JB-DET Copen Service Manual

SECTION I General information PI
i Maintenance m
Engine rn
Engine Mechanical Em
Intake System lira
Exhaust System mm
Lubrication System rn
Cooling System Ea
Fuel System rn
Engine Control System rn
Emission Control System Im
Ignition System Ea
Starting System / Charging System BlEl
Engine Mounting ma
Front suspension w
Rear Suspension m
Wheel & Tire mm
Drive Shaft / Propeller Shaft / Axle rn
Brake m
Parking Brake rn
Brake Control m
Clutch m
Manual Transmission / Manual Transaxle m
Steering Em
Power Steering Em
SRS Airbag System m
Body am
Exterior / Interior
Windshield Windowglass / Mirror
aa-
IB
SECTION 2 Door Lock & Theft Deterrent
Sunmof / T-Ber Roof /Convertible
mI
--
rn
-
Lighting
Wiper & Washer ma
Meter ma
Audio & Visual System m
Heater and Air Conditioner mI
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Wiring Diagrams A, B, C & D
A1 GENERAL INFORMATION
IMPORTANT SAFETY NOTICE ------------ A1 - 1 HANDLING INSTRUCTION OF

GENERAL DESCRIPTION--------------- A1 - 1 CONNECTOR .............................. A1 - 1 9
WARNINGS, CAUTIONS AND CONNECTOR
NOTES ------------------------------------- A1 - 1 REMOVAUINSTALLATION
GENERAL WARNINGS .................... A1 - 2 PROCEDURE A1 - 19
HOW TO USE THIS MANUAL------------- A1 - 3 CHECK PROCEDURE OF WIRE
ARTICLES TO BE PREPARED--------- A1 - 3 HARNESS AND CONNECTOR-------- A1 - 21
REMOVAL AND INSTALLATION CIRCUIT INSPECTION OF
PROCEDURES A1 - 3 COMPUTER UNIT A1 - 22
DESCRIPTION OF SERVICE HANDLING INSTRUCTION OF
STANDARD VALUE Af - 4 SYSTEM ..................................... A1 - 23
CONTENTS NOT DESCRIBED IN INSTRUCTIONS FOR RADIO
THIS MANUAL A1 - 5 INSTALLATION ------------------------. A1 - 24
DEFINITIONS OF TERMS ---------------- A1 - 5 HANDLING INSTRUCTIONSON
ABBREVlATlON CODES-------------------- A1 - 6 CATALYTIC CONVERTER-EQUIPPED
HOW TO GRASP SPECIFIED VEHICLES A1 - 24
TIGHTENING TORQUE FOR PRECAUTION FOR VEHICLES
GENERAL STANDARD BOLT AND EQUIPPED WlTH SRS AIRBAG AND
NUT A1 - 7 SEAT BELT PRETENSIONER A1 - 25
DETERMINING PROCEDURE FOR INSTRUCTIONS FOR SERVICE
TIGHTENING TORQUE FOR OPERATION -
A1 25
GENERAL STANDARD BOLTS AND VEHICLE IDENTIFICATION --------------- A1 - 27
NUTS A1 - 7 BODY COLOR CODE A1 - 27
UNIT A1 - 9 CHASSIS SERIAL NUMBER A1 - 27
NEW UNIT BECAUSE OF THE ENGINE TYPE AND ENGINE
INTRODUCTION OF THE SI UNIT----- A1 - 9 NUMBER A1 - 27
GENERAL SERVICE INSTRUCTION--- A1 - 10 MANUFACTURER'S PLATE
SUPPORTING POINTS FOR JACKS POS~TION A1 - 28
AND SAFETY STANDS A1 - 12
JACKING POINTS A1 - 12
SUPPORTING POINTS OF SAFETY
(.- STANDS A1 - 13
SUPPORTING POINTS OF LIFTS-------A1 - 14
SWING ARM TYPE ....................... A1 - 14
PLATE TYPE A1 - 14
TOWING INSTRUCTIONS---------------- A1 - 15
TOWING WlTH ROPE( ONLY FOR
EMERGENCY ) A1 - 15
USING FLAT BED TRUCK--------------A1 - 15
WHEEL LIFT TYPE A1 - 15
DIAGNOSTICS INSTRUCTIONS--------- A1 - 16
DIAGNOSIS A1 - 16
DATA LlNK CONNECTOR ----------------- A1 - 18
DATA LlNK CONNECTOR
TERMINAL ARRANGEMENT ---------- A1 - 18
CONNECTION METHOD OF DATA
LINK CONNECTOR ....................... A1 - 18
CONNECTION METHOD OF EACH
SYSTEM ..................................... A1 - 18
INSTRUCTIONS FOR SYSTEM
lNSPECTlON .................................. A1 - 19
A1-1 -.
,
1 IMPORTANT SAFETY NOTICE

1-1 GENERAL DESCRIPTION
1.The vehicle is a machine comprising a great number of parts. Basically speaking, the vehicle is
potentially hazard. However, one can handle it safely if he has the required knowledge.
2.Correct service methods and repair procedures are very vital for assuring not only the safety and
reliability of a vehicle, but also the safety of service personnel concerned.
3.The methods and procedures contained in this manual describe in a general way the techniques
which the manufacturer has recommended. Thus, they will contribute to ensuring the reliability of the
products. The contents of the servicing operations come in a wide variety of ways. Moreover,
techniques, tools and parts necessary for each operation are different widely from each other.
4.This manual does not cover all details of techniques, procedures, parts, tools and handling
instructions which are necessary for these operations, for such coverage is impossible. Hence, any
one who obtains this manual is expected first to make his responsible selection as to techniques,
tools and parts which are necessary for servicing the vehicle concerned properly. Furthermore, he
must assume responsibility for his actions in connection with his own safety.
S.Therefore, one should not perform any service if he is not capable of making responsible selection
i ~
and/or if he can not understand the contents herein described, for this manual has been prepared for
experienced service personnel.
1-2 WARNINGS, CAUTIONS AND NOTES

1.All these symbols have their specific purposes, respectively.
WARNING
r This symbol means that there is the possibility of personal injury of the operator himself or the
nearby workers if the operator fails to follow the operating procedure prescribed in this manual.
CAUTION
r This symbol means that there is the possibility of damage to the component being repaired if the
operator fails to follow the operating procedure prescribed in this manual.
NOTE
r To accomplish the operation in an efficient manner, additional instructions concerning the operation
are given in this section. i
:
I
,.-_,1
-
A1-2
!
1-3 GENERAL WARNINGS
1-3-1 WARNING OVER THE WHOLE SERVICE OPERATIONS
1.Always wear safety glasses for eye protection.
2.Use safety stands whenever a procedure requires you to be under the vehicle.
3.Be sure that the ignition switch is always in the OFF position, unless otherwise required by the
procedure.
-
4.Set the oarkina brake when workina - on the vehicle.
5.0perate the engine only in a well-ventilated area to avoid the danger of carbon monoxide.
6.Keep yourself and your clothing away from moving parts, when the engine is running, especially from
the fan and belts.
7.To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold,
tail pipe, catalytic converter and muffler.
8.Do not smoke while working on a vehicle.
9.To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before
beginning to work on a vehicle.
10.Keep hands and other objects clear of the radiator fan blades! The electric cooling fan is mounted
on the radiator and can start to operate anytime by a rise in coolant temperature or turning ON of the
air conditioner switch in the case of vehicles equipped with an air conditioner. The electric cooling
fan is also mounted on the condenser for air conditioner and starts to operate anytime when the air
conditioner switch is turned ON. For this reason care should be taken to ensure that the electric
cooling fan motor is completely disconnected when working under the hood.
2 HOW TO USE THIS MANUAL
2-1 ARTICLES TO BE PREPARED
When SST, tool, measuring instrument, a sort of fat and oil to be prepared before operation are
necessary, those are described by compiling in the table as preparation tools at the beginning of each
item.
However, the general tools, jacks, fixtures as considered being equipped aiways at the service shop are
usually omitted.
2-2 REMOVAL AND INSTALLATION PROCEDURES
1.Block diagrams are posted so as to show the installed state of each part.
2.The application of a sort of fat and oil and sealer are instructed in the figure with arrow. And the
indication of a tightening torque and non-reusable parts are also described. The explanation of
each code is posted below the block diagram concerned.
3.The removal and installation (disassembling and assembling ) procedure list is shown just beneath of
components figure.
The removal (disassembling) procedure, the installation (assembling) procedure and parts name are
described in the sequence from left side of list. And the alphabet written before a part name links
with alphabet in the figure.
4 . h principle, reverse the removal (or disassembly) procedure to install (or assemble) the parts.
NOTE
Only in cases where the installation (or assembly) can not be carried out by reversing the removal
(or disassembly) procedure, the installation (or assembly) procedure is provided.
5 . h cases where a special procedure is required for the operation, a marking " V A "is provided in front
of the removal (or disassembly) procedure. Furthermore, explanation is given in the "Main points of
Removal (Disassembly)" or the "Main points of Installation (Assembly)."
The marking shows that there are the "Main points of Removal (Disassembly)." whereas " A "
shows that there are the "Main points of lnstallation (Assembly).''
I
2-2-1 ENTRY EXAMPLE
) COMPONENTS
+ : Rubber grease
%: Non-reusable part
Unit:Nm(kgf.cm]
(2) DISASSEMBLY AND ASSEMBLY PROCEDURES
1 a Cap, cylinder slide pin 8 h Plate, disc brake pad guide
2 b Pin, cylinder slide. No.1 9 i Boot, cylinder
A 3 c Pad, disc brake, N o 2 r 10 j Piston, disc brake
4 d Shim, anti squeal, No.1 11 k Seal, piston
\.
A 5 e Pad, disc brake w/ indicator. No.? 12 1 Boot, pin
6 f Shim, anti squeal, No.1 13 rnPin, cylinder slide, No.1
7 g Plate, disc brake pad guide 14 n Bush, cylinder slide
2-3 DESCRIPTION OF SERVICE STANDARD VALUE

The necessary service standard value for inspection and service operation are described with bold letter
in the text as standard and allowable limit. The details of terms are described in the section for definition
of terms.
2-4 CONTENTS NOT DESCRIBED IN THIS MANUAL
The description of the next elemental operation may omit in this service manual, but please perform in an
actual operation.
1.Jacking operation and lifting operation
2.Cleaning and cleansing of removed parts to perform at need
3.Visual inspection
2-5 DEFINITIONS OF TERMS
This mark shows the standard value a! the time of the check or adjustment.
VALUE
This mark shows the maximum or minimum value at the time of the check or adjustment.
I LtWt, 4 I
DEVIATION Th~svaLe refers to lne d~flerencebe!ween tne maxlmm clearance ano the m i n i m ~clearance
~.
t
3 ABBREVIATION CODES
The abbreviation codes that appear in this manual stand for the following, respectively.
IABBREVIATION CODE I ORIGINAL WORD I ABBREVIATION CODE I ORIGINAL WORD I
FR Front W/ With
GND Ground WVTA Whole Vehicle Type Approval
HC Hydro Carbon @ Bolt
IG Ignition 0 Screw
IN Intake 0 Nut
ISC Idle Speed Control @ Washer
LED Light Emitting Diode 0 Clip
4 HOW TO GRASP SPECIFIED TIGHTENING TORQUE FOR
GENERAL STANDARD BOLT AND NUT
4-1 DETERMINING PROCEDURE FOR TIGHTENING TORQUE FOR GENERAL
STANDARD BOLTS AND NUTS
4-1-1 DETERMINING PROCEDURE FOR TIGHTENING TORQUE FOR BOLTS
Determine the strength division of bolts, based on the table below.
Then, obtain the value, based on the tightening torque table.
4-1-2 DETERMINING PROCEDURE FOR TIGHTENING TORQUE FOR NUTS
Determine with the aforesaid method, based on the mating bolt.
4-1 -3 IDENTIFICATION
Identification of strenglh division by checkhg bolts themselves Identificationby part number
Classification Shape of head (how to know strength division) Hexagonal bolt
(Strength division) Bolt without collar Bolt with collar Exampleofpartnumber9 1 1 1 1 - 4 0 6 2 0
@ @ ,saGqJ JJ
4 T Nominal diameter (mm)
0 0 Nominal length (mm)
f Nominal diameter
5 T
@ - t----i
Nominal length
0
4-1-4 TIGHTENING TORQUE TABLE FOR GENERAL STANDARD BOLTS
Nominal diameter Pitch Standard tightening torque (N.rn(kgf.cm))
Strength divisin
(mm) (mm) Bolt without collar 1 Bolt with collar
6 1.O 5.4 (55) I 5.9 160)
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5 UNlT
As for the units, the SI units (international unit system) have been posted. (The hitherto-employed units,
too, are posted.)
Example: 33.25k 13.25N -m{340_f135kgf .cmJ
5-1 NEW UNlT BECAUSE OF THE INTRODUCTION OF THE SI UNlT

1.SI unit is the international unit system established by aiming to proceed the communication in
technology smoothly by unifying the former unit system which were different internationally each
other into one value by one unit. The specification value is described in accordance with SI unit
system in this service manual.
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6 GENERAL SERVICE INSTRUCTION

1.Use fender covers, seat covers, and floor sheets so that the vehicle may not get dirty or be
scratched.
2.Jacking up
(1) When only front section or rear section of a vehicle is jacked up, be sure to place chocks at the
wheels so as to insure safe operations.
(2) When the vehicle has been jacked up, be sure to support the vehicle at the specified section
using the safety stands.
(3) When the vehicle has been lifted up, be sure to set the cradle of the lift at the specified location,
and lift it up. And after the jacking up, ensure to apply the protective safety device.
And after the jacking up, ensure to apply the protective safety device.
(4) The jack-up operation must be carried out only on a level, flat place.
(5) Never jack up the vehicle at the front and rear sides at the same time.
3.lnstallation and removal of battery terminal
(1) Before you start performing the electrical works, make certain to disconnect the battery ground
cable terminal from the negative terminal of the battery.
(2) Before disconnecting the battery ground cable terminal from the negative terminal of the battery,
be sure to read out the diagnosis code of the EFI systems if it is equipped.
(3) After reconnecting the battery ground cable terminal to the negative terminal of the battery, be
sure to reset the watch or radio, if the vehicle is equipped with such equipment.
(4) When it becomes necessary to disconnect the battery power supply for the purpose of carrying
out checks or repairs, always disconnect the negative terminal of the battery ground cable from
the negative terminal of the battery first.
(5) To avoid damaging battery plates, after the terminal nut has been loosened, pull out the battery
ground cable terminal straight upward, rather than turning or prying the terminal.
(6) Be sure to employ a battery terminal puller (commercially available) to remove battery ground
cable terminal from the negative terminal of the battery, if any difficulty is encountered.
(7) Clean the battery terminal posts or battery ground cable terminals, using a cloth. Never use a file
or other abrasive agents.
(8) Install the battery cable terminals to the battery posts after loosing the nuts, and tighten the nuts
after installation. Never tap the terminals on the battery posts using a hammer or the like.
(9) As for the cover at the positive (+) terminal side, be sure to install it at the correct position.
4.Repairing of fuel system
(1) Do not work near open flames.
(2) Be certain to place a suitable container, a cloth, etc. under the connected section of the fuel line
before disconnecting the fuel line.
(3) Before the fuel line is disconnected, be sure to release the inner pressure of the fuel tank by
detaching the fuel filler cap.
(4) Be sure to prevent the fuel from splashing with a cloth or the like, when the union bolt or other
connected section of the fuel line is loosened or slackened.
(5) Tighten each connecting section to the specified torque.
(6) Attach the specified clips to each connecting section.
5.For increased work efficiency and improved accuracy, be sure to utilize the SSTs (Special Service
Tools) effectively.
6.Removal, Disassembly
(1) In case for the operation at the complicate place, the stamping and mating mark shall be put at
the place where there is no influence to the function, so that the assembling operation becomes
easy.
(2) At every time when each parts are removed, check the condition when it was assembled ,
deformation, breakage, roughness and existence of scratch .
(3) Arrange the removed parts in order, and divide them to the parts to replace and parts to reuse .
(4) Each parts to be reused shall be performed enough cleaning and cleansing operation.
7.Check and measurement of parts
(1) As regards those parts to be used again, perform thorough checks and measurements, as
required.
8.lnstallation. Assembling
(1) Assemble the good parts with correct procedure following the specified standard (value for the
adjusting , tightening torque).
(2) Use the genuine parts when replace the parts.
(3) Ensure to apply the seal packing and grease by a place.
(4) Ensure to use new packing, gasket or the like, cotter pin etc.
(5) When use the seal bolt, apply the specified liquid gasket and seal lock agent on.
(6) As for bolts and nuts, use the specified ones. Unless otherwise specified, the side for which the
torque is indicated should be tightened to the specified torque, using a torque wrench. If there
is no means to prevent the turning at the opposite side, be sure to prevent turning with box
wrenches, spanners or the like.
S.Adjustment, Operation confirmation
(1) Adjust with the specified service standard value by using the gauge and the tester.
10.Handling of hose or the like
(1) Ensure to insert the fuel hose, water hose or the like without coming out or leakage.
(2) Be careful that fuel shall not splash on the parts near by when remove the fuel hose. (Deep care
shall be paid for engine mount rubber or the like, as there may be possibility to get material
deterioration for liquid of gasoline series.)
11.Touch up
(1) When removed the bolt or the like during body fitting operation and others, the scratch of the
paint finishing surface on the body and bolt shall be repaired by the body color.
7 SUPPORTING POINTS FOR JACKS AND SAFETY STANDS
7-1 JACKING POINTS
CAUTION
= Be sure to set the jack in such a way that jack may not interfere with the bumper.
Never apply a jack to the rear suspension intermediate beam section.
Failure to observe this instruction may hamper the controllability due to beam deformation or
breakage.
Jacking points
Front side: Central projection at the front of the front frame
?ear side: Transport hook section
@ :Jacking point
7-2 SUPPORTING POINTS OF SAFETY 'STANDS
CAUTION
Never support the vehicle at points other than the specified points.
a:Safetystand support
8 SUPPORTING POINTS OF LIFTS
8-1 SWING ARM TYPE
Supporting points of lifts:
Safety stands supporting point
asupporting points of lifts
I C13S5503ESZC
8-2 PLATE TYPE

Supporting points of lifts:
Drive the vehicle onto the center of the supporting platforms both at the right and left.
.Since the vehicle is heavier at the front than the rear, lift up the vehicle at the front wherever possible.
7
m:Supporting points of lifts

t
9 TOWING INSTRUCTIONS
1.Be certain to transfer the vehrcle by usmg the flat deck truck when the running system andlor driving
system seems to be abnormal.
9-1 TOWING WITH ROPE( ONLY FOR I Towing with rope 1
EMERGENCY )
Release parking brake, and turn IG switch to ACC position,
and then put the sift lever into neutral range.
9-2 USING FLAT BED TRUCK

1.Transfer the vehicle with applying parking brake and
I Using flat bed type
I
fixing the vehicle firmly.
9-3 WHEEL LIFT TYPE

CAUTION
Do not allow anyone to be in the vehicle being towed.
9-3-1 TO TOW WlTH REAR WHEELS ON GROUND

1.Release the parking brake.
9-3-2 TO TOW WlTH FRONT WHEELS ON GROUND
1.Use a towing dolly.
2.lf a towing dolly is not available, and turn IG switch to ACC position, and then put the sift lever into
neutral range (for manual transmission vehicle).
10 DIAGNOSTICS INSTRUCTIONS
10-1 DIAGNOSIS
10-1-1 HOW TO PROCEED DIAGNOSIS
1 Each electronic control system equipped on the vehicle is an important clue at performing trouble
shooting. Also this system has self-diagnosis function to inspect the malfunction portion which
occurred in corresponding system, and battery back up (the function that power source for diagnosis
code memory is supplied even if IG switch is OFF) is equipped for self-diagnosis function of
electronic control system with, and is designed so that diagnosis code is memorized to each system.
As the function of diagnosis code memory is different by each system, perform the confirmation /
elimination of code memory according to the right operation procedure after confirming equipped
diagnosis code memory function.
(Entry of malfunctioningvehicle)
I-------------- ----I when

1
Ask the customer concerning
Diaanosis throuoh auestion-and-answer the conditions and the environment
maifunction occurred.
t
onfirmation and record of diagnosis cod
s i
Erasure of diagnosis code
(~econfirmationof malfunctioning phenomenon)-- . .... I Conlirm phenomenon and
e
qrasp problem cono~tions.
Reconfirmation of diagnosis code
Abnormal code 1 Normal code

I 1
--{ Narrow down malfunctioning systems. /
t
rouble-shooting according)
+
\ to diagnosis code ,)
I f~rouble-shootinaaccordino\
1 ( malfunctioning &enomen& )
Repair or replace
Confirm that the malfunctioning

Confirmation test (Has vehicle resumed its normal operation?) phenomenon that customer spoke
about has been remedied completely.
YES )------'-
ce)
10-1-2 SYMPTOM CONFIRMATION
1.When conducting a trouble shooting, the operator cannot pinpoint the cause for the malfunction,
unless he actually confirms the phenomenon. For this purpose, it is indispensable to reproduce the
malfunctioning phenomenon by creating conditions and environments that are similar to those where
the malfunction actually took place, based on the information obtained through the inquiry with the
customer. As for phenomena which cannot be reproduced easily, it is necessary to produce running
conditions that are close to those when the malfunction took place (road surface condition, weather
condition, and driving condition), based on the information obtained through the inquiry with the
customer. To this end, it is of great importance to try to reproduce the malfunction persistently by
applying external factors, such as vibration (moving wire harnesses and relays by hand), heat
(applying hot air), and water (applying moisture). Furthermore, while the malfunction phenomenon is
being reproduced, it is essential to check diagnosis codes indicated before and after the
confirmation of the malfunction phenomenon. Checking whether the code that was indicated before
the confirmation is outputted or not is also an important step for confirming the malfunction
phenomenon.
10-1-3 CUSTOMER PROBLEM ANALYSIS !
1.For the vehicle which malfunctions occurred, confirm first the malfunction phenomenon, and study the
cause and then eliminate the cause. There is possibility that the vehicle does not return to normal
condition even if perform many operation without study of cause. An asking about problems is to
gather the information from the customer before confirming the malfunction phenomenon, and
become an important clue when attempt to reproduce the malfunction. When perform the asking
about problem, it is necessary to focus to the items relating to said malfunctions so that information
attained with an asking about problems becomes useful reference of trouble shooting.
11 DATA LlNK CONNECTOR
11-1 DATA LlNK CONNECTOR TERMINAL ARRANGEMENT
No Terminal code No Terminal code

@I BAT(DS-21) @ ITC-T
0 - @ SIO(DS-21)
0 - 0 -
@ ECU-T 0 E( Signal earth)
8 EFI-1 0 E( Body earth)
8 W (immobilizer) @ -
0 - 0 -
@ REV @ VF I
11-2 CONNECTION METHOD OF DATA LlNK CONNECTOR

Perform it by connecting the engine control system inspection wire (SST) with the data link connector.
Perform the system check of each system by using the terminal for Connect circuit (SST), the terminal for
detecting engine speed and the terminal for VF output monitoring (SST)
11-3 CONNECTION METHOD OF EACH SYSTEM
1.Diagnosis code output of engine control system
: Connect circuit between EFI-T - E
2,Functioning check of O2sensor for engine control system
: Measure between VF -E
3.Engine speed check of engine control system
: Measure between REV - Body earth
4.Diagnosis code output of ABS system
: Connect circuit between ECU-T - E
5.Diagnosis code output of SRS airbag system
6.Diagnosis code output of immobilizer system
: Connect circuit between ECU-T - E, SST between BAT(DS-21) -W(lmmobiiizer)
7.0peration check of body integrated controller and hazard lamp system
: Connect circuit between ITC-T - E
8.Diagnosis code output of electric openinglclosing roof system
12 INSTRUCTIONS FOR SYSTEM
INSPECTION
12-1 HANDLING INSTRUCTION OF CONNECTOR
1 .Connection or disconnection of the connector and each
terminal shall be performed basically after the removal of
negative termrnal of the battery.
However, there may be the case that diagnosis code is
erased when remove the negative terminal of battery, so
confirm the diagnosis code first before the removal of
battery negative terminal when need to confirm.
2.When disconnecting connectors, be sure to hold the
connector itself with the connector unlocked.
Never pull harnesses. When connecting connectors, be
sure to positively insert the connectors, until you hear a
clicking sound and the lock is engaged.
3.When inserting tester probes into a connector, insert them
from the rear side of the connector.
4.For water-proof connectors which cannot be accessed

from behind, take good care not to deform the connector
terminals.
5.Never touch the terminal of connector directly by hand.
6.When a tester probe is applied to a terminal to which
voltage is applied, care must be exercised so that two
tester probes may not come in contact with each other so
- -
that short circuit may not take place.
L DOnot insert the tester probe in place.
GO7E5024EnO
12-2 CONNECTOR REMOVALANSTALLATION

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PROCEDURE
12-2-1 CONNECTOR WITH LOCKING BUTTON
(1) Type 1
@ POINTS OF REMOVAL
1.lnsert a flat screwdriver with a thin forward end (approx. 2
mm wide) into the locking button at the point A. Raise the
locking button, utilizing lever principle, until you hear a
clicking sound, thus unlocking the connector. S1BC5012ETlO
- A1-20
2.lnsert a flat screwdriver with a thin forward end (approx. 2 m m wide) at the point B or C. Pry the point
with the screwdriver in the arrow direction, utilizing lever principle, thus removing the connector.
@ POINTS OF INSTALLATION
1.lnsert the connector firmly as far as it goes. Push and
Locking button
I I
lock the connector, until the locking button clicks.
(2) Type 2
@ POINTS OF REMOVAL
1.With a flat screwdriver with a thin forward end, pull out the
locking button in the arrow direction, thus unlocking the
lock. Then, remove the connector.
@ POINTS OF INSTALLATION
1.lnsert the connector firmly as far as it goes. Push and
lock the connector, until the locking button clicks.
12-2-2 CONNECTOR WITH LEVER LOCK

(1) POINTS OF REMOVAL
1.Push the lock of the lever section in the arrow direction,
thus unlocking the lock.
2.Turn the lever about 40"in the direction A. Then, apply
force in the direction B to turn the lever.
3.Ensure that the lever has been turned fully. Then, remove
the connector,
(2) POINTS OF INSTALLATION

1.lnsert the connector to the mating side. Turn tkle lever in
the direction A to lock the connector.
L
12-3CHECK PROCEDURE OF WIRE HARNESS AND CONNECTOR
Perform the inspection of wire harness and connector portion in the distinctive system inspection in
accordance with next points.
12-3-1 CONTINUITY INSPECTION Sensor side Computer side
1.Remove the connector of corresponding harness on both
ends.
2.Measure the electrical resistance between corresponding
terminals of connector on both end.
SPECIFIED VALUE: Not more than 1 Q
CAUTION
r Measure the electrical resistance while shaking wire
harness in top and down and right and left lightly.
NOTE
0 In case of open circuit, as it is seldom that open circuit
happen in central part of wiring harness, and most of
part the open circuit happen are connector area.
Particularly, check the connector of the sensor portion
carefully.
12-3-2 SHORT CIRCUIT INSPECTION Sensor side Computer side
end.
terminal of connector and body earth connecting. In
addition t o above, perform the inspection with the
connector of each side.
SPECIFIED VALUE: Not less than I M Q
CAUTION
r Measure the electrical resistance while shaking wire
harness in lop and down, and right and left lightly.
A1-22
3.Measure electrical resistance between terminals in same
connector with the connector of COrreSpondin~ - terminal
(except between each power supply lines or earth lines).
In addition to above, perform the inspection at the
connector of both sides.
SPECIFIED VALUE: Not less than 1MQ
CAUTION
There may be short circuits due to wiring in the vehicle
compartment which is pinched by the body or faulty
clamps.
12-3-3 VISUAL INSPECTION, CONTACT FORCE
INSPECTION
end.
2.Check visually the rust generation or mixing of the foreign
material at connector terminal portion.
3.Check whether there are looseness, damage at the
staking portion and check coming out from the coupler
by pulling the wire harness lightly.
4.Prepare the same male terminal as that of the connector

terminal. Insert it into the female terminal and check the
pulling force.
The terminal having a smaller pulling force, compared
with other terminals, may cause poor contact.
CAUTION
r If the terminal section has rust formation, admission of
foreign matters or poor contact pressure between the
male terminal and the female terminal, the contact
condition may change by disconnecting and
reconnecting the connector once, thus resulting in No
malfunction.
Therefore, if the check of the wire harness and
connector reveals that there is no malfunction, confirm
the malfunction phenomenon. At this time, if no
malfunction phenomenon is reproduced, most likely the
poor contact between the male terminal and the female
terminal was causing the malfunction.
12-4 CIRCUIT INSPECTION OF COMPUTER UNIT
Perform computer unit circuit inspection. If it is malfunction, repair the corresponding connector, circuit,
and if normal, change the computer unit.
A1-23
I.VISUAL CHECK OF CONNECTOR PORTION, CONTACT FORCE INSPECTION
Check the connector of computer unit according to visual check and the contact force check point
described in former page.
2.COMPUTER UNIT EARTH CONNECTING INSPECTION
Remove the connector of computer unit, and then measure the applied voltage between each power
source terminal, each earth connector and body earth connecting.
SPECIFIED VALUE: VOLTAGE OF EACH POWER SUPPLY TERMINAL
CAUTION
0 At the computer unit circuit check, there may be cases when the malfunction disappears by
removing and installing the connectors, due to change of contact condition. Accordingly, when the
result of computer unit circuit check is normal, judge that computer unit is malfunctioned after
confirming the malfunction again by connecting the computer unit connector.
12-5 HANDLING INSTRUCTION OF SYSTEM

1.The computer unit, sensors, etc. are precision parts. Be very careful not to give strong impacts to
those parts during the installation and removal. Never use those parts which impacts have been ,
t
given (for example, in case where the parts were dropped on the floor).
2.When the test is carried out on rainy day or the vehicle is washed, care must be exercised so that no
water may be admitted and the computer unit, connectors, sensors, actuators, etc. may not get wet.
3.ln cases where the computer unit was judged to be malfunctioning and the vehicle has been
remedied by replacing it, install the removed computer unit (which has been judged to be
malfunctioning) again to confirm that the original malfunction is reproduced. Then the computer unit
can be finally judged to have been malfunctioning.
1
13 INSTRUCTIONS FOR RADIO INSTALLATION

CAUTION
For those motor vehicles equipped with a mobile communication system, such as a bidirectional
wireless telephone and cellular phone, be sure to observe the following precautionary measures
l.lnstal1 the antenna as far away as possible from electronic control system.
2.As the electromagnetic wave is radiated from antenna feeder, set the antenna feeder within the
distance at least not less than 300 mm apart from computer unit and ECU harness. Do not arrange
both line in parallel for long distance.
3.Never bind the antenna feeder together with the engine harness with binding tape.
4.Regulate the antenna and the feeder to get rid of radio interference.
5.Never install a strong mobile communication system (exceeding 10 kW).
14 HANDLING INSTRUCTIONS ON CATALYTIC CONVERTER-

EQUIPPED VEHICLES
1.Use only unleaded gasoline to catalytic converter-equipped vehicles.
2.Utmost care must be paid as to the following points, for the catalyst will be damaged if a large
amount of unburned gasoline flows into the catalytic converter.
(1) Do not operate the engine with the fuel in the fuel tank almost empty.
(2) The spark jump test must be limited to cases where such test is absolutely necessary. Also, be
sure to finish the test in the shortest possible time.
(3) The spark check of the spark plug and engine compression pressure measurement must be
performed with the fuel pump relay and injector connector disconnected and fuel injection
stopped.
3.Do not dispose the waste catalyst along with parts contaminated with gasoline or oil.
15 PRECAUTION FOR VEHICLES EQUIPPED WITH SRS AIRBAG
AND SEAT BELT PRETENSIONER
15-1 INSTRUCTIONS FOR SERVICE OPERATION
Be sure to perform the service operation for the vehicle equipped with the airbag and seat belt
pretensioner according to the correct procedure and method, otherwise, the airbag or pretensioner may
occur the malfunction and lead serious accidents during the service operation.Be sure to perform the
service operation according to the correct procedure and method described in this manual.
15-1-1 PRECAUTION PRIOR TO SERVICE OPERATION
1.Before servicing the airbag components or the seat belt pretensioner device, perform the following
procedures.
(1) Check the status of airbag warning lamp.
(2) Read the diagnosis codes and put it on record
(3) .Turn OFF the ignition switch and detach the negative terminal of the battery cable.
(4) Then, wait for at least 60 seconds to prevent the airbag from the deployment.
WARNING
* If the operation is started within 60 seconds from disconnecting the negative terminal of the battery
i,
cable, the airbag may be deployed.
NOTE
As airbag system provide the back up capacitor (for ignition purpose), about 60 seconds is
necessary as discharging time even though the battery negative terminal cable is disconnected.
(natural discharge)
CAUTION
* Be careful that memory of computer of other system (such as engine control) may be erased
simultaneously when the battery negative terminal cable is disconnected.
2.Ensure to use the digital circuit tester for the electric inspection of the vehicle equipped with the
a~rbag,pretensioner, and use the circuit tester which satisfy the following standard.
WARNING
0 Ensure beforehand to measure the electric current value of circuit tester to be used for an
operation, and confirm if it satisfy the following specified value. When the circuit tester exceeding
L
specified value is used, there may be possibility that malfunction or deterioration of alrbag occur. In
addition to above, measure the electric current of the circuit tester with minimal resistance ( Q )
range.
SPECIFIED VALUE: Not more than 50 mA (0.05A)
15-1-2 PRECAUTION TO PREVENT MISS OPERATION

1.Be sure not to drop the airbag system component parts during removal and installation.
2.Be sure not to give impact or damage when removing the airbag system component parts.
3.Be sure to put the pad Ay and assistant driver's seat airbag unit with deployment surface upward
during the operation though it is temporary operations. And never stack the pad Ay. (It may lead to
serious accidents if metal surface is facing upward at an emergency)
4.Keep the airbag system component parts in the place where the effect of electricity noise, the
high-temperature (not less than atmosphere temperature 85"C), and high humidity can be avoided.
5.Do not expose the airbag system component parts directly to high-temperature or flames.
6.Considering the case an airbag is actuated at an emergency, perform the service operation with %
posture as not to get your body close to deploying portion as much as possible.
15-75 GENERAL SERVICE INSTRUCTION
1.Follow the indication of the caution plate affixed on the airbag system related parts.
2.Be sure to mate the center when the steering roll connector is installed.
3.Be sure to perform the mating of the center for steering roll connector and marking to the separating
portion when repair the related parts described beiow.lf the relation of mutual position of parts are
changed, the harness of roll connector may be snapped when the steering wheel is operated.
(1) STEERING CONCERNED
1.Steering wheel, steering column, steering gear or the like
(2) VEHICLE BODY CONCERNED
1.Instrument panel or the like
2.Body electrical malfunctioned
3.Multi-use lever switch or the like
(3) POWER TRAIN CONCERNED
1.The case when separate the connection of steering gear at the removal and installation of the engine
and transmission and so on.
15-1-4 PRECAUTION PRIOR TO BODY AND PAINT OPERATION
1.As an inflator or the like are installed in the steering wheel central part, the upper part of instrument
panel, the root of B pillar. Be sure not to give strong impact with hammer or the like, and high
temperature during repairing.
2.Perform the operation after removing airbag system component parts when use of electric welding
machine is needed.
3.Perform the operation after removing the airbag system component parts when use of impact and the
high temperature is needed.
4.Do not expose the painting surface near the airbag related parts to high temperature ( 85°C or more)
during drying it.
5.Be sure to change with new parts when an airbag related parts have the external scratch,
deformation.
p~ ~ - ~p
16 VEHICLE IDENTIFICATION
16-1 BODY COLOR CODE
Body color name Color code
Silver metalic S28
Red R40
White 056
Dark blue mica melalic 842
Sunflower yellow YO7
Dark green mica 6Q7
Black mica NO5
Pearl white W16
16-2 CHASSIS SERIAL NUMBER

1.The chassis serial number is stamped on the position as
shown in the illustration.
ber
CI3SIUml
16-3 ENGINE TYPE AND ENGINE NUMBER

1.The engine type and engine number are given on the
places as shown in the illustration.
-
A1-28
16-4 MANUFACTURER'S PLATE POSITION
1 The manufacturer's plate is given on the place as shown
in the illustration.
16-4-1 CONTENTS OF MANUFACTURER'S PLATE

(1) Australia specifications
Vehicle model
. . European s~ecifications
(2)
NO. Contents of indication
0 Manufacturer'sname
@ Authorized number of WVTA
0 Chassis No.
Vehicle model
Engine type
@ 1 Body colors
A2 MAINTENANCE
MAINTENANCE REQUIREMENTS ------- A2 - 1

MAINTENANCE SCHEDULE --------------- A2 - 2
SEVERE DRIVING CONDITION ----------- A2 - 4
I
1 MAINTENANCE REQUIREMENTS
1.The scheduled maintenance service is important to ensure trouble-free, safe and economical driving.
Failure to perform the scheduled maintenance may cause an accident or serious damage.
2.11 you conduct the periodical maintenance, Daihatsu car owners may reduce the chance of accidents
or car problems. Furthermore, it becomes possible for you to find at an earlier stage malfunctions
which may lead to serious damages. Consequently, potential vehicle damage can be prevented or
the degree of the damage can be minimized.
3.Therefore, all of the persons who are concerned with servicing the Daihatsu vehicles should offer the
periodical maintenance service to Daihatsu car owners in order that they may be protected from
accidents or unexpected problems.
4.To prevent malfunctions in advance, however, conducting the periodical maintenance service only is
insufficient. It is essential that owners themselves perform maintenance, such as the pre-starting
check described in the owner's manual, so that the vehicle exhibits no abnormal change or
phenomenon. Hence, please explain to owners about the necessity of maintenance performed by
them.
S.However, malfunction may occur on those vehicles which are always checked by their owners. For i
instance, if a part instructed to be replaced periodically should be used beyond the replacement
intervals and the life of the part has expired, there are cases where malfunction occurs suddenly
despite the fact that no malfunction had taken place until yesterday. To prevent such malfunction in
advance, b e sure to replace parts recommended to be replaced periodically at the specified
replacement intervals.
&This section describes those items of the scheduled maintenance service recommended by the
Daihatsu and their intervals. Be sure to 0 b S e ~ e
the maintenance schedule.
1
1
2 MAINTENANCE SCHEDULE
1.For improved maintenance, the maintenance schedule has been simplified.
NOTE
Perform the periodical maintenance at the specified mileage or the time whichever comes first,
unless otherwise specified.
2.Continue to perform the periodical maintenance after 90,000 km (54,000 miles) at the same intervals
as before 90,000 km.
3.lf the vehicle should be operated under severe driving conditions, operated occasionally, operated in
dusty areas, repeating short trip, operated under extremely cold climate and/or on salted roads, it is
necessary to perform some maintenance items more frequently than the regular maintenance
schedule.
4.This maintenance schedule has been prepared based on requirements mentioned in the owner's
manual which are to be performed by the Daihatsu owner thoroughly.
0......Check or inspect 0 ......Change or replace
Coolant
Change Every 2 years
(Long life coolant)
Drive belt Check
(Alternator. Tension
water pump. Crack
0 0 0 0 0 0
i power steering) Damage
Spark Plug Change Every 60,000 km (36,000 miles)
Check
Charcoal canister Function 0 0
Damage
Exhaust
Evaporative
emission
emission Change Every 8 years
control
hoses
system
Check
Exhaust pipe &
muffler mounting
.Tightness 0 0 0
.Dams
O......Check or ins tct .......Change or I lace
-
What to do x 1000 km 45 60
-
Section Inspection x 1000 miles 27 36
I 1interval Years 3 -
4
/check
Free travel
Clutch 0
Power Reserve travel
transmit- Damage -
ting Manual Check & Change
1
/system transmission I oil --
0
Check
Drive shaft boots
Dams
I ISus~ensionarm 1
(Front) Check
Suspen-
Control arm (Rear) Tightness
sion
Dust boots Rattle
system
Spring Damage
lFree play
Steering linkage
(Steering wheel)
Gear box
Steering Tightness
Dust boots
system Rattle
/ Damage --
Check
!z
Wheel alignment
Toe-in
l~heck
I Free play (Brake pedal)
I /
Reserve travel
I 1
(Brake pedal)
Brake pedal &
Working travel
parking brake
(Parking brake)
Tightness
Rattle
I
Damage
ICheck
3rake
I ~ i s&
c disc pad I
Wear
system
/
Damage
l~heck
Leakage
Brake hose & tube (Fluid level, connection)
Loose clamp
Brake fluid /Change Every

ICheck
Brake drum & I *Wear
I lDamage
Master & wheel /Check
[cylinder i Leakage
2hassis & Wheel hub nuts. /Check
wdy other bolts & nuts i Tightness
- A2-4
3 SEVERE DRIVING CONDITION
Severe driving conditions
1: Repeated short trips
2: Driving on rough roads
3: Driving dusty roads
4: Driving in extremely cold climate and/or on salted roads
0......Check or inspect 0 ......Change or replace

What to do X 1000 km
Section Item Inspection x 1000 miles
1 1 interval Years --
Cleaning
Air cleaner Check 0:Every 5,000 km (3,000 miles)
element Damage @:Every 15,000km (9,000 miles)/ 1 year
Engine
Change
Engine oil & khanae - -
Enaine oil : Ever
/oil filter /(Use API : SG or higher) I filter : Every t
Exhaust
Check
Tightness 0
Free play
Steering linkage
Steering (Steering wheel)
system
Gear box
Tightness
0
Dust boots
Rattle
1 IDamage
Check
Disc & disc pad Wear 3 0 0
Brake
system
Brake drum 8
lining
Wear 0
1-2-1 ENTRY EXAMPLE
(1) COMPONENTS
I I
Engine oil
(The inside of seal)-@- -@-9 Engine oil
a h (The inside of seal)
3 4
Liquid
t
B T:21.0i4OiZlOf42]
CllE8616ES30
X: Non-reusable parts
Unit :N.rn(kgf.crn]
1 a Cylinder head 7 g Seal, valve stem oil
2 b Cylinder head gasket 8 h Valve seat
3 c Lifter, valve 9 i Intake valve
4 d Lock, valve spring retainer 10 j Exhaust valve
5 e Retainer, valve sprlng 11 k Seal, valve stem oil
6 f Spring, cornpresston
1-3 DESCRIPTION OF SERVICE STANDARD VALUE

The necessary service standard value for inspection and service operation are described with bold letter
in the text as standard and allowable limit. The details of terms are described in the section for definition
of terms.
1-4 CONTENTS NOT DESCRIBED IN THIS MANUAL
The description of the next elemental operation may omit in this service manual, but please perform in an
actual operation.
?.Jacking operation and lifting operation
2.Cleaning and cleansing of removed parts to perform at need
3.Visual inspection
1-5 DEFINITIONS OF TERMS
This mark shows the standard value at the time of the check or adjustment.
VALUE
This mark shows the maximum or minimum value at the time of the check or adjustment.
LIMIT
DEVIATION This value refers to the difference between the maximum clearance and the minimum clearance.
Th's syrnjo. means lha: tnere is lke posso'lity of oersonal injury of me operator h~mselfor the nearoy workers
WARN'hc
.'f the opera!or fa Is lo iollow tne orescrioed in
,,, I l","
,,bnu l~his symbol means mat there IS me possioi ily o'oamage lo me
(failsto follow the operating procedure prescribed in this manual.
t~upolementarv
.. . exolanation
. which facilitates the ooeration is DOSted seoaratelv from the exolanation.
NOTE Because of difficulties in measurements to determine specified values.'there may be cases where the speci- j
fied values for simple measurement methods are indicated if malfunctions are unlikely to take place actually.
- A-4
2 ABBREVIATION CODES'
The abbreviation codes that appear in this manual stand for the following, respectively.
3 HOW TO GRASP SPECIFIED TIGHTENING TORQUE FOR

GENERAL STANDARD BOLT AND NUT
3-1 Determining Procedure for Tightening Torque for General Standard Bolts and
Nuts
3-1-1 Determining Procedure for Tightening Torque for Bolts
Deterinme the strength division of bolts, based on the table below
Then, obtain the value, based on the trghtening torque table
3-1-2 Determining Procedure for Tightening Torque for Nuts
Determrne wrth the aforesa~dmethod, based on the mating bolt.
A-5 -
3-1 -3 Identification \
Identificationof strength division by checking bolts themselves Identificationby pa* number
Classification Shape oi head (how to know strength division) Hexagonal bolt
(Strength division) Boll without collar Bollwith collar Example of pan number 9 1 1 1 1 - 4 0 6 2 0
4 T Nominal diameter (mm)

Nominal length (mm)
INominal diameter
I'-i
5 T - Nominal length
6 T
-
j
7 T -
LllS5003ES20
3-1-4 Tightening torque table for general standard bolts
Nominal diameter Pitch Standard tightening torque (N.m(kgf.cml)
Strength divisin
(mm) (mm) BOI~without collar 1 with collar
BOI~
1 1 5.4 (55) 5.9 (60)
-
A-6
I
4 UNlT
As for the units, the SI units (international unit system) have been posted. (The hitherto-employed units,
too, are posted.)
Example: 33.25+13.25N.m{340+ 135kgf.cm)
4-1 NEW UNlT BECAUSE OF THE INTRODUCTION OF THE SI UNlT

1.SI unit is the international unit system established by aiming to proceed the communication in
technology smoothly by unifying the former unit system which were different internationally each
other into one value by one unit. The specification value is described in accordance with SI unit
svstem in this service manual.
ITEM SI unit I Conventional units 1
Force 1 N 1
Torque kgfmn I 1kgf.m = 0.0980665 N-m
kgf/cmz I
Pressure kPa
mmHg I immng =
Spring constant 1 Nlmm kgflmm
Volume e cc
Power kW PS 1 ir:
5 GENERAL SERVICE INSTRUCTION
I.Removal, Disassembly
(1) In case for the operation at the complicate place, the stamping and mating mark shall be put at
the place where there is no influence to the function, so that the assembling operation becomes
easy.
(2) At every time when each parts are removed, check the condition when it was assembled ,
deformation, breakage, roughness and existence of scratch .
(3) Arrange the removed parts in order, and divide them to the parts to replace and parts to reuse .
(4) Each parts to be reused shall be performed enough cleaning and cleansing operation.
2.Check and measurement of parts
(1) As regards those parts to be used again, perform thorough checks and measurements, as
required.
3.lnstallation, Assembling
(1) Assemble the good parts with correct procedure following the specified standard (value for the
adjusting , tightening torque).
(2) Use the genuine parts when replace the parts.
(3) Ensure to apply the seal packing and grease by a place.
(4) Ensure to use new packing, gasket or the like, cotter pin etc.
(5) As for bolts and nuts, use the specified ones. Unless otherwise specified, the side for which the
torque is indicated should be tightened to the specified torque, using a torque wrench. If there
is no means to prevent the turning at the opposite side, be sure to prevent turning with box
wrenches, spanners or the like.
4.Adjustment, Operation confirmation
(1) Adjust with the specified service standard value by using the gauge and the tester.
B1 ENGINE
JB ------ 61 - 1
ENGINE 61 - 1
ARTICLES TO BE PREPARED---------- B1 - 1
BASIC CHECK AND ADJUSTMENT--- B1 - 1
B1-I -
I
JB
1 ENGINE
SST
(09991-87401-000)
(09286-87201-000)
Instrument
Belt tension gauge,Radiator cap tester,Radiator cap tester adapter,Tachometer,Timinglight,Torque wrench,Thickness
gauge,Cornpression gauge
1-2 BASIC CHECK AND ADJUSTMENT

1-2-1 CHECK OF COOLING WATER LEVEL AND WATER LEAKAGE
Check that the cooling water level is between the lower limit (LOW) and the upper limit (FULL)of the
reservoir tank.
1-2-2 WATER LEAKAGE
With the engine idling, visually check that there is no water
leakage from the radiator, radiator hose, heater hose, water
pump, heater hose, etc.
Moreover, apply pressure, using a radiator cap tester. Under
this condition, check that no water leakage is present.
SPECIFIED VALUE: Specified value for check
122.7kPa{l.25kgf/cm2)
1-2-3 FUNCTION CHECK OF RADIATOR CAP - I

1.Remove the radiator cap. Then, visually check the valve
seat surface for smear and damage. Also, move the
negative pressure valve by your hand and check that it
I
opens and closes. 1
~
I
!
j
LtlEmozm0/ :-
- 61-2
2.Check the valve openmg pressure of the cap, using a
radiator cap tester.
SPECIFIED VALUE: 108.0f 14.7kPa{1.I +O.l5kgf/cmq
CAUTION
Liberally apply water to the cap seal surface before the
installation to the tester.
1-2-4 CHECK OF ENJINE OIL LEVEL

1Stop the engine. Perform the check on a level place.
2.Pull out the or1 level gauge. Wipe out the oil adhered to the gauge and insert it again.
3.Check that the oil level is between the lower limit (L) and the upper limit (F).
1-2-5 CHECK OF SPARK PLUG
WARNING
Be very careful not to get scalded, for the spark plug is very hot.
1.Ensure that the designated plugs are used. Also, check that the plug exhibits no smoldering an1A the
plug is not burnt excessively. Check to see if the gap between the electric poles is normal.
CAUTION
In principle, do not clean iridium plugs so as to protect their electrodes.
Spark plug specifications
JB-DET
Type SK20PR-A8 1 IFRGJ
Kind iridium plug iridium plug
Electrode gap(mm) 0.7-0.8 0.7-0.8
1-2-6 CHECK AND ADJUSTMENT OF TENSION
(DEFLECTION AMOUNT) OF V-BELT FOR
ALTERNATOR
(1) CHECK Water pump pulley
1.Check the V-ribbed belt for cracks, deterioration and
significant wear. Measuring section
2.Check the tension of the V-ribbed belt, using a belt
tension gauge.
NOTE
The check can be performed by measuring the
deflection amount of the V-belt.
S~ecifiedvalue
When a new part During inspec- /
is installed tion Crankshaft pulley
/ 590A100 1 390+50
i (60k10) (40Zt51
Deflection amount ( mm) 1 3.8-4.7 4.9-5.4
I ( Pushing force 98N110kgf))
CAUTION
For checking the deflection amount of the belt, apply a
force of 98N(IOkgf) to the belt at a point between the
crankshaft pulley and the water pump pulley. Measure
the belt deflection amount.
* In cases where the tension is measured after the V-
ribbed belt has been assembled, the measurement
should be performed after cranking two turns.
When the belt is replaced with a new one, the belt
tension should be adjusted to the mid-value of the
specified value for "When a new part is installed."
As regards the belt that has been used for more than
five minutes, ensure that the belt tension conforms to
the specified value for "During inspection."
When the belt that has been used for more than five
minutes is assembled, the belt tension should be
adjusted to the mid-value of the specified value for
"During inspection."
(2) ADJUSTMENT
1.Loosen the bolts A and B.
2.lnstall the SST and a washer. Turn the adjusting nut to
adjust the tension.
SST:09286-87701-000
3.Tighten the bolt
TIGHTENING TORQUE:Bolt A
29.Of 5.8N.m{300&6Okgf .cm]
Bolt B
39.0t7.8N. m{400f80kgf .cm]
4.Confirm the belt tension.
1-2-7 Check and adjustment of belt tension (deflection amount) for vane pump
Refer to Page G2-36.
1-2-8 Check and adjustment of belt tension (deflection amount) for air conditioner
Refer to Page K1-3.
-
1-2-9 CHECK AND ADJUSTMENT OF VALVE CLEARANCE
(1) Specified value
S~ecified
~,~~
value
~~ ~ ~~
Valve clearance (rnrn)
JB-DET
IN
During
cold
period
7
1 0.20?~.~
0.30:zz
(2) CHECK AND ADJUSTMENT

CAUTION
For the removal and installation procedures of each
part, refer to the section under "Removal and
Installation of Camshaft."
Refer to Page B2-5.
1.Remove the cylinder head cover.

2.Align the timing mark of the crankshaft pulley with the
ignition timing adjustment indicator of the oil pump body
by turning the crankshaft clockwise.
3.Ensure that the mating marks of the drive gear and driven
gear of the camshaft are aligned with each other. If not,
turn the crankshaft one more turn so that the lower
mating mark is aligned. (No.1 cylinder top dead center
under compression)
4.ln order to prevent the piston from being interfered with
the valve, turn the crankshaft 9OS(crankangle) from the
top dead center so as to lower the piston.
5.Remove the chain sprocket from the camshaft.
CAUTION
* Be very careful not to drop the chain into the cylinder
head.
6.Align the mating marks of the timing gears, using the
service hexagonal section of the camshaft. (Return to
the state described in Step 3 above.)
7.Using a thickness gauge, check the valve clearances
shown in the right figure.
Measurement points at time of camshaft No.1 cylinder top
dead center under compression
Cylinder No.1 I Cylinder No.2 I Cylinder No.3 I Cylinder No.4
IN ! EX I IN / EX / IN I EX / IN I EX
0 1 0 l 0 1 - - 1 0 1 - -
CAUTION
The thickness gauge must be inserted from the spark
plug side (center side).
8,Turn the camshaft 180',using the service hexagonal
section of the camshaft.
9.Using a thickness gauge, check the valve clearances I
Measurement points at time of camshaft No.4 cylinder top
dead center under compression
Cyiinder No.1 I Cylinder No.2 I Cylinder No.3 I Cyiinder No.4
IN 1 EX / IN / EX I IN I EX I IN I EX
- - - iolol - !ole
CAUTION M~~ESOI~TI~
a The thickness gauge must be inserted from the spark
plug side (center side).
1O.lf the measured value is out of the specification, replace
the valve lifter, following the procedure given below.
CAUTION
a Record the position of the valve where the clearance
deviates from the specification, as well as the their
measurement results.
(1) Remove the camshaft No.1 and No.2.
(2) Using the following formula given below, select the
valve lifter.
Selected lifter = Thickness of assembled
lifter+(Measured clearance-Specified clearance)
CAUTION
The thickness of the selected lifter can be known by the- 1
stamp on the lifter side.
The lifter thickness should be measured at the central
section of the lifter.
-
\
Valve lifter thickness table
(3) Remove the lifters where the valve ciearances are out of specifications.
(4) Apply engine oil to the outer periphery of the selected lifters. Insert each valve lifter into the
cylinder head while turning it. Ensure that each lifter turns smoothly.
(5) Assemble the camshafts No. 1 and No. 2.
(6) Check the valve clearances.
(7) lnstall the cam sprocket.
(8) lnstall the cylinder head cover.
i
1-2-10 COMPRESSION CHECK
1.Warm up the engine thoroughly.
2.Turn OFF the ignition key switch.
3.Remove all of the IG coils and spark plugs.
4.Remove the fuel pump relay.
5.Remove all of the connector of injector.
6.lnstall the compression gauge.
7.Fully open the throttle valve and turn the starter. At this
time, measure the compression pressure.
SPECIFIED VALUE: 1079kPa 111.0 kgf/cm2)
ALLOWABLE LIMIT: 785kPa {8.0 kgfIcnF)
(400 rpm, Difference between
cylinders within 147 kPa)l.5kgf/cm3)
CAUTION
Be sure to use a fully-charged battery. The
measurement should be carried out in the shortest
possible time.
1-2-11 CHECK OF IGNITIONTIMING
1.Connect an engine tachometer to the terminal REV(@).
using the SST.
SST: 09991-87404-000
09991-87402-000
2.Warm up the engine (until the fan motor makes one turn).
DLC
MZlE5013ET11
3.lnstall a timing light.

CAUTION
Connect the timing light to the harness indicated in the
right figure.
4.Short the terminals EFI T and E (0-0) of the check

connector, using the SST.
SST: 09991-87404-000 EFI T
09991-87403-000 n l
CAUTION
0 Be sure to short the correct terminals. If wrong
terminals are shorted, it will lead to malfunction.
DLC
5.Check the ignition timing, using the timing light.
SPECIFIED VALUE: 0" f 2(BTDC)
-
NOTE
750+?Erpm
CAUTION
r The specified value is given as a guide for the
inspection. No adjustment is required.
cheking ignition
.timing
1-2-12 CHECK OF IDLE SPEED

CAUTION
r Be sure to mount an air cleaner.
Warm up the engine.
Do not apply electric load (headlamp, etc.).
The inspection should be carried out under a condition where each vacuum pipe is not
disconnected and exhibits no rupture, etc.
1.Connect an engine tachometer to the terminal REV(@),

using the SST.
SST: 09991-87402-000 n REV
09991-87404-000
2.Check the idle speed.
SPECIFIED VALUE: 750+!# rpm
CAUTION
DLC
The specified value is given as a guide for the
1-2-13 CHECK CO AND HC CONCENTRATIONS

1.Keep the engine speed at more than 2,500 rprn for two minutes, thus warming up the O2sensor
i
2.Short the terminals EFI T and E (0-0) of the check
connector, using the SST.
SST: 09991-87402-000
09991-87403-000
EFI T I
09991-87404-000
CAUTION
Be sure to short the correct terminals. If wrong
terminals are shorted, it will lead to malfunction. DLC
3.Connect the positive (+) terminal of the tester to the M21E5018ETiO
terminal VF @ of the check connector and the negative (-
)terminal to the body earth.
4.Keep the engine revolution speed at 2,500 rpm. At this
time, measure the indicated voltage (VF output) of the
tester.
SPECIFIED VALUE: O t 5 V (Repeating)
(Confirmation of O2feedback)
5.Release the short between the terminals EFI T and E (a-
@).
6.With the engine idling, measure the VF voltage.
SPECIFIED VALUE: 2.5V (Confirmation of N F learning
value)
7.With the engine idling, measure the CO and HC
concentrations.
SPECIFIED VALUE: 0.3% or less (CO concentration)
300 ppm or less (HC concentration)
CAUTION
The specified value is given as a guide for the
Perform the operations of Step 6 and subsequent steps
within a short length of time, because the O2sensor
gets cool.
1-2-14 CHECK OF AIR CONDITIONER IDLE-UP
1.Warm up the engine.
2.Turn ON the air conditioner switch while the engine is idling. Ensure that the engine revolution speed
is within the specified rpm.
SPECIFIED VALUE: 900-1200 rpm
3.The specified value is given as a guide for the inspection. No adjustment is required
B ENGINE UNIT
CAM SHAFT........................... - - - - - - - - B - 1
DISASSEMBLINGAND
ASSEMBLING....................... ----------- B - 1
CYLINDER HEAD ..................... --------- B - 17
DISASSEMBLING AND
ASSEMBLING................................ B - 17
WATER PUMP .................................. B - 30
REMOVAL AND INSTALLATION-------- B - 30
OIL PUMP........................................ B - 32
DISASSEMBLING AND
ASSEMBLING ................................ B - 32
TIMING CHAIN .................................. B - 42
DISASSEMBLINGAND
ASSEMBLING ................................ B-42
Cylinder block B - 48
DISASSEMBLING AND
ASSEMBLING ................................ B - 48
1 CAM SHAFT
1-1 DISASSEMBLING AND ASSEMBLING
1-1-1 ARTICLES TO BE PREPARED
ST
Shape Part No. Part name
09219-87701-000 Attachment, engine overhaul
e e
09219-87202-000 stand, engine overhaul
09504-87501-000
Wrench differential side bearing adjusting nut
(09504-00011-000)
Tools
IHexagon wrench (Width across flats : 5mrn )
.. .-.. -...-. ..-
l~orque
wrench.V-~na~ed
blocns.D~algauge,Mcrorneler.Pressgauge 1
Lubricants, bonds and others
[ ~ o l(Size:
t M5, Pitch: 0.8 mrn).Engine oil
t
1-1-2 COMPONENTS
Liq
%: Non-reusable parts
Unit :N-m (kgf.cm]
1 a Cover, cylinder head 9 i Cap, camshaft bearing, No.3 (exhaust side)
2 b Gasket, cylinder head cover 10 j Camshaft, No.2
3 c Plunger, chain tensioner 11 k Cap, camshaft bearing, No.3 (intake side)
4 d Plug, semi-circular 12 1 Camshaft, No.1
5 e Rotor, signal 13 mRing, shaft snap
6 f Sprocket, camshaft timing 14 n Washer, wave
7 g Cap, camshaft bearing, No.1 15 o Gear SIA, camshaft sub
8 h Cap, camshaft bearing. No2 16 p Spring, camshaft gear
1-1-3 POINTS OF DISASSEMBLY
1.lnstall the partial engine to the SST.
SST:09219-87101-000
09219-87202-000
NOTE
The conventional attachment can be used for Type JB
engine by drilling a 1Omm dia. hole on the attachment
at a point as indicated in the right figure.
(1) Removal of cylinder head cover

1.Remove the cylinder head cover.
(2) Removal of chain tensioner plunger

1.Put the No.1 cylinder at the top dead center under
compression by aligning the mating marks at the lower
section of the timing gear, as indicated in the right figure.
CAUTION
* When turning the camshaft, be sure to turn it by turning
the crankshaft in the normal direction with a tool
applied to the crankshaft pulley.
- B2-16
(12) Vacuum switching valve bracket (boost control VSV)
1.Install the VSV together with the vacuum switching valve
bracket (boost control VSV).
CAUTION
Install the hose as shown in the right figure.
Connected to air+
/ bvoass ~ i o e
(Air cle&er side)
CIlW17ETlO
(13) Vacuum switching valve bracket (purge VSV)

1.Install the VSV together with the vacuum switching valve
bracket (purge VSV).
CAUTION
Install the hose as shown in the right figure.
9 Canister
connection
connection
2-1-6 OPERATION AFTER INSTALLATION

1.If the camshaft has been replaced, adjust valve clearance.
Refer to Page B5-1.
2.lnstall the ignition coil.

Refer to Page B10-1.
3 ENGINE ASSY
3-1 REMOVAL AND INSTALLATION
WARNING
Never bring fire close during servicing the fuel system.
When removing the fuel hose, prevent the fuel from splashing.
When the coolant is hot, do not remove the radiator cap, drain plug or water hose.
When the oil is hot, do not remove the drain plug or oil cooler hose.

SST
(09090-04010-000)
(09611-87701-000)
Tool
High transmission jack
High transmissionjack
Instrument
l~orque
wrench
Lubricant,adhesive,others
l ~ n ~ i hanger
ne
lment parts)
No.1 (Replacement parts),Engine hanger No.2 (Replacement parts).Engine hanger attaching bolt (Replace- 1I
-
B2-18
3-1-2 OPERATION BEFORE REMOVAL
1.Remove the fuel pressure.
Refer to Page 87-1.
2.Remove the battery.

CAUTION
It must be noted that, when the negative 0terminal of the battery is removed, memories for the
diagnosis, radio setting, etc. will be erased at the same time.
3.Remove the front bumper.

Refer to Page 12-2.
4.Remove the air cleaner.

Refer to Page 83-2.
5.Remove the intercooler.

Refer to Page 63-12.
6.Drainthe coolant.
7.As for the M/T vehicle, remove the clutch release control cable.
Refer to Page F1-5.
8.Remove the drain plug and the gasket and drain transmission oil (M/T vehicle)
-
CAUTION
The gasket is a non-reusable part.
9.Remove the front wheel.

10.Remove the front exhaust pipe assembly
Refer to Page B4-2.
11.Remove the stabilizer bar and the lower arm (only the connection with the front frame).
Refer to Page C1-11.
12.Remove transaxle side of the drive shaft.

Refer to Page D2-8.
13.As for the Mfl vehicle, remove the shift & select shaft S/A and the extension rod SIA.
Refer to Page F2-8.
3-1-3 REMOVAL AND INSTALLATION PROCEDURES
1 COMPONENTS
%Nowreusable parts
Unit:N.mlkgf.cml
(2) REMOVAL AND INSTALLATION PROCEDURES
1 a Retainer, dust cover r 20 t COMPRESSORAY
2 b Cover, main shaft lower dust 21 u Block Ay, relay
r A 3 c Column Ay, steering r A 22 v Frame Ay
r 4 d Arm S/A, suspension lower arm A 23 w Belt, V (vane pump)
5 e Cover SIA, engine upper r 24 x Pump Ay, vane
6 f Hose, heater inlet water 25 y Stay, exhaust manifold
7 g Hose, heater outlet water r 26 z Insulator S/A, engine mounting, front
8 h Hose, fuel No.1 (main) r 27 A Insulator, engine mounting, lower left
A 9 i Hose, vacuum (canister - purge VSV) r 28 B Insulator S/A, engine mounting, rear
r A 10 j Cable Ay, accelerator control r A 29 v Frame Ay
11 k Hose, booster vacuum 30 C Stiffener, power train
r 12 1 Reservoir Ay, oil A 31 D Bracket, engine mounting, rear right
13 mHose, radiator N0.l A 32 E Bracket, engine mounting. front right
14 n Hose, radiator No.2 33 F Bar, adjusting
15 o Hose, turbo water 34 G Bracket, compressor mounting
r 16 p Hose, air cleaner No.2 35 H Starter Ay
17 q Hose. air bypass (air bypass pipe - air cleaner r A 36 1 Manual transaxle AY
hose No.2) 37 J ENGINE AY
18 r Pipe. intake NO.1
A 19 s Belt, V (air conditioner)
3-1-4 POINTS OF REMOVAL

(1) Steering column Ay
1.Put a match mark with the steering gear Ay and remove
the universal joint portion of the steering column Ay. Mating mark
- YilKXXnETlO
(2) Suspension, lower arm SIA

1.Use the SST to disconnect the steering knuckle and the
ball joint area of the suspension lower arm S/A.
CAUTION
When setting the SST, install a dummy nut to the
threaded portion of the lower arm to prevent damage to
the threaded portion.
Hang the SST using a cord.
Use care not to damage the ball joint dust cover.
SST: 09628-00011-000
(3) ACCELERATOR CONTROL CABLE AY
1.Loosen the bracket nut to remove the throttle body.
CAUTION
Be careful not to have the cable get curly when removing it.
(4) Oil reservoir Ay

1.Remove only the bracket portion without disconnecting the oil reservoir Ay piping.
(5) Air cleaner hose No.2
1.Rernove the Air cleaner hose No.2.
CAUTION
Cover the hole of the turbocharger with adhesive to prevent dirt or dust from entering.
(6) COMPRESSOR AY
1.Remove the compressor Ay.
(1) Remove the two mounting bolts of the compressor mounting bracket at the lower compressor and
then remove the bracket together with the compressor. Do not remove the pipe during this
operation.
(2) Use a cord or the like to hang the compressor. Hang the condenser as well.
(7) Frame Ay
1.Remove the engine Ay, transaxle Ay, steering gear Ay together with the frame S/A from the vehicle.
(1) install the engine hanger No.1 and engine hanger No.2.
NOTE
The engine hangers No.1 and No.2 and bolts with washers are supplied parts.
TIGHTENING TORQUE: 20.0k6.0 N.m }200+60kgf~cm}
(2) Disconnect the engine wire from the engine control computer, and pull it into the engine
compartment.
(3) Remove the connectors and clamps. Disconnect the engine wire from the vehicle.
(4) Disconnect each harness, and the earth wires of the engine section and transmission case cover
section.
(5) Securely fix the SST on the high transmission jack.
SST 09994-87201-000
TOOL: High transmission jack
NOTE
If the high transmission jack is not used, securely fix
the SST onto the low transmission jack or the rigid rack
and perform the following operations by lifting and
lowering the vehicle (two-post lift).
(6) Use the high transmission jack to set the SST on the
frame S/A.
NOTE
Match the stabilizer bar bracket (RH) mounting bolt
hole (one of the two holes, which is located at the rear
side of the vehicle) with the protrusion of the SST.
(7) Remove the mounting bolt of the frame S/A to the
body.
(8) Use the high transmission jack to remove the front
frame S/A from the vehicle with the engine Ay,
transaxle Ay and steering gear Ay mounted.
CAUTION
Slowly remove the engine assembly, making sure that
no connectors or hoses are left not removed or that
-they are not interfering with other parts.

Remove the drive shaft and the lower arm by giving
clearance to avoid interference.
(9) Use the SST (engine slinger devise) and the chain
block to support the engine Ay.
SST 09090-04020-000
CAUTION
= Securely hang the SST on the engine hanger.
(8) Vane pump Ay
1.Remove the vane pump Ay from the engine Ay.
CAUTION
Remove the vane pump, oil reservoir, hose, etc. as an integrated part, without removing the piping.
(9) Engine mounting front insulator SIA

1.Remove the bolt connecting with the engine mounting front bracket.
CAUTION
Make sure that the engine assembly is supported in a well balanced way during the removal.
NOTE
There is no need to remove on the frame side.
(10) Engine mounting lower left insulator

1.Remove the bolt connecting the bracket on the transmission side.
CAUTION
-
NOTE
(11) ENGINE MOUNTING REAR INSULATOR SIA

1.Remove the bolt connecting with the engine mounting rear bracket.
CAUTION
NOTE
(12) Frame SIA
1.Remove the power steering gear Ay and the ~nsulator( 3 pcs) together with the frame SIA.
NOTE
It is advised to remove the insulator and the frame if you have difficulty in disassembly. Reinstall
the insulator to the frame after disassembly.
(13) Manual transaxle Ay

1.As for the M/T vehicle, remove the manual transaxle Ay.
Refer to Page F2-2.
3-1-5 POINTS OF INSTALLATION

(1) Manual transaxle Ay
1.As for the M F vehicle, install the manual transaxle Ay.
Refer to Page F2-2.
(2) Engine mounting front right bracket

1.Temporarily tighten the bolt @ on the engine mounting
front right bracket, and tighten the bolts in the sequence
of @-@-@-a to the specifled torque.
(3) Engine mounting rear right bracket

1.Install the engine mounting rear right bracket.
(1) Temporarily tighten the bolt @ on the engine block.
(2) Tighten the bolts in the sequence of @-@-@I to the
specified torque.
( 3 ) Tighten the bolt @ to the specified torque.
(4) Tighten the bolt @ on the transaxle Ay t o the
specified torque.
(4) Frame Ay
1.Install the frame Ay to the engine Ay and the transaxle Ay together with the power steering gear Ay
and the insulator ( 3 pcs).
NOTE
Align each insulator with three mounting brackets and install.
2.lnstall bolts connecting each insulator and the mounting brackets.

(5) Belt, V (vane pump))
1.lnstall the V belt and adjust the tension.
(6) Frame Ay
1.Secure the SST on the high transmission jack.
SST 09994-87201-000
TOOL: High transmission jack
NOTE
If the high transmission jack is not used, securely fix
the SST onto the low transmission jack or on the rigid
rack and perform the following operations by lifting and
lowering the vehicle (the two-post lift).
2.Use the high transmission jack to set the SST on the
frame S/A.
CAUTION
Apply vinyl tape or the like on the protrusion of the SST
in order to prevent damage to the bolt hole.
NOTE
Match the stabilizer bar bracket (RH) mounting bolt
hole (one of the two holes, which is located at the rear
side of the vehicle) with the protrusion of the SST.
3.Use the high transmission jack to raise the frame Ay,
engine Ay, etc. as high as the mounting position to the
vehicle.
CAUTION
Be careful not to allow interference with parts in the
engine compartment to occur.
4.Tighten the mounting bolt to the frame Ay to the specified
torque.
5.lnstall each harness, connector and clamp.
6.Route the engine wire in the vehicle interior to connect it
to the engine control computer.
7.lnstall the earth wires of the engine section and transaxle
section.
(7) Belt, V (air conditioner)
1.Install the compressor Ay and the V belt (for A/C) and adjust the tension.
Refer to Page K1-15.

1.lnstall the accelerator control cable assembly to the throttle body. After adjusting the accelerator
pedal free play, tighten the nut to the specified torque.
SPECIFIED VALUE: 1-5mm (accelerator pedal free play)
- B2-26
-
(9) Vacuum hose (canister purge VSV)
1.lnstall the vacuum hose by setting the check valve with
the larger
- diameter flange on the VSV side as shown in
the right figure.
I+ Canister
connection
connection

1.lnstall the universal joir ~f the stee ring colu
matching the mark for the steering gear.
CAUTION mark
* In case you failed to set a mating mark and align the
wheel center on the steering wheel side, be sure to
align the roll connector position.

1.Install the drive shaft Ay.
Refer to Page D2-8.
2.lnstall the front stabilizer bar and the lower arm (connection with the front frame).
3.lnstall the front exhaust pipe assembly.

Refer to Page 84-2.
4.As for the M/T vehicle, install the shift & select shaft S/A and the extension rod S/A.
Refer to Page F2-8.
5.As for the M/T vehicle, install the clutch release control cable.
Refer to Page F1-5.
6.lnstall the intercooler.

7.lnstall the air cleaner.

Refer to Page 83-2.
8.lnstall the front bumper.

Refer to Page 12-2.
9.lnstall the front wheel.

10.After install~ngthe new gasket and tightening the drain plug to the specified torque, fill the
transmission oil (M/T vehicle) .
I 1 .Fill cooling water.
12.Remove the engine hanger if it has been installed.
13.lnstallthe battery.
A. GENERAL INFORMATION
B. ENGINE UNIT
C. ENGINE ELECTRICAL
D. SERVICE SPECIFICATIONS
A GENERAL INFORMATION
HOW TO USE THIS MANUAL---------------- A - 1

ARTICLES TO BE PREPARED------------A - 1
REMOVAL AND INSTALLATION
PROCEDURES.............................. A- 1
DESCRIPTION OF SERVICE
STANDARD VALUE .......................... A-2
CONTENTS NOT DESCRIBED IN
THIS MANUAL................................. A-3
DEFINITIONS OF TERMS------------------A 3
ABBREVIATION CODES ----------------------A- 4
-
HOW TO GRASP SPECIFIED
TIGHTENING TORQUE FOR
GENERAL STANDARD BOLT AND
NUT.................................................. A-4
Determining Procedure for Tightening
Torque for General Standard Bolts
and Nuts ........................................ -A-4
UNIT A-6
NEW UNIT BECAUSE OF THE
INTRODUCTIONOF THE SI UNIT-------A - 6
GENERAL SERVICE INSTRUCTION ------ A - 7
A-1
1,
1 HOW TO USE THIS MANUAL
When SST, tool, measuring instrument, a sort of fat and oil to be prepared before operation are
necessary, those are described by compiling in the table as preparation tools at the beginning of each
item.
However, the general tools, jacks, fixtures as considered being equipped always at the service shop are
usually omitted.
1.Block diagrams are posted so as to show the installed state of each part.
2.The application of a sort of fat and oil and sealer are instructed in the figure with arrow. And the
indication of a tightening torque and non-reusable parts are also described. The explanation of
each code is posted below the block diagram concerned.
3.The removal and installation ( disassembling and assembling ) procedure list is shown just beneath of
components figure.
The removal (disassembling) procedure, the installation (assembling) procedure and parts name are
described in the sequence from left side of list. And the alphabet written before a part name links i
with alphabet in the figure.
4.h principle, reverse the removal (or disassembly) procedure to install (or assemble) the parts.
NOTE
Only in cases where the installation (or assembly) can not be carried out by reversing the removal
(or disassembly) procedure, the installation (or assembly) procedure is provided.
2.Remove the chain tensioner plunger.
(3) Removal of semi-circular plug.

1.Remove the semi-circular plug, using a plastic hammer or
the like.
(4) Removal of camshaft timing sprocket

1.Set the SST to the hole of the signal rotor. Remove the
bolt, while paying attention not to apply a force to the
timing chain by taking a turn-preventive measure.
SST: 09504-87501-000
2.Remove the camshaft timing sprocket together with the
signal rotor.
3.Remove the signal rotor. With the tlming chain still

applied on the sprocket, displace it toward the engine
front side.
(5) Removal of camshaft bearing caps No.1 and No.2
1.After having - turned the crankshaft about 90" in the
engine rotating direction from the No.1 cylinder top dead
center under compression, turn the camshaft
counterclockwise in such a way that the cam noses of
the No. 2 and No. 4 cylinders of the camshaft come at
the bottom section and they push their lifters by the same
lift amount. Here, the camshaft should be turned with a
spanner applied to the hexagonal section of the exhaust
camshaft.
2.Remove the camshaft bearing caps No.1 and No.2.
TOOL: Hexagon wrench (Width across flats : 5mm )
Vo.4 cylinder of
he cam noses ! Same lift amount
A
No.2 dylinder of
the cam noses
(6) Removal of camshaft bearing cap No.3 (exhaust side)

1.Attach the sub-gear at the camshaft No.1 side to the
driven gear by means of a bolt.
Use a bolt whose outer diameter is 5 mm with a pitch of
0.8 mm).
2.Remove the camshaft bearing caps No.3 (4pieces) at the

exhaust side that are retaining the camshaft No.2 in
accordance with the sequence indicated in the right
figure.
TOOL: Hexagon wrench (Width across flats :5mm )
(7) Removal of camshaft No.2 (exhaust side)

1.Remove the camshaft No.2 by raising the gear side first
,-.
I
(8) Removal of camshaft bearing cap No.3 (intake side)
1.Turn the camshaft No.1 counterclockwise in such a way
that the cam noses of the No. 3 and No. 4 cylinders of
the camshaft No.1 come at the bottom section and they
push their lifters by the same lift amount. Here, the
camshaft No.1 should be turned with a spanner applied
to the hexagonal section of the camshaft. No.1.
2.Remove the camshaft bearing caps No.3 (4 pieces) at the

intake side that are retaining the camshaft No.1 in
accordance with the sequence indicated in the right
figure.
CAUTION
Upon completion of the camshaft removal, leave the
timing chain in an applied state on the camshaft timing
sprocket.
It should be noted that if the timing chain should drop
into the oil pump, the cylinder head and oil pump must
be removed.
(9) Removal of camshaft No.1 (intake side)
1.Remove the camshaft No.1 by raising the gear side first.
(10) Removal of camshaft sub-gear S/A
1.Clamp the hexagonal section of the No.1 camshaft in a vice with a protective sheet interposed
CAUTION
Be very careful not to scratch the cam section.
2.Remove the bolt for retaining the camshaft sub-gear.

(1) Set the SST to the two 66 holes of the camshaft sub-
gear SIA so as to retain the sub-gear.
SST: 09504-87501-000
- - ~
(2) When the SST is not used, put a M6 bolt into the
camshaft sub-gear Ay at a position as indicated in
the right figure. Insert a screwdriver or the like into
between the bolt and the camshaft journal so as to
retain the sub-gear.
CAUTION
Be certain to apply a cloth or the like to the camshaft
journal so as to prevent any scratch.
(3) Remove the bolt for retaining the sub-gear, while
maintaining - a state in which the tooth tips of the sub-
gear and driven gear are aligned with each other.
3.Detach the shaft snap ring, using snap ring pliers. Remove the wave washer, camshaft sub-gear SIA
and camshaft gear spring.
1-1-4 Clean
1 .Clean the attachment surface of the camshaft bearing
cap.
2.Clean the gasket from the attachment surfaces of the
cyiinder head cover of the cylinder head and the semi-
circular plug.
CAUTION
Care must be exercised not to drop the gasket into the
cylinder head.
1-16 INSPECTION
(1) Camshaft check
1.Check of camshaft for runout
(1) Measure the runout, using a Vee block and a dial
gauge. If the runout exceeds the allowable l~mit,
replace the camshaft.
ALLOWABLE LIMIT: 0.03 mm
CAUTION
The half of the runout reading that is obtained when the
camshaft makes a complete turn represents the runout
of the camshaft.
2.Check of cam lobe height
(1) Measure the cam lobe height, using a micrometer. If
the cam lobe height is below the specified value,
replace.
-
Cam lobe heiaht
------, I Specified value (mm) 1 Allowable limit (mrn)
Intake 1 33.86-33.94 1 33.81
Exhaust 33.21-33.29 33.16
3.Check of camshaft journal outer diameter

(1) Measure the journal outer diameter, using a
micrometer. If the measured value is out of the
specifred limit, replace the camshaft.
SPECIFIED VALUE: 22.979-22.995 mm
4.Measurement of camshaft backlash
(1) Install the camshaft in the cylinder head.
(2) Confirm the front mark and journal number of the
bearing cap. Tighten the bolts.
TIGHTENING TORQUE: 12.52 2.0 N.m (1305~20
kgf .cm)
-
CAUTION
Perform this operation with the sub-gear of the intake
shaft removed.
The installation should be made with the mating- marks
of the drive gear and the driven gear of the camshaft
aligned with each other.
5.With the camshaft at the intake side fixed, measure the
backlash, using a dial gauge.
SPECIFIED VALUE: 0.13-0.23 mrn
CAUTION
Conduct the measurement at four points or more.
6.Check of camshaft thrust clearance
(1) Measure the thrust clearance, using a dial gauge. If
the measured value is out of the specified limit,
replace the cylinder head or camshaft.
SPECIFIED VALUE: 0.06 mm-0.16 rnm
ALLOWABLE LIMIT 0.18 rnm
7.Check of camshaft oil clearance

(1) Set a press gauge to the journal section in the axial
direction. Confirm the bearing cap and journal
number. Tighten the bolts.
TIGHTENING TORQUE: 12.5t2.0 N.m {130+20
kgf .cm)
(2) Remove the bearing cap and measure the oil

clearance. If the oil clearance exceeds the
allowable limit, replace the cylinder head or the
camshaft.
1-1-6 POINTS OF ASSEMBLY
1.Assemble the parts in the sequence as indicated in the COMPONENT.
(1) Assembling of camshaft sub-gear SIA
1.Clamp the hexagonal section of the No.1 camshaft in a vice with a protective sheet interposed.
CAUTION
Be very careful not to scratch the cam section.
2.Set the camshaft gear spring, camshaft sub-gear SIA, and wave washer to the camshaft driven gear.
CAUTION
As for the sub-gear, the side where the spring stopper pin is projected should face toward the driven
gear side.
3.lnstall the shaft snap ring, using snap ring pliers.

TOOL: Snap ring pliers
4.lnstall the bolt for retaining the camshaft sub-gear.

(1) Set the SST to the two 6 6 holes of the camshaft sub-
gear SIA. Turn the sub-gear clockwise so that the
auxiliary hole for assembling the sub-gear may align
with the auxiliary hole for assembling the camshaft
driven gear and the tip-ends of the gear teeth may
be aligned with each other.
(2) When the SST is not used, put a M6 bolt into the
camshaft sub-gear S/A at a position as indicated in
the right figure. Insert a screwdriver or the like into
between the bolt and the camshaft journal. And turn
the sub-gear clockwise so that the auxiliary hole for
assembling the sub-gear may align with the auxiliary
hole for assembling the camshaft driven gear and
the tip-ends of the gear teeth may be aligned with
each other.
CAUTION
Be certain to apply a cloth or the like to the camshaft
journal so as to prevent any scratch.
(3) Install the bolt for retaining the sub-gear (size: M5,
pitch, 0.8 mrn) to the auxiliary hole above. (When
the SST is not used, remove the M6 bolt.)
(2) Assembling of camshaft No.1 (intake side)
1.Apply engine oil to the cam lobe and gear tooth surface of the camshaft and the journal sections of
the cylinder head.
LUBRICANT: Engine oil
2.Set the camshaft No.1 to the cylinder head in such a way
Same lift amount
that the cam noses of the No. 3 and No. 4 cylinders of
the camshaft No.1 come at the bottom section and they
push their lifters by the same lift amount.
(3) Assembling of camshaft bearing cap No.3 (intake

side)
1.Set the camshaft bearing caps No.3 (four pieces) to the
camshaft No.1 (intake side).
Here, the setting should be made in such a way that the
arrowheaded mark of the cap faces toward the front side
of the engine and the punched number comes at the
position as indicated in the right figure.
2.Tighten the cam: ;haft bearing cap No.3 in the sequence

indicated in the right figure.
TIGHTENING TORQUE: 12.5_f2.0 N . m {130+20
kgf - cm)
(4) Assembling of camshaft N0.2 (exhaust side)

1.Apply engine oil to the cam lobe and gear tooth surface of the camshaft and the journal sections of
the cylinder head.
2.0f the mating marks of the rear surface of the camshaft driven gear of the camshaft No.1 and the
camshaft drive gear of the camshaft No.2, first make the upper mating marks aligned. While turning
on the driven gear of the camshaft No.1, set the camshaft No.2 onto the cylinder head so that the
iower mating marks may be aligned.
I Camshaft centre line

Lower mating mark
Lower mating mark \

M l 1E5036ES21
3.Set the camshaft No.2 onto the cylinder head in such a

lift amount
way that the cam noses of the No. 2 and No. 4 cylinders
of the camshaft come at the bottom section and they
push their lifters by the same lift amount, as indicated in
the right figure.
4
(5) Assembling of camshaft bearing cap No.3 (exhaust
side)
1.Set the camshaft bearing caps No.3 (four pieces) to the Arrow
camshaft No.2 (exhaust side). Here, the setting should
be made in such a way that the arrowheaded mark of the
cap faces toward the front side of the engine and the
punched number comes at the position as indicated in
the right figure.
-
2.Tighten the camshaft bearlng cap No.3 in the sequence I
-
-
indicated in the riaht fiaure.
TIGHTENING TORQUE: 12.51f2.0 N.m (1301h20
kgf - cm}
-
3.Remove the bolt for retaining the sub-gear,
(6) Check and adjustment of valve clearances

1.Temporarily install the camshaft timing sprocket to the camshaft No.2 together with the signal rotor
2.Turn the crankshaft 90' (crank angle) from the top dead center.
3.Remove the camshaft timing sprocket from the camshaft.
4.Align the mating marks of the timing gears with each
other, using the hexagonal section of the camshaft for
servicing.
5.Using a thickness gauge, check the valve clearances at

the positions indicated in the right figure.
Measuring points at top dead center under compression of
camshaft No.1 cylinder
No.1 cylinder 1 No.2 cylinder I No.3 cylinder / No.4 cylinder
IN I EX / IN I EX / IN 1 EX 1 IN I EX
O l O I O l - - 1 0 1 - -
CAUTION
Insert the thickness gauge from the spark plug side
(central point).
6.Turn the camshaft 18O0(camangle), using the hexagonal
section of the camshaft for servicing.
p~~ p~~ - ~ -
7.Using a thickness gauge, check the valve clearances at

the positions indicated in the right figure.
Measuring points at top dead center under compression of
camshaft No.4 cylinder
No.1 cylinder I No.2 cylinder I No.3 cylinder I No.4 cylinder
IN 1 EX 1 IN 1 EX 1 IN I EX 1 IN / EX
- - - l o l o l o l o l o
CAUTION M11E5013510
Insert the thickness gauge from the spark plug side
(central point).
8.lf the measured value is out of the specified value,
replace the valve lifter, following the procedure given
below.
CAUTION
The positions of those valves proved to be out of the
specified value as well as their measured results
should be recorded.
(1) Remove the camshafts No.1 and No.2.
(2) Select a suitable valve lifter, using the following
formula given below.
Assembling lifter to be selected = Thickness of
assembling lifter f (Measured clearance -
Specified clearance)
CAUTION
The thickness of the lifter to be selected should be
judged based on the punched mark at the side of the
lifter.
The measurement of the lifter thickness should be
conducted at the central section of the lifter.
Table showing valve lifter thicknesses

I~uncheIValve lifter thickness /Punchel Valve lifter thickness I Punche I Valve lifter thickness / Punche /Valve lifter thickness I
d mark (mm) ci mark I (mm) d mark (mm) d mark (mm)
- 01
02
- 2.500
2.520
a 10 1 2.680
17
18
2.820
2.840
25
26
2.980
3.000
(3) Remove those lifters at points where the valve clearances are out of the specified values.
(4) Apply engine oil to the outer periphery of the selected lifters. While turning the valve lifter, insert it
into the cylinder head. Make sure that the lifter turns smoothly.
(5) Assemble the camshafts No.1 and No.2.
(6) Ensure that the valve clearances are correct.
B-I 5
(7) Assembling of camshaft timing sprocket
1.lnstall the camshaft timing sprocket to the camshaft No.2
together with the signal rotor.
2.Set the SST to the hole of the signal rotor hole. After
taking a turn-preventive measure so that no force may be
applied to the timing chain, install the bolt.
TIGHTENING TORQUE: 983-10 N.m {1000+l00
kgf .cm)
NOTE
At this point, if the grooves of the straight pin and the
sprocket at the forward end of the camshaft are not
aligned with each other, make sure to align them, by
turning the camshaft or the crankshaft.
(8) Assembling of semi-circular plug.
1.Appiy liquid gasket to the central section of the semi-
circular plug about 64-5mm. Within five minutes, install
the semi-circular plug to the arched section at the top of
the cylinder head.
ADHESIVE: Three Bond1207H
(9) Assembling of chain tensioner plunger

1.Depress the plunger by pushing the lock as indicated in
the right figure. Attach the hook to the plunger pin.
2.lnstall the plunger to the cylinder head in such a way that
the arrowheaded mark punched on the plunger faces
upward with a new gasket interposed.
TIGHTENING TORQUE: 9.0c2.0 N.m {90+20 kgf .cm)
CAUTION
Use a new gasket.
(10) Assembling of cylinder head cover

1.Install a new cylinder head cover gasket to the cylinder head cover.
2.Apply liquid to the cylinder head at thepositions
\
3.Within five minutes after the application of liquid gasket.
tighten the cylinder head cover retaining bolts according
to the sequence specified in the right figure. The
tightening should be carried out over several stages.
TIGHTENING TORQUE: 11.0k2.2N .m {I 12.522
kgf .cm)
8-1 7
2 CYLINDER HEAD
SST
09202-87702-000
Replacer, valve sprmg replacer
(09202-87701-000)
/ 09201-87210-000 Remover & replacer, valve gu~debush
09388-87701-000 Replacer, transfer Input gear rear oil seal
Tool
l ~ e x a ~ wrench
on (Width across flats : 8mm ),Scraper
Instrument
l~hicknessgauge,Microrneter.Torque wrench,Vernier calipers,Steel square,Precision straightedge
2-1-2 COMPONENTS (Perform the following operations successively after the removal of the
camshaft)
b c
%V---d-j
e- @
Engine oil
(The inside of seal)
Liquid gaskel
Liquid gasket +
%:Nor!-reusable parts
Unit :N.m {kgf.cm]
1 a Cylinder head 7 g Seal, valve stem oil
2 b Cylinder head gasket 8 h Seatvalve spring
3 c Lifter, valve 9 i Valve, intake
4 d Lock, valve spring retainer 10 j Valve, exhaust
5 e Retainer, valve spring 11 k Plug, semi-circular
6 f Spring, compression
2-1-3 DISASSEMBLY AND ASSEMBLY PROCEDURES
1.Remove the parts in the sequence as indicated in the COMPONENTS diagram.
(1) Removal of cylinder head
?.Removethe three flanged bolts of the cylinder head.
2.Slacken evenly and remove the ten cylinder head bolts I 1

over several stages according to the sequence indicated
in the right figure.
3.Remove the cylinder head and cylinder head gasket.
CAUTION
Be sure not to reuse the cylinder head gasket.
(2) Removal of valve lifters

1.Remove the valve lifters.
CAUTION
When removing the valve lifters, record the punched
mark of each valve lifter and keep them in order.
(3) Removal of valves

1.Remove the valve spring retainer locks, valve spring
retainers, compression springs, intake valves and
exhaust valves, using the SST.
SST 09202-87002-100
-
CAUTION
Sure to protect your eyes by wearing a pair of goggles,
etc. during the operation.
Care must be exercised to prevent the spring from
jumping out.
2.Remove the valve stem oil seals and valve spring seats.
CAUTION
Be sure not to reuse the valve stem oil seals.
3.Remove the semi-circular plug by tapping them by means
of a plastic hammer.
2-1-4 Clean
(1) Cleaning of valves
1.Remove carbon deposited on the valve with a wire brush.
(2) Cleaning of cylinder head

1.Clean the cylinder block surface of the cylinder head and
the manifold surface, using a scraper or the like.
CAUTION
Care must be exercised not to scratch the cylinder
head surface during the cleaning. Furthermore, be
very careful not to drop the gasket into the water jacket.
2.Remove the gasket from the cylinder head cover of the

cylinder head and the semi-circular plug - attaching
surface, using a scraper, wire brush or the like.
CAUTION
Care must be exercised not to scratch the cylinder
head surface during the cleaning. Furthermore, be
very careful not to drop the gasket into the water jacket.
3.Remove the gasket from the semi-circular plug, using a

scraper, wire brush or the like.
I
!
B-21
2-1-5 Inspection I
(I) Check of cylinder head
1.Measure the deformation at those points indicated in the
figure below, using a straightedge and thickness gauge.
ALLOWABLE LIMIT: 0.1 0 rnrn
r Surface of cylinder block Suriace of intake

manifold
L ~ u r f a c of
e exhaust manifold
(2) Check of valve springs

1.Measure the squareness of the valve spring, using a
straightedge. Replace the spring if the out-of-
squareness exceeds the allowable limit.
SPECIFIED VALUE: 1.4 rnrn
2.Measure the free length of the spring, using vernier

calipers.
SPECIFIED VALUE: ldentification color : Light green
41.56 rnrn
Identification color :White 42.10 mm
(3) Valve check
1.Valve check
(1) Check to see if the valve exhibits deformation or excessive wear.
(2) Inspect the valve head for its stock thickness.
SPECIFIED VALUE: 0.8-1.2 mm Overall lenoth
(3)
. . Measure the overall length of the valve.
Valve specifications
Specified Value (mm)
Intake valve I 92.75-93.25
Exhaust valve 94.65-95.15
2.Check of clearance between valve guide bush and valve

,Diameter point
stem
( 1 ) Measure the bore diameter of the valve guide, using a
caliper gauge. Also, measure the outer diameter of
the valve stem, using a micrometer.
w
Valve guide bush diameter place
TOlE9076ETiO
(2) Determine the clearance by calculating the difference

between the respective measured values. If the
clearance exceeds the allowable limit, replace the
valve or the bush, as required.
CAUTION
Conduct the measurements over several points, as
indicated in the right figure so as to establish the
clearance at the most worn section.
Clearance between valve guide bush and valve stem
Guide bush inner diameter Specified IN 4.500-4.512
(mm) Value EX 4.500-4.512
Valve stem outer diameter (rnrn)

Specified -
IN -4.465-4.480
Value EX 4.455-4.470
Specified IN 0.02-0.047
value EX 0.03-0.057
Clearance (mrn)
Allowabie IN 0.06
Limit EX 0.08
(4) Replacement of valve guide bush
1.Heat the cylinder head up to a temperature of 80-100'C:
using hot water or the like.
WARNING
The cylinder head may be very hot. Hence, care must
be exercised to avoid a burn during the operation.
2.Drive out the valve guide bush from the combustion
chamber, using the SST.
SST 09201-87210-000
CAUTION
Never reuse those bushes that have been driven out.
When driving out the valve guide bush, make sure to
remove it toward the combustion chamber.
3.Using the SST, drive a new valve guide bush until the
specified value in the satisfied.
SPECIFIED VALUE: Protrusion above the head driving
surface: 14.5 mm
CAUTION
Make sure to use a valve guide bush for replacement
use (01s 0.03) , because the fitting will become loose
in the cylinder head where the valve guide bush has
been once driven out.
Be certain to carry out the operation while confirming
the dimensions so as to prevent the valve guide bush
from being driven too far.
4.Using a hand reamer, grind the bore diameter of the valve
guide bush so as to attain the specified oil clearance.
(5) Valve contact surface .
1.Apply a thin film of red lead to the valve contact surface. Center of valve
contact position
qTFm
In order to check the contact width, lightly push the valve
to the valve seat while paying attention not to turn the
valve during the check.
CllE8587ET10
(6) Valve seat correction
1.Using a 45 degree cutter, cut the contact width to a width
slightly greater than the specified value.
2.Carry out grinding in such a way that the valve contact
position may come at the center of the valve face.
3.Using a 20 degree or 70 degree cutter, perform the
grinding in order that a satisfactory center seating of the
specified seat width may be obtained all around the
circumference of the valve.
4.Carry out the valve-to-valve seat grinding.

(1) Apply a small amount of slightly coarse compound to
the valve seat. Let the suction section of a grinding
rod suck the valve head.
(2) Lightly tap the valve on the valve seat. Repeat the
operation, while changing the tapping position
slightly after each of several tappings so that both
surfaces may be bedded with each other.
(3) When the bedded-in has been achieved, use fine
compound for finish use. Repeat the operation
described in Item (2).
(7) Assembling of replacement parts
1.Assemble the stud bolts on the cylinder head, following- the procedure given
- below,
(1) Cylinder head intake side
Stud bolt overall length:30mm
Protruding amount:18~lmm
stud bolt overall length:26rnm

Protruding amount:14f lmm t;i, bolt overall ,ength:26mm
Protruding amount:14f lmm
CllE8592ESl
(2) Cylinder head exhaust side
- Stud bolt overall length:40rnrn
Protruding arnount:24+ lrnrn
V
n 0
illinder head rear side
L ~ t ~bolt
d overall length:98mrn
Protruding arnount:86_+lrnrn
CllE8594ESl!
(8) Assembling of spark plug tube

1.Apply liquid gasket to the press-fitting section of the tube. Apply Three Bond
1
ADHESIVE:Three Bond1324
2.lnsert the tube into the grommet of the cylinder head
cover. Without setting the gasket, install the cover.
Tighten the bolts only to such an extent that no
displacement may occur.
3.Using the SST, drive the tube into position, while
confirming that the tube is aligned with the press-fitting
hole of cylinder head.
This driving of the tube should be made until the
upperlcenter section of the tube becomes flush with the
surface of the head cover.
SST: 09388-87701-000
CAUTION
Drive the tube, until the tube comes at the center of the
tube hole of the cylinder head cover.
6-26
(1) Assembling of semi-circular plug
1.Apply liquid gasket to the installing section of the semi-
circular plug No.1 and semi-circular plug No.2 about @4-
5mm and attach them to the top arch of the cylinder
head.
CAUTION
Do not wipe off the liquid gasket that oozed out from
MilE5098ET10
the top surface of the cylinder head. Install the cylinder
head cover within five minutes.
Wipe off the liquid gasket if the cylinder head cover is
not installed within five minutes.
(2) Assembling of valve spring seat and valve stem oil
seal
1.Install the valve spring seat and valve stem oil seal.
(1) Apply engine oil to the inside of the new valve stem oil
seal. Press the oil seal in place by pushing the
shoulder section of the oil seal.
CAUTION
Be sure to use a new valve stem oil seal,
After completion of the assembling, lightly pull the oil
seal by hand so as to confirm that the part has been
installed securely.
(3) Assembling of intake valve and exhaust valve
1.Prior to the assembling, apply engine oil to the tip-ends of
the intake valve and exhaust valve.
2.After the intake valve and exhaust valve have been
installed, apply engine oil to the lip section of the valve
stem oil seal.
(4) Assembling of compression spring

1.Install the compression spring.
2.The compression spring should be assembled in such a
way that the side having a greater pitch comes at the top
side.
B-27
\
(5) Assembling of valve spring retainer and valve spring
retainer locks
1.lnstall the valve spring retamer Using the SST, install the
retainer and valve spring retainer locks.
SST: 09202-87202-000
CAUTION
Be sure to protect your eyes by wearing a pair of
goggles, etc. during the operation.
Care must be exercised to prevent the spring from
jumping out. -
(6) Assembling of valve lifter
1.Apply engine oil to the valve lifter and assemble it.
CAUTION
The valve lifter bearing the same punched mark as
before removal should be installed for each valve,
After the valve lifter has been assembled, make sure
:
that the valve lifter can turn lightly.
(7) Assembling of cylinder head gasket

1.Using a micrometer, measure the diameters of threads of
the cylinder head bolt at several points in the shaded
range indicated in the right figure. If the measured
diameter is below the allowable limit, replace the cylinder
head bolt.
2.Using a scraper, clean the gasket installing surfaces of

the cylinder block and cylinder head so as to completely
remove foreign matter, oils, etc.
CAUTION
Care must be exercised not to drop scraped gasket
debris into the water jacket, oil holes and cylinder head
bolt installing holes. If any scraped debris should drop,
be sure to remove it.
'1
3.Apply liquid gasket (Three Bond 1 2 0 7 ~ to ) the mating 3rnm
surfaces of the cylinder block and oil pump and the top
surface of the oil pump that are indicated by the range in
the right figure.
CAUTION
* Be very careful not to apply the liquid gasket
excessively. Excessive application may cause the
admission of liquid gasket into the cooling system to . CTXESWETIO
occur.
After the liquid gasket has been applied, be certain to
assemble the cylinder head within 15 minutes.
4.lnstall a new cylinder head gasket, aligning with the
knocking pin of the cylinder block.
CAUTION
Make sure to use a new cylinder head gasket.
:.
(8) Assembling of cylinder head SIA
1 .Apply engine oil to the threaded sections and seat
surface of the cylinder head bolt. Then, install the bolt
into the bolt hole.
2.Tighten the ten cylinder head bolts over several stages

according to the sequence indicated in the right figure.
After tightening, torque them to the specified value.
TOOL: Hexagon wrench (Width across flats : 8mm ) Front 1 1
3.After the bolts have been tightened to the specified
torque, further retighten them 90 degrees according to
the same sequence.
TIGHTENING TORQUE: 34.0 N-m {350 kgf.cm)+90"*!:
NOTE
Apply a paint mark to the head section of every head
bolt in the same direction. After the head bolts have
been tightened 90' according to the sequence above, Paint mark Tighten further
90'degrees
ensure that the paint marks of all bolts come at a 90"
turned position.
4.Tighten the three flanged bolts (cylinder head x oil
pump) of the oil pump body section to the specified
torque.
TIGHTENING TORQUE: 21.O_f4.0 N.m {210rt42
kgf .cm)
CAUTION
This tightening should be made within five minutes
after the cylinder head bolts have been tightened.
3 WATER PUMP
Instrument
,
l~orquewrench J
cylinder head)
%:Nowreusableparts
Unit:N.m (kgf.cm)
1 a Pulley, water pump
2 b Pump Ay, water
3 c Gasket, water pump

1.Remove the parts in the sequence as indicated in the COMPONENTS diagram.
(1) Removal of water pump pulley
1.Remove the four bolts while preventing turning as shown
in the illustration by using a flat screwdriver.
(2) Removal of water pump Ay

1.Remove the water pump Ay by removing the four bolts and two nuts.
CAUTION
Do not reuse the water pump gasket once it has been removed.
3-1-4 INSPECTION
1.Clean the joint surface of the water pump and oil pump
3-1-5 INSPECTION
1.Check for deformation and damage.
2.Check to see if the rotor turns smoothly by turning it by hand

(1) Installation of water pump Ay
1.With a new water pump gasket interposed, install the water pump assembly. Tighten the four bolts
and two nuts to the specified toraue.
TIGHTENING TORQUE: 14.012.8 N.m {145_f29 kgf.cm}
CAUTION
Use a new water pump gasket.
(2) lnstallation of water pump pulley

1.Install the water pump pulley. Tighten the four bolts to the
specified torque while preventing turning as shown in the
illustration by using a flat screwdriver.
TIGHTENING TORQUE: 8.5+2.5 N.m { 8 5 t 2 5 kgf.cm}
4 OIL PUMP
SST
I
09032-00100-000 Cutter, oil pan seal
09213-87211-000 Holder, crankshaft pulley
09309-87201-000 Replacer, transmission bearing
Tool
/scraper
Instrument
-.
l~orquewrench,Thickness gauge,Precision straightedge
water pump)
i
%:Nan-reusable parts
Unit:N.rn {kgf.crn)
1 a Pan SIA, oil 6 f Gasket, oil pump, No. 1
2 b Strainer Ay, oil 7 g Gasket, oil pump, No. 2
3 c Gasket, oil strainer flange 8 h Retainer, oil seal
4 d Pulley, crankshaft
5 e Pump Ay, oil

1.Remove the parts in the sequence shown in the Components diagram.
(1) Removal of oil pan
1.Secure the timing chain tension arm and timing chain
guide with rubber bands or the like.
I
2.Remove the oil pan attaching bolts and nuts.
3.Remove the oil pan by inserting forcibly the SST into
between the oil pan and the cylinder block.
SST
CAUTION
Perform the operation slowly so that the oil pan flange
section may not be deformed.
SST: 09032-00100-000
LllE5087TlO
(2) Removal of oil pump strainer

1.Remove the oil pump strainer and oil strainer flange
gasket.
.
CAUTION
Do not reuse the oil strainer flange gasket once it has
been removed.
(3) Removal of crankshaft pulley

1.lnstall the crankshaft pulley with the SST.
(1) Apply the belt section of the SST to the second stage
(air conditioner compressor driving side) of the
crankshaft pulley, as indicated in the right figure.
SST: 09213-87211-000
CAUTION
Do not apply the belt section of the SST to the first
stage (alternator driving side), because there is a
potential of damaging the oil pressure switch.
(4) Removal of oil pump AY
, . 1.Remove the oil pump assembly by removing the seven
bolts and one nut.
CAUTION
The removal should be carried out carefully, while
paying utmost attention not to scratch the oil pump
installing surface.
Do not reuse the O-ring and oil pump gasket once they
have been removed.
2.Remove the oil seal retainer.

CAUTION
Do not reuse the oil seal retainer once it has been
removed.
B-35
4-1-4 Cleaning
1.Clean the gasket that may remain on the oil pan installing
surface or the oil pan flange section of the cylinder block,
using a scraper, wire brush or the irke.
4-1-5 AssemblinglDisassembling of oil pump
4-1-6 COMPONENTS
Z:Non-reusable parts
Unit: N.m {kgf.cm)
1 a O-ring 6 f Valve, oil pump relief
2 b Cover, oil pump 7 g Seal, type T oil
3 c Rotor set, oil pump
4 d Gasket
5 e Spring. compression

(1) Removal of O-ring
1.Remove the O-ring.
CAUTION
Do not reuse the O-ring once it has been removed.
2.Remove the oil pump cover.
3.Remove the oil pump rotor set.
. . Removal of oil relief control valve

(21
1.Remove the bolt, gasket, compression spring, and oil
relief control valve.
CAUTION
(3) Removal of Type T oil seal
1.Remove Type T oil seal.
CAUTION
Do not reuse the oil seal once it has been removed
4-1-8 Inspection
(1) Tip clearance measurement
1.lnstall it to the body in such a way that the marks of the oil
pump drive rotor and the oil pump driven rotor face
toward the cylinder block side.
2.Using a thickness gauge, measure the tip clearance

between the oil pump drive rotor and the oil pump driven
rotor.
(2) Body clearance measurement

1.Using a thickness gauge, measure the clearance
between the driven rotor and body.
(3) Side clearance measurement

1.Measure the side clearance between the body and the
rotor, using a straightedge and thickness gauge.
SPECIFIED VALUE: 0.035-0.085 m m
(4) Relief valve check
1.Check the relief valve for excessive wear or damage.
2.Measure the free length of the compression spring, using
vernier calipers.
SPECIFIED VALUE: 57.0 mm
(1) lnstallation of Type T oil seal
1.Apply engine oil to the lip section of the Type T oil seal.
Install the oil seal, using the SST.
SST:09309-87201-000
CAUTION
Do not reuse the oil seal once it has been removed.
The oozing out amount after the press-fitting should be
0.5 mm or less.
. .
(2) lnstallation of oil relief control valve

1.lnstall the oil relief control valve and compression spring
in this sequence. Tighten the bolts to the specified
torque with the gasket interposed.
TIGHTENING TORQUE: 3Q.2f4.9 N.m { 4 0 0 t 5 0
kgf .cm}
CAUTION
Do not reuse the gasket once it has been removed.
(3) lnstallation of oil pump set rotor

1.lnstall the oil pump set rotor to the body in such a way
that the front mark, too, faces toward the engine block
side.
2.lnstall the oil pump cover.
3.lnstall the 0-rrng.
CAUTION
CllE8548EilO
i
4-1-1 0 Installation
(1) Installation of oil seal retainer
1.Apply liquid gasket to the oil seal retainer.
I /
Apply liquid gasket

CAUTION
Apply liquid gasket to the center of the seal surface
with a width of 6 3 to 4mm.
The oil seal retainer should be installed to ihe cylinder
block within five minutes after the liquid gasket has
been applied.
2.After engine oil has been applied to the lip section of the
oil seal, install the oil seal retainer to the cylinder block.
TIGHTENING TORQUE: 8.5f 2.5 N.m &&25 kgf.crn}
(2) Installation of oil pump AY
1.Clean the oil pump installing surface and its installing
surface on the cylinder block so that foreign matter and
oil, etc. may be removed completely.
2.lnstall the oil pump gasket No.1 and oil pump gasket
No.2 to the cylinder block. Apply liquid gasket to the
area indicated in the right figure.
ADHESIVE: Three Bond1207H Oil pump gasket No2 Oil pump gasket No.1
CllE8556ET10
3.Ensure that the timing chain is not detached from the

crankshaft timing sprocket.
4.Apply engine oil to the shaft section of the oil pump.

Install the oil pump assembly to the cylmder block.
Tighten the seven bolts and one nut to the specified
torque.
CAUTION
Care must be exercised not to scratch the oil pump
- installing surface.
Wipe off any liquid gasket that has oozed out from the
cylinder block and the top surface of the oil pump.
After the installation of the cylinder head, apply liquid
gasket again.
(3) lnstallation of crankshaft pulley
1.Install the crankshaft pulley with the SST.
SST: 09213-87211-000
(4) Installation of oil pump strainer AY

l.lnstal1 a new oil pump strainer flange gasket. Install the
oil pump strainer assembly.
(5) Installation of oil pan SIA

CAUTION
If the oil pan is deformed, lightly tap the oil pan so as to flatten it.
If the oil pan is deformed badly and its flattening seems to be difficult, replace it with a new part.
1.Clean the gasket that may remain on the oil pan installing surface and oil pan flange section of the
cylinder block, using a scraper, wire brush or the like.
2.Apply liquid gasket to the oil pan S/A as indicated in the
right figure.
CAUTION
The liquid gasket should be applied without any
discontinuity with a width of 6 3 to 4 mm.
Apply liquid gasket to those sections, too, that are
corresponding to the mating surface of the cylinder
block X oil pump.
The assembling should be carried out within 15
minutes after the gasket has been applied.
CAUTION
Care must be exercised not to allow the liquid gasket to
stick to the cylinder block, etc.
3.Tighten the bolts and nuts to the specified torque.
TIGHTENING TORQUE: 8.5t2.5 N.m {85+25 kgf.cm}
B-42
5 TIMING CHAIN
Instrument
IEngine oil 1
5-1-2 COMPONENTS (Perform the following operations successively after the removal or
installation of the oil pump)
Unit:N.m {kgf-cm]
1 a Sprocket, camshaft timing 7 g Bolt, hexagon socket head cap
<
2 b Arm, timing chain tensioner 8 h Spring torsion
3 c Guide, timing chain 9 i Sprocket, oil pump drive
4 d Chain SIA, timing 10 j Shaft SIA, oil pump drive
5 e Sprocket, crankshaft timing 11 k Chain, oil pump
6 f Arm, oil pump chain tensioner 12 1 Nozzle SIA, chain oil

(1) Removal of camshaft timing sprocket
1.Remove the rubber bands etc. that retain the timing chain
tensioner arm and timing chain guide.
2.Remove the camshaft timing sprocket.
(2) Removal of timing chain tensioner arm and timing
chain guide
1.Remove the timing chain tensioner arm and timing chain
guide.
2.Remove the timing chain SIA..
(3) Removal of crankshaft timing sprocket

1.Remove the crankshaft timing sprocket.
(4) Removal of oil pump chain tensioner arm

1.Remove the oil pump chain tensioner arm.
(5) Removal of torsion spring

1.Remove the socket head cap bolt and remove the torsion
spring.
(6) Removal of oil pump chain SIA

1.Remove the oil pump drive sprocket, oil pump drive shaft,
and oil pump chain SIA as a set.
(7) Removal of chain oil nozzle SIA
1 .Remove the chain oil nozzle SIA.
5-1-4 Inspection
(1) Timing chain SIA check
1.Check the timing chain for wear, cracks, etc. Replace
any defective chain.
CAUTION
If the timing chain exhibits any abnormality, carry out
the check also at the sprocket side.
(2) Oil pump chain SIA check

1.Check the oil pump chain for wear, cracks, etc. Replace
any defective chain.
CAUTION
If the timing chain exhibits any abnormality, carry out
the check also at the sprocket side.
(3) Sprocket check

1.Check each sprocket for damage
i 5-1-5 Installation
(1) Assembling of oil pump chain SIA
1.Perform the installation in such a state that the oil pump
drive sprocket, oil pump drive shaft and oil pump chain
SIA are assembled together.
CAUTION
Apply engine oil to the axial section and spline section
of the oil pump drive shaft, both ends of the oil pump
drive sprocket and bearing section of the cylinder
block.
(2) Assembling of oil pump chain tensioner arm
1.Temporarily install the oil pump chain tensioner arm.
(3) Assembling of chain oil nozzle SIA

1.Insert the chain oil nozzle SIA into the installation hole of
the cylinder block. Tighten the socket head cap bolt with
the torsion spring interposed.
TIGHTENING TORQUE: 8.5rt2.5 N.m (85f25 kgfmn}
CAUTION
Leave one end of the torsion spring in contact with the
oil pump chain tensioner arm. Leave the other end
free.
(4) Assembling of timing chain guide and timing chain

arm
1.With the one end of the torsion spring in contact with the
timing chain guide, temporarily tighten the bolt @.
Tighten the bolt @2 first and then bolt @ to the specified
torque.
TIGHTENING TORQUE: l9.Of 3.8 N - m {195_+39
kgf .cm]
CAUTION
Ensure that the torsion spring is installed securely.
(5) Assembling of oil pump chain tensioner a h
1.Tighten the timing chain tensioner arm and oil pump
chain tensioner arm with the bolt.
TIGHTENING TORQUE: 19.05 3.8 N.m {l95f39
kgf .cm)
(6) Assembling of crankshaft timing sprocket

1.Install the crankshaft timing sprocket.
CAUTION
Perform the assembling with the timing mark facing the
engine front side.
bating mark
CllEffi73ETl
(7) Assembling of timing chain SIA

1.Install the timing chain S/A and camshaft timing sprocket.
(1) Align the marking plates (at two points) of the timing
chain with the timing marks of the crankshaft timing
sprocket and camshaft timing sprocket when
installing.
CAUTION
Face the front mark "F"of the camshaft timing sprocket
toward the engine front side, when installing.
Face the marking plate of the timing chain to the
engine front, when installing.
Marking plate
CllEW4ET2
2.Secure the timing chain tensioner arm and timing chain

6 Cylinder block
SST
-
09221-87207-000 Remover & replacer piston pin body

8
Tool
[scraper
Instrument
~ -~ ~- ~
lDial gauge.Press gauge,Micrometer,Precision straightedge.Thickness gauge,Cylinder gauge,Torque wrench

6-1-2 COMPONENTS (Perform the following operations successively after the removal or
installation of the timing chain)
L
Unit:N.m {kgf.cm]
1 a Cap, connecting rod bearing 8 h Nozzle SIA, oil
2 b Bearing, connecting rod 9 i Ring, compression, NO.l
3 c Piston Wlconnecting rod 10 j Ring. compression, N0.2
4 d Cap, crankshaft bearing 11 k Ring, oil
5 e Crankshaft 12 1 Piston
6 f Bearing. crankshaft 13 mRod, connecting
7 g Washer, crankshaft thrust 14 n Pin, piston
.~ . 8-50
(1) Connecting rod thrust clearance check
1.With a dial gauge or thickness gauge, measure the thrust
clearance of each connecting rod.
2.Set the magnet base of the dial gauge to the crankshaft.
3.lf the measured value exceeds the limit, replace the
connecting rod.
(2) Connecting rod bearing oil clearance check

1.Remove the connecting rod bearing cap and connecting
rod bearing.
CAUTION
Keep the parts which belong to the same cylinder
together.
2.Clean the bearing and crank pin.
3.Set a press gauge in the axial direction of the crank pin.

Tighten the bearing cap to the specified torque.
TIGHTENING TORQUE: 38.Of 4.0 N.m (390k40
kgf .cm)
CAUTION
Do not turn the crankshaft.
4.Remove the bearing cap. Measure the press gauge at its

greatest width.
ALLOWABLE LIMIT: 0.07 rnm
5.lf the measured value exceeds the limit, replace the
connecting rod bearing.
CAUTION
When replacing the bearing, align the fitting codes both
at the bearing cap side and connecting rod side.
The crankshaft has undergone rolling. Therefore do not
grind it.
Each soecified value
Identification /
item Specified Value ~ o u k aouter
l diameter code Crank pin code
code (Upper side:No.l) (Upper side:No.l)
1 1.486-1.490
2 1.490-1.494
Central stock thickness of con-
3 1.494-1.498
necting rod bearing (mrn)
4 1.498-1.502 -
5 1.502-1.506
1 34.976-34.984
Crankshaft pin diameter (rnm) 2 34.98434.992
3 34.992-35.000
4 38.000-38.008
Connecting rod big end bore
5 38.008-38.018 indentification code
diameter (mm) r? ?R 016-38 074
Connecting rod bearing selecting procedure

I Connecting rod big end hole code
I
Big end bore

5 4 3
code
6 5 4 3
CAUTION
Assemble the upper and lower bearings having the
same number.
NOTE
(Bearing code) = (Big end bore code) - (Crank pin
code)
The right figure shows points where the connecting rod
big end bore diameter is measured
(3) Removal of piston Wlconnecting rod

1.Remove the connecting rod bearing cap and connecting
rod bearing.
2.Wrap a rubber cap or the like around the bolt at the end
of the connecting rod. Being very careful not to damage
the cylinder a n d crankshaft, remove the piston
Wlconnecting rod by tapping it with a grip of a hammer.
CAUTION
Keep the parts which belong to the same cylinder
together.
(4) Crankshaft thrust clearance check
1.With a dial gauge, measure the thrust clearance
(movement in a longitudinal direction) of the crankshaft.
If the clearance exceeds the limit, replace the thrusl
washer or crankshaft.
SPECIFIED VALUE: 0.02-0.22mm
NOTE
* When the crankshaft thrust clearance exceeds the limit,
replace all the crankshaft thrust washers. (As for the
O/S thrust washers, refer to the servicing specifications 1
table.) If the clearance is out of specification even if

the replacement has been carried out, replace the
crankshaft.
(5) Crankshaft oil clearance adjust

1.Remove the crankshaft bearing cap.
If it is difficult to remove the bearing cap, lightly tap it with
a plastic hammer to remove.
(1) Clean the bearing inside, bearing cap inside, journal
section of the cylinder block, and journal section of
the crankshaft. Also, check for severe wear and
damage.
(2) Set a press gauge in the axial direction of the

crankshaft journal section. Tighten the crankshaft
bearing cap to the specified torque.
TIGHTENING TORQUE: 59.0k6.0N-rn{600+60
.
kgf cm)
(3) Remove the bearing cap. Measure the press gauge at
its greatest width.
SPECIFIED VALUE: 0.020-0.044mm
(4) If the measured value exceeds the limit, replace the
crankshaft bearing.
CAUTION
The crankshaft has undergone rolling. Therefore do not
grind it.
Cylinder block bearing bore diameter
Item ( Selecting I Specified Value
code 1
Cylinder block 4 I 46.000-46.008
Bearing bore diameter 5 46.008-46.016
lmml fi I AR nlR.AG n3A
Crankshaft journal outer diameter
Journal outer diameter 41.984-41.992
Crankshaft bearina thickness

ldentification Journal bore diarnet4
Item Specified Vaiue ;electina code
color (code)
Yellow ( 1 )
1.986-1.990
Central stock thickness of con- Green (2) 1.990-1.994
necting rod bearing (mm) Brown (3) 1.994-1.998
Black (4) 1.998-2.002
Blue (5) 2.002-2.006
Crankshaft bearing selecting procedure

Crank journal code Journal outer diameter code C{ank pincode
(Upper side No.1) (Upper side No.1)
Bearing bore CllE8513E710
5 4 2
code
5 3
CAUTION
Assemble the upper and lower bearings having the
same color.
NOTE
(Bearing code) = (Journal inner diameter
code)- (Crankshaft journal outer diameter code)
\
lndentificationpaint
2.Remove the crankshaft bearing cap. Then, remove the

crankshaft, crankshaft bearing and crankshaft thrust
washer.
3.Remove the oil nozzle S/A.
CAUTION
Loosen the crankshaft bearing cap bolts in the
sequence indicated in the right figure over two or three
stages.
-
4.Assembling/disassembling of piston Wlconnecting rod
(1) Using the piston ring tool, remove the compression
ring No. 1, compression ring No. 2, and the oil ring.
CAUTION
Keep the piston and piston ring in the right
combination.
(2) Using the SST, remove the piston, connecting rod and
piston pin.
SST:09221-87207-000
(3) Set the SST on the piston pin as shown in the right SST
figure.
(4) Set the SST to the piston under state mentioned

above, as shown in the right figure. Pull the piston
pin with a press and remove the piston and
connecting rod.
6-1-4 Cleaning
(1) Cylinder block cleaning
WARNING
Wear safety goggles to protect your eyes during the cleaning.
1.Clean the cylinder head of the cylinder block, oil pan, oil / I
pump and oil seal retainer installation section with a
scraper or the like.
(2) Piston cleaning

WARNING
Wear safety goggles to protect )rour eyes durin le cleaning.
1.Remove the carbon deposit in the right groove, using the

oil piston ring or the like.
2.Remove carbon on each section, using washing fluid.
CAUTION
Do not use a hard brush, such as a wire brush.
B-56
6-1-5 INSPECTION
(1) Cylinder block check
1.Cylinder block top surface distortion check
(1) With a straightedge and thickness gauge, measure
the distortion at the six points indicated in the right
figure.
ALLOWABLE LIMIT 0.08 mm
NOTE
If the distorfion exceeds the limit, machine and correct
the top surface of the cylinder block.
2.Cylinder bore measurement Thrust derection
(1) With a cylinder gauge, measure the bore at the six Crankshaft axial
derection
points indicated in the right figure. Calculate the
difference between the maximum value and
minimum value.
If the limit is exceeded, replace the cylinder block or
perform boring and use an 01s piston. Center
ALLOWABLE LIMIT 0.2mm
Specified
- cylinder bore diameter
Cylinder bore code Cylinder bore diameter (mm)
1 61.000-61.010
2 61.010-61.020
3 61.020-61.030
3.Cylinder block boring

(1) Taking the cylinder with the maximum wear diameter
and maximum damage depth as the reference,
select the O/S piston.
(2) Calculate the boring dimension based on the
selected OIS piston outer diameter. Then, perform
boring. Center
NOTE
Boring dimension CllEBUlETIO
= (Actually-measured01s piston outer
diameter)+(Piston clearance specified
value) - (Honing margin 0.02 mm)
(3) After boring, measure the ovality and taper of the
P
cylinder inner diameter.
NOTE
Ovality
A-B or a-b
Taper
A-a or B-b
(4) Check the piston clearance after boring. T01E9146TiO
(2) Piston check
1.Piston pin oil clearance check
(1) With a micrometer, measure the diameter of the piston pin over the entire circumference at the
positions indicated in the figure below. Assume the maximum value as the piston pin diameter.
(_ri
8mm 8mm
(2) With a caliper gauge, measure the piston pin bore diameter over the entire circumference at the
positions indicated in the figure below. Assume the minimum value as the piston pin bore
diameter.
(3) Calculate the difference between the piston pin diameter and piston pin bore diameter. If the
value is out of the specification, replace the piston and piston pin.
SPECIFIED VALUE: Clearance: 0.005-0.011 m m
2.Piston outer diameter measurement

(1) Perform the measurement at a position 11 mm from
the lower end of the piston skirt section in a direction
right angles to the piston bore.
SPECIFIED VALUE: 60.965-60.995 rnrn
3.Check of clearance between piston ring and ring groove

(1) With a thickness gauge, measure the clearance over
the entire circumference of the piston.
Specified clearance between piston ring and ring groove
Specified Value Limit (mm)
(mm)
Compression ring No.? 0.07-0.105 0.12
, Compression ring No.2 , 0.02-0.06 011
4.Mating end clearance check of piston ring
(1) Using the piston, push in the piston ring at a position

about 45 mm from the block top surface. Measure
the clearance with a thickness gauge.
CAUTION
The measurement should be performed with the ring
placed in the cylinder to which the ring was assembled.
Mating end clearance of piston ring
Specified Value Limit (mm)
0.25-0.38
Com ression rin No.2 0.38-0.53
Oil ring 0.15-0.45
5.Check of oil clearance between cylinder and piston

(1) Measure the piston outer diameter and cylinder inner
Piston pin outer
diameter (right figure) to obtain the oil clearance. If diameter
the clearance exceeds the limit, replace the piston or measuring paints
cylinder block, or perform boring.

Cylindw bore
ALLOWABLE LIMIT: 0.10 mm measuring points
NOTE
The oil clearance of the piston and cylinder block can
be obtained by subtracting the piston maximum outer
diameter (basic diameter) from the thrust direction
minimum inner diameter of the cylinder.
(2) If the piston or cylinder block has been replaced,
check the oil clearance again.
Specified cylinder inner diameter and piston outer diameter
I Selection code lcylinder inner diameter1 Piston outer diameter 1
B-59
6.Selecting oversized (01s) piston
(1) Measure the cylinder inner diameter and piston outer Selection code
diameter. If the wear exceeds the limit, choose the
standard (STD) or 01s piston.
Boring finish dimension =(actually measured 01s
piston outer diameter)+(Oil clearance)-(Honing
margin 0.02 mm)
As for the kind and outer diameter of O/S pistons,
refer to the servicing specifications table. CIIEESTIETIO
CAUTION
When using the 01s piston, use also a piston ring
which is for 01s.
I
(3) Crankshaft check
1.Crankshaft runout check
(1) With a dial gauge, measure the runout. If it exceeds
the limit, repiace the crankshaft.
ALLOWABLE LIMIT: 0.03 rnrn
CAUTION
The runout is the half of the gauge reading (runout)
when the crankshaft makes a turn.
2.Crankshaft wear check

(1) With a micrometer, measure the journal section at
positions indicated in the right figure. Calculate the
ovality and taper.
ALLOWABLE LIMIT: 0.01 rnrn
(2) With a micrometer, measure the pin section at

positions indicated in the right figure. Calculate the
ovality and taper.
6-1-6 Assembling of cylinder block
1.Perform assembling in the sequence shown in the Components diagram.
(1) Piston assembling
1.Using the SST, assemble the piston, connecting rod and piston pin, following the procedure given
below.
SST: 09221-87207-000
09221-97401-000
(1) Apply engine oil to the pin hole of the connecting rod.
Align the front mark of the piston with that of the
connecting rod, and assemble temporarily.
(2) Assemble the piston pin to the SST, as shown in the

right figure.
(3) Set the temporarily assembled piston pin and

connecting rod to the SST as shown in the right
figure.
(4) Apply engine oil to the piston pin. Assemble the
piston pin and connecting rod with a press.
CAUTION
The piston pin press-fitting should be performed from
the piston front mark direction.
The piston pin press-fitting should be performed at the
normal temperature.
During press fitting, the pin should be pushed from right
above. Do not apply force diagonally.
(2) Assembling of compression ring and oil ring
1.Assemble the compression ring No. 1, compression ring
No. 2 and oil ring in the following procedure given below.
II
~ --- -
2.Assembling of compression ring

Using the piston ring tool, install the compression ring
with the identification mark facing upward.
(1) Assemble each ring in such a way that the mating
ends of the No.1 ring comes at the thrust direction
(intake manifold side), whereas the mating ends of
the next ring comes at the direction opposite to the
thrust direction, 180 degrees away.
Engine front
TOiE9162ETiO
(2) Assembling of oil ring

Assemble the oil rings in such a way that the mating
ends of the upper oil ring rail comes at the same
direction as the No.1 ring, whereas the mating ends
of the lower rail comes at the same direction as the
No.2 ring. The end of the expander should be
deviated 90 degrees from the mating ends of the
rail.
(3) Assembling of cylinder block Oil npzzle installing points 1

1.Assemble the oil nozzle S/A at a position indicated in the
right figure.
2.Assemble the crankshaft bearing cap, crankshaft,

crankshaft bearing, crankshaft thrust washer in the
following procedure given below.
(1) Assemble the bearing (upper), aligning with the lock
width of the cylinder block.
(2) Apply engine oil to the crankshaft sliding surface of

the bearing (upper). Then, assemble the crankshaft.
(3) Insert and install the thrust washer, starting with the
side with no claw, so that the oil groove may face
toward the outside (crank side).
CAUTION
Prior to assembling, apply engine oil to the oil groove.
(4) Apply engine oil to the crankshaft sliding surface of

the crankshaft bearing (lower). Then, assemble the
crankshaft bearing cap with the front mark facing to
the front.
(5) Apply engine oil to the bolts. Tighten them to the

specified torque over two or three stages in the
sequence indicated in the right figure.
TIGHTENING TORQUE: 59.0f6.0 N.m I601 f 61
kgf .cm}
(6) After assembling, ensure that the crankshaft can turn
smoothly.
3.Assemble the piston W/ connecting rod, connecting rod

bearing and connecting rod bearing cap, following the
procedure given below.
(1) Confirm the direction of the mating ends of the
compression ring and oil ring.
(2) Wrap a vinyl tape or the like around the bolt of the
connecting rod. Be very careful not to damage the
cylinder block bore section and crankshaft during
the insertion into the cylinder block.
(3) Apply engine oil to the sliding surfaces of the piston I

and connecting rod
(4) Using a piston ring tool, insert the piston into the
cylinder block with the piston front mark facing to the
front.
-
CAUTION
Assemble the piston and each cylinder in the same
combination as before the disassembling.
(5) Assemble the connecting rod bearing cap and
connecting rod bearing, following the procedure
given below.
(6) Apply engine oil to the connecting rod bearing.
(7) When assembling the connecting rod bearing cap

and connecting rod, ensure that the knock pin is
aligned with the knock hole when the assembling is
carried out with the cap front mark coming at the
front.
ALLOWABLE LIMIT: When tightening the connecting rod
bolts, tighten the right and left bolts
alternately and finally to the specified
torque.
ALLOWABLE LIMIT: 38.0rt4.0N .m {390+40kgf.cm}
CAUTION
Assemble the connecting rod and connecting rod
bearing cap in the same combination as before the
disassembling.
B2 ENGINE MECHANICAL
JB B2 - 1
CYLINDER HEAD GASKET-----------------B2 - 1
REMOVAL AND INSTALLATION-------- 82 - 1
CAM SHAFT 82 - 5
REMOVAL AND INSTALLATION B2 - 5
ENGINE ASSY B2 - 17
REMOVAL AND INSTALLATION------ 82 - 17
JB
1 CYLINDER HEAD GASKET
WARNING
No fire should be brought near when servicing the fuel system.
* There is a risk of burn injuries. Do not open the drain plug or remove the water hose while the
engine is hot.

Tnnl
(hexagon wrench (Vvio:n across flats : 8mm )

1.Release the fuel pressure.
Refer to Page 87-1.
2.Remove the battery @ terminal.

CAUTION
When the battery negative @ terminal is disconnected, it should be noted that diagnosis results and
memories of the radio are erased simultaneously.
3.Remove the camshaft.

Refer to Page 82-5.
4.Remove the turbocharger.

Refer to Page B3-8.
COMPONENTS
%Nan-reusable parts
Unit:N.m{kgf.cm]
1 a Hose, booster vacuum 7 g Hose, water (inlet pipe-throttle body)
2 b Hose, heater inlet water r 8
A h Cable Ay, accelerator control
3 c Hose, heater outlet water 9 i Hose, fuel No.l(main)
4 d Hose, radiator No.1 r A 10 j Head S/A, cylinder
5 e Hose, radiator No.2 A 11 k Gasket, cyiinder head
6 f Hose, heater inlet water (inlet pipe-outlet pipe)

1.Loosen the bracket nut to remove the throttle body.
CAUTION
Be careful not to have the cable get curly when during disassembly.
(2) CYLINDER HEAD SIA
1.Remove the three flange bolts (cylinder head X oil pump)
on the oil pump body.
2.Remove the ten bolts of the cylinder head in the

sequence shown at the right figure by loosening them
evenly over several stages.
3.Remove the cylinder head S/A together with the intake
manifold, the exhaust manifold and the injector.
CAUTION
Do not reuse the cylinder head gasket.
1-16 POINTS OF INSTALLATION

(1) CYLINDER HEAD GASKET
1.Clean the cylinder block, the oil pump top surface and the cylinder head lower surface and
completely remove foreign matters, oil, etc.
2.Apply liquid gasket (Three Bond 1207H) on the mating
face of the cylinder block and the oil pump, and on the
top surface of the oil pump, in the area shown in the right
figure.
CAUTION
* Avoid excessive application, or the liquid will come to
be mixed in the cooling system.
Assemble the cylinder head within 15 minutes after
liquid gasket application.
3.lnstall the new cylinder head gasket, while matching the
cylinder block knock pin.
CAUTION
Use a new cylinder head gasket.
(2) CYLINDER HEAD S/A
1.Use a micrometer caliper to measure the thread diameter
of the cylinder head bolts at a few locations, the marked
areas shown in the right figure. If out of range, replace
the cylinder head bolt.
ALLOWABLE LIMIT: 8.63mm
2.Apply engine oil on the cylinder head thread and the
seating surface, and then insert into the bolt hole.
LUBRICANT Engine oil
3.Tighten ten (10) cylinder head bolts over several stages
in the sequence shown in the right figure, and then
tighten them to the specified torque.
4.After tightening to the specified torque, use the same
sequence to re-tighten 90" r;?
NOTE
Paint mark all the bolt heads in a same certain
direction. After tightening 90" in the sequence given
above, check If the bolt markings are located in the 90"
rotated position. Paint mark Tiohten further
i
5.Tighten the three (3) flange bolts (cylinder head X oil
pump) of the oil pump body section to the specified
torque.
CAUTION
Tighten them within 5 minutes after tightening the
cylinder head bolts.


1.Install the turbocharger.
Refer to Page 83-8.
2.lnstall the camshaft

Refer to Page 82-5.
3.lnstall the battery terminal

4.Replenish the coolant
5.Adjust the engine.
Refer to Page B1-1.
2 CAM SHAFT
SST
1 Shape Part No. Patt name
09504-87501-000
Wrench differential side bearing adjusting nut
(09504-00011-000)
I I I I
Tnnl
Isnap ring pliers,Hexagonwrench (Width across flats : 5mrn )
Instrument
l~orque
wrench
JBOI~(Size: M5. Pitch: 0.8 mrn),Engine oil

1.Remove the ignition coil
1) COMPONENTS
L
ENon-reusable parts
Unit:N.rn{kgf.cm)
1 a Pipe, intake No.1 r A 15 o Plunger, chain tensioner
r A 2 b Bracket, vacuum switching valve (purge VSV) r A 16 p Plug, semi-circular
3 c Hose, ventilation (head front side) 17 q Rotor, signal
4 d Pipe SIA air v A 18 r Sprocket, camshaft timing
v A 5 e Bracket, vacuum switching valve (boost control r 19 s Cap, camshaft bearing, No.1
VSV) v 20 t Cap, camshaft bearing, No.2
6 f Stay, surge tank No.1 r A 21 u Cap, camshaft bearing, No.3 (exhaust side)
7 g Hose. ventilation (head-intake manifold) r A 22 v Camshaft. No.2
8 h Guide SIA, oil level gage r A 23 w Cap, camshaft bearing. No.3 (intake side)
A 9 i Cover, cylinder head r A 24 x Camshaft. No.1
10 j Gasket, cylinder head cover 25 y Ring, shaft snap
11
A k Belt, V ribbed (vane pump) 26 z Washer, wave
r A 12 I Vane pump AY r A 27 A Gear SIA, camshaft sub
13 m Stay. manifold No.2 28 B Spring, camshaft gear
14 n Bracket, pump lower

(1) Vacuum switching valve bracket (purge VSV)
1.Remove the purge VSV vacuum hose, and then remove the purge VSV together with the vacuum
switching valve bracket.
(2) Vacuum switching valve bracket (boost control VSV)
1.Remove the boost control VSV hose, and then remove the boost control VSV together with the vacuum
switching valve bracket.
(3) Vane pump Ay
1.Remove the vane pump Ay mounting bolts, and then remove the manifold stay No.2 mounting nuts
and bolts.
2.Remove the vane pump Ay together with the manifold stay No.2. Give clearance to the vane pump
Ay rearward of the vehicle.
CAUTION
Do not remove the vane pump Ay oil piping.
(4) Chain tensioner plunger

1.Align the mating marks on the lower side of the timing
gear, as shown in the right figure, and position the
cylinder No.1 to the compression top dead center (TDC).
CAUTION
When turning the camshaft, place the tool on the
crankshaft pulley and turn the camshaft in the regular
rotative direction.
2.Give clearance to the vane pump rearward of the vehicle

and remove the chain tensioner plunger.
(5) Semicircular plug
1.Use a plast~chammer to remove the semicircular plug.
;haft timing sproc:ket

1.lnsert the cross bar into the signal rotor hole so that no
load may be applied to the timing chain and turning may
be prevented. Then remove the bolts.
CAUTION
Place a rag or the like between the cross bar and the
cylinder head to avoid damage.
2.Remove the camshaft timing sprocket together with the
signal rotor.
CAUTION
Leave the timing chain on the sprocket and slide to the
engine front side.
(7) ~ a r n r h a fbearing
t cap No.1, No.2
1 .After turning the crankshaft approx. 90" from the
compression top dead center (TDC) of the cylinder No.1
toward the engine rotational direction, place a spanner
on the hexagon portion of the exhaust camshaft. Turn
the camshaft counterclockwise by ensuring that the cam
noses of the cylinders No.2 and No.4 face downward
and depress the lifter by the identical amount.
2.Remove the camshaft bearing cap No.1 and the camshaft
bearing cap No.2.
TOOL:Hexagon wrench (Width across flats :5mm )
(8) Camshaft bearing cap No. 3 (exhaust side)
1.With a bolt, fix the sub-gear of the camshaft No.1 side on
the driven gear.
(bolt size: outer diameter 5mm, pitch: 0.8mm)
2.Remove the camshaft bearing cap No.3 (4 pcs) on the
exhaust side that secure the camshaft No.2 in the
sequence shown in the right figure.
M1~E5~DTlO
(9) Camshaft No.2 (exhaust side)

1.Remove the camshaft No.2 by lifting the gear side.
(10) Camshaft bearing cap No.3 (intake side)
1.Place a spanner on the hexagon portion of the camshaft
No.1. Turn the camshaft No.1 counterclockwise by
ensuring that the cam noses of the cylinders No.3 and
No.4 of the camshaft No.1 face downward and depress
the lifter by the identical amount.
2.Remove the camshaft bearing cap No.3 (4 pcs) on the

intake side that secure the camshaft No.1 in the
sequence shown in the right figure.
CAUTION
= After the camshaft is removed, leave the timing chain
on the camshaft timing sprocket.
= If the timing chain drops into the oil pump, the cylinder
head and the oil pump must be removed.
(11) Camshaft No.1 (intake side)

1.Remove the camshaft No.1 by lifting the gear side first.
(12) Camshaft sub-gear SIA
1.Secure the hexagonal
- section of the No.1 camshaft to a vice with protective metal sheets interposed.
CAUTION
Be very careful not to damage the cam section.
2.Remove the camshaft sub-gear fixing bolt.

(1) Set the SST on two holes of 6 6 of the camshaft sub-
gear S/A to hold the sub-gear.
SST 09504-87501-000
(2) When the SST is not used, put a bolt (M6) at the Sub-gear hold
position shown at the right figure of the camshaft bon,
sub-gear assembly. Then, hold the sub-gear by
inserting a screwdriver or the like between the bolt
and the camshaft journal.
CAUTION
Be very careful not to scratch the cam journal by
applying a cloth or the like.
(3) Remove the bolt securing the sub-gear, while keeping
the sub-gear teeth in mesh with the driven gear
teeth.
3.Use snap ring pliers to remove the shaft snap ring, the wave washer, camshaft sub-gear S/A and the
camshaft gear spring.
CAUTION
Before assembling the camshaft, turn the crankshafi approx. 90" from the compression top dead
center (TDC) of the cylinder No.1 toward the engine rotational direction in order to avoid the
interference between the valve and the piston that have been lifted.
(1) Camshaft sub-sear SIA

1.Secure the hexagonal section of the No.1 camshaft to a vice with protective metal sheets interposed.
CAUTION
Be very careful not to damage the cam section.
2.Set the camshaft gear spring, camshaft sub-gear S/A, and wave washer onto the camshaft driven
gear.
CAUTION
* As for the sub-gear, face the side where the stopper pin of the spring protrudes to the driven gear
side.
3.Using snap ring pliers, install the shaft snap ring.

TOOL: Snap ring pliers
4.lnstall the camshaft sub-gear fixing bolt.

(1) Set the SST on the two 6 6 holes of the camshaft sub-
SST
gear S/A. Turn the sub-gear clockwise until the
auxiliary hole for mounting the sub-gear matches
that of the camshaft driven gear to ensure the gear
tooth top matches.
SST 09504-87501-000
(2) If n o SST is used, insert the M6 bolts into the

camshaft sub-gear S/A at positions shown in the
right figure. Insert a screwdriver in between the bolt i
and the camshaft journal and turn the sub-gear
clockwise until the auxiliary hole for mounting the
sub-gear matches that of the camshaft driven gear
to ensure the gear tooth top matches.
CAUTION
* Be very careful not to scratch the cam journal by
applying a cloth or the like.
(3) Install the bolt (size: M5, pitch: 0.8 mm) for securing
the sub-gear to the auxiliary hole above. (If no SST
is used, remove the M6 bolt.)
(2) Camshaft No.1 (intake side)
1.Apply engine oil on the cam of the camshaft, gear tooth surface and the journal portion of the cylinder
head.
-
B2-12
2.As shown in the right figure, set on the cylinder head by Same lift amount
ensuring that the cam noses of the cylinder No.3 and
No.4 of the camshaft No.1 face downward and depress
the lifter by the identical amount.
(3) Camshaft bearing cap No.3 (intake side)

1.Set the camshaft bearing c a p No.3 (4 pcs) on the
camshaft No.1 side (intake side).
Ensure that the stamping No. is at the position shown at
the right figure so that the cap arrow faces the engine
front.
2.Tighten the camshaft bearing cap No.3 in the sequence

Cap,camshait bearing No.3

MIIESOJSETIO,
B2-13
(4) Camshaft No.2 (exhaust side)
1.Apply engine oil on the cam of the camshaft, gear tooth surface and journal portion of the cylinder
head.
LUBRICANT Engine oil
Camshaft centre line

Lower mating mark \
2.As shown in the right figure, set on the cylinder head by

Same l i t amount
ensuring the cam noses of the cylinder No.3 and No.4 of
the camshaft No.2 face downward and depress the lifter
by the identical amount.
M1IESJIETlO
-
-
B2-14
(5) Camshaft bearing cap No.3 (exhaust side)
1.Set the camshaft bearing cap No.3 (4 pcs) on the
camshaft No.2 side (exhaust side). Ensure that the Arrow
stamping No. is in the illustrated positton so that the cap
arrow faces the engine front.
2.Tighten the camshaft bearing cap No.3 in the sequence

3.Remove the sub-gear fixing bolt.
(6) Camshaft timing sprocket

1.Install the camshaft timing sprocket together with the signal rotor to the camshaft No.2.
2.lnsert the cross bar into the signal rotor hole so that no
load may be applied to the timing chain and turning may
be prevented. Then remove the bolts.
CAUTION
Place a rag or the like between the cross bar and the
cylinder head to avoid damage.
(7) Semicircular plug
1.Apply liquid gasket approx. @4-5rnmin the central part
of the semicircular plug and install to the arch area of the
Liquid gasket
upper head. I
(8) Chain tensioner plunger

1.Depress the lock and lower the plunger as shown in the
right figure, and engage a hook on the plunger pin.
2.Shifi the vane pump rearward of the vehicle and install to
the cylinder head through the new gasket with the arrow
stamped on the plunger facing upside.
CAUTION
Use a new gasket.
(9) Vane pump AY

1.lnstall the vane pump together with the manifold stay No.2.
(10) V ribbed belt (vane pump)
1.lnstall the V ribbed belt and adjust tension.
<RefCode=C114>
(11) CYLINDER HEAD COVER

1.lnstall the new cylinder head cover gasket to the cylinder head cover.
2.Apply liquid gasket on the cylinder head in the area
ADHESIVE: Three Bondl207H
3.Tighten the cylinder head cover mounting bolts in stages

in the sequence shown in the right figure within 5 minutes
after liquid gasket application.
B3 INTAKE SYSTEM
JB ....................................................... 03-1
AIR CLEANER ELEMENT 03 - 1
REPLACEMENT 83-1
AIR CLEANER B3-2
REMOVAL AND INSTALLATION 83 - 2
THROmLE BODY ............................. 03 - 3
REMOVAL AND INSTALLATION -------- 83 3 -
INTAKE MANIFOLD GASKET ------------- 83 - 5
TURBOCHARGER ............................. 03-8
REMOVAL AND INSTALLATION -------- B3 - 8
INTERCOOLER 03 - 12
REMOVAL AND INSTALLATION ------ 03 - 12
BOOST PRESSURE CONTROL
SYSTEM 83 - 14
SYSTEM DRAWING 03 - 14
FUNCTION CHECK 03-15
UNIT CHECK 8 3 - 15
AIR BYPASS VALVE CONTROL
SYSTEM 63-16
SYSTEM DRAWING ..................... 03 - 16
FUNCTION CHECK ....................... 03-16
UNIT CHECK B3-16
JB
1 AIR CLEANER ELEMENT
1-1 REPLACEMENT
1-1-1 REPLACEMENT PROCEDURE
1.Remove the air cleaner cap clips at two locations.
2.Remove the intake air temperature sensor coupler.
3.Remove the air cleaner cap and air cleaner hose No.2 clips
4.Remove the air cleaner cap and replace the element.
5.lnstall the air cleaner cap.
6.lnstall the air cleaner hose No.2 and lock the clips.
7.lnstall the intake temDerature sensor cou~ler.
2 AIR CLEANER
Refer to Page 12-2.
2.Remove the front cross member,


) COMPONENTS
Unit:N.m{kgf -cm]
1 a Air cleaner hose No.2
2 b Clip
3 c Air cleaner AY Wlelement

1.Install the front cross member.

Refer to Page 12-2.
3 THROTTLE BODY
WARNING
Never disassemble the water hose while the coolant is hot, for there is a risk of bum.
r~orquewrench

) COMPONENTS
%Nan - reusable parts

Unit:N.rn{kgf -cm]
1 a Cover SIA, engine upper 6 f Connector (throttle sensor)
2 b Pipe, intake No.1 7 g Connector (ISC valve)
r A 3 c Cable Ay, accelerator control 8 h Hose, purge
4 d Hose, water 9 i Body Ay, throttle
5 e Hose, water 10 j Gasket
- 63-4
I
1.Loosen the bracket nut to remove on the throttle body side.
CAUTION
Be careful not to have the cable get curly when removing it.
3-1-4 INSPECTION
(1) THROTTLE BODY
1.No excessive play should exist in the throttle shaft.
2.No clogging should exist in each port.
3.0peninglclosing motion of the throttle valve shall be smooth.
4.No clearance should exist between the stop screw and the lever at the throttle valve full close
position.
\
SPECIFIED VALUE: I-5mm (accelerator pedal free play)
4 INTAKE MANIFOLD GASKET
WARNING
Never disassemble any water hose while the engine 1s hot, for there is a risk of burn
Never use f~reduring the work.
Wear safety goggles durrng the cleaning so as to protect your eyes.

Refer to Page 87-1.
2.Remove the battery 0terminal.

CAUTION
When the battely negative terminal is disconnected, it should be noted that diagnosis results and
I
) COMPONENTS
E N o n - reusable parts
Unit:N.m{kgf.cm)
1 a Cover S/A, engine upper A 8 h Hose, vacuum (to ABV)
2 b Pipe, intake No.1 9 i Stay, surge tank No.1
3 c Hose, ventilation A 10 j Belt, V (vane pump)
4 d Hose, fuel (main) 11 k Stay, intake manifold No.1
5 e Hose, water 12 1 Stay, intake manifold No.2
6 f Hose, booster vacuum A 13 mManifold Ay, intake
r A 7 g Cable Ay, accelerator control 14 n Gasket, intake manifold

(1) Cable Ay, accelerator control
1 Loosen the bracket nut to remove the bracket on the throttle body s ~ d e
(1) Intake manifold
1.lnstall the intake manifold Ay. Tighten the three lower bolts to the specified torque, and then tighten
the three upper bolts to the specified torque.
(2) Belt, V (vane pump)
1.lnstall the V belt (vane pump) and adjust the tension.
(3) Vacuum house (to ABV)

1.lnstall the vacuum hose which leads to the ABV.
NOTE
Each hose shall be assembled as shown in the right
figure.
To intake maifoid / / I
. . Cable Ay, accelerator control

(4)
1.lnstall the accelerator control cable to the throttle body. After adjusting the accelerator pedal free
play, tighten the nut to the specified torque.
SPECIFIED VALUE: 1 -5mm (accelerator pedal free play)

1.Install the battery 0 terminal.
2.Refill the coolant.
i
5 TURBOCHARGER
WARNING
Never open the water hose and drain plug while the engine is hot, for there is a risk of burn.
Never perform the operation while the engine is hot, for there is a risk of bum.
Wear safety goggles during the cleaning so as to protect your eyes.

1.Remove the battery @terminal.
CAUTION
When the battery negative 0terminal is disconnected, it should be noted that diagnosis results and

Refer to Page 83-2.
3.Remove the radiator.

Refer to Page B6-6.

Refer to Page 83-12,
5.Remove the head lamp.

Refer to Page J1-7.
6.Remove the front fender.

7.Remove the hood lock striker.

8.Remove the cowl wire clamp which goes to the headlamp, which is installed on the radiator support
9.Remove the radiator support mounting bolt and shift forward.
NOTE
Removal is not necessaty, for shifting forward is enough to secure work space.
I) COMPONENTS
Z:Non - reusable parts

Unit:N.rn{kgf.crn]
v 1 a Hose, air cleaner No.2 8 h Maniverier Ay
r A 2 b Hose, actuator 9 i Gasket
3 c 0 2 sensor 10 j Pipe SIA, turbo oil inlet
4 d Insulator, exhaust manifold No.1 11 k Pipe SIA, turbo water
r A 5 e Insulator, exhaust manifold No.2 12 1 Pipe SIA. turbo oil outlet
6 f Stay, exhaust manifold A 13 mTurbocharger
7 g Stay, exhaust manifold 14 n Gasket

WARNING
Never perform the operation while the engine is hot, for there is a risk of burn.
I
(1) Air cleaner hose No.2.
1.Remove the air cleaner hose No.2.
(1) Remove the hose between the air bypass valve and the air cleaner hose No.2 on the air cleaner
hose No.2 side.
(2) Remove the air cleaner hose No.2.
CAUTION
Cover the hole of the turbo with adhesive tape or the like to prevent dirt or dust from entering.
(2) Actuator hose

1.Remove the actuator hose between the boost control VSV (pipe S/A, air) and the turbocharger.
(3) Exhaust manifold insulator No.2
1.Remove the exhaust manifold insulator No.2.
(1) Shift the radiator support forward to make path between the engine and the radiator support to
remove the insulator.
CAUTION
Use care not to apply load to the air conditioner pipe when shifting the radiator support.
(2) Remove the exhaust manifold insulator No.2 through the clearance.
(1) Turbocharger
1.Install the turbocharger Ay.
(1) Install the pipe S/A, turbo oil outlet and the turbocharger with the gasket interposed.
(2) Install the turbocharger Ay to the exhaust manifold to the specified torque with the new gasket
interposed.
CAUTION
After replacing the turbocharger, pour a small amount of the engine oil through the turbo oil inlet to
prevent seizure of the turbocharger.
(2) Exhaust manifold insulator No.2

1Shin the radiator support forward to make path between the engine and the radiator support to install
the insulator.
2.lnstall the exhaust manifold insulator No.2 through the clearance.
(3) Actuator hose
1.lnstall the actuator hose between the boost control VSV and the turbocharger.
1.lnstall the radiator support.
2.lnstall the clamp of the cowl wire which goes to the headlamp, which is installed on the radiator
support.
3.lnstall the hood lock striker.
4.lnstall the front fender.
5.lnstall the head lamp.

Refer to Page J1-7.
6.lnstall the intercooler.

7.lnstall the radiator.

Refer to Page B6-6.

Refer to Page 83-2.
6 INTERCOOLER
?.Remove the negative terminal @ of the battery.
CAUTION
It must be noted that, when the negative @ terminal of the battely is removed, memories for the
diagnosis, radio setting, etc. will be erased at the same time.

Refer to Page 12-2.
3.Remove the front cross member.


) COMPONENTS
d C
l
%:Nan - reusable parts

Unit:N. m(kgf.cm]
1 a Pipe, air intake N0.3
2 b 0 ring
3 c Guide
1 A 4 d Intercooler AY

(1) Intercooler AY
Remove the four condenser mounting bolts of the air conditioner. Lift the condenser, and shift the air
conditioner hose forward and remove the intercooler while giving clearance.
83-1 3 .
;
(1) Intercooler AY
With the condenser lifted, install the intercooler while giving clearance. Reinstall the air conditioner hose
to the original position and install the four condenser mounting bolts of the air conditioner.
1.Installthe cross member.

Refer to Page 12-2.
3.lnstall the negative @terminal of the battery.

7 BOOST PRESSURE CONTROL SYSTEM
-1 SYSTEM DRAWING
. cooler
Waste
Turbo charger
I Air cleaner
7-2 FUNCTION CHECK
CAUTION
With two people in the vehicle, perform a test drive at a
place where you can safely accelerate at wide-open
throttle in the second gear.
1.Remove the pressure sensor hose. Connect the three-
way with the turbocharger pressure gauge, and install
the gauge in the passenger compartment.
2.ARer warming up the engine, accelerate fully in the
range until the revolution reaches 5,000 rpm.
3.Check the pressure at 4500rpm.
If out of range, replace the turbocharger Ay.
SPECIFIED VALUE: 89.2-99.0kPa{0.91- 1.O1 kgf/cm2]
CAUTION
Do not adjust or disassemble the turbocharger.
7-3 UNIT CHECK
7-3-1 WAST GATE VALVE OPERATION INSPECTION
1.Remove the waste gate actuator hose on the actuator
side.
2.Connect the turbo charger pressure gauge and check if
the rod and the link operate properly when a pressure of
101.9kPa is applied and return smoothly when the
pressure is released.
3.Check if the hose is free from crack or damage.
CAUTION
Do not apply pressure exceeding 105kPa to the waste
gate actuator hose, othelwise damage to the
diaphragm may result.
7-3-2 VSV INSPECTION
8 AIR BYPASS VALVE CONTROL SYSTEM
-1 SYSTEM DRAWING
Turbo charger
8-2 FUNCTION CHECK

1.Remove the air bypass hose between the ABV and the air
cleaner hose on the ABV side.
2.Ensure that no intake air is discharged from the hose
wh~lethe engine is idling after it has started.
3.lntake air shall be discharged when the vehicle is
suddenly accelerated from idle speed, and then
suddenly the accelerator pedal is released at the pomt
when the tachometer reads 4000rpm.
8-3 UNIT CHECK

8-3-1 ABV OPERATION INSPECTION
1.The ABV valve shall open when the negative pressure is
applied to the diaphragm chamber (lower side).
No extreme pressure drop should result when this
negative pressure is held under this condition.
NOTE
Checkout negative pressure 53.3kpa {4OOmmHg}
B4 EXHAUST SYSTEM
JB B4-1
EXHAUST MANIFOLD GASKET----------- B4 - 1
EXHAUST PIPE 84-2
REMOVAL AND INSTALLATION -------- 84 - 2
JB
1 EXHAUST MANIFOLD GASKET
Instrument
l~orquewrench 1
Remove the turbocharger.
Refer to Page B3-8.

) COMPONENTS
L
%Nan - reusable parts
Unit:N .m{kgf.cm]
A 1 a Manifold Ay, exhaust
2 b Gasket. exhaust manifold

(1) Exhaust manifold
Attach the exhaust manifold. Temporarily tighten the five
nuts in the sequence shown in the figure. Tighten them to
the specified torque.

Install the turbocharger.
Refer to Page B3-8.
2 EXHAUST PIPE
Instrument
l ~ o r ~ wrench
ue

Remove the floor brace.

WARNING
Do not carly out operations while the exhaust manifold is still hot.
) COMPONENTS
Z:Non-reusable parts
Unit: N .rnlkgf .cm)
1 a Bolt, exhaust pipe support 6 f Support muffler No2
2 b Spring, exhaust manifold 7 g Pipe Ay, exhaust tail
3 c Support muffler No2 8 h Gasket
4 d Pipe Ay, exhaust, front 9 i Rear O2sensor
, 5 e Gasket, exhaust pipe
B4-3
Install the floor brace.
B5 LUBRICATION SYSTEM
JB B5 - 1
LUBRICATION SYSTEM B5 - 1
FUNCTION CHECK B5 - 1
ENGINE OIL 85-3
REPLACEMENT 85 - 3
OIL FILTER B5 - 4
REMOVAL AND INSTALLATION--------85 - 4
OIL PUMP 85 - 6
OIL PAN 8 5 - 12
85-1
JB
1 LUBRICATION SYSTEM
1-1 FUNCTION CHECK
WARNING
Never carry out the operation while the engine and engine oil are still hot, for there are hazard
potentials for getting scald.
1-1-1 D37BSE2BOh000lU\* MERGEFORMAT

ST
09991-87402-000 Wire, tacho-pulse pick up
09991-87404-000
Wire, engine control system inspection
(09991-87401-000)
Instrument
I~achometer.0ilpressure gauge.Torque wrench 1
l ~ h r e eBond1104
1-1-2 OIL PRESSURE

1.Attach an engine tachometer to the terminal REV@ ,
using the SST.
SST 09991-87402-000
09991-87404-000
DLC
2.Remove the oil pressure switch and install an oil pressure
gauge (thread diameter PT118).
3.Warrn up the engine (until the radiator fan starts rotating).
4.Measure the pressure at each revolution speed.
SPECIFIED VALUE: At time of 1,300rpm
147kPa(l .5kgf/cm2)
At time of 5,200rpm
343kPa(3.5kgf/cmz)
5.Attach the oil pressure switch.
(1) Clean the threaded section of the oil pressure switch
and the switch attaching section of the cylinder
block.
(2) Apply bond (Three Bond 1104) to the threaded
section of the oil pressure switch. After waiting for a
little while, proceed to the installation.
(Inasmuch as a liquid gasket does not have quick
drying feature, do not proceed to the installation
immediately after application.)
ADHESIVE: Three Bond1104
TIGHTENING TORQUE: 13.5 N.m {140kgf.cm}
2 ENGINE OIL
2-1 REPLACEMENT
WARNING

[€ngine oil 5W-30(API Grade SG or higher)
2-1-2 REPLACING PROCEDURE

1.Remove the engine cover at the top of the oil filler cap.
(1) Open the Ieftlupper section of the engine cover
upward.
(2) Remove the engine cover diagonaliy.
CllE5019TlO
2.Remove the oil filler cap.

3.Remove the drain plug of the oil pan. Drain the engine oil.
4.lnstall the drain plug with a new gasket interposed.
TIGHTENING TORQUE: 29.5k5.9N.m {295+59kgf .cm}
5.Fill engine oil.

LUBRICANT Engine oil 5W-30(API Grade SG or higher)
6.Check the oil level.

Refer to Page B1-2.
CAUTION
Prior to starting the check, wait for a little while so as to allow all engine oil to drip into the oil pan.
7.lnstali the oil filler cap.

8.Reverse the removal procedure to install the engine cover.
3 OIL FILTER
WARNING

SST
Shape 1 Part No. Part name 1
09228-87201-000 Wrench oil filtel
l ~ n ~ i oil
n e5W-30(API Grade SG or higher) 1
1.Lift up the vehicle.
2.Clean and remove any dirt from around the oil filter, front
engine mount bracket, etc. so that no foreign matter may
be admitted during the oil filter replacement.
3.Attach an oil filter wrench to the oil filter at the block side,
inserting the wrench into between the arms of front
engine mounting bracket, working from the underside.
4.Loosen the oil filter and let the remaining oil discharge 1
from the inside of the filter.
CAUTION
Pay attention as to the dripping oil.
Upon completion of the oil filter removal, wipe off any dripped oil.
5.Remove the oil filter. Turn the direction of the filter 90
degrees relative to the installation surface, that is the
lateral direction of the vehicle. Then, take out the oil filter
downward from between the arms of front engine
mounting bracket.
6.Wipe off the oil filter mounting surface at the block side,
using a rag, etc. Check to see if oil or scratches are
present at the mounting surface by applying a light beam
through the grill clearances at the front side of the
vehicle.
NOTE
At this time, it is advisable to check the union position
at the mounting surface.
7.Again ensure that no dirt is present at around the inner
sides of the front engine mounting bracket arms.
8.Apply engine oil to the gasket surface of a new oil filter.
CAUTION
Be sure to install an oil filter designed exclusively for
the Copen.
LUBRICANT: Engine oil 5W-30(API Grade SG or higher)
9.Reverse the removal procedure to install the oil filter.
CAUTION
Care must be exercised not to allow the oil filter gasket
to interfere with the engine bracket, etc.
10.Tighten the oil filter by hand until the filter contacts the
seal surface.
11.Check the mark position at the top of the oil filter through
the grill clearance at the front side of the vehicle.
12.Using an oil filter wrench, tighten the oil filter further a 1
turn.
(The turning angle can be checked based on the mark
position at the top of the oil filter.)
13.Run the engine at least three minutes. Ensure that the
engine exhibits no oil leakage.
14.Wipe off thoroughly any oil that may be stuck around.
4 OIL PUMP
WARNING

SST
09286-87701-000
bar, alternator adjustel
(09286-87201-000)
Instrument
w
ITorque wrench
09388-87702-000 Replacer, transfer input gear rear oil seal
l ~ h r e eBondl207C.Engine oil 5W-30(API Grade SG or higherpoap water-Wooden block

1.Remove the cylinder head Ay.
Refer to Page B2-1.
2.Rernove the oil pan.

) COMPONENTS
gasket
I
ZNon-reusable parts
Unit:N.m{kgf.cm)
1 a Strainer Ay.oil A 8 h Ring ,O
2 b Gasket,oil strainer flange A 9 i Gasketoil pump,N@
A 3 c Belt,V(For air conditioner use) A 10 j Gasket,oil purnp,Nol
A 4 d Belt,V(For alternator use) 11 k Pump Ay,water
r A 5 e Pulley.crankshafi 12 1 GaskeLwater pump
r A 6 f Pulley,water pump 13 rn Bar,fan belt adjusting
r A 7 g Pump Ay,oil A 14 n SeaiJype T oil
(3) CRANKSHAFT PULLEY

1.Remove the crankshaft pulley, using the SST.
SST: 09213-87211-000
CAUTION
Do not apply the SST to the first stage (alternator
driving side), for there is a potential of an oil pressure
switch damage.
- B5-8
(2) Insert the tool through the service hole so as to
remove the crankshaft pulley retain~ngbolt.
(4) WATER PUMP PULLEY

1.Remove the four bolts with a flat screwdriver used as a
means to prevent the turning, as indicated in the figure.
2.Using a garage jack, raise the engine about 10 mm with a

wooden block, etc. interposed at the transmission case
of the joint section between the engine assembly and the
transaxle assembly.
CAUTION
Never apply a jack to the oil pan of the engine
assembly or the transaxle assembly.
When using a jack, be sure to use rags or the like so as
to prevent any damage.
Do not raise the engine beyond a required amount.
NOTE
The gap between the body and the engine is very
small, not allowing the pulley to be taken out.
Therefore, raise the engine to provide a gap through
which the pulley may be taken out.
3.Remove the water pump pulley.
4.Lower the engine by operating the garage jack.
(5) OIL PUMP Ay
1.Secure the timing chain tension arm and timing chain
2.Remove the oil pump assembly by removing the eight
bolts and three nuts.
CAUTION
Carefully remove the oil pump so that no scratch be
made to the oil pump attaching surface.
Do not reuse the O-ring and oil pump gasket once they
have been used.
(1) TYPE T OIL SEAL
1.Apply engine oil to the lip-section of Type T oil seal
Assemble the oil seal, using the SST.
SST 09388-87702-000
LUBRICANT Engine oil 5W-30(API Grade SG or higher)
CAUTION
Use a new oil seal.
The oozing-out after the press-fitting should be 0.5mm
or less.
(2) OIL PUMP GASKET No.l,No.2

1.lnstall the oil pump gaskets No.1 and No.2 to the cylinder
block. Apply liquid gasket to the area indicated in the
right figure.
ADHESIVE: Three Bond1207C
(3) O-RING
1.Install a new O-ring to the water inlet pipe and apply soap
water to it.
LUBRICANT Soap water
(4) OIL PUMP Ay

1.Ensure that the timing chain is not detached from the
crankshaft timing sprocket. Then, install the oil pump
assembly to the cylinder block. Tighten the eight bolts
and three nuts to the specified torque.
-CAUTION
Carefully install the oil pump so that no scratch be
- made to the oil pump attaching surface.

Wipe off any oozed liquid gasket from the top surfaces
of the cylinder block and oil pump. When installing the
cylinder head, again apply liquid gasket.
Perform assembling so that the O-ring (oil pump) may
not be detached.
Be sure to perform the fitting of the water inlet pipe.
B5-10
1.Using a garage jack, raise the engine about 10 mrn with a
wooden block, etc. interposed at the transmission case
of the joint section between the engine assembly and the
transaxle assembly.
CAUTION
When using a jack, be sure to use a rag or the like so
as to prevent any scratch.
NOTE
The gap between the body and the engine is very
small, not allowing the pulley to be taken out.
Therefore, raise the engine to provide a gap through
--. which the pulley may be taken out.
i 2.lnstall the water pump pulley.
3.Lower the engine by operating the garage jack.
4.lnstall the four bolts with a flat 0screwdriver used as a
means to prevent the turning, as indicated in the figure.
(6) CRANKSHAFT PULLEY

1.Install the crankshaft pulley, using the SST.
crankshaft pulley, as indicated in the right figure
SST 09213-87211-000
CAUTION
Do not apply the SST to the first stage (alternator
driving side), for there is a potential of an oil pressure
switch damage.
(2) Pass the tool through the service hole. With the
handle section of the SST held firmly, tighten the bolt
to the specified torque, while paying attention not to
allow the belt to be twisted.
(7) V-BELT (FOR ALTERNATOR USE)
1.lnstall the V-belt(For alternator use).Adjust the belt tention.
Refer To Page 81-3.
(8) V-BELT (FOR AIR CONDITIONER USE)

1.lnstall the V-belt(For air conditiner use).Adjust the belt tention.
Refer To Page K1-3.

1.lnstall the oil pan.
Refer To Page B5-12.
2.lnstall the cylinder head Ay.

Refer To Page 82-1.
. .
5 OIL PAN
WARNING

SST
Shape Parl No. Part name
09032-00100-000 Cutter, oil pan seal
Instrument
[~hreeBondl207C.Engine oil 5W-30(API Grade SG or higher) 1
1.Drain the engine oil, by removing the drain plug and gasket.
CAUTION
Do not reuse the gasket once it has been used.
2.Rernove the front exhaust pipe Ay.

Refer to Page B4-2.
51-3 REMOVAL AND INSTALLATION PROCEbURES
I11) COMPONENTS
%Nan-reusable parts
Unit:N.mjkgf.crn]
1 a Stiffener,power train
r A 2 b Pan S/A.oil

(1) OIL PAN SIA
1.Remove the oil pan retaining bolts and nuts.
2.Remove the oil pan by inserting the SST forcibly between
the oil pan and the cylinder block.
CAUTION
Perform the operation slowly so that the oil pan flanged
section may not be deformed.
SST 09032-00100-000
- B5-14
NOTE
If any difficulty is encountered in removing the oil pan,
using a garage jack, raise the engine about 10 mm with
a wooden block, etc. interposed at the transmission
case of joint section between the engine assembly and
the transaxle assembly.
CAUTION
When using a jack, be sure to use a rag or the like so
as to prevent any scratch.
(1) OIL PAN SIA
CAUTION
If the oil pan is deformed, lightly tap the oil pan with a hammer so as to flatten it.
If it is difficult to flatten the oil pan due to being badly deformed, replace it with a new part.
1.Using a scraper, wire brush, etc., clean any gasket that may remain on the oil pan installing surface or
the oil pan flange section of the cylinder block.
2.Apply liquid gasket to the oil pan S/A, as indicated in the I 1
right figure.
ADHESIVE: Three Bond12O7C
CAUTION
Apply a liquid gasket without any missing portion with a
gauge of 6 3-4.
Apply liquid gasket to the section corresponding to the
mating surface of the cylinder block x the oil pump, as
The assembling should be made within 15 minutes
after the application of the gasket.
3.With the engine rear side of the oil pan SIA facing toward
the rear side of the vehicle, put it in the oil strainer and
install it to the block, while turning it.
CAUTION
Care must be exercised not to allow the liquid gasket to
get to the block, etc.
4.Tighten the bolts and nuts to the specified torque.

1.lnstall the front exhaust pipe Ay.
Refer to Page B4-2.
2.lnstall a new gasket in place and tighten the drain plug to the specified torque. Pour engine oil.
CAUTION
Use a new gasket.
.
~
B6 COOLING SYSTEM
JB 86-1
THERMOSTAT B6 - 1
REMOVAL AND INSTALLATION-------- B6 - 1
WATER PUMP B6-3
RADIATOR B6-6
REMOVAL AND INSTALLATION €36 - 6
JB
1 THERMOSTAT
WARNING
Do not remove the radiator cap or drain plug when the coolant is hot.

Instrument
[ ~ o r ~ wrench,Water
ue temperature gauge

1.Drain the coolant.
) COMPONENTS
Xf
L
.XNon-reusable parts
UnitN.m(kgf.cmJ
(2) REMOVAL AND INSTALLATlON PROCEDURES
1 a Hose, radiator No.2 6 f Hose, heater outlet water
2 b Inlet, water 7 g Hose, water inlet
A 3 c Thermostat 8 h Housing SIA, water outlet
4 d Sensor, water temperature 9 i Gasket, water outlet housing
5 e Gasket
NOTE
When the operation is limited only for the thermostat,
perform the operations up to Step 3.
1-1-4 INSPECTION
(1) Visual inspection
1.Ensure that the valve is completely closed at the room
temperature of 20°C, and that the spring is free.
2.Check to see if the rubber ring is not damaged.
3.Ensure that the bypass valve and jiggle pin move
smoothly.
- B6-2
(2) Check of valve opening temperature
1.Immerse the thermostat in water. Ra~sethe temperature
gradually and measure the temperature when the bypass
valve begins to open.
SPECIFIED VALUE: 82f l.5"C
2.Further raise the temperature. Measure the lift amount

when the temperature is 95°C.
SPECIFIED VALUE: 8.5mm or more
MllE5059ETll

(1) Thermostat
1.Assemble the thermostat to the water outlet housing in
such a way that its jiggle pin comes at top of the engine.
*water outlet housing

1.Fill the coolant.
2 WATER PUMP
WARNING
When the coolant is hot, do not remove the radiator cap and drain plug.

SST
I Shape Part No. Part name
09286-87701-000
bar, alternator adjuster
(09286-87201-000)
Instrument
l~orquewrench

<RefCode=E532>

I) COMPONENTS
%Nan-reusable parts
Unit:N.m(kgf.crn)
A 1 a Belt, V (for air conditioner) 6 f Gasket, water pump
A 2 b Belt, V (for vane pump)
A 3 c V-ben (for alternator)
r A 4 d Pulley, water pump
r A 5 e Pump Ay, water
1.Rernove the water pump pulley by removing the four
bolts, while preventing turning as shown in the figure,
using a flat screwdriver.
2.With a wooden piece or the like interposed, apply a

garage jack to the transmission case where the engine
assembly and transaxie assembly are connected. Then,
raise the engine about 10 mm.
CAUTION
Do not apply a jack to the oil pan of the engine
assembly or transaxle assembly.
When applying a jack, place a rag or the like so that no
damage is made to the section concerned.
Do not raise the engine more than necessaty.
NOTE
Because of lack of a gap between the body and the
engine, the pulley cannot be removed. Therefore, it is
necessaty to raise the engine to provide a wider gap so
as to remove the pulley.
3.Remove the water pump pulley.
4.Lower the engine by using the garage jack.
(2) Water pump Ay
1.Remove the water pump assembly by removing the four bolts and two nuts.
CAUTION
Once the water pump gasket is removed, it cannot be used again.
2-1-5 INSPECTION
1.Check to if there is any deformation or damage.
2.Check to see if the rotor turns smoothly by turning it by hanc
(1) Water pump Ay
1.Attach the water pump assembly with a new water pump
gasket interposed. Tighten the four bolts and two nuts to
the specified torque.
CAUTION
Use the new water pump gasket.
1.With a wooden piece or the like interposed, apply a
garage jack to the transmission case where the engine
assembly and transaxle assembly are connected. Then,
raise the engine about 10 mm.
CAUTION
Do not apply a jack to the oil pan of the engine
assembly or transaxle assembly.
When applying a garage jack, place a rag or the like so
that no damage is made to the section concerned.
Do not raise the engine more than necessary.
NOTE
Because of lack of a gap between the body and the
engine, the pulley cannot be installed. Therefore, it is
necessary to raise the engine to provide a wider gap so
as to install the pulley.
2.lnstall the water pump pulley.
3.Lower the engine by using the garage jack.
4.lnstall the four bolts, while preventing turning as shown in
the figure, using a flat screwdriver.
(3) V-belt (for alternator)

1.Install the V-belt (for alternator). Adjust the belt tension.
Refer to Page B1-3.
(4) V-belt (for vane pump)

1.lnstall the V-belt (for vane pump). Adjust the belt tension
(5) V-belt (for air conditioner)

1.lnstall the V-belt (for air conditioner). Adjust the belt tension
Refer to Page K1-3.

I .Install the air cleaner.
Refer to Page B3-2.
2.Reolenish the coolant.

-
B6-6
3 RADIATOR
WARNING
When the coolant is hot, do not remove the radiator cap and drain plug.

Instrument
l~orquewrench

2.Rernove the battery @ terminal.
CAUTION
When the battety negative @terminal is disconnected, it should be noted that diagnosis results and
3.Rernove the front bumper.

Refer to Page 12-2.
4.Rernove the front cross member

5.Rernove the four bolts that attach the condenser of the air conditioner.
(1I) COMPONENTS
r
ENon-reusable parts
A 1 a Hose, radiator reservoir r A 6 f RADIATOR AY
2 b Hose, turbo water
3 c Hose, radiator No.1
4 d Hose, radiator No.2
r A 5 e Bracket, radiator mounting, lower No.1

(1) Radiator mounting lower No.1 bracket
1.lnsert a flat screwdriver into the hole at the lower/left of
the bracket.
2.Unlock the bracket by turning the screwdriver to the left
(@ in the right figure) and pull the bracket toward you.
(@ in the right
- figure)
-
3.At the right hole, unlock the bracket by turning the
screwdriver to the right. Then, remove the bracket.
(2) RADIATOR AY
1.Move the radiator lower section to the front. Remove the
lower tank section from the radiator support. (@ in the
right figure)
2.Move the radiator downward. Remove the upper tank
section from the radiator support. (Q in the right figure)
3.Move the radiator upper section to the front. (@ in the
right figure) Separate the radiator from the radiator
support and lift and remove the radiator.
CAUTION
Do not allow the vehicle harness to contact the core
(including the tank caulking section). (Water leakage
will occur due to galvanic corrosion.)
Be careful not to damage or deform the fin when
removing the radiator.
(1) RADIATOR AY
1.Reverse the radiator assembly removal procedure to install the radiator assembly.
CAUTION
Do not allow the vehicle harness to contact the core (including the tank caulking section). (Water
leakage will occur due to galvanic corrosion.)
Be careful not to damage or deform the fin when installing the radiator.
(2) Radiator mounting lower No.1 bracket

1.Fit the new bracket to the radiator support and secure the radiator.
CAUTION
Once the bracket is removed, it cannot be used again.
(3) Radiator reservoir hose

1.lnstall the radiator reservoir hose.
CAUTION
Care must be exercised so that the hose may not be bent (restricted) midway.

1.lnstall the four attaching bolts for the air conditioner condenser
2.lnstall the front cross member.

Refer to Page 12-2.
4.lnstall the battery @ terminal

5.Fill the coolant.
6.Check the coolant leakage.
B7 FUEL SYSTEM
JB B7- 1
FUEL SYSTEM 87-1
INSTRUCTIONS FOR SERVICE
OPERATION 87-1
FUEL SUCTION TUBE 87-1
REPLACEMENT............................. 87 - 2
FUEL TANK B7 - 2
REMOVAL AND INSTALLATION------- B7 - 2
FUEL PUMP B7-7
INJECTOR 87 - 8
JB
1 FUEL SYSTEM
1-1 INSTRUCTIONS FOR SERVICE OPERATIQN
1-1-1 FUEL PRESSURE REMOVAL OPERATION
1.When you perform operations for the fuel system, remove the fuel pressure, following the procedure
given below.
(1) Turn OFF the IG switch.
(2) Remove the fuel pump relay.
(3) Start the engine. Keep on running the engine, until the engine stops naturally.
(4) Turn OFF the IG switch. Install the fuel pump relay.
CAUTION
Care must be exercised, for there is a residual pressure in the fuel line.
2 FUEL SUCTION TUBE

WARNING
Never allow a fire to be brought near the jobsite during the operation.
Be sure to take a precautionay measure to prevent fuel from being splashed.

CAUTION
When mud etc. gets to the tube, clean it prior to the
removal.
Make sure to perform the operation by hand without
using any tools so that no scratch may be made to the
tube etc.
If there is a seizure between the connector and the
tube, push and pull back with the retainer held by hand.
Pull out the tube from the connector after they can
move freely.
Cover the disconnected tubes and connectors with a
plastic bag etc. so that they may not be scratched or no
- matter be admitted.
foreian
1.While holding the both ends of the retainer, pull out the
connector under an unlocked state.
CAUTION
When the retainer is removed from the tube, be sure to
replace it by a new retainer, for the retainer is a non-
reusable part.
1.With the axis of the pipe and connector aligned with each
other, push in until you hear a clicking sound.
If the connection is stiff, apply a small amount of new
engine oil to the tip end of the pipe.
CAUTION
Ensure that no scratch or foreign matter is present at
the pipe connecting section.
NOTE
Retainer color
Fuel pump side: Orange
Body tube side: Blue green
2.After completion of the assembly, pull the tube and the
connector so as to ensure that they are connected
securely.
i 1.With the fuel pressure applied, check the fuel system for
leakage.
2-2 REPLACEMENT
2-2-1 REPLACEMENT PROCEDURES
1.Remove the connector and pipe, following the aforesaid procedure. Remove the retainer from the
pipe.
2.Align a replacement tube to the pipe and push in until you
hear a clicking sound. Pull out the checker.
NOTE
* Checker color
Fuel pump side: Orange
Body tube side: Blue green
3.After completion of the assembly, pull the tube and the
connector so as to ensure that they are connected
securely. 007E5M)6T10
2-2-2 OPERATION AFTER REPLACEMENT

?.With the fuel pressure applied, check the fuel system for leakage.
3 FUEL TANK
WARNING

Instrument
[~orauewrench
I
REFER TO PAGE 87-1.
2.Disconnect the battery negative terminal.

CAUTION
When the battery negative terminal is disconnected, it should be noted that diagnosis results and
3.Remove the pressure inside the fuel tank by removing the fuel filler cap.
WARNING
Be sure to take a precautionary measure to prevent fuel from being splashed.
4.Drain the fuel by removing the drain plug.

5.Turn over the carpet inside the boot at the left/front section of the vehicle.
\ COMPONENTS
%Nan-reusable parts
Unit:N.m(kgf.cm]
1 a Cap AySuel tank r A 10 k Hose,fuel emission
r 2 b Clamp,fuel filler pipe v A 11 mTank S/A.fuel
3 c Cover S/A,fuel inlet pipe r A 12 j Tube S/A.fuel suction
4 d Plate,fuel inlet pipe hole A 13 i Hose.fue1tank breather
5 e Shield.fue1inlet pipe,lower 14 n BracketSue1 pump
A 6 f Pipe S/A,fuel inlet,upper 15 o Gasketjuel pump
7 g Shield,fuel tank inlet pipe A 16 p Pump Ay,fuel
A 8 h Hose.fue1tank to filler pipe A 17 k tiose,fuel emission
r A 9 j Tube SiA.fuei suction 18 q Valve Ay.fuel cut off
-
\
3-1-4 POINTS OF REMOVAL I I
(1) FUEL FILLER PIPE CLAMP
1.Remove the clamps, using a flat screwdriver or the like.
(2) FUEL SUCTION TUBE

1.Remove the fuel suction tube S/A at the body tube side.
Refer to Page 87-1.
(3) FUEL EMISSION HOSE

1.Remove the fuel emission hose at the body tube side.
(4) FUEL TANK SIA
1.Remove the fuel tank S/A attaching bolts.
2.Make a gap between the fuel tank SIA and the body by lowering the fuel tank S/A slightly. Proceed to
remove the fuel pump connector and harness clamp.
3.Remove the fuel tank S/A.
1.Remove the fuel pump side of the fuel suction tube S/A.
Refer to Page 87-1.

1.Remove the fuel emission hose at the fuel cut off valve side
1.lnstall the side where there is no white marking of the fuel
emission hose to the fuel cut-off valve side.
CAUTION
Install the hose as indicated in the right figure.
I
(2) FUEL PUMP SfA
1.Install the fuel pump S/A.
(1) Install the fuel pump to the fuel tank with a new fuel
pump gasket interposed.
( 2 ) Align the fuel pump bracket hole with the projected
section of the fuel pump. Also, align the mating
marks of the fuel pump bracket and the fuel tank
wrth each other.
(3) Tighten the fuel pump bracket to the specified torque.
,.
(3) FUEL TANK BREATHER HOSE
1.Perform the installation in such a way that the white
marking side of the breather hose comes at the top
direction of the vehicle at the fuel pump side.
CAUTION
0-3mm. - 2-7mm
A l l E5025T10
(4) FUEL SUCTION TUBE SIA

1.lnstall the fuel pump side of the fuel suction tube SIA
Refer to Page 87-1.
(5) FUEL TANK SfA

1.Install the fuel tank SIA.
(1) With the fuel tank being brought toward the body side, install the fuel pump connector and
harness clamps.
(2) Install the fuel tank.
1.lnstall the side where there is the white marking of the fuel
emission hose to the body tube.
CAUTION

1 Install the fuel suction tube at the body tube side.
Refer to Page 87-1.
,
(8) FUEL TANK TO FILLER PlPE HOSE,FUEL INLET UPPER PlPE S/A
1.Pass the fuel inlet upper pipe SIA through the fuel inlet pipe lower shield and fuel inlet pipe hole plate.
2.lnstall the fuel tank inlet pipe shield to the body side and securely insert the fuel inlet upper pipe SIA.
3.Perform the assembling in such a way that the arrowheaded marking side of the fuel tank-to-filler pipe
hose comes at the top direction of the vehicle at the fuel pump side. Tighten the hose clamps, as
CAUTION
Perform the tightening until the band edge contacts the
stopper.
(Relative to the stopper claw +2 mm)
4.lnstall the fuel tank breather hose in the same way as with
the aforesaid procedure.
5.Align the forward end of the lower shield with the white
marking at the top of the inlet pipe.
6.lnstall the fuel filler pipe clamp.
e hose end surface

m Stopper
1.lnstall the carpet in the boots room.

2.Pour the fuel
3.lnstall the battery negative terminal.
4.Check the fuel system for leakage with the fuel pressure applied.
4 FUEL PUMP
WARNING
* Be sure to take a precautionary measure to prevent fuel from being splashed.

1.Remove the fuel tank.
Refer to Page 87-2.
) COMPONENTS

r 1 a Gauge Ay,sender
2 b Pump Ay,fuel
4-1-3 POINTS OF REMOVAL uel pump motor Ay

(1) FUEL SENDER GAUGE AY
1.Remove the fuel sender gauge Ay, while opening the two
claw sections of the gauge with your finger and pushing
Fuel sender gauge
them downward.
pawl
LllHSOIIETIO

1.Install the fuel tank.
Refer to Page 87-2.
5 INJECTOR
WARNING
Be sure to take a precautionaty measure to prevent fuel from being splashed

Instrument
~
wrench
l~orque

Refer to Page B7-1.
) COMPONENTS
L
%Nan-reusable parts
UnitN-m(kgf.cm]
1 a Cover S/A,engine upper 7 g Hose,fuel N d
r A 2 b Cable Ay,accelrator control 8 .h
Pipe S/A,fuel delivery
3 c Staysurge tank N d 9 i Injector Ay,fuel
4 d Hose,ventilation 10 j Ring,O
A 5 e Bracket,VSV 11 k lnsulator,injector vibration
A 6 f f hose, vacuum (For ABV control use)
5-14 POINTS OF REMOVAL

1.Remove the throttle body side by loosening the nut at the bracket section.
CAUTION
Care must be exercised during the removal so that the part will not get curled.
5-1-5 INSPECTION
(1) INJECTOR
- -- --

(1) VACUUM HOSE(F0R ABV USE)
1.Install the vacuum hose.
NOTE
Ensure that each hose is assembled as indicated in the
right figure.
(2) VSV BRACKET

1.lnstall the VSV bracket. Install the vacuum hose, as
Connected to air+
bypass pipe
&
(Air cleaner side)
CIlEMllETt
. , ACCELERATOR CONTROL CABLE AY

13)

1.Check the fuel system for leakage with the fuel pressure applied.
88 ENGINE CONTROL SYSTEM
JB 88-1
ENGINE CONTROL SYSTEM B8-1
ARTICLES TO BE PREPARED---------- 88 - 1
HANDLING INSTRUCTIONS OF
CONTROL SYSTEM -----------. 88-2
SYSTEM WIRING DIAGRAM B8 - 4
ARRANGEMENT OF ECU
TERMINAL 88 - 6
LOCATION OF COMPONENTS--------- B8 - 8
HOW TO PROCEED WITH
TROUBLE SHOOTING 88-9
INQUIRY B8- 15
SYMPTOM CONFIRMATION----------- B8-16
CONFIRMATION, RECORD AND
ERASURE OF DIAGNOSIS CODE --- B8 - 18
BASIC CHECK ------------------------- 88 - 23
TROUBLE SHOOTING ACCORDING
TO MALFUNCTION PHENOMENA--- 88 39 -
TO DIAGNOSIS CODE 88 - 44
UNIT CHECK 88 - 143
JB
-. -
Shape -. Part No. -- I -. - -. Pan name --
09842-87502-000 Sub-harness, EFI computer check
09268-41047-000
Tool set, injection measuring
(09268-41045-000)
09268-87701-000 Gauge, EFI fuel pressure
09268-87702-000 Tool set, measuring
09991-87402-000 Wire, tacho-pulse pick up
09991-87403-000 Wire, diagnosis check
09991-87404-000
(09991-87401-000)
09991-87301-000 Set,Diagnosis tester
09965-97230-000
Srouble-Shooting program card
(09965-97207-000)
- B8-2
1-2 HANDLING INSTRUCTIONS OF CONTROL SYSTEM
1-2-1 INSTRUCTIONS ON USE OF THIS SERVICE MANUAL
1.This service manual has been compiled in such a way that the manual may be used both in regions
where the type certification is implemented based on the EU exhaust emission approval, and AUS.
Hence, with regard to the assignment, reading, erasing of diagnostic trouble codes and those steps
of checks, repairs and confirmation, the service manual contains the procedures for both cases; One
is a procedure that uses the DS-21 diagnosis tester or the OBD II generic scan tool, and the other is
a procedure that does not use this tester or tool.
Therefore, the following instructions given below must be observed.
2.About Use of DS-21 Diagnosis Tester or OBD II Generic Scan Tool
(1) Regions where type certification is implemented based on EC exhaust emission approval; Make
sure to use the DS-21 diagnosis tester or the OBD II generic scan tool.
(2) AUS; You may use or not use the DS-21 diagnosis tester or the OBD II generic scan tool. You may
perform the operation, employing whichever method that will be easier to you.
3.lnstructions to be followed concerning Diagnosis Trouble Codes
i Diagnosis trouble codes, such as P0105/31 (four-digit codeltwo-digit code) are posted additionally.
i
(1) Regions where type certification is implemented based on EC exhaust emission approval
Make sure to use only four-digit trouble codes (e.g. P0105) whose have been assigned
according to the IS0 regulations.
(2) AUS;
You may perform the operation using the four-digit code, employing the DS-21 diagnosistester
or the OBD I1 generic scan tool. Or you may perform the operation using the two-digit codes
(e.g. 31),without the use of the tester or tool. You may perform the operation, employing
whichever method that will be easier to you.
Or you may perform the operation using the two-digit codes (e.g. 31), without the use of the
tester or tool.
You may perform the operation, employing whichever method that will be easier to you.
NOTE
The OBD II generic scan tool means a scan tool complying with the IS0 14230 (KWP2000) format.
In cases where the OBD II generic scan tool is employed, not all diagnostic trouble codes (four-digit
codes) can be read out. It should be noted that only those diagnostic trouble codes in which "zero"
follows after "P", for example, POXXX, can be read out.
The accuracy of the two-digit codes in diagnosing malfunctioning components is slightly inferior to
that of the four-digit codes.
Hereinafter, those regions where the type certification is implemented based on the EU exhaust
emission approval, is referred to as the "EU specifications".
1-2-2 PRECAUTIONARY MEASURES DURING TROUBLE-SHOOTING
1.Before the diagnosis information memorized in the EFI ECU memory is confirmed, never disconnect
the connector from the EFI ECU, the battery negative terminal, the EFI ECU earth wire from the
engine, or the main fuse.
2.The diagnosis information memorized in the EFI ECU memory can be erased by using the DS-21
diagnosis tester or the OBD-I1 generic scan tool in the same way as the check. Therefore, before
using the tester, read its instruction manual so as to understand the functions furnished and how to
use it.
3.Priority in trouble-shooting
(1) If the priority in trouble-shooting for a number of diagnostic trouble codes is given in the
concerned DTC flow chart, make sure to follow the priority.
(2) If not given, follow the priority given below and perform the trouble-shooting for each diagnostic
trouble code (DTC).
(1) DTC other than DTC P0171125, DTC PO172126 (too leanltoo rich in fuel system), and DTC
0300117, DTC P0301-P0304117, DTC P03141-(misfirefound)
(2) DTC P0171125, DTC PO172126 (too leanltoo rich in fuel system)
(3) DTC 0300/17, DTC P0301-P0304117, DTC P03141-(misfire found)
3
n
The lcrminal numbers given above arethesame as thore ol (he EFI campuler check sub-harness.
1-3-2 FOR AUS SPECIFICATIONS
1-4 ARRANGEMENT OF ECU TERMINAL
1-4-1 FOR EU SPECIFICATIONS
EFI ECU wire harness side
No. Terminal Contents of connection No. Terminal Contents oi connection

code code
1 BAT Back-up power supply 42 - -
2 - - 43 IE Ion current sensor ground
3 W Malfunction indicator lamp 44 VTH Linear throttle sensor
4 - - 45 THW Engine coolant temperature sensor
5 S102 Serial port for IMB 46 VCPM Manifold absolute pressure sensor power
1-4-2 FOR AUS SPECIFICATIONS
I No. /~erminaiI Contents of connection I No. l~erminalI Contents of connection 1

I code I I code
1 1 BAT I Back-up power supply 1 42 / - -
.
2 - - 43 - -
3 W Malfunction indicator lamp 44 VTH Linear throttle sensor
4 - - 45 THW Engine coolant temperature sensor
5 S102 Serial port for IMB 46 VCPM Manifold absolute pressure sensor power
\
1-5 LOCATION OF COMPONENTS
- I Pan name --
a Data link connector (DLC)

b Throttle position sensor
c VSVfor evaporative emission control system purge control (VSV for EVAP)
d Manifoldabsolute pressure sensor (MAP sensor)
e IVSV for boost pressure control I
f Ignition coil
9 Engine revolution sensor
h Intake air temperature sensor (IAT sensor)
I Oxygen sensor
I Knock sensor
k (Rear Oxygen sensor
I injector
m Ignitor
n Englne coolant temperature sensor (ECT sensor)
o Valve for ISC
P l ~ n g ~ control
ne computer (EFI ECU)
1-6 HOW TO PROCEED WITH TROUBLE SHOOTING
1-6-1 GENERAL INFORMATION
1.The engine and engine control system of this vehicle are controlled by the EFI ECU. Furthermore, the
vehicle is provided with the on-board diagnosis sysiem.
Therefore, when any abnormality takes place in the input/output systems (sensors, actuators,
harnesses, connectors, etc.) of the engine control system, the EFI ECU memorizes the system
concerned and informs the driver by making the malfunction indicator lamp (MIL) illuminate or flash.
Also the malfunction is informed to the operator by means of the malfunction indicator lamp (MIL).
When trouble-shooting the engine, it is imperative for you to get the general idea of the onboard
diagnostic system, and fully understand ihe precautionary measures in trouble-shooting, the items
diagnostic system, and fully understand the precautionary measures in trouble-shooting, the items to
be observed and how to use testers.
Then, conduct the trouble-shooting following the flow chart that indicates the correct procedure for
the engine troubleshooting.
(1) ON-BOARD DIAGNOSTIC SYSTEM OF VEHICLES FOR EUROPE
1.The vehicles for Europe have the following functions that comply with the 1999/102/EC (generally
called Euro-OBD) standards.
2.When the ignition switch is turned ON, the malfunction indicator lamp (MIL) goes on. When no
malfunction has been detected, the lamp will go out after the engine has started. (Check for a blown
bulb)
3.While the engine is .running, if the EFI ECU detects any
malfunction in the emission control system/components
that will affect the emissions from the vehicle, or in the
power train control components, or if any malfunction is
detected in the EFI ECU itself, the EFI ECU illuminates or
flashes the MIL (only when misfire is detected which will
damage the catalyst). Then, the EFI ECU memorizes the
malfunction area (DTC by IS015031-6/SAEJ2012).
If that malfunction will not occur in three successive
running, the MIL is automatically turned off. However, the
DTC will be recorded in the EFI ECU memory.
NOTE
The MIL is illuminated only by the malfunction that
affects the emissions from the vehicle. (Only items
bearing a circle ("0"mark) in the MIL column.)
4.lt is possible to read out various data from the engine
ECU by connecting the OBD II generic scan tool which
complies with the IS0 14230 format or DS-21 diagnosis
tester to the DLC of the vehicle. You can perform trouble-
shooting efficiently by checking these data (DTC, freeze-
frame data, current data, oxygen sensor monitor data,
etc.).
- B8-10
5.The DTC is composed of the ISO standard c o d e
(specified by I S 0 15031-6) and the manufacturer's P o 1 1 6 (Power train)
designation code. The IS0 standard code should be set
pursuant to the ISO. On the other hand, the
manufacturer's designation code can be freely set forth
0:Regulation
by the manufacturer within a specified limit.
1 & 2:Fuel and air metering
:Ignition system or misfire
7 & 8:Transmission
KlE3708ETiO
6.Many DTC have a two trip detection logic which assures
avoidance of wrong detection and functions only when a
malfunction is surely occurring. However, another
I F { \ 1 Mallunciim
edualionmethadl
diagnosis mode is provided, in which only a one-time

final confirmation test is necessary for a service
mechanic to confirm that the malfunction has been
completely remedied after the repair. The mode can be Fuel trim
2 trip
switched on with the OBD II generic scan tool or the DS-
21 diagnosis tester. (In the case of the DS-21 diagnosis
KiE3709EnO
tester, the 'Continuous monitor in^ results" of 'Vehicle
communication in CARB mode' must be selected.)
Vehicle communication v
7.When a malfunction is detected, the engine and running
Indication of malfunction code
conditions at that moment are memorized as a freeze-
Erasing of malfunction code
frame data in the EFI ECU memory. Data display for freeze frame data
8.Two trip detection logic lndication of current data
When a malfunction is detected for the first time, that Front 0 2 sensor test results
malfunction is temporarily memorized in the engine ECU
memory. (First running). If the same malfunction is
detected again during the second running, the MIL is
illuminated and the DTC is determined. (Second
runnina).
-.
(However, the ignition switch shouid be turned off
between the first running and the second running.)
(2) ON-BOARD DIAGNOSTIC SYSTEM OF VEHICLES OTHER THAN THOSE FOR EUROPE
1.When the ignition switch is turned ON, the MIL goes on. When no malfunction has been detected, the
lamp will go out after the engine has started; (Check for a blown bulb)
While the engine is running, if the ECU detects any malfunction in the engine control
systemlcomponents, or if any malfunction is detected in the EFI ECU itself, the EFI ECU illuminates
the MIL.
2.ln addition to the illumination of the MIL, the
Abnormal
corresponding diagnostic trouble code (DTC) is
memorized in the engine ECU memory. When the Normai
malfunction has been remedied or the system returns to Memorized
1
its normal state, the MIL automatically goes out.
However, the DTC remains memorized in the engine ECU Illuminated!
memory. ~xtin~uishedl 1
Extinguished
3.lt is possible to read out various data from the engine 5 sec.
ECU by connecting the DS-2ldiagnosis tester to the DLC UiE3711ET10
of the vehicle. You can perform trouble-shooting
accurately and efficiently by checking these data (DTC,
freeze-frame data, current data, oxygen sensor monitor
data, etc.). (Only when DS-21 diagnosis tester is used)
4.The DTC (diagnostic trouble code) is set to a four-digit
code in accordance with IS0 standard. Furthermore, the
conventional two-digit code is also provided. The four- Detection item
digit code can be read out by the DS-21 diagnosis tester.
The two-digit code has been set forth by the DMC itself.
This code can be read by observing the flashing pattern pressure circuit malfunction
of the MIL.
5.Some DTC have a two trip detection logic which assures
avoidance of wrong detection and functions only when a II POI 10143 I Intake air term. circuit malfunc.
U1E3712ET10
\ I
malfunction is surely taking place.
6.When a malfunction is detected, the engine and running
conditions at that moment are memorized as a freeze-
frame data in the EFI ECU memory.
7.Two trip detection logic
When a malfunction is initially detected, that malfunction
is temporarily memorized in the engine ECU memory.
(First running) If the same malfunction is detected again
during the second running, the MIL is illuminated and the
DTC is determined. (Second running)
(However, the ignition switch should be turned off
between the first running and the second running.) -.
1-6-2 DATA LINK CONNECTOR (DLC, COMMON +B ECU-T EFI-T REV
DESTINATIONS)
1.The vehicle engine ECU uses the IS014230 (Euro-OBD)
protocol. As regards the position, connector shape and
pin arrangement, the DLC is in accordance with the IS0
15031-3 (SAEJ1962) and has complied with the
IS014230 format. The OBD II serial data line (K line of
lS014230) is used for the OBD II generic scan tool or the
DS-21 diagnosis tester in order to communicate with the
KBody ECU ground
OBDUserial data line
(Kline of IS0 14230)
UXE3713ET10
ECU.
CAUTION
With the cable of the DS-21 diagnosis tester connected
to the DLC through the SST, turn ON the ignition
switch. If the power indicator of the tester will not go on,
conduct the following checks and repair any
malfunctioning parts.
SST 09991-87404-000
2.Connect the DS-21 diagnosis tester to another vehicle.
Turn ON the ignition switch.
1-6-3 CONNECTING PROCEDURE FOR SST (EFI COMPUTER CHECK SUB-HARNESS)

1.When the EFI ECU terminal voltage is measured with the EFI ECU connector connected to the engine
ECU, connect the SST, following the procedure given below.
NOTE
The terminal number of the SST connector is the same as the EFI ECU connector.
2.Turn OFF the ignition switch. Disconnect the battery negative terminal with the ignition switch turned
OFF.
T CAUTION
Be sure to memorize the diagnostic trouble code before
disconnecting the battery negative terminal. Otherwise,
the diagnostic trouble code(s) will be erased by
disconnecting the battery negative terminal.
3.Remove the glove compartment sub assembly.
4.Disconnect the wire harness connectors from the EFI ECU
connectors at the cowl side of the passenger seat.
5.Connect the following SST between the wire harness
/
connectors and the EFI ECU connectors. SST Arrow A
SST 09842-97203-000
m----@@@ connector
m----@@@
6.Reconnect the battery negative terminal. -----@@@I
CAUTION ~ - - - - @ @ @
When disconnecting or reconnecting the EFI ECU @@@-----
@@----@@@
connectors, be sure to disconnect the battery negative
terminal with the ignition switch and all accessory -----@@@
@@----
switches in the off state. @@@----m
When installing a new battery, care must be exercised ~ - - - - ~
not to mistake the battery polarity. Failure to observe <Viewed from arrow A> C13E5584Er21
this caution could cause EFI ECU malfunction.

Before using the SST, be sure to check to see if short
circuit or open wire exists between the terminals of the
SST.
1-6-4 TROUBLE-SHOOTING PROCEDURE
(1) Discription
1.The engine control system is equipped with diagnosis functions whose are capable of diagnosing
malfunctioning sections. These functions give important clues in trouble-shooting. The flow chart on
the next page shows how to proceed with trouble-shooting by using these diagnosis functions.
The flow chart shows how the diagnostic trouble code check can be used effectively. Moreover,
when its results are fully reviewed, you can determine whether you are going to do the trouble-
shooting according to diagnostic trouble codes or the trouble-shooting according to malfunctioning
phenomena.
The diagnosis of this system is equipped with a battery back-up function (a function which supplies
power for diagnosis memory even if the ignition switch is turned OFF.)
NOTE
When no DS-21 diagnosis tester or OBD-II generic scan tool is used, the DTC or freeze-frame data
in the flow chart can not be read out.
"",,
ENGINE DIAGNOSIS FLOW CHART
i :!
ringing a malfunctioningvehicle into sho
i
Diagnosis through inquiries 1 Get thorough information about
occurring
environmental
conditions
conditions
and
of
(confirmation and record of diagnosis code)
t
Erasure of diagnosis code
1
Confirmation of re~roduction
of
I Confirm the phenomena and grasp the
malfunction situation. (If
phenomena can not be reproduced,
the i
.*-
i
presume the possible causes by

malfunction phenomena conducting diagnosis through inquiries
I and by referring to the table showing
possible causes according to
malfunction phenomena.)
( Reconfirmationof diagnosis code)
Is diagnosis code Narrowing malfunctioning systems

the normal code?
., -.
Check of each system by trouble i
shooting according to malfunction
phenomena
Confirmation test Confirm that the malfunction the

Has vehicle been restored to customer was complaining has been
normal state? solved completely.
I
A Finish
(2) INQUIRY
@ Discription
1.h your attempt to remove the causes for a malfunction of the vehicle, you will not able to remove the
causes unless you actually confirm the malfunctioning phenomenon. No matter how long you
continue operations, the vehicle may not resume the normal state unless you confirm the
malfunctioning phenomenon. The inquiry with the customer is a vital information collecting activity
which is to be conducted previous to the confirmation of malfunctioning phenomenon.
2.This inquiry will provide you with an important clue in an effort to reproduce the malfunctioning
phenomenon. Furthermore, the information obtained by the inquiry can be referred to during the
trouble-shooting. Hence, instead of making general questions, it is necessary to focus your questions
on the items related to the malfunction.
3.The following five main points of the inquiry given below are the most important points in analyzing the
malfunction. In some cases, the information about malfunctions whose took place in the past and
about the history of previous repairs, which seem to have nothing to do with the current malfunction.
may prove to be helpful in solving the malfunction.
Hence, it is important to obtain as much information as possible and keep them accurately in mind
as reference information when trouble-shooting the malfunctioning phenomenon.
1-7 INQUIRY
1.If you make an inquiry sheet in advance, as shown in the example below, you can completely make
all necessary inquiries. The following shows a standard form. This should be altered according to the
characteristic of conditions of each market.
[INQUIRY SHEET]
-
Inquiry sheet
Name of customer Vehicle model -
Engine NIA, TIC, -
Transmission 4MR, 5Mn,
SIC, carburetor. 2WD. 4WD 2 N .3 N .
EFI, LPG 4 M
Frame No. Registrationdate . . Date of malfunction . . Running distance km
Defails Equipment:
Of
vehi* [Sex] of customer (driver) I[Age] 1 [Occupation] I[Places where vehicle is mainly used]. I[Park~ng
. place]
Male Female ( ~pdrox 1 ~rbandismc~sub~rolseam~~mc~ntan/otres ~~utooo&dco;
I -
( I
Poor starting I
/
.
/ NOinitial explosiontakes place.
Hard starting (cold engin;, hot engine, always) N . Explosion is incornolere allhouah initial exolosiontakes lace
; cranking takes ;lace. I
I /
I I Faulty idling I.
.
Other(
I Fast idling ineffective
)
Idling speed too high

- Idling speed too low
Idling unstable (cold engine, hot engine, always) 1
mm
Poor drive-ability
Other (
Backfire
)
Hesitation (during start, during acceleration,during deceleration, during a certain period)
Lack of power Poor acceleration Poor blow
. Knocking
Other ( )
t During idling (during warming up, after warming up) .. At time of starting During running ( )
Engine stall
I
.-...". ,
hh., I 1
Re-start impossible) Under loaded state(Air ccndtkmef, e m ioad, phv~sleeri~)
ImmediiekjafIer vehiclestops (Reestartpossib!e,
Frequencyof occurrence I At all times .

Fmn&nmathnnm~~sta2ed'I Since vehicle was purchased as a new car Recently (
Under a cenaln condition ( )
since what year/
Sometimes
month )
1
~eteorolo&cal
conditions .
At all times
Fine Cloudy Rain Snow Other ( )
JTemperature Temperature (about 'C)(Spring, summer, autumn, winter)
Engine condition When cold After warming-up Duringwarming-up (Water temperature about OC)
Road Urban district
No relation
Suburb . Highway
During racing under no load
Mountainous road (Uphill, downhill)
Driving conditions During running (Vehicle speed: kmlh, Engine speed: rpm, MT Which gear?)
During turn (right curve, lee curve)
Other situations
State of malfunction indicator lamp (MIL)

Indicationof DTC
Illuminatedor flashing at all times
During checking1 Normal
.illuminatedor flashing sometimas
Malfunction code ( )
Will not go on.
Reading out by using OBDU generic 2nd time Normal Malfunction code ( )
- scan tool or DS-21diagnosis tester

Reading-out of MIL flashing pattern by
shorting temlinal T
.- B8-16
1-8 SYMPTOM CONFIRMATION'
1-8-1 CONFIRMATION OF REPRODUCTION OF MALFUNCTIONING PHENOMENA
I .In the course of trouble-shooting, the operator can not pinpoint the cause for the malfunction unless
he confirms the phenomenon. For this purpose, it is indispensable to reproduce the malfunctioning
phenomenon by creating conditions and environments that are similar to those customer.
2.As for phenomena whose can not be reproduced easily, it is necessary to produce running conditions
that are similar to those when the malfunction occurred (road surface condition, weather condition,
driving condition). For this end, it is of great importance to try to reproduce the conditions that are
similar to those when the malfunction occurred (road surface condition, weather relays by hand),
heat (applying hot air) and water (applying moisture).
3.Vibration, heat or moisture can constitute causes for malfunction that are difficult to reproduce.
4.Therefore, with the vehicle in a stationary state, you can perform the following malfunction
reproduction simulation tests given below.
Moreover, if you presume a section (part) which can cause a malfunction and connect a tester, etc.
to that section so as to confirm the malfunctioning phenomenon, you can also achieve a function to
that section so as to confirm the malfunctioning phenomenon, you can also achieve a function
evaluation of that section (part).
(1) MALFUNCTION REPRODUCTION SIMULATION TEST
METHODS
@ Vibration method:
1.When vibration is thought to be the main cause
(1) Connector
Lightly shake the connector vertically and laterally.
(2) Wire harness

Lightly shake the wire harness vertically and
laterally.
The points to be checked are connector joints, the
vibrating point and the section where the wire
harness is passing through the body.
-hake
v
lightly iI
L21E37'27ET101
(3) Parts, sensors

With your finger, apply light vibrations to a part of the
sensor which is presumed to be the cause for the
malfunction. Check to see if the malfunction is
reproduced.
NOTE
Be careful not to apply too strong vibration to a relay,
for it can cause an open wire in the relay.
@ Coollhot method:
1.When a suspected section is likely causing the
malfunction when it is cold or hot.
(1) Heat a component which is presumed to be causing
the malfunction by using a dryer or the like. Check to
see if the malfunction occurs.
CAUTION
Do not heat the section beyond 60°C. (Temperature
limit to assure that no damage be made to the L21E3729EI
component.)
Do not directly heat the parts inside the ECU.
@ Water applying method:
1.When the malfunction is believed to occur on rainy days or under humid conditions. Apply water to
the vehicle. Check to see if the malfunction occurs.
NOTE
Never apply water directly to the engine compartment. By applying water to the front of the radiator,
you can indirectly change the temperature and humidity.
Never apply water directly to the electronic parts.
If rain leaks into the vehicle compartment, rain may get into the inside of the ECU through the wire
harnesses. If the vehicle has experienced any rain leakage before, utmost attention must be paid in
respect to this point.
1-8-2 RECHECK AND MAKING RECORD OF DTCIFREEZE-FRAME DATA

1.By checking the DTCIfreeze-frame data after confirming the reproduction of the malfunctioning
phenomenon, it is possible to judge whether the system related to the DTC that was indicated before
confirmation of the reproduction is now functioning properly or not. Then, you are to proceed to one
of the following three steps.
2.When a DTC was indicated at the time of checking the DTC and the same DTC is indicated after the
confirmation of reproduction of the malfunction, it indicates that the malfunction is still persisting in
the diagnosis circuit. Proceed to the trouble-shooting according codes.
3.When no abnormal code is indicated, although the occurrence of malfunction was observed during
the confirmation of reproduction of malfunction, a malfunction other than those related to the 1
diagnosis system is likely taking place. Proceed to the trouble-shooting according to malfunctioning
phenomena.
4.When no malfunction is observed during the confirmation of reproduction of malfunction, and the
normal code is indicated at the check of the DTC, it is presumed that an abnormality, such as poor
contacts at the harnesses and connectors, occurred in the past, but now they are functioning
properly. Check the harnesses and connectors of those systems related to the DTC that was
indicated before the confirmation of reproduction of the malfunctioning phenomenon.
B8-18
1-9 CONFIRMATION, RECORD AND ERASURE OF DIAGNOSIS CODE
1-9-1 CHECKING METHOD OF DIAGNOSIS
1.Prior to the check, check the malfunct~onindicator lamp (MIL), following the procedure given below.
2. CHECK OF MALFUNCTION INDICATOR LAMP
(1) Ensure that the malfunction mdrcator lamp goes on when the ignition switch is turned ON, but with
the engine not running.
NOTE
If the malfunction indicator lamp (MIL) fails to go on, perform the trouble-shooting for the
combination meter.
(2) Ensure that the malfunction indicator lamp goes out

when the engine starts. If the lamp remains
illuminated or is flashing, the diagnosis system is a ExtinguishedtI
400 rprn
detecting a malfunction. Therefore, a DTC is

memorized in the EFI ECU. If no DTC is memorized
in the EFI ECU, perform the trouble-shooting for the
malfunction indicator lamp circuit.
(1) CHECK OF DTC, USING DS-21 DIAGNOSIS TESTER

OR OBD I1 GENERIC SCAN TOOL
1.Prepare the DS-21 diagnosis tester or OBD II generic
scan tool.
2.Connect the DS-21 diagnosis tester or the OBD I1 generic
tester to the data link connector (DLC) located at the
lower section of the instrument panel on the driver's seat
side. At this time, the DS-21 tester should be connected
to the DLC with the following SST interposed, and the
OBD I1 generic tester should be connected directly
SST: 09991-87404-000
NOTE
When DS-21 diagnosis tester or OBD-ll generic scan
tool is used, refer the instruction manual for each
tester.
(2) CHECK OF DTC WITHOUT USING DS-21 DIAGNOSIS
TESTER OR OBD II GENERIC SCAN TOOL
1.With the ignition switch turned OFF, connect the following
SST to the data link connector (DLC) located at the lower
section of the instrument panel on the driver's seat side.
SST: 09991-87404-000
2.Connect the terminal between the EFI-T terminal and the EFI test terrnlnal
earth terminal of the SST connector with a jump wire as
indicated in the illustration.
SST: 09991-87403-000
3.Turn the ignition switch to the WON" position. At this time,
be careful not to start the engine. terrnlnal
connector
?2%372OETlO
4.Read out the diagnostic trouble code (DTC) by observing

the flashing number of the malfunction indicator lamp.
5.The illustration shows an example of the flashing pattern

of the normal code. The malfunction indicator lamp glows
for 0.25 second, right after the ignition switch has been
turned ON. After a lapse of 0.25 second, the malfunction
indicator lamp again glows for 0.25 second. Then, this
pattern will be repeated.
Extinguished
L2IW2zETIO
6.The illustration shows an example of the flashing pattern In case of malfunction code number 21
of the code No. 21. The diagnostic trouble code is 0.5 Sec.
composed of two digits. These two numbers are 0.5 Sec.
indicated by blinking of the malfunction indicator lamp. Glowing - - --0.5 Sec.
Four seconds after the ignition switch has been turned
ON, the malfunction indicator lamp indicates first the
number of the tens digit of the diagnostic trouble code by
--
Extinguished
glowing the same times as the number. The lamp glows
for 0.5 second each time and then it is extinguished for
0.5 second. After a pause of 1.5 seconds, the lamp
indicates the number of the units digit of the diagnostic
trouble code by glowing the same times as the number.
The lamp glows for 0.5 second each time and then it is
extinguished for 0.5 second. Then, this pattern will be
repeated after a pause of 4 seconds.
7.The illustration shows an example ofthe flashing pattern
of the codes No. 21 and 31. In cases where plural In case of malfunction code number 21 and 31
malfunction codes have been detected, the two-digit
diagnostic trouble codes are indicated in the sequence Glowina
of the code number, starting from a smaller number. Each
diagnostic trouble code is indicated in the above
described pattern. A pause of 2.5 seconds occurs
between the outputs of respective diagnostic trouble
codes, thus separating one from the others. After all of
the plural diagnostic trouble codes that have been
detected are indicated, the malfunction indicator lamp is
extinguished for four seconds. Then, the detected plural
diagnostic trouble codes will be indicated again.
8.For the details of malfunctions, refer to the DTC chart.
9.After completion of the check, disconnect the jump wire

and turn OFF the ignition switch. Then, disconnect the
SST from the DLC.
NOTE
In cases where plural malfunction codes have been
detected, the indication will be made progressively,
starting from the smaller number to the larger number.
* In cases where the DS-21 diagnosis tester or the OBD
I1generic scan tool is not used, it is impossible to take
a reading of unidentified two-trip DTC from the SST
connector.
When malfunctioning phenomena are to be reproduced
without using the DS-21 diagnosis tester or OBD II
generic scan tool, follow the procedure given below to
detect the DTC.
(1) It is assumed that two trip detection logic is used for
the DTC detection.
(2) Therefore, after a malfunctioning phenomenon is first
reproduced, turn OFF the ignition switch.
(3) Then, repeat the same reproduction procedure once
again.
(4) When the malfunction is reproduced again, the
malfunction indicator lamp goes on and the DTC is
memorized in the engine ECU. For reading out of the
DTC.
NOTE
When malfunctioning phenomena are to be reproduced
with the DS-21 diagnosis tester or OBD II generic scan
tool connected to the DLC, the "Continuous monitoring
results" function can be used. (In the case of the DS-21 Indication of current data
diagnosis tester, select the "Continuous monitoring
results" of the "Vehicle communication" in CARB
mode.) This function makes it possible to indicate the
DTC when the malfunctioning phenomenon is first
reproduced. (Request of onboard monitoring test
results of IS0 15031-5 Continuous monitoring system.)
1-9-2 CANCELING METHOD OF DIAGNOSIS
1.The DTC and freeze-frame data can be erased through the following methods.
(1) The DS-21 diagnosis tester or OBD I1 generic scan tool is used to erase the DTC. (For the
operating procedure, refer to the instruction manual.)
(2) The power supply to the EFI ECU is shut off to erase the DTC without using the DS-21 diagnosis
tester or OBD II generic scan tool. (Disconnect the battery negative terminal or detach the EFI i
fuse.)
(1) WHEN DS-21 DIAGNOSIS TESTER OR OBD 11 GENERIC SCAN TOOL IS USED:
I.ln the same way as the check of DTC, connect the DS-21 diagnosis tester to the data link connector
(DLC) with the following SST interposed. Or, connect the OBD II generic scan tool directly.
SST 09991-87404-000
NOTE
When DS-21 diagnosis tester or OBD-II generic scan tool is used, refer the instruction manual for
each tester.
@ I DS-21 DIAGNOSIS TESTER OR OBD II
WHEN
GENERIC SCAN TOOL IS NOT USED:
1.Erasure by disconnecting EFI fuse
To erase the diagnostic trouble codes (DTC) memorized
in the ECU after malfunctions have been repaired,
disconnect the EFI fuse from the relay block for at least
30 seconds with the ignition switch turned OFF. [When
ambient temperature is about 20'C.
NOTE
It is possible to complete this erasing for approximately
30 seconds. In some cases, however, it may take
longer. Furthermore, the erasing can be made by
disconnecting the circuit, such as the battery power
supply and fusible link. In cases where the battery
terminal is to be disconnected, record the radio
channels in advance. After completion of the operation,
set the radio channels the same as before.
In cases where the same malfunction (DTC) cannot be
detected again during the 40 cycles of the engine
warming-up, the DTC and freeze-frame data will be
automatically erased from the ECU memory. (Only in
the case of vehicles with EU specifications)
Warming-up cycle
The warming-up cycle refers to a driving cycle that
sufficiently allows the water temperature to rise by at
least 22°C above the temperature at the time of engine
starting and to reach at least 70°C.
Driving cycle
The driving cycle consists of the engine starting and
engine stopping.
1-10 BASIC CHECK
1-10-1 BASIC ENGINE CHECK FLOW CHART
1.When the ECU is detecting no DTC during the reproduction test of malfunctioning phenomena and
when no abnormality is found by the visual inspection, it is necessary to progressively perform the
trouble-shooting for circuits which are most likely causing the malfunctions.
2.117 many cases, sections causing malfunctions can be narrowed down quickly and effectively by
performing the basic engine check indicated in the following flow chart. Therefore, it is very important
to perform this check for the engine trouble-shooting.
(1) BASIC ENGINE CHECK
Dl. Check the battery voltage.
1.Is the battery voltage 11 V or more with the engine in a stopped state?
YES: Go to w2.
NO: Charae the batterv or re~laceit.
W 2 . Check the engine cranking.

1.Does the engine crank?
YES: Go to W 3 .
NO: Go to "Matrix Table for Trouble-Shootino Accordino to Malfunctionina Phenomena".
w3. Check the engine starting.

1.Does the engine start?
YES: Go to w4.
NO: Go to W 6 .
W4. Check the engine idle speed.

1.Warm up the engine, until the engine water temperature reaches 90°C or more.
2.Turn OFF all electric load switches (including A/C switch).
3.Set the transmission to neutral.
4.Connect the DS-21 tester to the DLC with the SST
interposed, or connect the general-purpose tester to the
DLC directly. Then, check the idle speed.
SST 09991-87404-000
5.When the DS-21 or general-purpose tester is not used,
connect a tachometer to the Tachometer terminal.
SPECIFIED VALUE: 750+!grpm
YES: Go to W 5 .
NO: Go to "Matrix Table for Trouble-Shootina According
to Malfunctionina Phenomena".
W 5 . Check the ignition timing.

1.When the DS-21 diagnosis tester is not used, connect the
terminal T of the SST connector to the earth terminal,
using a jump wire.
SST: 09991-87403-000
2.When the DS-21 diagnosis tester is used, select the
"Engine adjustment" on the course menu so as to
connect the EFI- T terminal.
3.Attach the clip of the timing light to the wire harness for
timing light connection wire.
4.1s the timing mark of the crankshaft within a range of the

indicator for ignition timing check provided on the timing
chain cover?
SPECIFIED VALUE: O'k 2"(BTDC)
5.Are the check results OK?
YES: Go to "Matrix Table for Trouble-Shootina According
to Malfunctionino Phenomena".
NO: Check the timina chain for wrona assemblina. Also,

check the ~lunaer~rotrudinaamount of the tensioner.
T terminal OFF
T terminal released
W 6 . Fuel pressure check (simple check).

@ When DS-21diagnosis tester is not used:
1.Ensure that the fuel tank is filled with sufficient fuel Relay block
C13E5580ET10
2.Remove the fuel pump relay and connect a jump wire, as

indicated in the illustration.
SST 09991-87403-000
3.Check that the pulsation damper screw rises when the
ignition switch is turned ON.
@ When DS-21 diagnosis tester is used:
1.Connect the DS-21 diagnosis tester to the DLC with the
SST interposed.
SST 09991-87404-000
2.Turn ON the ignition switch. Then, select the "Fuel pump
driving" of the actuator driving among the individual
functions so as to drive the fuel pump.
3.Does the pulsation damper screw rise?
YES: Goto W1.
NO: Go to "Check of Fuel Pumo and FIP Reaulator".
Fuel pump stopped

Fuel pump released
W 1 . Spark check.
1.Remove the fuel pump relay from the relay block.
2.Remove the IG coils and spark plugs (all cylinders #1, 2, Relay block
3 and 4).
3.Disconnect the fuel pump relay
4.Disconnect the connector of the injector.
CAUTION
Stop the fuel injection by the operations at Steps 3 and
4 above so as to prevent the catalyst from being C13E5574ET10
damaged by unburnt gas, etc.
When there is no fuel, the injector injection must be
avoided wherever possible, as this may damage the
injector.
5.lnstall the spark plug to the IG coil. Connect the IG coil
connector to the IG coil.
6.Ground the spark plug.
7.Crank the engine. At this time, check to see if each spark
plug sparks.
8.1s it in a good condition?
YES: Go to W2.
NO: Go to Check of IG Svstem.
W 2 . Confirmation of operation of fuel injector.

1.lnstall the spark plugs, IG coils and fuel pump relay. Connect the connector of the IG coil.
2.Using a sound scope, check each injector for operation sound while the engine is being cranked or
idling.
3.Can you hear operator sound of all injectors?
YES: Go to D3.
NO: Go to "Check of Fuel lniector Circuit".
1.
D3. Inspection of compression pressure.
2.With the IG switch turned OFF, remove all of the IG coils
and spark plugs.
3.Temporarily remove the main relay and fuel pump relay.
4.lnsert a compression gauge into the spark plug hole.
5.Depress the accelerator pedal fully.
6.While cranking the engine, measure the compression
pressure.
7.Repeat the steps 4, 5 and 6 to perform the measurement
for all cylinders.
NOTE
Be sure to use a fully-charged battery. Also the
measurement should be performed in the shortest
possible length of time.
:,
YES: Go to W 4 .
NO: Perform the checks. referrino to the section ENGINE
MECHANICAL.
D4. lnspection of idle CO and HC concentrations.

1.Warm up the engine completely.
NOTE
Warm up the engine, until the fan motor starts to operate.
2.Measure CO and HC concentrations at idle meed.
I CO concentration
HC concentration
Not to exceed 0.3 %
Not to exceed 300 pprn

YES: Go to "Matrix Table for Trouble-Shootina Accordina to Malfunctionino Phenomena".
NO: Perform the checks. referrina to the section ENGINE MECHANICAL.

(2) CHECK OF WIRE HARNESSES AND CONNECTORS
1.Check of open wire
This is caused by detached wire harness, poor contact inside the connector, detached connector
terminal, and so forth.
NOTE
The wires are rarely cut at the center. In most cases, an open wire occurs at the connectors.
Particularly, the connectors of the sensor and actuator should be checked very carefully.
Poor contact is caused by rust formation at the connector terminal, foreign substances adhered to
the terminal, or drop in the contact pressure between the male and female terminals of the
connector.
Simply disconnect the connector once, and then, reconnect it. It may change the contacting
condition, thus returning to the normal operation. Hence, if no abnormality was found when the wire
harness and connector were checked during the trouble-shooting, and if the malfunction ceases to
exist after completion of the checks, then the wire harness or connector was most likely causing the
malfunction.
2.Check of short circuit
This is caused b y a short circuit between the wire
harness and the body ground or by an internal short
circuit of the switches, etc.
NOTE
If a short circuit is present between the wire harness
and the body ground, thoroughly check to see if the
wire harness is caught in the body, if the wire is rubbed
and the insulator section is ruptured, thus contacting
other parts, and if the wire is clamped properly.
3.Continuity check (check for open wire)
ECU side
(1) Disconnect the connector on both sides of the EFI
ECU and sensor Sensor side 4a-.
(2) Measure the resistance between the relevant 1 I

terminals of the connector.
SPECIFIED VALUE: Resistance: 1 R or less
Y
Tester probes
NOTE
Lightly shake the wire harness in a longitudinal
direction as well as in a horizontal direction when the
resistance is measured.
In the case of non-waterproof connectors, the test
probe should be inserted into the connector from each
wire harness side.
In cases where the waterproof connector is checked
without removing the waterproof rubber, be vety careful
not to deform the connector terminal when applying the
test probes.
4.Continuity check (check for short circuit)
(1) Disconnect the connector on both sides.
(2) Measure the resistance between the relevant terminal
of the connector and the body ground. Moreover, be
sure to check for the connectors on both sides.
SPECIFIED VALUE: Resistance: 1 M Q or more
NOTE
Lightly shake the wire harness in a longitudinal
direction as well as in a horizontal direction when the
resistance is measured.
5.CHECK OF EFI ECU AND ITS CIRCUIT

The EFI ECU a n d its circuit can b e checked by
measuring the voltage and resistance at the EFI ECU
connector. In order to narrow down the cause further
after the cause has been decided to a certain system, it
is imperative to measure the voltage and resistance of
the external route of the EFI ECU.
The measurement of the voltage and resistance is
conducted during the system check, following the
procedure given below.
CAUTION
The EFI ECU cannot be checked by itself. Never
connect a voltmeter or an ohmmeter to the EFI ECU
with the connector disconnected from the EFI ECU.
When conducting the continuity test or measuring the
resistance, turn OFF the ignition switch once. Then,
disconnect the connector at the EFI ECU.
6.VOLTAGE CHECK
(1) Installation of SST
First, install the SST between the engine ECU and
the vehicle harness.
For the installation procedure, refer to the section
under.
/
SST ArmwA
m----m connector
@@@-----
~Viewedfrom arrow A> C~~E~SB~ETZO

~~~~ - --- p~
~-
(2) Measure the voltages between the respective terminals of the SST connectors.
(3) Check to see if the measured values conform to the specification in accordance with the following
table "Characteristics of ECU Output".
NOTE
Make sure that the battery voltage is 11 V or more with the ignition switch turned ON, for each
terminal voltage is affected by the battery voltage.
-
Characteristics of ECU
Output
System to be checked Terminals Measurement conditions Reference values
Power supply system 7(+B1) - 23(El) When IG switch is 'ON' Battery voltage
36 (+B2) - 23 (El) When IG switch is "ON"
1 (BAT) - 23 (El) At all time
Pressure sensor system -
46 (VCPM) 47 (E2PM) When IG switch is 'ON" 4.5 - 5.5V
15 (PIM) - 47 (E2PM) Sensor released atmosphere 3.2 - 4.1V
After engine starting Value changes, according
to accelerator opening an-
gle
I , 8
Throttle sensor system 16(VC)-17(E2) I When IG switch is 'ON' 4.5 - 5.54
-
44 (VTH) 17 (E2) 1 Throttle valve fully closed 0.4 - 0.8V
1 I Throttle valve fully opened I 3.2 - 5.0V
Engine coolant tempera- 1 45 (THW) - 17 (E2) I When warming up engine (Water tem- I 0.2 - 1.OV
ture sensor system 1 perature 60 - 120°C )
Intake air temperature 1 76 (THA) - 17 (E2) 1 When warming up engine 0.1 - 4.8V
Vehicle speed sensor 1 37 (SPD) - 23 (El) I When wheels are turned slowly 0=5V
Knock sensor system 1 53 (KNK) - 23 (El) I When idling, racing I Generation of wa>iofnrm
Engine revolution sensor I 22 (N+) - 52 (N-) I When i d l i n ~ I Genei " '
Oxygen I Front 1 75 (0x1) - 17 (E2) / After engine speed is held at 3000 rpm / 0.2 - 1.ov I
sensor 1 for four minutes I
system Rear
When engine is cranking
I
During idling (or when cranking) 2 V or less
; Wnen n-f_o.omcr switcn ,sOFF Battery voltage. ...

_
tern ---I--
laoiator ian contro sys- 13e
r~
l(k
1
) remperat~reswi!~h s .OW .
Vlnen wager lernperat~reswtch s OFF'
, . Approx 0 V
Battery voltage
..
7.RESISTANCE CHECK
(1) Installation of SST
First, install the SST between the engine ECU and
the vehicle harness. However, the SST connector at
the ECU side should not be connected.
For the installation procedure, refer to the section
under "Connecting Procedure for SST".
Refer to Page 88-1 1.
I
(2) Measure the resistances between the res~ectiveterminals.

(3) Check to see if the measured resistances conform to the specification in accordance with the
following table 'Standard Resistances".
NOTE
Make sure that the ignition switch is turned OFF during the measurement.
The following table shows the resistance at the time when the temperature of parts is 20°C.
STANDARD RESISTANCES
System to be checked I Terminals Circuit I Standard resistance
Front oxygen sensor 1 20 (OXHI) - 7 (fB1) 1 Front oxygen sensor and main I
~ - 11 - 14.5Q
system relay
Rear oxygen sensor 50 (OXH2) - 7 (f BI). Rear oxygen sensor and main 11.7 - 14.50
system relay
Engine revolution sen- 22 (N2f) - 52 (N2-) Engine revolution sensor sys- 1850 - 245052
sor system tem
Injector system 27 (#lo) - 7 (fB1) No.1 - 4 fuel injector 13.4 - 14.2Q
26 (#20) - 7 ( f BI)
25 (#SO) - 7 (+B1)
24 (#40) - 7 (+El)
VSV for evaporative -
79 (PRG) 7 (+El) Evaporative emission purge 30 - 34Q
emission control sys- control valve
tern purge control sys-
tem
VSV for boost pressure 80 (VSVl) - 7 (+B) Boost pressure control valve 30 - 34Q
svstem
ound Ground 10Qor less
ound
1-10-2 CHECK AND REPAIR BY CHART ACCORDING TO DTC
(1) SCAN TOOL DATA (ECU DATA)
1.The following data values given below are representative values obtained under the ""orma1
condition".
However, there are cases where the system is functioning normally even if the measured value is
different from the values listed here. Therefore, no judgment as to whether any malfunction is
occurring or not should be made only on the basis of these data under the 'normal conditionm.
NOTE
The data monitor value may vary significantly, depending on slight difference in the measurement,
difference in the measurement environment, deterioration due to passage of time in the vehicle, and
so forth. Therefore, it is difficult to indicate the definite reference values. Hence, there are cases
where malfunctions are occurring even when the measured value is within the reference value.
With regard to minor phenomenon, such as hesitation and rough idling, it is necessary to make total
evaluation, based on all the data monitor items, by sampling the data of the vehicle of the same
type under the same conditions and comparing them.
In the case of the OBD II generic scan tool, it is possible to take a reading of the values with an
asterisk mark in the following table.
When checking the data under a condition where the engine is "idling" or "racing", the shift lever
should be placed in the "neutral", the AIC switch should be turned OFF,and all accessory switches
should be turned OFF.
88-33
I
Items specified by CARB
0.05 - 0.95 V
" 13 OXYGEN SENSOR S2 0,RP When engine is running at 2000 rpm, for 3 min- 20 - 77 %
0,RV utes or longer after warming up. 0.05 - 0.95 V
* 14 MIL ON RUN DlST DWM When there is no DTC 0 km
tems specified by DMC
DS-21 diagnosis tester Signal name Reference values under
Vehicle condition
display normal condition
1 BATTERY VOLTAGE BAT When engine is running at 5000 rpm (25'C) Approx. 14 V
2 ELECTRIC LOAD DSW When light, heater blower, defogger or radiator
I I - I
'-.. ;- nh,
l c l l l 1 5 "I\ . I
OFF-ON
3 A,R COhD TlON,hG / AC Wnen a r coraltoner swllch 1s set to ON . OFF-ON
T~TTPsWIE~ I IDL I When tnrotl e valve is sw.1cneo lrom 1 ~ v1 c osso ON-OFF
state to opened state
5 INJ PULSE WIDTH TAU Value should be decreas-
Cold start - Warming up running
ing gradually
At idle speed after warming up 1 -3ms
6 ISC DUTY RATIO ISC When ignition switch is ON 0%
Cold start - Warming up running Value should be decreas-
1 ing gradually
At idle speed after warming up 5-15%
When air conditioner switch is set to ON 18 - 45%
When light, heater blower or defogger is ON 7-19%
At idle speed after warming up -
0 2'CA
7 ACTUAL DlS ANGLE OF VT The value chanaes.
- . de-
1 IN CAM 1 1 During vehicle running I pending on driving condi- 1
I tions.
At idle speed after warming up O'CA
8 1 TARGET DlSP ANGLE I VlT I The value changes, de-
I OFINCAM I I During vehicle running 1 pending on driving condi- I
NOTE
The items with an asterisk (') mark is provided only for the EU specifications. Therefore, in the case
of the non-EU specification vehicles, no indication will be made.
B8-35
(2) DTC CHART SPECIFICATIONS
1.The parameters indicated in the table may vary, depending upon the system types and
specifications. This applies to vehicles for all destinations.
For details of the checking of each code, refer to the DTC chart for each code.
Codes specified by ISOISAE
DTC No. Diagnosis Items Diagnosis contents Malfunction Warning indica
evaluation tion
method
PO105131 Manifold absolute pres- When abnormality takes place in the signal 1 trip 0
surelbarometric pressure from manifold absolute pressurelbarometric
circuit malfunction pressure circuit:
Malfunction of the sensor, or open wire or short
circuit in the manifold absolute pres-
surelbarometric pressure circuit.
PO110143 Intake air temperature When malfunctiontakes place in the signal Itrip 0
sensor circuit rnalfunc- from the intake air temperature sensor:
tion Malfunction of the sensor, or open wire or short
fl
PO115142 ( ~ n ~ icoolant
ne tempera- (when abnormality takes place in the signal I Itrip 1 0
ture sensor circuit mal- from the engine coolant temperature sensor:
function Malfunction of the sensor, or open wire or short
circuit in engine coolant temperature sensor
circuit.
'0116142'' Engine coolant tempera- When abnormality takes place in the signal 2 trip
ture sensor circuit from the engine coolant temperature sensor:
rangelperformance Malfunction of engine cooling system
problem
PO120141 Throttlelpedai position When abnormality takes place in the signal 1 trip
sensorlswitch from throttlelpedal position sensor:
circuit in throttlel~edalposition sensorlswitch
circuit. I
'0130121 Oxygen sensor circuit When abnormalities take place two times con- 2 trip 0
malfunction(Bank 1 sen- secutively in the signal from the oxygen sen-
sor 1) sor:
circuit in oxygen sensor circuit.
'0133R1" Oxygen sensor circuit When abnormalities take place two times con- 2 trip 0
slow response (Bankl secutively in the signal from the oxygen sen-
sensorl) sor:
circuit in oxygen sensor circuit.
0135123'' Oxygen sensor heater When abnormalities take place in the signal 2 trip 0
circuit malfunction from the oxygen sensor heater:
(Bank1 sensorl). Open wire or short circuit in oxygen sensor
1 1 heater circuit. I
'0136122 ear oxygen sensor cir- ]when abnormalities take place two limes con- I 2 trip 0
cuit malfunction (Bank 1 secutively in the signal from the rear oxygen
sensor 2) sensor:
I 1in the rear oxygen sensor circuit.
0141124' /oxygen ~- sensor heater l ~ h e abnormalities
n take place in the signal / 2 trip 1 0
circuit malfunction (Bank from the oxygen sensor heater:
1 sensor 2) Open wire or short circuit in oxygen sensor
heater circuit.
'0171125 Fuel trim system too lean When the air-to-fuel ratio deviates two times 2 trip 0
(Air-fuel ratio lean rnal- conseculiveiy to the iean side due to abnor-
function, bank 1) mality of the fuel trim system:
Abnormal combustion pressure, rnalfunction-
ing injector or oxygen sensor
PO172126 Fuel trim system too rich When the air-tofuel ratio deviates two times 2 trip 0
(Air-fuel ratio rich mal- consecutively tothe rich side due to abnormal
function, bank 1) ity of the fuel trim system:
Abnormal combustion pressure, malfunction-
ing injector or oxygen sensor
PO350116 Ignition system circuit When the ignition signal is not inputted con- ltrip 0
malfunction tinually.
P0300117" Randomlmultiple cylin- When malfunction takes place in the signal 2 trip AL flashing du
der misfire detected from the ion system i g misfire dele,
P0301117" Misfire detected tion.
PO302117" Cylinder 1 0
P0303117" Cylinder 2
PO304117" Cylinder 3
Cylinder 4
P03141-.' Single cylinder misfire

(Cylinder not specified)
PO325118 Knock sensor I circuitWhen malfunction takes place in the signal 1 trio -
malfunction from the knock sensor:
Malfunction of the sensor, or open wire or
short circuit in the signal system
PO335113 Engine revolution sensor When malfunction takes place in the signal 1 trip 0
circuit malfunction from the engine revolution sensor:
Jcircuitin engine revolution sensor circuit.
P0420127" l~atalystsystem effi- /when abnormalities take place in the signal 2 frip 0
2 trip 0
control system purge signal of the evaporative emission control sys-
control valve circuit mal- tem purge control valve:
function Open wire or short circuit in evaporative emis-
sion control system purge control circuit.
PO500152 Vehicle speed sensor When malfunction takes place in the signal 2 trip 0
circuit malfunction from the vehicle speed sensor:
Sensor malfunction, open wire or short circuit
-
P0505Pl Idle control system mal- When malfunction takes in the signal from the 1 trip 0
function valve for ISC.
Open wire or short in valve for ISC circuit
NOTE
2 trip: 2 trip detection logic
MIL;Malfunction indicator lamp
When the " 0mark is shown in the MIL column, the lamp will go on for that DTC number, but when
the "-" mark is shown, the lamp will not go on for that DTC number. However, the data other than
the switch signal system (P1520/51) are memorized in the backup memory. Therefore, it is possible
to read out the DTC number by using the diagnosis tester DS-21. As for the DTC number bearing
the mark, the MIL will go on except the EU specifications.
DTC number with ^I mark ..... Only for EU specifications
But, only in the case of DTC No. P0314,it is possible to read out this DTC No. by means of the
"Continuous monitoring results" in CARB mode
B8-37
Codes specified by DMC
DTC No. Diagnosis Items Diagnosis contents Malfunction Warning indica-
I evaluation tion
method
P1300136" Ion system malfunction When malfunction takes place in the signal 2 trip 0
from Ion system
PI510154 Starter relay output sys- When malfunction takes place in the starter 2tri~ 0
relay driving output
~ Pt520151 /switch signal circuit

Malfunction of the starter relav
/withthe terminal EFI-T connected

. circuit or
. out~ut
1 trip -
malfunction 1. When AC switch is turned ON:
2. When clutch start switch is turned ON.
3. When the accelerator pedal is depressed:
P1530144 AIC evaporator tem- When malfunction takes place in the signal 1 trip -
perature sensor circuit from the AIC evaporator temperature sensor:
malfunction Malfunctionof the sensor, or open wire or short
circuit in A/C evaporator temperature sensor
I (circuit.
PI560161 ECU back up power Open wire in back up power source circuit 1 trip 0
source circuit malfunc- Malfunction of the EFI ECU
tion
P1600183 Immobilizer signal cir- When abnormality occur in the wring and read- 1 trip -
cuit malfunction ing-out of the rolling codes intolfrom the im-
mobilizer ECU during immobilizer communica-
tion
P1601181 Immobilizer signal mal- When the rolling codes can not be exchanged 1 trip -
function between the EFI ECU and the immobilizer ECU
or the rolling codes are not matched.
NOTE
MIL; Malfunction indicator lamp
When the "On mark is shown in the MIL column, the lamp will go on for that DTC number, but when
the "-" mark is shown, the lamp will not go on for that DTC No. However, the data other than the
switch signal system (P1520151) are memorized in the backup memory. Therefore, it is possible to
read out the DTC No. by using the diagnosis tester DS-21. As for the DTC No. bearing the mark,
the MIL will go on except the EU specifications.
DTC No. with '1 mark ..... Only for EU specifications
But, only in the case of DTC No. P0314, it is possible to read out this DTC No. by means of the
"Continuous monitoring results" in CARB mode
I
(3)FAIL-SAFE FUNCTION
1.When any of the following DTC has been detected, the ECU enters the fail-safe mode in order to
make it possible for the vehicle to drive for evacuation and to ensure safety. When the malfunction is
remedied to a normal condition, the fail-safe control will be released.
However, the diagnosis results will remain memorized. Hence, it is necessary to determine whether
the malfunction still persists or not.
FAIL-SAFE SPECIFICATIONS -
-
DTC No. Fail-safe operation Fail-specifications

PO105131 (whenabnormality takes place in the signal from the l ~ h signal
e from the intake manifold pressure
manifold absolute pressurelbarometric~ressure cir- senso;is set to the value determined from the
cuit throttle opening angle, engine speed and ISC
opening angle.
If both the throttle opening angle and engine
speed exceed their set values, the fuel is cut.
'01 10143 When malfunction takes place in the signal from the The signal from the intake air temperature ser
c s o r ts set to a constant value
PO115/42 When malfunct~ontakes place in me stgnal from the The stgnal from the englne coolanr lempera-
coolant temperature sensor lure sensor 1s set to a constant value
PO12014' The %gnat from the thronle posttjon sensor 1s set io a Tne signa from the tnrotlte pos tlon sensor ,s
Jconstantvalue. (set to a constant value
PO136/22 /when abnormality takes place in the signal from the l ~ h feedback
e of the rear oxygen sensor is
rear oxygen sensor: I
stopped.
PO325118 (when malfunctiontakes place in the signal from the l ~ h ignitione- timing- is retarded.
1 knock sensor:
PI530144 -
/when malfunction takes place in the sianal from the l ~ h air e conditioner will be cut.
A/C evaporator temperature sensor.
PI600183 When abnormality occur in the wring and reading-out Prohibition of fuel injection and ignition.
of the rolling codes intolfromthe immobilizer ECU
/during immobilizer communication.
P1601/81 (whenthe rolling codes can not be exchanged be- l~rohibition of fuel injection and ignition.
.
tween the EFI ECU and immobilizer ECU or rolling
codes are not mached.
-
1-11 TROUBLE SHOOTING ACCORDING TO MALFUNCTION PHENOMENA
1-11-1 CHECK AND REPAIR BY MATRIX TABLE FOR TROUBLESHOOTING ACCORDING TO
MALFUNCTIONING PHENOMENA
(1) Discription
1.This table can be used when trouble-shooting a malfunction whrch persists although the normal code
is indicated at time of the DTC recheck. However, before performing trouble-shooting, carry out the
basic check to narrow down possible causes for the malfunction. For example, if the spark check of
the basic check proves that there is no problem, it can be presumed that the ignition system is
normal. Also, you can narrow down further possible causes based on the information obtained
through mquiry to the customer.
NOTE
If any malfunction can not be detected by the diagnosis system although the malfunctioning
phenomenon exists, that malfunction is not covered by the detection range of the diagnosis system
or the malfunction exists in a system other than the diagnosis-relatedsystems.
(2) CHECK OF MALFUNCTIONS WHICH OCCUR INTERMITTENTLY

1.Check parts where malfunctions occur intermittently, such as wire harnesses and connectors, by
following the section "Check of malfunctions which occur intermittently and poor contacts: At that
time, focus checks on the circuits related to the systems of the DTC that were indicated at the time of
initial DTC check.
(3) FINAL CONFIRMATION TEST
1.Confirm that the malfunctioning phenomenon pinpointed
by the customer has been completely eliminated. If the
remedied parts are related to the DTC, erase the DTC
once and carry out the DTC confirmation test. Ensure that
no DTC is indicated. At this time, for improved efficiency
of operations, use the kontinuous monitoring results"
function. (In the case of the DS-21 diagnosis tester,
select the 'Continuous monitoring results' of the vehicle
communication in CARB mode.)
-
:
1-11-2 MATRIX TABLE FOR TROUBLE-SHOOTING ACCORDING TO MALFUNCTIONING
PHENOMENA
1.In cases where no malfunction code was detected during the DTC check and no malfunction can be
still confirmed during the basic check, perform the trouble-shooting, referring to the following table.
In the trouble shooting according to malfunction phenomena, first arrange in order the contents of
diagnosis through inquiries, basic checks and ECU circuit checks. Next, narrow down possible
causes, referring to the table showing possible causes according to malfunction phenomena.
2.117 the trouble shooting according to malfunction phenomena, first arrange in order the contents of
diagnosis through inquiries, basic checks and ECU circuit checks. Next, narrow down possible
causes, referring to the table showing possible causes according to malfunction phenomena.
(1)
. . Poor starting
-
Malfunction phenom- Cause of malfunction
ena Suspect area Components Mode of malfunction
No initial combustion Power source ECU power source circuit Open wirelshort circuit
take place system IG switch Switch is not turned ON
Main relay -
Starter relay
Fuel supply sys- Fuel pump relay Switch is not turned ON
tem Fuel linelfuel filter Clogged
Injector Not inject, inject at all times
Fuel pump Not operate
Ignition system IG coil Spark is not existed
circuit Spark plug 1
Ignition timing l~eferenceof timing
Control system / ~ n ~ i revolution
ne sensor system /
NE signal is not existed
circuit
Although initial com- Fuel supply sys-
bustion take place, tem Fuel linelfuel filter Clogged
combustion is not Injector Leakage, not iniect, inject at all times
I
complete
Ignition system
lFuel pump
Ispark plug
--
(Not operate
1
Misfire
Air inlet system Air hose etc. Leakage

circuit
Control system Manifold absolute pressure sensor Deference of characteristic, open wire.
circuit Engine coolant temperature sensor short circuit
Engine revolution sensor Output signal is no good
%or start- Cold Air inlet system Throttle body Valve is not opened completely, not
ng condition circuit opened
Control system Engine coolant temperature sensor Deference of characteristic, open wire,
circuit short circuit
Warm up Fuel supply sys- Injector Leakage
condition tem
Air inlet system Valve for ISC Valve is not opened completely, not
circuit opened
At all time Fuel supply sys- Fuel pump relay Switch is not turned ON
tem Fuel lineifuel filter Clogged
Injector (Leakage
lgnition system Spark plug
circuit
Air inlet system Valve for ISC Valve is not opened completely
12) Poor idlina
Cause of m a ~ f u ~ c G n
Components Mode of malfunction
/First idle is not /Air inlet svstem circuit IValve for ISC iValve is not opened completel~,not
Open wirelshort circuit

Idle speed is Air inlet system circuit Air hose etc. Leakage
too high Throttle body Valve is not closed completely
Valve for ISC Valve is opened at all time
Control system circuit Manifold absolute pressure sensor Deference of characteristic, open wire,
/Tail lamp switch

/Heater blower switch
Oil pressure switch
Idle speed is Air lnlet system circuit Air hose etc. Clogged
too low Throttle body
Control system circuit Manifoid absolute pressure sensor Deference of characteristic
Defogger switch Switch is not turned ON

Tail lamp switch
Heater blower switch
Oil pressure switch
Hunting during Air inlet system circuit Air hose etc. Leakage
idling Throttle body-^-
Valve for ISC Valve is opened at all time
Control system circuit Manifold absolute pressure sensor Deference of characteristic
Engine revolutionsensor Defect of output signal
Poor idling Fuel supply system Injector Leakage,
Fuel pump Poor operation
Air inlet system circuit Throttle body Leakage
Ignition system circuit IG coil Poor contact
/spark plug /Misfire
Control system circuit Manifold absolute pressure sensor IPoor operation, poor contact
Oxygen sensor /Poor operation, poor contact
(3)Engine stalling
Malfunction Cause of malfunction
phenomena Suspect area Components Mode of malfunction
Engine stalls Fuel supply system
during idling Fuel linelfuel filter Clogged
Fuel pump Not operate
Control system circuit Engine coolant temperature sensor Deferenceof characteristic
Engine revolution sensor Defect of output signal
Engine stalls Control system circuit Manifold absolute pressure sensor Deference of characteristic
when accelera- b g c e coolant temperatuxsensor I
tor pedal is IEcgine revo ur on sensor /Defect of o u t p ~sl gnal
Itor pedal is / I 1 I
released
Engine stalls Air inlet system circuit Valve for ISC Valve is closed at all time
when AIC
switch is
turned on
Possible to Power source system ECU power source circuit Poor contact
restart after IG switch
(engine stalling 1 IMain relay I
I
Air inlet system circuit Valve for ISC (valve is closed at all time
Ignition system circuit IG coil 1poor contact
Control system circuit Manifold absolute pressure sensor 1Poor contact
Engine revolution sensor 1
Vehicle speed sensor lopen wire, short circuit
B8-43
(4) Poor running
running Injector Poor operation

Ignition system circuit IG coil Poor contact
Control system circuit Leaner throttle sensor Deference of characteristic
Vehicle speed sensor Fault operation
Engine revolution sensor Defect of output signal
Abnormally Control system circuit Manifold absolute pressure sensor Deference of characteristic, open wire.
knocking short circuit
Leaner throttle sensor Deference of characteristic
Knock sensor Deference of characteristic, open wire,
short circuit
i
1-12TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODE
1-12-1 DTC No.P0105/31 Manifold absolute ~ressure/barometricwressure circuit malfunction
- .
I) WIRING DIAGRAM
EFI ECU
(PIM) (VCPM) (E2PM)
15 46
-
47
Manifold absolute
pressure sensor
C13E55CQESZ
IAP sensor wire harness side
LJ
(2) CIRCUIT DESCRIPTION
1.The manifold absolute pressure sensor detects the intake manifold pressure as a voltage.
2.Since the manifold absolute pressure sensor does not use
the atmospheric pressure as a criterion, but senses the
absolute pressure inside the intake manifold (the
pressure in proportion to the present absolute vacuum 0),
it is not influenced by fluctuations in the atmospheric
pressure due to high altitude and other factors. This
permits it to control the air-fuel ratio at the proper level
under all conditions.
~ ~ "
Manifold absolute oressure LZ?E~OETI
(3) DTC DETECTING CONDITION

1.When the engine starts, the manifold absolute pressure sensor value is more than 4.7 V or less than
0.16 V for more than a certain length of time.
NOTE
* After confirming DTC P0105131, use the OBD II generic scan tool or DS-21 diagnosis tester to
confirm the manifold absolute pressure from "CURRENT DATA.
If the ECU detects DTC P0105/31, it operates the fail-safe function, keeping the ignition timing and
injection volume constant and making it possible to drive the vehicle.
(4) TROUBLE AREA

1.Open wire or short circuit in manifold absolute pressure sensor circuit
2.Manifold absolute pressure (MAP) sensor
3.EFI ECU
(5) POINTS OF INSPECTION
1.1s the signal from the MAP sensor inputted to the ECU?
2.1s the harness between the MAP sensor and the ECU proper?
3.1s the MAP sensor output proper?
(6) INSPECTION PROCEDURE
@ When using DS-21 diagnosis tester or OBD IIgeneric scan tool:
W1. Check of output value of Manifold absolution pressure (MAP)sensor.
1.With the IG switch turned OFF, connect the DS-21 diagnosis tester to DLC through the SST or connect
the OBD II generic scan tool directly to DLC.
SST 09991-87404-000
2.After turning ON the IG switch, turn ON the main switch of

the tester. Read the intake manifold absolute pressure
value of the DS-21 diagnosis tester or OBD I1 generic
scan tool.
3.1s the measured value the same as the atmospheric
pressure (approx. 100 kPa)?
YES: Check malfunction that occurs intermittentlv or Door
contact.
NO: Go to w2.
1
W2. Check of power supply voltage of MAP sensor.
1.After turning OFF the main switch of the tester, turn OFF the IG switch.
2.Connect the SST between the EFI ECU connectors and the wire harness connectors
SST 09842-97203-000
3.Ensure that the voltage between the SST terminals 46 (VCPM) and 47 (E2PM) is within the specified
valve when the ignition switch is turned to the ON position.
SPECIFIED VALUE: 4.5 - 5.5 V
4.1s the voltage within the specified value?

NOTE
If no voltage appears, check the EFI ECU power supply circuit.
YES: Go to W3.
NO: Check or reolace the EFI ECU.
,'
W3. Check of MAP sensor.
1.With the IG switch turned OFF, remove the MAP sensor from the throttle body with the harness
connected.
2.After turning ON the IG swltch, turn ON the maln switch of the tester.
3.Apply a negatlve pressure to the MAP sensor, uslng a MityVac.
4.Check the manifold absolute pressure value under I I
following conditions.
Applytng Vacuum D~splayedValue on Scan Tool
0 Approx. 100 kPa
(Approx 760 mmHg)
27 kPa (200 mmHg) Approx 73 kPa
(Approx. 560 rnmHg)
67 kPa (500 mmHg) Approx. 33 kPa
(Approx 260 mmHg)
G. C13E555tTIO
5.1s the measured value the same as that shown above?

YES: Check for intermittent trouble caused bv freeze in
the vacuum oassaae, wire hamess or connector.
NO: Go to w4.
W4. Check of harness between MAP sensor and ECU.

2.Disconnect the harness from the MAP sensor. Install the MAP sensor to the throttle body.
3.Disconnect the SST connectors at the EFI ECU side.
4.Check the harness and connector for open wire or short.
Connector 2 (E2PM) at sensor side - Connector 47 (E2PM) at ECU side.
Connector 1 (PIM) at sensor side - Connector 15 (PIM) at ECU side.
Connector 3 (VCPM) at sensor side - Connector 46 (VCPM) at ECU side.
5.Are the check results for open wire and short OK?
NOTE
Apply gasoline to the O-ring of the MAP sensor. Then, carefully insert it.
YES: Re~lacethe MAP sensor.

NO: Repair or reolace the harness or connector.
@ When not using DS-21 diagnosis tester or OBD I1generic scan tool:
W1. Check of ECU input signal PIM.
1.Set the SST (sub-harness).
SST 09842-97203-000
2.With the IG switch turned ON, measure the voltage between the SST terminals 15 (PIM) and 47
(E2PM).
3.1s the measured value within the specified value?

YES: Check malfunction that occurs intermittentlv or Door contact.
NO: Go to w2.
W2. Check of power supply voltage of MAP sensor.

1.Next, ensure that the voltage between the SST terminals 46 (VCPM) and 47 (E2PM) is within the
specified value.

NOTE
YES: Go to W3.
W3. Check of MAP sensor.

1.Remove the MAP sensor from the throttle body with the harness connected.
2.Apply a negative pressure to the MAP sensor, using a MityVac.
3.Ensure that the voltage between the SST terminals 15 (PIM) and 47 (E2PM) is within the tollowing
specified voltage under the following conditions.
Applying Vacuum Displayed Value on voltage meter
0 -
3.3 4.0 V
27 kPa (200 mmHg) -
2.6 3.1 V
67 kPa (500 rnrnHg) 1.1 - 1.4V
4.1s the measured value within the values in the table above?
YES: Check for intermittent trouble caused bv freeze in vacuum oassaae. wire harness or connector.
NO: Go to w4.
W4. Check of harness between MAP sensor and ECU.

1.Turn OFF the IG switch.
i 2.Dlsconnect the harness from the MAP sensor. Install the
MAP sensor to the throttle body.
3.Disconnect the SST connectors at the ECU side.
Connector 2 (E2PM) at sensor side - Connector 47
(E2PM)at ECU side.
Connector 1 (PIM) at sensor side - Connector 15 (PIM)
at ECU side.
Connector 3 (VCPM) at sensor side - Connector 46
(VCPM) at ECU side.
NOTE
Apply gasoline to the O-ring of the MAP sensor. Then,
carefully insert it.
YES: MAP sensor rewlace.
NO: R e ~ a ior
r rewlace of harness or connector.
1-12-2DTC No. PO110143 Intake air temwerature'/IAT)
. . sensor circuit malfunction
I) WIRING DIAGRAM
I EFI ECU
IAT sensor wire harness side

( (2) CIRCUIT DESCRIPTION
1.The IAT sensor, which detects the intake air temperature,
is located at the air cleaner. A thermistor built in the
sensor changes the resistance value according to the
intake air temperature. The lower the intake air
temperature, the greater the thermistor resistance value,
and the higher the intake air temperature, the lower the
thermistor resistance value. When the resistance value of
-
the intake air temp. sensor changes in accordance with
changes in the intake air temperature, the potential at
terminal THA also changes. Based on this signal, the EFI
ECU increases the fuel injection volume to improve
driveability during cold engine operation. t High
Temperature
,,-~ (3) DTC DETECTING CONDITION

i
1.Open wire or short circuit in the IAT sensor circuit
(4) TROUBLE AREA
1.Open wire or short circuit in the IAT sensor circuit
2.lntake air temperature (IAT) sensor
3.EFI ECU
1.1s the signal from the IAT sensor inputted to the EFI ECU proper ?
2.1s the harness between the IAT sensor and EFI ECU proper ?
3.1s the output of IAT sensor proper ?
O When using DS-21 diagnosis tester or OBD I1generic scan tool:
W 1 . Check of IAT sensor output value.
1.With the IG switch turned OFF, connect the DS-21 diagnosis tester to DLC through the SST or connect
the OBD II generic scan tool directly to DLC.
SST 09991-87404-000
2.After turning ON the IG switch, turn ON the maln switch of the tester. Read the intake air temperature
value of the DS-21 diagnosis tester or OBD I1generic scan tool.
3.1s the measured value the same as the actual intake air
temperature?
contact.
NO: Go to W 2 .
W 2 . Confirmation of IAT sensor output value.

When -40 "C: Go to W3.
When 140 "C or above: Go to D5.
@ When not using DS-21 diagnosis tester or OBD II generic scan tool:
W 1 . Check of ECU input signal THA.
2.With the IG switch turned ON, measure the voltage between the SST connectors 76 (THA) and 17
(E2) under the following condition given below.
Intake air temp ['C] Specified value [V]
20 1.8 - 2.9
fin I n 6 - I ?

YES: Check malfunction that occurs interrnittentlv or Door contact.
NO: Go to w2.
W 2 . Check of harness between IAT sensor and ECU.

2,Disconnect the harness from the IAT sensor.
Connector 1 (THA) at sensor side - Connector 76 (THA) at ECU side
Connector 2 (E2) at sensor side - Connector 17 (E2) at ECU side.
YES: Go to m3.
NO: ReDair or replace the harness or connector.
W 3 . Check of IAT sensor.

6.Carry out unit check of IAT sensor.
7.Are the unit check results OK?

YES: Check or re~lace the EFI ECU.
NO: ReDlace the IAT sensor,
1-12-3 DTC No.PO115142 Engine coolant temperature sensor (ECT) circuit malfunction
I)WIRING DIAGRAM
EFI ECU
Engine
coolant
temperature
sensor
ECT sensor wire harness side
THW
FI ECU wire harness side

BE2
1.A thermistor built into the ECT sensor changes the resistance valve according to the engine coolant
temperature. The structure of the sensor and connection to the EFI ECU is the same as in the DTC
PO110143 (IAT Sensor Circuit Malfunction).
1.Open wire or short circuit in the ECT sensor circuit
- B8-54
i
(4) TROUBLE AREA
l.Open wire or short circuit in the ECT sensor circuit
2.Engine coolant temperature (ECT) sensor
3.EFI ECU
1.1s the srgnal from the ECT sensor inputted to the EFI ECU proper ?
2.1s the harness between the ECT sensor and EFI ECU proper ?
3.1s the output of the ECT sensor proper ?
NOTE
If DTC P0110/43 (IAT Sensor Circuit Malfunction), PO115142 (ECT Sensor Circuit Malfunction), are
PO120141 (ThrottleIPedal Position Sensor/Switch A Malfunction) are outputted simultaneously, E2
(Sensor Ground) may be open.
Read the freeze frame data, using the DS-21 diagnosis tester or OED II generic scan tool. Because
the freeze frame data records the engine conditions when the malfunction was detected, when
troubleshooting the freeze frame data is useful to determine whether the vehicle was running or
stopped, the engine warmed up or not, the air-fuel ratio lean or rich, etc. at the time of the
malfunction.
@ When using DS-21 diagnosis tester or OBD II generic scan tool:

W1. Check of output value of ECT sensor.
1.With the IG switch turned OFF, connect the DS-21
diagnosis tester to DLC through the SST or connect the
OBD II generic scan tool directly to DLC.
SST: 09991-87404-000
the tester. Read the engine coolant temperature of the
DS-21 diagnosis tester or OBD I1 generic scan tool.
3.1s the measured value the same as the actual engine
coolant temperature?
contact.
NO: Go to W2.
W 2 . Confirmation of cooling water temperature sensor output

value.
When -40°C: Go to W3.
When 140°C or above: Go to W5.
W3. Check of open wire in harness or inside EFI ECU (1).

1.Afier turning OFF the main switch of the tester, turn OFF the IG switch.
2.Disconnect the connector of the ECT sensor.
-
3.Connect a jump wire between the harness terminals 1
(THW) and 2 (E2) of the ECT sensor.
SST 09991-87403-000
the tester. Read the engine coolant temperature value of ss
the DS-21 diagnosis tester or OBD I1 generic scan tool.
5.1s the measured value 140°C or above?
YES: Check the ECT sensor connector or terminal for
connectina condition. If thev are satisfactow. reolace the C13E5554TlO
ECT sensor.
NO: Go to w4.
W4. Check of open wire in harness or inside EFI ECU (2).
?.Afterturning OFF the main switch of the tester, turn OFF the IG switch.
SST 09842-97203-000
3.Disconnect the jump wire from the ECT sensor connector.

4.Next, connect the jump wire between the SST connector terminals 45 (THW) and 17(E2).
5.After turning ON the IG switch, turn ON the main switch of the tester. Read the engine coolant
temperature value of the DS-21 diagnosis tester or OBD II generic scan tool.
6.1s the measured value 140°C or above?
YES: The harness between the ECT sensor and the ECU is ooen. Reoair or reolace the harness.
NO: Check the EFI ECU connector and terminal for connectina condition. If thev are satisfactow,
reolace the EFI ECU.
W5. Check of short in harness or inside EFI ECU (1).

2.Disconnect the connector of the ECT sensor.
3.After turning ON the IG switch, turn ON the main switch of the tester. Read the coolant temperature
value of the DS-21 diagnosis tester or OBD II generic scan tool.
4.1s the measured value -40°C?
YES: Reolace the ECT sensor.
NO: Go to D6.
W6. Check of short in harness or inside EFI ECU (2).

2.Disconnect the connector B of the SST from the EFI ECU
connector.
- Ule connecto
the tester. Read the engine coolant temperature value of
the DS-21 diagnosis tester or OBD 1
4.1s the measured value -40°C?
I generic scan tool. , barn
YES: Reoair or reolace the harness or connector.

@ When not using DS-21 diagnosis tester or OBD IIgeneric scan tool:
W 1 . Check of ECU input signal THW.
2.With the IG switch turned ON, measure the voltage between the SST terminals 45 (THW) and 17 (E2)
under the following condition given below.
Engine coolant temp. ["C] Specified value [V]
20 1.8 - 2.9
60 0.5- 1.2

NO: Go to w 2 .
W 2 . Check of harness between ECT sensor and ECU.

2.Disconnect the harness from the ECT sensor.
Connector 1 (THW) at sensor side - Connector 45 (THW) at ECU side.
Connector 2(E2) at sensor side - Connector 17 (E2) at ECU side.
YES: Go to W 3 .
NO: Reoair or rewlace the harness or connector.
W 3 . Unit check of ECT sensor.

1.Carry out unit check of ECT sensor.

YES: Check or reolace the EFI ECU.
NO: Rewlace the ECT sensor.
1-12-4 DTC No.PO116142 Engine coolant temperature (ECT) sensor circuit rangelperformance
problem
(1) WIRING DIAGRAM
1.Refer to section DTC0115I42.

1.Refer to Engine Coolant Temperature Circuit Malfunction.

1.When the engine starts, the engine coolant temperature sensor value is more than 4.85 V or less than
0.15 V for more than a certain length of time.
(4) TROUBLE AREA
I.ECT sensor
2.Cooling system
1.1s the signal from the ECT sensor inputted to the ECU proper ?
2.1s the harness between the ECT sensor and the EFI ECU proper ?
3.1s the output of ECT sensor proper?
NOTE
If DTC PO115142 (ECT Sensor Circuit Malfunction) and PO116142 (ECT Sensor Circuit
Range/Performance Problem) are output simultaneously, ECT sensor circuit may be open. Perform
troubleshooting of DTC PO115142 first.
Read the freeze frame data, using the DS-21 diagnosis tester or OBD II generic scan tool. Because
malfunction.
In the troubleshooting for the water temperature sensor system, only the use of DS-21 diagnosis
tester or OBD II generic scan tool will be able to determine whether open wire, short (P0115) or
functional malfunction (P0116).
@ When using DS-21 diagnosis tester or OBD I1 generic scan tool:

Dl. Check of DTC.
1.Are codes other than DTC PO116/42 outputted?
YES: Go to ao~licableDTC flow chart.
NO: Go to D2.
W2. Check of thermostat.

l.(Conduct the check of thermostat in Section COOLING SYSTEM.)
YES: Reolace the ECT sensor.
NO: Reolace the thermostat.
[
1-12-5 DTC No.PO120141 ~hrottlelpedal
position sensorlswitch
I) WIRING DIAGRAM
Linear throttle sensor
Linear throttle sensor wire harness side
m
1.The linear throttle sensor is mounted in the throttle body Engine ECU
and detects the throttle valve opening angle. When the
throttle valve is fully closed, a voltage of approxrmately
0.4 - 0.8 V is applied to terminal VTH of the EFI ECU. The
voltage applied to the terminals VTH of the EFI ECU
increases in proportion to the opening angle of the
throttle valve and becomes approximately 3.5 - 5.0 V
when the throttle valve is fully opened. The EFI ECU C13E5552ET10
judges the vehicle driving conditions from these signals
input from terminal VTH, uses them as one of the
conditions for deciding the air-fuel ratio correction, power
increase correction and fuel-cut control etc.
1.Open wire or short circuit in the throttlelpedal position sensor/switch circuit
(4) TROUBLE AREA
1.Open wire or short circuit in the throttlelpedal position sensor/switch circuit
2.Linear throttle position sensor
3.EFI ECU
1.1s the signal from the linear throttle sensor inputted to the ECU proper ?
2.1s the harness between the linear throttle sensor and the EFI ECU proper ?
3.1s the supply voltage of the linear throttle sensor proper ?
4.1s the output of linear throttle sensor proper ?
@ WhenI using D S d l diagnosis tester or OBD II generic scan tool:
W 1. Check of output value of liner throttle sensor.
1.With the IG switch turned ON, connect the DS-21
diagnosis tester to DLC through the SST or connect the
OBD II generic scan tool directly to DLC.
SST: 09991-87404-000
the tester. Read the throttle valve opening value of the
DS-21 diagnosis tester or OBD II generic scan tool.
Throttle valve 1 Throttle valve opening [%I
Fully closed 0.0
Fully open 100.0

YES: Check malfunction that occurs interrnittentlv or Door
contact.
NO: Go to w2.
- B8-60
i
B2. Check of power supply voltage at linear throttle sensor harness side.
1 After turning OFF the main switch of the tester, turn OFF the IG switch.
2.Disconnect the connector of the h e a r throttle sensor.
3.Measure the voltage between the terminals 1 (VC) of wlre harness connector and body ground when
the ignition switch is turned to the ON position,
SPECIFIED VALUE: 4.5 - 5.5V
4.1s the voltage within the specified value?

YES: Go to W 3 .
NO: Go to B5.
B3. Check of linear throttle sensor.

2.Measure the resistance between the respective terminals.
Terrnlnal 1 Condition I Standard value [kQ]
1 (VC) - 2 (E2) I - 2.5 - 6.0
(") - (wH)
I Throttle valve fullv
closed
Throttle valve fully
opened
I
I 0.1 - 1.3
1.7 - 4.2

YES: Go to B4.
NO: Rewlace the linear throttle sensor.
>4. Check of ECU input signal VTH.

SST 09842-97203-000
2.With the IG switch turned ON, measure the voltage between the SST connector 44 (VTH) and 17 (E2)
Throttle valve 1 Specifiedvalue [V]
Fully closed 0.4 - 0.8
F U I I ~open I 3.5 - 5.0

YES Check or re~lacethe EFI ECU.
NO: Check the harness and connector between the EFI ECU and the linear throttle sensor fVTH line1
for owen wire or short.
W 5 . Check of power supply voltage at linear throttle sensor ECU side.
SST: 09842-97203-000
3.With the IG switch turned ON, measure the voltage between the SST connectors 16 (VC)and 17 (€2).
SPECIFIED VALUE: 4.5 - 5.5V

NOTE
YES: Check the harness and connector between the EFI ECU and the linear throttle sensor (VC line)
for owen wire or short.
@ When not using DS-21 diagnosis tester o r OBD IIgeneric scan tool:
W 1 . Check of ECU input signal VTH.
2.With the IG switch turned ON, measure the voltage between the SST connectors 44 (VTH)and 17 (E2)
Throttle valve I Specified value [V]
Fully closed 0.4- 0.8
FUII~ open I 3.5 - 5.0

NO: Go to W 2 .
W 2 . Check of linear throttle sensor.

1.Turn OFF the 1G switch.
2.Disconnect the linear throttle sensor.
3.Measure the resistance between the respective terminals.
Terminal Condition I Standard value [kR]
1 (VC)- 2 (E2) ( - 2.5 - 6.0
I Throttle valve fully / 0.1 - 1.3
11 (E2) - R7H)
closed
Throttle valve lulh
opened
/ 1.7 - 4.2

YES: Go to W3.
NO: Reolace the linear throttle sensor.
W 3 . Check of harness between ECU and linear throttle sensor.

1.Check the harness and connector between the EFI ECU and the linear throttle sensor (VC, VTH, E2
line) for open wire or short.
NO: Reoair or reolace the harness or connector.
- B8-62
1-12-6 DTC No.P0130/21 Oxygen sensor circuit malfunction (Bank 1 sensor 1)
(1) WIRING DIAGRAM
@ FOR EU SPECIFICATION
L
Sensor wire harness side
OXHl +B

) FOR AUS SPECIFICATION
ACC
1G1
IG2
ST
Front Rear C ~ ~ E ~ ~ M E S ~ O

1.The front oxygen sensor (bank 1, sensor 1) detects the concentration of oxygen contained in the
exhaust gas according to the magnitude of the electromotive force that is being generated in itself.
When the air-to-fuel ratio becomes richer than the stoichiometric ratio, a greater electromotive force
(approx. 1 volt) is applied to the ECU. Conversely, when the ratio becomes leaner than the
stoichiometric ratio, a smaller electromotive force (approx. 0 volt) is applied to the ECU. In this way,
the ECU determines whether the air-to-fuel ratio is rich or lean. Based on this evaluation, the injection
time is controlled.
i
-
B8-64
1.When the flowing conditions (a) and (b) continue for more than certain length of time.
(a) After engine warming up, the signal from the oxygen sensor continuously remains in the non-rich
state, not becoming rich even once.
(b) Voltage output of oxygen sensor remains at 0.3 V or more, or 0.6 V or less, during idling after
engine is warmed up.
(4) TROUBLE AREA
1.Air induction system
2.Fuel pressure
3.lnjector
4.0pen wire or short circuit in the oxygen sensor circuit
5.0xygen sensor
6.EFI ECU
CAUTION
.. If it is the case that any DTC besides misfire is memorized simultaneously, first pelform the
troubleshooting for them.
1.1s the signal from the oxygen sensor inputted to the EFI ECU proper ?
2.1s the harness between the oxygen sensor and the EFI ECU proper ?
3.1s the output of oxygen sensor proper ?
4.Are there the open wire or short circuit for the oxygen sensor heater circuit.
NOTE
Sensor 1 means a sensor which is located near the engine block.
* Using the DS-21 diagnosis tester or OBD II generic scan tool, confirm the output voltage of the
oxygen sensor (bank 1, sensor I) from the current data. If the output voltage of the oxygen sensor
(bank 1, sensor 1) is 0.1 V or less, most likely the circuit of the oxygen sensor (bank 1, sensor 1) is
open or shorted.
I
CONFIRMATION ENGINE RACING PATERN
Engine speed I
@With the IG switch turned OFF, connect the DS-21 diagnosis tester to DLC through the SST. Turn ON
the IG switch and the main switch of the tester. Set the tester to the Continuous monrtoring results' of the
CARB mode.
@Start the engine. Keep on warming the engine for more than five minutes until the engine cooling water
temperature reaches 90°C or above. ,
@Race the engine for about three minutes at 2500 to 3000 rpm. I
@After one minute of idling, press the F1 key of the tester. Check to see if the DTC PO130 is outputted.
CAUTION
If the condition in this test is not strictly followed, detection of the malfunction will not be possible.
If you do not have the DS-21 diagnosis tester, turn the ignition switch OFF after performing steps @
to @, then perform steps @ to @ again.

NOTE
Read the freeze frame data, using the DS-21 diagnosis tester or OBD I1generic scan tool. Because
malfunction.

Dl. Check of DTC.
1.Are other codes (those other than DTC P0130/21) outputted?
YES: Go to the relative DTC chart.
NO: Go to D2.
D2. Check of harness between oxygen sensor and ECU.

1.With the IG switch turned OFF, set the SST (sub-harness). However, the SST connectors at the EFI
ECU side should remain disconnected.
SST 09842-97203-000
2.Disconnect the oxygen sensor connector.

4.Are the check results for open wire and short between the connector 1 (0x1) of the oxygen sensor at
the harness side and the SST term~nal75 (0x1) OK?
YES: Go to D3.
NO: Reoair or redace the harness or connector.
-
D3. Check of output voltage of oxygen sensor during idling.

1.Connect the oxygen sensor and SST connectors, respectively.
2.Connect the DS-21 diagnosis tester to DLC through the SST
SST:09991-87404-000
3.Warm up the engine at 2500 rpm for about 90 seconds.

4.Turn ON the main switch of the tester to read the output voltage of oxygen sensor during idling.
SPECIFIED VALUE: The voltaae - varies repeatedly between a range from a voltage below 0.3 V and to
a voltage above 0.6 V. (see the diagram below.)

YES: Go to D l0.
NO: Go to D4.
D4. Check of misfire.

?.Check to see if any misfire is occurring by monitoring the DTC and data list.
YES: Go to D5.
NO: Perform troubleshootina for misfire. (Go to troubleshootina of DTC P0300117. PO301-0304117.)
D5. Check of air induction system.

1.Check the following items given below:
(1) Check of the engine oil level gauge, oil filler cap and PCV hose for disconnection.
(2) Check of parts of the air induction system between the cylinder head and the throttle body for
disconnection, looseness, or cracks.
YES: Go to D6.
NO: Reoair or reolace the induction svstem.
D6. Check of fuel pressure.

YES: Go to D 7 .
NO: Check and reoair fuel oumD, fuel pipe line and filter.
D7. Check of injector injection.

YES: Go to D8.
NO: Re~iaCethe iniector.
D8. Check of gas leakage of exhaust system.
YES: Go to D9.
NO: Reoair or reolace.
D9. Check of output voltage of oxygen sensor unit.

1.Warm up engine completely.
2.Disconnect the connector of the oxygen sensor with IG switch turned OFF.
3.Connect a voltmeter to the connector terminal of oxygen sensor.
4.Hold the engine racing speed for 3 minutes at 2000 rpm. At this time, ensure that the reading of the
volt meter is within the specified value.
SPECIFIED VALUE: The voltmeter exhibits an output voltage of 0.2 V or more at least one time.

NO: Reolace the oxvaen sensor. (Bank 1. sensor 1)
W10. Perform confirmation engine racing pattern.

1.1s there DTC P0130/21 being output again?
NO: Go to W11.
DIl. The past situation of vehicles operation is investigated.

1.Did the vehicle run out of fuel in the past?
YES: DTC PO130121 is caused bv runnina out of fuel.
NO: Check malfunction that occurs intermiitentlv or Door contact.
1-12-7 DTC No.PO133121 Oxygen sensor circuit slow response (Bank1 sensorl)
(1) WIRING DIAGRAM
1Refer to DTC P0130/21 (Oxygen sensor circuit malfunction)

1.Refer to DTC P0130/21 (Oxygen sensor circuit malfunction)

1.Response time for heated oxygen sensor voltage output to change from rich to lean, or from lean to
rich, is more than certain length of time during idling after engine is warmed up.
(4) TROUBLE AREA
1.Air induction system
2.Fuel pressure
3.Injector
4.0pen wire or short circuit in the oxygen sensor circuit
1.1s the signal from the oxygen sensor inputted to the EFI ECU proper ?
2.1s the harness between the oxygen sensor and the EFI ECU proper?
4.Are there the open wire or short circuit for the oxygen sensor heater circuit.
NOTE
Read the freeze frame data, using the DS-21 diagnosis tester or OED II generic scan tool. Because
malfunction.

W 1. Check of DTC.
1.Are other codes (those other than DTC P0130/21) outputted?
NO: Go to w2.
W2. Check of harness between oxygen sensor and ECU.

1.With the IG switch turned OFF, set the SST (sub-harness). However, the SST connectors at the EFI
ECU side disconnected.
SST 09842-97203-000

the harness side and the SST terminal 75 (0x1) OK?
YES: Go to W3.
NO: Reoair or replace the harness or connector.
W 3 . Check of output voltage of oxygen sensor during idling.
2.Connect the DS-21 diagnosis tester to DLC through the SST.
SST 09991 -87404-000
3.Turn OFF all accessory switches. Warm up the engine at 2500 rpm, until the radiator fan starts
operating one time.
4.Turn ON the main switch of the tester. Read the output voltage of the oxygen sensor when the engine
is idling and the radiator fan is not operating.
SPECIFIED VALUE: The voltage varies repeatedly between a range from a voltage below 0.32 V and
to a voltage above 0.58 V. (See the diagram below.)

YES: Go to W 8 .
NO: Go to w 4 .
5sec. or more
C13E5556ESlO
D 4 . Check of air induction system.

1.Check the following items given below.
YES: Go to W 5 .
NO: Reoair or reolace induction svstem.
W 5 . Check of fuel pressure.

YES: Go to W 6 .
NO: Check and reoair fuel Dumo. fuel oioe line and filter.
W 6 . Check of injector injection.

YES: Go to W 7 .
W 7 . Check of output voltage of oxygen sensor unit.
SPECIFIED VALUE: Does the voltmeter exhibit an output voltage of 0.2 V or more at least one time?

NO: Reolace the oxvaen sensor. (Bank 1. Sensor 1)
W 8 . Perform confirmation engine racing pattern (Refer to DTC P0130/21 chart).

1.1s there DTC PO133121 being output again?
NO: Check malfunction that occurs intermittentlv or Door contact.
- - -
1-12-8 DTC No.PO135123 Oxygen sensor heater circuit malfunction

DTC No.PO141124 E ~ E N O ~
EZ&ETA[ E~A[EAA[~M&B~KI
(1) WIRING DIAGRAM
@ FOR EU SPECIFICATION
1 OXHl +B OXH2 +B I
EFI ECU wire harness side -

@ FOR AUS SPECIFICATION
0 ACC
IG1
IG2
ST
J
- C13E5513ES20
ansor wire harness side
Front Rear ~13~5514~~11
C13E5545S10

?.Referto DTC P0130/21 (Oxygen sensor circuit malfunction (Bank 1 sensor 1)).

1.When the battery voltage is above 7.5 V and the heater terminal voltage of the EFI ECU is above 1.0 V
,\ , when the heater is operating or below 7.5 V when the heater is not operating.
(4) TROUBLE AREA
I.Open wire or short circuit for the oxygen sensor heater circuit
2.0xygen sensor heater
3.EFI ECU
CAUTION
If it is the case that any DTC besides misfire is memorized simultaneously, first perform the
1.1s the signal from the oxygen sensor inputted to the ECU proper ?
2.1s the harness between the oxygen sensor and the EFI ECU proper ?
4.Are there the open wire or short circuit for the oxygen sensor heater circuit?
NOTE
Read the freeze frame data, using the DS-21 diagnosis tester or OBD I1generic scan tool. Because
malfunction.

Dl. Check of output voltage of ECU.
SST 09842-97203-000
2.Measure the voltage

- between the SST connectors 20 (OXHI), 50 (OXH2) and the body ground under
the following conditions given below.
Measurement conditions
IG switch ON I
After engine started
V/lrnrnediateiy after
Rear Oxygen sensor heater Battery voltage Below 1.0 VIAfter more
. (Only for EU Specification) than 3 minutes

NO: Go to D2.
D2.Unit check of oxygen sensor.

1.Check the resistance of the front and rear oxygen sensor heaters.
2. Are the unit check results OK?

YES: Check and r e ~ a ithe
r harness or connector between the main relav and oxvaen sensor and the
EFI ECU.
NO: Redace the oxvaen sensor.
1-12-9 DTC No.PO136122 Rear oxygen sensor circuit malfunction (Bank 1 sensor 2)
(1) WIRING DIAGRAM
@ FORIEU SPECIFICATION
,.IG...
SW
...- ACC ACC
p4
IG NO. 1;
IG No. 2
lG1
IG2
------ ?,.? ST I
ST

9 FOR AUS SPECIFICATION
ACC
IG1
IG2
ST
Front Rear C13E5514ES10

?.Referto DTC P0130/21 (Oxygen sensor circuit malfunction (Bank 1 sensor 1))

1.Voltage output of heated oxygen sensor remains at 0.4 V or more or 0.5 V or less when vehicle is
driven at 100 kmlh or more after engine is warmed up.
(4) TROUBLE AREA
1.Open wire or short circuit in the oxygen sensor circuit
2.0xygen sensor
3.EFI ECU
CAUTION
2.1s the harness between the oxygen sensor and the ECU proper ?
CONFIRMATION DRIVING PATTERN
I I
. more
40 S ~ C 01
Vehicle speed
@With the IG switch turned OFF, connect the DS-21 diagnosis tester to DLC through the SST. Turn ON
the IG switch and the main switch of the tester. Set the tester to the "Continuous monitoring results" of the
CARB mode.
@Start the engine. With all switch turned OFF, keep on warming the engine for more than five minutes
until the engine coolant temperature reaches 90'C or above.
@Accelerate the vehicle until the vehicle speed reaches 50 kmlh or more in the 1st -+ 2nd gear . Keep
on running the vehicle at that speed for at least 40 seconds.
@Under this condition, release the foot off from the accelerator pedal so as to decelerate the vehicle.
Maintain the idling state.
@After one minute of idling, press the F1 key of the tester. Check to see if the DTC PO130 is outputted.
CAUTION
If the conditions in this test are not strictly followed, detection of the malfunction will not be possible.
If you do not have DS-21 diagnosis tester, turn the ignition switch OFF after performing steps @ to
@, then perform steps @ to @ again.

NOTE
malfunction.
W 1. Check of DTC.
1.Are other codes (those other than DTC P0136122) outputted?
NO: Go to W2.
W2. Check of harness between oxygen sensor and ECU.

1.With the IG switch turned OFF, set the SST (sub-harness). However, the SST connectors at the ECU
side should remain disconnected.
SST 09842-97203-000

the harness side and the SST terminal 74 (0x2) OK?
YES: Go to W3.
NO: Repair or replace the harness or connector.
W3. Check of output voltage of oxygen sensor during idling.

SST 09991-87404-000

4.Turn ON the main switch of the tester. Race the engine at 4000 rprn for three minutes by depressing
the accelerator pedal.
5.Under the condition of step 4, release the foot off from the accelerator pedal so as to allow the engine
l o idle.
6.Read the output voltage of the oxygen sensor between Steps 4 to 5.
SPECIFIED VALUE: The voltage should become 0.4 V or below and 0.55 V or more, respectively, at
least one time.

NO: Go to w4.
W4. Check of output voltage of oxygen sensor unit.

SPECIFIED VALUE: The voltmeter exhibits an output voltage of 0.2 V or more at least one time?

YES: Check or replace the EFI ECU.
NO: Replace the oxvaen sensor. (Bank 1, sensor 2)
1-12-10 DTC No.PO171125 Fuel trim system too lean (Air-fuel ratio lean malfunction, bank 1)
DTC No.PO172126 i ~ 6 0 8 n i u ( i a ~ b $ a ~ B i )
(1) WIRING DIAGRAM
I
23 (El)
17 (E2)
EFI ECI
75 (0x1)
20 (OXHl)
30 (FC2)
J
ClSE5575ESX
ront oxygen sensor wire harness side

1.The fuel trim means the feedback compensation value that will compensate the basic injection time.
The fuel trim comes in two kinds: the short-term fuel trim and the long-term fuel trim.
2.The short-term fuel trim is a short-term fuel compensation to be carried out to maintain the air-to-fuel
ratio at the stoichiometric air-to-fuel ratio. The signal from the oxygen sensor indicates whether the
current air-to-fuel ratio is rich or lean than the stoichiometric air-to-fuel ratio. Hence, if the air-to-fuel
ratio is rich, the fuel injection amount will be reduced. Conversely, if the air-to-fuel ratio is lean, the
fuel injection amount will be increased.
3.The long-term fuel trim is overall fuel compensation over a long period of time in order to compensate
a continues deviation of the short-term fuel trim from the central value, which will be caused by the
engine's inherent characteristics, the wear due to operation over a long period of time and the
change in operational environment.
(3) DTC DETECTING CONDlTION
1.When the following conditions given below occur while the air-to-fuel feedback after the engine
warming-up is being executed.
2.The air-to-fuel is too lean:(The total fuel trim (the sum of the short-term fuel trim and long-term fuel
trim) exceeds the set value.)
3.The air-to-fuel is too rich:(The total fuel trim is less than the set value.)
(4) TROUBLE AREA
1.Open wire or short circuit in the oxygen sensor circuit
2.0xygen sensor
3.ECT sensor
4.Evaporative emission purge VSV
5.EFI ECU
2.1s the harness between the oxygen sensor and the ECU proper ?
CONFIRMATION DRIVING PAlTERN
Vehicle speed
I
@With the IG sw~tchturned OFF, connect the DS-21 diagnosis tester to DLC through the SST. Turn ON
the IG switch and the main switch of the tester. Set the tester to the 'Continuous monitoring resultsbf the
CARB mode.
@Start the engine. Keep on warming the engine for more than five minutes until the engine cooling water
temperature reaches 90°C or above.
@Run the vehicle for more than five minutes at a speed of 70 km/h with the gear selected to the 5th gear.
@After one minute of idling, press the F1 key of the tester. Check to see if the DTC PO17110172 is
detected.
CAUTION
If you do not have DS-21 diagnosis tester, turn the ignition switch OFF after performing steps @ to
@, then perform steps @ to @ again.

NOTE
malfunction.
@ When using DS-21 diagnosis tester or OBD li generic scan tool:

>I.Check of DTC.
1.Are other codes (those other than DTC PO171125 or P0172126) outputted?
NO: Go to w2.
W2. Check of air induction system.

1.Check the following items given below.
YES: Go to >3.
NO: Reoair or redace the induction svstem.
W3. Check of injector injection.
YES: Go to W4.
NO: Revlace the injector.
W 4 . Check of purge VSV for EVAP.

1 .Go to trouble-shooting of DTC P0443176.

Go to W 5 .
Replace the ourae VSV for EVAP.
W 5 . Performance check of ECT sensor.

1.Go to trouble-shooting of DTC PO1 16/42

YES: Go to B6.
NO: Reolace the ECT sensor.
B6. Check of MAP sensor.

I .Go to trouble-shooting of DTC P0105131.

YES: Go to W7.
NO: Revlace the MAP sensor.

YES: Go to W 8 .
NO: Check and reoair fuel Dumo. fuel oioe line and filter.
W 8 . Check of gas leakage of exhaust system.

1 .Are the check results OK?
YES: Go to W 9 .
NO: Reoair or reelace.
D 9 . Check of harness between oxygen sensor and ECU.

1.With the IG switch turned OFF, set the SST (sub-harness). However, the SST connectors at the ECU
side should remain disconnected.
SST 09842-97203-000

the harness side and the SST terminal 7 5 (0x1) OK?
YES: Go to W10.
0
D10. Check of output voltage of oxygen sensor during idling.
SST: 09991-87404-000
3.Warm up the engine at 2500 rpm for about 90 seconds.

4.Turn ON the main switch of the tester to read the output voltage of oxygen sensor during idling.
SPECIFIED VALUE: The voltage varies repeatedly between a range from a voltage below 0.3 V and to
a voltage above 0.6 V. (See the diagram below.)
I I
1 ~13~5555~10/
YES: Go to D12.
NO: Go to D11.
D11. Check of output voltage of oxygen sensor unit.

4.Hold the engine racing speed for 3 minutes at 2000 rprn. At this time, ensure that the reading of the
SPECIFIED VALUE: The voltmeter exhibits an output voltage of 0.2V or more at least one time?

NO: Reolace the oxvaen sensor. (Bank 1. sensor 1)
D12. Perform confirmation driving pattern.

1.1s there DTC P0171/25 or PO172126 being output again?
NO: Go to D13.
D13.The past situation of vehicles operation is investigated.

1.Did the vehicle run out of fuel in the past?
YES: DTC PO171125 is caused bv runnina out of fuel.
D 1. Check of DTC.
1.Are other codes (those other than DTC PO171125 or P0172126) outputted?
NO: Go to D2.
W 2 . Check of air induction system.
1 .Check the following items given below.
disconnection, looseness or cracks.
YES: Go to W 3 .
NO: Reoair or redace.

YES: Go to W 4 .
NO: Check and reoair the fuel mrnD. fuel oioe line and filter.
W 4 . Check of injector injection.

YES: Go to W 5.
NO: Reolace the iniector.
w 5 . Performance check of ECT sensor.

1.(Go to trouble-shooting of DTC PO116/42.)

YES: Go to W 6 .
NO: Re~lacethe ECT sensor.
W 6 . Check of MAP sensor.

1.(Go to trouble-shooting of DTC PO105131.)

YES: Go to W 7 .
NO: Re~lace the MAP sensor.
W 7 . Perform the confirmation driving pattern.

1.After installing a satisfactory oxygen sensor (bank 1, sensor I ) , perform the confirmation driving
pattern.
2.1s the code (DTC PO171125 or P0172126) outputted?
NO: Re~lacethe oxvaen sensor (bank 1. sensor 1) that was mounted orioinallv on the vehicle.
- B8-84
1-12-11 DTC No.PO300117 Random/multiple cylinder misfire detected
DTC No.PO301M7 Misfire detected (cylinder 1)
DTC No.PO302117 Misfire detected (Cylinder 2)
DTC No.PO303117 Misfire detected (Cylinder 3
DTC No.PO304117 Misfire detected (Cylinder 4)
I ) WIRING DIAGRAM
) FOR EU SPECIFICATION
7 (+Bl) (EO1) 82
Injector wire harness side

i
@ MISFIRE:
1.The igniter unit detects the ion current that flows in proportion to the combustion pressure. This ion
current is converted into a voltage, which will be inputted to the ECU. If the voltage value is below a
certain value, the EFI ECU evaluate it as a misfire and counts its occurrence numbers.
2.When the misfire rate becomes or exceeds a number that indicates deteriorated engine conditions,
this state will cause the malfunction indicator lamp (MIL) to be illuminated. If such a misfire is
occurring whose misfire rate is high enough that the driving condition will most likely cause the
catalyst to be overheated, the malfunction indicator lamp (MIL) will flash.
0 ~03141-,~0300/17:
1.Misfiring of randomlmultiple cylinders is detected during any particular 400 or 2000 ignitions.
0 P0301/17,P0302~17,P0303I17:
1.For any particular 400 ignitions for engine, misfire is detected which can cause catalyst overheating.
(This causes MIL to blink.)
2.For any particular 2000 ignitions for engine, misfire is detected which can cause deterioration in
emissions.
NOTE
When the 2 or more codes for a misfiring cylinder are recorded repeatedly but no random/multiply
cylinder misfire code is recorded, it indicates that the misfire were detected and recorded at different
times.
When any one or any two or more of PO301 through PO303117 codes are outputted, the code
PO314 is memorized without fail. However, only when the function Continuous monitoring results of
the CARB mode is used, it is possible to read this code P0314.
(4) TROUBLE AREA

1.Open wirelshort circuit for the ignition system circuit
2.0pen wirelshort circuit for the ion system circuit
3.lnjector
4.Fuel pressure
5.Combustion pressure
6.MAP sensor
7.ECT sensor
8.EFI ECU
1.1s the signal from the igniter inputted to the ECU proper ?
2.Does the igniter operate proper ?
3.1s the harness between the injector and the ECU proper ?
4.Does the injector operate proper ?
5.1s the harness between the ECT sensor and the ECU proper ?
6.Does the ECT sensor operate proper ?
NOTE
In order to memorize DTC of misfire, it is necessary to drive around MISFIRE RPM, MISFIRE LOAD
in the data list for the following period of time.
CONFIRMATION DRIVING PATTERN
1 minutes 30 seconds or more
NOTE
malfunction.
When the vehicle is brought to the workshop and the misfire is not occurred, misfire can be
confirmed by reproducing the condition of freeze frame data. Also, after finishing the repair, confirm
that there is no misfire. (See the confirmation driving pattern)
When using DS-21 diagnosis tester or OBD II generic scan tool:

>I Visual
. check of inside of engine compartment.
1.Check the connecting conditions of the wire harnesses and connectors.
2.Check the vacuum hoses, purge hoses, fuel hoses and pipes for disconnection and breakage.
YES: Go to W2.
NO: Reoair or reolace. then confirm that there is no misfire. (See confirmation drivina oattern)
W2. Check of spark plug and spark of misfiring cylinder.
2.Disconnect the connector of the injector. Relay block
CAUTION
4 above so as to prevent the catalyst from being
avoided wherever possible, as this may damage the C13E5374ET10
injector.
3.Remove the IG coils and spark plugs (misfire cylinders).
4.lnstall the spark plug to the IG coil.
&Crank the engine at this time, check to see if the spark
plug sparks.
7.lf no spark occurs, conduct the check according to the
check procedure for spark plug. i
YES: Go to D3.
NO: Reolace the s ~ a r kplua or check the ianition svstem
and ion svstem.
CAUTION
Do not use any spark plugs other than those
designated.
W3. Check of ECU output signal of injector of misfiring cylinder.

1.With the IG switch turned OFF, perform restoration.
2.Set the SST (sub-harness).With the IG switch turned ON, measure the voltage between the SST
connector terminal of an injector in which misfire is taking place among the SST connectors 27 (#lo)
through 24 (#40) and the body ground.
SST: 09842-97203-000
SPECIFIED VALUE: Battety voltage
3.0bservation of injector waveform with oscilloscope

(reference).
4.Check voltage waveform between the SST connectors 27
(#lo) through 24 (#40) and 82 (E01) while engine is
idling.
YES: Go to W6.
NO: Go to m4.
NOTE
When an oscilloscope is used, the injector control
signal produces such waveforms, as shown in the
diagram below. (The frequency or injection time can not
be specified.)
D4. Unit check of injector of misfiring cylinder.
2.Disconnect the injector connector of the misfiring cylinder.
3.Measure the resistance between the injector terminals.
SPECIFIED VALUE: 12 R at 20°C

YES: Go to D5.
NO: Rewlace the iniector.
W5. Check of harness between injector and ECU.

1.Disconnect the SST connectors from the EFI ECU (with the IG switch turned OFF).
Connector 2 (#lo) of # I injector at harness side - SST connector 27 (#lo)
Connector 2 (#20) of #2 injector at harness side - SST connector 26 (#20)
YES: Check malfunction that occurs intermittentlv or woor contact.
NO: R e ~ a ior
r rewlace the harness or connector.
D6.Check of ion system.

1.(Go to trouble-shooting of DTC P1300136.)

YES: Go to D7.
D7.Check of fuel pressure.

1.YES: Are the check results OK?
NO: Go to D8.
Check and rewair the fuel Durn!& pressure reaulator, fuel oioe line and filter.
D 8 . Check of injector injection.

YES: Go to D9.
NO: RetIlace the iniector.
D 9 . Check of MAP sensor.


YES: Go to D10.
NO: Rewlace the MAP sensor.
W 10. Performance check of ECT sensor.
1.(Go to trouble-shooting of DTC PO116/42.)

YES: Check com~ressionDressure. valve clearance and valve timina.
NO: Redace the ECT sensor.
i
1-12-12 DTC No. PO325118 Knock sensor 1 circuit malfunction
) WIRING DIAGRAM
EFI ECU
(El) (KW
23 53
n
hv
--
: -j
:
j j
j :
: :
j
>.,j
0
-
Knock sensor --
--
-
C13E551SES2
Knock sensor wire harness side
C13E5520S10

1.Knock sensor are fitted to the cylinder block to detect engine knocking. This sensor contains a
piezoelectric element which generates a voltage when it becomes deformed, which occurs when the
cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retard to
suppress it.
1.When the signal from the knock sensor exceeds the voltage preset according to the engine revolution
speed continuous by for more than a certain engine revolution speed of 2000 rpm or more.
(4) TROUBLE AREA
l.Open wire or short circuit for knock sensor system circuit
2.Knock sensor
3.EFI ECU
1.Is the signal from the knock sensor inputted to the ECU proper ?
2.1s the harness between the knock sensor and the ECU proper ?
3.1s the output of knock sensor proper ?
NOTE
malfunction.
a When using DS-21 diagnosis tester or OBD 11 generic scan tool:

W1. Check of continuity of knock sensor circuit.
1.Set the SST (sub-harness). However, the SST connector
"A" should remain disconnected from the ECU connector.
SST: 09842-97203-000
2.With the IG switch turned OFF, measure the resistance
between the SST connector 53 (KNK) and the body
ground.
SPECIFIED VALUE: 1 MR or higher
YES: Go to D2.
NO:Go to w3.
W2. Check of knock sensor.

1.Disconnect the connector of the knock sensor with ignition switch OFF.
2.Remove the knock sensor from the cylinder block.
3.Using an ohmmeter, check the resistance between the terminal and body.
SPECIFIED VALUE: 1 MR or higher

YES: Go to D3.
NO: Replace the knock sensor.
D3. Check of harness between ECU and knock sensor.

1.Check the harness and connector between the EFI ECU and the knock sensor for open wire or short.
YES: Go to W4.
W4. Check the knock sensor.
1.Check the knock sensor for installing condition (e.g. looseness)
YES: Check or redace the EFI ECU.
NO: Tiahten the knock sensor.
@ Check by oscilloscope.
1.Connect the SST connector 'A" to the ECU
2.Start the engine and keep it idling.
3.Connect the positive (+) and negative (-) probes of scope to the SST connector terminals
53 (KNK) and 23 (El), respectively.
4.When the waveforms as shown in the right figure are
observed, the knock sensor circuit is functioning
properly. (The measurement can be conducted using the
oscilloscope function of the DS-21 diagnosis tester.)
NOTE
= The waveform at the time of racing becomes greater
than that at the time of idling.
1-12-13 DTC No.PO335113 Engine revolution sensor circuit Malfunction
I) WIRING DIAGRAM
Enaine revolution sensor wire harness side
C13E5523S10

1.The engine revolution sensor (NE signal) consists of a signal rotor and a pickup coil. The NE signal
rotor has 4+ 1 teeth and is mounted on the camshaft. The NE sensor generates four signals (one of
them being a signal for distinguishing cylinders) per two engine revolutions. The EFI ECU detects the
actual crankshaft angle and the engine speed by the NE signals, based on the N2+ signal.
?.No engine revolution signal to EFI ECU during cranking.
B8-94
*,
(4) TROUBLE AREA
?.Open wire or short circuit for engine revolution sensor system circuit
2.Engine revolution sensor
3.EFI ECU
1.Is the signal from the engine revolution sensor inputted to the ECU proper?
2.1s the harness between the engine revolution sensor and the ECU proper ?
3.1s the output of engine revolution sensor proper ?
NOTE
malfunction.
t
0 When using DS-21 diagnosis tester or OBD I1generic scan tool:
Dl. Check of resistance of engine revolution sensor circuit.
?.Set the SST (sub-harness). However, the SST connector
'A' should remain disconnected from the ECU connector.
SST: 09842-97203-000
2.With the IG switch turned OFF, measure resistance
between the SST terminals 22 (N2+) and 52 (N2-).
SPECIFIED VALUE: 950 to 1200R at 20°C
3.Are the check results OK? Connector A
YES: Go to W2.
NO: Go to D4.
D2. Unit check of engine revolution sensor.

1.Disconnect the coupler of the engine revolution sensors.
SPECIFIED VALUE: 950 to 1250R at 20°C

YES: Go to D3.
NO: Replace the enaine revolution sensor.
D3. Check of harness between ECU and engine revolution sensor.

?.Check the harness and connector between the EFI ECU and the engine revolution sensor for open
wire or short.
YES: Check malfunction that occurs intermittentlv or poor contact.
D4. Check the installation state of the sensor.
1.Check the sensor for installing condition and the signal
rotor for tooth condition. (Check for the air gap, sensor
for looseness, tooth distortion, adhesion of rust, foreign
matter, etc. Refer to Section IGNITION SYSTEM.)
YES: Tiahten the sensor. Redace the sianal rotor.
NO: Go to D5.
D5. Check of starter signal.

1.Connect the SST connector "A" to the EFI ECU.
2.Measure the voltage between the SST connector terminals 68 (STA) and 23 (El) while the engine is
being cranked.
SPECIFIED VALUE: Battery voltage

NO: Repair or reolace the harness or connector (Between EFI ECU - IG switch).
1Connect the SST connector "A' to the ECU.
2.Start the engine and keep it idling.
3.Connect the positive (+) and negative (-) probes of an oscilloscope to the SST connector terminals
between 22 (N2+) and 23 (N2-) respectively.
4.When the waveforms as shown in the right figure are
observed, the engine revolution sensor circuits are
functioning properly.
NOTE
The waveform at the time of racing becomes greater
than that at the time of idling.
1-12-14 Ignition system circuit ~alfunction
(1l l WIRING DIAGRAM
IG coil wire harness side

1.A DL1 (Distributorless lgnition) system has been employed.
2.The DL1 system has no distributor. Furthermore, the ignition coil is located just above the spark plug.
Consequently, there is no ignition energy loss due to the electricity distribution, thus making it
possible to directly furnish the electric energy induced at the coil. Therefore, an optimum ignition
condition can be obtained at all times.
1.When the ignition signal is not inputted continually.
(4) TROUBLE AREA
1.Open wirelshort circuit for the ignition system circuit
2.IG coil
3.Battery
4.EFI ECU
1.1s the power supply voltage of IG coil proper?
2.1s the harness between the IG coil and the ECU proper ?
3.1s spark in a good condition?
B8-97
i
@ When not using DS-21 diagnosis tester or OBD I1 generic scan tool:
PI.Spark check.
1.Remove the IG cotls and spark plugs (all cylinders # I , 2, 3 and 4).
2.Remove the fuel pump relay.
3,Disconnect the connector of the injector.
CAUTION
Stop the fuel injection by the operations at Steps 3 and 4 above so as to prevent the catalyst from
being damaged by unburnt gas, etc.
When there is no fuel, the injector injection must be avoided wherever possible, as this may
damage the injector.
4.Crank the engine. At this time, check to see if each spark plug sparks
YES: lanition svstem circuit is normal.
NO: Go to D2.
t
W2. Check of ECU output signal.
1.An oscilloscope is used.
2.While engine is being cranked, check the ignition signal between the following terminals.
ECU side connector 60 (IG1) - ECU side connector 23 (El)
SPECIFIED VALUE: Normal waveforms are outputted.
NOTE
Correct evaluation cannot be performed for the ignition signal, unless an oscilloscope is used.
YES: Go to W 3 .
NO: Check of EFI ECU circuit.
W 3 . Check of power supply voltage of IG coil.

1.With the IG switch turned ON, measure the voltage between the each connector 1 ( f B) at IG coil
harness side and the body ground.
YES: Go to D 4
NO: Rewair or redace the harness between the IG coil and the battew.
S4.Check of wire herness.

I.Check of continuity between the following terminals.
1G coil side connector 2 (IGI) - ECU side connector 60 (IGI)
IG coil side connector 2 (IG2) - ECU side connector 59 (IG2)
YES: Go to W 5 .
NO: Repair or rewlace the harness.
B8-98
i
m5.Check of wire hemess.
:....:......................................................
,,Check continuity of the between the terminals given ... ... ... ... ... ... ... ... ... ... ... ... ...
below. ................................................................
... ... ... ... ... ... ... ... ... ... ... ....
. .. .. .. .. .. .. .. .. .. .. ..
............................................................ .
Between harness side terminals Y' (E) of each IG coil ...
I....;
and ECU side connector 23 (El).
YES: Replace the IG coil. ... .... .... .... .... .... .... .... .... .... .... .... ....
.............................................................
NO: Reoair or replace the harness. .............................................................
.. ... ... ... ... ... ... ... ... ... ... ... ...
............................................................
NOTE
When an oscilloscope is used, the ignition signal- 1 HllE6077r10
becomes the waveform as indicated in the figure

above.
1-12-15 DTC No.PO420127 Catalyst system efficiency below threshold
I) WIRING DIAGRAM
FOR EU SPECIFICATION
.- - - - -- --
IG No. 2
.......'
EFI ECU
23 (El)
k.2
O X ~
Front
oxi Rear -.-

@ FOR AUS SPECIFICATION
ACC
IG1
IG2
ST
Q .---- 75 (OX?)
8 20 (OXH1)
$4 Main
relay 1 _,
-..
, ,
:._.. @in~k>gmgheater
Rear 02 sensor I1
2L-,
T .-WT
---,
,
....- c, 74 (0x2)

1.The ECU monitors the concentration of oxygen in the exhaust gas that is flowing through the three-
way catalytic converter, using the rear oxygen sensor. When the catalyst is functioning properly, the
varying cycle of the output voltage of the rear oxygen sensor is slower than that of the output voltage
of the front oxygen sensor. However, if both the output waveforms of the front and rear sensors are
varying at the same rate, it indicates that the catalyst performance has deteriorated.
\ (3) DTC DETECTING CONDITION
1.When both the output waveforms of the front and rear oxygen sensors are varying at the same rate
when the vehicle is running at predetermined speed.
(4) TROUBLE AREA
1.Three-way catalyst
2.0pen wire or short circuit for the oxygen sensor system circuit
3.0xygen sensor
CONFIRMATION DRIVING PAlTERN
I Vehicle speed / 1
Time
5 mi". or so Check
@With the iG switch turned OFF, connect the DS-21 diagnosis tester to DLC through the SST. Turn on the {
IG switch and the main switch of the tester. Set the tester to the "Continuous monitoring results" of the
CARB mode.
@Start the engine. With all switch turned OFF, keep on warming the engine for more than five minutes
until the engine coolant temperature reaches 90°C or above.
@Run at a constant speed of 50 km/h for about five minutes (in the 4th gear).
@After one minute of idling, press the F1 key of the tester. Check to see if the DTC PO420 in out putted.
CAUTION
* If you do not have DS-21 diagnosis tester, turn the ignition switch OFF after performing steps @ t o
@ then perform steps @ t o @ again.
NOTE
Read the freeze frame data, using the DS-21 diagnosis tester or OBD IIgeneric scan tool. Because
malfunction.

W 1. Check of DTC.
1.Are other codes (those other than DTC P0420127) outputted?
NO: Go to w2.
W2. Check of rear oxygen sensor (bank 1, sensor 1).

1.(Go to trouble-shooting of DTC P0130/21.)
2. Are the unit check results OK?

YES: Go to W 3 .
NO: R e ~ a ior
r reolace.
1
W 3 . Check of rear oxygen sensor (bank 1, sensor 2).

YES: Go to W4.
NO: Re~airor redace.
m4. Perform the confirmation driving pattern.

1.Perform the confirmation driving pattern.
2.1s DTC PO420127 being outputted again?
YES: Redace the three-wav catalvtic converter.
1-12-16 DTC No.P0443/76 VSV for evaporative emission control system purge control
(1) WIRING DIAGRAM
r ACC
IGl
162
ST
VSV for EVAP wire harness side

t (2) CIRCUIT DESCRIPTION
ThroHle body
F j
1.When the execution conditions for the evaporative
emission purging are met, the EFI ECU performs the duty
control for the VSV for evaporative emission purging and
purges the evaporative emissions into the combustion
chamber. Combustion
chamber
Charcoal Fuel tank
canister

I.At?er the engine starting, not operate the evaporative emission purge VSV by the control signal.
(4) TROUBLE AREA
1.VSV for evaporative emission control system purge control (Purge VSV for EVAP)
2.0pen wire or short circuit for the evaporative emission purge VSV control system circuit
3.EFI ECU
..r- (5) POINTS OF INSPECTION
1.1s the harness between the purge VSV for EVAP and the ECU proper ?
2.1s the control signal from the ECU outputted to the purge VSV for EVAP proper ?
3.1s the purge VSV for EVAP operated proper ?
NOTE
Read the freeze frame data, using the DS-21diagnosis tester or OBD I1generic scan tool. Because
stopped, the engine warmed up or not, the air-fuel ratio lean or rich, etc. t the time of the
malfunction.

W1. Operation check of Purge VSV for EVAP.
1.With the IG switch turned OFF, connect the DS-21 diagnosis tester to the DLC through the SST.
S S T 09991-87404-000
, .
i
2.Disconnect the hose going to the purge VSV for EVAP from the charcoal canister.
3.Turn ON the IG switch, and turn ON the main switch of the tester. Erase the DTC. Select the 'Purge
VSV' of the 'Actuator driving'.
4.When executing 'ON" and 'OFF" check the operation of
the VSV for purging.
No air continuity should exist when air is blown into the
vsv 'OFF'
hose.
Air continuity should exist when air is blown into the
VSV 'ON'
hose.

YES: Check malfunction that occurs intermittentlv and
poor contact.
NO: Go to W2.
B2.Check of purge hose and passage.

1.Execute the VSV Fielease' so as to return the purge VSV for EVAP to the original operating state.
s~ ~ 2.Start the engine and keep the engine racing.
3.Disconnect the hose going from the purge VSV for EVAP to the intake manifold.
4.Apply your finger to the disconnected hose. Ensure that a
negative pressure is applied.
SPECIFIED VALUE: Negative pressure should be applied.
5.Check the hose for connecting state, leakage, restriction,
bending and deterioration.
YES: Go to W 3 .
D3. Check of power supply voltage of Purge VSV for EVAP.

1.Turn OFF the main switch of the tester. Turn OFF the IG switch.
2.Disconnect the purge VSV for EVAP connector.
3.With the IG switch turned ON, measure the voltage between the harness side connector 1 (+B) of
purge VSV for EVAP and the body earth.

YES: Go to w4.
NO: Check the harness and connector between the VSV for ouraino and the batten/. and the main
relav for ooen wire or short. Reoair or reolace. as reauired.
D4. Check of harness between ECU and purge VSV for EVAP.
1.With the IG switch turned OFF, connect the SST (sub-harness).
CAUTION
Do not connect the SST connector to the ECU.

Connector 2 (PRG) at purge VSV for EVAP harness side - connector 79 (PRG) at ECU side.
YES: Go to w5.
$
88-1 06
D5. Unit check of purge VSV for EVAP.
1.Are the un~tcheck results OK?
YES: Go to W6.
NO: Reolace the ourae VSV for EVAP.
D6. Check of ECU output signal.

1.Connect the connector to VSV for purging. Connect the SST connector to the EFI ECU. Connect the
hoses that have been disconnected to the original places.
2.When the engine is cold, with the engine idling, measure the voltage between the SST connector 79
(PRG) and 82 (E01).
SPECIFIED VALUE: Battety voltage
3.After warming up the engine (after the radiator fan has operated at least one time), measure the
voltage between the SST connectors 79 (PRG) and 82 (E01) for more than two minutes with the
accelerator pedal depressed.
SPECIFIED VALUE: The voltage should become 0 to I V within the two minutes.

YES: Check malfunction that occurs intermittently and Door contact.
NO: Check or reolace the ECU.
W1. Check of ECU output signal.
SST 09842-97203-000
2.When the engine is cold, with the engine idling, measure the voltage between the SST connectors 79
(PRG) and 82 (E01).
SPECIFIED VALUE: Batteiy voltage
3.After warming up the engine (after the radiator fan has operated at least one time), measure the
voltage between the SST connectors 79 (PRG) and 82 (E01) for more than two minutes with the
accelerator pedal depressed.
SPECIFIED VALUE: The voltage should become 0 to 1 V within the two minutes.

YES: Go to W2.
B8-107
W 2 . Check of power supply voltage of purge VSV for EVAP.
2.Disconnect the purge VSV for EVAP connector.
3.With the IG switch turned ON, measure the voltage between the harness side connector 1 (+B) of
VSV and the body earth.

YES: Go to W 3 .
NO: Check the harness and connector between the uurae VSV for EVAP and the batterv. and the
main relav for oDen wire and short. R e ~ a ior
r reulace. as reauired.
cRefCode=SB08-0213>
W3. Check of harness between ECU and purge VSV for EVAP.
1.With the IG switch turned OFF, connect the SST (sub-harness).
SST: 09842-97203-000
CAUTION

Connector 2 (PRG) at VSV harness side - connector 79 (PRG) at ECU side.
YES: Go to W 4 .
NO: Reuair or reolace the harness or connector.
W4. Unit check of purge VSV for EVAP.

YES: Check malfunction that occurs intermittentlv and Door contact.

NO: Reolace the Durae VSV for EVAP.
1-12-17 DTC No.PO500152 Vehicle speed sensor circuit malfunction
I) WIRING DIAGRAM
ECU
37(SPD
~13~'5546~~21
Combination meter wire harness side
I ! ! I
C13E5545SlO

1.The veh~clespeed signals (pulses) are inputted from the ABS computer via the combination meter.
The EFI ECU calculates the vehicle speed based on the frequency of these pulse signals.
1.No vehicle speed sensor signal to EFI ECU during the fuel cut control is functioning.
I
(4) TROUBLE AREA
1.Combination meter
2.0pen wire or short in the veh~clespeed signal system circuit
3.EFI ECU
4.ABS ECU
1.1s the signal from the Combination meter inputted to the ECU proper ?
2.1s the harness between the Combination meter and the EFI ECU proper ?
3.Check to see if the vehicle signal output of the ABS ECU is correct.
W 1. Operation check of speedometer.
1.Run the vehicle .Does the speedometer indicate the vehicle speed correctly?
SPECIFIED VALUE: If the speedometer indication is normal, the speedometer system is functioning
normally.
YES: Go to W2. !.
NO: Check of ABS ECU and combination meter. (Refer to sections BODY ELECTRICAL SYSTEM
and BRAKE CONTROL.)
W2. Check of input signal to ECU.

SST 09842-97203-000
2.Check that the voltage- 1 - 1

between the SST terminals 37
(SPD) and 17 (E2) is within the following specified value
when the vehicle is moving with the ignition switch turned
ON.
SPECIFIED VALUE: Specified Value: 0 = 4.5 to 5.5 V
for pulse signal.
YES: Check or rewlace the EFI ECU.
NO: Go to w 3 .
W 3 . Check of harness between EFI ECU and combination meter.

?.TurnOFF the IG switch.
2.Remove the combination meter.
3.Disconnect the harness from the combination meter.
SST connector 37 (SPD) - Harness side connector 14 (SPD) of combination meter.
Harness side connector 22 (E) - Body ground.
5.Are the check results for oDen wire and short OK?
YES: Rewlace the combination meter
NO: R e ~ a ior
r rewlace the harness or connector.
t
1-12-18 DTC No.PO505ffl Idle Control System Malfunction
I) WIRING DIAGRAM
- - -- - - - -. ACC .
IG SW
.,.
ACC
4- 4
IG NO 2 1G2
ST
4
0
w (FAN1)13 To radiator fun relay
J
2 (PST) 78 To PIS oil pressure SW
(ACSW) 38 To AIC SW
(BLW) 39 To heater blower SW
(DW To defogger SW
10
(HIL) 71 To tail lamp SW
I &~(Fcz) ,---------
11
(ISC)5 4 0
-
Fuel
C'7(+B1)
436(+62) Br
Valve for ISC wire harness side
I

1.The rotary solenoid type valve for ISC is located in front of
the intake manifold and the intake air bypassing the
throttle valve is directed to the valve for ISC through a
passage. In this way the intake air volume bypassing the
throttle valve is regulated, controlling the engine speed.
The EFI ECU operates only the valve for ISC to perform
idle-up and provide feedback for the target idling speed.

1.When the value is for more than a certain length of time.
(4) TROUBLE AREA
l.Open wire or short circuit for ISC system circuit
2.Valve for ISC
3.EFI ECU
1.Is the valve for ISC operated proper ?
2.1s the harness between the valve for ISC and the ECU proper ?
NOTE
Read the freeze frame data, using the DS-21 diagnosis tester. Because the freeze frame data
records the engine conditions when the malfunction was detected, when troubleshooting the freeze
frame data is useful to determine whether the vehicle was running or stopped, the engine warmed
up or not, the air-fuel ratio lean or rich, etc. at the time of the malfunction.
@ When using DS-21 diagnosis tester or OBD 11generic scan tool:

W 1 . Operation check of valve for ISC.
diagnosis tester to the DLC through the SST.
SST 09991-87404-000
2.Warm up the engine fully.
3.Turn ON the main switch of the DS-21 diagnosis tester.
4.With the engine idling, select the 'ISCYn the 'Actuator
driving'. Execute the ' 5 % open" and "50 % open"
respectively.
5.Does the engine speed increase or decrease in
accordance with the change in the ISC duty ratio (5 %,
50 %)?
poor contact.
NO: Go to w2.
W 2 . Check of power supply voltage of valve for 1%.
1.Turn OFF the main switch of the tester. Turn OFF the IG switch
2.Disconnect the connector of the valve for ISC.
3.Measure the voltage between the terminals 2 (+B) of the wire harness connector and the body
ground when the ignition switch is turned to the ON position.
4.1s the measured value the specified value?

YES: Go to W 3 .
NO: Check the harness and connector between the valve for ISC and the battew, and main relav for
oDen wire and short.
W 3 . Check of input signal of valve for ISC.

1.After warming up the engine fully, turn ON the main switch of the DS-21 diagnosis tester.
2.With the engine idling, select the 7SCVn the Wctuator driving." Execute the '5% open" and "50 %
open7espectively. Measure the voltage between 1 (ISC) and 3 (El).
3.Does the voltage increase or decrease in accordance with the change in the ISC duty ratio (5 %, 50
%)?
YES: Reolace the valve for ISC.
NO: Go to -4.
W 4 . Check of output signal of valve for ISC of ECU.

2.Connect the SST between the EFI ECU connectors and the wire harness connectors
SST 09842-97203-000
3.Warm up the engine. With the engine idling, select the "ISCYn the 'Actuator driving". Execute the '5%
open" and "50 % open' respectively. Measure the voltage between the SST terminals 54 (ISC) and 23
(El).
4.Does the voltage increase or decrease in accordance with the change in the ISC duty ratio (5 %, 50
%)?
YES: Go to W 5 .
NO: Check or re~lace the EFI ECU.
W 5 . Check of harness between valve for ISC and ECU.

2.Disconnect the SST connector at the EFI ECU side.
Valve for ISC connector 1 (ISC) - SST terminal 54 (ISC)
Valve for ISC connector 3 (El) - SST terminal 23 (El)
poor contact. Duty ratio: 5 % Duty ratio: 50 %
NO: Re~airor reolace the harness or connector.
1.When an oscilloscope is used, the ISC control signal
becomes the waveform as indicated in the figure above.
@ When not using DS-21 diagnosis tester or OBD II
generic scan tool:
Dl.Operation check of valve for ISC.
1.Ensure that the engine revolution speed is high during the
cold period. Also, ensure that the engine revolution
speed drops as the engine warms up and that the idle
speed is maintained.
poor contact.
NO: Go to D2.
V2.Check of power supply voltage of Valve for ISC.

2.Disconnect the connector of the valve for ISC.
3.Measure the voltage between the terminals 2 (+B) of the wire harness connector and the body
ground when the ignition switch is turned to the ON position.

YES: Go to D3.
NO: Check the harness and connector between the valve for ISC and the b a t t e ~and
. main relav for
oDen wire and short.
D3. Check of input signal of valve for ISC.

1.Warming up the engine fully.
2.With the engine idling (with the valve for ISC connector disconnected), measure the voltage between
1 (ISC) and 3 (+B) at the harness connector side.
SPECIFIED VALUE: The voltage should be stable at a constant value. (The value of the voltage can
not be specified.)

YES: Reolace the valve for ISC.
NO: Go to D4.
D4. Check of output signal of valve for ISC of ECU.

2.Connect the SST between the ECU connectors and the wire harness connectors.
SST: 09842-97203-000
3.Warm up the engine. With the engine idling (with the valve for ISC connector disconnected), measure
the voltage between the SST terminals 54 (ISC) and 23 (El).
SPECIFIED VALUE: The voltage should be stable at a constant value. (The value of the voltage can
not be specified.)

YES: Go to D5.
[
D5. Check of harness between valve for ISC and ECU.
2.Disconnect the SST connector at the EFI ECU side.
Valve for ISC connector 1 (ISC) - SST terminal 54 (iSC)
Valve for ISC connector 3 (El) - SST terminal 23 (El)
YES: Check malfunction that occurs intermittentlv and Idling condition
poor contact. 1Electrical load "OFF") IElectrical load "ON")
NO: Reoair or replace the harness or connector.
@ CheckIby oscilloscope.
?.When an osciiloscope is used, the ISC control signal
becomes the waveform as indicated in the figure above.
(The duty ratio cannot be specified.)
1-12-19 DTC No. PI300136 ion svstem malfunction
) WIRING DIAGRAM
ACC
IG1
iG2
ST
1 W
To injector
C13E5528ESZI
u
Unit and switch wire harness side
igniter unit wire harness side Igniter unit wire harness side IG COIL wire harness side iG switch
(ECU side) (IG coil side) wire harness side
1 C13E5545Sll

1.This system detects any misfire of the engine by using an ion current which has the same waveforms
as those of the combustion pressure. When any misfire takes place, no ion current is produced.
Therefore, if the input voltage at the ECU side is below a certain value, it is judged that a misfire took
place. Since the detected ion current is very weak, it is amplified in the igniter unit. In addition, a
vibration waveform appears in the ion current waveform when knocking takes place. Hence,
knocking control is also performed by detecting vibration waveforms. This applies only to vehicles
with EU specifications.
B8-116
1.No ion current signal to EFI ECU during cranking or engine is running.
(4) TROUBLE AREA
I.Open wire or short circuit for ion system circuit
2.lgniter unit
3.IG coil
4.Spark plug
5.EFI ECU
1.Is the signal from the igniter unit inputted to the ECU proper ?
2.1s the harness between the igniter unit and the ECU proper ?
3.1s the igniter unit operated proper ?
NOTE
When PI300136 (ion system malfunction) is outputted, both PO300117 (random/multiple cylinder
misfire detected) and PO301117 - PO303117 (cylinders 1 to 3 misfire detected) may be outputted
simultaneously.
@ When using DS-21 diagnosis tester or OBD I1 generic scan tool:

PI.Spark check.
2.Disconnect the connector of the injector.
CAUTION
4 above so as to prevent the catalyst from being
a, Relay block

avoided wherever possible, as this may damage the
injector.
3.Remove the IG coils and spark plugs (all cylinders #1, 2
,3and 4).
4.lnstall the spark plug to the IG coil.
5.Connect the IG coil connector to the IG coil.
7.Crank the engine. at this time, check to see if each spark
plug sparks.
a
No spark takes place in some cylinders. 1 b
Spark takes place in all cylinders. c
a: Go to B2.
b: Go to B3.
c: Go to B7.
WARNING
Sparks will take place. Care must be exercised to the
surrounding combustible objects.
88-1 17
W 2 . Unit check of spark plug.
W 3 . unit check of the spark plug where no spark takes place
1.Perform the unit check of the spark plug for the cylinders where no spark takes place.
YES: Go to Steo D 5
NO: Go to W 4
W4. Spark check again.

1Replace the spark plug. Perform the spark check again.
No spark takes place. a
Sparks take place. b
a: Go to W 5 .
b: Go to w 7 .
WARNING
Never use spark plugs other than those designated.
W 5 . Check of power supply voltage of IG coil.

1.With the IG switch turned OFF, disconnect the connector of the IG coil of each cylinder.
2.With the IG switch turned ON, measure the voltage between the body earth and each of the harness-
side connectors terminal 3 (82) of each IG coil.

YES: Go to W 7 .
NO: Go to W 6 .
D 6 . Check of power supply voltage of IG coil.

1Check the harness, connector and fuse for open wire and short.
3.Disconnect the connectors at the ECU side of the IG switch and ignitor unit
Between connector 2 (IG2) at IG switch side - ignitor unit terminal 1 (61).
Between connector 2 (IGI) at IG switch side - each of terminal 3 (82) each IG coil.
YES: Reolace the IG switch.
NO: Repair or redace the harness or connector. Or reolace the fuse.
W 7 . Check of ignition signal and ion signal.

1.Check that the ignition signal and ion signal are outputted from the EFI ECU and inputted by using an
oscilloscope.
2.With the IG switch turned OFF, perform the restoration.
SST 09842-97203-000
4.Warm up the engine. (only when the engine can start).

5.With the engine idling or cranking, connect the negative (-) probe of the oscilloscope to the SST
terminal 82 (E01) , the positive (+) probe to each of the SST terminals 60 (IGl), 59 (lG2), 58 (IG3)
and 57 (IG4), respectively. Check the ignition signal for all cylinders.
F/F{
6.Pulse waveforms should be confirmed
(1)lgnltlon slgnal (2)lon slgnal wave form
lnd~cat~on for all cylinders

lor one cyl~nder lnd~cat~on
7.As has been done in Step 5 connect the positive (+) and negative (-) probes of the oscilloscope to
the SST terminals 14 (ICMB) and 43 (IE), respectively, and check the ion signal.
SPECIFIED VALUE: Waveforms as shown in the right figure should be obsewed without any
waveform missing.
8.Are the ignirion s~gnaland Ion signal observed?

IWhen sparks take place and the lgnluon signa waveform 1s ooserveo. ts tne Ion stgnal I YES a
I
I
waveform observed?
NO b
I I
When no spark takes place and the ignition signal waveform is observed, and no ion signal waveform is ob- I .,,.
served. I
When no spark takes place and no ignition signal waveform is observed, and no ion signal waveform is ob-
d
served.
a: Check malfunction that occurs intermittentlv and Door contact.

b: Go to D8.
c: Go to D12.
d: Check or reolace the ECU.
W 8 . Check of harness between ECU and ignitor unit.

1.Turn OFF IG switch.
2.Disconnect the SST connector of the EFI ECU.
3.Disconnect the ECU side connector of the ignitor unit.
SST terminal 14 (ICMB) - Harness side 5 (110) terminal of ign~torunit
5.Are the check results for open wrre and short OK?
W 9 . Check of harness between ignitor unit and IG coil.

2.Disconnect the IG coil side connector of the ignitor unit.
3.Disconnect the connector of each IG coil.
(1) Between harness side terminal 1 (I/C) of ignitor unit - Harness side terminals "1" of each IG coil
YES: Go to D l0.
W 1 0 . Unit check of ignitor unit.
YES: Go to W11.
NO: Realace the ionitor unit.
-11. Check of earth circuit of ignitor unit.

1.Measure the continuity between the engine earth and each of harness side terminals 2 (GI) and 8
(G2) of the ignitor unit.
SPECIFIED VALUE: Continuity exists.

YES: Reolace the IG coil. (All cvlinders)
NO: Reaair or realace the harness or connector.
W 1 2 . Check of harness between ignitor unit and IG coil.

3.Disconnect each IG coil and the IG coil side connector of the ignitor unit.
(1) Between harness side terminals Y? of each IG coil and harness side terminals 5 (CI), 4 (C2), 3
(C3) and 2 (C4) of ignitor unit.
YES: Go to W13.
NO: Reoair or realace the harness or connector.
W 1 3 . Check of harness between EFI ECU and ignitor unit

2.Disconnect the SST connector from the EFI ECU.
3.Disconnect the EFI ECU side connector of the ignitor unit.
4.Harness side terminals 7 (Sl),6 (S2). 4 (S3), 3 (S4) and 5 (110) of ignitor unit - SST connector
terminals 60 (IGl), 59 (IG2), 58(1G3), 57 (IG4) and 14 (ICMB).
YES: Go to WO.
NO: Reaair or realace the harness or connector.
1-12-20 DTC No.Pl510154 Starter relay output system
) WIRING DIAGRAM
ACC
lG1
162
- ST
T
Switch wire harness side
C13E5545SlI
. . CIRCUIT DESCRIPTION
(2)
1.The starter signal is manly used to increase the fuel injection volume for the starting injection control
and after-start injection control. While engine is being cranked, the battery positive voltage is applied
to the terminal STA of the EFI ECU.
~~
1.No signal of starter while rising the engine revolution speed to the specified value at the vehicle
stopped state.
B8-121
(4) TROUBLE AREA I
1.Open wire or short circuit for the starter system circuit.

2.EFI ECU
1.1s the harness between the starter and EFI ECU proper ?
Dl. Check of ECU input signal STA.
SST: 09842-97203-000
2.Measure the voltage between the SST connectors 68 (STA) and 82 (€01) under the following
conditions.
1
i
Condition Specified value
Engine being cranked 6 -lOV
After engine has started 0V

NO: Go to D2.
D2. Check of harnesses between IG switch and ECU.

2.Disconnect the connector of the IG switch.
3.Disconnect the SST connector at ECU side
Connector 6 (STA) at IG switch side - Connector 68 (STA) at ECU side.
NO: ReDair or re~lace the harness or connector.
1-12-21 DTC No.P1520/51 Switch signal
- circuit malfunction
I) WIRING DIAGRAM
ACC
IR1
T lG7
ST
I - MAIN
I Linear
throttle
sensor
Sensor and switch wire harness side
VC E2 VTH +B BLW ACSW
Linear throttle sensor

wire harness side AIC SW wire harness side

?.This is used as the normal state judging code for the switch system. While the terminal T is ON, if the
idle switch becomes OFF or the air conditioner becomes ON, the DTC is outputted. However, the
DTC is diagnosed only when the terminal T is ON. No memorization is made.
(3) TROUBLE AREA
1.Open wire or short circuit for the air conditioner system circuit
2.AlC switch
3.0pen wire or short circuit for the linear throttle sensor system circuit
4.Linear throttle sensor
5.EFI ECU
1 .Is the signal from the air conditioner switch inputted to the EFI ECU proper ?
2.1s the harness between the air conditioner switch and EFI ECU proper ?
3.1s each switch for the air conditioner operated proper ?
NOTE
If DTC PO110143 P0115142, PO120141 are output simultaneously, E2 (Sensor Ground) may be
open.

Dl. Check of input signal by A/C switch and idle switch to
ECU.
1.Turn OFF the IG switch. Connect the DS-21 diagnosis
tester to the DLC through the SST.
SST: 09991 -87404-000
2.Turn ON the IG switch. Turn ON the main switch of the
tester. Check the signals of the A/C switch and idle
switch. (As for the operation, refer to the instruction
manual of the DS-21 diagnosis
- tester.)
AIC switch
r OFF
i A/C signal indication
OFF
-
Throttle valve
-
Fully closed
Fully opened
IDL signal indication
ON
OFF 1
poor contact.
NO: Go to w2.
D2. Check of hamesses between N C switch and ECU and between linear throttle sensor and ECU.
SST 09842-97203-000
CAUTION

(1) AIC switch
Switch side connector 4 (ACSW) - ECU side connector 38 (ACSW)
(2) Linear throttle sensor
Sensor side connector 2 (E2) - ECU side connector 17 (E2)
Sensor side connector 3 (VTH) - ECU side connector 44 (VTH)
Sensor sde connector 1 (VC) - ECU side connector 16 (VC)
YES: Go to D3.
D3. Unit check of N C switch and liner throttle sensor.

NO: Re~lace the AIC switch or liner throttle sensor.
Dl. Check of ECU input signal.
SST: 09842-97203-000
2.With the IG switch turned ON, measure the voltage between SST 16 (VC) and 17 (E2), between 44
(VTH) and 17 (E2), between 38 (ACSW) and 23 (El).
16 (VC) - 17 (E2) 4.5-5.5 V
-
44 (VTH) 17 (E2) When throttle lever is changed from full ciose state to full open state, voltage should
increase proportlonaliy from 0 to 4.8 V.
38 (ACSW) - 23 (El) When A/C switch is ON. Battery voltage
When AIC switch is OFF. 0-0.5 V

NO: Go to D2.
W2. Check of harness between linear throttle sensor, AIC switch and ECU.
?.Turn OFF the IG switch. Disconnect the SST connector from the ECU.
(1) Linear throttle sensor
Sensor side connector 2 (E2) - ECU side connector 17 (E2)
Sensor side connector 3 (VTH) - ECU side connector 44 (VTH)
Sensor side connector 1 (VC) - ECU side connector 16 (VC)
(2) AIC switch
Switch side connector 4 (ACSW) - ECU side connector 38 (ACSW)
i
1-12-22 DTC No.Pl530144 Air conditioner evaporator temperature sensor circuit malfunction
(1) WIRING DIAGRAM
r
EFI ECU
I
13 (FAN1)
(ACEV) 72
12 (MGC) 5$ ;- -;
Air conditioner temDerature sensor wire harness side
ACEV
D E 2 1
1 C13E5545SlO

1.This circuit, located at the rear of the evaporator of the air
conditioner unit, detects the temperature of the air
passing through the evaporator. A thermistor is
incorporated in the sensor. This thermistor has -E l , \
m
characteristics that its resistance decreases as the 2

temperature rise, while the resistance increases as the
0
temperature drops. When the temperature becomes O"C, -10 o 10 20
the thermistor disengages the magnet clutch through the A/C evaporator temperature [°C]L2,E3852ET10
MGC relay, thus preventing frosting.
1.When the engine starts, the air conditioner evaporator temperature sensor value is more than 4.85 V
or less than 0.1 V for more than a certain length of time.
(4) TROUBLE AREA
1.Air conditioner (A/C) evaporator temperature sensor
2.0pen wire or short circuit for the air conditioner evaporator temperature sensor
3.EFI ECU
1.Is the signal from the A/C temperature sensor inputted to the EFI ECU proper ?
2.1s the harness between the AIC evaporator temperature sensor and EFI ECU proper ?
3.1s the output of the N C evaporator temperature sensor proper ?
NOTE
B8-128
Dl. Check of ECU output voltage.
SST: 09842-97203-00097203-000
2.With the IG switch turned "ON" measure the voltage between the SST connector 72 (ACEV) and 29
(E21).
SPECIFIED VALUE: 0.1 - 4.8 V (Varies, depending upon the temperature.) (Reference: 1.8 - 2.9 V
at 20°C)

YES: Check malfunction that occurs interrnittentlv and Door contact.
NO: Go to D 2
D2. Check of harness between N C evaporator temperature sensor and ECU.

1.With the IG switch turned OFF, d~sconnectthe SST connector from the ECU
Harness side connector 1 (ACEV) of sensor - ECU 72 (ACEV)
Harness side connector 2 (E21) of sensor - ECU 29 (E21)
YES: Go to D3.
NO: Rewair or replace the harness or connector.
D3. Unit check of N C evaporator temperature sensor.

YES: Check or rewlace the EFI ECU.
NO: Rewlace the A/C evaworator temDerature sensor
..
1-12-23 DTC No.Pi560161 ECU back UD Dower source circuit malfunction
I) WIRING DIAGRAM
ACC
IG1
IG2
ST
To lniector
Wire harness side
+B
A
BAT
Connector B Connector C
C13E5538ES10
u
C13E5h45S18
(2)
1.The battery positive voltage is supplied to the terminal BAT of the EFI ECU even when the ignition
switch is OFF for use by the DTC memory and air-to-fuel ratio adaptive control valve memory, etc.
(3) TROUBLE AREA
1.Open wire or short circuit for the back-up power supply system circuit.
2.EFI ECU
1.If the MIL is not illuminated when the ignition switch is turned ON, it is not to supply the power sauce
to the EFI ECU.
NOTE
a When not using DS-21 diagnosis tester or OBD I1 generic scan tool:
W1. Check of ECU backup power supply voltage.
SST 09842-97203-000
2.With the IG switch turned OFF, measure the voltage between the SST connector 1 (BAT) and the body
ground.

YES: Check malfunction that occurs intermittentlv and ooor contact.
NO: Go to w2.
w2. Check of harness between relay block and ECU.

1.With the IG switch turned OFF, disconnect the SST connector from the EFI ECU,
2.Remove the harness from the battery positive terminal.
Harness side connector B-20 (BAT) of the relay block - ECU 1 (BAT)
Stud bolt of the relay block and the battery positive terminal.
YES: Go to D3.
NO. Reoair or reolace the harness or connector.
w3. Unit check of EFI fuse.

1.Remove the EFI fuse from the relay block.
2.Check continuity of the EFI fuse.
SPECIFIED VALUE: Continuity should exist.
NO: Reolace the EFI fuse.
1-12-24 DTC No.PI600183 Immobilizer signal circuit malfunction
r-
Antenna
(IG switch)
Immobilizer
.
ECU wire harness side
I
L
1.This circuit performs collation and updating of the rolling code in the communication between the
immobilizer ECU and the EFI ECU. The engine can start only when the collation and updating of the
rolling code can be done. The rolling code is collated and updated by reading out or writing to non
volatile memory (E2PROM) of both ECUs.
1.When the engine starts, the rolling code can not reading out or writing to the EFI ECU.
I (4) TROUBLE AREA
I.EFI ECU
O When using DS-21 diagnosis tester or OBD I1generic scan tool:
*I. Re-confirmation of DTC.
diagnosis tester to the DLC through the SST.
SST: 09991-87404-000
2.Turn ON the IG switch, and turn ON the main switch of the
tester. Erase the DTC. (As for the operation, follow the
instruction manual of the DS-21 diagnosis tester.)
3.Turn OFF the main switch of the tester. Turn OFF the IG
switch.
4.Turn ON the IG switch. Turn ON the main switch of the
tester.
(
5.Check the DTC.
6.1s PI600 indicated?
YES: Replace the EFI ECU.
NO: Check or replace the EFI ECU.
@ When not using DS-21 diagnosis tester or OBD I1
generic scan tool:
*I. Reconfirmation of DTC.
1.With the IG switch turned OFF, connect the DS-21 diagnosis tester to the DLC through the SST.
SST: 09991-87404-000
2.Connect the EFI-T terminal and the earth terminal of the

SST connector with a jump wire.
SST 09991-87403-000
3.Remove the EFI fuse. Erase the DTC. (As for the erasing
method.)
4.Set the EFI fuse to the original position.

5.Turn ON the IG switch.
6.Check the DTC. (Read out the flashing pattern of the
MIL.)
7.1s "83" indicated?
YES: Redace the EFI ECU.
NO: Check or re~lace the EFI ECU.
1-12-25 DTC No.Pl601181 Immobilizer signal
- malfunction
I) WIRING DIAGRAM
IG swltch
EFI ECU
(5102)
5
,
DLC
Antenna
IIG switch)
Immobilizer ECU wire harness side
C13E5E40S10

1.When the ignition switch is turned ON, communication starts between the immobilizer ECU and EFI
ECU. The engine can start only when the communication between the two ECU is possible and the
rolling codes are matched. In order cases, fuel injection and ignition are prohibited, thus making
engine starting impossible.
1.When the engine starts, the rolling codes are not matched.
(4) TROUBLE AREA
I.Open wire or short circuit for the immobilizer system circuit
2.lmmobilizer ECU
3.EFI ECU
When not using DS-21 diagnosis tester or OBD II generic scan tool:
W1. Check of harness between immobilizer ECU and EFI ECU.
SST 09842-97203-000
CAUTION
Do not connect the SST connector to the EFI ECU.
2.Disconnect the immobilizer ECU connector.

3.Check the harness and connector for open wire or short, with the IG switch turned OFF.
Connector 8 (S101) at immobilizer ECU harness side - SST terminal 8 (S101)
Connector 7 (S102) at immobilizer ECU harness side - SST terminal 5 (S102)
YES: Go to D2.
W2.Check of immobilizer system (1).

1.Connect the connector of the immobilizer ECU.
2.Replace the EFI ECU with a new one. Connect the SST connector to the EFI ECU
3.Start the engine with the master key.
NO: Go to D3.
Master key
(black) c13E5567ET1
w3.Check of immobilizer system (2).

1.Replace the immobilizer-ECU with a new one, with the IG switch turned OFF.
2.Connect the SST to the DLC.
SST: 09991-87404-000
3.Connect the ECU-T and the earth terminal of the SST \\ I

connector with a jump wire.
SST: 09991-87403-000
4.Start the engine with the master key.
YES: Check the IG kev. antenna coil, etc. (Refer to
section BODY ELECTRICAL SYSTEM.)
NO: Check or reolace the immobilizer ECU. (Refe
section BODY ELECTRICAL SYSTEM3
-
~ a a ,i
1-12-26 ECU Power Source Circuit
I) WIRING DIAGRAM
IG switch
ACC
IG1
162
ST
EFI ECU
1 1 (BAT)
23 ( E l )
82 (E01)
7 (+Bl)
36 ( f B 2 )
L L
To Injector ~ 1 3 ~ ~ 4 ~ ~ 2 1
Switch wire harness side
C13E5542ESlO

I
*I. Check of power supply voltage of ECU.
SST: 09842-97203-000
2.With the IG switch turned ON, measure the voltage

- between the SST connectors 7 (+B1), 36 (+B2)
through 82 (E01).
SPECIFIED VALUE: Batte~yvoltage

NO: Go to D2.
W2. Check of harness between relay block and ECU.

i 1.With the IG switch turned OFF, disconnect the SST connector from the EFI ECU.
2.Disconnect the harness from the battery positive terminal.
Connector C-18 (FC2) of the relay block at the harness side and the SST terminal 7 (+Bl) and 36
(+B2)
Stud bolt of the relay block and the battery positive terminal.
YES: Go to -3.
NO: Reaair or reolace the harness or connector.
W3. Unit check of EFI main relay.

1.Disconnect the EFI main relay from the relay block
2.Perform the check.
YES: Go to w4.
NO: Redace the EFI main replay.
m4. Unit check of IG switch.

1 .Disconnect the connector from the IG switch.
2.With the IG switch disconnected, check continuity
between the terminals given below.
Terminal No. to continuity
1-2-3-4
START 1-2-4-5
j
3.Are the check results OK? 1 C13E556111
YES: Go to D5.
NO: Reulace the ianition switch.
I t
W 5 . Check of harness between IG switch, relay block and body ground.
1.Check the harness and connector between the IG switch, relay block and the body ground for open
wire or short.
YES: Go to W6.
NO: Re~air or reolace the harness or connector.
D6. Unit check of EFI fuse.

1.Disconnect the EFI fuse from the relay block.
2.Check the EFI fuse for continuity.
NO: Reolace the EFI fuse.
1-12-27 Fuel Pump Control Circuit
1) WIRING DIAGRAM
Wire harness side
+B
A
BAT
C13E5542ESlO

I
W1. Operation check of fuel pump.
?.With the IG switch turned OFF, connect the DS-21 diagnosis tester to DLC through the SST.
2.After turning ON the IG switch, turn ON the main switch of the tester. Select the actuator driving.
3.Select the fuel pump ON so as to actuate the fuel pump. (If the DS-21 diagnosis tester is not
available, connect a jump wire between the EFI-terminal of the DLC and the earth terminal.)
4.Ensure that the screw of the pulsation damper rises in
Step 3.
YES: Go to W2.
NO: Check malfunction that occurs intermittentlv or o w r
contact.
W 2 . Check of power supply circuit of EFI ECU.

1.Perform the check according to the trouble-shooting of the ECU power source circuit.
YES: Go to D O .
W3. Unit check of fuel pump relay.

1.With the IG switch turned OFF, disconnect the fuel pump
relay from the relay block.
2.Perform the check.
YES: Go to DO.
NO: Reolace the fuel ourno relav.
W 4 . Check of voltage at the terminal FC2 of EFI ECU.

SST 09842-97203-000
2.Turn ON the IG switch.

3.Measure the voltage between the SST connector 30 (FC2) and the body ground.

YES: Go to D5.
NO: Check the harness and connector between the relav block and the EFI ECU for oDen wire or
short.
I W 5 . Unit check of fuel pump.
YES: Go to W 6 .
NO: Repair or replace the fuel oumo.
W 6 . Check of harness between relay block and fuel pump.

Relay block - Fuel pump
Fuel pump - Body earth
NO: Reuair or reolace the harness or connector.
1 WIRING DIAGRAM
ACC
IG1
162
ST
EFI ECU
(EO1) 82
vsv for boost pressure control ' 30 (FC2)

)
- 12-
T e ? E Y
p ao cvsvi)
+B@vs:
VSV for boost pressure control wire harness side
(2)
1.The computer controls the supercharging pressure according to the input from the pressure sensors,
the vehicle speed signals and the engine revolution speed.
2.This control is carried out by changing the pressure of the actuator chamber of the waste gate valve
through the duty control over turning ON and OFF of VSV. The control is classified into two methods:
All closed control and the feedback control.
(3) TROUBLE AREA
1.VSV for boost pressure control
2.0pen wire or short circuit for the VSV for boost pressure control system circuit
(4)POINTS OF INSPECTION
1.Are the hoses of the boost pressure control system normal?
2.1s the valve for waste gate operated proper ?
3.1s the power supply voltage of VSV for boost pressure control proper?
4.1s the harness between the purge VSV for boost pressure control and the ECU proper?
5.1s the VSV for boost pressure control operated proper ?
Dl. Check of the hose for boost pressure control system.
1.Check the hoses of the boost pressure control system for disconnection and damage.
YES: Go to D2.
D2. Operation check of valve for waste gate.

YES: Go to D3.
NO. Reolace the turbocharaer SIA.
D3. Check of power supply voltage of VSV for boost pressure control.
1.Disconnect the VSV for boost pressure control system connector.
2.With the IG switch turned ON, measure the voltage between the connector 2 (+B) at VSV for boost
pressure control harness side and the body ground.
YES: Go to D4.
Check or reoair the harness between b a t t e ~
and VSV for boost pressure control.
D4. Check of harness between ECU and VSV for boost pressure control.
1.Check continuity of the between the terminals given below.
Connector 80 (VSVI) at VSV for boost pressure control harness side - connector 2 (+B) at ECU
side.
YES: Go to D5.
NO: Repair the harness or connector.
D5. Check of VSV for boost pressure control.

1.Carry out unit check of VSV for boost pressure control
YES: Go to D6.
NO: Reolace the VSV for boost oressure control.
D6. Check of connectins condition of each connector

Check of circuit of EFI ECU.
NO: Reoair the connector.
1-13 UNIT CHECK
1-13-1 ENGINE REVOLUTION SENSOR
I .Connect the SST.
SST: 09842-97203-000
2.Measure the output voltage between the terminals for the

engine revolution sensor during cranking, using the
oscilloscope.
3.Measure the resistance between the terminals or engine

-
revolution sensor proper.
SPECIFIED VALUE: 1100 _f 150Q (at 20°C)
1-13-2 ENGINE COOLANT TEMPERATURE SENSOR

I .Measure the resistance between the terminals for sensor
Engine coolant temperature sensor
Temperature ('C) / -20 1 20 1 80 1 110
Resistance ( k ~ ) 1 15.06 1 2.44 1 0.31 1 0.14
I
I Thermister for EFl
:-I--" ', temperature
Thermister for water
meter
- LllE7065ETll
1-13-3 INTAKE AIR TEMPERATURE SENSOR

1.Measure the resistance between the terminals for sensor.
Intake air temDerature sensor
Temperature ('C) / -30 / -20 1 20 1 80 / 120
Resistance(kC2) 1 (28.6) 1 16.2 1 2.45 ! 0.33 1 (0.18)
B8-144
, 1-13-4 OXYGEN SENSOR
1.Measure the resistance between the terminal of OXHl
and +B
SPECIFIED VALUE: 5.6%B(20&1 OC)
2.Confirm the continuity exists between the following
terminals.
Oxygen sensor body - Terminal of the OX1
Oxygen sensor body - Terminal of the E2
Oxygen sensor body - Terminal of the OHX1
Oxygen sensor body - Terminal of the +B
OX1 - OXH1
0 x 1 - +B
€2 - OXH1
E2 - +B
SPECIFIED VALUE: No continuity exists
CAUTION
Confirm the output voltage for the oxygen sensor on
the vehicle.
1-13-5 KNOCK SENSOR
1.Confirm that the no continuity exists between the knock
sensor body and each terminals.
2.Connect the SST.
SST 09842-97203-000
3.Measure the output voltage between the terminal of KNK

and Elat the SST, using the oscilioscope.
4.Start the engine, confirm that the waveform exists at idling
and racing by using the oscilloscope.
1-13-6 LEANER THROTTLE POSITION SENSOR
1.Measure the resistance between the terminal of VC and
E2.
SPECIFIED VALUE: 2.5 - 6.0kB
2.Measure the change in resistance between the terminal of
VC and E2.
SPEClFlED VALUE: The resistance value should increase
in proportion to be the opening degree
of the throttle lever.
NOTE
When the throttle lever is fully closed, the resistance
value should be about 0.4 k 8 .
Throttle valve
* When the throttle lever is fully opened, the resistance opening angle
value should be about 3.4 k 8 .
1-13-7 VSV for boost pressure control connector

1.Perform continuity check between ports.
SPECIFIED VALUE: No continuity should exist.
2.With a voltage applied to the VSV for boost pressure
control connector terminals, perform continuity check
between ports.
3.Measure the resistance value between the terminals.
SPECIFIED VALUE: Approx. 3262 at 20'C JME7091T10
1-13-8 VSV for evaporative emission control system

purge system
1.Perform continuity check between ports.
SPECIFIED VALUE: No continuity should exist.
2.With a voltage applied to the VSV for evaporative
emission control system purge system connector
terminals, perform continuity check between ports.
3.Measure the resistance value between the terminals.
SPECIFIED VALUE: Approx. 328 at 20°C
B8-146
f 1-13-9 MAIN RELAY & FUEL POMP RELAY
1.Turn ON the IG switch. Check to see if the relay is
functioning through sound and vibration.
CAUTION
The relay may be very hot through its operation. Do not
touch it with your hand.
2.Measure the resistance between the terminals 1 and 3.
SPECIFIED VALUE: 131 - 23052 at 20'C
CAUTION
@
WllW059T10
The measurement should be conducted after the relay
unit has been soaked at least one hour in an ambient
temperature of 0°C to40°C.
3.Ensure that no continuity exrsts except between terminals
1and 3.
4.Apply the battery voltage between 1 and 3. Ensure that
continuity exists between terminals land 3.
1-13-10 IGNITOR UNIT
1.Measure the resistance between terminals given below
1-13-11 INJECTOR
WARNING
Utmost care must be exercised so that no fire is brought close to the working area during the
operation.
Be sure to place a cloth or the like so that no fuel may splash.
1.Rernove the injector to be checked.

CAUTION
After the removal, install another injector.
2.Disconnect the fuel hose from between the fuel inlet pipe and the fuel pipe.
3.Set the injector to be checked on the fuel hose that has
been removed, using the SST (sub-harness, measuring
tool, EFI inspection wire).
SST 09842-87502-000
09268-41047-000
09991-87404-000
4.Short the terminals SST30 (FC2) and 23 (El).With the IG
switch turned 'ON', drive the fuel pump.
5.Apply the battery voltage to the injector for 15 seconds.
At this time, measure the injection amount.
SPECIFIED VALUE: 44 - 56cc
CAUTION
Be sure to perform the "ON" and "OFF" operations at
the batte~yside.
6.Remove the battery under the injection amount checking
condition. Measure the leakage amount from the injector
for one minute.
SPECIFIED VALUE: One drop or less
7.Measure the resistance across the injector terminals.
SPECIFIED VALUE: 1 2 8 at 20%
99 EMISSION CONTROL SYSTEM
JB B9 - 1
EXHAUST EMISSION PURIFICATION
SYSTEM B9- 1
PURPOSE OF SYSTEM----------------- B9 - 1
SCHEMATIC DIAGRAM 89 - 3
LOCATION OF COMPONENTS--------- 89 - 5
ARTICLES TO BE PREPARED--------- B9 - 6
AIR-TO-FUEL RATIO CONTROL
DEVICE B9 - 6
IGNITION TIMING CONTROL
DEVICE B9 - 6
CONTROL DEVICE DURING
DECELERATION B9 - 6
FUEL EVAPORATIVE EMISSION
CONTROL SYSTEM........................ B9 - 7
JB
1 EXHAUST EMISSION PURIFICATION SYSTEM
1-1 PURPOSE OF SYSTEM
For EU Specifications
Device name 1
Device method
Catalyst device 'hree-way catalyst IMonolith catalyst I Reduction of CO. HC and
(0.55 litter /NOX.
Air-to-fuel ratio control device ilectronically-controlledfuel /Injector IReduction of CO, HC and
~jectionmethod Oxygen sensor (with a heater) NOx.
Rear oxygen sensor (with a The air-to-fuel ratio of the mix
heater) ture sucked into the combus-
Computer for control tion chamber is controlled
Operation control devices: approximately to the
Linear throttle sensor, pres- stoichiometric air-to-fuel ratio
Sure sensor, coolant tempera- so that the three-way catalyst
lure sensor, intake air tem- can exert the best emission
perature sensor, engine revo- control performance. Purpose
lution sensor and function.
7
Ignition timing control device lectronic control method Computer for control
Operation control devices:
Reduction of NOx.
An ignition timing control best
Pressure sensor, coolant tern- suited to the running condi-
perature sensor, linear hrottle tions is performed.
sensor, engine revolution sen-
sor, ignitor unit or knock sen-
sor
Injector Reduction of CO and HC dur-
Computer for control ing deceleration.
Operation control devices: Improvement of fuel consump
Engine revolution sensor, lin- tion.
ear throttle sensor Prevention of overheating of
catalyst.
Fuel cut during deceleration is
performed by the control de-
vices.
anister method Charcoal canister Fuel evaporative emission
control device 0.6 liter control device.
VSV for evaporative emission
purging
ICheck valve
Blow-by gas recirculation de- osed type (ventilationhose /Reductionof CO and HC.
vice PCV valve The blow-by gas is burnt
again to reduce CO and HC
or Aus Specifications
Device name
:atalyst device
0.55 litter Nox.
\ir-to-fuel ratio control devicc :lectronically-controlledfuel Injector Reduction of CO, HC and
ijection method Oxygen sensor (with a heater) NOx.
Rear oxygen sensor The air-to-fuei ratio of the mi)
Computer for control ture sucked into the combus.
Operation control devices: tion chamber is controlled
Linear throttle sensor, pres- approximately to the
sure sensor, coolant tempera- stoichiometric air-to-fuel ratio
ture sensor, intake air tem- so that the three-way catalysl
perature sensor, engine revo- can exert the best emission
lution sensor control performance. Purpost
Operation control devices: An ignition timing control bes

Pressure sensor, coolant tem- suited to the running condi-
perature sensor, linear hrottle tions is performed.
sensor, engine revolution sen-
sor, knock sensor
:ontrol device during decel- Injector Reduction of CO and HC dur.
?ration Computer for control ing deceleration.
Operation control devices: Improvement of fuel cons urn^
Engine revolution sensor, lin- tion.
ear throttle sensor Prevention of overheating of
catalyst.
Fuel cut during deceleration i!
performed by the control de-
vices.
:uel evaporative emission mister method Charcoal canister Fuel evaporative emission
:ontrol device 0.6 liter control device.
VSV for evaporative emission
purging
Check valve
Now-by gas recirculation de- 3sed type Ventilation hose Reduction of CO and HC.
ice PCV valve The blow-by gas is burnt
again to reduce CO and HC
1-2 SCHEMATIC DIAGRAM
For EU S~ecifications
Engine revolution sensor

I
b
Check valve
Charcoal canister
11 Rear oxygen sensor (with heater) I 1 111

i
For Aus Specifications
II Engine revolution sensor

I
b
Check valve
Charcoal canister
or EU Specifications
-Engine revolution sensor

(Ignition timing control system)
(Fuel evaporative emission control)
VSV for evaporative emission control system purge control
Rear 0 2 sensor (With heater)
-Blowby gas hose (Blowby gas measure)
lr Aus Specifications
r Engine revolution sensor (Ignition timing control system)
rManifold
, ,
absolute pressure sensor
Electronic fuel injection system
(Air-to-fuel ratio control system)
(Control system during deceleration)
I I
L ~ l o w gas
b hose
~ (Blowby gas measure)
I
SST
09991-874M-000
(09991-87401-000)
,a" 09991-87402-000 Wire, tacho-pulse pick up
Instrument
~~achometer,~lectr~cal
Tester,T~mmglight,
1-5 AIR-TO-FUEL RATIO CONTROL DEVICE

1-6 IGNITION TIMING CONTROL DEVICE

<The electronically-controlled method>
1-6-1 FUNCTION CHECK
1-7 CONTROL DEVICE DURING DECELERATION

<Fuel cut device>
1-7-1 FUNCTION CHECK
1.Connect the tachometer to the 8 (REV) terrnmal of DLC by usmg the SST.
SST 09991-87404-000
09991-87402-000
CAUTION
If not using the SST, remove the DLC from the vehicle. Afterfinish the operation, fix the DLC to the
bracket properly.
2.Warrn up the engine.

3.Using a sound scope, check each injector for operation sound.
4.Rise the engine speed to 3000 rpm.
5.When the throttle lever is released, confirm that the operation sound of the injector is stopped at a
moment and reach the operation sound again.
1-8 FUEL EVAPORATIVE EMISSION CONTROL SYSTEM
Canister method
8-1 SCHEMATIC DIAGRAM
( Computer 1
0 Check valve
rJ
[
canister Fuel tank ]
L
1-8-2 UNIT INSPECTION

(1) Charcoal canister
1.Visually inspect the charcoal canister case for cracks or
damage.
2.Check of charcoal canister for air leakage
( I ) Continuity check between the port at fuel tank side
and at atmospheric side. Apply the posftive pressure
4.41 kPa (0.045 kgf/cm2) to the port at fuel tank side
~ t m o s ~ h & iport
c -
while the purge port is plugged by your finger.
SPECIFIED VALUE: Continuity exists between the port at
fuel tank side and at atmospheric side.
(2) Continuity check between the port at fuel tank side
and at the atmospheric port side. Apply the negative
pressure 1.96 kPa (0.020 kgf/cm2)to the port at fuel
tank side while the purge port is plugged by your
finger.
SPECIFIED VALUE: Continuity exists between the port at
fuel tank side and the atmospheric port
side.
(3) Continuity check between the purge port and at
atmospheric port. Apply the negative pressure 1.96
kPa (0.020 kgf/cm2) to the purge port side while the
port at fuel tank side is plugged by your finger.
SPECIFIED VALUE: Continuity exists between the purge
port side and the atmospheric port
side.
(4) Continuity check the port at fuel tank side. Apply the
negative pressure 19.6kPa (0.199 kgf/crn2) to the
port at fuel tank side while the purge port side and
the atmospheric port side are plluged by your finger.
SPECIFIED VALUE: There is no leakage.
- B9-8
(2) Inspection of VSV for EVAP
610 IGNITION SYSTEM
JB ---- B10-1
-
IGNITION SYSTEM .................... ------ B10 1
SYSTEM DIAGRAM-------------- B10-1
SPARK PLUG.................................. 810-1
REMOVAL AND INSTALLATION ------ B10 - 1
JB
1 IGNITION SYSTEM
1-1 D37BSE2B1001-0000
I
Engine 1630
control
computer1649
C13E32MESZI
2 SPARK PLUG
Instrument

1.Disconnectthe battery negative terminal.
CAUTION
L
%Non-reusable parts
Unit:N.m(kgf.crn)
1 a Cover S/A,engine upper 6 f Plug,spark
2 b P~pe,airbypass
3 c Hose,air bypass
A 4 d Valve Ay,air bypass
5 e Coil Ay(Coil Ay,W/ignitor)
2-1-4 INSPECTION
(I) IGNTION COIL
Check to see if the ignition coil is satisfactory or not by conducting the check of the ignition system
Refer to Page 88-96
(2) SPARK PLUG

Refer to Page 81-2.
(1) AIR BYPASS VALVE AY
1.lnstall the air bypass valve assembly. Install the hose, as

2.Check of charcoal canister for air leakage
B11 STARTING SYSTEMICHARGING SYSTEM
JB 811 - 1
STARTING SYSTEM...................... 611 - 1
SYSTEM DIAGRAM 811 - 1
STARTER ------------ 611 - 2
REMOVAL AND INSTALLATION----- 611 - 2
CHARGING SYSTEM ....................... 611 - 4
SYSTEM DIAGRAM 611 - 4
IN-VEHICLE CHECK...................... 611 - 4
ALTERNATOR B11 - 6
REMOVAL AND INSTALLATION------- 611 - 6
JB
1 STARTING SYSTEM
-1 SYSTEM DIAGRAM
2 STARTER
7 Remove the battery negative terminal.
CAUTION

) COMPONENTS
%Nan-reusable parts
Unit:N.rn{kgf.crn)
1 Starter Ay
2-1-3 INSPECTION
(1) POINT TO BE OBSERVED AND TERMINAL
POSITIONS
CAUTION
Make sure to perform each check in a short length Of
time (three to five seconds).
(2) OPERATION CHECK
CAUTION
A large current will flow during the test. Hence, be
certain to employ a heavy lead wire.
1.Secure the starter with a vice etc.
2.Perform wiring to the cable and tester, as indicated in the
figure. (At this time, do not connect the wire for the
terminal @ .)
3.Connect the terminal @ . Ensure that the pinion gear
jumps out and turns.
4.Disconnect the terminal @ . Ensure that the pinion gear
stops its turning and returns to the original position.
(3) NO-LOAD TEST
CAUTION
A large current will flow during the test. Hence, be
certain to employ a heavy lead wire.
1.Secure the starter with a vice etc.
2.Perform wiring to the cable and tester, as indicated in the
figure. (At this time, do not connect the wire for the
terminal @ .)
3.Connect the terminal @ . When the ammeter reading has
stabilized, take the reading of the ammeter.
SPECIFIED VALUE: 50A or less (Standard specification
vehicle)
90A or less (Cold region specification
vehicle)
3 CHARGING SYSTEM
3-1 SYSTEM DIAGRAM
I
I CllE1015ES21
3-2 IN-VEHICLE CHECK

3-2-1 PRE-CHECK
1.After conducting the checks given below, carry out the in-vehicle check.
(1) Check the battery terminals for connecting state.
(2) Check the deflection amount of the V-belt.
Refer to Page 81-3.
(3) Check the fuse.

(4) Check the wiring.
(5) Check that the alternator emits abnormal noise while the engine is running.
3-2-2 NO-LOAD TEST
1.Connect a tester to the harness connected to the terminal
B in the right figure.
2.Gradually raise the engine speed u p to 2500 rpm.
Measure the current.
SPECIFIED VALUE: 10A or less (25°C)
3.Measure the battery voltage at this time.
SPECIFIED VALUE: 14.2-14.8V(25'C)
B11-5 . .
i
3-2-3 LOAD TEST
1.Under the conditions of the no-load test , turn ON the high beams of the headlamps and set the
heater blower switch to the high position.
2.Gradually raise the engine speed up to 2500 rprn. Measure the current.
SPECIFIED VALUE: 30A or more
NOTE
It should be noted that the charging current may become smaller when the battery is in a fully
charged state. Therefore, replace the present battery with a battery that has been discharged to
some extent or increase the electrical load (hazard lamps or defogger etc.) Carry out the
measurement again.
4 ALTERNATOR
SST
09286-87701-000
bar, alternator adjuster
(09286-87201-000)
09628-00011-000 Puller, tie-rod end

(09611-87701-000)
, Instrument
l ~ o r q u ewrench

1.Rernove the battery negative terminal.
CAUTION
2.Rernove the right front tire.

1) COMPONENTS
%Nan-reusable parts
Unit:N.rn(kgf.crn)
A 1 a Belt V(For alternater use)
r A 2 b Alternater Ay

(1) ALTERNATOR AY
1.Disconnect the ball joint section of the suspension lower
arm S/A from the steering knuckle, using the SST.
CAUTION
When setting the SST, install a dummy nut to the
threaded section of the lower arm so as to prevent the
threaded section from being damaged.
* Hang the SST with a cord.
Be very careful not to damage the ball joint dust cover.
SST 09628-00011-000
2.Disconnect the alternator assembly.
3.Remove the attaching bolts of the alternator assembly.
4.Take out the alternator assembly by passing it through the
gap between the right fender apron and the front frame.
NOTE
Turning the right front wheel to the lefi will facilitate this
removal operation.
(1) ALTERNATOR AY
~ ~
1.Install the alternator assembly by passing it through the gap between the right fender apron and the
front frame. Then, tighten the bolts temporarily.
NOTE
Turning the right front wheel to the left will facilitate this removal operation.
2.lnstall the connector of the alternator assembly.

3.lnstall the tie rod end to the steering knuckle. Tighten the nut to the specified torque.
(2) V-BELT (FOR ALTERNATOR USE)
1.Install the V-belt. Adjust the tension of the belt.
Refer to Page 61-3.

l.lnstal1 the right front tire.
B12 ENGINE MOUNTING
ENGINE MOUNTING FRONT

INSULATOR --------------------- ---- -
812 1
REMOVAL AND INSTALLAT10N -
B12 1
ENGINE MOUNTING LEFT
INSUWR -
812 3
REMOVAL AND INSTALLATION -
B12 3
ENGINE MOUNTING REAR
INSULATOR................................... B12 - 5
REMOVAL AND INSTALLATION ------ I312 - 5
BIZ-1
1 ENGINE MOUNTING FRONT INSULATOR
Instrument
l~orquewrench
/wooden block

Refer to Page 12-2.

3.Remove the front floor center brace S/A.
4.Remove the bolts connecting the exhaust pipe with the exhaust manifold. Move the exhaust pipe.
Refer to Page 83-2.


) COMPONENTS
Unit:N.m(kgf .cm)
r A 1 a Insulator S/A, engine mounting, front
(1) ENGINE MOUNTING FRONT INSULATOR SIA
1.Place a garage jack at a connecting point between the engine assembly and the transaxle assembly
so as to sustain it.
CAUTION
When applying a garage jack, interpose a wooden
block or cloth so as not to cause any scratch.
2.Remove the bolts connecting the engine mounting front
insulator S/A with the engine mounting front right bracket.
3.Lift up the engine assembly and transaxle assembly,
using the garage jack.
4.Remove the engine mounting front insulator SIA.
1-1-5 INSPECTION
Replace any insulator that exhibits cracks, fluid leakage or a
flattened condition.
l.lnstal1 the engine mounting front insulator S/A to the frame assembly.
2.Fit the engine mounting front right bracket into the engine mounting front insulator SIA, while adjusting
the position of the engine assembly, using a garage jack. Temporarily tighten the bolts.
3.After the garage jack has been lowered fully, securely tighten the bolts connecting the engine
mounting front insulator S/A with the engine mounting front right bracket, with the engine mounting
front insulator S/A in a loaded state.
I.Install the intercooler.

Refer to Page 83-2.
3.lnstall the exhaust pipe.

Refer to Page 84-2.
4.lnstall the front floor center brace S/A.

5.Lift down the vehicle.

Refer to Page 12-2.
2 ENGINE MOUNTING LEFT INSULATOR
Instrument
l ~ o r ~ wrench
ue
]wooden block

2.Remove the battery carrier subassembly No.2 as well as the battery carrier sumort located
underneath the subassembly.
4.install the front disc wheels LH.
) COMPONENTS
L
Unit:N.m{kgf.cmJ
v A 1 a lnsulator,engine mounting,lower left

(1) ENGINE MOUNTING LOWER LEFT INSULATOR
1.Place a garage jack at a connecting point between the
engine assembly and the transaxle assembly so as to
sustain it.
CAUTION
* When applying a garage jack, interpose a wooden
2.Turn the steering wheel to the left as far as it will go.
3.Remove the bolts connecting the frame assembly with the
engine mounting lower left insulator.
NOTE
As for the bolts at the front side of the vehicle, it is
advisable to carry out the work from around the battery
carrier that was removed in the work prior to removal,
using a long extension bar.
4.Lift up the engine assembly and transaxle assembly,
using the garage jack.
5.Remove the engine mounting lower left insulator from the

engine mounting leit bracket.
2-1-5 INSPECTION
Replace any insulator that exhibits cracks, fluid leakage or a flattened condition.
1.lnstall the engine mounting lower left insulator to the frame assembly.
2.Fit the engine mounting left bracket into the engine mounting lower left insulator, while adjusting the
position of the transaxle assembly, using a garage jack. Temporarily tighten the bolts.
3.After the garage jack has been lowered fully, securely tighten the bolts connecting the engine
mounting lower left insulator with the engine mounting left bracket, with the engine mounting lower
left insulator in a loaded state.
1.lnstall the front disc wheels LH.
TIGHTENING TORQUE: 103.0k14.7N .rn{10505 150kgf.cm)

3.lnstall the battery carrier support and battery carrier subassembly No.2.
4.lnstall the battery.
3 ENGINE MOUNTING REAR INSULATOR
Instrument
/Wooden block I

1.Remove the foot rest.
2.Turn over the carpet near the steering column hole.
3.Remove the dust cover retainer.
4.Remove the steering shaft dust cover.
5.Separate the universal joint at the steering gear side of the steering column assembly.
6.Push out the steering column hole shield to the vehicle outside under a condition where it is attached
to the steering gear assembly.
7.Remove the pressure feed hose (pressure side) from the engine mounting rear right bracket.
8.Disconnect the alternator harness that is attached to the engine mounting rear right bracket.
NOTE
Raise the claw of the clamp so as to unlock the lock,
as indicated in the right figure.
10.Remove the front disc wheels.
11.Remove the front floor center brace SIA.
12.Disconnect the connector of the rear O2sensor.
13.Remove the two bolts connecting the exhaust pipe with
the manifold converter assembly.
14.Separate the shift & select shaft and extension rod from
the transmission.
Refer to Page F2-8.
t
) COMPONENTS
Unit:N.m(kgf.cm)
r A 1 c Bracket,engine mounting,rear right
r 2 a Frame Ay
r 3 b Gear assembly, power steering
r A 4 c Bracket,engine mounting,rear right
r A 5 d Insulator SIA. engine mounting, rear
(1) ENGINE MOUNTING REAR RIGHT BRACKET
1.Place a garage jack at a connecting point between the engine assembly and the transaxle assembly
so as to sustain it.
CAUTION
When applying a garage jack, interpose a wooden
Care must be exercised not to allow the engine to
lower while the engine is sustained with the jack.
2.Disconnect the engine mounting rear insulator SIA from
the engine mounting rear right bracket.
NOTE
It is advisable to carry out the work from the tire house
at the left side of the vehicle, using a long extension
bar.
3.Remove the engine mounting rear right bracket from the
engine block. Temporarily secure it.
(2) Frame Ay
Slacken the retaining bolts of the frame assembly a little at a time so as to lower the front side about 15
mm; the rear side about 25mm.
CAUTION
Since there are possibilities that the frame assembly
may drop, do not lower it more than 25 mm.
(3) POWER STEERING GEAR AY

kemove the retaining bolts that attach the power steering gear assembly to the frame assembly.
Pull out the engine mounting rear right bracket from the right side of the vehicle.
Remove the engine mounting rear insulator SIA. Pull it out from the right side of the vehicle.
3-1-5 INSPECTION
Replace any insulator that exhibits cracks, or a flattened condition.
Install the engine mounting rear insulator SIA to the frame assembly.
1.lnstall the engine mounting rear right bracket.
(1) Temporarily secure the engine mounting rear right
bracket to the engine block by means of the bolt A.
(2) Tighten the bolt C to the specified torque.
(3) Securely tighten the bolts B and D to the specified
torque.
(4) Securely tighten the bolt A to the specified torque.
(5) Tighten the bolt E to the transaxle assembly to the
specified torque.
lnstall the power steering gear assembly to the frame assembly.
(4) Frame Ay
Install the frame assembly to the body. At this time, push the steering column hole cover into the column
hole.
1.Temporarily connect the engine mounting rear insulator SIA to the engine mounting rear right bracket,
while adjusting the position of the transaxle assembly, using a garage jack.
2.Afier lowering the garage jack, securely tighten the engine mounting rear insulator SIA to the engine
mounting rear right bracket.
1.Install the shift & select shaft and extension rod to the transmission
Refer to Page F2-8.
2.lnstall the exhaust pipe

Refer to Page 84-2.
3.Connect the connector of the rear O2sensor.

4.lnstall the front floor center brace S/A.
TIGHTENING TORQUE: Front side:33.9+7.3N -m{345k74kgf.cm]
Rear side:23.5f 5.9N .rn{240+59kgf .cm}
5.lnstall the front disc wheels.

CAUTION
The rotating direction of the tire has been specified. Hence, confirm the indication of the rotating
direction (arrowheaded mark) provided at the tire side. Mount the tire according to the forward
moving direction.
TIGHTENING TORQUE: lO3.Of l4.7N.m{lO5O+l5Okgf.cm}

7.Attach the pressure feed hose (pressure side) to the engine mounting rear right bracket.
TIGHTENING TORQUE: 15.7f2.9N.m{160+29kgf a n }
8.Secure the alternator harness to the engine mounting rear right bracket.
9.lnstall the universal joint at the steering gear side of the steering column assembly
Refer to Page GI-4.
I0.lnstall the steering shaft dust cover.

I 1.Install the dust cover retainer.
TIGHTENING TORQUE: 5 . 4 f 1.5N.m{55+ 15kgf .cm]
12.Place the carpet near the steering column hole.

13.lnstall the foot rest.
14.Check the front alignment.
Refer to Page C1-I.
C1 FRONT SUSPENSION
FRONT SUSPENSlON C1 - 1
BASIC CHECK AND ADJUSTMENT--- C1 - 1
FRONT SHOCK ABSORBER AND
FRONT COIL SPRING........................ C1 - 6
REMOVAL AND INSTALLATION-------- C1 - 6
FRONT STABILIZER BAR AND FRONT
SUSPENSlON (31- 11
REMOVAL AND INSTALLATION ------ C1 - 11
1 FRONT SUSPENSION
1-1-1 FRONT WHEEL ALIGNMENT
(1) ARTICLES TO BE PREPARED
Tool
ICCK gauge compensator,Brake pedal pusher
Instrument
r~urnin
radius
~ gauge,Tire pressure gauge,Camber, caster gauge.Diai gauge
CAUTION
The wheel alignment should be measured under the unloaded condition (However, the fuel tank
must be filled fully and the spare tire, jack and tools must be removed.).
(2) CHECKS PRIOR TO MEASUREMENT
@ CHECK OF TIRE SIZE AND WEAR CONDlRlON
Check that there is no difference in size. Also, check that there is no significant difference in wear
between the right and left sides nor uneven wear.
@ CHECK OF TIRE AIR INFLATION PRESSURE
SPECIFIED VALUE:
Air inflation pressure [kPalkgf/cm21]
Tlre size
Front wheel I Rear wheel
16515OR15 24012.4)
@ CHECK OF TIRES FOR RUNOUT

Check the tire for runout, using a dial gauge.
ALLOWABLE LIMIT MAX 1.4 mm (Vertical runout)
ALLOWABLE LIMIT MAX 2.0 mm (Lateral runout)
@ I OF BOLTS FOR TIGHTENING CONDITION AT RESPECTIVE SECTIONS

CHECK
Check each installation section related to the axles and suspensions for looseness and deformation.
@ CHECK OF RESPECTIVE SECTIONS FOR EXCESSIVE PLAY.
1.Ball joint for excessive play
2.Steering linkage for excessive play
3.Suspension-related parts for excessive play
4.Front wheel bearing for excessive play
(3) TOE-IN
@ CHECK
1.Rock the vehicle so that it may be stabilized.
CAUTION
If the suspension parts have been changed, rock the vehicle greatly so that the suspension can be
settled. Then, proceed with the measurement.
2.Move the vehicle about 5 m straight forward by pushing it by hands.

CAUTION
When the vehicle has been moved backward, be sure to move it forward by the distance that the
vehicle traveled backward.
3.Align the height of the pointer of the toe-in gauge with the
center height of the front disc wheel axle, and place the
gauge behind the tires.
4.Mark the tread center at the rear section of the front tyres,
Measure the distance (A) between marks.
5.Slowly move the vehicle forward by pushing it, until the
front wheels make 180" turn.
CAUTION
Be very careful not to turn the wheel more than 180".
If the wheel is turned more than 180", repeat the
operations from Step 3.
6.Measure the distance (B) between the marks at the front
section of the front tyres.
7.Calculate the toe-in (A - B).
SPECIFIED VALUE: O.Ot2.0mm
@ ADJUSTMENT
1.Loosen the lock nut of the tie-rod end.
2.Turn the rack ends at the right and left sides by the same
amount in the opposite direction, respectively, so as to
adjust the toe-in to the range of the specified value.
SPECIFIED VALUE: 0.Okl.Omm
3.Tighten the lock nut of the tie-rod end.
TIGHTENING TORQUE: 36.8t7.3N - m(375f 74kgf.cm)
CAUTION
Make sure that the moving amount of the tie rods at the
right and lefi sides is the same.
Make sure that the length indicated in the right figure is
the same. (Failure to observe this caution may cause
differences in the wheel turning angle.)
Be very careful not to twist the boots during the
adjustment.
4.Check the toe-in again.
SPECIFIED VALUE: O . O k 1 .Omm
(4) CAMBER, CASTER AND KINGPIN INCLINATION
ANGLE
@ CHECK
1.Setting of turning radius gauge
2.Set the turning radius gauge to the 0" point and lock it.
3.Drive the vehicle so that the center of the ground-
contacting surface of the tire may be aligned with the
center of the turning radius gauge.
CAUTION
The checks should be conducted under the unloaded
state and with the service brake applied, using a brake pedal pressure, so that the front wheels may
not turn.
In cases where a portable type turning radius gauge is used, make certain to keep the vehicle
horizontal by placing a stand of the same height as the gauge at the rear wheel.
* During the inspection, remove the stop lamp fuse so that the stop lamp switch may not be turned
on.
4.lnstall a compensator to the wheel. Then, install a
camberlcasterlkingpin gauge.
5.Set the pointer of the turning radius gauge to 0".
6.lnstail the gauge, while aligning the tip end of the center
rod of the camber-caster-kingpin gauge with the
designated position of the compensator.
7.Check the camber.

8.Confirm the straight-ahead position.
9.Set the gauge horizontally so that a level bubble of the gauge comes at the center.
10.Read out the graduation at the center position of the bubble of the gauge for the camber
measurement.
SPECIFIED VALUE:
L88ORK
Vehicle model
KMVZW 1 KMVZQ
Camber angle O'f 45' 0'13'i45'
11.Check the caster angle and kingpin angle (right wheel).

aster angle
ingpin angle
C1-5
I
12.Turn the steering wheel clockwise until the turning radius gauge points 20 ".
13.Turn the adjusting screws for caster angle and kingpin angle of the gauge so that each bubble
come at 0" .
14.Turn the steering wheel counterclockwise until the turning radius gauge points 20 ".
15.Read the graduation of the bubble center position at the caster angle measuring gauge and kingpin
angle measuring - gauge.
- -
SPECIFIED VALUE:
L880RK
Vehicle model
KMVZW KMVZO
Caster angle 3'40'11' 3'32'1 1'
Kingpin angle 12'16'+1' 11'55'f 1'
16.Check the caster angle and kingpin inclination angle (left wheel).
NOTE
This is a non-adjustable type, in which the camber, caster and kingpin inclination angle have
already been adjusted to the specified values.
17.Remove the gauge and SST.

(5) WHEEL TURNING ANGLE
6 CHECK
Turn the steering wheel fully to the right and to the left. At this
time, check the wheel turning angle.
SPECIFIED VALUE:
L880RK
Vehicle model
KMVNV 1 KMVZO
in( A) 36'25' f2' 37'00' 52-
Out( B) 31e30' f2' 1 31'48' f2~
@ ADJUSTMENT
If there is a difference in turning angle between the right and left sides, or the turning angle deviates from
the standard value, check and adjust the toe-in.
(6) FRONT SIDE SLIP
@ CHECK
NOTE
Even when the side slip value is within the range of the specified value, if there is any abnormality,
be sure to check and adjust the above items.
Check the side slip with a side slip tester.

SPECIFIED VALUE: In 5 mm - out 5 mm
2 FRONT SHOCK ABSORBER AND FRONT COIL SPRING
WARNING
If the lock nut is removed without using the SST, the coil spring jumps out, posing extreme danger,
Therefore, be sure to use the SST for this removal.
Shape Palt No. Part name
09727-30021-000
Compressor, front coil spring
(09727-30020-000)
09729-97202-000 Socket, lock nut17
09729-97203-000 Socket, hexagon wrenchG(T0NE 3KH-6L)
Instrument --
!Torque wrench

1.Jack up the vehicle.
2.Rernove the front disc wheel.
Refer to Page 12-2.
4.Remove the front fender liner and front fender.

5.Remove the clamp of the flexible brake hose.

6.Remove the clamp of the speed sensor harness
) COMPONENTS
L
Unit:N.m(kgf.cm)
1 a Nut, hexagon r A 6 f Support Ay. front suspension
2 b Bolt, hexagon 7 g Seat, front spring damper
3 c Nut, hexagon 8 h Bumper, front spring
4 d Cover, bearing dust A 9 i Spring, coil. front
5 e Nut, lock 10 j Absorber Ay, front shock
2-14 POINTS OF REMOVAL

(1) FRONT SUSPENSION SUPPORT AY
?.Install the SST to the coil spring.
WARNING
At this time, make sure that the SST is installed in such
a way that the distance between the hooks becomes
the greatest.
When compressing the spring, do not use an impact
wrench.
SST 09727-30021-000
- C1-8
2.Remove the lock nut, uslng the SST.
SST 09729-97202-000
09729-97203-000
CAUTION
Do not use an impact wrench to remove the lock nut.
Only when you are encountered with a difficulty in
removing the lock nut because of a broken hexagonal
section of the front shock absorber assembly or the
SST due to a seizure, etc. of the lock nut, you can use
an impact wrench to remove the lock nut.However, in
this case, do not reuse the front shock absorber
assembly.
2-1-5 INSPECTION
(1) OPERATION CHECK OF SHOCK ABSORBER
Extend and compress the shock absorber.
SPECIFIED VALUE: Ensure that the shock absorber is
extended and compressed with a
certain resistance and it exhibits no
abnormal noise.

(1) COIL SPRING
Install the coil spring to the shock absorber assembly, using
the SST.
WARNING
At this time, make sure that the SST is installed in such
a way that the distance between the hooks becomes
the greatest.
When compressing the spring, do not use an impact
wrench.
* Make sure to align the groove of the spring seats at the
upper and lower sides with the edge of the spring.
SST 09727-30021-000
(2) FRONT SUSPENSION SUPPORT AY
1.Install the lock nut, using the SST.
SST 09729-97202-000
09729-97203-000
CAUTION
As for the tightening torque to be used when the SST is employed, it is calculated as follows.
The extended length of 09729-97202-000 is 40 mm.
AilC508OSX
NOTE
* Reading value of torque wrench[N.rn]=Effective length of torque wrenchB[rn] X Specified
torque[N .m]/(Effective length of torque wrench B[m]+Length of extension A[m])
When the effective diameter of the torque wrench is 380mrn:
Reading value of torque wrench[N.m]=0.38[rn] X63.7[N - rny(0.38[m]+0.04[rn])=57.6[N .m]
Reading value of torque wrench[N - m]=38[crn] X 650[kgf. cm]/(38[crn]+4[cm])=588[kgf. cm]
2.lnstall the front suspension support S/Ato the body. At this time, the installation should be carried out
in such a way that the side bearing a paint mark comes to the right side of the vehicle
CAUTION
If the identification paint mark at the tip-end of the bolt is not clear, the correct installing direction
must be judged from the inclination of the support SIA, referring to the under figure.
LH RH
A-A 0-0
CllC5043Sll
i
1.lnstall the clamp of the speed sensor harness.
2.lnstall the clamp of the flexible brake hose.
3.lnstall the front disc wheel.
TIGHTENING TORQUE: 103.0L-14.7N~rn{1050~150kgf~crn)
4.Jack down the vehicle.

C1-11
3 FRONT STABILIZER BAR AND FRONT SUSPENSION
SST
W628000"-000 Puller, f e r o d end

(09611-89701-000)
I
...- - .-...-..-
l ~ o r ~ wrench
ue

1) COMPONENTS

Unit:N.m(kgf.cmJ
r 1 a Nut, hexagon 7 g Cushion, strut bar
2 b Nut, lock 8 h Bush, stabilizer
3 c Cushion, retainer 9 i Nut, hexagon(RH only)
4 d Bolt, hexagon 10 j Bolt, hexagon
A 5 e Bracket, stabilizer A 11 k Arm SIA, suspension lower arm wlbush
A 6 f Bar, stabilizer 12 1 Cushion, strut bar
SST 09628-00011-000
(1) SUSPENSION LOWER ARM SIA
1.Fill grease to the arrowheaded point in the lower ball joint
dust cover.
LUBRICANT MP grease
2.Press the dust cover to the lower ball joint of the lower
arm, using the SST in combination with a press.
CAUTION
The press operation is under an unstable state.
Hence, full attention must be paid while you are
sustaining it by hand.
SST 09618-87301-000
3.lnstall the lower arm to the knuckle.

CAUTION
When assembling, make sure to check to see if any
lubricant, such as grease, gets to the threaded portion
of the ball stud, taper section and knuckle installing
section of of the lower arm. If any lubricant gets to the
parts, be sure to degrease it.
(2) STABILIZER BAR
1.Install the stabilizer bush to the stabilizer bar, referring to
the right figure.
2.lnstall the lower arm to the stabilizer bar. However, do not
tighten it securely yet.
Stabilizer bush
Lower arm
CAUTION
Different strut bar cushions are used in the front and
rear side. Hence, care must be exercised so that they
are not installed in a wrong position.
The strut bar cushion at the rear side of the vehicle has
a correct installing direction. Be sure to install this
cushion in such a way that the side bearing a paint
mark faces the rear side of the vehicle.
Care must be exercised so that the strut bar cushion
may not be caught by the stabilizer bar and cushion
retainer. I
I Identification
I
Strut bar cushion ~ t i udar
t cushion
(FR) (RR)
(3) STABlLlZER BRACKET

Install the stabilizer bar in such a way that the side having a
cut comes at the rear side of the vehicle. Tighten the
retaining bolt, while paying attention not to allow the bracket
to tilt. Tightening should be made alternately between the
front and rear sides a little at a time. Do not tighten the bolt
securely yet.
,.
(4) SUSPENSION LOWER ARM SIA.STABILIZER BAR
Tighten the suspension lower arm and stabilizer bar according to the dimensions specified in the
drawing. Or temporarily tighten the suspension lower arm and stabilizer bar at this time. Then, later
securely tighten them after rocking the vehicle several time under a weighted condition.
I
SPECIFIED VALUE:
Sections Dimensions[rnrn]
L88ORK- KMVZW L880RK- KMVZQ
Body installation surface at the frame side - upper edge of FR 76.8+5 87.8f 5
A
the lower arm RR 25.4+5 36.4*5
FR 2.8t5 15.835
B Lowest edge of the bracket at the frame side
RR 4.4f 5 17.4+5
CAUTION
The retaining bolt of the right suspension lower arm may be installed either from the front side or
from the rear side. However, make sure to install the washer at the nut side and tighten the nut.

TIGHTENING TORQUE: lO3.Of l4.7N.m{lO5O+ 150kgf.cm)

C2 REAR SUSPENSION
REAR SHOCK ABSORBER AND

REAR COIL SPRING ( 2WD ) -------------- C2 - 1
DISPOSAL C2-4
REAR SUSPENSION ARM ( 2WD )------ C2 - 5
REAR STABILIZER BAR --------------------- C 2 - 8
REMOVAL AND INSTALLATION------- C2 - 8
1 REAR SHOCK ABSORBER AND REAR COIL SPRING ( 2WD )
Instrument

WARNING
Make sure to observe the jacking points. Failure to observe this caution can cause the vehicle to
incline, resulting in hazard potential.
CAUTION
When jacking up the vehicle, be very careful not to allow any interference with the bumper.

2.Remove the rear disc wheel.
3.Support the rear suspension arm with the garage jack.
CAUTION
Be certain to apply the garage jack to the trailing arm
section. Never apply the garage jack to the bracket
section at the lower side of the shock absorber or to the
torsion beam section .
When applying a garage jack to the suspension arm,
be sure to interpose cloth or the like so as not to
scratch the parts.
--

111 COMPONENTS
Unit:N.rn(kgf.crn)
1 a Nut, hexagon
2 b Bolt, hexagon
3 c Nut
A 4 d Absorber Ay.shock rear
5 e Nut, hexagon

(1) REAR COIL SPRING
When you remove the rear coil spring, be sure to gradually lower the jack supporting the suspension
arm, after the rear spring bumper has been disconnected from the suspension arm.
NOTE
If the rear spring bumper has been disconnected from the suspension arm, this will facilitate the
spring removal.
1-1-5 INSPECTION
1.Extend and compress the shock absorber. If any abnormality is present, replace the shock absorber.
SPECIFIED VALUE: When the shock absorber is compressed by hand, ensure that it can be
compressed with a certain resistance, but without binding. When you release your
hand after compressing the shock absorber, ensure that it is extended at a constant
speed by itself.
2.Check the spring for cracks, wear and damage. If any damage is present, replace the spring
(1) REAR SHOCK ABSORBER AY
Place the rear coil spring at the specified position. Then, slowly raise the jack that is supporting the
suspension arm to compress the spring. Lift up the suspension arm to a position where the shock
absorber can be installed and, then, install the shock absorber.
(2) REAR COIL SPRING
CAUTION
Install the lower edge of the spring by aligning it with
the groove of the suspension a n .
Set the upper and lower sections of the spring, as
indicated in the figure on the right.
S
e
a
t, surface flat
fi Body side
8 Lower side
(Arm s~de)
Seat surface slanting
NllC5047ETiO

?.Removethe garage jack.
2.lnstall the rear disc wheel.
TIGHTENING TORQUE: 103.0k14.7N .m{1050+150kgf .cm]
3.Jack down the vehicle. Rock the vehicle up and down several times so that the suspensions may be
settled.
4.Under a condition where the vehicle weight is applied, tighten the attaching bolts and nuts of the rear
shock absorber to the specified torque.
--
1-2 DISPOSAL
1-2-1 Disposal Procedure
D~sposalProcedure
(1) Mono-tube type shock absorber with a separate tank
WARNING
The gas is colorless, odorless and not harmful. However, the pressure of gas being released may
fly off chips, etc. Hence, take a measure to prevent scattering of chips, such as putting a cloth on
the metal saw. Furthermore, care must be exercised for safety precautions for the drilling operation,
such as wearing safety goggles.
As for the mono-tube type shock absorber with a separate tank, be sure to obsewe the correct
drilling procedure.
1.Put it horizontally with the rod in an extended state.

2.ln order to discharge the gas, make a hole at a point indicated by A in the figure, using a metal saw.
3.After having discharged the gas from A, make a hole at a point indicated by B so as to drain the oil.
2 REAR SUSPENSION ARM ( 2WD )
Instrument
~~~~
(~orque
wrench

WARNING
Make sure to observe the jacking points. Failure to observe this caution can cause the vehicle to
incline, resulting in hazard potential.
CAUTION
When jacking up the vehicle, be very careful not to allow any interference with the bumper.

2.Remove the rear disc wheel.
3.Remove the rear shock absorber and spring
Refer to Page C2-1.
4.Remove the rear brake

Refer to Page El-26.
5.Remove the rear wheel speed sensor from the rear suspension arm.
Refer to Page E3-6.
6.Remove the parking brake cable assembly from the rear suspension arm
Refer to Page E2-2.
\
) COMPONENTS
Unit:N.m(kgf.cm)
A 1 a Arm Ay,rear suspension

When installing the suspension arm to the vehicle, temporarily tighten the bolts and nuts in advance.
1.Install the parking brake cable assembly to the rear suspension arm.
Refer to Page E2-2.
2.lnstall the rear wheel speed sensor to the rear suspension arm
Refer to Page E3-6.
3.lnstall the rear brake.

4.lnstall the rear shock absorber and rear spring.

Refer to Page C2-1.
CAUTION
Temporarily tighten the rear shock absorber in advance.

TIGHTENING TORQUE: 103.0-+ 14.7N - m{1050f 150kgf. cm}
6.Jack down the vehicle. Rock the vehicle up and down several times so that the suspensions may be
settled.
7.Under a condition where the vehicle weight is applied, tighten the attaching bolts and nuts of the rear
suspension arm and rear shock absorber to the specified torque.
- C2-8
3 REAR STABILIZER BAR
Instrument
l~orque
wrench
Unit:N m(kgf,cm]
i
1 a Bar,rear stabilizer
2 b Bracket
C3 WHEEL & TIRE
TIRE PUNCTURE REPAIR AGENT------- C3 - 1

DRAINING-- C3-1
1 TIRE PUNCTURE REPAIR AGENT
1-1 DRAINING
1-1-1 BRIEF DESCRIPTION
When you repair or replace a tire for which the repair tire kit (tire puncture emergency repair set) has
been used, it is necessary to drain any repair agent remaining inside the tire.
1-1-2 ARTICLE TO BE PREPARED
l ~ r n prepair
t ~ agent bottle(with cap),Vinyl hose 1
1-1-3 ITEMS TO BE OBSERVED
CAUTION
* Care must be exercised not to allow the repair agent to flow from the tire during the operation.
1-1-4 DRAINING PROCEDURE

1.Take out the tire from the vehicle that has undergone the puncture emergency repair.
2.Drop the bead to the inside of the rim.
NOTE
If any difficulty is encountered in dropping the bead from the rim, pour detergent solvent diluted with
water into between the bead and the rim.
3.Detach the attached hose from the empty repair agent

bottle. Install a prepared vinyl hose with an inner Attached hose
diameter 6 7 to 8 mm and a length of about 600 mm.
4.With the tire erected, insert a tool, etc. into between the
bead and the rim to make a gap. Insert a vinyl hose into
the gap so that the tip-end of the vinyl hose may be
submerged into the repair agent liquid.
5.Squeeze the empty repair agent bottle so as to push out

the inner air so as to suck the repair agent.
NOTE
Put the tire on a bench, etc. so that the tire may be set
at a higher level than the repair agent bottle. This will
make the work more easily.
6.Repeat the operation in Step 5 until it is no longer
possible t o suck the repair agent, by changing the
position of the vinyl hose.
!
1-1-5 OPERATION AFTER DRAINING
Remove the tire from the disc wheel. Wipe off any remaining repair agent.
When you are able to locate the puncture hole, carry out an ordinary puncture repair.
If you can not locate the puncture hole, replace the tire.
1-1-6 DISPOSAL
Be sure to dispose the drained repair agent as waste oil.
D SERVICE SPECIFICATIONS
D-1
1 Maintenans specified value
Camshaft
Cvlinder head
------------_-
-- Speciflea vatJe I ....A lowaote limit Appltcable
Flatness
Block surface 1 - I 0.10 I
Manifold surface - 0.10
)Contactwidth (IN 1.2-1.6 -
I I I -
I
(mm) EX 1.2-1.6 i
Valve seat -
Contact width IN 20-45-70
(7 EX I - 20-45-70
Valve s ~ r i n a
Specified value Allowable limit I Applicable
1.4 1.6
I -
Free length (mm)
42.1
41.56 - I
White paint
Light green paint i
Valve
Contact width (rnm)

--
I E
-
IN
tnX
I Spec 5eo va be
1.2-1.6
..-
12.-1.6 .-.
' Al~owaoteI mi1
-
- I
Aoplicable
Valve head stock thickness (mm) 0.8-1.2 0.75

IN 92.75-93.25 92.6
Overall length (mm)
- - EX 94.65-95.15 94.5
Stem outer diameter IN 466-4 AF
4.465-4.480
A -
(mm) EX 4.45-4.470 -
-
Valve auid bush
r
I Bush diameter (mm) I IN I
Specified value
4.500-4.51;> I
Allowable limit
- I
Applicable
1
FX
-, . A..--"
5nfl.A ..- -
51. !> -
Stemx Bush of clear- IN 0.020-0.047 0.06
ance (mm) EX 0.03-0.057 0.08
Valve guid bush O/S (mm) 1 - - 0.03
Cylinder block
-
Specified value -
Allowable limit -
Applicable
Head for deformation (mm) 0.05 0.08
Cylinder bore diameter wear amount (mm) - 0.2
Sylinder of true roundness(') - 0.03
D-2
Piston , Piston ring
Connecting rod
Oil clearance (rnrn) 0.02-0.044 0.07
:
-
Crankshaft
Specified value Allowable limit Applicable
Thrust clearance (rnrn) 0.02-0.22 0.3
Oil clearance (rnm) 0.020-0.044 0.07
Check of bend (rnm) - 0.03
I True round- - n 01
Check of journal wear (mm) ness
Taper - 0.01
True round- - 0.01
I ,
Check of pin journal wear (mrn) / ness
. ,
Specified value Allowable limit
pp
Applicable
Tip clearance(rnm) 0.02-0.14 0.2
Body clearance (rnm) 0.09-0.25 0.2
Side clearance (mrn) 0.035-0.085 0.1
Relief valve spring (rnrn) 57 -
2 Tightening Torque
Components Tightening Torque (N-m(kg.cm))
Cylinder head x Cylinder block 34.0{350)90°!A: . Wet (angle)
Cyiinder head x Cylinder head cover 11.0f 2.211 1 2 f 22)
Cylinder block X Crankshaft bearing cap 59.0k6.01600f 60) Wet
Oil seal retainer x Cylinder biock 8.5+12.5{85* 251
Cylinder block drain plug 39.0f 7.81400f 801
Connecting rod X Connecting rod cap 38.0f 4.01390f 40) Wet
Crankshaft X Crank pulley 103.0f 10.011.050t100l
Camshaft x Camshaft timing sprocket 98.0f 10.0[1,000f100)
Cylinder head X Camshait bearing cap 12.5f2.0{130f20)
Timing chain guid X Cylinder block 19.0f3.81195f 39)
Timing chain tensioner arm X Cylinder block 19.0t3.8(195+39I
Oil chain nozzle X
water pump X Oil pump , Cylinder block I 14.0f 3.01145f 29)

Water pump puily X Water pump 8.5f2.5185k25)
D2 DRIVE SHAFTIPROPELLER SHAFTIAXLE
FRONT AXLE ................................... D2-1

REMOVAL AND INSTALLATION------- D2- 1
FRONT DRIVE SHAFT D2 - 8
REMOVAL AND INSTALLATION-------- D2 - 8
DISASSEMBLING AND
ASSEMBLING D2- 12
REAR AXLE BEARING ( 2WD )---------- D2 - 17
REMOVAL AND INSTALLATION ------ D2 - 17
1 FRONT AXLE
SST
Shape
09628-00011-000
Puller, tie-rod end
(09611-87701-000)
09511-87202-000 Wrench rear axle bearing lock nut
09520-00031-000
Puller, rear axle shaft
(09520-00030-000)
09950-97201-000
Puller, universal
(09950-20017-000)
09510-87301-000 Puller, awle shaft
09506-87302-000 Replacer, differential drive pinion bearing corn, rear
09527-87301-000 Remover, rear axle shaft bearing
09950-70010-000 Set, handle

Tool
[snap ring expander 1
Instrument
/Dial gauge,Torque wrench 1
IMP grease

3.Remove the stabilizer bar.
4.Remove the front speed sensor.

5.Remove the front disc brake caliper assembly and hang it, using a wire or the like.
CAUTION
* Be very careful not to damage the flexible hose.
6.Remove the brake disc.

1-1-3 INSPECTION
(1) Check of bearing for axial play
?.Set a dial gauge to a point on the periphery at the tip-end
of the drive shaft. Check the bearing for axial play.
If the play exceeds the limit, replace the axle hub and
radial ball bearing.
(2) Check of front axle runout

1.Set a dial gauge to the outer periphery of the axle hub.
Turn the axle hub to check the runout.
If the runout exceeds the limit, replace the axle hub and
radial ball bearing.
) COMPONENTS
L
E N o n - reusable parts
Unit:N.m(kgf.cmj
r A 1 a Shaft Ay, front drive r 6
A e Hub SIA, front axle
r 2 b End SIA, tie rod 7 f Knuckle, steering
r A 3 c Arm SIA, suspension lower wlbush 8 g Rotor, skid control sensor
r 4 a Shaft Ay, front drive r A 9 h Bearing, radial ball
5 d Absorber Ay, front shock

(1) FRONT DRIVE SHAFT
I .Remove the nut.
(1) Release the staked portion, using a chisel or the like.
I
(2) Remove the nut, using the SST.
SST 09511-87202-000
(2) TIE ROD END S1A

1.Disconnect the tie rod end SIA from the steering knuckle,
using the SST.
SSI: 09628-00011-000
CAUTION
When the SST is to be installed, install a dummy nut to
the threaded section of the tie rod end so that the
threaded section may not be damaged.
Hang the SST, using a cord.

1.Remove the lower arm ball joint, using the SST.
SST 09628-00011-000
CAUTION
the threaded section of the lower arm so that the
.Hang the SST, using a cord.

1.Disconnect the front axle hub SIA with steering knuckle
from the drive shaft, using the SST.
SST 09510-87301-000
CAUTION
Hang the drive shaft by means of wire or the like.
(5) FRONT AXLE HUB

1.Remove the front axle hub SIA with steering knuckle from the shock absorber.
CAUTION
The bolt is a nonreusable part.
2.Remove the front axle hub SIA.

(1) Secure the front axle hub SIA with steering knuckle in a vice by means of the bolt that was used to
attach the steering knuckle to the shock absorber.
-- ~- -- ~ ~ ~~ ~~ -
(.2.) Remove the front axle hub S/A from the front axle hub i I
S/A with steering knuckle, using the SST.
SST 09520-00031-000
(3) Remove the skid control sensor rotor.
(4) Remove the radial ball bearing inner race, using the
SST.
SST 09950-97201-000
(6) RADIAL BALL BEARING

1.Detach the hole snap ring, using a snap ring expander.
2.Remove the radial b a l l bearing, using the SST in
combination with a press.
SST 09527-87301-000
09550-10013-000[09556-10011-0001
09950-70010-000[09951-07200-0001

1.Press the radial ball bearing to the steering knuckle SIA,
using the SST in combination with a press. Install the hole
snap ring.
SST 09506-87301-000
09550-10013-000[09554-10011-0001
09950-70010-000[09951-07200-0001
2.lnstall the skid control sensor rotor.
3.Press the front axle hub S/A into the steering knuckle,
using the SST in combination with a press.
SST 09550-10013-000[09556-10011-0001
09950-70010-000[09951-07200-0001
I .Install the lower arm to the knuckle.
CAUTION
When assembling, make sure to check to see if any
lubricant, such as grease, gets to the threaded portion
of the ball stud, taper section and knuckle installing
section of the lower arm. If any lubricant gets to the
parts, be sure to degrease it. No grease has adhea
2.lnstall the front axle hub Ay with knuckle to the shock

j
absorber, while inserting the drive shaft. f l wShock absorber
CAUTION
The tightening should be made while any looseness of
the bolt hole is brought to the arrow-headed direction in
the figure.
Use new bolts and nuts.
Do not pull out the drive shaft beyond the required
extent.

1.lnstall the nut.
(1) Tighten the nut to the specified torque, using the SST.
SST 09511-87202-000
(2) Using a chisel, firmly stake the tip-end of the front

drive shaft and nut, as indicated in the right figure. Too' Depth of staking
/ /
CAUTION
The staked section of the nut and the threaded section
of the drive shaft should not exhibit cracks. (Peeling-off
of the nut plating is permissible.)
As for the staking direction, the staking depth of the
drive shaft is 3.323nm in the center direction. Good Bad Bad
1.lnstall the brake disc.
2.lnstall the front disc brake caliper assembly
3.lnstall the front speed sensor.

4.lnstall the front stabilizer bar.
Refer to Page C1-1 I .

TIGHTENING TORQUE: 103.0+14.7N.m {1050i-150kgf.cm)

Refer to Page C1-1.
7.Lift down the vehicle

I
2 FRONT DRIVE SHAFT
WARNING
Do not carry out the operation while the exhaust pipe is still hot, for there is a possibility of getting
scalded.

SST
09511-87202-000 Wrench rear axle bearing lock nut
09628-0001
Puller, tie-rod end
(09611-87701-000)
09912-87301-000 Puller, slide hammer
09510-87301-000 Puller, axle shaii
Instrument
l ~ o r q u ewrench 1
l~ransmissiongear oil SAE75W-90 or SAE75W-85 or SAE75W-80 (API Classification GL3 or GL4).MP grease

2.Rernove the front wheel.
3.Drain the transaxle oil.
4.Remove the front stabilizer bar.
) COMPONENTS
+: MP grease
Unit: N.rn(kgfan)
1 a Shaft Ay, front drive
2 b End SIA, tie rod
3 c Arm SIA, suspension lower arm wlbush
4 a Shaft Ay, front drwe
5 d Ring, snap

(1) FRONT DRIVE SHAFT AY
1.Rernove the lock nut.
(1) Release the staked portion, using a chisel or the like.
(2) Remove the nut by using the SST to prevent turning.
SST 09511-87202-000
(2) TIE ROD END S/A

1.Remove the tie rod end assembly from the steering
knuckle, uisng the SST.
SST 09628-00011-000
CAUTION
the threaded section of the tie rod end so that the
Hang the SST, using a cord.

1.Disconnect the front drive shaft assembly from the
steering knuckle, using the SST.
SST: 09510-87301-000
SST
2.Rernove the front drive shaft assembly, using a hub nut

wrench or the like.
CAUTION
Turn over the dust cover and apply the sharp end of the
hub nut wrench to the edge suriace of the drive shaft.
Be very careful not to scratch the dust cover.
2-1-5 INSPECTION
Check the boot for brekage or damage. Replace any faulty part.
1.lnsert the front drive shaft assembly to the differential
carrier assembly, using the SST.
SST 09912-87301-000
CAUTION
This insertion should be carried out in such a way that
the lip section of the oil seal may not be damaged.
Apply MP grease to the oil seal contact surface and
serration of the drive shaft.
(2) SUSPENSION LOWER ARM
1.Install the suspension lower arm to the body.
CAUTION
As for the retaining bolt of the suspension lower arm, right, you can insert it either from the front or
rear. However, be sure to install the washer at the nut side and tighten the nut.

1.lnstall the nut.
(1) Tighten the nut to the specified torque, using the SST.
SST 09511-87202-000
\
(2) Using a chisel, firmly stake the tip-end of the front
drive shaft and nut, as indicated in the right figure. Too' Depth of staking
CAUTION / /
* The staked section of the nut and the threaded section
of the drive shaft should not exhibit cracks. (Peeling-off
of the nut plating is permissible.)
As for the staking direction, the staking depth of the
drive shaft is 35
.%%nm in the center direction.
Good Bad Bad
LilK5135ETlO

1.Install the front stabilizer bar.
Refer to Page C1-1I.
2.Fill oil to the transaxle assembly

(1) MK vehicle
Refer to Page F2-1.
3.lnstall the front wheel

TIGHTENING TORQUE: 103.0~14.7N~m
{1050+150kgf .cm)

-- D2-12
NOTE
The boot at the outboard side of the right drive shaft can not be replaced.

Tool
[snap ring pliers

) COMPONENTS
I CllK5058S3:
(2) DISASSEMBLING AND ASSEMBLING PROCEDURE
1 a Ring, snap r A 6 f Band, boot
r A 2 b Band, boot r 7 g Boot, front axle inboard joint
r A 3 c Joint SIA, front axle ~nboard r 8 h Boot, front axle outboard joint
r A 4 d Ring, shaft snap 9 i Shaft. front axle
r A 5 e Tr~podAy, Inboard joint
(1) FRONT AXLE INBOARD JOINT SIA
1.Remove the boot band (at the inboard side).
Using - a flat screwdriver, release the locking at the bent section of the boot band (at the inboard
side).
CAUTION
When removing the boot band, be very careful not to
scratch the boot.
2.Displace the front axle inboard joint boot and wipe off the
grease. Then, put mate marks on the front axle inboard yating mark
joint S/A and the drive shaft.
CAUTION
As for the mate marks, use paint. (Do not use punching.)
3.Remove the front axle inboard joint SIA.
(2) INBOARD JOINT TRIPOD S/A

1.Detach the hole snap ring, using a snap ring expander.
2.Put mate marks on the inboard joint triport Ay and the vde
ir-
shaft.
3.Remove the inboard joint tripod Ay, using a brass bar.
I
- D2-14
CAUTION
Be sure to apply a brass bar to the boss section of the
tripod, not at the roller section.
(3) REMOVAL OF BOOT

1.Using a flat screwdriver, release the locking at the bent section of the boot band (at the outboard
side).
CAUTION 1 I
When removing the boot band, be very careful not to
scratch the boot.
2.Remove the boots (at the inboard and outboard sides)

CAUTION
Tape
When pulling out the boot, wind a tape around the I C
spline section so as to prevent boot damage.

(1) BOOT (OUTBOARD SIDE)
1.Fill the outboard joint section and the inside of the boot with the grease furnished in the boot set.
Assemble the boot (at the outboard side).
NOTE
Filling amount 65f l o g
CAUTION
Wind a tape around the spline section at the inboard side. Then, proceed to assemble the boot.
2.Bend and assemble the boot band in the sequence I I
indicated in the figure.
(2) INBOARD JOINT TRIPOD SIA

1.Assemble the boot (inboard side) and boot band to the front axle shaft.
CAUTION
Do not fail to install the boot band in place.
2.Assembie the inboard joint tripod Ay, aligning the mate

marks with the drive shaft. Mating mark
CAUTION
Assemble the inboard joint tripod Ay, starting from the
chamfered section at the spline.
When the brass bar is used for driving, be sure to apply
the brass bar to the boss section of the tripod, not to
the roller section.
CItKWETIO
3.lnstail the shaft snap ring, using a snap ring expander.
(3) FRONT AXLE INBOARD JOINT SIA

1.Fill the front axle inboard joint S/A with the grease
furnished in the boot set. Assemble the front axle
inboard joint S/A, aligning with the mate mark with the
drive shaft.
NOTE
* Filling amount 90+ 109
.
1
-- D2-16
2.Bend and assemble the boot band, as indicated in the
right figure.
..'.-..
_--_-
I,
D2-17
3 REAR AXLE BEARING ( 2WD )
WARNING
Since it is unstable during the press operation, utmost care must be exercised when you hold it by
hand.

SST
6-;=3 09301-87702-000 Tool, clutch guide
09510-87301-000 Puller, axle shaft
Instrument
[~orque
wrench
IMPgrease
2.Remove the rear disc wheels.
!,
3-1-3 REMOVAL AND INSTALLATIONPROCEDURES
I) COMPONENTS
--
%:NO~ -reusable pans

Unit:N.m{kgimn]
A I a Cap, rear hub grease
r 2 b Drum, brake rear
r A 3 c Bearing, radial ball (outer side)
A 4 d Retainer, rear axle bearing
r A 5 e Bearing, radial ball (inner side)

(1) BRAKE DRUM
1.Remove the brake drum.
NOTE
If difficulty is encountered in removing the brake drum,
remove it by using the SST.
SST:09510-87301-000
1.Removethe radial ball bearing (outer side), using the SST
in combination with a press.
SST 09301-87702-000
2.Remove the radial ball bearing (inner side), using the SST
in combination with a Dress.
3-1-5 INSPECTION
Check each of the following parts. Replace any faulty part.

1.Using the SST in combination with a press, install the new
radial ball bearing (inner side) in such a way that the
bearing seal surface faces the inside of the vehicle.
SST 09950-60010-000
09950-70010-000[09951-07200-0001
2.lnstall the rear axle bearing retainer in the direction shown

at the right figure.
3.Pack MP grease to the points shown at the right figure.
4.Pack the new radial ball bearing (outer side) with 3 cc of

MP grease. Install the radial ball bearing to the brake
drum, using the SST in combination with a press.
SST 09950-60010-000
09950-70010-000[09951-07200-0001
(2) BRAKE DRUM

1.Tighten the castle nut to the specified torque. Line up the
hole positions by turning the nut in the tightening
direction. Install the new cotter pin.
CAUTION
Split the cotter pin vertically and bend the cotter pin,
until it comes in contact with the shaft.
2.Pack the inside of the rear hub grease cap with 15 cc of
MP grease. Install the rear hub grease cap.

1.lnstall the rear wheel.
TIGHTENING TORQUE: lO3.Of l4.7N.m { I ,0501t: 150kgf.cm)
E l BRAKE
BRAKE El - 1
BASIC CHECK AND ADJUSTMENT--- E l - 1
BRAKE PEDAL El - 5
REMOVAL AND INSTALLATION-------- E l 5 -
BRAKE MASTER CYLINDER-------------- E l - 6
REMOVAL AND INSTALLATION El - 6
DISASSEMBLING AND
ASSEMBLING El -10
BRAKE BOOSTER E l - 13
REMOVAL AND INSTALLATION ------ E l - 13
FRONT DISC BRAKE PAD ---------------- E l - 17
FRONT DISC CALIPER E l - 20
DISASSEMBLING AND
ASSEMBLING E l - 22
FRONT BRAKE DISC ....................... E l - 24
REMOVAL AND INSTALLATION E l - 24
REAR BRAKE DRUM E l - 26
1 BRAKE
1-1-1 BRAKE PEDAL
(1) HEIGHT CHECK
1.Turn over the carpet near the brake pedal.
2.Measure the height from the left center section of the
brake pedal depressing surface to the upper surface of
the dash panel.
SPECIFIED VALUE: AA45.5-150.5mm
(2) HEIGHT ADJUSTMENT

~ ~
1.Disconnect the connector of the stop lamp SW, loosen the nut (a), turn the switch and make the free
travel of the brake pedal SIA.
2.Adjust the pedal height by loosening the nut (b) and turning the push rod (c).
TIGHTENING TORQUE: 25.5f 2.9N.m{260+3Okgf-cm)
3.Turn the switch main body until the gap between the stop lamp SW threaded section edge and the
+
brake pedal cushion becomes 1 1mm. Lock the nut.
TIGHTENING TORQUE: l9.6f 7.8N.m{200+80kgf.cm}
4.After adjusting the pedal height, check the pedal free

travel and lighting of the stop lamp.
(3) FREE PLAY CHECK
1.After stopping the engine, depress the brake pedal
several times so that no vacuum could remain in the
brake booster Ay.
2.Check the pedal free travel by pushing the brake pedal
lightly by hand.
SPECIFIED VALUE: A:0.5 - 3.0 mm
(4) FREE PLAY ADJUSTMENT

1.Adjust the pedal free travel by loosening the nut (a) and turning the push rod(b) .
TIGHTENING TORQUE: 14.7+2.9N.m{150f 29kgf.cm)
2.After adjusting, check the pedal height and lighting of the stop lamp.
(5) RESERVE TRAVEL CHECK
1.Turn over the carpet near the brake pedal.
2.With the parking brake released while idling, depress the
brake pedal with the specified force. At this time.
measure the height from the left center section of the
brake pedal depressing surface to the upper surface of
the dash panel.
SPECIFIED VALUE: A:95 mm or more
(Pedal applying force 294N {3Okgf))
1-14! BLAKE BOOSTER

(2) AIR-TIGHT PERFORMANCE CHECK

Start the engine, then stop it one or two minutes later and
Good Faulty I
check the height of the brake pedal when depressing the
pedal with usual pedal applying force.
SPECIFIED VALUE: The pedal position of 2nd application
should be higher than that of the 1st
application, meanwhile that of the 3rd
application should be higher than that
of the 2nd application. (Each intervals
of depressing the pedal should be at
least five seconds.)
(3) OPERATION CHECK
1.While engine stopped, depress the brake pedal several
times with same level of pedal applying force. Check to
see that the pedal height does not vary each time.
2.Start the engine with the brake pedal depressed and
check the change of the pedal height.
SPECIFIED VALUE: The pedal should move slightly
toward the floor when starting the
engine with the brake pedal depressed
condition.
(4) AIR-TIGHT PERFORMANCE CHECK UNDER LOADED whiletheengine isrunning The pedal is heldfor
CONDITION 30seconds alter
With the engine running, depress the brake pedal. With this
condition stop the engine and hold the pedal position for 30
seconds. Check the change of the pedal height.
SPECIFIED VALUE: There should be no change in the
pedal height.
(5) CHECK BY MEANS OF PORTABLE BRAKE BOOSTER TESTER

@ OPERATIONS PRIOR TO CHECK
:onnect a portable brake booster tester, as indicated in the figure, to perform air bleeding of the tester.
I-
Negative pressure gauge
Applying force gauge
Vacuum hose
@ AIR-TIGHT PERFORMANCE CHECK

1.Start the engine. When a pressure gauge (negative pressure gauge) indicates a negative pressure of
66.7 kPa (500 rnmHg}, stop the engine and measure the pressure (negative pressure).
SPECIFIED VALUE: After the engine has been stopped, there should be no change in pressure (drop
of negative pressure) for 15 seconds.
2.Start the engine and depress the brake pedal with a pedal applying force of 196 N (20 kgf]. When
the pressure gauge (negative pressure gauge) indicates 66.7 kPa (500 mmHg}, stop the engine and
measure the pressure (negative pressure).
SPECIFIED VALUE: After the engine has been stopped, the change in pressure (drop of negative
pressure) should be within 2.7 kPa {20 rnmHg) for 20 seconds.
t
@ NO-BOOSTER OPERATION CHECK
1.With the engine in a stopped state, set the value of the pressure gauge (negative pressure gauge) to
zero. At this time, check the relationship between the pedal applying force and the hydraulic
pressure.
SPECIFIED VALUE:
Pedal applying force [N Ikgf)] 98(10) 2941301
Fluid pressure [MPa (kgflcm'll 0.21{2.1) 2.35(24.0)
2.Start the engine. Set the reading of the pressure gauge (negative pressure gauge) to
60,0kPa(45OmmHg). After stopping the engine, check the hydraulic pressure of the master cylinder
for each pedal applying force.
SPECIFIED VALUE:
]
Pedal ap lying force [N (k f)] 147115) 196120)
Fluid pressure [MPa (kgf/cm?l i 1.91(19.5) 4.16(42.4) 6.47166.0) 6.98f71.2)
2 BRAKE PEDAL
Instrument

Remove the instrument panel finish lower panel.
) COMPONENTS
*:MP grease
Unil:N.m(kgf.crnl
1 a Pin Wlhole
2 b Shatt, pedal
3 c Pedal Ay, brake
4 d Bush
5 e Spring, torsion
2-34 3PERAX3N AFTER INSTALLATIDb?

1.Check and adjust the brake pedal.
Refer to Page El-I.
2.lnstall the instrument panel finish lower panel.

-
I -
3 BRAKE MASTER CYLINDER
CAUTION
Care must be exercised so that no brake fluid may adhere to the paint surface. If brake fluid is
adhered to the paint surface, immediately wipe it out and wash it with water.
Never reuse the wiped-out brake fluid.
Never turn ON the IG, until air bleeding is finished. Failure to observe this caution may allow air to
admit into the actuator, thus making it difficult to perform air bleeding.

SST
09023-00100-000 Wrench, union nut
09730-87401-000 Gauge set. brake booster gauge
IBrake fIuld(DOT3) 1
1.Rernove the power steering reserve tank from the bracket
without cutting the hydraulic pressure pipe.
2.Detach the clamp retaining the hose pressure feed (return
side) and the vacuum hose Ay.
3.Detach the clamp retaining the hose reservoir-to-pump
and the brake tube.
4.Drain the brake fluid from the master cylinder reservoir.
) COMPONENTS
L
Unit:N.m(kgf.cm)
v 1 a Tube, brake
A 2 b Cylinder SIA, brake master
3 c Gasket, master cylinder
4 d Seal, master cylinder piston

(1) BRAKE TUBE
Disconnect the brake tube from the brake master cylinder
AY.
SST: 09023-00100-000
CAUTION
Plug the disconnected brake tube, using a bleeder plug
cap, etc.
(1) BRAKE MASTER CYLINDER SIA
I .Check the clearance of the brake booster push rod.
2.Fit an O-ring into the groove at the rod section of the
gauge(SST). Then, install an attachment to the same
place. Moreover, apply silrcone grease to the surface of
the attachment in advance.
SST: 09730-87401-000
09730-87401-000[09737-87003-0001
09730-87401-000[09733-87401-0001
09730-87401-000[09731-87401-0001
3.0n the other hand, install the oil seal, that is mounted
between the master cylinder and the booster, to the
booster side. Furthermore, install the booster hose to the
booster.
CAUTION
Apply grease to the lip section of the oil seal.
4.Set the gauge (SST) to a position where the rod of the

gauge (SST) may come in contact lightly with the piston
of the master cylinder.
CAUTION
Install the gasket to the master cylinder.
5.lnstall the SST at the booster side in an inverted state.
6.Start the engine and apply a negative pressure of about
66.7 kPa (500 mmHg] to the booster.
7.Then, check the clearance between the rod of the SST

and the push rod of the booster.
SPECIFIED VALUE: Clearance: 0 rnrn
8.lf it is out of specifications, loosen the double nuts of the
push rod at the brake booster pedal. Perform the
adjustment by turning the nut at the booster side.
9.Connect the brake tube to the brake master cylinder Ay,
using the SST.
CAUTION
Tighten the union nut of the front brake tube
temporarily by hand till flare portion of the tube contacts
securely to the seat, and then tighten it with the
specified tightening torque.
Never turn ON the IG, until air bleeding is finished.
TIGHTENING TORQUE: 15.5k2.5N.m
1159k26kgf .cm}
1.Install the bracket to the power steering reserve tank.
2.Perform air bleeding of the brake system.
CAUTION
* After completion of the air bleeding of the brake system, check that no air has been admitted once
again.
3.Replenish the reservoir tank with brake fluid up to the MAX line
4.Confirm that there is no brake dragging.
IBrake fluid(DOT3).Rubber grease
(1) COMPONENTS
I I
. .):Rubber grease
34:Non-reusable parts
N.m{kgf.cm]
1 a Bolt. set 9 i Seal, master cylinder piston
2 b Cap , reservoir filler r A 10 j Ring, hole snap
3 c Diaphragm, reservoir 11 k Guide, master cylinder piston
4 d Strainer, master cylinder reservoir 12 1 Cup, cylinder
5 e Flort, switch operating 13 m Ring, 0
6 f ReSe~oirSIA, master cylinder r 14 n Piston SIA, master cylinder No.1
7 g Grommet, reservoir r 15 o Piston SIA, master cylinder No.2
8 h Pin

(1) HOLE SNAP RING
1.Clamp the master cylinder in a vice with aluminum sheets, etc. interposed.
CAUTION
Do not clamp the cylinder section, because there is a potential for deformation.
2.Remove the pin by means of a screwdriver with the piston
in a pushed-in state.
3.Remove the hale snap ring with the piston pushed into,
by using a snap ring expander.
CAUTION
Be careful so that the oil may not scatter when pushing
the piston.
(2) MASTER CYLINDER PISTON SIA No.1

Take out the brake master cylinder No. 1 piston SIA straight.
CAUTION
Be very careful not to scratch the cylinder inner surface during the removal operation.
(3) MASTER CYLINDER PISTON SIA No.2

1.Tap flange portion lightly against a chip of wood until the
end of the brake master cylinder No. 2 piston S/A comes
out.
2.When the end of the brake master cylinder No. 2 piston
SIA comes out, then pull out the piston straight.
CAUTION
Be very careful not to scratch the cylinder inner surface
during the removal operation.
3-2-4 INSPECTION
(1) BRAKE MASTER CYLINDER
1.Check to see if the cvlinder bore exhibits scratches.
2.Check to see if the cvlinder exhibits deformation and scratches
(1) HOLE SNAP RING
?.With the piston in a pushed state, assemble the hole snap
ring, using a snap ring expander.
- El-12
2 Care must b e exercrsed so that the hole at the arrow-
headed section may not b e p l u g g e d d u r ~ n gthe
lnstallat~onof the hole snap rlng
AllC5(144TlO
4 BRAKE BOOSTER
CAUTION
Never turn ON the IG,until air bleeding is finished. Failure to observe this caution may allow air to I
II
admit into the actuator, thus making it difficult to perform air bleeding. t
I
I
4-1-1 ARTICLES TO BE PREPARED I
I
SST !
i
i
i
j
i
1
@+ 09258-00030-000 Plug set, hose
I
@& i i
i
I!
09730-87401-000 Gauge set, brake booster gauge
i1
j

1.Remove the instrument panel finish lower panel.
2.Remove the fender.

3.Remove the brake master cylinder.

Refer to Page El-6.
4.Disconnect the suction hose of the air conditioner from the bracket
5,Disconnect the two brake tubes attached to the ABS
actuator, using the SST. Remove the disconnected brake
tubes.
SST 09023-00100-000
CAUTION
Clog the disconnected brake tube, using a bleeder plug
cap or the like.
6.Slacken the bolts and nuts that are attached to the
bracket. Move the vane pump toward the front side of the
vehicle.

COMPONENTS
K N o n - reusable parts
Unit:N-m(kgf.cm]
1 a Clip 6 f Booster Ay, brake
A 2 b Hose Ay, vacuum 7 g Gasket,brake booster bracket
3 c Clevis, master cylinder push rod
4 d Nut
5 e Nut
4-1-4 INSPECTION
(1) CHECK VALVE (VACUUM HOSE)
1.Ensure that there is air continuity from the booster side to the engine.
- Furthermore, ensure that there
is no air continuity from the engine to the booster side.
2.Replace the vacuum hose Ay in case that the above condition is not satisfied.
1: Engine side
2: Booster side
(2) BRAKE BOOSTER PUSH ROD
Check and adjust the brake booster push rod clearance.
Refer to Page E l -6.

(1) VACUUM HOSE
Install the vacuum hose.
CAUTION I I
Make sure that the vacuum hose is connected in the
correct direction. Ensure that the paint of "ENGINE +"
comes at the intake manifold side of the engine. If the Engine side
print mark has been erased, check air continuity and <=.
carry out the installation in such a way that air
continuity exists from the booster side to the intake
manifold side.
CAUTION
Be sure to insert the vacuum hose up to the stopper
surface of the union. Moreover, install the clip so that
the dimension A indicated in the figure may become 2 -.---
*----,
to 5.5 mm.
N16C7005T10
- El -1 6
1.Install the vane pump.
2.lnstall the two brake tubes to the ABS actuator at the motor side.
3.lnstall the brake master cylinder.
Refer to Page El-6.
CAUTION
Tighten the union nut of the front brake tube temporarily by hand till flare portion of the tube
contacts securely to the seat, and then tighten it with the specified tightening torque.
4.lnstall the power steering reservoir tank and suction hose to the bracket.
5.Adjust the brake pedal height.
CAUTION
After completion of the air bleeding of the brake system, check that no air has been admitted once
again.
-/.Replenish the reservoir tank with brake fluid up to the MAX line,
9.lnstall the fender.

5 FRONT DISC BRAKE PAD
WARNING
Keep the position of the jack-up point to avoid causing serious accident due to inclining of the
vehicle.
CAUTION
Any kind of lubricants applied to the disc brake pad or the brake disc could reduce the efficiency of
the brake.

Instrument
l ~ o r q u wrench
e

2.Remove the front disc wheel.
3.Check the pad for thickness as follows: In the case of the
pad at the inner side, perform the check through
inspection hole of the cylinder. In the case of the pad at
the outside, perform the check from the rear of the
caliper.
NOTE
New part: 9.5mrn
1
) COMPONENTS
Unit:N.m(kgf.cm]
1 a Bolt, disc brake cylinder 6 f Shim, anti squeal, No.2
A 2 b Pad, disc brake Wlwear indicator 7 g Shim, anti squeal, No.4
3 c Pad, disc brake, No.2
4 d Shim, anti squeal, No.3
5 e Shim, anti squeal, No.1
5-1-4 INSPECTION
(1) BRAKE PAD THICKNESS
1.Suspend the disc brake cylinder, using a wire or the like.
2.Check the thickness of the disc brake pad, and replace it
if the thickness is less than the allowable limit.
ALLOWABLE LIMIT: 1Smm
NOTE
New part: 9.5mm

(1) DISC BRAKE PAD WI WEAR INDICATOR
Install the disc brake pad with a wear indicator at the inner
side of the vehicle. At this time, make sure that the wear
indicator comes at the vehicle upper side during the
installation.
5-16 OPERATION AFTER INSTALLATION

1.Replenish the reservoir tank with brake fluid up to the MAX line
TIGHTENING TORQUE: 103.Of l4.7N ~m{1050+150kgf~cm)

6 FRONT DISC CALIPER
WARNING
vehicle.
CAUTION
Never reuse the wiped-out brake fluid.
Care must be exercised so that no oil, grease, etc. may adhere to the sliding surface between the
brake pad and the brake disc.

Tool
rake pedal pusher
Instrument
l~orque
wrench
1Brake fluid(DOT3) 1
1.Check the front wheel bearing for excessive looseness.
2.Measure the runout of the disc edge surface, using a dial gauge.
3.Drain brake fluid from the reservoir tank.
I) COMPONENTS
Unit:N.m(kgf-crn)
1 a Caliper Ay, disc brake front
2 b Disc, brake

1.Replenish the reservoir tank with brake fluid up to the MAX line.
CAUTION
again.

TIGHTENING TORQUE: lO3.Of 14.7N.m{1050f 150kgf.crnl
Confirm that there is no brake dragging

:
CAUTION
While using compressed air, put on safety glasses.
When blowing on compressed air, be careful not to pinch fingers and so on by the piston came out
intensely.
Any kind of lubricants applied to the disc brake pad or the brake disc could reduce the efficiency of
the brake.

Instrument
l ~ o r q u wrench
e 1

) COMPONENTS
f
I
*:Rubber grease
33:Non-reusable parts
Unit:N.m(kgi.crnJ
(2) DISASSEMBLY AND ASSEMBLY PROCEDURES
1 a Bon,disc brake cylinder 9 i Shim,anti squeai.No4
2 b Pin,cylinder slide 10 j Boot, pin
3 c Mounting, disc brake cylinder 11 k Plate, disc brake pad guide
4 d Pad,disc brake Wlindicator No.1 A12 1 Boot, cylinder
5 e Pad,disc brake No.2 r A 13 mPiston, disc brake
6 f Shimvantisqueal,No3 A 14 n Seal, piston
7 g Shirn,anti squeal,Nol 15 o Cylinder,disc brake
8 h Shim,anti squeal,No2

(1) DlSC BRAKE PISTON
Remove the piston seal by pulling out the disc brake piston, using compressed air. When compressed
air is blown to the brake piston, reduce the pressure with a cloth, etc. interposed so as to avoid scores
on the components.
CAUTION
Be very careful not to scratch the cylinder inner -%
8 t
surface.
6-24 POINTS OF ASSEMBLY

Prior to the assembling, wash each part with brake fluid that is the same as the one to be used
LUBRICANT Brake fluid(DOT3)

Before the disc brake piston is assembled to the disc brake cylinder, apply brake fluid to the disc brake
piston.
LUBRICANT Brake fluid(DOT3)
/
(2) PISTON SEAL

As for the piston seal, be sure to use a new part. Prior to the installation to the disc brake cylinder, apply
brake fluid to the new piston seal.
Securely assemble it in the disc brake cylinder groove, while paying attention not to allow any twisting.
LUBRICAM: Brake fluid(DOT3)
(3) CYLINDER BOOT

Before the disc brake piston is assembled to the disc brake cylinder, install the cylinder boot to the disc
brake piston edge.
install the cylinder boot to the boot groove provided at the inside of the disc brake cylinder. Ensure that
the cylinder boot is fitted securely into the boot groove.
Make sure to manually insert the disc brake piston to the disc brake cylinder.
7 FRONT BRAKE DISC
WARNING
vehicle.

Instrument
...- .. -...-. ..
( ~ o r q uwrench
e 1
2.Rernove the front disc wheel.
I) COMPONENTS
(2) REMOVAL AND INSTALLATION PRPCEDURES
1 a Caliper Ay, disc brake front
2 b Disc, brake
7-1-4 INSPECTION
(1) RUNOUT
1.Confirm that there is no excessive play in the front wheel bearing.
2.Measure the runout of the disc end face, using a dial
gauge.
SPECIFIED VALUE: O.1Omm
(Measure it at a point 10mm from outer
periphery edge of the disc)
3.ln case that the disc runout exceeds the limit, check the
axle hub runout. And replace the disc ifno abnormality is
found on the axle hub.
(2) DISC THICKNESS

1.Measure the thickness of the brake rotor disc, and
replace it if the thickness is less than the limit.
ALLOWABLE LIMIT 16mm
NOTE
New palt: 17mm
1 CllC5015Tl

1.Install the front disc wheel.
TIGHTENING TORQUE: lO3.Of 14.7N.m{1050f 150kgfa n )

-
8 REAR BRAKE DRUM
WARNING
vehicle.
CAUTION
Care must be exercised so that no oil, grease, etc. may adhere to the sliding surface between the
brake lining and the brake drum.

SST
09510-87301-000 Puller, axle shaft
Instrument

2.Remove the rear wheel.
3.Disconnect the brake tube from the brake wheel cylinder assembly.
I) COMPONENTS
+:Rubber grease
.): Brake grease
Unit:N.m{kgf%mj
1 a Cap, rear wheel grease retainer 15 o Washer, web
2 b Pin, cotter 16 p pin.automatic adjust
A 3 c Nut, castle 17 q Spring, torsion
4 d Washer 18 r Latch.automatic adjust
r 5 e Drum SIA, brake rear 19 s Shoe Ay, brake
6 f Cup, shoe hold down spring 20 t Washer, type C
7 g Spring, compression 21 u Lever SIA, parking brake shoe
6 h Pin, shoe hold down spring 22 v Shoe Ay, brake
9 i Spring, tension 23 w Cylinder. wheel brake, rear
10 j Spring, tension 24 x Plate SIA, brake backing, rear
11 k Spring, tension 25 A Boot, wheel cylinder
12 1 Strut, parking brake shoe 26 B Cup. cylinder
13 rn Lever SIA, parking brake shoe 27 C Piston, wheel brake cylinder
14 n Washer, type C 28 D Spring.compression
. . -~ El-28
Remove the brake drum, using the SST.
SST 09510-87301-000
8-1-5 INSPECTION
(1) Brake drum inner diameter
If the brake drum exhibits excessive uneven wear, grind or
replace the brake drum.
SPECIFIED VALUE: 180mm
ALLOWABLE LIMIT: 181mm
(2) BRAKE SHOE THICKNESS

If the thickness of the shoe lining is below the limit or it
exhibits excessive uneven wear, replace the brake shoe.
SPECIFIED VALUE: 4.0mm
ALLOWABLE LIMIT: l.Omm
CAUTION
When replacing the rear brake shoe Ay, replace both
shoes in right and left wheels as a set in order to
prevent the pulling of brake.
(3) Contact between shoe lining and brake drum

Apply chalk to the inner surface of the brake drum. Slide the
brake shoe assembly, while it is being pressed against the
inner surface of the drum. If poor contact is present, be sure
to grind the brake shoe lining.
SPECIFIED VALUE: No significant poor contact is
present.
CAUTION
After completion of the check, be sure to wipe off the
chalk.
(4) WHEEL BRAKE REAR CYLINDER AY
Check the wheel brake rear cylinder assembly for corrosion and damage.
(5) BRAKE BACKING REAR PLATE S/A
Check the brake backing rear plate subassembly for wear and damage.
El-29
Install a new cotter pin after aligning the hole positions in the
tightening direction of the castle nut.
I LllK523OTlO

1.Connect the brake tube to the wheel brake rear cylinder assembly, using the SST.
SST: 09023-00100-000
CAUTION
Tighten the union nut of the front brake tube temporarily by hand till flare portion of the tube
contacts securely to the seat, and then tighten it with the specified tightening torque.
TIGHTENING TORQUE: 15.2+_2.5N.m{155+25kgf .cm]
CAUTION
again.
4.Check for brake fluid leakage.

5.lnstall the rear wheel.
TIGHTENING TORQUE: 103.0+14.7N~m{10501150kgf.cm]
6.Depress the brake pedal several times, thus activating the adjuster mechanism of the shoe
clearance, so that the shoe clearance may be adjusted to an optimum condition.
7.Check and adjust the pulling amount of the parking brake.
Refer to Page El-1 .

E2 PARKING BRAKE
PARKING BRAKE E2 - 1
BASIC CHECK AND ADJUSTMENT--- E2 - 1
PARKING BRAKE.............................. E2 - 2
REMOVAL AND INSTALLATION-------- E2 - 2
E2-1
1 PARKING BRAKE
1-1-1 PARKING BRAKE LEVER
(1) Check of pulling amount
1.Depress the brake pedal several times.
2.Operate the parking brake lever. At this time, ensure that
the brake warning lamp goes on.
SPECIFIED VALUE: Ensure that the brake warning lamp
goes on before the parking brake lever
is engaged one notch after the lever
starts to be pulled out.
3.0perate the parking brake lever several times. Then,
return the lever fully.
4.Slowly pull the parking brake lever with the specified
force. At this time, count the number of clicking sounds.
SPECIFIED VALUE: 4 to 7 notches
(Operating force: 196N (20kgf))
(2) Adjustment of pulling amount
1.Depress the brake pedal several times.
Adjusting nut
\ 1
2.Rernove the rear console box.
3.Perform the adjustment to the specified value by turning
the adjusting nut.
SPECIFIED VALUE: 4 to 7 notches
(Operating force: 196N (20kgf))
4.Check that the parking brake exhibits no dragging.
- E2-2
2 PARKING BRAKE
Instrument
[~or~u e
wrench

1.Remove the rear console box.

3.Remove the rear disc wheel
4.Remove the brake drum.
Refer to Page E1-26.

) COMPONENTS
1 a Lever Ay, parking brake
2 b Cable Ay, parking brake(Rear left)
3 c Cable Ay, parking brake(Rear right)

1.lnstall the brake drum.

TIGHTENING TORQUE: I O ~ . O + ~ ~ . ~ N . I ~ { I O
150kgf.cm)
~O+

4.Check and adjust the pulling amount of the parking brake lever.
Refer to Page El-I.
5.lnstall the rear console box.

E3 BRAKE CONTROL
ABS E3-1
ABS ACTUATOR UNIT ...................... E3 - 1
FRONT WHEEL SPEED SENSOR-------- E3 - 4
REAR WHEEL SPEED SENSOR--------- E3 - 6
REMOVAL AND INSTALLATION-------- E3 6
CONTROL SYSTEM
-
E3-7
ARTICLES TO BE PREPARED---------- E3 - 7
HANDLING INSTRUCTIONSOF
CONTROL SYSTEM E3-7
SYSTEM WIRING DIAGRAM E3 - 8
ARRANGEMENT OF ECU
TERMINAL .................................... E3 - 8
ARRANGEMENT OF VEHICLE
HARNESS SIDE CONNECTOR
TERMINALS E3-9
LOCATION OF COMPONENTS E3 - 10
HOW TO PROCEED WITH
TROUBLE SHOOTING------------------ E3 - 11
INQUIRY ------------------------------------ E3- 12
DlAGNOSlS ................................. E3- 12
FAIL-SAFE FUNCTION ------------------ E3-16
SENSOR CHECK FUNCTION (TEST
MODE) E3 - 16
BASIC CHECK E3 - 17
TO DIAGNOSIS E3 - 19
TO MALFUNCTION PHENOMENA--- E3 - 25
UNIT CHECK E3 - 31
ABS
1 ABS ACTUATOR UNIT
SST
Instrument
/ ~ o r q u wrench
e
1-1-2 OPERATION BEFORE REMOVAL i

1.Remove the negative terminal of the battery.
CAUTION
When the negative (-) terminal of the battery is removed, the memories of some systems will be
erased. Therefore, record the contents of the memoly of each system, as required, and input them
afler the operation.
2.Prevent the brake fluid from flowing out by the following procedure.
(1) Remove the disc wheel (four wheels).
(2) Connect a bottle for air bleeding to the bleeder plug
of the front wheel calipers at both right and left
sides. Then, open the bleeder plug.
(3) Depress the brake pedal more than 60 rnm. At this

point, secure the brake pedal.
NOTE
This closes the master cylinder port, thus preventing
the brake fluid from flowing out from the brake
hydraulic circuit.
(4) Close the bleeder plug of the front wheels at the right
and leli sides.

Refer to Page 12-23
I) COMPONENTS
1
r
r
Unlt:N.m(kgf.crnJ

1 a BRAKETUBE
2
3
4
5
b Nut
c Nut
d Actuator Ay, Brake (ABS)
e Bracket, brake actuator

(1) ABS ACTUATOR
1.Remove the connector by pulling up the lock lever fully.
2.Remove the brake tube, using the SST.
(1) Remove the four tubes at the upper surface of the
ABS actuator.
(2) Remove the two tubes at the right side.
SST:09023-00100-000
3.Clog the disconnected brake tube, using a bleeder plug
cap or the like.
4.Remove the ABS actuator together with the bracket.
(1) ABS actuator
1.lnstall the ABS actuator to the ABS actuator bracket with
the flange bolt turning prevention section facing upward.
2.Using the SST, install the brake tube to the brake actuator
assembly.
CAUTION
Temporarily tighten the union nut until the flare section
of the tube closely contacts with the seat. After that,
tighten the nut to the specified torque.
TIGHTENING TORQUE: l 5 . 2 f 2.4N.m
{155+-25kgf.cm)
SST 09023-00100-000
CAUTION
After completion of the air bleeding of the brake system, check that no air has been admitted once
again.
2.Check for brake fluid leakage.

5.lnstall the disc wheels.

TIGHTENING TORQUE: 103.0~14.7N.m{1050+ 150kgf.cm)

7.lnstall the negative terminal of the battery.
I
2 FRONT WHEEL SPEED SENSOR
Instrument
ITorque wrench

1.Remove the negative terminal of the battery.
CAUTION
When the negative (-) terminal of the battery is removed, the memories of some systems will be
erased. Therefore, record the contents of the memory of each system, as required, and input them
after the operation.
2.Lifi up the vehicle.

t 4.Rernove the front fender liner.
1 ) COMPONENTS
Unit:N.rn(kgf.crn)
1 a Sensor, skid control front
2-1-4 INSPECTION
Carry out the unit check of the front wheel speed sensor
1.Install the front fender liner.
TIGHTENING TORQUE: 103.0+14.7N .m {1050+150kgf~cm)

3 REAR WHEEL SPEED SENSOR
Instrument

1.Disconnect the negative terminal of the battery.
CAUTION
When the negative terminal of the battery is disconnected, the memories of all system ECUs and
the radio settings will be erased, so after the power is restored these need to be reset.

3.Remove the rear wheels.
\ COMPONENTS
L
Unit:N.m(kgf.crnJ
1 a Sensor, skid control rearlright
2 b Sensor, skid control rearlleft
3-1-4 INSPECTION
1.Conduct an individual inspection of the skid control rear sensor.

1.Install the rear wheels.
TIGHTENING TORQUE: 103.0+ 14.7N.m {1050+ 150kgf -cm}
2.Connect the negative terminal of the battery.

3.Lifi down the vehicle.
4 CONTROL SYSTEM
SST
Shape I Part No. 1 Part name
09991-87404-000
(09991-87401-000)
/ 09991-87403-000 Wire, diagnosis check

1.The ABS actuator and sensors are precision components. Do not subject them to a large shock
during removal and installation. Do not use components that have been subjected to a large shock
(such as being dropped on the floor). (
2.Make sure water does not get in the system when conducting an inspection during rainy weather or
when the vehicle is washed, and do not get water on the ABS actuators or sensors.
3.lf an error is detected in the ABS ECU and the vehicle returned to normal when the ABS actuator was
replaced, reinstall the replaced ABS actuator (the one that was deemed to be faulty) and confirm that
the initial error occurred again before finally determining that the ABS ECU is defective.
4.Do not disassemble the ABS actuator.
5.Make sure that all of the wheel brake related parts are installed properly.
&When a wireless device is installed, take the following precautions.
(1) Move the antenna as far away as possible from the computer unit.
(2) Place the antenna feeder as far away as possible from the ABS computer and wire harness
(minimum distance of 30 cm). Keep the antenna feeder level and avoid pulling it around.
(3) The antenna is matched well.
(4) Do not install wireless devices with a high output.
1-3 SYSTEM WIRING DIAGRAM
C13C501iES23
-4 ARRANGEMENT OF ECU TERMINAL

BS ECU
Terminal name
4-5 ARRANGEMENT OF VEHICLE HARNESS SIDE CONNECTOR TERMINALS

ABS ECU
...
C13C5W2510
As for the name of the terminal of the ABS ECU vehicle harness side connector, see the computer connector terminal
arrangement diagram.
WHEEL SPEED SENSOR
Combination meter
I BRL
\ -
iagnosis check connector
ECUT,
-
a ABS actuator
b Brake fluid level SW
c Stop lamp SW
d ABS warning lamp
e Brake warning lamp
f DLC
9 Wheel speed sensor&rotor front
h Parking brake SW
i Wheel speed sensor&rotor rear
i
This system is equipped with a diagnosis function capable of performing the self-diagnosis of
malfunctioning sections. This will be an important help at the time of trouble-shooting.
The diagnosis of this system has a backup that uses an EEPROM (non-volatile ROM). Hence, the
diagnosis code is stored in memory even if the power is cut off.
Thoroughly ask the

user about malfunction
and environmental
phenomena
+
Erase the diagnosis codes
Erasing is impossible
Erasing is possible
(~unning test using sensor check function)
c"?Basic checks
I
Confirm the phenomenon
and grasp the malfunctioning
condition
The malfunction is
reproduced and t
he normal code is not reproduced and
outputted the normal code is
outputted the abnormality code
was outputted in the
., first check.
rouble-shooting according to phenomeno Trouble-shooting according to system
1 I I
Erasing is impossible
c Erase the diagnosis codes
Erasing is possible
unning test using sensor check functio
Abnormality code
1 Make sure that the I

Is the vehicle restored .......... mallunct~onpheno.nenon
bv the customer
1 isclalmed
remedied positively
~ ~ E3-12
4-8 INQUIRY
When the vehicle is encountered with a malfunction, even if an attempt is made to remove its cause, it is
impossible to find out the cause, unless the malfunction phenomenon can be actually confirmed. Hence,
the vehicle may not be remedied to the normal condition regardless of the repairing operations. The
diagnosis through inquiries to the customer is to be performed in order to collect information from the
customer before confirming the malfunction phenomenon. This step will be a very important help in
reproducing the malfunction phenomenon.
Moreover, the information obtained by the diagnosis through inquiries to the customer can be used as
reference at the time of trouble-shooting. Therefore, it is essential to ask the customer mainly about the
items related to the malfunction.
In addition, during the diagnosis through inquiries, utmost attention must be paid to complaints of the
customer, for it may include phenomena peculiar to the ABS-equipped vehicles.
4-9 DIAGNOSIS
4-9-1 OUTLINE
When any abnormality code of the diagnosis is indicated, it is necessary to confirm the relationship with
, i the reproduced malfunction phenomenon by ascertaining whether the system malfunction has occurred
in the past or it still persists up to the present. To this end, the diagnosis code should be indicated twice
before and after the confirmation of the phenomenon.
1.While the vehicle is stopped, use the SST to short circuit the ECUT terminal in DLC with the E
terminal.
SST: 09991-87404-000
09991-87403-000
2.After the IG SW has been set to "ON" position, read the number of times the ABS warning lamp
flashes.
CAUTION
Connecting the connector in the wrong location could cause a malfunction, so make sure the
connection is correct.
NOTE
When the system is functioning normally, the flashing interval is 0.25 second.
If there is one malfunction code, the lamp will flash at an interval of 4 seconds and the same code
will be outputted. If multiple codes are outputted, the respective codes will be outputted in order at
an interval of 2.5 seconds, and after all the codes have been outputted, there will'be another 4
second pause before the output of the codes starts over again.
When multiple codes are outputted, the codes will be outputted in order, starting - from a smaller
code.
-
ON ON I
ECUT I ECUT i
OFF 1 OFF I
1 1
0.25sec. -0.5sec.
I I
I -0.5sec.
I I I /
warning warning
lamp , lamp ,
OFF ' 3sec. II OFF I, 14sec.~;;jc/
3sed. >
J+
ec. I
/AI
1,2.5sec
:
I Code31 . ~e~etitidn
0.25sec.
e 2
i ~ o d 21
<Normal code> <Plural codes (No.21 and 31) >
-- --

The diagnosis of this system has a backup that uses an EEPROM (non-volatile ROM). Hence, the
diagnosis code is stored in memory even if the power is cut off. Therefore, the following method is the
only way the diagnosis code can be deleted.
1Stop the vehicle.
2.Short the terminal T of the ECU of DLC with the terminal E, using the SST. Then, turn ON the ignition
sw.
SST: 09991-87404-000
09991-87403-000
3.Repeat turning ON and OFF the stop lamp SW at least

eight times for five seconds by depressing the brake
pedal. (If the codes have not been erased, repeat this
operation again.)
LllC5i28ETl
4.Release the terminal T of the ECU of DLC and terminal E.

CAUTION
When the diagnosis codes are erased, the ABS warning lamp outputs the test mode codes, thereby
automatically executing the sensor check function (test mode). At this point, release the short. Turn
LOCK the IG SW once. Conduct the function check of each sknsor by'running the vehicle.
IGSW 4
LOCK j
0 N - I
ECU T I Once Three times 5 times 7 times
OFF I Twice 14 times16 timed I 8 times
ON I
Stop lamp switch r l M n L p
OFF I
I
Within 3sec:. Within 5sec. I

d
I ,
Erasure of all diagnosis code memories I
I
NOmemories exist. Memories exist
Test mode code ;
1
46s warning lamp

OFF ,
I 3sec. ! 4sec. 1 , lFlashina (Test mode indication)
'Test mode '
biagnosis code output Code output
4-9-4 CONTENTS OF DIAGNOSIS
List of diagnosis
- codes
Code No. I
ABS Brake
Diagnosis system Diagnosis item
0:illuminated
x : Extinguished
W1:This shows the output code when the diagnostic tester is used. W2:llluminated in cases where two wheels or more are
malfunctioning.
4-10 FAIL-SAFE FUNCTION
1.If the signal system of the ABS computer encounters with any abnormality, the ABS warning lamp
goes on, thereby indicating an abnormality. Simultaneously, the solenoid relay incorporated inside the
ABS actuator is turned OFF. Consequently, the control signal to the solenoid is prohibited, thus
allowing the system to return to the normal braking function.
2.lf the ABS computer encounters with any abnormality, the ABS warning lamp goes on, thereby
indicating an abnormality. Furthermore, the solenoid relay is turned OFF.
3.lf an abnormality, in which the EBD can not function, should occur, the brake warning lamp goes on
simultaneously and the EBD control is prohibited.
4-11 SENSOR CHECK FUNCTION (TEST MODE)
The test mode is executed either immediately after the trouble codes have been erased through the
brake pedal operation or when the ignition SW is turned ON for the first time after a new ABS actuator
has been installed. When the switching is made from the regular mode to the test mode, first the ABS
computer memorizes all the test mode codes. Then, the checks are conducted for each sensor while the
vehicle is being run. The test mode codes that have been judged to be normal by the ABS computer will
be erased from the memory. Therefore, if no driving is performed or if driving is performed but the test
mode inspection conditions have not been satisfied, the test mode codes in memory will not be deleted
but will be displayed as abnormal test mode codes.
4-11-1 OUTPUT OF TEST MODE CODE
?.Release the short circuit of DLC and set the ignition SW to the ON position. At this time, ensure that
the ABS warning lamp is illuminated for three seconds and, then, flashes at an interval of 0.13
second.
CAUTION
* At this time, if the ABS warning lamp remains lit, then there is probably a problem with the system.
Check the diagnosis code and make repairs.
2.Start the engine.

3.Perform a running at a speed of about 45 kmlh.
4.Stop the vehicle.
5.Use the SST to short circuit DLC ECUT terminal with the E terminal, and then read how many times
the ABS warning lamp flashes.
NOTE
When the system is functioning normally, the flashing interval is 0.25 second.
If there is one malfunction code, the lamp will flash at an interval of 4 seconds and the same code
will be outputted. If multiple codes are outputted, the respective codes will be outputted in order at
an interval of 2.5 seconds, and after all the codes have been outputted, there will be another 4
second pause before the output of the codes starts over again.
When multiple codes are outputted, the codes will be outputted in order, starting from a smaller
code.
List of test mode codes
Performa straight running at a speed of 7 krnlh.
Drive the vehicle straight for five seconds or more at a

speed of 10 kmlh to 40 kmlh. (Or drive the vehicle
straight until the vehicle speed reach over 40 kmh.
%:This shows the output code when the diagnostic tester is used.
4-12 BASIC CHECK
4-12-1 ABS ECU
(1) CIRCUIT INSPECTION
Perform the ABS computer circuit check during the system check operation, following the procedure
given below. If any circuit or connector proves to be faulty, repair the circuit or connector concerned. If
the circuits and connectors are satisfactory, replace the ABS actuator.
CAUTION
When you apply a tester probe to the ABS computer connector or you make a short to the body
earth, use the diagnosis check wire (SST). This will prevent any damage to the terminal.
(2) VISUAL INSPECTION AND CONTACT FORCE INSPECTION

1.Disconnect the negative terminal of the battery.
CAUTION
When the negative terminal (-) of the battery is removed, all setting memories of the computers in
each system and the radio will be erased. Hence, it is necessary to redo the settings when the
battery terminal is restored.
2.Check the connector of the ABS actuator.

(3) EARTH CIRCUIT CHECK
1.Remove the negative terminal (-) of the battery.
CAUTION
When the negative terminal (-) of the battery is removed, all setting memories of the computers in
each system and the radio will be erased. Hence, it is necessary to redo the settings when the
battery terminal is restored.
2.Disconnect the connector of the ABS actuator. Check that there is continuity between the following
harness side connector terminal and the body earth.
(1) Harness side connector 2- Body earth
(2) Harness side connector 18- Body earth
SPECIFIED VALUE: Continuity exists
(4) POWER SUPPLY CIRCUIT CHECK
1.With the ABS actuator connector disconnected, measure the voltage between each power supply
terminal and the body earth.
CAUTION
While checking the ABS computer, there are instances where you may conclude that there are "No
trouble'' in the system because the terminal contact conditions have been altered due to the
detachment of the connectors. Hence, when you get the check results of the ABS computer circuit
that suspect a faulty ABS computer, it is advisable to reconnect the connectors concerned to see if
there will occur any deficiency in order that you may correctly evaluate whether or not the ABS
computer is satisfactory.
4-12-2 BATTERY VOLTAGE MEASUREMENT

Measure the battery voltage while the engine is off.
SPECIFIED VALUE: 10 -14 V (while engine is off)
4-12-3 BRAKE FLUID INSPECTION

Check if the specified amount of brake fluid is in the master
cylinder reservoir and make sure there are no brake system
fluid leaks.
4-12-4 BRAKING FORCE CHECK

Check to see if the braking forces are more than the specified values, using a brake tester.
1 Braking force
Sum of braking forces of rear wheels 10% of axle weight or more
Difference in braking force between right and left
8% of axle weight or less
"..,.,.,,"
,",h.S.Slr
Total sum ! 50% of the vehicle weight at time of inspection or more
4-12-5 WARNING LAMP CHECK

Check when the ignition SW is turned to "ON" if the ABS warning lamp lights up for approximately 3
seconds and then turns off.
NOTE
Conduct the brake warning lamp check with the parking brake in a released state.
E3-19
As for the troubleshooting according to system, perform the related troubleshooting, based on the
followina table aiven
" below
Troubleshooting according to diagnosis code No.21 to
Replace the ABS actuator.
%:This shows the output code when the diagnostic tester is used
- -
4-13-1 DIAGNOSIS CODE N~.~I,~~(SOLENOID RELAY SYSTEM DIAGRAM)

(1) DIAGNOSIS CODE OUTPUT CONDITIONS
1.The ABS ECU monitors the solenoid relay circuit at all times. When the [OFF] state of the solenoid
relay continues even if the ABS ECU turns ON the solenoid relay, the system judges it as a solenoid
relay system open wire. As a result, an abnormal code is outputted. (No.11)
2.When the [ON] state of the solenoid relay continues even if the ABS ECU turns OFF the solenoid relay,
the system judges it as a solenoid relay system short. As a result, an abnormal code is outputted.
(No.12)
(2) CHECKING POINTS
1.Is the ABS fusible link normal?
2.1s the harness between the ABS fusible link and the ABS actuator normal?
3.Are all connected connectors normal?
(3) CHECKING METHOD
Dl.Check the ABS fusible link
SPECIFIED VALUE: The fusible link should not burn out.
If it is QK. ao to D2.
If it is NG. ao to D3.
D2. Continuity check between ABS fusible link and ABS actuator
1.After the IG SW has been set to [LOCK] position, disconnect the negative terminal of the battery.
2.Disconnect the ABS fusible link and the connector from the ABS actuator. Check the harness.
(1) ABS fusible link connector downstream side -ABS actuator harness side connector l(+BS)
SPECIFIED VALUE: lOQ or less (Continuity exists)
If it is OK. reolace the ABS actuator.

If NG. reoair the harness between the ABS actuator and the ABS fusible link and the connector.
D3. Continuity check between the ABS fusible link and the ABS actuator
1.After the IG SW has been set to [LOCK] position, disconnect the negative terminal of the battery.
(1) ABS fusible link connector downstream side -Body earth
SPECIFIED VALUE: 1M Q or more (No continuity)
If it is OK. ao to D4.
IfNG, r e ~ a ithe
r harness between the ABS actuator and the ABS fusible link and the connector.
W4.Check of ABS fusible link for operating state

1 .After the ABS fusible link has been replaced, install the connector and the battery negative terminal.
Turn ON the IG SW.
SPECIFIED VALUE: The fusible link is not fused.
If OK. observe the condition for a while.

If it is NG, reolace the ABS actuator.
-
!
4-13-2 DIAGNOSIS CODE No.l3,14(MOTER RELAY SYSTEM DIAGRAM)
?.TheABS ECU monitors the motor relay circuit at all times. When the [OFF] state of the motor relay
continues even if the ABS ECU turns ON the motor relay, the system judges it as a motor relay
system open wire. As a result, an abnormal code is outputted. (No.13)
2.When the [ON] state of the motor relay continues even if the ABS ECU turns OFF the motor relay, the
system judges it as a motor relay system short. As a result, an abnormal code is outputted. (No.14)
(2) CHECKING POINTS
1.1s the harness between the ABS fusible link and the ABS actuator normal?
2.Are all connected connectors normal?
3.When the ABS fusible link is abnormal, the diagnosis code No.11 is detected. The motor relay will not
turn ON.
(3) CHECKING METHOD
*I. Check continuity between the ABS fusible link and the ABS actuator
1.After the iG SW has been set to [LOCK] position, disconnect the negative terminal of the battery.
(1) ABS fusible link connector downstream side -ABS actuator harness side connector 17(+BM)
SPECIFIED VALUE: 1 0 8 or less (Continuity exists)
If it is OK. r e ~ l a c e
the ABS actuator.
If NG, r e ~ a ithe
r harness between the ABS actuator and the ABS fusible link and the connector.
.. E3-22
4-13-3 DIAGNOSIS CODE No.lS,No.lG(ABS ECU POWER SUPPLY SYSTEM)
1.The ABS ECU monitors the power voltage.
2.lf the power supply voltage of the ABS ECU drops below 9+0.5V during the running (with a vehicle
speed of 5 km/h or more) and this condition continues for more than 224 ms, this is regarded as a
power supply voltage abnormality. Consequently, an abnormality code is outpuned.(No.l5)
3.lf the power supply voltage of the ABS ECU exceeds 18k2.OV and this condition continues for more
than 224 ms, this is regarded as a power supply voltage abnormality. Consequently, an abnormality
code is outputted.(No.l6)
(2) CHECKING POINTS
1.Is the alternator normal?
2.1s the battery normal?
3.Are the harness and connector between the battery and ABS actuator normal?
(3) CHECKING METHOD
Dl. Check of N B fuse
.( SPECIFIED VALUE: The fusible link should not burn out.
If it is NG, ao to D4.
D2. Voltage check between N B fuse and ABS actuator

1. After the IG SW has been set to the [LOCK] position, disconnect the connector from the ABS actuator.
2. After the IG SW has been set to "ON" position, measure the voltage between the ABS actuator vehicle
side connector 6(+IG) and the terminal 2(GND1).
SPECIFIED VALUE: 9.5V- 16V
If it is OK, reolace the ABS actuator.

D3. Continuity check between the AIB fuse and the ABS actuator
After the IG SW has been set to the [LOCK] position, measure the resistance between the ABS actuator
vehicle side connector 6 (+IG) and the N B fuse downstream side terminal.
SPECIFIED VALUE: 100 or less (Continuity exists)
If OK. check and reoair the battew or alternator.

-
If NG
Harness check between A/B fuse and ABS actuator
Reoair or reolace the harness and connector.
*4. Continuity check between the N B fuse and the ABS actuator
1. After the IG SW has been set to the [LOCK] position, disconnect the connector from the ABS actuator.
2. Measure the resistance between the ABS actuator vehicle side connector 6(+IG) and the terminal
2(GNDl).
SPECIFIED VALUE: 1M B or more (No continuity)
If OK, reolace the N B fuse. Observe the condition.

If NG, reoair the harness between the ABS actuator and the A/B fuse and the connector. Then,
reolace the ABS fuse.
~ ~ ~ - p
4-13-4 DIAGNOSIS CODE No.21 to 28(WHEEL SPEED SENSOR SYSTEM DIAGRAM)

This abnormal code is outputted when open wire or short is detected in the wheel speed sensor system.
Furthermore, when no wheel speed sensor signal is inputted during the running, the said signal is
missing, or a noise is mixed into the said signal, the abnormal code is outputted. When this code is
outputted, it is necessary to check not only the circuit itself or but also the installing state of the sensor.
(2) CHECKING POINTS
1.1s the wheel speed sensor installation condition normal? (Is there any factor to make the wheel speed
sensor output unstable?)
2.Check to see if the wheel speed sensor and the wheel speed sensor rotor are normal.
3.Are the harness and connector between the wheel speed sensor and ABS actuator normal?
(3) CHECKING METHOD
W 1 . Unit check of wheel speed sensor
1.Perform the unit check of the wheel speed sensor.
DIAGNOSIS CODE
No.21, No25
No.22. No26
Items to be checked
/wheel speed sensor front right
1 Wheel speed sensor front left
1
No.23. No27 /wheel speed sensor rear right
No.24, No28 l ~ h e espeed
l sensor rear left
If it is OK. ao to D 2 .
If it is NG. ao to W 5 .
W 2 . Continuity check between wheel speed sensor and ABS actuator

1.Disconnect the connector of the related wheel speed sensor and the ABS actuator. Check the
harness.
CONTENTS OF CHECKS ACCORDING TO DIAGNOSIS CODES
Wheel speed sensor front harness side connector I ( - ) -ABS actuator harness side connector 22(FR-)
No.21, No25
Wheei speed sensor front harness side connector 2(+)-ABS actuator harness side connector 23(FR+)
Wheel speed sensor front harness side connector I ( - ) -ABS actuator harness side connector 8(FL-)
N0.22. No26
Wheei speed sensor front harness side connector 2(+)-ABS actuator harness slde connector 9(FL+)
Wheei speed sensor rear harness side connector 2(-) -ABS actuator harness side connector 20(RR-)
N0.23, No27
Wheel speed sensor rear harness side connector I(+) -ABS actuator harness side connector 19(RR+)
Wheel speed sensor rear harness side connector 2(-) -ABS actuator harness side connector 4(RL-)
Wheel speed sensor rear harness side connector I ( + ) -ABS actuator harness side connector 5(RL+)
If it is OK. oo to W 3 .
If NG, reoair the harness between the wheel speed sensor and the ABS actuator and the connector.
W 3 . Harness check between the wheel speed sensor and the ABS actuator
1.Visually check the related wheel speed sensor and the harness between the related wheel speed
sensor and the ABS actuator. In this inspection, check to see if damage is present at each harness
or poor connect~onis present at the connectors.
If it is OK. ao to W 4 .
If NG, r e ~ a ithe
r harness between the wheel meed sensor and the ABS actuator and the connector.
?
D4.Check of wheel speed sensor
1.Check to see if the installing state of the wheel speed sensor and the wheel speed sensor rotor are
not abnormal.
If it is OK. replace the ABS actuator.
If NG, rewair the installina state of the wheel soeed sensor and replace the wheel s ~ e e sensor
d rotor.
D5. Check of wheel speed sensor

1.Perform checks given below.
(1) Check of the installing state of the wheel speed sensor
(2) Adjust, repair or replace the wheel speed sensor rotor.
(3) Check the axle bearing for looseness.
I
4-14TROUBLE SHOOTING ACCORDING TO MALFUNCTION PHENOMENA
4-14-1 WITH THE IG SWITCH TURNED ON, THE WARNING LAMP ILLUMINATES AT ALL TIMES.
(1) CHECKING POINTS
If the ABS warning lamp remain illuminated, most likely the causes are that malfunctioning components
are detected by means of diagnosis functions, open wire in the ABS warning lamp lighting circuit or
malfunctioning ABS actuator.
(2) CHECKING METHOD
Dl. Confirm the diagnosis code
1.The indication of diagnosis code output is performed by means of the ABS warning lamp.
2.After the IG SW has been turned ON, confirm the lighting state of the ABS warning lamp.
SPECIFIED VALUE: Abnormality code is outputted.
If OK, oerform a trouble-shootina corresoondina to the diaanosis code table.

W 2 . Confirmation of connector fitting state

1.After the IG SW has been set to the [LOCK]position, disconnect the connector of the ABS actuator.
Again connect the connector.
SPECIFIED VALUE: Abnormality code is outputted.
If OK. oerform a trouble-shootina corresoondina to the diaanosis code table.

W 3 . Confirm the diagnosis code

SPECIFIED VALUE: Indicates normal code or goes out.
Low voltaae abnormal (Normal code indicated).

ABS actuator malfunctionina (extinauished)
If it is NG, ao to W4.
W4. Check of engine fuse

SPECIFIED VALUE: Normal
If it is OK. ao to W5 .
If NG. reolace the enaine fuse svstem and check the enaine fuse svstem.
W5. Confirmation of ABS warning lamp for lighting state
?.Afterthe IG SW has been set to the [LOCK] position, disconnect the battery negative terminal so as to
eliminate the short of the check connector.
2.Disconnect the connector from the ABS actuator. Connect the ABS actuator vehicle side connector
terminal 10 (WA) to the body earth. Install the negative terminal of the battery.
SPECIFIED VALUE: Extinguishes.
If OK. ABS actuator malfunctioning

If it is NG,
Faulty harness between the combination meter 2(WA) and ABS actuator 10(WA)
Combination meter malfunctioning
4-14-2 WITH THE IG SWITCH TURNED ON,THE BRAKE WARNING LAMP ILLUMINATES AT ALL
TIMES.
(1) CHECKING POINTS
1.When the brake warning lamp is illuminated at all times, most likely the parking brake is applied, or
the brake fluid level is low. In addition, there are possibilities that the brake fluid level SW and parking
brake SW are maifunctioning, the brake warning lamp lighting circuit is encountered with abnormality,
or the ABS actuator is maifunctioning.
2.The check should be carried out with the parking brake released.
(2) CHECKING METHOD
Dl. Check of brake fluid level
1.Check that the brake fluid is filled up to the specified level in the master cylinder reservoir.
SPECIFIED VALUE: There exists up to the specified level .
If it is OK, ao to W2.
If NG, fill the brake fluid UD to the swecified level.
D2. Check of engine fuse

1.Check to see if the engine fuse is damaged.
SPECIFIED VALUE: No abnormality exists.
If NG. check the enaine fuse svstem and reolace the enaine fuse.
D3. Confirmation of the brake warning lamp for lighting state

1.Disconnect the connector from the ABS actuator. Connect the ABS actuator vehicle side connector
14 (BRL) to the body earth.
2.After the IG SW has been turned ON, confirm the lighting state of the brake warning lamp.
SPECIFIED VALUE: Extinguishes.
If it is OK, ao to D 4 .
-
if NG
Faultv harness between the combination meter4 (BRL) and ABS actuator 141BRL)
W4. Continuity check between the ABS actuator and the body earth
1.Harness check between the ABS actuator and the body earth
(1) ABS actuator vehicle side connector 7(PKB)- Body earth
SPECIFIED VALUE: l0.Q or less (Continuity exists)
&2K
Brake fluid level SW malfunctioninq
Faultv harness between the ABS actuator and the brake fluid level SW
Parkina brake SW malfunctioning
Faultv harness between the ABS actuator and the warkina brake SW
p
--
1
E3-28
4-14-3 THE ABS WARNING LAMP FAILS TO ILLUMINATE FOR THREE SECONDS AFTER THE IG
SWITCH IS TURNED ON.
(1) CHECKING POINTS
When the ignition SW is turned ON, the ABS ECU makes the ABS warning lamp illuminated for about
three seconds to check the ABS warning system.
(2) CHECKING METHOD
B l . Check of warning lamp for lighting state
?.After the IG SW has been turned ON, check to see if other warning lamps go on.
SPECIFIED VALUE: Illuminates.
If it is NG.
Combination meter power supply system malfunctioning
W 2 . Confirmation of ABS warning lamp

?.Afterthe IG SW has been set to [LOCK] position, remove the negative terminal of the battery.
2.Disconnect the connector from the ABS actuator. Install the negative terminal of the battery and turn
ON the IG SW.
3.Check the ABS warning lamp for lighting state
SPECIFIED VALUE: Remains extinguished.
If it is OK. ao to WO .
If NG. the ABS actuator is malfunctioning
W 3 . Short check between the combination meter and the ABS actuator
1.After the IG SW has been set to the [LOCK] position, check to see if short exists in the harness
between the combination meter 2(WA) and the ABS actuator 10 (WA).
Combination meter malfunctionina

.ABS warnina lam^ faulty
If NG, faultv harness between the combination meter (WA) and the ABS actuator 10 (WA)
4-14-4THE BRAKE WARNING LAMP FAILS TO ILLUMINATE FOR THREE SECONDS AFTER THE
IG SWITCH IS TURNED ON.
(1) CHECKING POINTS
When the ignition SW is turned ON, the ABS ECU makes the brake warning lamp illuminated for about
three seconds to check the brake warning system.
(2) CHECKING METHOD
W1. Check of warning lamp for lighting state
1.After the IG SW has been turned ON, check to see if other warning lamps go on.
If it is OK. oo to W 2 .
If it is NG,
Combination meter power supply system malfunctioning
W 2 . Confirmation of brake warning lamp

I.After the IG SW has been set to [ON] position, remove the negative terminal of the battery.
2,Disconnect the connector from the ABS actuator. Install the negative terminal of the battery and turn
ON the IG SW.
3.Confirm the lighting state of the brake warning lamp.
SPECIFIED VALUE: Remains extinguished
If NG, the ABS actuator is malfunctioning
W 3 . Short check between the combination meter and the ABS actuator
1.After the IG SW has been set to the [LOCK] position, check to see if short exists in the harness
between the combination meter4 (BRL) and the ABS actuator 14 (BRL).
-
If OK
Combination meter malfunctionina
Brake warnina IamD faulty
If NG. faultv harness between the combination meter4 IBRL) and the ABS actuator 14 (BRL)
!
4-14-5 MALFUNCTIONS OF THE BRAKE OPERATIONS (UNEVEN BRAKING, LACK OF BRAKING
FORCE, THE ACTUATION OF ABS DURING NORMAL BRAKING AND PEDAL VIBRATION
DURING THE ABS OPERATION) AND THE ABS WARNING LAMP GOES ON DURING
RUNNING.
(1) CHECKING POINTS
Different driving conditions and road conditions make it difficult to determine the problem. When the
diagnostic code shows a normal code, conduct an inspection following the flow chart.
(2)CHECKING METHOD
Dl. Confirmation of ABS warning lamp
1.The diagnosis code output is indicated.
SPECIFIED VALUE: The normal code is flashing.
If NG. oerform the trouble-shootina accordina to the diaanosis code table.
W 2 . Check each wheel speed sensor for installing state.

I.Confirm the installing state of each wheel speed sensor.
SPECIFIED VALUE: Normally installed. The retaining bolt exhibits no looseness.
If NG. faultv installation of the wheel soeed sensor
W3. Continuity check between terminals of each wheel speed sensor

1.Disconnect the connector from the ABS actuator. Check continuity between the terminals of each
sensor at the harness side.
If NG.faultv wire harness
D4. Check of harness for connecting state

1.While moving the harnesses and connectors, check the continuity state.
SPECIFIED VALUE: Abnormality exists.
If OK. the ioint of the wire harness is Door.

D5. Check of wheel speed sensor system

1.Perform the check of the wheel speed sensor system.
If it is OK. reolace the ABS actuator.
Wheel soeed sensor svstem malfunctioninq

p
- Wheel weed sensor malfunctioning
4-15 UNIT CHECK
4-15-1 STOP LAMP SWITCH
1.Check continuity between the stop lamp SW connector terminals.
SPECIFIED VALUE: When the brake pedal is depressed: Continuity exists.
4-15-2 FRONT WHEEL SPEED SENSOR

(1) MEASUREMENT AND VISUAL INSPECTION
1.Measure the resistance between the connector terminals
1- 2.
SPECIFIED VALUE: 1.4f0.15kQ
2.Check the sensor for installation condition.

SPECIFIED VALUE: The sensor should not float above
the sensor installation surface.
3.Check the sensor installation bolt tightness.
TIGHTENING TORQUE: 19.1 +3.9N .mil 95f
40kgf .cm}
4.Check that no foreign substance is adhered to the tip end
of the sensor.
SPECIFIED VALUE: No foreign substance should be
adhered.
(2) INSPECTIONUSING AN OSCILLOSCOPE
1.Connect the SST. The figure indicates the output
waveform of the skid control sensor when running at a
speed of 20 kmlh or more.
SPEClFlED VALUE: C is 0.5 V or more.
B is 70% or more of A.
D should not occur.
NOTE
If C is outside the standard, replace the wheel speed
sensor sensor.
= If B is outside the standard, replace the wheel speed
sensor rotor (front axle hub).
If D occurs, inspect the end of the sensor.
4-15-3 FRONT WHEEL SPEED SENSOR ROTOR
1.lnspect the axle hub wheel speed sensor rotor.
SPECIFIED VALUE: The rotor should exhibit no abnormality, such as scratches, chip and deformation.
,
'{
--
4-15-4 REAR WHEEL SPEED SENSOR
(1) MEASUREMENT AND VISUAL INSPECTION
1-2.
SPECIFIED VALUE: 1.4_f0.4kR
2.Check the sensor installation bolt tightness.
TIGHTENING TORQUE: 8.4+1.4N.m{85f 14kgf.cm)
3.Check that no foreign substance is adhered to the tip end
of the sensor.
SPECIFIED VALUE: No foreign substance should be
adhered.
(2) INSPECTION USING AN OSCILLOSCOPE
1.Connect the SST. The figure indicates the output
waveform of the wheel speed sensor when running at a
speed of 20 kmlh or more.
SPECIFIED VALUE: C is 0.5 V or more.
B is 70% or more of A.
D should not occur.
NOTE
If C is outside the standard, replace the wheel speed
sensor.
If B is outside the standard, replace the wheel speed
sensor rotor (rear brake drum).
If D occurs, inspect the end of the sensor.
4-15-5 REAR WHEEL SPEED SENSOR ROTOR
1.Remove the rear brake drum. Check the wheel speed sensor rotor.
SPECIFIED VALUE: The rotor should exhibit no abnormality, such as scratches and deformation.
4-15-6 WARNING LAMP

(1)
. . ABS WARNING LAMP
1.Turn the ignition SW to "LOCK," and disconnect the ABS
actuator connector.
2.h this state, check if the brake warning lamp goes on
when the ignition SW is turned to 'ON."
3.Next, check if the ABS warning lamp goes out when the
disconnected ABS actuator's vehicle side connector 18
terminal is connected to the ground. S16C5061T10
(2) BRAKE WARNING LAMP

1.Turn the ignition SW to "LOCK," and disconnect the ABS
actuator connector.
2.ln this state, check if the brake warning lamp goes on
when the ignition SW is turned to 'ON.'
3.Next, check if the ABS warning lamp goes out when the
disconnected ABS actuator's vehicle side connector 12
terminal is connected to the ground
w~3C6012T10
4-15-7 ABS ECU (ABS ACTUATOR)
1.Conduct the following inspection with the engine turned off.
(1) Check the battery voltage.
SPECIFIED VALUE: 10-14 V (when the ignition SW is "ON")
(2) Check continuity between the ground terminal and the body ground.
SPECIFIED VALUE: Continuity exists. (when the ignition SW is "LOCK).
( 3 )After the IG SW has been turned ON, disconnect the actuator connector. At this time, check the
voltage, resistance, and continuity between the respective terminals of the vehicle side
connector as well as between the terminal and the body earth.
Vehicle harness side connector
I
ABS
- - ECU
- - - Check
- ..- -..
Connection Measuring condition Specification Malfunctioning points not satisfying the
value requirements
9 / F L + / 8 1 FL- / The IG SW is turned 1 1.4f 0.4kQ l ~ r o nwheel
t Weed sensor. LH.
LOCK. I
23 FR+ 22 FR- The IG SW is turned 1.4+0.4kQ Front wheel speed sensor. RH.
LOCK.
5 RL+ 4 RL- The IG SW is turned 1.4k0.4kQ Rear wheel speed sensor. LH.
LOCK.
19 RR+ 20 RR- The IG SW is turned 1.4t0.4kR I Rear wheel weed sensor. RH.
LOCK.
1 i-BS - Body earth The IG SW is turned 10 - 14 V ABS fusible link
- - - - LOCK.
6 +IG - Body earth -7
LOCK.
1 1 when the brake pedal is /
10 - 14 V I
24 STP - Body earth
depressed:
Stop lamp SW
When the brake pedal is! ov
I
released:
2 GND1 - Body earth The IG SW is turned I
Continuity exists Body earth
F1 CLUTCH
CLUTCH SYSTEM --------..................... F1 - 1

BASIC CHECK AND ADJUSTMENT-- F1 - 1
CLUTCH PEDAL--.............................. F1 - 3
REMOVAL AND INSTALLATION -------- F1 - 3
CLUTCH CABLE F1 - 5
REMOVAL AND INSTALLATION F1 - 5
CLUTCH -- .............................. F1 - 9
1 CLUTCH SYSTEM
1.Loosen the lock nut @ and adjust the pedal height by
turning the adjusting bolt @.
CAUTION
The measurement should be carried out at the center
of the pedal at the right side.
SPECIFIED VALUE: Height of clutch pedal
156.8- 161.8mm
1-1-1 Adjustment of clutch pedal free travel

1.Move the clutch release lever by your left hand and stop it
at a position where it comes in contact lightly with the
diaphragm spring of the clutch cover.
Clutch outer cable
\a
(The arrow mark in the figure shows the direction in which Vibration isolating rubber
the release lever is moved.)
2.Pull up the clutch outer cable by your right hand and hold
it at a position where there is no slack of the inner cable.
Then, release your left hand.
3.Screw in the adjusting screw by your left hand, until it
comes in contact with the rotation stopper protrusion of
the vibration preventive rubber.
At this time, if the rotation stopper protrusion is not
aligned with the groove position of the adjusting screw, /
Clutch release lever cible end
perform the alignment b y backing off the adjusting CtlKSOMETI
screw.
4.Release your hand under a condition where the groove
position of the adjusting screw is aligned with the rotation
stopper protrusion.
5.Ensure that the free travel of the clutch pedal conforms to
the specified value.
(When carrying out the operations above, the operations
to be performed by your right hand can b e performed by
your left hand and vice versa.)
SPECIFIED VALUE: Free travel of clutch pedal
10 to30mm
(Upper suriace of pedal pad)
- F1-2
1-1-2 Check of distance to the floor panel when the clutch is disengaged
1.Check and adjust the clutch pedal height.
2.With the engine idling, pull the parking brake lever fully. Then, move the shift lever to the 1st gear
position and slowly release the pedal. Check the distance between the pedal at a moment
immediately before the clutch is engaged and the position when the clutch pedal is depressed fully
to the floor.
SPECIFIED VALUE: 20 mm or more (Reserve travel)
2 CLUTCHPEDAL
Instrument
l~orquewrench I
IMP grease


I) COMPONENTS
*:MP grease
Unit: N-m{kgf.crn]
1 a Cable Ay, clutch release 6 f PAD, CLUTCH PEDAL
2 b Pedal SIA, clutch
3 c Spring, torslon
4 d Bush
A 5 e Cushion (for clutch pedal)
2-1-4 INSPECTION
Check each of the following parts. Replace any faulty part.
Weaj
Wear
Damage
Darnage,deforrnation

(1) CUSHION (FOR CLUTCH PEDAL)
1.Apply soap water to the trp end of the cushion. Then,
install rt to the clutch pedal subassembly.

1.Adjust the clutch pedal height and free travel.
Refer to Page F1-1.

3 CLUTCH CABLE
Instrument
r~orquewrench
IMP grease 1
1.Remove the instrument panel Ay.

(1) COMPONENTS
+:MP grease
%:Nan -reusable parts
Unit: N.m(kgf - c m )
-
r A 1 a Bracket, clutch release cable No.1
2 b Clip
r 3 c Heater Ay
r A 4 d Cable Ay, clutch release

(1) CLUTCH RELEASE CABLE No.1
1.Loosen the adjusting nut of the clutch release cable
assembly.
2.While pulling up the clutch release lever subassembly by
your hand, take out the clutch release cable bracket No. 1
from the clutch release lever subassembly.
3.Route the cable at the cutout section of the clutch release

cable bracket No.1. Then, remove the clutch release
cable bracket No.1 by raising it 90'.
(2) HEATER AY
1.After removing the bolt and nut (front heater Ay x dash panel), pull the lower side of the heater
assembly and place a wooden block or the like between the healer assembly and the dash panel,
thus keeping the heater assembly in a pulled state.
1.Pull the clutch release cable assembly toward the vehicle inside and remove it.
3-1-5 INSPECTION
Check the following items. Replace any faulty part.
- - .
1.Push and pull the inner cable of the clutch release cable assembly. At this time, ensure that there is
no abnormal resistance and binding.
!.Check each part of the clutch release cable assembly for scores, deformation, wear and cracks.
Deformation
\
Wear Damage,wear
/
3.Clutch release cable bracket No.1 for damage and wear
Damage. weal

I .Install the clutch release cable assembly.
CAUTION
Utmost care must be exercised so that the inner cable may not be bent.
2.Carry out routing the clutch cable in the engine

compartment as shown in the right figure.
(2) CLUTCH RELEASE CABLE BRACKET No.1
1.Install the clutch release cable No.1.
(1) Connect the cable by routing it at the cutout section
of the clutch release cable bracket No.1. Then, tilt
the cable 90".
(2) Lightly pull the clutch release lever subassembly by
your hand. When the clutch release lever
subassembly comes in contact with the clutch cover,
apply the clutch cable bracket No.1 to the clutch CllK5008Tl
release lever subassembly. Then, tighten the
adjusting nut to adjust the play.
Refer to Page F1-1.
CAUTION
Be very careful not to damage the grommet section.
1.lnstall the instrument panel assembly.
4 CLUTCH
SST
Shape
09210-87701400 Holder, fiy wheel
09301-87501-000 Tool, clutch guide
09302-87701-000 Gauge. clutch diaphragm spring height No.4
09333-00013-000
aligner, clutch diaphragm spring
(09301-00012-000)
Instrument
l~orque
wrench,Dial gauge,Thickness gauge,Vernier calipers
IMPgrease,EP greaseCiutch grease
1.Remove the transaxle assembly from the vehicle.
Refer to P a g e IF2-2.
) COMPONENTS
i
Unit: N.m{kgf.cml
r A 1 a Cover Ay, clutch A 6 f Bush
A 2 b Disc Ay, clutch A 7 c Yoke, clutch release lever
3 c Yoke, clutch release lever A 8 g Hub SIA,clutch release bearing
4 d Lever SIA,clutch release fork
5 e Spring, torsion
(1) CLUTCH COVER AY
1.Prevent the ring gear from turning, using the SST. Under
this condition, remove the clutch cover assembly and
clutch disc assembly.
SST: 09210-87701-000
4-16 INSPECTION
1.Flywheel and pressure plate surface of clutch cover
assembly for streak, cracks and discoloration.
3.Pressure plate (diaphragm spring finger section) of clutch

cover assembly for wear, rust formation and breakage
4.Clutch disc assembly for wear and runout

ALLOWABLE LIMIT Wear limit
0.3mm(Sagging of rivet
Lateral runout limit
1.Omm
CAUTION
The measurement of the lateral runout should be Clutch disc
I
carried out under a condition where the clutch disc
assembly is assembled with a new input shaft.
5.When the sliding section (the contact surface with the

clutch cover) of the clutch release bearing hub
subassembly is turned, and when pressure is applied to
push the sliding section in the turning direction, ensure
that there is no abnormal resistance nor binding.
6.Check the clutch release bearing hub subassembly for

damage and wear. Also, check the clip contact surface
and sliding section of the housing for damage and wear. I Clip contact surface
A
Damage, wear

(1) CLUTCH RELEASE BEARING HUB SIA,
1.Apply EP grease over all the per~pheryof the bore
LUBRICANT: EP grease
(2) CLUTCH RELEASE LEVER YOKE

1.Apply EP grease to the sliding section with the clutch release bearing hub SIA.
LUBRICANT EP grease
(3) Bush
1.Apply MP grease over all the inside and outside periphery.
LUBRICANT MP grease
(4) CLUTCH DISC AY I I 4 i
1.Install the clutch disc Ay.
(1) Thinly apply Clutch grease to the hub inside (the
spline section) of the clutch disc assembly.
CAUTION
As regards the grease applying direction, grease
should be applied from the clutch cover side. Be sure
to apply grease as thinly as possible so that the
excessive grease may not ooze out to the flywheel
side.
LUBRICANT Clutch grease
(2) Install the clutch disc assembly to the flywheel by
centering it, using the SST.
SST 09301-87501-000
(5) CLUTCH COVER AY

1.lnstall the clutch cover assembly while aligning it with the
knock pin of the flywheel. While preventing the flywheel
from turning, using the SST, tighten the bolts to the
specified torque.
SST 09210-87701-000
CAUTION
The bolts should be tightened in the following
sequence: @ Temporaly tightening, @to @Tightening
securely.
2.Check the diaphragm spring section for unevenness in
height, using the SST.
SST 09302-87701-000
3.lf the above check has revealed that the unevenness

exceeds the limit, correct the unevenness in height,
using the SST.
SST: 09333-00013-000
-
F1-14
, 4-1-7 OPERATION AFTER INSTALLATION
1.Install the transaxle assembly.
Refer to Page F2-2.
F2 MANUAL TRANSMISSION/MANUAL TRANSAXLE
MANUALTRANSAXLE -
F2 1
BASIC CHECK AND ADJUSTMENT--- F2 - 1
TRANSMISSION GEAR
REPLACEMENT
--
F2 1
F2 1
MANUAL TRANSAXLE F2 - 2
REMOVAL AND INSTALLATION -------- F2 2-
-
DIFFERENTIAL SIDE OIL SEAL----------- F2 4
REMOVAL AND INSTALLATION -------- F2 4
BACK UP LAMP SWITCH--------------
-
F2-6
SHIFT LEVER F2-8
REMOVAL AND INSTALLATION -------- F2 8-
DISASSEMBLING AND
ASSEMBLING F2- 11
1 MANUAL TRANSAXLE
1-1-1 Check of transmission oil level
1.Remove the filler plug. With the vehicle placed in a horizontal state, ensure that the oil level is at the
specified level.
SPECIFIED VALUE: 5 mm or less below lower edge of filler plug hole
TIGHTENING TORQUE: 39.2f 9.8N.m {4OOf 100kgf.cm)
CAUTION
If the oil level is low, check for oil leakage.
Never reuse the gasket.
2 TRANSMISSION GEAR OIL

2-1 REPLACEMENT
LUBRICANT Transmission gear oil SAE75W{{-}I90 or SAE75W{{-))85 or SAE75W{{-}}80 (API
Classification GL3 or GL4)-90 or SAE75W-85 or SAE75W-80 (API Classification GL3
or GL4)
SPECIFIED VALUE: Total capacity approx. 2.1 - 2.292
5 mm or less below lower edge of filler plug hole
TIGHTENING TORQUE: 39.2k9.8N.m {400_f1OOkgf~cm}
CAUTION
Never reuse the removed gasket.
3 MANUAL TRANSAXLE AY
Instrument
l ~ o r ~ wrench
ue

1.Remove the transaxle together with the engine

I ) COMPONENTS

Unit:N.m{kgf.cml
1 a Stiffener, power train
A 2 b Transaxle Ay
I
(1) TRANSAXLE AY
1.After cleaning the seal bolt holes of the engine block,
install the transaxle assembly.
CAUTION
* Never reuse the removed seal bolts.

I.Install the transaxle together with the engine
4 DIFFERENTIAL SIDE OIL SEAL
SST
Shape Parl No. Part name
l~ransrnissiongear oil SAE75W-90 or SAE75W-85 or SAE75W-80 (API Classification GL3 or GL4)

1.Remove the drive shaft.
Refer to Page D2-8

I) COMPONENTS
%:Nan - reusable Darts

v A 1 a Seal, type T oil
4-1-4 POINTS OF REMOVAL \-TG=2

(1) TYPE T OIL SEAL
1.Rernove the type T oil seal, using the SST.
SST 09308-00010-000 ~ a ? ~
,
(1) TYPE T OIL SEAL
1.Drive the type T oil seal in place, using the SST.
SST: 09518-87709-000

1.lnstall the drive shaft.
Refer to Page D2-8.
-
5 BACK UP LAMP SWITCH

Instrument
l~orque
wrench,Electrical Tester
~
~,~~
~
-- -.~
Lubricant.adhesive.others ~ ~
[ ~ r a n s mssio? gear 0'1 SAE75W-90 or SAE75W-85 o: SAE75W-80 (API C4ass'ficalionGL3 or GL4)

1.Drain the transaxle oil.
I) COMPONENTS
Unit:N.rn(kgf.cmJ
1 a Switch Ay, back up lamp
5-1-4 INSPECTION
1.Ensure that continuity exists when the switch of the
backup lamp switch assembly is pushed (ON).
Conversely, ensure that no continuity exists when the
switch is not pushed (OFF).

1.Fill transaxle oil.
Refer to Page F2-1.
- F2-8
6 SHIFT LEVER
WARNING
Do not carly out the operation while the exhaust pipe is still hot, for there is a possibility of getting
scalded.

Tool
Isnap ring pliers
Instrument
I ~ o r q u wrench
e
IMP grease I
I .When the support No.2 is riveted with the extension rod S/A, remove the exhaust pipe.
Refer to Page 84-2.
(1) COMPONENTS
-
%:Nan reusable parts
.): MP grease
Unit: N.m(kgf.cmJ
A 1 a Knob, shift lever
2 b Suppon, floor shift, No.2
3 c Support, floor shift, No.1
4 d Rod SIA, extension
A 5 e Shaft SIA, shift & select
6-14 INSPECTION
Check that each joint section of the assembly turns smoothly without any binding.
- If any malfunction is
found, perform the replacement, following the procedure under "Disassembly and Assembly."

(1) SHIFT & SELECT SHAFT SIA
1.Install the shift & select shaft SIA.
(1) Ensure that the O-ring has been installed securely to
the bush.
(2) Apply MP grease t the shaft at the transmission side
(the entire periphery indicated by the slanting line in
the figure on the right).
LUBRICANT: MP grease
CAUTION
Never reuse the attaching .bolts.
(2) EXTENSION ROD SIA
1.Securely fit the dust boots into the groove of the extension
rod SIA.
-
i
(3) SUPPORT N0.2
1.When the support No.2 is bolted to the extension rod SIA, tighten the support No.2 and extension rod
SIA to the specified torque after the support No.1 and support No.2 have been installed to the
vehicle..
CAUTION
Do not reuse the support No.1 attaching bolts once they are used.
(4) SHIFT LEVER KNOB

1.Install the shift lever hole cover.
2.lnstall the shift lever knob.
Screw it in the shift & select lever assembly until it can be attached temporarily. Then, tighten it
further by 1.5 turns.
1.lnstall the exhaust pipe.
Refer to Page B4-2.

Tool
l ~ a n grinder,Snap
d ring pliers
Instrument
6-2-2 OPERATION BEFORE DISASSEMBLY

1.Remove the floor shift assembly from the vehicle.
Refer to Page F2-8.
) COMPONENTS
-
%:Nan reusable parts
.): MP grease
Unit: N.m(kgf.cm]
1 a Ring, snap 12 k Bush
2 b Sheet, shift lever 13 1 Ring, 0
3 c Rod SIA, extension r A 14 c Rod SIA, extension
v A 4 d Shaft SIA, shift & select 14 msupport, floor shift, No.2
5 e Lever SIA, shift & select 16 n Nut (Replacement parts)
6 f Boot, shift lever retainer dust 17 o Washer (Replacement parts)
8 g Nut (Replacement parts) 18 p Collar (Replacement parts)
9 h Bolt (Replacement parts) 18 q Supporl, floor shift, No.1 (Replacement parts)
10 i Ring.0 20 r Bush
11 j Bush
(1) SHIFT & SELECT SHAFT S/A
1.Separate the shift & select shaft SIA and shift & select
lever S/A by removing caulking with a grinder.
CAUTION
Never reuse the pin whose staked section has been cut
off.
1 LlIKYISIT10

1.Separate the extension rod SIA and support No.2, and the extension rod S/A and support No.1,
respectively, by removing caulking with a grinder.
CAUTION
Do not reuse the pin where caulking was broken and support No.1 once they are used.
6-2-5 INSPECTION
1.Assemble the extension rod SIA and support No.1.
CAUTION
In the case of replacement parts, the connecting method is of a nut securing type. Utmost care
must be exercised so that no wrong installation method is employed.
2,Temporarily assemble the extension rod S/A and support No.2. Securely tighten when they are
mounted on the vehicle.
CAUTION
In the case of replacement parts, the connecting method is of a nut securing type. Utmost care
(2) SHIFT & SELECT SHAFT SIA

1.Assemble the shift & select lever SIA and shift & select shaft SIA.
CAUTION
* In the case of replacement parts, the connecting method is of a bolt securing type. Utmost care
6-2-7 OPERATION AFTER ASSEMBLY

1.lnstall the floor shift assembly to the vehicle
Refer to Page F2-8.
G I STEERING
STEERING WHEEL ........................... GI - 1

. .-...- .. .- AND
RFMOVAL
STEERING COLUMN
- INSTALLATION-------- G I 1
- -
---- G 1 - 4
REMOVAL AND INSTALLATION--------G I - 4
1 STEERING WHEEL
WARNING
The following operations will affect the SRS airbag. Hence, prior to the operation, be sure to confirm
the instructions for the SRS airbag in order to perform reliable operations.
Refer to Page HI-1

Instrument
ITorque wrench I

?.After the IG SW has been set to [LOCK] position, remove the negative terminal of the battery. Leave
the engine under this state for 60 seconds or more.
CAUTION
It should be noted that the memory of the computers of other systems (engine control, etc.) and the
radio will be erased at the same time when the cable is disconnected from the negative negative
terminal of the battery.
The SRS airbag system is provided with a backup condenser (for the squib). Therefore, about 60
seconds are necessary for the backup condenser to discharge after the negative negative terminal
of the battery is removed. (Natural discharge)
* If you begin the operation before 60 seconds pass, there is a danger that the airbag is mistakenly
deployed.
2.Ensure that the steering wheel is in the straight ahead condition.

3.Remove the horn pad subassembly.
Refer to Page HI-7.
) COMPONENTS
Unit:N-rn(kgf.crn]
A 1 a Wheel SIA, steering
A 2 b Cable S/A. spiral
3 c Switch S/A, turn signal

(1) SPIRAL CABLE S/A
1.Ensure that the tires are in a straiaht-ahead state.
2.Adjust the center position of the spiral c a b l e
subassembly.
(1) Turn the spiral cable S/A in the arrowheaded direction

until it is locked.
NOTE
It should be noted that the number of lock-to-lock turns
of the spiral cable subassembly is about six.
(2) Make about three turns in the clockwise direction from 1 I
I Center mark 1
the position where the spiral cable SIA is locked and
align the center mark from this position.
(2) STEERING WHEEL SIA

1.lnstall the steering wheel S/A to the steering shaft.
CAUTION
-
As for the installation of the steerina wheel SIA. install
the steering wheel S/A deeply and positively. Turn it
two or three times clockwise and counterclockwise so
that the canceling pin of the turn signal switch S/A (at
the spiral cable SIA side) is accurately aligned with the
assembling groove of the steering wheel SIA.

1.lnstall the horn pad subassembly.
Refer to Page HI-7.
2.Confirrn the steering wheel center position.

3.lnstall the negative negative terminal of the battery.
4.Turn ON the ignition switch. Ensure that the airbag
warning lamp is illuminated for about six seconds and,
then, it goes out.
2 STEERING COLUMN
WARNING
Refer to Page HI-1

Tool
[center ponch.Drill,Tap

1.After the IG SW has been set to [LOCK] position, remove the negative termrnal of the battery. Leave
CAUTION
radio will be erased at the same time when the cable is disconnected from the negative negative
seconds are necessary for the backup condenser to discharge after the negative negative terminal
of the battery is removed. (Natural discharge)
If you begin the operation before 60 seconds pass, there is a danger that the airbag is mistakenly
deployed.
2.Remove the horn pad subassembly.

Refer to Page HI-7.
3.Remove the steering wheel SIA.

Refer to Page G 1-1.

6.Turn over the carpet.
-
(1) COMPONENTS
Unit:N.m{kgf.cm)
1 a Retainerdust cover A 6 f Cable SIA. spiral
2 b Cover, steering shaft dust 7 g Switch SIA, turn signal
3 c Shield, steering column hole r A 8 h Columu Ay. steering
4 d Cover, steering column, lower r A 9 i Lock Ay, steering
r 5 e Cover, steering column, upper
--
(1) STEERING COLUMN UPPER COVER
Remove the steering column upper cover with the operation lever of the telescopic and tilt mechanism
set to the unlock position and the steering column assembly lowered fully to the lowest position.
(2) STEERING COLUMN AY
I .Immediately before removing the steering column assembly, set the operation lever of the telescopic
and tilt mechanism to the unlock position. Also, raise the steering column assembly fully to the
uppermost position and push it toward the front side of the vehicle. Then, lock the operation lever.
NOTE
Do not release the operation lever of the telescopic & tilt mechanism until the steering column
assembly is installed. If the lever was released, correction should be made to get the specified
position as indicated in the "Main Points of Installation." After the operation lever has been locked,
install the steering column assembly.
2.Do not remove the nuts attaching the steering column

assembly, but loosen the nuts up to the edge of the bolts.
3.Remove the steering column Ay.
CAUTION
During the removal, be very careful not to give impacts
to the assembly or drop it.
If the serration of the intermediate shaft is pulled out
from the tube, put it back, aligning the paint positions.
Be very careful not to allow any foreign matter to get to
the components.
(3) STEERING LOCK AY
1.Remove the steering lock assembly. Install it to a new
steering column assembly.
(1) Make a hole, using a drill, to such an extent that the
reverse tapping of the steering lock set bolt is
possible.
TOOL: Center ponch
Drill
(2) Remove the steering lock set bolt, using the reverse
tapping. Then, remove the steering lock assembly.
CAUTION
Never reuse the removed bolts.
TOOL: Tap
~ ~ p ~- ~ p
2-1-5 INSPECTION
?.The steering column assembly is of an impact-absorbing construction. Therefore, measure the
dimensions indicated in the figure below after the removal. If the measured value is considerably
short, replace the assembly.
SPECIFIED VALUE: 503.5mm

(1) STEERING LOCK AY
1.lnstall a new steering lock set bolt. Tighten it, until the head of the bolt is cut off.
1.Do not release the operation lever of the telescopic & till
mechanism until the steering column assembly is
installed.
If the lever was released, set the distance between the
brackets to the reference dimension given below. After
the operation lever has been locked, install the steering
column assembly.
SPECIFIED VALUE:
2.Temporarily tighten the nuts, that are attaching the

steering column assembly, to the stud bolts of the pillar-
to-pillar member.
3.Temporarily secure the steering column tube assembly by
attaching the lower side bracket of the steering column
assembly to the temporarily-tightened nuts.
4.Tighten the upper side bracket of the steering column
assembly to the specified torque. Then, securely tighten
the nuts of the lower side bracket.
5.Remove the retaining bolt (reversing screw) of the
telescopic & tilt mechanism and spacer. (In cases where
a new steering column assembly is installed)
CAUTION
If this removal fails to be carried out, the tilt and
telescopic will not function.
6.Positively insert the universal joint (lower side) of the
steering column assembly to the steering gear pinion,
until the joint bottoms. Tighten the bolt to the specified
torque.
CAUTION
Be sure to start the installation of bolts from the
direction where the spot facing of the universal joint is
present..
(3) SPIRAL CABLE SIA
1.Ensure that the tires are in a straight-ahead state.
2.Adjust the center position of the spiral cable
subassembly.
(1) Turn the spiral cable SIA in the arrowheaded direction
until it is locked.
NOTE
(2) Make about three turns in the clockwise direction from Center mark
the position where the spiral cable S/A is locked and
align the center mark from this position.

1.Connect the connector to each harness, etc.
2.lnstall the steering wheel subassembly.
Refer to Page G1-1.
3.lnstail the horn pad subassembly.

Refer to Page HI-7.
4.Confirm the steering wheel center position.

5.Place the carpet.
6.lnstall the foot rest.
8.lnstall the negative negative terminal of the battery.
9.Turn ON the IG SW. Ensure that the airbag warning lamp
is illurnmated for about six seconds and, then, it goes
out.
G2 POWER STEERING
HYDRAULIC POWER STEERING ------------ G2 1-

POWER STEERING SYSTEM ------------- 6 2 - 1
HYDRAULIC POWER STEERING
1 POWER STEERING SYSTEM
WARNING
The following operations will affect the SRS airbag. Hence, prior to the operation, be sure to
confirm the instructions for the SRS airbag in order to perform reliable operations.
Refer to Page HI-I.

Instrument
/Power steering pressure gauge set,Beh tension gauge.Rernote Cable,Temperature gauge.Tachorneter.Torque wrench

1-3-1 STEERING WHEEL
(1) FREE PLAY CHECK
1.Set the tires to a straight-ahead state.
2.Start the engine and keep the engine idling.
3.Lightly turn the steering wheel by hand to the right and left. At this time, measure the free play
(amount of movement before the tires start moving) on the outer periphery of the steering wheel.
SPECIFIED VALUE: 0 - 10 rnrn
(2) CHECK OF EXCESSIVE PLAY

1.Move the steering wheel in up-and-down, right-and-left and fore-and-aft directions by holding it by
hand. At this time, check that no excessive play is present.
1-3-2 V BELT
(1) CHECK BY THE USE OF A TENSIOMETER
Use a tensiometer to inspect if the belt tension meets the specification.
SPECIFIED VALUE:
When installing new part [NlkgfJ] 1 392.0k98.0 ( 4 0 f 9)
During a check (when used for 2min or 269.5-t 122.5
(longer) [Nlkgf)] (27f121
(2) INSPECT BY DEFLECTION

Check if the deflection is acceptable when the central part of
the belt between pulleys is presses by force of approx.
98N(lOkgf].
SPECIFIED VALUE:
When installing new part [rnrn] 5.5- 7.5
During a check (when used for 2rnin or 6.4- 9.5
longer) [mrn]
(3) ADJUSTMENT
1.Loosen the vane pump Ay attaching nut and bolt.
2.Ternporarily tighten the nut and bolt with the vane pump bracket pressed and the V-belt tightened.
3.Check the V-belt for tension or deflection. If acceptable, fully tighten the nut and bolt for the vane
pump AY.
TIGHTENING TORQUE: Upper nut: 15.7+2.9N~m{l60Jr29kgf~cm]
Lower bolt: 21.0+4.2N.m{214+42kgf .cm]
1-3-3 POWER STEERING FLUID
(1) LEVEL CHECK
1.Keep the vehicle in a horizontal position and start the engine
2.Raise the fluid temperature.
(1) Give the steering wheel a few turns lock to lock with
the engine running at 1000 rpm or lower and raise
fluid temperature.
SPECIFIED VALUE: 40-8O0C(reserve tank area)
3.Ensure that there is no white turbidity or foaming.

CAUTION
If the fluid temperature is low during the fluid level
check, residual foam will be created, misleading the
outcome. It is important to turn the steering wheel with
the tires in stationary state so that the check is
conducted at 40-80°C.
NOTE
White turbidity or foaming indicates that air is mixed in
the power steering system or fluid level is low.
4.Check the fluid level on the reserve tank.
(1) Measure the fluid level difference between engine
start and engine stop.
CAUTION
SPECIFIED VALUE: A:Smm or less
(2) Measure the fluid level change caused by steering
operation.
CAUTION
SPECIFIED VALUE: A:5mm or less
(3) Ensure that fluid level is within the limits (max.-min.)
at engine stop condition.
NOTE
When fluid temperature is high (8O0C), check within
range of the HOT level. When fluid temperature is low
(20°C), check within the range of the COLD level.
(2) LEAKAGE CHECK

1.Inspect the following positions for fluid leak.
(1) Vane pump
(2) Reserve tank main unit
(3) Piping of the oil hose, oil tube, etc.
(4) Each pipe connection
2.Replace if fluid leaks.
1-4 FUNCTION CHECK
1-4-1 Check of the turning force required t o turn the steering wheel with the tires in stationary
state
1.Park the vehicle on a flat concrete road and set the tires to the straight ahead condition.
2.Start the engine and keep the engine idling.
3.lnstall a spring scale to the steering wheel.
4.Give the steering wheel one right turn from the straight ahead position. At this position, place the
spring scale in the tangent to the periphery and measure the turning force as the tires begin to move.
5.Likewise, give the steering wheel one left turn from the
-
straight ahead position and perform the same

measurements.
SPECIFIED VALUE: 30Ni3.l kgf) or less
1-4-2 Hydraulic pressure check

(1) PRESSURE GAUGE INSTALLATION
1.Remove the pressure feed hose (pressure side) from the vane- wmD.
2.lnstall the pressure gauge IN side to the vane pump
union.
CAUTION
* Install the pressure gauge valve in the full open state.
3.lnstall the pressure gauge OUT side hose to the pressure
feed hose (pressure side).
CAUTION
Install the pressure gauge valve in the full open state.
Install the adapter (ORB) to connect the pressure Adapter(0RB)
gauge IN side (hose) and the vane pump (union) with -TO pressure gauge 1
the seal tape applied to the screw area.
\ Tovane pump
(IN)
d
CAUTION
Install the adapter (2ST) to connect the pressure gauge
OUT side (hose) and the pressure feed hose (IN side). -To pressure feed hose
4.Perform air bleeding.
Refer to Page G2-6.
-
\ To pressure gauge
%heck the fluid level,
Refer to Page G2-2.
6.Start the engine.

i \
AdaptergST) out
(2) CHECK OF HYDRAULIC PRESSURE GENERATED IN

THE VANE PUMP
1.lnsert the oil temperature gauge into the reserve tank to
I& Temperature gauge
measure the oil temperature.

SPECIFIED VALUE: 55°C
2.Close the pressure gauge valve at idle speed and Steerlng
measure the hydraulic pressure generated in the vane Vane pump
pump.
CAUTION
If the valve is closed at length during measurements,
oil temperature will excessively go up, affecting the
vane pump. Therefore do not close the valve
exceeding 10 sec.
SPECIFIED VALUE: 5.4-5.9MPaf55-60 kgf/cm2)
3.lf the hydraulic pressure is low, the vane pump shall be
re~laced.
(3) CHECK OF PRESSURE DIFFERENCE UNDER NO r n Thermometer I
LOAD
1.Fully open the pressure gauge valve.
2.Measure hydraulic pressure at the engine speeds of 1000
Engine revolution speed
1000rprn and 3000rpm
k i
rpm and 3000 rpm to see the difference.
CAUTION
Do not operate the steering wheel. Vane pump
SPECIFIED VALUE: Max. 0.5 MPa{5kgf/cm2)
3.Replace the vane pump if the specified value is not LllC5052ET10
satisfied.
(4) CHECK THE HYDRAULIC PRESSURE GENERATED IN
THE STEERING GEAR AY
1.Wide open the pressure gauge valve at idle speed.
2.Measure the hydraulic pressure generated when the
steering wheel is turned all the way to either right or left.
SPECIFIED VALUE: 5.4-5.9MPa{55-60 kgflcm2}
3.Low hydraulic pressure indicates fluid leak within the
steering gear, in this case overhaul is required.
14-3 CHECK THE IDLE SPEED CONTROL UNIT

(1) CHECK ENGINE REVOLUTIONS
Ensure that no notable drop in idle speed nor rough revolutions are found, when the steering wheel is
turned all the way from the straight ahead position with the vehicle stopped.
SPECIFIED VALUE: 700-850 rpm (at idle)
(2) PRESSURE SWITCH CHECK

1.Disconnect the vane pump pressure switch from the harness connector of the vehicle.
CAUTION
Do not remove the pressure switch from the vane pump.
2.Check continuity between the pressure switch terminal

and the body earth while the engine running.
(1) When the steering wheel is at the straight ahead
position
SPECIFIED VALUE: At idle speed, no continuity shall
exist between the pressure switch
terminal to the body earth
(2) When the steering wheel is turned all the way to the
right or left.
SPECIFIED VALUE: At idle speed, continuity should exist
between the pressure switch terminal
to the body earth.
2 POWER STEERING FLUID
2-1 REPLACEMENT
/Power steering fluid

(1) REMOVAL
1.Remove the reserve tank from the reservoir bracket and dra~nthe fluid from the reserve tank.
2.Remove the oil reservoir to pump hose (the suction hose
between the reserve tank and the vane pump) from the
reserve tank side and receive the fluid in a contamer
such as a tray.
CAUTION
Do not crank longer than is required.
Do not spatter fluid on the engine compartment.
3.Start the engine.
4.Slowly turn the steering wheel lock to lock with the engine
running at 1000 rpm or lower and drain the fluid.
CAUTION
Do not raise the engine revolution speed.
5.stop the engine.
Tachometer
(1000rpm or less)
6.lnstall the oil reservoir to pump hose (the suction hose

between the reservoir tank and the vane pump) as shown
in the figure on the right and receive the fluid in a
container such as a tray.
(1) Match the marking of the oil reservoir to pump hose
(suction hose) with a protrusion of the tank port of
the lower reserve tank and securely insert the hose
up to the stopper surface.
(2) The clip shall be installed upward of the vehicle and
the distance B shall be 4fk 1mm.
(3) Install the oil reservoir to pump hose (suction hose)
clamp to the brake tube.
7.Check if the clip of the return hose (between the steering gear and the reserve tank) is installed,
facing upward of the vehicle and the distance A is 2f lmm.
8.lnstall the reserve tank to the reservoir bracket.
TIGHTENING TORQUE: l 2 . 3 f 2.4N .m{l25+24kgf .cm]
9.lnstall the clamp of the return hose to the brake vacuum
hose.
(2) FILLING
?.Fillthe power steering fluid to the reserve tank.
CAUTION
- During operation, fill the tank with fluid so that it will not be emptied.
Use care not to generate foam when filling.
2.Crank for 1 to 2 sec. to feed fluid to the vane pump, and repeat this procedure a few times
-
CAUTION
Do not start the engine until fluid filling is complete.
3.Fill the fluid up to the max. level.

(3) AIR BLEEDING
1 .Start the engine.
62-8
2.Give the steering wheel a turn fromthe lock to the lock
(repeat this procedure a few times) with the engine
running below idle speed and bleed.
CAUTION
When turning the steering wheel lock to lock, keep the
steering wheel at each lock for 2 to 3 sec and quickly
turn the steering wheel.
Do not raise the engine revolution speed.
NOTE (3000rprn or less)
ClIC7016EllO
If the fluid level changes by 5mm or more and the level
will not drop to a lower value, the piping should be
checked.
If the piping is found normal, repeat the step 2
mentioned above.
3.When there is no change in the fluid level in the tank, hold
for 5 to 6sec while turning the steering wheel to either
right or left, with the tires in stationary state.
4.With the engine speed kept at between the idle speed
and 3000 rpm and the vehicle stopped, turn the steering
wheel. Ensure that there is no abnormal noise, white
turbidity or foaming.
5.Perform the fluid level check.
Refer to Page G2-2.
6.Fill the fluid up to the max. level.

NOTE
When one of the following cases is encountered after
bleeding, check each piping component for leak and
repeat the step 2.
Refer to Page G2-3.
(1) Fluid becomes clouded when engine revolutions

surge.
(2) Steering operation is not smooth and produces
abnormal noise.
(3) There is 5mm or more fluid level difference between
engine start and engine stop.
(4) Fluid level changes 5mm or more by steering
operation .
(5) Abnormal noise is created while running.
3 STEERING GEAR
SST
09258-00030-000 Plug set, hose
09628-0001 l-Oo0
Puller, tie-rod end
(09611-87701-000)
09631-22020-000 wrench set, power steering hose nut
Instrument
l~orque
wrench

1.Remove the engine upper cover.
2.Remove the A/C suction hose from the power steering
reservoir bracket.
3.Remove the power steering reserve tank from the
reservoir bracket.
4.Drain the power steering fluid.
Refer to Page G2-6.
suction hose bracke
5.Plug the oil reservoir to pump hose, which has been

removed using the SST.
SST 09258-00030-000
7.Turn over the carpet near the steering column hole.
%.Removethe dust cover retainer.
9.Remove the steering shaft dust cover.
10Separate the universal joint at the steering gear side of
the steering column assembly.
11.Push out the steering column hole shield to the vehicle
outside under a condition where it is attached to the
steering gear assembly.
13.Remove the front wheels. (RH, LH)
14.Remove the front floor center brace S/A.
15.Disconnect the connector of the rear Ozsensor.
16.Remove the two bolts that secure the exhaust pipe and
the maniverter.
17.Separate the shift & select shaft and extension rod from
the transmission.
Refer to Page F2-8.
) COMPONENTS
-
3%: Non reusable parts
Unit:N.m{kgf.cmJ
(2) REMOVAL PROCEDURES
r 1 a Knuckle, steering. RHILH r 6 f Bracket, steering rack housing, LH
r 2 b Frame Ay r 7 g Gear assembly, power steering
r 3 c Hose, pressure feed
r 4 d Hose, Return
r 5 e Bracket, steering rack housing, RH
(3) INSTALLATION PROCEDURES

A 1 g Gear assembly, power steering A 6 c Hose, pressure feed
A 2 f Bracket, steering rack housing, LH A 7 b Frame Ay
A 3 e Bracket, steering rack housing, RH A 8 a Knuckle, steering, RHILH
A 4 g Gear assembly, power steering
A 5 d Hose, Return
(1) KNUCKLE, STEERING, RHILH
Separate the steering knuckles RH and LH from the ball joint
section of the tie-rod end, using the SST.
CAUTION
When setting the SST, attach a dummy nut to the
threaded portion of the tie-rod end so that the threaded
portion may not be damaged.
Hang the SST using a cord.
SST 09628-00011-000
(2) FRAME AY
Loosen the frame Ay mounting bolt little by little to lower the front by approx. 15mm and to lower the rear
by approx. 25 mm.
CAUTION . , I
Do not lower the frame Ay more than 25mm to avoid a

fall.
(3) PRESSURE FEED HOSE

Use the SST to remove the pressure feed hose from the
power steering gear Ay.
SST 09631-22020-000
(4) RETURN HOSE

Use the SST to remove the return hose from the power steering gear Ay.
SST: 09631-22020-000
(5) STEERING RACK HOUSING BRACKET RHILH

Remove the steering rack housing bracket RH and LH.
(6)POWER STEERING GEAR AY
Turn the power steering gear Ay approx. 45' to rearward of the vehicle and take it out into the right side
of the vehicle.
CAUTION
Use care not to damage the pressure tube.
NOTE
When pulling out the power steering gear Ay, turn it back and forth in order to fend off the turn
pressure tube.
3-1-5 INSPECTION
bend, deformation ,-Oil leakage

Install the power steering gear Ay from the right side of the vehicle to the center of the vehicle.
-
(2) STEERING RACK HOUSING BRACKET RHILH Upper side
ln&all the steering rack housing bracket RH and LH to the
I
power steering gear Ay. Notch
CAUTION
* Ensure that up-and-down and RWLH orientation of the
bracket is correct. The bracket RH has larger
thickness and smaller bend radius, while LH has
smaller thickness and larger bend radius. Install each
bracket with the notch faced upward of the vehicle.
NOTE
If you are not sure where to install the LH bracket, use
the mounting hole on the RH bracket as reference and
install the LH bracket in such a way that the distance A
in the figure on the right becomes 250* 1rnm.
l.lnstal1the power steering gear Ay to the frame Ay.
2.lnstall the steering column hole s h ~ e l dto the power
steering gear assembly.
CAUTION
Make sure that the cutout section of the steering
column hole shield is securely installed to the pawl
section of the power steering gear assembly.
(4) RETURN HOSE

Use the SST to install the return hose to the power steering
gear Ay.
CAUTION
Ensure that the hose is installed in place.
Installationshall be performed in proper orientation free
from interference with hoses.
SST: 09633-00020-000
(5) PRESSURE FEED HOSE

Use the SST to install the pressure feed hose to the power steering gear Ay.
CAUTION
Ensure that the hose is installed in place.
Shall be installed in proper orientation free from interference with hoses.
(6) FRAME AY
Install the frame Ay to the body. During this installation, push the steering column shield into the column
hole.
(7) KNUCKLE, STEERING, RHlLH
Install the ball joint of the tie rod end to the steering knuckle RH and LH.
1.lnstall the shift & select shaft and extension rod to the transmission.
Refer to Page F2-8.
2.lnstall the exhaust pipe

Refer to Page 84-2.
3.Connect the connector of the rear 02sensor.

4.lnstall the front floor center brace SIA.
5.lnstall the front wheels. (RH, LH)

TIGHTENING TORQUE: 103.0+ 14.7N~rn{l050~15Okgf~cm)
&Lift down the vehicle.

7.lnstall the universal joint at the steering gear side of the steering column assembly.
Refer to Page GI-4.
8.lnstall the steering shaft dust cover.

9.lnstall the dust cover retainer.
TIGHTENING TORQUE: 5.4f 1.5N.m{55*15kgf .cm)
10.Place the carpet near the steering column hole.

1l.lnstall the foot rest.
12.lnstall the power steering reserve tank to the power steering reservoir bracket.
13.lnstall the A/C suction hose to the power steering reservoir bracket.
14.Bleed after filling the power steering fluid.
Refer to Page G2-6.
15.Check the proper operation of the power steering gear Ay

16.lnstall the engine upper cover SIA.
TIGHTENING TORQUE: 8.0+1.6N~m{80~16kgf~cm)
17.Check and adjust the front wheel alignment

Refer to Page C1-1.
;ST
Shape 1 Part No. Part name
@c 09043-30190-000
09612-00012-000
Wrench, hexagon
stand, rack & pinion steering rack housing

(09612-00011-000)
09612-87180-000 Tool set, steering gear housing overhaul
09613-87701-000 Puller, steering rack shaft bush
09616-87702-000 Socket, steering pinion bearing adjusting
09630-24014-000
Tool set, steering rack oil seal
(09630-24013-000)
09950-70010-000 Set, handle
09631-12071-000
Tool, steering rack oil seal test
(09631-12070-000)
8 09631-20070-000 guide. seal ring
09922-10010-000 Wrench, steering rack end

Tool
]cutter kn~fe.Wirebrush
Instrument
[ ~ l t y ~ a c . ~ - s h a pblocks.D~al
ed gauge,Torque wrench,M~crometer
/~ov/ersteering iluio,Mo yboenum d su pnice I i t l l ~ m
oase grease.S~*icon
grease.Tnree Bono1'04.Dryer..'Nire.Prorec1.vetape 1
Remove the power steering gear Ay.
Refer to Page G2-9.
- 62-1 8
I) COMPONENTS
L
%:Nan-reusable parts
Unit:N.rn(kgf.cmJ
+:Power steering fluid
+:Molybdenum disulphide lithium base grease
e:Silicone grease
-:Three Bond1 104
(2) Disassembly procedures
a Tube, LH turn pressure 21 s Washer, claw
b Ring, 0 v 22 t Steering rack end SIA
c Ring. 0 '
I 23 u Nut, lock
d Tube, RH turn pressure v 24 v Rack guide cap
e Ring, 0 25 w Spring, compression
f Ring. 0 26 x Rack guide
i End SIA, steering tie-rod end, RH v 27 P Housing SIA, control valve
j End SIA, steering tie-rod end. LH 28 F Bearing, cylindrical roller
g Grommet, steering rack housing, RH 29 G Seal, type Toil
h Grommet, steering rack housing. LH v 30 A Valve SIA, power steering control
i End SIA, steering tie-rod end, RH 31 M Ring. seal, No.1
i End SIA, steering tie-rod end, LH 32 B Ring, shaft snap
k Band, steerina- rack boot N o 2 33 C Stopper, cylinder end
I Band, steering rack boot 34 D Bush SIA, power steering rack
m Boot, steering rack 35 E Rack SIA, power steering
16 n Band. steering rack boot No.2 36 H Ring, seal, No.2
17 p Band, steering rack boot 37 J Ring. 0
18 o Boot, steering rack 38 K Ring. 0
19 q Washer. claw 39 L Seal, type S oil
20 r Steering rack end S/A 40 N Housing Ay, power steering rack
(3) Assembly procedures

N Housing Ay, power steering rack A 22 q Washer. claw
L Seal, type S oil A 23 r End SIA, steering rack
K Ring. 0 A 24 q Washer. claw
D Bush SIA, power steering rack 25 p Band, steering rack boot
J Ring. 0 A 26 o Boot, steering rack
H Ring, seal, No2 27 p Band, steering rack boot
E Rack SIA, power steering 28 n Band. steering rack boot No.2
C Stopper,
.. cylinder end 29 1 Band, steering rack boot
B Ring, shaft snap A 30 msteering rack boots
A 10 MRing. seal, No.? 31 1 Band, steering rack boot
A 11 A Valve SIA, power steering control 32 k Steering rack boot band No2
A 12 G Seal, type T oil A 33 j End SIA, steering tie-rod end, LH
A 13 F Bearing, cylindrical roller A 34 i End SIA, steering tie-rod end, RH
A 14 P Housing SIA, control valve A 35 h Grommet, steering rack housing, LH
A 15 x Rack guide 36 g Grommet, steering rack housing, RH
16 w Spring, compression 37 f Ring, 0
A 17 v Rack guide cap 38 e Ring. 0
A 18 u Nut,lock 39 d Tube, RH turn pressure
A 19 s Washer, claw 40 c Ring, 0
A 20 t Steering rack end S/A 41 b Ring, 0
A 21 s Washer, claw 42 a Tube, LH turn pressure
CAUTION
The hydraulic power steering gear is a precision hydraulic instrument. Use care not to contaminate
the environment by dirt, dust, iron powder or debris and work with your bare hands wherever
possible.
Keep all the components free from contamination. Wash your hands clean before starting work
activities.
All the disassembled seals shall be replaced with new ones. Do not clean plastic and rubber parts
with thinner.
Do not reassemble the defective parts, which were used before replacement.
(1) STEERING TIE-ROD END SIA RHILH

Put mating marks on the steering tie-rod end subassemblies
RH and LH as well as on the steering rack end subassembly. Ma!ing mark
CAUTION
When putting mating marks, ensure that the right and
left sides can be discerned.
(2) STEERING RACK HOUSING GROMMET LH

Put a mating mark on the power steering rack housing
assembly so that the installation position of the steering rack
housing grommet LH can be discerned. Then, remove the
steering rack housing grommet LH.
(3) STEERING TIE-ROD END SIA RWLH

Secure the power steering gear in a vice by applying the
SST to the steering rack housing section. Then, remove the
steering tie-rod end subassemblies RH and LH.
CAUTION
Do not secure the rack housing section of the power
steering gear assembly directly in a vice.
SST: 09612-00012-000
(4) STEERING RACK BOOT

Remove the steering rack boot band No.2 and steering rack boot band. Then, remove the steering rack
boots. (Both right and left sides)
(5) STEERING RACK END SIA
@ Claw Washer
Loosely fix the ball joint area of the steering rack end S/A on
a vise and release caulking of the claw washers (both
RHILH) with a flat screwdriver.
CAUTION
Be vety careful not to apply impacts to the power
steering rack housing assembly.
@ STEERING RACK END SIA

Remove the steering rack end subassembly, using the SST
in combination with a spanner. (Both right and left sides)
SST: 09922-10010-000
(6) LOCK NUT

Remove the lock nut, using the SST.
SST: 09922-10010-000
(7) RACK GUIDE SPRING CAP

Use the SST to remove the rack guide spring cap.
CAUTION
After completion of the removal, completely wipe off
any bond adhered to the threaded portion.
SST: 09043-30190-000
(8) POWER STEERING CONTROL VALVE AY

Remove the bolts (at two locations) which secure the control
valve housing S/A and remove the control valve housing S/A,
while holding the power steering control valve housing SIA.
CAUTION
Pulling out only the control valve housing SIA might
cause damage to the seal in the housing.
(9) CONTROL VALVE HOUSING
1.Place the mating surfaces of the control valve housing
SIA on the hand press and lightly depress the tip of the
power steering control valve SIA to push out the valve
area.
CAUTION
Depress the power steering control valve SIA straight
down. Failure to do so might cause damage to the seal
in the valve housing by the valve SIA spline area.
2.Use the SST to remove the cylindrical roller bearing

together with the type T oil seal with a press.
CAUTION
Do not reuse the disassembled bearing and the oil
seal.
SST 09630-24014-000[09620-24011-000]
(10) POWER STEERING CONTROL VALVE SIA

Use a cutter knife or the like to cut off the seal ring No.1 (4 pcs) one by one from the power steering
control valve SIA.
CAUTION
When cutting the seal ring No.1, do not damage the ring groove and the side face.
The disassembled seal ring shall not be reused.
TOOL: Cutter knife
(11) PAWER STEERING RACK SIA

1.Turn the cylinder end stopper clockwise with a long-nose
pliers to take out the end of the shaft snap rlng from the
power steering rack housing.
2.Turn the cylinder end stopper counterclockwise to remove

the shaft snap ring from the cylinder end stopper.
3.Using the SST, gently hammer the power steering rack
S/A with a plastic hammer to remove the cylinder end
stopper, power steering rack bush S/A and power
steering rack S/A at a time.
CAUTION
Use care not to damage each component when
removed.
Use wash oil to clean the disassembled power steering
rack SfA and remove the residual grease in the tooth
gullet.
Care should be taken, as fluid in the cylinder might
spatter.
SST: 09612-87180-000[09612-10061-OOO]
4.Use a cutter knife or the like to cut off the seal ring No.2
from the power steering rack S/A.
CAUTION
When cutting the seal ring No.2, do not damage the
ring groove and the side face.
The disassembled seal ring shall not be reused.
TOOL:Cutter knife
5.Remove the O-ring with a baby screwdriver or the like.
(12) POWER STEERtNG RACK BUSH SIA

1.Remove the Oring.
2.Use the SST to remove the typeB oil seal inside the rack
bush.
CAUTION
Use care not to damage insidefoutside of the rack bush
when setting the SST or removing type S oil seal.
SST: 09613-87701-000
,-
;l
'i
3-2-5 INSPECTION
(1) TURN PRESSURE TUBE RWLH
Check the following parts. Replace any part exhibiting abnormality.
(1) Damage and spoilage to the turn pressure tube RHILH.
(2) STEERING RACK HOUSING GROMMET RHILH
(1) Crack and damage to the steering rack housing grommet RH and LH.
(1) Dust boot of steering tie-rod end subassemblies RH and LH for rupture, and ball joint section for
non-smooth operation
(1) Steering rack boot for cracks, damage and aging
(1) Rack end ball for excessive play and non-smooth operation
(2) Rack end for foreign matter and grease for discoloration
(3) Tie-rod section of rack end for bending and cracks
(6) RACK GUIDE
(1) Sliding surface seat of rack guide for abnormal wear
(7) CONTROL VALVE HOUSING SIA
(1) Crack and deformation of the control valve housing.
(2) Damage and foreign material deposit on the seat surface of each control valve housing port.
(3) Operation of the bearing not smooth
(4) Damage or wear-out on oil seal lip area.
(8) POWER STEERING CONTROL VALVE SIA
(1) Unusually worn, damaged or broken seal.
(2) Damage to the sleeve periphery.
(3) Damage, wear-out or foreign material deposit on the pinion oil seal.
(4) Excessive play and malfunction
(5) Deformation of the bearing caulking ring
(6) Crack and abnormal wear on the pinion teeth.
(7) Damage to the shaft area and serration area of the control valve shaft.
(9) POWER STEERING RACK SIA
1Check wear and damage of the teeth.
2.Use a V-block and a dial gauge to check the rack for
bent.
SPECIFIED VALUE: Deflection 0.15mm (midsection of the
rack)
3.Check the ist ton for excessive play . . and damage- to its
periphery.
4.Check the seal for unusual ware.
(10) POWER STEERING RACK BUSH SIA
(1) Damage and dent of the oil seal groove inside of the power steering rack bush.
(2) Damage and dent of the O-ring groove of the power steering rack bush periphery
(3) Unusual wear of the inner diameter of the power steering rack bush.
(4) Damage or wear-out on oil seal lip area.
(5) Wear-out or foreign material deposit on O-ring.
(11) POWER STEERING RACK HOUSING AY
(1) Crack and damage to the power steering rack housing.
(2) Harmful scores in groove where large-diameter boot is assembled
(3) Damage to the screw in the mounting area of the control valve housing S/A.
(4) Damage to the bore of the cylinder and damageldeformation to theexternal of the cylinder.
(5) Damage and foreign material deposit on the seat surface of each port.
(6) Operation is not smooth for needle roller bearing inside of the power steering rack housing S/A
(the power steering control valve S/A seat).
(1) POWER STEERING RACK BUSH S/A
1.Apply power steering fluid all over the new type S oil seal.
Use the SST to press fit into the power steering rack
bush.
CAUTION
Ensure that press fit orientation for the oil seal is
correct.
Use care not to damage the oil seal due to the
excessive overload during press fitting.
SST:09950-70010-000
09630-24014-000
LUBRICANT Power steering fluid

2.Apply power steering fluid all over the new O-ring and
install it to the ring groove of the power steering rack
bush.
CAUTION
Use care not to twist or damage an O-ring.
(2) POWER STEERING RACK S1A
1.Apply power steering fluid all over the new O-ring. Finger
the ring to enlarge and install it to the ring groove of the
power steering rack bush.
CAUTION
Use care not to twist or damage an O-ring.
2.Apply power steering fluid all over the new seal ring No.2.
Finger the ring to enlarge and install it to the ring groove
of the power steering rack.
CAUTION
Do not twist or damage the seal ring No.2.
3.After installation, reapply the power steering fluid to the

ring groove. Application of power steering fluid
LUBRICANT: Power steering fluid I
4.Manually contract the expanded seal ring No.2, while
pressing and settling.
5.Apply long life grease to the gullet of the teeth of the
power steering rack S/A and apply power steering fluid
to the piston seal area.
CAUTION
Do not allow grease to clog the vent hole of the power
steering rack.
LUBRICANT: Power steering fluid
Molybdenum disulphide lithium base grease
6.Cut the rack cover tube in such a way the tube covers the
Rack cover tube
teeth and the port and is longer than the rack end by h
approx. 3cm.
7.Prepare some paper close to the thickness of newspaper,
and cut it as wide as it covers the tooth surface and as
long as the tube.
CAUTION covering
The rack cover tube is used to protect the oil seal teeth
surface Approx.3crn Teeth surface
inside of the power steering rack housing, so damage LllC5195ETlO
to the tube surface might cause oil leak. Therefore
check the tube surface prior to contraction for burr,
crack or damage before use.
NOTE
Contracting action will create tooth form of the rack on
the tube. Use paper to prevent the tooth form.
8.Place paper so that it covers all over the teeth of the
power steering rack S/A.
9.lnsert the rack cover tube in the bending orientation
shown in the figure as deep as it covers the port.
1
A-A'
LllC5196ETlO
10.Use the backside of the teeth to crossly place the power

steering rack S/A at a drier nozzle as shown in the figure.
Rack cover tube
Move the power steering rack SIA so as to push out the
air inside of the rack cover tube to side B, contracting the
rack cover tube from point A to point 8.
CAUTION
Always use the backside of the teeth, as the use of the
tooth surface will create tooth form on the rack cover
tube and makes it difficult to remove the tube.
NOTE
It is recommended to use a drier with a narrow nozzle,
as the tube bend is to be contracted one side at a time.
11.Turn the rack cover tube only by 180".
12.Along with the operation above, use the backside of the I Rack cover tube
teeth to contract the rack cover tube.
13.Pull out the paper.
CAUTION
If the paper is broken, pull out the rack cover tube and
remove the paper. When installing the rack cover tube,
securely insert the tube as deep as it covers the port.
14.Heat only the end section of the power steering rack

SIA, while turning it. Quickly twist the rack cover tube
and push into the screw hole of the rack end.
CAUTION
* Heat only the end of the teeth, as heating the tooth
surface will create tooth form, thus making it difficult to
remove the tube.
15.Ensure that the end has no protrusion or edge.
Screw hole Forward end
16.lf the end has a protrusion or an edge, loosen the end section
of rack end
again and press into the screw hole with a ball point pen
or the like.
17.Ensure that the rack cover tube surface has no sharp
groove. 0
k a c k cover tube Ll,C5 199m1
18.Apply Ammix power steering fluid to the rack cover tube

periphery, the O-ring and the seal ring No.2.
Rack cover tube
19.lnstall the power steering rack SIA with the rack cover
tube to the power steering rack housing Ay.
20.Remove the rack cover tube.
CAUTION
Do not reuse the rack cover tube.
When the rack cover tube is removed, it is important LIICSMOETIO
not to move the rack more than is necessaty until the
power steering control valve Ay is installed, as the rack
over stroke and the port might damage the teeth and
the oil seal, respectively.
21.Appiy power steering fluid all over the O-ring of the
power steering bush SIA and then insert the power
steering bush S/A to the power steering rack SIA in order
to assemble it to the inside of the power steering rack
SIA.
CAUTION
Ensure that the assembly orientation of the power
steering bush SIA is correct.
62-29
22.lnsert the cylinder end stopper to the power steering
a
rack S/A and assemble to the power steering rack Cylinder end stopper
housing Ay.
CAUTION
Ensure that the insert orientation of the cylinder end
stopper is correct.
d
Match the shaft snap ring mounting hole of the cylinder
end stopper with the long hole of the rack housing side. Aligh hole position
23.lnstall the new shaft snap ring to the cylinder end

stopper.
(1) Insert the claws of the shaft snap ring to the wire hole
of the cylinder end stopper.
(2) Turn the cylinder end stopper clockwise with a long-
nose pliers to slowly feed the wire inside the
housing.
(3) Ensure that the wire rear end does not interfere with
the long hole of the housing.
CAUTION
The rotational range of the cylinder end stopper shall
be within approx. 400" -500".
24.Perform air tightness test.
(1) Install the SST to the power steering rack housing Ay
union area.
CAUTION
Install the O-ring to the SST before use.
SST: 09631-12071-000
(2) Install a MityVac on the SST.
(3) Apply pressure (negative pressure) of approx. 53.3

kPa(400mmHgJand hold for approx. 30sec to see
that the indicator indicates no change.
CAUTION
If there is a leak, check the oil seal within the power
steering rack housing and replace as required.
Oil 'seal oil seal
(3) POWER STEERING CONTROL VALVE SIA I I
1.Apply power steering fluid all over the new seal ring No.1,
insert it from the minor diameter of the SST into the major
diameter and expand. Then install rings (4 pcs) one by
one to the ring groove of the power steering control
valve.
CAUTION
Ensure that the seal ring No.1 and the SST are free
from damage or contamination.
Do not make the seal ring No.1 larger than is
necessaty.
Use care not to damage the seal ring No.1.
SST 09631-20070-000
2.Manually hold the seal ring No.1 (4 pcs) installed to the
power steering control valve and contract it while
pressing and settling.
CAUTION
Use care not to damage the seal end and periphery
with nails.
3.Reapply power steering fluid to the seal ring No.1 (4pcs)

and use the SST to additionally contract the seal while
settling.
CAUTION
Provide good cleaning to the SST and ensure that the
SST is free from damage or contamination.
Apply power steering fluid to the inside of the SST.
SST 09631-20087-000
4.Apply long life grease to the pinion teeth area of the

power steering control valve SIA, the bearing area and
the contact surface with the needle roller bearing inside
of the power steering rack housing Ay. Then assemble to
the power steering rack housing Ay.
LUBRICANT: Molybdenum disulphide lithium base grease
62-31
(4) CONTROL VALVE HOUSING SIA I
1.Apply power steering fluid all over the new type Toil seal.
Use the SST to press f ~ the
t seal into the control valve
housing.
CAUTION
Do not overload during press fitting.
* Ensure that seal is properly oriented.
SST 09950-70010-000
09630-24014-000
2.Use the SST to press fit the new cylindrical roller bearing
to the control valve housing.
CAUTION
Do not overload during press fitting.
* Press fit the bearing with the stamped side on your
side.
SST 09950-70010-000
09630-24014-000
3.Check for the smooth rotational movement after the

cylindrical roller bearing is press fit.
4.Apply protective tape to the serration portion of the power
steering control valve S/A and apply power steering fluid
to the seal ring No.1 area of the power steering control
valve SIA and to the type T oil seal lip area of the control
valve housing S/A. Then assemble the control valve
housing SIA to the power steering rack housing Ay.
CAUTION
Use a plastic hammer to evenly hammer the upper
area of the control valve housing to settle.
(5) RACK GUIDE
?.Apply long life grease to the inside of the rack guide (contact surface with the rack shaft). Then
assemble to the power steering rack housing Ay.
LUBRICANT
(6) RACK GUIDE SPRING CAP
1.Apply liquid packing to the threaded portion of the rack guide spring cap.
2.lnstall the compression spring to the rack guide. Then, install the rack guide spring cap and
temporarily tighten it.
3.Adjust the preload.
(1) Use the SST to tighten the rack guide spring cap to the specified torque.
SST: 09043-30190-000
TIGHTENING TORQUE: 12.3+2.4N.m{l25~24kgf.cm]
(2) From this point, return the rack guide spring cap
approx. 10".
(3) Use the SST to turn control valve S/A and operate
steering rack one or two times at full stroke to help
smooth operation.
CAUTION
Ensure that the end section of the power steering rack
SIA does not go deeper than that of the cylinder end
stopper and the power steering rack housing Ay.
SST 09616-87702-000
(4) Use the SST to loosen the rack guide spring cap until
the rack guide compression spring is inoperative.
CAUTION
Heat the end section of the power steering rack S/A
only until it is movable by hand.
SST 09043-30190-000
(5) When turning the power steering control valve S/A

using the SST, tighten the rack guide spring cap so
as to set the turning preload as standard.
SST: 09616-87702-000
09043-30190-000
SPECIFIED VALUE: 1.03+0.25N -m{l0.5+2.5kgf.cm)
(during turning)
(6) Next, apply liquid packing to the screw area of the
lock nut (for the rack guide spring cap) and the end
of the rack housing. Use the SST to tighten to the
specified torque.
CAUTION
Completely remove residual bond when disassembling.
SST: 09922-10010-000
09043-30190-000
TIGHTENING TORQUE: 39.2f 9.8N.m{4OOf 99kgf.cm)
(7) Turn the power steering control valve subassembly
again, using the SST. At this time, ensure that the
preload during turning conforms to the specified
value.
SST: 09616-87702-000
SPECIFIED VALUE: 1.03~0.25N~m{l0.5+2.5kgf~cm)
(during turning)
@ CLAW WASHER
Install the new claw washer to the rack shaft in the direction
shown in the figure on the right. (RHILH)
CAUTION
* Securely fix claws of claw washers on the rack shaft
notch.
@ STEERING RACK END SIA

Install the steering rack end subassembly and tighten it to
the specified torque, using the SST in combination with a
spanner. (Both right and left sides)
CAUTION
While tightening, be very careful not to twist the power
steering rack subassembly.
SST: 09612-87180-000
09628-10020-000
@ CLAW WASHER
Loosely fix the ball joint area of the steering rack end S/A on
the vise and caulk the claw washers which have been
installed before.
-
CAUTION
Caulk the claw washer in two positions.
- Use care not to make an impact during caulking.

Caulking area shall be free from damage or burr.
@ STEERING RACK END S/A
1.lnsert a wire (outer diameter: approx. 2 rnrn, length:
approx. 50 rnrn) into the vent hole of the steering rack
end. At this time, ensure that the vent hole is not
clogged with grease.
NOTE
The vent hole of the steering rack end equalizes
pressure difference in both sides of the rack boot right
and left. For this reason, if the vent hole is blocked, the
pressure in the boot when the steering is turned may
vary so that the boot may be deflected or broken.
2.Applv silicone grease
- to the rack boot installation Groove
&'the steering rack end subassembly. (Both right and
left sides)
LUBRICANT Silicon grease

I
u Application of grease
LIIC~~I~ETIOI
1. Apply the steering rack boot band through the power steering rack housing Ay. Then install the
steering rack boot (both RHILH).
2.Caulk the steering rack boot band, which have been
installed before. (Both RHILH)
CAUTION
Securely tighten the boot band.
3.Use the SST to turn the power steering control valve S/A
and check the rack boot for smooth expanding and
contracting motion.
SST: 09616-87702-000
1.Temporarily install the steering tie-rod ends RH and LH,
while referring to the mating marks that have been put Mating mark
during the removal.
CAUTION
Make sure that the right and lefl steering tie-rod ends
are installed at the correct positions.
* While tightening, be very careful not to twist the
steering rack.
After the power steering gear assembly is mounted on
the vehicle, securely tighten the lock n h s of the
steering tie-rod end subassembly at the time of the
front wheel alignment adjustment.
2.Remove the SST for securing the steering rack housing.
SST:09612-00012-000
(10)STEERING RACK HOUSING GROMMET LH
1.lnstall the steering rack housing grommet LH, while
referring to the mating mark that has been put during the
disassembling.

1.Install the power steering gear Ay.
Refer to Page G2-9.
- --- -- -
4 VANE PUMP
SST
Shape 1 Part No. I Part name
0925800030-000 Plug set, hose
Instrument
)Belt tension gauge,Remote Cable.Torque wrench I
[power steering fluid

1.Remove the engine upper cover SIA.
2.Remove the AIC suction hose from the power steering reser )ir bracket,
3.Remove the power steering reserve tank from the power
steering reservoir bracket.
4.Drain the power steering fluid.
Refer to Page G2-6.
5.Plug the oil reservoir to pump hose, which has been

removed using the SST.
SST 09258-00030-000
6.Remove the brake master cylinder.
Refer to Page El-6.
) COMPONENTS

Unit:N;m(kgf.cm]
1 a Clarnp 7 g Hose, oil reservoir to pump
2 b Rese~oirAy, oil 8 h Hosepessure feed
3 c Clip 9 i Gasket
4 d Hose, return 10 j Belt, V
5 e Clip r 11 k Pump Ay,vane
6 f Clip r 12 1 Stayjntake manifold, No.2

A 1 I Stayjntake manifold, No.2 7 e Clip
A 2 k Pump Ay,Vane A 8 d Hose, return
3 h Hose,pressure feed 9 c Clip
4 i Gasket 10 b Rese~oirAy, oil
A 5 g Hose, oil reservoir to pump A 11 a Clarnp
6 f Clip A 12 j Belt, V
- 4-1-4 POINTS OF REMOVAL
62-38
(1) VANE PUMP AY
Remove the vane pump Ay and the intake manifold No.2 stay at a time
NOTE
When the bolt on the downside of the vane pump cannot be pulled out easily, press the engine to
the left to help the operation.
4-16 INSPECTION
(1) VANE PUMP AY
Inspect oil leak or exudation, and replace in the event of problems.
(1) VANE PUMP AY
Install the vane pump Ay and the intake manifold No.2 stay at a time.
(2) OIL RESERVOIR TO PUMP HOSE
1.lnstall the oil reservoir to pump hose (the suction hose between the reservoir tank and the vane
pump) as shown in the lower right figure.
(1) Match the marking of the oil reservoir to pump hose (suction hose) with a protrusion of the tank
port of the lower reserve tank and securely insert the hose up to the stopper surface.
(2) The clip shall be installed upward of the vehicle and the distance B shall be 4 f lmm.
(3) lnstall the oil reservoir to pump hose (suction hose) clamp to the brake tube.
(3) RETURN HOSE
1.Install the return hose (between the steering gear and the
reserve tank) to the reserve tank.
(1) Ensure that the hose is ~ n s e r t e dto the stopper
surface.
(2) The clip shall be installed so that it faces to the front
of the vehicle and the distance A shall be 2,lmm.
(3) Install the clamp of the return hose to the brake

vacuum hose. \ Brake vacuum hose 1
(4) V BELT
1.Adjust the V-belt tension.
Refer to Page G2-1.
-
1 Install the brake master cvl~nder.
Refer to Page El-6.
2.lnstall the power steering reserve tank to the power steering reservoir bracket.
3.lnstall the A/C suction hose to the power steering reservoir bracket.
4.Fill the power steering fluid and bleed.
Refer to Page G2-6.
5.lnstall the engine upper cover.

TIGHTENING TORQUE: 8.0+1.6N~m{80_f16kgf~cm)
H I SRS AIRBAG SYSTEM
SRS AIRBAG SYSTEM ......................

H1 - 1
OPERATION Hf - 1
SRS AIRBAG (DRIVER'S SEAT SIDE)--- H1 - 7
REMOVAL AND INSTALLATION-------- H1 - 7
DISPOSAL HI - 9
STEERING ROLL CONNECTOR -------- H I - 14
REMOVAL AND INSTALLATION------ H I - 14
SRS AIRBAG (FRONT PASSENGER
SEAT SIDE) ------------------------.-----------
H1 - 19
REMOVAL AND INSTALLATION H I - 19
DISPOSAL H I - 21
SEAT BELT WlTH PRETENSIONER
MECHANISM H1 - 26
REMOVAL AND INSTALLATION H I - 26
DISPOSAL H I - 26
SENSOR UNIT H1 - 31
REMOVAL AND INSTALLATION------ H1 - 31
CONTROL SYSTEM H I - 34
ARTICLES TO BE PREPARED-------- H I - 34
SYSTEM WIRING DIAGRAM ---------- H1 - 34
ARRANGEMENT OF ECU
TERMINAL H1 - 35
TERMINALS ------------------------------ H I - 36
LOCATION OF COMPONENTS------- H I - 38
HOW TO PROCEED WlTH
TROUBLE SHOOTING------------------ H I - 39
DlAGNOSlS H1 - 40
BASIC CHECK H I - 45
TO DIAGNOSIS CODE ------------------H I - 46
TO MALFUNCTION PHENOMENA--- H1 - 81
HI-1
1 SRS AIRBAG SYSTEM
1-1-1 OUTLINE
If the correct procedures and methods specified are not observed during the operation of the SRS
airbag and seat belts with the pretensioner mechanism, these devices may operate in incorrect ways,
leading to serious accidents. Moreover, if wrong repairs are performed, these devices may not operate
when they should operate. Therefore, before starting services (removal/installation of parts, inspection,
replacement, etc.) of the SRS airbag and seat belt with the pretensioner mechanism, be sure to read the
following information and perform the correct procedures and methods prescribed in this book.
NOTE
SRS refers to Supplemental Restraint System for passengers.
1-1-2 CAUTION TIPS BEFORE SERVICING

1.Before starting the removal of the driver's seat SRS airbag, front passenger's seat SRS airbag and
pretensioner-equipped seat belt, ensure that the illuminating state of the warning lamp. After the IG
SW has been set to [LOCK] position, remove the negative terminal of the battery. Wait 60 seconds.
Then, proceed to the removal operation.
CAUTION
seconds are necessary for the backup condenser to discharge after the negative terminal of the
battery is removed. (Natural discharge)
deployed.
* it should be noted that the memory of the computers of other systems (engine control, etc.) and the
radio will be erased at the same time when the cable is disconnected from the negative terminal of
the battery.
2.To check the SRS airbag system electrically, be sure to use a digital circuit tester which complies with
the following requirements given below.
CAUTION
In advance, be sure to measure the current of the tester to be used. Make sure that it satisfies the
following specified value given below. If the tester which exceeds the specified value is used, the
airbag may be actuated mistakenly or damaged. When performing the current measurement for the
tester, use the minimum range of the resistance (8).
SPECIFIED VALUE: About 50 mA (0.05A) or less
1-1-3 REPLACEMENT PARTS AFTER DEPLOYMENT

(1) SRS AIRBAG & PRETENSlONER MECHANISM-EQUIPPEDSEAT BELT
1.When the SRS airbag & pretensioner mechanism-equipped seat belt have been actuated and
deployed for example in an accident, the following parts should be replaced with new parts.
(1) Airbag computer
(2) Driver's seat SRS airbag (Pad S/A, horn)
(3) Front passenger's seat SRS airbag (Airbag Ay, instrument panel passenger)
(4) Driver's seat pretensioner mechanism + force limiter mechanism-equipped seat belt (Belt Ay,
front seat, outer RH)
(5) Front passenger's seat pretensioner mechanism + force limiter mechanism-equipped seat belt
(Belt Ay, front seat, outer LH)
2.When the SRS airbag & pretension'er mechanism-equipped seat belt have been actuated and
deployed for example in an accident, be sure to check the following parts. If there are problems,
repair or replace the parts.
(1) Steering wheel S/A
(3) Steering roll connector(cable S/A, spiral)
(4) Body-related
3.Check to see if harnesses are caught, connectors damaged, or terminals deformed.
1-14 Caution tips to maintain performance
(1) SRS AIRBAGSEAT BEKT WlTH THE PRETENSTIONER MECHANISM
1.Never use the driver's seat SRS airbag, front passenger's seat SRS airbag, pretensioner mechanism-
equipped seat belt and airbag computerthat are designed for other vehicles. Be sure to use the new
specified parts when replacing the parts.
2.Do not drop the driver's seat SRS airbag, front passenger's seat SRS airbag, pretensioner
mechanism-equipped seat belt, steering roll connector and airbag computer. If they exhibit cracks,
,, dents or chips, replace them with new parts.
3.Never disassemble the driver's seat SRS airbag, front passenger's seat SRS airbag, pretensioner
mechanism-equipped seat belt and airbag computer.
4.Follow the instructions and caution tips written on a label affixed to each of the driver's seat SRS
airbag, front passenger's seat SRS airbag, pretensioner mechanism-equipped seat belt, steering roll
connector and airbag computer. If the label is dirty or torn, replace the label with a new one.
5.Do not apply grease to the driver's seat SRS airbag, front passenger's seat SRS airbag, pretensioner
mechanism-equippedseat belt and airbag computer. Do not allow cleaning detergent, oil or water to
get to these parts.
1-1-5 Caution tips to prevent wrong operation
(1) SRS AIRBAGSEAT BELT WlTH THE PRETENSIONER MECHANISM
1.Be very careful not to drop the driver's seat SRS airbag, front passenger's seat SRS airbag,
pretensioner mechanism-equipped seat belt and airbag computer when installinglremoving these
parts.
2.Be very careful not to give shocks or damages to the driver's seat SRS airbag, front passenger's seat
SRS airbag, pretensioner mechanism-equipped seat belt and airbag computer when removing these
parts.
3.When placing the driver's seat SRS airbag or front passenger's seat SRS airbag even temporarily,
face its deploying surface upward. Do not place the driver's seat SRS airbags stacked. (If the
airbag is deployed, it may lead to a serious accident when the metal surface faces upward.)
4.Store the driver's seat SRS airbag, front passenger's seat SRS airbag, pretensioner mechanism-
equipped seat belt and airbag computer in a place which is not hot (ambient temperature of 85 ' C or
more) or humid and hardly exposed to electric noises.
5.Do not directly expose the driver's seat SRS airbag, front passenger's seat SRS airbag and
pretensioner mechanism-equipped seat belt to high temperature or fire.
1-1-6 Caution tips for body repair and paint
(1) SRS AIRBAG&SEAT BELT WITH THE PRETENSIONER MECHANISM
1.When repairing the driver's seat SRS airbag, front passenger's seat SRS airbag, pretensioner
mechanism-equipped seat belt and airbag computer, do not give strong impacts to these parts by a
hammer or the like, or do not expose these parts to high temperature,
2.When using an electric welding machine, remove the driver's seat SRS airbag, front passenger's seat
SRS airbag, pretensioner mechanism-equipped seat belt and airbag computer before welding.
3.When there is the possibility that the SRS airbag system is exposed to impacts or high temperature,
remove the SRS airbag system components before the operation.
4.When drying the paint around the airbag related parts, do not allow the temperature to exceed 85°C
in those areas.
5.lf the airbag-related parts exhibit external damages or deformation, be sure to replace them with new
ones.
1-1-7 CAUTION TIPS OF SRS AIRBAG SYSTEM COMPONENTS
(1) DRIVER'S SEAT SRS AIRBAG, FRONT PASSENGER'S SEAT SRS AIRBAG
1.Never measure the resistance of the driver's seat SRS airbag or front passenger's seat SRS airbag.
(There is the possibility that the tester current triggers the airbag deployment.) For the checks of the
system, be sure to use the specified digital circuit tester.
2.lf the vehicle was involved in a minor collision in which the airbag was not deployed, check the
driver's seat SRS airbag and front passenger's seat SRS airbag.
3.When the airbag-mounted vehicle or the airbag unit is to be scrapped, deploy the airbag before
scrapping.
4.During the operation, follow the instructions given at the caution plate provided at the back of the
driver's seat SRS airbag or front passenger's seat SRS airbag.
I
(2) PRETENSIONER MECHANISM-EQUIPPED SEAT BELT
1.Never measure the resistance of the pretensioner mechanism. (There is the possibility that the tester
current triggers the pretensioner mechanism.) For the checks of the system, be sure to use the
specified digital circuit tester.
2.lf the vehicle was involved in a minor collision in which the airbag was not deployed, check the
pretensioner mechanism.
3.When the vehicle with the pretensioner mechanism-equipped seat belt or the seat belt itself is to be
scrapped, deploy the pretensioner before scrapping.
4.During the operation, follow the instructions given at the caution plate provided at the side of the
retractor.
(3) STEERING ROLL CONNECTOR (INCLUDING THE TURN SIGNAL SWITCH)
1.When installing the steering roll connector, be sure to perform centering.
2.lf the positional relationship between parts changes after \ Center mark
the following operation, there is the possibility that the
steering roll connector may have open wires when the
steering wheel is operated. Therefore, centering of the
steering roll connector and marking of the disconnecting
sections should be performed.
NOTE
Steering wheel-related
Steering wheel, steering wheel column, steering gear,
etc.
Body-related
Instrument panel, etc.
Body electrical-related
Multi-use lever SW etc.
i (4) AIRBAG COMPUTER
1.Perform connection/disconnectionof the connector with the airbag computer installed to the vehicle.
CAUTION
If the connector is connected with the airbag computer disconnected from the vehicle, the airbag
may be actuated mistakenly.
2.When removing/installing the airbag computer, be sure to

remove the negative terminal of the battery. Wait 60
seconds before starting the operation. When installing
the airbag computer, be sure to use the specified bolts
and tighten them to the specified torque.
(5) WIRE HARNESS, CONNECTOR

1.The SRS airbag system connectors and the branch wire harness exclusively used for the system are
yellow colored, except exposed portions in the engine compartment, thus distinguishing themselves
from other systems. Therefore, please pay utmost care so that these connectors and harnesses are
not damaged.
2.Since special connectors are used for the SRS airbag system, be very careful not to damage the
connector when handling it
@ TERMINAL DOUBLE LOCK MECHANISM
The connector is of a two-piece construction consisting of the housing and spacer. The terminal is
retained doubly by a lance (first lock) and spacer (second lock). This enhances the terminal retaining
rce so as to prevent the terminal from being pulled off.
cer (Secondary lock)
<Female side> <Male side> <Connector cross-section>
@ TERMINAL SHORT MECHANISM

This mechanism is provided to prevent explosion during servicing. A short spring plate is provided
inside the male connector. When the connector is disconnected, the power supply side terminal and
earth side terminal are automatically shorted, forming a closed circuit. (No potential is generated
between both terminals.)
CAUTION
When checking the harness, there is the possibility that wrong judgment, for example, that a short
exists between the harnesses may be made because of this terminal short mechanism. Therefore,
when checking the harness, insert the SST for airbag deployment (part numbec09082-87710-000)
into the connector to be checked and check the connector together with the SST. If the harness is
found to be faulty
- by this check, perform the check by inserting
- an insulation into between the short
spring plate and the terminal or by removing the short spring plate.
Terminal Short spring plate "ON"

Short spring plate "OFF
// / ,Steering roll connector
// Steering roll connector
U
Ignition system
The short spring plate is
,Male side housing contact with the male
Short spring plate s~determinal
emale side housing
4aie side term'hal b e m a l e side terminal

<When open>
i
@ HALF FIT DETECTING MECHANISM
This is a mechanism which detects whether the airbag computer is firmly connected with the vehicle
side harness connector or not.
If the IG SW is set to ON position with the connector being half flt, the airbag warning lamp keeps
illuminated. When the airbag system is normal and the connector is firmly connected, the airbag
warning lamp is extinguished.
connector on the airbag computer side
I
Half-fittingdetecting terminal
A
2 SRS AIRBAG (DRIVER'S SEAT SIDE)
Tool
ITORX"wrench T30

1.After the IG SW has been set to [LOCK] position, remove the negative terminal of the battery.
CAUTION
the battery.
2.Wait at least 60 seconds.

CAUTION
deployed.

) COMPONENTS
Unit:N.m[kgf.cm]
v A 1 a Pad S/A, horn
(1) HORN PAD SIA
1.Loosen the right and left torx bolts provided at the side of
the horn pad SIA as much as possible.
CAUTION
Remove the horn pad SIA slowly, for the airbag
harness and horn harness are wired.
2.Remove the horn connector (except for the M O M 0 7

steering).
3.Before removing the air bag connector, pull the white

double lock portion upward.
CAUTION
When placing the horn pad SIA, be sure to face the
deploying surface upward.
Store the horn pad SIA in a place where it will not drop.
2-1-5 INSPECTION
(1) CHECK OF HORN PAD SIA
1.When the following cases have occurred, perform visual checks or system checks. If there are any
faulty parts, replace them.
(1) Case where the vehicle is damaged, including minor collisions where the airbag has not been
deployed.
(2) Case where problems have been found out by the diagnosis check
(2) EXTERNAL CHECK OF HORN PAD SIA
1.When the following cases have occurred, replace the horn pad S/A.
(1) Case where the airbag has been deployed.
(2) Case where the airbag deploying surface of the horn pad S/A has scratches or cracks.
(3) Case where the connector or harness has dents or chips.
(4) Case where grease, water, detergent or oil has got to the horn pad S/A in a large quantity.
(5) Case where the horn pad S/A dropped and got damaged.
(1) HORN PAD S/A
1.Connect the connector until it locks and securely fixe it on
the holder of the steering wheel S/A side. Securely fix
the harness on the clamp of the steering wheel.
2.When installing the horn pad S/A, hold the lower side of
the horn pad SIA.

- terminal of the batterv.
1.Install the neaative
2.After the IG SW has been set to [LOCK] position. At this
time, ensure that the airbag warning iamp goes on about
six seconds and then goes out.
I
2-2 DISPOSAL
2-2-1 OUTLINE
When scrapping a vehicle equipped with the SRS airbag system, deploy the driver seat SRS airbag
system and the front passenger seat SRS airbag system so that the airbag system can be scrapped as a
single part. In the event of scrapping the airbag system that has not been deployed, it is absolutely
important to deploy the system prior to scrapping. Follow the instructions below on how to scrap the
airbag system.
CAUTION
Do not scrap the driver's seat SRS airbag system or the front passenger seat SRS airbag system
until airbags have been deployed.
* When scrapping the the driver's seat SRS airbag or front passenger's seat SRS airbag that has
been deployed by a customer, follow the "Airbag scrapping procedure."
i 2-2-2 DEPLOYMENT OF HORN PAD SIA
SST
09082-87710-000
Wire, a!r bag deployment
(09082-87701-000)
Tool
ITORX~
wrench T30
Wire harness (1.25mrn2),Twobolts (Nominal length of 35 mm or more, pitch of 1.0 mrn, nominal diameter of 6.0 mm),l2V bat-
tery for car use,2 tires with disc wheel3 tires.Vinyl bag
'i (2) INSTRUCTIONS ON THE HORN PAD S/A DEPLOYMENT

1.The deployment of the SRS airbag should be performed at an outdoor flat place where safety can be
ensured. Deploying the airbag in a residential area should be avoided whenever possible.
2.Use SST to keep at least 5 m away from the horn pad SIA.
3.Allow at least 30min after activation, because the deployed horn pad SIA is extremely hot.
4.Do not pour water or other liquid over the deployed horn pad SIA.
5.Wear protective glasses and gloves in handling the deployed horn pad SIA.
6.Put the deployed horn pad S1A in a plastic bag, seal and scrap it.
7.Wash your hands with water after operation is complete.
(3) IN-VEHICLE DEPLOYMENT OF HORN PAD SIA
WARNING
Before connecting the SST terminal to the battery, once again make sure there are no one around.
Keep at least 5 m away from the site, as the operation produces a large sound.
CAUTION
the battery.

CAUTION
deployed.
3.Short the terminal with the alligator clip of the SST (Airbag
deployment wire).
SST: 09082-87710-000
CAUTION
Before starting work, ensure that there is no excessive
play in the steering wheel area.
5.Remove the column cover lower.
6.Connect the SST connector to the connector for the

airbag (yellow 2P).
NOTE
Disconnect the spiral cable SIA from the connector on
the vehicle side, and connect the SST there.
7.Place the battery at a position where the SST has been
extended as long as possible.
CAUTION
At this time, close all the doors and windows.
Make sure that there is no one inside and around the
vehicle.
Since a big sound will be emitted at the time of
deployment, keep at least 5 m away.
8.0nce again make sure of the safety inside and around
the vehicle, and then connect the SST to the battery [with
the alligator clip on battery side, and the terminal on
side] and deploy the airbag.
CAUTION
Give warning loudly to those nearby before deploying
the airbag.
(4) DEPLOYMENT OF HORN PAD SIA

WARNING
Since a big sound will be emitted at the time of deployment, keep at least 5 m away.
?.Afterthe IG SW has been set to [LOCK] position, remove the negative terminal of the battery.
CAUTION
the battery.

CAUTION
deployed.
-- - --
3.Attach plate washers to two bolts. By your hands, fully

tighten the bolts to the two attaching holes of the horn
pad SIA.
--
t KC',
4.Secure the steering horn pad S/A to a disc wheel, using

. a wire harness for car use (cross-sectional
area of core wire: 1.25 rnrn2or more).
Wire harness
Cross-section area
1.25mm20rmore
0 Disc wheel
Wind ;least doubly
CllA7052ESi,
CAUTION
Perform the installation in such adirection that the airbag deploying surface faces upward.
A great force will be applied to the wire harness at the time of airbag deployment. Therefore,
secure the wire harness securely by winding it triple.
deployment wire).
SST: 09082-87710-000
CAUTION
Deployment activity for the horn pad S/A shall be done
outdoors.
6.Connect the SST connector and the airbag connector
(yellow 2P) on the lower disk wheel.
\
SST
7.Next, pile up at least three tires on the disc wheel to which the horn pad SIA has been secured.
Then, place a tire with a disc wheel on the top.
8.Connect the tires with wire harnesses or ropes so that the tires will not be scattered when the airbag is
deployed.
9.Make doubly sure of the safety around the vehicle, and then connect the SST to the battery [with the
~ ~
alligator clip on battery side, and the battery terminal on side] and deploy the airbag Ay.
Tyre without disc wheel
/
Extend the SST as far as it goes.
r Tyre with disc wheel
LllA5062ESl
CAUTION
Give warning loudly to those nearby before deploying the airbag.
Never mount and reuse the tires and wheels used for the deployment on vehicles.
(5) SCRAPPING OF HORN PAD SIA

Seal the deployed horn pad S/A in a plastic bag before it is
scrapped.
CAUTION
Scrap only after deployment is complete.
Allow at least 30min after activation, because the
- deployed horn pad SIA is extremely hot.

Do not apply water, etc. to the deployed steering wheel
pad assembly.
Wear protective glasses and gloves in handling the
deployed horn pad SIA.
After completion of the operation, be sure to wash your
hands with water.
HI-14
3 STEERING ROLL CONNECTOR
1 After the IG SW has been set to [LOCK] positron, remove the negat~veterrnrnal of the battery
CAUTION
It should be noted that the memory of the computers of other systems (engrne control, etc.) and the
radio wrll be erased at the same time when the cable is disconnected from the negative termmal of
the battery.

CAUTION
deployed.
3.Ensure that the steering wheel is in the straight ahead condition.

4.Rernove the horn pad subassembly.
Refer to page HI-7.
5.Remove the steering wheel SIA

Refer to page GI-1.

7.Lower the steering column as far as it goes.
8.Remove the column cover lower.
9.Remove the column cover upper.
CAUTION
Be very careful not to scratch the column cover during the removal.
1) COMPONENTS

r A 1 a Cable S/A, spiral
2 b Switch SIA, turn signal

(1) SPIRAL CABLE SIA
Before removing the air bag harness, unlock the double
locks of the connector.
3-1-4 INSPECTION
(1) CHECK STANDARD FOR SPIRAL CABLE SIA
Check the spiral cable S/A in the following cases. Replace it if problems are found.
(1) Case where the vehicle is involved in a collision.
CAUTION
Perform the check whether the airbag has been deployed or not.
As for the checking procedure, follow the trouble shooting instructions.
(2) Check of external appearance of spiral cable SIA

Replace the spiral cable SIA in the following cases.
. --
.<
HI-16
(1) When the spiral cable S/A dropped.
(2) Connector section having worn out portions, cracks or breakage
(3) Spiral cable S/A having deformation, cracks or breakage
(4) Harness section being damaged
CAUTION
Never disassemble the spiral cable S/A.
(I) SPIRAL CABLE SIA
1 .Ensure that the steering wheel is in the straight ahead state.
2.lnstall the spiral cable SIA to the turn signal SW S/A.
CAUTION
Assemble by inserting the convex portion of the turn
signal SW cancel cam into the groove of the spiral
cable SIA.
Before connecting a white connector, ensure that a
lead wire is seated on the hook located at the cover on
the back of the turn signal SW.
3.Connect the connector.

CAUTION
* When installing the yellow connector, make sure to turn
the double lock portion to fix the connector.

1.Install the column upper cover upper.
2.lnstall the column upper cover lower.
4.Adjust the center position of the spiral cable
subassembly.
/ Neutral securing pin
/
CAUTION
If the new spiral cable SIA is to be installed, ensure
that the neutral holddown pin stays. Following
operations are required, only if the pin is out.
(1) Give the spiral cable S/A counterclockwise turns until /
it locks.
NOTE
(2) Give the spiral cable SIA approx. 3 clockwise

I Center mark
counter-rocking turns from the lock position, followed
by the additional turn to whichever direction close to
the center mark in order to match with the mark.
5.lnstall the steering wheel S/A to the steering shaft.
Refer to page GI-1.
6.lf the new spiral cable SIA is installed, pull out the neutral
holddown pin at this point.
7.lnstall the horn pad subassembly.
Refer to page HI-7.
%Confirm the steering wheel center position.

1O.Turn ON the IG SW. Ensure that the airbag warning
lamp is illuminated for about six seconds and, then, it
goes out.
4 SRS AlRBAG (FRONT PASSENGER SEAT SIDE)
Instrument
l~orque
wrench

CAUTION
the battery.

CAUTION
* The SRS airbag system is provided with a backup condenser (for the squib). Therefore, about 60
deployed.
3.Remove the instrument panel box assembly.

(1) COMPONENTS
CllA7M5S22
Un~tN rnlkgi-crn)
r A 1 a A~rbagAy, mstrurnent panel passenger
'I 4-1-4 POINTS OF REMOVAL
(1) INSTRUMENT PANEL PASSENGER AIRBAG AY
1.Remove the two bolts and the one nut which secure the instrument panel passenger airbag assembly
with the pillar-to-pillar member .
2.Remove the claw of the instrument panel passenger
airbag Ay on the vehicle front side.
3.Slide the instrument panel passenger airbag Ay frontward

of the vehicle and remove.
CAUTION
When placing the instrument panel passenger airbag
assembly, be sure to face the deploying surface
upward.
Use care not to drop the instrument panel passenger
airbag Ay.
4-1-5 INSPECTION
(1) CHECK OF INSTRUMENT PANEL PASSENGER AIRBAG AY
Perform checks in the following cases. Replace any faulty parts.
(1) Case where the vehicle is damaged, including minor collisions where the airbag has not been
deployed.
(2) Case where problems have been found out by the diagnosis check
(2) EXTERNAL CHECK OF INSTRUMENT PANEL PASSENGER AIRBAG Ay
When the following cases have occurred, replace the instrument panel passenger airbag Ay
(1) Case where the airbag has been deployed.
(2) Case where the airbag deploying surface of the instrument panel passenger airbag Ay has
scratches or cracks.
(4) Case where grease, water, detergent or oil has got to the instrument panel passenger airbag
assembly in a large quantity.
(5) Case where the instrument panel passenger airbag assembly dropped and got damaged.
(I)INSTRUMENT PANEL PASSENGER AIRBAG AY
1 .Insert the claw of the instrument panel passenger airbag
Ay, starting with the claw on the vehicle rear side.
Claw (Vehicle front side) CtlAmSIETlO
2.Hoid it down to fit into the instrument panel.
4-1-7 OPERATION AF-TER INSTALLATION

1.Install the instrument panel box assembly.
3.Turn ON the IG SW. Ensure that the airbag warning lamp
is illuminated for about six seconds and, then, it goes
out.
4-2 DISPOSAL
4-2-1 OUTLINE
When scrapping a vehicle equipped with the SRS airbag system, deploy the driver seat SRS airbag
system and the front passenger seat SRS airbag system so that the airbag system can be scrapped as a
single part. In the event of scrapping the airbag system that has not been deployed, it is absolutely
important to deploy the system prior to scrapping. Follow the instructions below on how to scrap the
airbag system.
CAUTION
Never scrap the driver's seat SRS airbag or front passenger's seat SRS airbag that has not been
deployed.
When scrapping the driver's seat SRS airbag or front passenger's seat SRS airbag that has been
deployed by a customer, follow the "Airbag scrapping procedure."
'i
4-2-2 Deployment of instrument panel passenger airbag assembly
SST
1 Shape Part No. Part name
09082-87710-000 Wire, air bag deployment

(09082-87701-000)
/wire harness (1.25mm2).12Vbattery for car use,l tire with disc wheel.4 tires.Vinyl bag
(2) INSTRUCTIONS ON DEPLOYING THE INSTRUMENT PANEL PASSENGER AIRBAG Ay.

1.This operation shall be done outdoors where safety is assured.
2.Use SST to keep at least 5 m away from the instrument panel passenger airbag Ay.
3.Allow at least 30min after activation, because the deployed instrument panel passenger airbag Ay is
extremely hot.
4.Do not apply water, etc. to the deployed instrument panel passenger airbag assembly.
5.Wear protective glasses and gloves in handling the deployed instrument panel passenger airbag Ay.
6.Put the deployed instrument panel passenger airbag Ay in a plastic bag, seal and scrap it.
7.After completion of the operation, be sure to wash your hands with water.
(3) ON-VEHICLE DEPLOYMENT OF INSTRUMENT PANEL PASSENGER AIRBAG Ay
WARNING
CAUTION
the battery.

CAUTION
deployed.
3.Connect the following two SSTs.

SST: 09082-87710-000
09082-00760-000
deployment wire).
SST: 09082-87710-000
CAUTION
* Before starting work, ensure that the instrument panel
passenger airbag Ay is securely fixed on the
instrument panel and the instrument panel passenger
airbag Ay is securely fixed on the pillar to pillar
member.
5.Remove the instrument panel box Ay.
6.Connect the SST connector to the airbag connector

(yellow 2P) located on the right side of the instrument
panel box Ay opening.
7.Place the battery at a position where the SST has been
extended as long as possible.
CAUTION
Keep all the doors and windows closed during this
operation.
Make sure that there is no one inside and around the
vehicle.
Since a big sound will be emitted at the time of
deployment, keep at least 5 m away.
&Once again make sure of the safety inside and around
the vehicle, and then connect the SST to the battery [with
the alligator clip on battery side, and the terminal on
side] and deploy the unit.
CAUTION
Give warning loudly to those nearby before deploying
the airbag.
(4) DEPLOYMENT OF INSTRUMENT PANEL PASSENGER AIRBAG AY AS UNIT

WARNING
1.rAfter the IG SW has been set to [LOCK] position, remove the negative terminal of the battery.
CAUTION
the battery.

CAUTION
deployed.
3.Remove the instrument panel passenger airbag assembly.
4.Secure the unlt to a disc wheel, using a wire harness for car use (cross-sectional area of core wire:
I Wire harness
CAUTION
Triple the wire harness and securely fix it.
deployment wire).
SST 09082-87710-000
CAUTION
Deployment activity of the instrument panel passenger
airbag Ay shall be done outdoors.
6.Connect the SST connector to the connector for the airbag (yellow 2P).
?.Place two or more tires on each upper and lower side of the tire with instrument panel passenger
airbag Ay fixed. And place the tire equipped with the disk wheel on top of those tires.
8.Connect the tires with wire harnesses or ropes so that the tires will not be scattered when the airbag is
deployed.
9.Once again make sure of the safety around the vehicle, and then connect the SST to the battery [with
the alligator clip on battery side, and the terminal on side] and deploy the instrument panel
passenger airbag Ay.
Tire with disc wheel .

Wire harness or rope
Extend the SST as far as it goes
CAUTION
Give warning loudly to those nearby before deploying the airbag.
Never mount and reuse the tires and wheels used for the deployment on vehicles.
(5) SCRAPPING OFTHE INSTRUMENT PANEL

PASSENGER AIRBAG AY
1.Seal the deployed instrument panel passenger airbag
assembly in a plastic bag before it is scrapped.
CAUTION
Scrap only after deployment is complete.
Allow at least 30min after activation, because the
deployed instrument panel passenger airbag Ay is
extremely hot.
Do not apply water, etc. to the deployed instrument
panel passenger airbag assembly.
Wear protective glasses and gloves in handling the
deployed instrument panel passenger airbag Ay.
hands with water.
-
5 SEAT BELT WITH PRETENSIONER MECHANISM

Refer to Page 12-32
5-2 DISPOSAL
5-2-1 OUTLINE
1.The driver's seat and the front passenger seat are equipped with seatbelts with the pretensioner
mechanism (hereinafter referred to as 'pretensioner").
2.When scrapping a vehicle equipped with the pretensioner, it is necessary to remove the pretensioner
and scrap it as a single part. An undeployed pretensioner needs to be deployed before scrapping.
CAUTION
Do not scrap a vehicle equipped with an undeployed pretensioner until the pretensioner has been
deployed.
Do not scrap the undeployed pretensioner.
Do not disassemble the pretensioner.
5-2-2 CONFIRMATION OF ACTUATED PRETENSIONER

The pretensioner deploys simultaneously with the airbag. This means that when the airbag is deployed
in a crash or for some other reason, the pretensioner is also deployed.
CAUTION
The pretensioner can be actuated with or without seatbelt fastened.

SST
-.
Shape Part No. 1 Part name
09082-87710-000 Wire, air bag deployment

(09082-87701-000)
09082-00770-000 Sub-harness 5. air bag deployment wire
1 1 2 battery
~ for car use.2 tires with disc wheel,A steel sheet(a thickness t = 1 to 2mm).Vinyl bag
5-2-4 Instructions on the pretensioner deployment

1Scrap only after deployment is complete.
2.Deployment activity shall be done outdoors where safety is assured.
3.Use SST to keep at least 5 m away from the pretensioner.
4.Allow at least 30min after activation, because the deployed pretensioner is extremely hot.
5.Do not pour water or other liquid over the deployed pretensioner.
6.Wear protective glasses and gloves in handling the deployed pretensioner.
7.Put the deployed pretensioner in a plastic bag, seal and scrap it.
&Wash your hands after operation.
5-2-5 Onboard pretensioner deployment
1.Wait for at least 60 sec to start work after turning the IG SW LOCK and disconnecting the negative
battery terminal.
CAUTION
the battery.
2.Remove the quarter trim panel assembly.

3.With a flat screwdriver or the like, pull out the locking
- button of the pretensioner connector toward you
to unlock and disconnect the pretensioner connector.
WARNING
Check that there is no excessive play at the pretensioner installing section.

SST: 09082-87710-000
09082-00770-000
deployment wire).
SST: 09082-87710-000
6.With the SST connector locking button locked, connect the SST to the pretensioner.
i 1
L- ~ x t e n dthe SST(wire) as far as it goes

7.Fully extend the SSTfrom the vehicle, and place the battery a distance of 5 m or more.
WARNING
* At this time, close all the doors and windows.
Do not cut off the belt until deployment is complete.
8.Connect the SST (airbag deployment wire) to the battery

[with the alligator clip on battery side, and the terminal
on side] and deploy the pretensioner.
WARNING
Before deployment operation, it is absolutely necessary
to ensure nobody is in and around the vehicle.
to alert people around in a loud voice.
5-2-6 Pretensioner deployment as a single part
WARNING
Deployment operation shall be done outdoors on a flat ground where safety is assured. Wherever
possible, avoid residential districts.
People around must be well informed of the deployment activity, as the operation produces a large
sound.
?.Wait for at least 60 sec to start work after turning the IG SW LOCK and disconnecting the battery
terminal.
CAUTION
the battery.
2.Remove the rear door scuff plate.

3.Remove the quarter trim panel assembly.
4.With a flat screwdriver or the like, pull out the locking button of the pretensioner connector toward you
to unlock and disconnect the pretensioner connector.
5.Cut the belt of the front seat outer belt assembly at the
retractor section.
SST 09082-8771O-OOO
09082-00770-000
deployment wire).
SST: 09082-8771O-OOO
%With the SST connector locking button locked, connect the SST to the pretensioner.
9.Place the pretensioner on the ground with its connector side facing upward. Place a tyre with a disc
wheel on it.
10.Place a steel plate (with the thickness o f t = I-2mrn) on top of the tire equipped with the disk wheel.
Again place another tire equipped with the disk wheel on top of the plate.
11.Fully extend the SST from the pretensioner, and place the battery at a distance of 5 m or more.
12.When safety around the vehicle is assured, connect the

SST (airbag deployment wire) to the battery [with the
alligator clip on battery side, and the terminal on side]
and deploy the pretensioner.
WARNING
to ensure nobody is in and around the vehicle.
to aleri people around in a loud voice.
5-2-7 Scrapping of pretensioner

Put the activated pretensioner in a strong and clear plastic
bag, seal and scrap it.
WARNING
The temperature of the pretensioner that has been
actuated is a few hundred "Cat some sections.
Therefore, leave it at least 30 minutes after it is
actuated.
Do not splash water on the actuated pretensioner.
When handling the actuated pretensioner, wear dust
protective goggles and gloves.
hands with water.
a Never scrap the undeployed pretensioner.
C1185026T16
HI-31
6 SENSOR UNIT
Instrument
l~orquewrench

1.After the iG SW has been set to [LOCK] position, remove the negative terminal of the battery.
CAUTION
-
radio will be erased at the same time when the cable is disconnected from the neaative terminal of
the battery.

CAUTION
deployed.

(1) COMPONENTS
Unit:N.rn(kgf.cm]
r A 1 a Cover, airbag sensor
r A 2 b Computer Ay, airbag
'I
(1) AIRBAG COMPUTER COVER
Follow instructions below to remove the airbag sensor cover.
(1) Remove the two clips that secure the airbag sensor cover.
(2) Horizontally turn the airbag sensor cover approx. 90"
clockwise and pull it out to the left side of the
vehicle.
(2) AIRBAG COMPUTER AY

1.Disconnect the connector of the airbag computer assembly.
CAUTION
Connection or disconnection of the connector must be performed with the airbag computer
assemblv installed on the vehicle.
If the connector is connected while the airbag computer Ay is removed from the vehicle, the airbag
might deploy.
2.Rernove the airbag computer Ay.

6-1-5 INSPECTION
(1) CHECK STANDARD FOR AIRBAG COMPUTER Ay
Check the airbag computer assembly in the following cases. Replace it if it is faulty.
(1) Case where the vehicle is involved in a collision.
CAUTION
Perform the check whether the airbag has been deployed or not.
As for the checking procedure, follow the trouble shooting instructions.
(2) EXTERNAL APPEARANCE CHECK OF AIRBAG COMPUTER Ay

Replace the airbag computer Ay in the following cases.
SPECIFIED VALUE: . The airbag computer assembly dropped.
.The connector section has damage or cracks.
.The airbag computer assembly has deformation or cracks.
CAUTION
Never perform the circuit check of the airbag computer assembly, for there is the possibility that the
airbag can be deployed unexpectedly.
It is prohibited to use the airbag computer assembly that has been disassembled and assembled.
(1) AIRBAG COMPUTER AY
1.lnstall the airbag computer Ay.
CAUTION
* Never use the airbag computer assembly that are designed for other vehicles. Be sure to use the
new specified assembly when replacing.
2.Connect the connector of the airbag computer assembly.

CAUTION
Connect or disconnect the connector for the airbag computer Ay with the sensor unit mounted on
the vehicle.
If the connector is connected while the airbag computer Ay is removed from the vehicle, the airbag
might deploy.
Care must be exercised so that the harness or connector may not interfere with other parts or may
not be caught by other parts.
(2) AIRBAG COMPUTER COVER

Follow instructions below to install the airbag sensor cover.
(1) Install the airbag sensor cover, while horizontally
turning it approx. 90" counterclockwise from the left
side of the vehicle.
(2) Secure the airbag sensor cover on the airbag

computer Ay bracket.
(3) Install the two clips that secure the airbag sensor
cover.

1.Install the negative terminal of the battery.
2.After the IG SW has been set to [LOCK]- .position. At this I I
time, ensure that the airbag warning lamp goes on about
six seconds and then goes out.
t -
H1-34
7 CONTROL SYSTEM
SST
Shape Part No Pad name
09991-87404-000
W~re,e n g i n e control system i n s p e c t t o n
(09991-87401-000)
/ 09991-87403-000 Wre, d~agnos~s

check
Fmm passenger
seal pretensioner
7
mechanismsquib
37 SIO
From passenger
seal side airbag squib
- - --
7-3 ARRANGEMENT OF ECU TERMINAL
Airbag computer
I 1
1 ( -
C-LOCKLA ]vehicle right side connector half fining 1 26 / - I -
I /squib (-)
14 1 PR+ I~river'sseat pretensioner mechanism / 39 1 TC / ~ i a roft diagnosis
.
squib (+)
15 - - 40 LA Airbag warning lamp
16 - - 41 GSWl
17 AD+ Driver's seat airbag squib (+) 42 IG1 iG1 power supply
18 AD- Driver's seat airbag squib (-) 43 - -
19 - - 44 El Earth
.+,
/
seat a~rbagsclulb (-) 4 8 I -
-
I --
passenger's s&a;atroag saub ( s)I 49 1 --
Airbaa comwter
Check connector
ECUT,
-
Combination meter
/
IG+
(A) /
GND
L
Connector leading to steering roll connector
AD; ADi
Steering roll connector
I I
\
AD-
Vehicle harness Connector leading
connecting connector airbag
C13MKESlO
Front passenger seat airbag unit
Driver'sseat pretensioner mechanism
PR+
S18A5014SlO
ront passenger seat pretensioner mechanism

,,
'i!
a ~SRSatrbag at driver's seat side

b Steering roll connector
c SRS airbag at front passenger seat side
d Seat belt at driver's seat with preiensioner mechanism and force limiter mechanism
e Seat belt at front passenger seat with pretensioner mechanism and force limiter mechanism
f Airbag computer
7-6-1 HOW TO PROCEED DIAGNOSIS
The SRS airbag is provided with a diagnosis function which diagnoses malfunctioning sections. This
function gives important clues in carrying out the trouble shooting. This system is provided with a
backup function (EEPROM) which memorizes the diagnosis code. Therefore, even if the power supply is
cut off, the diagnosis contents are retained.
The diagnosis code is indicated by illumination of the airbag warning lamp inside the combination meter.
(,Bringing-in of malfunctioning vehicle), X
1 L
inquiry
- .inouire
lThorouohlv . about conditions
.........and environmental phenomenon
11
I when the mallunction took place
Lamp fails to go on. .. . Malfunction is takin

not illuminated
Lamp remains illumin
Confirm the phenomenon

and grasp the malfunctioningc
(Reconfirmation of diagnosis c o d 9
Output of diagnosis code
Malfunction not discovered Malfunction discovered

malfunctioning
Reproducing method
( Erasing of diagnosis code)

4
Confirmation and recording of diagnosis code
Output of diagnosis code 1
Output of normal code
Confirmation test
Has the vehicle ...... the malfunction
returned to the
ondition? claimed by the
Inu customer has
1 been remedied I
LllA5070ES36
CAUTION
In the trouble shooting of the SRS airbag, it might be difficult to confirm the items bearing % marks
given above due to the characteristics of the system (safety device).
If wrong operations are performed during checks or repairs, the system may have malfunction or
wrong operation. Therefore, care must be exercised to observe the notes given and perform the
operations according to the instructions of this manual.
7-6-2 DIAGNOSIS THROUGH INQUIRIES
In an effort to remove causes for malfunction from the vehicle concerned, it is impossible to determine
the cause without confirming the malfunction phenomenon. If the phenomenon is not confirmed, the
vehicle may not be able to return to the normal conditions even if you continue your work. The diagnosis
through inquiries is to collect information from the customer before confirming the malfunction
phenomena. The diagnosis through inquiries provides very important clues in reproducing malfunction
phenomena.
Since the information obtained by the diagnosis through inquiries is referred to during the trouble
shooting, it is imperative to make an inquiry of the customer, centering on the items related to the
malfunction, instead of simply asking general questions.
7-6-3 Confirmation of phenomenon
When the diagnosis code is indicated, confirm whether the malfunction took place sometimes in the
system or is still persisting. Also it is necessary to check any relation between the code and the
reproduced malfunction (malfunction mode). For this purpose, the diagnosis code should be indicated
twice, namelv before and after the confirmation of the phenomena.
7-7 DIAGNOSIS
(1) INDICATION BY AIRBAG WARNING LAMP
1.Stop the vehicle.
2.With the IG SW set to ON position, connect (short) ECUT
terminal and E terminal inside the DLC located under the
instrument panel.
CAUTION
To short the check terminals, be sure to use the
specified SST.
If the short is made for wrong check terminals, it may
cause malfunction. Be very careful not to select wrong
terminals
SST: 09991-87404-000
3.The airbag warning lamp inside the combination meter flashes, thus indicating the malfunction code.
NOTE
When the check terminals are shorted, warning lamps other than the airbag warning lamp will flash.
But this does not indicate system malfunction.
All the malfunction codes memorized are shown repeatedly in the sequence of malfunction number,
starting from the smallest number.
When there is one malfunction code, the malfunction code is indicated again after a pause of four
second. When there are more than one code, the codes are shown starting from the smaller
number with a pause of 2.5 seconds made between each code indication. When all codes have
been shown, after a pause of 4 seconds, the codes are again indicated one by one from the smaller
one.
Durimg abnormal period

Durimg normal period (In the case of code No.21)
IG gi
LOCK IG%-1
LOCK
--Ip0.25sec. I
t I
' -HJ
1 )
,-
;""~:I: 1.5sec.
Glowing ' Glowing I , I
iirbag warning lamp Airbag warning lamp

Extinguished , Extinguished-,
_/ 6sec. /_
(1) ERASURE BY DLC
When the section which is responsible for the malfunction code has been checked and repaired, erase
the memory, following the procedure given below.
1.Make the diagnosis code be outputted to the airbag warning lamp by using the diagnosis code
output rndicating method.
2.While looking at a clock (having a second hand), connect (short) the ECUT terminal and E terminal of
the DLC 1 f 0.4 second, and release these terminals 1 k 0 . 4 second. Repeat connectingJreleasing
four times. Then, when the ECUT terminal and E terminal are connected (shorted) fifth time, these
terminals should be kept connected.
3.lf the diagnosis code has been erased by now, the airbag warning lamp will flash quickly.
CAUTION
In order to short the check terminal, be sure to use the specified SST.
SST 09991-87404-000
09991-87403-000
NOTE
If the airbag warning lamp does not flash quickly, repeat this operation from the beginning.
?e Five
?S times
Twice Four I
t i istart of deletion
Shorted
ECU T
Ooen
Airbag warning lamp

-
Extinauished
" Erasing completion signal
4.After the memory has been erased, ensure that the airbag warning lamp is extinguished. Let the
diagnosis code be outputted again. Ensure that the normal code is outputted.
Contents of diaanosis
NO.
Diagnosis item Diagnosis contents
Lamp lSOX
,':
.. 1/
n
c
, DU,"G
,,
,
,,Earth short of airbag squib systern at
lcr ver s seat s 00
D"'uL
Po&ers~pptyshon 01 a roag squ b sys-

- Earth short of the harness between the airbag computer and the airbag
J S ~ J I Osystem
1.
Pofler suppiy snon of the narness between me a rbag compbter and the
tem at driver's seat side airbag squib system
l3 BO1OO
Short between wires of airbag squib . Short between wires of the harness between the airbag computer and
system at driver's seat side the airbag squib system
l4 BO1O1
Open wire of airbag squib system at . Open wire of the harness between the airbag computer and the airbag
driver's seat side squib system
31 81100 Abnormality of airbag computer Malfunction of airbag computer main body
51 B0107
Earth short of airbag squib system at .
Earth short of the harness between the airbag computer and the airbag
front passenger seat side squib system
,, , ,,, Power supply short of airbaa squib sys-
, .
Power supply short of the harness between the airbaa
- comwuter and the
:1 Du'"'
,,,
,system at lront passerge:seat wje
Open wlre of alrbag sousosystem at
,a~rbagsqutb system
I Snort wtween vnres ol the narness oerween tPc a rbag como~terand
h e a'bagswm waem
1. Open wlre of the narness between tne a rbas cornpuler an0 tne alrbag
61 80132 of pretensioner squib system at driver's of the harness between the airbag computer and the pretensioner squib
seat side system
Power supply short Power suppiy shorl of the harness between the airbag computer and the
62 60133 of pretensioner squib system at driver's pretensioner squib system
I
seat side
I ~ h o rbetween
t wires 1. Short between wires of the harness between the airbag computer and
63 1 80130 ]of pretensioner squib system at driver's /the pretensioner squib system
64 80131
Open wire of pretensioner squib system . Open wire of the harness between the airbag computer and the preten-
at driver's seat side Sioner squib system
Earth shori Earth short of the harness between the airbag computer and the preten-
71 80137 of pretensioner sauib system at front sioner squib system
Ipassenger seat side
1 IPower supply short 1. Power supply short of the harness between the airbag computer and the
72 80138 of pretensioner squib system at front pretensioner squib system
passenger seat side
Short between wires Short between wires of the harness between the airbag computer and
73 80135 of pretensioner squib system at front the pretensioner squib systern
passenger seat side
74 B0136
Open wire of pretensioner squib system . Open wire of the harness between the airbag computer and the preten-
at front passenger seat side sioner squib system
%:This shows the output code when the diagnostic tester is used.
NOTE
After the SRS front airbag and seat belt with pretensioner mechanism have operated and deployed,
the airbag warning lamp flashes at an interval of 0.5 second.
The code No.31 may be emitted, not only when the airbag computer inside is malfunctioning, but
also when the squib system circuit has an abnormality.
(1) CONFIRMATION OF PHENOMENON
In carrying out the trouble shooting, the operator cannot find out the cause unless he confirms the
malfunctioning phenomenon. For this end, it is imperative to reproduce the malfunction phenomenon by
creating conditions and environments similar to the situation where the rnalfunction took place, based on
the information obtained by the diagnosis through inquiries.
As for the phenomenon that is hard to be reproduced, it is necessary to create the conditions similar to
the running conditions under which the rnalfunction took place (road condition, meteorological condition
and running condition), based on the information obtained by the diagnosis through inquiries.
For this purpose it is most important to try to reproduce the phenomenon patiently by applying external
factors, such as vibration (moving wire harnesses or relays by hand), heat (applying hot wind) and water
(giving humidity).
(2) RECHECK OF DIAGNOSIS CODE
After confirming the malfunction phenomenon, check the illuminating condition of the warning lamp
(malfunction mode). Note whether any change has occurred before and after the confirmation. In this
way, judge whether the system is currently normal or not.
7-8 BASIC CHECK
The basic check enables you to narrow down the malfunctioning system.
7-8-1 MEASUREMENT OF BATTERY VOLTAGE
With the engine stopped, measure the battery voltage.
SPECIFIED VALUE: 10 - 14 V
7-8-2 CHECK OF SRS AIRBAG SYSTEM POWER SUPPLY AND EARTH CIRCUIT
(1) CHECK OF POWER SUPPLY CIRCUIT
1.Perform the measurement, using the connector on the vehicle side, connected t o the airbag
computer.
CAUTION
The airbag computer shall be dismounted from the vehicle.
2.Check each voltage after IG SW set to 'ON.

(1) Harness side connector 42(IG1) - 44(E1)
SPECIFIED VALUE: 10 - 14V(Battery voltage)
(2) CHECK OF EARTH CIRCUIT

Disconnect the connector on the vehicle side from the airbag computer, and check each connector for
continuity.
(1) Airbag computer - Body earth
(2) Vehicle side connector 44(E1) - Body earth

7-9 TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODE
7-9-1 WARNING LAMP CIRCUIT SYSTEM
(1) CHECKING POINTS
1.Is the fuse normal?
2.1s the combination meter normal?
3.1s there any abnormality in the harness of the warning lamp system?
(2) CHECKING METHOD
W1.Confirm the lighting state of the warning lamp
1.After the IG SW has been set to [ON] position, check the lighting state of the airbag warning lamp.
Proceed to W2when the lamo remains illuminated even after an elapse of 6 seconds.
If distinauished. oroceed to B4.

1.After the IG SW has been set to [LOCK] position, remove the negative terminal of the battery. Leave
WARNING
deployed.
CAUTION
When the negative terminal of the battery is disconnected, the memory of some systems will be
erased. Record the memory contents of each system, as required, and set the memory again after
completion of the operation.
2.Disconnect the connector from the airbag computer. Short the airbag computer harness side
connector 40(LA) with earth, using the SST.
SST: 09991-87403-000
3.lnstall the negative terminal of the battery. With the IG SW set to [ON] position, check the lighting
state of the airbag warning lamp.
SPECIFIED VALUE: Distinguishes.
If distinauished. reolace the airbaa comouter.

If it remains illuminated. oroceed to D3.
B3.Check continuity between the combination meter and the airbag computer
1.After the IG SW has been set to [LOCK] position, disconnect the combination meter connector.
2.Check the harness between the combination meter and the airbag computer.
(1) Between the connector 18(LA) at the combination meter harness side and the airbag computer
40(W
If it is OK. reoair or reolace the combination meter.

If it is NG, reolace the harness and connector.
( I

WARNING
deployed.
CAUTION
2.Disconnect the connector from the airbag computer.

3.lnstall the negative terminal of the battery. With the IG SW set to [ON] position, check the lighting
state of the warning lamp.
f '
If liahted, replace the airbaa cornouter.

If distinauished. oroceed to W5.
W5.Check the fuse

?.After the IG SW has been set to [LOCK] position, remove the negative terminal of the battery. Check
the fuse.
SPECIFIED VALUE: Not fused.
If it is OK. ao to steo W6.

If it is NG. ao to steo W8.
W6.Check continuity between the combination meter and the fuse and continuity between the
combination meter and the earth
1.Check to see if open wire exists between the combination meter and the fuse as well as between the
combination meter and the earth. I
(1) Between combination meter harness side connector 12(IGf) and gauge fuse (downstream side)
(2) Between combination meter harness side connector 22(GND) and body earth

If it is NG. reolace the harness and connector.
D7.Check short between the combination meter and the airbag computer
1.Check to see if there is a short at the harness between the combination meter and the airbag
computer.
(1) Between the connector 40(LA) at the airbag computer harness side and the body earth
SPECIFIED VALUE: 1MB or more (No continuity)
If it is OK, re~airor re~lacethe combination meter.

*&Check continuity between the combination meter and the fuse
1.Check the harness between the combination meter and the fuse.
(1) Between combination meter harness side connector 12(IG+) and IG SW (+B side)
If it is OK. rewlace the fuse. Then. wait for a little while.

If it is NG, rewlace the fuse. Also. rewlace the harness and connector.
7-9-2 DIAGNOSIS CODE No.II(DRIVER'S SEAT AIRBAG SQUIB CIRCUIT SYSTEM)
(1) DIAGNOSTIC CODE OUTPUT CONDITIONS
When the harness between the driver's seat airbag and the airbag computer is shorted with the earth:
(2) CHECKING POINTS
Is there abnormality in the harness and connector between the driver's seat airbag and the airbag
computer?
CAUTION
The steering roll connector is provided with a connector with a terminal short mechanism. Hence,
there is a possibility for wrong diagnosis of short in harness. Therefore, for this check it is advisable
to use the SST (Part No :09082-87710-000) for deploying airbag. First, ensure that there is no
damage, such as open wire and short in this SST. Then, install the SST on the steering roll
connector and carry out check for the harness together with the SST.
(3) CHECKING METHOD

W1.Check short between the steering wheel pad Ay and the airbag computer
the englne under this state for 60 seconds or more.
WARNING
deployed.
CAUTION
2.Remove the airbag computer and steering wheel pad Ay. Check to see if short exists in harness
between the pad Ay and the airbag computer.
(1) Connector 1 (AD+) leading to the steering roll connector side airbag and the body earth
(2) Connector 2 (AD-) leading to the steering roll connector side airbag and the body earth
SPECIFIED VALUE: 1MQ or more (No continuity)
If it is OK. ao to stet, D2.

If it is NG. ao
- to stet, D4.
S2.Confirm the diagnosis code

1.After the IG SW has been set to [LOCK] position, install the airbag computer to the vehicle. Connect
the connector.
2.lnstall the negative terminal of thebattery. With the IG SW set to [ON] position, erase the diagnosis
codes. Then, check the diagnosis code.
SPECIFIED VALUE: Diagnosis code No.11 is not outputted. (Other codes may be outputted.)
If not outputted, oroceed to D3.

If outoutted, reolace the airbaa comouter.
t
W3.Confirm the diagnosis code
WARNING
deployed.
CAUTION
The memories of some systems are erased when the negative terminal of the battery is
disconnected. Therefore, it is necessaty to record the contents of the memories, as required. After
completion of the operation, be sure to reset the memories.
2.lnstall the steering wheel pad assembly.

3.lnstall the negative terminal of the battery. With the IG SW set to [ON] position, erase the diagnosis
If not outoutted. a normal state has been restored. Erase the diaanosis code. Then. wait for a little
while.
If outoutted, reolace the steerina wheel oad Av.
W4.Check short between the steering roll connector and the airbag computer
1.Disconnect the vehicle harness side connector of the steering roll connector.
2.Check to see if there is a short at the harness between the steering roll connector and the airbag
computer.
(1) Vehicle harness roll connector side connector 1(AD-) - body earth
If it is OK. ao to steD D5.

If it is NG. reolace the vehicle harness and connector.
D5.Check short in the steering roll connector

1.Check to see if there rs a short at the steering roll connector.
(1) Connector 1 (AD+) leading to the steering roll connector side airbag and the body earth
If it is OK. a normal state has been restored. Erase the diaanosis code. Then, wait for a little while.
If it is NG, reolace the steerina roll connector.
HI-51
7-9-3 DIAGNOSIS CODE No.l2(DRIVER'S SEAT AIRBAG SQUIB CIRCUIT SYSTEM)
When the harness between the driver's seat airbag and the airbag computer is shorted with the power
supply;
(2) CHECKING POINTS
computer?
CAUTION
(3) CHECKING METHOD

W1.Check short between the steering wheel pad Ay and the airbag computer
the englne under this state for 60 seconds or more.
WARNING
deployed.
CAUTION
* When the negative terminal of the battery is disconnected, the memory of some systems will be
2.Remove the airbag computer and steering wheel pad Ay.

3.lnstall the negative terminal of the battery. With the IG SW set to [ON] position, check to see if short
exists in the harness between the pad Ay and the airbag computer.
(1) Connector 1 ( A D + leading to the steering roil connector side airbag and the body earth
(2) Connector 2 (AD-) leading to the steering roll connector side airbag and the body earth !
SPECIFIED VALUE: 0 V (No continuity with +B)
If it is OK. ao to stew W2.

If it is NG. ao to stew W 4 .

1.After the iG SW has been set to [LOCK] position, install the airbag computer to the vehicle. Connect
the connector.
If not outoutted, wroceed to B3.

If outwutted, replace the airbaa comDuter.
HI-52
i- W3.Confirm the diagnosis code
the engrne under this state for 60 seconds or more.
WARNING
deployed.
CAUTION
2.lnstall the steering wheel pad assembly.

If not outoutted. a normal state has been restored. Erase the diaanosis code. Then. wait for a little
while:
If out~utted.reolace the steerina wheel oad Av.
W4.Check short between the steering roll connector and the airbag computer
1.After the IG SW has been set to [LOCK] position, disconnect the vehicle harness side connector of
the steering roll connector.
2.After the IG SW has been set to [ON] position, check to see if short exists in the harness between the
steering roll connector and the airbag computer.
(1) Vehicle harness roll connector side connector l(AD-) - body earth

If it is NG. reolace the vehicle harness and connector.
I
W5.Check short in the steering roll connector

1.Set the IG SW to [LOCK] position.
2.With the IG SW set to [ON] position, check to see if short exists in the steering roll connector
(1) Between steering roll connector pad side connector l(AD+) and body earth
If it is OK. a normal state has been restored. Erase the diaanosis code. Then. wait for a little while.
If it is NG. reolace the steerina roll connector.
.T\
i v
7-9-4 DIAGNOSIS CODE No.l3(DRIVER'S SEAT AIRBAG SQUIB CIRCUIT SYSTEM)
When a short between wires takes place in the harness between the driver's seat airbag and the airbag
computer:
(2) CHECKING POINTS
computer"?
CAUTION
there is a possibility for wrong diagnosis of short in hamess. Therefore, for this check it is advisable
(3) CHECKING METHOD

W1 .Confirm the diagnosis code
B
-
WARNING
deployed.
CAUTION
2.Remove the steering wheel pad Ay. Short both terminals of the steering roll connector pad side
connector.
3.lnstall the negative terminal of the battery. Erase the diagnosis codes. Then, check the diagnosis
code.
SPECIFIED VALUE: Diagnosis code No.13 is outputted. >
If outoutted. oroceed to W 2 .
If not outoutted. reolace the airbaa cornouter.

1.After the IG SW has been set to [LOCK] position, release short between the terminals of the
connector leading to the steering roll connector side airbag.
2.After the IG SW has been set to [ON] position, erase the diagnosis codes. Then, check the diagnosis
code.
SPECIFIED VALUE: Diagnosis code No.13 is outputted. (Other codes may be outputted.)
If not outoutted. oroceed to D3.

If outoutted, ~r0Ceedto W4.
H1-54
'i
m3.Confirm the diagnosis code
1.After the IG SW has been set to [LOCK] position, remove the negative terminal of the battery. Install
the steering wheel pas Ay.
2.After the IG SW has been set to [ON] position, check the diagnosis code.
If not outputted. a normal state has been restored. Erase the diaanosis code. Then. wait for a little
while.
If out~utted,rewlace the steerina wheel ad Av.
W4.Confinn the diagnosis code

1.After the IG SW has been set to [LOCK] position, disconnect the connector of the steering roll
connector at the vehicle harness side.
2.ARer the IG SW has been set to [ON] position, erase the diagnosis codes. Then, check the diagnosis
code.
If not outputted. proceed to W5.

If outputted. proceed to W6.
W5.Check short in the steering roll connector

1.After the IG SW has been set to [LOCK] position, remove the steering roll connector from the vehicle.
2.Connect the SST to the steering roll connector vehicle side connector.
SST 09082-87710-000
3.Ensure that the SST terminals for connecting battery are not interfering each other. Also, check for
short in the steering roll connector.
(1) Connector 1 (AD+) leading to the steering roll connector side airbag
- connector 2(AD-) leading to the steering roll connector side airbag
If it is OK. a normal state has been restored. Erase the diaanosis code. Then. wait for a little while.
If it is NG. replace the steerina roll connector.
m6.Check short between the steering roll connector and the airbag computer
1.After the IG SW has been set to [LOCK] position, remove the connector of the airbag computer.
Remove the short terminal of the airbag computer vehicle side connector.
2.Check to see if there is a short at the harness between the steerrng roll connector and the airbag
computer.
(1) Connectorl(AD-) leading to the vehicle harness roll connector
-connector 2(AD+) leading to the vehicle harness roll connector
SPECIFIED VALUE: 1M B or more (No continuity)
If it is OK, a normal state has been restored. Erase the diaanosis code. Then, wait for a little while.
If it is NG. replace the vehicle side harness.
HI-55
7-9-5 DIAGNOSIS CODE No.l4(DRIVER'S SEAT ADRBAG SQUIB CIRCUIT SYSTEM)
When open wire takes place in the harness between the driver's seat a~rbagand the airbag computer.:
(2) CHECKING POINTS
computer?
CAUTION
(3) CHECKING METHOD

W1 .Check continuity between the steering wheel pad Ay and the airbag computer
WARNING
deployed.
CAUTION
2.Remove the airbag computer and steering wheel pad Ay.

3.Check to see if open wire exists in the harness between the pad Ay and the airbag computer.
(1) Connector 1 (AD+) leading to the steering roll connector side airbag
- airbag computer vehicle side connector 17 (AD+)
(2) Connector 2 (AD-) leading to the steering roll connector side airbag
- airbag computer vehicle side connector 18(AD-)
If it is OK, ao to steo W2.

If it is NG, ao to steo W4.

1.Short between the connectors I(AD+) and 2 (AD-) leading to the steering roll connector pad Ay
side airbag.
2.lnstall the airbag computer on the vehicle. Connect the connector.
If not outoutted. Droceed to W3.

If 0 u t ~ ~ t t e reolace
d. the airbaa comouter.
D3.Confirm the diagnosis code
CAUTION
WARNING
deployed.
2.Release short between the terminals of the steering roll connector. install the steering wheel pad Ay.
If not outoutted, a normal state has been restored. Erase the diaanosis code. Then. wait for a little
while.
If 0~tDLItted.realace the steerina wheel oad Av.
D4.Check continuity between the steering roll connector and the airbag computer
1.Disconnect the vehicle harness side connector of the steering roll connector.
2.Check to see if open wire exists in the harness between the steering roll connector and the airbag
computer.
(1) Connectorl(AD-) leading to the vehicle harness roll connector
-connector 2(ADf) leading to the vehicle harness roll connector
If it is OK. ao to steo D5.

If it is NG. r e ~ l a c e
the vehicle harness and connector.
W5.Check continuity in the steering roll connector

?.Check to see if there is an open wire in the steering roll connector.
(1) Connector l(AD+) leading to the steering roll connector side airbag
- connector 2(AD-) leading to the steering roll connector side airbag
If it is OK, a normal state has been restored. Erase the diaanosis code. Then. wait for a little while.
if it is NG. reolace the steerina roll connector.
~ - - ~ - ~ ~ ----
7-9-6 DIAGNOSIS CODE No.Sl(FRONT PASSENGER SEAT AIRBAG SQUIB CIRCUIT SYSTEM)
When the harness between the front passenger's seat airbag and the airbag computer is shorted with
the earth.
(2) CHECKING POINTS
Is there abnormality in the harness and connector between the front passenger's seat airbag and the
airbag computer?
(3) CHECKING METHOD
W1.Check short between the front passenger seat airbag unit and the airbag computer
WARNING
deployed.
CAUTION
2.Disconnect the connectors from the airbag computer and the front passenger seat airbag unit.
3.Check the harness for short between the front passenger seat airbag unit and the airbag computer.
(1) Between front passenger's seat airbag unit vehicle side connector I(AP+) and body earth
(2) Between front passenger's seat airbag unit vehicle side connector 2(AP-) and body earth
SPECIFIED VALUE: 1MB (No continuity)

If it is NG, reolace the vehicle side harness.
m2.Confirm the diagnosis code

1.Connect the connector to the airbag computer.
2.The IG SW set to [ON] position, erase the diagnosis codes. Then, check the diagnosis code.
If not outoutted. proceed to W3.

If outoutted, reolace the airbaa cornouter.
WARNING
deployed.
CAUTION
2.Connect the connector to the front passenger seat airbag unit.

3.lnstali the negative terminal of the battery. With the IG SW set to [ON] position, erase the diagnosis
SPECIFIED VALUE: Diagnosis code No.51 Is not outputted. (Other codes may be outputted.)
If not outoutted, a normal state has been restored. Erase the diaanosis code and see how the
svstem works for a while.
If out~utted,reolace the front oassenaer seat SRS airbaa unit.
HI-59
7-9-7 DIAGNOSIS CODE No.52(FRONT PASSENGER SEAT AIRBAG SQUIB CIRCUIT SYSTEM)
When the harness between the front passenger's seat airbag and the airbag computer is shorted with
the power supply.
(2) CHECKING POINTS
airbag computer?
(3) CHECKING METHOD
W 1 .Check short between the front passenger seat airbag unit and the airbag computer
WARNING
deployed.
CAUTION
2.Disconnect the connectors from the airbag computer and the front passenger seat airbag unit. Install
the negative terminal of the battery.
3.With the IG SW set to [ON] position, check to see if short exists between the front passenger seat
airbag unit and the airbag computer.
(1) Between front passenger's seat airbag unit vehicle side connector l(AP+) and body earth
(2) Between front passenger's seat airbag unit vehicle side connector 2(AP-) and body earth

If it is NG. rewlace the vehicle side harness.

1.After the IG SW has been set to [LOCK] position, connect the connector to the airbag computer.
code.
If not outoutted, oroceed to W 3 .

If out~utted.reolace the airbaa comouter.
HI-60
WARNING
deployed.
CAUTION
2.Connect the connector to the front passenger seat airbag unit.

If not out~utted.a normal state has been restored. Erase the diaanosis code and see how the
If outoutted. re~lace
the front Dassenaer seat SRS airbaa unit.
~.
i
7-9-8 DIAGNOSIS CODE No.S3(FRONT PASSENGER SEAT AIRBAG SQUIB CIRCUIT SYSTEM)
When shorts take place in the wires of the harness between the front passenger's seat airbag and the
airbag computer.
(2) CHECKING POINTS
airbag computer?
(3) CHECKING METHOD
W 1.Confirm the diagnosis code
WARNING
deployed.
CAUTION
When the negative terminal of the battery is disconnected, the memory of some systems will be i
2.Disconnect the connector from the front passenger seat airbag unit. Short between both terminals of
the front passenger seat airbag unit vehicle side connector.
3.lnstall the negative terminal of the battery. Erase the diagnosis codes. Then, check the diagnosis
code.
SPECIFIED VALUE: Diagnosis code No. 53 is outputted.
If outoutted. oroceed to W2.

If not outoutted. reolace the airbaa computer.

1.After the IG SW has been set to [LOCK] position, release short between the terminals of the front
passenger seat airbag unit side connector.
code.
If not outoutted. oroceed to W3.

If 0ut~utted.~roceedto W4.

1.After the IG SW has been set to [LOCK] position, install the negative terminal of the battery. Connect
the connector to the front passenger seat airbag unit.
If not outputted, a normal state has been restored. Erase the diaanosis code. Then. wait for a little
while.
If outoutted. re~lace
the front oassenaer seat airbaa unit.
W4.Check short between the front passenger seat airbag unit and the airbag computer
1.After the IG SW has been set to [LOCK] position, disconnect the connector from the airbag computer.
Remove the short terminal of the airbag computer vehicle side connector.
2.Check the harness for short between the front passenger seat airbag unit and the airbag computer.
(1) Between front passenger's seat airbag unit veh~cleside connector l(AP+) and front passenger's
seat airbag unit vehicle side connector 2(AP-)
SPECIFIED VALUE: 1MB or more (No continuity)
If it is OK, a normal state has been restored. Erase the diaanosis code. Then, wait for a little while.
If it is NG. reolace the vehicle harness.
7-9-9 DIAGNOSIS CODE No.54(FRONT PASSENGER SEAT AIRBAG SQUIB CIRCUIT SYSTEM)
When open wires take place in the harness between the front passenger's seat airbag and the airbag
computer.
(2) CHECKING POINTS
airbag computer?
(3) CHECKING METHOD
W 1 .Check continuity between the front passenger seat airbag unit and the airbag computer
WARNING
deployed.
CAUTION
2.Disconnect the connectors from the airbag computer and the front passenger seat airbag unit. Check
to see if open wire exists in the harness between the front passenger seat airbag unit and the airbag
computer.
(1) Between front passenger's seat airbag unit vehicle side connector I(APf) and airbag computer
vehicle side connector 24(AP+)
(2) Between front passenger's seat airbag unit vehicle side connector 2(AP-) and airbag computer
vehicle side connector 23(AP-)
If it is OK, ao to steo W2.

If it is NG, reulace the vehicle harness and connector.
8
1.Short between the front passenger seat airbag vehicle side connectors l(AP+) and 2(AP-).
Connect the connector to the airbag computer.
If not outuutted. uroceed to W 3 .

If outuutted, re~lace the airbaa comuuter.
WARNING
deployed.
CAUTION
2.Release short between the terminals at the front passenger seat airbag unit vehicle side. Connect the
connector to the front passenger seat airbag unit.
If not outoutted, a normal state has been restored. Erase the diaanosis code and see how the
If outoutted. reolace the front oassenaer seat airbaa unit.
HI-65
i .'
7-9-10 DIAGNOSIS CODE No.Gl(FRONT DRIVERS PRETENSIONER SQUIB CIRCUIT SYSTEM)
When the harness between the driver's seat seat belt and the airbag computer is shorted with the earth;
(2) CHECKING POINTS
Is there abnormality in the harness and connector between the driver's seat pretensioner and the airbag
computer?
(3) CHECKING METHOD
W 1 Check short between the driver's seat seat belt and the airbag computer
WARNING
deployed.
CAUTION
I
2.Disconnect the connectors from the airbag computer and the seat belt in the driver's seat.
3.Check to see if short exists in the harness between the driver's seat seat belt and the airbag
computer.
(1) Between driver's seat belt vehicle side connector I(PR+) and body earth
(2) Between driver's seat belt vehicle side connector 2(PR-) and body earth
SPECIFIED VALUE: 1 M Q or more (No continuity)
If it is OK. oo to steD W2.

If it is NG, rewlace the vehicle side hamess.

codes. Then, check the diagnos~scode.
If not outoutted, wroceed to W 3 .

If out~uned.rewlace the airbaa comouter.
>- ,
HI-66
l[
S3.Confirm the diagnosis code
WARNING
deployed.
CAUTION
2.Connect the connector to the driver's seat seat belt.

.i SPECIFIED VALUE: Diagnosis code No.61 is not outputted. (Other codes may be outputted.)
If not out~utted.a normal state has been restored. Erase the diaanosis code and see how the
If outwtted. redace the driver's seat seat belt.
7-9-11 DIAGNOSIS CODE No.62(FRONT DRIVER'S PRETENSIONER SQUIB CIRCUIT SYSTEM)
When the harness between the driver's seat seat belt and the airbag computer is shorted with the power
supply;
(2) CHECKING POINTS
computer?
(3) CHECKING METHOD
Dl.Check short between the driver's seat seat belt and the airbag computer
WARNING
deployed.
CAUTION
exists in the harness between the driver's seat seat belt and the airbag computer.
(1) Between the connector I(PR+) at the seat belt in the driver's seat and the body earth,
(2) Between the connector 2(PR-) at the seat belt in the driver's seat and the body earth,
If it is OK. ao
. to steo D2.
If it is NO. re~lacethe vehicle side hamess.

1.After the IG SW has been set to [LOCK] position, connect the connector to the airbag computer.
code.
p
If outoutted. reolace the airbao comwter.
~-

1.After the IG SW has been set to [LOCK]position, remove the negative terminal of the battery. Leave
WARNING
deployed.
CAUTION
erased. Record the memoty contents of each system, as required, and set the memory again after

If not outwutted, a normal state has been restored. Erase the diaanosis code and see how the
If outwutted, rewlace the driver's seat seat belt.
When a short between wires takes place in the harness between the driver's seat seat belt and the
airbag computer.
(2) CHECKING POINTS
computer?
(3) CHECKING METHOD
WARNING
deployed.
CAUTION
2.Disconnect the connector from the driver's seat seat belt.

3.Short between both terminals of the driver's seat seat belt vehicle side connector.
4.lnstall the negative terminal of the battery. With the IG SW set to [ON]position, erase the diagnosis
SPECIFIED VALUE: Diagnosis code No.63 is outputted.
If outwutted. wroceed to W2.

If not outwutted, reolace the airbaa comouter.

1.After the IG SW has been set to [LOCK] position, release short between the terminals of the driver's
seat seat belt vehicle side connector.
2.After the IG SW has been set to [ON]position, erase the diagnosis codes. Then, check the diagnosis
code.
If not outwutted. wroceed to W3.

If outwutted. wroceed to W4.

the connector to the driver's seat seat belt.
If not outwutted, a normal state has been restored. Erase the diaanosis code and see how the
If outwutted, rewlace the driver's seat seat belt.
W4.Check short between the driver's seat seat belt and the airbag computer
2.Check to see if short exists in the harness between the driver's seat seat belt and the airbag
computer.
(1) Between driver's seat belt vehicle side connector I(PR+) and driver's seat belt vehicle side
connector 2(PR-)
SPECIFIED VALUE: 1 M Q or more (No continuity)
If it is NG. rewlace the vehicle side harness.
HI-71
When open wire takes place in the harness between the driver's seat seat belt and the airbag computer.
(2) CHECKING POINTS
computer?
(3) CHECKING METHOD
W1.Check continuity between the driver's seat seat belt and the airbag computer
WARNING
deployed.
CAUTION
erased. Record the memory contents of each system, as required, and set the memory again after !
3.Check to see if open wire exists in the harness between the driver's seat seat belt and the airbag
computer.
(1) Between the driver's seat seat belt vehicle side connector I (PR+) and the airbag computer
vehicle side connector 14 (PR+)
(2) Between driver's seat belt vehicle side connector 2(PR-) and the airbag computer vehicle side
connector 13(PR-)
If it is OK. ao to stew W2.

If it is NG, rewlace the vehicle harness and connector.

1Short between the driver's seat belt vehicle side connector l(PR+) and the driver's seat belt vehicle
side connector 2(PR-).
If not out~utted.wroceed to B3.

If outwutted. rewlace the airbaa comwuter.
- HI-72
1
B3.Confirm the diagnosis code
1.After the IG SW has been set to [LOCK] posit~on,remove the negative terminal of the battery. Leave
WARNING
deployed.
CAUTION
2.Release between both terminals of the driver's seat seat belt vehicle side connector.
If not outputted. a normal state has been restored. Erase the diaanosis code and see how the
If out~utted.reolace the driver's seat seat belt.
I
7-9-14 DIAGNOSIS CODE No.71(FRONT PASSENGER'S PRETENSIONER SQUIB CIRCUIT SYSTEM)
When the harness between the front passenger's seat seat belt and the airbag computer 1s shorted wrth
the earth.
(2) CHECKING POINTS
Is there abnormality in the harness and connector between the front passenger's seat pretensioner and
the airbag computer?
(3) CHECKING METHOD
D l.Check short between the front passenger seat belt and the airbag computer
1.After the IG SW has been set to [LOCK] position, remove the negative terminal of the battery. Leave I
I
the engine under this state for 60 seconds or more. i
WARNING I
If you begin the operation before 60 seconds pass, there is a danger that the airbag is mistakenly iI
deployed.
i
I
CAUTION
When the negative terminal of the battery is disconnected, the memory of some systems will be I Ii
completion of the operation. I
!
2.Disconnect the connectors from the airbag computer and the seat belt in the front passenger seat.
3.Check to see if short exists in the harness between the front passenger seat seat belt and the airbag
computer.
(1) Between the front passenger seat seat belt vehicle side connector I(PL+) and the body earth
(2) Between the front passenger seat seat belt vehicle side connector 2(PL-) and the body earth
j
If it is OK, ao to steo D2.
1
If it is NG. reolace the vehicle side harness. I
i
j
.
i
i
If not out~utted.oroceed to D3.

It outoutted. reolace the airbaa comouter.
WARNING
deployed.
CAUTION
2.Connect the connector to the front passenger seat belt.

If not outoutted. a normal state has been restored. Erase the diaanosis code and see how the
If outputted. replace the front oassenaer seat seat belt.
When the harness between the front passenger's seat seat belt and the airbag computer is shorted with
the power supply.
(2) CHECKING POINTS
(3) CHECKING METHOD
B1.Check short between the front passenger seat belt and the airbag computer
WARNING
deployed.
CAUTION
When the negative terminal of the battery is disconnected, the memory of some systems will be I
exists in the harness between the passenger's seat seat belt and the airbag computer.
(1) Between the front passenger seat seat belt vehicle side connector l(PL3.) and the body earth
(2) Between the front passenger seat seat belt vehicle side connector 2(PL-) and the body earth
If it is OK. ao to steu -2.

If it is NG. replace the vehicle side harness.

1.After the IG SW has been set to [LOCK] position, remove the negative terminal of the battery. Leave ,
WARNING
deployed.
CAUTION

If not outoutted. uroceed to W 3 .

If outuutted, reolace the airbaa comuuter.
- HI-76
1.Afier the IG SW has been set to [LOCK] position, remove the negative terminal of the battery. Leave
WARNING
deployed.
CAUTION

If not outwutted. a normal state has been restored. Erase the diaanosis code and see how the
If 0ut~Lttted.rewlace the front wassenaer seat seat belt.
When shorts take place in the wires of the harness between the front passenger's seat seat belt and the
airbag computer.
(2) CHECKING POINTS
(3) CHECKING METHOD
WARNING
deployed.
CAUTION
2.Disconnect the connector from the front passenger seat seat belt.
3.Short between terminals of the front passenger seat seat belt vehicle side connector.
SPECIFIED VALUE: Diagnosis code No.73 is outputted.
If 0 u t ~ ~ t t eoroceed
d. to -2.
If not outoutted. replace the airbaa comouter.

1.After the IG SW has been set to [LOCK] position, release short between the terminals of the front
passenger seat seat belt vehicle connector.
code.
If not outoutted. oroceed to W3.

If outoutted. oroceed to W4.

the connector to the front passenger seat seat belt.
If outoutted. redace the front oassenaer seat seat belt.
-
HI-78
'I
m4.Check short between the front seat seat belt and the airbag computer
2.Check to see if short exists in the harness between the front passenger seat seat belt and the airbag
computer.
(1) Between the front passenger seat seat belt vehicle side connector 1(PL+) and the front
passenger seat seat belt vehicle side connector 2(PL-)
If it is NG, reolace the vehicle side harness.
i
When open wires take place in the harness between the front passenger's seat seat belt and the airbag
computer.
(2) CHECKING POINTS
(3) CHECKING METHOD
W1.Check continuity between the front passenger seat belt and the airbag computer
WARNING
deployed.
CAUTION
3.Check to see if open circuit exists in the harness between the front passenger seat seat belt and the
airbag computer.
(1) Between the front passenger seat seat belt vehicle side connector 1(PL+) and the airbag
computer vehicle side connector 27(PL+)
(2) Between the front passenger seat seat belt vehicle side connector 2(PL-) and the airbag
computer vehicle side connector 28 (PL-)
If it is OK. ao to step W2.

If it is NG. reulace the vehicle harness and connector.

1.Short between the front passenger seat seat belt vehicle side connectors I(PLf) and 2(PL-).
If not outuutted. proceed to W3.

If outuutted, reulace the airbaa comuuter.
WARNING
deployed.
CAUTION
2.Release short between terminals at the front passenger seat seat belt vehicle side.
If outoutted, reolace the front oassenaer seat seat belt.
7-1OTROUBLE SHOOTING ACCORDING TO MALFUNCTION PHENOMENA
7-10-1 NO DIAGNOSIS CODE IS INDICATED
(1) CHECKING POINTS
l.Open wires in the harness and connector between the airbag computer and the DLC
2.Abnormality of airbag computer
(2) CHECKING METHOD
W1.Check continuity between the airbag computer and the DLC
1.Afier the IG SW has been set to [LOCK] position, remove the negative terminal of the battery. Leave
WARNING
deployed.
CAUTION

3.Check that open wire exists in harness between the airbag computer and the DLC.
( I ) airbag computer harness side connector 39(TC) - DLC 4(ECUT)
(2) airbag computer harness side connector 37(SIO) - DLC lO(SI0)

W2.Check continuity between the DLC and the earth

1.Check to see if open wire exists in the harness between the DLC and the earth
(1) Between the DLC 13 (earth) and the body earth
If it is OK. connect the connector to the airbaa com~uter.Then, wait for a little while.
If it is NG, re~lacethe harness and connector.
7-10-2THE DIAGNOSIS CODE IS ALWAYS INDICATED
(1) CHECKING POINTS
1.Short in the harness between the airbag computer and the diagnosis check connector
*1 .Check short between the airbag computer and the DLC
WARNING
deployed.
CAUTION

3.Check to see if short exists in the harness between the airbag computer and the DLC.
(1) airbag computer harness side connector 39(TC) - DLC 4(ECUT)
If it is OK. reolace the airbaa comuuter.
If it is NG. reulace the harness and connector.
7-10-3 How t o reproduce
It is absolutely necessary for the accurate trouble shooting to simulate conditions and an environment
where a particular malfunction has occurred.
The following shows how to reproduce the malfunction phenomenon hard to reproduce with the vehicle
stopped by applying external factors (vibration, heat, water, etc.).
(1) VIBRATION APPLYING METHOD
Case that malfunction may be caused by vibration.
@ HARNESS
Check to see if malfunction takes place by lightly swinging the wire harness vertically and laterally.
CAUTION
In the case of harnesses, focus on checking the neck of the connector, a fulcrum of vibration, body
pass-through section.
@ CONNECTORS
1.Visually check if the terminal is not pulled out, with the connector connected.
2.Lightly pull harnesses on the connector one by one to
check if all the harnesses are seated fully
LllA5051TlI
:t the connec
for bent or alignment.
:heck the male terminal
n
4.Disconnect the connector and check the female terminal
for deformation such as spread open condition in its
connected portion.
5.Ensure that the pressure is not extremely low when the
male terminal is inserted to the female terminal.
6.Check each connecting portion of the connector for
disturbance or disorder at the connector joint section.
- HI-84
7.When the connector is connected to the .wart,. ensure that I
the harness does not apply undesired force t o the
connector and that the harness has proper amount of
slack.
(2) COLDIHEAT METHOD

1.Case where malfunction seems to take place during - cold period or hot period
2.With a hair dryer or refrigerant, heat or cool the parts of the system thought to be responsible for the
malfunction. See if the malfunction is reproduced.
CAUTION
When heating, do not heat the part beyond +60°C (temperature at which the part can be touched
by hand).
3.When heating or cooling, do not open the lid of the unit, such as a sensor, to heat or cool directly
electronic parts.
(3) WATER APPLYING METHOD
1.Case where the malfunction seems to take place on a rainy day or humid day
2.Apply water to the vehicle and see if the malfunction takes place.
CAUTION
Do not apply water directly to electronic parts.
NOTE
If rain leak takes place inside the vehicle, the rainwater may go along the harness, entering the
inside of the parts. This should be kept in mind especially when the vehicle has had rain leak
before.
I1 BODY
BODY 11 - 1
BASIC CHECK AND ADJUSTMENT---- I1 - 1
FRONT DOOR 11 - 15
DISASSEMBLING AND
ASSEMBLING(TR1M-RELATED) ------ 11 - 15
DISASSEMBLING AND
ASSEMBLING(GLASS-RELATED)----- 11 - 19
DISASSEMBLING AND
ASSEMBLING(L0CK-RELATED)------- 11 - 21
FENDER 11 - 23
REMOVAL AND INSTALLATION--------I1 - 23
FRONT CROSSMEMBER------------------- 11 - 25
RADIATOR SUPPORT 11 - 26
REMOVAL AND INSTALLATION------ I1 - 26
CENTER CROSS MEMBER---------------- I1 - 29
REMOVAL AND INSTALLATION------ I1 - 29
FLOOR BRACE 11 - 32
REMOVAL AND INSTALLATION----- I1 - 32
LOWER ARM BRACKET BRACE--------- I1 - 33
FLOOR CORNER BRACE I1 - 34
HOOD LOCK CONTROL CABLE---------- I1 - 35
REMOVAL AND INSTALLATION-------- I1 - 35
FUEL LID OPENER 11 - 37
REMOVAL AND INSTALLATION-------- I1 - 37
FUEL FILLER OPENING LID--------------- I1 - 39
REMOVAL AND INSTALLATION----- I1 - 39
LUGGAGE DOOR LOCK OPENER------- I1 - 42
REMOVAL AND INSTALLATION------- I1 - 42
1 BODY
1-1-1 FIRING ADJUSTMENT
) HOOD
) FITTING DIMENSIONS
r Grille
Section A-A Section B-B
FITTING DIMENSIONSOF HOOD
Measuring point I Specified gap (a) I Stagger (b)

I y;e~ne 1 Deviationvalue I
1 right and left I
A-A I H O O ~X Front fender 3.4f1.5 O+ 1.5 I Not to exceed 2.0 1 Not to exceed 1.5
8-0 ( H O O ~X Radiator grille 10.5Z:; - - INot to exceed 2.0
Unit : mm
!
@ FITTING ADJUSTMENT
1.To adjust the hood panel in a fore-and-aft direction and in
a right-and-left direction at the rear end, loosen the hood
hinge bolts.
2.To adjust the hood in up-and-down and right-and-left

directions at the front end, loosen the hood lock bolts.
CAUTION
In cases where the centering bolt has been used,
replace it with a bolt supplied for adjustment use in
advance.
NOTE
Pan number of bolt:91511 -G0612-000
2) FRONT FENDER
Section A-A
Fender
* ender
Section 5-5
Rocker panel
Section C-C Section D-D
FlnlNG DIMENSIONS OF FRONT FENDER

Difference
Measuring point Specified gap (a) Stagger (b) between Deviation value
right and left
A-A Front fenderx Hood 3.4t1.5 Ot1.5 Not to exceed 2.0 Not to exceed 1.5
8-8 Front fenderx Front door 4 . 3 t 1.5 0+1.5 - Not to exceed 1.5
- 0 . 6 f 2.0
C-C Front fender X Rocker 4.5k1.5
(With the rocker - -
panel used as
reference)
-0.7f 1.0
D- D (With the fender
Front fender X Front bumper 0 Not to exceed 1.5 Not to exceed 1.0
panel used as
reference)
Unit : mrn
,-,
11-4
0 FITTING ADJUSTMENT
1.Adjust the clearance between the front pillar and the rocker by the bolt tightening adjustment @ and
0.
2.Adjust the clearance with the hood by the bolt tightening adjustment @ and @.
3.Adjust the difference in height with the rocker and the clearance with the door by the bolt tightening
adjustment @ and @.
4.Finaily, install the bolt @ and clip @.
11-5
(3) FRONT DOOR
@ ARTICLES TO BE PREPARED
SST
09812-00010-000
Wrench door hinge set bolt
(09812-22010-000)
I FITTING DIMENSIONS
,-Front door rFront
u ender
Section A - A
Front door
k
Section B - B
Rocker panel
P Quarter panel
-
Section C C
FllTlNG DIMENSIONS OF FRONT DOOR
Measuring point Specified gap 1 Stagger I Difference

between
right and left
Deviation value
A-A Front doorx Front fender 4.3k 1.5 Ok1.5 - Not to exceed 1.5
B-B Front door x Rocker 5.5k1.5 - - Not to exceed 2.0
C-C Front doorXQuarter panel 4.3+1.5 Ok1.5 - Not to exceed 1.5
Unit : mm
SST 09812-00010-000
1.To adjust the rear end of the door and to perform

adjustment in up-and-down and right-and-left directions,
loosen the bolts at the pillar side.
2.To adjust the door in an up-and-down direction and the

front end of the door in a right-and-left direction, loosen
the bolts at the door side.
3.To adjust the door in fore-and-aft and right-and-left

directions and to adjust the front door lock striker, loosen
the striker attaching screws to such an extent that the
striker can be moved. Then, perform the adjustment by
lightly tapping the striker.
4.After adjustment of the striker, fully tighten.
(4) DOOR & QUARTER GLASS
@ ARTICLES TO BE PREPARED
SST
09842-97208-000 Sub-harness se1,removal roof drive
@ FITTING DIMENSIONS
FITTING DIMENSIONS OF FRONT DOOR
I Difference
Measuring point Specified gap (a) Stagger (b) between Deviationvalue
right and left
A-A Door glassx Roof mold 7.5k3.0 - - -
B-B Door glassx FR roof mold 7.4f 3.0 - - -
3f 2.5
C-C Door glassxQuarter window 5.7f2.0 "With the glass - -
used as reference'
D-D l ~ u a r t ewindowx
r RR roof mold 7.4+3 - - -
Unit : m m
@ FITTING ADJUSTMENT (DOOR GLASS)
1.Fully close the roof.
2.Loosen the bolts and nuts shown at the right figure and
keep them in a temporarily tightened state.
(1) Front door mirror bracket installing nut. (Adjust bolt
securing nut)
(2) Front door glass installing nut.
(3) Front door power window regulator installing nut
.(Adjust bolt securing nut)
(4) Door window upper stop installing bolt.
NOTE
Temporarily tighten the door window upper stop at the
highest end position.
3.Raise the door glass and stop it 3 mm before the full
close position.
i 4.Perform the vehicle lateral direction adjustment by turning
the adjusting bolts of the door mirror bracket and
regulator. Then, fully tighten the door mirror bracket and
regulator.
5.Adjust each section for the vertical direction, longitudinal

direction and inclination. Then, fully tighten the door
glass-installing nut.
6.With the door window upper stop kept lightly applied to

the stopper of the door glass, fully tighten the installing
bolt.
7.After fully opening the door glass, close it fully. Check the
following items.
(1) Check the alignment at all the points.
(2) While the glass is rising, the roof side weatherstrip
and glass should be kept parallel to each other. Also
the door window stoppers at the front and rear and
the glass stoppers should make contact at the same
time.
&With the door glass fully closed, open and close the door. At this time, ensure that the roof drip side
finish front molding and removable roof front molding do not interfere with the door glass.
@ FITTING ADJUSTMENT (QUARTER GLASS)
SST 09842-97208-000
1.Remove the center floor side member RHILH

2.Fully close the roof.
3.Loosen the bolts and nuts shown at the right figure and
keep them in a temporarily tightened state.
( I ) Quarter window installing nut (3 points)
(2) Quarter window regulator installing nut (1 point)
4.Remove the coupler of the quarter window regulator motor. Set the SST. (For battery voltage supply.)
SST 09842-97208-000
5.Apply the battery voltage to the quarter window regulator motor and make the quarter window fully
closed.
6.Perform the vehicle lateral direction adjustment by turning
the adjusting bolt of the quarter window regulator shown
at the right figure. Fully close the nut.
Adjust bo
7.Adjust each section for the vertical direction, longitudinal

direction and inclination. Then, fully tighten the quarter
glass.
NOTE
Ifthere is no margin for the vertical adjustment, loosen
the bolt shown at the right figure. Raise the position of
the quarter window up stopper.
8.Confirm the alignment state of the quarter window at all
the points with the window fully closed.
9.lnstall the center floor side member RHILH.
5) ROOF
IT r
Roof panel
Section A -A Section B -B
C1186507E%
FlTlNG DIMENSIONS OF ROOF PANEL

Difference
Measuring point Specified gap Stagger between Deviation value
right and left
A-A Roof XHeader panel 7.0k 1.5 Of 1.0 - -
B-B Roof x Back panel 7.0k1.5 Ok1.0 - -
Roof x Header panel stagger -
a Roof x Back panel stagger
- o+ 1.o
I
-
Unit : rnrn
@ ALIGNMENT ADJUSTMENT(WHEN ROOF PANEL HAS
BEEN REPLACED OR REMOVED)
1.Loosen the bolts at the positions shown in the right figure
(Both right and left). Perform the vehicle longitudinal and
lateral direction adjustment.
CAUTION
At this time, do not adjust the adjusting bolts of the roof
link or back panel by loosening the bolt.
2.Ensure that the roof link stopper is in light contact with the
link (Zero contact).
3.After completion of the adjustment, ensure that the roof
can be openedlclosed smoothly.
@ ALIGNMENT ADJUSTMENT (WHEN REMOVABLE
ROOF UNIT ASSEMBLY HAS BEEN REPLACED OR
REMOVED)
1.Remove the bolt shown at the right figure. Insert shims
between the link and the body so as to perform the
vehicle lateral direction adjustment.
2.Remove the bolt shown at the right figure. Insert shims

between the link and the body so as to perform the
vehicle lateral direction adjustment.
NOTE
Shim number:52331-97201-OOO(0.5mm)
52331-97202-000(1.Omm)
52331-97202-OOO(2.0mm)
3.Loosen the bolts shown in the right figure (Both right and
left). Perform the vehicle longitudinal and vertical
adjustment.
CAUTION
* At this time, do not adjust the adjusting bolts of the roof
panel or back panel by loosening the bolt.
can be openedlclosed smoothly.
i) BACK PANEL
-
Section A - A Reference hole f '
Section B-B,C-C
Section 1
FllTlNG DIMENSIONS OF BACK PANEL

Difference
Measuring point Specified gap Stagger between right Dimensions
and leit
A-A Roofx Back panel 7.0f 1.5 - - -
B-B Back panel xTrunk lid 7.0f 1.5 - - -
C -C Back panel x Quarter panel 21.7i1.0 - 1 - 1 -
@ Back panel point a-quarter panel standart hole - - 1 - 16.0f 1.0
Unit : mrn
1.Loosen the bolts shown in the right figure (Both right and
left). Perform the vehicle longitudinal and vertical
direction adjustment.
CAUTION
At this time, do not adjust the adjusting bolts of the roof
panel or roof link by loosening the bolt.
2.Ensure that the roof link stopper is in light contact with the
link (Zero contact).
can be opened/closed smoothly.
') TRUNK LID
Quarter panel
Rear bumpe
Section A-A Section B-B
FITTING DIMENSIONS OF TRUNK LID
Measuring point
Specified gap
Stagger (b) II Difference
between II
right Deviation value
and left
-
A A Trunk lid XQuarter panel 1 6.8f1.5 Oi1.5 - --
Not to exceed Not to exceed
( B-B l ~ r u n kIidxRear bumper 1 5.4f2.0 1 -0.7k2.0 1 - , I

/ Not to,exceed
Unit : mm
!
I .Loosen the trunk lid installing bolts. Perform the vehicle
longitudinal and lateral direction adjustment.
2.Loosen the installing bolts (At three points) of the luggage

link. Perform the vehicle longitudinal and vertical
direction adjustment.
NOTE
As for the alignment dimension of the back panel X
trunk lid, see the section under "Back panel alignment
adjustment."
Refer to Pge 11-12.
CAUTION
Only when the luggage link has been replaced or
removed, adjustment should be made by moving the
luggage link.
Do not adjust the trunk lid by moving the luggage
compartment door striker.
3.After completion of the adjustment, ensure that the trunk
lid can be opened/closed (Both t o the forward and
rearward) smoothly.
4.After completion of the adjustment, ensure that the easy
closer function of the trunk lid can function properly.
11-15
2 FRONT DOOR
2-1 DISASSEMBLING AND ASSEMBLING(TR1M-RELATED)
Tool
(clipremover
Lubricant, adhesive, others
1 ~
(1I) COMPONENTS

r A 1 a Bezel, FR door inside handle 6 f Speaker Ay
r 2 b Cover, door assist grip A 7 g Cover, front door service hole
r 3 c Panel Ay, FR door trim
r 4 d Weatherstrip, front door glass, inner
A 5 e Handle SIA, FR door, inside
, -- 11-1 6
(1) FR DOOR INSIDE HANDLE BEZEL
1.Rernove the cap then, remove the screw.
2.lnsert a flat screwdriver whose tip end is wound with a

protective tape into between the door lock knob and the
inside handle bezel so as to disengage the pawl. In the
same way, disengage the pawl between the inside
handle and inside handle bezel. Remove the inside
handle bezel.
CAUTION
When the temperature is low, there is the possibility &:Pawl position
that the pawl fitting section may be broken. Hence, CllBM18ETlO
warm up the fitting section with a dryer before removal.
(2) DOOR ASSIST GRIP COVER / / -/
/ L, /
\
n:Pawi position I
(3) FRONT DOOR TRIM PANEL AY

1.Rernove the screw (Two section) by detaching its fitting.
2.Rernove the front door trim panel by disengaging the clip

i
I
(4) FRONT DOOR GLASS INNER WEATHERSTRIP I
1.By lightly applying a drill vertically to the mandrel of the nner weatherstrip
rivet, grind the mandrel to remove it. (At two points)

(1) FRONT DOOR SERVICE HOLE COVER
l.lnstal1 the front door service hole cover, following the main points given below.
(1) Affix butyl tape along the panel groove as shown in the figure below. At this time, do not stretch
the tape.
(2) When affixing the service hole cover, securely press the butyl tape affixing section.
(3) If the service hole cover has rupture, this will cause water leakage. Be sure to replace the service
hole cover.
Butyl end-( (--Butyl end

The assembling 1s performed
with the trim clip holes used
as the reference.
II
I I
-
Using butyl tape, cover the lower section of the water drain hole of the service hole cover.
The butyl tape route leading to the hole should have an inclination.
The affixingshould be carried out so that the hole center section may become the lowest point.
I
(2) FRONT DOOR INSIDE HANDLE SIA
CAUTION
Be vefy careful not to break the threaded hole by
tightening the screw with an excessive torque, for an
ET screw has been employed. Do not use an impact
driver when tightening the screw.
If the threaded section should be broken, be sure to
use an over sized ET screw.
NOTE
ET screw: This is a screw by which a female screw is
threaded as it is tightened, utilizing the shape at the tip
end which has a self-drilling effect.
(3) FRONT DOOR INSIDE HANDLE BEZEL
CAUTION
Be vety careful not to break the threaded hole by
tightening the screw with an excessive torque, for an
ET screw has been employed. Do not use an impact
driver when tightening the screw.
If the threaded section should be broken, be sure to
use an over sized ET screw.
NOTE
ET screw: This is a screw by which a female screw is
threaded as it is tightened, utilizing the shape at the tip
end which has a self-drilling effect.
2-2 DISASSEMBLING AND ASSEMBLING(GLASS-RELATED)
IMP grease,Butyl tape.Protective tape

1.Remove the front door service hole cover.
Refer to Page 11-5.

1 COMPONENTS
r 1 a Stopper, FR door window, upper 6 f Bracket S/A,FR door mirror
2 b Door, glass frame stabilizer 7 g Pad. FR door outside molding
3 c Weatherstrip Ay door glass outer 8 h Pad, FR door lower flame garnish
r 4 d Glass SIA,front door
r 5 e Regulator Ay,FR door power window

(1) FRONT DOOR WINDOW UPPER STOPPER
1.Remove the cap and remove the screw by detaching its
fitting. (Two point)
(2) FRONT DOOR GLASS SIA

1.Ra1sethe door glass to the position shown in the right
figure. Remove the three nuts and remove the front door
glass assembly.
(3) FRONT DOOR POWER WINDOW REGULATOR Ay

1Shown in the right figure remove the five bolt and two nut,
remove the front door power window regulator Ay.

?.Performthe door glass alignment adjustment
Refer to Page 11-7.
2 - 2 6 OPERATION AFTER ASSEMBLY

1.lnstall the front door service hole cover.
11-21 -
2-3 DISASSEMBLING AND ASSEMBLING(L0CK-RELATED)

IMP grease,Butyl tape,Protectwe tape 1

I .Remove the front door service hole cover.
t

1 a Link, FR door lock remote control (For locking 6 f Cylinder Ay, front door lock
knob)
2 b Link. FR door lock remote control (For inside
handle)
3 c Lock Ay, FR door
4 d Actuator Ay, FR door lock
5 e Handle Ay, FR door lock

1.Install the front door service hole cover.
3 FENDER
1.Remove the radiator grille.
Refer to Page 12-1.
2.Remove the front bumper cover.

Refer to Page 12-2.
3.Remove the cowl top ventilator louver.

Refer to Page 12-5.

I) COMPONENTS
I ! !

F
11-24
A 1 a Liner, front fender
2 b Lamp Ay, side turn s~gnai
A 3 c Fender, FR

(1) FRONT FENDER
1.Perform the front fender alignment adjustment.
Refer to Page 11-3.
(2) FRONT FENDER LINER

1.When installing the front fender liner, insert both ends of the slit section of the fender liner into the

1.Install the cowl top ventilator louver SIA.
Refer to Page 12-5.
2.lnstall the front bumper cover.

Refer to Page 12-2.
3.lnstall the radiator grille,

4 FRONT CROSSMEMBER
Refer to Page 12-2.

) COMPONENTS

1 a Member S/A,
FR cross

1.Install the front bumper.
Refer to Page 12-2.
5 RADIATOR SUPPORT
1.Remove the radlator grille.
Refer to Page 12-1.

Refer to Page 12-2.
3.Remove the front fender.

4.Remove the head lamp.

Refer to Page J1-7.
5.Remove the front cross member SIA


Refer to Page B3-2.
7.Remove the inter cooler Ay.

8.Remove the condenser Ay.

9.Remove the radiator Ay.

Refer to Page B6-6.
) COMPONENTS

1 a Support SIA, radiator
1.Install the radiator Ay.
Refer to Page B6-6.
2.lnstall the condenser Ay.

3.lnstall the inter cooler Ay.


Refer to Page 83-2.
5.lnstall the front cross member SIA.

6.lnstall the head lamp.

Refer to Page J1-7.
7.lnstall the front fender.

8.lnstall the front bumper cover

Refer to Page 12-2.
9.lnstall the radiator grille.

Refer to Page 12-1.
-
6 CENTER CROSS MEMBER

Instrument
l~orquewrench

1.Remove the window deflector board Ay.
2.Remove the back panel trim

3.Remove the roof stay.

Refer to Page 15-7.
I COMPONENTS
Unit:N.mJkgf/crn)
r 1 a Bar SiA, roll over 6 f Bracket SiA, body mounting No.1. RHILH
2 b Reinforcement, cross member floor No.3 7 g Base SIA, quarter trim, RHILH
3 c Member SIA, center floor side, RHiLH
4 d Member, center floor
5 e Member SIA, center floor cross
(1) ROLL OVER BAR SIA
1.Disengage the clip of the quarter trim upper panel. With
the quarter trim upper panel floating, remove the two
bolts and remove the roll over bar SIA.

I.Install the roof stay.
Refer to Page 15-7.
2.lnstall the back panel trim

3.lnstall window deflector board Ay.

- 11-32
7 FLOOR BRACE
Instrument
l~orque
wrench

COMPONENTS
Unit:N.m}kgf/cmJ
1 a Brace, FR floor center
2 b Brace, FR floor side member
3 c Brace, floor corner, RHILH

11-33
8 LOWER ARM BRACKET BRACE
Instrument
l~orquewrench

I) COMPONENTS
L
Unit:N~rn)kgf/crn]
1 a Brace, lower arm bracket, RHILH

11-34
9 FLOOR CORNER BRACE
Instrument
wrench
[~orque

I) COMPONENTS
L
Unit:N.rn)kgf/cm)
1 a Brace, floor RR corner, RH/LH
10 HOOD LOCK CONTROL CABLE
Refer to Page 12-1.

Refer to Page 12-2.
3.Remove the instrument panel.


I
Hood lock control cable Ay
Secure the hood lock cable by installing it to the

hole of the resin radiator support.
passing-through
position locating.)
C Lock x cable assembling state>
the vehicle exterior

Hood lock control cable Ay
ecure by bending it.
<Indoor>
^As for the radius of curvature during the cable

routing, make sure to assure at least W O O .
1.Install the instrument panel.

Refer to Page 12-2.
3.lnstall the radiator grille.

Refer to Page 12-1.
11 FUEL LID OPENER
2.Remove the back panel trim.

.. - component trim cover, LH.

3.Remove the luggage
lid lock retainer
With the retainer assembled to the cable Turn it about 90 degrees and stop It.
lock section, insert it into the inlet box hole.
Drawing as viewed from arrow A
NOTE: As for the radius of curvature during

the cable routing, make sure to assure
at least R100.
Enlarged section B
1 Install the luggage component trim cover, LH.
2.lnstall the back panel trlm.

12 FUEL FILLER OPENING LID
Tool

1.Remove the tonneau cover holder LH.
2.Remove the luggage comportment trim cover LH.

I) COMPONENTS
(2) DISASSEMBLING AND ASSEMBLING PROCEDURES

v A 1 a Lid Ay, fuel filler opening.
- 11-40
(1) FUEL FILLER OPENING LID AY
1.Mask the gap by filling rags or the like there from the vehicle ~nsideso that the removed rivet may not
fall into the locker section.
CAUTION
When the head section of the rivet is removed, be sure to secure it so that the rivet may not fall
down to the locker section.
2.Apply a protective tape or cloth to prevent the fuel filler opening lid Ay from being damaged
I I
CllB5099ETtO
3.Lightly apply a drill to the rivet vertically. Then, grind the mandrel section of the rivet, using the drill.
-
CAUTION
Be very careful not to damage the section around the fuel filler opening lid.
4.After the flange section of the rivet has been removed, stop the drilling operation. Then, remove the
remaining fragments of the rivet, using pliers or the like.
CAUTION
Care must be exercised, for the removed rivet has been very hot.

(1) FUEL FILLER OPENING LID AY
CAUTION
Utmost care must be exercised so that your finger may not be caught by the roof or luggage link
during the operation.
1.Select a nose piece with the minimum diameter for which I

the mandrel of the rivet can be inserted. I
-
CAUTION
Any wrong selection of the nose piece will cause
improper rivet tightening and malfunctions of riveter.
i
i
2.Mount the nose piece to the hand riveter and insert the
mandrel section of the rivet into the nose piece.
NOTE
Part number of rivet:90042- 69027- 000
3.With the rivet applied strongly and vertically to the
installation hole, operate the hand riveter to install the
rivet.
CAUTION
Be very careful not to damage the section around the
fuel filler opening lid.
In cases where the rivet has not been tightened by one
riveter operation (the mandrel has not been cut), repeat
the operation again.
CAUTION
If the operation is performed by prying during the hand
riveter operation, the mandrel section of the rivet will be
bent, leading to improper rivet tightening and
malfunctions of the hand riveter.
CAUTION
If the hand iweter is operated with the rivet tilted or
floating, it will lead to improper rivet tightening.
CAUTION
If the rivet is installed without press-fitting the
installation parts, it will lead to improper rivet tightening.

I.Install the luggage component trim cover, LH,
2.lnstall the tonneau cover holder LH.
13 LUGGAGE DOOR LOCK OPENER
2.Remove the back panel trim.

3.Remove the center floor side member RHILH .

4.Remove the tonneau cover holder RH.

F-
5.Remove the luggage component trim cover, RH.
6.Remove the lower back trim.
rTrunk lid closer Ay

Bodv harness- 1 .
Drawing as viewed
from arrow A
Insert the cable into th; bracket up
to a point that enables a secure holding.
Console boxmounting RR bracket
Insert the cabie into the bracket up

to a point that enables a secure holding
11-43 F:
r ,
1.Install the lower back trim.
2.lnstall the luggage component trim cover, RH.
3.lnstall the tonneau cover holder RH.

5.lnstall the back panel trim.


12 EXTERIOWINTERIOR
RADIATOR GRILLE 12 - 1
REMOVAL AND INSTALLATION--------- 12 - 1
BUMPER 12 - 2
REAR BUMPER -----------------.---------------
12 - 4
COWL TOP VENTILATOR LOUVER------ 12 - 5
WEATHER STRIP(FR0NT HEADER
SECTION) 12 - 6
WEATHER STRIP(FR0NT DOOR
SECTION) 12 - 9
REMOVAL AND INSTALLATION --------- 12 - 9
WEATHER STRIP(TRUNK SECTION) --- 12 - 11
WEATHER STRIP(RO0F SECTION) 12 - 17
REMOVAL AND INSTALLATION-------- 12-17
INSTRUMENT PANEL--------------------- 12 - 22
REMOVAL AND INSTALLATION-------12 - 22
WINDOW DEFLECTOR BOARD ---------- 12 - 27
REMOVAL AND INSTALLATION-------12 - 27
TRIM PANEL 12 - 28
FRONT SEAT 12 - 31
FRONT SEAT OUTER BELT---------------- 12 - 32
ROOF HEADLINING 12 - 35
REMOVAL AND INSTALLATION------ 12 - 35
BACK PANEL GARNISH------------------ 12 - 36
TONNEAU COVER 12 - 37
REAR CONSOLE BOX 12 - 38
12-1
1 RADIATOR GRILLE
Tool
/clipremover

) COMPONENTS
i
1 a Grille, radiator
2 BUMPER
Tool
lChp remover

Refer to Page 12-1.

I) COMPONENTS

v 1 a Cover, front bumper
2 b Bracket, FR fog lamp, RHILH
3 c Lamp Ay. FR fog & turn, RHILH
12-3 -
2-1-4 POINTS OF REMOVAL I
(1) FRONT BUMPER COVER

1.Remove the bolt(four pieces)and clip.(eight pieces)
2.Remove the nuts (RH and LH) located on the back side of
the front fog lamp bracket.
3.Loosen the screws (Three on each side) and remove the

front bumper.

1.Install the radiator grille.
Refer to Page 12-1.
3 REAR BUMPER
Tool
~CIIPremover

) COMPONENTS

I a Lamp Ay, back up
2 b Cover, rear bumper

1.Remove the back up lamp Ay
Refer to Page J1-15.
4 COWL TOP VENTILATOR LOUVER
Tool

1.Remove the wiper arm Ay.
. I S REMOVALAND INSTALLATION PROCEDURES
) COMPONENTS

v 1 a Louver SIA, cowl top
2 b Seal, hood to cowl top
3 c Cover, cowl vent

(1) COWL TOP LOUVER SIA
1.Keep the hood ajar to remove the cowl top louver.
4-1-5 OPERATION AFFER INSTALLATION
I .Install the wiper arm Ay.
12-6
5 WEATHER STRIP(FR0NT HEADER SECTION)
l~lcoholor white gasoline
Tool
/clipremover

) COMPONENTS
KNon -reusable parts

A 1 a Weatherstrip, removable roof front
(1) REMOVABLE ROOF FRONT WEATHERSTRIP
1.Using alcohol, degrease the panel surface where double-faced adhesive is to be applied.
2.lnsert the clip of the weatherstrip into the fixing hole. (One on each side.)
CAUTION
When degreasing the panel surface, do not wipe out the seal surface of the weatherstrip.
Securely insert the clip all the way.
of weatherstrip
Section A
CllB6013ESI€
3.lnsert the clip into the fixing hole. (Two clips on each side.)
4.lnstall rest of the weatherstrip to the molding.
CAUTION
Place the upper surface of the marked area on the weatherstrip drain groove in order to avoid
appearance problem.
I Fixing holes of weatherstripi

Fender panel
Section B C1186014ES11
5.lnsert the hook @ into the retainer.
6.Press the seal surface to assemble the hook @ to the retainer.
CAUTION
Use care not to catch the trim lip inside the garnish, as the weatherstrip trim lip is designed to be
placed on the garnish.
I I
Section C-C
7.lnstall the secondary seal to the panel flange

8.When applying the primary seal, press the outer surface of the primary seal and remove the backing
sheet of the double-faced adhesive.(Refer to section E.)
CAUTION
When assembling the weatherstrip to the panel flange, securely insert all the way into the panel.
When applying the primary seal, stripping the backing sheet in advance might cause appearance
problem such as misalignment. Therefore carefully peel off the paper, while pressing the outer
-surface of the weatherstrip.

When applying the primary seal, press the outer surface of the primary seal and remove the
backing sheet of the double-faced adhesive.
After the primary seal is applied, press the outer surface to press-fit.
Press-fit force:19.6kPa{2kgf/cm2}
If the double-faced adhesive needs correction due to misalignment, the part shall be replaced, as
the double-faced adhesive will lose adhesion and cannot be reused.
Hollow section
Section D - D section E
Cl lB6016ES16
6 WEATHER STRIP(FR0NT DOOR SECTION)
Remove the front door mirror bracket.

) COMPONENTS

A 1 a Weatherstrip, front door No.2 RH
A 2 b Weatherstrip, front door RH
A 3 c Weatherstrip, front door No.2 LH
A 4 d Weatherstrip, front door LH
(1) FRONT DOOR WEATHERSTRIP RHILH
l.First assemble the front door weatherstrip, and then assemble front door mirror bracket.
CAUTION
If assembled in the reverse order, the thin portion of the front door weatherstrip, marked area shown
in the illustration, will be caught, affecting the appearance and water tightness.
bracket
1 C1186022ES16
(2) FRONT DOOR N0.2 WEATHERSTRIP RHJLH

1.Fix the weatherstrip with three clips on the panel.
CAUTION
Securely fix the hook shape portion of the panel into the notch of the quarter outer panel.

l.1nstall the front door mirror bracket.
<RefCode=B110>
7 WEATHER STRIP(TRUNK SECTION)
[~lcoholor white gasoline
Tool
/Clip remover

I ) COMPONENTS
Xb
I

A 1 a Weatherstrip, luggage compartment door
A 2 b Weatherstrip, luggage compartment door No.2
A 3 c Weatherstrip, back door, upper RH
A 4 d Weatherstrip, back door, upper LH
,r.
12-1 2
i
(1) BACK DOOR, UPPER WEATHERSTRIP RH/LH
2.lnstall the locating tab into the hole.
3.Match the marked area A with the panel to control the rotation direction.
4.When applying weatherstrip, peel-off the backing sheet of the double-faced adhesive, while pressing
the outer surface of the primary seal.
CAUTION
Stripping the backing sheet in advance might cause appearance problem such as misalignment.
Therefore carefully peel off the paper, while pressing the outer surface of the weatherstrip.
Press-fit force:l 9.6kPa{2kgf/cm2)
rLuggage inner panel
Hole position hating, i/r,
- Protrusion
faces f(
\\ \* L~wo-sidedadhesive
Section A tape
CiiB6018ES1
(2) LUGGAGE COMPARTMENT DOOR WEATHERSTRIP N0.2
CAUTION
2.lnsert the clip of the weatherstrip into the hole F section of the back panel.
3.Carefully strip the backing sheet on the edge and apply the adhesive.
4.When applying the double-faced adhesive 0, fold back the end portion of the backing sheet @ of
the double-faced adhesive. Keep the tab upside and pull it out in the direction indicated by an arrow.
(Refer to the cross section E.)
Section A Section E
5.lnstall the secondary seal to the panel flange.
the outer surface of the primary seal.(Refer to figure C.)
CAUTION
When applying the primaty seal, press the outer surface of the primary seal and remove the
After the primaly seal is applied, press the outer surface to press-fit.
Press-fit force:l9.6kPa{2kgf/cm~}
Section B-B
l.lnsert the luggage compartment door weatherstrip into the flange @.
2.lnsert the clip of the weatherstrip into the fixing hole.
3.lnsert the rest into the flange. [Area around @]
CAUTION
Ensure that the cut water is securely inserted into the notch of the quarter outer panel.
Water break section

Fixing holes of weatherstrip
Fixing holes of weatherstrip
ter body piliar pane

Section A
CAUTION
Install the quarter outer panel so that its corner area (%Marked area in the above illustration) can
be sealed with EPT-sealer.
. . as much as it
Imperfect sealing can cause water intrusion, therefore EPT-sealer shall be aoolied
slightly runs off the quarter outer panel . ( ~ e f eto
r the cross section)
rEPT sealer
Weatherstr~p
Quarter outer panel

L~ehicle
exterior
<Cross-section> side
~~~
~~~~p ~p
1
4.Match the marking located on the bottom of the extrusion section shown in the illustration below with
the bumper locating hole on the vehicle side.
I
Bumper installation locating hole
&
refere
When assembling,
be sure to align
Push out section marking
5.lnstall the weatherstrip to the panel flange.

CAUTION
Ensure that the cut water is securely inserted into the notch of the quarter outer panel.
rTrunk lid
uld be made securely.

Quarter outer panel
Section B-B
8 WEATHER STRIP(RO0F SECTION)
l~lcoholor white gasoline
Tool
(clip remover

) COMPONENTS

A 1 a Weatherstrip, removable roof RR
A 2 b Weatherstrip, roof side rail RH
A 3 c Weatherstrip, roof side rail LH
(1) ROOF SIDE RAIL RR WEATHERSTRIP RHILH
1 .Using alcohol, degrease the panel surface where double-faced adhesive is to be applied.
2.lnsert the section A clip of the weatherstrip into the fixing hole.
3.lnstall of the retainer on side@.
CAUTION
Install the weatherstrip to the retainer @ so as not to create a gap on side E.
r Two-sided adhesive tape

,EPT sealer
I /
Front J' Section A
4.lnsert the clip into the fixing hole at the rear of the vehicle (Position B) in the same way as in front.
5.lnstall of the retainer on side@.
yRoof, panel
rI
Fixing holes of
Weatherstrip
+tetainer
-I
EPT sealer ' h t Y l
I
Section B
12-1 9
6 Insert the section hook @ I retarner.
into the
7.Press the seal surface to assemble the hook to the retarner.
CAUTION
Use care not to catch the trim lip inside the garnish, as the weatherstrip trim lip is designed to be
placed on the garnish.
Section C-C
C1186CU3ESi6
CAUTION
First assemble the weatherstrip to the retainer, and then position the double-faced adhesive. Peel-
off the backing sheet and apply.
Press-fit force:l9.6kPa{2kgf/ctW]
;I
(2) REMOVABLE ROOF RR WEATHERSTRIP
2.Match the locating block A with the flange on the panel side and install to the panel.
3.lnstall the weatherstrip to the fitting portion of the retainer on side E.
CAUTION
* Install the weatherstrio to the retainer @ so as not to create a aao in area O.
Block for position
r~ocating.
Two-sided adhesiv~
Section A
4.Match the stopper surface B of the weatherstrip with the retainer edge and install it to the retainer.
5.When applying weatherstrip, peel-off the backing sheet of the double-aced adhesive, while pressing
CAUTION
Press-fit force:l 9.6kPa{2kgf/cm2)
/ Section B
'
6.lnse1-t the section hook O into the retainer.
7.Press the seal surface to assemble the hook @to the retainer.
8.Peei-off the backing sheet of the double-faced adhesive, while pressing the trim lip onto the back
panel inner.
CAUTION
Assemble the trim lip, being careful not to create excessive sagging in the lip G of the trim lip.
When assembling the trim lip, be sure to press the tape on to the panel to press-fit.
Retainer
I Section C-C
ClIB6W7ES16
9.lnstali the secondary seal to the panel flange.
10.When applying the primary seal, peel-off the backing sheet of the double-faced adhesive, while
pressing the outer surface of the primarv seal.
CAUTION
When applying the primary seal, press the outer surface of the primary seal and remove the
After the primary seal is applied, press the outer surface to ~ress-fit.
Secondary sealel
Section D - D Section H
C11BR48ESl€
'i
9 INSTRUMENT PANEL
WARNING
Since the following operation will affect the SRS airbag, be sure to confirm the notes for the SRS
airbag system before the operation and perform safe operation.
Refer to Page HI-1.

Tool

1.D~sconnectthe battery negatlve terminal.
CAUTION
It should be noted that the memories of the computers (Engine control etc.) of other systems or
radio settings are erased at the same time when the battery negative terminal of the battery is
disconnected.

I) COMPONENTS
12-25
i
1 a Cover, fuse box opening 13 m Box SIA, ash receptacle
2 b Panel, instrument panel finish, lower 14 n Cigar, lighter
3 c Panel Ay, instrument cluster iinish 15 o Bezel, shifting hole
4 d Meter Ay, combination 16 p Box Ay, console FR
5 e Cover, steering column lower 17 q Airbag Ay, instrument passenger
6 f Cover, steering column upper 18 r Panel, instrument
7 g Tube SIA, steering column 19 s Nozzle Ay, defroster
8 h Box Ay, instrument panel 20 t Duct SIA, heater to register, center
9 i Lock Ay, glove compartment door 21 u Striker, glove compartment door lock
r 10 j Panel SlA, instrument cluster finish, center 22 v Pin. instrument panel.No.1
11 k Box Ay, instrument panel center 23 w Register Ay, instrument panel
12 1 Control Ay, heater

(1) INSTRUMENT CLUSTER FINISH CENTER PANEL SIA
1.Access through the glove box opening and unhook the
clip indicated by an arrow.
2.Disengage the clip. Insert a bamboo spatula into where
the clip is floated and detach other clips.
CAUTION
When detaching the clip, apply force to a point close to
the clip and pull it horizontally.
3.Hold the cluster and pull the clip, shown in the right
illustration, in horizontal direction to unhook. Then remove
the instrument cluster finish panel.
CAUTION
* Do not remove the clip while rotating the cluster as
shown in the right illustration, for this might damage the
clip.
CllBS505T10
2.Connect the battery negative terminal.

10 WINDOW DEFLECTOR BOARD
l~rotectivetape

) COMPONENTS

r 1 a Retainer, windshield support bracket
2 b Board Ay, window deflector
3 c Bracket, windshield support

(1) WINDSHIELD SUPPORT BRACKET RETAINER
1.Apply the protective tape to a flat screwdriver and insert
\ \ /,:Pawl position
the screwdriver between the retainer and the roll over
bar. Then pry the windshield support bracket retainer to
disengage the pawl.
11 TRIM PANEL
Tool
lchp remover 1
IProtective tape

Remove the window deflector board Ay.
) COMPONENTS

1 a Lens, map lamp 7 g Board, cowl side trim RHILH
2 b Unit Ay,map lamp 8 h Plate, front door scuff, RHILH
3 c Visor Ay,RHILH 9 i Trim Ay,back panel
4 d Catch, center lock, RHILH r 10 j Panel, quarter trim upper. RHILH
5 e Cover, roof header garnish 11 k Panel, quarter trim RHILH
6 f Garnish, FR pillar RHILH 12 1 Trim, back panel
(1) QUARTER TRIM UPPER PANEL RWLH
1 .Detach the clip of the quarter trim upper.
2.Lift up the quarter trim upper panel to remove the roll over
bar mounting bolts (Two peaces). Then remove the roll
over bar and remove the quarter trim upper panel.

1.lnstall the window deflector board.
12-31
12 FRONT SEAT
Instrument
[~orquewrench

I) COMPONENTS

1 a Seat Ay, FR
-
13 FRONT SEAT OUTER BELT

Instrument

CAUTION
It should be noted that the memories of the computers
(Engine control etc.) of other systems or radio settings
are erased at the same time when the battery negative
terminal is disconnected.
Before starting the operation, set the ignition switch to
OFF position (LOCK) and disconnect the battery
negative terminal. Wait at least 60 seconds.
2.Remove quarter trim upper panel.
) COMPONENTS

1 a Belt Ay, front seat outer
13-1-4 INSPECTION
(1) CHECK OF PRETENSIONER MECHANISM-EQUIPPED
SEAT BELT
1.Check of inclination angle at time of ELR lock.
2.Gently move the retractor from the installation state.
Ensure that the belt locking does not take place within
15"in all directions. Also ensure that the lock is retained
beyond 45".
CAUTION
Never disassemble the retractor.
~ ~ - ~-
~ ~
(2) ELR LOCK POINT

1.Suddenly pull out the seat belt that is assembled to the vehicle. Ensure that locking takes place.
2.Check the following items. Replace any faulty parts.
(1) Case where problems have been found out by the diagnosis check.
(3) EXTERNAL APPEARANCE CHECK OF PRETENSIONER MECHANISM-EQUIPPED SEAT BELT
1.Replace the seat belt in the following cases.
(1) Case where the pretensioner mechanism has been actuated.
(2) Case where the vehicle is damaged in a collision, including a minor one in which pretensioner
mechanism has not been actuated.
(3) Case where the seat belt (Hereinafter referred to as the pretensioner) is damaged or cracked.
(5) Case where grease, water, detergent or oil get to the pretensioner in a large quantity.
(6) Case where the pretensioner dropped and got damaged.
1.install the quarter trim panel.
Connect battery negative terminal.

CAUTION
Afler connecting the battery negative terminal, set the
IG switch to ON position. Ensure that the airbag
warning lamp illuminate for about six seconds, and
then goes out.
14 ROOF HEADLINING
Tool
\clip remover

]protective tape

Remove the removable roof auxiliary hook RHILH.

I) COMPONENTS

1 a Garnish, roof side rail, RHILH
2 b Headlining Ay, roof

1.Install the removable roof auxiliary hook RH/LH
- - -
15 BACK PANEL GARNISH

Tool
/clip remover 1
lprotectlve tape

) COMPONENTS
c:: Clip position
-
1 a Cover, roof headlining molding end
2 b Garnish, back panel lower
3 c Garnish, roof side inner RHILH
16 TONNEAU COVER
I) COMPONENTS
L
1 a Holder, tonneau cover
2 b Cover, cigarette lighter hole
3 c Cover Ay, tonneau
17 REAR CONSOLE BOX
) COMPONENTS

1 a Cover, console box, FR 6 f Cylinder Ay, console compartment door lock
2 b Cover, cigarette lighter hole 7 g Box Ay, console RR
3 c Cover, console box. RR
4 d Cover, console, upper
5 e Cover, console, lower
13 WINDSHIELD WINDOWGLASSIMIRROR
WINDSHIELD GLASS.......................... 13 - 1
BACK WINDOW GRASS ...................... 13 - 6
POWER WINDOW SYSTEM ---------------- 13 - 9
ARTICLES TO BE PREPARED----------- 13 - 9
CONTROL SYSTEM ........................ 13 - 9
SYSTEM WIRING DIAGRAM ------------- 13 - 9
HARNESS SlDE CONNECTOR
TERMINALS 13 - 10
LOCATION OF COMPONENTS--------- 13 - 11
BASIC CHECK 13 - 11
TO MALFUNCTION PHENOMENA ---- 13 - 12
UNIT CHECK 13- 16
REAR QUARTER WINDOW---------------- 13 - 18
QUARTER WINDOW REGULATOR------ 13 - 20
SYSTEM WIRING DIAGRAM------------ 13 - 20
TERMINALS 13 - 20
LOCATION OF COMPONENTS -------- 13 - 20
UNIT CHECK................................. 13 - 20
OUTER REAR VlEW MIRROR------------- 13 - 21
REMOVAL AND INSTALLATION------ 13 21 -
MIRROR SURFACE MOTOR-DRIVEN
MOVABLE TYPE OUTER REAR-VIEW
MIRROR 13 - 23
ARTICLES TO BE PREPARED ---------
13 - 23
TERMINALS 13 - 23
UNIT CHECK................................. 13 - 25
INNER REAR VlEW MIRROR-------------- 13 - 26
-- -
1 WINDSHIELD GLASS
Tool
[sealant gun.DrilI or eyeleteer (heavy needle to make a hole).Cutter kn~fe,Rubbersuctlon cups 1
/seal set (Part number 999-09600-U9-001),Woodenblock,Protectne tape,Cloth.Alcohol or white gasollne

1.Remove the cowl top ventilator louver.
Refer to Page 12-5.


I) COMPONENTS
X:Non - reusable parts

1
A a Molding, windshield outside
r A 2 b Glass, windshield
A 3 c Dam, windshield glass adhesive
A 4 d Stopper, windshield glass, No.1
A 5 e Stopper, windshield glass, No.2
I
(1) WINDSHIELD GLASS
1.Apply a protective seal to the body around the edge of
the glass.
2.Make a hole in the adhesive layer and pass a piano wire

through it.
3.Using the piano wire, saw the adhesive layer.
CAUTION
When cutting the glass adhesive layer, attach a
wooden block to each end of the piano wire or fit vice
pliers to it.

(1) WINDSHIELD GLASS STOPPER No.2
1.Use a cutter knife to smooth the cut adhesive layers on Adhesive
Yo\
the body side and glass s~de.
CAUTION
Degrease the cutter knife.
Leave a thin film of the adhesive layer.
2.Apply body primer to exposed body surfaces of the body
side adhesion area.
CAUTION
Do not coat thickly.
Do not coat the adhesive.
Go to the next step after the primer has dried. (After
about 3 min.)
13-3
3.Attach the windshield glass stopper No.2 to the body
hook section. (Two secttons at both right and left.)
(2) WINDSHIELD GLASS STOPPER No.1

1.Affix the windshield glass stopper No.1 to the position shown at the figure below. (Two sections at
both right and left)
/
With the C. p center aligned u tn the cente, of
O~tsicieof veh~cle
the three cut-out sections, aff~xit to the glass side
Cli8504iESi6
(3) WINDSHIELD GLASS ADHESIVE DAM

?.Affix the window glass adhesive dam to a position as
CAUTION
Attach the lower edge linearly, using the white-punched
mark of the windshield glass as a guide.
CllB5042ET16
2.Cut the cartridge nozzle tip as shown in the illustration at 1 1
right.
3.Load the cartridge into the gun and apply adhesive all the
way around the dam.
CAUTION
about 3 min.)
Apply the adhesive amply to the corners.
(4) WINDSHIELD GLASS
1.Using a suction rubber pad, attach the windshield glass stopper No.1 to the windshield glass stopper
No.2 attached to the hook section of the body.
2.Attach the windshield and lightly push the glass front
surface to fit it firmly.
CAUTION
After applying the adhesive, immediately install the
glass.
3.Using a spatula or the like, correct any adhesive oozing

out from the glass top section and side sections.
r Adhesive
1
(5) WINDSHIELD OUTSIDE MOLDING
1.Before the adhesive hardens, install the windshield outside molding.
2.Afier the adhesive hardens, check water leaks. If there is water leak, remove the water and install the
glass again from the first step.
CAUTION
If you move the vehicle after the glass installation, move the vehicle gently.
NOTE
Refer to the seal set instruction manual for information regarding the adhesive's minimum drying
time.

1.lnstall the instrument panel.
2.lnstall the cowl top ventilator louver, RHILH.

Refer to Page 12-5.
--
i
2 BACK WINDOW GRASS
Tool
[sealant gun,Drill or eyeleteer (heavy needle to make a hole),Cutter knife,Rubber suction cups 1
(seal set (Part number : 999-09600-U9-001).Wooden block.Protectivetape,Cloth.Alcohol or white gasoline J
1.Remove the roof side inner garnish RH/LH

COMPONENTS
i
r A 1 a Glass, back window
A 2 b Clip, back window glass, RH
A 3 c Clip, back window glass, LH
' I
2-1-4 POiNTS OF REMOVAL
(1) BACK WINDOW GLASS
1.Apply a protectwe tape to the body around the edge of
the glass.
2.Make a hole in the adhesive layer and pass a piano wire

through it.
1
3.Using the piano wire, saw the adhesive layer.
CAUTION
When cutting the glass adhesive layer, attach a
wooden block to each end of the piano wire or fit vice
pliers to it.

(1) BACK WINDOW GLASS CLIP RHILH
1.Use a cutter knife to smooth the cut adhesive layers on
the body side and glass side.
CAUTION
Degrease the cutter knife.
Leave a thin film of the adhesive layer.
2.Apply body primer to exposed body surfaces of the body
side adhesion area.
CAUTION
* Do not coat thickly.
Do not coat the adhesive.
about 3 min.)
13-8
3.0verlap the back window glass RH clip on the back window cllass
- LH c l i ~ Then,
. affix it to a ~osition
specified in the figure below.
I
'is
l i affixina
~ oosition <A-A>
(2) BACK WINDOW GLASS

1.lnstall the cartridge to a gun and apply the adhesive
agent to a position specified in the right figure.
CAUTION
about 3 min.)
Apply the adhesive amply to the corners.
2.Using a suction rubber, install the glass. Install it firmly by I

lightly pushing the glass front surface.
CAUTION
After applying the adhesive, immediately install the
glass.
3.Using a spatula or the like, correct any adhesive oozing

out from the glass top section and side sections.
Adhesive
4.After the adhesive hardens, check water ieaks. If there is Glass 1
water leak, remove the water and install the glass again
from the first step.
CAUTION
If you move the vehicle after the glass installation,
Dam
move the vehicle gently.
NOTE
Refer to the seal set instruction manual for information
regarding the adhesive's minimum drying time.
1 .Install the roof side inner garnish RHILH.
3 POWER WINDOW SYSTEM

...- - .-...- ...
[voltage tester

3-2-1 OPERATIONS WHICH REQUIRE INITIAL SETTING OF POWER WINDOW
l.lt becomes necessary to carry out the initial setting of the power window when the battery terminal
has been removed or the connector of the power window ECU has been disconnected.
(1) HOW TO CARRY OUT INITIAL SETTING OF POWER WINDOW
1.After connecting the battery terminal or connector of the power window ECU, manually perform the
'UP" oweration of the driver's seat side Dower window. After the window has closed fully, keep on the
"UP" switch oweration for three seconds or more.
B SN
Fuse block
Power window ECU(ECU side)
Power window ECU(Vehicle harness side )
Window lock SW Driver's seat SW Front passenger seat switch
Driver's seat motor Passenger seat motor

-5 LOCATION OF COMPONENTS
r'
Part name Part name

Power window lock switch(Australia specifica-
a d Power window switch
tions only)
b FR door regulator motor RH e FR door regulator motor LH
c Power window master switch f Power window ECU
3-6 BASIC CHECK

36-1 POWER WINDOW OPERATING CONDlTlONS
1.When the following conditions given below are satisfied, the openinglclosing of the window can be
made through the power window switch operation.
(1) Condition for the roof opening
When the roof system is opened fully.
(2) Condition for the roof closing
When one of the roof lock switches RHILH is "ON". (Condition in which one of them is locked.)
3-6-2 MANUAL OPERATION
1.With the ignition switch set to ON position, perform the following checks.
2.The up and down operation of each door glass can be carried out by means of the driver's seat
master switch and the front passenger seat power window switch.
3.When the window lock switch is set to the [LOCK] position, it becomes impossible to operate the
power window switches at the driver's seat and front passenger seat. (Only the Australia
specifications)
3-6-3 AUTOMATIC OPERATION FUNCTION
1.With the ignition switch set to ON position, perform the following checks.
(1) Perform a two-stage operation for the door glass at the driver's seat to the down side of the
driver's seat master switch. After the down auto has been made, the door glass stops under the
fully opened state.
(2) If the power window switch is operated to the UP side during the auto down operation, the auto
down operation will be stopped.
3-7-1 POWER WINDOW AT THE DRIVER'S SEAT WILL NOT OPERATE.
*I.CONFIRMATION OF DIAGNOSIS CODE OF ROOF SYSTEM
?.After setting the IG switch to "ON" position, confirm the diagnosis code of the roof system.
SPECIFIED VALUE: No abnormality code should be outputted.
If NG. proceed to the trouble-shootina of the motor-driven owenina/closina roof.

If it is OK (Australia swecificationsl. ao to D2.
r If it is OK (EC swecificationsl. ao to *4.
D2.CONTINUITY CHECK OF POWER WINDOW LOCK SWITCH

1.Disconnect the connectors from the window lock switch and power window ECU.
2.Check the harness between the window lock switch and the power window ECU.
(1) Vehicle harness side connector 5 of window lock switch-Vehicle harness side connector 37.
(2) Vehicle harness side connector 4 of window lock switch- Ignition switch (IGI).
If it OK. ao to W3.
W3.POWER WINDOW LOCK SWITCH UNIT CHECK

1.Check for the window lock switch unit check.
<RefCode=B238>
If it OK. ao to W4.
If it is NG, rewlace the power window lock switch.
W4.CONTINUITY CHECK THE POWER SUPPLY CIRCUIT OF POWER WINDOW ECU

1.Disconnect the connectors from the power window ECU.
2.Check the power supply circuit of the power window ECU and ground circuit.
(1) Vehicle harness side connector 14(+B1), 25 (+B2) of power window ECU -Battery (+)terminal.
(2) Vehicle harness side connector 5(IG) of power window ECU - Ignition switch (IG1) .
(3) Vehicle harness side connector 48(RE), 47(ECU E) of power window ECU - Body ground.
If it OK. ao to D5.
If it is NG, rewair the oower suowlv circuit and around circuit.
W5. CONTINUITY CHECK BETWEEN POWER WINDOW ECU - DRIVER'S SEAT POWER WINDOW
SWITCH
1.Disconnect the connectors from the power window ECU and driver's seat power window switch.
2.Check the harness between the power window ECU and the driver's seat power window switch.
(1) Vehicle harness side connector 27 of power window ECU - Vehicle harness side connector 4 of
driver's seat power window switch .
driver's seat power window switch.
driver's seat power window switch.
If it OK. ao to W6.
If it is NG. replace the harness. Also, reolace the connector.
W6.DRIVER SEAT SW UNIT CHECK

1.Perform the unit check of the driver's seat switch
Refer t o Page 13-16.
If it OK. ao to P7.
If NG, reolace the driver's seat switch.
W7. CONTINUITY CHECK BETWEEN POWER WINDOW ECU - DRIVER'S SEAT POWER WINDOW
SWITCH
1,Disconnect the connectors from the power window ECU and driver's seat power window motor.
2.Check the harness between the power window ECU and the driver's seat power window motor.
(1) Vehicle harness side connector 38 of power window- Vehicle harness side connector 4 of
driver's seat power window motor.
(2) Vehicle harness side connector 39 of power window- Vehicle harness side connector 1 of
driver's seat power window motor.
If it OK, ao to W8.
If it is NG, redace the harness. Also. reolace the connector.
V8. POWER WINDOW MOTOR OPERATION CHECK

1.Check the operating condition when a voltage of 12V is applied directly to the power window motor.
SPECIFIED VALUE: The motor should turn smoothly.
If OK. reolace the Dower window ECU.

D
3-7-2 POWER WINDOW AT THE FRONT PASSENGER SEAT WILL NOT OPERATE.
W 1 . CONFIRMATION OF DIAGNOSIS CODE OF ROOF SYSTEM
1.After setting the ig switch to "ON" position, confirm the diagnosis code of the roof system.
SPECIFIED VALUE: No abnormality code should be outputted.
If it is OK (Australia specifications). ao to W2.

If it is OK (EC soecifications), ao to W4.
If NG. Droceed to the trouble-shootina of the motor-driven o~eninalclosinaroof.
- 13-1 4
:
D2.CONTINUITY CHECK OF POWER WINDOW LOCK SWITCH
1.Disconnect the connectors from the w~ndowlock switch and power window ECU.
2.Check the harness between the window lock switch and the power window ECU.
(1) Vehicle harness side connector 5 of window lock switch-Vehicle harness side connector 37.
(2) Vehicle harness side connector 4 of window lock switch- lgnition switch (IG1).
If it OK. ao to W3.
the harness. Also. redace the connector.
D3.POWER WINDOW LOCK SWITCH UNlT CHECK

1.Perform the unit check of the window lock switch.
If it OK. ao to W4.
If it is NG, r e ~ l a c e
the Dower window lock switch.
%4.CONTINUIN CHECK THE POWER SUPPLY CIRCUIT OF POWER WINDOW ECU

1.Disconnect the connectors from the power window ECU.
2.Check the power supply circuit of the power window ECU and ground circuit.
(1) Vehicle harness side connector 14(+B1), 25 (+B2) of power window ECU -Battery (+)terminal
(2) Vehicle harness side connector 5(IG) of power window ECU - Ignition switch (IG1).
(3) Vehicle harness side connector 48(RE), 47(ECU E) of power window ECU - Body ground.
If it OK. oo to W5.
If it is NG. r e ~ a ithe
r Dower suoolv circuit and around circuit.
D5. CONTINUITY CHECK BETWEEN POWER WINDOW ECU - DRIVER'S SEAT POWER WINDOW
SWITCH
1.Disconnect the connectors from the power window ECU and passenger's seat power window switch.
2.Check the harness between the power window ECU and the passenger's seat power window switch.
passenger's seat power window switch.
If it OK. ao to W6.
If it is NG. reolace the harness. Also. re~lacethe connector.
W6.DRIVER SEAT SW UNlT CHECK

1.Check of the passenger's seat unit check
If it OK, ao to W7.
If NG, re~lacethe front oassenoer seat switch.
D7.CONTINUITY CHECK BETWEEN POWER WINDOW ECU - DRIVER'S SEAT POWER WINDOW
SWITCH
1.Disconnect the connectors from the power window ECU and passenger's seat power window motor.
2.Check the harness between the power window ECU and the passenger's seat power window motor.
(1) Vehicle harness side connector 13 of power window- Vehicle harness side connector 1 of front
passenger's seat power window motor.
(2) Vehicle harness side connector 26 of power window- Vehicle harness side connector 2 of front
passenger's seat power window motor.
If it OK. ao to W 8 .
If it is NG, replace the harness. Also, re~lace
the connector.
W 8 . POWER WINDOW MOTOR OPERATION CHECK

1.Check the operating condition when a voltage of 12V is applied directly to the power window motor.
SPECIFIED VALUE: The motor should turn smoothly.
If OK. reolace the Dower window ECU.

If NG, reolace the ~assenaer'sseat Dower window reaulator assemblv.
3-8 UNIT CHECK
3-8-1 POWER WINDOW LOCK SW
1.Check continuity between terminals of the switch
M:
Conlinuily should exist
Terminal No. @ @ @ @ @@ @@
1 I I I 1 I
Free
I I I I
CllB5080EL08
3-8-2 DRIVER'S SEAT POWER WINDOW SW

1Check continuity between terminals of the master SW.
: Continuity should e
@ 0 0
UP MANUAL **
I OFF
X
I DOWN MANUAL
DOWN AUTO o ' i ' o

Cl lB5078EL'
3-8-3 PASSENGER SEAT POWER WINDOW SW
1Check continuity between terminals of the switch.
Continuily should exist
Terminal No.
I
@
I
G
I
0
I
I I I
OFF I
1 I
DOWN 0
CllB5079EL08
13-1 7 -
3-8-4 REGULATOR MOTOR

(1) DRIVER'S SEAT REGULATOR MOTOR
1.Connect the battery terminals to the terminals @ and @
as shown in the table below. Confirm the rotating
direction.
2.Ensure that no abnormal noise nor shaft looseness or
warp are observed during the motor rotation.
CAUTION
Utmost care should be paid so that the terminals @
CllBJD76TlO
and @ of the battery are not shorted.
Motor rotating direction
Measuring condition
(As viewed from the pinion gear side)
BattervQ- 1
Right turn
~ermkal~
Left turn
Battery@-
Terminal0
(2) FRONT PASSENGER SEAT REGULATOR MOTOR

1.Connect the battery terminals to the terminals @ and @
as shown in the table below. Confirm the rotating
direction.
2.Ensure that no abnormal noise nor shaft looseness or
warp are observed during the motor rotation.
CAUTION
Utmost care should be paid so that the terminals @
- and @of the battery are not shorted. N1185101T10
Motor rotating direction
Measuring condition
Battery@-
Terminal@
Battery@-+
I Right turn
Terminal@
Battery@-
Terminal@
Left turn
Battery* ,
4 REAR QUARTER WINDOW
Lubricant.adhesive.others
IMP grease,Butyl tape

I.Remove the Center floor side member RHILH.

) COMPONENTS
I

1 a Weatherstrip, front door glass, outer
2 b Retainer, quarter trim, upper
v 3 c Regulator Ay, quarter window
A 4 d Glass SIA, rear door

(1) QUARTER WINDOW REGULATOR AY
1.Remove the bolt and nut at the position shown in the right
figure. Remove the quarter window regulator assembly
together with the rear door glass S/A.
4-1-5 POINTS OF INSTALLATION I
(1) REAR DOOR GLASS S/A(QUARTER WINDOW GLASS)
1.Temporarily tighten the rear door glass S/A to the quarter window regulator. Install the quarter window
regulator assembly to the vehicle.
2.Perform the alignment adjustment of the rear door glass S/A.
Refer to Page 11-7.

1.Install the center floor side member RHILH.
- - - -- -
1
5 QUARTER WINDOW REGULATOR



5-5 UNIT CHECK

6 OUTER REAR VIEW MIRROR
1.Remove the front door trim.
2.Remove the speaker Ay.

3.Turn over the front door service hole cover of the speaker installing hole,
) COMPONENTS
C:: Clip position

:<;,:Pawl position

v 1 a Cover, outer mirror
2 b Mirror SIA, outer rear view

(1) OUTER MIRROR COVER
>.Tilt the outer mirror halfway toward the vehicle rear side.
(Do not tilt it completely.)
2.Wrap a flat screwdriver with protective tape and insert it
into the cover cutout section to make the cover float
slightly.
C::Clip position
C1185122ETiO
, --\
13-22
3.lnsert a flat screwdriver into a gap created at the floated
cover, as shown in the right figure. Push the cover toward
the frontloutside of the vehicle to disengage the pawl.
4.lnsert a flat screwdriver into the cutout section of the
cover again and push the cover outward to disengage
the clip.
5.With the pawl of the vehicle front side cover disengaged

from the clip, slide the cover toward the vehicle rear side
to take it out.

1.Affix the front door service hole cover.
CAUTION
When the service hole cover is torn, replace it.
2.lnstall the speaker Ay.

3.lnstall the front door trim.

7 MIRROR SURFACE MOTOR-DRIVEN MOVABLE TYPE OUTER
REAR-VIEW MIRROR
Instrument
'-2 SYSTEM WIRING DIAGRAM

Outer mirror SW
O~eratinaSW
I
RighVleft I I
selection
switch \. b

, 7-4 LOCATION OF COMPONENTS
1 Part name 1 Part name

a /outer rear view mirror RH c 1 Outer rear view mirror LH
b louter mirror switch - -
7-5 UNIT CHECK
7-5-1 MIRROR SW
1 .While operating the switch, check continuity between
terminals.
RightLeft Switching SW Mirror operation
SW section 0-0:Continuity should exist
7-5-2 CHECK OF OPERATION OF ACTUATOR SECTION

1.Apply the battery voltage to each terminal. Check the
operation.
-
Down
0 ' I
i I ' 0
C7-c
I Left
Right
Cl lB5088EL12
i
8 INNER REAR VlEW MIRROR
(1) COMPONENTS
C1185216511

r 1 a Mirror Ay, inner rear view

(1) INNER REAR VlEW MIRROR Ay
1.Remove the inner rear-view mirror by turning the bottom
section 90 degrees.
14 DOOR LOCK & THEFT DETERRENT
IMPACT SENSING SAFETY SYSTEM -------- 14 - 1 TRANSPONDER KEY COMPUTER(

IMPACT SENSING SAFETY SYSTEM 14 - 1 lMMoBlLlzER E c u ) 14 - 42
ARTICLES TO BE PREPARED----------- 14 - 1 REMOVAL AND INSTALLATION-------- 14 - 42
SYSTEM WIRING DIAGRAM ------------- 14 - 1
TERMINALS 14 - 2
LOCATION OF COMPONENTS ---------- 14 - 3
BASIC CHECK 14 - 4
TO MALFUNCTION PHENOMENA------ 14 4
UNIT CHECK
-
14 - 7
ITC COMPUTER 14- 10
KEY-LESS ENTRY SYSTEM ------------------- 14-12
KEY-LESS ENTRY SYSTEM 14 - 12
ARTICLES TO BE PREPARED --------- 14 - 12
TERMINALS 14-13
REGISTRATION OF
IDENTIFICATION CODE------------------ 14- 15
TO MALFUNCTION PHENOMENA---- 14 - 15
UNIT CHECK 14 - 23
ITC COMPUTER 14 - 26
DOOR CONTROL RECEIVER 14 - 27
~MMOBILIZERSYSTEM -----------------me-----14 - 29
IMMOBILIZER SYSTEM ..................... 14 - 29
ARTICLES TO BE PREPARED 14 - 29
TERMINALS................................. 14 - 30
HOW TO PROCEED WITH
TROUBLE SHOOTING 14 - 31
INQUIRY ...................................... 14 - 32
DlAGNOSlS .................................. 14 - 32
TO DIAGNOSIS CODE.................... 14 - 35
UNIT CHECK 14 - 38
STEERING COLUMN WISWITCH
BRACKET--............................... 14 - 40
TRANSPONDER KEY COIL(
lMMOBlLlZER COIL) ......................... 14 - 41
14-1 -
IMPACT SENSING SAFETY SYSTEM

1 IMPACT SENSING SAFETY SYSTEM
SST
i
I
i
I
I
(09991-87401-000)
I
instrument
t
I
i
I
(voltage tester
iI
I
+B IG1 CRL CHR
ITC CU
14-2
TERMINAL NAME OF ITC COMPUTER CONNECTOR
-3 ARRANGEMENT OF VEHICLE HARNESS SIDE CONNECTOR--TERMINALS
The body integration controller

<Vehicle harness side>
n
Driver's seat control SW Passenger's seat door lock motor

Driver's seat door lock motor
code Sales name code Sales name

a Front turn lamp g Side turn lamp LH
b Side turn lamp RH h Front door lock motor LH
c ITC ECU i Courtesy switch LH
d Courtesy switch RH j RR turn lamp LH
e Front door lock motor LH k RR turn lamp RH
f Airbag unit - -
-- 14-4
1-5 BASIC CHECK
1-5-1 OUTLINE
By shorting the ECU T terminal of the diagnosis check connector, it is possible to check whether the
impact sensing signal outputted from the airbag ECU is normally outputted or not, and whether the door
lock system is abnormal or not.
1-5-2 PROCEDURE
1.With the IG switch set to ON position, short the ECU T
terminal and E terminal of the diagnosis check connector.
2.lf the impact sensing signal outputted from the airbag
ECU is normal, the hazard lamp flashes three times.
3.Release short circuit of the terminal T and finish the i
check.
<Diagnosis check connector>
I C1185198ETI(

1-6-1 MALFUNCTION OF POWER DOOR LOCK
(1) ALL DOORS ARE NOT LOCKED INTERLOCKINGWITH LOCK OPERATION AT DRIVER'S SEAT
G. VOLTAGE CHECK BETWEEN BODY INTEGRATION CONTROLLER (HEREINAFTER REFERRED
TO AS "ITC") AND BODY GROUND
1.Check the voltage between the vehicle harness side connector 19 (+B)of ITC ECU and the body
ground.
SPECIFIED VALUE: 12-14V (Battery voltage)
D2. CONFIRMATION OF POWER SUPPLY CIRCUIT OF ITC ECU

1.Check that the following sections exhibit no abnormality.
(1) Check the external appearance of the fuse (door lock) and fusible link for abnormality.
(2) Confirmation of battery voltage.
(3) Check the harness of the power supply system for abnormality, such as open wire.
D3. CONTINUITY CHECK OF ITC ECU GROUND SYSTEM
1.Disconnect the ITC ECU connector.
2.Check the harness between the ITC ECU and the body ground.
(1) Vehicle harness side connector 14 (El) of ITC ECU - Body ground.
If it is OK, ao to D4.
If it is NG, repair the around circuit.
W4. CHECK OF THE DRIVER'S SEAT DOOR CONTROL SWITCH UNlT CHECK
1.Conduct the unit check of the driver's seat door control switch.
Refer to Page 14-7.
If it is OK. ao to W5.
If it is NG, revlace the door control switch.
D5. CONTINUITY CHECK BETWEEN ITC ECU AND DOOR CONTROL SWITCH
1.Disconnect the connectors of the ITC ECU and door control switch.
2.Check the harness between the ITC ECU and the door control switch.
(1) Vehicle harness side connector 2(UKS) of ITC ECU - Vehicle harness side connector 2 of door
control switch.
(2) Vehicle harness side connector 6(LKS) of ITC ECU - Vehicle harness side connector 5 of door
control switch.
(3) Body ground - Vehicle harness side connector 1 of door control switch.
W6. VOLTAGE CHECK BETWEEN ITC ECU TERMINALS

1.Check the voltage between the ITC ECU terminals when the door control switch is operated.
(1) Vehicle harness side connector I 5 (LKM), 22 (ULM) of ITC ECU - All door lock motors.
SPECIFIED VALUE: Voltage of 12 to 14v. (Around 0.5 second.)
If it is NG, reolace ITC ECU.
D7.CHECK OF DOOR LOCK MOTOR UNlT CHECK

1.Check of all door lock motor unit check.
Refer to Page 14-7.
If it is NG. revlace door lock motor.
D8. REPAIR OR REPLACE THE HARNESS BETWEEN THE ITC ECU AND THE DOOR LOCK MOTOR
1.Repair or replace the harness and connector between the ITC ECU and each door lock motor.
(1) Vehicle harness side connector I 5 (LKM), 22 (ULM) of ITC ECU - All door lock motors.
-- 14-6
(2) SOME DOORS ARE NOT LOCKED INTERLOCKING WITH LOCK OPERATION AT DRIVER'S
SEAT
W1.DOOR LOCK MOTOR UNIT CHECK
1.Conduct the unit check of the door lock motor that IS not functlonlng.
Refer to Page 14-7.
If it is OK. r e ~ a ior
r reolace the harness and connector between the door lock motor and the ITC ECU
<15(LKM) and 22lULMb
If it is NG, replace the door lock motor.
(3) MALFUNCTION OF POWER SENSING SYSTEM
@ MALFUNCTION WHEN OPERATION IS CONFIRMED BY SHORTING T TERMINAL
W1. OPERATION CHECK AFTER POWER DOOR LOCK
1.Check the operation of the power door lock with the IG set to the "OFF' position.
SPECIFIED VALUE: The system should operate properly.
If it is NG. ~roceed to the trouble-shootina of malfunction of the Dower door lock.
W2. CHECK OF ROOM LAMP AND HAZARD LAMP FOR OPERATION

1.With the IG set to the 'OFF' position, operate the room lamp and hazard lamp. Check their lighting
state.
SPECIFIED VALUE: The room lamp: Illuminated
The hazard lamp: Flashing
If it is NG. ao to W3.
W3. OPERATION CHECK AFTER LAMP REPLACEMENT

1.After the lamp bulb that failed to illuminate or flash has been replaced, check its operation.
If it is OK. reolace the l a m .

If it is NG. check or re~air the fuses. hamesses and switches.
W4. OPERATION CONFIRMATION CHECK BY CONNECT TERMINAL T

1.Check to see if the procedure of 'operation check by connect terminal T" was correct.
If it is OK. re~lacethe ITC.
Refer to Page 14-4.
If it is NG. conduct "o~erationcheck bv connect terminal T" once more from the beainnina.
@ CERTAIN LAMPS FAIL TO OPERATE.
>I OPERATION
. CHECK OF ROOM LAMP AND HAZARD LAMP
1.With the IG switch set to the "OFF" position, turn "ON" the switch of the lamp that fails to operate.
Check to see if the lamp illuminates properly.
If it is OK, redace the ITC.

W2. OPERATION CHECK AFTER LAMP REPLACEMENT

?.After the lamp bulb that failed to illuminate or flash has
been replaced, check its operation.
If it is OK. reolace the larno bulb.
If it is NG. check or repair the fuses, harnesses and
switches.
1-7 UNIT CHECK
1-7-1 DRIVER'S SEAT DOOR CONTROL SWITCH,
DRIVER'S SEAT DOOR LOCK MOTOR
1.Check the door locking operation when the battery
voltage is applied to between the terminals of the lock
motor of all the doors.
2.Check continuity between the terminals of the driver's
seat door control switch.
Driver's Seat door control switch C-C Continuity should exist
Terminal No. E l @ @ @ @
Operating Lack BaneryO Batterm
direction
Unlock 0 1 0 BanervO Banerye
A11BS117ELO6
1-7-2 FRONT PASSENGER SEAT DOOR LOCK MOTOR

1.Check the door locking operation when the battery
voltage is applied to between the terminals of the door
lock motor.
FRONT PASSENGER SEAT DOOR LOCK MOTOR
Section 1 Terminal O I Terminal @
Door lock motor
Lock I Battery @ I Battery O
Unlock I Battery @ I Battery @
- -
1-7-3 ITC INPUTIOUTPUT SIGNAL CHECK

(1) CHECKING METHOD
1.With the SST, check the voltage, pulses and contlnu~tybetween the terminals.
SST 09842-97401-000
SPECIFIED VALUES FOR INPUTIOUTPUT SIGNALS
Door control switch
%: See the oscilloscope waveforms of the next paragraph.

(2) OSCILLOSCOPE WAVEFORMS
@ I
OUTLINE
Waveforms measured by the oscilloscope function of diagnosis tester (DS-21) are shown below as
reference.
Hazard lamp system waveform
1.Measuring terminals : OCHR-@ E l
2.Measuring conditions : Hazard switch D O N" 1:SIGl 1 0 V AUTO f1:SlGl
~. ...... ?i.s!.=?
. . . ....... ?:"..E."EL.f!.~.?~."
~ ~
3.Measuring range : 10V (Voltage axis), I S (Time axis)

@ AIRBAG ECU COMMUNICATION WAVE FORM
1.Measuring terminals : @CSI--@ E l
2.Measuring conditions : Ignition switch "ON"
3.Measuring range : 5V (Voltage axis), IS (Time axis)
-
14-1 0
2 ITC COMPUTER
CAUTION
Be careful not to drop the computer or give great impacts to it.
* If the computer dropped or was subjected to great impacts, replace it with a new one even if there is
no abnormality in its external appearance.

1.Disconnect battery negative terminal.
CAUTION
It should be noted that the memories of the computers (Engine control computer etc.) of other
systems or radio settings are erased at the same time when the battery negative terminal is
disconnected.

) COMPONENTS

1 a Box Ay, instrument panel
r 2 b Panel SIA, instrument cluster finish, center
3 c Relay Ay, door control

(1) INSTRUMENT CLUSTER FINISH CENTER PANEL S/A
14-1 1
2-1-4 INSPECTION
(1) COMPUTER EXTERNAL APPEARANCE CHECK
1.Replace the computer with a new one in the following cases.
(1) Case where the computer has deformation, abrasion, cracks or breakage.
CAUTION
Never disassemble the computer.

14-1 2
KEY-LESS ENTRY SYSTEM
1 KEY-LESS ENTRY SYSTEM
SST
09842-97401-000 Sub-harness, ITC computer check
Instrument
/Voltage tester
I I I
Fuse block I
+B IG1 CRL CHR KEY
ITC ECU
CONNECTOR TERMINAL NAME
RECEIVER CONNECTOR TERMINAL NAME

Terminal Terminal Terminal Terminal
Terminal name Terminal name
No. code No. code
1 GND l ~ r o u n d 4 - -
2 - - 5 +B Receiver power supply
3 SIG Key less signal - - -
1-3 ARRANGEMENT OF VEHICLE

- HARNESS SIDE CONNECTOR TERMINALS
I

<Vehicle harness side>
The body integration controller.
Receiver
Driver's seat control SW Passenger's seat door lock motor
code Sales name code Sales name

a Front turn lamp g Front door lock motor LH
b Side turn lamp RH h Courtesy switch LH
c ITC ECU i RR turn lamp LH
d Courtesy switch RH j RR turn lamp RH
e Front door lock motor RH k Receiver
f Side turn lamp LH - -
14-1 5
1-5 REGISTRATION OF IDENTIFICATION CODE
1-5-1 OUTLINE
l.lf the transmitter is lost or added, the registration of the identification code is required.
2.Up to two identification codes can be registered for the receiver, thus making it possible to use two
transmitters. When registering two transmitters, register them successively following the procedures
given below.
3.lf a new transmitter is registered, all the former identification codes registered in the receiver will be
erased.
4.The memory of the identification code will not be lost even if the battery is disconnected.
1-5-2 HOW TO REGISTER IDENTIFICATION CODE
CAUTION
disconnected.
(1) VEHCLE IN AN INITIAL REGISTRATION CONDITION

1.The initial condition refers to the condition that satisfies the following given below.
(1) No key is inserted into the key cylinder.
(2) The battery negative terminal or receiver connector is disconnected.
(2) INITIAL REGISTRATION METHOD OF TRANSMITTER
The following is the initial registration procedure for the transmitter.
1.Put the vehicle in an initial registration condition.
2.Connect the battery negative terminal or receiver connector. (Supply power to the receiver.)
3.Close all the doors.
4.Within 15 seconds after completion of the connection, keep pressing the UNLOCK switch and LOCK
switch of the transmitter simultaneously at least for five seconds.
5.As a response operation, an operation of LOCK and UNLOCK takes place automatically.
6.After receiving the response operation, within five seconds, keep pushing the UNLOCK switch or
LOCK switch of the transmitter to be registered at least one second.
7.As a response operation of the registration completion, an operation of LOCK and UNLOCK takes
place automatically.
CAUTION
When you want to register the second transmitter in succession, repeat the operations described in
Step 4 onward.

1-6-1 KEYLESS FUNCTION (REMOTE CONTROL) WILL NOT OPERATE (CASE WHERE THERE IS
NO NEW OR NORMAL TRANSMITTER OF THE SAME TYPE OF VEHICLE)
CAUTION
= It should be noted that the memories of the computers (Engine control computer etc.) of other
disconnected.
D l . VEHICLE CONDITIONS
1.Put the vehicle in an initial registration condition
- 14-1 6
D2. KEYLESS BASIC CHECK
1.Conduct the LOCK operation and UNLOCK operation consecutively at least three times as the
standard operation. Check the operation.
SPECIFIED VALUE: The operation takes place from the third time onward.
CAUTION
The standard operation refers to the procedure given below.
(1) Stand about one meter away in the right direction from the outside handle of the driver's seat.
(2) Direct the transmitter toward the vehicle. Keep pressing each switch for about one second.
W 3 . CHECK OF ANSWER BACK OPERATION

1.Set the room lamp switch to the door interlocking position.
2.Check the room lamp and hazard lamp for lighting state during the standard operation check.
<RefCode=Si04-0044>
SPECIFIED VALUE: OPERATION REQUIREMENTS OF ROOM LAMP AND HAZARD LAMP

--
Operat ng condllton Measuring point Anwer oack
-
Room lamp
At time of LOCK
Hazard lamp Flashes once
Illuminates for 15
Room lamp
AT TIME OF UNLOCK seconds
Hazard lamp Flashing two times
If it is OK. this section is normal.
-
NOTE
The operating distance varies, depending upon the person who operates, the way one holds and
place.
Since the electric wave used is vely weak, the operating distance can be shortened in the presence
of strong electric waves or noises in the frequency used.
-4. CHECK OF LAMP FOR OPERATION

?.Check the room lamp and hazard lamp for lighting state when they are operated
If it is NG, check the bulbs of the room lamp and hazard larno. fuse and harness.
- ~ ~ ~~~ ~~ ~
i
D5.CONTINUITY CHECK BETWEEN LAMPS, ETC. AND ITC
1.Disconnect the connectors of the room lamp, hazard lamp and ITC.
2.Check the harness between the room lamp and the ITC ECU and the harness between the hazard
lamp and the ITC ECU.
If it is OK. re~lacethe ITC.

If it is NG. re~lacethe harness and connector.
D6. OPERATION CHECK OF TRANSMITTER

1.Check to see if the transmitter is functioning as follows when the keyless basic check of the
transmitter is carried out.
(1) The transmitter operates only first or second times. However, it fails to operate at the third time
onward.
(2) Afterward, when the transmitter is left for a little while, there are cases where the transmitter starts
to operate again.
SPECIFIED VALUE: The transmitter shall not function as described above.
If it is OK. ao to -7.
D7.REPLACEMENT OF TRANSMITER BATTERY

1.After the transmitter battery has been replaced, conduct the keyless basic function check. Confirm
that the transmitter functions properly.
If it is OK. re~lacethe batterv.

D8.PUT THE VEHICLE IN AN INITIAL REGISTRATION CONDITION

?.Put the vehicle in an initial registration condition.
D9.OPERATION CHECK OF TRANSMITER REGISTRATION FUNCTION

1.Change the receiver to the registration mode by conducting the following operations given below.
(1) Disconnect the battery negative terminal or the receiver connector.
(2) Connect the disconnected battery negative terminal or receiver connector.
(3) Close all the doors.
(4) Within 15 seconds after completion of the connection, keep pressing the UNLOCK switch and
LOCK switch of the transmitter simultaneously at least for five seconds.
Go to D10.
--
14-1 8
W 1 0 . OPERATION CONFIRMATION AFTER CHANGE TO THE REGISTRATION MODE HAS BEEN
MADE
1.After the receiver has been changed to the registration mode, check to see if the door lock motor
exhibits a response operation.
SPECIFIED VALUE: The change from LOCK to UNLOCK takes place.
If it is OK. ao to W 1 2 .
If itis NG. aoto W11.
W 1 1 . CONFIRMATION OF REGISTRATION MODE PROCEDURE

1.Confirm the procedure by which the receiver is changed to the registration mode.
SPECIFIED VALUE: Change the receiver to the registration mode according to the correct procedure.
If it is OK. proceed to S 1 4 .
If it is NG, ao to S O .
W 1 2 . CONFIRMATION OF OPERATION OF REGISTRATION COMPLETION

1.After a response operation for the registration mode change, within five seconds, keep pressing the
UNLOCK switch or the LOCK switch at least one second. Check to see if there is a response
operation of the door lock motor.
If it is OK. ao to W 1 3 .
If it is NG. re~lace the receiver.
W 1 3 . KEYLESS OPERATION CHECK

1.Conduct the keyless operation check. Check that the operation takes place.
If it is OK. this section is normal.

If it is NG. redace the receiver.
D14. CHECK OF RECEVER CONDITION
1.Conduct the continuity check and voltage check between each terminal of the receiver vehicle
harness side connector and the body ground.
RECEIVER TERMINAL NAME AND CHECK REQUIREMENTS
Terminal Check
Check conditions Standard
No. items
1 Continuity Body ground and short Continuity exists
* terminal
visual confirmation Is a blank terminal.
(1) Waveform at the time when the "LOCK" switch of the transmitter is Refer to the keyless signal
1 / pressed
/(2)Waveform at the time when the ZiNLOCK. switch of the transmitter
lis pressed
system waveform
[Refer to the keyless signal
Jsystemwaveform
I
5
1
/
used [visual confirmation
terminal
Voltage l ~ a i t evoltage
r~ check
Is a blank terminal.
tall times 10-16V
NOTE
For the connector shape of the receiver, refer to the vehicle harness side connector terminal
For the keyless signal system waveform, refer to the unit check.
Refer to Page 14-13
If it is OK. replace the receiver or the transmitter.

If it is NG. replace the vehicle side harness or connector. or replace the ITC ECU.
1-6-2 KEYLESS FUNCTION (REMOTE CONTROL) WILL NOT OPERATE (CASE WHERE THERE IS
NEW OR NORMAL TRANSMITTER)
CAUTION
disconnected.
D l . VEHICLE CONDITIONS
-. 14-20
W2. KEYLESS BASIC CHECK
1.Conduct the LOCK operation and UNLOCK operation consecutively at least three times as the
standard operation. Check the operation.
CAUTION
The standard operation refers to the procedure given below.
(1) Stand about one meter away in the right direction from the outside handle of the driver's seat.
(2) Direct the transmitter toward the vehicle. Keep pressing each switch for about one second.
W3.CHECK OF ANSWER BACK OPERATION

1.Set the room lamp switch to the door interlocking position.
2.Check the room lamp and hazard lamp for lighting state during the standard operation check.
SPECIFIED VALUE: OPERATION REQUIREMENTS OF ROOM LAMP AND HAZARD LAMP

Operating condition
At time of LOCK
ATTIME OF UNLOCK
I Measuring point
Room lamp
Hazard lamp
Room lamp
I Answer back
-
Flashes once
Illuminatesfor
15 seconds
1
Hazard lamp / Flashing two times
If it is OK, this section is normal.

NOTE
The operating distance varies, depending upon the person who operates, the way one holds and
place.
Since the electric wave used is very weak, the operating distance can be shortened in the presence
of strong electric waves or noises in the frequency used.
If it is NG. ao to m4.
W4. CHECK OF LAMP FOR OPERATION

1.Check the room lamp and hazard lamp for lighting state when they are operated.
If it is NG, check the bulbs of the room lamw and hazard lamw, fuse and harness.
W5. CONTINUITY CHECK BETWEEN LAMPS, ETC. AND ITC

1.Disconnect the connectors of the room lamp, hazard lamp and ITC ECU.
2.Check of between room lamp and ITC ECU, hazard lamp and ITC ECU.
If it is OK. rewlace the ITC.

If it is NG, rewlace the harness and connector.
14-21
D6.OPERATION CHECK OF TRANSMITTER
1.Check to see if the transmitter is functioning as follows when the keyless basic check of the
transmitter is carried out.
(1) The transmitter operates only first or second times. However, it fails to operate at the third time
onward.
(2) Afterward, when the transmitter is left for a little while, there are cases where the transmitter starts
to operate again.
SPECIFIED VALUE: The transmitter shall not function as described above.
W 7 . REPLACEMENT OF TRANSMITER BAlTERY

1.After the transmitter battery has been replaced, conduct the keyless basic function check. Confirm
that the transmitter functions properly.
If it is OK. re~lace the battew.

D8.PUT THE VEHICLE IN AN INITIAL REGISTRATION CONDITION.

D9.OPERATION CHECK OF TRANSMITER REGISTRATION FUNCTION

1.Change the receiver to the registration mode by conducting the following operations given below.
CAUTION
As for the transmitter, use another one that can function normally.
(1) Disconnect the battery negative terminal or the receiver connector.

(2) Connect the disconnected battery negative terminal or receiver connector.
(3) Close all the doors.
(4) Within 15 seconds after completion of the connection, keep pressing the UNLOCK switch and
LOCK switch of the transmitter simultaneously at least for five seconds.
Go to DO.
D10.OPERATION CONFIRMATION AFTER CHANGE TO THE REGISTRATION MODE HAS BEEN

MADE
IfitisNG.aoto*ll.
- 14-22
W11. CONFIRMATION OF REGISTRATION MODE PROCEDURE
1.Confirm that the procedure whereby the receiver is changed to the registration mode was correct.
SPECIFIED VALUE: The procedure where by the receiver is changed to the registrationmode was
correct.
If it is NG, ao to D O .
W12. CANCELING REGISTRATION MODE

1.Cancel the registration mode.
CAUTION
Canceling method: Do not press the button of the transmitter for five seconds or more.
Go to D O .
W13. TRANSMllTER CHECK BY REGISTRATION MODE

CAUTION
As for the transmitter, use the one that did not function.
The changing method to the registration mode is the same as step 9.
D14. OPERATION CONFIRMATION AFTER CHANGE HAS BEEN MADE TO REGISTRATION MODE
D15. CONFIRMATION OF REGISTRATION MODE PROCEDURE

1.Confirmthat the procedure whereby the receiver is changed to the registration mode was correct.
SPECIFIED VALUE: The procedure where by the receiver is changed to the registration mode was
correct.
If it is OK, re~lacethe transmitter.

If it is NG, ao to WO.
D16. CONFIRMATION OF OPERATION AFTER REGISTRATION COMPLETION

1.After a response operation for the registration mode change, within five seconds, keep pressing the
UNLOCK switch or the LOCK switch at least one second. Check to see if there is a response
operation of the door lock motor.
If it is NG. reolace the receiver.
D17. KEYLESS OPERATION CHECK
1.Conduct the keyless operation check. Check that the operation takes place

If it is NG. re~lace the receiver.
D18. CHECK OF RECEVER CONDITION

1.Conduct the continuity check and voltage check between each terminal of the receiver vehicle
harness side connector and the body ground.
RECEIVER TERMINAL NAME AND CHECK REQUIREMENTS
Terminal
Check items Check conditions Standard
No.
1 I
Continuity I B Oground
~ ~ and short I Continuity exists
2 / wed lvisuai confirmation
terminal
Is a blank terminal.
I(1) Waveform at the time when the 'LOCK' switch of the transmitter i s l ~ e f eto
r the keyless signal
1 3 1 Signal 1
pressed Isystem waveform
(2) Waveform at the time when the "UNLOCK"switch of the transmit- /Refer to the kevless sianal -
Jteris pressed \systemwaveform
Not used
4 Visual confirmation is a blank terminal.
terminal
5 I Voltage IBattery voltage check IA~
all times 10-16V
NOTE
For the connector shape of the receiver, refer to the vehicle harness side connector terminal
For the keyless signal system waveform, refer to the unit check.
If it is OK. re~lacethe receiver.

If it is NG. re~lacethe vehicle side harness or connector, or reolace the ITC ECU.
1-7 UNIT CHECK
SST
Shape Part No. Part name 1
09842-97401-000 Sub-harness, ITC computer check
1-7-2 ITC AND KEY LESS RECEVER INPUTIOUTPUT SIGNAL CHECK

(1) CHECKING METHOD
1.Check the voltage, pulses and continuity between the terminals, using the SST
SST 09842-97401-000
!
(2) INPUTIOUTPUT SIGNAL CHECK
ITC SPECIFIED FOR INPUT/OUTPUT SIGNALS
Reference
value
Check system Terminal ( Example
Of
I 1 I I I measured I
Door lock motor
Door control switch
All doors 'OPEN' at all time
All doors "PEN' at all time
+%: See the oscilloscope waveforms of the next paragraph.

RECEIVER INPUTIOUTPUT SIGNAL SPECIFICATION
i Reference
value
Check system Terminal ( Example
Of
measured
-- value)
Power supply @(+B)-@(GND) At all times Battery voltage 12.W
When keyless operation is not being
About 5V 5V
done
Key less signal @(SIG)-@(GND)
When 'LOCK" is operated Pulse generation X
'UNLOCK' is operated Pulse generation X
Ground Continuity
@(GND)-body ground At all times Continuity exists
exists
%: See the oscilloscope waveforms of the next paragraph.
(3) OSCILLOSCOPE WAVEFORMS
@ OUTLINE
Waveforms measured by the oscilloscope function of diagnosis tester (DS-21) are shown below as
reference.
@ HAZARD LAMP SYSTEM WAVEFORM
1 .Measuring terminals : @CHR-@I E l 1:SIGl IOV AUTO 7l:SIG
.............................................................
2:SIG2 1VLEVEL-I-10.15V
. .. .. .. .. .. .. .. .. .. .. .. ..
2.Measuring conditions : Hazard switch "ON"
3.Measuring range : 10V (Voltage axis), I S (~imeaxii) .. .. .. .. .. .. ... ... ... ... ... ... ...
...............................................................
. ... ... ... ... ... ... ... ... ... ... ... ...
... .... .... .... .... .... .... .... .... .... .... .... ....
............................................................
pk .... :....:....:..-.:.... :....:.... :.... :.... ;....:.........
... ... ... ... ... ... ... ... ... ... ... .... ....
...............................................................
. ... ... ... ... ... ... ... ... ... ... ... ...
. .. .. .. .. .. .. .. .. .. .. .. ..
............................................................
............................................................
@ KEYLESS SIGNAL SYSTEM WAVEFORM

1.Measuring terminals : OSIG-@ El
2.Measuring condition: When "LOCK' is operated
3.Measuring range : 2V (Voltage axis), 50ms (Time axis)
4.Measuring terminals : OSIG-@I El

0:SIGl 2V SINGL 11:SIGl
5.Measurement condition: 'UNLOCK' has been operated
... ............?.I.?!..?...? ... .......
HOLD . .1V..CEVE.L,.+0?,:02V
. . . . . .
Measuring range : 2V (Voltage axis), 50ms (Time axis) .. .. .. .. .. .... .... .... .... .... .... .... ....
............................................................
.. .. .. .. .. .. .. .. .. .. .. .. ..
............................................................
.. .. ., ..
... ... ... ...
..............................................................
. ... ... ... ... ... ... .... .... .... .... .... ....
... ... ... ... ... ... ... ... ... ... ... ... ...
............................................................
. . . . . . . . . . . .
............................................................ .
-- 14-26
2 ITC COMPUTER
Refer to Page 14-10
3 DOOR CONTROL RECEIVER
3.Remove the wind deflector board.

4.Remove roll over bar.


) COMPONENTS

1 a Trim Ay, back panel
2 b Panel, quarter trim upper, RHILH
3 c Panel, quarter trim, RHILH
4 d Trim, back panel
5 e Receiver, door control
-
14-28
1.Install the roll over bar.
2.lnstall the wind deflector board.



5,Register the identification code. (Only when receiver is replaced.)
$Jj=~I
14-29
IMMOBILIZER SYSTEM
1 IMMOBILIZER SYSTEM
SST
/ 09991-87403-000 Wire, dlagnosls check
09991-97201-000
Lamp, diagnosis check
(09991-87211-000)
Instrument
r~oltagetester
.2 SYSTEM WIRING DIAGRAM
Main
Fuse block
EYLi
Check connector 2
<
rn
I.
i
5
lmmobilizer ECU
GND Engine control computer
52'
g Twist pair iead
I
Immobilizer coii
TERMINAL NAME OF IMMOBILIZER COMPUTER CONNECTOR

Terminal Terminal Terminal Terminal
Terminal name Terminal name
No. code No. code
1 +B ECU power supply 6 T Diagnostic tester communication
- 2 KSW Key switch 7 S102 Immobilizer communication
3 COIL+ Transponder communication 8 SlOl Diagnostic tester communication
4 GND Ground 9 COIL- Transponder communication
5 1 IG Ignition switch power supply 10 W Diagnostic tester communication
I Immobilizer ECU
<Vehicle hamess side>
Immobilizer ECU
code
- code Part name
a Steering column upper Wlswitch bracket 1 d Master key (Grip section 'black')
b Immobilizer ECU / e Sub key (Grip section 'gray")
r FFI FCI i I - -
14-31 -
1
1.The immobilizer system is equipped with a diagnosis function which diagnoses malfunctioning
sections and gives important clues in the trouble shooting.
2.The diagnosis function of the immobilizer system is equipped with the battery backup. (Which keeps
supplying power for diagnosis memory even when the ignition switch is set to LOCK position.)
(Bringing-in of malfunctioning vehicle)
Diagnosis through inquiries

I
onfirmation and recording of diagnosis cod

I
Reproduction and confirmation of malfunction phenomenon

I
4
Confirmation test
Has the vehicle been restored to the normal condition?
\
NO YES
/'
(- End 1
.- .
1-6 INQUIRY
I.In an effort to remove causes for malfunction from the vehicle concerned, it is impossible to determine
the cause without confirming the malfunction phenomenon. If the phenomenon is not confirmed, the
vehicle may not be able to return to the normal conditions even if you continue your work. The
diagnosis through inquiries is to collect information from the customer before confirming the
malfunction phenomena. The diagnosis through inquiries provides very important clues in
reproducing malfunction phenomena.
2.Since the information obtained by the diagnosis through inquiries is referred to during the trouble
shooting, it is imperative to make an inquiry of the customer, centering on the items related to the
malfunction, instead of simply asking general questions.
1-7 DIAGNOSIS
1-7-1 OUTLINE
1.When the diagnosis code is indicated, confirm whether the malfunction took place sometimes in the
reproduced malfunction. For this purpose, the diagnosis code should be indicated twice, namely
before and after the confirmation of the phenomena.
1.Connect the SST to between the terminal BAT+ and terminal W of the diagnosis check connector
Located under the instrument panel. Connect the terminal €CUT and terminal E and start the
diagnosis check mode. The SST lamp will flash, thus indicating the diagnosis code.
SST 09991-87403-000
09991-97201-000
2.All the diagnosis codes memorized are shown repeatedly in the sequence of diagnosis number,
starting from the smallest number.
CAUTION
The SST lamp section uses a light emitting diode. Therefore, connect the "red" wire of the SST to
the terminal "BAT" of the diagnosis check connector; the "black" wire of the SST to the terminal "W"
of the connector.
BAT ECUT W
SST(BATTerminal8 WTerminaI)
Shoned(ECUT terminal 8 E terminal)
Normal code Abnannality cade(No.21.31)
2sw
OFF
J
- LpJ
P,"SW
OFF
Illuminated illuminated
SST LED SST LED
Extinguished Extinguished
Initial exlinguishinotime Code 21 Code 31 Remated extinauishina

1.When the section which is responsible for the malfunction code has been checked and repaired,
erase the memory, following the procedure given below. After the erasure, let the diagnosis code be
outputted again and confirm that the normal code is outputted.
CAUTION
The code No.12 will be erased even when the normal main key (Registered main key) is used.
The diagnosis codes No. 23 and No. 31 are not memorized.
~ ~
(1) ERASURE BY DISCONNECTING EFI FUSE

1.The memorized diagnosis code can be erased by setting the ignition knob to the "LOCK" position and
disconnecting the "hazard fuse' for at least 30 seconds.
NOTE
The "hazard fuse" is located inside the engine compartment (Relay box).
The codes can be erased usually in about 30 seconds, but in some cases it may take more than 30
seconds.
CAUTION
systems or radio settings are erased at the same time when the battery negative terminal of the
battery is disconnected.

CONTENTS OF DIAGNOSIS
Code No.
Diagnosis items Diagnosis contents
2 digits 1 4 digits
Cases where there is no reply from the key after the
12 82796 Key or immobilizer coil faulty
immobilizer coil has been energized.
Cases where an unregistered key is used to
21 B2795 ID code of key unmatched.
operate the system.
Cases where no key has been registered in the
23 82787 ID code of key unregistered
immobilizer ECU.
Cases where the terminal T is "OFF' or the sub-key
31 82790 Abnormality of regislration mode
is inputted.
When the code collation has revealed that the code
41 82788 Faultv communication with EFI ECU @I is unmatched durina - the communication with the
/EFI ECU.
Cases where there is no reply during the
42 82789 Faulty communication with EFI ECU @
communication with the EFI ECU.
1-8 TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODE
1-81 DIAGNOSIS CODE N0.12
(1) CHECKING POINTS
1.Is immobilizer coil normal?
2.Are the harness and connector between the immobilizer coil and the immobilizer ECU normal?
(2) CHECKING METHOD
Dl. HARNESS CONTINUITY CHECK BETWEEN IMMOBILIZER COIL-IMMOBILIZER ECU
1.Disconnect the connectors of the immobilizer coil and immobilizer ECU.
2.Check the harness between the immobilizer coil and the immobilizer ECU.
(1) Vehicle harness side connector 1 of immobilizer coil - Vehicle harness side connector 3
(COIL+) of immobilizer ECU.
(2) Vehicle harness side connector 2 of immobilizer coil - Vehicle harness side connector 9(COIL-)
of immobilizer ECU.
If it is NG. replace the harness and connector.
2.1MMOBILIZER COIL UNIT CHECK

If it is NG, reolace the trans~onderkev coil.
D3. OPERATION CHECK BY OTHER KEY

1.Check the operation by the master key or another sub key.
If it is OK. oerform the kev reolacement and re-reaistration.

If it is NG. re~lacethe transoonder kev coil.
1-8-2 DIAGNOSIS CODE N0.21
(1) CHECKING POINTS
1.Is the registered key use?
(2) CHECKING METHOD
W1. OPERATION CHECK BY THE MASTER KEY
1.Check to see if the engine can start by the master key.
SPECIFIED VALUE: The engine can start.
If it is OK. oerform the kev re-registration.

NOTE
The ID code of the key used has not been registered yet.
W2. CHECK OF KEY USE CONDITIONS

1.Check to see if the key is used in a wrong way.
SPECIFIED VALUE: Do not use the keys in an overlapped state. Use the key correctly.
If it is OK. reolace the immobilizer ECU. Then, oroceed to W3.

If it is NG. use the kev correctlv.
B3.CHECK OF IMMOBILIZER ECU OPERATION

1.After the key ID code has been registered on the immobilizer ECU, check that the system functions
normally.
If it is OK, this comoletes the check.

If it is NG. reolace the trans~onderkev coil.
(1) CHECKING POINTS
1.Is the registered key use?
2.Are the harness and connector between the immobilizer coil and the immobiiizer ECU normal?
(2) CHECKING METHOD
W1. OPERATION CHECK BY RE-REGISTRATIONOF KEY ID CODE
1.Check the operation after the ID code of the master key and sub key has been re-registered.
If it is OK, this com~letesthe check.

If it is NG. ao to -2.
W2.CONTINUITY CHECK BETWEEN 1MMOBlLlZER COIL AND IMMOBILIZER ECU

1.Disconnect the connectors of the immobilizer coil and immobiiizer ECU.
2.Check the harness between the immobilizer coil and the immobilizer ECU.
(1) Vehicle harness side connector 1 of immobilizer coil - Vehicle harness side connector 3
(COIL+) of immobilizer ECU.
(2) Vehicle harness side connector 2 of immobilizer coil -
Vehicle harness side connector 3
(COIL-) of immobilizer ECU.
If it is OK. oroceed to W3.

If it is NG, replace the harness and connector.
W3. OPERATION CHECK BY NORMAL KEY

1.Check the operating state when another normal key is used
If it is OK. perform the kev reolacement and re-reaistration of the kev ID code.
If it is NG. reolace the immobilizer ECU. Then. proceed toW4.
W4. CHECK OF IMMOBILIZER ECU OPERATION

1.After the key ID code has been registered on the immobilizer ECU, check that the system functions
normally.
If it is OK. this completes the check.

If it is NG, replace the transponder kev coil.
---
14-38
. .
i
1.There is a problem in the key registration. Redo the registrationfrom the beginning.
1-8-5 DIAGNOSIS CODE N0.41,42
(1) CHECKING POINTS
1.Are the harness and connector between the EFI ECU and the immobilizer ECU normal?
(2) CHECKING METHOD
% I . CONTINUITY CHECK BETWEEN EFI ECU AND IMMOBILIZER ECU
1.Disconnect the connectors of the EFI ECU and immobilizer ECU.
2.Check the harness between the EFI ECU and the immobilizer ECU.
(1) Vehicle harness side connector 7 (902) of EFI ECU - Vehicle harness side connector 7 of
immobilizer ECU.
If it is OK, reolace the immobilizer ECU. Then. ~roceed

to B2.
If it is NG. reolace the harness and connector.
W2. CHECK OF IMMOBILIZER ECU OPERATION

1.After the key ID code has been registered on the immobilizer ECU,check that the system functions
normally.
If it is OK, this comoletes the check.

If it is NG. replace EFI ECU.
1-9 UNIT CHECK
1-9-1 STEERING COLUMN UPPER WISWITCH BRACKET Ay
(1) KEY INSERTION SWITCH
1.At the LOCK position of the ignition switch, insert and pull out the key to check continuity between the
terminals.
I
Connector color(black)
Ci186512ET1,
KEY SW CONTINUITY TABLE
Lock cylinder
Key not inserted I No continuity exists
Key inserted I Continuity exists
(2) IMMOBILIZER COIL
1.Check continuity between the terminals @ and 0.
(Connector color: white)
CAUTION
Even if continuity exists, no judgment can be made
about whether the coil is normal or not.
Connector color (white)
-- 14-40
2 STEERING COLUMN WISWITCH BRACKET
Refer to Page G1-4.
3 TRANSPONDER KEY COIL( IMMOBILIZER COIL)
CAUTION
disconnected.

) COMPONENTS
L
1 a Panel, instrument panel finish, lower
2 b Cover, steering column lower
3 c Cover, steering column upper
4 d Coil, transponder key

:
4 TRANSPONDER KEY COMPUTER( IMMOBILIZER ECU)
CAUTION
systems or radio settings are erased at the same time when the battely negative terminal is
disconnected.

(1) COMPONENTS

1 a Panel Ay, instrument cluster finish
2 b Meter Ay, combination
3 c Computer Ay, transponder key
CAUTION
If the computer dropped or was subjected to great impacts, replace it with a new one even if there is
4-1-3 INSPECTION
CAUTION
Never disassemble the computer.
14-43 d
i
2.When the computer has been replaced with a new one, perform the ID code registration for the
master key and sub key.
ACTIVE TOP (MOTOR DRIVEN
OPENING ROOF) 15 - 1
ROOF PANEL ................................... 15 - 1
REMOVAL AND INSTALLATION
BACK PANEL
--------- 15 - 1
15 - 3
REMOVABLE ROOF HINGE (ROOF
LINK) 15 - 5
LUGGAGE COMPARTMENT DOOR
HINGE(LUGGAGE LINK)...................... 15 - 7
DISASSEMBLING AND
ASSEMBLING 15 - 7
BACK DOOR LOCK ACTUATOR (SIDE
LATCH) 15-14
REMOVAL AND INSTALLATION------15 - 14
ROOF LOCK 15- 16
LIMIT SWITCH AY(0PENING COVER
sw AY) 15 - 17
LIMIT SWITCH AY(LUGGAGE
PARTITION sw ~ y ) 15- 18
REMOVAL AND INSTALLATION----- 15 - 18
METAL TOP ROOF CONTROL
COMPUTER AY(P0WER WINDOW
ECU) 15-19
METAL TOP ROOF CONTROL
COMPUTER AY(RO0F ECU) ------------- 15 - 20
CONTROL SYSTEM 15 21 -
ARTICLES TO BE PREPARED --------- 15 - 21
CONTROL SYSTEM ....................... 15 - 21
SYSTEM WIRING DIAGRAM------------15 - 35
TERMINALS............................... 15 - 38
HOW TO PROCEED WITH
TROUBLE SHOOTING.................... 15 - 43
DIAGNOSIS 15 - 45
FAIL-SAFE FUNCTION.................... 15 - 48
TO DIAGNOSIS CODE.................... 15 - 49
UNIT CHECK................................. 15 - 96
ACTIVE TOP (MOTOR DRIVEN OPENING ROOF)
1 ROOF PANEL
1.Remove the roof headlining.

) COMPONENTS

r A 1 a Panel SIA, removable roof
2 b Molding SIA, removable roof, FR RHILH
- ~-
i
(1) REMOVABLE ROOF PANEL RHILH
1.Remove the bolts shown in the right-hand illustration to
remove the roof panel. (both RH and LH)
WARNING
Be careful not to allow your finger to be caught by the
link.
CAUTION
Do not remove the back panel and the roof link at a
time.
(1) REMOVABLE ROOF PANEL SIA
After installing the roof panel, perform the alignment adjustment of the roof panel.

1.lnstall the roof headlining.
15-3
2 BACK PANEL
1.Remove the roof side inner garnish RHJLH.

(1) COMPONENTS
1

r A 1 a Panel S/A, back
2 b Molding S/A, roof drip side finish, RR RH/LH
15-4
I
(1) BACK PANEL SIA
1.Remove the bolts shown in the right-hand illustration to
remove the back panel. (both RH and LH)
WARNING
link.
CAUTION
Do not remove the roof panel and roof link at the same
time.
(1) BACK PANEL SIA
After the back panel is installed, adjust the alignment of the back panel.

Install the roof side inner garnish RHILH.
3 REMOVABLE ROOF HINGE (ROOF LINK)
1.Remove the quarter trrm panel RHILH.
2.Remove the center floor side member RHILH.

3.Remove the hydraulic cylinder

Refer to Page 15-7.

) COMPONENTS
a

r A 1 a Hinge, removable roof RHILH
2 b Shim body mounting
\
( I ) REMOVABLE ROOF HINGE RWLH (ROOF LINK)
?.Remove the bolts that tighten the roof panel to the
removable roof hinge.
3.Remove the coupler of the defogger harness and remove

the bolts shown in the right-hand illustration to remove
the removable roof hinge.
CAUTION
Do not remove the removable roof hinges RH and LH
at a time. When removing both hinges RH and LH,
install either side of the hinge to adjust alignment and
remove the other side of the removable roof hinge.

(1) REMOVABLE ROOF HINGE RHILH (ROOF LINK)
1.Adjust the removable roof hinge so that the attaching bolt may come at the center of the removable
roof hinge installation hole (at the three positions), and temporarily tighten them.
2.After installing the removable roof hinge, adjust the alignment of the roof panel and back panel.

1.lnstall the hydraulic cylinder.
Refer to Page 15-7.

3.lnstall the quarter trim panel RHILH.

I
4 LUGGAGE COMPARTMENT DOOR HINGE(LUGGAGE LINK)
CAUTION
It should be noted that the memories of the computers (engine control computer etc.) of other
systems or radio settings are erased at the same time when the battely negative terminal is
disconnected.
2.Remove the tonneau cover holder RH/LH.(luggage partition holder RHILH)

3.Remove the tonneau cover Ay.(luggage partition)

4.Rernove the luggage compartment cover RHILH.

5.Remove the back door lock actuator.(side latch)
6.Remove the luggage compartment door panel.

WARNING
Be careful not to allow your finger to be caught by the link.
) COMPONENTS
L
r 1 a Cover luggage compartment door hinge, RHILH r A 7 g Striker Ay, luggage compartment door
r 2 b Stay Ay, removable roof. RHILH r A 8 h Cushion, luggage compartment door
r A 3 c Power supply Ay 9 i Cushion, luggage compartment door,No.2
r 4 d Stay Ay, luggage door r A 10 j Hinge Ay, luggage compartment door
5 e Switch, luggage door closer r A 11 j Hinge Ay, luggage compartment door
6 f Switch, luggage lock closer
(1) LUGGAGE COMPARTMENT DOOR HINGE COVER
1.Remove the screws [seven locations] shown in the right.
hand illustration to remove the luggage door hinge cover.
(2) REMOVABLE ROOF STAY AY

1.Remove the mounting bolts [two locations] to the center
floor side member.
2.Remove the E-ring shown in the right-hand illustration to

remove the removable roof stay cable and then remove
the removable roof stay Ay.
(3) POWER SUPPLY AY

I.Use a flat screwdriver to slide up the back door stay
plate, located at upper end of the roof hydraulic cylinder.
Roof hydraulic cyli
2.Use a flat screwdriver to pry the lower end of the roof

hydraulic cylinder to disengage from the roof link and I
remove the roof hydraulic cylinder.
CAUTION
Care should be taken not to bend the hydraulic hose. 1
- 15-1 0
i
3.Pull the sliding hook shown in the right-hand illustration to
the rearward of the vehicle to disengage from the pin and
remove the sliding hook.
CAUTION
When the sliding hook is removed while the side latch
is uninstalled, the luggage link can be opened both in
front and to the rear. If the luggage link is moved in this
condition, the link might be disassembled or damaged.
Therefore, care should be take.
4.Cut off the harness band to remove the luggage hydraulic
cylinder from the luggage door hinge.
5.Remove the harness coupler to remove the hydraulic
pump mounting bolts [three locations] and remove the
power supply Ay.
CAUTION
Care should be taken not to bend the hydraulic hose.
(4) LUGGAGE DOOR STAY AY
1.Use a flat screwdriver to pry the luggage door stay plate,
located at both ends of the luggage door stay and
remove the luggage door stay Ay.
(5) LUGGAGE COMPARTMENT DOOR STRIKER

CAUTION
= Do not remove the luggage compartment door striker or loosen the mounting nut unless the striker
unit is to be replaced.
(6) LUGGAGE COMPARTMENT DOOR CUSHION

CAUTION
Do not remove the luggage compartment door cushion or loosen the mounting nut unless the
cushion unit is to be replaced.
(7) LUGGAGE COMPARTMENT DOOR HINGE AY

(LUGGAGE LINK)
1.Remove the bolts [three locations] shown in the right-
hand illustration to remove the luggage compartment
door hinge Ay.
WARNING
link.
CAUTION
* Now the luggage link can be opened both in front and
to the rear. If the luggage link is moved in this
condition, the link might be disassembled or damaged.
Therefore, care should be taken not to move the link.
15-1 1 -
6 .

1) LUGGAGE COMPARTMENT DOOR HINGE AY (LUGGAGE LINK)
1.Adjust the mounting bolts so that the bolts sit at the center of the mounting holes [three locations] of
the luggage compartment door hinge and temporarily tighten them.
CAUTION
As the side latch is not installed, the luggage link can be opened both in front and to the rear when
the sliding hook is removed. If the luggage link is moved in this condition, the link might be
disassembled or damaged. Therefore, care should be taken.
(2) LUGGAGE COMPARTMENT DOOR CUSHION

1.When installing the luggage compartment door cushion,
adjust the distance between the link and the cushion
lower to maintain 22mm prior to installation.
SPECIFIED VALUE: 22mm
CAUTION
Do not remove the luggage compartment door cushion
or loosen the mounting nut unless the cushion unit is to
be replaced.
- 15-1 2
(3) LUGGAGE COMPARTMENT DOOR STRIKER AY
1. lnstall the striker and temporarily tighten it.
2.Full-lock the back door lock actuator Ay (side latch) unit, which had been removed, onto the striker
and then give temporary tightening.
CAUTION
* Care should be taken not to bend the tube that holds the back door lock actuator (side latch) cable.
Latch is locked(full lock) securely.
Do not move the link carelessly until the latch is locked onto the striker and the side latch mounting
bolt is installed to ensure that the trunk lid opens at the rear.
3.Ensure that the cushion portion in front and the rear of the luggage link is in contact (zero touch) with
the link as shown in the illustration below.
SPECIFIED VALUE: Luggage compartment door cushion:22mm.
SPECIFIED VALUE: Luggage compartment door cushion No2:5mm.
4.ln case of misalignment, loosen the striker mounting nut to shift the striker up and down for
adiustment and tiahten the nut.
5.Remove the back door lock actuator Ay (side latch) from the luggage link.
(4) POWER SUPPLY AY
1.Install the luggage hydraulic cylinder to the luggage
compartment door hinge.
2.lnstall the sliding hook to the luggage compartment door
hinge.
CAUTION
Install the sliding hook so that the notch of the hook
fits into the luggage hydraulic cylinder slot.
After the sliding hook is installed, press the sliding
hook fully toward the vehicle front to prevent
unevenness created in right and left.
As the side latch is not installed, the luggage link can
be opened both in front and to the rear when the
sliding hook is disengaged from the pin. If the luggage
link is moved in this condition, the link might be
disassembled or damaged. Therefore, care should be
taken not to move the link.
4-1-5 OPERATION AFTER ASSEMBLY t
1.lnstall the luggage compartment door panel.

2.lnstall the back door lock actuator.(side latch)
3.Adjust the trunk lid alignment.

4.lnstall the rear floor carpet.

5.lnstall the tonneau cover holder RH/LH.(luggage partition holder RHILH)
6.lnstall the tonneau cover Ay.(luggage partition)


8.0pen the trunk lid in the roof mode (front opening) and in the trunk mode (rear opening) to ensure the
smooth operation.
5 BACK DOOR LOCK ACTUATOR (SIDE LATCH)
CAUTION
disconnected.
2.Remove the luggage compartment door cover.

I) COMPONENTS
- - --

A 1 a Motor Ay, door control, RR
2 b Latch SIA, side gate support
(1) DOOR CONTROL REAR MOTOR AY
1.Bring the stone at the forward end of the cable into light
contact with the stopper by moving each of the cables
leading to RH and LH to the forward direction of the
vehicle.
CAUTION
Ensure that the stones touch both RH and LH latch
stoppers in order to prevent RH and LH latches from
being out of synchronizing.
2.lnstall the door control motor while the stones touch the
stopper. Then initialize the side latch before closing the
trunk lid.

1.lnstall the luggage compartment door cover
6 ROOF LOCK
1.Disconnect the battery negative term~nal.
CAUTION
disconnected.

I) COMPONENTS
a
I

1 a Hook, removable roof auxiliary, RHILH
2 b Catch, center lock. RHLH

7 LIMIT SWITCH AY(0PENING COVER SW AY)
1,Disconnect battery negative terminal.
CAUTION
disconnected.

) COMPONENTS
L
1 a Cover, package tray trim
2 b Switch Ay, limit switch

8 LIMIT SWITCH AY(LUGGAGE PARTITION SW AY)
1 Disconnect the battery negative terminal.
CAUTION
disconnected.

I ) COMPONENTS

1 a Holder tonneau cover, LH
2 b Switch Ay, limit

. .
9 METAL TOP ROOF CONTROL COMPUTER AY(P0WER WINDOW
ECU)
CAUTION

TOOL: Clip remover

CAUTION
systems or radio settings are erased at the same time when the battety negative terminal is
disconnected.
2.Remove the luggage compartment cover RH.


1 a Cover, computer
2 b Computer Ay, metal top roof control
9-1-4 INSPECTION
(1) Case where the computer has deformation, abrasion, cracks or breakage
1.lnstall the luggage compartment door cover RH.
- 15-20
10 METAL TOP ROOF CONTROL COMPUTER AY(RO0F ECU)
CAUTION

1.Disconnect the battery negative terminal
CAUTION
disconnected.
2.0pen the cover of the rear floor carpet rear end.

11I COMPONENTS

1 a Cover, computer
2 b Computer Ay, metal top roof control
10-1-3 INSPECTION
1Replace the computer with a new one in the following cases.
2.Close the cover of the rear floor carpet rear end.
11 CONTROL SYSTEM
SST
09991-87404-000
(09991-87401-000)
09842-97207-000 Sub-harness set, roof computer check
09842-97208-000 Sub-harness set,removal roof drive
Instrument
]Voltage tester 1

WARNING
Use caution in openinglclosing the roof or the trunk lid manually or forcibly by the hydraulic pump to
prevent your finger(s) from being caught in the link mechanism.
CAUTION
Before the hydraulic pump drives forced full open of the roof or forced openlclose of the trunk lid,
ensure that no luggage sits in the trunk room.
11-2-1 HOW TO CLOSE THE ACTIVE TOP (POWER OPENICLOSE ROOF) MANUALLY
[Rope 1
(2) OPERATING PROCEDURE

1.For the vehicle equipped with the opening cover, unlock
the opening cover hooks at four locations to lift up and
remove the opening cover.
-
NOTE
If the trunk lid can be opened by means of the trunk lid
open switch or remote control of the transmitter, open
the trunk lid and remove the opening cover. Proceed to
Step 5 and open the trunk lid.
i
2.Remove the bottom cover located inside the console box.
NOTE
Use a flat screwdriver to remove the cover, as the
cover is not easily opened by hand.
3. Pull the emergency trunk lid opener to unlock the trunk.

(Unlock the center latch.)
CAUTION
Ensure that the cable that had been pulled is back into
position.
4.Pull the side latch emergency cable (blue hook) located

on both sides of the trunk lid and rotate 90"to prevent the
cable from turning.
CAUTION
- Pull both hooks fully.

Ensure that the cable is pulled and held.
5.Fully depress the trunk lid.

6.Rotate the side latch emergency cable (blue hook) fixed
on both sides in the direction indicated by an arrow in the
right-hand illustration and return the cable.
CAUTION
Ensure that the side latch emergency cable is back into
position.
7.Hang the string over the sliding hook on the RH and LH

luggage links and carefully pull it until disengaged form
the pin.
CAUTION
* Wear gloves during the operation.
8.Close the trunk lid until it is slightly raised.

CAUTION
Close the center latch just before the latch is locked.
If the latch is locked, pull the trunk lid opener to release
the lock. (Ensure that the cable is back into position
after the lock is released.)
9.0pen the trunk lid in the roof mode (front opening) to
allow access. Then, carefully lift up the bottom of the
hinges of the RH and LH luggage links to open in the
roof mode. And push the hinges up while holding the
trunk lid from both sides until click. (Lock the side latch
and the striker of the luggage link.)
WARNING
link.
10.Slowly open the trunk lid to its full open posrtron m the
roof mode. (front open~ng)
CAUTION
Keep opening the trunk lid until it opens fully at the roof
mode. (front opening)
Do not apply excessive force to the trunk lid.
11.Hold the back panel and the roof on both sides of the
vehicle and slowly lift them up in a parallel motion to
close the roof.
WARNING
Be careful not to allow your fingers or the like to be
caught at the gap between the roof and the back panel.
CAUTION
This operation requires two people. Each person shall
stand on each side at the rear of the vehicle and
perform the operation in harmony.
Do not lift up only the roof or the back panel, but hold
both the roof and the back panel to lift.
Before lifting, ensure that the roof lock and the roof
stay are not engaged. If they are engaged, use a
screwdriver or some other tool to ply and disengage
from the roof stay.
12.Close the roof and then push up the roof lock lever at
the roof front to lock it.
13.To open the trunk lid in the trunk mode (rear opening),
close the trunk lid until just before the lock engages.
While pulling the side latch emergency cable (blue
hook), rotate and lock the cable to prevent returning.
Then switch from the roof mode (front opening) to the
trunk mode.
CAUTION
Close the center latch just before the latch is locked.
If the center latch is locked, pull the trunk lid opener
(for emergency) to release the lock. (Ensure that the
cable is back into position.)
14.0pen the trunk lid in the trunk mode (rear opening) while
holding the RH and LH front ends of the trunk lid.
CAUTION
Now the luggage link can be moved in the roof mode
(front opening) direction, too. Therefore, hold RH and
LH front ends of the trunk lid to prevent moving in the
roof mode direction.
-
15.Press the hinge of the luggage link from the top until the I I
sliding hook reaches in alignment with the pin.
NOTE
As the sliding hook of the luggage link and the pin are
not engaged, the luggage link can also be operated in
roof mode. (front opening)
16.Use a hammer handle or the like to slide down the

sliding hooks of RH and LH luggage links so that the
trunk lid will not open in the roof mode. (front opening)
CAUTION
In Step 15, securely press the hinge and ensure that
the sliding hook and the pin are at the position shown
in the right-hand illustration.
Press the sliding hook fully to prevent unevenness
created in right and left.
17.Rotate the side latch emergency cable (blue hook) fixed

on both sides in the direction indicated by an arrow in the
right-hand illustration and return the cable.
CAUTION
Ensure that the side latch emergency cable is back into
position.
18.Close the trunk lid.
NOTE
Do not close the trunk lid when performing malfunction
diagnosis.
* When opening the trunk lid manually, easy-closure
function is inoperative. Press both sides and the rear
center of the trunk lid to lock the center latch and the
side latch manually. ARer manual lock is complete,
press the trunk lid.
11-2-2 FORCED DRIVING OF HYDRAULIC PUMP

1.Connect the SST (for battery supply voltage) to the service connector (4P female) located under the
quarter window RH lower. Supply battery voltage to the hydraulic pump in order to force openlclose
the trunk lid.
SST 09842-97208-000
CAUTION
Supply voltage while RH and LH roof locks are "locked", as both the roof and the trunk lid move
simultaneously when voltage is supplied.
-
15-28
11-2-3 FORCED DRIVING OF SIDE LATCH MOTOR
1.Connect the SST (for battery . supply
. . to the side latch motor connector (8P female) located left
~ voltage)
. ~
front of the trunk lid in order to force the side latch motor to activate.
SST: 09842-97208-000
CAUTION
Do not force the side latch motor to activate while the trunk lid is front opening.
Rotate the side latch slowly while checking its condition.
Initialize the side latch after the SST is used to force the motor to activate.
For to the side latch

motor connecto:
I
11-2-4 INITIALIZING THE SlDE LATCH (INITIALIZATION)
Initialize the side latch (initialization) when any of the following operations is performed or condition is
encountered.
(1) When the SST is used to force the side latch motor to act~vate.
(2) When the side latch motor is removed.
(3) When the active top (power openlclose roof) system is given emergency maintenance.
(4) When the trunk lid will not open.
CAUTION
= In cases (1) to (3), initializationshall be performed while the trunk lid is open.
NOTE
When the trunk lid will not open, initializing the side latch might correct the condition back to normal.
(1) HOW TO INITIALIZE

1.Press and hold the trunk lid open switch for 10 seconds or more.
2.Take your hand off the switch and press the switch again within 2 seconds.
11-2-5 SYSTEM MAINTENANCE WORK PROCEDURE (IN CASE THE SlDE LATCH EMERGENCY
CABLE CANNOT BE PULLED.)
When the power open/close roof system is given emergency maintenance, some system shutdown
status might create a condition where the side latch emergency cable cannot be pulled, causing manual
opening operation of the trunk lid inoperative. In this case, follow the procedures given below to perform
emergency maintenance. If the trunk lid can be opened manually, go to the relevant troubleshooting and
initialize the side latch prior to operation checks.
(1) WORK PROCEDURE FROM HALF WAY STOPPAGE OF THE ROOF
1.The roof stops.
2.Be sure to disconnect the battery negative terminal.
CAUTION
The vehicle harnesses are used to connect the SST (for battery supply voltage). If the operation is
carried out without removing the battery negative terminal, connect will occur.
3.Make the trunk lid fully open at the front by hand.

4.Remove the connector (8P) leading to the side latch motor located at the lefttfront of the trunk lid.
Connect the SST. (sub wire)
5.Fully close the trunk lid by hand.

6.Connect the SST terminal to the battery and unlock the side latch.
NOTE
Battery connection terminal: 4 (SLDM+ /@terminal) , 1 (SLDM- /battery negative terminal)
7.While-holding the forward end of the trunk lid, lift the rear end so that the trunk lid opens at the rear.
CAUTION
The luggage link can be opened both in front and to the rear when the sliding hook is disengaged
from the pin. If the luggage link is moved in this condition, the link might be disassembled or
damaged. When opening the trunk lid to the rear, hold the front end of the door and carefully do so
by preventing the door from opening in front.
8.Push the sliding hooks at both right and left of the luggage link as far as they will go.
9.Perform the troubleshooting.
10,With the trunk lid opening at the rear, pull the sliding hooks at both right and left of the luggage link
to disengage them from the pin.
CAUTION
from the pin. If the link is moved in front while opening to the rear, the link might be disassembled or
damaged. Therefore, care should be taken not to move the link in front.
11Close the trunk lid. (Confirm that the SST is connected to the connector (8P) leading to the side latch
motor)
12.With the trunk lid held at both right and left, connect the SST terminal to the battery and lock the side
latch.
NOTE
Battery connection terminal: 4 (SLDMf / @terminal) , 1 (SLDM- /battery negative terminal)
13.With the trunk lid opening at the front, remove the SST. Reinstall the connector leading to the side
latch motor and connect the battery.
14.Set the ignition key to the "ON' position. Operate the roof open/close switch in the close direction to
fully close the roof.
15.Press the trunk lid open switch and make the trunk lid open at the rear. Press the open switch again
for at least ten seconds. Then, within two seconds, press the open switch again to initialize the side
latch.
(2) WORK PROCEDURE FROM THE TRUNK LID FULL CLOSE AND THE ROOF FULL OPEN (IN
CASE OF A VEHICLE EQUIPPED WITH THE OPENING COVER)
1.The roof stops. (Side latch emergency cable inoperative.)
2.Be sure to disconnect the battery negative terminal.
CAUTION
The vehicle hamesses are used to connect the SST (for battery supply voltage). If the operation is
carried out without removing the battery negative terminal, shori-circuit will occur.
3.Unlock the center latch by pulling the trunk lid opener (for emergency use) inside the rear console
box.
quarter window RH lower. (sub wire)
5.Connect the battery to the SST and make the trunk lid fully open at the front.
6.Rernove the opening cover.
7.Remove the SST and reinstall the connector.
8.Fully close the roof by hand.
9.Remove the connector (8P) leading to the side latch motor located at the leftlfront of the trunk lid.
Connect the SST (sub wire).

NOTE
Battery connection terminal: 4 (SLDM+ / terminal@) , 1 (SLDM- / battety negative terminal).
12.While holding the forward end of the trunk lid, lift the rear end so that the trunk lid opens at the rear.
CAUTION
damaged. When opening the trunk lid to the rear, hold the front end of the lid and carefully do so by
preventing the lid from opening in front.
13.Push the sliding hooks at both right and left of the luggage link as far as they will go. (The trunk lid
becomes open at the rear.)
CAUTION

15.With the trunk lid opening at the rear, pull the sliding hooks at both right and left of the luggage link
CAUTION
16.Close the trunk lid. (Confirm that the SST is connected to the connector (8P) leading to the side latch
motor.)
latch.
NOTE
0 Battery connection terminal: 4 (SLDM +I @terminal) , 1 (SLDM- / battery negative terminal).
18.With the trunk lid opening at the front, remove the SST. Reinstdl the connector leading to the side
19.Set the ignition key to the 'ON" position. Operate the roof openlclose switch in the close direction to
fully close the roof.
for at least ten seconds. Then, within two seconds, press the open switch again to initialize the side
latch.
21.Complete the procedure by confirming the operation.
(3) WORK PROCEDURE FROM THE TRUNK LID FULL CLOSE AND THE ROOF FULL CLOSE
1.The roof stops. (Side latch emergency cable inoperative.)
3.Unlock the center latch by pulling the trunk lid opener (for emergency use) inside the rear console
box.
quarter window RH lower.
5.With the roof locks at both right and left applied, connect the battery to the SST. Make the trunk lid
fully open at the front.
CAUTION
Supply voltage while RH and LH roof locks are "locked", as both the roof and the trunk lid move
simultaneously when voltage is supplied.
6.Remove the SST and reinstall the connector.

7.Remove the connector (8P) leading to the side latch motor located at the left/front of the trunk lid.
Connect the SST (sub wire).

NOTE
Battery connection terminal: 4 (SLDM+ /terminal@) , 1 (SLDM- / battery negative terminal)
10.While holding the forward end of the trunk lid, lift the rear end so that the trunk lid opens at the rear.
CAUTION
11.Push the sliding hooks at both right and left of the luggage link as far as they will go. (The trunk lid
becomes open at the rear.)
CAUTION
from the pin. If the trunk lid is moved to the rear while opening the trunk lid in front, the link might be
disassembled or damaged. When opening the trunk lid to the rear, hold the front end of the lid and
carefully open the lid by preventing the lid from opening in front.

13.With the trunk lid opening at the rear, pull the sliding hooks at both right and left of the luggage link
CAUTION
* The luggage link can be opened both in front and to the rear when the sliding hook is disengaged
from the pin. If the trunk lid is moved to the rear while opening the trunk lid in front, the link might be
disassembled or damaged. When opening the trunk lid to the rear, hold the front end of the lid and
carefully open the lid by preventing the lid from opening in front.
15-34
14.Close the trunk lid. (Confirm that the SST is connected to the connector (8P) leading to the side latch
motor.)
latch.
NOTE
Battery connection terminal: 4 (SLDM + I
@terminal) , I(SLDM- /battery negative terminal).
16.With the trunk lid opening at the front, remove the SST. Reinstall the connector leading to the side
17.Release the roof lock. Set the ignition key to the "ON" position. Fully close the roof by operating the
roof open/close switch in the closing direction.
for at least ten seconds. Then, within two seconds, press the open switch again to initiaiize the side
latch.
TERMINAL NAMES OF POWER WINDOW ECU CONNECTOR
TERMINAL NAME OF ROOF ECU CONNECTOR
Power window ECU(ECU SIDE)
Power window ECU(Vehicle harness side)
Roof ECU(ECU side)
Roof ECU(Vehicle harness side )
Roof o~enlcloseSwitch Trunk lid open switch Parking brake switch .

Opening cover switch
Luggage patition switch
Roof lockswitch RHILH
Driver's seat power Passenger seat power Window lock switch Driver's seat power
window switch window switch window motor
Passenger seat power

window motor Warning lamp Warning buzzer Trunk lid
Quaulor window motor RHJLH Courtesy switch
Key-less receiver Combination meter Center latch
(connector color:white,pale nomber 22P)
Trunk lid latch drive(Side latch motor) Side latch sensor

Hydraulic pump
Roof openlclose sensor

Trunk lid openlclose sensor
Part name
lid open switch
'ator motor LH I
Part name Part name
a Roof hydraulic cylinder RH --j Luggage link LH
b Luggage hydraulic cylinder RH k Side latch LH
I c /side latch RH
I I
Center latch (center latch half lock switch, rear
center latch open switch, rear center latch closed
switch)
- . . . . . . .
uacK aoor LOCK acruaror ~y
d Roof stay RH rn
(trunk lid latch speed sensor
Roof hydraulic cylinder LH(roof open sensor, roof
e Roof stay LH n
closed sensor)
f Hydraulic pump (motor temperature sensor) o Luggage link RH
g Roof link LH p Side latch sensor RH
Luggage hydraulic cylinder (trunk lid open sensor,
q Roof link RH
trunk lid closed sensor )
i Side latch sensor LH - -
I
The active top system (power open/close roof system) features diagnostic function for troubleshooting,
which provides an important clue as to malfunction diagnosis. The diagnosis of the active top system
features the battery backup. (function that supplies power to diagnostic memory even if the ignition
switch is turned "OFF'.)
11-6-1 DIAGNOSTIC INTERVIEW
When trying to remove the cause of the problem occurred to the vehlcle, the phenomenon of the
malfunction must be identified. Otherwise, whatever operation is done to the vehicle, the vehicle may
never be back to normal. Diagnostic interview provides information from the user prior to identifying the
phenomenon of the malfunction, which will be a very important clue as to reproduce the malfunction
phenomenon.
(1) INTERVIEW SHEET FOR DIAGNOSTIC PROCEDURE
1.The diagnostic interview sheet is a checklist that can be used when conducting malfunction diagnosis
of the active top system (power open/close roof system). Use this sheet for diagnostic interview w~th
your customer or for malfunction diagnosis procedure.
Diagnosis interview sheet
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11-7 DIAGNOSIS
1.When the diagnosis code is indicated, confirm whether the malfunction took place sometimes in the
reproduced malfunction. For this purpose, the diagnosis code should be indicated twice, namely
before and after the confirmation of the phenomena.
2.The malfunction codes are displayed by flashing the warning lamp located in the heater control when
the ECUT terminal and E terminal of the diagnostic check connector (installed under the instrument
panel) are short-circuited and the ignition
- switch is turned "ON". All the malfunction codes stored are
displayed repeatedly in numeric order, starting from the small number.
Normal code Abnormality code(No.ll.23)

IGSW ON IGSW ON
ECUT terminal ECUT terminal

OFF OFF
WARNING LAM
Note 1) Header O.25sec.-0.5sec. Note 1) When the terminal ECUT is ON with the IG SW set to
Note 2) When the terminal ECUT is ON with the IG SW set to 'OFF', the code is outputted in three seconds after
'OFF',the code is outputted in three seconds after IG SW is set to "ON'.
IG SW is set to 'ON'.
' 11-7-2 CANCELING METHOD OF DIAGNOSIS
1.Diagnosis codes can be erased by short-circuiting the ECUT-terminal of the diagnosis check
connector to the E-termrnal, followed by operations below withrn 1Oseconds of the ignition switch
'ON'.
NOTE
The sequence of the ignition switch " O N+short-circuiting the diagnosis check connector can be
reversed. In this case, diagnosis codes can be erased by conducting the following operation within
10 seconds of short-circuit the terminal.
CAUTION
When erasing diagnosis codes, allow 60ms or more for the switch "OFF"and 220ms for "ON. If
time allowed for switch "ON and "OFF" is too short, diagnosis codes will not be erased.
Perform the switch operation shown in the illustration below four times or more within 10seconds of
the ignition switch "ON"(or short-circuit in ECUT-terminal) to erase diagnosis codes.
Shorled(ECUT terminal & E terminal)
ECUTterrniMl ON
ON
lGSW OR -
ON
Operating SW
OFF
W e 1)A~rcowktbnof wasure. 8 the malunnion perrisls.

3pen operation Close operation me disgwis M e ip mermizedwin.Anw beingextingubhed
Erasing power window ECU Erasing roof ECU tortour ,- me diagnrais mde is dmy&
jiagnosis code memory diagnosiscode memory ~ o l e 2~heowakm
) isme same w k n the lsrminab ~ C u ~ a 1Gareexchanged
nd
inuehefieure.
CllIOB6EST
CONTENTS OF DIAGNOSIS
-
ECL bout. NO.
neasl Trouble I m;.--.-.
ing area / 2 digits ( 4 digits / uraynosizicontents
poin
Roof
ECU I I3~trne out of the center larch actlon tune
..-
L3
I ,,,, ,
rnL3jD
/The status 01 the :run& 110cour:esy switch and tne center latch/s.de latcn sen-
26 82594 Trunk lid operation time out

31 B2529 Malfunction, open or short-circuit of the side latch sensor RH
32 82530 Malfunction,open or short-circuit of the side latch sensor LH
ide latch @Abnormal pulse of the trunk lid latch drive speed sensor
33 B2561 @The output signal is different from the control output for the side latch motor
ower
ndou
.CU
-
!
11-8 FAIL-SAFE FUNCTION
I.In case abnormality has occurred in the input-output control system of the power window ECU or the
roof ECU, system operation will be shut down or limited, or the warning lamp will be illuminated.
Once abnormality is detected and later recovered, fail-safe function will be released, but the
diagnostic results will be stored.
FAIL-SAFE SPECIFICATIONS
Cord Lamp Contents of control
Contents of malfunction
No. indication
11 Abnormality of the roof open sensor
Roof open disabled
12 Abnormality of the roof closed sensor
Hydraulic pump relay
13 Roof openlclose disabled
Abnormal of hydraulic system temperature sensor
Hydraulic pump heating(leve1 1) Roof open disabled
14
Hydraulic pump heating(level 2) Roof openlclose disabled
Roof and trunk lid open/close
Open 'ON' state and close 'ON' state of roof openlc ose
switch occurs simultaneously.
Roof openlclose disabled
Short the luggage partition SW
62
Short opening cover SW
Lamp
CordNo' Contents of malfunction Contents of control
indication
63 Short the roof lock SW RH.
- -XI
64 Short the roof lock SW LH.
65 Discontinued vehicle speed signal -
I'FUIIooen" or 'full ciose' is not detected for loseconds or
66 more after the power window motor on the driver's seat is
turned on.
During the roof operation, full open status is not detected
67 for 10 seconds or more after the passenger seat power
window motor is turned on.
PauseX2
68 - for 10 seconds or more after the quarter window motor
RH is turned on.
69 for 10 seconds or more after the quarter window motor
LH is turned on.
Power window ECU supply voltage too low. (less than
71
9'4
Power window ECU supply voltage too high. (17V or
72 Roof openlclose disabled
more)
Transmitting error from the power window ECU to the
81 Illuminated
roof ECU.
%l:Open operation is disabled when both of the roof lock switches RHlLH are short-circuited.
Z2:Operation resumes when the switch 1s operated again after a pause
11-9-1 DIAGNOSIS CODE No.ll(ROOF OPEN SENSOR SYSTEM)
W 1 .VISUAL CHECK OF ROOF OPEN SENSOR
1.Check the sensor for external appearance.
SPECIFIED VALUE: The sensor should not be damaged and dropped. Also, the sensor should exhibit
no excessive play.
If OK. oroceed to W 2 .
If it is NG, reolace the hvdraulic pumo Av.
W2.CHECK CONTINUITY BETWEEN THE SIDE LATCH MOTOR AND THE ROOF ECU
1.Disconnect the connector from the roof open sensor and roof ECU.
2.Check the harness between the roof open sensor and the roof ECU.
(1) Vehicle harness side connector 1 of roof open sensor - Vehicle harness side connector 9
(SENSC) of roof ECU.
(2) Vehicle harness side connector 3 of roof open sensor - Vehicle harness side connector 2 (TOS)
of roof ECU.
If it is NG, reuair the harness and connector.
W3.CHECK OF VOLTAGE BETWEEN ROOF OPEN SENSOR TERMINALS

1.Check the voltage between the roof open sensor terminals.
If it is OK. reulace of the roof ECU.

If it is NG, reulace the hvdraulic DumD Av.
15-50
11-9-2 DIAGNOSIS CODE No.I2(ROOF CLOSED SENSOR SYSTEM)
W 1.VISUAL CHECK OF ROOF CLOSED SENSOR
ICheck the sensor for external appearance.
SPECIFIED VALUE: The sensor should not be damaged and dropped. Also, the sensor should exhibit
no excessive play.
If it is NG. rewlace the hvdraulic m m w Av.
D2.CHECK CONTINUITY BETWEEN THE ROOF CLOSED SENSOR AND THE ROOF ECU
1.Disconnect the connector from the roof closed sensor and roof ECU.
2.Check the harness between the roof closed sensor and the roof ECU.
(1) Vehicle harness side connector 2 of roof closed sensor - Vehicle harness side connector 9
(2) Vehicle harness side connector 4 of roof closed sensor - Vehicle harness side connector 3 (TCS)
of roof ECU.
If it is NG. rewair the harness and connector.
W3.CHECK OF VOLTAGE BETWEEN ROOF CLOSED SENSOR TERMINALS

1.Check the voltage between the roof closed sensor terminals.
If it is OK. re~laceof the roof ECU.

If it is NG, re~lace the hvdraulic wumw assemblv.
11-9-3 DIAGNOSIS CODE No.l3(HYDRAULIC PUMP CONTROL SYSTEM)
D l.CHECK OF CONDITIONS OF HYDRAULIC SYSTEM AND EACH OPERATING SECTION
1.Check that there is no oil leakage. Also, check the hydraulic hose for breakage and bending.
2.Check that no obstacle is present on the operating path of the roof, back panel and trunk lid.
3.Check that the roof, back panel and trunk lid exhibit no seizure.
4.Check that the sliding sections of the roof link and luggage link exhibit no abnormal resistance.
5.Check to see if the cable of the roof stay is operating.
6.Check to see if the cylinder is operating.
NOTE
If the active top is not operated for several week, the hydraulic pressure of the active top will drop.
When the active top is actuated, it will take a little time until the hydraulic pressure is built up, even
though you can hear an operating sound.
Then, when you operate the active top, it can operate normally, only requiring an ordinary operating
time. The aforesaid phenomena are not showing a malfunction.
If it is OK (there is no abnormalitv at the hvdraulic svstem side.). wroceed to W2.

If it is NG (there is an abnormalitv at the hvdraulic svstem side.). rewair the malfunctionina sections
amona the sections that have been checked above.
15-51
W2.CHECK CONTINUITY BETWEEN HYDRAULIC PUMP MOTOR AND ROOF ECU
1.Disconnect the connector from the hydraulic pump motor and roof ECU.
2.Check the harness between the hydraulic pump motor and the roof ECU.
(1) Vehicle harness side connector 1 of hydraulic pump - Vehicle harness side connector 50 (PD2)
of roof ECU.
(2) Vehicle harness side connector 5 of hydraulic pump - Vehicle harness side connector 46(PD1)
of roof ECU.
(3) Vehicle harness side connector 3 of hydraulic pump - Vehicle harness side connector 38(GND
TS) of roof ECU.
(4) Vehicle harness side connector 8 of hydraulic pump - Vehicle harness side connector 29(TS) of
roof ECU.
(5) Vehicle harness side connector 45 (30HYD) of roof ECU - Battery @ terminal.
If it is NG, re~airthe harness and connector.
W3.CHECK RESISTANCE HYDRAULIC PRESSURE PUMP TERMINALS

1.Measure the resistance between the hydraulic pump side connectors 3 and 8.
SPECIFIED VALUE: Within 400kQ
If it is OK, re~lace of the roof ECU.

If it is NG, replace the hvdraulic Dumo Av.
11-9-4 DIAGNOSIS CODE No.l4(HYDRAULIC PUMP HEATED)

W I .CHECK OF CONDITIONS OF HYDRAULIC PUMP
1.Wait until the temperature of the hydraulic pump drops.
2.Check to see if the pump operates.
SPECIFIED VALUE: The hydraulic pump operates at normal temperatures.

W2.CHECK RESISTANCE HYDRAULIC PRESSURE PUMP TERMINALS

1.Keep the hydraulic pump in a thoroughly cooled-down state.
SPECIFIED VALUE: Within 60kB
If it is NG. re~lacethe hvdraulic DumD.
W3.CHECK OF CONDITIONS OF HYDRAULIC SYSTEM AND EACH OPERATING SECTION
4.Check that the sliding sections of the roof iink and luggage iink exhibit no abnormal resistance.
NOTE
If it is OK (there is no abnormalitv at the hvdraulic svstem side.). the svstem is functionina normallv.
If it is NG fthere is an abnormalitv at the hvdraulic svstem side.). reoair the malfunctionina sections
11-9-5 DIAGNOSIS CODE No.151ROOF OPERATED TIME OUT)
W1.OPERATION CHECK OF ROOF
1.Check the operating condition of the roof.
NOTE
It is assumed that the trunk lid operates.
If the roof ooerates normallv. oroceed to W4.

If the trunk lid ooerates and the roof fails to operate normallv. ~roceedto D2.
W2.CONFIRMATION OF ROOF OPERATIONAL ENVIRONMENT

1.Have you ever operated the roof at low temperature or at low voltage?
If YES. oroceed toW3.
If NO. ~roceedtoD4.
D3.0PERATION CHECK OF ROOF WITH TRUNK LID OPENED

1.Manually move the trunk lid to a fully-opened position. (open at the front)
2.Confirm the condition at the time when the roof open switch is operated.
SPECIFIED VALUE: The roof operates.
If OK. the svstem is satisfactonl,

NOTE
There are cases where the operation becomes slow at a low temperature or with a low voltage.
If it is NG, oroceed to D4.

15-53
[.)
NOTE
When the active top is actuated, ii will take a little time until the hydraulic pressure is built up, even
If it is NG (there is an abnormalitv at the hvdraulic svstem side.). re~airthe malfunctionino sections :

arnona the sections that have been checked above.
11-9-6 DIAGNOSIS CODE No.21(TRUNK LID OPEN SENSOR SYSTEM)
D1.VISUAL CHECK OF TRUNK LID OPEN SENSOR
SPECIFIED VALUE: It should not be damaged and dropped. Also, there should be no excessive play.
If it is NG. reolace the hvdraulic oumo Av.
D2.CHECK CONTINUITY BETWEEN THE TRUNK LID OPEN SENSOR AND THE ROOF ECU
1.Disconnect the connector from the trunk lid open sensor and roof ECU.
2.Check the harness between the trunk lid open sensor and the roof ECU.
(1) Vehicle harness side connector 2 of trunk lid open sensor - Vehicle harness side connector
9(SENSC) of roof ECU.
4(LOS) of roof ECU.
D3. CHECK OF VOLTAGE BETWEEN ROOF OPEN SENSOR TERMINALS

1Check the voltage between the roof open sensor terminals.

If it is NG. reulace the hvdraulic uumo Av.
11-9-7 DIAGNOSIS CODE No.22(TRUNK LID CLOSED SENSOR SYSTEM)
D l .VISUAL CHECK OF TRUNK LID CLOSED SENSOR
If it is NG, reolace the hvdraulic oumo Av.
W2.CHECK CONTINUITY BETWEEN THE TRUNK LID CLOSED SENSOR AND THE ROOF ECU
1.Disconnect the connector from the trunk lid closed sensor and roof ECU.
2.Check the harness between the trunk lid closed sensor and the roof ECU.
(1) Vehicle harness side connector 1 of trunk lid closed sensor - Vehicle harness side connector 9
(sENSC) of roof ECU.
(LOS) of roof ECU.
If it is NG. reoair the harness and connector.
W3.CHECK OF VOLTAGE BETWEEN TRUNK LID CLOSED SENSOR TERMINALS
1.Check the voltage between the trunk lid closed sensor terminals.
If it is OK. reolace of the roof ECU.

If it is NG. reolace the hvdraulic ourno Av.
11-9-8 DIAGNOSIS CODE No.23(BOOT LID BULB SYSTEM)
D1.CHECK CONTINUITY BETWEEN THE TRUNK LID BULB AND ROOF ECU
1.Disconnect the connector from the trunk lid valve and roof ECU.
2.Check the harness between the trunk lid valve and the roof ECU.
(1) Vehicle harness side connector 2 of hydraulic pump - Vehicle harness side connector 48(LV
GND) of roof ECU.
(2) Vehicle harness side connector 6 of hydraulic pump - Vehicle harness side connector 43(LV) of
roof ECU.
If it is NG. reoair the hamess and connector.
W2.CHECK OF RESISTANCE BETWEEN TRUNK LID VALVE HYDRAULIC PUMP TERMINALS

1.Separate connector at the trunk lid bulb.
SPECIFIED VALUE: Resistance value within a range between 9 and 158.
If it is NG, reolace the hvdraulic oumo Av.
W3.CHECK SIGNAL BETWEEN ROOF ECU TERMINALS

?.Measurethe voltage between the roof ECU 43 (LV) and 48 (LV GND) while the roof open/close switch
is operated.
SPECIFIED VALUE: 10 V or more.
If it is OK. reolace the hvdraulic oumo Av.

If it is NG. replace of the roof ECU.
.
,
i ,'
W5.CHECK CONTINUITY ROOF ECU POWER SUPPLY SYSTEM
1.Disconnect the connector from the roof ECU.
2.Check the power supply system of the roof ECU.
(1) Vehicle harness side connector 30 (30 LAT) of roof ECU - Battery @.
(2) Vehicle harness side connector 21 (GND LAT) of roof ECU - Body ground.
W6.CENTER LATCH UNIT CHECK

I.If OK, the system is satisfactory.
If OK. the svstem is satisfactow.

If it is NG, reolace of the center latch.
11-9-10 DIAGNOSIS CODE No.26(TRUNK LID OPERATED TIME OUT)
W1.CHECK OF ROOF OPERATION CONDITION
1.Check the operating condition of the roof.
NOTE
It is assumed that the trunk lid operates.
*
If the roof ooerates normallv. oroceed to W4.
W2.CONFIRMATION OF ROOF OPERATIONAL ENVIRONMENT

1.Have you ever operated the roof at low temperature or at low voltage?
If YES. ~roceed to W3.
If NO. oroceed toW4.
W3.0PERATION CHECK OF ROOF WITH TRUNK LID OPENED

1.Manually move the trunk lid to a fully-opened position (open at the front).
2.Confirm the condition at the time when the roof open switch is operated.
SPECIFIED VALUE: The roof operates.

NOTE
There are cases where the operation becomes slow at a low temperature or with a low voltage.
If it is NG. oroceed to W4.

NOTE
If it is OK fthere is no abnormalitv at the hvdraulic svstem side.). the svstem is functionina normallv.
If it is NG (there is an abnormality at the hvdraulic svstem side.), r e ~ a ithe
r malfunctionina sections
amono the sections that have been checked above.
11-9-11 DIAGNOSIS CODE No.31/32(SIDE LATCH SENSOR RWLH)
CAUTION
The diagnosis code No. 31 means a malfunction of the side latch sensor RH system, whereas the
diagnosis code No. 32 denotes a malfunction of the side latch sensor LH system. In instances
where only one of these diagnosis codes is indicated, the sensor for which the diagnosis code is not
indicated is functioning normally. Be sure to check and repair the sensor for which the diagnosis
code is indicated.
D1.VISUAL CHECK OF SlDE LATCH SENSOR RHILH

1Check the sensor for external appearance.
If it is NG. redace of the side latch sensor.
W2.CHECK CONTINUITY OFTHE SlDE LATCH SENSOR BETWEEN THE ROOF ECU
1.Disconnect the connector from the trunk lid courtesy switch and roof ECU.
2.Check the harness between the trunk lid courtesy switch and the roof ECU.
(1) Vehicle harness side connector 1 of side latch sensor RH - Vehicle harness side connector 9
(RIL) of roof ECU.
(3) Vehicle harness side connector 1 of side latch sensor LH - Vehicle harness side connector 9
(LEL) of roof ECU.
If it is NG, re~airthe harness and connector.
\
S3.CHECK OF VOLTAGE BETWEEN THE SIDE LATCH SENSOR RHILH TERMINALS
1.Check the voltage between the side latch sensor RHILH terminals.

If it is NG, reolace of the side latch sensor.
11-9-12 DIAGNOSIS CODE No.33($IDE LATCH MOTOR SYSTEM)
D l .VISUAL CHECK OF SlDE LATCH OPERATION
1.Check that no foreign matter is caught in the side latch.
SPECIFIED VALUE: Ensure that there is no foreign body.
If it is NG. remove the foreian matter.
D2.CHECK OF THE SlDE LATCH MOTOR

1.Disconnect the connector from the side latch motor.
2.Connect the SST.
3.Check the condition when it is forcibly driven in locking and unlocking directions.
SST 09842-97208-000
SPECIFIED VALUE: Ensure that the operation is smooth.
If it is OK. a0 to D3.
If it is NG, replace of the side latch SIA.
D3.CHECK OF MARKING POSITION OF TRUNK LID STRIKER

1.Check that the marking of the trunk lid striker is not deviated.
SPECIFIED VALUE: Ensure that the marking is not deviated.
If it is OK. oo to D4.
If it is NG, adiust the striker.
D4.CHECK CONTINUITY BETWEEN THE SlDE LATCH MOTOR AND THE ROOF ECU
1.Disconnect the connector from the side latch motor and roof ECU.
2.Check the harness between the side latch motor and the roof ECU.
(1) Vehicle harness side connector 1 of side latch motor - Vehicle harness side connector
1l ( S L D M t ) of roof ECU.
18(SSSLD) of roof ECU.
(3) Vehicle harness side connector 3 of side latch motor - Vehicle harness side connector 9(SENSC)
of roof ECU.
(4) Vehicle harness side connector 4 of side latch motor - Vehicle harness side connector I9(GND
LSW) of roof ECU.
2O(SLDM-) of roof ECU.
If it is NG. repair the harness and connector.
D5.CHECK CONTINUITY POWER SUPPLY SYSTEM OF THE ROOF ECU

2.Check the power supply system of the roof ECU.
( I ) Vehicle harness side connector 30 (30 LAT) of roof ECU - Battery @.
(2) Vehicle harness side connector 21 (GND LAT) of roof ECU - Body ground.
B6.SIDE LATCH MOTOR UNIT CHECK
1.Perform the unit check of the side latch motor.

If it is NG. reolace of the side latch motor.
11-9-13 DIAGNOSIS CODE No.411SYSTEM POSITION RECOGNIZED SYSTEM)
WI .CHECK OF TRUNK LID OPERATION
1.Manually close the trunk lid fully. Then, check that the abnormality is remedied.
SPECIFIED VALUE: The operation becomes normal.
If OK. the svstem is satisfactorv.

NOTE
The error position was taken due to an inevitable reason.
D2.VISUAL CHECK EACH SENSOR

1.Check the following sensors, etc. for external appearance.
(1) Roof open sensor.
(2) Roof closed sensor.
(3) trunk lid open sensor.
(4) trunk lid closed sensor.
If it is NG. re~lacethe hvdraulic DumD Av.
- 15-62
I
W3.CHECK CONTINUITY B m E E N ROOF AND TRUNK LID OPENICLOSED SENSORS AND ROOF
ECU
1.Disconnect the connector from the roof and trunk lid openlclosed sensors and from the roof ECU.
2.Check continuity between the roof and trunk lid open/close sensor as well as between the roof ECU.
(1) Vehicle harness side connector 1 of roof open sensor - Vehicle harness side connector 9
(2) Vehicle harness side connector 3 of roof open sensor - Vehicle harness side connector 2 (TOS)
of roof ECU.
(3) Vehicle harness side connector 2 of roof closed sensor - Vehicle harness side connector 9
(4) Vehicle harness side connector 4 of roof closed sensor - Vehicle harness side connector 3 (TCS)
of roof ECU.
9(SENSC) of roof ECU.
4(LOS) of roof ECU.
(LOS) of roof ECU.
If it is NG. reuair the harness and connector.
W4.SENSOR UNIT CHECK

1.Perform the unit check of the roof openlclosed sensors and trunk lid openlclosed sensors
(1) Roof open sensor unit check.
(2) Roof closed sensor unit check

(3) Trunk lid open sensor unit check

(4) Trunk lid closed sensor unit check.

If OK, the svstem is satisfactow.
NOTE
The error position was taken due to an inevitable reason.
W5.CHECK OF VOLTAGE BETWEEN ROOF ECU AND BODY GROUND

1.Check the voltage between the ECU side connector 9 (SECSC) of the roof and the body ground
SPECIFIED VALUE: Approx. 12V (Battery voltage).
If it is OK. reulace the hvdraulic uumD Av.

If it is NG. reolace of the roof ECU.
11-9-14 DIAGNOSIS CODE N0.42 (LOW-TEMPERATURE OPERATION PROHIBITED)
W1.CHECK OF ROOF OPEN SWITCH OPERATION
1.Check the opening operation of the roof at - 10°C or above under a condition where it is not frozen.
SPECIFIED VALUE: Ensure that there is no abnormality.
If OK, the svstem is satisfactorv.

NOTE
The operation stops due to low temperature.
If it is NG, re~laceof the roof ECU.

11-9-15 DIAGNOSIS CODE N0.43 (TRUNK LID OPEN SWITCH SYSTEM)
W1.TRUNK LID OPEN SW UNIT CHECK
1.Perform the unit check of the trunk lid open switch.
If it is NG, reolace of the trunk lid oDen SW.
W2.CHECK SHORT BETWEEN TRUNK LID OPEN SW AND POWER WINDOW ECU & ROOF ECU
1.Disconnect the connector from between the trunk lid open switch and the power window ECU & roof
ECU.
2.Ensure that no continuity exists between the following terminals of the trunk lid open switch and power
window ECU & roof ECU.
(1) Vehicle harness side connector 40 (TRLID) of power window ECU - Body ground.
(2) Harness side connector 25 of roof ECU - Body ground.
SPECIFIED VALUE: No continuity exists.
If OK, the svstem is satisfactow..

NOTE
Because the switch has been pushed continuously for 30 seconds or more.

11-9-16 DIAGNOSIS CODE No.44/45(ROOF ECU POWER SUPPLY SYSTEM)
CAUTION
* The diagnosis code No. 44 means the drop of supply voltage to the roof ECU, whereas the
diagnosis code No. 45 denotes excessive supply voltage to the roof ECU.
* Since the low-voltage error and over-voltage error are not caused by malfunctions of the ECU, it is
not necessaly to replace the ECU.
W 1.BATTERY VOLTAGE CHECK

1.Measure the battery voltage with the engine in a stopped state.
SPECIFIED VALUE: 10- 14V.
If it is NG, replace of the batte~.
-
15-64
D2.CHECK CONTINUITY BETWEEN THE ROOF ECU AND THE BATTERY
2.Check the harness between the roof ECU and the battery.
(1) Vehicle harness side connector 49 (ECU+B) of roof ECU - Battery@.
(2) Vehicle harness s~deconnector 47 (GND MC) of roof ECU - Battery @.
B3.VISUAL CHECK OF HARNESS AND BATTERY TERMINALS

1.Check the battery terminals and harness for external appearance.
SPECIFIED VALUE: Ensure that there is no corrosion. (At time of low-voltage error)
If it is NG. reulace the terminal or harness.
B4.CHECK THE ALTERNATOR

1.Check that the alternator exhibits no abnormality.
If OK. the svstem is satisfactorv. Observe for a while.

If it is NG. reuair or replace the alternator.
11-9-17 DIAGNOSIS CODE NOS1 (COMMUNICATION SYSTEM BETWEEN THE ROOF ECU AND
THE POWER WINDOW ECU)
CAUTION
The diagnosis code No. 51 means the time out of data sending from the roof ECU to the power
window ECU, whereas the diagnosis code No. 52 denotes abnormal data sent from the roof ECU to
the power window ECU.
B I.CHECK CONTINUITY BETWEEN THE POWER WINDOW ECU AND THE ROOF ECU.
1.Disconnect the connector from the power window ECU and roof ECU.
2.Check the harness between the power window ECU and the roof ECU.
(1) Veh~cieharness side connector 15 (TX) of power wrndow ECU - Vehicle harness side connector
24 (RX) of roof ECU.
(2) Vehicle harness side connector 32 (RX) of power window ECU - Veh~cleharness side connector
23 (TX) of roof ECU.
If it is OK, ao to D 2
W2.CHECK CONTINUITY POWER SUPPLY SYSTEM OF THE ROOF ECU
2.Check that there is no open wire in the harness of the roof ECU power supply system
(1) Vehicle harness side connector 49 (ECU+B) of roof ECU - Battery @.
(2) Vehicle harness side connector 47 (GND MC) of roof ECU - Body ground.
(3) Vehicle harness side connector 22 (IG) of roof ECU - Ignition switch (IGI).
lf it is OK. reolace of the roof ECU.

- 15-66
11-9-18 DIAGNOSIS CODE No.53 (ROOF ECU ABNORMALITY)
The diagnosis code No. 53 means abnormality inside the roof ECU. Replace the roof ECU.
11-9-19 DIAGNOSIS CODE No.61(ROOF OPENICLOSE SWITCH SYSTEM)
Dl.CHECK CONTINUITY BETWEEN THE ROOF CLOSED SENSOR AND THE POWER WINDOW
ECU
1.Disconnect the connector from the roof openlclose switch and power window ECU.
2.Check the harness between the roof openlclose switch and the power window ECU.
(1) Vehicle harness side connector 1 of roof openlclose SW - Vehicie harness side connector
23(CLOSE) of power window ECU.
(2) Vehicle harness side connector 3 of roof openlclose SW - Vehicie harness side connector 24
(OPEN) of power window ECU.
(3) Vehicle harness side connector 4 of roof SW - Ignition SW(IG1).
If it is NG, rewair the hamess and connector.
W2.ROOF OPENICLOSE SW UNIT CHECK

1.Perform the unit check of the roof openlclose switch

If it is NG. reolace of the roof ooenlclosed SW.
11-9-20 DIAGNOSIS CODE N0.62 (OPENING COVER SWITCH OR LUGGAGE PARTITION SWITCH
SYSTEM)
D l .VISUAL CHECK OF OPENING COVER SWITCH AND LUGGAGE PARTITION SWITCH
1.Check that no foreign matter is caught in the switch sections of the opening cover switch and
luggage partition switch.
*&CHECK SHORT BETWEEN LUGGAGE PARTITION SW & OPENING COVER SW AND POWER
WINDOW ECU
1.Disconnect the connectors between the luggage partition switch and the opening cover switch and
power window ECU.
2.Check the harness between the luggage partition switch & opening cover switch and the power
window ECU.
(1) Vehicle harness side connector 1 of luggage partition switch - Vehicle harness side connector
50 (COVER-) of power window ECU.
(2) Vehicle harness side connector 2 of luggage partition sw~tch- Vehicle harness side connector 1
of power window ECU.
(3) Vehicle harness side connector 2 of opening cover switch - Vehicle harness side connector 16
(COVER+) of power window ECU.
SPECIFIED VALUE: Ensure that no continuity exists between the connector enumerated above and
the body ground.
D3.LUGGAGE PARTITION SW UNIT CHECK
1.Perform the unit check of the luggage partition switch
If it is NG. reolace of the luaaaae oartition SW.
D4.0PENING COVER SW UNIT CHECK

1.Perform the unit check of the opening cover switch.

If it is NG, replace of the opwnina cover SW.
11-9-21 DIAGNOSIS CODE No63 (ROOF LOCK SWITCH RH SYSTEM)
Dl. VISUAL CHECK OF ROOF LOCK LEVER
1.Check the condition at the time when the roof lock lever is applied to the hook.
SPECIFIED VALUE: Ensure that the lever is engaged securely.
If it is NG. oetform the fitting adiustment or reolace the center lock catch RH Av.
D2.VISUAL CHECK OF ROOF LOCK SWITCH

1.Check that no foreign matter is caught in the roof lock switch.
D3. CHECK SHORT BETWEEN ROOF LOCK SW LH AND POWER WINDOW ECU
1.Separate connector at the roof lock SW RH and power window ECU.
2.Check the harness between the roof lock switch RH and the power window ECU.
(1) Vehicle harness side connector I of roof lock switch RH - Vehicle harness side connector 51
(LOCK RH-) of power window ECU.
(2) Vehicle harness side connector 2 of roof lock switch RH - Vehicle harness side connector 18
(LOCK RH+) of power window ECU.
the body ground.
D4.ROOF LOCK SW UNIT CHECK

1.Perform the unit check of the roof lock switch.
If OK, the svstem is satisfactow

If it is NG, reolace the center lock catch RH Av.
11-9-22 DIAGNOSIS CODE No64 (ROOF LOCK SWITCH LH SYSTEM)
1.Check the cond~tionat the time when the roof lock lever is applied to the hook.
SPECIFIED VALUE: Ensure that the lever is engaged securely.
If it is NG. perform the fittina adiustment or replace the center lock catch LH Av.
D2.VISUAL CHECK OF ROOF LOCK

If it is OK, ao to m3.
D3. CHECK SHORT BETWEEN ROOF LOCK SW LH AND POWER WINDOW ECU
1.Separate connector at the roof lock SW RH and power window ECU.
2.Check the harness between the roof lock switch and the power window ECU.
(1) Vehicle harness side connector 1 of roof lock switch LH - Vehicle harness side connector 51
(LOCK LH-) of power window ECU.
(LOCK LH+) of power window ECU.
the body ground.

1.Performthe unit check of the roof lock switch.
If it is NG. reolace of the center lock catch LH Av.
11-9-23 DIAGNOSIS CODE No65 (VEHICLE SPEED SENSOR SYSTEM)
D1.CHECK CONTINUITY BETWEEN THE POWER WINDOW ECU AND THE COMBINATION METER
1.Separate connector at the power window ECU and combination meter.
2.Check the harness between the power window ECU and the combination meter
(1) Vehicle harness side connector 19 (SPD) of power window ECU - Vehicle harness side
connector 14 (vehicle speed sensor) of combination meter.
If it is NG, repair the harness and connector.
W2.CHECK OF SPEEDOMETER
1.Drive the vehicle. Then, check the pointer indicating position of the speedometer.
SPECIFIED VALUE: The pointer is indicating the speed correctly.
If OK. the system is satisfactorv.

If it is NG. check the combination meter or vehicle speed sensor.
11-9-24 DIAGNOSIS CODE No.66 to N0.69 (POWER WINDOW SYSTEM)
CAUTION
The diagnosis codes No. 66 to No. 69 denote malfunctions of the power window system, not
malfunctions of the ECU. Therefore, it is not necessary to replace the power window ECU.
W1 .BATTERY VOLTAGE CHECK

SPECIFIED VALUE: 10-14V.
If it is OK, ao tom2.
If it is NG. this section is normal.
W2.CHECK OF POWER WINDOW SWITCH OPERATION

1.Check the operation of the power window at normal temperatures under a condition where it is not
frozen.

If it is NG. oroceed to the troubleshootinu of the Dower window.
11-9-25 DIAGNOSIS CODE No71172 (POWER WINDOW ECU POWER SUPPLY SYSTEM)
CAUTION
The diagnosis code No. 71 means the drop of supply voltage to the power window ECU, whereas
the diagnosis code No. 72 denotes excessive supply voltage to the power window ECU.
Furthermore, since the low-voltage error and over-voltage error are not caused by malfunctionsof
the ECU, it is not necessary to replace the ECU.
*I.BATTERY VOLTAGE CHECK

SPECIFIED VALUE: 10-14V.
~fa is OK. oo to ~ 2 .
If NG, charoe or reolace the battew.
W2.VISUAL CHECK OF BATTERY TERMINALS AND HARNESS

1.Check the battery terminals and harness for external appearance.
SPECIFIED VALUE: Ensure that there is no corrosion. (At time of low-voltage error)
If it is NG, reolace the terminals and harness.
D3.CHECK THE ALTERNATOR
1.Check that the alternator exhibits no abnormality.

If it is NG, reoair or replace the alternator.
11-9-26 DIAGNOSIS CODE NO. 81 (POWER WINDOW ECU BETWEEN ROOF ECU
COMMUNICATION SYSTEM)
D1.CHECK CONTINUITY BETWEEN THE POWER WINDOW ECU AND THE ROOF ECU.
1.Separate connector at the power window ECU and roof ECU.
2.Check the harness between the power window ECU and the roof ECU.
(1) Vehicle harness side connector 15 (TX) of power window ECU - Vehicle harness side connector
24 (RX) of roof ECU.
(2) Vehicle harness side connector 32 (RX) of power window ECU - Vehicle harness side connector
23 (TX) of roof ECU.
If it is OK. replace the power window ECU

11-IOTROUBLE SHOOTING ACCORDING TO MALFUNCTION PHENOMENA
11-10-1 THE TRUNK LID WILL NOT OPEN AT THE FRONT (THE DIAGNOSIS CODE IS NORMAL)
D l.VISUAL CHECK OF TRUNK LID
1.Check if debris is trunk lid.
SPECIFIED VALUE: Ensure that the door is not open.
If it is NG. confirm the operation with the trunk lid closed.
D2.CHECK OF TRUNK LID OPEN SW OPERATION

1.Check to see if the trunk lid operates by pushing the trunk open switch
SPECIFIED VALUE: The door opens at the rear.
CAUTION
The check should be conducted with the trunk lid fully closed.
If it is NG. proceed to the troubleshootina of the center latch and side latch.

1
B3.CHECK OF THE ROOF LOCK OPRATION
1.Check the illuminating condition of the roof warning lamp when the roof lock is released one at a time.
SPECIFIED VALUE: Warning lamp goes on.
CAUTION
The check should be conducted with the roof fully closed.
The check should be conducted for each of the right and left sides at a time.
If it is OK. ao to B4.
If it is NG. check the roof lock switch. harness and roof lock switch lever.
W4.CHECK OF THE ROOF OPENICLOSE SW

1.Check the illuminating condition of the roof warning lamp when the roof open/close switch is operated
in an opening or closing direction.
t
SPECIFIED VALUE: The warning lamp flashes.
If it is OK. check the followina switches and harnesses.
(1) Opening cover SW and harness.
(2) Luggage partition SW and harness.

(3) Trunk lid courtesy SW and harness.

(4) Center latch half lock SW and harness.

W5.CHECK OF TRUNK LID OPENER (FOR EMERGENCY USE)

1.Check the condition of the trunk lid opener cable.
SPECIFIED VALUE: Ensure that the cable is not pulled.
If it is NG. carrv out the followina o~erations.
(1) Return the cable.
(2) Open the trunk lid at the rear.
(3) Push the trunk lid open switch.
(4) When the latch operates, close the trunk lid
D6.CHECK OF TRUNK LID COURTESY SWITCH CONDITIONS
1.Check the condition of the emergency cable.
If it is NG. carw out the followina o~erations.
(2) Finish the roof mode while pushing the forward end of the trunk lid at both sides.
NOTE
Perform this operation in order to set the side latch sensor to the ON condition.
B7.CHECK OF PUMP OPERATING SOUND

1.Check the pump for operating sound when the roof openlclose switch is operated.
SPECIFIED VALUE: The operating sound is emitted.
B8.CHECK OF CONDITIONS OF HYDRAULIC SYSTEM AND EACH OPERATING SECTION

NOTE
If it is OK (there is no abnormalitv at the hvdraulic svstem side.). the svstem is functionina norm all^
If it is NG (there is an abnormalitv at the hvdraulic svstem side.). r e ~ a ithe
r malfunctionina sections
D9.CHECK CONTINUITY BETWEEN PARKING BRAKE SWITCH AND POWER WINDOW ECU
1.Separate connector at the power window ECU and parking brake.
2.Check the harness between the power window ECU and the parking brake.
(1) Vehicle harness side connector 22 of power window ECU - Parking brake SW 1.
If it is NG. re~airor re~lacethe oarkina brake switch and replace the harness.
15-73
i
W1O.CHECK CONTINUITY ROOF OPENJCLOSE SW AND HARNESS
1.Check continuity between the roof openlclose SW and harness.
If it is NG, reoair or replace the roof ooenlclose switch, and reolace the harness.
W11.CHECK CONTINUITY HYDRAULIC PUMP MOTOR AND HARNESS

1.Check the harness of the hydraulic pump motor.
If it is NG, replace the harness and connector of the hvdraulic Dump motor.
W12.CYLINDER HOLE SENSOR VOLTAGE CHECK

1.Check the voltage of the cylinder hall sensor.
If it is OK, oo to D13,
If it is NG. check the harness of the cvlinder hall sensor.
D13.CHECK CONTINUITY THE ROOF ECU AND POWER WINDOW ECU POWER SUPPLY SYSTEM
1.Separate connector at the roof ECU and the power window ECU.
2.Check the harness between the roof ECU and the power window ECU.
(1) Vehicle harness side connector 49 (ECU+B) of roof ECU - Battery @terminal.
(2) Vehicle harness connector 47(GND MC) of roof ECU - Body ground.
(3) Vehicle harness side connector 14 (+Bl) of power window - Battery @ terminal.
(4) Vehicle harness side connector 25 (+B2) of power window - Battery @terminal.
(5) Vehicle harness side connector 47 (ECU E) of power window ECU - Body ground.
(6) Vehicle harness side connector 5 (IG) of power window ECU - Ignition switch.
If it is OK, reolace of the roof ECU.

If it is NG. repair the harness.
i
11-10-2 THE ROOF WILL NOT OPEN
D l.VISUAL CHECK OF DOOR & QUARTER WINDOW
1.Check the door and quarter window operation.
SPECIFIED VALUE: It operates properly.
CAUTION
Check the quarter window by operating the roof open/close switch.
If it is NG. ~roceedto the troubleshootina of the Dower window.
D2.ROOF LOCK OPERATION CHECK

CAUTION
If it is NG. check the roof lock switch. harness and roof lock switch lever.
Refer to Page 15-68
W3.CHECK OF THE ROOF OPEN/CLOSE SWITCH OPERATION

in an opening direction.
If it is NG. oo to D4.
If it is OK, check the followina switches and harnesses.
(2) Luggage partition SW and harness.

(3) Trunk lid courtesy SW and harness


D4.CHECK OF SIDE LATCH EMERGENCY CABLE CONDITIONS
If it is NG. carw out the following owerations.
NOTE
D5.CHECK OF PUMP FOR OPERATING SOUND

1.Check the pump for operating sound when the roof open/close switch is operated.
D6.CHECK OF CONDITIONS OF HYDRAULIC SYSTEM AND EACH OPERATING SECTION

NOTE
Then, when you operate the active top, it can operate normally, only requiring an ordinaty operating
If it is OK (there is no abnormalitv at the hvdraulic svstem side.). the svstem is functionino normallv.
If it is NG (there is an abnormalitv at the hvdraulic system side.!. re~airthe malfunctionina sections
D7.CHECK CONTINUITY PARKING BRAKE SWITCH AND HARNESS

1.Check the illuminating condition of the brake warning lamp when the parking brake is operated.
SPECIFIED VALUE: The lamp goes on.

(1) Vehicle harness side connector 22 of power window ECU - Parking brake SW 1
If it is NG, rewair or replace the ~arkinabrake switch and reolace the harness.
D8.CHECK CONTINUITY ROOF OPENICLOSE SW AND HARNESS
1.CHECK THE ROOF OPEN/CLOSE AND HARNESS.
If it is NG, reoair or reolace the roof ooen/close switch, and reolace the harness.
D9.CHECK CONTINUITY HYDRAULIC PUMP MOTOR

If it is NG. reolace the harness and connector of the hvdraulic pumo motor.
D10.CYLINDER HALL SENSOR VOLTAGE CHECK

D1l.CHECK CONTINUITY BETWEEN THE ROOF ECU AND POWER WINDOW ECU POWER
SUPPLY SYSTEM
(1) Vehicle harness side connector 49 (ECU+B) of roof ECU - Battery @ terminal.
(3) Vehicle harness side connector 14 ( f B 1 ) of power window - Battery @terminal.
(4) Vehicle harness side connector 25 (+B2) of power window - Battery @ terminal.
(6) Vehicle harness side connector 5 (IG) of power window ECU - Ignition switch.
If it is OK, reolace of the roof ECU.

If it is NG, reoair the harness.
11-10-3 THE ROOF WILL NOT BE CLOSED
D l .CHECK OF DOOR & QUARTER WINDOW OPERATION
1.Check the door and quarter window operation.
CAUTION
Check the quarter window by operating the roof open/close switch.
If it is NG. oroceed to the troubleshootina of the oower window or auarter window.

D2.CHECK OF ROOF OPEN/CLOSE SWITCH OPERATION
If it is OK. check the followino switches and harnesses.
(2) Luggage partition SW and harness




If it is OK. ao to p4.
If it is NG. carrv out the followina owerations.
( I ) Return the cable.
NOTE
W4.CHECK OF PUMP FOR OPERATING SOUND

1.Check the pump for operating sound when the roof open/close switch is operated.
NOTE
If it is OK (there is no abnorrnalitv at the hvdraulic svstem side.). the svstem is functionina normallv.
If it is NG (there is an abnormalitv at the hvdraulic svstem side.), reuair the malfunctionina sections
W6.CHECK PARKING BRAKE SWITCH AND HARNESS POWER SUPPLY SYSTEM


(1) Vehicle harness side connector 22 of power window ECU - Parking brake SW 1
If it is NG. reuair or reulace the ~arkinabrake switch and reulace the harness.
W7.CHECK CONTINUITY ROOF OPENICLOSE SWITCH AND HARNESS

1.Check the roof openlclose and harness.
If it is NG. reoair or reulace the roof ouen/close switch and harness.
W8.CHECK CONTINUITY HYDRAULIC PUMP MOTOR

If it is NG. reulace the harness and connector of the hydraulic uumu motor.
11-10-4 THE TRUNK LID WILL NOT BE CLOSED AT THE FRONT (THE DIAGNOSIS CODE IS
NORMAL)
W I .CHECK OF PARKING BRAKE SWITCH
If it is NG. reoair or rewlace the warkina brake switch and rewlace the harness.
D2.CHECK OF ROOF LOCK OPERATION

CAUTION
If it is NG. check the roof lock switch. hamess and roof lock switch lever.
W3.CHECK OF THE ROOF OPENICLOSE SW

If it is NG. ao to D 4 .
If it is OK, check the followina switches and harnesses.
(2) Luggage partition SW and harness



15-81
, .
W4.CHECK OF TRUNK LID OPENER (FOR EMERGENCY USE) CONDITIONS
If it is NG, carw out the followina operations.
(2) Open the trunk lid at the rear.
(3) Push the trunk lid open switch.
(4) When the latch operates, close the trunk lid.

If it is NG, carrv out the followina ooerations.
NOTE
B6.CHECK OF PUMP FOR OPERATING SOUND

1.Check the pump for operating sound when the roof openlclose switch is operated.
D7.CHECK OF CONDITIONS OF HYDRAULIC SYSTEM AND EACH OPERATING SECTION

If it is OK (there is no abnormalitv at the hvdraulic svstem side.). the svstem is functionina normallv.
If it is NG (there is an abnormalitv at the hvdraulic svstem side.). reoair the malfunctionina sections
NOTE
15-82
W8.CHECK CONTINUITY ROOF OPENICLOSE
1.CHECK THE ROOF OPENICLOSE AND HARNESS.
If it is NG, reoair or reolace the roof o~enlcloseswitch. and reolace the harness.
D9.CHECK CONTINUITY HYDRAULIC PUMP MOTOR

If it is OK. go to W10.
If it is NG. reulace the harness and connector of the hvdraulic oumo motor.
WlO.CYLINDER HALL SENSOR VOLTAGE CHECK

Wl1.CHECK CONTINUITY ROOF ECU AND POWER WINDOW ECU POWER SUPPLY SYSTEM
(3) Vehicle harness side connector 14 (+Bl) of power window - Battery @ terminal.
(4) Vehicle harness side connector 25 ( f B 2 ) of power window - Battery @ terminal.
(6) Vehicle harness side connector 5 (1G) of power window ECU - Ignition switch.

11-10-5THE TRUNK LID DOES NOT OPEN TO THE REAR(DIAGN0SIS CODE IS NORMAL)
W1 .CHECK OF THE ROOF AND INDICATOR CONDITION
1.Check the conditions of the roof and ind~cator.
SPECIFIED VALUE: Roof : Fully opened or fully closed
Indicator : Extinguished
If it is NG. fullv oDen or fullv close the roof svstem.
W2.CHECK OF SIDE LATCH INITIALIZATION

1.Push the trunk lid open switch for at least 10 seconds.
2.0nce release your hand from the switch. Then, within two seconds push the switch again. At this time,
check the operation of the trunk lid.
SPECIFIED VALUE: The trunk lid opens.

15-83
D3.CHECK OF LINK MECHANISM
?.Performthe following checks given below.
(1) Presence of an obstacle on the operating path
(2) Seizure of luggage door
(3) Abnormal resistance of luggage link sliding section
(4) Abnormal resistance of stay damper
If it is NG. reoair the abnormal ooint.
D4.VISUAL CHECK OF SlDE LATCH RHILH

If it is OK, ao to -5.
D5.CHECK OF TRUNK LID COURTESY SWITCH CONDITIONS

1.When the trunk lid is closed, check the condition of the trunk lid courtesy switch.
SPECIFIED VALUE: It is firmly pushed.
If it is NG. adjust the trunk lid alianment.
D6.VISUAL CHECK OF SlDE LATCH SENSOR RWLH

1Check the sensor for external appearance.
If it is NG. install or re~lace
the sensor.
D7.CHECK CONTINUITY BETWEEN TRUNK LID OPEN SWITCH AND POWER WINDOW ECU
1.Separate connector at the trunk lid open SW and power window ECU.
2.Check the harness between the trunk lid open switch and power window ECU.
(1) Vehicle harness side connector 1 of trunk lid open SW - Body ground.
(2) Vehicle harness side connector 2 of trunk lid open switch - Vehicle harness side connector
40(TRLID) of power window ECU.
If it is NG, reoair the harness and connector.
D8.CHECK CONTINUITY BETWEEN TRUNK LID OPEN SWITCH AND ROOF ECU
1.Separate connector at the trunk lid open SW and roof ECU.
2.Check the harness between the trunk lid open switch and roof ECU.
25(TLO) of roof ECU.
15-84
W9.TRUNK LID OPEN SW UNlT CHECK
1 Perform the un~tcheck of the trunk hd open sw~tch.
Refer to Page 15-100
If it is NG. re~laceof the trunk lid oaen SW.
W10.CHECK OF TRUNK LID KEY-LESS ENTRY OPERATION

1.Check the operation of the keyless entry system of the trunk lid.
If it is NG. Droceed to the troubleshootina of the kevless entrv system.
W1I.CHECK CONTINUITY BETWEEN CENTER LATCH AND ROOF ECU

i
1.Separate connector at the center latch and roof ECU.
2.Check the harness between the center latch and the roof ECU.
(1) Vehicle harness side connector 1 of center latch - Vehicle harness side connector 26 (OPN) of
roof ECU.
(2) Vehicle harness side connector 3 of center latch - Vehicle harness side connector 37 (GND CL)
of roof ECU.
(3) Vehicle harness side connector 4 of center latch - Vehicle harness side connector 28 (CTY) of
roof ECU.
(4) Vehicle harness side connector 5 of center latch - Vehicle harness side connector 27 (CLS) of
roof ECU.
(5) Vehicle harness side connector 2 of center latch - Vehicle harness side connector 40 (LCM+) of
roof ECU.
(6) Vehicle harness side connector6 of center latch - Vehicle harness side connector 31 (LCM-) of
roof ECU.
If it is OK. go to B I Z .
r harness and connector.
D12.CENTER LATCH UNlT CHECK

1.Perform the unit check of the center latch
If it isOK. aotoD13.
of the center latch.
D13.CHECK CONTINUITY BETWEEN TRUNK LID COURTESY SWITCH AND ROOF ECU
1.Disconnect the connectors of the trunk lid courtesy SW and roof ECU.
(1) Vehicle harness side connector 1 of trunk lid courtesy switch - Vehicle harness side connector 8
(LSW) of roof ECU.
(2) Vehicle harness side connector 2 of trunk lid courtesy switch - Vehicle harness side connector
19 (GNDLSW) of roof ECU.
If it is OK, ao to D l 4 .
D14.UNIT CHECK OF TRUNK LID COURTESY SW

1.Perform the unit check of the trunk lid courtesy switch.
If itisOK. aotoD15.
If it is NG, reolace the trunk lid courtesv SW.
D15.CHECK CONTINUITY BETWEEN SIDE LATCH SENSOR AND ROOF ECU

1.Separate connector at the side latch sensor and roof ECU.
2.Check the harness between the side latch sensor and roof ECU.
(RIL) of roof ECU.
(LEL) of roof ECU.
D16.SIDE LATCH SENSOR RHILH UNIT CHECK

1.Perform the unit check of the side latch sensor.
CAUTION
Perform the check both at the right and left.
If it is OK. oo to D I 7 .
If it is NG. reolace of the side latch sensor.
Wl7.CHECK CONTINUITY BETWEEN SIDE LATCH MOTOR AND ROOF ECU
1.Separate connector at the side latch motor and roof ECU.
1l(SLDM+) of roof ECU.
of roof ECU.
(4) Vehicle harness side connector 4 of side latch motor - Vehicle harness side connector 19(GND
LSW) of roof ECU.
20(SLDM-) of roof ECU.
If it is OK. ao to D l 8 .
WI8.SIDE LATCH MOTOR UNIT CHECK

?.Perform the unit check of the side latch motor.
IfitisOK. aoto W19.

If it is NG, rewlace of the side latch sensor.
D19.CHECK CONTINUITY BETWEEN ROOF ECU AND BAlTERY

1.Separate connector at the roof ECU and the battery.

r harness and connector.
11-10-6 THE TRUNK LID DOES NOT CLOSE AT THE REAR(N0RMAL DIAGNOSIS CODE)
W 1 .CHECK OF THE ROOF AND INDICATOR CONDITION
1.Check the conditions of the roof and indicator.
SPECIFIED VALUE: Roof : Fully opened or fully closed
Indicator : Extinguished
If it is NG, fullv open or fullv close the roof svstem.
W2.CHECK OF TRUNK LID OPEN SW OPERATION

1.Check the operation of the trunk lid when the trunk lid open switch is pressed.

B3.CHECK OF LINK MECHANISM
1.Perform the following checks given below.
(1) Presence of an obstacle on the operating path.
(2) Seizure of trunk lid.
(3) Abnormal resistance of luggage link sliding section
(4) Abnormal resistance of stay damper.
If it is NG. reoair the abnormal point.
B4.CHECK OF TRUNK LID OPENER (FOR EMERGENCY USE) CONDITIONS

If it is NG, carrv out the followina ooerations.
(2) Check the operation of the trunk lid opener again.
B5.CHECK OF SlDE LATCH EMERGENCY CABLE CONDITIONS

If it is OK, ao to W 6 .
If it is NG. carrv out the followina ooerations.
(1) Return the emergency cable l o the original position by hand
(2) Confirm the operation of the side latch again.
W6.CHECK OF SlDE LATCH FOR PRESENCE OF FOREIGN MATTERS

If it is OK, ao to -7.
B7.CHECK OF TRUNK LID COURTESY SW CONDITIONS

1.When the trunk lid is closed, check the condition of the trunk lid courtesy switch.
SPECIFIED VALUE: It is firmly pushed.
If it is OK. ao to B 8 .
If it is NG. adiust the trunk lid alianment.
W8.VISUAL CHECK OF SlDE LATCH SENSOR RH/LH

If it is OK, ao to W 9 .
If it is NG, install or re~lacethe sensor.
W9.CHECK CONTINUITY BETWEEN TRUNK LID OPEN SWITCH AND POWER WINDOW ECU
?.Separateconnector at the trunk lid open SW and power window ECU.
2.Check the harness between the trunk lid open switch and power window ECU.
(1) Vehicle harness side connector 1 of trunk lid open SW - Body ground.
40(TRLID) of power window ECU.
If it is OK. ao to D l0.
WIO.TRUNK LID OPEN SW UNlT CHECK

1.Perform the unit check of the trunk lid open switch.
If it is NG. replace of the trunk lid open SW.
W11.CHECK CONTINUITY BETWEEN CENTER LATCH AND ROOF ECU

1.Separate connector at the center latch and roof ECU.
2.Check the harness between the center latch and the roof ECU.
(1) Vehicle harness side connector 1 of center latch - Vehicle harness side connector 26 (OPN) of
roof ECU.
(2) Vehicle harness side connector 3 of center latch - Vehicle harness side connector 37 (GND CL)
of roof ECU.
(3) Vehicle harness side connector 4 of center latch - Vehicle harness side connector 28 (CTY) of
roof ECU.
(4) Vehicle harness side connector 5 of center latch - Vehicle harness side connector 27 (CLS) of
roof ECU.
(5) Vehicle harness side connector 2 of center latch - Vehicle harness side connector 40 (LCM+) of
roof ECU.
(6) Vehicle harness side connector 6 of center latch - Vehicle harness side connector 31 (LCM-) of
roof ECU.
DI2.CENTER LATCH UNlT CHECK

1.Perform the unit check of the center latch.
If it is OK, ao to >Is.
If it is NG. replace of the center latch.
W13.CHECK CONTINUITY BETWEEN TRUNK LID COURTESY SWITCH AND ROOF ECU
1.Disconnect the connectors of the trunk lid courtesy SW and roof ECU.
(1) Vehicle harness side connector 1 of trunk lid courtesy switch - Vehicle harness side connector 8
(LSW) of roof ECU.
(2) Vehicle harness side connector 2 of trunk lid courtesy switch - Vehicle harness side connector
19 (GNDLSW) of roof ECU.
If it is OK. ao to D l 4 .
D14.UNIT CHECK OF TRUNK LID COURTESY SW

1.Perform the unit check of the trunk lid courtesy switch.
If it is OK. ao to steD 15.

If it is NG, re~lacethe trunk lid courtesv SW.
D15.CHECK CONTINUITY CHECK BETWEEN SIDE LATCH SENSOR AND ROOF ECU
1.Separate connector at the side latch sensor and roof ECU.
2.Check the harness between the side latch sensor and roof ECU.
(RIL) of roof ECU.
(LEL) of roof ECU.
Ifit is OK,aoto Wl6.

Dl6.SIDE LATCH SENSOR RHILH UNIT CHECK

1.Perform the unit check of the side latch sensor.
CAUTION
Perform the check both at the right and left.
If it is NG. reolace of the side latch sensor.
- 15-90
Dl7.CHECK CONTINUITY BETWEEN SIDE LATCH MOTOR AND ROOF ECU
1.Separate connector at the side latch motor and roof ECU.
1l(SLDM+) of roof ECU.
(2) Vehicle harness side connector 2 of side latch motor - Vehicle harness slde connector
of roof ECU.
(4) Vehicle harness side connector 4 of side latch motor - Vehicle harness side connector 19(GND
LSW) of roof ECU.
20(SLDM-) of roof ECU.
D18.SIDE LATCH MOTOR UNIT CHECK

1.Perform the unit check of the side latch motor.
If it is NG, replace of the side latch sensor.
D19.CHECK CONTINUITY BETWEEN ROOF ECU AND BATTERY

1.Separate connector at the roof ECU and the battery.
If it is OK, replace of the roof ECU.

11-10-7THE WARNING LAMP DOES NOT GO ON
W1.CHECK OF WARNING LAMP OPERATION
1.Check the lighting state of the warning lamp at the time of the bulb checking immediately after the IG
switch is set to "ON" position.
If OK. the svstem is satisfactorv.

W2.CHECK CONTINUITY BETWEEN WARNING BUZZER AND POWER WINDOW ECU

1.Separate connector at the warning buzzer and power window ECU.
2.Check the harness between the warning iamp and the power window ECU.
-
(1) Vehicle harness side connector 2 of warning iamp 44 (WRNG LAMP).
(2) Vehicle harness side connector 3 of warning lamp - Ignition SW(IG1).
W3.WARNING LAMP UNIT CHECK

1.Perform the unit check of the warning lamp.
If it is OK. re~laceof the Dower window ECU.

If it is NG. re~laceof the indicator.
11-10-8 WARNING LAMP REMAINS ILLUMINATED(N0RMAL OF THE DIAGNOSIS CODE)
NOTE
When the ECU has detected a diagnosis code, the warning lamp is illuminated. In this case perform
the troubleshooting according to diagnosis codes.
DI.WARNING LAMP CHECK

1.Set the IG switch to the QFF" position and set it to the "ON" position again. At this time, check the
lighting state of the warning lamp.
SPECIFIED VALUE: It does not go on.

NOTE
Lighting due to operation time-out, etc.
D2.CHECK OF MOTOR DRIVEN OPENING ROOF SYSTEM CONDITIONS

1.Check the conditions of the motor driven opening roof system.
SPECIFIED VALUE: The roof is not midway.
W3.WARNING LAMP CHECK
1.Check the warning lamp for the lighting state when the motor-driven opening/closing type roof system
is opened fully or closed fully.
SPECIFIED VALUE: Not illuminated.

If it is NG, ao to B4.
B4.CHECK OF THE ROOF LOCK LEVER CONDITION.

1.Check the state of the lever when the hook is applied.
SPECIFIED VALUE: It is engaged securely.
If it is OK, ao to B 5 .
If it is NG. adiust the alianment, or replace the center lock catch Av IRH or LH).
D5.VISUAL CHECK OF ROOF LOCK SW

D6.CONTINUITY CHECK BETWEEN ROOF LOCK SWITCH RHILH AND POWER WINDOW ECU
1.Separate connector at the roof lock SW RH/LH and power window ECU.
2.Check the harness between the roof lock switch RH and the power window ECU.
(LOCK RH-) of power window ECU.
(LOCK RH+) of power window ECU.
(LOCK LH-) of power window ECU.
(LOCK LH+) of power window ECU.
B7.ROOF LOCK SW UNIT CHECK

1.Perform the unit check of the r w i lock switch.
Refer to Page 15-68
If it is OK, ao to B8.
If it is NG, replace the center lock catch AV (RH or LH).
i
W8.CHECK CONTINUITY BETWEEN WARNING LAMP AND POWER WINDOW ECU
2.Check the harness between the warning lamp and the power window ECU.
(1) Vehicle harness side connector 1 of warning lamp - Vehicle harness side connector 44(WRNG
LAMP) of power window ECU.
(2) Vehicle harness s ~ d econnector 2 of warning lamp - Ignition SW(IG1).
3.Perform short check with the body ground.

If it is OK. rewlace of the Dower window ECU.

If it is NG, rewair the harness and connector.
11-10-9WARNING BUZZER CONTINUOUS SOUND
D l .CONFIRMATION OF BUZZER SOUNDING CONDITION
1.Check to see if the buzzer keeps sounding only when the vehicle is running with the motor driven
openrng roof system fully closed. (The buzzer does not sound when the roof is full open.)
W2.CHECK OF THE ROOF LOCK SW AND THE HARNESS

1.Check the roof lock switch and harness.
If it is NG. reolace the center lock catch roof lock catch RH/LH Av or rewlace the harness.
W3.CHECK CONTINUITY BETWEEN WARNING BUZZER AND POWER WINDOW ECU

2.Check the harness between the warning buzzer and the power window ECU.
(1) Vehicle harness side connector 1 of warning buzzer - Vehrcle harness side connector 43(BZZR)
(2) Vehicle harness side connector 2 of warnrng buzzer - Ignition SW (IGI).
3.Perform short check with the body ground

If it is NG. rewair the harness and connector.
W4.WARNING BUZZER UNIT CHECK

1.Perform the unit check of the warning buzzer.
If it is OK. rewlace of the Dower window ECU.

If it is NG, rewlace of the warnina buzzer.
11-10-10THE WARNING BUZZER DOES NOT SOUND
D1.CHECK CONTINUITY BETWEEN WARNING BUZZER AND POWER WINDOW ECU
2.Check the harness between the warning buzzer and the power window ECU.
(1) Vehicle harness side connector 1 of warning buzzer - Vehicle harness side connector 43(BZZR)
(2) Vehicle harness side connector 2 of warning buzzer - Ignition SW (IG1).
D2.WARNING BUZZER UNIT CHECK

If it is OK. reolace of the Dower window ECU.

If it is NG. reolace of the warnina buzzer.
I
11-10-11 THE QUARTER WINDOW WlLL NOT OPERATE
W1.CHECK CONTINUITY BETWEEN QUARTER WINDOW MOTOR AND POWER WINDOW ECU
1.Separate connector at the power window ECU and quarter window ECU.
2.Check the harness between the quarter window motor and the power window ECU.
(1) Vehicle harness side connector 1 of quarter window motor RH - Vehicle harness side connector
55(QL-) of power window ECU.
(2) Vehicle harness side connector 2 of quarter window motor RH - Vehicle harness side connector
45(QR-) of power window ECU.
(3) Vehicle harness side connector 1 of quarter window motor LH - Vehicle harness side connector
6(QL+) of power window ECU.
(4) Vehicle harness side connector 2 of quarter window motor LH - Vehicle harness side connector
6(QL-) of power window ECU.
W2.QUARTER WINDOW MOTOR UNIT CHECK

1.Perform the unit check of the quarter window motor.
If it is OK. re~laceof the Dower window ECU.

If it is NG. re~lacethe auarter window reaulator Av.
11-10-12 THE BOOT LID OPENER SWITCH WlLL NOT OPERATE
*I .CHECK OF TRUNK LID KEY-LESS ENTRY OPERATION
1.Check the operation of the keyless entry system of the trunk lid.
If it is OK. oroceed to the troubleshootina of the trunk lid not o~eninaat the rear. (normal diaanosis
code.)
If it is NG. Droceed to the troubleshootina of the kevless enttv svstern.

11-11 UNIT CHECK
11-11-1 CENTER LATCH
I."LOCKnand "UNLOCKYhe latch to check continuity
between the connector terminal @ and 0.
Position of the center latch Continuity

I
LOCK No continuity exists
UNLOCK Continuity exists
I C1185181TlO
2.Check proper operation of the motor when battery voltage
is applied between the connector terminals @ and @.
11-11-2 SIDE LATCH MOTOR

(1) PULSE OUTPUT CHECK I
1.Measure pulse between the connector terminals @ and
@ when pressing the center latch using a screwdriver
while pushing the trunk lid courtesy switch lever.
Trunk lid Center latch

-
2.Shown is the wave ~ r o f i l emeasured usina oscilloscooe I I \
function of the diagnostic tester (DS-21). O : S I G ~I O V AUTO 11:SIGl
(1) Measuring terminals :@-a .. ........
HOLD .. .. .......
..?.!.S!.6? .. !." .. L.E.".EL..+!,O:.?5"
.. ... .. .. .. .. ..
..............................................................
. . . . . . . . . . . .
. .. .. .. .. .. .. .. .. .. .. .. ..
(2) Condition : side latch motor is operating.
(3) Measuring terminals : 10V (voltage axis), I S (time , .............................................................
.. ... ... ... ... ... ... ... ... ... ... ... ...
axis) . ... ... ... ... ... ... ... ... ... ... ... ... ...
(2) MOTOR CHECK

1.When the battery voltage is applied t o between the
connector terminals @ and 0, check the operation of the
side latch. (side latch motor.)
CAUTION
Do not remove the motor when checking proper
operation of the side latch motor.
When supplying voltage, rotate the motor in several
small steps.
Check condition
Battery +-terminal@
UNLOCK
Battery --terminal@
Battery +-terminals
Battery --terminal@
(3) AFTER COMPLETION OF THE CHECK OPERATION

After checking the side latch motor, initialize the side latch by pressing the trunk lid open switch once
with the trunk lid open.
(
- 15-98
, 11-11-3 ROOF & TRUNK LID OPENICLOSE SENSOR
1.Use the SST (for the sensor check) to open/close the f hydraul~c
cyilnder
trunk lid (front opening) and measure voltage at 'OPEN"
or "full close'.
SST 09842-97207-000
MEASURING TERMINALS
Check connector measure
Kinds of sensor
terminal
Roof open sensor Hydraulic cyiindera-@
Roof closed sensor
Trunk lid open sensor Hydraulic cylinder@-@
Trunk lid closed sensor Hydraulic cylinders-@
SPECIFIED VALUE r trunk Ibd open sensor

Measure the voltage(V) &trunk hd closed sensor
Kinds of sensor connector
Fully opened / Fully closed
C1185210_1ET16
Roof open sensor 11.4 8.2
Roof closed sensor 8.2 11.4
Trunk lid open sensor 11.4 8.2
Trunk lid closed sensor 8.2 11.4
NOTE
Measurements and reference values might somewhat
vary according to the tester used.
Reference voltage refers to the value at the ignition
switch "ON".
CAUTION
When the trunk lid is closed manually, the hydraulic
cylinder might not reach "full close" position, which will
not allow the trunk lid closed sensor to take accurate
measurement. Open the trunk lid to the rear and push
the sliding hook fully before taking measurements.
11-11-4 SIDE LATCH SENSOR RHILH I I
1.Use the SST (for the sensor check) to openlclose the
trunk lid (rear opening) and measure voltage at "open" 01
/ I
"full close".
SST: 09842-97207-000
MEASURING TERMINALS
Check connector measure
Kinds of sensor
terminal
Side latch sensor Side latch 0-0
SPECIFIED VALUE
Measure the voltage(V)
Kinds of sensor
Open I Fully closed
Side latch sensor RH 8.2 I 11.4
Side latch sensor LH 8.2 11.4
NOTE
Measurements and reference values might somewhat vary according to the tester used.
atch sensor LH
<The left side of the vehicle>
11-11-5 ROOF LOCK SW

Check continuity between connector terminals when the roof
lock switch lever is pressed.
Check condition Continuity

Not operated NOcontinuity exists
When the roof lock switch lever is I Continuitv exists
pressed
11-11-6 ROOF OPENICLOSE SW
Check continuity between connector terminals when the
switch is pressed.
O-():
Continuty exist
0 0 0 0 0
Position
PULL ol-o 0--0
X
; x / ; X
OFF
I
X !
,! X !
I
!, X
PUSH
C1185187EL08
11-11-7 TRUNK LID OPEN SW
switch is pressed.
0-0:
Continuty exist
@
,
Free
Full stroke 0 0
CllBS186EL06
11-11-8 LUGGAGE PARTITION SW

switch is pressed.
Check condition Continuity

Not operated No continuity exists
When the switch is pressed Continuity exists
11-11-9 OPENING COVER SW

sw~tchis pressed.
Checn condltlon Con! n ~ l t y

No! ooeraled Cont~nulryex~sts -
I h o contlnu.ty exlsfs
11-11-10 TRUNK LID COURTESY SWITCH I
Check continuity betweell connector terminal when the lever
is pressed.
Check condition
Not operated
When the switch is n ressed I
Continuity
Continuity exists
No continuity exists 1
I
I
11-11-11 WARNING LAMP

Check if the lamp is lit up when battery voltage is applied
between the connector terminals @ and 0.
Check condition I Lamp condition

Battery +-terminal@
lliuminated
Battery --terminal@
11-11-12 WARNING BUZZER

Check if the buzzer sounds when the battery voltage is
applied between the connector terminals @ and 0.
Check condition Buzzer condition

Battery +-terminal@
Sound signal
Battery --terminal@
11-11-13 QUARTER MOTOR UNIT CHECK

Use the SST (for the sensor check) to check if the motor
rotates when the battery voltage is applied between the
connector terminals @ and 0.
SST:09842-97208-000
Check condition 1 Motor rotating direction

Battery +-terminal@
Right turn
Battery --terminal@
Battery +-terminal@
Left turn
Battery --terminal@
J1 LIGHTING
LIGHTING J1 - 1
BASIC CHECK AND ADJUSTMENT --- J1- 1
FUNCTION CHECK ......................... J1 - 3
UNIT CHECK J1-3
HEADLAMP ~y.................................. J1-7
REMOVAL AND INSTALLATION--------- J1 - 7
HEAD LAMP BULB(L0W BEAM)-----------J1 - 9
REMOVAL AND INSTALLATION--------- J1 - 9
HEAD LAMP BULB(HIGH BEAM) J1 - 10
REMOVAL AND INSTALLATION-------J1- 10
CLEARANCE LAMP BULB---------------- J1 - 10
REMOVAL AND INSTALLATION------- J1 - 10
FRONT FOG LAMP AND TURN
SIGNAL LAMP AY --------------------------- J1 - 11
FRONT FOG LAMP J1 - 12
REMOVAL AND INSTALLATION----- J1 - 12
FRONT TURN SIGNAL LAMP BULB---- J1 - 12
REMOVAL AND INSTALLATION------ J1 - 12
SIDE TURN SIGNAL LAMP BULB ------- J1 - 13
REMOVAL AND INSTALLATION-------J1 - 13
TAIL AND STOP LAMP BULB ------------- J1- 14
BACK UP LAMP BULB J1 - 15
REAR TURN SIGNAL LAMP BULB------ J1 - 15
REAR FOG LAMP BULB ------------------J1 -15
LICENSE PLATE LAMP BULB ------------ J1 - 16
REMOVAL AND INSTALLATION------- J I - 16
HIGH MOUNTED STOP LAMP AY ------- J1 - 17
ROOM LAMP AY J1 - 18
MULTI-USE LEVER SWITCH------------- J1 - 19
1 LIGHTING
1-1-1 HEADLAMP PHOTOMETRIC AXlS ADJUSTMENT
(1) OPERATION PRiOR TO PHOTOMETRIC AXlS ADJUSTMENT
1.Adjust the tire air inflation pressure to the specified value.
2.Seat one person at the Driver's seat.
3.Replenish oils to the specified levels. Fill gasoline to the full capacity.
4.Mount the tools, jack and spare tire at the specified positions.
5.Rock the vehicle in the up-and-down direction as well as in the right-and-left direction so that the
suspension may bed well.
6.Set the engine
- speed to a level of 1500 rpm or more. (If the engine speed is too low, the lamp terminal
voltage drops, thus making it difficult to recognize the cut-off line.
NOTE
Cut-off line: Boundary line between the bright zone and dark zone in the low beam.
(2) PHOTOMETRIC AXlS ADJUSTMENT

1.Adjust the photometric axis of the low beam according to
the instruction manual of the headlamp tester to be used. fl For UD and down
F& right and left direction

adjustment
A figure shows head lamp right-hand side.
CI1HSWiE
SPECIFIED VALUE: REFERENCE RANGE OF CUT-OFF
- .. .- -
I INF -- - . . .POINTS
ELBOW - .. .. -
,. . . ~ ~ . ~ ]Range from 1.0% to 1.5% below the horizontal line that passes through the lamp center
verrlcal pos~uon
(Fleference position: 1.2% below)
Range between 1.7 % right and left from the vertical line that passes through the lamp center
Horizontal position
(Reference position: On the vertical line that passes through the lamp center)
1
-Center of the headlamp
0 :Reference range of Elbow points

Unit : %
NOTE
Elbow point: Point where the cut-off line is articulated
1-1-2 FRONT FOG LAMP PHOTOMETRIC AXlS ADJUSTMENT

(I) OPERATION PRIOR TO PHOTOMETRIC AXlS ADJUSTMENT
1.Turn over the fender liner only to such an extent that allows the photometric adjustment.
2.Adjust the tire air inflation pressure to the specified value.
3.Set the engine speed to a level of 1500 rpm or more.
(2) PHOTOMETRIC AXlS ADJUSTMENT
1.Prepare a screen for the adjustment use as indicated in the figure.
I
Unit : rnm
2.Place the screen normally at a distance of three meters ahead of the lamp. Align line H with the center
of the headlamp.
NOTE
This normal placing can be carried out easily when a screen is affixed to the lens of the headlamp
tester.
3.Turn ON the front fog lamp. Perform adjustment in such a
I Front
way that the light distribution comes in the shaded
section on the screen.
CAUTION
* Perform the adjustment by turning the aiming screw in
the tightened direction. (When performing the
adjustment in the loosening direction, first loosen the
screw, then turn it in the tightened direction.)
NOTE
As viewed from v derside ciwsonmi
No screw is provided for the right-and-left
- adiustment.
1-2 FUNCTION CHECK
1-2-1 REAR FOG LAMP ON & LIGHT ON WARNING
BUZZER, KEY REMAINING-STATE & LIGHT ON
WARNING BUZZER
1.Make sure that the buzzer is set off according to the
operation table.
Operation
- table (European specifications)
Rear
IG SW Tail SW Courtesy SW Buzzer
lamp^^
OFF OFF X
OFF ON OFF ON 0
OFF OFF ON ON 0
OFF ON ON ON 0
%Oindicates condition to activate.
Operation table (Australian specifications)
Key SW
OFF OFF
OFF ON ON ON
%O indicates condition to activate.

1-3 UNIT CHECK
1-3-1 LIGHTING SWITCH
1.Check continuity between terminals in each state of the switch
European specifications
Australian specifications
Light & dimmer passing switch m : C o n t i n u i l y exists
I
HFPassing HLLow HU: High AllH5046EL14
Turn signal swich 0-0Continuity exists

FO L R
L 0 0
N
R 0 1 II 0
A1 lH5047EL06
1-3-2 FRONT FOG LAMP SWITCH

1.Check continuity between terminals when the front fog
lamp switch is turned ON.
SPECIFIED VALUE:
Switch condition I Terminal No. Standard
ON 3-4 / Continuity exists.
1-3-3 REAR FOG LAMP SWITCH I I
1.Check continuity between terminals when the rear fog
lamp switch is turned ON.
SPECIFIED VALUE:
Switch condition 1 Terminal No. 1 Standard
ON 3 4 - I Continuity exists.
1-3-4 HAZZARD SWITCH

1.Check continuity between terminals when the hazzard
switch is turned ON.
7
SPECIFIED VALUE:
Switch condition I Terminal No. Standard
ON 2-3 ( Continuity exists.
1-3-5 COURTESY SWITCH

1.With the courtesy switch shaft extended, check continuity
between the switch side connector terminal and the
switch body.
2.With the shaft retracted, perform continuity check.
I CllH502TT10
1-3-6 REAR FOG LAMP ON & LIGHT ON WARNING BUZZER, KEY REMAINING-STATE & LIGHT ON
WARNING BUZZER
--AM- BW TURNIBACK
Tail SW
-
,______.__specifications
~ustr&an .________/______________________I/______________________I/______________________I.,
-L
Buzzer side connector
l
-
.
-
.
-
.-
.
-
L
lamp S W ;
European specifications
-
&
I
-
Buzzer Ay
Courtesy Courtesy
C13H100552
1.When the terminal 4 is connected to the battery positive terminal and the terminals 1 and 2 are
connected to the battery negative terminal, ensure that the buzzer is set off.
2.When the terminal 3 is connected to the battery positive terminal and the terminals 1 and 2 are
connected to the battery negative terminal, ensure that the buzzer is set off.
2 HEADLAMP AY
(Protectivetape

Refer to Page 12-2.

1) COMPONENTS

r 1 a Headlamp Ay r 6 f Bulb (clearance lamp)
2 b Bolt, stud
r 3 c Bulb (high beam)
4 d Cover
v 5 e Bulb (low beam)
(1) HEADLAMP AY
1.When the headlamp assembly is taken out from the
vehicle, the lens may interfere with the fender panel.
Hence, affix a protective tape to the lens so that no
scratch may be made.
2.After the attaching bolts, nuts and clips have been
removed, lightly float the fender panel. Pull out the lamp
assembly to the front, facing downward so that it may be
taken out.
Pull out the lamp assembly

to the front, facing downward
SO that it may be taken out.

Refer to Page 12-2.
2.Perform the photometric axis adjustment for the headlamp.

Refer to Page J1-1.
J1-9
3 HEAD LAMP BULB(L0W BEAM)
1 Turn over the fender liner so as to assure a space that
allows the removal of the bulb

(1) BULB (LOW BEAM)
1.After the cover has been removed, remove the socket
and bulb spring.

1.Return the fender liner to the original state.
- 51-10
4 HEAD LAMP BULB(HIGH BEAM)
1.Remove the headlamp assembly. '
Refer to Page J 1-7

(1) BULB (HIGH BEAM)
1.Disconnect the bulb from the headlamp assembly.
l.lnstal1 the headlamp assembly.
Refer to Page J1-7.
2.Perform the photometric axis adjustment for the headlamp

Refer to Page J I - I .
5 CLEARANCE LAMP BULB

1.Turn over the fender liner so as to assure a space that
allows the removal of the bulb.

(1) BULB (CLEARANCE LAMP)
1.D1sconnectthe bulb from the headlamp assembly.
6 FRONT FOG LAMP AND TURN SIGNAL LAMP AY
Refer to Page 12-2.

I) COMPONENTS

1 a Bracket, fog lamp r 6 f Bulb (front fog lamp)
2 b Lamp Ay, front fog &turn
3 c Grornmet,screw
4 d Socket
v 5 e Bulb (turn signal lamp)

Refer to Page 12-2.
2.Perform the photometric axis adjustment for the front fog lamp
Refer to Page J1-2.
-- J1-12
7 FRONT FOG LAMP BULB
1 Turn over the fender h e r so as to assure a space that allows the removal of the bulb.
(1) BULB (FRONT FOG LAMP)
1.D~sconnectthe bulb from the lamp assembly

8 FRONT TURN SIGNAL LAMP BULB
1.Remove the front turn signal lamp bulb in the same way as the front fog lamp bulb.
Refer to Page Jl-12.
9 SlDE TURN SIGNAL LAMP BULB
I) COMPONENTS

r 1 a Lens, side turn signal lamp
2 b Socket
3 c Bulb ( side turn signal lamp)

(1) SlDE TURN SIGNAL LAMP LENS
1.While pushing the lens from the front side of the vehicle,
remove the lens from the vehicle.
10 TAIL AND STOP LAMP BULB
(1) COMPONENTS
I
C13HSW5Sli

1 a Cover, rear lamp
r 2 b Lamp Ay, rear combination
3 c Socket
4 d Bulb (tail & stop lamp)

(1) REAR COMBINATION LAMP AY
1.After the bolts have been removed, remove the rear
combination lamp assembly by inserting a spatula
wound by a cloth, as indicated in the figure.
11 BACK UP LAMP BULB
I) COMPONENTS
L
r A 1 a Lamp Ay, back-up
2 b Harness Ay
3 c Bulb (turn signal lamp)
4 d Bulb (back-up lamp or rear fog lamp)

(1) BACKUP LAMP AY
1.Working from the backside of the rear bumper, push the
metal sheet spring so as to remove the lamp assembly.

(1) BACKUP LAMP AY
1.When installing the lamp assembly onto the rear bumper, make sure that you hear a clicking sound
emitted as the sheet spring fits.
12 REAR TURN SIGNAL LAMP BULB
1.Remove the rear turn signal lamp bulb in the same way as the back-up lamp bulb.
13 REAR FOG LAMP BULB

1.Remove the rear fog lamp bulb in the same way as the back-up lamp bulb.
14 LICENSE PLATE LAMP BULB
) COMPONENTS

1 a Lamp Ay, licence plate
2 b Socket
3 c Bulb (license plate lamp)
15 HIGH MOUNTED STOP LAMP AY
) COMPONENTS

A 1 a Lamp Ay, stop center

(1) STOP CENTER LAMP AY
1.After the claw @ has been attached, make the claw @
deflected, and fit the claw @ into place.
CAUTION
If a complete fitting fails to be performed, there is a
possibility of water leakage.
. .
16 ROOM LAMP AY
) COMPONENTS

1 a Lens,map lamp
2 b Bulb (map lamp)
3 c Lamp Ay, map
17 MULTI-USE LEVER SWITCH
WARNING
Refer to Page H1-1.

1 .Remove the steering wheel.
Refer to Page H1-7.
Refer to Page G1-1.
2.Remove the steering roll connector.

Refer to Page H1-14.
NOTE
The muiti-use lever switch can be removed even if the steering roll connector is attached.

I) COMPONENTS

1 a Switch S/A, turn signal

I .Install the steering roll connector.
Refer to Page H1-14.
2.lnstall the steering wheel.

Refer to Page G1-1.
Refer to Page H1-7.

J2 WIPER & WASHER
WIPER AND WASHER ........................ J2 - 1

SYSTEM WIRING DIAGRAM-------------J2 1 -
BASIC CHECK AND ADJUSTMENT --- J2 - 2
UNIT CHECK J2 - 2
FRONT WIPER J2 - 6
REMOVAL AND INSTALLATION--------- J2 6
FRONT WASHER
-
J2 - 9
REMOVAL AND INSTALLATION---------J2 - 9
1 WIPER AND WASHER
1-1SYSTEM WIRING DIAGRAM
1-1-1 FRONT WIPER & WASHER
Multiuse lever SW
F
Wiper motor
1-2-1 WATER APPLYING POSITION OF WASHER
1.Adjust the water applying position of the washer as shown in the figure.
Center
/ I- 220
,- 240
-I \
@:Washer blast-off point(6 100)
Unit : rnm
1-3 UNIT CHECK
1-3-1 FRONT WIPER MOTOR
Refer to Page J2-7.
.3-2 FRONT WIPER SWITCH ( EUROPEAN SPECIFICATIONS )
Multiuse lever SW
I
1.Remove the multi-use lever switch.

2.With the wiper switch set to the [OFF], [LO] or [HI]

position, respectively, ensure that there is continuity
between the terminals according to the connection table.
3.With the switch set to the [INTI position, connect the
terminal [WB] to the battery positive terminal and
connect the terminal [EW] to the battery negative
terminal. Ensure that there occurs an operating sound of
the relay.
4.Under the state of Item 2, connect the positive terminal of
the battery to the terminal [WS]. After one second of
connecting the terminal, this time connect the negative
terminal of the battery to the terminal [WS]. At this point,
ensure that there occurs an operating sound of the relay.
Moreover ensure that, about four seconds later, there
occurs an operating sound of the relay again.
- 52-4
1-3-3 FRONT WIPER SWITCH (AUSTRALIAN SPECIFICATIONS )
Multiuse lever SW
1.Remove the multi-use lever switch

2.With the wiper switch set to the [OFF], [LO] or [HI]

position, respectively, ensure that there is continuity
between the terminals according to the connection table.
3.With the switch set to the [INTI position, connect the
terminal [WB] t o the battery positive terminal and
connect the terminal [EW] to the battery negative
terminal. Ensure that there occurs an operating sound of
the relay.
4.Under the state of Item 2, connect the positive terminal of
the battery to the terminal [WS]. After one second of
connecting the terminal, this time connect the negative
terminal of the battery to the terminal [WS]. At this point,
ensure that there occurs an operating sound of the relay.
Moreover ensure that, about four seconds later, there
occurs an operating sound of the relay again.
1-3-4 WASHER PUMP
1-3-5 FRONT WASHER SWITCH ( EUROPEAN
SPECIFICATIONS )
2.With the washer switch set to ON position, ensure that

continuity exists between the (EW) terminal and (W)
terminal.
1-3-6 FRONT WASHER SWITCH (AUSTRALIAN

SPECIFICATIONS )
2.With the washer switch set to ON position, ensure that

continuity exists between the (EW) terminal and (W)
terminal.
2 FRONT WIPER
) COMPONENTS

A 1 a
Blade, front wiper, RH A 7 g Arm Ay, wiper, No.2
2 b
Rubber, wiper blade, RH 8 h Louver SiA, cowl top ventilator
A 3 c
Blade, front wiper, LH A 9 i Packing. wiper link
4 d
Rubber, wiper blade, LH 10 j Motor & bracket Ay, wiper
5 Cap, wiper arm head
e 11 k Link Ay, front wiper
A 6 f Arm Ay, wiper, No.1
2-1-2 INSPECTION
(1) WIPER MOTOR AND BRACKET AY
@ LOW OPERATION CHECK
1Connect the earth of the wiper motor to the negative (-)
2.Connect the (+ 1) terminal to the battery (+) terminal.
Ensure that the motor operates at a low speed.
@ HIGH OPERATION CHECK

1.Connect the earth of the wiper motor to the negative (-)terminal of the battery.
2.Connect the (+2) terminal to the battery (+) terminal. Ensure that the motor operates at a high speed.
o OPERATION CHECK FOR AUTOMATIC STOP POSITION

1 . h the LO operation check, while operating the wiper motor at a low speed, remove the terminal (+I)
from the positive (+) terminal of the battery, thereby stopping the motor crank at a position other than
the automatic stop position.
2.Afier shorting the terminal ( + I ) with the terminal (S), connect the terminal (+) to the positive (+)
terminal of the battery. At this time, ensure that the motor operates again at the low speed and that
the crank stops at the automatic stop position.
(I) WIPER LINK PACKING
1.Be very careful not to inadvertently leave the wiper link packing disconnected, for example, after the
removal/installationof the cowl top ventilator louver or front wiper link assembly.
CAUTION
If it should be lefi disconnected, water may get to the link joint sections, resulting in an operating
malfunction.
(2) FRONT WIPER BLADE

1.When assembling the front wiper blade to the front wiper arm, take into consideration the following
blade length as they differ in length between the right and left.
W i ~ eblade
r dimensions
Front passenger
Driver's seat side
seat side
Blade length (rnm) / 450 ! 400
- 52-8
i
(3) WIPER ARM AY
1.When assembling the front wiper arm, take into consideration the following arm length as they differ in
length - and left.
- between the riaht
Wiper arm dimensions
Front passenger
Driver's seat side
seat side
Arm length (mm) I 406 495
2.Ensure that the stopping position of the blade comes as indicated in the figure.
I
Unit : mm
3 FRONT WASHER
CAUTION
When the battery negative (-) terminal is disconnected, it should be noted that diagnosis results and
2.Remove the battery carrier.

) COMPONENTS

A 1 a Nozzle, windshield washer 6 f Cap, windshield washer jar
r 2 b Jar Ay, windshield washer
3 c Hose Ay
4 d Motor & pump Ay, windshield washer
5 e Grommet

(1) WINDSHILD WASHER JAR AY
When you take out the washer jar from the vehicle, turn the
jar, as indicated in the figure. Then, let the jar pass through
below the liquid tube and take it out from the vehicle.
- 52-1 0
3-1-4 INSPECTION
(1) WINDSHIELD WASHER MOTOR & PUMP AY
I .Put water into the washer jar.
2.Connect the connector terminal 1 of the washer pump to
the battery (-) terminal; the terminal 2 to the battery (+)
terminal. At this time, ensure that the water is sent from
the pump under a pressurized condition.

(1) WlNDSHlLD WASHER NOZZLE
1Check and adjust the water applying position of the washer,
Refer to Page J2-2.

1.Install the battery carrier.
2.lnstall the battery.
J3 METER
1 METER
w
-1 SYSTEM WIRING DIAGRAM
-----I
Rear I*
8 -
.uel sender gauge
1,-
ter temperature sensor
METER CONNECTOR TERMINAL ARRANGEMENT DIAGRAM
I
u
Connector A Connector B
METER TERMINAL NAME

- . .. .---- - - I
' AI I +B
CONNECTOR A
I+B power supply 1 1 ~ 1 )- I- - -
A2 I ILL+ I lllurn~nat~on
+ /1 82 / ABS ~ABS
- -
1-2 FUNCTION CHECK
1-2-1 SPEEDOMETER
1.Place the vehicle on a speedometer tester.
2.Check the measured speed of the speedometer tester at the time when the speedometer of the test
vehicle re~isters60 kmlh readina.
Specifications 1 Standard
European specifications 52 - 59 kmlh
Australian specifications 1 54 - 64 kmlh
NOTE
Indicating errors are caused by excessive or lack of the tire air inflation pressure and tire wear.
3.Check to see if the speedometer pointer exhibits oscillations at the time when the speedometer
registers 40 km/h reading.
SPECIFIED VALUE: Within +3km/h
4.Check that the odometer is functioning properly.

1-2-2 VEHICLE SPEED SIGNAL
(1) VEHICLE SPEED SIGNAL INPUT CHECK
1.Check the frequency of the voltage pulses between the terminal SPDl and GGND when the vehicle is
running at the speed of 10 kmlh.
Terminal No.
Frequency
(Nomenclature of terminal)
A13(SPDI) - All(GGND) I Approx. 7Hz
CAUTION
With the connector connected, perform the check from behind the connector at the vehicle harness
side.
NOTE
For easier check, follow the procedure given below.
1. Insert a lead wire to the back of the vehicle harness side connector.
2. Secure the vehicle harness and lead wire with adhesive tape.
3. Check the signal from the lead wire.
(2) VEHICLE SPEED SIGNAL OUTPUT CHECK

1,Check the frequency of the voltage pulses between the terminal SPDO and GGND when the vehicle
is running at the speed of 10 kmlh.
Terminal No.
Frequency
(Nomenclature of terminal)
A14(SPDO) - All(GGND) Approx. 7Hz
CAUTION
With the connector connected, perform the check from behind the connector at the vehicle harness
side.
NOTE
For easier check, follow the procedure given below.
1. Insert a lead wire to the back of the vehicle harness side connector.
2. Secure the vehicle harness and lead wire with adhesive tape.
3. Check the signal from the lead wire.
1-2-3 TACHOMETER
1.With a tachometer connected, start the engine. Check the indicating error of the tachometer.
CAUTION
Do not raise the engine revolution beyond the permissible revolution speed (red zone).
Standard
800 1000 2000 3000 4000 5000 6000 7000 8000
revolution speed
Indication error 1 5100 1 +I00 1 2125 1 5150 1 5150 / 9170 I f190 1 f210 / 1225
1-2-4 FUEL GAUGE

CAUTION
After the vehicle stops, if the negative terminal of the
battery is removed before performing this check, run
the vehicle once. Then, perform this check.
1.Remove the connector of the fuel sender gauge.
2.Check the state of the indicator when the IG switch is set
to the ON position (without running the engine).
SPECIFIED VALUE: The pointer of the fuel gauge
registers "E.
3.Short the vehicle harness side connector terminal 1 and
terminal 2 of the fuel sender gauge.
SPECIFIED VALUE: The pointer should register "F".
1-2-5 WATER TEMPERATURE GAUGE
WARNING
While conducting this check, the radiator fan will start
rotating due to the fail-safe function of the radiator fan
motor control. Therefore, care must be exercised so as
not to be caught-in.
CAUTION
When this check is conducted, the diagnosis code No.
42 will be outputted by the engine control computer. C~~HSW~T~O
Therefore, it is necessary to cancel the code concerned
after completion of the check.
1.Remove the connector of the water temperature sensor.
SPECIFIED VALUE: The pointer should register "C".
3.Earth the vehicle harness side connector terminal 3 of the
water temperature sensor to the body.
SPECIFIED VALUE: The pointer should register "H".
1-3 UNIT CHECK
1-3-1 FUEL SENDER GAUGE
1.Remove the fuel sender gauge
Refer to Page 87-7.
2.Ensure that the float can move without any binding.

3.Move the float position from the point E to the point F.
Check the resistance between the terminals.
d L@
Gauge +
terminal terminal
Level Float position (rnrn) Resistance ( Q ) M~~E~ZZ>EI
F 28.1 3k1
112 108.7 32.5+3
E 176.2 120k1
1-3-2 WATER TEMPERATURE SENSOR

1.Measure the resistance between the sensor terminal @
and the sensor bodv.
Temperature ('C) 1 Resistance ( Q )
50 176a35
115 20k1.5
1-3-3 MOTOR DRIVEN OPENING ROOF WARNING BUZZER

Refer to Page J3-6.
2 COMBINATION METER
1.Lower the steering column as far as it will go.
2.Remove the instrument cluster finish panel.
3.Remove the combination meter.

I) COMPONENTS

1 a Glass, combination meter
2 b Buzzer Ay
3 c Bulb, wlsocket
2-1-3 INSPECTION
(1) BUZZER AY
1.Ensure that the buzzer sounds when the terminal 1 is
connected to the battery negative terminal; the terminal 2
to the battery positive terminal.
J3-7
,
1.lnstall the combinat~onmeter.
2.lnstall the instrument cluster finish panel.

3.Return the steering column to the specified position
J4 AUDIO & VISUAL SYSTEM
1 SPEAKER
1.Remove the door trim.

) COMPONENTS
a
I

1 a Speaker Ay, wlbox

1.Install the door trim.
Refer to Page Jll-15.
2 ANTENNA
COMPONENTS

1 a Rod, antenna
2 b Cable, antenna
A 3 c Antenna Ay, Amplifier
A 4 d Holder Ay, antenna

(1) ANTENNA HOLDER AY
1.Be sure to securely install the antenna holder assembly so that no water enters.
(2) AMPLIFIER ANTENNA AY
1 .Be sure to securely insert the antenna assembly into the holder assembly so that no water enters.
K1 HEATER & AIR CONDITIONER
HEATER AND AIR CONDITIONER K1 - 1

OPERATION Kf-1
ARTICLES TO BE PREPARED----------K 1 - 2
BASIC CHECK AND ADJUSTMENT--- K 1 - 3
1 HEATER AND AIR CONDITIONER
1-1-1 REFRIGERANT AND COMPRESSOR OIL SPECIFICATIONS
Refrigerant HFC- 134a
Refrigerant replenishing amount (g) 350+30
Compressor oil ND-OIL8
CAUTION
During the adjustment of the refrigerant replenishing amount, all of the refrigerant in the cycle
should be recovered. Then, fill in the refrigerant of the replenishing amount above. [Prohibition of
additional replenishment]
NOTE
Refrigerant service can
1OOg:88728-87501- 000
250gS8728-87601-000
1-1-2 INSTRUCTIONS FOR REFRIGERANT AND SERVICE CAN

WARNING
Any wrong handling may cause toxic substances to generate or the service can to explode, thus
leading to serious injuries. Or, the liquid may splash, resulting in blindness, frostbite, etc.
1.Be sure to use the refrigerant HFC-134a.

2.When taking out the refrigerant during the repair, etc. of the air conditioner, b e sure to use a
refrigerant recovery machine. Never allow the refrigerant to be discharged to the atmosphere.
3.Be sure to recover the refrigerant when the vehicle is scrapped or the car air conditioner is disposed
of.
4.When the refrigerant gas is exposed to open flame or very high temperature, it will be dissolved, thus
generating toxic substances. Therefore, utmost care must be exercised so that the refrigerant gas
may not leak at such a place.
5.Do not perform operations at a place with poor ventilation.
6.Never use a halide torch type leak detector, which not only is incapable of detecting leakage of
HFC- 134a gas, but also dissolves the inhaled HFC- 134a, thus generating toxic substances.
7.Do not heat up the service can. When heating of the service can is absolutely necessary, use hot
water at a temperature below 40°C.
8.Do not recycle the can by returning the refrigerant into the service can.
9.Be very careful not to shake the service can strongly. There is a danger that the can valve may be
detached if it has been installed improperly.
10.Do not handle the can near your face in preparation for the explosion of the can. Also, be certain to
wear protective goggles.
1l.Do not open the valve of the manifold gauge at the high-pressure side while the engine is running.
There is a danger that the high-pressure gas flows backward, thus leading to the explosion of the
can.
12.in cases where the refrigerant should enter your eyes, do not rub your eyes with your hands or
handkerchief, but immediately wash your eyes with clean water for more than 15 minutes. Then,
immediately receive medical treatment at an eye doctor.
--- K1-2
1-1-3 INSTRUCTIONS FOR COMPRESSOR OIL
1.Make sure to use the compressor oil ND-OIL8.
2.The compressor oil has high moisture-absorption characteristics. Hence, when an air conditioner part
is removed, be sure to immediately shut off the exposure to the atmosphere, using plugs, vinyl tape,
etc.
3.The compressor oil has an adverse influence on the paint surface and resin. Therefore, utmost care
must be exercised so that the compressor oil may not adhere to such places. If the compressor oil
should be adhered to such places, immediately wipe off the oil, using cloth.
1-1-4 INSTRUCTIONS FOR INSTALLATION OF O-RINGS AND PIPES
1.Be certain to use O-rings for HFC- 134a.
2.Be sure to use new O-rings when the pipes are connected.
3.When the O-rings are detached, use a soft object, such as a toothpick, being very careful not to
damage the pipes.
4.Liberally apply compressor oil to the O-ring.
5.Route the hose pipes naturally. Be very careful not to twist them or bend them forcibly.
6.lf a foreign substance, such as a lint, is adhered to the joint section of the pipes and O-rings, it will
cause the refrigerant gas to leak. Therefore, make sure that no foreign substance is present before
connecting the pipes. Also, do not touch the joint section of the pipes and O-rings with cotton work
gloves.
7.When the pipes are replaced with new ones, replenish the following amount of compressor oil.
Replacement parts I Pipes and hoses
Replenishing amount of compressor oil / 5 cc (per 1 piece)

Instrument
/ D I ~gauge.Torque
I wrench.Tachometer.Dry and wet bulb hygrometer,Temperaturegauge
Tool
I Manlfoldgauge 1
1-3-1 CHECK AND ADJUSTMENT OF AIR CONDITIONER
COMPRESSOR BELT TENSION (DEFLECTION
Compressor pulley
AMOUNT)
\
Refer to Page 83-2.
2.Adjust the compressor belt tension (deflection amount) to

the specified value.
Soecified value
Used belt
New belt When conductino I
Crankshaft pulley
490f 49 3 4 3 f 49
Belt tension (Nlkgf])
1501.51 1351.51
Belt deflection amount (mm) 11 - 14
(Pushingforce: 98N(10kgf))
CAUTION
When a new belt is assembled, perform the adjustment
to the mid-value of the specified value for the "New
belt."
In the case of the belt that has been used for more than
five minutes, perform the adjustment to the mid-value
of the specified value for the "Used belt, When
conducting adjustment again."
1-3-2 CHECK AND ADJUSTMENT OF MAGNET CLUTCH I I
AIR GAP
1.Remove the compressor.
2.lnstall the dial gauge to the magnet clutch hub vertically.

3.Connect the connector terminal of the magnet clutch to
the positive (+) terminal of the battery, and the body
earth of the compressor to the negative (-) terminal of
the battery. Then, start the operation of the magnet
clutch. At this time, check the air gap.
SPECIFIED VALUE: O.52Bnm
4.lf the check results fail to conform to the specified value,
remove the magnet clutch hub and perform the
adjustment by means of the plate washer.
CAUTION
The number of plate washers to be used should be 3
pcs. or less.
1-4 FUNCTION CHECK
1-4-1 HEATER CONTROL PANEL
1.Make sure that all controls, the selection dials for air discharging ports, the temperature setting dial
and the selection lever for inside /outside air, are functioning properly from one end to the other end.
Also, ensure that no reaction force occurs.
2 REFRIGERANT
2-1 REPLACEMENT
CAUTION
During the adjustment of the refrigerant replenishing amount, all of the refrigerant in the cycle
should be recovered. Then, fill in the refrigerant of the replenishing amount the following.
[Prohibition of additional replenishment]

Tool
/Vacuum pump,Manifold gauge,Halogen leak detector
--- ..- -. ..,- -. .- -.. - ,- ...- .-
(~hlorofluorocarbonrecovery and regenerating machine,Refrigerant gus HFC- 134a(R134a)

(1) RECOVERY PROCEDURE
1.Turn ON the A/Cswitch.
2.Stat-t the engine and operate the compressor for about 5 to 6 minutes. Recirculate the cycle together
with the refrigerant so that the residual compressor oil in each function part may be recovered to the
compressor.
3.Perform the recovery of the refrigerant,
- following the instruction manual of the refrigerant recovery and
recycling machine to be used.
(2) REPLENISHING PROCEDURE
Abnormality of gauge indication

Fill refrigerant in the form of gas up
Check correction of to gauge pressure of 0.1 MPa (1kgf/cm2]
Air tightness check
SPECIFIED VALUE: Replenishing amount of refrigerant: 350+30g
NOTE
Refrigerant service can
1OOg88728- 87501 - 000
25Og:88728- 87601 - 000
- -
3 HEATER CONTROL PANEL

Tool

(1) COMPONENTS

r A 1 a Cable SIA, defroster damper control 6 f Plate, heater control name
r A 2 b Cable SIA, temperature damper control 7 g Switch Ay, air conditioner control
r A 3 c Cable SIA, air inlet damper control 8 h Lamp Ay, telltale
4 d Knob SIA, control 9 i Nut, heater blower switch
5 e Knob, heater control lever 10 j Switch, heater blower

(1) DAMPER CONTROL CABLE SIA
1.ln cases where the damper control cable subassembly is
removed from the heater control panel, perform the
II
:
removal operation, while opening the pawl section of the

cable clip, using snap ring pliers, as indicated in the
figure.
1,
CAUTION
The cable at the heater control panel side is of a pawl
!
securing type. Therefore, there is the possibility that, if
the pawl is opened forcibly, the securing force becomes
weak, thus becoming unable to secure the cable again.
Hence, be sure to use snap ring pliers.
.!
3-1-4 INSPECTION
(1) AIR CONDITIONER CONTROL SWITCH AY
1.Operate the switch. At this t~me,check continuity between
the terminals 2 and 4.
Switch condition Standard
ON Continuity exists.
1
(2) HEATER BLOWER SWITCH

1.Ensure that continuity exists between the respective
terminals of the connector, as indicated in the connection
table.
=:Continuity exists
CilH5045EL08

(1) AIR INLET DAMPER CONTROL CABLE SIA
1.Set the insideloutside air selection lever to the inside air.
2.Push the insideloutside air selection link of the cooler unit Outer cable
against the stopper pin at the inside air side.
3.While pulling the cable outer i n the arrowheaded
direction, clamp the cable.
selection link
(2) TEMP DAMPER CONTROL CABLE SIA

1 .Set the temperature adjusting dial to the MAX COOL.
2.Push the control link of the heater unit against the stopper
pin at the COOL side.
3.While pushing the cable outer in the arrowheaded
OOL side
I
(3) DEFROSTER DAMPER CONTROL CABLE SIA
Outer cable
1.Set the register selection dial to the VENT position.
2.Push the mode link of the heater unit against the stopper
Innercable Stopper pin at
pin at the VENT side.
3.While pulling the cable outer in the arrowheaded
,
4 HEATER UNIT
2.Rernove the P-P member.

) COMPONENTS
1 a Clamp, hose 9 i Element, air refiner (air mix lever)
2 b Hose, heater outlet water 10 j Clamp
3 c Hose, heater inlet water 11 k Clamp, piping
4 d Heater Ay, front 12 1 Bracket
5 e Grommet 13 rnClamp
r 6 t Motor SIA, heater blower 14 n Damper, heater duct (air mix door)
7 g Resistor, heater blower 15 o Damper, heater duct (mode door)
8 h Element, air refiner (mode lever) 16 p Unit SIA, radiator heater

(1) HEATER BLOWER MOTOR SIA
1.Detach the three screws. Detach the heater blower motor
subassembly while turning it in the arrowheaded
direction, and pushing the claw toward you.
4-1-4 INSPECTION
(1) HEATER BLOWER REGISTER
1.Measure the resistance between the respective terminals
of the connector of the blower register.

1.Install the P-Pmember.
K1-10
5 COOLING UNIT
SST
09870-00025-000 Remover, quick joint
l~ompressoroil (ND-OIL8)

1.Dra1nthe refr~gerant.
Refer to Page K1-4.
2.Rernove the instrument panel.

) COMPONENTS
7--@
L
E:Non - reusabie parts
Unit:N.m(kgf .cm]
r A 1 a Clamp, piping 14 n Damper SIA
2 b Tube, liquid 15 o Cover, cooler
3 c O-ring 16 p Thermistor
v A 4 d Hose, suction 17 q Parts, cooling unit
5 e O-ring 18 r Tube. liquid
6 f Hose, drain 19 s O-ring
7 g Grommet 20 t Packing
8 h Grommet 21 u Holder, remote bulb, parts
9 i Cover, cooler 22 v Valve. expansion
10 j Spring, holding 23 w O-ring
11 k Spring A 24 x Evaporator SIA
12 i Case. cooling unit 25 y Case SIA, cooling unit
13 m Packing
(1) PIPING CLAMP
WARNING
When removing the piping clamps, first ensure that the pressure inside the freezing cycle is OMPa
{Okgflcm~.If the gas should remain, the gas may blow out, resulting in injuries, such as frostbite.
CAUTION
The use of tools other than the quick joint remover may cause damage
.
to the clamp. Therefore, be
certain to employ the quick joint remover.
1.Prior to the use of a quick joint remover, make sue to

confirm the correct direction in using the tool. See to it
that the two claws of the remover are inserted into the
hole of the clamp.
2.lnsert the remover.
3.Ensure that the clamp is released.
4.Raise the remover once so that the clamp may be

separated from the pipe.
t
5.Pull out the remover from the pipe, while pushing the lock
release lever.
6.Take out the clamp from the remover.
(2) SUCTION HOSE

1.When you loose the nut of the suction hose, be sure to
employ two spanners, as indicated in the figure.
CAUTION
If you fail to use two spanners in loosing the nut, there
is a possibility that the pipe is distorted.
CllH506ST18
5-1-51 INSPECTION
(1) THERMISTOR
Temperature ('C) I Resistance (kQ)
0 -
4.8 5.1
15 2.2 - 2.6
I LllE7078TlC

(1) EVAPORATOR SIA
1.When the evaporator is replaced with a new one, replenish the following amount of compressor oil.
REPLACEMENT PARTS Evaporator
Replenishingamount of compressor oil (CC) 1 25
(2) PIPING CLAMP
1.Ensure that the each clamp is fitted securely.
NOTE
After completion of the assembly, the clamp may move,
if turned. This, however, is not a defect.
Should be fitted
securelv without
(3) SUCTION HOSE

1.When you tighten the nut of the suction hose, be sure to
employ two spanners, as indicated in the figure.
CAUTION
If you fail to use two spanners in tightening the nut,
there is a possibility that the pipe is distorted.

2.Replenish refrigerant
Refer to Page K1-4.
6 COMPRESSOR
Tool
/Snap ring pliers

1.Drain the refrigerant.
Refer to Page K1-4.

Refer to Page 12-2.
3.Remove the air cleaner,

Refer to Page B3-2.
Unit:N.rn[kgf.cmJ
1 a COMPRESSOR AY 8 h Bar, adjusting
r 2 b Stay,compressor 9 i Bracket, compressor mounting
3 c Belt, V (air conditioner) r 10 j Clutch Ay, magnet
4 d Hose, discharge 11 k Washer, plate
5 e O-ring 12 1 Ring, snap
6 f Hose, suction 13 m Ring, snap
7 g O-ring
K1-17
i
A 1 a Compressor Ay 9 f Hose, suction
A 2 m Ring, snap 10 e O-ring
3 1 Ring, snap 11 d Hose, discharge
4 k Washer, plate A 12 c Belt, V (air conditioner)
A 5 j Clutch Ay, magnet 13 b Stay,compressor
6 i Bracket, compressor mounting A 14 a Compressor Ay
A 7 h Bar, adjusting A 15 j Clutch Ay, magnet
8 g O-ring

(1) COMPRESSOR STAY
1.When you remove the V-belt (air conditioner), prior to the removal, remove the bolt that is retaining the
compressor stay and adjusting bar.
NOTE
Slackening the bolt does not release completely the compressor. Therefore, the belt can not be
removed under this state.
(2) MAGNET CLUTCH AY

1.Energize the magnet clutch, thus securing the hub and rotor.
2.Wind the V-belt around the pulley section and secure it by
your hand.
3.Remove the bolt.

(1) COMPRESSOR AY Compressor to be
New compressor replaced
1.When a new compressor assembly is installed, drain the
excessive oil of the new compressor so that the amount
of the oil may become the same as that of the oil inside
the compressor to be replaced.
NOTE
Oil necessary for the entire air conditioner cycle has
been sealed in a new compressor. Therefore, when
only the compressor is replaced, oil is remaining inside
the condenser and cooling unit. Hence, it is necessary
to drain the oil of the amount concerned.
(2) SNAP RING
1.Install the snap rlng in such a way that the chamfered side faces upward.
1.Tghten
- the magnet clutch assembly attach~ngbolt as far as rt can be tightened.
2.Energize the magnet clutch, thus securing the hub and rotol
3.Wind the V-belt around the pulley section and secure it by
your hand.
4.Securely tighten the bolt.
5.Check the air gap of the magnet clutch. If the check
results fail to conform to the specified value, remove the
magnet clutch hub and perform the adjustment by
means of the plate washer.
Refer to Page K1-3.
(4) ADJUSTING BAR

1.The bolt and nut attaching the adjusting bar should be
tightened in the sequence of @ and @ in order to
prevent abnormal noise and looseness of the belt.
(5) V BELT
1.After the belt has been assembled, adjust the belt tension (deflection amount). When a new belt has
been assembled, there is an initial stretch of the belt. Therefore, operate the compressor for five
minutes or more after the refrigerant has been replenished. Then, adjust the belt tension (deflection
amount) again.
Refer to Page K1-3.
(6) COMPRESSOR AY
1.The bolts attaching the compressor should be tightened
in the sequence of @ @ and
I,@ in order to prevent
abnormal noise and looseness of the belt.

1.Be certain to route the lead wire of the magnetic clutch in
such a way that the lead wire passes through the radiator
support ring.

1Replenish refrigerant.
Refer to Page K1-4.
2.When a new belt has been assembled, operate the compressor for five minutes or more. Then, adjust
the belt tension (deflection amount) again.
Refer to Page K1-3.

Refer to Page B3-2.
4.lnstall the front bumper,

Refer to Page 12-2.
-
7CONDENSER
,~~ ~~.
Lubricant.adhesive.others
l~ompressoroil (ND- OILB) 1
1.Drain the refrigerant.
<RefCode=SKI-002>
2.Remove the front bumper

<RefCode=B101>

) COMPONENTS
X:Non - reusable parts

Unit:N.rn(kgf.crn]
1 a Clamp, piping A 6 f Condenser Ay
2 b Hose, discharge
3 c O-ring
4 d Tube, liquid
5 e O-ring

(1) CONDENSER AY
1.When the condenser is replaced with a new one, replenish the following amount of compressor oil
1
Replenishing amount oi compressor oil (cc) 1 20
1.Install the front bumper.
Refer to Page 12-2.
2.Replenish refrigerant.
Refer to Page K1-4.
A GENERAL INFORMATION
CONFIGURATION OF THlS MANUAL----- A - 1

HOW TO READ THlS MANUAL ------------- A - 2
HANDLING INSTRUCTIONS -----------------A - 5
HANDLING OF HARNESS AND
CONNECTOR----------- -.................... A - 5
RELEASE OF CONNECTOR LOCK ----- A - 7
lNSPECTlON................................... A-8
CAUTIONS ON HANDLING OF SRS
AIRBAG ........................................ A - 10
ITEMS OMITTED IN THlS MANUAL------A - 10
ABBREVIATION CODES ..................... A - 11
SYMBOL MARK -------------------------------- A - 12
MODEL VARIATION --------------------------- A - 13
EUROPEAN SPECIFICATIONS---------A - 13
AUSTRALIAN SPECIFICATIONS-------A - 13
1 CONFIGURATION OF THIS MANUAL
1.This wiring diagram manual consists of the following five sections given below.
Section Contents of configuration
( A 1
I
GENERAL
INFORMATION
This section exolains the confiauration of this manual, how to read this manual, handling
instructions. - -
~.ca;tions on handlina of SRS airbaas, items omitted in this manual. abbreviation.
symool martis, 1ao.e of vehice m0de.s and labe of narness codes
/
-
u I
/
POWER SUPPLY
SYSTEM DIAGRAM
Tnis diagram expatns sysrems (f~nct:onsJwn cn :ne wirmgs from rne pos'live @ lermlnat 01
the battery to the main fuse as well as to various fuses are used for.
- I EARTHSYSTEM
This diagram explains the earth route of each system (function).
l-t-- DIAGRAM
CIRCUIT DIAGRAM
BY FUNCTION
~
p~
This section consists of two portions, namely circuit diagrams and equipment diagrams.
The circuit diagrams show electric circuits from the battery or fuse of each system (function)
to the earth. Also the circuit diagrams explain the shapes of the connectors used in that
system (function) and connector terminal arrangement. The equipment diagrams explain
the installing positions of all the connectors used in that system (function), the number of
I connector pins, connector colors and connector names.
E / INDEX The index shows page which each part can be found at.
-- A-2
2 HOW TO READ THIS MANUAL
..:
Equipment diagram .r
%.
The equipment diagram illustrates
the installation positions of each :.!'
..I
connector, ground and unit as .;
well as the harness routing on the :;
actual vehicle. :i
- &*-;-& **u- ,,-~...q.-wF-.:
i
I .CONNECTOR TERMINAL NUMBER
(1) The connector terminal position indicates a position
when the connector is viewed from the joint surface
direction. Only the female connector side is
indicated. Blank terminals are also given numbers.
(2) The same terminal number is given to the terminals

that are shorted in the same short terminal.
2.WIRE COLOR CODE

(1) The wire color in the circuit diagram is indicated by a
code. The table showing the relationship between
the code and color is given at right table.
(2) The wires come in two kinds; mono-color wires and White(6asic color)
dual color wires. The mono-color wire has only a
basic color, whereas the dual color wire has stripes
W
on the basic color background.
I White(Basic color)
Black(Stripe color)
M21W102DETll
3.EARTH
The circuit diagram by function in this manual explains three
kinds of earth.
Earth connection is made within a part, and this part is

Inside par1 earth @ Inside part earth
I
.
:
-
.
C13W513OTlO
A-5
4.WIRE TO WIRE JUNCTION CONNECTOR (W to W JIC)
(1) This connector is a junction connector in which a
shorting pin shorts two connectors. The connector
diagram of the W to W J/C is given at the right figure.
5.FUSE BLOCK, RELAY BLOCK

(1) The position of each fuse is indicated when the fuse
block or relay block is viewed from the front. The
Omark indicates the power supply plus side of the No fuse is set
fuse and the Omark indicates the power supply
minus side of the fuse. No fuse is provided where
no 0 0 mark is provided.
/
ishows the power supply side
M21W1018ETlO
3 HANDLING INSTRUCTIONS
3-1 HANDLING OF HARNESS AND
CONNECTOR
1.When assembling the wire harness, do not pull or step on
the connectors. Be careful not to allow the harness to be
damaged by burrs or edges.
2.When installing the harness, be careful not to allow the
harness to wind or twist.
3.Ensure that the clamp section of the resin clamp has

been inserted into the body hole. clamp I
CAUTION
Ensure that the clamp section cannot be pulled out by
lightly pulling it.
4.Never touch the terminal of connector directly by hand.

5.Modification of wire harness.The wire diameter and
capacity of each harness have been determined to
assure the normal operation of the electrical system.
Hence, do not take power for accessories carelessly
through the original wiring harness. Failure to observe
this caution may cause system malfunction or fire.
6.When a band type resin clamp is used, never use tools,
such as pliers or radio pliers.
7.ln the case of a locking connector, be sure to connect it
firmly by pushing and inserting it. After connecting the
connector, confirm that it has been locked by lightly
pulling it.
8.Be careful not to pull out the connected connector by
forcibly pulling the harness.
9.When disconnecting connectors, b e sure to hold the

connector itself with the connector unlocked.
10.Connection or disconnection of the connector and each

terminal shall be performed basically after the removal of
negative terminal of the battery.
CAUTION
However, there may be the case that diagnosis code is
erased when remove the negative terminal of battery,
so confirm the diagnosis code first before the removal
of battery negative terminal when need to confirm.
11.Check visually the rust generation or mixing of the
foreign material at connector terminal portion.
12.Check whether there are looseness, damage at the
staking portion and check coming out from the coupler
r
by pulling the wire harness lightly.
Looseness
13.When inserting tester probes into a connector, insert

them from the rear side of the connector.
Tester probe
G07E5018ETII
14.For water-proof connectors which cannot be accessed
from behind, take good care not to deform the connector
terminals.
. .
Do not insert the tester probe in place.
W7E5024ETll
15.When a tester probe is applied to a terminal to which

voltage is applied, care must be exercised so that two
tester probes may not come in contact with each other so
that short circuit may not take place.
3-2 RELEASE OF CONNECTOR LOCK OPress down

3-2-1 PUSHTYPE
1.To pull out the connector, unlock the connector by
pushing down the pawl of the locking section in the arrow
direction with your finger or a tool.
3-2-2 PULL-UP TYPE

1.To pull out the connector, unlock the connector by
pushing up the pawl of the locking section in the arrow
direction with your finger or a tool.
!
3-2-3 LEVER TYPE DRaise the lever i
1.Detach the pawl and raise the lock lever in the arrow
direction. Then, the mating connector will be pushed
out.
V
@The con"ec1or will be pushed out ,
M21W1006~10l
A-8
3-2-4 DOUBLE LOCK TYPE
1.First unlock the primary locking. Then, disconnect the
connector by uniocking the secondary locking in the
same way as the aforesard push type connector.
3-3 INSPECTION
3-3-1 TESTER (VolWohmmeter)
1.For the inspection, use a tester having an internal
resistance of more than 10 kilo-ohmsN. Use of a tester
with a low internal resistance may cause wrong
measurement or secondary troubles.
3-3-2 VOLTAGE CHECK

1.When conducting this check, let the voltage apply to the
check point.
2.Connect the (-) line of the voltmeter to the ground or (-)
terminal of the battery; the (+) line to the connector
terminal. This check can be performed by using a test
lam^ instead of a voltmeter.
Example
Check point Connecting condition
A Ignition switch:ON
B Ignition switch:ON. Switch A:ON
C Ignition switch:ON, Switch A:ON. Switch B:ON. Relay:ON
3-3-3 INSPECTION OF SHORT CIRCUIT
1.Remove a melt fuse or fusible link.
2.Disconnect all connectors for loads being applied to the Test lamp
melt fuse.
IG switch
3.Connect a test lamp at the position where the melt fuse or
fusible link was installed.
4.Search for the short circuit by providing the minimum
conditions which make the test lamp glow.
5.Perform repairs or wiring harness replacement, as
Switch A
required.
Example Short @
r -.
~h . n rsectinn
t I - ...... -........cnnditinn
Connectinn -. ... 1
.A. ......-.. switch
1 lnnitinn - ... . . n-N
..
B /Ignition switch : ON,Switch A : ON
Ignition switch : ON.Switch A : ON.Switch B : ON,Relay :
i
Switch B
3-3-4 RESISTANCE AND CONTINUITY CHECK Sensor side Computer side

ends.
terminals of connector on both end.
CAUTION
Measure the electrical resistance while shaking wire
harness in top and down and right and left lightly.
3.11 a diode is built in the circuit, perform continuity test by

changing the polarities of the measuring terminals. In
case of a general type tester, ensure that continuity exists
when the negative (-) lead of the tester is connected to
the positive (+) side of the diode; the positive (+) lead of
the tester to the negative ( - ) side of the diode. Also
ensure that no continuity exists when the polarities are
changed. Since some testers have different polarities,
be sure to read the instruction manual of a tester to be
used for the check before using it. The inspection
procedure for light emitting diodes (LED) is the same as
normal diodes. However, there may be cases where the
LED emits no light, unless a tester with LED check mode
is used. If an adequate tester is not available, apply the
battery voltage to the LED and ensure that the LED emits
light.
A-I 0
4 CAUTIONS ON HANDLING OF SRS AIRBAG
1.If the SRS airbag is not handled with the correct procedure and method, the airbag may be deployed
unexpectedly during the operation, resulting in a serious accident. Moreover, if wrong repairs are
made, there is the possibility that the airbag fails to operate when it should operate. Therefore, the
airbag-related service (installation, check and replacement of parts) should be performed with the
correct procedure and method. For that purpose, please read the repair manual carefully. Also,
strictly observe the cautions about the airbag service.
r
-- -
5 ITEMS OMITTED IN THIS MANUAL

?.This manual does not cover the following item given below. When performing the electric system
checks and service, please read the General section of this manual and related repair manuals.
Moreover, before starting the check operations and service, be sure to be well versed in those
operations by reading the General sections of the repair manuals.
(1) GENERAL SERVICE INSTRUCTION
(2) SUPPORTING POINTS FOR JACKS AND SAFETY STANDS
(3) SUPPORTING POINTS OF LIFTS
(4) SERVICE INSTRUCTIONS FOR FOUR WHEEL DRIVE VEHICLES
(5) DATA LINK CONNECTOR
(6) INSTRUCTIONS FOR SYSTEM INSPECTION
(7) INSTRUCTIONS FOR RADIO INSTALLATION
A-I 1
6 ABBREVIATION CODES
ORIGINAL WORD
Two wheel drive
Air control valve
LH Left- hand
MIT Manual transaxle, Manual transmission
PIS Power steering
RAD Radiator
RH Right- hand
. .. .
RR .Resr
.--,
RIB Relay block
SRS Supplemental restrain system
SW Switch
TEMP. Temperature
VSV Vacuum switching valve
W to W Wire to wire connector
SYMBOL MARK
Fuse Zener diode
LED Resistor / Variable resistor Condenser
PNP transistor Reed swytch Bulo Motor

I
I
NPN transistor Shielding wire
Switch Horn Solenoid Stator coil

A-1 3
8 MODEL VARIATION
8-1 EUROPEAN SPECIFICATIONS
Model code I Steering position I Engine Drive I Transmission I Body type
L880RK-KMVZW RHD JB-DET 2WD 5Mn Open top
8-2 AUSTRALIAN SPECIFICATIONS

Model code 1 Steering position / Engine Drive / Transmission 1 Body type
L880RK - KMVZO RHD JB-DET 2WD 5Mfl Open top
B POWER SUPPLY SYSTEM DIAGRAM
POWER SUPPLY SYSTEM DIAGRAM ---- B - 1

B-1
1 POWER SUPPLY SYSTEM DIAGRAM
C EARTH SYSTEM DIAGRAM
EARTH SYSTEM DIAGRAM------------------ C - 1

- - -
I
1 EARTH SYSTEM DIAGRAM
Section Contents of configuration
This section explains the configuration of this manual, how to read this manual, handling
GENERAL
A instructions, cautions on handling of SRS airbags, items omitted in this manual, abbreviation,
lNFoRMATloN
symbol marks, table of vehicle models and table of harness codes.
POWER SUPPLY This diagram explains systems (functions) which the wirings from the positive @terminal of
SYSTEM DIAGRAM the battery to the main fuse as well as to various fuses are used for.
EARTH SYSTEM
C This diagram explains the earth route of each system (function).
DIAGRAM
This section consists of two portions, nameiy circuit diagrams and equipment diagrams.
The circuit diagrams show electric circuits from the battery or fuse of each system (function)
CIRCUIT DIAGRAM to the earth. Also the circuit diagrams explain the shapes of the connectors used in that
D
BY FUNCTION -
system (function) and connector terminal arranaement. The eaui~ment
. . -
diaorams exolain
the installing positions of all the connectors used in that system (function), the number of 1
connector pins, connector colors and connector names
INDEX I The index shows page wh~cheach part can be found at.
II METER ILLUMINATION
I CLEARANCELAMP LICENSE LAMP.
&
I I TAIL LAMP, FOG LAMP

I I I
BACK UP LAMP U)
FRONT WIPER 8 WASHER 8
COMBINATION METER !?
RADIO N
N
CIGARETTE LIGHTER 8
CLOCK 2
I
1 HEATER .AIR CONDITIONER N
01
SEATHEATER N
m
WARNING BUZZER N
U
DATA LINK CONNECTOR 2

D CIRCUIT DIAGRAM BY FUNCTION
WARNING BUZZER ........................... D - 93

DATA LINK CONNECTOR-------------------D - 95
D-I
1 POWER SOURCE
ABS
m 1 0
(HEATER, 30A)
HEATER
(TAIL, 40A)
(HEAD, 40A)
HEAD
(RAD ,3OA)
(AM. 60A)
Relay blosk
I
e I
ACC
101
162
ST
\ [Bfack , GP , Ignition switch)
2 STARTING SYSTEM
I Fuse black
lBbl JEe( (FA) m

-
i,
FA (Fuseblock)
Mx (Gray, 1P)
3 CHARGING SYSTEM
TOpower supply
I
(FA)
.
7 Ex (22P Combination meter)
, '
I '
:, :'
(Black. 3P ,Alternator) , *
-- --FOR
4-1 - - -AUSTRALIA
- a
I +B(WB) 4
IG2 T b
L------*
TO power supply 4~
Cb I
1130 WO VSVl PRG I
Engine control computer
(2P. N C evap. temp. sensor) (22P. Combination meter)
(2W
.,
, a (Elad. 16P. Data link connector) :

:
..
8 8
(17P , Engine control computer)
I
. a
:, :. (24P , Engine control computer)
---I
, ,
: : @ (31P. Engine control computer)
0
, ,__________________.-----------------.----------.--.---------
0 8
___________________---------.--..-.-
0 .
@ (Gray. 2P , Injector No.4) (Brown, 3P, Thronle sensor)

(Brown ,2P, Injector No.3)
(Gray ,2P , Injector No2) (Black, 2P, Purge VSV)
/ (Green, 1P , Knock sensor)
.
(Black. 3P Pressure sensor)
(Gray, 1P , Power st
oil pressure switch) (4P, EFI main relay)
(Black, 2P, ABV VSV) (4P, Fuel pump relay)
(Brown, 2P, lnjector No.1)
a (Black, 2P , Engine revolution sensor)
(3P, ignition coil No.1)
(Black. 2P , Intake ai
( 3 ~Ignition
. coii NO.?) (Gray. 3P. Water temp. sensor)
(Gray, 2P , Rear 0 2 sensor)
(3P, ignition coil No.3)
(Gray. 4P, Front02 sensor)
(3P. Ignition coii No.4)
C13W5017ES48
(Black, 4 P , Fuel pump,
Fuel sender gauge)
(Blue. 14P)
-v
.
(Blue t4P)
a (2P. N C evap. temp. sensor) (22P. Combination meter)
----.----- ------------.-------.--A-
(2W
.,
8 8
.
(Black, t 6 P Data link connector) :
.i i
8 8
(17P , Engine control computer)
j, i. (24P , Engine control computer)

.: :
. (31P Engine control computer)
.--------------------.------......----------.------.-~--------..~~
0
8
.
0
---------.---__-_----------.----.-~--.---
8 %
@ (Gray, 2P .injector No.4) Hd (Brown .3P. Throttle sensor)

(Brown. 2P. lnjector No.3)
(Gray, 2P, Injector N o 4
@ (Green, 1P .Knock sensor)

/ \+m
He (Gray. 3P. ISC valve)
(Black. 2. Purge VSV)
(Black, 3P, Preswresensor)
(Gray. 1P , Powers
oil pressure switch) (4P. EFI main relay)
(Black. 2P. ABV VSV) (4P , Fuel pump relay)
@ (Brown. 2P, Injector No.1)

@ (Mack, 2P , Engine revolution sensor)
(3P, lgnition coil No.1)
(Black. 2P, Intake airtemp. sensor)
@ (3P, Ignition coil No.1) (Gray, 3P. Water temp. sensor)
(3P, lgnition coil No.3) (Yellow, 4P. Rear 0 2 sensor)

v/
( 3 ,~Ignitioncoil No.4) (Gray. 4P. Front Ozsensor)
(Gray, 8P , Igniter unit) (Gray .6P , igniter unit) C13W5109ES48
\ (Black, 4 P . Fuel pump,
Fuel sender gauge)
5 RADIATOR FAN
Relay block mde
Theamah represents
the power supply of the fuse
\ FA (Fuse block)
a (Fuse)
fan relay)
(Black, 2P. Radiator fan motor)

6 ABS WITH EBD CONTROL
1 ABS ECU
Fmnl speed s e n m LH Front speed sensor RH Rear speed senrar LH Rear speed gemor RH
(Black. 16P,Data link connector)
(Gray .2P.Brake oil

level switch)
\
(Black. 25P, ABS ECU) ----------A

(El& .1 P ,Parking brake switch) 2
/ (2P ,Rear spaed sensor LH) (2P. Rear speed sensor RH)
C13W5025ES48
7 SRS AIRBAG SYSTEM, SEAT BELT WITH PRETENSIONER
Airbag ECU
- 10 4
Data lhnk connector

.
i5LY
5
(MEMO)
m (4P)
(Yeaow, 2 P ,
Passenger'sairbag squib)
(Yellow, 2 P , Drivehairbag squib)
(Blaclc , 6 P . Ignition switch)
(Yellow, l 2 P , Airbag ECU)

16P. Data link connector)
/ (/(Yew, 20P, Airbag ECU)
.
(Yeilow , l Z P Airbag ECU)
a
(Yellow. 2 P . Pretensioner
seal belt squib LH)
& .
(Yellow. 2P Pretensioner
seat belt squib RH)
i
8 IMPACT SENSING SAFETY SYSTEM
ITC ECU
1 El CSl T LKS UKS
12
R-B mi RB ~ 1 7 R-B
I -u
.......
1 2 3 4 5 6 7
0 00 0 0 00
~hemmackrepvsrantr tne power

supply side O I the luae.
heh ha* rev- me W P
w p"
h r sue dme hne.
16P. Data link connector)
P FB (Fuse)
)(2P. Room lamp)
-
(2P, Door lock motor RH)
((3P, Door control switch RH)
,
9 ROOM LAMP, POWER DOOR LOCK, KEYLESS ENTRY SYSTEM
IGi
L------T
To power supply
,':
ITC ECU
L KEY KLSW
opening roof system
,-
R-B $1
I
I
Relay block
L T
(For Australia)
f 1 R-B $3" R-B

(Blue, 14P)
v
v\
(IOP , ITC ECU)
( l a p , ITC ECU)
(Black ,2P,Key switch)
A=
FB (Fuse)
(1P. Courresy switch RH)
j( I P , Room lamp)
(2P, Door lock motor RH),-

(3P, Door control switch RH)
1 /
(1P , Courtesy switch LH)
(2P ,Door lock

motor LH)
10 IMMOBILIZAR SYSTEM
I Immobilizer ECU
I
(Blue. 14P)
v + (Orange, 14P)
\ /- (Orange, 14P)
(Gray, 10P,Immobilizer ECU)
---------------.---.---------
j I(26P)
j (Wac%.16P. Data link connector)
,@ (Fuse)
block
11 OUTER REAR VIEW MIRROR
I
Rear view mirror LH
Rearview m
,,",i swnc*
(FA)
TheOmar* reprssentsthepower supply side ofthe fuse.

(MEMO)
'switch)
D-39 -
12 REAR WINDOW DEFOGGER
To power supply
(MEMO)
Cq (Blue, 14P) (Green. 5P , Rear window
=------7 defogger switch)
(Fuse block)
(Black, 1 P . Rear window defogger)
@ (Black, 1 P . Rear window defogger)
(Black, 2P)
13 POWER WINDOW, MOTOR DRIVEN OPENING ROOF SYSTEM
1111 Power window ECU

Pump
n n
21 19
sj sj
CHG SPD
Roof ECU
ON"
OR* OR. oL+
-----
Bmt lid latch drive
(Orange. 14P)
(Black, 2P,Warning buzzer)
(Black .6P.Power window lock switch)

-For Australia
(Black, 3P, Roof warning lamp)
\-m (Bkck. 16P. Data link connector)

(5P , Power window switch LH)
(ZP, Roof lockswitch RH)

(Black .2P , Boot lid open switch)
- - . ~ motor
, - , o r , rower wlnoow
,way ~. .nn)-... 7
\ V i I/-
(2P. Roof lock switch LH)
(Gray, 2P ,Power window
(6P. Power window master switch) ------------/
(Blue, 5P. Roof openlciose switch)
(5P. Boot lid latch drive)
.
(2P Boot lid courtesy switch)
(2P , Side latch sensor RH)
(2P ,Side latch sensor LH)

(Gray, 2P ,Power window quarter
(18P. Power window ECU)
(25P , Power window ECU)

(4P, Luggage door sensor)
(2P. Luggage partition switch) -

(12P. Power window ECU)
(iOP, Roof ECU)
(2P ,Opening cover switch)
Trap. Pump Ay)

14 HEAD LAMP, HORN I
. -For Europe
"--For Australia
(6P, Hornswkch)
(2ZP. Combination meter)
relay)
-
-
(Black, 2 P , Headlarnp RH Hi)
(Gray. 4 ~ Headlamp
.
. RH LO)
- Kw -
(Black. 2 P , Headlamp LH Hi)
(Gray, 4 P , Headlamp LH Lo)
(Black. l P , Horn LH)

(Black. l P Horn RH)
(Black, l P , Horn RH) 7 (Black, .

1P Horn LH)
C13W5067ES48
- D-50
i
(MEMO)
15 REAR FOG LAMP
15-1 FOR EUROPE
3 Mdti use lever switch

i
Rear lqlampswitch
3 P 8
1
Meter iuuminatim
License lamp
@18.Ciearanse lamp r
R-L 2
Fcg lamp
Tail lamp
Theamark represents the power

SYPP~Yside *the lure.
(MEMO)
(22P.Combination meter)
1 p (Blank.6P , Rear fog lamp switch)
(10P.Muili use lever switch)

( I P , Rear fog lamp LH) . Rear fag lamp RH)
E ,I
/Turn I Back,
I Turn signal flasher relay
.-For Europe
++-For Auslralia
W lCul (FA) 0 ILa( /M,I
T h e e m a l ,eprasen,r the oowe,

~ ~ p rae p ~otyine fuse.
m e ~ m a leprenenlr
a tne parer supply ride ol me fuse. C13W5069ES48
I / (Blue. 14P)
.
(Black, 4P Hazard switch)
(22P. Combination meter)
.
(Blue 18P, combination meter)
-----.----------.------
(2W
(8P ,Turn signal flasher :

relay)
L Ap (12P ,Multi use lever switch)
(GI;, 2 P Side turn lamp
a (Gray , 2 P . Side turn lamp RH)
I
Battery
@ (Gray , 2 P , Front turn lamp RH) (Gray . 2 P . Front turn lamp LH)
(3P,Back Irear turn lamp LH)
(3P, Back1 rear turn lamp RH)

17 STOP LAMP, HIGH MOUNTED STOP LAMP
TheOrnark represents the power

supply ride 01 the luse.
( m e , 12P)
(Blue, 12P)
L,
Bh (Black, 2P, Stop lamp switch)
@ (Fuse)
(2P.High mounted stop lamp)
7
\ ((Gray. 3P. Rear combination

lamp RH)
18 METER ILLUMINATION, CLEARANCE LAMP, LICENSE LAMP,
--TAlL LAMP, FOG LAMP
-- - - - -
- - --- - - -
I TAIL y
To power rupply
- I.
Fuse block
m 2 0
(Tail. 10A)
-.For Europe
"-For Australia
'?
I
l g
i
' @
I
I
I
L.
1'
(For I
jsxl lcvi (FA) m /Mm(

(22P. Combination meter)
(4P, Fog lamp switch)
(Blue. 12P)
(Blue. 12P)
...-.----------.------------ ---.------------------
: a (26P) (4P. Fog lamp relay) :
.
(4P Multi use lever switch)
.
(10P Multi use lever switch)
(Gray, UP. Clearance lamp LH)
'
i L
Banely
(Gray, 4P , Clearance lamp RH)
' Mh (Brown. 2 P , Fog lamp LH)

~ w n 2 . ~~ .o lamp
g RH)
C13W5078ES48
\ (Gray, 2P, License lamp)
19 BACK UP LAMP
To power supply
I
/
(Len hand drive
regom in Eumpe
) \- -
(For Australia)
(Rig! h y d drive )
regions m Europe
(MEMO)
Battery
2P.Back lamp switch)

.
(3P Back / rear turn lamp LH)
20 FRONT WIPER & WASHER
- .--For Europe
"-For Australia
i / (Black, l2P)
ij (Black. l2P)
i (26P) @ (Fuse block)
(12P, Multiuse lever witch)
p .
Mv (Black, 4P Front wiper motor)
(Black, 3P , Front
washer motor1
21 COMBINATION METER
- -- - -- - - -1 a
I +B(WB) 4
IG2
L------'I! b
To power supply
[El (back up, 10A)
Combination meter
@ (Orange, l4P) (22P.Combination meter)
----- (Blue, 18P, Combination meter)
@ (Black. 1P ,Oil pressure gauge)

(Gray, 3 P . Thermo. sender gauge)
(Black, 4P,Fuel pump,
Fuel sender gauge)
22 RADIO
Cr (Orange, 4P)
I
Battery
.
' Rear pale antenna)
23 CIGARETTE LIGHTER
- -- - - --
I
-
ACC 4
To power supply
Tnamark represents the powersupptyrideol the fuse

r"
At (2P, Cigarene lighter)
24 CLOCK
24-1 FOR EUROPE
p .
(Back up 10A)
Clock
P-'
OP 3 R-L
j l (Black, 4P,Clock)
P
FB (Fuse)
25 HEATER, AIR CONDITIONER
7-------
/ HEATER
+B(WB)
-d
IG1 r-l
a
b
c
@ 18.Tail lamp. Fog l w .

Clearance lamp.
License lamp, Meter itlumimiin 1
Heater
motor
1 Heater bbwer switch
L-w I
L-W
$h
(Relay block side) C13W5096ES48

(FA)
.
11112121313(4 0 1
0 0 9 * . 1 7 0
.
11111212/31414
<
.2
3 0 0
0 0 1 0 .
1 1 . . 1 8 0
4 OO12..19O
0 5 OO13..200 0 0 0 0 0 0 (Ralay block side1
(Black, 4P .Air condisioner switch)
.
(Black 2P , Heater blower motor)
: )(Black , 8 P . Heater blower switch) I-- (Black, 4P. Heater blower resister)
pressure swilch)
I
/ ( I P ,Magnet clutch) A
(MEMO)
26 SEAT HEATER
(Stit heater .)
(MEMO)
PSt (Green. 5P, Seat heater switch RH)
/P
Sq (Black, 5P,Seat heater switch LH)
(2P, Seat healel

27 WARNING BUZZER
4
8r
I IG KEY 1
1 Warning Buzzer
TAIL
ia
\\ cowl wire
1
\
28 DATA LINK CONNECTOR
Theernark represents the power supply side of the fuse.

@ (Orange, 14P)
-
.
(Black. 16P Data link mnnector)
E INDEX
1 INDEX
--
ITEM PAGE ITEM PAGE
AIC evap. t e m ~sensor

.
I -- Door control switch RH
(AUS)
U-8
I/
(Kevless entrv svstem)
AIC evap. temp. sensor Driver's airbag squib
D-12
(EU) Dual pressure switch
ABS ECU D-17 EFI main relay (AUS)
ABV VSV (AUS) D-8 EFI main relay (EU)
ABV VSV (EU) D-12 Engine control computer
Air conditioner switch D-85 (AUS)
Airbag ECU D-21 Engine control computer
Alternator D-5 - (EU)
Back lamp D-67 Engine revolution sensor
Back lamo switch D-67 IAUS)
Boot lid courtesy I D-44 Engine revolution sensor
Boot lid latch drive I D-44 IEU)
Boot lid o ~ e switch
n I D-44 I/ Foa lamo
Brake oil level switch D-18 Fog lamp relay
Senter latch D-44 Fog lamp switch
Sigarette lighter D-81 Front door lock motor
Iearance lamp I /I
D-63 (Impact sensing safety
;lock D-83 system)
2ourtesy switch D-29 Front door lock motor
Iata link connector D-95 (Keyless entry system)
Iata link connector I II Front door soeaker
Motor driven opening roof D-44 Front 0 2 sensor (AUS)
iystem) Front 0 2 sensor (EU)
3ata link connector (ABS) D-18 Front passenger's seat
3ata link connector pretensioner mechanism
D-21
Airbag) squib
lata link connector (AUS) D-8 Front passenger's seat
Iata link connector (EU) D-12 side airbag squib
lata link connector Front speed sensor
D-33
Immobilizar) Front turn lamo
)ata link connector (ITC) 1 D-25 11 Front washer motor
loor control switch RH 11 Front w i ~ e motor
r
impact sensing safety /I
D-25 Fuel (AUS)
ystem) 1 /I Fuel pump (EU)
I ITEM I PAGE /I ITEM PAGE
I Fuel pump relay (AUS)

/ Fuel pump relay (EU)
1 Fuel sender gauge
Hazard switch
Headlamo
Headlamr, relav
Heater blower motor ,I - - - -
Heater blower resister D-85 I/ Luggage partition switch

Heater blower switch D-85 )( Magnet clutch
Heater relay Magnet clutch relay
High mounted stop lamp
.Hnrn
..
Horn relay
Horn switch Charae
- Unit
laniter I Checi enaine (AUS)
lanition coil (AUS)
lanition coil ~ E U ')
Ignition switch 1 Hiahbeam indicator
Immobilizer ECU I Illumination
Immobilizer coil
lnjector (AUS)
Injector (EU) D-11 11 ( Turn indicator
Intake air temp. sensor -- 1) Multi use lever switch
] WS)
Intake air temp. sensor
(EU)
I U-1 1
(Front wiper & washer)
1 (Head lamp,Horn)
ISC valve (AUSI D-8 11 Multi use lever switch
ISC valve (EU) D-12 1 (Rear fog lamp)
ITC ECU D-25 11 Multi use lever switch
ITC ECU -1 (Turn sianal switch)
(Hazard warning & Turn 11
D-55 Oil pressure switch
signal lamp) I/ Opening cover switch
ITC ECU (Keyless entry PIS oil pressure switch
system)
Key switch PIS oil Dressure switch
Kevless receiver
ITEM PAGE ITEM PAGE
Parking brake switch D-18 Room lamp

Passenger's airbag squib D-21 (Impact sensing safety
Power window ECU D-43 system)
Power window lock Room lamp
D-43
-switch . -
(Kevless . svstem)
entrv .
Power window motor / D-43 11 Seat belt switch I D-73
Power window motor - /I Seat heater II D-89
auarter I D-44 // Seat heater switch 1 D-89
Power window switch D-43 Side latch sensor D-44
Pressure sensor (AUS) D-7 Side turn lamp D-56
Pressure sensor (EU) D-11 Starter D-3
Pretensioner seat belt Stop lamp D-59
0-2 1
squib LH Stop lamp switch D-59
'retensioner seat belt - -. Tail lamr, 0-63
I I/ Tail switch 1 D-63
'ump Assy D-44 Thermo. sender gauge D-73
3adiator fan motor D-15 Throttle sensor (AUS) D-7
3adiator fan Relay D-15 Throttle sensor (EU) D-11
?adio D-77 Turn signal flasher relay D-55
3ear fog lamp D-51 Turn signal switch D-55
?ear fog lamp switch 0-51 Warning buzzer D-93
?ear 0 2 sensor (AUS) D-8 Warning buzzer
3ear 0 2 sensor (EU) D-12 (Motor driven opening roof D-43
3ear pole antenna D-77 system)
3ear speed sensor D-17 Warning lamp
?earturn lamp D-56 (Motor driven opening roof D-43
3ear view mirror D-35 system)
3ear view mirror switch D-35 Washer switch D-71
3ear window defogger 0-39 Water temp.sensor (AUS) D-7
{ear window defogger Water temp.sensor (EU) D-11
D-39
witch wiper relay D-71
loof closed sensor D-44 Wiper switch D-71
loof ECU D-44 1
loof lock switch D-43 1
loof o ~ e sensor
n D-44 I
loof open/close switch 1 D-43 /I 7
C ENGINE ELECTRICAL
1 STARTER
SST
1 Shape Part No. Part name
09608-87302-000 Tool set, axle hub bearmg & drive pinion bearing
Tool
/soldering iron
...- ..-. . .- ...
Instrument
l~orque
wrencn.Spr~ngseparates .D.al ga:ge.Vern'er cal~pers,lo.lageiesrer V-snapeo b.ocks
r~i~h-temperature
grease
.2 CIRCUIT DIAGRAM
Mfr
ignition switch
Battery
, =
- 2
0.6kW 1.OkW
Starter oerformance
Rated output (kW) I 0.6 I 1.O
No-load characteristics 50A or less [at time of 11.5 V] 90A or less [at time of 11.5 V]
6000 rpm or more 3000 rpm or more
Number of pinion teeth 9 10
Rotational direction I Counterclockwise as viewed from ini ion 1 Counterclockwise as viewed from ini ion I
side side
Weight (kg) 3.1 3.05
1-2-1 Starter unit check

CAUTION
Each check should be performed within a short length of time (3-5 seconds).
(1) Pull-in check

1.Apply the battery voltage to the terminal a. Connect the
earth wire to the terminal C and the starter body. Ensure
that the pinion gear jumps out.
CAUTION
This test should be carried out with the lead wire of the
magnet switch disconnected.
(2) Retention check of holding coil

1.Under the pull-in check state, disconnect the wire leading
to the terminal C. Ensure that the pinion gear remains in
the jump-out state.
(3) Plunger return check

1.Under the retention check state of the holding coil,
disconnect the earth wire from the starter body. Ensure
that the pinion gear returns.
C-3
(4) No-load test
1.Clamp the starter in a vice, etc.
2.Hook up the cables and tester, as indicated in the figure.
(At this time, do not connect a wire to the terminal @.)
3.Connect the terminal @. Read the current reading when
the reading of the ammeter has stabilized.
SPECIFIED VALUE: 0.6 kW type: 50 A or less at 11.5 V
1.O W type: 90 A or less at 11.5 V
CAUTION
A comparatively . large
- current flows during the test.
heref fore a heavy lead wire should be employed.
1-2-2 Starter disassembling and assembling (0.6 kW type)
) COMPONENTS
L
%: Non-reusable pans
Unit :N.m(kgf.cml
1 a Magnet switch 7 g Starter york Ay
2 b Through bolt 8 h Starter armature Ay
3 c Starter commutator end frame 9 i Starter drive pinion lever
4 d Brush holder insulator 10 j Starter drive housing Ay
5 e Spring 11 k Starter pinion stop nut or collar
6 f Starter brush holder 12 1 Snap ring
(2) Disassembling
1.Remove the parts in the sequence of the Components diagram
-
(3) Inspection
1.Armature check
(1) Check the insulation between the commutator and
armature coil core.
(2) Check continuity between segments.

SPECIFIED VALUE: Continuity should exist between each
segment.
(3) Check the run-out of the commutator.

(4) Measure the outer diameter of the commutator.

SPECIFIED VALUE: 28 mm
ALLOWABLE LIMIT: 27 mm
(5) Check the under-cut depth of each segment.

SPECIFIED VALUE: 0.60k0.15 rnrn
ALLOWABLE LIMIT: 0.2 mrn
2.Field coil check
(1) Check the continuity between the field coil flange C
terminal lead wires.
(2) Check the insulation between the field coil brush and
the field.
3.Brush check 1
(1) Check the roughness of the contact surface and
brush length.
CAUTION
The measurement of brush length should be conducted 1 I
at the center recessed section.
(2) When the contact surface is corrected or replaced, TOtE9513TiO
wrap an abrasive paper (400#) around the.
commutator and remedy the contact surface.
4.Spring check
(1) vkually inspection for spring.
5.Starter clutch check
(1) Check the gear for wear and damage.
(2) Ensure that the gear locks when the gear is turned in
the driving direction (M/T, clockwise). Furthermore,
ensure that the gear turns smoothly when the gear is
turned in the opposite direction.
6.Magnet clutch check
(1) When the plunger is pushed in and released, ensure
that the plunger returns quickly to the original
position.
(2) Check continuity between the terminal @ and the

terminal 0.

magnet switch body.
7.Bush replacement
(1) Remove the bush, using the SST
SST: 09208-87201-000 SST
!
!
i
(2) Press the bush, using the SST in combination with a

press.
SST: 09608-87302-000
(4) Assembling
1.Apply High-temperature grease to the starter clutch bush and spline section
LUBRICANT: High-temperature grease
2.Assemble the starter clutch assembly, starter pinion stop nut or collar.
3.Assemble the snap ring, following the procedure given
below.
(1) Install one collar onto the armature and put the snap
ring onto the shaft.
(2) Fit the snap ring into the groove of the collar by
pushing the snap ring with a screwdriver or the like.
CAUTION
Be sure to use a new snap ring.
4.Set the spring to the starter brush holder. Then, assemble

the brush holder insulator.
5.Set the starter commutator end frame, starter armature

Ay, starter drive pinion lever and starter drive housing Ay.
Assemble them by means of the through bolts.
TIGHTENING TORQUE: 5.9tl.4 N.m {6Of14 kgf - cm}
6.W1ththe joint section attached securely to the drrve prnion

lever, install the magnet switch.
TIGHTENING TORQUE: Magnet switch retaining nut :
8.3k2.5 N.m {85+25 kgf.crn}
C terminal retaining nut :
9.8k2.0 N.m {100+20 kgf-cm) 1
- - procedure
1-2-3 Assembling/disassembling - (1.0 kW type)
-. .
I) COMPONENTS
L
Z: Non-reusable parts
Unit :N-rn(kgf.cm)
1 a Swltch Ay, starter magnet 8 h Lever, starter pinion drive
2 b Yoke Ay, starter 9 i Housing Ay, starter drive
3 c Frame Ay, starter commutator end 10 j Gear SIA, planetary
4 d Holder Ay, starter brush 11 k Ring, snap
5 e Armature Ay, starter 12 1 Shaft SIA, planet carrier
6 f Clutch SIA, starter 13 m Gear, internal
7 g Bear~ngSIA, center
(2) Disassembling
1 Maanetic switch I
1.Remove the magnet starter switch Ay.
2.Remove the two through bolts. Remove the starter yoke
Ay and starter commutator end frame Ay as a set.
3.Remove the starter commutator end frame Ay.

CAUTION
Remove the end frame, while tilting it so as to prevent
the interfering of the brush holder with the water drain
cover at the inside.
Remove the lead wire, while pushing it toward the yoke
side so that it may not be pulled by the end frame.
4.Remove the starter brush holder with the following

Leadw~
End framYoke\
Screws
Y-
,,,,,,,,
Drain pipe
procedure.
(1) Lift the brush spring and remove the brush.
(2) Remove the brush holder from the yoke.
5.Remove the starter armature Ay and starter clutch SIA.

6.Disassemble the center bearing S/A, starter pinion drive
lever and starter drive housing as shown in the right
figure.
7.Remove the plate as shown in the right figure and remove 1 Center bearinn
"
Planet gear
T01E9530ETlO
8.As shown in the right figure, remove the snap ring and
stop collar so as to separate the clutch.
9.Remove the snap ring and disassemble the center

bearing and planet carrier shaft SIA.
10.Disassemble the recessed section of the internal gear

circumference, center bearing and planet carrier shaft
SIA.
(3)Inspection
mature core
1.Armature coil
(1) Check the insulation between the commutator and the
armature coil core.
(2) Check the continuity between segments.

SPECIFIED VALUE: Continuity should exist between the Amature core
segments.
(3) Check the runout of the commutator.
(4) Measure the outer diameter of the commutator.

m
(5) Check the under-cut depth of each segment.
SPECIFIED VALUE: 0.60+0.15 rnm
ALLOWABLE LIMIT: 0.2 mrn
Mica Segment
2.Yoke check
(1) Field coil check
Confirm continuity between the brushes
(2) Check continuity between the brush and the C

terminal lead wire.
CAUTION
* Check the both brush.
(3) Check the insulation between the brush and yoke.
Yoke
TO1 E95di E m 0
. . Brush check
(4)
Check the roughness of the cont :t surfac e and t)rush
length.
ALLOWABLE LIMIT: 9 mm
(5) Brush replacement procedure

(6) @ Cut the brush lead wire at the terminal side.
CAUTION
It is possible to replace the two brushes only at the
yoke side (@ side). As for the @ side brush, however,
the replacement can be made only by the brush holder
Yoke
unit. \
(7) @ Grind the welding trace of the brush terminal by

means of a file, etc. so that the terminal may be
remedied to the specified dimensions.
SPECIFIED VALUE: Thickness 1.4k0.1 mm
Width 5 mm
CAUTION
Grind the area of the brush holder unit. as indicated in
I
the right figure. Since the section to be ground is very
narrow, care must be exercised not to scratch the field
A-B cutting I
I
coil.
Terminal at
yoke side
Section to
be removed I
TOIE95d5ET10.
F
(8) @ Overlap the plate section of the replacement
brush onto the lead wire fusing side and press-fit the
section with pliers.
Welding side of
CAUTION lead wire
Make sure not to make a mistake concerning the
removal direction of the brush lead wire. ,&
., ,
I.
~
: ,., I,f l
\
TOlE9546ET10
(9) @ Solder the press-fitting section. Grind the area

with a file or the like so as to attain the specified
dimensions as indicated in the right figure.
TOOL: Soldering iron
CAUTION 3.3mrn
When performing the soldering, thoroughly heat the

section to be soldered so that no solder may flow to the 7mm
positive side lead wire.
Make sure that the solder flows thoroughly to the inside
TOIE9547TlO
of the plate.
Ensure that the solder may not drip onto the field side.
(10) Check of brush spring load
Using a spring scale, observe the reading at the moment
when the spring separates from the brush.
SPECIFIED VALUE: 15.7k2.0 N.m {160&20 kgf.cm)
ALLOWABLE LIMIT: 8.8 N.m {90 kgf.cm}
(11) Check of brush holder

Conduct an insulation check between the brush holder at the
@side and the brush holder at the side.
3.Clutch check I
(1) Check the gear for wear and damage. I
(2) Ensure that the gear locks when the gear is turned in
the driving direction (MF, clockwise). Furthermore, I
ensure that the gear turns smoothly when the gear is i
turned in the opposite direction.
! j
4.Magnet switch check
(1) When the plunger is pushed in and released, ensure
that the plunger returns quickly to the originai
position.

magnet switch body.

terminal @.
5.Check of planet carrier shaft

Measure the outer diameter of the center bearing sliding
section of the planet carrier shaft.
SPECIFIED VALUE: 15 rnrn
6.Check of center bearing oil clearance

(1) Measure the inner diameter of the center bearing.
Determine the clearance from the outer diameter of
the planet carrier shaft obtained at Step 4.
If the clearance exceeds the allowable limit, replace
the oilless bearing or the planet carrier shaft, as
required.
SPECIFIED VALUE: 0.03 rnm
(2) Bearing replacement
Remove the bearing, using the SST in combination with a
press, etc.
CAUTION
When removing the bearing, be sure to remove it,
starting from the inside, as indicated in the right figure.
NOTE
* The SST is handled by Denso. "95208 - 10090
@ Install a new bearing, using the SST in combination with a

press, etc.
NOTE
The SST is handled by Denso. "95208 - 10090"
CAUTION
When installing the bearing, be sure to install it starting
from the outside.
CAUTION
Drive the bearing into place in such a way that the
bearing is 0.5 mm or less in relation to the edge of the
center bearing.
7.Check of end frame oil clearance

(1) As is the case with the center bearing oil clearance,
measure the outer diameter "a" of the end frame
sliding section of the armature shaft. Also, measure
the inner diameter "b"of the end frame so as to
determine the clearance. If the clearance exceeds
the allowable limit, replace either part, as required.
SPECIFIED VALUE: a:0.035 mm
ALLOWABLE LIMIT: a-b:0.10 mm
(2) Replacement of flange oilless bearing

@ Remove the oilless bearing, using a tap, as indicated in
the right figure.
11 (
-
CAUTION
When clamping the end frame in a vice, care must be
exercised not to deform or damage the fitting section. 1
!
i
~ran/geoil less bearing

j TOIESS6OETlO
i
@ Press a new oilless bearing, as indicated in the right Oil less
figure. bearing
lnstall the bearing.
cified value
.04-22.36rnrn
8.Check of shock absorber of enter bearing

(1) Clamp the flange section of the starter housing in a
vice. Install the center bearing, using the guide
mark.
CAUTION
When clamping the starter housing in a vice, do not
tighten the housing forcibly. Tighten the housing only
to such an extent that the housing will not move.
Assemble the center bearing. Confirm that the center
bearing will not turn.
(2) Assemble the SST, as indicated in the right figure.
Turn the SST slightly so that it may engage with the
shock absorber.
NOTE
The SST is handled by Denso. "95208- 10100
(3) Working from above the center bearing, as indicated

in the right figure, secure the SST to the through-bolt
C-I 7
(4) As indicated in the right figure, using a torque
wrench, apply torque through the SST. Observe a
sliding torque reading at the moment when the
rotation starts.
When the reading is deviated from the allowable
limit, the replacement should be made together with
the center bearing.
SPECIFIED VALUE: 29.4k3.9 N.m {300+40 kgf.cm)
ALLOWABLE LIMIT: 21.6 N.m{220 kgf.cm) TBlE9555ETiO
CAUTION
Never disassemble or wash the shock absorber
section. If it has been disassemble or washed, do not
reuse it.
NOTE
The SST is handled by Denso. "95208 - 1010 0
9.Check of planet bush oil clearance
Determine the oil clearance based on the planet pin
diameter "b" and the planet bush inner diameter "a"
If the allowable limit is exceeded, determine the clearance
based on the planet bush inner diameter "a".
SPECIFIED VALUE: 0.1 0 mm
(4) Assembling
1.Apply 29 or more of High-temperature grease to the fitting
section between the internal gear and the shock
absorber as well as to the inside of the internal gear, as
indicated in the right figure. Assemble them, aligning
with the guide marks.
2.Apply turbine oil to the inner bore of the center bearing.

Also, apply High-temperature grease to both sides of the
washer. Assemble it to the planet carrier shaft and
proceed to assemble the center bearing.
LUBRICANT: High-temperature grease Planet carrier I
shaft
\
Turbine oil
Plate washer
j
I
TOlE9568ETl~l
3.lnstall a new snap ring.
CAUTION
Do not reuse the snap ring.
Ensure that the washer has been installed.
4.Assemble the starter clutch SIA, following the procedure

Snap ring
given below.
(1) Apply High-temperature grease to the contact section
between the clutch and the spline as well as to the
stop collar snap ring.
LUBRICANT: High-temperaturegrease
TOIE9570ET1
(2) While holding the outer periphery of the pinion, tap

lightly the planet carrier shaft, using a plastic
hammer so that the stop collar may move toward
over the snap ring.
T01E957IT10
5.Apply 0.59 or more of High-temperature grease, as Grease

indicated in the right figure. Proceed to install the
planetary gear S/A (three gears) and washer.
CAUTION
Install the plate in place, aligning with the guide mark of
the center bearing.
Planet gear
TM E9572ET
6.Apply 0.59 or more of High-temperature grease, as
Q
Turbin oil
indicated in the right figure. Proceed to install the
planetary gear S/A (three gears) and washer.
CAUTION
Install the plate in place, aligning with the guide mark of
the center bearing. Starter housing
rive lever
TOiE9573EllO
7.As indicated in the right figure, assemble the drive 1 Center bearing I Mpting mark
housing and center bearing SIA, respectively, aligning
with the miirk rnarks~
Drive h o u s i n g J r v
8.lnstall the brush spring to the starter brush holder

assembly. Erect the brush spring and install the brush to
the starter armature assembly,
/
Hunger
CAUTION
Make sure that the lead wire of the brush is not
interfering with the brush spring.
9. Install the spring commutator end frame assembly.

CAUTION
Install the end frame, while tilting it so as to prevent the
interfering of the brush holder with the water drain
cover at the inside.
TIGHTENING TORQUE: 1.5kO.3 N.m (15t3 kgf.crn)
10.The installation should be made, while the recessed

section of the starter yoke assembly, the protruding
section of the plate and the protruding section of the
center bearing are aligned with.
Then, install the through bolt.
TIGHTENING TORQUE: 5.9+1.5 N.m (60+15 kgf-crn)
Mating mark
TOlE9578ETlI
C-20
11.Attach the stud bolt of the magnet starter switch
assembly to the drive lever, working from above the lever
and secure it with two nuts.
Furthermore, install the terminal C of the magnet switch
and lead wire.
TIGHTENING TORQUE: 8.3k2.5 N.rn { 8 5 k 25 kgf.crn)
2 ALTERNATOR
SST
Shape Part No. I Part name
09820-87208000 Wrench alternator pulley set nut
09612-10061-000 Replacer, steering pinion bearing
09812-00010-000
Wrench door hinge set bolt
(09812-22010-000)
Instrument
l ~ o r ~ wench.Vernier
ue calipers.Voltage tester 1
2-2 CIRCUIT DIAGRAM
$ Alternator
.
-
,
Alternator performance
C-22
?
Engine type JB-DET

ITEM (MR vehicle)
Rated voltage - Rated output (V-A) 12-65
Output characteristics [13.5V. 5000rpml (A) 67 or more
Permissible max, revolution speed (rpm) 18,000
Regulator regulating voltage
14.2-14.8
[5,00Orpm, 10A, 251 (V)
Rotational direction Clockwise as viewed from pulley side
125.5163
Weight (kg) 3.29
-
2-2-1 Alternator disassemblina & Assemblina -
) COMPONENTS
nit :N.m (kgf.cm)

1 a Insulator, terminal, No. 2 7 g Pulley, alternator
2 b Cover, rear end 8 h Collar, spacer
3 c Holder alternator brush 9 i Frame Ay, rectifier end
4 d Regulator Ay, generator 10 j Rotor Ay, alternator
5 e Holder, alternator Wlrectifie! 11 k Frame Ay, alternator drive end
6 f Nut, pulley lock
(2) DISASSEMBLING
1.Remove the terminal insulator No.2 and rear end cover.
TOlE95821
2.Rernove the alternator brush holder and generator

regulator assembly.
3.After removing the screws, remove the alternator holder 1

Wlrectifier by extending the wire.
4.Remove the pulley lock nut, alternator pulley and spacer

collar, following the procedure given below.
(1) Tighten the SST 0 to the specified torque. Secure
the SST @ to the pulley shaft section.
TIGHTENING TORQUE: 39 N.m{400 kgf-cm)
CAUTION
Attach the SST to the pulley shaft section securely.
SST: 09820-87201-000[09820-06010-0001
(2) Clamp the SST in a vice. Under the state above, set
the SST.
SST: 09820-87201-000[09820-87202-0001
(4) Turn the SST @ in the arrowheaded direction so as to
remove the SST @ from the alternator.
(5) Remove the alternator pulley and spacer collar.
5.Remove the end frame,
-
6.Separate the alternator rotor assembly from the alternator
drive end frame assembly, using a press.
(3) INSPECTION
1Rotor check
(1) Measure the resistance between the two slip rings.
SPECIFIED VALUE: 2.3f 0.1 C J
2.Measure the insulation resistance between the slip ring
and the rotor core.
3.Slip ring check

(1) Check the slip ring for damage.
If the slip ring exhibits damage, rectify it, using an
abrasive paper (#400).
(2) Measure the outer diameter of the slip ring.
4.Rectifier check
(1) Conduct the continuity test, using the k B range.
SPECIFIED VALUE: Change the polarity. There should
be continuity in one direction, while
there should be no continuity in the
opposite direction.
CAUTION
The diode has such a property that it allows current to
flow in one direction only.
When the test is conducted by means of an electrical
tester or a circuit tester, a current flows from the
internal cell of the tester to the diode.
The continuity of a diode (good or bad) is judged
based on whether or not that current flows. However,
the value of resistance varies, for the current being
flown differs depending upon testers.
5.Brush length
(1) Check the brush length.
SPECIFIED VALUE: 10.5 rnm
CAUTION
Replace the brush, if it exceeds the allowable limit.
-
C-26
6 Stator cod check I I
(1) Measure the resistance belween the phases.

SPECIFIED VALUE: Approx. 0.1-0.2B
7.Diode check of IC regulator

(1) Conduct the continuity test for the diode between the
terminal B and the terminal F, using the k B range of
the tester.
SPECIFIED VALUE: There should be continuity in one
direction, while there should be no
continuity in the opposite direction.
8.Rear bearing replacement
(1) Check the bearing. Replace the bearing if it exhibits
defect.
(2) Remove the bearing, using the SST.
SST 09820-00021-000
(3) Press the bearing, using the SST in combination with

a press.
SST: 09612-8718O-OOO[O96l2-lOO6l-OOO]
CAUTION
Perform the press-fitting at the inner race side of the
bearing.
(4) ASSEMBLING
1.Attach the alternator rotor assembly to the alternator drive en
2.Press the rectifier end frame assembly, using a 29 mm
socket wrench in combination with a press.
3.install the spacer collar, alternator pulley and pulley lock
nut, following the procedure given below.
(1) Install the spacer collar and alternator pulley to the
pulley shaft. Tighten them with the nut.
(2) Tighten the SST@ to the specified torque so that the
SST@ may be attached to the pulley shaft.
SST 09820-87201-000[09820-06010-0001
TIGHTENING TORQUE: 39 N.rn(400 kgf.crn)
CAUTION
Install the SST to the pulley shaft securely.
(3) Clamp the SST in a vice. Set the alternator and the
SST.
SST: 09820-87201-000[09820-87202-0001
(4) Tighten the nut by turning the SST @.
TIGHTENING TORQUE:
(5) Remove the alternator from the SST. Slacken the SST
@ so as to remove the SSTs@ and @.
4.lnstall the alternator holder with rectifier wire, as indicated
in the right figure.
5.lnstall the generator regulator assembly, alternator brush

holder, rear end cover and terminal insulator No.2 in this
sequence.

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SECTION I General information PI

IMPORTANT SAFETY NOTICE ------------ A1 - 1 HANDLING INSTRUCTION OF

1 IMPORTANT SAFETY NOTICE

1-2 WARNINGS, CAUTIONS AND NOTES

2-3 DESCRIPTION OF SERVICE STANDARD VALUE

IABBREVIATION CODE I ORIGINAL WORD I ABBREVIATION CODE I ORIGINAL WORD I

0 0 Nominal length (mm)

5-1 NEW UNlT BECAUSE OF THE INTRODUCTION OF THE SI UNlT

6 GENERAL SERVICE INSTRUCTION

asupporting points of lifts

8-2 PLATE TYPE

m:Supporting points of lifts

9-2 USING FLAT BED TRUCK

9-3 WHEEL LIFT TYPE

9-3-1 TO TOW WlTH REAR WHEELS ON GROUND

I-------------- ----I when

Erasure of diagnosis code

(~econfirmationof malfunctioning phenomenon)-- . .... I Conlirm phenomenon and

Reconfirmation of diagnosis code

Abnormal code 1 Normal code

Confirm that the malfunctioning

No Terminal code No Terminal code

11-2 CONNECTION METHOD OF DATA LlNK CONNECTOR

4.For water-proof connectors which cannot be accessed

12-2 CONNECTOR REMOVALANSTALLATION

12-2-2 CONNECTOR WITH LEVER LOCK

(2) POINTS OF INSTALLATION

4.Prepare the same male terminal as that of the connector

12-5 HANDLING INSTRUCTION OF SYSTEM

13 INSTRUCTIONS FOR RADIO INSTALLATION

14 HANDLING INSTRUCTIONS ON CATALYTIC CONVERTER-

SPECIFIED VALUE: Not more than 50 mA (0.05A)

15-1-2 PRECAUTION TO PREVENT MISS OPERATION

16-2 CHASSIS SERIAL NUMBER

16-3 ENGINE TYPE AND ENGINE NUMBER

16-4-1 CONTENTS OF MANUFACTURER'S PLATE

MAINTENANCE REQUIREMENTS ------- A2 - 1

0......Check or inspect 0 ......Change or replace

Brake fluid /Change Every

0......Check or inspect 0 ......Change or replace

1-3 DESCRIPTION OF SERVICE STANDARD VALUE

3 HOW TO GRASP SPECIFIED TIGHTENING TORQUE FOR

4 T Nominal diameter (mm)

4-1 NEW UNlT BECAUSE OF THE INTRODUCTION OF THE SI UNlT

1-2 BASIC CHECK AND ADJUSTMENT

1-2-3 FUNCTION CHECK OF RADIATOR CAP - I

1-2-4 CHECK OF ENJINE OIL LEVEL

Valve clearance (rnrn)

(2) CHECK AND ADJUSTMENT

1.Remove the cylinder head cover.

3.lnstall a timing light.

4.Short the terminals EFI T and E (0-0) of the check

1-2-12 CHECK OF IDLE SPEED

1.Connect an engine tachometer to the terminal REV(@),

1-2-13 CHECK CO AND HC CONCENTRATIONS

09219-87701-000 Attachment, engine overhaul

09219-87202-000 stand, engine overhaul

(1) Removal of cylinder head cover

(2) Removal of chain tensioner plunger