

9

27

2

10

B: B135 :

NA

1

8

2

9

20 21

3

10 11 12 13 14 15

22 23 24 25

4 5 6 7

16 17 18 19

26 27 28

C: B136 :

NA

1 2

7 8

3

9

18 19 20

10 11 12 13 14 15 16 17

21 22 23 24

4 5 6

25 26

D: B137 :

NA

1

5

14

2

6

15

7 8 9 10 11

16 17 18

3 4

12 13

19 20

B: B135 :

TB

C: B136 :

TB

8

1

28

9

20 21

2 3 4

10 11 12 13 14 15

22 23 24 25

29 30 31 32 33

5 6 7

16 17 18 19

26 27

34 35

1

7 8

2

9

3

10

4 5 6

11 12 13 14 15 16

17 18 19 20 21

28 29 30

22 23

31

24

32

25 26 27

33 34 35

D: B137 :

TB

3 4

22 23

28 29

16 17

24 25

30 31

B201

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

B202

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

A: i48

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

B: i49

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

AC-00883

AC-17



1

2

3

4

5

6

7

8

Step Check

CHECK FUSE.


2) Remove the main fan fuse and sub fan fuse in main fuse box.


Is the fuse blown out?

Yes No

Replace the fuse.

Go to step 2.

CHECK THE POWER SUPPLY TO PRES-

SURE SWITCH.

1) Disconnect the connector from pressure switch.


3) Measure the voltage between harness connector and chassis ground.


(F79) No. 1 (+) — Chassis ground (

−

):


Go to step 4.

CHECK THE HARNESS BETWEEN PRES-

SURE SWITCH AND A/C RELAY HARNESS.


2) Remove the A/C relay in the main fuse box.

3) Measure the resistance between A/C relay and pressure switch connector.


(F27) No. 17 — (F79) No. 2:


Ω?

CHECK THE PRESSURE SWITCH.

Measure the resistance between pressure switch terminals.

Terminals

No. 1 — No. 2:


Ω?

Go to step 5.

Repair the harness for pressure switch power supply circuit.

Repair the harness between A/C relay and pressure switch.

Replace the pressure switch.

CHECK THE A/C CUT SIGNAL CIRCUIT.

1) Disconnect the connector from auto A/C control module.

2) Measure the resistance between auto A/C control module and pressure switch connector.


(i48) No. 10 — (F79) No. 2:


Ω?

CHECK THE A/C ON SIGNAL CIRCUIT.

1) Disconnect the connector from ECM.

2) Measure the resistance between ECM and auto A/C control module connector.


Turbo model

(B137) No. 17 — (i49) No. 17:

Non-turbo model

(B136) No. 11 — (i49) No. 17:


Ω?

CHECK A/C RELAY.

1) Remove the A/C relay in main fuse box.

2) Check the A/C relay. <Ref. to AC-42,

INSPECTION, Relay and Fuse.>

Is the operation of the relay

OK?

Go to step 6.

Go to step 7.

Go to step 8.

Is the voltage more than 10.5 V

(at normal temperature)?

Go to step 9.

CHECK POWER SUPPLY TO MAGNET

CLUTCH OF A/C COMPRESSOR.

1) Turn the ignition switch to OFF, and then connect the A/C relay connector and all removed connectors.

2) Start the engine, and turn A/C switch to

ON.

3) Set the temperature control dial to maximum cold position.

4) Measure the voltage between magnet clutch harness connector and chassis ground.



−

):

Repair the harness between auto

A/C control module and pressure switch.


A/C control module and ECM.

Replace the A/C relay.

Repair the harness for power supply line of A/C compressor.

AC-18

9

10

11

12

13

14



Step Check

CHECK OPERATION OF MAIN FAN MOTOR.

1) Start the engine and turn the A/C switch to

ON.

2) Check the operation of main fan motor.

Does the main fan motor operate normally?

Yes

Go to step 14.

CHECK POWER SUPPLY TO MAIN FAN MO-

TOR.

Is the voltage more than 10 V? Go to step 11.

CAUTION:

Be careful not to overheat the engine during repair.


2) Disconnect the connector from main fan motor.

3) Start the engine, and warm it up until engine coolant temperature increases over

100

°C (212°F).

4) Stop the engine and turn ignition switch to

ON.

5) Measure the voltage between main fan motor harness connector and chassis ground.


Except turbo AT model:


−

):

Turbo AT model:


−

):

CHECK GROUND CIRCUIT OF MAIN FAN

MOTOR.

Measure the resistance between main fan motor harness connector and chassis ground.



(F17) No. 1 — Chassis ground:




Ω?

CHECK MAIN FAN MOTOR.

Connect the battery positive (+) terminal to terminal No. 2, and ground (

−) terminal to terminal No. 1 of main fan motor connector to make sure that main fan motor rotate.

Does the main fan rotate?

CHECK POOR CONTACT IN MAIN FAN MO-

TOR CONNECTOR.

Check poor contact in main fan motor harness connector.


CHECK OPERATION OF SUB FAN MOTOR.

1) Start the engine and turn the A/C switch to

ON.

2) Check the operation of sub fan motor.

Does the sub fan motor operate normally?

Go to step 12.

Go to step 13.

Go to step 14.

Go to step 19.

No

Go to step 10.

Repair the harness for main fan motor power supply circuit.

Repair the harness for main fan motor ground circuit.

Replace the main fan motor.

Repair the poor contact in main fan motor connector.

Go to step 15.

AC-19



15

16

17

18

19

Step

CHECK POWER SUPPLY TO SUB FAN MO-

TOR.

CAUTION:

Be careful not to overheat the engine during repair.

Check Yes



2) Disconnect the connector from sub fan motor.

3) Start the engine, and warm it up until engine coolant temperature increases over

100

°C (212°F).

4) Stop the engine and turn ignition switch to

ON.

5) Measure the voltage between sub fan motor harness connector and chassis ground.




−

):



−

):

CHECK GROUND CIRCUIT OF SUB FAN

MOTOR.

Measure the resistance between sub fan motor harness connector and chassis ground.







Ω?

Go to step 17.

CHECK SUB FAN MOTOR.

Connect the battery positive (+) terminal to terminal No. 2, and ground (

−) terminal to terminal No. 1 of sub fan motor connector to make sure that sub fan motor rotate.

Does the sub fan motor rotate? Go to step 18.

Go to step 19.

CHECK POOR CONTACT IN SUB FAN MO-

TOR CONNECTOR.

Check poor contact in sub fan motor connector.


CHECK POOR CONTACT IN AUTO A/C

CONTROL MODULE CONNECTOR.



Replace the auto

A/C control module.

No

Repair the harness for sub fan motor power supply circuit.

Repair the harness for sub fan motor ground circuit.

Replace the sub fan motor.

Repair the poor contact in sub fan motor connector.


AC-20

Diagnostic Procedure for Actuators


7. Diagnostic Procedure for Actuators

A: INTAKE DOOR ACTUATOR


FRESH/RECIRC mode is not changed.

WIRING DIAGRAM:

F/B NO.17

IGNITION

SWITCH

SBF-4

BATTERY

SBF-1

A: i48

B: i49

AUTO A/C CONTROL

MODULE i41 :

LHD i40 :

RHD

B202 : LHD B201 : RHD

LHD : LHD MODEL

RHD : RHD MODEL

*

*

1

2

: LHD MODEL : 2

: RHD MODEL : 1

: LHD MODEL : 1

: RHD MODEL : 2

B91

1 2 3 4

B201

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

A: i48

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

B91

INTAKE DOOR

ACTUATOR

B: i49

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

B202

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

AC-00153

AC-21



1

2

3

4

Step

CHECK POWER SUPPLY FOR INTAKE

DOOR ACTUATOR.


2) Disconnect the intake door actuator connector.


4) Measure the voltage between intake door actuator connector and chassis ground.



−

):

Check

Is the voltage 7 V (at normal temperature)?

CHECK HARNESS BETWEEN AUTO A/C

CONTROL MODULE AND INTAKE DOOR

ACTUATOR.


2) Disconnect the auto A/C control module connector.

3) Measure the resistance between intake door actuator connector and auto A/C control module connector.


LHD model:

(i49) No. 18 — (B91) No. 2:

(i49) No. 19 — (B91) No. 3:

(i49) No. 20 — (B91) No. 1:

RHD model:

(i49) No. 18 — (B91) No. 1:

(i49) No. 19 — (B91) No. 3:

(i49) No. 20 — (B91) No. 2:


Ω?

CHECK OPERATION OF INTAKE DOOR AC-

TUATOR.

1) Connect the intake door actuator connector.

2) Ground the auto A/C control module connector with a suitable wire.

3) Turn the ignition switch to ON, and check the operation of intake door actuator.



Does the actuator move to

FRESH side?

CHECK OPERATION OF INTAKE DOOR AC-

TUATOR.


2) Ground the auto A/C control module connector with a suitable wire.

3) Turn the ignition switch to ON, and check the operation of intake door actuator.

Connector & terminal:


Does the actuator move to

RECIRC side?

Yes

Go to step 2.

Go to step 3.

Go to step 4.

No

Check open or short circuit in harness between intake door actuator and fuse.


A/C control module and intake door actuator.

Replace the intake door actuator.

Replace the auto

A/C control module.

Replace the intake door actuator.

AC-22



B: MODE DOOR ACTUATOR


Air flow outlet is not changed.

WIRING DIAGRAM:

A: i48 B: i49


MODULE i41

B202

LHD : LHD MODEL

RHD : RHD MODEL

B77

1 2 3 4 5 6 7 8 9 10

A: i48

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

B77

MODE ACTUATOR

B: i49

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

B202

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

AC-00154

AC-23



1

2

3

4

5

Step Check Yes

CHECK POWER SUPPLY FOR AUTO A/C

CONTROL MODULE SIDE.


2) Turn the mode control dial to VENT position.

3) Press the defroster switch and measure the voltage between auto A/C control module and chassis ground when VENT is changed to DEF position.



−

):


CHECK POWER SUPPLY FOR ACTUATOR

SIDE.

1) Turn the mode control dial to VENT position.

2) Press the defroster switch and measure the voltage between mode door actuator harness connector and chassis ground when VENT is changed to DEF position.



−

):


Go to step 3.

CHECK POWER SUPPLY FOR AUTO A/C

CONTROL MODULE SIDE.


2) Turn the mode control dial to VENT position and measure the voltage between auto A/C control module and chassis ground when DEF is changed to VENT position.



−

):


CHECK POWER SUPPLY FOR ACTUATOR

SIDE.


2) Turn the mode control dial to VENT position and measure the voltage between mode door actuator harness connector and chassis ground when DEF is changed to VENT position.



−

):


Go to step 5.

CHECK ACTUATOR.


2) Disconnect the connector from mode door actuator.

3) Connect the battery positive (+) terminal to terminal No. 1 and ground (

−) terminal to terminal No. 2 of mode door actuator to make sure that actuator operates.

4) Connect the battery positive (+) terminal to terminal No. 2 and ground (

−) terminal to terminal No. 1 of mode door actuator to make sure that actuator operates.

Does the motor operate normally?

Go to step 6.

No

Replace the auto

A/C control module.


A/C control module and mode door actuator.

Replace the auto

A/C control module.



Replace the mode door actuator.

AC-24

6

7

8

9

10



Step Check

CHECK AUTO A/C CONTROL MODULE SIG-

NAL VOLTAGE.


2) Turn the mode control dial and measure voltage between auto A/C control module harness connector and chassis ground for each mode.



−

):

Is the voltage 5 V when HEAT,

D/H, DEF position and 0 V when VENT, BI-LEVEL position?

Yes

Go to step 9.


NAL POWER SUPPLY.




4) Measure the voltage between mode door actuator harness connector and chassis ground.



−

):

Is the voltage 5 V?


CONTROL MODULE AND MODE DOOR AC-

TUATOR.


2) Disconnect the connectors from auto A/C control module and mode door actuator.

3) Measure the resistance of harness between auto A/C control module and mode door actuator.


(i48) No. 4 (+) — (B77) No. 5 (

−

):


Ω?

Go to step 9.

Replace the auto

A/C control module.


NAL VOLTAGE.

1) Turn ignition switch to ON.




−

):

Is the voltage 5 V when VENT,

D/H position and 0 V when BI-

LEVEL, HEAT, DEF position?

Go to step 12.








(B77) No. 6, 9 (+) — Chassis ground (

−

):

Is the voltage 5 V?

Go to step 12.

No

Go to step 7.

Go to step 8.



Go to step 10.

Go to step 11.

AC-25



11

12

13

14

15

Step



TUATOR.





(i48) No. 12 — (B77) No. 6, 9:

Check


Ω?


NAL VOLTAGE.





−

):

Is the voltage 5 V when BI-

LEVEL, DEF position and 0 V when VENT, HEAT, D/H position?









−

):

Is the voltage 5 V?

Yes

Replace the auto

A/C control module.

Go to step 15.

Go to step 15.



TUATOR.





(i48) No. 5 — (B77) No. 4, 7:


Ω?

Replace the auto

A/C control module.


NAL VOLTAGE.





−

):

Is the voltage 5 V when VENT,

BI-LEVEL, HEAT position and

0 V when D/H, DEF position?

Go to step 19.

No



Go to step 13.

Go to step 14.



Go to step 16.

AC-26

16

17

18

19



Step Check






4) Measure the voltage between mode door actuator and chassis ground.



−

):

Is the voltage 5 V?



TUATOR.





(i48) No. 13 — (B77) No. 8:


Ω?

CHECK ACTUATOR GROUND CIRCUIT.





(i48) No. 16 — (B77) No. 10:


Ω?




Yes

Go to step 18.

No

Go to step 17.

Replace the auto

A/C control module.



Replace the mode door actuator.



Repair the poor contact in auto A/C control module.


AC-27



C: AIR MIX DOOR ACTUATOR


Outlet air temperature does not change.

WIRING DIAGRAM:

• LHD model

A: i48 B: i49


MODULE i65

1 2

3 4 5 6

A: i48

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

i65

AIR MIX DOOR

ACTUATOR

B: i49

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

AC-28

AC-00106

• RHD model



A: i48

B: i49


MODULE i41

B202

B293

1 2

3 4 5 6

A: i48

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

B293

AIR MIX DOOR

ACTUATOR

B: i49

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

B202

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

AC-00155

AC-29



1

2

3

4

Step Check

CHECK POWER SUPPLY FOR AIR MIX

DOOR ACTUATOR POSITION SWITCH.


2) Disconnect the air mix door actuator connector.

3) Turn the ignition switch and AUTO switch to

ON.

4) Measure the voltage between auto A/C control module connector terminals.


(i48) No. 7 (+) — (i48) No. 16 (

−

):

Is the voltage approx. 5 V?


DOOR ACTUATOR.

Measure the voltage between auto A/C control module connector and chassis ground after turning the temperature control dial to maximum COOL position.



−

):



DOOR ACTUATOR.

Measure the voltage between auto A/C control module connector and chassis ground after turning the temperature control dial to maximum HOT position.



−

):



CONTROL MODULE AND AIR MIX DOOR

ACTUATOR.

1) Turn the A/C and ignition switch to OFF.

2) Disconnect the auto A/C control module connector.

3) Measure the resistance between auto A/C control module and air mix door actuator connector.


LHD model:

(i65) No. 1 — (i49) No. 1:

(i65) No. 2 — (i49) No. 7:

(i65) No. 3 — (i48) No. 16:

(i65) No. 4 — (i48) No. 7:

(i65) No. 6 — (i49) No. 6:

RHD model:

(B293) No. 1 — (i49) No. 1:

(B293) No. 2 — (i49) No. 7:

(B293) No. 3 — (i48) No. 16:

(B293) No. 4 — (i48) No. 7:

(B293) No. 6 — (i48) No. 6:


Ω?

Yes

Go to step 2.

Go to step 3.

Go to step 4.

Go to step 5.

No

Replace the auto

A/C control module.

Replace the auto

A/C control module.

Replace the auto

A/C control module.


A/C control module and air mix door actuator.

AC-30

5

6



Step Check


Check poor contact in auto A/C control module and connector.


Yes

CHECK AIR MIX DOOR ACTUATOR POSI-

TION SWITCH SIGNAL.

1) Connect the connector of auto A/C control module and air mix door actuator.

2) Turn the ignition switch and AUTO switch to

ON.

3) Check the voltage between auto A/C control module connector terminals while changing the setting temperature between maximum

COOL and maximum HOT.


(i49) No. 1 (+) — (i48) No. 16 (

−

):

Does the voltage change between 0.5 (Max. HOT) — 4.5

(Max. COOL) V?

Go to step 6.


No

Replace the air mix door actuator.

Replace the auto

A/C control module.

AC-31

Diagnostic Procedure for Sensors


8. Diagnostic Procedure for Sensors

A: AMBIENT SENSOR


• Fan speed is not switched when the fan speed control dial is in AUTO position.

• Malfunction related to ambient sensor is indicated in self diagnosis.

WIRING DIAGRAM:

• LHD model

B: i10

COMBINATION

METER i3

B38

B202 i41 i2

B37

15

14

B62 F45

1

2

F78

AMBIENT

SENSOR

A: i48

B: i49

AUTO A/C

CONTROL

MODULE

B: i10

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

B38

1 2 3 4

10 11 12 13 14 15

22 23 24 25

16

5 6

17

26 27 28 29

18

30

7 8

19 20

31

9

21

32

A: i48

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

B202 B37

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

B: i49

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

F45

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16

AC-32

F78

1 2

AC-00107

• RHD model



B: i10

COMBINATION

METER

B202 i41 i2

B37

B100

15

14

F2

1

2

F78

AMBIENT

SENSOR

MT : MT MODEL

AT : AT MODEL

A: i48 B: i49

AUTO A/C

CONTROL

MODULE

B: i10 A: i48 B: i49

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

1 2 3 4 5

B202

6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

i2 : AT

F2

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20 21 22

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

i2 : MT

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

F78

1 2

AC-00884

AC-33



1

2

3

Step Check

CHECK HARNESS CONNECTOR BETWEEN

AUTO A/C CONTROL MODULE AND COM-

BINATION METER.


2) Disconnect the connector from auto A/C control module and combination meter.

3) Measure the resistance in harness between auto A/C control module and combination meter.


(i10) No. 30 — (i48) No. 14:


Ω?

CHECK AMBIENT SENSOR CIRCUIT.

Check the ambient sensor circuit. <Ref. to IDI-

8, CHECK OUTSIDE TEMPERATURE INDI-

CATOR, INSPECTION, Combination Meter

System.>

Is the ambient sensor circuit normal?




Yes

Go to step 2.

Go to step 3.


No


A/C control module and combination meter.

Repair the ambient sensor circuit.

Replace the A/C control module.

AC-34



B: IN-VEHICLE SENSOR


• Blower fan speed, outlet port and inlet port do not change after turning the AUTO switch to ON.

• Malfunction related to ambient sensor is indicated in self diagnosis.

WIRING DIAGRAM: i55 :

LHD

B314 : RHD

IN-VEHICLE

SENSOR

RHD

RHD

B202 i41

RHD

RHD

LHD LHD : LHD MODEL

RHD RHD

: RHD MODEL

A: i48 B: i49

AUTO A/C

CONTROL

MODULE i55 :

LHD

B314 : RHD

1 2

A: i48

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

B: i49

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

B202

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

AC-00157

AC-35



1

2

3

4

5

6

Step Check

CHECK IN-VEHICLE SENSOR.


2) Remove the instrument panel lower cover.

3) Disconnect the connector from in-vehicle sensor.

4) Measure the resistance between connector terminals of in-vehicle sensor.

Terminals

No. 1 — No. 2:

Is the resistance approx. 2.7 k

Ω at 20°C (68°F)?


CHECK INPUT SIGNAL FOR IN-VEHICLE

SENSOR.


2) Measure the voltage between in-vehicle sensor harness connector terminal and chassis ground.


LHD model:


−

):

RHD model:


−

):


OUTPUT SIGNAL.


2) Remove the auto A/C control module.


4) Measure the voltage between connector terminals of auto A/C control module.


(i49) No. 12 (+) — (i48) No. 16:



CONTROL MODULE AND IN-VEHICLE SEN-

SOR.



3) Measure the resistance in harness between auto A/C control module and in-vehicle sensor.


LHD model:

(i55) No. 2 — (i49) No. 12:

RHD model:

(B314) No. 2 — (i49) No. 12:


Ω?


CONTROL MODULE AND IN-VEHICLE SEN-

SOR.

Measure the resistance in harness between auto A/C control module and in-vehicle sensor.


LHD model:

(i55) No. 1 — (i48) No. 16:

RHD model:

(B314) No. 1 — (i48) No. 16:


Ω?




Yes

Go to step 2.

Go to step 6.

Go to step 4.

Go to step 5.

Go to step 6.


No

Replace the invehicle sensor.

Go to step 3.

Go to step 6.


A/C control module and in-vehicle sensor.


A/C control module and in-vehicle sensor.

Replace the auto

A/C control module.

AC-36



C: EVAPORATOR SENSOR

WIRING DIAGRAM:

B256

EVAPORATOR

SENSOR

B202 i41

LHD : LHD MODEL

RHD : RHD MODEL

A: i48 B: i49

AUTO A/C

CONTROL

MODULE

B256

1

2

3

B202

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

A: i48

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

B: i49

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

AC-00158

AC-37



1

2

3

4

5

6

Step Check

CHECK EVAPORATOR SENSOR.



3) Disconnect the connector from evaporator sensor.

4) Measure the resistance between connector terminals of evaporator sensor.

Terminals

No. 1 — No. 2:

Is the resistance approx. 2.7 k

Ω at 20°C (68°F)?

Yes

Go to step 2.

CHECK INPUT SIGNAL FOR EVAPORATOR

SENSOR.


2) Measure the voltage between connector

(B256) terminal and chassis ground.



−

):


Go to step 5.


OUTPUT SIGNAL.






(i49) No. 2 (+) — (i48) No. 16 (

−

):


Go to step 4.


AUTO A/C CONTROL MODULE AND EVAP-

ORATOR SENSOR.



3) Measure the resistance in harness between auto A/C control module and evaporator sensor.


(B256) No. 1 — (i49) No. 2:


Ω? Go to step 5.

Go to step 6.


AUTO A/C CONTROL MODULE AND EVAP-

ORATOR SENSOR.

Measure the resistance in harness between auto A/C control module and evaporator sensor.


(B256) No. 3 — (i48) No. 16:


Ω?





No

Replace the evaporator sensor.

Go to step 3.

Go to step 6.

Repair the open circuit in harness between auto A/C control module and evaporator sensor.

Repair the open circuit in harness between auto A/C control module and evaporator sensor.

Replace the auto

A/C control module.

AC-38



D: SUNLOAD SENSOR


• Sensor identifies that sunlight is at maximum. Then, A/C system is controlled to COOL side.

• Sensor identifies that sunlight is at minimum. Then, A/C system is controlled to HOT side.

NOTE:

When the sunload sensor check is conducted indoors or in the shade, open circuit might be indicated. Always check the sunload sensor at the place where the sun shines directly on it.

WIRING DIAGRAM:

LHD LHD : LHD MODEL

RHD RHD

: RHD MODEL

MT : MT MODEL

AT : AT MODEL i51

SUNLOAD

SENSOR

RHD

RHD i3

B38

RHD

RHD

B202 i41 i2

B37

A: i48 B: i49

AUTO A/C

CONTROL

MODULE i51 B38 A: i48 B: i49

1 2

B202

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

1 2 3 4

10 11 12 13 14 15

22 23 24 25

16

5 6

17

26 27 28 29

18

30

7 8

19 20

31

9

21

32

i2 : AT

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20 21 22

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

i2 :

MT

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

AC-00885

AC-39



1

2

3

4

5

6

Step

CHECK POWER SUPPLY VOLTAGE FOR

SUNLOAD SENSOR.


2) Disconnect the connector from sunload sensor.


4) Measure the power supply voltage for sunload sensor.



−

):


OUTPUT SIGNAL.






(i49) No. 3 (+) — (i48) No. 16 (

−

):

Check



Yes

Go to step 4.

Go to step 3.


AUTO A/C CONTROL MODULE AND SUN-

LOAD SENSOR.



3) Measure the resistance in harness between auto A/C control module and sunload sensor.


(i51) No. 2 — (i49) No. 3:


Ω?


AUTO A/C CONTROL MODULE AND SUN-

LOAD SENSOR.

Measure the resistance in harness between auto A/C control module and sunload sensor.


(i51) No. 1 — (i48) No. 16:


Ω?

Go to step 4.

Go to step 5.

CHECK INPUT VOLTAGE FOR AUTO A/C

CONTROL MODULE.

1) Connect the connector of auto A/C control module.




(i49) No. 3 (+) — (i48) No. 16 (

−

):

Is the voltage approx. 2.5 V?

Go to step 6.





No

Go to step 2.

Go to step 6.


A/C control module and sunload sensor.


A/C control module and sunload sensor.

Replace the sunload sensor.

Replace the auto

A/C control module.

AC-40

General Diagnostic Table


9. General Diagnostic Table

A: INSPECTION

A/C system fails to operate.

Fuse is blown out.

Illumination cannot dim.

Compartment temperature does not decrease. (No cool air is discharged.)

Compartment temperature is higher or lower than setting temperature.

Compartment temperature does not quickly respond to setting temperature.

Symptom

Blower fan does not rotate or fan speed cannot be controlled.

Unable to switch suction vents.

Unable to switch blow vents.

Compartment temperature does not increase. (No hot air is discharged.)

Radiator fan does not rotate during A/C operation.

Problem parts

• Fuse

• Connector (Poor contact)

• Ground

• Auto A/C control module

• Blower fan motor

• Blower fan relay

• A/C Relay

• Compressor (Magnet clutch)

• Evaporator sensor

• Fuse


• Fuse



• Fuse


• Ground


• Blower fan motor

• Blower fan relay



• Intake door actuator



• Mode door actuator



• Air mix door actuator

• In-vehicle sensor, ambient sensor, evaporator sensor and sunload sensor

• In-vehicle sensor aspirator hose




• A/C Relay

• Compressor (Magnet clutch)

• Radiator fan motor

• Radiator fan relay










• Radiator fan motor

• Radiator fan relay

AC-41

General Diagnostic Table


AC-42

AIRBAG SYSTEM

AB

Page

1.


2.

Airbag Connector ........................................................................................9

3.

Inspection Locations After a Collision .......................................................12

4.

Driver’s Airbag Module..............................................................................14

5.

Passenger’s Airbag Module ......................................................................15

6.

Side Airbag Module...................................................................................16

7.

Airbag Control Module ..............................................................................18

8.

Side Airbag Sensor ...................................................................................19

9.

Roll Connector ..........................................................................................20

10.

Front Sub Sensor ......................................................................................21

11.

Airbag Module Disposal (Deployment Processing On Vehicle) ................22

12.

Disposal of Airbag Module (Deploying After Removal from Vehicle) ........26

AIRBAG SYSTEM


A: COMPONENT

1. SRS AIRBAG


(1)

T3

(3)

(2)

T4

T3

(2)

(11)

(10)

(9)

(5)

(4)

(8)

T2

T5

(7)

T2

(6)

T1

(1) Combination switch ASSY with roll connector

(2)

TORX

®

bolt T30

(3) Airbag module ASSY (Driver’s side)

(4) Airbag module ASSY (Passenger’s side)

(5) Airbag control module

(6) Side airbag sensor

(7) Wiring harness rear

(8) Side airbag module

(9) Wiring harness CTR

(10) Wiring harness front

(11) Front sub sensor

AB-00685


T1: 5.9 (0.59, 4.4)

T2: 7.4 (0.75, 5.4)

T3: 10 (1.0, 7.2)

T4: 20 (2.0, 14.5)

T5: 25 (2.5, 18.1)

AB-2

B: CAUTION


• When servicing a vehicle, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait for more than 20 seconds before starting work.

• The airbag system is fitted with a backup power source. If the airbag system is serviced within 20 seconds after the ground cable is disconnected, it may inflate.

AIRBAG SYSTEM

• When checking, use a test harness (1). Do not directly apply the tester probe to any connector terminal of the airbag. Damage to the connector terminal may cause the airbag to activate erroneously.

(1)

FU-00009

• If the airbag warning light illuminates, repair the vehicle immediately. Airbag or pretensioner may inflate incorrectly, or not inflate in collision.

• If sensors, airbag module, airbag control module, pretensioner or harness are deformed or damaged, replace them with new parts.

AB-00122

• Do not check continuity of either of the airbag modules for driver, passenger or side, or pretensioner.

AB-00120

• When checking the airbag system, be sure to use a digital circuit tester.

Infinitesimal electric current in an analog circuit tester may cause the airbag to activate erroneously.

AB-00006

AB-00121

AB-3


AIRBAG SYSTEM

• Do not drop the airbag modulator parts, subject them to high temperature over 93

°C (199°F), or let water, oil, or grease get on them; otherwise, the internal parts may be damaged and reliability greatly lowered.

• Do not allow water or oil to come in contact with the connector terminals. Do not touch the connector terminals.

AB-00126

• Either of the airbag modules for driver, passenger or side, or pretensioner must not be disassembled.

AB-00123

• If any damage, opening, or rust is found on the airbag system wire harness, do not attempt to repair using soldering equipment. Be sure to replace the faulty harness with a new genuine part.

AB-00779

• The removed front seat with the airbag module must be kept at least 200 mm (8 in) away from walls and other objects.

(1)

AB-00124

• Install the wire harness securely with the specified clips to avoid interference or tangled up with other parts.

AB-00128

(1) More than 200 mm (8 in)

• Do not use the airbag or pretensioner parts from other vehicles. Always replace defective parts with new ones.

• Never reuse a deployed airbag or pretensioner.

• When painting or performing sheet metal work on the front part of the vehicle, including the front wheel apron, front fender, and front side frame, remove the front sub sensors and wire harness of the airbag system.

AB-00125

AB-4


• When painting or performing sheet metal work on the side of the vehicle, including the side sill, center pillar, and front and rear doors, remove the side airbag sensors and wire harness of the airbag system.

AIRBAG SYSTEM

AB-00129

AB-5


AIRBAG SYSTEM

• When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object, a serious accident may result.

(1)

(2)

(1) Driver’s airbag module (2) Passenger’s airbag module

AB-6

AB-00130


AIRBAG SYSTEM

C: PREPARATION TOOL

1. SPECIAL TOOL

ILLUSTRATION TOOL NUMBER

98299FC030

DESCRIPTION

DEPLOYMENT

ADAPTER A

REMARKS

• Used for deploying the side airbag module.

• Used with DEPLOYMENT TOOL

(98299PA030).

ST98299FC030

98299SA010 TEST HARNESS

ADAPTER D

• Used for deploying the driver’s airbag module and seat belt pretensioner.


(98299PA030).

• Can not reuse.

ST98299SA010


ADAPTER E

• Used for deploying the passenger’s airbag module.


(98299PA030).

ST98299SA030


ADAPTER F

• Used for deploying lap seat belt pretensioner.


(98299PA030).

ST98299SA050

AB-7

AIRBAG SYSTEM

ILLUSTRATION


TOOL NUMBER

98299PA030

DESCRIPTION

DEPLOYMENT

TOOL

REMARKS

• Used for deploying the airbag module.

• Used with DEPLOYMENT ADAPTER A

(98299FC030).

ST98299PA030

2. GENERAL TOOL

TOOL NAME

TORX

®

T30

REMARKS

Used for removal/installation of driver’s airbag module.

AB-8

2. Airbag Connector

A: OPERATION

Airbag Connector

1. POWER SUPPLY

1) How to disconnect:

(1) Move the slide lock (A) in the direction of arrow.

(2) Pull the female connector in the direction of arrow with slide lock (A) moved.

AIRBAG SYSTEM

2. DRIVER’S AIRBAG (BETWEEN AIRBAG

HARNESS AND ROLL CONNECTOR), PAS-

SENGER’S AIRBAG AND SIDE AIRBAG


(1) Push the lock arm (A).

(2) With the lock arm (A) pushed in, move the slide lock (B) in the direction of arrow.

(B)

(A)

AB-00015

CAUTION:

When pulling, be sure to hold onto the connector and not the wire.

2) How to connect:

Holding the connector (A), push it in carefully until a connecting sound is heard.

AB-00017

(3) With the slide lock pulled, remove the lock arm to its original position, and then pull in the direction of arrow to separate connector.

CAUTION:


AB-00016

CAUTION:

Be sure to insert the connector in until it locks.

Then pull on it gently to make sure that it is locked.

AB-00018

2) How to connect:

Holding the connector, and push it in carefully until a connecting sound is heard.

CAUTION:



AB-00019

AB-9


AIRBAG SYSTEM

3. DRIVER’S AIRBAG MODULE AND PRE-

TENSIONER


(1) Using a flat tip screwdriver, pry the push lock upward to unlock.

4. FRONT SUB-SENSOR AND SIDE AIR-

BAG SENSOR


Holding outer part (A), pull it in the direction of arrow.

CAUTION:


AB-00478

(2) Pull the connector to disconnect from driver’s side airbag module assembly or retractor assembly.

AB-00024

2) How to connect:


CAUTION:

• Do not put your hand on the outer part, since outer (A) moves back.

• Be sure to insert the connector in until it locks. Then pull it gently to make sure that it is locked.

AB-00479

2) How to connect:

Connect the connector in reverse order of disconnecting. At this time, be sure to insert the connector in until a connecting sound is heard.

CAUTION:

• Be sure to insert the connector in until it locks. Then pull it gently to make sure that it is locked.

• Be sure to insert the push lock in.

AB-00025

5. PASSENGER’S AIRBAG


(1) Move the slide lock (A) in the direction of arrow.

( A )

AB-00480

AB-00021

AB-10


(2) With the slide lock pushed, pull the connector in the direction of arrow and disconnect it.

AIRBAG SYSTEM

(2) Pull the connector to disconnect from lap seat belt pretensioner.

AB-00022

CAUTION:


2) How to connect:


CAUTION:



AB-00026

CAUTION:


2) How to connect:

Connect the connector in reverse order of disconnecting. At this time, be sure to insert the connector in until a connecting sound is heard.

CAUTION:

• Be sure to insert the connector in until it locks.

Then pull it gently to make sure that it is locked.

• Be sure to lock the push lock securely.

AB-00023

6. LAP SEAT BELT PRETENSIONER


(1) Using a flat tip screwdriver, pry the push lock (A) upward to unlock.

(A)

AB-00115

AB-11

AB-00027

Inspection Locations After a Collision

AIRBAG SYSTEM

3. Inspection Locations After a

Collision

A: REPLACEMENT

When airbag system is deployed, replace the following parts.

1. FRONT COLLISION

1) Driver’s airbag module

2) Passenger’s airbag module

3) Driver’s seat belt (pretensioner, lap seat belt pretensioner)

4) Passenger’s seat belt (pretensioner)

5) Airbag control module

6) Front sub-sensor

7) Roll connector

2. SIDE COLLISION

1) Airbag control module

2) Side airbag module (operating side seat bag)

3) Side airbag sensor (operating side)

3. INSPECTION OF OTHER PARTS

Check for the following parts, replace the damaged parts with new ones.

1) Steering wheel and steering shaft

Check the steering wheel and steering shaft for mounting condition and deflection of axial and radial direction. Check the steering shaft for deflection of axial direction with tilt lever released. (After a collision, absorbing part of steering shaft may inflate.)

2) Check the direct type connector of driver’s airbag module, pretensioner, etc. for damage, and also check each harness for pinch and connector damage. If damage is found, replace the harness as a unit.

B: INSPECTION

If the vehicle is involved in a collision on any side, even if it is a slight collision, be sure to check the following system parts.

1. DRIVER’S AIRBAG MODULE

1) Check for the following, and replace damaged parts with new ones.

• Airbag module is cracked or deformed.

• Harness and/or connector is cracked, deformed or open. Lead wire is exposed.

• The module surface is fouled with grease, oil, water or cleaning solvent.

2) When installing a new driver’s airbag module, check the following. If necessary, install a new airbag module and steering wheel.

• The steering wheel is in the way, making it difficult to install the airbag module.

• The clearance between the driver’s airbag module and steering wheel is not constant.

• The steering wheel deformation in axial and radial directions exceed limits.

Specifications:

Height deflection A

Less than 6 mm (0.24 in)

O.D. deflection L

Less than 17 mm (0.67 in)

A

L

AB-00028

2. PASSENGER’S AIRBAG MODULE

Check for the following, and replace damaged parts with new ones.

• Airbag module is cracked or deformed.

• Harness and/or connector is cracked, deformed or open. Lead wire is exposed.

• Mounting bracket is cracked or deformed.

3. SIDE AIRBAG MODULE


• Front seat is damaged or deformed.

• Harness and/or connector is cracked, deformed or open.

• Lead wire is exposed.

4. AIRBAG CONTROL MODULE


• Control module is cracked or deformed.


• Connector is scratched or deformed.

• Airbag is deployed.

• Side airbag is deployed.

AB-12


5. FRONT SUB SENSOR

If the front section of vehicle as shown in the figure is damaged:

AIRBAG SYSTEM

8. STEERING SHAFT


• Overall length of steering column should be within specifications.

Specifications:

Overall length L

815.6

±

1.5 mm (32.1

±

0.06 in)

AB-00029


• Front sub sensor is cracked or deformed.


• Connector is scratched or cracked.


6. SIDE AIRBAG SENSOR

If the side section of vehicle as shown in the figure is damaged:

L

If necessary, replace it with a new part.

AB-00717

AB-00030


• Side airbag sensor is cracked or deformed.


• Connector is scratched or cracked.

• Side airbag is deployed. (operating side)

7. ROLL CONNECTOR


• Combination switch or steering roll connector is cracked or deformed.

AB-13

Driver’s Airbag Module

AIRBAG SYSTEM

4. Driver’s Airbag Module

A: REMOVAL

CAUTION:

Refer to “CAUTION” in General Description be-

fore handing the airbag module. <Ref. to AB-3,

CAUTION, General Description.>

1) Position the front wheels straight ahead. (After moving the vehicle more than 5 m (16 ft) with front wheels positioned straight ahead, make sure that the vehicle moves straight ahead).


3) Disconnect the ground cable from battery, and wait for at least 20 seconds before starting work.

4) Using the TORX

®

BIT T30, remove the two

TORX

®

bolts on side of steering wheel.

B: INSTALLATION


CAUTION:

Do not allow harness and connectors to interfere or get tangled up with other parts.


Refer to “COMPONENT” in “General Descrip-

tion” <Ref. to AB-2, SRS AIRBAG, COMPO-


C: INSPECTION

CAUTION:





• Airbag module, harness, connector, and mounting

bracket are damaged. <Ref. to AB-12, DRIVER’S

AIRBAG MODULE, INSPECTION, Inspection Locations After a Collision.>

(1)

CC-00018

(1) TORX

®

BIT T30

5) Disconnect the airbag connector on the back of airbag module, and then remove the airbag module.

AB-00033

6) Refer to “CAUTION” for handling of removed air-

bag module. <Ref. to AB-3, CAUTION, General Description.>

AB-14

Passenger’s Airbag Module

5. Passenger’s Airbag Module

A: REMOVAL

CAUTION:







AL, Glove Box.>

4) Detach the airbag connector from support beam bracket, and then disconnect the airbag connector.

AIRBAG SYSTEM

AB-00117

5) Remove the three bolts, and then carefully remove the airbag module.

6) Refer to “CAUTION” for handling of removed air-

bag module. <Ref. to AB-3, CAUTION, General

Description.>

B: INSTALLATION


CAUTION:

Do not allow harness and connectors to interfere or get tangled up with other parts.





C: INSPECTION

CAUTION:





• Airbag module, harness, connector, and mounting

bracket are damaged. <Ref. to AB-12, PASSEN-

GER’S AIRBAG MODULE, INSPECTION, Inspection Locations After a Collision.>

AB-15

Side Airbag Module

AIRBAG SYSTEM

6. Side Airbag Module

A: REMOVAL

CAUTION:

Before working on the airbag module, refer to

the “CAUTION” in General Description. <Ref. to

AB-3, CAUTION, General Description.>

NOTE:

Remove the passenger’s side by referring to driver’s side.



3) Remove the front seat from the vehicle. <Ref. to

SE-6, REMOVAL, Front Seat.>

4) Remove the clip from slide rail IN (A) and reverse side of seat cushion assembly, and then remove the side airbag harness.

7) Remove the side airbag module (A) from backrest frame assembly.

(A)

AB-00476

B: INSTALLATION

1) Ensure there are no foreign particles on side airbag module.

2) Install the side airbag module (A) to backrest frame assembly.


5.9 N·m (0.59 kgf-m, 4.4 ft-lb)

(A)

(A)

AB-00474

5) Remove the backrest cover. <Ref. to SE-6, DIS-

ASSEMBLY, Front Seat.>

6) Remove the side airbag harness from backrest frame assembly.

AB-00477

AB-00475

AB-16

Side Airbag Module

3) Install the side airbag harness to backrest frame assembly.

NOTE:

Secure the harness to its original position of seat.

AB-00475

4) Install the backrest cover. <Ref. to SE-11, AS-

SEMBLY, Front Seat.>

5) Install the side airbag harness to slide rail IN (A).

AIRBAG SYSTEM

C: INSPECTION

CAUTION:

Before working on the airbag module, refer to

the “CAUTION” in General Description. <Ref. to

AB-3, CAUTION, General Description.>

Perform the inspection of following items, and replace

the damaged parts with new ones. <Ref. to AB-12,

SIDE AIRBAG MODULE, INSPECTION, Inspection Locations After a Collision.>

1) With side clash (when side airbag is deployed)

<Replacement parts>

• Side airbag module assembly

• Backrest pad assembly

• Backrest frame assembly

• Backrest cover assembly

<Other replacement parts, which found to be damaged by visual check>

• Headrest assembly

• Bushing

• Slide rail OUT

• Slide rail IN

• Seat hinge cover

• Seat lifter lever

• Reclining lever

• Side airbag harness and connector (body side)

2) With side clash (when side airbag is not deployed)

Check the seat and airbag module visually, and then replace them with new ones if damaged or cracked.

Specially inspect the damage of airbag module body, installing bracket, harness connector.

3) Without side clash (dirt and damage of cover)

Replace the corresponding part with a new one.

(A)

AB-00474

6) Recline the seat or slide it backward and forward. Check there is no contact between seat backrest assembly, cushion cover assembly and side airbag harness.

AB-17

Airbag Control Module

AIRBAG SYSTEM

7. Airbag Control Module

A: REMOVAL

CAUTION:

• Do not disassemble the airbag control module.

• If the airbag control module is deformed or if water damage is suspected, replace the airbag control module with a new part.

• Do not drop the airbag control module.

• After removal, keep the airbag control module on a dry, clean surface away from moisture, heat, and dust.



3) Remove the console cover. <Ref. to EI-39, RE-

MOVAL, Console Box.>

4) Remove the center console panel. <Ref. to EI-

40, REMOVAL, Instrument Panel Assembly.>

5) Disconnect the connector from airbag control module.

6) Remove the four bolts, and then remove the airbag control module.

AB-00035

B: INSTALLATION

CAUTION:

Use new bolts (for airbag control module only) during reassembly.






C: INSPECTION


• Control module, connector, and mounting bracket are damaged.



AB-18

Side Airbag Sensor

8. Side Airbag Sensor

A: REMOVAL



3) Remove the outer belt (FRONT). <Ref. to SB-

10, FRONT OUTER BELT, REMOVAL, Front Seat

Belt.>

4) Detach the side airbag sensor, and then disconnect the airbag connector.

AIRBAG SYSTEM

AB-00036

B: INSTALLATION

CAUTION:

Use new TORX

®

bolts T30 when reassembling.






C: INSPECTION

Check for the following, and replace damaged parts with new parts.

• Bracket connector for side airbag sensor is damaged.


AB-19

Roll Connector

AIRBAG SYSTEM

9. Roll Connector

A: REMOVAL



3) Remove the driver’s airbag module. <Ref. to AB-

14, Driver’s Airbag Module.>

4) Remove the steering wheel. <Ref. to PS-23, RE-

MOVAL, Steering Wheel.>

5) Remove the steering column cover.

6) Remove the screws, and then remove the roll connector.

AB-00593

B: INSTALLATION


2) Before installing the steering wheel, be sure the direction of roll connector is adjusted with steering.

<Ref. to AB-20, ADJUSTMENT, Roll Connector.>

C: INSPECTION


• Combination switch and roll connector are cracked or deformed.

D: ADJUSTMENT

1) Check that the front wheels are positioned in straight ahead direction.

2) Turn the roll connector pin (A) clockwise until it stops.

3) Turn the roll connector pin (A) counterclockwise approx. 2.65 turns until “

▲” marks are aligned.

(A)

AB-00594

AB-20

Front Sub Sensor

10.Front Sub Sensor

A: REMOVAL



3) Remove the front grille and front grille side.

<Ref. to EI-18, REMOVAL, Front Grille.>

4) Disconnect the connector from front sub sensor.

AIRBAG SYSTEM

AB-00040

5) Loosen the nut, and then detach the front sub sensor.

AB-00116

B: INSTALLATION

CAUTION:

Use new nuts when reassembling.






C: INSPECTION


• Front sub sensor, mounting bracket, and connector are damaged.


AB-21

Airbag Module Disposal (Deployment Processing On Vehicle)

AIRBAG SYSTEM

11.Airbag Module Disposal (Deployment Processing On Vehicle)

A: OPERATION

CAUTION:

• Do not discard an undeployed airbag modules because it may cause a serious personal injury when accidentally deployed.

• As a rule, the airbag module should be deployed while still installed in the vehicle. Do not remove the airbag modules unless necessary.

• Deployment of the airbag module should be done on a flat place free from any possible danger. Avoid deploying outdoors during rainy or windy weather.

• Deploying the airbag module causes a high explosive noise, be sure to warn people in the area, and do not allow anyone within a 5 m (16 ft) radius of the disposal site.

• Some smoke will be emitted from deployment of the airbag module. Therefore, it must be deployed in a well-ventilated place with no smoke detector nearby.

• Wear protective gloves, safety goggles and earplugs during this operation. Wash your hands afterwards.

• After deployment, the airbag module will be especially hot, leave it unattended for 40 minutes, and then discard it.

• Do not let water get on the deployed airbag module.

• Wrap the deployed airbag module in an airtight vinyl bag, and discard it.

• If circumstances do not permit the airbag module deployment, contact the SUBARU dealer.



2) Disconnect the ground cable from battery and wait for at least 20 seconds before starting work.

3) Remove the lower cover. <Ref. to EI-40, RE-

MOVAL, Instrument Panel Assembly.>

4) Disconnect the airbag connector (AB30) and

(AB2) below steering column.

AB30

AB2

AB-00197

5) Short the terminal to alligator clip furnished as deployment tool (A).

6) Connect the deployment tool and deployment adapter A (B).

CAUTION:

The deployment tool should be kept shorted terminals until just before deployment of airbag module.

(A) Deployment tool:

(Tool number 98299PA030)

(B) Deployment adapter A:

(Tool number 98299SA030)

7) Connect the deployment adapter A to airbag connector (AB30).

AB30

SB-00016

(1)

AB-00198

(1) Deployment adapter A:


AB-22


AIRBAG SYSTEM

8) Extend the wiring of deployment tool to the limit, and make sure that the vehicle is empty. Close all the windows, sunroof and rear gate completely.

SB-00017

9) Move the battery at least 5 m (16 ft) from vehicle, and secure the nearby area. Connect the deployment tool alligator clip to the battery negative (

−) terminal.

10) Connect the other cable of deployment tool to the battery positive (+) terminal, and deploy the airbag module.





4) Disconnect the airbag connectors (AB4) and

(AB27).

5) Short the terminal to alligator clip furnished as deployment tool (A)

6) Connect the deployment tool (A) and deployment adapter E (B).

CAUTION:


SB-00018

CAUTION:



11) Remove the airbag module. <Ref. to AB-14,

Driver’s Airbag Module.>

12) Wrap the deployed airbag module in airtight vinyl bag, and discard it.

SB-00016



(B) Deployment adapter E:


7) Connect the deployment adapter E to the airbag connector (AB27).

AB27

(1)

AB-00199

(1) Deployment adapter E:


AB-00043

AB-23


AIRBAG SYSTEM


SB-00017


−) terminal.





3) Disconnect the side airbag module connector

(yellow) under the front seat cushion.

4) Set the backrest at most standing position, and then set the seat position at center of slide rail.



CAUTION:


SB-00018

CAUTION:



11) Remove the airbag module. <Ref. to AB-15,

Passenger’s Airbag Module.>

12) Wrap the airbag module in an airtight vinyl bag, and discard it.

SB-00016




(Tool number 98299FC030)

7) Connect the deployment adapter A (1) to the side airbag module connector (yellow).

CAUTION:

• Do not place any object on front seat.

• Deploy the side airbag one by one to discard it.

(1)

AB-00652

AB-00043

AB-24


AIRBAG SYSTEM


SB-00017


−) terminal.


SB-00018

CAUTION:



11) Remove the side airbag module. <Ref. to AB-

16, REMOVAL, Side Airbag Module.>


AB-00043

AB-25

Disposal of Airbag Module (Deploying After Removal from Vehicle)

AIRBAG SYSTEM

12.Disposal of Airbag Module

(Deploying After Removal from Vehicle)

A: OPERATION

CAUTION:

• Do not discard an undeployed airbag module because it may cause serious personal injury when accidentally deployed.

• As a rule, the airbag module should be deployed while still installed in the vehicle. Do not remove the airbag modules unless necessary.

• Deployment of the airbag module should be done on a flat place free from any possible danger. Avoid deploying outdoors during rainy or windy weather.

• Do not damage the airbag module or drop it.

• Deploying the airbag module causes a high explosive noise, be sure to warn people in the area, and do not allow anyone within a 5 m (16 ft) radius of the disposal site.

• Some smoke will be emitted from deployment of the airbag module. Therefore, it must be deployed in a well ventilated place with no smoke detector nearby.

• Wear protective gloves, safety goggles and earplugs during this operation. Wash your hands afterwards.



• Wrap the deployed airbag module in an airtight vinyl bag, and discard it.

• If circumstances do not permit the airbag module deployment, contact the SUBARU dealer.






4) Install the removed bolts to airbag module.

AB-00780

5) Bundle three automotive wire harnesses [each with a sectional area of 1.25 mm

2

(0.00194 sq in) or more], and bind them twofold around airbag module stay.

AB-00048


7) Connect the deployment tool and deployment adapter D (B).

CAUTION:


(B)

(A)

SB-00021



(B) Deployment adapter D:


8) Connect the deployment adapter D connector to airbag module.

AB-26


AIRBAG SYSTEM

9) Install the airbag module with pad side facing upward on a wheel with tire.


AB-00050

10) Put three tires without wheels on the tire installed with the airbag module. Put on an additional tire with a wheel, and then fasten them tight with a rope.

SB-00018

CAUTION:




SB-00025


−

) terminal.

(1)

(1) 5 m (16 ft) or more

SB-00065

AB-00043




3) Remove the passenger airbag module. <Ref. to

AB-15, Passenger’s Airbag Module.>


2

(0.00194 sq in) or more], route them through airbag module bracket

(A). Then, twist them to add strength.

(A)

AB-00051

AB-27


AIRBAG SYSTEM


6) Connect the deployment tool and deployment adapter E (B).

CAUTION:



−

) terminal.

SB-00016



(B) Deployment adapter E:


7) Connect the deployment adapter E connector to the airbag module.

8) Install the airbag module with opening side facing upward on 14-inch or greater size wheel with tire.

(1)

SB-00065

(1) 5 m (16 ft) or more


SB-00018

CAUTION:




AB-00052

9) Put three tires without wheels on the tire installed with the airbag module. Put on an additional tire with a wheel on top, and then fasten them tight with a rope.

AB-00043

SB-00025

AB-28


AIRBAG SYSTEM




3) Remove the front seats. <Ref. to SE-6, REMOV-

AL, Front Seat.>

4) Remove the side airbag module. <Ref. to AB-16,

REMOVAL, Side Airbag Module.>


2

(0.00194 sq in) or more], and then bind them through the holes in airbag module bracket.

9) Install the airbag module on 14-inch or greater size tire without wheel.

(A)

(B)

AB-00145

(A)

(B)

(A) Pad

(B) Airbag module bracket

10) Put two tires without wheels (A) under the tire installed with the side airbag module (B). Put on an additional tire without a wheel (C), and then put a tire with a wheel (D) on top. Fasten them tight with a rope.

AB-00144

(A) Airbag module bracket

(B) Side airbag module



CAUTION:


(A)

(D)

(C)

(B)

AB-00146


−

) terminal.

SB-00016




(Tool number 98299FC030)

8) Connect the deployment adapter A connector to the airbag module.

AB-29

(1)

(1) 5 m (16 ft) or more

SB-00065


AIRBAG SYSTEM


SB-00018

CAUTION:

• After deployment, the airbag module will be especially hot, leave it unattended for 40 minutes, and discard it.



AB-00043

AB-30

AIRBAG SYSTEM (DIAGNOSTIC)

AB

Page

1.

Basic Diagnostic Procedure ........................................................................2

2.

Check List for Interview...............................................................................3

3.


4.

Electrical Components Location................................................................19

5.

Airbag Control Module I/O Signal..............................................................21

6.

Airbag Connector ......................................................................................27

7.

Airbag Warning Light Illumination Pattern.................................................30

8.

Read Diagnostic Trouble Code (DTC) ......................................................31

9.

Inspection Mode........................................................................................32

10.

Clear Memory Mode..................................................................................33

11.

Airbag Warning Light Failure.....................................................................34

12.

List of Diagnostic Trouble Code (DTC) .....................................................43

13.

Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................46

Basic Diagnostic Procedure

AIRBAG SYSTEM (DIAGNOSTIC)

1. Basic Diagnostic Procedure

A: PROCEDURE

1

2

3

Step Check Yes

READ DTC.

<Ref. to AB-31, Read Diagnostic Trouble Code

(DTC).>

Is the normal code detected?

Finish the diagnosis.

Go to step 3.

READ DTC.

<Ref. to AB-31, Read Diagnostic Trouble Code

(DTC).>

Is DTC displayed?

Is DTC displayed?

Replace the airbag warning light.

<Ref. to AB-34,

Airbag Warning

Light Failure.>

Perform the procedure 1) to 5) in step 3.


PERFORM THE DIAGNOSIS.

1) Judge the possible cause from “List of

Diagnostic Trouble Code (DCT)” <Ref. to AB-

43, List of Diagnostic Trouble Code (DTC).>

2) Inspect using “Diagnostic Procedure with

Diagnostic Trouble Code (DTC)”.

3) Repair the cause of the trouble.

4) Perform the clear memory mode. <Ref. to

AB-33, Clear Memory Mode.>

5) Perform the inspection mode. <Ref. to AB-

32, Inspection Mode.>

6) Read any DTC again.

No

Go to step 2.

AB-2

Check List for Interview

2. Check List for Interview

A: CHECK


Customer’s Name Inspector’s Name

Date Vehicle Brought In

Odometer Reading

Date Problem Occurred

Weather

Temperature

Road Condition

Vehicle Operation

/ /

/ /

Registration No.

km miles

VIN

Registration Year / /

❏ Fine ❏ Cloudy ❏ Rainy ❏ Snowy ❏ Other:

°C (°F)

❏ Level road ❏ Uphill ❏ Downhill ❏ Rough road ❏ Others:

❏ Starting

❏ Driving (❏ Constant speed

❏ Steering wheel turn

❏ Idling

❏ Acceleration

❏ Others:

❏ Deceleration

)

Details of Problem

Check Airbag Warning Light

Check DTC

❏ Normal (After turning the ignition switch to ON, lit for 7 seconds and goes off.)

❏ Remains ON ❏ Remains OFF

❏ Normal Code ❏ DTC: (Code:

)

AB-3




A: CAUTION

• When servicing a vehicle, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait for more than 20 seconds before starting work.

• The airbag system is fitted with a backup power source. If the airbag system is serviced within 20 seconds after the ground cable is disconnected, it may inflate.

• When checking, use a test harness. Do not directly apply the tester probe to any connector terminal of the airbag.

(1)

AB-00002

• If sensors, airbag module, airbag control module, pretensioner, and harness are deformed or damaged, replace them with new genuine parts.

AB-00122

(1) Test harness

• Do not drop the airbag modulator parts, subject them to high temperature over 93

°C (199°F), or let water, oil, or grease get on them; otherwise, the internal parts may be damaged and reliability greatly lowered.

AB-00120

• Do not use the airbag system and pretensioners on other vehicles. When replacing parts, be sure to replace them with new parts.

• When checking the system, be sure to use a digital circuit tester. Use of an analog circuit tester may cause the airbag to activate erroneously.

AB-00121

AB-4

AB-00123


• If any damage, opening, or rust is found on the airbag system wiring harness, do not attempt to repair using soldering equipment. Be sure to replace the faulty harness with a new genuine part.


• Either of the airbag modules for driver, passenger or side, or pretensioner must not be disassembled.

AB-00124

• Install the wiring harness securely with the specified clips to avoid interference or tangled up with other parts.

AB-00127

• The airbag module cannot be used again once inflated.

• After removal, keep the airbag module with the pad facing upward on a dry, clean, and flat surface away from heat and light sources, and moisture and dust.

AB-00125

• Do not allow water or oil to come in contact with the connector terminals. Do not touch the connector terminals.

AB-00056

• Do not check continuity of either of the airbag modules for driver, passenger or side, or pretensioner.

AB-00126

AB-00006

AB-5



• The removed front seat with the airbag module must be kept at least 200 mm (8 in) away from walls and other objects.

(1)

AB-00128

(1) More than 200 mm (8 in)

• When painting or performing sheet metal work on the front part of the vehicle, including the front wheel apron, front fender, and front side frame, remove the front sub sensors and wire harness of the airbag system.

• When painting or performing sheet metal work on the side of the vehicle, including the side sill, center pillar, and front and rear doors, remove the side airbag sensors and wiring harness of the airbag system.

AB-00129

• Do not discard undeployed airbag modules.

They could easily cause a serious accident if accidentally deployed.

AB-6



• When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object, a serious accident may result.

(1)

(2)

(1) Driver side airbag module (2) Passenger side airbag module

AB-7

AB-00130



B: INSPECTION

Before diagnosing, check the following items that might be related to the engine problem:

1. BATTERY

Measure the battery voltage and specific gravity of electrolyte.

Standard voltage: 12 V

Specific gravity: Above 1.260


1. SPECIAL TOOL

• TEST HARNESS M


98299FE020

DESCRIPTION REMARKS

TEST HARNESS M • Used when measuring voltage, resistance of airbag system.

• Used with test harness T (98299SA060).

4M

3M

5M

2M

1M

ST98299FE020

1

11

10

4

2

8

18

5

16

7

6

9

5M

5M

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

3M

2 1

4M

1 2

3M 4M

1M

2

6 5

1

4 3

2M

1

3 4

2

5 6

100

6

5

4

3

2

1

2M

1M

1

2

3

4

5

6

AB-00425

AB-8

• TEST HARNESS F

ILLUSTRATION



TOOL NUMBER

98299FC010

DESCRIPTION REMARKS

TEST HARNESS F Used when measuring voltage, resistance of airbag module harness.

3F

2F

1F

ST98299FC010

3F

5

6

4

3

2F

1

2

2

1

1F

3F

1 2

3 4 5 6

2F

1 2

1F

2 1

AB-00719

AB-9



• TEST HARNESS G


98299FC020

DESCRIPTION REMARKS

TEST HARNESS G Used when measuring voltage, resistance of side airbag sensor.

2G

3G

1G

ST98299FC020

3G

6

7

3

8

4

5

1

2

3G

1 2 3

4 5 6 7 8

2G

1 2

3 4

1G

4

2

3

1

2G

1

2

3

4

4

3

2

1

1G

AB-00428

AB-10

• TEST HARNESS H

ILLUSTRATION

1H

3H

2H



TOOL NUMBER

98299FA030

DESCRIPTION REMARKS

TEST HARNESS H Used when measuring voltage, resistance of front sub-sensor.

ST98299FA030

3H

3

4

5

6

3H

1 2

3 4 5 6

2H

1 2

1H

2 1

2H

1

2

2

1

1H

AB-00720

AB-11



• TEST HARNESS L


98299FE000

DESCRIPTION REMARKS

TEST HARNESS L Used when measuring voltage, resistance of seat belt pretensioner.

3L

2L

1L

ST98299FE000

3L

3

4

5

6

3L

1

3 4 5

2

6

2L

1 2

1L

2 1

2L

1

2

1

2

1L

AB-00430

AB-12

• TEST HARNESS R

ILLUSTRATION

5R

6R



TOOL NUMBER

98299FE030

DESCRIPTION REMARKS

TEST HARNESS R Used when measuring voltage, resistance of airbag control module.

3R

4R

2R

1R

ST98299FE030

1R

46

42

45

41

33

14

31

5

1

6

2

13

19

29

39

40

20

28

15

17

23

25

22

26

18

11

16

35

34

36

30

24

43

4

44

3

37

27

21

38

32

12

10

9

7

51

8

48

52

50

49

47

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

4R

5

6

7

8

9

3

4

1

2

10

11

12

13

14

15

16

17

18

19

20

3R

1 2 3 4 5 6 7 8 9 10 11 12 13 14

2R

1R

46 45 44 43 42 41

52 51 50 49 48 47

18

29

40

17 16

28 27 26 25 24 23

39 38 37 36 35 34

22

15

21

14 13

20 19

33 32 31 30

6

12

5 4

11 10

3

9

2

8

1

7

1 2

5R

1 2

6R

4R

1 2 3

9 10

4 5 6 7

11 12 13 14 15 16

8

17 18

3R

1

10

2 3 4 5

11 12 13 14 15 16

6 7 8 9

17 18 19 20

2R

1 2 3 4 5 6

7 8 9 10 11 12 13 14

5R

2 1

6R

1 2

AB-00606

AB-13



• TEST HARNESS P


98299SA020

DESCRIPTION REMARKS

TEST HARNESS P Used when measuring voltage, resistance of driver’s airbag module harness and passenger airbag module harness.

1P

2P

3P

ST98299SA020

2P

1 2

1 2

4 3 2 1

1P

4

3

2

1

3P

4 3

3 4

AB-00679

AB-14

• TEST HARNESS N

ILLUSTRATION

2N



TOOL NUMBER

98299SA000

DESCRIPTION REMARKS

TEST HARNESS N Used when measuring voltage, resistance of driver’s airbag module and seat belt pretensioner.

1N

ST98299SA000

2N

1

2

1 2

2N

1N

2 1

1N

1

2

AB-00675

AB-15



• TEST HARNESS T


98299SA060

DESCRIPTION REMARKS

TEST HARNESS T • Used when measuring voltage, resistance of airbag system.

• Used with test harness M (98299FE020).

2T

1T

ST98299SA060

2T

3

4

2

6

5

1

2T

1 2

3 4 5 6

1T

2

6 5 4

1

3

1T

4

5

6

1

2

3

AB-00607

AB-16

• TEST HARNESS Q

ILLUSTRATION



TOOL NUMBER

98299SA040

DESCRIPTION REMARKS

TEST HARNESS Q Used when measuring voltage, resistance of driver’s airbag module.

2Q

1Q

ST98299SA040

2Q

1

2

1 2

2Q

1Q

2 1

1Q

1

2

AB-00678

AB-17



• AIRBAG RESISTOR


98299PA040

DESCRIPTION REMARKS

AIRBAG RESISTOR Used in replacement of airbag module which resistance value is same as airbag module.

ST98299PA040

3

4

2

6 5 4

1

3

2

1

3

AB-00433

AB-18

Electrical Components Location


4. Electrical Components Location

A: LOCATION

1. LHD MODEL

(1)

(2)

AB18 AB15

AB14

AB13

AB21

AB26

AB2

(3)

(a)

B31

AB1

(7)

AB7

(5)

AB4

(6)

(8)

(4)

AB3

AB8

(9)

(10)

AB19

(b)

AB10

(12)

AB9

(14)

AB11

(15)

(a) To body harness (b) To seat belt pretensioner (LH)

(1) Front sub sensor (LH)

(2) Front sub sensor (RH)

(3) Front sub sensor harness (LH)

(4) Front sub sensor harness (RH)

(5)

Airbag control module with built-in safety and electric sensor

(6) Passenger’s airbag inflator

(7) Roll connector

(8) Airbag main harness

(9) Driver’s airbag inflator

(10) Side airbag harness (LH)

(11) Side airbag harness (RH)

(11)

AB20

(c)

AB12

(13)

AB-00737

(c) To seat belt pretensioner (RH)

(12) Side airbag sensor (LH)

(13) Side airbag sensor (RH)

(14) Side airbag inflator (LH)

(15) Side airbag inflator (RH)

Connector

No.

Pole

Color

(AB1)

6

Yellow

(AB2)

2

Yellow

(AB3)

28

Yellow

(AB4)

4

Yellow

(AB7)

12

Yellow

(AB8)

12

Yellow

(AB9)

2

Yellow

(AB10)

4

Yellow

(AB11)

2

Yellow

(AB12)

4

Yellow

(AB13)

2

Yellow

(AB14)

2

Yellow

Male/Female Male Female Female Female Female Female Female Female Female Female Female Male

Connector

No.

Pole

(AB15) (AB18) (AB19) (AB20) (AB21) (AB26)

Color

2

Yellow

2

Yellow

2

Yellow

2

Yellow

2

Yellow

2

Yellow

Male/Female Female Female Female Female Female Male

AB-19



2. RHD MODEL

(1)

AB18

AB15

(2)

(6)

(3)

AB4

(5)

B31

(4)

(a)

AB3

AB7

(8)

AB1

AB2

(7)

AB14

AB13

AB21

AB26

(11)

AB8

(10)

(9)

AB19

(b)

AB10

(12)

AB9

(14)

AB11

(15)

AB25

(16)

AB20

(c)

AB12

(13)

AB-00738

(c) To seat belt pretensioner (RH) (a) To body harness (b) To seat belt pretensioner (LH)

(1) Front sub sensor (LH)

(2) Front sub sensor (RH)

(3) Front sub sensor harness (LH)

(4) Front sub sensor harness (RH)

(5)

Airbag control module with built-in safety and electric sensor

(6) Passenger’s airbag inflator

(7) Roll connector

(8) Airbag main harness

(9) Driver’s airbag inflator

(10) Side airbag harness (LH)

(12) Side airbag sensor (LH)

(13)

(14)

(15)

(16)

Side airbag sensor (RH)

Side airbag inflator (LH)

Side airbag inflator (RH)

Lap pretensioner

Connector

No.

Pole

Color

(AB1)

6

Yellow

(AB2)

2

Yellow

(AB3)

28

Yellow

(AB4)

4

Yellow

(AB7)

12

Yellow

(AB8)

12

Yellow

(AB9)

2

Yellow

(AB10)

4

Yellow

(AB11)

2

Yellow

(AB12)

4

Yellow

(AB13)

2

Yellow

(AB14)

2

Yellow

Male/Female Male Female Female Female Female Female Female Female Female Female Female Male

Connector

No.

Pole

Color

(AB15)

2

Yellow

(AB18)

2

Yellow

(AB19)

2

Yellow

(AB20)

2

Yellow

(AB21)

2

Yellow

(AB25)

2

Orange

(AB26)

2

Orange

Male/Female Female Female Female Female Female Female Male

AB-20

Airbag Control Module I/O Signal


5. Airbag Control Module I/O Signal

A: WIRING DIAGRAM

1. LHD MODEL

TO POWER SUPPLY ROUTING

FB-33

F/B FUSE No. 14

(IG)

IG

IGNITION RELAY

(IG)

FB-20

F/B FUSE No. 11

(IG)

FB-21

F/B FUSE No. 6

(IG)

METER

AIRBAG

WARNING LED

AIRBAG

CIRCUIT

B9 GR GR 5 GR

C8 GB GB 19 GR i2 B37

B10 B B i3

28 B

B38

B31

AB1

CHECK

CONNECTOR

GW 7

GR

L

W

6

2

3

B

B79

8

DIAGNOSIS

CONNECTOR

L 1

W

B82

2

DIAGNOSIS

TERMINAL

B

B

B81

AB3 AIRBAG CONTROL MODULE

REF. TO GND(L)-02 REF. TO GND(L)-04

B31 (YELLOW)

1 2

3 4 5 6

B82 (BLACK)

1 2

3 4 5 6

1 2 3

AB3 (YELLOW)

4 5 6

7 8 9 10 11 12 13 14 15 16 17

C: i11 (GREEN) B79 (GRAY) B37

1 2 3 4 5 6 7 8 9 10

B: i10 (GREEN)

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

1 2 3 4

1 2 3 4 5 6 7

8 9 10 11 12 13 14

B38

1 2 3 4

10 11 12 13 14 15

22 23 24 25

16

5 6

17

26 27 28 29

18

30

7 8

19 20

31

9

21

32

5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

18 19 20 21 22 23 24 25 26 27 28

WI-03204

AB-21



FRONT SUB SENSOR LH FRONT SUB SENSOR RH

AB18

AB14

AB13

AB15


AB21

AB26

STEERING

ROLL CONNECTOR

AB2 AB4

AB13 (YELLOW)

AB21 (YELLOW)

1 2

INFLATOR (DRIVER SIDE)

AB2 (BLACK)

1 2

AB15

AB18

1 2

(YELLOW)

(YELLOW)

GAB-1

AB4 (YELLOW)

1 2 3 4

INFLATOR (PASSENGER SIDE)

AB3 (YELLOW)

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

GA

WI-03205

AB-22



AIRBAG CONTROL MODULE

AB7 AB8

AB19 AB9 AB10 AB12 AB11 AB20

PRETENSIONER

LH

(YELLOW) AB9 AB11 (YELLOW)

(YELLOW) AB19 AB20 (YELLOW)

1 2

INFLATOR

(SIDE LH)

AB10 (YELLOW)

AB12 (YELLOW)

1

3

2

4

SIDE AIR BAG

SENSOR LH

SIDE AIR BAG

SENSOR RH

AB7 (YELLOW)

1 2 3 4 5 6

7 8 9 10 11 12

INFLATOR

(SIDE RH)

AB8 (YELLOW)

1 2 3 4 5 6

7 8 9 10 11 12

PRETENSIONER

RH

WI-03411

AB-23



2. RHD MODEL

TO POWER SUPPLY ROUTING

FB-36

F/B FUSE No. 14

(IG)

IG

IGNITION RELAY

(IG)

FB-20

F/B FUSE No. 11

(IG)

FB-21

F/B FUSE No. 6

(IG) i10 i11

COMBINATION

METER

AIRBAG WARNING

LED LIGHT

B9 GY GY 16 GY

AIRBAG

CIRCUIT

C8 GR GR 10 GR

B10 B B 20 i3

B

B38

CHECK

CONNECTOR

GW 7

GR 6

L

W

B

B79

8

2

3

DIAGNOSIS

CONNECTOR

L 1

W

B82

2

B31

DIAGNOSIS

TERMINAL

BL

BL

B81

REF. TO E/G(RNA)-05

REF. TO E/G(RTB20)-05

REF. TO E/G(RTB25)-05

AB1

B31 (YELLOW)

1 2

3 4 5 6

B82

(BLACK)

1 2

3 4 5 6

B: i10 (GREEN)

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

REF. TO GND(R)-05

C: i11 (GREEN)

1 2 3 4 5 6 7 8 9 10

REF. TO GND(R)-04

B79 (GRAY)

1 2 3 4 5 6 7

8 9 10 11 12 13 14

i3

1 2 3 4

10 11 12 13 14 15

22 23 24 25

16

5 6

17 18

7 8

19 20

26 27 28 29 30 31

9

21

32


AB3 (YELLOW)

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

WI-03206

AB-24



FRONT SUB SENSOR LH FRONT SUB SENSOR RH

AB18 AB15

AB14

AB13


AB21

AB26

STEERING

ROLL CONNECTOR

AB2 AB4

AB13 (YELLOW)

AB21 (YELLOW)

1 2

INFLATOR (DRIVER SIDE)

AB2 (BLACK)

1 2

AB15

AB18

1 2

(YELLOW)

(YELLOW)

AB4 (YELLOW)

1 2 3 4

INFLATOR (PASSENGER SIDE)

AB3 (YELLOW)

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

GA

WI-03207

AB-25




AB7 AB8

AB19 AB9 AB10 AB12 AB11 AB25 AB20

PRETENSIONER

LH

AB9 (YELLOW)

AB11 (YELLOW)

AB19 (YELLOW)

AB20 (YELLOW)

1 2

INFLATOR

(SIDE LH)

AB25 (YELLOW)

1 2

SIDE AIRBAG

SENSOR LH

SIDE AIRBAG

SENSOR RH

AB10 (YELLOW)

AB12 (YELLOW)

1

3

2

4

INFLATOR

(SIDE RH)

LAP

SEAT BELT

PRETENSIONER

AB7

(YELLOW)

1 2 3 4 5 6

7 8 9 10 11 12

PRETENSIONER

RH

AB8

(YELLOW)

1 2 3 4 5 6

7 8 9 10 11 12

WI-03208

AB-26

6. Airbag Connector

A: OPERATION


1. POWER SUPPLY


(1) Move the slide lock (A) in the direction of the arrow.

(2) Pull the female connector in the direction of the arrow with slide lock (A) moved.


2. DRIVER’S AIRBAG (AIRBAG MAIN HAR-

NESS AND ROLL CONNECTOR), SIDE AIR-

BAG AND PRETENSIONER



(2) With the lock arm (A) pushed in, move the slide lock (B) in the direction of the arrow.

(B)

(A)

AB-00015

CAUTION:


2) How to connect:

Holding the connector (A), and push it in carefully until a connecting sound is heard.

AB-00017

(3) With the slide lock pulled, remove the lock arm to its original position, and then pull in the direction of the arrow and separate the connector.

CAUTION:


AB-00016

CAUTION:



AB-00018

2) How to connect:


CAUTION:



AB-00019

AB-27



3. DRIVER’S AIRBAG, PRETENSIONER


(1) Using a flat tip screwdriver, pry the push lock upward to unlock.

4. PASSENGER’S AIRBAG



(2) With the lock arm (A) pushed in, pull the connector in direction of arrow to separate.

( A )

AB-00478

(2) Pull the connector to disconnect from driver’s side airbag module assembly.

AB-00021

CAUTION:

When disconnecting the connector, be sure to hold onto the connector and not the wire.

AB-00479

2) How to connect:

Connect the connector in reverse order of disconnecting. At this time, be sure to insert the connector in until connecting sound is heard.

CAUTION:

• Be sure to insert the connector in until it locks. Then pull on it gently to make sure that it is locked.

• Be sure to insert the push lock.

AB-00022

2) How to connect:


CAUTION:



AB-00480

AB-00023

AB-28


5. FRONT SUB-SENSOR AND SIDE AIR-

BAG SENSOR


Holding outer part (A), pull it in the direction of the arrow.

CAUTION:



6. LAP PRETENSIONER


(1) Using a flat tip screwdriver, pry the push lock (A) upward to unlock.

(A)

AB-00115

(2) Pull the connector to disconnect from lap pretensioner.

AB-00024

2) How to connect:


CAUTION:

• Outer (A) moves back, and so do not put your hand on the outer part.

• Be sure to insert the connector in until it locks. Then pull on it gently to make sure that it is locked.

AB-00025

AB-00026

CAUTION:

When pulling the side lock, be sure to hold onto the connector and not the wire.

2) How to connect:

Connect the connector in reverse order of disconnecting. At this time, be sure to insert the connector in until connecting sound is heard.

CAUTION:

• Be sure to insert the connector in until it locks.


• Be sure to push the push lock in.

AB-00027

AB-29

Airbag Warning Light Illumination Pattern


7. Airbag Warning Light Illumination Pattern

A: INSPECTION

Keep the ignition switch to ON, and confirm that the airbag warning light remains off approx. 6 seconds after being turned on.

(2)

(1)

ON

OFF

(3)

(1) Airbag warning light

(2) Approx. 6 seconds

(3) Ignition switch ON

AB-00135

AB-30

Read Diagnostic Trouble Code (DTC)


8. Read Diagnostic Trouble

Code (DTC)

A: OPERATION


2) Connect the ground terminal to diagnosis connector terminal No. 1 in the instrument panel lower cover area.

(1)

3) Read the DTC by identifying the way airbag warning light flashes.

The airbag warning light flashes a code corresponding to the faulty parts.

The long segment (1.2 sec on) indicates a “ten”, and the short segment (0.3 sec on) indicates a

“one”.

NOTE:

• “List of Diagnostic Trouble Code (DTC)” <Ref. to

AB-43, List of Diagnostic Trouble Code (DTC).>

• “Airbag Warning Light Failure” <Ref. to AB-34,

Airbag Warning Light Failure.>

(2)

1 2

3 4 5 6

B82

AB-00136

(1) Diagnosis connector

(2) Ground terminal

(1)

(2)

ON

OFF

10

1.2

0.3

1

0.3

1

0.3

0.3

1.2

10

(5)

(3)

ON

OFF

10

1.2

0.3

10

1.2

0.3

1

0.3

1.2

10

(5)

(4)

ON

OFF

1

0.6

0.6

(5)

10

1

1

AB-00137

(1) Example

(2) Flashing code 12:

(3) Flashing code 21:

(4) Flashing normal code:

4) Turn the ignition switch to OFF, and disconnect the ground terminal from the diagnosis connector terminal No 1.

5) Wind tape around the ground terminal and return it to its original position.

(5) Sec

AB-31

Inspection Mode


9. Inspection Mode

A: OPERATION

Recreate the circumstance by referring to the conditions described in the checklist.

AB-32

Clear Memory Mode

10.Clear Memory Mode

A: OPERATION


2) Connect the ground terminal (ground, terminal

“A”) to diagnosis connector terminal No. 1 in the instrument panel lower cover area.

(2)


(3)

(1)

1 2

3 4 5 6

B82

AB-00138

(1) Diagnosis connector

(2) Ground terminal “B”

(3) Ground terminal “A”

3) While the airbag warning light flashes, connect another ground terminal (ground, terminal “B”) to diagnosis connector terminal No. 2.

4) Once the memory is erased, the airbag warning light returns to the normal flash rate (0.6 sec on).

The failure to recover the normal flash rate indicates that trouble parts still remain. Having repaired such parts, erase the memory again and confirm that the normal flash rate has returned.

5) When the memory has been cleared, disconnect the ground terminal from the diagnosis connector.

6) Wind tape around the ground terminal and return it to its original position.

AB-33


Airbag Warning Light Failure

11.Airbag Warning Light Failure

A: AIRBAG WARNING LIGHT REMAINS ON.

DIAGNOSIS:

• Airbag warning light unit is faulty.

• Airbag control module to airbag warning light circuit is shorted or open.

• Grounding circuit is faulty.

• Airbag control module is faulty.

• (AB1) and (B31) are not connected properly.

• (AB3) is not connected properly to the airbag control module.

CAUTION:

• Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait more than 20 seconds before starting to work.

• After replacing the airbag module, seat belt pretensioner, roll connector, control module or sensor, reconnect each part and confirm that the airbag warning light operates properly.

• When inspecting the airbag main harness, disconnect the airbag module connector of the driver and passenger seats for safety reasons.

AB-34



1. LHD MODEL

WIRING DIAGRAM:

B: i10

C: i11

COMBINATION

METER

AIRBAG

WARNING

LIGHT

AIRBAG

CIRCUIT

B9

B8

B10

5

19 i2 B37 i3

28

B38

NO.14

IGNITION

SWITCH

B31

AB1

E


1

B31

1 2

3 4 5 6

i11

1 2 3 4 5 6 7 8 9 10

C: AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

B: i10

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

AB-00739

Step Check

CHECK POOR CONTACT IN CONNECTORS

(AB1) AND (B31).

1) Turn the ignition switch to OFF, disconnect the battery ground cable, and wait more than

20 seconds.

2) Remove the side sill cover. (Driver’s side)

3) Confirm that firm contact is secured between connectors (AB1) and (B31).

Is the poor contact in connectors (AB1) and (B31)?

Yes No

Repair the body harness or replace the airbag main harness with body harness.

Go to step 2.

AB-35



2

3

4

5

6

Step Check

CHECK AIRBAG WARNING LIGHT.


20 seconds.

2) Connect the connector (1T) in test harness

T to body harness connector (B31).

3) Connect the connector (1M) in test harness

M to connector (2T) in test harness T.

4) Connect the battery ground cable and turn the ignition switch to ON.

5) Connect the connectors, (3M) and (4M) in test harness M.

Is the airbag warning light turned off?

Yes

Go to step 4.

No

Go to step 3.

CHECK BODY HARNESS.

Check the body harness.

NOTE:

After problem has been eliminated, disconnect the connectors (3M) and (4M).


Confirm that firm contact is secured between the airbag control module and the connector

(AB3). <Ref. to AB-18, Airbag Control Module.>

Is the anything unusual to body harness?

Is the poor contact in connector (AB3)?


Repair the body harness.

Replace the combination meter printed circuit.

<Ref. to IDI-10,

Combination

Meter Assembly.>

Replace the airbag main harness with body harness or replace the airbag control module.

<Ref. to AB-18,

Airbag Control

Module.>

Go to step 5.

Go to step 6.

Replace the airbag main harness with body harness.

CHECK AIRBAG MAIN HARNESS.


20 seconds.

2) Connect the connector (AB1) to (B31).

3) Disconnect the connectors (AB2) and

(AB30).

4) Remove the glove box and disconnect the connectors (AB4).

5) Disconnect the connector (AB3) from the airbag control module, and connect the con-

nector (1R) in test harness R. <Ref. to AB-18,

Airbag Control Module.>


7) Connect the connectors (5R) and (6R) in test harness R.

NOTE:

After problem has been eliminated, disconnect the connectors (5R) and (6R).

CHECK GROUNDING CIRCUIT.


20 seconds.

2) Disconnect the connector (AB3) from the airbag control module.

3) Connect the connector (1R) in test harness

R to body harness connector (AB3).

4) Measure the resistance between connector

(2R) in test harness R and the chassis ground.


(2R) No. 10 — Chassis ground:



Ω?

Replace the airbag control module.

<Ref. to AB-18,

Airbag Control

Module.>

Repair the bodygrounding circuit.

AB-36



2. RHD MODEL

WIRING DIAGRAM:

B: i10

C: i11

COMBINATION

METER

AIRBAG

WARNING

LIGHT

AIRBAG

CIRCUIT

B9

B8

B10

16

10 i3

20

B38

NO.14

IGNITION

SWITCH

B31

AB1

E


1

B31

1 2

3 4 5 6

i11

1 2 3 4 5 6 7 8 9 10

AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

i10

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

AB-00740

Step Check

CHECK POOR CONTACT IN CONNECTORS

(AB1) AND (B31).


20 seconds.

2) Remove the side sill cover. (Driver’s side)

3) Confirm that firm contact is secured between connectors (AB1) and (B31).

Is the poor contact in connectors (AB1) and (B31)?

Yes No

Repair the body harness or replace the airbag main harness with body harness.

Go to step 2.

AB-37



2

3

4

5

6

Step Check

CHECK AIRBAG WARNING LIGHT.


20 seconds.


M to body harness connector (B31).


4) Connect the connectors, (3M) and (4M) in test harness M.


Yes

Go to step 4.

No

Go to step 3.

CHECK BODY HARNESS.

Check the body harness.

NOTE:

After problem has been eliminated, disconnect the connectors (3M) and (4M).


Confirm that firm contact is secured between the airbag control module and the connector

(AB3). <Ref. to AB-18, Airbag Control Module.>

Is the anything unusual to body harness?

Is the poor contact in connector (AB3)?




<Ref. to IDI-10,

Combination

Meter Assembly.>

Replace the airbag main harness with body harness or replace the airbag control module.

<Ref. to AB-18,

Airbag Control

Module.>

Go to step 5.

Go to step 6.




20 seconds.



(AB26).

4) Remove the glove box and disconnect the connectors (AB4).





7) Connect the connectors (5R) and (6R) in test harness R.

NOTE:

After problem has been eliminated, disconnect the connectors (5R) and (6R).

CHECK GROUNDING CIRCUIT.


20 seconds.

2) Disconnect the connector (AB3) from the airbag control module.


R to body harness connector (AB3).







Ω?


<Ref. to AB-18,

Airbag Control

Module.>

Repair the bodygrounding circuit.

AB-38



B: AIRBAG WARNING LIGHT REMAINS OFF.

DIAGNOSIS:

• Fuse No. 14 (in fuse box) is blown.

• Body harness circuit is open.

• Airbag warning light is faulty.

• Airbag main harness is faulty.


CAUTION:




1. LHD MODEL

WIRING DIAGRAM:

B: i10 C: i11

COMBINATION

METER

AIRBAG

WARNING

LIGHT

AIRBAG

CIRCUIT

B9

B8

B10

5

19 i2 B37 i3

28

B38

NO.14

IGNITION

SWITCH

B31

AB1

E

AB3


B31

1 2

3 4 5 6

i11

1 2 3 4 5 6 7 8 9 10

C:

AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

B: i10

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

AB-00739

AB-39



1

2

3

4

Step Check

CHECK COMBINATION METER.

Turn the ignition switch to ON, and confirm that warning lights equipped in the combination meter are turned on.

Do the warning lights not for airbag turn on?

CHECK FUSE NO. 14 (IN FUSE&RELAY

BOX).

Remove the fuse No. 14 and perform visual inspection.

Is the fuse No. 14 (in fuse & relay box) blown out?

CHECK AIRBAG WARNING LIGHT CIRCUIT

(IN COMBINATION METER).


20 seconds.

2) Disconnect the connector (AB1) from

(B31).


Is the airbag warning light turned on?



20 seconds.


3) Disconnect the connector (AB3) from the

airbag control module. <Ref. to AB-18, Airbag

Control Module.>



Yes

Go to step 2.

No

Repair the combination meter power supply.

<Ref. to IDI-3,

Combination

Meter System.>

Replace the fuse

No. 14. If fuse No.

14 blows again, go to step 3.

Go to step 3.

Go to step 4.

Replace the airbag warning light bulb or combination meter printed cir-

cuit. <Ref. to IDI-

10, Combination

Meter Assembly.>


<Ref. to AB-18,

Airbag Control

Module.>


AB-40



2. RHD MODEL

WIRING DIAGRAM:

B: i10

C: i11

COMBINATION

METER

AIRBAG

WARNING

LIGHT

AIRBAG

CIRCUIT

B9

B8

B10

16

10 i3

20

B38

NO.14

IGNITION

SWITCH

B31

AB1

E


B31

1 2

3 4 5 6

i11

1 2 3 4 5 6 7 8 9 10

AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

i10

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

AB-00740

AB-41



1

2

3

4

Step Check

CHECK COMBINATION METER.

Turn the ignition switch to ON, and confirm that warning lights equipped in the combination meter are turned on.

Do the warning lights not for airbag turn on?

CHECK FUSE NO. 14 (IN FUSE&RELAY

BOX).

Remove the fuse No. 14 and perform visual inspection.

Is the fuse No. 14 (in fuse & relay box) blown out?

CHECK AIRBAG WARNING LIGHT CIRCUIT

(IN COMBINATION METER).


20 seconds.


(B31).





20 seconds.




Control Module.>



Yes

Go to step 2.

No

Repair the combination meter power supply.

<Ref. to IDI-3,

Combination

Meter System.>

Replace the fuse

No. 14. If fuse No.

14 blows again, go to step 3.

Go to step 3.

Go to step 4.

Replace the airbag warning light bulb or combination meter printed cir-

cuit. <Ref. to IDI-

10, Combination

Meter Assembly.>


<Ref. to AB-18,

Airbag Control

Module.>


AB-42

List of Diagnostic Trouble Code (DTC)


12.List of Diagnostic Trouble Code (DTC)

A: LIST

DTC

Memory function

11

12

15

16

21

22

23

24

25

31

Provided.

Provided.

Provided.

Provided.

Provided.

Provided.

Not provided.

Not provided.

Provided.

Provided.

Contents of diagnosis Index No.

• Airbag main harness circuit is open, shorted or shorted to ground.

• Airbag module harness circuit (driver) is open, shorted or shorted to ground.

• Roll connector circuit is open, shorted or shorted to ground.


• Driver’s airbag module is faulty.


• Airbag module harness circuit (passenger) is open, shorted or shorted to ground.


• Passenger’s airbag module is faulty.

• Airbag main harness circuit (driver) is shorted to power supply.

• Airbag module harness (driver) is shorted to power supply.

• Roll connector is shorted to power supply.



• Airbag main harness circuit (passenger) is shorted to power supply.

• Airbag module harness (passenger) is shorted to power supply.



<Ref. to AB-46, DTC 11,

Diagnostic Procedure with Diagnostic Trouble

Code (DTC).>



Code (DTC).>



Code (DTC).>



Code (DTC).>

Airbag control module is faulty.

Front airbag module and seat belt pretensioner (LH/

RH) are inflated.

(AB3), (AB7) and (AB8) are not connected properly to airbag control module.


• Airbag main harness circuit is open.

• Fuse No. 11 (in joint box) is blown.






• Front sub-sensor harness circuit (RH) is shorted, opened or shorted to power supply.

• Airbag main harness circuit is shorted, opened or shorted to power supply.

• Front sub-sensor (RH) is faulty.




Code (DTC).>



Code (DTC).>



Code (DTC).>



Code (DTC).>



Code (DTC).>



Code (DTC).>

AB-43



DTC

32

41

42

45

46

51

52

53

54

55

61

62

65

Memory function

Provided.

Provided.

Provided.

Provided.

Provided.

Provided.

Provided.

Provided.

Provided.

Provided.

Provided.

Provided.

Provided.


• Front sub-sensor harness circuit (LH) is shorted, opened or shorted to power supply.

• Airbag main harness circuit is shorted, opened or shorted to power supply.

• Front sub-sensor (LH) is faulty.


• Side airbag harness (RH) is faulty.

• Side airbag module (RH) is faulty.


• Side airbag harness (LH) is faulty.

• Side airbag module (LH) is faulty.


• Side airbag harness (RH) is shorted to power supply.



• Side airbag harness (LH) is shorted to power supply.



• Side airbag sensor (RH) is faulty.



• Side airbag sensor (LH) is faulty.



Side airbag sensor (RH) is faulty.

Side airbag sensor (LH) is faulty.

Side airbag module is operate.



Code (DTC).>



Code (DTC).>



Code (DTC).>



Code (DTC).>



Code (DTC).>



Code (DTC).>



Code (DTC).>



Code (DTC).>



Code (DTC).>



Code (DTC).>



Code (DTC).>

• Seat belt pretensioner circuit (RH) is open, shorted or shorted to ground.


• Pretensioner is faulty.

• Pretensioner harness is faulty.

• Seat belt pretensioner circuit (LH) is open, shorted or shorted to ground.




• Seat belt pretensioner circuit (RH) is shorted to power supply.






Code (DTC).>



Code (DTC).>

AB-44

76

81

85

DTC

66

72



Memory function

Provided.

Provided.

Provided.

Provided.

Provided.


• Seat belt pretensioner circuit (LH) is shorted to power supply.





• Airbag module harness circuit (passenger) is open, shorted or shorted to ground.



• Airbag main harness circuit (passenger) is shorted or shorted to power supply.

• Airbag module harness circuit (passenger) is shorted to power supply.



• Lap seat belt pretensioner circuit (RH) is open, shorted or shorted to ground.

• Lap pretensioner is faulty.

• Lap pretensioner harness is faulty.


• Lap seat belt pretensioner circuit (RH) is shorted to power supply.






Code (DTC).>



Code (DTC).>



Code (DTC).>



Code (DTC).>



Code (DTC).>

AB-45

Diagnostic Procedure with Diagnostic Trouble Code (DTC)


13.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC 11

DIAGNOSIS:


• Airbag module harness circuit (Driver) is open, shorted or shorted to ground.

• Roll connector circuit is open, shorted or shorted to ground.



CAUTION:


• When replacing the airbag module, seat belt pretensioner, roll connector, control module and sensor, confirm that airbag warning light is turn normally after reconnect the each parts.

• When inspecting the airbag main harness, disconnect the driver’s airbag module and passenger’s airbag module connectors for safety reasons.

WIRING DIAGRAM:


AB21

1 2

AB2

AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

INFLATOR

(DRIVER SIDE)

AB2

1 2

AB21

AB26

STEERING

ROLL CONNECTOR

AB-46

AB-00741

1

2

3

4



Step Check

CHECK DRIVERS AIRBAG MODULE.


20 seconds.

2) Remove the driver’s airbag module. <Ref. to AB-14, Driver’s Airbag Module.>

3) Connect the connector (1N) in test harness

N to connector (AB2).

4) Connect the airbag resistor to connector

(2N) in test harness N.


Is the airbag warning light turned on normally?

Yes

Replace the driver’s airbag

module. <Ref. to

AB-14, Driver’s

Airbag Module.>

No

Go to step 2.

CHECK ROLL CONNECTOR.


20 second.

2) Disconnect the test harness N from the connector (AB2).

3) Remove the instrument panel lower cover, disconnect the connector (AB26) from (AB21) and connect the connector (1F) in test harness

F to connector (AB21).


(3F) in test harness F.


Is the airbag warning light turn on normally?

Replace the roll

connector. <Ref. to

AB-20, Roll Connector.>

Go to step 3.

Go to step 4.



1) Turn the ignition switch to OFF, disconnect the ground cable, and wait more than 20 seconds.

2) Disconnect the airbag resistor from the connector (3F) in test harness F.

3) Remove the glove box, and disconnect connectors (AB4) and passenger’s airbag module

(AB27). <Ref. to AB-15, Passenger’s Airbag

Module.>





(2R) in test harness R and the connector (3F) in test harness F.


(2R) No. 2 — (3F) No. 4:

(2R) No. 4 — (3F) No. 3:


Ω?


Measure the resistance of the connector (2R) in test harness R.


(2R) No. 2 — (2R) No. 4:



Is the resistance more than 1

M

Ω?


<Ref. to AB-18,

Airbag Control

Module.>


AB-47



B: DTC 12

DIAGNOSIS:


• Airbag module harness circuit (Passenger) is open, shorted or shorted to ground.



CAUTION:


• When replacing the airbag module, seat belt pretensioner, roll connector, control module and sensor, confirm that airbag warning light is turn normally after reconnect the each parts.


WIRING DIAGRAM:

AB3


AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

AB4

1 2 3 4

AB4

AB27

INFLATOR

(PASSENGER SIDE)

AB-48

AB-00742

1

2

3



Step Check

CHECK PASSENGERS AIRBAG MODULE.


20 seconds.


3) Disconnect the passenger’s airbag connector (AB27) and (AB4).

4) Connect the connector (1P) in test harness

P to connector (AB4).


(2P), (3P) in test harness P.





20 seconds.

2) Disconnect the airbag resistor from the connector in test harness P.

3) Remove the instrument panel lower cover and disconnect the connector (AB21) from

(AB26).





(2R) in test harness R and the connector (2P) in test harness P.


(2R) No. 3 — (2P) No. 3:

(2R) No. 5 — (2P) No. 4:


Ω?




(2R) No. 3 — (2R) No. 5:




M

Ω?

Yes

Replace the passenger airbag

module. <Ref. to


Go to step 3.

No

Go to step 2.



<Ref. to AB-18,

Airbag Control

Module.>


AB-49



C: DTC 15

DIAGNOSIS:

• Airbag main harness circuit (Driver) is shorted to the power supply.

• Airbag module harness (Driver) is shorted to the power supply.

• Roll connector is shorted to the power supply.



CAUTION:




WIRING DIAGRAM:


AB21

1 2

AB2

AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

INFLATOR

(DRIVER SIDE)

AB2

1 2

AB21

AB26

STEERING

ROLL CONNECTOR

AB-50

AB-00741

1

2

3



Step

CHECK DRIVERS AIRBAG MODULE.


20 seconds.

2) Remove the driver’s airbag module. <Ref. to AB-14, Driver’s Airbag Module.>

3) Connect the connector (AB2) to connector





Check


CHECK ROLL CONNECTOR.


20 seconds.

2) Disconnect the test harness N from the connector (AB2).


(AB26).

4) Connect the connector (1F) in test harness

F to connector (AB21).





Yes

Replace the driver’s airbag

module. <Ref. to

AB-14, Driver’s

Airbag Module.>

No

Go to step 2.

Replace the roll

connector. <Ref. to

AB-20, Roll Connector.>

Go to step 3.



20 seconds.

2) Disconnect the airbag resistor from the connector (3F) in test harness F.

3) Remove the glove box, and disconnect the connectors (AB4) and passenger’s airbag module (AB27).




5) Connect the battery ground cable and turn the ignition switch to ON. (engine OFF)




(2R) No. 2 (+) — Chassis ground (

−

):


−

):

Is the voltage less than 1 V? Replace the airbag control module.

<Ref. to AB-18,

Airbag Control

Module.>


AB-51



D: DTC 16

DIAGNOSIS:

• Airbag main harness circuit (Passenger) is shorted to the power supply.

• Airbag module harness (Passenger) is shorted to the power supply.



CAUTION:




WIRING DIAGRAM:

AB3


AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

AB4

1 2 3 4

AB4

AB27

INFLATOR


AB-52

AB-00742

1

2



Step Check



20 seconds.


3) Disconnect the passenger’s airbag connector (AB27) and (AB4).


P to connector (AB4).


(2P), (3P) in test harness P.





20 seconds.

2) Disconnect the airbag resistor from the connector in test harness P.


(AB26).









−

):


−

):

Is the voltage less 1 V?

Yes

Replace the passenger airbag

module. <Ref. to


No

Go to step 2.


<Ref. to AB-18,

Airbag Control

Module.>


AB-53



E: DTC 21

DIAGNOSIS:

Airbag control module is faulty.

CAUTION:



1

Step Check Yes No

CHECK IF DTC 21 IS INDICATED.

Read the DTC. <Ref. to AB-31, Read Diagnostic Trouble Code (DTC).>

Is the airbag warning light DTC

21 indicated?


<Ref. to AB-18,

Airbag Control

Module.>

Perform the clear memory mode.

<Ref. to AB-33,

Clear Memory

Mode.>

AB-54



F: DTC 22

1. LHD MODEL

WIRING DIAGRAM:


AB7 AB8

AB3

AB21

AB26

STEERING

ROLL

CONNECTOR

AB19

AB2 AB4 AB20

PRETENSIONER LH

INFLATOR

(DRIVER SIDE)

INFLATOR


PRETENSIONER RH

AB19

AB20

AB21

1 2

AB4

1 2 3 4

AB2

1 2

AB7

1 2 3 4 5 6

7 8 9 10 11 12

AB8

1 2 3 4 5 6

7 8 9 10 11 12

AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

AB-00743

This code is indicated when the front airbag and the pretensioner are in operation.

Once this code is indicated, memory is not erasable; therefore replace the following parts.

• Airbag control module. <Ref. to AB-18, Airbag Control Module.>

• Driver’s airbag module. <Ref. to AB-14, Driver’s Airbag Module.>

• Passenger’s airbag module. <Ref. to AB-15, Passenger’s Airbag Module.>

• Front sub-sensor of both sides. <Ref. to AB-21, Front Sub Sensor.>

• Front seat belt outer with pretensioner of both sides. <Ref. to SB-10, Front Seat Belt.>

AB-55



2. RHD MODEL

WIRING DIAGRAM:


AB7 AB3 AB8

AB21

AB26

STEERING

ROLL

CONNECTOR

AB19 AB2

AB4

AB20

AB25

PRETENSIONER LH

AB19

AB20

AB21

1 2

AB4

1 2 3 4

AB2

1 2

INFLATOR

(DRIVER SIDE)

AB25

1 2

INFLATOR


PRETENSIONER RH

LAP SEAT BELT

PRETENSIONER

AB7

1 2 3 4 5 6

7 8 9 10 11 12

AB8

1 2 3 4 5 6

7 8 9 10 11 12

AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

This code is indicated when the front airbag, pretensioner and lap pretensioner are in operation.

Once this code is indicated, memory is not erasable; therefore replace the following parts.


• Driver’s airbag module. <Ref. to AB-14, Driver’s Airbag Module.>

• Passenger’s airbag module. <Ref. to AB-15, Passenger’s Airbag Module.>

• Front sub-sensor of both sides. <Ref. to AB-21, Front Sub Sensor.>

• Front seat belt outer with pretensioner of both sides. <Ref. to SB-10, Front Seat Belt.>

AB-00744

AB-56



G: DTC 23

DIAGNOSIS:

(AB3), (AB7) and (AB8) are not connected properly to airbag control module.

CAUTION:

Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait more than 20 seconds before starting to work.

1

2

Step

CHECK POOR CONTACT IN CONECTORS

(AB3), (AB7) AND (AB8).


20 seconds.

2) Disconnect the connectors (AB3), (AB7) and (AB8) from the airbag control module.

<Ref. to AB-18, Airbag Control Module.>

Check

Check if rust or damage appear on the harness connector and the control module connector.

CHECK POOR CONTACT IN CONECTORS

(AB3), (AB7) and (AB8).

1) Ensure that connectors are firmly reconnected.



Yes No


<Ref. to AB-18,

Airbag Control

Module.> Replace

the airbag main harness with body harness.Replace the side airbag harness with body harness.

Go to step 2.



<Ref. to AB-18,

Airbag Control

Module.>

AB-57



H: DTC 24

DIAGNOSIS:



• Fuse No. 11 (in fuse and relay box) is blown.


CAUTION:




1. LHD MODEL

WIRING DIAGRAM:

IG SW

NO.11

B31

AB1

AB3


B31

1 2

3 4 5 6

AB1

2

6 5 4

1

3

AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

AB-58

AB-00623

1

2

3

4




CHECK AIRBAG CONTROL MODULE.


20 seconds.



Control Module.>


R to connector (AB3).



(2R) in test harness R and chassis ground.



−

):

Is the voltage more than 10 V? Replace the airbag

Go to step 2.

control module.

<Ref. to AB-18,

Airbag Control

Module.>



20 seconds.

2) Disconnect the airbag connector (AB1) from the body harness (B31).


M to connector (AB1).


(5M) in test harness M and the connector (2R) in test harness R.


(5M) No. 2 — (2R) No. 1:


Ω?


M

Ω?


Measure the following resistance with the above-mentioned condition maintained.


(5M) No. 2 — Chassis ground:


CHECK FUSE No. 11 (IN JOINT BOX).

1) Confirm that the ignition switch is turned

OFF.

2) Remove the fuse No. 11 (in fuse and relay box) and perform visual inspection.

Is the fuse No. 11 blown out?

Go to step 3.

Go to step 4.

Replace the fuse

No. 11. If fuse No.

11 blows out again, repair the body harness.




AB-59



2. RHD MODEL

WIRING DIAGRAM:

IGNITION

SWITCH

NO.11

B31

AB1


B31

1 2

3 4 5 6

AB1

2

6 5 4

1

3

AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

AB-00745

AB-60

1

2

3

4






20 seconds.



Control Module.>





(2R) in test harness R and chassis ground.



−

):


Go to step 2.

control module.

<Ref. to AB-18,

Airbag Control

Module.>



20 seconds.



M to connector (AB1).


(5M) in test harness M and the connector (2R) in test harness R.


(5M) No. 9 — (2R) No. 1:


Ω?

Go to step 3.







M

Ω?

Go to step 4.

CHECK FUSE No. 11 (IN FUSE AND RELAY

BOX).


OFF.

2) Remove the fuse No. 11 (in fuse and relay box) and perform visual inspection.

Fuse No. 11 is not blown out. Replace the fuse

No. 11. If fuse No.

11 blows out again, repair the body harness.




AB-61



I: DTC 25

DIAGNOSIS:





CAUTION:




1. LHD MODEL

WIRING DIAGRAM:

IG SW

NO.6

B31

AB1

AB3


B31

1 2

3 4 5 6

AB1

2

6 5 4

1

3

AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

AB-62

AB-00624

1

2

3

4



Step Check



20 seconds.



M to the airbag connector (AB1).

4) Measure the resistance between the connector (5M) in test harness M and the connector (2R) in test harness R.


(5M) No. 4 — (2R) No. 6:


Ω?

Yes No



20 seconds.

2) Disconnect the connector (AB3) from air-

bag control module. <Ref. to AB-18, Airbag

Control Module.>



4) Connect the battery ground cable, and turn the ignition switch to ON.

5) Measure the voltage between the connector (2R) in test harness R and the chassis ground.



−

):


Go to step 2.

control module.

<Ref. to AB-18,

Airbag Control

Module.>

Go to step 3.



M

Ω?

Go to step 4.







CHECK FUSE NO. 6 (IN FUSE AND RELAY

BOX).


OFF.

2) Remove the No. 6 fuse (in fuse and relay box) and perform visual inspection.

Is the fuse No. 6 blown out? Replace the fuse

No. 6. If fuse No. 6 is blown out again, repair the body harness.


AB-63



2. RHD MODEL

WIRING DIAGRAM:

IGNITION

SWITCH

NO.6

B31

AB1


B31

1 2

3 4 5 6

AB1

2

6 5 4

1

3

AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

AB-00746

AB-64

1

2

3

4



Step Check



20 seconds.



M to the airbag connector (AB1).

4) Measure the resistance between the connector (5M) in test harness M and the connector (2R) in test harness R.


(5M) No. 4 — (2R) No. 6:


Ω?

Yes No



20 seconds.



Control Module.>




5) Measure the voltage between the connector (2R) in test harness R and the chassis ground.



−

):


Go to step 2.

control module.

<Ref. to AB-18,

Airbag Control

Module.>

Go to step 3.



M

Ω?

Go to step 4.







CHECK FUSE NO. 6 (IN FUSE AND RELAY

BOX).


OFF.

2) Remove the No. 6 fuse (in fuse and relay box) and perform visual inspection.

Is the fuse No. 6 blown out?

Replace the fuse

No. 6. If fuse No. 6 is blown out again, repair the body harness.


AB-65



J: DTC 31

DIAGNOSIS:

• Front sub-sensor harness circuit (RH) is shorted, open or shorted to power supply.

• Airbag main harness circuit is shorted, open or shorted to power supply.

• Front sub-sensor (RH) is faulty.


CAUTION:




WIRING DIAGRAM:

AB3


LHD

LHD

AB13

AB14

LHD

LHD

AB15

AB13

1 2

AB15

1 2

FRONT SUB SENSOR RH

AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

AB-00747

AB-66

1

2

3

4

5

6



Step

CHECK FRONT SUB-SENSOR (RH) AND

AIRBAG HARNESS.


20 seconds.




3) Measure the resistance of the connector

(3R) in test harness R.


(3R) No. 7 — (3R) No. 9:

Is the resistance 750

Ω and 1

K

Ω?

Check

CHECK AIRBAG MAIN HARNESS AND

FRONT SUB-SENSOR HARNESS (RH).


front sub-sensor. <Ref. to AB-21, Front Sub

Sensor.>

2) Connect the connector (IH) in test harness

H to connector (AB15).


(3R) in test harness R and connector (3H) in test harness H.


(3R) No. 7 — (3H) No. 5:

(3R) No. 9 — (3H) No. 6:


Ω?


FRONT SUB-SENSOR HARNESS (RH).

Measure the resistance between connector






M

Ω?

Yes No


<Ref. to AB-18,

Airbag Control

Module.>

Go to step 2.

Go to step 3.

Go to step 8.

Go to step 5.

LHD model:

Replace the airbag main harness and front sub-sensor harness with body harness.

RHD model:

Go to step 4.

LHD model:


RHD model:

Go to step 4.


CHECK AIRBAG MAIN HARNESS


(AB14), and connect the connector (1L) in test harness L to connector (AB13).


(3R) in test harness R and connector (3L) in test harness L.


(3R) No. 7 — (3L) No. 4:

(3R) No. 9 — (3L) No. 3:


Ω?








M

Ω?

CHECK FRONT SUB-SENSOR HARNESS

(RH).

1) Connect the connector (2L) in test harness

F to the connector (AB14).


(3H) in test harness H and connector (3L) in the test harness L.


(3L) No. 5 — (3H) No. 5:

(3L) No. 6 — (3H) No. 6:


Ω?

Go to step 6.

Go to step 7.


Replace the front sub-sensor harness (RH) with body harness.

AB-67



7

8

9

Step Check


(RH).


(3L) in test harness L and the chassis ground.


(3L) No. 5 — Chassis ground:



M

Ω?

CHECK FRONT SUB-SENSOR (RH).

1) Connect the connector (2H) in test harness

H to front sub-sensor (RH).


(3H) in test harness H.


(3H) No. 3 — No. 4:


Ω and 1

K

Ω?

CHECK FRONT SUB-SENSOR (RH).


(3H) in test harness H and the chassis ground.


(3H) No. 3 — Chassis ground:



M

Ω?

Yes

Go to step 8.

Go to step 9.


No

Replace the front sub-sensor harness (RH) with body harness.

Replace the front sub-sensor (RH).

<Ref. to AB-21,

Front Sub Sensor.>

Replace the front sub-sensor (RH).

<Ref. to AB-21,

Front Sub Sensor.>

AB-68



K: DTC 32

DIAGNOSIS:

• Front sub-sensor harness circuit (LH) is shorted.is shorted, open or shorted to power supply.

• Airbag main harness circuit is shorted, open or shorted to power supply.

• Front sub-sensor (LH) is faulty.


CAUTION:


• After replacing the airbag module, seat belt pretensioner, roll connector, control module or sensor, reconnect each part and confirm that the airbag warning light operates properly


WIRING DIAGRAM:


RHD

RHD

AB13

AB14

RHD

RHD

AB18

AB13

1 2

AB18

1 2

FRONT SUB SENSOR LH

AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

AB-00748

AB-69



1

2

3

4

5

6

Step

CHECK FRONT SUB-SENSOR (LH) AND

AIRBAG HARNESS.


20 seconds.

2) Disconnect the connector (AB3) from the airbag control module, and connect connector

(1R) in the test harness R to connector (AB3).

<Ref. to AB-18, Airbag Control Module.>


(3R) in the test harness R.


(3R) No. 6 — (3R) No. 8:

Check


Ω and 1

K

Ω?


FRONT SUB-SENSOR HARNESS (LH).


front sub-sensor. <Ref. to AB-21, Front Sub

Sensor.>


H to connector (AB18).


(3R) in test harness R and connector (3H) in test harness H.


(3R) No. 6 — (3H) No. 5:

(3R) No. 8 — (3H) No. 6:


Ω?


FRONT SUB-SENSOR HARNESS (LH).







M

Ω?

Yes No


<Ref. to AB-18,

Airbag Control

Module.>

Go to step 2.

Go to step 3.

Go to step 8.

Go to step 5.

LHD model:

Go to step 4.

RHD model:


LHD model:

Go to step 4.

RHD model:





(AB14), and connect the connector (1L) in test harness L to connector (AB13).


(3R) in test harness R and connector (3L) in test harness L.


(3R) No. 6 — (3L) No. 4:

(3R) No. 8 — (3L) No. 3:


Ω?








M

Ω?


(LH).

1) Connect the connector (2L) in test harness

L to the connector (AB14).


(3H) in test harness H and connector (3L) in the test harness L.


(3L) No. 5 — (3H) No. 5:

(3L) No. 6 — (3H) No. 6:


Ω?

Go to step 6.

Go to step 7.


Replace the front sub-sensor harness (LH) with body harness.

AB-70

7

8

9



Step Check


(LH).


(3L) in test harness L and the chassis ground.





M

Ω?

CHECK FRONT SUB-SENSOR (LH).


H to front sub-sensor (LH).


(3H) in test harness H.


(3H) No. 3 — (3H) No. 4:


Ω and 1

K

Ω

CHECK FRONT SUB-SENSOR (LH).


(3H) in test harness H and the chassis ground.





M

Ω?

Yes

Go to step 8.

Go to step 9.


No

Replace the front sub-sensor harness (LH) with body harness.

Replace the front sub-sensor (LH).

<Ref. to AB-21,

Front Sub Sensor.>

Replace the front sub-sensor (LH).

<Ref. to AB-21,

Front Sub Sensor.>

AB-71



L: DTC 41

DIAGNOSIS:




CAUTION:




• When inspecting the side airbag harness, disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons.

WIRING DIAGRAM:

AB8


AB12

AB11

AB11

1 2

AB12

1

3

2

4

SIDE AIRBAG

SENSOR RH

AB8

1 2 3 4 5 6

7 8 9 10 11 12

INFLATOR

(SIDE RH)

AB-72

AB-00627

1

2

3

4



Step Check

CHECK SIDE AIRBAG MODULE.


20 seconds.

2) Disconnect the connector (AB11) from side airbag module (RH), and connect the connector (1F) in test harness F to (AB11).





CHECK SIDE AIRBAG HARNESS (RH).


20 seconds.


seat belt pretensioner (RH). <Ref. to SB-10,

Front Seat Belt.>

3) For the vehicle with lap seat belt pretensioner, disconnect the connector (AB25) from lap pretensioner.

4) Disconnect the airbag resistor from test harness F.

5) Disconnect the connector (AB8) from air


Control Module.>




(3R) in test harness R and connector (3F) in test harness F.


(3R) No. 18 — (3F) No. 3:

(3R) No. 20 — (3F) No. 4:


Ω?




(3R) No. 18 — (3R) No. 20:


M

Ω?








M

Ω?

Yes

Replace the front seat with side airbag module (RH).

<Ref. to SE-6,

Front Seat.>

Go to step 3.

Go to step 4.

No

Go to step 2.

Replace the side airbag harness with body harness.



<Ref. to AB-18,

Airbag Control

Module.>


AB-73



M: DTC 42

DIAGNOSIS:




CAUTION:





WIRING DIAGRAM:

AB7


AB9

AB9

1 2

AB10

1

3

2

4

INFLATOR

(SIDE LH)

AB7

1 2 3 4 5 6

7 8 9 10 11 12

SIDE AIRBAG

SENSOR LH

AB10

AB-74

AB-00628

1

2

3

4



Step Check



20 seconds.

2) Disconnect the connector (AB9) from side airbag module (LH), and connect the connector (1F) in test harness F to (AB9).





CHECK SIDE AIRBAG HARNESS (LH).

1) Turn ignition switch to OFF, disconnect the battery ground cable, and wait more than 20 seconds.


seat belt pretensioner (LH). <Ref. to SB-10,

Front Seat Belt.>

3) Disconnect the airbag resistor from the test harness.



Control Module.>






(3R) No. 12 — (3F) No. 4:

(3R) No. 10 — (3F) No. 3:


Ω?




(3R) No. 12 — (3R) No. 10:








M

Ω?


M

Ω?

Yes

Replace the front seat with side airbag module (LH).

<Ref. to SE-6,

Front Seat.>

Go to step 3.

Go to step 4.

No

Go to step 2.




<Ref. to AB-18,

Airbag Control

Module.>


AB-75



N: DTC 45

DIAGNOSIS:

• Side airbag harness (RH) is shorted to power supply.



CAUTION:





WIRING DIAGRAM:

AB8


AB12

AB11

AB11

1 2

AB12

1

3

2

4

SIDE AIRBAG

SENSOR RH

AB8

1 2 3 4 5 6

7 8 9 10 11 12

INFLATOR

(SIDE RH)

AB-76

AB-00627

1

2



Step Check



20 seconds.

2) Disconnect the connector (AB11) from side airbag module (RH), and connect the connector (1F) in test harness F to (AB11).





Yes

Replace the front seat with side airbag module (RH).

<Ref. to SE-6,

Front Seat.>

No

Go to step 2.



20 seconds.



Front Seat Belt.>





Control Module.>








−

):


−

):

Is the voltage less than 1 V?


<Ref. to AB-18,

Airbag Control

Module.>


AB-77



O: DTC 46

DIAGNOSIS:

• Side airbag harness (LH) is shorted to power supply.



CAUTION:





WIRING DIAGRAM:

AB7


AB9

AB9

1 2

AB10

1

3

2

4

INFLATOR

(SIDE LH)

AB7

1 2 3 4 5 6

7 8 9 10 11 12

SIDE AIRBAG

SENSOR LH

AB10

AB-78

AB-00628

1

2



Step



20 seconds.

2) Disconnect the connector (AB9) from side airbag module (LH), and connect the connector (1F) in test harness F to (AB9).




Check


Yes

Replace the front seat with side airbag module (LH).

<Ref. to SE-6,

Front Seat.>

No

Go to step 2.



20 seconds.



Front Seat Belt.>




Control Module.>








−

):


−

):



<Ref. to AB-18,

Airbag Control

Module.>


AB-79



P: DTC 51

DIAGNOSIS:


• Side airbag harness is faulty.


CAUTION:





WIRING DIAGRAM:

AB8


AB12

AB11

AB11

1 2

AB12

1

3

2

4

SIDE AIRBAG

SENSOR RH

AB8

1 2 3 4 5 6

7 8 9 10 11 12

INFLATOR

(SIDE RH)

AB-80

AB-00627

1

2



Step Check

CHECK SIDE AIRBAG (RH) HARNESS.


20 seconds.



Front Seat Belt.>


4) Disconnect the connector (AB11) from side airbag module (RH).



Control Module.>


R to the connector (AB8).

7) Disconnect the connector (AB12) from the side airbag sensor (RH), and connect the connector (1G) in test harness G to connector

(AB12).


(4R) in test harness R and connector (3G) in test harness G.


(4R) No. 5 — (3G) No. 2:

(4R) No. 6 — (3G) No. 4:

(4R) No. 7 — (3G) No. 1:

(4R) No. 8 — (3G) No. 5:


Ω?

CHECK SIDE AIRBAG HARNESS.









M

Ω?

Yes

Go to step 2.

No


Replace the side airbag sensor

(RH). <Ref. to AB-

19, Side Airbag

Sensor.> When

sensor replacement is not OK, replace the airbag control module.

<Ref. to AB-18,

Airbag Control

Module.>


AB-81



Q: DTC 52

DIAGNOSIS:




CAUTION:





WIRING DIAGRAM:

AB7


AB9

AB9

1 2

AB10

1

3

2

4

INFLATOR

(SIDE LH)

AB7

1 2 3 4 5 6

7 8 9 10 11 12

SIDE AIRBAG

SENSOR LH

AB10

AB-82

AB-00628

1

2



Step Check

CHECK SIDE AIRBAG (LH) HARNESS.


20 seconds.



Front Seat Belt.>

3) Disconnect the connector (AB9) from side airbag module (LH).



Control Module.>



6) Disconnect the connector (AB10) from the side airbag sensor (LH), and connect the connector (1G) in test harness G to connector

(AB10).


(4R) in test harness R and connector (3G) in test harness G.


(4R) No. 4 — (3G) No. 2:

(4R) No. 3 — (3G) No. 4:

(4R) No. 2 — (3G) No. 1:

(4R) No. 1 — (3G) No. 5:


Ω?










M

Ω?

Yes

Go to step 2.

No


Replace the side airbag sensor

(LH). <Ref. to AB-

19, Side Airbag

Sensor.> When

sensor replacement is not OK, replace the airbag control module.

<Ref. to AB-18,

Airbag Control

Module.>


AB-83



R: DTC 53

DIAGNOSIS:


When Code 53 is displayed, the circuit within the side airbag sensor (RH) is faulty. Replace the side airbag sensor (RH).

<Ref. to AB-19, Side Airbag Sensor.>

S: DTC 54

DIAGNOSIS:


When Code 53 is displayed, the circuit within the side airbag sensor (LH) is faulty. Replace the side airbag sensor (LH).

<Ref. to AB-19, Side Airbag Sensor.>

T: DTC 55

This code is displayed when the side airbag is operate.

When this code is displayed, the memory cannot be erased. Replace the following parts.


• Front seat with side airbag module. (Operating side) <Ref. to SE-6, Front Seat.>

• Side airbag sensor. (Operating side) <Ref. to AB-19, Side Airbag Sensor.>

AB-84



U: DTC 61

DIAGNOSIS:

• Seat belt pretensioner circuit (RH) is open, shorted or shorted to ground.




CAUTION:




WIRING DIAGRAM:

AB8


AB20

1 2

AB8

1 2 3 4 5 6

7 8 9 10 11 12

AB20

PRETENSIONER RH

AB-85

AB-00086



1

2

3

4

Step Check

CHECK SEAT BELT PRETENSIONER.


20 seconds.



Front Seat Belt.>


F to (AB20).







20 seconds.




(AB8) from the airbag control module. <Ref. to

AB-18, Airbag Control Module.>






(3R) No. 17 — (3F) No. 3:

(3R) No. 19 — (3F) No. 4:


Ω?




(3R) No. 17 — (3R) No. 19:


M

Ω?








M

Ω?

Yes

Replace the seat belt pretensioner

(RH). <Ref. to SB-

10, Front Seat

Belt.>

Go to step 3.

Go to step 4.

No

Go to step 2.




<Ref. to AB-18,

Airbag Control

Module.>


AB-86



V: DTC 62

DIAGNOSIS:

• Seat belt pretensioner circuit (LH) is open, shorted or shorted to ground.




CAUTION:




WIRING DIAGRAM:


AB19

1 2

AB7

1 2 3 4 5 6

7 8 9 10 11 12

AB19

PRETENSIONER LH

AB-87

AB-00087



1

2

3

4

Step Check



20 seconds.



Front Seat Belt.>


F to (AB19).

4) Connect the airbag resistor to the connector (3F) in test harness F.





20 seconds.









(3R) in test harness R and the connector (3F) in test harness F.


(3R) No. 11 — (3F) No. 3:

(3R) No. 13 — (3F) No. 4:


Ω?




(3R) No. 11 — (3R) No. 13:


M

Ω?


Measure the resistance between the connector






M

Ω?

Yes


(LH). <Ref. to SB-

10, Front Seat

Belt.>

Go to step 3.

Go to step 4.

No

Go to step 2.




<Ref. to AB-18,

Airbag Control

Module.>


AB-88



W: DTC 65

DIAGNOSIS:

• Seat belt pretensioner circuit (RH) is shorted to the power supply.




CAUTION:




WIRING DIAGRAM:

AB8


AB20

1 2

AB8

1 2 3 4 5 6

7 8 9 10 11 12

AB20

PRETENSIONER RH

AB-89

AB-00086



1

2

Step Check



20 seconds.



Front Seat Belt.>


F to (AB20).





Yes


(RH). <Ref. to SB-

10, Front Seat

Belt.>

No

Go to step 2.



20 seconds.













−

):


−

):



<Ref. to AB-18,

Airbag Control

Module.>


AB-90



X: DTC 66

DIAGNOSIS:

• Seat belt pretensioner circuit (LH) is shorted to the power supply.




CAUTION:




WIRING DIAGRAM:


AB19

1 2

AB7

1 2 3 4 5 6

7 8 9 10 11 12

AB19

PRETENSIONER LH

AB-91

AB-00087



1

2

Step Check



20 seconds.



Front Seat Belt.>


F to (AB19).

4) Connect the airbag resistor to the connector (3F) in test harness F.



Yes


(LH). <Ref. to SB-

10, Front Seat

Belt.>

No

Go to step 2.



20 seconds.













−

):


−

):



<Ref. to AB-18,

Airbag Control

Module.>


AB-92



Y: DTC 72

DIAGNOSIS:

• Airbag harness is open, shorted or shorted to ground.

• Airbag module harness circuit (Passenger) is open, shorted or shorted to ground.



CAUTION:

• Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work.



WIRING DIAGRAM:

AB3


AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

AB4

1 2 3 4

AB4

INFLATOR


AB-93

AB-00621



1

2

3

Step Check


1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds.


3) Disconnect the connector passenger’s airbag module from (AB4).


K to connector (AB4).

5) Connect two airbag resistors to connectors

(2P) and (3P) in test harness P.

6) Connect the battery ground cable and turn the ignition switch ON.




2) Disconnect two airbag resistors from the connectors (2P) and (3P) in test harness P.

3) Remove the lower cover and disconnect the connector (AB21) from (AB26).

4) Disconnect the connector (AB3) from the air bag control module, and connect the con-




(2R) in test harness R and the connector (2P) in test harness P.


(2R) No. 9 — (3P) No. 3:

(2R) No. 13 — (3P) No. 4:


Ω?




(2R) No. 9 — No. 13:




M

Ω?

Yes

Replace the passenger’s airbag

module. <Ref. to


Go to step 3.

No

Go to step 2.

Replace the airbag main harness together with body harness as a unit.


<Ref. to AB-18,

Airbag Control

Module.>


AB-94



Z: DTC 76

DIAGNOSIS:

• Airbag main harness circuit (Passenger) is shorted to the power supply.

• Airbag module harness (Passenger) is shorted to the power supply.



CAUTION:

• Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work.



WIRING DIAGRAM:

AB3


AB3

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28

AB4

1 2 3 4

AB4

INFLATOR


AB-95

AB-00621



1

2

Step Check




3) Disconnect the connector (AB4) from passenger’s airbag module.


D to connector (AB4).

5) Connect two airbag resistors to connectors

(2P) and (3P) in test harness P.

6) Connect the battery ground cable and turn the ignition switch ON.


Yes

Replace the passenger’s airbag

module. <Ref. to


No

Go to step 2.



2) Disconnect two airbag resistors from the connectors (2P) and (3P) in test harness P.

3) Remove the lower cover and disconnect the connector (AB21) from (AB26).








−

):


−

):



<Ref. to AB-18,

Airbag Control

Module.>


AB-96



AA:DTC 81

DIAGNOSIS:

• Lap seat belt pretensioner circuit (RH) is open, shorted or shorted to ground.




CAUTION:




WIRING DIAGRAM:


AB8

1 2 3 4 5 6

7 8 9 10 11 12

AB25

1 2

AB25

LAP SEAT BELT PRETENSIONER

FOR AUSTRALIA MODEL

AB-97

AB-00749



1

2

3

Step Check

CHECK LAP SEAT BELT PRETENSIONER.


20 seconds.

2) Disconnect the connector (AB25) from the lap seat belt pretensioner (RH).

3) Connect the connector (1Q) in test harness

Q to (AB25).


(2Q) in test harness Q.





20 seconds.



4) Disconnect the connectors (AB20) from seat belt pretensioner.



Control Module.>




(3R) in test harness R and connector (2Q) in test harness Q.


(3R) No. 2 — (2Q) No. 2:

(3R) No. 4 — (2Q) No. 1:


Ω?

CHECK SIDE AIRBAG HARNESS.

Measure the resistance between the connector



(3R) No. 2 — (3R) No. 4:




M

Ω?

Yes

Replace the lap seat belt preten-

sioner (RH). <Ref. to SB-10, FRONT

OUTER SEAT

BELT WITH LAP

SEAT BELT PRE-

TENSIONER,

REMOVAL, Front

Seat Belt.>

No

Go to step 2.

Go to step 3.



<Ref. to AB-18,

Airbag Control

Module.>


AB-98



AB:DTC 85

DIAGNOSIS:

• Lap seat belt pretensioner circuit (RH) is shorted to the power supply.




CAUTION:




WIRING DIAGRAM:


AB8

1 2 3 4 5 6

7 8 9 10 11 12

AB25

1 2

AB25

LAP SEAT BELT PRETENSIONER

FOR AUSTRALIA MODEL

AB-99

AB-00749



1

2

Step Check

CHECK LAP SEAT BELT PRETENSIONER.


20 seconds.

2) Disconnect the connector (AB25) from the lap seat belt pretensioner (RH).

3) Connect the connector (1Q) in test harness

Q to (AB25).

4) Connect the airbag resistor to the connector (2Q) in test harness Q.



Yes

Replace the lap seat belt preten-

sioner (RH). <Ref. to SB-10, FRONT

OUTER SEAT

BELT WITH LAP

SEAT BELT PRE-

TENSIONER,

REMOVAL, Front

Seat Belt.>

No

Go to step 2.



20 seconds.



4) Disconnect the connector (AB20) from seat belt pretensioner.











−

):


−

):


Replace the airbag Replace the side control module.

<Ref. to AB-18,

Airbag Control

Module.>

airbag harness with body harness.

AB-100

SEAT BELT SYSTEM

SB

Page

1.


2.

Inspection Locations After a Collision .........................................................6

3.

Seat Belt Warning System ..........................................................................7

4.

Front Seat Belt ..........................................................................................10

5.

Rear Seat Belt...........................................................................................12

6.

Disposal of Pretensioner ...........................................................................14

SEAT BELT SYSTEM


A: COMPONENT

1. FRONT SEAT BELT


T3

(1)

T2

(2)

T2

(2)

T2

(3)

T1

T2

(4)

(1) Adjuster anchor ASSY

(2) Anchor cover

(3) Outer belt ASSY with lap pretensioner (For Australia model)

(4) Outer belt ASSY

(5) Inner belt ASSY

T1

T2

T2

(5)

T2

SB-00001

Tightening torque: N

⋅

m (kgf-m, ft-lb)

T1: 7.5 (0.76, 5.5)

T2: 30 (3.1, 22)

T3: 53 (5.4, 39)

SB-2

2. REAR SEAT BELT


SEAT BELT SYSTEM

T2

(7)

(1)

T1

(6)

(2)

T1

(6)

T1

T1

(3)

(4)

(5)

T1

T1

T1

(1) Outer seat belt RH

(2) Outer seat belt CENTER

(3) Outer seat belt LH

(4) Inner seat belt RH

(5) Inner seat belt LH

(6) Anchor cover

(7) Adjuster anchor ASSY

SB-00064


⋅


T1: 30 (3.1, 22)

T2: 53 (5.4, 39)

SB-3


SEAT BELT SYSTEM

B: CAUTION

• Before starting, turn the ignition switch to OFF, disconnect the battery ground cable and wait for 20 seconds or more.

• The pretension system has a backup power source.

The pretensioner might deploy if you do not wait for 20 seconds or more before starting work.

• Do not drop or apply any impact to the pretensioner.

• If oil, grease, or water gets on the pretensioner, wipe it off immediately with a dry cloth.

• Do not expose the pretensioner to high temperature or flame.

• Do not allow current to flow through or voltage to reach the pretensioner. Do not use a circuit tester to check resistance of the pretensioner.

• Do not disassemble or attempt to repair the pretensioner. If it is dented, cracked, or deformed, replace it with a new one.

• Do not use the airbag or pretensioner parts from other vehicles. Always replace parts with new parts.

• When handling a seat belt with a deployed pretensioner, wear gloves and goggles. Wash your hands afterwards.

• Do not re-use a seat belt with a deployed pretensioner again.

• Be sure to deploy pretensioner before disposal.

<Ref. to SB-14, OPERATION, Disposal of Pretensioner.>

• If the material gets in your eyes or on your skin during deployment, wash it away with clean water, and then consult a doctor.

SB-4


SEAT BELT SYSTEM


1. SPECIAL TOOL


98299SA010

DESCRIPTION

DEPLOYMENT

ADAPTER D

REMARKS

• Used for deploying the pretensioner.


(98299PA030).

ST98299SA010

98299SA050 DEPLOYMENT

ADAPTER F

• Used for deploying the lap seat belt pretensioner.


(98299PA030).

ST98299SA050

98299PA030 DEPLOYMENT

TOOL

• Used for deploying the pretensioner.

• Used with DEPLOYMENT ADAPTER D

(98299SA010) or DEPLOYMENT ADAPTER F

(98299SA050).

ST98299PA030

2. GENERAL TOOL

TOOL NAME

Circuit tester

REMARKS

Used for measuring resistance and voltage.

SB-5


SEAT BELT SYSTEM

2. Inspection Locations After a

Collision

A: INSPECTION

Check for the following, and then replace with new parts if necessary.

• Center pillar lower garnish is discolored or cracked.

• Wiring harness and/or connector is damaged.

SB-6

Seat Belt Warning System

3. Seat Belt Warning System


<Ref. to WI-255, WIRING DIAGRAM, Seat Belt Warning System.>

B: INSPECTION

TROUBLE SYMPTOM:

• Seat belt warning light does not come on or go off.

• Buzzer does not beep.

1

2

3

4

5

Step

CHECK HARNESS BETWEEN SEAT BELT

TIMER MODULE AND CHASSIS GROUND.


2) Disconnect the connector from seat belt timer module.

3) Measure the resistance between seat belt timer module harness connector and chassis ground.


(B44) No. 3 — Chassis ground:

CHECK POWER SUPPLY OF SEAT BELT

TIMER MODULE.


2) Measure the voltage between seat belt timer module connector and chassis ground.


(B44) No. 9 (+) — Chassis ground (–):


Ω?

Check Yes

Go to step 2.


CHECK HARNESS AND SEAT BELT

SWITCH.


2) Disconnect the connector from seat belt timer module.

3) Hold the tang plate disconnected from seat belt buckle.

4) Measure the resistance between seat belt timer module harness connector and chassis ground.




Ω?

Go to step 4.

CHECK SEAT BELT SWITCH AND HAR-

NESS.


2) Insert the tang plate into seat belt buckle.

3) Measure the resistance between seat belt timer module connector and chassis ground.




M

Ω?


TIMER MODULE AND SEAT BELT SWITCH.

Measure the resistance of harness between seat belt timer module connector and seat belt switch.


(B44) No. 6 — (R8) No. 2:


Ω?

Go to step 7.

Go to step 6.

SEAT BELT SYSTEM

No

Repair the open circuit of harness between seat belt timer module and chassis ground.

Repair the open harness, short circuit and poor contact of connector between seat belt timer module and battery.

Repair the short circuit of harness between seat belt timer module connector and chassis ground.

Go to step 5.

Repair the open circuit of harness and poor contact of connector between seat belt timer module connector and seat belt switch.

SB-7


SEAT BELT SYSTEM

6

7

8

9

10

11

12

13

Step


SWITCH AND CHASSIS GROUND.

Measure the resistance of harness between seat belt switch and chassis ground.


(R8) No. 1 — Chassis ground:


M

Ω?

Check

CHECK SEAT BELT SWITCH.


2) Measure the resistance between seat belt switch terminals.

Terminals

(R8) No. 1 — (R8) No. 2:


Ω?

Yes

Go to step 7.

CHECK SEAT BELT SWITCH.

1) Insert the tang plate into seat belt buckle.

2) Measure the resistance between seat belt switch terminals.

Terminals

(R8) No. 1 — (R8) No. 2:


M

Ω?

Go to step 9.

CHECK OPERATION OF SPEEDOMETER IN

COMBINATION METER.

Check the speedometer indicates vehicle speed correctly.

Does the speedometer operate correctly?

Go to step 10.

CHECK VEHICLE MODEL.

Check the model of vehicle.

Is the vehicle MT model?

Go to step 11.

CHECK HARNESS BETWEEN VEHICLE

SPEED SENSOR AND SEAT BELT TIMER

MODULE.


2) Disconnect the connector of vehicle speed sensor.

3) Measure the resistance between vehicle speed sensor harness connector and seat belt timer module connector.


(B17) No. 1 — (B44) No. 7:


Ω?


SPEED SENSOR AND SEAT BELT TIMER

MODULE.

Measure the resistance between seat belt timer module harness connector and chassis ground.




M

Ω?

CHECK HARNESS BETWEEN TCU AND

SEAT BELT TIMER MODULE.


2) Disconnect the connector of TCU.

3) Measure the resistance of harness between TCU harness connector and seat belt timer module harness connector


(B56) No. 17 — (B44) No. 7:


Ω?

Go to step 8.

Go to step 12.

Go to step 15.

Go to step 14.

No

Repair the open circuit of harness between seat belt switch and chassis ground.

Replace the inner belt assembly.

Replace the inner belt assembly.

Check the speedometer circuit.

Go to step 13.

Repair the open harness between vehicle speed sensor and seat belt timer module.

Repair the short of harness.

Repair the open harness between

TCU and seat belt timer module.

SB-8

16

17

14

15

18


SEAT BELT SYSTEM

Step

CHECK HARNESS BETWEEN TCU AND

SEAT BELT TIMER MODULE.

Measure the resistance between seat belt timer module harness connector and chassis ground.



CHECK SEAT BELT TIMER MODULE OUT-

PUT SIGNAL.


2) Measure the voltage between seat belt timer module harness connector and chassis ground.




Check the poor contact of seat belt warning light circuit.

CHECK SEAT BELT TIMER MODULE.

1) Connect all connectors.

2) Lift-up the vehicle and place rigid racks.

NOTE:

Raise all wheels off floor.


4) Start the engine, and set the vehicle speed less than 19 km/h (12 MPH)

NOTE:

The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunction. When diagnosis is finished, perform the ABS memory clearance procedure of OBD system. <Ref. to ABS-23, Clear

Memory Mode.>

Check seat belt warning light comes on.

CHECK SEAT BELT TIMER MODULE.

1) Connect all connectors.

2) Lift-up the vehicle and place rigid racks.

Does the seat belt warning light come on and buzzer beep?

NOTE:

Raise all wheels off floor.


4) Start the engine, and set the vehicle speed more than 25 km/h (16 MPH).

NOTE:

The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunction. When diagnosis is finished, perform the ABS memory clearance procedure of OBD system. <Ref. to ABS-23, Clear

Memory Mode.>

Check seat belt warning light comes on and buzzer beeps.

occurs?

Check


Ω?

Is there any poor contact

Does the seat belt warning light come on?

contact.

contact.

Yes

Go to step 15.


Repair the poor

Go to step 18.

Temporary poor contact of connector or harness may be the cause.

Check the poor

Repair the short of harness.

No

Check the wiring harness and combination meter, and then repair or replace them.

Go to step 17.

Replace the seat belt timer module.

Replace the seat belt timer module.

SB-9

Front Seat Belt

SEAT BELT SYSTEM

4. Front Seat Belt

A: REMOVAL

1. FRONT OUTER BELT

1) Fold backrest all the way forward, and then move front seat all the way forward.

2) Turn the ignition switch to OFF, disconnect the ground cable from battery, and wait for more than

20 seconds before starting work.

3) Remove the center pillar lower trim. <Ref. to EI-

44, REMOVAL, Lower Inner Trim.>

4) Remove the anchor cover. Loosen the shoulder anchor bolt, and then detach the shoulder anchor from center pillar.

CAUTION:

• Do not drop or apply any impact to the pretensioner.

• Pretensioner and bracket should be treated as an assembly. Do not attempt to disassemble it.

2. FRONT OUTER SEAT BELT WITH LAP

SEAT BELT PRETENSIONER

1) Fold backrest forward, and then move front seat forward.





4) Remove the anchor cover. Loosen the shoulder anchor bolt, and then detach the shoulder anchor from center pillar.

SB-00003

5) Turn over the floor mat to remove the bolts.

SB-00003

5) Turn over the floor mat to remove the bolts.

SB-00004

6) Disconnect the yellow connector of pretensioner harness, and remove the front outer belt.

7) Remove the center pillar upper trim. <Ref. to EI-

43, REMOVAL, Upper Inner Trim.>

8) Remove the two bolts and adjustable anchor assembly.

SB-00007

6) Disconnect the yellow connector of pretensioner harness and orange connector of lap pretensioner harness, and remove the front outer belt.

7) Remove the center pillar upper trim. <Ref. to EI-

43, REMOVAL, Upper Inner Trim.>

SB-00005

SB-10

Front Seat Belt


SB-00005

CAUTION:

• Do not drop or apply any impact to the pretensioner.

• Pretensioner and bracket should be treated as an assembly. Do not attempt to disassemble it.

3. FRONT INNER BELT

1) Disconnect the connector.

2) Remove the anchor bolt, and then detach the inner belt.

SB-00006

SEAT BELT SYSTEM

B: INSTALLATION



CAUTION:

• The parts on right and left are not identical.

Before installation, make sure that the correct part is used.

• Be careful not to twist the belts during installation.


<Ref. to SB-2, FRONT SEAT BELT, COMPO-


2. FRONT OUTER BELT WITH LAP SEAT

BELT PRETENSIONER


CAUTION:

• The parts on right and left are not identical.

Before installation, make sure that the correct part is used.

• Be careful not to twist the belts during installation.









C: INSPECTION


Check for the following, and replace with new parts if necessary.

• Pretensioner is cracked or deformed.

• Seat belt is slackened, bent or frayed. Seat belt is abnormally wound or extended.



• Inner belt is deformed or damaged.

• Seat belt buckle is engaged improperly.

SB-11

Rear Seat Belt

SEAT BELT SYSTEM

5. Rear Seat Belt

A: REMOVAL

1. OUTER BELT SIDE

1) Remove the luggage floor mat. <Ref. to EI-50, RE-

MOVAL, Luggage Floor Mat.>

2) Remove the rear seat. <Ref. to SE-13, REMOV-

AL, Rear Seat.>

3) Remove the rear quarter trim. <Ref. to EI-45, RE-

MOVAL, Rear Quarter Trim.>

4) Remove the seat belt lower anchor bolt.


SB-00011

2. OUTER BELT CENTER

1) Remove the anchor cover. Remove the bolt and then detach the shoulder anchor from pillar.

SB-00008

5) Remove the anchor cover. Remove the bolt and shoulder anchor from pillar.

SB-00009

6) Remove the rear quarter trim. <Ref. to EI-45, RE-


7) Remove the bolts, and then detach the outer belt side.

SB-00009

2) Remove the strut cap. <Ref. to EI-45, REMOV-

AL, Rear Quarter Trim.>

3) Remove the rear rail trim. <Ref. to EI-45, RE-


4) Remove the rear pillar upper trim. <Ref. to EI-45,

REMOVAL, Rear Quarter Trim.>

5) Remove the rear skirt trim. <Ref. to EI-45, RE-


6) Remove the rear quarter lower trim. <Ref. to EI-

45, REMOVAL, Rear Quarter Trim.>

7) Remove the cover (B) while detaching snap lock carefully. Put the outer belt center tongue (A) out to the other side of the trim through the hole.

SB-00010

SB-00012

8) Remove the clips and hang down rear end of roof trim.

SB-12

Rear Seat Belt

9) Disconnect the harness and connector, and then remove the outer belt center assembly.

SB-00036

3. INNER BELT

1) Remove the rear cushion.

2) Remove the bolt, and then detach the inner belt.

SB-00014

B: INSTALLATION



CAUTION:

• During installation, make sure that the seat belts are not twisted.

• After installation, make sure that the seat belts can be smoothly extended and wound.


<Ref. to SB-3, REAR SEAT BELT, COMPO-




CAUTION:

• During installation, make sure that the seat belts are not twisted.

• After installation, make sure that the seat belts are smoothly extended and wound.




SEAT BELT SYSTEM

3. INNER BELT


CAUTION:

During installation, make sure that the seat belts are not twisted.




C: INSPECTION



• Seat belt is slackened, bent, or frayed. Seat belt is abnormally wound or extended.



• Seat belt is slackened, bent, or frayed. Seat belt is abnormally wound or extended.

3. INNER BELT


• Inner belt is deformed or damaged.

• Seat belt buckle is engaged improperly.

SB-13

Disposal of Pretensioner

SEAT BELT SYSTEM

6. Disposal of Pretensioner

A: CAUTION

• Do not discard undeployed pretensioners, because they may cause serious personal injury when accidentally deployed.

• Deployment of the pretensioners should be done on a flat place free from any possible danger. Avoid deploying outdoors during heavy rainy or strong windy weather.

• Do not drop or damage the pretensioner.

• Because deploying the pretensioners causes a high-explosive noise, be sure to warn people in the area, and do not allow anyone within a 5 m (16 ft) radius of the disposal site.

• Some smoke will be emitted after deployment of the pretensioners. Therefore, it must be deployed in a well-ventilated area with no smoke alarms nearby.

• Wear gloves, goggles, and earplugs during this operation. Wash your hands afterwards.

• After deployment, the pretensioner is especially hot. Leave it unattended for 40 minutes or longer, and then discard it.

• Do not let water get on the deployed pretensioner.

• Wrap the deployed pretensioner in an airtight vinyl bag, and then discard it.

• If circumstances do not permit pretensioner deployment, contact a SUBARU dealer.

B: OPERATION

1. DEPLOYING OF PRETENSIONER WHILE

INSTALLED IN VEHICLE

1) Fold backrest all the way forward, and then move front seat all the way forward.





4) Disconnect the connector (A) of pretensioner.

6) Connect the deployment tool and deployment adapter D (B).

CAUTION:

The deployment tool terminals should be kept shorted until just before deployment of the pretensioner.

(B)

(A)

SB-00021

(A) Deployment tool: (Tool No. 98299PA030)

(B) Deployment adapter D: (Tool No. 98299SA010)

7) Connect the deployment adapter D connector and pretensioner yellow connector.

8) Extend the deployment tool to the limit, and make sure that the vehicle is empty. Close all windows, sunroof, and rear gate completely.

SB-00017

9) Move the battery at least 5 m (16 ft) from the vehicle, and secure the nearby area. Connect the deployment tool alligator clip to the battery negative (

−

) terminal.

10) Connect the other cable of deployment tool to the battery positive (+) terminal. Then deploy the pretensioner.

(A)

SB-00129


SB-14

SB-00018


CAUTION:

• After deployment, pretensioner is especially hot. Leave it unattended for 40 minutes or longer.

• Do not let water get on the deployed pretensioner.

11) Perform the following steps 12) through 17) for the vehicle with lap pretensioner.

12) Disconnect the orange connector (a) from lap pretensioner.

SEAT BELT SYSTEM

15) Extened the deployment tool to the limit, and make sure that the vehicle is empty. Close all windows, sunroof and rear gate completely.

(a)

SB-00017

16) Move the battery at least 5 m (16 ft) from the vehicle, and secure the nearby area. Connect the deployment tool alligator clip to the battery negative

(

−) terminal.


SB-00020

13) Connect the deployment tool (A) and deployment adapter F (B).

CAUTION:


(A)

(B)

SB-00021


(B) Deployment adapter F: (Tool No. 98299SA050)

14) Connect the deployment adapter F connector and lap seat belt pretensioner orange connector.

SB-00018

CAUTION:



18) Remove the front outer belt. <Ref. to SB-10,

REMOVAL, Front Seat Belt.>

19) Wrap the deployed pretensioner in an airtight vinyl bag, and discard it.

SB-00131

SB-15


SEAT BELT SYSTEM

2. DEPLOYING OF RETRACTOR PRETEN-

SIONER AFTER REMOVAL FROM VEHICLE

1) Fold backrest all the way forward, then move front seat all the way forward.



3) Remove the front outer belt. <Ref. to SB-10, RE-

MOVAL, Front Seat Belt.>

4) Cut off the seat belt as close to retractor as possible.

8) Install the pretensioner on a wheel with tire.

Then, bundle three wire automotive harness [each with a sectional area of 1.25 mm

2

(0.00194 sq in) or more], and bind them twofold around the pretensioner bracket and wheel.

SB-00024

9) Put three tires without a wheel on the tire installed with pretensioner. Put on an additional tire with a wheel on top, and then fasten them tight with a rope.

SB-00130

5) Short the terminal to alligator clip furnished as a deployment tool.

6) Connect the deployment tool (A) and deployment adapter D (B).

CAUTION:


(A)

SB-00025


(

−) terminal.

(B)

SB-00021


(B) Deployment adapter D: (Tool No. 98299SA010)

7) Connect the deployment adapter D connector and pretensioner yellow connector.

(1)

(1) 5 m (16 ft) or more

SB-00065

SB-16



SEAT BELT SYSTEM

5) Short the terminal to alligator clip furnished as a deployment tool (A).

6) Connect the deployment tool and deployment adapter F (B).

CAUTION:


(A)

SB-00018

CAUTION:




(B)

SB-00021


(B) Deployment adapter F: (Tool No. 98299SA050)

7) Connect the deployment adapter F connector to pretensioner yellow connector.

8) Install the pretensioner on a wheel with tire.

Then, bundle three wire automotive harness [each with a sectional area of 1.25 mm

2

(0.00194 sq in) or more], and bind them twofold around the pretensioner bracket and wheel.

SB-00131

3. DEPLOYING LAP PRETENSIONER AF-

TER REMOVAL FROM VEHICLE

1) Fold backrest all the way forward, then move front seat all the way forward.



3) Remove the fornt outer belt. <Ref. to SB-10, RE-

MOVAL, Front Seat Belt.>

4) Cut off the seat belt as close to lap seat belt pretensioner as possible.

SB-00028

9) Put three tires without a wheel on the tire installed with pretensioner. Put on an additional tire with a wheel on top, and then fasten them tight with a rope.

SB-00025

SB-00027

SB-17


SEAT BELT SYSTEM


(

−) terminal.

(1)

SB-00065

(1) 5 m (16 ft) or more


SB-00018

CAUTION:




SB-00022

SB-18

LIGHTING SYSTEM

LI

Page

1.


2.

Headlight and Tail Light System .................................................................3

3.

Front Fog Light System...............................................................................4

4.

Rear Fog Light System ...............................................................................5

5.

Turn Signal Light and Hazard Light System................................................6

6.

Back-up Light System .................................................................................7

7.

Stop Light System .......................................................................................8

8.

Room Light System.....................................................................................9

9.

Headlight Beam Leveler System...............................................................10

10.

Combination Switch (Light) .......................................................................11

11.

Headlight Assembly ..................................................................................13

12.

Headlight Bulb...........................................................................................16

13.

Front Turn Signal Light Bulb .....................................................................17

14.

Clearance Light Bulb.................................................................................18

15.

Front Fog Light Assembly .........................................................................19

16.

Front Fog Light Bulb..................................................................................20

17.

Rear Combination Light Assembly ............................................................21

18.

Tail/Stop Light Bulb ...................................................................................22

19.

Back-up Light Bulb ....................................................................................23

20.

Rear Turn Signal Light Bulb ......................................................................24

21.

Rear Fog Light Bulb ..................................................................................25

22.

License Plate Light....................................................................................26

23.

High-mounted Stop Light ..........................................................................27

24.

Side Turn Signal Light...............................................................................28

25.

Spot Map Light ..........................................................................................29

26.

Room Light................................................................................................30

27.

Luggage Room Light.................................................................................31

28.

Glove Box Light .........................................................................................32


LIGHTING SYSTEM



Headlight

Front turn signal light

Clearance light

Side marker light

Front fog light

Rear combination light

License plate light

High-mounted stop light

Room light

Spot light

Luggage room light

Tail/Stop light

Turn signal light

Back-up light

Standard type

Rear spoiler built-in type

12 V — 55 W/60 W

12 V — 21 W

12 V — 5 W

12 V — 5 W

12 V — 55 W

12 V — 5/21 W

12 V — 21 W

12 V — 16 W

12 V — 5 W

12 V — 13 W

12 V — 1.2 W

12 V — 8 W

12 V — 8 W

12 V — 5 W

B: PRECAUTIONS

• Before removing and installing parts, always disconnect the battery ground cable. When replacing audio, control module, and other parts provided with memory functions, record memory contents before disconnecting the battery ground cable. Otherwise, the memory will be erased.

• Reassemble in reverse order of disassembly, unless otherwise indicated.

• Adjust parts to the given specifications.

• Connect the connectors and hoses securely during reassembly.

• After reassembly, make sure functional parts operate smoothly.

WARNING:

• Airbag system wiring harness is routed near electrical parts and switches. All airbag system wiring harnesses and connectors are yellow. Do not use electric test equipment on these circuits.

• Be careful not to damage the airbag system wiring harness when servicing electrical parts and switches.


1. GENERAL TOOL

Circuit tester

TOOL NAME REMARKS


LI-2

Headlight and Tail Light System

2. Headlight and Tail Light System


1. HEADLIGHT

<Ref. to WI-221, WIRING DIAGRAM, Headlight

System.>

2. CLEARANCE LIGHT AND ILLUMINA-

TION LIGHT

<Ref. to WI-210, WIRING DIAGRAM, Clearance

Light and Illumination Light System.>

B: INSPECTION

1. HEADLIGHT SWITCH

<Ref. to LI-11, INSPECTION, Combination Switch

(Light).>

2. HEADLIGHT RELAY

Measure the headlight relay resistance between terminals when connecting terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground terminal.

LIGHTING SYSTEM

3. TAIL AND ILLUMINATION RELAY

Measure the tail and illumination relay resistance between terminals when connecting terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground terminal.

(1)

(2)

(3)

Current

Flow

No flow

(2)

(4)

(3)

Terminal No.

1 and 2

(1)

(4)

LI-00001

Standard

Less than 1

Ω

More than 1 M

Ω

(1)

(2)

(3)

Current

Flow

No flow

(2)

(3)

(4)

(1)

(4)

Terminal No.

1 and 2

LI-00001

Standard

Less than 1

Ω

More than 1 M

Ω

LI-3

Front Fog Light System

LIGHTING SYSTEM

3. Front Fog Light System


1. FRONT FOG LIGHT

<Ref. to WI-219, WIRING DIAGRAM, Front Fog

Light System.>

B: INSPECTION

1. FRONT FOG LIGHT SWITCH

Measure the resistance between front fog light switch terminals.

LI-00051

Switch position

OFF

ON

Terminal No.

3 and 5

Standard

More than 1 M

Ω

Less than 1

Ω

2. FRONT FOG LIGHT RELAY

Measure the front fog light relay resistance between terminals when connecting terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground terminal.

(1)

(2)

(3)

Current

Flow

No flow

(2)

(3)

(4)

(1)

(4)

Terminal No.

1 and 2

LI-00001

Standard

Less than 1

Ω

More than 1 M

Ω

LI-4

Rear Fog Light System

4. Rear Fog Light System


1. REAR FOG LIGHT

<Ref. to WI-249, WIRING DIAGRAM, Rear Fog

Light System.>

B: INSPECTION

1. REAR FOG LIGHT SWITCH


2) Turn on the headlight or front fog light.

3) Push the rear fog light switch and check if the rear fog light turns on.

2. REAR FOG LIGHT RELAY

Measure the rear fog light relay resistance between terminals when connecting terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground terminal.

(1)

(2)

(3)

Current

Flow

No flow

(2)

(3)

(4)

(1)

(4)

Terminal No.

1 and 2

LI-00001

Standard

Less than 1

Ω

More than 1 M

Ω

LIGHTING SYSTEM

LI-5

Turn Signal Light and Hazard Light System

LIGHTING SYSTEM

5. Turn Signal Light and Hazard

Light System


1. TURN SIGNAL LIGHT AND HAZARD

LIGHT

<Ref. to WI-229, WIRING DIAGRAM, Turn Signal

Light and Hazard Light System.>

B: INSPECTION

1. TURN SIGNAL SWITCH

<Ref. to LI-11, INSPECTION, Combination Switch

(Light).>

2. HAZARD SWITCH

Measure the resistance between hazard switch terminals.

4 3 2 1

8 7 6 5

LI-00002

Switch position

OFF

ON

Terminal No.

6 and 7

1, 3 and 4

7 and 8

Standard

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

3. TURN SIGNAL AND HAZARD MODULE

Connect the battery and the turn signal light bulb to module, as shown in the figure. The module is properly functioning if it blinks when power is supplied to the circuit.

LI-00003

LI-6

6. Back-up Light System


Back-up Light System

LIGHTING SYSTEM

2. INHIBITOR SWITCH (AT MODEL)

Measure the resistance between inhibitor switch terminals.

1. BACK-UP LIGHT

<Ref. to WI-209, WIRING DIAGRAM, Back-up

Light System.>

B: INSPECTION

1. BACK-UP LIGHT SWITCH (MT MODEL)

Measure the resistance between back-up light switch terminals.

6

12

5

11

4 3 2 1

10 9 8 7

(A)

2 1

Switch position

When select lever is set in “R” range

Other positions

Terminal No.

1 and 2

LI-00005

Standard

Less than 1

Ω

More than 1 M

Ω

(B)

2

4

1

3

LI-00317

(A) Non-turbo model

(B) Turbo model

Switch position

When shift lever is set in reverse position

Other positions

Terminal No.

Non-turbo model:

1 and 2

Turbo model:

2 and 4

Standard

Less than 1

Ω

More than 1 M

Ω

LI-7

Stop Light System

LIGHTING SYSTEM

7. Stop Light System


1. STOP LIGHT

<Ref. to WI-228, WIRING DIAGRAM, Stop Light

System.>

B: INSPECTION

1. STOP LIGHT SWITCH

Measure the resistance between stop light switch terminals.

(A)

2 1

(B)

2

4

1

3

LI-00064

(A) Without cruise control

(B) With cruise control

Switch position

When brake pedal is depressed

When brake pedal is released

Terminal No.

1 and 2:

Without cruise control

2 and 3:

With cruise control

Standard

Less than 1

Ω

More than 1 M

Ω

LI-8

Room Light System

8. Room Light System


1. ROOM LIGHT

<Ref. to WI-224, WIRING DIAGRAM, In Compartment Light System.>

B: INSPECTION

1. DOOR SWITCH

Measure the resistance between door switch terminals.

1

2

3

LI-00007

Switch position

When door is open

When door is closed

Terminal No.

1 and 3

Standard

Less than 1

Ω

More than 1 M

Ω

2. REAR GATE LATCH SWITCH

Measure the resistance between rear gate latch switch terminals.

Switch position

When rear gate is open

When rear gate is closed

Terminal No.

1 and 2

Standard

Less than 1

Ω

More than 1 M

Ω

LIGHTING SYSTEM

LI-9

Headlight Beam Leveler System

LIGHTING SYSTEM

9. Headlight Beam Leveler System


1. HEADLIGHT BEAM LEVELER

<Ref. to WI-191, WIRING DIAGRAM, Headlight

Beam Leveler System.>

B: INSPECTION

1. HEADLIGHT BEAM LEVELER ACTUA-

TOR

1) Turn on the headlights.

2) Confirm the headlight beam level is lowered by changing the switch position to 0

→ 1 → 2 → 3 →

4

→ 5.

2. HEADLIGHT BEAM LEVELER SWITCH

Connect the battery, headlight beam leveler switch connector, circuit tester and resistor (470

Ω) as shown in the figure. Measure the current at each switch position.

Switch position

0

1

4

5

2

3

6 5 4 3 2 1

RH LH

470

A

LI-00008

Current (mA)

3.8

7.0

9.8

14.7

20.3

25.5

LI-10

Combination Switch (Light)

10.Combination Switch (Light)

A: REMOVAL


2) Remove the instrument panel lower cover. <Ref.

to EI-40, REMOVAL, Instrument Panel Assembly.>

3) Remove the screw which secure upper column cover to lower column cover.

LIGHTING SYSTEM

C: INSPECTION

Measure the combination switch resistance.

LI-00009

4) Disconnect the connector from combination switch.

5) Remove the screws which secure switch, and then remove the switch.

B: INSTALLATION


LI-00068

(A)

8 7

17 16

6 5 4 3 2 1

1514131211 10 9

(B)

8 7

17 16

6 5 4 3 2 1

1514 131211 10 9

(C)

2 1

4 3

LI-00066

(A) Lighting & turn signal switch connector (LHD and RHD model with rear fog light)

(B) Lighting & turn signal switch connector (RHD model without rear fog light)

(C) Parking switch connector

1. LIGHTING SWITCH

LHD and RHD model with rear fog light:

Switch position

OFF

Tail

Head

Terminal No.

—

14 and 16

13, 14 and 16

Standard

More than 1 M

Ω

Less than 1

Ω

Less than 1

Ω

RHD model without rear fog light:

Switch position

OFF

Tail

Head

Terminal No.

—

9 and 15

9, 14 and 15

Standard

More than 1 M

Ω

Less than 1

Ω

Less than 1

Ω

LI-11

Combination Switch (Light)

LIGHTING SYSTEM

2. DIMMER AND PASSING SWITCH

LHD and RHD model with rear fog light:

Switch position

Passing

Low beam

High beam

Terminal No.

7, 8 and 16

16 and 17

7 and 16


Switch position

Passing

Low beam

High beam

Terminal No.

1, 2 and 9

9 and 10

2 and 9

Standard

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Standard

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

3. TURN SIGNAL SWITCH

LHD and RHD with rear fog light:

Switch position

Left

Neutral

Right

Terminal No.

1 and 2

—

2 and 3

Standard

Less than 1

Ω

More than 1 M

Ω

Less than 1

Ω


Switch position

Left

Neutral

Right

Terminal No.

6 and 7

—

7 and 8

Standard

Less than 1

Ω

More than 1 M

Ω

Less than 1

Ω

4. PARKING SWITCH

Switch position

OFF

ON

Terminal No.

2 and 4

1 and 4

Standard

Less than 1

Ω

Less than 1

Ω

LI-12

Headlight Assembly

2) Remove the five screws.

11.Headlight Assembly

A: REMOVAL


2) Remove the air intake duct (when removing the headlight RH). <Ref. to IN(H4SO)-7, REMOVAL,

Air Intake Duct.>

3) Remove the front grille and headlight side cover.

<Ref. to EI-18, REMOVAL, Front Grille.> <Ref. to

EI-23, REMOVAL, Front Bumper.>

4) Disconnect the headlight bulb connector.

3) Remove the two clips.

LIGHTING SYSTEM

LI-00045

LI-00012

5) Remove the three bolts, and disconnect the connectors, and then detach the headlight assembly.

LI-00046

4) Remove the rubber cap, and then detach the bulb.

5) Heat the seal portion using a dryer through the bulb mounting hole.

CAUTION:

Avoid heating one specific point of the seal portion and heating the headlight assembly to

120

°C (248°F) or more.

LI-00013

B: INSTALLATION


C: DISASSEMBLY

CAUTION:

• Do not touch the bulb glass portion.

• Do not touch inside the lens (extension portion) or reflector portion.

• Replace the packing with a new one.

1) Remove the headlight assembly. <Ref. to LI-13,

REMOVAL, Headlight Assembly.>

LI-00059

6) Unhook the hook, and then take the lens off the headlight assembly.

LI-00047

LI-13

(A) Packing

(A)

(A)


LIGHTING SYSTEM

7) Remove the packing (A) from seal groove.

CAUTION:

Completely remove the packing not to leave any chips behind.

LI-00060

D: ASSEMBLY

1) Cut the tip of packing (A) at an angle of 45

°.

2) With the cut end facing upward, insert the packing (A) into groove around seal.

CAUTION:

• If the packing protrudes, slowly take it off the groove.

• Do not stretch the packing. If the packing is stretched, seal fails.

LI-00061

(A) Packing

3) After making a round of the seal, cut its tip at an angle of 45

°, with its length 10 mm (0.39 in) longer than the circumference of seal so that the tip overlaps the other. Then, press it onto the seal, using a screwdriver.

4) Match the positions of the lens and headlight assembly, and then insert the lens into headlight assembly.

5) Secure the hook, and then install the clip and screw.

6) Put the seal portion of headlight assembly into the water and check that water does not enter inside the headlight.

CAUTION:

Be sure that water does not enter inside the headlight through the bulb socket or ventilation hole.

E: ADJUSTMENT

1. HEADLIGHT AIMING

CAUTION:

Turn off the light before adjusting headlight aiming. If the light is necessary to check aiming, do not turn on for more than two minutes.

NOTE:

Before checking the headlight aiming, be sure of the following:

• The area around the headlight has not sustained any accident, damage or other type of deformation.

• Vehicle is parked on a level surface.

• The inflation pressure of tires is correct.

• Vehicle’s fuel tank is fully charged.

1) Bounce the vehicle several times to normalize the suspension.

2) Make certain that someone is seated in the driver’s seat.

3) Turn the headlights on and then adjust the low beam pattern by following positions on the screen.

NOTE:

• Set the headlight beam leveler switch to “0” position.

• Adjust the vertical aim (A) first, then horizontal aim (B).

(A)

(B)

10mm

LI-00015

LI-00062

LI-14


LIGHTING SYSTEM

• This illustration is for LHD model. The pattern for RHD model is symmetrically opposite.

h

W1

(A)

W2

W

H

W

W2

W1 h

H

(A)

(B)

3m (10 ft)

LI-00054

(A) Vehicle center

W mm (in)

1,140 (44.88)

(B) Bulb center

H mm (in)

733 (28.9) h mm (in) at 3 m (10 ft)

30 (1.18)

LI-15

Headlight Bulb

LIGHTING SYSTEM

12.Headlight Bulb

A: REMOVAL

CAUTION:

• Because the halogen bulb operates at a high temperature, dirt and oil on the bulb surface reduces the bulb’s service life. Hold the flange portion when replacing the bulb. Never touch the glass portion.

• Do not leave the headlight without a bulb for a long time. Dust, moisture, etc. entering the headlight may affect its performance.


2) Remove the air intake duct (when removing the headlight RH).

3) Disconnect the harness connector.

4) Remove the rubber cap.

LI-00017

5) Remove the light bulb retaining spring to remove the bulb.

LI-00018

B: INSTALLATION


CAUTION:

Attach the rubber cap with letters TOP on the top so the drain hole will be on the lower side.

C: INSPECTION

1) Visually check the bulb for blow out.

2) Check the bulb specification. <Ref. to LI-2,

SPECIFICATION, General Description.>

3) If NG, replace the bulb with a new one.

LI-16

Front Turn Signal Light Bulb

13.Front Turn Signal Light Bulb

A: REMOVAL



2) Turn the socket and remove the bulb.

LIGHTING SYSTEM

LI-00021

B: INSTALLATION


C: INSPECTION





LI-17

Clearance Light Bulb

LIGHTING SYSTEM

14.Clearance Light Bulb

A: REMOVAL




LI-00022

B: INSTALLATION


C: INSPECTION





LI-18

Front Fog Light Assembly

15.Front Fog Light Assembly

A: REMOVAL


2) Remove the two clips and lower mudguard.

LIGHTING SYSTEM


4) Remove the lower bolts.

LI-00023

LI-00024

5) Remove the mounting bolts and clip, and then detach the fog light assembly.

B: INSTALLATION


LI-00025

LI-19

Front Fog Light Bulb

LIGHTING SYSTEM

16.Front Fog Light Bulb

A: REMOVAL

1) Remove the front fog light assembly. <Ref. to LI-

19, REMOVAL, Front Fog Light Assembly.>

2) Remove the back cover.

LI-00026

3) Remove the spring retainer, and then detach the fog light bulb.

LI-00027

B: INSTALLATION


C: INSPECTION





LI-20

Rear Combination Light Assembly

17.Rear Combination Light Assembly

A: REMOVAL


2) Remove the two bolts, and then turn the socket and disconnect cord assembly to remove rear combination light.

LIGHTING SYSTEM

LI-00028

B: INSTALLATION


LI-00029

LI-21

Tail/Stop Light Bulb

LIGHTING SYSTEM

18.Tail/Stop Light Bulb

A: REMOVAL

1) Remove the rear combination light assembly.

<Ref. to LI-21, REMOVAL, Rear Combination Light

Assembly.>


LI-00056

B: INSTALLATION


C: INSPECTION


2) Check the bulb specification. <Ref. to LI-2, SPEC-

IFICATION, General Description.>


LI-22

Back-up Light Bulb

19.Back-up Light Bulb

A: REMOVAL



Assembly.>


LIGHTING SYSTEM

LI-00032

B: INSTALLATION


C: INSPECTION





LI-23

Rear Turn Signal Light Bulb

LIGHTING SYSTEM

20.Rear Turn Signal Light Bulb

A: REMOVAL



Assembly.>


LI-00031

B: INSTALLATION


C: INSPECTION





LI-24

Rear Fog Light Bulb

21.Rear Fog Light Bulb

A: REMOVAL

NOTE:

Rear fog light bulb is attached only to driver’s side combination light.



Assembly.>


LIGHTING SYSTEM

LI-00033

B: INSTALLATION


C: INSPECTION





LI-25

License Plate Light

LIGHTING SYSTEM

22.License Plate Light

A: REMOVAL

1) Remove the license plate light mounting screw

(A), and then remove the lens.

(A)

LI-00034

2) Remove the bulb.

B: INSTALLATION


C: INSPECTION





LI-26

High-mounted Stop Light

23.High-mounted Stop Light

A: REMOVAL


2) Remove the cap (a) by prying on the edge with screwdriver.

3) Remove the screws (b), and then detach the cover (c).

4) Remove the screws (d), disconnect the connector, and then detach the high-mounted stop light.

(d)

(c)

(b)

(a)

LI-00036

B: INSTALLATION


C: INSPECTION





LIGHTING SYSTEM

LI-27

Side Turn Signal Light

LIGHTING SYSTEM

24.Side Turn Signal Light

A: REMOVAL


2) Pull out the light from body while pushing it in direction of vehicle front.

3) Disconnect the harness connector and remove the light.

LI-00067

B: INSTALLATION


C: INSPECTION

1) Check the bulb for blow out using tester.

2) If NG, replace the side turn signal light assembly with a new one.

LI-28

Spot Map Light

25.Spot Map Light

A: REMOVAL


2) Insert a flat tip screwdriver to the slot of lens, and then pry the lens to remove.

LIGHTING SYSTEM

LI-00038

3) Remove the spot map light installation screws.

LI-00039

4) Disconnect the harness connectors and remove the spot map light.

B: INSTALLATION


C: INSPECTION

1. SPOT MAP LIGHT BULB





2. SPOT MAP LIGHT SWITCH

Measure the spot map light switch resistance.

Switch position

OFF

ON

Terminal No.

—

1 and 2

Standard

More than 1 M

Ω

18

±5.4 Ω

LI-29

Room Light

LIGHTING SYSTEM

26.Room Light

A: REMOVAL


2) Remove the lens (A) and room light mounting screws (B).

(B)

(B)

(A)

LI-00040

3) Disconnect the harness connectors and remove the room light.

B: INSTALLATION


C: INSPECTION

1. ROOM LIGHT BULB





2. ROOM LIGHT SWITCH

Measure the resistance between room light switch terminals.

R52

3 2 1

Switch position

OFF

ON

DOOR

Terminal No.

—

1 and 3

1 and 2

LI-00041

Standard

More than 1 M

Ω

1.5

±0.5 Ω

1.5

±0.5 Ω

LI-30

27.Luggage Room Light

Luggage Room Light

A: REMOVAL


2) Remove the lens (A) and luggage room light mounting screws (B).

LIGHTING SYSTEM

C: INSPECTION

1. LUGGAGE ROOM LIGHT BULB





2. LUGGAGE ROOM LIGHT SWITCH

Measure the resistance between luggage room light switch terminals.

(3)

(1)

(B)

(B)

(A)

LI-00042

3) Disconnect the harness connectors and remove the luggage room light.

B: INSTALLATION


Switch position

OFF

ON

DOOR

Terminal No.

—

1 and 3

1 and 2

(2)

LI-00043

Standard

More than 1 M

Ω

1.5

±0.5 Ω

1.5

±0.5 Ω

LI-31

Glove Box Light

LIGHTING SYSTEM

28.Glove Box Light

A: REMOVAL



AL, Glove Box.>


4) Remove the glove box light.

LI-00044

B: INSTALLATION


C: INSPECTION





LI-32

WIPER AND WASHER SYSTEM

WW

Page

1.


2.

Wiper and Washer System .........................................................................6

3.

Combination Switch (Wiper)........................................................................7

4.

Wiper Blade.................................................................................................9

5.

Washer Tank and Motor............................................................................11

6.

Front Wiper Arm........................................................................................12

7.

Front Wiper Motor and Link.......................................................................13

8.

Front Washer Nozzle ................................................................................15

9.

Rear Wiper Arm ........................................................................................16

10.

Rear Wiper Motor......................................................................................17

11.

Rear Washer .............................................................................................18

12.

Wiper Control Relay ..................................................................................19

13.

Headlight Washer......................................................................................20


WIPER AND WASHER SYSTEM



Front wiper motor

Rear wiper motor

Front washer motor

Rear washer motor

Input

Input

Pump type

Input

Pump type

Input

B: COMPONENT

1. FRONT WIPER

12 V — 72 W or less


Centrifugal


Centrifugal


(1)

(2)

T1

T1

(3)

(1)

T2

(4)

(2)

T1

(5)

T1

T2

(3)

(1) Wiper rubber

(2) Wiper blade ASSY

(3) Wiper arm

(4) Wiper rink

(5) Wiper motor

WW-2

WW-00223


T1: 6.0 (0.61, 4.4)

T2: 20 (2.0, 14.5)

2. REAR WIPER



T3

(10)

(9)

(8)

T2

(7)

(6)

(5)

T1

(4)

(1)

(3)

(1) Wiper rubber

(2) Wiper blade ASSY

(3) Wiper arm

(4) Wiper motor

(5) Spacer A

(6) Cushion

(7) Spacer B

(8) Nut

(9) Cap

(10) Wiper arm cover

(2)

WW-00190


T1: 6.0 (0.61, 4.4)

T2: 7.5 (0.76, 5.5)

T3: 8.0 (0.82, 5.9)

WW-3


3. WASHER TANK

(1)

(10)

(11)

(2)


(4)

(9)

(8)

(12)

T

(1)

(2)

(13)

(3)

(5)

(6)

(7)

(1)

(2)

(2)

(1)

(2)

(3)

(4)

(5)

(6)

Washer nozzle

Washer hose

Washer tank

Washer tank cap

Front washer motor

Rear washer motor

(7)

(8)

Grommet

Headlight washer motor

(9) Motor bracket

(10) Headlight washer case

(11) Headlight washer upper nozzle

(12) Headlight washer lower nozzle

WW-00097

(13) Valve


T: 6.0 (0.61, 4.4)

WW-4


C: CAUTION

• Reconnect the connectors and hoses securely.

After reconnecting, confirm that each function operates normally.

• Be careful that wiring harnesses of airbag system pass near electrical parts and switches.

• Wiring harnesses and connectors of all airbag system are yellow color. Do not use a tester on these circuits.

• Care must be taken when installing the piping hose so that no bending, jamming, etc. are caused.

• If even a little oil or grease such as silicon oil gets in the tank and washer passages, an oil film easily forms on the glass, causing the wiper to chatter and judder. Therefore, be careful not to let this happen.


WW-5

Wiper and Washer System


2. Wiper and Washer System


1. WIPER AND WASHER (FRONT)

<Ref. to WI-264, WIRING DIAGRAM, Wiper and Washer System (Front).>

2. WIPER AND WASHER (REAR)

<Ref. to WI-265, WIRING DIAGRAM, Wiper and Washer System (Rear).>

B: INSPECTION

Symptom

Wiper and washers do not operate.

Wipers do not operate in LO or HI.

Wipers do not operate in INT.

Washer motor does not operate.

Wipers do not operate when washer switch is ON.

Washer fluid spray does not operate.

Repair order

(1) Wiper fuse (F/B No. 14, 15)

(2) Combination switch

(3) Wiper motor

(4) Wiring harness


(2) Wiper motor

(3) Wiring harness


(2) Wiper motor

(3) Wiring harness

(1) Washer switch

(2) Washer motor

(3) Wiring harness

(1) Washer motor

(2) Wiring harness

(1) Washer motor

(2) Washer hose and nozzle

WW-6

Combination Switch (Wiper)

3. Combination Switch (Wiper)

A: REMOVAL

1) Loosen the screw to remove the steering column cover.


C: INSPECTION

1) Inspect the continuity between each connector terminal.

WW-00004

2) Disconnect the connectors from combination switches.

3) Loosen the screw to remove combination switch.

B: INSTALLATION


WW-00045

9

18

8 7 6 5 4 3 2 1

17 16 15 14 13 12 11 10

WW-00046

LHD and RHD for Europe model:

FRONT

REAR

Switch position Terminal No.

OFF

INT

LO

7 and 16

7 and 16

7 and 17

HI

Washer ON

Washer ON

8 and 17

2 and 11

2 and 10

10 and 12

2 and 12

OFF

INT

ON

Washer ON

—

2 and 13

2 and 10

2 and 10

10 and 12

2 and 12

Standard

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

More than 1 M

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

WW-7

Combination Switch (Wiper)


RHD except for Europe model:

FRONT

REAR

Switch position Terminal No.

OFF 3 and 12

INT

LO

HI

Washer ON

3 and 12

3 and 11

2 and 11

Washer ON

OFF

INT

ON

8 and 17

8 and 18

18 and 16

8 and 16

—

8 and 15

Washer ON

8 and 18

8 and 18

18 and 16

8 and 16

Standard

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

More than 1M

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

2) If continuity is not as specified, replace the switch.

• Intermittent operation inspection

(1) Turn the wiper switch to INT.

(2) Adjust the intermittent control switch to MAX.

(3) Apply battery voltage to switch terminals 16 and 2.

(4) Measure the voltage between combination switch terminal.

Terminals:

No. 7 — No. 2:

(A) (B)

(C)

(D)

(E)

(F)

(G)

(F)

(G)

(F)

(G)

(H)

(I)

(J)

(A) Switch position

(B) Voltage

(C) MIN.

(D) MAX.

(E) Non variable type

(F) 12 V

(G) 0 V

(H) Approx. 2 sec.

If operation is not as specified, replace the switch.

(I) 16

±6 sec.

(J) 3

±1 sec.

WW-00053

WW-8

4. Wiper Blade

Wiper Blade


2) Make sure the wiper rubber is securely fastened to the pull stopper (A).

A: REMOVAL

While pushing the locking clip (A) up, pull out the blade from arm to arrow direction.

WW-00037

WW-00008

B: INSTALLATION


2) Confirm that the clip is locked securely.

C: DISASSEMBLY

Pull on side (A) of the wiper rubber stopper and remove the rubber from the blade assembly.

WW-00009

D: ASSEMBLY

1. METAL TYPE

1) Insert the wiper rubber onto the blade so that the stopper is in the position shown.

WW-00049

WW-9


2. RESIN TYPE

Wiper Blade

A B C D

1) Insert the wiper rubber through the claw (B).

WW-00193

3) Insert the wiper rubber into the claw (A).

A

A

B

WW-00198

2) Insert the wiper rubber top until it protrudes about

20 mm (0.79 in) from the stopper (D).

D

(A)

WW-00147

E: INSPECTION

1) When the wiper does not perform well, inspect the following:

• Make sure the movable part of the blade assembly moves smoothly.

• Make sure the wiper rubber is not deformed or damaged.

2) Replace with a new part if damage is found.

WW-00199

(A) 20 mm (0.79 in)

WW-10

Washer Tank and Motor

5. Washer Tank and Motor

A: REMOVAL

1) Open the hood.


3) Remove the two bolts, hose and connector, and then remove the tank.


C: DISASSEMBLY

1) Remove bolt, and then pull out washer motor from tank. (Model with headlight washer)

2) Pull out the washer motor from tank.

WW-00100

WW-00011

4) For the model with headlight washer, proceed to step 5) and 6).

5) Lift the washer tank, and then disconnect the connector from headlight washer motor. Disconnect washer hoses.

WW-00098

6) Disconnect the washer hose from the motor, and then detach the washer tank.

WW-00012

D: ASSEMBLY

1) Assemble in the reverse order of disassembly.

2) Confirm that water does not leak from installation area of motor.

E: INSPECTION

Apply battery voltage to the connector terminal of the washer motor and make sure the motor operates.

WW-00013

B: INSTALLATION



6.0 N·m (0.61 kgf-m, 4.4 ft-lb)

WW-00099

WW-11


6. Front Wiper Arm

A: REMOVAL

1) Open the hood.

2) Remove the cap.

3) Loosen the nut to remove arm.

Front Wiper Arm

WW-00047

B: INSTALLATION


2) Operate the wiper once.

3) Align the wiper blade to ceramic print point mark

(A) of front window panel.

(A)

WW-00048



<Ref. to WW-2, FRONT WIPER, COMPO-


C: ADJUSTMENT

Operate the wiper once. Align the wiper blade to ceramic print point mark (A) of front window panel.

(A)

WW-00048

WW-12

Front Wiper Motor and Link

7. Front Wiper Motor and Link

A: REMOVAL


2) Remove the cowl panel. <Ref. to EI-32, REMOV-

AL, Cowl Panel.>

3) Disconnect the connector of motor.

4) Loosen the bolts and nuts to remove wiper link.





<Ref. to WW-2, FRONT WIPER, COMPO-


C: INSPECTION

1) When the battery is connected to wiper motor connectors and confirm that motor operates at low speed.

3 2

5 4

1

WW-00050

5) Loosen the bolts and nuts to remove motor.

3 2

5 4

1

WW-00051

B: INSTALLATION

1) Install the wiper link to the vehicle, and then connect the motor connector.

2) Connect the battery ground cable to battery.

3) To confirm that the motor is at auto stop position, connect the harness to motor and turn the wiper switch ON/OFF once.


5) Tighten the nut where rod (A) and link plate (B) is aligned in a straight line.

WW-00225

3) Connect the battery to terminals of connector, and remove the terminal connection with motor rotated at low speed, and stop the wiper motor through operation.

3 2

5 4

1

(A)

WW-00224

2) When the battery is connected to terminal of connectors and confirm that motor operates at high speed.

(B)

WW-00226

WW-00052

WW-13

Front Wiper Motor and Link


4) Connect the battery and confirm that the motor stops at automatic stop position after the motor operates at low speed again.

3 2

5 4

1

WW-00227

WW-14

Front Washer Nozzle

8. Front Washer Nozzle

A: REMOVAL

1) Remove the washer hose from the washer nozzle.

2) Open the clips on the underside of the hood with a thin screwdriver or other tool, and remove the washer nozzle.


WW-00023

B: INSTALLATION


NOTE:

Hoses have rib as eyemark for twist-proof.

2) Adjust the position of the washer liquid sprayer.

<Ref. to WW-15, ADJUSTMENT, Front Washer

Nozzle.>

C: INSPECTION

• Make sure the nozzle and hose are not clogged.

• Check hoses for twist or fold.

D: ADJUSTMENT

NOTE:

It is not necessary to adjust the washer injection position because of spreading nozzle type.

WW-15


9. Rear Wiper Arm

A: REMOVAL

1) Remove the wiper arm cover (A).

Rear Wiper Arm

C: ADJUSTMENT

1) Operate the rear wiper once.

2) Align the blade to the center of rear defogger heat wire (A).

WW-00191

2) Loosen the nut to remove wiper arm.

WW-00200

WW-00192

B: INSTALLATION


2) Operate the rear wiper once.

3) Align the blade to the center of rear defogger heat wire (A).

WW-00200



<Ref. to WW-3, REAR WIPER, COMPONENT,


WW-16

10.Rear Wiper Motor

Rear Wiper Motor


C: INSPECTION

1) Connect the battery to wiper motor connector and confirm that the wiper motor operates.

A: REMOVAL


2) Remove the rear wiper arm.

3) Remove the cap (A), nut (B), and spacer (C) from rear wiper shaft.

2 1

4 3

WW-00027

4) Remove the rear gate lower trim. <Ref. to EI-48,

REMOVAL, Rear Gate Trim.>

5) Unclip the clip of harness and disconnect the connector of wiper motor.

6) Loosen the bolts to remove the wiper motor assembly (A).

WW-00030

2) Connect the battery to terminal of connector and remove the terminal connections with motor rotated, and stop the wiper motor through operation.

2 1

4 3

WW-00031

3) Connect the battery and confirm that the motor stops at automatic stop position after the motor operates at low speed again.

WW-00028

B: INSTALLATION


2) Install the rear wiper cushion with the arrow mark facing up, as shown in the figure.

2 1

4 3

WW-00032

WW-00029



<Ref. to WW-3, REAR WIPER, COMPONENT,


WW-17

Rear Washer


11.Rear Washer

A: REMOVAL

1) Remove the rear gate upper trim. <Ref. to EI-48,


2) Remove the washer hose from the washer nozzle.

3) Push the anchor portion of washer nozzle with a thin screwdriver or other tool, and remove the washer nozzle.

WW-00201

B: INSTALLATION


2) Adjust the position of the washer liquid sprayer.

<Ref. to WW-18, ADJUSTMENT, Rear Washer.>

C: INSPECTION

• Make sure the nozzle and hose are not clogged.

• Check hoses for twist or fold.

D: ADJUSTMENT

1) Turn the wiper switch to OFF position.

2) When the vehicle stops, adjust the washer injection position as shown in the figure.

Injection position:

A: 35 mm (1.38 in)

B: 72

°

(1)

A

B

WW-00054

(1) Nozzle

WW-18

12.Wiper Control Relay

Wiper Control Relay


3) Measure the voltage when the wiper relay is operated.

A: REMOVAL


2) Remove the right quarter lower trim. <Ref. to EI-


3) Loosen the nut to remove control unit.

(A) (B)

(C)

(D)

(E)

(F)

WW-00034

B: INSTALLATION


C: INSPECTION

1) Disconnect the connector from the wiper control relay.

2) Connect the positive (+) lead from the battery to terminal 8 and the negative (

−) lead to terminal 6.

Connect the positive (+) lead from the voltmeter to terminal 3 and the negative (

−) lead to ground.

WW-00055

(A) Switch position

(B) Voltage

(C) ON

(D) 12 V

(E) 0 V

(F) 9

±2 sec.

If operation is not as specified, replace the switch.

4 3

8 7

2 1

6 5

WW-00035

WW-19

Headlight Washer


13.Headlight Washer

A: REMOVAL

1) Disconnect the ground cable from the battery.

2) Remove the front grille. <Ref. to EI-18, REMOV-

AL, Front Grille.>

3) Remove the headlight. <Ref. to LI-13, REMOV-

AL, Headlight Assembly.>

4) Draw out headlight washer hose.

5) Disconnect hose (A) from valve (B).

NOTE:

Washer fluid may drain from valve. Put a pan under the valve, then disconnect valve from hose while pinching the hose edge.

B: INSTALLATION


(A)

(A)

(B)

6) Remove nozzle cover (A).

(A)

WW-00102

WW-00109

7) Push the three pawls to remove outer nozzle (A).

Then pull out inner nozzle (B).

NOTE:

Before pushing the outer nozzle pawls, cover the bumper to avoid scratches.

(A)

(B)

WW-00110

WW-20

ENTERTAINMENT

ET

Page

1.


2.

Radio System..............................................................................................3

3.

Front Accessory Power Supply Socket System ..........................................4

4.

Radio Body..................................................................................................5

5.

Front Speaker .............................................................................................6

6.

Antenna.......................................................................................................7

7.

Antenna Amplifier........................................................................................8

8.

Front Accessory Power Supply Socket .......................................................9


ENTERTAINMENT


A: CAUTION

• Before disassembling or reassembling parts, always disconnect the battery ground cable. When replacing radio, control module and other parts provided with memory functions, record memory contents before disconnecting the battery ground cable.

Otherwise, the memory will be erased.





B: PREPARATION TOOL

1. GENERAL TOOL

TOOL NAME

Circuit tester

Conductive silver composition

(DUPONT No. 4817 or equivalent)

REMARKS


Used for repairing antenna wire.

ET-2

Radio System

ENTERTAINMENT

2. Radio System


1. RADIO

<Ref. to WI-101, WIRING DIAGRAM, Audio System.>

B: INSPECTION

Symptom Repair order

No power coming in. (No display and no sound from speakers.) (1) Check the fuse and power supply for radio.

(2) Check the radio ground.

(3) Remove the radio for repair.

A specific speaker does not operate.

(1) Check the speaker.

(2) Check the output circuit between radio and speaker.

Radio generates noise with engine running.

AM and FM modes are weak or noisy.


(2) Check the generator.

(3) Check the ignition coil.


(1) Check the antenna.

(2) Check the antenna amplifier.

(3) Check the noise suppressor.



ET-3

Front Accessory Power Supply Socket System

ENTERTAINMENT

3. Front Accessory Power Supply Socket System


1. FRONT ACCESSORY POWER SUPPLY

SOCKET SYSTEM

<Ref. to WI-190, WIRING DIAGRAM, Front Accessory Power Supply System.>

ET-4

4. Radio Body

A: REMOVAL


2) Remove the front cover. <Ref. to EI-39, RE-



NOTE:


Radio Body

ENTERTAINMENT


CAUTION:

Do not insert the flat tip screwdriver into any portion except for indicated in the figure. The instrument panel may be damaged.

(A) (A)

(A)


(C)

(B)

(A)

(A) Screw

(B) Clip

(C) Claw

(A)

EI-00728

EI-00731

(C)

EI-00732



7) Remove the fitting screws, and slightly pull out the radio from center console.

8) Disconnect the harness connectors and antenna feeder cord.

B: INSTALLATION


ET-5

Front Speaker

ENTERTAINMENT

5. Front Speaker

A: REMOVAL


2) Remove the front door trim. <Ref. to EI-35, RE-

MOVAL, Front Door Trim.>

3) Remove the front speaker mounting screws.

ET-00003

4) Disconnect the harness connector and remove front speaker.

B: INSTALLATION


ET-6

6. Antenna

A: INSPECTION

Measure the resistance between antenna terminal and each antenna wire.

If an antenna wire is OK, resistance will be less than 1

Ω. If an antenna wire is broken, the resistance will be more than 1 M

Ω.

NOTE:

When checking the continuity, wind a piece of aluminum foil around the tip of tester probe and press aluminum foil against wire with your finger.

Antenna

ENTERTAINMENT

3) Deposit conductive silver composition (DU-

PONT No. 4817) on the broken portion with a drawing pen.

(B)

(C)

(A)

ET-00009

(A)

(B)

(C)

(A) Broken portion

(B) Masking thin film

(C) Conductive silver composition

4) Dry out the deposited portion.

5) After repair has been completed, measure the resistance in repaired wire.

ET-00007

(A) Tester probe

(B) Aluminum foil

(C) Antenna wire

To locate the broken point, move the probe along antenna wire.

ET-00008

B: REPAIR

1) Clean the antenna wire and surrounding area with a cloth dampened by alcohol.

2) Paste a thin masking film on the glass along broken wire.

ET-7

Antenna Amplifier

ENTERTAINMENT

7. Antenna Amplifier

A: REMOVAL


2) Remove the rear quarter upper trim. <Ref. to EI-


3) Disconnect the harness connector and terminal.

4) Remove the mounting screws and detach antenna amplifier.

ET-00018

B: INSTALLATION


C: INSPECTION

Measure the antenna amplifier resistance.

(1)

(2)

(4)

(3)

ET-00019

1) Check cable swagging portion for insulation failure (short).

Terminal No.

1 and Amplifier body




Standard

More than 10 k

Ω

More than 10 k

Ω

More than 10 k

Ω

More than 10 k

Ω

2) Check antenna amplifier.

Disconnect each connector, and then measure direct-current electricity value at point described above by the tester check.

Standard value:

(+B = 13.5 V)

⇒

50

±

10 mA

ET-8

Front Accessory Power Supply Socket

8. Front Accessory Power Supply Socket

A: REMOVAL


2) Remove the front cover. <Ref. to EI-39, RE-


3) Disconnect the harness connectors and remove the front accessory power supply socket.

ENTERTAINMENT

B: INSTALLATION


ET-00016

ET-9

ENTERTAINMENT

Front Accessory Power Supply Socket

ET-10

COMMUNICATION SYSTEM

COM

Page

1.


2.

Horn System ...............................................................................................3

3.

Horn ............................................................................................................4

4.

Horn Switch.................................................................................................5


COMMUNICATION SYSTEM


A: CAUTION

• Before disassembling or reassembling parts, always disconnect the battery ground cable. When replacing radio, control module and other parts provided with memory functions, record memory contents before disconnecting the battery ground cable.

Otherwise, the memory will be erased.






1. GENERAL TOOL

TOOL

NAME

Circuit tester

REMARKS


COM-2

Horn System

2. Horn System


1. HORN

<Ref. to WI-193, WIRING DIAGRAM, Horn System.>

B: INSPECTION

1. HORN RELAY

Measure the horn relay resistance between terminals (indicated in table below) when connecting terminal No. 4 to battery positive terminal and terminal

No. 3 to battery negative terminal.

(1)

(2)

(3)

Current

Flow

No Flow

(2)

(3)

(4)

(1)

(4)

Terminal No.

1 and 2

COM00001

Standard

Less than 1

Ω

More than 1M

Ω


COM-3


3. Horn

A: REMOVAL


2) Remove the front fog light assembly (LH). <Ref.

to LI-19, REMOVAL, Front Fog Light Assembly.>

3) Remove the horn bracket mounting bolt (A).

4) Disconnect the harness connector and remove the horn assembly (B).

Horn

(A)

(B)

COM00002

B: INSTALLATION


C: INSPECTION

With 12 V direct current supplied between horn terminal and case ground, check that the horn sounds properly.

COM00003

COM-4

Horn Switch

4. Horn Switch

A: REMOVAL

WARNING:

Before servicing, be sure to read the notes in the AB section for proper handling of the driver

airbag module. <Ref. to AB-3, CAUTION, General Description.>




3) Remove the horn switch from the steering wheel as shown in the figure.


B: INSTALLATION


C: INSPECTION

Measure the horn switch resistance.

COM00004

2

5 4

1

Switch position

When horn switch is pushed.

When horn switch is not pushed.

Terminal No.

1 and body ground

COM00005

Resistance

Less than 1

Ω

More than 1M

Ω

COM-5


Horn Switch

COM-6

GLASS/WINDOW/MIRROR

GW

Page

1.


2.

Power Window System ...............................................................................6

3.

Power Window Control Switch ....................................................................7

4.

Remote Control Mirror System..................................................................10

5.

Scalp Cap..................................................................................................11

6.

Outer Mirror Assembly ..............................................................................12

7.

Outer Mirror...............................................................................................14

8.

Remote Control Mirror Switch ...................................................................15

9.

Front Door Glass.......................................................................................17

10.

Front Regulator and Motor Assembly .......................................................21

11.

Rear Door Glass .......................................................................................22

12.

Rear Regulator and Motor Assembly ........................................................24

13.

Windshield Glass ......................................................................................25

14.

Inner Rearview Mirror................................................................................28

15.

Rear Gate Glass .......................................................................................29

16.

Rear Window Defogger System................................................................30

17.

Rear Window Defogger.............................................................................31

18.

Rear Quarter Glass ...................................................................................32

19.

Roof Window Glass...................................................................................34

GLASS/WINDOW/MIRROR


A: COMPONENT

1. FIXED GLASS


(5) (6)

(2)

(1)

(3)

(4)

(10)

(5)

(9)

(11)

(8)

(3)

(7)

(8)

(8)

(6)

(1) Windshield glass

(2) Dam rubber

(3) Molding

(4) Rearview mirror mount

(5) Locate pin

(6) Fastener

(7) Rear quarter glass

(8) Locate pin

(9) Rear gate glass

(10) Spring

(11) Cover C pillar

GW-00326

GW-2

2. FRONT DOOR GLASS

(1)


GLASS/WINDOW/MIRROR

(4)

T1

T1

(3)

(2)

T2

(6)

T3

(5)

T2

GW-00136

(1) Glass (5)


(2) Door sash (Front)

(3) Door sash (Rear)

(6) Guide rail

T1: 7.5 (0.75, 5.4)

T2: 14 (1.4, 10.3)

(4) Regulator ASSY

T3: 6 (0.6, 4.3)

GW-3

GLASS/WINDOW/MIRROR

3. REAR DOOR GLASS


(2)

(3)

(1)

(1) Door sash (Front)

(2) Glass

(3) Door sash (Rear)

(4) Regulator ASSY

T2

T2

(5) Motor ASSY

(4)

T1

(5)

T1

GW-00003


T1: 7.5 (0.75, 5.4)

T2: 14 (1.4, 10.3)

GW-4

4. MIRRORS


(1)

(3)

(6)

(5)

(7)

(3)

GLASS/WINDOW/MIRROR

(2)

(4)

GW-00298

(1) Outer mirror (Large-sized)

(2) Outer mirror (Standard)

(3) Mirror

(4) Scalp cap

(5) Rearview mirror

(6) Mount

(7) Spring

B: CAUTION

• When the electrical connectors are disconnected, always conduct an operational check after connecting them again.

• Avoid impact and damage to glass.


TOOL NAME

Circuit Tester

Piano Wire

Windshield Knife

REMARKS

Used for checking voltage and continuity.

Used for window glass removal.

Used for window glass removal.

GW-5

Power Window System

GLASS/WINDOW/MIRROR

2. Power Window System


1. POWER WINDOW

<Ref. to WI-240, WIRING DIAGRAM, Power Window System.>

B: INSPECTION

Symptom

All power windows does not operate.

One window does not operate.

“Window Lock” does not operate.

Repair order

(1) Fuse (SBF-6) (F/B No. 18)

(2) Power window circuit breaker

(3) Power window relay

(4) Wire harness

(1) Power window main switch

(2) Power window sub switch

(3) Power window motor

(4) Wire harness

Power window main switch

GW-6

Power Window Control Switch

GLASS/WINDOW/MIRROR

3) Remove the switch panel.

3. Power Window Control

Switch

A: REMOVAL

1. MAIN SWITCH


2) Using a flat tip screwdriver, remove the screw cover.

GW-00327

3) Loosen the screw to remove the power window main switch.


B: INSTALLATION

1. MAIN SWITCH


2. SUB-SWITCH


GW-00008

GW-00328


2. SUB-SWITCH


2) Remove the screw which secures switch panel.

GW-00007

GW-7

GLASS/WINDOW/MIRROR

C: INSPECTION

1. MAIN SWITCH

Measure the switch resistance.

• LHD model


Driver’s side

Front passenger’s side

Rear LH

Rear RH

Switch position

AUTO UP

UP

OFF

DOWN

AUTO DOWN

UP

OFF

DOWN

UP

OFF

DOWN

UP

OFF

DOWN

Terminal No.

13 and 2, 1 and 5

13 and 2, 1 and 5

1 and 2

1 and 5

2 and 5

13 and 1, 2 and 5

13 and 1, 2 and 5

13 and 7, 6 and 5

5 and 6

5 and 7

6 and 7

13 and 6, 7 and 5

10 and 13, 11 and 5

5 and 11

5 and 10

11 and 10

13 and 11, 10 and 5

13 and 15, 16 and 5

5 and 15

5 and 16

15 and 16

13 and 16, 15 and 5

If NG, replace the main switch.

Standard

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

GW-8


• RHD model

Driver’s side

Front passenger’s side

Rear LH

Switch position

AUTO UP

UP

OFF

DOWN

AUTO DOWN

UP

OFF

DOWN

UP

OFF

DOWN

UP

OFF Rear RH

If NG, replace the main switch.

2. SUB-SWITCH

Measure the switch resistance.

DOWN

Front passenger’s side and rear

Switch position

UP

OFF

DOWN

If NG, replace the sub-switch.

Terminal No.

12 and 7, 6 and 1

12 and 7, 6 and 1

1 and 6

1 and 7

6 and 7

12 and 6, 7 and 1

12 and 6, 7 and 1

12 and 2, 3 and 1

1 and 2

1 and 3

2 and 3

12 and 3, 2 and 1

12 and 10, 9 and 1

1 and 9

1 and 10

9 and 10

12 and 9, 10 and 1

12 and 14, 13 and 1

1 and 13

1 and 14

13 and 14

12 and 13, 14 and 1

Terminal No.

8 and 5, 6 and 7, 1 and 8, 1 and

5

4 and 5, 6 and 7

8 and 7, 4 and 5, 1 and 8, 1 and

7

GLASS/WINDOW/MIRROR

Standard

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Standard

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

GW-9

Remote Control Mirror System

GLASS/WINDOW/MIRROR

4. Remote Control Mirror System


1. REMOTE CONTROL MIRROR

<Ref. to WI-253, WIRING DIAGRAM, Remote Controlled Rearview Mirror System.>

B: INSPECTION

Symptom

All function does not operate.

One side of the mirror motor does not operate.

Heated mirror does not operate.

Repair order

(1) Fuse (F/B No. 4) (F/B No. 13) (F/B No. 17) (F/B No. 18)

(2) Mirror switch

(3) Wiring harness

(1) Mirror switch

(2) Mirror motor

(3) Wiring harness

(1) Mirror switch

(2) Heated mirror

(3) Wiring harness

GW-10

Scalp Cap

5. Scalp Cap

A: REPLACEMENT

1) Turn the rearview mirror downward.

2) Insert a thin screw driver, push the clip part of scalp cap, and remove the scalp cap.

GLASS/WINDOW/MIRROR

GW-00224

3) Insert the claw at the bottom of scalp cap into door mirror.

4) Install the scalp cap securely.

GW-00299

GW-11

Outer Mirror Assembly

GLASS/WINDOW/MIRROR

6. Outer Mirror Assembly

A: REMOVAL

1) Remove the door trim. <Ref. to EI-35, REMOV-

AL, Front Door Trim.>

2) Remove the mirror gusset cover.

: (1)

GW-00061

(1) Hook

3) Disconnect the mirror connector.

4) Remove the grommet, and then loosen the screws to remove mirror assembly.

B: INSTALLATION


GW-00010

GW-12

Outer Mirror Assembly

GLASS/WINDOW/MIRROR

C: INSPECTION

Check to ensure that the rearview mirror moves properly when battery voltage is applied to terminals.

Heated mirror not-equipped model:

Switch position

OFF

UP

DOWN

LEFT

RIGHT

Terminal No.

—

1 (+) and 3 (

−)

3 (+) and 1 (

−)

2 (+) and 3 (

−)

3 (+) and 2 (

−)

If NG, replace the mirror.

Heated mirror equipped model:

Switch position

OFF

UP

DOWN

LEFT

RIGHT

Terminal No.

—

2 (+) and 4 (

−)

4 (+) and 2 (

−)

3 (+) and 4 (

−)

4 (+) and 3 (

−)

If NG, replace the mirror.

GW-13

Outer Mirror

GLASS/WINDOW/MIRROR

7. Outer Mirror

A: REPLACEMENT

1) Remove the door mirror assembly. <Ref. to GW-

12, REMOVAL, Outer Mirror Assembly.>

2) Warm the area around the mirror holder (1) with a hair drier until the edges of the mirror holder become soft (about 2 or 3 minutes with a 1,000 W drier.)

3) Use a flat tip screwdriver without sharp edges to lift the mirror out of the mirror holder. (Also disconnect the heated mirror connector from the back of mirror.)

(1)

GW-00062

4) When installing the mirror, warm the area around the mirror holder with a hair drier until the edges of the mirror holder become soft again (about 2 or 3 minutes with a 1,000 W drier.)

5) Remove the backing of the new double-stick tape, and push the mirror in to install it.

NOTE:

Unless the mirror holder is warmed sufficiently, the mirror holder edges may be damaged or the mirror cracked.

GW-14

Remote Control Mirror Switch

8. Remote Control Mirror

Switch

A: REMOVAL

Refer to Power Window Control Switch, because the remote control mirror switch is integrated with power

window control switch. <Ref. to GW-7, REMOVAL,

Power Window Control Switch.>

B: INSTALLATION

Refer to Power Window Control Switch, because the remote control mirror switch is integrated with power

window control switch. <Ref. to GW-7, INSTALLA-

TION, Power Window Control Switch.>

GLASS/WINDOW/MIRROR

GW-15

Remote Control Mirror Switch

GLASS/WINDOW/MIRROR

C: INSPECTION

Move the rearview mirror switch to each position and check continuity between terminals.

10 9 8

7

6

5 4 3

2 1

Change over switch right position:

Switch position

OFF

UP

DOWN

LEFT

RIGHT

Change over switch left position:

Switch position

OFF

UP

DOWN

LEFT

RIGHT

If NG, replace the switch.

GW-00012

Terminal No.

—

8 and 3, 6 and 7

8 and 6, 3 and 7

8 and 2, 6 and 7

8 and 6, 2 and 7

Terminal No.

—

8 and 4, 6 and 7

8 and 6, 4 and 7

8 and 5, 6 and 7

8 and 6, 5 and 7

Standard

More than 1M

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Standard

More than 1M

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

GW-16

9. Front Door Glass

Front Door Glass

GLASS/WINDOW/MIRROR

7) Remove the rear end of door weather strip and weather strip outer.

A: REMOVAL



2) Remove the front speaker. <Ref. to ET-6, RE-

MOVAL, Front Speaker.>

3) Remove the sealing cover. <Ref. to EB-13, RE-

MOVAL, Front Sealing Cover.>

4) Remove the outer mirror assembly. <Ref. to GW-

12, REMOVAL, Outer Mirror Assembly.>

5) Remove the front end of door weather strip and gusset.

GW-00015

8) Operate the power window switch to move the glass to position shown in the figure, and then remove the three nuts from service holes.

6) Remove the stabilizers.

GW-00013

GW-00017

9) Take out the door glass.

NOTE:

• Do not turn the regulator in closing direction after removal of the glass. Otherwise gear may be disengaged.

• Avoid impact and damage to the glass.

GW-00014

GW-17


GLASS/WINDOW/MIRROR

B: INSTALLATION


CAUTION:

Make sure that the glass stay is placed securely in sash.

2) Adjust the front door glass. <Ref. to GW-18, AD-

JUSTMENT, Front Door Glass.>



tion. <Ref. to GW-3, FRONT DOOR GLASS,

COMPONENT, General Description.> <Ref. to

GW-2, FIXED GLASS, COMPONENT, General

Description.>

C: ADJUSTMENT

NOTE:

Before adjustment, ensure that all adjusting bolts of stabilizer, upper stopper and sash are loose and door glass is raised so that it is in contact with weather strip.

1) Temporarily tighten one adjusting bolt on one side of rear sash at the midpoint of slotted hole in the inner panel.

2) Temporarily tighten the regulator B-channel in a position at the top of slotted hole.

3) Lower the door glass 10 to 15 mm (0.39 to 0.59

in) from fully closed position. While applying outward pressure of 45.0

±5 N (4.6±0.5 kg, 11.0±1.1

lb) (F) to upper edge of glass above midpoint of two outer stabilizers, press the inner stabilizer at pressure of 25

±5 N (2.5±0.5 kg, 5.5±1.1 lb) to the glass, then secure it.

(1) F

(3)

4) For adjustment of clearance between front glass and center pillar cover, loosen the nuts (A), and move the rear sash back and forward until clearance becomes the value shown. (Clearance between upper side and lower side is within 1.5 mm

(0.059 in).)

A A

(A)

(1)

A-A

GW-00019

(1)

GW-00064

(1) 12

±1 mm (0.472±0.039 in)

5) For adjustment of upper and lower ends of center pillar, loosen the adjusting nut (A) of B-channel

(B).

(2)

A A

A = A

(2)

(1) Full close

(2) Stabilizer

(3) 10 — 15 mm (0.39 — 0.59 in)

GW-00063

(B)

(A)

GW-00021

GW-18


6) Adjust so that the upper and lower ends of center pillar are the same size.

GLASS/WINDOW/MIRROR

For preventing wind noise, adjust the glass at the position where tip of gusset is raised up a little.

(3)

(1)

(2)

(5)

(4)

(2)

(1)

(6)

GW-00139

(1) Narrow

(2) Wide

(3) Glass tilts too far rearward

(4) Glass tilts too far forward

(5) Raise B channel

(6) Lower B channel

7) For glass stroke adjustment, close the door, raise glass until positional relationship between glass and weather strip becomes as shown. And secure the glass so that the upper stopper lightly touches the glass holder.

(1)

A

A

(2)

GW-00066

(1) 3.5

±0.8 mm (0.137±0.031 in)

(2) 9.5

±1 mm (0.374±0.039 in)

GW-00024

(A) 0 — 1.5 mm (0 — 0.059 in)

8) After stabilizer adjustment, carry out the glass crimp adjustment. First, visually ensure positional relationship between retainer & molding and glass of the roof side, and then begin with rear sash adjustment. Adjust two adjusting bolts alternately step by step to obtain dimensions shown below (crosssection A).

NOTE:

If two nuts are loosened at the same time, sash moves back and forth. Therefore, when one nut is adjusted, secure the other.

9) Make the same adjustment of two adjusting bolts of rear sash.

(1)

A

A

(2)

GW-00066

(1) 3.5

±0.8 mm (0.137±0.031 in)

(2) 9.5

±1 mm (0.374±0.039 in)

GW-19


GLASS/WINDOW/MIRROR

NOTE:

Do not tilt the sash bracket to inner panel during adjustment. Otherwise smooth regulator operation cannot be achieved.

(1)

(4)

(3)

(2)

(5)

GW-00026

(1) Sash bracket

(2) Rear sash

(3) Adjust a line parallel

(4) Rear sash

(5) Inner panel

10) Make adjustment of front sash in the same manner as that of rear sash.

NOTE:

Although front and rear sashes must, as a rule, be adjusted in the same manner, in some door installation, the adjustment in a different manner may be required. However, adjustment of one sash to the maximum amount and the other to the minimum amount is not permitted. Such adjustment may result in application of excessive load to regulator.

11) After adjustments, tighten the nuts.

12) After adjustment to glass, close the door. If there is a gap between outer lip of gusset and glass surface, adjust the gap with adjusting nut (A) in lower fitting part of the gusset to prevent generation of wind noise.

13) During adjustments, loosen the other three clamping screws.

(A)

GW-00056

14) After adjustment, tighten the bolts and nuts.

GW-20

Front Regulator and Motor Assembly

10.Front Regulator and Motor

Assembly

A: REMOVAL

1) Remove the door glass. <Ref. to GW-17, RE-

MOVAL, Front Door Glass.>

2) Loosen the nuts to remove rear sash.

GLASS/WINDOW/MIRROR

C: INSPECTION

1) Make sure that the power window motor rotates properly when battery voltage is applied to the terminals of motor connector.

2) Change polarity of battery connections to terminals to ensure that the motor rotates in reverse direction.

GW-00027

3) Disconnect the motor connector.

4) Loosen the four bolts and two nuts to remove regulator assembly.

GW-00028

5) Loosen the screw to remove motor assembly.

GW-00029

B: INSTALLATION


2) Adjust the front door glass. <Ref. to GW-18, AD-

JUSTMENT, Front Door Glass.>



tion. <Ref. to GW-3, FRONT DOOR GLASS,


GW-21

Rear Door Glass

GLASS/WINDOW/MIRROR

11.Rear Door Glass

A: REMOVAL

1) Remove the rear door trim. <Ref. to EI-36, RE-

MOVAL, Rear Door Trim.>




MOVAL, Rear Sealing Cover.>

4) Remove the stabilizer.

6) Loosen the two screws to remove the weather strip outer.

5) Remove the door weather strip.

GW-00030

GW-00032

7) Operate the power window switch to remove glass as shown in the figure, and then remove two nuts.

GW-00057

GW-00031

8) Take out the door glass.

CAUTION:

Avoid impact and damage to the glass.

GW-22

B: INSTALLATION


Rear Door Glass

GLASS/WINDOW/MIRROR

2) Adjust the crimp of glass using the following dimensions as a guide line.

CAUTION:

Make sure that the glass stay is placed securely in sash.

2) Adjust the rear door glass. <Ref. to GW-23, AD-

JUSTMENT, Rear Door Glass.>



tion. <Ref. to GW-4, REAR DOOR GLASS,


C: ADJUSTMENT

NOTE:

The rear door glass, as a rule, should be adjusted in the same manner as front glass, although they are different in dimension. Special notes for the rear glass are given below.

1) Adjust the glass position using the following dimensions as a guide line. (Clearance between upper side and lower side is within 1.5 mm (0.059 in).)

A

A

(2)

(1) 3.5

±0.8 mm (0.137±0.031 in)

(2) 9.5

±1 mm (0.374±0.039 in)

(1)

GW-00068

NOTE:

• If the crimp of rear glass is higher than necessary, glass may get caught in weather strip of center pillar corner, resulting in early wear of weather strip. Be careful when adjusting.

• After adjustment, move the glass up and down to check whether it is caught.

(1)

(1)

A A

A-A

GW-00067

(1) 12

±1 mm (0.472±0.039 in)

NOTE:

• If the dimensions are smaller than the given dimensions, glass may get caught in weather strip during lifting/lowering operation. In the worst case, it may cause the glass not to be opened fully.

• After adjustment, move the glass up and down to check whether it is caught.

GW-23

Rear Regulator and Motor Assembly

GLASS/WINDOW/MIRROR

12.Rear Regulator and Motor Assembly

A: REMOVAL

1) Remove the door glass. <Ref. to GW-22, RE-

MOVAL, Rear Door Glass.>

2) Remove the front sash.

3) Disconnect the motor connector.

4) Loosen the four bolts and two nuts to remove regulator assembly.

GW-00035

5) Loosen the screws to remove motor assembly.

GW-00036

B: INSTALLATION


2) Adjust the rear door glass. <Ref. to GW-23, AD-

JUSTMENT, Rear Door Glass.>



tion. <Ref. to GW-4, REAR DOOR GLASS,


C: INSPECTION

1) Make sure that the power window motor rotates properly when battery voltage is applied to the terminals of motor connector.

2) Change polarity of battery connections to the terminals to ensure that the motor rotates in reverse direction.

GW-24

Windshield Glass

13.Windshield Glass

A: REMOVAL

1. USING WINDSHIELD KNIFE


AL, Cowl Panel.>

2) Remove the glass molding.

3) Tape the body side of the circumference of windshield glass for protection.

4) Apply sufficient amount of soapy water to the adhesive layer.

5) Insert the windshield knife into the adhesive layer.

6) While holding the knife edge and windshield glass edge at a right angle, move the windshield knife in parallel to the windshield glass edge along face and edge of windshield glass to cut the adhesive layer.

NOTE:

• Do not twist the windshield knife.

• Cutting of adhesive layer shall be started with wider gap between windshield glass and body.

• Because the matching pins are bonded to corners of glass, use piano wire to cut the pin.

(1)

A

A

(1)

GLASS/WINDOW/MIRROR

(2)

(3)

A-A

GW-00070

(1) Matching pin

(2) Body panel

(3) Glass

2. USING PIANO WIRE


AL, Cowl Panel.>

2) Remove the roof molding and upper front molding.

3) Tape the body side of the circumference of windshield glass for protection.

4) Make a hole in the adhesive layer using a drill or knife.

5) Pass the piano wire through the hole, and attach securely both the wire ends to pieces of wood.

(1)

A-A

(3)

(2)

A

(1)

(4)

(3)

A

GW-00069

(1) Putty knife

(2) Protective tape

(3) Matching pin

(4) Windshield glass knife

GW-00039

6) Pull the wire ends alternately to cut off the adhesive layer.

CAUTION:

• Do not tightly pull the piano wire against the windshield glass edge.

• Be careful not to damage the interior and exterior parts.

• When removal is made with area close to instrument panel, place a protection plate over it.

Pay particular attention to the removal.

• Do not cross piano wires. Otherwise they may be cut.

GW-25


GLASS/WINDOW/MIRROR

B: INSTALLATION

1) Clean the external circumference of windshield glass with alcohol or white gasoline.

2) Remove the adhesive layer on the body using cutter knife to obtain smooth face 2 mm (0.08 in) thick.

CAUTION:

Be careful not to damage the body and paint surface.

4) Apply the dam rubber to back of glass.

(1)

(4)

(3)

(2)

(1)

(3)

(4)

(4)

(2)

(4)

GW-00071

(1) Adhesive

(2) 2 mm (0.08 in)

(3) Dam rubber

(4) Glass

3) Clean the body with alcohol or white gasoline to remove thoroughly chips, dusts and dirts from body face.

GW-00072

(1) Matching pin

(2) Dam rubber

(3) Fastener

(4) 13 mm (0.512 in)

5) Remove the backing of double-faced adhesive tape, and then align the molding mark (B) to notch

(A). Attach the molding around the edge of glass, and then press it evenly to fit.

GW-26

GW-00042


6) Apply primer to the adhesive layer of glass using sponge.

Glass primer:

Dow Automotive

U-401 or U-402

7) Apply primer to the adhesive layer of body.

Painted surface primer:


U-413

NOTE:

• Primer once attached to the painted surface of the body and internal trim is hard to wipe off. Mask the circumference of such areas.

• Let the primer dry for about ten minutes before installing the glass.

• Do not touch the surface coated with primer.

GLASS/WINDOW/MIRROR

9) Apply adhesive to the glass end surface as shown.

Adhesive:


ESSEX U-400 HV

10) Fit the matching pins using suction rubber cup to install the windshield glass.

(2)

(1)

(1) Application of primer

(2) Glass side

(3) Body side

8) Cut off the cartridge nozzle tip and set it in sealant gun as shown.

(1)

(2)

(3)

GW-00073

GW-00045

11) Lightly press the windshield glass for tight fit.

12) Make flush the adhesive surface jutted out using spatula.

13) After completion of all work, allow the vehicle to stand for about 24 hours.

NOTE:

• When the door is opened/closed after glass is bonded, always lower the door glass and then open/close it carefully.

• Move the vehicle slowly.

• For minimum drying time and time the vehicle must be left standing before driving after bonding, follow instructions or instruction manual from the adhesive manufacturer.

14) After curing of adhesive, pour water on external surface of vehicle to check that there are no water leaks.

NOTE:

When a vehicle is returned to the user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days.

15) Install the cowl panel. <Ref. to EI-32, INSTAL-

LATION, Cowl Panel.>

(3)

(4)

GW-00074

(1) 10 — 13 mm (0.39 — 0.51 in)

(2) 13 mm (0.51 in)

(3) 10 mm (0.39 in)

(4) 15 mm (0.59 in)

GW-27

Inner Rearview Mirror

GLASS/WINDOW/MIRROR

14.Inner Rearview Mirror

A: REMOVAL

NOTE:

The spring cannot be reused. Prepare a new spring before removal.

1) Turn the mirror base 90 degrees clockwise or counterclockwise to remove it.

GW-00046

2) Remove the spring from mirror base.

GW-00047

CAUTION:

Be careful not to damage the mirror surface.

3) If the mirror base is damaged, remove the mirror base using piano wire or spatula, etc.

CAUTION:

Be careful not to damage the windshield glass.

B: INSTALLATION

1) If removing the mirror base, remove the remaining adhesive thoroughly, and then fit the mirror base to mark on windshield glass to install.

Adhesive:

REPAIR KIT IN MR (Part No. 65029FC000)

2) Verify that the mirror base is adhered securely, and then install the spring.


C: INSPECTION

1) Check that the mirror is not damaged.

2) Check that the spring is not damaged.

GW-28

15.Rear Gate Glass

Rear Gate Glass

GLASS/WINDOW/MIRROR

2) Install the glass in same procedure as for windshield glass.

A: REMOVAL

1) Remove the rear gate garnish. <Ref. to EB-20,

REMOVAL, Rear Gate Garnish Assembly.>

2) Remove the electrical connector from rear defogger terminal.

3) Remove the glass in same procedure as for wind-

shield glass. <Ref. to GW-25, REMOVAL, Windshield Glass.>

NOTE:

A matching pin is cemented to corners of the glass on the compartment side. Use a piano wire when cutting each pin.

(A)

(B)

(5)

(6)

(4)

(1)

(3)

(2)

(7)

(3)

(2)

(7)

A

(3)

A (2)

(1)

(4)

(5)

(1)

(3)

A-A

GW-00297

(1) Body panel

(2) Glass

(3) Matching pin

B: INSTALLATION

1) Install a new rubber strip (A) by aligning it with the end of the rear gate glass (B).

(9)

(8)

(B)

(A)

GW-00049

GW-00075

A) Upper side

B) Left and right side

(1) Adhesive

(2) Strip rubber

(3) Glass

(4) Primer

(5) 12 mm (0.47 in)

(6) 14 mm (0.55 in)

(7) 10 — 13 mm (0.39 — 0.51 in)

(8) 8 mm (0.31 in)

(9) 12 mm (0.47 in)

3) About one hour after installation, conduct a leak test.


NOTE:




• When a vehicle is returned to the user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days.

5) Connect the rear defogger terminals.

6) Install the rear gate garnish. <Ref. to EB-20, IN-

STALLATION, Rear Gate Garnish Assembly.>

GW-29

Rear Window Defogger System

GLASS/WINDOW/MIRROR

16.Rear Window Defogger System


1. REAR WINDOW DEFOGGER

<Ref. to WI-251, WIRING DIAGRAM, Rear Window Defogger System.>

B: INSPECTION

Symptom

Rear window defogger does not operate.

Repair order

(1) Fuse (M/B No. 1) (F/B No. 17)

(2) Rear defogger relay

(3) Rear defogger timer

(4) Defogger switch

(5) Rear defogger condenser

(6) Defogger wire

(7) Wiring harness

GW-30

Rear Window Defogger

17.Rear Window Defogger

A: INSPECTION

CAUTION:

When wiping stain on glass off with cloth, use a dry and soft cloth and move it in the direction of heat wire extension to avoid damage to heat wire.


2) Turn the defogger switch to ON.

3) Wrap the tips of tester pins with aluminum foil to avoid damage to heat wire.

GLASS/WINDOW/MIRROR

5) Apply positive lead of voltmeter to positive terminal of heat wire, and then move the negative lead along the wire up to negative terminal end. If voltage changes from zero to several volts during movement of lead, heat wire is open at the voltage change point.

B: REPAIR

1) Clean the broken portion with alcohol or white gasoline.

2) Mask both side of wire with thin film.

3) Apply conductive silver composition (DUPONT

No. 4817) to broken portion.

(1)

(4)

(1)

(3)

(2)

GW-00076

(1) Tester probe

(2) Tin foil

(3) Heat wire

(4) PRESS

4) Measure the voltage at wire center with DC voltmeter.

Standard voltage:

Approx. 6 V

(1)

(3)

(2)

(4)

GW-00078

(1) Broken portion

(2) Masking thin film

(3) Broken wire

(4) Conductive silver composition (DUPONT No.

4817)

4) After repair, check the wire.

GW-00077

(1) Center

Voltage

Approx. 6 V

Approx. 12 V or 0 V

Criteria

OK

Broken

NOTE:

• If the measured value is 12 volts, heat wire is open between wire center and positive (+) end.

• If zero volt, heat wire is open between wire center and ground.

GW-31

Rear Quarter Glass

GLASS/WINDOW/MIRROR

18.Rear Quarter Glass

A: REMOVAL

Remove the glass in the same procedure as for windshield glass. <Ref. to GW-25, REMOVAL, Windshield

Glass.>

A

A-A D-D

B

C

(3)

(1)

(2)

(4)

(3)

(4)

(2)

(1)

D

(5)

B-B

(2)

C-C

(6)

(3)

(3)

(2)

(1)

(8)

(7)

(5)

(5)

GW-00054

(1) Molding

(2) Adhesive

(3) Interior trim

(4) Locating pin

(5) Body

(6) Cover C pillar

B: INSTALLATION

1) Cut off the nozzle tip as shown in the figure.

(4)

(5)

(6)

(1)

(3)

(2)

(3)

(1) Molding

(2) Matching pin

(3) Adhesive

(4) 10 mm (0.39 in)

(5) 15 mm (0.59 in)

(6) 10 — 13 mm (0.39 — 0.51 in)

(1)

GW-00079

(7) Weather strip

(8) Rear door glass

2) Install the glass in the same procedure as for wind-

shield glass. <Ref. to GW-26, INSTALLATION,

Windshield Glass.>


NOTE:




4) After curing of adhesive, pour water on external surface of vehicle to check that there are no water leaks.

GW-32

Rear Quarter Glass

NOTE:

When a vehicle is returned to the user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days.

GLASS/WINDOW/MIRROR

GW-33

Roof Window Glass

GLASS/WINDOW/MIRROR

19.Roof Window Glass

A: REMOVAL

<Ref. to SR-5, REMOVAL, Sunroof Lid.>

B: INSTALLATION

<Ref. to SR-5, INSTALLATION, Sunroof Lid.>

C: ADJUSTMENT

<Ref. to SR-5, ADJUSTMENT, Sunroof Lid.>

GW-34

BODY STRUCTURE

BS

Page

1.


2.

Datum Points...............................................................................................3

3.

Datum Dimensions ....................................................................................11


BODY STRUCTURE


A: PREPARATION TOOL

TOOL NAME

Tram tracking gauge

Tape measure

REMARKS

Used for measuring dimension.

Used for measuring dimension.

BS-2

Datum Points

BODY STRUCTURE

2. Datum Points

A: LOCATION

NOTE:

• Datum points are specified for body repair.

• Guide holes, locators, and indents are provided to facilitate panel replacement and to increase alignment accuracy.

• Both right and left reference points are symmetrical.

(35)

(38)

(39)

(40)

(13)

(32)

(30)

(29)

(33)

(36)

(13)

(23)

(34)

(9)

(12)

(10)

(31)

(11)

(6)

(26)

(25)

(7)

(3)

(22)

(21)

(20)

(4)

(5)

(2)

(8)

(2)

(1)

(3)

(4)

(5)

(8) (7)

(14)

(6)

(9)

(12)

(10)

(17)

(15)

(16)

(37)

BS-00001

BS-3

Datum Points

BODY STRUCTURE

(1) Radiator panel gauge hole 6 mm

(0.24 in) dia. (Vehicle center)

(2) Radiator attaching hole 12 mm

(0.47 in) dia.

(3) Headlight attaching hole 7 mm

(0.28 in) dia. (Symmetrical)

(4) Frame plate gauge hole 8 mm


(5) Bumper beam attaching hole 11 mm (0.43 in) dia. (Symmetrical)

(6) Fender attaching hole 7 mm (0.28 in) dia. (Symmetrical)


(8) Power steering tank attaching hole

RH ATF cooler pipe attaching hole

LH 9 mm (0.35 in) dia.

(9) Fender attaching hole 10 mm



(11) Modular bracket gauge hole 8 mm

(0.31 in) dia. (Vehicle center)

(12) Front strut attaching hole 9.5 mm


(13) Front glass attaching hole LH

6.5

×10.5 mm (0.26×0.41 in) RH

6.5

×7 mm (0.26×0.28 in)





(16) Front door hinge attaching hole 12 mm (0.47 in) dia. (Symmetrical)

(17) Front door hinge attaching hole 12 mm (0.47 in) dia. (Symmetrical)

(20) Front door switch attaching hole

4.1 mm (0.16 in) dia. (Symmetrical)

(21) Rear door hinge attaching hole 12 mm (0.47 in) dia. (Symmetrical)

(22) Rear door hinge attaching hole 12 mm (0.47 in) dia. (Symmetrical)

(23) Front weather strip attaching hole


(25) Rear weather strip attaching hole


(26) Rear door switch attaching hole


(29) Trim attaching hole 8.5 mm (0.33 in) dia. (Symmetrical)

(30) Pad attaching hole 5 mm (0.20 in) dia. (Symmetrical)

(31) Harness attaching hole 7 mm



(33) Trim attaching hole 7 mm (0.28 in) dia. (Symmetrical)

(34) Harness attaching hole 7

×7 mm

(0.28

×0.28 in) (Symmetrical)

(35) Tonneau cover bracket attaching hole 5.5 mm (0.22 in) dia. (Symmetrical)

(36) Rear strut attaching hole 10 mm

(0.39 in) (Symmetrical)

(37) Floor mat attaching hole 8 mm

(0.31 in) dia.

(38) Trim attaching hole 9

×9 mm

(0.35

×0.35 in) (Symmetrical)



BS-4

Datum Points

BODY STRUCTURE

(27)

(29)

(18)

(28)

(31)

(44)

(18)

(19)

(44)

(45)

(46)

(47)

(48)

(24)

(45)

(46)

(47)

(43)

(43)

(41)

(42)

(48)

BS-00002

(18) Front weather strip attaching hole




(27) Front pillar gauge hole 12 mm


(28) Insulator attaching hole 8 mm



(31) Harness attaching hole 7 mm


(41) Harness attaching hole 7.5 mm

(0.30 in) dia.

(42) Bumper beam attaching hole 12 mm (0.47 in) dia.

(43) Striker gauge hole 5 mm (0.20 in) dia. (Symmetrical)

(44) Harness attaching hole 7

×7 mm

(0.28

×0.28 in) dia. (Symmetrical)

(45) Combination light attaching hole


(46) Combination light attaching hole 7 mm (0.28 in) dia. (Symmetrical)

(47) Combination light attaching hole

8

×15 mm (0.31×0.59 in) (Symmetrical)

(48) Bumper bracket attaching hole 7 mm (0.28 in) dia. (Symmetrical)

BS-5

Datum Points

BODY STRUCTURE

(52) (53) (54) (65) (12) (55)

(56) (57) (58) (59) (60)

(61) (66)

(36)

(62) (63)

(64)

(51)

(51)

(64)

(52) (53) (54) (65) (12) (55) (56) (57) (58) (59) (60)

(61) (66)

(36)

(62)

(63)

BS-00003

(12) Front strut attaching hole 9.5 mm


(36) Rear strut attaching hole 10 mm


(51) Radiator lower frame gauge hole

12 mm (0.47 in) dia. (Symmetrical)

(52) Side frame gauge hole 20 mm


(53) Sub-frame attaching hole 16 mm


(54) Front cross member attaching hole 12.4 mm (0.49 in) dia. (Symmetrical)

(55) Transverse link attaching hole 17 mm (0.69 in) dia. (Symmetrical)

(56) Transverse link attaching hole 16 mm (0.63 in) dia. (Symmetrical)

(57) Sub-frame attaching hole 16 mm


(58) Transmission cross member attaching hole 14 mm (0.55 in) dia. (Symmetrical)

(59) Rear side frame gauge hole 15 mm (0.59 in) dia. (Symmetrical)

(60) Rear side frame gauge hole 18 mm (0.71 in) dia. (Symmetrical)

(61) Rear differential attaching hole 16 mm (0.63 in) dia. (Symmetrical)

(62) Rear cross member gauge hole


(63) Rear cross member attaching hole


(64) Rear bumper beam attaching hole

RH 15 mm (0.57 in) dia. LH 19

×15 mm (0.75

×0.59 in)

(65) Front cross member attaching hole 12.4 mm (0.49 in) dia. (Symmetrical)

(66) Rear cross member attaching hole


BS-6

Datum Points

BODY STRUCTURE

(2)

(1)

(2)

(3)

(4)

(5)

BS-00005

(9)

(12)

(10)

BS-00004

(8)

(6)

(7)

BS-00006

(13)

(8)

BS-00007

BS-00008

(11)

(16)

(14)

(18)

BS-00009

(19)

(17)

(15)

BS-00010

BS-00011

BS-7

Datum Points

BODY STRUCTURE

(23)

(21)

(20)

(22)

(32)

(33)

BS-00014

(25)

(26)

BS-00016

(29)

(30)

BS-00018

(35)

(36)

BS-00020

(31)

(37)

(34)

(24)

BS-00015

(27)

(28)

BS-00017

BS-00019

BS-00021

BS-8

(38)

(39)

(40)

Datum Points

(41)

BS-00022

(45)

(47)

(55)

(43)

(56)

(58)

(46)

BS-00024

(48)

BS-00026

(57)

BS-00028

BODY STRUCTURE

(42)

BS-00023

(52)

(53)

(51)

(44)

(54) (65)

BS-00025

BS-00027

(59)

(60)

BS-00029

BS-9

BODY STRUCTURE

Datum Points

(63)

(61)

BS-00030

(64)

(66) (62)

BS-00032

BS-00031

BS-10

Datum Dimensions

3. Datum Dimensions

A: MEASUREMENT

Refer to LOCATION for details on measurement

points. <Ref. to BS-3, LOCATION, Datum Points.>

NOTE:

• Using a tram tracking gauge, measure all dimensions.

• When using a tape measure, carefully measure dimensions without letting the tape measure sag or twist.

• Measure the linear dimensions between cores of holes.

• Suffixes “RH” and “LH” indicate right-hand and left-hand.

(1)

BS-00033

(1) Tram tracking gauge

• Measure at the center of the circle around the outside of the body panel.

(1)

(3)

(2)

(1) Datum point

(2) Body panel

(3) Outside

BS-00034

BODY STRUCTURE

BS-11

BODY STRUCTURE

1. CENTER STRUCTURE


(12)

3

(36)

3

1

(51)

(52) (53) (54) (62)

(55) (57)(58) (59)

317(12.48)

9(0.35)

20(0.79) 14(0.55)

485(19.09)

11(0.43)

474(18.66) 329(12.95)

694(27.32)

135(5.31)

356(14.02)

230(9.06)

77(3.03)

1070(42.13)

(61)

585(23.03)

620(24.41)

1270(50.00)

(64)

(53)

(52) (54)

(12)

(55)

(57)

(56)

(59) (60)

(58)

(61)

(36)

(62)

(63)

(64)

2

1

(51)

(52)

(53)

(54)

(12)

(56)

(55)

(57)

(58)

(59) (60)

(61)

(62)

(63)

(36)

(64)

*1: Standard line

*2: Side sill

*3: Upper surface

Unit: mm (in)

(53)

(52) (54)

1124(44.25)

1005(39.57)

1209(47.60)

924(36.38)

917(36.10)

878(34.57)

(57)

(53) (55)

(59) (60)

1438(56.61)

1332(52.44)

(61)

1207(47.52)

(62)

1205(47.44)

(64)

BS-00035

BS-12

2. SUSPENSION CROSSMEMBER


BODY STRUCTURE

1

(54) (65)

206(8.11) 139(5.47) 2547(100.28)

(66)

(62)

(63)

75(2.95)

150(5.91)

2

1

(62)

(66)

(63)

(66)

(63)

(62)

*1: Standard line

*2: Side sill

Unit: mm (in)

(54)

(65)

(65)

(54)

BS-00036

BS-13


BODY STRUCTURE

3. FRONT STRUCTURE

(13)

(6)

(9)

(10)

(12)

(13)

(5)

(4)

Point to point

(1) to (11)

(2) RH to (11)

(2) LH to (11)

(3) RH to (3) LH

(4) RH to (4) LH

(5) RH to (5) LH

(6) RH to (6) LH

(6) RH to (9) RH

(6) LH to (9) LH

(6) RH to (11)

(6) LH to (11)

(7) RH to (14) RH

(7) LH to (14) LH

(7) RH to (15) RH

(3)

(3)

(5)

(4)

(2)

(8)

(1)

(2)

(8)

(7)

(11)

(12)

(9)

(6)

(10)

(14)

(15)

Dimension

822 (32.36)

842 (33.15)

875 (34.45)

716 (28.19)

978 (38.50)

1,049 (41.30)

1,341 (52.80)

349 (13.74)

349 (13.74)

944 (37.17)

944 (37.17)

1,155 (45.47)

1,155 (45.47)

1,067 (42.01)

Unit: mm (in)

Point to point

(7) LH to (15) LH

(8) RH to (8) LH

(9) RH to (9) LH

(9) RH to (10) RH

(9) LH to (10) LH

(9) RH to (11)

(9) LH to (11)

(10) RH to (11)

(10) LH to (11)

(10) RH to (13) RH

(10) LH to (13) LH

(11) to (12) RH

(11) to (12) LH

(12) RH to (12) LH

Dimension

1,067 (42.01)

921 (36.26)

1,396 (54.96)

398 (15.67)

398 (15.67)

767 (30.20)

767 (30.20)

722 (28.43)

722 (28.43)

907 (35.71)

907 (35.71)

565 (22.24)

565 (22.24)

1,065 (41.93)

BS-00037

BS-14

Point to point

(16) RH to (20) RH

(16) LH to (20) LH

(17) RH to (20) RH

(17) LH to (20) LH

(21) RH to (25) RH

(21) LH to (25) LH

(22) RH to (26) RH

(22) LH to (26) LH

(23) LH to (23) RH

(29) RH to (32) RH

(29) LH to (32) LH

(30) RH to (33) RH


(29)

(30)

(32)

(35)

(33)

(36)

(38)

(39)

(40)

(34)

(31)

(16)

(37) (23)

(21)

(20)

(22)

(17)

(25)

(36)

(26)

BODY STRUCTURE

Dimension

980 (38.58)

980 (38.58)

982 (38.66)

982 (38.66)

853 (33.58)

853 (33.58)

895 (35.24)

895 (35.24)

1,429 (56.26)

674 (26.54)

674 (26.54)

796 (31.34)

Unit: mm (in)

Point to point

(30) LH to (33) LH

(31) RH to (34) RH

(31) LH to (34) LH

(35) RH to (38) RH

(35) LH to (38) LH

(35) RH to (39) RH

(35) LH to (39) LH

(35) RH to (40) RH

(35) LH to (40) LH

(36) LH to (36) RH

(36) RH to (37) RH

(36) LH to (37) LH

Dimension

796 (31.34)

759 (29.88)

759 (29.88)

665 (26.18)

665 (26.18)

711 (27.99)

711 (27.99)

784 (30.87)

784 (30.87)

1,221 (48.07)

1,067 (42.01)

1,067 (42.01)

BS-00038

BS-15


BODY STRUCTURE

4. REAR STRUCTURE

Point to point

(18) RH to (18) LH

(19) RH to (19) LH

(27) RH to (29) RH

(27) LH to (29) LH

(28) RH to (31) RH

(28) LH to (31) LH

(24) RH to (24) LH

(41) RH to (41) LH

(18)

(19)

(18)

(27)

(19)

(28)

(29)

(44)

(24)

(31)

(44)

(24)

(41)

Dimension

1,449 (57.05)

1,459 (57.44)

1,007 (39.65)

1,007 (39.65)

813 (32.01)

813 (32.01)

1,438 (56.61)

950 (37.40)

Unit: mm (in)

Point to point

(41) RH to (43) RH

(41) LH to (43) LH

(42) RH to (42) LH

(44) RH to (44) LH

(45) RH to (45) LH

(46) RH to (46) LH

(47) RH to (47) LH

(48) RH to (48) LH

(42)

(46)

(45)

(47)

(48)

(46)

(45)

(47)

(48)

Dimension

794 (31.26)

805 (31.69)

1,110 (43.70)

878 (34.57)

1,474 (58.03)

1,252 (49.29)

1,552 (61.10)

1,210 (47.64)

BS-00039

BS-16

INSTRUMENTATION/DRIVER INFO

IDI

Page

1.


2.

Combination Meter System .........................................................................3

3.

Combination Meter Assembly ...................................................................10

4.

Speedometer.............................................................................................13

5.

Tachometer ...............................................................................................14

6.

Fuel Gauge ...............................................................................................15

7.

Water Temperature Gauge .......................................................................16

8.

Ambient Sensor.........................................................................................17


INSTRUMENTATION/DRIVER INFO



Combination meter

Speedometer

Temperature gauge

Fuel gauge

Tachometer

Turn signal indicator light

Charge indicator light

Oil pressure indicator light

ABS warning light

Malfunction indicator light

HI-beam indicator light

Door open warning light

Seat belt warning light

Brake fluid and parking brake warning light

FWD indicator light

AIRBAG warning light

Meter illumination light

AT OIL TEMP. warning light

LO indicator light

HOLD indicator light

Immobilizer indicator light

Rear differential oil temperature warning light

Cruise indicator light

Rear fog light indicator light

POWER indicator light

Low fuel warning light

AT select lever position indicator light

LCD back light

Electric pulse type

Cross coil type

Cross coil type

Electric pulse type

14 V — 2 W

14 V — 1.4 W

LED

14 V — 1.4 W

LED

14 V — 2 W

LED

LED

14 V — 2 W

LED

LED

14 V — 3.4 W, 14 V — 2 W

LED

LED

LED

LED

14 V — 2 W

14 V — 1.4 W

14 V — 2 W

14 V — 1.4 W

LED

14 V — 100 mA

14 V — 1.4 W

B: CAUTION

• Be careful not to damage meters and instrument panel.

• Be careful not to damage meter glasses.

• Make sure that electrical connector is connected securely.

• After installation, make sure that each meter operates normally.

• Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces.

• Do not apply excessive force to the printed circuit.

• Do not drop or otherwise apply impact.


1. GENERAL TOOL

Circuit tester

TOOL NAME REMARKS


IDI-2

Combination Meter System


2. Combination Meter System


1. COMBINATION METER

<Ref. to WI-106, WIRING DIAGRAM, Combination Meter.>

2. OUTSIDE TEMPERATURE INDICATOR

<Ref. to WI-236, WIRING DIAGRAM, Outside Temperature Display System.>

IDI-3



B: INSPECTION

CAUTION:

When measuring voltage and resistance of the ECM, TCM, or each sensor, use a tapered pin with a diameter of less than 0.64 mm (0.025 in) in order to avoid poor contact. Do not insert the pin more than 2 mm (0.08 in).

1. SYMPTOM CHART

Symptom

Combination meter assembly does not operate.

Speedometer does not operate.

Tachometer does not operate.

Fuel gauge does not operate.

Water temperature gauge does not operate.

Outside temperature indicator does not operate.

(1) Power supply

(2) Ground circuit

Repair order

(1) (MT model) Vehicle speed sensor

(AT model) TCM

(2) Harness

(3) Speedometer

(1) ECM

(2) Harness

(3) Tachometer

(1) Fuel level sensor

(2) Harness

(3) Fuel gauge

(1) Engine coolant temperature sensor

(2) Harness

(3) Water temperature gauge

(1) Ambient sensor

(2) Harness

(3) Combination meter

Reference

<Ref. to IDI-5, CHECK

POWER SUPPLY AND

GROUND CIRCUIT,

INSPECTION, Combination Meter System.>

MT model: <Ref. to IDI-

5, CHECK VEHICLE

SPEED SENSOR,


AT model: <Ref. to IDI-

6, CHECK TRANSMIS-

SION CONTROL MOD-

ULE (TCM),



ENGINE CONTROL

MODULE (ECM),



FUEL LEVEL SEN-

SOR, INSPECTION,

Combination Meter

System.>


ENGINE COOLANT

TEMPERATURE SEN-

SOR, INSPECTION,

Combination Meter

System.>


OUTSIDE TEMPERA-

TURE INDICATOR,


IDI-4



2. CHECK POWER SUPPLY AND GROUND CIRCUIT

1

2

3

Step Check Yes

CHECK POWER SUPPLY FOR COMBINA-

TION METER.

1) Remove the combination meter. <Ref. to

IDI-10, REMOVAL, Combination Meter

Assembly.>

2) Disconnect the combination meter harness connector.


4) Measure the voltage between combination meter connector and chassis ground.



−

):



CHECK POWER SUPPLY FOR COMBINA-

TION METER.

Measure the voltage between combination meter connector and chassis ground.



−

):

CHECK GROUND CIRCUIT OF COMBINA-

TION METER.


2) Measure the resistance of harness between combination meter connector and chassis ground.




Ω?


No

Check the harness for open or short between ignition switch and combination meter.

Check the harness for open or short between fuse and combination meter.

Repair the wiring harness.

3. CHECK VEHICLE SPEED SENSOR

1

2

Step

CHECK VEHICLE SPEED SENSOR.

1) Lift-up the vehicle and support it with rigid racks.

2) Remove the combination meter with harness connector.

3) Drive the vehicle at a speed greater than 20 km/h (12 MPH).

Check Yes

Is the voltage 1 V

← → 5 V?

Check the speed-

ometer. <Ref. to

IDI-13, INSPEC-

TION, Speedometer.>

Warning:

Be careful not to get caught in the running wheels.

4) Measure the voltage between combination meter connector and chassis ground.



−

):

CHECK VEHICLE SPEED SENSOR POWER

SUPPLY.


2) Disconnect the vehicle speed sensor harness connector.


4) Measure the voltage between vehicle speed sensor connector and engine ground.


(B17) No. 3 (+) — Engine ground (

−

):


No

Go to step 2.

Check the harness for open or short between ignition switch and vehicle speed sensor.

IDI-5



3

4

Step


SPEED SENSOR AND ENGINE GROUND.


2) Measure the resistance between vehicle speed sensor connector and engine ground.


(B17) No. 2 — Engine ground:


Ω?

Check


SPEED SENSOR AND COMBINATION

METER.

1) Disconnect the connector from combination meter.

2) Measure the resistance between vehicle speed sensor harness connector and combination meter harness connector.


(B17) No. 1 — (i10) No. 12:


Ω?

Yes

Go to step 4.

Replace the vehicle speed sensor.

No



4. CHECK TRANSMISSION CONTROL MODULE (TCM)

1

2

Step

CHECK TCM SIGNAL.

1) Lift-up the vehicle and support it with rigid racks.

2) Drive the vehicle faster than 10 km/h (6

MPH).

Check Yes

Is the voltage 1 V

← → 5 V?

Go to step 2.

Warning:

Be careful not to get caught in the running wheels.

3) Measure the voltage between TCM connector and chassis ground.



−

):

CHECK HARNESS BETWEEN TCM AND



2) Disconnect the connector from TCM and combination meter.

3) Measure the resistance between TCM harness connector and combination meter harness connector.


(B56) No. 17 — (i10) No. 12:


Ω?

No

Check TCM. <Ref. to 4AT(H4SO)-2,

Basic Diagnostic

Procedure.>

Check the speedo

meter. <Ref. to IDI-

13, INSPECTION,

Speedometer.>


IDI-6



5. CHECK ENGINE CONTROL MODULE (ECM)

1

2

Step

CHECK ECM SIGNAL.

1) Start the engine.

2) Measure the voltage between ECM connector and engine ground.




−

):

Turbo model


−

):

Check Yes

Is the voltage 0 V

← → 14 V? Go to step 2.

CHECK HARNESS BETWEEN COMBINA-

TION METER AND ECM.


2) Disconnect the connector from ECM and combination meter.

3) Measure the resistance between ECM harness connector and combination meter harness connector.



(B134) No. 10 — (i10) No. 11:

Turbo model

(B134) No. 23 — (i10) No. 11:


Ω?

No

Check ECM. <Ref. to EN(H4SO)-2,

Basic Diagnostics

Procedure.> <Ref. to EN(H4DOTC)-2,

Basic Diagnostics

Procedure.>

Check the tachom-

eter. <Ref. to IDI-

14, INSPECTION,

Tachometer.>


6. CHECK FUEL LEVEL SENSOR

1

2

3

Step

Is the resistance 0.5 to 2.5

Ω

(FULL) and 50 to 52

Ω

(EMPTY)?

Check

CHECK FUEL LEVEL SENSOR.

1) Remove the fuel level sensor. <Ref. to

FU(H4SO)-57, REMOVAL, Fuel Level Sensor.>

2) Measure the resistance between fuel level sensor terminals when setting the float to

FULL and EMPTY position.

Terminals

No. 3 — No. 5:

CHECK FUEL SUB LEVEL SENSOR.

1) Remove the fuel sub level sensor. <Ref. to

FU(H4SO)-58, REMOVAL, Fuel Sub Level

Sensor.>

2) Measure the resistance between fuel sub level sensor terminals when setting the float to

FULL and EMPTY position.

Terminals

No. 1 — No. 2:

Is the resistance 0.5 to 2.5

Ω

(FULL) and 42 to 44

Ω

(EMPTY)?

CHECK HARNESS BETWEEN FUEL SUB

LEVEL SENSOR AND COMBINATION

METER.


2) Measure the resistance between fuel sub level sensor harness connector terminal and combination meter harness connector terminal.


(R59) No. 1 — (i11) No. 1:


Ω?

Yes

Go to step 2.

Go to step 3.

Go to step 4.

No

Replace the fuel level sensor.

Replace the fuel sub level sensor.


IDI-7



4

5

Step Check

CHECK HARNESS BETWEEN FUEL LEVEL

SENSOR AND FUEL SUB LEVEL SENSOR.

Measure the resistance between fuel level sensor harness connector terminal and fuel sub level sensor harness connector terminal.


(R58) No. 3 — (R59) No. 2:


Ω?

CHECK FUEL LEVEL SENSOR GROUND

CIRCUIT.

Measure the resistance between fuel level sensor harness connector terminal and chassis ground.


(R58) No. 5 — Chassis ground:


Ω?

Yes

Go to step 5.

Check the fuel

gauge. <Ref. to

IDI-15, INSPEC-

TION, Fuel

Gauge.>

No



7. CHECK ENGINE COOLANT TEMPERATURE SENSOR

1

2

3

Step Check

CHECK ENGINE COOLANT TEMPERATURE

SENSOR.

Check the engine coolant temperature sensor.

<Ref. to EN(H4SO)-2, Basic Diagnostics Procedure.>

Is the engine coolant temperature sensor OK?

CHECK HARNESS BETWEEN ENGINE

COOLANT TEMPERATURE SENSOR AND



2) Disconnect the connector from engine coolant temperature sensor and combination meter.

3) Measure the resistance between engine coolant temperature sensor harness connector and combination meter harness connector.


(E8) No. 3 — (i11) No. 10:


Ω?

CHECK WATER TEMPERATURE GAUGE

GROUND CIRCUIT.

Measure the resistance between combination meter harness connector terminal and chassis ground.




Ω?

Yes

Go to step 2.

Go to step 3.

Check the water temperature

gauge. <Ref. to

IDI-16, INSPEC-

TION, Water Temperature Gauge.>

No

Replace the engine coolant temperature sensor.



8. CHECK OUTSIDE TEMPERATURE INDICATOR

1

Step

CHECK POWER SUPPLY FOR AMBIENT

SENSOR.


2) Disconnect the connector from outside temperature sensor.


4) Measure the voltage between outside temperature sensor harness connector terminal and chassis ground.



−

):

Check Yes

Is the voltage more than 4 V?

Go to step 3.

No

Go to step 2.

IDI-8

2

3

4



Step Check

CHECK HARNESS BETWEEN AMBIENT

SENSOR AND COMBINATION METER.



3) Measure the resistance between ambient sensor harness connector terminal and combination meter harness connector terminal.


(F78) No. 1 — (i10) No. 25:

(F78) No. 2 — (i10) No. 24:


Ω?

CHECK AMBIENT SENSOR.

1) Remove the ambient sensor.

2) Check the ambient sensor. <Ref. to IDI-17,

INSPECTION, Ambient Sensor.>

Is the ambient sensor OK?

CHECK OUTSIDE TEMPERATURE INDICA-

TOR.

1) Connect the combination meter harness connector.

2) Connect a resistor (3 k

Ω) between terminals of ambient sensor harness connector.

3) Turn the ignition switch to ON and check the outside temperature indicator display.

Does the outside temperature indicator indicate 25

°C (77°F)?

Yes


Go to step 4.


No

Replace the ambient sensor.

Repair the poor contact of ambient sensor harness connector.


IDI-9


Combination Meter Assembly

3. Combination Meter Assembly

A: REMOVAL


2) Set the tilt steering at lowest position.

3) Remove the screws and detach meter visor.

IDI00001

4) Remove the screws of combination meter and pull out the meter toward you.

IDI00002

5) Disconnect the connector in the upper area of combination meter to remove meter.

CAUTION:

• Be careful not to damage the meter or instrument panel.

• Pay particular attention to avoid damaging the meter glass.

B: INSTALLATION


CAUTION:

• Make sure that electrical connector is connected securely.

• Make sure that each meter operates normally.

IDI-10



C: DISASSEMBLY

CAUTION:

Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces.

1) Disengage the claw (E) to remove case (B) from back cover (A).

2) Disengage the claw (F) to remove meter glass (D) and reflector (C) from inner case.

(D)

(C)

(E)

(F)

(A)

(B)

IDI00003

3) Pull up the claw (A) in portion (B) of combination meter printed circuit (C) with combination pliers.

Push out the speedometer (D), tachometer (E) and fuel gauge & water temperature gauge assembly

(F) using hole (G).

4) Pull up the claw in center of combination meter printed circuit (C), and remove the printed circuit from case (H).

(I)

(B)

(C)

(H)

(F)

(A)

(D)

(E)

(G)

IDI00123

5) Remove the AT select indicator light (I) from printed circuit (C).

IDI-11



1. BULB REPLACEMENT

(3)

(4)

(5)

(6)

(7) (8) (9)

(10)

(11)

(2)

(12)

(1)

(15)

(13)

(14)

IDI00024

(1) Charge warning

(2) Tachometer

(3) Speedometer and tachometer

(4) Rear fog light indicator light

(5) HI-beam indicator

(6) Turn signal indicator RH

(7) Speedometer

(8) Turn signal indicator LH

(9) Cruise indicator light or rear differential oil temperature warning light

(10) Brake warning

(11) ABS warning

(12) AT power mode indicator light

(13) Fuel gauge

(14) Temperature gauge

(15) LCD (Outside temperature indicator, Odometer and tripmeter)

D: ASSEMBLY

Assemble in the reverse order of disassembly.

IDI-12

Speedometer

4. Speedometer

A: REMOVAL

Disassemble the combination meter, and then re-

move the speedometer. <Ref. to IDI-11, DISAS-

SEMBLY, Combination Meter Assembly.>

B: INSTALLATION


C: INSPECTION

Measure the speedometer resistance.


(1)

(2)

(3)

(4)

IDI00006

(1) COS

−

(2) COS+

(3) SIN

−

(4) SIN+

Terminal

Terminals SIN + and SIN

−

Terminals COS + and COS

−

Resistance

200

±8 Ω

200

±8 Ω

If NG, replace the speedometer.

If OK, replace the combination meter printed circuit.

IDI-13

Tachometer


5. Tachometer

A: REMOVAL

Disassemble the combination meter, and then re-

move the tachometer. <Ref. to IDI-11, DISASSEM-

BLY, Combination Meter Assembly.>

B: INSTALLATION


C: INSPECTION

Measure the tachometer resistance.

(1)

(2)

(3)

(4)

IDI00006

(1) COS

−

(2) COS+

(3) SIN

−

(4) SIN+

Terminal

Terminals SIN + and SIN

−

Terminals COS + and COS

−

Resistance

200

±8 Ω

200

±8 Ω

If NG, replace the tachometer.


IDI-14

Fuel Gauge

6. Fuel Gauge

A: REMOVAL

Disassemble the combination meter, and then remove the water temperature gauge and fuel gauge assem-

bly. <Ref. to IDI-11, DISASSEMBLY, Combination

Meter Assembly.>

B: INSTALLATION


C: INSPECTION

Measure the fuel gauge resistance.

(2)

(3)

(1)

IDI00007

(1) UNIT

(2) IGN

(3) GND

Terminal

Terminals IGN and GND

Terminals IGN and UNIT

Terminals UNIT and GND

Resistance

170

±10 Ω

35

±10 Ω

136

±10 Ω

If NG, replace the water temperature gauge and fuel gauge assembly.



IDI-15


Water Temperature Gauge

7. Water Temperature Gauge

A: REMOVAL

Disassemble the combination meter, and then remove the water temperature gauge and fuel gauge assem-

bly. <Ref. to IDI-11, DISASSEMBLY, Combination

Meter Assembly.>

B: INSTALLATION


C: INSPECTION

Measure the water temperature gauge resistance.

(1)

(3)

(2)

IDI00023

(1) GND

(2) IGN

(3) UNIT

Terminal

Terminals IGN and GND

Terminals IGN and UNIT

Terminals UNIT and GND

Resistance

208

±10 Ω

56

±10 Ω

264

±10 Ω

If NG, replace the water temperature gauge & fuel gauge assembly.


IDI-16

Ambient Sensor

8. Ambient Sensor

A: REMOVAL


2) Disconnect the ambient sensor connector.

3) Remove the ambient sensor (A) from radiator lower panel.

(A)


B: INSTALLATION


C: INSPECTION

Measure the ambient sensor resistance.

IDI00008

2 1

IDI-00009

Terminal

1 and 2

Resistance

3 k

Ω/25°C (77°F)

If NG, replace the ambient sensor.

IDI-17


Ambient Sensor

IDI-18

SEAT

SE

Page

1.


2.

Front Seat ...................................................................................................6

3.

Rear Seat ..................................................................................................13

SEAT


A: COMPONENT

1. FRONT SEAT


(5)

T3

(4)

(3)

(1)

(2)

(6)

(7)

T5

(8)

(9)

T2

(12)

T2

(11)

(10)

T7

(13)

(14)

T3

(22)

(20)

(15)

(16)

T4

(28)

(21)

T6

(19)

(18)

(17)

T7

(26)

(27)

(23)

(24)

T1

(25)

SE-00254

SE-2

(1) Backrest cover

(2) Backrest pad

(3) Backrest side cover

(4) Armrest ASSY

(5) Hinge cover cap

(6) Seat hinge outer cover LH

(7) Seat hinge inner cover LH

(8) Bolt cover LH

(9) Seat cushion cover

(10) Seat cushion pad ASSY

(11) Seat cushion frame ASSY

(12) Inner belt

(13) Inner slide rail


(14) Connecting wire

(15) Outer slide rail

(16)

TORX

®

bolt

(17) Bolt cover RH

(18) Reclining lever

(19) Seat hinge outer cover RH

(20) Seat lifter dial

(21) Seat hinge inner cover RH

(22) Seat heater unit

(23) Side airbag module ASSY

(24) Support pad (A)

(25) Support pad (B)

(26) Headrest ASSY

SEAT

(27) Headrest lock bushing

(28) Backrest frame ASSY


T1: 5.9 (0.6, 4.4)

T2: 10 (1.0, 7.4)

T3: 17.7 (1.8, 13.0)

T4: 20 (2.0, 14.8)

T5: 30 (3.0, 22.1)

T6: 52 (5.3, 38.3)

T7: 53 (5.4, 39.0)

SE-3


SEAT

2. REAR SEAT

(1)

(2)

(6)

T1

T2

Webbing guide cap

Webbing guide

(3) Center pillow

(4) Headrest free bushing

(5) Backrest cover RH

Backrest frame RH

(7) Backrest pad

(6)

(9)

(8)

(2)

(1)

(4)

(3)

(12)

(5)

(7)

T2

(4)

(13)

(14)

T2

(8) Seat cushion cover

(9) Seat cushion pad

(10) Hinge CTR

(11) Hinge LH

(12) Headrest

(13) Rear backrest knob

(14) Striker

(10)

T1

(16)

(17)

(15)

T2

(11)

T2

SE-00253

(15) Backrest cover LH

(16) Backrest frame LH

(17) Backrest pad LH


T1: 24.5 (2.5, 18.1)

T2: 33 (3.3, 24.6)

SE-4


SEAT

B: CAUTION

When removing the front seat from a side airbag loaded vehicle, follow cautions given in the airbag section.


1. GENERAL TOOL

Long nose pliers

Hog ring pliers

TORX

®

TOOL NAME REMARKS

Used for removing hog ring.

Used for installing hog ring.

Used for removing and installing slide rail.

SE-5

Front Seat

SEAT

2. Front Seat

A: REMOVAL


WARNING:

The airbag system is fitted with a backup power source. If the airbag system is serviced within 20 seconds after the ground cable is disconnected, it may inflate.

2) While pressing the headrest lock button, remove the headrest.

8) Remove the two bolts at front side of seat rail.

SE-00006

9) Disconnect the side airbag connector under seat.

• Side airbag connector

• Seat belt warning light connector (Driver’s seat)

• Seat heater connector (Model with seat heater)

SE-00003

3) Tilt forward the backrest.

4) Move the seat to full front end.

5) Remove the bolt cover at rear end of slide rail.

SE-00048

6) Remove the two bolts at rear side of seat rail.

SE-00050

10) Remove the front seat from the vehicle.

B: INSTALLATION




tion. <Ref. to SE-2, FRONT SEAT, COMPO-


C: DISASSEMBLY

1. DRIVER’S SEAT

1) Remove the seat from the vehicle. <Ref. to SE-

6, REMOVAL, Front Seat.>

2) Remove the reclining lever and reclining hinge cover.

7) Move the seat to full rear end.

SE-00049

SE-00040

SE-6

Front Seat

3) Loosen the screw, and then remove the hinge cover.

SEAT

6) Remove the hook at bottom of seat backrest.

SE-00042

4) Remove two reclining hinge securing bolts on each side.

7) Open the zipper behind backrest.

SE-00051

SE-00044

5) Remove the cover (A), and then loosen the nuts to remove arm rest and arm rest guide plate.

(A)

SE-00058

SE-7

SE-00262

8) Remove the hog rings (A) at side of inside backrest from backrest frame. (Side airbag equipped seat)

(A)

(A)

SE-00246

Front Seat

SEAT

9) Remove the hog rings (A) which secure the backrest cover and backrest pad.

14) Remove the connecting wire (A), and then loosen the bolts and nuts to remove slide rail.

(A)

SE-00242

10) Remove the headrest bushes.

NOTE:

Push the headrest bushes to outside of seat from inside, and then remove them.

(A)

15) Remove the inner belt.

SE-00295

SE-00243

11) Pull out the backrest frame.

12) Remove the hog rings (A) at bottom of seat back.

(A)

SE-00244

13) Remove the hog rings (A) at front of seat back, and then remove the seat back cover from seat back.

(A)

SE-00297

16) Remove the hook (A), and then remove the seat cushion frame.

(A)

SE-00268

SE-00378

SE-8

Front Seat

17) Remove the hog rings (A), and then remove the seat cushion cover from seat cushion pad.

SEAT

4) Remove two bolts from the reclining hinge on each side.

: (A)

SE-00299

18) Open the zipper at bottom of headrest, and then remove the headrest cover from headrest.

SE-00271

2. PASSENGER’S SEAT

1) Remove the seat from vehicle. <Ref. to SE-6,

REMOVAL, Front Seat.>

2) Remove the reclining lever cover and hinge cover.

SE-00043

5) Remove the cover (A), and then loosen the nuts to remove arm rest and arm rest guide plate.

(A)

SE-00058

6) Remove the hook at bottom of seat back rest.

SE-00379

3) Loosen the screw, and then remove the hinge cover.

SE-00051

SE-00041

SE-9

SEAT

7) Open the zipper behind backrest.

Front Seat

10) Remove the headrest bushes.

NOTE:

Push the headrest bushes to outside of seat from inside, and then remove them.

SE-00262

8) Remove the hog rings (A) at side of inside backrest from backrest frame. (Side airbag equipped seat)

(A)

SE-00243

11) Pull out the backrest frame.

12) Remove the hog rings (A) at bottom of seat back. (Side airbag equipped seat)

(A)

SE-00241

9) Remove the hog rings (A) which secure the backrest cover and backrest pad.

(A)

(A)

SE-00244

13) Remove the hog rings (A) at front of seat back, and then remove the seat back cover from seat back.

(A)

SE-00245

SE-00242

SE-10

Front Seat

14) Loosen the bolts and nuts to remove the seat cushion from slide rail.

SEAT

17) Remove the hog rings (A), and then remove the seat cushion cover from seat cushion pad.

: (A)

SE-00299

18) Open the zipper at bottom of headrest, and then remove the headrest cover from headrest.

SE-00306

15) Remove the inner belt.

SE-00307

16) Remove the hooks (A), and then remove the seat cushion frame.

(A)

SE-00271

D: ASSEMBLY

1. DRIVER’S SIDE


2. PASSENGER’S SIDE


CAUTION:

Because it may cause the side airbag to activate incorrectly, observe the following steps to install the side airbag correctly.

• Be careful not to dirty or damage the backrest cover.

• Always use new hog rings.

• Secure the hog ring using hog ring pliers.

• Install the hog ring to its original position, and not to twist or wrinkle the backrest cover.


Refer to “COMPONENT” of “General Descrip-

tion”. <Ref. to SE-2, FRONT SEAT, COMPO-


SE-00268

SE-11

Front Seat

SEAT

E: INSPECTION

Inspect that there is no tear and fray on backrest cover assembly.

NOTE:

When there is tear or fray on the door side of backrest cover assembly, replace the backrest cover assembly with a new one, because there is a possibility that the side airbag will not operate normally.

SE-12

3. Rear Seat

A: REMOVAL

1) Remove the bolts, and then detach the rear seat cushion.

Rear Seat

SEAT

C: DISASSEMBLY


AL, Rear Seat.>

2) Remove the hog rings (A) from around the seat backrest.

SE-00023

2) Remove the headrest.

3) Remove the luggage floor mat.

<Ref. to EI-50, REMOVAL, Luggage Floor Mat.>

4) Fold down the rear seat backrest.

5) Turn over the mat to remove bolts.

: (A)

SE-00154

3) Remove the hog rings (A) on front side of cushion pad, and then remove the cover.

6) Remove the rear seat backrest.

SE-00153

: (A)

SE-00155

4) Remove the hog rings (A) from around the seat cushion.

SE-00025

B: INSTALLATION




tion. <Ref. to SE-4, REAR SEAT, COMPO-


: (A)

SE-00156

5) Remove the hog rings (A), and then remove the cover.

: (A)

SE-00157

SE-13

Rear Seat

SEAT

D: ASSEMBLY


NOTE:

• Do not contaminate or damage the cover.

• While installing the hog rings, prevent the seat from getting wrinkled.

SE-14

SECURITY AND LOCK

SL

Page

1.


2.

Door Lock Control System ..........................................................................9

3.

Keyless Entry System ...............................................................................14

4.

Front Inner Remote ...................................................................................22

5.

Front Outer Handle ...................................................................................23

6.

Front Door Latch Assembly.......................................................................24

7.

Front Door Lock Actuator ..........................................................................25

8.

Rear Inner Remote....................................................................................26

9.

Rear Outer Handle ....................................................................................27

10.

Rear Door Latch Assembly .......................................................................28

11.

Rear Door Lock Actuator...........................................................................29

12.

Rear Gate Outer Handle ...........................................................................30

13.

Rear Gate Latch Assembly .......................................................................31

14.

Rear Gate Latch Lock Actuator.................................................................32

15.

Front Hood Lock Assembly .......................................................................33

16.

Remote Openers.......................................................................................34

17.

Ignition Key Lock.......................................................................................35

18.

Key Lock Cylinder .....................................................................................36

19.

Immobilizer Control Module ......................................................................37

20.

Immobilizer Antenna .................................................................................38

21.

Keyless Entry Control Module...................................................................39

22.

Double Lock Module .................................................................................40

23.

Keyless Transmitter ..................................................................................41

SECURITY AND LOCK


A: COMPONENT

1. DOOR LOCK ASSEMBLY

Without double lock:


T1

(5)

(1)

(3)

(2)

T2

(6)

(3)

T2

(4)

T2

T1

(5)

T3

T3

(1)

(4)

(6)

T2

T2

(7)

(2)

(1) Inner remote ASSY

(2) Inner remote cover

(3) Auto-door lock actuator

(4) Door latch

(5) Striker

(6) Door outer handle

(7) Key cylinder

SL-00288


⋅


T1: 6.4 (0.65, 4.7)

T2: 7.4 (0.75, 5.5)

T3: 17.6 (1.8, 13.0)

SL-2


SECURITY AND LOCK

With double lock:

(6)

T1

(5)

(1)

T2

T2

(2)

(3)

(1)

T2

(6)

(3)

T2

(4)

T2

T1

(5)

T3

T3

(4)

(7)

(8)

(9)

T2

(2)

(1) Inner remote ASSY

(2) Inner remote cover

(3) Auto-door lock actuator

(4) Door latch

(5) Striker

(6) Door outer handle

(7) Key cylinder (switch)

(8) Key cylinder retainer

(9) Key cylinder retainer cover

SL-00289


⋅


T1: 6.4 (0.65, 4.7)

T2: 7.4 (0.75, 5.5)

T3: 17.6 (1.8, 13.0)

SL-3

SECURITY AND LOCK

2. REAR GATE LOCK


(2)

T1

(4)

(1)

T2

(1) Rear gate latch ASSY

(2) Rear gate actuator

T2

(3)

(3) Striker

(4) Rear gate outer handle

SL-00103


⋅


T1: 7.5 (0.75, 5.4)

T2: 25 (2.5, 18.4)

SL-4


3. HOOD LOCK AND REMOTE OPENERS

SECURITY AND LOCK

T1

(4)

T2

(1)

(5)

(3)

(2)

(1) Hood lock ASSY

(2) Lever ASSY

(3) Hood cable ASSY

(4) Pull handle ASSY

(5) Fuel flap cable ASSY

SL-00104


⋅


T1: 7.4 (0.75, 5.4)

T2: 33 (3.4, 24.6)

SL-5

SECURITY AND LOCK

4. IMMOBILIZER SYSTEM

(1)


(2)

(4)

(3)

(1) Antenna

(2) Immobilizer indicator light (LED bulb)

(3) Immobilizer control module (IMM

ECM)

NOTE:

IMM ECM location for RHD model is symmetrically opposite.

(4) Transponder

IM-00004

SL-6

5. KEYLESS ENTRY SYSTEM


(3)

(2)

(1)

SECURITY AND LOCK

(4)

(5)

SL-00055

(1) Double lock module (with double lock)

(3) Rear gate latch switch

(4) Keyless entry control module

(RHD model)

(2) Keyless entry control module

(LHD model)

B: CAUTION

• Before disassembling or reassembling parts, always disconnect the ground cable from battery.

When repairing radio, control module, etc. which are provided with memory functions, record the memory contents before disconnecting the ground cable from battery. Otherwise, these contents are cancelled upon disconnection.

• Reassemble parts in the reverse order of disassembly procedure unless otherwise indicated.

• Adjust parts to specifications contained in this manual if so designated.

• Connect the connectors and hoses securely

during reassembly.

• After reassembly, ensure all functional parts

operate smoothly.

• Airbag system wiring harness is routed near

the electrical parts and switch.

• All airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits.

(5) Door switch

• Be careful not to damage the airbag system wiring harness when servicing the ignition key cylinder.

SL-7


SECURITY AND LOCK


1. SPECIAL TOOL


925580000

DESCRIPTION

PULLER

REMARKS

Used for removing trim clip.

ST-925580000

2. GENERAL TOOL

TOOL NAME

Circuit tester

Drill

REMARKS


Used for replacing ignition key lock.

SL-8

Door Lock Control System

SECURITY AND LOCK

2. Door Lock Control System


1. DOOR LOCK CONTROL

<Ref. to WI-198, WIRING DIAGRAM, Door Lock System.>

B: INSPECTION


ate.

Symptom

The door lock control system does not operate.

The door lock switch does not oper-

A specific door lock actuator does not operate.

The key cylinder lock switch does not operate. (with double lock)

The double lock does not operate.

(with double lock)

1. Check the fuse.

Repair order

2. Check the power supply and ground circuit for keyless entry control module (without double lock) or double lock module (with double lock).

3. Check the door lock switch and the circuit.

4. Check the door lock actuator and the circuit.

Check the door lock switch and the circuit.

Check the door lock actuator and the circuit.

Check the key cylinder lock switch and circuit.

Check the door lock actuator (double lock) and circuit.

Reference

<Ref. to SL-10, CHECK FUSE,

INSPECTION, Door Lock Control

System.>

<Ref. to SL-10, CHECK POWER

SUPPLY AND GROUND CIRCUIT,


System.>

<Ref. to SL-11, CHECK DOOR

LOCK SWITCH AND CIRCUIT,


System.>


LOCK ACTUATOR AND CIRCUIT,


System.>


LOCK SWITCH AND CIRCUIT,


System.>


LOCK ACTUATOR AND CIRCUIT,


System.>

<Ref. to SL-12, CHECK KEY CYL-

INDER LOCK SWITCH AND CIR-

CUIT, INSPECTION, Door Lock

Control System.>


LOCK ACTUATOR (DOUBLE

LOCK) AND CIRCUIT, INSPEC-

TION, Door Lock Control System.>

SL-9


SECURITY AND LOCK

2. CHECK FUSE

1

Step

CHECK FUSE.

Remove and visually check the fuse No. 2 (in the main fuse box).

Check

In the fuse blown out?

Yes

Replace the fuse with a new one.

No

Check the power supply and ground

circuit. <Ref. to

SL-10, CHECK

POWER SUPPLY

AND GROUND

CIRCUIT,

INSPECTION,

Door Lock Control

System.>


1

2

Step

CHECK POWER SUPPLY.

1) Disconnect the keyless entry control module or double lock module harness connector.

2) Measure the voltage between the harness connector terminal and chassis ground.


Without double lock:


−

):

With double lock:


−

):

Check Yes


CHECK GROUND CIRCUIT.

Measure the resistance between the harness connector terminal and chassis ground.



(B176) No. 6, 14 — Chassis ground:




Ω?

No

Check the harness for open circuits or shorts between the keyless entry control module or double lock module and the fuse.

The power supply and ground circuit is OK.

Repair the harness.

SL-10


SECURITY AND LOCK

4. CHECK DOOR LOCK SWITCH AND CIRCUIT

1

2

3

4

Step

CHECK DOOR LOCK SWITCH CIRCUIT.


2) Measure the resistance between the harness connector terminal and chassis ground when moving the door lock switch to LOCK.






CHECK DOOR LOCK SWITCH CIRCUIT.

Measure the resistance between the harness connector terminal and chassis ground when the door lock switch is moved to UNLOCK.






CHECK DOOR LOCK SWITCH.

1) Disconnect the door lock switch harness connector.

2) Measure the resistance between the door lock switch terminals when moving the door lock switch to LOCK.


LHD model:

(D7) No. 5 — No. 9

RHD model:

(D7) No. 15 — Switch ground:


Ω?

Check


Ω?


Ω?

CHECK DOOR LOCK SWITCH.

Measure the resistance between the door lock switch terminals when moving the door lock switch to UNLOCK.


LHD model:

(D7) No. 5 — No. 8

RHD model:

(D7) No. 16 — Switch ground:


Ω?

Yes

Go to step 2.

The door lock switch is OK.

Go to step 4.

No

Go to step 3.

Go to step 3.

Replace the door lock switch.

Check the harness for open circuits or shorts between the keyless entry control module or double lock module and the door lock switch.

Replace the door lock switch.

SL-11


SECURITY AND LOCK

5. CHECK DOOR LOCK ACTUATOR AND CIRCUIT

1

2

3

Step Check Yes

CHECK OUTPUT SIGNAL.

Measure the voltage between the harness connector terminal of keyless entry control module or double lock module and chassis ground when moving the door lock switch to LOCK.




−

):



−

):


No

Replace the keyless entry control module or double lock module.


Measure the voltage between the harness connector terminal of keyless entry control module or double lock module and chassis ground when moving the door lock switch to UNLOCK.




−

):



−

):


Replace the keyless entry control module or double lock module.

CHECK DOOR LOCK ACTUATOR.

Check the door lock actuator.

Front door lock actuator: <Ref. to SL-25, Front

Door Lock Actuator.>

Rear door lock actuator: <Ref. to SL-29, Rear


Rear gate latch lock actuator: <Ref. to SL-32,

Rear Gate Latch Lock Actuator.>

Is the door lock actuator OK?

Check the harness Replace the door for open circuits or shorts between the keyless entry control module or lock actuator.

double lock module and the door lock actuator.

6. CHECK KEY CYLINDER LOCK SWITCH AND CIRCUIT

1

2

Step Check

CHECK KEY CYLINDER LOCK SWITCH CIR-

CUIT.

1) Disconnect the double lock module harness connector.

2) Measure the resistance between harness connector terminal and chassis ground when turning the key cylinder lock switch to lock position.




Ω?

CHECK KEY CYLINDER LOCK SWITCH CIR-

CUIT.

Measure the resistance between harness connector terminal and chassis ground when turning the key cylinder lock switch to unlock position.




Ω?

Yes

Go to step 2.

Key cylinder lock switch is normal.

No

Go to step 3.

Go to step 3.

SL-12


1

2

3

SECURITY AND LOCK

3

4

Step

CHECK KEY CYLINDER LOCK SWITCH.

1) Disconnect the key cylinder lock switch connector.

2) Measure the resistance between key cylinder lock switch terminals when turning the key cylinder lock switch to lock position.

Terminals

No. 1 — No. 2

CHECK KEY CYLINDER LOCK SWITCH.

Measure the resistance between key cylinder lock switch terminals when turning the key cylinder lock switch to unlock position.

Terminals

No. 2 — No. 3

Check


Ω?


Ω?

Yes

Go to step 4.

No

Replace the key cylinder lock switch.

Check the harness for open or short circuits between double lock module and key cylinder lock switch.

Replace the key cylinder lock switch.

7. CHECK DOOR LOCK ACTUATOR (DOUBLE LOCK) AND CIRCUIT



Measure the resistance between double lock module harness connector terminal and chassis ground when turning the key cylinder lock switch to lock position.



−

):


Measure the resistance between double lock module harness connector terminal and chassis ground when turning the key cylinder lock switch to unlock position.



−

):



CHECK DOOR LOCK ACTUATOR.

Check door lock actuator.

Front door lock actuator: <Ref. to SL-25, Front


Rear door lock actuator: <Ref. to SL-29, Rear


Is the door lock actuator normal?

Replace the double lock module.

Replace the double lock module.

Check the harness for open or short circuits between double lock module and door lock actuator.

Replace the door lock actuator.

SL-13

Keyless Entry System

SECURITY AND LOCK

3. Keyless Entry System


<Ref. to WI-200, WIRING DIAGRAM, Keyless Entry System.>

B: ELECTRICAL SPECIFICATION

10

18

9 8

17

7

16

6

15 14

5 4

13

3

12

2 1

11

Content

Key warning switch

Registration connector

Door switch

Power supply

Empty

Empty

Door lock switch (Unlock)

Empty

Door lock switch (Lock)

Room light/Ignition switch illumination

Turn signal light (Left)

Terminal No.

1 (INPUT)

2 (INPUT)

3 (INPUT)

5

6

7

8 (INPUT)

9

10 (INPUT)

11 (OUTPUT)

12 (OUTPUT)

Turn signal light (Right) 13 (OUTPUT)

Ground

Power supply (Hazard light)

Power supply

Door, rear gate lock actuator (Without double lock) or double lock module (With double lock)

Door, rear gate lock actuator (Without double lock) or double lock module (With double lock)

14

15

16

17 (OUTPUT)

18 (OUTPUT)

SL-00036

Measuring condition

Battery voltage is present when inserting the key into ignition switch.

0 V is present when connecting the registration connector.

0 V is present when any door is open.

Battery voltage is constantly present.

—

—

0 V is present when the door lock switch is turned to unlock position.

—

0 V is present when the door lock switch is turned to lock position.

• 0 V is present when pressing the transmitter OPEN button.

• 0 V is present when any door is open.

Battery voltage is present when pressing the transmitter OPEN or LOCK button.

Battery voltage is present when pressing the transmitter OPEN or LOCK button.

0 V is constantly present.



Battery voltage is present when pressing the transmitter OPEN button.

Battery voltage is present when pressing the transmitter LOCK button.

SL-14


SECURITY AND LOCK

C: INSPECTION


operate.

Symptom

None of the functions of keyless entry system operate.

The transmitter cannot be registered.

The door lock or unlock does not

NOTE:

If the door lock control system does not operate when using the door lock switch, check the door lock control

system. <Ref. to SL-9, INSPECTION,

Door Lock Control System.>

The hazard light does not operate.

Repair order

1. Check the transmitter battery.

2. Check the fuse.

3. Check the keyless entry control module power supply and ground circuit.

4. Replace the keyless entry control module.


2. Check the registration connector circuit.

3. Check the door lock switch and circuit.



2. Make sure the registration connector is not connected.

3. Check the key warning switch.

4. Check the door switch.

5. Check output signal to double lock module.

(With double lock)


1. Check the hazard light operation.


Reference

<Ref. to SL-16, CHECK TRANSMIT-

TER BATTERY, INSPECTION, Keyless Entry System.>

<Ref. to SL-16, CHECK FUSE,

INSPECTION, Keyless Entry System.>

<Ref. to SL-17, CHECK POWER

SUPPLY AND GROUND CIRCUIT,


<Ref. to SL-39, Keyless Entry Control

Module.>



<Ref. to SL-17, CHECK REGISTRA-

TION CONNECTOR CIRCUIT,



SWITCH, INSPECTION, Keyless

Entry System.>


Module.>



Make sure the registration connector is not connected because keyless entry system does not operate during the registration connector connected.

<Ref. to SL-19, CHECK KEY WARN-

ING SWITCH, INSPECTION, Keyless

Entry System.>


SWITCH, INSPECTION, Keyless

Entry System.>

<Ref. to SL-21, CHECK OUTPUT

SIGNAL TO DOUBLE LOCK MOD-

ULE, INSPECTION, Keyless Entry

System.>


Module.>

<Ref. to SL-20, CHECK HAZARD

LIGHT OPERATION, INSPECTION,

Keyless Entry System.>


Module.>

SL-15


SECURITY AND LOCK

Symptom

The room light and ignition switch illumination operation does not activate.

Repair order

1. Check the room light operation.

2. Check the ignition switch illumination circuit.


(without double lock)

4. Replace the double lock module. (with double lock)

2. CHECK TRANSMITTER BATTERY

Reference

<Ref. to SL-20, CHECK ROOM

LIGHT OPERATION, INSPECTION,


<Ref. to SL-21, CHECK IGNITION

SWITCH ILLUMINATION CIRCUIT,



Module.>

<Ref. to SL-40, Double Lock Module.>

1

Step Check Yes

CHECK TRANSMITTER BATTERY.

1) Remove the battery from transmitter. <Ref. to SL-41, REMOVAL, Keyless Transmitter.>

2) Check the battery voltage. <Ref. to SL-41,

INSPECTION, Keyless Transmitter.>

NOTE:

If the transmitter battery voltage is 2.5 V or less, the range of transmission becomes very short.

Is the voltage more than 2.5 V? If further inspection is necessary, refer to “SYMP-

TOM CHART”.

<Ref. to SL-15,

SYMPTOM

CHART, INSPEC-

TION, Keyless

Entry System.>

No

Replace the transmitter battery.

3. CHECK FUSE

1

Step Check

CHECK FUSE.

Remove and visually check the fuse No. 2 (in the main fuse box), No. 3 (in the fuse and relay box) and SBF-6 (in the main fuse box)


Yes


No

Check the power supply and ground

circuit. <Ref. to

SL-17, CHECK

POWER SUPPLY

AND GROUND

CIRCUIT,

INSPECTION,


SL-16


SECURITY AND LOCK


1

2

Step


Measure the resistance between harness connector terminal and chassis ground.


(B176) No. 6, No. 14 — Chassis ground:

Check Yes


1) Disconnect the keyless entry control module harness connector.

2) Measure the voltage between harness connector terminal and chassis ground.


(B176) No. 5, No. 16 (+) — Chassis ground (

−

):



Ω?

The power supply and ground circuit are OK.

No

Check the harness for open circuits or shorts between keyless entry control module and fuse.

Repair the harness.

5. CHECK REGISTRATION CONNECTOR CIRCUIT

1

2

Step Check Yes

REGISTRATION CONNECTOR INPUT VOLT-

AGE INSPECTION

1) Disconnect the registration connector.

2) Measure the voltage between keyless entry control module harness connector and chassis ground.



−

):


REGISTRATION CONNECTOR INPUT VOLT-

AGE INSPECTION

1) Connect the registration connector.

2) Measure the voltage between keyless entry control module harness connector and chassis ground.



−

):


Registration connector circuit is

OK.

No

Repair the harness, and (or) connector.

Repair the harness, and (or) connector.

SL-17


SECURITY AND LOCK

6. CHECK DOOR SWITCH

1

2

3

4

Step

CHECK DOOR SWITCH CIRCUIT.

Measure the voltage between keyless entry control module harness connector terminal and chassis ground.

NOTE:

The voltage is not 0 V due to noise, etc.



−

):

CHECK DOOR SWITCH CIRCUIT.

Measure the voltage between keyless entry control module harness connector terminal and chassis ground.



−

):

CHECK DOOR SWITCH.

1) Disconnect the door switch harness connector.

2) Measure the resistance between door switch terminals.

Terminal

Door switch No. 1 — No. 3:

Rear gate latch switch No. 1 — No. 2:

CHECK DOOR SWITCH.

Measure the resistance between door switch terminals.

Terminal

Door switch No. 1 — No. 3:

Rear gate latch switch No. 1 — No. 2:

Check Yes

Is the voltage approx. less than

0 V when any one of the doors or rear gate is opened?

Go to step 2.


M

Ω when the door switch is pressed?

Go to step 4.

No

Go to step 3.

Is the voltage more than 10 V when all doors and rear gate are closed?

The door switch is

OK.

Go to step 3.

Replace the door switch.


Ω when the door switch is released?

Check the harness for open circuits or shorts between keyless entry control module and door switch.

Replace the door switch.

SL-18


SECURITY AND LOCK

7. CHECK KEY WARNING SWITCH

1

2

3

4

5

Step

CHECK FUSE.

Remove and visually check the fuse No. 6 (in the main fuse box).

Check


Yes

Go to step 2.

CHECK KEY WARNING SWITCH CIRCUIT.

1) Disconnect the keyless entry control module harness connector.

2) Insert the key into ignition switch. (LOCK position)




−

):


CHECK KEY WARNING SWITCH CIRCUIT.

1) Remove the key from ignition switch.


Is the voltage approx. less than

0 V?

The key warning switch is OK.

NOTE:

The voltage is not 0 V due to noise, etc.



−

):

CHECK KEY WARNING SWITCH.

1) Disconnect the key warning switch harness connector.

2) Insert the key into ignition switch. (LOCK position)

3) Measure the resistance between key warning switch terminals.

Terminal

No. 1 — No. 2:


Ω?



2) Measure the resistance between key warning switch terminals.

Terminal

No. 1 — No. 2:


M

Ω?

Go to step 5.

No


Go to step 4.

Go to step 4.

Replace the key warning switch.

Check the following:

• Harness for open circuits or shorts between the key warning switch and fuse

• Harness for open circuits and shorts between the keyless entry control module and key warning switch


SL-19


SECURITY AND LOCK

8. CHECK HAZARD LIGHT OPERATION

1

2

Step Check

CHECK HAZARD LIGHT OPERATION.

Make sure the hazard light blinks when hazard switch is turned ON.

Does the hazard light blink?

Yes

Go to step 2.

No

Check the hazard light circuit.



2) Close all doors and rear gate.

3) Measure the voltage between keyless entry control module harness connector terminal and chassis ground when LOCK or OPEN button of transmitter is pressed.


(B176) No. 12, No. 13 (+) — Chassis ground (

−

):

Is the voltage more than 10 V? Check the harness for open or short between keyless entry control module and turn signal lights.

Replace the keyless entry control module.

9. CHECK ROOM LIGHT OPERATION

1

2


CHECK ROOM LIGHT OPERATION.

Make sure the room light illuminates when the room light switch is turned ON.

Does the room light illuminate? Go to step 2.

CHECK HARNESS BETWEEN ROOM LIGHT

AND KEYLESS ENTRY CONTROL MODULE

(WITHOUT DOUBLE LOCK) OR DOUBLE

LOCK MODULE (WITH DOUBLE LOCK).

1) Disconnect the keyless entry control module or double lock module harness connector and room light harness connector.

2) Measure the resistance between keyless entry control module or double lock module harness connector terminal and room light harness connector terminal.



(B176) No. 11 — (R52) No. 2:


(B325) No. 1 — (R52) No. 2:


Ω?

The room light operation circuit is

OK.

Check the room light circuit.

Check the harness for open circuits or shorts between keyless entry control module (Without double lock) or double lock module (With double lock) and room light.

SL-20


SECURITY AND LOCK

10.CHECK IGNITION SWITCH ILLUMINATION CIRCUIT

1

2

Step Check Yes

CHECK IGNITION SWITCH ILLUMINATION

POWER SUPPLY.

1) Disconnect the ignition switch illumination harness connector.

2) Measure the voltage between ignition switch illumination harness connector terminal and chassis ground.



−

):


CHECK HARNESS BETWEEN IGNITION

SWITCH ILLUMINATION AND KEYLESS EN-

TRY CONTROL MODULE (WITHOUT DOU-

BLE LOCK) OR DOUBLE LOCK MODULE

(WITH DOUBLE LOCK).


2) Measure the resistance between keyless entry or double lock module harness connector terminal and ignition switch illumination harness connector.



(B176) No. 11 — (R224) No. 1:


(B325) No. 1 — (R224) No. 2:


Ω?

No

Check the harness for open circuit or shorts between ignition switch illumination and fuse.

Check the ignition switch illumination. If NG, replace the ignition switch illumination.

Repair the harness.

11.CHECK OUTPUT SIGNAL TO DOUBLE LOCK MODULE

1

2

Step


Measure the voltage between the keyless entry control module harness connector terminal and chassis ground when OPEN button of transmitter is pressed.



−

):


Measure the voltage between the keyless entry control module harness connector terminal and chassis ground when LOCK button of transmitter is pressed.



Check Yes


Is the voltage more than 10 V? Replace the double lock module.

No

Replace the keyless entry control module.

Check the harness for open circuit or shorts between the keyless entry control module and double lock module.

SL-21

Front Inner Remote

SECURITY AND LOCK

4. Front Inner Remote

A: REMOVAL





3) Remove a screw and two cables.

4) Remove the front inner remote.

SL-00007

B: INSTALLATION


NOTE:

Make sure the inner remote works properly after installation.

C: INSPECTION

1) Make sure the cable is not deformed.

2) Make sure the lever and cable work smoothly.

NOTE:

If the remote handle is metalclad type, make sure that grease is sufficiently applied to the cable connection portion. If the grease is insufficient, apply additional grease to the cable connection portion before connecting the cable.

SL-22

Front Outer Handle

5. Front Outer Handle

A: REMOVAL



CAUTION:

Do not use excessive force to remove the door panel. This will deform it.



3) Remove the front inner remote. <Ref. to SL-22,

REMOVAL, Front Inner Remote.>

4) Remove the cable from cable holder to make cable move freely.

5) Remove two bolts and rod clamp, and then remove the front outer handle.

NOTE:

The rear bolt can be removed from service hole (A) of inner panel by adjusting the glass position.

(A)

SL-00009

B: INSTALLATION


NOTE:

Make sure the outer handle works properly after installation.

C: INSPECTION


2) Make sure the lever and rod work smoothly.

SECURITY AND LOCK

SL-23

Front Door Latch Assembly

SECURITY AND LOCK

6. Front Door Latch Assembly

A: REMOVAL






4) Remove the front inner remote. <Ref. to SL-22,

REMOVAL, Front Inner Remote.>

5) Remove two bolts and nut, and then remove the guide rail.

B: INSTALLATION


NOTE:

Make sure the lock works properly after installation.

C: INSPECTION


2) Make sure the lever, rod and cable work smoothly.

6) Remove the three screws and bolt.

SL-00008

SL-00010

7) Remove the front door latch assembly, and then disconnect the connector.

SL-24

Front Door Lock Actuator

7. Front Door Lock Actuator

A: REMOVAL

1) Remove the front door latch assembly. <Ref. to

SL-24, REMOVAL, Front Door Latch Assembly.>

2) Loosen the two screws to remove front door lock actuator.

SECURITY AND LOCK

DOOR ACTUATOR RH:

Terminal No.

No. 1 (+) and No. 4 (–)

No. 4 (+) and No. 1 (–)

No. 6 (+) and No. 3 (–)

No. 3 (+) and No. 6 (–)

Actuator operation

Unlocked

→ Locked

Locked

→ Unlocked

Double lock released

→

Double lock set

Double lock set

→ Double lock released

DOOR ACTUATOR LH:

Terminal No.

No. 6 (+) and No. 3 (–)

No. 3 (+) and No. 6 (–)

No. 1 (+) and No. 4 (–)

No. 4 (+) and No. 1 (–)

Actuator operation

Unlocked

→ Locked

Locked

→ Unlocked


→

Double lock set

Double lock set


SL-00011

B: INSTALLATION


NOTE:


C: INSPECTION

1) Disconnect the door lock actuator harness connector.

2) Connect the battery to door lock actuator terminals.

If NG, replace the door lock actuator.

1. Without Double Lock

2

4

1

3

Terminal No.

No. 2 (+) and No. 4 (–)

No. 4 (+) and No. 2 (–)

2. With double lock:

SL-00058

Actuator operation

Unlocked

→ Locked

Locked

→ Unlocked

3

6

2

5

1

4

SL-00059

SL-25

Rear Inner Remote

SECURITY AND LOCK

8. Rear Inner Remote

A: REMOVAL





3) Remove a screw and two cables.

4) Remove the inner remote.

SL-00007

B: INSTALLATION


NOTE:

Make sure the inner remote works properly after installation.

C: INSPECTION



3) Make sure the child safety lock on rear doors work properly, when applicable.

NOTE:

If the remote handle is metalclad type, make sure that grease is sufficiently applied to the cable connection portion. If the grease is insufficient, apply additional grease to the cable connection portion before connecting the cable.

SL-26

Rear Outer Handle

9. Rear Outer Handle

A: REMOVAL



CAUTION:

Do not use excessive force to remove the door panel. This will deform it.



3) Remove the rear inner remote. <Ref. to SL-26,

REMOVAL, Rear Inner Remote.>

4) Remove the rear door latch assembly. <Ref. to

SL-28, REMOVAL, Rear Door Latch Assembly.>

5) Remove two bolts, and then remove the rear outer handle.

SECURITY AND LOCK

SL-00013

B: INSTALLATION


NOTE:


C: INSPECTION

1) Make sure the resinous lever is not deformed, damaged or cracked.

2) Make sure the resinous lever operate smoothly.

SL-27

Rear Door Latch Assembly

SECURITY AND LOCK

10.Rear Door Latch Assembly

A: REMOVAL






4) Remove the rear inner remote. <Ref. to SL-26,

REMOVAL, Rear Inner Remote.>

5) Remove the three screws and bolt.

SL-00014

6) Remove the rear door latch assembly, and then disconnect the connector.

B: INSTALLATION


NOTE:


C: INSPECTION



SL-28

Rear Door Lock Actuator

11.Rear Door Lock Actuator

A: REMOVAL



2) Loosen the two screws to remove rear door lock actuator.

SECURITY AND LOCK

DOOR ACTUATOR RH:

Terminal No.

No. 1 (+) and No. 4 (–)

No. 4 (+) and No. 1 (–)

No. 6 (+) and No. 3 (–)

No. 3 (+) and No. 6 (–)

Actuator operation

Unlocked

→ Locked

Locked

→ Unlocked


→

Double lock set

Double lock set


DOOR ACTUATOR LH:

Terminal No.

No. 6 (+) and No. 3 (–)

No. 3 (+) and No. 6 (–)

No. 1 (+) and No. 4 (–)

No. 4 (+) and No. 1 (–)

Actuator operation

Unlocked

→ Locked

Locked

→ Unlocked


→

Double lock set

Double lock set


SL-00015

B: INSTALLATION


NOTE:


C: INSPECTION



If NG, replace the door lock actuator.

1. Without Double Lock:

2

4

1

3

Terminal No.

No. 2 (+) and No. 4 (–)

No. 4 (+) and No. 2 (–)

2. With double lock:

SL-00058

Actuator operation

Unlocked

→ Locked

Locked

→ Unlocked

3

6

2

5

1

4

SL-00059

SL-29

Rear Gate Outer Handle

SECURITY AND LOCK

12.Rear Gate Outer Handle

A: REMOVAL

1) Remove the rear gate trim. <Ref. to EI-48, RE-

MOVAL, Rear Gate Trim.>

2) Remove the rear wiper motor assembly.

<Ref. to WW-17, REMOVAL, Rear Wiper Motor.>

3) Remove the rear finisher.

4) Remove the cable, and then remove two nuts.

SL-00016

5) Remove the rear gate outer handle.

B: INSTALLATION


NOTE:


C: INSPECTION

1) Inspect the cable for deformation.

2) Make sure the lever and cable move smoothly.

SL-30

Rear Gate Latch Assembly

13.Rear Gate Latch Assembly

A: REMOVAL




3) Remove two bolts.

SECURITY AND LOCK

SL-00017

4) Remove the rear gate latch assembly, and then disconnect the connector.

5) Remove the rear gate outer handle cable, and then remove the rear gate latch assembly.

B: INSTALLATION


NOTE:


C: INSPECTION


2) Make sure the lever, cable, rear gate latch switch and door lock operate smoothly.

SL-31

Rear Gate Latch Lock Actuator

SECURITY AND LOCK

14.Rear Gate Latch Lock Actuator

A: REMOVAL

1) Remove the rear gate latch assembly. <Ref. to

SL-31, REMOVAL, Rear Gate Latch Assembly.>

2) Remove three pawls, and then remove the rear gate latch lock actuator from rear gate latch assembly.

CAUTION:

Do not use excessive force to remove the rear gate latch lock actuator. The pawl surroundings of rear gate latch assembly will be deformed.

SL-00018

B: INSTALLATION


CAUTION:

Be sure to align the lever groove of rear gate latch assembly and actuator lever.

NOTE:


C: INSPECTION



2 1

4 3

2 1

4 3

SL-00012

Terminal No.

No. 4 (+) and No. 2 (–)

No. 2 (+) and No. 4 (–)

Actuator operation

Unlocked

→ Locked

Locked

→ Unlocked

If NG, replace the rear gate latch lock actuator.

SL-32

Front Hood Lock Assembly

15.Front Hood Lock Assembly

A: REMOVAL

1) Open the hood.

2) Remove the front grille.

3) Remove the bolt. Remove the hood lock assembly.

4) Remove the release cable from lock assembly.

SECURITY AND LOCK

SL-00019

B: INSTALLATION


NOTE:

• Apply grease to parts that rub.

• Make sure the release cable works properly after installation.

C: ADJUSTMENT

Loosen the bolt. Adjust the lock assembly while moving it up and down.

SL-00020

D: INSPECTION

1) Check the striker for bending or abnormal wear.

2) Check the safety lever for improper movement.

3) Check other levers and the spring for rust formation and unsmooth movement.

SL-33

Remote Openers

SECURITY AND LOCK

16.Remote Openers

A: REMOVAL

1. HOOD OPENER

1) Remove the front hood lock assembly. <Ref. to

SL-33, REMOVAL, Front Hood Lock Assembly.>

2) Remove the release cable from hood lock.

3) Remove the bolt. Remove the opener lever.

6) Rotate the fuel lock inside the quarter panel to left and remove.

SL-00038

2. FUEL FLAP OPENER


AL, Rear Seat.>

2) Remove the center pillar lower trim and side sill cover. Remove the rear pillar lower trim. Pull back the floor mat.

3) Remove the right rear quarter trim. <Ref. to EI-


Remove the clip holding the cable.

4) Remove the bolt. Remove the opener pull handle.

5) Remove the cable (A) from opener pull handle

(B).

SL-00023

B: INSTALLATION

1. HOOD OPENER


2. FUEL FLAP OPENER


C: INSPECTION

Make sure the fuel flap opens and closes smoothly.

SL-00022

SL-34

Ignition Key Lock

17.Ignition Key Lock

A: REPLACEMENT

1) Remove the ground cable from battery.

2) Remove the steering column. <Ref. to PS-26,

REMOVAL, Tilt Steering Column.>

3) Secure the steering column in a vise. Remove the bolt with a drill.

SECURITY AND LOCK

SL-00024

4) Remove the ignition key lock.

5) Use a new torn bolt. Tighten the torn bolt to end of thread.

SL-00025

B: INSPECTION


2) Remove the lower column cover.

3) Unfasten the holddown clip which secures harness and disconnect the connector of ignition switch from body harness.

4) Turn the ignition key plate to each position and check the continuity between terminals of ignition connector.

Switch position

LOCK

ACC

ON

ST

Terminal No.

—

No. 1 and No. 2

No. 1 and No. 2

No. 1 and No. 4

No. 2 and No. 4

No. 1 and No. 3

No. 1 and No. 4

No. 3 and No. 4

Standard

—

Less than 1

Ω

Less than 1

Ω

Less than 1

Ω

If NG, replace the ignition switch.

SL-35

Key Lock Cylinder

SECURITY AND LOCK

18.Key Lock Cylinder

A: REPLACEMENT

1. FRONT DOOR

• Without double lock:

1) Remove the door trim. <Ref. to EI-35, REMOVAL,

Front Door Trim.>

2) Pull back the sealing cover. <Ref. to EB-13, RE-


3) Close the front door glass completely.

4) Remove the rod clamp (A). Remove the lock plate (B). Replace the key cylinder.

NOTE:

Be sure to replace the lock plate (B) with a new one.

(B)

(A)

SL-00026

• With double lock:

1) Remove the door trim. <Ref. to EI-35, REMOVAL,

Front Door Trim.>



3) Close the front door glass completely.

4) Remove the key cylinder retainer cover, and then remove the rod clamp (A).

CAUTION:

Be sure to replace the key cylinder retainer cover with a new one when removing.

5) Remove the bolt (B) and key cylinder retainer to replace the key cylinder.

(B)

(A)

SL-00060

SL-36

Immobilizer Control Module

19.Immobilizer Control Module

A: REMOVAL

NOTE:

The following positions for removal and installation are for LHD models. The positions for RHD models are symmetrically opposite.




3) Disconnect the connector from immobilizer control module.

4) Remove the immobilizer control module.

SECURITY AND LOCK

B: INSTALLATION


SL-00061

SL-37

Immobilizer Antenna

SECURITY AND LOCK

20.Immobilizer Antenna

A: REMOVAL




3) Remove the screws, separate upper column cover and lower column cover.

SL-00062

4) Disconnect the immobilizer antenna connector (A) from immobilizer control module.

5) Remove the screw, and detach the immobilizer antenna (B).

(A)

(B)

B: INSTALLATION


SL-00063

SL-38

Keyless Entry Control Module

21.Keyless Entry Control Module

A: REMOVAL



AL, Glove Box.>

3) Remove the nut, and then remove the keyless entry control module while disconnecting connector.

SECURITY AND LOCK

B: INSTALLATION


SL-00047

SL-39

Double Lock Module

SECURITY AND LOCK

22.Double Lock Module

A: REMOVAL




3) Remove the nut, then remove the double lock module while disconnecting the connector.

B: INSTALLATION


SL-00064

SL-40

23.Keyless Transmitter

A: REMOVAL

1. TRANSMITTER BATTERY

Remove the battery from transmitter.

NOTE:

To prevent static electricity damage to transmitter printed circuit board, touch the steel area of building with hand to discharge the static electricity carried on body or clothes before disassembling transmitter.

SL-00065

B: INSTALLATION



C: INSPECTION


Measure the voltage between battery (+) terminal and (–) terminal.

NOTE:

• Battery discharge occurs during measurement.

Complete the measurement within 5 seconds.

• During battery voltage measurement, voltage falls more than 1.8 volts in 3 seconds period.

Keyless Transmitter

SECURITY AND LOCK

If NG, replace the battery. (Use CR1620 or equivalent.)

D: REPLACEMENT

1. TRANSMITTER REGISTRATION

NOTE:

• A maximum of three transmitters can be registered for each individual vehicle.

• When replacing the transmitter (key), registration to immobilizer system is also necessary.

1) Remove the side sill cover at driver’s side, then connect the registration connectors at front pillar lower section.

2) Unlock the door lock.

3) Press any button of the transmitter twice while pressing driver’s door lock switch to unlock side to be registered.

4) The door lock will automatically lock and unlock in sequence. This indicates the completion of transmitter registration for first transmitter.

5) If the registration of second and third transmitter is now to be carried out, repeat the procedure 3) and 4).

6) Disconnect the registration connectors after the completion of all registration operations. After confirming the operation of door lock using newly registered transmitter(s), reinstall the side sill cover at driver’s side.

(A)

SL-00066

(A) Resistance 300

Ω

(+)

Tester connection

(–)

Battery (+) terminal

Battery (–) terminal

Standard

2.5 — 3.0 V

SL-41

SECURITY AND LOCK

Keyless Transmitter

SL-42

SUNROOF/T-TOP/CONVERTIBLE TOP

(SUNROOF)

SR

Page

1.


2.

Sunroof Control System ..............................................................................4

3.

Sunroof Lid..................................................................................................5

4.

Sunroof Assembly .......................................................................................6

5.

Sunroof Motor .............................................................................................8

6.

Sunroof Switch ............................................................................................9


SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF)


A: COMPONENT

(1)

(2)

(3)

(12)

(5)

(4)

(13)

(6)

(11)

T

T

(10)

T

T

(7)

(8)

(6)

(9)

(1) Sunroof lid

(2) Rear drain ASSY

(3) Frame ASSY

(4) Motor ASSY

(5) Drive unit

(6) Drain tube

(7) Harness

(8) Sunshade

(9) Garnish

(10) Frame bracket

(11) Cover

(12) Deflector

SR-00013

(13) Shim


T: 7.4 (0.75, 5.4)

SR-2



B: CAUTION

• Before disassembling or reassembling parts, always disconnect battery ground cable. When replacing radio, control module and other parts provided with memory functions, record memory contents before disconnecting the battery ground cable. Otherwise, the memory will be erased.



• Connect connectors and hoses securely during reassembly.



1. GENERAL TOOL

TOOL NAME

Circuit tester

REMARKS


SR-3

Sunroof Control System


2. Sunroof Control System


1. SUNROOF

<Ref. to WI-263, WIRING DIAGRAM, Sunroof System.>

B: INSPECTION

Water leaks.

Booming noise

Symptom

Abnormal motor noise

Failure of sunroof

(Motor operates properly.)

Motor does not rotate or rotates improperly.

Checking order

(1) Check roof panel and sunroof lid for improper or poor sealing.

(2) Check drain tube for clogging.

(3) Check sunroof frame seal and body for improper fit.

(1) Check sunroof lid and roof panel for improper clearance.

(2) Check sunshade and roof trim for improper clearance.

(1) Check motor for looseness.

(2) Check gears and bearings for wear.

(3) Check cables for wear.

(4) Check cable pipe for deformities.

(1) Check guide rail for foreign particles.

(2) Check guide rail for improper installation.

(3) Check parts for mutual interference.

(4) Check cable slider for improper clinching.

(5) Check cable for improper installation.

(6) Check clutch adjusting nut for improper tightness.

(1) Check fuse for blow-out.

(2) Check switch for improper function.

(3) Check motor for incorrect terminal voltage.

(4) Check relay for improper operation.

(5) Check poor grounding system.

(6) Check harness for open or short and terminals for poor connections.

(7) Check limit switch for improper operation.

SR-4

3. Sunroof Lid

Sunroof Lid


A: REMOVAL

1) Completely close sunroof lid and open sunshade.

2) Detach the four covers (A) and then remove eight nuts.

C: ADJUSTMENT

1. ALIGNMENT OF HEIGHT BETWEEN

SUNROOF LID AND ROOF PANEL

Loosen sunroof lid nuts and then adjust height by adding (max: four pieces) or extracting (min: zero piece) shims (standard: two pieces) between sunroof lid and roof panel.

Difference in height between sunroof lid and roof panel

2.0

±

1.0 mm (0.079

±

0.039 in)

(C)

2.0 1.0 mm (0.079 0.039 in)

(B)

3) Carefully remove sunroof lid.

B: INSTALLATION


SR-00002

(A) Shim

(B) Sunroof lid

(C) Roof panel

(A)

SR-00003

SR-5

Sunroof Assembly


4. Sunroof Assembly

A: REMOVAL


2) Remove roof trim. <Ref. to EI-47, REMOVAL,

Roof Trim.>

3) Remove sunroof lid. <Ref. to SR-5, REMOVAL,

Sunroof Lid.>

4) Disconnect the four drain tubes (A) from sunroof frame.

5) Disconnect sunroof harness connector.

6) Remove the bolts, and then remove the frame bracket.

B: INSTALLATION


CAUTION:

Be careful not to snag harness.

NOTE:

• Make sure to connect harness connector.

• When installing drain tube, insert it securely into drain pipe.

Length A:

15 mm (0.59 in) or more

A

SR-00014

7) Remove bolts and nuts and then detach sunroof frame.

SR-00005

C: DISASSEMBLY

1) Remove sunroof frame.

2) Cut the pawl (A) of front sunshade RH.

3) Remove the front slider RH.

(A)

(A)

SR-00015

(A)

SR-00006

4) Pull out the sunshade (B) from sunroof frame.

SR-6

SR-00007

D: ASSEMBLY


Sunroof Assembly


E: INSPECTION

1. CHECK FOR MOVEMENT OF SUN-

SHADE

1) Attach a spring scale to sunshade edge using a cloth.

SR-00008

2) Pull the spring scale to measure force required to move the sunshade.

Force required to move sunshade:

25 N (2.5 kgf, 5.5 lb) or less

NOTE:

Considerable effort is required to start sunshade moving, so take a scale reading while sunroof panel is moving smoothly.

3) If force required exceeds specifications, check the sunroof glass lid, sunshade, deflector, and guide rail assembly for improper installation

SR-7

Sunroof Motor


5. Sunroof Motor

A: REMOVAL

CAUTION:

• Fully close sunroof when removing sunroof motor.

• When removing clip, use great care to not damage the roof trim.

1) Completely close the sunroof.


3) Remove roof trim. <Ref. to EI-47, REMOVAL,

Roof Trim.>

4) Disconnect harness connector (A) and remove sunroof motor mounting screw (B) and nut (C).

(C)

(B)

(A)

(C) SR-00016

B: INSTALLATION

CAUTION:

Be careful not to move the sunroof cable when installing sunroof motor.

1) Install sunroof motor.

2) Connect sunroof motor harness connector and then connect battery ground cable.

3) Reset the sunroof motor. <Ref. to SR-8, AD-

JUSTMENT, Sunroof Motor.>

4) Check sunroof operation with the following procedure.

Checking order

(1) Completely close sunroof.

(2) Open sunroof 500 mm (19.7 in) away from completely closed position.

(3) Completely open sunroof.

(4) Close sunroof 200 mm (7.87 in) from completely closed position.

(5) Completely close sunroof.

Switch position

Closed

Open

Open

Closed

Closed

5) Install the roof trim. <Ref. to EI-47, INSTALLA-

TION, Roof Trim.>

C: ADJUSTMENT

1) Reset the sunroof motor.

(1) Close the sunroof lid completely, and then push the switch to close for more than 1 second.

(At this time, the sunroof operates 50 mm (1.97

in) each intermittently. And also the switch is needed to push for several times.)

(2) Open the sunroof lid approx. 400 mm (15.75

in).

(3) Close the sunroof lid completely, and then push the switch to close for more than 1 second.

(Sunroof operates automatically by performing this operation.)

D: INSPECTION

1. AUTO REVERSE FUNCTION

1) Open the sunroof lid.

2) While the sunroof lid closing automatically, press the switch to open and check if auto reverse function operates properly.

3) Check that the sunroof opens 150 mm (5.91 in) by auto reverse function operated.

CAUTION:

Do not check the auto reverse operation with pinching any object.

NOTE:

• Auto function is canceled if auto reverse function operates more than five times.

• Reset if auto function is canceled. <Ref. to SR-8,

ADJUSTMENT, Sunroof Motor.>

SR-8

Sunroof Switch


6. Sunroof Switch

A: REMOVAL

1) Disconnect ground cable from battery.

2) Remove the spot map light. <Ref. to LI-29, RE-

MOVAL, Spot Map Light.>

3) Disconnect harness connectors and remove sunroof switch (A).

(A)

B: INSTALLATION


C: INSPECTION

SR-00017

5 4 3 2 1

SR-00011

Check continuity between terminals when operating the switch.

Switch

Open

Close

Terminal No.

1 — 3

3 — 4

Standard value

Less than 1

Ω

More than 1 M

Ω

SR-9

Sunroof Switch


SR-10

EXTERIOR/INTERIOR TRIM

EI

Page

1.


2.

Front Grille ................................................................................................18

3.

Hood Grille ................................................................................................19

4.

Front Under Cover ....................................................................................22

5.

Front Bumper ............................................................................................23

6.

Rear Bumper.............................................................................................30

7.

Mud Guard ................................................................................................31

8.

Cowl Panel ................................................................................................32

9.

Side Sill Spoiler .........................................................................................33

10.

Side Garnish .............................................................................................34

11.

Front Door Trim .........................................................................................35

12.

Rear Door Trim .........................................................................................36

13.

Glove Box..................................................................................................37

14.

Roof Rail ...................................................................................................38

15.

Console Box..............................................................................................39

16.

Instrument Panel Assembly ......................................................................40

17.

Upper Inner Trim .......................................................................................43

18.

Lower Inner Trim .......................................................................................44

19.

Rear Quarter Trim .....................................................................................45

20.

Sun Visor...................................................................................................46

21.

Roof Trim ..................................................................................................47

22.

Rear Gate Trim .........................................................................................48

23.

Floor Mat ...................................................................................................49

24.

Luggage Floor Mat ....................................................................................50

25.

Instrument Panel Center Compartment ....................................................51

26.

Heat Shield Cover .....................................................................................52

EXTERIOR/INTERIOR TRIM


A: COMPONENT

1. FRONT GRILLE


(3)

(1)

(4)

(1) Front grille

(2) Front grille emblem

2. UNDER COVER

(2)

(3)

(3) Clip

(1)

(4) Hook

T

EI-00230

(1) Under cover

(2) Service hole cover

T

(2)

(4)

(3) Clip

(4) Bolt

(3)

(3)

EI-00002


T: 18 (1.84, 13.3)

EI-2

3. HOOD GRILLE

(1)


(8)


(6)

(2)

(3)

(7)

(9)

(5)

T

(4)

(3)

(10)

(1) Hood grille

(2) Black clip

(3) Black clip

(4) Packing B

(5) Bolt

4. HEAT SHIELD COVER

(6) Grille duct

(7) Clip

(8) Packing C

(9) Packing A

(10) Duct bellows

(3)

(2)

EI-00003


T: 4.4 (0.45, 3.25)

(1)

(1) Front heat shield cover (2) Center heat shield cover

EI-3

(3) Rear heat shield cover

EI-00089


5. FRONT BUMPER


T2

(6)

(5)

T1

(1) Bumper face

(2) E/A form

(3) Fog light

(4) Side bracket

(5) Main beam

T2

(4)

(9)

(9)

(2)

(7)

(8)

(10)

(9)

T1

(3)

(9)

(1)

(6) Upper beam

(7) Lower beam

(8) Lower beam reinforcement

(9) Clip

(10) Slider side front

EI-00751


T1: 32 (3.3, 24)

T2: 69 (7.0, 51)

EI-4



6. REAR BUMPER

(2)

T1

(8)

(7)

T1

(6)

(5)

T2

(4)

T5

T4

T3

T3

(3)

(1)

(1) Bumper face

(2) Rear bumper upper beam

(3) Rear arch cover

(4) Rear bumper front side bracket

(5) Center bracket

(6) Stay COMPL

EI-00005

(7) Rear bumper side bracket ASSY


(8) Rear bumper upper beam side

T1: 32 (3.3, 24)

T2: 7.4 (0.75, 5.46)

T3: 4.4 (0.45, 3.26)

T4: 93 (9.5, 68.7)

T5: 1.8 (0.18, 1.3)

EI-5


7. MUD GUARD


(1)

(3)

(4)

(1) Mud guard

(2) Clip

(2)

(2)

(5)

(2)

(3) Screw

(4) Clip (S-shape)

(5) Air flap

EI-00238

EI-6

8. COWL PANEL

(2)



(3)

(1)

(1) Cowl panel (2) Cowl side panel (3) Seal

(2)

EI-00724

EI-7


9. SIDE SILL SPOILER


(2)

(3)

(5)

(4)

(1)

(1) Side garnish (Front fender)

(2) Side garnish (Front door)

(3) Side garnish (Rear door)

(4) Side garnish (Rear quarter)

(5) Side garnish (Side sill)

EI-00009

EI-8

10.ROOF RAIL



(1)

(1) Roof rail

11.DOOR TRIM

(1)

(3)

(2)

(4)

(A)

(A) Front door trim

(1) Gusset cover

(2) Bracket

(3) Weather strip upper

T

EI-00010


T: 7.5 (0.76, 5.53)

(5)

(6)

(2)

(3)

(5)

(6)

(4)

(B)

(B) Rear door trim

(4) Clip

(5) Trim panel

(6) Power window switch cover

(7) Ash tray

(7)

EI-00233

EI-9


12.REAR GATE TRIM


EI-00012

EI-10

13.CONSOLE BOX



(4)

(3)

(2)

(1)

(1) Rear cup holder

(2) Console lid

(3) Console cover

(7)

(6)

(4) Console front cover

(5) Console box

(6) Console pocket

(5)

(7) Accessory socket

EI-00225

EI-11


14.INSTRUMENT PANEL

• LHD MODEL


(12)

(14)

(2)

(4)

(15)

(5)

(3)

(6)

(7)

A

(8)

(10)

(1)

(9)

(11)

(1) Pad & frame

(2) Center compartment

(3) Grille cover

(4) Lower cover

(5) Coin box

(6) Meter visor

(7) Center panel

(8) Air vent grille

(9) Cup holder

(10) Glove box panel

(11) Glove box lid

(12) Steering beam

(13)

A

(16)

(13) Grille cover

(14) Air vent grille (Defroster)

(15) Switch panel

(16) Passenger’s airbag module

EI-00793

EI-12



• RHD MODEL

(12)

(14)

(2)

(3)

A

(6)

(15)

(4)

(16)

(1) Pad & frame

(2) Center compartment

(3) Grille cover

(4) Lower cover

(5) Coin box

(6) Meter cover

(13)

(7)

(8)

(9)

(1)

(10)

(8)

(7)

A

(11)

Center panel

Air vent grille

(9) Cup holder

(10) Glove box panel

(11) Glove box lid

(12) Steering beam

(5)

EI-00226

(13) Grille cover

(14) Air vent grille (Defroster)

(15) Switch panel

(16) Passenger’s airbag module

EI-13



15.INNER TRIM

(3)

T

(2)

(14)

(15)

(16)

(7)

(5)

(6)

(1)

T

(13)

(10)

(12)

(11)

(9)

(8)

(1) Front pillar upper trim

(2) Center pillar upper trim

(3) Rear pillar upper trim

(4) Rear rail trim

(5) Insulator

(6) Rear quarter lower trim

(7) Strut cap

(4)

(8) Rear skirt trim

(9) Side sill rear cover

(10) Center pillar lower trim

(11) Side sill front cover

(12) Front garnish

(13) Rear garnish

(14) Front pillar inner rib

EI-00015

(15) Center pillar inner rib

(16) Bracket


T: 2 (0.20, 1.46)

EI-14

16.ROOF TRIM



17.FLOOR MAT

(A) Vehicle front

(1) Floor mat

(A)

EI-00016

(1)

EI-00111

EI-15


18.LUGGAGE FLOOR MAT


(3)

(2)

(4)

(5)

(1)

(1) Front floor mat

(2) Floor box

(3) Side floor mat RH

(4) Center floor mat

(5) Side floor mat LH

EI-00220

EI-16

19.INNER ACCESSORIES



(1)

T

T

T

(2)

(3)

T

T

EI-00229

(1) Hook

(2) Sun visor


TOOL NAME

Clip remover

Clip clamp pliers

(3) Assist grip (Retractable)


T: 2 (0.20, 1.46)

REMARKS

Used for removal of trim.

Used for removal of various clips and clamps.

EI-17

Front Grille


2. Front Grille

A: REMOVAL


2) Remove the two upper clips of front grille side.

Slide the front grille side to vehicle outside, then remove the four lower hooks (A) to remove front grille side.

B: INSTALLATION

1) Remove the three hooks remained on body during removal, then install them to front grille.

: (A)

EI-00019

(A) Hook

3) Remove the four upper clips (A) of front grille, then pull the front grille up and remove the three hooks (B) to remove front grille.

EI-00021

NOTE:

Make sure that the clip direction is correct.

2) Install the front grille to body.

3) Install the front grille side.

: (A)

(A) Clip

(B) Hook

: (B)

EI-00020

EI-18

Hood Grille

3. Hood Grille

A: REMOVAL

1) Remove the five screws and clip (A) to remove hood duct.

(A)


2) Remove the five nuts.

EI-00022

EI-00023

3) Remove the three black clips to remove hood grille.

EI-00024

EI-19


B: INSTALLATION

Hood Grille

(A)

(B)

(2)

(3)

(1)

(B)

(A) Black clip (B) Black clip

1) Replace the black clip (1), (2) with a new one. Install the clip with arrow mark facing the front side of grille (A).

(A)

(C)

(C) Bolt

4) Install the five nuts.


4.4 N·m (0.45 kgf-m, 3.25 ft-lb)

EI-00025

EI-00026

2) Replace the black clip (3) with a new one.

3) Insert the hood grille clip and engage the three clips.

NOTE:

Make sure that the anchor portion of each clip is firmly engaged.

EI-00028

5) Catch the two hooks (A) of hood duct to the hood holes.

(A)

EI-00029

EI-00027

EI-20

Hood Grille

6) Install the hood duct with clip (A) and five screws.

(A)


EI-00022

C: INSPECTION

Make sure that the clip is firmly engaged.

Make sure that there is no abnormal gap at whole periphery of hood grille.

Make sure that there is no damage on hood grille.

EI-21

Front Under Cover


4. Front Under Cover

A: REMOVAL

1) Lift-up the vehicle.

2) Loosen the bolts, remove the clips, and then remove the under cover.

B: INSTALLATION



18 N·m (1.84 kgf-m, 13.3 ft-lb)

EI-00030

EI-22

5. Front Bumper

Front Bumper

A: REMOVAL


2) Loosen the two clips to remove the mud guard and front under cover.


5) Remove the front grille and front grille side.

<Ref. to EI-18, REMOVAL, Front Grille.>

6) Remove the eight clips, and pull out the bumper slightly.

EI-00031

3) Turn over the mud guard, and remove two inside clips which securing front bumper to fender.

EI-00034

7) Remove the E/A FORM from bumper beam.

E/A FORM may easily break. Do not apply excessive force to it during removal.

8) Remove the bumper beam.

EI-00035

EI-00032

4) Turn over the mud guard, and disconnect the fog light connector before removing a bolt and clip which installed to under side of fog light hole.

EI-00036

9) Remove the eight bolts to disassemble the front bumper beam.

EI-00095

EI-00033

EI-23

Front Bumper


B: INSTALLATION




<Ref. to EI-4, FRONT BUMPER, COMPO-


EI-24

Front Bumper

C: REPAIR

1. COATING METHOD FOR PP BUMPER

Process

No.

Process name Job contents


(1)

2

3

4

5

1

6

7

8

9

10

11

Bumper mounting

Set the bumper on paint worktable if required.

Use paint worktable conforming to inner shape of bumper when possible.

Masking

(2)

EI-00038

(1) Bumper

(2) Set bumper section

Mask specified part (black base) with masking tape. Use masking tape for PP (example, Nichiban

No. 533, etc.).

Degreasing, cleaning

Primer paint

Clean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt, oil, fat, etc.

Drying

Top coat paint (I)

Drying

Apply primer one to all parts to be painted, using air gun. Use primer (clear).

Dry at normal temperature [10 to 15 min. at 20

°C (68°F)].

In half-dried condition, PP primer paint is dissolved by solvent, e.g. thinner, etc.

Therefore, if dust or dirt must be removed, use ordinary alcohol, etc.

Solid color Metallic color

Use section (block) paint for top coat.

• Paint in use (for each color):

Solid paint

Hardener PB

Thinner T-301

• Mixing ratio:

Main agent vs. hardener = 4:1

• Viscosity: 10 — 13 sec/20

°C (68°F)

• Film thickness: 35 — 45

µ

• Spraying pressure: 245 — 343 kPa

(2.5 — 3.5 kg/cm

2

, 36 — 50 psi)

Not required.

Use section (block) paint for top coat.

• Paint in use (for each color):

Metallic paint

Hardener PB

Thinner T-306

• Mixing ratio:

Main agent vs. hardener = 10:1


°C (68°F)


µ


(2.5 — 3.5 kg/cm

2

, 36 — 50 psi)

Dry at normal temperature [10 min. or more at

20

°C (68°F)].

In half-dried condition, avoid dust, dirt.

Apply a clear coat to parts with top coat paint

(I), three times, at 5 — 7 minutes intervals.

• Paint in use:

Metallic paint

Hardener PB

Top coat paint (II)

Drying

Not required.

Thinner T-301

• Mixing ratio: Clear vs. hardener = 6:1


°C (68°F)


µ


(2.5 — 3.5 kg/cm

2

, 36 — 50 psi)

60

°C (140°F), 60 min. or 80°C (176°F), 30 min.

If higher than 80

°C (176°F), PP may be deformed. Keep maximum temperature of 80°C (176°F).

Inspection Paint check.

Masking removal Remove the masking in process No. 2.

EI-25

Front Bumper


2. REPAIR INSTRUCTIONS FOR COLORED PP BUMPER

NOTE:

All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be restored to its former condition. Damage limited to shallow scratches that cause only a change in the lustre of the base material or coating, can be almost fully restored. Before repairing a damaged area, explain this point to the customer and get an understanding about the matter. Repair methods are outlined below, based on a classification of the extent of damage.

1) Minor damage causing only a change in the lustre of the bumper due to a light touch

Almost restorable.

Process

No.

1

2

3

Process name

Cleaning

Sanding

Finish

Job contents

Clean the area to be repaired using water.

Grind the repairing area with #500 sand paper in a “feathering” motion.

Resin section Coated section

Repeatedly apply wax to the affected area using a soft cloth (such as flannel). Recommended wax: NITTO KASEI Soft 99 TIRE WAX

BLACK, or equivalent.

Polish the waxed area with a clean cloth after 5 to 10 minutes.

Perform either the same operation as for the resin section or process No. 18 and subsequent operations in the “3)” section, depending on the degree and nature of damage.

2) Deep damage caused by scratching fences, etc.

A dent cannot be repaired but a whitened or swelled part can be removed.

Process

No.

1

Process name

Clean the damaged area with water.

Job contents

2

3

Cleaning

Removal of damaged area

Sanding

Cut off protruding area, if any, due to collision, using a putty knife.

4 Finish

Grind the affected area with #100 to #500 sand paper.

Resin section

Same as Process No. 3 in the “1)” section.

Coated section

Perform Process No. 12 and subsequent operations in the “3)” section.

EI-26

Front Bumper


3) Deep damage such as a break or hole that requires filling

Much of the peripheral grained surface must be sacrificed for repair, and the degree of restoration is not really worth the expense. (The surface, however, will become almost flush with adjacent areas.)

Recommended repair kit: PP Part Repair Kit (NRM)

Process

No.

1

2

Process name

Bumper removal

Part removal

Job contents

Remove the bumper as required.

Remove the parts built into bumper as required.

3

4

5

6

7

(1)

Bumper placement

Place the bumper on a paint worktable as required.

It is recommended that contour of worktable accommodate internal shape of bumper.

Surface preparation

(2)

EI-00038

(1) Bumper

(2) Set bumper section

Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable solvent

(NRM No. 900 Precleno, white gasoline, or alcohol).

Cutting

Sanding (I)

Cleaning

(3)

(1)

If nature of damage are cracks or holes, cut a guide slit of 20 to 30 mm (0.79 to 1.18 in) in length along the crack or hole up to the bumper’s base surface. Then, bevel or “vee-out” the affected area using a knife or grinder.

(4)

(2)

EI-00235

(1) Paint surface

(2) PP base surface

(3) 20 — 30 mm (0.79 — 1.18 in)

(4) 3 mm (0.12 in)

Grind beveled surface with sand paper (#40 to #60) to smooth finish.

Clean the sanded surface with the same solvent as used in Process No. 4.

Grind the side just opposite the beveled area with sand paper (#40 to #60) and clean using a solvent.

Temporarily spot-weld the side, using a PP welding rod and heater gun.

(1)

8 Temporary welding

(2)

(3)

(1) Welded spot (Use heater gun and PP welding rod)

(2) PP base surface

(3) Beveled section

NOTE:

• Do not melt the welding rod until it flows out. This results in reduced strength.

• Leave the welded spot unattended until it cools completely.

EI-00236

EI-27

Front Bumper


Process

No.


Using a heater gun and PP welding rod, weld the beveled spot while melting the rod and damaged area.

(2)

(2)

9 Welding

(3)

(1)

EI-00237

(1) Melt hatched area

(2) Welding rod

(3) Section

NOTE:

• Melt the sections indicated by hatched area.

• Do not melt the welding rod until it flows out, in order to provide strength.

• Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.

• Leave the welded spot unattended until it cools completely.

Remove excess part of weld with a putty knife. If a drill or disc wheel is used instead of the knife, operate it at a rate lower than 1,500 rpm and grind the excess part little by little. A higher rpm will cause the PP substrate to melt from the heat.

10 Sanding (II)

11

12

13

14

15

16

17

18

Masking

Cleaning/ degreasing

Primer coating

Leave unattended.

Primer surfacer coating

Drying

Sanding (III)

Cleaning/ degreasing

EI-00042

Sand the welded spot smooth with #240 sand paper.

Mask the black substrate section using masking tape.

Recommended masking tape: Nichiban No. 533 or equivalent

Completely clean the entire coated area, using solvent similar to that used in Process No. 4.

Apply a coat of primer to the repaired surface and its surrounding areas. Mask these areas, if necessary.

Recommended primer: Mp/ 364 PP Primer

NOTE:

Be sure to apply one coat of primer at a spraying pressure of 245 to 343 kPa

(2.5 to 3.5 kg/cm

2

, 36 to 50 psi) with a spray gun.

Leave the repaired area unattended at 20

°C (68°F) for 10 to 15 minutes until primer is half-dry.

NOTE:

If dirt or dust comes in contact with the coated area, wipe it off with a cloth dampended with alcohol.

(Do not use thinner since the coated area tends to melt.)

Apply a coat of primer surfacer to the repaired area two or three times at an interval of 3 to 5 minutes.

Recommended surfacer:

• UPS 300 Flex Primer

• No. 303 UPS 300 Exclusive hardener

• NPS 725 Exclusive Reducer (thinner)

• Mixing ratio: 2: 1 (UPS 300: No. 303)


°C (68°F)

• Coated film thickness: 40 — 50

µ

Allow the coated surface to dry for 60 minutes at 20

°C (68°F) [or 30 minutes at 60°C (140°F)].

Sand the coated surface and its surrounding areas using #400 sand paper and water.

Same as Process No. 12.

EI-28

Front Bumper


22

23

24

25

26

Process

No.

19

20

21


Top coat (I)

Leave unattended.

Top coat (II)

Drying

Inspection

Masking removal

Solid color

Use a “block” coating method.

• Recommended paint:

Suncryl (SC)

No. 307 Flex Hardener

SC Reducer (thinner)

• Mixing ratio: 3: 1

Suncryl (SC) vs. No. 307 Flex Hardener


°C (68°F)


µ

• Spraying thickness: 245 — 343 kPa

(2.5 — 3.5 kg/cm

2

, 36 — 50 psi)

Not required.

Metallic color

Use a “block” coating method.


Suncryl (SC)






°C (68°F)


µ

• Spraying thickness: 245 — 343 kPa

(2.5 — 3.5 kg/cm

2

, 36 — 50 psi)

Leave unattended at 20

°C (68°F) for at least 10 minutes until the topcoated area is half-dry.

NOTE:

Be careful to keep dust or dirt from coming in contact with the affected area.

Not required.

Apply a clear coat three times at an interval of 3 to 5 minutes.


SC710 Overlay Clear






°C (68°F)


µ


(2.5 — 3.5 kg/cm

2

, 36 — 50 psi)

Allow the coated surface to dry at 20

°C (68°F) for two hours or 60°C (140°F) for 30 minutes.

NOTE:

Do not allow the temperature to exceed 80

°C (176°F) since this will deform the PP substrate.

Carefully check the condition of the repaired area.

Remove the masking tape applied in Process No. 11 and 13.

Parts installation Install the parts on bumper in reverse order of removal.

Bumper installation Install the bumper.

EI-29


6. Rear Bumper

A: REMOVAL


2) Remove the bolts and clips.

Rear Bumper

7) Remove the rear skirt trim.

8) Remove the bolt to remove bracket from bumper.

EI-00047

9) Loosen the four nuts to remove rear bumper.

EI-00043

3) Remove the clips from bumper and bracket.

EI-00046

10) Disengage the clips to remove bumper upper beam.

EI-00044

4) Remove the rear combination light assemblies

from each side. <Ref. to LI-21, REMOVAL, Rear

Combination Light Assembly.>

5) Remove the two clips from each side.

EI-00048

B: INSTALLATION




<Ref. to EI-5, REAR BUMPER, COMPONENT,


C: REPAIR

Refer to front bumper repair. <Ref. to EI-23, RE-

MOVAL, Front Bumper.>

EI-00045

6) Remove the floor box.

EI-30

Mud Guard

7. Mud Guard

A: REMOVAL

1) Jack-up the vehicle.

2) Remove the clip to remove air flap.

3) Remove the screws and clips to remove mud guard.


B: INSTALLATION


EI-00049

EI-31

Cowl Panel


8. Cowl Panel

A: REMOVAL


2) Remove the wiper arm. <Ref. to WW-12, RE-

MOVAL, Front Wiper Arm.>

3) Remove the clips to remove cowl side panels.

EI-00050

4) Loosen the clips to remove cowl panel.

: (A)

(A) Clip

B: INSTALLATION


EI-0725

EI-32

Side Sill Spoiler

9. Side Sill Spoiler

A: REMOVAL

Remove the clips (one on front fender arch, six on bottom of side sill spoiler, one on top of side sill spoiler), then remove the side sill spoiler.


B: INSTALLATION


EI-00053

EI-33

Side Garnish


10.Side Garnish

A: REMOVAL

1) Incise the edge of garnish using cutter, and then remove the garnish with pulling towards you by hands.

NOTE:

Remove the garnish carefully. Forced removal of garnish may damage garnish and clips.

2) Adhere the masking tape around area where the double-sided tape of side garnish was adhere.

3) Apply the solvent (SUMITOMO 3M 4000 or equivalent) to the area where double-sided tape was adhered.

NOTE:

• Wipe off immediately when the solvent is touched on the garnish surface.

• Do not use the solvent to the body which repaired with lacquer paint.

4) Cover the area where the solvent applied using plastic wrap, and then heat the double-sided tape was adhered for 5 to 15 minutes in 40 to 60

°C (104 to 140

°F) using heat lamp.

5) Remove the double-sided tape of side garnish side tape by following above step 3) and 4).

NOTE:

When the double-sided tape is not removed completely using above steps, use the scraper.

B: INSTALLATION

1) Apply the PRIMER (SUMITOMO 3M K-500 or equivalent) widely to the slightly larger area where double-sided tape was adhered, and then adhere the double-sided tape (SUMITOMO 3M 5305 or equivalent).

NOTE:

Use 5 mm (0.2 in) width and 1 mm (0.04 in) thickness double-sided tape.

(2)

(2)

(1)

(1)

EI-00109

EI-00110

(1) Double-sided tape

(2) Front side

2) Heat the vehicle body to 40 to 60

°C (104 to

140

°F) and garnish to 20 to 30°C (68 to 86°F) using heat lamp.

3) Remove the double-sided tape backing sheet, and then align the clips to vehicle body holes. Press and install the side garnish applying 69 — 98 N (7 — 10 kgf, 15 — 22 lbf) by the hands, using care to avoid air entering.

NOTE:

• To keep the adhesion, do not wash the vehicle within 24 hours.

• After the adhesion, use care not to move the side garnish up and down.

C: INSPECTION

• Check the side garnish is not damaged or cracked.

• Check the clips are not broken.

EI-34

Front Door Trim

11.Front Door Trim

A: REMOVAL

CAUTION:

Do not apply excessive force to the clip. Otherwise the clip may be broken.


2) Remove the gusset cover.

3) Pull up the inner remote cover toward you to remove upper hook. Pull down it to remove the lower hook. Remove the inner remote cover.


EI-00054

4) Remove the power window control switch. <Ref.

to GW-7, REMOVAL, Power Window Control

Switch.>

5) Remove the clips of trim panel using clip remover to remove trim panel.

B: INSTALLATION


EI-00055

EI-35

Rear Door Trim


12.Rear Door Trim

A: REMOVAL

CAUTION:

Do not apply excessive force to the clip. Otherwise the clip may be broken.


2) Pull up the inner remote cover toward you to remove upper hook. Pull down it to remove the lower hook. Remove the inner remote cover.

EI-00054

3) Remove the power window control switch. <Ref. to

GW-7, REMOVAL, Power Window Control Switch.>

4) Remove the clips of trim panel using clip remover to remove trim panel.

B: INSTALLATION


EI-00098

EI-36

13.Glove Box

A: REMOVAL

1) Open the glove box.

2) Loosen the screws to remove glove box.

(B)

(B)

(A)

Glove Box

(A) Hook

(B) Clip

B: INSTALLATION


EI-00057


EI-37

Roof Rail


14.Roof Rail

A: REMOVAL

1) Remove the roof trim. <Ref. to EI-47, REMOVAL, Roof Trim.>

2) Remove the five mounting nuts.

3) Detach the clip at front edge sideways carefully to remove the roof rail upwards.

C

A

A

A

A

B

A

B

C a

NOTE:

Remove the clip at “C” area upwards while applying sideway force to deflect hook at “a” area.

B: INSTALLATION


CAUTION:

Be careful not to scratch the body panels with roof rail stud bolts when removing and installing them.


7.5 N·m (0.76 kgf-m, 5.53 ft-lb)

EI-38

EI-00058

15.Console Box

A: REMOVAL


2) Remove the console front cover.

Console Box



(A)

(A)

(A)

(A)

(A)

EI-00726

(A) Hook pawl

3) Remove the shift knob (MT model).

4) Loosen the screws to remove console cover.

(B)

(A)

(A) Hook pawl

(B) Clip

(B)

(A)

EI-00060

EI-00061

6) Remove the hook pawl of console side panel to remove console box.

B: INSTALLATION


EI-00062

EI-39

Instrument Panel Assembly


16.Instrument Panel Assembly

A: REMOVAL

CAUTION:


• Be careful not to damage the airbag system harness when servicing the instrument panel.

1. REMOVAL OF INSTRUMENT PANEL

ONLY


2) Loosen the screws and clips, and then remove the lower cover.


(C)

(A)

(A)

(A)

(A)

(B)

(C)

(A)

EI-00728

(A) Screw

(B) Clip

(C) Claw


CAUTION:

Do not insert the flat tip screwdriver into any portion except for indicated in the figure.The instrument panel may be damaged.

EI-00727

(A) Clip

3) Disconnect the in-vehicle sensor hose and connector.

4) Remove the console front cover and console

cover. <Ref. to EI-39, REMOVAL, Console Box.>


NOTE:


(A) (A)

EI-00732


8) Disconnect the connectors of A/C control panel and hazard switch.

(A)

EI-00731

EI-40


9) Loosen the screws and clips, and then remove the side console panel.

EI-00103


NOTE:

Remove the front pillar upper trim if necessary.

<Ref. to EI-43, REMOVAL, Upper Inner Trim.>


CAUTION:

Do not disconnect the connector by pulling harness.

2. REMOVAL OF INSTRUMENT PANEL

WITH STEERING BEAM


2) Loosen the screws and clips (A), and then remove the lower cover.

(A)

(A)

(A)

EI-00062

10) Remove the passenger’s airbag module. <Ref.

to AB-15, REMOVAL, Passenger’s Airbag Module.>

11) Remove the two steering column installation bolts.

<Ref. to PS-26, REMOVAL, Tilt Steering Column.>

12) Loosen the four instrument panel installation bolts. (Do not remove the lower bolts for alignment of install location.)

EI-00727

3) Remove the console front cover and console

cover. <Ref. to EI-39, REMOVAL, Console Box.>

4) Loosen the screws and clips, and then remove the side console panel.

EI-00223

13) Remove the combination meter assembly. <Ref.

to IDI-10, REMOVAL, Combination Meter Assembly.>

14) Loosen the instrument panel installation screws.

15) Remove the instrument panel center compart-

ment. <Ref. to EI-51, REMOVAL, Instrument Panel

Center Compartment.>

16) Remove the radio. <Ref. to ET-5, REMOVAL,

Radio Body.>

17) Remove the side cover of instrument panel assembly (both side), and then loosen two bolts.

18) Remove the instrument panel assembly.

EI-41

5) Remove the steering column.

EI-00103



6) Loosen the four instrument panel installation bolts.

B: INSTALLATION


CAUTION:

• Be careful not to snag the harness.

• Make sure to connect the harness connector.

NOTE:

When setting the instrument panel into position, push the hook into grommet (A) on the body panel.

(A)

(A)

(A)

EI-00066

7) Remove the driver’s and passenger’s airbag mod-

ule. <Ref. to AB-14, REMOVAL, Driver’s Airbag

Module.> <Ref. to AB-15, REMOVAL, Passenger’s

Airbag Module.>

8) Loosen the steering beam installation bolts.

9) Loosen the brake pedal installation bolts. <Ref.

to BR-50, REMOVAL, Brake Pedal.>

10) Remove two clips from the edge of instrument panel assembly.

11) Remove the instrument panel assembly.

CAUTION:

Do not disconnect the connector by pulling harness.

NOTE:

• If necessary, make matching marks for easy reassembly.

• When storing the removed instrument panel, place it standing up on the floor.

EI-00069

EI-00068

EI-42

Upper Inner Trim

17.Upper Inner Trim

A: REMOVAL

1) Remove the lower inner trim. <Ref. to EI-44, RE-

MOVAL, Lower Inner Trim.>

2) Remove the front molding (A).

3) Remove the front pillar upper trim (B).

4) Detach the front seat belt shoulder anchor, then remove the center pillar upper trim (C).

(A)

(C)

(B)

: (D)

EI-00105

(D) Clip

B: INSTALLATION


CAUTION:

Be sure to securely hook pawls of inner trim panel to body flange.

NOTE:

When installing the center pillar upper trim and front pillar upper trim, be sure to set the front molding as shown in the figure.

(A) (B)

(C)

(D)

(E)

(F)

(A) Outside

(B) Inside

(C) Molding

(D) Weather strip

(E) Trim

(F) Body

EI-00106


EI-43

Lower Inner Trim


18.Lower Inner Trim

A: REMOVAL

1) Remove the side sill front cover (A).

2) Remove the rear seat cushion <Ref. to SE-13,

REMOVAL, Rear Seat.>, then remove side sill rear

cover (B).

3) Remove the center pillar lower trim (C).

(B)

(C)

(A)

: (D)

EI-00072

(D) Clip

B: INSTALLATION


CAUTION:


EI-44

19.Rear Quarter Trim

Rear Quarter Trim

A: REMOVAL


AL, Rear Seat.>

2) Remove the side sill rear cover.

3) Remove the rear rail trim (A).

4) Remove the strut cap.

5) Remove the shoulder anchor of rear seat belt.

6) Loosen the screws and clips to remove rear quarter upper trim (B).

7) Remove the rear skirt trim (C).

8) Loosen the screws and clips to remove rear quarter lower trim (D).


B: INSTALLATION


CAUTION:


NOTE:

When installing the rear quarter upper trim, be sure to set the rear molding as shown in the figure.

(A)

(C)

(B)

(D)

(E)

(A)

(F)

EI-00106

(B)

(A) Outside

(B) Inside

(C) Molding

(D) Weather strip

(E) Trim

(F) Body

(C)

(D)

: (E)

(E) Clip

(F) Hook

: (F)

EI-00073

EI-45

Sun Visor


20.Sun Visor

A: REMOVAL

Remove the mounting screws then detach sun visor (A) and hook (B).

(B)

(A)

B: INSTALLATION


EI-00074

EI-46

Roof Trim


8) Remove the clips, and then remove the roof trim.

21.Roof Trim

A: REMOVAL

CAUTION:

When removing the clip, use great care not to damage the roof trim.


2) Remove the over head console. (Sunroof model)

<Ref. to SR-9, REMOVAL, Sunroof Switch.>

3) Remove the room light. <Ref. to LI-30, REMOV-

AL, Room Light.>

4) Remove the sun visor and hook or both sides.

<Ref. to EI-46, REMOVAL, Sun Visor.>

5) Remove the assist grip cap to remove assist grip

(A).

B: INSTALLATION


EI-00077

(A)

EI-00075

6) Remove the upper inner trim. <Ref. to EI-43, RE-

MOVAL, Upper Inner Trim.>

7) Remove the rear quarter upper trim shown in the fig-

ure. <Ref. to EI-45, REMOVAL, Rear Quarter

Trim.>

(1) Remove the rear rail trim (A).

(2) Remove the rear quarter upper trim (B) of both sides.

(A)

(B)

: (C)

(C) Clip

EI-00076

EI-47

Rear Gate Trim


22.Rear Gate Trim

A: REMOVAL

CAUTION:

Be careful not to damage the clips or their holes.

Remove the rear gate inner handle (A) from rear gate and then detach trim panel.

(A)

B: INSTALLATION


EI-00078

EI-48

Floor Mat

23.Floor Mat

A: REMOVAL

1) Remove the front seats. <Ref. to SE-6, REMOV-

AL, Front Seat.>

2) Remove the rear seat cushion. <Ref. to SE-13,

REMOVAL, Rear Seat.>

3) Remove the console box. <Ref. to EI-39, Console Box.>

4) Remove the side sill front cover, side sill rear

cover and center pillar lower trim. <Ref. to EI-44,

REMOVAL, Lower Inner Trim.>

5) Remove the footrest or clips from floor mat.

6) Remove the mat hook.

7) Remove the mat from toe board area.

8) Remove the mat from rear heater duct.

9) Roll the mat, and then take it out of opened rear door.

(A)

(1)

EI-00079

(A) Vehicle front

(1) Floor mat

B: INSTALLATION


NOTE:

• Secure the mat firmly with hook and Velcro tape.

• Insert the mat edge firmly into the groove of side sill cover.


EI-49

Luggage Floor Mat


24.Luggage Floor Mat

A: REMOVAL

1) Remove the back mat of rear seat backrest.

2) Remove the clips, then detach the rear floor mats and boxes.

B: INSTALLATION


EI-00080

EI-50

Instrument Panel Center Compartment


25.Instrument Panel Center

Compartment

A: REMOVAL


2) Insert a flat tip screwdriver, and then pry up to remove the clips.

: A

EI-00081

(A) Clip

3) Remove the instrument panel center compartment from instrument panel.

4) Disconnect the connector from clock.

B: INSTALLATION


EI-51

Heat Shield Cover


26.Heat Shield Cover

A: REMOVAL

1. FRONT HEAT SHIELD COVER

Loosen the four bolts to remove front heat shield cover.

(A)

DI-00211

(A) Transmission mount

2. CENTER HEAT SHIELD COVER

Loosen the four bolts to remove center heat shield cover.

EI-00107

3. REAR HEAT SHIELD COVER

1) Remove the muffler. <Ref. to EX(H4SO)-13, RE-

MOVAL, Muffler.>

2) Loosen the four bolts to remove rear heat shield cover.

B: INSTALLATION


EI-00108

EI-52

EXTERIOR BODY PANEL

EB

Page

1.


2.

Front Hood Panel ........................................................................................9

3.

Front Fender Panel ...................................................................................10

4.

Front Door Panel.......................................................................................11

5.

Front Sealing Cover ..................................................................................13

6.

Rear Door Panel .......................................................................................14

7.

Rear Sealing Cover...................................................................................16

8.

Rear Gate Panel .......................................................................................17

9.

Rear Gate Garnish Assembly ...................................................................20

EXTERIOR BODY PANEL




(A)

(B)

(E)

(C)

(F)

(D)

(1)

(2)

(A)

(2)

(B)

(3)

(3)

(4)

(C)

(6)

(4)

(5)

(D) (E),(F)

(1) Front hood panel

(2) Front fender panel

(3) Front door panel

Section

(A)

(B)

(C)

(D)

(E), (F)

(4)

(5)

(6)

Rear door panel

Rear quarter panel

Door panel

Part

Front hood panel to Front fender panel

Front fender panel to Front door panel

Front door panel to Rear door panel

Rear door panel to Rear quarter panel

Door panel to Side sill

(7) Side sill

Specification

3.5

±1.0 mm (0.14±0.04 in)

4.7

±1.0 mm (0.19±0.04 in)

5.0 mm (0.20 in)

4.6 mm (0.18 in)

5.9 mm (0.23 in)

(7)

EB-00001

EB-2

B: COMPONENT

1. FRONT HOOD


EXTERIOR BODY PANEL

(1)

T1

(1) Front hood

(2) Hinge

(3)

(3) Seal

T1

(2)

EB-00038

Tightening torque: N·m (kgf-m, ft-lb)

T1: 24.5 (2.5, 18.1)

EB-3

EXTERIOR BODY PANEL

2. FRONT FENDER PANEL


T

(1) Front fender panel

(1)

T

EB-00003


T: 7.4 (0.75, 5.5)

EB-4


EXTERIOR BODY PANEL

3. FRONT DOOR PANEL

T7

T1

(2)

(3)

(4)

(10)

(1)

(5)

T6

T4

(9)

T6

T3

T4

T3

(1) Gusset

(2) Weather strip

(3) Stabilizer (Outer)

(4) Stabilizer (Inner)

(5) Door panel

(6) Checker

(7) Sealing cover

(8) Lower hinge

T1

T5

T6

(7)

(6)

T2

T2

(8)

T6

T2

T2

(13)

(12)

(11)

(9) Upper hinge

(10) Key cylinder (Driver’s side only)

(11) Front sash

(12) Rear sash

(13) Guide rail

EB-00183


T1: 7.5 (0.76, 5.5)

T2: 14 (1.4, 10.3)

T3: 25 (2.5, 18)

T4: 30 (3.1, 22)

T5: 33 (3.4, 24)

T6: 6 (0.6, 4.4)

T7: 1.5 (0.15, 1.1)

EB-5


EXTERIOR BODY PANEL

4. REAR DOOR PANEL

(1)

T1

T6

(4)

T3

T6

T2

T3

T2

(10)

T1

(9)

(2)

(3)

(5)

(7)

T5

(8)

T5

T5

(6)

T5

T4

(1) Weather strip

(2) Stabilizer (Outer)

(3) Stabilizer (Inner)

(4) Door panel

(5) Checker

(6) Sealing cover

(7) Front sash

(8) Rear sash

(9) Lower hinge

(10) Upper hinge

EB-00174


T1: 7.5 (0.76, 5.5)

T2: 25 (2.5, 18)

T3: 30 (3.1, 18)

T4: 33 (3.4, 24)

T5: 14 (1.4, 10.3)

T6: 1.5 (0.15, 1.1)

EB-6

5. REAR GATE PANEL


EXTERIOR BODY PANEL

T3

(2)

(3)

(1) Damper stay

(2) Hinge

T1

T2

(1)

T1

T1

T1

(4)

(3) Rear gate

(4) Rear gate garnish

EB-00037


T1: 7.5 (0.76, 5.5)

T2: 14 (1.4, 10.1)

T3: 25 (2.5, 18.1)

EB-7


EXTERIOR BODY PANEL


1. SPECIAL TOOL


925610000

DESCRIPTION

WRENCH

REMARKS

Used for removing and installing door hinge.

ST-925610000

2. GENERAL TOOL

TOOL NAME

Support jack

REMARKS

Used for supporting door panel.

EB-8

Front Hood Panel

EXTERIOR BODY PANEL

3) Rotate the hood buffer to adjust lateral height.

2. Front Hood Panel

A: REMOVAL

1) Open the front hood to remove washer nozzles.

2) Release the clips to remove front hood insulator.

EB-00010

EB-00008

3) Remove the bolts to remove front hood from hinges.

EB-00009

B: INSTALLATION


2) Adjust the clearance between front hood panel and front fender panel. Clearance must be equal at both sides.


24.5 N·m (2.5 kgf-m, 18.1 ft-lb)

C: ADJUSTMENT

1) Use the hinge mounting holes to align the front hood longitudinally and laterally.

EB-00009

2) Adjust the height at front end of hood. <Ref. to

SL-33, ADJUSTMENT, Front Hood Lock Assembly.>

EB-9

Front Fender Panel

EXTERIOR BODY PANEL

3. Front Fender Panel

A: REMOVAL


2) Remove the front bumper face. <Ref. to EI-23,

REMOVAL, Front Bumper.>

3) Remove the mud guard. <Ref. to EI-31, RE-

MOVAL, Mud Guard.>

4) Remove the side sill spoiler. <Ref. to EI-33, RE-

MOVAL, Side Sill Spoiler.>

5) Remove the side protector. <Ref. to EI-34, RE-

MOVAL, Side Garnish.>

6) Loosen the bolts and clip to remove front fender panel.

EB-00011

B: INSTALLATION


2) When the front fender panel is installed, clearance between front fender panel and front hood panel must be equal.


7.4 N·m (0.75 kgf-m, 5.5 ft-lb)

EB-10

Front Door Panel

EXTERIOR BODY PANEL

11) Remove the checker bolts.

4. Front Door Panel

A: REMOVAL




3) Remove the outer mirror assembly. <Ref. to

GW-12, REMOVAL, Outer Mirror Assembly.>

4) Remove the front sealing cover. <Ref. to EB-13,

REMOVAL, Front Sealing Cover.>

5) Remove the front door glass. <Ref. to GW-17,

REMOVAL, Front Door Glass.>

6) Remove the front door regulator and motor. <Ref.

to GW-21, REMOVAL, Front Regulator and Motor

Assembly.>

7) Remove the front door latch assembly. <Ref. to

SL-24, REMOVAL, Front Door Latch Assembly.>

8) Remove the front outer handle. <Ref. to SL-23,

REMOVAL, Front Outer Handle.>

9) Remove the front pillar lower trim to disconnect the connector from body harness.

EB-00014

12) Remove the door-side bolts for upper and lower hinges to remove the front door panel.

EB-00015

13) Using the ST, remove the body-side bolts for upper and lower hinges, and remove door hinges.

ST 925610000 WRENCH

EB-00012

10) Put a wooden block on jack and place jack under door. Support the door with a jack to protect it from damage.

ST

EB-00013

NOTE:

When supporting the door with a jack, be careful not to deform the door hinges while working.

EB-00016

B: INSTALLATION


2) Apply grease to the sliding area of door hinges.

3) Refer to COMPONENT in General Description for

tightening torque. <Ref. to EB-6, REAR DOOR PAN-

EL, COMPONENT, General Description.>

EB-11

Front Door Panel

EXTERIOR BODY PANEL

C: ADJUSTMENT

1) Using the ST, loosen the body-side bolts of upper and lower hinges to align the position of front door panel longitudinally and vertically.

ST 925610000 WRENCH

ST

EB-00016

2) Loosen the door-side bolts of upper and lower hinges to align the position of front door panel vertically and laterally at the front end.

EB-00015

3) Loosen the screw (A) and lightly tap striker (B) using a plastic hammer to adjust striker to align the position of front door panel vertically and laterally at the rear end.

CAUTION:

Do not use an impact wrench. Welding area on the striker nut plate is easily broken.

(A)

(B)

EB-00017

EB-12

5. Front Sealing Cover

Front Sealing Cover

EXTERIOR BODY PANEL

C: INSPECTION

If the sealing cover is damaged, replace it with a new one.

A: REMOVAL


2) Remove the front door trim. <Ref. to EI-35,

REMOVAL, Front Door Trim.>



4) Remove the door trim bracket.

EB-00034

5) Remove the sealing cover.

NOTE:

• Carefully remove the butyl tape. Excessive force will easily break the cover.

• If the cover gets broken, replace it with a new one.

EB-00018

B: INSTALLATION


2) When replacing the sealing cover, use butyl tape.

3) Press the butyl tape-applied area firmly to prevent any floating on surface.

Butyl tape:

3M8626 or equivalent

NOTE:

• Apply a uniform bead of butyl tape.

• Attach the sealing cover, keeping it from becoming wrinkled.

• Breaks in the bead will allow water leakage and contamination.

EB-13

Rear Door Panel

EXTERIOR BODY PANEL

6. Rear Door Panel

A: REMOVAL




3) Remove the rear sealing cover. <Ref. to EB-16,

REMOVAL, Rear Sealing Cover.>

4) Remove the rear door glass. <Ref. to GW-22,

REMOVAL, Rear Door Glass.>

5) Remove the rear door regulator and motor as-

sembly. <Ref. to GW-24, REMOVAL, Rear Regulator and Motor Assembly.>



7) Remove the rear outer handle. <Ref. to SL-27,

REMOVAL, Rear Outer Handle.>



9) Remove the seat belt bracket and blind plug.

Disconnect the connector of door harness and remove the door hinge nut.

11) Remove the checker bolts.

EB-00014

12) Remove the door-side bolts for upper and lower hinges to remove the rear door panel.

EB-00019

10) Put a wooden block on the jack and place the jack under the door. Support the door with the jack to protect it.

EB-00015

13) Using the ST, remove the body-side bolts for upper and lower hinges, and remove door hinges.

ST 925610000 WRENCH

B: INSTALLATION


2) Apply grease to the sliding area of door hinges.

3) Refer to COMPONENT in General Description for

tightening torque. <Ref. to EB-6, REAR DOOR

PANEL, COMPONENT, General Description.>

C: ADJUSTMENT

1) Using the ST, loosen the body-side bolts of upper and lower hinges to align the position of rear door panel longitudinally and vertically.

ST 925610000 WRENCH

EB-00013

NOTE:

When supporting the door with a jack, be careful not to deform the door hinges while working.

ST

EB-00016

EB-14

Rear Door Panel

2) Loosen the door-side bolts of upper and lower hinges to align the position of rear door panel vertically and laterally at front-end.

EXTERIOR BODY PANEL

EB-00015

3) Loosen the screw (A) and lightly tap striker (B) using plastic hammer to adjust striker to align the position of rear door panel vertically and laterally at the rear end.

CAUTION:

Do not use an impact wrench. The welding area on the striker nut plate is easily broken.

(A)

(B)

EB-00017

EB-15

Rear Sealing Cover

EXTERIOR BODY PANEL

7. Rear Sealing Cover

A: REMOVAL




3) Remove the door trim bracket.

EB-00034

4) Remove the sealing cover.

NOTE:

• Carefully remove the butyl tape. Excessive force will easily break the cover.

• If the cover gets broken, replace it with a new one.

EB-00018

B: INSTALLATION


2) When replacing the sealing cover, use butyl tape.

3) Press the butyl tape-applied area firmly to prevent any floating on surface.

Butyl tape:

3M8626 or equivalent

NOTE:

• Apply an uniform bead of butyl tape.

• Attach the sealing cover, keeping it from becoming wrinkled.

• Breaks in the bead will allow water leakage and contamination.

C: INSPECTION

If the sealing cover is damaged, replace it with a new one.

EB-16

8. Rear Gate Panel

A: REMOVAL

Rear Gate Panel

EXTERIOR BODY PANEL

11) Using a support, support the rear gate and then remove damper stay mounting bolts.



2) Open the rear gate.



4) Remove the rear wiper motor. <Ref. to WW-17,

REMOVAL, Rear Wiper Motor.>

5) Remove the rear gate garnish assembly. <Ref. to

EB-20, REMOVAL, Rear Gate Garnish Assembly.>

6) Remove the rear gate outer handle. <Ref. to SL-

30, REMOVAL, Rear Gate Outer Handle.>

7) Remove the rear gate latch assembly. <Ref. to

SL-31, REMOVAL, Rear Gate Latch Assembly.>

8) Disconnect the connectors of rear wiper, rear defogger, and other lighting devices.

9) Disconnect the washer hose.

10) Remove the rubber duct (A) connection, and pull out the harness and washer hose from rear gate.

EB-00021

(A)

EB-00022

NOTE:

When the rear gate is released, it may hit and damage the body. To prevent this, place a shop cloth between the body and gate.

12) Loosen the rear gate bolts to remove rear gate.

EB-00020

EB-00023

EB-17

Rear Gate Panel

EXTERIOR BODY PANEL

2. REAR GATE DAMPER STAY

1) Open the rear gate. Use a support to support the rear gate.

EB-00021

NOTE:

After the rear gate damper stay is removed, the rear gate cannot stay open. Supporting the rear gate with a jack, remove the bolts.

CAUTION:

• Do not damage the piston rods and oil seals.

• Never disassemble the cylinders: They contain gas.

2) Loosen the bolts to remove the rear gate damper stay from rear gate.

B: INSTALLATION



2) Install the rear gate panel with uniform clearance to the body.

3) Refer to COMPONENT of General Description for

tightening torque. <Ref. to EB-7, REAR GATE PAN-

EL, COMPONENT, General Description.>

NOTE:

After supporting the rear gate with a jack, start working.


1) Install the mounting bolt (A) to the rear gate panel and body.


14 N·m (1.43 kgf-m, 10.3 ft-lb)

2) Firmly install the rear gate damper stay (B) to mounting bolt (A).

(B)

(A)

EB-00075

3) Tighten the bolts at upper side of rear gate damper stay.


7.5 N·m (0.76 kgf-m, 5.5 ft-lb)

EB-00024

EB-18

Rear Gate Panel

C: DISPOSAL


CAUTION:

Gas is colorless, odorless and harmless. However, gas pressure may spray cutting powder or oil. Be sure to wear dust-resistant goggles.

1) Cover with a vinyl case as shown in the figure.

(1)

(2)

EB-00031

(1) Rear gate damper stay

(2) Vinyl sack

NOTE:

Prevent the vinyl case from being caught by drill cutting edge.

2) Lift the body-side slightly with piston rods fully extended, and secure the body side on vise stand.

Drill a hole in 2 to 3 mm (0.08 to 0.12 in) diameter at a point 10 to 200 mm (0.39 to 7.87 in) from the door side, and bleed the rear gate damper stay completely.

(1) (2)

(3) (4)

(5)

(6)

(1) Body-side

(2) Door-side

(3) 190 mm (7.48 in)

(4) 10 mm (0.39 in)

(5) Piston rod

(6) Cylinder

(7) Portion to be drilled

(7)

EB-00032

EB-19

EXTERIOR BODY PANEL

Rear Gate Garnish Assembly

EXTERIOR BODY PANEL

9. Rear Gate Garnish Assembly

A: REMOVAL

1) Remove the rear gate panel trim. <Ref. to EI-48,


2) Remove the rear wiper motor. <Ref. to WW-17,

REMOVAL, Rear Wiper Motor.>

3) Remove the seven frange nuts from inside of rear gate panel.

4) Remove the license plate light assembly.

5) Close the gate, and then remove the rear gate garnish assembly, pulling it forward by hand.

NOTE:

Be careful not to pull it strongly to avoid damage to clips.

(1)

(2)

(3)

EB-00033

(1) Rear gate garnish ASSY

(2) Licence plate light bracket

(3) Licence plate light

B: INSTALLATION


C: INSPECTION

Check for serious scratches or cracks in rear gate garnish assembly.

EB-20


CC

Page

1.


2.

Actuator.......................................................................................................5

3.

Cruise Control Module ................................................................................7

4.

Cruise Control Main Switch.........................................................................8

5.

Cruise Control Command Switch ................................................................9

6.

Stop and Brake Switch..............................................................................10

7.

Clutch Switch ............................................................................................11

8.

Inhibitor Switch (AT model) .......................................................................12

9.

Neutral Position Switch (MT model) ..........................................................13

CRUISE CONTROL SYSTEM


A: COMPONENT

1. EXCEPT 2.5 L TURBO MODEL


(2)

(1)

(3)

(4)

(5)

(6)

(7)

CC-00001

(1) Actuator

(2) Inhibitor switch (AT model)

(3) Cruise control command switch

(4) Cruise control main switch

(5) Clutch switch (MT model)

(6) Stop and brake switch

(7) Cruise control module

NOTE:

Electrical component location are for LHD vehicles. Cruise control actuator and cruise control module location for RHD vehicles are symmetrically opposite.

CC-2

2. 2.5 L TURBO MODEL


(1)


(7)

(2)

(6)






(6) Engine control module

(3)

(4)

(5)

CC-00262

(7) Neutral position switch (MT model)

CC-3



B: CAUTION

• Before disassembling or reassembling parts, always disconnect the battery ground cable. When repairing the radio, control module and other parts with memory functions, make note of the memory before disconnecting the battery ground cable. All memory will be erased.

• Reassemble parts in the reverse order of disassembly unless otherwise indicated.

• Adjust parts to specifications specified in this manual.


• After reassembly, ensure functional parts operate properly.


TOOL NAME

Circuit Tester

REMARKS


CC-4

Actuator

2. Actuator

A: REMOVAL

CAUTION:

• Be careful not to apply excessive load to the wire cable when adjusting and/or installing; otherwise, the actuator may be deformed or damaged.

• Do not bend the cable sharply with a radius less than 100 mm (3.94 in); otherwise, cable may bend permanently, resulting in poor performance.

• When installing the cable, be careful not to sharply bend or pinch the inner cable; otherwise, the cable may break.


2) Remove the clip bands from cruise control cable.

3) Loosen the nut which secures cruise control cable end to throttle cam, and then remove the cable from throttle cam.

• RHD model

CC-00009

4) Remove the four actuator attaching bolts.

5) Remove the actuator while disconnecting the connector.

• LHD model


CC-00070

B: INSTALLATION



ACTUATOR:

7.4 N

⋅

m (0.75 kgf-m, 5.4 ft-lb)

Cable end nut:

12 N

⋅

m (1.2 kgf-m, 8.7 ft-lb)

NOTE:

(A): Must be adjusted when the cable end outer is fixed in place, so that gap between throttle cam and lever is 0 — 1 mm (0 — 0.04 in), otherwise, inner cable deflection (D) is 1 — 8 mm (0.039 — 0.315 in) when the throttle cable is installed.

(Must be attached while the throttle cam is being pulled by wire cable.)

(B): Must be coated evenly on the cam end inner connection.

(C): Cover must be inserted securely, until tip of cable touches cover stopper.

(C)

(D)

(A)

(B)

CC-00037

CC-00010

CC-5


C: INSPECTION

Measure the cruise control actuator resistance.

Actuator

3

6

2

5

1

4

CC-00012

Terminal No.

4 and 1

4 and 2

4 and 5

3 and 6

Standard

Approx. 5

Ω

Approx. 5

Ω

Approx. 5

Ω

Approx. 39

Ω

If NG, replace the cruise control actuator.

CC-6

Cruise Control Module

3. Cruise Control Module

A: NOTE

Engine Control Module (ECM) controls cruise control system (Turbo model).

B: REMOVAL

1. NON-TURBO MODEL



AL, Glove Box.>

3) Disconnect the connector from cruise control module.

4) Remove the bolt, then detach the cruise control module (A).

(A)


CC-00013

2. TURBO MODEL

<Ref. to FU(H4DOTC)-50, REMOVAL, Engine

Control Module (ECM).>

C: INSTALLATION

1. NON-TURBO MODEL


NOTE:

Attach the part number label, facing the rear side of the vehicle.

2. TURBO MODEL

<Ref. to FU(H4DOTC)-50, INSTALLATION, Engine Control Module (ECM).>

CC-7

Cruise Control Main Switch


4. Cruise Control Main Switch

A: REMOVAL


2) Remove the screws and clip from instrument panel lower cover.


B: INSTALLATION


C: INSPECTION

Measure the cruise control main switch resistance.

2

6 5 4

1

3

CC-00014

4) Disconnect the connector from cruise control main switch.

CC-00073

Switch position

OFF (released)

ON (depressed)

Terminal No.

LHD, RHD (For

Europe) model : 1 and 2

RHD (Except for

Europe) model : 3 and 5

Standard

More than 1 M

Ω

Less than 1

Ω

If NG, replace the cruise control main switch.

CC-00015

5) Remove the main switch by pushing it outward.

• For Europe model

• For Australia model

CC-00071

CC-00072

CC-8

5. Cruise Control Command

Switch

A: REMOVAL

Cruise Control Command Switch


7) Disconnect the horn and cruise control command switch connector, then remove the cruise control command switch.

WARNING:

Before servicing, be sure to read the notes in the AB section for proper handling of the driv-

er’s airbag module. <Ref. to AB-3, CAUTION,

General Description.>

1) Set the front wheels in straight ahead position.



4) Using the TORX

®

BIT T30 (Tamper resistant type), loosen the two TORX

®

bolts which secure driver’s airbag module.

CC-00020

B: INSTALLATION


C: INSPECTION

Measure the cruise control command switch resistance.

(1)

CC-00018

(1) TORX ®

BIT T30

5) Disconnect the airbag module connector on back of airbag module.

6) Remove the horn switch from steering wheel as shown.

3 2 1

CC-00038

Switch

CANCEL

SET/COAST

RESUME/

ACCEL

Position Terminal No.

ON

ON

OFF

ON

OFF

ON

Standard

1 (+) and 2 (

−)

Less than 1

Ω

1 (+) and 3 (

−)

Less than 1

Ω

1 and 2 More than 1 M

Ω

1 and 2

1 and 3

1 and 3

Less than 1

Ω

More than 1 M

Ω

Less than 1

Ω

If NG, replace the cruise control command switch.

CC-00019

CC-9

Stop and Brake Switch


6. Stop and Brake Switch

A: REMOVAL


2) Disconnect the connector from stop and brake switch, and then remove the switch. <Ref. to BR-

54, REMOVAL, Stop Light Switch.>

B: INSTALLATION


C: INSPECTION

Measure the brake switch (A) and stop light switch

(B) resistance.

2

4

1

3

(A)

(B)

1 2 3 4

CC-00022

Switch

Brake

Stop light

Pedal

Released

Depressed

Released

Depressed

Terminal No.

1 and 4

1 and 4

2 and 3

2 and 3

Standard

Less than 1

Ω

More than 1 M

Ω

More than 1 M

Ω

Less than 1

Ω

If NG, replace the stop and brake switch.

CC-10

Clutch Switch

7. Clutch Switch

A: REMOVAL


2) Disconnect the connector from clutch switch, and then remove the switch. <Ref. to CL-34, RE-

MOVAL, Clutch Pedal.>

B: INSTALLATION


C: INSPECTION

Measure the clutch switch resistance.


CC-00023

Switch

Clutch

Pedal

Released

Depressed

Terminal No.

1 and 2

1 and 2

If NG, replace the clutch switch.

Standard

Less than 1

Ω

More than 1 M

Ω

CC-11

Inhibitor Switch (AT model)


8. Inhibitor Switch (AT model)

A: REMOVAL


2) Disconnect the connector from inhibitor switch, and then remove the switch. <Ref. to 4AT-52, RE-

MOVAL, Inhibitor Switch.>

B: INSTALLATION


C: INSPECTION

Measure the inhibitor switch resistance.

6

12

5

11

4

10

3

9

2

8

1

7

CC-00024

Selector lever position

P

N

Except P and N

Terminal No.

7 and 12

If NG, replace the inhibitor switch.

Standard

Less than 1

Ω

Less than 1

Ω

More than 1 M

Ω

CC-12

Neutral Position Switch (MT model)


9. Neutral Position Switch (MT model)

A: REMOVAL


2) Disconnect the connector from neutral position switch, and then remove the switch. <Ref. to 5MT-

43, BACK-UP LIGHT AND NEUTRAL POSITION

SWITCH, REMOVAL, Switches and Harness.>

B: INSTALLATION


C: INSPECTION

Measure the neutral position switch resistance.

• Non-turbo model

2 1

Gear shift position

Neutral position

Other positions

• Turbo model

MT-00110

Terminal No.

Specified resistance

Less than 1

Ω

1 and 2

More than 1 M

Ω

2

4

1

3

MT-00111

Gear shift position

Neutral position

Other positions

Terminal No.

Specified resistance

1 and 3

Less than 1

Ω

More than 1 M

Ω

If NG, replace the neutral position switch.

CC-13


Neutral Position Switch (MT model)

CC-14


(DIAGNOSTIC)

CC(H4SO)

Page

1.


2.


3.

Electrical Components Location..................................................................6

4.

Cruise Control Module I/O Signal................................................................7

5.

Subaru Select Monitor.................................................................................9

6.

Diagnostic Procedure with Symptom ........................................................11

7.


8.


2

3


CRUISE CONTROL SYSTEM (DIAGNOSTIC)


A: PROCEDURE

1

4

5

6

7

8

Step

START DIAGNOSIS.

1) Perform the pre-inspection. <Ref. to

CC(H4SO)-5, INSPECTION, General Description.>

2) Check the cruise control main switch operation.

Check

Is the cruise control main switch turned ON?

Yes

Go to step 2.

No

Go to symptom 1.

<Ref. to

CC(H4SO)-11,

SYMPTOM

CHART, Diagnostic Procedure with

Symptom.>

Go to step 4.

PREPARE SUBARU SELECT MONITOR.

PERFORM CRUISE CANCEL CONDITIONS

DIAGNOSIS.

Perform the cruise cancel conditions diagno-

sis. <Ref. to CC(H4SO)-9, Subaru Select Monitor.>

CHECK CRUISE CONTROL SET OPERA-

TION.

Check the cruise control set operation.

CHECK VEHICLE SPEED IS HELD WITHIN

SET SPEED.

Make sure the vehicle speed is held within set speed.

Is Subaru Select Monitor available?

Is DTC indicated?

Can the cruise control be set while driving at 40 km/h (25

MPH)?

Is the vehicle speed held within set speed

±3 km/h (±2 MPH)?

Go to step 3.

Go to “List of Diagnostic Trouble

Code (DTC)”.

<Ref. to

CC(H4SO)-27, List of Diagnostic Trouble Code (DTC).>

Go to step 4.

Go to step 5.

Go to step 6.

Go to symptom 2.

<Ref. to

CC(H4SO)-11,

SYMPTOM


Symptom.>

Go to symptom 3.

<Ref. to

CC(H4SO)-11,

SYMPTOM


Symptom.>

CHECK RESUME/ACCEL OPERATION.

Check the RESUME/ACCEL operation.

Does the vehicle speed increase or return to set speed after RESUME/ACCEL switch has been pressed?

Go to step 7.

CHECK SET/COAST OPERATION.

Check the SET/COAST operation.

CHECK CANCEL OPERATION.

Check the CANCEL operation.

Does the vehicle speed decrease after SET/COAST switch has been pressed?

Is the cruise control released after CANCEL switch has been pressed?

Go to step 8.

Go to step 9.

Go to symptom 4.

<Ref. to

CC(H4SO)-11,

SYMPTOM


Symptom.>

Go to symptom 5.

<Ref. to

CC(H4SO)-11,

SYMPTOM


Symptom.>

Go to symptom 6.

<Ref. to

CC(H4SO)-11,

SYMPTOM


Symptom.>

CC(H4SO)-2

9

10



Step

CHECK CRUISE CONTROL RELEASE OP-

ERATION.

Check the cruise control release operation.

Check

Is the cruise control released after brake pedal has been depressed?

Yes

Go to step 10.


ERATION.


Is the cruise control released after clutch pedal has been depressed? (MT model)

Finish the diagnostics.

No

Go to symptom 7.

<Ref. to

CC(H4SO)-11,

SYMPTOM


Symptom.>

Go to symptom 8.

<Ref. to

CC(H4SO)-11,

SYMPTOM


Symptom.>

CC(H4SO)-3




A: CAUTION

1. SUPPLEMENTAL RESTRAINT SYSTEM

AIRBAG

Airbag system wiring harness is routed near the cruise control module and cruise control command switch.


1. SPECIAL TOOL

CAUTION:


• Be careful not to damage the airbag system wiring harness when servicing the cruise control module and cruise control command switch.


24082AA230

(Newly adopted tool)

DESCRIPTION

CARTRIDGE

REMARKS

Troubleshooting for electrical systems.

ST24082AA230

22771AA030 SUBARU SELECT

MONITOR KIT


• English:

22771AA030 (Without printer)

• German:


• French:


• Spanish:


ST22771AA030

2. GENERAL TOOL

TOOL NAME

Circuit tester

REMARKS

Used for measuring resistance, voltage and ampere.

CC(H4SO)-4



5. CABLE FREE PLAY

C: INSPECTION

1. BATTERY



12 V, or more

Specific gravity:

Above 1.260

2. CRUISE CONTROL CABLE

(1)

CC-00043

(C)

(D)

(B)

(A)

CC-00037

1) Check that the throttle cam-to-lever clearance

(A) or cable (B) deflection amount (D) is within specifications.

Throttle cam-to-lever clearance:

0 — 1 mm (0 — 0.04 in)

Inner cable deflection:

1 — 8 mm (0.04 — 0.31 in)

2) If NG, adjust the clearance with the adjusting nut.

NOTE:

Check that the cap (C) is positioned in the groove.

(1) Cruise control cable

1) Check the cruise control cable installation.

2) If NG, install the cable securely.

3. ACCELERATOR CABLE

(1)

CC-00044

(1) Accelerator cable

1) Check the movement of accelerator cable when the cruise control throttle is moved by hand.

2) If NG, check the throttle cam.

4. THROTTLE CAM

Check that the throttle cam moves smoothly.

If NG, repair the throttle cam.

CC(H4SO)-5




A: LOCATION

(2)

(1)

(3)

(4)

(5)

(6)

(7)

(1) Actuator






(7) Cruise control module

CC-00001

CC(H4SO)-6

Cruise Control Module I/O Signal


4. Cruise Control Module I/O Signal


10 9 8

7 6

5 4 3

2

1

20 19 18 17 16 15 14 13 12 11


Inhibitor switch (AT model)

Motor B

Ground

Motor A

Main power supply

Ignition switch

Motor C

Content

RESUME/ACCEL switch

SET/COAST switch

Motor clutch

Cruise control main switch

CC-00027

Terminal No.

1

4

5

6

7

9

10

11

12

13

14

15

Measuring conditions and I/O signals (ignition switch ON and engine idling)

• Battery voltage is present when main switch is turned ON.

• “0” volt is present when main switch is turned OFF.

• Battery voltage is present when selector lever is other than “P” or “N” position.

• “0” volt is present when selector lever is set to “P” or “N” position.

• ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated while cruise control is operating.


—



• Battery voltage is present when command switch is turned to RESUME/ACCEL position.

• “0” volt is present when command switch is released.

• Battery voltage is present when command switch is turned to SET/COAST position.

• “0” volt is present when command switch is released.

• Battery voltage is present when main power is turned ON.

• “0” volt is present when main power is turned OFF.

• Battery voltage is present when ignition switch is turned ON.

• “0” volt is present when ignition switch is turned OFF.




• “0” volt is present when vehicle is stopped.

• Battery voltage is present while pressing the main switch.

• “0” volt is present when main switch is released.

CC(H4SO)-7

Cruise Control Module I/O Signal


Content

Brake switch/Clutch switch

(MT model)

Data link connector

Data link connector

Vehicle speed sensor (MT model)

TCM (AT model)

Terminal No.

16


Leave clutch pedal released (MT model), while cruise control main switch is turned ON.

Then check that;

• Battery voltage is present when brake pedal is released.

• “0” volt is present when brake pedal is depressed.

Additionally only in MT model, keep the cruise control main switch to ON and leave brake pedal released.

Then check that;

• Battery voltage is present when clutch pedal is released.

• “0” volt is present when clutch pedal is depressed.

— 17

18

19

—

Lift-up the vehicle until all four wheels are raised off ground, and then rotate any wheel manually.

Approx. “5” and “0” volt pulse signals are alternately input to cruise control module.

Stop light switch 20 Turn ignition switch to OFF.

Then check that;

• Battery voltage is present when brake pedal is depressed.

• “0” volt is present when brake pedal is released.

NOTE:

Voltage at terminals 5, 7, 13 and 14 cannot be checked unless vehicle is driving by cruise control operation.

B: WIRING DIAGRAM

<Ref. to WI-110, WIRING DIAGRAM, Cruise Control System.>

CC(H4SO)-8

5. Subaru Select Monitor

A: OPERATION

Subaru Select Monitor


2. CRUISE CANCEL CONDITIONS DIAG-

NOSIS

1) Prepare the Subaru Select Monitor kit.

1. GENERAL

The on-board diagnosis function of the cruise control system uses an external Subaru Select Monitor.

The on-board diagnosis function operates in two categories, which are used depending on the type of problems;

1) Cruise cancel conditions diagnosis:

(1) This category of diagnosis requires actual vehicle driving in order to determine the cause,

(as when cruise speed is cancelled during driving although cruise cancel condition is not entered).

(2) Cruise control module memory stores the cancel condition (Code No.) which occurred during driving. When there are plural cancel conditions (Code No.), they are shown on the Subaru

Select Monitor.

CAUTION:

• The cruise control memory stores not only the cruise “cancel” which occurred (although “cancel” operation is not entered by the driver), but also the “cancel” condition input by the driver.

• The content of memory is cleared when ignition switch or cruise main switch is turned OFF.

2) Real-time diagnosis:

The real-time diagnosis function is used to determine whether or not the input signal system is in good order, according to signal emitted from switches, sensors, etc.

(1) Vehicle cannot be driven at cruise speed because problem occurs in the cruise control system or its associated circuits.

(2) Monitor the signal conditions from switches and sensors.

CC-00028

2) Connect the diagnosis cable to Subaru Select

Monitor.

3) Insert the cartridge into Subaru Select Monitor.

<Ref. to CC(H4SO)-4, SPECIAL TOOL, PREPA-

RATION TOOL, General Description.>

CC-00029

4) Connect the Subaru Select Monitor to data link connector.

(1) Data link connector is located in the lower portion of the instrument panel (on the driver’s side).

ME-00325

(2) Connect the diagnosis cable to data link connector.

5) Start the engine and turn the cruise control main switch to ON.

CC(H4SO)-9



6) Turn the Subaru Select Monitor switch to ON.

(1)

CC-00045

(1) Power switch

7) On the Main Menu display screen, select the {All

System Diagnosis} and press [YES] key.

NOTE:

DTC is also shown in the {Each System Check} mode.

This mode is called up on the Cruise Control Diagnosis screen by selecting the item {Cancel Code(s) Display}.

8) Drive the vehicle at least 30 km/h (19 MPH) with cruise speed set.

9) If the cruise speed is canceled itself (without doing any cancel operations), DTC will appear on select monitor display.

CAUTION:

• DTC will also appear when cruise cancel is effected by driver. Do not confuse.

• Have a co-worker ride in the vehicle to assist in diagnosis during driving.

NOTE:

DTC will be cleared by turning the ignition switch or cruise control main switch to OFF.

3. REAL-TIME DIAGNOSIS

1) Connect the select monitor.

2) Turn the ignition switch and cruise control main switch to ON.


4) On the Main Menu display screen, select the

{Each System Check} and press [YES] key.

5) On the System Selection Menu display screen, select the {Cruise Control} and press [YES] key.

6) Press the [YES] key after displayed the information of engine type.

7) On the Cruise Control Diagnosis display screen, select the {Current Data Display & Save} and press

[YES] key.

8) Make sure that normal indication is displayed when controls are operated as indicated below:

• Depress/release the brake pedal. (Stop light switch and brake switch turn ON or OFF.)

• Turn ON or OFF the “SET/COAST” switch.

• Turn ON or OFF the “RESUME/ACCEL” switch.

• Depress/release the clutch pedal. (MT model)

• Set the selector lever to P or N. (AT model)

NOTE:

• For detailed operation procedure, refer to the

SUBARU SELECT MONITOR OPERATION MAN-

UAL.

• For detailed concerning DTC, refer to the List of

Diagnostic Trouble Code (DTC).

<Ref. to CC(H4SO)-27, List of Diagnostic Trouble

Code (DTC).>

CC(H4SO)-10

Diagnostic Procedure with Symptom


6. Diagnostic Procedure with Symptom

A: SYMPTOM CHART

1

2

3

4

5

6

Symptom

Cruise control main switch is not turned ON.

Repair area Reference

(1) Check the power supply.

<Ref. to CC(H4SO)-13, CHECK POWER SUPPLY, Diagnostic Procedure with Symptom.>

(2) Check the cruise control main switch.

<Ref. to CC(H4SO)-15, CHECK CRUISE CONTROL

MAIN SWITCH, Diagnostic Procedure with Symptom.>

Cruise indicator light does not illuminate.

Check the cruise indicator light.

Cruise control cannot be set. (1) Check the SET/COAST switch.

(2) Check the stop light switch and brake switch.

<Ref. to CC(H4SO)-17, CHECK CRUISE INDICATOR

LIGHT, Diagnostic Procedure with Symptom.>


COMMAND SWITCH, Diagnostic Procedure with Symptom.>

<Ref. to CC(H4SO)-21, CHECK STOP LIGHT SWITCH

AND BRAKE SWITCH, Diagnostic Procedure with Symptom.>

Vehicle speed is not held within set speed

MPH).

±3 km/h (±2

(3) Check the clutch switch

(MT model).

(4) Check the inhibitor switch

(AT model).

(5) Check the vehicle speed sensor.

(6) Check the motor drive system.

(7) Check the motor clutch drive system.



<Ref. to CC(H4SO)-23, CHECK CLUTCH SWITCH (MT

MODEL), Diagnostic Procedure with Symptom.>

<Ref. to CC(H4SO)-25, CHECK INHIBITOR SWITCH

(AT MODEL), Diagnostic Procedure with Symptom.>

<Ref. to CC(H4SO)-30, DTC 22 VEHICLE SPEED SEN-

SOR, Diagnostic Procedure with Diagnostic Trouble

Code (DTC).>

<Ref. to CC(H4SO)-34, DTC 35 AND 36 ACTUATOR

MOTOR, Diagnostic Procedure with Diagnostic Trouble

Code (DTC).>

<Ref. to CC(H4SO)-36, DTC 37 ACTUATOR MOTOR

CLUTCH, Diagnostic Procedure with Diagnostic Trouble

Code (DTC).>

<Ref. to CC(H4SO)-30, DTC 22 VEHICLE SPEED SEN-

SOR, Diagnostic Procedure with Diagnostic Trouble

Code (DTC).>



Code (DTC).>


Vehicle speed does not increase or does not return to set speed after RESUME/

ACCEL switch has been pressed.

Vehicle speed does not decrease after SET/COAST switch has been pressed.

(1) Check the RESUME/

ACCEL switch.



(1) Check the SET/COAST switch.





Code (DTC).>





Code (DTC).>



Code (DTC).>





Code (DTC).>



Code (DTC).>

CC(H4SO)-11



7

8

9

Symptom

Cruise control is not released after CANCEL switch has been pressed.

Cruise control is not released after brake pedal has been depressed.

Cruise control is not released after clutch pedal has been depressed (MT model).

(1) Check the CANCEL switch.

Repair area






Reference





Code (DTC).>



Code (DTC).>

<Ref. to CC(H4SO)-21, CHECK STOP LIGHT SWITCH

AND BRAKE SWITCH, Diagnostic Procedure with Symptom.>



Code (DTC).>



Code (DTC).>

(1) Check the clutch switch.

<Ref. to CC(H4SO)-23, CHECK CLUTCH SWITCH (MT

MODEL), Diagnostic Procedure with Symptom.>




Code (DTC).>




Code (DTC).>

CC(H4SO)-12



B: CHECK POWER SUPPLY


Cruise control can be set normally, but indicator does not come on. (When main switch is pressed.)

WIRING DIAGRAM:

BATTERY

IGNITION

SWITCH

F/B No.18

SBF-4

F/B No.14

B: i10

COMBINATION

METER i3

16

B38

CRUISE CONTROL

MAIN SWITCH

B: i10 i3

B38

IC

IS

IC

IS

: INDICATOR ON

COMBINATION METER

: INDICATOR ON

MAIN SWITCH

IC

B161

B161

1 2

3 4 5 6

i3

1 2 3 4

10 11 12 13 14 15

22 23 24 25

16

5 6

17

26 27 28 29

18

30

7 8

19 20

31

9

21

32

B94 CRUISE CONTROL MODULE

B94

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

E

B: i10

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

CC-00253

CC(H4SO)-13



1

2

Step Check Yes



2) Disconnect the cruise control module harness connector.





−

):



1) Turn the ignition switch OFF.

2) Measure the resistance between harness connector terminal and chassis ground.




Ω?

Power supply and ground circuit are

OK.

No

• Check the fuse

No. 18 (in fuse & relay box).

• Check the harness for open or short between cruise control module and fuse & relay box.

Repair the harness.

CC(H4SO)-14



C: CHECK CRUISE CONTROL MAIN SWITCH


Cruise control main switch is not turned ON and cruise control cannot be set.

NOTE:

When the main relay (built-in cruise control module) operates, the main switch circuit is in normal condition.

The main relay operation can be checked by hearing the operation sound.

This operation sound will be heard when the ignition switch and cruise control main switch is turned to ON.

WIRING DIAGRAM:

BATTERY

IGNITION

SWITCH

F/B No.18

SBF-4

F/B No.14

B: i10

COMBINATION

METER i3

16

B38

CRUISE CONTROL

MAIN SWITCH

B: i10 i3

B38

IC

IS

IC

: INDICATOR ON


IS

: INDICATOR ON

MAIN SWITCH

IC

B161

B161

1 2

3 4 5 6

i3

1 2 3 4

10 11 12 13 14 15

22 23 24 25

16

5 6

17

26 27 28 29

18

30

7 8

19 20

31

9

21

32

B94

CRUISE CONTROL MODULE

B94

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

CC(H4SO)-15

E

B: i10

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

CC-00253



1

2

3

Step

CHECK CRUISE CONTROL MAIN SWITCH

CIRCUIT.

1) Turn the ignition switch OFF.


3) Measure the resistance between cruise control module harness connector terminal and cruise control main switch harness connector terminal.


With indicator built in combination meter:

(B94) No. 15 — (B161) No. 5:

With indicator built in main switch:

(B94) No. 15 — (B161) No. 1:

Check


Ω?

Yes


CIRCUIT.


2) Disconnect the cruise control main switch harness connector.






−

):



−

):


Go to step 3.

CHECK CRUISE CONTROL MAIN SWITCH.

Remove and check the cruise control main

switch. <Ref. to CC-8, Cruise Control Main

Switch.>

Is the cruise control main switch OK?

No

• Check the fuse


• Check the harness for open or short between cruise control main switch and fuse & relay box.

Repair the harness.

Replace the cruise control module.

Replace the cruise control main switch.

CC(H4SO)-16



D: CHECK CRUISE INDICATOR LIGHT


Cruise control can be set normally, but indicator light does not come on. (When main switch is pressed.)

WIRING DIAGRAM:

BATTERY

IGNITION

SWITCH

F/B No.18

SBF-4

F/B No.14

B: i10

COMBINATION

METER i3

16

B38

CRUISE CONTROL

MAIN SWITCH

B: i10 i3

B38

IC

IS

IC

IS

: INDICATOR ON


: INDICATOR ON

MAIN SWITCH

IC

B161

B161

1 2

3 4 5 6

i3

1 2 3 4

10 11 12 13 14 15

22 23 24 25

16

5 6

17

26 27 28 29

18

30

7 8

19 20

31

9

21

32


B94

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

E

B: i10

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

CC-00253

CC(H4SO)-17



1

2

3

Step

CHECK CRUISE INDICATOR LIGHT CIR-

CUIT.



3) Measure the resistance between cruise control module harness connector terminal and combination meter harness connector terminal.



(B94) No. 1 (+) — (i10) No. 16:


(B94) No. 1 (+) — (B161) No. 4:

Check


Ω?

Yes


CUIT.


2) With indicator built in combination meter:

Disconnect the combination meter harness connector.

With indicator built in main switch:

Disconnect the cruise control main switch harness connector.






−

):



−

):


Go to step 3.


CUIT.

Ground the cruise control module harness connector terminal with a suitable wire.



Does the cruise indicator light illuminate?

No

• Check the fuse


• Check the harness for open or short between combination meter and fuse & relay box.

Repair the harness.


• With indicator built in combination meter: Check the cruise indicator light bulb in combination meter, and replace it if malfunction occurred.No malfunction found, replace the printed circuit of combination meter.

• With indicator built in main switch: Replace the cruise control main switch.

CC(H4SO)-18



E: CHECK CRUISE CONTROL COMMAND SWITCH


Cruise control cannot be set. (Cancelled immediately.)

WIRING DIAGRAM:

BATTERY

M/B No.6

HORN SWITCH

RESUME/

ACCEL

SWITCH

CANCEL

SWITCH

SET/

COAST

SWITCH

CRUISE CONTROL

COMMAND SWITCH

S1

STEERING

ROLL CONNECTOR

HORN RELAY

HORN

F37

:

LHD

F144 : RHD

B236

LHD

B62

13

F45

LHD

LHD

LHD

: LHD MODEL

RHD

RHD : RHD MODEL

S1

1 2 3

B236

1

3

2

4 5


F37

:

LHD

F144

: RHD

1 2 3

4 5 6

B94

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

F45

1 2 3

8 9 10

4 5 6 7

11 12 13 14 15 16

CC-00040

CC(H4SO)-19



1

2

3

4

5

Step Check

CHECK SET/COAST SWITCH CIRCUIT.



3) Measure the voltage between harness connector terminal and chassis ground when SET/

COAST switch is pressed and not pressed.



−

):

Is the voltage 0 V when the

SET/COAST switch is not pressed? Is the voltage more than 10 V when the SET/

COAST switch is pressed?

Yes

Go to step 2.

No

Go to step 4.

CHECK RESUME/ACCEL SWITCH CIRCUIT.

Measure the voltage between harness connector terminal and chassis ground when

RESUME/ACCEL switch is pressed and not pressed.



−

):


RESUME/ACCEL switch is not pressed? Is the voltage more than 10 V when the RESUME/

ACCEL switch is pressed?

Go to step 3. Go to step 4.

CHECK CANCEL SWITCH CIRCUIT.

Measure the voltage between harness connector terminal and chassis ground when CAN-

CEL switch is pressed and not pressed.



−

):


−

):


CANCEL switch is not pressed? Is the voltage more than 10 V when the CANCEL switch is pressed?

CHECK POWER SUPPLY FOR COMMAND

SWITCH.

Check the horn operation.

CHECK CRUISE CONTROL COMMAND

SWITCH.

Remove and check the cruise control com-

mand switch. <Ref. to CC-9, Cruise Control

Command Switch.>

Cruise control command switch circuit is OK.

Go to step 4.

Does the horn sound?

Is the cruise control command switch OK?

Go to step 5.

• Check the fuse

No. 6 (in main fuse box).

• Check the horn

relay. <Ref. to

COM-3, INSPEC-

TION, Horn System.>

• Check the harness for open or short between cruise control command switch and fuse & relay box.

Check the harness between cruise control command switch and cruise control module.

Replace the cruise control command switch.

CC(H4SO)-20



F: CHECK STOP LIGHT SWITCH AND BRAKE SWITCH


Cruise control cannot be set.

WIRING DIAGRAM:

BATTERY

F/B No.16

SBF-1 SBF-2

CLUTCH

SWITCH (MT MODEL)

AT

MT

1

2

B107

:AT MODEL

:MT MODEL

MT

MT

CRUISE

CONTROL

MODULE

B94

B107

1 2

B65

1 2

3 4

B94

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

1

3

B65

2

4

STOP LIGHT SWITCH

AND BRAKE SWITCH

STOP LIGHT

SWITCH

BRAKE

SWITCH

CC-00033

CC(H4SO)-21



1

2

3

4

Step Check Yes

CHECK STOP LIGHT SWITCH AND BRAKE

SWITCH CIRCUIT.


2) Disconnect the stop light switch and brake switch harness connector.


4) Turn the cruise control main switch to ON.




−

):



SWITCH CIRCUIT.

Measure the voltage between harness connector terminal and chassis ground.



−

):



SWITCH CIRCUIT.

1) Turn the cruise control main switch and ignition switch to OFF.


3) Measure the resistance between cruise control module harness connector terminal and stop light switch and brake switch harness connector terminal.


(B94) No. 20 — (B65) No. 3:

(B94) No. 16 — (B65) No. 1:


Ω?


SWITCH.

Remove and check the stop light switch and

brake switch. <Ref. to CC-10, Stop and Brake

Switch.>

Are the stop light switch and brake switch are OK?

Go to step 4.

Stop light switch and brake switch circuit are OK.

No

• Check the fuse


• Check the harness for open or short between stop light/brake switch and fuse & relay box.

• Check the harness for open or short between stop light/brake switch and cruise control module (AT model).

• Check the clutch switch and circuit

(MT model).

Repair the harness.

Replace the stop light switch and brake switch.

CC(H4SO)-22



G: CHECK CLUTCH SWITCH (MT MODEL)



WIRING DIAGRAM:

BATTERY

F/B No.16

SBF-1 SBF-2

CLUTCH

SWITCH (MT MODEL)

AT

MT

1

2

B107

:AT MODEL

:MT MODEL

MT

MT

CRUISE

CONTROL

MODULE

B94

B107

1 2

B65

1 2

3 4

B94

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

1

3

B65

2

4



STOP LIGHT

SWITCH

BRAKE

SWITCH

CC-00033

CC(H4SO)-23



1

2

3

Step

CHECK CLUTCH SWITCH CIRCUIT.

1) Turn the cruise control main switch and ignition switch OFF.


3) Measure the resistance between clutch switch harness connector terminal and stop light switch and brake switch harness connector terminal.


(B107) No. 1 — (B65) No. 4:

Check


Ω?

Yes



2) Disconnect the clutch switch harness connector.






−

):


Go to step 3.

CHECK CLUTCH SWITCH.

Remove and check the clutch switch. <Ref. to

CC-11, Clutch Switch.>

Is the clutch switch OK? Clutch switch circuit is OK.

No

Check the harness for open or short between clutch switch and cruise control module.

Repair the harness.

Replace the clutch switch.

CC(H4SO)-24



H: CHECK INHIBITOR SWITCH (AT MODEL)



WIRING DIAGRAM:

BATTERY

M/B No.2

SBF-1

CRUISE

CONTROL

MODULE

B94

WS

SECURITY RELAY

3

4

2

1

B323

TO SECURITY

SYSTEM

WS

B12

T3

T7

WS

:WITH SECURITY SYSTEM

OS

:WITHOUT SECURITY SYSTEM

B323

1 2

3 4

B12

1 2 3 4

5 6 7 8

9 10 11 12

INHIBITOR

SWITCH (AT MODEL)

T7

1 2 3 4 5 6

7 8 9 10 11 12

B14

STARTER

MOTOR

B94

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

CC-00254

CC(H4SO)-25



1

2

3

Step Check


Ω?

Yes

CHECK INHIBITOR SWITCH CIRCUIT.


2) Disconnect the inhibitor switch harness connector.





(T7) No. 12 (+) — Chassis ground (

−

):


Go to step 3.


1) Turn the cruise control main switch and ignition switch to OFF.

2) Disconnect the starter motor harness connector.

3) Measure the resistance between inhibitor switch harness connector terminal and starter motor harness connector terminal.


(T7) No. 7 — (B14) No. 1:

CHECK INHIBITOR SWITCH.

Remove and check the inhibitor switch. <Ref. to CC-12, Inhibitor Switch (AT model).>

Is the inhibitor switch OK? Inhibitor switch circuit is OK.

No

Check the harness for open or short between inhibitor switch and cruise control module.

Repair the harness.

Replace the inhibitor switch.

CC(H4SO)-26



7. List of Diagnostic Trouble Code (DTC)

A: LIST

DTC

21

22

24

25

28

35

36

37

Item

Inner relay is seized.

Vehicle speed sensor

Cruise control module is abnormal.


Wiring harness opened.

Motor drive system is abnormal.

Trouble of motor turning speed

Motor clutch drive system is abnormal.

Cruise control module inner relay is seized when main switch is OFF.

Contents of diagnosis

Vehicle speed signal changes more than 10 km/h (6

MPH) within 350 ms.

Two vehicle speed values stored in cruise control module memory are not the same.

Two output values stored in cruise control module memory are not the same.

Open wiring harness circuit is detected via control module relay when main switch is ON.

• Motor output circuit is open or shorted.

• Motor drive circuit is open or shorted.

Motor turning speed is low.

• Motor clutch output circuit is open or shorted.

• Motor clutch drive circuit is open or shorted.

Reference

<Ref. to CC(H4SO)-29,

DTC 21, 24, 25 AND 2A

CRUISE CONTROL

MODULE BUILT-IN

RELAY, CPU RAM, Diagnostic Procedure with

Diagnostic Trouble Code

(DTC).>


DTC 22 VEHICLE SPEED

SENSOR, Diagnostic Procedure with Diagnostic

Trouble Code (DTC).>


DTC 21, 24, 25 AND 2A

CRUISE CONTROL

MODULE BUILT-IN



(DTC).>


DTC 21, 24, 25 AND 2A

CRUISE CONTROL

MODULE BUILT-IN



(DTC).>


DTC 28 WIRING HAR-

NESS OPENED., Diagnostic Procedure with


(DTC).>


DTC 35 AND 36 ACTUA-

TOR MOTOR, Diagnostic

Procedure with Diagnostic Trouble Code (DTC).>


DTC 35 AND 36 ACTUA-

TOR MOTOR, Diagnostic



DTC 37 ACTUATOR

MOTOR CLUTCH, Diagnostic Procedure with


(DTC).>

CC(H4SO)-27



DTC

38

39

2A

Item

Motor drive shaft does not engage properly.

Motor is overloaded.



Motor drive gear engagement is not properly adjusted.

Current flows through motor more frequently than under normal conditions.

Cruise control module self-diagnosis function senses abnormality.

Reference


DTC 38 MOTOR DRIVE

SHAFT DOES NOT

ENGAGE PROPERLY.,

Diagnostic Procedure with


(DTC).>


DTC 39 MOTOR IS

OVERLOADED., Diagnostic Procedure with


(DTC).>


DTC 21, 24, 25 AND 2A

CRUISE CONTROL

MODULE BUILT-IN



(DTC).>

CC(H4SO)-28



8. Diagnostic Procedure with

Diagnostic Trouble Code

(DTC)

A: DTC 21, 24, 25 AND 2A CRUISE

CONTROL MODULE BUILT-IN RE-

LAY, CPU RAM

DIAGNOSIS:

• Poor welding of built-in relay of cruise control module.

• Failure of built-in CPU RAM of cruise control module.


• Cruise control is canceled and memorized cruise speed is also canceled.

• Once cruise control is canceled, cruise control cannot be set until the ignition switch and cruise control main switch turns OFF, and then turns ON again.

NOTE:

Check input/output signal and vehicle speed signal with select monitor. When signals are in good condition, failure is in cruise control module. (Check the power supply and ground conditions of cruise control module.)

CC(H4SO)-29



B: DTC 22 VEHICLE SPEED SENSOR

DIAGNOSIS:

Disconnection or short circuit of vehicle speed sensor system.



WIRING DIAGRAM:

BATTERY

IGNITION

RELAY

M/B No.5

TCM

C17

C:

B56

AT : AT MODEL

MT : MT MODEL

LT

XL

LT

XL

TB

: LHD TURBO

MODEL

: EXCEPT LHD

TURBO MODEL

: TURBO MODEL

NA

: NON-TURBO

MODEL

B17

:

NA

1 2 3

B17

:

TB

1 2

3 4

B94

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

F2

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20

AT MT

CRUISE

CONTROL

MODULE

B94

B21

:

XL

F60

:

LT

1 2 3 4

5 6 7 8

9 10 11 12

13 14 15 16

E E

GE

C: B56

1 2 3 4

10 11 12 13

5 6

14 15

7

16

8

17

9

18

19 20 21 22 23 24

LT

B21

E2

LT

B17

2

3

1

VEHICLE SPEED

SENSOR

(MT MODEL)

B100

F2

F60

E2

CC-00042

CC(H4SO)-30

1

2

3

4

5

6



Step

CHECK TRANSMISSION TYPE.

Check

Is the target MT model?

Yes

Go to step 2.

No

Go to step 6.

CHECK HARNESS BETWEEN BATTERY

AND VEHICLE SPEED SENSOR.


2) Disconnect the harness connector from vehicle speed sensor.


4) Measure the voltage between vehicle speed sensor harness connector terminal and chassis ground.



−

):


CHECK HARNESS BETWEEN CRUISE CON-

TROL MODULE AND VEHICLE SPEED SEN-

SOR.


2) Disconnect the harness connector from cruise control module.

3) Measure the resistance between vehicle speed sensor harness connector terminal and cruise control module harness connector terminal.


(B17) No. 1 — (B94) No. 19:


Ω?




2) Measure the resistance between vehicle speed sensor harness connector terminal and engine ground.




Ω?

Is the voltage less than 0 V

←

→ more than 5 V?


1) Connect the harness connector to vehicle speed sensor.

2) Lift-up the vehicle and support with rigid racks.

3) Drive the vehicle at speed greater than 20 km/h (12 MPH).

Go to step 4.

Go to step 5.

Check the harness for open or short between fuse relay and vehicle speed sensor.

Repair the harness.

Repair the harness.


<Ref. to CC-7,

Cruise Control

Module.>


Warning:

Be careful not to be caught up by the running wheels.

4) Measure the voltage between cruise control module harness connector terminal and chassis ground.



−

):

CHECK HARNESS BETWEEN CRUISE CON-

TROL MODULE AND TCM.


2) Disconnect the harness connector from

TCM and cruise control module.

3) Measure the resistance between cruise control module harness connector terminal and TCM harness connector terminal.


(B94) No. 19 — (B56) No. 17:


Ω?

Go to step 7.

Repair the harness.

CC(H4SO)-31



7

Step

CHECK TCM.

1) Connect the harness connector to TCM.


3) Drive the vehicle faster than 10 km/h (6

MPH).

Warning:

Be careful not to be caught by the running wheels.

4) Measure the voltage between TCM harness connector terminal and chassis ground.



−

):

Check

Is the voltage less than 0 V

←

→ more than 5 V?

Yes No


<Ref. to CC-7,

Cruise Control

Module.>

Replace the TCM.

<Ref. to 4AT-77,

Transmission Control Module

(TCM).>

CC(H4SO)-32



C: DTC 28 WIRING HARNESS OPENED.

1

2

Step

CHECK BATTERY.

Measure the battery specific gravity of electrolyte.

CHECK FUSES, CONNECTORS AND HAR-

NESSES.

Check the condition of fuses, and harnesses and connectors. Also check for proper grounding.

Check

Is the battery specific gravity more than 1.260?

Is there anything unusual about the appearance of fuse, harness, connector and grounding?

Yes

Go to step 2.

Repair or replace the faulty parts.

No

Charge or replace

the battery. Go to step 2.

End of inspection.

CC(H4SO)-33



D: DTC 35 AND 36 ACTUATOR MOTOR

DIAGNOSIS:

Open or poor contact of cruise control actuator motor.



WIRING DIAGRAM:

CRUISE CONTROL

MODULE

B94

B7

1 2 3

4 5 6

B94

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

CRUISE CONTROL

ACTUATOR

B7

E

CC(H4SO)-34

CC-00036

1

2

3

4

5



Step Check Yes



2) Disconnect the harness connector from cruise control actuator.



5) Measure the voltage between cruise control actuator harness connector terminal and chassis ground.

Terminals


−

):


No

Check the harness for open or short between cruise control module and cruise control actuator.

CHECK GROUND CIRCUIT OF ACTUATOR.

1) Turn the ignition switch and cruise control main switch to OFF.

2) Measure the resistance between cruise control actuator harness connector terminal and chassis ground.

Terminals



Ω?

Go to step 3.

MEASURE RESISTANCE OF ACTUATOR.

Measure the resistance of cruise control actuator motor.

Terminals

No. 4 — No. 1:

No. 4 — No. 2:

No. 4 — No. 5:

Is the resistance approx. 5

Ω? Go to step 4.

Go to step 5.

CHECK HARNESS BETWEEN ACTUATOR

AND CRUISE CONTROL MODULE.


2) Measure the resistance between cruise control module harness connector terminal and cruise control actuator harness connector terminal.


(B7) No. 1 — (B94) No. 7:


Ω?



Measure the resistance between cruise control module harness connector terminal and cruise control actuator harness connector terminal.


(B7) No. 5 — (B94) No. 5:


Ω?

Repair the harness.

Replace the cruise control actuator.

<Ref. to CC-5,

Actuator.>

Repair the harness.


<Ref. to CC-7,

Cruise Control

Module.>

Repair the harness.

CC(H4SO)-35



E: DTC 37 ACTUATOR MOTOR CLUTCH

DIAGNOSIS:

Open or poor contact of cruise control actuator motor clutch.



WIRING DIAGRAM:

CRUISE CONTROL

MODULE

B94

B7

1 2 3

4 5 6

B94

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

CRUISE CONTROL

ACTUATOR

B7

E

CC(H4SO)-36

CC-00036

1

2

3

4

5



Step Check Yes






5) Measure the voltage between cruise control actuator harness connector terminal and chassis ground.

Terminals


−

):


No

Check the harness for open or short between cruise control module and cruise control actuator.

CHECK GROUND CIRCUIT OF ACTUATOR.

1) Turn the ignition switch and cruise control main switch to OFF.

2) Measure the resistance between cruise control actuator harness connector terminal and chassis ground.

Terminals



Ω?

Go to step 3.

MEASURE RESISTANCE OF ACTUATOR

CLUTCH.

Measure the resistance of cruise control actuator clutch.

Terminals

No. 3 — No. 6:

Is the resistance approx. 39

Ω? Go to step 4.

Go to step 5.




2) Measure the resistance between cruise control module harness connector terminal and cruise control actuator harness connector terminal.


(B7) No. 2 — (B94) No. 13:


Ω?



Measure the resistance between cruise control module harness connector terminal and cruise control actuator harness connector terminal.


(B7) No. 3 — (B94) No. 14:


Ω?

Repair the harness.


<Ref. to CC-5,

Actuator.>

Repair the harness.


<Ref. to CC-7,

Cruise Control

Module.>

Repair the harness.

CC(H4SO)-37



F: DTC 38 MOTOR DRIVE SHAFT DOES NOT ENGAGE PROPERLY.

1

Step

CHECK ACTUATOR MOTOR.



3) Remove the cruise control actuator from mounting bracket.

4) Pull the cable by hand to check for looseness or status of inner gear engagement.

Check

Are foreign particles caught in the inner gear or does inner gear engage and disengage improperly?

Yes No


<Ref. to CC-5,

Actuator.>

Check the cruise control cable

adjustment. <Ref. to CC(H4SO)-5,

CABLE FREE

PLAY, INSPEC-

TION, General

Description.>

G: DTC 39 MOTOR IS OVERLOADED.

1


CHECK THE OPERATING CURRENT TO AC-

TUATOR MOTOR.


2) Try to drive the vehicle while operating the cruise control system.

3) Measure the operation current to the cruise control actuator motor.



Is the voltage more than 10 A? Replace the cruise Check the power control module.

<Ref. to CC-7,

Cruise Control

Module.>

supply circuit.

<Ref. to

CC(H4SO)-13,

CHECK POWER

SUPPLY, Diagnostic Procedure with

Symptom.>

CC(H4SO)-38


(DIAGNOSTIC)

CC(H4DOTC)

Page

1.






Specifications for 2.0 L turbo model are included in

CC(H4SO) section. <Ref. to CC(H4SO)-2, Basic Diagnostic Procedure.>

CC(H4DOTC)-2


(DIAGNOSTIC)

CC(H4DOTC 2.5)

Page

1.


2.


3.


4.

Engine Control Module (ECM) I/O Signal ...................................................6

5.


6.

Diagnostic Procedure with Symptom ........................................................10

7.


8.


2

3




A: PROCEDURE

1

4

5

6

7

8

9

Step

CHECK MALFUNCTION INDICATOR LIGHT.

Check the malfunction indicator light illuminates.

CHECK CRUISE INDICATOR LIGHT.

Check the cruise indicator light blinks.


OPERATION.

Check the cruise control main switch operation. (Check the cruise indicator light illuminates.)

Check Yes

Does the malfunction indicator light illuminate?

Go to step 5.

Does the cruise indicator light blink?

Is the cruise control main switch set to on? (Does the cruise indicator light illuminate?)

Go to step 5.

Go to step 4.

No

Go to step 2.

Go to step 3.

Go to symptom 1.

<Ref. to

CC(H4DOTC 2.5)-

10, SYMPTOM


Symptom.>

Go to step 5.

CHECK CRUISE CONTROL SET OPERA-

TION.

Check the cruise control set operation.

PERFORM CRUISE CONTROL CANCEL

CONDITION DIAGNOSIS.

Perform the cruise control cancel condition diagnosis.

CHECK VEHICLE SPEED IS HELD WITHIN

SET SPEED.

Make sure the vehicle speed is held within set speed.

CHECK RESUME/ACCEL OPERATION.

Check the RESUME/ACCEL switch operation.

CHECK SET/COAST OPERATION.

Check the SET/COAST switch operation.

CHECK CANCEL OPERATION.

Check the CANCEL switch operation.

Can the cruise control be set while driving at 40 km/h (25

MPH)?

Are any DTC indicated?

Is the vehicle speed held within set speed

±3 km/h (±2 MPH)?

(Make an inspection on a level road.)

Does the vehicle speed increase or return to set speed after RESUME/ACCEL switch has been pressed?

Does the vehicle speed decrease after SET/COAST switch has been pressed?

Is the cruise control released after CANCEL switch has been pressed?

Go to step 6.

Go to “List of

DTC”. <Ref. to

CC(H4DOTC 2.5)-

13, List of Diagnostic Trouble

Code (DTC).>

Go to step 7.

Go to step 8.

Go to step 9.

Go to step 10.

Go to symptom 2.

<Ref. to

CC(H4DOTC 2.5)-

10, SYMPTOM


Symptom.>

Go to symptom 3.

<Ref. to

CC(H4DOTC 2.5)-

10, SYMPTOM


Symptom.>

Go to symptom 4.

<Ref. to

CC(H4DOTC 2.5)-

10, SYMPTOM


Symptom.>

Go to symptom 5.

<Ref. to

CC(H4DOTC 2.5)-

10, SYMPTOM


Symptom.>

Go to symptom 6.

<Ref. to

CC(H4DOTC 2.5)-

10, SYMPTOM


Symptom.>

CC(H4DOTC 2.5)-2

10

11

12



Step


ERATION.



ERATION.



ERATION.


Check

Is the cruise control released after brake pedal has been depressed?

Is the cruise control released after clutch pedal has been depressed?

Is the cruise control released after shifting to neutral position?

Yes

Go to step 11.

Go to step 12.


No

Go to symptom 7.

<Ref. to

CC(H4DOTC 2.5)-

10, SYMPTOM


Symptom.>

Go to symptom 8.

<Ref. to

CC(H4DOTC 2.5)-

10, SYMPTOM


Symptom.>

Go to symptom 9.

<Ref. to

CC(H4DOTC 2.5)-

10, SYMPTOM


Symptom.>

CC(H4DOTC 2.5)-3




A: CAUTION

1. SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG”

Airbag system wiring harness is routed near the cruise control command switch.

CAUTION:


• Be careful not to damage the airbag system wiring harness when servicing the cruise control command switch.


1. SPECIAL TOOL


24082AA230


DESCRIPTION

CARTRIDGE

REMARKS


ST24082AA230

22771AA030 SUBARU SELECT

MONITOR KIT


• English:


• German:


• French:


• Spanish:


ST22771AA030

2. GENERAL TOOL

Circuit tester

TOOL NAME REMARKS


C: INSPECTION

1. BATTERY



12 V, or more

Specific gravity:

Above 1.260

CC(H4DOTC 2.5)-4




A: LOCATION

(1)

(7)

(2)

(6)





(5) Stop light and brake switch

(6) Engine control module (ECM)

(3)

(4)

(5)

CC-00262

(7) Neutral switch (MT model)

CC(H4DOTC 2.5)-5

Engine Control Module (ECM) I/O Signal


4. Engine Control Module (ECM) I/O Signal


To A: B134

7

17 16

6

15

27 26

34 33

25

5

14

24

13

23

4 3

12 11

2

10 9

1

8

22 21 20 19 18

32 31 30 29 28

To B: B135

7

19 18

6 5

17 16 15

4

27 26

35 34

25

33

3

14

24

32

13

2

12 11 10

23

31

9

22 21

1

8

20

30 29 28

To C: B136

6

16 15

5

14 13

4 3

12 11 10

27 26

35

25

34 33

24 23

32 31

22 21

9

2

8

1

7

20 19 18 17

30 29 28

To D: B137

7 6

17 16 15

25

31

24

30

14

5

13

4 3

12 11 10

2

9

1

8

23 22 21 20 19 18

29 28 27 26

Clutch switch

Content


Main power supply

VB (CONTROL 1)

VB (CONTROL 2)

Vehicle speed signal

SET/COAST switch

RESUME/ACCEL switch

Brake switch 1

(Brake switch)

Brake switch 2

(Stop light switch)

Main switch

Ground

Ignition switch

GND (CONTROL 1)

GND (CONTROL 2)

Neutral switch (MT model)

Inhibitor switch (AT model)

CC-00197

Terminal

No.

A1

A15

B6

B5

B26

C11

C10

C9

C8

C7


• Battery voltage is present when the clutch pedal is released.

• “0 V” volt is present when the clutch pedal is depressed.

• Battery voltage is present when the main switch is turned to OFF.

• “0 V” volt is present when the main switch is turned to ON.

• Battery voltage is present when the main power supply is turned to ON.

• “0 V” volt is present when the main power supply is turned to OFF.

Lift-up the vehicle until all four wheels are raised off the ground, and then rotate any wheel manually. Approx. “5 V” and “0 V” pulse signals are alternately input to

ECM.

• Battery voltage is present when the command switch is turned to SET/COAST position.

• “0 V” volt is present when the command switch is released.

• Battery voltage is present when the command switch is turned to RESUME/

ACCEL position.

• “0 V” volt is present when the command switch is released.

• Battery voltage is present when the brake pedal is released.

• “0 V” volt is present when the brake pedal is depressed.

• Battery voltage is present when the brake pedal is depressed.

• “0 V” volt is present when the brake pedal is released.

• Battery voltage is present while the main switch is depressed or is turned to

ON.

• “0 V” volt is present when the main switch is turned to OFF.

D2

D1

D15

—

D9

D9

• Battery voltage is present with the ignition switch is turned to ON.

• “0 V” volt is present when the ignition switch is turned to OFF.

• Battery voltage is present when the shift lever is in anywhere except neutral position.

• “0 V” volt is present when the shift lever is in neutral position.

• “0 V” volt is present when the select lever is in anywhere except N or P position.

• “5 V” volt is present when the select lever is in N or P position.

CC(H4DOTC 2.5)-6

Engine Control Module (ECM) I/O Signal


B: WIRING DIAGRAM

<Ref. to WI-110, WIRING DIAGRAM, Cruise Control System.>

CC(H4DOTC 2.5)-7




A: OPERATION

1. GENERAL

The on-board diagnosis function of the cruise control system uses the Subaru Select Monitor.

The on-board diagnosis function operates in two categories, which are used depending on the type of problems;

1) Cruise cancel conditions diagnosis:

(1) This category of diagnosis requires actual vehicle driving in order to determine the cause, (as when cruise speed is cancelled during driving although cruise cancel condition is not entered).

(2) Cruise control memory of ECM stores the cancel condition (Code No.) which occurred during driving. When there are plural cancel conditions (Code No.), they are shown on the Subaru

Select Monitor.

CAUTION:

• The cruise control memory stores not only the cruise “cancel” which occurred (although “cancel” operation is not entered by the driver), but also the “cancel” condition input by the driver.

• The content of memory is cleared when ignition switch or cruise main switch is turned OFF.

2) Real-time diagnosis:

The real-time diagnosis function is used to determine whether or not the input signal system is in good order, according to signal emitted from switches, sensors, etc.

(1) Vehicle cannot be driven at cruise speed because problem occurs in the cruise control system or its associated circuits.

(2) Monitor the signal conditions from switches and sensors.

2. CRUISE CANCEL CONDITIONS DIAG-

NOSIS



<Ref. to CC(H4DOTC 2.5)-4, SPECIAL TOOL,

PREPARATION TOOL, General Description.>

CC-00029


(1) Data link connector is located in the lower portion of the instrument panel (on the driver’s side).

CC-00134


5) Start the engine and turn the cruise control main switch to ON.


(1)

CC-00028


Monitor.

CC-00045

(1) Power switch

7) On the «Main Menu» display screen, select the

{2. Each System Diagnosis} and press [YES] key.

Select the {Engine} on the System Selection display screen and press [YES] key. Press [YES] key after the engine type displayed.

8) Drive the vehicle at least 40 km/h (25 MPH) with cruise speed set.

CC(H4DOTC 2.5)-8



9) If the cruise speed is canceled itself (without doing any cancel operations), DTC will appear on select monitor display after {Cancel Code(s) Display} is selected on the Engine Diagnosis display screen and [YES] key is pressed.

CAUTION:

• DTC will also appear when cruise cancel is effected by driver. Do not confuse.

• Have a co-worker ride in the vehicle to assist in diagnosis during driving.

NOTE:

DTC will be cleared by turning the ignition switch or cruise control main switch to OFF.

3. REAL-TIME DIAGNOSIS

1) Connect the select monitor.

2) Turn the ignition switch and cruise control main switch to ON.



{2. Each System Check} and press [YES] key.

5) On the «System Selection» display screen, select the {Engine} and press [YES] key.

6) Press the [YES] key after the information of engine type displayed.

7) On the «Engine Diagnosis» display screen, select the {Current Data Display & Save} and press

[YES] key.

8) Make sure that normal indication is displayed when controls are operated as indicated below:

• Depress/release the brake pedal. (Stop light switch and brake switch turn ON.)

• Turn ON the “SET/COAST” switch.

• Turn ON the “RESUME/ACCEL” switch.

• Turn ON the “CANCEL” switch. (The “SET/

COAST” and “RESUME/ACCEL” switch are turned

ON at same time.)

• Depress/release the clutch pedal.

• Set the shift lever to except for neutral position.

NOTE:

• For detailed operation procedure, refer to the “SUB-

ARU SELECT MONITOR OPERATION MANUAL.”

• For details concerning DTCs, refer to the “List of

Diagnostic Trouble Code (DTC).” <Ref. to

CC(H4DOTC 2.5)-13, List of Diagnostic Trouble

Code (DTC).>

CC(H4DOTC 2.5)-9



6. Diagnostic Procedure with Symptom

A: SYMPTOM CHART

1

2

3

4

5

6

7

8

9 nate)

Symptom

Cruise control main switch is not turned to ON. (Cruise indicator light does not illumi-


Repair area

(1) Check the cruise indicator light.

(2) Check the cruise control command switch.

(1) Check the cruise control command switch


(3) Check the clutch switch.

(4) Check the neutral switch.


Vehicle speed is not held within set speed

±3 km/h (±2

MPH).

Vehicle speed does not increase or does not return to set speed after RESUME/

ACCEL switch has been pressed.

Vehicle speed does not decrease after SET/COAST switch has been pressed.

Cruise control is not released after CANCEL switch has been pressed.

Cruise control is not released after the brake pedal has been depressed.

Cruise control is not released after the clutch pedal has been depressed.

Cruise control is not released after shifting to neutral position.

Check the vehicle speed sensor.

Check the RESUME/ACCEL switch.

Check the SET/COAST switch.

Check the CANCEL switch.

Check the stop light switch and brake switch.

Check the clutch switch.

Check the neutral switch.

Reference

<Ref. to CC(H4DOTC 2.5)-11, CHECK CRUISE INDICA-

TOR LIGHT, Diagnostic Procedure with Symptom.>

<Ref. to CC(H4DOTC 2.5)-16, DTC 11, 15, 21 AND 24

CRUISE CONTROL COMMAND SWITCH, Diagnostic





<Ref. to CC(H4DOTC 2.5)-18, DTC 12 AND 25 STOP

LIGHT SWITCH AND BRAKE SWITCH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

<Ref. to CC(H4DOTC 2.5)-20, DTC 13 CLUTCH

SWITCH, Diagnostic Procedure with Diagnostic Trouble

Code (DTC).>

<Ref. to CC(H4DOTC 2.5)-22, DTC 14 NEUTRAL POSI-

TION SWITCH, Diagnostic Procedure with Diagnostic


<Ref. to CC(H4DOTC 2.5)-26, DTC 22 AND 32 VEHICLE

SPEED SENSOR, Diagnostic Procedure with Diagnostic


<Ref. to CC(H4DOTC 2.5)-26, DTC 22 AND 32 VEHICLE

SPEED SENSOR, Diagnostic Procedure with Diagnostic











<Ref. to CC(H4DOTC 2.5)-18, DTC 12 AND 25 STOP

LIGHT SWITCH AND BRAKE SWITCH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

<Ref. to CC(H4DOTC 2.5)-20, DTC 13 CLUTCH

SWITCH, Diagnostic Procedure with Diagnostic Trouble

Code (DTC).>

<Ref. to CC(H4DOTC 2.5)-22, DTC 14 NEUTRAL POSI-

TION SWITCH, Diagnostic Procedure with Diagnostic


CC(H4DOTC 2.5)-10



B: CHECK CRUISE INDICATOR LIGHT


Cruise control can be set, but cruise indicator light does not illuminate.

WIRING DIAGRAM:

BATTERY

IGNITION

SWITCH

F/B No.18

SBF-4

F/B No.14

ILLUMINATION

CIRCUIT

CRUISE

INDICATOR

LIGHT

B38 i3

COMBINATION METER i10

CRUISE CONTROL

MAIN SWITCH

CUSTOM

CPU

B161 i2

B37

A: B134

C: B136

ECM i2

1 2 3

9 10

4 5 6 7

11 12 13 14 15 16

8

17 18

A: B134

8

1 2 3 4 5 6 7

18

28

9

19

29

10

20

30

11

21

31

12

22

32

13

23

14

24

15

25

16

26

33

17

27

34

i10

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

C: B136

17

28

7

1 2 3 4

18

8

19

9

20

10

21

11

22

12

23

29 30 31

13

32

5

14

24 25

15

26

33 34

6

16

27

35

i3

1 2 3 4

10 11 12 13 14 15

22 23 24 25

16

5 6

17 18

26 27 28 29 30

7 8

19 20

31

9

21

32

B161

1 2

3 4 5 6

CC-00255

CC(H4DOTC 2.5)-11



1

2

3

Step


CUIT.


2) Disconnect the ECM harness connector.

3) Measure the resistance between ECM harness connector terminal and combination meter harness connector terminal.


(B134) No. 15 — (i10) No. 16:

Check


Ω?

Yes


CUIT.







−

):


Go to step 3.


CUIT.

Ground the ECM harness connector terminal with a suitable wire.



Does the cruise indicator light illuminate?

Check the poor contact of ECM connector.

No

• Check the fuse


• Check the harness for open or short between combination meter and fuse & relay box.

Repair the harness.

Replace the meter main assembly.

CC(H4DOTC 2.5)-12




A: LIST

DTC

11

12

13

14

15

16

Main switch

Item

Stop and brake switch

Clutch switch

Neutral switch

Cancel switch

Ignition switch


Cruise control is released after the main switch of cruise control command switch is turned to OFF.

Cruise control is released after the stop light switch or brake switch is turned to ON.

Cruise control is released after the clutch switch is turned to ON.

Cruise control is released after the neutral position switch is turned to ON.

Cruise control is released after the cancel switch is turned to ON.

Cruise control is released after the ignition switch is turned to OFF.

Reference

This DTC is indicated without operating the main

switch. <Ref. to

CC(H4DOTC 2.5)-16,

DTC 11, 15, 21 AND 24

CRUISE CONTROL

COMMAND SWITCH,



(DTC).>

This DTC is indicated without depressing the

brake pedal. <Ref. to

CC(H4DOTC 2.5)-18,

DTC 12 AND 25 STOP

LIGHT SWITCH AND

BRAKE SWITCH, Diagnostic Procedure with


(DTC).>

This DTC is indicated without depressing the

clutch pedal. <Ref. to

CC(H4DOTC 2.5)-20,

DTC 13 CLUTCH

SWITCH, Diagnostic Procedure with Diagnostic


This DTC is indicated without shifting to neutral

position. <Ref. to

CC(H4DOTC 2.5)-22,

DTC 14 NEUTRAL POSI-

TION SWITCH, Diagnostic Procedure with


(DTC).>

This DTC is indicated without operating the can-

cel switch. <Ref. to

CC(H4DOTC 2.5)-16,

DTC 11, 15, 21 AND 24

CRUISE CONTROL

COMMAND SWITCH,



(DTC).>

This DTC is indicated without operating the igni-

tion switch. <Ref. to

CC(H4DOTC 2.5)-24,

DTC 16 IGNITION

SWITCH, Diagnostic Procedure with Diagnostic


CC(H4DOTC 2.5)-13



DTC

21

22

23

24

25

26

32

33 abnormal.

abnormal.

Item

Cruise control switch is abnormal when the ignition switch is turned to ON.

Vehicle speed variation is

Engine-related sensor is

Cruise control-related switch is abnormal.

Brake switch input circuit is abnormal.


Each switch of cruise control command switch has already been ON when the ignition switch is turned to

ON.

Abnormality of command switch is detected. (Open circuit is detected when continuing to be ON for an extremely long time [approx. two minutes].)

Engine speed signal.

Out of vehicle speed range of cruise control operation.

• Abnormal increase of engine speed is detected.

• Gear is shifted to neutral, 1st or reverse position.

• Vehicle speed becomes under the control limit during cruise driving.

• Set operation is conducted out of vehicle speed range for setting

• RESUME operation is conducted without vehicle speed memory.

Prohibition of WAIT after acceleration operation.

Abnormality of vehicle speed variation is detected.

Abnormality related to engine is detected.

Abnormality of brake switch input circuit in ECM is detected.

Vehicle speed becomes over the control limit during cruise driving.

Reference

This DTC is indicated without operating the main

switch. <Ref. to

CC(H4DOTC 2.5)-16,

DTC 11, 15, 21 AND 24

CRUISE CONTROL

COMMAND SWITCH,



(DTC).>

<Ref. to CC(H4DOTC

2.5)-26, DTC 22 AND 32

VEHICLE SPEED SEN-

SOR, Diagnostic Procedure with Diagnostic


<Ref. to CC(H4DOTC

2.5)-2, Basic Diagnostic

Procedure.>

This DTC is indicated with

normal operation. <Ref. to

CC(H4DOTC 2.5)-16,

DTC 11, 15, 21 AND 24

CRUISE CONTROL

COMMAND SWITCH,



(DTC).>

<Ref. to CC(H4DOTC

2.5)-18, DTC 12 AND 25

STOP LIGHT SWITCH

AND BRAKE SWITCH,



(DTC).>

Cruise with more than 2nd shift position.

This DTC is also indicated when increasing the speed to the cruise set available vehicle speed and conducting the set

operation again. <Ref. to

CC(H4DOTC 2.5)-26,

DTC 22 AND 32 VEHICLE

SPEED SENSOR, Diagnostic Procedure with


(DTC).>

This DTC is indicated when running at the high speed which is not suitable for cruise control. In this case, conduct the cruise set operation again after decreasing the speed to the cruise set available vehicle speed.

CC(H4DOTC 2.5)-14

DTC

34

35



Item

Prohibition when accelerator pedal position is continued to be large.

Prohibition when vehicle speed feedback is impossible.


Vehicle is driven at the higher speed than set vehicle speed for an extremely long time (approx. 10 minutes) during cruise driving.

During cruise driving, set vehicle speed cannot be maintained for some reasons such as sharp upslope, parking brake and engine output abnormal decrease.

Reference

This DTC is indicated when running for a long time at the higher speed than cruise set available vehicle speed by accelerator operation. In this case, release the cruise set.

This DTC is indicated when the driving condition is not suitable for cruise control. Conduct the cruise set operation again after clearing the estimated reasons.

CC(H4DOTC 2.5)-15



8. Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC 11, 15, 21 AND 24 CRUISE CONTROL COMMAND SWITCH


• Cruise control cannot be set. (Cancelled immediately.)

• Cruise control cannot be released.

WIRING DIAGRAM:

BATTERY

M/B No.6

SBF-4

IGNITION

SWITCH

F/B No.18

HORN

RELAY

HORN

F37

CRUISE CONTROL

MAIN SWITCH

B161

1

2

3

B236

CRUISE CONTROL

COMMAND SWITCH

SET

SWITCH

RESUME

SWITCH

CANCEL

SWITCH

B161

1 2

3 4 5 6

B236

1

3

2

4 5

B136 ECM

F37

1 2

4 5

3

6

B136

17

28

7

1 2 3 4

8 9 10 11 12

18

29

19

30

20 21 22 23

31

13

24 25

32

14

5 6

15 16

33

26

34

27

35

CC(H4DOTC 2.5)-16

CC-00256

1

2

3

4

5

6



Step Check


CIRCUIT.




4) Measure the voltage between harness connector terminal and chassis ground when the main switch is pressed and is not pressed.



−

):

Is the voltage 0 V when the main switch is not pressed? Is the voltage more than 10 V when the main switch is pressed?

Yes

Go to step 2.

No

• Check the fuse


• Check the harness for open or short between cruise control command switch and fuse & relay box. If no malfunction is found after checking above,

Go to step 6.

Go to step 5.

CHECK SET/COAST SWITCH CIRCUIT.



3) Measure the voltage between harness connector terminal and chassis ground when SET/

COAST switch is pressed and not pressed.



−

):

Is the voltage 0 V when SET/

COAST switch is not pressed?

Is the voltage more than 10 V when SET/COAST switch is pressed?

Go to step 3.

CHECK RESUME/ACCEL SWITCH CIRCUIT.

Measure the voltage between harness connector terminal and chassis ground when

RESUME/ACCEL switch is pressed and not pressed.



−

):

Is the voltage 0 V when

RESUME/ACCEL switch is not pressed? Is the voltage more than 10 V when RESUME/

ACCEL switch is pressed?

Go to step 4.

CHECK CANCEL SWITCH CIRCUIT.

Measure the voltage between harness connector terminal and chassis ground when CAN-

CEL switch is pressed and not pressed.



−

):


−

):

Is the voltage 0 V when CAN-

CEL switch is not pressed? Is the voltage more than 10 V when CANCEL switch is pressed?

Cruise control command switch circuit is OK.

CHECK POWER SUPPLY FOR COMMAND

SWITCH.

Check the horn operation.

CHECK CRUISE CONTROL COMMAND

SWITCH.

Remove and check the cruise control com-

mand switch. <Ref. to CC-9, Cruise Control

Command Switch.>

Go to step 5.

Go to step 5.

Does the horn sound?

Go to step 6.

• Check the fuse

No. 6 (in main fuse box).

• Check the horn

relay. <Ref. to

COM-3, HORN

RELAY, INSPEC-

TION, Horn System.>

• Check the harness for open or short between cruise control command switch and fuse & relay box.

Is the cruise control command switch OK?

Check the harness between cruise control command switch and ECM.

Replace the cruise control command switch.

CC(H4DOTC 2.5)-17



B: DTC 12 AND 25 STOP LIGHT SWITCH AND BRAKE SWITCH


• Cruise control cannot be set.


WIRING DIAGRAM:

BATTERY

F/B No.16

SBF-1 SBF-2

IGNITION

SWITCH

F/B No.11

SBF-4

CLUTCH

SWITCH

(MT MODEL)

2

1

B107

AT

MT

4

3

B65

2

1



STOP LIGHT

SWITCH

BRAKE

SWITCH

MT

:MT MODEL

AT

:AT MODEL

B107

1 2

B65

1 2

3 4

A: B134

C: B136

ECM

A: B134

8

1 2 3 4 5 6 7

18

28

9

19

29

10

20

30

11

21

31

12

22

32

13

23

14

24

15

25

16

26

33

17

27

34

C: B136

17

28

7

1 2 3 4

18

29

8

19

30

9

20

10

21

11

22

12

23

13

31 32

14

5

24 25

33

15

26

34

6

16

27

35

CC-00257

CC(H4DOTC 2.5)-18

1

2

3

4



Step


SWITCH CIRCUIT.







−

):



SWITCH CIRCUIT.

Measure the voltage between harness connector terminal and chassis ground.



−

):

Check Yes



SWITCH CIRCUIT.



3) Measure the resistance between ECM harness connector terminal and stop light switch and brake switch harness connector terminal.


(B136) No. 8 — (B65) No. 3:

(B136) No. 9 — (B65) No. 4:


Ω?


SWITCH.

Remove and check the stop light switch and

brake switch. <Ref. to CC-10, Stop and Brake

Switch.>

Are the stop light switch and brake switch OK?

Go to step 4.

Stop light switch and brake switch circuit are OK.

No

• Check the fuse



• Check the fuse



• Check the clutch switch and circuit.

Repair the harness.

Replace the stop light switch and brake switch.

CC(H4DOTC 2.5)-19



C: DTC 13 CLUTCH SWITCH


• Cruise control cannot be set.


WIRING DIAGRAM:

BATTERY

F/B No.16

SBF-1 SBF-2

IGNITION

SWITCH

F/B No.11

SBF-4

CLUTCH

SWITCH

(MT MODEL)

2

1

B107

AT

MT

4

3

B65

2

1



STOP LIGHT

SWITCH

BRAKE

SWITCH

MT

:MT MODEL

AT

:AT MODEL

B107

1 2

B65

1 2

3 4

A: B134

C: B136

ECM

A: B134

8

1 2 3 4 5 6 7

18

28

9

19

29

10

20

30

11

21

31

12

22

32

13

23

14

24

15

25

16

26

33

17

27

34

C: B136

17

28

7

1 2 3 4

18

29

8

19

30

9

20

10

21

11

22

12

23

13

31 32

14

5

24 25

33

15

26

34

6

16

27

35

CC-00257

CC(H4DOTC 2.5)-20

1

2

3



Step Check Yes



2) Disconnect the clutch switch harness connector.





−

):



Ω?

Go to step 3.




3) Measure the resistance between clutch switch harness connector terminal and ECM harness connector terminal.


(B107) No. 1 — (B134) No. 1:

CHECK CLUTCH SWITCH.

Remove and check the clutch switch. <Ref. to

CC-11, Clutch Switch.>

Is the clutch switch OK? Clutch switch circuit is OK.

No

• Check the fuse

No. 11 (fuse & relay box).

• Check the harness for open or short between clutch switch and fuse & relay box.

Repair the harness.

Replace the clutch switch.

CC(H4DOTC 2.5)-21



D: DTC 14 NEUTRAL POSITION SWITCH



WIRING DIAGRAM:

B137

ECM

AT

B128

T9

NEUTRAL

POSITION

SWITCH

T9

B128

B12

T3

MT

:MT MODEL

AT

:AT MODEL

B128

1 2

3 4

T7

1 2 3 4 5 6

7 8 9 10 11 12

B12

B21

1 2 3 4

5 6 7 8

9 10 11 12

13 14 15 16

T7

B21

E2

E

GE-2

F2

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20

INHIBITOR

SWITCH

(AT MODEL)

B137

8

1 2 3 4 5 6 7

18

9

19

10

20

11

21

12

22

13

23

14 15 16

24

17

25

26 27 28 29 30 31

B14

STARTER

MOTOR

CC-00258

CC(H4DOTC 2.5)-22

4

5

1

2

3

6

7



Step


Check


Yes

Go to step 2.

CHECK NEUTRAL POSITION SWITCH CIR-

CUIT.


2) Disconnect the neutral position switch harness connector.





−

):


CHECK NEUTRAL POSITION SWITCH CIR-

CUIT.


2) Measure the resistance between neutral position switch harness connector terminal and chassis ground.




Ω?

Go to step 4.

No

Go to step 5.

Check the harness for open or short between neutral position switch and

ECM.

Repair the harness.

CHECK NEUTRAL POSITION SWITCH.

Remove and check the neutral position switch.

Is the neutral position switch

OK?

Neutral position switch circuit is

OK.



2) Disconnect the inhibitor switch harness connector.




(T7) No. 12 (+) — Chassis ground (

−

):




2) Measure the resistance between inhibitor switch harness connector terminal and chassis ground.


(T7) No. 7 — Chassis ground:


Ω?

CHECK INHIBITOR SWITCH.

Remove and check the inhibitor switch.

Is the inhibitor switch OK?

Go to step 7.

Replace the neutral position switch.

Check the harness for open or short between inhibitor switch and ECM.

Repair the harness.

Inhibitor switch circuit is OK.

Replace the inhibitor switch.

CC(H4DOTC 2.5)-23



E: DTC 16 IGNITION SWITCH



WIRING DIAGRAM:

BATTERY

SBF-1 SBF-4

IGNITION

SWITCH

F/B No.11

D: B137

8

1 2 3 4 5 6 7

18

26

9

19

27

10

20

11

21

12

22

28

13

23

29

14 15 16

24

30

17

25

31

CC(H4DOTC 2.5)-24

D: B137

ECM

CC-00259

1



Step Check Yes

CHECK IGNITION SWITCH CIRCUIT.







−

):

Is the voltage more than 10 V? Check the poor contact of ECM connector.

No

• Check the fuse

No. 11 (fuse & relay box).

• Check the harness for open or short between ignition switch and

ECM.

CC(H4DOTC 2.5)-25



F: DTC 22 AND 32 VEHICLE SPEED SENSOR

DIAGNOSIS:

Disconnection or short circuit of vehicle speed sensor system.



WIRING DIAGRAM:

F/B No.5

BATTERY

SBF-4

IGNITION

SWITCH

IGNITION RELAY

10

13

11

9

B225

B56

TCM

(AT MODEL)

1

E

MT

B17

2

3

1

VEHICLE SPEED

SENSOR

(MT MODEL)

AT

:AT MODEL

MT :MT MODEL

B21

E2

B: B135

D: B137

ECM

B17 B21

1 2

3 4

1 2 3 4

5 6 7 8

9 10 11 12

13 14 15 16

B56

1 2

10 11 12

3 4 5 6

13 14 15 16 17

22 23 24 25 26 27 28

18

7 8 9

19 20 21

29 30 31

B225

1 2

3 4

5 6

7 8

9

10

11 12 13

14 15 16

17

18

19

20

21 22 23

24 25 26

27

28

29

30

34 35 36

31 32 33

37

38

D: B137

8

1 2 3 4 5 6 7

18

26

9

19

27

10

20

11

21

12

22

28

13

23

29

14 15 16

24

30

17

25

31

E

GE

B: B135

8

1 2

9

20 21

10

22

11

23

28 29 30 31

12

3 4 5 6 7

13 14 15 16 17 18 19

24 25

32 33

26 27

34 35

CC-00260

CC(H4DOTC 2.5)-26

1

2

3

4

5

6



Step


Check


Yes

Go to step 2.

CHECK HARNESS BETWEEN BATTERY

AND VEHICLE SPEED SENSOR.


2) Disconnect the harness connector from vehicle speed sensor.


4) Measure the voltage between vehicle speed sensor harness connector terminal and chassis ground.



−

):


CHECK HARNESS BETWEEN ECM AND VE-

HICLE SPEED SENSOR.



ECM.

3) Measure the resistance between vehicle speed sensor harness connector terminal and

ECM harness connector terminal.


(B17) No. 1 — (B135) No. 26:


Ω?

Go to step 4.




2) Measure the resistance between vehicle speed sensor harness connector terminal and engine ground.




Ω?


1) Connect the harness connector to vehicle speed sensor.



Go to step 5.

Is the voltage 1 V

← → 5 V?

Check the poor contact of ECM connector.

Warning:


4) Measure the voltage between ECM harness connector terminal and chassis ground.



−

):

CHECK HARNESS BETWEEN ECM AND

TCM.



ECM and TCM.

3) Measure the resistance between ECM harness connector terminal and TCM harness connector terminal.


(B135) No. 26 — (B56) No. 1:


Ω?

Go to step 7.

No

Go to step 6.

Check the harness for open or short between fuse and vehicle speed sensor.

Repair the harness.

Repair the harness.


Repair the harness.

CC(H4DOTC 2.5)-27



7

Step

CHECK TCM

1) Connect the harness connector to TCM.



Warning:


4) Measure the voltage between TCM harness connector terminal and chassis ground.



−

):

Check Yes

Is the voltage 1 V

← → 5 V?

Check the poor contact of ECM harness connector.

No

Check the poor contact of TCM harness connector.

CC(H4DOTC 2.5)-28

IMMOBILIZER (DIAGNOSTIC)

IM

Page

1.


2.


3.


4.

Immobilizer Control Module I/O Signal........................................................6

5.


6.

Read Diagnostic Trouble Code (DTC) ........................................................8

7.

Clear Memory Mode....................................................................................9

8.

Diagnostics Chart for Immobilizer Warning Light ......................................10

9.


10.

Diagnostics Procedure with Diagnostic Trouble Code (DTC) ...................15

3

4


IMMOBILIZER (DIAGNOSTIC)


A: PROCEDURE

1

2

5

6

Step

CHECK ILLUMINATION OF IMMOBILIZER

WARNING LIGHT.

1) Turn the ignition switch to OFF or ACC position.

2) Wait at least 60 seconds.


WARNING LIGHT.

Remove the key from ignition switch.

Does the immobilizer warning light blink?

Check

Does the immobilizer warning light begin to blink within 1 second after the key is removed?

Yes

Go to step 2.

Go to step 3.

CHECK ENGINE START.

Turn the ignition switch to START position.


WARNING LIGHT.

Turn the ignition switch to ON.

Does the engine start?

Go to step 4.

Does the immobilizer warning light illuminate?

Check the immobilizer warning light

circuit. <Ref. to IM-

10, CHECK

IMMOBILIZER

WARNING CIR-

CUIT, INSPEC-

TION, Diagnostics

Chart for Immobilizer Warning

Light.>

Immobilizer system is normal.

Go to step 6.

Repair the related parts.

CHECK INDICATION OF DTC ON DISPLAY.


2) Connect the Subaru Select Monitor to data

link connector. <Ref. to IM-7, Subaru Select

Monitor.>

3) Turn the ignition switch and Subaru Select

Monitors witch to ON.

4) Read any DTC on the display.

Are DTCs indicated on display?

PERFORM THE DIAGNOSIS.

1) Inspect using “Diagnostics Chart with Trou-

ble Code”. <Ref. to IM-15, Diagnostics Procedure with Diagnostic Trouble Code (DTC).>

2) Repair the trouble cause.

3) Perform the clear memory mode.

4) Read any DTC again.

Are DTCs indicated on display?

Inspect using

“Diagnostic Procedure with Diagnostic Trouble Code

(DTC)”. <Ref. to

IM-15, Diagnostics Procedure with Diagnostic

Trouble Code

(DTC).>

Finish the diagnostics.

No

Check the immobilizer warning light

circuit. <Ref. to IM-

10, CHECK

IMMOBILIZER

WARNING CIR-

CUIT, INSPEC-

TION, Diagnostics


Light.>

Check the key switch circuit.

<Ref. to IM-12,

CHECK KEY

WARNING

SWITCH CIR-

CUIT, INSPEC-

TION, Diagnostics


Light.>

Go to step 5.

IM-2



A: CAUTION

CAUTION:

• The airbag system wiring harnesses routed near the immobilizer control module. All airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits.

• Be careful not to damage the airbag system wiring harness when servicing the immobilizer control module.

• While diagnostic items are being checked, do not operate radios, portable telephones, etc.

which emit electromagnetic waves near or inside the vehicle.


• When repeatedly turning the ignition switch to ON or OFF while diagnostic items are being checked, it should be switched in cycles of

“ON” for at least 5 seconds

→ “OFF” for at least

8 seconds.

(1)

ON

OFF

5 8 (2)

IM-00003

(1) Ignitions witch position

(2) Sec.

• If the engine fails to start with a registered ignition key, detach the ignition key from ignition switch and wait for approx. 1 second until immobilizer warning light begins to flash. Start the engine again.

• Before checking the diagnostic items, obtain all keys for the vehicle to be checked possessed by owner.

IM-00001

• When the ignition switch is being turned ON or

OFF while diagnostic items are being checked, do not allow keys with different ID codes close to the ignition switch. If the ignition key is in a key holder, remove it from the holder before carrying out diagnoses.

IM-00002

IM-3




1. SPECIAL TOOL

ILLUSTRATION TOOLNUMBER

24082AA230


DESCRIPTION

CARTRIDGE

REMARKS


ST24082AA230

22771AA030 SUBARUSELECT

MONITOR KIT


• English:


• German:


• French:


• Spanish:


ST22771AA030

2. GENERAL TOOL

TOOLNAME

Circuit tester

REMARKS


IM-4




A: LOCATION

(1)

(2)

(4)

(3)

(1) Antenna

(2) Immobilizer warning light (LED)

(3) Immobilizer control module (IMM

ECM)

NOTE:

IMM ECM location for RHD model is symmetrically opposite.

(4) Transponder

IM-00004

IM-5


Immobilizer Control Module I/O Signal

4. Immobilizer Control Module I/O

Signal


1. IMMOBILIZER

<Ref. to WI-194, WIRING DIAGRAM, Immobilizer

System.>

IM-6


A: OPERATION



5) Turn the ignition switch to ON (engine OFF), and then Subaru Select Monitor switch to ON.

1. HOW TO USE SUBARU SELECT MONI-

TOR


(1)

CC-00028


Monitor.


CC-00029


(1) Data link connector is located in the lower portion of the instrument panel (on driver’s side).

ME-00325


CAUTION:

Do not connect the scan tools except for Subaru Select Monitor.

CC-00045

(1) Power switch

6) Using the Subaru Select Monitor, call up any

DTCs and various data, and then record them.

2. READ DIAGNOSTIC TROUBLE CODE

(DTC) FOR ENGINE.

Refer to Read Diagnostic Trouble Code for informa-

tion about how to indicate DTC. <Ref. to IM-8, Read

Diagnostic Trouble Code (DTC).>

3. COMMUNICATION LINE CHECK

NOTE:

The communication line between ECM and IMM

ECM can be checked in «System Operation Check

Mode». This is referred to as “communication line check”.

1) Connect the Subaru Select Monitor.

2) Set the «System Operation Check Mode» menu display screen, and then select {Immobilizer System}.

3) Start the communication line check.

4) Does “Communication Line not Shorted” appear on screen?

If “YES”. Go to step 5).

If “NO”. Go to step 6).

5) After diagnostic results, it is determined that the short circuit is not a diagnostic item. This completes communication line check.

6) If a problem is detected, repair. <Ref. to IM-16,

DTC P1572 IMM CIRCUIT FAILURE (EXCEPT

ANTENNA CIRCUIT), Diagnostics Procedure with


IM-7


Read Diagnostic Trouble Code (DTC)

6. Read Diagnostic Trouble

Code (DTC)

A: OPERATION


{Each System Check}, and then press the [YES] key.

2) On the «System Selection Menu» display screen, select the {Engine Control System}, and then press the [YES] key.

3) Press the [YES] key after displayed information of engine type.

4) On the «Engine Diagnosis» display screen, select the {Diagnostic Code(s) Display}, and then press the [YES] key.

5) On the «Diagnostic Code(s) Display» display screen, select the {Current Diagnostic Code(s)} or

{History Diagnostic Code(s)}, and then press the

[YES] key.

NOTE:

• For detailed operation procedure, refer to the

SUBARU SELECT MONITOR OPERATION MAN-

UAL.

• For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC).

<Ref. to IM-14, LIST, List of Diagnostic Trouble

Code (DTC).>

IM-8

Clear Memory Mode

7. Clear Memory Mode

A: OPERATION


{Each System Check}, and then press the [YES] key.

2) On the «System Selection Menu» display screen, select the {Engine Control System}, and then press the

[YES] key.

3) Press the [YES] key after displayed information of engine type.

4) On the «Engine Diagnosis» display screen, select the {Clear Memory}, and then press the [YES] key.

5) When the `Done’ is shown on the display screen, turn the Subaru Select Monitor and ignition switch to OFF.

NOTE:

• After the memory has been cleared, the ISC must be initialized.To do this, turn the ignition switch to ON position. Wait 3 seconds before starting the engine.

• For detailed operation procedure, refer to the SUB-

ARUSELECT MONITOR OPERATION MANUAL.


IM-9

Diagnostics Chart for Immobilizer Warning Light


8. Diagnostics Chart for Immobilizer Warning Light

A: INSPECTION

1. CHECK IMMOBILIZER WARNING CIRCUIT

WIRING DIAGRAM:

BATTERY

M/B No.2

SBF-1

LHD

IGNITION

SWITCH

SBF-5 SBF-4

F/B No.11

B37 i2

LHD

F44

B61

7

F2 B100

9 LT

RHD

B37 i2

LHD

LHD

A: i12


B: i10 C: i11

IMMOBILIZER

WARNING

LIGHT

B8

2

LHD

LHD : LHD MODEL

RHD

RHD

: RHD MODEL

LT

: LHD TURBO MODEL

XL : EXCEPT LHD TURBO MODEL

1 : Non-turbo AT MODEL: 14

: MT MODEL AND

TURBO AT MODEL:4

2 : LHD MODEL: A4

: RHD MODEL: C5

3 : Non-turbo AT MODEL: 22

: MT MODEL AND

TURBO AT MODEL: 18

F60

E3

LT

E

B21

E2

B141 IMM ECM i3

B38

LHD i2

B37

B141

1 2

6 7

3 4 5

8 9 10 11 12

B37

:

LHD

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

A: i12

1 2 3

7 8

4 5 6

9 10 11 12 13 14

1 2 3 4

F2

LHD

5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20

B38

1 2 3 4

10 11 12 13 14 15

22 23 24 25

16

5 6

17 18

26 27 28 29 30

7 8

19 20

9

21

31 32

B21

F60

1 2 3 4

5 6 7 8

9 10 11 12

13 14 15 16

F44

1 2 3 4

5 6 7 8

B: i10

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

1 2

i2

3 4 5

: RHD

6 7

AT

8 9 10

11 12 13 14 15 16 17 18 19 20 21 22

C: i11

1 2 3 4 5 6 7 8 9 10

1

i2

2 3 4

:

RHD MT

5 6 7 8

9 10 11 12 13 14 15 16 17 18

IM-00081

IM-10

1

2

3

4

5

6



Step

CHECK IMMOBILIZER WARNING LIGHT.



IMM ECM.

3) Connect a resistor (750

Ω) between IMM

ECM harness connector terminal No. 9 and chassis ground.

CHECK IMM ECM GROUND CIRCUIT.

Measure the resistance between IMM ECM harness connector terminal and chassis ground.



Check

Does the immobilizer warning light illuminate?


Ω?

Yes

Go to step 2.

Go to step 3.

No

Go to step 5.

Repair the open circuit of IMMECM ground circuit.

CHECK IMM ECM IGNITION CIRCUIT.

1) Turn the ignition switch to ON. (engine

OFF.)

2) Measure the voltage between IMM ECM harness connector terminal and chassis ground.


(B141) No. 12 (+) — Chassis ground(

−

):


Check the harness for open or short between IMM

ECM and ignition switch.

CHECK IMM ECM POWER SUPPLY CIR-

CUIT.




(B141) No. 10, No. 11 (+) — Chassis ground(

−

):

CHECK COMBINATION METER CIRCUIT.

1) Remove the combination meter. <Ref. to

IDI-10, Combination Meter Assembly.>

2) Measure the voltage between combination meter harness connector terminal and chassis ground.



−

):

Is the voltage more than 10 V? Replace the IMM

ECM <Ref. to SL-

37, Immobilizer

Control Module.>

and then replace all ignition keys

(including the transponder). Then perform teaching operation. Refer to teaching operation manual (Pub.

No. S0820GZ).


ECM and fuse.


Check the harness for open or short between combination meter and fuse.

CHECK COMBINATION METER CIRCUIT.

Measure the resistance between IMM ECM harness connector terminal and combination meter harness connector terminal.


LHD model

(B141) No. 9 — (i12) No. 4:

RHD model

(B141) No. 9 — (i11) No. 5:


Ω?

Faulty LED.


<Ref. to IDI-11,

DISASSEMBLY,

Combination

Meter Assembly.>

Repair the harness or connector.

IM-11



2. CHECK KEY WARNING SWITCH CIRCUIT

WIRING DIAGRAM:

BATTERY

M/B No.6

LHD

F44

B61

LHD

LHD : LHD MODEL

RHD

: RHD MODEL

B74

2

1

KEY WARNING

SWITCH

B74

1

2

B141

1 2

6 7

3 4 5

8 9 10 11 12

B141 IMM ECM

F44

1 2 3 4

5 6 7 8

IM-00006

IM-12

1

2

3

4



Step Check


1) Insert the ignition key to the ignition switch.

(OFF or ACC position)

2) Measure the resistance between key warning switch connector terminals.

Terminal

No. 1 — No. 2:


Ω?

Yes

CHECK POWER SUPPLY CIRCUIT.

1) Disconnect the harness connector from key warning switch.

2) Measure the voltage between key warning switch harness connector terminal and chassis ground.



−

):


Go to step 3.


1) Remove the ignition key from the ignition switch.

2) Measure the resistance between key warning switch connector terminals.

Terminal

No. 1 — No. 2:

Is the resistance more than

1 M

Ω?

CHECK HARNESS BETWEEN KEY WARN-

ING SWITCH AND IMM ECM.

1) Disconnect the harness connector from key warning switch.


IMM ECM.

3) Measure the resistance between key warning switch harness connector terminal and

IMM ECM harness connector terminal.


(B74) No. 1 — (B141) No. 4:


Ω?

Go to step 4.

No

Check the harness for open or short between key warning switch and fuse.



Replace the IMM

ECM <Ref. to SL-

37, Immobilizer

Control Module.>


(including the transponder). Then perform teaching operation. Refer to teaching operation manual (Pub.

No. S0820GZ).

Repair the harness between key warning switch and IMM ECM.

IM-13




A: LIST

DTC

P1571

P1572

P1574

P1576

P1577

Item

Reference Code Incompatibility

EGI — Immobilizer Communication

(Except Antenna Circuit)

Key — Immobilizer Communication

P0513 Incorrect Immobilizer Key

EGI Control Module

EEPROM

IMMControl Module

EEPROM

P1570 ANTENNA


Reference code incompatibility between IMM ECM and ECM

Communication failure between

IMM ECM and ECM

Failure of IMM ECM to verify key

(transponder) ID code

Incorrect immobilizer key (Use of unregistered key in IMM ECM)

ECM malfunctioning

IMM ECM malfunctioning

Faulty antenna

Index No.

<Ref. to IM-15, DTC P1571 REFERENCE CODE

INCOMPATIBILITY, Diagnostics Procedure with


<Ref. to IM-16, DTC P1572 IMM CIRCUIT FAIL-

URE (EXCEPT ANTENNA CIRCUIT), Diagnostics


<Ref. to IM-19, DTC P1574 KEY COMMUNICA-

TION FAILURE, Diagnostics Procedure with Diagnostic Trouble Code (DTC).>

<Ref. to IM-20, DTC P0513 INCORRECT IMMOBI-

LIZER KEY, Diagnostics Procedure with Diagnostic


<Ref. to IM-20, DTC P1576 EGI CONTROL MOD-

ULE EEPROM, Diagnostics Procedure with Diagnostic Trouble Code (DTC).>

<Ref. to IM-20, DTC P1577 IMM CONTROL MOD-

ULE EEPROM, Diagnostics Procedure with Diagnostic Trouble Code (DTC).>

<Ref. to IM-21, DTC P1570 ANTENNA, Diagnostics


NOTE:

Perform the engine DTC when the DTC except immobilizer DTC is detected. <Ref. to EN(H4SO)-72, List of

Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)-74, List of Diagnostic Trouble Code (DTC).> <Ref.

to EN(H4DOTC 2.5)-65, List of Diagnostic Trouble Code (DTC).>

IM-14

Diagnostics Procedure with Diagnostic Trouble Code (DTC)


10.Diagnostics Procedure with Diagnostic Trouble Code (DTC)

A: DTC P1571 REFERENCE CODE INCOMPATIBILITY

DIAGNOSIS:

Reference code incompatibility between IMM ECM and ECM

1

Step

PERFORM TEACHING OPERATION ON IG-

NITION KEY.

Perform teaching operation on all keys of the vehicle. Refer to the teaching operation manual.

Check

Is teaching operation for all keys completed?

END

Yes No

Replace the ECM

<Ref. to

FU(H4SO)-44,

Engine Control

Module (ECM).>

<Ref. to

FU(H4DOTC)-50,

Engine Control

Module (ECM).>

<Ref. to

FU(H4DOTC 2.5)-

41, Engine Control Module

(ECM).>, IMM

ECM <Ref. to SL-

37, Immobilizer

Control Module.>


(including the transponder). Then perform teaching operation. Refer to the teaching operation manual (Pub.

No. S0820GZ).

IM-15



B: DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT)

DIAGNOSIS:

Communication failure between IMM ECM and ECM

WIRING DIAGRAM:

BATTERY

IGNITION

SWITCH

SBF-1 SBF-4 F/B No.11

SBF-5

TB TB : TURBO MODEL

NA NA : NON-TURBO MODEL

LHD : LHD MODEL

RHD : RHD MODEL

LT

: LHD TURBO MODEL

XL : EXCEPT LHD TURBO MODEL

1 : LHD MODEL: D18

: RHD MODEL: D17

2 : LHD MODEL: D17

: RHD MODEL: D18

NA

RHD

F44

7

B61

LHD

NA

D:

B137 ECM

NA

B: B135

ECM

TB

D:

B137

:

NA

1

5

14

2

6

15

7 8 9 10 11

16 17 18

3 4

12 13

19 20

F44

1 2 3 4

5 6 7 8

D:

B137

:

TB

8

1

9

2

10

3 4 5 6 7

11 12 13 14 15 16 17

18 19 20 21

26 27

22 23

28 29

24 25

30 31

F2

B100

9 LT

F60

E3

B21

E2

LT

E

B141 IMM ECM

B141

1 2

6 7

3 4 5

8 9 10 11 12

F2

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20

B21

F60

1 2 3 4

5 6 7 8

9 10 11 12

13 14 15 16

IM-00082

IM-16

1

2

3

4

5



Step

CHECK POWER SUPPLY CIRCUIT OF IMM

ECM.



IMM ECM.



(B141) No. 10, No. 11 (+) — Chassis ground(

−

):

Check Yes


CHECK IGNITION SWITCH CIRCUIT.


OFF.)




−

):


CHECK GROUND CIRCUIT OF IMM ECM.


2) Measure the resistance between IMM ECM harness connector terminal and chassis ground.




Ω?

CHECK HARNESS BETWEEN IMM ECM

AND ECM.


ECM and IMM ECM.

2) Measure the resistance between IMM ECM harness connector terminal and ECM harness connector terminal.



Ω?

Non-turbo LHD model

(B141) No. 1 — (B137) No. 17:

Non-turbo RHD model

(B141) No. 1 — (B137) No. 18:

Turbo model

(B141) No. 1 — (B137) No. 19:

CHECK HARNESS BETWEEN IMM ECM

AND ECM.

Measure the resistance between IMM ECM harness connector terminal and ECM harness connector terminal.



Ω?

Non-turbo LHD model

(B141) No. 6 — (B137) No. 18:


(B141) No. 6 — (B137) No. 17:

Turbo model

(B141) No. 6 — (B137) No. 27:

Go to step 4.

Go to step 5.

Go to step 6.

No


ECM and fuse.


ECM and ignition switch.

Repair the open circuit of IMMECM ground circuit.

Repair the open circuit of harness between IMM

ECM and ECM.

Repair the open circuit of harness between IMM

ECM and ECM.

IM-17



6

7

8

Step Check

CHECK HARNESS OF COMMUNICATION

LINE.


OFF.)



(

(B141) No. 1, No. 6 (+) — Chassis ground

−

):

Is the voltage 0 V?

Is the voltage 0 V?

CHECK HARNESS OF COMMUNICATION

LINE.

Measure the voltage between ECM harness connector terminal and engine ground.



(B137) No. 17, No. 18 (+) — Engine ground(

−

):

Turbo model

(B137) No. 19, No. 27 (+) — Engine ground(

−

):

Yes

Go to step 7.

Go to step 8.

No

Repair the harness between IMM

ECM and ECM, because there is short circuit with battery voltage line or ignition switch

“ON” line.

Repair the harness between IMM

ECM and ECM, because there is short circuit with battery voltage line or ignition switch

“ON” line.

CHECK ECM BY COMMUNICATION LINE

CHECK.

1) Connect the harness connector to ECM.


IMM ECM.

3) Perform communication line check. <Ref. to

IM-7, COMMUNICATION LINE CHECK,

OPERATION, Subaru Select Monitor.>

Does “Communication Line not

Shorted” appear on the screen?

Replace the IMM

ECM <Ref. to SL-

37, Immobilizer

Control Module.>



No. S0820GZ).

Replace the ECM.

<Ref. to

FU(H4SO)-44,

Engine Control

Module (ECM).>

<Ref. to

FU(H4DOTC)-50,

Engine Control

Module (ECM).>

<Ref. to

FU(H4DOTC 2.5)-

41, Engine Control Module

(ECM).> Then perform teaching operation. Refer to the teaching operation manual (Pub.

No. S0820GZ).

IM-18



C: DTC P1574 KEY COMMUNICATION FAILURE

DIAGNOSIS:

Failure of IMM ECM to verify key (transponder) ID code

1

2

Step

CHECK IMM ECM FUNCTION.

Insert the key to ignition switch (LOCK position), measure changes in voltage between

Antenna connector.


(B142) No. 1 (+) — No. 2: (

−

)

CHECK IGNITION KEY (TRANSPONDER).


2) Start the engine using other keys that have undergone the teaching operation, furnished with vehicle.

Check

Is the voltage

−30 to 30 V?

(Approx. 0.1 second after inserting the key)

Is the voltage 0 V?

(Approx. 1 second after inserting the key)


Yes

Go to step 2.

Replace the ignition key (including the transponder).

Then perform teaching operation. Refer to the teaching operation manual (Pub.

No. S0820GZ).

No

Replace the IMM

ECM <Ref. to SL-

37, Immobilizer

Control Module.>



No. S0820GZ).

Replace the IMM

ECM <Ref. to SL-

37, Immobilizer

Control Module.>



No. S0820GZ).

IM-19



D: DTC P0513 INCORRECT IMMOBILIZER KEY

DIAGNOSIS:

Use of unregistered key in IMM ECM

1

2

Step


NITION KEY.

Perform teaching operation on all keys of the vehicle. Refer to the teaching operation manual (Pub. No. S0820GZ).


NITION KEY.

Perform teaching operation on all keys with vehicle. Refer to the teaching operation manual (Pub. No. S0820GZ).

Check



END

Yes

END

No

Replace all ignition keys (including the

transponder). Go to step 2.

Replace the IMM

ECM <Ref. to SL-

37, Immobilizer

Control Module.>



No. S0820GZ).

E: DTC P1576 EGI CONTROL MODULE EEPROM

DIAGNOSIS:

ECM malfunctioning

1. REPLACE ECM.

Replace the ECM.

<Ref. to FU(H4SO)-44, Engine Control Module (ECM).> <Ref. to FU(H4DOTC)-50, Engine Control Module

(ECM).> <Ref. to FU(H4DOTC 2.5)-41, Engine Control Module (ECM).>

Then perform teaching operation. Refer to the teaching operation manual (Pub. No. S0820GZ).

F: DTC P1577 IMM CONTROL MODULE EEPROM

DIAGNOSIS:

IMM ECM malfunctioning

1. REPLACE IMM ECM.

Replace the IMM ECM <Ref. to SL-37, Immobilizer Control Module.>, and then replace all ignition keys (in-

cluding the transponder). Then perform teaching operation. Refer to the teaching operation manual (Pub.

No. S0820GZ).

IM-20



G: DTC P1570 ANTENNA

DIAGNOSIS:

Faulty antenna

WIRING DIAGRAM:

ANTENNA

B142

1 2

B142

IMM ECM

IM-21

IM-00008



1

2

3

4

5

6

7

Step

CHECK ANTENNA CIRCUIT.

Measure the resistance between antenna harness connector and chassis ground.



Check



2) Disconnect the harness antenna connector

from IMM ECM. <Ref. to SL-38, Immobilizer

Antenna.>

3) Measure the resistance of antenna circuit.


(B142) No. 1 — No. 2:


Ω?


Ω?


Measure the resistance between antenna harness connector and chassis ground.





OFF.)

2) Measure the voltage between antenna harness connector and chassis ground.



−

):


Ω?

Is the voltage 0 V?


Measure the voltage between antenna harness connector and chassis ground.



−

):

Is the voltage 0 V?

CHECK IMM ECM FUNCTION.


2) Connect the antenna harness connector to

IMM ECM.

3) Insert the key to ignition switch, measure changes in voltage between antenna harness connector.


(B142) No. 1 (+) — No. 2 (

−

):

Is the voltage

−30 to 30 V?

(Approx. 0.1 second after inserting the key)

Is the voltage 0 V?

(Approx. 1 second after inserting the key)

CHECK IGNITION KEY (TRANSPONDER).


2) Start the engine using other keys that have undergone the teaching operation, furnished with vehicle.


Yes

Go to step 2.

Replace the

antenna. <Ref. to

SL-38, Immobilizer Antenna.>

Replace the

antenna. <Ref. to


Go to step 5.

Go to step 6.

No

Replace the

antenna. <Ref. to


Go to step 3.

Go to step 4.

Replace the

antenna. <Ref. to


Replace the

antenna. <Ref. to


Go to step 7.

Replace the ignition key (including the transponder).

Then perform teaching operation. Refer to the teaching operation manual (Pub.

No. S0820GZ).

Replace the IMM

ECM <Ref. to SL-

37, Immobilizer

Control Module.>



No. S0820GZ).

Replace the IMM

ECM <Ref. to SL-

37, Immobilizer

Control Module.>



No. S0820GZ).

IM-22

2004 forester service manual quick reference index body section

HVAC SYSTEM

(HEATER, VENTILATOR AND A/C)

AC

1. General Description

1. HEATER SYSTEM

2. A/C SYSTEM

1. HEATER COOLING UNIT

2. BLOWER MOTOR UNIT

3. CONTROL UNIT

4. AIR CONDITIONING UNIT

5. COMPRESSOR

6. HEATER DUCT

1. HFC-134a A/C SYSTEM

4. HANDLING OF REFRIGERANT

2. COMPRESSOR OIL

3. REFRIGERANT

5. O-RING CONNECTIONS

2. Refrigerant Pressure with Manifold Gauge Set

3. Refrigerant Recovery Procedure

4. Refrigerant Charging Procedure

5. Refrigerant Leak Check

6. Compressor Oil

7. Blower Motor Unit Assembly

8. Blower Resistor (Manual A/C

Model)

9. Heater Core

10.Control Unit

11.Compressor

1. MAGNETIC CLUTCH CLEARANCE

2. MAGNETIC CLUTCH OPERATION

12.Condenser

13.Condenser (Sub Fan)

14.Heater Cooling Unit

15.Evaporator

16.Hose and Tube

17.Relay and Fuse

18.Pressure Switch (Triple Pressure Switch)

19.Ambient Sensor (Auto A/C

Model)

20.Sunload Sensor (Auto A/C

Model)

21.Air Vent Grille

1. CENTER GRILLE

2. SIDE GRILLE

22.Heater Duct

23.Heater Vent Duct

24.Heater Cock Solenoid Valve

25.General Diagnostics

HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)

AC

1. Basic Diagnostics Procedure

2. General Description

1. BATTERY

2. ASPIRATOR HOSE

3. A/C LINE

4. CONTROL LINKAGE

5. CONTROL SWITCHES

3. Electrical Component Location

1. ENGINE COMPARTMENT

2. PASSENGER COMPARTMENT

4. Auto A/C Control Module I/O Signal

5. Diagnostic Chart for Self-Diagnosis

1. SENSOR CHECK TABLE

2. OPERATING MODE TABLE

6. Diagnostics for A/C System Malfunction

7. Diagnostic Procedure for Actuators

8. Diagnostic Procedure for Sensors

9. General Diagnostic Table

AIRBAG SYSTEM

AB

1. General Description

1. SRS AIRBAG

1. SPECIAL TOOL

2. GENERAL TOOL

2. Airbag Connector

1. POWER SUPPLY

2. DRIVER’S AIRBAG (BETWEEN AIRBAG

HARNESS AND ROLL CONNECTOR), PAS-

SENGER’S AIRBAG AND SIDE AIRBAG