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FOREWORD This manual contains on-vehicle service and diagnosis procedures for the Chery A3 Sedan. A thorough familiarization with this manual is important for proper repair and maintenance. It should always be kept in a handy place for quick and easy reference. The contents of this manual, including drawings and specifications, are the latest available at the time of printing. As modifications affecting repair or maintenance occur, relevant information supplementary to this volume will be made available at Chery dealers. This manual should be kept up-to-date. Chery Automobile Company, Ltd. reserves the right to alter the specifications and contents of this manual without obligation or advance notice. All rights reserved. No part of this book may be reproduced or used in any form or by any means, electronic or mechanical including photocopying and recording and the use of any kind of information storage and retrieval systemwithout permission in writing.
NOTE: This A3 Sedan service manual only applies to the following engines and transaxles: 1.6L with M/T 1.8L with M/T
CONTENTS
Title Section
GENERAL INFORMATION ENGINE ELECTRONIC ENGINE CONTROLS FUEL DELIVERY STARTING & CHARGING COOLING EXHAUST TRANSAXLE DRIVELINE & AXLE SUSPENSION STEERING BRAKES HEATING & AIR CONDITIONING RESTRAINTS BODY & ACCESSORIES WIRING ALPHABETICAL INDEX
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 AI
GENERAL INFORMATION
01
page Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1 Vehicle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9 Electrical Circuit Diagnosis Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-15 Electrical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-20
01
CONTENTS
SERVICE INFORMATION
HOW TO USE THIS MANUAL
Topics Service Procedures Diagnostic Procedures Specifications 01-2 01-2 01-2 01-2 01-2 01-3 01-3 01-3 01-4 01-4
01-5 01-5 01-5 01-5 01-6 01-6 01-6 01-7 01-7 01-8 01-8 01-8
011
Service Procedures
Most repair procedures begin with an illustration. It identifies the components, shows how the parts fit together and describes visual part inspection. Removal & Installation procedures have written instructions. Service procedures include the following elements: Detailed removal & installation instructions Integrated torque specifications Integrated illustrations Component specifications
Diagnostic Procedures
The diagnostic procedures are grouped into the following: Diagnostic Trouble Codes (DTC) DTCs are important hints for repairing malfunctions that are difficult to simulate. Perform the specific DTC diagnostic inspection to quickly and accurately diagnose the malfunction. Diagnostic Symptoms Symptom troubleshooting quickly determines the location of the malfunction according to symptom type.
Specifications
This manual contains specifications that are divided into the following groups: Torque specifications Clearance specifications Capacity specifications
012
01
BESM010004
BESM010005
013
Special Tools
Use special tools when they are required.
BESM010006T
VISM010001
014
01
BESM010007
Component Disassembly
If the disassembly procedure is complex, requiring many parts to be disassembled, make sure that all parts are disassembled in a way that will not affect their performance or external appearance. Identify each part so reassembly can be performed easily and efficiently.
BESM010008
Inspection of Parts
When removed, inspect each part for possible malfunction, deformation, damage or other problems.
BESM010009
015
Arrangement of Parts
All disassembled parts should be carefully arranged for reassembly. Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.
BESM010010
Cleaning of Parts
Carefully and thoroughly clean all parts to be reused.
BESM010011
WARNING!
Using compressed air can cause dirt and other particles to fly out causing injury to the eyes. Wear protective eyewear whenever using compressed air.
Component Reassembly
Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. If removed, replace these parts with new ones: Oil seals Gaskets O-rings Lock washers Cotter pins Nylon nuts
BESM010012
016
01
BESM010013
Adjustments
Use suitable gauges and testers when making adjustments.
BESM010014
BESM010015
CAUTION: Exposing rubber components to gasoline or oil can deteriorate the rubber components.
017
Hose Clamps
When reinstalling, position the hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit.
BESM010016
Vise
When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.
BESM010017
Dynamometer
When test-running a vehicle on a dynamometer: Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle. Connect an exhaust gas ventilation unit.
WARNING!
Exhaust gases can injure or kill. They contain carbon monoxide (CO), which is colorless and odorless. Breathing it can make you unconscious and can eventually poison you. Cool the exhaust pipes with a fan. Keep the area around the vehicle uncluttered. Monitor the engine coolant temperature gauge.
018
VEHICLE INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN)
VIN Location VIN Identification Codes
FASTENER USAGE
01-10 01-10 01-11 01-13 01-13 Fastener Usage
01-14 01-14
01
INTERNATIONAL SYMBOLS
International Symbols
019
The VIN is printed on a plastic tag attached to the top left corner of the upper instrument panel. The VIN is also found on the vehicle certification (VC) label.
0110
01
BESM010002
NUMBER DESIGNATION 1 2 3 4 5 6 7 8 9 10
DEFINITION World Manufacturer Identifier Brand Of The Vehicle Vehicle Chassis Type Transmission Type Engine Type Restraint System Check Digit Model Year Assembly Plant Production Sequence Number
Digits #1, #2, #3 The first 3 vehicle identification number (VIN) positions are the world manufacturer identifier: LVV represents Chery Automobile Co., Ltd. Digit #4 The fourth digit of the VIN code represents the brand of the vehicle: The brand Chery is represented by the letter D. Digit #5 The fifth digit of the VIN code represents the body configuration of the vehicle: A represents three compartments, five-door, and 4X2. B represents two compartments, five-door, and 4X2. C represents three compartments, four-door, two-lid, and 4X2. D represents two compartments, five-door, and 4X4. Digit #6 The sixth digit of VIN code represents the type of transmission: 1 represents manual transmission. 2 represents automatic transmission. Digit #7 The seventh digit of VIN code represents the type of engine: 1 represents electronically controlled gasoline engines 1.5L - 2.0L (excluding 2.0L) series. 2 represents engines smaller than 1.5L (excluding 1.5L). 4 represents 2.0L - 2.5L engines (excluding 2.5L).
0111
0112
INTERNATIONAL SYMBOLS
International Symbols
The graphic symbols illustrated in the following International Control and Display Symbols chart are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.
01
1 - High Beam 2 - Fog Lamps 3 - Headlamp, Parking Lamps, Panel Lamps 4 - Turn Signals 5 - Hazard Warning 6 - Windshield Washer 7 - Windshield Wiper 8 - Windshield Wiper and Washer 9 - Windshield Defroster 10 - Blower Motor Fan 11 - Rear Window Defroster 12 - Rear Window Wiper
13 - Rear Window Washer 14 - Fuel 15 - Engine Coolant Temperature 16 - Battery Charging Condition 17 - Engine Oil 18 - Seat Belt 19 - Brake Failure 20 - Parking Brake 21 - Hood 22 - Trunk 23 - Horn 24 - Lighter
BESM010003
0113
FASTENER USAGE
Fastener Usage
WARNING!
Use of an incorrect fastener may result in component damage. Failure to follow these instructions may result in personal injury or death. Fasteners and torque specification references in this Service Manual are identified in metric format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used.
0114
01
0115
Step 3
0116
01
Freezing Test
The customer may indicate the incident goes away after the vehicle warms up (winter time). The cause could be related to water freezing somewhere in the wiring/electrical system. There are two methods to check for this: The first method is to arrange for the owner to leave the vehicle overnight. Make sure it will get cold enough to demonstrate the complaint. Leave the vehicle parked outside overnight. In the morning, do a quick and thorough diagnosis of those electrical components which could be affected. The second method is to put the suspect component into a freezer long enough for any water to freeze. Reinstall the part into the vehicle and check for the reoccurrence of the incident. If it occurs, repair or replace the component as needed.
0117
0118
01
LTSMD030028
0119
ELECTRICAL INFORMATION
HOW TO READ ELECTRICAL SCHEMATICS
Connector Symbols Option Splices Electrical Schematic - Example 01-21 01-21 01-22 01-23
01-25 01-25
0120
01
In wiring diagrams, male terminals are shown in black and female terminals are shown in white. NOTE : Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams.
BESMW010003T
BESMW010004T
0121
Option Splices
Option splices are shown with solid diamond-shaped boxes with identification numbers inside.
BESMW010002T
0122
01
BESMW010001T
0123
13
Page crossing
14 15 16
17
Connector color
18 19
0124
01
02 - Engine
Engine Control Module (ECM) Engine Coolant Temperature Sensor Knock Sensor Upstream Oxygen Sensor Downstream Oxygen Sensor Crankshaft Position Sensor Camshaft Position Sensor Ignition Coil Canister Control Valve Front Fuse and Relay Box A/C Compressor Immobilizer Fuel Injectors Manifold Absolute Pressure Sensor (1.6L Only) Air Flow Sensor (1.8L Only) Accelerator Pedal Position Sensor Vehicle Speed Sensor Throttle Pedal Position Sensor Power Steering Switch Clutch Pedal Switch (if equipped) Electronic Throttle Control Actuator
04 - Fuel Delivery
Starter Motor Ignition Switch Clutch Pedal Switch (if equipped) Generator
06 - Cooling System
Cooling Fan
0125
10 - Suspension
11 - Steering
Power Steering Switch Electronic Power Steering (EPS) Control Unit Steering Torque Sensor EPS Motor
12 - Brakes
Antilock Brake System (ABS) Module Wheel Speed Sensors Brake Switch Parking Brake Switch Brake Fluid Level Switch
Automatic Temperature Control System Blower Motor In-Car Temperature Sensor Outside Temperature Sensor A/C Compressor Refrigerant Pressure Switch
14 - Restraints
Airbag Module Seat Belt Buckle Switch Front Crash Sensors Driver Airbag Passenger Airbag
0126
01
16 - Wiring
Power Distribution Front Fuse and Relay Box Power Fuse Box Ignition Switch Ground Distribution
Abbreviation List
TERM Antilock Brake System Accelerator Sensor Accelerator Pedal Position Sensor Automatic Temperature Control Body Control Module Brake Pressure Sensor Camshaft Position Sensor Clutch Pedal Position Switch Crankshaft Position Sensor Data Link Connector Diagnostic Trouble Code Engine Control Module Engine Coolant Temperature Engine Speed Evaporative Emission Evaporative Emission Canister Evaporative Emission System Exhaust Gas Recirculation Valve Electronic Power Steering Chery Automobile Co., Ltd. ABBREVIATION ABS AES APS ATC BCM BPS CMP Sensor CPP Switch CKP Sensor DLC DTC ECM ECT RPM EVAP EVAP Canister EVAP System EGR Valve EPS
0127
0128
ENGINE
02
page 1.6L & 1.8L Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-1
CONTENTS
02
ON-VEHICLE SERVICE
Accessory Drive Belt - With Conventional Power Steering Removal & Installation Accessory Drive Belt - With Electronic Power Steering Removal & Installation Air Cleaner Element Removal & Installation Air Cleaner Housing Removal & Installation Cylinder Head Cover Removal & Installation Camshaft Removal & Installation Cylinder Head Removal & Installation
021
02-50 02-50 02-50 02-50 02-52 02-52 02-53 02-53 02-54 02-55 02-57 02-58 02-58 02-58 02-59 02-59 02-60 02-60 02-60 02-61 02-62
02-63 02-63 02-63 02-63 02-65 02-65 02-66 02-66 02-67 02-67 02-69 02-70 02-70 02-70 02-72 02-73 02-73 02-73 02-74 02-75 02-75
022
GENERAL INFORMATION
Description
The 1.6L & 1.8L in-line four cylinder engines have the following features: Dual overhead camshafts Four valves per cylinder Aluminum cylinder head Aluminum cylinder block (1.6L Engine) Cast iron cylinder block (1.8L Engine)
02
Operation
The 1.6L & 1.8L engines utilize 4 valve-per-cylinders and a dual overhead camshaft design. The engines use an individual coil ignition system. The 1.6L engine uses an aluminum cylinder block, and the 1.8L engine is made of cast iron The bearing caps are integrated into the lower cylinder block assembly. An aluminum oil pan bolts to the bottom of the lower cylinder block. The camshafts are mounted in the cylinder head and act against valve tappets to open and close the valves. The camshafts are driven off the front of the cylinder head by one timing belt. The belt is driven by a sprocket that is located on the crankshaft. The piston assembly is an aluminum piston with a cast iron connecting rod. The aluminum cylinder head contains dual overhead camshafts with 4 valve-per-cylinder construction. The valves are arranged in two in-line banks. The cylinder head incorporates powdered metal valve guides and seats. The cylinder head is sealed to the block using a multi-layer steel head gasket and retaining bolts.
Specifications
1.6L Engine Specifications
DESCRIPTION Type Number of Cylinders Compression Ratio Compression Pressure Maximum Compression Pressure Variation Between Cylinders Stroke Bore Displacement Firing Order SPECIFICATION In-Line OHV, DOHC 4 10.5:1 10 - 15 Bar 25% 77.5 mm 81 mm 1597 cc 1-3-4-2
023
GENERAL INFORMATION
Mechanical Specifications
Description ITEM Lower Idle Speed (800 50 r/min) Engine Oil Pressure High Idle Speed (2000 r/min) High Speed (4000 r/min) Surface Distortion Engine Block Clearance Inner Diameter Out-Of-Round Taper Piston Ring Groove Clearance Piston Ring End Gap Clearance Piston To Piston Pin Clearance Piston Diameter Ring Groove Clearance Connecting Rod Radial Clearance Connecting Rod Axial Clearance Diameter Of Crankshaft Main Journals Diameter Of Crankshaft Rod Journals Out-Of-Round Maximum Of Crankshaft Main Journals Axial Clearance Of Crankshaft Radial Clearance Of Crankshaft Coaxality Crankshaft Main Journal Thrust Washer Thickness Oil Clearance Of Crankshaft Rod And Main Journals Cylinder Head Flatness Intake Valve Deflection Exhaust Valve Deflection Spring Height Spring Height At 620 Newtons Of Pressure Intake Cam Lobe Height First Ring Second Ring First Ring Second Ring First Ring Second Ring STANDARD 1.2 - 1.5 bar 3.2 - 3.5 bar 3.7 0.5 bar 81.000 - 81.010 mm 0.04 - 0.08 mm 0.0251 - 0.01 mm 0.2 - 0.4 mm 0.4 - 0.6 mm 0.002 - 0.013 mm 80.946 - 80.964 mm 0.04 - 0.08 mm 0.01 - 0.0251 mm 0.016 - 0.051 mm 0.002 - 0.013 mm 53.981 - 54 mm 47.884 - 47.9 mm 0.07 - 0.265 mm 0.0035 - 0.034 mm 2.4 - 2.405 mm 0.022 mm 47.7 mm 32.0 mm 37.15 mm LIMIT 0.15 mm Less than 0.008 mm Less than 0.01 mm 0.8 mm 1.0 mm Less than 0.008 mm Less than 0.005 mm 0.058 mm Less than 0.04 mm Less than 0.02 mm Less than 0.04 mm -
024
GENERAL INFORMATION
Description Exhaust Cam Lobe Height Camshaft Journal #1 Outer Diameter Camshaft Journal #2, #3, #4, #5, Outer Diameter Camshaft Cam Bearing #1 Inner Diameter Camshaft Cam Bearing #2, #3, #4, #5, Inner Diameter Camshaft Journal #1 Clearance Camshaft Journal #2, #3, #4, #5 Clearance Intake Camshaft Axial Clearance Exhaust Camshaft Axial Clearance Intake Valve Guide Clearance Exhaust Valve Guide Clearance Valve Outer Diameter Valve Guide Inner Diameter Fringe Thickness On Top Of Valve Valve Tilt Angle Valve Height ITEM Intake Valve Exhaust Valve Intake Valve Exhaust Valve Intake Valve Exhaust Valve Intake Valve Exhaust Valve Intake Valve Exhaust Valve STANDARD 37.05 mm 31.934 - 31.95 mm 23.947 - 23.96 mm 32 - 32.025 mm 24 - 24.021 mm 0.05 - 0.091 mm 0.04 - 0.074 mm 0.15 - 0.20 mm 0.15 - 0.20 mm 0.012 - 0.043 mm 0.032 - 0.063 mm 5.98 0.008 mm 5.96 0.008 mm 5.4 0.1 mm 5.4 0.1 mm 0.3 0.15 mm 0.3 0.15 mm 65 68 107.998 mm 106.318 mm LIMIT -
02
Torque Specifications
CAUTION: When torquing a fastener in two steps, DO NOT use a torque wrench for the second step.
DESCRIPTION Accessory Drive Belt Tensioner Pulley Bolt Camshaft Bearing Cap Bolts Clutch Pressure Plate Bolts Connecting Rod Cap Bolts Crankshaft Holder Crankshaft Main Bearing Cap Bolts TORQUE (Nm) 35 11 25 1st Step: Tighten the bolt to 25 Nm 2nd Step: Tighten the bolt an additional 90 28 1st Step: Tighten the bolt to 45 Nm 2nd Step: Tighten the bolt an additional 180
025
GENERAL INFORMATION
DESCRIPTION Crankshaft Timing Belt Pulley Bolt Crankshaft Vibration Damper Bolts Cylinder Head Cover Bolts Cylinder Head Bolts Dipstick Bracket Bolts Engine Left Mount Bolt Engine Right Mount Bolt Engine Rear Mount Bolt Engine To Transaxle Bolts Exhaust Manifold Nuts Exhaust Manifold Heat Shield Bolts Exhaust Camshaft Timing Belt Pulley Bolt Flywheel Bolts Fuel Rail Bracket Bolts Idler Pulley Bolt Intake Camshaft Timing Belt Pulley Bolt Intake Manifold Bolts Intake Manifold Nuts Intake Manifold Bracket Bolts Lower Idler Pulley Bolt Lower Cylinder Block Bolts Oil Filter Oil Pan Bolts Oil Drain Plug Oil Strainer Bolts Oil Pump Bolts Rear Timing Cover Bolts Timing Belt Upper Cover Bolts Timing Belt Lower Cover Bolts Timing Belt Tensioner Assembly Timing Belt Tensioner Pulley Bolt Throttle Body Bolts Upper Idler Pulley Bolt TORQUE (Nm) 1st Step: Tighten the bolt to 130 Nm 2nd Step: Tighten the bolt an additional 65 25 11 1st Step: Tighten the bolt to 40 5 Nm 2nd Step: Tighten the bolt an additional 90 5 3rd Step: Tighten the bolt an additional 90 5 11 120 120 120 80 25 15 120 75 11 40 120 10 11 25 45 23 25 18 40 18 11 (Apply with Loctite 5910 Thread-Locker) 7 11 11 27 30 11 45
026
GENERAL INFORMATION
Special Tools
02
027
GENERAL INFORMATION
028
GENERAL INFORMATION
02
029
GENERAL INFORMATION
Engine Hoist
Lubrication System
The engine lubrication system operates as follows: Oil is drawn into the oil pump through the oil pump strainer tube in the sump of the oil pan. Oil is pumped through the oil filter on the cylinder block. Oil enters the main oil gallery where it is distributed to the crankshaft main journals and to the cylinder head. From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate the connecting rod bearings. Controlled leakage through the crankshaft main bearings and connecting rod bearings is slung radially outward to cool and lubricate the cylinder walls as well as the entire connecting rod, piston and piston ring assembly. The engine lubrication system is a full-flow filtration, pressure feed type. The oil pump body is mounted to the engine block. The pump inner rotor is driven by the crankshaft. Engine Oil Pressure Lower Idle Speed (800 50 RPM) High Idle Speed (2000 RPM) High Speed (4000 RPM) 1.2 - 1.5 bar 3.2 - 3.5 bar 3.7 0.5 bar
0210
GENERAL INFORMATION
Engine Oil Flow Diagram
02
1 Oil Pump Strainer 2 Baffle Plate 3 Oil Pan 4 Oil Pump 5 Turbocharger Inlet Oil Passage (if equipped) 6 To Cylinder Head 7 Oil Return Passage 8 To Front Bearing Cap
9 To Middle Bearing Cap 10 Oil Dipstick 11 To Crankcase 12 Crankcase Pipe 13 Oil Filter Bracket 14 Oil Pressure Switch 15 Oil Cooler 16 Oil Filter
BESM020088
0211
1 - Oil Dipstick 2 - Oil Dipstick Bolt 3 - Oil Dipstick Bracket 4 - Oil Dipstick Guide 5 - Crankshaft Rear Oil Seal 6 - O-Ring 7 - Oil Filter Bracket Cushion 8 - Oil Filter Bracket 9 - Pressure-Relief Plunger 10 - Flange Bolt 11 - Flange Bolt 12 - Oil Cooler 13 - Oil Filter Connector 14 - Oil Filter 15 - Dowel Pin
16 - Oil Pan Bolt 17 - Oil Pan Bolt 18 - Oil Pan Bolt 19 - Oil Pan 20 - O-Ring 21 - O-Ring 22 - Oil Pump Strainer Bolt 23 - Oil Pump Strainer 24 - Baffle Plate 25 - O-Ring 26 - O-Ring 27 - Crankshaft Front Oil Seal 28 - Oil Pump Bolt 29 - Oil Pump Assembly 30 - Oil Pump Assembly Gasket
LTSM020161
0212
02
1. Weak battery. 2. Corroded or loose battery connections. 3. Faulty starter. 4. Faulty coil(s) or control unit. 5. Incorrect spark plug gap. 6. Contamination in fuel system. 7. Faulty fuel pump. 8. Incorrect timing.
1. 2. 3. 4.
Idle speed too low. Incorrect fuel mixture. Intake manifold leakage. Faulty ignition coil(s).
1. Dirty or incorrectly gapped spark plugs. 2. Contamination in fuel system. 3. Faulty fuel pump. 4. Incorrect valve timing. 5. Leaking cylinder head gasket. 6. Low compression. 7. Burned, warped, excessive clearance or pitted valves. 8. Plugged or restricted exhaust system. 9. Faulty ignition coil(s). 10. Burned spark plugs. 1. Dirty or incorrectly gapped spark plugs. 2. Contamination in fuel system. 3. Burned, warped, or pitted valves. 4. Faulty ignition coil(s). 1. Dirty or incorrect spark plug gap. 2. Faulty ignition coil(s). 3. Dirty fuel injector(s). 4. Contamination in fuel system.
0213
1. Insufficient oil supply. 2. Low oil pressure. 3. Thin or diluted oil. 4. Excessive bearing clearance. 5. Connecting rod journal out-ofround. 6. Connecting rod out-of-round. 7. Misaligned connecting rods.
1. Insufficient oil supply. 2. Low oil pressure. 3. Thin or diluted oil. 4. Excessive bearing clearance. 5. Excessive end play. 6. Crankshaft journal out-of-round or worn. 7. Loose flywheel or torque converter.
1. 2. 3. 4. 5. 6.
Low oil level. Faulty oil pressure sending unit. Low oil pressure. Clogged oil filter. Thin or diluted oil. Excessive bearing clearance.
OIL LEAKS
1. Misaligned or deteriorated gaskets. 2. Loose fastener, broken or porous metal part. 3. Misaligned or deteriorated cup or threaded plug. 1. PCV system malfunction. 2. Worn, scuffed or broken rings. 3. Carbon in oil ring slots. 4. Rings fitted too tightly in grooves. 5. Worn valve guide(s). 6. Valve stem seal(s) worn or damaged.
0214
02
0215
ON-VEHICLE SERVICE
Accessory Drive Belt - With Conventional Power Steering
Removal & Installation
1 - Drive Belt 2 - Generator Bolt 3 - Tensioner Pulley Bolt 4 - Tensioner 5 - Compressor 6 - Generator 7 - Idler Pulley 8 - Generator Bracket 9 - Generator Bracket Bolt
10 - Generator Bracket Bolts 11 - Power Steering Pump Bolt 12 - Power Steering Pump Bolt 13 - Power Steering Pump Bolt 14 - Power Steering Pump Bracket 15 - Power Steering Pump Bracket Bolts 16 - Power Steering Pump 17 - Idler Pulley 18 - Compressor Bolts
LTSM020163
WARNING!
Inspect the drive belt only when the engine is stopped. 1. While using a suitable tool and securely holding the hexagonal portion of the drive belt tensioner, rotate the pulley counterclockwise to loosen the drive belt.
WARNING!
Avoid placing hands near the drive belt tensioner while it is being held.
0216
ON-VEHICLE SERVICE
2. Remove the drive belt. 3. If replacing the accessory drive belt tensioner, remove the accessory drive belt tensioner pulley bolt (1). (Tighten: Accessory drive belt tensioner pulley bolt to 35 Nm) 4. Installation is in the reverse order of removal.
02
LTSM020196
WARNING!
Avoid placing hands near the drive belt tensioner while it is being held. 2. Remove the drive belt. 3. If replacing the accessory drive belt tensioner, remove the accessory drive belt tensioner pulley bolt (1). (Tighten: Accessory drive belt tensioner pulley bolt to 35 Nm) 4. Installation is in the reverse order of removal.
VISM020006
0217
ON-VEHICLE SERVICE
VISM020011
VISM020007
3. Loosen the clamps (1) between the air intake hose and the air cleaner.
VISM020001
0218
ON-VEHICLE SERVICE
4. Remove the bolts (1) securing the air cleaner housing to its base.
02
VISM020004
5. Remove the air cleaner housing. 6. Installation is in the reverse order of removal.
BESM020022
0219
ON-VEHICLE SERVICE
7. Remove the cylinder head cover bolts (1). (Tighten: Cylinder head cover bolts to 11 Nm) 8. Remove the cylinder head cover (2) from the cylinder head. 9. Remove the cylinder head cover gasket (3). 10. Installation is in the reverse order of removal.
LTSM020198
Camshaft
Removal & Installation
NOTE : The following special tools are required to perform the repair procedure: CH-20002 - Camshaft seal installer CH-20010 - Camshaft holder 1. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine). 2. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine). 3. Remove the cylinder head cover (See Cylinder Head Cover Removal & Installation in Section 02 Engine). 4. Remove the intake or exhaust camshaft timing belt pulleys. (Tighten: Camshaft timing belt pulley bolt to 120 Nm)
0220
ON-VEHICLE SERVICE
5. Remove the rear timing cover of the timing pulley. (Tighten: Rear timing cover bolts to 7 Nm)
02
BESM020034
6. Remove the camshaft bearing cap bolts. (Tighten: Camshaft bearing cap bolts to 11 Nm) NOTE: Equally loosen camshaft bearing cap bolts in several steps. 7. Remove the camshaft bearing caps and place them in proper order. NOTE: The camshaft bearing caps are marked for identification.
BESM020035
8. Remove the camshafts and then remove the camshaft seals. 9. Installation is in the reverse order of removal.
0221
ON-VEHICLE SERVICE
Installation Notes: Use special tool CH-20010 (1), to install the camshaft holder to hold the camshafts in place. NOTE : The camshaft holder will prevent the camshafts from rotating in either direction.
Use special tool CH-20002 (1), to install the camshaft seal. Install the intake and exhaust camshaft bearing caps in the proper order. Slowly tighten bolts to the specified torque.
BESM020016
LTSM020215
BESM020036
0222
ON-VEHICLE SERVICE
Cylinder Head
Removal & Installation
02
1 - Rocker Arm 2 - Hydraulic Tappet 3 - Valve Keeper 4 - Valve Spring Upper Retainer
5 - Valve Spring 6 - Valve Oil Seal 7 - Valve Spring Lower Retainer 8 - Valve
LTSM020167
NOTE : Replacement cylinder head comes complete with valves, seals, springs, retainers, keepers, and camshafts. 1. Remove engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine). 2. Remove the cylinder head cover (See Cylinder Head Cover Removal & Installation in Section 02 Engine). 3. Remove the camshafts (See Camshaft Removal & Installation in Section 02 Engine). 4. Remove intake manifold (See Intake Manifold Removal & Installation in Section 02 Engine). 5. Remove exhaust manifold (See Exhaust Manifold Removal & Installation in Section 02 Engine). 6. Remove water pipe and thermostat assembly.
0223
ON-VEHICLE SERVICE
7. Remove the cylinder head bolts in the order shown.
BESM020065
8. Remove cylinder head gasket. 9. Installation is in the reverse order of removal. Installation Notes: Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged. The cylinder head bolts should not be reused. The new bolts should be examined before use. If the bolts are stretched, the bolts should be replaced. Position the new cylinder head gasket on the engine block with the part number facing up. Ensure gasket is seated over the locating dowels in the block. Before installing the bolts, the threads should be lightly coated with engine oil.
0224
ON-VEHICLE SERVICE
Install the cylinder head bolts in the order shown. Torque the cylinder head bolts in the following three step sequence: 1st Step: Tighten the bolt to 40 5 Nm 2nd Step: Tighten the bolt an additional 90 5 3rd Step: Tighten the bolt an additional 90 5
02
LTSM020236
BESM020055
0225
ON-VEHICLE SERVICE
4. Remove the crankshaft timing belt pulley bolt (2) from the crankshaft. (Tighten: Crankshaft timing belt pulley bolt to 130 Nm and an additional 65) 5. Remove the key-way from the crankshaft. 6. Use an appropriate tool and remove the front crankshaft oil seal (1).
CAUTION: Be careful not to damage the front cover seal surface while removing the seal.
LTSM020199
7. Installation is in the reverse order of removal. Installation Notes: Use the front crankshaft seal installer CH-20008 (1), to install the new seal. Lubricate the new front seal with engine oil prior to assembly.
LTSM020216
LTSM080145
0226
ON-VEHICLE SERVICE
3. Remove clutch pressure plate retaining bolts (1) and then remove the clutch pressure plate. (Tighten: Clutch pressure plate bolts to 25 Nm)
02
BESM080046
4. Remove the engine flywheel mounting bolts (1), and then remove the flywheel. (Tighten: Flywheel mounting bolts to 75 Nm)
BESM020058
5. Remove the rear oil seal using a suitable tool. 6. Installation is in the reverse order of removal. Installation Notes: When installing seal, lubricate seal guide with clean engine oil. Position the seal over the rear crankshaft seal guide. Use special tool CH-20005 (2) and CH-20006 (1), to install the rear crankshaft oil seal. Ensure that the lip of the seal is facing toward the crankcase during installation.
LTSM020217
0227
ON-VEHICLE SERVICE
Engine Mounts
Left Mount - Removal & Installation
NOTE : The following special tools are required to perform the repair procedure: Engine Hoist 1. 2. 3. 4. Disconnect the positive and negative battery cables. Remove the battery (See Battery Removal & Installation in Section 05 Starting & Charging). Remove the front fuse and relay box. Remove the battery tray retaining bolts (1).
VISM080003
5. Remove the left transaxle mount bolts (2) and the left transaxle mount bracket bolts (1). (Tighten: Left transaxle mount bolt to 120 Nm)
VISM020005
0228
ON-VEHICLE SERVICE
02
VISM030003
4. Remove the vapor canister retaining bolts (1) and set the canister aside.
VISM030002
5. Remove the right engine mount bolts (1) and the right engine mount bracket bolts (2). (Tighten: Right engine mount bolts to 120 Nm)
VISM020002
0229
ON-VEHICLE SERVICE
VISM020003
Engine Assembly
Removal & Installation
NOTE : The following special tools are required to perform the repair procedure: CH-20001 - Right engine mount bolt remover Engine hoist NOTE : The engine is removed with the transaxle as an assembly. 1. Remove the vehicle hood. 2. Remove the battery, battery hold downs, and battery tray (See Battery Removal & Installation in Section 05 Starting & Charging). 3. Loosen the clamps (1) between the air intake hose and the air cleaner, then remove the air inlet hose. NOTE: For 1.8L engine, disconnect the air flow sensor electrical connector.
VISM020001
0230
ON-VEHICLE SERVICE
4. Remove the retaining bolts (1) and remove the air cleaner and air cleaner housing assembly.
02
VISM020004
5. Remove the power fuse box (1) and set it aside. 6. Remove the front fuse and relay box (2).
VISM080015
7. Remove the front air intake hose retaining bolt (1) and take off the front air intake hose (2).
VISM080037
8. Evacuate the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating and Air Conditioning). 9. Drain the cooling system (See Cooling System Draining and Filling in Section 06 Cooling). 10. Remove the coolant reservoir retaining bolts (1) and the hose clamps (2). 11. Remove the coolant reservoir.
VISM030003
0231
ON-VEHICLE SERVICE
12. Remove the vapor canister retaining bolts (1) and set the canister aside.
VISM030002
13. Remove the coolant fan & radiator assembly (See Coolant Fan & Radiator Assembly Removal & Installation in Section 06 Cooling). 14. Remove the starter motor wiring. 15. Remove the negative battery cable from the engine. 16. Relieve the fuel pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery). 17. Disconnect and remove the fuel line at the fuel rail. 18. Remove the ground cable bolt from the cylinder head. 19. Disconnect and remove the following electrical connectors: Coolant temperature sensor Coolant level sensor Camshaft position sensor Ignition coil Four fuel injectors Intake manifold air pressure sensor (1.6L engine only) Air flow sensor (1.8L engine only) Carbon canister solenoid valve Throttle body control A/C compressor Oil pressure sensor Power steering pump pressure switch Generator 20. Remove the pipe from the canister control valve. 21. Disconnect the heater hoses (1) on the vehicle. 22. Remove the vacuum line from the brake booster (2). 23. Remove the dipstick.
BESM020025
0232
ON-VEHICLE SERVICE
24. Remove the transaxle shift cable (1).
02
BESM080051
25. Remove the shift cable clamp (1) from the shift cable bracket.
VISM080026
VISM080025
VISM080031
0233
ON-VEHICLE SERVICE
28. Disconnect the hydraulic line (1) from the hydraulic clutch cylinder and position it aside.
BESM080063
CAUTION:While hoses are disconnected, plug all openings to prevent foreign material from entering them. 29. Remove the hydraulic line clamp (1).
VISM080038
30. Remove the A/C compressor line bolt (1) from the A/C compressor. (Tighten: A/C compressor line bolts to 20 Nm) NOTE: After removing the A/C lines, plug the A/C lines to prevent any debris from entering the A/C system.
VISM130017
31. If equipped with conventional power steering,remove the high pressure line (1) and low pressure line (2) from the power steering pump (drain fluid from lines). (Tighten: High pressure line to power steering pump 40 5 Nm) (Tighten: Low pressure line to power steering pump 40 5 Nm)
BESM110011
0234
ON-VEHICLE SERVICE
32. Remove the exhaust manifold heat shield bolts (1) and then remove heat shield. (Tighten: Exhaust manifold heat shield bolts to 15 Nm)
02
BESM020078
33. Disconnect the upstream and downstream oxygen sensor connectors. 34. Remove the catalytic converter to exhaust manifold bolts (1).
LTSM020201
Raise the vehicle. Remove the front axle shaft (See Front Axle Shaft Removal & Installation in Section 09 Driveline & Axle). Drain the engine oil. Lower the vehicle and install engine lift chain hangers. Remove the rear engine mount bolts (2) and the rear engine mount bracket bolt (1). (Tighten: rear engine mount bolt to 120 Nm)
VISM020003
0235
ON-VEHICLE SERVICE
40. Remove the left transaxle mount bolts (2) and the left transaxle mount bracket bolts (1). (Tighten: Left transaxle mount bolt to 120 Nm)
VISM020005
41. Remove the right engine mount bolts (1) and the right engine mount bracket bolts (2). (Tighten: Right engine mount bolt to 120 Nm)
VISM020002
42. Verify all components between the engine and vehicle are disconnected. 43. Remove the front sub-frame (See Front Sub-frame Removal & Installation in Section 10 Suspension). 44. Hoist the engine from vehicle.
CAUTION: Verify all electrical connectors are disconnected prior to engine/transaxle removal.
45. Separate engine and transaxle. 46. Remove the accessory drive belt (1) and the idle pulley (See Accessory Drive Belt Removal & Installation in Section 02 Engine).
LTSM020200
0236
ON-VEHICLE SERVICE
47. Remove the generator (1) from the bracket (See Generator Removal & Installation in Section 05 Starting & Charging). 48. Remove the A/C compressor (2) (See A/C Compressor Removal & Installation in Section 13 Heating and Air Conditioning).
02
BESM020029
49. If equipped with conventional power steering, remove the power steering pump (1) with the lines attached, set aside and secure with wire (See Power Steering Pump Removal & Installation in Section 11 Steering).
BESM020028
0237
ON-VEHICLE SERVICE
1 - Timing Belt Upper Cover Bolts 2 - Timing Belt Upper Cover 3 - Timing Belt Upper Cover Gasket 4 - Timing Belt 5 - Timing Belt Pulley 6 - Camshaft Timing Belt Pulley Bolts 7 - Camshaft Timing Belt Pulleys 8 - Timing Belt Rear Cover Bolts
9 - Timing Belt Rear Cover 10 - Idler Pulley 11 - Tensioner Pulley 12 - Tensioner Pulley Bolt 13 - Timing Belt Lower Cover 14 - Timing Belt Lower Cover Bolts 15 - Timing Belt Upper Cover Bolts
LTSM020162
NOTE : The following special tools are required to perform the repair procedure: CH-20001 - Right engine mount bolt remover CH-20003 - Crankshaft holder CH-20010 - Camshaft holder Engine hoist 1. Disconnect the negative battery cable. 2. Disconnect the coolant level sensor electrical connector. 3. Release the coolant system pressure.
WARNING!
Never remove the pressure relief cap under any conditions while the engine is operating or hot. Failure to follow these instructions could result in personal injury or damage to the cooling system or engine. To avoid having scalding hot coolant or steam blow out of the cooling system, use extreme care when removing the pressure relief cap. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly one turn (counterclockwise). Step back while the pressure is released from the cooling system. When you are certain all the pressure has been released, (with a cloth) turn and remove the pressure relief cap. Failure to follow these instructions may result in serious personal injury.
0238
ON-VEHICLE SERVICE
4. Drain the cooling system (See Cooling System Draining and Filling in Section 06 Cooling). 5. Remove the coolant reservoir retaining bolts (1) and the hose clamps (2). 6. Remove the coolant reservoir.
02
VISM030003
7. Remove the vapor canister retaining bolts (1) and set the canister aside.
VISM030002
8. Attach an engine hoist and support the engine using an engine hoist. 9. Using special tool CH-20001, remove the right engine mount bolts (1) and bracket bolts (2).
VISM020002
10. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine). 11. Remove the crankshaft vibration damper bolts (1). (Tighten: Crankshaft vibration damper bolts to 25 Nm)
BESM020055
0239
ON-VEHICLE SERVICE
12. Remove the timing belt upper cover (1) and timing belt lower cover (2). (Tighten: Timing belt upper cover bolts to 11 Nm) (Tighten: Timing belt lower cover bolts to 11 Nm)
BESM020020
13. Remove the cylinder head cover (See Cylinder Head Cover Removal & Installation in Section 02 Engine). 14. Remove the plug in the cylinder block. 15. Using special tool CH-20003 (1), install the crankshaft holder into the cylinder block and rotate the crankshaft until the crankshaft tool completely holds the crankshaft in place. (Tighten: Crankshaft holder to 28 Nm) NOTE: The crankshaft holder will prevent the crankshaft from rotating in either direction.
LTSM020234
16. Using special tool CH-20010 (1), install the camshaft holder to hold the camshafts in place. NOTE: The camshaft holder will prevent the camshafts from rotating in either direction.
BESM020016
CAUTION: Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious damage to the valves or pistons.
0240
ON-VEHICLE SERVICE
17. Loosen the bolt of the timing belt tensioner pulley (1), remove the pulley. (Tighten: Timing belt tensioner pulley bolt to 30 Nm) 18. Remove the timing belt (3). 19. Installation is in the reverse order of removal. Installation Notes: Install the timing belt and rotate the tensioner pulley with an Allen wrench in order to apply tension to the belt and align the finger pointer of the tensioner to the middle of the U-slot opening. Tighten the tensioner pulley bolt (1) to 30 Nm, then tighten the intake and exhaust camshaft pulley bolts (2) & (4) to 120 Nm.
02
PZSM020037
0241
ON-VEHICLE SERVICE
Intake Manifold
Removal & Installation
1 - Fuel Rail Bolts 2 - Fuel Rail 3 - Electronic Throttle Control Actuator Bolts 4 - Electronic Throttle Control Actuator 5 - Electronic Throttle Control Actuator Gasket 6 - Air Intake Pressure Temperature Sensor Bolt
7 - Air Intake Pressure Temperature Sensor 8 - Intake Manifold Bolt 9 - Intake Manifold 10 - Intake Manifold Support Bracket 11 - Intake Manifold Gasket
LTSM020164
WARNING!
Never remove the pressure relief cap under any conditions while the engine is operating or hot. Failure to follow these instructions could result in personal injury or damage to the cooling system or engine. To avoid having scalding hot coolant or steam blow out of the cooling system, use extreme care when removing the pressure relief cap. Wait until the engine is cool, then wrap a thick cloth around the pressure relief cap and turn it slowly one turn (counterclockwise). Step back while the pressure is released from the cooling system. When you are certain all the pressure has been released, (with a cloth) turn and remove the pressure relief cap. Failure to follow these instructions may result in serious personal injury.
0242
ON-VEHICLE SERVICE
3. Disconnect the four fuel injector electrical connectors (1). 4. Disconnect the throttle body control electrical connector (2).
02
LTSM020221
5. Disconnect the air pressure sensor electrical connector (1) (1.6L engine only). 6. Remove MAP sensor (2) from intake manifold.
LTSM020227
7. Disconnect the air flow sensor electrical connector (1) (1.8L engine only).
VISM020007
8. Loosen the clamp between the air intake hose and the air cleaner. 9. Loosen the clamp between the air intake hose and the throttle body and then remove the intake pipe. 10. Loosen the clamp on the PCV hose and then disconnect the PCV hose.
0243
ON-VEHICLE SERVICE
11. Remove the fuel rail bracket bolts (1). (Tighten: Fuel rail bracket bolts to 11 Nm) 12. Remove the fuel rail with 4 fuel injectors and set aside.
LTSM020222
Remove the screws securing the vacuum valve bracket to the intake manifold. Set aside the vacuum valve and pipe. Disconnect intake manifold electrical harness, and vacuum hose. Remove the bolts (2) & (3) securing the engine oil dipstick to intake manifold. Remove the dipstick. (Tighten: Dipstick bracket bolts to 11 Nm) 17. Disconnect the oil pressure switch connector (4). 18. Remove the nuts (1) securing the intake manifold to cylinder head. (Tighten: Intake manifold nuts to 11 Nm)
LTSM020223
NOTE: Replace a new intake manifold gasket. 19. Installation is in the reverse order of removal. Installation Notes: Clean all surfaces of manifold and cylinder head. Install new O-rings on the fuel injectors.
Exhaust Manifold
Removal & Installation
1. Remove the engine cover. 2. Remove the bolts (1) attaching the exhaust manifold heat shield. (Tighten: Exhaust manifold heat shield bolts to 15 Nm) 3. Remove the exhaust manifold heat shield.
BESM020078
0244
ON-VEHICLE SERVICE
4. Remove the three bolts (1) securing the exhaust manifold to the catalytic converter assembly. 5. Disconnect the catalytic converter assembly from the manifold.
02
LTSM020201
6. Remove the exhaust manifold nuts (1). (Tighten: Exhaust manifold nuts to 25 Nm)
BESM020033
LTSM020169
0245
ON-VEHICLE SERVICE
Installation Notes: Clean all surfaces of manifold and cylinder head.
Idler Pulley
Removal & Installation
1. While using a suitable tool and securely holding the hexagonal portion of the drive belt tensioner, rotate the pulley counterclockwise to loosen the drive belt.
WARNING!
Avoid placing hands near the drive belt tensioner while it is being held. 2. Remove the drive belt. Upper Accessory Drive Belt Idler Pulley (1) Remove the bolt and the upper accessory drive belt idler pulley. (Tighten: Upper idler pulley bolt to 45 Nm) Lower Accessory Drive Belt Idler Pulley (2) Remove the bolt and the lower accessory drive belt idler pulley. (Tighten: Lower idler pulley bolt to 45 Nm) 3. Installation is in the reverse order of removal.
LTSM020203
Oil Filter
Removal & Installation
NOTE : The following special tools are required to perform the repair procedure: CH-10003 - Oil filter remover
CAUTION: When servicing the oil filter, avoid deforming the filter by installing the special tool against the base of the filter.
1. Using special tool CH-10003 oil filter remover, remove the oil filter (1). (Tighten: Oil filter to 25 Nm)
LTSM020206
2. Installation is in the reverse order of removal. Installation Notes: Clean all surfaces, and verify the oil filter does not leak.
0246
ON-VEHICLE SERVICE
Oil Pan
Removal & Installation
1. Remove the oil dipstick. 2. Raise the vehicle on hoist. 3. Remove the oil pan drain plug and drain the engine oil. (Tighten: Oil pan drain plug to 40 Nm) NOTE : Do not pry on cylinder block to remove oil pan. 4. Remove oil pan bolts (1). (Tighten: Oil pan bolts to 18 Nm)
02
LTSM020205
5. Using a putty knife, loosen seal around oil pan. 6. Remove the oil pan. 7. Installation is in the reverse order of removal. Installation Notes: Oil pan sealing surfaces must be free of grease or oil. Install the four oil pan corner bolts in the sequence shown (1-2-3-4). Install the remaining oil pan bolts. Torque all the oil pan bolts to the proper specification.
VISM020013
0247
ON-VEHICLE SERVICE
Oil Pump
Removal & Installation
1. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine). 2. Remove the crankshaft vibration damper retaining bolts (1). (Tighten: Crankshaft vibration damper bolts to 25 Nm)
BESM020055
3. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine). 4. Remove the crankshaft timing belt pulley bolt (2) from the crankshaft. (Tighten: Crankshaft timing belt pulley bolt to 130 Nm and an additional 65) 5. Remove the key-way from the crankshaft. 6. Use an appropriate tool and remove the front crankshaft oil seal (1).
LTSM020199
four oil pump bolts (1). pump bolts to 11 Nm) oil pump (2) using a suitable tool. oil pump gasket (3).
BESM020032
10. Installation is in the reverse order of removal. Installation Notes: Before installing, prime the new oil pump. Fill the oil pump with engine oil and rotate the oil pump. Replace the oil pump gasket.
0248
ON-VEHICLE SERVICE
Oil Strainer
Removal & Installation
1. Raise the vehicle on hoist. 2. Remove the oil pan (See Oil Pan Removal & Installation in Section 02 Engine). 3. Remove the oil strainer retaining bolts (1). (Tighten: Oil strainer bolts to 18 Nm)
02
BESM020018
4. Carefully remove the oil strainer. 5. Installation is in the reverse order of removal. Installation Notes: Install new O-rings on the oil strainer pipe.
0249
Clearance Specifications
DESCRIPTION Surface Distortion Limit Inner Diameter Standard Out-Of-Round Taper SPECIFICATION 0.15 mm 81 mm Less than 0.008 mm Less than 0.01 mm
Disassembly
1. Remove the oil pan and then remove oil baffle. 2. Remove the oil strainer.
BESM020060
3. For each connecting rod / piston assembly to be removed, rotate the crankshaft to the bottom dead center position for each cylinder. NOTE : Before removing the connecting rod / piston assembly, check the connecting rod side clearance.
0250
02
BESM020042
BESM020043
6. Using a hammer handle or similar tool, push the connecting rod / piston assembly (1) out through the top of the cylinder block.
BESM020044
7. Remove the connecting rod bearings (See Connecting Rod Removal & Installation in Section 02 Engine).
BESM020045
CAUTION: When removing the connecting rod side bearings, note the installation position. Keep them in the correct order. Chery Automobile Co., Ltd.
0251
Inspection
NOTE : All measurements should be taken with the engine block at room temperature, 21C. Engine Block Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking. Examine block and cylinder bores for cracks or fractures. Check block deck surfaces for flatness. Deck surface must be within service limit of 0.050 mm. Cylinder Bore The cylinder walls should be checked for out-of-round and taper with cylinder indicator or equivalent. If the cylinder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted. Measure the cylinder bore at three levels in directions X and Y. Top measurement should be 10 mm down and bottom measurement should be 10 mm up from bottom of bore.
BESM020063
Assembly
NOTE : Cleanliness is extremely important during the engine assembly procedure. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. NOTE : Assemble all components in their original position. 1. Install the pistons to the connecting rods. 2. Using a piston ring expander, install the piston rings. 3. Assemble all components in the reverse order of disassembly.
0252
Pistons
Specifications
Clearance Specifications - Pistons
DESCRIPTION Surface Distortion Limit Inner Diameter Standard Out-Of-Round Taper SPECIFICATION 0.15 mm 81 mm Less than 0.008 mm Less than 0.01 mm
02
0253
Disassembly
Piston Ring Removal Using a suitable ring expander, remove upper and intermediate piston rings. Remove the upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston. Clean ring grooves of any carbon deposits.
BESM020047
CAUTION: Before removing the piston rings (1), check the piston ring side clearance. Be careful to mark the location of the piston rings if they are to be reused.
Piston Pin Snap Ring Removal Using snap ring pliers, remove the snap ring (1). Heat the pistons if necessary.
BESM020046
BESM020048
0254
02
Connecting Rod & Piston Disassembly Remove the piston from the connecting rod.
BESM020049
BESM020041
Inspection
Check the piston diameter.
BESM020050
0255
BESM020063
Check piston ring to groove side clearance: Clean the ring slot using a suitable tool. Measure piston ring to groove side clearance.
BESM020051
RING GROOVE CLEARANCE First Ring Second Ring 0.04 - 0.08 mm 0.01 - 0.0251 mm
Check piston ring end gap clearance: Wipe the cylinder bore clean. Insert ring and push down with piston to ensure it is square in the bore. The ring end gap measurement must be made with the ring positioned at least 13 mm from bottom of cylinder bore and below the bottom of the oil ring travel where the cylinder bore has minimal wear. Check the ring end gap with feeler gauge.
BESM020052
0256
02
BESM020053
BESM020054
Assembly
1. Install the piston to the connecting rod. Assemble the components in their original positions. 2. Using a piston ring expander, install the piston rings. Assemble the components in their original positions. 3. Assemble all components in the reverse order of disassembly.
0257
Connecting Rods
Specifications
Torque Specifications
DESCRIPTION Connecting Rod Bolts TORQUE (Nm) 1st Step: Tighten bolts to 25 Nm 2nd Step: Tighten the connecting rod bolts an additional 90
Clearance Specifications
DESCRIPTION Connecting Rod Radial Clearance Connecting Rod Axial Clearance SPECIFICATION 0.016 - 0.051 mm 0.002 - 0.013 mm
Disassembly
1. Remove the connecting rod cap bolts. 2. Remove the connecting rod bearing cap.
BESM020043
BESM020044
0258
02
BESM020045
NOTE: Before removing the piston and connecting rod assembly, check the connecting rod side clearance. 4. Remove the connecting rod bearings. CAUTION:When removing the connecting rod side bearings, note the installation position. Keep them in the correct order.
Inspection
Check the radial clearance of connecting rod bearing. CONNECTING ROD RADIAL CLEARANCE Radial Clearance 0.016 - 0.051 mm
Assembly
NOTE : The rod bolts should not be reused. 1. Before installing the NEW rod bolts, the threads and under the bolt head should be oiled with clean engine oil. 2. Install each bolt finger tight, then alternately tighten each bolt to assemble the cap properly. 3. Tighten the connecting rod bolts using the two step torque-turn method: 1st Step: Tighten bolts to 25 Nm 2nd Step: Tighten the connecting rod bolts an additional 90
LTSM020208
0259
BESM020064
Crankshaft
Specifications
Torque Specifications
DESCRIPTION Main Bearing Cap Bolts Lower Cylinder Block Bolts TORQUE (Nm) 1st Step: Tighten the bolt to 45 Nm 2nd Step: Tighten the bolt an additional 180 23
Clearance Specifications
DESCRIPTION Diameter of Crankshaft Main Journals Diameter of Crankshaft Rod Journals Out-of-Round Maximum of Crankshaft Main Journals Axial Clearance of Crankshaft Radial Clearance of Crankshaft Coaxality Crankshaft Main Journal Thrust Washer Thickness SPECIFICATION 53.981 - 54 mm 47.884 - 47.9 mm 0.008 mm 0.07 - 0.265 mm 0.0035 - 0.034 mm 0.05 mm 2.4 - 2.405 mm
Disassembly
1. Remove the front crankshaft oil seal (See Front Crankshaft Oil Seal Removal & Installation in Section 02 Engine). 2. Remove the rear crankshaft oil seal (See Rear Crankshaft Oil Seal Removal & Installation in Section 02 Engine). 3. Remove the pistons with connecting rod assemblies.
0260
02
BESM020074
5. Remove the lower cylinder block. 6. Remove the crankshaft. 7. Remove the main bearings and thrust bearings from the cylinder block and lower cylinder block. NOTE: If reusing the bearings, identify and number the bearings so that they are assembled in the same position and direction.
Inspection
Inspect the crankshaft rod and main journals for the following: The crankshaft main journals should be checked for excessive wear, roundness and scoring. Main journal limits of roundness should be held to 0.008 mm. Rod journal limits of roundness should be held to 0.005 mm. DO NOT nick crank pin or bearing fillets.
Check the axial clearance after installation: Standard axial clearance should be 0.07 mm. Limits of axial clearance should be held to 0.265 mm.
BESM020076
0261
BESM020077
Assembly
1. Install the main bearings and thrust bearings to the upper cylinder block and lower cylinder block. NOTE: Identify and number the bearings, if reusing them, so that they are assembled in the same position and direction. 2. Assemble the crankshaft and main bearings in the reverse order of disassembly.
0262
02
DESCRIPTION Cylinder Head Bolts Cylinder Head Cover Bolts TORQUE (Nm) 1st Step: Tighten the bolt to 40 5 Nm 2nd Step: Tighten the bolt an additional 90 5 3rd Step: Tighten the bolt an additional 90 5 11
Clearance Specifications
DESCRIPTION Cylinder Head Flatness Intake Valve Deflection Exhaust Valve Deflection Spring Height SPECIFICATION 0.04 mm 0.02 mm 0.04 mm 47.7 mm
Disassembly
NOTE : The following special tools are required to perform the repair procedure: CH-20010 - Camshaft Holder CH-20011 - Valve seal installer CH-20012 - Valve stem seal installer guide CH-20013 - Valve seal remover CH-20017 - Valve keeper installer CH-20018 - Valve spring compressor NOTE : Replacement cylinder head comes complete with valves, seals, springs, retainers, keepers, tappets, and camshafts. 1. Remove camshafts (See Camshaft Removal & Installation in Section 02 Engine). 2. Remove the hydraulic tappet assembly (1).
BESM020071
0263
BESM020067
4. Remove the valve keeper (1), valve spring retainer (2) and valve spring (3). 5. Push the valve stem from the cylinder head and remove the valve (4).
VISM080041
6. Using special tool CH-20013 (1), remove the valve oil seal.
LTSM020225
0264
Inspection
Inspect the cylinder head for the following: Cylinder head must be flat within 0.04 mm. Inspect camshaft bearing journals for scoring. Remove carbon and varnish deposits from inside of valve guides with a valve guide cleaner. Verify the valve tappets move freely in their bores, and that they have been rotating. Check the valve guide height.
02
BESM020068
Assembly
1. Install new valve guide if necessary. 2. Install new valve seat if necessary. 3. Using special tool CH-20011 (1) and CH-20012 (2), install the new valve oil seal.
LTSM020224
4. Install the valves into the cylinder head (larger diameter on intake side). 5. Install the valve springs. 6. Install the valve spring retainers.
0265
BESM020067
9. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly. 10. Install valve tappets in the head. 11. Install the camshafts. Installation Notes: Coat the valve oil seal with engine oil.
Camshaft
Specifications
Camshaft Specifications
DESCRIPTION Intake Cam Lobe Height Exhaust Cam Lobe Height Journal #1 Outer Diameter Journal #2, #3, #4, #5, Outer Diameter Cam Bearing #1 Inner Diameter Cam Bearing #2, #3, #4, #5, Inner Diameter Journal #1 Clearance Journal #2, #3, #4, #5 Clearance Intake Camshaft Axial Clearance Exhaust Camshaft Axial Clearance SPECIFICATION 37.15 mm 37.05 mm 31.934 - 31.95 mm 23.947 - 23.96 mm 32 - 32.025 mm 24 - 24.021 mm 0.05 - 0.091 mm 0.04 - 0.074 mm 0.15 - 0.20 mm 0.15 - 0.20 mm
0266
Disassembly
1. Remove the camshaft bearing caps bolts. NOTE: Equally loosen camshaft bearing cap bolts in several steps.
02
BESM020035
2. Remove the camshaft bearing caps and place them in proper order. NOTE: The camshaft bearing caps are marked for identification. 3. Remove the camshafts and then remove the camshaft seals.
Inspection
Inspect the camshaft for the following: Measure the camshaft cam lobe height. If wear is beyond the limit, replace the camshaft.
BESM020037
CAMSHAFT CAM LOBE HEIGHT Intake Cam Lobe Height Exhaust Cam Lobe Height 37.15 mm 37.05 mm
0267
BESM020038
OUTER DIAMETER OF CAMSHAFT JOURNAL Journal #1 Outer Diameter Journal #2, #3, #4, #5, Outer Diameter Measure the inner diameter of the camshaft bearing. 31.934 - 31.95 mm 23.947 - 23.96 mm
BESM020039
INNER DIAMETER OF CAMSHAFT BEARING Cam Bearing #1 Inner Diameter Cam Bearing #2, #3, #4, #5, Inner Diameter 32 - 32.025 mm 24 - 24.021 mm
Calculation of camshaft journal clearance Journal clearance = (inner diameter of camshaft bearing) - (outer diameter of camshaft journal) CAMSHAFT JOURNAL CLEARANCE Journal #1 Clearance Journal #2, #3, #4, #5 Clearance 0.05 - 0.091 mm 0.04 - 0.074 mm
0268
02
BESM020070
CAMSHAFT AXIAL CLEARANCE Intake Camshaft Exhaust Camshaft 0.15 - 0.20 mm 0.15 - 0.20 mm
Assembly
1. Using special tool CH-20010 (1), install the camshaft holder to hold the camshafts in place. NOTE : The camshaft holder will prevent the camshafts from rotating in either direction.
BESM020016
2. Installation is in the reverse order of removal. Installation Notes: Install the intake and exhaust camshaft bearing caps in the proper order. Slowly tighten bolts to the specified torque. Follow the torque sequence as shown.
BESM020036
0269
Disassembly
NOTE : The following special tools are required to perform the repair procedure: CH-20011 - Valve seal installer CH-20012 - Valve stem seal installer guide CH-20013 - Valve seal remover CH-20017 - Valve keeper installer CH-20018 - Valve spring compressor 1. Using the special tool CH-20018 (1), compress the valve springs.
BESM020067
0270
02
VISM080041
0271
Inspection
BESM020066
ITEM Valve Outer Diameter Valve Guide Inner Diameter Fringe Thickness On Top Of Valve Valve Tilt Angle Valve Height Intake Valve Exhaust Valve Intake Valve Exhaust Valve Intake Valve Exhaust Valve Intake Valve Exhaust Valve Intake Valve Exhaust Valve
SPECIFICATION (mm) 5.98 0.008 5.96 0.008 5.4 0.1 5.4 0.1 0.3 0.15 0.3 0.15 65 68 107.998 106.318
Inspect the valves for the following: Clean all valves thoroughly and discard burned, warped and cracked valves. Check valve seats and valve faces for damage. When reconditioning valves follow the specifications outlined for both intake and exhaust valves. Measure valve deflection. VALVE DEFLECTION LIMIT (DIAL GAUGE READING) Intake Exhaust 0.02 mm 0.04 mm
0272
02
BESM020073
VALVE TO VALVE GUIDE CLEARANCE STANDARD Intake Exhaust 0.012 - 0.043 mm 0.032 - 0.063 mm
Assembly
1. 2. 3. 4. Install the valves into the cylinder head (larger diameter on intake side). Install the valve springs. Install the valve spring retainers. Using valve spring compressor CH-20018 (1), compress the valve springs. 5. Install the valve keepers.
BESM020067
6. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.
Valve Springs
Specifications
Valve Spring Specifications
DESCRIPTION Spring Free Length Spring Height At 620 Newtons Of Pressure SPECIFICATION 47.7 mm 32.0 mm
0273
Disassembly
NOTE : The following special tools are required to perform the repair procedure: CH-20011 - Valve seal installer CH-20012 - Valve stem seal installer guide CH-20013 - Valve seal remover CH-20017 - Valve keeper installer CH-20018 - Valve spring compressor 1. Using the special tool CH-20018 (1), compress the valve springs.
BESM020067
2. Remove the valve keeper (1), valve spring retainer (2). 3. Remove the valve springs (3) from the cylinder head.
VISM080040
0274
Inspection
Inspect the valve springs for the following: Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested for correct load. Discard the springs that do not meet specifications. The following specifications apply to both intake and exhaust valve springs.
02
BESM020072
VALVE SPRING LENGTH/HEIGHT Spring Free Length Spring Height At 620 Newtons Of Pressure If it is not within specifications, replace the valve spring. 47.7 mm 32.0 mm
Assembly
1. Install the valve springs. 2. Install the valve spring retainers. 3. Using a valve spring compressor CH-20018 (1), compress the valve springs. 4. Install the valve keepers.
BESM020067
5. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.
0275
03
page 1.6L & 1.8L Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-1 Engine Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-200 Ignition Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-222 Evaporative Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-230
CONTENTS
03
03-83
03-44
03-142
031
P0562 - System Voltage Low Voltage, P0563 - System Voltage High Voltage P0604 - Internal Controller Module Random Access Memory (RAM) Error, P0605 - Internal Controller Module ROM Test Error, P0606 - ECM Processor P0602 - Control Module ECM Programming Error P0645 - A/C Clutch Relay Circuit P1545 - Throttle Position Control Performance P2138 - Pedal Position Sensor Performance U1000 - High Speed CAN Defective
03-158
Crankshaft Position Sensor Description Operation Removal & Installation Camshaft Position Sensor Description Operation Removal & Installation Manifold Absolute Pressure Sensor 1.6L Description Operation Removal & Installation Air Flow Sensor - 1.8L Description Operation Removal & Installation Accelerator Pedal Position Sensor Description Operation Removal & Installation Electronic Throttle Control Actuator Description Operation Removal & Installation Engine Control Module (ECM) Description Operation Removal & Installation
03-193 03-193 03-193 03-193 03-194 03-194 03-194 03-194 03-195 03-195 03-195 03-195 03-196 03-196 03-196 03-196 03-196 03-196 03-196 03-196 03-197 03-197 03-197 03-197 03-198 03-198 03-198 03-198
03-163 03-165 03-167 03-170 03-177 03-185 03-191 03-191 03-191 03-191 03-191 03-192 03-192 03-192 03-192 03-192 03-192 03-192 03-192
ON-VEHICLE SERVICE
Engine Coolant Temperature Sensor Description Operation Removal & Installation Knock Sensor Description Operation Removal & Installation Oxygen Sensor Description Operation Removal & Installation
032
GENERAL INFORMATION
Description
The Engine Control Module (ECM) controls the engine management system. The ECM can adjust for varying driving conditions and modify fuel and ignition requirements as needed to maintain optimum performance and economy. The following are the input and output components monitored by the ECM. ECM Inputs Brake Switch Sensor A/C Pressure Sensor Camshaft Position (CMP) Sensor Crankshaft Position (CKP) Sensor Engine Coolant Temperature (ECT) Sensor Manifold Absolute Pressure (MAP) Sensor (1.6L) Air Flow Sensor (1.8L) Electric Throttle Control Actuator Power Steering Switch Accelerator Pedal Position (APP) Sensor Knock Sensor Upstream Oxygen Sensor Downstream Oxygen Sensor Clutch Pedal Switch Immobilizer CAN Bus
03
ECM Outputs Canister Control Valve Fuel Injectors Fuel Pump Relay Electronic Throttle Control Actuator Ignition Coil A/C Compressor Cooling Fan Oxygen Sensor Heater (Upstream & Downstream) CAN Bus
Operation
The ECM is a pre-programmed, microprocessor-based digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The ECM can adapt its programming to meet changing operating conditions. The ECM monitors components and circuits and tests them in various ways depending on the hardware, function, and type of signal. For example, analog inputs such as throttle position or engine coolant temperature are typically checked for opens, shorts and out-of-range values. This type of monitoring is carried out continuously. Some digital inputs like vehicle speed or crankshaft position rely on rationality checks - checking to see if the input value makes sense at the current engine operating conditions. These types of tests may require monitoring several components and can only be carried out under appropriate test conditions.
033
GENERAL INFORMATION
Specifications
Torque Specifications
DESCRIPTION Engine Coolant Temperature (ECT) Sensor Knock Sensor Oxygen Sensors Crankshaft Position (CKP) Sensor Camshaft Position (CMP) Sensor Air Flow Sensor Bolts Engine Control Module (ECM) Bolts Accelerator Pedal Position (APP) Sensor Electronic Throttle Control Actuator Manifold Absolute Pressure (MAP) Sensor TORQUE (Nm) 20 20 45 10 7 5 6 11 10 6
Special Tools
034
GENERAL INFORMATION
03
Compression Gauge
035
GENERAL INFORMATION
Hardware Requirements
The hardware configuration of X-431 is as follows: Diagnostic Scan Tool Configuration
ITEM
NAME
Function To Display Operational Buttons, Test Results, Help Information, etc. To Print Test Results. (Optional) To Store Diagnostic Software and Data To Connect CF Card Reader/ Writer and Computer To Read or Write Data On The CF Card To Diagnose Mitsubishi Electronic Control Systems On Chery M11 & M12 Series To Diagnose Vehicles With Fiat-3 Pin Diagnostic Connector
ITEM
NAME
Function To Diagnose Other Systems Of Vehicle With OBDII-16 Pin Diagnostic Connector To Connect AC 100 - 240 V Outlet and Power Adapter To Get Power From Vehicle Cigarette Lighter To Get Power From Vehicle Battery To Convert 100 240 V AC Power Into 12 V DC Power To Connect The Diagnostic Connector and Smartbox To Perform Vehicle Diagnosis
Mini-Printer
Power Cord
CF Card
10
USB Cable
11
CF Card Reader/Writer
12
Power Adapter
13
Main Cable
14
Smartbox
036
GENERAL INFORMATION
Electrical Schematics
Electronic Engine Controls (Page 1 of 11)
03
VISMW030030T
037
GENERAL INFORMATION
Electronic Engine Controls (Page 2 of 11)
VISMW030040T
038
GENERAL INFORMATION
Electronic Engine Controls (Page 3 of 11)
03
VISMW030031T
039
GENERAL INFORMATION
Electronic Engine Controls (Page 4 of 11)
VISMW030032T
0310
GENERAL INFORMATION
Electronic Engine Controls (Page 5 of 11)
03
VISMW030033T
0311
GENERAL INFORMATION
Electronic Engine Controls (Page 6 of 11)
VISMW030034T
0312
GENERAL INFORMATION
Electronic Engine Controls (Page 7 of 11)
03
VISMW030035T
0313
GENERAL INFORMATION
Electronic Engine Controls (Page 8 of 11)
VISMW030037T
0314
GENERAL INFORMATION
Electronic Engine Controls (Page 9 of 11)
03
VISMW030036T
0315
GENERAL INFORMATION
Electronic Engine Controls (Page 10 of 11)
VISMW030038T
0316
GENERAL INFORMATION
Electronic Engine Controls (Page 11 of 11)
03
VISMW030039T
0317
GENERAL INFORMATION
0318
GENERAL INFORMATION
PIN 35 36 37 38 39 40 41 CIRCUIT IDENTIFICATION Sensor (GND) Sensor (GND) Manifold Absolute Pressure Sensor (With 1.6L Engine) Air Flow Sensor (With 1.8L Engine) Electronic Throttle Control Actuator (Position Sensor) Engine Coolant Temperature Sensor Accelerator Pedal Position Sensor 79 80 81 Camshaft Position Sensor GND (Power) CAN-L PIN 76 77 78 CIRCUIT IDENTIFICATION Power Steering Switch Sensor (GND)
03
0319
Ground Inspection
Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This added resistance can alter the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can effect the circuit. Perform the following when inspecting a ground connection: 1. Remove the ground bolt or screw. 2. Inspect all mating surface for tarnish, dirt, rust, etc. 3. Clean as required to assure good contact. 4. Reinstall bolt or screw securely. 5. Inspect for add-on accessories which may be interfering with the ground circuit. 6. If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are crimped to one eyelet, make sure no excess wire insulation has been crimped creating a bad ground.
0320
Self-Learning Components
Self-Learning should be performed on these components under the following conditions: After replacing the ECM. After disconnecting and reconnecting the ECM. After replacing the Accelerator Pedal or Electronic Throttle Control Actuator.
03
Self-Learning Condition
The self-learning condition is known as the Electronic Throttle Control Actuator Self-Learning Condition.
CAUTION: Make sure that the Electronic Throttle Control Actuator self-learning procedure lasts for at least 10 seconds according to the Electronic Throttle Control Actuator self-learning condition. If the selflearning procedure fails, the engine cannot be started, or the EPC lamp will be lit. If this condition occurs, the self-learning procedure should be performed again after the DTCs have been erased in ECM.
0321
0322
03
0323
0324
03
VISMW030003T
0325
14 44 45 63
Voltage (11 - 14 V)
0326
03
VISMW030004T
0327
Confirmation Procedure:
Before performing the following procedure, confirm that battery voltage is more than 12 V. Turn ignition switch off. Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available. Start the engine and warm it to normal operating temperature. With the scan tool, select view data stream. If the data stream is not detected, the condition is current. Go to Diagnostic Procedure - Step 1. If the data stream is detected, the condition is intermittent (See Diagnostic Help and Intermittent DTC Troubleshooting in Section 03 Electronic Engine Controls for more information).
0328
Diagnostic Procedure
1.
PRELIMINARY INSPECTION
Is engine running?
Yes No
03
2.
Turn ignition switch off and then on. Check voltage between ECM terminal 13 and ground with a digital multimeter. Battery voltage should exist.
LTSMD030061
3.
Check the following: Fuse FB1 (5A) Ignition relay R5 Front fuse and relay box connector K & E Harness between ECM and fuse Ground connection A-201 Open or short in ignition relay supply circuit or ground circuit
4.
Check the voltage between ECM terminal 12 and ground with a digital multimeter. Battery voltage should exist.
>> Go to the next step. >> Check and repair the following:
Fuse FB18 (7.5A) Front fuse and relay box connector K9 Harness open or short between ECM connector E-001 terminal 12 and battery
0329
5.
CHECK GROUND CONNECTIONS Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Layout Engine Room Harness in Section 16 Wiring).
6.
VISMD030014
7.
DETECT MALFUNCTIONING PART Check the harness for an open or short between ECM terminals 3, 51, 53, 61, 80 and ground.
>> Go to the next step. >> Repair the circuit for an open or short to power in harness or connectors.
0330
8.
CHECK ECM POWER SUPPLY CIRCUIT - (3) Turn ignition switch on and then off. Check voltage between ECM terminals 44, 45, 63 and ground with a digital multimeter. Turn the ignition switch on, battery voltage should exist. Turn the ignition switch off, battery voltage will exist for a few seconds, then drop to approximately 0 V.
03
LTSMD030062
9.
10.
Disconnect the ECM harness connector. Disconnect the ECM power supply circuit connector K in front fuse and relay box harness connector. Check harness continuity between ECM terminals 44, 45, 63 and front fuse and relay box terminal K11 (refer to wiring diagram for circuit information). Check harness for a short to ground or short to power.
>> Go to step 12. >> Repair the circuit for an open or short in harness or connectors.
0331
11.
Disconnect the ECM harness connector. Disconnect the ECM power supply circuit connector K in front fuse and relay box harness connector. Check harness continuity between ECM terminal 14 and front fuse and relay box terminal K10 (refer to wiring diagram for circuit information). Continuity should exist. Check EMS relay R2. Check harness for a short to ground or short to power.
>> Go to the next step. >> Repair or replace the malfunctioning components.
CHECK FUSE
12.
Disconnect fuse SB2 (30A), fuse FB12 (20A), fuse FB18 (7.5A) in the front fuse and relay box. Check the fuses for an open.
13.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
0332
03
VISMW030018T
0333
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION Mass or Volume Air Flow (MAF) circuit low input DTC DETECTION CONDITION Ignition switch on or engine is running DTC SET CONDITION ECM detected that the input signal is out of the acceptable range. POSSIBLE CAUSE MAF sensor Intake air leaks Harness or connectors ECM
P0102
0334
Diagnostic Procedure
1.
Check the following components for proper connections. Air duct Vacuum hoses Intake air passage between air duct and manifold.
>> Go to the next step. >> Reconnect the connectors or replace the malfunctioning part.
CHECK MAF SENSOR POWER SUPPLY CIRCUIT
03
2.
VISMD030005
Turn ignition switch on. Check voltage between terminal 2 and ground in the MAF sensor electrical connector E-009 with a digital multimeter. Battery voltage should exist.
0335
3.
Check the following parts: EMS relay R2 Front fuse and relay box K Fuse SB2 (30A), fuse FB12 (20A), fuse FB18 (7.5A) Harness for an open or short between MAF sensor and fuse Repair or replace any malfunctioning part. With X-431, view DTCs in ECM.
>> Go to the next step. >> The system is now operating properly at this time.
CHECK MAF SENSOR REFERENCE VOLTAGE
4.
Check voltage between MAF sensor terminal 4 and ground in the MAF sensor electrical connector E-009 with a digital multimeter. 5 V should exist.
>> Go to the next step. >> Repair or replace the circuit for an open
or short in harness or connectors. If circuit is normal, go to the next step.
LTSMD030042
5.
Turn ignition switch off. Disconnect the ECM harness connector. Check harness continuity between MAF sensor terminal 3 and ECM terminal 17. Continuity should exist. Check harness for a short to ground.
>> Go to the next step. >> Repair or replace circuit for an open or short in harness or connectors.
CHECK THE MAF SENSOR OUTPUT SIGNAL CIRCUIT FOR AN OPEN OR SHORT
6.
Check harness continuity between MAF sensor terminal 5 and ECM terminal 37. Continuity should exist. Check harness for a short to ground.
>> Go to the next step. >> Repair or replace the circuit for an open or short to ground in harness or connectors.
0336
7.
Install all removed parts. Start engine. Check MAF sensor signal with X-431.
MAF SENSOR SIGNAL - WITH THE X-431 SCAN TOOL TERMINAL NO. DATA (AVERAGE DC VOLTAGE)
ITEM
CONDITION
03
37
Engine is running ECT: 78 C Idle: 795 RPM IAT: 36 C IAT signal: 1.88 V
Approximately 1.39 V
If without the X-431, check voltage between MAF sensor terminal 5 and ground with a digital multimeter.
MAF SENSOR SIGNAL - WITHOUT THE X-431 SCAN TOOL TERMINAL NO. DATA (AVERAGE DC VOLTAGE)
ITEM
CONDITION
37
Engine is running ECT: 78 C Idle: 795 RPM IAT: 36 C IAT signal: 1.88 V
Approximately 1.39 V
If the signal voltage is out of specification, proceed to the following. Check the following for the cause of uneven air flow through the MAF sensor: Crushed air ducts Air cleaner seal Clogged air cleaner element If any components are malfunctioning, repair or replace them. If the components are OK, clean the MAF sensor, then check the signal of the MAF sensor.
0337
8.
CHECK DTC
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
0338
03
VISMW030018T
0339
37
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION Mass or Volume Air Flow (MAF) circuit high input DTC DETECTION CONDITION Ignition switch on or engine is running DTC SET CONDITION ECM detected that the input signal is out of the acceptable range. POSSIBLE CAUSE MAF sensor Harness or connectors ECM
P0103
0340
Diagnostic Procedure
1.
Check the following components for proper connections. Air cleaner Intake air duct
03
2.
VISMD030005
Turn ignition switch on. Check voltage between MAF sensor terminal 4 and ground in the MAF sensor connector E-009 with a digital multimeter (refer to wiring diagram for circuit information). 5 V should exist.
0341
3.
Check harness for short to power between the air flow sensor and ECM.
>> Go to the next step. >> Repair or replace the circuit for a short to power in harness or connectors.
CHECK THE MAF SENSOR GROUND CIRCUIT FOR A SHORT
4.
Turn ignition switch off. Disconnect the ECM harness connector. Check harness continuity between MAF sensor terminal 3 and ECM terminal 17. Continuity should exist. Check harness for a short to power.
>> Go to the next step. >> Repair or replace the circuit for a short to power in harness or connectors.
CHECK THE MAF SENSOR OUTPUT SIGNAL CIRCUIT
5.
Check harness continuity between the MAF sensor terminal 5 and ECM terminal 37. Continuity should exist. Check harness for short to power.
>> Go to the next step. >> Repair or replace the circuit for a short to power in harness or connectors.
0342
6.
Install all removed parts. Start engine. Check MAF signal in data stream with X-431.
MAF SENSOR SIGNAL - WITH THE X-431 SCAN TOOL TERMINAL NO. ITEM CONDITION Engine is running Warm-up condition: 78 C Idle: 795 RPM IAT: 36 C IAT signal voltage: 1.88 V DATA (AVERAGE DC VOLTAGE)
03
37
Approximately 1.39 V
If without X-431, check voltage between MAF sensor terminal 5 and ground with a digital multimeter.
MAF SENSOR SIGNAL - WITHOUT THE X-431 SCAN TOOL TERMINAL NO. ITEM CONDITION Engine is running Warm-up condition: 78 C Idle: 795 RPM IAT: 36 C IAT signal: 1.88 V DATA (AVERAGE DC VOLTAGE)
37
Approximately 1.39 V
7.
With the X-431 scan tool, read ECM DTCs. See DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
0343
P0105 - Manifold Absolute Pressure/Barometric Pressure Circuit P0106 - Manifold Absolute Pressure Or Barometric Pressure Range/Performance - 1.6L
VISMW030009T
0344
03
Up to approximately 4 V (instantaneous)
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION Manifold absolute pressure/barometric pressure circuit Manifold absolute pressure or barometric pressure range/performance DTC DETECTION CONDITION DTC SET CONDITION POSSIBLE CAUSE MAP sensor Harness or connectors ECM MAP sensor Harness or connectors ECM
P0105
P0106
0345
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
2.
LTSMD030076
Turn ignition switch on. Check supply voltage between terminal 1 and 3 in MAP sensor connector E-033 terminal side. 5 V should exist.
VISMD030010
0346
3.
CHECK THE MAP SENSOR POWER SUPPLY CIRCUIT FOR AN OPEN OR SHORT
Check supply voltage between terminal 3 and ground in the MAP sensor connector E-033 with a digital multimeter. Approximately 5 V should exist.
>> Go to the next step. >> Repair or replace the circuit for an open
or short to ground or short to power in harness or connectors. If circuit is normal, go to the next step.
LTSMD030057
03
4.
Turn ignition switch off. Disconnect the ECM sensor harness connector E-001. Check harness continuity between terminal 1 in MAP sensor connector E-033 and terminal 17 in ECM connector E-001. Continuity should exist.
>> Go to the next step. >> Repair or replace the circuit for an open in harness or connectors.
CHECK THE MAP SENSOR OUTPUT SIGNAL CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
5.
Check harness continuity between MAP sensor terminal 4 and ECM terminal 37. Continuity should exist.
>> Go to the next step. >> Repair or replace the circuit for an open or high resistance in harness or connectors.
0347
6.
Check sensor signal between sensor terminal 4 and ground with a digital multimeter.
MAP SENSOR OUTPUT SIGNAL MAP SENSOR TERMINAL NO. DATA (DC VOLTAGE)
ITEM
CONDITION
MAP sensor
Engine: Running
Engine running: Idle Press accelerator pedal slowly Press accelerator pedal quickly
Approximately 1.3 V
Up to approximately 4V (instantaneous)
7.
Check the sensor as follows: Remove the sensor mounting bolt. Remove the sensor. Visually check the sensor for blockage or damage, and clean the pressure port of the sensor.
>> Replace the MAP sensor with a known good MAP sensor.
8.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
0348
P0107 - Manifold Absolute Pressure Or Barometric Pressure Low Input P0108 - Manifold Absolute Pressure Or Barometric Pressure High Input- 1.6L
03
VISMW030009T
0349
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION Manifold Absolute Pressure or Barometric Pressure low input Manifold Absolute Pressure or Barometric Pressure high input DTC DETECTION CONDITION DTC SET CONDITION Signal output is below minimum acceptable range for a few seconds continuously. Signal output is above maximum acceptable range for a few seconds continuously. POSSIBLE CAUSE MAP sensor Harness or connectors ECM MAP sensor Harness or connectors ECM
P0107
P0108
0350
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
03
>> Go to the next step. >> Repair or replace ground harness or connections.
CHECK MAP SENSOR POWER SUPPLY
2.
LTSMD030076
Turn ignition switch on. Check supply voltage between terminal 1 and terminal 3 in MAP sensor connector E-033. 5 V should exist.
VISMD030010
0351
3.
CHECK THE MAP SENSOR POWER SUPPLY CIRCUIT FOR AN OPEN OR SHORT
Check supply voltage between sensor terminal 3 and ground in the MAP sensor connector E-033 with a digital multimeter. Approximately 5 V should exist.
>> Go to the next step. >> Repair or replace the circuit for an open
or short to ground or short to power in harness or connectors. If circuit is normal, go to the next step.
LTSMD030057
4.
Turn ignition switch off. Disconnect the ECM harness connector E-001. Check harness continuity between MAP sensor terminal 1 and ECM terminal 17. Continuity should exist.
>> Go to the next step. >> Repair or replace the circuit for an open or high resistance or short to power in harness or connectors.
5.
CHECK THE MAP SENSOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT
Check harness continuity between MAP sensor terminal 4 and ECM connector E-001, terminal 37. Continuity should exist. Check harness for a short to ground or short to power.
>> Go to the next step. >> Repair or replace the circuit for an open or short to ground or short to power in harness or connectors.
0352
6.
Check sensor signal between sensor terminal 4 and ground with a digital multimeter.
MAP SENSOR OUTPUT SIGNAL MAP TERMINAL NO. DATA (DC VOLTAGE)
ITEM
CONDITION
MAP sensor
Engine: Running
Engine running: Idle Press accelerator pedal slowly Press accelerator pedal quickly
03
Approximately 1.3 V
Up to approximately 4V (Instantaneous)
7.
Check the sensor as follows: Remove the sensor mounting bolt. Remove the sensor. Visually check the sensor for blockage or damage, and clean the pressure port of the sensor.
>> Replace the MAP sensor with a known good MAP sensor.
8.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
0353
VISMW030018T
0354
03
VISMW030009T
0355
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION Intake air temperature circuit low input DTC DETECTION CONDITION Ignition switch on or after engine start DTC SET CONDITION When output signal is wrong or out of acceptable range. POSSIBLE CAUSE IAT sensor Harness or connectors ECM
P0112
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace ground harness or connections.
0356
2.
Disconnect IAT sensor (For 1.6L engine: IAT sensor is built-into MAP sensor) harness connector E-033 (1).
03
LTSMD030076
Turn ignition switch on. Check reference voltage between IAT sensor terminal 2 and ground in the IAT sensor electrical connector E-003 with a digital multimeter. 5 V should exist.
VISMD030011
Disconnect IAT sensor (For 1.8L engine: IAT sensor is built-into MAF sensor) harness connector E-009 (1).
VISMD030005
Turn ignition switch on. Check reference voltage between IAT sensor terminal 1 and ground in the IAT sensor electrical connector E-009 with a digital multimeter. 5 V should exist.
0357
3.
Turn ignition switch off. Disconnect the ECM harness connector. Check the harness for a short to ground between IAT connector terminal 2 and ECM connector E-001, terminal 42.
>> Go to the next step. >> Repair circuit for a short to ground in harness or connectors.
CHECK THE IAT SENSOR
4.
Connect IAT sensor connector. Connect the ECM harness connector. Turn ignition switch on. Check the IAT signal under the following conditions: For 1.6L engine (IAT sensor is built-into MAP sensor): Check signal between terminal 2 and ground in MAP sensor connector E-033. For 1.8L engine (IAT sensor is built-into MAF sensor): Check signal between terminal 1 and ground in MAF sensor connector E-009. IAT SENSOR OUTPUT SIGNAL REFERENCE DATA IAT SENSOR TERMINAL NO. 1 (For 1.8L engine) 2 (For 1.6L engine) ITEM IAT sensor CONDITION Ignition switch: ON IAT: 36 C DATA (DC VOLTAGE) 1.88 V
5.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
0358
03
VISMW030018T
0359
VISMW030009T
0360
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION Intake air temperature circuit high input DTC DETECTION CONDITION Ignition switch on or after engine start DTC SET CONDITION Output signal is wrong or out of acceptable range. POSSIBLE CAUSE IAT sensor Harness or connectors ECM
03
P0113
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace ground harness or connections.
0361
2.
Disconnect IAT sensor (For 1.6L engine: IAT sensor is built-into MAP sensor) harness connector E-033 (1).
LTSMD030076
Turn ignition switch on. Check supply voltage between IAT sensor terminal 2 and ground in the IAT sensor electrical connector E-033 with a digital multimeter. 5 V should exist.
VISMD030011
Disconnect IAT sensor (For 1.8L engine: IAT sensor is built-into MAF sensor) harness connector E-009 (1).
LTSMD030075
Turn ignition switch on. Check supply voltage between IAT sensor terminal 1 and ground in the IAT sensor electrical connector E-009 with a digital multimeter. 5 V should exist.
>> Go to the next step. >> Repair circuit for an open or short to
power in harness or connectors. If circuit is normal, go to the next step.
LTSMD030031
0362
3.
Turn ignition switch off. Disconnect the ECM harness connector. Check harness continuity between the following terminals: For 1.6L engine, check continuity between IAT sensor terminal 1 and ECM terminal 17. CHECK SENSOR GROUND CIRCUIT - 1.6L
03
IAT SENSOR CONNECTOR TERMINAL ECM CONNECTOR TERMINAL
17
Check harness continuity between the following terminals: For 1.8L engine, check continuity between IAT sensor terminal 3 and ECM terminal 17. CHECK SENSOR GROUND CIRCUIT - 1.8L
17
Refer to wiring diagram for circuit information. Continuity should exist. Check harness for a short to power.
>> Go to the next step. >> Repair or replace the circuit for an open or short to power in harness or connectors.
0363
4.
Connect IAT sensor connector. Connect the ECM harness connector. Turn ignition switch on. Check the IAT signal under the following conditions: For 1.6L engine (IAT sensor is built-into MAP sensor): Check signal between terminal 2 and ground in MAP sensor connector E-033. For 1.8L engine (IAT sensor is built-into MAF sensor): Check signal between terminal 1 and ground in MAF sensor connector E-009. IAT SENSOR OUTPUT SIGNAL REFERENCE DATA IAT SENSOR TERMINAL NO. 1 (For 1.8L engine) 2 (For 1.6L engine) ITEM IAT sensor CONDITION Ignition switch: ON IAT: 36 C DATA (DC VOLTAGE) 1.88 V
5.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
0364
03
VISMW030014T
0365
VISMW030006T
0366
03
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION POSSIBLE CAUSE CMP sensor CKP sensor Harness or connectors Camshaft signal plate Crankshaft signal plate Timing misalignment ECM
P0016
Engine is running
ECM detected that the CMP sensor is out of phase with CKP sensor.
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace ground harness or connections.
0367
2.
CHECK THE CMP SENSOR POWER SUPPLY CIRCUIT FOR AN OPEN OR SHORT
VISMD030001
Turn ignition switch on. Check supply voltage between terminal 3 and ground in CMP sensor connector E-007 terminal side with a digital multimeter. Battery voltage should exist.
3.
Check the following: Front fuse and relay box K Fuse SB2, fuse FB12, and fuse FB18 Harness for an open or short between CMP sensor and fuse Repair or replace malfunctioning part as necessary. With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
>> Go to the next step. >> The system is now operating correctly at this time.
CHECK THE CMP SENSOR GROUND CIRCUIT FOR AN OPEN OR SHORT
4.
Turn ignition switch off. Check harness continuity between CMP sensor terminal 1 and ground. Continuity should exist.
>> Go to the next step. >> Repair or replace the circuit for an open or short.
0368
5.
CHECK THE CMP SENSOR INPUT SIGNAL CIRCUIT FOR AN OPEN OR SHORT
Turn ignition switch on. Check voltage between terminal 2 and ground in CMP sensor connector E-007 terminal side. 11 V should exist.
>> Go to the next step. >> Repair or replace circuit for an open or short to power or short to ground in harness or connectors.
If circuit is normal, go to the next step.
03
6.
Turn ignition switch off. Connect CMP sensor connector. Check the CMP output signal between terminal 2 and ground in CMP sensor connector E-007 harness side, with the engine running. Approximately 6 V square wave signal should exist. CMP SENSOR SIGNAL OUTPUT CMP SENSOR SIGNAL
0369
7.
Remove the CMP sensor (1). Inspect and clean the CMP sensor and mounting area for any condition that would result in an incorrect signal, such as damage, foreign material, or excessive movement.
Perform the following to check the resistance of the CMP sensor: CMP SENSOR RESISTANCE
BESM030016
TERMINAL NO.
RESISTANCE (25 C)
1&2
1&3
Except 0 or
2&3
Remove the CMP sensor (1). Inspect and clean the CMP sensor and mounting area for any condition that would result in an incorrect signal, such as damage, foreign material, or excessive movement.
>> Replace the CMP sensor with a known good CMP sensor.
0370
8.
Check signal between terminal 1 and ground, terminal 2 and ground in CKP sensor (1) connector E-006 harness side, with the engine running.
03
VISMD030004
0371
9.
Remove the CKP sensor (1). Inspect and clean the CKP sensor and mounting area for any condition that would result in an incorrect signal, such as damage, foreign material, or excessive movement.
Perform the following to check the resistance of the CKP sensor: CKP SENSOR RESISTANCE
BESM030025
TERMINAL NO.
RESISTANCE (25 C)
1&2
Approximately 1000
>> Replace the CKP sensor with a known good CKP sensor.
0372
10.
Remove the cylinder head cover and timing belt cover (See Timing Belt Removal & Installation in Section 02 Engine). Check the installed clearance (See CMP Sensor Removal & Installation in Section 03 Electronic Engine Controls). NOTE : 0.8 - 1.2 mm should exist. Check the camshaft and camshaft signal plate for any condition that would result in an incorrect signal, such as damage, become flexible, foreign material when rotate the camshaft.
03
>> Remove debris and clean the signal plate of camshaft rear end or replace camshaft.
Reinstall the CMP sensor.
11.
Check the installed clearance (See Crankshaft Position Sensor Removal & Installation in Section 03 Electronic Engine Controls). NOTE : 0.8 - 1.2 mm should exist. Check the crankshaft and camshaft signal plate for any condition that would result in an incorrect signal, such as damage, become flexible, foreign material when rotate the camshaft.
>> Remove debris and clean the signal plate of crankshaft rear end or replace crankshaft.
Reinstall the CKP sensor.
12.
>> Align the engine timing belt (See Timing Belt Removal & Installation in Section 02 Engine). >> Go to the next step.
CHECK DTC
13.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
0373
VISMW030008T
0374
03
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION Engine coolant temperature circuit low input DTC DETECTION CONDITION Ignition switch on or after engine start DTC SET CONDITION Signal output is below minimum acceptable range for a few seconds continuously. POSSIBLE CAUSE ECT sensor Harness or connectors ECM
P0117
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace ground harness or connections.
0375
2.
BESM030019
Turn ignition switch on. Check ECT sensor reference voltage between sensor terminal 2 and ground in the sensor electrical connector E-019 with a digital multimeter. 4.5 - 4.9 V should exist.
3.
Turn ignition switch off. Disconnect the ECM harness connector. Check the harness for a short to ground between the ECT sensor connector terminal 2 and ECM connector E-001, terminal 39.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
0376
4.
Check the resistance between the ECT sensor terminal 1 and 2. ECT RESISTANCE REFERENCE DATA ECT C RESISTANCE K
-10 C
8.62 - 10.28
03
20 C
2.37 - 2.63
80 C
0.299 - 0.345
Connect ECT sensor connector. Connect the ECM harness connector. Turn ignition switch on. Check sensor output signal. ECT SENSOR OUTPUT SIGNAL REFERENCE DATA ECT TERMINAL NO. 17 39 ITEM Sensor (GND) ECT sensor Ignition switch: ON CONDITION ECT: 59 C ECT: 78 C ECT: 90 C DATA (DC VOLTAGE) Approximately 0 V 1.89 V 1.25 V 0.94 V
5.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
0377
VISMW030008T
0378
03
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION Engine coolant temperature circuit high input DTC DETECTION CONDITION Ignition switch on or after engine start DTC SET CONDITION Signal output is above maximum acceptable range for a few seconds continuously. POSSIBLE CAUSE ECT sensor Harness or connectors ECM
P0118
0379
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace ground harness or connections.
CHECK ECT SENSOR SIGNAL CIRCUIT FOR A SHORT
2.
BESM030019
Turn ignition switch on. Check the ECT sensor reference voltage between sensor terminal 2 and ground in the sensor electrical connector E-019 with a digital multimeter. 5 V should exist.
>> Go to the next step. >> Repair or replace the harness for an
open or short to power between ECT connector terminal 2 and ECM connector E-001, terminal 39. If harness is normal, replace the ECM.
LTSMD030032
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls).
0380
3.
Turn ignition switch off. Check harness continuity between the following terminals (see wiring diagram for circuit information). Continuity should exist. Check harness for a short to power. SENSOR GROUND CIRCUIT
03
ECT SENSOR TERMINAL ECM TERMINAL CONTINUITY
17
Yes
>> Go to the next step. >> Repair or replace the circuit for an open or short to power in harness or connectors.
0381
4.
Check resistance between ECT sensor terminal 1 and 2. ECT RESISTANCE REFERENCE DATA ECT C RESISTANCE K
-10 C
8.62 - 10.28
20 C
2.37 - 2.63
80 C
0.299 - 0.345
Connect ECT sensor connector. Connect the ECM harness connector. Turn ignition switch on. Check sensor output signal. ECT SENSOR OUTPUT SIGNAL REFERENCE DATA ECT TERMINAL NO. 17 39 ITEM Sensor (GND) ECT sensor Ignition switch: ON CONDITION ECT: 59 C ECT: 78 C ECT: 90 C DATA (DC VOLTAGE) Approximately 0 V 1.89 V 1.25 V 0.94 V
5.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
0382
P0122 - Throttle Position Sensor A Circuit Low Input P0123 - Throttle Position Sensor A Circuit High Input
03
VISMW030005T
0383
38
0.72 V
0.74 V
54
Ignition switch: ON
64 65 66 67 73 78
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION Throttle position sensor A circuit low input Ignition switch on or after engine start P0123 Throttle position sensor A circuit high input DTC DETECTION CONDITION DTC SET CONDITION Signal output is below minimum acceptable range for a few seconds continuously. Signal output is above maximum acceptable range for a few seconds continuously. POSSIBLE CAUSE TPS or misalignment Harness or connectors ECM TPS or misalignment Harness or connectors ECM
P0122
0384
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
03
>> Go to the next step. >> Repair or replace ground harness or connections.
CHECK THE TPS POWER SUPPLY CIRCUIT
2.
VISMD030006
Turn ignition switch on. Check throttle position sensor supply voltage between sensor terminal 3 and ground in the sensor electrical connector E-027 with a digital multimeter. 5 V should exist.
>> Go to the next step. >> Repair circuit for an open or short to
ground or short to power in harness or connectors. If the circuit is normal, go to the next step.
LTSMD030035
0385
3.
Turn ignition switch off. Disconnect the ECM harness connector. Check harness continuity between the following terminals (see wiring diagram for circuit information): Continuity should exist. TPS SIGNAL CIRCUIT TPS TERMINAL 6 5 ECM TERMINAL 54 38
4.
Check the harness for an open, a short to ground or a short to power between TPS connector terminal 2 and ECM connector E-001, terminal 78
5.
Check resistance between TPS terminal 2 and 3. 2 k 20 % (20 C) should exist. Check resistance between TPS terminal 2 and 6 with a digital multimeter. Slowly open the throttle, the TPS resistance value should change in a linear movement with the throttle as it opens.
0386
6.
Turn ignition switch off. Connect the ECM harness connector. Connect TPS connector. Turn ignition switch on. Check voltage between the TPS terminal 3 and ground under the following conditions: TPS OUTPUT SIGNAL TERMINAL NO. 32 ITEM Regulated sensor supply 2 Electronic throttle control actuator (Position Sensor) CONDITION Engine stopped Accelerator pedal: Fully released Engine stopped Accelerator pedal: Fully depressed Engine stopped Accelerator pedal: Fully released Engine stopped Accelerator pedal: Fully depressed DATA (DC VOLTAGE) Approximately 5 V 4.24 V
03
38
0.72 V
0.74 V
54
Ignition switch: ON
64 65 66 67 73 78
7.
CHECK DTC
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
0387
P0031 - O2 Sensor 1 Heater Control Circuit Low P0032 - O2 Sensor 1 Heater Control Circuit High
VISMW030015T
0388
28 36 48
03
55
Approximately 100 mV
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. P0031 DTC DEFINITION O2 sensor 1 heater control circuit low Engine is running P0032 O2 sensor 1 heater control circuit high DTC DETECTION CONDITION POSSIBLE CAUSE Oxygen sensor Harness or connectors ECM Oxygen sensor Harness or connectors ECM
0389
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace ground harness or connections.
CHECK OXYGEN SENSOR HEATER POWER SUPPLY CIRCUIT
2.
BESM030017
Turn ignition switch on. Check supply voltage between oxygen sensor terminal 2 and ground in the oxygen sensor electrical connector E-004 with a digital multimeter. Battery voltage should exist.
3.
Check the following: Front fuse and relay box K Fuse SB2, fuse FB10, fuse FB18 Harness for an open or short between oxygen sensor and fuse Repair or replace any malfunctioning part. With X-431, select view DTC.
0390
4.
CHECK THE OXYGEN SENSOR HEATER CONTROL CIRCUIT FOR AN OPEN OR SHORT
Turn ignition switch off. Disconnect the ECM connector. Check harness continuity between ECM terminal and oxygen sensor terminal (refer to wiring diagram for circuit information). Continuity should exist. OXYGEN SENSOR HEATER CONTROL CIRCUIT COMPONENT ECM Upstream Oxygen Sensor Check harness for a short to ground or short to power. TERMINAL 48 1
03
>> Go to the next step. >> Repair or replace the circuit for an open or short to ground or short to power in harness or connectors.
5.
TERMINAL NO.
RESISTANCE
Check resistance between oxygen sensor terminals. CHECK OXYGEN SENSOR TERMINAL NO. RESISTANCE
1 & 3 and 1 & 4 (Continuity should not exist) 4 & 1 and 4 & 2
0391
6.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
0392
03
VISMW030015T
0393
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION POSSIBLE CAUSE Fuel quality Oxygen sensor 1 (upstream) Harness or connectors ECM
P0132
Engine is running
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace ground harness or connections.
0394
2.
03
Disconnect the ECM harness connector. Check harness continuity between ECM terminal 18 and oxygen sensor terminal 4 (refer to wiring diagram for circuit information). Continuity should exist. Check the harness for an open and a short to power supply circuit.
BESM030017
>> Go to the next step. >> Repair circuit for an open or short to power in harness or connectors.
CHECK OXYGEN SENSOR INPUT SIGNAL CIRCUIT FOR AN OPEN OR SHORT
3.
Check the harness continuity between ECM terminal and oxygen sensor terminal as follows (refer to wiring diagram for circuit information). Continuity should exist. OXYGEN SENSOR SIGNAL CIRCUIT COMPONENT ECM Upstream Oxygen Sensor Check the harness for a short to power supply circuit. TERMINAL 18 4
>> Go to the next step. >> Repair or replace the circuit for an open or short to power in harness or connectors.
0395
4.
Connect oxygen sensor connector. Connect the ECM harness connector. If using the X-431, reference data stream value. If not using the X-431, perform the following: Start engine and warm it up to normal operating temperature 350 C. Turn ignition switch off. Start engine and keep the engine speed between 3,500 RPM and 4,000 RPM for at least 1 minute. Let engine idle for 1 minute. Connect the digital multimeter probes between ECM terminal 4 and ground.
OXYGEN SENSOR OUTPUT SIGNAL
CHECK ITEM
CHECK CONTENT Warm-up condition Become lean while decelerate Decelerate from approximately 4,000 RPM suddenly Accelerate suddenly
Oxygen sensor
Warm-up condition Become rich while accelerate Warm-up condition Check with oxygen sensor signal
5.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
0396
03
VISMW030018T
0397
VISMW030009T
0398
03
VISMW030011T
0399
VISMW030012T
03100
03
VISMW030013T
03101
Voltage: 11-14 V
ITEM Sensor (GND) Regulated sensor supply 1 Manifold Absolute Pressure (MAP) sensor (1.6L)
CONDITION Ignition switch: ON Engine running: Idle Press accelerator pedal slowly Engine running: 2000 RPM Press accelerator pedal quickly
DATA (AVERAGE DC VOLTAGE) 0V Approximately 5 V Approximately 1.3 V Approximately 1.5 V Up to Approximately 4 V (Instantaneous)
37
ITEM
CONDITION Engine is running IAT: 36 C Idle: 795 RPM ECT: 78 C IAT signal voltage: 1.88 V
37
On Board Diagnostic Logic Self-diagnosis detection logic. DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION
DTC NO.
POSSIBLE CAUSE Intake air leaks MAP sensor MAF sensor Fuel injector Exhaust gas leaks Incorrect fuel pressure Lack of fuel Incorrect PCV hose connection Upstream O2 sensor ECM
P0171
Engine is running
The amount of mixture ratio compensation is too large (The mixture ratio is too lean).
03102
Diagnostic Procedure
03
1.
Start engine and run it at idle. Listen for any exhaust gas leaks before the three way catalyst.
2.
Turn ignition switch on. Listen for intake air leak after the MAF sensor. Check PCV hose connector.
3.
With X-431, select view data stream. INJECTOR REFERENCE DATA MONITOR ITEM CONDITION Engine Temp: Warm-up 78 C Transaxle Position: N Air Conditioner: Off Engine load: No load DATA
Injector pulse
Idle
Approximately 2.5 ms
03103
4.
Turn ignition switch off. Disconnect upstream O2 sensor 1 harness connector (1).
Disconnect the ECM harness connector. Check the harness continuity between the following terminals (refer to wiring diagram for circuit information). Continuity should exist. OXYGEN SENSOR CIRCUIT COMPONENT TERMINAL Check harness for a short to ground. ECM TERMINAL 36 18 OXYGEN SENSOR TERMINAL 3 4
BESM030017
>> Go to the next step. >> Repair or replace the circuit for an open or short to ground in harness or connectors.
CHECK THE MAP OR MAF SENSOR SIGNAL
5.
For the 1.6L engine, check MAP signal in data stream. 1.6L MAP SIGNAL DATA ECM TERMINAL NO. ITEM CONDITION Engine running: Idle Press accelerator pedal slowly Engine: Running Engine running: 2000 RPM Press accelerator pedal quickly DATA (DC VOLTAGE) Approximately 1.3 V Approximately 1.5 V Up to Approximately 4 V (instantaneous)
37
03104
37
MAF sensor
03
>> Go to the next step. >> Check connectors for rusted terminals or loose connectors in the MAP or MAF sensor circuit or
ground.
6.
CHECK FUEL PRESSURE Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery). Install fuel pressure gauge (2) and check the fuel pressure (See Fuel Pressure Test in Section 04 Fuel Delivery).
Observe the following fuel pressures when testing: FUEL PRESSURES Key On Key Off Engine Idle 400 kPa (4.0 bar)
BESM030020
380 kPa (3.8 bar) in 10 minutes 400 - 420 kPa (4.0 - 4.2 bar)
03105
7.
Check the following: Fuel lines Fuel pump and circuit Fuel pressure regulator Fuel filter for clogging
8.
Start engine. Select ACTIVE TEST menu. Perform injector active test. Make sure that each test produces a momentary drop in engine speed.
9.
Listen to each injector for an operating sound. Operating sound should exist.
03106
10.
Turn ignition switch off. Disconnect the injector harness connectors (1).
03
BESM040006
Turn ignition switch on. Check injector supply voltage between sensor terminal and ground in the injector harness connector with a digital multimeter. Battery voltage should exist.
LTSMD030024
Turn ignition switch off Disconnect the ECM harness connector. Check harness continuity between the following terminals (see wiring diagram for circuit information). Continuity should exist. FUEL INJECTOR CIRCUIT
INJECTOR NO. 1 2 3 4
ECM TERMINAL 27 6 7 47
INJECTOR TERMINAL 2 2 2 2
>> Go to the next step. >> Repair or replace circuit for an open or short to power in harness or connectors.
03107
11.
Disconnect the injector harness connectors. Check harness continuity between the following terminals (see wiring diagram for circuit information).
FUEL INJECTOR RESISTANCE INJECTOR NO. INJECTOR TERMINAL RESISTANCE (APPROXIMATELY) (20 C)
1 2 3 4
12.
CHECK INJECTOR
WARNING!
Confirm that the engine is cooled down and there are no fire hazards near the vehicle. Remove fuel delivery rail with injectors (See Fuel Injector Rail Removal & Installation in Section 04 Fuel Delivery). NOTE : Be careful not to drop the fuel injectors when removing the fuel delivery rail. Keep fuel hose and all injectors connected to injector rail. Disconnect all ignition coil harness connectors. Prepare pans or saucers under each injector. Crank engine for approximately 3 seconds. Fuel should be sprayed evenly from each injector.
>> Go to the next step. >> Clean any injector that sprays unevenly or replace any injector that does not spray fuel.
03108
13.
CHECK DTC
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
03
03109
VISMW030018T
03110
VISMW030009T
03111
03
VISMW030011T
03112
VISMW030012T
03113
VISMW030013T
03114
Voltage: 11-14 V
03
ECM TERMINAL NO. 17 33 ITEM Sensor (GND) Regulated sensor supply 1 Manifold Absolute Pressure (MAP) sensor (1.6L) CONDITION Ignition switch: ON Engine running: Idle Press accelerator pedal slowly Engine running: 2000 RPM Press accelerator pedal quickly DATA (AVERAGE DC VOLTAGE) 0V Approximately 5 V Approximately 1.3 V Approximately 1.5 V Up to Approximately 4 V (instantaneous)
37
ITEM
CONDITION Engine is running IAT: 36 C Idle: 795 RPM ECT: 78 C IAT signal: 1.88 V
37
On Board Diagnostic Logic Self-diagnosis detection logic. DTC DEFINITION DTC DETECTION CONDITION
DTC NO.
POSSIBLE CAUSE MAP sensor MAF sensor Fuel injector Exhaust gas leaks Incorrect fuel pressure Upstream O2 sensor ECM
P0172
Engine is running
The amount of mixture ratio compensation is too large (The mixture ratio is too rich).
03115
Diagnostic Procedure
1.
Start engine and run it at idle. Listen for any exhaust gas leaks before the three way catalyst.
2.
With X-431, select view data stream. INJECTOR REFERENCE DATA MONITOR ITEM CONDITION Engine Temp: Warm-up 78 C Transaxle Position: N Air Conditioner: Off Engine load: No load DATA
Injector pulse
Idle
Approximately 2.5 ms
3.
Turn ignition switch off. Disconnect upstream O2 sensor harness connector (1).
Disconnect the ECM harness connector. Check harness continuity between the following terminals (refer to wiring diagram for circuit information). Continuity should exist. OXYGEN SENSOR CIRCUIT COMPONENT TERMINAL ECM 36 18 OXYGEN SENSOR 3 4
BESM030017
03116
>> Go to the next step. >> Repair or replace circuit for an open or short to power in harness or connectors.
CHECK FUEL PRESSURE Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery). Install fuel pressure gauge (2) and check the fuel pressure (See Fuel Pressure Test in Section 04 Fuel Delivery).
4.
03
Observe the following fuel pressures when testing: FUEL PRESSURES Key On Key Off Engine Idle 400 kPa (4.0 bar)
BESM030020
380 kPa (3.8 bar) in 10 minutes 400 - 420 kPa (4.0 - 4.2 bar)
03117
5.
Check the following: Fuel pump and circuit Fuel pressure regulator
6.
Turn ignition switch off. Install all previously removed parts. For 1.6L engine, check MAP signal. 1.6L MAP DATA ECM TERMINAL NO. ITEM CONDITION Engine running: Idle Press accelerator pedal slowly Engine: Running Engine running: 2000 RPM Press accelerator pedal quickly For 1.8L engine, check MAF signal in data stream. 1.8L MAF DATA ECM TERMINAL NO. ITEM CONDITION Engine is running IAT: 36 C Idle: 795 RPM Warm-up condition: 78 C IAT signal voltage: 1.88 V DATA Approximately 322 kg/h Approximately 1.39 V DATA (DC VOLTAGE) Approximately 1.3 V Approximately 1.5 V Up to Approximately 4 V (instantaneous)
37
37
MAF sensor
>> Check connectors for damaged or MAP signal circuit for short to power circuit.
03118
7.
Start engine. Select ACTIVE TEST menu. Perform injector active test. Make sure that each test produces a momentary drop in engine speed.
03
8.
Listen to each injector for operating sound. Operating sound should exist.
9.
Turn ignition switch off. Disconnect the injector harness connectors (1).
Disconnect the ECM harness connector. Check harness for short to ground between following terminals (refer to wiring diagram for circuit information). Continuity should not exist. FUEL INJECTOR CIRCUITS INJECTOR NO. 1 2 3 4 ECM TERMINAL 27 6 7 47 INJECTOR TERMINAL 2 2 2 2
BESM040006
03119
>> Go to the next step. >> Repair circuit for a short to ground in harness or connectors.
CHECK INJECTOR RESISTANCE
10.
Disconnect the injector harness connectors. Check harness continuity between the following terminals (refer to wiring diagram for circuit information). FUEL INJECTOR RESISTANCE INJECTOR INJECTOR NO. TERMINAL 1 2 3 4 1&2 1&2 11 - 16 1&2 1&2 RESISTANCE (APPROXIMATELY) (20 C)
11.
CHECK INJECTORS
WARNING!
Confirm that the engine is cooled down and there are no fire hazards near the vehicle. Remove fuel delivery rail with injectors (See Fuel Injector Rail Removal & Installation in Section 04 Fuel Delivery). NOTE : Be careful not to drop the fuel injectors when removing the fuel delivery rail. Keep fuel hose and all injectors connected to injector rail. Disconnect all injector harness connectors. Disconnect all ignition coil harness connectors. Prepare pans or saucers under each injector. Crank engine for approximately 3 seconds. Make sure fuel does not drip from injectors.
>> Go to the next step. >> Replace any injectors from which fuel is dripping. Always replace O-ring with new one.
03120
12.
CHECK DTC
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
03
03121
1 2 3 4
VISMW030011T
03122
03
VISMW030012T
03123
VISMW030013T
03124
Voltage: 11 - 14 V
03
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. P0201 P0202 P0203 P0204 DTC DEFINITION Cylinder 1 - Injector Circuit Cylinder 2 - Injector Circuit Cylinder 3 - Injector Circuit Cylinder 4 - Injector Circuit Engine is running Injector Harness or connectors ECM DTC DETECTION CONDITION POSSIBLE CAUSE
03125
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace ground harness or connections.
PRELIMINARY INSPECTION
2.
>> Go to step 5.
PERFORM ACTIVE TEST FUNCTION
3.
Start engine. Select ACTIVE TEST menu. Perform injector active test. Make sure that each test produces a momentary drop in engine speed.
4.
Listen to each injector for operating sound. Operating sound should exist.
03126
5.
Turn ignition switch off. Disconnect the injector harness connector (1).
03
BESM040006
Turn ignition switch on. Check injector supply voltage between sensor terminal and ground in the electrical connector with a digital multimeter. Battery voltage should exist.
6.
Check the following: Front fuse and relay box K Fuse FB2, fuse FB12, fuse FB18 Harness for an open or short to ground between injector and fuse
>> With X-431, check the system, If OK, go to the next step. >> Repair or replace malfunctioning parts.
03127
7.
8.
Turn ignition switch off. Disconnect the ECM harness connector. Check harness continuity between the following terminals (see wiring diagram for circuit information). Continuity should exist. CHECK INJECTOR CIRCUIT INJECTOR NO 1 2 3 4 ECM TERMINAL 27 6 7 47 INJECTOR TERMINAL 2 2 2 2
>> Go to the next step. >> Repair circuit for an open in harness or connectors.
03128
9.
CHECK INJECTOR Refer to wiring diagram for circuit information. FUEL INJECTOR RESISTANCE
03
11 - 16 1&2 1&2 Check sensor signal output. Connect the ECM harness connector. Connect injector connector. Refer to wiring diagram for circuit information. INJECTOR REFERENCE DATA TERMINAL NO. 6 7 27 47 INJECTOR NO 2 3 1 4 CONDITION Engine is running Warm-up condition Idle Accelerate suddenly DATA (AVERAGE DC VOLTAGE)
Voltage: 11 - 14 V
10.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
03129
VISMW030005T
03130
03
VISMW030010T
03131
38
0.72 V
0.74 V
54
Ignition switch: ON
64 65 66 67 73 78
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION Rationally incorrect voltage is sent to ECM compared with the signals from TPS1 and TPS2. POSSIBLE CAUSE Electric throttle control actuator (TPS1 and TPS2) Harness or connectors Accelerator pedal position sensor 2 ECM
P0221
03132
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
03
>> Go to the next step. >> Repair or replace ground harness or connections.
CHECK THE TPS POWER SUPPLY CIRCUIT
2.
VISMD030006
Turn ignition switch on. Check supply voltage between TPS terminal 3 and ground in the sensor electrical connector E-027 with a digital multimeter. Approximately 5 V should exist.
3.
Turn ignition switch off. Disconnect the ECM harness connector. Check harness continuity between TPS terminal 3 and ECM terminal 32 (refer to wiring diagram for circuit information). Continuity should exist.
>> Go to the next step. >> Repair or replace circuit for an open.
03133
4.
Check harness for short to power and short to ground, between the following terminals: TPS POWER SUPPLY ECM TERMINAL 32 or 73 32 or 73 33 TPS / APPS TERMINAL TPS terminal 3 APP sensor terminal 3 APP sensor terminal 6
03
>> Go to the next step. >> Repair circuit for a short to ground or short to power in harness or connectors.
CHECK THE APP SENSOR
5.
Connect all harness connectors disconnected. Turn ignition switch on. Check voltage between ECM terminals 16 (APP sensor 1 (APPS1) signal), 40 (APP sensor 2 (APPS2) signal) and ground under the following conditions:
APP SENSOR SIGNAL ECM TERMINAL NO. APP SENSOR TERMINAL ITEM CONDITION Engine stopped Accelerator pedal: Fully released Engine stopped Accelerator pedal: Fully depressed Engine stopped Accelerator pedal: Fully released Engine stopped Accelerator pedal: Fully depressed DATA (DC VOLTAGE)
0.72 0.74 V
16
3.95 V
Ignition switch: ON
0.36 0.37 V
40
1.97 V
>> Go to step 10. >> Replace the Accelerator Pedal Assembly (See Accelerator Pedal Position Sensor Removal & Installation in Section 03 Electronic Engine Controls). Perform accelerator pedal position learning. Perform throttle valve position learning.
03134
6.
Turn ignition switch off. Disconnect the ECM harness connector. Check harness continuity between the electronic throttle control actuator terminal 5 and ECM terminal 38 (refer to wiring diagram for circuit information). Continuity should exist. Check harness for a short to power and short to ground.
>> Go to the next step. >> Repair circuit for an open or short to power or short to ground in harness or connectors.
CHECK TPS GROUND CIRCUIT FOR AN OPEN
03
7.
Check harness continuity between the electronic throttle control actuator terminal 2 and ECM terminal 78 (refer to wiring diagram for circuit information). Continuity should exist. Check harness for short to power.
>> Go to the next step. >> Repair circuit for an open or short to power in harness or connectors.
03135
8.
CHECK TPS
Connect all harness connectors that have been disconnected. Turn ignition switch on. Check voltage between TPS terminals 6 (TPS1) and ground, terminal 5 (TPS2) and ground under the following conditions:
TPS TERMINAL TPS TERMINAL NO. ITEM CONDITION Engine stopped Accelerator pedal: Fully released Engine stopped Accelerator pedal: Fully Ignition depressed switch: Engine ON stopped Accelerator pedal: Fully released Engine stopped Accelerator pedal: Fully depressed VOLTAGE (DC VOLTAGE)
4.24 V
0.72 V
0.74 V
4.62 V
>> Go to the next step. >> Replace electronic throttle control actuator, and perform throttle valve position learning.
CHECK DTC
9.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
03136
VISMW030006T
03137
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION ECM detected that the input signal is out of the acceptable range. POSSIBLE CAUSE CKP sensor Crankshaft signal plate Harness or connectors ECM
P0321
Engine is running
03138
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
03
>> Go to the next step. >> Repair or replace ground harness or connections.
CHECK THE CKP SENSOR REFERENCE VOLTAGE CIRCUIT
2.
VISMD030004
Turn ignition switch on. Check CKP sensor supply voltage between sensor connector E-006, terminal 1 and ground, terminal 2 and ground in the sensor electrical connector with a digital multimeter. 3 V should exist.
3.
Check the harness for an open or short between CKP sensor and ECM.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
>> Repair or replace the circuit for an open or short in harness or connectors.
03139
4.
Connect the ECM harness connector. Connect CKP sensor connector. Check sensor output signal when engine is running. CKP SENSOR OUTPUT SIGNAL CKP SENSOR SIGNAL
5.
Check the sensor as follows: Remove the sensor mounting bolt. Remove the sensor. Visually check the sensor for any damage. Check the sensor resistance as shown in the following table: CKP SENSOR RESISTANCE
TERMINAL NO.
1&2
Approximately 860
03140
>> Replace the CKP sensor with a known good CKP sensor.
6.
03
Check the installed clearance (See Crankshaft Position Sensor Removal & Installation in Section 03 Electronic Engine Controls). NOTE : 0.8 - 1.2 mm should exist.
7.
8.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
03141
P0324 - Knock Control System Error P0327 - Knock Sensor 1 Circuit Low Input P0327 - Knock Sensor 1 Circuit High Input
03
VISMW030007T
03142
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. P0324 DTC DEFINITION Knock control system error Knock sensor 1 circuit low input Knock sensor 1 circuit high input DTC SET CONDITION ECM detected that the input signal is out of the acceptable range. ECM detected that the input signal is low condition. ECM detected that the input signal is high condition. Knock sensor Harness or connectors ECM POSSIBLE CAUSE
P0327
P0328
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
03143
2.
Disconnect knock sensor harness connector. Check resistance between knock sensor connector E-017, terminal 1 and terminal 2. The resistance should be above 1 M.
3.
Disconnect the ECM harness connector. Check harness continuity between sensor connector E-017, terminal 1 and ECM terminal 19, sensor terminal 2 and ECM terminal 20 with a digital multimeter. Continuity should exist. KNOCK SENSOR CIRCUIT
ECM TERMINAL
19
20
>> Go to step 4. >> Repair or replace the circuit for an open or short in harness or connectors.
03144
4.
Check knock sensor (1) output signal as shown in table. Set digital multimeter on voltage range.
03
BESM030018
KNOCK SENSOR OUTPUT SIGNAL KNOCK SENSOR TERMINAL NO. TEST METHOD
Method 1: Knock at cylinder with rubber hammer 1-2 Method 2: Knock at sensor slightly Output signal voltage should exist.
5.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
03145
VISMW030014T
03146
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. P0340 P0341 DTC DEFINITION Camshaft Position (CMP) sensor circuit Camshaft Position (CMP) sensor performance Camshaft Position (CMP) sensor circuit low input Camshaft Position (CMP) sensor circuit high input Engine is running ECM detected that the input signal is out of the acceptable range. CMP sensor Camshaft Harness or connectors (The sensor circuit is open or shorted) ECM DTC DETECTION CONDITION DTC SET CONDITION POSSIBLE CAUSE
03
P0342
P0343
03147
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace ground harness or connections.
CHECK CMP SENSOR POWER SUPPLY CIRCUIT FOR OPEN OR SHORT
2.
VISMD030001
Turn ignition switch on. Check CMP sensor supply voltage between sensor connector E-007, terminal 3 and ground in the sensor electrical connector with a digital multimeter. 12 V should exist.
3.
Check the following: Front fuse and relay box K Fuse SB2, fuse FB12, fuse FB18 Harness for open or short between CMP sensor and fuse
>> Go to the next step. >> Repair or replace the malfunctioning part(s).
03148
4.
Turn ignition switch off. Check harness continuity between CMP sensor terminal 1 and ground. Continuity should exist. Check harness for short to power.
>> Go to the next step. >> Repair or replace the circuit for an open or short to power in harness or connectors.
CHECK CMP SENSOR INPUT SIGNAL CIRCUIT FOR AN OPEN OR SHORT TO POWER
03
5.
Turn ignition switch on. Check voltage between CMP sensor terminal 2 and ground. 10 V should exist.
>> Go to the next step. >> Repair or replace the open circuit or short to power in harness or connectors.
If circuit is normal, go to the next step.
6.
Connect CMP sensor connector. Check signal voltage between CMP sensor terminal 2 and ground when engine is running. Approximately 6 V square wave signal should exist. CKP SENSOR SIGNAL CMP SENSOR SIGNAL
03149
7.
Check the sensor as follows: Remove the sensor mounting bolt. Remove the sensor. Visually check the sensor for any damage. Check the sensor resistance as shown in the following table: CKP SENSOR RESISTANCE
TERMINAL NO.
RESISTANCE (25 C)
1-2
1-3
Except 0 or
2-3
>> Replace the CMP sensor with a known good CMP sensor.
8.
Check the installed clearance (See Camshaft Position (CMP) Sensor Removal & Installation in Section 03 Electronic Engine Controls). 0.8 - 1.2 mm should exist.
03150
9.
CHECK CAMSHAFT Check the following: Accumulation of debris on the signal plate at the rear of the camshaft. Chipped signal plate teeth at the rear of the camshaft.
>> Go to the next step. >> Remove debris and clean the signal plate at the rear of the camshaft or replace camshaft.
03
10.
CHECK DTC
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
03151
VISMW030022T
03152
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION Evaporative (EVAP) emission system purge control valve circuit open DTC DETECTION CONDITION DTC SET CONDITION ECM detected that the improper voltage signal is sent to ECM. POSSIBLE CAUSE EVAP canister control Harness or connectors ECM
03
P0444
Engine is running
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace ground harness or connections.
CHECK EVAP CANISTER CONTROL VALVE ACTION
2.
Start engine and warm it up to the normal operating temperature then select view DTC. Touch the EVAP canister valve body, raise engine speed up to 2,000 RPM. With the X-431 scan tool, use the ACTIVE TEST function of the EVAP canister valve, touch the EVAP canister valve body, perform the action test. The EVAP canister valve should have a slight vibration.
03153
3.
VISMD030007
Turn ignition switch on. Check supply voltage between EVAP canister control valve terminal 1 and ground with a digital multimeter. 12 V should exist.
4.
Check the following: Front fuse and relay box K Fuse SB2, fuse FB12, fuse FB18 Harness for an open or short between EVAP canister control valve and fuse
5.
Check voltage between EVAP canister control valve terminal 2 and ground with a digital multimeter. Approximately 3.6 V should exist.
>> Go to the next step. >> Repair or replace circuit for an open in harness or connectors.
If harness is normal, replace and match ECM.
03154
6.
Turn ignition switch off. Remove EVAP canister control valve. Check the resistance as shown in the following table: EVAP CANISTER CONTROL VALVE
TERMINAL NO.
RESISTANCE (20 C)
1&2
Approximately 26
Check air passage continuity and operation when applying 12 V current supply voltage between terminals 1 and 2. The air passage should be opened.
>> Go to the next step. >> Replace EVAP canister control valve.
CHECK DTC
7.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
03155
P0506
ECM detected that the idle speed is less than the acceptable range.
03156
Diagnostic Procedure
1.
Start the engine and let it idle. Listen for an intake air leak after the mass air flow sensor.
>> Go to the next step. >> Repair the air leak as necessary.
CHECK THE ELECTRONIC THROTTLE CONTROL ACTUATOR
03
2.
Check the electronic throttle open degree. Check the electronic throttle clearance.
3.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
03157
P0562 - System Voltage Low Voltage P0563 - System Voltage High Voltage
03
VISMW030003T
03158
VISMW030004T
03159
P0562
P0563
03160
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
03
2.
Check ECM supply between terminal 12 and ground in the ECM electrical connector E-001, harness side.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
LTSMD030063
3.
Connect the ECM harness connector. Start the engine, raise the speed over 1000 RPM. Measure the charging system voltage with the voltmeter at battery positive and negative.
4.
Start the engine, raise the speed over 1000 RPM for a few minutes. Turn ignition switch off. Measure the voltage drop with the voltmeter at battery positive and negative while cranking the engine. Battery voltage should be more than approximate 9 V.
03161
5.
Measure the resistance between ECM terminal 12 and battery positive terminal. Continuity should exist.
6.
Start the engine and raise the engine speed over 1000 RPM. Measure the charge voltage with the voltmeter at battery positive and negative.
7.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
03162
P0604 - Internal Controller Module Random Access Memory (RAM) Error P0605 - Internal Controller Module ROM Test Error P0606 - ECM Processor
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. P0604 P0605 P0606 DTC DEFINITION Internal Controller Module Random Access Memory (RAM) Error Internal Controller Module ROM Test Error ECM Processor DTC DETECTION CONDITION POSSIBLE CAUSE
03
ECM
03163
Diagnostic Procedure
1.
CHECK DTC
>> Go to the next step. >> The conditions that caused this code to set are not present at this time (See Diagnostic Help in
Section 03 Electronic Engine Controls).
2.
Check the ECM supply voltage circuit, ground circuit open, high resistance or short circuits existing.
>> Go to the next step. >> Repair or replace the circuit for open or short in harness and connectors.
CHECK DTC
3.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
>> The system is now operating properly. >> Replace the ECM.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls).
03164
03
03165
Diagnostic Procedure
1.
CHECK DTC
>> Go to the next step. >> The conditions that caused this code to set are not present at this time (See Diagnostic Help in
Section 03 Electronic Engine Controls).
2.
Check the ECM supply voltage circuit, ground circuit open, high resistance or short circuits existing.
>> Go to the next step. >> Repair circuit for an open or short in harness and connectors.
MATCH ECM
3.
With X-431 scan tool, match the ECM before replacing the ECM. and view the DTC with X-431. With X-431 scan tool view the DTCs
4.
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
>> The system is now operating properly. >> Replace the ECM.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls).
03166
03
VISMW030019T
03167
69
0 V or 12 V
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION ECM detected that the input signal is out of the acceptable range. POSSIBLE CAUSE Fuse A/C compressor relay Harness or connectors ECM
P0645
Engine is running
03168
Diagnostic Procedure
1.
CHECK GROUND CONNECTIONS Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
03
>> Go to the next step. >> Repair or replace ground harness or connections.
CHECK A/C COMPRESSOR RELAY CONTROL CIRCUIT POWER SUPPLY CIRCUIT FOR OPEN Turn ignition switch on. Turn A/C switch off. Check A/C compressor relay control circuit supply voltage between ECM terminal 69 and ground in the ECM electrical connector E-001 with a digital multimeter. 12 V should exist.
2.
3.
DETECT MALFUNCTIONING PART Check the following: Body fuse and relay box K, E Fuse FB1, FB18, SB2 A/C compressor relay, ignition relay, EMS relay Harness for an open or short
4.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
03169
VISMW030005T
03170
03
VISMW030010T
03171
38
0.72 V
54
Electronic throttle control actuator (position sensor) Motor 4 Motor 3 Motor 2 Motor 1 Regulated sensor supply 2 Sensor (GND)
0.74 V
Ignition switch: ON
64 65 66 67 73 78
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION Rationally incorrect voltage is sent to ECM compared with the signals from TPS1 and TPS2. POSSIBLE CAUSE Electric throttle control actuator (TPS1 and TPS2) Harness or connectors Accelerator pedal position sensor 2 ECM
P1545
03172
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
03
>> Go to the next step. >> Repair or replace ground harness or connections.
CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT - (1)
2.
VISMD030006
Turn ignition switch on. Check supply voltage between sensor terminal 3 and ground in the TPS electrical connector E-027 with a digital multimeter. Approximately 5 V should exist.
3.
Turn ignition switch off. Disconnect the ECM harness connector. Check harness continuity between TPS terminal 3 and ECM terminal 32 (refer to wiring diagram for circuit information). Continuity should exist.
>> Go to the next step. >> Repair or replace the open circuit.
03173
4.
Check harness for a short to power and short to ground, between following terminals: TPS POWER SUPPLY CIRCUIT ECM TERMINAL 32 or 73 32 or 73 33 TPS TERMINAL TPS terminal 3 APP sensor terminal 3 APP sensor terminal 6
>> Go to the next step. >> Repair or replace short to ground or short to power in harness or connectors.
CHECK THE APP SENSOR
5.
Connect all harness connectors that have been disconnected. Turn ignition switch on. Install a digital multimeter to the APP sensor as shown in the following: APP SENSOR CIRCUIT ECM TERMINAL APPS TERMINAL
16
40
Check voltage between ECM terminals 16 (APP sensor 1 signal), 40 (APP sensor 2 signal) and ground under the following conditions: APP SENSOR REFERENCE DATA TERMINAL NO. ITEM CONDITION Engine stopped Accelerator pedal: Fully released Engine stopped Accelerator pedal: Fully depressed Engine stopped Accelerator pedal: Fully released Engine stopped Accelerator pedal: Fully depressed DATA (DC VOLTAGE) 0.72 - 0.74 V
16
Accelerator Pedal Position Sensor Ignition switch: ON Accelerator Pedal Position Sensor
3.95 V
0.36 - 0.37 V
40
1.97 V
03174
>> Go to step 10. >> Replace the Accelerator Pedal Assembly (See Accelerator Pedal Position Sensor Removal & Installation in Section 03 Electronic Engine Controls). Perform accelerator pedal position learning. Perform throttle valve position learning.
6.
Turn ignition switch off. Disconnect the ECM harness connector. Check harness continuity between electronic throttle control actuator terminal 5 and ECM terminal 38, electronic throttle control actuator terminal 6 and ECM terminal 54 (refer to wiring diagram for circuit information). Continuity should exist. Check harness for short to power or short to ground.
03
>> Go to the next step. >> Repair or replace the open circuit or short to power or short to ground in harness or connectors.
CHECK THE TPS GROUND CIRCUIT FOR AN OPEN OR SHORT
7.
Check harness continuity between the electronic throttle control actuator terminal 2 and ECM terminal 78 (refer to wiring diagram for circuit information). Continuity should exist. Check harness for a short to power and short to ground.
>> Go to the next step. >> Repair or replace the open circuit or short to power or short to ground in harness or connectors.
03175
8.
CHECK TPS Connect all harness connectors disconnected. Turn ignition switch on. Check voltage between ECM terminals 54 (TPS 1 signal), 38 (TPS 2 signal) and ground under the following conditions:
TPS REFERENCE DATA
ITEM
CONDITION Engine stopped Accelerator pedal: Fully released Engine stopped Accelerator pedal: Fully depressed Engine stopped Accelerator pedal: Fully released Engine stopped Accelerator pedal: Fully depressed
4.24 V
0.72 V
Ignition switch: ON
0.74 V
4.62 V
>> Go to the next step. >> Replace the electronic throttle control actuator, and perform throttle valve position learning.
CHECK DTC With the X-431 scan tool, read ECM DTCs. See DTC Confirmation Procedure.
9.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
03176
03
VISMW030010T
03177
VISMW030005T
03178
16
Accelerator Pedal Position Sensor 1 (APPS1) Regulated sensor supply 2 Regulated sensor supply 1 Sensor (GND) Sensor (GND) Accelerator Pedal Position Sensor 2 (APPS2) Regulated sensor supply 1
3.95 V
03
Approximately 5 V Approximately 5 V Approximately 0 V Approximately 0 V 0.36 - 0.37 V
32 33 35 36
40
1.97 V Approximately 5 V
73
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION POSSIBLE CAUSE Accelerator pedal position sensor 1 and 2 Harness or connectors Electric throttle control actuator (TPS1 and TPS2) ECM
P2138
Rationally incorrect voltage is sent to ECM compared with the signals from APPS1 and APPS2.
03179
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace ground harness or connections.
CHECK ACCELERATOR PEDAL POSITION SENSOR 1 (APPS1) POWER SUPPLY CIRCUIT
2.
VISMD030008
Turn ignition switch on. Check supply voltage between sensor terminal 6 and ground in the APPS1 electrical connector with a digital multimeter. Approximately 5 V should exist.
03180
3.
Check the following: Harness connectors E-102, C-102, C-109, C-401 Harness for an open or short between APPS1 and ECM Refer to wiring diagram for circuit information.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
03
4.
Check supply voltage between APPS2 terminal 3 and ground in the sensor electrical connector C-301 with a digital multimeter (refer to wiring diagram for circuit information). Approximately 5 V should exist.
5.
Check the following: Harness connectors E-102, C-102, C-109, C-401 Harness for open or short between APPS2 and ECM Refer to wiring diagram for circuit information.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
03181
6.
CHECK TPS POWER SUPPLY CIRCUIT Check harness for short to power and short to ground between the following terminals: TPS POWER SUPPLY CIRCUIT ECM TERMINAL 32 or 73 TPS TERMINAL 3
>> Go to the next step. >> Repair circuit for short to ground or short to power in harness or connectors.
CHECK THE TPS Connect all harness connectors disconnected. Turn ignition switch on. Check voltage between ECM terminals 54 (TP sensor 1 (TPS1) signal), 38 (TP sensor 2 (TPS2) signal) and ground under the following conditions:
TPS REFERENCE DATA
7.
ITEM
CONDITION Engine stopped Accelerator pedal: Fully released Engine stopped Accelerator pedal: Fully depressed Engine stopped Accelerator pedal: Fully released Engine stopped Accelerator pedal: Fully depressed
4.24 V
0.72 V
Ignition switch: ON
0.74 V
4.62 V
>> Go to the next step. >> Repair or replace the TPS circuits for a short or open.
If the TPS circuits are normal, replace the electronic throttle control actuator. Perform throttle valve position self-learning.
03182
8.
CHECK THE APPS GROUND CIRCUIT FOR AN OPEN OR SHORT Turn ignition switch off. Disconnect the ECM harness connector. Check harness continuity between APPS2 terminal 2 and ECM terminal 35, APPS1 terminal 5 and ECM terminal 36 (refer to wiring diagram for circuit information). Continuity should exist. Check harness for a short to power.
>> Go to the next step. >> Repair or replace the open circuit or short to power in harness or connectors.
CHECK APPS SIGNAL CIRCUIT FOR AN OPEN OR SHORT Check harness continuity between APPS1 terminal 4 and ECM terminal 16, APPS2 terminal 1 and ECM terminal 40 (refer to wiring diagram for circuit information). Continuity should exist. Check harness for a short to power or short to ground.
03
9.
>> Go to the next step. >> Repair or replace the open circuit or short to power or short to ground in harness or connectors.
CHECK APP SENSOR
10.
Connect all harness connectors that have been disconnected. Turn ignition switch on. Check voltage between ECM terminals 16 (APP sensor 1 signal), 40 (APP sensor 2 signal) and ground under the following conditions: APP SENSOR REFERENCE DATA TERMINAL NO. ITEM CONDITION Engine stopped Accelerator pedal: Fully released Engine stopped Accelerator pedal: Fully depressed Engine stopped Accelerator pedal: Fully released Engine stopped Accelerator pedal: Fully depressed VOLT (DC VOLTAGE) 0.72 - 0.74 V
16
Accelerator pedal position sensor 1 (APPS1) Ignition switch: ON Accelerator pedal position sensor 2 (APPS2)
3.95 V
0.36 - 0.37 V
40
1.97 V
>> Go to the next step. >> Replace the Accelerator Pedal Assembly (See Accelerator Pedal Position Sensor Removal & Installation in Section 03 Electronic Engine Controls). Perform accelerator pedal position learning. Perform throttle valve position learning. Chery Automobile Co., Ltd.
03183
11.
CHECK DTC
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
03184
03
VISMW030021T
03185
U0001
03186
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Controls). Inspect ground connections E-201 and E-202 mounting positions (See Vehicle Wiring Harness Information Engine Control Harness in Section 16 Wiring).
03
>> Go to the next step. >> Repair or replace ground harness or connections.
CHECK DTC
2.
Turn ignition switch on. With the scan tool, select view ECM DTCs and data stream.
>> Go to the next step. >> The conditions that caused this code to set are not present at this time (See Diagnostic Help in
Section 03 Electronic Engine Controls).
3.
With the X-431 scan tool, attempt to enter all the other CAN communication modules such as FBCM, ABS module, Restraints control module, Unified meter control unit, EPS control unit. Read CAN DTCs.
>> If all of the other modules have the CAN DTC High speed CAN Communication, go to the next
step. If all of the other modules have the CAN DTC about Lost communication with ECM, and havent the High speed CAN Communication, replace the ECM.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). No
>> Go to step 8.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls).
03187
4.
Turn ignition switch off. Disconnect the negative battery cable. Disconnect the ECM harness connector. Check resistance between ECM connector terminal 62 and terminal 81. CAN TERMINAL RESISTANCE
RESISTANCE
62
81
123.3
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). The problem caused by the ECM is an internal error.
5.
Turn ignition switch off. Connect all disconnected modules. Check CAN Bus line total resistance between DLC terminal 14 and 6. CAN TERMINAL RESISTANCE
RESISTANCE
14
60
03188
6.
Disconnect all other module connectors with CAN Bus lines. Check harness continuity between the following terminals:
CAN-H CONTINUITY
CAN NETWORK
DLC TERMINAL
TERMINAL
CONTINUITY
03
CAN-H
Ground
No
CAN NETWORK
DLC TERMINAL
TERMINAL
CONTINUITY
CAN-L
14
Ground
No
>> Go to the next step. >> Repair or replace the CAN Bus line for an open or short.
03189
7.
Connect all other disconnected CAN Bus modules connectors. Disconnect CAN Bus module one by one. Connect the negative battery cable. Turn ignition switch on. Check CAN Bus voltage between the following terminals after disconnecting CAN Bus modules one at a time. CAN-H: Voltage should be more than 2.5 V. CAN-L: Voltage should be less than 2.5 V. CAN BUS LINE VOLTAGE DLC TERMINAL TERMINAL
8.
Inspect the ECM electrical connector pins for proper fit or any chafed, pierced, pinched, or partially broken wires. With the X-431 scan tool, read ECM DTCs.
Is the check result normal and CAN DTC U0001 not present?
Yes No
>> The system is now operating properly. >> Replace the ECM.
Reassemble the vehicle and road test to verify the customers complaint is repaired.
NOTE : The ECM must be matched to the vehicle Immobilizer (See ECM Removal & Installation in Section 03 Electronic Engine Controls). The problem caused by the ECM is an internal error.
03190
ON-VEHICLE SERVICE
Engine Coolant Temperature Sensor
Description
The Engine Coolant Temperature (ECT) sensor threads into the coolant outlet connector. The ECT is a negative thermal coefficient sensor.
Operation
The ECT provides an input to the Engine Control Module (ECM). As temperature increases, resistance of the sensor decreases. As coolant temperature varies, the ECT sensor resistance changes resulting in a different voltage value at the ECT sensor signal circuit. The ECM uses the input to control air-fuel mixture, timing, and radiator fan on/off times.
03
WARNING!
Never remove the pressure relief cap under any conditions while the engine is operating or hot. Failure to follow these instructions could result in personal injury or damage to the cooling system or engine. To avoid having scalding hot coolant or steam blow out of the cooling system, use extreme care when removing the pressure relief cap. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly one turn (counterclockwise). Step back while the pressure is released from the cooling system. When you are certain all the pressure has been released, (with a cloth) turn and remove the pressure relief cap. Failure to follow these instructions may result in serious personal injury. 3. Disconnect the coolant temperature sensor electrical connector.
CAUTION: Remove the coolant temperature sensor when the engine is cold.
4. Remove the engine coolant temperature sensor (1). (Tighten: Engine coolant temperature sensor to 20 Nm) 5. Discard the O-ring. 6. Installation is in the reverse order of removal.
LTSM030035
03191
ON-VEHICLE SERVICE
Installation Notes: After installing the coolant temperature sensor, check and adjust the coolant level.
Knock Sensor
Description
The knock sensor is attached to the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation.
Operation
Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the ECM while the engine operates. As the intensity of the crystals vibration increases, the knock sensor output voltage also increases. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the Engine Control Module (ECM). In response, the ECM retards ignition timing for all cylinders by a specified amount. The ECM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed.
BESM030018
Oxygen Sensor
Description
This oxygen sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1 volt in richer conditions to 0 volt in leaner conditions. This vehicle is equipped with two oxygen sensors (upstream oxygen sensor & downstream oxygen sensor). The oxygen sensors are located before and after the three way catalyst.
Operation
The oxygen sensor has a much longer switching time between rich and lean than the air flow sensor. The oxygen storage capacity of the three way catalyst (manifold) causes the longer switching time. The oxygen senses the oxygen content in the exhaust flow and outputs a voltage between 0 and 1.0 volt. Lean of stoichiometric, air/fuel ratio of approximately 14.7:1, the oxygen sensor generates a voltage between 0 and 0.45 volt. Rich of stoichiometric, the oxygen sensor generates a voltage between 0.45 and 1.0 volt. The oxygen sensor senses the oxygen content in the exhaust flow and outputs a voltage between 0 and 1.0 volt. Lean of stoichiometric, air/fuel ratio of approximately 14.7:1, the oxygen sensor generates a voltage between 0 and 0.45 volt. Rich of stoichiometric, the oxygen sensor generates a voltage between 0.45 and 1.0 volt.
03192
ON-VEHICLE SERVICE
CAUTION: Remove the oxygen sensor when the exhaust pipe is cold.
3. Remove the upstream oxygen sensor (1) and downstream oxygen sensor (2). (Tighten: Oxygen sensor to 45 Nm) 4. Installation is in the reverse order of removal.
03
BESM030017
Operation
When the engine is running, the high and low parts of the teeth cause the gap with the sensor to change. The changing gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltage from the sensor changes. The Engine Control Module (ECM) receives the voltage signal and detects the fluctuation of the engine revolution.
LTSM030036
03193
ON-VEHICLE SERVICE
Operation
When the engine is running, the high and low parts of the teeth cause the gap with the sensor to change. The changing gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltage from the sensor changes. The Engine Control Module (ECM) detects the voltage signal and identify piston position and cylinder timing.
BESM030016
03194
ON-VEHICLE SERVICE
Operation
The MAP sensor monitors the pressure in the intake manifold. The pressure in the manifold moves a diaphragm connected to resistors which alter their resistance values. The output voltage of the MAP sensor signals the ECM about the pressure in the intake manifold.
03
LTSM030037
03195
ON-VEHICLE SERVICE
Operation
The air flow sensor controls the temperature of the hot wire to a certain amount. The heat generated by the hot wire is reduced as the intake air flows around it. The more air,the greater the heat loss. Therefore, the electric current supplied to the hot wire is changed to maintain the temperature of the hot wire as air flow increases. The ECM detects the air flow by means of this current change.
VISM020007
4. Pull sensor up and remove it. 5. Installation is in the reverse order of removal.
Operation
The accelerator pedal position (APP) sensor works according to the Hall principal. the sensor is integrated into the pedal lever axis. It consists of a shaft with a ring magnet. This rotates in a printed circuit board with a stator in the fixed Hall elements. This produces a change in the voltage. The accelerator pedal position sensor is supplied with 5 volts from the Engine Control Module (ECM). The information regarding accelerator position is supplied to the ECM by means of two voltages.
03196
ON-VEHICLE SERVICE
3. Disconnect the APP sensor electrical connector (2). 4. Remove the three APP sensor mounting bolts (1). (Tighten: APP sensor mounting bolts to 11 Nm) 5. Remove the APP sensor with the pedal. 6. Installation is in the reverse order of removal.
03
LTSM030038
Operation
Filtered air from the air cleaner enters the intake manifold through the throttle body. A throttle valve (plate) is used to supply air for idle and driving conditions. The throttle position sensor is part the throttle body. The throttle position sensor signal is used by the ECM to determine throttle position. The ECM controls the electronic throttle control to meter air into the engine. This regulates engine power. The vehicle is in sense a Drive by Wire system.
BESM030022
03197
ON-VEHICLE SERVICE
Operation
The ECM is a pre-programmed, microprocessor-based digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The ECM can adapt its programming to meet changing operating conditions.
VISM030001
03198
ON-VEHICLE SERVICE
7. Remove the ECM retaining bolts (1). (Tighten: ECM retaining bolts to 6 Nm) 8. Remove the ECM.
03
VISM030006
9. Installation is in the reverse order of removal. Perform the following to match the ECM to the Immobilizer: With the X-431 scan tool, choose M11 or M12 series. Choose immobilize. Choose input code. Input the safety code. Click the small keyboard. Click OK. Choose Immobilizer adapt. Choose read Immobilizer to ECM immediately. Click OK.
03199
03200
Visual Inspection
Check Check Check Check Check Check the the the the the the fuel system for any fuel leakage. vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses. intake air pipe for being jammed, leaking, or damaged. ignition system for any broken or aging spark plug wires and verify the engine firing order is correct. engine ground cable and verify a clean and tight connection. sensors and actuators electrical connectors and verify good contact and tight connection.
03
NOTE : Repair any of the above conditions first before continuing with symptom diagnostics.
Diagnostic Help
Confirm there are no current engine DTCs. Confirm that the failure exists and the customer complaint can be verified. Inspect the engine following the above steps and verify all engine features are operating properly. While servicing the vehicle, verify the service record, vehicle maintenance, engine compression pressures, mechanical ignition timing and fuel conditions. If replacing the Engine Control Module (ECM), carry out the validation test. If the failure no longer exists, the failure is in the ECM; if the failure still exists, reinstall the original ECM and repeat the diagnostic test.
03201
Engine Cranks Normal But Will Not Start The following conditions apply to this symptom:
The engine cranks at normal speed. The engine will not start. The battery is fully charged.
1.
PRELIMINARY CHECKS
CAUTION: Extended cranking because of a No Start can load the exhaust system with raw fuel, damaging the catalytic converter after the engine starts.
Carry Yes No out the following preliminary checks: Fuel quality Electrical connections Intake air tube integrity Fuses and relays
2.
CHECK DTC
Turn the ignition switch on. With the scan tool X-431, select view DTC.
>> Check for cause (See Diagnostic Trouble Code (DTC) Index). >> Go to the next step.
TRY TO START THE ENGINE WITH THE THROTTLE CLOSED
3.
>> Verify the symptom no longer exists. >> Go to the next step.
03202
4.
5.
03
>> Verify test results. If OK, see Diagnostic Test List to repair any additional symptoms. >> Check for cause.
03203
Engine Will Not Crank The following conditions apply to this symptom:
The engine will not crank.
1.
PRELIMINARY CHECKS out the following preliminary vehicle inspection: Fuel quality Battery connections Starter relay connections Manual transmission clutch fully depressed Engine immobilizer activated Fuses/Fuse links
Carry Yes No
2.
Is a clicking sound heard from the starter relay when the ignition key is turned to START?
Yes No
3.
Check the starter, starter ground, starter relay cable to starter and battery.
Is a fault indicated?
Yes No
4.
03204
5.
CHECK DTC
Turn the ignition switch on. With the scan tool X-431, read the DTC.
6.
03
Check the starting system primary circuits as follows: Starter relay Ignition switch
>> Ensure customers concern has been resolved. >> Repair as necessary.
03205
Hard Start / Long Crank / Erratic Start / Erratic Crank The following conditions apply to this symptom:
The engine cranks for an extended period of time. The engine starts hard during a long cranking time.
1.
PRELIMINARY CHECKS
Confirm that the correct starting procedure was used by the customer before proceeding with diagnosis. Carry out the following preliminary checks: Vacuum leaks Fuel quality (concerns such as correct octane, contamination, winter/summer blend) Intake air system (tubes) Air cleaner (restrictions) Battery condition and starter current draw.
2.
With scan tool X-431, select view DTC and data stream in ECM.
>> Check for cause of DTC (See Diagnostic Trouble Code (DTC) List in Section 03 Electronic Engine
Controls).
3.
Perform the following to test the secondary ignition system: Disconnect the injector fuse. Remove any of the 4 spark plugs. Connect the spark plug to spark plug wire. Ground the spark plug on the cylinder block. Crank the engine to test the secondary ignition system with the spark plugs removed.
Is a strong blue spark visible at each spark plug while cranking the engine?
Yes No
If CMP sensor is OK, check the following: Crankshaft Position (CKP) sensor malfunction Faulty spark plug wires Faulty spark plugs
>> Go to the next step. >> Check Camshaft Position (CMP) sensor signal at ECM.
03206
4.
Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery). Check fuel system pressure (See Fuel Pressure Test in Section 04 Fuel Delivery).
>> Go to the next step. >> If the fuel pressure is greater than 400 kPa (4.0 Bar):
Install a new fuel pressure regulator. If the fuel pressure is less than 400 kPa (4.0 Bar): Check the fuel supply system for restrictions or leaks. If no problems, repair or replace fuel filter, pressure regulator or fuel pump assembly.
03
5.
6.
>> Repair the engine cooling system. >> Go to the next step.
CHECK POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM
7.
03207
8.
Disconnect the canister control valve (1) hose. Place a stiff piece of paper over the hose end and start the engine.
>> Check for a vacuum leak in EVAP system (refer to EVAP system) and refer to EVAP control circuit relative DTC.
No
VISMD030007
9.
>> Install a new MAF/IAT or MAP/IAT sensor. >> See Diagnostic Help for additional information.
03208
1.
Does the engine appear to be either overheating or not reaching normal operating temperature?
Yes No
>> Repair the engine cooling system. >> Go to the next step.
PRELIMINARY CHECKS out the following preliminary checks: Vacuum leaks Throttle plate and linkage Intake air tube (leaks) Correct sealing of intake manifold and components attached to intake air tube
03
2.
Carry Yes No
3.
Turn the ignition switch on. With the scan tool X-431, select view DTC and data stream in ECM.
>> Check for causes. See Diagnostic Trouble Code (DTC) index Engine Control Module (ECM). >> See Diagnostic Help for additional information.
03209
1.
PRELIMINARY CHECKS
Verify symptom is reported under normal driving conditions without excessive engine/vehicle load conditions. Carry out the following preliminary checks: Fuel quality Vacuum lines (check for damage and correct routing) Intake air system (check for damaged tubes and dirty air filter) Vehicle wiring (disconnected, corroded/damaged) Throttle linkage Radiator (obstructed) Transaxle NOTE : Be aware of the over RPM limiting functions of the ECM.
2.
Turn ignition switch on. With the scan tool X-431, read the DTC.
>> Check for causes. See Diagnostic Trouble Code (DTC) index Engine Control Module (ECM). >> Go to the next step.
CHECK FUEL SYSTEM PRESSURE
3.
Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery). Check fuel system pressure (See Fuel Pressure Test in Section 04 Fuel Delivery).
>> Go to the next step. >> If the fuel pressure is greater than 400 kPa (4 Bar):
Install a new fuel pressure regulator. If the fuel pressure is less than 400 kPa (4 Bar): Check fuel supply system for restriction or leak. If no problems, repair or replace fuel filter, pressure regulator or fuel pump assembly.
03210
4.
Perform the following to test the secondary ignition system: Disconnect the injector fuse. Remove any of the 4 spark plugs. Connect the spark plug to spark plug wire. Ground the spark plug on the cylinder block. Crank the engine to test the secondary ignition system with the spark plugs removed.
Is a strong blue spark visible at each spark plug while cranking the engine?
Yes No
If CMP sensor is OK, check the following: Crankshaft Position (CKP) sensor malfunction Spark plug wires Spark plugs
>> Go to the next step. >> Check Camshaft Position (CMP) sensor signal at ECM.
03
5.
6.
7.
Check for base engine concerns (such as improper compression, worn camshaft/valve train, gasket leaks).
Is a fault indicated?
Yes No
8.
03211
9.
CHECK FOR BRAKE SYSTEM CONCERNS Check the operation of the brakes.
Is a fault indicated?
Yes No
10.
Check the following for possible additional causes: Customer driving habits (such as excessive loads or over RPM limiting functions enabled). Clutch. Charging system. Ignition base timing (if not previously checked). If the base timing is not correct, align the engine timing belt (See Engine Timing Belt Removal & Installation in 02 Engine).
>> See Diagnostic Help for additional information. >> Repair as necessary.
Verify the symptom no longer exists.
03212
1.
PRELIMINARY CHECKS
Carry out the following preliminary checks: Vacuum lines (check for damage and correct routing). Spark plug wire routing (correct firing order).
03
>> Go to the next step. >> Repair as necessary. Verify symptom no longer exists.
CHECK ECM DTC
2.
Turn the ignition switch on. With the scan tool X-431, select view DTC and stream data in ECM.
See Diagnosis trouble code (DTC) index Engine Control Module (ECM).
3.
Perform the following to test the secondary ignition system: Disconnect the injector fuse. Remove any of the 4 spark plugs. Connect the spark plug to spark plug wire. Ground the spark plug on the cylinder block. Crank the engine to test the secondary ignition system with the spark plugs removed.
Is a strong blue spark visible at each spark plug while cranking the engine?
Yes No
If CMP sensor is OK, check the following: Crankshaft Position (CKP) sensor malfunction Spark plug wires Spark plugs
>> Go to the next step. >> Check Camshaft Position (CMP) sensor signal at ECM.
4.
03213
5.
6.
CHECK TIMING
>> Go to the next step. >> Align the engine timing belt (See Engine Timing Belt Removal & Installation in 02 Engine).
CHECK FUEL SYSTEM PRESSURE
7.
Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery). Check fuel system pressure (See Fuel Pressure Test in Section 04 Fuel Delivery).
>> Go to the next step. >> If the fuel pressure is greater than 400 kPa (4 Bar):
Install a new fuel pressure regulator. If the fuel pressure is less than 400 kPa (4 Bar): Check fuel supply system for restriction or leak. If no problems, repair or replace fuel filter, pressure regulator or fuel pump assembly.
8.
Check for base engine concerns (such as improper cylinder compression, worn camshaft/valve train, gasket leaks).
Is a fault indicated?
Yes No
>> Repair as necessary. >> See Diagnostic Help for additional information.
03214
1.
03
PRELIMINARY CHECKS
NOTE : Be aware of the over RPM limiting functions of the ECM. Carry out the following preliminary checks: Fuel quality Vacuum lines (check for damage and correct routing) Intake air system (check for damaged tubes and dirty air filter) Vehicle wiring (disconnected, corroded/damaged) Throttle linkage. Radiator (obstructed) Transaxle
>> Go to the next step. >> Repair as necessary. Verify symptom no longer exists.
CHECK FOR STALL AT IDLE
2.
Check for engine stall at idle. NOTE : Confirm that proper vehicle maintenance has been performed before continuing with engine diagnosis. Inspect the following components: Clean the injectors Fuel filter Intake air filter Throttle body Spark plugs Spark plug wires
03215
3.
Check for engine rough idle. NOTE : Confirm that proper vehicle maintenance has been performed before continuing with engine diagnosis. Inspect the following components: Clean the carbon deposit on intake and exhaust valves Valve stem Spark plugs Throttle body Spark plugs and combustion chamber
4.
Turn the ignition switch on. With the scan tool X-431, read the DTC.
5.
Start engine and let idle. While checking for RPM drop or engine stall, disconnect ETC actuator connector.
Did RPM drop or engine stall when the ETC connector was disconnected?
Yes No
6.
Perform the following to test the secondary ignition system: Disconnect the injector fuse. Remove any of the 4 spark plugs. Connect the spark plug to spark plug wire. Ground the spark plug on the cylinder block. Crank the engine to test the secondary ignition system with the spark plugs removed.
Is a strong blue spark visible at each spark plug while cranking the engine?
Yes No
If CMP sensor is OK, check the following: Crankshaft Position (CKP) sensor malfunction Spark plug wires Spark plugs
>> Go to the next step. >> Check Camshaft Position (CMP) sensor signal at ECM.
03216
7.
CHECK FUEL SYSTEM PRESSURE Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery). Check fuel system pressure (See Fuel Pressure Test in Section 04 Fuel Delivery).
>> Go to the next step. >> If the fuel pressure is greater than 400 kPa (4 Bar):
Install a new fuel pressure regulator. If the fuel pressure is less than 400 kPa (4 Bar): Check fuel supply system for restriction or leak. If no problems, repair or replace fuel filter, pressure regulator or fuel pump assembly.
03
8.
9.
10.
Disconnect the canister control valve (1) hose. Place a stiff piece of paper over the hose end, start engine.
VISMD030007
>> Check for a vacuum leak in EVAP system (refer to EVAP system) and refer to EVAP control circuit
relative DTC.
03217
11.
Check engine cylinder compression. Compression should not be less than 1,000 kPa, and not vary more than 25 percent from cylinder to cylinder.
12.
Check the following for possible additional causes: Driveline Transaxle Charging system A/C system (for surge with A/C on)
>> See Diagnostic Help for additional information. >> Repair as necessary.
03218
Low Idle / Stalls During Deceleration The following conditions apply to this symptom:
Engine stops unexpectedly at beginning of deceleration or recovery from deceleration.
1.
PRELIMINARY CHECKS out the following preliminary checks: Vacuum lines (routing, leaks) Intake air tubes Wiring connections
Carry Yes No
03
2.
Check for rough idle or stall at idle. NOTE : Confirm that proper vehicle maintenance has been performed before continuing with engine diagnosis. Inspect the following components: Clean the carbon deposit on intake and exhaust valves Valve stem Spark plugs and combustion chamber
3.
Turn the ignition switch on. With the scan tool X-431, read the DTC.
4.
Start engine and let idle. Disconnect ETC actuator connector and check for RPM drop or engine stall.
Did RPM drop or engine stall when the ETC connector was disconnected?
Yes No
03219
5.
6.
Start engine. Cycle A/C switch from on to off (verify A/C clutch engages condition). Check the A/C system operation.
7.
Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery). Check fuel system pressure (See Fuel Pressure Test in Section 04 Fuel Delivery).
>> Go to the next step. >> If the fuel pressure is greater than 400 kPa (4 Bar):
Install a new fuel pressure regulator. If the fuel pressure is less than 400 kPa (4 Bar): Check fuel supply system for restriction or leak. If no problems, repair or replace fuel filter, pressure regulator or fuel pump assembly.
8.
Check for base engine concerns (such as improper compression, worn camshaft/valve train, gasket leaks).
Is a fault indicated?
Yes No
>> Repair as necessary. >> See Diagnostic Help for additional information.
03220
Idle Speed Slow Return To Normal Idle The following conditions apply to this symptom:
Slow return to idle.
1.
PRELIMINARY CHECKS out the following preliminary checks: Vacuum leaks Intake air system Throttle body
Carry Yes No
03
2.
Turn the ignition switch on. With the scan tool X-431, read the DTC.
3.
>> Install PCV valve, go to the next step. >> Replace the PCV valve.
CHECK PCV SYSTEM
4.
Start engine and bring to normal operating temperature. Disconnect crankcase ventilation hose from PCV valve. Place a stiff piece of paper over the hose. Wait 1 minute.
>> Verify test results. If OK, see diagnostic index to repair any additional symptom. >> Check for vacuum leaks, obstructions in the PCV system, oil cap, PCV valve, rocker cover bolt
torque/gasket leak. Repair as necessary.
03221
IGNITION CONTROL
GENERAL INFORMATION
Description Operation Specifications Special Tools Electrical Schematics 03-223 03-223 03-223 03-223 03-224 03-225 03-227 03-227 03-227 Operation Removal & Installation Spark Plug Wire Removal & Installation Spark Plug Removal & Installation 03-227 03-227 03-228 03-228 03-229 03-229
ON-VEHICLE SERVICE
Ignition Coil Description
03222
GENERAL INFORMATION
Description
The electronic ignition system consists of the following components: Engine Control Module (ECM) Ignition Coil Spark Plugs Spark Plug Wires Camshaft Position Sensor Crankshaft Position Sensor
Operation
The ignition coil is split and each side supplies voltage to two cylinders. When the ignition coil discharges, two spark plugs fire at the same time. The coil is controlled by the Engine Control Module (ECM) based on inputs from the Crankshaft Position Sensor and the Camshaft Position Sensor. The ignition coil consists of a primary and secondary coil. The primary coil is powered on one side, and on the other side is connected to the ECM. The secondary coil connects to two spark plugs, they form a loop and provide a high-voltage output.
03
Specifications
Torque Specifications
DESCRIPTION Spark Plugs Ignition Coil Bolts TORQUE (Nm) 30 6
03223
GENERAL INFORMATION
Special Tools
03224
GENERAL INFORMATION
Electrical Schematics
Ignition Control System (Page 1 of 2)
03
VISMW030016T
03225
GENERAL INFORMATION
Ignition Control System (Page 2 of 2)
VISMW030017T
03226
ON-VEHICLE SERVICE
Ignition Coil
Description
The ignition coil consists of primary and secondary groups of wire. The primary wire is located on one end of the coil. One end of the wire is connected to power and the other end is connected to the Engine Control Module (ECM). The secondary coil connects two spark plugs. They form a loop and provide high-voltage output.
Operation
When the primary wire is connected to power, current will flow causing a strong magnetic field to form. When the primary wire is disconnected, the magnetic field will collapse into the secondary wire causing very high voltage output.
03
LTSM030040
NOTE : Mark the sequence number when removing the spark plug wires from ignition coil. 4. Remove the 4 ignition coil retaining bolts (1). (Tighten: Ignition coil retaining bolts to 6 Nm)
BESM030015
03227
ON-VEHICLE SERVICE
LTSM030040
3. Remove the PCV hose (2). 4. Twist the spark plug wire (1) from the spark plug.
LTSM030039
BESM030013
03228
ON-VEHICLE SERVICE
Spark Plug
Removal & Installation
1. Disconnect the negative battery cable. 2. Remove the PCV hose (1). 3. Twist the spark plug wire (2) from spark plug then pull the spark plug wire straight up.
03
LTSM030039
4. Remove the spark plug. (Tighten: Spark plugs to 30 Nm) 5. Inspect the spark plug condition. 6. Installation is in the reverse order of removal. Installation Notes: Verify the proper spark plug gap before installing the spark plugs. Spark plug gap (A) : 0.7 - 1.1 mm
BESM030011
03229
EVAPORATIVE EMISSIONS
GENERAL INFORMATION
Description Operation Electrical Schematics Specifications Special Tools 03-231 03-231 03-231 03-232 03-233 03-233 03-234 03-234 03-234 Operation Removal & Installation Vapor Canister Description Operation Diagnosis & Testing Removal & Installation 03-234 03-234 03-235 03-235 03-235 03-235 03-235
ON-VEHICLE SERVICE
Canister Control Valve Description
03230
GENERAL INFORMATION
Description
The evaporation control system prevents the emission of fuel tank vapors into the atmosphere. When fuel evaporates in the fuel tank, the vapors pass through vent hoses or tubes to an activated carbon filled evaporative canister. The canister temporarily holds the vapors. The Engine Control Module (ECM) allows intake manifold vacuum to draw vapors into the combustion chambers during certain operating conditions.
Operation 03
6 - Canister Control Valve 7 - Throttle Valve 8 - Air Filter Assembly 9 - To Engine 10 - Intake Air
BESM030026
The ECM will only energize the solenoid when the engine is at operating temperature, but will de-energize it during periods of deceleration. When de-energized, no vapors are purged. The pulse-width modulated canister control valve modulates the fuel vapor purge rate from the vapor canister and fuel tank to the engine intake manifold.
03231
GENERAL INFORMATION
Electrical Schematics
Canister Control Valve (Page 1 of 1)
VISMW030022T
03232
GENERAL INFORMATION
Specifications
Torque Specifications
DESCRIPTION Vapor Canister Bolts TORQUE (Nm) 10
Special Tools 03
03233
ON-VEHICLE SERVICE
Canister Control Valve
Description
This vehicle uses a pulse-width modulated canister control valve. The canister control valve regulates the rate of vapor flow from the vapor canister to the throttle body. The Engine Control Module (ECM) controls the frequency at which the canister control valve operates in order to accommodate the vapor volume for each cylinder.
Operation
The canister control valve is installed near the engine air filter. The Engine Control Module (ECM) controls the opening and closing of the canister control valve. When the ECM relay is energized, the canister control valve switches from closed to open.
VISM030005
BESM030014
03234
ON-VEHICLE SERVICE
5. Installation is in the reverse order of removal.
Vapor Canister
Description
The vapor canister is located on the RH-side of the core support and (beside the generator) is filled with activated carbon granules.
Operation
This vehicle uses a vapor canister filled with activated carbon granules. Fuel tank vapors are vented into the canister where they are absorbed by the activated carbon granules. The canister temporarily holds the fuel vapors until intake manifold vacuum draws them into the cylinder chamber. The Engine Control Module (ECM) purges the canister through the pulse-width modulated canister control valve. The ECM purges the canister at predetermined intervals and engine conditions.
03
VISM030003
4. Remove two hoses at the vapor canister. 5. Remove vapor canister retaining bolts (1). (Tighten: Vapor canister retaining bolts to 10 Nm) 6. Remove the vapor canister. 7. Installation is in the reverse order of removal.
VISM030002
03235
FUEL DELIVERY
04
page Fuel Delivery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-1
CONTENTS
04
ON-VEHICLE SERVICE
Fuel Pressure Relief Procedure Fuel Pressure Relief Procedure Fuel Pump Description Operation Removal & Installation Fuel Pump Inspection
041
GENERAL INFORMATION
Description
The fuel system consists of a fuel tank with a reservoir, fuel pump, fuel filter, fuel delivery line, fuel rail, fuel rail pulse damper and fuel injectors. The Engine Control Module (ECM) controls the fuel system based on signal inputs. The immobilizer module signals the ECM to activate the fuel system. If the ECM does not receive the proper signal from the immobilizer module, the ECM will not allow the fuel system to operate. The ACTECO engine utilizes a returnless fuel delivery system.
WARNING!
Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
042
GENERAL INFORMATION
04
043
GENERAL INFORMATION
Operation
The fuel delivery system is enabled when it reaches the following conditions: Turn the ignition switch ON (engine off), the fuel delivery system is enabled for 3-6 seconds. The Engine Control Module (ECM) receives a Crankshaft Position (CKP) sensor signal. The fuel injectors are a solenoid-operated valve that meter fuel flow to each cylinder. The fuel injectors are opened and closed constantly during engine operation. The amount of fuel is controlled by the length of time the fuel injector is held open. The fuel injectors are powered by a 12 V source and are controlled through the ground side of the circuit by the ECM. The fuel pump operation is defined in the fuel system control strategy and is controlled by the ECM.
Specifications
Torque Specifications
DESCRIPTION Fuel Rail Bracket Bolt Fuel Filter Mounting Bolt TORQUE (Nm) 11 2
044
GENERAL INFORMATION
Special Tools
04
Service Jack
045
GENERAL INFORMATION
Electrical Schematics
Fuel Delivery System (Page 1 of 4)
VISMW040001T
046
GENERAL INFORMATION
Fuel Delivery System (Page 2 of 4)
04
VISMW040002T
047
GENERAL INFORMATION
Fuel Delivery System (Page 3 of 4)
VISMW040003T
048
GENERAL INFORMATION
Fuel Delivery System (Page 4 of 4)
04
VISMW040004T
049
BESM030020
WARNING!
Wrap towels around fuel lines to catch any gasoline spillage. 1. Remove the protective cap and connect the fuel pressure gauge (2) to the fuel rail service test port pressure fitting (1) on the fuel rail (3). 2. Start and warm the engine and note pressure gauge reading. Fuel pressure should be 420 kPa (4.2 bar) at idle. 3. If engine runs, but pressure is below 420 kPa (4.2 bar), check for a kinked fuel supply line somewhere between the fuel rail (3) and the fuel pump. If the line is not kinked, replace the fuel pump (See Fuel Pump Removal & Installation in Section 04 Fuel Delivery). 4. If operating pressure is above 420 kPa (4.2 bar), the electric fuel pump is OK, but fuel pressure regulator is defective. Replace the fuel pressure regulator (See Fuel Pump Removal & Installation in Section 04 Fuel Delivery). NOTE: The fuel pressure regulator is integrated into the fuel pump assembly and is not serviced separately. 5. Install the protective cap to the service test port pressure fitting (1) on the fuel rail.
0410
04
Stalls Under Aggressive Maneuvers/ Loss Of Fuel Pressure Cannot Refill Fuel Tank/Excessive Pressure in Fuel Tank When Cap is Removed
Restricted or damaged fuel filter Contaminated fuel Damaged fuel tank Sticking or damaged fuel tank fill/vent valve, hose or lines.
0411
ON-VEHICLE SERVICE
Fuel Pressure Relief Procedure
Fuel Pressure Relief Procedure
WARNING!
Fuel in the fuel system remains under high pressure, even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel. Failure to follow these instructions may result in serious personal injury. Perform the following procedure to relieve fuel pressure from the fuel system: 1. Remove the cover of the front fuse and relay box. 2. Identify and remove the fuel pump relay from the front fuse and relay box. 3. Start and run engine until it stalls. 4. Attempt to restart engine until it will no longer run. 5. Turn the ignition key to OFF position. NOTE : Replace the fuel pump relay when the fuel system service is complete.
Fuel Pump
Description
The fuel pump assembly contains the fuel pump motor, fuel level sensor and fuel pressure regulator.
Operation
The Engine Control Module (ECM) activates the fuel pump relay for several seconds after the ignition switch is turned ON. When the relay is activated, it provides voltage to the fuel pump. When the ECM receives an engine speed signal from the Crankshaft Position (CKP) sensor, the ECM will again energize the fuel pump relay. If the engine speed signal is not received when the ignition switch is ON, the ECM will de-energize the fuel pump relay.
0412
ON-VEHICLE SERVICE
4. Using a screwdriver, remove the fuel pump cover (1).
VISM040002
5. Disconnect the fuel pump electrical connector. 6. Disconnect the fuel lines (1).
04
VISM040001
7. Using special tool CH-20032, remove the fuel pump mounting cover. 8. Pull the fuel pump up and out of the fuel tank.
WARNING!
Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuelrelated component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.
NOTE : Make sure not to spill fuel inside of vehicle. 9. Tip the fuel pump on its side and drain the fuel from the fuel pump and remove the fuel pump from vehicle. 10. Cover the fuel pump hole in the fuel tank to keep any debris from entering the fuel system. 11. Remove and discard the seal from the fuel tank. 12. Installation is in the reverse order of removal. Installation Notes: Install a new seal on the fuel pump sealing surface. Turn the ignition switch to ON (without starting the engine) to apply fuel pressure to the fuel system, then check the fuel line connections for fuel leaks. Start the engine and let it idle and check for fuel leaks at the fuel line connections.
0413
ON-VEHICLE SERVICE
CAUTION: These tests must be completed within 10 seconds to prevent the coil from burning out. WARNING!
Keep the fuel pump as far away from the battery as possible. Always switch the voltage on and off on the battery side, not on the fuel pump side. 1. Check the fuel pump resistance: Use the following table to test fuel pump resistance. Connect a digital multimeter to terminals 2 and 3. If the result is not as specified, replace the fuel pump. 2. Check the fuel pump operation: Use the following table to test fuel pump operation. Apply battery voltage to terminals 2 and 3. Check that the pump operates within 10 seconds. If the pump does not operate, replace the fuel pump. MEASURING CONDITION SPECIFICATION INSPECTION DIAGRAM
Digital Multimeter Positive (+) to terminal 2 Digital Multimeter Negative (-) to terminal 3
< 130
8 - 16 V
0414
ON-VEHICLE SERVICE
Fuel Filter
Description
The fuel filter consists of a housing with an integrated filter element.
Operation
The fuel flows through the filter from the outside to the inside. As a result, any impurities are trapped inside the filter.
04
VISM040003
4. Remove the fuel lines. 5. Remove the fuel filter. 6. Installation is in the reverse order of removal. Installation Notes: Verify there are no leaks at the fuel line connections of the fuel filter.
0415
ON-VEHICLE SERVICE
Operation
The fuel rail supplies the necessary fuel to each individual fuel injector and is located above the intake manifold and fuel injectors.
VISM040006
0416
ON-VEHICLE SERVICE
7. Remove the fuel rail with the four fuel injectors (1).
BESM040005
8. Installation is in the reverse order of removal. Installation Notes: Install a new seal on the fuel injector sealing surfaces.
04
Fuel Injector
Description
The fuel injectors are positioned in the intake manifold with the nozzle ends directly above the intake valve port.
Operation
Injector operation is controlled by a ground path provided for each injector by the Engine Control Module (ECM). Injector on-time (pulse-width) is variable, and is determined by the ECM. Based on the engine operating conditions, the ECM will control injector pulse-width operation to obtain optimum performance.
0417
ON-VEHICLE SERVICE
4. Disconnect the electrical connectors (1) from the fuel injectors. 5. Remove the fuel line (2) from the fuel rail. 6. Remove the two fuel rail bracket bolts (3) that mount the fuel rail (4) to the intake manifold. (Tighten: Fuel rail bracket bolts to 11 Nm)
VISM040006
7. Remove the fuel rail with the four fuel injectors. 8. Remove the clip holding the fuel injector to the fuel rail. 9. Remove the four fuel injectors (1) from the fuel rail.
BESM040005
10. Installation is in the reverse order of removal. Installation Notes: Install new seals on the fuel injector sealing surfaces.
0418
ON-VEHICLE SERVICE
Fuel Tank
Description
The fuel tank is constructed of a plastic composite material. The fuel tank stores fuel and the fuel pump module is mounted in the fuel tank.
Operation
The fuel tank stores fuel and the fuel pump delivers fuel from the tank to the fuel injectors.
04
VISM040008
8. Raise and support the vehicle. 9. Remove the muffler (See Muffler Removal & Installation in Section 07 Exhaust). 10. Remove the fuel tank protector.
CAUTION: There may be fuel in the fill tube. Remove hose carefully to reduce fuel splash.
11. Disconnect the fuel tank from the rubber fill hose (2). 12. Disconnect the fuel tank vapor hose (1).
VISM040009
0419
ON-VEHICLE SERVICE
13. Using a service jack, support the fuel tank. 14. Remove the four bolts (1) from the fuel tank straps.
VISM040005
15. Remove the fuel tank from the vehicle. 16. Installation is in the reverse order of removal.
0420
05
page Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1 Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-10
CONTENTS
STARTING SYSTEM
GENERAL INFORMATION
Description Operation Specifications Special Tools Electrical Schematics 05-2 05-2 05-2 05-3 05-3 05-4 05-5 05-5 05-5 05-6 05-6 05-6 05-6 Removal & Installation Positive Battery Cable Removal & Installation Negative Battery Cable Removal & Installation Battery Hold Down Removal & Installation Battery Tray Removal & Installation Starter Motor Assembly Description Operation Removal & Installation 05-6 05-7 05-7 05-7 05-7 05-7 05-7 05-8 05-8 05-8 05-8 05-9 05-9
05
ON-VEHICLE SERVICE
Battery Description Operation
051
GENERAL INFORMATION
Description
LTSM050007T
The starting system consists of the following components: Starter motor (including an integral starter solenoid) Battery Battery cables Ignition switch and key lock cylinder Wire harnesses and connections Start relay and fuse Charge fuse
Operation
The battery, starting, and charging systems operate in conjunction with one another, and must be tested as a complete system. For correct operation of starting/charging systems, all components used in these three systems must perform within specifications. When attempting to diagnose any of these systems, it is important to keep their interdependency in mind. These components form two separate circuits, a high amperage circuit that feeds the starter motor up to 150 A, and a control circuit that operates on less than 20 A.
052
GENERAL INFORMATION
Specifications
Torque Specifications
DESCRIPTION Starter Mounting Bolt Starter Solenoid Nut TORQUE (Nm) 30 13
Special Tools
05
Digital Multimeter Fluke 15B & 17B
053
GENERAL INFORMATION
Electrical Schematics
Starting System (Page 1 of 1)
VISMW050001T
054
05
VISM050007
055
ON-VEHICLE SERVICE
Battery
Description
This vehicle is equipped with a single 12 V battery. All of the battery system components are located within the engine compartment of the vehicle. The battery system for this vehicle contains the following components: Battery - The battery provides a reliable means of storing a renewable source of electrical energy within the vehicle. Battery Cables - The battery cables connect the positive and negative charged battery terminal posts to the vehicle electrical system. Battery Hold Down - The battery hold down hardware secures the battery in the battery tray. Battery Tray - The battery tray provides a secure mounting location in the vehicle for the battery and an anchor point for the battery hold down hardware.
Operation
The battery is designed to store electrical energy in a chemical form. When an electrical load is applied to the terminals of the battery, an electrochemical reaction occurs. This reaction causes the battery to discharge electrical current from its terminals. As the battery discharges, a gradual chemical change takes place within each cell. The sulfuric acid in the electrolyte combines with the plate materials, causing both plates to slowly change to lead sulfate. At the same time, oxygen from the positive plate material combines with hydrogen from the sulfuric acid, causing the electrolyte to become mainly water. The chemical changes within the battery are caused by the movement of excess or free electrons between the positive and negative plate groups. This movement of electrons produces a flow of electrical current through the load device attached to the battery terminals.
VISM050002
VISM050001
056
ON-VEHICLE SERVICE
05
VISM050001
4. Remove the battery hold down. 5. Installation is in the reverse order of removal.
057
ON-VEHICLE SERVICE
Battery Tray
Removal & Installation
1. Disconnect the negative and positive battery cables retaining nuts (1).
VISM050002
VISM050001
3. Remove the battery. 4. Remove the bolts (1) connecting the battery tray to car body.
VISM080003
5. Lift the battery tray out of the engine compartment and remove from the vehicle. 6. Installation is in the reverse order of removal.
058
ON-VEHICLE SERVICE
Operation
The starter motor is equipped with a planetary gear reduction system. The planetary gear reduction system consists of a gear that is integral to the output end of the electric motor armature shaft that is in continual engagement with a larger gear that is splined to the input end of the starter pinion gear shaft. This feature makes it possible to reduce the dimensions of the starter and at the same time, it allows higher armature rotational speed and delivers increased torque through the starter pinion gear to the starter ring gear.
05
BESM050004
7. Remove the two starter mounting bolts (1) connecting the starter and transaxle. (Tighten: Starter mounting bolts to 30 Nm)
VISM050006
8. Remove the starter from the engine. 9. Installation is in the reverse order of removal.
059
CHARGING SYSTEM
GENERAL INFORMATION
Description Operation Specifications Special Tools Electrical Schematics 05-11 05-11 05-11 05-11 05-11 05-12 05-13 05-13
ON-VEHICLE SERVICE
Generator Removal & Installation Generator Inspection
0510
GENERAL INFORMATION
Description
05
LTSM050009T
The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. The generator produces DC voltage.
Operation
As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. The Y-type stator winding connections deliver the induced AC current to three positive and three negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicles electrical system through the generator, battery, and ground terminals.
Specifications
Torque Specifications
DESCRIPTION Generator Cable Nut Generator Mounting Bolt TORQUE (Nm) 13 30
Special Tools
0511
GENERAL INFORMATION
Electrical Schematics
Charging System (Page 1 of 1)
VISMW050002T
0512
05
0513
ON-VEHICLE SERVICE
Generator
Removal & Installation
1. 2. 3. 4. Disconnect the negative battery cable. Disconnect the generator electrical connector. Remove the engine drive belt (See Drive Belt Removal & Installation in Section 02 Engine). Remove the generator cable nut (1) connecting the positive cable to the generator. (Tighten: Generator cable nut to 10 Nm)
VISM050004
5. Remove two generator mounting bolts (1). (Tighten: Generator mounting bolts to 30 Nm) 6. Remove the generator from the engine. 7. Installation is in the reverse order of removal.
BESM050003
Generator Inspection
1. Start the engine. NOTE: If the battery warning lamp lights, there may be a problem with the charging system. 2. With the engine running, check the output voltage of the generator with a digital multimeter (note the voltage). 3. If the voltage is between 14.1v - 14.7v, the generator is good.
0514
COOLING
06
page Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06-1
CONTENTS
COOLING SYSTEM
GENERAL INFORMATION
Description Operation Specifications Special Tools Electrical Schematics 06-2 06-2 06-2 06-2 06-3 06-4 06-7 06-7 06-7 06-8 06-8 06-8 06-8 06-9 06-9 06-9 06-9 Thermostat Inspection Coolant Pump Removal & Installation Coolant Pump Inspection Radiator Description Operation Removal & Installation Cooling Fan Description Operation Removal & Installation Cooling Fan Inspection Coolant Level Sensor Description Operation Removal & Installation 06-10 06-10 06-10 06-11 06-11 06-11 06-11 06-11 06-13 06-13 06-13 06-13 06-14 06-15 06-15 06-15 06-15
06
ON-VEHICLE SERVICE
Cooling System Draining and Filling Cooling System Draining Procedure Cooling System Filling Procedure Thermostat Description Operation Removal & Installation
061
GENERAL INFORMATION
Description
The cooling system regulates engine operating temperature. It allows the engine to reach normal operating temperature as quickly as possible, maintains normal operating temperature and prevents overheating. The cooling system also provides a means of heating the passenger compartment. The cooling system is pressurized and uses a centrifugal water pump to circulate coolant throughout the system. The cooling system consists of the following components: Radiator Coolant Coolant pump Electric cooling fans Electric cooling fans control module Thermostat Coolant reservoir Hoses and clamps Coolant temperature sensor Coolant level sensor Heater core
Operation
The primary purpose of a cooling system is to maintain engine temperature in a range that will provide satisfactory engine performance and emission levels under all expected driving conditions. It also provides hot coolant for heater performance. It does this by transferring heat from engine metal to coolant, moving this heated coolant to the radiator, and then transferring this heat to the ambient air.
Specifications
Torque Specifications
DESCRIPTION Coolant Pump Mounting Bolt Radiator Support Mounting Bolt Coolant Fan Mounting Bolt Thermostat Mounting Bolt TORQUE (Nm) 15 5 5 15
Fluid Specifications
DESCRIPTION Cooling System CAPACITY (L) 7.0
062
GENERAL INFORMATION
Special Tools
06
063
GENERAL INFORMATION
Electrical Schematics
Cooling System (Page 1 of 3)
VISMW060001T
064
GENERAL INFORMATION
Cooling System (Page 2 of 3)
06
VISMW060002T
065
GENERAL INFORMATION
Cooling System (Page 3 of 3)
VISMW060003T
066
CAUTION: Do not pressurize the cooling system beyond the maximum pressure listed in the specifications table in this section, or cooling system components can be damaged.
1. Turn the engine off. 2. Check the engine coolant level. Adjust the coolant level as necessary. 3. Attach the pressure tester to the coolant recovery reservoir. Install a pressure test pump to the quick-connect fitting of the test adapter. 4. Pressurize the engine cooling system. Observe the gauge reading for approximately 2 minutes. Pressure should not drop during this time. If the pressure drops within this time, inspect for leaks and repair as necessary. 5. If no leaks are found and the pressure drops, the pressure relief cap may be leaking. Install a new pressure relief cap and retest the system. 6. If no leaks are found after a new pressure relief cap is installed, and the pressure drops, the leak may be internal to the radiator transmission cooler (if equipped). Inspect the coolant for transmission fluid and the transmission fluid for coolant. Repair as necessary. 7. If there is no contamination of the coolant or transmission fluid, the leak may be internal to the engine. Inspect the coolant for engine oil and the engine oil for coolant. 8. Release the system pressure by loosening the pressure relief cap. Check the coolant level and adjust as necessary.
06
067
ON-VEHICLE SERVICE
Cooling System Draining and Filling
Cooling System Draining Procedure
WARNING!
Never remove the pressure relief cap, under any conditions, while the engine is operating or hot. Failure to follow these instructions could result in personal injury or damage to the cooling system or engine. To avoid having scalding hot coolant or steam blow out of the cooling system, use extreme care when removing the pressure relief cap. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly one turn (counterclockwise). Step back while the pressure is released from the cooling system. When you are certain all the pressure has been released, (with a cloth) turn and remove the pressure relief cap. Failure to follow these instructions may result in serious personal injury. Perform the following procedure when draining the cooling system: 1. DO NOT remove the pressure cap first with the engine hot. 2. With the engine cold, remove the pressure cap. 3. Raise and support the vehicle on a hoist and locate the radiator drain plug. 4. Attach one end of a hose to the drain plug (1). Put the other end into a clean container. Remove the drain plug (1) and drain the coolant from the radiator. 5. After the coolant is empty, install the radiator drain plug.
VISM060007
068
ON-VEHICLE SERVICE
Perform the following procedure when filling the cooling system: 1. Fill the system using the proper mixture of antifreeze/coolant and water. Fill the coolant recovery reservoir to the MAX line and install the pressure cap.
06
VISM060011
2. With the heater control in the HEAT position, start and operate the engine with coolant recovery reservoir cap installed. 3. Add coolant to the coolant recovery reservoir as necessary. Only add coolant to the coolant recovery reservoir when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion.
Thermostat
Description
A pellet-type thermostat controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator. On all engines the thermostat begins to close below 90 C. Above this temperature, coolant is allowed to flow to the radiator. This provides quick engine warm up and overall temperature control.
Operation
The wax pellet is located in a sealed container at the spring end of the thermostat. When heated, the pellet expands, overcoming closing spring tension and coolant pump pressure to force the thermostat to open.
069
ON-VEHICLE SERVICE
2. Remove the thermostat mounting bolts (1). (Tighten: Thermostat mounting bolts to 15 Nm)
VISM060001
3. Remove the thermostat and gasket. 4. Installation is in the reverse order of removal. Installation Notes: Verify the cooling system is filled to proper specifications.
Thermostat Inspection
1. Inspect the sealing surface of the thermostat (the seat should be tight at room temperature). 2. Inspect the opening temperature and maximum stroke of the thermostat. Opening temperature of the thermostat is 87 2 C Maximum stroke of the thermostat is 8 mm Full opening temperature of the thermostat is 104 C 3. Verify the thermostat closes 5 C lower than the opening temperature. 4. If the thermostat fails any of the inspection steps, replace the thermostat.
LTSM060014
Coolant Pump
Removal & Installation
WARNING!
Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury. 1. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System). 2. Remove the timing belt (See Timing Belt Removal & Installation in Section 02 Engine).
0610
ON-VEHICLE SERVICE
3. Remove the coolant pump mounting bolts (1). (Tighten: Coolant pump mounting bolts to 15 Nm)
BESM060001
06
BESM060002
5. Installation is in the reverse order of removal. Installation Notes: Verify the cooling system is filled to proper specifications.
Radiator
Description
The radiator is a cross-flow type (horizontal tubes) with design features that provide greater strength, as well as sufficient heat transfer capabilities to keep the engine coolant within operating temperatures.
Operation
The radiator functions as a heat exchanger, using air flow across the exterior of the radiator tubes. Heat from the coolant is then transferred from the radiator into the moving air.
0611
ON-VEHICLE SERVICE
3. Disconnect the radiator coolant upper hose (2) and coolant return hose (1) from the radiator.
VISM060004
VISM060008
5. 6. 7. 8.
Disconnect the cooling fan electrical connectors. Remove the cooling fan (See Cooling Fan Removal & Installation in Section 06 Cooling). Remove the grille (See Grille Removal & Installation in Section 15 Body & Accessories). Remove the two radiator mounting bolts (1).
VISM060009
0612
ON-VEHICLE SERVICE
9. Remove the radiator from the engine compartment. 10. Installation is in the reverse order of removal. Installation Notes: Verify the cooling system is filled to proper specifications.
Cooling Fan
Description
The radiator cooling fans are dual-speed electric motor driven fans. The radiator fan assembly includes two electric motors, two five-blade fans, and a support shroud that is attached to the radiator. The radiator fans are serviced as an assembly.
Operation
The radiator cooling fan operation is controlled by the Engine Control Module (ECM) and the fan relays, with inputs from the following: Engine coolant temperature A/C signal Inspect the cooling fan for proper low speed and high speed operation: The low speed fan should be switched on at 98 C and switched off at 94 C. The high speed fan should be switched on at 105 C and switched off at 101 C. If the water temperature is greater than 101 C after the fan is switched off, the fan will continue to operate for 1 minute. If the water temperature is greater than 94 C after the fan is switched off, the fan will continue to operate for 0.5 minute. If the water temperature is less than 85 C after the fan is switched off, the fan will stop operating.
06
VISM060004
0613
ON-VEHICLE SERVICE
5. Remove the cooling fans mounting bolts (1) to the radiator. (Tighten: Cooling fans mounting bolts to 5 Nm)
VISM060010
6. Remove the radiator fan from the engine compartment. 7. Installation is in the reverse order of removal. Installation Notes: Verify the cooling system is filled to proper specifications.
0614
ON-VEHICLE SERVICE
Operation
When the coolant level is lower than the MIN level in the coolant reservoir, the coolant level sensor sends a signal to instrument cluster to illuminate the coolant temperature warning light and let the driver know the coolant level is low.
WARNING!
Never remove the pressure relief cap under any conditions while the engine is operating or hot. Failure to follow these instructions could result in personal injury or damage to the cooling system or engine. To avoid having scalding hot coolant or steam blow out of the cooling system, use extreme care when removing the pressure relief cap. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly one turn (counterclockwise). Step back while the pressure is released from the cooling system. When you are certain all the pressure has been released, (with a cloth) turn and remove the pressure relief cap. Failure to follow these instructions may result in series personal injury. 3. Disconnect the coolant level sensor electrical connector. 4. Remove the coolant reservoir hose clamp (2). 5. Remove the coolant reservoir retaining bolts (1). (Tighten: Coolant reservoir bolts to 10 Nm) 6. Remove the coolant reservoir with the coolant level sensor. 7. Installation is in the reverse order of removal.
06
VISM030003
0615
EXHAUST
07
page Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-1
CONTENTS
EXHAUST SYSTEM
GENERAL INFORMATION
Description Operation Specifications 07-2 07-2 07-2 07-3 07-4 07-4
ON-VEHICLE SERVICE
Exhaust Pipe Assembly Removal & Installation Muffler Removal & Installation Catalytic Converter Description Operation Removal & Installation
07
071
GENERAL INFORMATION
Description
Exhaust System
VISM070001
The exhaust system contains the following components: Catalytic converter assembly Muffler assembly Exhaust brackets with isolators Heated oxygen sensors mounted to the exhaust pipes Tailpipe assembly The exhaust system provides an exit for exhaust gases and reduces engine noise by moving exhaust gases through the catalytic converter, a muffler inlet pipe and a muffler. Rubber exhaust hanger insulators attach the exhaust system to the mounting hooks.
WARNING!
Exhaust gases contain carbon monoxide which can be harmful to your health and are potentially lethal. Exhaust system leaks should be repaired immediately. Never operate the engine in enclosed areas. Failure to follow these instructions may result in personal injury or death.
Operation
In order to reduce vehicle emissions released by the engine, the catalytic converter is required to perform in all operating conditions. This reduction is especially beneficial during the cold start and warm up phases of operation. It is during these phases when a majority of the tailpipe emissions occur on todays cars because the catalytic converter has not yet reached its operating temperature. The exhaust system channels exhaust gases from the engine and away from the vehicle.
072
GENERAL INFORMATION
Specifications
Torque Specifications
DESCRIPTION Exhaust Manifold Flange Bolts Catalytic Converter Mounting Nuts Muffler Nuts TORQUE (Nm) 50 50 50
07
073
074
ON-VEHICLE SERVICE
Exhaust Pipe Assembly
Removal & Installation
WARNING!
The normal operating temperature of the exhaust system is very high. Therefore, never work around, or attempt to service any part of the exhaust system until it has cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operation. 1. Raise and support the vehicle. 2. Remove the catalytic converter to exhaust manifold flange bolts (1). (Tighten: Exhaust manifold flange bolts to 50 Nm)
07
LTSM070005
BESM030017
4. Remove all the support isolators. 5. Remove the exhaust pipe assembly.
Muffler
Removal & Installation
WARNING!
The normal operating temperature of the exhaust system is very high. Therefore, never work around, or attempt to service any part of the exhaust system until it has cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operation. 1. Raise and support the vehicle.
075
ON-VEHICLE SERVICE
2. Remove the muffler mounting bolts (1) and gaskets. (Tighten: Muffler mounting bolts to 50 Nm)
VISM070002
3. Remove the support isolators. 4. Remove the muffler. 5. Clean the ends of the pipes and the muffler to assure proper mating of all parts. Discard broken or worn isolators, rusted or overused clamps, supports, and attaching parts. 6. Installation is in the reverse order of removal.
Catalytic Converter
Description
The catalytic converter is attached to the exhaust manifold using fasteners and a gasket for sealing. The catalytic converter plays a major role in the emission control system by operating as a gas reactor. Its catalytic function is to speed the heat-producing chemical reaction of components in the exhaust gases in order to reduce air pollutants.
Operation
Catalyst operation is dependent on its ability to store and release the oxygen needed to complete the emissionsreducing chemical reactions. As a catalyst deteriorates, its ability to store oxygen is reduced. Since the catalysts ability to store oxygen is somewhat related to proper operation, oxygen storage can be used as an indicator of catalyst performance.
CAUTION: Unleaded gasoline must be used in order to avoid damaging the catalyst core. CAUTION: Do not allow the engine to operate above 1200 RPM in Neutral for more than 5 minutes. This may result in excessive exhaust system/floor pan temperatures because of the lack of air movement under the vehicle.
076
ON-VEHICLE SERVICE
07
VISM070003
4. Remove the catalytic converter. 5. Clean ends of the pipes to assure mating of all parts. Discard broken or worn isolators, rusted or overused clamps, supports, and attaching parts. 6. Installation is in the reverse order of removal.
077
TRANSAXLE
08
page 5-Speed Manual Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-1 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-33 Clutch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-39
CONTENTS
08
ON-VEHICLE SERVICE
Manual Transaxle Removal & Installation Gear Selector & Shifter Assembly Removal & Installation
081
GENERAL INFORMATION
Description
The QR519MHA five-speed transaxle is a constant-mesh manual transaxle that is synchronized in all gear ranges, including reverse. The transaxle consists of three major sub-assemblies: Input shaft Output shaft Differential assembly The transaxle shift system consists of the following components: Mechanical shift cover Shift rails Shift forks Shift cables QR519MH External View
BESM080029
Operation
The following are the details of the manual transaxle:
Neutral
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. Since no synchronizers are engaged on either the input or output shafts, power is not transmitted to the output shafts, power is not transmitted to the output shaft and the differential does not turn.
1st Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft first gear is integral to the input shaft, and is in constant mesh with the intermediate shaft first speed gear. Because of this constant mesh, the output shaft first speed gear freewheels until first gear is selected. As the gearshift lever is moved to the first gear position, the 1-2 fork moves the 1-2 synchronizer sleeve towards first gear on the output shaft. The synchronizer sleeve engages the first gear clutch teeth, engaging the gear to the output shaft, and allowing power to transmit through the output shaft to the differential.
082
GENERAL INFORMATION
2nd Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft second gear is integral to the input shaft, and is in constant mesh with the output shaft second speed gear. Because of this constant mesh, the output shaft second speed gear freewheels until second gear is selected. As the gearshift lever is moved to the second gear position, the 1-2 fork moves the 1-2 synchronizer sleeve towards second gear on the output shaft. The synchronizer sleeve engages the second gear clutch teeth, engaging the gear to the output shaft, and allowing power to transmit through the output shaft to the differential.
3rd Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft third speed gear is in constant mesh with the output shaft 3-4 cluster gear which is fixed to the output shaft. Because of this constant mesh, the input shaft third speed gear freewheels until third gear is selected. As the gearshift lever is moved to the third gear position, the 3-4 fork moves the 3-4 synchronizer sleeve towards third gear on the input shaft. The synchronizer sleeve engages the third gear clutch teeth, engaging the gear to the input shaft, and allowing power to transmit through the output shaft to the differential.
4th Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft fourth speed gear is in constant mesh with the output shaft 3-4 cluster gear which is fixed to the output shaft. Because of this constant mesh, the input shaft fourth speed gear freewheels until fourth gear is selected. As the gearshift lever is moved to the fourth gear position, the 3-4 fork moves the 3-4 synchronizer sleeve towards fourth gear on the input shaft. The synchronizer sleeve engages the fourth gear clutch teeth, engaging the gear to the input shaft, and allowing power to transmit through the output shaft to the differential.
5th Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft fifth speed gear is pressed on to the input shaft, and is in constant mesh with the output shaft fifth speed gear. Because of this constant mesh, the output shaft fifth speed gear freewheels until fifth gear is selected. As the gearshift lever is moved to the fifth gear position, the 5-R fork moves the 5-R synchronizer sleeve towards the output shaft fifth speed gear. The synchronizer sleeve engages the fifth gear clutch teeth, engaging the gear to the input shaft, and allowing power to transmit through the output shaft to the differential.
08
Reverse Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft reverse gear integral to the input shaft, and is in constant mesh with the reverse idler gear. The reverse idler gear, which reverses the rotation of the output shaft, is in constant mesh with the output shaft reverse gear. Because of this constant mesh, the output shaft reverse gear freewheels until reverse gear is selected. As the gearshift lever is moved to the reverse gear position, the 5-R fork moves the 5-R synchronizer sleeve towards the output shaft reverse gear. The synchronizer sleeve engages the reverse gear clutch teeth, engaging the gear to the output shaft, and allowing power to transmit through the output shaft to the differential.
083
GENERAL INFORMATION
1 Output Shaft 2 Input Shaft 3 5th Gear Synchronizer 4 5th Driving Gear 5 4th Driving Gear 6 3rd & 4th Gear Synchronizer 7 3rd Driving Gear 8 2nd Driving Gear 9 Reverse Driving Gear 10 1st Driving Gear 11 Idler Gear Shaft 12 Clutch 13 Crankshaft
14 Idler Gear 15 Differential Driving Gear 16 1st Driven Gear 17 Axle Shaft 18 Differential Side Gear 19 Pinion Gear 20 Differential Case 21 Differential Driven Gear 22 1st & 2nd Gear Synchronizer 23 2nd Driven Gear 24 3rd Driven Gear 25 4th Driven Gear 26 5th Driven Gear
BESM080033
VISM080005
084
GENERAL INFORMATION
Specifications
Torque Specifications
DESCRIPTION Differential Driven Gear Bolt Drain Plug Transaxle External Housing-to-Case Bolt Fork Shaft Seat End Cover Bolt Reverse Idler Shaft-to-Case Bolt Reverse Fork Mechanism Bolt Backup Lamp Switch Assembly Bearing Retainer Bolt 5th Gear-to-Input Shaft Bolt Release Bearing-to-Case Bolt Gear Shift Mechanism Assembly Bolt Reverse Lock Mechanism Bolt Engine To Transaxle Bolt TORQUE (Nm) 120 - 130 30 - 35 22 - 26 45 - 50 18 - 23 45 - 50 22 - 26 18 - 23 15 - 20 140 - 150 22 - 26 22 - 26 15 - 22 78 - 80
08
Gear Ratio Specifications
GEAR 1st 2nd 3rd 4th 5th Reverse Final Drive Ratio RATIO 3.546 2.048 1.346 0.972 0.816 3.333 4.2
lubrication Specifications
DESCRIPTION Transaxle Fluid Quantity Fluid Type ITEM 2.1 L API 75W-90 GL-4
085
GENERAL INFORMATION
Special Tools
086
GENERAL INFORMATION
08
087
Symptom Diagnostics
Hard Shifting
Hard shifting may be caused by a mis-adjusted crossover cable. If hard shifting is accompanied by gear clash, synchronizer clutch and stop rings or gear teeth may be worn or damaged.
Clutch Problems
Worn, damaged, or misaligned clutch components can cause difficult shifting, gear clash, and noise. A worn or damaged clutch disc, pressure plate, or a faulty slave cylinder can cause hard shifting and gear clash.
Abnormal Noise
Transaxle noise is most often a result of worn or damaged components. Chipped, broken gear or synchronizer teeth, and worn bearings all cause noise. Inspect the following: Insufficient lubrication Incorrect lubricant Improperly assembled or damaged internal components
088
ON-VEHICLE SERVICE
Manual Transaxle
Removal & Installation
1. Raise and support the vehicle. 2. Disconnect the negative battery cable. 3. Loosen the clamps (1) between the air intake hose and the air cleaner and remove the air intake hose.
VISM020001
4. Disconnect the air flow sensor electrical connector (1.8L engine). 5. Remove the retaining bolts (1) and remove the air cleaner and air cleaner housing assembly.
08
VISM020004
6. Remove the power fuse box (1) and set it aside. 7. Remove the front fuse and relay box (2).
VISM080015
089
ON-VEHICLE SERVICE
8. Remove the front air intake hose retaining bolt (1) and take off the front air intake hose (2).
VISM080037
9. Remove the battery and battery tray (See Battery Removal & Installation in Section 05 Starting & Charging). 10. Disconnect the hydraulic line (1) from the hydraulic clutch cylinder and position it aside.
BESM080063
CAUTION: While hoses are disconnected, plug all openings to prevent foreign material from entering them. 11. Remove the hydraulic line clamp (1).
VISM080038
0810
ON-VEHICLE SERVICE
12. Remove the two shift cables (1) from the transaxle.
BESM080051
13. Remove the shift cable clamp (1) from the shift cable bracket.
08
VISM080026
VISM080025
15. Disconnect the electrical connector for the backup lamp switch (1) and remove the ground cable (2).
VISM080039
0811
ON-VEHICLE SERVICE
16. Disconnect the crankshaft sensor connect. 17. Remove the intake manifold (See Intake Manifold Removal & Installation in Section 02 Engine). 18. Remove the coolant pipe bracket retaining bolts(1).
VISM080031
19. Remove the starter motor (See Starter Removal & Installation in Section 05 Starting & Charging). 20. Support the engine using an engine support fixture or suitable jack. 21. Remove the left transaxle mount bolts (2) and bracket bolts (1).
VISM020005
22. Raise the vehicle. 23. Remove the engine undercover and splash shields. 24. Remove the drain screw plug (1) and drain the transaxle fluid.
VISM080012
25. Remove both front axle shafts (See Front Axle Shaft Removal & Installation in Section 09 Driveline & Axle).
0812
ON-VEHICLE SERVICE
26. Disconnect the rear transaxle mount bolts (2) and the rear transaxle mount bracket bolts (1).
VISM020003
27. Remove the front sub-frame assembly (See Front Sub-frame Removal & Installation in Section 10 Suspension). 28. Remove the engine to transaxle bolts (1). (Tighten: Engine to transaxle bolts to 78 - 80 Nm)
08
VISM080002
29. Separate the transaxle from the engine and remove it from the vehicle.
WARNING!
Support the transaxle with a suitable jack while removing the transaxle. 30. Installation is in the reverse order of removal. Installation Notes: When installing the transaxle, be careful to avoid interference between the transaxle input shaft and the clutch. After installation, remove the filling hole bolt (1) and fill the transaxle fluid until it bleeding from the filling hole.
VISM080011
0813
ON-VEHICLE SERVICE
1 Gear Selection & Shift Shaft 2 Top Base For 5th-Reverse Return Spring 3 Pin Shaft Reverse Lock Mechanism 4 Torsion Spring Reverse Lock Mechanism 5 Reverse Lock Plate 6 Reverse Lock Mechanism Bolts 7 Reverse Lock Plate Bracket 8 5th-Reverse Return Spring 9 Bottom Base For 5th-Reverse Return Spring 10 5th-Reverse Return Spring Retainer 11 Linear Bearing 12 Gear Selection & Shift Mechanism Housing 13 Air Duct 14 Air Duct Cap 15 Selector Lever Assembly 16 Spring Pin 17 Boot Gear Selection & Shift Shaft
18 Oil Seal Gear Selection & Shift Shaft 19 Sleeve Selector Lever Nut 20 Nut 21 Slide Block Selector Lever 22 Large Gasket Selector Lever 23 Small Gasket Selector Lever 24 Selector Lever Assembly 25 Boot Selector Lever 26 Selector Lever Bracket Assembly 27 Selector Lever Bracket Bolt 28 Interlock Plate 29 Shift Finger 30 Spring Pin 31 Split Baffle Ring 1st-2nd Return Spring Assembly 32 Bottom Base For 1st-2nd Return Spring 33 1st-2nd Return Spring 34 Top Base For 1st-2nd Return Spring
BESM080027
0814
ON-VEHICLE SERVICE
1. Disconnect the negative battery cable. 2. Remove the power fuse box (1). 3. Remove the front fuse and relay box (2).
VISM080015
4. 5. 6. 7.
Remove the battery and battery tray (See Battery Removal & Installation in Section 05 Starting & Charging). Remove the air cleaner housing assembly. Raise and support the vehicle. Remove the two shift cables (1) from the transaxle.
08
BESM080051
8. Remove the shift cable clamp (1) from the shift cable bracket.
VISM080026
0815
ON-VEHICLE SERVICE
9. Remove the gearshift knob. 10. Remove the gearshift boot from the lower console.
VISM080017
11. Apply the parking brake (apply parking brake handle to clear lower console upon removal).
VISM080018
12. Remove the lower console (See Lower Console Removal & Installation in Section 15 Body). 13. Remove the crossover cable and the selector cable (1) from the gearshift mechanism.
BESM080054
14. Remove the four bolts (1) and then remove the gearshift mechanism from the bracket.
BESM080053
0816
ON-VEHICLE SERVICE
15. Remove the selector cable clamp (1) and bracket retaining bolts (2). 16. Remove the gear selector & shifter assembly. 17. Installation is in the reverse order of removal.
VISM080006
NOTE : Selector cable can be adjusted with the adjustment bolt (1).
08
LTSM080180
0817
Disassembly
1. Place the transaxle on bench. 2. Remove the fluid drain plug (1) and drain the transaxle fluid. (Tighten: Drain plug to 30 - 35 Nm)
VISM080012
3. Disconnect the hydraulic release bearing seat and the quick coupler (1) for the release bearing. 4. Remove the two release bearing bolts (2) and then the release bearing. (Tighten: Release bearing bolts to 22 - 26 Nm)
BESM080001
0818
BESM080002
08
BESM080003
8. Place the shift fork in the 5th gear position to lock the gear train. Remove the 5th driven gear retaining bolt (1). NOTE: Engage the 5th gear and put a thin copper bar (or any other low-hardness metal bar) between the 5th driving and driven gears, and then use a torque wrench to remove the nut for the 5th driven gear.
BESM080004
BESM080005
0819
BESM080006
BESM080007
BESM080008
13. Remove the bearing retainer bolts (1) and then remove the bearing retainer.
BESM080009
0820
BESM080010
15. Remove the snap ring from the rear input shaft bearing. 16. Remove the gearshift mechanism assembly bolts (1) from the transaxle housing. (Tighten: Gearshift mechanism assembly bolts to 22 - 26 Nm)
08
BESM080011
VISM080024
VISM080008
0821
BESM080012
VISM080009
VISM080010
BESM080013
0822
VISM080019
24. Remove the reverse idler gear assembly (1). 25. Remove the reverse shift fork mechanism bolts (2) and remove the reverse shift fork.
08
BESM080022
BESM080014
27. Grasp the input shaft assembly, output shaft assembly, 1st-2nd shift fork, 3rd-4th shift fork and 5th-reverse fork shaft together and remove. 28. Remove the differential assembly.
Assembly
1. Assemble the transaxle in the reverse order of disassembly.
0823
Input Shaft
Specifications
Clearance Specifications
SYNCHRONIZER RING 1st-2nd Gear 3rd-4th Gear 5th Gear VALUE OF A 1.10 - 1.17 mm 1.35 - 1.90 mm 1.10 - 1.17 mm WEARING LIMIT 0.05 mm 0.05 mm 0.05 mm
Disassembly
1 Front Input Shaft Bearing 2 Input Shaft 3 3rd-5th Needle Roller Bearing 4 3rd Driving Gear 5 3rd-4th Synchronizer Cone 6 Synchronizer Ring 3rd-4th Synchronizer 7 Steel Ring Spring For 3rd-4th Synchronizer
8 Guide Block For 3rd-4th Synchronizer 9 Gear Hub For 3rd-4th Synchronizer 10 Gear Sleeve For 3rd-4th Synchronizer 11 Steel Ring Spring For 3rd-4th Synchronizer 12 4th Gear Needle Roller Bearing 13 4th Driving Gear 14 3rd-4th Synchronizer Cone
BESM080015
NOTE : The following special tools are required to perform the repair procedure: MB-998801 - Bearing Detacher
0824
LTSM080038
Inspection
1. Clean all components. 2. Inspect the input shaft for the following: Any damage, abnormal wear or lockup of the needle roller bearings. Any damage or wear of the spline. Gears for correct fit and assembly. Smooth rotation of gears. Any loose components or noise. 3. Inspect the 3rd and 4th driving gears for the following: Any damage or wear on tooth surfaces of helical gear and clutch gear. Any damage, wear or coarsening on the synchronizers conical surface. Any damage or wear on the inner-diameter, front and rear surfaces.
08
BESM080016
4. Inspect the gear sleeve and gear hub of the 3rd-4th synchronizer: Assemble the gear sleeve and gear hub together and check whether they can slide smoothly or whether theyare locked up as shown.
BESM080017
Inspect for any damage in the front and rear of the gear sleeves inner surface.
0825
BESM080018
BESM080019
SYNCHRONIZER RING CLEARANCE SYNCHRONIZER RING 1st-2nd Gear 3rd-4th Gear 5th Gear VALUE OF A 1.10 - 1.17 mm 1.35 - 1.90 mm 1.10 - 1.17 mm WEARING LIMIT 0.05 mm 0.05 mm 0.05 mm
Assembly
1. Assemble the transaxle in the reverse order of disassembly.
0826
Output Shaft
Disassembly
1 Front Bearing Inner Race for Output Shaft 2 Output Shaft 3 1st-2nd Needle Roller Bearing 4 1st Driven Gear 5 1st-2nd Synchronizer Cone Ring 6 1st-2nd Synchronizer Ring (Outer) 7 1st-2nd Synchronizer Ring (Inner) 8 Guide Block for 1st-2nd Synchronizer
9 Gear Hub - 1st-2nd Synchronizer 10 Gear Sleeve - 1st-2nd Synchronizer 11 1st-2nd Needle Roller Bearing 12 1st-2nd Synchronizer Cone Ring 13 2nd Driven Gear 14 3rd Driven Gear 15 3rd-4th Driven Shaft Sleeve 16 4th Driven Gear
BESM080020
08
1. Using special tool MB-998801, remove the rear output shaft bearing and the 4th driven gear. 2. Remove the 3rd-4th driven collar. 3. Using special tool MB-998801 (2), remove the 3rd driven gear (1), 2nd driven gear, take out 1st-2nd synchronizer cone ring, out synchronizer ring, inner synchronizer ring and 2nd needle roller bearing.
LTSM080065
0827
BESM080021
5. Using special tool MB-998801 (1), remove the 1st2nd synchronizer assembly and take out the 1st driven gear and 1st needle roller bearing.
PZSM080040
6. Using special tool MB-998801 (1), Remove the front output shaft inner bearing from the front end of output shaft.
PZSM080039
Inspection
1. Clean all components. 2. Inspect the following components for wear: Output shaft Needle roller bearing 1st driven gear 2nd driven gear 1st-2nd synchronizer gear sleeve and hub Outer synchronizer ring, inner synchronizer ring and synchronizer cone ring Damage on the tooth surfaces and conical surfaces
Assembly
1. Assemble is in the reverse order of disassemble.
0828
Idler Gear
Disassembly
VISM080042
1. Remove the reverse shift arm bracket retaining bolts (1) and the reverse shift arm (3) then remove the idle gear shaft (2).
08
PZSM080015
2. Separate the reverse idle gear from idle gear shaft and take off the idle gear gasket.
PZSM010008
Assembly
1. Assemble is in the reverse order of disassemble.
0829
VISM010008
VISM020016
2. Use a suitable tool to remove the shift fork spring pin from the shift fork and the shift fork shaft.
VISM020015
0830
VISM010011
08
VISM020016
0831
1 3rd-4th Shift Fork Shaft 2 Spring Pin 3 Spring Pin 4 3rd-4th Shift Fork 5 Split Baffle Ring
6 Reverse Shaft 7 Interlock Pin 8 5th-Reverse Shift Fork Shaft 9 5th-Reverse Shift Fork 10 Spring Pin for Fork Shaft
BESM080026
2. 3. 4. 5. 6. 7.
Remove the spring pins (2) & (3) from the 3rd-4th shift fork shaft (1). Remove the split baffle ring (5). Separate the 3rd-4th shift fork shaft (1) and 3rd-4th shift fork (4). Separate the reverse shaft (6). Remove the interlock pin (7) and spring pin (10) Separate the 5th-reverse shift fork shaft (8) from 5th-reverse shift fork (9).
0832
DIFFERENTIAL
GENERAL INFORMATION
Description Operation Specifications Special Tools 08-34 08-34 08-34 08-35 08-35
08
0833
GENERAL INFORMATION
Description
The differential includes the differential side gears and the shaft mounted differential pinion gears. Direct contact between the gears and the differential case is prevented by the differential side gear thrust washers installed under the gears. The differential pinion shaft is held in position by a differential pinion shaft lock pin that extends through the end of the differential pinion shaft and the differential case. The differential assembly consists of the following components: Differential case (part of the final drive carrier) 2 pinion gears supported by a pinion shaft 2 side gears supported by the differential case and half shafts
1 Front/Rear Differential Bearing 2 Final Drive Driven Gear 3 Differential Housing 4 Bolts - Final Drive Driven Gear and Differential Housing 5 Driving Gear - Odometer 6 Spherical Washer Planetary Gear
7 Planetary Gear Shaft 8 Adjusting Washer - Side Gear 9 Spring Pin - Planetary Gear 10 Side Gear 11 Planetary Gear
BESM080028
Operation
The differential operates through the gear mesh with the ring gear bolted to the differential case. The engine power is transmitted to the axle shafts through the pinion mate and side gears. The side gears are connected to the axle shafts.
0834
GENERAL INFORMATION
Specifications
Clearance Specifications
Clearance between side gear and planetary gear Adjusting washer 0.025 - 0.150 mm 0.93 - 1.00 mm
Special Tools
08
0835
Disassembly
1 Front/Rear Differential Bearing 2 Final Drive Driven Gear 3 Differential Housing 4 Bolts - Final Drive Driven Gear and Differential Housing 5 Driving Gear - Odometer 6 Spherical Washer Planetary Gear
7 Planetary Gear Shaft 8 Adjusting Washer - Side Gear 9 Spring Pin - Planetary Gear 10 Side Gear 11 Planetary Gear
BESM080028
0836
LTSM080117
3. Tap the drive gear off the differential case assembly using a suitable tool. 4. Remove the pinion mate shaft use suitable tool.
08
LTSM080112
5. Turn the pinion mate gear, then remove the pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from the differential case.
Inspection
1. Clean all components. 2. Inspect the following components for wear: Ring gear Adjusting washers Side gears Spherical washers Planetary gears Planetary gear shaft
0837
Assembly
Installation of the adjusting washers, side gears, spherical washers, planetary gears and the planetary gear shaft: Install the adjusting washers respectively on the backs of the side gears and put the side gears in place within the differential. NOTE : The adjusting washer for any new side gear have an appropriate thickness (0.93 - 1.00 mm). Engage two planetary gears with side gears behind the spherical washers on the backs of the planetary gears (rotate the gears for proper alignment). Insert the planetary gear shaft. Measure the clearances between side gear and planetary gear. NOTE : Standard value: 0.025 - 0.150 mm
BESM080032
DIFFERENTIAL SIDE GEAR CLEARANCE Standard Adjusting Washer 0.025 - 0.150 mm 0.93 - 1.00 mm
If any measured clearance is not within specifications, select and install the appropriate adjusting washer(s) and then measure the clearances again. NOTE : Adjust the side clearance equally on both sides.
0838
CLUTCH SYSTEM
GENERAL INFORMATION
Description Operation Specifications Special Tools 08-40 08-40 08-40 08-41 08-41 08-42 08-42 08-42 Clutch Master Cylinder Description Operation Removal & Installation Clutch Slave Cylinder Removal & Installation Bleeding Hydraulic Clutch Operation 08-43 08-43 08-43 08-44 08-46 08-46 08-46 08-46
08
0839
GENERAL INFORMATION
Description
VISM080044
The hydraulic clutch system consists of a clutch master cylinder (2), slave cylinder (3), and an interconnecting hydraulic fluid line. Hydraulic fluid is supplied by the clutch system via the clutch master cylinder reservoir (1).
Operation
The clutch hydraulic system is responsible for engaging and disengaging the clutch. Depressing the clutch pedal develops fluid pressure in the clutch master cylinder. This pressure is transmitted to the integral release bearing which is in contact with the pressure plate diaphragm spring. As additional force is applied, the bearing depresses the diaphragm spring fingers inward on the fulcrums. The action moves the pressure plate rearward, relieving clamping force on the clutch disc.
0840
GENERAL INFORMATION
Specifications
Torque Specifications
DESCRIPTION Slave Cylinder Bolt Clutch Pressure Plate Bolt Flywheel Bolts TORQUE (Nm) 17 25 75
Special Tools
08
0841
LTSM080145
3. Make the mark (1) before remove the clutch pressure plate.
PZSM010005
4. Remove the clutch pressure plate bolts (1). (Tighten: Clutch pressure plate bolts to 25 Nm) 5. Remove the modular clutch assembly.
BESM080046
0842
BESM020058
08
VISM010009
Operation
When the clutch pedal is depressed, the push rod moves the piston in the master cylinder, displacing fluid through the hydraulic line and into the release bearing. As the release bearing extend it is forced into the fingers of the clutch diaphragm springs. As the fingers move, they release the clamping pressure on the clutch disc between the clutch pressure plate and the flywheel. The clutch becomes disengaged as this pressure is released. When the clutch pedal is released, the system hydraulic pressure is released. This allows the force of the clutch diaphragm springs to return themselves to their original position, re-clamping the clutch disc between the flywheel and the clutch pressure plate. Also, the release bearing is forced to return, which reverses the movement of the hydraulic system and returns the pedal to its original position against the up stop.
0843
VISM020004
2. Disconnect hydraulic supply tube to clutch master cylinder (1). To completely drain clutch master cylinder and tubing.
VISM010010
3. Disconnect hydraulic tube (1) and drain fluid into suitable container.
BESM080063
4. Remove instrument panel lower trim panel (1) (See Instrument Panel Removal & Installation In Section 15 Body & Accessories).
VISM150144
0844
VISM080021
6. Remove hydraulic tube from rail retainer. 7. Release master cylinder by rotating to disengage from pedal bracket assembly.
CAUTION: Use care when removing clutch master cylinder from engine compartment. Aggressive handling can result in a damaged hydraulic tube and improper clutch release operation upon reassembly. CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it off immediately with water.
8. Remove the master cylinder assembly (1) from the mounting position and carefully maneuver the hydraulic pipe from the engine compartment.
08
VISM010010
0845
BESM080001
VISM080023
BESM080064
5. Actuate the clutch pedal until the brake master cylinder fluid drains from the bleed port.
0846
NOTE : Do not allow clutch master cylinder to run dry while fluid exits bleed port. 10. Close the hydraulic bleed circuit, remove the drain hose and replace the dust cap on bleed port. 11. Top off the brake master cylinder fluid level with DOT 4 brake fluid as necessary.
CAUTION: Make sure the brake master cylinder fluid in bleeding process is always full.
08
0847
09
page Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-1 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-8
CONTENTS
FRONT AXLE
GENERAL INFORMATION
Description Operation Specifications 09-2 09-2 09-2 09-3 09-4 09-4 09-4 09-4 Shudder Or Vibration During Acceleration Vibration At Highway Speeds 09-4 09-4 09-5 09-5 09-5 09-5 09-5
ON-VEHICLE SERVICE
Front Hub and Bearing Removal & Installation Front Axle Shaft Removal & Installation
09
091
GENERAL INFORMATION
Description
1 - Left Brake Rotor 2 - Left Strut Assembly 3 - Left Front Axle Shaft 4 - Right Front Axle Shaft
VISM090001
This vehicle is equipped with an unequal length half shaft system consisting of short left and long right half shafts. The half shafts consist of a fixed Constant Velocity (CV) joint at the outboard end connected by a solid shaft to a plunging CV joint on the inboard end. The inner CV joint has a splined end and is attached to the transaxle and is retained with a snap ring. The outer joint has a splined connection to the wheel hub and is retained with a lock nut.
Operation
The front axle transmits torque from the transaxle to the wheels. In order to allow vertical and horizontal movement of the wheels, the axle shafts have plunging CV joints on the inboard ends of the axle shafts.
092
GENERAL INFORMATION
Specifications
Torque Specifications
DESCRIPTION Axle Shaft Hub Nut Brake Caliper Adapter To Steering Knuckle Bolts Brake Caliper To Adapter Bolts Dust Shield Bolts Steering Knuckle to Strut Assembly Bolt Wheel Mounting Nuts TORQUE (Nm) 270 85 5 22 1 81 120 10 110
09
093
NOTE : If the CV seal boot is damaged, this will result in the loss and/or contamination of the joint grease, resulting in inadequate lubrication of the joint.
094
ON-VEHICLE SERVICE
Front Hub and Bearing
Removal & Installation
1. Raise and support the vehicle. 2. Remove the wheel mounting nuts and then remove the wheel. (Tighten: Wheel mounting nuts to 110 Nm) 3. Remove the front axle hub nut (1) from the front knuckle. (Tighten: Front axle hub nut to 270 Nm)
LTSM090006
4. Remove the front brake rotor (See Front Brake Rotor Removal & Installation in Section 12 Brakes). 5. Using the bearing puller, remove the wheel hub bearing from the front knuckle.
09
LTSM090003
095
ON-VEHICLE SERVICE
3. Remove the front wheel speed sensor (1).
VISM110003
4. Remove the front axle hub nut (1) from the front knuckle. (Tighten: Front axle hub nut to 270 Nm)
LTSM090006
5. Remove the front brake caliper (See Front Brake Caliper Removal & Installation in Section 12 Brake). 6. Remove the two bolts (1) connecting the steering knuckle to the front strut assembly. (Tighten: Steering knuckle to front strut mounting bolts to 120 10 Nm)
VISM100023
096
ON-VEHICLE SERVICE
CAUTION: When removing the front axle shaft, do not subject the constant velocity joint to an excessive angle. Also, be careful not to excessively extend the slide joint.
7. 8. 9. 10. Remove the front axle one end from the steering knuckle. Remove the front axle shaft other end from the transaxle. Pull out the front axle shaft. Installation is in the reverse order of removal.
Installation Notes: Move the CV joint up/down, left/right, and in axial direction, check for any rough movement or significant looseness. Check the CV seal boot for cracks or other damage, and for grease leakage. If damaged, disassemble axle shaft to verify damage, and repair or replace as necessary. After installing the front axle shaft, check the front wheel alignment (See Alignment in Section 10 Suspension).
09
097
REAR AXLE
GENERAL INFORMATION
Description Operation Specifications 09-9 09-9 09-9 09-9 09-10 09-10 Vibration At Highway Speeds 09-10 09-11 09-11 09-11
ON-VEHICLE SERVICE
Rear Hub and Bearing Removal & Installation
098
GENERAL INFORMATION
Description
The rear axle utilizes an independent design. This suspension system incorporates a separate wheel knuckle for each wheel and allows the wheels to react to road imperfections independent of each other. This independent action offers improved isolation from the effects of jounce and rebound. The rear axle consists of the following components: Wheel hub Wheel studs Wheel bearing Knuckle
09
1 - Rear Knuckle Assembly 2 - Rear Backing Plate 3 - Rear Knuckle Assembly Mounting Nuts 4 - Rear Hub and Bearing Assembly
5 - Rear Brake Rotor 6 - Rear Brake Caliper Bolts 7 - Rear Brake Caliper Assembly 8 - Hub, Rotor and Caliper Assembly
LTSM120002
Operation
The rear axle utilizes a sealed wheel bearing housed in the rear knuckle assembly.
Specifications
Torque Specifications
DESCRIPTION Brake Caliper Adapter To Rear Knuckle Bolts Brake Caliper To Adapter Bolts Rear Axle Hub Nut Wheel Mounting Nuts TORQUE (Nm) 85 22 230 110
099
0910
ON-VEHICLE SERVICE
Rear Hub and Bearing
Removal & Installation
1. Raise and support the vehicle. 2. Remove the wheel mounting nuts and the wheel assembly. (Tighten: Wheel mounting nuts to 110 Nm) 3. Remove the rear brake rotor (See Rear Brake Rotor Removal & Installation in Section 12 Brakes). 4. Remove the rear hub and bearing (1).
VISM120010
09
0911
SUSPENSION
10
page Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
CONTENTS
FRONT SUSPENSION
GENERAL INFORMATION
Description Operation Specifications Special Tools 10-2 10-2 10-3 10-3 10-4 10-5 10-5 10-6 10-6 10-6 10-6 10-6 10-8 10-8 10-8 10-8 10-9 10-10 10-10 Front Stabilizer Bar Removal & Installation Front Strut Assembly Description Operation Diagnosis & Testing Removal & Installation Front Coil Spring Description Operation Removal & Installation Sub-Frame Assembly Removal & Installation 10-11 10-11 10-12 10-12 10-14 10-14 10-14 10-15 10-15 10-15 10-15 10-16 10-16 10-21 10-21 10-21 10-22 10-22 10-23
ON-VEHICLE SERVICE
Front Steering Knuckle Description Operation Removal & Installation Front Lower Control Arm Description Operation Removal & Installation Inspection Front Stabilizer Bar Link Removal & Installation
10
UNIT REPAIR
Front Strut Disassembly Inspection Dispose Notices Assembly
101
GENERAL INFORMATION
Description
The suspension system incorporates a strut assembly that takes the place of the upper control arm and upper ball joint. The strut carries out the function of a shock absorber and is encompassed by a coil spring. The strut and spring assembly supports the weight of the vehicle and is also the pivot point for the steering knuckle. This system uses a lower control arm and ball joint for the lower pivot point of the steering knuckle.
1 - Front Strut Assembly 2 - Front Stabilizer Bar Link 3 - Front Stabilizer Bar 4 - Front Sub-Frame
5 - Front Lower Control Arm 6 - Front Steering Knuckle 7 - Front Hub And Bearing
VISM100020
102
GENERAL INFORMATION
WARNING!
Do not remove the strut rod nut while the strut assembly is installed in the vehicle, or before the coil spring is compressed with a spring compressor. The spring is held under high pressure and must be compressed before the strut rod nut can be removed.
CAUTION: At no time when servicing a vehicle can a sheet metal screw, bolt, or other metal fastener be installed in the shock tower to replace the original plastic clip. It may come in contact with the strut or coil spring. CAUTION: Wheel bearing damage will result if the vehicle is rolled or the weight of the vehicle is allowed to be supported by the tires for any length of time with the axle hub nut loose.
Operation
The front suspension utilizes a Macpherson strut system. This suspension system incorporates a strut assembly that takes the place of the upper arm and ball joint. The strut performs the function of a shock absorber and is encompassed by a coil spring.
Specifications
Torque Specifications
DESCRIPTION Sub-Frame Mounting Bolt Dust Shield Bolt Lower Ball Joint Nut Lower Control Arm Front Pivot Bolt Lower Control Arm Rear Pivot Bolt Wheel Speed Sensor Bolt Stabilizer Bar Mounting Bracket Bolt Stabilizer Bar Link Nut Steering Knuckle to Strut Assembly Bolt Strut Clevis To Steering Knuckle Nut Front Strut to Strut Tower Nut Front Strut to Steering Knuckle Bolt Front Axle Shaft Nut Inner Tie Rod Adjuster Jam Nut Outer Tie Rod End to Steering Knuckle Nut Wheel Mounting Nut TORQUE (Nm) 110 10 60 5 120 10 120 10 120 10 10 1 20 2 50 5 120 10 110 10 30 3 110 10 270 20 35 3 35 3 110
10
103
GENERAL INFORMATION
Special Tools
104
Road Wander
Lateral Pull
Unequal tire pressure. Incorrect front wheel camber. Wheel braking. Excessive cross-caster.
10
105
ON-VEHICLE SERVICE
Front Steering Knuckle
Description
The steering knuckle is a single casting with legs machined for attachment to the front strut assembly on the top and steering linkage on the trailing leading end. The steering knuckle also has two machined, drilled legs on the end casting to support and align the front disc brake caliper adapter.
Operation
The steering knuckle supports the hub and bearing. The front suspension steering knuckle is not a repairable component of the front suspension. It must be replaced if found to be damaged in any way. If it is determined that the steering knuckle is bent when servicing the vehicle, no attempt should be made to straighten the steering knuckle.
VISM100022
4. Access and remove the Front Brake Rotor (See Front Brake Rotor Remove & Installation in Section 12 Brakes).
106
ON-VEHICLE SERVICE
5. Remove the wheel speed sensor mounting bolt (1) and set it aside. (Tighten: Wheel speed sensor mounting bolt to 10 1 Nm) 6. Remove the wheel speed sensor.
VISM110003
7. Remove the lower ball joint mounting nut (1) attaching the lower control arm to the knuckle. (Tighten: Lower ball joint mounting nut to 120 10 Nm)
10
VISM080029
8. Remove the nut (1) attaching the outer tie rod end to the steering knuckle. (Tighten: Outer tie rod end to the steering knuckle nut to 35 3 Nm) 9. Using the special tool CH-10002, remove the outer tie rod end from the steering knuckle.
LTSM110034
107
ON-VEHICLE SERVICE
10. While holding the bolt heads stationary, remove the two nuts (1) from the bolts attaching the strut assembly to the steering knuckle. (Tighten: Strut assembly to steering knuckle bolts to 120 10 Nm)
VISM100023
NOTE : Do not allow the half shaft to hang by the inner C/V joint, it must be supported to keep the joint from separating during this operation. 11. Pull the knuckle off the half shaft outer C/V joint splines and remove the knuckle from the vehicle. 12. Remove the screws fastening the shield to the knuckle. Remove the shield. 13. Using the suitable tool, slide the hub and bearing out of the knuckle. 14. Installation is in the reverse order of removal.
Operation
The front lower control arm supports the steering knuckle. The lower control arm controls the vehicle steering by maintaining the proper wheel alignment through all driving conditions.
VISM080029
108
ON-VEHICLE SERVICE
4. Remove the lower control arm rear pivot bolt (1). (Tighten: Lower control arm rear pivot bolt to 120 10 Nm)
LTSM100055
5. Remove the lower control arm front pivot bolt (1). (Tighten: Lower control arm front pivot bolt to 120 10 Nm)
LTSM100057
6. Remove the lower control arm from the sub-frame. 7. Installation is in the reverse order of removal.
Inspection
1. 2. 3. 4. Check for smooth rotation. Inspect ball stud for damage. Inspect dust cover for damage or grease leak. inspect for play in ball joint, if found defective, replace the ball joint.
10
VISM100026
109
ON-VEHICLE SERVICE
LTSM100010
4. Remove the bolt (1) connecting the front stabilizer bar link to the front stabilizer bar. (Tighten: Front stabilizer link and the front stabilizer bar nut to 50 5 Nm)
VISM100025
5. Installation is in the reverse order of removal. Installation Notes: After installation, each bolt must be tightened to the required tightening torque.
1010
ON-VEHICLE SERVICE
10
VISM100004
6. Remove the front stabilizer bar mounting brackets and the rubber bushings. 7. Remove the front stabilizer bar. 8. Installation is in the reverse order of removal.
1011
ON-VEHICLE SERVICE
1012
ON-VEHICLE SERVICE
10
1 - Mounting Nut 2 - Upper Mount 3 - Pivot Bearing 4 - Bearing and Upper Spring Seat 5 - Upper Spring Isolator
1013
ON-VEHICLE SERVICE
Operation
The strut assembly cushions the ride of the vehicle, controlling vibration, jounce and rebound of the suspension. The coil spring controls ride quality and maintains proper ride height. The spring isolators isolate the coil spring at the top and bottom from coming into metal-to-metal contact with the upper mounting seat and the strut. The strut dampens jounce and rebound motions of the coil spring and suspension.
BESM100024
5. Remove the nut (1) from the front stabilizer bar link bracket on the front strut. (Tighten: Front stabilizer bar link bracket nut to 50 5 Nm)
LTSM100010
1014
ON-VEHICLE SERVICE
6. Remove the strut to the steering knuckle bolts (1). (Tighten: Strut to steering knuckle bolts to 120 10 Nm)
VISM100023
7. Remove the strut assembly from the vehicle. 8. Installation is in the reverse order of removal. Installation Notes: After installation, each bolt must be tightened to the required tightening torque. Four-wheel alignment inspection is required after the installation.
Operation
Coil springs are designed to store energy and subsequently release it and to absorb shock and maintain a force between contacting surfaces. Coil springs are rated for specific vehicle applications. NOTE : Each component is serviced by removing the strut assembly from the vehicle and disassembling it. Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. If a coil spring requires replacement, be sure that it is replaced with a spring meeting the correct load rating for the vehicle and its specific options.
10
WARNING!
Do not remove the strut rod nut before the coil spring is properly compressed. The coil spring is held under pressure. The coil spring must be compressed, removing spring tension from the upper mount and bearing, before the strut rod nut is removed.
1015
ON-VEHICLE SERVICE
2. Position the strut assembly in the strut coil spring compressor following the manufacturers instructions and set the lower and upper hooks of the compressor on the coil spring. 3. Compress the coil spring until all coil spring tension is removed from the upper mount and bearing.
LTSM100014
4. Once the spring is sufficiently compressed, install the strut nut wrench on the strut rod nut. 5. Install a deep socket on the end of the strut rod. 6. While holding the strut rod, remove the nut using the strut nut wrench. (Tighten: Strut rod nut to 110 10 Nm)
LTSM100015
7. 8. 9. 10. 11.
Remove the lower spring isolator from the strut seat. Remove the dust shield and jounce bumper. Remove the upper mounting bracket. Remove the upper spring seat and isolator. Release the tension from the coil spring by backing off the compressor drive completely. Release the compressor hooks and remove the coil spring. 12. Assembly is in the reverse order of disassembly.
10
Sub-Frame Assembly
Removal & Installation
WARNING!
Before removing the sub-frame assembly, properly support the engine and transaxle assembly. 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts and the tire and wheel assemblies from both sides. (Tighten: Wheel mounting nuts to 110 Nm) 3. Support the engine using an engine support fixture or suitable jack. 4. Remove the engine undercover and splash shields.
1016
ON-VEHICLE SERVICE
5. Remove the intermediate shaft coupling bolt (1). (Tighten: Intermediate shaft coupling bolt to 30 3 Nm)
VISM110005
6. Remove the exhaust pipe assembly mounting bolts (1). (Tighten: Exhaust pipe assembly mounting bolts to 25 3 Nm)
VISM110016
7. Remove the exhaust pipe assembly (See Exhaust Pipe Removal & Installation in Section 07 Exhaust). 8. Remove the wheel speed sensor (1) and set it aside. (Tighten: Vehicle speed sensor bolts to 10 1 Nm)
VISM110003
1017
ON-VEHICLE SERVICE
9. Remove the lower control arm ball joint retaining bolts (1). (Tighten: Lower control arm bolt to 120 10 Nm)
VISM010003
10. On each side of the steering gear, remove the nut (1) attaching the outer tie rod end to the steering knuckle. (Tighten: Outer tie rod end nut to 35 3 Nm)
LTSM110034
NOTE : Using special tool CH-10002, separate the outer tie rod ends from both steering knuckles. 11. Remove the left and right front stabilizer bar links (See Front Stabilizer Bar Link Removal & Installation in Section 10 Suspension). 12. Remove the rear transaxle mount bolts (2) and the rear transaxle mount bracket bolts (1). (Tighten: Rear transaxle mount bolts to 90 5 Nm)
10
VISM020003
1018
ON-VEHICLE SERVICE
13. Remove the high pressure and low pressure lines (1) from the steering gear. (Tighten: High pressure line to steering gear 50 5 Nm) (Tighten: Low pressure line to steering gear 50 5 Nm)
LTSM110007
14. Remove the power steering lines from the sub-frame. NOTE : Before removing the front suspension sub-frame from the vehicle, the location of the sub-frame must be marked on the body of the vehicle. Do this so the sub-frame can be relocated, upon reinstallation, against the body of vehicle in the same location as before removal. If the front suspension sub-frame is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) may be lost. 15. Use a jack to support the front sub-frame assembly.
1019
ON-VEHICLE SERVICE
16. Remove the front sub-frame retaining bolts (1) of each side. (Tighten: Front sub-frame bolts to 110 10 Nm)
VISM100001
17. Lower the jack with the front sub-frame. 18. Remove the steering gear mounting bolts (1). (Tighten: Steering gear mounting bolts 120 10 Nm)
to
10
VISM110011
19. Separate the steering gear. 20. Separate the front lower control arm and the front stabilizer bar from sub-frame assembly. 21. Installation is in the reverse order of removal.
1020
UNIT REPAIR
Front Strut
Disassembly
NOTE : The strut assembly must be removed from the vehicle for it to be disassembled and assembled. For the disassembly and assembly of the strut assembly, use a strut spring compressor, or the equivalent, to compress the coil spring. Follow the manufacturers instructions closely. 1. Remove the front strut assembly (See Front Strut Removal & Installation in Section 10 Suspension). 2. If both struts are being serviced at the same time, mark both the coil springs and strut assemblies according to which side of the vehicle the strut is being removed from.
WARNING!
Do not remove the strut rod nut before the coil spring is properly compressed. The coil spring is held under pressure. The coil spring must be compressed, removing spring tension from the upper mount and bearing, before the strut rod nut is removed. 3. If the spring compressor fixture is unable to attach to a workbench, attach the spring compressor to a bench vise.
LTSM100013
4. Position the strut assembly in the strut coil spring compressor following the manufacturers instructions and set the lower and upper hooks of the compressor on the coil spring. 5. Loosen the spring compressor, then attach the clamps between the top and bottom of the spring.
LTSM100014
6. Compress the coil spring until all coil spring tension is removed from the upper mount and bearing.
CAUTION: Never use impact or high speed tools to remove the strut rod nut. Damage to the strut internal bearings can occur.
1021
UNIT REPAIR
7. Once the spring is sufficiently compressed, install the strut nut wrench on the strut rod nut. 8. Install a deep socket on the end of the strut rod. While holding the strut rod, remove the nut using the strut nut wrench. (Tighten: Strut rod nut to 110 10 Nm)
LTSM100015
Remove the lower spring isolator from the strut seat. Remove the dust shield and jounce bumper. Remove the upper mounting bracket. Remove the upper spring seat and isolator. Release the tension from the coil spring by backing off the compressor drive completely. Release the compressor hooks and remove the coil spring.
Inspection
Inspect the strut assembly for damage and evidence of fluid running from the upper end of the fluid reservoir (actual leakage will be a stream of fluid running down the side of the reservoir tube and dripping off lower end of unit). Inspect the strut assembly components for the following and replace if necessary: Inspect the dust shield for cracks and tears. Check the upper mount for cracks and distortion and its retaining studs for any sign of damage. Check the bearing and upper spring seat for any binding. Inspect the upper and lower spring isolators for material deterioration and distortion. Inspect the coil spring for any sign of damage to the coating.
10
LTSM100011
Dispose Notices
NOTE : Follow the procedure below to properly dispose of the strut assembly. Pull the strut rod to extend the strut rod out as far as possible.
1022
UNIT REPAIR
Drill a hole to discharge the gas in the strut assembly cylinder (Drill a hole in the cylinder body according to the figure to discharge the gas).
LTSM100012
Assembly
1. Replace all necessary parts prior to reassembly: 1. Cushion Pad 2. Dust Boot 3. Cushion Block 4. Upper Spring Seat 5. Upper Spring Mount
LTSM100016
LTSM100017
3. Insert the coil spring into the spring compressor. 4. Compress the coil spring to a distance of 120 mm between the two clamps.
LTSM100018
1023
UNIT REPAIR
5. Ensure the cushion stopper mark (1) is in line with the mark on the strut .
LTSM100019
6. Install the cushion block and pull the piston rod to the bottom. 7. Align the coil spring on the bottom spring holder (1) (the end of the spring should be indexed in the spring pocket).
LTSM100020
8. Install the upper spring holder with the index position of 180 angle between the punched hole and the spring strut mounting position (1).
10
LTSM100021
9. Install the upper spacer and bearing. 10. Install the strut rod nut to the strut rod.
1024
REAR SUSPENSION
GENERAL INFORMATION
Description Operation Specifications 10-26 10-26 10-27 10-27 10-28 10-28 10-28 10-29 10-29 10-29 10-30 10-30 10-30 10-30 Rear Trailing Arm Removal & Installation Rear Shock Absorber Description Operation Removal & Installation Inspection Rear Coil Spring Description Operation Removal & Installation Rear Stabilizer Bar Removal & Installation Rear Stabilizer Bar Link Removal & Installation 10-31 10-31 10-32 10-32 10-32 10-32 10-33 10-33 10-33 10-33 10-33 10-33 10-33 10-34 10-34
ON-VEHICLE SERVICE
Rear Lower Control Arm Removal & Installation Rear Upper Control Arm Removal & Installation Rear Guide Bar Removal & Installation
1025
GENERAL INFORMATION
Description
10
1 - Rear Shock Absorber 2 - Rear Coil Spring 3 - Rear Sub-Frame 4 - Rear Stabilizer Bar Assembly 5 - Rear Lower Control Arm 6 - Rear Guide Bar
7 - Rear Knuckle 8 - Rear Upper Control Arm 9 - Rear Trailing Arm Bracket 10 - Rear Trailing Arm 11 - Rear Stabilizer Bar Link
VISM100002
WARNING!
Only frame contact or wheel lift hoisting equipment can be used on this vehicle. It cannot be hoisted using equipment designed to lift a vehicle by the rear axle. If this type of hoisting equipment is used, damage to rear suspension components will occur.
1026
GENERAL INFORMATION
CAUTION: If a rear suspension component becomes bent, damaged or fails, no attempt should be made to straighten or repair it. Always replace it with a new component.
Operation
The rear suspension utilizes an independent multi-link arm design. This suspension system allows the wheels to react to road imperfections independent of each other. This independent action offers improved isolation from the effects of jounce and rebound.
Specifications
Torque Specifications
DESCRIPTION Parking Brake Cable Mounting Bolt Rear Lower Control Arm Mounting Bolt Rear Shock Absorber Lower Mounting Bolt Rear Shock Absorber Upper Mounting Nut Rear Trailing Arm Mounting Bolt Rear Upper Control Arm to The Rear Sub-Frame Bolt Rear Upper Control Arm to The Rear Knuckle Bolt Rear Guide Bar to The Rear Sub-Frame Bolt Rear Guide Bar to The Rear Knuckle Bolt Rear Trailing Arm to The Knuckle Bolt Rear Trailing Arm to The Trailing Arm Bracket Bolt Rear Trailing Arm Bracket to Body Bolt Rear Stabilizer Bar Mounting Bracket Bolt Rear Stabilizer Bar Link Bolt TORQUE (Nm) 10 1 90 5 200 10 35 3 90 5 150 10 200 10 90 5 200 10 90 5 90 5 50 5 20 2 50 5
1027
10
1028
ON-VEHICLE SERVICE
Rear Lower Control Arm
Removal & Installation
1. Raise and support the vehicle. 2. Remove the wheel mounting nuts and the wheel assembly. (Tighten: Wheel mounting nuts to 110 Nm) 3. Use a jack to support the lower control arm. 4. Remove the rear shock absorber lower mounting bolt (1). (Tighten: Rear shock absorber lower mounting bolt to 200 20 Nm)
VISM100009
5. Remove the rear lower control arm to the rear steering knuckle retaining bolt (1). (Tighten: Rear lower control arm mounting bolts to 90 5 Nm)
VISM010005
6. Lower the jack and remove the rear coil spring. 7. Remove the rear lower control arm to the rear subframe mounting bolts (1). (Tighten: Rear lower control arm mounting bolts to 90 5 Nm)
VISM010004
8. Remove the rear lower control arm. 9. Installation is in the reverse order of removal.
1029
ON-VEHICLE SERVICE
Installation Notes: After installing the rear lower control arm, check and adjust the alignment.
VISM100011
4. Remove the rear upper control arm to the steering knuckle nut (1). (Tighten: Rear upper control arm to the rear subframe nut to 200 10 Nm) 5. Remove the rear upper control arm.
10
VISM100016
6. Installation is in the reverse order of removal. Installation Notes: After installing the rear upper control arm, check and adjust the alignment.
1030
ON-VEHICLE SERVICE
3. Remove the rear guide bar to the rear sub-frame bolt (1). (Tighten: Rear guide bar to rear sub-frame bolt to 90 5 Nm) 4. Remove the rear guide bar to the rear knuckle bolt (2). (Tighten: Rear guide bar to rear knuckle bolt to 200 10 Nm)
VISM100013
5. Remove the rear guide bar. 6. Installation is in the reverse order of removal.
VISM100005
4. Remove the trailing arm to the rear knuckle bolt (1). (Tighten: Trailing arm to rear knuckle bolt to 90 5 Nm)
VISM100006
1031
ON-VEHICLE SERVICE
5. Remove the parking brake cable mounting bolt (1). (Tighten: Parking brake cable mounting bolt to 10 1 Nm)
VISM100024
6. Remove the parking brake cable clamp on the rear trailing arm. 7. Remove the rear stabilizer bar link to trailing arm bolt. (Tighten: Rear stabilizer bar link to trailing arm bolt to 50 5 Nm) 8. Remove the trailing arm and trailing arm bracket assembly. 9. Separate the trailing arm and the trailing arm bracket. (Tighten: Trailing arm to trailing arm bracket bolt to 90 5 Nm) 10. Installation is in the reverse order of removal.
Operation
The shock absorber assembly cushions the ride of the vehicle, controls vibration, jounce and rebound of the suspension. The shock absorber dampens jounce and rebound motions of the coil spring and suspension.
10
VISM100019
1032
ON-VEHICLE SERVICE
3. Raise and support the vehicle. 4. Remove the rear shock absorber to rear knuckle lower mounting bolt (1). (Tighten: Rear shock absorber to rear knuckle lower mounting bolt to 200 10 Nm) 5. Remove the rear shock absorber. 6. Installation is in the reverse order of removal.
VISM100009
Inspection
1. Inspect shock absorber for oil leakage, replace it if necessary. Then inspect the damping force of the shock absorber, and replace it if not conform to specification.
Operation
Coil springs are designed to store energy and subsequently release it and to absorb shock and maintain a force between contacting surfaces. Coil springs are rated for specific vehicle applications.
VISM010005
6. Lower the jack and remove the rear coil spring. 7. Installation is in the reverse order of removal.
1033
ON-VEHICLE SERVICE
2. Remove the rear stabilizer bar to rear stabilizer bar link bolt (1). (Tighten: Rear stabilizer bar to rear stabilizer bar link bolt to 50 5 Nm)
VISM100014
3. Remove the rear stabilizer bar mounting bracket to rear sub-frame mounting bolts (1). (Tighten: Rear stabilizer bar mounting bracket to rear sub-frame mounting bolts to 20 2 Nm) 4. Remove the rear stabilizer bar. 5. Installation is in the reverse order of removal.
VISM100008
10
VISM100007
5. Remove the rear stabilizer bar link. 6. Installation is in the reverse order of removal.
1034
ALIGNMENT
GENERAL INFORMATION
Description Operation Pre-Wheel Alignment Inspection Wheel Alignment Setup Specifications 10-36 10-36 10-36 10-36 10-37 10-38 10-39 10-39 10-39 10-39 Alignment Troubleshooting Chart 10-40 10-41 10-41 10-41 10-41 10-42 10-42 10-42
ON-VEHICLE SERVICE
Front Wheel Alignment Front-axle Toe-in Adjustment Front Wheel Alignment Specifications Rear Wheel Alignment Rear-axle Camber Adjustment Rear-axle Toe-in Adjustment
1035
GENERAL INFORMATION
Description
Vehicle wheel alignment is the positioning of all interrelated front and rear suspension angles. These angles affect the handling and steering of the vehicle when it is in motion. Proper wheel alignment is essential for efficient steering, good directional stability, and proper tire wear. The method of checking a vehicles front and rear wheel alignment varies depending on the manufacturer and type of equipment used. The manufacturers instructions should always be followed to ensure accuracy of the alignment. On this vehicle, the suspension angles that can be adjusted are as follows: Front-axle Camber Toe-in Caster Rear-axle Camber Toe-in Check the wheel alignment and make all wheel alignment adjustments with the vehicle standing at its proper curb height specification. Curb height is the normal riding height of the vehicle. It is measured from a certain point on the vehicle to the ground or a designated area while the vehicle is sitting on a flat, level surface.
Operation
Curb Height Measurement
The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a new or known good coil spring. The heights should vary if the suspect spring is weak. NOTE : Prior to reading the curb height measurement, the front and rear of the vehicle must be jounced to settle the suspension. Induce jounce by pushing down on the center of the bumper (fascia), using care not to damage the vehicle, moving the vehicle up and down, gradually increasing the suspension travel with each stroke. Release the bumper at the bottom of each stroke, repeating this action several times. Perform this to both front and rear suspensions an equal amount of times.
10
1036
GENERAL INFORMATION
3. Check the tires on the vehicle. The tires are to be inflated to the recommended air pressure. All tires must be the same size and in good condition with approximately the same tread wear.
LTSM100027
4. 5. 6. 7.
Check the front tire and wheel assemblies for excessive radial runout. Inspect all suspension component fasteners for looseness and proper torque. Inspect all ball joints and all steering linkage for looseness and any sign of wear or damage. Inspect the rubber bushings on all the suspension components for signs of wear or deterioration. If any bushings show signs of wear or deterioration, they should be replaced prior to aligning the vehicle. 8. Check vehicle curb height.
10
LTSM110026
2. Install all required alignment equipment on the vehicle, per the alignment equipment manufacturers instructions. On this vehicle, a four-wheel alignment is recommended. 3. Read the vehicles current front and rear alignment settings. Compare the vehicles current alignment settings to the vehicle specifications for camber, caster and toe-in. NOTE : Prior to reading the vehicles alignment readouts, the front and rear of vehicle should be jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing each end of vehicle an equal number of times. The bumper should always be released when vehicle is at the bottom of the jounce cycle.
1037
GENERAL INFORMATION
Specifications
Torque Specifications
DESCRIPTION Camber Adjustment Bolt Inner Tie Rod Adjuster Jam Nut Rear Lower Control Arm Eccentric Cam Bolt Rear Upper Control Arm Eccentric Cam Bolt Wheel Mounting Nut TORQUE (Nm) 110 10 35 3 120 10 150 10 110
1038
Tire Wear
Inspect the following for accurate tire wear: Check the depth of tire remaining tread. Standard tire: not less than 1.6 mm. Snow tire: 50% tire tread. If the tread is below the specifications, the tire should be replaced.
BESM100022
1 Condition:
(3) Cracked Treads (3) Tire Damage (10) Under Inflation Or Excessive Speed
(5) Feathered Edge (2) Excessive Tire Wear (12) Incorrect Toe-in
(7) Scalloped Wear (7) Excessive Tire Wear (15) Lack Of Rotation / Tires Worn / Alignment / Suspension (20) Rotate Tires / Replace Tires / Check Alignment / Suspension
2 Effect:
3 Cause:
4 Correction:
(17) Adjust (18) Adjust (19) Camber To Toe-In To Balance Specifications Specifications Wheels
1039
Tire Noise
Loose wheel nut or axle. Unbalanced tire. Crack or wearing of engine mounting rubber. Crack or wearing of transmission bracket rubber. Loose wheel nut or axle. Unbalanced tire. Deficient tire pressure. Damage or wearing of front wheel bearing. Failure of steering system. Incorrect tire pressure. Excessive tire wearing. Failure of steering system. Failure of suspension system.
10
Unstable Driving
Incorrect tire pressure. Failure of steering system. Failure of suspension system. Incorrect wheel alignment.
1040
ON-VEHICLE SERVICE
Front Wheel Alignment
Front-axle Toe-in Adjustment
CAUTION: Do not twist the inner tie rod steering gear boot (bellows) while turning the inner tie rod during front toe-in adjustment. It may be necessary to remove the clamp where the boot meets the inner tie rod.
1. Loosen the tie rod adjusting jam nut (1). (Tighten: Tie rod adjusting jam nut to 35 3 Nm) 2. Grasp the inner tie rod shaft and adjust the tie rod end until the front toe-in is set to specifications.
VISM100021
3. Make sure the inner tie rod steering gear boot is not twisted. If removed, reinstall the clamp where the boot meets the inner tie rod. 4. Remove the alignment equipment. 5. Lower vehicle and jounce the front and rear of the vehicle.
1041
ON-VEHICLE SERVICE
VISM100012
10
VISM100011
REAR WHEEL ALIGNMENT ALIGNMENT ANGLE Camber Toe-Individual PREFERRED SETTING -20 -7 ACCEPTABLE RANGE 0 to -40 +3 to -17
1042
ON-VEHICLE SERVICE
Tire Replacement & Repair Description
1043
GENERAL INFORMATION
Description
Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicles requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life.
Operation
Driving habits have more effect on tire life than any other factor. Careful drivers obtain, in most cases, greater mileage than drivers whose habits result in severe tire wear and usage. A few of the driving habits which will shorten the life of any tire are: Rapid acceleration Severe application of brakes High-speed driving Taking turns at excessive speeds Striking curbs and other obstacles Operating vehicle with over or under inflated tire pressures
Specifications
Torque Specifications
DESCRIPTION Wheel Mounting Nut TORQUE (Nm) 110
10
1044
1045
ON-VEHICLE SERVICE
Tire Replacement & Repair
Description
Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicles requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life.
WARNING!
Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure. In order to maintain the speed capability of the vehicle, replacement tires must have speed ratings equal to or higher than those fitted to the vehicle as original equipment. If tires with lower speed ratings are fitted, the vehicles handling may be affected and the speed capability of the vehicle may be lowered to the maximum speed capability of the replacement tires. To avoid an accident resulting in severe or fatal injury, consult the tire manufacturer in regards to maximum speed ratings.
Replacement Procedure
Note the following guidelines when replacing a tire: It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The use of tires smaller than the minimum tire size approved for the vehicle can result in tire overloading and failure. Use tires that have the approved load rating for the vehicle and never overload them. Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure and loss of vehicle control. The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. Perform the following when replacing a tire: 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts and the wheel assembly. 3. Deflate the tire completely before removing the tire from the wheel. 4. Use lubrication such as a mild soap solution when dismounting or mounting tire. 5. Replace the tire with a tire approved for the vehicle. 6. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. 7. Before mounting the tire on the wheel, make sure all rust is removed from the rim bead and repaint if necessary. 8. Balance the wheel assembly. 9. Install the wheel assembly and install the wheel mounting nuts. (Tighten: Wheel mounting nuts to 110 Nm)
10
Repair Procedure
Note the following guidelines when performing a tire repair: For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the defect, or puncture, is in the tread area. The tire should be replaced if the puncture is located in the sidewall. Perform the following when repairing a tire: 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts and the wheel assembly. 3. Deflate the tire completely before removing the tire from the wheel. 4. Use lubrication such as a mild soap solution when dismounting or mounting tire. 5. Repair the tire only if the defect, or puncture, is in the tread area. 6. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. 7. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary.
1046
ON-VEHICLE SERVICE
8. Install the wheel assembly and install the wheel mounting nuts. (Tighten: Wheel mounting nuts to 110 Nm)
Wheel Assembly
Description
Original equipment wheels are designed for operation up to the specified maximum vehicle capacity. Inspect wheels for the following: Dents or cracks Damaged wheel bolt holes Air leaks from any area or surface of the rim Excessive run out NOTE : Do not attempt to repair a wheel by hammering, heating or welding. NOTE : The wheel nuts are designed for specific applications. Do not use replacement fasteners with a different design or lesser quality.
VISM100031
Wheel Balance
Description
Balance the wheel assembly if necessary following the wheel balancer manufacturers instructions. Road test the vehicle for at least 5 miles. If the vibration persists, continue with Diagnosis & Testing procedure. NOTE : Balance equipment must be calibrated and maintained per equipment manufacturers specifications. Wheel weight must fit the rim.
1047
ON-VEHICLE SERVICE
CAUTION: Use caution not to damage wheel weights during tire and wheel installation.
5. Install the wheel assembly and install the wheel mounting nuts. (Tighten: Wheel mounting nuts to 110 Nm)
Tire Rotation
Description
BESM100020
Tires on the front and rear operate at different loads and perform different steering, driving, and braking functions. For these reasons they wear at unequal rates and tend to develop irregular wear patterns. These effects can be reduced by rotating the tires at regular intervals. The benefits of tire rotation are: Increase tread life Maintain traction levels A smooth, quiet ride
10
1048
ON-VEHICLE SERVICE
Non-Directional Tires
BESM100021
The suggested method of tire rotation is shown. Other rotation methods can be used, but they will not provide all the tire longevity benefits. NOTE : Only the four-tire rotation method may be used if the vehicle is equipped with a compact or temporary spare tire. 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts and the wheel assembly. 3. Rotate the tire to the desired location.
10
CAUTION: Use caution not to damage wheel weights during tire and wheel installation.
4. Install the wheel assembly and install the wheel mounting nuts. (Tighten: Wheel mounting nuts to 110 Nm)
Directional Tires
Some vehicles may be fitted with special high-performance tires having a directional tread pattern. These tires are designed to improve traction on wet pavement. To obtain the full benefits of this design, the tires must be installed so that they rotate in the correct direction. This is indicated by arrows on the tire sidewalls. When being installed, extra care is needed to ensure that this direction of rotation is maintained. 1. Remove the wheel mounting nuts and the wheel assembly. 2. Rotate the tire to the desired location.
CAUTION: Use caution not to damage wheel weights during tire and wheel installation.
3. Install the wheel assembly and install the wheel mounting nuts. (Tighten: Wheel mounting nuts to 110 Nm)
1049
STEERING
11
page Steering System - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 Steering Column - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8 Steering Gear - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20 Steering System - Electronic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-29 Steering Column - Electronic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-34 Steering Gear - Electronic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45 Electronic Power Steering Electrical Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-55 Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-69
CONTENTS
ON-VEHICLE SERVICE
Power Steering Filling and Flushing Filling Flushing Inspection
11
111
GENERAL INFORMATION
Description
The steering system uses a power steering pump which is a constant flow rate and displacement vane type pump. The pump reservoir supplies fluid to the pump body. The pump is connected to the steering gear assembly by the pressure and return hoses. The steering gear used is a rack and pinion type gear.
1 - Power Steering Fluid Reservoir 2 - Power Steering Fluid Return Hose 3 - Power Steering Wheel 4 - Power Steering Column
5 - Power Steering Gear Assembly 6 - Power Steering Fluid Pressure Hose 7 - Power Steering Pump
VISM110009
112
GENERAL INFORMATION
Operation
Turning of the steering wheel is converted into linear travel through the meshing of the helical pinion teeth with the rack teeth within the steering gear. The lateral travel pushes and pulls the tie rods to change the direction of the vehicles front wheels. Power assist steering is provided by a belt driven rotary pump. It directs fluid through power steering fluid hoses to the power steering gear where it is used to assist the drivers turning effort. Manual steering control of the vehicle can be maintained if power steering assist is lost. However, under this condition, steering effort is significantly increased.
WARNING!
Power steering fluid, engine components and the exhaust system may be extremely hot if the engine has been running. Do not start the engine with any loose or disconnected hoses. Do not allow hoses to touch the hot exhaust manifold or catalyst. Fluid level should be checked with the engine off to prevent personal injury from moving parts.
Special Tools
11
Ball Joint Separator CH-10002
Specifications
Fluid Specifications
DESCRIPTION Power Steering Fluid (ATF III) CAPACITY (L) 1.2
113
Low power steering fluid level. Steering Catches, Surges Or Sticks In Certain Positions Or Is Difficult To Turn
Tire(s) not properly inflated. Loose or slipping power steering/ accessory drive belt. Lack of lubrication in steering gear outer tie rod end(s).
Power steering gear loose on cradle/Sub-frame. Excessive Steering Wheel Kickback From Road Inputs Steering column, coupling or intermediate shaft worn or loose.
114
11
Aerated Fluid Air leak at power steering supply hose, reservoir or pump.
115
ON-VEHICLE SERVICE
Power Steering Filling and Flushing
Filling
1. 2. 3. 4. 5. 6. Fill the power steering fluid reservoir to the proper level and let the fluid settle for at least two minutes. Start the engine and let it run for a few seconds, then turn the engine off. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. When the steering fluid temperature is relatively high, the steering fluid level will approach to the MAX position. When the steering fluid cools down, the steering fluid level may approach to the MIN position.
NOTE : If the fluid is extremely foamy or milky looking, allow the vehicle to stand a few minutes and repeat the procedure.
Flushing
1. 2. 3. 4. 5. 6. 7. 8. Raise and support the vehicle. Siphon out the contaminated power steering fluid from the power steering liquid reservoir. Remove the power steering fluid return hose from the power steering liquid reservoir. Insert the power steering fluid return hose into a container for the discharged power steering fluid. Start the engine and idle. Fill the power steering fluid reservoir. When the return hose discharges clean power steering fluid, stop the engine and install the return hose. Slowly turn the steering wheel several times to the right and left, lightly contacting the wheel stops at each turn.
NOTE : Approximately 1.2L of power steering fluid should be needed to fully flush the power steering reservoir.
116
ON-VEHICLE SERVICE
Inspection
1. If the power steering fluid level is low, inspect the entire power steering system for potential leaks.
CAUTION: DO NOT operate the vehicle with foamy steering fluid for an extended period. This may cause pump damage.
2. Perform the following to inspect the power steering fluid reservoir level: Park the vehicle on a level surface. Start the engine. Turn the steering wheel several times to heat the power steering fluid to 50 - 60C. With the engine running, turn the steering wheel left and right to the wheel stops and repeat this several times. Check the power steering fluid reservoir to see whether there is foam or milky fluid present. Check the fluid level difference between engine off (2) and engine running (1). If the fluid level variation exceeds 5 mm, air is in the system and should be removed.
LTSM110030
11
117
ON-VEHICLE SERVICE
Steering Wheel Removal & Installation Inspection - Hydraulic System Steering Column Shroud Removal & Installation Steering Column Shaft Removal & Installation
118
GENERAL INFORMATION
Description
The steering column has been designed so that the wiring, switches, shrouds and steering wheel can be serviced without removing the steering column from the vehicle.
Operation
The steering column is the mechanical linkage between the steering wheel and the steering gear. The steering column shaft connects the steering column to the steering gear. The tilt function of the steering column is controlled by a mechanical lever on the underside of the steering column, which uses a cam to lock and unlock the steering column.
11
119
GENERAL INFORMATION
Specifications
Torque Specifications
DESCRIPTION Steering Wheel Lock Nut TORQUE (Nm) 35 5
Special Tools
1110
11
1111
ON-VEHICLE SERVICE
Steering Wheel
Removal & Installation
WARNING!
Before servicing the steering column, the airbag system must be disarmed. Failure to do so may result in accidental deployment of the airbag and possible personal injury (See Airbag System Disarming Procedure in Section 14 Restraints).
NOTE : To help maintain alignment of the spiral cable connector during reassembly, apply a small piece of tape to the spiral cable and the steering column to keep them in alignment. 1. 2. 3. 4. 5. Set the front wheels to straight-ahead position. Disconnect the negative battery cable. Remove the driver airbag (See Driver Airbag Removal & Installation in Section 14 Restraints). Disconnect the spiral cable electrical connector. Remove the steering wheel lock nut (1). (Tighten: Steering wheel lock nut to 35 5 Nm)
VISM110013
6. Using the steering wheel puller, remove the steering wheel. 7. Installation is in the reverse order of removal. Installation Notes: The spiral cable could be damaged if installed in an improper position. Do not rotate the spiral cable quickly or beyond the limit of turns (this can cause the cable to break). Verify the airbag system is operating properly after the repair is complete.
1112
ON-VEHICLE SERVICE
Slightly turn steering wheel to the right and left, and before the wheels begin turning, measure the free play of steering wheel.Maximum Limit: 40 mm.
If the free play exceeds the limit value, inspect the gap between the steering shaft joint and the steering linkage, repair or replace the related parts as necessary. If the free play still exceeds the limit value, turn the steering wheel to the right position with the engine off. Apply 5 Nm of load to the steering wheel and inspect the free-play again.(Standard value: Less than 15 mm steering wheel free play with the engine off) If free play exceeds standard value, remove steering gear housing and inspect the gross torque of pinion gear. 2. Static Steering Force Inspection Park the vehicle on a level surface, and turn the steering wheel to the straight-ahead position. Start the engine, adjust engine speed to 1000 100 RPM.
LTSM110025
CAUTION: After adjusting the engine speed, return it back to standard idle speed.
Connect a spring scale to the outer circle of steering wheel. Measure the steering force required when turning the steering wheel leftward and rightward (within 1.5 circles) at straight-ahead position. If obvious steering force fluctuation exists, inspect the steering force as necessary. Standard steering force: Less than 34 Nm Fluctuation tolerance: Less than 5.9 Nm If the measured force exceeds the standard value, see the trouble shooting section for inspection and adjustment. 3. Steering Wheel Return to Center Inspection NOTE: This test shall be performed during a road test. The following procedures should be performed during the road teat: Make smooth turns and sharp turns. Check the driving sense to ensure there is no difference between the left and right turns in terms of steering force and the steering wheel returning to center. When the vehicle speed is between 20 to 30 km/h turn the steering wheel 90 for 1 or 2 seconds and release the steering wheel. If the steering wheel returns over 70, the steering wheel return function can be considered good.
11
LTSM110029
NOTE : When rapidly turning the steering wheel, there will be a sense of heavy, however, this does not indicate a problem with the steering system (this is due to insufficient steering fluid supplied to the steering fluid pump during idle speed). Chery Automobile Co., Ltd.
1113
ON-VEHICLE SERVICE
NOTE : To help maintain alignment of the spiral cable connector during reassembly, apply a small piece of tape to the spiral cable and the steering column to keep them in alignment. 1. Disconnect the negative battery cable. 2. Remove the driver airbag (See Driver Airbag Removal & Installation in Section 14 Restraints). 3. Remove the steering wheel lock nut (1). (Tighten: Steering wheel lock nut to 35 5 Nm)
VISM110013
1114
ON-VEHICLE SERVICE
4. Using the steering wheel puller, remove the steering wheel. 5. Remove 4 retaining bolts (1). (Tighten: Steering column shroud bolts to 10 1 Nm)
VISM110017
11
VISM080028
7. Remove the steering column shroud. 8. Installation is in the reverse order of removal. Installation Notes: The spiral cable could be damaged if installed in an improper position. Do not rotate the spiral cable quickly or beyond the limit of turns (this can cause the cable to break). Verify the airbag system is operating properly after the repair is complete.
1115
ON-VEHICLE SERVICE
VISM110013
6. Using the steering wheel puller, remove the steering wheel. 7. Remove the steering column shroud (See Steering Column Shroud Removal & Installation in Section 11 Steering) 8. Remove the lower console side panel retaining bolts (1).
VISM080027
1116
ON-VEHICLE SERVICE
9. Remove the instrument panel lower shroud retaining bolts (1) and remove the lower shroud.
VISM150144
10. Disconnect the multi-function switch and the wiper and washer switch electrical connector.
11
VISM110004
11. Remove the spiral cable retaining bolts (1) and remove the spiral cable assembly with the switch. 12. Disconnect the ignition switch electrical connector.
1117
ON-VEHICLE SERVICE
13. Remove the intermediate shaft coupling bolt (1). (Tighten: Intermediate shaft coupling bolt to 30 3 Nm)
VISM110005
14. Remove the steering column upper retaining bolts (1). (Tighten: Steering column upper retaining bolts to 22 1 Nm)
VISM110001
1118
ON-VEHICLE SERVICE
15. Remove the steering column lower retaining bolts (1). (Tighten: Steering column lower retaining bolts to 25 3 Nm)
VISM110002
16. Remove the steering column. 17. Installation is in the reverse order of removal.
11
1119
ON-VEHICLE SERVICE
Steering Gear Removal & Installation Tie Rod Removal & Installation
1120
GENERAL INFORMATION
Description
The steering gear used is the rack-and-pinion type with power assist. It is mounted on the front suspension subframe. The outer ends of the outer tie rods attach to the front steering knuckles. NOTE : The power steering gear should not be serviced or adjusted. If a steering gear malfunction or steering gear leak occurs, the complete steering gear assembly should be replaced.
Operation
The steering wheel turns the pinion. The rack is a long flat bar with teeth on one side. The rack teeth mesh with the teeth on the pinion. Rotation of the pinion moves the rack from left to right and right to left. The tie rod then causes the wheels to turn to the left or right.
Specifications
Torque Specifications
DESCRIPTION Front Sub-Frame and Vehicle Body Connection Heat Shield Bolt Intermediate Shaft Coupling Bolt Lower Control Arm Pinch Bolt Lower Control Arm Front Mounting Bolt Lower Control Arm Rear Mounting Bolt Power Steering Hose Routing Clamp Bolt Power Steering Pressure Line to Steering Gear Power Steering Return Line to Steering Gear Pressure/Return Hose Routing Clamp Screws to Sub-Frame Rear Sub-Frame and Vehicle Body Connection Rear Transaxle Mount Bolt Steering Gear Mounting Bolt Tie Rod End Nut Tie Rod Jam Nut Wheel Mounting Nut TORQUE (Nm) 110 10 10 1 30 3 120 10 120 10 120 10 10 1 50 5 50 5 10 1 120 10 90 5 120 10 35 3 35 3 110
Special Tools
1121
Tire pressure. Wheel alignment. Lack of lubrication. High friction in steering gear. Ball joints binding.
11
1122
ON-VEHICLE SERVICE
Steering Gear
Removal & Installation
WARNING!
Before servicing the steering column, the airbag system must be disarmed. Failure to do so may result in accidental deployment of the airbag and possible personal injury (See Airbag System Disarming Procedure in Section 14 Restraints).
NOTE : The following special tools are required to perform the repair procedure: CH-10002 - Ball Joint Separator 1. Siphon out as much power steering fluid as possible from the reservoir. 2. Disconnect the negative battery cable. 3. Position the front wheels of vehicle in the straight-ahead position, turn the ignition switch off, and lock the steering wheel. 4. Remove the lower console side panel retaining bolts (1).
VISM080027
5. Reposition the floor carpeting to access the intermediate shaft coupling at the base of the steering column. 6. Remove the instrument panel lower shroud retaining bolts (1) and remove the lower shroud.
VISM150144
7. Reposition the floor carpeting to access the intermediate shaft coupling at the base of the steering column.
1123
ON-VEHICLE SERVICE
8. Remove the intermediate shaft coupling bolt (1). (Tighten: Intermediate shaft coupling bolt to 30 3 Nm)
VISM110005
9. Use a service jack to support the engine. 10. Raise and support the vehicle. 11. Remove both front wheel mounting nuts and the wheel assemblies. (Tighten: Wheel mounting nuts to 110 Nm) 12. Remove the exhaust pipe assembly mounting bolts (1). (Tighten: Exhaust pipe assembly mounting bolts to 25 3 Nm)
VISM110016
13. Remove the exhaust pipe assembly (See Exhaust Pipe Assembly Removal & Installation in Section 07 Exhaust).
11
1124
ON-VEHICLE SERVICE
14. Remove the wheel speed sensor (1) and set aside. (Tighten: Wheel speed sensor bolts to 10 1 Nm)
VISM110003
15. Remove the lower control arm pinch bolts (1). (Tighten: Lower control arm pinch bolt 120 10 Nm)
to
VISM080029
16. On each side of the steering gear, remove the nut (1) attaching the outer tie rod end to the steering knuckle. (Tighten: Outer tie rod end nut to 35 3 Nm)
LTSM110034
NOTE : Using special tool CH-10002, separate the outer tie rod ends from both steering knuckles.
1125
ON-VEHICLE SERVICE
17. Remove the rear transaxle mount bolts (2) and the rear transaxle mount bracket bolts (1). (Tighten: Rear transaxle mount bolts to 90 5 Nm)
VISM020003
18. Remove the high pressure and low pressure lines (1) from the steering gear. (Tighten: High pressure line to steering gear 50 5 Nm) (Tighten: Low pressure line to steering gear 50 5 Nm)
11
LTSM110007
19. Remove the power steering lines from the sub-frame. NOTE : Before removing the front suspension sub-frame from the vehicle, the location of the sub-frame must be marked on the body of the vehicle. Do this so the sub-frame can be relocated, upon reinstallation, against the body of vehicle in the same location as before removal. If the front suspension sub-frame is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) may be lost. 20. Use a service jack to support the front sub-frame assembly.
1126
ON-VEHICLE SERVICE
21. Remove the front sub-frame retaining bolts (1) on each side. (Tighten: Front sub-frame bolts to 110 10 Nm)
VISM100001
22. Lower the service jack with the front sub-frame. 23. Remove the steering gear mounting bolts (1). (Tighten: Steering gear mounting bolts to 120 10 Nm)
VISM110011
24. Separate the steering gear. 25. Installation is in the reverse order of removal. Installation Notes: After installing the new steering gear, perform a front end alignment procedure to reset the toe-in (See Front Wheel Alignment in Section 10 Suspension).
1127
ON-VEHICLE SERVICE
Tie Rod
Removal & Installation
NOTE : The following special tools are required to perform the repair procedure: CH-10002 - Ball Joint Separator 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts and the wheel assembly. (Tighten: Wheel mounting nuts to 110 Nm) 3. Loosen the tie rod jam nut (1). (Tighten: Tie rod jam nut to 35 3 Nm)
VISM100021
4. Remove the nut (1) attaching the outer tie rod end to the steering knuckle. (Tighten: Outer tie rod end nut to 35 3 Nm) 5. Using special tool CH-10002, separate the outer tie rod end from the steering knuckle.
11
LTSM110034
6. Remove the outer tie rod end from the steering rack. NOTE : When removing the outer tie rod end, count the number of revolutions when removing. This will aid in installation, getting the toe setting close to where it needs to be when setting the final toe-in wheel alignment. 7. Installation is in the reverse order of removal. Installation Notes: After installing the new tie rod end, perform a front end alignment procedure to reset the toe-in (See Front Wheel Alignment in Section 10 Suspension).
1128
1129
GENERAL INFORMATION
Description
The Electronic Power Steering (EPS) system provides power steering assist to the driver by replacing the conventional hydraulic valve system with an electric motor coupled to the steering shaft. The motor is controlled by the EPS control unit that senses the steering effort through the use of a torque sensor mounted between the steering column shaft and the steering gear. Steering assist is provided in proportion to the steering input effort and vehicle speed.
11
VISM110006
The EPS system consists of these major components: Steering Wheel (1) Steering Column (2) EPS Motor (3) Steering Clutch EPS Module (4) Steering Torque Sensor Wheel Speed Sensor Steering Direction Sensor Steering Gear Assembly (5)
1130
GENERAL INFORMATION
Operation
The vehicle speed, which is sent by the Engine Control Module (ECM) over the CAN bus, provides the necessary vehicle speed information to the electronic power steering system to determine the amount or level of power assist. As vehicle speed increases, the amount of power assist provided by the system is reduced to improve and enhance road feel at the steering wheel. If the vehicle speed is missing or out of range, the Electronic Power Steering (EPS) control unit defaults to a reduced level of assist. If the vehicle speed returns to the correct in-range values, the EPS control unit adjusts the steering assist level accordingly. The EPS control unit manages the electronic power steering system. The power steering control unit receives vehicle speed information from the ECM via the CAN bus, the unit also receives information from the steering shaft torque sensor to determine the amount of assist that is needed. At lower speeds, the control unit will provide greater assist. At higher speeds, the control unit will provide less assist. The power steering control unit is part of the steering column and is not serviceable separately.
Specifications
Torque Specifications
DESCRIPTION Steering Wheel Lock Nut TORQUE (Nm) 35 5
Special Tools
1131
11
1132
1133
ON-VEHICLE SERVICE
Steering Wheel Removal & Installation Steering Column Shroud Removal & Installation Steering Column Shaft Removal & Installation
11
1134
GENERAL INFORMATION
Description
The steering column has been designed so that the wiring, switches, shrouds and steering wheel can be serviced without removing the steering column from the vehicle.
1 - Steering Wheel 2 - Steering Wheel Lock Nut 3 - Driver Airbag 4 - Spiral Cable
5 - Steering Column Shaft 6 - Electronic Power Steering Module 7 - Electronic Power Steering Motor
VISM110012
Operation
The steering column is a mechanical/electronic intelligent linkage between the steering wheel and the steering gear. The steering column shaft then connects the steering column to the steering gear. The tilt function of the steering column is controlled by a mechanical lever on the underside of the steering column, which uses a cam to lock and unlock the steering column. The electronic power steering motor is controlled by the Electronic Power Steering (EPS) control unit.
1135
GENERAL INFORMATION
Specifications
Torque Specifications
DESCRIPTION Steering Wheel Lock Nut TORQUE (Nm) 35 5
Special Tools
11
1136
1137
11
1138
ON-VEHICLE SERVICE
Steering Wheel
Removal & Installation
WARNING!
Before servicing the steering column, the airbag system must be disarmed. Failure to do so may result in accidental deployment of the airbag and possible personal injury (See Airbag System Disarming Procedure in Section 14 Restraints).
NOTE : To help maintain alignment of the spiral cable connector during reassembly, apply a small piece of tape to the spiral cable and the steering column to keep them in alignment. 1. 2. 3. 4. 5. Set the front wheels to straight-ahead position. Disconnect the negative battery cable. Remove the driver side airbag (See Driver Airbag Removal & Installation in Section 14 Restraints). Disconnect the spiral cable electrical connector. Remove the steering wheel lock nut (1). (Tighten: Steering wheel lock nut to 35 5 Nm)
VISM110013
6. Using the steering wheel puller, remove the steering wheel. 7. Installation is in the reverse order of removal. Installation Notes: The spiral cable could be damaged if installed in an improper position. Do not rotate the spiral cable quickly or beyond the limit of turns (this can cause the cable to snap). Verify the airbag system is operating properly after the repair is complete.
1139
ON-VEHICLE SERVICE
NOTE : To help maintain alignment of the spiral cable connector during reassembly, apply a small piece of tape to the spiral cable and the steering column to keep them in alignment. 1. Disconnect the negative battery cable. 2. Remove the driver side airbag (See Driver Airbag Removal & Installation in Section 14 Restraints). 3. Remove the steering wheel lock nut. (Tighten: Steering wheel lock nut to 40 Nm) 4. Using the steering wheel puller, remove the steering wheel. 5. Remove the four retaining bolts (1). (Tighten: Steering column shroud screws to 10 1 Nm)
11
VISM110017
6. Remove the steering column shroud. 7. Installation is in the reverse order of removal. Installation Notes: The spiral cable could be damaged if installed in an improper position. Do not rotate the spiral cable quickly or beyond the limit of turns (this can cause the cable to snap). Verify the airbag system is operating properly after the repair is complete.
1140
ON-VEHICLE SERVICE
VISM110013
6. Remove the steering column shroud (See Steering Column Shroud Removal & Installation in Section 11 Steering). 7. Using the steering wheel puller, remove the steering wheel. 8. Remove the lower console side panel retaining bolts (1).
VISM080027
9. Remove the instrument panel lower shroud retaining bolts (1) and remove the lower shroud.
VISM150144
1141
ON-VEHICLE SERVICE
10. Disconnect the multi-function switch and the wiper and washer switch electrical connector. 11. Remove the spiral cable retaining bolts (1) and remove the spiral cable assembly with the switch.
VISM110004
12. Disconnect the ignition switch electrical connector. 13. Remove the intermediate shaft coupling bolt (1). (Tighten: Intermediate shaft coupling bolt to 30 3 Nm)
11
VISM110005
1142
ON-VEHICLE SERVICE
14. Remove the steering column upper retaining bolts (1). (Tighten: Steering column upper retaining bolts to 21 1 Nm)
VISM010006
15. Remove the steering column lower retaining bolts (1). (Tighten: Steering column lower retaining bolts to 25 3 Nm) Remove the steering column.
VISM110008
1143
ON-VEHICLE SERVICE
Installation Notes Hold the electronic power steering column in a fixed position (2) & (3) when installing the electronic power steering column.
CAUTION: Do not hold position (1) when removing or installing the electronic power steering column.
VISM110021
11
1144
ON-VEHICLE SERVICE
Electronic Power Steering Gear Removal & Installation Tie Rod Removal & Installation
1145
GENERAL INFORMATION
Description
The steering gear used is the rack-and-pinion type with power assist. It is mounted on the front suspension subframe. The outer ends of the outer tie rods attach to the front knuckles.
Operation
The steering wheel turns the pinion. The rack is a long flat bar with teeth on one side. The rack teeth mesh with the teeth on the pinion. Rotation of the pinion moves the rack from left to right and right to left. The tie rod then causes the wheels to turn to the left or right.
Specifications
Torque Specifications
DESCRIPTION Front Sub-Frame and Vehicle Body Connection Heat Shield Bolt Intermediate Shaft Coupling Bolt Lower Control Arm Pinch Bolt Lower Control Arm Front Mounting Bolt Lower Control Arm Rear Mounting Bolt Power Steering Hose Routing Clamp Bolt Power Steering Pressure Line To Steering Gear Power Steering Return Line To Steering Gear Pressure/Return Hose Routing Clamp Screws To Sub-frame Rear Sub-Frame And Vehicle Body Connection Rear Transaxle Mount Bolt Steering Gear Mounting Bolt Tie Rod End Nut Tie Rod Jam Nut Wheel Mounting Nut TORQUE (Nm) 110 10 10 1 30 3 120 10 120 10 120 10 10 1 50 5 50 5 10 1 120 10 90 5 120 10 35 3 35 3 110
11
Special Tools
1146
GENERAL INFORMATION
Electrical Schematics
Steering System (Page 1 of 1)
VISMW110004T
1147
11
1148
1149
ON-VEHICLE SERVICE
Electronic Power Steering Gear
Removal & Installation
WARNING!
Before servicing the steering column, the airbag system must be disarmed. Failure to do so may result in accidental deployment of the airbag and possible personal injury (See Airbag System Disarming Procedure in Section 14 Restraints).
NOTE : The following special tools are required to perform the repair procedure: CH-10002 - Ball Joint Separator 1. Disconnect the negative battery cable. 2. Position the front wheels of vehicle in the straight-ahead position and turn the ignition switch lock and lock the steering wheel. 3. Remove the lower console side panel retaining bolts (1).
VISM080027
4. Remove the instrument panel lower shroud retaining bolts (1) and remove the lower shroud.
11
VISM150144
1150
ON-VEHICLE SERVICE
5. Remove the intermediate shaft coupling bolt (1). (Tighten: Intermediate shaft coupling bolt to 30 3 Nm)
VISM110005
Reposition the floor carpeting to access the intermediate shaft coupling at the base of the steering column. Use a service jack to support the engine. Raise and support the vehicle. Remove the wheel mounting nuts and the tire and wheel assemblies from both sides. (Tighten: Wheel mounting nuts to 110 Nm) 10. Remove the exhaust pipe assembly mounting bolts (1). (Tighten: Exhaust pipe assembly mounting bolts to 25 3 Nm)
6. 7. 8. 9.
VISM110016
11. Remove the exhaust pipe assembly (See Exhaust Pipe Assembly Removal & Installation in Section 07 Exhaust).
1151
ON-VEHICLE SERVICE
12. Remove the wheel speed sensor (1). (Tighten: Wheel speed sensor bolts to 10 1 Nm)
VISM110003
13. Remove the lower control arm pinch bolts (1). (Tighten: Lower control arm pinch bolt 120 10 Nm)
to
11
VISM080029
14. On each side of the steering gear, remove the nut (1) attaching the outer tie rod end to the steering knuckle. (Tighten: Outer tie rod end nut to 35 3 Nm) NOTE : Using special tool CH-10002, separate the outer tie rod ends from both steering knuckles.
LTSM110034
1152
ON-VEHICLE SERVICE
15. Remove the rear transaxle mount bolts (2) and the transaxle mount bracket bolts (1). (Tighten: Rear transaxle mount bolts to 90 5 Nm) 16. Use a service jack to support the front sub-frame assembly.
VISM020003
17. Remove the front sub-frame retaining bolts (1). (Tighten: Front sub-frame bolts to 110 10 Nm) 18. Lower the service jack with the front sub-frame.
VISM100001
19. Remove the steering gear mounting bolts (1). (Tighten: Steering gear mounting bolts 120 10 Nm) 20. Remove the steering gear. 21. Installation is in the reverse order of removal. Installation Notes: After installing the new steering gear, perform a front end alignment procedure to reset the toe-in (See Front Wheel Alignment in Section 10 Suspension).
to
VISM110011
1153
ON-VEHICLE SERVICE
Tie Rod
Removal & Installation
NOTE : The following special tools are required to perform the repair procedure: CH-10002 - Ball Joint Separator 1. Raise and support the vehicle. 2. Remove the wheel mounting nuts and the wheel assembly. (Tighten: Wheel mounting nuts to 110 Nm) 3. Loosen the tie rod jam nut (1). (Tighten: Tie rod jam nut to 35 3 Nm)
VISM100021
4. Remove the nut (1) attaching the outer tie rod end to the steering knuckle. (Tighten: Outer tie rod end nut to 35 3 Nm) 5. Using special tool CH-10002, separate the outer tie rod end from the steering knuckle.
11
LTSM110034
6. Remove the outer tie rod end from the steering rack. NOTE : When removing the outer tie rod end, count the number of revolutions when removing. This will aid in installation, getting the toe setting close to where it needs to be when setting the final toe-in wheel alignment. 7. Installation is in the reverse order of removal. Installation Notes: After installing the new tie rod end, perform a front end alignment procedure to reset the toe-in (See Front Wheel Alignment in Section 10 Suspension).
1154
11-62 11-64
1155
GENERAL INFORMATION
Description
The Electronic Power Steering (EPS) control unit manages the electronic steering system. The EPS control unit receives vehicle speed information from the Engine Control Module (ECM) via the CAN bus, the EPS control unit also receives information from the steering shaft torque sensor to determine the amount of assist that is needed. At lower speeds, the EPS control unit will provide greater assist. At higher speeds, the EPS control unit will provide less assist. The power steering control unit is part of the steering column and is not serviced separately.
Operation
The Electronic Power Steering (EPS) control unit is self-monitoring and has the capability of setting DTCs. If a fault occurs in the system, the EPS control unit will set a DTC. Depending on the DTC set, the EPS control unit will enter into a safe mode and will provide a set amount of assist to the steering system.
11
1156
GENERAL INFORMATION
Electrical Schematics
Electronic Power Steering System (Page 1 of 1)
VISMW110004T
1157
GENERAL INFORMATION
11
1158
Ground Inspection
Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This added resistance can alter the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can effect the circuit. Perform the following when inspecting a ground connection: 1. Remove the ground bolt or screw. 2. Inspect all mating surface for tarnish, dirt, rust, etc. 3. Clean as required to assure good contact. 4. Reinstall bolt or screw securely. 5. Inspect for add-on accessories which may be interfering with the ground circuit. 6. If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are crimped to one eyelet, make sure no excess wire insulation has been crimped creating a bad ground.
1159
Diagnostic Tools
Diagnostic Scan Tool X-431 Digital Multimeter Jumper Wire
11
1160
1161
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. C1323 C1324 C1325 U1027 DTC DEFINITION ECU is faulted Module configuration failure Flash programming malfunction Missing ECU Message Electronic Power Steering (EPS) control unit detected an internal failure EPS control unit DTC DETECTION CONDITION POSSIBLE CAUSE
11
1162
Diagnostic Procedure
1.
CHECK DTC
>> Go to the next step. >> The conditions that caused this code to set are not present at this time (See Diagnostic Help for
more information).
2.
CHECK THE EPS CONTROL MODULE POWER SUPPLY AND GROUND CIRCUITS
Check the EPS control unit voltage supply circuit and ground circuits for an open, high resistance or a shorted condition.
3.
With the X-431 scan tool, read EPS control unit DTCs. Refer to DTC Confirmation Procedure.
>> Replace the EPS control unit. >> The system is now operating properly.
1163
11
VISMW110001T
1164
VISMW110002T
1165
C1902
Ignition switch: ON
C1901
11
Diagnostic Procedure
1.
Turn the ignition switch off. Loosen and retighten ground connectors B-203 and C-202 (See Ground Inspection in Section 11 Steering). Inspect the ground connection C-202 position (See Vehicle Wiring Harness Information - Main Harness in Section 16 Wiring). Inspect the ground connection B-203 position (See Vehicle Wiring Harness Information - Body Harness in Section 16 Wiring).
>> Go to the next step. >> Repair the ground connections if necessary.
1166
2.
Disconnect the EPS actuator electrical connector C-008. Turn the ignition switch on. Start the engine.
VISMD110001
Check the EPS actuator power supply circuit between terminal 1 in the EPS actuator electrical connector C-008 terminal side and ground.
3.
Connect the EPS actuator electrical connector. Start the engine, raise the engine speed to over 1000 RPM. Measure the charging system voltage with a multimeter at the battery positive and negative terminals.
1167
4.
CHECK BATTERY
Maintain the engine speed over 1000 RPM for a few minutes. Turn the ignition switch off. Measure the voltage drop with a multimeter between the battery positive and negative terminals while cranking the engine. Battery voltage should be more than approximately 9 V.
5.
Measure the resistance between the EPS actuator electrical connector terminal 1 and battery positive. Continuity should exist.
6.
Start the engine and raise the engine speed to over 1000 RPM. Measure the charging voltage with a multimeter at the battery positive and negative terminals.
11
7.
With the X-431 scan tool, read EPS control unit DTCs. Refer to DTC Confirmation Procedure.
>> Replace the EPS control unit. >> The system is now operating properly.
1168
ON-VEHICLE SERVICE
Power Steering Pump Removal & Installation Power Steering Fluid Reservoir Removal & Installation Power Steering Pressure and Return Hoses Removal & Installation
1169
GENERAL INFORMATION
Description
The power steering pump uses hydraulic pressure to operate the power steering gear. The power steering pump is a belt driven droop-flow type power steering pump.
Operation
The power steering pump is mounted to the engine and driven by the engine accessory drive belt. Power steering fluid enters the pump from the reservoir. The power steering fluid is then trapped between the pump vanes and moved to the high-pressure side of the pump creating a flow of fluid. The restriction of this flow by the steering gear creates the pressure that provides the steering assist.
Specifications
Torque Specifications
DESCRIPTION Power Steering Hose Routing Clamp Bolt Power Steering Pressure Line To Steering Gear Power Steering Return Line To Steering Gear Power Steering Pressure Line To Power Steering Pump Power Steering Return Line To Power Steering Pump Power Steering Pump Mounting Bolt Pressure/Return Hose Routing Clamp Bolt To Sub-frame Power Steering Pump Reservoir Line To Power Steering Pump TORQUE (Nm) 10 1 50 5 50 5 40 5 40 5 23 2 10 1 10 1
Fluid Specifications
DESCRIPTION Power Steering Fluid (ATF III) CAPACITY (L) 1.2
11
1170
Rattle Or Clunk
Chirp Or Squeal
Adjust or replace. Verify belt routing is correct. Fill to proper level. Reposition hose. Replace pump. Perform pump initial operation. Replace clamp. Replace O-ring. Fill to proper level. Repair if necessary.
Whine Or Growl
Scrubbing Or Knocking
Tire pressure. Wheel alignment. Lack of lubrication. High friction in steering gear. Ball joints binding.
1171
ON-VEHICLE SERVICE
Power Steering Pump
Removal & Installation
1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine). 3. Remove the high pressure line (1) and low pressure line (2) from the power steering pump (drain fluid from lines). (Tighten: High pressure line to power steering pump 40 5 Nm) (Tighten: Low pressure line to power steering pump 40 5 Nm)
BESM110011
4. Remove the three power steering pump mounting bolts (1). (Tighten: Power steering pump mounting bolts to 23 2 Nm) 5. Remove the power steering pump. 6. Installation is in the reverse order of removal.
11
LTSM110045
1172
ON-VEHICLE SERVICE
VISM110007
BESM110011
1173
ON-VEHICLE SERVICE
4. Remove the high pressure and low pressure lines (1) from the steering gear (drain fluid from lines). (Tighten: High pressure line to power steering gear 50 5 Nm) (Tighten: Low pressure line to power steering gear 50 5 Nm)
LTSM110007
5. Remove the pressure and return hoses mounting bracket bolts. (Tighten: Power steering lines routing clamp bolts to 10 1 Nm) 6. Remove the pressure and return hoses. 7. Installation is in the reverse order of the removal.
11
1174
BRAKES
12
page Base Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Antilock Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-87
CONTENTS
BASE BRAKES
GENERAL INFORMATION
Description Operation Specifications Special Tools Electrical Schematics 12-2 12-2 12-5 12-5 12-6 12-7 12-8 12-8 12-9 12-9 12-10 12-10 12-10 12-10 12-11 12-11 12-12 12-12 12-12 12-12 12-13 12-13 12-13 12-13 12-15 12-15 12-16 12-16 Rear Brake Caliper Description Operation Removal & Installation Front Brake Rotor Removal & Installation Inspection Rear Brake Rotor Removal & Installation Inspection Front Brake Pads Removal & Installation Inspection Rear Brake Pads Removal & Installation Inspection Brake Pedal Removal & Installation Rear Brake Backing Plate Removal & Installation 12-17 12-17 12-17 12-17 12-17 12-17 12-18 12-19 12-19 12-20 12-21 12-21 12-22 12-22 12-22 12-23 12-24 12-24 12-25 12-25 12-26 12-26 12-26 12-27 12-28 12-29 12-29 12-30 12-31
ON-VEHICLE SERVICE
Brake Bleeding Procedure Brake Bleeding Information Brake Bleeding Procedure Manual Bleeding Pressure Bleeding Master Cylinder Description Operation Removal & Installation Power Brake Booster Description Operation Removal & Installation Front Brake Caliper Description Operation Removal & Installation
12
UNIT REPAIR
Front Brake Caliper Disassembly Inspection Assembly Rear Brake Caliper Disassembly Inspection Assembly
121
GENERAL INFORMATION
Description
Base Brakes
VISM120001
The base brake system consists of the following components: Power brake booster (1) Master cylinder (2) Brake pedal (3) Disc brakes (front) (4) Parking brake (5) Brake tubes and hoses (6) Disc brakes (rear) (7)
122
GENERAL INFORMATION
Front Disc Brake
12
1 - Front Brake Rotor 2 - Front Wheel Hub Assembly 3 - Dust Board Bolt 4 - Dust Board
5 - Brake Caliper Assembly 6 - Front Wheel Knuckle 7 - Front Wheel Knuckle Bearing
VISM120002
The front disc brake assembly consists of the following major components: Caliper Caliper adapter bracket Brake pads Rotor
123
GENERAL INFORMATION
Rear Disc Brake
1 - Rear Brake Caliper Assembly 2 - Parking Brake Bracket 3 - Rear Parking Brake Assembly 4 - Rear Bearing
5 - Rear Brake Rotor 6 - Rear Axle Nut 7 - Rear Steering Knuckle Assembly
VISM120003
The rear disc brake assembly consists of the following major components: Caliper Caliper adapter bracket Brake pads Rotor Parking brake shoes
124
GENERAL INFORMATION
CAUTION: Use DOT 4 brake fluid or equivalent from a tightly sealed container. Do not use petroleum-based fluids, which would cause seal damage in the brake system. Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it off immediately with water. Never use gasoline, kerosene, alcohol, motor oil, transmission fluid or any fluid containing mineral oil to clean system components. These fluids damage rubber cups and seals. During service procedures, grease or any other foreign material must be kept off the caliper assembly, brake linings, brake rotor and external surfaces of the hub. When handling the brake rotor and caliper, be careful to avoid damaging the brake rotor and caliper, and scratching or nicking the brake shoe lining.
Operation
Applying the brake pedal uses lever action to push a rod into the brake booster, which through the use of vacuum, boosts the force of the rod and then transmits this force into the master cylinder. This produces hydraulic pressure in the master cylinder. On vehicles not equipped with an Antilock Brake System (ABS), the hydraulic pressure is transmitted by brake fluid through the brake tubes to the individual brake calipers or wheel cylinders. On vehicles equipped with ABS, the hydraulic pressure is transmitted by brake fluid through the brake tubes to the ABS Hydraulic Control Unit (HCU), which then distributes that pressure to the individual brake calipers and wheel cylinders. The brake calipers use hydraulic pressure to apply the brake pads. The application of the brake pads or shoes will cause the rotation of the wheels to slow or stop depending on how much brake pressure is applied. The parking brakes carry out the same function except that they are mechanically actuated by a cable that connects only to the rear brakes.
Specifications
Torque Specifications
DESCRIPTION Axle Shaft Hub Nut Brake Disc Mounting Bolt Brake Flex Hose Fitting Front Caliper Brake Pedal/Booster Mounting Nut Brake Tube Nut Disc Brake Caliper Adapter Bracket (To Knuckle) - Front Disc Brake Caliper Adapter Bracket (To Support) - Rear Disc Brake Caliper Guide Pin Bolt - Front Disc Brake Caliper Guide Pin Bolt - Rear Disc Brake Caliper Bleeder Bolt Fluid Reservoir Mounting Bolt Master Cylinder Mounting Nut Parking Brake Lever Mounting Nut Rear Hub and Bearing Nut Rear Dust Shield to Rear Knuckle Bolt Wheel Mounting Nut TORQUE (Nm) 270 20 81 17 1 22 1 10 1 85 5 85 5 22 1 22 1 10 1 11 2 25 2 30 5 230 10 63 1 110
12
125
GENERAL INFORMATION
Rotor Specifications
ROTOR THICKNESS 25 mm 10 mm MINIMUM ROTOR THICKNESS 23 mm 7 mm ROTOR THICKNESS VARIATION 0.005 mm 0.015 mm
Special Tools
Dial Indicator
126
GENERAL INFORMATION
Electrical Schematics
Brake System (Page 1 of 1)
12
VISMW120011T
127
128
Brake Noise
CONDITION Disc Brake Chirp POSSIBLE CAUSES Excessive brake rotor runout. Small metal particles Broken or missing spring clips. Caliper guide pin bolts loose. Missing abutment shims. Small metal particles CORRECTION Diagnose and correct as necessary. Replace brake pads Tighten guide pin bolts. Replace missing abutment shims. Replace brake pads. Inspect, correct or replace faulty component(s).
Disc Brake Rattle Or Clunk Disc Brake Squeak At Low Speed (While Applying Light Brake Pedal Effort) Scraping Or Whirring
Brake shoe linings. ABS wheel speed sensor hitting tone wheel.
Braking Concerns
CONDITION POSSIBLE CAUSES Obstruction of brake pedal. Low power brake booster assist. Glazed brake linings. Brake pad lining transfer to brake rotor. CORRECTION Inspect, remove or move obstruction. Refer to Power Brake Booster in this section. Resurface or replace brake rotors as necessary. Replace brake pads. Resurface or replace brake rotors as necessary. Replace brake pads. Check booster vacuum hose and engine tune for adequate vacuum supply. Bleed brakes. Isolate condition as rear or front. Resurface or replace brake rotors as necessary. Bleed brakes. Replace frozen piston or caliper. Bleed brakes. Inspect and clean, or replace pads/shoes. Repair source of contamination. Replace pinched line. Replace piston seal or brake caliper. See the Suspension section. Adjust rear parking brake shoes on vehicles with rear disc brakes.
Excessive Pedal Effort (Hard Pedal Cannot Skid Wheels) Excessive Pedal Travel (Vehicle Stops OK) Pedal Pulsates/Surges During Braking Pedal Is Spongy
Power brake booster runout (vacuum assist). Air in brake lines. Disc brake rotor has excessive thickness variation. Air in brake lines. Frozen brake caliper piston. Contaminated brake pad/shoe lining (most likely front lining). Pinched brake lines. Leaking piston seal. Suspension problem.
12
129
ON-VEHICLE SERVICE
Brake Bleeding Procedure
Brake Bleeding Information
WARNING!
When bleeding the brake system, wear safety glasses. A clear bleed tube must be attached to the bleeder screws and submerged in a clear container filled partially with clean brake fluid. Direct the flow of brake fluid away from yourself and the painted surfaces of the vehicle. Brake fluid at high pressure may come out of the bleeder screws when opened.
CAUTION: Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder reservoir. Use brake fluid or an equivalent from a fresh, tightly sealed container. Brake fluid must conform to DOT 4 specifications.
NOTE : During the brake bleeding procedure, be sure the brake fluid level remains close to the MAX level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add brake fluid as required. NOTE : Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding process. This will only increase the amount of air in the system and make additional bleeding necessary. Do not allow the master cylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air into the brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system.
1210
ON-VEHICLE SERVICE
Manual Bleeding
NOTE : To bleed the brakes manually, the aid of a helper will be required. Attach a clear plastic hose to the bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose.
BESM120001
1. 2. 3. 4. 5. 6. 7. 8. 9.
Turn the ignition switch off. Have a helper pump the brake pedal three or four times and hold it in the down position. With the pedal in the down position, open the bleeder screw at least one full turn. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir to make sure it does not go dry. Check and adjust brake fluid level to the MAX mark. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct.
Pressure Bleeding
NOTE : Follow pressure bleeder manufacturers instructions for use of pressure bleeding equipment. Attach the pressure bleeding equipment to the master cylinder. Attach a clear plastic hose to the bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose.
12
BESM120001
1. Turn the ignition switch off. 2. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 3. After approximately 120-240 ml of fluid have been bled through the brake circuit and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 4. Repeat this procedure at all the remaining bleeder screws. 5. Check and adjust brake fluid level to the MAX mark on the reservoir. 6. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary. 7. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct.
1211
ON-VEHICLE SERVICE
Master Cylinder
Description
The master cylinder body is an anodized aluminum casting. It has a machined bore to accept the master cylinder pistons and also has threaded ports with seats for hydraulic brake tube connections. The master cylinder has the brake fluid reservoir mounted on top of it and supplies brake fluid to the master cylinder as required. The brake fluid reservoir also feeds the clutch hydraulic circuit. The reservoir is made of clear plastic and it houses the brake fluid level switch.
Operation
When the brake pedal is pressed, the master cylinder pistons apply brake pressure through the chassis brake tubes to each brake assembly. The brake fluid reservoir supplies the brake hydraulic system with the necessary fluid to operate properly.
VISM120020
7. Remove the clamps (1) and remove the clutch actuator hose off the reservoir port.
VISM120006
1212
ON-VEHICLE SERVICE
8. Clean the area around where the master cylinder attaches to the power brake booster using a suitable brake cleaner such as Brake Parts Cleaner or an equivalent. 9. Remove the two nuts (1) attaching the master cylinder to the power brake booster. (Tighten: Master cylinder mounting nuts to 25 2 Nm)
VISM120013
10. Slide the master cylinder straight out of the power brake booster. 11. Installation is in the reverse order of removal. NOTE : After installation, bleed the master cylinder or bleed the whole brake system as necessary.
Operation
A vacuum line connects the check valve to engine source vacuum. The booster input rod extends through the dash panel and connects to the brake pedal.
VISM120021
1213
ON-VEHICLE SERVICE
3. Remove the spring-type cotter pin (2) and clevis pin (1) from the brake booster rod (3).
BESM120009
4. Remove the nuts (2) attaching the power brake booster to the dash panel. (Tighten: Brake pedal/Power brake booster mounting nuts to 25 Nm) 5. Slide the power brake booster (1) forward until its mounting studs clear the dash panel, then remove it through the engine compartment. 6. Installation is in the reverse order of removal.
VISM120014
1214
ON-VEHICLE SERVICE
12
LTSM120007
1 - Locating Guide Rod 2 - Dust Cap 3 - Brake Gasket 4 - Brake Lining Assembly 5 - Lining Damper 6 - Brake Caliper Bracket 7 - Brake Caliper Body
8 - Bleeding Screw 9 - Dust Cover 10 - Connecting Bolt Of Brake Caliper Body 11 - Piston Dust Cap 12 - Piston 13 - Piston Seal 14 - Brake Caliper Bracket Bolt
The calipers are a single piston type. The calipers are free to slide laterally on the anchor, this allows continuous compensation for lining wear. The calipers are directly bolted to the wheel hub with mounting bolts. The disc brake rotor dust shield is mounted to the hub.
1215
ON-VEHICLE SERVICE
Operation
When the brakes are applied, fluid pressure is exerted against the caliper piston. The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bores will be equal. Fluid pressure applied to the pistons is transmitted directly to the inboard brake pad. This forces the pad lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bores forces the caliper to slide inward on the slide pins. This action brings the outboard brake pad lining into contact with the outer surface of the disc brake rotor.
LTSM120009
5. Remove the front brake hose (2) from the front brake caliper. (Tighten: Front caliper brake hose to 17 1 Nm) 6. Remove the front caliper guide pin bolts (3). (Tighten: Front caliper guide pin bolts to 22 1 Nm) 7. Slide the front brake caliper (1) from the disc brake adapter bracket and remove.
VISM120023
8. Remove the disc brake adapter bolts (1) and remove the brake adapter bracket. (Tighten: Disc brake adapter bolts to 85 5 Nm)
VISM120024
1216
ON-VEHICLE SERVICE
9. Installation is in the reverse order of removal. Installation Notes: Completely retract the caliper piston back into the bore of the caliper. After installation bleed the caliper as necessary.
Operation
When the brakes are applied, fluid pressure is exerted against the caliper piston. The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bores will be equal. Fluid pressure applied to the pistons is transmitted directly to the inboard brake pad. This forces the pad lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bores forces the caliper to slide inward on the slide pins. This action brings the outboard brake pad lining into contact with the outer surface of the disc brake rotor.
12
8. Installation is in the reverse order of removal. Installation Notes: Completely retract the caliper piston back into the bore of the caliper. After installation bleed the caliper as necessary.
1217
ON-VEHICLE SERVICE
3. Remove the front brake rotor locating bolt (1). (Tighten: Front brake rotor locating bolt to 8 1 Nm)
VISM120028
4. Remove front caliper (2) and adapter (1) together (See Front Caliper Removal & Installation in Section 12 Brakes). 5. Slide the front brake rotor (3) off the hub and bearing. 6. Installation is in the reverse order of removal.
VISM120026
Inspection
Excessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This increases guide pin sleeve wear due to the tendency of the caliper to follow the rotor wobble.
BESM120004
CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness.
1218
ON-VEHICLE SERVICE
Rotor Runout
1. Install standard wheel mounting nuts, flat side to rotor, on all the wheel bolts (2). Progressively tighten the bolts in a crisscross pattern to 110 Nm. 2. Mount a dial indicator (1), with wheel, or equivalent, to the knuckle. Position the dial indicator wheel to contact the rotor braking surface approximately 10 mm from the outer edge of the rotor. 3. Slowly rotate the brake rotor (3) checking lateral runout, marking the low and high spots. Record these measurements. 4. Check and record the runout on the opposite side of the rotor in the same fashion, marking the low and high spots. 5. Compare runout measurement to specification. 6. If runout is in excess of specifications, check the lateral runout of the hub face.
VISM120016
ROTOR THICKNESS 25 mm
12
VISM120029
4. Remove rear caliper (1) and adapter (2) together (See Rear Caliper Removal & Installation in Section 12 Brakes). 5. Slide the rear brake rotor (3) off the hub and bearing.
VISM120017
1219
ON-VEHICLE SERVICE
6. Installation is in the reverse order of removal.
Inspection
Excessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This increases guide pin sleeve wear due to the tendency of the caliper to follow the rotor wobble.
BESM120004
CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness.
Rotor Runout
1. Install standard wheel mounting nuts, flat side to rotor, on all the wheel bolts (2). Progressively tighten the bolts in a crisscross pattern to 110 Nm. 2. Mount a dial indicator (1), with wheel, or equivalent, to the knuckle. Position the dial indicator wheel to contact the rotor braking surface approximately 10 mm from the outer edge of the rotor. 3. Slowly rotate the brake rotor (3) checking lateral runout, marking the low and high spots. Record these measurements. 4. Check and record the runout on the opposite side of the rotor in the same fashion, marking the low and high spots. 5. Compare runout measurement to specification. 6. If runout is in excess of specifications, check the lateral runout of the hub face.
VISM120016
ROTOR THICKNESS 10 mm
1220
ON-VEHICLE SERVICE
5. Remove the inboard brake pad from the caliper adapter bracket. 6. Remove the outboard brake pad from the caliper by prying the brake pad retaining clip over the raised area on the caliper. Slide the brake pad off of the brake caliper. 7. Installation is in the reverse order of removal. Installation Notes: Before installing brake pads, completely retract the caliper piston back into the bore of the caliper. After installation and before moving the vehicle, pump the brake pedal several times to set the pads to the brake rotor. Check and adjust the brake fluid level in the reservoir as necessary. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. After installation and before moving the vehicle, pump the brake pedal several times to set the pads to the brake rotor.
12
1221
ON-VEHICLE SERVICE
Inspection
Visually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators (if equipped) on the pads and the brake rotors. If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake pads from the vehicle. Measure the brake pad minimum thickness. Brake pads must be replaced when usable material on a brake pad lining measured at its thinnest point measures one millimeter or less. Replace both disc brake pads (inboard and outboard) at each caliper. It is also necessary to replace the pads on the opposite side of the vehicle as well as the pads failing inspection to maintain proper braking characteristics. If the brake pad assemblies do not require replacement, be sure to reinstall the brake pads in the original position from which they were removed.
LTSM120033
New Brake Pad Thickness 11 mm Check the front brake pad thickness.
VISM120018
1222
ON-VEHICLE SERVICE
5. Slide the rear brake pads off of the brake caliper adapter.
LTSM120018
Inspection
Visually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators (if equipped) on the pads and the brake rotors. If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake pads from the vehicle. Measure the brake pad minimum thickness. Brake pads must be replaced when usable material on a brake pad lining measured at its thinnest point measures one millimeter or less. Replace both disc brake pads (inboard and outboard) at each caliper. It is also necessary to replace the pads on the opposite side of the vehicle as well as the pads failing inspection to maintain proper braking characteristics. If the brake pad assemblies do not require replacement, be sure to reinstall the brake pads in the original position from which they were removed.
12
LTSM120033
New Brake Pad Thickness 10.2 mm Check the rear brake pad thickness.
1223
ON-VEHICLE SERVICE
Brake Pedal
Removal & Installation
1. Disconnect the negative battery cable. 2. Remove the instrument panel lower shroud retaining bolts (1) and remove the instrument panel lower shroud.
VISM150144
3. Disconnect the stop lamp switch electrical connector. 4. Remove the spring-type cotter pin (2) and clevis pin (1) from the brake booster rod (3).
BESM120009
5. Remove the nuts (3) attaching the brake pedal (1) and power brake booster to the dash panel. (Tighten: Brake pedal/Power brake booster mounting nuts to 25 5 Nm) 6. Remove the retaining nut (2) attaching the brake pedal (1) to the dash panel. (Tighten: Brake pedal/Power brake booster mounting nut to 25 5 Nm) 7. Remove the brake pedal (1). 8. Installation is in the reverse order of removal.
VISM120025
1224
ON-VEHICLE SERVICE
VISM120030
6. Remove four bolts (1) that mount rear brake backing plate to trailing link. (Tighten: Rear brake backing plate bolts to 63 1 Nm) 7. Remove the rear brake backing plate assembly.
VISM080035
12
1225
UNIT REPAIR
Front Brake Caliper
Disassembly
Before disassembling the brake caliper, clean and inspect it.
VISM120033
WARNING!
Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personal injury could result from such a practice. Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do not use high pressure. 1. Place a wooden block (1) in the caliper. 2. Apply low pressure compressed air to the caliper fluid inlet port in short spurts to force the piston out. 3. Remove the piston from the caliper.
VISM080034
4. Remove the dust boot from the piston and discard it.
CAUTION: Do not use a screwdriver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges.
LTSM120010
1226
UNIT REPAIR
5. Using a soft tool such as a plastic trim stick (1), work the piston seal (2) out of its groove in caliper piston bore. Discard the used seal.
BESM120003
6. Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth.
VISM120035
Inspection
1. Inspect both the piston and bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. 2. Remove deposits on the piston using a soft brass wire brush or a rough shop towel. Do not clean piston with a polishing or emery cloth because this will damage the chrome-plated surface. Replace the piston if the chrome plated surface is damaged. If the piston is jammed or if the cylinder bores are scored or rusted, replace the complete brake caliper. Remove small, light rust spots in the cylinder bore with a polishing cloth. Remove heavy rust spots in front of the groove for the piston seal using fine-grit emery paper (grit size 380 to 500). 3. Inspect the caliper guide sleeves for smooth operation. Repair and grease caliper sleeves as necessary.
12
VISM120033
1227
UNIT REPAIR
Assembly
NOTE : Always have clean hands when assembling a brake caliper. Always use fresh, clean brake fluid when assembling a brake caliper. Never use an old piston seal. Bleed the brakes as necessary. Perform the following procedure to assemble the brake caliper: 1. Lubricate the caliper piston, piston seals and piston bore with clean brake fluid. 2. Install the new piston seal into the seal groove. NOTE : Verify seal is fully seated into seal groove and not twisted.
LTSM120014
3. Install the new dust boot on the caliper piston and seat the dust boot lip into the piston groove. 4. Stretch the dust boot rearward to straighten the boot folds, then move the boot forward until the fold snaps into place.
LTSM120015
5. Install the piston into the caliper bore and press the piston down to the bottom of the caliper bore by hand or with the handle of a hammer as show direction. NOTE: Apply a small amount of air pressure into the caliper to help during assembly.
LTSM120016
CAUTION: When assembling, the force applied to the piston to seat it in the bore, must be applied uniformly to avoid cocking and binding of the piston.
6. Install the new caliper bleed screw. 7. Install the caliper (See Front Brake Caliper Removal & Installation in Section 12 Brakes).
1228
UNIT REPAIR
VISM120035
WARNING!
Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personal injury could result from such a practice. Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do not use high pressure. 1. Place a wooden block (1) in the caliper. 2. Apply low pressure compressed air to the caliper fluid inlet in short spurts to force the piston out. 3. Remove the piston from the caliper.
12
VISM080034
4. Remove the dust boot from the piston and discard it.
LTSM120010
1229
UNIT REPAIR
CAUTION: Do not use a screwdriver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges.
5. Using a soft tool such as a plastic trim stick (1), work the piston seal (2) out of its groove in caliper piston bore. Discard the used seal.
BESM120003
6. Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth.
VISM010012
Inspection
1. Inspect both the piston and bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. 2. Remove deposits on the piston using a soft brass wire brush or a rough shop towel. Do not clean piston with a polishing or emery cloth because this will damage the chrome-plated surface. Replace the piston if the chrome plated surface is damaged. If the piston is jammed or if the cylinder bores are scored or rusted, replace the complete brake caliper. Remove small, light rust spots in the cylinder bore with a polishing cloth. Remove heavy rust spots in front of the groove for the piston seal using fine-grit emery paper (grit size 380 to 500). 3. Inspect the caliper seal rings. Repair the seal rings as necessary.
VISM120034
1230
UNIT REPAIR
Assembly
NOTE : Always have clean hands when assembling a brake caliper. Always use fresh, clean brake fluid when assembling a brake caliper. Never use an old piston seal. Bleed the brakes as necessary. Perform the following procedure to assemble the brake caliper: 1. Lubricate the caliper piston, piston seals and piston bore with clean brake fluid. 2. Install the new piston seal into the seal groove. NOTE : Verify seal is fully seated into seal groove and not twisted.
LTSM120014
3. Install the new dust boot on the caliper piston and seat the dust boot lip into the piston groove. 4. Stretch the dust boot rearward to straighten the boot folds, then move the boot forward until the fold snaps into place.
LTSM120015
12
5. Install the piston into the caliper bore and press the piston down to the bottom of the caliper bore by hand or with the handle of a hammer. NOTE: Apply a small amount of air pressure into the caliper to help during assembly.
LTSM120016
CAUTION: When assembling, the force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston.
6. Install the new caliper bleed screw. 7. Install the caliper (See Front Brake Caliper Removal & Installation in Section 12 Brakes). Chery Automobile Co., Ltd.
1231
ANTILOCK BRAKES
GENERAL INFORMATION
Description Operation Specifications Special Tools Electrical Schematics Antilock Brake System (ABS) Module Connector Pin-Out Table 12-33 12-33 12-34 12-34 12-35 12-36 12-39 12-40 12-40 12-40 12-40 12-40 12-41 12-41 12-43 12-43 12-47 12-51 12-55 12-59 12-63 0X403406 - Front Right Wheel Speed Sensor Open 0X403706 - Rear Left Wheel Speed Sensor Open 0X900001 - 12 Volt System Supply Voltage - Above Maximum Threshold, 0X900002 - 12 Volt System Supply Voltage - Below Minimum Threshold 0Xf00003 - Control Module-Component Internal Failure 12-67 12-71
12-75 12-80 12-81 12-81 12-81 12-81 12-82 12-82 12-83 12-83 12-84 12-84 12-85 12-85 12-86 12-86
ON-VEHICLE SERVICE
Antilock Brake System (ABS) Bleeding Procedure ABS Bleeding Information ABS Bleeding Instructions Manual Bleeding Instructions Pressure Bleeding Instructions Antilock Brake System (ABS) Hydraulic Control Module Removal & Installation Yaw Rate Sensor Removal & Installation Front Wheel Speed Sensor Removal & Installation Rear Wheel Speed Sensor Removal & Installation
1232
GENERAL INFORMATION
Description
12
LTSM120040
This Antilock Brake System (ABS) uses components of the base brake system, but also features the following components: Hydraulic Control Unit (HCU) and Antilock Brake System (ABS) Module Wheel Speed Sensors (wheel speed sensor) - Four sensors (one sensor at each wheel making it a four-channel system) The purpose of the ABS is to prevent wheel lockup under braking conditions on virtually any type of road surface. Antilock braking is desirable because a vehicle that is stopped without locking the wheels retains directional stability and some steering capability. This allows the driver to retain greater control of the vehicle during braking.
1233
GENERAL INFORMATION
Operation
ABS Braking ABS operation is activated when the ABS hydraulic control module senses a wheel lock-up condition. If a wheel lock-up is detected during a brake application, the brake system enters the ABS mode. During ABS braking, hydraulic pressure in the four wheel circuits is modulated to prevent any wheel from locking. Each wheel circuit is designed with a set of electric solenoids to allow modulation. The system can build and release pressure at each wheel, depending on signals generated by the wheel speed sensors at each wheel and received at the ABS hydraulic control module. There are a few performance characteristics of the ABS that may at first seem abnormal, but in fact are normal. These characteristics are described below. If the electrical system malfunctions, the Fail-Safe function is activated, the ABS becomes inoperative and the ABS warning lamp turns on. During ABS operation, the brake pedal may vibrate lightly and a mechanical noise may be heard. This is normal. Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel, or snow-covered (fresh, deep snow) roads.
Specifications
Torque Specifications
DESCRIPTION ABS Mounting Bolt (To Bracket) ABS Mounting Bracket Bolt (To Frame) ABS Mounting Bracket Screw And Nut (To Frame) ABS Wheel Speed Sensor Head Mounting Bolt - Rear Brake Tube Nut Wheel Mounting Nut TORQUE (Nm) 10 1 20 2 20 2 10 1 15 3 110
1234
GENERAL INFORMATION
Special Tools
12
1235
GENERAL INFORMATION
Electrical Schematics
Antilock Brake System (Page 1 of 3)
VISMW120013T
1236
GENERAL INFORMATION
Antilock Brake System (Page 2 of 3)
12
VISMW120014T
1237
GENERAL INFORMATION
Antilock Brake System (Page 2 of 3)
VISMW120015T
1238
GENERAL INFORMATION
12
1239
Ground Inspection
Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This added resistance can alter the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can affect the circuit. Perform the following when inspecting a ground connection: 1. Remove the ground bolt or screw. 2. Inspect all mating surfaces for tarnish, dirt, rust, etc. 3. Clean as required to assure good contact. 4. Reinstall bolt or screw securely. 5. Inspect for add-on accessories which may be interfering with the ground circuit. 6. If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are crimped to one eyelet, make sure no excess wire insulation has been crimped creating a bad ground.
Diagnostic Tools
Diagnostic Scan Tool X-431 Digital Multimeter Jumper Wire
1240
12
1241
1242
12
VISMW120007T
1243
0X403A0A
RR wheel speed sensor Harness is open or shorted Bearing clearance ABS module
1244
Diagnostic Procedure
1.
With the scan tool select: View ABS Data Stream. With an assistant driving the vehicle, check the following data stream list items while driving the vehicle over 40 km/h (25 mph). Front Left Wheel Speed. Front Right Wheel Speed. Rear Left Wheel Speed. Rear Right Wheel Speed. With the scan tool, read active DTCs in the ABS module.
Is DTC 0X403A0A present and the Rear Right Wheel Speed signal normal?
Yes No
>> Go to the next step. >> See Diagnostic Help in Section 12 Brakes for more information on intermittent DTC troubleshooting.
CHECK AND ADJUST TIRE PRESSURE
2.
Turn ignition switch off. Check and adjust the tire pressure in the Rear Right tire (Check for a slow leak). Check and adjust all other tire pressures. Inspect for mismatched tires on the vehicle.
>> Repair Rear Right tire as necessary. >> Go to the next step.
CHECK CLEARANCE BETWEEN RR WHEEL SPEED SENSOR AND SENSOR RING
3.
Inspect the wheel speed sensor and sensor ring for the following conditions that would result in an incorrect signal: Damaged sensor Loose sensor Foreign material Check the clearance between RR wheel speed sensor and sensor ring. 1 - 2 mm should exist.
12
>> Go to the next step. >> Clean/replace the wheel speed sensor or sensor ring.
1245
4.
Inspect the RR wheel bearing for excessive runout or clearance before replacing the wheel bearing assembly. Replace the RR wheel bearing assembly (See Rear Hub and Bearing Removal & Installation in Section 09 Driveline & Axle).
WARNING!
To avoid personal injury or death, verify vehicle braking before road testing. Connect the module and sensor connectors. Road test the vehicle over 40 km/h (25 mph). NOTE : Vehicle must be driven above 40 km/h (25 mph) for fault setting conditions to be met. With the X-431 scan tool, read ABS DTCs.
>> Replace the ABS module (See ABS Module Removal & Installation in Section 12 Brakes). >> The system is now operating properly.
Reassemble the vehicle and road test to verify the customers complaint is repaired.
1246
12
VISMW120006T
1247
0X403A06
Diagnostic Procedure
1.
With the scan tool select: View ABS Data Stream. With an assistant driving the vehicle, check the following data stream list items while driving the vehicle over 40 km/h (25 mph). Front Left Wheel Speed. Front Right Wheel Speed. Rear Left Wheel Speed. Rear Right Wheel Speed. With the scan tool, read active DTCs in the ABS module.
Is DTC 0X403A06 present and the Rear Right Wheel Speed signal normal?
Yes No
>> Go to the next step. >> See Diagnostic Help in Section 12 Brakes for more information.
1248
2.
VISM120012
Turn ignition switch on. Check reference voltage between terminal 2 and ground in sensor connector B-022 with a digital multimeter.
Is approximately 11 V present?
Yes No
>> Go to the next step. >> Repair or replace the open circuit in
connector or harness.
VISMD120003
3.
12
VISMD120005
1249
4.
Turn ignition switch off. Disconnect ABS module connector. Check continuity between terminal 10 in ABS module connector B-015 and terminal 1 in RR wheel speed sensor B-022. Continuity should exist.
>> Go to the next step. >> Repair or replace the open circuit.
VISMD120008
5.
CHECK DTC
With the X-431 scan tool, read ABS module DTCs. Refer to DTC Confirmation Procedure.
>> Replace ABS module >> The system is now operating properly.
Erase all codes and test drive the vehicle to verify the repair is complete.
1250
12
VISMW120004T
1251
0X40310A
FL wheel speed sensor Harness is open or shorted Bearing clearance ABS module
1252
Diagnostic Procedure
1.
With the scan tool select: View ABS Data Stream. With an assistant driving the vehicle, check the following data stream list items while driving the vehicle over 40 km/h (25 mph). Front Left Wheel Speed. Front Right Wheel Speed. Rear Left Wheel Speed. Rear Right Wheel Speed. With the scan tool, read active DTCs in the ABS module.
Is DTC 0X40310A present and the Front Left Wheel Speed signal normal?
Yes No
>> Go to the next step. >> See Diagnostic Help in Section 12 Brakes for more information on intermittent DTC troubleshooting.
CHECK AND ADJUST TIRE PRESSURE
2.
Turn ignition switch off. Check and adjust the tire pressure in the left front tire (check for a slow leak). Check and adjust all other tire pressures. Inspect for mismatched tires on the vehicle.
>> Repair Front Left tire as necessary. >> Go to the next step.
CHECK CLEARANCE BETWEEN FL WHEEL SPEED SENSOR AND SENSOR RING
3.
Inspect the wheel speed sensor and sensor ring for the following conditions that would result in an incorrect signal: Damaged sensor Loose sensor Foreign material Check the clearance between FL wheel speed sensor and sensor ring. 1 - 2 mm should exist.
12
>> Go to the next step. >> Clean/replace the wheel speed sensor or sensor ring.
1253
4.
Inspect the FL wheel bearing for excessive runout or clearance before replacing the wheel bearing assembly. Replace the FL wheel bearing assembly (See Rear Hub and Bearing Removal & Installation in Section 09 Driveline & Axle).
WARNING!
To avoid personal injury or death, verify vehicle braking before road testing. Connect the module and sensor connectors. Road test the vehicle over 40 km/h (25 mph). NOTE : Vehicle must be driven above 40 km/h (25 mph) for fault setting conditions to be met. With the X-431 scan tool, read ABS DTCs.
>> Replace the ABS module (See ABS Module Removal & Installation in Section 12 Brakes). >> The system is now operating properly.
Reassemble the vehicle and road test to verify the customers complaint is repaired.
1254
12
VISMW120005T
1255
0X40340A
FR wheel speed sensor Harness is open or shorted Bearing clearance ABS module
1256
Diagnostic Procedure
1.
With the scan tool select: View ABS Data Stream. With an assistant driving the vehicle, check the following data stream list items while driving the vehicle over 40 km/h (25 mph). Front Left Wheel Speed. Front Right Wheel Speed. Rear Left Wheel Speed. Rear Right Wheel Speed. With the scan tool, read active DTCs in the ABS module.
Is DTC 0X40340A present and the Front Right Wheel Speed signal normal?
Yes No
>> Go to the next step. >> See Diagnostic Help in Section 12 Brakes for more information on intermittent DTC troubleshooting.
CHECK AND ADJUST TIRE PRESSURE
2.
Turn ignition switch off. Check and adjust the tire pressure in the front right tire (check for a slow leak). Check and adjust all other tire pressures. Inspect for mismatched tires on the vehicle.
>> Repair Front Right tire as necessary. >> Go to the next step.
CHECK CLEARANCE BETWEEN FR WHEEL SPEED SENSOR AND SENSOR RING
3.
Inspect the wheel speed sensor and sensor ring for the following conditions that would result in an incorrect signal: Damaged sensor Loose sensor Foreign material Check the clearance between FR wheel speed sensor and sensor ring. 1 - 2 mm should exist.
12
>> Go to the next step. >> Clean/replace the wheel speed sensor or sensor ring.
1257
4.
Inspect the FR wheel bearing for excessive runout or clearance before replacing the wheel bearing assembly. Replace the FR wheel bearing assembly (See Rear Hub and Bearing Removal & Installation in Section 09 Driveline & Axle).
WARNING!
To avoid personal injury or death, verify vehicle braking before road testing. Connect the module and sensor connectors. Road test the vehicle over 40 km/h (25 mph). NOTE : Vehicle must be driven above 40 km/h (25 mph) for fault setting conditions to be met. With the X-431 scan tool, read ABS DTCs.
>> Replace the ABS module (See ABS Module Removal & Installation in Section 12 Brakes). >> The system is now operating properly.
Reassemble the vehicle and road test to verify the customers complaint is repaired.
1258
12
VISMW120006T
1259
0X40370A
RL wheel speed sensor Harness is open or shorted Bearing clearance ABS module
1260
Diagnostic Procedure
1.
With the scan tool select: View ABS Data Stream. With an assistant driving the vehicle, check the following data stream list items while driving the vehicle over 40 km/h (25 mph). Front Left Wheel Speed. Front Right Wheel Speed. Rear Left Wheel Speed. Rear Right Wheel Speed. With the scan tool, read active DTCs in the ABS module.
Is DTC 0X40370A present and the Front Left Wheel Speed signal normal?
Yes No
>> Go to the next step. >> See Diagnostic Help in Section 12 Brakes for more information on intermittent DTC troubleshooting.
CHECK AND ADJUST TIRE PRESSURE
2.
Turn ignition switch off. Check and adjust the tire pressure in the rear left tire (check for a slow leak). Check and adjust all other tire pressures. Inspect for mismatched tires on the vehicle.
>> Repair Rear Left tire as necessary. >> Go to the next step.
CHECK CLEARANCE BETWEEN RL WHEEL SPEED SENSOR AND SENSOR RING
3.
Inspect the wheel speed sensor and sensor ring for the following conditions that would result in an incorrect signal: Damaged sensor Loose sensor Foreign material Check the clearance between RL wheel speed sensor and sensor ring. 1 - 2 mm should exist.
12
>> Go to the next step. >> Clean/replace the wheel speed sensor or sensor ring.
1261
4.
Inspect the RL wheel bearing for excessive runout or clearance before replacing the wheel bearing assembly. Replace the RL wheel bearing assembly (See Rear Hub and Bearing Removal & Installation in Section 09 Driveline & Axle).
WARNING!
To avoid personal injury or death, verify vehicle braking before road testing. Connect the module and sensor connectors. Road test the vehicle over 40 km/h (25 mph). NOTE : Vehicle must be driven above 40 km/h (25 mph) for fault setting conditions to be met. With the X-431 scan tool, read ABS DTCs.
>> Replace the ABS module (See ABS Module Removal & Installation in Section 12 Brakes). >> The system is now operating properly.
Reassemble the vehicle and road test to verify the customers complaint is repaired.
1262
12
VISMW120004T
1263
0X403106
Diagnostic Procedure
1.
With the scan tool select: View ABS Data Stream. With an assistant driving the vehicle, check the following data stream list items while driving the vehicle over 40 km/h (25 mph). Front Left Wheel Speed. Front Right Wheel Speed. Rear Left Wheel Speed. Rear Right Wheel Speed. With the scan tool, read active DTCs in the ABS module.
Is DTC 0X403106 present and the Front Left Wheel Speed signal normal?
Yes No
>> Go to the next step. >> Refer to Diagnostic Help for an intermittent fault.
1264
2.
VISMD120001
Turn ignition switch on. Measure reference voltage between terminal 2 and ground in sensor connector B-011 with a digital multimeter.
Is approximately 11 V present?
Yes No
>> Go to the next step. >> Repair or replace the open circuit in
connector or harness.
VISMD120003
3.
12
VISMD120005
1265
4.
Turn ignition switch off. Disconnect ABS module connector. Check continuity between terminal 28 in ABS module connector B-015 and terminal 1 in FL wheel speed sensor B-011. Continuity should exist.
>> Go to the next step. >> Repair or replace the open circuit.
VISMD120004
5.
CHECK DTC
With the X-431 scan tool, read ABS module DTCs. Refer to DTC Confirmation Procedure.
>> Replace ABS module >> The system is now operating properly.
Erase all codes and test drive the vehicle to verify the repair is complete.
1266
12
VISMW120005T
1267
0X403406
Diagnostic Procedure
1.
With the scan tool select: View ABS Data Stream. With an assistant driving the vehicle, check the following data stream list items while driving the vehicle over 40 km/h (25 mph). Front Left Wheel Speed. Front Right Wheel Speed. Rear Left Wheel Speed. Rear Right Wheel Speed. With the scan tool, read active DTCs in the ABS module.
Is DTC 0X403406 present and the Front Right Wheel Speed signal normal?
Yes No
>> Go to the next step. >> See Diagnostic Help in Section 12 Brakes for more information.
1268
2.
VISMD120001
Turn ignition switch on. Measure reference voltage between terminal 2 and ground in sensor connector B-020 with a digital multimeter.
Is approximately 11 V present?
Yes No
>> Go to the next step. >> Repair or replace the open circuit in
connector or harness.
VISMD120003
3.
12
VISMD120005
1269
4.
Turn ignition switch off. Disconnect ABS module connector. Check continuity between terminal 4 in ABS module connector B-015 and terminal 1 in FL wheel speed sensor B-020. Continuity should exist.
>> Go to the next step. >> Repair or replace the open circuit.
VISMD120006
5.
CHECK DTC
With the X-431 scan tool, read ECM DTCs. Refer to DTC Confirmation Procedure.
>> Replace ABS module >> The system is now operating properly.
Erase all codes and test drive the vehicle to verify the repair is complete.
1270
12
VISMW120006T
1271
0X403706
Diagnostic Procedure
1.
With the scan tool select: View ABS Data Stream. With an assistant driving the vehicle, check the following data stream list items while driving the vehicle over 40 km/h (25 mph). Front Left Wheel Speed. Front Right Wheel Speed. Rear Left Wheel Speed. Rear Right Wheel Speed. With the scan tool, read active DTCs in the ABS module.
Is DTC 0X403706 present and the Rear Left Wheel Speed signal normal?
Yes No
>> Go to the next step. >> See Diagnostic Help in Section 12 Brakes for more information.
1272
2.
VISM120012
Turn ignition switch on. Measure reference voltage between terminal 2 and ground in sensor connector B-021 with a digital multimeter.
Is approximately 11 V present?
Yes No
>> Go to the next step. >> Repair or replace open circuit in connector or harness.
VISMD120003
3.
12
VISMD120005
1273
4.
Turn ignition switch off. Disconnect ABS module connector. Check continuity between terminal 35 in ABS module connector B-015 and terminal 1 in RL wheel speed sensor B-021. Continuity should exist.
>> Go to the next step. >> Repair or replace the open circuit.
VISMD120007
5.
CHECK DTC
With the X-431 scan tool, read ABS module DTCs. Refer to DTC Confirmation Procedure.
>> Replace ABS module. >> The system is now operating properly.
Erase all codes and test drive the vehicle to verify the repair is complete.
1274
0X900001 - 12 Volt System Supply Voltage - Above Maximum Threshold 0X900002 - 12 Volt System Supply Voltage - Below Minimum Threshold
12
VISMW120002T
1275
VISMW120003T
1276
0X900001
0X900002
Diagnostic Procedure
12
1.
Turn ignition switch off. Loosen and retighten ground connections B-201 and B-202 (See Diagnosis & Testing Ground Inspection in Section 12 Brakes). Inspect the ground connections B-201 and B-202 position (See Vehicle Wiring Harness Information Body Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace the ground connections.
1277
2.
Turn ignition switch off. Disconnect ABS module electrical connector. Turn ignition switch on. Start engine.
Check ABS module power supply between terminal 7, 25, 33 and terminal 13, 38 in the ABS module electrical connector B-015 terminal side.
>> Replace the ABS module. >> If the voltage is less than 9 V, go to
step 3. If the voltage is more than 17 V, go to step 6.
VISMD120009
3.
Connect ABS module connector. Start the engine, raise the engine speed over 1000 rpm. Measure the charging voltage with a digital multimeter at battery positive and negative.
4.
Start the engine, raise the engine speed over 1000 rpm for a few minutes. Turn ignition switch off. Measure the voltage drop with the voltmeter at battery positive and negative while crank engine. Battery voltage should be more than approximately 9 V.
5.
Measure continuity between ABS module terminal 25 and battery positive. Continuity should exist.
1278
6.
Start the engine, raise the engine speed over 1000 rpm. Measure the charging voltage with a digital voltmeter at the battery positive and negative terminals.
7.
With the X-431 scan tool, read ABS module DTCs. Refer to DTC Confirmation Procedure.
>> Replace ABS module. >> The system is now operating properly.
12
1279
Diagnostic Procedure
1.
CHECK DTC
>> Go to the next step. >> The conditions that caused this code to set are not present at this time.
See Diagnostic Help in Section 12 Brakes for more information
2.
Check the ABS module supply voltage circuit and ground circuit for an open or high resistance or short.
>> Go to the next step. >> Repair or replace the circuit for an open, high resistance or short in harness and connectors.
CHECK DTC
3.
With the X-431 scan tool, read ABS module DTCs. Refer to DTC Confirmation Procedure.
>> Replace ABS module. >> The system is now operating properly.
Reassemble the vehicle and road test to verify the customers complaint is repaired.
1280
ON-VEHICLE SERVICE
Antilock Brake System (ABS) Bleeding Procedure
ABS Bleeding Information
WARNING!
When bleeding the brake system, wear safety glasses. A clear bleed tube must be attached to the bleeder screws and submerged in a clear container filled partially with clean brake fluid. Direct the flow of brake fluid away from yourself and the painted surfaces of the vehicle. Brake fluid at high pressure may come out of the bleeder screws when opened.
CAUTION: Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder reservoir. Use brake fluid or an equivalent from a fresh, tightly sealed container. Brake fluid must conform to DOT 4 specifications.
NOTE : During the brake bleeding procedure, be sure the brake fluid level remains close to the MAX level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add brake fluid as required. NOTE : Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding process. This will only increase the amount of air in the system and make additional bleeding necessary. Do not allow the master cylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air into the brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system.
12
1281
ON-VEHICLE SERVICE
BESM120001
1. 2. 3. 4. 5. 6. 7. 8. 9.
Turn the ignition switch off. Have a helper pump the brake pedal three or four times and hold it in the down position. With the pedal in the down position, open the bleeder screw at least one full turn. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir to make sure it does not go dry. Check and adjust brake fluid level to the MAX mark. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct.
BESM120001
1. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 2. After approximately 120-240 ml of fluid have been bled through the brake circuit and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 3. Repeat this procedure at all the remaining bleeder screws. 4. Check and adjust brake fluid level to the MAX mark on the reservoir. 5. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary. 6. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct.
1282
ON-VEHICLE SERVICE
VISM120022
7. Position the brake tubes as necessary without bending them. 8. Remove the ABS hydraulic control module from vehicle. 9. Remove the ABS mounting bolts and mounting bracket as necessary. (Tighten: ABS mounting bolts to 10 1 Nm) 10. Installation is in the reverse order of removal. Installation Notes: After installation connect the X-431 scan tool to initialize the ABS hydraulic control module and bleed the brake system (See Antilock Brake System (ABS) Bleeding Procedure in Section 12 Brakes).
12
1283
ON-VEHICLE SERVICE
VISM120005
1284
ON-VEHICLE SERVICE
VISM110003
12
1285
ON-VEHICLE SERVICE
VISM120012
5. Remove the rear wheel speed sensor (1). 6. Installation is in the reverse order of removal.
VISM080033
1286
PARKING BRAKE
GENERAL INFORMATION
Description Operation Specifications Special Tools Electrical Schematics 12-88 12-88 12-88 12-88 12-88 12-89 12-90 12-90 12-90 12-90
ON-VEHICLE SERVICE
Parking Brake Lever Removal & Installation Parking Brake Cable Removal & Installation Parking Brake Shoes Removal & Installation
12
1287
GENERAL INFORMATION
Description
The parking brakes consist of the following components: Hand-operated parking brake lever Parking brake cables (one each side) Parking brake controls
Operation
All vehicles are equipped with a center-mounted, hand-operated parking brake lever mounted between the front seats. A tensioner is built into the equalizer mounted on the end of the levers output cable. There is an individual parking brake cable for each rear wheel that joins a parking brake cable equalizer, attached to the parking brake lever, to the rear parking brakes. The parking brake cables are made of flexible steel cable.
Specifications
Torque Specifications
DESCRIPTION Parking Brake Cable Routing Clamp Bolt Parking Brake Cable Bracket Bolts Parking Brake Lever Nut Wheel Mounting Nut TORQUE (Nm) 10 1 10 1 30 5 110
Special Tools
1288
GENERAL INFORMATION
Electrical Schematics
Parking Brake System (Page 1 of 1)
12
VISMW120012T
1289
VISM120019
1290
VISM120027
6. Reach inside the vehicle and fully apply and release the parking brake. 7. With the parking brake lever in the fully applied (up) position, attempt to rotate the rear rotors by hand (to ensure that the parking brake shoes are working properly). 8. With the parking brake lever in the released (down) position, attempt to rotate the rear rotors by hand (to ensure that the parking brake shoes are not dragging). 9. Install both rear tire and wheel assemblies and the wheel mounting nuts. (Tighten: Wheel mounting nuts to 110 Nm) 10. Lower the vehicle.
12
1291
ON-VEHICLE SERVICE
Parking Brake Lever
Removal & Installation
1. Disconnect the negative battery cable. 2. Block the tire and wheel assemblies so the vehicle does not move once the vehicle parking brake lever is released. 3. Remove the center console (See Center Console Removal & Installation in Section 15 Body & Accessories). 4. Release and lower the parking brake lever. 5. Loosen the adjusting nut on the levers output cable, taking tension off parking brake cables. 6. Back the nut off until it is flush with the end of the output cable. 7. Remove the screws connecting the rear air outlet and bracket. 8. Remove the bolts connecting the bracket and floor plate and remove the bracket. 9. Remove the parking brake cables (1) from the parking brake cable equalizer (2).
BESM120011
10. Disconnect the electrical connector from the parking brake switch. 11. Remove the bolts (1) attaching the parking brake lever to the vehicle. (Tighten: Parking brake lever nuts to 30 5 Nm) 12. Remove the parking brake assembly (2). 13. Installation is in the reverse order of removal.
BESM120012
Installation Notes: After installation, adjust the parking brake cable as necessary (See Parking Brake Adjustment in Section 12 Brakes).
1292
ON-VEHICLE SERVICE
7. Remove the parking brake cables (1) from the parking brake cable equalizer (2). 8. Fold the rear carpeting forward to expose the parking brake cables at the end of the rear floor. 9. Remove the bolts connecting the parking brake cable bracket and floor plate, and remove the cable from the bracket. (Tighten: Parking brake cable bracket bolts to 10 1 Nm)
BESM120011
10. Raise and support the vehicle. 11. Remove the rear wheel mounting nuts and both rear tire and wheel assemblies. (Tighten: Wheel mounting nuts to 110 Nm) 12. Access and remove the parking brake shoes (See Parking Brake Shoes Removal & Installation in Section 12 Brakes). 13. Pull the parking brake cable bracket (1) from the support plate and parking brake cable clamp (2) from the rear trailing arm.
VISM080032
14. Remove the parking brake cable from the rear trailing arm (1). 15. Remove the parking brake cable with sealing grommet through the hole in the floor pan of the vehicle. 16. Installation is in the reverse order of removal.
12
VISM100024
Installation Notes: After installation, adjust the parking brake cable as necessary (See Parking Brake Adjustment in Section 12 Brakes).
1293
ON-VEHICLE SERVICE
LTSM120037
5. Remove the brake shoe hold-down springs (2) and pins (3). Rotate the pins 90 to disengage. 6. Remove the parking brake cable from the arm on the rear parking brake shoe. 7. Remove the brake shoes (5), adjuster (6) and lower return spring (4) as an assembly from the support plate. 8. Remove the lower return spring (4) and adjuster (6) from the shoes (5). 9. Remove the upper return spring (1). 10. Remove the parking brake shoes.
VISM080030
1294
ON-VEHICLE SERVICE
Installation Notes: Perform the following to measure and adjust parking brake shoes: 1. Using a brake measuring gauge or equivalent, measure the inside diameter of parking brake drum (1). 2. Place the brake measuring gauge over the parking brake shoes at their widest point.
BESM120024
3. Using the adjuster wheel, adjust the parking brake shoes until the linings on both parking brake shoes just touch the jaws on the brake measuring gauge. After installation, adjust the parking brake cable as necessary (See Parking Brake Adjustment in Section 12 Brakes).
LTSM120039
12
1295
13
page Manual/Automatic Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 System Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14 Air Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26 System Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-32
CONTENTS
ON-VEHICLE SERVICE
Manual/Automatic Temperature Control Module Removal & Installation
13
131
GENERAL INFORMATION
Description
VISM130002
132
GENERAL INFORMATION
Operation
VISM130001T
13
Specifications
Torque Specifications
DESCRIPTION All General Service Screws Evaporator House Bolt Expansion Valve Bolt Pipeline Stent Refrigerant Lines To A/C Accumulator Condenser Bolt Refrigerant Lines To A/C Compressor Bolt Refrigerant Lines Refrigerant Lines To A/C Evaporator Bolt TORQUE (Nm) 2 91 7.5 1 4 6 6 30 10 25
133
GENERAL INFORMATION
A/C Pressure Specifications
AMBIENT TEMPERATURE 15.5 C 21.1 C 26.6 C 32.2 C 37.7 C 43.3 C A/C HIGH SIDE PRESSURE 8.4 - 11.9 kgf/cm 120 - 170 psi
2
A/C LOW SIDE PRESSURE 1.9 - 2.1 kgf/cm2 28 - 31 psi 1.9 - 2.1 kgf/cm2 28 - 31 psi 1.9 - 2.1 kgf/cm2 28 - 31 psi 1.9 - 2.1 kgf/cm2 28 - 31 psi 1.9 - 2.4 kgf/cm2 28 - 35 psi 1.9 - 2.6 kgf/cm2 28 - 38 psi
10.5 - 17.5 kgf/cm2 150 - 250 psi 12.6 - 19.3 kgf/cm2 180 - 275 psi 14.0 - 21.8 kgf/cm2 200 - 310 psi 16.1 - 23 kgf/cm2 230 - 330 psi 18.9 - 25.3 kgf/cm2 270 - 360 psi
AMBIENT TEMPERATURE 35 C 30 C
A/C HIGH SIDE PRESSURE 1.4 - 1.8 MPa 1.3 - 1.8 MPa
A/C LOW SIDE PRESSURE 0.26 - 0.33 MPa 0.26 - 0.33 MPa
Special Tools
134
GENERAL INFORMATION
Electrical Schematics
Climate Control System (Page 1 of 5)
13
VISMW130001T
135
GENERAL INFORMATION
Climate Control System (Page 2 of 5)
VISMW130002T
136
GENERAL INFORMATION
Climate Control System (Page 3 of 5)
13
VISMW130003T
137
GENERAL INFORMATION
Climate Control System (Page 4 of 5)
VISMW130004T
138
GENERAL INFORMATION
Climate Control System (Page 5 of 5)
13
VISMW130005T
139
1310
Normal Pressures, But A/C Performance Test Air Temperatures At Center Panel Outlet Are Too High
The Low Side Pressure Is Normal Or Slightly Low, And The High Side Pressure Is Too Low
The Low Side Pressure Is Normal Or Slightly High, And The High Side Pressure Is Too High
Condenser air flow restricted. Inoperative cooling fan. Refrigerant system overcharged. Air in the refrigerant system. Engine overheating.
13
The Low Side Pressure Is Too High, And The High Side Pressure Is Too Low
Accessory drive belt slipping. Faulty compressor. Restricted refrigerant flow through the refrigerant lines. Restricted refrigerant flow through the A/C accumulator. Restricted refrigerant flow through the condenser.
The Low Side Pressure Is Too Low, And The High Side Pressure Is Too High.
1311
Heater Performance
Engine coolant is delivered to the heater core through heater hoses. With the engine idling at normal operating temperature, set the temperature control knob in the full hot position, the mode control switch knob in the floor heat position, and the blower motor switch knob in the highest speed position. Using a test thermometer, check the temperature of the air being discharged at the HVAC housing floor outlets. Compare the test thermometer reading to the heater performance chart. HEATER PERFORMANCE Ambient Air Temperature Minimum Air Temperature at Floor Outlet 15.5 C (60 F) 62.2 C (144 F) 21.1 C (70 F) 63.8 C (147 F) 26.6 C (80 F) 65.5 C (150 F) 32.2 C (90 F) 67.2 C (153 F)
Both of the heater hoses should be hot to the touch. The coolant return heater hose should be slightly cooler than the coolant supply heater hose. If the return hose is much cooler than the supply hose, locate and repair the engine coolant flow obstruction in the cooling system.
Mechanical Problems
Possible locations or causes of insufficient heat: An obstructed cowl air intake. Obstructed heater system outlets. A blend door not functioning properly. An air-bound system.
Temperature Control
If the heater outlet air temperature cannot be adjusted with the temperature control knob(s) on the HVAC control panel, the following could require service: The HVAC control panel. The blend door actuator(s). The wire harness circuits for the HVAC control panel or the blend door actuator(s). The blend door(s). Improper engine coolant temperature.
1312
ON-VEHICLE SERVICE
Manual/Automatic Temperature Control Module
Removal & Installation
1. Disconnect the negative battery cable. 2. Remove the lower console (See Lower Console Removal & Installation in Section 15 Body & Accessories). 3. Remove the center control panel bezel retaining screws (1).
VISM150001
Temperature
VISM130018
5. Remove the Manual/Automatic Temperature Control module. 6. Installation is in the reverse order of removal.
13
1313
SYSTEM CONTROLS
GENERAL INFORMATION
Description Operation Specifications Special Tools 13-15 13-15 13-15 13-19 13-19 13-20 13-20 13-20 13-21 13-21 13-21 Mode Door Actuator Removal & Installation Defrost Door Actuator Removal & Installation Recirculation Door Actuator Removal & Installation Blower Control Module Removal & Installation Inside Temperature Sensor Removal & Installation 13-22 13-22 13-22 13-22 13-23 13-23 13-24 13-24 13-25 13-25
ON-VEHICLE SERVICE
Blend Door Actuator Removal & Installation
1314
GENERAL INFORMATION
Description
This vehicle is equipped with a common Heating, Ventilation and Air Conditioning (HVAC) housing assembly. The system combines air conditioning, heating, and ventilating capabilities in a single unit housing mounted under the instrument panel. The driver can choose the following functions from the HVAC control panel: The inside temperature The speed of the blower Five different modes of operation A/C compressor clutch operation Recirculation door position NOTE : To maintain the performance level of the HVAC system, the engine cooling system must be properly maintained. Any obstructions in front of the radiator or A/C condenser will reduce the performance of the A/C and engine cooling systems.
Operation
1 2 3 4
Temperature Control Dial A/C Control Switch Blower Speed Control Dial Recirculation Control Switch
5 6
13
VISM130019
1315
GENERAL INFORMATION
TEMPERATURE CONTROL DIAL
The Temperature Control Dial increases or decreases the interior set temperature.
DEFROSTER SWITCH
The Defroster Switch causes the air outlet doors to move to the defrost position. Also, when the Defroster Switch is selected, outside air is drawn into the cabin and the A/C compressor is energized.
1316
GENERAL INFORMATION
Air Discharge
Air Flow Discharge
13
Air is directed from the outlets in the instrument panel. Each of these outlets can be individually adjusted to direct the flow of air. Air is directed from both the instrument panel outlets, floor outlets and defrost. A slight amount of air is also directed through the side window demister outlets. Air is directed from the floor outlets. A slight amount of air is directed through the defrost and side window demister outlets.
LTSM130012
1. Panel Mode
4. Mix Mode
Air is directed from the floor, defrost and side window demister outlets. This mode works best in cold or snowy conditions. Air is directed from the windshield and side window demister outlets. Use this setting when necessary to defrost your windshield and side windows.
2. Bi-Level Mode
5. Defrost Mode
3. Floor Mode
1317
GENERAL INFORMATION
Air Distribution Doors
1 - Recirculation Door
2 - Defogger Door
3 - Blend Door
4 - Mode Door
VISM130003
1318
GENERAL INFORMATION
Specifications
Torque Specifications
DESCRIPTION All General Service Screw Blend Door Actuator Screw Mode Door Actuator Screw Defrost Door Actuator Screw Recirculation Door Actuator Screw TORQUE (Nm) 2 2 2 2 2
Special Tools
13
1319
Temperature Control
If the heater outlet air temperature cannot be adjusted with the temperature control knob(s) on the HVAC control panel, the following could require service: The HVAC control panel. The blend door actuator(s). The wire harness circuits for the HVAC control panel or the blend door actuator(s). The blend door(s). Improper engine coolant temperature.
1320
ON-VEHICLE SERVICE
Blend Door Actuator
Removal & Installation
1. Remove the instrument panel (See Instrument Panel Removal & Installation in Section 15 Body & Accessories). 2. Remove the HVAC housing assembly (See HVAC Housing Assembly Removal & Installation in Section 13 Heating & Air Conditioning). 3. Remove the rod connected to the blend door actuator. 4. Disconnect the blend door actuator electrical connector. 5. Remove the screws (1) connecting the blend door actuator to the bracket. (Tighten: Blend door actuator screws to 2 Nm)
VISM130009
6. Installation is in the reverse order of removal. Installation & Inspection: Turn the ignition switch to the ACC position. Start the engine and turn on the air conditioner. Set the air conditioner temperature adjusting knob to HOTTEST or COLDEST. Close the air conditioner panel until the motor stops. Adjust the mixing damper manually to HOTTEST or COLDEST position according to the status. Adjust the rod to the proper position to connect to the actuator.
13
1321
ON-VEHICLE SERVICE
VISM130010
5. Remove the mode door actuator. 6. Installation is in the reverse order of removal. Installation & Inspection: Turn the ignition switch to the ACC position. Start the engine and turn on the air conditioner. Close the air conditioner panel until the motor stops. Adjust the rod to the proper position to connect to the actuator.
1322
ON-VEHICLE SERVICE
4. Remove the screws (1) connecting the defrost door actuator to the bracket. (Tighten: Defrost door actuator screws to 2 Nm)
VISM130011
5. Remove the defrost door actuator. 6. Installation is in the reverse order of removal.
13
VISM130020
1323
ON-VEHICLE SERVICE
CAUTION: Do not operate the blower motor with the blower motor resistor removed from the circuit. Failure to take this precaution can result in vehicle damage.
1. Disconnect the negative battery cable. 2. Remove the instrument panel (See Instrument Panel Removal & Installation in Section 15 Body & Accessories). 3. Remove the HVAC Housing assembly (See HVAC Housing Assembly Removal & Installation in Section 13 Heating & Air Conditioning). 4. Disconnect the blower control module electrical connector. 5. Remove the screw (1) attaching the blower motor module to the evaporator housing.
VISM130006
6. Remove the blower control module. 7. Installation is in the reverse order of removal.
1324
ON-VEHICLE SERVICE
VISM150144
4. Remove the inside temperature sensor (1) on the left lower panel.
VISM130025
5. Disconnect the inside temperature sensor electrical connector. 6. Remove the inside temperature sensor from the HVAC housing assembly. 7. Installation is in the reverse order of removal.
13
1325
AIR DISTRIBUTION
GENERAL INFORMATION
Description Operation Specifications Special Tools 13-27 13-27 13-27 13-27 13-28 13-29 13-29 13-29 13-29
ON-VEHICLE SERVICE
HVAC Housing Assembly Removal & Installation Blower Motor Description Operation Removal & Installation
1326
GENERAL INFORMATION
Description
All models are equipped with a common Heating, Ventilation and Air Conditioning (HVAC) housing assembly that combines A/C and heating capabilities into a single unit mounted within the passenger compartment. The HVAC housing assembly consists of three separate housings: HVAC housing The HVAC housing is mounted to the dash panel behind the instrument panel and contains the A/C evaporator. The HVAC housing has mounting provisions for the air inlet housing, blower motor and the air distribution housing. Air distribution housing The air distribution housing is mounted to the rear of the HVAC housing and contains the heater core, blend-air and mode-air doors and door linkage. Air inlet housing The air inlet housing is mounted to the passenger side end of the HVAC housing. The air inlet housing contains the recirculation-air door and actuator.
Operation
The A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an A/C evaporator to cool and dehumidify the incoming air prior to blending it with the heated air. A temperature control determines the discharge air temperature by operating the temperature control cable, which moves the blend-air door. This allows an almost immediate control of the output air temperature of the system. The mode door cable operates the mode-air doors which direct the flow of the conditioned air out the various air outlets, depending on the mode selected. When equipped with A/C, the recirculation door actuator operates the recirculation-air door which closes off the fresh air intake and recirculates the air already inside the vehicle. The electric recirculation door actuator and the blower motor are connected to the vehicle electrical system by the instrument panel wire harness. The blower motor controls the velocity of air flowing through the HVAC housing assembly by spinning the blower wheel within the HVAC housing at the selected speed by use of the blower motor resistor, which is located in the dash panel in the engine compartment. The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors. The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator.
Specifications
Torque Specifications
DESCRIPTION All General Service Screw Evaporator House Bolt Expansion Valve Bolt Pipeline Stent Refrigerant Lines To A/C Accumulator Condenser Bolt Refrigerant Lines To A/C Compressor Bolt Refrigerant Lines Refrigerant Lines To A/C Evaporator Bolt TORQUE (Nm) 2 91 7.5 1 4 6 6 30 10 25
13
1327
GENERAL INFORMATION
Special Tools
1328
13
1329
ON-VEHICLE SERVICE
HVAC Housing Assembly
Removal & Installation
1. Evacuate the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating and Air Conditioning). 2. Disconnect heater core hoses (1).
VISM130024
3. Remove the instrument panel (See Instrument Panel Removal & Installation in Section 15 Body). 4. Remove the HVAC housing assembly retaining nuts (1) in the engine compartment.
VISM130008
5. Remove the HVAC housing assembly retaining bolt (1) from the instrument panel. (Tighten: Evaporator assembly retaining bolt to 25 2 Nm) 6. Disconnect the electrical connector (2).
VISM130016
7. Remove the HVAC housing assembly. 8. Installation is in the reverse order of removal.
1330
ON-VEHICLE SERVICE
Installation Notes: Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Recharge the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating and Air Conditioning).
Blower Motor
Description
The blower motor is mounted in the HVAC housing. The following are blower motor functions: The blower motor will operate whenever the ignition switch is in the ON position and the blower motor control is in any position except Off. The blower motor can be accessed for service from underneath the instrument panel. The blower motor and blower motor wheel are factory balanced as an assembly and cannot be adjusted or repaired and must be replaced if found inoperative or damaged.
Operation
The blower motor is used to control the velocity of air moving through the HVAC housing by spinning the blower wheel within the HVAC air inlet housing at the selected speed. The blower motor is a 12-volt, direct current (DC) motor mounted within a plastic housing with an integral wire harness connector. The blower wheel is secured to the blower motor shaft and is positioned within the air inlet housing on the passenger side of the HVAC housing.
13
VISM130005
3. Pull out the blower motor. 4. Installation is in the reverse order of removal.
1331
SYSTEM PLUMBING
GENERAL INFORMATION
Description Operation Specifications Special Tools 13-33 13-33 13-33 13-33 13-34 13-35 13-35 13-35 13-36 13-36 13-37 13-37 13-37 13-38 13-38 13-39 13-39 13-39 13-39 Evaporator Description Operation Removal & Installation Condenser Description Operation Removal & Installation Accumulator Description Operation Removal & Installation Liquid Line Description Operation Removal & Installation Suction Line Description Removal & Installation Heater Core Removal & Installation 13-41 13-41 13-41 13-41 13-41 13-41 13-41 13-42 13-42 13-42 13-42 13-43 13-43 13-43 13-43 13-43 13-45 13-45 13-45 13-47 13-47
ON-VEHICLE SERVICE
A/C System Evacuation and Recharge Connecting Refrigerant Recovery/ Recycling Station A/C System Evacuation A/C System Recharge Compressor Description Operation Removal & Installation
1332
GENERAL INFORMATION
Description
The A/C refrigerant lines and pipes are used to carry the refrigerant between the various A/C system components. Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire A/C system and can reduce the flow of refrigerant within the system.
Operation
High pressure is produced in a refrigerant system when the A/C compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. Depending on vehicle, model and market application, refrigerant lines are connected to each other or other A/C system components with block-type or quick-connect type fittings. To ensure the integrity of the refrigerant system, O-rings and/or gaskets may be used to seal the refrigerant system connections. The refrigerant lines and hoses cannot be repaired and must be replaced if leaking or damaged.
WARNING!
The A/C system contains refrigerant under high pressure. Repairs should only be performed by qualified service personnel. Serious or fatal injury may result from improper service procedures. If an accidental A/C system discharge occurs, ventilate the work area before resuming service. Large amounts of refrigerant released in a closed work area will displace the oxygen and cause suffocation and serious or fatal injury.
CAUTION: Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12 equipment or parts on an R-134a A/C system. These refrigerants are not compatible and damage to the A/C system will result. Do NOT run the engine while using a vacuum pump on the A/C system or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head pressure and can cause compressor noise and A/C system failure.
Specifications
Torque Specifications
DESCRIPTION A/C Compressor Bracket Bolt A/C Compressor Line Bolt TORQUE (Nm) 40 20
13
1333
GENERAL INFORMATION
A/C Oil Specifications
DESCRIPTION Compressor Condenser Evaporator Accumulator ML 150 30 30 20
Special Tools
1334
13
1335
CAUTION: A leak detector only designed for R-12 refrigerant will not detect leaks in an R-134a refrigerant system.
1336
ON-VEHICLE SERVICE
A/C System Evacuation and Recharge
Connecting Refrigerant Recovery/Recycling Station
13
VISM130026
WARNING!
The A/C system is under high pressure, use caution when working on the A/C system.
1337
ON-VEHICLE SERVICE
1. Connect the refrigerant recovery/recycling station to the vehicles high and low side A/C line connectors. NOTE: The refrigerant recovery/recycling station blue connector (1) is connected to the A/C low side fitting and the Red connector (2) is connected to the A/C high side fitting.
VISM130027
CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process.
1. Evacuate the refrigerant system (See A/C System Evacuation And Recharge In Section 13 Heating & Air Conditioning). 2. A manifold gauge set and an R-134a refrigerant recovery/recycling/refrigerant recovery/recycling station that meets SAE standard J2210 should be connected to the refrigerant system. 3. Open both the suction and discharge valves, then open the charge valve to allow the refrigerant to flow into the system.
1338
ON-VEHICLE SERVICE
4. When the transfer of refrigerant has stopped, close both the suction and discharge valves. 5. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is operating and the blower motor is running at its lowest speed setting. Run the engine at a steady high idle (approx. 2000 RPM). 6. Open the low-pressure valve to allow the remaining refrigerant to transfer to the refrigerant system.
WARNING!
Take care not to open the discharge (high pressure) valve at this time. Failure to follow this warning could result in possible personal injury or death. 7. Disconnect the refrigerant recovery/recycling station and manifold gauge set from the refrigerant system service ports. 8. Reinstall the caps onto the refrigerant system service ports.
Compressor
Description
The A/C system uses a 7-piston incline-disk compressor. The compressor is a variable displacement compressor. The variable displacement compressor has a swash plate that rotates to reciprocate pistons, which compress refrigerant. The variable displacement compressor changes the swash plate angle to change the refrigerant displacement. The variable displacement compressor manages displacement by controlling refrigerant differential pressure before and after a throttle at the discharge side; achieving precise cooling capability in accordance with the cabin environment and driving conditions.
CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage.
NOTE : The compressor drive hub and the pulley and bearing assembly cannot be serviced separately from the A/C compressor. In the event of drive hub or pulley and bearing assembly damage or failure, the A/C compressor, drive hub and pulley and bearing must be replaced as an assembly.
Operation
The A/C compressor is controlled by the Engine Control Module (ECM), depending on engine application. The ECM calculates compressor displacement required by A/C system load and demand by monitoring vehicle speed, A/C high side pressure, engine speed, evaporator temperature, accelerator pedal position, ambient temperature and A/Cheater request signals. The ECM then sends a pulse width modulated signal to the A/C compressor control solenoid to increase or decrease refrigerant flow through an orifice located within the compressor housing. The amount of refrigerant allowed to pass through the orifice in the compressor determines the head pressure which controls the angle of the swash plate, which in turn, determines the amount of compressor displacement. When there is no demand for A/C, the swashplate is adjusted to nearly a zero degree angle, which removes compressor torque drag from the engine. NOTE : The A/C compressor cannot be repaired and it must be replaced if found inoperative or damaged. If an internal failure of the A/C compressor has occurred, the A/C accumulator and the A/C liquid line must also be replaced.
13
1339
ON-VEHICLE SERVICE
CAUTION: The A/C accumulator and the A/C liquid line must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C accumulator and the A/C liquid line can cause serious damage to the replacement A/C compressor.
NOTE : When replacing multiple A/C system components, determine how much oil should be removed from the new A/C compressor. NOTE : Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. 1. Evacuate the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Conditioning). 2. Disconnect the A/C compressor electrical connector. 3. Remove the engine drive belt (See Drive Belt Removal & Installation in Section 02 Engine). 4. Remove the A/C compressor line bolt (1) from the A/C compressor. (Tighten: A/C compressor line bolts to 20 Nm) NOTE: After removing the A/C lines, plug the A/C lines to prevent any debris from entering the A/C system.
VISM130017
5. Remove the A/C compressor mounting bolts (1). 6. Remove the A/C compressor assembly.
VISM130004
7. Installation is in the reverse order of removal. Installation Notes: Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Recharge the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Conditioning).
1340
ON-VEHICLE SERVICE
Evaporator
Description
The evaporator coil is located in the HVAC housing, under the instrument panel. The evaporator coil is positioned in the HVAC housing so that all air that enters the housing must pass over the fins of the evaporator before it is distributed through the system ducts and outlets. However, air passing over the evaporator coil fins will only be conditioned when the compressor is engaged and circulating refrigerant through the evaporator coil tubes.
Operation
Refrigerant enters the evaporator from the orifice tube as a low-temperature, low-pressure liquid. As air flows over the fins of the evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas before it leaves the evaporator. The evaporator core housing directs airflow from the blower motor through the evaporator core and heater core. All airflow from the blower motor passes through the evaporator core. The airflow is then directed through or around the heater core by the temperature blend door(s).
VISM130021
5. Installation is in the reverse order of removal. Installation Notes: Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Recharge the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Conditioning).
13
Condenser
Description
The condenser is located in the air flow in front of the engine cooling radiator. The condenser transforms the refrigerant from a gas into a liquid. It is attached to the vehicle with bolts and the A/C lines with fittings.
Operation
When the refrigerant gas releases its heat, it condenses. When the refrigerant leaves the condenser, it has become a high-pressure liquid refrigerant. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the air conditioning system. Therefore, it is important that there are no objects placed in front of the radiator grille openings in the front of the vehicle or foreign material on the condenser fins that might obstruct proper Chery Automobile Co., Ltd.
1341
ON-VEHICLE SERVICE
air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or condenser service.
VISM130015
7. Remove the condenser from the engine compartment. 8. Installation is in the reverse order of removal. Installation Notes: Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Recharge the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Conditioning).
Accumulator
Description
The accumulator is connected directly to the evaporator outlet and stores excess liquid refrigerant. Accumulators are used on systems that use an orifice tube to meter refrigerants into the evaporator.
Operation
The primary function of the accumulator is to isolate the compressor from any damaging liquid refrigerant. The accumulator removes debris and moisture from the air conditioning system.
1342
ON-VEHICLE SERVICE
2. Evacuate the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Conditioning). 3. Remove the nuts (2) connect the suction lines to accumulator. 4. Remove the accumulator mounting bolts (1).
VISM130014
5. Remove the accumulator. Remove and discard the O-ring seals and gaskets. NOTE: After removing the A/C lines, plug the A/C lines to prevent any debris from entering the A/C system. 6. Installation is in the reverse order of removal. Installation Notes: Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Recharge the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Conditioning).
13
Liquid Line
Description
The A/C liquid line connects the A/C condenser to the A/C accumulator and the A/C accumulator to the A/C evaporator.
Operation
The high pressure A/C liquid line is the refrigerant line that carries refrigerant from the A/C condenser to the A/C accumulator. Air conditioning hoses are designed to control liquid and gas at high pressures and temperatures. The hoses are usually flexible and manufactured with special metal fittings at the ends to prevent leaks and provide a sure seal and connection between components.
1343
ON-VEHICLE SERVICE
3. Remove the bolt (2) that secures the A/C liquid and suction line assembly to the A/C expansion valve. 4. Remove the two retaining clamps (1) for the refrigerant lines..
VISM130013
5. Remove the nut (1) connecting the liquid line to the condenser.
VISM130023
6. 7. 8. 9.
Remove the A/C liquid line assembly from the A/C evaporator to compressor and remove and discard the seals. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports. Remove the A/C liquid line assembly from accumulator to condenser and from accumulator to evaporator. Installation is in the reverse order of removal.
1344
ON-VEHICLE SERVICE
Installation Notes: Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Recharge the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Conditioning).
Suction Line
Description
The A/C suction line connects the A/C evaporator to the A/C compressor and the A/C compressor to the A/C condenser.
13
VISM130013
5. Remove the bolt (1) connecting the suction line to the A/C compressor.
VISM130017
1345
ON-VEHICLE SERVICE
6. Remove the nut (1) connecting the suction line to the condenser.
VISM130022
7. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports. 8. Remove the A/C suction line assembly from evaporator to compressor. 9. Installation is in the reverse order of removal. Installation Notes: Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Recharge the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Conditioning).
1346
ON-VEHICLE SERVICE
Heater Core
Removal & Installation
1. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System). 2. Evacuate the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Conditioning). 3. Remove the HVAC housing assembly (See HVAC Housing Removal & Installation in Section 13 Heating & Air Conditioning). 4. Remove the heater core retaining screws (1).
VISM130007
5. Remove the heater core. 6. Installation is in the reverse order of removal. Installation Notes: Verify the cooling system is filled to proper specifications.
13
1347
RESTRAINTS
14
page Airbag System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1 Seat Belt System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-41
CONTENTS
AIRBAG SYSTEM
GENERAL INFORMATION
Description Operation Specifications Special Tools Electrical Schematics Restraints Control Module Connector Pin-Out Table 14-2 14-2 14-3 14-3 14-4 14-6 14-9 14-10 14-10 14-10 14-10 14-10 14-11 14-11 14-15 14-15 14-20 B1346 - Driver Airbag Resistance Too High Or Open (1St Stage) B1352 - Passenger Airbag Resistance Too High Or Open (1St Stage) B1361 - Pretensioner Front-Driver Resistance Too High, B1363 Pretensioner Front-Driver Resistance Circuit Short To Ground 14-22 14-28
14-33 14-38 14-38 14-38 14-38 14-38 14-39 14-39 14-40 14-40
ON-VEHICLE SERVICE
Airbag System Disarming Procedure Description Driver Side Airbag Removal & Installation Front Passenger Side Airbag Removal & Installation Restraints Control Module (RCM) Removal & Installation
14
141
GENERAL INFORMATION
Description
4 - Restraints Control Module Electrical Harness 5 - Front Passenger Side Airbag 6 - Restraints Control Module
VISM140001
Available occupant restraints for this vehicle include both active and passive types. Active restraints are those which require the vehicle occupants to take some action to employ, such as fastening a seat belt; while passive restraints require no action by the vehicle occupants to be employed.
142
GENERAL INFORMATION
Active Restraints Front Seat Belts Rear Seat Belts Passive Restraints Driver Airbag Passenger Airbag Seat Belt Tensioner
Operation
Active Restraints
The primary passenger restraints are the seat belts. Seat belts are referred to as an active restraint because the vehicle occupants are required to physically fasten and properly adjust these restraints in order to benefit from them.
Passive Restraints
The passive restraints are referred to as a supplemental restraint system because they were designed and are intended to enhance the protection for the occupants of the vehicle only when used in conjunction with the seat belts. They are referred to as passive restraints because the vehicle occupants are not required to do anything to make them operate; however, the vehicle occupants must be wearing their seat belts in order to obtain the maximum safety benefit from the supplemental restraint system. The supplemental restraint system electrical circuits are continuously monitored and controlled by a microprocessor and software contained within the Restraints Control Module (RCM). An airbag indicator in the Instrument Cluster illuminates for about seven seconds as a bulb test each time the ignition switch is turned to the ON or START positions. Following the bulb test, the airbag indicator is turned ON or OFF by the RCM to indicate the status of the supplemental restraint system. If the airbag indicator comes ON at any time other than during the bulb test, it indicates that there is a problem in the supplemental restraint system electrical circuits. Such a problem may cause airbags not to deploy when required, or to deploy when not required. Deployment of the supplemental restraints depends upon the angle and severity of an impact. When an impact is severe enough, the microprocessor in the RCM signals the inflator of the appropriate airbag units to deploy their airbag cushions. The front seat belt tensioners are provided with a deployment signal by the RCM in conjunction with the front airbags.
Specifications
Torque Specifications
DESCRIPTION Driver Side Airbag Mounting Bolt Restraints Control Module Mounting Nut Front Passenger Side Airbag Mounting Bolt TORQUE (Nm) 10 10 10
14
143
GENERAL INFORMATION
Special Tools
General Airbag Special Load Tool - Resistor Harness (For Drivers and Passengers (Front) Airbag)
144
GENERAL INFORMATION
General Airbag Special Load Tool - Resistor Harness (For Seat Belt Pre-tensioner)
14
145
GENERAL INFORMATION
Electrical Schematics
Restraint System (Page 1 of 3)
VISMW140013T
146
GENERAL INFORMATION
Restraint System (Page 2 of 3)
VISMW140014T
147
GENERAL INFORMATION
Restraint System (Page 3 of 3)
14
VISMW140015T
148
GENERAL INFORMATION
14
149
Ground Inspection
Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This added resistance can alter the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can affect the circuit. Perform the following when inspecting a ground connection: 1. Remove the ground bolt or screw. 2. Inspect all mating surface for tarnish, dirt, rust, etc. 3. Clean as required to assure good contact. 4. Reinstall bolt or screw securely. 5. Inspect for add-on accessories which may be interfering with the ground circuit. 6. If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are crimped to one eyelet, make sure no excess wire insulation has been crimped creating a bad ground.
Diagnostic Tools
Diagnostic Scan Tool X-431
Read the following when connecting the X-431 scan tool: Connect the scan tool to the Data Link Connector (DLC) for communication with the vehicle. The DLC is located on the driver side compartment under the steering column (it is attached to the instrument panel and accessible from the driver seat). The DLC is rectangular in design and capable of accommodating up to 16 terminals. The electrical connector has keying features to allow easy connection.
1410
Digital Multimeter
Read the following when using the digital multimeter: Use a multimeter to troubleshoot electrical problems and wiring systems. Use a multimeter for basic fault finding and bench testing. Use a multimeter to measure voltage, current and resistance.
14
1411
1412
14
1413
1414
14
VISMW140002T
1415
VISMW140003T
1416
B1102
Ignition switch: ON
14
1417
Diagnostic Procedure
1.
Turn ignition switch off. Disconnect the negative battery cable. Loosen and retighten ground screws on the body (See Ground Inspection in Section 14 Restraints for more information). Inspect the ground connection C-203 position (See Vehicle Wiring Harness Information - Main Harness in Section 16 Wiring).
2.
Turn ignition switch off. Disconnect the Restraints Control Module (RCM) electrical connector (1).
Turn ignition switch on Check voltage between terminal 1 and terminal 25 in the RCM electrical connector C-036 terminal side.
LTSM140006
VOLTAGE
1 & 25
Less than 9 V
1418
3.
Start the engine, raise the engine speed to above 1000 rpm. Measure the charging system voltage with a digital multimeter at the battery positive and negative terminals.
4.
Maintain engine speed above 1000 rpm for a few minutes. Turn the ignition switch off. Measure the voltage drop with a digital multimeter at the battery positive and negative terminals while cranking the engine. Battery voltage should be more than approximately 9.0 V.
5.
Turn the ignition switch off. Disconnect the battery positive terminal. Measure continuity between the RCM connector terminal 25 and the battery positive terminal. Continuity should exist.
6.
CHECK DTC
With the X-431 scan tool, read RCM DTCs. Refer to DTC Confirmation Procedure.
14
>> Replace the RCM. >> The system is now operating properly.
1419
B1322
RCM
1420
Diagnostic Procedure
1.
CHECK DTC
>> Go to the next step. >> The conditions that caused this code to set are not present at this time (See Diagnosis & Testing
Diagnostic Help in Section 14 Restraints).
2.
CHECK RESTRAINTS CONTROL MODULE (RCM) POWER SUPPLY AND GROUND CIRCUIT
Check the RCM voltage supply and ground circuits for an open, high resistance or short circuits.
>> Go to the next step. >> Replace the circuit for open or shorts as necessary.
CHECK DTC
3.
With the X-431 scan tool, read RCM DTCs. Refer to DTC Confirmation Procedure.
>> Replace the Restraints Control Module (RCM). >> The system is now operating properly.
14
1421
VISMW140006T
1422
WARNING!
After installing the Restraints Control Module (RCM), make sure all of the connectors are firm, and all of the harness are normal. The resistance between the RCM shell and body is less than 100 m.
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION Restraints Control Module (RCM) detected that the resistance of RCM connector terminals is out of the specification range. POSSIBLE CAUSE Spiral cable Driver airbag Driver airbag connector Harness is open between spiral cable and RCM RCM
B1346
Ignition switch: ON
14
1423
Diagnostic Procedure
1.
Turn the ignition switch off. Disconnect the negative battery cable.
WARNING!
To avoid serious or fatal injury, turn ignition switch off, disconnect the negative battery cable and wait two minutes before proceeding. Disconnect driver airbag electrical connector C-037. NOTE : Check connectors - Clean and repair as necessary. Connect the airbag special load tool (connect special tool dummy resistor to special tool resistor harness) to the spiral cable side of the vehicle harness (in place of the driver airbag).
WARNING!
To avoid serious or fatal injury, the driver airbag should not be checked with a multimeter.
NOTE : If the airbag special load tool is not available, connect a known good driver airbag. Connect the negative battery cable.
WARNING!
To avoid serious or fatal injury, reconnect the battery, then turn ignition switch on. Turn With Turn With the ignition switch on. the scan tool, erase the DTC memory. ignition switch off, and wait a few seconds, then turn ignition switch on. the scan tool, read the RCM DTCs
>> Go to the next step. >> Replace the driver airbag (See Driver Airbag Removal & Installation in Section 14 Restraints).
Reassemble the vehicle and road test to verify the customers complaint is repaired.
1424
2.
CHECK DRIVER AIRBAG CONTROL CIRCUITS Disconnect the airbag special load tool (or disconnect the known good driver airbag).
WARNING!
To avoid serious or fatal injury, turn the ignition switch off, disconnect the negative battery cable and wait two minutes before proceeding. Disconnect the RCM connectors C-036 (1).
LTSM140006
NOTE : Check connectors - Clean and repair as necessary. Check harness continuity of the driver airbag circuit between the RCM electrical connector terminal 4 and the spiral cable electrical connector terminal 11.
RCM TERMINAL
CONTINUITY
11
Yes
14
Check harness continuity of the driver airbag circuit between the RCM electrical connector terminal 3 and the spiral cable electrical connector terminal 12.
1425
RCM TERMINAL
CONTINUITY
12
Yes
3.
WARNING!
To avoid serious or fatal injury, turn the ignition switch off, disconnect the negative battery cable and wait two minutes before proceeding. Check harness continuity of the driver airbag circuit between the driver airbag electrical connector terminal 1 and the spiral cable electrical connector terminal 11.
CONTINUITY
11
Yes
1426
CONTINUITY
12
Yes
4.
NOTE : Diagnose and repair all active codes before diagnosing stored codes (See Restraints Control Module DTC List in Section 14 Restraints). With the scan tool, record and erase all RCM DTCs. Using the electrical schematic as a guide, inspect the following: Inspect the wiring and connectors of the related airbag system wiring and connectors. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related connectors.
5.
14
Reconnect all disconnected components and harness connectors. With the X-431 scan tool, read RCM DTCs. Refer to DTC Confirmation Procedure.
>> Replace the RCM. >> The system is now operating properly.
Reassemble the vehicle and road test to verify the customers complaint is repaired.
1427
VISMW140007T
1428
WARNING!
After the Restraints Control Module (RCM) is installed, make sure all of the connectors are firm, and all of the harnesses are normal. The resistance between the RCM shell and body is less than 100 m.
On Board Diagnosis Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION Restraints Control Module (RCM) detected that the resistance of RCM connector terminals is out of the specification range. POSSIBLE CAUSE Passenger airbag Spiral cable Passenger airbag connector Harness is open between passenger airbag and RCM RCM
B1352
Ignition switch: ON
14
1429
Diagnostic Procedure
1.
Turn the ignition switch off. Disconnect the negative battery cable.
WARNING!
To avoid serious or fatal injury, turn ignition switch off, disconnect the negative battery cable and wait two minutes before proceeding. Disconnect passenger airbag electrical connector C-038. NOTE : Check connectors - Clean and repair as necessary. Connect the airbag special load tool (connect special tool dummy resistor to special tool resistor harness) to the spiral cable side of the vehicle harness (in place of the passenger airbag). Connect the negative battery cable.
WARNING!
To avoid serious or fatal injury, the passenger airbag should not be checked by a multimeter.
NOTE : If the airbag special load tool is not available, connect a known good passenger airbag.
WARNING!
To avoid serious or fatal injury, reconnect the battery, then turn ignition switch on. Turn With Turn With the ignition switch on. the scan tool, erase the DTC memory. ignition switch off, and wait a few seconds, then turn ignition switch on. the scan tool, read the active RCM DTCs
>> Go to the next step. >> Replace the passenger airbag (See Passenger Airbag Removal & Installation in Section 14
Restraints). Reassemble the vehicle and road test to verify the customers complaint is repaired.
1430
2.
WARNING!
To avoid serious or fatal injury, turn ignition switch off, disconnect the negative battery cable and wait two minutes before proceeding. Disconnect the airbag special load tool (or disconnect the known good passenger airbag). Disconnect the RCM connectors (1). NOTE : Check connectors - Clean and repair as necessary.
Check harness continuity of the passenger airbag circuit between the RCM electrical connector terminal 5 and passenger airbag electrical connector terminal 1.
LTSM140006
CONTINUITY
Yes
Check harness continuity of the passenger airbag circuit between the RCM electrical connector terminal 6 and passenger airbag electrical connector terminal 2.
14
CONTINUITY
Yes
1431
3.
NOTE : Diagnose and repair all active codes before diagnosing stored codes (See Restraints Control Module DTC List in Section 14 Restraints). With the scan tool, record and erase all RCM DTCs. Using the electrical schematic as a guide, inspect the following: Inspect the wiring and connectors of the related airbag system. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related connectors.
4.
Reconnect all disconnected components and harness connectors. With the X-431 scan tool, read RCM DTCs. Refer to DTC Confirmation Procedure.
>> Replace the RCM. >> The system is now operating properly.
Reassemble the vehicle and road test to verify the customers complaint is repaired.
1432
B1361 - Pretensioner Front-Driver Resistance Too High B1363 - Pretensioner Front-Driver Resistance Circuit Short To Ground
14
VISMW140004T
1433
WARNING!
After installing the Restraints Control Module (RCM), make sure all of the connectors are firm, and all of the harness are normal. The resistance between the RCM shell and body is less than 100 m.
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION Restraints Control Module (RCM) detected that the harness of driver seat belt pretensioner is open. Ignition switch: ON Pretensioner front-driver resistance circuit short to ground Restraints Control Module (RCM) detected that the harness of driver seat belt pretensioner short to ground. POSSIBLE CAUSE Harness or connector Harness open between driver seat belt pretensioner and RCM RCM Harness or connector Harness short to ground between driver seat belt pretensioner and RCM RCM
B1361
B1363
1434
Diagnostic Procedure
1.
Turn the ignition switch off. Disconnect the negative battery cable.
WARNING!
To avoid serious or fatal injury, turn ignition switch off, disconnect the negative battery cable and wait two minutes before proceeding. Disconnect driver seat belt pretensioner connector B-024. NOTE : Check connectors - Clean and repair as necessary. Connect the airbag special load tool (connect special tool dummy resistor to special tool resistor harness) to driver seat belt pretensioner connector B-024 of the vehicle harness (in place of the driver seat belt pretensioner).
WARNING!
To avoid serious or fatal injury, the driver seat belt pretensioner should not be checked with a multimeter.
NOTE : If the airbag special load tool is not available, connect a known good driver seat belt pretensioner. Connect the negative battery cable.
WARNING!
To avoid serious or fatal injury, reconnect the battery, then turn ignition switch on. Turn With Turn With the ignition switch on. the scan tool, erase the DTC memory. ignition switch off, and wait a few seconds, then turn ignition switch on. the scan tool, read the RCM DTCs
>> Go to the next step. >> Replace the driver seat belt pretensioner (See Driver Seat Belt Pretensioner Removal & Installation
in Section 14 Restraints). Reassemble the vehicle and road test to verify the customers complaint is repaired.
14
1435
2.
CHECK DRIVER SEAT BELT PRETENSIONER CONTROL CIRCUITS Disconnect the airbag special load tool (or disconnect the known good driver seat belt pretensioner).
WARNING!
To avoid serious or fatal injury, turn the ignition switch off, disconnect the negative battery cable and wait two minutes before proceeding. Disconnect the RCM connectors J-001 (1).
LTSM140006
NOTE : Check connectors - Clean and repair as necessary. Check harness continuity between the RCM electrical connector terminal 37 and the driver seat belt pretensioner electrical connector B-024, terminal 2. Continuity should exist.
CONTINUITY
37
Yes
Check harness continuity between the RCM electrical connector terminal 38 and the driver seat belt pretensioner electrical connector terminal 1. Continuity should exist.
1436
CONTINUITY
38
Yes
Check harness continuity between the driver seat belt pretensioner electrical connector terminal 1 and ground. Check harness continuity between the driver seat belt pretensioner electrical connector terminal 2 and ground. Continuity should not exist.
3.
NOTE : Diagnose and repair all active codes before diagnosing stored codes (See Restraints Control Module DTC List in Section 14 Restraints). With the scan tool, record and erase all RCM DTCs. Using the electrical schematic as a guide, inspect the following: Inspect the wiring and connectors of the related airbag system wiring and connectors. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related connectors.
4.
14
CHECK DTC Reconnect all disconnected components and harness connectors. With the X-431 scan tool, read RCM DTCs. Refer to DTC Confirmation Procedure.
>> Replace the RCM. >> The system is now operating properly.
Reassemble the vehicle and road test to verify the customers complaint is repaired.
1437
ON-VEHICLE SERVICE
Airbag System Disarming Procedure
Description
WARNING!
The steering column contains the drivers airbag. The airbag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the airbag system components, you must first disconnect and isolate the negative battery (ground) cable. Then wait two minutes for the system capacitor to discharge. Failure to do so could result in accidental deployment of the airbag and possible personal injury. The fasteners, screws, and bolts, originally used for the airbag components, have special coatings and are specifically designed for the airbag system. They must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. 1. 2. 3. 4. Turn the ignition off. Disconnect and isolate the negative battery cable. Wait two minutes for the system capacitor to discharge. The airbag system can now be serviced safely.
WARNING!
Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag development, serious or fatal injury (See Airbag System Disarming Procedure in Section 14 Restraints). 2. Remove two driver side airbag retaining bolts (1). (Tighten: Driver side airbag retaining bolts to 10 Nm)
14
VISM140006
3. Take out the driver side airbag and disconnect the airbag squib electrical connector. 4. Installation is in the reverse order of removal.
1438
ON-VEHICLE SERVICE
WARNING!
Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag development, serious or fatal injury (See Airbag System Disarming Procedure in Section 14 Restraints). 2. Remove the glove box mounting bolts (1).
VISM150015
VISM140007
4. Disconnect the front passenger side airbag squib electrical connector. 5. Remove the front passenger side airbag from the vehicle. 6. Installation is in the reverse order of removal.
1439
ON-VEHICLE SERVICE
WARNING!
Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag development, serious or fatal injury (See Airbag System Disarming Procedure in Section 14 Restraints). 2. Remove the lower console (See Lower Console Removal & Installation in Section 15 Body & Accessories). 3. Disconnect the Restraints Control Module (RCM) electrical connector. 4. Remove the RCM retaining bolts (1). (Tighten: RCM retaining bolts to 10 Nm)
VISM140002
5. Remove the RCM from the vehicle. 6. Installation is in the reverse order of the removal.
14
1440
ON-VEHICLE SERVICE
Front Seat Belt and Pre-Tensioner Removal & Installation
1441
GENERAL INFORMATION
Description
The primary passenger restraints are the seat belts. Seat belts are referred to as an active restraint because the vehicle occupants are required to physically fasten and properly adjust these restraints in order to benefit from them.
Operation
The passive restraints are referred to as a supplemental restraint system because they were designed and are intended to enhance the protection for the occupants of the vehicle only when used in conjunction with the seat belts.
Specifications
Torque Specifications
DESCRIPTION Adjustable Shoulder Belt Anchor Bolt Front Seat Belt Buckle Retaining Bolt Front Seat Belt Pre-Tensioner Lower Retaining Bolt Front Seat Belt Upper Turning Loop Retaining Bolt Rear Seat Belt Pre-Tensioner Upper Retaining Bolt Rear Seat Belt Pre-Tensioner Lower Retaining Bolt TORQUE (Nm) 50 50 50 50 50 50
Special Tools
14
1442
ON-VEHICLE SERVICE
Front Seat Belt and Pre-Tensioner
Removal & Installation
1. Disconnect the negative battery cable. 2. Remove the seat belt lower mounting bolt (1).
LTSM150076
LTSM150077
1443
ON-VEHICLE SERVICE
4. Remove the B-pillar retaining screw (1). 5. Use plastic stick to remove the B-pillar lower trim panel.
VISM150005
6. Remove the front seat belt pre-tensioner retaining bolts (1). (Tighten: Front seatbelt retaining bolts to 50 Nm)
VISM140005
7. Remove the front seat belt and pre-tensioner. 8. Installation is in the reverse order of removal.
14
1444
ON-VEHICLE SERVICE
VISM150005
2. Use a plastic stick to remove the B-pillar lower trim panel. 3. Remove the two bolts (1) and then remove the adjustable shoulder belt anchor. (Tighten: Adjustable shoulder belt anchor bolts to 50 Nm)
BESM140006
1445
ON-VEHICLE SERVICE
VISM140004
3. Remove the C-pillar (See C-Pillar Removal & Installation in Section 15 Body & Accessories). 4. Remove the tensioner mounting bolts (1).
14
VISM140003
1446
15
page Body Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 Body Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-236
CONTENTS
BODY INTERIOR
AUDIO SYSTEM
Description Operation Electrical Schematics CD Player Removal & Installation Antenna Removal & Installation 15-4 15-4 15-4 15-5 15-7 15-7 15-8 15-8 15-9 15-9 15-9 15-10 15-10 15-11 15-11 15-11 15-11 15-12 15-12 15-12 15-12 15-13 15-13 15-13 15-13 15-14 15-14 15-15 15-15 15-15 15-16
CHIME
Description Operation Electrical Schematics
15-18 15-18 15-18 15-19 15-26 15-26 15-26 15-27 15-31 15-31 15-32 15-32 15-38
DOOR LOCKS
Description Operation Electrical Schematics Power Lock Switch Removal & Installation Power Lock Motor Removal & Installation Door Lock Assembly Inspection
15-39 15-39 15-39 15-41 15-50 15-52 15-52 15-52 15-52 15-53 15-53 15-55 15-55 15-60 15-65 15-70
15
151
B1063 - Parking Lights Control Circuit Open B1064 - Parking Lights Control Circuit Low Voltage B1320 - Central Lock Control Circuit Low Current B1353 - FL Window Down Control Circuit Low Current B1385 - Horn Control Circuit Open B1386 - Horn Control Circuit Low Voltage B1400 - Front Power Supply Voltage Low, B1401 - Front Power Supply Voltage High B2311 - Boot Lid Release Control Circuit Open U1000 - CAN Bus Off-Transmit Error
Operation Specifications Special Tools Electrical Schematics Instrument Cluster Module Connector Pin-Out Table
15-144 15-144 15-145 15-146 15-151 15-152 15-152 15-152 15-152 15-152 15-153 15-153 15-153 15-154 15-154 15-158
ON-VEHICLE SERVICE
Front Body Control Module (FBCM) Removal & Installation
15-121 15-121 15-121 15-122 15-124 15-125 15-125 15-125 15-125 15-126 15-126 15-127 15-127 15-131 15-135 15-135 15-135 15-136 15-136 15-136 15-139 15-139 15-143 15-143
15-162 15-167 15-168 15-174 15-174 15-174 15-175 15-175 15-176 15-176 15-176 15-177 15-182 15-182 15-182 15-182 15-183 15-183 15-184 15-184 15-184 15-185 15-186 15-186 15-187 15-187 15-187
ON-VEHICLE SERVICE
Instrument Cluster Removal & Installation Driver Information Center Removal & Installation
INTERIOR LAMPS
Description Operation Electrical Schematics Front Courtesy/Dome Lamp Assembly Removal & Installation Rear Room Lamp Removal & Installation Keyhole Lamp Removal & Installation
ON-VEHICLE SERVICE
Rear Body Control Module (RBCM) Removal & Installation
POWER OUTLET
Description Operation Electrical Schematics Power Outlet Removal & Installation
INSTRUMENT PANEL
Instrument Panel Removal & Installation Lower Console Removal & Installation
152
15-214
SEATS
General Information Description Operation Front Seat Removal & Installation Rear Seat Removal & Installation
15-218
15-223
IMMOBILIZER
Description Operation Electrical Schematics Immobilizer Module Connector Pin-Out Table
ON-VEHICLE SERVICE
Immobilizer Removal & Installation Remote Keyless Entry (RKE) Inoperative No Response From Remote Keyless Entry (RKE) Transmitter
15
153
AUDIO SYSTEM
Description
The audio system consists of the following components: Audio unit Front speakers: two on left and right front door Front tweeters: two on left and right front door Rear Speakers: two on left and right rear door Antenna (audio) The audio system is standard factory-installed equipment. The system uses an ignition switched source of battery current so that the system will operate when the ignition switch is in the LOCK/ACC/ON positions. The radio will also operate for up to one hour with the ignition switch in the OFF position.
Operation
With audio system on, radio signals are received by the window antenna, the audio unit then sends audio signals to front speakers, rear speakers and front tweeters.
154
AUDIO SYSTEM
Electrical Schematics
Audio System (Page 1 of 2)
15
VISMW150029T
155
AUDIO SYSTEM
Audio System (Page 2 of 2)
VISMW150030T
156
AUDIO SYSTEM
CD Player
Removal & Installation
1. 2. 3. 4. Disconnect the negative battery cable. Open the instrument panel storage compartment and remove the upper radio bezel bolts. Remove the lower console (See Lower Console Removal & Installation in Section 15 Body & Accessories). Remove the radio bezel bolts (1).
VISM150001
5. Remove the CD player mounting bolts (1). (Tighten: CD player mounting bolts to 8 1 Nm)
VISM150002
6. Disconnect the radio electrical connector. 7. Remove the radio. 8. Installation is in the reverse order of removal.
15
157
AUDIO SYSTEM
Antenna
Removal & Installation
1. 2. 3. 4. Disconnect the negative battery cable. Remove the headliner (See Headliner Removal & Installation in Section 15 Body & Accessories). Disconnect the antenna connectors (1). Remove the antenna mounting nut (2)
VISM150168
VISM150003
158
VISM150004
3. Installation is in the reverse order of removal. Installation Notes: The A-pillar trim panel clips should be installed to allow the trim panel a tight fit between the roof and the weatherstrip.
15
159
VISM150005
3. Using a plastic trim stick, remove the B-pillar lower trim panel. 4. Using a plastic trim stick, remove the B-pillar upper trim panel. 5. Installation is in the reverse order of removal.
1510
VISM150006
15
BESM150128
1511
Scuff Plate
Removal & Installation
1. Grasp the scuff plate and gently pull it away to release the retaining clips. 2. Using a plastic trim stick, remove the scuff plate from the front door sill.
BESM150124
Pedal Pad
Removal & Installation
1. Remove the cover for the pedal pad bolts. 2. Remove the pedal pad bolts (1). (Tighten: Pedal pad bolts to 8 1 Nm)
VISM150007
3. Remove the pedal pad for the left foot. 4. Installation is in the reverse order of removal.
1512
Sun Visor - LH
Removal & Installation
1. Disconnect the sun visor from the retaining clip. 2. Remove the retaining screws (1) on the sun visor hinge. 3. Remove the sun visor assembly. 4. Installation is in the reverse order of removal. Installation Notes: Do not overtighten the sun visor mounting screw. Tighten the sun visor mounting screw at the sun visor hinge just enough to allow for free movement of the sun visor.
VISM150008
Sun Visor - RH
Removal & Installation
1. Disconnect the sun visor from the retaining clip. 2. Remove the retaining screws on the sun visor hinge. NOTE : Over tightening the sun visor retainer screws could prevent the sun visor from working properly. 3. Remove the sun visor assembly. NOTE : The sun visor hinge could seize-up preventing the sun visor from working properly. 4. Installation is in the reverse order of removal. Installation Notes: Do not overtighten the sun visor mounting screw. Tighten the sun visor mounting screw at the sun visor hinge just enough to allow for free movement of the sun visor.
15
1513
Headliner
Removal & Installation
1. Remove the passenger grab handle (See Passenger Grab Handle Removal & Installation in Section 15 Body & Accessories). 2. Remove the two rear grab handles (See Passenger Grab Handle Removal & Installation in Section 15 Body & Accessories). 3. Remove the front courtesy lamp (See Front Courtesy Lamp Removal & Installation in Section 15 Body & Accessories). 4. Remove the rear room lamp (See Rear Room Lamp Removal & Installation in Section 15 Body & Accessories). 5. Remove the A/B/C pillar trim panel (See A/B/C Pillar Trim Panel Removal & Installation in Section 15 Body & Accessories.) 6. Remove the left and right sun visors (See Sun Visor Removal & Installation in Section 15 Body & Accessories.) 7. Using a trim stick, remove the eye glass storage compartment from the overhead console (1).
VISM150166
8. Remove all the retaining clips. 9. Remove the headliner. 10. Installation is in the reverse order of removal. Installation Notes: The front edge of the headliner should fit tight to the roof and not interfere with the view of the front windshield. The headliner corners should fit tight to the roof and not be visible outside the car. The headliner should fit tight with the weatherstrip around the door openings and the luggage compartment. The headliner should fit tight to the roof around the arcs of the upper trim panels (A, B, and C pillars) with a clearance less than 0.2 mm.
1514
Operation
The CAN network uses a twisted pair of circuits to transmit data (+) and data (-). The data (+) and the data (-) circuits are each regulated to approximately 2.5 volts during neutral or rested network traffic. As bus messages are sent on the data (+) circuit, voltage is increased by approximately 1.0 volt. Inversely, the data (-) circuit is reduced by approximately 1.0 volt when a bus message is sent. Multiple bus messages can be sent over the CAN circuits allowing multiple modules to communicate with each other.
15
1515
Electrical Schematics
CAN Vehicle Communications (Page 1 of 2)
VISMW150025T
1516
15
VISMW150026T
1517
CHIME
Description
The chime is located in the Instrument Cluster (IC). The chime warning system is an audible notification to the driver. The chime warning system is designed to alert the driver of a vehicle problem or condition.
Operation
The Instrument Cluster (IC) uses hard wired inputs from various sensors and switches to activate the chime. The sensors and switches are located throughout the vehicle. The following conditions will cause the chime to operate: Turn signal on Hazard warning flashers on Seat belt unbuckled Low fuel level Low oil pressure Low brake fluid Doors unlocked Charging system fault Engine performance fault Airbag system fault Low coolant level EPC fault Immobilizer fault Engine overheating
1518
CHIME
Electrical Schematics
Chime (Page 1 of 7)
15
VISMW150031T
1519
CHIME
Chime (Page 2 of 7)
VISMW150032T
1520
CHIME
Chime (Page 3 of 7)
15
XLSMW150025T
1521
CHIME
Chime (Page 4 of 7)
XLSMW150026T
1522
CHIME
Chime (Page 5 of 7)
15
XLSMW150027T
1523
CHIME
Chime (Page 6 of 7)
XLSMW150028T
1524
CHIME
Chime (Page 7 of 7)
15
VISMW150037T
1525
DOOR LOCKS
Description
The power door locks allow the doors to be locked or unlocked electronically. The power door lock switch is located on the left front door trim panel. The power door locks can also be operated by the Remote Keyless Entry (RKE) transmitter.
Operation
The power lock system receives non-switched battery current, so that the power locks remain operational, regardless of the ignition switch position.
1526
DOOR LOCKS
Electrical Schematics
Power Door Lock System (Page 1 of 4)
15
VISMW150039T
1527
DOOR LOCKS
Power Door Lock System (Page 2 of 4)
VISMW150040T
1528
DOOR LOCKS
Power Door Lock System (Page 3 of 4)
15
VISMW150041T
1529
DOOR LOCKS
Power Door Lock System (Page 4 of 4)
VISMW150042T
1530
DOOR LOCKS
VISM150009
15
VISM150010
4. Remove the retaining screws and remove the power lock switch assembly. 5. Installation is in the reverse order of removal.
1531
DOOR LOCKS
VISM150009
VISM150010
1532
DOOR LOCKS
4. Using a trim stick, pry up the inside door handle panel (1).
VISM150084
5. Remove the retaining bolt (1) from the inside door handle panel. (Tighten: Door retaining bolts to 7 1 Nm)
VISM150156
15
1533
DOOR LOCKS
6. Remove the retaining bolt (1) from the door handle panel. (Tighten: Door retaining bolts to 7 1 Nm)
VISM150087
CAUTION: While servicing the door panels, care should be taken to maintain a clean work environment. 7. Using a trim stick, remove the step lamp cover (1).
VISM150085
1534
DOOR LOCKS
8. Remove the step lamp bracket (1).
VISM150151
VISM150086
15
1535
DOOR LOCKS
10. Using a trim stick, remove the inside cover (1) for the mirror bolts from the door trim panel.
VISM150167
11. Using a screwdriver, remove the door trim panel upper retaining screw (1).
VISM150155
12. Using a screwdriver, remove the door trim panel lower four retaining screws (1).
VISM150152
13. Remove the door trim panel and disconnect the speaker electrical connector.
1536
DOOR LOCKS
14. Loosen the inside door handle control cable (1).
VISM150153
15. Remove the protective film from the front door. 16. Disconnect the power lock motor electrical connector. 17. Remove the power lock retaining bolts (1). (Tighten: Power lock motor retaining bolts to 8 1 Nm) 18. Remove the retaining bolt (2) connecting the window glass guide rail and the door. (Tighten: Glass guide rail and door connecting bolt to 7 1 Nm)
VISM150011
19. Remove the door lock switch bracket retaining bolts (1). 20. Remove the door handle control cable retaining screws (2).
15
VISM150154
21. Disconnect the door lock motor connecting rod to the door outside handle. Chery Automobile Co., Ltd.
1537
DOOR LOCKS
22. Remove the power lock motor.
VISM150012
23. Disconnect the power lock motor electric connectors. 24. Installation is in the reverse order of removal.
1538
Operation
The Front Body Control Module (FBCM) uses hard wired inputs from various sensors and switches. The sensors and switches are located throughout the vehicle. The following components are inputs to the FBCM: Key switch Rear window defogger switch Hazard lamp switch Front power window switches Power door lock switches Door ajar switches Front fog lamp switch Backup lamp switch Trunk lid open switch Backlight switch Horn switch Lighting and turn signal switch Outside mirror switch Engine hood switch Trunk lamp switch and trunk release solenoid Trunk lid open switch Wiper and washer switch The following components are outputs from the BCM: Key lamp High/low beam relay Rear defogger grid Front combination lamps Rear combination lamps Courtesy lamps Turn signal lamps Security lamp Step lamps Front power window motor Power door lock motor Washer motor Wiper motor
15
1539
FUSE NO. 1 2 3 4 5 6
FUNCTION Front Power Window Not Used Left Parking Lamps IP Lamps Right Parking Lamps Lock
FUSE NO. 7 8 9 10 11 12
AMPERAGE RATING 25 A 10 A 10 A 15 A 25 A 15 A
FUNCTION Wiper and Washer Interior Lamps Horn Front Fog Lamps Defogger Turn Signal and Warning Lamps
VISM150138
1540
Electrical Schematics
Front Body Control Module (Page 1 of 9)
15
VISMW150100T
1541
VISMW150101T
1542
15
VISMW150102T
1543
VISMW150103T
1544
15
VISMW150104T
1545
VISMW150105T
1546
15
VISMW150106T
1547
VISMW150107T
1548
15
VISMW150108T
1549
1550
15
1551
Ground Inspection
Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This added resistance can alter the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can effect the circuit. Perform the following when inspecting a ground connection: 1. Remove the ground bolt or screw. 2. Inspect all mating surface for tarnish, dirt, rust, etc. 3. Clean as required to assure good contact. 4. Reinstall bolt or screw securely. 5. Inspect for add-on accessories which may be interfering with the ground circuit. 6. If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are crimped to one eyelet, make sure no excess wire insulation has been crimped creating a bad ground.
Diagnostic Tools
Diagnostic Scan Tool X-431 Digital Multimeter Jumper Wire
1552
15
1553
1554
15
VISMW150079T
1555
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION When the Front Body Control Module (FBCM) detects the RH turn signal lamp control circuit open condition. POSSIBLE CAUSE Front or rear LH turn lamps Harness or connectors LH turn lamp fuse FBCM
B1001
1556
Diagnostic Procedure
1.
VISMD150045
Turn ignition switch off. Check turn lamp fuse (1-1) (15A) in FBCM.
2.
Turn LH turn signal switch off. Disconnect front LH turn signal lamp (2) connector.
15
VISMD150060
1557
VISM150104
LIGHT BULB POWER RATINGS 1 2 3 4 5 Rear Fog Lamp Reverse Lamp Turning Lamp Stop Lamp Rear Parking Lamp 12 V (21 W) 12 V (21 W) 12 V (21 W) 12 V (18 W) 12 V (5 W)
>> Go to the next step. >> Replace the LH turn signal bulbs.
CHECK THE LH TURN SIGNAL LAMPS SUPPLY CIRCUIT POWER SUPPLY
3.
Turn ignition switch on. Turn the LH turn signal lamp on. Check voltage between the front LH turn signal lamp harness connector A-021, terminal 2 and ground.
1558
>> Go to the next step. >> Repair or replace circuit for an open in harness or connectors between FBCM and LH turn signal
lamp.
4.
Turn ignition switch off. Disconnect the LH turn signal lamps connectors. Check resistance between the front LH turn signal lamp harness connector A-021, terminal 1 and ground. Check resistance between the rear LH turn signal lamp harness connector B-004, terminal 8 and ground. Continuity should exists.
>> Go to the next step. >> Repair or replace ground circuit for an open or high resistance in harness or connectors.
CHECK DTC
5.
With the X-431 scan tool, read FBCM DTCs. Refer to DTC Confirmation Procedure.
15
1559
VISMW150078T
1560
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION Ignition switch: ON With right turn lights activated DTC SET CONDITION The Front Body Control Module (FBCM) detects the RH turn signal lights control circuit open condition. POSSIBLE CAUSE Front or rear RH turn light Harness or connectors RH turn lamp fuse FBCM
B1004
15
1561
Diagnostic Procedure
1.
VISMD150045
Turn ignition switch off. Check turn lamp fuse (1-1) (15A) in FBCM.
2.
Turn RH turn signal switch off. Disconnect front RH turn signal lamp (2) connector.
VISMD150060
1562
VISM150104
LIGHT BULB POWER RATINGS 1 2 3 4 5 Rear Fog Lamp Reverse Lamp Turning Lamp Stop Lamp Rear Parking Lamp 12 V (21 W) 12 V (21 W) 12 V (21 W) 12 V (18 W) 12 V (5 W)
>> Go to the next step. >> Replace the RH turn signal bulbs.
CHECK THE RH TURN SIGNAL LAMPS POWER SUPPLY
3.
Turn ignition switch on. Turn the RH turn signal light on. Check voltage between the front RH turn signal lamp harness connector A-022 , terminal 2 and ground.
15
1563
>> Go to the next step. >> Repair or replace supply circuit for an open in harness or connectors between FBCM and RH turn
signal lamp.
4.
Turn ignition switch off. Disconnect the LH turn signal lamps connectors. Check resistance between the front RH turn signal lamp harness connector A-022, terminal 1 and ground. Check resistance between the rear RH turn signal lamp harness connector B-005, terminal 8 and ground. Continuity should exists.
>> Go to the next step. >> Repair or replace ground circuit for an open or high resistance in harness or connectors.
CHECK DTC
5.
With the X-431 scan tool, read FBCM DTCs. Refer to DTC Confirmation Procedure.
1564
15
VISMW150076T
1565
12 V
71
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION Ignition switch: ON The headlamp switch should be on PARK position or on LOW position With the front fog lights activated DTC SET CONDITION When the Front Body Control Module (FBCM) detects the front fog lights control circuit open condition. POSSIBLE CAUSE
B1045
1566
Diagnostic Procedure
1.
VISMD150045
Turn ignition switch off. Check front fog lamp fuse (1-3) (15A) in FBCM.
2.
Turn the front fog lamps switch off. Disconnect the front fog lamps (1) connector. Remove and inspect the front fog lamp bulbs.
>> Go to the next step. >> Replace the two damaged front fog
lamp bulbs.
15
VISMD150060
1567
3.
Turn ignition switch on. Turn the front parking lights on or turn the headlight switch to the LOW position. Turn front fog lamp switch on. Check voltage between the front lamp harness connector A-003 or A-004, terminal 2 and ground.
TERMINAL
VOLTAGE
Ground
12 V
4.
Turn ignition switch off. Disconnect FBCM connectors B-026. Check harness continuity between terminal 70 or 71 in FBCM connector B-026 terminal side and terminal 2 in front fog lamp LH connector A-003 or RH connector A-004 terminal side.
FBCM TERMINAL
70 or 71
>> Go to the next step. >> Repair or replace the circuit for an open in harness or connectors between FBCM and front fog
lamps. Repair or replace front fuse and relay box C, E.
1568
5.
Check front fog lamp ground circuits for an open between front fog lamp LH connector A-003, terminal 1 and ground. Check front fog lamp ground circuits for an open between front fog lamp LH connector A-003, terminal 1 and ground. Continuity should exist.
>> Go to the next step. >> Repair or replace the ground circuit for an open in harness or connectors.
CHECK DTC
6.
With the X-431 scan tool, read FBCM DTCs. Refer to DTC Confirmation Procedure.
15
1569
VISMW150076T
1570
12 V
71
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION When the Front Body Control Module (FBCM) detects the front fog lights control circuit high condition. POSSIBLE CAUSE
B1047
15
1571
Diagnostic Procedure
1.
Turn ignition switch off. Disconnect front fog lamp harness connectors (1).
VISMD150060
Turn ignition switch on. Turn front fog lamp switch off. Disconnect the front fog lamps connector. Check voltage between the front fog lamp harness connector A-003 or A-004, terminal 2 and ground.
TERMINAL
VOLTAGE
Ground
Not exist
1572
2.
CHECK THE FRONT FOG LAMPS SUPPLY CIRCUIT FOR A SHORT TO POWER CIRCUIT
Turn all related components off. Disconnect FBCM connectors. Check continuity between front fog lamp supply circuits and related components supply circuits. Continuity should not exist. Also check the front fog lamp supply circuits for a short to power. Continuity should also not exist.
>> Go to the next step. >> Repair or replace circuit for a short in harness or connectors.
CHECK DTC
3.
With the X-431 scan tool, read FBCM DTCs. Refer to DTC Confirmation Procedure.
15
1573
VISMW150075T
1574
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION Ignition switch: ON The lamp switch should be on PARK position. DTC SET CONDITION When the Front Body Control Module (FBCM) detects the parking lights control circuit open condition. POSSIBLE CAUSE Parking lamp bulbs Harness or connectors FBCM
B1063
15
1575
Diagnostic Procedure
1.
Turn parking lights switch off. Disconnect the front parking lamps connector (3). Remove and inspect the parking lamp bulbs.
VISM150102
LIGHT BULB POWER RATINGS 1 2 3 Low Beam Lamp High Beam Lamp Front Parking Lamp 12 V (55 W) 12 V (55 W) 12 V (5 W)
Disconnect the rear parking lamps connector (5). Remove and inspect the parking lamp bulbs.
VISM150104
LIGHT BULB POWER RATINGS 1 2 3 4 5 Rear Fog Lamp Reverse Lamp Turning Lamp Stop Lamp Rear Parking Lamp 12 V (21 W) 12 V (21 W) 12 V (21 W) 12 V (18 W) 12 V (5 W)
>> Go to the next step. >> Replace the damaged parking lamp bulbs.
1576
2.
Turn ignition switch on. Turn the parking lamps on. Check voltage between the front LH combination lamp connector A-001, terminal 6 and ground or between the front RH combination lamp connector A-002, terminal 6 and ground.
Check voltage between the rear LH combination lamp connector B-004, terminal 3 and ground or between the rear RH combination lamp connector B-005, terminal 3 and ground.
15
1577
3.
Check continuity between FBCM connector B-027, terminal 94 or 96 and front parking lamps connector A-001 or A-002, terminal 6.
VISMD150032
94 6 96
>> Go to the next step. >> Repair or replace the circuit for an open in harness or connectors between FBCM and parking
lamps.
4.
Check continuity between front parking lamps connector A-001 or A-002, terminal 4 and ground. Check continuity between rear parking lamps connector B-004 or B-005, terminal 8 and ground. Continuity should exist.
>> Go to the next step. >> Repair or replace ground circuit for an open in harness or connectors.
1578
5.
CHECK DTC
Connect all disconnected connectors. With the X-431 scan tool, read FBCM DTCs. Refer to DTC Confirmation Procedure.
>> Replace FBCM in accordance with the service information. >> The system is now operating properly.
15
1579
VISMW150075T
1580
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION Ignition switch: ON The lamp switch should be on PARK position. DTC SET CONDITION When The Front Body Control Module (FBCM) detects the parking lights control circuit low voltage condition. POSSIBLE CAUSE
B1064
15
1581
Diagnostic Procedure
1.
Turn parking lights switch off. Disconnect the front parking lamps connector (3). Remove and inspect the parking bulbs.
VISM150102
LIGHT BULB POWER RATINGS 1 2 3 Low Beam Lamp High Beam Lamp Front Parking Lamp 12 V (55 W) 12 V (55 W) 12 V (5 W)
Disconnect the rear parking lamps connector (5). Remove and inspect the parking bulbs.
VISM150104
LIGHT BULB POWER RATINGS 1 2 3 4 5 Rear Fog Lamp Reverse Lamp Turning Lamp Stop Lamp Rear Parking Lamp 12 V (21 W) 12 V (21 W) 12 V (21 W) 12 V (18 W) 12 V (5 W)
>> Go to the next step. >> Replace the damaged parking lamp bulbs.
1582
2.
Turn ignition switch on. Turn the parking lamps on. Check voltage between the LH combination lamp connector A-001, terminal 6 and ground or between the RH combination lamp connector A-002, terminal 6 and ground.
15
1583
3.
Check resistance between the LH combination lamp connector A-001, terminal 6 and ground or between the RH combination lamp connector A-002, terminal 6 and ground.
VISMD150032
TERMINAL
Ground
>> Go to the next step. >> Repair circuit for a short to ground in harness or connectors between FBCM and parking lamps.
Repair circuit for a short to ground in front fuse and relay box E, L.
4.
CHECK DTC
With the X-431 scan tool, read FBCM DTCs. Refer to DTC Confirmation Procedure.
>> Replace and program FBCM in accordance with the service information. >> The system is now operating properly.
1584
15
VISMW150082T
1585
VISMW150083T
1586
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION When the Front Body Control Module (FBCM) detects the lock control circuit low condition. POSSIBLE CAUSE Door lock actuator Harness or connectors FBCM
B1320
15
1587
Diagnostic Procedure
1.
VISMD150045
Turn ignition switch off. Check central lock fuse (2-1) (15A) in FBCM.
1588
2.
Disconnect central lock actuator harness connector D-006. Turn ignition switch on.
Check voltage between the central lock actuator harness connector D-006 , G-006 , I-003 or H-003 terminal 1 and ground while operating the left front power window switch in the up position.
VISM150012
12 V should exist.
>> Go to the next step. >> Repair or replace the lock control circuit between FBCM connector B-026, terminal 77 and door lock
actuator connectors for open or high resistance.
15
1589
3.
Check voltage between central lock actuator harness connector D-006 , G-006 , I-003 or H-003, terminal 1 and terminal 2 while operating the left front power window switch in the up position.
12 V should exist.
>> Go to the next step. >> Repair or Replace the lock return circuit between FBCM connector B-026, terminal 76 and door lock
actuator connectors for open or high resistance.
4.
>> Go to the next step. >> Replace all the central lock actuators.
CHECK DTC
5.
With the X-431 scan tool, read FBCM DTCs. Refer to DTC Confirmation Procedure.
1590
15
VISMW150084T
1591
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION When the Front Body Control Module (FBCM) detects the FL window down control circuit low condition. POSSIBLE CAUSE FL power window motor Harness or connectors FBCM
B1353
1592
Diagnostic Procedure
1.
VISMD150045
Turn ignition switch off. Check front power window motor fuse (2-6) (30A) in FBCM.
15
1593
2.
Disconnect front LH power window motor harness connector D-002. Turn ignition switch on.
Check voltage between front LH power window motor harness connector D-002, terminal 1 and ground while operating the left front power window switch in the down position.
VISM150092
12 V should exists.
>> Go to the next step. >> Repair or replace the circuit between FBCM connector B-027, terminal 86 and front LH power window motor connectors D-002, terminal 1 for open or high resistance.
3.
>> Go to the next step. >> Replace all the front LH power window motor.
1594
4.
CHECK DTC
With the X-431 scan tool, read FBCM DTCs. Refer to DTC Confirmation Procedure.
15
1595
VISMW150080T
1596
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION Turn ignition switch on With the horn activated DTC SET CONDITION When the Front Body Control Module (FBCM) detects the horn control circuit open condition. POSSIBLE CAUSE Horn Harness or connectors FBCM
B1385
15
1597
Diagnostic Procedure
1.
VISMD150045
Turn ignition switch off. Check horn fuse (1-4) (10A) in FBCM.
1598
2.
Disconnect horn connector A-006 or A-005 (1). Turn ignition switch on.
Check voltage between the horn connector A-006, terminal 1 and ground or A-005, terminal 1 and ground when press the horn switch.
VISMD150058
HORN TERMINAL
GROUND
3.
15
1599
4.
Turn ignition switch off. Disconnect FBCM connectors. Check harness continuity between FBCM connector terminal 84 and horn connector terminal 1.
FBCM TERMINAL
HORN TERMINAL
84
>> Go to the next step. >> Repair or replace circuit for an open in harness or connectors between FBCM and horns.
Repair or replace front fuse and relay box.
5.
CHECK HORNS
6.
With the X-431 scan tool, read FBCM DTCs. Refer to DTC Confirmation Procedure.
15100
15
VISMW150080T
15101
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION Turn ignition switch on With the horn activated. DTC SET CONDITION When the Front Body Control Module (FBCM) detects the horn control circuit low voltage condition. POSSIBLE CAUSE Horn Harness or connectors FBCM
B1386
15102
Diagnostic Procedure
1.
Turn ignition switch off. Disconnect horn connector A-006 or A-005 (1). Turn ignition switch on.
Check voltage between the horn connector A-006, terminal 1 and ground or A-005, terminal 1 and ground when press the horn switch.
VISMD150058
HORN TERMINAL
GROUND
15
15103
2.
Turn ignition switch off. Disconnect FBCM connector B-026. Check resistance between the horn connector A-006, terminal 1 and ground or horn harness connector A-005, terminal 1 and ground.
HORN TERMINAL
GROUND
>> Go to the next step. >> Repair circuit for a short to ground in harness or connectors between FBCM and horns.
Repair or replace front fuse and relay box.
3.
CHECK HORNS
4.
With the X-431 scan tool, read FBCM DTCs. Refer to DTC Confirmation Procedure.
>> Replace FBCM in accordance with the service information. >> The system is now operating properly.
15104
B1400 - Front Power Supply Voltage Low B1401 - Front Power Supply Voltage High
15
VISMW150073T
15105
VISMW150074T
15106
B1400
B1401
Diagnostic Procedure
1.
Turn the ignition switch off. Loosen and retighten ground connectors B-204 (See Ground Inspection in Section 15 Body & Accessories). Inspect the ground connection B-204 position (See Vehicle Wiring Harness Information - Body Harness in Section 16 Wiring).
15
>> Go to the next step. >> Repair the ground connections if necessary.
15107
2.
VISMD150032
Turn ignition switch on. Check FBCM power supply between terminal 11, 47, 63 and terminal G in the FBCM electrical connector terminal side.
3.
Start the engine, raise the engine speed over 1000 rpm for a few minutes. Turn ignition switch off. Measure the voltage drop with the voltmeter at the battery positive and negative terminals while cranking the engine. Battery voltage should more than approximately 9 V.
4.
Start the engine, raise the engine speed over 1000 rpm. Measure the charging voltage with a digital multimeter at the battery positive and negative terminals.
15108
5.
Disconnect the battery positive cable. Measure the resistance between FBCM terminal 11 and battery positive. Continuity should exist.
Check the harness for an open or short to ground or high resistance. Check related components.
6.
Start the engine, raise the engine speed over 1000 rpm. Measure the charging voltage with a digital multimeter at the battery positive and negative terminals.
7.
With the X-431 scan tool, read FBCM DTCs. Refer to DTC Confirmation Procedure.
15
15109
15
VISMW150088T
15110
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION When the Front Body Control Module (FBCM) detects the trunk release solenoid control circuit open condition. POSSIBLE CAUSE Trunk release solenoid Harness or connectors FBCM
B2311
15
15111
Diagnostic Procedure
1.
VISMD150045
Turn ignition switch off. Check trunk release solenoid fuse (2-1) (15A) in FBCM.
15112
2.
Open the trunk lid. Disconnect trunk release solenoid harness connector B-401 (1).
Close the trunk lid release latch. Turn ignition switch on. Check voltage between the trunk release solenoid harness connector B-401, terminal 2 and ground while press the trunk release switch.
VISM150127
TERMINAL
VOLTAGE
Ground
12 V
3.
15
>> Go to the next step. >> Repair or replace the ground circuit.
15113
4.
>> Go to the next step. >> Replace the trunk release solenoid.
CHECK TRUNK RELEASE SOLENOID SUPPLY CIRCUIT
5.
Turn ignition switch off. Disconnect FBCM connectors. Check harness continuity between FBCM connector B-026, terminal 78 and trunk release solenoid connector B-401, terminal 2.
FBCM TERMINAL
78
>> Go to the next step. >> Repair or replace open circuit in harness or connectors between FBCM and the trunk release solenoid.
6.
CHECK DTC
With the X-431 scan tool, read FBCM DTCs. Refer to DTC Confirmation Procedure.
15114
15
VISMW150111T
15115
U1000
Diagnostic Procedure
1.
Turn the ignition switch off. Loosen and retighten ground connectors B-204 (See Ground Inspection in Section 15 Body & Accessories). Inspect the ground connection B-204 position (See Vehicle Wiring Harness Information - Body Harness in Section 16 Wiring).
>> Go to the next step. >> Repair the ground connections if necessary.
CHECK DTC
2.
Turn ignition switch on. With the scan tool, select view FBCM DTCs and data stream.
>> Go to the next step. >> The conditions that caused this code to set are not present at this time (See Diagnostic Help in
Section 15 Body & Accessories).
15116
3.
With the scan tool X-431, attempt to enter all the other CAN communication modules such as ECM, ABS module, Restraints control module, Unified meter control unit, EPS control unit. Read CAN DTCs.
>> If all of the other modules have the CAN DTC High speed CAN Communication, Go to the next
step. If all of the other modules have the DTC about Lost communication with BCM, and not have the CAN Bus off-Transmit Error, Replace FBCM.
No
>> Go to step 7.
CHECK CAN-BUS LINE TOTAL RESISTANCE
4.
Turn ignition switch off. Check CAN-Bus line total resistance between DLC terminal 14 and 6.
CAN-H
CAN-L
RESISTANCE
14
60
15
15117
5.
Disconnect all other module connectors with CAN-Bus lines. Check harness continuity between the following terminals. CAN-H CIRCUIT CONTINUITY
CAN
DLC TERMINAL
TERMINAL
CONTINUITY
CANH
Ground
No
Check harness continuity between the following terminals. CAN-L CIRCUIT CONTINUITY
CAN
DLC TERMINAL
TERMINAL
CONTINUITY
CANL
14
Ground
No
15118
6.
Connect all other disconnected CAN-Bus modules connectors. Disconnect CAN-Bus modules one by one. Connect battery negative. Turn ignition switch on. Check CAN-Bus voltage between the following terminals after one CAN-Bus module has been disconnected. CAN-H: Voltage should be more than 2.5 V. CAN-L: Voltage should be less than 2.5 V. CAN CIRCUIT VOLTAGE DLC TERMINAL GROUND
7.
Inspect the BCM electrical connector pins for proper fit or any chafed, pierced, pinched, or partially broken wires. With the X-431 scan tool, read BCM DTCs.
Reassemble the vehicle and road test to verify the customers complaint is repaired. The problem caused by FBCM internal error.
15
15119
ON-VEHICLE SERVICE
Front Body Control Module (FBCM)
Removal & Installation
1. Disconnect the negative battery cable. 2. Remove the left lower trim panel assembly of the instrument panel (See Instrument Panel Removal & Installation in Section 15 Body & Accessories). 3. Remove the retaining bolts (1).
VISM150032
4. Disconnect the FBCM electrical connector. 5. Remove the FBCM. 6. Installation is in the reverse order of removal.
15120
Operation
The Rear Body Control Module (RBCM) is through the LIN to connect with the Front Body Control Module (FBCM). The following components are inputs to the BCM: Parking sonar Rear fog lamp switch Rear power window switch The following components are outputs from the BCM: Rear fog lamp Rear power window motor
15
15121
Electrical Schematics
Rear Body Control Module (Page 1 of 2)
VISMW150109T
15122
15
VISMW150110T
15123
15124
Ground Inspection
Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This added resistance can alter the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can effect the circuit. Perform the following when inspecting a ground connection: 1. Remove the ground bolt or screw. 2. Inspect all mating surface for tarnish, dirt, rust, etc. 3. Clean as required to assure good contact. 4. Reinstall bolt or screw securely. 5. Inspect for add-on accessories which may be interfering with the ground circuit. 6. If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are crimped to one eyelet, make sure no excess wire insulation has been crimped creating a bad ground.
15
Diagnostic Tools
Diagnostic Scan Tool X-431 Digital Multimeter Jumper Wire
15125
15126
15
VISMW150077T
15127
12
12 V
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION Ignition switch: ON The headlamp switch should be on PARK position or on LOW position With the rear fog lights activated DTC SET CONDITION The Rear Body Control Module (RBCM) detects the rear fog lights control circuit open condition. POSSIBLE CAUSE Rear fog lamp bulbs Harness or connectors RBCM
B1048
15128
Diagnostic Procedure
1.
Turn rear fog lamp switch off. Disconnect the rear fog lamps connector (1). Remove and inspect the rear fog lamp bulbs.
VISM150104
LIGHT BULB POWER RATINGS 1 2 3 4 5 Rear Fog Lamp Reverse Lamp Turning Lamp Stop Lamp Rear Parking Lamp 12 V (21 W) 12 V (21 W) 12 V (21 W) 12 V (18 W) 12 V (5 W)
>> Go to the next step. >> Replace the two rear fog bulbs.
CHECK REAR FOG LAMPS POWER SUPPLY
2.
Turn ignition switch on. Turn the headlamp switch on PARK position or on LOW position. Turn the rear fog lamp switch on. Check voltage between the rear lamp harness connector B-004 or B-005, terminal 6 and ground.
15
GROUND
15129
3.
Turn ignition switch off. Check harness continuity between FBCM connector B-028, terminal 12 and rear fog lamp connector B-004 or B-005, terminal 6.
RBCM TERMINAL
CONTINUITY
12
Yes
>> Go to the next step. >> Repair or replace open circuit in harness or connectors between RBCM and rear fog lamps.
CHECK REAR FOG LAMPS GROUND CIRCUIT
4.
Check rear fog lamp ground circuits for an open between rear fog lamp LH connector B-004, terminal 8 and ground. Check rear fog lamp ground circuits for an open between rear fog lamp RH connector A-005, terminal 8 and ground.
>> Go to the next step. >> Repair or replace the ground circuit or ground connection in harness or connectors.
CHECK DTC
5.
With the X-431 scan tool, read RBCM DTCs. Refer to DTC Confirmation Procedure.
15130
15
VISMW150086T
15131
On Board Diagnostic Logic Self-diagnosis detection logic. DTC NO. DTC DEFINITION DTC DETECTION CONDITION DTC SET CONDITION The Rear Body Control Module (RBCM) detects the RL window up control circuit low condition. POSSIBLE CAUSE RL power window motor Harness or connectors RBCM
B1362
15132
Diagnostic Procedure
1.
Turn ignition switch off. Disconnect rear LH power window motor harness connector I-001. Turn ignition switch on.
Check voltage between rear LH power window motor harness connector I-001, terminal 1 and ground while operating the left rear power window switch in the up position.
VISM150092
12 V should exist.
>> Go to the next step. >> Repair or replace circuit between RBCM connector B-028, terminal 6 and rear LH power window
motor connectors I-001, terminal 1 for open or high resistance.
2.
15
>> Go to the next step. >> Replace the rear LH power window motor.
15133
3.
CHECK DTC
With the X-431 scan tool, read RBCM DTCs. Refer to DTC Confirmation Procedure.
15134
ON-VEHICLE SERVICE
Rear Body Control Module (RBCM)
Removal & Installation
1. Disconnect the negative battery cable. 2. Remove the left floor mat in the luggage compartment. 3. Remove the RBCM retaining bolts (1).
VISM150031
4. Disconnect the RBCM electrical connector. 5. Remove the RBCM. 6. Installation is in the reverse order of removal.
15
15135
INSTRUMENT PANEL
Instrument Panel
Removal & Installation
1. Disconnect the negative battery cable. 2. Remove the instrument cluster (See Instrument Cluster Removal & Installation in Section 15 Body & Accessories). 3. Remove the driver airbag (See Driver Airbag Removal & Installation in Section 14 Restraints). 4. Remove the steering wheel (See Steering Wheel Removal & Installation in Section 11 Steering). 5. Remove the driver information center (See Driver Information Center Removal & Installation in Section 15 Body & Accessories). 6. Remove the lower console (See Lower Console Removal & Installation in Section 15 Body & Accessories). 7. Remove the CD player (See CD Player Removal & Installation in Section 15 Body & Accessories). 8. Remove the HVAC control panel (See HVAC Control Panel Removal & Installation in Section 13 HVAC). 9. Remove the A-pillar panel (See A-Pillar Panel Removal & Installation in Section 15 Body & Accessories). 10. Remove the main harness connecting with the body harness front door harness, the front end modules harness, the engine control harness and the air conditioning harness connectors. 11. Remove the shroud retaining screws (1) to remove the shroud.
VISM110017
12. Disconnect the spiral cable connector and remove the spiral cable.
15136
INSTRUMENT PANEL
13. Remove the wiper switch and high beam switch retaining screws (1).
VISM110004
14. Remove the left lower trim panel assembly of the instrument panel retaining bolts (1).
VISM150144
15
VISM150015
15137
INSTRUMENT PANEL
17. Remove the left blanking cover assembly and remove the retaining bolts (1). (Tighten: Left retaining bolts to 11 1 Nm)
VISM150018
18. Remove the right blanking cover assembly and remove the retaining bolts (1). (Tighten: Right retaining bolts to 11 1 Nm)
VISM150019
15138
INSTRUMENT PANEL
19. Remove the lower retaining bolts (1) and the ground cable. (Tighten: Lower retaining bolts to 11 1 Nm) (Tighten: Ground cable bolts to 8 1 Nm)
VISM150020
20. Remove the instrument panel assembly. 21. Installation is in the reverse order of removal.
Lower Console
Removal & Installation
1. Remove the lower console panel retaining screws. 2. Remove the left and right console panel (1).
VISM150021
3. Remove the mounting screws (1) connecting the instrument panel bracket.
15
VISM150143
15139
INSTRUMENT PANEL
4. Remove the screws (1) connecting the lower console and the center bezel.
VISM150027
VISM150022
15140
INSTRUMENT PANEL
6. Remove the bolts (1) connecting the lower console and the gearshift base. (Tighten: Lower console and gearshift base bolts to 8 1 Nm)
VISM150025
7. Using a trim stick, remove the parking brake level shield (1).
VISM150024
15
15141
INSTRUMENT PANEL
8. Remove the ashtray and remove the bolts (1) as shown. (Tighten: Lower console bolts to 8 1 Nm)
VISM150023
VISM150026
15142
INSTRUMENT CLUSTER
Description
The Instrument Cluster (IC) is located in the instrument panel directly in front of the driver. The IC is used to inform the driver of specific vehicle information. The IC uses indicator lamps and gauges to warn the driver of potentially critical operating conditions.
VISM150131
The IC indicator lights are listed below: EPS Warning Light (1) Airbag Light (2) Charging System Light (3) Oil Pressure Light (4) Tachometer (5) Speedometer (6) Malfunction Indicator Light (7) Anti-Lock Warning Light (ABS) (8) Left Turn Light (9) Immobilizer Light (10) High Beam Indicator Light (11) Brake System Warning Light (12) Right Turn Light (13)
15
15143
INSTRUMENT CLUSTER
Seat Belt Reminder Light (14) Fuel Gauge (15) Temperature Gauge (16) Temperature Warning light (17) Low Fuel Warning Light (18) Electronic Throttle Control Indicator Light (19) Odometer/Trip Odometer (20) Parking Brake System Warning Light (21) Parking Light (22) Door Open Warning Display (23) ESP Warning Light (24) Maintenance Indicator Light (25)
VISM150134
The driver information center lights are listed below: Front Fog Light Indicator Light (1) Trunk Lid Open Warning Display (2) Outside Temperature Display (3) Rear Fog Light Indicator Light (4)
Operation
The Instrument Cluster (IC) uses hard wired inputs from various sensors and switches. The sensors and switches are located throughout the vehicle. The IC displays the following gauges: Speedometer - The IC displays the vehicle speed as determined by the Engine Control Module (ECM) indicating the vehicle speed. Tachometer - The IC displays the engine speed as determined by the Engine Control Module (ECM) indicating engine speed. Temperature Gauge - The IC displays the engine coolant temperature as determined by the Engine Control Module (ECM) indicating engine coolant temperature. Fuel Gauge - The IC displays the amount of fuel in the fuel tank as determined by the fuel level sensor.
Specifications
Torque Specifications
DESCRIPTION Instrument Cluster Bezel Fasteners Instrument Cluster Fasteners TORQUE (Nm) 2 9
15144
INSTRUMENT CLUSTER
Special Tools
15
15145
INSTRUMENT CLUSTER
Electrical Schematics
Instrument Cluster (Page 1 of 4)
VISMW150089T
15146
INSTRUMENT CLUSTER
Instrument Cluster (Page 2 of 4)
15
VISMW150090T
15147
INSTRUMENT CLUSTER
Instrument Cluster (Page 3 of 4)
VISMW150091T
15148
INSTRUMENT CLUSTER
Instrument Cluster (Page 4 of 4)
15
VISMW150092T
15149
INSTRUMENT CLUSTER
Driver Information Center (Page 1 of 1)
VISMW150010T
15150
INSTRUMENT CLUSTER
15
15151
Diagnostic Help
1. The X-431 scan tool connects to the Data Link Connector (DLC) and communicates with the vehicle electronic modules through the data network. 2. Confirm that the malfunction is current and carry-out the diagnostic tests and repair procedures. 3. If the DTC can not be deleted, it is a current fault. 4. Use a digital multimeter to perform voltage readings on electronic systems. 5. Refer to any Technical Bulletins that may apply to the failure. 6. Visually inspect the related wiring harness. 7. Inspect and clean all Instrument Cluster (IC) grounds that are related to the most current DTC. 8. If numerous trouble codes were set, use a wiring schematic and look for any common ground circuits or voltage supply circuits that may apply to the DTC.
Ground Inspection
Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This added resistance can alter the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can effect the circuit. Perform the following when inspecting a ground connection: 1. Remove the ground bolt or screw. 2. Inspect all mating surface for tarnish, dirt, rust, etc. 3. Clean as required to assure good contact. 4. Reinstall bolt or screw securely. 5. Inspect for add-on accessories which may be interfering with the ground circuit. 6. If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are crimped to one eyelet, make sure no excess wire insulation has been crimped creating a bad ground.
15152
Diagnostic Tools
Diagnostic Scan Tool X-431 Digital Multimeter Jumper Wire
15
15153
VISMW150006T
15154
B1701
Ignition switch: ON
Diagnostic Procedure
1.
CHECK DTC
Turn ignition switch on, with the scan tool, view and erase stored DTCs in the IC. Turn ignition switch off, and wait a few seconds, then turn ignition switch on. With the scan tool, view active DTCs in the IC module.
>> Go to the next step. >> The condition that caused the DTC is currently not present. Monitor the scan tool data relative to
this circuit while wiggle test the wiring and connectors and look for if the DTC reset.
15
15155
2.
Turn ignition switch off. Disconnect the fuel level sensor and fuel pump assembly electrical connector. Turn ignition switch on. Check if the fuel level sensor reference voltage is present between the fuel level sensor connector B-032, pin 1 and ground. The voltage (less than 1 V) should exist.
VISMD150022
3.
CHECK FUEL LEVEL SENSOR CIRCUIT FOR OPEN AND SHORT TO POWER
Turn ignition switch off. Disconnect the IC module connector. Check harness continuity between the following terminals:
IC TERMINAL
21
Refer to Wiring Diagram. Continuity should exist. Check harness for short to power.
>> Go to the next step. >> Repair or replace the fuel level sensor supply circuit as necessary.
Check harness connector C-101, B-101, terminal 13 between IC connector C-001, terminal 21 and fuel level sensor connector B-032, terminal 1.
15156
4.
Using a 12 V test light connected to battery (+), probe fuel level sensor ground circuit.
>> Connect a jumper wire between the fuel level sensor connector B-032 pin 1 and pin 2, go to the
next step.
>> Repair or replace the fuel level sensor ground circuit for an open.
CHECK FUEL LEVEL METER INDICATE
5.
Turn the ignition switch off. Connect the IC connector. Turn ignition switch on. With the scan tool, view active DTCs and data stream in the IC. Check the fuel meter indicate full or if the DTC B1701 is not currently present.
6.
Check the fuel level sensor as follows: FUEL LEVEL SENSOR REFERENCE DATA FUEL GAUGE POINTER POSITION EMPTY RESERVE 1/4 1/2 3/4 FULL POINTER DEPART () 0 11.25 22.5 45 67.5 90 SENDER RESISTANCE () 283 189 137 89 62 40 POINTER TOLERANCE 3 3 3 3 3 3
>> Go to the next step. >> Replace the fuel level sensor.
CHECK DTC
15
7.
With the X-431 scan tool, read IC DTCs. Refer to DTC Confirmation Procedure.
>> Replace the IC. >> The system is now operating properly.
15157
VISMW150006T
15158
B1702
Ignition switch: ON
Diagnostic Procedure
1.
CHECK DTC
Turn ignition switch on, with the scan tool, view and erase stored DTCs in the IC. Turn ignition switch off, and wait a few seconds, then turn ignition switch on. With the scan tool, view active DTCs in the IC.
>> Go to the next step. >> The condition that caused the DTC is currently not present. See Diagnostic Help for more information.
2.
Turn ignition switch off. Disconnect the fuel level sensor and fuel pump assembly electrical connector. Turn ignition switch on. Check if the fuel level sensor reference voltage is present between the fuel level sensor connector B-032, pin 1 and ground. The voltage (less than 1 V) should exist.
15
15159
3.
Turn ignition switch off. Disconnect the IC connector. Check harness for a short to ground as follows:
GROUND
Ground
>> Go to the next step. >> Repair or replace the fuel level sensor supply circuit as necessary.
Check harness connector C-101, B-101, terminal 13 between IC connector C-001, terminal 21 and fuel level sensor connector B-032, terminal 1.
4.
Turn ignition switch off. Connect the IC connector. Turn ignition switch on. With the scan tool, view active DTCs and data stream in the IC. Check the fuel meter indicate low or the DTC B1702 is not currently present.
15160
5.
Turn ignition switch off. Check the fuel level sensor as follows: FUEL LEVEL SENSOR REFERENCE DATA FUEL GAUGE POINTER POSITION EMPTY RESERVE 1/4 1/2 3/4 FULL POINTER DEPART () 0 11.25 22.5 45 67.5 90 SENDER RESISTANCE () 283 189 137 89 62 40 POINTER TOLERANCE 3 3 3 3 3 3
>> Go to the next step. >> Replace the fuel level sensor.
CHECK DTC
6.
With the X-431 scan tool, read IC DTCs. Refer to DTC Confirmation Procedure.
>> Replace the IC. >> The system is now operating properly.
15
15161
B1705 - Vehicle Power Supply Too Large B1706 - Vehicle Power Supply Too Small
VISMW150004T
15162
15
VISMW150005T
15163
B1705
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 15 Body & Accessories). Inspect ground connections C-201 and C-202 positions (See Vehicle Wiring Harness Information - Main Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace ground harness or connections.
15164
2.
Turn ignition switch off. Disconnect IC electrical connector. Turn ignition switch on. Check power supply between IC terminal 11, 13 and terminal 3, 5 in the IC electrical connector C-001 terminal side.
3.
Start the engine, raise the engine speed over 1000 rpm. Measure the charging voltage with a digital voltmeter at the battery positive and negative terminals.
4.
Start the engine, raise the engine speed over 1000 rpm for a few minutes. Turn ignition switch off. Measure the voltage drop with a digital voltmeter at the battery positive and negative terminals while cranking the engine. Battery voltage should more than approximately 9 V.
5.
Disconnect the battery positive cable. Measure the continuity between IC terminal 11, 13 and battery positive. Continuity should exist.
15
15165
6.
Start the engine, raise the engine speed over 1000 rpm. Measure the charging voltage with a digital voltmeter at the battery positive and negative terminals.
7.
With the X-431 scan tool, read IC DTCs. Refer to DTC Confirmation Procedure.
15166
Diagnostic Procedure
1.
CHECK DTC
>> Go to the next step. >> The conditions that caused this code to set are not present at this time (See Diagnostic Help in
Section 15 Body & Accessories).
2.
Check the IC supply voltage circuit, ground circuit open, high resistance or short circuits existing.
>> Go to the next step. >> Repair circuit for open or short in harness and connectors.
CHECK DTC
3.
15
With the X-431 scan tool, read IC DTCs. Refer to DTC Confirmation Procedure.
>> The system is now operating properly. >> Replace and program IC.
15167
VISMW150164T
15168
U0073
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 15 Body & Accessories). Inspect ground connections C-201 and C-202 positions (See Vehicle Wiring Harness Information - Main Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace ground harness or connections.
CHECK DTC
15
2.
Turn ignition switch on. With the scan tool, select view IC DTCs and data stream.
>> Go to the next step. >> The conditions that caused this code to set are not present at this time (See Diagnostic Help in
Section 15 Body & Accessories).
15169
3.
With the scan tool X-431, attempt to enter all the other CAN communication modules such as ECM, ABS module, Restraints Control Module, Body Control Module (BCM), EPS control unit. Read CAN DTCs.
>> If all of the other modules have the CAN DTC High Speed CAN Communication, go to the next
step. If all of the other modules have the DTC about Lost communication with ICM, and not have the High Speed CAN Communication, Replace IC.
No
>> Go to step 8.
CHECK CAN-BUS LINE TERMINAL RESISTANCE IN IC
4.
Turn ignition switch off. Disconnect the battery negative cable. Disconnect IC connector. Check the resistance between IC connector 29 and 30. CAN BUS CIRCUIT RESISTANCE
CAN-H
CAN-L
RESISTANCE
30
29
123.6
15170
5.
CHECK CAN BUS LINE TOTAL RESISTANCE Turn ignition switch off. Check CAN-Bus line total resistance between DLC terminal 14 and 6. CAN BUS CIRCUIT RESISTANCE
CAN-H
CAN-L
RESISTANCE
14
60
6.
CAN
DLC TERMINAL
TERMINAL
CONTINUITY
CANH
Ground
No
15
15171
CAN
DLC TERMINAL
TERMINAL
CONTINUITY
CANL
14
Ground
No
7.
15172
8.
Inspect the IC electrical connector pins for proper fit or any chafed, pierced, pinched, or partially broken wires. With the X-431 scan tool, read IC DTCs.
>> The system is now operating properly. >> Replace the IC.
Reassemble the vehicle and road test to verify the customers complaint is repaired. The problem was caused by the IC internal error.
15
15173
ON-VEHICLE SERVICE
Instrument Cluster
Removal & Installation
1. Disconnect the negative battery cable. 2. Remove the two instrument cluster cover retaining screws (1).
VISM150165
VISM150016
VISM150017
15174
ON-VEHICLE SERVICE
5. Disconnect the instrument cluster electrical connector (1).
VISM150164
VISM150135
3. Remove the driver information center and then disconnect the sun sensor. 4. Installation is in the reverse order of removal.
15
15175
INTERIOR LAMPS
Description
The interior lamps are controlled by the Front Body Control Module (FBCM). Interior lamps consist of the following: Keyhole Lamp Front Courtesy Lamp Rear Room Lamp Front Step Lamp Backlight Adjusting Switch Instrument Cluster Headlamp Aiming Switch Driver Information Center Combination Lamp Switch Hazard Switch ESP Switch Trunk Lid Open Switch Console Power Socket (Illumination) Audio Unit Door Mirror Remote Control Switch Main Power Window And Door Lock/Unlock Switch Front Power Window Switch Rear Power Window Switch Glove Box Lamp
Operation
The Front Body Control Module (FBCM) receives switch inputs and controls voltage output to the interior lamps. The supply voltage is transmitted from the fuse box to the lamps.
15176
INTERIOR LAMPS
Electrical Schematics
Interior Lamps (Page 1 of 5)
15
VISMW150065T
15177
INTERIOR LAMPS
Interior Lamps (Page 2 of 5)
VISMW150066T
15178
INTERIOR LAMPS
Interior Lamps (Page 3 of 5)
15
VISMW150067T
15179
INTERIOR LAMPS
Interior Lamps (Page 4 of 5)
VISMW150068T
15180
INTERIOR LAMPS
Interior Lamps (Page 5 of 5)
15
VISMW150069T
15181
INTERIOR LAMPS
VISM150028
VISM150029
3. Disconnect the electrical connector. 4. Remove the rear room lamp. 5. Installation is in the reverse order of removal.
15182
INTERIOR LAMPS
Keyhole Lamp
Removal & Installation
1. Disconnect the negative battery cable. 2. Turn off the ignition switch. 3. Remove the steering column shroud retaining screws (1).
VISM110017
4. Disconnect the keyhole lamp electrical connector. 5. Remove the keyhole lamp. 6. Installation is in the reverse order of removal.
15
15183
POWER OUTLET
Description
There are two 12 volt electrical outlets. One is under the center console which is used for the cigarette lighter. The other is located on the right trim panel, near the front passenger area.
CAUTION: This power outlet is designed for 12V (120W) only. Do not use any type of accessory above this voltage.
Operation
The power outlets are powered when the ignition switch is in the ACC/ON position.
15184
POWER OUTLET
Electrical Schematics
Power Outlet (Page 1 of 1)
15
VISMW150024T
15185
POWER OUTLET
Power Outlet
Removal & Installation
1. Disconnect the negative battery cable. 2. Using an appropriate tool, pry the power outlet (1) out of the trim panel. 3. Disconnect the power outlet electrical connector. 4. Installation is in the reverse order of removal.
VISM150030
15186
POWER WINDOWS
Description
The power window system allows each of the door windows to be raised and lowered electrically by actuating a switch on each door trim panel. The drivers window switch allows the driver to lock out the individual rear window switches from operation. The power window system includes the power window switches on the drivers door trim panel, passenger door and rear doors, and the power window motors.
Operation
The front and rear power window motors are permanent magnet type. A battery positive and negative connection to either of the two motor terminals will cause the motor to rotate in one direction. Reversing current through these same two connections will cause the motor to rotate in the opposite direction. Each individual motor is grounded through their respective switch.
15
15187
POWER WINDOWS
Electrical Schematics
Power Window System (Page 1 of 4)
VISMW150044T
15188
POWER WINDOWS
Power Window System (Page 2 of 4)
15
VISMW150045T
15189
POWER WINDOWS
Power Window System (Page 3 of 4)
VISMW150046T
15190
POWER WINDOWS
Power Window System (Page 4 of 4)
15
VISMW150047T
15191
POWER WINDOWS
VISM150009
VISM150010
4. Remove the retaining screws and remove the power window switch assembly. 5. Installation is in the reverse order of removal.
15192
POWER WINDOWS
VISM150009
15
VISM150010
15193
POWER WINDOWS
4. Using a trim stick, pry up the inside door handle panel (1).
VISM150084
5. Remove the retaining bolt (1) in the inside door handle panel. (Tighten: Door retaining bolts to 7 1 Nm)
VISM150156
15194
POWER WINDOWS
6. Remove the retaining bolt (1) in the door handle panel. (Tighten: Door retaining bolts to 7 1 Nm)
VISM150087
CAUTION: While servicing the door panels, care should be taken to maintain a clean work environment. 7. Using a trim stick, remove the step lamp cover (1).
15
VISM150085
15195
POWER WINDOWS
8. Remove the step lamp bracket (1).
VISM150151
VISM150086
10. Using a screwdriver, remove the door trim panel lower three retaining screws (1).
VISM150152
15196
POWER WINDOWS
11. Using a trim stick, remove the triangular panel (1).
VISM150167
12. Using a screwdriver, remove the door trim panel upper retaining screw (1).
VISM150155
13. Remove the door trim panel and disconnect the speaker electrical connector. 14. Loosen the inside door handle control cable (1).
15
VISM150153
15. Remove the protective film from the front door. 16. Disconnect the power lock motor electrical connector. Chery Automobile Co., Ltd.
15197
POWER WINDOWS
17. Remove the retaining bolts (1). (Tighten: Power lock motor retaining bolts to 8 1 Nm) 18. Remove the retaining bolt (2) connecting the window glass guide rail and the door. (Tighten: Glass guide rail and door connecting bolt to 7 1 Nm)
VISM150011
19. Remove the door lock switch bracket retaining bolts (1). 20. Remove the door handle control cable retaining screws (2). 21. Remove the inside door glass weatherstrip (3).
VISM150157
15198
POWER WINDOWS
22. Lower the glass to a proper position, remove the power window motor retaining bolts (1). 23. Remove the window glass. 24. Disconnect the connector of the window motor. 25. Remove the guide rail mounting bolts (3). 26. Remove the window regulator retaining nuts (2) on the inner door panel. (Tighten: Window regulator retaining nuts to 9 1 Nm)
VISM150091
VISM150092
15
15199
POWER WINDOWS
Down
Up
15200
SEATS
General Information
Description
The power seat switches are on the outboard side of the seat near the floor. The power seat system is capable of allowing a user to adjust the power seat to the desired driving position.
Operation
Use the switch to move the seat up, down, forward, rearward, or to tilt the seat. The power seat can be adjusted to control eight different seating positions.
Front Seat
Removal & Installation
1. Move the seat to the furthest front end, and remove the protection cover of guide rail. 2. Move seat to the furthest back end, and remove the protection cover of guide rail. 3. Remove the mounting bolts at the front end of the guide rail (1).
VISM150033
15
15201
SEATS
4. Remove the mounting bolts at the back end of the guide rail (1).
VISM150034
5. The removal & installation of right front seat is similar to the left front seat. 6. Installation is in the reverse order of removal.
15202
SEATS
Rear Seat
Removal & Installation
1. Remove the rear seat cushion (1).
VISM150163
15
VISM150162
3. Pull the seat release upward to fold the rear seat. Chery Automobile Co., Ltd.
15203
SEATS
4. Open the trunk lid. 5. Remove the seats mounting bolts (1).
VISM150160
VISM150161
15204
IMMOBILIZER
Description
The vehicle security system uses a Vehicle Security Module (VSM) as an anti-theft device that prevents the engine from starting if an incorrect key is inserted into the ignition switch.
Operation
When an incorrect key is inserted into the ignition switch, the vehicle security system senses the incorrect key and sends a signal to the VSM. The Engine Control Module (ECM) receives the signal from VSM via the R-line. The ECM then disables the engine from starting.
15
15205
IMMOBILIZER
Electrical Schematics
Immobilizer (Page 1 of 1)
VISMW150012T
15206
IMMOBILIZER
15
15207
Ground Inspection
Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This added resistance can alter the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can effect the circuit. Perform the following when inspecting a ground connection: 1. Remove the ground bolt or screw. 2. Inspect all mating surface for tarnish, dirt, rust, etc. 3. Clean as required to assure good contact. 4. Reinstall bolt or screw securely. 5. Inspect for add-on accessories which may be interfering with the ground circuit. 6. If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are crimped to one eyelet, make sure no excess wire insulation has been crimped creating a bad ground.
Diagnostic Tools
Diagnostic Scan Tool X-431 Digital Multimeter Jumper Wire
15208
15
15209
15210
VISMW150012T
Diagnostic Procedure
1.
CHECK DTC
>> Go to the next step. >> The conditions that caused this code to set are not present at this time (See Diagnostic Help in
Section 15 Body & Accessories).
2.
Check the Immobilizer supply voltage circuit, ground circuit open, high resistance or short circuits existing.
>> Go to the next step. >> Repair circuit for open or short in harness and connectors.
15
15211
3.
Turn ignition switch off. Disconnect the Immobilizer electrical connector C-026 (1).
Check the resistance between the Immobilizer coil connector C-026, pin 9 and pin 11.
LTSMD150019
RESISTANCE
11
5 - 20 ohms
The resistance should be 5 to 20 ohms. Check the resistance between the Immobilizer coil connector C-026, pin 9 and pin 10. Check the resistance between the Immobilizer coil connector C-026, pin 11 and pin 10.
CONTINUITY
10 Not
11
10
15212
4.
CHECK DTC
With the X-431 scan tool, read the Immobilizer DTCs. Refer to DTC Confirmation Procedure.
15
15213
B3042 - W-Line Short Circuit To Ground B3043 - W-Line Short Circuit To Battery
Immobilizer
VISMW150012T
15214
B3042
B3043
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 15 Body & Accessories). Inspect ground connection C-204 position (See Vehicle Wiring Harness Layout - Main Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace ground harness or connections.
CHECK IMMOBILIZER DTC
2.
15
With the scan tool, view DTCs in the Immobilizer. Refer to DTC confirmation procedure.
>> Go to the next step. >> The condition that caused the DTC is currently not present. See Diagnostic Help for more information.
15215
3.
Turn ignition switch off. Disconnect the Engine Control Module (ECM) electrical connector E-001 (1).
VISMD150056
For DTC B3042, check the resistance of K-Line between the Immobilizer connector C-025, pin 8 and ground.
LTSMD150019
IMMOBILIZER TERMINAL
TERMINAL
RESULT
Ground
15216
IMMOBILIZER TERMINAL
TERMINAL
RESULT
Ground
>> Go to the next step. >> Repair the circuits fault as necessary.
REPLACE AND PROGRAM THE IMMOBILIZER
4.
Replace and program the Immobilizer with the X-431. Reconnect all disconnected electrical harness connectors. With the X-431 scan tool, view the DTCs in the Immobilizer.
>> Go to the next step. >> The system is now operating properly.
The DTC caused by Immobilizer.
5.
With the X-431 scan tool, view the DTCs in the ECM. Refer to DTC Confirmation Procedure.
>> Replace and program ECM. >> The system is now operating properly.
15
15217
B3050 - Relay External Line Short Circuit To Ground Or Open Circuit, Relay External Line Malfunction B3053 - Relay External Line Short Circuit To Battery
VISMW150012T
15218
B3050
B3053
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 15 Body & Accessories). Inspect ground connection C-204 position (See Vehicle Wiring Harness Layout - Main Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace ground harness or connections.
CHECK IMMOBILIZER DTC
2.
15
With the scan tool, view DTCs in the Immobilizer. Refer to DTC confirmation procedure.
>> Go to the next step. >> The condition that caused the DTC is currently not present. See Diagnostic Help for more information.
15219
3.
Turn ignition switch off. Disconnect the Immobilizer electrical connector C-025 (1).
Turn ignition switch on. Check voltage between the Immobilizer connector C-025, pin 4, 1 and ground.
LTSMD150019
IMMOBILIZER TERMINAL
GROUND
VOLTAGE
>> Replace and program the Immobilizer. Refer to DTC B3077 Diagnostic Procedure. >> For DTC B3050, go to the next step.
For DTC B3053, go to the step 5.
15220
4.
Turn ignition switch off. Disconnect the negative battery cable. Disconnect the body fuse and relay box electrical connector A. Refer to Wiring Diagram. Continuity should exist. Check harness continuity between the following terminals: Front Fuse and Relay Box
CONTINUITY
C6
Yes
Check harness continuity between the following terminals: Body Fuse Box
IMMOBILIZER TERMINAL
CONTINUITY
C20
Yes
Check harness for short to ground. Continuity between Immobilizer power supply and ground should not exist.
15
Repair or replace the open or high resistance circuit or short to ground in harness or connectors.
15221
5.
Turn ignition switch off. Disconnect the negative battery cable. Disconnect the body fuse and relay box electrical connector A. Check the resistance between Immobilizer ignition switch circuit terminal 4 and Immobilizer power supply circuit terminal 1.
IMMOBILIZER TERMINAL
IMMOBILIZER TERMINAL
CONTINUITY
No
Check resistance between Immobilizer ignition switch circuit and other power circuits. Refer to Wiring Diagram.
>> Go to the step 7. >> Repair or replace short to power circuits in harness or connectors.
DETECT MALFUNCTIONING PART
6.
Check fuse 15 (7.5A), fuse SB7 (30A). Check body fuse box, front fuse and relay box. Check harness connector B-103, C-103, terminal 11. Harness between battery and body fuse box, harness between battery and front fuse and relay box.
7.
With the X-431 scan tool, view the DTCs in the Immobilizer. Refer to DTC Confirmation Procedure.
>> Replace and program Immobilizer. >> The system is now operating properly.
15222
15
VISMW150012T
15223
B3055
B3056
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 15 Body & Accessories). Inspect ground connection C-204 position (See Vehicle Wiring Harness Layout - Main Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace ground harness or connections.
CHECK IMMOBILIZER DTC
2.
With the scan tool, view DTCs in the Immobilizer. Refer to DTC confirmation procedure.
>> Go to the next step. >> The condition that caused the DTC is currently not present. See Diagnostic Help for more information.
15224
3.
Turn ignition switch off. Disconnect the Immobilizer electrical connector C-026 (1).
Check the resistance between the Immobilizer coil connector C-026, pin 9 and pin 11.
LTSMD150019
11
4.
Check the resistance between the Immobilizer coil connector C-026, pin 9 and pin 10. Check the resistance between the Immobilizer coil connector C-026, pin 11 and pin 10.
15
CONTINUITY
10 Not
11
10
15225
5.
Reconnect the Immobilizer electrical connector C-026. Replace the chip (1) with a new one.
VISMD150018
Turn ignition switch on and perform the following: With the X-431 scan tool, choose M11 series. Choose immobilize. Choose input code. Input the safety code. Click the small keyboard. Click OK. Choose Immobilizer adapt. Choose Key learning immediately. Click OK.
VISMD150019T
This concern may have been caused by the transponder. Erase all codes before returning the vehicle to the customer.
VISMD150020T
15226
6.
Using the wiring schematic as a guide, inspect the related wiring and connectors of the Immobilizer. Verify that there is good terminal contact in the related connectors. Try to start the engine. With the X-431 scan tool, view active DTCs in Immobilizer.
Is the warning light flashing and DTC B3055 or B3056 still present?
Yes No
>> Replace and match the Immobilizer (This concern may have been caused by Immobilizer internal
fault). Refer to DTC B3077 Diagnostic Procedure.
This concern may have been caused by a loose or corroded terminal or connector. Erase all codes before returning the vehicle to the customer.
15
15227
B3060 - Unprogrammed Transponder Fixed Code Received B3061 - Disturbed Or No Challenge/Response Transponder Communication B3077 - Read-Only Transponder Detected
VISMW150012T
15228
B3060
B3061
B3077
Diagnostic Procedure
1.
Turn ignition switch off. Loosen and retighten ground screws on the body (See Ground Inspection in Section 15 Body & Accessories). Inspect ground connection C-204 position (See Vehicle Wiring Harness Layout - Main Harness in Section 16 Wiring).
>> Go to the next step. >> Repair or replace ground harness or connections.
15
15229
2.
With the scan tool, view DTCs in the Immobilizer. Refer to DTC confirmation procedure.
For DTC B3061, go to the next step. For DTC B3077, go to step 6.
No
>> The condition that caused the DTC is currently not present. Monitor the scan tool data relative to
this circuit while wiggle test the wiring and connectors and look for if the DTC reset. Using the wiring schematic as a guide, inspect the related wiring and connectors of the Immobilizer. Verify that there is good terminal contact in the related connectors.
3.
Turn ignition switch off. Disconnect the Immobilizer electrical connector C-026 (1).
Check the resistance between the Immobilizer coil connector C-026, pin 9 and pin 11.
LTSMD150019
11
15230
4.
Check the resistance between the Immobilizer coil connector C-026, pin 9 and pin 10. Check the resistance between the Immobilizer coil connector C-026, pin 11 and pin 10.
CONTINUITY
10 Not
11
10
5.
Using the X-431 scan tool, program the vehicle security system. Turn ignition switch on and perform the following: With the X-431 scan tool, choose M11 series. Choose immobilize. Choose input code. Input the safety code. Click the small keyboard. Click OK. Choose Immobilizer adapt. Choose Key learning immediately. Click OK.
Try to start the engine. With the X-431 scan tool, view active DTCs in Immobilizer.
VISMD150019T
15
This concern may have been caused by the not programmed transponder. Erase all codes before returning the vehicle to the customer.
15231
6.
VISMD150018
Turn ignition switch on. Repeat step 5. Try to start the engine. With the X-431 scan tool, view DTCs in Immobilizer.
No
This concern may have been caused by the transponder fault. Erase all codes before returning the vehicle to the customer.
VISMD150019T
7.
Try to start the engine. With the X-431 scan tool, view active DTCs in the Immobilizer.
This concern may have been caused by the Immobilizer fault. Erase all codes before returning the vehicle to the customer.
8.
Using the wiring schematic as a guide, inspect the related wiring and connectors of the ECM. Verify that there is good terminal contact in the related connectors. Try to start the engine. With the X-431 scan tool, view active DTCs in Immobilizer.
>> Replace the ECM and match the ECM to the Immobilizer (See Electronic Control Module Removal
& Installation in Section 03 Electronic Engine Controls) (This concern may have been caused by an ECM internal fault).
No
15232
ON-VEHICLE SERVICE
Immobilizer
Removal & Installation
1. Remove the instrument panel (See Instrument Panel Removal & Installation in Section 15 Body & Accessory) 2. Remove the retaining bolt (1) on the steering column.
VISM150035
3. Disconnect the Immobilizer harness. 4. Installation is in the reverse order of removal. Perform the following to match the Immobilizer to the ECM: With the X-431 scan tool, choose M11 series. Choose immobilize. Choose input code. Input the safety code. Click the small keyboard. Click OK. Choose Immobilizer adapt. Choose read EMS to Immobilizer immediately. Click OK. NOTE : If replacing the ECM with a new one, choose read Immobilizer to EMS immediately.
15
15233
ON-VEHICLE SERVICE
1.
CHECK BATTERY
>> Go to the next step. >> This concern has been caused by the transmitter battery.
Go to step 4.
2.
>> Go to the next step. >> Repair or replace the ignition lock cylinder key switch.
PERFORM THE RKE TRANSMITTER MATCH PROCEDURE
3.
Close all the doors. Insert the ignition key into the ignition switch which has lost synchronization in LOCK position. Press any button on the RKE transmitter within 5 seconds. Pull the ignition key out of the ignition switch. Try to operate the RKE transmitter.
>> Erase all codes before returning the vehicle to the customer. >> Go to the next step.
15234
ON-VEHICLE SERVICE
4.
Replace the RKE transmitter. Connect the X-431 scan tool to the Data Link Connector (DLC), press the POWER key to start the X-431 (use the most current software available). Turn ignition switch on. Enter the Diagnostic Program. Select Chery main program. Select diagnostic version. Enter download program. Select M11 series, and then select ISU. Select Remoter Match.
Press the lock button on the RKE transmitter for less than 2 seconds. Remove the key from the ignition switch. Try to operate the RKE transmitter.
LTSMD150020T
>> Erase all codes before returning the vehicle to the customer.
The concern was caused by the RKE transmitter.
>> Replace the FBCM (See FBCM Removal & Installation in Section 15 Body & Accessories).
Refer to the RKE transmitter match procedure with X-431 as the description. Perform match between the RKE transmitter and FBCM with the X-431.
15
15235
BODY EXTERIOR
BODY DIMENSIONS
Description Frame Body Frame Dimensions (Units: mm) Front View Body Front Dimensions Rear View Body Rear Dimensions Side View Body Side Dimensions (Units: mm) Engine Compartment Engine Compartment Dimensions (Units: mm) Windshield Windshield Dimensions (Units: mm) Body Openings Body Opening Dimensions 15-238 15-238 15-239 15-239 15-240 15-240 15-243 15-243 15-246 15-246 15-251 15-251 15-252 15-252 15-253 15-253 15-255 15-255 15-255 15-256 15-256 15-258 15-258 15-258 15-260 15-269 15-269 15-269 15-269 15-269 15-270 15-274 15-274 15-275 15-275 15-275 15-275 15-276 15-290 15-290 15-291 15-291 15-292 15-292 Front Fog Lamp Removal & Installation Backup/Stop/Rear Position/Rear Turn Signal/Rear Fog Lamp Removal & Installation High Mounted Stop Lamp Removal & Installation Turn Signal Lamp Removal & Installation License Plate Lamp Removal & Installation 15-292 15-292 15-293 15-293 15-294 15-294 15-295 15-295 15-295 15-295 15-296 15-296 15-296 15-298 15-298 15-298 15-299 15-299 15-299 15-300 15-300 15-300 15-301 15-301 15-302 15-302 15-302 15-303 15-304 15-304 15-305 15-305 15-305 15-306 15-310 15-310 15-311 15-311 15-311
FENDER
Front Fender Removal & Installation
FUEL DOOR
Fuel Door Removal & Installation
BUMPERS
Front Bumper Removal & Installation Rear Bumper Removal & Installation
GRILLE
Grille Removal & Installation
HOOD DOORS
Front Door Removal & Installation Disassembly Assembly Power Window System Inspection Replacing Front Door Hinge Rear Door Removal & Installation Disassembly Assembly Replacing Rear Door Hinge Hood Removal & Installation Hood Release Cable Removal & Installation
HORN
Description Operation Electrical Schematics Horn Removal & Installation
EXTERIOR LAMPS
Description Operation Specification Electrical Schematics Front Combination Lamp Assembly Removal & Installation Rear Combination Lamp Assembly Removal & Installation Headlamp Removal & Installation
MIRRORS
Description Operation Electrical Schematics Outside Mirror Removal & Installation
PAINT
Paint Codes Specification
15236
TRUNK LID
Description Operation Electrical Schematics Trunk Lid Removal & Installation Power Trunk Lid Release Removal & Installation
15-324 15-324 15-324 15-325 15-327 15-327 15-328 15-328 15-330 15-330 15-330 15-331 15-333 15-333 15-333 15-333 15-334 15-334 15-334 15-334 15-335 15-335 15-335 15-335
RADIATOR SUPPORT
Radiator Support Removal & Installation
STATIONARY GLASS
Description Electrical Schematics Front Windshield Removal Installation Rear Window Removal Installation
15
15237
BODY DIMENSIONS
Description
All measurements should be made from the bare metal, remove trim and bumper covers as necessary. Repair the badly damaged areas before taking measurements for underbody alignment. Monitor the upper body structure for excessive stress or movement while making any corrections to the underbody structure. Remove all the necessary glass to prevent breakage. All dimensions are shown in millimeters (mm).
Frame
Body Frame Dimensions (Units: mm)
VISM150036
15238
BODY DIMENSIONS
Front View
Body Front Dimensions
VISM150037
The clearance between the front hood and the air inlet grille at A-1: 7 0.9 mm.
15
1 - Front Hood
15239
BODY DIMENSIONS
The clearance between the front bumper and the front hood at A-2: 6 1 mm.
1 - Front Hood
2 - Front Bumper
VISM150039
The clearance between the headlamp and the front hood at A-3: 5 1 mm.
1 - Headlamp
2 - Front Hood
VISM150040
The clearance between the front hood and the front windshield at A-4: 13 1 mm.
1 - Front Hood
2 - Front Windshield
VISM150041
15240
BODY DIMENSIONS
The clearance between the headlamp and the front bumper at A-5: 2.5 0.7 mm.
1 - Headlamp
2 - Front Bumper
VISM150042
The clearance between the front window and the roof at A-6: 3.2 1 mm.
1 - Front Window
2 - Roof
VISM150043
The clearance between the front hood and the front bumper at A-7: 4 1 mm.
15
1 - Front Hood
2 - Front Bumper
VISM150044
15241
BODY DIMENSIONS
The clearance between the front bumper and the air inlet grille at A-8: 2.7 1 mm.
1 - Front Bumper
Rear View
Body Rear Dimensions
VISM150046
15242
BODY DIMENSIONS
The clearance between the rear bumper and middle luggage compartment cover at B-1: 5 1.3 mm
2 - Rear Bumper
VISM150047
The clearance between the rear window and the luggage compartment cover at B-2: 7.3 1.9 mm
1 - Rear Window
The clearance between the rear window and the roof at B-3: 3.5 0.9 mm
15
1 - Rear Window
2 - Roof
VISM150049
15243
BODY DIMENSIONS
The clearance between the taillamp and the luggage compartment cover at B-4: 2.5 1 mm
1 - Taillamp
The clearance between the taillamp and the rear bumper at B-5: 4 1 mm
1 - Taillamp
2 - Rear Bumper
VISM150051
The clearance between the luggage compartment cover and the rear bumper at B-6: 6 1.5 mm
2 - Rear Bumper
VISM150052
15244
BODY DIMENSIONS
The clearance between the rear fender and the luggage compartment cover at B-7: 4 1 mm
1 - Rear Fender
Side View
Body Side Dimensions (Units: mm)
VISM150054
The clearance between the front door and the front fender at C-1: 4 0.7 mm
15
1 - Front Fender
2 - Front Door
VISM150055
15245
BODY DIMENSIONS
The clearance between the front fender and A pillar at C-2: 4 0.7 mm
1 - Front Fender
2 - A Pillar
VISM150056
The clearance between upper front door and upper rear door at C-3: 4 0.7 mm
1 - Front Door
2 - Rear Door
VISM150057
The clearance between middle front door and middle rear door at C-4: 4 0.7 mm
1 - Front Door
2 - Rear Door
VISM150058
15246
BODY DIMENSIONS
The clearance between the front fender and the front door at C-5: 6 1.1 mm
1 - Roof
2 - Front Door
VISM150059
The clearance between the rear door and the rear fender at C-6: 4 0.7 mm
1 - Rear Door
2 - Rear Fender
VISM150060
The clearance between the fuel door and the rear fender at C-7: 3 0.8 mm
15
1 - Fuel Door
2 - Rear Fender
VISM150061
15247
BODY DIMENSIONS
The clearance between the taillamp and the rear fender at C-8: 1.5 0.8 mm
1 - Taillamp
2 - Rear Fender
VISM150062
The clearance between the rear bumper and the rear fender at C-9: 0.5 + 0.7 mm, 0.5 - 0.5 mm.
1 - Rear Bumper
2 - Rear Fender
VISM150063
The clearance between the front bumper and the front fender at C-10: 0.5 + 0.7 mm, 0.5 - 0.5 mm.
1 - Front Bumper
2 - Front Fender
VISM150064
15248
BODY DIMENSIONS
The clearance between the rear door and upper rear fender at C-11: 6 1.1 mm.
1 - Rear Door
2 - Rear Fender
VISM150065
The clearance between the rear fender and the side panel at C-12: 6.6 1.5 mm.
1 - Side Panel
2 - Rear Fender
VISM150066
The clearance between the side panel and the front door at C-13: 6 1.5 mm.
15
1 - Side Panel
2 - Front Door
VISM150067
15249
BODY DIMENSIONS
The clearance between the front fender and the side panel at C-14: 6 1.5 mm.
1 - Front Fender
2 - Side Panel
VISM150068
Engine Compartment
Engine Compartment Dimensions (Units: mm)
VISM150069
15250
BODY DIMENSIONS
Windshield
Windshield Dimensions (Units: mm)
15
VISM150070
15251
BODY DIMENSIONS
MARK AB BC NAME Joint Place of Front Windshield Lower Cross Beam and Front Fender Joint Place of Top Cover and Side Panel MARK CD EF NAME Joint Place of Top Cover and Side Panel (on Rear Fender) Joint Place of Rear Windshield Cross Beam and Side Panel (on Rear Fender)
VISM150070
Body Openings
Body Opening Dimensions
VISM150071
15252
MARK AB CD EF
NAME Mounting hole for the lock column of the rear door Mounting hole for the upper hinge of the rear door Mounting hole for the lower hinge of the rear door
MARK GH IJ
NAME Mounting hole for the upper hinge of the front door Mounting hole for the lower hinge of the front door
15
VISM150072
15253
BUMPERS
BUMPERS
Front Bumper
Removal & Installation
1. Open the engine hood. 2. Remove the upper bumper six retaining bolts (1).
VISM150073
VISM150074
4. Raise and support the vehicle. 5. Remove the lower retaining bolts (1) (left and right). (Tighten: Lower retaining bolts to 9 1 Nm)
VISM150075
6. Remove the bottom connecting bolts. (Tighten: Bottom connecting bolts to 11 1 Nm) 7. Disconnect the front fog lamp (left and right) and turn-signal lamp (left and right).
15254
BUMPERS
8. Lower the vehicle and then remove the front bumper.
VISM150077
Rear Bumper
Removal & Installation
1. Remove the dust shield connecting bolts (1) (left and right). (Tighten: Dust shield connecting bolts to 5 0.5 Nm)
VISM150078
15
VISM150079
15255
BUMPERS
3. Raise the vehicle and remove the bottom connecting clamps (1).
VISM150080
4. Lower the vehicle and remove the rear bumper. 5. Disconnect the parking sonar and the plate lamp. 6. Using a screwdriver, remove the parking sonar (1).
VISM150081
15256
DOORS
Front Door
Removal & Installation
1. Turn off the ignition switch. 2. Disconnect the inner electrical harness connector (1) on the front door.
VISM150095
3. Remove the retaining bolts (1) connecting the door and the A pillar. (Tighten: Retaining bolt to 63 5 Nm)
15
VISM150136
4. Remove the front bumper (See Front Bumper Removal & Installation in Section 15 Body & Accessories). 5. Remove the bolts connecting the fender and the dust shield.
15257
DOORS
6. Remove the bolt (1) connecting the fender and the upper A pillar. (Tighten: Connecting bolt to 11 1 Nm)
VISM150096
7. Remove the bolt (1) connecting the fender apron and the lower A pillar. (Tighten: Connecting bolt to 11 1 Nm)
VISM150097
VISM150098
VISM150099
15258
DOORS
11. Remove the front door mounting bolts (1). (Tighten: Front door mounting bolts to 36 4 Nm)
VISM150100
12. Installation is in the reverse order of removal. Installation Notes: Adjust the door in left, right and vertical directions.
Disassembly
1. Remove the outside mirror inner trim strip to the front door. 2. Remove the mounting nuts (1), and remove the outside mirror electrical connector. (Tighten: Outside mirror mounting nuts to 7 1 Nm)
15
VISM150090
15259
DOORS
5. Using a trim stick, remove the power lock switch assembly (1) on the left front door.
VISM150009
VISM150010
15260
DOORS
7. Using a trim stick, pry up the inside door handle panel (1).
VISM150084
8. Remove the retaining bolt (1) in the inside door handle panel. (Tighten: Door retaining bolts to 7 1 Nm)
VISM150156
15
15261
DOORS
9. Remove the retaining bolt (1) in the door handle panel. (Tighten: Door retaining bolts to 7 1 Nm)
VISM150087
CAUTION: While servicing the door panels, care should be taken to maintain a clean work environment. 10. Using a trim stick, remove the step lamp cover (1).
VISM150085
15262
DOORS
11. Remove the step lamp bracket (1).
VISM150151
VISM150086
13. Using a screwdriver, remove the door trim panel lower three retaining screws (1).
15
VISM150152
15263
DOORS
14. Using a trim stick, remove the inside cover (1) for the mirror bolts from the door trim panel.
VISM150167
15. Using a screwdriver, remove the door trim panel upper retaining screw (1).
VISM150155
16. Remove the door trim panel and disconnect the speaker electrical connector. 17. Loosen the inside door handle control cable (1).
VISM150153
15264
DOORS
19. Remove the speaker screws (1) and disconnect the speaker electrical connector.
VISM150089
20. Remove the speaker. 21. Remove the door lock switch bracket retaining bolts (1). 22. Remove the door handle control cable retaining screws (2). 23. Remove the inside door glass weatherstrip (3).
VISM150157
15
15265
DOORS
24. Lower the glass to a proper position, remove the power window motor retaining bolts (1). 25. Remove the window glass. 26. Disconnect the connector of the window motor. 27. Remove the guide rail mounting bolts (3). 28. Remove the window regulator retaining nuts (2) on the inner door panel. (Tighten: Window regulator retaining nuts to 9 1 Nm)
VISM150091
VISM150092
15266
DOORS
30. Remove the power lock motor retaining bolts (1). (Tighten: Power lock motor retaining bolts to 8 1 Nm) 31. Remove the retaining bolt (2) connecting the window glass guide rail and the door. (Tighten: Glass guide rail and door connecting bolt to 7 1 Nm)
VISM150011
32. Disconnect the door lock motor connecting rod to the door outside handle. 33. Remove the power door lock motor.
VISM150012
34. Remove the side turn signal lamp (1) and disconnect the connector.
15
VISM150093
35. Remove the manual door lock switch bracket retaining bolts and then remove the door lock switch bracket. (Tighten: Door lock switch bracket retaining bolts to 7 1 Nm)
15267
DOORS
36. Remove the front door outside handle retaining bolts (1). (Tighten: Front door outside handle retaining bolts to 7 1 Nm) 37. Remove the power door lock motor connectors and tie rods.
Assembly
1. Assembly is in the reverse order of disassembly.
Rear Door
Removal & Installation
1. Turn off the ignition switch. 2. Disconnect the inner electrical harness connector (1) on the rear door.
VISM150117
15268
DOORS
3. Remove the retaining bolt (1) connecting the door and the B pillar. (Tighten: Retaining bolt to 63 5 Nm)
VISM150118
4. Remove the four rear door mounting bolts (1). (Tighten: Rear door mounting bolts to 36 4 Nm)
VISM150119
5. Installation is in the reverse order of removal. Installation Notes: Adjust the door in left, right and vertical directions.
Disassembly
1. Using a screwdriver, remove the door trim panel and door connecting screws. 2. Using a trim stick, remove the door lock switch. 3. Remove the power window switch (1) and disconnect the electrical connector.
15
VISM150108
15269
DOORS
5. Remove the retaining bolt (1) in the inside handle panel. (Tighten: Retaining bolt to 7 1 Nm)
VISM150109
6. Remove the retaining bolt (1) connecting the trim panel and the door in the power window switch. (Tighten: Retaining bolt to 7 1 Nm)
VISM150110
VISM150158
8. Loosen the inside door handle control cable (1) and then remove the inner door handle.
VISM150153
15270
DOORS
9. Remove the door trim panel. CAUTION: While servicing the door panels, care should be taken to maintain a clean work environment. 10. Remove the protective film from the rear door. 11. Remove the speaker screws and disconnect the speaker electrical connector. 12. Remove the speaker. 13. Remove the rear door inner and outside weatherstrip. 14. Remove the glass run. 15. Remove the bolts (1) connecting the inner handle and the rear door. (Tighten: Inner handle retaining bolts to 7 1 Nm)
VISM150111
16. Remove the bolts connecting the outside handle and the rear door (1). (Tighten: Outside handle retaining bolts to 8 1 Nm)
VISM150112
17. Remove the rear door outside handle and door lock connecting rod (1).
15
VISM150113
15271
DOORS
18. Remove the door lock switch bracket retaining bolts (1). 19. Remove the door handle control cable retaining screws (2). 20. Remove the inside door glass weatherstrip (3).
VISM150157
21. Remove the rear door outside handle. 22. Lower the glass to a proper position, remove the retaining bolts (1). 23. Remove the window glass. 24. Disconnect the connector of the window regulator. 25. Remove the window regulator retaining nuts (2). (Tighten: Window regulator retaining nuts to 9 1 Nm) 26. Remove the rear door lock bracket retaining bolts (3).
VISM150115
VISM150114
15272
DOORS
28. Remove the power lock motor retaining bolts (1). (Tighten: Power lock motor retaining bolts to 8 1 Nm) 29. Remove the retaining bolt (2) connecting the window glass guide rail and the door. (Tighten: Glass guide rail and door connecting bolt to 7 1 Nm)
VISM150011
30. Remove the power lock motor and disconnect the harness.
VISM150116
Assembly
1. Assembly is in the reverse order of disassembly.
15
15273
EXTERIOR LAMPS
Description
The exterior lamps consist of the following: Headlamps Turn Signal Lamps Fog Lamps Stop Lamps Backup Lamps Position Lamps
Operation
Headlamps: With the light switch in the 2nd position, the Front Body Control Module (FBCM) receives input requesting head lamp operation. The FBCM then supplies power to the head lamps. Turn Signal Lamps: When the turn signal switch is in LH or RH position with the ignition switch in ON position, the FBCM detects the RH or LH turn signal request. The FBCM supplies power to the respective turn signal lamp. Hazard Lamps: When the hazard switch is in ON position, the FBCM detects the hazard switch signal. The FBCM outputs the flasher signal (right and left). The FBCM then activates the hazard indicator and audible buzzer. Fog Lamps: When the front/rear fog lamp switch is in ON position and also the light switch is in the 1st or 2nd position. The FBCM/RBCM receives input requesting fog lamp operation. The FBCM/RBCM then supplies power to the fog lamps. Stop Lamps: When the brake pedal is applied, the stop lamp switch sends the signal to the RBCM. The RBCM then supplies power to the stop lamps. Backup Lamps: When the FBCM receives the signal from the backup lamp switch. The FBCM then sends a signal to the RBCM, then the RBCM supplies power to the backup lamp.
Specification
Torque Specification
DESCRIPTION Front Combination Lamp Fixing Bolts Rear Combination Lamp Fixing Bolts Nm 81 81
15274
EXTERIOR LAMPS
Electrical Schematics
Headlamp Aiming System (Page 1 of 3)
15
VISMW150049T
15275
EXTERIOR LAMPS
Headlamp Aiming System (Page 2 of 3)
VISMW150050T
15276
EXTERIOR LAMPS
Headlamp Aiming System (Page 3 of 3)
15
VISMW150051T
15277
EXTERIOR LAMPS
Parking, License Plate and Tail Lamps (Page 1 of 2)
VISMW150053T
15278
EXTERIOR LAMPS
Parking, License Plate and Tail Lamps (Page 2 of 2)
15
VISMW150054T
15279
EXTERIOR LAMPS
Fog Lamps (Page 1 of 3)
VISMW150055T
15280
EXTERIOR LAMPS
Fog Lamps (Page 2 of 3)
15
VISMW150056T
15281
EXTERIOR LAMPS
Fog Lamps (Page 3 of 3)
VISMW150057T
15282
EXTERIOR LAMPS
Turn Signal and Hazard Warning Lamps (Page 1 of 3)
15
VISMW150058T
15283
EXTERIOR LAMPS
Turn Signal and Hazard Warning Lamps (Page 2 of 3)
VISMW150059T
15284
EXTERIOR LAMPS
Turn Signal and Hazard Warning Lamps (Page 3 of 3)
15
VISMW150060T
15285
EXTERIOR LAMPS
Stop Lamps (Page 1 of 1)
VISMW150052T
15286
EXTERIOR LAMPS
Backup Lamp (Page 1 of 2)
15
VISMW150061T
15287
EXTERIOR LAMPS
Backup Lamp (Page 1 of 2)
VISMW150062T
15288
EXTERIOR LAMPS
VISM150101
1 2 3
12 V (55 W) 12 V (55 W) 12 V (5 W)
VISM150102
15
15289
EXTERIOR LAMPS
VISM150103
4. Disconnect the rear combination lamp electrical connectors. 5. Pull out the rear combination lamp assembly carefully.
1 2 3 4 5
Rear Fog Lamp Backup Lamp Rear Turn Signal Lamp Stop Lamp Rear Position Lamp
VISM150104
15290
EXTERIOR LAMPS
Headlamp
Removal & Installation
1. Remove the front combination lamp assembly (See Front Combination Lamp Assembly Removal & Installation in Section 15 Body & Accessories). 2. Remove the headlamp bulb cover. 3. Disconnect the headlamp bulb electrical connector (1).
VISM150145
4. 5. 6. 7.
Remove the headlamp bulb clip. Carefully remove the bulb for the headlamp. Replace the bulb. Installation is in the reverse order of removal.
15
VISM150105
15291
EXTERIOR LAMPS
4. Replace the bulb (1). 5. Installation is in the reverse order of removal.
VISM150146
VISM150147
15292
EXTERIOR LAMPS
VISM150142
VISM150140
6. Remove the high mounted stop lamp. 7. Replace the bulb. 8. Installation is in the reverse order of removal.
15
15293
EXTERIOR LAMPS
VISM150148
VISM150093
5. Disconnect the side turn signal lamp electrical connector. 6. Replace the bulb. 7. Installation is in the reverse order of removal.
VISM150141
15294
FENDER
Front Fender
Removal & Installation
1. Remove the front bumper (See Front Bumper Removal & Installation in Section 15 Body & Accessories). 2. Remove the bolts connecting the fender and the dust shield. 3. Remove the bolt (1) connecting the fender and the upper A pillar. (Tighten: Connecting bolt to 11 1 Nm)
VISM150096
4. Remove the bolt (1) connecting the fender apron and the lower A pillar. (Tighten: Connecting bolt to 11 1 Nm)
VISM150097
15
VISM150098
15295
FENDER
6. Remove the bolts (1) connecting the fender to the body.
VISM150099
15296
FUEL DOOR
Fuel Door
Removal & Installation
1. 2. 3. 4. Open the fuel door. Remove the two fuel door retaining bolts (1). Remove the fuel door. Installation is in the reverse order of removal.
VISM150106
15
15297
GRILLE
Grille
Removal & Installation
1. Open the engine hood. 2. Remove the grille from the vehicle.
VISM150074
15298
HOOD
Hood
Removal & Installation
1. Remove the retaining clips with a screwdriver, and remove the under hood heat shield (1).
VISM150120
2. Loosen the windshield washer hose, and then remove the spray nozzle clip (1) to remove the spray nozzle.
15
VISM150121
15299
HOOD
3. Remove the retaining bolts (two each side) and set the hood aside.
BESM150133
VISM150123
15300
HORN
Description
A dual note electric horn system is installed on this vehicle. The horn system features electromagnetic horns. The horn system includes the following components: Horn - The horns are located under the headlamp in the front bumper. Horn Switch - The horn switch is located under the driver airbag.
Operation
The horn system operates on battery current received through a fuse in the Front Body Control Module (FBCM). The horn system circuit is designed so that the system will remain operational, regardless of the ignition switch position.
15
15301
HORN
Electrical Schematics
Horn (Page 1 of 1)
VISMW150017T
15302
HORN
Horn
Removal & Installation
1. Disconnect the negative battery cable. 2. Disconnect the horn electrical connectors. 3. Remove the horn retaining bolts (1) and remove the horns.
VISM150124
15
15303
MIRRORS
Description
The mirrors are controlled by a single switch assembly located on the drivers door trim panel. A three-position switch selects the right or left power mirror for adjustment. A momentary joystick directional switch allows the driver to adjust the selected power mirror in the Up & Down or Right & Left directions. The heated mirror system is controlled by Front Body Control Module (FBCM). When there is water vapor on the mirrors, the heated mirrors will eliminate the water vapor.
Operation
Use the mirror select switch, located on the drivers door trim panel, to adjust the view obtained in the outside mirrors. Rotate the joystick for Left or Right mirror selection. Select a mirror and press the joystick that correspond with the direction that you want the mirror to move.
15304
MIRRORS
Electrical Schematics
Power Mirrors (Page 1 of 2)
15
VISMW150020T
15305
MIRRORS
Power Mirrors (Page 2 of 2)
VISMW150021T
15306
MIRRORS
Heated Mirrors (Page 1 of 2)
15
VISMW150022T
15307
MIRRORS
Heated Mirrors (Page 2 of 2)
VISMW150023T
15308
MIRRORS
Outside Mirror
Removal & Installation
1. Disconnect the negative battery cable. 2. Remove the outside mirror inner trim strip to the front door. 3. Remove the mounting nuts (1), and remove the outside mirror electrical harness. (Tighten: Rear view mirror mounting nuts to 7 1 Nm) 4. Remove the outside mirror.
VISM150090
5. Installation is in the reverse order of removal. Installation Notes: If replacing the side view mirror lens, remove the lens and replace it before reinstalling the mirror.
15
15309
PAINT
Paint Codes
Specification
NO 1 2 3 4 5 COLOR Nasdaq Silver Wolfsburg Gray Aegean Blue Magic Black Chery White ITEM CODE KH GF HU CB BK
15310
PARKING SONAR
Description
When the transaxle selector lever is in the R position, a stationary object will be detected by the rear sonar sensor causing the sonar buzzer to sound a tone. As the vehicle moves closer to the object, the rate of the tone will increase. When the object is very close to the vehicle, the tone will sound continuously.
Operation
With power and ground supplied, transaxle gear selector lever in R position, the rear sonar sensor will detect obstacles within 1.5 m of the rear sonar sensors. The sensor signal inputs are transmitted to the Rear Body Control Module (RBCM) and the Front Body Control Module (FBCM). The RBCM and the FBCM communicate this signal to the instrument cluster via CAN communication to activate the buzzer. The vehicle operator is notified of obstacles by a varied rate of tone from the sonar buzzer depending on the distance of the obstacle being sensed.
15
15311
PARKING SONAR
Electrical Schematics
Parking Sonar (Page 1 of 2)
VISMW150027T
15312
PARKING SONAR
Parking Sonar (Page 2 of 2)
15
VISMW150028T
15313
PARKING SONAR
Sonar Sensor
Removal & Installation
1. Disconnect the negative battery cable. 2. Using a screwdriver, carefully remove the sonar sensor (1) from the bumper.
VISM150081
3. Disconnect the sonar sensor electrical connector. 4. Installation is in the reverse order of removal.
Sonar Alarm
Removal & Installation
NOTE : The sonar alarm is located at the instrument cluster. 1. Remove the instrument cluster (See Instrument Cluster Removal & Installation in Section 15 Body & Accessories). 2. Installation is in the reverse order of removal.
15314
RADIATOR SUPPORT
Radiator Support
Removal & Installation
1. Remove the radiator support retaining bolts (1) (on each side). 2. Remove the radiator support. 3. Installation is in the reverse order of removal.
VISM150129
15
15315
STATIONARY GLASS
Description
The stationary glass is comprised of the following: Front Windshield Rear Window Rear Window Defogger
15316
STATIONARY GLASS
Electrical Schematics
Rear Window Defogger (Page 1 of 1)
15
XLSMW150001T
15317
STATIONARY GLASS
Front Windshield
Removal
1. Remove the wiper arms and the lower trim panel from the windshield (See Wiper Arm Removal & Installation in Section 15 Body & Accessories). 2. Using piano wire, insert the piano wire between the body and the glass. Attach wooden blocks to both ends of the piano wire.
CAUTION: To prevent vehicle paint damage, use adhesive tape on painted surfaces during windshield removal. Place a plastic cover between the piano wire and the instrument panel to prevent the instrument panel from being scuffed when removing the glass.
BESM150013
3. Pull the piano wire around the glass, and cut off the bonding agent to remove the glass. NOTE : Leave as much bonding agent as possible on the body when removing the bonding portion of the glass.
BESM150014
Installation
1. Remove the rough portions on the body with a knife and clean the cut bonding agent with a rag soaked with cleaning solvent.
CAUTION: Even if the entire bonding agent has been cleared, you should also clean the body surface. Do not touch the glass surface after cleaning.
2. Remove the stopper with a knife. 3. Clear the bonding agent adhered to the glass with a scraper and clean the glass with glass cleaner. NOTE : Do not touch the glass after cleaning.
15318
STATIONARY GLASS
4. Replace the clamping piece if necessary: Remove the stopper with a knife Remove the old clamping piece Replace with a new clamping piece 5. Position the glass: Place the glass in the proper position Make reference marks on the glass and the body Remove the glass 6. Clean the contact surface of the glass: Clear any residue around the peripheral contact face of the glass with glass cleaner NOTE : Do not touch the glass surface after cleaning. 7. Install the water resistance piece: Install the water resistance piece using double face adhesive tape as shown in the figure. 8. Apply a layer of primer M on the contact surface of the body and apply a layer of primer M on the contact face of the body with a brush.
BESM150015
1 - Primer M
2 - Primer M
3 - Primer M
BESM150016
NOTE : Allow the primer coat to dry for a minimum of 3 minutes. Do not apply the primer to the bonding agent. Do not save the opened primer M for later use. 9. Apply a layer of primer G on the contact surface of the glass: Apply a layer of primer G on the edges and the contact surface of the glass with a brush or sponge. Wipe the excess primer off with a clean rag before it dries. NOTE : Allow the primer coat to dry for a minimum of 3 minutes. Do not apply the primer to the bonding agent. Do not save the opened primer G for later use. 10. Mixing the bonding agent: Clean a mixing board and a scraper completely with solvent. Thoroughly mix 500 grams of host crystal with 75 grams of hardener on a mixing board with a scraper. NOTE : Make sure that the molding be installed before the bonding agent has cured.
15
15319
STATIONARY GLASS
11. Applying the bonding agent: Cut off the pot tip and fill the bonding agent into the pot. Place the pot into the sealant gun. Apply the bonding agent on the glass as shown in the figure.
BESM150017
CAUTION: Verify that the water resistant piece is adhered to the panel of the body as shown in the figure.
13. To install the glass, align the reference marks on the glass and the body and then lightly press the glass into the body opening. 14. Apply the bonding agent on the edges of the glass with a scraper. 15. Remove any excessive or over flown bonding agent with a scraper. 16. Clamp the glass until the bonding agent has hardened. 17. Check for water leakage: Perform the leakage test after the hardening period. Seal any leaks with the proper sealant. 18. Install the upper molding of the windshield: Install the upper windshield molding on the body and tap it lightly to fasten it. Install the outer windshield molding.
BESM150018
Rear Window
Removal
1. Lay the seat back down and remove the coat track. 2. Remove the lower molding. 3. Remove the double face adhesive tape at both ends of the molding with a scraper as shown in the figure.
BESM150019
4. Rear window removal: Using piano wire, insert the piano wire between the body and the glass. Attach wooden blocks to both ends of the piano wire. Pull the piano wire through between the body and the glass from inside of the vehicle. Pull the piano wire along the bonding agent to cut it off.
15320
STATIONARY GLASS
CAUTION: Do not let the piano wire damage the two stoppers.
Remove the rear window.
Installation
1. Place the rear window molding around the glass and fit it manually. 2. Remove the rough portions on the body with a knife and clean the cut bonding agent with a rag soaked with cleaning solvent.
CAUTION: Even if the entire bonding agent has been cleared, you should also clean the body surface. Do not touch the glass surface after cleaning.
3. Remove the stopper with a knife. 4. Clean the removed rear window: Clean any bonding agent adhered to the glass with a scraper. Remove the stopper with a knife. Clean the glass with glass cleaner. NOTE : Do not touch the glass after cleaning 5. Position the glass: Place the glass in the proper position Make reference marks on the glass and the body Remove the glass 6. Clean the contact surface of the glass: Clear any residue around the peripheral contact face of the glass with glass cleaner. NOTE : Do not touch the glass surface after cleaning. 7. Apply a layer of primer M on the contact surface of the body with a brush. NOTE : Allow the primer coat to dry for a minimum of 3 minutes. Do not apply the primer to the bonding agent. Do not save the opened primer M for later use. 8. Apply a layer of primer G on the contact surface of the glass: Apply a layer of primer G on the edges and the contact surface of the glass with a brush or sponge. Wipe the excess primer off with a clean rag before it dries. NOTE : Allow the primer coat to dry for a minimum of 3 minutes. Do not apply the primer to the bonding agent. Do not save the opened primer G for later use. 9. Mixing the bonding agent: Clean a mixing board and a scraper completely with solvent. Thoroughly mix 500 grams of host crystal with 75 grams of hardener on a mixing board with a scraper. NOTE : Make sure that the molding be installed within the application period of the bonding agent, and the bonding agent should be mixed within 5 minutes.
15
15321
STATIONARY GLASS
10. Applying the bonding agent: Cut off the pot tip and fill the bonding agent into the pot. Place the pot into the sealant gun. Apply the bonding agent on the glass as shown in the figure.
BESM150017
CAUTION: Verify that the water resistant piece is adhered to the panel of the body as shown in the figure.
12. To install the glass, align the reference marks on the glass and the body and then lightly press the glass into the body opening. 13. Apply the bonding agent on the edges of the glass with a scraper. 14. Remove any excessive or over flown bonding agent with a scraper. 15. Clamp the glass until the bonding agent has hardened. 16. Check for water leakage: Perform the leakage test after the hardening period. Seal any leaks with the proper sealant. 17. Install the rear window molding: Install the rear window outer lower molding on the body and tap it lightly to fasten it. Connect the leads of the rear window defroster.
BESM150018
15322
TRUNK LID
Description
The trunk lid is located at the back of the vehicle.
Operation
The trunk lid can be opened with the key, remote key FOB or by using the trunk lid release button on the left lower trim panel.
15
15323
TRUNK LID
Electrical Schematics
Trunk Lid (Page 1 of 2)
VISMW150013T
15324
TRUNK LID
Trunk Lid (Page 2 of 2)
15
VISMW150014T
15325
TRUNK LID
Trunk Lid
Removal & Installation
1. Disconnect the negative battery cable. 2. Remove the retaining clips with a screwdriver, and remove the under trunk shield (1). NOTE: Trunk shield has 13 clips.
VISM150122
VISM150127
4. Remove the retaining bolts (1) of the lock actuator. (Tighten: Lock actuator retaining bolts to 9 1 Nm)
VISM150125
15326
TRUNK LID
5. Remove the luggage compartment lock retaining bolt (1). (Tighten: Luggage compartment lock retaining bolt to 9 1 Nm)
VISM150126
6. Remove the trunk lid stay bar clips (2). 7. Remove the four bolts (1) (two at left and right) to detach the luggage compartment door. (Tighten: Luggage compartment door bolts to 10 1 Nm)
VISM150128
8. 9. 10. 11.
Remove the luggage compartment wheel house trim assembly and the floor mat. Remove the weatherstrip of the rear luggage compartment. Lift the luggage compartment floor mat up to remove the spare tire. Installation is in the reverse order of removal.
15
VISM150122
15327
TRUNK LID
4. Disconnect the electrical connector (1) of the trunk lid release.
VISM150127
5. Remove the retaining bolts of the lock actuator. (Tighten: Lock actuator retaining bolts to 9 1 Nm)
VISM150125
6. Remove the luggage compartment lock. (Tighten: Luggage compartment lock retaining bolts to 9 1 Nm)
VISM150126
7. Installation is in the reverse order of removal. Installation Notes: Adjust the luggage compartment lock to maintain a clearance of 5 0.5 mm between the luggage compartment cover and the rear side enclosure.
15328
Operation
The wiper system is controlled by the wiper and washer switch. The wiper and washer system operate with the ignition switch is in the ON position. All wiper and washer functions are controlled by rotating the control knob on the end of the control stalk to the MIST, OFF, INT, LO or HI wiper positions.
15
15329
Electrical Schematics
Wiper and Washer System (Page 1 of 2)
VISMW150015T
15330
15
VISMW150016T
15331
Wiper Motor
Removal & Installation
1. Remove the protection caps from the left and right wiper arms. 2. Remove the retaining nuts (1) from the wiper arms. 3. Remove the two wiper arms.
VISM150137
4. Remove the lower trim panel of front windscreen. 5. Remove the fixing bolts of linking mechanism. 6. Disconnect the motor (1), remove the linking mechanism retaining bolts (2).
VISM150130
Wiper Arm
Removal & Installation
1. Remove the protection cap of the fixing nuts from the wiper arm. 2. Remove the retaining nuts (1) from the wiper arm. 3. Remove the wiper arm. 4. Installation is in the reverse order of removal.
VISM150137
15332
Wiper Linkage
Removal & Installation
1. 2. 3. 4. Remove the left lower trim panel from the front windshield. Disconnect the motor electrical connector (1). Remove the wiper linkage retaining bolts (2). Installation is in the reverse order of removal.
VISM150130
Washer Bottle
Removal & Installation
1. Remove the front bumper (See Front Bumper Removal & Installation in Section 15 Body & Accessories). 2. Disconnect the washer hose and the washer pump (2) electrical connector. 3. Remove the retaining bolts (1) to remove the washer bottle. 4. Installation is in the reverse order of removal.
VISM150139
15
15333
Washer Pump
Removal & Installation
1. Remove the front bumper (See Front Bumper Removal & Installation in Section 15 Body & Accessories). 2. Disconnect the negative battery cable. 3. Disconnect the washer hose and the washer pump (2) electrical connector. 4. Remove the washer pump assembly. 5. Remove the retaining bolts (1) as shown to remove the washer bottle if need. 6. Installation is in the reverse order of removal.
VISM150139
Wiper Switch
Removal & Installation
1. 2. 3. 4. Disconnect the negative battery cable. Remove the steering wheel. Disconnect the wiper switch electrical connector. Remove the wiper switch retaining screws (1).
VISM150132
15334
6WIRING
16
page Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 Vehicle Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-12 Vehicle Ground Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-25 Vehicle Fuse Box Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-34 Vehicle Wiring Harness Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-41
CONTENTS
WIRING INFORMATION
GENERAL INFORMATION
Description Electrical Schematics International Symbols 16-2 16-2 16-2 16-3 16-5 16-5 16-5 16-5 16-5 16-5 Voltmeter Ohmmeter 16-6 16-7 16-8 16-8 16-8 16-9 16-9 16-9 16-9
ELECTRICAL REPAIR
Wire Repair Fuse Replacement
ELECTRICAL TROUBLESHOOTING
Troubleshooting Wiring Problems Testing For Voltage Testing For Continuity Testing For A Short To Ground Intermittent and Poor Connections
ELECTRICAL COMPONENTS
Battery Cable Sensors, Switches, and Relays Connectors
16-6 16-6
16
161
GENERAL INFORMATION
Description
The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wiring harness components, splices and grounds.
Electrical Schematics
The electrical schematics are grouped into individual service manual chapters. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Engine Control Module (ECM) is most likely to be found in Chapter 03 (Electronic Engine Controls), so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Chery electrical schematics are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chery vehicles, it is important to understand the following features and characteristics: Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown with a solid line around the component. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. Switches and other components are shown as simply as possible, with regard to function only.
162
GENERAL INFORMATION
International Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world.
16
BESMW010001T
163
GENERAL INFORMATION
Below is a list of the symbols and their definitions that are used in the wiring diagrams. NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 ITEM Power source Fuse Current rating Fuse location Connectors Terminal number Component name Connector number Splice Optional splice Option abbreviation Ground (GND) DESCRIPTION This represents the condition when the system receives battery positive voltage. The single line represents that this is a fuse. This represents the current rating of the fuse. This represents the location of the fuse in the Power Fuse Box or Front Fuse and Relay Box. This represents connector E-101 is female and connector C-101 is male. This represents the terminal number of a connector. This represents the name of a component. This represents the connector number. The letter represents which harness the connector is located in. The shaded circle represents that the splice is always on the vehicle. The open circle represents that the splice is optional depending on vehicle application. This represents that the circuit is optional depending on vehicle application. This represents the ground connection (See Ground Distribution in Section 16 Wiring). Ground connector number has no view face. This arrow represents that the circuit continues to an adjacent page. The A corresponds with the A on the adjoining page of the electrical schematic. This represents that the system branches to another system identified by cell data code. This represents a description of the option abbreviation used on the page. This represents the connector information. This component side is described by the connector symbols. This shows a code for the color of the connector: B = Black W = White R = Red G = Green L = Blue Y = Yellow BR = Brown O = Orange GR = Gray The line enclosed by broken line circle represents shielded wire. As an illumination tool, in the circuit and instrument cluster.
13
Page crossing
14 15 16
17
Connector color
18 19
164
ELECTRICAL TROUBLESHOOTING
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory equipped components added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Perform the following when troubleshooting a wiring problem: 1. Verify the problem. 2. Verify any related symptoms (do this by performing operational checks on components that are in the same circuit). 3. Analyze the symptoms (use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue). 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation (for this step, check for proper operation of all items on the repaired circuit).
16
165
CAUTION: Do not connect a jumper wire from the power source line to a body ground. This may cause burning or other damage to wiring harnesses or electronic components.
BESM010026
Voltmeter
The DC voltmeter is used to measure circuit voltage. A voltmeter with a range of 15 V or more is used by connecting the positive (+) probe (red lead wire) to the point where voltage will be measured and the negative (-) probe (black lead wire) to a body ground.
BESM010027T
166
Ohmmeter
The ohmmeter is used to measure the resistance between two points in a circuit and to check for continuity and short circuits.
CAUTION: Do not connect the ohmmeter to any circuit where voltage is applied. This will damage the ohmmeter.
BESM010028
16
167
ELECTRICAL REPAIR
Wire Repair
NOTE : When splicing a wire it is important that the correct gage be used. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip. 4. Using a crimping tool, crimp the splice clip and wires together. NOTE : Do not use acid core solder when making wiring repairs. 5. Solder the connection together using a soldering iron and rosin core type solder only. 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing.
Fuse Replacement
When replacing a fuse, be sure to replace it with one of the same capacity. If a fuse fails again, the circuit probably has a short and the wiring should be checked. Be sure the negative battery terminal is disconnected before replacing a main fuse. When replacing a pullout fuse, use the fuse puller.
BESM010025
168
ELECTRICAL COMPONENTS
Battery Cable
Before disconnecting connectors or removing electrical parts, disconnect the battery cables (1).
VISM050002
BESM010024
Connectors
Disconnecting Connectors
When disconnecting 2 connectors, grasp the connectors, not the wires.
16
BESM010018
169
ELECTRICAL COMPONENTS
Connectors can be disconnected by pressing or pulling the lock lever as shown.
BESM010019
Locking Connector
When locking connectors, listen for a click indicating they are securely locked.
BESM010020
Connector Terminals
Pull lightly on individual wires to check that they are secured in the terminal.
BESM010023
1610
ELECTRICAL COMPONENTS
Connector/Terminal Replacement
Use the appropriate tools to remove a terminal as shown. While installing a terminal, be sure to insert it until it locks securely. Insert a thin piece of metal from the terminal side of the connector and with the terminal locking tab pressed down, pull the terminal out from the connector.
BESM010029
16
1611
ELECTRICAL SCHEMATICS
Electrical Schematics
16-14 16-14
1612
GENERAL INFORMATION
Description
The power distribution system is designed to provide safe, reliable, centralized and convenient access to the distribution of the electrical power required to operate all vehicle electrical and electronic systems. The following components are used for power distribution: Battery Power Fuse Box Front Fuse and Relay Box Body Fuse Box Ignition Switch Fuses Circuit Breakers Relays
Operation
The power distribution system operates all electrical and electronic engine, transaxle, chassis, safety, comfort and convenience systems.
16
1613
ELECTRICAL SCHEMATICS
Electrical Schematics
The power distribution electrical schematics include all wiring information detailed on the power side of all vehicle circuits. This is helpful when attempting to troubleshoot a specific electrical failure, and shows connector pin-out information and splices. Power Distribution (Page 1 of 11)
VISMW160020T
1614
ELECTRICAL SCHEMATICS
Power Distribution (Page 2 of 11)
16
VISMW160021T
1615
ELECTRICAL SCHEMATICS
Power Distribution (Page 3 of 11)
VISMW160022T
1616
ELECTRICAL SCHEMATICS
Power Distribution (Page 4 of 11)
16
VISMW160023T
1617
ELECTRICAL SCHEMATICS
Power Distribution (Page 5 of 11)
VISMW160024T
1618
ELECTRICAL SCHEMATICS
Power Distribution (Page 6 of 11)
16
VISMW160026T
1619
ELECTRICAL SCHEMATICS
Power Distribution (Page 7 of 11)
VISMW160027T
1620
ELECTRICAL SCHEMATICS
Power Distribution (Page 8 of 11)
16
VISMW160028T
1621
ELECTRICAL SCHEMATICS
Power Distribution (Page 9 of 11)
VISMW160029T
1622
ELECTRICAL SCHEMATICS
Power Distribution (Page 10 of 11)
16
VISMW160030T
1623
ELECTRICAL SCHEMATICS
Power Distribution (Page 11 of 11)
VISMW160031T
1624
ELECTRICAL SCHEMATICS
Electrical Schematics
16-27 16-27
16
1625
GENERAL INFORMATION
Description
The ground distribution system is designed to provide centralized and convenient ground locations for the entire vehicle electrical system.
Operation
The ground distribution system provides a grounding path for all electrical and electronic engine, chassis, safety, comfort and convenience systems.
1626
ELECTRICAL SCHEMATICS
Electrical Schematics
The ground distribution electrical schematics include all wiring information detailed on the ground side of all vehicle circuits. This is helpful when attempting to troubleshoot a specific electrical failure, and shows connector pin-out information and splices. Ground Distribution (Page 1 of 7)
16
VISMW160040T
1627
ELECTRICAL SCHEMATICS
Ground Distribution (Page 2 of 7)
VISMW160041T
1628
ELECTRICAL SCHEMATICS
Ground Distribution (Page 3 of 7)
16
VISMW160042T
1629
ELECTRICAL SCHEMATICS
Ground Distribution (Page 4 of 7)
VISMW160043T
1630
ELECTRICAL SCHEMATICS
Ground Distribution (Page 5 of 7)
16
VISMW160044T
1631
ELECTRICAL SCHEMATICS
Ground Distribution (Page 6 of 7)
VISMW160045T
1632
ELECTRICAL SCHEMATICS
Ground Distribution (Page 7 of 7)
16
VISMW160046T
1633
1634
GENERAL INFORMATION
Description
Fuses are used to protect the vehicle wiring. Fuses are sized and located to protect the wire they are connected to. If a component suddenly draws enough current to blow the fuse, the fuse is there to protect the wiring harness from damage. The vehicle fuses are located in the following locations: Power Fuse Box Front Fuse and Relay Box Body Fuse Box
Operation
When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected.
Operation
All of the electrical current from the battery and the generator output enters the power fuse box. The positive cable and eyelet are secured with a nut to the power fuse box B(+) terminal stud located on one end of the power fuse box housing. The power fuse box terminal stud cover is unlatched and opened to access the fuses.
16
1635
GENERAL INFORMATION
Overview
Power Fuse Box
VISMW160003T
1636
GENERAL INFORMATION
Operation
All of the circuits entering and leaving the front fuse and relay box do so through connectors. There are several separate wiring harness connectors that connect to the front fuse and relay box.
16
1637
GENERAL INFORMATION
Overview
Front Fuse and Relay Box
VISMW160001T
1638
GENERAL INFORMATION
Operation
All of the circuits entering and leaving the body fuse box, do so through connectors. There are several separate wiring harness connectors that connect to the body fuse box.
16
1639
GENERAL INFORMATION
Overview
Body Fuse Box
VISMW160004T
1640
16
1641
GENERAL INFORMATION
Description
This section provides illustrations identifying component and ground locations in the vehicle. To help locate all electrical components on the drawings, the following harness layouts use a map style grid: Front End Module Harness Engine Control Harness Main Harness Body Harness Front Door LH Harness Front Door RH Harness Rear Door LH Harness Rear Door RH Harness Roof Harness Air Conditioner Harness Tail Harness
Operation
Use the wiring harness diagrams in each harness section for component and ground identification. Refer to the appropriate index for the specific vehicle harness.
1642
16
VISMW160002T
1643
VISMW160012T
1644
16
1645
VISMW160015T
1646
16
1647
Main Harness
VISMW160006T
1648
16
1649
1650
Body Harness
16
VISMW160013T
1651
1652
16
1653
VISMW160008T
1654
16
1655
VISMW160009T
1656
16
1657
VISMW160010T
1658
16
1659
VISMW160011T
1660
16
1661
Roof Harness
VISMW160014T
1662
VISMW160016T
N-001 N-002 N-003 N-004 N-005 N-006 N-008 N-009 N-017 N-018 N-100
B/20 B/16 W-Y/2 B/6 W/6 B/6 W/2 W/4 B/3 Y/6 W/15
Automatic Temperature Control (ATC) Module Automatic Temperature Control (ATC) Module Blower Motor Recirculation Door Actuator Blend Door Actuator Mode Door Actuator Inside Temperature Sensor Sun Sensor Blower Control Module Defrost Door Actuator To C-109
16
1663
Tail Harness
VISMW160005T
B-301 B-401
W/6 W/3
1664
INDEX A
A-Pillar Trim Panel, Body Interior . . . . . . . . . . . . . . . . . 15-9 A/C System Evacuation and Recharge, System Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . 13-37 Accelerator Pedal Position Sensor, 1.6L & 1.8L Engine Controls . . . . . . . . . . . . . . . . . 3-196 Accessory Drive Belt - With Conventional Power Steering, 1.6L & 1.8L Engine Mechanical . . . . . 2-16 Accessory Drive Belt - With Electronic Power Steering , 1.6L & 1.8L Engine Mechanical . . . . 2-17 Accumulator, System Plumbing . . . . . . . . . . . . . . . . . 13-42 Adjustable Shoulder Belt Anchor, Seat Belt System . . . . 14-45 Air Cleaner Element, 1.6L & 1.8L Engine Mechanical . . . 2-18 Air Cleaner Housing, 1.6L & 1.8L Engine Mechanical . . . 2-18 Air Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26 Air Flow Sensor - 1.8L, 1.6L & 1.8L Engine Controls . . 3-196 Airbag System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1 Airbag System Disarming Procedure, Airbag System . . . 14-38 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 Antenna, Body Interior . . . . . . . . . . . . . . . . . . . . . . . . 15-8 Antilock Brake System (ABS) Bleeding Procedure, Antilock Brakes . . . . . . . . . . . . . . . . . . . 12-81 Antilock Brake System (ABS) Hydraulic Control Module, Antilock Brakes . . . . . . . . . . . . . . . 12-83 Antilock Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32 Audio System, Body Interior . . . . . . . . . . . . . . . . . . . . 15-4
C
C-Pillar Trim Panel, Body Interior . . . . . . . . . . . . . . . . 15-11 Camshaft Position Sensor, 1.6L & 1.8L Engine Controls . . . . . . . . . . . . . . . . . 3-194 Camshaft, 1.6L & 1.8L Engine Mechanical . . . . . . 2-20, 2-66 CAN Vehicle Communications, Body Interior . . . . . . . . 15-15 Canister Control Valve, Evaporative Emissions . . . . . . . 3-234 Catalytic Converter, Exhaust System . . . . . . . . . . . . . . . . 7-6 CD Player, Body Interior . . . . . . . . . . . . . . . . . . . . . . . 15-7 Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Chime, Body Interior . . . . . . . . . . . . . . . . . . . . . . . . 15-18 Clutch and Pressure Plate, Clutch System . . . . . . . . . . . 8-42 Clutch Assembly Service, Clutch System . . . . . . . . . . . . 8-42 Clutch Master Cylinder, Clutch System . . . . . . . . . . . . . 8-43 Clutch Slave Cylinder, Clutch System . . . . . . . . . . . . . . 8-46 Clutch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39 Compressor, System Plumbing . . . . . . . . . . . . . . . . . 13-39 Condenser, System Plumbing . . . . . . . . . . . . . . . . . . 13-41 Connecting Rods, 1.6L & 1.8L Engine Mechanical . . . . . 2-58 Coolant Level Sensor, Cooling System . . . . . . . . . . . . . 6-15 Coolant Pump, Cooling System . . . . . . . . . . . . . . . . . . 6-10 Cooling Fan, Cooling System . . . . . . . . . . . . . . . . . . . 6-13 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Cooling System Draining and Filling, Cooling System . . . . 6-8 Crankshaft Position Sensor, 1.6L & 1.8L Engine Controls . . . . . . . . . . . . . . . . . 3-193 Crankshaft, 1.6L & 1.8L Engine Mechanical . . . . . . . . . 2-60 Cylinder Head Cover, 1.6L & 1.8L Engine Mechanical . . . 2-19 Cylinder Head Unit Repair, 1.6L & 1.8L Engine Mechanical . . . . . . . . . . . . . . . . 2-63 Cylinder Head, 1.6L & 1.8L Engine Mechanical . . . 2-23, 2-63
B
B-Pillar Trim Panel, Body Interior . . . . . . . . . . . . . . . . 15-10 Backup/Stop/Rear Position/Rear Turn Signal/Rear Fog Lamp, Body Exterior . . . . . . . . . . . . . . . . . . . 15-292 Base Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Battery Hold Down, Starting System . . . . . . . . . . . . . . . 5-7 Battery Tray, Starting System . . . . . . . . . . . . . . . . . . . . 5-8 Battery, Starting System . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Bleeding Hydraulic Clutch, Clutch System . . . . . . . . . . . 8-46 Blend Door Actuator, System Controls . . . . . . . . . . . . 13-21 Blower Control Module, System Controls . . . . . . . . . . 13-24 Blower Motor, Air Distribution . . . . . . . . . . . . . . . . . . 13-31 Body Dimensions, Body Exterior . . . . . . . . . . . . . . . . 15-238 Body Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-236 Body Fuse Box, Vehicle Fuse Box Information . . . . . . . 16-39 Body Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 Body Interior Trim, Body Interior . . . . . . . . . . . . . . . . . 15-9 Body Openings, Body Exterior . . . . . . . . . . . . . . . . . 15-252 Brake Bleeding Procedure, Base Brakes . . . . . . . . . . . 12-10 Brake Pedal, Base Brakes . . . . . . . . . . . . . . . . . . . . . 12-24 Bumpers, Body Exterior . . . . . . . . . . . . . . . . . . . . . 15-254
D
Defrost Door Actuator, System Controls . . . . . . . . . . . 13-22 Diagnosing An Electrical Failure, Electrical Circuit Diagnosis Information . . . . . . . . . . . 1-16 Diagnosis & Testing, 1.6L & 1.8L Engine Controls . . . . . 3-20 Diagnosis & Testing, 1.6L & 1.8L Engine Mechanical . . . 2-13 Diagnosis & Testing, 5-Speed Manual Transaxle . . . . . . . 8-8 Diagnosis & Testing, Air Distribution . . . . . . . . . . . . . 13-29 Diagnosis & Testing, Airbag System . . . . . . . . . . . . . . 14-10 Diagnosis & Testing, Diagnosis & Testing, Diagnosis & Testing, Diagnosis & Testing, Body Interior . . . . Alignment . . . . . . . . . . . . . . . . . 10-39 Antilock Brakes . . . . . . . . . . . . . 12-40 Base Brakes . . . . . . . . . . . . . . . . 12-8 . . . . . . . 15-125, 15-152, 15-208, 15-52
AI
AI-1
INDEX
Diagnosis & Testing, Electronic Power Steering Electrical Diagnostics . . . . . . . . . . . . . . . . 11-59 Diagnosis & Testing, Front Axle . . . . . . . . . . . . . . . . . . 9-4 Diagnosis & Testing, Front Suspension . . . . . . . . . . . . . 10-5 Diagnosis & Testing, Fuel Delivery System . . . . . . . . . . 4-10 Diagnosis & Testing, Manual/Automatic Temperature Control . . . . . . . . . . . . . . . . . . . . . . . 13-10 Diagnosis & Testing, Parking Brake . . . . . . . . . . . . . . 12-90 Diagnosis & Testing, Power Steering Pump . . . . . . . . . 11-71 Diagnosis & Testing, Rear Axle . . . . . . . . . . . . . . . . . . 9-10 Diagnosis & Testing, Rear Suspension . . . . . . . . . . . . 10-28 Diagnosis & Testing, Steering Column - Electronic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-37 Diagnosis & Testing, Steering Column - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11 Diagnosis & Testing, Steering Gear - Electronic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-48 Diagnosis & Testing, Steering Gear - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22 Diagnosis & Testing, Steering System - Electronic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32 Diagnosis & Testing, Steering System - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4 Diagnosis & Testing, System Controls . . . . . . . . . . . . 13-20 Diagnosis Diagnosis Diagnosis Diagnosis & Testing, System Plumbing . . . . . . . . . . . . 13-35 & Testing, Wheels and Tires . . . . . . . . . . . . 10-45 and Testing, Cooling System . . . . . . . . . . . . . 6-7 and Testing, Exhaust System . . . . . . . . . . . . . 7-4 Driver Information Center, Body Interior . . . . . . . . . . 15-175 Driver Side Airbag, Airbag System . . . . . . . . . . . . . . . 14-38
E
Electrical Electrical Electrical Electrical Electrical Circuit Diagnosis Information . . . . . . . . Components, Wiring Information . . . . . Information . . . . . . . . . . . . . . . . . . . . Repair, Wiring Information . . . . . . . . . . Schematics, Vehicle Ground Distribution . . . . . 1-15 . . . . . 16-9 . . . . . 1-20 . . . . . 16-8 . . . . 16-27
Electrical Schematics, Vehicle Power Distribution . . . . . 16-14 Electrical Troubleshooting Tools, Wiring Information . . . . 16-6 Electrical Troubleshooting, Wiring Information . . . . . . . . 16-5 Electronic Power Steering Electrical Diagnostics . . . . . . 11-55 Electronic Power Steering Gear, Steering Gear - Electronic Power Steering . . . . . . . . . . . . . . 11-50 Electronic Throttle Control Actuator, 1.6L & 1.8L Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 3-197 Engine Assembly, 1.6L & 1.8L Engine Mechanical . . . . . 2-30 Engine Block, 1.6L & 1.8L Engine Mechanical . . . . . . . . 2-50 Engine Compartment, Body Exterior . . . . . . . . . . . . . 15-250 Engine Control Module (ECM), 1.6L & 1.8L Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 3-198 Engine Coolant Temperature Sensor, 1.6L & 1.8L Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 3-191 Engine Mounts, 1.6L & 1.8L Engine Mechanical . . . . . . 2-28 Engine Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . 3-200 Engine Timing Belt, 1.6L & 1.8L Engine Mechanical . . . . 2-38 Engine Unit Repair, 1.6L & 1.8L Engine Mechanical . . . . 2-50 Evaporative Emissions . . . . . . . . . . . . . . . . . . . . . . . 3-230 Evaporator, System Plumbing . . . . . . . . . . . . . . . . . . 13-41 Exhaust Manifold, 1.6L & 1.8L Engine Mechanical . . . . . 2-44 Exhaust Pipe Assembly, Exhaust System . . . . . . . . . . . . 7-5 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Exterior Lamps, Body Exterior . . . . . . . . . . . . . . . . . 15-274
Diagnosis and Testing, Starting System . . . . . . . . . . . . . 5-5 Diagnostic Help, Antilock Brakes . . . . . . . . . . . . . . . . 12-40 Diagnostic Trouble Code (DTC) List, Airbag System . . . 14-11 Diagnostic Trouble Code (DTC) List, Antilock Brakes . . . 12-41 Diagnostic Trouble Code (DTC) List, Body Interior . . . 15-126, 15-153, 15-209, 15-53 Diagnostic Trouble Code (DTC) List, Electronic Power Steering Electrical Diagnostics . . . . . . . . . . . . . . . . 11-61 Diagnostic Trouble Code (DTC) Tests, 1.6L & 1.8L Engine Controls . . . . . . . . . . . . . . . . . . 3-33 Diagnostic Trouble Code (DTC) Tests, Airbag System . . 14-15 Diagnostic Trouble Code (DTC) Tests, Antilock Brakes . . 12-43 Diagnostic Trouble Code (DTC) Tests, Body Interior . . . . . . . . . . . 15-127, 15-154, 15-210, 15-55 Diagnostic Trouble Code (DTC) Tests, Electronic Power Steering Electrical Diagnostics . . . . . . . . . . . . . . . . 11-62 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33 Differential Carrier, Differential . . . . . . . . . . . . . . . . . . . 8-36 Differential Unit Repair, Differential . . . . . . . . . . . . . . . . 8-36 Door Locks, Body Interior . . . . . . . . . . . . . . . . . . . . . 15-26 Doors, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . 15-257
F
Fastener Usage, Vehicle Information . . . . . . . . . . . . . . . 1-14 Fender, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . 15-295 Frame, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . 15-238 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Front Axle Shaft, Front Axle . . . . . . . . . . . . . . . . . . . . . 9-5 Front Body Control Module (FBCM), Body Interior . . . 15-120 Front Body Control Module - Front BCM, Body Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-39 Front Brake Caliper, Base Brakes . . . . . . . . . . . 12-15, 12-26 Front Brake Pads, Base Brakes . . . . . . . . . . . . . . . . . 12-21 Front Brake Rotor, Base Brakes . . . . . . . . . . . . . . . . . 12-17 Front Bumper, Body Exterior . . . . . . . . . . . . . . . . . . 15-254
AI-2
INDEX
Front Coil Spring, Front Suspension . . . . . . . . . . . . . . 10-15 Front Combination Lamp Assembly, Body Exterior . . . 15-289 Front Courtesy/Dome Lamp Assembly, Body Interior . . 15-182 Front Crankshaft Oil Seal, 1.6L & 1.8L Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Front Door, Body Exterior . . . . . . . . . . . . . . . . . . . . 15-257 Front Fender, Body Exterior . . . . . . . . . . . . . . . . . . . 15-295 Front Fog Lamp, Body Exterior . . . . . . . . . . . . . . . . 15-291 Front Fuse and Relay Box, Vehicle Fuse Box Information . . . . . . . . . . . . . . . . . . . . . . . . . . 16-37 Front Hub and Bearing, Front Axle . . . . . . . . . . . . . . . . 9-5 Front Lower Control Arm, Front Suspension . . . . . . . . . 10-8 Front Front Front Front Front Front Passenger Side Airbag, Airbag System . . . . . . . . 14-39 Seat Belt and Pre-Tensioner, Seat Belt System . . . 14-43 Seat, Body Interior . . . . . . . . . . . . . . . . . . . . . 15-201 Stabilizer Bar Link, Front Suspension . . . . . . . . . 10-10 Stabilizer Bar, Front Suspension . . . . . . . . . . . . . 10-11 Steering Knuckle, Front Suspension . . . . . . . . . . . 10-6 General Information, Base Brakes . . . . . . . . . . . . . . . . 12-2 General Information, Body Interior . . . . . . . . . . . . . . 15-201 General Information, Charging System . . . . . . . . . . . . . 5-11 General Information, Clutch System . . . . . . . . . . . . . . . 8-40 General Information, Cooling System . . . . . . . . . . . . . . . 6-2 General Information, Differential . . . . . . . . . . . . . . . . . . 8-34 General Information, Electronic Power Steering Electrical Diagnostics . . . . . . . . . . . . . . . . 11-56 General Information, Evaporative Emissions . . . . . . . . . 3-231 General Information, Exhaust System . . . . . . . . . . . . . . . 7-2 General Information, Front Axle . . . . . . . . . . . . . . . . . . . 9-2 General Information, Front Suspension . . . . . . . . . . . . . 10-2 General Information, Fuel Delivery System . . . . . . . . . . . 4-2 General Information, Ignition Control . . . . . . . . . . . . . 3-223 General Information, Manual/Automatic Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . 13-2 General Information, Parking Brake . . . . . . . . . . . . . . 12-88 General Information, Power Steering Pump . . . . . . . . . 11-70 General Information, Rear Axle . . . . . . . . . . . . . . . . . . . 9-9 General Information, Rear Suspension . . . . . . . . . . . . 10-26 General Information, Seat Belt System . . . . . . . . . . . . 14-42 General Information, Starting System . . . . . . . . . . . . . . . 5-2 General Information, Steering Column - Electronic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35 General Information, Steering Column - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9 General Information, Steering Gear - Electronic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-46 General Information, Steering Gear - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21 General Information, Steering System - Electronic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30 General Information, Steering System - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 General Information, System Controls . . . . . . . . . . . . . 13-15 General Information, System Plumbing . . . . . . . . . . . . 13-33 General Information, Vehicle Fuse Box Information . . . . 16-35 General Information, Vehicle Ground Distribution . . . . . 16-26 General Information, Vehicle Power Distribution . . . . . . 16-13 General Information, Vehicle Wiring Harness Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-42 General Information, Wheels and Tires . . . . . . . . . . . . 10-44 General Information, Wiring Information . . . . . . . . . . . . 16-2 Generator, Charging System . . . . . . . . . . . . . . . . . . . . 5-14 Grille, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . . 15-298 Grille, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . .298
Front Strut Assembly, Front Suspension . . . . . . . . . . . 10-12 Front Strut, Front Suspension . . . . . . . . . . . . . . . . . . 10-21 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Front Front Front Front Fuel Fuel Fuel Fuel Fuel Fuel Fuel Fuel View, Body Exterior . . . . . . . . . . . . . . . . . . . . 15-239 Wheel Alignment, Alignment . . . . . . . . . . . . . . . 10-41 Wheel Speed Sensor, Antilock Brakes . . . . . . . . . 12-85 Windshield, Body Exterior . . . . . . . . . . . . . . . . 15-318
Delivery System . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Door, Body Exterior . . . . . . . . . . . . . . . . . . . . . 15-297 Door, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . .297 Filter, Fuel Delivery System . . . . . . . . . . . . . . . . . 4-15 Injector Rail, Fuel Delivery System . . . . . . . . . Injector, Fuel Delivery System . . . . . . . . . . . . . Pressure Relief Procedure, Fuel Delivery System Pump, Fuel Delivery System . . . . . . . . . . . . . . . . . . . . . . . 4-16 . 4-17 . 4-12 . 4-12
G
Gear Selector & Shifter Assembly, 5-Speed Manual Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 General Information, 1.6L & 1.8L Engine Controls . . . . . . 3-3 General Information, 1.6L & 1.8L Engine Mechanical . . . . 2-3 General Information, 5-Speed Manual Transaxle . . . . . . . . 8-2 General Information, Air Distribution . . . . . . . . . . . . . . 13-27 General Information, Airbag System . . . . . . . . . . . . . . . 14-2 General Information, Alignment . . . . . . . . . . . . . . . . . 10-36 General Information, Antilock Brakes . . . . . . . . . . . . . 12-33
AI
AI-3
INDEX H
Headlamp, Body Exterior . . . . . . . . . . . . . . . . . . . . . 15-291 Headliner, Body Interior . . . . . . . . . . . . . . . . . . . . . . 15-14 Heater Core, System Plumbing . . . . . . . . . . . . . . . . . 13-47 High Mounted Stop Lamp, Body Exterior . . . . . . . . . . 15-293 Hood Release Cable, Body Exterior . . . . . . . . . . . . . . 15-300 Hood, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . . 15-299 Hood, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . .299 Horn, Body Exterior . . . . . . . . . . . . . . . . . . 15-301, 15-303 How To Locate Electrical Schematics In The Service Manual, Electrical Information . . . . . . . . . 1-25 How To Read Electrical Schematics, Electrical Information . . . . . . . . . . . . . . . . . . . . . . . 1-21 How To Use This Manual, Service Information . . . . . . . . 1-2 HVAC Housing Assembly, Air Distribution . . . . . . . . . . 13-30 Master Cylinder, Base Brakes . . . . . . . . . . . . . . . . . . 12-12 Mirrors, Body Exterior . . . . . . . . . . . . . . . . . . . . . . 15-304 Mode Door Actuator, System Controls . . . . . . . . . . . . 13-22 Muffler, Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . 7-5
N
Negative Battery Cable, Starting System . . . . . . . . . . . . . 5-7
O
Oil Filter, 1.6L & 1.8L Engine Mechanical . . . . . Oil Pan, 1.6L & 1.8L Engine Mechanical . . . . . . Oil Pump, 1.6L & 1.8L Engine Mechanical . . . . Oil Strainer, 1.6L & 1.8L Engine Mechanical . . . On-Vehicle Service, 1.6L & 1.8L Engine Controls On-Vehicle On-Vehicle On-Vehicle On-Vehicle On-Vehicle On-Vehicle Service, Service, Service, Service, Service, Service, . . . . . . 2-46 . . . . . . 2-47 . . . . . . 2-48 . . . . . . 2-49 . . . . . 3-191
I
Idler Gear, 5-Speed Manual Transaxle . . . . . . . . . . . . . . 8-29 Idler Pulley, 1.6L & 1.8L Engine Mechanical . . . . . . . . . 2-46 Ignition Coil, Ignition Control . . . . . . . . . . . . . . . . . . . 3-227 Ignition Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-222 Immobilizer, Body Interior . . . . . . . . . . . . . . 15-205, 15-233 Input Shaft, 5-Speed Manual Transaxle . . . . . . . . . . . . . 8-24 Inside Temperature Sensor, System Controls . . . . . . . . 13-25 Instrument Cluster, Body Interior . . . . . . . . . 15-143, 15-174 Instrument Panel, Body Interior . . . . . . . . . . . . . . . . 15-136 Instrument Panel, Body Interior . . . . . . . . . . . . . . . . . . .136 Intake Manifold, 1.6L & 1.8L Engine Mechanical . . . . . . 2-42 Interior Lamps, Body Interior . . . . . . . . . . . . . . . . . . 15-176 International Symbols, Vehicle Information . . . . . . . . . . 1-13
1.6L & 1.8L Engine Mechanical . . . . 2-16 5-Speed Manual Transaxle . . . . . . . . 8-9 Air Distribution . . . . . . . . . . . . . . 13-30 Airbag System . . . . . . . . . . . . . . . 14-38 Alignment . . . . . . . . . . . . . . . . . . 10-41 Antilock Brakes . . . . . . . . . . . . . . 12-81
On-Vehicle Service, Base Brakes . . . . . . . . . . . . . . . . 12-10 On-Vehicle Service, Body Interior . . . 15-120, 15-135, 15-174, 15-233 On-Vehicle Service, Charging System . . . . . . . . . . . . . . 5-14 On-Vehicle Service, Cooling System . . . . . . . . . . . . . . . . 6-8 On-Vehicle On-Vehicle On-Vehicle On-Vehicle On-Vehicle Service, Service, Service, Service, Service, Evaporative Emissions . . . . . . . . . . 3-234 Exhaust System . . . . . . . . . . . . . . . . 7-5 Front Axle . . . . . . . . . . . . . . . . . . . 9-5 Front Suspension . . . . . . . . . . . . . . 10-6 Fuel Delivery System . . . . . . . . . . . 4-12
K
Keyhole Lamp, Body Interior . . . . . . . . . . . . . . . . . . 15-183 Knock Sensor, 1.6L & 1.8L Engine Controls . . . . . . . . 3-192
L
License Plate Lamp, Body Exterior . . . . . . . . . . . . . . 15-294 Liquid Line, System Plumbing . . . . . . . . . . . . . . . . . . 13-43 Lower Console, Body Interior . . . . . . . . . . . . . . . . . . 15-139
On-Vehicle Service, Ignition Control . . . . . . . . . . . . . . 3-227 On-Vehicle Service, Manual/Automatic Temperature Control . . . . . . . . . . . . . . . . . . . . . . . 13-13 On-Vehicle Service, Parking Brake . . . . . . . . . . . . . . . 12-92 On-Vehicle Service, Power Steering Pump . . . . . . . . . . 11-72 On-Vehicle Service, Rear Axle . . . . . . . . . . . . . . . . . . . 9-11 On-Vehicle Service, Rear Suspension . . . . . . . . . . . . . 10-29 On-Vehicle Service, Seat Belt System . . . . . . . . . . . . . 14-43 On-Vehicle Service, Starting System . . . . . . . . . . . . . . . . 5-6 On-Vehicle Service, Steering Column - Electronic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-39 On-Vehicle Service, Steering Column - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12 On-Vehicle Service, Steering Gear - Electronic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-50 On-Vehicle Service, Steering Gear - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23
M
Manifold Absolute Pressure Sensor - 1.6L, 1.6L & 1.8L Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 3-195 Manual Transaxle, 5-Speed Manual Transaxle . . . . . . . . . 8-9 Manual/Automatic Temperature Control . . . . . . . . . . . . . 13-1 Manual/Automatic Temperature Control Module, Manual/Automatic Temperature Control . . . . . . . . . . . 13-13
AI-4
INDEX
On-Vehicle Service, Steering System - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 On-Vehicle Service, System Controls . . . . . . . . . . . . . 13-21 On-Vehicle Service, System Plumbing . . . . . . . . . . . . . 13-37 On-Vehicle Service, Wheels and Tires . . . . . . . . . . . . . 10-46 Output Shaft, 5-Speed Manual Transaxle . . . . . . . . . . . . 8-27 Outside Mirror, Body Exterior . . . . . . . . . . . . . . . . . . 15-309 Oxygen Sensor, 1.6L & 1.8L Engine Controls . . . . . . . 3-192 Rear Body Control Module Rear BCM, Body Interior . . . . . . . . . . . . . . . . . . . 15-121 Rear Brake Backing Plate, Base Brakes . . . . . . . . . . . . 12-25 Rear Brake Caliper, Base Brakes . . . . . . . . . . . 12-17, 12-29 Rear Brake Pads, Base Brakes . . . . . . . . . . . . . . . . . . 12-22 Rear Brake Rotor, Base Brakes . . . . . . . . . . . . . . . . . 12-19 Rear Bumper, Body Exterior . . . . . . . . . . . . . . . . . . 15-255 Rear Coil Spring, Rear Suspension . . . . . . . . . . . . . . . 10-33 Rear Combination Lamp Assembly, Body Exterior . . . . 15-290 Rear Crankshaft Oil Seal, 1.6L & 1.8L Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Rear Door, Body Exterior . . . . . . . . . . . . . . . . . . . . 15-268 Rear Guide Bar, Rear Suspension . . . . . . . . . . . . . . . 10-30 Rear Hub and Bearing, Rear Axle . . . . . . . . . . . . . . . . 9-11 Rear Lower Control Arm, Rear Suspension . . . . . . . . . 10-29 Rear Room Lamp, Body Interior . . . . . . . . . . . . . . . 15-182 Rear Rear Rear Rear Rear Rear Rear Rear Seat Belt and Tensioner, Seat Belt System . . . . . . 14-46 Seat, Body Interior . . . . . . . . . . . . . . . . . . . . . 15-203 Shock Absorber, Rear Suspension . . . . . . . . . . . 10-32 Stabilizer Bar Link, Rear Suspension . . . . . . . . . . 10-34 Stabilizer Bar, Rear Suspension . . . . Suspension . . . . . . . . . . . . . . . . . . Trailing Arm, Rear Suspension . . . . . Upper Control Arm, Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33 . 10-25 . 10-31 . 10-30
P
Paint Codes, Body Exterior . . . . . . . . . . . . . . . . . . . 15-310 Paint, Body Exterior . . . . . . . . . . . . . . . . . . . . . . . . 15-310 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-87 Parking Brake Cable, Parking Brake . . . . . . . . . . . . . . 12-92 Parking Brake Lever, Parking Brake . . . . . . . . . . . . . . 12-92 Parking Brake Shoes, Parking Brake . . . . . . . . . . . . . . 12-94 Parking Sonar, Body Exterior . . . . . . . . . . . . . . . . . . 15-311 Passenger Grab Handle, Body Interior . . . . . . . . . . . . 15-11 Pedal Pad, Body Interior . . . . . . . . . . . . . . . . . . . . . . 15-12 Pistons, 1.6L & 1.8L Engine Mechanical . . . . . . . . . . . . 2-53 Positive Battery Cable, Starting System . . . . . . . . . . . . . 5-7 Power Brake Booster, Base Brakes . . . . . . . . . . . . . . . 12-13 Power Fuse Box, Vehicle Fuse Box Information . . . . . . 16-35 Power Lock Motor, Body Interior . . . . . . . . . . . . . . . . 15-32 Power Lock Switch, Body Interior . . . . . . . . . . . . . . . 15-31 Power Outlet, Body Interior . . . . . . . . . . . . . 15-184, 15-186 Power Steering Filling and Flushing, Steering System - Hydraulic Power Steering . . . . . . . . . . . . . . 11-6 Power Steering Fluid Reservoir, Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . 11-73 Power Steering Pressure and Return Hoses, Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . 11-73 Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . 11-69 Power Steering Pump, Power Steering Pump . . . . . . . 11-72 Power Supply and Ground Circuit Test, 1.6L & 1.8L Engine Controls . . . . . . . . . . . . . . . . . . 3-25 Power Trunk Lid Release, Body Exterior . . . . . . . . . . 15-327 Power Window Motor, Body Interior . . . . . . . . . . . . . 15-193 Power Window Switch, Body Interior . . . . . . . . . . . . 15-192 Power Windows, Body Interior . . . . . . . . . . . . . . . . . 15-187 Proper Service Practices, Service Information . . . . . . . . . 1-5
Rear View, Body Exterior . . . . . . . . . . . . . . . . . . . . 15-242 Rear Wheel Alignment, Alignment . . . . . . . . . . . . . . . 10-42 Rear Wheel Speed Sensor, Antilock Brakes . . . . . . . . . 12-86 Rear Window, Body Exterior . . . . . . . . . . . . . . . . . . 15-320 Recirculation Door Actuator, System Controls . . . . . . . 13-23 Remote Keyless Entry (RKE) Inoperative, Body Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-234 Restraints Control Module (RCM), Airbag System . . . . . 14-40 Reverse Shift Fork, 5-Speed Manual Transaxle . . . . . . . . 8-30
S
Scuff Plate, Body Interior . . . . . . . . . . . . . . . . . . . . . 15-12 Seat Belt System . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-41 Seats, Body Interior . . . . . . . . . . . . . . . . . . . . . . . . 15-201 Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Side View, Body Exterior . . . . . . . . . . . . . . . . . . . . . 15-245 Sonar Alarm, Body Exterior . . . . . . . . . . . . . . . . . . . 15-314 Sonar Sensor, Body Exterior . . . . . . . . . . . . . . . . . . 15-314 Spark Plug Wire, Ignition Control . . . . . . . . . . . . . . . . 3-228 Spark Plug, Ignition Control . . . . . . . . . . . . . . . . . . . 3-229 Starter Motor Assembly, Starting System . . . . . . . . . . . . 5-8 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Stationary Glass, Body Exterior . . . . . . . . . . . . . . . . 15-316
AI
R
Radiator Support, Body Exterior . . . . . . . . . . . . . . . . 15-315 Radiator Support, Body Exterior . . . . . . . . . . . . . . . . . . .315 Radiator, Cooling System . . . . . . . . . . . . . . . . . . . . . . 6-11 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Rear Body Control Module (RBCM), Body Interior . . . 15-135
AI-5
INDEX
Steering Column - Electronic Power Steering . . . . . . . . 11-34 Steering Column - Hydraulic Power Steering . . . . . . . . . 11-8 Steering Column Shaft, Steering Column - Electronic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-41 Steering Column Shaft, Steering Column - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16 Steering Column Shroud, Steering Column - Electronic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40 Steering Column Shroud, Steering Column - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14 Steering Gear - Electronic Power Steering . . . . . . . . . . 11-45 Steering Gear - Hydraulic Power Steering . . . . . . . . . . 11-20 Steering Gear, Steering Gear - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23 Steering System - Electronic Power Steering . . . . . . . . 11-29 Steering System - Hydraulic Power Steering . . . . . . . . . 11-1 Steering Wheel, Steering Column - Electronic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-39 Steering Wheel, Steering Column - Hydraulic Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12 Sub-Frame Assembly, Front Suspension . . . . . . . . . . . 10-16 Suction Line, System Plumbing . . . . . . . . . . . . . . Sun Visor - LH, Body Interior . . . . . . . . . . . . . . . Sun Visor - RH, Body Interior . . . . . . . . . . . . . . . Symptom Diagnostic List, Electronic Power Steering Electrical Diagnostics . . . . . . . . . . . . . . . . . . . . Symptom Diagnostic Tests, Engine Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . System Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-45 . . . 15-13 . . . 15-13 . . . 11-60 . . . 3-201 . . . 13-14 Trunk Lid, Body Exterior . . . . . . . . . . . . . . . 15-323, 15-326 Turn Signal Lamp, Body Exterior . . . . . . . . . . . . . . . 15-294
U
Unit Repair, Base Brakes . . . . . . . . . . . . . . . . . . . . . 12-26 Unit Repair, Front Suspension . . . . . . . . . . . . . . . . . . 10-21
V
Valve & Valve Guides, 1.6L & 1.8L Engine Mechanical . . 2-70 Valve Springs, 1.6L & 1.8L Engine Mechanical . . . . . . . 2-73 Vapor Canister, Evaporative Emissions . . . . . . . . . . . . 3-235 Vehicle Fuse Box Information . . . . . . . . . . . . . . . . . . 16-34 Vehicle Ground Distribution . . . . . . . . . . . . . . . . . . . . 16-25 Vehicle Harness Routing Maps, Vehicle Wiring Harness Information . . . . . . . . . . . . . . . . . . . . . . . 16-43 Vehicle Identification Number (VIN), Vehicle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Vehicle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Vehicle Power Distribution . . . . . . . . . . . . . . . . . . . . 16-12 Vehicle Service Preparation, Service Information . . . . . . . 1-3 Vehicle Wiring Harness Information . . . . . . . . . . . . . . 16-41
W
Washer Bottle, Body Exterior . . . . . . . . . . . . . . . . . . 15-333 Washer Pump, Body Exterior . . . . . . . . . . . . . . . . . . 15-334 Wheel Assembly, Wheels and Tires . . . . . . . . . . . . . . 10-47 Wheel Balance, Wheels and Tires . . . . . . . . . . . . . . . . 10-47 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43 Windshield, Body Exterior . . . . . . . . . . . . . . . . . . . . 15-251 Wiper Arm, Body Exterior . . . . . . . . . . . . . . . . . . . . 15-332 Wiper Linkage, Body Exterior . . . . . . . . . . . . . . . . . . 15-333 Wiper Motor, Body Exterior . . . . . . . . . . . . . . . . . . . 15-332 Wiper Switch, Body Exterior . . . . . . . . . . . . . . . . . . 15-334 Wipers and Washers, Body Exterior . . . . . . . . . . . . . 15-329 Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
T
Thermostat, Cooling System . . . . . . . . . . . . . . . . . . . . . 6-9 Tie Rod, Steering Gear - Electronic Power Steering . . . 11-54 Tie Rod, Steering Gear - Hydraulic Power Steering . . . . 11-28 Tire Replacement & Repair, Wheels and Tires . . . . . . . 10-46 Tire Rotation, Wheels and Tires . . . . . . . . . . . . . . . . . 10-48 Transaxle Unit Repair, 5-Speed Manual Transaxle . . . . . . 8-18 Transaxle, 5-Speed Manual Transaxle . . . . . . . . . . . . . . 8-18
Y
Yaw Rate Sensor, Antilock Brakes . . . . . . . . . . . . . . . 12-84
AI-6