6 - Body - Ken Gilbert

6 - Body - Ken Gilbert

I

2002 IMPREZA SERVICE MANUAL

BODY SECTION

QUICK REFERENCE INDEX

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, reas- sembling, inspection and adjustment of components and diagnostics for guid- ance 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.

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

FUJI HEAVY INDUSTRIES LTD.

Gl830BE6

.

HVAC SYSTEM

(HEATER. VENTILATOR AND

A/C)

A C a

9 .

10

.

11 .

12

.

13

.

14

.

5 .

6

.

7

.

8

.

15

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16

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17

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18 .

19

.

20

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21

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1 .

2

.

3

.

4

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Page

General Description

....................................................................................

2

Refrigerant Pressure with Manifold Gauge Set

.........................................

15

Refrigerant Recovery Procedure

...............................................................

16

Refrigerant Charging Procedure

...............................................................

17

Refrigerant Leak Check

............................................................................

20

Compressor Oil

.........................................................................................

21

Blower Motor Unit Assembly

.....................................................................

22

Blower Resistor

.........................................................................................

23

Heater Core

...............................................................................................

24

Control Unit

...............................................................................................

25

Compressor

...............................................................................................

26

Condenser

.................................................................................................

27

Heater and Cooling Unit

............................................................................

28

Evaporator

.................................................................................................

29

Hose and Tube

..........................................................................................

30

Relay and Fuse

.........................................................................................

31

Pressure Switch (Dual Switch)

..................................................................

32

Air Vent Grille

............................................................................................

33

Heater Duct

...............................................................................................

34

Heater Vent Duct

.......................................................................................

35

General Diagnostics

..................................................................................

36

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND N C )

1. General Description

A:

SPECIFICATIONS

1.

HEATER SYSTEM

Heating capacity

Item

Air flow rate

Max air flow rate

Heater core size

(height

x

length

x

width)

Blower motor

Type

Fan type and size

(diameter

x

width)

SDecifications

5.0 kW (4,300 kcal/h, 17,062 BTU/ h) or more

Condition

Mode selector switch: HEAT

Temperature control switch: FULL HOT

Temperature difference between hot water and inlet air: 65°C (1 49°F)

Hot water flow rate: 360

79.2 Imp gal)/h

Q

(95.1 US gal,

280 m3 (9,888 cu ft)/h

450 m3 (15,892 cu ft)/h

Heat mode (FRESH), FULL HOT at 12.5 V

Temperature control switch: FULL COLD

Blower fan speed: 4th position

Mode selector lever: RECIRC

163.9

x

200

x

25.0 mm

(6.45

x

7.87 x 0.984 in)

Maanet motor 200 W or less

Sirocco fan type

150

x

75 mm (5.91 x 2.95 in) at 12 V

AC-2

I

Item

1

Cooling capacity

Refrigerant

I

Compressor

Magnet clutch

Condenser

Receiver drier

Expansion valve

Evaporator

Blower fan

1

Condenser fan (Sub fan)

Radiator fan (Main fan) ldlina SDeed 1NC ON)

.

, I

Dual switch

(Pressure switch)

Low-pressure switch operating pressure

Type

Discharge

Max. permissible speed

Tvpe

Power consumption

Type of belt

Pulley dia. (effective dia.)

Pulley ratio

Type

I c e alea

I

Core thickness

I

Radiation area

Effective inner capacity

Type

TvDe

I

Dimensions (W x H x T)

I

Fan type

Outer diameter x width

Power consumption

Motor t w e

I

Power consumption

I

Fan outer diameter

Motor type

Power consumption

Fan outer diameter

I

MPFI model

I

I

I

I

ON

-+

OFF

OFF

+

ON

ON

-+

OFF

High-pressure switch operating pressure

DlFF

~

Thermo control amplifier working temperature

(Evaporator outlet air)

OFF

Specifications

5.1 kW

(4.385 kcal/h. 17,402 BTU/h)

HFC-134a (CH,FCF,)

[0.5f0.05 kg (0.99f0.11 Ib)]

Vane rotary, fix volume (CR-14)

144 cm3 (8.79 cu in)/rev

7,000 rpm

Drv, single-disc type

47 w

V-Ribbed 4 PK

125 mm (4.92 in)

1.064

Corrugated fin (Sub cool type)

0.21 m2 (2.26 sq ft)

16 mm (0.63 in)

5.34 m2 157.5 sa ft)

250 cm3 (1 5.26 cu in)

Internal equalizing

Sinale tank

255 x 200 x 48 mm

(1 0 x 7.87 x 1.89 in)

Sirocco fan

150 x 75 mm (5.91 x 2.95 in)

200 W at 12 V

Magnet

70 W at 12 V

320 mm (12.6 in)

Magnet

70 W at 12 V

320 mm (1 2.6 in)

850f100 rpm

278f29 kPa

(2.83+0.3 kg/cm2, 40.3f4.2 psi) kg/cm2, 42+5.7

2,800f100 kPa

(29fl kg/cm2, 406+15 psi)

600f200kPa

(6.12f2 kg/cm2, 87229 psi)

Diff. 2.5*0.5"C(36.5&0.9"F)

1.5zkO.5"C(35+0.9"F)

ON

HV004!

AC-3

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER. VENTILATOR AND A/C)

B: COMPONENT

1. HEATER COOLING UNIT

~~

(1)

Unit cover

(2) Side link

(3) Mode acutuator lever

(4)

Foot lever

( 5 )

Spring

(6) Mode acutuator link

(7) Defroster lever

(8) Foot nozzle

(9) Unit duct cover

(1 1) Drain hose

(12) Mix acutuator lever

(13) Unit assembly

(14) Foot duct

(15) Clip

(16) Packing

(17) Cooling unit block

(18) O-ring

(1

9) Expansion valve

(20) Evaporator

(21) Evaporator cover

(22) Thermistor

Tightening torque:

N.m

(kgf-m, ft-lb)

T:

7.35

(0.750, 5.421)

AC-4

I

2.

BLOWER MOTOR

UNIT

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND NC)

(1) Upper case

(2)

Blower link

(3) Blower link lever

A

(4)

Blower link lever B

(5)

Clip

(6) Filter cover

(7)

Filter

(8)

Blower motor assembly

(9) Hose

Tightening toque:

N-m (kgf-m, ft-lb)

T:

7.35 (0.750,5.421)

AC-5

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER. VENTILATOR AND

A/C)

3.

CONTROL UNIT

(1) Dial

(2) Fan control plate

(3) Temperature control plate

(4)

Mode control plate

( 5 )

Heater control knob

(6) Heater control panel

(7) Air conditioner knob

(8) Plug knob

(9)

Heater control base

(IO)

Intake cable

(1 1)

Mode cable

(12) Temperature cable

(13) Bulb

(1 4) Fan switch ASSY

(15)

Harness

HV0054

AC-6

I

4.

AIR

CONDITIONING UNIT

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND N C )

(5)

(1) Condenser

(2) Hose (High-pressure)

(3) Hose (Low-pressure)

(4)

Bracket

(5) Compressor

(6) O-ring

(7) ClampA

( 8 ) Clamp B

(9)

Tube (To condenser)

(IO)

Tube (To evaporator)

HV0055

Tightening torque: N-m (kgf-m, ft-lb)

T1: 7.4 (0.75, 5.4)

T2: l S ( 1 . 5 , 10.8)

AC-7

I

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

5. COMPRESSOR

(1) Idler pulley bracket

(2) Idler pulley adjuster

( 3 ) Idler pulley

(4) Compressor bracket upper

(5)

Compressor

(6) Compressor bracket lower

(7) V-belt

(8) Compressor belt cover

HV0051

Tightening torque:

N.m (Irgf-m, ft-lb)

T I : 7.4 (0.75, 5.4)

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-8

I

6.

HEATER DUCT

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND N C )

(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 (LH)

(7) Rear heater duct (RH)

HV0056

AC-9

I

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER. VENTILATOR AND N C )

C: CAUTION

1.

HFC-134A A/C

SYSTEM

Unlike the old conventional HFC-12 system com- ponents, the cooling system components for the

HFC-134a system such as the refrigerant and com- pressor oil are incompatible.

Vehicles with the HFC-134a system can be iden- tified by the label

“ A

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

2.

COMPRESSOR OIL

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

Use only the manufacturer-authorized compres- sor oil for the HFC-134a system; only use DH-PR.

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 us- ing a plug or tape. In order to avoid moisture, store the oil in a container with its cap tightly 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 lu- brication will result and the compressor itself may be damaged.

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 refriger- ant 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 di- rectly 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 ex- plosion of the can.

The refrigerant is non-toxic and harmless under normal operating circumstance, but it may change to phosgene (a noxious fume) under open flames or high temperatures (caused by a cigarette or heater).

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

Never perform a gas leak test using a halide torch-type leak tester.

In order to avoid destroying the ozone layer, pre- vent HFC-134a from being released into the atmo- sphere. Using a refrigerant recovery system, discharge and reuse it.

Goggles

Avoid open flame

Gloves

N o

direct heat Do not on container discharge

Loosen

G4M097S

AC-10

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND N C )

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 towels.

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 contamination from entering.

Use the oil specified in the service manual to Iu- bricate the O-rings.

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

Apply the oil to the area including the O-rings and tu be beads.

Kea'

G4M050'i

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

Install the O-rings at right angle to the tube beads.

,-O-ring

O.K.

Bead

HV0062

After tightening, use a clean shop towel to re- move excess 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 con- nections, remove the O-rings, and check the rings, threads, and connections.

0-

Not O.K.

Not O.K.

HV0046

a

AC-11

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND N C )

D: PREPARATION TOOL

CAUTION:

When working on vehicles with the HFC-134a system, only use HFC-134a specified tools and parts.

Do

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

Tool & screw type

Valve type

HFC-134a

Millimeter size

Quick joint type

Tools and Equipment

Wench

Various

WRENCHES

will be required to service any

A/C

40

N.m (0.7 to 4.1 kg-m, 5 to 30 ft-lb) torque wrench with various crow- loot wrenches will be needed. Open end or flare nut wrenches will be ieeded for back-up on the tube and hose fittings.

Description

CFC-12

Inch size

Screw-in type

G4M0571

Applicator bottle

A small APPLICATOR BOlTLE is recommended to apply refrigerant

3il to the various parts. They can be obtained at a hardware or drug store.

G4M0572

Manifold gauge set

A MANIFOLD GAUGE SET (with hoses) can be obtained from either a sommercial refrigeration supply house or from an auto shop equipment

s

I i

AC-12

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND

N C )

Description

Tools and Equipment

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.

G4M0574

Syringe

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

G4M0575

Vacuum pump

A VACUUM PUMP (in good working condition) is necessary, and may be obtained from either a commercial refrigeration supply house or an automotive equipment supplier.

Can tap

A

CAN TAP for the 397 g (14

02)

can is available from an auto supply store.

A

G4MQ576

G4M0577

AC-13

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR

AND

N C )

Tools and Equipment

Thermometer

Pocket THERMOMETERS are available from either industrial hard- ware store or commercial refrigeration supply houses.

Description

Electronic leak detector

An ELECTRONIC LEAK DETECTOR can be obtained from either a

G4M0570

G4M0579

Weight scale

A WEIGHT SCALE such as an electronic charging scale or a bath- room scale with-digital display will be needed if a

13.6. erant container is used.

AC-14

REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET

HVAC SYSTEM (HEATER, VENTILATOR AND N C )

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 to 1,500 rpm.

6)

Turn ON the A/C switch.

7)

Turn the temperature control switch to MAX COOL.

8)

Put in RECIRC position.

9) Turn the blower control switch to HI.

10) Read the gauge.

Standard:

Low

pressure: 127

-

196 kPa (1.3

-

2.0 kg/cn?, 18

Ambient temperature: 30

-

35 OC (86

-

95 OF)

-

28 psi)

High pressure: 1,471

-

1,667 kPa (15

-

17 kg/cn?, 213

-

242 psi)

B: INSPECTION

-. r

I

Svmntnm

High-pressure side is unusually high.

High-pressure side is unusually low.

Low-pressure side is unusually high.

Low-pressure side is unusually low.

I

Probable cause

I

Defective condenser fan motor

Clogged condenser fan

Too much refrigerant

Air inside the system

Defective receiver dryer

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 fan motor.

Clean the condenser fin.

Discharge refrigerant.

Replace the receiver dryer.

Replace the compressor.

Check for leaks.

Replace the expansion valve.

Replace the compressor.

Replace the expansion valve.

Discharge refigerant.

Check for leaks.

Replace the expansion valve

Replace the receiver dryer.

AC-15

I

REFRIGERANT RECOVERY PROCEDURE

HVAC SYSTEM (HEATER, VENTILATOR AND

N C )

3.

Refrigerant Recovery Proce- dure

A: OPERATION

CAUTION:

During operation, be sure to wear safety gog- gles and protective gloves.

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

When reusing the discharged refrigerant, keep service cans on hand. Because the dis- charge rate with the recovery system is approx.

90%,

service cans are necessary to charge the refrigerant.

Follow the detailed operation procedure de- scribed in the operation manual attached to the refrigerant recovery system.

1) Perform the compressor oil return opera- tion.cRef. to AC-21, OPERATION, Compressor

"Oi I. >

2) Stop the engine.

3) Close the valves on the low-/high-pressure sides of the manifold gauge set.

Low-pressure gauge

(Compound pressure gauge)

Close

Close

I

G4M0585

4)

Install the low-/high-pressure hoses to the ser- vice ports on the low-/high-pressure sides of the vehicle respectively.

Low-pressure gauge

(Compound pressure gauge)

5)

Connect the center hose to the refrigerant recov- ery system.

6)

Follow the operation manual to activate the re- frigerant recovery system.

AC-16

REFRIGERANT CHARGING PROCEDURE

HVAC SYSTEM (HEATER, VENTILATOR AND

N C )

4.

Refrigerant Charging Proce- dure

A: OPERATION

CAUTION:

During operation, be sure to wear safety gog- gles and protective gloves.

Before charging the refrigerant, evacuate the system to remove small amounts of moisture remaining in the system.

The moisture in the system can be completely evacuated only under the minimum vacuum level. The minimum vacuum level affects the temperature in the system.

The list below shows the vacuum values nec- essary to boil water in various temperature. In addition, the vacuum levels indicated on the gauge are approx.

3.3

kPa (25 mmHg,

0.98

inHg) lower than those measured at

304.8

m (1,000 ft) above sea level.

-.

I

Vacuum level required to boil water (at sea level)

I

I

TemDerature

I

I

Vacuum

I

I

1.7"C (35°F)

1

100.9 kPa (757 "Ha. 29.8 inHal

I

I

-.

"I

I

7.2"C (45°F)

I

100.5 kPa (754 mmHa 29.7 inHa)

I

12.8"C (55°F)

I

99.8 kPa (749 mmHa 29.5 inHq)

I

18.3"C (65°F)

I

99.2 kPa (744 mmHg, 29.3 inHg)

23.9"C (75°F)

1

98.5 kPa (739 mmHg, 29.1 inHg)

I

29.4"C (85°F) 97.2 kPa (729 mmHg, 28.7 inHg)

35°C (95°F)

95.8 kPa (71 9 mmHg, 28.3 inHg)

1) Close the valves on low-/high-pressure sides of the manifold gauge.

4)

Carefully open the valves on the low-/high-pres- sure sides to activate the vacuum pump.

I

Low-pressure gauge

(Compound pressure gauge)

Slowly open

High-pressure gauge

Slowly

G o p e n

4M0597

5) After the low-pressure gauge reaches 100.0 kPa

(750 mmHg, 29.5 inHg) or higher, evacuate the system for approx. 15 minutes.

I

G4M0598

6) After 15 minutes of evacuation, if the reading shows 100.0 kPa (750 mmHg, 29.5 inHg) or higher, close the valves on the both sides to stop the vac- uum pump.

Low-pressure gauge

(Compound pressure gauge)

High-pressure gauge

Low-pressure gauge

(Compound pressure gauge)

Close

Close

Close Close

Vacuu

Turn

OFF

G4M0599

7) Note the low-pressure gauge reading. u l d u

G4M0596

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

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

AC-17

I

REFRIGERANT CHARGING PROCEDURE

HVAC SYSTEM (HEATER, VENTILATOR AND

A/C)

8) Leave it at least 5 minutes, and then check the low-pressure gauge reading for any changes.

When a gauge indicator shows near to zero point, this is a sign of leakage. Check pipe connector points, repair them, make sure there is no leakage by air bleeding.

9) Following the can tap operation manual instruc- tions, install it to the refrigerant can.

I

Tap valve

Center manifold hose

\

15) Carefully open the high-pressure valve with the engine stopping.

CAUTION:

Do

not open the low-pressure valve.

Low-pressure gauge

(Compound pressure

Close

G4M0601

G4M0980

10) Disconnect the center manifold hose from the

,.vacuum pump, and connect the hose to the tap valve.

11) When a 13.6 kg (30 Ib) refrigerant container is used, measure the refrigerant amount in use using a weight scale.

CAUTION:

Never run the engine during charging from the high-pressure side.

16) Close the high-pressure valve when the low- pressure gauge reaches 98 kPa (1 kg/cm2, 14 psi).

Using a leak tester, check the system for leaks.

If any leakage is found after the refrigerant recov- ery is completed, repair the applicable area.

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

Refrigerant container

CAUTION:

Never run the engine during charging from the high-pressure side.

(HFC-I 34a)

18) Close the high-pressure valve when; the readings of low- / high-pressure gauges be- come almost equal, after the charging speed is re- duced,

Weight

scale

c

G4M0981 the HFC-134a source becomes empty, or the system is filled with the gas.

12) Confirm that all the 3 hoses are tightly connect- ed to the manifold gauge set.

Low-pressure gauge

(Compound pressure gauge)

Close Close

I

G4M0603

I

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

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

AC-18

G4M060E

REFRIGERANT CHARGING PROCEDURE

HVAC SYSTEM (HEATER, VENTILATOR AND

N C )

19) If the HFC-134a source is empty, close the high-pressure valve, close the valve on the can tap, and replace the HFC-134a source with a new one to restart the operation.

27) Disconnect the hose from the service port, and install the service port cap.

Low-pressure gauge

(Compound pressure High-pressure gauge a

I

G4M0606

20) Confirm that both the low- / high-pressure valves can be closed. Start the engine with the

A/C

switch OFF.

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

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”

Windows open

23) While reading the low-pressure gauge, careful- ly open the low-pressure valve with the refrigerant source connected and the service hose purged.

CAUTION:

Never open the high-pressure valve with the en- gine is running.

G4M0608

24) Adjust the refrigerant flow to maintain the pres- sure on the low-pressure side at 276 kPa (2.81 kg/ cm2, 40 psi) max.

25) After the system is fully charged, close the low- pressure valve.

26) Close the valve on the refrigerant source.

I

Refrigerant

HFC-134a

Refrigerant amount

Minimum Maximum

0.6 kg (1.3 Ib) 0.7 kg (1.5

Ib)

I

AC-19

I

REFRIGERANT LEAK CHECK

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

5. Refrigerant Leak Check

A: INSPECTION

1)

Operate the A/C system for approx. 10 minutes, and confirm that the high-side pressure shows at least 690 kPa (7.03 kg/cm2, 100 psi). Then stop the engine to start the leak test.

2) Starting from the connection between the high- pressure tube 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 (dual switch) and receiver dryer.

4)

Check the connections between the condenser and tubes, 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 thermal limiter (if equipped) on the compressor housing.

8) 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

.O

9)

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

Connection between the tube and tube fitting

Connection between 2 parts

Connection between the tube and nut

IO)

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

Check the entire length of the flexible hose, espe- cially the connection with the metal hose end.

CAUTION:

Carefully check the external surface of hoses and tubes at approx.

25

mm

(0.98

in) per sec- ond.

Flexible hose

G4M0617

11) Disconnect the drain hose from the evaporator case, and check the hose end for at least 10 sec- onds.

After the test is finished, reconnect the drain hose.

12) Turn the ignition key to ON position, and run the blower at high speed for 1 minute. Stop the blower to check the ventilation grille on the instrument pan- el. 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.

13) Check the valve in the service port.

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

AC-20

COMPRESSOR OIL

HVAC SYSTEM (HEATER. VENTILATOR AND A/Cl

6.

Compressor Oil

A: OPERATION

NOTE:

Before making repairs, conduct the oil return oper- ation to return the compressor oil in circulation with the refrigerant to the compressor.

1) Increase the engine to 1,500 rpm.

2) Turn ON the A/C switch.

3) Turn the temperature control switch to

COOL.

4)

Put in RECIRC position.

5)

Turn the blower control switch to

HI.

6)

Leave in this condition for 10 minutes.

MAX

B: REPLACEMENT

NOTE:

If a component is replaced, add an appropriate amount of compressor oil.

When replacing the compressor, the new com- pressor 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 com- pressor removed.

I

Replacement parts

I

Amount of oil replenishment

I

Evaporator

I

114 m

8

(3.9 US fl

02,

4.0 Imp fl

02)

I

Condenser

I

7 m

8

(0.24

US

fl

02,

0.25

Imp

fl

02)

I

I

I

I

Hose

I

1 m

8

(0.03 US fl

02.

0.04 ImD fl

02)

I

AC-21

BLOWER MOTOR UNIT ASSEMBLY

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

7.

Blower Motor Unit Assembly

A: REMOVAL

1 ) Disconnect the ground terminal from battery.

2)

Remove the glove box. <Ref. to EI-39, REMOV-

AL, Glove Box.>

3) Loosen the nut to remove support beam stay.

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

Connect the motor connector terminal 1 from the battery to the positive (+) lead and terminal 2 to the negative (-) lead. Make sure the motor runs smoothly.

I

4) Disconnect the blower motor connector.

--

404

5 )

Disconnect the blower resistor connector

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

HV0013

AC-22

BLOWER RESISTOR

HVAC SYSTEM (HEATER, VENTILATOR AND N C )

8.

Blower Resistor

A: REMOVAL

1)

Remove the glove box. <Ref. to El-39, REMOV-

AL, Glove Box.>

2)

Disconnect the blower resistor connector.

3)

Loosen two screws to remove the blower resis- tor.

B: INSTALLATION

IKstall in the reverse order of removal.

C: INSPECTION

HVO0.57

I

I

I

3 and 1

3 and

2

3 and

4

I

Approx.

0.51 0

I

I

Approx.

2.70 0

I

I

Approx.

1.43 0

I

If NG, replace the blower resistor

AC-23

HEATER CORE

HVAC SYSTEM (HEATER, VENTILATOR AND

N C )

9.

Heater Core

A: REMOVAL

1)

Remove the heater and cooling unit. <Ref. to

AC-28, REMOVAL, Heater and Cooling Unit.>

2) Loosen the screws to remove heater core cover.

3) Remove the heater core.

--

HVOOOl

B: INSTALLATION

Install in the reverse order of removal.

HV0002

AC-24

1O.Control Unit

CONTROL UNIT

HVAC SYSTEM (HEATER, VENTILATOR AND N C )

A: REMOVAL

1)

Disconnect the ground terminal from battery.

2) Remove the glove box. <Ref. to El-39, REMOV-

AL, Glove Box.>

3)

Remove the lower panel. <Ref. to El-42, Instru- ment Panel Assembly.>

4) Remove the control wires.

5 )

Remove the center console panel. x

-1-

BOO1 1

i

7)

Pull out the control unit and disconnect connec- tors.

B: INSTALLATION

Install in the reverse order of removal.

1

r

Clip

=J

6)

Remove four screws.

AC-25

COMPRESSOR

HVAC SYSTEM (HEATER, VENTILATOR AND N C )

11

.Compressor

A:

INSPECTION

1.

MAGNETIC CLUTCH CLEARANCE

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

Standard:

0.45-M. mm (0.01 77-M.0059 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.

Ground the negative terminal to the body.

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

8) Disconnect the compressor harness from body harness.

9) Loosen the bolts to remove compressor bracket.

84M2407

3) Make sure the magnet clutch engages.

If

NG, replace the compressor.

B: REMOVAL

1) Perform the compressor oil return operation.

<Ref. to AC-21, OPERATION, Compressor Oil.>

2)

Turn A/C switch OFF and stop the engine.

3) Using refrigerant recovery system, discharge re- frigerant. <Ref. to AC-16, OPERATION, Refriger- ant Recovery Procedure.>

4) Disconnect the ground terminal from battery.

5) Remove the V-belt. <Ref. to ME(S0HC)-43, RE-

MOVAL, V-belt.> or <Ref. to ME(D0HC TURBO)-

44, REMOVAL, V-belt.>

6) Remove the generator. <Ref. to SC-13, RE-

MOVAL, Generator .>

10) Remove the bolts and then separate compres- sor and bracket.

HVOOI

1

C: INSTALLATION

1)

Install in the reverse order of removal.

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

3) When replacing the compressor, adjust amount of compressor oil. <Ref. to AC-21, OPERATION,

Compressor Oil.>

4) Charge refrigerant. <Ref. to AC-17, OPERA-

TION, Refrigerant Charging Procedure.>

AC-26

I

12.Condenser

CONDENSER

HVAC SYSTEM (HEATER, VENTILATOR AND N C )

A:

REMOVAL

1) Using the refrigerant recovery system, discharge refrigerant. <Ref. to AC-16, OPERATION, Refriger- ant Recovery Procedure. >

2) Disconnect the ground terminal from battery.

3) Disconnect the pressure hose and pipe from condenser.

B: INSTALLATION

1) Install in the reverse order of removal

CAUTION:

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

4rRemove the radiator bracket (A).

1

I

Y

B4M 1822A

I

2) Charge refrigerant. <Ref. to AC-17, OPERA-

TION, Refrigerant Charging Procedure.>

C: INSPECTION

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

2) Confirm that no oil leaks from condenser. If a fail- ure is found, replace the condenser with a new one.

5 )

Remove two bolts. While lifting condenser, pull it out through space between the radiator and the ra- diator panel.

CAUTION:

Be careful not t o damage the 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 t o the compressor.

<Ref. t o AC-21, REPLACEMENT, Compressor

Oil.>

AC-27

C .

HEATER AND COOLING UNIT

HVAC SYSTEM (HEATER, VENTILATOR AND

N C )

13.Heater and Cooling Unit

A: REMOVAL

1) Disconnect the ground terminal from battery.

2) Using the refrigerant recovery system, discharge refrigerant. <Ref. to AC-16, OPERATION, Refriger- ant Recovery Procedure.>

3) Drain LLC from the radiator. <Ref. to CO-25, RE-

PLACEMENT, Engine Coolant.>

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

B: INSTALLATION

1) Install in the reverse order of removal.

2) Charge refrigerant. <Ref. to AC-17, OPERA-

TION, Refrigerant Charging Procedure.>

HVOOE

5) Remove the instrument panel. <Ref. to El-42,

REMOVAL, Instrument Panel Assembly.>

6) Remove the support beam.

7) Remove the blower motor unit assembly. <Ref. to AC-22, REMOVAL, Blower Motor Unit Assem- bly.>

8)

Loosen the bolt and nuts to remove the heater and cooling unit.

AC-28

I

EVAPORATOR

HVAC SYSTEM (HEATER, VENTILATOR AND

N C )

14.Evaporator

A: REMOVAL

1)

Remove the heater and cooling unit. <Ref. to

AC-28, REMOVAL, Heater and Cooling Unit.>

2) Loosen the screws and clip to remove the evap- orator cover.

3)

Remove the evaporator.

HV0024

4)

Loosen two bolts to remove the expansion valve.

HV0026

CAUTION:

If the evaporator is replaced, add appropriate amount of compressor oil to evaporator. <Ref. to AC-21, REPLACEMENT, Compressor Oil.>

B: INSTALLATION

Install in the reverse order of removal.

AC-29

HOSE AND TUBE

HVAC SYSTEM (HEATER, VENTILATOR AND

N C )

15.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 vi- nyl tape to prevent contamination from enter- ing.

1 ) Disconnect the ground terminal from battery.

2) Using the refrigerant recovery system, discharge refrigerant. <Ref. to AC-16, OPERATION, Refriger-

13) Remove the high-pressure tube from the vehi- cle.

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

4) Remove the low-pressure hose attaching bolts

(B).

5)

Disconnect the low-pressure hose from evapora-

6)

Disconnect the low-pressure hose from com- pressor.

7)

Remove the low-pressure hose from the vehicle.

8) Remove the high-pressure hose attaching bolts

(C).

9)

Disconnect the high-pressure hose from com- pressor.

10) Disconnect the high-pressure hose from con- denser.

11) Remove the high-pressure hose from the vehi- cle.

12) Remove the high-pressure tube attaching bolt

0 .

B: iNSTALLATlON

CAUTION:

When disconnectingkonnecting hoses, do not apply an excessive force to them. Confirm that no torsion and excessive tension exists af- ter installing.

Seal the disconnected hose with a plug or vi- nyl tape to prevent contamination from enter- ing.

1)

Install in the reverse order of removal.

2) Charge refrigerant. <Ref. to AC-17, OPERA-

TION, Refrigerant Charging Procedure.>

C: INSPECTION

NOTE:

If cracking, damage, or swelling is found on a hose, replace it with a new one.

AC-30

I

16.Relay and Fuse

A:

LOCATION

-

Joint box

RELAY AND FUSE

HVAC SYSTEM (HEATER, VENTILATOR AND N C )

B:

INSPECTION

Main Fan Relay 1

Main Fan Relay 2

Sub Fan Relay 1

Sub Fan Relay 2

Main Fan Fuse

Sub Fan Fuse

N C

Fuse

Main

fuse

box

A

B

C

H V 0 0 2 2

G

H

H V 0 0 6

(3)

- Continuity exists.

(1)

-

No continuity

While applying battery voltage to the cable be- tween (3) and

(4),

(2).

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

AC-31

PRESSURE SWITCH (DUAL SWITCH)

HVAC SYSTEM (HEATER, VENTILATOR AND N C )

17.Pressure Switch (Dual

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 opera- tion of the pressure switch.

High and low pressure switch

1

and2

1

Operation

Increasing to

Turns OFF.

Decreasing

to

I

Turns ON.

Decreasing to

Standard kPa (kg/cm2, psi)

1

AC-32

AIR VENT GRILLE

HVAC SYSTEM (HEATER, VENTILATOR AND N C )

18.Air Vent Grille

A: REMOVAL

1. CENTER GRILLE

1 )

Disconnect the ground terminal from battery.

2) Remove the center console panel (A).

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

(B).

1 Disconnect the ground terminal from battery.

2)

Remove the heater vent duct. <Ref. to AC-35,

REMOVAL, Heater Vent Duct.>

3) Loosen the screws to remove the side air vent grille.

B:

INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

The direction and amount of air should be adjusted smoothly.

The adjustment should be kept in each position.

AC-33

I

HEATER DUCT

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

19.Heater Duct

A: REMOVAL

1)

Remove the heater unit. <Ref. to AC-28, Remov- al.>

2)

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

AL,

Front Seat.>

3) Remove the front side sill cover.

4)

Pull off the floor mat to remove the heater duct.

IB:

INSTALLATION

Install in the reverse order of removal.

AC-34

HEATERVENTDUCT

HVAC SYSTEM (HEATER, VENTILATOR AND N C )

20.Heater Vent Duct

A: REMOVAL

1)

Remove the instrument panel. <Ref. to El-42,

REMOVAL, Instrument Panel Assembly.>

2)

Remove the screws.

3) Remove the heater vent duct.

c3

I

B: INSTALLATION

Install in the reverse order of removal.

HV0064

I

AC-35

GENERAL DIAGNOSTICS

HVAC SYSTEM (HEATER. VENTILATOR AND A/C)

21

.General Diagnostics

A: INSPECTION

Blower motor

Warm air not emitted.

Unable to switch blow vents.

Unable to switch suction vents.

Doesn't move.

~

Stranqe noise.

Doesn't move.

Strange noise

Temperature of air from vents does not change.

I

Fuse

Blower motor relay

Blower motor

Blower motor resistor

Blower switch

I

Wire harness

1

Blower motor

Refrigerant

Fuse

Air conditioning relay

Maanet clutch

(Comoressor

I

Pressure switch

I

A/C switch

Blower switch

Wire harness

V-Belt

Magnet clutch

Compressor

I

Refrigerant

I

V-Belt

Magnet clutch

Compressor

Pressure switch m w i t c h

I

Blower switch

I

Wire harness

I

Heater duct

Heater vent duct

~

Enaine coolant

~ ~~~

Blower switch

Heater core

Engine coolant

Mode actuator

Wire harness

Mode actuator

Air flow switch

Wire harness

Air inlet select switch

FRESH/RECIRC actuator

Wire harness

AC-36

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

AIRBAG

SYSTEM

5

.

6

.

7

.

8

.

9

.

10

.

1

.

2

.

3

.

4

.

A 5

m

Page

General Description

Airbag Connector

....................................................................................

2

........................................................................................

8

Inspection Locations After a Collision

.......................................................

10

Driver's Airbag Module

..............................................................................

12

Passenger's Airbag Module

......................................................................

13

Side Airbag Module

...................................................................................

14

Airbag Control Module

..............................................................................

15

Side Airbag Sensor

...................................................................................

16

Roll Connector

..........................................................................................

17

Front Sub Sensor

......................................................................................

18

I

AI RBAG SYSTEM

1.

General Description

A: COMPONENT

GENERAL DESCRIPTION

\

(1) Combination switch ASSY with roll (7) Side airbag sensor connector

(8) Side airbag harness

(2)

[email protected]

(9) Side airbag module

(3) Airbag module ASSY (Driver) (1 0) Airbag main harness

(4) Airbag module ASSY (Passenger) (1 1) Front sub sensor harness

(5) Airbag control module (1 2) Front sub sensor

(6)

T O R P bolt T40 (1 3) [email protected] bolt T30

RE0031

Tightening torque: N.m (kgf-m, ft-lb)

T1: 7.4 (0.75, 5.4)

T2: l O ( 1 . 0 , 7.2)

T3: 20 (2.0, 14.5)

T4: 25 (2.5, 18.1)

AB-2

B: CAUTION

GENERAL DESCRIPTION

AIRBAG

SYSTEM

When checking, use a test harness. Do not di- rectly apply the tester probe to any connector termi- nal of the airbag.

When servicing a vehicle, be sure to turn the ig- nition switch OFF, disconnect the ground terminal 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 terminal is disconnected, it may inflate.

NO GOOD GOOD

G5M0293

NO GOOD

\

1

G5M0292

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

I

I

NO GOOD

I

I

GOOD

Test harness

G5M0291

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

Never re-use a deployed airbag or pretensioner.

When checking the system, be sure to use a dig- ital circuit tester.

Use of an analog circuit tester may cause the air- bag to activate erroneously.

G5M0294

Do not check continuity of the driver, passenger, side airbag modules and pretensioner.

I

NO GOOD

G5M0302

AB-3

I

GENERAL DESCRIPTION

AIRBAG SYSTEM

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

Do not touch the connec-

Install the wire harness securely with the speci- fied clips to avoid interference or tangled up with other parts.

NO GOOD

G5M0298

The airbag module (driver, passenger and side) and pretensioner must not be disassembled.

NO GOOD

G5M0297

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, re- move 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 wire harness of the airbag system. v

~’

G5M0299

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

\ \

NO GOOD

G5M0310

NO GOOD

G5M0296

AB-4

GENERAL DESCRIPTION

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 in- ternal parts may be damaged and reliability greatly lowered.

AIRBAG

SYSTEM

NO GOOD

G5M0295

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

I

I

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 rea- son when it is placed with its pad side facing down- ward or under any object, a serious accident may result.

AB-5

AIRBAG SYSTEM

Driver side GOOD

GENERAL DESCRIPTION

Passenger side

NO GOOD

L

NO GOOD

G5M0604

AB-6

C: PREPARATION TOOL

1. GENERAL TOOL

GENERAL DESCRIPTION

T O R P T40 (Tamper resistant type)

AIRBAG SYSTEM

Used for removaVinstallation of drivers airbag module

Used for removaVinstallation of airbag control module

Used for removal of side airbag sensor.

AB-7

I

AIRBAG CONNECTOR

AIRBAG

SYSTEM

2. Airbag Connector

A:

OPERATION

1.

POWER SUPPLY

1) How to disconnect:

(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, PASSENGER'S AIR-

BAG, SIDE AIRBAG

1)

How to disconnect:

(1)

Push the lock arm (A).

(2)

With the lock arm (A) pushed in, move the slide lock

RE0012

CAUTION:

When pulling, be sure to hold onto the connec- tor and not the wire.

2) How to connect:

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

lY

1

(3)

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

CAUTION:

When pulling, be sure to hold onto the connec- tor and not the wire.

/

RE0013

I

CAUTION:

Be sure to insert the connector in until it locks.

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

B5M1154

2) How to connect:

Holding the connector, and push it in carefully until a 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.

AB-8

I

AIRBAG CONNECTOR

3.

FRONT SUB-SENSOR, SIDE AIRBAG

SENSOR

1) How to disconnect:

(1) Holding the outer part

(A),

pull it in the direc- tion of the arrow.

CAUTION:

When pulling, be sure to hold onto the connec- tor and not the wire.

AIRBAG

SYSTEM

4.

PRETENSIONER

1)

How to disconnect:

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

(2) Pull the connector

(B)

arrow with slide lock

(A)

moved.

2)

How to connect:

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

C A UTI 0 :

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.

CAUTION:

When pulling, be sure to hold onto the connec- tor and not the wire.

2) How to connect:

Holding the connector

(A),

and push it in carefully until a 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.

AB-9

I

INSPECTION LOCATIONS AFTER A COLLISION

AIRBAG SYSTEM

3.

Inspection Locations After a

Collision

A: 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.

AIRBAG MODULE (DRIVER)

1) Check for the following, and replace the dam- aged parts with new parts.

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 air- bag module and steering wheel.

The steering wheel is in the way, making it diffi-

3.

AIRBAG MODULE (SIDE)

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

Front seat is damaged or deformed.

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

Lead wire is exposed.

4.

AIRBAG CONTROL MODULE

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

Control module is cracked or deformed.

Mounting bracket is cracked or deformed.

Connector is scratched or deformed.

Airbag is deployed.

Side airbag is deployed.

5.

FRONT SUB SENSOR

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

The clearance between the driver's airbag mod- ule and steering wheel is not constant.

When steering wheel deformation in axial and ra- dial directions exceed limits.

Speci fica tions:

Axial direction play A

Less than 6 mm (0.24 in)

Radial direction play

L

Less than 17 mm (0.67 in)

I I

I

2.

AIRBAG MODULE (PASSENGER)

I

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

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.

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

Front sub sensor is cracked or deformed.

Mounting bracket is cracked or deformed.

Connector is scratched or cracked.

Airbag is deployed.

6. FRONT SUB SENSOR HARNESS

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

Harness is open, lead wire is exposed, and cor- rugated tube is noticeably cracked.

Connector is scratched or cracked.

AB-I 0

INSPECTION LOCATIONS AFTER A COLLISION

AIRBAG

SYSTEM

7. SIDE AIRBAG SENSOR

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

8.

SIDE AIRBAG SENSOR HARNESS

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

Harness is open, lead wire is exposed, and cor- rugated tube is noticeably cracked.

Connector is scratched or cracked.

9. MAIN HARNESS

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

Harness is open, lead wire is exposed, and cor- rugated tube is noticeably cracked.

Connector is scratched or cracked.

05M0514

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

Side airbag sensor is cracked or deformed.

Mounting bracket is cracked or deformed.

Connector is scratched or cracked.

Side airbag is deployed. (operating side)

r .

10.ROLL CONNECTOR

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

Combination switch or steering roll connector is cracked or deformed.

11 .STEERING SHAFT

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

Overall length of steering column should be within specifications.

Specifications:

Overall length

L

825.751.5

mm

(32.5H.06 in)

If necessary, replace it with new part.

L

AB-1 1

RE0032

I

DRIVER’S AIRBAG MODULE

AIRBAG

SYSTEM

4.

Driver’s Airbag Module

A: CAUTION

Refer to the “CAUTION” of General Description be- fore handling the airbag module. <Ref. to AB-3,

CAUTION, General Description.>

B: REMOVAL

1)

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

2)

Turn the ignition switch OFF.

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

4)

Using [email protected] BIT T30, remove the two [email protected] bolts on the side of steering wheel.

D: INSPECTION

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

Airbag module, harness, connector, and mount- ing bracket are damaged.

H5M0662A

5)

Disconnect the airbag connector on the back of airbag module, and then remove the airbag mod- ule.

6)

Refer to the “CAUTION” for handling of a re- moved airbag module. <Ref. to AB-3, CAUTION,

General Description.>

C: INSTALLATION

1)

Install in the reverse order of removal.

CAUTION:

Do not allow harness and connectors to inter- fere or get tangled up with other parts.

AB-I 2

PASSENGER’S AIRBAG MODULE

5.

Passenger’s Airbag Module

A: CAUTION

Refer to the “CAUTION” of General Description be- fore handling the airbag module. <Ref. to AB-3,

CAUTION, General Description.>

B:

REMOVAL

1)

Turn the ignition switch OFF.

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

3) Remove the glove box. <Ref. to El-39, REMOV-

AL, Glove Box.>

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

5)

Remove the three bolts, and then carefully re- move the airbag module.

AIRBAG SYSTEM

6)

Refer to the “CAUTION” for handling of a re- moved airbag module. <Ref. to AB-3, CAUTION,

General Description.>

C: INSTALLATION

Install in the reverse order of removal.

CAUTION:

Do not allow harness and connectors to inter- fere or get tangled up with other parts.

D: INSPECTION

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

Airbag module, harness, connector, and mount- ing bracket are damaged.

AB-I 3

I

SIDE AIRBAG MODULE

AIRBAG SYSTEM

6.

Side Airbag Module

A:

CAUTION

Refer to the “CAUTION” of General Description be- fore handling the airbag module. <Ref. to AB-3,

CAUTION, General Description.>

B: REMOVAL

CAUTION:

The side airbag module cannot be detached from the front seat assembly.

When replacing side airbag module, replace front seat assembly.

<Ref. to

SE-6,

REMOVAL, Front Seat.>

C: INSTALLATION

<Ref. to SE-6, INSTALLATION, Front Seat.>

D: INSPECTION

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

-*

Front seat is deformed or damaged.

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

Lead wire is exposed.

AB-1 4

AIRBAG CONTROL MODULE

7 .

Airbag Control Module

A: REMOVAL

CAUTION:

Do not disassemble the airbag control mod- ule.

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

Do not drop the airbag control module.

After removal, keep the airbag control mod- ule on a dry, clean surface away from moisture, heat, and dust.

1) Turn the ignition switch OFF.

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

3) Remove the console box. <Ref. to El-41, RE-

MOVAL, Console Box.>

4)

Disconnect the connector from the airbag control module.

5 )

Using

[email protected]

TORX bit (Tamper resistant type), remove the four [email protected] bolts.

AIRBAG SYSTEM

B: INSTALLATION

CAUTION:

Use new

[email protected]

bolts during re-assembly.

Install in the reverse order of removal.

C: INSPECTION

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

Control module, connector, and mounting brack- et are damaged.

Airbag is deployed.

Side airbag is deployed.

AB-I 5

I

SIDE AIRBAG SENSOR

AIRBAG

SYSTEM

8.

Side Airbag Sensor

A: REMOVAL

1) Turn the ignition switch OFF.

2)

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

3) Remove the outer belt (FRONT). <Ref. to SB-8,

OUTER BELT (FRONT), REMOVAL, Front Seat

Belt.>

4)

Using T30 [email protected] bit (Tamper resistant type), remove the two [email protected] bolts.

5) Detach the side airbag sensor, and then discon- nect the airbag connector.

I

c-

REO018

B: INSTALLATION

CAUTION:

Use new [email protected] bolts during re-assembly.

Install in the reverse order of removal.

C: INSPECTION

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

Bracket connector for side airbag sensor is dam- aged.

AB-I 6

9. Roll Connector

ROLL CONNECTOR

A: REMOVAL

1) Turn the ignition switch OFF.

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

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

12, Driver’s Airbag Module.>

4)

Remove the steering wheel. <Ref. to PS-19,

REMOVAL, Steering Wheel.>

5) Remove the steering column cover.

6 )

Remove the screws, and then remove the roll connector.

AIRBAG SYSTEM

D: ADJUSTMENT

1) Check that 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

\

I

~~ approximately 2.65 turns until are aligned.

I J

W

H5M0663B

B: INSTALLATION

1) Install the roll connector and steering column cover in the reverse order of removal.

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

<Ref. to AB-1 7, ADJUSTMENT, Roll Connector.>

3) Install the steering wheel and airbag module.

C: INSPECTION

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

Combination switch and roll connector is cracked or deformed.

AB-I 7

FRONT SUB SENSOR

1O.Front Sub

Sensor

A: REMOVAL

1)

Turn the ignition switch OFF.

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

3) Remove the front bumper. <Ref. to El-23, RE-

MOVAL, Front Bumper.>

4)

Loosen the two bolts to remove sensor cover.

5) Remove the bolt, and then detach the front sub sensor.

6) Disconnect the connector from the front sub sen- sor.

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

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

Front sub sensor, mounting bracket, and con- nector are damaged.

AB-I 8

AIRBAG SYSTEM (DIAGNOSTICS)

A 5

5

.

6

.

7

.

8

.

9

.

10

.

11

.

12

.

13

.

1

.

2 .

3

.

4

.

Basic Diagnostic Procedure

Page

........................................................................

2

Check List for Interview

...............................................................................

3

General Description

....................................................................................

4

Electrical Components Location

................................................................

18

A/B Control Module I/O Signal

Airbag Connector

..................................................................

20

......................................................................................

21

Airbag Warning Light Illumination Pattern

.................................................

23

Read Diagnostic Trouble Code

.................................................................

24

Inspection Mode

........................................................................................

25

Clear Memory Mode

..................................................................................

26

Airbag Warning Light Failure

.....................................................................

27

List of Diagnostic Trouble Code

................................................................

32

Diagnostic Chart with Trouble Code

.........................................................

36

BASIC DIAGNOSTIC PROCEDURE

AIRBAG SYSTEM (DIAGNOSTICS)

1.

Basic Diagnostic Procedure

A: PROCEDURE

!

I

Step

Read Diagnostic Trouble Code.

<Ref. to AB-24, Read Diagnostic Trouble

Code.>

Read Diagnostic Trouble Code.

<Ref. to AB-24, Read Diagnostic Trouble

Code.>

Check s

the normal code being letected? s the trouble code being jetected?

Perform the diagnosis.

1)Judge the possible cause from “List of Diag- nostic Trouble Code” <Ref. to AB-32, List of

Diagnostic Trouble Code.>

.

2)lnspect using “Diagnostic Chart with Trouble

Code”. (DTC)

3)Repair the cause of the trouble.

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

AB-26, Clear Memory Mode.>

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

25, Inspection Mode.>

6)Read diagnostic trouble code. s the trouble code being

Jetected?

No

Yes

-inish the diagno-

;is.

30

to step

3.

Go to step

2.

I

Go to “Airbag

Warning Light Fail, ure”.<Ref. to AB-

27, Airbag Warn- ing Light Failure.>

Perform the proce-

Finish the diagno- jure 1) to

5)

sis.

AB-2

CHECK LIST FOR INTERVIEW

AIRBAG SYSTEM (DIAGNOSTICS)

2.

Check List for Interview

A: CHECK

Customer's Name

Inspector's Name

Date Vehicle Brought In

Odometer Reading

I I

~

Registration

No.

Miles

Vin No.

I I

Registration Year

I I

-.

-

Weather D Fine D Cloudy D Rainy D Snowy I2 Other:

"C

( O F )

I2 Level road D Uphill

CI

Downhill D Rough road

CI

Others:

CI

Starting D Idling

Driving

(El

Constant Speed tl

Acceleration D Deceleration

I2 Steering wheel turn

CI

Other: )

I2 Remains ON

D Remains OFF r -

Ll

Normal Code D Trouble Code: (Code:

)

AB-3

GENERAL DESCRIPTION

AIRBAG SYSTEM (DIAGNOSTICS)

3.

General Description

A: CAUTION

When servicing a vehicle, be sure to turn the ig- nition switch OFF, disconnect the ground terminal from the 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 terminal is disconnected, it may inflate.

When checking, use a test harness. Do not di- rectly apply the tester probe to any connector termi- nal of the airbag.

NO

GOOD GOOD

G5M029:

NO

GOOD

c-

1

G5M0292

\

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

NO

GOOD

GOOD

G5M0291

I

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

Never re-use a deployed airbag and pretension- er.

When checking the system, be sure to use a dig- ital circuit tester.

Use of an analog circuit tester may cause the air- bag to activate erroneously.

G5M0294

Do not check continuity of the driver, passenger, side airbag modules and pretensioner.

NO GOOD

\

G5M0302

I

GENERAL DESCRIPTION

AIRBAG SYSTEM (DIAGNOSTICS)

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

Install the wire harness securely with the speci- fied clips to avoid interference or tangled up with other parts.

NO GOOD

I

G6M0298

I

The airbag module (driver, passenger, side) and pretensioner must not be disassembled.

NO GOOD

r

G5M0297

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, re- move 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 wire harness of the airbag system.

G5M0299

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

\ \

NO GOOD

G5M0310

NO GOOD

G5M0296

AB-5

GENERAL DESCRIPTION

AIRBAG SYSTEM (DIAGNOSTICS)

Do not drop the airbag modulator parts, subject them to high temperature over 93°C (1 99"F), or let water, oil, or grease get on them; otherwise, the in- ternal parts may be damaged and reliability greatly lowered.

NO GOOD

G5M029C

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

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 rea- son when it is placed with its pad side facing down- ward or under any object, a serious accident may result.

AB-6

Driver side

GOOD

GENERAL DESCRIPTION

AIRBAG

SYSTEM (DIAGNOSTICS)

NO GOOD

A

NO GOOD

AB-7

G5M0604

GENERAL DESCRIPTION

AIRBAG SYSTEM (DIAGNOSTICS)

Do not discard undeployed airbag modules.

They could easily cause a serious accident if acci- dentally deployed.

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: 12V

Specific gravity: Above 1.260

AB-8

GENERAL DESCRIPTION

AIRBAG SYSTEM (DIAGNOSTICS)

C: PREPARATION TOOL

1. SPECIAL TOOLS

TEST HARNESS

M

ILLUSTRATION TOOLNUMBER

98299FE020

I

DESCRl PTlON

I

TEST HARNESS M

REMARKS

Used when measuring voltage, resistance of air- bag system.

RE0033

6 5 4 3

RE0034

AB-9

I

AIRBAG SYSTEM (DIAGNOSTICS)

TEST HARNESS F

GENERAL DESCRIPTION

ILLUSTRATION

I

TOOLNUMBER

1

DESCRIPTION

98299FC010

I

TEST HARNESS

F

REMARKS

Used when measuring voltage, resistance of air- bag module harnesses.

RE0035

RE0036

AB-I 0

GENERAL DESCRIPTION

AIRBAG SYSTEM (DIAGNOSTICS)

TEST HARNESS

G

ILLUSTRATION

TOOL NUMBER

98299FC020 side airbag sensor.

G3

1 1

RE0037

&,

4 5 6 7 8 l - 4

RE0038

AB-1 1

AIRBAG SYSTEM (DIAGNOSTICS)

TEST

HARNESS

H

GENERAL DESCRIPTION

DESCRIPTION

TESTHARNESSH

REMARKS

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

I

RE0039

I

@

RE0040

AB-I 2

TEST HARNESS L

GENERAL DESCRIPTION

AIRBAG SYSTEM (DIAGNOSTICS)

I

seat belt pretensionei

RE0041

I

a

RE0042

AB-I

3

GENERAL DESCRIPTION

AIRBAG SYSTEM (DIAGNOSTICS)

TEST HARNESS 12

ILLUSTRATION

I

TOOLNUMBER

I

DESCRIPTION

98299FC041

I

TEST HARNESS 12

1

REMARKS

I

Used when measuring voltage, resistance of air-

REO045

I

r 5

II 1 i 3 I

It

I

I I

1

1

a

RE0046

AIRBAG SYSTEM (DIAGNOSTICS)

AIRBAG

RESISTOR

GENERAL DESCRIPTION

ILLUSTRATION

TOOL NUMBER

98299PA040

DESCRIPTION

AIRBAG RESISTOR

REMARKS

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

RE0047

I

RE0048

AB-1 6

GENERAL DESCRIPTION

AIRBAG SYSTEM (DIAGNOSTICS)

a

ELECTRICAL COMPONENTS LOCATION

AIRBAG SYSTEM (DIAGNOSTICS)

4.

Electrical Components Location

A: LOCATION

*@--

*@-

r

Male connector

RE0049

AB-1 8

ELECTRICAL COMPONENTS LOCATION

AI RBAG SYSTEM (DIAGNOSTICS)

(1) Driver’s airbag module

(2)

Roll connector

(3) Passenger’s airbag module

(4)

Airbag control module

(5) Side airbag module (LH)

(6) Side airbag module (RH)

(7) Seat belt pretensioner (LH)

(8) Seat belt pretensioner (RH)

(9) Front sub-sensor (LH)

(IO)

Front sub-sensor (RH)

(1 1) Side airbag sensor (LH)

(12)

Side airbag sensor (RH)

(1 3) Airbag main harness

(14) Front sub-sensor harness (LH)

(1 5) Front sub-sensor harness (RH)

(1 6) Side airbag harness (LH)

(17) Side airbag harness

(RH)

AB-1 9

I

A/B

CONTROL MODULE I/O SIGNAL

AIRBAG SYSTEM (DIAGNOSTICS)

5. A/B Control Module

I/O Signal

A: SCHEMATIC

<Ref.

to WI-31,

Airbag System.>

AB-20

6.

Airbag

Connector

A: OPERATION

AIRBAG CONNECTOR

1.

POWER SUPPLY

1)

How to disconnect:

(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.

AIRBAG SYSTEM

(DIAGNOSTICS)

2.

DRIVER'S AIRBAG, PASSENGER'S AIR-

BAG, AND SIDE AIRBAG

1)

How to disconnect:

(1)

Push the lock arm

(A).

(2) With lock arm

(A)

pushed in, move the slide lock

(B)

in the direction of the arrow.

91

*

RE0012

CAUTION:

When pulling, be sure to hold onto the connec- tor and not the wire.

2)

How to connect:

Holding the connector

(A),

and push it in carefully until a connecting sound is heard.

I

\ \

B5M1153AI

(3) With slide lock (B) pulled, remove the lock arm

(A)

to its original position, and then pull in the direction of the arrow and separate the con- nector.

CAUTION:

When pulling, be sure t o hold onto the connec- tor and not the wire.

/

RE0015

CAUTION:

Be sure to insert the connector in until it locks.

Then pull on it gently t o make sure that it is locked.

B5M1154

2) How to connect:

Holding the connector, and push it in carefully until a 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.

AB-21

I

AIRBAG

CONNECTOR

AIRBAG SYSTEM fDIAGNOSTICS)

3.

FRONT SUB-SENSOR, SIDE AIRBAG

SENSOR

1)

How to disconnect:

(1)

Holding the outer part

(A),

pull it in the direc- tion of the arrow.

CAUTION:

When pulling, be sure to hold onto the connec- tor and not the wire.

4. PRETENSIONER

1)

How to disconnect:

(1)

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

(2)

Pull the connector (B) in the direction of the arrow with slide lock

(A)

moved.

/ /

-

( A )

2) How to connect:

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

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.

CAUTION:

When pulling, be sure to hold onto the connec- tor and not the wire.

2)

How to connect:

Holding the connector

(A),

and push it in carefully until a 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.

AB-22

AIRBAG WARNING LIGHT ILLUMINATION PATTERN

AIRBAG SYSTEM (DIAGNOSTICS)

7. Airbag Warning Light Illumi- nation Pattern

A: INSPECTION

Keep the ignition switch

ON, and confirm that the airbag warning light remains off approximately

6 seconds after being turned on.

Airbag warning

ON

A-1

OFF

Approx.

6 seconds m light igniiion switch

ON

I

READ DIAGNOSTIC TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

8.

Read Diagnostic Trouble

Code

A: OPERATION

1) Turn the ignition switch ON.

2) Connect the diagnosis terminal (1) to the diagno- sis connector (2) terminal No. 1 in the driver’s seat lower cover area.

3) Read trouble code by identifying the way the air bag warning light flashes.

The airbag warning light flashes a code corre- sponding to the faulty parts.

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

NOTE:

“List of Diagnostic Trouble Code” <Ref. to AB-32,

List of Diagnostic Trouble Code.>

“Airbag Warning Light Failure” <Ref. to AB-27,

Airbag Warning Light Failure.>

Example:

Flashing

code 12:

Flashing

code21:

OFF

-

10

1.2

-

10

,.

0.3

_.

1.2

1

1

0.3

1 .

0.3

1’

1.2

(Set)

Flashing

normal

code:

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

5 )

Wind the tape around the diagnosis terminal and return it to its original position.

B5M0117A

AB-24

INSPECTION MODE

9.

Inspection Mode

A: OPERATION

According to the contents of check list, reproduce the condition which problem has occurred as much as possible.

AIRBAG SYSTEM (DIAGNOSTICS)

AB-25

I

CLEAR MEMORY MODE

AIRBAG SYSTEM (DIAGNOSTICS)

1O.Clear Memory Mode

A: OPERATION

1)

Turn the ignition switch ON.

2) Connect the diagnosis terminal (1) to the diagno- sis connector (2) terminal No. 1 in the driver's seat lower cover area.

3) While the warning light flashes, connect another diagnosis terminal (3) to the diagnosis connector

Jerminal No.2.

4)

Once the memory is erased, the warning light re- turns to the normal flash rate (0.6 sec on). The fail- ure 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 diagnosis terminal from the diagnosis connec- tor.

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

AB-26

AIRBAG WARNING LIGHT FAILURE

AIRBAG

SYSTEM (DIAGNOSTICS)

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 (831) are not connected properly.

(AB6) is not connected properly to airbag control module.

CAUTION:

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

Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and sensor, reconnect each part and confirm that the 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-27

AIRBAG WARNING LIGHT FAILURE

AIRBAG SYSTEM (DIAGNOSTICS)

WIRING DIAGRAM:

INDICATOR

CIRCUIT r

IG SW

N0.13

"

I

=

UI

I

@

AIRBAG CONTROL MODULE

1

RE0052

Step

I

Check

CHECK POOR CONTACT IN CONNECTORS

I

Is the

Door contact in connec-

(ABl) AND (831).

tors (ABI) and (B31)?

1)Turn the ignition switch OFF, disconnect the battery ground terminal, 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 (831). harness or replace

I

No

Go to step 2. r the body harness with airbag main harness.

AB-28

I

2

3

AIRBAG WARNING LIGHT FAILURE

AIRBAG SYSTEM

(DIAGNOSTICS)

Step

CHECK AIRBAG WARNING LIGHT.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Connect the connector (1 1\11) in the test har- ness M to the body harness connector (831).

3)Connect the battery ground terminal and turn the ignition switch ON.

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

CHECK BODY HARNESS.

Check the body harness.

NOTE:

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

Check

s the airbag warning light s the anything unusual to body iarness?

Yes

Go to step 4.

Repair the body harness.

CHECK POOR CONTACT.

connector (AB6). <Ref. to

AB-15, Airbag Con- s the poor contact in connec- or (AB6)?

Replace the body harness with air- bag main harness or replace the air- bag control mod- ule. <Ref. to AB-

15, Airbag Control

Module.>

Go to step 6.

CHECK AIRBAG MAIN HARNESS.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Connect the connector (ABI) to

(831).

3)Disconnect the connectors (AB3) and (AB8).

4)Remove the glove box and disconnect the s the airbag warning light urned off?

No

;o to step

3.

3eplace combina- ion meter printed

:ircuit. <Ref. to

DI-11, Combina- ion Meter Assem-

,lY.>

So to step

5.

3eplace the body iarness with air-

)ag main harness

5)Disconnect the connector (AB6) from the air- bag control module, and connect the connector

(1 I) in the test harness I or 12. <Ref. to AB-15,

Airbag Control Module.>

6)Connect the battery ground terminal and turn the ignition switch ON.

7)Connect the connectors (41) and (51) in the test harness

I or 12.

NOTE:

After problem has been eliminated, disconnecl connectors (41) and (51).

CHECK GROUNDING CIRCUIT.

1)Turn the ignition switch

OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the connector (AB6) from the air- bag control module.

3)Connect the connector (1

I) in the test har- ness I or 12 to body harness connector (AB6).

4)Measure the resistance between connector

(21) in the test harness I or 12 and the chassis

2?

ground.

Connector

&

terminal

(21)

No.

9

-

(211 No.

10

- control module.

<Ref. to

AB-1

5,

Airbag Control

3epair body- jrounding circuit.

a

AB-29

I

AIRBAG WARNING LIGHT FAILURE

AIRBAG SYSTEM (DIAGNOSTICS)

B: AIRBAG WARNING LIGHT REMAINS OFF.

DIAGNOSIS:

Fuse No.

13

(in fuse box) is blown.

Body harness circuit is open.

Airbag warning light is faulty.

Airbag main harness is faulty.

Airbag control module is faulty.

CAUTION:

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

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

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

WIRING DIAGRAM:

AB-30

1

F

I

@

AIRBAG CONTROL MODULE

RE0052

1

2

3

4

r-

-

AIRBAG WARNING LIGHT FAILURE

AIRBAG SYSTEM (DIAGNOSTICS)

Step

CHECK COMBINATION METER.

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

Check

Do warning lights not for the airbag turn on?

Go

Yes

to step 2.

No

Repair the combi- nation meter power supply.

<Ref. to 101-4,

Combination

Meter System.>

Go to step

3. CHECK FUSE NO. 13 (IN MAIN FUSE BOX).

Remove the fuse

No.

13 and perform visual inspection.

Is the fuse No. 13 (in main fuse box) blown?

Replace the fuse

No. 13. If the fuse

No. 13 blows again, go to step

3.

Go to step 4.

CHECK AIRBAG WARNING LIGHT CIRCUIT

(IN COMBINATION METER).

1)Turn the ignition switch

OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the connector (ABI) from (831).

3)Connect the battery ground terminal and turn the ignition switch ON.

Is the airbag warning light

CHECK AIRBAG MAIN HARNESS.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Connect the connector (ABI) to (831).

3)Disconnect the connector (AB6) from the air- bag control module. <Ref. to AB-15, Airbag

Control Module.>

4)Connect the battery ground terminal and turn the ignition switch

ON.

Is the airbag warning light turned on?

Replace the airbag warning light bulb or combination meter printed cir- cuit. <Ref. to IDI-

11,

Combination

Meter Assembly.>

Replace the airbag Replace the body control module.

<Ref. to AB-15,

Airbag Control

Module.> harness with air- bag main harness.

AB-31

I

LIST

OF DIAGNOSTIC TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

12.List

of Diagnostic Trouble Code

A: LIST

Memory function

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 (driver) circuit is open, shorted or shorted to ground.

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

Airbag control module is faulty.

Driver's airbag module is faulty.

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

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

Airbag control module is faulty.

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 control module is faulty.

Driver's airbag module is faulty.

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

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

Airbag control module is faulty.

Passenger's airbag module is faulty.

<Ref. to AB-36, TROU-

BLE CODE 11, Diag- nostic Chart with

Trouble Code.>

<Ref. to AB-38, TROU-

BLE CODE 12, Diag- nostic Chart with

Trouble Code.>

<Ref. to AB-40, TROU-

BLE CODE 15, Diag- nostic Chart with

Trouble Code.>

<Ref. to AB-42, TROU-

BLE CODE 16, Diag- nostic Chart with

Trouble Code.>

Airbag control module is faulty.

Front airbag module and seat belt pretensioner (LH/

RH) are inflated.

(AB6), (AB1 7) and (AB1 8) are not connected prop- erly to airbag control module.

Airbag control module is faulty.

Airbag main harness circuit is open.

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

Body harness circuit is open.

Airbag control module is faulty.

Airbag main harness circuit is open.

Fuse No. 6 (in joint box) is blown.

Body harness circuit is open.

Front sub-sensor harness (RH) circuit is shorted.

Front sub-sensor harness (RH) circuit is open.

Front sub-sensor (RH) is faulty.

Airbaq control module is faulty.

<Ref. to AB-43, TROU-

BLE CODE 21, Diag- nostic Chart with

Trouble Code.>

<Ref. to AB-44, TROU-

BLE CODE 22, Diag- nostic Chart with

Trouble Code.>

<Ref. to AB-44, TROU-

BLE CODE 23, Diag- nostic Chart with

Trouble Code.>

<Ref. to AB-46, TROU-

BLE CODE 24, Diag- nostic Chart with

Trouble Code.>

<Ref. to AB-48, TROU-

BLE CODE 25, Diag- nostic Chart with

Trouble Code.>

<Ref. to AB-50, TROU-

BLE CODE 31, Diag- nostic Chart with

Trouble Code.>

AB-32

-.

.

Trouble code/

Contents of troubles

42

45

46

51

52

53

54

55

61

LIST OF DIAGNOSTIC TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

Memory function

Provided.

Provided.

Provided.

Provided.

Provided.

Provided.

Provided.

Provided.

Provided.

Contents of diagnosis Index

No.

Front sub-sensor harness (LH) circuit is shorted.

Front sub-sensor harness (LH) circuit is open.

Front sub-sensor (LH) is faulty.

Airbag control module is faulty.

Side airbag harness (RH) is faulty.

Side airbag module (RH) is faulty.

Airbag control module is faulty.

Side airbag harness (LH) is faulty.

Side airbag module (LH) is faulty.

Airbag control module is faulty.

Side airbag harness

(RH) is shorted to power sup-

Ply.

Airbag control module is faulty.

Side airbag harness (LH) is shorted to power sup-

Ply.

Airbag control module is faulty.

Side airbag sensor (RH) is faulty.

Side airbag harness (RH) is faulty.

Airbag control module is faulty.

Side airbag sensor (LH) is faulty.

Side airbag harness (LH) is faulty.

Airbag control module is faulty.

Side airbag sensor (RH) is faulty.

Side airbag sensor (LH) is faulty.

Side airbag module is inflated.

<Ref. to AB-54, TROU-

BLE CODE 32, Diag- nostic Chart with

Trouble Code.>

<Ref. to AB-58, TROU-

BLE CODE 41, Diag- nostic Chart with

Trouble Code.>

_____

<Ref. to AB-60, TROU-

BLE CODE 42, Diag- nostic Chart with

Trouble Code.>

<Ref. to AB-62, TROU-

BLE CODE 45, Diag- nostic Chart with

Trouble Code.>

<Ref. to AB-64, TROU-

BLE CODE 46, Diag- nostic Chart with

Trouble Code.>

<Ref. to AB-66, TROU-

BLE CODE 51, Diag- nostic Chart with

Trouble Code.>

<Ref. to AB-68, TROU-

BLE CODE 52, Diag- nostic Chart with

Trouble Code.>

<Ref. to AB-69, TROU-

BLE CODE 53, Diag- nostic Chart with

Trouble Code.>

<Ref. to AB-69, TROU-

BLE CODE 54, Diag- nostic Chart with

Trouble Code.>

<Ref. to AB-70, TROU-

BLE CODE 55, Diag- nostic Chart with

Trouble Code.>

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

Airbag control module is faulty.

Pretensioner is faulty.

Pretensioner harness is faulty.

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

Airbag control module is faulty.

Pretensioner is faulty.

Pretensioner harness is faulty.

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

Pretensioner is faulty.

Pretensioner harness is faulty.

Airbag control module is faulty.

<Ref. to AB-72, TROU-

BLE CODE 61, Diag- nostic Chart with

Trouble Code.>

<Ref. to AB-74, Trouble

Code 62, Diagnostic

Chart with Trouble

Code.>

<Ref. to AB-76, TROU-

BLE CODE 65, Diag- nostic Chart with

Trouble Code.>

AB-33

Trouble codel

Contents of troubles

66

Memory function

Provided.

Contents of diagnosis

Seat belt pretensioner

(LH) circuit is shorted to power supply.

Pretensioner is faulty.

Pretensioner harness is faulty.

Airbag control module is faulty.

Index

No.

<Ref. to

AB-78,

TROU-

BLE CODE 66, Diag- nostic Chart with

Trouble Code.>

AB-34

LIST OF DIAGNOSTIC TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

AB-35

DIAGNOSTIC CHART WITH TROUBLE CODE

AI

RBAG SYSTEM (DIAGNOSTICS)

13.Diagnostic Chart with Trouble Code

A:

TROUBLE CODE 11

DIAGNOSIS:

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

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

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

Driver's airbag module is faulty.

Airbag control module is faulty.

CAUTION:

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

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

When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's airbag module connectors for safety reasons.

WIRING DIAGRAM:

@(YELLOW) @(YELLOW)

AB-36

B5M109f

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

Step

CHECK DRIVER'S AIRBAG MODULE.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Remove the driver's airbag module. <Ref. to

AB-12, Driver's Airbag Module.>

3)Connect the connector (1 F) in the test har- ness F to connector (AB7).

4)Connect the airbag resistor to connector (3F) in the test harness

F.

5)Connect the battery ground terminal and turn the ignition switch

ON.

CHECK ROLL CONNECTOR.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the test harness F from the con- nector (AB7).

3)Remove the lower cover panel, disconnect the connector (AB3) from (AB8) and connect the connector (1 F) in the test harness F to con. nector (AB8).

4)Connect the airbag resistor to connector (3F) in the test harness F.

5)Connect the battery ground terminal and turn the ignition switch ON.

CHECK AIRBAG MAIN HARNESS.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the airbag resistor from the con- nector (3F) in the test harness F.

3)Remove the glove box, <Ref. to AB-1 3, Pas- senger's Airbag Module.> and disconnect the connectors (ABIO) and (AB9).

4)Disconnect the connector (AB6) from the air- bag control module, and connect the connector

(1 I) in the test harness I or 12. <Ref. to

AB-1 5,

Airbag Control Module.>

5)Measure the resistance between connector

(21) in the test harness

I or 12 and the connec- tor (3F) in the test harness F.

Connector & terminal

(2l) NO. 1

(21)

NO. 4

-

-

NO. 4:

NO. 3:

CHECK AIRBAG MAIN HARNESS.

Measure the resistance of the connector (21) in the test harness I or 12.

Connector & terminal

(21) NO. 1 -NO. 4:

(21) No. 4

-

(21)

No.

1

Chassis ground:

-

Check

)oes the airbag warning light iperate properly?

)oes the airbag warning light iperate properly?

1?

;the resistance more than 1

1R?

Yes

3eplace the iriver's airbag nodule. <Ref. to

4B-12, Driver's

4irbag Module.>

No

30

to step

2.

3eplace the roll

:onnector. <Ref. o

AB-17,

Roll

:onnector.>

30

to step

3.

;o

to step 4.

3eplace the body iarness with air- lag main harness

3eplace the airbag

:ontrol module.

:Ref. to AB-1 5,

\irbag Control

Aodule.>

3eplace the body iarness with air-

)ag main harness

AB-37

~

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

B: TROUBLE CODE 12

DIAGNOSIS:

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

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

Passenger's airbag module is faulty.

Airbag control module is faulty.

CAUTION:

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

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

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

WIRING DIAGRAM:

@

AIRBAG CONTROL MODULE

INFLATOR

(PASSENGER SIDE)

AB-38

I

!

I

r-

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

~

Step

CHECK PASSENGER'S AIRBAG MODULE.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Remove the glove box.

No

;o

to step 2.

(AB9).

4)Connect the connector (1 F) in the test har- ness F to connector (AB9).

5)Connect the airbag resistor to connector (3F) in the test harness

F.

6)Connect the battery ground terminal and turn the ignition switch ON.

CHECK AIRBAG MAIN HARNESS.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the airbag resistor from the con- nector (3F) in test harness F.

3)Remove lower cover and disconnect the con- nector (AB3) from (AB8).

4)Disconnect the connector (AB6) from the air- bag control module, and connect the connector

(1 I) in the test harness I or 12. <Ref. to AB-15,

Airbag Control Module.>

5)Measure the resistance between connector

(21) in the test harness I or 12 and the connec- tor (3F) in the test harness

F.

Connector & terminal

(21) NO. 2

-

NO.

3:

(21) NO. 5

-

NO. 4:

CHECK AIRBAG MAIN HARNESS.

Measure the resistance of the connector (21) in the test harness I or 12.

Connector

81 terminal

(21) NO. 2

-

(21) No. 2

NO. 5:

-

(21) No. 5

Chassis ground:

- s the resistance less than 10

Z? s

the resistance more than 1

An?

I

Go to step

3.

eeplace airbag control module.

<Ref. to AB-15,

Airbag Control

Module.> leplace the body iarness with air- lag main harness. leplace the body larness with air- lag main harness.

AB-39

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

C: TROUBLE CODE 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.

Driver's airbag module is faulty.

Airbag control module is faulty.

CAUTION:

Before diagnosing the airbag system, be sure to turn the ignition switch

OFF, disconnect the ground terminal from the battery, and wait more than 20 seconds before starting to work.

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

When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's airbag module connectors for safety reasons.

WIRING DIAGRAM:

r

AB6 AIRBAG CONTROL MODULE

IO

I

STEERING

ROLL CONNECTOR

@(YELLOW)

@(YELLOW) m

@(YELLOW)

U

IN FLATOR

AB-40

B5M109t

?

I

r-

i

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

Step

CHECK DRIVER'S AIRBAG MODULE.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Remove the driver's airbag module. <Ref. to

AB-1 2, Driver's Airbag Module.>

3)Connect the connector (AB7) to connector

(1 F) in the test harness F.

4)Connect the airbag resistor to connector (3F) in the test harness F.

5)Connect the battery ground terminal and turn the ignition switch ON.

Check

Ioes the airbag warning light

)perate properly?

CHECK ROLL CONNECTOR.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the test harness

F from the con- nector (AB7).

3)Remove the lower cover panel and discon- nect the connector (AB3) from (AB8).

4)Connect the connector (1

F) in the test har- ness F to the connector (AB8).

5)Connect the airbag resistor to connector (3F) in the test harness F.

6)Connect the battery ground terminal and turn the ignition switch ON.

CHECK AIRBAG MAIN HARNESS.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the airbag resistor from the con- nector (3F) in test harness F.

3)Remove the glove box, and disconnect the connectors (AB1 0) and (AB9).

4)Disconnect the connector (AB6) from the air- bag control module, and connect the connector

(1 I) in the test harness I or 12. <Ref. to AB-1 5,

Airbag Control Module.>

5)Connect the battery ground terminal and turn the ignition switch ON. (Engine OFF)

6)Measure the voltage between connector (21) in the test harness I or 12 and the chassis ground.

Connector & terminal

(21)

No. 4 (+)

(21)

No. 1 (+)

-

-

I (

Ioes the airbag warning light

)perate properly?

I

Yes

Replace the driver's airbag module. <Ref. to

AB-12, Driver's

Airbag Module.>

Replace the roll connector. <Ref. to AB-1 7 , Roll

Connector.> control module.

<Ref. to AB-1 5,

Airbag Control

Module.>

No

20

to step 2.

20

to step

3.

3eplace the body iarness with air-

)ag main harness.

AB-41

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

D: TROUBLE CODE 16

DIAGNOSIS:

Airbag main harness circuit (Passenger) is shorted to the power supply.

Airbag module harness (Passenger) is shorted to the power supply.

Passenger's airbag module is faulty.

Airbag control module is faulty.

CAUTION:

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

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

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

WIRING DIAGRAM:

1

r

INFLATOR

(PASSENGER SIDE)

AB-42

RE0053

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG

SYSTEM (DIAGNOSTICS)

!

r -

Step

CHECK PASSENGER'S AIRBAG MODULE.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Remve the glove box.

3)Disconnect the connector (AB1 0) from (AB9

4)Connect the connector (1 F) in the test har- ness F to the connector (AB9).

5)Connect the airbag resistor to connector (3F) in the test harness

F.

6)Connect the battery ground terminal and turn the ignition switch ON.

CHECK AIRBAG MAIN HARNESS.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the airbag resistor from the con- nector (3F) in the test harness F.

3)Remove the lower cover and disconnect the connector (AB3) from (AB8).

4)Disconnect the connector (AB6) from the air bag control module, and connect the connector

(1 I) in the test harness I or

12. <Ref. to AB-1 5,

Airbag Control Module.>

5)Measure the voltage between connector (21) in the test harness I or 12 and the chassis ground.

Connector

&

terminal

(21) No. 2

(21) No.

5

-

-

Check

)es the airbag warning light

'erate properly? ;enger airbag nodule. <Ref. to

4B-I 3, Passen- jerk Airbag Mod- the voltage less than 1 V?

4irbag Control vlodu1e.r

E: TROUBLE CODE 21

DIAGNOSIS:

Airbag

control module is faulty.

CAUTION:

Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground terminal from the battery, and wait more than

20

seconds before starting to work.

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

1

Step

CHECK IF TROUBLE CODE 21 IS INDICAT-

ED.

Read Diagnostic Trouble Code. <Ref. to AB-

24, Read Diagnostic Trouble Code.>

Check Yes No

Is the airbag warning light trou- Replace the airbag Perform clear ble code 21 indicated? control module. memory. <Ref. to

<Ref. to AB-1 5, AB-26, Clear

Airbag Control

Module.>

Memory Mode.>

AB-43

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

F:

TROUBLE CODE 22

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-1 5 , Airbag Control Module.>

Driver's airbag module. <Ref. to AB-12, Driver's Airbag Module.>

Passenger's airbag module. <Ref. to AB-1 3, Passenger's Airbag Module.>

Front sub-sensor of both sides. <Ref. to AB-18, Front Sub Sensor.>

Front seat belt outer with pretensioner of both sides. <Ref. to SB-8, Front Seat Belt.>

G: TROUBLE CODE 23

DIAGNOSIS:

7) and (AB1 8) are not connected properly to airbag control module.

CAUTION:

Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground terminal from the battery, and wait more than

20

seconds before starting to work.

1

. .

2

Step Check

CHECK POOR CONTACT IN CONECTORS

(Ass), (AB17) and (AB18).

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20

Check if the rust or damage appear on the harness con- nector and the control module connector. seconds.

2)Disconnect the connectors (AB6), (AB17) and (AB1 8) from the airbag control module.

<Ref. to AB-1 5, Airbag Control Module.>

CHECKPOORCONTACTINCONECTORS

(Ass), (AB17) and (AB18).

1)Ensure that the connectors are firmly recon- nected.

2)Connect the battery ground terminal and turn the ignition switch ON. operate properly?

Yes

No

Replace the airbag control module.

<Ref. to AB-1 5,

Airbag Control

Module.> Replace the body harness with airbag main harness.

Go to step 2.

Replace the body harness with side airbag harness.

Finish the diagno- sis.

I

I

Replace the airbag control module.

<Ref. to AB-1 5,

Airbag Control

Module.>

AB-44

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

AB-45

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

H: TROUBLE CODE 24

DIAGNOSIS:

Airbag control module is faulty.

Airbag main harness circuit is open.

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

Body harness circuit is open.

CAUTION:

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

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

When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's airbag module connectors for safety reasons.

WIRING DIAGRAM:

IG SW

N0.11

1

I

W

I

I

AIRBAG CONTROL MODULE

I

RE0054

AB-46

DIAGNOSTIC CHART WITH TROUBLE CODE

At RBAG SYSTEM (DIAGNOSTICS)

Step

CHECK AIRBAG CONTROL MODULE.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the connector (AB6) from the air- bag control module. <Ref. to

AB-15, Airbag

Control Module.>

3)Connect the connector (1 I) in the test har- ness I or 12 to connector (AB6).

4)Connect the battery ground terminal and turn the ignition switch

ON.

5)Measure the voltage between connector (21) in the test harness I or 12 and chassis ground.

Connector & terminal

(21) No. 3

(+)

CHECK AIRBAG MAIN HARNESS.

1)While checking control module, turn the igni- tion switch OFF and disconnect the battery ground terminal. Wait more than 20 seconds before operation.

2)Disconnect the airbag connector (AB1 ) from the body harness (B31).

3)Connect the connector (2M) in the test har- ness M to connector (AB1).

4)Measure the resistance between connector

(5M) in the test harness M and the connector

(21) in the test harness I or 12.

Connector & terminal

(5M)

NO.

2

-

:

CHECK AIRBAG MAIN HARNESS.

Measure the following resistance with the above-mentioned condition maintained.

Connector & terminal

(5M) No. 2

(21)

No.

3

-

-

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 joint box) and perform visual inspection.

Check

3

the voltage more than 10

V?

s the resistance less than 10

2?

s the resistance more than 1

dfi?

s fuse No. 11 blown?

Yes

3eplace the airbag

:ontrol module.

:Ref. to AB-15,

4irbag Control vlodule.>

30

to step

3.

30

to step 4.

3eplace fuse No.

11. Iffuse No. 11

lows again, repair

:he body harness.

No

) to step 2.

.mess with air-

.g main harness.

?place the body irness with air- ig main harness

?pair the body irness.

m

AB-47

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

I: TROUBLE CODE 25

DIAGNOSIS:

Airbag control module is faulty.

Airbag main harness circuit is open.

Fuse No. 6 (in joint box) is blown.

Body harness circuit is open.

CAUTION:

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

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

When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's airbag module connectors for safety reasons.

WIRING DIAGRAM: r Y

AB6 AIRBAG CONTROL MODULE

AB-48

RE0055

!

1

I

-.

.

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

~~ ~~ ~

Step

CHECK AIRBAG CONTROL MODULE.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the connector (AB6) from airbag control module. <Ref. to AB-1 5, Airbag Control

Module. >

3)Connect the connector (1

I )

in the test har- ness I or 12 to the connector (AB6).

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

5)Measure the voltage between the connector

(21) in the test harness I or 12 and the chassis ground.

Connector & terminal

(21)

No.

6

(+)

CHECK AIRBAG MAIN HARNESS.

1) While checking control module, turn the igni tion switch OFF and disconnect the battery ground terminal. Wait more than 20 seconds before operation.

2)Disconnect the airbag connector (ABI) from the body harness (B31).

3)Connect the connector (2M) in the test har- ness M to the airbag connector (AB1).

4)Measure the resistance between the con- nector (5M) in the test harness M and the con- nector (21) in the test harness I or 12.

Connector & terminal

(5M) NO. 2

-

NO. 6:

CHECK AIRBAG MAIN HARNESS.

Measure the following resistance with the above-mentioned condition maintained.

Connector & terminal

(5M) No. 2

-

(21) No. 6

-

CHECK FUSE NO. 6 (IN JOINT BOX).

1)Confirm that the ignition switch is turned

OFF.

2)Remove the fuse No. 6 (in joint box) and per form visual inspection.

Check

the voltage more than 10 V?

Yes

Replace the airbag control module.

<Ref. to AB-15,

Airbag Control

Module.>

No

i o to step 2. the resistance less than 10

I

Go to step

3.

No.

If the fuse

No. 6 is blown again, repair the bodv harness.

3eplace the body iarness with air-

)ag main harness

1

the resistance more than 1 Go to step 4. 3eplace the body iarness with air- lag main harness

3epair the body iarness.

m

AB-49

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

J: TROUBLE CODE 31

DIAGNOSIS:

Front sub-sensor harness (RH) circuit is shorted.

Front sub-sensor harness (RH) circuit is open.

Front sub-sensor (RH) is faulty.

Airbag control module is faulty.

CAUTION:

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

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

When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's airbag module connectors for safety reasons.

WIRING DIAGRAM:

7

E m

FRONT SUB SENSOR RH

AB-50

RE0029

DIAGNOSTIC CHART WITH TROUBLE CODE

AI RBAG

SYSTEM (D I

AG

NOSTICS1

Step

CHECK FRONT SUB-SENSOR (RH) AND

FRONT SUB-SENSOR HARNESS (RH).

Check

Is the resistance between

7 5 0 0

and 1 KQ?

Yes

30

to step 2.

No

I

Go to step

3. iim

Connector & terminal

(31) NO. 2

-

CHECK FRONT SUB-SENSOR (RH) AND

FRONT SUB-SENSOR HARNESS (RH).

Measure the resistance between connector

(31) in the test harness

I or 12 and the chassis ground.

Connector & terminal

(31) No.

(31)

No.

-

-

Is the resistance more than 1

MQ?

CHECK AIRBAG MAIN HARNESS

AND

FRONT SUB-SENSOR HARNESS (RH).

1)Disconnect the connector (AB1 6) from the front sub-sensor. <Ref. to AB-18, Front Sub

Sensor.>

2)Connect the connector (IH) in test harness H to the connector (AB16).

3)Measure the resistance between connector

(31) in test harness I or 12 and connector (3H) in the test harness H.

Connector & terminal

(31)

NO.

2

(31) NO. 4

-

-

NO.

5:

NO. 6:

Is the resistance less than

1 on?

Is the resistance more than 1

MQ?

CHECK AIRBAG MAIN HARNESS AND

FRONT SUB-SENSOR HARNESS (RH).

Measure the resistance between connector

(31) in the test harness I or 12 and the chassis ground.

Connector

&

terminal

(3l)

No.

(31)

No.

-

-

CHECK AIRBAG MAIN HARNESS

1)Disconnect the connector (AB1 5) from

(AB1 4), and connect the connector (1 F) in test harness F to the connector (AB14).

2)Measure the resistance between connector

(31) in the test harness I or 12 and connector

(3F) in the test harness F.

Connector & terminal

(31) NO. 2

(31) NO. 4

-

-

NO.

4:

NO.

3:

Is the resistance less than 10

R?

CHECK AIRBAG MAIN HARNESS

Measure the resistance between connector

(31) in the test harness I or 12 and the chassis ground.

Connector & terminal

(31) No.

-

(31)

No.

4

Chassis ground:

-

Is the resistance more than 1

MR?

3eplace the airbag

:ontrol module.

Go to step

3.

:Ref. to AB-15,

4irbag Control vlodule.>

20

to step 4.

20

to step 10.

20

to step 6.

20

to step

7.

Go to step

5.

Go to step

5.

Replace the body harness with air- bag main harness

Replace the body harness with air- bag main harness

AB-51

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

I

I

0

1

Step

CHECK FRONT SUB-SENSOR HARNESS

(RH).

1)Connect the connector (2F) in the test har- ness F to the connector (AB1

5).

2)Measure the resistance between connector

(3H) in the test harness H and connector (3F) in the test harness F.

Connector & terminal

(3F) NO.

5

-

(3F)

NO.

6

CHECK FRONT SUB-SENSOR HARNESS

(RH).

Measure the resistance between connector

(3H) in the test harness H and connector (3F) in the test harness F.

Connector & terminal

(3F) NO. 6

-

NO. 6:

(3F) NO. 5

-

CHECK FRONT SUB-SENSOR HARNESS

(RH).

Measure the resistance between connector

(3F) in the test harness F and the chassis ground.

Connector & terminal

(3F) No. 5

(3F)

No.

6

-

-

CHECK FRONT SUB-SENSOR (RH).

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

H to the front sub-sensor (RH).

2)Measure the resistance of the connector

(3H) in the test harness H.

Connector & terminal

(3H)

NO.

3

-

4:

CHECK FRONT SUB-SENSOR (RH).

Measure the resistance between connector

(3H) in the test harness H and the chassis ground.

Connector & terminal

(3H) No. 3

-

(3H) No. 4

Chassis ground:

-

Check

Is the resistance less than 10

R?

Is the resistance more than 1 M

R?

Is the resistance more than 1

MR?

Is the resistance between

750R

and 1

KR?

Is the resistance more than 1

MR?

Yes

30

to step 8.

20

to step 9.

20

to step 10. i o to step 11.

'inish the diagno-

;is.

No

Replace the body harness with front sub-sensor har- ness (RH).

Replace the body harness with front sub-sensor har- ness.

Replace the body harness with front sub-sensor har- ness (RH).

Replace the front sub-sensor (RH).

<Ref. to AB-1 8,

Front Sub Sen- sor.>

Replace the front sub-sensor

(RH).

<Ref. to AB-1 8,

Front Sub Sen- so r.

>

AB-52

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG

SYSTEM (DIAGNOSTICS)

AB-53

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

K: TROUBLE CODE

32

DIAGNOSIS:

Front sub-sensor harness (LH) circuit is shorted.

Front sub-sensor harness (LH) circuit is open.

Front sub-sensor (LH) is faulty.

Airbag control module is faulty.

CAUTION:

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

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

When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's airbag module connectors for safety reasons.

WIRING DIAGRAM: r

AB6 AIRBAG CONTROL MODULE

t rA

I

I

FRONT SUB SENSOR LH

AB-54

RE0056

1

2

4

5

6

--

3 a

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

Step Check

CHECK FRONT SUB-SENSOR (LH) AND

FRONT SUB-SENSOR HARNESS (RH).

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the connector (AB6) from the air- bag control module, and connect connector

(1 I) in the test harness I or 12 to the connector

(AB6). <Ref. to AB-1 5, Airbag Control Mod- ule.>

3)Measure the resistance of the connector (31) in the test harness I or

12.

Connector & terminal

(31)

NO.

1

-NO.

3:

5

the resistance between

‘50Q and 1 KR? s the resistance more than 1

AQ?

CHECK FRONT SUB-SENSOR (LH) AND

FRONT SUB-SENSOR HARNESS (RH).

Measure the resistance between connector

(31) in the test harness

I

or 12 and the chassis ground.

Connector & terminal

(34 No. 1

-

(31)

No.

3

s the resistance less than 10

2?

CHECK AIRBAG MAIN HARNESS AND

FRONT SUB-SENSOR HARNESS (LH).

1)Disconnect the connector (AB1 3) from the front sub-sensor. <Ref. to AB-18, Front Sub

Sensor.>

2)Connect the connector (1

H)

ness H to the connector (AB1 3).

3)Measure the resistance between connector

(31) in the test harness I or 12 and connector

H.

Connector & terminal

(31) NO. 3

(31)

NO. 1

-

-

NO. 6:

NO. 5:

CHECK AIRBAG MAIN HARNESS AND

FRONT SUB-SENSOR HARNESS (LH).

Measure the resistance between connector

(31) in the test harness I or 12 and the chassis ground.

Connector & terminal

(31) No. 3

-

(31) No. 1

-

CHECK AIRBAG MAIN HARNESS.

1)Disconnect the connector (AB1 1) from

(AB12), and connect the connector

(IF) in the test harness F to (AB1 1).

2)Measure the resistance between connector

(31) in the test harness I or 12 and connector

(3F) in the test harness F.

Connector & terminal

(31) NO. 3

-

NO. 3:

(31) NO. 1

-

NO.

4:

CHECK AIRBAG MAIN HARNESS.

Measure the resistance between connector

(31) in the test harness I or 12 and the chassis ground.

Connector & terminal

(31)

No.

3

-

(31) No. 1

Chassis ground:

- s the resistance more than 1

AR? s the resistance less than 10

2?

s the resistance more than 1

AR?

Yes

30

to step 2.

No

Go to step

3.

3eplace the airbag Go to step

3.

:ontrol module.

:Ref. to AB-15,

4irbag Control vlodu1e.i

30

to step

4.

30

I

Go to step

5.

3

to step 10. Go to step 5.

Replace the body harness with air- harness with air- bag main harness

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

1

1

,

0

1

Step

CHECK FRONT SUB-SENSOR HARNESS

(LH).

1)Connect the connector (2F) in the test har- ness F to the connector (AB1 2).

2)Measure the resistance between connector

(3H) in the test harness H and connector (3F) in the test harness F.

Connector & terminal

(3F)

NO.

5

-

NO.

(3F) NO.

-

NO.

CHECK FRONT SUB-SENSOR HARNESS

W ) .

Measure the resistance between connector

(3H) in the test harness H and connector (3F) in the test harness F.

Connector & terminal

(3F) NO. 6

(3F)

NO.

-

-

NO.

NO.

CHECK FRONT SUB-SENSOR HARNESS

( L W

Measure the resistance between connector

(3F) in the test harness F and the chassis ground.

Connector & terminal

(3F)

No.

5

-

(3F)

No.

6

CHECK FRONT SUB-SENSOR (LH).

1)Coonect connector (2H) in the test harness

H to the front sub-sensor (LH).

2)Measure the resistance of the connector

(3H) in the test harness H.

Connector & terminal

(3H)

NO.

-NO.

4:

CHECK FRONT SUB-SENSOR (LH).

Measure the resistance between connector

(3H) in the test harness H and the chassis ground.

Connector & terminal

(3H)

No.

-

(3H) No.

Check

the resistance less than 10

? the resistance more than 1 M

?

30

to step 9. the resistance more than 1 n? the resistance between

OR

and 1 KR?

Yes

30

to step 10.

30

to step 11.

No

Replace the body harness with front sub-sensor har- ness (LH).

Replace the body harness with front sub-sensor har- ness (LH).

Replace the body harness with front sub-sensor har- ness

(LH).

Replace the front sub-sensor (LH).

<Ref. to AB-1 8,

Front Sub Sen- sor.> the resistance more than 1 n?

-inish the diagno-

;is.

Replace the front sub-sensor (LH).

<Ref. to AB-1 8,

Front Sub Sen- sor.>

AB-56

--

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

AB-57

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

L: TROUBLE CODE 41

DIAGNOSIS:

Side airbag harness (RH) is faulty.

Side airbag module (RH) is faulty.

Airbag control module is faulty.

CAUTION:

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

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

When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's airbag module connectors for safety reasons.

When inspecting the side airbag harness, disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons.

WIRING DIAGRAM:

SIDE AIRBAG

SENSOR RH

Ih

(SIDE RH)

AB-58

B5M1105

1

2

3

4

5

r

6

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

Step

CHECK SIDE AIRBAG MODULE.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the connector (AB26) from the seat belt pretensioner (RH). <Ref. to SB-8,

Front Seat Belt.>

3)Disconnect the connector (AB25) from

(AB24), and connect the connector (1 F) in the test harness F to (AB24).

4)Connect the airbag resistor to the connector

(3F) in the test harness F.

5)Connect the battery ground terminal, and turn the ignition switch

ON.

CHECK SIDE AIRBAG HARNESS (RH).

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the airbag resistor from the test harness F.

3)Disconnect the connector (AB1 8) from the air bag control module. <Ref. to AB-1 5, Airbag

Control Module.>

4)Connect the connector (1 I) in the test har- ness I or 12 to the connector (AB18).

5)Measure the resistance between connector

(31) in the test harness I or 12 and connector

(3F) in the test harness F.

Connector & terminal

(31)

NO.

7

-

NO.

(31) NO. 9

-

CHECK SIDE AIRBAG HARNESS (RH).

Measure the resistance of the connector (31) in the test harness

I or 12.

Connector & terminal

(31)

NO.

7

-

CHECK SIDE AIRBAG HARNESS (RH).

Measure the resistance of the connector (3F) in the test harness F.

Connector & terminal

(3F)

NO.

3 -NO. 4:

CHECK SIDE AIRBAG HARNESS (RH).

Measure the resistance between connector

(3F) in the test harness F and the chassis ground.

Connector

&

terminal

(3F) No.

(3F)

No.

-

-

CHECK SIDE AIRBAG HARNESS (RH).

Measure the resistance between connector

(31) in the test harness I or 12 and the chassis ground.

Connector & terminal

(31)

No.

7

-

(31) No.

Chassis ground:

-

Check

)oes the airbag warning light lperate properly? s the resistance less than 10

2?

s the resistance more than 1

dQ?

s the resistance more 1 MR? s the resistance more than 1

\nQ? s the resistance more than 1

VIR?

Yes

3eplace the front

;eat with side air- lag module (RH).

:Ref. to SE-6,

?ant Seat.>

30

to step

3.

30 4.

30 5.

Go to step

6.

No

i o to step 2. leplace the body iarness with side iirbag harness.

3eplace the body iarness with side airbag harness.

3eplace the body iarness with side airbag harness.

3eplace the body iarness with side iirbag harness.

Replace the airbag control module.

<Ref. to AB-15,

Airbag Control

Module.>

3eplace the body iarness with side

3irbag harness.

AB-59

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

M: TROUBLE CODE 42

DIAGNOSIS:

Side airbag harness (LH) is faulty.

Side airbag module (LH) is faulty.

Airbag control module is faulty.

CAUTION:

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

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

When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's airbag module connectors for safety reasons.

When inspecting the side airbag harness, disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons.

WIRING DIAGRAM:

I -

l l

AIRBAG

CONTROL MODULE

[G]

II

INF

[

(SI1

1)

R

SIDE AIRBAG

SENSOR LH

AB-60

B5M1106

I

I

I

1 i

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

Step

CHECK SIDE AIRBAG MODULE.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the connector (AB21) from the seat belt pretensioner (LH). <Ref. to SB-8,

Front Seat Belt.>

3)Disconnect the connector (AB20) from

(AB19), and connect the connector (1 F) in the test harness F to (AB1 9).

4)Connect the airbag resistor to the connector

(3F) in the test harness F.

5)Connect the battery ground terminal, and turn the ignition switch ON.

Check

Ioes the airbag warning light iperate properly?

CHECK SIDE AIRBAG HARNESS (LH).

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the airbag resistor from the test harness F.

3)Disconnect the connector (AB1 7) from the airbag control module. <Ref. to AB-1 5, Airbag

Control Module.>

4)Connect the connector (1 I) in the test har- ness I or 12 to the connector (AB17).

5)Measure the resistance between connector

(31) in the test harness I or 12 and connector

(3F) in the test harness F.

Connector & terminal

(31)

NO.

10

-

NO.

3:

(31) NO. 12

- s the resistance less than 10

R?

CHECK SIDE AIRBAG HARNESS (LH).

Measure the resistance of the connector (31) in the test harness I or 12.

Connector & terminal

(31) NO. 10

-

12:

IS the resistance more than 1

MR?

CHECK SIDE AIRBAG HARNESS (LH).

Measure the resistance of the connector (3F) in the test harness F.

Connector & terminal

(3F) NO. 3

-

Is the resistance more than 1

MR?

Is the resistance more than 1

MR?

CHECK SIDE AIRBAG HARNESS (LH).

Measure the resistance between connector

(3F) in the test harness F and the chassis ground.

Connector & terminal

(3F) No. 3

-

(3F) No. 4

-

CHECK SIDE AIRBAG HARNESS (LH).

Measure the resistance between connector

(31) in the test harness I or 12 and the chassis ground.

Connector & terminal

(31)

No. 10

-

(31) No. 12

-

Is the resistance more than 1

MR?

Yes

3eplace the front

;eat with side air- lag module (LH).

:Ref. to SE-6,

3ont Seat.>

No

Go to step

2.

20

to step

3.

30

to step 4.

20

to step 5.

30

to step

6.

Replace the body harness with side airbag harness.

Replace the body harness with side airbag harness.

Replace the body harness with side airbag harness.

Replace the body harness with side airbag harness.

3eplace the airbag Replace the body

:ontrol module.

:Ref. to AB-1 5,

4irbag Control

Module.> harness with side airbag harness.

m

AB-61

I

~

DIAGNOSTIC CHART WITH TROUBLE CODE

At RBAG SYSTEM f D IAG NOSTlCSl

N: TROUBLE CODE 45

DIAGNOSIS:

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

Airbag control module is faulty.

CAUTION:

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

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

When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's airbag module connectors for safety reasons.

When inspecting the side airbag harness, disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons.

WIRING DIAGRAM:

e

7

1

SIDE

L

AIR1

SENSOR

IN FLATOR

J

(SIDE

RH)

@

[email protected]

AB-62

I

!

r-

-

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

Step

CHECK SIDE AIRBAG MODULE.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the connector (AB26) from the seat belt pretensioner (RH). <Ref. to SB-8,

Front Seat Belt.>

3)Disconnect the connector (AB25) from

(AB24), and connect the connector (1 F) in the test harness F to (AB24 ).

4)Connect the airbag resistor to the connector

(3F) in the test harness F.

5)Connect the battery ground terminal, and turn the ignition switch ON.

CHECK SIDE AIRBAG HARNESS (RH).

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the airbag resistor from the test harness F.

3)Disconnect the connector (AB18) from the airbag control module. <Ref. to AB-1 5, Airbag

Control Module.>

4)Connect the connector (1 I) in the test har- ness I or 12 to the connector (AB18).

5)Connect the battery ground terminal, and turn the ignition switch

ON.

6)Measure the voltage between connector (31) in the test harness I or 12 and the chassis ground.

Connector & terminal

(31) No. 7

(+)

(31) No. 9

(+)

-

-

Check

>oes the airbag warning light

)perate properly?

Yes

Replace the front seat with side air- bag module (RH).

<Ref. to SE-6,

Front Seat.> control module.

<Ref. to AB-15,

Airbag Control

No

i o to step 2.

3eplace the body iarness with side iirbag harness.

AB-63

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

0: TROUBLE CODE 46

DIAGNOSIS:

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

Airbag control module is faulty.

CAUTION:

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

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

When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's airbag module connectors for safety reasons.

When inspecting the side airbag harness, disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons.

WIRING DIAGRAM:

AIRBAG CONTROL MODULE

m

R

1)

SIDE AIRBAG

SENSOR LH

AB-64

B5M1106

I

?

r.

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

Step

CHECK SIDE AIRBAG MODULE.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the connector (AB21) from the seat belt pretensioner (LH). <Ref. to SB-8,

Front Seat Belt.>

3)Disconnect the connector (AB20) from

(AB1 9), and connect the connector (1 F) in the test harness F to (AB1

9).

4)Connect the airbag resistor to the connector

(3F) in the test harness F.

5)Connect the battery ground terminal and turn the ignition switch

ON.

CHECK SIDE AIRBAG HARNESS (LH).

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the airbag resistor from the test harness F.

3)Disconnect the connector (AB1 7) from the airbag control module. <Ref. to AB-15, Airbag

Control Module.>

4)Connect the connector (1 I) in the test har- ness I or 12 to the connector (AB1 7).

5)Connect the battery ground terminal, and turn the ignition switch ON.

6)Measure the voltage between connector (31) in the test harness I or 12 and the chassis ground.

Connector & terminal

(31) No. 10 (+)

-

(-):

(31) No. 12 (+)

-

(-):

Check

)perate properly? seat with side air- bag module (LH).

<Ref. to SE-6,

Front Seat.>

No

30

to step 2.

Airbag Control

Module.>

3eplace the body iarness with side iirbag harness. l

AB-65

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

P: TROUBLE CODE 51

DIAGNOSIS:

Side airbag sensor (RH) is faulty.

Side airbag harness (RH) is faulty.

Airbag control module is faulty.

CAUTION:

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

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

When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's airbag module connectors for safety reasons.

When inspecting the side airbag harness, disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons.

WIRING DIAGRAM: t r

@ @

I

SIDE AIRBAG

SENSOR RH

Ih

(SIDE RH)

AB-66

B5MllOL

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

Step Check

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the connector (AB26) from the seat belt pretensioner (RH). <Ref. to SB-8,

Front Seat Belt.>

3)Disconnect the connector (AB25) from

(AB24).

4)Disconnect the connector (AB18) from the airbag control module. <Ref. to AB-1 5, Airbag

Control Module.>

5)Connect the connector (1 I) in the test har- ness I or 12 to the connector (AB18).

6)Disconnect the connector (AB28) from the side airbag sensor (RH), and connect the con- nector (1 G) in the test harness G to the con- nector (AB28).

7)Measure the resistance between connector

(31) in the test harness I or 12 and connector

(3G) in the test harness G.

Connector & terminal

(31) NO. 17

-

NO.

2:

(31) NO. 18

-

(31) NO. 19

-

NO.

5:

(31)

NO.

20

-

NO.

4:

R?

CHECK SIDE AIRBAG HARNESS (RH).

Measure the resistance between connector

(31) in the test harness I or 12 and the chassis ground.

Connector & terminal

(31) No. 17

-

(31) No. 18

(31) No. 19

-

-

(31)

No.

20

Is the resistance more than 1

MR?

Yes

30

to step 2.

No

Replace the body harness with side airbag harness.

3eplace the side iirbag sensor

RH). <Ref. to AB.

16, Side Airbag

Sensor.> When he sensor eplacement is not

I K , replace the iirbag control nodule. <Ref. to

4B-15, Airbag

2ontrol Module.>

Replace the body harness with side airbag harness.

AB-67

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

Q:

TROUBLE CODE

52

DIAGNOSIS:

Side airbag sensor (LH) is faulty.

Side airbag harness (LH) is faulty.

Airbag control module is faulty.

CAUTION:

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

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

When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's airbag module connectors for safety reasons.

When inspecting the side airbag harness, disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons.

WIRING DIAGRAM:

INF 'R

(SIDE LH)

-

SIDE AIRBAG

SENSOR LH

AB-68

B5M1

IO€

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG

SYSTEM (DIAGNOSTICS)

!

Step

CHECK SIDE AIRBAG HARNESS (LH).

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the connector (AB21) from the seat belt pretensioner (LH). <Ref. to SB-8,

Front Seat Belt.>

3)Disconnect the connector (AB20) from

Check

5

the resistance less than 10

2?

Yes

30

to step 2.

No

Replace the body harness with side airbag harness.

4)Disconnect the connector (AB1 7) from the airbag control module. <Ref. to AB-1 5, Airbag

Control Module.>

5)Connect the connector (1 I) in the test har- ness

I

or 12 to the connector (AB17).

6)Disconnect the connector (AB23) from the side airbag sensor (LH), and connect the con- nector (1 G) in the test harness G to the con- nector (AB23).

7)Measure the resistance between connector

(31) in the test harness I or 12 and connector

(3G) in the test harness G.

Connector & terminal

(31)

NO.

-

(31)

NO.

(3G)

NO.

-

NO.

5:

(31)

NO.

.~

NO.

16

-

,

CHECK SIDE AIRBAG HARNESS (RH).

Measure the resistance between connector

(31) in the test harness I or 12 and the chassis ground.

Connector & terminal

(31) No. 5

-

(31) No. 14

Chassis ground:

-

(31)

No.

15

Chassis ground:

-

(31) No. 16

Chassis ground:

- s the resistance more than 1

AR?

3eplace the side iirbag sensor

LH). <Ref. to AB-

16, Side Airbag

Sensor.> When he sensor

Replace the body harness with side airbag harness.

.eplacement is not

3K, replace the airbag control nodule. <Ref. to

4B-15, Airbag

Zontrol Module.>

R: TROUBLE CODE 53

DIAGNOSIS:

Side airbag sensor (RH) is faulty.

When Code 53 is displayed, the circuit within the side airbag sensor (RH) is faulty. Replace the side airbag sensor (RH).

<Ref. to AB-16, Side Airbag Sensor.>

S: TROUBLE CODE 54

DIAGNOSIS:

Side airbag sensor (LH) is faulty.

When Code 54 is displayed, the circuit within the side airbag sensor (LH) is faulty. Replace the side airbag sensor (LH).

<Ref. to AB-16, Side Airbag Sensor.>

AB-69

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

T: TROUBLE CODE 55

This code is displayed when the side airbag is deployed.

When this code is displayed, the memory cannot be erased. Replace the following parts.

Airbag control module. <Ref. to AB-15, Airbag Control Module.>

Front seat assembly with side airbag module. (Operating side) <Ref. to SE-6, Front Seat.>

Side airbag sensor. (Operating side) <Ref. to AB-1 6, Side Airbag Sensor.>

AB-70

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

AB-71

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG

SYSTEM (DIAGNOSTICS)

U: TROUBLE CODE

61

DIAGNOSIS:

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

Airbag control module is faulty.

Pretensioner is faulty.

Pretensioner harness is faulty.

CAUTION:

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

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

When inspecting the side airbag harness, disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons.

WIRING DIAGRAM:

AB18 AIRBAG CONTROL MODULE

0 r

c

-

PRETENSIONER RH

AB-72

B5M11 OE

DIAGNOSTIC CHART WITH TROUBLE CODE

AI RBAG SYSTEM (DIAGNOSTICS)

Step

CHECK SEAT BELT PRETENSIONER.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the connector (AB26) from the seat belt pretensioner (RH). <Ref. to SB-8,

Front Seat Belt.>

3)Connect the connector (1 L) in the test har- ness L to (AB26).

4)Connect the airbag resistor to the connector

(3L) in the test harness L.

5)Connect the battery ground terminal and turn the ignition switch ON.

CHECK SIDE AIRBAG HARNESS (RH).

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the airbag resistor from the test harness L.

3)Disconnect the connector (AB25) from

(AB24).

4)Disconnect the connectors (AB17) and

(AB1 8) from the airbag control module. <Ref. to AB-1 5, Airbag Control Module.>

5)Connect the connector (1 I) in the test har- ness

I or 12 to the connector (AB18).

6)Measure the resistance between connector

(31) in the test harness I or 12 and connector

(3L) in the test harness L.

Connector & terminal

(31) NO. 8

-

6:

-

CHECK SIDE AIRBAG HARNESS (RH).

Measure the resistance of the connector (31) in the test harness I or 12.

Connector & terminal

(31)

NO.

6

-

8:

CHECK SIDE AIRBAG HARNESS (RH).

Measure the resistance between connector

(31) in the test harness I or 12 and the chassis ground.

Connector & terminal

(31) No. 6

(31)

No. 8

-

-

Check

Ies the airbag warning light erate properly?

~~~

Yes

No

Ieplace the seat

)elt pretensioner

RH). <Ref. to SB-

20

to step 2.

3elt.r

> the resistance less than 10

20

to step

3.

the resistance more than 1

n?

30

to step 4.

3eplace the body iarness with side

3irbag harness.

3eplace the body iarness with side

3irbag harness. the resistance more than 1

n?

3eplace the airbag

:ontrol module.

:Ref. to AB-15,

Vrbag Control vlodule.>

3eplace the body iarness with side

3irbag harness.

31

AB-73

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

V: TROUBLE CODE 62

DIAGNOSIS:

Seat belt pretensioner

(LH)

circuit is open, shorted or shorted to ground.

Airbag control module is faulty.

Pretensioner is faulty.

Pretensioner harness is faulty.

CAUTION:

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

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

When inspecting the side airbag harness, disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons.

WIRING DIAGRAM:

AIRBAG CONTROL MODULE

1

PRETENSIONER LH

AB-74

B5M1108

-_

I

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

Step

CHECK SEAT BELT PRETENSIONER.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the connector (AB21) from the seat belt pretensioner (LH). <Ref. to SB-8,

Front Seat Belt.>

3)Connect the connector (1 L) in the test har- ness L to (AB21).

4)Connect the airbag resistor to the connector

(3L) in the test harness L.

5)Connect the battery ground terminal and turn the ignition switch

ON.

CHECK SIDE AIRBAG HARNESS (LH).

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the airbag resistor from the test harness L.

3)Disconnect the connector (AB20) from

(AB19).

4)Disconnect the connectors (AB1 7) and

(AB18) from the airbag control module. <Ref. to AB-15, Airbag Control Module.>

5)Connect the connector (1 I) in the test har- ness I or 12 to the connector (AB17).

6)Measure the resistance between connector

(31) in the test harness I or 12 and the connec- tor (3L) in the test harness L.

Connector & terminal

NO. 1 1

NO. 13

-

-

6:

5:

CHECK SIDE AIRBAG HARNESS (LH).

Measure the resistance of the connector (31) in the test harness I or 12.

Connector & terminal

1 1

-

CHECK SIDE AIRBAG HARNESS (LH).

Measure the resistance between the connector

(31) in the test harness I or 12 and the chassis ground.

Connector & terminal

No.

1 1

-

13

-

Check

loes the airbag warning light iperate properly? s the resistance less than 10 n?

Is the resistance more than 1

MQ?

Is the resistance more than 1

MQ?

Yes

Ieplace the seat

)elt pretensioner

LH). <Ref. to SB-

b,

Front Seat

3elt.>

No

30

to step

2.

;o

to step

3.

30

to step 4.

3eplace the body iarness with side

3irbag harness.

3eplace the body iarness with side airbag harness.

3eplace the airbag

:ontrol module.

:Ref. to AB-1

5,

4irbag Control vlodu1e.r

3eplace the body iarness with side airbag harness.

AB-75

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG

SYSTEM (DIAGNOSTICS)

W: TROUBLE CODE 65

DIAGNOSIS:

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

Pretensioner is faulty.

Pretensioner harness is faulty.

Airbag control module is faulty.

CAUTION:

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

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

When inspecting the side airbag harness, disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons.

WIRING DIAGRAM:

7

E

r

-

PRETENSIONER RH

AB-76

B5M110!

I

!

-

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

Step

CHECK SEAT BELT PRETENSIONER.

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the connector (AB26) from the seat belt pretensioner (RH). <Ref. to SB-8,

Front Seat Belt.>

3)Connect the connector (1 L) in the test har- ness L to (AB26).

4)Connect the airbag resistor to the connector

(3L) in the test harness L.

5)Connect the battery ground terminal, and turn the ignition switch ON.

CHECK SIDE AIRBAG HARNESS (RH).

1)Turn the ignition switch OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the airbag resistor from the test harness L.

3)Disconnect the connector (AB25) from

(AB24).

4)Disconnect the connectors (AB1 7) and

(AB1 8) from the airbag control module. <Ref. to AB-15, Airbag Control Module.>

5)Connect the connector (1 I) in the test har- ness I or 12 to the connector (AB18).

6)Connect the battery ground cable and turn the ignition switch

ON.

7)Measure the voltage between connector (31) in the test harness I or 12 and the chassis ground.

Connector

81 terminal

(31) No.

6 (+)

(31)

No.

8

(+)

-

-

(-):

Check

iperate properly? belt pretensioner

(RH). <Ref. to SB-

8, Front Seat

Belt.> control module.

<Ref. to AB-1 5,

Airbag Control

Module.>

3eplace the body iarness with side iirbag harness.

m

AB-77

I

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM (DIAGNOSTICS)

X: TROUBLE CODE 66

DIAGNOSIS:

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

Pretensioner is faulty.

Pretensioner harness is faulty.

Airbag control module is faulty.

CAUTION:

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

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

When inspecting the side airbag harness, disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons.

WIRING DIAGRAM:

-

PRETENSIONER LH

AB-78

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG SYSTEM IDIAGNOSTICS)

Step Check

CHECK SEAT BELT PRETENSIONER.

Does the airbag warning light

1)Turn the ignition switch OFF, disconnect the operate properly? battery ground terminal, and wait more than 20 seconds.

2)Disconnect the connector (AB21) from the seat belt pretensioner (LH). <Ref. to SB-8,

Front Seat Belt.>

3)Connect the connector (1 L) in the test har- ness L to (AB21).

4)Connect the airbag resistor to the connector

(3L) in the test harness L.

5)Connect the battery ground terminal and turn the ignition switch ON.

s

the voltage less than 1

V? CHECK SIDE AIRBAG HARNESS (LH).

1)Turn the ignition switch

OFF, disconnect the battery ground terminal, and wait more than 20 seconds.

2)Disconnect the airbag resistor from the test harness L.

3)Disconnect the connector (AB20) from

(AB19).

4)Disconnect the connectors (AB1 7) and

(AB1 8) from the airbag control module. <Ref. to AB-15, Airbag Control Module.>

5)Connect the connector (1

I) in the test har- ness I or

12

to the connector (AB17).

6)Connect the battery ground terminal and turn the ignition switch ON.

7)Measure the voltage between connector (31) in the test harness

I

or 12 and the chassis ground.

Connector & terminal

(30

No.

11

(+)

(31) No. 13

(+)

-

-

(-):

(-):

Yes

No

Replace the seat belt pre-tensioner

(LH). <Ref. to SB-

8, Front Seat

Belt.>

Go to step

2.

Replace the airbag Replace the body control module. harness with side

<Ref. to AB-15, airbag harness.

Airbag Control

Module.>

AB979

DIAGNOSTIC CHART WITH TROUBLE CODE

AIRBAG

SYSTEM (DIAGNOSTICS)

--

AB-80

~~

SEAT BELT

SYSTEM

SB

~ ~~ ~ ~ ~ ~~

Page

1

.

General Description

...................................................................................

.2

2.

Pretensioner Connector

.............................................................................

.6

3. Inspection Locations After a Collision

.........................................................

7

4.

Front Seat Belt

............................................................................................

8

5.

Rear Seat Belt

...........................................................................................

10

SEAT BELT SYSTEM

1. General Description

A: COMPONENT

1.

FRONT SEAT BELT

GENERAL DESCRIPTION

(1) Adjuster anchor ASSY

(2) Anchor cover

(3) Outer belt ASSY

(4) Inner belt ASSY

SB-2

000239

Tightening torque: N.m (kgf-m, ff-lb)

T l : 7.5 (0.76, 5.5)

T2: 30 (3.1,22)

T3: 53 (5.4,39)

I

2.

REAR SEAT BELT (SEDAN)

GENERAL DESCRIPTION

SEAT BELT SYSTEM

I

I

(1) Outer seat belt RH

(2) Outer seat belt CENTER

(3) Outer seat belt LH

(4)

Inner seat belt RH

(5) Inner seat belt CENTER

(6) Inner seat belt LH

(7) Case center ELR

( 8 ) Anchor cover

(9) Adjustable anchor ASSY

Tightening torque: N.m (kgf-m, ff-lb)

T: 30 (3.1,22)

SB-3

I

GENERAL DESCRIPTION

SEAT BELT SYSTEM

3. REAR SEAT BELT (WAGON)

(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)

Adjustable anchor ASSY

Tightening torque:

N.m (kgf-m, ff-lb)

T: 30 (3.1,22)

SB-4

GENERAL DESCRIPTION

6:

CAUTION

Before starting, turn the ignition switch OFF, dis- connect 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 preten- sioner.

If oil, grease, or water gets on the pretensioner, wipe it off immediately with a dry cloth.

Do not expose the pretensioner to high tempera- ture 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 pre- tensioner. If it is dented, cracked, or deformed, re- place it with a new one.

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

parts.

When handling a seat belt with a deployed pre- tensioner, wear gloves and goggles. Wash your hands afterwards.

Do not re-use a seat belt with a deployed preten- sioner again.

If the material gets in your eyes or on your skin during deployment, wash it away with clean water, and then consult a doctor.

SEAT BELT SYSTEM

SB-5

PRETENSIONER CONNECTOR

SEAT BELT SYSTEM

2.

Pretensioner Connector

A:

OPERATION

1) How to disconnect:

(1) Move the slide lock

(A)

in the direction of the arrow.

(2) Pull the connector (B) in the direction of the arrow with slide lock

(A)

moved.

CA

JTION:

When pulling, be sure to hold onto the connec- tor and riot the wire.

2)

How to connect:

Holding connector

(A),

and push it in carefully until a 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.

SB-6

INSPECTION LOCATIONS AFTER A COLLISION

SEAT BELT SYSTEM

3. 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.

Wire harness and/or connector is damaged.

SB-7

SEAT BELT SYSTEM

4.

Front Seat Belt

A: REMOVAL

1.

OUTER BELT (FRONT)

1)

Fold backrest all the way forward, and then move the front seat all the way forward.

2)

Turn the ignition switch 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 El-

46,

REMOVAL, Lower Inner Trim.>

4)

Remove the anchor cover. Loosen the shoulder anchor bolt, and then detach the shoulder anchor from center pillar.

L

B5M1070

5 )

Turn over the floor mat to remove the bolts.

FRONT SEAT BELT

2.

INNER BELT (FRONT)

1)

Disconnect the connector.

2)

Remove the anchor bolt, and then detach the in- ner belt.

S5M0234

6) Disconnect the yellow connector of pretensioner harness, and remove the outer belt (front).

CAUTION:

Do

not drop or apply any impact to the pre- tensioner.

Pretensioner and bracket should be treated as an assembly. Do not attempt to disassemble it.

SB-8

I

I

B: INSTALLATION

FRONT SEAT BELT

1. OUTER BELT (FRONT)

Install in the reverse order of removal.

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 instal- lation.

2.

INNER BELT (FRONT)

Install in the reverse order of removal.

SEAT BELT SYSTEM

C: INSPECTION

1.

OUTER BELT (FRONT)

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.

2.

INNER BELT (FRONT)

Check for the following, and replace with new parts if necessary.

Inner belt is deformed or damaged.

Seat belt buckle is engaged improperly.

SB-9

REAR SEAT BELT

SEAT BELT SYSTEM

5.

Rear Seat Belt

A: REMOVAL

1. OUTER BELT SIDE (SEDAN)

1) Remove the rear seat. <Ref. to SE-I 1, REMOV-

AL, Rear Seat.>

2)

Remove the side sill rear lower cover. <Ref. to

El-46, REMOVAL, Lower Inner Trim.>

3) Remove the seat belt lower anchor bolt.

7) Remove the two bolts and adjustable anchor AS-

SY.

2.

OUTER BELT CENTER (SEDAN)

1) Remove the rear seat. <Ref. to SE-11, REMOV-

AL, Rear Seat.>

2) Remove the seat belt lower anchor bolt.

4) Remoce the anchor cover. Remove the bolt and shoulder anchor from pillar.

I

RE0059

I

5) Remove the quarter pillar trim. <Ref. to El-47,

REMOVAL, Rear Quarter Trim.>

6) Remove the bolts, and then detach the seat belt.

\ \

\

3) Remove the quarter pillar trim. <Ref. to El-47,

Removal, Rear Quarter Trim.>

4)

Remove the rear shelf trim. <Ref. to El-53, RE-

MOVAL, Rear Shelf Trim.>

5) Remove the bolts, and then detach the seat belt.

RE0005

SB-I 0

REAR SEAT BELT

3. INNER BELT (SEDAN)

1) Remove the rear cushion. <Ref. to SE-11

,

RE-

MOVAL, Rear Seat.>

2)

Remove the bolts, and then detach the inner belt.

SEAT BELT SYSTEM

7)

Remove the bolts, and then detach the outer belt side.

~

4.

OUTER BELT SIDE (WAGON)

1) Remove the luggage floor mat. <Ref. to El-56,

REMOVAL, Luggage Floor Mat.>

2) Remove the rear seat. <Ref. to SE-11, REMOV-

AL, Rear Seat.>

3) Remove the side sill rear lower cover. <Ref. to

El-46, REMOVAL, Lower Inner Trim.>

4)

Remove the seat belt lower anchor bolt.

, . .

.

RE0062

I

8) Remove the two bolts and adjustable anchor AS-

SY.

5) Remove the anchor cover. Remove the bolt and shoulder anchor from pillar.

6)

Remove the rear quarter trim. <Ref. to

REMOVAL, Rear Quarter Trim.>

El-47,

SB-11

REAR SEAT BELT

SEAT BELT SYSTEM

5.

OUTER BELT CENTER (WAGON)

1)

Loosen the shoulder anchor bolt, and then de- tach the shoulder anchor from quarter pillar.

6.

INNER BELT (WAGON)

1)

Remove the rear cushion.

2) Remove the bolt, and then detach the inner belt.

B5MO919 0008

2) Remove the quarter trim. <Ref. to El-47,

RE-

MOVAL,

Rear Quarter Trim.>

3) Remove the three bolts, and then detach the out- er belt center.

/

'

RE0009

SB-I 2

B: INSTALLATION

1. OUTER BELT SIDE (SEDAN)

Install in the reverse order of removal.

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.

2.

OUTER BELT CENTER (SEDAN)

Install in the reverse order of removal.

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.

3.

INNER BELT (SEDAN)

Install in the reverse order of removal.

CAUTION:

During installation, make sure that the seat belts are not twisted.

4.

OUTER BELT SIDE (WAGON)

Install in the reverse order of removal.

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.

5.

OUTER BELT CENTER (WAGON)

Install in the reverse order of removal.

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.

6.

INNER BELT (WAGON)

Install in the reverse order of removal.

CAUTION:

During installation, make sure that the seat belts are not twisted.

REAR SEAT BELT

SEAT BELT SYSTEM

C: INSPECTION

1.

OUTER BELT SIDE (SEDAN)

Check for the following, and replace with new parts if necessary.

Seat belt is slackened, bent, or frayed. Seat belt is abnormally wound or extended.

2.

OUTER BELT CENTER (SEDAN)

Check for the following, and replace with new parts if necessary.

Seat belt is slackened, bent, or frayed. Seat belt is abnormally wound or extended.

3.

INNER BELT (SEDAN)

Check for the following, and replace with new parts if necessary.

Inner belt is deformed or damaged.

Seat belt buckle is engaged improperly.

4.

OUTER BELT SIDE (WAGON)

Check for the following, and replace with new parts if necessary.

Seat belt is slackened, bent, or frayed. Seat belt is abnormally wound or extended.

5.

OUTER BELT CENTER (WAGON)

Check for the following, and replace with new parts if necessary.

Seat belt is slackened, bent, or frayed. Seat belt is abnormally wound or extended.

6.

INNER BELT (WAGON)

Check for the following, and replace with new parts if necessary.

Inner belt is deformed or damaged.

Seat belt buckle is engaged improperly.

SB-13

SEAT BELT SYSTEM

REAR SEAT BELT

SB-14

LIGHTING SYSTEM

10

.

11

.

12

.

13

.

14

.

15

.

16

.

17

.

18

.

19

.

20

.

21

.

6

7

.

.

.

8

.

9

.

1

.

2

.

3

.

4

.

22

.

23

24

.

.

25

.

26

.

27

.

General Description

Page

....................................................................................

2

Headlight and Tail Light System

.................................................................

3

Front Fog Light System

...............................................................................

4

Turn Signal and Hazard Light System

........................................................

5

Back-up Light System

.................................................................................

6

Stop Light System

.......................................................................................

Interior Light System

...................................................................................

7

8

Combination Switch (Light)

.........................................................................

9

Headlight Assembly

..................................................................................

10

Headlight Bulb

...........................................................................................

12

Front Turn Signal Light Bulb

.....................................................................

13

Clearance/Parking Light Bulb

....................................................................

14

Front Fog Light Assembly

.........................................................................

15

Front Fog Light Bulb

..................................................................................

16

Front Side Marker Light Assembly

............................................................

17

Rear Combination Light Assembly

............................................................

18

Stopnail Light Bulb

Back-up Light Bulb

...................................................................................

19

....................................................................................

20

Rear Turn Signal Light Bulb

......................................................................

21

Rear Side Marker Light Bulb

.....................................................................

22

License Plate Light

....................................................................................

23

High-mounted Stop Light

..........................................................................

24

Spot Light

..................................................................................................

25

Room Light

................................................................................................

26

Luggage Room Light

.................................................................................

27

Trunk Room Light

......................................................................................

28

Glove Box Light

.........................................................................................

29

F

LIGHTING SYSTEM

1.

General Description

A: SPECIFICATIONS

GENERAL DESCRIPTION

Headliaht

Front turn signal light

Side marker light

Parking light

Front fog light

Rear combination light

Sedan

I

Tail/Stou liaht

I

Tail liqht

I

Stop light

1

Turn signal light

Back-up light

Tail/Stop light

Turn signal light

Wagon

Back-uD liaht

I

Side marker liqht

License plate light

High-mounted stop light

Sedan

I

Waaon d

Room light

.

"

Luggage room light

Trunk room light

Glove box light

B: PRECAUTIONS

Before disassembling or reassembling parts, al- ways disconnect the battery ground cable. When replacing the radio, control module, and other parts provided with memory functions, record the memo- ry contents before disconnecting the battery ground cable. Otherwise, the memory will be erased.

Reassemble in reverse order of disassembly, un- less otherwise indicated.

Adjust parts to the given specifications.

Connect the connectors and hoses securely dur- ing reassembly.

C: PREPARATION TOOL

1. GENERAL

TOOLS

TOOL NAME

Circuit Tester

I

I

I

I

I

12 V

-

(Haloaen)

1 2 v - 2 1 w

1 2 V - 5 W

1 2 V - 5 W

12 V - (Halogen)

1 2 v - 2 1 w / 5 w

1 2 v - 2 1 w T 5 w

1 2 v - 2 1

1 2 v - 2 1

1 2 v - 2 1 w w w

1 2 v - 2 1 w / 5 w

1 2 v - 2 1

1 2 v - 2 1 w w

1 2 V - 5 W

1 2 V - 5 W

1 2 v - 2 1 w

1 2 V - 1 3 W

1 2 V - 8 W

1 2 V - 8 W

1 2 V - 1 3 W

1 2 V - 5 W

1 2 V - 1 . 4 W

REMARKS

Used

for measuring resistance and voltage.

1

After reassembly, make sure functional parts op- erate smoothly.

WARNING:

The air bag system wiring harness is routed near electrical parts and switches. All air bag system wiring harnesses and connectors are yellow. Do not use an electric test equipment on these circuits.

Be careful not to damage the air bag system wiring harness when servicing electrical parts and switches.

I

I

I

I

I

i

LI-2

2. tem

A:

SCHEMATIC

HEADLIGHT AND TAIL LIGHT SYSTEM

Headlight and Tail Light Sys-

1. HEADLIGHT

<Ref. to WI-98, SCHEMATIC, Headlight System.>

2.

CLEARANCE LIGHT AND ILLUMINA-

TION LIGHT

<Ref. to WI-94, SCHEMATIC, Clearance Light and

Illumination Light System.>

6 :

INSPECTION

1.

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

2.

TAIL AND ILLUMINATION RELAY

Measure the tail and illumination relay resistance between terminals when connectina terminal No. 4 to battery positive terminal and teyminal No.

3 to battery ground terminal.

Current

Flow

No

flow

B0030f

I

Terminal

No.

1

Standard

I

Less than 1Q

1 and

2

More than 1MQ

-

Current

Flow

No flow

Terminal No.

1 and2

800308

Standard

Less than 1R

More than 1 MR

LI-3

FRONT FOG LIGHT SYSTEM

LIGHTING SYSTEM

3. Front Fog Light System

A: SCHEMATIC

1.

FRONT FOG LIGHT

<Ref. to

WI-97,

SCHEMATIC, Front Fog Light Sys- tem.>

B: INSPECTION

1.

FRONT FOG LIGHT SWITCH

Measure the front fog light switch resistance.

I

I *

B6M1482

I

Switch position

I

Terminal No.

I

Standard

I

2.

FRONT FOG LIGHT RELAY

Measure the front fog light relay resistance be- tween terminals when connectinq terminal No.

4

to battery positive terminal and terminal No.

3 to

tery ground terminal. bat-

I

Current

Flow

No flow

B0030e

I

Terminal No.

1 and 2

I

Standard

Less than

la

More than

1

MR

I

LI-4

TURN SIGNAL AND HAZARD LIGHT SYSTEM

LIGHTING SYSTEM

4. Turn Signal and Hazard Light

System

A: SCHEMATIC

1.

TURN SIGNAL LIGHT AND HAZARD

LIGHT

<Ref. to WI-104, SCHEMATIC, Turn Signal Light and Hazard Light System.>

B:

INSPECTION

1.

TURN SIGNAL SWITCH

<Ref. to LI-9, INSPECTION, Combination Switch

(Light).>

2.

HAZARD SWITCH

Measure the hazard switch resistance.

0 7 6 5

B6M 1 483

OFF

ON

6 and

7

1 , 3 a n d 4

7 and

8

I

Less than 1!2

Less than

If2

Less than IC2

3.

TURN SIGNAL

&

HAZARD MODULE

Connect the battery and turn signal light bulb to the module,

as

shown in the figure. The module is properly functioning if it blinks when power

is

sup- plied to the circuit.

LI-5

BACK-UP LIGHT SYSTEM

LIGHTING SYSTEM

5.

Back-up Light System

A:

SCHEMATIC

1.

BACK-UP LIGHT

<Ref. to WI-93, SCHEMATIC, Back-up Light Sys- tem.>

B: INSPECTION

1.

BACK-UP LIGHT SWITCH

(M/T)

Measure the back-up light switch resistance.

2.

INHIBITOR SWITCH

(A/T)

Measure the inhibitor switch resistance. r m

I

Switch Dosition

I

Terminal No.

I

Standard

I

I

When select lever

I is set in “R” posi- tion

I

1 and2

I

I

Other positions

Less than

1 0

More than 1MSL

I

I

I

BO0344

(A) Non-turbo model

(B) Turbo model

Switch position Terminal No.

I

When shift lever is set in reverse position

I

Turbo model:

2 and

4

Non-t,urb;drydel:

Other Dositions

Standard

Less than

In

LI-6

STOP LIGHT SYSTEM

6.

Stop Light System

A: SCHEMATIC

1.

STOP LIGHT

<Ref. to WI-103, tem.>

SCHEMATIC, Stop Light

Sys-

B: INSPECTION

1. STOP

LIGHT SWITCH

Measure the stop light switch resistance.

Without cruise control

LIGHTING SYSTEM

With cruise control

B6M1486A

I

Switch position

When brake pedal is deDressed

is released

I

I

Terminal No.

I

Standard

I and 2: Without cruise control

IWhenbrabpedalI

2and3:With cruise control

1

Less than

,*

7

L 1-7

INTERIOR LIGHT SYSTEM

LIGHTING SYSTEM

7.

Interior Light System

A: SCHEMATIC

1. INTERIOR LIGHT

<Ref. to WI-101, SCHEMATIC, In Compartment

Light System.>

B: INSPECTION

1.

DOOR SWITCH

Measure the door switch resistance.

0001 57

[-

Switch position

When door is

I

Terminal No.

I

Standard

Less than l R

1 and3

More than

1

MR closed

2.

REAR GATE LATCH SWITCH

Measure the rear gate latch switch resistance.

I

Standard

I

Switch Dosition

I

Terminal No.

When rear gate is kl

When rear gate is l a n d 2

Less than 1R

More than 1 M n

I

3.

TRUNK ROOM LIGHT SWITCH

Measure the trunk room light switch resistance.

I

Switch Dosition

I

Terminal No.

I

Standard

When trunk lid is opened

1 and2

Less than In

When trunk lid is

closed

More than

1

Mi2

1

LI-8

8.

COMBINATION SWITCH (LIGHT)

Combination Switch (Light)

A: REMOVAL

1)

Remove the instrument panel lower cover. <Ref. to El-42, REMOVAL, Instrument Panel Assembly.>

2)

Remove the screws which secure upper column cover to lower column cover.

LIGHTING SYSTEM

C: INSPECTION

Measure the combination switch resistance.

-

1 r

17 16 1514131211 10 9

Lighting and turn signal switch connector

06M1184

3) Disconnect the connector from combination switch.

4)

Remove the screws which secure switch and re- move the siitch.

Parking switch connector

06M 1488A

1.

LIGHTING SWITCH

I

Switch position

I

Terminal No.

I

Standard

I

OFF

I

-

I

More than

1MR

I

Tail and

16

I

Less than

1R

B: INSTALLATION

Install in the reverse order of removal.

2.

DIMMER AND PASSING SWITCH

m w i t c h position

Passing

Low beam

High beam

I

Terminal No.

I

Standard

I and

16

Less than

IR

16

and

17

and

16

Less than

1R

Less than

1R

Switch position Terminal No.

1

and

2

Neutral

Right

2 and 3

4.

PARKING SWITCH

Switch position

OFF

ON

Terminal No.

2 and

4

1

and

4

Standard

Less than

1R

More than 1MR

Less than

1R

Standard

Less than

1R

Less than I R

LI-9

HEADLIGHT ASSEMBLY

LIGHTING SYSTEM

9. Headlight Assembly

A: REMOVAL

1) Disconnect the ground terminal from battery.

2)

Remove the duct (A) (when right side headlight is removed).

3) Remove the front grille and headlight side cover.

<Ref. to El-18, REMOVAL, Front Grille.> and <Ref. to

El-23, REMOVAL, Front Bumper.>

4)

Disconnect the headlight bulb connector.

5) Remove three bolts and disconnect the connec- tors, and then detach the headlight assembly.

B: INSTALLATION

Install in the reverse order of removal.

C: ADJUSTMENT

1.

HEADLIGHT AIMING

NOTE:

As this headlignt is the “VISUAL AIMING TYPE”, it is possible to adjust aiming only in the vertical di- rection. It cannot be adjusted in the horizontal di- rection.

CAUTION:

Turn off the light before adjusting headlight aiming. If the light is necessary to check aim- ing, 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 level ground.

The inflation pressure of tires is correct.

Vehicle’s fuel tank is fully filled.

Bounce the vehicle several times to normalize the suspension.

Make certain that someone is seated in the driv- er’s seat.

Turn the headlight on and then adjust the low beam pattern to the following positions on the screen.

NOTE:

Adjust the headlight aiming by turning the adjusting screw (A).

LI-I 0

HEADLIGHT ASSEMBLY

LIGHTING SYSTEM

Sedan

RS, WRX

620 (24.41)

H

Bulb center marking

H

t-

3 m (10 ft)

H mm (in)

TS,

WRX

620 (24.41)

Wagon

Outback

630 (24.80)

BOO400 h mm (in) at 3 m (10 ft)

21 (0.83)

LI-I 1

HEADLIGHT BULB

LIGHTING SYSTEM

1O.Headlight

Bulb

A: REMOVAL

CAUTION:

Because the tungsten 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 the performance.

1) Disconnect the ground terminal from battery.

2)

Remove the duct (A) (when right side headlight is removed).

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

1) Visually check the bulb for blow out.

2)

Check the bulb specification. <Ref. to LI-2,

SPECIFICATIONS, General Description.>

3) If NG, replace the bulb with a new one.

3)

Disconnect the harness connector.

4)

Remove the cap

(A).

5 )

Remove the headlight bulb (A).

LI-I 2

FRONT TURN SIGNAL LIGHT BULB

11

.Front Turn Signal Light Bulb

A: REMOVAL

1) Remove the headlight assembly. <Ref. to LI-10,

REMOVAL, Headlight Assembly.>

2) Turn the socket (A) and remove the bulb.

LIGHTING SYSTEM

- u

BO0031

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

1)

Visually’check the bulb for blow out.

2) Check the bulb specification.

<Ref.

SPECIFICATIONS, General Description.> to LI-2,

3) If NG, replace the bulb with a new one.

LI-I 3

CLEARANCE/PARKlNG LIGHT BULB

LIGHTING SYSTEM

12.Clearance/Parking Light Bulb

A: REMOVAL

1) Remove the headlight assembly. <Ref. to LI-10,

REMOVAL, Headlight Assembly.>

2) Turn the socket (A) and remove the bulb.

I

B: INSTALLATION

Install in the reverse order of removal.

BOO032

C: INSPECTION

1) Visually check the bulb for blow out.

2) Check the bulb specification. <Ref. to LI-2,

SPECIFICATIONS, General Description.>

3) If NG, replace the bulb with a new one.

LI-I 4

FRONT FOG LIGHT ASSEMBLY

13.Front Fog Light

Assembly

A: REMOVAL

1)

Disconnect the ground terminal from battery.

2) Remove the mounting bolts, and then detach the fog light assembly.

LIGHTING SYSTEM

3) Disconnect the harness connector.

B: INSTALLATION

Install in the reverse order of removal.

LI-15

FRONT FOG LIGHT BULB

LIGHTING SYSTEM

14.Front Fog Light Bulb

A:

REMOVAL

1)

Remove the front fog light assembly. <Ref. to LI-

15, REMOVAL, Front Fog Light Assembly.>

2) Remove the back cover.

3) Remove the spring retainer then detach the fog light bulb.

6: INSTALLATION

Install inthe reverse order of removal.

C: INSPECTION

1)

Visually check the bulb for blow out.

2) Check the bulb specification. <Ref. to LI-2,

SPECIFICATIONS, General Description.>

3) If NG, replace the bulb with a new one.

LI-I 6

FRONT SIDE MARKER LIGHT ASSEMBLY

15.Front Side Marker Light

As-

sembly

A: REMOVAL

1)

Disconnect the ground terminal from battery.

2) Pull out the light from body while pushing it up.

LIGHTING SYSTEM

3) Disconnect the harness connector and remove

the

light.

4) Turn the socket and remove the bulb.

I

B: INSTALLATION

Install in the reverse order of removal.

B003X

C: INSPECTION

1)

Visually check the bulb for blow out.

2)

Check the bulb specification. <Ref. to LI-2,

SPECIFICATIONS, General Description.>

LI-I 7

REAR COMBINATION LIGHT ASSEMBLY

LIGHTING

SYSTEM

16.Rear Combination Light As- sembly

A:

REMOVAL

1.

SEDAN

1)

Disconnect the ground terminal from battery.

2) Remove the clips and then detach the trunk rear trim.

3)

Remove two bolts.

4) Remove the rear quarter trim.

<Ref. to El-47, WAGON, REMOVAL, Rear Quarter

Trim.>

5) Disconnect the connector and then detach the rear combination light assembly.

BOO0

3) Remove the trunk side trim of rear portion.

4)

Remove four nuts and then detach the rear com- bination light while disconnecting the connector.

-

B: INSTALLATION

Install in the reverse order of removal.

2. WAGON

1) Disconnect the ground terminal from battery.

2) Remove the clips and then detach the rear com- bination light covers.

LI-I 8

STOP/TAIL LIGHT BULB

17.StoplTaiI Light Bulb

A: REMOVAL

1.

SEDAN

1)

Remove the trunk side trim of rear portion.

2) Turn the socket and remove the bulb.

I

LIGHTING SYSTEM

(C) BOO351

(A)

Stop light

(B) Tail light

(C) ‘TaiVstop lignt

2.

WAGON

1) Remove the rear combination light assembly.

<Ref. to LI-18, WAGON, REMOVAL, Rear Combi- nation Light Assembly.>

2)

Turn the socket and remove the bulb.

I

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

1)

Visually check the bulb for blow out.

2) Check the bulb specification. <Ref. to LI-2,

SPECIFICATIONS, General Description.>

3) If NG, replace the bulb with a new one.

LI-I 9

BACK-UP LIGHT BULB

LIGHTING SYSTEM

18.Back-up Light

Bulb

A: REMOVAL

1. SEDAN

1)

Remove the trunk side trim of rear portion.

2)

Turn the socket and remove the bulb.

2.

WAGON

1)

Remove the rear combination light assembly.

<Ref. to LI-18, WAGON, REMOVAL, Rear Combi- nation Light Assembly.>

2) Turn the socket and remove the bulb.

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

1)

Visually check the bulb for blow out.

2) Check the bulb specification. <Ref. to LI-2,

SPECIFICATIONS, General Description.>

3) If NG, replace the bulb with a new one.

LI-20

REAR TURN SIGNAL LIGHT BULB

19.Rear Turn Signal Light Bulb

A: REMOVAL

1.

SEDAN

1)

Remove the trunk side trim of rear portion.

2) Turn the socket and remove the bulb.

LIGHTING SYSTEM

042

2. WAGON

1) Remove the rear combination light assembly.

<Ref. to Ll-18, WAGON, REMOVAL, Rear Combi- nation Light Assembly.>

2) Turn the socket and remove the bulb.

9:

INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

1)

Visually check the bulb for blow out.

2) Check the bulb specification. <Ref. to LI-2,

SPECIFICATIONS, General Description.>

3) If NG, replace the bulb with a new one.

LI-21

REAR SIDE MARKER LIGHT BULB

LIGHTING

SYSTEM

20.Rear Side Marker Light Bulb

A: REMOVAL

1)

Remove the rear combination light assembly.

<Ref. to LI-18, WAGON, REMOVAL, Rear Combi- nation Light Assembly.>

2) Turn the socket and remove the bulb.

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

1) Visually check the bulb for blow out.

2) Check the bulb specification. <Ref. to LI-2,

SPECIFICATIONS, General Description.>

3)

If

NG, replace the bulb with a new one.

LI-22

LICENSE PLATE LIGHT

21

.License Plate Light

A: REMOVAL

1) Disconnect the ground terminal from battery.

2)

Remove the license plate light mounting screw

(A)

and then remove the lens (B)

LIGHTING SYSTEM

BOO1

22

I

3) Remove the bulb.

B: INSTALLATION

Install in the reverse order of removal.

c:

INSPECTION

1)

Visually check the bulb for blow out.

2)

Check the bulb specification. <Ref. to LI-2,

SPECIFICATIONS, General Description.>

3) If NG, replace the bulb with a new one.

LI-23

HIGH-MOUNTED STOP LIGHT

LIGHTING SYSTEM

22.High-mounted Stop Light

A: REMOVAL

1.

SEDAN

1)

Disconnect the ground terminal from battery.

2) Disconnect the connector of high-mounted stop light from body harness.

3) Remove the bolts, then detach the high-mounted stop light assembly.

2.

WAGON

1) Disconnect the ground terminal from battery.

2)

Remove the screws (A) and then detach the cov- er (B).

3) Remove the screws (C) and then detach the high-mounted stop light while disconnecting the connector.

I

I

B:

INSTALLATION

Install in the reverse order of removal.

BO0401

C: INSPECTION

1)

Visually check the bulb for blow out.

2) Check the bulb specification. <Ref. to LI-2,

SPECIFICATIONS, General Description.>

3) If NG, replace the bulb with a new one.

LI-24

SPOT LIGHT

23.Spot Light

A: REMOVAL

1)

Disconnect the ground terminal from battery.

2 )

Remove the lens (A) and spot light mounting screw (B).

LIGHTING SYSTEM i_

I

BOO046

ON 1 and 2

1.5

*

0.58

LI-25

ROOM LIGHT

LIGHTING SYSTEM

24.Room Light

A: REMOVAL

1 Disconnect the ground terminal from battery.

2) Remove the lens (A) and room light mounting screws (6).

B )

B6M1479P

3) Disconnect the harness connectors and remove the light.

B:

INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

1. ROOM

LIGHT BULB

1) Visually check the bulb for blow out.

2 )

Check the bulb specification. <Ref. to LI-2,

SPECIFICATIONS, General Description.>

3) If NG, replace the bulb with a new one.

2. ROOM

LIGHT SWITCH

Measure the room light resistance.

(fig)

B6M1489A

Switch position

OFF

Terminal No.

-

Standard

More than

1MR

ON 1 and 3 1.5

0.5R

I

DOOR

I

1 and2

I

1 . 5 f 0 . 5 R

I

LI-26

25.Luggage

LUGGAGE ROOM LIGHT

Room Light

A: REMOVAL

1

) Disconnect the ground terminal from battery.

2) Remove the lens (A)and luggage room light mounting screws (B).

LIGHTING SYSTEM

2. LUGGAGE

ROOM

LIGHT SWITCH

Measure the luggage room light resistance.

Switch position

DOOR

Terminal No.

1 and3

1 and2

Standard

More than

1MQ

1.5 k

3)

Disconnect the harness connectors and remove the luggage room light.

B: INSTALLATION

Install in the reverse order of removal.

C:

INSPECTION

1.

LUGGAGE

ROOM

LIGHT BULB

1)

Visually check the bulb for blow out.

2) Check the bulb specification. <Ref. to LI-2,

SPECIFICATIONS, General Description.>

3) If NG, replace the bulb with a new one.

LI-27

TRUNK ROOM LIGHT

LIGHTING SYSTEM

26.Trunk Room Light

A: REMOVAL

1) Disconnect the ground terminal from battery.

2) Disconnect the harness connectors and remove the trunk room light.

B:

INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

1)

Visually check the bulb for blow out.

2)

Check the bulb specification. <Ref. to LI-2,

SPECIFICATIONS, General Description.>

3) If NG, replace the bulb with a new one.

LI-28

GLOVE BOX LIGHT

27.Glove Box Light

A: REMOVAL

1)

Disconnect the ground terminal from battery.

2) Remove the glove box. <Ref. to El-39, REMOV-

AL, Glove Box.>

3)

Disconnect the harness connector.

4)

Remove the glove box light.

LIGHTING SYSTEM

I \

B:

INSTALLATION

Install in the reverse order of removal.

/

800040

C: INSPECTION

1)

Visually check the bulb for blow out.

2) Check the bulb specification. <Ref. to LI-2,

SPECIFICATIONS, General Description.>

3) If NG, replace the bulb with a new one.

LI-29

LIGHTING SYSTEM

GLOVE BOX LIGHT

LI-30

WIPER AND WASHER SYSTEMS

ww

5

.

6

.

7

.

8

.

9

.

10

.

11

.

1

.

2

.

3

.

4

.

12

.

General Description

Page

....................................................................................

2

Wiper and Washer System

.........................................................................

5

Combination Switch (Wiper)

........................................................................

7

Wiper Blade

.................................................................................................

9

Washer Tank and Motor

............................................................................

11

Front Wiper Arm

........................................................................................

12

Front Wiper Motor and Link

.......................................................................

13

Front Washer Nozzle

................................................................................

Rear Wiper Arm

........................................................................................

Rear Wiper Motor

15

16

......................................................................................

17

Rear Washer Nozzle

.................................................................................

18

Wiper Control Relay

..................................................................................

19

.

GENERAL DESCRIPTION

WIPER AND WASHER SYSTEMS

1.

General Description

A: SPECIFICATIONS

I

Front wiper motor

Rear wiDer motor

1

Front washer motor

I

Rear washer motor

[

Input

I

Input

Pump type lnout

I

PumDtvDe

I

B: COMPONENT

1.

FRONT WIPER

12 V-72 W or less

12

V -

Centrifugal

12

V -

36

W or less

Centrifuaal

I

.

.

(1) Wiper rubber

(2) Wiper blade ASSY

(3) Wiper arm

(4)

( 5 )

Wiper link

Wiper motor

ww-2

BOO272

Tightening torque:

N.m

(kgf-m, ft-lb)

T1: 6.0 (0.61, 4.4)

T2: 20 (2.0, 14.5)

2.

REARWIPER

GENERAL DESCRIPTION

WIPER AND WASHER SYSTEMS

(1) Wiper rubber

(2) Wiper blade ASSY

(3) Wiper arm

(4) Wiper motor

(5) SpacerA

(6)

Cushion

(7)

(8)

(9)

SpacerB

Nut

Cap

Tightening toque:

N.m (kgf-my ft-lb)

T1: 6.0 (0.61, 4.4)

T2: 7.5 (0.76, 5.5)

T3:

8.0 (0.82,

5.9)

ww-3

WIPER AND WASHER SYSTEMS

3. WASHER TANK

GENERAL DESCRIPTION

BOO295

(1) Washer nozzle

(2)

Washer hose

(3)

Washer tank

(4)

Washer tank cap

(5)

(6)

(7)

Front washer motor

Rear washer motor

Grommet

Tightening torque:

N-m (kgf-m, ft-lb)

T:

6.0 (0.61, 4.4)

C: CAUTION

Reconnect the connectors and hoses securely.

After reconnecting, confirm that each function operates normally.

Be careful that the wire harnesses of airbag system pass near electrical parts and switches.

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-4

WIPER AND WASHER SYSTEM

WIPER

AND

WASHER SYSTEMS

2.

Wiper and Washer System

A:

SCHEMATIC

1.

WIPER AND WASHER (FRONT)

<Ref. to WI-127, SCHEMATIC, Wiper and Washer

System (Front).>

2.

WIPER AND WASHER (REAR)

<Ref. to WI-128, SCHEMATIC, Wiper and Washer

System (Rear).>

ww-5

WIPER

AND

WASHER SYSTEMS

WIPER AND WASHER SYSTEM

B: INSPECTION

Svmotom

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 sprav does not operate.

Repair order

(1) Wiper fuse (FIB No. 14,

15)

(2)

Combination switch

(3)

Wiper motor

(4) Wire harness

(1) Combination switch

(2) Wiper motor

(3) Wire harness

(1

) Combination switch

(2) Wiper motor

(3) Wire harness

(1) Washer switch

(2) Washer motor

(3) Wire harness

(1) Washer motor

(2)

Wire harness

(1

1

Washer hose and nozzle

W W-6

3.

COMBINATION SWITCH (WIPER)

WIPER AND WASHER SYSTEMS

Combination Switch (Wiper)

A: REMOVAL

1)

Loosen the screw to remove a steering column

C: INSPECTION

Measure the combination switch.

I

B6M1184

2) Disconnect the connectors from combination switches.

3) Loosen the screw to remove combination switch.

B: INSTALLATION

Install in the reverse order of removal.

S6M0137

FRONT

OFF

I

7and16

I less than 1R

I

INT

I

7and16

I lessthan 1R

I

LO

I

7and17

I lessthan 1R

8

and 17 less than 1R

2 and 10

2 and 12 Washer ON

less than 1R

10 and 12

REAR

Washer ON

2 and 10

2 and 10

2 and 12

10 and 12 more than 1MR less than 1R less than 1R

If continuity is not as specified, replace the switch.

ww-7

COMBINATION SWITCH (WIPER)

WIPER AND WASHER SYSTEMS

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, and inspect the voltage of terminals 7 and 2. (Measure the voltage from after the second time the wiper stops.)

Switch position Voltage

I

Non variable type

I

If operation is not as specified, replace the switch. o v

1 2 v

T

1

1

*5 sec.

T

3 i 1

sec.

B6M1465A

I

WW-8

4.

Wiper Blade

WIPER

BLADE

A: REMOVAL

While pushing the locking clip (A) up, pull out the blade from arm to arrow direction.

WIPER AND WASHER SYSTEMS

D: ASSEMBLY

1.

METALTYPE

1)

Insert the wiper rubber onto the blade so that the stopper is in the position shown.

B: INSTALLATION

1)

Install in the reverse order of removal.

2)

Confirm that the clip is locked securely.

c:

DISASSEMBLY

1.

METALTYPE

Pull on side

(A)

of the wiper rubber stopper and re- move the rubber from the blade assembly.

I

B6M1497

2)

Make sure the wiper rubber is securely fastened to the pull stopper (A).

I

B6M1498A I I

I I- I

B6M1496A

2.

RESINTYPE

Pull the wiper rubber top slightly from the stopper and pull out fully.

I

I

BOO1 96

ww-9

b

WIPER AND WASHER SYSTEMS

2. RESINTYPE

WIPER BLADE

B

C

1) Insert the wiper rubber through the claw (B).

3) Insert the wiper rubber into the claw

(A).

BOOl 97

A

N .

\

2) Insert the wiper rubber top until it protrudes about 20" (0.79 in) from the stopper

(D).

20mm

(

0.79

E: INSPECTION

1) When the wiper does not perform well, inspect the following:

Make sure the movable part of the blade assem- bly moves smoothly.

Make sure the wiper rubber is not deformed or damaged.

2) Replace with a new part if damage is found.

BOOl

95 ww-10

5. Washer

WASHER TANK AND MOTOR

WIPER AND WASHER SYSTEMS

Tank and Motor

A:

REMOVAL

1) Open the hood.

2)

Disconnect the ground terminal from battery.

3) Remove the two bolts, hose and connector and then remove the tank.

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 oper- ates.

W

B6M 1567

B: INSTALLATION

Install in the reverse order of removal.

C: DISASSEMBLY

Pull out the washer motor from tank.

ww-11

WIPER AND WASHER SYSTEMS

6.

Front Wiper Arm

A: REMOVAL

1) Open the hood.

2) Remove the cap.

3) Loosen the nut to remove arm.

FRONT WIPER ARM

C: ADJUSTMENT

Operate the wiper once. Align the wiper blade to ceramic print point mark (A) of front window pane.

B6M 1 193L

B: INSTALLATION

1) Install in the reverse order of removal.

2)

Operate the wiper once.

3) Align-the wiper blade to ceramic print point mark

(A) of front window pane.

\

I

B6M1193A ww-12

7.

FRONT WIPER MOTOR AND LINK

WIPER

AND

WASHER SYSTEMS

Front Wiper Motor and Link

A: REMOVAL

1)

Disconnect the ground terminal from battery.

2)

Remove the cowl panel. <Ref. to El-33, RE-

MOVAL, Cowl Panel.>

3) Disconnect the connector of motor.

4)

Loosen the bolts and nuts to remove wiper link.

C: INSPECTION

1)

When the battery is connected to the terminal of connectors, confirm that motor operates at low speed.

5 )

Loosen the bolts and nuts to remove motor.

I

60020'

2) When the battery is connected to the terminal of connectors, confirm that motor operates at high speed.

I

B5M 1467

I

B: INSTALLATION

1)

Connect the battery ground terminal to battery.

2)

To confirm that the motor is at auto stop position, connect the harness to motor and turn the wiper switch ON/OFF once.

3)

Disconnect the ground terminal from battery.

4)

Tighten the nut where rod (A) and link plate (B) is aligned in a straight line.

BO0202

3) Connect the battery to terminals of connector, and remove the terminal connection with motor ro- tated at low speed, and stop the wiper motor through operation.

80020:

5 )

Install in the reverse order of removal.

ww-13

FRONT WIPER MOTOR AND LINK

WIPER AND WASHER

SYSTEMS

4)

Connect the battery and confirm that the motor stops at automatic stop position after the motor op- erates at low speed again.

BOO204 ww-14

8.

FRONT WASHER NOZZLE

WIPER AND WASHER SYSTEMS

Front Washer Nozzle

A: REMOVAL

1)

Remove the washer hose from the washer noz- zle.

2) Open the clips on the underside of the hood with a thin screwdriver or other tool, and remove the washer nozzle.

B: INSTALLATION

1) Install in the reverse order of removal.

2) Adjust the position of the washer liquid sprayer.

<Ref. to WW-15, ADJUSTMENT, Front Washer

I

I

-

C: INSPECTION

Make sure the nozzle and hose are not clogged.

Make sure the hose is not bent.

D: ADJUSTMENT

1) Turn the wiper switch to OFF position.

2) When the vehicle stops, adjust the washer injec- tion position as shown in the figure.

lnjection position:

A:

257

mm

(10.12 in)

B:

512

mm

(20.16 in)

B6M1505

BO0362 ww-15

WIPER AND WASHER

SYSTEMS

9. Rear Wiper Arm

A: REMOVAL

1) Raise the wiper arm cover (A).

2) Loosen the nut to remove wiper arm.

REAR WIPER ARM

I

B6M1201

A

B: INSTALLATION

1)

Install in the reverse order of removal.

2) Operate the rear wiper once.

3) Align the blade to rear defogger heat wire (A).

\

\

I

F

BOO206

C: ADJUSTMENT

1)

Operate the rear wiper once.

2) Align the blade to rear defogger heat wire (A).

WW-16

10.Rear Wiper Motor

REAR WIPER MOTOR

WIPER AND WASHER SYSTEMS

C: INSPECTION

1) Connect the battery to wiper motor connector and confirm that wiper motor operates.

A: REMOVAL

1

) Disconnect the ground terminal from battery.

2)

Remove the rear wiper arm.

3) Remove the cap from rear wiper shaft.

(A),

nut

(B), and spacer

(C)

06M 12021

4)

Remove the rear gate lower trim. <Ref. to El-52,

REMOVAL,

Rear Gate Trim.>

5)

Unclip we clip of harness and disconnect con- nector of wiper motor.

6)

Loosen the bolts to remove wiper motor assem- bly

(A).

S6M0072

2) Connect the battery to terminal of connector and remove the terminal connections with motor rotat- ed, and stop the wiper motor through operation.

S6M0073

3) Connect the battery and confirm that the motor stops at automatic stop position after the motor op- erates at low speed again.

I

B:

INSTALLATION

1)

Install in the reverse order of removal.

2) Install the rear wiper cushion with the arrow mark facing up, as shown in the figure.

I

05M1463

ww-17

REAR WASHER NOZZLE

WIPER AND WASHER

SYSTEMS

11 .Rear Washer Nozzle

A: REMOVAL

1) Remove the high-mount stop light. <Ref. to LI-

24, REMOVAL, High-mounted Stop Light.>

2) Remove the washer hose from the washer noz- zle.

3) Open the clips on the underside of the hood with a thin screwdriver or other tool, and remove the washer nozzle.

B: INSTALLATION

1) Install in the reverse order of removal.

2) Adjust the position of the washer liquid sprayer.

<Ref. to WW-18, ADJUSTMENT, Rear Washer

Nozzle.>

C: INSPECTION

Make sure the nozzle and hose are not clogged.

Make sure the hose is not bent.

D: ADJUSTMENT

1) Turn the wiper switch to OFF position.

2) When the vehicle stops, adjust the washer injec- tion position as shown in the figure.

Injection position:

A: 39 mm (1.54 in)

B: 72"

B6M1200( ww-I a

WIPER CONTROL RELAY

WIPER AND WASHER SYSTEMS

12.Wiper Control Relay

A: REMOVAL

1) Disconnect the ground terminal from battery.

Remove the right quarter lower trim. <Ref. to El-47,

REMOVAL,

Rear Quarter Trim.>

2) Loosen the nut to remove control unit.

B: INSTALLATION

Install in the reverse order of removal.

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 negative lead to ground.

U

BO0276

3) Measure the voltage when the wiper relay is op- erated.

Switch position

Voltage

B6M1523,

If operation is not as specified, replace the switch.

ww-19

WIPER AND WASHER SYSTEMS

WIPER CONTROL RELAY ww-20

ENTERTAINMENT

1

.

General Description

Page

....................................................................................

2

2

.

3

.

Radio System

..............................................................................................

3

Cigarette Lighter System

.............................................................................

5

4

.

Radio Body

..................................................................................................

6

5

.

Front Speaker

6

.

Tweeter

.............................................................................................

7

.......................................................................................................

8

7

. Rear Speaker

..............................................................................................

9

8

.

Antenna

.....................................................................................................

10

9

.

Cigarette Lighter

........................................................................................

11

.

GENERAL DESCRIPTION

ENTERTAINMENT

1. General Description

A: CAUTION

Before disassembling or reassembling parts, al- ways 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.

Reassemble in reverse order of disassembly, un- less otherwise indicated.

Adjust the parts to the given specifications.

Connect the connectors and hoses securely dur- ing reassembly.

After reassembly, make sure functional parts op- erate smoothly.

B: PREPARATION TOOL

1. GENERAL TOOLS

I

TOOL NAME

I

Circuit Tester

REMARKS

Used for measuring resis- tance and voltage.

1

ET-2

RADIO SYSTEM

~~~ ~ ~~~

2. Radio System

A: SCHEMATIC

1. RADIO

<Ref. to WI-52, SCHEMATIC,

Audio System.>

ENTERTAINMENT

ET-3

RADIO SYSTEM

ENTERTAINMENT

B: INSPECTION

Symptom

No power coming in (No display and no sound from speakers)

A specific speaker does not operate.

Radio generates noise with engine running

AM and FM modes are weak or noisy

Repair order

(1) Check fuse and power supply for radio.

(2) Check radio ground.

(3) Remove radio for repair.

(1) Check speaker.

(2) Check output circuit between radio and speaker.

(1) Check radio ground.

(2) Check generator.

(3) Check ignition coil.

(4)

Remove radio for repair.

(1) Check antenna.

(2) Check radio ground.

(3) Remove radio for repair.

-

ET-4

CIGARETTE LIGHTER SYSTEM

3.

Cigarette Lighter System

A: SCHEMATIC

1.

CIGARETTE LIGHTER

<Ref. to WI-88, SCHEMATIC, Front Accessory

Power Supply System.>

ENTE

RTAl

NM ENT

B

ET-5

RADIO BODY

ENTERTAINMENT

4.

Radio Body

A: REMOVAL

1) Disconnect the battery ground cable.

2) Remove the center panel while disconnecting connector

.

0

: Hook pawl

\

3) Remove the fitting screws, and slightly pull radio out from the center console.

4)

Disconnect the electric connectors and antenna feeder cord.

B: INSTALLATION

Install in the reverse order of removal.

ET-6

FRONT SPEAKER

5. Front Speaker

A: REMOVAL

1) Disconnect the battery ground cable.

2) Remove the front door trim. <Ref. to El-37, RE-

MOVAL,

Front Door Trim.>

3) Remove the front speaker mounting screws.

ENTERTAINMENT

60001 9

4)

Disconnect the harness connector and remove the front speaker.

B: INSTALLATION

Install in the reverse order of removal.

ET-7

TWEETER

ENTERTAINMENT

6.

Tweeter

A: REMOVAL

1)

Disconnect the battery ground cable.

2 )

Remove the front door trim. <Ref. to El-37, RE-

MOVAL, Front Door Trim.>

3)

Remove the tweeter mounting screws.

4)

Disconnect the harness connector and remove the tweeter.

B:

INSTALLATION

Install in the reverse order of removal.

ET-8

REAR SPEAKER

7. Rear Speaker

A:

REMOVAL

1) Disconnect the battery ground cable.

2) Remove the rear door trim. <Ref. to El-38, RE-

MOVAL, Rear Door Trim.>

3) Remove the rear speaker mounting screws.

ENTERTAINMENT

S6M05

4)

Disconnect the harness connector and remove the rear speaker.

B: INSTALLATION

Install in the reverse order of removal.

ET-9

ANTENNA

ENTERTAINMENT

8.

Antenna

A:

REMOVAL

1)

Remove the mounting screws and detach anten- na.

2) Disconnect the harness connector.

B: INSTALLATION

Install in the reverse order

of

removal.

ET-1 0

CIGARETTE LIGHTER

9. Cigarette Lighter

A: REMOVAL

1) Disconnect the battery ground cable.

2) Remove the center panel. <Ref. to ET-6, RE-

MOVAL, Radio Body.>

3) Disconnect the harness connectors and remove the cigarette lighter.

ENTERTAINMENT

B:

INSTALLATION

Install in

the reverse order of removal.

BO0023

ET-1 1

ENTERTAINMENT

CIGARETTE LIGHTER

ET-I 2

COMMUNICATION SYSTEM

COM

1

.

General Description

Page

....................................................................................

2

2

.

Horn System

...............................................................................................

3

3

.

Horn

............................................................................................................

4

4

.

Horn Switch

.................................................................................................

5

COMMUNICATION SYSTEM

1.

General Description

A:

PREPARATION TOOL

1.

GENERAL TOOLS

GENERAL DESCRIPTION

TOOL

NAME

Circuit

Tester

REMARKS

Used for measuring resistance and voltage.

COM-2

HORN SYSTEM

2.

Horn

System

A: SCHEMATIC

1.

HORN

<Ref. to WI-89, SCHEMATIC, Horn System.>

B:

INSPECTION

1.

HORN

RELAY

Measure the horn relay resistance between termi- nals (indicated in table below) when connecting ter-

minal No. 4 to battery positive terminal and terminal

No. 3 to battery ground terminal.

COMMUNICATION SYSTEM

I

Flow

No

Flow

1 and2

800308

Less than

1R

More than 1MR

COM-3

HORN

COM

MU N

CATION SYSTEM

3.

Horn

A:

REMOVAL

1) Disconnect the battery ground cable.

2)

Remove the horn bracket mounting bolt (A).

3) Disconnect the harness connector and remove the horn assembly

(B).

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

With 12

V

direct current supply between horn termi- nal and case ground, check that the horn sounds properly.

COM-4

4.

Horn Switch

HORN SWITCH

COMMUNICATION SYSTEM

C: INSPECTION

Measure the horn switch resistance.

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, Gen- eral Description.>

1) Disconnect the battery ground cable.

2) Remove the driver's airbag module. <Ref. to

AB-12, Driver's Airbag Module.>

3) Remove the horn switch from the steering wheel as shown.

B6M1493

Switch position

When horn switch is pushed.

I

Terminal No.

1

Resistance

Less than 1R

When horn switch is not Dushed.

More than

1

MR

I

B: INSTALLATION

Install in the reverse order of removal.

COM-5

COMMUNICATION SYSTEM

HORN SWITCH

COM-6

GLASSNVlNDOWS/MIRRORS

W

8

.

9

.

10

.

11

.

12

.

13

.

14

.

15

.

16

.

17

.

18

.

1

.

2

.

3

.

4

.

5

.

6

.

7 .

Page

General Description

....................................................................................

2

Power Window System

...............................................................................

9

Rear Window Defogger System

................................................................

11

Remote Control Mirror System

..................................................................

13

Front Door Glass

.......................................................................................

15

Front Regulator and Motor Assembly

.......................................................

19

Rear Door Glass

.......................................................................................

20

Rear Regulator and Motor Assembly

........................................................

22

Windshield Glass

......................................................................................

23

Rear Gate Glass

.......................................................................................

26

Rear Quarter Glass

...................................................................................

27

Rear Window Glass

..................................................................................

28

Inner Rearview Mirror

................................................................................

Power Window Control Switch

29

..................................................................

30

Rear Window Defogger

.............................................................................

32

Outer Mirror Assembly

..............................................................................

33

Outer Mirror

...............................................................................................

35

Remote Control Mirror Switch

...................................................................

36

GLASSNVINDOWS/MI

RRORS

1.

General Description

A: COMPONENT

1.

FIXED GLASS (SEDAN)

GENERAL DESCRIPTION

Windshield glass

(2) Dam rubber

(3) Molding

(4) Rearview mirror mount

(5) Locate pin

(6) Rear window glass

(7)

Spring

BO0391

G W-2

2. FIXED

GLASS (WAGON)

GENERAL DESCRIPTION

GLASSMI NDOWS/M I RRORS

(1) Windshield glass

(2) Dam rubber

(3) Molding

(4) Rearview mirror mount

(5) Locate pin

(6) Fastener

(7)

Rear quarter glass

(8)

(9)

Locate pin

Glass

BOO392

GW-3

G LASSNVI N DOWS/M I RRORS

3. FRONT DOOR GLASS

GENERAL DESCRIPTION

(1)

(2)

Glass

Door sash (Front)

(3)

Door sash (Rear)

(4)

Regulator

ASSY

(5) Motor ASSY

Tightening torque: N.m (kgf-m, ft-lb)

T1: 7.4 (0.75, 5.5)

T2: 13.7(1.4, 10.1)

GW-4

4.

REAR DOOR GLASS

GENERAL DESCRIPTION

LASSNVl N DOWS/M I R

RS

(1) Glass

(2) Door sash (Front)

(3)

(4)

Door sash (Rear)

Regulator ASSY

(5)

Motor ASSY

Tightening torque: N-m (kgf-m, ft-lb)

T1: 7.4 (0.75, 5.5)

T2: 13.7(1.4, 10.1)

G W-5

GLASSNVINDOWSIMIRRORS

5.

MIRRORS

GENERAL DESCRIPTION

(1)

Outer mirror

(2) Inner rearview mirror

(3)

(4)

Mount

Spring

(5) Mirror

B O ~ E

GW-6

GENERAL DESCRIPTION

B: CAUTION

When electrical connectors are disconnected, al- ways conduct an operational check after connect- ing them again.

Avoid impact and damage to the glass.

GLASSNVI N DOWS/M I R RORS

GW-7

GLASS/WINDOWS/MIRRORS

C: PREPARATION TOOL

GENERAL DESCRIPTION

TOOL NAME

Circuit Tester

Piano Wire

I

Windshield Knife

REM ARKS

Used for checking voltage and continuity.

Used for window alass removal.

I

Used for window glass removal.

I

G W-8

POWER WINDOW SYSTEM

2.

Power Window System

A: SCHEMATIC

<Ref. to WI-109, Power Window

System.>

GLASSNVINDOWS/MIRRORS

G W-9

GLASSNVINDOWSIMIRRORS

B: INSPECTION

Symptom

All

power windows does not operate.

One window does not operate.

“Window Lock does not operate.

POWER WINDOW SYSTEM

Repair order

(1)

Fuse

(SBFS)

(2)

Power window circuit breaker

I41

Wire harness

(1)

Power window main switch

(2) Power window sub switch

(3) Power window motor

I41

Wire harness

(1

1

Power window main switch

GW-10

I

REAR WINDOW DEFOGGER SYSTEM

GLASS/WINDOWS/M I RRORS

3.

Rear Window Defogger System

A:

SCHEMATIC

<Ref. to WI-117, Rear Window Defogger System.>

GW-11

REAR WINDOW DEFOGGER SYSTEM

GLASSNVINDOWSIMIRRORS

B: INSPECTION

Symptom

Rear window defogger does not operate.

Repair order

(1) Fuse (M/B No. 1) (F/B No.

11)

(2)

Rear defogger relay

(3)

Rear defogger timer

(4)

Defogger switch

(5)

Rear defogger condenser

(6) Deffogger wire

GW-12

I

I

REMOTE CONTROL MIRROR SYSTEM

GLASSMIINDOWSIMIRRORS

4.

Remote Control Mirror System

A: SCHEMATIC

<Ref.

to WI-118, Remote Controlled Rearview Mir- ror

System.> i

E

1

I

GW-13

Mirror heater does not operate.

REMOTE CONTROL MIRROR SYSTEM

B:

INSPECTION

Symptom

All

function does not operate.

One side of the mirror motor does not operate.

ReDair order

(1)Fuse (F/B No. 1 ) (F/B No. 4) (F/B No. 19)

(2)

Mirror switch

(3) Wire harness

(1)

Mirror switch

(2) Mirror motor

(3) Wire harness

(1)

Mirror switch

(2) Mirror heater

(3) Wire harness

GW-14

5. Front Door

Glass

FRONT DOOR GLASS

GLASS/WINDOWS/MIRRORS

6)

Remove the rear end of door weather strip and weather strip outer

A: REMOVAL

1) Remove the front door trim. <Ref. to El-37, RE-

MOVAL, Front Door Trim.>

2) Remove the sealing cover. <Ref. to EB-14, RE-

MOVAL, Front Sealing Cover.>

3) Remove the outer mirror assembly. <Ref. to

GW-33, REMOVAL, Outer Mirror Assembly.>

4)

Remove the gusset.

7) Operate the power window switch to move glass to position shown in the figure, and then remove the two nuts from the service holes.

I

8) Remove the door glass.

5 )

Remove the stabilizers and trim hooks.

BO0086

CAUTION:

Do not turn regulator in the closing direction after removal of the glass. Otherwise gear may be disengaged.

Avoid impact and damage to the glass.

GW-15

FRONT

DOOR GLASS

GLASS/WINDOWS/MIRRORS

B: INSTALLATION

1)

Install in the reverse order of removal.

CAUTION:

Make sure that glass stay

is

placed securely

in

sash.

2)

Adjust the front door glass. <Ref. to GW-17, AD-

JUSTMENT, Front Door Glass.>

-

GW-16

FRONT DOOR GLASS

GLASSNVINDOWSIMIRRORS

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 weatherstrip.

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 8-channel in a position at the top of slotted hole.

Lower the door glass

10 15

mm

(0.39 0.59

in) from fully closed position. While applying out- ward pressure of N

(4.6k0.5

Ib) (F) to upper edge of glass above midpoint of two outer stabilizers, press the inner stabilizer at pres- sure of

1 Of5

N then secure it.

(1.0k0.5

Full close

,

10

-

15 mm

(0.39 ter pillar, loosen the adjusting nut (A) of B-channel

(B).

'

B5M0729A

so

that the upper and lower ends of center pillar are the same size. u

G5M0421

4)

For adjustment of clearance between front glass and center pillar cover, loosen the nuts (A), and move the glass sash back and forward until clear- ance becomes the value shown.

Lower B channel

,,,(-TE

Wide

Glass tilts too far forward

Narrow

Unit: mm (in)

-

7

Raise B channel BOO389

7) For glass stroke adjustment, close door, raise glass until positional relationship between glass and weatherstrip becomes as shown. And secure the glass so that the upper stopper lightly touches the glass holder.

2-3

\

(0.079-0.1 18)

A-A

800388

GW-17

FRONT DOOR

GLASS

GLASSNVl N DO WS/M I RRORS

For preventing wind noise, adjust the glass at the position where tip of gusset is raised up a little.

10) Make adjustment of front sash in the same manner as that of rear sash.

CAUTION:

Although front and rear sashes must, as a rule, be adjusted in the same manner, in some door installation, the adjustment in a different man- ner 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 exces- sive load to regulator.

11)

After adjustments, tighten the nuts.

12)

After adjustment of glass, if there is a gap be- tween outer lip of gusset and glass surface, adjust the gap with adjusting bolt (A) in lower fitting part of gusset to prevent generation of wind noise.

13)

During adjustments, loosen other three clamp- ing bolts.

(A)

0-1.5 mm

(0-0.059

8)

After stabilizer adjustment, carry out glass crimp adjustment. First, visually ensure positional rela- tionship between retainer & molding and glass of the roof side, and then begin with rear sash adjust- ment. Adjust two adjusting bolts alternately step by step to obtain dimensions shown below (cross-sec- tion A).

NOTE:

If two nuts are loosened at the same time, the 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.

I

2-3

\

(0.079-0.1 18)

Unit:

mm (in)

BO0267

CAUTION:

Do not tilt sash bracket to inner panel during adjustment. Otherwise smooth regulator opera- tion cannot be achieved.

14)

After adjustment, tighten the bolts and nuts.

GW-18

6.

FRONT REGULATOR AND MOTOR ASSEMBLY

GLASSMI

N DO WS/M I RRORS

Front Regulator and Motor

Assembly

A: REMOVAL

1)

Remove the door glass. <Ref. to GW-15, RE-

MOVAL, Front Door Glass.>

2)

Loosen the nuts to remove the rear sash.

I

B: INSTALLATION

1) Install in the reverse order of removal.

2) Adjust the front door glass. <Ref. to GW-17, AD-

JUSTMENT, Front Door Glass.>

C: INSPECTION

1) Make sure that the power window motor rotates properly when the battery voltage is applied to the terminals of motor connector.

2) Change the polarity of battery connections to ter- minals to ensure that the motor rotates in reverse direction.

00089

I I

3) Disconnect the motor connector.

4)

Loosen four bolts and two nuts to remove the regulator assem bl y

.

5) Loosen the screw to remove motor assembly.

800091

GW-19

REAR DOOR GLASS

GLASSNVINDOWSIMIRRORS

7.

Rear Door Glass

A: REMOVAL

1) Remove the rear door trim. <Ref. to El-38, RE-

MOVAL, Rear Door Trim.>

2)

Remove the sealing cover. <Ref. to EB-17, RE-

MOVAL, Rear Sealing Cover.>

3) Remove the stabilizer.

5 )

Loosen two screw to remove weather strip outer.

I

4)

Remove the door weather strip.

B5M 1 044

\

/

BOO093

6) Operate the power window switch to remove glass as shown in the figure, and remove two nuts.

\

BO0092

7)

Loosen two rear sash installation nuts, and move the rear sash backward.

8) Remove the glass.

CAUTION:

Avoid impact and damage to the glass.

GW-20

9:

INSTALLATION

~~

REAR DOOR GLASS

1)

Install in the reverse order of removal.

CAUTION:

Make sure that glass stay is placed securely in sash.

2) Adjust rear door glass. <Ref. to GW-21, AD-

JUSTMENT, 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 rear glass are given below.

1)

Adjust the glass position using the following di- mensions as a guide line.

GLASS/WINDOWS/MIRRORS

After adjustment, move glass up and down to check whether it is caught.

12 (0.472) 12 (0.472)

B

A-A

Unit: mm (in)

BOO394

CAUTION:

If dimensions are smaller than the given di- mensions, glass may get caught in weather- strip during liftinghowering operation. In the worst case, it may cause glass not to be opened fully.

After adjustment, move glass up and down to check whether it is caught.

2) Adjust the crimp of glass using the following di- mensions as a guide line.

Unit:

mm

(in)

1%

(41

6 (0.236)

2-3

2- g

BO0269

CAUTION:

If crimp of rear glass is higher than neces- sary, glass may get caught in weatherstrip of center pillar corner, resulting in early wear of weatherstrip. Be careful when adjusting.

GW-21

REAR REGULATOR AND MOTOR ASSEMBLY

GLASSNVINDOWSIM IRRORS

8.

Rear Regulator and Motor As- sembly

A:

REMOVAL

1) Remove the door glass. <Ref. to GW-20, RE-

MOVAL, Rear Door Grass.>

2) Remove the front sash.

3) Disconnect the motor connector.

4)

Loosen four bolts and two nuts to remove r lator assembly.

5 )

Loosen' screws to remove motor assembly.

I

1 V

B0009E

B: INSTALLATION

1) Install in the reverse order of removal.

2) Adjust the rear door glass. <Ref. to GW-21, AD-

JUSTMENT, Rear Door Glass.>

C: INSPECTION

1) Make sure that the power window motor rotates properly when the battery voltage is applied to the terminals of motor connector.

2) Change the polarity of battery connections to the terminals to ensure that the motor rotates in re- verse direction.

GW-22

9. Windshield Glass

A: REMOVAL

WINDSHIELD GLASS

GLASSMI N DO W S/M I RRORS

NOTE:

Because the matching pins are bonded to the cor- ners of glass, use piano wire to cut the pin.

1. USING WINDSHIELD KNIFE

1) Remove the cowl panel. <Ref. to

MOVAL, Cowl Panel.>

2) Remove the glass molding.

El-33,

RE-

3)

Tape the body side of the circumference of wind- shield glass for protection.

4) Apply the sufficient amount of soapy water to the adhesive layer.

5)

Insert the windshield knife into the adhesive lay- er.

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 adhe- sive layer.

CAUTION:

Do not twist windshield knife.

Cutting'of adhesive layer shall be started with wider gap between windshield glass and body.

Matching pin

A-A

G5M0412

2.

USING

PIANO

WIRE

1) Remove the cowl panel. <Ref. to

MOVAL, Cowl Panel.>

El-33,

RE-

2) Remove the roof molding and upper front mold- ing.

3)

Tape the body side of the circumference of wind- shield glass for protection.

4)

Make a hole in the adhesive layer using drill or knife.

5) Pass the piano wire through the hole, and attach securely both the wire ends to pieces of wood.

I

A-A

/-

G5M041

e

\ \

G5M0494

6)

Pull the wire ends alternately to cut off the adhe- sive layer.

CAUTION:

Do not tightly pull the piano wire against the windshield glass edge.

Be careful not to damage interior and exterior parts.

When removal is made with area close to in- strument panel, place a protection plate over it.

Pay particular attention to the removal.

Do not cross piano wires. Otherwise they may be cut.

GW-23

WINDSHIELD GLASS

GLASSNVI NDOWS/M I RRORS

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.

8) Fit the molding mark (B) to notch (A).

'

2 m m

(0.08 in)

G5M0553

3) Clean l h e body with alcohol or white gasoline to remove thoroughly chips, dusts, and dirts from the body face.

4)

Place the glass on body.

5) Adjust the glass position to make uniform clear- ance between body and glass in four corners.

6) Bond the matching pins and dam rubber.

BOO270

9)

Apply the primer to the adhesive layer of glass using sponge.

10)

Apply the primer to the adhesive layer of body.

CAUTION:

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 primer dry for about ten minutes before installing the glass.

Do not touch surface coated with primer.

/I

/

Matching pin Fastener

Dam rubber

Application of primer

11 (0.433)

711

Ill i

15 (0.591)

Glass side Body side

G5M0495

Unit: mm (in)

7) Remove the glass from body.

80039:

GW-24

WINDSHIELD GLASS

11) Cut off the cartridge nozzle tip and set it in seal- ant gun as shown.

1

(0.39)

12) Apply the adhesive to the glass end surface as shown.

13) Fit the matching pins using suction rubber cup to install windshield glass.

14) Lightly press the windshield glass for tight fit.

15) Make the adhesive surface flush using spatula.

CAUTION:

When door is openedklosed after glass is bonded, always lower door glass and then open/close it carefully.

Move vehicle slowly.

16) After completion of all work, allow vehicle to stand for about 24 hours.

NOTE:

For minimum drying time and time the vehicle must be left standing before driving after bonding, follow instructions or instruction manual from the adhe- sive manufacturer.

17) After curing of adhesive, pour water on external surface of vehicle to check that there are no water leaks.

CAUTION:

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.

18) Jnstall the cowl panel. <Ref. to

El-33,

INSTAL-

LATION, Cowl Panel.>

GW-25

REAR GATE GLASS

GLASSNVINDOWSIM

I

RRORS

10.Rear Gate Glass

A: REMOVAL

1) Remove the rear wiper motor. <Ref. to WW-17,

REMOVAL, Rear Wiper Motor.>

2) Remove the electrical connector from the rear defogger terminal.

3) Remove the glass in the same procedure as for windshield glass. <Ref. to GW-23, REMOVAL,

Windshield Glass.>

B: INSTALLATION

1) Apply the adhesive evenly to the glass attach- ment area.

2) Insert the glass clip pin into the rear gate hole, and after pushing on the area around the clip pin to secure it, push lightly all around the area to seal it.

3) About one hour after installation, conduct a leak test.

4) After completion of all work, allow vehicle to stand for about 24 hours.

NOTE:

For minimum drying time and time the vehicle must be left standing before driving after bonding, follow instructions or instruction manual from the adhe- sive manufacturer.

CAUTION:

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 wiper. <Ref. to WW-17, INSTAL-

LATION, Rear Wiper Motor.>

Upper side

Lower side

BOO396

CAUTION:

When door is openedklosed after glass is bonded, always lower door glass and then open/close it carefully.

Move vehicle slowly.

G W-26

REAR QUARTER GLASS

GLASSNVINDOWSIMIRRORS

11 .Rear Quarter Glass

A:

REMOVAL

Remove the glass in the same procedure as for windshield glass. <Ref. to GW-23, REMOVAL, Windshield

Glass.>

<

\Molding

B-B

Dam rubber

7

-

Rear quarter glass

Adhesive

7

B: INSTALLATION

1)

Cut

off

the nozzle tip as

shown

in the figure.

Unit:

mm

(in)

10 (0.39)

-Ti- l l

D l 5

(0.59)

12

-

15

(0.47 -

.59

LAdhesive

5M0414

2) Install the glass in the same procedure as for windshield the glass. <Ref. to GW-24, INSTALLA-

TION, Windshield Glass.>

CAUTION:

When door is opened/closed after glass is bonded, always lower door glass and then openklose it carefully.

Move vehicle slowly.

BOO21 C

3) After completion of all work, allow vehicle to stand for about 24 hours.

NOTE:

For minimum drying time and time the vehicle must be left standing before driving after bonding, follow instructions or instruction manual from the adhe- sive manufacturer.

4) After curing of adhesive, pour the water on exter- nal surface of vehicle to check that there are no wa- ter leaks.

CAUTION:

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.

GW-27

REAR WINDOW GLASS

GLASSMI N DO WS/M I

RRORS

12.Rear

Window Glass

A: REMOVAL

1)

Disconnect the electrical connectors from the rear defogger terminals.

2) Remove the glass in the Same Procedure as for windshield glass. <Ref. to GW-23, REMOVAL,

Windshield Glass.>

B: INSTALLATION

1)

Bond the dam rubber and matching pin.

5 )

After curing of adhesive, pour the water on exter- nal surface of vehicle to check that there are no wa- ter leaks.

CAUTION:

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.

Unit: mm (in)

BO0271

2) Install the glass in the same procedure as for windshield glass. <Ref. to GW-24, INSTALLA-

TION, Windshield Glass.>

3) Connect the rear defogger terminals.

CAUTION:

When door is openedclosed after glass is bonded, always lower door glass and then opedclose door carefully.

Move vehicle slowly.

4) After completion of all work, allow the vehicle to stand for about 24 hours.

NOTE:

For minimum drying time and time the vehicle must be left standing before driving after bonding, follow instructions or instruction manual from the adhe- sive manufacturer.

GW-28

INNER REARVIEW MIRROR

13.lnner 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.

GLASSMI N DOWS/M I RRORS

B5M1059

I

2) Remove the spring from the mirror base.

CAUTION:

Be careful not to damage the mirror surface.

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

Do not let mirror be damaged.

Do not let spring deteriorate.

GW-29

GLASS/WINDOWS/MIRRORS

POWER WINDOW CONTROL SWITCH

14.Power Window Control

Switch

A: REMOVAL

1.

MAIN SWITCH

1) Disconnect the ground terminal from battery.

2)

Loosen the screw to remove power window main switch.

3) Disconnect the connector.

2.

SUB-SWITCH

1) Disconnect the ground terminal from battery.

2)

Remove the switch panel.

3) Disconnect the connector.

B: I

N STAL LATlO N

1.

MAIN SWITCH

Install in the reverse order of removal.

2.

SUB-SWITCH

Install in the reverse order of removal.

C: INSPECTION

1.

MAIN SWITCH

Measure switch resistance.

Driver's switch:

Switch position

UP

OFF

DOWN

AUTO DOWN

Switch position

UP

OFF

DOWN

I

Terminal No.

13 and 2.1 and

5

1 and2

1 and 5

2 and

5

13 and 1 , 2 and 5

13 and 1,2 and 5

Terminal No.

13

7 and

5

6 and 7 and

5

13 and 7 , 6 and

5

GW-30

Standard less than l R less than 1R less than 1R less than 1R

Standard less than la less than 1R less than 1R

Switch position

UP

OFF

DOWN

Switch position

UP

OFF

DOWN

2. SUB-SWITCH

POWER WINDOW CONTROL SWITCH

GLASSNVINDOWS/MIRRORS

Terminal No.

10

and 13,9 and

5

10

and

9

10

and

5

9 and

5

13

9,

10

and 5

Terminal No.

13

and 16,15 and 5

16 and

15

16 and 5

5 and

15

13

and 15,

16 and 5

Standard less than 1R less than 1R less than I R

Standard

less than 1R less than 1R less than 1R

Switch position

UP

OFF

DOWN

Terminal No.

8 and 5,6 and 7

4

and 5,6 and

7

8 and 7,4 and 5

Standard less than IC2 less than 1R less than 1R

GW-31

REAR WINDOW DEFOGGER

GLASSNVINDOWSIMIRRORS

15.Rear Window Defogger

A: INSPECTION

CAUTION:

When wiping stain on glass off with cloth, use a drv and soft cloth and move it in the direction of the heat wire extension to avoid damage to the heat wire.

1) Turn the ignition switch to ON.

2) Turn the defogger switch to ON.

3) Wrap the tips of tester pins with aluminum foil to avoid damage to heat wire.

B: REPAIR

1) Clean the broken portion with alcohol or white gasoline.

2) Mask both side of wire with thin film.

3)

Apply the conductive silver composition

(Du-

PONT No. 4817) to the broken portion.

I

Broken portion, e

Conductive composition

4) After repair, check wire.

G6M0138

I

G6M0136

1

4)

Measure the voltage at wire center with DC volt- meter.

Standard voltage:

Approx.

6

volts

Voltage

Criteria

I

Acmrox.

12

V or

0

V

I

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 cen- ter and ground.

5) Apply positive lead of voltmeter to positive termi- nal of voltmeter, and then move negative lead along the wire up to the negative terminal end. If voltage changes from zero to several volts during movement of lead, heat wire is open at the voltage change point.

I

GW-32

16.0uter

OUTER MIRROR ASSEMBLY

Mirror Assembly

A: REMOVAL

1)

Disconnect the ground terminal from battery.

2) Remove the door trim. <Ref. to El-37, REMOV-

AL, Front Door Trim.>

3) Remove the mirror gusset cover.

GLASSWIN DOWS/M I RRORS

B: INSTALLATION

Install in the reverse order of removal.

~

4)

Disconnect the mirror connector.

5) Loosen the screws to remove mirror assembly.

GW-33

OUTER MIRROR ASSEMBLY

GLASSNVINDOWS/MIRRORS

C: INSPECTION

Check to ensure that the rearview mirror moves properly when the battery voltage is applied to ter- minals.

I

I

Switch position

OFF

UP

DOWN

LEFT

RIGHT

OFF

UP

DOWN

LEFT

RIGHT

I

I

Terminal

No.

-

4 (+) and 6 (-)

6

(+) and

4

(4

5

I+) and

6

I-)

6

(+) and 5 (-)

-

6

(+) and 8 (-)

8 (+) and

6

(-)

7 (+) and

8

(-)

8 (+) and 7 (-)

I

I

GW-34

OUTER MIRROR

17.0uter

Mirror

A: REPLACEMENT

1)

Remove the door mirror assembly. <Ref. to GW-

33,

REMOVAL, Outer Mirror Assembly.>

2) Warm the area around the mirror holder with a hair drier until the edges of the mirror holder be- come soft (about 2 or 3 minutes with a 1,000 W dri- er.)

3) Use a flat-bladed screwdriver without sharp edg- es to lift the mirror out of the mirror holder. (Also re- move the connector from the back of mirrors with heaters.)

I

Mirror holder

GLASSNVI NDOWS/M I RRORS

I

85M1144A

4)

Warm the area around the mirror holder with a hair drier until the edges of the mirror holder be- come soft (about 2 or 3 minutes with a 1,000 W dri- er.)

5) Remove the backing of the new two-sided tape, and push the mirror in to install it.

CAUTION:

Unless the mirror holder is warmed sufficiently, the mirror holder edges may be damaged or the mirror cracked.

GW-35

I

REMOTE CONTROL MIRROR SWITCH

GLASSNVINDOWSIM IRRORS

18.Remote Control Mirror

Switch

A: REMOVAL

1) Disconnect the ground terminal from battery.

2) Remove the console cover.

3) Disconnect the connector.

B: INSTALLATION

Install in the reverse order of removal.

GW-36

REMOTE CONTROL MIRROR SWITCH

GLASSNVINDOWSIMIRRORS

C: INSPECTION

Move the rearview mirror switch to each position and measure switch resistance.

1

I

~

I

Switch position

OFF

UP

DOWN

LEFT

RIGHT

OFF

UP

DOWN

LEFT

RIGHT

B5M1132

Terminal No.

All

terminal

4

and

6 , 2

and

1

6

and

2 , 4

and

1

4

and

8 , 2

and 1

8

and

2 , 4

and

1

All terminal

4

and

7 , 2

and 1

7

and

2 , 4

and 1

4

and

9 , 2

and 1

9

and

2 , 4

and 1

Standard more than

IMR

less than Is2 less than 1R less than 1R less than

IR

more than 1MR less than 1R

less than

IR

less than

IR

less than

IR

-

I

GW-37

GLASSMI NDO WS/M I RRORS

REMOTE CONTROL MIRROR SWITCH

GW-38

BODY STRUCTURE

Refer to

G1831

BE SUPPLEMENT for this section.

BS

Page

BODY STRUCTURE

Page

1

.

General Description

..................................................................................

..2

2. Datum

Points

...............................................................................................

3

3.

Datum Dimensions

....................................................................................

1 1

GENERAL DESCRIPTION

BODY STRUCTURE

Tram tracking gauge

Tape measure

Used for measuring dimen- sion.

Used for measuring dimen- sion.

BS-2

I

,

I

1

I

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.

1.

WAGONEEDAN

BO0404

Radiator attaching hole 12 mm

(0.47 in) dia. (Symmetrical)

Fender attaching hole 7 mm

(0.28 in) dia. (Symmetrical)

Fender attaching hole 10 mm

(0.39 in) dia. (Symmetrical)

Hood hinge attaching hole 12 mm

(0.47 in) dia. (Symmetrical)

Radiator panel side gauge hole 20 mm (0.79 in) dia. (Symmetrical)

Fender attaching hole 9 mm (0.35 in) dia. (Symmetrical)

Gauge hole 12 mm

(0.47 in) dia.

(Symmetrical)

Front suspension cross member attaching hole 12.4 mm (0.488 in) dia. (Symmetrical)

(10)

(12)

Cowl panel attaching hole 6 mm

(0.24 in) dia. (Vehicle center)

Front glass attaching hole Right

6.5 mm (0.256 in) dia. Left 6.5

x

10 mm (0.256 x 0.39 in) dia.

(18) Fender attaching hole 12 mm

(0.47 in) dia. (Symmetrical)

(19) Fender attaching hole 12 mm

(0.47 in) dia. (Symmetrical)

(20) Outer panel center pillar gauge hole 12 mm (0.47 in) dia. (Sym- metrical)

(21) Outer panel center pillar gauge hole 12 mm (0.47 in) dia. (Sym- metrical)

(22)

Weather strip patch attaching hole

5.2 mm (0.205 in) dia. (Symmetri- cal)

(24)

Roof panel repair locator hollow

(62) Belt anchor attaching hole 11 mm

(0.43 in) dia. (Symmetrical)

(70) Trim clip attaching hole 8.5 mm

(0.335 in) dia. (Symmetrical)

(71) Harness clip attaching hole 7 mm

(0.28 in) dia. (Symmetrical)

(73) Harness clip attaching hole 7 mm

(0.28 in) dia. (Symmetrical)

(74) Trim clip attaching hole 10 mm

(0.39 in) dia. (Symmetrical)

(75) Insulator attaching hole 8 mm

(0.31 in) dia. (Symmetrical)

BS-3

1

6

BODY STRUCTURE

2. WAGON (REAR SECTION)

DATUM POINTS

BO0405

(30) Child anchor attaching hole 11 mm (0.43 in) dia.

(33) Two striker attaching hole 15 mm (67) Gusset floor rear side gauge hole

(0.59 in) dia.

11.5 mm (0.453 in) dia. (Symmet-

(31) Washer hose attaching hole Left 7 (58) Rear bumper plate nut attaching mm (0.28 in) dia. hole 11 mm (0.43 in) dia. (Sym-

(32) Rear combination light mounting metrical) rical)

(72) Trim upper clip attaching hole 8.5 mm (0.335 in) dia. (Symmetrical) hole 7 mm (0.28 in) dia. (Symmet- (65) Floor mat clip attaching hole 8 mm (77) Harness clip attaching hole 7 mm rical) (0.31 in) dia. (0.28 in) dia. (Symmetrical)

BS-4

3. SEDAN (REAR SECTION)

DATUM POINTS

BODY STRUCTURE

(50)

Repair locator hollow (Vehicle center)

(51) Glass attaching hole Right 6.5 mm

(0.256 in) dia. Left 6.5 x 10 mm

(0.256 x 0.39 in) dia.

(55) Rear combination light mounting hole 8 mm (0.31 in) dia. (Symmet- rical)

(56)

Bumper attaching hole 7 mm

(0.28 in) dia. (Symmetrical)

(58) Rear bumper attaching hole 11 mm (0.43 in) dia. (Symmetrical)

(60) Choke coil harness attaching hole

5.4 mm (0.21 3 in) dia.

(63) Feeder line fixing hole 7 mm (0.28 in). (Symmetrical)

(65) Floor mat clip attaching hole 8 mm

(0.31 in) dia.

(66) Bulkhead rear gauge hole 10 mm

(0.39 in) dia. (Symmetrical)

(67) Gusset floor rear side gauge hole

11.5 mm (0.453 in) dia. (Symmet- rical)

(68)

Rear skirt inner side gauge hole

10 mm (0.39 in) dia. (Symmetri- cal)

(69) Rear panel (reinforcement) repair locator hollow (Vehicle center)

(76)

Press location hole 15 mm (0.59 in) dia. (Symmetrical)

BS-5

BODY STRUCTURE

4.

UNDERBODY SECTION

DATUM POINTS

BOO407

I

Radiator lower frame gauge hole

12 mm (0.47 in) dia. (Symmetri- cal)

Side frame gauge hole 20 mm

(0.79 in) dia. (Symmetrical)

Front crossmember (Ft) attaching hole 12.4 mm (0.488 in) dia.

(Symmetrical)

Suspension attaching hole 17 mm

(0.67

in)

dia. (Symmetrical)

Side frame gauge hole 20 mm

(0.79 in) dia. (Symmetrical)

(85) Transmission mount attaching hole 14 mm (0.55 in) dia.

(90)

(86) Side frame gauge hole 18 mm

(0.71 in) dia. (Symmetrical)

(91

)

(87) Rear differential attaching hole 16 (92) mm (0.63 in) dia. (Symmetrical)

(88) Rear suspension attaching hole (93)

(89) cal)

Rear side frame gauge hole 15 mm (0.59 in) dia. (Symmetrical)

(94)

Strut mount attaching hole 9.5 mm

(0.374 in) dia. (Symmetrical)

Strut mount attaching hole 10 mm

(0.39 in) dia. (Symmetrical)

Sub frame attaching hole 16 mm

(0.63 in) dia. (Symmetrical)

Bumper beam attaching hole

Right 15 mm (0.59 in) dia. Left 19

x

15 mm (0.75 x 0.59 in) dia.

Side frame gauge hole 15 mm

(0.59 in) dia. (Symmetrical)

BS-6

DATUM POINTS

BODY STRUCTURE

BOO408

600409

/

. .

WAGON

BO041

1

\

BS-7

BOO4 1

7

BODY STRUCTURE

WAGON

(72)

WAGON

DATUM POINTS

SEDAN

SEDAN

.I 9

WAGON

SEDAN

BS-8

BO0426

SEDAN

DATUM POINTS

(67)

BOO427

BODY STRUCTURE

1)

BOO433

BOO430

BS-9

BODY STRUCTURE

DATUM POINTS

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 the di- mensions.

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.

Tram tracking gauge

A

...

G5M0122

Measure at the center of the circle around the outside of the body panel.

Datum point

\

Body panel

B5M1133A

BODY STRUCTURE

BS-I 1

BODY STRUCTURE

1. CENTER STRUCTURE

DATUM DIMENSIONS

'1 :

Side sill

BS-12

BO0438

DATUM DIMENSIONS

2. WAGONEEDAN (FRONT STRUCTURE)

BODY STRUCTURE

(5)’

~~~

(1)

LH

to

(90)

to

(90)

(10) (2)

(4)

to

RH to

(3)

LH to

(3)

RH to

(90)

RH to

(2) to

(2)

74)

RH

to (4)

912 (35.91)

912 (35.91)

566 (22.28)

566 (22.28)

581 (22.87)

581 (22.87)

778 (30.63)

778 (30.63)

430 (16.93)

430 (1 6.93)

894 (35.20)

349 (1 3.74)

349 (1 3.74)

720 (28.35)

BOO439 to

(18)

LH

to (1 to

(1

LH

to (1 to

(2) to (4)

RH to

(3)

RH to

(9) to

(8) to (4)

LH to

(4)

-

860 (33.86)

931 (36.65)

931 (36.65)

-

BS-13

BODY STRUCTURE

DATUM DIMENSIONS

I

Point to point Dimension Point to Doint

BO0440

Unit: mm (in)

Dimension

BS-14

DATUM DIMENSIONS

3.

WAGONEEDAN (REAR STRUCTURE)

BODY STRUCTURE

>

\

(58)

~

~

1

(58) RH to (58) LH

(62) RH to (62) LH

(62) RH to (65)

(62) LH to (65)

(62) RH to (73) RH

(62) LH to (73) LH

.

, to (73) LH

(62) LH to (73) RH

(62) RH to (74) RH

(62) LH to (74) LH

(65) to (67) RH

(65) to (67) LH

(65) to (71) RH

(65) to (71) LH

(65) to (74) RH

(65) to (74) LH

~

(65) to (75) RH

(65) to (75) LH

(65) to (91) RH

(65) to (91) LH

1,128 (44.41)

1,332 (52.44)

915 (36.02)

915 (36.02)

762 (30.00)

762 (30.00)

1,561 (61.46)

1,561 (61.46)

592 (23.31) Wagon

603 (23.74) Sedan

1,501 (59.09)

1,501 (59.09)

823 (32.40)

823 (32.40)

1,275 (50.20) Wagon

1,282 (50.47) Sedan

1,450 (57.09)

1,450 (57.09)

1,064 (41.89)

1,064 (41.89)

(67) RH to (67) LH

(67) RH to (91) LH

(67) LH to (91) RH

(70) RH to (70) LH

(70) RH to (73) RH

(70) LH to (73) LH

(70) RH to (73) LH

(70) LH to (73) RH

(70) RH to (75) RH

(70) LH to (75) LH

(70) RH to (91) LH

(70) LH to (91) RH

(71) RH to (71) LH

(71) RH to (74) RH

(71) LH to (74) LH

(74) RH to (74) LH

(74) RH to (74) LH

(75) RH to (75) LH

(91) RH to (91) LH

-

1,110 (43.70)

1,381 (54.37)

1,381 (54.37)

1,060 (41.73)

948 (37.32)

948 (37.32)

1,542 (60.71)

1,542 (60.71)

1,443 (56.81)

1,443 (56.81)

1,532 (60.32)

1,532 (60.32)

1,361 (53.58)

954 (37.56) Wagon

949 (37.36) Sedan

1,135 (44.69) Wagon

1,147 (45.16) Sedan

1,399 (55.08)

1,205 (47.44)

-

BS-15

DATUM DIMENSIONS

BODY STRUCTURE

4. WAGON (FRONT STRUCTURE)

BO0442

Unit: mm

(in\

BS-I 6

5. WAGON (REAR STRUCTURE)

DATUM DIMENSIONS

BODY STRUCTURE

BOO443

Unit: mm (in)

BS-17

BODY STRUCTURE

6.

SEDAN (FRONT STRUCTURE)

DATUM DIMENSIONS

Point to point

(50) to (71) RH

(50) to (71) LH

(60) to (62) RH

(60) to (62) LH

(62) RH to (63) RH

(62) LH to (63) LH

(62) RH to (66) LH

(62) LH to (66) RH

Dimension

1,562 (61

5 0 )

1,562 (61.50)

1,338 (52.68)

1,338 (52.68)

773 (30.43)

773 (30.43)

1,449 (57.05)

1.449 (57.051

Point to point

(63) RH to (65)

(63) LH to (65)

(63) RH to (71) RH

(63) LH to (71) LH

(65) to (66) RH

(65) to (66) LH

(66) RH to (66) LH

-

Dimension

1,118 (44.02)

1,118 (44.02)

1,283 (50.51)

1,283 (50.51)

956 (37.64)

956 (37.64)

840 (33.07)

-

BS-I 8

7.

SEDAN (REAR STRUCTURE)

DATUM DIMENSIONS

BODY STRUCTURE

(56)

Point to point

(50) to (60)

(50) to (65)

\ I .

(51) RH to

I~

,

(51) RH to (60)

(55) RH to (55) LH

(55) RH to (58) LH

(55) LH to (58) RH

(56) RH to (56) LH

(60) to (63) RH

(60) to (63) LH

(63) RH to (63) LH

(65) to (76) RH

~~

T

I

Dimension

501 (19.72)

1.082 (42.601

1.025 (40.35)

734 (28.90)

1,406 (55.35)

1,297 (51.06)

1,297 (51.06)

1,426 (56.1 4)

764 (30.08)

764 (30.08)

1,183 (46.57)

1,544 (60.79)

I

I

Point to point

(65) to (76) LH

(67) RH to (69)

(67) LH to (69)

(68) RH to (68) LH

(68) RH to (69)

(68) LH to (69)

(69) to (76) RH

(69) to (76) LH

(76) RH to (76) LH

-

I

I

BO0445

Unit: mm

(in\

Dimension

1,544 (60.79)

1,581 (62.24)

I

I

1,581 (62.24)

784 (30.87)

784 (30.87)

1,020 (40.16)

681 (26.81)

681 (26.81)

537 (21.14)

537 (21.1 4)

600 (23.62)

-

BS-19

DATUM DIMENSIONS

BS-20

BODY STRUCTURE

-

BS-2

INSTRUMENTATION/DRIVER INFO

1

.

2

.

3

.

4

.

5

.

6

.

7

.

8

.

General Description

Page

....................................................................................

2

Combination Meter System

.........................................................................

4

Combination Meter Assembly

...................................................................

11

Speedometer

Tachometer

.............................................................................................

13

...............................................................................................

14

Fuel Gauge

...............................................................................................

15

Water Temperature Gauge

.......................................................................

16

Ambient Sensor

.........................................................................................

17

.

NSTRUM ENTATION/DRIVE

R INFO

GENERAL DESCRIPTION

1.

General Description

A: SPECIFICATIONS

Speedometer

Temperature qauqe

Fuel gauge

Tachometer

Turn signal indicator light

Charge indicator light

Oil Dressure indicator liaht

ABS warninq liqht

CHECK ENGINE warning light

(Malfunction indicator light)

HI-beam indicator light

Combination meter

Door oDen warnina liaht

~~ ~

Seat belt warnina liaht

Brake fluid and parking brake warning

liaht

I

I

I

I

FWD indicator light

AIRBAG warning light

Meter illumination liaht

AT OIL TEMP. warnina liaht

Security indicator light

Low fuel warning light

AT select lever position indicator light

LCD back light

I

I

Electric pulse type

Thermistor cross coil type

Resistance cross coil type

Electric impulse type

14 V

-

LED

LED

LED

LED

14 V

-

LED

LED

LED

LED

LED

1 4 V - 3 W w , 1 4 V - 2 W

LED

LED

LED

14 V - mA

1 4 V - 1 . 4 W

IDI-2

GENERAL DESCRIPTION

NSTRUM ENTATION/DR

IVE R

INFO

Circuit Tester

TOOL NAME REMARKS

Used for measuring resistance and voltage.

IDI-3

COMBINATION METER SYSTEM

NSTRU

M

ENTATION/D

R IVER IN FO

2.

Combination Meter System

A:

SCHEMATIC

1.

COMBINATION METER

<Ref. to WI-56, SCHEMATIC, Combination

Meter.>

2.

OUTSIDE TEMPERATURE INDICATOR

<Ref. to WI-107, SCHEMATIC, Outside Tempera- ture Display System.>

B: INSPECTION

CAUTION:

When measuring the voltage and resistance of the ECM, TCM, or each sensor, use a tapered pin with a diameter of less the an 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

>ombination meter assembly does not operate.

Speedometer does not operate. rachometer does not operate.

%el gauge does not operate.

Nater temperature gauge does not operate.

3utside temperature indicator does not operate.

~~

ReDair order

(1)

Power supply

(2) Ground circuit

(1)

(MT) Vehicle speed sensor

(AT) Transmission control module

(2)

Harness

(3) Speedometer

(1)

Engine control module

(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, Combi- nation Meter System.>

MT: <Ref. to IDI-6,

CHECK VEHICLE

SPEED SENSOR,

INSPECTION, Combi- nation Meter System.>

AT: <Ref. to IDI-7,

CHECK TRANSMIS-

SION CONTROL MOD-

ULE, INSPECTION,

Combination Meter

System.>

<Ref. to 101-7, CHECK

ENGINE CONTROL

MODULE, INSPEC-

TION, Combination

Meter System.>

<Ref. to IDI-8, CHECK

FUEL LEVEL SEN-

SOR, INSPECTION,

Combination Meter

System.>

<Ref. to IDI-9, CHECK

ENGINE COOLANT

TEMPERATURE SEN-

SOR,

INSPECTION,

Combination Meter

System.>

<Ref. to IDI-10, CHECK

OUTSIDE TEMPERA-

TURE INDICATOR,

INSPECTION, Combi- nation Meter System.>

I DI-4

COMBINATION METER SYSTEM

INSTRUMENTATION/DRIVER INFO

2.

CHECK POWER SUPPLY AND GROUND CIRCUIT

I

Step

Check

TlON METER.

1)Remove the combination meter. <Ref. to

IDI-

1 1, REMOVAL, Combination Meter Assem- bly.>

2)Disconnect the combination meter harness connector.

3)Turn the ignition switch to ON.

4)Measure the voltage between the combina- tion meter connector (i10) and chassis ground.

Connector

&

terminal

(110) No. 7

(+)

-

(-):

CHECK POWER SUPPLY FOR COMBINA-

TION METER.

Is the voltage more than 10 V?

Measure the voltage between the combination meter connector (i10) and chassis ground.

Connector

&

terminal

(i10)

No. 10 (+)

-

(-):

CHECK GROUND CIRCUIT

OF COMBINA-

UON

METER.

1)Turn the ignition switch to OFF.

Is the resistance less than 10 n?

2)Measure the resistance of harness between the combination meter connector (i10) and chassis ground.

Connector

&

terminal tilo) No. 6

-

30

to step

3.

3eplace the com-

)ination meter

Irinted circuit. tion switch and meter.

Check the harness for open or short between the fuse and combination meter.

Repair the wiring harness.

IDI-5

COMBINATION METER SYSTEM

INSTRUMENTATION/DRIVER INFO

3. CHECK VEHICLE SPEED SENSOR

I

?

i

I

Step

CHECK VEHICLE SPEED SENSOR.

1)Set the vehicle on a free roller, or lift-up the vehicle and support it with safety stands.

2)Remove the combination meter with harness connector.

Check

s the voltage less than

1V

-+ more than 4 V?

Warning:

Be careful not to get caught in the running wheels.

3)Drive the vehicle at a speed greater than 20 km/h (12 MPH).

4)Measure the voltage between the combina- tion meter connector (il0) and chassis ground.

Connector & terminal

(i10) No. 2 (+)

-

I (

CHECK VEHICLE SPEED SENSOR POWER

SUPPLY.

1)Turn the ignition switch to OFF.

2)Disconnect the vehicle speed sensor har- ness connector.

3)Turn the ignition switch to

ON.

4)Measure the voltage between the vehicle speed sensor connector

(817) and engine ground.

Connector & terminal

(B 17) No. 3

(+)

-

CHECK HARNESS BETWEEN VEHICLE

SPEED SENSOR AND ENGINE GROUND.

1)Turn the ignition switch to OFF.

2)Measure the resistance between the vehicle speed sensor connector (817) and engine ground.

Connector

&i

(B17) No. 2

-

CHECK HARNESS BETWEEN VEHICLE

SPEED SENSOR AND COMBINATION

METER.

1)Disconnect the connector from the combina- tion meter.

2)Measure the resistance between the vehicle speed sensor harness connector and combi- nation meter harness connector.

Connector & terminal

(B17) NO. 1

-

NO.

2:

s the voltage more than

10 V? s the resistance less than

10

2?

s the resistance less than

10

L?

Yes

;heck the speed-

)meter. <Ref. to

DI-13,

3EMOVAL,

Speedometer.>

;o to step 3.

20

to step

4.

3eplace the vehi-

:le speed sensor.

No

30

to step

2.

;heck the harnesz or open or short letween the igni- ion switch and iehicle speed sen

;or.

3epair the wiring iarness.

3epair the wiring iarness.

I DI-6

I

B

COMBINATION METER SYSTEM

I NSTRU

M

ENTATION/DR IVER

IN FO

!

4. CHECK TRANSMISSION CONTROL MODULE

Step

CHECK TRANSMISSION CONTROL MOD-

ULE SIGNAL.

1)Set the vehicle on a free roller, or lift-up the vehicle and support it with safety stands.

~~

Check

s the voltage less than 1 V

-+ more than

4

V?

Warning:

Be careful not to get caught in the running wheels.

2)Drive the vehicle faster than 10 km/h (6

MPH).

3)Measure the voltage between the transmis- sion control module connector (856: turbo model) or (855: non-turbo model) and chassis ground.

Connector & terminal

Turbo model:

(B56) No.

17

(+)

Non-turbo model:

(B55)

No. 13 (+)

-

CHECK HARNESS BETWEEN TRANSMIS-

SlON CONTROL MODULE AND COMBINA- llON METER.

1)Turn the ignition switch to OFF.

2)Disconnect the connector from the transmis- sion control module and combination meter.

3)Measure the resistance between the trans- mission control module harness connector

(856: turbo model) or (855: non-turbo model) and combination meter harness connector

(il0).

Connector & terminal

Turbo model:

(B56) NO. 17- (i10) NO. 2:

Non-turbo model:

(B55) NO. 13

-

NO.

2:

s the resistance less than

10

R?

50

to step

2.

Check the trans- mission control t

AT-2, Basic Diag- nostic Procedure.>

:heck the speedo neter. <Ref. to

IDI-

3epair the wiring iarness.

3, REMOVAL,

;peedometer.>

5.

CHECK ENGINE CONTROL MODULE

Step

NAL.

1)Start the engine.

Check

CHECK ENGINE CONTROL MODULE SIG-

Is the voltage

0

+-+ more?

2)Measure the voltage between the engine control module connector (B136: turbo model) or (8134: non-turbo model) and engine ground.

Connector & terminal

Turbo model:

(6136) No.

9

Non-turbo model:

(8134) No. 30 (+)

Yes

I

Go to step 2.

No

Check the engine control module.

<Ref. to

EN(S0HC)-2,

Basic Diagnostic

Procedure.> or

<Ref. to

EN(D0HC

TURBO)-2, Basic

Diagnostic Proce- dure.>

IDI-7

COMBINATION METER SYSTEM

INSTRUMENTATION/DRIVER INFO

2

Step Check

CHECK HARNESS BETWEEN COMBINA-

TlON METER AND ENGINE CONTROL MOD-

Is the resistance less than 10

R?

Yes No

Check the tachom- Repair the wiring eter. <Ref. to IDI- harness.

!

I

I

~~~ ~~

Step

~

Check Yes

CHECK FUEL LEVEL SENSOR.

1)Remove the fuel level sensor. <Ref. to fU(SOHC)-62, REMOVAL, Fuel Level Sen- sor.> or <Ref. to FU(D0HC TURBO)-62,

REMOVAL, Fuel Level Sensor.>

2)Measure the resistance between the fuel level sensor terminals when setting the float to

FULL and EMPTY position.

Terminals

NO. 2

-

CHECK FUEL SUB LEVEL SENSOR.

1)Remove the fuel sub level sensor. <Ref. to

FU(SOHC)B3, REMOVAL, Fuel Sub Level

Sensor.> or <Ref. to

FU(D0HC TURBO)-63,

REMOVAL, Fuel Sub Level Sensor.>

2)Measure the resistance between the fuel sub level sensor terminals when setting the float to

FULL and EMPTY position.

Terminals

NO. 1

-

CHECK HARNESS BETWEEN FUEL SUB

LEVEL SENSOR AND COMBINATION

METER.

1)Disconnect the connector from the combina- tion meter.

2)Measure the resistance between the fuel sub level sensor harness connector terminal and combination meter harness connector termi- nal.

Connector

&

terminal

(R59) No. 1

-

CHECK HARNESS BETWEEN FUEL LEVEL

SENSOR AND FUEL SUB LEVEL SENSOR.

. Measure the resistance between the fuel level sensor harness connector terminal and fuel sub level sensor harness connector terminal.

Connector

&

terminal

(R58) NO. 3

-

Is the resistance

0.5 to 2.5 R IGo to step 2.

(FULL) and 50 to 52 R

(EMPTY)?

Is the resistance 0.5 to 2.5 R

(FULL) and 42 to 44

R

(EMPTY)?

Is the resistance less than

10

n?

Is the resistance less than 10 n?

30

to step

3.

30

to step 4.

30

to step 5.

~~ ~

No

Replace the fuel

I

Repair the wiring harness.

I

I

Repair the wiring harness.

IDI-8

COMBINATION METER SYSTEM

INSTRUMENTATION/DRIVER

INFO

I

!

5

Step

Check

CHECK FUEL LEVEL SENSOR GROUND

CIRCUIT.

Measure the resistance between the fuel level sensor harness connector terminal and chas- sis ground.

Connector & terminal

(R58) 2

-

Is the resistance less than 10

a?

1

Yes

Check the fuel gauge. <Ref. to

IDI-15,

REMOVAL, Fuel

Gauge.>

I

No

Repair the wiring harness.

7.

CHECK ENGINE COOLANT TEMPERATURE SENSOR

~ ~~ ~

Step Check Yes

CHECK ENGINE COOLANT TEMPERATURE

Is the engine coolant tempera-

I

Go to step 2.

SENSOR.

ture sensor

OK?

Check the engine coolant temperature sen- sor. <Ref. to EN(S0HC)-120, DTC PO1 17

-

ENGINE COOLANT TEMPERATURE SEN-

SOR CIRCUIT LOW INPUT

-,

Diagnostic

Procedure with Diagnostic Trouble Code

(DTC).> or <Ref. to EN(D0HC TURBO)-126,

DTC PO1 17

-

ATURE SENSOR CIRCUIT LOW INPUT

-,

Diagnostic Procedure with Diagnostic Trouble

Code (DTC).>

CHECK HARNESS BETWEEN ENGJNE

COOLANT TEMPERATURE SENSOR AND

COMBINATION METER.

1)Turn the ignition switch to OFF.

2)Disconnect the connector from the engine coolant temperature sensor and combination meter.

3)Measure the resistance between the engine coolant temperature sensor harness connector

(E8) and combination meter harness connec- tor (i12).

Connector

&

terminal

(E8) No.

-

No.

9:

Is the resistance less than

10

a?

Check the water temperature gauge. <Ref. to

IDI-16,

REMOVAL, Water

Temperature

Gauge.>

No

Replace the

I engine coolant temperature sen- sor.

3epair the wiring iarness.

IDI-9

COMBINATION METER SYSTEM

INSTRUMENTATION/DRIVER

INFO

8.

CHECK OUTSIDE TEMPERATURE INDICATOR

I

!

I

I

Step

CHECK POWER SUPPLY FOR AMBIENT

SENSOR.

1)Turn the ignition switch OFF.

2)Disconnect the connector from the combina- tion meter.

3)Turn the ignition switch ON.

4)Measure the voltage between the combina- tion meter terminal and chassis ground.

Connector & terminal

( i l l ) No. 11

(+)

-

CHECK HARNESS BETWEEN AMBIENT

SENSOR AND COMBINATION METER.

1)Turn the ignition switch OFF.

2)Disconnect the connector from the ambient sensor.

3)Measure the resistance between the ambi- ent sensor harness connector terminal and combination meter harness connector termi- nal.

Connector

(F78)

&

terminal

No. 1

-

No. 11:

(F78)

NO.

2

-

CHECK AMBIENT SENSOR.

1)Remove the ambient sensor.

2)Check the ambient sensor. <Ref. to IDI-17,

INSPECTION, Ambient Sensor.>

CHECK OUTSIDE TEMPERATURE INDICA-

TOR.

1)Connect the combination meter harness connector.

2)Connect a resistor

(2.2 kCl) between the ter- minals of ambient sensor harness connector.

3)Turn the ignition switch ON and check the outside temperature indicator display.

Check

s the voltage more than 4V? s the resistance less than

10

2?

s the ambient sensor OK?

Yes

to step

2. step

3.

20

to step 4.

No

Replace the com- bination meter printed circuit.

Repair the wiring harness.

Replace the ambi- ent sensor. s the outside temperature indi,

:ator indicating

25°C

(77"F)?

Iepair the poor

:ontact of ambient

;ensor harness

:onnector.

Replace the com- bination meter printed circuit.

I DI-IO

3.

COMBINATION METER ASSEMBLY

INSTRUMENTATION/DRIVER INFO

~~

Combination Meter Assem- bly

A: REMOVAL

1) Disconnect the battery ground cable.

2)

Set the tilt steering at the lowest position.

3)

Remove the screws and detach the meter visor.

B:

INSTALLATION

Install in the reverse order of removal.

CAUTION:

Make sure the electrical connector is con- nected securely.

Make sure that each meter operates normally.

4)

Remove the screws of combination meter and pull out the meter toward you.

5 )

Disconnect the connector in the upper area of combination meter to remove the meter.

CAUTION:

Be careful not to damage the meter or instru- ment panel.

Pay particular attention to avoid damaging the meter glass.

IDI-I 1

COMBINATION METER ASSEMBLY

INSTRUMENTATION/DRIVER INFO

C: DISASSEMBLY

CAUTION:

Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces.

1)

Disengage claw (F) to remove case (B) from back cover

(A).

2) Disengage claw (G) to remove meter glass (E), reflector (D) and window plate (C) from inner case.

I

3) Pull up claw

(A)

meter printed circuit in portion

(C)

(B) of combination with combination pliers.

Push out speedometer and tachometer assembly

(D) and fuel gauge and water temperature gauge assembly (E) using hole (F).

4)

Pull up the claw in the center of combination meter printed circuit (C), and remove the combina- tion meter printed circuit from case (G).

1. BULB REPLACEMENT

BOO01 4

(1

)

(2)

(3)

(4)

Tachometer

Speedometer and tachometer

Turn RH

HI-beam

(5)

(6)

(7)

Speedometer

Turn LH

Fuel gauge

( 8 )

Temperature gauge

(9) LCD

(Outside temperature indicator)

(IO)

LCD (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 and tachometer assembly.

<Ref. to IDI-12, DISASSEMBLY, Combination

Meter Assembly.>

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

Measure the speedometer resistance.

INSTRUMENTATION/DRIVER INFO

I

Terminal

SIN+ and

SIN-

1

Resistance

2oM8 R

1

IDI-I

3

TACHOMETER

NSTR

U M

ENTATION/DR IVER INFO

5. Tachometer

A:

REMOVAL

Disassemble the combination meter, and then re- move the speedometer and tachometer assembly.

<Ref. to IDI-12, DISASSEMBLY, Combination

Meter Assembly.>

B: INSTALLATION

Install in the reverse order of removal.

C:

INSPECTION

Measure the tachometer resistance.

Terminal

06M1232A

Resistance

If

NG, replace the speedometer and tachometer assembly.

If OK, replace the combination meter printed circuit.

IDI-I 4

FUEL GAUGE

6.

FuelGauge

A:

REMOVAL

Disassemble the combination meter, and then re- move the water temperature gauge and fuel gauge assembly. <Ref. to IDI-12, DISASSEMBLY, Com- bination Meter Assembly.>

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

Measure the fuel gauge resistance.

INSTRUMENTATION/DRIVER INFO

Terminal

IGN and GND

IGN and UNIT

UNIT and GND

Resistance

If NG, replace the water temperature gauge and fuel gauge assembly.

If

OK,

replace the combination meter printed circuit.

IDI-I 5

WATER TEMPERATURE GAUGE

INSTRUMENTATION/DRIVER INFO

7.

Water Temperature Gauge

A: REMOVAL

Disassemble the combination meter, and then re- move the water temperature gauge and fuel gauge assembly. <Ref. to IDI-12, DISASSEMBLY, Com- bination Meter Assembly.>

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

Measure the water temperature gauge resistance.

B6M1233A

Terminal

IGN and GND

IGN and UNIT

I

UNIT and GND

Resistance

208H R

I

264+10 R

If NG, replace the water temperature gauge and fuel gauge assembly.

If

OK,

replace the combination meter printed circuit.

I

IDI-I 6

AMBIENT SENSOR

8. Ambient

Sensor

A:

REMOVAL

1)

Disconnect the battery ground cable.

2) Disconnect the ambient sensor connector.

3) Remove ambient sensor

(A)

from the radiator lower panel.

NSTRU

M

ENTATION/DR IVE

R IN FO

________c

B: INSTALLATION

Install in the reverse order of removal.

C:

INSPECTION

Measure the ambient sensor resistance.

BOO277

1 and2

2.2 W25"C (77°F)

If NG, replace the ambient sensor.

IDI-I 7

I

NSTRU

M

ENTATION/D

R

IVER

IN FO

AMBIENT SENSOR

IDI-I 8

SEATS

SE

1

.

.

.

General Description

Page

....................................................................................

2

Front Seat

...................................................................................................

6

Rear Seat

..................................................................................................

1

1

.

SEATS

1. General Description

A: COMPONENT

1. FRONT SEAT

GENERAL DESCRIPTION

T

(1)

Front seat ASSY

(2) Rail cover IN

(3)

(4)

Rail cover OUT

Slide rail OUT

(5) Slide rail IN

(6)

Seat hinge

(7)

Seat hinge cover

(8)

(9)

Seat lifter lever

Reclining lever

BOO354

Tightening toque: N.m (kgf-my ft-/&)

T1: 24.5(2.5, 18)

T2: 30 (3.1 22)

T3: 53 (5.4,39)

SE-2

2.

REAR SEAT (SEDAN)

GENERAL DESCRIPTION

SEATS

(1) Backrest

(2) Head restraint

(3)

Cushion

(4)

Arm rest

(5) Center through frame

(6) Hook

Tightening toque: N-m (kgf-m, ft-lb)

T: 24.5(2.5,

18.1)

SE-3

SEATS

3.

REAR SEAT (WAGON)

GENERAL DESCRIPTION

(1)

Cushion

(2) Backrest RH

(3)

Backrest LH

(4)

(5)

Head restraint

Striker

E l

BOO247

Tightening torque: N.m (kgf-m, ft-lb)

T: 24.5 (2.5, 18.1)

S E-4

GENERAL DESCRIPTION

SEATS

Long Nose Pliers

TOOL NAME

REMARKS

Used for removing and installing the hog ring

SE-5

2. Front Seat

FRONT SEAT

8) Remove the two bolts at front side of seat rail.

\

A: REMOVAL

1)

Disconnect the ground terminal from battery.

2) While pressing the headrest lock button, remove the headrest.

H5M0704

3) Tilt forward the backrest.

4)

Move the seat to full front end.

5)

Remove the bolt cover at rear end of slide rail.

9) Disconnect the side airbag connector under the seat. (Side airbag equipped vehicle)

10)

Disconnect the connector of seat belt warning.

BOO1 59

6) Remove the two bolts at rear side of seat rail.

11) Remove the front seat from vehicle.

CAUTION:

When removing the seat from vehicle, take care not to damage body, seat or trim.

B: INSTALLATION

Install in the reverse order of removal.

CAUTION:

Confirm that the seat can move smoothly and be locked securely at any position.

A

BOO1 6C

7)

Move the seat to full rear end.

S E-6

C: DISASSEMBLY

FRONT SEAT

SEATS

6) Turn the cover, and remove the two bolts from hinge.

\

/

1. DRIVER’S SEAT

1) Remove the seat from the vehicle. <Ref. to SE-

6, REMOVAL, Front Seat.>

2) Remove the reclining hinge cover.

BOOl 66

7)

Loosen the bolt and nuts to remove slide rail.

3) Remove the hook at bottom of seat backrest.

4)

Remove the hinge cover and screw.

BOOl 63

” ’

5) Remove the two bolts.

BOO164

BOOl 6;

8) Remove the hog rings, and then remove seat back rest cover.

Without side airbag model:

3

: Hog ring

BOO1 61

S E-7

With side airbag model:

FRONT SEAT

3)

Turn the cover, and remove the two bolts from hinge.

3

: Hog ring e 0 0 3 5 7

9) Remove the hog rings, and then remove the seat cushion cover.

Standard type model:

4)

Remove the hinge screw cover and screw, and remove seat back rest from hinge.

3

: Hog ring

Sporty type model:

B0035€

5)

Remove the reclining lever cover and hinge cov- er.

3

: Hog ring

BO0359

2.

PASSENGER'S SEAT

1) Remove the seat from the vehicle. <Ref. to SE-

6, REMOVAL, Front Seat.>

2) Remove the hook at bottom of seat back rest.

1

B5M0970

SE-8

FRONT SEAT

6) Loosen four bolts to remove the seat cushion.

SEATS

9)

Remove the hog rings, and then remove the seat back rest cover.

Without side airbag model:

With side airbag model:

3

: Hog ring

BOO1 60

B5M096E

7)

Loosen four screws to remove the hinge.

3

: Hog ring

10) Remove the hog rings, and then remove the seat cushion cover.

Standard type model:

8) Loosen two bolts to remove the slide rail.

The lower side of seat rail

3

: Hog ring

1

Sporty type model:

B0035E

3

: Hog ring

BOO359

I

SE-9

FRONT SEAT

SEATS

D: ASSEMBLY

1.

DRIVER’S SEAT

Assemble in the reverse order of disassembly.

NOTE:

Do not contaminate or damage the cover.

While installing the hog rings, prevent the seat from getting wrinkled.

2.

PASSENGER’S SEAT

Assemble in the reverse order of disassembly.

NOTE:

Do not contaminate or damage the cover.

While installing the hog rings, prevent the seat from getting wrinkled.

SEI0

3.

Rear Seat

A: REMOVAL

REAR SEAT

SEATS

2. SEDAN

1)

Remove the bolts, and then detach rear seat cushion.

1. WAGON

1) Remove the bolts, and then detach rear seat cushion.

2) Remove the headrest.

3) Remove the luggage floor mat. <Ref. to El-56,

REMOVAL, Luggage Floor Mat.>

4)

Turn over the mat to remove bolts.

2) Remove the bolts securing lower portion of back- rest and then open the center trunk through lid.

3) Lift the rear seat backrest and then remove it.

5 )

Remove the rear seat backrest.

SE-11

REAR SEAT

SEATS

B: INSTALLATION

1.

WAGON

Install in the reverse order of removal.

2.

SEDAN

1)

Hook and fasten the upper-back side of the rear seat backrest to the body hook.

i

I

2) Remove the hog rings from around the seat backrest.

BOO1

72

3) Remove the hog rings on front side of cushion pad, and then remove the cover.

2) Tighten the bolts.

3) Hook and fasten the seat cushion to the hook on the lower part of the rear seat backrest.

4)

Remove the hog rings from around the seat cushion.

I

I

5 )

Remove the hog rings, and then remove the cov- er.

C: DISASSEMBLY

1.

WAGON

1)

Remove the rear seat. <Ref. to SE-11, WAG-

ON, REMOVAL, Rear Seat.>

SE-12

REAR SEAT

2.

SEDAN

1) Remove the rear seat. <Ref. to SE-11, SEDAN,

REMOVAL, Rear Seat.>

2)

Remove the hog rings from around the seat backrest.

SEATS

D:

ASSEMBLY

1.

WAGON

Assemble in the reverse order

Of disassembly.

NOTE:

Do not contaminate or damage the cover.

While installing the hog rings, prevent the seat from getting wrinkled.

2.

SEDAN

Assemble in the reverse order of disassembly.

NOTE:

Do not contaminate or damage the cover.

While installing the hog rings, prevent the seat from getting wrinkled.

-log ring

BOO 180

I

3) Remove the hog rings, and then remove the seat cover. ring

BOO1

82

4)

Remove the hog rings around the seat cushion.

5) Remove the hog rings, and then remove the seat cover.

I

BO0362

SE-13

SEATS

REAR

SEAT

SE-14

SECURITY AND LOCKS

Sf

19

.

20

.

21 .

22

.

23

.

24

.

25

.

26 .

27

.

28

.

6 .

7

.

8

.

9

.

10

.

11

.

1

.

2

.

3

.

4

.

5

.

12

.

13

.

14

.

15

.

16

.

17

.

18

.

General Description

....................................................................................

2

Door Lock Control System

..........................................................................

8

Keyless Entry System

Security System

...............................................................................

12

........................................................................................

21

Front Inner Remote

...................................................................................

28

Front Outer Handle

...................................................................................

29

Front Door Latch Assembly

.......................................................................

30

Front Door Lock Actuator

..........................................................................

31

Rear Inner Remote

....................................................................................

32

Rear Outer Handle

....................................................................................

33

Rear Door Latch Assembly

.......................................................................

34

Rear Door Lock Actuator

Rear Gate Outer Handle

...........................................................................

35

...........................................................................

36

Rear Gate Latch Assembly

.......................................................................

37

Rear Gate Latch Lock Actuator

.................................................................

38

Trunk Lid Lock Assembly

..........................................................................

39

Trunk Lid Release Handle

.........................................................................

40

Front Hood Lock Assembly

.......................................................................

41

Remote Openers

Ignition Key Lock

.......................................................................................

42

.......................................................................................

43

Key Lock Cylinders

...................................................................................

44

Security Control Module

Security Horn

............................................................................................

Security Horn Relay

............................................................................

45

46

..................................................................................

47

Interrupt Relay

...........................................................................................

48

Keyless Entry Control Module

...................................................................

49

Integrated Module

.....................................................................................

50

Keyless Transmitter

..................................................................................

51

I

SECURITY AND LOCKS

1. General Description

A: COMPONENT

1. DOOR LOCK ASSEMBLY

GENERAL DESCRIPTION

FRONT

(4)

(1) Inner remote ASSY

(2) Inner remote cover

( 3 )

Bell crank

(4)

Auto-door lock actuator

( 5 )

Door latch

(6) Striker

(7) Door outer handle

(8)

Key cylinder

BOO397

Tightening torque: N.m (kgf-m, ft-lb)

T l : 6.4 (0.65, 4.7)

T2: 7.4 (0.75, 5.4)

T3: 14 (1.4, 10.1)

SL-2

GENERAL DESCRIPTION

2.

TRUNK LID AND REAR GATE LOCK

TRUNK

REAR GATE

SECURITY AND LOCKS

5

‘(8)

(1) Key cylinder

(2) Cable

(3) Striker

(4)

Trunk lid lock ASSY

(5) Rear gate outer handle

(6)

Rear gate actuator

( 7 )

Trunk lid release handle

( 8 )

Rear gate latch

B0032E

Tightening torque: N.m (kgf-m, ff-lb)

T1: 4.5 (0.46, 3.3)

T2: 18 (1.84, 13.3)

T3: 25 (2.5, 18.1)

s

L-3

GENERAL DESCRIPTION

SECURITY AND LOCKS

3. HOOD LOCK AND REMOTE OPENERS

(1) Hood lock ASSY

(2) Lever ASSY

(3) Cable

(4)

Cover

(5)

Pull handle ASSY

BO0244

Tightening torque: N.m (kgf-m, ft-lb)

T1: 6.4 (0.65, 4.7)

T2: 32 (3.3, 23.9)

SL-4

4.

KEYLESS ENTRY SYSTEM

GENERAL DESCRIPTION

SECURITY AND LOCKS

(1)

Keyless entry control module

(2) Rear gate latch switch (Wagon)

(3)

Door switch

(4) Integrated module

SL-5

SECURITY AND LOCKS

5.

SECURITY SYSTEM

GENERAL DESCRIPTION

BO031

0

(1) Horn

(2) Security horn

(3)

Security control module

( 5 )

Trunk room light switch (Sedan), rear gate latch switch (Wagon)

(6)

Door switch

(4) Security indicator light (in combi-

(7) Keyless entry control module nation meter)

.

CAUTION

Before disassembling or reassembling the parts, always disconnect the battery ground cable. When repairing the radio, control module, etc. which are provided with memory functions, record the memory contents before disconnecting battery ground cable.

Otherwise, these contents are cancelled upon disconnection.

Reassemble the parts in the reverse order of disassembly procedure unless otherwise indicated.

Adjust the parts t o the specifications contained in this manual if so designated.

Connect the connectors and hoses securely during reassembly.

After reassembly, ensure the functional parts operate smoothly.

The airbag system wiring harness is routed near the electrical parts and switch.

(8) Passive arm connector

(9)

Security horn relay

(1 0)

Interrupt relay

(1 1) Horn relay (in main fuse box)

All airbag system wiring harness and

COnneCtOrS are colored yellow. DO not Use the electrical test equipment on these circuits.

Be careful not to damage the Airbag system

Wiring harness when Servicing the ignition key cylinder-

SL-6

C: PREPARATION TOOL

1.

SPECIAL TOOLS

GENERAL DESCRIPTION

925580000

PULLER

SECURITY AND LOCKS

Used for removing trim clip

B5M1120

2.

GENERAL TOOLS

TOOL NAME

Circuit Tester

Drill

REMARKS

Used for measuring resistance and voltage.

Used for replacing ignition key lock.

SL-7

DOOR LOCK CONTROL SYSTEM

SECURITY AND LOCKS

2. Door

Lock

Control System

A: SCHEMATIC

1. DOOR

LOCK CONTROL

<Ref.

to

WI-64, SCHEMATIC, Door Lock System.>

SL-8

DOOR LOCK CONTROL SYSTEM

SECURITY AND LOCKS

B: INSPECTION

1. SYMPTOM

CHART

Symptom

The door lock control system does lot operate.

The driver side or passenger side door lock switch does not operate.

1. Check the fuse.

Reoair order

2.

Check the power supply and ground circuit for the integrated module.

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.

A

specific door lock actuator does not operate.

Check the door lock actuator and the circuit.

~

Reference

<Ref. to SL-9, CHECK FUSE,

INSPECTION, Door Lock Control

Svstem.>

<Ref. to SL-IO, CHECK POWER

SUPPLY AND GROUND CIRCUIT,

INSPECTION, Door Lock Control

System.>

<Ref. to SL-10, CHECK DOOR

LOCK SWITCH AND CIRCUIT,

INSPECTION, Door Lock Control

System.>

<Ref. to SL-11, CHECK DOOR

LOCK ACTUATOR AND CIRCUIT,

INSPECTION, Door Lock Control

System. >

<Ref. to SL-IO, CHECK DOOR

LOCK SWITCH AND CIRCUIT,

INSPECTION, Door Lock Control

System.>

<Ref. to SL-11, CHECK DOOR

LOCK ACTUATOR AND CIRCUIT,

INSPECTION, Door Lock Control

System.>

2.

CHECKFUSE

1

Step

CHECK FUSE.

Remove and visually check the fuse No. 2 (in the main fuse box) and No. 3 (in the fuse and relay box).

Check

Is the fuse blown (15A)?

Yes

Replace the fuse with a new one.

No

Check the power supply and ground circuit. <Ref. to

SL-IO, CHECK

POWER SUPPLY

AND GROUND

CIRCUIT,

INSPECTION,

Door Lock Control

System.>

SL-9

DOOR LOCK CONTROL SYSTEM

SECURITY AND LOCKS

3.

CHECK POWER SUPPLY AND GROUND CIRCUIT

I

1

2

Step

CHECK POWER SUPPLY.

1 )Disconnect the integrated module harness connector.

2)Measure the voltage between the harness connector terminal and chassis ground.

Connector & terminal

(6281)

No. 1

(+)

-

(6281) No. 2

(+)

-

(-):

CHECK GROUND CIRCUIT.

Measure the resistance between the harness connector terminal and chassis ground.

Connector & terminal

(6281) No. 4, 13

-

Check

s the voltage more than 10

V?

s the resistance less than 10

2?

is OK.

4.

CHECK DOOR LOCK SWITCH AND CIRCUIT

!

I

I for open circuits or shorts between the integrated module and the fuse.

Step

CHECK DOOR LOCK SWITCH CIRCUIT.

1 )Disconnect the integrated module harness connector.

2)Measure the resistance between the har- ness connector terminal and chassis ground when moving the door lock switch to LOCK.

Connector & terminal

Driver side:

(6280) No. 12

Passenger side:

(6280) No. 12

-

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.

Connector & terminal

Driver side:

(6280) No. 11

Passenger side:

(6280) No. 11

-

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.

Terminal

Driver side: No. 5

-

Passenger side: No. 5

9:

-

4:

CHECK DOOR LOCK SWITCH.

Measure the resistance between the door lock switch terminals when moving the door lock switch to UNLOCK.

Terminal

Driver side: No. 5

-

Passenger side:

No.

5

8:

-

2:

Check

the resistance less than 10

?

Yes

30

to step

2.

the resistance less than 10

? the resistance less than 1

? the resistance less than 1

>

30

to step

4.

No

Go to step

3.

switch is OK.

Replace the door lock switch.

;heck the harness Replace the door or open circuits or lock switch. shorts between he integrated nodule and the loor lock switch.

SL-10

DOOR LOCK CONTROL SYSTEM

SECURITY

AND

LOCKS

5.

CHECK DOOR LOCK ACTUATOR AND CIRCUIT

1

2

3

~

Step

Check

Yes

No

CHECK OUTPUT SIGNAL.

Measure the voltage between the harness con-

Is the voltage more than 10 V? nector terminal and chassis ground when mov- ing the door lock switch to LOCK.

connector & terminal

(8281)

No.

6

(+)

-

CHECK OUTPUT SIGNAL.

Measure the voltage between the harness con- nector terminal and chassis ground when mov- ing the door lock switch to UNLOCK.

Is the voltage more than 10 V? Go to step

3.

Connector & terminal

(8291) No. 7, 8

(+)

-

CHECK DOOR LOCK ACTUATOR.

Check the door lock actuator.

Front door lock actuator: <Ref. to SL-31, Front

Door Lock Actuator.>

Rear door lock actuator: <Ref. to SL-35, Rear

Door Lock Actuator.>

Rear gate latch lock actuator: <Ref. to SL-38,

Rear Gate Latch Lock Actuator.>

Is the door lock actuator OK?

Go to step 2.

Replace the inte- grated module.

Replace the inte- grated module.

Check the harness for open circuits

01

shorts between the integrated module and the door lock actuator.

Replace the door lock actuator.

SL-11

KEYLESSENTRYSYSTEM

SECURITY AND LOCKS

3. Keyless Entry System

A: SCHEMATIC

1.

KEYLESS ENTRY

<Ref. to WI-90, SCHEMATIC, Keyless Entry Sys- tem.>

B: ELECTRICAL SPECIFICATION

1.

KEYLESS ENTRY CONTROL MODULE

Inl

1 7 6

5 4 '

I I I I I I

1

I

'

3 2

Inl

I

I

1 ' 1

I I

Content

Integrated module

Power supply (Back-up)

Door lock switch

Trunk room light switch (Sedan), rear gate latch switch (Wagon)

Ground

Integrated module

Security control module

Securitv control module

Horn relay

Ignition switch (ON)

Door unlock switch

Key warning switch

Terminal No.

3

(OUTPUT)

5 (INPUT)

Measuring condition

Battery voltage is present when pressing the transmitter LOCWARM button one time.

Battery voltage is constantly present.

0 V is present when operating the door lock switch.

6 (INPUT)

0 V is present when opening the trunk lid or rear gate.

8

(OUTPUT)

110

I 1 1

l 2

(OUTPUT)

0 V is constantlv Dresent.

I ,

I

I

Battery voltage is present when pressing the transmitter UNLOCWDIS-

ARM button one time.

-

-

I

I

0 V is present when pressing the transmitter UNLOCWDISARM or

LOCWARM button. p-ppI

I

14

(INPUT)

I

Battery voltaqe is present when ianition switch is turned ON.

I

15 (INPUT)

I

0 V is present when operating the door lock switch.

I

16 (INPUT)

I

Battery voltage is present when inserting the key into the ignition switch.

I

I

SL-12

2.

INTEGRATED MODULE

KEYLESSENTRYSYSTEM

SECURITY AND LOCKS

1 0 9

8 7 6 5

4 3

2

1

20 19 18 17 1 6 15 14 13

12

11

BOO31 1

Content

Door switch (Except driver's door)

Door switch (Driver's door)

Door unlock switch

Door lock switch

Keyless entry control module

Keyless entry control module

Ignition switch (ON)

Key warning switch

Power

SUPP~V

Power supply

Ground

Room light

Door and rear gate lock actuator

Door and rear gate lock actuator

(Except driver side)

Door lock actuator (Driver side)

Ground

Terminal No.

A7 (INPUT)

Measuring condition

0

V

is present when any door is open (Except driver's door).

0

V

is present when driver's door is open.

A8 (INPUT)

A1 1 (INPUT) 0

V

is present when operating the door lock switch.

I

A12 (INPUT)

I

0 V is present when operating the door lock switch.

I

A13

I

-

A14

-

A19 (INPUT) Battery voltage is present when iginition switch is turned ON.

A20 (INPUT)

B1

I

82

B4

85 (OUTPUT)

Battery voltage is present when inserting the key into ignition switch.

Battery voltage is constantly present.

I

Battery voltage is constantly present.

0

V

is constantly present.

0

V

is present when pressing the transmitter UNLOCWDISARM button one time*

B6 (OUTPUT)

B7 (OUTPUT)

B8 (OUTPUT)

1813

Battery voltage is present when pressing the transmitter LOCWARM button one time.

Battery voltage is present when pressing the transmitter UNLOCWDIS-

ARM button two times.

Battery voltage is present when pressing the transmitter UNLOCWDIS-

ARM button one time.

I o

v

is constantly present.

SL-13

KEYLESSENTRYSYSTEM

SECURITY AND LOCKS

C: INSPECTION

1.

SYMPTOM CHART

Symptom

None of the functions of the keyless entry system operate.

The transmitter cannot be pro- grammed.

The door lock or unlock does not operate.

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 panic alarm does not operate.

2.

2.

3.

Check the fuse.

Repair order

1. Check the transmitter battery and function.

3. Check the keyless entry control module power supply and ground circuit.

4. Replace the keyless entry control module.

1. Check the transmitter battery and function.

Check the ignition switch circuit.

Check the door switch.

4. Replace the keyless entry control module.

1. Check the transmitter battery and function.

2. Check the key warning switch.

3. Check the door switch.

4. Check the output signal to integrated module.

5.

Replace the keyless entry control module.

1. Check the transmitter battery and function.

2.

3.

Check the horn operation.

Replace the keyless entry control module.

Reference

<Ref. to SL-16, CHECK TRANSMIT-

TER BATTERY AND FUNCTION,

INSPECTION, Keyless Entry Sys- tem.>

<Ref. to SL-17, CHECK FUSE,

INSPECTION, Keyless Entry Sys- tem.>

<Ref. to SL-17, CHECK POWER

SUPPLY AND GROUND CIRCUIT,

INSPECTION, Keyless Entry Sys- tem.>

<Ref. to SL-49, Keyless Entry Control

Module.>

<Ref. to SL-16, CHECK TRANSMIT-

TER BATTERY AND FUNCTION,

INSPECTION, Keyless Entry Sys- tem.>

<Ref. to SL-17, CHECK IGNITION

SWITCH CIRCUIT, INSPECTION,

Keyless Entry System.>

<Ref. to SL-18, CHECK DOOR

SWITCH, INSPECTION, Keyless

Entry System.>

<Ref. to SL-49, Keyless Entry Control

Module.>

<Ref. to SL-16, CHECK TRANSMIT-

TER BATTERY AND FUNCTION,

INSPECTION, Keyless Entry Sys- tem.>

<Ref. to SL-19, CHECK KEY WARN-

ING SWITCH, INSPECTION, Keyless

Entry System.>

<Ref. to SL-18, CHECK DOOR

SWITCH, INSPECTION, Keyless

Entry System.>

<Ref. to SL-20, CHECK OUTPUT

SIGNAL TO INTEGRATED MOD-

ULE, INSPECTION, Keyless Entry

System .>

<Ref. to SL-49, Keyless Entry Control

Module.>

<Ref. to SL-16, CHECK TRANSMIT-

TER BATTERY AND FUNCTION,

INSPECTION, Keyless Entry Sys- tem.>

<Ref. to SL-19, CHECK HORN

OPERATION, INSPECTION, Key- less Entrv Svstem.>

<Ref. to SL-49, Keyless Entry Control

Module.>

SL-14

KEYLESSENTRYSYSTEM

SECURITY AND LOCKS

Symptom

The horn chirp does not operate.

The room light operation does not activate.

The door warning does not operate.

Repair order

1. Check the horn chirp function.

2. Check the transmitter battery and function.

3.

4.

5.

Check the key warning switch.

Check the door switch.

Check the horn operation.

6. Replace the keyless entry control module.

1. Check the transmitter battery and function.

2. Check the room light operation.

3. Check the key warning switch.

4. Check the door switch.

5.

Check the output signal to integrated module.

6. Replace the keyless entry control module.

1. Check the transmitter battery and function.

2. Check the door switch.

3. Check the horn operation.

4. Replace the keyless entry control module.

Reference

<Ref. to SL-16, CHECK HORN

CHIRP SETTING, INSPECTION,

Keyless Entry System.>

<Ref. to SL-16, CHECK TRANSMIT-

TER BATTERY AND FUNCTION,

INSPECTION, Keyless Entry Sys- tem.>

<Ref. to SL-19, CHECK KEY WARN-

ING SWITCH, INSPECTION, Keyless

Entrv Svstem.>

<Ref. to SL-18, CHECK DOOR

SWITCH, INSPECTION, Keyless

Entry System.>

<Ref. to SL-19, CHECK HORN

OPERATION, INSPECTION, Key- less Entry System.>

<Ref. to SL-49, Keyless Entry Control

Module.>

<Ref. to SL-16, CHECK TRANSMIT-

TER BATTERY AND FUNCTION,

INSPECTION, Keyless Entry Sys- tem.>

<Ref. to SL-20, CHECK ROOM

LIGHT OPERATION, INSPECTION,

Keyless Entry System.>

<Ref. to SL-19, CHECK KEY WARN-

ING SWITCH, INSPECTION, Keyless

Entrv Svstem.>

<Ref. to SL-18, CHECK DOOR

SWITCH, INSPECTION, Keyless

Entry System.>

<Ref. to SL-20, CHECK OUTPUT

SIGNAL TO INTEGRATED MOD-

ULE, INSPECTION, Keyless Entry

System.>

<Ref. to SL-49, Keyless Entry Control

Module.>

<Ref. to SL-16, CHECK TRANSMIT-

TER BATTERY AND FUNCTION,

INSPECTION, Keyless Entry Sys- tem.>

<Ref. to SL-18, CHECK DOOR

SWITCH, INSPECTION, Keyless

Entry System.>

<Ref. to SL-19, CHECK HORN

OPERATION, INSPECTION, Key- less Entry System.>

<Ref. to SL-49, Keyless Entry Control

Module.>

SL-15

I

KEYLESSENTRYSYSTEM

SECURITY AND

LOCKS

2.

CHECK TRANSMllTER BATTERY AND FUNCTION

1

2

3

4

5

Step

CHECK TRANSMITTER BATTERY.

1)Remove the battery from the transmitter.

<Ref. to SL-51, REMOVAL, Keyless Transmit- ter.>

2)Check the battery voltage. <Ref. to SL-51,

INSPECTION, Keyless Transmitter.>

Check

Is the voltage more than 2 V?

CHECK LED OF TRANSMITTER.

1)Press the LOCWARM or UNLOCWDISARM button six times to synchronize with the key- less entry control module.

2)Press the LOCWARM button.

Does the LED blink one time?

CHECK LED OF TRANSMITTER.

Keep the LOCWARM button pressed.

Does the LED blink one time and then turn on?

I

CHECK LED OF TRANSMITTER.

Press the UNLOCWDISARM button.

CHECK LED OF TRANSMITTER.

Keep the UNLOCWDISARM button pressed.

Does the LED blink one time?

Yes

Go to step

2.

Go to step

Go to step

3.

Go to step

4.

5.

Does the LED blink two times? The transmitter is

OK.

No

Replace the trans- mitter battery.

I

Replace the trans- mitter. <Ref. to SL-

51, REPLACE-

MENT, Keyless

Transmitter.>

Replace the trans- mitter. <Ref. to SL-

51, REPLACE-

MENT, Keyless

Transmitter.>

Replace the trans- mitter. <Ref. to SL-

51, REPLACE-

MENT, Keyless

Transmitter.>

Replace the trans- mitter. <Ref. to SL-

51, REPLACE-

MENT, Keyless

Transmitter.>

1

2

3.

CHECK HORN CHIRP SETTING

Step

CHECK HORN CHIRP SETTING.

Check the current setting of the horn chirp.

1)Remove the key from the ignition switch.

2)Close all doors and the rear gate or trunk lid.

3)Press the LOCWARM or UNLOCWDISARM

I

I

I

I

Does the horn signal chirp? lThe horn chirp IGo to step

2.

I

I

Check Yes

function is OK.

No

I button.

The horn chirp function is OK.

CHECK HORN CHIRP SETTING.

1)Press the UNLOCWDISARM button once.

2)Press both the LOCWARM and UNLOCK/

DISARM button for more than 2 seconds.

3)Press the LOCWARM or UNLOCWDISARM button.

Does the horn signal chirp?

Check the trans- mitter function.

<Ref. to SL-16,

CHECK TRANS-

MITTER BAT-

TERY AND

FUNCTION,

INSPECTION,

Keyless Entry Sys- tem.>

SL-16

KEYLESSENTRYSYSTEM

SECURITY AND LOCKS

4.

CHECKFUSE

1

Step

CHECK FUSE.

Remove and visually check the fuse No. 2 (in the main fuse box)

Check

Is the fuse blown? (1 5 A)

Yes

Replace the fuse with a new one.

No

Check the power supply and ground circuit. <Ref. to

SL-17, CHECK

POWER SUPPLY

AND

GROUND

CIRCUIT, Keyless

Entry System.>

5.

CHECK POWER SUPPLY AND GROUND CIRCUIT

1

2

Step Check Yes

CHECK POWER SUPPLY.

1)Disconnect the keyless entry control module

Is the voltage more than 10 V? harness connector.

2)Measure the voltage between the harness connector terminal and chassis ground.

Connector & terminal

(B176) No. 3

(+)

-

(-):

Go to step 2.

CHECK GROUND CIRCUIT.

Measure the resistance between the harness connector terminal and chassis ground.

Connector & terminal

(8176)

No.

- and ground circuit are OK.

No

Check the harness for open circuits and shorts between the key- less entry control module and fuse.

Repair the har- ness.

6. CHECK IGNITION SWITCH CIRCUIT

1

Step

CHECK IGNITION SWITCH SIGNAL.

1)Disconnect the keyless entry control module harness connector.

2)Turn the ignition switch ON.

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

Connector & terminal

(61 76) No.

14

(+)

-

Check Yes No

Is the voltage more than 10 V? The ignition switch circuit is OK.

Check the harness for open circuits and shorts between the key- less entry control module and igni- tion relay.

SL-17

KEYLESS ENTRY SYSTEM

SECURITY AND LOCKS

7. CHECK

DOOR

SWITCH

I

1

Step

CHECK DOOR SWITCH CIRCUIT.

Measure the voltage between the keyless entry control module harness connector terminal and chassis ground.

Connector & terminal

Front and rear door:

-

Rear gate or trunk lid:

(61

Check

s the voltage 0 V when each joor, rear gate and trunk lid is

Ipened?

CHECK DOOR SWITCH CIRCUIT.

Measure the voltage between the keyless entry control module harness connector terminal and chassis ground.

Connector & terminal

Front and rear door:

(61

Rear gate or trunk lid:

No.

(+)

-

CHECK DOOR SWITCH.

1)Disconnect the door switch harness connec- tor.

2)Measure the resistance between the door switch terminals.

Terminal

Front LH No.

1

-

Front RH No.

1

-

Rear LH No. 1

-

Rear RH No. I

-

Rear gate No.

1

-

2:

Trunk lid No. 1

-No.

2:

CHECK DOOR SWITCH.

Measure the resistance between the door switch terminals.

Terminal

Front LH No.

1

-No. 3:

Front RH No.

Rear LH No.

1

1

-

-

Rear RH No. 1 -No. 3:

Rear gate

No.

1

-

2:

Trunk lid No. 1

-

2:

s the voltage approx. 10 V

Nhen each door, rear gate and runk lid is closed? s the resistance more than 1 vlR when the door switch is iushed? s the resistance less than 1 C2

Nhen the door switch is

.eleased?

Yes

;o to step 2.

The door switch is

IK.

20

to step 4.

No

20

to step

3.

30

to step

3.

3eplace the door

;witch.

:heck the harness or open circuits md shorts

)etween the key- ess entry control nodule and door

;witch.

3eplace the door

;witch.

SL-18

KEYLESSENTRYSYSTEM

SECURITY AND LOCKS

8.

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 KEY WARNING SWITCH CIRCUIT.

1)Disconnect the keyless entry control module harness connector.

2)lnsert the key into the ignition switch. (LOCK position)

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

Connector & terminal

(8176) No. 16

(+)

-

CHECK KEY WARNING SWITCH CIRCUIT.

1)Remove the key from the ignition switch.

2)Measure the voltage between the harness connector terminal and chassis ground.

Connector & terminal

(B176) No. 16

(+)

-

CHECK KEY WARNING SWITCH.

1)Disconnect the key warning switch harness connector.

2)lnsert the key into the ignition switch. (LOCK position)

3)Measure the resistance between the key warning switch terminals.

Terminal

NO.

1

-

CHECK KEY WARNING SWITCH.

1)Remove the key from the ignition switch.

2)Measure the resistance between the key warning switch terminals.

Terminal

NO. 1

-

2:

Check

s the fuse blown? (15A)

Yes

Replace the fuse with a new one. s the voltage more than 10 V?

Go to step

3.

s the voltage 0 V? s the resistance less than 1

2?

Cthe resistance more than 1

m?

The key warning switch is OK.

Go to step 5.

Check the following:

Harnessfor open circuits and shorts between the key warning switch and fuse

Harness for open circuits and shorts between the keyless entry control module and key warning switch

No

So to step 2.

So to step

4.

Go to step 4.

Replace the key warning switch.

Replace the key warning switch.

9.

CHECK HORN OPERATION

1

2

Step Check

CHECK HORN OPERATION.

Make sure the horn sounds when the horn switch is pushed.

CHECK HORN OPERATION.

1)Disconnect the keyless entry control module harness connector.

2)Ground the harness connector terminal with

Does the horn sound?

Does the horn sound? a suitable wire.

Connector & terminal

(B176)

No. 12

-

Yes

Go to step 2.

No

Check the horn cir. cuit.

Replace the key- less entry control module.

Check the harness for open circuits and/or shorts between the key- less entry control module and horn relay.

SL-19

KEYLESSENTRYSYSTEM

SECURITY AND LOCKS

10.CHECK ROOM LIGHT OPERATION

1

2

Step

CHECK ROOM LIGHT OPERATION.

Make sure the room light illuminates when the room light switch is turned ON.

Check

Yes

Does the room light illuminate?

Go to step 2.

CHECK HARNESS BETWEEN ROOM LIGHT

AND INTEGRATED MODULE.

1)Disconnect the integrated module harness connector and room light harness connector.

2)Measure the resistance between the inte- grated module harness connector terminal and the room light harness connector terminal.

Connector & terminal

(6281) NO. 5

-

Is resistance less than 10

Q?

No

Check the room

The room light operation circuit is

OK.

Check the harness for open circuits and/or shorts between the inte- grated module and room light.

1

2

3

Step

Check

Yes

CHECK OUTPUT SIGNAL.

Measure the voltage between the keyless entry control module harness connector terminal and chassis ground when UNLOCWDISARM button of transmitter is pressed.

Connector & terminal

(61 76)

No.

(+)

-

(-):

Is the voltage more than 10 V?

Go to step 2.

CHECK OUTPUT SIGNAL.

Measure the voltage between the keyless entry control module harness connector terminal and chassis ground when LOCWARM button of transmitter is pressed.

Connector & terminal

(61 76) No.

(+)

Is the voltage more than 10 V?

Go to step

3.

CHECK HARNESS BETWEEN KEYLESS EN-

TRY CONTROL MODULE AND INTEGRAT-

Is the resistance less than 10 n?

ED MODULE.

1)Disconnect the keyless entry control module harness connector and integrated module har- ness connector.

2)Measure the resistance between the keyless entry control module harness connector termi- nal and integrated module harness conector terminal.

Connector & terminal

(61 76) NO.

(61 76)

NO.

-

-

No

Replace the key- less entry control module.

Replace the key- less entry control module. shorts between the keyless entry control module and integrated module.

s

L-20

SECURITY SYSTEM

4. Security System

A: SCHEMATIC

<Ref. to

WI-121,

Security System.>

B: ELECTRICAL SPECIFICATION

SECURITY AND LOCKS

U

06M0972

Content

Empty

Ignition switch (ON)

Passive arm

Trunk room light switch (Sedan), rear gate latch switch (Wagon)

Door switch

Empty

Keyless entry control module

Keyless entry control module

Securitv indicator liaht

Kevless entry control module

Power supply for clearance light

(Back-uo\

I - - r,

Clearance light

Power SUDDIV

Ground--

Interrupt relay

Security horn relay

Security horn

Securitv horn relav

I

Terminal No.

I

1

2 (INPUT)

3

Measuring condition

-

Battery voltage is present when ignition switch is turned ON.

-

(INPUT)

5

(INPUT)

6

7

8

9 (OUTPUT)

I

10

0 V is present when trunk room light switch or rear gate latch switch is turned ON.

0 V is present when any door is open.

-

-

-

0 V is Dresent when activating the alarm operation.

I

I

Battery voltage is constantly present.

-

12 (OUTPUT)

13

114

15

(OUTPUT)

16 (INPUT)

Battery voltage is present when activating the alarm operation.

Batterv voltaae is constantlv Dresent.

I o v is constantly present.

Battery voltage is present when activating the alarm operation.

Battery voltage is present when activating the alarm operation.

17 (OUTPUT)

18

(INPUT)

Battery voltage is present when activating the alarm operation.

Batterv voltaae is Dresent when activatina the alarm operation.

SL-21

I

SECURITY SYSTEM

SECURITY AND LOCKS

C: INSPECTION

1.

BASIC DIAGNOSTIC PROCEDURE

Step

CHECK SECURITY SYSTEM SET OPERA-

TION.

1)Before starting this diagnosis, open all win- dows.

2)Remove the key from ignition key cylinder, and then close all doors and rear gate or trunk lid.

3)Press the LOCWARM button of transmitter.

Check

Can the security system be set?

Yes

Go to step 2.

No

Go to symptom 1.

<Ref. to SL-23,

SYMPTOM

CHART, INSPEC-

TION, Security

System.>

CHECK SECURITY INDICATOR LIGHT AND

CLEARANCE LIGHT BLINKING.

Check the security indicator light and clear- ance light blinking.

Do the security indicator light and clearance light blink?

CHECK SECURITY ALARM OPERATION.

1)Unlock all doors using the door lock switch on front door.

2)Open any door, rear gate or trunk lid.

I

Does the security system not alarm when one of the doors is opened?

Go to step

3.

Go to symptom 2.

<Ref. to SL-23,

SYMPTOM

CHART, INSPEC-

TION, Security

System.>

Go to symptom 3.

<Ref. to SL-23,

SYMPTOM

CHART, INSPEC-

TION, Security

System.>

Go to step

4.

CHECK SECURITY ALARM OPERATION.

Check the security alarm operation.

Does the security alarm (horn, clearance light and security indicator light) operate? And is the starter motor deactivated?

Go to step 5.

CHECK SECURITY ALARM CANCEL OPER-

Does the security alarm (horn

ATION.

Press the UNLOCWDISARM button of trans- and clearance light) stop? And is the starter motor activated? mitter.

Go to step 6.

CHECK BATTERY DISCONNECT PROTEC-

TION.

Check the battery disconnect protection. <Ref. to SL-22, CHECK BATTERY DISCONNECT

PROTECTION, INSPECTION, Security Sys- tem.>

Is the battery disconnect pro- tection OK?

Go to step 7.

PERFORM IMPACT SENSITIVITY TEST.

Perform the impact sensitivity test. <Ref. to SL-

Is the impact sensitivity OK?

Press the

45, IMPACT SENSITIVITY TEST, INSPEC-

TION, Security Control Module.> transmitter, and finish the diagno- sis.

Go to symptom 4.

<Ref. to SL-23,

SYMPTOM

CHART, INSPEC-

TION, Security

System .>

Go to symptom 5.

<Ref. to SL-23,

SYMPTOM

CHART, INSPEC-

TION, Security

System.

>

Replace the secu- rity control mod- ule.

Replace the secu-

2.

CHECK BATTERY DISCONNECT PROTECTION

1) Remove the key from the ignition switch. If NG, replace the security control module.

2) Close all the doors and rear gate or trunk lid.

3)

Open the front hood.

4) Press the LOCWARM button of the transmitter.

5) Disconnect the ground cable from the battery.

6)

Reconnect the cable to the battery.

7)

Check that the security indicator light blinks after reconnecting the battery cable.

s

L-22

SECURITY SYSTEM

SECURITY AND LOCKS

3. SYMPTOM CHART

activate.

SvmDtom

The security system cannot be set.

The security system can be set, but the security indicator light or clearance light does not blink.

The security system does not alarm when one of the door is opened.

The security alarm does not

The security system cannot be canceled.

Security indica- tor light

Clearance light

All functions

Security indica- tor light

Security horn

Clearance light

Starter motor deactivation

Transmitter

Ignition switch

1. Check the transmitter func- tion

3. Check the security control module power supply and ground circuit.

4. Check the door switch.

5.

Replace the security control module.

Check the security indicator light circuit.

Repair order

2. Check the fuse.

Check the clearance light opera- tion.

Check the door switch.

Check the door switch.

Check the security indicator light circuit.

Check the security horn.

Check the clearance light opera- tion.

Check the interrupt relay circuit.

Check the transmitter function.

Check the ignition switch circuit.

Reference

<Ref. to SL-16, CHECK TRANS-

MITTER BATTERY AND FUNC-

TION, INSPECTION, Keyless Entry

System.>

<Ref. to SL-24, CHECK FUSE,

INSPECTION, Securitv Svstem.>

<Ref. to SL-24, CHECK POWER

SUPPLY AND GROUND CIRCUIT,

INSPECTION, Security System.>

<Ref. to SL-24, CHECK DOOR

SWITCH, INSPECTION, Security

System .>

<Ref. to SL-45, Security Control

Module.>

<Ref.cSL-25, CHECK SECURITY

INDICATOR LIGHT CIRCUIT,

INSPECTION, Security System.>

<Ref. to SL-27, CHECK CLEAR-

ANCE LIGHT OPERATION,

INSPECTION, Security System.>

<Ref. to SL-24, CHECK DOOR

SWITCH, INSPECTION, Security

Svstem.>

<Ref. to SL-24, CHECK DOOR

SWITCH, INSPECTION, Security

System.>

<Ref. to SL-25, CHECK SECURtTY

INDICATOR LIGHT CIRCUIT,

INSPECTION, Security System.>

<Ref. to SL-26, CHECK SECURITY

HORN, INSPECTION, Security Sys. tem.>

<Ref. to SL-27, CHECK CLEAR-

ANCE LIGHT OPERATION,

INSPECTION, Security System.>

<Ref. to SL-27, CHECK INTER-

RUPT RELAY CIRCUIT, INSPEC-

TION, Security System.>

<Ref. to SL-16, CHECK TRANS-

MITTER BATTERY AND FUNC-

TION, INSPECTION, Keyless Entry

System.>

<Ref. to SL-27, CHECK IGNITION

SWITCH CIRCUIT, INSPECTION,

Security System.>

S L-23

SECURITY SYSTEM

SECURITY

AND LOCKS

4.

CHECKFUSE

1

Step

Check

CHECK FUSE.

Remove and visually check the fuse No. 2 and

7

(in main fuse box).

Is the fuse blown? (15 A and

20

A)

Yes

Replace the fuse with a new one.

~~

No

Check the power supply and ground circuit. <Ref. to

SL-24, CHECK

POWER SUPPLY

AND GROUND

CIRCUIT,

INSPECTION,

Securitv %stem.>

5.

CHECK POWER SUPPLY

AND

GROUND CIRCUIT

Step

CHECK POWER SUPPLY.

1)Disconnect the security control module har- ness connector.

2)Measure the voltage between the harness connector terminal and chassis ground.

Connector & terminal

No.

1 1

(+)

-

CHECK POWER SUPPLY.

1)Disconnect the security control module har- ness connector.

2)Measure the voltage between the harness connector terminal and chassis ground.

Connector & terminal

No.

13

(+)

-

(-):

CHECK GROUND CIRCUIT.

Measure the resistance between the harness connector terminal and chassis ground.

Connector & terminal

14

-

Check

Is the voltage more than 10 V?

Yes

So to step 2.

Is the voltage more than 10 V? Go to step

3.

Is the resistance less than 10

a?

No

Check the harness for open circuits and shorts between the secu- rity control module and fuse.

Check the harness for open circuits and shorts between the secu- rity control module and fuse.

The power supply and ground circuit are OK.

Repair the har- ness.

6.

CHECK DOOR SWITCH

1

Step Check

CHECK DOOR SWITCH CIRCUIT.

Is the voltage 0 V when each

Measure the voltage between the security con- door, rear gate or trunk lid is trol module harness connector terminal and chassis ground. opened?

Connector & terminal

Front and rear door:

-

Rear gate or trunk lid:

-

(-):

CHECK DOOR SWITCH CIRCUIT.

Is the voltage approx. 10 V

Measure the voltage between the security con- when each door, rear gate or trol module harness connector terminal and chassis ground. trunk lid is closed?

Connector & terminal

Yes

Go to step 2.

No

Go to step

3.

The door switch is

OK.

Go to step

3.

SECURITY SYSTEM

I

2

3

SECURITY AND LOCKS

I

I

Step Check Yes No

CHECK DOOR SWITCH.

Is the resistance more than 1 IGo to step 4.

1)Disconnect the door switch harness connec- tor.

MR when the door switch is pushed?

2)Measure the resistance between the door switch terminals.

Terminal

Front LH

No.

1

-

3:

Front RH No. 1

-

3:

Rear LH No. 1

-

3:

Rear RH

No. 1

-

3:

Rear gate No. 1

-

2:

Trunk lid

No.

1

-

2:

CHECK DOOR SWITCH.

Measure the resistance between the door switch terminals.

Terminal

Front LH No. 1

-

3:

Front RH

No.

1

-No.

3:

Rear LH No. 1

-

3:

Rear RH

No.

1

-No.

3:

Rear gate No. 1

-

2:

Trunk lid No. 1

I

I

Is the resistance less than 1

Q

when the door switch is released?

Replace the door

1 switch.

I

Check the harness Replace the door for open circuits switch. and shorts between the secu- rity control module and door switch.

7.

CHECK SECURITY INDICATOR LIGHT CIRCUIT

Step Check Yes No

CHECK SECURITY INDICATOR LIGHT.

1)Disconnect the security control module har- ness connector.

2)Ground the harness connector terminal with a suitable wire.

Connector & terminal

(B93)

No. 9

-

Does the security indicator light illuminate?

CHECK POWER SUPPLY FOR SECURITY

INDICATOR LIGHT.

1)Disconnect the connector from the combina- tion meter.

2)Measure the voltage between the combina- tion meter harness connector terminal and chassis ground.

Is the voltage more than 10

V?

Connector & terminal

(i10)

No. 10

(+)

-

CHECK SECURITY INDICATOR LIGHT CIR-

CUIT.

Measure the resistance between the combina- tion meter harness connector terminal and security control module harness connector ter-

Is the resistance less than 10

R? minal.

Connector & terminal

( i l l ) No. 6

-

No.

9:

Replace the secu- rity control mod- ule.

Go to step

3.

Replace the com-

Dination meter

Drinted circuit.

Go to step 2.

Check the harness for open circuits and shorts between the com- bination meter and the fuse.

Check the harness for open circuits and shorts between the com- bination meter and security control module.

SL-25

SECURITY SYSTEM

SECURITY AND LOCKS

8. CHECK SECURITY HORN

,

I

I

I

I

I

Step

CHECK SECURITY HORN RELAY.

Remove and check the security horn relay.

<Ref. to SL-47, Security Horn Relay.>

CHECK POWER SUPPLY FOR SECURITY

HORN RELAY.

Measure the voltage between the security horn relay harness connector terminal and chassis ground.

Connector & terminal

(6243)

No.

1

(+)

-

(-):

CHECK POWER SUPPLY FOR SECURITY

HORN RELAY.

Measure the voltage between the security horn relay harness connector terminal and chassis ground.

Connector & terminal

(6243)

No.

(+)

-

(

CHECK HARNESS BETWEEN SECURITY

HORN RELAY AND SECURITY CONTROL

MODULE.

1)Disconnect the security control module har- ness connector.

2)Measure the resistance between the security horn relay harness connector terminal and security control module harness connector ter- minal.

Connector & terminal

(8243)

NO.

3

-

NO.

18:

CHECK HARNESS BETWEEN SECURITY

HORN RELAY AND SECURITY CONTROL

MODULE.

Measure the resistance between the security horn relay harness connector terminal and security control module harness connector ter- minal.

Connector & terminal

(6243) NO. 4

-

CHECK HARNESS BETWEEN SECURITY

CONTROL MODULE AND SECURITY HORN

1)Disconnect the security horn harness con- nector.

2)Measure the resistance between the security control module harness connector terminal and security horn harness connector terminal.

Connector & terminal

(693) NO.

17

-

NO.

1:

CHECK SECURITY HORN.

Remove and check the security horn. <Ref. to

SL-46, Security Horn.>

Check

the security horn relay OK?

~

Yes

Go to step 2. the voltage more than 10 V? Go to step

3.

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

)

Go to step

5.

the resistance less than 10

)

Go to step 6. the resistance less than 10

)

Go to step 7. the security horn OK?

~~

No

Replace the secu- rity horn relay.

Check the harness for open circuits and shorts between the secu- rity horn relay and horn relay.

Check the harness for open circuits and shorts between the secu- rity horn relay and the fuse.

Check the harness for open circuits and shorts between the secu- rity horn relay and security control module.

Check the harness for open circuits and shorts between the secu- rity horn relay and security control module.

Check the harness for open circuits and shorts between the secu- rity control module and security horn.

Replace the secu- rity control mod- ule.

Replace the secu- rity horn.

SL-26

SECURITY

SYSTEM

SECURITY AND LOCKS

9.

CHECK CLEARANCE LIGHT OPERATION

I

2

3

Step

CHECK CLEARANCE LIGHT OPERATION.

Turn the parking switch ON and check if the clearance light illuminates.

CHECK POWER SUPPLY FOR SECURITY

CONTROL MODULE.

1)Turn the parking switch OFF.

2)Disconnect the security control module har- ness connector.

3)Measure the voltage between the security control module harness connector terminal and chassis ground.

Connector & terminal

(693) No. 11

(+)

Check Yes

l o e s the clearance light illumi- late?

Go to step 2. s the voltage more than 10 V? Go to step

3.

CHECK HARNESS BETWEEN SECURITY

CONTROL MODULE AND FUSE BOX.

1)Disconnect the fuse box harness connector

(B152).

2)Measure the resistance between the security control module harness connector terminal and fuse box harness connector terminal.

Connector & terminal

(693) NO. 12

-

NO. 11:

s the resistance less than 10

n?

No

Check the clear- ance light circuit.

Check the harness for open circuits and shorts between the secu- rity control module and the fuse.

Replace the secu- rity control mod- ule.

Check the harness for open circuits and shorts between the secu- rity control module and the fuse.

10.CHECK INTERRUPT RELAY CIRCUIT

1

2

3

Step

CHECK INTERRUPT RELAY.

Remove and check the interrupt relay. <Ref. to

SL-48,

Interrupt Relay.>

Check

Is the interrupt relay OK?

CHECK POWER SUPPLY FOR INTERRUPT

RELAY.

Measure the voltage between the interrupt relay harness connector terminal and chassis ground.

Connector & terminal

(659) No. 1

(+)

-

(-):

Is the voltage more than 10 V when the ignition switch is turned to START?

Is the resistance less than 10

!2?

CHECK HARNESS BETWEEN INTERRUPT

RELAY AND SECURITY CONTROL MOD-

ULE.

Measure the resistance between the interrupt relay harness connector terminal and security control module harness connector terminal.

Connector & terminal

(659) NO. 4

-

NO.

15:

Yes

Go to step 2.

Go to step

3.

No

Replace the inter- rupt relay.

Check the harness for open circuits and shorts between the inter- rupt relay and igni- tion switch.

Replace the secu- rity control mod- ule.

Check the harness for open circuits and shorts between the inter- rupt relay and security control module.

11 .CHECK IGNITION SWITCH CIRCUIT

1

Step

CHECK IGNITION SWITCH SIGNAL.

1)Disconnect the security control module har- ness connector.

2)Turn the ignition switch ON.

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

Connector & terminal

(693) No. 2 (+)

-

Check Yes

No

Is the voltage more than 10 V? The ignition switch circuit is OK.

Check the harness for open circuits and shorts between the secu- rity control module and ignition switch

SL-27

FRONT INNER REMOTE

SECURITY AND LOCKS

5.

Front Inner Remote

A: REMOVAL

1) Remove the door trim. <Ref. to El-37, REMOV-

AL, Front Door Trim.>

2)

Remove the sealing cover. <Ref. to EB-14, RE-

MOVAL, Front Sealing Cover.>

3) Remove the screw and the two rod joints.

4) Remove the front inner remote.

B: INSTALLATION

Install in the reverse order of removal.

CAUTION:

Make sure the lock works properly after ins,al- lation.

C: INSPECTION

1)

Make sure the rod is not deformed.

2) Make sure the lever and rod work smoothly.

S L-28

FRONT OUTER HANDLE

6.

Front Outer Handle

A: REMOVAL

1) Remove the door trim. <Ref. to El-37, REMOV-

AL, Front Door Trim.>

2)

Remove the sealing cover. <Ref. to EB-14, RE-

MOVAL, Front Sealing Cover.>

3)

Remove bolt (A).

4)

Move the front door glass downward. Remove the bolt and rod clamp.

5 )

Remove the front outer handle.

SECURITY AND LOCKS

CAUTION:

Do not use excessive force to remove the door panel. This will deform it.

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

1)

Make sure the rod is not deformed.

2) Make sure the lever and rod work smoothly.

SL-29

FRONT DOOR LATCH ASSEMBLY

SECURITY AND LOCKS

7.

Front Door Latch Assembly

A: REMOVAL

1)

Disconnect the ground terminal from battery.

2) Remove the front door trim. <Ref. to El-37, RE-

MOVAL, Front Door Trim.>

3) Remove the sealing cover. <Ref. to EB-14, RE-

MOVAL, Front Sealing Cover.>

4)

Remove the front inner remote. <Ref. to SL-28,

REMOVAL, Front Inner Remote.>

5) Remove the three screws and bolt.

6) Disconnect the connector. Remove the front door latch assembly.

B: INSTALLATION

Install in the reverse order of removal.

CAUTION:

Make sure the lock works properly after instal- lation.

C: INSPECTION

1)

Make sure the rod is not deformed.

2) Make sure the lever and rod work smoothly.

SL-30

FRONT DOOR LOCK ACTUATOR

8.

Front Door Lock Actuator

A: REMOVAL

1)

Remove the front door latch assembly. <Ref. to

SL-28, REMOVAL, Front Inner Remote.>

2) Loosen two screws to remove the front door lock acutuator.

SECURITY AND LOCKS

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

1)

Disconnect the door lock actuator harness con- nector.

2) Connect the battery to the door lock actuator ter- minals.

No. 3 (+) and No. 1 (-)

No. 1 (+) and No.

3

(-)

Unlocked

+

Locked

Locked

-+

Unlocked

S L-3 1

REAR INNER REMOTE

SECURITY AND LOCKS

9.

Rear Inner Remote

A: REMOVAL

1) Remove the rear door trim. <Ref. to El-38, RE-

MOVAL, Rear Door Trim.>

2)

Remove the sealing cover. <Ref. to EB-17, RE-

MOVAL, Rear Sealing Cover.>

3) Remove the screw and the two rod joints.

4)

Remove the inner remote.

B:

INSTALLATION

Install in the reverse order of removal.

CAUTION:

Make sure the lock works properly after instal- lation.

C: INSPECTION

1) Make sure the rod is not deformed.

2) Make sure the lever and rod work smoothly.

3) Make sure the child safety lock on rear doors work properly, when applicable.

SL-32

REAR OUTER HANDLE

1 O.Rear Outer Handle

A: REMOVAL

1) Remove the rear door trim. <Ref. to El-38, RE-

MOVAL, Rear Door Trim.>

2) Remove the sealing cover. <Ref. to EB-17, RE-

MOVAL, Rear Sealing Cover.>

3) Remove the rear inner remote. <Ref. to SL-32,

REMOVAL, Rear Inner Remote.>

4) Remove the rear door latch assembly. <Ref. to

SL-34, REMOVAL, Rear Door Latch Assembly.>

5) Loosen two bolts and nut to remove the rear out- er handle.

SECURITY AND LOCKS

I

-

"r/

BOO1

. .

I11

CAUTION:

Do not use excessive force to remove the door panel. This

will

deform it.

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

1)

Make sure the rod is not deformed.

2) Make sure the lever and rod work smoothly.

SL-33

REAR DOOR LATCH ASSEMBLY

SECURITY AND LOCKS

11

.Rear Door Latch Assembly

A: REMOVAL

1) Disconnect the ground terminal from battery.

2) Remove the rear door trim. <Ref. to El-38, RE-

MOVAL, Rear Door Trim.>

3) Remove the sealing cover. <Ref. to EB-17, RE-

MOVAL, Rear Sealing Cover.>

4)

Remove the rear inner remote. <Ref. to SL-32,

REMOVAL, Rear Inner Remote.>

5 )

Remove the three screws and bolt.

6) Disconnect the connector, and then remove the rear door latch assembly.

B: INSTALLATION

Install in the reverse order of removal.

CAUTION:

Make sure the lock works properly after instal- lation.

C: INSPECTION

1)

Make sure the rod is not deformed.

2) Make sure the lever and rod work smoothly.

SL-34

REAR DOOR LOCK ACTUATOR

12.Rear Door Lock Actuator

A: REMOVAL

1)

Remove the rear door latch assembly. <Ref. to

SL-34, REMOVAL, Rear Door Latch Assembly.>

2)

Loosen two screws to remove the rear door lock acutuator

SECURITY AND LOCKS

BOO1 10

6 :

INSTALLATION

Install in the reverse order of removal.

CAUTION:

Make sure the lock works properly after instal- lation.

C: INSPECTION

1) Disconnect the door lock actuator harness con- nector.

2) Connect the battery to the door lock actuator ter- minals.

Terminal No.

No.

3 (+) and No.

1 (-)

No.

1

(+) and No. 3

(4

Actuator operation

Unlocked

+

Locked

Locked

+

Unlocked

~~

If

NG, replace the door lock actuator.

s

L-35

REAR GATE OUTER HANDLE

SECURITY AND LOCKS

13.Rear Gate Outer Handle

A: REMOVAL

1)

Remove the rear gate trim. <Ref. to El-52, RE-

MOVAL, Rear Gate Trim.>

2) Remove the rear gate latch assembly. <Ref. to

SL-37, REMOVAL, Rear Gate Latch Assembly.>

3)

Loosen two nuts to remove the rear gate outer handle.

I

I

B: INSTALLATION

Install in the reverse order of removal.

BOO1 14

C:

INSPECTION

1)

Inspect the rod for deformation.

2) Make sure the lever and rod move smoothly.

SL-36

REAR GATE LATCH ASSEMBLY

14.Rear Gate Latch Assembly

A: REMOVAL

1)

Disconnect the ground terminal from battery.

2) Remove the rear gate trim. <Ref. to El-52, RE-

MOVAL, Rear Gate Trim.>

3) Remove the rear gate key cylinder rod clamp.

4)

Remove the three bolts.

SECURITY AND LOCKS

4--

/

4

BOO1 12

5) Disconnect the connectors, and then remove the rear gate latch assembly.

B: INSTALLATION

Install in the reverse order of removal.

CAUTION:

Make sure the lock works properly after instal- lation.

C: INSPECTION

1) Make sure the rod is not deformed.

2) Make sure the lever and rod work smoothly.

SL-37

REAR GATE LATCH LOCK ACTUATOR

SECURITY AND LOCKS

15.Rear Gate Latch Lock Actua- tor

A: REMOVAL

1) Remove the rear gate latch assembly. <Ref. to

SL-37, REMOVAL, Rear Gate Latch Assembly.>

2)

Loosen two screws to remove the rear gate lock actuator.

800113

I

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

1)

Disconnect the door lock actuator harness con- nector.

2) Connect the battery to the door lock actuator ter- minals.

BOO191

I

No. 1 (+) and

No.

2

(-1

I

Unlocked

+

Locked

I

I

No. 2 (+) and

No.

1 (-)

I

Locked

-+

Unlocked

I

If NG, replace the rear gate latch lock actuator.

SL-38

TRUNK LID LOCK ASSEMBLY

16.Trunk Lid Lock Assembly

A: REMOVAL

1) Remove the trunk lid key cylinder rod clamp.

2)

Loosen two bolts to remove the trunk lid lock as- sembly.

SECURITY AND LOCKS

BOO1 15

9:

INSTALLATION

Install in the reverse order of removal.

CAUTION:

Apply grease to the parts that rub.

Make sure the lock works properly after in- stallation.

C: 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 forma- tion and unsmooth movement.

s

L-39

TRUNK LID RELEASE HANDLE

SECURITY AND LOCKS

17.Trunk Lid Release Handle

A: REMOVAL

1)

Remove the five clips.

I

2) Remove the cable from trunk lid release handle.

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

1)

Make sure the cable is not deformed.

2) Make sure the lever works smoothly.

BOO331

SL-40

FRONT HOOD LOCK ASSEMBLY

~~

18.Front Hood Lock Assembly

A: REMOVAL

1) Open the hood.

2) Remove the bolt. Remove the hood lock assem- bly.

3) Remove the release cable from the lock assem- bly.

I

I

SECURITY AND LOCKS

I

B: INSTALLATION

Install in the reverse order of removal.

BOO1 87

CAUTION:

Apply grease to the 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. r

I

I

BOO1 88

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 forma- tion and unsmooth movement.

SL-41

REMOTE OPENERS

SECURITY

AND LOCKS

19. Remote

Openers

A: REMOVAL

1.

HOOD OPENER

1) Remove the release cable from the hood lock.

2) Remove the bolt. Remove the opener lever.

3.

FUEL FLAP OPENER

1) Remove the rear seat. <Ref. to SE-11, REMOV-

AL, Rear Seat.>

2) Remove the center pillar lower trim and side sill cover on the passenger side. Remove the rear pil- lar lower trim. Pull back the floor mat. Remove the clip holding the cable.

3) Remove the bolt. Remove the opener pull han- dle.

4

2.

TRUNK LID OPENER

1) Remove the rear seat. <Ref. to SE-11, REMOV-

75 1

AL, Rear Seat.>

2)

Remove the center pillar lower trim and side sill cover on the passenger side. Remove the rear pil- lar lower trim. Pull back the floor mat. Remove the clip holding the cable.

3)

Remove the bolt. Remove the opener pull han- dle.

Wagon

8

I 9

4)

Remove the cable from the opener pull handle.

5)

Remove the right rear quarter trim. <Ref. to El-

47,

REMOVAL, Rear Quarter Trim.>

6)

Rotate the fuel lock inside the quarter panel to the left and remove.

Waaon

? W e

-

Cover

Pull handle

ASSY

G5M0151

4)

Remove the cable from the opener pull handle.

5) Remove the striker from the trunk lid.

6)

Remove the cable from the striker.

B: INSTALLATION

1.

HOOD OPENER

Install in the reverse order of removal.

2.

TRUNK LID OPENER

Install in the reverse order of removal.

3.

FUEL FLAP OPENER

Install in the reverse order of removal.

C: INSPECTION

Make sure the fuel flap opens and closes smoothly.

G5M0147

SL-42

IGNITION KEY LOCK

20.Ignition Key Lock

A: REPLACEMENT

1)

Disconnect the ground terminal from battery.

2) Remove the steering column. <Ref. to PS-23,

REMOVAL, Tilt Steering Column.>

3)

Secure the steering column in a vise. Remove the bolt with a drill.

SECURITY

AND

LOCKS

4)

Remove the ignition key lock.

5 )

Use a new torn bolt. Tighten the torn bolt to the end of the thread.

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.

No. 1 and No. 3

No. 1 and No.

4

No. 3 and No.

4

If NG, replace the ignition switch.

Standard

-

less than 1

R

less than 1

R

less than 1

R

SL-43

KEY LOCK CYLINDERS

SECURITY AND LOCKS

21

.Key Lock Cylinders

A: REPLACEMENT

1.

FRONT DOOR

1)

Remove the door trim. <Ref. to El-37, REMOV-

AL, Front Door Trim.>

2) Pull back the sealing cover.

3) Move the front door glass downward.

4)

Remove the rod clamp. Remove the bolt. Re- place the key cylinder.

3.

REARGATE

1) Remove the rear gate trim. <Ref. to El-52, RE-

MOVAL, Rear Gate Trim.>

2) Remove the rod clamp. Remove the lock plate.

Replace the key cylinder.

-

BOO1

90

2.

TRUNKLID

1) Remove the trunk lid release handle. <Ref. to

SL-40, Trunk Lid Release Handle.>

2) Remove the rod clamp. Remove the lock plate.

Replace the key cylinder.

B5M1085

s

L-44

SECURITY CONTROL MODULE

22.Security Control Module

A: REMOVAL

1)

Disconnect the ground terminal from battery.

2) Remove the console cover.

SECURITY AND LOCKS

7) Hit the center of the windshield with your palm and make sure the alarm operates. r-

Center of windshield

.

0 .

-I

:

Hook pawl

I+

1

:

: Clip

\

\

000072

3) Disconnect the connector from the security con- trol module.

4) Remove bolt (A) and loosen bolt (B).

NOTE:

Loosen bolt (B) without completely removing it.

06M1424A

If NG, adjust the impact sensitivity. <Ref. to SL-45,

ADJUSTMENT, Security Control Module.>

D: ADJUSTMENT

1.

IMPACT SENSITIVITY

NOTE:

Before adjustment, make sure the security control module has been securely installed on the bracket.

1)

Remove the security control module. <Ref. to

SL-45, REMOVAL, Security Control Module.>

2 )

Adjust the sensitivity adjust screw in the security control module.

NOTE:

After adjusting, be sure to plug the adjust screw hole.

5) Remove the security control module.

B: INSTALLATION

Install in the reverse order of removal.

NOTE:

To install the security control module, tighten the bolts securely so that the bolts do not come loose.

C: INSPECTION

1.

IMPACT SENSITIVITY TEST

1) Remove the key from the ignition switch.

2) Close all windows.

3) Close all doors and the rear gate or trunk lid.

4) Cover the hood with a blanket.

5) Press the LOCWARM button of the transmitter.

6)

Confirm that the security indicator light blinks ev- ery 2 seconds.

3) Install the security control module.

4) Perform the impact sensitivity test.

B6M1309A

SL-45

SECURITY HORN

SECURITY AND LOCKS

23.Security Horn

A: REMOVAL

1) Disconnect the ground terminal from battery.

2)

Remove the nuts and then detach the security horn while disconnecting the connector.

B0038t

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

Connect the battery to the security horn terminal and case ground and make sure the horn sounds properly.

If NG, replace the security horn.

B6M1397

SL-46

SECURITY HORN RELAY

24.Security Horn Relay

A: REMOVAL

1)

Disconnect the ground terminal from battery.

2) Remove the mounting bolt and detach the secu- rity horn relay (near thefuse box).

SECURITY AND LOCKS

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

Measure the security horn relay resistance be- tween terminals (indicated in the table below) when connecting terminal

No.

4

to battery positive termi- nal and terminal No. 1 to battery ground terminal.

I

Current

I

Terminal No.

I

Standard

T L l

2 a n d 3

I

If NG, replace the security horn relay.

B6M1391

SL-47

INTERRUPT RELAY

SECURITY AND

LOCKS

25lnterrupt Relay

A:

REMOVAL

1) Disconnect the ground terminal from battery.

2) Remove the mounting nuts and detach the inter- rupt relay (near the fuse box).

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

Measure the interrupt relay resistance between ter- minals (indicated in the table below) when connect- ing terminal No.4 to battery positive terminal and terminal No.1 to battery ground terminal.

Current

Flow

No

flow

Terminal No.

2 and 6

Standard

Less than 1

R

More than 1

M R

If NG, replace the interrupt relay.

86M0994

S L-48

KEYLESS ENTRY CONTROL MODULE

SECURITY AND

LOCKS

26.Keyless Entry Control Mod- ule

A: REMOVAL

1)

Disconnect the ground terminal from battery.

2) Remove the instrument panel lower cover. <Ref. to El-42, REMOVAL, Instrument Panel Assembly.>

3)

Remove the nut, then remove the keyless entry control module while disconnecting the connector.

/------

B: INSTALLATION

Install in the reverse order of removal.

SL-49

INTEGRATED MODULE

SECURITY AND LOCKS

27.

Integrated Module

A: REMOVAL

1) Disconnect the ground terminal from battery.

2)

Remove the instrument panel lower cover. <Ref. to

El-42, REMOVAL, Instrument Panel Assembly.>

3)

Remove the nut, then remove the integrated module while disconnecting the connector.

6: INSTALLATION

Install in the reverse order of removal.

S L-50

KEYLESS TRANSMITTER

28. Keyless Transmitter

A: REMOVAL

1.

TRANSMITTER BATTERY

Remove the battery from the transmitter.

NOTE:

To prevent static electricity damage to the transmit- ter printed circuit board, touch the steel area of building with hand to discharge static electricity car- ried on body or clothes before disassembling the transmitter.

B6M0950

B:

I N STA L LATlO N

1.

TRANSMITTER BATTERY

Install in the reverse order of removal.

C: INSPECTION

1.

TRANSMITTER BATTERY

Measure the voltage between the battery (+) termi- nal and (-) terminal.

NOTE:

Battery discharge occurs during the measure- ment. Complete the measurement within 5 sec- onds.

During the battery voltage measurement, the voltage falls more than 1.8 volts in 3 seconds peri- od.

SECURITY AND LOCKS

\

(+\

,

Battery (+) termi- nal

Battery (-) termi- nal

More than 2 V

If NG, replace the battery. (Use CR2032 or equiva- lent.)

D: REPLACEMENT

1.

TRANSMITTER PROGRAMMING

NOTE:

Perform the programming when the transmitter is replaced and when an additional transmitter is re- qui red.

NOTE:

Finish the operation from step 1) through 4) within

45 seconds.

1) Sit on the driver's seat and close all doors, rear gate and trunk lid.

2) Open the driver's door.

3) Close the driver's door.

4)

Turn the ignition switch from ON to LOCK ten times within 15 seconds.

NOTE:

Do not start the engine at this time.

5) The horn chirps one time to indicate that the sys- tem has entered in the programming mode.

6)

Open the driver's door.

7)

Close the driver's door.

8) Press any button on the transmitter that you wish to program into the system.

9) Horn will chirp two times to indicate that the transmitter has been programmed.

NOTE:

Any additional transmitter can also be programmed at this time. Repeat steps 6) through 9) for an addi- tional transmitter.

10) Remove the ignition key from the ignition switch.

11) The horn will chirp three times to indicate that the system has exited the programming mode.

12) Check the keyless entry system properly oper- ates by operating each transmitter.

i A

SL-51

SECURITY AND

LOCKS

KEYLESS TRANSMITTER

SL-52

EXTERIOR/INTERIOR TRIM

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

.

Page

General Description

....................................................................................

2

Front Grille

................................................................................................

18

Hood Grille

................................................................................................

19

Front Under Cover

Front Bumper

....................................................................................

22

............................................................................................

23

Rear Bumper

.............................................................................................

30

Mud Guard

................................................................................................

32

Cowl Panel

................................................................................................

33

Roof Spoiler

..............................................................................................

34

Rear Spoiler

..............................................................................................

35

Side Sill Spoiler

.........................................................................................

36

Front Door Trim

.........................................................................................

37

Rear Door Trim

.........................................................................................

38

Glove

Box

Roof Rail

..................................................................................................

39

...................................................................................................

40

Console Box

..............................................................................................

41

Instrument Panel Assembly

......................................................................

42

Upper Inner Trim

.......................................................................................

45

Lower Inner Trim

.......................................................................................

46

Rear Quarter Trim

.....................................................................................

47

Sun Visor

...................................................................................................

49

Roof Trim

..................................................................................................

50

Rear Gate Trim

.........................................................................................

52

Rear Shelf Trim

.........................................................................................

53

Trunk Trim

.................................................................................................

54

Floor Mat

...................................................................................................

55

Luggage Floor Mat

....................................................................................

56

Trunk Room Mat

.......................................................................................

57

EXTERIOR/INTERlOR TRIM

1.

General Description

A: COMPONENT

1. FRONT

GRILLE

GENERAL DESCRIPTION

(1)

Front grille

2.

UNDER

COVER

(2) Front grille emblem (3) Clip

BOO293

(1

Under cover

(2) Clip (side)

(3) Clip

El-2

BOO294

Tightening torque: N.m (kgf-m, ft-lb)

T: 14 (1.42, 10.3)

3.

HOOD GRILLE

GENERAL DESCRIPTION

EXTERIOFUINTERIOR TRIM

(1)

Hood grille

(2) Bolt

(3) Metal washer

(4)

Foam rubber washer

( 5 )

Grille duct

(6) Grille lower duct

(7) Clip

(8) Black clip

(9) White clip

(IO)

Packing

(11) Packing

BOO403

Tightening torque:

N-m

(kgf-my ft-lb)

T: 4.4 (0.45, 3.25)

El-3

EXTERIOWINTERIOR TRIM

4.

FRONT BUMPER

I

GENERAL DESCRIPTION

I

(1) Bumper face

( 2 )

Head light side cover

(3) Bumper side bracket

(4)

Bumper corner bracket

(5) License plate bracket

(6)

Bumper energy absorber

(7)

Bumper back beam

BO0281

Tightening torque: N.m (kgf-m, ft-lb)

T1: 32 (3.3,24)

T2: 69 (7.0,51)

El-4

5.

REAR BUMPER

GENERAL DESCRIPTION

EXTERIOWINTERIOR TRIM

(1)

Bumper face

( 2 )

Bumper upper beam

( 3 )

Bumper corner bracket

(4)

Bumper side bracket

(5) Bumper side cover

(6) License plate base

(7) Bumper energy absorber

( 8 )

Bumper back beam

BO0282

Tightening torque:

N.m (kgf-m, ft-lb)

T1: 33 (3.4,24)

T2: 34 (3.5,25)

T3: 95 (9.7, 70)

El-5

EXTERIOR/INTERIOR TRIM

6. MUDGUARD

GENERAL DESCRIPTION

(1)

Mud guard

(2) Clip

7. COWLPANEL

Q

(3)

Sub frame cover

(4) Brake duct plate

(5)

Mud guard plate

BOO

(1) Cowl panel

(2) Cowl side panel

(3) Protector

(4) Seal

El-6

%

BO0297

8.

ROOF SPOILER

GENERAL DESCRIPTION

EXTERIOWINTERIOR TRIM

(1)

Roof spoiler

(2)

Cap

9.

REAR SPOILER

(3) Clip

Tightening torque: N.m (kgf-m, ft-lb)

T: 7.35 (0.749, 5.42)

(1) Rear spoiler

(2) Protector

(3) Clip

(4)

Grommet

( 5 )

Seal (only RH side)

( 6 )

High mount stop lamp

BOO299

Tightening torque: N.m (kgf-m, ft-lb)

E

7.4 (0.75, 5.46)

El-7

EXTERIOR/INTERIOR TRIM

10.SIDE SILL SPOILER

GENERAL DESCRIPTION

(1) Side sill spoiler

(2) End cover

(3)

Protector

(4)

Rivet clip

( 5 )

Clip

(6) Spoiler clip

BOO300

El-8

11

.DOOR TRIM

GENERAL DESCRIPTION

EXTERIOWINTERIOR TRIM

(1)

Gusset cover

(2)

Bracket

(3)

Weatherstrip upper

(4)

Clip

(5)

Trim panel

(6)

Power window switch cover

(7)

Lower trim

BOO253

El-9

EXTERIOR/INTERIOR TRIM

12.ROOF RAIL

GENERAL DESCRIPTION

(1)

Roof rail

I

@--m

BOO301

Tightening torque: N.m (kgf-m, ft-lb)

T: 7.4 (0.75, 5.46)

El-1

0

13.CONSOLE BOX

GENERAL DESCRIPTION

EXTERIOR/INTERIOR TRIM

m

(1 ) Console cover

(2) Cup holder

(3) Bracket

(4) Strip

( 5 )

Upper lid

(6)

Lid hinge

(7)

Rear lid

(8)

Console box

(9) Console pocket

(1 0) Upper bracket

(11) Pad

(12) Lower bracket

(13) Lock

(1 4) Front cover (MT)

(15) Boot

(1 6) Front cover (AT)

BOO302

El-I 1

EXTERIOWINTERIOR TRIM

14.1NSTRUMENT PANEL

GENERAL DESCRIPTION

(1) Pad &frame

(2) Center upper panel

(3) Air vent grille (Defroster)

(4)

Grille cover

(5) Meter visor

(6) Defroster grille

(7) Cup holder

( 8 )

Air vent grille (Center)

(9) Air vent grille (Side)

(1 0) Lower cover

(1 1)

Console cover

(1 2) Center panel

(1

3) Center pocket

(14)

Ash tray

(1 5) Audio bracket

(16) Glove box lid

80030:

(1 7) Glove box panel

(1 8) Console rein forcement

(19) Coin box

Tightening torque: N.m (kgf-m, ft-lb)

T: 7 (0.71, 5.2)

El-1 2

15.1NNER TRIM (SEDAN)

GENERAL DESCRIPTION

EXTERIOWINTERIOR TRIM

(1)

Front pillar upper trim

(2) Center pillar upper trim

(3) Rear pillar upper trim

(4)

Rear shelf trim

(5)

Rear bulk trim

(6) Trunk rear trim

(7) Trunk side trim

(8) Rear pillar lower trim

(9) Side sill rear cover

(1 0) Center pillar lower trim

(1 1)

Side sill front cover

(1 2) Front garnish

(1 3) Rear garnish

BOO38C

El-1 3

EXTERIOR/INTERlOR TRIM

16.INNER TRIM (WAGON)

GENERAL DESCRIPTION

(1)

Front pillar upper trim

(2)

Center pillar upper trim

(3) Rear pillar upper trim

(4)

Rear rail trim

(5) Rear pillar lower trim

(6) Rear quarter lower trim

(7)

Hook

(8) Rear skirt trim

(9) Side sill rear cover

(1 0) Center pillar lower trim

(1 1) Side sill front cover

(1 0) Front garnish

(1 1 Rear garnish

(1 2)

Front garnish

(1 3) Rear garnish

BO0381

El-1 4

17.ROOF TRIM (SEDAN)

GENERAL DESCRIPTION

EXTERIOWINTERIOR TRIM

BO0304

(1)

Roof trim

18.ROOF TRIM (WAGON)

(1)

Roof trim

(2)

Roof trim (sun roof model)

(3)

Sun roof garnish

BOO305

El-I 5

EXTERIOR/INTERIOR TRIM

19.LUGGAGE FLOOR MAT

GENERAL DESCRIPTION

(1) Front floor mat

(2)

Floor box

(3) Side floor mat (RH)

(4) Center floor mat

(5) Side floor mat (LH)

BO0306

El-I 6

20.1NNER ACCESSORIES

GENERAL DESCRIPTION

EXTERIOWINTERIOR TRIM

I

Clip remover

TOOL NAME

I

Used for removal of trim.

REMARKS

I

El-1 7

EXTERIOR/INTERIOR TRIM

2. Front Grille

A: REMOVAL

1)

Open the hood.

2) Remove the four clips.

FRONT GRILLE

I L

.-----J

0

: clip

BOO055

3) Remove the two hooks.

B: INSTALLATION

Install in the reverse order of removal.

El-I 8

HOOD GRILLE

EXTERIOWINTERIOR TRIM

3.

Hood Grille

A: REMOVAL

1)

Remove the four clips of hood insulator. d

80037'

2)

Remove seven bolts and clip

(A)

to remove the hood duct.

/(A)

I

3) Remove three nuts.

0

4)

Remove three white clips and two black clips to remove the hood grille.

v

I

El-I 9

EXTERIOR/INTERlOR TRIM

B: INSTALLATION

HOOD GRILLE

(A)

White clip (6) Black clip

1)

Replace the black clip ( I ) , (2) with a new one. In- stall the clip with arrow mark facing the front side of grille (A).

(C) Bolt

3) Attach the metal washer

(A)

only to bolt (6). At- tach the foam rubber washer (B) to bolt (6),

BOO376

2) Replace the white clip

(3),

(4),

with a new one. Install the white clip

(3),

(4) by aligning the rib of clip parallel with the grille fronthear direction (A).

CAUTION:

Do not use foam rubber washer with new white clips.

I I

B0037E

El-20

HOOD GRILLE

4)

Insert the hood grille clip and engage the five clips.

CAUTION:

Make sure that the anchor portion of each clip is firmly engaged.

0

EXTERIOR/INTERlOR

TRIM

7) Install the hood duct with clip (A) and seven bolts.

8) Install the hood insulator with four new clips.

5 )

Install the three nuts.

Tightening torque:

4.4

N-m

(0.45 kgf-m, 3.25

fWb)

0

6) Catch the two hooks of hood duct to the hood holes.

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.

El-21

FRONT UNDER COVER

EXTERlORllNTERlOR TRIM

4.

Front Under Cover

A: REMOVAL

1)

Lift-up the vehicle.

2)

Loosen the bolts and clips to remove the under cover.

Q

BO0382

B: INSTALLATION

Install in the reverse order of removal.

El-22

5. Front Bumper

FRONT BUMPER

EXTERIOWINTERIOR TRIM

6)

Disconnect the fog light connector to remove the bumper.

A: REMOVAL

CAUTION:

Handle the bumper carefully t o avoid damage to the bumper face.

Do not damage the body during removal or installation of bumper.

To avoid damage to the bumper, lay the re- moved bumper on sheet spread on the floor. Do not lay it directly on the floor.

1 ) Disconnect the ground terminal from battery.

2)

Remove the front grille. <Ref. to El-18, REMOV-

AL, Front Grille.>

3) Loosen the three clips to remove the head light side cover.

I

‘\I

B0005E

7)

Remove the E/A FORM from bumper beam.

CAUTION:

E/A FORM may easily break. Do not apply ex- cessive force t o it during removal.

4) Pull off the front side of front mud guard to re- move the clip.

8) Remove the bumper beam.

B0006C

d

BO0391

5) Remove clips, and pull out bumper slightly.

El-23

FRONT BUMPER

EXTERIOR/INTERlOR TRIM

B: INSTALLATION

CAUTION:

Handle the bumper carefully to avoid damage to the bumper face.

Do

not damage the body during removal or installation of bumper.

1) install in the reverse order of removal.

2) Fit the slider

(A)

to guide plate (B) securely.

Tightening torque:

Refer to COMPONENT of General Description for tightening torque. <Ref. to El-4, FRONT

BUMPER, COMPONENT, General Descrip- tion.>

El-24

FRONT BUMPER

C: REPAIR

1.

COATING METHOD

FOR PP BUMPER

~~

Pro- cess

No.

Process name

Job contents

EXTERIOWINTERIOR TRIM

1 Bumper mounting

Set the bumper on paint worktable if required.

Use paint worktable conforming to inner shape of bumper when possible.

Set bumper section G5M0164

2 Masking

Mask specified part (black base) with masking tape. Use masking tape for PP (example, Nichiban

No. 533, etc.).

3

4

5

Degreasing, clean- ing

Primer paint

Clean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt, oil, fat, etc.

Drying

Drying

8

Top coat paint (11)

9

10

11

Top coat paint (I)

Drying

Inspection

Masking removal

Apply primer one to all parts to be painted, using air gun. Use primer (clear).

Dry at normal temperature

[IO

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:l

Viscosity: 10

-

Film thickness: 35

-

Spraying pressure: 245

-

(2.5

- -

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 = 1O:l

Viscosity: 10

-

Film thickness: 15

-

Spraying pressure: 245

-

(2.5

- kg/cm2, 36

-

Dry at normal temperature [ l o min. or more at

20°C (68"F)I.

In half-dried condition, avoid dust, dirt.

Not required.

Apply a clear coat to parts with top coat paint

(I), three times, at 5

-

Paint in use:

Metallic paint

Hardener PB

Thinner T-301

Mixing ratio: Clear vs. hardener

=

6:l

Viscosity: 14

-

Film thickness: 25

-

Spraying pressure: 245

-

(2.5

-

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).

Faint check.

Remove masking in process No. 2.

El-25

FRONT BUMPER

EXTERIOR/INTERIOR TRIM

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 re- stored 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.

Minor damage causing only a change in the lustre of the bumper due to a light touch

Almost restorable.

Process name Job contents

Cleaning

Sanding

Finish

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). Recom- mended wax: NITTO KASEI Soft 99 TIRE WAX

BLACK, or eauivalent.

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 subse- quent operations in the “(3)” section, depending on the degree and nature of damage.

Deep damage caused by scratching fences, etc.

A

dent cannot be repaired but a whitened or swelled part can be removed.

Pro- cess

No.

1

3

Process name

I cleaning

Removal of dam- aaed area

I

Sandina

4

I

Finish

Job contents

L

I

Clean damaged area with water.

1

Cut off protruding area, if any, due to collision, using a putty knife.

I

I

Grind the affected area with #lo0 to #500 sand DaDer.

Resin section

Same as Process No. 3 in the “(1)” section.

Coated section

I

Perform Process No. 12 and subsequent oper- ations in the “(3)” section.

I

I

El-26

FRONT BUMPER

EXTERIOR/INTERIOR TRIM

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)

Pro- cess

No.

1

2

Process name

BumDer removal

Part rem ova I

Job contents

Remove the bumper as required.

Remove the parts built into bumper as required.

I

Bumper placement

Place the bumper on a paint worktable as required.

It is recommended that contour of worktable accommodate internal shape of bumper.

I

Set bumper section G5M0164

Surface prepara- tion

Cutting

7

Sandina

(I)

Cleaning

If nature of damage are cracks or holes, cut a guide slit of 20 to 30 mm (0.79 to 1.1 8 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.

Unit: mm (in)

20

-

(0.79- 1.18)

1

f

3

( 0 , ~ ~ ) surface

G5M0165

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.

Grind the side just opposite the beveled area with sand paper (#40 to #60) and clean using a sol, vent.

TemDorarilv sDot-weld the side, usinq a PP welding rod and heater gun.

Welded spot (Use heater gun and

PP welding rod)

8

Temporary welding

Beveled section

NOTE:

.

Do not melt welding rod until it flows out. This results in reduced strength.

Leave the welded mot unattended until it cools completely.

G5M016E

El-27

FRONT BUMPER

EXTERIOR/INTERIOR TRIM

Pro- cess

No.

Process name

Job contents

Using a heater gun and PP welding rod, weld the beveled spot while melting the rod and dam- aged area.

9

Welding

Melt

hatched area

Section

G5M0167

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 sDot 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 (11)

G5M0168

11 Masking

Sand the welded spot smooth with #240 sand paper.

~~

Mask the black substrate section using masking tape.

Recommended maskina taDe: Nichiban No. 533 or eauivalent

Completely clean the entire coated area, using solvent similar to that used in Process No. 4.

12

Cleaning/ degreasing

13 Primer coating

14 Leaveunattended.

Apply a coat of primer to the repaired surface and its surrounding areas. Mask these areas, if nec- essary.

Recommended primer: Mpl364 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/cm2, 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.

15

Primer surfacer coating

16 Drying

17 Sanding (Ill)

18

C

I degreasing

Apply a

COG utes.

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)

Viscosity: 12

-

Coated film thickness: 40

-

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.

El-28

22

23

24

25

26

FRONT BUMPER

EXTERIOWINTERIOR TRIM

Pro- cess

No.

19

20

21

~

Process name

Top coat (I)

Top coat (11)

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

Viscosity: 1 1

-

Coated film thickness: 40

-

Spraying thickness: 245

-

(2.5

- -

Leave unattended.

Not required.

Not required.

Job contents

Metallic 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

Viscosity: 11

-

Coated film thickness: 20 -

Spraying thickness: 245

-

(2.5

- -

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 ir contact with the affected area.

Apply a clear coat three times at an interval of 3 to 5 minutes.

Recommended paint:

SC710 Overlay Clear

No. 307 Flex Hardener

SC Reducer (thinner)

Mixing ratio: 3 : 1

Suncryl (SC) vs. No. 307 Flex Hardener

Viscosity: 10

-

Coated film thickness: 20

-

Spraying pressure: 245

-

(2.5

-

" I

-

Drying

NOTE:

Do not allow the temperature to exceed 80°C (1 76°F) since this will deform the PP substrate.

Inspection

Maskina removal

Parts installation

Bumper installation

Carefully check the condition of the repaired area.

Remove the masking tape applied in Process No. 11 and 13.

Install parts on the bumper in reverse order of removal.

Install the bumper.

El-29

REAR BUMPER

EXTERIOR/I NTERIOR TRIM

6. Rear Bumper

A: REMOVAL

1.

WAGON

CAUTION:

Handle the bumper carefully t o avoid damage to the bumper face.

Do not damage the body during removal or installation of bumper.

To avoid damage to the bumper, lay the re- moved bumper on sheet spread on the floor. Do not lay it directly on the floor.

1 ) Disconnect the ground terminal from battery.

2)

Remove the bolts and clips.

7 )

Pull off the rear end of rear quarter lower trim, and then loosen the two nuts from each side to re- move the rear bumper.

8) Loosen the clips to remove the bumper beam.

BOO283

9)

Remove the E/A FORM from bumper beam.

CAUTION:

E/A FORM may easily break. Do not apply ex- cessive force to it during removal.

I

I

\ -

BOO063

3) Remove the rear combination light assembly.

<Ref. to LI-18, REMOVAL, Rear Combination Light

Assembly.>

4)

Remove the screw and two clips from each side.

10) Remove the bolt.

5)

Remove the floor box.

6)

Remove the rear skirt trim.

BOO064

El-30

U

BOO285

REAR BUMPER

~

~~

11) Remove the canister. <Ref. to EC(S0HC)-5,

REMOVAL, Canister.>

12)

Remove the three bolts, then remove the bumper beam.

EXTERIOR/INTERIOR TRIM

~

2.

SEDAN

Refer to rear bumper removal WAGON. <Ref. to

El-30, WAGON, REMOVAL, Rear Bumper.>

B: INSTALLATION

1.

WAGON

CAUTION:

Handle the bumper carefully to avoid damage to the bumper face.

Do not damage the body during removal or installation of bumper.

1)

Install in the reverse order of removal.

Tightening torque:

Refer to COMPONENT of General Description for tightening torque. <Ref. to €1-5, REAR

BUMPER, COMPONENT, General Descrip- tion.,

2.

SEDAN

CAUTION:

Handle the bumper carefully to avoid damage to the bumper face.

Do

not damage the body during removal or installation of bumper.

1) Install in the reverse order of removal.

Tightening torque:

Refer to COMPONENT

of

General Description

for

tightening torque. <Ref. to €1-5, REAR

BUMPER, COMPONENT, General Descrip- tion.>

C: REPAIR

Refer to front bumper repair. <Ref. to El-23, RE-

MOVAL, Front Bumper.>

El-31

MUD GUARD

EXTERIOR/INTERlOR TRIM

7.

MudGuard

A: REMOVAL

1)

Jack-up the vehicle.

2)

Loosen the screws and clips to remove the mud guard.

BO0399

B: INSTALLATION

Insert the hook into body, and tighten it with screw and clip.

El-32

COWL PANEL

8.

Cowl

Panel

A: REMOVAL

1) Open the hood.

2)

Remove the wiper arm. <Ref. to WW-12, RE-

MOVAL, Front Wiper Arm.>

3) Remove the front panel seal.

EXTERIOWINTERIOR TRIM

4)

Loosen the clips to remove the cowl panel.

,

/

0

\

B: INSTALLATION

Install in the reverse order of removal.

El-33

ROOF SPOILER

EXTERIOR/INTERlOR TRIM

9.

Roof Spoiler

A: REMOVAL

1) Remove the bolt cap, then remove the two bolts.

2)

Detach the roof spoiler.

I\\

\

B: INSTALLATION

Install in the reverse order of removal.

BO030

El-34

REAR SPOILER

10.Rear Spoiler

A: REMOVAL

1)

Disconnect the ground terminal from battery.

2) Open the trunk lid.

3) Remove the electrical connector (A) of high- mounted stop light.

4)

Loosen the mounting nut of rear spoiler to re- move the rear spoiler.

CAUTION:

When removing the nut, do not drop it into trunk lid.

Pay attention to avoid damage during remov-

al

or installation.

EXTERIOR/INTERIOR TRIM

B: INSTALLATION

1) install in the reverse order of removal.

2) Clean the mounting surfaces of trunk lid spoiler before installation. and

El-35

SIDE SILL SPOILER

EXTERIOR/INTERIOR TRIM

11 .Side Sill Spoiler

A: REMOVAL

Remove the clips (1 on front, 6 on lower), then re- move the side sill spoiler.

6: INSTALLATION

Install in the reverse order of removal.

BO0004

El-36

12.Front Door Trim

FRONT DOOR TRIM

EXTERIOWINTERIOR TRIM

B:

INSTALLATION

Install in the reverse order of removal.

A: REMOVAL

CAUTION:

Do

not apply excessive force to the clip. Other- wise the clip may be broken.

1 ) Disconnect the ground terminal from battery.

2)

Pull up the inner remote cover toward you to re- move the upper hook. Pull down it to remove the lower hook. Remove the inner remote cover.

3)

Remove the screw.

4)

Remove the power window switch assembly and disconnect the harness connector.

5 )

Remove the screw.

6) Remove the clips of trim panel using clip remov- er to remove the trim panel.

El-37

REAR DOOR TRIM

EXTERIOR/INTERlOR TRIM

13.Rear Door Trim

A: REMOVAL

CAUTION:

Do

not apply excessive force to the clip. Other- wise the clip may be broken.

1 ) Disconnect the ground terminal from battery.

2)

Pull up the inner remote cover toward you to re- move the upper hook. Pull down it to remove the lower hook. Remove the inner remote cover.

5)

Disconnect the power window harness connec- tor.

1

B: INSTALLATION

Install in the reverse order of removal.

3)

Remove the screw and clip.

4) Remove the clips of trim panel using clip remov- er to remove the trim panel.

El-38

14.Glove Box

A: REMOVAL

1)

Open the glove box.

2) Loosen the screws to remove glove box.

GLOVE BOX

EXTERIORANTERIOR TRIM

B: INSTALLATION

Install in the reverse order of removal

El-39

I

ROOF RAIL

EXTERIOR/I NTERIOR TRIM

15.Roof Rail

A:

REMOVAL

1)

Remove the roof trim. <Ref. to El-50, REMOVAL, Roof Trim.>

2) Remove the four mounting nuts and then detach the roof rail carefully.

B: INSTALLATION

Install in the reverse order of removal.

CAUTION:

Be careful not to scratch the body panels with roof rail stud bolts when removing and install- ing them.

El-40

16.Console Box

CONSOLE BOX

EXTERIOFUINTERIOR TRIM

B: INSTALLATION

Install in the reverse order of removal.

A: REMOVAL

1)

Disconnect the ground terminal from battery.

2) Remove the console cover.

I

'.,I:

Hook

pawl

E

i ~ , :

'

BOO072

3) Remove the shift knob (MT model) and front cov- er.

4)

Loosen the screws to remove the console box.

I

I--

I

BOO074

El-41

INSTRUMENT PANEL ASSEMBLY

EXTE R I ORA NTE R IO R TR I M

17.lnstrument Panel Assembly

A: REMOVAL

WARNING:

All

airbag system wiring harness and con- nectors are colored yellow.

Do

not use electri- cal test equipment on these circuits.

Be careful not to damage the airbag system harness when servicing the instrument panel.

1) Disconnect the ground terminal from battery.

2) Loosen the screws and clips to remove the lower cover.

I

I

8) Remove the two nuts and disconnect the connectors. two

W

'

S5M0044A

1

3) Remove the glove box. <Ref. to El-39, REMOV-

AL, Glove Box.>

4)

Remove the center console panel. <Ref. to AC-

25,

REMOVAL, Control Unit.>

5)

Remove the passenger airbag module. <Ref. to

AB-1 3, Passenger's Airbag Module.>

6) Loosen the four screws and two nuts to remove the lower console panel.

BOO

7) Loosen the hooks to remove the defroster panel.

El-42

INSTRUMENT PANEL ASSEMBLY

EXTERIOR/INTERlOR TRIM

9) Remove the instrument panel mounting bolts.

10) Remove the instrument panel.

CAUTION:

Do not pull the harness when disconnecting the connector.

NOTE:

If necessary, make matching marks for easy reas- sembly.

El-43

CAUTION:

Take care not to scratch the instrument panel and related Parts.

INSTRUMENT PANEL ASSEMBLY

EXTERIOWINTERIOR TRIM

When storing the removed instrument panel, place it standing up on the floor.

B: INSTALLATION

Install in the reverse order of removal.

CAUTION:

Be careful not to snag the harness.

Make sure to connect the harness connector.

Take care not to scratch the instrument panel and related parts.

NOTE:

When setting the instrument panel into position, push the hook into grommet (A) on the body panel.

G5M060;

I

“ ‘ 2

L

BOO1 52

El-44

UPPER INNER TRIM

18.Upper Inner Trim

A: REMOVAL

1)

Remove the lower inner trim. <Ref. to El-46, RE-

MOVAL, Lower Inner Trim.>

2) Remove the front mole (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).

I

EXTERIOWINTERIOR TRIM

I

B5M1021A

B: INSTALLATION

Install in the reverse order of removal.

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 mole as shown in figure.

Outside

1

Inside

Weatherstrip

Trim

B5M0673A

El-45

LOWER INNER TRIM

EXTERIOR/INTERIOR TRIM

19.Lower Inner Trim

A: REMOVAL

1)

Remove the side sill front cover

(A).

2) Remove the rear seat cushion <Ref. to SE-11,

REMOVAL, Rear Seat.>, then remove side sill rear cover (B).

3) Remove the center pillar lower trim (C).

‘,-I

..

Hook pawl

BO0075

B: INSTALLATION

Install in the reverse order of removal.

CAUTION:

Be sure

to

securely

hook

pawls of inner trim panel

to

body flange.

El-46

20.Rear Quarter Trim

REAR QUARTER TRIM

A: REMOVAL

1.

SEDAN

1) Remove the rear seat. <Ref. to SE-11, REMOV-

AL, Rear Seat.>

2)

Remove the side sill rear cover. <Ref. to El-46,

REMOVAL, Lower Inner Trim.>

3) Remove the rear pillar lower cover (A).

4) Remove the seatbelt lower anchor bolt, and then remove the rear pillar upper trim (B).

EXTERIOWINTERIOR TRIM

2. WAGON

1) Remove the rear seat. <Ref. to SE-11, REMOV-

AL, Rear Seat.>

2) Remove the side sill rear cover.

3) Remove the rear rail trim (A).

4) Loosen the screws and clips to remove the rear quarter upper trim (B).

5) Remove the rear skirt trim

(C).

6) Loosen the bolts and clips to remove the rear quarter lower trim (D).

m

,Clip

80038:

El-47

I

REAR QUARTER TRIM

EXTERIOR/INTERIOR TRIM

B: INSTALLATION

Install in the reverse order of removal.

CAUTION:

Be sure to securely

hook

pawls of inner trim panel to body flange.

NOTE:

When installing the rear quarter upper trim, be sure to set the rearmole as shown in the figure.

b 1

Inside

Weatherstrip

Trim

El-48

SUN VISOR

21.Sun Visor

A: REMOVAL

Remove the mounting screws then detach the sun visor

(A),

hook

(B) and

center visor

(C).

I

I -

B: INSTALLATION

Install in the reverse order of removal.

B V V V l t

--

EXTERIOWINTERIOR TRIM

El-49

I

ROOF TRIM

EXTERIORANTERIOR TRIM

22.Roof Trim

A:

REMOVAL

CAUTION:

When removing the clip, use great care not to damage the roof trim.

1.

SEDAN

1 ) Disconnect the ground terminal from battery.

2) Remove the spots light. <Ref. to LI-25, REMOV-

AL, Spot Light.>

3)

Remove the room light. <Ref. to LI-26, REMOV-

AL, Room Light.>

4) Remove the sun visor and hook on both sides.

<Ref. to El-49, REMOVAL, Sun Visor.>

5) Remove the assist-grips (A). r

I

2.

WAGON

1) Disconnect the ground terminal from battery.

2)

Remove the room light. <Ref. to LI-26, REMOV-

AL, Room Light.>

3)

Remove the sun visor and hook on both sides.

<Ref. to El-49, REMOVAL, Sun Visor.>

4) Remove the assist-grips (A).

5) Remove the upper inner trim. <Ref. to El-45, RE-

MOVAL, Upper Inner Trim.>

6) Remove the rear quarter upper trim shown in the figure.

7) Remove the rear rail trim (A).

8) Remove the rear quarter upper trim (B) of both sides.

6) Remove the upper inner trim. <Ref. to El-45, RE-

MOVAL, Upper Inner Trim.>

7) Remove the quarter upper trim. <Ref. to El-47,

SEDAN, REMOVAL, Rear Quarter Trim.>

8) Remove the clips, and then remove the roof trim.

BOO1

26

BO0382

El-50

ROOF TRIM

9) Remove the clips, and then remove the roof trim.

EXTERIOR/INTERIOR TRIM

6:

INSTALLATION

Install in the reverse order of removal.

El-51

I

REAR GATE TRIM

EXTERIOR/INTERlOR TRIM

23.Rear Gate Trim

A: REMOVAL

CAUTION:

Be careful not to damage the clips

or

their holes.

1) Remove the clips and detach the rear gate trim.

B: INSTALLATION

Lnstall in the reverse order of removal.

El-52

REAR SHELF TRIM

24.Rear Shelf Trim

A: REMOVAL

1) Disconnect the ground terminal from battery.

2) Remove the high-mounted stop light.

d

0 0

EXTERIOWINTERIOR TRIM

3) Remove the rear quarter upper trim. <Ref. to El-

47,

REMOVAL, Rear Quarter Trim.>

4)

Remove the seat belt center lower anchor bolt.

5) Remove the rear shelf trim.

B: INSTALLATION

Install in the reverse order of removal.

BOO1 27

El-53

I

TRUNK TRIM

EXTERIOR/INTERIOR TRIM

25.Trunk Trim

A: REMOVAL

1) Remove the rear seat backrest. <Ref. to SE-11,

SEDAN, REMOVAL, Rear Seat.>

2)

Remove the clip (A).

3) Loosen the clips, and then detach the trunk rear trim (B).

4)

Loosen the clips to remove the trunk side trim

(C).

C .

B: INSTALLATION

Install in the reverse order of removal.

El-54

FLOOR MAT

26.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-11,

REMOVAL, Rear Seat.>

3) Remove the console box.

<Ref. to El-41, Con- sole

Box.>

4) Remove the side sill front cover, side sill rear cover and center Dillar lower trim. <Ref. to El-46,

REMOVAL, Lowe; Inner Trim.>

5) Remove the 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.

EXTERIOR/INTERIOR TRIM

BO0123

B:

INSTALLATION

Install in the reverse order of removal.

NOTE:

Secure the mat firmly with hook and Velcro tape.

Insert the mat edge firmly into the groove of side sill cover.

El-55

I

LUGGAGE FLOOR MAT

EXTERIOR/INTERIOR TRIM

27. Luggage

Floor Mat

A: REMOVAL

Remove the clips, then detach the rear floor mats and boxes.

I

B: INSTALLATION

Install in the reverse order of removal.

BO0081

__. .

El-56

28,Trunk Room Mat

A: REMOVAL

Draw out the trunk room mat.

TRUNK ROOM MAT

EXTERIOWINTERIOR TRIM

B: INSTALLATION

Install in the reverse order of removal.

El-57

I

EXTERIOR/INTERIOR TRIM

TRUNK ROOM MAT

El-58

..

EXTERIOR BODY PANELS

E 6

1

.

2

.

3

.

4

.

5

.

6

.

7

.

8

.

9

.

Page

General Description

....................................................................................

2

Front Hood

................................................................................................

10

Fender Panel

.............................................................................................

11

Front Door Panel

.......................................................................................

12

Front Sealing Cover

..................................................................................

14

Rear Door Panel

.......................................................................................

15

Rear Sealing Cover

...................................................................................

17

Trunk Lid Panel

.........................................................................................

18

Rear Gate Panel

.......................................................................................

19

EXTERIOR BODY PANELS

1.

General Description

A: SPECIFICATIONS

GENERAL DESCRIPTION

Front hood

--f/---

Front fender

??'k

SECTION

A

Front fender

SECTION

B

\

Front door

Front door

SECTION C

Rear door

SECTION D

Rear quarter

I

I

A

B

C

D

E, F

I

Front hood to Front fender

Front fender to

Front door

Front door to Rear door

Rear door to Rear auarter

I

Door panel to Side sill

SECTION E,F

NA:

4.0 mm

f

TURBO: 3.7 mm f

.O

(0.15 f

4.6 mm f f

5.0

(0.20 in)

4.6 mm (0.18 in)

I

5.9 mm (0.23 in)

I

EB-2

B: COMPONENT

1.

FRONT HOOD

GENERAL DESCRIPTION

EXTERIOR BODY PANELS

Ia

(1) Front hood

( 2 )

Seal (Front panel)

( 3 ) Hinge

(4)

Hood grille

(5) Packing

(6) Clip

(7)

Locking piece

( 8 ) Seal (Intake duct)

(Only turbo model)

(9)

Seal (Hood)

BOO364

Tightening torque: N.m (kgf-m, ft-lb)

F

7.35 (0.75, 5.4)

T1: 24.5 (2.5, 18.1)

EB-3

EXTERIOR BODY PANELS

2. FRONT FENDER PANEL

GENERAL DESCRIPTION

(1) Front fender panel

BOO321

Tightening torque: N-m (kgf-m, ft-lb)

T: 7.35 (0.75, 5.4)

E B-4

3.

FRONT

DOOR PANEL

GENERAL DESCRIPTION

EXTERIOR BODY PANELS

(1) Gusset

(2) Weatherstrip (Outer)

(3) Clip (Weatherstrip, outer)

(4)

Stabilizer (Outer)

(5) Stabilizer (Inner)

(6)

Sealing cover

(7)

Checker

(8) Lower hinge

(9) Upper hinge

(1 0) Door panel

Tightening torque: N.m (kgf-m, ft-lb)

T I : 7.4 (0.75, 5.5)

T2: 24.5(2.49, 18)

T3: 29.4 (3.0, 21.7)

T4: 32.3 (3.29,23.8)

E 8-5

I

EXTERIOR

BODY PANELS

4. REAR DOOR PANEL

GENERAL DESCRIPTION

(1) Weatherstrip (Outer)

(2)

Clip (Weatherstrip, outer)

(3) Stabilizer (Outer)

(4)

Stabilizer (Inner)

(5) Door panel

(6) Bracket

(7)

Sealing cover

(8)

Checker

(9) Lower hinge

(IO)

Upper hinge

B0036t

Tightening torque:

N-m

(kgf-m, ft-lb)

T1: 7.4 (0.75, 5.5)

T2: 24.5(2.49, 18)

T3: 29.4 (3.0, 21.7)

T4: 32.3 (3.29,23.8)

EB-6

I

5.

TRUNK LID PANEL

GENERAL DESCRIPTION

EXTERIOR BODY PANELS

(1) Torsion bar

(2) Trunk lid

(3)

Weatherstrip

(4)

Hinge

ASSY

Tightening torque: N-m (kgf-mJ ft-lb)

T1: 7.5 (0.7S, 5.5)

T2: 14

11.8, 13)

E B-7

EXTERIOR BODY PANELS

6. REAR GATE PANEL

GENERAL DESCRIPTION

(1) Gas stay

(2) Hinge

(3) Rear gate

C: CAUTION

Exterior body panels are heavy. Do not drop and damage the panels. During removal and installa- tion, do not damage the panel painting surface.

While removing mounting bolts, using assistance devices such as a support jack will help support the panel.

Be careful not to lose small parts.

E 8-8

BOO367

~~

Tightening torque: N-m (kgf-m, ft-lb)

T: 14(1.43, 10.3)

T1: 25 (2.5, 18.1)

GENERAL DESCRIPTION

EXTERIOR

BODY PANELS

D: PREPARATION TOOL

1.

SPECIAL TOOLS

ILLUSTRATION

TOOL NUMBER

92561 0000

DESCRIPTION

WRENCH

REMARKS

Used for removing and installing door hinge.

B5M1117

927780000 REMOVER Used for removing and installing trunk torsion bar.

B5M1118

2. GENERAL TOOL

TOOL NAME REMARKS

EB-9

I

EXTERIOR BODY PANELS

2. Front Hood

FRONT HOOD

2) Adjust the height at front end of hood. <Ref. to

SL-41 ADJUSTMENT, Front Hood Lock Assem-

.

.

zles.

2) Release the clips to remove the hood insulator.

3) Remove the bolts to disconnect the hood from hinges.

'47

4) Remove the hood grille. (Turbo model) <Ref. to

B: INSTALLATION

1) Install in the reverse order of removal.

2) Adjust the clearance between hood and fender.

Clearance must be equal at both sides.

Tightening torque:

24.5

N-m (2.49 kgf-m, 18 ft-lb)

C: ADJUSTMENT

1) Use the hinge mounting holes to align the front hood longitudinally and laterally.

EB-10

FENDER PANEL

3. Fender Panel

A:

REMOVAL

1)

Disconnect the ground terminal from battery.

2) Remove the side sill spoilers. <Ref. to El-36,

Side Sill Spoiler.> (If fitted)

3) Remove the front bumper face. <Ref. to El-23,

REMOVAL, Front Bumper.>

4)

Remove the mud guard. <Ref. to El-32,

RE-

MOVAL, Mud Guard.>

5) Loosen the bolts to remove front fender.

EXTERIOR BODY PANELS

a

I

6 :

INSTALLATION

1) Install in the reverse order of removal.

2) When the fender panel is installed, the clearance between fender panel and hood or front fender must be equal.

Tightening torque:

7.35 N.m (0.75 kgf-m, 5.4 &/6)

EB-11

FRONT DOOR PANEL

EXTERIOR

BODY PANELS

4.

Front Door Panel

A: REMOVAL

1 ) Disconnect the ground terminal from battery.

2) Remove the front door trim. <Ref. to El-37, RE-

MOVAL, Front Door Trim.>

3) Remove the outer mirror assembly. <Ref. to

GW-33, REMOVAL, Outer Mirror Assembly.>

4)

Remove the front door glass. <Ref. to GW-15,

REMOVAL, Front Door Glass.>

5) Remove the front door regulator and motor.

<Ref. to GW-19, REMOVAL, Front Regulator and

Motor Assembly.>

6) Remove the front door latch assembly. <Ref. to

SL-30, REMOVAL, Front Door Latch Assembly.>

7) Remove the front outer handle. <Ref. to SL-29,

REMOVAL, Front Outer Handle.>

8) Remove the front pillar lower trim to disconnect connector from the body harness.

10) Remove the checker bolts.

11) Remove the door-side bolts for upper and lower hinges to remove the door.

r.

-

9) Put a wooden block on jack and place jack under the door. Support the door with a support jack to protect it from damage.

CAUTION:

During removal and installation of doors, do not damage body.

Doors are heavy. Be careful not

to

drop and damage them.

B: INSTALLATION

1) Install in the reverse order of removal.

2) Apply grease to sliding area of the door hinges.

Refer to COMPONENT of General Description for tightening torque. <Ref. to EB-5, FRONT DOOR

PANEL, General Description.>

EB-12

FRONT DOOR PANEL

C: ADJUSTMENT

1) Using special tool, loosen the body-side bolts of upper and lower hinges to align the position of front door panel longitudinally and vertically.

ST

925610000 DOOR HINGE WRENCH

EXTERIOR BODY PANELS

2) Loosen the screw

(A)

and tap striker (B) using plastic hammer to adjust striker to align the position of front door panel vertically and laterally at the rear end.

CAUTION:

Do not use impact wrench. Welding area on striker nut plate is easily broken.

EB-13

FRONT SEALING COVER

EXTERIOR BODY PANELS

5. Front Sealing Cover

A: REMOVAL

1) Disconnect the battery ground cable.

2) Remove the front door trim. <Ref. to El-37, RE-

MOVAL, Front Door Trim.>

3) Remove the front speaker. <Ref. to ET-7, RE-

MOVAL, Front Speaker.>

4) Using a spatula, remove the sealer.

CAUTION:

Carefully remove sealer. Excessive force will easily break the cover.

If

one. cover gets broken, replace

it

with a new

B: INSTALLATION

1) Install in the reverse order of removal.

2) When replacing sealing cover, use the CEME-

DINE 5430L sealer.

3) Press the sealer-applied area firmly to prevent any floating on surface.

Sealer:

CEMEDINE

54301.

or equivalent

CAUTION:

Apply a uniform bead of sealer.

Attach sealing cover, keeping

it

from becom- ing 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-14

REAR DOOR PANEL

EXTERIOR BODY PANELS

10)

Remove the checker bolts.

6. Rear Door Panel

A: REMOVAL

CAUTION:

During removal and installation of doors, do not damage body.

Doors are heavy. Be careful not to drop and damage them.

1)

Disconnect the ground terminal from battery.

2) Remove the rear door trim. <Ref. to El-38, RE-

MOVAL, Rear Door Trim.>

3) Remove the rear door glass. <Ref. to GW-20,

REMOVAL, Rear Door Glass.>

4) Remove the rear door regulator and motor as- sembly. <Ref. to GW-22, REMOVAL, Rear Regula- tor and Motor Assembly.>

5) Remove the rear door latch. <Ref. to SL-34, RE-

MOVAL, Rear Door Latch Assembly.>

6) Remove the rear outer handle. <Ref. to SL-33,

REMOVAL, Rear Outer Handle.>

Remove the center pillar lower trim. <Ref. to El-

46, REMOVAL, Lower Inner Trim.>

8) Disconnect the connector of door harness.

1 1) Remove the door-side bolts for upper and lower hinges to remove door.

-

B: INSTALLATION

1)

Install in the reverse order of removal.

2) Apply grease to sliding area of the door hinges.

Refer to COMPONENT of General Description for tightening torque. <Ref. to

EB-6,

REAR DOOR

PANEL, General Description.>

BOO1

54

9) Put a wooden block on the jack and place the jack under the door. Support the door with the jack to protect it.

im

S5M051

EB-15

REAR DOOR PANEL

EXTERIOR BODY

PANELS

C: ADJUSTMENT

1)

Open the front door, loosen the door-side bolts of upper and lower hinges to align the position of rear door panel longitudinally and vertically.

2) Loosen the screw

(A)

and tap striker (B) using plastic hammer to adjust striker to align the position of front door panel vertically and laterally at the rear end.

JXUTION:

Do

not use an impact wrench. The welding area on the striker nut plate is easily broken.

EB-16

REAR SEALING COVER

7.

Rear Sealing Cover

A: REMOVAL

1)

Disconnect the battery ground cable.

2) Remove the rear door trim. <Ref. to El-38, RE-

MOVAL, Rear Door Trim.>

3) Remove the rear speaker. <Ref. to ET-9, RE-

MOVAL, Rear Speaker.>

4) Using a spatula, remove the sealer.

CAUTION:

Carefully remove sealer. Excessive force will easily break the cover.

If cover gets broken, replace it with a new one.

EXTERIOR BODY PANELS

B:

INSTALLATION

1)

Install in the reverse order of removal.

2) When replacing sealing cover, use the CEME-

DINE 5430L sealer.

3) Press the sealer-applied area firmly to prevent any floating on surface.

Sealer:

CEMEDINE

5430L

or equivalent

CAUTION:

Apply an uniform bead of sealer.

Attach sealing cover, keeping it from becom- ing wrinkled.

Breaks in the bead will allow water leakage and contamination.

C: INSPECTION

If the sealing cover gets damaged, replace it with a new one.

EB-17

I

tbnk lid from the hinges.

TRUNK LID PANEL

EXTERIOR BODY PANELS

8.

Trunk Lid Panel

A: REMOVAL

1. TRUNK LID

1) Open the trunk lid.

2) Remove the trunk lid release handle. <Ref.to>

B: INSTALLATION

1. TRUNK LID

1)

Install in the reverse order of removal.

2) Install the trunk lid with uniform clearance.

Tightening torque:

14

N-m

(1.8

kgf-m,

13 ft-lb)

2.

TORSION BAR

1) Install in the reverse order of removal.

2) Apply the grease to rotating area of hinges and mating surface of torsion bar.

2; TORSION BAR

1) Open the trunk lid.

2) Using special tool, remove the torsion bar from the hinge link.

ST 927780000 REMOVER

CAUTION:

During removal and installation, carefully han- dle torsion bar. It will generate reactive force.

3) Remove the rightheft torsion bars.

CAUTION:

After the torsion bar is removed, the trunk lid will slam shut. Be careful not to get hit by the trunk lid.

EB-18

9.

Rear Gate Panel

A: REMOVAL

REAR GATE PANEL

EXTERIOR

BODY PANELS

10) Using a support, support the rear gate while re- moving gas stay mounting bolts.

1. REAR GATE PANEL

1) Disconnect the battery ground cable.

2)

Open the rear gate.

3) Remove the rear gate outer handle. <R f. to SL-

36, REMOVAL, Rear Gate Outer Handle.>

4) Remove the rear gate latch assembly. <Ref. to

SL-37, REMOVAL, Rear Gate Latch Assembly.>

5 ) Remove the rear gate key lock cylinders. <Ref. to SL-44, REAR GATE, REPLACEMENT, Key

Lock Cy1 i nders. >

6) Remove the rear wiper. <Ref. to WW-17,

MOVAL, Rear Wiper Motor.>

RE-

7) Disconnect the connectors of rear wiper, rear de- fogger, and other lighting devices.

8) Disconnect the washer hose.

9) Remove the rubber duct (A) connection, and pull

Qut the harness and washer hose from the rear gate.

BOO1 55

CAUTION:

When the rear gate is released, it may hit and damage the body.

To

prevent this, place a shop cloth between body and gate.

11) Loosen the rear gate bolts to remove the rear gate.

EB-19

I

REAR GATE PANEL

EXTERIOR BODY PANELS

2. GASSTAY

1)

Open the rear gate. Using a support jack to sup- port the rear gate.

CAUTION:

After gas stay is removed, rear gate cannot stay open. Supporting the rear gate with a jack, remove the bolts.

Do not damage piston rods and oil seals.

-.

-

Never gas. disassemble cylinders: They contain

2) Loosen the bolts to remove gas stay from rear gate.

B: INSTALLATION

1. REAR GATE PANEL

1)

Install in the reverse order of removal.

2) Install the rear gate panel with uniform clearance to the body.

Refer to COMPONENT of General Description for tightening torque. <Ref. to EB-8, REAR GATE

PANEL, General Description.>

CAUTION:

Do not damage painted surfaces of body and rear gate.

2. GASSTAY

1) Install mounting bolt (A) to the rear gate panel and body.

Tightening torques

14

N-m

(1.8

kgf-m,

13 ft-16)

2) Firmly install the gas stay (B) to mounting bolt

(A).

/

BO0368

CAUTION:

After supporting rear gate with a jack, start op- eration.

BOO1

5E

EB-20

REAR GATE PANEL

C: DISPOSAL

1.

GAS STAY

CAUTION:

Gas is colorless, odorless, and harmless. How- ever, gas pressure may spray cutting powder or oil. Be sure to wear dust-resistant goggles.

1) Cover with a vinyl sack as shown in the figure.

Gas stay

@ L h ! $ j

Vinyl

sack

800261

WLJTION:

Prevent the vinyl sack from being caught by drill cutting edge

2) Lift the body side slightly with piston rods fully ex- tended, 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 door side, and bleed gas stay completely.

Bodv side Door side

190"

(7.48 in)

10"

(0.39 in)

I / \

Portion to be drilled

Piston rod Cylinder

BO0262

EXTERIOR BODY PANELS

m

EB-21

EXTERIOR BODY PANELS

REAR GATE PANEL

EB-22

CRUISE CONTROL SYSTEM

cc

~~

1

Page

.

General Description

....................................................................................

2

2

.

Actuator

.......................................................................................................

4

3

.

Cruise Control Module

................................................................................

5

4

.

Cruise Control Main Switch

.........................................................................

6

5

.

Cruise Control Command Switch

................................................................

7

6

.

Stop and Brake Switch

................................................................................

8

7

.

Clutch Switch

..............................................................................................

9

8

.

Inhibitor Switch

..........................................................................................

10

I

CRUISE CONTROL SYSTEM

1.

General Description

A: COMPONENT

GENERAL DESCRIPTION

(1) Actuator

(2) Inhibitor switch (AT)

(3) Cruise control command switch

(4) Cruise control main switch

(5)

Clutch switch (MT)

(6) Stop and brake switch

.

(7)

Cruise control module

BO0322

c c - 2

GENERAL DESCRIPTION

B: CAUTION

Before disassembling or reassembling parts, al- ways 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 the parts in the reverse order of dis- assembly unless otherwise indicated.

Adjust the parts to specifications specified in this manual.

Connect the connectors and hoses securely dur- ing reassembly.

After reassembly, ensure functional parts oper- ate properly.

C: PREPARATION TOOL

TOOL NAME

Circuit Tester

REMARKS

Used for measuring resis- tance and voltage.

CRUISE CONTROL SYSTEM

c c - 3

I

ACTUATOR

CRUISE CONTROL SYSTEM

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 cable sharply with a radius less than

100 mm (3.94 in); otherwise, cable may bend permanently, resulting in poor perfor- mance.

When installing cable, be careful not to sharply bend or pinch the inner cable; other- wise, the cable may break.

1)

Disconnect the ground terminal from battery.

2) Remove the clip bands from cruise control cable.

3) Loosen the nut which secures cruise control ca- ble end to throttle cam and then remove the cable from throttle cam.

r -

,

B: INSTALLATION

Install in the reverse order of removal.

Tightening torque:

7.4 N.m (0.75 kgf-m, 5.4 ff-lb)

NOTE:

(A): Must be adjusted when cable end outer is fixed in place, so that the gap between throttle cam and lever is 0 - mm (0

- in).

(Must be attached while throttle cam is being pulled by wire cable.)

(B):

Must be coated evenly on cam end inner con- nection.

(C): Cover must be inserted securely, until tip of ca- ble touches cover stopper.

B6M1213A

C: INSPECTION

Measure the cruise control actuator resistance

4) Remove the actuator attaching bolts.

5 ) Remove the actuator while disconnecting con- nector.

I

I

Terminal

No.

4

and 1

4

and 2 and

5

3 6

I

I

Standard

Approx.

5R

Approx.

5R

Approx.

552

Approx.

3952

-1

I c c - 4

I

CRUISE CONTROL MODULE

3.

Cruise Control Module

A: REMOVAL

1) Disconnect the ground terminal from battery.

2) Remove the side sill front cover.

CRUISE CONTROL SYSTEM

,

BOO321

3)

Disconnect the connector from the cruise control module.

4) Remove the cruise control module

(A).

B: INSTALLATION

Install is in the reverse order of removal.

B0032E

cc-5

CRUISE CONTROL MAIN SWITCH

CRUISE CONTROL SYSTEM

4.

Cruise Control Main Switch

A:

REMOVAL

1) Disconnect the ground terminal from battery.

2)

Remove the screws and clip from the instrument panel lower cover.

3) Remove the instrument panel lower cover.

C: INSPECTION

Measure the cruise control main switch resistance.

Main switch side

Efzl

4)

Disconnect the connector from the cruise control main switch(A).

r -

I

G6M0244

Switch position

OFF

ON

Terminal

No.

3 and 5

3 and 5

Standard

More than 1 Mi2

Less than

In

If NG, replace the cruise control main switch.

5) Remove the main switch by pushing it outward.

B: INSTALLATION

Install is in the reverse order of removal.

B0032E

CC-6

5.

CRUISE CONTROL COMMAND SWITCH

CRUISE CONTROL SYSTEM

Cruise Control Command

Switch

A: REMOVAL

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.

2) Turn ignition switch OFF.

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

4)

Using [email protected] BIT T30 (Tamper resistant type), loosen two [email protected] bolts which secure driver's air- bag module.

7) Disconnect the horn and cruise control com- mand switch connector, then remove the cruise control command switch.

B: INSTALLATION

Install is in the reverse order of removal.

C: INSPECTION

Measure the cruise control command switch resis- tance.

m

5)

Disconnect the airbag module connector on back of the airbag module.

6) Remove the horn switch from the steering wheel as shown.

Switch

CANCEL

1

SET/COAST

RESUME/

ACCEL

Position

ON

ON

OFF

Terminal No.

1 (+) and 2 (-)

1 (+) and 3

(4

1 and 3

1 and

3

1 and 2

1 and 2

Standard

Less than 1R

Less than 1R

More than 1MQ

Less than 1R

More than 1 MR

Less than 1R

If NG, replace the cruise control command switch.

cc-7

I

STOP AND BRAKE SWITCH

CRUISE CONTROL SYSTEM

6.

Stop and Brake Switch

A: REMOVAL

1) Disconnect the ground terminal from battery.

2) Disconnect the connector from the switch, and then remove the switch. <Ref. to BR-55, REMOV-

AL, Stop Light Switch.>

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

Measure the brake switch (1) and stop light switch

(2) resistance.

I

B6M 1564A

Switch

Brake

Pedal

Stop light

If

NG, replace the stop and brake switch.

CC-8

I

CLUTCH SWITCH

7.

Clutch Switch

A: REMOVAL

1) Disconnect the ground terminal from battery.

2) Disconnect the connector from the clutch switch, and then remove the switch. <Ref. to CL-26, DIS-

ASSEMBLY, Clutch Pedal.>

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

Measure the clutch switch resistance.

CRUISE CONTROL SYSTEM

im

I

I

Switch

I

Pedal

I

Terminal No.

I

Standard

Clutch

I

Released

Depressed

I

1 and 2

I

Less than 1 Q

I

1 and 2

1

More than 1MQ

1

If

NG, replace the clutch switch.

c c - 9

INHIBITOR SWITCH

CRUISE CONTROL SYSTEM

8.

Inhibitor Switch

A: REMOVAL

1)

Disconnect the ground terminal from the battery.

2) Disconnect the connector from the switch, and then remove the switch. <Ref. to AT-29,

REMOV-

AL, Inhibitor Switch.>

B: INSTALLATION

Installation is in the reverse order of removal.

C: INSPECTION

Measure the inhibitor switch resistance.

Selector lever position

P

N

Except P and N

Terminal No,

7 and 12

B6M1530

Standard

Less than In

Less than la

More than 1MQ

cc-10

.

CRUISE CONTROL

SYSTEM

(D

I

AG N OSTI CS)

cc

4

.

5

.

6

.

7

.

.

1

.

2

.

Page

Basic Diagnostic Procedure

........................................................................

2

General Description

....................................................................................

3

Electrical Components Location

..................................................................

5

Cruise Control Module I/O Signal

................................................................

6

Subaru Select Monitor

.................................................................................

9

Diagnostics Chart with Symptom

..............................................................

11

List of Diagnostic Trouble Code (DTC)

.....................................................

26

Diagnostics Chart with Diagnostic Trouble Code

......................................

28

I

BASIC DIAGNOSTIC PROCEDURE

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

1.

Basic Diagnostic Procedure

A: PROCEDURE

1

2

3

4

. _

5

6

7

8

9

10

~ ~~~

Step

START DIAGNOSIS.

1)Perform pre-inspection. <Ref. to CC-4,

INSPECTION, General Description.>

2)Check cruise control main switch operation.

CHECK VEHICLE SPEED IS HELD WITHIN

SET SPEED.

Make sure vehicle speed is held within set speed.

CHECK RESUMWACCEL OPERATION.

Check RESUME/ACCEL operation.

CHECK SETKOAST OPERATION.

Check SET/COAST operation.

CHECK CANCEL OPERATION.

Check CANCEL operation.

CHECK CRUISE CONTROL RELEASE OP-

ERATION.

Check cruise control release operation.

Check

Is cruise control main switch turned ON?

Is vehicle speed held within set speed

+3

km/h

(f2

?

Does vehicle speed increase or return to set speed after

RESUME/ACCEL switch has been pressed?

So to step 7.

Does vehicle speed decrease after SET/COAST switch has been pressed?

Is cruise control released after

CANCEL switch has been pressed?

So to step

6.

Go

to step 8.

Go

to

Yes

So to step

2.

PREPARE SUBARU SELECT MONITOR.

PERFORM CRUISE CANCEL CONDITIONS

DIAGNOSIS.

Perform cruise cancel conditions diagnosis.

<Ref. to CC-9, Subaru Select Monitor.>

CHECK CRUISE CONTROL SET OPERA-

TION.

Check cruise control set operation.

Is the select monitor available?

So to step

3.

Is trouble code indicated?

So to “Diagnos- tics Chart with

Trouble Code”.

Can cruise control be set while driving at 40 km/h (25 MPH)?

So to step 5. step 9.

Is cruise control released after brake pedal has been depressed?

Go to step 10.

CHECK CRUISE CONTROL RELEASE OP-

ERATION.

Check cruise control release operation.

Is cruise control released after clutch pedal has been depressed? (MT)

Finish the diag- nostics.

No

Go to symptom 1.

<Ref. to CC-I 1,

SYMPTOM

CHART, Diagnos- tics Chart with

Symptom.>

Go to step 4.

Go to step 4.

Go to symptom 2.

<Ref. to CC-11,

SYMPTOM

CHART, Diagnos- tics Chart with

Symptom.>

Go to symptom 3.

<Ref. to CC-11,

SYMPTOM

CHART, Diagnos- tics Chart with

Symptom.>

Go to symptom 4.

<Ref. to CC-11,

SYMPTOM

CHART, Diagnos- tics Chart with

Symptom.>

Go to symptom 5.

<Ref. to CC-11,

SYMPTOM

CHART, Diagnos- tics Chart with

Symptom.>

Go to symptom 6.

<Ref. to CC-11,

SYMPTOM

CHART, Diagnos- tics Chart with

Symptom.>

Go to symptom 7.

<Ref. to CC-11,

SYMPTOM

CHART, Diagnos- tics Chart with

Symptom.>

Go to symptom 8.

<Ref. to

CC-11,

SYMPTOM

CHART, Diagnos- tics Chart with

Symptom.>

cc-2

GENERAL DESCRIPTION

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

2. General Description

A:

CAUTION

1. SUPPLEMENTAL RESTRAINT SYSTEM

"AIRBAG"

Airbag system wiring harness is routed near the cruise control module and cruise control command switch.

B: PREPARATION TOOL

1.

SPECIAL TOOLS

CAUTION:

All Airbag system wiring harness and con- nectors are colored yellow. Do not use electri- cal test equipment on these circuits.

Be careful not to damage Airbag system wir- ing harness when servicing the cruise control module and cruise control command switch.

ILLUSTRATION REMARKS

Troubleshooting for electrical systems.

(Newly adopted tool)

B2M3876

22771AA030

I

SELECT MONITOR

KIT

Troubleshooting for electrical systems.

b

English:

22771 AA030 (Without printer)

German:

22771 AA070 (Without printer)

French:

22771 AA080 (Without printer)

Spanish:

22771 AA090 (Without printer)

2.

GENERAL TOOLS

TOOL NAME

Circuit Tester

REMARKS

Used for measuring resistance, voltage and ampere.

cc-3

I

GENERAL DESCRIPTION

CRUISE CONTROL

SYSTEM (DIAGNOSTICS)

5.

CABLE FREE PLAY

C: INSPECTION

1.

BATTERY

Measure the battery voltage and specific gravity of electrolyte.

Standard voltage:

12 V, or more

Specific gravity:

Above 1.260

2.

CRUISE CONTROL CABLE

I

1

0,

mm

(0.04

PO,,

in)

]

B6M0241A

Check that the throttle cam-to-lever clearance is within specifications.

Throttle cam-to-lever clearance:

0

-

mm (0

-

in)

If NG, adjust the clearance with the adjust nut.

NOTE:

Check that the cap is positioned in the groove.

a

Check the cruise control cable installation.

If NG, install the cable securely.

3.

ACCELERATOR CABLE

Check movement of the accelerator cable when the cruise control throttle is moved by hand.

If

NG, check the throttle cam.

4.

THROTTLE CAM

Check that the throttle cam moves smoothly.

If NG, repair the throttle cam.

cc-4

I

ELECTRICAL COMPONENTS LOCATION

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

3. Electrical Components Location

A: LOCATION

(1) Actuator

(2) Inhibitor switch (AT)

(3) Cruise control command switch

(4)

Cruise control main switch

(5)

Clutch switch (MT)

(6) Stop and brake switch

(7) Cruise control module

cc-5

CRUISE CONTROL MODULE I/O SIGNAL

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

4.

Cruise Control Module I/O Signal

A: ELECTRICAL SPECIFICATION

11111-1..11

1 1 1 1 1 1 1 1 1 1

1 0 9 8

7

6

5

4 3 2

1

20 19 18 17 16 15 14 13 12

1 1

G6M001!

Main light

~~ ~

Inhibitor switch (AT)

I

1

Battery voltage is present when main switch is turned OFF.

I

“ 0 volt is present when main switch is turned ON.

Battery voltage is present when selector lever is other than “ P or “N” position.

Motor B cruise control is operating.

OFF.

6

-

Ground

Motor A

RESUME/ACCEL switch

7

I

ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated while

---I---

SET/COAST switch 10 cruise control is operating.

“ 0 volt is present when main switch is turned OFF.

Battery voltage is present when command switch is turned to RESUMUACCEL position.

“ 0 volt is present when command switch is released.

Battery voltage is present when command switch is turned to SET/COAST position.

I

*

“0”

volt is present when command switch is released.

I

Battery voltage is present when main power is turned

ON

Main power supply

“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.

Ignition switch

Motor C

13 ON-and-OFF (‘‘0”-and-battery voltage) operation is alternately repeated while cruise control is operating.

Motor clutch

1

“ 0 volt is present when main switch is turned OFF.

ON-and-OFF (“0-and-battery voltage) operation is alternately repeated while cruise control is operating.

Cruise control main switch

1

Battery voltage is present during pressing the cruise control main switch, and then battery voltage is present while main switch is turned ON.

“0”

volt is present when main switch is turned OFF.

CC-6

CRUISE CONTROL MODULE

I/O SIGNAL

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

Content

Brake switch

Terminal No.

16

Measuring conditions and I/O signals (ignition switch ON and engine idling)

Leave clutch pedal released (MT), 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 vehicle, 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.

-

Data link connector

Data link connector

Vehicle speed sensor (MT)

TCM (AT)

Stop light switch

17

18

19

20

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 mod- ule.

Turn ignition switch to OFF.

Then check that:

Battery voltage is present when brake pedal is depressed.

“0”

volt is Dresent when brake Dedal is released.

NOTE:

Voltage at terminals 5, 7, 13 and 14 cannot be checked unless vehicle is driving by cruise control operation.

c c - 7

CRUISE CONTROL MODULE I/O SIGNAL

CRUISE CONTROL

SYSTEM

(DIAGNOSTICS)

B:

SCHEMATIC

1.

CRUISE CONTROL

<Ref. to WI-61, SCHEMATIC, Cruise Control Sys- tem.>

CC-8

5.

SUBARU SELECT MONITOR

CRUISE CONTROL

SYSTEM

(DIAGNOSTICS)

Subaru Select Monitor

A:

OPERATION

1.

GENERAL

The on-board diagnosis function of the cruise con- trol system uses an external Subaru Select Moni- tor.

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 driv- ing although cruise cancel condition is not en- tered).

(2) Cruise control module memory stores the cancel condition (Code No.) which occurred dur- ing driving. When there are plural cancel condi-

-. tions (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 igni- tion switch or cruise main switch is turned

OFF.

2) Real-time diagnosis

The real-time diagnosis function is used to deter- mine 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 be- cause problem occurs in the cruise control sys- tem or its associated circuits.

(2) Monitor the signal conditions from switches and sensors.

2.

CRUISE CANCEL CONDITIONS DIAG-

NOSIS

1) Prepare Subaru Select Monitor kit.

S2M0285

2) Connect the diagnosis cable to the Subaru Se- lect Monitor.

3) Insert the cartridge into the Subaru Select Moni- tor.

<Ref. to CC-3, SPECIAL TOOLS, PREPARATION

TOOL, General Description.>

S2M0286A

4)

Connect the Subaru Select Monitor to the data link connector.

(1) Data link connector located in the lower por- tion of the instrument panel (on the driver’s side).

m c c - 9

(2) Connect the diagnosis cable to the data link connector.

SUBARU SELECT MONITOR

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

5) Start the engine and turn the cruise control main switch to ON.

6) Turn the Subaru Select Monitor switch to ON.

Power switch

7)

On the Main Menu display screen, select the {All

System Diagnosis} and press the [YES] key.

NOTE:

The diagnostic trouble code is also shown in the

{Each System Check} mode. This mode is called up on the Cruise Control Diagnosis screen by se- lecting the item {Cancel Code(s) Display}.

8) Drive vehicle at least 30 km/h (19 MPH) with cruise speed set.

9) If the cruise speed is canceled itself (without do- ing any cancel operations), a diagnostic trouble code will appear on select monitor display.

CAUTION:

A

diagnostic trouble code will also appear when cruise cancel is effected by driver. Do not confuse.

Have a co-worker ride in vehicle to assist in diagnosis during driving.

NOTE:

Diagnostic trouble code will be cleared by turning 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.

3) Turn the Subaru Select Monitor switch to ON.

4)

On the Main Menu display screen, select the

{Each System Check} and press the [YES] key.

5) On the System Selection Menu display screen, select the {Cruise Control} and press the [YES] key.

6) Press the [YES] key after displayed the informa- tion of engine type.

7) On the Cruise Control Diagnosis display screen, select the {Current Data Display & Save} and press the [YES] key.

8) Make sure that normal indication is displayed when controls are operated as indicated below:

Depresshelease the brake pedal. (Stop light switch and brake switch turn ON.)

Turn ON the “SETKOAST” switch.

Turn ON the “RESUME/ACCEL” switch.

Depresshelease the clutch pedal. (MT)

Set the selector lever to P or N. (AT)

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 TROU-

BLE CODE.

<Ref. to CC-26, LIST OF DIAGNOSTIC TROUBLE

CODE (DTC), .>

cc-10

DIAGNOSTICS CHART WITH SYMPTOM

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

6.

Diagnostics Chart with Symptom

A: SYMPTOM CHART

4

5

6

Svmptom

Cruise control main switch is not turned ON.

Cruise control cannot be set.

Vehicle speed is not held within set speed k3 km/h (+2

MPH).

Vehicle speed does not increase or does not return to set speed after RESUME/

ACCEL switch has been

Dressed.

Vehicle speed does not jecrease after SET/COAST

;witch has been pressed.

2ruise control is not released

3fter CANCEL switch has

Deen pressed.

-

2ruise control is not released

3fter brake pedal has been jepressed.

7

-

Repair area Reference

(1) Check power supply.

(2) Check cruise control main switch.

<Ref. to CC-14, CHECK POWER SUPPLY, Diagnostics

Chart with SvmDtom.>

I

<Ref. to CC-16, CHECK CRUISE CONTROL MAIN

SWITCH, Diagnostics Chart with Symptom.>

(1) Check SET/COAST switch.

(2) Check stop light switch and brake switch.

<Ref. to CC-18, CHECK CRUISE CONTROL COM-

I

MAND SWITCH. Diaanostics Chart with SvmDtom.>

<Ref. to CC-20, CHECK STOP LIGHT SWITCH AND-

BRAKE SWITCH, Diagnostics Chart with Symptom.>

(3) Check clutch switch (MT).

<Ref. to CC-22, CHECK CLUTCH SWITCH (MT), Diag- nostics Chart with Symptom.>

(4) Check inhibitor switch

(AT).

(5) Check vehicle speed sen- sor.

(6) Check motor drive sys- tem.

(7) Check motor clutch drive system.

(1) Check vehicle speed sen- sor.

(2) Check motor drive sys- tem.

(3) Check motor clutch drive system.

(1) Check RESUME/ACCEL switch.

(2) Check motor drive sys- tem.

(3) Check motor clutch drive system.

(1) Check SET/COAST switch.

(2) Check motor drive sys- tem.

(3) Check motor clutch drive system.

(1) Check CANCEL switch.

(2) Check motor drive sys- tem.

(3) Check motor clutch drive system.

(1) Check stop light switch and brake switch.

(2) Check motor drive sys- tem.

(3) Check motor clutch drive system.

<Ref. to CC-24, CHECK INHIBITOR SWITCH (AT),

Diagnostics Chart with Symptom.>

<Ref. to CC-30, DTC 22 VEHICLE SPEED SENSOR,

Diagnostics Chart with Diagnostic Trouble Code.>

<Ref. to CC-34, DTC 35 AND 36 ACTUATOR MOTOR,

Diaanostics Chart with Diaanostic Trouble Code.>

<Ref. to CC-36, DTC 37 ACTUATOR MOTOR CLUTCH,

Diagnostics Chart with Diagnostic Trouble Code.>

<Ref. to CC-30, DTC 22 VEHICLE SPEED SENSOR,

Diagnostics Chart with Diagnostic Trouble Code.>

<Ref. to CC-34, DTC 35 AND 36 ACTUATOR MOTOR,

Diagnostics Chart with Diagnostic Trouble Code.>

<Ref. to CC-36, DTC 37 ACTUATOR MOTOR CLUTCH,

Diagnostics Chart with Diagnostic Trouble Code.>

<Ref. to CC-18, CHECK CRUISE CONTROL COM-

MAND SWITCH, Diaqnostics Chart with SvmDtom.>

<Ref. to CC-34, DTC 35 AND 36 ACTUATOR MOTOR,

Diagnostics Chart with Diagnostic Trouble Code.>

<Ref. to CC-36, DTC 37 ACTUATOR MOTOR CLUTCH,

Diagnostics Chart with Diagnostic Trouble Code.>

<Ref. to CC-18, CHECK CRUISE CONTROL COM-

MAND SWITCH, Diagnostics Chart with Symptom.>

<Ref. to CC-34, DTC 35 AND 36 ACTUATOR MOTOR,

Diagnostics Chart with Diagnostic Trouble Code.>

<Ref. to CC-36, DTC 37 ACTUATOR MOTOR CLUTCH,

Diagnostics Chart with Diagnostic Trouble Code.>

<Ref. to CC-18, CHECK CRUISE CONTROL COM-

MAND SWITCH, Diagnostics Chart with Symptom.>

<Ref. to CC-34, DTC 35 AND 36 ACTUATOR MOTOR,

Diagnostics Chart with Diagnostic Trouble Code.>

<Ref. to CC-36, DTC 37 ACTUATOR MOTOR CLUTCH,

Diagnostics Chart with Diagnostic Trouble Code.>

<Ref. to CC-20, CHECK STOP LIGHT SWITCH AND

BRAKE SWITCH, Diagnostics Chart with Symptom.>

<Ref. to CC-34, DTC 35 AND 36 ACTUATOR MOTOR,

Diagnostics Chart with Diaqnostic Trouble Code.>

<Ref. to CC-36, DTC 37 ACTUATOR MOTOR CLUTCH,

Diagnostics Chart with Diagnostic Trouble Code.>

a cc-11

DIAGNOSTICS CHART WITH SYMPTOM

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

8

Symptom

Cruise control is not released after clutch pedal has been depressed (MT).

Repair area

(1) Check clutch switch.

(2) Check motor drive sys- tem.

(3) Check motor clutch drive svstem.

Reference

<Ref. to CC-22, CHECK CLUTCH SWITCH (MT), Diag- nostics Chart with Symptom.>

<Ref. to CC-34, DTC 35 AND 36 ACTUATOR MOTOR,

Diagnostics Chart with Diagnostic Trouble Code.>

<Ref. to CC-36, DTC 37 ACTUATOR MOTOR CLUTCH,

Diaunostics Chart with Diaunostic Trouble Code.>

cc-12

DIAGNOSTICS CHART WITH SYMPTOM

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

CC-13

DIAGNOSTICS CHART WITH SYMPTOM

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

B: CHECK POWER SUPPLY

TROUBLE SYMPTOM:

Cruise control can be set normally, but indicator does not come on. (When main switch is pressed.)

WIRING DIAGRAM:

-e

0

SBF-4 FIB No.18

CRUISE CONTROL

MAIN SWITCH

r

I

CC-14

BO0287

1

2

DIAGNOSTICS CHART WITH SYMPTOM

CRUISE CONTROL

SYSTEM

(DIAGNOSTICS)

Step

CHECK POWER SUPPLY.

1)Disconnect cruise control module harness connector.

2)Turn ignition switch

ON.

3)Measure voltage between harness connec- tor terminal and chassis ground.

Connector & terminal

(894)

No.

12

-

Check

CHECK GROUND CIRCUIT.

Measure resistance between harness connec- tor terminal and chassis ground.

Is the resistance less than 10 n?

Connector & terminal

(894)

No.

6

-

I

I

Power supply and ground circuit are

IOK.

No

Check fuse No.

18 (in fuse & relay box).

Check harness for open or short between cruise control module and fuse & relay box.

Repair harness.

CC-15

I

DIAGNOSTICS CHART WITH SYMPTOM

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

C: CHECK CRUISE CONTROL MAIN SWITCH

TROUBLE SYMPTOM:

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 sounds.

This operation sounds will be heard when ignition switch and cruise control main switch is turned to ON.

WIRING DIAGRAM:

SBF-4

- 0

e

-

FIB No.18

CC-16

i

I

BOO287

-.

I

DIAGNOSTICS CHART WITH SYMPTOM

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

Step

CHECK CRUISE CONTROL MAIN SWITCH

CIRCUIT.

1)Disconnect cruise control main switch har- ness connector.

2)Turn ignition switch ON.

3)Measure voltage between harness connec- tor terminal and chassis ground.

Connector & terminal

(8161) No. 3

(+)

CHECK CRUISE CONTROL MAIN SWITCH

CIRCUIT.

1)Turn ignition switch OFF.

2)Disconnect cruise control module harness connector.

3)Measure resistance between cruise control module harness connector terminal and cruise control main switch harness connector termi- nal.

Connector & terminal

(894)

NO.

15

-

5:

(894)

NO.

1

-

NO.

6:

(894)

NO.

11

-

NO.

1:

CHECK CRUISE CONTROL MAIN SWITCH.

Remove and check cruise control main switch.

<Ref. to CC-6, Cruise Control Main Switch.>

Check

s the voltage more than 10 V? s the resistance less than 10

2?

s cruise control main switch

3K?

Yes

;o to step

3.

3eplace cruise

:ontrol module.

No

'

Check fuse No.

I 8 (in fuse & relay lox).

Check harness or open or short letween cruise

:ontrol main

;witch and fuse &

.e I ay box.

3epair harness.

3eplace cruise

:ontrol main

;witch.

m

CC-17

DIAGNOSTICS CHART WITH SYMPTOM

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

D: CHECK CRUISE CONTROL COMMAND SWITCH

TROUBLE SYMPTOM:

Cruise control cannot be set. (Cancelled immediately.)

WIRING DIAGRAM:

1-

-

-

HORN S W C H

1

1'

RESUME/

ACCEL

0

SWITCH

0 ob

CANCEL

*

:G

I I

CRUISE CONTROL

COMMAND SWITCH

1

B

HORN RELAY

n

1 12 13141 516171819110

1 1 ~ 1 2 ~ 1 3 [ 1 4 1 1 5 ~ 1 6 ~ 1 7 ~ 1 8 ~ 1 9 ~ 2 0

1121314151 16171819110111

1 2 ~ 1 3 ~ 1 4 [ 1 5 [ 1 6 ~ 1 7 ~ 1 8 ~ 1 9 ~ 2 0 ~ 2 1 ~ 2 2 ~ 2 3 ~ 2 4

BO0288

CC-18

DIAGNOSTICS CHART WITH SYMPTOM

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

Step

CHECK SETKOAST SWITCH CIRCUIT.

1)Disconnect cruise control module harness connector.

2)Turn ignition switch ON.

3)Measure voltage between harness connec- tor terminal and chassis ground when SET/

COAST switch is pressed and not pressed.

Connector i? terminal

(694) No. 10

(+)

-

(-):

CHECK RESUMWACCEL SWITCH CIRCUIT

Measure voltage between harness connector terminal and chassis ground when RESUME/

ACCEL switch is pressed and not pressed.

Connector i? terminal

(694) No. 9

(+)

CHECK CANCEL SWITCH CIRCUIT.

Measure voltage between harness connector terminal and chassis ground when CANCEL switch is pressed and not pressed.

Connector i? terminal

(694) No. 9

(+)

(694)

No.

10

(+)

-

-

CHECK POWER SUPPLY FOR COMMAND

SWITCH.

Check horn operation.

CHECK CRUISE CONTROL COMMAND

SWITCH.

Remove and check cruise control command switch. <Ref. to CC-7, Cruise Control Com- mand Switch.>

Check

Yes

;the voltage 0 V when SET1

:OAST switch is not pressed?

Go to step 2.

,hen SET/COAST switch is ressed? s the voltage 0 V when

IESUME/ACCEL switch is not ressed? Is the voltage more han 10 V when RESUME/

CCEL switch is pressed?

Go to step

3.

s the voltage 0 V when CAN-

:EL switch is not pressed? IS he voltage more than 10 V vhen CANCEL switch is

)ressed?

Cruise control command switch circuit is OK.

>oes horn sound? s cruise control command

;witch OK?

No

Go to step 4.

Go to step 4.

Go to step 4.

Go to step 5.

Check harness between cruise control command switch and cruise control module.

Check fuse No.

6 (in fuse & relay box).

Check horn relay. <Ref. to

COM-3, HORN

RELAY, INSPEC-

TION, Horn Sys- tem.>

Check harness for open or short between cruise control command switch and fuse & relay box.

Replace cruise control command switch.

cc-19

DIAGNOSTICS CHART WITH SYMPTOM

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

E: CHECK STOP LIGHT SWITCH AND BRAKE SWITCH

TROUBLE SYMPTOM:

Cruise control cannot be set.

WIRING DIAGRAM:

BATTERY

0 0

SBF-1 SBF-2 F/B N0.16

CLUTCH

SWITCH

(Mn

@

: AT MODEL

@

.

MT MODEL m

Q

3 4

I

CRUISE

I

cc-20

STOP LIGHT SWITCH

AND BRAKE SWITCH

BO0289

I

I

1

DIAGNOSTICS CHART WITH SYMPTOM

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

Step

Check

CHECK STOP LIGHT SWITCH AND BRAKE

SWITCH CIRCUIT.

1)Disconnect stop light switch and brake switch harness connector.

2)Turn ignition switch

ON.

3)Turn cruise control main switch ON.

4)Measure voltage between harness connec- tor terminal and chassis ground.

Connector & terminal

(665) No.

2

(+)

-

(-):

CHECK STOP LIGHT SWITCH AND BRAKE

SWITCH CIRCUIT.

Measure voltage between harness connector terminal and chassis ground.

Connector & terminal

(665)

No.

4 (+)

-

(-):

Is the voltage more than 10 V?

Is the voltage more than 10 V?

Yes

;o to step 2.

3.

CHECK STOP LIGHT SWITCH AND BRAKE

SWITCH CIRCUIT.

1)Turn cruise control main switch and ignition switch OFF.

2)Disconnect cruise control module harness connector.

3)Measure resistance between cruise control module harness connector terminal and stop light switch and brake switch harness connec- tor terminal.

Connector & terminal

(694) NO. 20

(694)

NO.

16

-

-

NO.

3:

NO.

1:

CHECK STOP LIGHT SWITCH AND BRAKE

SWITCH.

Remove and check stop light switch and brake switch. <Ref. to CC-8, Stop and Brake

Switch.>

Is the resistance less than 10

a?

Are stop light switch and brake switch OK?

20

to step 4.

;top light switch ind brake switch

;ircuit are OK.

No

Check fuse No.

I6 (in fuse & relay

)OX).

Check harness or open or short

)etween stop light,

)rake switch and use & relay box.

Check harness or open or short letween stop light,

)rake switch and m i s e control

I nodule (AT).

Check clutch

;witch and the cir-

:uit (MT).

3epair harness.

3eplace stop light switch and brake switch.

H cc-21

r.

DIAGNOSTICS CHART WITH SYMPTOM

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

F: CHECK CLUTCH SWITCH (MT)

TROUBLE SYMPTOM:

Cruise control cannot be set.

WIRING DIAGRAM:

BAlTERY

I -

0 0

SBF-1 SBF-2 F/B

No.16

CLUTCH

SWITCH

(NIT)

STOP LIGHT SWITCH

AND BRAKE SWITCH

@

: AT

MODEL

@

.

MT MODEL m

I

CRUISE

CONTROL

MODULE

I

cc-22

BOO289

DIAGNOSTICS CHART WITH

SYMPTOM

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

Step

Check

CHECK CLUTCH SWITCH CIRCUIT.

1 )Disconnect clutch switch harness connector.

2)Turn ignition switch ON.

3)Turn cruise control main switch ON.

4)Measure voltage between harness connec- tor terminal and chassis ground.

Connector & terminal

(6107)

No. 2 (+)

-

Is the voltage more than 10

V?

CHECK CLUTCH SWITCH CIRCUIT.

1)Turn cruise control main switch and ignition switch OFF.

2)Disconnect stop light switch and brake switch harness connector.

3)Measure resistance between clutch switch harness connector terminal and stop light switch and brake switch harness connector ter, minal.

Is the resistance less than 10

2?

Connector & terminal

(6107) NO. 1

-

NO.

4:

CHECK CLUTCH SWITCH.

Remove and check clutch switch. <Ref. to CC

9, Clutch Switch.>

IS

clutch switch OK?

Yes

;o to step

3.

2lutch switch cir-

:uit is OK.

No

Check harness for open or short between clutch switch and cruise control module.

Repair harness. deplace clutch switch.

iil

CC-23

DIAGNOSTICS CHART WITH SYMPTOM

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

G: CHECK INHIBITOR SWITCH (AT)

TROUBLE

SYMPTOM:

Cruise control cannot be set.

WIRING DIAGRAM:

CRUISE

CONTROL

MODULE

r .

TO SECURITY SYSTEM

4-1

WS :WITH SECURITY SYSTEM

:WITHOUT SECURITY SYSTEM

I

@ dq$fI

9 10 11 12

INHIBITOR

SWITCH(AT)

1 [ ' 2 [ 3 1 4 [ 5 [ 6 [ 7 [ 8 [ 9 1 1 0

111121 131 14[15[16[17[18[19120

BOO290

CC-24

. .

DIAGNOSTICS CHART WITH SYMPTOM

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

Step

CHECK INHIBITOR SWITCH CIRCUIT.

tor.

2)Turn ignition switch ON.

3)Turn cruise control main switch

ON.

4)Measure voltage between harness connec- tor terminal and chassis ground.

Connector & terminal

(T7)

No.

12

(+)

-

Check

s the voltage more than 10 V?

Yes

So to step

2.

No

Check the follow- ing.

Interrupt relay

(with security sys- tem) <Ref. to

SL-

48, Interrupt

Relay.>

Harness for open or short between inhibitor switch and cruise control module.

Repair harness.

CHECK INHIBITOR SWITCH CIRCUIT.

1)Turn cruise control main switch and ignition switch OFF.

2)Disconnect starter motor harness connector.

3)Measure resistance between inhibitor switch harness connector terminal and chassis ground.

Connector & terminal

(V)

7 - (614)

NO.

CHECK INHIBITOR SWITCH.

Remove and check inhibitor switch. <Ref. to

CC-IO, Inhibitor Switch.>

3

the resistance less than 10

I?

3

inhibitor switch OK?

Go to step

3.

Inhibitor switch cir- cuit is OK.

Replace inhibitor switch

.

m

CC-25

I

LIST OF DIAGNOSTIC TROUBLE CODE (DTC)

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

7. List of Diagnostic Trouble Code (DTC)

A: LIST

DTC

21

22

24

25

28

35

36

37

38

Item

Inner relay is seized.

Vehicle speed sensor

Cruise control module is abnormal.

Cruise control module is abnormal.

Wiring harness opened.

Motor drive system is abnormal.

Trouble of motor

Motor clutch drive system is abnormal.

Contents of diaanosis

Cruise control module inner relay is seized when main switch is

OFF.

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 mem- ory are not the same.

Open wiring harness circuit is detected via control mod- ule 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.

Motor drive shaft does not engage properly.

Motor drive gear engagement is not properly adjusted.

Reference

<Ref. to CC-28, DTC 21,

24,25 AND 2A CRUISE

CONTROL MODULE

BUILT-IN RELAY, CPU

RAM, Diagnostics Chart with Diagnostic Trouble

Code.>

<Ref. to CC-30, DTC 22

VEHICLE SPEED SEN-

SOR, Diagnostics Chart with Diagnostic Trouble

Code.>

<Ref. to CC-28, DTC 21,

24,25 AND 2A CRUISE

CONTROL MODULE

BUILT-IN RELAY, CPU

RAM, Diagnostics Chart with Diagnostic Trouble

Code.>

<Ref. to CC-28, DTC 21,

24,25 AND 2A CRUISE

CONTROL MODULE

BUILT-IN RELAY, CPU

RAM, Diagnostics Chart with Diagnostic Trouble

Code.>

<Ref. to CC-33, DTC 28

WIRING HARNESS

OPENED., Diagnostics

Chart with Diagnostic

Trouble Code.>

<Ref. to CC-34, DTC 35

AND 36 ACTUATOR

MOTOR, Diagnostics

Chart with Diagnostic

Trouble Code.>

<Ref. to CC-34, DTC 35

AND 36 ACTUATOR

MOTOR, Diagnostics

Chart with Diagnostic

Trouble Code.>

<Ref. to CC-36, DTC 37

ACTUATOR MOTOR

CLUTCH, Diagnostics

Chart with Diagnostic

Trouble Code.>

<Ref. to CC-38, DTC 38

MOTOR DRIVE SHAFT

DOES NOT ENGAGE

PROPERLY., Diagnostics

Chart with Diagnostic

Trouble Code.>

CC-26

DTC

39

2A

LIST OF DIAGNOSTIC TROUBLE CODE (DTC)

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

Item

Motor is overloaded.

Contents of diagnosis normal conditions.

Cruise control module is abnormal.

Cruise control module self-diagnosis function senses abnormality.

Reference

MOTOR IS OVER-

LOADED., Diagnostics

Chart with Diagnostic

Trouble Code.>

<Ref. to CC-28, DTC 21,

24,25 AND 2A CRUISE

CONTROL MODULE

BUILT-IN RELAY, CPU

RAM, Diagnostics Chart with Diagnostic Trouble

Code.>

CC-27

I

DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

8.

Diagnostics Chart with Diagnostic Trouble Code

A: DTC 21,24,25 AND 2A CRUISE CONTROL MODULE BUILT-IN RELAY, CPU

RAM

DIAGNOSIS:

Poor welding of built-in relay of cruise control module.

Failure of built-in CPU RAM of cruise control module.

TROUBLE

SYMPTOM:

Cruise control is canceled and memorized cruise speed is also canceled.

Once the cruise control is canceled, the cruise control cannot be set until the ignition switch and cruise con- trol main switch turns OFF, and then turns ON again.

NOTE:

Check the input/output signal and vehicle speed signal with select monitor. When the signals are in good condition, failure is in cruise control module. (Check power supply and ground conditions of cruise control module.)

CC-28

I

DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

CC-29

I

DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

B: DTC

22

VEHICLE SPEED SENSOR

DIAGNOSIS:

Disconnection or short circuit of vehicle speed sensor system.

TROUBLE SYMPTOM:

Cruise control cannot be set. (Cancelled immediately.)

WIRING DIAGRAM:

IGNITION

BAlTERY

--

@

: TURBO MODEL

@

: NON-TURBO MODEL

@

'

AT

MODEL

@

: MT MODEL

@ : N A @ : T B

A:

.:a

BOO291

CC-30

I

I

!

)

-.

I

DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

No Step Check

CHECK TRANSMISSION TYPE.

CHECK HARNESS BETWEEN BATTERY

AND VEHICLE SPEED SENSOR.

1)Disconnect harness connector from vehicle speed sensor.

2)Turn ignition switch to ON.

3)Measure voltage between vehicle speed sensor harness connector terminal and chas- sis ground.

Connector & terminal

No.

3 (+)

-

(-):

CHECK HARNESS BETWEEN CRUISE CON-

TROL MODULE AND VEHICLE SPEED SEN-

SOR.

1)Turn ignition switch to

OFF.

2)Disconnect harness connector from cruise control module.

3)Measure resistance between vehicle speed sensor harness connector terminal and cruise control module harness connector terminal.

Connector & terminal

(81 7) NO. 1

-

NO. 19:

CHECK HARNESS BETWEEN VEHICLE

SPEED SENSOR AND ENGINE GROUND.

Measure resistance between vehicle speed sensor harness connector terminal and engine ground.

Connector & terminal

No. 2

-

CHECK VEHICLE SPEED SENSOR.

1)Connect harness connector to vehicle speed sensor.

2)Set the vehicle on free roller, or lift-up the vehicle and support with safety stands. s the resistance less than 10

2?

s the resistance less than 10

2?

-+ more than 4 V?

I

I

I

Go to step 4.

1

1

Go to step 5. control module.

<Ref. to CC-5,

Cruise Control

Module.>

Warning:

Be careful not to be caught up by the run- ning wheels.

3)Drive the vehicle at speed greater than 20 km/h (12 MPH).

4)Measure voltage between cruise control module harness connector terminal and chas- sis ground.

Connector & terminal

(894)

No.

19

(+)

-

:heck harness for

)pen or short letween ignition

;witch and vehicle

;peed sensor.

3epair harness.

3epair harness.

3eplace vehicle

;peed sensor.

a

CC-31

I

DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

i r

_ . _

..

Step

Check

CHECK HARNESS BETWEEN CRUISE CON-

TROL MODULE AND TRANSMISSION CON-

TROL MODULE.

1)Disconnect harness connector from trans- mission control module and cruise control module.

2)Measure resistance between cruise control module harness connector terminal and trans- mission control module harness connector ter- minal. s the resistance less than 10

2?

CAUTION:

To measure the voltage andlor resistance, use a tapered pin with a diameter of less than 0.64 mm (0.025 in). Do not insert the pin more than 5 mm (0.20 in).

Connector & terminal

Turbo model:

(B94) NO. 19

-

Non-turbo model:

(B94) NO. 19

-

CHECK TRANSMISSION CONTROL MOD-

ULE.

1)Connect harness connector to transmission control module.

2)Set the vehicle on free roller, or lift-up the vehicle and support with safety stands.

Warning:

Be careful not to be caught by the running wheels.

3)Drive the vehicle faster than 10 km/h (6

MPH).

4)Measure voltage between transmission con- trol module harness connector terminal and chassis ground. s the voltage less than 1 V

-+ more than 4 V?

CAUTION:

To measure the voltage andlor resistance, use a tapered pin with a diameter of less than 0.64 mm (0.025 in). Do not insert the pin more than 5 mm (0.20 in).

Connector & terminal

Turbo model:

(856) No. 17 (+)

-

I (

Non-turbo model:

(B55) No. 13

(+)

-

) (

Yes

;o to step 7 . leplace cruise

:ontrol module.

:Ref. to CC-5,

;ruise Control nodule.>

No

3epair harness

:onnector letween cruise

:ontrol module ind transmission

:ontrol module.

3eplace transmis-

;ion control mod- de. <Ref. to

AT

15, Transmission

:ontrol Module

TCM).>

CC-32

DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

C: DTC 28 WIRING HARNESS OPENED.

1

2

Step Check Yes

CHECK BATTERY.

Measure battery specific gravity of electrolyte.

Is battery specific gravity more than 1.250?

Go to step 2.

CHECK FUSES, CONNECTORS AND HAR-

NESSES.

Check the condition of the main and other fuses, and harnesses and connectors.

Also

check for proper grounding.

Is there anything unusual Repair or replace about the appearance of main faulty parts. fuse, fuse, harness, connector and grounding?

No

Charge or replace battery.

Go to step

2.

End of inspection.

cc-33

DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

D: DTC 35 AND 36 ACTUATOR MOTOR

DIAGNOSIS:

Open or poor contact of cruise control actuator motor.

TROUBLE SYMPTOM:

Cruise control cannot

be

set. (Cancelled immediately.)

WIRING DIAGRAM:

IGNITION

SWITCH

FIB No.18

8 -

CRUISE

ACTUATOR

I

CRUSE

MODULE

BO0292

cc-34

1

2

3

4

5 m

DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

Check Yes

CHECK HARNESS BETWEEN ACTUATOR

AND CRUISE CONTROL MODULE.

1)Disconnect harness connector from cruise control module.

2)Measure resistance between cruise control module harness connector terminal and cruise control actuator harness connector terminal.

Connector & terminal

(67) NO. 1

-

NO. 7:

Is resistance less than 10 Q? io to step 5.

CHECK HARNESS BETWEEN ACTUATOR

AND CRUISE CONTROL MODULE.

Measure resistance between cruise control module harness connector terminal and cruise control actuator harness connector terminal

.

Connector & terminal

(67) NO. 5

-

NO.

5:

Is resistance less than 10

R?

Replace cruise control module.

<Ref. to CC-5,

Cruise Control

Module.>

No

Step

CHECK POWER SUPPLY.

1)Turn ignition switch

OFF.

2)Disconnect harness connector from cruise control actuator.

3)Turn ignition switch

ON.

4)Turn cruise control main switch

ON.

5)Measure voltage between cruise control actuator harness connector terminal and chas- sis ground.

Terminals

Is the voltage more than 10

V?

Go to step 2. Sheck harness for

3pen or short between cruise sontrol main switch and cruise sontrol actuator.

(67) No. 4

(+)

CHECK GROUND CIRCUIT OF ACTUATOR.

Measure resistance between cruise control actuator harness connector terminal and chas- sis ground.

Terminals

(67) No. 6

-

MEASURE RESISTANCE OF ACTUATOR.

Measure resistance of cruise control actuator

Is resistance less than 10

R?

Go to step

3.

Q?

I

I

Is resistance approximately 5 IGo to step 4.

Repair harness.

Replace cruise control actuator.

<Ref. to CC-4, motor.

Terminals

Actuator.>

NO.

4

-NO.

NO. 4

-

1:

2:

NO. 4

-

Repair harness.

Repair harness.

cc-35

DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

E: DTC 37 ACTUATOR MOTOR CLUTCH

DIAGNOSIS:

Open or poor contact of cruise control actuator motor clutch.

TROUBLE SYMPTOM:

Cruise control cannot be set. (Cancelled immediately.)

WIRING DIAGRAM:

BATERY

0 0

SBF-4

IGNITION

SWITCH

FIB No.18

CRUISE CONTROL

L m

CRUISE

CONTROL

ACTUATOR

CRUISE

:oNTRot

MODULE

11213141516171819110

1 1 ~ 1 2 ~ 1 3 ~ 1 4 ~ 1 5 ~ 1 6 ~ 1 7 ~ 1 8 ~ 1 9 ~ 2 0

CC-36

BOO292

I

!

I

>

..

.

I

DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

Step Check Yes

No

CHECK POWER SUPPLY.

1)Turn ignition switch

OFF.

2)Disconnect harness connector from cruise control actuator.

3)Turn ignition switch ON.

4)Turn cruise control main switch ON.

5)Measure voltage between cruise control actuator harness connector terminal and chas- sis ground.

Is the voltage more than 10 V?

Terminals

No.

4

-

) (

CHECK GROUND CIRCUIT

OF

ACTUATOR.

Is resistance less than 10

a?

Go to step 2.

I

Go to step

3.

Measure resistance between cruise control actuator harness connector terminal and chas- sis ground.

Terminals

No. 6

MEASURE RESISTANCE OF ACTUATOR

CLUTCH.

Measure resistance of cruise control actuator clutch.

Is resistance approximately 39 n?

I

Go to step 4.

Terminals

NO.

-

6:

CHECK HARNESS BETWEEN ACTUATOR

AND CRUISE CONTROL MODULE.

1)Disconnect harness connector from cruise control module.

2)Measure resistance between cruise control module harness connector terminal and cruise control actuator harness connector terminal.

Connector & terminal

NO. 2

-

Check harness for open or short between cruise control main switch and cruise

Eontrol actuator.

Repair harness.

Replace cruise

:ontrol actuator.

<Ref. to CC-4,

Actuator.>

Is resistance less than 10

a?

Go to step 5. Repair harness.

------I

Repair harness.

CHECK HARNESS BETWEEN ACTUATOR

AND CRUISE CONTROL MODULE.

Measure resistance between cruise control module harness connector terminal and cruise control actuator harness connector terminal.

Connector & terminal

(87)

3

-

Is resistance less than 10

R?

'

Replace cruise control module.

<Ref. to CC-5,

Cruise Control l

Module.>

cc-37

I

DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

F: DTC 38 MOTOR DRIVE SHAFT DOES NOT ENGAGE PROPERLY.

1

Step Check

CHECK ACTUATOR MOTOR.

1)Disconnect harness connector from cruise control actuator.

2)Remove cruise control actuator from mount- ing bracket.

3)Pull cable by hand to check for looseness or status of inner gear engagement.

Are foreign particles caught in inner gear or does inner gear engage and disengage improperly?

Yes No

Replace cruise Check the cruise control actuator. control cable

<Ref. to CC-4,

Actuator.> adjustment.<Ref. to CC-4, CABLE

FREE PLAY, Gen- eral Description.>

CC-38

DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

G: DTC 39 MOTOR IS OVERLOADED.

1

Step

CHECK THE OPERATING CURRENT TO AC-

TUATOR MOTOR.

1)Connect Subaru Select Monitor to data link connector.

2)Try to drive the vehicle while operating the cruise control system.

3)Check the operation current to the cruise control actuator motor.

Check Yes

Replace cruise control module.

<Ref. to CC-5,

Cruise Control

Module.>

No

Check the power supply circuit.

<Ref. to

CC-14,

CHECK

POWER

SUPPLY,

Diagnos tics Chart with

Symptom.>

m cc-39

DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

CC-40

OPTION PARTS

Refer to

GI831

OP

Page

OPTION PARTS

OP

1

.

General Description

...................................................................................

.2

2. Rear Spoiler

................................................................................................

5

3. Crossbar

....................................................................................................

..6

4.

Trailer Hitch

...............................................................................................

..7

5. Rear Differential Protector

.........................................................................

..8

OPTION PARTS

1.

General Description

GENERAL DESCRIPTION

A: COMPONENT

1. REAR SPOILER

(1) Rear spoiler

(2) High mount stop lamp

2. CROSSBAR

(3) Retention cable

BO0454

Tightening torque:

N-m (kgf-m, ft-lb)

T: 7.4 (0.75, 5.46)

(1)

Front crossbar

(2)

Caution label (Front crossbar)

(3)

Rear crossbar

BOO455

OP-2

3. TRAILER HITCH

GENERAL DESCRIPTION

OPTION PARTS

(1) Receiver hitch

(2) Ball mount

(3) Ball mount pin

(4)

Ball mount clip

(5) Receiver cover

BO0456

Tightening torque: N.m (kgf-m, ft-/&)

T:

95 (9.7, 70)

OP-3

GENERAL DESCRIPTION

OPTION PARTS

4. REAR DIFFERENTIAL PROTECTOR

.\, i i i

I i

P

i

9

(1)

Differential front member

(2) Differential rear member

(3) Spacer (Short)

(4) Spacer (Long)

(5)

Rear differential protector

(6) Washer

Tightening toque:

N-m (kgf-m, ft-lb)

T:

70

(7.1, 51.6)

OP-4

c

2.

.

REAR SPOILER

A: REMOVAL

1)

Disconnect the ground terminal from battery.

2) Open the trunk lid.

3) Disconnect the connector of high mounted stop- light.

OPTION PARTS

B:

INSTALLATION

Install in the reverse order of removal.

Tightening torque:

Rear spoiler to trunk lid

7.5 N.m (0.76 kgf-m, 5.5 ft-lb)

Retention cable to trunk hinge

13.7 N.m (1.4 kgf-m, 10.1 fi-lb)

(1)

Connector

(2) Trunk hinge

4) Rembve the retention cable with the trunk hinge lower side bolt.

5 ) Remove the mounting nuts of rear spoiler.

(1) Retention cable

(2) Mounting nut

6) Remove the rear spoiler with retention cable.

CAUTION:

Pay attention to avoid damage during removal or installation.

OP-5

CROSSBAR

OPTION PARTS

3.

Crossbar

A:

REMOVAL

1) Remove the [email protected] port.

2) Rotate the lower clamp of each end support about 90 degress downward to remove the cross- bar.

B: INSTALLATION

1) Rotate the lower clamp of each end support about 90 degrees downward.

2) Set the front crossbar so that front direction mark on the right side top face of crossbar point in the di- rection of vehicle front.

3) Place the crossbar end support at position 76.2 mm (3 in) behind the joint of front roof rail support and roof rail.

Length A:

76.2 mm

(3

(1) [email protected] bolt T30

(2)

End support

(3) Roof rail

(4)

Lower clamp

CAUTION:

Pay attention to avoid damage to the roof panel during removal or installation.

80044s

(1) Front of vehicle

(2) Front direction mark

(3) Caution label (Front crossbar)

4) Set the rear crossbar so that front direction mark on the right side top face of crossbar point in the di- rection of vehicle front.

5 ) Place the crossbar end support on a joint of rear roof rail support and roof rail.

0 - f -

BOO450

(1) Front of vehicle

(2) Front direction mark

6) Tighten the end support and clamp using [email protected] bolt T30.

OP-6

4.

Trailer Hitch

TRAILER HITCH

A:

REMOVAL

CAUTION:

Because the trailer hitch is heavy, two people are required to remove it.

1)

Lift-up the vehicle.

2) Remove the rubber cushion from tail pipe.

OPTION PARTS

5) Remove the trailer hitch while lowering tail pipe.

B: INSTALLATION

CAUTION:

Because the trailer hitch is heavy, two people are required to install it.

Install in the reverse order of removal.

Tightening torque:

Trailer hitch to body:

95

N-m

(9.7 kgf-m, 70 W b )

Canister:

23 N-m (2.3 kgf-m, 17 ft-lb)

3)

Remove the three nuts and canister.

4)

Remove the trailer hitch installation bolts. w

BO0453

OP-7

REAR DIFFERENTIAL PROTECTOR

OPTION PARTS

5. Rear Differential Protector

A:

REMOVAL

1)

Remove the rear exhaust pipe and muffer.

2) Remove the differential front member installation bolts.

B:

INSTALLATION

Install in the reverse order of removal.

Tightening torque:

70 N-m (7.1 kgf-m, 51.6 ft-16)

DR0022

3) Loosen the nuts until the rear differential protec- tor can be removed.

DR002:

NOTE:

Install the protector between the nuts and differen- tial rear member.

Tightening torque:

70 N-m (7.7 kgf-m, 51.6 ft-16)

4)

Remove the rear differential protector.

OP-8

OPTION

PARTS

r.

OP-2

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