2006 Daihatsu Terios j2 SM

FOREWORD
This service manual has been prepared to provided information covering general service repairs
for the model J2 series (J200, J210 and J211) manufactured in February, 2006 afterward.
For the service specifications and repair procedures of the model J2 series other than those listed
in this manual, refer to the following manuals.
All information used in this service manual was in effect at time when the manual was printed.
However, the specifications and procedures may be revised owing to continuing improvements in
design without advance notice and without incurring any obligation to us.
Published in February, 2006
REFERENCE
MANUAL NAME MANUAL NO. PUBLISHED
TECHNICAL INFORMATION TERIOS (J2 series) No. 9514 February, 2006
TERIOS (J2 series) WIRING DIAGRAM No. 9644 February, 2006
TYPE K3 ENGINE SERVICE MANUAL No. 9737 May, 2000
TYPE K3 ENGINE SERVICE MANUAL (Rev. 1) No. 9232 July, 2000
TYPE K3 ENGINE SERVICE MANUAL (Rev. 2) No. 9237 September, 2000
TYPE A4Q, A4R AUTOMATIC TRANSMISSION No. 9738 May, 2000
SERVICE MANUAL
TERIOS (J2 series) BODY REPAIR MANUAL No. 9437 February, 2006
No. 9708
©2006
All rights reserved. This material may not be reproduced or copied, in whole or in part, without the
written permission of Daihatsu Motor Co., LTD.
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INTRODUCTION IN
PREPARATION PP
SERVICE SPECIFICATIONS SS
ENGINE ENGINE CONTROL ES
ENGINE MECHANICAL EM
FUEL FU
EMISSION CONTROL EC
EXHAUST EX
COOLING CO
LUBRICATION LU
IGNITION IG
STARTING ST
CHARGING CH
TRANSMISSION / TRANSAXLE AUTOMATIC TRANSMISSION AT
CLUTCH CL
MANUAL TRANSMISSION MT
DRIVE LINE / AXLE TRANSFER TF
PROPELLER SHAFT PR
DRIVE SHAFT DS
DIFFERENTIAL DF
AXLE AH
SUSPENSION SUSPENSION SP
TIRE AND WHEEL TW
BRAKE BRAKE CONTROL BC
BRAKE BR
PARKING BRAKE PB
STEERING STEERING COLUMN SR
POWER STEERING PS
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AIR CONDITIONER
HEATER AND AIR CONDITIONER / VENTILATION AC
SRS AIRBAGS AND SEAT SRS AIRBAG RS
BELTS SEAT BELT SB
BODY AND ELECTRICAL ENGINE IMMOBILISER EI
LIGHTING LI
WIPER AND WASHER WW
DOOR LOCK DL
METER ME
AUDIO AND VISUAL AV
OTHER ELECTRICAL OT
GLASS AND WINDOW WS
MIRROR MI
INSTRUMENT PANEL IP
SEAT SE
ENGINE / HOOD DOOR ED
BODY EXTERIOR ET
BODY INTERIOR IR
CONTROL SYSTEM BODY MULTIPLEX COMMUNICATION SYSTEM [LIN] MP
CAN COMMUNICATION CA
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TO INDEX
INTRODUCTION
INTRODUCTION
HOW TO USE THIS MANUAL
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-1
VEHICLE IDENTIFICATION NUMBER, ENGINE SERIAL NUMBER
IN
AND TRANSMISSION SERIAL NUMBER
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-4
VEHICLE OPERATION AND PRECAUTION
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-5
SUPPORT POSITIONS FOR JACK, RIGID RACK AND LIFT . . . . . . . . . . IN-17
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
NEW DIAGNOSTIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-24
DESCRIPTION OF BASIC DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . IN-26
CUSTOMER PROBLEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-28
CONFIRMING SYMPTOMS AND CHECKING DIAGNOSTIC TROUBLE
CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-30
REPRODUCTION METHOD OF PROBLEM SYMPTOM . . . . . . . . . . . . . . IN-33
DIAGNOSTIC TROUBLE CODE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . IN-34
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-35
DTC SYSTEM-SPECIFIC INSPECTION PROCEDURE . . . . . . . . . . . . . . . IN-36
ELECTRONIC CIRCUIT INSPECTION PROCEDURE . . . . . . . . . . . . . . . . IN-38
TERMS
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-44
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IN–1 INTRODUCTION - HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL

INTRODUCTION
GENERAL INFORMATION
1. GENERAL DESCRIPTION
IN (a) Repair work can be divided into three processes: (1) diagnosis;
(2) installation, replacement, disassembly / reassembly and
checking / adjusting; and (3) final inspection.
(b) This manual describes processes (1) diagnosis; and (2)
installation, replacement, disassembly / reassembly and
checking / adjustment. Procedure (3) final inspection is omitted.
(c) The following procedures are omitted from this manual.
However, these procedures must be performed.
(1) The use of a jack or lift to perform operations.
(2) The washing and cleaning of removed parts, as needed.
(3) Visual checks.
2. PREPARATION
(a) To prepare you before performing work, a list of Special Service
Tools (SST), service tools, recommendations, as well as
lubricants and other items are in the PREPARATION section of
this manual. However, equipment that is considered to be
readily available in a repair facility, such as tool stands, jacks,
and rigid racks, is omitted.
(b) Tools or devices other than Special Service Tools (SST) that are
listed in the PREPARATION section of this manual are merely
guides. They are not meant to designate specific suppliers,
product names or part numbers.
3. WORK PROCEDURE
(a) A component illustration is placed under each section or title
where necessary.
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INTRODUCTION - HOW TO USE THIS MANUAL
IN–2
(b) Non-reusable parts, lubricant application areas, precoated bolts

and tightening torque are noted in the component illustrations.
Example:
IN
REAR AXLE SHAFT
OIL SEAL LH
ADJUSTING
LOCK CAP
REAR AXLE SHAFT

BEARING LH
REAR DISC BRAKE
COTTER PIN
REAR AXLE CARRIER LH
REAR AXLE SHAFT LH
REAR AXLE SHAFT

SNAP RING LH
REAR AXLE SHAFT OIL SEAL LH

PARKING BRAKE FLUID ASSEMBLY
NON-REUSEABLE PART
MP GREASE TIGHTENING TORQUE
(c) Tightening torque, lubricant application areas and non-reusable

parts are noted in the procedures.
NOTICE:
In some cases, the information listed above can only be
explained by using an illustration. In these cases, torque,
lubrication type and other information are described in the
illustration.
(d) Only items with key points are described in the text. What to do
and other details are explained using illustrations next to the
text. Both the text and illustrations are accompanied by
specified values and notices.
(e) Illustrations of similar vehicle models are sometimes used. In
these cases, minor details may be different from the actual
vehicle under repair.
Example:
Operation
17. CRANKSHAFT DAMPER INSTALLATION
(1) Using the SST, hold the crankshaft damper and
SST tighten the bolt.

SST 09278-87201
Standard
A137588
Explanation: A detailed explanation of the operation method
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IN–3 INTRODUCTION - HOW TO USE THIS MANUAL
4. SERVICE SPECIFICATIONS
(a) SPECIFICATIONS and LIMITS are presented in boldface text
throughout the manual.
5. TERM DEFINITIONS
Standard Refers to a range of acceptable values during checking and adjusting.
IN Maximum limit Refers to minimum and maximum values that are not to be exceeded during checking and adjusting.
In some cases, the method used to determine whether or not a measurement falls within the specified values is difficult. In
Reference value these cases, if there is no danger that an actual malfunction will occur, reference values may be provided to help you make
simpler measurements.
CAUTION Indicates the possibility of injury to you or other people. Ignoring CAUTIONS may lead to accident or injury.
Indicates items that require special attention because of the possibility of damage to the vehicle and its components. This
NOTICE
includes essential procedures as well as actions that should not be performed.
HINT Provides additional information to help you perform repairs.
6. INTERNATIONAL SYSTEM OF UNITS

(a) The units used in this manual comply with the International
System of Units (SI) standard. Units from the metric system are
also provided.
(Example)
Torque: 28 N*m (286 kgf*cm)
Table of International System of Units Conversions
Conversion Factor into
Item International System of Units Former Units
International System of Units
Acceleration m/s2 G 9.80665
Torque, Moment N*m kgf*cm 0.0980665
Force N kgf 9.80665
MPa kgf/cm2 0.0980665
Pressure
kPa mmHg 0.133322
kW PS 0.735499
Power, Power Efficiency
W kcal/h 1.16279
Volume cm3 cc 1
Spring Constant N/mm kgf/mm 9.80665
International System of Units Prefixes

M (mega-) 106 d (deci-) 10-1=0.1
K (kilo-) 103 c (centi-) 10-2=0.01
H (hecto-) 102 m (milli-) 10-3=0.001
Da (deca-) 101 µ (micro-) 10-6=0.000001
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INTRODUCTION - VEHICLE IDENTIFICATION NUMBER, ENGINE SERIAL NUMBER AND TRANSMISSION
SERIAL NUMBER
IN–4
VEHICLE IDENTIFICATION NUMBER, ENGINE SERIAL

INTRODUCTION
NUMBER AND TRANSMISSION SERIAL NUMBER

LOCATION
1. Vehicle Identification Number
IN
(a) The vehicle identification number is stamped on the vehicle
body (labeled A in the illustration) and on the certification label
(labeled B in the illustration).
A:
A
Vehicle Identification Number
B:
B
Certification Label
D101216J01
2. Engine Serial Number and Transmission Serial Number

(a) The engine serial number is stamped on the cylinder block of
the engine.
A:
3SZ, K3
D101218J01
(b) The transmission serial number is stamped on the certification

A/T label of the transmission case.
A:
A4Q-D1
B:
M5S
A
M/T
D101219J01
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IN–5 INTRODUCTION – VEHICLE OPERATION AND PRECAUTION
VEHICLE OPERATION AND PRECAUTION

INTRODUCTION
PRECAUTIONS
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT
PRETENSIONER
IN (a) HANDLING AND OPERATING PRECAUTIONS
(1) Failure to carry out the service operations in the correct
sequence could cause the airbag or pretensioner to
unexpectedly deploy during servicing and lead to serious
life-threatening injury. Furthermore, if a mistake is made
when servicing, it is possible that the airbag or pretension
may fail to operate properly. Service operations (including
checking and adjusting) should be carried out in the correct
sequence as stated in this manual.
(b) DISCONNECTING POWER SOURCE
(1) Always check the Diagnostic Trouble Codes (DTCs) before
performing work. Before beginning work, wait at least 90
seconds after the engine switch is turned OFF and after the
cable is disconnected from the negative (-) battery terminal.
CAUTION:
The airbag and pretensioner are equipped with a
backup power source. If work is started within 90
seconds after turning the engine switch OFF and
disconnecting the cable from the negative (-) battery
terminal, the airbag or pretensioner may deploy.
(c) GENERAL PRECAUTIONS
(1) When performing an electrical check, use an electrical
tester. However, never measure the resistance of the
airbag squib.
CAUTION:
This may cause the airbag or pretensioner to inflate,
which could cause serious injury.
(2) Information labels are attached to the SRS components.
Follow the instructions on the labels.
(3) Never disassemble an SRS airbag.
(4) Replace any dropped, cracked, dented, broken or
otherwise defective SRS components with new ones.
(5) Never use airbag or pretensioner parts from another
vehicle. When replacing parts, use new parts.
(6) Do not directly expose any of the SRS components to hot
air or flames.
(7) After a collision, perform a DTC check, even if the the
airbag or pretensioner have not deployed.
(8) Lubricants, oil, water, or detergents of any kind should not
be applied to any of the SRS components. If any of the
SRS components come into contact with liquid, quickly
wipe them off with a dry cloth.
(9) Store the SRS components in an area where the ambient
temperature is below 93°C [80°C for the pretensioner], the
humidity is not high and there is no electrical noise.
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INTRODUCTION – VEHICLE OPERATION AND PRECAUTION
IN–6
(d) AIRBAG AND PRETENSIONER DISPOSAL PRECAUTIONS

(BEFORE DEPLOYMENT)
(1) Never dispose of an airbag or pretensioner that has not
deployed. (Be sure to deploy airbags with SSTs before
disposal.)
(2) Airbags and pretensioners should be deployed in a flat area
in the open air, where safety can be ensured. In addition,
avoid deploying air bags and pretensioners in residential
IN
areas.
(3) Because the sound an airbag or pretensioner makes when
it is deployed is rather loud, give prior notice of deployment
to those around you.
(4) When deploying the airbag or pretensioner, use the SST
and stand at least 5 m away from the airbag or
pretensioner.
(5) Because static electricity may cause the airbag or
pretensioner to deploy, take prior measures to avoid static
electricity.
(6) When deploying the airbag, be careful that the airbag
deployment side is not facing downward.
CAUTION:
Deployment of the airbag with the airbag deployment
side facing downward may lead to serious, life-
threatening injury.
(e) AIRBAG AND PRETENSIONER DISPOSAL PRECAUTIONS
(AFTER DEPLOYMENT)
(1) Because the temperature of the airbag or pretensioner can
reach several hundred degrees after deployment, you
should not handle it for at least 30 minutes after
deployment.
(2) Do not apply water, etc. to a steering pad with a deployed
airbag or pretensioner.
(3) Use gloves and protective glasses when handling an airbag
or pretensioner that has been deployed.
(4) Place an airbag or pretensioner that has been deployed in
a clean, sturdy bag. Tie the opening of the bag tightly and
dispose of the bag.
(5) Always wash your hands with water after completing work.
(f) PRECAUTIONS FOR AIRBAG STORAGE
(1) When removing the airbag, always store it with the
deployment side facing upward. Do so even when
removing the airbag only temporarily to perform work.
CAUTION:
Operating the airbag, for any reason, with the
deployment side facing downward may lead to serious,
life-threatening injury.
(2) When storing airbags, do not place anything on top of
them. Also, do not stack airbags on top of each other.
(g) PRECAUTIONS FOR WIRE HARNESSES AND
CONNECTORS
(1) With the exception of parts in the engine compartment that
are not visible, airbag connectors are yellow. Be careful
when handling these connectors.
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(h) PROCEDURE FOR VEHICLES SUBJECTED TO IMPACT IN A

COLLISION
(1) When using electric welders on the vehicle, disconnect the
airbags and pretensioners before performing work.
(2) If any kind of impact is likely to occur, remove the center
airbag sensor assembly, front airbag sensor, side airbag
IN sensor assembly, airbag sensor rear, and seat position
airbag sensor before beginning work.
(3) Do not expose the center airbag sensor assembly, front
airbag sensor, side airbag sensor assembly, airbag sensor
rear, or seat position airbag sensor to high temperature
(4) Because the temperature of some airbags or pretensioners
can reach several hundred degrees after deployment,
make sure that the surrounding wire harness and
connectors are not damaged or melted.
2. BASIC REPAIR HINTS
(a) General
3
2
4
6
D101220J01
• Always wear a clean uniform.

1 Attire
• Hat and safety shoes must be worn.
2 Vehicle protection • Lay down a grille cover, fender cover, seat cover and floor mat before performing work.
• Use wheel chocks to secure the vehicle.
• When working with 2 or more persons, be sure to check for the safety of one another.
• When working with the engine running, make sure that there is adequate ventilation.
• When working on parts that get hot, or on high pressure, rotating, moving, or vibrating
3 Safe operation
parts, take extra care not to burn or injure yourself.
• When jacking up the vehicle, support the vehicle using a rigid rack at the specified
location.
• When lifting up the vehicle, use appropriate safety equipment.
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IN–8
Preparation of tools and • Before performing work, prepare a tool stand, SST, gauge, oil and parts for
4
measurement gauges replacement.
• Diagnose with a thorough understanding of proper procedures and of the reported
problem.
• Before removing parts, check the general condition of the assembly. Also, check for
Removal and installation,
deformation and damage.
5 disassembly and assembly
• When the assembly is complicated, take notes and add matchmarks to ensure that
operations
parts can be replaced and reinstalled correctly. IN
• Clean and wash the removed parts if necessary and assemble them after a thorough
check.
• Keep removed parts in sequence to avoid mixing them up with the new parts or
contaminating the new parts.
6 Removed parts • For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them
with new parts as instructed in this manual.
• Retain the removed parts in a box and present them to the customer.
(b) GASKETS
(1) Because it is not possible to reuse gaskets, always replace
it with a new one.
(2) When necessary, use a sealer on gaskets to prevent leaks.
(c) BOLTS, NUTS AND SCREWS
(1) Check the tightening torque on bolts, nuts and screws.
Always use a torque wrench.
(d) REPLACE FUSES
(1) When replacing fuses, use fuses of the correct amperage
rating. When the use of fuses with different ratings is
BE01367J01
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unavoidable, use fuses with a lower rating than the

specified amperage.
IN Diagram Symbol Part Name Abbreviation
Fuse Fuse
Medium Current Fuse M Fuse
High Current Fuse H Fuse
Fusible Link FL
Circuit Breaker CB
Fusible Link Assembly FL
D100151J02
(e) Clip
(1) When separating and disengaging the clip and claw
positions, apply protective tape to prevent damaging the
vehicle.
(2) The removal and installation methods of typical clips used
for vehicle body parts are shown in the table.
HINT:
• If clips are damaged during installation, always replace
them with new clips.
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IN–10
• The pmark in the illustration refers to clips, and the

{mark refers to claws.
IN
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Shapes (Examples) Removal And Installation
Clip Clip Remover
IN Pliers
Clip
Screwdriver
Protective Tape
Claw
Roof Molding Remover
Removal Installation
Clip
Removal Installation
Clip
D100768J01
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IN–12
(f) FRAMING ADJUSTMENTS

(1) When centering bolts are used on hinges of hoods, doors
Centering Bolt or luggage compartment doors, etc. perform framing
adjustments before replacing the supplied bolts.
(g) JACKING UP, LOWERING AND SUPPORTING VEHICLE
(1) Always observe precautions when jacking up, lowering and
supporting the vehicle. (See page IN-17 for support
positions for jacks, the rigid rack and lifts.)
IN
D032152J01
(h) REMOVAL AND INSTALLATION OF VACUUM HOSES

(1) To disconnect a vacuum hose, pull from the end of the
hose.
D025063J01
(2) When disconnecting vacuum hoses, use tags to identify

where they should be reconnected.
(3) When using a vacuum gauge, do not connect a hose that is
too large. If the hose is a little small, use an adapter for
adjustment. If a hose has been stretched, it may leak air.
D025064J01
(i) TORQUE WHEN USING TORQUE WRENCH WITH

EXTENSION TOOL
L1 L2 (1) If an extension tool or SST is combined with a torque
wrench, do not tighten to the torque specified in this
manual. Doing so will result in excessive actual torque.
(2) In this manual, only standard tightening torque is listed.
Use the formula below to calculate special torque values for
situations where an SST or an extension tool is combined
with the torque wrench.
L1 L2 (3) Calculation Formula T' = T × L2/(L1 + L2)
Reading of torque wrench (N*m

T'
[kgf*cm])
Reading of tightening torque
T
(N*m[kgf*cm])
L1 Length of SST or extension tool (cm)
D100769J01
L2 Length of torque wrench (cm)
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3. ELECTRICAL CONTROL
(a) REMOVAL AND INSTALLATION OF BATTERY TERMINAL
(1) Before performing work on electrical systems, first
Loosen
disconnect the cable from the negative (-) battery terminal
to prevent component and wire damage caused by
accidental short circuits.
IN (2) When disconnecting and reconnecting the battery cable,
turn the engine switch OFF and turn the headlight switch
OFF. Also, loosen the terminal nut completely. Perform
D001555J01 these operations without bending the terminals.
(3) Clock settings, DTCs and other data are erased when the
negative (-) battery terminal is disconnected. Therefore,
write down any necessary data before disconnecting the
negative (-) battery terminal.
(4) After disconnecting the battery terminals, settings may be
erased. Therefore, make sure to perform the necessary
set-up operations after reconnecting the terminals. (See
page SS-10 for details)
(b) HANDLING OF ELECTRONIC PARTS
(1) Do not open the cover or case of the ECU. (If the IC
terminals are touched, the IC may be rendered inoperative
by static electricity.)
(2) Avoid any impact to electronic components such as
sensors or relays. If they are dropped, they should be
replaced.
(3) Do not expose any electronic parts to high temperature or
humidity.
D001556J01 (4) When cleaning the engine with steam, protect the
electronic components, air filter and emission-related
components from water.
(5) Do not touch the connector terminals in order to prevent
deformation or malfunctions due to static electricity.
(6) Do not use an impact wrench to remove or install a
temperature switch or temperature sensor.
4. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) PLACE FOR REMOVING AND INSTALLING FUEL CONTROL
PARTS
(1) Work in a location with good air ventilation that does not
have welders, grinders, drills, electric motors, stoves, or
any other sources of sparks or flames.
(2) Never work in a pit or near a pit as vaporized fuel can
collect in those places.
(b) REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(1) Prepare a fire extinguisher before starting work.
(2) To prevent static electricity, install a ground wire to the fuel
changer, vehicle and fuel tank. Also, wet the ground
moderately so that the the area around your feet is not
slippery.
(3) Avoid using electric pumps, working lights or other
electrical equipment that can cause sparks or high
temperatures.
(4) Avoid using iron hammers as they may create sparks
during work.
(5) Dispose of fuel-contaminated cloth separately.
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IN–14
5. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS

(a) If any metal particles enter inlet system parts, this may have a
harmful effect on the engine.
(b) When removing and installing inlet system parts, cover the
openings of the removed inlet system parts. Also, cover the
engine side openings. Use gummed tape or a clean rag.
(c) When installing the inlet system parts, confirm that no metal
particles have entered the installed parts.
IN
D001563J01
6. HANDLING OF HOSE CLAMPS

(a) Before removing a hose, confirm the hose plug depth and the
Pull The Tabs To Open The Clamp
clamp position so that the hose can be reinstalled in the same
position.
(b) Replace any deformed or dented clamps with new ones.
(c) When reusing a hose, attach the clamp by aligning it with the
track portion of the hose.
(d) After attaching a spring type clamp, apply force and push in the
Clamp Mark direction of the arrows.
D001559J01 7. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION
SYSTEMS
(a) Install the antenna as far away from the computer sensors of
the vehicle electronic systems as possible.
(b) Install the antenna feeder at least 20 cm (7.87 in.) away from
the computer sensors of the vehicle electronic systems.
(c) Do not put the antenna feeder together with other wires. Keep
the antenna feeder separate from other wiring as much as
possible.
(d) Install the antenna securely, using the appropriate installation
manual as a reference.
(e) Do not install a high-powered mobile communication system.
8. CHECKING AND ADJUSTING HEADLIGHTS
Do Not Illuminate More Than 3 Minutes (a) When the discharge headlights are ON, never touch the high
voltage socket.
(b) Do not use a cover when the headlights are ON for more than 3
minutes.
NOTICE:
• Observe the precautions on handling discharge
headlights when checking and adjusting. (For
precautions on the lighting system, see page LI-1.)
D101221J01 • Because the outer lens of the headlight is made of
resin, it may melt if it is covered for extended periods of
time.
9. TRACTION CONTROL (TRC) AND VEHICLE STABILITY
CONTROL (VSC)
(a) PRECAUTIONS FOR USING 2-WHEEL DRUM TESTER
(1) When using a 2-wheel drum tester such as a speedometer
tester, a combination tester for the speedometer and brake,
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or a chassis dynamometer, turn the TRC or VSC system

OFF before performing measurements.
CAUTION:
When using a drum tester, there is a danger that the
vehicle may jump out of the tester if TRC and VSC
system are not disabled.
IN NOTICE:
• To see if TRC or VSC operation is prohibited, check
that the VSC OFF light on the combination meter is
flashing and that the slip indicator light on the
combination meter is illuminated.
• Secure the vehicle with a lock chain for safety.
HINT:
For the suppression method for the TRC and VSC system,
see PRECAUTIONS WHEN USING DRUM TESTERS in
the PRECAUTIONS section regarding the ABS system with
electronic brake force distribution, as well as the TRC, VSC
and BA systems.
(2) When inspection using the drum tester is completed,
always turn the ignition switch to the OFF position. Also
release the prohibition on TRC and VSC system.
CAUTION:
Never drive the vehicle in PROHIBIT OPERATION
MODE.
(b) NOTICES OF OPERATIONS RELATED TO VSC
(1) Do not carry out unnecessary installation and removal as it
might affect the adjustment of VSC related parts.
(2) When performing operations related to VSC, be sure to
follow the instructions for work preparation in this manual
and final confirmation of the VSC system.
10. PRECAUTIONS FOR CHECKING AND ADJUSTING FULL TIME
FOUR WHEEL DRIVE VEHICLES
NOTICE:
It is not possible to use a tester that only has a biaxial load
setting mechanism (kinds that only have 2-wheel motion
absorption mechanisms, such as a 2-wheel chassis
dynamometer or a combination tester for a chassis
dynamometer, speedometer and brake tester).
(a) Speedometer Tester Measurements
HINT:
• BFR-60 Type (Manufactured by Banzai)
• IFR-600 Type (Manufactured by Iyasaka)
NOTICE:
• When starting off rapidly, do not race the engine.
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IN–16
(1) Drive the rear wheels onto the roller.

(2) Turn off the differential lock switch.
(3) Free the front wheels using a free roller.
(4) Secure the vehicle with a lock chain.
(5) Start the engine and, in the D position, gradually increase
the vehicle speed. Then perform measurements.
(6) After completing measurements, gradually decelerate using
the brake and stop the engine.
IN
11. MEASURING BRAKE TESTER
D101274 NOTICE:
• Testers with a load setting mechanism cannot be used.
• High speed models of brake testers cannot be used.
(a) Turn off the differential lock switch.
(b) Drive the vehicle to be measured (front wheels or back wheels)
onto the roller.
(c) Set the shift position to neutral.
(d) Run the roller tester and perform measurements.
12. TOWING FR VEHICLES
(a) Tow vehicles with the rear wheels or all 4 wheels raised.
Furthermore, when towing with all 4 wheels on the ground, tow
facing forward with a towing speed of less than 30 km/hour (19
mph). Do not tow the vehicle a distance greater than 80 km
(approximately 50 miles).
NOTICE:
Towing at speeds or for distances that exceed these
figures, or towing facing backwards will have a harmful
effect on and may damage the transaxle.
13. TOWING FULL TIME FOUR WHEEL DRIVE VEHICLES
(a) Tow vehicles with all 4 wheels on the ground or with all 4 wheels
raised. Furthermore, when towing with all 4 wheels on the
Prohibited ground, tow facing forward with a towing speed of less than 30
km/hour (19 mph). Do not tow the vehicle a distance greater
than 80 km (approximately 50 miles).
NOTICE:
Towing at speeds or for distances that exceed these
figures, or towing facing backwards will have a adverse
effect on and may damage the transmission.
(b) Do not tow with only the front or back wheels raised.
Furthermore, if there is a malfunction in the running or driving
Prohibited system, only tow with all four wheels raised.
NOTICE:
Towing with only the front or only the back wheels raised
may cause the vehicle to jump out of the wheel dolly.
D101224
GETtheMANUALS.org
(c) Tow using one of the methods shown in the illustration.
Car Carrier Tow Truck (Raising All Four Wheels) Tow Truck (All Tires In
Contact With The Road)
Towing Speed Less Than 30 km/h

IN Towing Distance Less Than 80 km
Direction To Tow
D101225
NOTICE:
• If there is a malfunction in the chassis or drive line, use
a carrier car.
• Do not tow using a method not shown in the illustration.
PARKING BRAKE AND SHIFT LEVER CONDITIONS WHEN TOWING
Transmission
Towing Method Parking brake
Shift Lever Position
Carrier Car Brake is ON Either position is OK
Tow truck (with 4 wheels) Brake is ON Either position is OK
Tow truck (with 4 wheels on the ground) Brake is OFF Neutral
14. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER

(a) If a large amount of unburned gasoline flows into the converter,
it will cause damage to the catalytic converter. To avoid this,
observe the following precautions.
(1) Use only unleaded gasoline.
(2) If a spark check of the spark plugs is required, stop the fuel
jet and remove the injector connectors.
(3) When measuring the compression pressure of the engine,
stop the fuel jet and remove the injector connectors.
(4) Do not run the engine when the fuel tank is nearly empty.
This may cause the engine to misfire and put an extra load
on the converter.
SUPPORT POSITIONS FOR JACK,

RIGID RACK AND LIFT
1. NOTICE ABOUT JACKING UP VEHICLE
(a) The vehicle must be almost completely unloaded before jacking
up / lifting up the vehicle. Never jack up / lift up a heavily loaded
vehicle.
(b) When removing heavy parts such as the engine or
transmission, the center of gravity of the vehicle may shift. To
stabilize the vehicle, place a balance weight in a location where
it will not roll or shift, or use a mission jack to hold the jacking
support.
GETtheMANUALS.org
IN–18
(c) When jacking up the vehicle, be sure to support the specified

location with a jack, rigid rack, receiving block or other
attachments.
(d) Do not jack up or lift up a vehicle that exceeds the ability of the
jack or lift.
IN
GETtheMANUALS.org
2. NOTICE ABOUT SUPPORT POSITIONS WHEN JACKING UP

VEHICLE
IN
1500mm
1175mm
700mm
Do not jack up the vehicle by the oil

pan.
(Caution)
Position the jack carefully in order not
to mistake the jacking position. Garage Jack Support Position
Rigid Rack, Lift Up Support Position

Vehicle Center Of Gravity
(Approximate Center Of Gravity When Vehicle Is Empty )
D101222J01
3. PRECAUTIONS FOR USING JACKS AND RIGID RACKS

(a) Work on a level surface. Use wheel chocks at all times.
GETtheMANUALS.org
IN–20
(b) Rigid racks contain a rubber attachment like the one shown in
Rubber Attachment the illustration.
(c) The jack supports the specified location securely at the center
of the jack plate .
NOTICE:
Because the shape of the oil pan makes it easy to mistake
for the jack support location, take care not to use a garage
jack.
IN
(d) The rigid rack supports the specified location securely.
D101226J01 (e) When jacking up the front wheels, release the parking brake
and make sure wheel chocks are behind the rear wheels. When
jacking up the rear wheels, make sure wheel chocks are in front
of the front wheels.
(f) When jacking up only the front wheels or rear wheels of the
vehicle, make sure wheel chocks are both in front of and behind
the wheels of the vehicle that are on the ground.
HINT:
Do not perform any work on or leave unattended a vehicle that
is supported solely by a jack. Rigid racks must be used to
support the vehicle.
(g) When lowering a vehicle that has been jacked up on only under
its front wheels, release the parking brake and use wheel
chocks only in front of the rear wheels. When lowering a vehicle
that has been jacked up on only its rear wheels, use wheel
chocks only in back of the front wheels.
4. PRECAUTIONS FOR USING PLATE LIFT
(a) Perform work safely, following the instructions in the lift manual.
(b) Use a lift that can securely set the support position of the
vehicle.
(c) Use a receiving block and try not to hit the rocker moulding, etc.
(d) Check that the vehicle's center of gravity is properly located
over the lift cylinder.
NOTICE:
If the vehicle load is outside the lift's acceptable load
range, there is a possibility that the vehicle will shake when
raising and lowering it.
HINT:
If the acceptable vehicle load range is not clear, contact the
maker of the lift.
GETtheMANUALS.org
Acceptable Range For Vehicle Center Of Gravity
Offset Weight Offset Weight

IN Front Rear
Lift Cylinder Center

D026693
(e) Always drive the vehicle onto the specified position.
Left and right set positions Drive the vehicle onto the center of the lift.
Align the edges of the underside of the attachment with the rubber
edges of the plate cushion. (Part A, Part C)
Front and rear set position
Align the edges of the underside of the attachment with the front side
of the rigid rack support position. (Part B)
(f) Lift up the vehicle so that the tires rise slightly and shake the
vehicle to check that the vehicle is stabilized.
Plate Lift
B
A C
D101227
GETtheMANUALS.org
IN–22
5. PRECAUTIONS FOR USING SWING ARM LIFT
IN
Vehicle Center Of Gravity (Vehicle Empty)
D101228J01
(a) Perform work safely, following the instructions in the lift manual.
(b) Receiving stands use a rubber attachment like the one shown in
the illustration.
(c) Position the vehicle so that the center of the lift and the center
of gravity of the vehicle are as close as possible. (L is as short
as possible.)
(d) Keep the vehicle level and adjust the height of the receiving
stand so that it does not hit the rocker moulding. Securely align
the rigid rack support position with the receiving stand groove.
(e) Always keep the swing arm locked when performing work.
(f) Lift up the vehicle so that the tires rise slightly and shake the
vehicle to check that the vehicle is stabilized.
6. PRECAUTIONS WHEN USING 4 POST LIFT AND DRIVE-ON TYPE
LIFT
(a) Perform work safely by following the lift manual.
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(b) Do not damage the tires or wheels with the free wheel beam.
(c) Use wheel chocks to secure the vehicle.
IN
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INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
IN–24
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

INTRODUCTION
NEW DIAGNOSTIC SYSTEM

1. DESCRIPTION
(a) The new diagnostic system is a new diagnostic system
DLC
compatible with the vehicle's highly developed and IN
sophisticated electronic system. The function of the malfunction
SIL Diagnostic Communication
diagnostic system can be utilized with the DS-II diagnostic tool.
(Communication Speed 10.4 kbps or
2. FUNCTIONS OF DS-II DIAGNOSTIC TOOL
9.6 kpbs)
(a) The functions of the DS-II diagnostic tool, which is compatible
CAN Diagnostic Communication
with this new diagnostic system, are shown below.
(Communication Speed 500 kbps)
ECU
Communicating
DS-II
Each Diagnostic
Diagnostic Tool DS-II
Communication
Connection
D100834J03
Function Description
ALL diagnosis
Vehicle Diagnosis
CAN bus diagnosis
Diagnostic code freeze data
ECU DATA LIST
ACTIVE TEST
Diagnosis
Mode change
System Diagnosis
Freeze data operation
TEST MODE INSPECTION
BASIC INSPECTION
Specified operation / Control record
OPERATION SUPPORT Required operation support functions when replacing ECU or actuator
Stored Data Functions for outputting / Erasing stored data
Measure Load voltmeter side and oscilloscope functions
3. COMPUTERS AND SENSORS RELATED TO DIAGNOSTIC

COMMUNICATION
Freeze Frame
Data
DTC Check DS-II and
Computer DTC Check Computer Data Data Monitor
(Check Mode, ACTIVE TEST Communication
Sensor Name Normal Mode) When a Save / Display
Test Mode) Line
Malfunction
Occurs
EFI ECU { - { { {(*) CAN
Automatic ECU { - { { {(*) SIL
ABS ECU { { { { { SIL
Airbag ECU { - - - - SIL
Immobilizer ECU { - - { - SIL
*: Data monitor can be used simultaneously
GETtheMANUALS.org
IN–25 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
4. HOW TO USE DS-II DIAGNOSTIC TOOL

(a) CONNECT TO VEHICLE
(1) Connect the DS-II to the DLC (data link connector No. 3)
located in the area around the driver's foot.
IN
D101229J01
(b) HOW TO USE DS-II DIAGNOSTIC TOOL

(1) When the power switch of the diagnosis tool DS-II is turned
ON, the menu screen will be displayed.
(2) Select the options you wish to perform. Then perform work,
following the prompts on the screen.
D101275
5. DIAGNOSIS CONNECTOR
DLC
(a) With the adoption of the new diagnostic system, the functions
BAT CANL ECU-T EFIT REV are consolidated on the DLC (located in the lower portion of the
driver instrument panel).
(b) DLC Terminals and Functions
Terminal Name Function

BAT Battery power supply
Each computer and its diagnosis CAN
CANL
communication LO
SIO CANH E E EPS-TS D101231J01
ECU-T ECU-T check terminal
ECU-T EFI-T check terminal
REV Engine revolution signal
SIO Each computer and diagnostic communication
Each computer and its diagnostic CANHI
CANH
communication
GETtheMANUALS.org
IN–26
Terminal Name Function

E Signal ground
E Body ground
EPS-TS EPS-TS check terminal
6. HOW TO PROCEED WHEN ERRORS OCCUR

Power Indicator NOTICE:
Perform the following inspections if the DS-II power indicator
IN
does not light.
D100835J02
(a) WHEN DS-II POWER INDICATOR FAILS TO ILLUMINATE

DLC (1) Connect the DS-II to another vehicle and start the DS-II.
BAT CANL
Operating Condition Trouble area Suspected Area
1. Check the DLC BAT terminal
If the DS-II power voltage
indicator turns red or Vehicle side 2. Check the continuity between
green the DLC CG terminal and the
body ground
If the DS-II power
SIO CANH E indicator light does not DS-II tester -
D101232J01
illuminate
DESCRIPTION OF BASIC DIAGNOSTIC

PROCEDURES
HINT:
Perform troubleshooting in accordance with the procedures below. The
following shows only basic procedures. Details about the most effective
methods for each circuit are listed in the sections for each system. Confirm
the troubleshooting procedures for the circuit you are working on before
beginning troubleshooting.
1 VEHICLE BROUGHT TO WORKSHOP
2 CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the
problem occurred and create a customer problem analysis check.
3 SYMPTOM CONFIRMATION AND DTC (AND FREEZE FRAME DATA) CHECK
(a) Using an electrical tester, check the battery voltage.
GETtheMANUALS.org
Standard:
10 to 14 V (during engine stop)
(b) Visually check for broken fuses, disconnected wire harnesses, short
circuits and connectors with bad connections.
(c) Confirm the problem symptoms and conditions, and check the
following chart for DTCs.
IN DTC is output:
Proceed to DTC Chart
DTC is not output:
Proceed to Problem Symptoms Chart
4 UNDERSTANDING VEHICLE CONDITION
(a) Memory is erased when the negative (-) battery terminal is

disconnected. Therefore, in order to restore initial settings for
replacement parts, make a note of initial system settings before
conducting repairs.
HINT:
• For operation settings when disconnecting and reconnecting the
negative (-) battery terminal.(See page SS-10)
• For operation settings when installing and removing parts. (See
page SS-11)
5 CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Using the DTC chart or problem symptom table, confirm whether a
check of circuit system or parts is necessary.
6 REPAIR OF PROBLEMS
(a) Following the directions found in step 5, repair the malfunctioning

system or part.
7 CONFIRMATION TEST
(a) When the repair is completed, confirmed that the malfunction has
disappeared. If the malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same
environment as when the malfunction occurred the first time.)
(b) If the malfunction outputs a DTC, confirm the diagnostic result.
GETtheMANUALS.org
IN–28
8 RESTORING VEHICLE
(a) Restore all vehicle settings using the procedure found in step 4.
HINT:
Explain to the customer that there may be some settings that cannot
be restored. IN
OK
CUSTOMER PROBLEM ANALYSIS

1. In troubleshooting, confirm that the problem symptoms have been
accurately identified. Preconceptions should be discarded in order to
make an accurate judgment. To clearly understand what the problem
symptoms are, it is extremely important to ask the customer about the
problem and the conditions at the time the malfunction occurred.
2. The following 5 questions are important points in the problem analysis.
Because past problems that seem unrelated may also help in some
cases, when troubleshooting it is necessary to gather as much
information as possible and possess a clear understanding of their
relationship to the problem symptoms. Customer problem analysis is
listed in the diagnosis section for each system.
• What? Vehicle model, system name
• When? Date, time, occurrence frequency
• Where? Road conditions
• Under what conditions? Driving conditions, weather conditions
• How did it happen? Problem symptoms
HINT:
The following shows one example of a customer problem analysis.
GETtheMANUALS.org
Engine Problem Diagnosis Check Sheet

Model Date vehicle brought in Service history No/Yes (__times)
IN VIN Date registered Registration No.
Date problem first occurred Odometer reading km
Accessories
Previous vehicle Main region/purpose of travel

Customer profile/characteristics
Description of symptoms
Warning light illumination Off/On ( )
Driving Problem
System Conditions Road Conditions Others
Conditions Frequency
Speed problem first Starting off Level Accelerator Always
occurred( )km/h Cruising Uphill opening One time only
Shift position ( ) range Increasing ( )%
speed Downhill Sometimes
Starting off Dry paved road Ambient air (_)times a day
Immediately after Decreasing
start off speed Wet paved road temperature (_)times a week
( ) min after start Braking Unpaved/rough ( ) (_)times a month
Check Turning road
Results After ( )min driving Weather
Cold Stopped Snowy/icy road
( )
Warm Not related Uneven,
Idling Others manholes etc.
Others ( ) ( ) Others ( )
Additional Items
DTC Inspection
Malfunction Indicator Normal Code(s) Fuel pressure when
Lamp (MIL) Off/On Malfunction code(s)(all noted) engine stopped
Fuel pressure 1 min.

after engine stopped
Problem details
Inspection Driving conditions and location when problem first
Results occurred and reoccurred
Reoccurrence conditions
Always Occasional Once problem occurs, it continues Does not reoccur
Dealer Name Office Person in charge Technician
A066666J09
GETtheMANUALS.org
IN–30
CONFIRMING SYMPTOMS AND

CHECKING DIAGNOSTIC TROUBLE
CODES
HINT:
The diagnostic system has various functions. During troubleshooting, IN
whenever a malfunction occurs in the signal circuits to the ECU, a
Diagnostic Trouble Code (DTC) is recorded and stored in the ECU memory.
By using these functions, the problem areas can quickly be narrowed down
and troubleshooting is more effective. Diagnostic functions are
incorporated in the following system.
DTC Check
DTC DTC Check
(Normal
Check (Normal DTC Check
Mode)
System [ECU] (Normal Mode) (Check Mode)
DLC
Mode) Panel (Test Mode)
(ECUT-E
DS-II Diagnosis
short circuit)
EFI System (3SZ-VE) [Engine ECU] { { - -
Electronic controlled automatic transmission <ECT>
{ { - -
(A4Q-D1,M5S) (Transmission ECU)
ABS with EBD, TRC,VSC, and BA system (skid control ECU) { { - {
{
SRS Airbag System (Airbag ECU) { { -
(*1)
Body electrical area network system <LIN> (door control relay) (keyless
- { - -
ECU) (combination meter)
CAN COMMUNICATION SYSTEM { { - -
(*1):
Check Mode
In the DTC check, it is very important to determine whether the problem
indicated by the DTC is either 1) still occurring, or 2) occurred in the past
bust has since returned to normal. In addition, the DTC should be
compared to the problem symptom to see if they are related.
For this reason, DTCs should be checked before and after the confirmation
of symptoms to determine current system conditions. Failure to check
DTCs may, depending on the case, result in unnecessary troubleshooting
for systems operating normally. Failure to check DTCs may also make it
difficult to find where problems are occurring, or lead to repairs not related
to the problem. Therefore, always perform a DTC check by following the
proper procedure.
HINT:
• The following flowchart shows how to proceed with troubleshooting
using the DTC check.
• The flowchart indicates how to utilize the DTC check effectively.
Depending on the results of the check, it indicates how to proceed
either to DTC troubleshooting or to the troubleshooting chart containing
each problem symptom.
1 VERIFICATION OF PROBLEM (CUSTOMER INQUIRY)
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2 CHECK FOR DTCs
NOTICE:
Always check ALL diagnoses and panel diagnoses.
IN A
Cannot read from all of the ECU
connections
B DTC is not output
C DTC is output
A GO TO STEP 7
B GO TO STEP 8
3 SAVING DTCs AND FREEZE FRAME DATA
(a) SAVING RECORDED DTCs AND FREEZE FRAME DATA

NOTICE:
• Never delete without saving. Doing so will delete all DTCs,
freeze frame data and history data.
• Always take notes, as it is not possible to save panel
diagnosis.
HINT:
• When multiple codes are recorded, determine the chief cause
from all the DTCs.
• The EFI, AT and ABS utilizes the estimated data when DTCs are
output.
• DTCs can be output even when no problem occurs. (Unlearned
data from the air conditioning solar sensor, and from after clearing
the battery)
Diagnosis of systems other than

A
communication systems
Diagnosis of communication systems
B
only
Diagnosis of communication systems
C
and other systems
A GO TO STEP 5
B For bus (communication line) trouble .(See

Page CA-5 (CAN) or MP-11 (LIN))
4 DETERMINING PROBLEM CAUSE
(a) Decide from all the DTCs if the main cause of the problem stems from
parts or from the bus (communication line).
GETtheMANUALS.org
IN–32
HINT:
It is possible that a communication diagnosis may not be shared because
of a part malfunction.
A Bus (communication line) malfunction

B Part malfunction
A Perform bus (communication line) IN

troubleshooting. For the CAN
communication system see CA-5. For the
body electrical area network system (LIN),
see MP-1.
5 DELETING DTCs AND FREEZE FRAME DATA
6 Road test, DTC check
A DTC is output
B DTC is not output
A TROUBLESHOOTING WITH DTC-SPECIFIC

INSPECTION PROCEDURE
Perform symptom reproduction using the reproduction method appropriate for the
problem symptoms
7 CONNECT DS-II TO ANOTHER VEHICLE AND CHECK FOR DTC
No DTCs are output on other vehicle as

A
well.
B Normal on other vehicle
A DS-II malfunction (For procedure when DS-II

errors occur, see IN-24.)
Bus (communication line) malfunction (For CAN communication system see CA-5. For
body electric area network system (LIN), see MP-1.)
GETtheMANUALS.org
8 CHECK PROBLEM SYMPTOM
(a) Utilizing the customer inquiry results and ECU data monitor,
determine whether the problem is the same as the malfunction
described by the customer.
IN
NG TROUBLESHOOTING WITH DTC-SPECIFIC
OK
SYSTEM NORMAL
REPRODUCTION METHOD OF
PROBLEM SYMPTOM
HINT:
• The most difficult case in troubleshooting is when no problem
symptoms occur. In such a case, a thorough problem analysis must be
carried out. A simulation of the same or similar conditions and
environment in which the problem occurred in the customer's vehicle
should be carried out. Troubleshooting without confirming the problem
symptoms will lead to important repairs being overlooked and mistakes
or delays.
• For example, with a problem that only occurs when the engine is cold or
as a result of vibration caused by the road during driving, the problem
can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine.
• Vibration, heat or water penetration (moisture) is difficult to reproduce.
The symptom reproduction tests that are introduced here are effective
substitutes for these conditions and can be applied on a stationary
vehicle.
IMPORTANT POINTS IN SYMPTOM REPRODUCTION TEST
In the symptom reproduction test, the problem symptoms as well as the
problem area or parts must be confirmed. First, narrow down the possible
problem circuits according to the symptoms. Then, connect the tester and
carry out the symptom reproduction test. After that, determine whether the
circuit being tested is defective or normal. Also, confirm the problem
symptoms at the same time. Refer to the problem symptoms table for each
system to narrow down the possible causes.
GETtheMANUALS.org
IN–34
1. VIBRATION METHOD (MALFUNCTION APPEARS TO OCCUR AS

RESULT OF VIBRATION)
Lightly Tap
(a) Parts and sensors
(1) Apply slight vibration with a finger to the part of the sensor
suspected to be the cause of the problem, and check
whether or not the malfunction occurs.
HINT:
Applying strong vibration to relays may open them.
IN
(b) Connectors
(1) Slightly shake the connector vertically and horizontally.
(c) Wire harness
(1) Slightly shake the wire harness vertically and horizontally
and check whether or not the malfunction occurs.
Lightly Wiggle HINT:
The connector joint, the fulcrum of the vibration, and the
penetrating part of the body are the major areas that should
be checked thoroughly.
Lightly Wiggle
D020016J04
2. HEAT METHOD (MALFUNCTION APPEARS TO OCCUR WHEN

AREA IS HOT OR COLD)
(a) Heat or cool the component that is the possible cause of the
Malfunction
malfunction with a hair dryer or cooling agent. Check if the
Occurs Cooling
Spray
malfunction occurs.
NOTICE:
• Do not heat to more than 60°C (140°F) (a temperature at
which you can still touch it with your hand).
• Open the lid of the ECU, but do not apply heat or cold
D020021J01 directly to the electronic parts.
HINT:
Cooling agents can be obtained at an electronic parts store.
3. WATER SPRINKLING METHOD (MALFUNCTION APPEARS TO
OCCUR ON RAINY DAYS OR IN HIGH HUMIDITY)
(a) Sprinkle water onto the vehicle and check if the malfunction
occurs.
NOTICE:
• Never sprinkle water directly into the engine
compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the
radiator.
D101233J01 • Never apply water directly onto the electronic
components.
4. OTHER METHOD (MALFUNCTION APPEARS TO OCCUR
BECAUSE ELECTRICAL LOAD IS EXCESSIVE)
(a) Turn on the heater blower, headlights, rear window defogger
and all other electrical loads. Check if the malfunction reoccurs.
DIAGNOSTIC TROUBLE CODE CHART

Using the DTCs listed in the diagnostic trouble code chart, you can perform
accurate and effective troubleshooting. Perform troubleshooting based on
GETtheMANUALS.org
the inspection procedure of the corresponding diagnosis chart for the DTCs
that are listed. The following is an example of a DTC for the EFI system.
The left side is the SAE Output

Code No./ The right side
IN indicates the Output Code when
the Check Engine Warning Light
Indicates the contents of the
system that is malfunctioning
is used.
Engine Control - EFI System
DTC Table
Diagnosis Item Light Illuminated Code Memory Reference Page
P0110/43 Intake Air Temperature Sensor Signal ○○-○○
P0115/42 Water Temperature Sensor Signal ○○-○○
P0120/41 Throttle Sensor Signal ○○-○○
Indicates repair manual instructions and the

page on which each circuit detection
procedure can be found.
D101251
PROBLEM SYMPTOMS TABLE

The suspected areas (circuits or parts) for each problem symptom are
listed below. When a NORMAL code is output during a DTC check but the
problem is still occurring, use the problem symptoms table to troubleshoot.
Items in the suspected trouble area indicate circuits or parts that should be
checked.
HINT:
In some cases, the problem is not detected by the diagnostic system even
though a problem symptom is present. It is possible that the problem is
occurring outside the detection range of the diagnostic system, or that the
problem is occurring in a completely different system.
GETtheMANUALS.org
IN–36
Indicates on which page the detection

Indicates a symptom for which a Indicates part name and the circuit requirements and flow chart for each
DTC No. is not displayed. for each system to be inspected. circuit are found.
Problem Symptoms
IN
Table
Symptoms Inspection Item Reference Page
Starter or Starter Relay
Does not crank
Neutral Starter Switch
ECU Power ES
Fails to start Igniter ES
(No initial combustion) Fuel Pump ES
Fuel Injector
Crankshaft Angle Sensor ES
Fuel Pump ES
Fails to start Igniter ES
(Combustion not complete) Fuel Injector
Crankshaft Angle Sensor ES
Starter ES
ISCV ES
Fails to start
Fuel Pump ES
(Cranking is normal)
Igniter ES
Spark Plug
D100011
DTC SYSTEM-SPECIFIC INSPECTION

PROCEDURE
DTC SYSTEM-SPECIFIC INSPECTION PROCEDURE
How to read and use each page is listed below.
• Troubleshooting indicates a procedure for each symptom, system and
DTC, and makes it easy to determine problem symptoms and
investigate their causes.
GETtheMANUALS.org
• Troubleshooting covers different diagnostic areas: DTC, circuit

description, detection conditions, circuit diagrams and inspection
procedures.
This HINT is used to judge whether the circuit is

normal or malfunctioning. This reference is used to
IN determine if the malfunction is in the sensor, actuator,
wire harness, or ECU.
DTC DTC Name
HINT:
COOLANT TEMPERATURE SENSOR SIGNAL SYSTEM Read the freeze frame data using the DS-?.Freeze frame data records
DESCRIPTION aspects of the engine’s condition when malfunctions occur.
This information is helpful when troubleshooting.
The resistance of the thermistor buit into the coolant temperature sensor varies
according to the coolant temperature.
READ DS-? DATA (COOLANT TEMPERATURE)
DTC Detection Condition
1.Diagnosis Condition (a) Connect the DS-? to the DLC
2.Malfunction Condition Suspected Area (b) Read the engine coolant temperature displayed
3.Malfunction Time on the DS-? while the ignition switch is
4.Other turned to the ON position and the engine is stopped.
Tester Display Proceed to
1.IG ON
2.Open or short in coolant temperature Wire harness or connector
circuit Coolant temperature Equivalent to actual coolant temperature
3.0.5 seconds or more Engine control computer
4.1 trip GO TO STEP 4
CHECK FOR INTERMITTENT PROBLEMS
READ DS-? DATA (CHECK FOR OPEN IN ENGINE CONTROL COMPUTER)

Detection Conditions SST 09843-18020
CIRCUIT DIAGRAM (a) Disconnect the connector of the coolant
temperature sensor.
(b) Shot the circuit between terminals 2 (+)
and 1(-) of the water temperature vehicle
Engine control computer
Coolant temperature side connector using the SST(diagnosis
check wire No.2).
(c) Connect the DS-? to the DLC.
(d) Turn the ignition switch to the ON position.
(e) Read the engine coolant temperature displayed
on the DS-?.
Standard;
140°C
REPLACE COOLANT TEMPERATURE SENSOR
READ DS-? DATA (CHECK FOR OPEN IN ENGINE CONTROL COMPUTER)

SST 09843-18020
Circuit Diagram (a) Shot the circuit between terminals 54 (THW)
and 19(E2) of the engine control computer
using the SST(diagnosis check wire No.2).
(For terminal layout,see page ES-16.)
(b) Read the engine coolant temperature displayed
on the DS-?.
Standard;
140°C
CHECK AND REPLACE ENGIN CONTROL COMPUTER
REPAIR OR REPLACE WIRE HARNESS OR CONNECTOR
Indicates the condition of the ECU

connector during inspection.
The (+) and (-) after the terminal name The ground side is not noted when
indicate the tester connection. inspecting body ground. Connectors are
disconnected during inspection.
D101252
GETtheMANUALS.org
IN–38
ELECTRONIC CIRCUIT INSPECTION

PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements
should be made at an ambient temperature of 20°C (60°F).
IN
Resistance measurements may be inaccurate if measured
at high temperatures, i.e. immediately after the vehicle has
been running. Measurements should be made after the
engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a locked connector, first squeeze the
(2) Separate mating halves tightly together to release the lock, and then
The Lock press the lock claw and separate the connector.
(2) When disconnecting a connector, do not pull on the
(1) Push
The Side harnesses. Grasp the connector directly and separate it.
That Engages
(3) Before connecting a connector, check that there are no
deformed, damaged, loose or missing terminals.
(4) When connecting a connector, press firmly until it locks with
a click sound.
(5) When checking a connector with an electrical tester, check
the connector from the backside (harness side) using a
mini test lead.
NOTICE:
• As a waterproof connector cannot be checked from
the backside, check it by connecting a sub-harness.
• Do not damage the terminals by moving the
inserted tester needle.
(c) CHECKING CONNECTORS
(1) To check whether a connector is still connected, grasp the
D001558J04
connector housing to confirm that it is fully inserted and
locked. (Engaged condition)
(2) To check whether a connector is disconnected, pull the wire
Loose harness lightly (missing terminals, caulked terminals,
Core Conductor broken conductor wires). Check visually for corrosion,
Broken metal fragments, moisture, or bent terminals (corrosion,
foreign matter, deformed terminals).
NOTICE:
Terminal When testing a gold-plated female terminal, always use
Deformed a gold-plated male terminal.
Lightly Pull
D020035J03
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(3) When checking the contact pressure of a terminal, prepare

a spare male terminal. Insert it into a female terminal, and
check for ample tension when inserting and after full
engagement.
IN
Male Inspection Terminal
D020036J02
(d) REPAIR METHOD FOR CONNECTOR TERMINAL

(1) If there is any foreign matter on the terminal, clean the
contact point using an air gun or cloth. Never rub the
contact point using sandpaper, as the plating may come off.
(2) If there is abnormal contact pressure, replace the female
terminal. If the male terminal is gold-plated (gold color), use
a gold-plated female terminal. If the male terminal is silver-
plated (silver color), use a silver-plated female terminal.
(3) If the terminal is not defective, clean the contact point with
D020024J01 an air gun and apply connector grease. (This prevents
oxidation and abrasion of the contact points.)
(e) CONNECTOR GREASE
(1) Fill non-weather packed connectors that can easily get wet,
such as the alternator or headlights with grease (white
lithium) to prevent terminal decay.
(2) If there is insufficient connector grease when repairing the
terminals, use your hand to fill the female terminal with
100g of connector grease.
NOTICE:
• Keep the terminals free of dust.
• Do not use a screwdriver or any other tool to fill the
Z
terminals with grease.
(3) It is not a problem for grease to come in contact with
waterproof connectors such as O-rings or rubber plugs.
However, should grease come in contact with other rubber
parts (such as weatherstrip or grommets for wire
harnesses), there is a risk of deterioration and
discoloration. In the event that grease does come in contact
with these parts, quickly wipe them off.
D100014
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IN–40
(f) HANDLING OF WIRE HARNESSES

(1) When removing a wire harness, check the position of the
wiring and clamping before proceeding so that the parts
can be restored in the same way.
(2) Never twist or pull the wire harness more than necessary.
(3) The wire harness should never come into contact with a
high temperature part, or rotating, moving, vibrating or
sharp-edged parts. Avoid contact with panel edges, screw
IN
tips and other sharp items.
D001557J01 (4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut
or broken, replace it or repair it with vinyl tape.
2. CHECKING FOR OPEN CIRCUITS
Diagram 1 (a) For an open circuit in the wire harness in Fig. 1, check the
continuity or voltage for an open circuit.
Sensor Open
C B A
D025065J04
(b) Check the continuity.

Diagram 2 (1) Disconnect connectors A and C and measure the
resistance between them.
Standard:
1Ω or less
HINT:
Sensor Measure the resistance while lightly shaking the wire
harness vertically and horizontally.
C B A
(2) In Fig. 2, there is no continuity between terminal 1 of
D025066J02 connector A and terminal 1 of connector C (open circuit)
and there is continuity between terminal 3 of connector A
and terminal 2 of connector C. As a result, there is an open
circuit between terminal 1 of connector A and terminal 1 of
connector C.
(3) Disconnect connector B and measure the resistance
Diagram 3 between the connectors.
(4) In Fig. 3, there is continuity between terminal 1 of
connector A and terminal B1 of connector C and there is no
Sensor continuity between terminal 1 of connector B2 and terminal
1 of connector C (open circuit). As a result, there is an open
circuit between terminal 1 of connector B2 and terminal 1 of
connector C.
C B2 B1 A
D025067J02
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(c) Check the voltage.

Diagram 4 (1) In a circuit in which voltage is applied to the ECU connector
terminal, an open circuit can be checked by conducting a
voltage check.
5V (2) As shown in fig. 5, with each connector still connected,
0V
measure the voltage between the body ground and the
Sensor 5V
IN 2
1 1
2 2
1 ECU5 output terminals. Measure the voltages of the
terminals in the following order: 1) terminal 1 of connector
C B A A; 2) terminal 1 of connector B; and 3) terminal 1 of
D100900J01 connector C.
(3) In the case of the results below, an open circuit exists in the
wire harness between terminal 1 of connector B and
terminal 1 of connector C.
Standard:
The connector A terminal 1 - Body ground is 5V
The voltage between connector B terminal 1 and
body ground is 5V.
The voltage between connector C terminal 1 and
body ground is 0V
3. CHECKING FOR SHORT CIRCUITS
Diagram 5 (a) As shown in Fig. 5, if a wire harness is shorted to ground, locate
the section by conducting a resistance check with the body
ground.
Sensor short
C B A
D025069J03
(b) Check the continuity with the body ground.

Diagram 6 (1) Disconnect connectors A and C and measure the
resistance between the body ground and terminals 1 and 2
of connector A.
Standard:
1Ω or less
Sensor HINT:
C A Measure the resistance while lightly shaking the wire
B
harness vertically and horizontally.
D025070J02 (2) In Fig. 6, there is continuity between the body ground and
terminal 1 of connector A (short circuit) and there is no
continuity between the body ground and terminal 2 of
connector A. This indicates that there is a short circuit
between terminal 1 of connector A and terminal 1 of
connector C.
GETtheMANUALS.org
IN–42
(3) Disconnect connector B and measure the continuity

Diagram 7 between the body ground and connector A of terminal 1
and between the body ground and connector B2 of terminal
1. There is no continuity between the body ground and
Sensor terminal 1 of connector A, and there is continuity (short
circuit) between the body ground and terminal 1 of
connector B2. This indicates that a short circuit exists
between terminal 1 of connector B2 and terminal 1 of
IN
C B2 B1 A connector C.
D025071J02
4. VISUAL CHECK AND CONTACT PRESSURE CHECK

Loose (a) Disconnect both ends of the connector.
Core Conductor (b) Check that there is no rust or foreign matter on the connector
Broken terminals.
(c) Confirm that no damage has occurred to rounded parts due to
loosening, and check that the terminals are fixed in a firmly
Terminal locked position.
Deformed HINT:
Lightly Pull Check that the terminals do not come out if lightly pulled from
D020035J03 behind.
(d) Insert a spare male test terminal into a female terminal and pull
it out.
HINT:
If the test terminal can be more easily removed than other
terminals then the contact of that part is not good.
5. CHECKING AND REPLACING ECUs
NOTICE:
• The connectors should not be disconnected from the ECU.
Perform the inspection from the backside of the connectors
on the wire harness side.
• When no measuring condition is specified, perform the
inspection with the engine stopped and with the ignition
switch in the ON position.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is
Example:
normal, the ECU may be faulty. Temporarily replace the ECU
with a known-good ECU and check if the symptoms occur.
(1) Measure the resistance between the ECU ground terminal
and body ground.
Standard:
Ground 1Ω or less
D025072J01
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(2) Disconnect the ECU connector. Check the ground terminal

ECU Side on the ECU side and wire harness side for bending. Lastly,
check the contact pressure.
Ground
IN W/H Side
Ground D025073J01
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INTRODUCTION - TERMS
IN–44
TERMS
INTRODUCTION
ABBREVIATIONS
Abbreviation Meaning
ABS
A/C
Antilock Brake System
Air Conditioner
IN
ACC Accessory
ACV Air Control Valve
A/F Air-Fuel Ratio
AI Artificial Intelligence
ALT Alternator
AMP Amplifier
ANT Antenna
API American Petroleum Institute
ASSY Assembly
ASV Air Switching Valve
A/T Automatic Transmission (Transaxle)
ATF Automatic Transmission Fluid
AV Audio & Visual
+B Battery Plus
BTDC Before Top Dead Center
BVSV Bimetallic Vacuum Switching Valve
CAN Controller Area Network
CB Circuit Breaker
CCD Charge Coupled Device
CD Compact Disc
CRT Cathode-Ray Tube
CRS Child Restraint System
CTR Center
CVT Continuously Variable Transmission
DLC Data Link Connector
DLI Distributorless Ignition
DTC Diagnostic Trouble Code
EBD Electronic Brake force Distribution
ECU Electronic Control Unit
EFI* Electronic Fuel Injection

EGR Exhaust Gas Recirculation
ELR Emergency Locking Retractor
EPS Electronic Power Steering
ESA Electronic Spark Advance
EX Exhaust
F/L Fusible Link
FP Fuel Pump
FR Front
HAC High Altitude Compensator
HCV Heat Control Valve
HDD Hard Disc Drive
HIC Hot Idle Compensator
HID High Intensity Discharge (Headlight)
GETtheMANUALS.org
IN–45 INTRODUCTION - TERMS
Abbreviation Meaning
IC Integrated Circuit
IG Ignition
IN Intake
ISC Idle Speed Control
IN ISCV
J/B
Idle Speed Control Valve
Junction Block
LAN Local Area Network
LED Light-Emitting Diode
LH Left hand
LLC Long-Life Coolant
LSD Limited Slip Differential
LSPV Load Sensing Proportioning Valve
M/T Manual Transmission (Transaxle)
OCV Oil Control Valve
O/D Overdrive
OPT Option
O/S Oversize
PCV Positive Crankcase Ventilation
PKB Parking Brake
PPS Progressive Power Steering
PRV Pressure Regulator Valve
P/S Power Steering
PTO Power Take-Off
P/W Power Window
R&P Rack and Pinion
R/B Relay Block
RH Right Hand
ROM Read-Only Memory
RR Rear
SAE Society of Automotive Engineers
SRS Supplemental Restraint System
SST Special Service Tool
STD Standard
SW Switch
T Torque
TRC* Traction Control

U/S Undersize
VCV Vacuum Control Valve
VSC* Vehicle Stability Control

VSV Vacuum Switching Valve
VTV Vacuum Transmitting Valve
W/ With
Wire Harness Wire harness
HINT:
*:"EFI", "TRC", and "VSV" are registered trademarks of Toyota Motor
Corporation.
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TO INDEX TO NEXT SECTION
TO INDEX
ëçê‡
PREPARATION
ENGINE CONTROL
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-1
Lubricant and others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-1
PP
ENGINE MECHANICAL
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-2
Service tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-3
FUEL
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-5
EMISSION CONTROL
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-6
EXHAUST
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-7
COOLING
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-8
LUBRICATION
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-10
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-10
IGNITION
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-11
STARTING
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-12
CHARGING
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-13
AUTOMATIC TRANSMISSION
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-14
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-14
CLUTCH
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-17
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-17
MANUAL TRANSMISSION
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-18
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-18
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TRANSFER
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-20
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-20
PROPELLER SHAFT
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-21
DRIVE SHAFT
PP SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-22
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-22
DIFFERENTIAL
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-23
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-25
AXLE
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-27
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-28
SUSPENSION
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-29
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-29
TIRE AND WHEEL
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-31
BRAKE CONTROL
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-32
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-32
BRAKE
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-33
Service tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-33
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-33
PARKING BRAKE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-35
STEERING COLUMN
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-36
POWER STEERING
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-37
Service tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-37
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-37
AIR CONDITIONER
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-38
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-38
SUPPLEMENTAL RESTRAINT SYSTEM
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-40
Service tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-40
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Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-40
SEAT BELT
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-43
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-43
AUTO ALARM
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricant and others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PP-44
PP-44
PP
ENGINE IMMOBILISER
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-45
LIGHTING
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-46
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-46
WIPER AND WASHER
Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-48
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-48
DOOR LOCK
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-49
METER
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-50
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-50
AUDIO / VISUAL
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-51
OTHER SYSTEM
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-52
GLASS AND WINDOW
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-53
MIRROR
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-55
INSTRUMENT PANEL
SEAT
Service tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-57
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-57
BODY
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-58
Service tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-58
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-58
GETtheMANUALS.org
BODY EXTERIOR
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-60
BODY INTERIOR
Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-61
BODY MULTIPLEX COMMUNICATION SYSTEM [LIN]
PP SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-62
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-62
CAN COMMUNICATION
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-63
GETtheMANUALS.org
PREPARATION - ENGINE CONTROL
PP–1
ENGINE CONTROL
PREPARATION
ëçê‡
SST
09842-97209 EFI Computer Check Sub-Harness EFI SYSTEM
PP
09843-18020 Diagnosis Check Wire EFI SYSTEM
09843-97201 Wire, EFI Inspection EFI SYSTEM
O9268-41047 Injection Measuring Tool Set EFI SYSTEM
Introduction
09960-97001 DS-II EFI SYSTEM
CAMSHAFT TIMING OIL CONTROL
VALVE ASSEMBLY
Torque Wrench THROTTLE BODY

KNOCK CONTROL SENSOR
VALVE ASSEMBLY
Thermometer E.F.I.WATER TEMPERATURE
Electrical Tester EFI SYSTEM
VALVE ASSEMBLY
E.F.I.WATER TEMPERATURE
E.F.I.COMPUTER RELAY
THROTTLE POSITION SENSOR
Lubricant and others

Wire Harness for Inspection CAMSHAFT TIMING OIL CONTROL
VALVE ASSEMBLY
Engine Oil CAMSHAFT TIMING OIL CONTROL
VALVE ASSEMBLY
Automotive 12V Battery CAMSHAFT TIMING OIL CONTROL
VALVE ASSEMBLY
GETtheMANUALS.org
PP–2 PREPARATION - ENGINE MECHANICAL
ENGINE MECHANICAL
PREPARATION
ëçê‡
SST
09210-87701 Flywheel Holder PARTIAL ENGINE ASSEMBLY
PP
09223-87202 Crankshaft Front Oil Seal Replacer TIMING CHAIN (BELT) COVER OIL
SEAL
09278-87201 Timing Belt Pulley Holding Tool CYLINDER HEAD GASKET

TIMING CHAIN (BELT) COVER OIL
SEAL
09306-87501 Counter Gear Front Bearing Puller CYLINDER HEAD GASKET

SEAL
09608-87302 Axle Hub Bearing & Drive Pinion ENGINE REAR OIL SEAL
Bearing Tool Set
Service tool
09032-00100 Oil Pan Seal Cutter ENGINE REAR OIL SEAL
09040-00020 Socket Hexagon Wrench Set VALVE CLEARANCE

CAMSHAFT
(09043-20100) Socket Hexagon Wrench 10 VALVE CLEARANCE

CAMSHAFT
09043-50080 Double Hexagon 8 Wrench CYLINDER HEAD GASKET
09090-04020 Engine Sling Device PARTIAL ENGINE ASSEMBLY
GETtheMANUALS.org
PREPARATION - ENGINE MECHANICAL
PP–3
Introduction
Engine Lifter PARTIAL ENGINE ASSEMBLY
ML450 High-mission Jack PARTIAL ENGINE ASSEMBLY
09960-97001 DS-II ENGINE MECHANICAL SYSTEM

PP
CYLINDER HEAD GASKET
Torque Wrench FAN & ALTERNATOR V-BELT

VALVE CLEARANCE
PARTIAL ENGINE ASSEMBLY
CHAIN
CAMSHAFT
SEAL
ENGINE REAR OIL SEAL
Vernier Calipers PARTIAL ENGINE ASSEMBLY
SEAL
Micrometer (0-25mm) VALVE CLEARANCE
Dial Indicator VALVE CLEARANCE
Straightedge,Push-Pull Gauge FAN & ALTERNATOR V-BELT
Thickness Gauge VALVE CLEARANCE
95506-00091 Belt Tension Gauge FAN & ALTERNATOR V-BELT
KTL-12C Timing Light ENGINE MECHANICAL SYSTEM

(Current Detection Type)
TBGCG-100 Gasoline Compression ENGINE MECHANICAL SYSTEM

Gauge Set
TIGCG-100 Gasoline Compression ENGINE MECHANICAL SYSTEM

Gauge Set
TL-12C Timing Light ENGINE MECHANICAL SYSTEM

(Current Detection Type)
Chain Block PARTIAL ENGINE ASSEMBLY
GETtheMANUALS.org
PP–4 PREPARATION - ENGINE MECHANICAL

Manual Transmission Gear Oil PARTIAL ENGINE ASSEMBLY
(API GL-3 or GL-4, API 75W-90,
75W-85 or 75W-80)
MP Grease TIMING CHAIN (BELT) COVER OIL
SEAL
PP DEXRON-III
Engine Oil
CHAIN
CAMSHAFT
VALVE STEM OIL SEAL (O-RING)
Gasoline CYLINDER HEAD GASKET
Cutter Knife TIMING CHAIN (BELT) COVER OIL
SEAL
Gummed Tape CAMSHAFT
Sandpaper (No.400) TIMING CHAIN (BELT) COVER OIL
SEAL
Paint VALVE CLEARANCE
CAMSHAFT
Rope or Wire VALVE CLEARANCE
CAMSHAFT
Three Bond 1207B VALVE CLEARANCE
CAMSHAFT
Three Bond 1324 VALVE CLEARANCE
CAMSHAFT
Protective Tape CYLINDER HEAD GASKET
SEAL
Wooden block CYLINDER HEAD GASKET
VALVE STEM OIL SEAL (O-RING)
Vinyl Tape CAMSHAFT
Engine Hanger No.1 (Replacement PARTIAL ENGINE ASSEMBLY
parts)
Engine Hanger No.2 (Replacement PARTIAL ENGINE ASSEMBLY
parts)
Engine Hanger Attachment Bolt PARTIAL ENGINE ASSEMBLY
(Replacement parts)
GETtheMANUALS.org
PREPARATION - FUEL
PP–5
FUEL
PREPARATION
ëçê‡
SST
09268-41047 Injection Measuring Tool Set FUEL SYSTEM
PP
09843-97201 EFI Inspection Wire FUEL INJECTOR ASSEMBLY
O9268-41047 Injection Measuring Tool Set FUEL INJECTOR ASSEMBLY
Introduction
Clip Remover FUEL PUMP
09960-97001 DS-II FUEL SYSTEM
FUEL INJECTOR ASSEMBLY
FUEL TANK ASSEMBLY
Torque Wrench FUEL INJECTOR ASSEMBLY

FUEL PUMP
FUEL TANK ASSEMBLY
Stopwatch FUEL INJECTOR ASSEMBLY
Graduated Cylinder FUEL INJECTOR ASSEMBLY
Electrical Tester FUEL INJECTOR ASSEMBLY
FUEL PUMP

Wire Harness for Inspection FUEL INJECTOR ASSEMBLY
Butyl Tape FUEL PUMP
Gasoline FUEL INJECTOR ASSEMBLY
Cutter Knife FUEL INJECTOR ASSEMBLY
Fuel Hose FUEL INJECTOR ASSEMBLY
Automotive 12 V Battery FUEL PUMP
Vinyl Bag FUEL INJECTOR ASSEMBLY
FUEL PUMP
FUEL TANK ASSEMBLY
GETtheMANUALS.org
PP–6 PREPARATION - EMISSION CONTROL
EMISSION CONTROL
PREPARATION
ëçê‡
Introduction
B20D-22H O2 Sensor Socket OXYGEN SENSOR
OXYGEN SENSOR NO.2
PP
09960-97001 DS-II EMISSION CONTROL SYSTEM
Torque Wrench OXYGEN SENSOR

OXYGEN SENSOR NO.2
Electrical Tester OXYGEN SENSOR
TB-501 Mighty-Vac EMISSION CONTROL SYSTEM
6890 Mighty-Vac EMISSION CONTROL SYSTEM
GETtheMANUALS.org
PREPARATION - EXHAUST
PP–7
EXHAUST
PREPARATION
ëçê‡
Introduction
Torque Wrench EXHAUST PIPE ASSEMBLY
Vernier Calipers EXHAUST PIPE ASSEMBLY
PP
GETtheMANUALS.org
PP–8 PREPARATION - COOLING
COOLING
PREPARATION
ëçê‡
Introduction
Torque Wrench RADIATOR ASSEMBLY
WATER PUMP ASSEMBLY
Vernier Calipers THERMOSTAT
PP Radiator Cap Tester COOLANT
Radiator Cap Tester Adapter COOLANT
Electrical Tester COOLING FAN RELAY

RCT-2A Radiator Cap Tester COOLING SYSTEM
RCT-2A-30S Radiator Cap Tester COOLING SYSTEM

Adapter Set A
TMA-20 Thermometer THERMOSTAT
RCT-3 Radiator Cap Tester COOLING SYSTEM
RCT-3-AST Radiator Cap COOLING SYSTEM

Tester Adapter Set A
TH-10A Thermometer THERMOSTAT
QL-25N Preset Torque Wrench(25N) THERMOSTAT

Ethylene glycol based anti-freeze COOLANT
solution
GETtheMANUALS.org
PREPARATION - COOLING
PP–9
String THERMOSTAT
PP
GETtheMANUALS.org
PP–10 PREPARATION - LUBRICATION
LUBRICATION
PREPARATION
ëçê‡
SST
09228-87201 Oil Filter Wrench OIL FILTER
PP
Introduction
Torque Wrench OIL PUMP ASSEMBLY
OIL FILTER
OPG-210 Automatic Transmission LUBRICATION SYSTEM
Oil Pressure Gauge Set
(OPG-230) Adapter D LUBRICATION SYSTEM
ATG-100 Automatic Transmission LUBRICATION SYSTEM

Oil Pressure Gauge Set
(ATG-OP20) Adapter D LUBRICATION SYSTEM

Engine Oil OIL PUMP ASSEMBLY
OIL FILTER
White Gasoline LUBRICATION SYSTEM
Hose OIL FILTER
Three Bond 1194J LUBRICATION SYSTEM
GETtheMANUALS.org
PREPARATION - IGNITION
PP–11
IGNITION
PREPARATION
ëçê‡
Introduction
Torque Wrench CLUNK POSITION SENSOR
SPARK PLUG
Plug Gap Gauge SPARK PLUG
Electrical Tester CAM POSITION SENSOR
CLUNK POSITION SENSOR
PP
QL-25N Preset Torque Wrench(25N) CAM POSITION SENSOR

Engine Oil CAM POSITION SENSOR
CLUNK POSITION SENSOR
GETtheMANUALS.org
PP–12 PREPARATION - STARTING
STARTING
PREPARATION
ëçê‡
Introduction
ML450 High-mission Jack STARTER ASSEMBLY
PP
Torque Wrench STARTER ASSEMBLY
Vernier Calipers STARTER ASSEMBLY
Inspection Cable STARTER ASSEMBLY
Electrical Tester STARTER ASSEMBLY
STARTER RELAY ASSEMBLY
BE4-270 Extension Bar (270mm, 12.7 sp) STARTER ASSEMBLY
BE4-600 Extension Bar (600mm, 12.7 sp) STARTER ASSEMBLY
QL-100N Preset Torque Wrench (100N) STARTER ASSEMBLY
QL-25N Preset Torque Wrench (25N) STARTER ASSEMBLY

Automotive 12V Battery STARTER ASSEMBLY
GETtheMANUALS.org
PREPARATION - CHARGING
PP–13
CHARGING
PREPARATION
ëçê‡
Introduction
Torque Wrench ALTERNATOR ASSEMBLY
PP
GETtheMANUALS.org
PP–14 PREPARATION - AUTOMATIC TRANSMISSION
PREPARATION
ëçê‡
SST
09302-87201 Neutral Start Switch Adjust Gauge NEUTRAL START SWITCH ASSEMBLY
PP
09308-00010 Oil Seal Puller EXTENSION HOUSING OIL SEAL
09350-97201 Manual Valve Idler Shaft Holder TRANSMISSION VALVE BODY

ASSEMBLY
09351-87211 Manual Valve Setting Tool TRANSMISSION VALVE BODY

ASSEMBLY
09990-97201 A/T Solenoid Wire Check Sub- ELECTRONICALLY CONTROL

Harness AUTOMATIC TRANSMISSION [ECT]
O9325-87201 A/T PRESSURE GAUGE NO.1 ELECTRONICALLY CONTROL

ADAPTOR AUTOMATIC TRANSMISSION [ECT]
Introduction
HMJ450-TW High-mission Jack AUTOMATIC TRANSMISSION
ASSEMBLY
ML450 High-mission Jack AUTOMATIC TRANSMISSION

ASSEMBLY
09960-97001 DS-II ELECTRONICALLY CONTROL

AUTOMATIC TRANSMISSION [ECT]
TRANSMISSION REVOLUTION SEN-
SOR
GETtheMANUALS.org
PREPARATION - AUTOMATIC TRANSMISSION
PP–15
Torque Wrench NEUTRAL START SWITCH ASSEMBLY

TRANSMISSION REVOLUTION SEN-
SOR
ASSEMBLY
TRANSMISSION FLOOR SHIFT
ASSEMBLY
TRANSMISSION WIRE
TRANSMISSION VALVE BODY
ASSEMBLY
SHIFT LOCK RELEASE CABLE
PP
ASSEMBLY
Vernier Calipers AUTOMATIC TRANSMISSION
ASSEMBLY
SHIFT LOCK RELEASE CABLE
ASSEMBLY
Dial Indicator TORQUE CONVERTER CLUTCH AND
DRIVE PLATE
Straightedge AUTOMATIC TRANSMISSION
ASSEMBLY
Electrical Tester ELECTRONICALLY CONTROL
TRANSMISSION [ECT]
NEUTRAL START SWITCH ASSEMBLY
TRANSMISSION WIRE
AUTOMATIC TRANSMISSION 3 WAY
SOLENOID ASSEMBLY
CLUTCH CONTROL SOLENOID NO.1
LOCKUP CONTROL SOLENOID
OPG-210 Automatic Transmission Oil ELECTRONICALLY CONTROL
Pressure Gauge Set AUTOMATIC TRANSMISSION [ECT]
BE4-600 Extension Bar (600mm, 12.7sp) AUTOMATIC TRANSMISSION

ASSEMBLY
QL-100N Preset Torque Wrench (100N) AUTOMATIC TRANSMISSION

ASSEMBLY
QL-25N Preset Torque Wrench (25N) NEUTRAL START SWITCH ASSEMBLY

TRANSMISSION WIRE

MP Grease AUTOMATIC TRANSMISSION
ASSEMBLY
EXTENSION HOUSING OIL SEAL
DEXRON-III TRANSMISSION REVOLUTION SEN-
SOR
ASSEMBLY
GETtheMANUALS.org
PP–16 PREPARATION - AUTOMATIC TRANSMISSION
Paint AUTOMATIC TRANSMISSION

ASSEMBLY
Battery AUTOMATIC TRANSMISSION THREE-
WAY SOLENOID ASSEMBLY
LOCKUP CONTROL SOLENOID
Bulb (12V-21W) CLUTCH CONTROL SOLENOID NO.1
PP CLUTCH CONTROL SOLENOID NO.2
GETtheMANUALS.org
PREPARATION - CLUTCH
PP–17
CLUTCH
PREPARATION
ëçê‡
SST
09210-87701 Flywheel Holder CLUTCH UNIT
PP
09301-00110 Clutch Guide Tool CLUTCH UNIT
09302-87701 Clutch Diaphragm Spring Height CLUTCH UNIT

No.4 Gauge
09333-00013 Clutch Diaphragm Spring CLUTCH UNIT

Aligner
Introduction
Torque Wrench CLUTCH PEDAL (MTM)
CLUTCH MASTER CYLINDER
ASSEMBLY (MTM)
CLUTCH RELEASE CYLINDER
ASSEMBLY
CLUTCH UNIT
CLUTCH START SWITCH ASSEMBLY
Vernier Calipers CLUTCH PEDAL (MTM)
CLUTCH UNIT
Dial Indicator CLUTCH UNIT
Electrical Tester CLUTCH START SWITCH ASSEMBLY

MP Grease CLUTCH PEDAL (MTM)
Clutch Grease CLUTCH UNIT
Rubber Grease CLUTCH RELEASE CYLINDER
ASSEMBLY
EP Grease CLUTCH UNIT
FMVSS116 DOT3 or DOT4 CLUTCH RELEASE CYLINDER
ASSEMBLY
GETtheMANUALS.org
PP–18 PREPARATION - MANUAL TRANSMISSION
MANUAL TRANSMISSION
PREPARATION
ëçê‡
SST
09308-00010 Oil Seal Puller TRANSMISSION EXTENSION HOUSING
OIL SEAL (MTM) (2WD)
PP
09309-87201 Transmission Bearing Replacer TRANSMISSION EXTENSION HOUSING
OIL SEAL (MTM) (2WD)
Introduction
Clip Remover SHIFT LEVER ASSEMBLY (MTM)
HMJ450-TW High-mission Jack TRANSMISSION UNIT ASSEMBLY
(MTM)
ML450 High-mission Jack TRANSMISSION UNIT ASSEMBLY

(MTM)
Torque Wrench MANUAL TRANSMISSION SYSTEM

(MTM)
TRANSMISSION UNIT ASSEMBLY
(MTM)
SHIFT LEVER ASSEMBLY (MTM)
TRANSMISSION CONTROL CABLE
ASSEMBLY (MTM)
BE4-600 Extension Bar (600mm,12.7sp) TRANSMISSION UNIT ASSEMBLY
(MTM)
QL-100N Preset Torque Wrench (100N) TRANSMISSION UNIT ASSEMBLY

(MTM)

Manual Transmission Gear Oil (API TRANSMISSION EXTENSION HOUSING
GL-3 or GL-4, API 75W-90, 75W-85 OIL SEAL (MTM) (2WD)
or 75W-80)
MP Grease TRANSMISSION EXTENSION HOUSING
OIL SEAL (MTM)(2WD)
Wire MANUAL TRANSMISSION SYSTEM
(MTM)
Engine Hanger No.1 TRANSMISSION UNIT ASSEMBLY
(MTM)
GETtheMANUALS.org
PREPARATION - MANUAL TRANSMISSION
PP–19
Engine Hanger No.2 TRANSMISSION UNIT ASSEMBLY

(MTM)
PP
GETtheMANUALS.org
PP–20 PREPARATION - TRANSFER
TRANSFER
PREPARATION
ëçê‡
SST
09308-00010 Oil Seal Puller TRANSFER EXTENSION HOUSING OIL
SEAL (4WD)
PP
09309-87201 Transmission Bearing Replacer TRANSFER EXTENSION HOUSING OIL
SEAL(4WD)
09310-87301 Counter Shaft Front Bearing TRANSFEREXTENSION HOUSING OIL

Replacer SEAL(4WD)
Introduction
Scraper TRANSFER ASSEMBLY (4WD)
Torque Wrench TRANSFER OIL (4WD)
TRANSFER EXTENSION HOUSING OIL
SEAL(4WD)
TRANSFER ASSEMBLY (4WD)
Electrical Tester DIFFERENTIAL LOCK SWITCH (4WD)
TB-501 Mighty-Vac TRANSFER SYSTEM (4WD)
6810 Mighty-Vac TRANSFER SYSTEM (4WD)

Manual Transmission Gear Oil (API TRANSFER OIL (4WD)
GL-3 or GL-4, API 75W-90, 75W-85
or 75W-80)
MP Grease TRANSFER EXTENSION HOUSING OIL
SEAL(4WD)
White Gasoline TRANSFER ASSEMBLY (4WD)
Three Bond TB 1217 TRANSFER ASSEMBLY (4WD)
GETtheMANUALS.org
PREPARATION - PROPELLER SHAFT
PP–21
PROPELLER SHAFT
PREPARATION
ëçê‡
Introduction
Torque Wrench FRONT PROPELLER SHAFT
ASSEMBLY (4WD)
PROPELLER SHAFT ASSEMBLY
V Block FRONT PROPELLER SHAFT
ASSEMBLY (4WD) PP
Dial Indicator FRONT PROPELLER SHAFT
ASSEMBLY (4WD)
Spiring Balance FRONT PROPELLER SHAFT
ASSEMBLY (4WD)
GETtheMANUALS.org
PP–22 PREPARATION - DRIVE SHAFT
DRIVE SHAFT
PREPARATION
ëçê‡
SST
09511-87202 Brake Drum Stopper FRONT DRIVE SHAFT ASSEMBLY
(4WD)
PP
09628-00011 Ball Joint Puller FRONT DRIVE SHAFT ASSEMBLY
(4WD)
09648-87201 Drive Shaft Replacer FRONT DRIVE SHAFT ASSEMBLY

(4WD)
09648-97202 Drive Shaft Boots Band Pliers B FRONT DRIVE SHAFT ASSEMBLY
(4WD)
Recommended tool
Chisel FRONT DRIVE SHAFT ASSEMBLY
(4WD)
Torque Wrench FRONT DRIVE SHAFT ASSEMBLY
(4WD)

MP Grease FRONT DRIVE SHAFT ASSEMBLY
(4WD)
Protective Tape FRONT DRIVE SHAFT ASSEMBLY
(4WD)
GETtheMANUALS.org
PREPARATION - DIFFERENTIAL
PP–23
DIFFERENTIAL
PREPARATION
ëçê‡
SST
09213-58013 Crankshaft Pulley Holding Tool FRONT DIFFERENTIAL CARRIER
ASSEMBLY (4WD)
PP
09219-87202 Engine Overhaul Stand FRONT DIFFERENTIAL CARRIER
ASSEMBLY (4WD)
REAR DIFFERENTIAL CARRIER
ASSEMBLY
09219-87701 Engine Overhaul Attachment FRONT DIFFERENTIAL CARRIER

ASSEMBLY (4WD)
09257-87202 Crankshaft Bearing Replacer FRONT DIFFERENTIAL CARRIER

ASSEMBLY (4WD)
09308-00010 Oil Seal Puller FRONT DIFFERENTIAL CARRIER

ASSEMBLY (4WD)
09308-10010 Oil Seal Puller FRONT DIFFERENTIAL CARRIER OIL

SEAL(4WD)
FRONT DIFFERENTIAL CARRIER
ASSEMBLY (4WD)
REAR DIFFERENTIAL CARRIER OIL
SEAL
ASSEMBLY
09309-87201 Transmission Bearing Replacer FRONT DIFFERENTIAL CARRIER
ASSEMBLY (4WD)
09310-87301 Counter Shaft Front Bearing REAR DIFFERENTIAL CARRIER

Replacer ASSEMBLY
09330-00021 Companion Flange Holding Tool FRONT DIFFERENTIAL CARRIER

ASSEMBLY (4WD)
09350-87202 Automatic Transmission Tool Set FRONT DIFFERENTIAL CARRIER

ASSEMBLY (4WD)
GETtheMANUALS.org
PP–24 PREPARATION - DIFFERENTIAL
09504-87501 Differential Side Bearing Adjusting REAR DIFFERENTIAL CARRIER

Nut Wrench ASSEMBLY
09510-87301 Front Hub & Drum Puller FRONT DIFFERENTIAL CARRIER

ASSEMBLY (4WD)
PP
09515-87302 Rear Hub Bearing Replacer REAR DIFFERENTIAL CARRIER
ASSEMBLY
09530-87504 Differential Drive Pinion Adjust FRONT DIFFERENTIAL CARRIER

Gauge Set ASSEMBLY (4WD)
09548-87202 Differential Overhaul Attachment REAR DIFFERENTIAL CARRIER

ASSEMBLY
09564-97401 Starting Torque Measurement Tool REAR DIFFERENTIAL CARRIER

ASSEMBLY
09608-03071 Replacer REAR DIFFERENTIAL CARRIER

ASSEMBLY
09608-87302 Axle Hub Bearing & Drive Pinion REAR DIFFERENTIAL CARRIER
Bearing Tool Set ASSEMBLY
09636-20010 Upper Ball Joint Dust Cover FRONT DIFFERENTIAL CARRIER OIL
Replacer SEAL (4WD)
ASSEMBLY (4WD)
09707-87302 Spring Bush Remover & Replacer REAR DIFFERENTIAL CARRIER

ASSEMBLY
09950-60010 Replacer Set FRONT DIFFERENTIAL CARRIER

ASSEMBLY (4WD)
09950-97201 Universal Puller REAR DIFFERENTIAL CARRIER

ASSEMBLY
GETtheMANUALS.org
PREPARATION - DIFFERENTIAL
PP–25
O9213-31021 Crankshaft Pulley Adjust Puller REAR DIFFERENTIAL CARRIER

ASSEMBLY
O9330-87301 Drive Pinion Flange Holding Tool FRONT DIFFERENTIAL CARRIER

ASSEMBLY (4WD)
SEAL
REAR DIFFERENTIAL CARRIER PP
ASSEMBLY
O9502-10012 Differential Side Bearing Puller FRONT DIFFERENTIAL CARRIER
ASSEMBLY (4WD)
Introduction
Bearing Pillaring FRONT DIFFERENTIAL CARRIER
Attachment NO.145 ASSEMBLY (4WD)
ASSEMBLY
Torque Wrench DIFFERENTIAL OIL
Torque Wrench DIFFERENTIAL OIL
FRONT DIFFERENTIAL CARRIER OIL
SEAL (4WD)
ASSEMBLY (4WD)
SEAL
ASSEMBLY
Dial Indicator REAR DIFFERENTIAL CARRIER
ASSEMBLY
Preset Torque Wrench (20-100N*m) DIFFERENTIAL OIL
(Parts Number : CL100N - 15D-MH)
RH15DX24 Ring Head (24mm) DIFFERENTIAL OIL
HMJ-450TWS High-mission Jack FRONT DIFFERENTIAL CARRIER

(Allowance load 450 Kg) ASSEMBLY (4WD)
ASSEMBLY

MP Grease FRONT DIFFERENTIAL CARRIER OIL
SEAL (4WD)
GETtheMANUALS.org
PP–26 PREPARATION - DIFFERENTIAL
Limited Slip Differential Gear Oil (API FRONT DIFFERENTIAL CARRIER OIL
GL-5, SAE 80W-90) SEAL(4WD)
ASSEMBLY (4WD)
ASSEMBLY
Red Lead Primer REAR DIFFERENTIAL CARRIER
ASSEMBLY
PP Three Bond 1216 FRONT DIFFERENTIAL CARRIER

ASSEMBLY (4WD)
GETtheMANUALS.org
PREPARATION - AXLE
PP–27
AXLE
PREPARATION
ëçê‡
SST
09308-00010 Oil Seal Puller REAR AXLE ASSEMBLY
PP
09506-87302 Rear Differential Drive Pinion STEERING KNUCKLE LH
Bearing Corn Replacer FRONT AXLE HUB LH
09515-21010 Rear Axle Shaft Bearing Replacer REAR AXLE ASSEMBLY
09517-12010 Rear Axle Shaft Oil Seal Replacer REAR AXLE ASSEMBLY
09520-00031 Rear Axle Shaft Puller STEERING KNUCKLE LH

FRONT AXLE HUB LH
REAR AXLE ASSEMBLY
09550-10012 Replacer Set B STEERING KNUCKLE LH

FRONT AXLE HUB LH
(09554-10010) Differential Drive Pinion Oil Seal STEERING KNUCKLE LH

Replacer FRONT AXLE HUB LH
09608-32010 Steering Knuckle Oil Seal Replacer REAR AXLE ASSEMBLY
09628-00011 Ball Joint Puller STEERING KNUCKLE LH
09718-87702 Front Disk Brake Dust Cover STEERING KNUCKLE LH

Replacer
09950-40011 Puller B Set STEERING KNUCKLE LH

FRONT AXLE HUB LH
GETtheMANUALS.org
PP–28 PREPARATION - AXLE
O9023-00100 Union Nut Wrench REAR AXLE HOUSING ASSEMBLY
Introduction
PP Chisel STEERING KNUCKLE LH
REAR AXLE ASSEMBLY
Snap Ring Expander STEERING KNUCKLE LH
FRONT AXLE HUB LH
Hand Grinder REAR AXLE ASSEMBLY
HMJ450-TW High-mission Jack REAR AXLE HOUSING ASSEMBLY
ML450 High-mission Jack REAR AXLE HOUSING ASSEMBLY
Torque Wrench STEERING KNUCKLE LH

FRONT AXLE HUB LH
REAR AXLE ASSEMBLY
REAR AXLE HOUSING ASSEMBLY
Dial Indicator AXLE SYSTEM
STEERING KNUCKLE LH

MP Grease REAR AXLE ASSEMBLY
Three Bond 1212 REAR AXLE HOUSING ASSEMBLY
GETtheMANUALS.org
PREPARATION - SUSPENSION
PP–29
SUSPENSION
PREPARATION
ëçê‡
SST
09628-00011 Ball Joint Puller FRONT SUSPENSION LOWWER ARM
ASSEMBLY LH
PP
09727-30021 Coil Spring Compressor FRONT SHOCK ABSORBER W/COIL
SPRING
09729-97203 Hexagon Wrench 6 Socket (TONE FRONT STABILIZER BAR

3KH-6L)
Introduction
Brake Pedal Pressure FRONT WHEEL ALIGNMENT
Metal Saw FRONT SHOCK ABSORBER W/COIL
SPRING
CCK-IN CCK Gauge Compensator FRONT WHEEL ALIGNMENT
MB-40B-21 Brake Pedal Pressure FRONT WHEEL ALIGNMENT
BPD-10W Brake Pedal Pressure FRONT WHEEL ALIGNMENT
Torque Wrench FRONT WHEEL ALIGNMENT

FRONT SHOCK ABSORBER W/COIL
SPRING
FRONT SUSPENSION LOWER ARM
ASSEMBLY LH
FRONT STABILIZER BAR
REAR SHOCK ABSORBER LH
UPPER CONTROL ARM ASSEMBLY RR
LH
LOWER CONTROL ARM ASSEMBLY LH
Camber Caster Kingpin FRONT WHEEL ALIGNMENT
Gauge
Turning Radius Gauge FRONT WHEEL ALIGNMENT
Tire Pressure Gauge FRONT WHEEL ALIGNMENT
Dial Indicator FRONT WHEEL ALIGNMENT
GETtheMANUALS.org
PP–30 PREPARATION - SUSPENSION
MB-35K Turning Radius Gauge FRONT WHEEL ALIGNMENT
MB-56FK Toe-in Gauge FRONT WHEEL ALIGNMENT
PP
TG-XU Toe-in Gauge FRONT WHEEL ALIGNMENT
TRG-3 Turning Radius Gauge FRONT WHEEL ALIGNMENT
MB-B Magnetic Base FRONT WHEEL ALIGNMENT

Metal Saw REAR SHOCK ABSORBER ASSEMBLY
LH
Protective Tape FRONT SHOCK ABSORBER W/COIL

SPRING
GETtheMANUALS.org
PREPARATION - TIRE AND WHEEL
PP–31
TIRE AND WHEEL

PREPARATION
ëçê‡
Introduction
Torque Wrench WHEEL AND TIRE
Tire Pressure Gauge WHEEL AND TIRE SYSTEM

PP
Dial Indicator WHEEL AND TIRE SYSTEM
GETtheMANUALS.org
PP–32 PREPARATION - BRAKE CONTROL
BRAKE CONTROL
PREPARATION
ëçê‡
SST
09843-18020 Diagnosis Check Wire ABS WITH EBD SYSTEM
PP
O9023-00100 Union Nut Wrench BRAKE ACTUATOR ASSEMBLY
BRAKE ACTUATOR ASSEMBLY (WITH
VSC)
Introduction
09960-97001 DS-II ABS WITH EBD SYSTEM
ABS & TRC & VSC & BA SYSTEM WITH
EBD
Torque Wrench BRAKE ACTUATOR ASSEMBLY

BRAKE ACTUATOR ASSEMBLYÅiWITH
VSCÅj
FRONT SPEED SENSOR LH
REAR SPEED SENSOR LH
DECELERATION SENSOR (4WD)
DECELERATION SENSOR (WITH VSCÅj
Electrical Tester ABS WITH EBD SYSTEM
ABS & TRC & VSC & BA SYSTEM WITH
EBD

Protective Tape FRONT SPEED SENSOR LH
GETtheMANUALS.org
PREPARATION - BRAKE
PP–33
BRAKE
PREPARATION
ëçê‡
SST
09703-30011 Tool Set, Brake Shoe Return Spring REAR DRUM BRAKE
PP
09730-87401 Brake Booster Gauge Gauge Set BRAKE MASTER CYLINDER
ASSEMBLY
O9023-00100 Union Nut Wrench BRAKE MASTER CYLINDER

ASSEMBLY
REAR DRUM BRAKE
Service tool
09023-00100 Union Nut Wrench BRAKE FLUID
Introduction
Snap Ring Pliers BRAKE MASTER CYLINDER
ASSEMBLY
Box Wrench(7 mm) BRAKE MASTER CYLINDER

ASSEMBLY
Pin Punch BRAKE MASTER CYLINDER

ASSEMBLY
Torque Wrench BRAKE FLUID

BRAKE PEDAL
BRAKE MASTER CYLINDER
ASSEMBLY
BRAKE BOOSTER ASSEMBLY
FRONT DISK BRAKE
REAR DRUM BRAKE
Vernier Caliper BRAKE PEDAL
FRONT DISK BRAKE
REAR DRUM BRAKE
Micrometer FRONT DISK BRAKE
Dial Indicator FRONT DISK BRAKE
GETtheMANUALS.org
PP–34 PREPARATION - BRAKE
BT-4 Portable Brake Tester BRAKE SYSTEM

PP MP Grease BRAKE PEDAL
Brake Grease BRAKE MASTER CYLINDER

ASSEMBLY
FRONT DISK BRAKE
REAR DRUM BRAKE
FMVSS116 DOT3 or DOT4 BRAKE FLUID
ASSEMBLY
FRONT DISK BRAKE
Brake Cleaner FRONT DISK BRAKE
(Spray Type) 08834-00090
Chalk REAR DRUM BRAKE
GETtheMANUALS.org
PREPARATION - PARKING BRAKE
PP–35
PARKING BRAKE
PREPARATION
ëçê‡
Introduction
Torque Wrench PARKING BRAKE
PARKING BRAKE PEDAL ASSEMBLY
PARKING BRAKE CABLE ASSEMBLY
NO.1
NO.2
PP
NO.3
PARKING BRAKE LEVER
GETtheMANUALS.org
PP–36 PREPARATION - STEERING COLUMN
STEERING COLUMN
PREPARATION
ëçê‡
Introduction
Reverse Tap STEERING COLUMN ASSEMBLY
Torque Wrench STEERING COLUMN ASSEMBLY

PP

Drill STEERING COLUMN ASSEMBLY
GETtheMANUALS.org
PREPARATION - POWER STEERING
PP–37
POWER STEERING
PREPARATION
ëçê‡
SST
09612-00012 Rack & Pinion Steering Rack STEERING GEAR ASSEMBLY
Housing Stand
PP
09616-87502 Steering Pinion Bearing Adjusting STEERING GEAR ASSEMBLY
Socket
09628-00011 Ball Joint Puller STEERING GEAR ASSEMBLY
09922-10010 Variable Open Wrench STEERING GEAR ASSEMBLY
Service tool
Simple Spinner STEERING GEAR ASSEMBLY
Introduction
09960-97001 DS-II ELECTRIC POWER STEERING SYS-
TEM
Torque Wrench ELECTRIC POWER STEERING SYS-

TEM
STEERING GEAR ASSEMBLY
Electrical Tester ELECTRIC POWER STEERING SYS-
TEM

EP Grease STEERING GEAR ASSEMBLY
Long Life Grease STEERING GEAR ASSEMBLY
GETtheMANUALS.org
PP–38 PREPARATION - AIR CONDITIONER
AIR CONDITIONER
PREPARATION
ëçê‡
SST
09843-18020 Diagnosis Check Wire HEATER & AIR CONDITIONING
SYSTEM
PP
Introduction
Snap Ring Plier COMPRESSOR ASSEMBLY
Vacuum Pump REFRIGERANT HFC-134a (R134a)
Vacuum Pump Adapter REFRIGERANT HFC-134a (R134a)
Air Conditioning Tool Set REFRIGERANT HFC-134a (R134a)

HFC-134a (R134a)
Halogen Leak Detector REFRIGERANT HFC-134a (R134a)
95048-10290 Quick Joint Remover AIR CONDITIONING RADIATOR

(Low Pressure) ASSEMBLY
95048-10300 Quick Joint Remover AIR CONDITIONING RADIATOR

(High Pressure) ASSEMBLY
09960-97001 DS-II HEATER & AIR CONDITIONING

SYSTEM
Torque Wrench AIR CONDITIONING RADIATOR

ASSEMBLY
COOLER COMPRESSOR ASSEMBLY
AIR CONDITIONING AMPLIFIER
ASSEMBLY
CONDENSER ASSEMBLY (WITH
RECEIVER)
Dial Indicator COOLER COMPRESSOR ASSEMBLY
Thermometer HEATER & AIR CONDITIONING

SYSTEM
HEATER & AIR CONDITIONING
SYSTEM
GETtheMANUALS.org
PREPARATION - AIR CONDITIONER
PP–39
Electrical Tester HEATER & AIR CONDITIONING SYS-

TEM
HEATER & AIR CONDITIONING SYS-
TEM
HEATER CONTROL No.1
HEATER CONTROL No.2
HEATER CONTROL No.3
BLOWER REGISTER
BLOWER REGISTER TRANSISTOR
ASSEMBLY
PP
COOLER THERMISTOR NO.1
HEATER RELAY NO.1
AIR CONDITIONER TUBE AND ACCES-
SORY ASSEMBLY
COOLER THERMISTOR (INNER AIR
SENSOR)
COOLER THERMISTOR(OUTER AIR
SENSOR)
COOLER THERMISTOR(DAYLIGHT
SENSOR)
MAGNETIC CLUTCH RELAY

REFRIGERANT GAS HFC-134a REFRIGERANT HFC-134a (R134a)
(R134a)
Automotive 12V Battery HEATER & AIR CONDITIONING SYS-

TEM
HEATER & AIR CONDITIONING SYS-
TEM
HEATER CONTROL ASSEMBLY
HEATER CONTROL No.1
HEATER CONTROL No.2
HEATER CONTROL No.3
AIR CONDITIONER RADIATOR
ASSEMBLY
COMPRESSOR ASSEMBLY
HEATER RELAY NO.1
BLOWER MOTOR (WITH FAN)
Protective Tape AIR CONDITIONER RADIATOR
ASSEMBLY
Vinyl Tape AIR CONDITIONER RADIATOR

ASSEMBLY
COMPRESSOR ASSEMBLY
RECEIVER)
Bulb (12V-3.4W) HEATER & AIR CONDITIONING
SYSTEM
Compressor Oil (ND-OIL8) AIR CONDITIONER RADIATOR

ASSEMBLY
COMPRESSOR ASSEMBLY
RECEIVER)
Chlorofluorocarbon Recovery And REFRIGERANT HFC-134a (R134a)
Regenerating Machine
GETtheMANUALS.org
PP–40 PREPARATION - SUPPLEMENTAL RESTRAINT SYSTEM
SUPPLEMENTAL RESTRAINT SYSTEM

PREPARATION
ëçê‡
SST
09082-00760 Airbag Deployment Wire Sub- HORN BUTTON ASSEMBLY
harness No.4 INSTRUMENT PANEL PASSENGER
AIRBAG ASSEMBLY
FRONT SEAT SIDE AIRBAG ASSEMBLY
PP RH
09082-00802 Airbag Deployment Wire Sub- HORN BUTTON ASSEMBLY
Harness No. 8 INSTRUMENT PANEL PASSENGER
AIRBAG ASSEMBLY
CURTAIN SHIELD AIRBAG ASSEMBLY
RH
(09082-10801) Wire A HORN BUTTON ASSEMBLY
INSTRUMENT PANEL PASSENGER
AIRBAG ASSEMBLY
RH
(09082-20801) Wire B HORN BUTTON ASSEMBLY
AIRBAG ASSEMBLY
RH
09082-87710 Air Bag Deployment Wire HORN BUTTON ASSEMBLY
AIRBAG ASSEMBLY
RH
RH
09843-18020 Diagnosis Check Wire SRS AIRBAG SYSTEM
Service tool
09013-1C120 "TORX" Socket Wrench HORN BUTTON ASSEMBLY
T30
Introduction
09960-97001 DS-II SRS AIRBAG SYSTEM
GETtheMANUALS.org
PREPARATION - SUPPLEMENTAL RESTRAINT SYSTEM
PP–41
Torque Wrench HORN BUTTON ASSEMBLY

RH
RH
AIRBAG COMPUTER ASSEMBLY
FRONT AIRBAG SENSOR RH
SIDE AIRBAG SENSOR ASSEMBLY RH
NO.2 PP
Electrical Tester SRS AIRBAG SYSTEM
SPIRAL CABLE

Wire Harness HORN BUTTON ASSEMBLY
(wire cross-section: 1.25mm2 or INSTRUMENT PANEL PASSENGER
more) AIRBAG ASSEMBLY
RH
RH
Wire with diameter 1.8 mm or more HORN BUTTON ASSEMBLY
Regular Iron Wire for general INSTRUMENT PANEL PASSENGER
purposes AIRBAG ASSEMBLY
JIS Standard SWM-B or equivalent CURTAIN SHIELD AIRBAG ASSEMBLY
RH
RH
Automotive 12V Battery HORN BUTTON ASSEMBLY
AIRBAG ASSEMBLY
RH
RH
Protective Tape HORN BUTTON ASSEMBLY
Bolt x 2(Length under neck 35mm or HORN BUTTON ASSEMBLY

longer, pitch 1.0 mm,nominal diame-
ter 6.0 mm)
Tire x 4 (Tire width 185mm HORN BUTTON ASSEMBLY

Tire Caliber 14 inch level) INSTRUMENT PANEL PASSENGER
AIRBAG ASSEMBLY
Tire with Disc Wheel x 2 HORN BUTTON ASSEMBLY
Tire x 3
Tire with Disc Wheel x 1 INSTRUMENT PANEL PASSENGER

Tire x 4 AIRBAG ASSEMBLY
RH
RH
GETtheMANUALS.org
PP–42 PREPARATION - SUPPLEMENTAL RESTRAINT SYSTEM
Dust-proof Safety Glasses and Vinyl HORN BUTTON ASSEMBLY

Bag INSTRUMENT PANEL PASSENGER
AIRBAG ASSEMBLY
RH
RH
PP
GETtheMANUALS.org
PREPARATION - SEAT BELT
PP–43
SEAT BELT
PREPARATION
ëçê‡
SST
09082-87710 Air Bag Deployment Wire FRONT SEAT OUTER BELT ASSEMBLY
RH
PP
09082-97201 Air Bag Deployment Wire Sub- FRONT SEAT OUTER BELT ASSEMBLY
Harness D1 RH
Introduction
Torque Wrench FRONT SEAT OUTER BELT ASSEMBLY
RH
FRONT SEAT INNER BELT ASSEMBLY
RH
REAR SEAT 3 POINT TYPE BELT ASSY
OUT RH
REAR SEAT WRAP TYPE BELT
ASSEMBLY RH
REAR SEAT WRAP TYPE BELT
ASSEMBLY CTR LH
REAR SEAT INNER BELT ASSEMBLY
RH
Electrical Tester FRONT SEAT CUSHION COVER & PAD
LH
RH
LH

Wire Harness FRONT SEAT OUTER BELT ASSEMBLY
2
(wire cross-section:1.25mm or RH
more)
12V Battery FRONT SEAT OUTER BELT ASSEMBLY

RH
Protective Tape FRONT SEAT OUTER BELT ASSEMBLY

RH
REAR SEAT 3 POINT TYPE BELT
ASSEMBLY OUT RH
Tire with Wheel x 1 FRONT SEAT OUTER BELT ASSEMBLY
Åitire width approx. 185mm) RH
Dust Protect Glass,Glove,Vinyl Bag FRONT SEAT OUTER BELT ASSEMBLY

RH
GETtheMANUALS.org
PP–44 PREPARATION - AUTO ALARM
AUTO ALARM
PREPARATION
ëçê‡
Introduction
Electrical Tester SECURITY ALARM SYSTEM
PP Lubricant and others

Battery SECURITY ALARM SYSTEM
GETtheMANUALS.org
PREPARATION - ENGINE IMMOBILISER
PP–45
ENGINE IMMOBILISER
PREPARATION
ëçê‡
Introduction
09960-97001 DS-II ENGINE IMMOBILISER SYSTEM
PP
Electrical Tester ENGINE IMMOBILISER SYSTEM
GETtheMANUALS.org
PP–46 PREPARATION - LIGHTING
LIGHTING
PREPARATION
ëçê‡
SST
09843-18020 Diagnosis Check Wire LIGHTING SYSTEM
PP
Introduction
Torque Wrench HEADLIGHT ASSEMBLY LH
FOG LIGHT ASSEMBLY LH
TAIL IGHT (REAR COMBINATION
LIGHT) ASSEMBLY LH
LICENSE PLATE LIGHT ASSEMBLY
FOG LIGHT BULB
HEADLIGHT DIMMER SWITCH ASSY
Tire Pressure Gauge LIGHTING SYSTEM
Electrical Tester LIGHTING SYSTEM

MAP LIGHT ASSEMBLY
ROOM LIGHT ASSEMBLY NO.2
ROOM LIGHT ASSEMBLY NO.3
HEADLIGHT DIMMER SWITCH
ASSEMBLY
HAZARD WARNING SIGNAL SWITCH
ASSY
HEADLIGHT LEVELING SWITCH
STOP LIGHT SWITCH ASSEMBLY
FRONT DOOR COURTESY SWITCH
ASSEMBLY
REAR DOOR COURTESY SWITCH
ASSEMBLY
BACK DOOR COURTESY SWITCH
ASSEMBLY
HEIGHT CONTROL SENSOR RR LH
TURN SIGNAL FLASHER ASSEMBLY
HEADLIGHT RELAY
FOG LIGHT RELAY
REAR FOG LIGHT SWICH
AG-8006 Tire Pressure Gauge HEADLIGHT ASSEMBLY LH

Sandpaper (No.100, No.400) HEADLIGHT ASSEMBLY LH
Sandpaper (No.500 to No.1000) HEADLIGHT ASSEMBLY LH
GETtheMANUALS.org
PREPARATION - LIGHTING
PP–47
Screens for Test Use HEADLIGHT ASSEMBLY LH

Headlight Cover Tape
Screens for Test Use HEADLIGHT ASSEMBLY LH
Thick Paper HEADLIGHT ASSEMBLY LH
Automotive 12V Battery HEADLIGHT RELAY

PP
FOG LIGHT RELAY
GETtheMANUALS.org
PP–48 PREPARATION - WIPER AND WASHER
WIPER AND WASHER

PREPARATION
ëçê‡
Service Tool
09061-1C100 Clip Remover WINDSHIELD WIPER MOTOR
ASSEMBLY
PP
Introduction
Torque Wrench WINDSHIELD WIPER MOTOR
ASSEMBLY
REAR WIPER MOTOR ASSEMBLY
WINDSHIELD WIPER SWITCH
ASSEMBLY
Electrical Tester WINDSHIELD WIPER SWITCH
ASSEMBLY

DENSO No.50 Grease WINDSHIELD WIPER MOTOR
ASSEMBLY
Automotive 12V Battery WINDSHIELD WIPER MOTOR

ASSEMBLY
WINDSHIELD WIPER SWITCH
ASSEMBLY
WINDSHIELD WASHER MOTOR &
PUMP ASSEMBLY
Protective Tape WINDSHIELD WIPER MOTOR
ASSEMBLY
GETtheMANUALS.org
PREPARATION - DOOR LOCK
PP–49
DOOR LOCK
PREPARATION
ëçê‡
Introduction
Precision Phillips Screwdriver DOOR CONTROL TRANSMITTER MOD-
ULE SET
09960-97001 DS-II KEY FREE SYSTEM

PP
Electrical Tester ELECTRIC DOOR LOCK SYSTEM

KEY FREE SYSTEM
WIRELESS DOOR LOCK CONTROL
SYSTEM(WITHOUT SMART DOOR
LOCK)
WIRELESS DOOR LOCK CONTROL
SYSTEM(WITH SMART DOOR LOCK)
KEY REMINDER WARNING SYSTEM
FRONT DOOR MOTOR LOCK ASSEM-
BLY RH
FRONT DOOR OUTSIDE HANDLE
ASSEMBLY RH
UNLOCK WARNING SWITCH
ASSEMBLY

Automotive 12V Battery ELECTRIC DOOR LOCK SYSTEM
BLY RH
BLY LH
REAR DOOR MOTOR LOCK ASSEMBLY
RH
REAR DOOR MOTOR LOCK ASSEMBLY
LH
BACK DOOR LOCK ASSEMBLY
Protective Tape TRANSMITTER BATTERY (SMART KEY)
GETtheMANUALS.org
PP–50 PREPARATION - METER
METER
PREPARATION
ëçê‡
SST
09843-18020 Diagnosis Check Wire METER / GAUGE SYSTEM
PP
Introduction
09960-97001 DS-II METER / GAUGE SYSTEM
Electrical Tester METER / GAUGE SYSTEM

ENGINE OIL PRESURE SWITCH
ASSEMBLY
FUEL SENDER GAUGE ASSEMBLY

Automotive 12V Battery INDICATOR ASSEMBLY
GETtheMANUALS.org
PREPARATION - AUDIO / VISUAL
PP–51
AUDIO / VISUAL
PREPARATION
ëçê‡
Introduction
Torque Wrench AMPLIFIER ANTENNA ASSEMBLY
Electrical Tester AUDIO SYSTEM

FRONT SPEAKER ASSEMBLY NO.1 PP
SPEAKER ASSEMBLY RR
GETtheMANUALS.org
PP–52 PREPARATION - OTHER SYSTEM
OTHER SYSTEM
PREPARATION
ëçê‡
Introduction
Torque Wrench POWER OUTLET SOCKET
Electrical Tester HORN RELAY

PP IGNITION(STARTER) SWITCH
ASSEMBLY

Automotive 12V Battery HORN RELAY
GETtheMANUALS.org
PREPARATION - GLASS AND WINDOW
PP–53
GLASS AND WINDOW

PREPARATION
ëçê‡
Introduction
Sealant Gun WINDSHIELD GLASS
BACK WINDOW GLASS
QUARTER WINDOW ASSEMBLY LH
Scraper WINDSHIELD GLASS
BACK WINDOW GLASS PP
09960-97001 DS-II POWER WINDOW SYSTEM
Torque Wrench WINDSHIELD GLASS
Electrical Tester POWER WINDOW SYSTEM

WINDSHIELD DEICER SYSTEM
REAR WINDOW DEFOGGER SYSTEM
POWER WINDOW REGULATOR
MOTOR ASSEMBLY RH
MOTOR ASSEMBLY LH
WINDSHIELD GLASS
DEICER RELAY
DEFOG RELAY

Soapy Water WINDSHIELD GLASS
BACK WINDOW GLASS
White Gasoline WINDSHIELD GLASS
BACK WINDOW GLASS
Cutter Knife WINDSHIELD GLASS
BACK WINDOW GLASS
Gummed Tape WINDSHIELD GLASS
BACK WINDOW GLASS
Piano Wire WINDSHIELD GLASS

BACK WINDOW GLASS
Battery POWER WINDOW REGULATOR
MOTOR ASSEMBLY LH
MOTOR ASSEMBLY RH
Automotive 12V Battery WINDSHIELD DEICER SYSTEM
MOTOR ASSEMBLY RH
DEICER RELAY
DEFOG RELAY
Suction Rubber WINDSHIELD GLASS
BACK WINDOW GLASS
QUARTER WINDOW ASSY LH
GETtheMANUALS.org
PP–54 PREPARATION - GLASS AND WINDOW
Seal Set WINDSHIELD GLASS

(Part number:999-09600-U9-001) BACK WINDOW GLASS
Protective Tape WINDSHIELD GLASS
BACK WINDOW GLASS
Wooden Block WINDSHIELD GLASS
BACK WINDOW GLASS
PP QUARTER WINDOW ASSY LH
GETtheMANUALS.org
PREPARATION - MIRROR
PP–55
MIRROR
PREPARATION
ëçê‡
Introduction
Torque Wrench OUTER REAR VIEW MIRROR ASSEM-
BLY RH
Electrical Tester OUTER MIRROR SWITCH ASSEMBLY

OUTER REAR VIEW MIRROR ASSEM- PP
BLY RH
OUTER REAR VIEW MIRROR ASSEM-
BLY LH

Gummed Tape FRONT FENDER SIDE VIEW DEVICE
ASSEMBLY LH
Battery OUTER REAR VIEW MIRROR ASSEM-

BLY RH
OUTER REAR VIEW MIRROR ASSEM-
BLY LH
Protective Tape OUTER REAR VIEW MIRROR ASSEM-
BLY RH
INNER REAR VIEW MIRROR ASSEM-
BLY
GETtheMANUALS.org
PP–56 PREPARATION - INSTRUMENT PANEL
INSTRUMENT PANEL
PREPARATION
ëçê‡

Protective Tape INSTRUMENT PANEL
PP
GETtheMANUALS.org
PREPARATION - SEAT
PP–57
SEAT
PREPARATION
ëçê‡
Service Tool
09130-00160 Hog Ring Pliers FRONT SEAT ASSEMBLY
REAR SEAT ASSEMBLY RH (6:4 Divi-
sion, Double Fold Type)
REAR SEAT ASSEMBLY LH(6:4 Division,
Double Fold Type) PP
Introduction
Torque Wrench FRONT SEAT ASSEMBLY
REAR SEAT ASSEMBLY RH(6:4 Division,
Double Fold Type)
Double Fold Type)
Electrical Tester SEAT HEATER SWITCH
FRONT SEATBACK HEATER RH
FRONT SEAT CUSHION HEATER RH

Hog Ring FRONT SEAT ASSEMBLY
REAR SEAT ASSEMBLY RH(6:4 Division,
Double Fold Type)
Double Fold Type)
Protective Tape FRONT SEAT ASSEMBLY
GETtheMANUALS.org
PP–58 PREPARATION - BODY
BODY
PREPARATION
ëçê‡
SST
09812-00010 Door Hinge Set Bolt Wrench FRONT DOOR
REAR DOOR
BACK DOOR
PP
Service tool
09013-1C110 "TORX" Socket Wrench FRONT DOOR
T25 REAR DOOR

T30 REAR DOOR
BACK DOOR

T40 REAR DOOR
BACK DOOR
Clip Remover FRONT DOOR

REAR DOOR
Introduction
AP201-W Handy Remover Wide Type REAR DOOR
Torque Wrench BONNET(HOOD)

BONNET(HOOD) LOCK CONTROL
CABLE ASSEMBLY
FRONT DOOR
REAR DOOR
BACK DOOR
FUEL LID LOCK CONTROL CABLE
FRONT FENDER LH

MP Grease FRONT DOOR
REAR DOOR
Butyl Tape FRONT DOOR

REAR DOOR
BACK DOOR
White Gasoline FRONT DOOR
FRONT FENDER LH
GETtheMANUALS.org
PREPARATION - BODY
PP–59
Cutter Knife FRONT FENDER LH
Drier FRONT DOOR

FRONT FENDER LH
PP
GETtheMANUALS.org
PP–60 PREPARATION - BODY EXTERIOR
BODY EXTERIOR
PREPARATION
ëçê‡
Introduction
Clip Remover ROOF RACK ASSEMBLY LH
FRONT DOOR GLASS WEATHER
STRIP ASSEMBLY OUT LH
REAR DOOR GLASS WEATHER STRIP
PP ASSEMBLY OUT LH
Rubber Pallet NO. 2 BLACK OUT TAPE LH
NO. 3 BLACK OUT TAPE LH
AP201-W Handy Remover Wide Type ROOF DRIP SIDE FINISH MOULDING
LH
ROCKER PANEL MOULDING LH
Torque Wrench FRONT BUMPER

REAR BUMPER
NO. 2 BLACK OUT TAPE
ROOF RACK ASSEMBLY LH
FRONT DOOR GLASS WEATHER-
STRIP ASSEMBLY OUT LH
REAR DOOR GLASS WEATHERSTRIP
ASSEMBLY OUT LH

White Gasoline ROOF DRIP SIDE FINISH MOULDING
LH
Drier ROOF DRIP SIDE FINISH MOULDING
LH
Cemedine EP001 ROOF DRIP SIDE FINISH MOULDING
LH
Protective Tape ROOF DRIP SIDE FINISH MOULDING

LH
GETtheMANUALS.org
PREPARATION - BODY INTERIOR
PP–61
BODY INTERIOR
PREPARATION
ëçê‡
Service tool
Clip Remover ROOF HEADLINING ASSEMBLY
Lubricant and others PP

Protective Tape ROOF HEADLINING ASSEMBLY
GETtheMANUALS.org
PP–62 PREPARATION - BODY MULTIPLEX COMMUNICATION SYSTEM (LIN)
BODY MULTIPLEX COMMUNICATION SYSTEM (LIN)

PREPARATION
ëçê‡
SST
09843-18020 Diagnosis Check Wire MULTIPLEX BODY COMMUNICATION
SYSTEM (LIN)
PP
Introduction
Electrical Tester MULTIPLEX BODY COMMUNICATION
SYSTEM (LIN)
GETtheMANUALS.org
PREPARATION - CAN COMMUNICATION
PP–63
CAN COMMUNICATION
PREPARATION
ëçê‡
Introduction
09960-97001 DS-II CAN COMMUNICATION SYSTEM
PP
Electrical Tester CAN COMMUNICATION SYSTEM
GETtheMANUALS.org
TO INDEX
SERVICE SPECIFICATIONS
STANDARD BOLT
HOW TO DETERMINE BOLT STRENGTH . . . . . . . . . . . . . . . . . . . . . . . . . SS-1
SPECIFIED TORQUE FOR STANDARD BOLTS . . . . . . . . . . . . . . . . . . . . SS-2
HOW TO DETERMINE NUT STRENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . SS-4
LUBRICANTS AND COOLANTS
SPECIFIED LUBRICANTS AND CAPACITY. . . . . . . . . . . . . . . . . . . . . . . . SS-5 SS
REFERENCE VALUES FOR PERIODIC MAINTENANCE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-6
APPARATUS FOR PREVENTING RELEASE OF HARMFUL GASES
SUCH AS FUMES AND ODOROUS GASES . . . . . . . . . . . . . . . . . . . . . SS-7
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-7
DRIVING APPARATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-7
BRAKE APPARATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-8
STEERING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-8
OPERATION SETTING WHEN DISCONNECTING AND RECON-
NECTING NEGATIVE BATTERY TERMINAL
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-10
OPERATION SETTINGS WHEN INSTALLING, REMOVING AND
REPLACING PARTS
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-11
GETtheMANUALS.org
SS–1 SERVICE SPECIFICATIONS - STANDARD BOLT
STANDARD BOLT
HOW TO DETERMINE BOLT

STRENGTH
Bolt Types
SS Hexagonal Bolt
Stud Bolt Class
Welded Bolt
Normal Recess Bolt Deep Recess Bolt
No Mark No Mark No Mark
w/ Washer w/ Washer
D025089J01
GETtheMANUALS.org
SERVICE SPECIFICATIONS - STANDARD BOLT
SS–2
SPECIFIED TORQUE FOR STANDARD

BOLTS
1. SPECIFIED TORQUE
HINT:
The torque values listed below are the specifications for tightening
unlubricated zinc-plated bolts.
Specified Torque (Hexagon

Hexagon Flange Bolt
Class Diameter (mm) Pitch (mm) Head Bolt)
(N*m [kgf*cm])
(N*m [kgf*cm])
SS
4T 6 1.0 5{55} 6{60}
↑ 8 1.25 12.5{130} 14{145}
↑ 10 1.25 26{260} 29{290}
↑ 12 1.25 47{480} 53{540}
↑ 14 1.5 74{760} 84{850}
↑ 16 1.5 115{1150} 127{1300}
5T 6 1.0 6.5{65} 7.5{75}
↑ 8 1.25 15.5{160} 17.5{175}
↑ 10 1.25 32{330} 36{360}
↑ 12 1.25 59{600} 65{670}
↑ 14 1.5 91{930} 100{1050}
↑ 16 1.5 140{1400} 157{1600}
6T 6 1.0 8{80} 9{90}
↑ 8 1.25 19{195} 21{210}
↑ 10 1.25 39{400} 44{440}
↑ 12 1.25 71{730} 80{810}
↑ 14 1.5 110{1100} 125{1250}
↑ 16 1.5 170{1750} 191{1950}
7T 6 1.0 10.5{110} 12{120}
↑ 8 1.25 25{260} 28{290}
↑ 10 1.25 52{530} 58{590}
↑ 12 1.25 95{970} 105{1050}
↑ 14 1.5 145{1500} 165{1700}
↑ 16 1.5 230{2300} 255{2600}
8T 6 1.0 12{125} 14{145}
↑ 8 1.25 29{300} 33{330}
↑ 10 1.25 61{620} 68{690}
↑ 12 1.25 110{1100} 120{1250}
↑ 14 1.5 170{1750} 195{2000}
↑ 16 1.5 260{2700} 299{3050}
9T 8 1.25 34{340} 37{380}
↑ 10 1.25 70{710} 78{790}
↑ 12 1.25 125{1300} 140{1450}
10T 8 1.25 38{390} 42{430}
↑ 10 1.25 78{800} 88{890}
↑ 12 1.25 140{1450} 155{1600}
11T 8 1.25 42{430} 47{480}
↑ 10 1.25 87{890} 97{990}
GETtheMANUALS.org
SS–3 SERVICE SPECIFICATIONS - STANDARD BOLT
Specified Torque (Hexagon

Hexagon Flange Bolt
Class Diameter (mm) Pitch (mm) Head Bolt)
(N*m [kgf*cm])
(N*m [kgf*cm])
↑ 12 1.25 155{1600} 175{1800}
SS
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SERVICE SPECIFICATIONS - STANDARD BOLT
SS–4
HOW TO DETERMINE NUT STRENGTH
Nut Types
Old Standard Hexagon Nut Class
Standard Hexagonal Bolt
Cold Forged Nut Cutting Processed Nut
SS
No Mark
No Mark (w/ Washer ) No Mark (w/ Washer) No Mark
No Mark
More than one mark on the back of the nut
D025090J01
HINT:
When replacing a nut, use a nut with a nut strength classification that is
equal or higher than the strength classification number of the opposing bolt.
(Example: Bolt = 4 T, Nut = 4 N or more)
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SS–5 SERVICE SPECIFICATIONS - LUBRICANTS AND COOLANTS
LUBRICANTS AND COOLANTS

SPECIFIED LUBRICANTS AND CAPAC-

ITY
1. ENGINE OIL
Engine oil viscosity chart
Oil and Oil Filter
Oil Only Replacement
C -29 -18 -7 4 16 27 38 Engine Model Filling Volume When
SS TEMP.
F -20 0 20 40 60 80 100
Filling Volume (L)
Replacing (L)
3SZ-VE 2.9 3.2
Engin oil 10W-30,10W-40,10W-50
K3-VE 2.0 3.5
(4 stroke) 20W-40,20W-50
HINT:
5W-30
The filling volume when replacing the oil or the oil filer is the amount
5W-20* of oil that is drained from the drain plug.
0W-20* NOTICE:
• Based on the table, use an oil with a viscosity that is best
30
suited to the air temperature.
• Close the drain plug after confirming that the old oil has been
* Standard recommended oil sufficiently drained.
D101273
• With an oil level gauge, always perform a final check of the
amount of oil. (After warming up the engine, with the engine
stopped and after it has been allowed to idle for 5 minutes,
check that the amount of oil is at the F level of the gauge.)
2. LUBRICANTS AND COOLANTS OTHER THAN ENGINE OIL
Item (Type) Capacity (L) (Reference) Specified Lubricant

Coolant (3SZ-VE) M/T: 4.6 Ethylene glycol based anti-freeze solution
↑ A/T: 4.4 ↑
Coolant (K3-VE) M/T: 4.3 ↑
↑ A/T: 4.2 ↑
Automatic transmission fluid
4.6 DEXRON-III
(Transmission)
Transfer oil
Manual Transmission Gear Oil
(Four wheel drive vehicles with automatic trans- 1.6
(API GL-3 or GL-4, SAE 75W-90, 75W-85 or 75W-80)
mission)
Manual transmission oil
1.2 ↑
(FR vehicle)
Manual transmission oil 2.2
↑
(4WD) (Including transfer)
Differential Gear Oil
Front differential oil 0.45
(API GL-5, SAE 80W-90)
Rear differential oil (excluding vehicles equipped
1.8 ↑
with limited slip differential)
Rear differential oil Limited Slip Differential Gear Oil
1.8
(Vehicles equipped with limited slip differential) (API GL-5, SAE 80W-90)
Power steering fluid 0.7 DEXRON-III
Brake fluid - FMVSS116 DOT3 or DOT4
Clutch fluid - ↑
A/C compressor oil - ND-OIL8
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SERVICE SPECIFICATIONS - REFERENCE VALUES FOR PERIODIC MAINTENANCE
SS–6
REFERENCE VALUES FOR PERIODIC MAINTENANCE

ENGINE
1. ENGINE-RELATED
Standard:
Item 3SZ-VE K3-VE

W/P pulley and P/S pump belt deflection (thrust force 100 N [10.2 kgf])
(mm): when installing new parts (when cold)
9-11 ←
SS
W/P pulley and P/S pump belt deflection (thrust force 100 N [10.2 kgf])
13-15 ←
(mm): for maintenance (when cold)
W/P pulley and P/S pump belt tension (N [kgf]): when installing new parts
883 ± 49{90 ± 5} 637 ± 49{65 ± 5}
(when cold)
W/P pulley and P/S pump belt tension (N [kgf]): for maintenance (when
441 ± 98{45 ± 10} ←
cold)
Battery fluid specific gravity (fluid temperature 20 °C [68°F]): specified
1.25-1.29 ←
values
Battery fluid specific gravity (fluid temperature 20°C [68°F]): difference
Below 0.04 ←
between cells
Ignition timing (BTDC)/(r/min): EFI-T short circuit (*1) 4-8/600-750 ←
Ignition timing (BTDC)/(r/min): EFI-T open circuit (*1) 0-15/600-750 ←
Ignition timing (using the DS-II): TC terminal ON BTDC 4-8CA ←
Ignition timing (using the DS-II): TC terminal OFF BTDC 0-15CA ←
Idle speed (N and P range) (r/min) 600-750 ←
IN valve clearance (when cold) (mm) 0.145-0.235 ←
EX valve clearance (when cold) (mm) 0.275-0.365 ←
Check is unnecessary due to tight-
Tightening torque [N*m{kgf*cm} ] ←
ening of plasticity area
Intake manifold tightening torque (N*m [kgf*cm]) 19{194} ←
Exhaust manifold tightening torque [N*m{kgf*cm}] 35{357} ←
2 1.47{15.0} ←
Compression pressure (330 r/min) (MPa [kgf/cm ]): standard value
Compression pressure (330 r/min) (MPa [kgf/cm2]): limit 1.08{11.0} ←
Compression pressure (330 r/min) (MPa [kgf/cm2]): difference between

0.15 (1.5) or below ←
cylinders
Spark plug gap (mm): specified values 0.8-0.9(*2) 1.0-1.1
Spark plug gap (mm): maximum 1.1 ←
Radiator cap valve opening pressure (kPa[kgf/cm2]): specified values 93.3-122.7{0.95-1.25} ←
Radiator cap valve opening pressure (kPa[kgf/cm2]): maximum 78.5{0.8} ←
(*1):
Between terminals EFI-T and E of the DLC
(*2):
No adjustments required because the iridium plug is used.
GETtheMANUALS.org
SS–7 SERVICE SPECIFICATIONS - REFERENCE VALUES FOR PERIODIC MAINTENANCE
APPARATUS FOR PREVENTING

RELEASE OF HARMFUL GASES SUCH
AS FUMES AND ODOROUS GASES
1. EXHAUST GAS PREVENTION-RELATED APPARATUSES
Standard:
Item 3SZ-VE K3-VE

SS Idle CO Concentration (%) Below 0.2 ←
Idle HC Concentration (ppm) Below 200 ←
SUSPENSION
1. FRONT SUSPENSION-RELATED
Standard:
Item J200LG J210LG J211LG J200RG J210RG

Front side slip (per 1 m) (mm) 0±5 ← ← ← ←
Front toe-in (mm) 0±2 ← ← ← ←
Front camber (degree) 0°30' ± 45' ← ← ← ←
Front caster (degree) 4°47' ± 1° ← ← ← ←
Front steering axis inclination
12°25' ± 1° ← ← ← ←
(degree)
Tire turning angle (vehi- Inside 40°32' ± 2° ← ← ← ←
cles with tire size of
215/65 R16) Outside 34°05' ± 2° ← ← ← ←
Tire turning angle (vehi- Inside 39°06' ± 2° ← - 39°06' ± 2° ←

cles with tire size of
235/60 R16) Outside 33°06' ± 2° ← - 33°06' ± 2° ←
DRIVING APPARATUS
1. DRIVING APPARATUS
Standard:

Looseness of front axle hub (mm) Below 0.05 ← ← ← ←
Looseness of rear axle hub (mm) Below 0.8 ← ← ← ←
Wheel nut tightening torque
103{1050} ← ← ← ←
(N*m[kgf*cm])
Remaining tire groves (mm) 1.6 or more ← ← ← ←
2. AIR PRESSURE
(a) Same for both general and high speeds
Standard:
Front wheels Rear wheels

Tire Size
(kPa [kgf/cm2]) (kPa [kgf/cm2])
215 / 65R16 98S 200{2.0} ←
235 / 60R16 100H 210{2.1} ←
GETtheMANUALS.org
SERVICE SPECIFICATIONS - REFERENCE VALUES FOR PERIODIC MAINTENANCE
SS–8
BRAKE APPARATUS
1. BRAKE-RELATED
Standard:

Brake pedal free play
0.5-2 ← ← ← ←
(without vacuum) (mm)
122 or more
Brake pedal reserve
distance (mm)
(The engine is idling after
warmed up, and pedaling force is
← ← ← ← SS
294 N [30 kgf])
Parking brake pedal
release rate
(Operating force of 196 4-7 ← ← ← ←
N [20 kgf] ) (number of
notches)
Parking brake engage- Above 20% of vehicle weight
← ← ← ←
ment: braking force upon inspection
Thickness of rear drum 1.0
brake shoe lining (Reference: 5.5 for a new prod- ← ← ← ←
(mm): maximum uct)
Inner diameter of rear 229.6
brake drum (mm): max- (Reference: 228.6 for a new prod- ← ← ← ←
imum uct)
Thickness of front disc 1.0
brake pad (mm): maxi- (Reference: 10.0 for a new prod- ← ← ← ←
mum uct)
15.0 (solid disc)
(Reference: 16.0 for a new prod-
Thickness of front disc uct)
← ← ← ←
rotor (mm): maximum 21.0 (ventilated disc)
(Reference: 22.0 for a new prod-
uct)
Brake engagement
(braking force) (*): total Over 10% of the axle load ← ← ← ←
of back wheels
Brake engagement
(braking force) (*):
Under 8% of the axle load ← ← ← ←
asymmetry in each
wheel
Brake engagement
Above 50% of vehicle weight
(braking force) (*): sum ← ← ← ←
upon inspection
total
(*):
For vehicles where all front wheels are locked and therefore
difficult to measure, presume in such a situation that this con-
forms with the sum total.
STEERING MECHANISM
1. CHASSIS-RELATED
Standard:
GETtheMANUALS.org
SS–9 SERVICE SPECIFICATIONS - REFERENCE VALUES FOR PERIODIC MAINTENANCE

Steering wheel free play
(Outer circumference of wheel) 0-30 ← ← ← ←
(mm)
SS
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SERVICE SPECIFICATIONS - OPERATION SETTING WHEN DISCONNECTING AND RECONNECTING NEGATIVE
BATTERY TERMINAL
SS–10
OPERATION SETTING WHEN DISCONNECTING AND

RECONNECTING NEGATIVE BATTERY TERMINAL

SERVICE
Non-compliant Behavior, Non-work-
Work item Work procedure Remarks
ing Functions
1. Disconnect the negative (-)
terminal of the battery or the
connector to the power win-
SS
dow master switch.
2. After 5 seconds or more has
elapsed, connect the nega-
tive (-) terminal of the battery • Automatic opening and closing func-
or the connector to the power tion of the door window
Initialization of power win- Settings are required for the
window master switch. • Jam protection function
dow system driver seat master switch
3. Fully open the window of the • Remote operation of each seat with
driver seat door. the driver seat switch
4. Make the window of the driver
seat door go up and continue
to keep the switch in the UP
direction for at least 2 sec-
onds even after the window is
fully closed.
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SS–11 SERVICE SPECIFICATIONS - OPERATION SETTINGS WHEN INSTALLING, REMOVING AND REPLACING PARTS
OPERATION SETTINGS WHEN INSTALLING, REMOVING

AND REPLACING PARTS

SERVICE
1. Replacement Work
Non-compliant Behavior, Non-

Replacement Part Required Work Remarks
SS working Functions
• Automatic transmission assembly
1. Automatic transmis-
• Valve body assembly • Transmission harsh engage-
sion learned value ini-
• Engine assembly ment
tialization
• Transmission wire
1. Acquire yaw rate sen- • Slip indicator light comes on
sor and G sensor and • Buzzer sounds
• Yaw rate sensor
master cylinder pres- • VSC control prohibition or
sure sensor zero point erroneous operation
• Actuator assembly (equipped in skid sor and G sensor and • Buzzer sounds
control ECU) master cylinder pres- • VSC control prohibition or
sor and G sensor and • Buzzer sounds
• Master cylinder pressure sensor
master cylinder pres- • VSC control prohibition or
1. Identification code
• Immobiliser code computer (ID code registration (see the • Wireless functions
box) manual for registra- • Engine start
tion method)
• Automatic opening and clos-
• Power window master switch assem-
ing function of the door win-
bly
dow
• Power window regulator motor 1. Initialization of power • Settings are required for the
• Jam protection function
assembly (driver seat) window system driver seat master switch
• Remote operation of each
• Front door window regulator (driver
seat with the driver seat
seat)
switch
2. AUTOMATIC TRANSMISSION LEARNED VALUE INITIALIZATION

NOTICE:
Wait at least 1 minute after connecting the battery terminal
before performing the initialization of the automatic transmis-
sion learned values.
HINT:
Learned values will not be initialized (erased) by simply disconnecting
the negative (-) terminal of the battery.
(a) After confirming that the shift position is in the P range, connect
the DS-II to the DLC and turn the ignition switch ON and the
DS-II power ON.
NOTICE:
Do not start the engine.
(b) Conduct AT learned value initialization
(1) To initialize learned values, follow the DS-II screen display,
select MAIN MENU [OPERATION SUPPORT] → OPERA-
TION SUPPORT CLASSIFICATION [A/T] → [AT LEARNED
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SERVICE SPECIFICATIONS - OPERATION SETTINGS WHEN INSTALLING, REMOVING AND REPLACING PARTS
SS–12
VALUE INITIALIZATION] and run [AT LEARNED VALUE

INITIALIZATION].
HINT:
Initialization will complete in about 1 minute.
3. ACQUIRE YAW RATE SENSOR AND G SENSOR AND MASTER
CYLINDER PRESSURE SENSOR ZERO POINT
NOTICE:
Always measure the zero point on a level surface (incline of less
than 1%). Do not open or close the doors or shake the vehicle
during the operation. Also, do not start the engine to avoid idling
vibration.
SS
(a) ACTIVATE SENSOR ZERO POINT ACQUISITION MODE
(1) Stop the vehicle on a level surface.
(2) Turn the ignition switch to the ON position, and press the
TRC OFF switch to activate the sensor zero point acquisi-
tion mode.
HINT:
The slip indicator turns on and a buzzer will sound at the
same time.
(b) Acquire zero point for yaw rate sensor and master cylinder
pressure sensor.
(1) Leave the vehicle stationary and release the brake pedal
for 1 second or more.
HINT:
When the zero point of the master cylinder pressure sensor
is successfully acquired, only the buzzer will turn off.
(2) When the zero point of each sensor is acquired, the zero
point acquisition mode ends and the slip indicator turns off.
HINT:
• If wheel speed is detected, the acquire zero point mode
will be canceled and the slip indicator light will go out.
• If the TRC OFF switch is handled during the acquire
zero point mode the slip indicator light will go out and
the acquire zero point mode will be cancelled. (Turning
off the ignition switch will cancel the acquire zero point
mode as well.)
• Pressing the TRC OFF switch again will restart the
acquire zero point mode. However, the zero point acqui-
sition mode will not be performed for the items which
have been completed.
• If malfunction items are detected, the acquire zero point
mode is terminated due to handling of the TRC OFF
switch, and the applicable items cannot be reexamined
without restarting the acquire zero point mode.
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TO INDEX
ENGINE
ENGINE CONTROL
EFI SYSTEM (3SZ-VE, K3-VE)
BASIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-1
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-2
DIAGNOSTIC TROUBLE CODE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . ES-3
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-4
HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . ES-6
CUSTOMER PROBLEM ANALYSIS CHECK SHEET. . . . . . . . . . . . . . . . . ES-7
CHECK / CLEAR DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FREEZE FRAME DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ES-8
ES-10
ES
CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-12
ECU TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-16
ECU DATA LIST / ACTIVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-21
FAIL-SAFE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-27
P0105/31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-28
P0110/43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-31
P0115/42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-35
P0120/41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-38
P0130/21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-43
P0135/23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-47
P0141/24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-47
P0136/22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-50
P0171/25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-53
P0172/26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-53
P0300/17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-58
P0301/17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-58
P0302/17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-58
P0303/17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-58
P0304/17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-58
P0325/18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-63
P0335/13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-66
P0340/14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-69
P0350/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-72
P0420/27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-75
P0443/76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-79
P0500/52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-81
P0505/71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-83
P0535/44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-87
P1105/32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-89
P1300/36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-90
P1346/75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-94
P1349/73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-95
P1351/62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-99
P1510/54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-100
P1560/61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-103
P1600/83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-105
P1601/81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-106
P1656/74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-109
U0101/82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-112
U0121/86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-112
U0156/87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-112
U1000/85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-112
U1002/88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-112
FUEL PUMP CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-115
GETtheMANUALS.org
ECU POWER SOURCE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-120
THROTTLE BODY ASSEMBLY (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-125
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-127
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-128
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-129
KNOCK CONTROL SENSOR (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-130
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-133
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-134
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-134
ES CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-135
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-136
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-136
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-136
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-137
ENGINE CONTROL COMPUTER (3SZ-VEÅj
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-138
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-139
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-139
E.F.I. WATER TEMPERATURE (3SZ-VE)
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-140
E.F.I. COMPUTER RELAY (3SZ-VE)
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-141
THROTTLE POSITION SENSOR (3SZ-VE)
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-142
GETtheMANUALS.org
ENGINE CONTROL - EFI SYSTEM (3SZ-VE, K3-VE)
ES–1
EFI SYSTEM (3SZ-VE, K3-VE)

ENGINE CONTROL
BASIC INSPECTION
HINT:
If the malfunction cannot be determined by troubleshooting, the problem
area can be narrowed down by performing the following basic inspection.
1. CHECK BATTERY VOLTAGE

(a) Check the condition of the battery.(See page CH - 3.)
2. CHECK WHETHER ENGINE CRANKS

(a) Make sure that the engine cranks.
HINT:
ES
If the engine does not crank, check the starting systems.
3. CHECK WHETHER ENGINE STARTS

(a) Make sure that the engine starts.
HINT:
If the engine does not start, check fuel pressure and spark.
4. CHECK AIR FILTER

(a) Check the air filter.
HINT:
If the air filter is dirty, clean or replace it.
5. CHECK ENGINE IDLE SPEED (See page EM - 2)
6. CHECK IGNITION TIMING (See page EM - 1)
7. CHECK FUEL PRESSURE (See page FU - 3)
8. CHECK FOR SPARK (See page IG - 1)
9. CHECK COMPRESSION (See page EM - 2)
GETtheMANUALS.org
ES–2 ENGINE CONTROL - EFI SYSTEM (3SZ-VE, K3-VE)
LOCATION
ENGINE ROOM R/B INSTRUMENT PANEL J/B
EFI FUSE ST RELAY

FAN RELAY E/G FUSE
ES EFI RELAY
F/P RELAY
AM2 FUSE
DLC COMBINATION METER

THROTTLE BODY ASSEMBLY
THROTTLE POSITION SENSOR
ISCV
VACUUM SENSOR
CAMSHAFT POSITION SENSOR
EVAP PURGE VSV
INLET AIR TEMPERATURE

SENSOR

FUEL PUMP
AUTOMATIC CONTROL
COMPUTER
ENGINE CONTROL COMPUTER
OXYGEN SENSOR NO. 2
COOLANT TEMPERATURE
IGNITION COIL ASSEMBLY

OXYGEN SENSOR
CRANKSHAFT POSITION SENSOR
CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
A135187J02
GETtheMANUALS.org
ES–3
DTC No. Diagnostic Item Lamp Code Memory See Page

Air intake pressure sensor
P0105/31 { { ES - 28
signal system
Intake air temperature
P0110/43 { { ES - 31
sensor signal system
Coolant temperature
P0115/42 { { ES - 35
Throttle sensor signal
P0120/41 { { ES - 38
system
P0130/21
Front O2 sensor signal
{ { ES - 43
ES
system
Front O2 sensor heater
P0135/23 { { ES - 47
signal system
Rear O2 sensor signal
P0136/22 { { ES - 50
system
P0141/24 Rear O2 sensor heater { { ES - 47
Fuel system (lean
P0171/25 { { ES - 53
malfunction)
Fuel system (rich
P0172/26 { { ES - 53
malfunction)
P0300/17 Misfire { { ES - 58
P0301/17 Misfire (#1 cylinder) { { ES - 58
Knock sensor signal
P0325/18 × { ES - 63
system
Engine revolution sensor
P0335/13 { { ES - 66
signal system
Cam angle sensor signal
P0340/14 { { ES - 69
system
P0350/16 Ignition primary system { { ES - 72
P0443/76 EVAP purge VSV { { ES - 79
P0420/27 Catalyst deterioration { { ES - 75
Vehicle speed signal
P0500/52 { { ES - 81
system
P0505/71 ISC valve system { { ES - 83
A/C evaporator
P0535/44 temperature sensor signal × { ES - 87
system
Atmospheric pressure
P1105/32 { { ES - 89
P1300/36 Ionic current system { { ES - 90
VVT control system (valve
P1346/75 { { ES - 94
timing fail)
VVT control (advance
P1349/73 { { ES - 95
angle and retard angle fail)
Timing chain control
P1351/62 × { ES - 99
system
P1510/54 Starter signal system { { ES - 100
Short to back up power
P1560/61 { { ES - 103
source
GETtheMANUALS.org

Keyless system/
immobiliser system
P1600/83 × { ES - 105
communication system
(malfunction in ECU)
Keyless / immobiliser
system communication
P1601/81 system (code does not × { ES - 106
match, communication
error)
P1656/74 OCV control system { { ES - 109
EAT/ CVT communication
{ {
ES U0101/82
(reception)
ES - 112
ABS communication
U0121/86 { { ES - 112
(reception)
Meter communication
U0156/87 { { ES - 112
(receiving)
EAT communication
U1000/85 { { ES - 112
(transmission)
U1002/88 CAN communication { { ES - 112
Symptom Suspected Area See Page

1. Starter assembly ST - 10
Engine does not crank 2. Starter relay ST - 21
3. Neutral start switch system AT - 57
1. See flowchart (ECU power source) ES - 120
2. Igniter system IG - 1
No initial combustion (engine does not start) 3. See flowchart (fuel pump control system) ES - 115
4. Injector FU - 12
5. Crank position sensor system IG - 14
1. See flowchart (fuel pump control system) ES - 115
Incomplete combustion (engine does not start)
3. Injector FU - 12
1. Throttle body system ES - 129
Engine does not start but cranks normally) 4. Spark plug IG - 18
5. Compression EM - 2
6. Injector FU - 12
3. Injector FU - 12
Engine does not start (when cold)
5. Spark plug IG - 18
GETtheMANUALS.org
ES–5

3. Injector FU - 12
Engine does not start (when warm)
Fast idle problem
Idle speed is too high 2. See flowchart (ECU power source)
3. Neutral start switch system
ES - 120
AT - 57
ES
Idle speed is too low
4. Injector FU - 12
2. Injector FU - 12
Idle is unstable
4. Compression EM - 2
2. See flowchart (ECU power source) ES - 120
Hunting
2. Injector FU - 12
Stumbling, poor acceleration
After fire
2. Injector FU - 12
Surging 2. Spark plug IG - 17
3. Injector FU - 12
Engine stall (right after starting engine)
1. Injector FU - 12
Engine stall (right after slowing down) 3. Engine control computer ES - 16
Engine stall (when the shift lever is in the D position)
GETtheMANUALS.org
HOW TO PROCEED WITH

TROUBLESHOOTING
2 CONDUCT CUSTOMER PROBLEM ANALYSIS AND CHECK SYMPTOMS (See page ES - 7.)
ES
3 CHECK CAN COMMUNICATION SYSTEM (See page CA - 4.)
(a) Using the DS-II, select CAN BUS DIAGNOSIS / CHECK ECU
CONNECTED TO CAN BUS LINE screen (see CA - 8), and make
sure all ECU and sensors that are connected to the CAN
communication are displayed on the screen.
NG GO TO CAN COMMUNICATION SECTION
OK
4 CHECK FOR DIAGNOSTIC TROUBLE CODES (See page ES - 8.)
(a) Check for DTCs and freeze frame data.

(b) Delete DTCs and freeze frame data.
(c) Recheck for DTCs.
(1) If DTCs are present, go to A.
(2) If DTCs are not present, go to B.
B GO TO STEP 7
5 TROUBLESHOOT USING DTCS OR DIAGNOSTIC TROUBLE CODE CHART (MAIN SUSPECTED

AREAS)
(a) If the location of the problem is determined, go to A.

(b) If the location of the problem is not determined, go to B.
A GO TO STEP 12
B GO TO STEP 9
6 PROBLEM SYMPTOMS TABLE (See page ES - 4.)

GETtheMANUALS.org
ES–7
A GO TO STEP 12
7 BASIC INSPECTION (See page ES - 1.)

A GO TO STEP 12
B ES
8 CHECK USING DS-II (See page ES - 21.)
(a) Select ECU data list or active test.

(b) If the location of the problem is determined, go to A.
(c) If the location of the problem is not determined, go to B.
A GO TO STEP 12
9 CHECK VOLTAGE OF ECU VOLTAGE AND CIRCUIT (See page ES - 16.)
10 REPAIR PROBLEM AREAS
11 CHECK FOR DIAGNOSTIC TROUBLE CODES (See page ES - 8.)
END

CHECK SHEET
1. Ask the customer about problems and concerns.
(a) Follow the previous troubleshooting procedure, and use the
customer problem analysis check sheet to make sure that the
proper questions are asked when interviewing the customer
about problems.
GETtheMANUALS.org
Engine Problem Diagnosis Check Sheet

Model Date vehicle brought in Service history No/Yes (__times)
VIN Date registered Registration No.
Date problem first occurred Odometer reading km
Accessories
Previous vehicle Main region/purpose of travel

Customer profile/characteristics
ES
Warning light illumination Off/On ( )
Driving Problem
System Conditions Road Conditions Others
Conditions Frequency
Speed problem first Starting off Level Accelerator Always
occurred( )km/h Cruising Uphill opening One time only
Shift position ( ) range Increasing ( )%
speed Downhill Sometimes
Starting off Dry paved road Ambient air (_)times a day
Immediately after Decreasing
start off speed Wet paved road temperature (_)times a week
( ) min after start Braking Unpaved/rough ( ) (_)times a month
Check Turning road
Results After ( )min driving Weather
Cold Stopped Snowy/icy road
( )
Warm Not related Uneven,
Idling Others manholes etc.
Others ( ) ( ) Others ( )
Additional Items
DTC Inspection
Malfunction Indicator Normal Code(s) Fuel pressure when
Lamp (MIL) Off/On Malfunction code(s)(all noted) engine stopped
Fuel pressure 1 min.

after engine stopped
Problem details
Inspection Driving conditions and location when problem first
Results occurred and reoccurred
Reoccurrence conditions
Always Occasional Once problem occurs, it continues Does not reoccur
Dealer Name Office Person in charge Technician
A066666
CHECK / CLEAR DTCs

1. PREPARE FOR INSPECTION
(a) Make sure that the throttle valve is fully closed.
GETtheMANUALS.org
ES–9
(b) Move the shift lever to the N or P position.

(c) Turn off the air conditioner.
2. CHECK DTCs (using DS-II)
(a) Connect the DS-II to the DLC.
DS
(b) Turn the ignition switch to the ON position.
(c) Turn the DS-II power ON.
(d) Following the prompts on the screen, select CHECK DTCs/
FREEZE FRAME DATA on the DIAGNOSIS - EFI scree, and
check for DTCs.
HINT:
DLC If a DTC is displayed on the DS-II, see IN - 30.
A136722J02 ES
3. CHECK DTCs (using the check engine warning light)
EFIT NOTICE:
• Turn the ignition switch to the ON position before reading the
DTCs, and check that the check engine warning light is
flashing.
• The CHECK MODE cannot be used.
(a) Turn the ignition switch off.
(b) Using the diagnosis check wire, short terminals 12 (EFIT) and 4
(E) of the DLC.
E
G100942 SST 09843-18020-000
NOTICE:
• Do not connect the diagnosis check wire to the wrong
terminals. Doing so may cause malfunctions.
• Use only the dedicated diagnosis check wire.
(c) Turn the ignition switch to the ON position, and count the
Normal Code number of flashes of the check engine warning light.
0.25 Sec.
HINT:
• If the indicator light does not indicate a DTC (the light does
0.25 Sec. not blink), there may be a malfunction in the TC terminal, VC
2 Sec. terminal, or the computer.
Abnormal Code (Example [11] [23] )
• If the check engine warning light remains on, the wire
harness may have a short circuit (due to being pinched or
Repeated
4 Sec. 1.5 Sec. 2.5 Sec.
for other reasons) or the computer may be malfunctioning.
0.5 Sec. 0.5 Sec.
C040092J07 • If an irrelevant DTC is detected, the computer may be
malfunctioning.
• If the check engine warning light comes on at engine speed
of approximately1000 r/min or more and no DTC is output,
turn the ignition switch to the OFF position and recheck.
(d) Disconnect diagnosis check wire No.2.
4. CHECK FREEZE DATA (using DS-II)
(a) Using the DS-II, follow the prompts on the screen, and select
the DTC that records the freeze data (marked !) from the DTC /
FREEZE DATA screen.
HINT:
• The engine condition (ECU data) before and after DTCs are
detected can be checked using the time series freeze frame
data. (See page ES - 10.)
• The time series freeze frame data is helpful in
troubleshooting when the symptom cannot be reproduced.
GETtheMANUALS.org
5. DELETE RECORDED DTCs (using DS-II)

(a) Following the prompts on the screen, select the DTC / FREEZE
DATA screen and delete the DTCs.
NOTICE:
• If the DTCs cannot be deleted, turn the ignition switch
off, then perform the procedure again.
• Until the cause of problems are clarified, do not delete
the DTCs using the DS-II.
• Write the DTCs down before deleting them.
6. DELETE DTCs (by removing a fuse)
Engine Room R/B (a) The recorded codes can be deleted by removing the EFI fuse
ES (15A) for more than 60 seconds after turning the ignition switch
to the OFF position.
NOTICE:
• Be sure to clear the DTCs and check that a normal code
is output after the EFI system inspection is finished.
• Do not delete the DTCs by clearing the battery
EFI Fuse (removing a fuse) until the cause of the problems is
A133909J01 clarified.
• Write the DTCs down before deleting them.
Freeze Frame Data

1. CHECK FREEZE FRAME DATA
(a) If the symptom can not be reproduced even though a DTC is
detected, check the freeze frame data.
(1) Connect the DS-II to the DLC.
(2) Turn the ignition switch to the ON position.
(3) Select DIAGNOSIS → EFI → DTC / FREEZE DATA.
(4) Detected DTCs will be displayed on the DTC screen.
(5) Select the DTCs to check the desired freeze data.
HINT:
The DTCs are marked with the character, !, and the
highlighted codes contain freeze data.
2. CHECK TIME SERIES FREEZE FRAME DATA
Time Sequence Of Data Recording Timing (a) Select the item to check the desired time series freeze data on
the freeze data screen.
DTC Detection Point
▼
HINT:
• The previous version of freeze data recorded ECU data only
when DTCs occurred (when detected), but time series
1 2 3
freeze frame data also records ECU data before and after
:Time Sequence of Data Recording Point
DTCs are detected.
(Recorded At 0.5 Second Intervals) • Time series freeze frame data can be checked when TIME
A138074J01 SERIES FREEZE DATA CAN BE CHECKED is displayed
on the freeze data screen.
• The time series freeze frame data can display up to 3 data
points, including the DTC inspection point, 1 point for before
inspection, and 1 point after inspection.
3. FREEZE DATA CHART
Item Shorted Item

Coolant temperature ECT
Air intake pressure MAP
Engine speed r/min
GETtheMANUALS.org
ES–11
Item Shorted Item

Vehicle speed VS
Ignition timing advance angle ITA
Injection volume TAUX
Injection timing TAUZ
ES
GETtheMANUALS.org
CIRCUIT DIAGRAM
General Export
Starter
AM2 A/T ECU

ST Relay
Ignition Switch
ES MAIN EFI 15A

E/G 10A ST 7.5A
120 107
IGSW STSW
38
Battery BAT
59 1
39 N1+ Crankshaft
MRO 128 2 Position Sensor
N1-
EFI Relay 58 1
N2+ Camshaft
127 2 Position Sensor
N2-
27
+B
121 2 Knock Control 1

KNK
F/P Relay Sensor
35
FC1
To Fuel Pump 123 2 4
OX1
1 Oxygen Sensor 3 To +B
15
OXH1
Injector No. 1
1 2 24
#10
18 1 Oxygen Sensor 2
OX2
Injector No. 2 NO. 2
1 2 23
#20
56 1 2
VC Throttle Position
Injector No. 3 53 3 Sensor
VTH
1 2 22
#30
Injector No. 4 54 2 1
THW Coolant Temperature
1 2 21
#40
55 1 Inlet Air Temperature 2

THA
2 1 16 Sensor
EVAP Purge VSV PRG
19
E2
20
2 E01
1 65 125
Indicator E1 3 ISCV ISC E1
Engine Control Computer
A135479J01
GETtheMANUALS.org
ES–13
General Export
Stop Light Switch Assembly
To Battery
To IG2 1 3 63 STP 10A
IG1
Ignition Coil Assembly 43
4 (No. 1 Cylinder) STP
Stop Light
1 3 62
Ignition Coil Assembly IG2 11
DEF Defogger
4 (No. 2 Cylinder)
Defogger Switch
To DEF Fuse
ES
1 3 61
Ignition Coil Assembly IG3
4 (No. 3 Cylinder)
26 1 2
OCV+ OCV
25
60 OCV-
1 3
57 3
4 (No. 4 Cylinder) VCPM 1
52 2 Vacuum Sensor
PIM
122
To Ignition Plugs E2PM
45 1 A/C Evaporator 2
ACEV
Temperautre Sensor
116
Engine Check Light E21
13
W
12
EPS P/S Oil Pressure Switch
FAN Relay
37
FAN1 9
Fan Motor 117
SIO2 Immobiliser ECU*
44
FPOF Airbag ECU
135 42
Alternator ALT BLW
45 To A/C
ACSW
9 118
HCAN REV Tachometer
Meter ECU 8
LCAN
7 113 DLC
CANH EFIT
6
A/T ECU CANL
4
ATNE
: Immobiliser Equipped Vehicles
A135480J01
GETtheMANUALS.org
EU Specifications
Starter
AM2 A/T ECU

ST Relay
Ignition Switch
MAIN EFI15A E/G 10A ST 7.5A
120 107
IGSW STSW
ES Battery
38
BAT
N1+
59 1
39 Crankshaft Position
MRO 128 2
N1- Sensor
EFI Relay 58 1
N2+ Camshaft Position
127 2 Sensor
N2-
27
+B
121 2 Knock Control 1

KNK
F/P Relay Sensor
34
FAN2
To Fuel Pump
123 2 4
OX1
15 1 Oxygen Sensor 3 To B
OXH1
Injector No. 1
1 2 24
#10
18 2 4
OX2 Oxygen Sensor
14 1 3 To B
OXH2 NO. 2
Injector No. 2
1 2 23
#20
56 1 2
VC Throttle Position
Injector No. 3 53 3
VTH Sensor
1 2 22
#30
54 2 Coolant Temperature 1
Injector No. 4 THW
Sensor
1 2 21
#40
55 1 Intake Air Temperature 2

THA
2 1 16 Sensor
EVAP Control VSV PRG
19
E2
20
2 E01
1 65 125
To E1 3 ISCV ISC E1

A138429J01
GETtheMANUALS.org
ES–15
EU Specifications
Stop Light Switch Assembly
To Battery
To IG2 63 STP 10A
1 3
2 51 43
4 (No. 1 Cylinder) ICMB1 STP
Stop Light
1 3 62
IG2 11
Ignition Coil Assembly 2 50 DEF Defogger
4 (No. 2 Cylinder) ICMB2
Defogger Switch
To DEF Fuse
ES
1 3 61
IG3
Ignition Coil Assembly 2 49
4 (No. 3 Cylinder) ICMB3
26 1 2
OCV+ OCV
25
OCV-
1 3 61
IG4
Ignition Coil Assembly 2 48 57 3
4 (No. 4 Cylinder) ICMB4 VCPM Intake Air 1
52 2
PIM Pressure Sensor
To Ignition Plugs 122

E2PM
Condensor
45 1 A/C Evaporator 2
ACEV
Temperature Sensor
Engine Check Light 116

E21
13
W
12 P/S Oil Pressure Switch
PST
Fan Relay
37
FAN1 9
Fan Motor 117
SIO2 Immobiliser ECU
44
FPOF Airbag ECU
Alternator 135 42
ALT BLW
45 To A/C
ACSW
9 118
HCAN REV Tachometer
Meter ECU 8
LCAN
7 113 DLC
CANH EFIT
6
A/T ECU CANL
4
ATNE *
A/T To Deicer
* : Specifications For Cold Region Vehicles
A138430J01
GETtheMANUALS.org
ECU TERMINALS
Connector A Connector B Connector C Connector D
27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28
106105 104103102101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 72 71 70
135134 133132 131130129 128127 126125 124123 122 121 120119 118 117 116 115 114 113 112 111 110109 108107
ES
Connector A Connector B
*2
+B OCV+ OCV- #10 #20 #30 #40 E01 E2 OX2 PRG OXH1 OXH2
*2 *2 *2 *2
ISC IG1 IG2 IG3 IG4 N1+ N2+ VCPM VC THA THW VTH PIM ICM ICM ICM ICM
B1 B2 B3 B4
ALT ALTC N1- N2- E1 PST OX1 E2PM KNK
Connector C Connector D
W DEF HCAN LCAN CANH CANL ATNE ACSW

*1 *2
ACEV FPOF STP BLW A/T MRO BAT FAN1 MGC FC1 FAN2
IGSW REV SIO2 E21 EFIT STSW
*1 : Only For General Export

*2 : Only For Europe
A139505J01
GETtheMANUALS.org
ES–17
ECU TERMINAL VOLTAGE CHART (EFI SYSTEM)

Terminal Name Input / Standard
Measurement condition
(Terminal No.) Output (V)
BAT ←→ E1
Input Always 10-14
(38←→125)
+B ←→ E1
Input Engine is stopped, ignition switch is ON 10-14
(27←→125)
IGSW ←→ E1
(120←→125)
MRO ←→ E1
(39←→125)
VC ←→ E2
(56←→19)
Input Engine is stopped, ignition switch is ON 4.5-5.5
ES
IG1 ←→ E1 Pulse is generated
Output Engine is idling
(63←→125) (Waveform 1)
(62←→125) (Waveform 1)
(61←→125) (Waveform 1)
(60←→125) (Waveform 1)
N1+ ←→ N1- Pulse is generated
Input Engine is idling
(59←→128) (Waveform 2)
N2+ ←→ N2- Pulse is generated
(58 ←→ B127) (Waveform 3)
# 10 ←→ E1 Pulse is generated
(24←→125) (Waveform 4)
(23←→125) (Waveform 4)
(22←→125) (Waveform 4)
(21←→125) (Waveform 4)
OX1 ←→ E2 Pulse is generated
Input O2 sensor is warmed up, constant engine speed of 3000 r/min
(123←→19) (Waveform 5)
OX2 ←→ E2 Pulse is generated
Input O2 sensor is warmed up, constant engine speed of 3000 r/min
(18←→19) (Waveform 5)
KNK ←→ E2 Pulse is generated
(121←→19) (Waveform 6)
THW ←→ E2
Input Coolant temperature 60 to 120°C 0.3-1.3
(54←→19)
THA ←→ E2
Input Engine is warmed up 0.5-4.3
(55←→19)
W ←→ E1 Engine is idling
Output 10-14
(13←→125) (the check engine light is off)
W ←→ E1 Disconnect the connector of the coolant temperature sensor.
Output 0-3.5
(13←→125) (the check engine light is on)
STSW ←→ E1
Input Starter switch is ON 10-14
(107←→125)
VTH ←→ E2
Input Throttle valve is fully closed 0.4-0.8
(53←→19)
VTH ←→ E2
Input Throttle valve is fully opened 3.2-5.0
(53←→19)
ISC ←→ E1 Engine is idling Pulse is generated
Output
(65←→125) Air conditioner switch is OFF → ON (Waveform 7)
OXH1 ←→ E1
Output After engine idles for more than 5 seconds 0-1
(15←→125)
GETtheMANUALS.org
Terminal Name Input / Standard

(Terminal No.) Output (V)
OXH1 ←→ E1
Output Engine is stopped, ignition switch is ON 10-14
(15←→125)
STP ←→ E1
Input Stop light switch is ON 10-14
(43←→125)
STP ←→ E1
Input Stop light switch is OFF 0-0.5
(43←→125)
ATNE ←→ E1
(16←→125)
ATNE ←→ E1 Pulse is generated
Output Engine is warmed up, accelerator pedal is depressed
(16←→125) (Waveform 8)
ES FC1 ←→ E1
(35←→125)
FC1* ←→ E1
Output Engine is idling Below 1.2
(35←→125)
REV ←→ E1 Pulse is generated
(118←→125) (Waveform 9)
FAN1 ←→ E1
Output Magnetic clutch is OFF 10-14
(37←→125)
FAN1 ←→ E1
Output Magnetic clutch is ON Below 1
(37←→125)
OCV+ ←→ OCV- Pulse is generated
Output Engine is stopped, ignition switch is ON
(26←→25) (Waveform 10)
EPS ←→ E1 Engine is idling
Input 10-14
(12←→125) Steering wheel is centered
EPS ←→ E1 Engine is idling
Input 0-1
(12←→125) Steering wheel is turned
ALTC ←→ E1
(134←→125)
ALT ←→ E1
(135←→125)
VCPM ←→ E2PM
Input Engine is stopped, ignition switch is ON 4.5-5.5
(57←→122)
PIM ←→ E2PM
Input Sensor adjusted to stable ambient temperature 3.1-4.1
(52←→122)
ACEV ←→ E21
Input Air conditioning is ON 0.15-4.8
(45←→116)
E1 ←→ Body ground
Ground Always (continuity check) Continuity
(125)
(19)
(20)
(116)
*: FAN2 terminal for European models
GETtheMANUALS.org
ES–19
1. Oscilloscope waveform
(a) Waveform 1
Tester Connection IG1, IG2, IG3, IG4 ←→ E1

Tool setting 5 V/DIV, 10 ms/DIV
Measurement
Engine is idling after warming up
condition
HINT:
• As the engine speed increases, the waveform cycle
A134282
becomes shorter.
• The oscilloscope waveform shown as an example, does not
include noise or chattering waveforms.
(b) Waveform 2
ES
Tester Connection N1+ ←→ N1-
Measurement
Engine is idling
condition
HINT:
becomes shorter.
A134283
• As the engine speed increases, each waveform cycle
becomes shorter.
• Noise may cause DTCs to be recorded.
(c) Waveform 3
Tester Connection N2+ ←→ N2-

Measurement
Engine is idling
condition
HINT:
becomes shorter.
A134284
• As the engine speed increases, each waveform cycle
becomes shorter.
• Noise may cause DTCs to be recorded.
(d) Waveform 4
Tester Connection # 10, # 20, # 30, # 40 ←→ E1

Measurement
Engine is idling
condition
HINT:
As the engine speed increases, the waveform cycle becomes
shorter.
A134285
GETtheMANUALS.org
(e) Waveform 5
Tester Connection OX1, OX2 ←→ E1

Tool setting 0.2 V/DIV, 500 ms/DIV
Measurement Oxygen sensor is warmed up, constant engine speed of
condition 3000 r/min
HINT:
Repeat between 0 (LEAN) ←→ 1(RICH)V
A134286
ES (f) Waveform 6
Tester Connection KNK ←→ E1

Tool setting 1 V/DIV, 1 ms/DIV.
Measurement
Engine is idling
condition
HINT:
• The oscilloscope waveform shown as an example does not
A134287
• The waveform amplitudes differ slightly depending on the
vehicle.
(g) Waveform 7
Tester Connection ISC ←→ E1

Air Conditioner OFF
Measurement
Engine is idling, air conditioning is OFF → ON
condition
HINT:
The duty ratio changes if the air conditioning is turned ON.
Air Conditioner ON
A134289
GETtheMANUALS.org
ES–21
(h) Waveform 8
Tester Connection ATNE ←→ E1

Measurement
Engine is idling
condition
HINT:
If the waveform shown in the illustration is not indicated, idle the
engine for 10 minutes and recheck the waveform.
A134290
(i) Waveform 9
ES
Tester Connection REV ←→ E1
Measurement
Engine is idling
condition
HINT:
shorter.
A134291
(j) Waveform 10
Tester Connection OCV+ ←→ OCV-

Measurement
Engine is idling
condition
HINT:
shorter.
A134292
ECU DATA LIST / ACTIVE TEST

1. ECU DATA LIST CHART
NOTICE:
• As the data list values may vary widely depending on slight
measurement errors, the measurement environment, or the
state of the vehicle due to wear and tear, it is very difficult to
indicate specific standard values (reference
values).Therefore, in some cases, an error may occur within
the range of reference values.
• For delicate symptoms such as stumbling, rough idle, obtain
and compare multiple test data using the same vehicle under
the same conditions, and determine problems wholistically
by considering all suspected items on the data list.
CARB SPECIFIED DATA CHART
Item
Item Description Inspection Condition Reference Value Problem Area
(Shorted Item)
•Illumination condition of
MIL status the check engine Check engine warning light
ON → OFF W voltage
(MIL) warning light is on → off
•ON: on, OFF: off
GETtheMANUALS.org
Item
(Shorted Item)
•Indicates the number of
Number of power train
DTCs
trouble codes - 0 -
•Displayed range: 0 to
(DIAG)
255
•Fuel system status of
bank 1 is indicated
•OL (open loop):
conditions are not
satisfied to go from open
loop to closed loop
ES •CL (close loop): oxygen

sensor is used as
Fuel system status of bank feedback for fuel control
Engine is idling after
1 •OL - Drive: open loop CL OX1 Voltage
warming up
(FS1) due to drive condition
•OL - Fault: open loop
due to detected system
malfunction
•CL- Fault: close loop,
but at least one oxygen
sensor is malfunctioning.
Only one oxygen sensor
is used for fuel control
•Fuel system status of
bank 2 is indicated
•OL (open loop):
conditions are not
satisfied to go from open
loop to closed loop
•CL (close loop): oxygen
sensor is used as
Fuel system status of bank feedback for fuel control
2 •OL - Drive: open loop - - -
(FS2) due to drive condition
•OL - Fault: open loop
due to detected system
malfunction
•CL- Fault: close loop,
but at least one oxygen
sensor is malfunctioning.
Only one oxygen sensor
is used for fuel control
•Existence of bank 1
O2 sensor position
sensor 1 is indicated - ON -
(O2S11)
•ON: yes, OFF: no
O2 sensor position
sensor 2 is indicated - ON -
(O2S12)
•ON: yes, OFF: no
O2 sensor position
sensor 3 is indicated - - -
(O2S13)
•ON: yes, OFF: no
O2 sensor position
(O2S14)
•ON: yes, OFF: no
O2 sensor position
(O2S21)
•ON: yes, OFF: no
O2 sensor position
(O2S22)
•ON: yes, OFF: no
GETtheMANUALS.org
ES–23
Item
(Shorted Item)
O2 sensor position
(O2S23)
•ON: yes, OFF: no
O2 sensor position
(O2S24)
•ON: yes, OFF: no
OBD requirements OBD requirements are
- EOBD -
(OBD) indicated (EOBD)
•Engine load amount is
Engine is idling (air
Calculated load value indicated Air cleaner condition
(LOAD) •Displayed range: 0 to
100%
conditioner is OFF, shift
lever is in N position)
0-5%
Throttle valve condition ES
•Engine load amount is Engine speed is 2000 r/
Calculated load value indicated min (air conditioning is Air cleaner condition
5-7%
(LOAD) •Displayed range: 0 to OFF, shift lever is in N Throttle valve condition
100% position)
•Indicates engine coolant
Coolant temperature temperature Engine warmed up
80 to 102°C THW Voltage
(ECT) •Displayed range: -40 to completely
140°C
Coolant temperature temperature
Short circuit in sensor 119 to 140°C THW Voltage
(ECT) •Displayed range: -40 to
140°C
Coolant temperature temperature
Short circuit in sensor -40°C THW voltage
(ECT) •Displayed range: -40 to
140°C
•Air intake pressure is
indicated as absolute
Air intake pressure Ignition switch is in ON •VCPM voltage
pressure 70 to 104 kPa
(MAP) position, engine is stopped •PIM voltage
120 kPa
•Air intake pressure is
indicated as absolute Engine is warmed up and
Air intake pressure •VCPM voltage
pressure idling, air conditioner is 20 to 40 kPa
(MAP) •PIM voltage
•Displayed range: 0 to OFF
120 kPa
Engine speed Engine is stopped
Indicates the engine speed 0 r/min N voltage
(R/MIN) (IG ON)
Engine speed No significant
Indicates the engine speed Constant engine speed N voltage
(R/MIN) fluctuation
Vehicle speed
Indicates vehicle speed The vehicle is stopped 0 km/h SPD voltage
(VS)
Vehicle speed Vehicle is running at No significant
Indicates vehicle speed SPD voltage
(VS) constant speed fluctuation
•Indicates ignition timing
Ignition timing advance Engine is cranking (air
of the 1-cylinder IG voltage
angle conditioner is OFF, shift 4-8°
•Displayed range: BTDC Each sensor voltage
(ITA) lever is in N position)
63.5 to ATDC 64°
Ignition timing advance Engine is idling (air
of the No.1 cylinder IG voltage
angle conditioner is OFF, shift 0-15°
(ITA) lever is in N position)
63.5 to ATDC 64°
Ignition timing advance Engine speed is 2000 r/
of the No.1 cylinder IG voltage
angle min (air conditioner is OFF, 20-40°
(ITA) shift lever is in N position)
63.5 to ATDC 64°
GETtheMANUALS.org
Item
(Shorted Item)
•Indicates air
Intake air temperature temperature Equivalent to ambient
IG ON THW voltage
(IAT) •Displayed range: -40 to temperature
140°C
•Indicates intake air
Intake air temperature temperature
Short circuit in sensor 119 to 140°C THW voltage
(IAT) •Displayed range: -40 to
140°C
•Indicates intake air
Intake air temperature temperature
Short circuit in sensor -40°C THW voltage
ES (IAT) •Displayed range: -40 to
140°C
•Indicates opening angle
Opening angle of absolute Accelerator pedal fully VC, VTH voltage
of throttle valve 1
throttle sensor depressed 10-24% (Throttle position sensor
(TP) (IG ON) No.1)
100 %
•Indicates opening angle
Opening angle of absolute Accelerator pedal fully VC, VTH voltage
of throttle valve 1
throttle sensor released 64-96% (Throttle position sensor
(TP) (IG ON) No.1)
100 %
•Indicates front O2
FrO2 sensor output
sensor output voltage 2500 r/min
voltage 0 to 1.0 V OX1 voltage
•Displayed range: 0 to Constant engine speed
(O2FV)
1.275 V
•Indicates front O2
sensor feedback trim
FrO2 short-term fuel trim 2500 r/min
ratio -20-20% OX1 voltage
(O2FP) Constant engine speed
•Displayed range: -100
to 99.2%
•Indicates rear O2
RrO2 sensor output
sensor output voltage 2500 r/min
voltage 0.1 to 0.95 V OX2 voltage
•Displayed range: 0 to Constant engine speed
(O2RV)
1.275 V
•Indicates rear O2
sensor feedback trim
RrO2 short-term fuel trim 2500 r/min
factor 10-70% OX2 voltage
(O2RP) Constant engine speed
•Displayed range: -100
to 99.2%
•Indicates distance
Driven distance at time of driven at time DTC is
malfunction recorded - 0 to 65535 km -
(DWM) •Displayed range: 0 to
65535 km
•Indicates duty ratio of
evaporation purge VSV
Evaporation purge output Engine is idling after PRG voltage
output 0%
(EVAP) warming up Voltage of each sensor
100 %
•Indicates barometric
Barometric pressure pressure Ignition switch is in ON
73 to 110 kPa -
(BARO) •Displayed range: 0 to position, engine is stopped
255 kPa
•Indicates battery voltage
Power source voltage
•Displayed range: 0 to 16 IG ON 11 to 14 V BAT voltage
(BAT)
V
DMC SPECIFIED DATA CHART
GETtheMANUALS.org
ES–25
Item
(Shorted Item)
Electrical load Indicates that there is Light, defogger
OFF → ON Voltage of each switch
(DSW) electrical load OFF → ON
Air conditioner signal Indicates that air conditioner is
Air conditioner OFF → ON OFF → ON Voltage of each switch
[A/C] operating
• Indicates injection timing
Injection timing Engine is cool when started
• Displayed range: 0 to 200 1.4 to 2.5 msec PIM, THW, OX1 voltage
(TAUZ) → completely warmed up
msec
• Indicates injection timing Engine warmed up and
Injection timing
• Displayed range: 0 to 200 idling (air conditioner is OFF, 1.4 to 1.8 msec PIM, THW, OX1 voltage
(TAUZ)
msec shift lever is in N position)
Injection timing
• Indicates injection timing Engine speed is 2000 r/min ES
• Displayed range: 0 to 200 (air conditioner is OFF, shift 1.3 to 1.8 msec PIM, THW, OX1 voltage
(TAUZ)
msec lever is in N position)
• Indicates injection timing Engine speed is 3000 r/min
Injection timing
• Displayed range: 0 to 200 (air conditioner is OFF, shift 1.0 to 1.5 msec PIM, THW, OX1 voltage
(TAUZ)
msec lever is in N position)
• Indicates duty ratio of ISC
Engine warmed up and VC voltage
ISC duty ratio drive signal
idling (air conditioner is OFF, 6-14% VTH voltage
(ISCD) • Displayed range: 0 to
shift lever is in N position) THW voltage
100%
• Indicates duty ratio of ISC
Engine warmed up and VC voltage
ISC duty ratio drive signal
idling (air conditioner is ON, 20-60% VTH voltage
(ISCD) • Displayed range: 0 to
shift lever is in N position) THW voltage
100%
• Indicates actual
Actual displacement
displacement angle of Engine is idling after
angle 0-5° OCV voltage
VVT warming up
(VT)
• Displayed range: 0 to 50°
• Indicates actual
Actual displacement
displacement angle of Engine is warmed up and
VVT running at constant speed
(VT)
• Indicates target
Target displacement
displacement angle of Engine is idling after
VVT control warming up
(VTT)
• Indicates target
Target displacement
displacement angle of Engine is warmed up and
VVT control running at constant speed
(VTT)
• Indicates whether air-fuel
O2 sensor signal 2500 r/min
ratio measured by front - OX voltage
(OX) Constant engine speed
O2 sensor is lean or rich
• Indicates learned value of
air-fuel ratio
VF monitor 2500 r/min
compensation 0.75 to 1.25 V OX voltage
(VF) Constant engine speed
• Displayed range: 0.75 to
1.25 V
• Indicates whether the idle
switch is ON or OFF (if the
vehicle does not have an
Idle signal Accelerator pedal fully VC voltage
idle switch, the ON status ON → OFF
(IDL) depressed → released VTH voltage
is when the throttle is
completely closed from
the open status)
GETtheMANUALS.org
Item
(Shorted Item)
• Indicates ISC learned
Engine warmed up and
ISC learned value value ISC voltage
idling (air conditioner is OFF, 6-14%
(DLRN) • Displayed range: 0 to Voltage of each sensor
shift lever is in N position)
100%
• Indicates ISC learned
Engine warmed up and
ISC learned value value ISC voltage
idling (air conditioner is ON, 6-14%
(DLRN) • Displayed range: 0 to Voltage of each sensor
shift lever is in N position)
100%
Purge trim ratio • Indicates purge trim ratio Engine is idling after PRG voltage
0
(FPG) • Displayed range: 0 to 0.5V warming up Voltage of each sensor
ES Knocking trim advance

angle
• Indicates knock sensor
trim advance angle
Engine is idling after
0-3° KNK voltage
warming up
(AKNK) • Displayed range: 0 to 20°
Knocking trim advance • Indicates knock sensor
4000 r/min
angle trim advance angle 0-3° KNK voltage
Constant engine speed
(AKNK) • Displayed range: 0 to 20°
• Indicates VVT angle
TVVT angle equivalency Engine is warmed up and
equivalency 15-52° VTH voltage
(VTB) idling
• Indicates VVT angle
TVVT angle equivalency 3000 r/min
equivalency 15-62° VTH voltage
(VTB) Constant engine speed
• Indicates duty ratio of VVT
Control duty ratio control Engine is warmed up and
20-50% VTH voltage
(DVT) • Displayed range: 0 to idling
100%
• Indicates duty ratio of VVT
Control duty ratio control 3000 r/min
20-50% VTH voltage
(DVT) • Displayed range: 0 to Constant engine speed
100%
• Indicates the actual air
Actual air intake
intake pressure
pressure Engine is stopped 80 to 110 kPa PIM voltage
• Displayed range: 0 to 120
(PMVTB)
kPa
Actual air intake
intake pressure Engine is warmed up and
pressure 20 to 40 kPa PIM voltage
• Displayed range: 0 to 120 idling
(PMVTB)
kPa
Actual air intake
intake pressure 2000 r/min
pressure 19 to 39 kPa PIM voltage
• Displayed range: 0 to 120 Constant engine speed
(PMVTB)
kPa
Power steering signal • Indicates power steering Steering wheel is centered
OFF → ON EPS voltage
(PST) signal input → turned
Stop lamp signal • Indicates stop lamp signal Brake pedal is released →
OFF → ON STP voltage
(STP) input depressed
• Indicates the number of
Number of DTCs
DTCs - - -
(DIAG)
• Displayed range: 0 to 255
2. ACTIVE TEST
Item Condition Constraint Condition

Fuel pump Fuel pump is ON (active) / OFF (stopped) -
Purge control VSV is ON (current) / OFF (no
Purge VSV -
current)
All VSV for purge control are ON (current) / OFF
All VSV -
(no current)
GETtheMANUALS.org
ES–27
Item Condition Constraint Condition

T terminal T terminal is ON (short) / OFF (short released) -
Radiator fan Radiator fan is ON (active) / OFF (stopped) -
ISC active duty ratio setting (50 % open / 5 %
ISC stepper Vehicle is stopped, engine is idling
open)
FAIL-SAFE CHART
If the codes shown below are recorded on the ECU, it will go to a fail-safe
mode.
Diagnostic Trouble Code Fail-safe Operation Fail-safe Mode Deactivation Condition

• Vacuum sensor value is the pressure
ES
estimated from the throttle opening angle
and the engine speed.If the signal from
the throttle position sensor is abnormal,
P0105/31 use the signal from the vacuum sensor as Return to normal condition
the constant value.
• If both the throttle opening angle and the
engine speed exceed the constant value,
decrease the fuel amount.
Use the signal from the intake air temperature
P0110/43 Return to normal condition
sensor as the constant value.
Use the signal from the coolant temperature
Use the signal from the throttle position
P0136/22 Set feedback control to open control. Return to normal condition
P0325/18 Lag the ignition timing. Return to normal condition
Stop the fuel injection to the cylinder that has
ignition signal problems.
P0535/44 Turn off the air conditioner. Return to normal condition
P1600/83
Stop fuel injection and ignition. Return to normal condition
P1601/81
P1656/74 Prohibit the oil control valve current control. Return to normal condition
GETtheMANUALS.org
AIR INTAKE PRESSURE SENSOR SIGNAL

DTC P0105/31
SYSTEM
DESCRIPTION
Using a built-in sensor, the vacuum sensor detects the intake manifold pressure as voltage. At the same time, the engine control
computer determines the basic injection and ignition timing based on this voltage.The vacuum sensor does not detect barometric
pressure as a standard value, but it detects the absolute pressure of the inside of the intake manifold, so it is not effected by high
latitude or other barometric pressure changes.Therefore, a constant standard air-fuel ratio is maintained under all conditions.
ES Voltage (V)
(3.96)
3.6
2.4
1.2
mmHg
150 450 750 (840)
kPa
20 60 100 (112)
Intake Manifold Internal Pressure
A051845J01

1.Diagnosis Condition
DTC No. 2.Malfunction Condition Suspected Area
3.Malfunction Time
4.Other
1. IG ON
• Vacuum sensor
2. Open or short to vacuum sensor circuit
P0105/31 • Wire harness and connector
3. 0.5 seconds or more
• Engine control computer
4. 1 trip
GETtheMANUALS.org
ES–29
CIRCUIT DIAGRAM
Vacuum Sensor
1
2 52
PIM
3 57
VCPM ES
122
E2PM
A133545J02
HINT:
Read the freeze frame data using the DS-II. Freeze data records aspects of the engine's condition when malfunctions occur. This
information is helpful when troubleshooting.
1 READ DS-II DATA (AIR INTAKE PRESSURE)

(b) Read the air intake pressure shown on the DS-II while the ignition
switch is turned to the ON position and the engine is stopped.
Result
Vehicle Condition Standard

Engine is stopped, ignition switch is ON 80 to 110 kPa
Engine is warmed up and idling (air conditioner is OFF) 20 to 40 kPa
Engine is running at a constant speed of 2000 r/min (air
19 to 39 kPa
conditioner is OFF)
OK CHECK FOR INTERMITTENT PROBLEMS
NG
GETtheMANUALS.org
2 CHECK WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER VACUUM SENSOR)
(a) Disconnect the vacuum sensor connector and the engine control
computer connector B.
(b) Using a tester, check whether there is continuity or a short between
the engine control computer and the vacuum sensor.(For terminal
Engine Control Computer layout, see page ES - 16.)
Standard
Inspection Terminal (Terminal Name)

Engine control computer ←→
ES Vacuum sensor
Standard
57 (VCPM) ←→ 3 (VC) There is continuity and no shorts

between other terminals and body
52 (PIM) ←→ 2 (PIM)
E2PM ground
VCPM PIM
There is continuity, and no short
Intake Pressure Sensor 122 (E2PM) ←→ 1 (E2)
between other terminals
Vehicle Side Connector
NG REPAIR OR REPLACE WIRE HARNESS OR

CONNECTOR
E2 PIM VC
A133546J01
OK
3 CHECK VACUUM SENSOR
(a) Turn the ignition switch to the ON position.

(b) Measure the voltage between the terminals of the vacuum sensor
connecter using the tester.
Intake Pressure Sensor Standard
Inspection Terminal (Terminal Name) Standard

3 (VC) ←→ 1 (E2) 4.5 to 5.5 V
1 2 3
2 (PIM) ←→ 1 (E2) 3.1 to 4.1 V
(c) Remove the fuel pump relay and crank the engine, then measure the
E2 PIM VC voltage between the terminals of the vacuum sensor connector.
A133547J01 Standard
Inspection Terminal (Terminal Name) Standard

2 (PIM) ←→ 1 (E2) Voltage value fluctuates
OK REPLACE THE VACUUM SENSOR
NG
CHECK AND REPLACE ENGINE ECU
GETtheMANUALS.org
ES–31
INTAKE AIR TEMPERATURE SENSOR SIGNAL

DTC P0110/43
SYSTEM
DESCRIPTION
The intake air temperature sensor detects the intake air temperature. The resistance of the thermistor built into intake air
temperature sensor changes depending on the temperature of the intake air. When the intake air temperature is low, the
resistance of the thermistor increases. Conversely, when the temperature of the intake air is high, the resistance of the thermistor
drops. The intake air temperature sensor is connected to the engine control computer, and, through resistance R, 5V power
source voltage is supplied to the intake air temperature sensor from terminal THA of the engine control computer. Because
resistance R and the intake air temperature sensor are connected in series, the resistance changes depending on the intake air
temperature and the potential of terminal THA changes. Based on this signal, the engine control computer increases the fuel ES
injection volume to improve drivability during cold engine operation.
Resistance
[kΩ]
30
20
10
5
3
2
0.5
0.3
0.2
0.1
-20 0 20 40 60 80 100
Temperature [°C]
A032255J11

3.Malfunction Time
4.Other
1. IG ON • Wire harness or connector
2. Open or short to intake air temperature sensor • INTAKE AIR TEMPERATURE SENSOR
P0110/24 circuit • Engine control computer
4. 1 trip
GETtheMANUALS.org
CIRCUIT DIAGRAM
Inlet Air Temperature Sensor
1 55
THA
2 19
ES E2
G100102J24
HINT:
• Read the freeze frame data using the DS-II.Freeze data records aspects of the engine's condition when malfunctions occur.
This information is helpful when troubleshooting.
1 READ DS-II DATA (INTAKE AIR TEMPERATURE)

(b) Read the intake air temperature indicated on the DS-II while the
ignition switch is turned to the ON position and the engine is stopped.
Result

-40°C A
140°C B
Equivalent to ambient temperature C
B GO TO STEP 4
C CHECK FOR INTERMITTENT PROBLEMS
2 READ DS-II DATA (WIRE HARNESS OPEN CIRCUIT INSPECTION)
SST 09843-18020
GETtheMANUALS.org
ES–33
(a) Disconnect the intake air temperature sensor connector.

Inlet Air Temperature Sensor (b) Short the circuit between terminals 2 (-) and 1 (+) of the inlet air
Vehicle Side Connector temperature sensor vehicle side connector using the SST (diagnosis
check wire).
(c) Connect the DS-II to the DLC.
(e) Read the inlet air temperature displayed on the DS-II.
Standard:
(+) (-) 140°C
A133551J01
OK REPLACE INTAKE AIR TEMPERATURE
SENSOR
ES
NG
3 READ DS-II DATA (CHECK FOR OPEN IN ENGINE CONTROL COMPUTER)
SST 09843-18020
(a) Short the circuit between terminals 55 (THA) and 19 (E2) of the
engine control computer using the SST (diagnosis check wire).
Engine Control Computer (b) Read the intake air temperature displayed on the DS-II.
Standard:
140°C
NG CHECK AND REPLACE ENGINE CONTROL

COMPUTER
E2 THA
A133549J01
OK
4 READ DS-II DATA (INSPECT WIRE HARNESS SHORT CIRCUIT)
(a) Disconnect the intake air temperature sensor connector.

(c) Read the intake air temperature displayed on the DS-II.
Standard:
-40°C
OK REPLACE INTAKE AIR TEMPERATURE

SENSOR
NG
GETtheMANUALS.org
5 CHECK WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER INTAKE

TEMPERATURE SENSOR)
(a) Disconnect the engine control computer connector B and the intake
air temperature sensor connector.
the engine control computer vehicle side connector and the intake air
temperature sensor vehicle side connector.(For terminal layout, see
page ES - 16.)
Standard
ES Tester Connection (Terminal Symbol)
Engine control computer ←→ Inlet Standard
E2 air temperature sensor
THA
There is continuity and no shorts
55(THA) ←→ 1(+) between other terminals and body
Inlet Air Temperature Sensor ground
Vehicle Side Connector There is continuity, and no short
19(E2) ←→ 2(-)

CONNECTOR
(+) (-)
A133550J01
OK
CHECK AND REPLACE ENGINE CONTROL COMPUTER
GETtheMANUALS.org
ES–35
COOLANT TEMPERATURE SENSOR SIGNAL

DTC P0115/42
SYSTEM
DESCRIPTION
The resistance of the thermistor built into the coolant temperature sensor varies according to the coolant temperature.

1. Diagnosis Condition
DTC No. 2. Malfunction Condition Suspected Area
3. Malfunction Time
4. Other
1.
2.
IG ON
Open or short in coolant temperature circuit
• Wire harness or connector ES
P0115/22 • Coolant temperature
4. 1 trip
CIRCUIT DIAGRAM
Coolant Temperature
2 54
THW
1 19
E2
G100102J25
HINT:
• Read the freeze frame data using the DS-II.Freeze frame data records aspects of the engine's condition when malfunctions
occur. This information is helpful when troubleshooting.
1 READ DS-II DATA (COOLANT TEMPERATURE)

(b) Read the engine coolant temperature displayed on the DS-II while the
ignition switch is turned to the ON position and the engine is stopped.
Result

-40 °C A
140 °C B
Equivalent to actual coolant temperature C
B GO TO STEP 4
GETtheMANUALS.org
2 READ DS-II DATA (INSPECT WIRE HARNESS OPEN CIRCUIT)
SST 09843-18020
(a) Disconnect the connector of the coolant temperature sensor.
Coolant Temperature (b) Short the circuit between terminals 2 (+) and 1 (-) of the water
Vehicle Side Connector temperature vehicle side connector using the SST (diagnosis check
ES (c)
wire No.2).
Connect the DS-II to the DLC.
(e) Read the engine coolant temperature displayed on the DS-II.
Standard:
(-)
(+) 140°C
A075082J04
OK REPLACE COOLANT TEMPERATURE
SENSOR
NG
3 READ DS-II DATA (CHECK FOR OPEN IN ENGINE CONTROL COMPUTER)
SST 09843-18020
(a) Short the circuit between terminals 54 (THW) and 19 (E2) of the
engine control computer using the SST (diagnosis check wire
Engine Control Computer No.2).(For terminal layout, see page ES - 16.)
(b) Read the engine coolant temperature displayed on the DS-II.
Standard:
140°C

E2
COMPUTER
THW
A133549J02
OK
4 READ DS-II DATA (INSPECT WIRE HARNESS SHORT CIRCUIT)
(a) Disconnect the connector of the coolant temperature sensor.

(c) Read the engine coolant temperature displayed on the DS-II.
Standard:
-40°C
OK REPLACE COOLANT TEMPERATURE

SENSOR
GETtheMANUALS.org
ES–37
NG
5 CHECK WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER COOLANT

TEMPERATURE)
(a) Disconnect connector B of the engine control computer and the

connector of the coolant temperature sensor.
the vehicle side connector or the engine control computer and the
vehicle side connector of the coolant temperature sensor.(For
terminal layout, see page ES - 16.)
Standard
ES
Tester Connection (Terminal Symbol)
Engine control computer ←→ Standard
E2 THW Coolant temperature
There is continuity and no short
E.F.I. Coolant Temperature
54(THW) ←→ 2(+) between other terminals and body
ground
19(E2) ←→ 1(-)

(-) CONNECTOR
(+)
A133552J01
OK
GETtheMANUALS.org
DTC P0120/41 THROTTLE SENSOR SIGNAL SYSTEM

DESCRIPTION
The throttle position sensor is mounted on the throttle body to detect the opening angle of the throttle valve.
When the throttle valve is fully closed, voltage of approximately 0.7 V is applied to the VTH terminal of the engine control
computer.The voltage that is applied to the VTH terminal of the engine control computer increases in proportion to the opening
angle of the throttle valve, and the voltage increases from approximately 3.5 V to 5.0 V when the throttle valve is fully opened.The
engine control computer determines the operating condition of the vehicle by the voltage input from the VTH terminal, and adjusts
the air-fuel ratio, performs fuel-cut control, etc.
ES
Engine
Throttle Control
Position Computer
Sensor
5V
VC
VTH
E2
A133572

DTC No. 2.Malfunction Condition Trouble Area
3.Malfunction Time
4.Other
1. IG ON
2. Open or short circuit in throttle position • Throttle position sensor
P0120/41 sensor circuit • Wire harness or connector
3. 0.5 seconds or more • Engine control computer
4. 1 trip
GETtheMANUALS.org
ES–39
CIRCUIT DIAGRAM

Throttle Position Sensor
1 B16
56
VC
ES
3 B13
53
VTH
2 B6
19
E2
A133553J01
HINT:
• Read the freeze frame data using the DS-II. Freeze frame data records aspects of the engine's condition when malfunctions
1 READ DS-II DATA (ABSOLUTE THROTTLE OPENING ANGLE)

(b) Read the opening angle of the throttle valve.
Result
Throttle Valve Standard

Fully open 64-96%
Fully Closed 10-24%
FI07052
NG
GETtheMANUALS.org
2 CHECK WIRE HARNESS OR CONNECTOR (CHECK VOLTAGE)
(a) Disconnect the connector of the throttle position sensor.

(c) Using a tester, measure the voltage between terminal 1(VC) and 2
(E2) of the vehicle side connector of the throttle position sensor.
Vehicle Side Connector Standard:
4.5 to 5.5 V
NG GO TO STEP 6
ES
VC E2
A133554J01
OK
3 INSPECT THROTTLE POSITION SENSOR
(a) Disconnect the connector of the throttle position sensor.

(b) Using a tester, measure the resistance between the connector
Throttle Position Sensor terminals of the throttle position sensor.
Standard
Tester Connection
Throttle Valve Resistance
(Terminal Symbol)
1 (VC) to 3 (VTH) - 2.5 to 5.9 k
3 2 1
3 (VTH) to 2 (E2) Fully closed 0.2 to 5.7 k
3 (VTH) to 2 (E2) Fully open 2.0 to 10.2 k
VC
VTH E2 A133573J01
NG REPLACE THROTTLE POSITION SENSOR
OK
4 INSPECT ENGINE CONTROL COMPUTER
SST 09842-97209
(a) Connect the SST (sub harness, EFI computer check) to the engine
control computer.
(c) Using a tester, measure the voltage between terminal 53 (VTH) and
19 (E2) of the engine control computer connector.(For terminal
Standard
Throttle Valve Standard

Fully closed 0.3 to 1.0 (V)
Fully open 2.7 to 5.2 (V)
E2 VTH
OK CHECK AND REPLACE ENGINE CONTROL
A133549J03
COMPUTER
GETtheMANUALS.org
ES–41
NG
5 CHECK WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER THROTTLE

POSITION SENSOR)
(a) Disconnect the engine control computer connector B and the throttle
position sensor connector.
the engine control computer vehicle side connector and the throttle
position sensor vehicle side connector.(For terminal layout, see page
ES - 16.)
Standard
ES
Throttle position sensor
53 (VTH) ←→ 3 (VTH) between other terminals and body
VTH
ground
Throttle Position Sensor NG REPAIR OR REPLACE WIRE HARNESS OR

Vehicle Side Connector CONNECTOR
VTH
A133574J01
OK
SST 09842-97209
control computer.
(c) Using a tester, measure the voltage between terminals 56 (VC) and
19 (E2) of the engine control computer connector. (For terminal
Standard:
4.5 to 5.5 V

COMPUTER
E2 VC
A133549J04
GETtheMANUALS.org
OK
7 CHECK WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER THROTTLE

POSITION SENSOR)
(a) Disconnect the engine control computer connector B and the throttle
the engine control computer vehicle side connector and the throttle
position sensor vehicle side connector.(For terminal layout, see page
ES ES - 16.)
Standard

Throttle position sensor
E2 56 (VC) ←→ 1 (VC) between other terminals and body
VC
ground
19 (E2) ←→ 2 (E2)
Throttle Position Sensor between other terminals
COMPUTER
VC E2
A133574J03
NG
GETtheMANUALS.org
ES–43
DTC P0130/21 FRONT 02 SENSOR SIGNAL SYSTEM

DESCRIPTION
A three-way catalytic converter is used to efficiently remove CO, HC and NOx from the exhaust gas. The three-way catalytic
converter works most efficiently when the air-fuel ratio is close to the stoichiometric ratio.Therefore, if the engine does not operate
close to the stoichiometric air-fuel ratio. CO, HC and NOx cannot be converted efficiently. An oxygen sensor is provided in order
help the system maintain the stoichiometric ratio. The oxygen sensor is used to detect the oxygen concentration of the exhaust
gas. The oxygen sensor has a characteristic where its voltage output changes suddenly near the stoichiometric air-fuel ratio, if
normal combustion is occurring. The engine control computer uses this signal characteristic to allow air-fuel ratio control. When
the air-fuel ratio is lean, the oxygen level in the exhaust gas increases. The engine control computer recognizes the lean air-fuel
ratio detected by the oxygen sensor. (Low voltage variation: < 0.45 V) When the air-fuel ratio is rich, oxygen levels in the exhaust ES
gas decrease, and the engine control computer recognizes the rich air-fuel ratio detected by the oxygen sensor. (High voltage
variation: > 0.45 V) The engine control computer determines whether the air-fuel ratio is rich or lean by the electromotive force
signal of the oxygen sensor, and controls injection volume. The oxygen sensor has a heater which warms a zirconium element.
The heater is controlled by the engine control computer, which applies current to the heater in order to prevent sensor inaccuracy
that may occur if the sensor gets cold when the exhaust gas temperature is low (such as when there is a low amount of intake
air).
Atmosphere
Output Voltage Air-Fuel Ratio
Housing
Platinum Electrode
Zirconia Element
Platinum Electrode
Heater
Rich Lean
Cover Ceramic Coating Stoichiometric Air-Fuel Ratio
Exhaust Gas
A069512

3.Malfunction Time
4.Other
1. Engine warmed up and engine speed lower than 2,500 r/min
2. Steady oxygen sensor output voltage of less than 0.3 V or more • Wire harness or connector
P0130/21 than 0.6 V • Oxygen sensor
3. 400 seconds or more after engine started • Engine control computer
4. 2 trip
HINT:
Using the DS-II, check the FrO2 sensor output voltage on the data monitor screen. If the FrO2 sensor output voltage stays at 0.02
V or less, the O2 sensor voltage system circuit may be open.
DESCRIPTION
1. Start the engine and drive the vehicle for more than 20 seconds at speed above 10 km/h.[*1]
2. Allow the engine to idle for approximately 400 seconds.[*2]
3. Check the voltage of the FrO2 sensor output.
NOTICE:
If this test is not performed accurately, it will be impossible to determine exactly where problems are occurring.
GETtheMANUALS.org
HINT:
If there are any abnormalities, the check warning light will remain on while the procedure is performed. [*2].
Vehicle Speed
More Than 20 Sec.[*1]
10 km/h
ES IG OFF
Idling More Than 400 Sec. [*2]
A140624J01
CIRCUIT DIAGRAM
EFI Relay Engine Control Computer

EFI
C8
MRO
Front O2 Sensor
2 1 B2
OXH1
MAIN
4 3 B30
OX1
Rear O2 Sensor
2 1 B1
OXH2
4 3 B5
Battery OX2
B6
E2
A135516
GETtheMANUALS.org
ES–45
HINT:
Read the freeze frame data using the DS-II.Freeze frame data records aspects of the engine's condition when malfunctions
1 READ DS-II DATA (FrO2 SENSOR OUTPUT VOLTAGE)

(b) Start the engine and warm it up until it reaches a temperature that
allows the oxygen sensor to start feedback.
(c) Warm up the oxygen sensor for approximately 90 seconds at an
engine speed of 2500 r/min.
ES
(d) Using the DS-II, read FrO2 sensor voltage B1S1 while the engine is
idling.
Result:
Repeated output of voltage that is less than 0.3 V or more than 0.6 V.
HINT:
• It is easier to see the changes in the line graph mode on the monitor
screen.
OK GO TO STEP 3
NG
2 CHECK WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER OXYGEN SENSOR)
(a) Disconnect the engine control computer connector B and the oxygen
sensor connector.
the engine control computer and the oxygen sensor (For terminal
layout, see page ES - 16).
Standard

Oxygen sensor
E2 OX1 There is continuity and no short

123 (OX1) ←→ 3 (OX1) between other terminals and body
ground
Oxygen Sensor There is continuity, and no short
19 (E2) ←→ 4 (E2)
Vehicle Side Connector between other terminals

CONNECTOR
OX1 E2
A133576J04
OK
REPLACE OXYGEN SENSOR
GETtheMANUALS.org
3 ROAD TEST TO CHECK OPERATION

(b) Turn the ignition switch to the ON position, and delete the DTCs by
following the prompts on the DS-II screen.
(c) To check the system, warm up the oxygen sensor by performing a
road test.
HINT:
Refer to DESCRIPTION for the procedure.
ES NEXT
4 READ DTCS

(b) Turn the ignition switch to the ON position, and read the DTCs by
(1) Check if DTC P0130/21 is indicated.
Result

Indicates P0130/21 A
Indicates a normal code B
B CHECK FOR INTERMITTENT PROBLEMS
GETtheMANUALS.org
ES–47
DTC P0135/23 FRONT 02 SENSOR HEATER SIGNAL SYSTEM
DTC P0141/24 REAR 02 SENSOR HEATER

DESCRIPTION
See ES - 43.

3.Malfunction Time
4.Other ES
1. IG ON
• Wire harness or connector
2. Open in oxygen sensor heater circuit
P0135/23 • Oxygen sensor
4. 2 trip
1. IG ON
2. Open in oxygen sensor No.2 heater circuit
P0141/24 • OXYGEN SENSOR NO.2
4. 2 trip
CIRCUIT DIAGRAM
HINT:
For the wiring diagram, see page ES - 44.
HINT:
1 INSPECT OXYGEN SENSOR
(a) Disconnect the oxygen sensor connector.

Front Rear O2 Sensor (b) CHECK SENSOR HEATER RESISTANCE
+B HT1A HT2A (1) Using a tester, measure the resistance between the terminals.
Standard
2 1 Tester Connection Standard (Measurement
Sensor
(Terminal Symbol) Condition)
Oxygen sensor 2 (+B) ←→ 1 (HT1A) 5 to 10 (20°C)
4 3 Oxygen sensor No.2 2 (+B) ←→ 1 (HT2A) 5 to 10 (20°C)
E2 (c) Check short in sensor heater

A133577J02
(1) Using the tester, check for the short between terminals 1
(HT1A) and 4 (E2).
Standard
Tester Connection
Sensor Standard
(Terminal Symbol)
Oxygen sensor 1 (HT1A) ←→ 4 (E2) No continuity
Oxygen sensor No.2 1 (HT2A) ←→ 4 (E2) No continuity
NG REPLACE OXYGEN SENSOR
GETtheMANUALS.org
OK
2 CHECK WIRE HARNESS AND CONNECTOR (SENSOR HEATER POWER SOURCE CIRCUIT)

Oxygen Sensor (b) Turn the ignition switch to the ON position.
Vehicle Side Connector (c) Using a tester, measure the voltage of the terminals of the oxygen
+B sensor vehicle side connecter.
Standard
Tester Connection
ES Installed position
(Terminal Symbol)
Standard
Front, rear 2 (+B) ←→ body ground 10 to 14 V
A133578J01
NG GO TO STEP 4
OK
sensor connector.
the engine control computer and the oxygen sensor. (For terminal
layout, see page ES - 16.)
Standard

Oxygen sensor
OXH1
OXH2 There is continuity and no short
15 (OXH1) ←→ 1 (HT1A) between other terminals and body
ground
02 Sensor Vehicle Side Connector There is continuity and no short
14 (OXH2) ←→ 1 (HT2A) between other terminals and body
HT1A HT2A ground

CONNECTOR
A133576J03
OK
4 CHECK WIRE HARNESS AND CONNECTOR (OXYGEN SENSOR EFI RELAY)
GETtheMANUALS.org
ES–49
(b) Remove the EFI relay.

Oxygen Sensor (c) Using a tester, check whether there is continuity or a short between
Vehicle Side Connector the relay block holder for the EFI relay and the oxygen sensor.
+B Standard
Tester Connection
(Terminal Symbol)
Installed position Relay block holder for Standard
EFI relay ←→ Oxygen
sensor
There is continuity and
no short between other
Front, rear 4 ←→ 3 (+B)
terminals and body
ground ES
CONNECTOR
2
5 3
1
A133579J01
OK
CHECK ECU POWER SOURCE SYSTEM (SEE ECU POWER SOURCE SYSTEM)
GETtheMANUALS.org
DTC P0136/22 REAR 02 SENSOR SIGNAL SYSTEM

DESCRIPTION
(See Page ES - 43)

3.Malfunction Time
4.Other
1. During feedback after engine is warmed up
2. Open in oxygen sensor circuit or no rich signals are input • Wire harness or connector
ES P0136/27 during feedback • Oxygen sensor No.2
3. 500 seconds or more • Engine control computer
4. 2 trip
HINT:
• Using the DS-II, check the RrO2 sensor output voltage on the data monitor screen. If the RrO2 sensor output voltage stays at
0.1 V or less, there be an open in the RrO2 sensor voltage circuit.
• The conditions of the oxygen sensor No.2 output voltage and the air-fuel ratio feedback (F/B calibration value) can be read by
using DS-II.
DESCRIPTION
1. Start the engine and drive the vehicle for more than 20 seconds at speed above 10 km/h.[*1]
2. Allow the engine to idle for approximately 400 seconds.[*2]
3. Warm up the engine. [*3]
4. Drive the vehicle for 50 seconds or more at a vehicle speed of 70 km/h or more. [*4]
5. Check the voltage of the RrO2 sensor output.
NOTICE:
If this test is not performed accurately, it will be impossible to determine exactly where problems are occurring.
HINT:
• Because oxygen sensor No.2 does not have heater control, drive with a moderate level of load after the engine is
completely warmed up.
• If there are any abnormalities, the check engine warning light will remain on while the procedure is performed. [*4].
Vehicle Speed
More Than 50 Sec. [*4]
70 km/h
More Than 20 Sec. [*1]
10 km/h
IG OFF
Idling More Than 400 Sec. [*2] Driving With The

Engine Warm [*3]
A140625J01
CIRCUIT DIAGRAM
(See Page ES - 44)
GETtheMANUALS.org
ES–51
HINT:
occur. This information is helpful whnen troubleshooting.
1 READ DTCs

following the prompts on the DS-II screen.(See page ES - 8.)
(c)
(d)
Perform a road test.
Check for DTCs following the prompts on the DS-II screen. (See
ES
page ES - 8.)
Result

Indicates P0136/27 A
Indicates P036/27 and other codes B
Indicates a normal code C
HINT:
If DTC P0136/27 and other DTCs are output at the same time,
check the other codes first.
B GO TO RELEVANT DTC CHART
GETtheMANUALS.org
2 CHECK WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER OXYGEN SENSOR
NO.2)
Engine Control Computer sensor No.2 connector.
the engine control computer and oxygen sensor No.2. (For terminal
Standard

ES Engine Control Computer ←→ Standard
Oxygen Sensor No.2
E2 There is continuity and no short

OX2
18 (O2X2) ←→ 1 (+) between other terminals and body
ground
Rear O2 Sensor There is continuity, and no short
Vehicle Side Connector 19(E2) ←→ 2(-)

1 2 CONNECTOR
(+) (-)
A133580J01
OK
3 READ DS-II DATA (RrO2 SENSOR OUTPUT VOLTAGE)

(b) Following the prompts on the DS-II screen, select ECU DATA
MONITOR, then RrO2 SENSOR OUTPUT VOLTAGE. Then select
MODE CHANGE and LINE GRAPH.
(c) Warm up oxygen sensor No.2 for approximately 90 seconds at an
(d) Read the voltage of the RrO2 sensor output while racing the engine
at a speed of 4000 r/min several times.
Result:
Voltage output is 0.4 V or less and 0.5 V or more
HINT:
• Oxygen sensor No.2 does not have a heater control, so perform
the tests after the engine is completely warm.
• If changes are difficult to see, perform a road test.(See
DESCRIPTION.)
NG REPLACE OXYGEN SENSOR NO.2
OK
REPLACE ENGINE CONTROL COMPUTER
GETtheMANUALS.org
ES–53
DTC P0171/25 FUEL SYSTEM (LEAN MALFUNCTION)
DTC P0172/26 FUEL SYSTEM (RICH MALFUNCTION)

DESCRIPTION
There are two types of air-fuel ratio corrections. One is the normal operating air-fuel ratio correction (air-fuel ratio F/B). The other
is the memory air-fuel ratio correction (air-fuel ratio F/B learned). Air-fuel ratio F/B is the air-fuel ratio correction that is used to
maintain a stoichiometric ratio. The oxygen sensors send signals to the engine control computer indicating whether the current
air-fuel ratio is rich or lean comparing to the stoichiometric ratio. When the signal indicates that the condition is rich the injection
volume is decreased. When the signal indicates that the condition is lean the injection volume is increased. Air-fuel ratio F/B
learned value refers to a value that shows the air-fuel ratio F/B value over a long period of time. Because of differences specific to ES
each engine (such as differences caused by wear over time and changes in the operating environment) this air-fuel ratio F/B
learned value varies from a central value.If either the air-fuel ratio F/B value or the air-fuel ratio F/B learned value exceeds a
certain value and becomes lean or rich, the engine control computer illuminates the check warning light.

3.Malfunction Time
4.Other
• Intake system
1. While operating the vehicle at 70 km/h with the engine
• Fuel system
warm, during a normal air-fuel ratio F/B
• Ignition system
2. Fuel trim is corrected heavily on the increase side
P0171/25 • Wire harness or connector
(approx.+ 40 %)
• Oxygen sensor
3. 60 seconds or more
4. 2 trip
• Gas leakage from exhaust system
• Intake system
1. While operating the vehicle at 70 km/h with the engine
• Fuel system
warm, during a normal air-fuel ratio F/B
• Ignition system
2. Fuel trim is corrected heavily on the decrease side
(approx.+ -35%)
• Oxygen sensor
4. 2 trip
• Gas leakage from exhaust system
HINT:
If the total of the air-fuel F/B value and the air-fuel F/B learned value is within 25%, the system is normal.
CIRCUIT DIAGRAM
See Page ES - 44.
HINT:
• Check if the engine has stopped in the past because of a fuel cut.If so, the DTC P0171/25 may be recorded.
1 INSPECT EMISSION CONTROL SYSTEM
HINT:
For inspection procedures, see page EC - 1.
NG REPAIR OR REPLACE EMISSION CONTROL

SYSTEM
GETtheMANUALS.org
OK
2 INSPECT FUEL INJECTOR ASSEMBLY
SST 09843-97201, O9268-41047

(a) Check the resistance.
(1) Using the tester, measure the resistance between the injector
terminals.
Resistance:
12 (20°C)
ES HINT:
If the value is not within the standard range, replace with a
known-good part.
(b) Fuel injection volume
NOTICE:
Work in a location with good air ventilation and watch out for
fire.
(1) Connect the SST (injection measuring tool set) to the fuel pipe
(vehicle side).
NOTICE:
Be extremely careful when handling the fuel tube
connector.
(2) Attach the injector to a graduated cylinder.
HINT:
To prevent fuel from spraying, install the correct-sized vinyl
tube, etc.
(3) Connect the DS-II to the DLC and operate the fuel pump.
(4) Connect the injector to the SST (EFI inspection wire).
A (5) Connect the SST (EFI inspection wire) to the battery, perform
Injector fuel injection (15 seconds each) 2 or 3 times, and calculate the
B average value.
SST:
09842-30055
Fuel Pipe Standard
Difference Between Individual

Injection Volume
Injectors
A139327 60 to 73ml 13 ml or less
HINT:
If the value is not within the standard range, replace with
known-good parts.
(c) Check for leakage.
(1) When removing the SST from the battery under the conditions
described above, check that there is no leakage from the
injector.
Standard:
1 drop or less per 12 minutes
NG REPLACE FUEL INJECTOR ASSEMBLY
B000069
GETtheMANUALS.org
ES–55
OK
3 CHECK COOLANT TEMPERATURE

(1) Using the tester, inspect the resistance between the terminals.
Standard
Measurement Condition Standard

When approx. 20°C 2.32 to 2.59 kΩ
ES
NOTICE:
Protect the terminal area from getting wet when checking
the sensor by applying water.Also, wipe the sensor dry
after the check.
Resistance NG REPLACE COOLANT TEMPERATURE

SENSOR
[kΩ]
Temperature [°C]
A050330
OK
4 INSPECT THE IGNITION SYSTEM
HINT:
For inspection procedures, see page IG - 1.
NG REPAIR OR REPLACE IGNITION SYSTEM
OK
5 CHECK FUEL SYSTEM
HINT:
For inspection procedures, see page FU - 3.
NG REPAIR OR REPLACE FUEL SYSTEM
OK
6 CHECK FOR EXHAUST GAS LEAKS
NG REPAIR OR REPLACE EXHAUST GAS

LEAKAGE AREA
GETtheMANUALS.org
OK
7 READ DS-II DATA (FrO2 SENSOR OUTPUT VOLTAGE)
(a) Warm up the oxygen sensor for approx. 90 seconds at an engine

speed of 2500 r/min.
(b) Using the DS-II, read the output voltage of the oxygen sensor while
the engine is idling.
Standard:
Repeated output of voltage that is less than 0.3 V or
ES more than 0.6 V
OK GO TO STEP 9
NG
(a) Disconnect connector B of the engine control computer.

(b) Disconnect the connector of the oxygen sensor.
(c) Using a tester, check whether there is continuity or a short between
Engine Control Computer the engine control computer and the oxygen sensor connector.(For
Standard

Engine Control Computer ←→ Oxygen Standard
Sensor
123 (OX1) ←→ 3 (OX1) between other terminals and body
OX1 ground
OK REPLACE OXYGEN SENSOR

Front O2 Sensor
CONNECTOR
OX1
A133576J02

(c) To check the system, warm up the oxygen sensor by performing a
road test.
HINT:
Refer to the oxygen sensor output voltage inspection procedure.
GETtheMANUALS.org
ES–57
GO
10 READ DTCs

(b) Turn the ignition switch to the ON position, and read the DTC by
(1) Check if DTC P0171/25 is detected.
Result
A B
P0171/25 is not output again P0171/25 is output again
ES
B CHECK AND REPLACE ENGINE CONTROL
COMPUTER
GETtheMANUALS.org
DTC P0300/17 MISFIRE
DTC P0301/17 MISFIRE (#1 CYLINDER)
ES DTC P0304/17 MISFIRE (#4 CYLINDER)

DESCRIPTION
The igniter detects ionic current that is generated by combustion. This ionic current is represented by ionic voltage and input to
the engine control computer.If the voltage is lower than the specified value, the engine control computer determines that there
has been a misfire and counts the number of detected misfires. If the number of misfires reaches or exceeds a specified value,
the engine check warning light illuminates to indicate a problem. If the number of misfires reaches or exceeds the point at which
the catalyst may overheat, the engine check warning light flashes.

3.Malfunction Time
4.Other
• Ignition system
1. When driving at vehicle speed of 30 to 70
• Intake system
km/h
• Fuel system
2. DTCs P0301/17 through P0304/17 are
output repeatedly
• Coolant temperature
4. 2 trip
• Fuel injector
• Ignition system
• Intake system
km/h
• Fuel system
2. Rate of misfires is higher than the set
value
4. 2 trip
• Fuel injector
• Ignition system
• Intake system
km/h
• Fuel system
value
4. 2 trip
• Fuel injector
• Ignition system
• Intake system
km/h
• Fuel system
value
4. 2 trip
• Fuel injector
• Ignition system
• Intake system
km/h
• Fuel system
value
4. 2 trip
• Fuel injector
GETtheMANUALS.org
ES–59
CIRCUIT DIAGRAM
Ignition Coil Assembly Engine Control Computer

( No. 1 Cylinder)
Injector No. 1
1 3 A11
To E/G Fuse IG1
A4 2 1
4 2 B11 #10
ICMB1
Ignition Coil Assembly

( No. 2 Cylinder) Injector No. 2
1 3 A10
IG2 #20
A3 2 1 ES
4 2 B10
ICMB2
Injector No. 3
( No. 3 Cylinder) A2 2 1
#30
1 3 A9
IG3
4 2 B9
ICMB3 Injector No. 4
Ignition Coil Assembly A1 2 1

#40
( No. 4 Cylinder)
1 3 A8
IG4
4 2 B8
ICMB4
To EFI Relay
A135528
HINT:
• If any codes are detected other than misfire malfunction, perform troubleshooting for those DTCs first.
• To confirm that the repair has been completed, operate the vehicle using one of the driving patterns shown below.
Driving patterns
Engine speed Time
Idle 3 and a half minutes or more
1000 r/min 3 minutes or more
2000 r/min 1 and a half minutes or more
3000 r/min 1 minute or more
(See page IG - 1)
OK
GETtheMANUALS.org
2 CHECK FUEL PRESSURE
(See page FU - 3)
OK
ES (a) Check the resistance.

Standard:
At approx. 20°C : 2.32 to 2.59 kΩ
At approx. 80°C : 0.310 to 0.326 kΩ
NOTICE:
Protect the terminal area from getting wet when checking
the sensor by applying water. Also, wipe the sensor dry
after the check.
NG REPLACE COOLANT TEMPERATURE

SENSOR
Resistance
[kΩ]
Temperature [°C]
A050330
OK
4 INSPECT FUEL INJECTOR ASSEMBLY
SST 09843-97201, O9268-41047

(1) Using the tester, measure the resistance between the injector
terminals.
Standard:
12 Ω (20°C)
HINT:
known-good parts.
(b) CHECK INJECTION VOLUME
NOTICE:
Work in a location with good air ventilation and watch out for
fire.
(1) Connect the SST (injection measuring tool set) to the fuel pipe
(vehicle side).
GETtheMANUALS.org
ES–61
NOTICE:
Be extremely careful when handling the fuel tube
connector.
(2) Attach the injector to a graduated cylinder.
HINT:
To prevent fuel from spraying, install the correct-sized vinyl
tube, etc.
(3) Connect the DS-II to the DLC and operate the fuel pump.
A (5) Connect the SST (EFI inspection wire) to the battery, perform
Injector fuel injection (15 seconds each) 2 or 3 times, and calculate the
B average value.
Standard
ES
Difference Between Individual
Injection Volume
Fuel Pipe Injectors
60 to 73 ml 13ml or less
HINT:
A139327
known-good parts.
(c) Check for leakage.
(1) When removing the SST from the battery under the conditions
described above, check that there is no leakage from the
injector.
Standard:
B000069
OK
5 CHECK VACUUM SENSOR

(b) Measure the voltage between the terminals of the vacuum sensor
connecter using the tester.
Intake Pressure Sensor Standard
Tester Connection (Terminal Symbol) Standard

3 (VC) ←→ 1 (E2) 4.5 to 5.5 V
1 2 3
2 (PIM) ←→ 1 (E2) 3.1 to 4.1V
(c) Remove the fuel pump relay and crank the engine, then measure the
E2 PIM VC voltage between the terminals of the vacuum sensor connector.
A133547J01 Standard

2 (PIM) ←→ 1 (E2) Voltage value fluctuates
NG REPLACE THE VACUUM SENSOR
OK
GETtheMANUALS.org
6 CHECK WIRE HARNESS AND CONNECTOR
(a) Disconnect connector A of the engine control computer and

disconnect the connectors of each fuel injector.
the engine control computer vehicle side connector and the fuel
injector vehicle side connector.
Standard
Terminal Connection
Installed position Standard
ES (Terminal Symbol)
#1 Cylinder 2←→24(#10)
terminals and body
ground
#2 Cylinder 2←→23(#20)
terminals and body
ground
#3 Cylinder 2←→22(#30)
terminals and body
ground
#4 Cylinder 2←→21(#40)
terminals and body
ground

CONNECTOR
OK
GETtheMANUALS.org
ES–63
DTC P0325/18 KNOCK SENSOR SIGNAL SYSTEM

DESCRIPTION
The knock control sensor is mounted to the cylinder block to detect engine knocking.Inside the knock control sensor, there is a
sensing element. When the sensing element is deformed due to the cylinder block vibration caused by knocking, it generates
electricity. When the engine computer senses this voltage, it retards the ignition timing to control the knocking.

3.Malfunction Time
1. IG ON
4.Other
ES
2. Open or short in knock control sensor circuit • Knock control sensor
P0325/52
3. 0.9 seconds or more • Installation tightness of knock control sensor
4. 1 trip • Engine control computer
CIRCUIT DIAGRAM
Shield Line
Knock Control Sensor
2 121
KNK
1 19
E2
A133581J01
HINT:
GETtheMANUALS.org
HINT:
The communication between the engine control computer and the knock
control sensors can be checked using the oscilloscope function of the DS-
II.
(a) Connect the DS-II to terminals 121(KNK) and 19 (E2) of the engine
control computer connectors.(For terminal layout, see page ES - 16.)
ES
E2 KNK
A133549J05
(b) Set the DS-II to the oscilloscope function.(See the DS-II instruction
manual for the setting procedures.)
Item Condition
Tester Connection KNK ←→ E2
Engine is warmed up and an engine speed of
4000 r/min is maintained
HINT:
A134287 • The oscilloscope waveform shown as an example does not
• The waveform amplitudes differ slightly depending on the vehicle.

COMPUTER
NG
2 INSPECT SENSOR INSTALLATION PART
(a) Check the condition of the knock control sensor installation.
NG REPAIR OR REPLACE SENSOR

INSTALLATION PART
OK
3 CHECK WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER KNOCK CONTROL
SENSOR)
(a) Disconnect the engine control computer connector B and the knock
control sensor connector.
GETtheMANUALS.org
ES–65

the engine control computer and the knock control sensor(For
Standard

Engine Control Computer ←→ Standard
121 (KNK) ←→ 2 (+) between other terminals and body
ground
E2 KNK
19(E2) ←→ 1(-) between other terminals and body
Knock Control Sensor ground ES
CONNECTOR
(-) (+)
A133582J01
OK
4 REPLACE KNOCK CONTROL SENSOR
(a) Replace the knock control sensor.(See page ES - 133, ES - 134.)

(b) Connect the DS-II to the DLC.
(c) Turn the ignition switch to the ON position, and delete the DTC
memory by following the prompts on the DS-II screen.
(d) Perform a road test.
GO
5 READ DTCs

Result
A B
Indicates P0325/52 Does not indicate P0325/52
B SYSTEM NORMAL
GETtheMANUALS.org
ENGINE REVOLUTION SENSOR SIGNAL

DTC P0335/13
SYSTEM
DESCRIPTION
The crank position sensor system consists of the crank angle sensor plate No.1 and the pickup coil. The crank angle sensor is
installed on the crankshaft. It has 30 teeth with 6 missing teeth to allow top dead center to be detected. The NE signal sensor
outputs 30 signals per engine revolution.The engine control computer detects the cylinder number and the relative position of the
camshaft and angle based on the N2 signal. It detects crankshaft angle and engine speed based on the N1 signal.

ES DTC No. 2.Malfunction Condition Suspected Area
3.Malfunction Time
4.Other
1. Cranking • Wire harness or connector
2. N1 signal is not input • Crank position sensor
P0335/13
3. 2 seconds or more • Crank angle sensor plate No.1
CIRCUIT DIAGRAM
Crankshaft Position Sensor

1 59
N1+
2 128
N1-
A133583J02
HINT:
• If the problem is not detected after first troubleshooting DTC P0335/13, this may indicate a mechanical system problem.
GETtheMANUALS.org
ES–67
1 CHECK ENGINE CONTROL COMPUTER
HINT:
The function of the engine control computer crank position sensor can be
checked using the oscilloscope function of the DS-II.
(a) Connect the DS-II to terminals 59 (N1+) and 128 (N1-) of the engine
control computer connectors.(For terminal layout, see page ES - 16.)
ES
N1+ N1-
A133549J06
(b) Set the DS-II to the oscilloscope function.
Item Condition
Tester connection N1+ ←→ N1-
Measurement condition While engine is idling
HINT:
• As engine speed increases, the amplitudes become larger.
• As engine speed increases, the cycles become shorter.
A134283
• DTCs may be recorded due to noise.

COMPUTER
NG
2 CHECK CRANK POSITION SENSOR

Crankshaft Position Sensor (1) Using a tester, measure the resistance between the connector
terminals.
Standard:
1630 to 2740 Ω (when cold)
2 1 2065 to 3225Ω (when warm)
NOTICE:
(-) (+) The terms, cold and warm, refer to the temperature of the
parts inspected.Cold is designated as a temperature
A133584J01 between -10 and 50°C. Warm is designated as a
temperature between 50 to 100 °C.
NG REPLACE CRANK POSITION SENSOR
OK
GETtheMANUALS.org
3 CHECK WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER CRANK POSITION
SENSOR)
(a) Disconnect the engine control computer connector B and the crank
the engine control computer and the crank position sensor.(For
Engine Control Computer terminal layout, see page ES - 16.)
Standard

ES Engine Control Computer ←→ Crank Standard
Position Sensor
59 (N1+) ←→ 1 (+) between other terminals and body
N1+ N1- ground
Crankshaft Position Sensor 128 (N1-) ←→ 2 (-) between other terminals and body
Vehicle Side Connector ground

CONNECTOR
(+) (-)
A133585J01
OK
(a) Check the tightness and installation condition of the crank position
sensor bolt.

INSTALLATION PART
OK
5 CHECK CRANK ANGLE SENSOR PLATE NO.1
(a) Check the concave and protruding parts of crank angle sensor plate
No.1 and check the installation condition.
NG REPAIR OR REPLACE CRANK ANGLE

SENSOR PLATE NO.1
OK
GETtheMANUALS.org
ES–69
DTC P0340/14 CAM ANGLE SENSOR SIGNAL SYSTEM

DESCRIPTION
The cam position sensor (N2 signal) consists of the pickup coil and the timing rotor that is mounted on the camshaft. When the
camshaft rotates, the relative positions of the protruding part of the timing rotor and the air gap on the top of the pickup coil
changes. This causes the magnetic field to change, generating electromotive force in the pickup coil.

3.Malfunction Time
1. When cranking
4.Other
ES
2. No input of a certain number of cam position sensor • Cam position sensor
P0340/14
3. - • Camshaft
CIRCUIT DIAGRAM
Camshaft Position
1 58
N2
2 12
N2
A133586J02
GETtheMANUALS.org
HINT:
• If the problem is not detected after first troubleshooting DTC P0340/14, this may indicate a mechanical system problem.
HINT:
The function of the engine control computer cam position sensors can be
ES checked using the oscilloscope function of the DS-II.

(a) Connect the DS-II to terminals 58(N2+) and 127 (N2-) of the engine
control computer connectors. (For terminal layout, see page ES - 16.)
N2+ N2-
A133549J07
(b) Set the DS-II to the oscilloscope function.
Item Condition
Tester Connection :N2+ ←→ N2-
Measurement condition While engine is idling
HINT:
• As engine speed increases, the amplitudes become larger.
• As engine speed increases, the cycles become shorter.
A134284
• DTCs may be recorded due to noise.

COMPUTER
NG
2 CHECK CAM POSITION SENSOR

(1) Using a tester, measure the resistance between the connector
terminals.
Camshaft Position Sensor
Standard:
835 to 1400 (when cold)
1060 to 1645 (when warm)
2 1 NOTICE:
The terms, cold and warm, refer to the temperature of the
parts inspected.Cold is designated as a temperature
(-) (+) between -10 and 50°C. Warm is designated as a
A105341J11
temperature between 50 to 100 °C.
NG REPLACE CAM POSITION SENSOR
GETtheMANUALS.org
ES–71
OK
3 CHECK WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER CAM POSITION
SENSOR)
(a) Disconnect the engine control computer connector B and the cam
Engine Control Computer the engine control computer and the cam position sensor.(For
Standard:
ES
Engine Control Computer ←→ Crank Standard
Position Sensor
58 (N2+) ←→ 1 (+) between other terminals and body
N2+ N2- ground
Camshaft Position Sensor 127 (N2-) ←→ 2 (-) between other terminals and body
Vehicle Side Connector ground

CONNECTOR
(+) (-)
A133587J01
OK
(a) Check the tightness and installation condition of the cam position
sensor bolt.

INSTALLATION PART
OK
5 Inspect camshaft
(a) Check the concave and protruding parts of the camshaft and check
the installation condition.
NG REPAIR OR REPLACE CAMSHAFT
OK
GETtheMANUALS.org
DTC P0350/16 IGNITION PRIMARY SYSTEM

DESCRIPTION
A direct ignition system has been adopted. Along with increasing ignition accuracy, the direct ignition system reduces high voltage
loss and enhances the overall reliability of the ignition system.The direct ignition system performs ignition, using 1 ignition coil for
each cylinder.The engine control computer determines the ignition timing and transmits ignition signals (IG) to each
cylinder.Based on the IG signals, the power transistor in the igniter cuts off the current in the primary coil. This generates
electromotive force in the secondary coil. The electromotive force in the secondary coil ignites the spark plug.
ES Battery
Ignition Coil Assembly No. 1
(N1 Signal) No. 1 Cylinder
Camshaft Position Sensor
(N2 Signal)
No. 2 Cylinder
Ingnition Coil Assembly No. 3
No. 3 Cylinder

Intake Pressure Sensor No. 4 Cylinder
Coolant Temperature
Sensor
Starter Signal
Neutral Start Switch
A133588

3.Malfunction Time
4.Other
1. At time of engine start and when engine is • Wire harness or connector
operating at 1500 r/min or less • IGNITION COIL ASSEMBLY
P0350/16 2. No IG signals continuously • Engine control computer
3. Approx. 30 seconds
4. 1 trip
GETtheMANUALS.org
ES–73
CIRCUIT DIAGRAM
Ignition Coil Assembly Engine Control Computer

(No. 1 Cylinder)
1 3 63
To IG2 Fuse IG1
4

(No. 2 Cylinder)
1 3 62
IG2 ES
4

(No. 3 Cylinder)
1 3 61
A9
IG3
4

(No. 4 Cylinder)
1 3 A8
60
IG4
A133589J01
HINT:
• The inspection method for the No.1 cylinder circuit is shown below. If the DTC P0350/16 is still shown after the test, check the
circuit of each cylinder.
1 CHECK WIRE HARNESS AND CONNECTOR (POWER SOURCE CIRCUIT CHECK)
(a) Disconnect the ignition coil assembly connector.

(c) Using a tester, check the voltage between terminals in the ignition coil
Ignition Coil Assembly assembly vehicle side connector.
Vehicle Side Connector Standard

1 (+B) ←→ 4 (GND) 9 to 14 V
NG CHECK POWER SOURCE CIRCUIT

+B GND
A109396J05
OK
GETtheMANUALS.org
2 CHECK WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER IGNITION COIL
ASSEMBLY)
(a) Disconnect the engine control computer connector A and ignition coil
assembly connector.
Engine Control Computer the engine control computer vehicle side connector and the ignition
coil assembly vehicle side connector. (For terminal layout, see page
ES - 16.)
Standard
ES Tester Connection (Terminal Symbol)
63 (IG1) ←→ 3 (IG1) between other terminals and body
IG1
ground
Ignition Coil Assembly NG REPAIR OR REPLACE WIRE HARNESS OR

CONNECTOR
IG1
A133590J01
OK
3 REPLACE IGNITION COIL ASSEMBLY
GO
4 CHECK FOR DTCs

(b) Read the DTCs by following the prompts on the screen.
Result
A B
P0350/16 Indicates a normal code
B SYSTEM RETURNS TO NORMAL
GETtheMANUALS.org
ES–75
DTC P0420/27 CATALYST DETERIORATION

DESCRIPTION
The rear O2 sensor detects oxygen levels after the catalyst. If the catalyst has deteriorated, the rear O2 sensor signal looks like
that of the front O2 sensor, repeating lean/rich signals in short cycles.Therefore, the timing of the voltage of the lean/rich signal
from the rear O2 sensor is calculated and compared to the lean/rich signal from the front 02 sensor. If this voltage exceeds a set
value, and the response of the rear O2 sensor from the front O2 sensor signal becomes more rapid than the set value, this
indicates that the catalyst has deteriorated. In this case, the DTC shown below will be recorded.

DTC No. 2.Malfunction Condition
3.Malfunction Time
Suspected Area
ES
4.Other
1. The vehicle is driven at a speed of 50 km/ • Exhaust system
h, after the engine is completely warmed- • Ignition system
up • Fuel system
P0420/27 2. The voltage of the rear O2 sensor signal • Engine control computer
is large, and the response is rapid • Wire harness or connector
4. 2 trip
CIRCUIT DIAGRAM
(See Page ES - 44)
1 INSPECT EMISSION CONTROL SYSTEM
HINT:
For inspection procedures, See page EC - 1.
NG REPAIR OR REPLACE EMISSION CONTROL

SYSTEM
OK
2 INSPECT FUEL INJECTOR ASSEMBLY (See page ES - 54)
OK
GETtheMANUALS.org

Standard

NOTICE:
ES Protect the terminal area from getting wet when checking
the sensor by applying water. Also, wipe the sensor dry
after the check.
Resistance NG REPLACE COOLANT TEMPERATURE

SENSOR
[kΩ]
Temperature [°C]
A050330
OK
HINT:
For inspection procedures, see page IG - 1.
OK
5 CHECK FUEL SYSTEM
HINT:
For inspection procedures, see page FU - 3.
OK
6 CHECK FOR EXHAUST GAS LEAKS
NG REPAIR OR REPLACE EXHAUST GAS

LEAKAGE AREA
OK
GETtheMANUALS.org
ES–77
7 READ DS-II DATA (RrO2 SENSOR OUTPUT VOLTAGE)

(b) Following the prompts on the DS-II screen, select ECU DATA
MONITOR, then RrO2 SENSOR OUTPUT VOLTAGE. Then select
MODE CHANGE and LINE GRAPH.
(c) Warm up oxygen sensor No.2 for approximately 90 seconds at an
(d) Read the voltage of the RrO2 sensor output while racing the engine
at a speed of 4000 r/min several times.
Result: ES
Voltage output is 0.4 V or less and 0.5 V or more
OK GO TO STEP 9
NG
8 CHECK WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER OXYGEN SENSOR
NO.2)
(a) Disconnect the engine control computer connector B and the

connector of oxygen sensor No.2.
Engine Control Computer the engine control computer and oxygen sensor No.2. (For terminal
Standard

Engine Control Computer ←→ Oxygen Standard
Sensor
18 (OX2) ←→ 3 (OX2) between the other terminals and
OX1 body ground
19 (E2) ←→ 4 (E2) between the other terminals and
Oxygen Sensor NO. 2 body ground
CONNECTOR
A133576J05
OK
REPLACE OXYGEN SENSOR NO.2
GETtheMANUALS.org
(c) To check the system, warm up the oxygen sensor No.2 by performing
a road test.
HINT:
Refer to the procedure for the oxygen sensor No.2 output voltage
inspection.
GO
10 READ DTCs
ES
Result
A B
P0420/27 is output again P0420/27 is not output again
GETtheMANUALS.org
ES–79
DTC P0443/76 EVAP PURGE VSV

DESCRIPTION
Evap purge VSV controls evaporation purge volume based on a signal (duty signal) from the engine control computer.Purge
volume is determined based on the ON/OFF time ratio (duty ratio).

3.Malfunction Time
4.Other
P0443/76
1.
2.
After engine start
Evap purge control signal malfunction
•
•
Evap purge VSV
Wire harness or connector
ES
3. VSV operates more than 3 times
4. 2 trip
CIRCUIT DIAGRAM
EVAP Purge VSV
To EFI Relay 2 1 16
PRG
A138379J01
GETtheMANUALS.org
1 INSPECT EVAP PURGE VSV
(a) Check the air-flow.

(1) Check for air-flow between the ports when voltage is applied to
Port the connector terminals.
Standard
Inspection Condition Air-flow

No current No air-flow
ES Current Air-flow
(b) Check the resistance.

A134303J01 (1) Using the tester, inspect the resistance between the terminals.
Standard:
30 to 34 Ω (20°C)
NG REPLACE EVAP PURGE VSV
OK
2 CHECK WIRE HARNESS AND CONNECTOR (POWER SOURCE VOLTAGE CHECK)
(a) Disconnect the connector of the evap purge VSV connector.

(c) Using a tester, measure the voltage between evap purge VSV vehicle
side connector terminal 2 (+) and the body ground.
Standard:
9 to 14 V
NG CHECK POWER SOURCE CIRCUIT
OK
3 CHECK WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER EVAP PURGE VSV)
(a) Disconnect connector A of the engine control computer and the

connector of the evap purge VSV.
the engine control computer vehicle side connector terminal 16
(PRG) and evap purge VSV vehicle side connector terminal 1 (-). (For
Standard:
There is continuity and no short between the other terminals
and body ground

CONNECTOR
OK
GETtheMANUALS.org
ES–81
DTC P0500/52 VEHICLE SPEED SIGNAL SYSTEM

DESCRIPTION
The vehicle speed signal is transmitted to the engine control computer via CAN communication.

3.Malfunction Time
4.Other
1. While driving (when slowing down and
• Combination meter
during fuel-cut)
P0500/52 2. Vehicle speed signal is not input
•
•
Speed sensor
Wire harness or connector
ES
4. 2 trip
CIRCUIT DIAGRAM

Combination Meter
21 9
CANH HCAN
22 8
CANL LCAN
A134898J01
1 READ DS-II DATA (VEHICLE SPEED)
(a) Make sure that the speedometer operates normally.

(c) Read the vehicle speed displayed on the DS-II.
Standard:
The DS-II and speedometer displays are identical.
NG
GETtheMANUALS.org
2 GO TO METER AND GAUGE SYSTEM
3 READ DTCs

ES following the prompts on the DS-II screen.

Standard

DTC P0500/52 is detected A
DTC P0500/52 is not detected B
REPAIR OR REPLACE ENGINE CONTROL COMPUTER
GETtheMANUALS.org
ES–83
DTC P0505/71 ISC VALVE SYSTEM

DESCRIPTION
The throttle body idle speed control valve assembly (ISCV) of the rotary solenoid type is installed on the throttle body. The intake
air that by-passes the throttle valve passes through the passage to the ISCV.
To control the idle speed, the engine control computer controls the intake air passage of the ISC valve and sends a signal to allow
the idle speed to be adjusted towards the target idling speed.
Throttle Valve
ES
Intake Air Surge Tank
Signal
Engine ECU
To Cylinder
ISC Valve
A050586

3.Malfunction Time
4.Other
1. While engine is idling
• ISCV
2. Short or open in ISCV circuit
4. 1 trip
GETtheMANUALS.org
CIRCUIT DIAGRAM

ISCV
2 1 65
To EFI Relay ISC
3
ES
A133591J01
HINT:
1 PERFORM DS-II ACTIVE TEST (ISC DUTY RATIO)
(a) Following the prompts on the DS-II screen , select ACTIVE TEST.
(b) Check that the engine speed changes when the ISC duty ratio is
changed.
Standard:
The engine speed increases or decreases in response to
changes in the ISC duty ratio.
NG
GETtheMANUALS.org
ES–85
2 CHECK THROTTLE BODY IDLE SPEED CONTROL VALVE ASSEMBLY (POWER SOURCE CIRCUIT)
(a) Disconnect the ISCV connector.

ISCV Vehicle Side Connector (c) Using a tester, measure the voltage of the ISCV vehicle side
connecter terminals.
Standard

2 (B) ←→ 3 (RSC) 9 to 14 V
RSO B RSC NG CHECK POWER SOURCE CIRCUIT

ES
A133868
OK
3 CHECK WIRE HARNESS OR CONNECTOR (ISC CIRCUIT)
(a) Disconnect the engine control computer connector A and ISCV

connector.
Engine Control Computer the engine control computer and the ISCV.(For terminal layout, see
page ES - 16.)
Standard

Standard
Engine Control Computer ←→ ISCV
65 (ISC) ←→ 1 (RSO) between the other terminals and
body ground
ISC

CONNECTOR
ISCV Vehicle Side Connector
RSO B RSC
A133869
OK
4 CHECK THROTTLE BODY IDLE SPEED CONTROL VALVE ASSEMBLY
NOTICE:
• Delete the DTCs after the inspection.
(a) Remove the ISCV.
(b) CHECK OPERATION
(1) Connect the wire harness to the removed ISCV.
GETtheMANUALS.org
(2) With the ignition in the ON position, check the operation of the
valve.
Standard:
Neutral (50% open) → Fully closed → Fully open →
Neutral (50% open)
HINT:
Operation should start within 0.5 seconds.
NG REPLACE THROTTLE BODY IDLE SPEED

CONTROL VALVE ASSEMBLY
OK
ES
GETtheMANUALS.org
ES–87
A/C EVAPORATOR TEMPERATURE SENSOR

DTC P0535/44
SIGNAL SYSTEM
DESCRIPTION
Cooler thermistor No.1 (evaporator rear sensor) is installed in the evaporator of the air conditioner unit. Cooler thermistor No.1
senses the temperature of the cooled air that has passed through the evaporator as a change in resistance. It outputs this change
in resistance to the engine control computer.

3.Malfunction Time
4.Other
ES
1. IG ON
2. Open or short in cooler thermistor No.1 (evaporator • Cooler thermistor No.1 (evaporator rear sensor)
P0535/44 rear sensor) circuit • Wire harness or connector
3. Continuously for 0.5 seconds or more • Engine control computer
4. 1 trip
CIRCUIT DIAGRAM

Cooler Thermistor NO. 1
(Post-EVAP Sensor)
1 45
ACEV
2 116
E21
A134276J01
1 CHECK COOLER THERMISTOR NO.1 (EVAPORATOR REAR SENSOR)
(a) Disconnect the connector of cooler thermistor No.1 (evaporator rear

sensor).
GETtheMANUALS.org
(b) Using a tester, check the resistance between terminals 1 and 2 of the
connector of cooler thermistor No.1 (evaporator rear sensor).
Standard
Temperature Standard
1
0°C 4.6 to 5.1 kΩ
15 °C 2.1 to 2.6 kΩ
2
NOTICE:
• If you touch the temperature sensor with your hand, you
A133916 body temperature will confuse the measurement.Therefore,
make sure to hold the connector side when performing the
ES measurements.
• Wait until the sensor adjusts to a stable ambient temperature
before performing the inspection.
NG REPLACE COOLER THERMISTOR NO.1

(EVAPORATOR REAR SENSOR)
OK
2 INSPECT WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER COOLER

THERMISTOR NO.1 [EVAPORATOR REAR SENSOR])
(a) Disconnect the engine control computer connector C and the

connector of cooler thermistor No.1.
the engine control computer vehicle side connector C and the
Engine Control Computer connector terminals of cooler thermistor No.1.(For terminal layout,
see page ES - 16.)
Standard

Engine Control Computer ←→
Standard
Cooler Thermistor No.1 (Evaporator
Rear Sensor)
ACEV E21
45 (ACEV) ←→ 1 (+) between the other terminals and
body ground
Cooler Thermistor No.1 There is continuity and no short
Vehicle Side Connector 116 (E21) ←→ 2 (-) between the other terminals and
body ground

CONNECTOR
(+)
(-)
A133915J01
OK
GETtheMANUALS.org
ES–89
ATMOSPHERIC PRESSURE SENSOR SIGNAL

DTC P1105/32
SYSTEM
DESCRIPTION
The atmospheric pressure sensor is built into the EFI ECU.

3.Malfunction Time
4.Other
1. After engine start
2. No signals from atmospheric pressure
ES
P1105/32 sensor • Engine control computer
3. 1 second or more
4. 1 trip
1 CLEAR DTCs.

(b) Delete the DTCs using the DS-II.
2 READ DTCs

(b) Read the DTCs using the DS-II.
Standard
Result Proceed to
DTC P1105/32 is detected A
DTC P1105/32 is not detected B
REPAIR OR REPLACE ENGINE CONTROL COMPUTER
GETtheMANUALS.org
DTC P1300/36 IONIC CURRENT SYSTEM

DESCRIPTION
This system detects engine misfires by using the fact that the ionic current generated by combustion pressure has an identical
waveform.If a misfire occurs, ionic current is not generated. Therefore, when the voltage transmitted to the engine control
computer is lower than specified, the engine control computer detects a misfire.If the detected ionic current is extremely weak it is
amplified by the igniter.
ES Engine Control Computer Battery
Ignition Coil Assembly No.1

( N1 Signal ) Ion Current Detection
Circuit
Camshaft Position
Sensor ( N2 Signal )
No. 1 Cylinder
Throttle Position
Sensor
No. 2 Cylinder
Intake Pressure Sensor
Coolant Temperature
Sensor Ignition Coil Assembly No. 3 No. 3 Cylinder
Starter Signal
Ignition Coil Assembly No.4. No. 4 Cylinder

Neutral Starter Switch
A135529

3.Malfunction Time
4.Other
1. Engine is warmed up and running • IGNITION COIL ASSEMBLY
2. ICMB signal is not input (continuously • Fuel system
P1300/36 input) • Ignition system
3. Approx.30 seconds • Wire harness or connector
GETtheMANUALS.org
ES–91
CIRCUIT DIAGRAM

( No. 1 Cylinder ) Engine Control Computer
1 3 A11
To E/G Fuse IG1
4 2 B11
ICMB1

( No. 2 Cylinder )
1 3 A10
IG2 ES
4 2 B10
ICMB2

( No. 3 Cylinder)
1 3 A9
IG3
4 2 B9
ICMB3

( No. 4 Cylinder)
1 3 A8
IG4
4 2 B8
ICMB4
A135526
HINT:
• The inspection method for the No.1 cylinder circuit is shown below. If the DTC P1300/36 is still shown after the test, check the
circuit of each cylinder.
1 INSPECT IGNITION SYSTEM
(See page IG - 1)
OK
2 CHECK ENGINE CONTROL COMPUTER (IG SYSTEM)
HINT:
The communication between the engine control computer and the ignition
coil assembly can be checked using the oscilloscope function of the DS-II.
GETtheMANUALS.org
(a) CHECK OUTPUT WAVEFORM

(1) Connect the DS-II between the terminals of the engine control
computer and set the DS-II to the oscilloscope function.
Tester Connection IG1, IG2, IG3, IG4 ←→ E1

Measurement Condition Engine is warmed up and idling
HINT:
A134282 becomes shorter.
ES include noise or chattering waveforms.
NG REPLACE ENGINE CONTROL COMPUTER
OK
3 CHECK WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER IGNITION COIL)
(a) Disconnect engine control computer connectors A and B and the

ignition coil assembly connector.
the engine control computer vehicle side connector and the ignition
coil assembly vehicle side connector.(For terminal layout, See page
ES - 16)
Standard

63 (IG1) ←→ 3 (IG1) between the other terminals and
body ground
IG1 ICMB1 There is continuity and no short

51 (ICMB1) ←→ 2 (ION) between the other terminals and
Ignition Coil Assembly body ground

CONNECTOR
ION IG1
A135525
OK
(a) Disconnect the ignition coil assembly connector.

GETtheMANUALS.org
ES–93
(c) Using a tester, check the voltage between the terminals in the ignition
Ignition Coil Assembly coil assembly vehicle side connector.

1 (+B) ←→ 4 (GND) 9 to 14 V
NG REPAIR OR REPLACE POWER SOURCE

+B GND
SYSTEM
A109396J05
OK ES
5 CHECK ENGINE CONTROL COMPUTER (ICBM)
HINT:
The communication between the engine control computer and the ignition
coil assembly can be checked using the oscilloscope function of the DS-II.
(a) CHECK OUTPUT WAVEFORM
(1) Connect the DS-II between the terminals of the engine control
computer and set the DS-II to the oscilloscope function.
CH1: IG1, IG2, IG3, IG4 ←→ E1

Tester Connection
1 CH2: ICMB1, ICMB2, ICMB3, ICMB4
Engine is warmed up and idling, coolant
2
Measurement Condition temperature is 80°C or higher, air
conditioner is ON
A140669
HINT:
• The output waveform (CH2) of the ionic current combustion
control signal generated between the output waveform of
the ignition signal is the ionic current combustion control
signal of cylinder #4 when cylinder #1 is inspected. (When
cylinder #2 is inspected, cylinder #3).
NG REPLACE IGNITION COIL
OK
TO FUEL SYSTEM
GETtheMANUALS.org
DTC P01346/75 VVT CONTROL SYSTEM (VALVE TIMING FAIL)

DESCRIPTION
The VVT system controls the open/close timing of the air intake valve to achieve the appropriate timing in accordance with
vehicle operating conditions.The engine control computer controls the camshaft and camshaft oil control valves in order to
properly adjust the open/close timing of the air intake valve, and changes the relative position between the camshaft and
crankshaft by operating the camshaft timing gear assembly.

ES 3.Malfunction Time
4.Other
1. While engine is running
• Mechanical system malfunction (timing chain jumped
2. Valve timing deviation (cannot achieve targeted valve
a tooth or chain stretched)
P1346/18 timing)
• VALVE TIMING
• ENGINE CONTROL COMPUTER
4. 2 trip
1 CHECK VALVE TIMING
Standard:
See the illustration.
NG ADJUST VALVE TIMING
Timing Marks
Notch
A138143J01
OK
GETtheMANUALS.org
ES–95
VVT CONTROL (ADVANCE ANGLE AND

DTC P1349/73
RETARD ANGLE FAIL)
DESCRIPTION
vehicle operating conditions.The engine control computer controls the camshaft and camshaft oil control valve assembly in order
to properly adjust the open/close timing of the air intake valve, and changes the relative position between the camshaft and

DTC No. 2.Malfunction Condition Suspected Area ES
3.Malfunction Time
4.Other
1. Engine speed of 500 to 4000 r/min, and coolant • VALVE TIMING
temperature between 80 to 110°C • CAMSHAFT TIMING OIL CONTROL VALVE
2. Cannot achieve valve timing within ±5°of target, or valve ASSEMBLY
P1349/59
timing is fixed, does not vary • CAMSHAFT TIMING GEAR ASSEMBLY
3. 5 seconds or more • VVT SYSTEM OIL PATH
CIRCUIT DIAGRAM

Camshaft Timing Oil Control
Valve Assembly
1 26
OCV+
2 25
OCV-
G100100J14
HINT:
Read the freeze frame data using the DS-II. Freeze frame data records aspects of the engine's condition when malfunctions
1 READ DTCs

(c) Perform a road test.
(d) Check for DTCs following the prompts on the DS-II screen.
(1) Check if DTC P1349/73 is output.
Result:
GETtheMANUALS.org
A B
ES Standard:
Timing Marks
Notch
A138143J01
OK
3 CHECK CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(1) Using a tester, measure the resistance between the terminals.
Standard:
6.9 to 7.9 (20°C)
GETtheMANUALS.org
ES–97
(b) CHECK OPERATION

(1) Apply battery voltage across the terminals, then check that the
spool valve operates.
(+) (-) NOTICE:
Make sure the spool valve is not stuck.
HINT:
If the spool valve does not return due to foreign matter like
sludge, the pressure may leak slightly toward the advanced
side. This leakage may cause DTCs to be recorded.
View of A NG REPLACE CAMSHAFT TIMING OIL

A
ES
A133914
OK
4 CHECK CAMSHAFT TIMING GEAR ASSEMBLY
(a) Make sure that the camshaft timing gear assembly is not damaged.
NG REPLACE CAMSHAFT TIMING GEAR

ASSEMBLY
OK
5 CHECK OIL CONTROL VALVE FILTER
(a) Check that the oil control valve filter is not blocked.
Standard:
There is no blockage or foreign matter.
NG REPLACE OIL CONTROL VALVE FILTER
Mesh Portion
A079997
OK
6 READ DTCs

(c) Perform a road test.
GETtheMANUALS.org
(d) Check for DTCs following the prompts on the DS-II screen.
(1) Check if DTC P1349/73 is output.
Result:
A B
ES
GETtheMANUALS.org
ES–99
DTC P1351/62 TIMING CHAIN CONTROL SYSTEM

DESCRIPTION
vehicle operating conditions. The engine control computer controls the camshaft and the camshaft timing oil control valve in order
to properly adjust the open/close timing of the air intake valve, and changes the relative position between the camshaft and

3.Malfunction Time
4.Other
ES
1. While engine is running • Mechanical system malfunction (timing
2. Valve timing deviation chain jumped a tooth or chain stretched)
P1351/62
3. 5 seconds or more • VALVE TIMING
Standard:
Timing Marks
Notch
A138143J01
OK
REPLACE CHAIN
GETtheMANUALS.org
DTC P1510/54 STARTER SIGNAL SYSTEM

DESCRIPTION
The starter operation signal is transmitted to the STSW terminal of the engine control computer while the engine cranks.The
starter operating signal is used primarily for increasing fuel injection volume when the engine starts.

3.Malfunction Time
4.Other
ES 1. After engine start

2. There are no ON signals even when
engine speed reaches a set value at a • Wire harness or connector
P1510/54
vehicle speed of 0 km/h • Engine control computer
3. -
4. 1 trip *
* : 2 trip for EU specifications.
GETtheMANUALS.org
ES–101
CIRCUIT DIAGRAM
Ignition Switch
5 1
Starter Relay ES
3 2
S
10
AM STS
MAI
Transmission Control Computer
Starter
A133870J02
HINT:
This diagnosis procedure assumes that the engine is not malfunctioning and can be cranked with the starter. If the engine cannot
be cranked, determine the suspected area using a problem symptoms table. (See page ES - 4)
SST 09842-97209
control computer.
GETtheMANUALS.org
(c) Using a tester, measure the voltage between terminals D26 (STSW)
and B32 (E1) of the engine control computer connector. (For terminal
Standard:
10 to 14 V

COMPUTER
E1 STSW
A133549J16
ES NG
2 CHECK WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER STARTER RELAY)
(a) Disconnect the engine control computer connector D.

(b) Remove the starter relay.
(c) Using a tester, check whether there is continuity or a short between
Engine Control Computer the engine control computer and the starter relay block holder
terminal. (For terminal layout, see page ES - 16.)
Standard

Engine Control Computer ←→ Relay
Standard
Block Holder For Installing Starter
Relay
107 (STSW) ←→ 4 between the other terminals and
STSW body ground
NOTICE:
When applying the tester probe to the holder during inspection,
be careful not to damage the holder part by pressing it too hard.
2
5 3
1
CONNECTOR
A133871J01
OK
CHECK AND REPAIR POWER SOURCE SYSTEM
GETtheMANUALS.org
ES–103
DTC P1560/61 SHORT TO BACK UP POWER SOURCE

DESCRIPTION
Even when the ignition switch is turned off, battery power is supplied to the BAT terminal of the engine control computer. This
power is used for recording DTC or data when malfunctions occur.

3.Malfunction Time
4.Other
1. Ignition is in ON position (battery voltage
exceeds 10 V) • Engine control computer ES
P1560/61 2. Open to back-up power source circuit • Wire harness or connector
3. - • EFI fuse
4. 3 trip
CIRCUIT DIAGRAM
MAIN EFI
C7
38
BAT
B32
125
E1
Battery
A133908J01
SST 09842-97209
control computer.
GETtheMANUALS.org
(b) Measure the voltage between the engine control computer terminals
using a tester. (For terminal layout, see page ES - 16.)
Engine Control Computer Standard

38 (BATT) ←→ 125 (E1) 10 to 14 V

E1 BAT
A133549J08
ES NG
2 CHECK FUSE (EFI FUSE)
(a) Remove the EFI fuse from the inside of the engine room R/B.
Engine Room R/B (b) Using a tester, check the EFI fuse for continuity.
Standard:
Continuity
NG REPLACE FUSES
EFI Fuse
A133909J01
OK
CHECK OR REPLACE ENGINE ECU POWER CIRCUIT
GETtheMANUALS.org
ES–105
KEYLESS SYSTEM / IMMOBILISER SYSTEM

DTC P1600/83 COMMUNICATION SYSTEM (MALFUNCTION IN
ECU)
DESCRIPTION
The transponder key computer assembly (immobiliser ECU) ensures security by controlling the START/END of the
communication of matching codes with the engine control computer. It does so in accordance with ignition ON/OFF status and the
immobiliser SET/UNSET status. If the communication cannot be matched due to a malfunction in the engine control computer, a
DTC is recorded.

ES
3.Malfunction Time
4.Other
1. IG ON
2. Communication stopped with immobiliser
P1600/83 ECU • Engine control computer
3. 1 second or more
4. 1 trip
1 READ DTCs

HINT:
If P1600/83 is detected, this indicates that the engine computer is
malfunctioning. Replace the engine control computer.
GETtheMANUALS.org
KEYLESS / IMMOBILISER SYSTEM

DTC P1601/81 COMMUNICATION SYSTEM (CODE DOES NOT
MATCH, COMMUNICATION ERROR)
DESCRIPTION
The transponder key computer assembly (immobiliser ECU) ensures security by controlling the START/END of the
communication of matching codes with the engine control computer. It does so in accordance with the ignition ON/OFF status and
the immobiliser SET/UNSET status.
ES DTC No.
2.Malfunction Condition Suspected Area
3.Malfunction Time
4.Other
1. IG ON
2. Communication problem with transponder • TRANSPONDER KEY COMPUTER
key computer assembly (immobiliser ASSEMBLY (IMMOBILISER ECU)
P1601/81
ECU) or code mismatch • Engine control computer
3. 1 second or more • Wire harness or connector
4. 1 trip
CIRCUIT DIAGRAM
Smart ECU
9 117
SIO2 SIO2
A133872J02
1 READ DTCs

GETtheMANUALS.org
ES–107
Standard:
DTC P1601/81 is not output
NG
(a) Disconnect the engine control computer connector C and the

immobiliser ECU connector.
the engine control computer vehicle side connector and the
ES
immobiliser ECU vehicle side connector. (For terminal layout, see
page ES - 16.)
Standard

Engine Control Computer ←→ Smart Standard
ECU
There is continuity and no shorts
117 (SIO2) ←→ 8 (SIO2) between other terminals and body
ground
SIO2
Connector C
Transponder Key Computer Assembly
CONNECTOR
SIO2
B143232J01
OK
3 RE-REGISTRATION (ENGINE CONTROL COMPUTER IMMOBILISER ECU

(b) Delete the DTCs using the DS-II.
(c) Register the matching codes for the engine control computer and
immobiliser ECU.
(d) Turn the ignition switch to the ON position, and read the DTCs by
Standard:
OK SYSTEM RETURNS TO NORMAL
NG
4 REPLACE ENGINE CONTROL COMPUTER
(a) Replace with a new or a known-good engine control computer.
GETtheMANUALS.org
(b) After replacing the engine control computer, register the keys, turn
the ignition switch to the ON position, then read the DTCs.
Standard:
OK SYSTEM RETURNS TO NORMAL
NG
REPLACE TRANSPONDER KEY COMPUTER ASSEMBLY
ES
GETtheMANUALS.org
ES–109
DTC P1656/74 OCV CONTROL SYSTEM

DESCRIPTION
(See ES - 95)

DTC No. 2.Malfunction Condition Trouble Area
3.Malfunction Time
4.Other
1. IG ON
2. Short or open to camshaft timing oil control valve • Wire harness or connector
P1656/39 assembly and circuit • Camshaft timing oil control valve assembly ES
3. 1 second or more • Engine control computer
4. 1 trip
CIRCUIT DIAGRAM
(See ES - 95)
HINT:
1 CHECK CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(1) Using a tester, measure the resistance between the terminals.
Standard:
6.9 to 7.9 (20°C)
(b) Check operation.
(1) Apply battery voltage across the terminals, then check that the
spool valve operates.
(+) (-) NOTICE:
HINT:
sludge, the pressure may leak slightly toward the advanced
side. This leakage may cause DTCs to be recorded.
View of A NG REPLACE CAMSHAFT TIMING OIL

A
A133914
OK
2 CHECK WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER CAMSHAFT TIMING
OIL CONTROL VALVE ASSEMBLY)
(a) Disconnect the engine control computer connector A and the

connector of the camshaft timing oil control valve assembly.
GETtheMANUALS.org

Engine Control Computer the engine control computer and the camshaft timing oil control valve
assembly.(For terminal layout, see page ES - 16.)
Standard

Engine Control Computer ←→
Standard
Camshaft Timing Oil Control Valve
Assembly
26 (OCV+) ←→ 1 (+) between the other terminals and
body ground
OCV-
ES OCV+
25 (OCV-) ←→ 2 (-) between the other terminals and
Oil Control Valve body ground
CONNECTOR
A103589J02
OK
HINT:
The communication between the engine control computer and the cam
shaft oil control valves can be checked using the oscilloscope function of
the DS-II.
(a) Connect the DS-II between terminals 26 (OCV+) and 25 (OCV-) of
the engine control computer connector. (For terminal layout, see page
Engine Control Computer ES - 16.)
OCV+ OCV-
A103583J06
(b) Set the DS-II to the oscilloscope function. (See the DS-II instruction
manual for the setting procedures.)
Item Condition
Tester Connection OCV+ ←→ OCV-
Measurement Condition While engine is idling
HINT:
As the engine speed increases, the waveform cycle becomes shorter.
A134292

COMPUTER
GETtheMANUALS.org
ES–111
OK
ES
GETtheMANUALS.org
DTC U0101/82 EAT / CVT COMMUNICATION (RECEPTION)
DTC U0121/86 ABC COMMUNICATION (RECEPTION)
DTC U0156/87 METER COMMUNICATION (RECEPTION)
DTC U1000/85 EAT COMMUNICATION (TRANSMISSION)
ES DTC U1002/88 CAN COMMUNICATION

DESCRIPTION
Via CAN communication. the engine control computer sends and receives signals to and from the transmission control computer,
the skid control computer and the combination meter.

3.Malfunction Time
4.Other
1. IG ON
2. CANH, CANL open or transmission
U0101/82 control computer malfunction
• Transmission control computer
3. 1 second
4. 1 trip
1. IG ON
2. CANH, CANL open
U0121/86 • Wire harness or connector
3. 1 second
4. 1 trip
1. IG ON
2. HCAN, LCAN open
3. 1 second
4. 1 trip
1. IG ON
2. CANH, CANL open or transmission
U1000/85 control computer malfunction • Wire harness or connector
3. 1 second
4. 1 trip
1. IG ON
2. CANH, CANL open or short
3. 1 second
4. 1 trip
GETtheMANUALS.org
ES–113
CIRCUIT DIAGRAM
Combination Meter
ES
CANH CANL
CANH CANL
Actuator Assembly
CAN J/C
CANH CANL CANH CANL
CANH CANL
HCAN HCAN
LCAN LCAN
Engine Control Transmission Control

Computer Computer
A138315J01
1 READ DTCs
(a) Record the output DTCs.

HINT:
When CAN communication DTCs and related sensor DTCs are
detected at the same time, troubleshoot the sensor DTCs after CAN
communication has returned to its normal status.
GETtheMANUALS.org
GO TO TROUBLESHOOTING FOR CAN COMMUNICATION SYSTEM
ES
GETtheMANUALS.org
ES–115
FUEL PUMP CONTROL SYSTEM

DESCRIPTION
While the engine cranks, current flows from the ST terminal of the ignition switch to the starter relay coil, and from the ST terminal
to the STSW terminal (STSW signal) of the engine control computer. When the STSW signal and N1 signal are input to the
engine control computer, current flows to the fuel pump relay coil via an internal transistor. This turns the relay switch turns ON.
The fuel pump receives current and operates. While N1 is input (with the engine running), the fuel pump continues to operate
because the transistor switch inside the engine control computer remains ON (F/P relay ON).
CIRCUIT DIAGRAM
ES

F/P Relay
E/G
35
FC1*
M Fuel Pump
Ignition Switch
EFI Relay
39
MRO
AM2 EFI
From Starter Circuit
STSW
MAIN N1+
From Crankshaft Sensor
N1-
Battery
* : FAN 2 For Europe

A138423J01
GETtheMANUALS.org
1 PERFORM DS-II ACTIVE TEST (FUEL PUMP)
(a) Following the prompts on the DS-II screen, select the active test
mode .
(b) Turn the ignition switch to the ON position, and perform the active test
with the engine stopped.
Standard:
ES Fuel pump operates.
NG GO TO STEP 7
OK
2 CHECK ECU POWER SUPPLY SYSTEM
NG CHECK, REPAIR OR REPLACE ECU POWER

SOURCE SYSTEM
OK
3 CHECK FUEL PUMP RELAY
(a) Check for continuity.

(1) Using a tester, inspect the resistance between the terminals.
Standard
Terminals Continuity
1←→2 Continuity
3←→5 No continuity
(2) Using a tester, make sure that there is continuity between

terminals 3 and 5 when battery voltage is applied between
A133875 terminals 1 and 2.
Standard:
Continuity
NG REPLACE FUEL PUMP RELAY
OK
GETtheMANUALS.org
ES–117
4 CHECK EFI RELAY

Standard
1←→2 Continuity

terminals 3 and 5 when battery voltage is applied between ES
A133875 terminals 1 and 2.
Standard:
Continuity
NG REPLACE EFI RELAY
OK
5 CHECK WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER F/P RELAY)
(a) Disconnect the engine control computer connector D.

(b) Remove F/P relay.
(c) Using a tester, check for the continuity and short between the engine
control computer and the relay block holder for the fuel pump relay.
Engine Control Computer (For terminal layout, see page ES - 16.)
Standard:

Engine control computer ←→ Relay Standard
block holder for F/P relay
Continuity and no short between
35 (FC1*) ←→ 3 terminal
other terminals and body ground
FC
(FAN 2 For Europe)
*: FAN2 for European spec.
NOTICE:
Be careful not to damage the holder part by pressing it too hard,
when inspecting by applying the tester probe to the holder.

CONNECTOR
2
5 3
1
A133876J02
OK
6 CHECK WIRING HARNESS OR CONNECTOR
(a) Remove EFI fuse, E/G fuse and relay (fuel pump relay, EFI relay).
(b) Using a tester, check for the continuity and short between terminals of
each socket.
GETtheMANUALS.org
Standard:

Continuity and no short between other terminals and body
F/P relay 2 terminal ←→ EFI relay 4 terminal
ground
F/P relay 1 terminal ←→ E/G fuse 2 terminal
ground
EFI relay 2 terminal ←→ EFI fuse 2 terminal
ground
EFI relay 1 terminal ←→ EFI fuse 2 terminal
ground
ES NOTICE:
Be careful not to damage the holder part by pressing it too hard,
when inspecting by applying the tester probe to the holder.

CONNECTOR
OK
7 CHECK FUEL PUMP
(a) CHECK RESISTANCE

(1) Using a tester, measure the resistance between terminal 3 (+)
and 4 (-) of the fuel pump connector.
E Reference Value:
0.2 to 3.0 Ω (20 °C)
2 1 (b) CHECK OPERATION
4 3 (1) Apply the battery voltage between terminal 3 (+) and 4 (-) of the
fuel pump connector, and check the motor rotates.
NOTICE:
A134990 • Perform the check for a very short time (less than 10
seconds)
• Keep the pump as far away from the battery as
possible.
• Make sure to perform the switching on the battery
terminal side.
NG REPLACE FUEL PUMP
OK
8 CHECK WIRE HARNESS OR CONNECTOR (BETWEEN EFI CIRCUIT OPENNING RELAY AND FUEL
PUMP)
(a) Disconnect the connector of fuel pump.

(b) Remove F/P relay.
GETtheMANUALS.org
ES–119
(c) Using a tester, check for the continuity and short between relay block
holder for F/P relay and fuel pump, and between fuel pump and body
Fuel Pump Relay
ground.
Standard
E
Tester Connection
Relay Block Holder For EFI Relay ←→ Standard
1 2 Fuel Pump
3 4 There is continuity and no short

3←→3(+) between the other terminals and
body ground
Tester Connection
Fuel Pump ←→ Body Ground
Standard
ES
4 (-) ←→ Body ground Continuity
NOTICE:
When applying the tester probe to the holder during inspection,
2 be careful not to damage the holder part by pressing it too hard.
5 3
1
CONNECTOR
A138316J01
OK
GO TO RELEVANT CIRCUIT INSPECTION SPECIFIED IN PROBLEM SYMPTOMS TABLE
GETtheMANUALS.org
ECU POWER SOURCE SYSTEM

DESCRIPTION
When the ignition switch is ON, current from the battery flows to the EFI relay coil, causing the EFI relay connection to close.
Power is then supplied to the +B terminal of the engine control computer.
CIRCUIT DIAGRAM

ES E/G
120
IGSW
Ignition Switch
EFI Relay
27
+B
39
MRO
AM2 EFI
MAIN
125
E1
Battery
A138424
1 CHECK ENGINE CONTROL COMPUTER (CHECK VOLTAGE)
SST 09842-97209
control computer.
GETtheMANUALS.org
ES–121

(c) Measure the voltage between the terminals of the engine control
Engine Control Computer computer connector using a tester.(For terminal layout, see page ES -
16.)
Standard
27 (+B) ←→ 125 (E1) 10 to 14V
+B E1 OK CHECK AND REPLACE ENGINE CONTROL

A133549J09
COMPUTER
NG ES
2 CHECK WIRE HARNESS OR CONNECTOR (ECU GROUND)
(a) Disconnect the negative battery terminal.

Engine Control Computer (b) Disconnect connector B of the engine control computer.
(c) Measure the voltage between the engine control computer and the
body ground using the tester. (For terminal layout, see page ES - 16.)
Standard
125 (E1) ←→ Body ground Continuity
E1 NG REPAIR OR REPLACE WIRE HARNESS OR

A133911J01
CONNECTOR
OK
SST 09842-97209
control computer.
Engine Control Computer computer connector using a tester. (For terminal layout, see page ES
- 16.)
Standard
120 (IGSW) ←→ 125 (E1) 9 to 14 V
E1 IGSW
OK GO TO STEP 7
A133549J10
NG
GETtheMANUALS.org
4 INSPECT FUSE (E/G)
(a) Remove the E/G fuse, and check for continuity using a tester.
Standard:
Continuity
NG CHECK ALL WIRE HARNESSES AND

E/G Fuse DEVICES CONNECTED TO IGN FUSE
ES
A133912J01
OK
5 INSPECT FUSE (AM2)
(a) Remove the AM2 fuse, and check for continuity using a tester.
Standard:
Engine Room R/B
Continuity

DEVICES CONNECTED TO AM2 FUSE
AM2 Fuse
A134899J01
OK
GETtheMANUALS.org
ES–123
6 INSPECTION OF IGNITION (STARTER) SWITCH ASSEMBLY

(1) Using the tester, check the continuity between each of the
Standard
Switch Terminal No. Standard
LOCK - No continuity
ACC Terminal 1 ←→ Terminal 3 Continuity
Terminal 1 ←→ terminal 2 ←→
ON terminal 3, terminal 5 ←→ terminal Continuity ES
6
Terminal 1 ←→ terminal 2, terminal
START Continuity
4 ←→ terminal 5 ←→ terminal 6
NG REPLACE IGNITION (STARTER) SWITCH

ASSEMBLY
B059612
OK
SST 09842-97209
control computer.
Engine Control Computer computer connector using a tester. (For terminal layout, see page ES
- 16.)
Standard
39 (MRO) ←→ 125 (E1) 9 to 14 V
E1 MRO
A133549J13
COMPUTER
OK
GETtheMANUALS.org
8 INSPECT FUSE (EFI)
(a) Remove the EFI fuse from the engine room R/B, and check for
Engine Room R/B continuity using a tester.
Standard:
Continuity

DEVICES CONNECTED TO EFI FUSE
ES EFI Fuse
A133909J01
OK
9 CHECK EFI COMPUTER RELAY

Standard
1←→2 Continuity

terminals 3 and 5 when battery voltage is applied between
terminals 1 and 2.
A133875
Standard:
Continuity
NG REPLACE EFI COMPUTER RELAY
OK
10 CHECK WIRE HARNESS OR CONNECTOR (BETWEEN MRO AND GROUND)

Engine Control Computer (b) Disconnect connector C of the engine control computer.
(c) Measure the continuity between the engine control computer terminal
and the body ground using the tester. (For terminal layout, see page
ES - 16.)
Standard
39 (MRO) ←→ Body ground Continuity
MRO
A133913J01 NG REPAIR OR REPLACE WIRE HARNESS OR
CONNECTOR
OK
GETtheMANUALS.org
ENGINE CONTROL - THROTTLE BODY ASSEMBLY (3SZ-VE)
ES–125
THROTTLE BODY ASSEMBLY (3SZ-VE)

ENGINE CONTROL
COMPONENTS
ACCELERATOR CONTROL
T=3.5{36} BATTERY CLAMP
CABLE ASSEMBLY
BATTERY
T=8.5{87}
ES
×3
BATTERY CARRIER
ENGINE UNDER COVER
×11
T=5.4{55}
TIGHTENING TORQUE [N*m{kgf*cm}]

A137009J01
GETtheMANUALS.org
ES–126 ENGINE CONTROL - THROTTLE BODY ASSEMBLY (3SZ-VE)
AIR CLEANER ASSEMBLY
T=7.5{76}
ES COOLANT BYPASS
HOSE NO. 2 ×2
O-RING T=18{184}
COOLANT T=7.5{76}
BYPASS HOSE T=7.5{76}
T=21{214}
×2
AIR CLEANER HOSE NO. 1

O-RING
THROTTLE BODY
ASSEMBLY T=7.5{76}
×2
VENTILATION HOSE NO. 2
THROTTLE BODY
BRACKET NO. 2
TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PART

A137008J02
GETtheMANUALS.org
ES–127
REMOVAL
1. DISCONNECT NEGATIVE BATTERY TERMINAL
(See page RS-164.)
2. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT (See page CO-9)
4. REMOVE AIR CLEANER HOSE NO.1 (See page CO-15)
5. REMOVE AIR CLEANER ASSEMBLY (See page EM-146)
6. DISCONNECT ACCELERATOR CONTROL CABLE ASSEMBLY

(See page EM-147)
ES
7. REMOVE VENTILATION HOSE NO.2 (See page EM-147)
8. DISCONNECT WATER BY-PASS HOSE
Blue Paint (a) Disengage the clamps and disconnect the water by-pass hose.
A131806
9. DISCONNECT WATER BY-PASS HOSE NO.2

Red Paint
(a) Disengage the clamps and disconnect water by-pass hose
No.2.
A134985
10. REMOVE THROTTLE BODY ASSEMBLY

(a) Disconnect the connector of the throttle body assembly and the
ISC Connector
wire harness clamps.
Throttle Sensor Connector

A136086
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ES–128 ENGINE CONTROL - THROTTLE BODY ASSEMBLY (3SZ-VE)
(b) Remove the 2 bolts and throttle body bracket No.2.

(c) Remove the 3 bolts and the throttle body assembly.
(d) Remove the O-rings.
A131805
ES
INSTALLATION
1. INSTALL THROTTLE BODY ASSEMBLY
(a) Install a new O-ring.
(b) Install the throttle body assembly with the 3 bolts.
Torque: 21 N*m (214 kgf*cm) Throttle body bracket side
7.5 N*m (77 kgf*cm) Intake manifold side
(c) Install throttle body bracket No.2 with the 2 bolts.
Torque: 7.5 N*m (76 kgf*cm)
A131805
(d) Connect the connectors to the throttle body assembly.
ISC Connector
Throttle Sensor Connector

A136086
2. CONNECT WATER BY-PASS HOSE

Red Paint
(a) Connect the water by-pass hose and install the clamp.
A134985
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ES–129
3. CONNECT WATER BY-PASS HOSE NO.2

Blue Paint (a) Connect water by-pass hose No.2 and install the clamp.
4. INSTALL VENTILATION HOSE NO.2 (See page EM-166)
5. INSTALL ACCELERATOR CONTROL CABLE ASSEMBLY (See

page EM-165)
6. INSTALL AIR CLEANER ASSEMBLY (See page EM-167)
7. INSTALL AIR CLEANER HOSE NO.1 (See page CO-19)

A131806 8. ADD COOLANT (See page CO-9)
9. CHECK FOR COOLANT LEAKS (See page CO-10)
10. INSTALL ENGINE UNDER COVER (See page EM-69)

ES
11. CONNECT NEGATIVE BATTERY TERMINAL
12. PERFORM INTIALIZATION

(See page SS-10.)
INSPECTION
1. INSPECT THROTTLE BODY ASSEMBLY
(a) Check that the throttle shaft is not loose.
(b) Check that none of the ports is clogged.
(c) Check that the throttle valve can open and close smoothly.
(d) Check that there is no clearance between the throttle stop
screw and the lever when the throttle valve is fully open.
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ES–130 ENGINE CONTROL - KNOCK CONTROL SENSOR (3SZ-VE)
KNOCK CONTROL SENSOR (3SZ-VE)

ENGINE CONTROL
COMPONENTS
ACCELERATOR CONTROL
T=3.5{36} BATTERY CLAMP
CABLE ASSEMBLY
BATTERY
ES T=8.5{87} ×3
BATTERY CARRIER
ENGINE UNDER COVER
×11
T=5.4{55}

A137009J01
GETtheMANUALS.org
ENGINE CONTROL - KNOCK CONTROL SENSOR (3SZ-VE)
ES–131
T=7.5{76}
COOLANT PIPE HOSE NO. 2 ×2
O-RING T=18{184}
ES
T=7.5{76}
T=7.5{76} AIR CLEANER
COOLANT PIPE HOSE ×2
T=21{214} HOSE NO. 1
×2 T=7.5{76}
×2
THROTTLE BODY GASKET

THROTTLE BODY
O-RING
T=19{194} GASKET NO. 2
×2 T=19{194}
×3 T=21{214}
VACUUM HOSE ×2
ASSEMBLY OIL LEVEL GAUGE GUIDE
INTAKE MANIFOLD TO T=8.5{87}

INTAKE MANIFOLD HEAD GASKET NO. 1
VENTILATION HOSE
O-RING

A137017J01
GETtheMANUALS.org
FUEL DELIVERY PIPE
T=21{214}
ES FUEL HOSE NO. 1

×2
×4
×4 O-RING
×4
INJECTOR VIBRATION
INSULATOR
T=20{204}

A137018J01
GETtheMANUALS.org
ENGINE CONTROL - KNOCK CONTROL SENSOR (3SZ-VE)
ES–133
REMOVAL
(See Page RS-164)
3. DISCHARGE FUEL SYSTEM PRESSURE (See page EM-146)
4. REMOVE BATTERY
5. REMOVE BATTERY CARRIER (See page EM-146)
7. REMOVE AIR CLEANER HOSE NO.1 (See page CO-15) ES


(See page EM-147)
10. REMOVE VENTILATION HOSE (See page EM-147)
11. REMOVE VENTILATION HOSE NO.2 (See page EM-147)
12. DISCONNECT FUEL HOSE NO.1 (See page FU-10)
13. REMOVE FUEL DELIVERY PIPE (See page FU-10)
14. DISCONNECT WATER BY-PASS HOSE NO.2 (See page ES-127)
15. DISCONNECT WATER BY-PASS HOSE (See page ES-127)
16. REMOVE THROTTLE BODY ASSEMBLY (See page ES-127)
17. REMOVE THROTTLE BODY BRACKET (See page EM-149)
18. REMOVE OIL LEVEL GAUGE GUIDE (See page EM-148)
19. DISCONNECT VACUUM HOSE ASSEMBLY
20. REMOVE INTAKE MANIFOLD (See page EM-149)
21. REMOVE KNOCK CONTROL SENSOR

(a) Disconnect the connector.
(b) Remove the nut, then remove the knock control sensor.
A107018
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INSTALLATION
1. INSTALL KNOCK CONTROL SENSOR
(a) Install the knock control sensor with the nut in the direction
shown in the illustration.
(b) Connect the connector.
45°
15° 2. INSTALL INTAKE MANIFOLD (See page EM-164)
3. INSTALL THROTTLE BODY ASSEMBLY (See page EM-164)
15° 4. INSTALL FUEL INJECTOR ASSEMBLY (See page FU-11)

ES A107019J01
5. INSTALL FUEL DELIVERY PIPE (See page FU-11)
6. INSTALL OIL LEVEL GAUGE GUIDE (See page EM-58)
7. CONNECT FUEL HOSE NO.1 (See page FU-12)
8. CONNECT ACCELERATOR CONTROL CABLE ASSEMBLY (See

page EM-165)
9. INSTALL VENTILATION HOSE (See page EM-166)
10. INSTALL VENTILATION HOSE NO.2 (See page EM-166)
11. INSTALL BATTERY CARRIER (See page EM-167)
12. INSTALL BATTERY
13. CONNECT NEGATIVE BATTERY TERMINAL (See page EM-167)
15. INSTALL AIR CLEANER HOSE NO.1 (See page CO-19)
16. ADD COOLANT (See page CO-9)
17. CHECK FOR COOLANT LEAKS (See page CO-10)
18. CHECK COOLANT (See page CO-10)
19. PERFORM INITIALIZATION

(See page SS-10.)
INSPECTION
1. CHECK KNOCK CONTROL SENSOR
(1) Using a tester, measure the resistance between the
connector terminals.
Standard:
120 to 280 Ω
A065174J01
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ENGINE CONTROL - CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (3SZ-VE)
ES–135

ENGINE CONTROL
(3SZ-VE)
COMPONENTS
ES
O-RING
T=7.5{76}
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ES–136 ENGINE CONTROL - CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (3SZ-VE)
REMOVAL
1. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(b) Remove the bolt, then remove the camshaft timing oil control
valve assembly.
ES
A136191
INSTALLATION
1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Apply engine oil to a new O-ring.
(b) Install the camshaft timing oil control valve assembly with the
bolt.
(c) Connect the connector.
A136191
ON-VEHICLE INSPECTION
1. CHECK CAMSHAFT OIL CONTROL VALVE ASSEMBLY
OPERATION
(b) Warm up the engine.
(c) Following the prompts on the screen, select ACTIVE TEST,
then VVT CONTROL and check the idling speed in both the
INACTIVE or ACTIVE modes.
Standard
Item Standard
Inactive
Normal engine speed
(OCV OFF)
Active
Rough idle or engine stop
(OCV ON)
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ENGINE CONTROL - CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (3SZ-VE)
ES–137
(d) Following the prompts on the screen, select ACTIVE TEST,

then VVT LINEAR DRIVE BANK 1 and check the idling speed
at the max retard angle (-100%).
Standard
Item Standard
When normal Normal engine speed
Max retard angle
Rough idle or engine stop
(-100%)
INSPECTION
1. CHECK CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ES
terminals.
Standard:
6.9 to 7.9 Ω (when 20°C)
(b) Check operation.
Side Side
(1) Apply battery voltage across the terminals, then check
that the spool valve operates.
NOTICE:
Current Applied
HINT:
sludge, the pressure may leak slightly toward the
advanced side. This leakage may cause DTCs to be
Current Not Applied Valve A136208 recorded.
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ES–138 ENGINE CONTROL - ENGINE CONTROL COMPUTER (3SZ-VE)
ENGINE CONTROL COMPUTER (3SZ-VE)

ENGINE CONTROL
COMPONENTS
ES
GLOVE COMPARTMENT
DOOR ASSEMBLY

BRACKET NO. 1
ENGINE CONTROL COMPUTER ASSEMBLY

BRACKET NO. 2
COWL SIDE TRIM BOARD LH
INSTRUMENT PANEL UNDER COVER NO. 2

FRONT DOOR SCUFF PLATE LH
A137037J01
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ENGINE CONTROL - ENGINE CONTROL COMPUTER (3SZ-VE)
ES–139
REMOVAL
(See page RS-164.)
2. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY ( See page

IP-11)
3. INSTALL INSTRUMENT PANEL UNDER COVER NO.2 ( See page

IP-12)
4. REMOVE FRONT DOOR SCUFF PLATE LH
5. REMOVE COWL SIDE TRIM BOARD LH
6. REMOVE ENGINE CONTROL COMPUTER

ES
(a) Remove each connector.
(b) Remove the 2 bolts and the engine control computer.
NOTICE:
Be careful not to drop the engine control computer.
7. REMOVE ENGINE CONTROL COMPUTER BRACKET NO.1

(a) Disengage the claw and remove engine control computer
bracket No.1 from the engine control computer.
8. REMOVE ENGINE CONTROL COMPUTER BRACKET NO.2

(a) Disengage the claw and remove engine control computer
bracket No.2 from the engine control computer.
INSTALLATION
1. INSTALL ENGINE CONTROL COMPUTER BRACKET NO.2
(a) Install engine control computer bracket No.2 to the engine
control computer.
2. INSTALL ENGINE CONTROL COMPUTER BRACKET NO.1

(a) Install engine control computer bracket No.1 to the engine
control computer
3. INSTALL ENGINE CONTROL COMPUTER

(a) Install the engine control computer with the 2 bolts.
(b) Connect each connector.
4. INSTALL COWL SIDE TRIM BOARD LH
5. INSTALL FRONT DOOR SCUFF PLATE LH
6. INSTALL INSTRUMENT PANEL UNDER COVER NO.2 ( See page

IP-17)
7. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY ( See page

IP-18)

(See page SS-10.)
GETtheMANUALS.org
ES–140 ENGINE CONTROL - E.F.I. WATER TEMPERATURE (3SZ-VE)
E.F.I. WATER TEMPERATURE (3SZ-VE)

ENGINE CONTROL
INSPECTION
1. CHECK EFI COOLANT TEMPERATURE
terminals.
Standard
ES When approx. 20°C

When approx. 80°C
2.32 to 2.59 kΩ
0.310 to 0.326 kΩ
NOTICE:
Make sure that the terminal area does not get wet
when applying the sensor to water during
Resistance inspection.Wipe the sensor dry after the check.
[kΩ]
Temperature [°C]
A050330J09
GETtheMANUALS.org
ENGINE CONTROL - E.F.I. COMPUTER RELAY (3SZ-VE)
ES–141
E.F.I. COMPUTER RELAY (3SZ-VE)

ENGINE CONTROL
INSPECTION
1. EFI COMPUTER RELAY
(1) Using the SST (electrical tester), check the continuity
between the terminals of the connector.
Standard
1←→2 Continuity ES

A133875 terminals 3 and 5 when battery voltage is applied between
terminals 1 and 2.
Standard:
Continuity
GETtheMANUALS.org
ES–142 ENGINE CONTROL - THROTTLE POSITION SENSOR (3SZ-VE)
THROTTLE POSITION SENSOR (3SZ-VE)

ENGINE CONTROL
INSPECTION
1. CHECK RESISTANCE
(a) Disconnect the throttle position sensor connector.
(b) Using a tester, measure the resistance between the throttle
Throttle Position Sensor position sensor connector terminals.
Standard
Tester Connection
Throttle Valve Resistance
(Terminal Symbol)
ES 1 (VC) ←→ 3 (VTH) - 2.5 to 5.9 kΩ
3 2 1
3 (VTH) ←→ 2 (E2) Fully Closed 0.2 to 5.7 kΩ
3 (VTH) ←→ 2 (E2) Fully open 2.0 to 10.2 kΩ
VC
VTH E2 A133573J01
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TO INDEX
ENGINE
ENGINE MECHANICAL
ENGINE MECHANICAL SYSTEM (3SZ-VE)
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-1
ENGINE MECHANICAL SYSTEM (K3-VE)
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-4
FAN AND ALTERNATOR V BELT (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-8
FAN AND ALTERNATOR V BELT (K3-VE)
EM
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-12
VALVE CLEARANCE (3SZ-VE)
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-15
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-16
VALVE CLEARANCE (K3-VE)
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-25
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-26
PARTIAL ENGINE ASSEMBLY (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-54
PARTIAL ENGINE ASSEMBLY (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-70
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-78
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-89
CHAIN (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-104
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-107
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-109
CHAIN (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-112
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-115
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-117
CAMSHAFT (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-120
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-122
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-126
CAMSHAFT (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-130
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-132
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-136
CYLINDER HEAD GASKET (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-140
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-145
GETtheMANUALS.org
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-155
CYLINDER HEAD GASKET (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-168
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-173
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-183
TIMING CHAIN (BELT) COVER OIL SEAL (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-196
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-199
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-200
TIMING CHAIN (BELT) COVER OIL SEAL (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-202
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-205
EM INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-206
ENGINE REAR OIL SEAL (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-208
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-209
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-210
ENGINE REAR OIL SEAL (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-212
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-213
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-214
GETtheMANUALS.org
ENGINE MECHANICAL - ENGINE MECHANICAL SYSTEM (3SZ-VE)
EM–1
ENGINE MECHANICAL SYSTEM (3SZ-VE)

ENGINE MECHANICAL
OPERATION CHECK
1. CHECK COOLANT (Ethylene glycol based anti-freeze solution)
(See page CO-1)
2. CHECK ENGINE OIL QUALITY (See page LU-1)

3. INSPECT BATTERY SPECIFIC GRAVITY
(a) Check the specific gravity of each cell.
Standard:
1.25 to 12.9 V (Liquid temperature: 20°C)
HINT:
If the specific gravity is not as specified, charge the battery. EM
4. CHECK AIR CLEANER FILTER ELEMENT
(a) Check for dirt and blockage in the air cleaner pipe.
A001259
5. CHECK V-BELT TENSION AND DEFLECTION

(a) Check the V-belt tension and deflection using the belt tension
Measuring Position gauge.
Water Pump
Idler Pulley No. 2 Standard
Idler Pulley When Installing New
Alternator Item When Inspecting
Part
Tension [N (kgf)] 883±49{90±5} 441±98{45±10}
Deflection (Thrust
power: 100 N (10.2 kg)) 9-11 13-15
(mm)
Crankshaft A/C Compressor
NOTICE:
A136268
• Measure the belt deflection between the specified
pulleys.
• Crank the engine 2 times before measuring the tension.
• To install a new belt, adjust the belt so that the tension
is in the middle of the specified value given for WHEN
INSTALLING NEW PART in the table above.
• When installing a new belt, check the tension within 2.5
minutes after installation.
• For the belt that has been used for 5 minutes or more,
check the tension using the specified value in WHEN
INSPECTION in the table above.
• To reassemble the belt that has been used for 5 minutes
or more, adjust the belt so that the tension is in the
middle of the specified value given for WHEN
INSPECTING in the table above.
• To use a belt tension gauge, check its accuracy with the
master gauge before measuring the tension.
6. CHECK IGNITION TIMING

(a) Check the timing with the DS-II.
GETtheMANUALS.org
EM–2 ENGINE MECHANICAL - ENGINE MECHANICAL SYSTEM (3SZ-VE)
(2) Follow the prompts on the screen to display the DATA

LIST / IGNITION TIMING #1 screens, and measure the
ignition timing.
Standard:
BTDC 0-15°CA
NOTICE:
Check the ignition timing with the A/C off, the
electrical fan off, and the shift lever in the N and P
positions.
(3) Check that the ignition timing advances immediately when
the engine speed is increased.
(b) Check the timing with commonly-used gauges.
(1) Using the diagnosis check wire, short-circuit between
EM EFIT
terminals 12 (EFIT) and 4 (E) of the DLC.
NOTICE:
• Do not short-circuit the wrong terminals. Doing so
may cause malfunctions.
• Check the ignition timing with the A/C off, the
electrical fan off, and the shift lever in the N and P
positions.
E
G100942 (2) Connect the timing light clip to the coil connector wire
harness for the cylinder No. 1.
NOTICE:
Use a timing light that can detect the first signal.
(3) Check that the ignition timing is as the specified value.
Standard:
BTDC 4 to 8°
(4) Open the circuit between terminals 12 (EFIT) and 4 (E) of
the DLC.
(6) Remove the timing light.
7. CHECK IDLE SPEED

(b) Follow the prompts on the screen to display the DATA LIST /
IGNITION TIMING #1 screens, and measure the engine speed
(r/min).
Specified value:
600 to 750 r/min
NOTICE:
Check the ignition timing with the A/C off, the electrical fan
off, and the shift lever in the N and P positions.
8. CHECK COMPRESSION
(a) Fully warm up the engine and then stop it.
NOTICE:
A warmed up engine should have an engine coolant
temperature of over 85°C, have an engine oil temperature
of 60°C, and the engine rpm should be stabilized.
(b) Remove the air cleaner assembly.
(c) Remove all the ignition coils.
(d) Remove all the spark plugs.
GETtheMANUALS.org
ENGINE MECHANICAL - ENGINE MECHANICAL SYSTEM (3SZ-VE)
EM–3
(e) Disconnect all the injector connectors.

NOTICE:
Stop fuel injection to prevent unburned fuel from damaging
the catalyst.
(f) Check the compression.
Compression Gauge (1) Install a compression gauge to the plug hole.
(2) Fully open the throttle.
(3) Crank the engine, then check the compression.
Standard:
147 kPa (15.0 kgf/cm2)
Maximum limit:
1079 kPa (11.0 kgf/cm2)
A136273
Reference value:
Maximum difference between cylinders: 147 kPa
EM
(1.5 kgf/cm2)
NOTICE:
• The measurement must be done as quickly as
possible.
• After all work is completed, be sure to clear all
DTCs and check that a normal code is output.
9. CHECK DENSITY OF CO AND HC

(a) Keep the engine speed at 2,500 r/min for 2 minutes and then
check the density of CO and HC at idle.
Standard:
CO density: 0.2%
HC density: 200 ppm
NOTICE:
As the specified value is used for reference only, no
adjustment is required.
GETtheMANUALS.org
EM–4 ENGINE MECHANICAL - ENGINE MECHANICAL SYSTEM (K3-VE)
ENGINE MECHANICAL SYSTEM (K3-VE)

ENGINE MECHANICAL
OPERATION CHECK
1. CHECK COOLANT (Ethylene glycol based anti-freeze solution)
(See page CO-3)
2. CHECK ENGINE OIL QUALITY (See page LU-2)

3. INSPECT BATTERY SPECIFIC GRAVITY
(a) Check the specific gravity of each cell.
Standard:
1.25 to 12.9 V (Liquid temperature: 20°C)
HINT:
EM If the specific gravity is not as specified, charge the battery.
4. CHECK AIR CLEANER FILTER ELEMENT

(a) Check for dirt and blockage in the air cleaner pipe.
A001259
5. CHECK V-BELT TENSION AND DEFLECTION

(a) Check the V-belt tension and deflection using the belt tension
Measuring Position gauge.
Water Pump
Idler Pulley No. 2 Standard
Idler Pulley When Installing New
Alternator Item When Inspecting
Part
Tension [N (kgf)] 883±49{90±5} 441±98{45±10}
Deflection (Thrust
power: 100 N (10.2 kg)) 9-11 13-15
(mm)
Crankshaft A/C Compressor NOTICE:

A136268
• Measure the belt deflection between the specified pul-
leys.
• Crank the engine 2 times before measuring the tension.
• To install a new belt, adjust the belt so that the tension
is at the middle of the specified value given for WHEN
• When installing a new belt, check the tension within 2.5
minutes after installation.
• For the belt that has been used for 5 minutes or more,
check the tension using the specified value in WHEN
• To reassemble the belt that has been used for 5 minutes
or more, adjust the belt so that the tension is in the mid-
dle of the specified value given for WHEN INSPECTING
in the table above.
• To use a belt tension gauge, check its accuracy with the
master gauge before measuring the tension.
6. CHECK IGNITION TIMING

(a) Check the timing with the DS-II.
GETtheMANUALS.org
ENGINE MECHANICAL - ENGINE MECHANICAL SYSTEM (K3-VE)
EM–5
(2) Follow the prompts on the screen to display the DATA

LIST / IGNITION TIMING #1 screens, and measure the
ignition timing.
Standard:
BTDC 0-15°CA
NOTICE:
Check the ignition timing with the A/C off, the electri-
cal fan off, and the shift lever in the N and P positions.
(b) Check the timing with commonly-used gauges.
EFIT (1) Using the diagnosis check wire, short-circuit between ter-
minals 12 (EFIT) and 4 (E) of the DLC.
NOTICE: EM
• Do not short-circuit the wrong terminals. Doing so
may cause malfunctions.
• Check the ignition timing with the A/C off, the elec-
trical fan off, and the shift lever in the N and P
positions.
E
G100942 (2) Connect the timing light clip to the coil connector wire har-
ness for the cylinder No. 1.
NOTICE:
Use a timing light that can detect the first signal.
(3) Check that the ignition timing is as the specified value.
Standard:
BTDC 4 to 8°
(4) Open the circuit between terminals 12 (EFIT) and 4 (E) of
the DLC.
(6) Remove the timing light.
7. CHECK IDLE SPEED

(b) Follow the prompts on the screen to display the DATA LIST /
IGNITION TIMING #1 screens, and measure the engine speed
(r/min).
Standard:
600 to 750 r/min
NOTICE:
Check the ignition timing with the A/C off, the electrical fan
off, and the shift lever in the N and P positions.
8. CHECK COMPRESSION
(a) Fully warm up the engine and then stop it.
NOTICE:
A warmed up engine should have an engine coolant tem-
perature of over 85°C, have an engine oil temperature of
60°C, and the engine rpm should be stabilized.
(b) Remove the air cleaner assembly.
(c) Remove all the ignition coils.
(d) Remove all the spark plugs.
(e) Disconnect all the injector connectors.
NOTICE:
Stop fuel injection to prevent unburned fuel from damaging
the catalyst.
GETtheMANUALS.org
EM–6 ENGINE MECHANICAL - ENGINE MECHANICAL SYSTEM (K3-VE)
(f) Check the compression.

Compression Gauge (1) Install a compression gauge to the plug hole.
(2) Fully open the throttle.
(3) Crank the engine, then check the compression.
Standard:
147 kPa (15.0 kgf/cm2)
Maximum limit:
1079 kPa (11.0 kgf/cm2)
Reference value:
A136273
Maximum difference between cylinders: 147 kPa
(1.5 kgf/cm2)
NOTICE:
• The measurement must be done as quickly as
EM possible.
• After all work is completed, be sure to clear all
DTCs and check that a normal code is output.
9. CHECK DENSITY OF CO AND HC

(a) Keep the engine speed at 2,500 r/min for 2 minutes and then
check the density of CO and HC at idle.
Standard:
CO density: 0.2%
HC density: 200 ppm
NOTICE:
As the specified value is used for reference only, no adjust-
ment is required.
GETtheMANUALS.org
ENGINE MECHANICAL - FAN AND ALTERNATOR V BELT (3SZ-VE)
EM–7
FAN AND ALTERNATOR V BELT (3SZ-VE)

ENGINE MECHANICAL
COMPONENTS
EM
FAN AND ALTERNATOR V BELT
A137038J01
GETtheMANUALS.org
EM–8 ENGINE MECHANICAL - FAN AND ALTERNATOR V BELT (3SZ-VE)
REMOVAL
1. REMOVE FAN AND ALTERNATOR V BELT
(a) Loosen the alternator fixing bolt (B).
Bolt C
(b) Loosen the adjusting bar fixing bolt (A).
(c) Rotate the adjusting bolt (C) of the adjusting bar to reduce the
Bolt A
tension.
(d) Remove the fan and alternator V belt.
Bolt B INSTALLATION
1. INSTALL FAN AND ALTERNATOR V BELT
(a) Temporarily install the fan and alternator V belt to each pulley
EM as shown in the illustration.
A108949J02
Idler Pulley Water Pump Pulley Idler Pulley

Water Pump Pulley
Vane Pump
Vane Pump
Alternator Pulley Alternator Pulley

A/C Pulley
Crankshaft Pulley Crankshaft Pulley A137721
(b) Check that the fan and alternator V belt is correctly installed to
each pulley.
A088652
GETtheMANUALS.org
ENGINE MECHANICAL - FAN AND ALTERNATOR V BELT (3SZ-VE)
EM–9
2. ADJUST FAN AND ALTERNATOR V BELT

(a) Rotate adjusting bolt C to adjust the fan and alternator V belt
Bolt C
tension.
(b) Tighten fixing bolts A and B.
Bolt A
Torque: 19 N*m (194 kgf*cm) (Bolt A)
44 N*m (449 kgf*cm) (Bolt B)
3. CHECK FAN AND ALTERNATOR V BELT

Bolt B (a) Check there is no cracks, deterioration or significant wear on
the fan and alternator V belt.
EM
A108949J02

Water Pump Pulley
Vane Pump
Vane Pump
Measurement Measurement
Position Position

A/C Pulley
(b) Check the tension of the fan and alternator V belt using a belt
tension gauge.
HINT:
The deflection of the fan and alternator V belt is also available
to check the tension.
When Installing New Part When Inspecting

Tension [N (kgf)] 883±49{90±5} 441±98{45±10}
Deflection (mm) [100 N 9-11 13-15
(10.2 kgf)]
HINT:
• Measure the belt deflection when the belt is pressed
between the water pump pulley and the idle pulley at a
strength of 100 N (10.2 kgf) and then measure the belt
deflection.
• When measuring the tension after installing the belt, crank 2
times in the direction that the engine rotates.
• To replace the belt with a new one, adjust the belt so that the
value is at the middle of the specified value given for WHEN
• For the belt that has been used for 5 minutes or more, check
that the tension is within the specified value in WHEN
GETtheMANUALS.org
EM–10 ENGINE MECHANICAL - FAN AND ALTERNATOR V BELT (3SZ-VE)
• To assemble the belt that has been used for 5 minutes or

more, adjust the belt so that the tension is in the middle of
the specified value given for WHEN INSPECTING in the
table above.
EM
GETtheMANUALS.org
ENGINE MECHANICAL - FAN AND ALTERNATOR V BELT (K3-VE)
EM–11
FAN AND ALTERNATOR V BELT (K3-VE)

ENGINE MECHANICAL
COMPONENTS
EM
A137038J01
GETtheMANUALS.org
EM–12 ENGINE MECHANICAL - FAN AND ALTERNATOR V BELT (K3-VE)
REMOVAL
1. REMOVE FAN AND ALTERNATOR V BELT
(a) Loosen the alternator fixing bolt (B).
Bolt C
(b) Loosen the adjusting bar fixing bolt (A).
(c) Rotate the adjusting bolt (C) of the adjusting bar to reduce the
Bolt A
tension.
(d) Remove the fan and alternator V belt.
Bolt B INSTALLATION
(a) Temporarily install the fan and alternator V belt to each pulley
EM as shown in the illustration.
A108949J02

Water Pump Pulley
Vane Pump
Vane Pump

A/C Pulley
(b) Check that the fan and alternator V belt is correctly installed to
each pulley.
A088652
GETtheMANUALS.org
ENGINE MECHANICAL - FAN AND ALTERNATOR V BELT (K3-VE)
EM–13
2. ADJUST FAN AND ALTERNATOR V BELT

(a) Rotate adjusting bolt C to adjust the fan and alternator V belt
Bolt C
tension.
(b) Tighten fixing bolts A and B.
Bolt A
3. CHECK FAN AND ALTERNATOR V BELT

Bolt B (a) Check there is no cracks, deterioration or significant wear on
the fan and alternator V belt.
EM
A108949J02

Water Pump Pulley
Vane Pump
Vane Pump
Measurement Measurement
Position Position

A/C Pulley
(b) Check the tension of the fan and alternator V belt using a belt
tension gauge.
HINT:
The deflection of the fan and alternator V belt is also available
to check the tension.
When Installing New Part When Inspecting

Tension [N (kgf)] 637±49{95±5} 441±98{54±10}
Deflection (mm) [100 N 9-11 13-15
(10.2 kgf)]
HINT:
• Measure the belt deflection when the belt is pressed
between the water pump pulley and the idle pulley at a
strength of 100 N (10.2 kgf) and then measure the belt
deflection.
• When measuring the tension after installing the belt, crank 2
times in the direction that the engine rotates.
• To replace the belt with a new one, adjust the belt so that the
value is at the middle of the specified value given for WHEN
• For the belt that has been used for 5 minutes or more, check
that the tension is within the specified value in WHEN
GETtheMANUALS.org
EM–14 ENGINE MECHANICAL - FAN AND ALTERNATOR V BELT (K3-VE)
• To assemble the belt that has been used for 5 minutes or

more, adjust the belt so that the tension is in the middle of
the specified value given for WHEN INSPECTING in the
table above.
EM
GETtheMANUALS.org
ENGINE MECHANICAL - VALVE CLEARANCE (3SZ-VE)
EM–15
VALVE CLEARANCE (3SZ-VE)

ENGINE MECHANICAL
INSPECTION
(See page RS-160.)
4. REMOVE AIR CLEANER HOSE NO. 1 (See page CO-15)
6. REMOVE RADIATOR HOSE NO. 1 (See page CO-15)

EM
(See page EM-147)
9. REMOVE VENTILATION HOSE NO. 2 (See page EM-147)
10. REMOVE ENGINE ROOM MAIN WIRE (See page EM-147)
11. REMOVE RADIATOR PIPE (See page EM-147)
12. REMOVE IGNITION COIL ASSEMBLY (See page EM-150)
13. REMOVE CYLINDER HEAD COVER (See page EM-151)
14. INSPECT VALVE CLEARANCE

NOTICE:
Check the valve clearance in cool conditions.
(a) Turn the crankshaft pulley clockwise and align the matchmarks
as shown in the illustration, and then set cylinder No. 1 to TDC /
compression.
HINT:
If the matchmarks are not aligned, turn the crankshaft to align
the marks again.
Timing Marks
A133561
(b) Using a thickness gauge, measure the valve clearance at the

IN position shown in the illustration.
HINT:
The thickness gauge should be inserted from the spark plug
side (center).
Standard (in cool conditions)
Intake side 0.145 to 0.235 mm

Exhaust side 0.275 to 0.365 mm
EX A133562 Valves to be checked when cylinder No. 1 is set

to TDC / compression
Cylinder No. 1 Cylinder No. 2 Cylinder No. 3 Cylinder No. 4
IN EX IN EX IN EX IN EX
{ { { - - { - -
GETtheMANUALS.org
EM–16 ENGINE MECHANICAL - VALVE CLEARANCE (3SZ-VE)
HINT:
If not as specified, measure the clearance and record it.
(c) Turn the crankshaft pulley 360°clockwise, and then set cylinder
No. 4 to TDC / compression.
(d) Using a thickness gauge, measure the valve clearance at the
HINT:
side (center).

EM EX A133563 Check the valves with cylinder No. 1 at TDC /

ventilation
- - - { { - { {
HINT:
ADJUSTMENT
1. ADJUST VALVE CLEARANCE
(a) Remove the 2 bolts and the timing chain cover No. 2.
A137452
(b) Turn the crankshaft pulley clockwise and check that the timing
marks of the camshaft timing gear are positioned as shown in
the illustration.
NOTICE:
If the timing marks are not aligned, turn the crankshaft pul-
ley clockwise again and align the marks.
Timing Marks
A133561
GETtheMANUALS.org
EM–17
(c) Place a paint mark on each plate of the chains at the points
where the camshaft timing gear and the timing mark of the cam-
shaft timing sprocket are aligned.
Paint Mark Paint Mark
Timing Marks
EM
A107964J01
(d) Using the hexagon head portion of the camshaft, loosen the
camshaft timing sprocket installation bolt.
A133812
(e) Using a 10 mm socket hexagon wrench, remove the chain

cover service hole screw plug.
A137724
(f) Using a screwdriver, access the tensioner stopper plate through

the chain tensioner service hole, move it downward and hold it
with the lock released.[*1]
NOTICE:
If it is difficult to release the stopper plate lock, use the
hexagon head portion of the camshaft and rotate the cam-
shaft a little to the right and left.
(g) Under the conditions noted at [*1], use the hexagon head por-
tion of the camshaft to rotate the camshaft a little to the right
and hold.[*2]
HINT:
Rotating the camshaft to the right will press the tensioner
plunger.
A133813
GETtheMANUALS.org
(h) Under the conditions noted at [*2], remove the screwdriver from
the chain tensioner service hole, align the stopper plate and the
tensioner holes, and insert a bar of 3 mm in diameter.
NOTICE:
• If the 3 mm diameter bar is difficult to insert, rotate the
camshaft a little to the left and then back a little to the
right and insert the bar again.
• Hold the camshaft in the position using the hexagon
head portion.
• Fix the 3 mm diameter bar using tape or similar so it
does not come out.
EM
A136104
(i) Remove the timing chain from the camshaft timing sprocket.
A133815
(j) Remove the bolt and the camshaft timing sprocket.

Hold NOTICE:
When rotating the camshaft with the timing chain removed,
rotate the crankshaft 90° (crank angle) in the direction that
the engine rotates from cylinder No. 1 TDC / compression
so the valve does not interfere with the piston.
A136076
GETtheMANUALS.org
EM–19
90°
A107973J01
(k) Remove the camshaft bearing cap No. 1 in the order indicated
in the illustration.
2 EM
4
A133124
(l) Remove the camshaft bearing cap No. 2 in the order indicated
HINT:
2 10 14 6
Uniformly loosen the bolts keeping the camshaft level.
(m) Remove the camshaft.
4 12 16 8
(n) Remove the camshaft No. 2.
3 11 15 7
1 9 13 5
A133125
(o) After removing the camshaft, attach the timing chain to a rope
or wire so that it does not drop.
NOTICE:
Do not allow any foreign matter to enter the timing chain
cover.
(p) Remove the valve lifter.
A133818
(q) Using a micrometer, measure the valve lifter thickness.

Measurement
Point B
A033166
GETtheMANUALS.org
(r) Select and install a valve lifter so that the valve clearance is
within the specified range.
Standard:
Intake: :
Valve (Selected lifter thickness) = (Removed lifter thickness)
Thickness of Lifter
+ [(Measured clearance) - 0.18 mm]
Selection No. Exhaust: :
Marking (Selected lifter thickness) = (Removed lifter thickness)
+ [(Measured clearance) -0.31mm]
A133819 HINT:
Shims are available in 41 increments of 0.02 mm (0.0008 in.),
from 5.120 mm to 5.680mm.
Number Lifter Thickness Number Lifter Thickness Number Lifter Thickness Number Lifter Thickness
EM (mm) (mm) (mm) (mm)
12 5.120 28 5.280 44 5.440 60 5.600
14 5.140 30 5.300 46 5.460 62 5.620
16 5.160 32 5.320 48 5.480 64 5.640
18 5.180 34 5.340 50 5.500 66 5.660
20 5.200 36 5.360 52 5.520 68 5.680
22 5.220 38 5.380 54 5.540 - -
24 5.240 40 5.400 56 5.560 - -
26 5.260 42 5.420 58 5.580 - -
(s) Install the valve lifter.

(t) Apply engine oil to the cam of camshaft No. 2 and the journal of
the cylinder head, and then install the camshaft No. 2.
NOTICE:
Position it so the cam nose of cylinders No. 2 and 4 of the
camshaft sub-assembly No. 2 push down the lifter valve.
(u) Apply engine oil to the cam of the camshaft and the journal part
of the cylinder head, and then install the camshaft.
NOTICE:
camshaft sub-assembly No. 1 pushes down the lifter valve.
(v) Confirm the front mark and number of camshaft bearing cap No.
2 and install it.
I2
I3
I4
I5
(w) Tighten the camshaft bearing cap No. 2 in the order shown in
the illustration.
NOTICE:
15 7 3 11
• Uniformly tighten the bolts, keeping the camshaft level.
• Position the cap so the arrow on it faces toward the
13 5 1 9 front of the engine, and install it so the punched num-
14 6 2 10
bers are positioned as shown in the illustration.
16 8 4 12
E2
E4
E5
E3
A133070
GETtheMANUALS.org
EM–21
(x) Tighten the camshaft bearing cap No. 1 in the order shown in
the illustration.
3
NOTICE:
1
Tighten the bolts after checking that the thrust part of the
camshaft is aligned with the groove on camshaft bearing
2 cap No. 1.
4
A133071
(y) Position the timing marks of the camshaft timing sprocket and
the camshaft timing gear as shown in the illustration.
(z) Position the timing mark (groove) of the crankshaft pulley so it is EM
at 0°.
Timing Marks
Notch
A137723
(aa) Align the camshaft knock pin and the camshaft timing sprocket
pin hole, and install the camshaft timing sprocket to the cam-
Pin Hole Knock Pin
shaft.
NOTICE:
• If the knock pin and pin hole do not align, use the hexa-
gon head portion of the camshaft and rotate the cam-
shaft a little to the right and left so they align.Do not
Do Not Remove press too firmly on the camshaft timing sprocket as the
seal surface can be easily damaged by the end of the
A136098 knock pin which may cause the seal to fail.
• Do not remove the 3 bolts.If the bolts are removed,
replace the camshaft timing sprocket.
GETtheMANUALS.org
(ab) Apply a small amount of engine oil to the camshaft timing

Hold sprocket installation bolt thread and seating surface to tempo-
rarily install them.
(ac) Using the hexagon head portion of the camshaft, tighten the
A136076
(ad) Install the chain so the matchmarks of the camshaft timing gear
and the chain are aligned.
EM
Timing Marks
A133561
(ae) Pull the 3 mm diameter bar out from the chain tensioner.
NOTICE:
Using the hexagon head portion of the camshaft, rotate the
camshaft a little to the left with the chain slightly slack on
the tensioner side, and pull out the 3 mm diameter bar.
A136104
GETtheMANUALS.org
EM–23
(af) Make sure that each timing mark is positioned as shown in the
illustration.
(ag) Apply Amix TB1324 to the first 2 to 3 threads of the chain cover
service hole screw plug bolt.
NOTICE:
Clean and degrease the bolt and bolt hole.
Timing Marks
EM
Notch
A137746
(ah) Using a 10 mm socket hexagon wrench, install the chain cover

service hole screw plug.
A137724
(ai) Apply Amix TB1207B to the position shown in the illustration.

Apply Liquid Gasket NOTICE:
• Clean and degrease the installation surfaces.
• Install within 3 minutes of applying Amix TB1207B.
• Do not start the engine within 2 hours of the installation.
A139347
(aj) Install the timing chain cover No. 2 with the 2 bolts.
2. INSTALL CYLINDER HEAD COVER (See page EM-162)
3. INSTALL IGNITION COIL ASSEMBLY (See page EM-162)
4. INSTALL RADIATOR PIPE (See page EM-166)
5. INSTALL ENGINE ROOM MAIN WIRE (See page EM-165)

A137452
7. INSTALL VENTILATION HOSE NO. 2 (See page EM-166)
GETtheMANUALS.org

page EM-165)
9. INSTALL RADIATOR HOSE NO. 1 (See page CO-18)
11. INSTALL AIR CLEANER HOSE NO. 1 (See page CO-19)
12. ADD ENGINE COOLANT (See page CO-9)
13. CHECK FOR ENGINE COOLANT LEAKS (See page CO-10)
14. CHECK COOLANT LEVEL (See page CO-10)
EM 16. CONNECT NEGATIVE BATTERY TERMINAL

GETtheMANUALS.org
ENGINE MECHANICAL - VALVE CLEARANCE (K3-VE)
EM–25
VALVE CLEARANCE (K3-VE)

ENGINE MECHANICAL
INSPECTION
(See page RS-164.)

EM
(See page EM-175)
14. INSPECT VALVE CLEARANCE

NOTICE:
Check the valve clearance in cool conditions.
(a) Turn the crankshaft pulley clockwise and align the matchmarks
as shown in the illustration, and then set cylinder No. 1 to TDC /
compression.
HINT:
If the matchmarks are not aligned, turn the crankshaft to align
the marks again.
Timing Marks
A133561
(b) Using a thickness gauge, measure the valve clearance at the

HINT:
side (center).

EX A133562 Valves to be checked when cylinder No. 1 is set

to TDC / compression
{ { { - - { - -
GETtheMANUALS.org
EM–26 ENGINE MECHANICAL - VALVE CLEARANCE (K3-VE)
HINT:
(c) Turn the crankshaft pulley 360° clockwise, and then set cylinder
No. 4 to TDC / compression.
(d) Using a thickness gauge, measure the valve clearance at the
HINT:
side (center).

EM EX A133563 Check the valves with cylinder No. 1 at TDC /

ventilation.
- - - { { - { {
HINT:
ADJUSTMENT
1. ADJUST VALVE CLEARANCE
(a) Remove the 2 bolts and the timing chain cover No. 2.
A137452
(b) Turn the crankshaft pulley clockwise and check that the timing
marks of the camshaft timing gear are positioned as shown in
the illustration.
NOTICE:
If the timing marks are not aligned, turn the crankshaft pul-
ley clockwise again and align the marks.
Timing Marks
A133561
GETtheMANUALS.org
EM–27
(c) Place a paint mark on each plate of the chains at the points
Timing Marks
EM
A107964J01
(d) Using the hexagon head portion of the camshaft, loosen the
A133812
(e) Using a 10 mm socket hexagon wrench, remove the chain

A137724
(f) Using a screwdriver, access the tensioner stopper plate through

NOTICE:
If it is difficult to release the stopper plate lock, use the
hexagon head portion of the camshaft and rotate the cam-
shaft a little to the right and left.
(g) Under the conditions noted at [*1], use the hexagon head por-
and hold.[*2]
HINT:
plunger.
A133813
GETtheMANUALS.org
(h) Under the conditions noted at [*2], remove the screwdriver from
NOTICE:
head portion.
• Fix the 3 mm diameter bar using tape or similar so it
does not come out.
EM
A136104
(i) Remove the timing chain from the camshaft timing sprocket.
A133815
(j) Remove the bolt and the camshaft timing sprocket.

Hold NOTICE:
When rotating the camshaft with the timing chain removed,
rotate the crankshaft 90° (crank angle) in the direction that
the engine rotates from cylinder No. 1 TDC / compression
so the valve does not interfere with the piston.
A136076
GETtheMANUALS.org
EM–29
90°
A107973J01
(k) Remove the camshaft bearing cap No. 1 in the order indicated
2 EM
4
A133124
(l) Remove the camshaft bearing cap No. 2 in the order indicated
HINT:
2 10 14 6
(m) Remove the camshaft.
4 12 16 8
(n) Remove the camshaft No. 2.
3 11 15 7
1 9 13 5
A133125
(o) After removing the camshaft, attach the timing chain to a rope
or wire hoist so that it does not drop.
NOTICE:
cover.
(p) Remove the valve lifter.
A133818
(q) Using a micrometer, measure the valve lifter thickness.

Measurement
Point B
A033166
GETtheMANUALS.org
(r) Select and install a valve lifter so that the valve clearance is
within the specified range.
Standard:
Intake: :
Valve
(Selected lifter thickness) = (Removed lifter thickness)
Thickness of Lifter
+ [(Measured clearance) - 0.18 mm]
Selection No. EXHAUST:
Marking (Selected lifter thickness) = (Removed lifter thickness)
+ [(Measured clearance) -0.31mm]
A133819 HINT:
Shims are available in 41 increments of 0.02 mm (0.0008 in.),
from 5.120 mm to 5.680mm.
Number Lifter Thickness Number Lifter Thickness Number Lifter Thickness Number Lifter Thickness
EM (mm) (mm) (mm) (mm)
12 5.120 28 5.280 44 5.440 60 5.600
14 5.140 30 5.300 46 5.460 62 5.620
16 5.160 32 5.320 48 5.480 64 5.640
18 5.180 34 5.340 50 5.500 66 5.660
20 5.200 36 5.360 52 5.520 68 5.680
22 5.220 38 5.380 54 5.540 - -
24 5.240 40 5.400 56 5.560 - -
26 5.260 42 5.420 58 5.580 - -
(s) Install the valve lifter.

(t) Apply engine oil to the cam of camshaft No. 2 and the journal of
the cylinder head, and then install the camshaft No. 2.
NOTICE:
camshaft sub-assembly No. 2 push down the lifter valve.
(u) Apply engine oil to the cam of the camshaft and the journal part
of the cylinder head, and then install the camshaft.
NOTICE:
camshaft sub-assembly No. 1 pushes down the lifter valve.
(v) Confirm the front mark and number of camshaft bearing cap No.
2 and install it.
I2
I3
I4
I5
(w) Tighten the camshaft bearing cap No. 2 in the order shown in
the illustration.
NOTICE:
15 7 3 11
14 6 2 10
16 8 4 12
E2
E4
E5
E3
A133070
GETtheMANUALS.org
EM–31
(x) Tighten the camshaft bearing cap No. 1 in the order shown in
the illustration.
3
NOTICE:
1
camshaft is aligned with the groove on camshaft bearing
2 cap No. 1.
4
A133071
(y) Position the timing marks of the camshaft timing sprocket and
the camshaft timing gear as shown in the illustration.
(z) Position the timing mark (groove) of the crankshaft pulley so it is EM
at 0°.
Timing Marks
Notch
A140652
(aa) Align the camshaft knock pin and the camshaft timing sprocket
Pin Hole Knock Pin
shaft.
NOTICE:
shaft a little to the right and left so they align. Do not
GETtheMANUALS.org
(ab) Apply a small amount of engine oil to the camshaft timing

(ac) Using the hexagon head portion of the camshaft, tighten the
A136076
(ad) Install the chain so the matchmarks of the camshaft timing gear
EM
Timing Marks
A133561
(ae) Pull the 3 mm diameter bar out from the chain tensioner.
NOTICE:
A136104
GETtheMANUALS.org
EM–33
(af) Make sure that each timing mark is positioned as shown in the
illustration.
(ag) Apply Three Bond TB1324 to the first 2 to 3 threads of the chain
cover service hole screw plug bolt.
NOTICE:
Timing Marks Clean and degrease the bolt and bolt hole.
EM
Notch
A140612
(ah) Using a 10 mm socket hexagon wrench, install the chain cover

A137724
(ai) Apply Three Bond TB1207B to the position shown in the illustra-
Apply Liquid Gasket tion.
NOTICE:
• Install within 3 minutes of applying Three Bond
TB1207B.
• Do not start the engine within 2 hours of the installation.
A139347
(aj) Install the timing chain cover No. 2 with the 2 bolts.

A137452
GETtheMANUALS.org

page EM-193)
EM 16. CONNECT NEGATIVE BATTERY TERMINAL

GETtheMANUALS.org
ENGINE MECHANICAL - PARTIAL ENGINE ASSEMBLY (3SZ-VE)
EM–35
PARTIAL ENGINE ASSEMBLY (3SZ-VE)

ENGINE MECHANICAL
COMPONENTS
T=7.5{76}
T=3.5{36} ×2
BATTERY
EM
CLAMP
T=18{184}
T=7.5{76}
×2
BATTERY
FUEL HOSE NO. 2

T=8.5{87} ×3
ACCELERATOR CONTROL HEATER OUTLET COOLANT HOSE

CABLE ASSEMBLY
BATTERY CARRIER
RADIATOR HOSE NO. 1
RADIATOR HOSE NO. 2
HEATER INLET COOLANT HOSE
OIL COOLER INLET HOSE NO. 1
ENGINE UNDER COVER RR RH
OIL COOLER OUTLET HOSE NO. 1
T=5.4{55}
×7
T=5.4{55}
×4
ENGINE UNDER COVER RR LH
T=5.4{55} ×11 ENGINE UNDER COVER
TIGHTENING TORQUE [N*m{kgf*cm}] A136755J01
GETtheMANUALS.org
EM–36 ENGINE MECHANICAL - PARTIAL ENGINE ASSEMBLY (3SZ-VE)
ENGINE ROOM R/B

CYLINDER HEAD
A/T COVER GROUND
TRANSMISSION CONTROL WIRE HARNESS
CHARCOAL CANISTER PIPE NO. 1
CABLE ASSEMBLY
GROUND WIRE
HARNESS
M/T
TRANSMISSION CONTROL
CABLE ASSEMBLY
EM T=7.5{76}
VACUUM HOSE ASSEMBLY
T=29.4{300}
T=29.4{300}
STEERING INTERMEDIATE SHAFT ASSEMBLY

COOLER COMPRESSOR WITH
MAGNETIC CLUTCH ASSEMBLY
T=25{255}
SPEED SENSOR FR LH
T=10{102}
O-RING
T=8.4{86}
O-RING COOLER REFRIGERANT

DISCHARGE HOSE NO. 1 EXHAUST PIPE GASKET
T=25{225}
EXHAUST PIPE SUPPORT BRACKET
COOLER REFRIGERANT
SUCTION HOSE NO. 1
T=19{194}
T=10{102}
T=19{194}
EXHAUST PIPE ASSEMBLY FR

EXHAUST PIPE GASKET
T=46{469}
TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PART A136756J02
GETtheMANUALS.org
EM–37
2WD PROPELLER WITH CENTER ×4

BEARING SHAFT ASSEMBLY
T=60{612}
FRONT DISC BRAKE ×2

T=37{377}
CYLINDER ASSEMBLY LH
VANE PUMP WITH BRACKET FRONT SHOCK ABSORBER

×2 WITH COIL SPRING
T=112.8{1150}
T=20.6{210}
EM
T=97.5{976}
FRONT DISC BRAKE
×2
CYLINDER ASSEMBLY RH
×2
T=20.6{210} T=112.8{1150}
×6 ×2
FRONT SUSPENSION
CROSS MEMBER
T=125{1275}
4WD FRONT PROPELLER SHAFT ASSEMBLY

T=60{612}
×4
×4
T=60{612}
×2
FRONT DISC BRAKE T=37{377} PROPELLER WITH CENTER
CYLINDER ASSEMBLY RH BEARING SHAFT ASSEMBLY
×2
VANE PUMP WITH BRACKET
T=112.8{1150} FRONT SHOCK ABSORBER
T=20.6{210} WITH COIL SPRING
T=95.7{976}
×2 FRONT DISC BRAKE
×2
T=20.6{210} CYLINDER ASSEMBLY LH
T=112.8{1150}
FRONT SUSPENSION
CROSS MEMBER ×2
×6
T=125{1275}
TIGHTENING TORQUE A137621J01
GETtheMANUALS.org

T=7.5{76}
SPARK PLUG
REAR END PLATE
EM FAN PULLEY
T=7.5{76}
×3
T=11.5{117}
T=44{449} ENGINE OIL PRESSURE

SWITCH ASSEMBLY
IDLER PULLEY NO. 1

OIL FILTER BRACKET
COMPRESSOR MOUNTING
BRACKET NO. 1 T=7.5{76}
A/T
T=78{800}
T=27.5{280}
×2
ENGINE MOUNTING ×6
INSULATOR FR RH ×3
T=19{194}
×6
T=37{377} T=28{286} O-RING
×4
FLYWHEEL RING GEAR
T=48.1{490}
ENGINE MOUNTING
BRACKET FR NO. 2
M/T
CLUTCH DISC ASSEMBLY
×4 T=19.1{195}
×3
T=18{184}
×6
T=30.4{310}
×6
T=30.4{310}
×2
ENGINE MOUNTING
BRACKET FR NO. 1 RH
T=78{800}
ENGINE MOUNTING INSULATOR FR LH FLYWHEEL CLUTCH COVER ASSEMBLY

A137889J01
GETtheMANUALS.org
EM–39
4WD
×7
T=37{375}
T=36.8{375}
T=7.9{80}
OIL COOLER
HOSE
T=34.3{349}
×2
OIL COOLER TUBE GASKET EM
TRANSFER ASSEMBLY
OIL COOLER HOSE
T=58.8{596}
TRANSMISSION ASSEMBLY
T=58.8{596}
TORQUE CONVERTER WIRE HARNESS

ASSEMBLY
O-RING
T=84.5{85}
x6
TRANSMISSION
T=27.5{280} REVOLUTION
T=58.8{596} SENSOR
T=84.5{85} ENGINE MOUNTING

T=36.8{375} BRACKET RR
T=36.8{375}
T=68{693}
T=68{693}
T=37{375}
T=68{693}
FRONT SUSPENSION
CROSS MEMBER LWR ENGINE REAR SUPPORT MEMBER
T=68{693}
APPLY MP GREASE APPLY ATF
C139184J09
GETtheMANUALS.org
BACK-UP LIGHT SWITCH ASSEMBLY
TRANSMISSION ASSEMBLY T=58.8{596} T=32{325}
T=37{375}
EM T=58.8{596}
T=58.8{596}
T=18{185}
T=36.8{375}
T=36.8{375}
T=68{693}
T=68{693}
FRONT SUSPENSION CROSS MEMBER LWR

C140480J01
GETtheMANUALS.org
EM–41
OIL LEVEL GAUGE GUIDE
T=8.5{87}
COOLANT BYPASS HOSE NO. 2

COOLANT BYPASS HOSE O-RING
T=7.5{76}
T=21{214}
THROTTLE BODY
×2
EM
ASSEMBLY T=7.5{76}
×2 THROTTLE BODY BRACKET NO. 2
T=19{194}
O-RING
×2
T=19{194} T=21{214}
×2 ×3 THROTTLE BODY BRACKET
T=7.5{76}
RADIATOR PIPE
VENTILATION HOSE INTAKE MANIFOLD

TO HEAD GASKET
INTAKE MANIFOLD
T=7.5{76}
O-RING
EXHAUST MANIFOLD
HEAT INSULATOR NO. 1
T=8.5{87}
VALVE ASSEMBLY
FANBELT ADJUSTING BAR T=8.5{87}
T=10{102}
T=19{194}
T=19{194}
T=44{449}
T=35{357}
ALTERNATOR ASSEMBLY ×2
MANIFOLD STAY ×3
T=35{357}
EXHAUST MANIFOLD TO HEAD GASKET
T=9.3{95}
EXHAUST MANIFOLD
TIGHTENING TORQUE NON-REUSEABLE PART A137041J01
GETtheMANUALS.org
FUEL DELIVERY PIPE
COOLANT TEMPERATURE T=21{214}

SENSOR ×2
RADIATOR HOSE NO. 4

GASKET
×4
EM CAMSHAFT POSITION
SENSOR ×4
T=7.5{76} INJECTOR VIBRATION ×4

INSULATOR
T=19.0{200} T=20{204}
GASKET
GASKET ×2
COOLANT BYPASS PLATE
T=9.0{92} FUEL INJECTOR
ASSEMBLY
T=20{204}
WATER INLET
T=8.8{90}
THERMOSTAT
×2
WATER BYPASS HOSE NO. 4
T=37{377}
STARTER ASSEMBLY
RADIATOR HOSE NO. 2
COOLANT RADIATOR HOSE NO. 3
TIGHTENING TORQUE NON-REUSEABLE PART

A137074J01
GETtheMANUALS.org
EM–43
REMOVAL
2. CHECK THAT FRONT TIRES FACE STRAIGHT AHEAD

See page RS-164.
4. REMOVE FRONT TIRE
6. REMOVE ENGINE UNDER COVER RR RH
7. REMOVE ENGINE UNDER COVER RR LH
8. REMOVE REFRIGERANT HFC - 134a (R134a) (Steering type:

LHD) (See page AC-27)
EM
10. DRAIN ENGINE OIL

(a) After draining the engine oil, install the drain plug using a new
gasket.
11. DRAIN AUTOMATIC TRANSMISSION FLUID (AUTOMATIC

TRANSMISSION) (See page AT-69)
12. DRAIN MANUAL TRANSMISSION OIL (MANUAL TRANSMIS-

SION) (See page MT-9)
13. DRAIN TRANSFER OIL (for 4WD) (See page TF-7)
15. DISCONNECT FUEL HOSE NO. 2 (See page EM-148)
16. DISCONNECT OIL COOLER INLET HOSE NO. 1 (AUTOMATIC

TRANSMISSION) (See page CO-15)
17. DISCONNECT OIL COOLER OUTLET HOSE NO. 1 (AUTOMATIC

18. REMOVE BATTERY

(a) Remove the battery clamp.
(b) Remove the battery.
21. DISCONNECT RADIATOR HOSE NO.1(See page CO-15)
23. REMOVE FAN AND ALTERNATOR BELT (See page EM-8)
GETtheMANUALS.org
24. REMOVE VANE PUMP WITH BRACKET

(a) Remove the 3 bolts and the vane pump with bracket.
25. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO.

1 (STEERING TYPE: LHD) (See page AC-51)
26. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO. 1

(STEERING TYPE: LHD) (See page AC-51)
27. REMOVE COOLER COMPRESSOR WITH MAGNETIC CLUTCH

ASSEMBLY (See page AC-51)
A137622
28. DISCONNECT HEATER INLET WATER HOSE

(a) Detach the clamp and disconnect the heater inlet water hose.
EM
A136001
29. DISCONNECT HEATER OUTLET WATER HOSE

(a) Detach the clamp and disconnect the heater outlet water hose.
A136002
30. REMOVE CHARCOAL CANISTER PIPE NO. 1

(a) Remove the bolt and the charcoal canister pipe No. 1.

(See page EM-147)
32. DISCONNECT VACUUM HOSE ASSEMBLY (See page EM-148)
33. DISCONNECT ENGINE WIRE HARNESS

(a) Remove the glove compartment door assembly and then dis-
connect the connectors of the engine control computer.
A133920
(b) Pull the wire harness out through the engine room side.
A133249
GETtheMANUALS.org
EM–45
(c) Remove the bolt and disconnect the ground wire harness.
A133248
(d) Remove the connectors and clamps from the engine room R/B,
and then disconnect the wire harness.
EM
A133247
(e) Disconnect the ground connector of the cylinder head cover.

(f) Remove the bolt and disconnect the ground wire harness.
(g) Disconnect all the wire harnesses and connectors, and check
that the wire harness is not connected between the body and
the engine.
34. REMOVE STEERING SHAFT UNIVERSAL JOINT ASSEMBLY
A133250
35. REMOVE EXHAUST PIPE ASSEMBLY FR

(a) Remove the 2 nuts.
A134988
(b) Disconnect the oxygen sensor No. 2 connector.
A133302
GETtheMANUALS.org
(c) Remove the 2 bolts and 2 springs.

(d) Remove the exhaust support cushion, and then remove the
exhaust pipe assembly FR.
36. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEM-

BLY (See page PR-6)
37. REMOVE FRONT SUSPENSION CROSS MEMBER LWR (for 4WD)

(See page PR-3)
38. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)

A134989
(See page PR-3)
39. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(AUTOMATIC TRANSMISSION) (See page AT-70)
EM 40. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY (MAN-

UAL TRANSMISSION) (See page MT-26)
41. DISCONNECT SPEED SENSOR FR LH
(a) Remove the bolt, and disconnect the speed sensor FR LH from
the steering knuckle.
C133716
(b) Remove the bolt and nut, and disconnect the wire harness
clamp from the shock absorber.
42. DISCONNECT SPEED SENSOR FR RH

(a) Perform the same procedure for the RH as for the LH.
C133715
43. SEPARATE FRONT DISC BRAKE CYLINDER ASSEMBLY LH

(a) Remove the 2 bolts, and separate the front disc brake cylinder
assembly LH.
(b) Hang the disconnected front disc brake cylinder assembly LH
with wire or similar.
44. SEPARATE FRONT DISC BRAKE CYLINDER ASSEMBLY RH

C139221
GETtheMANUALS.org
EM–47
45. SEPARATE FRONT SHOCK ABSORBER WITH COIL SPRING

(a) Remove the 4 bolts and 4 nuts, and disconnect the front shock
absorber with coil spring LH and RH from the steering knuckle.
C135148
46. REMOVE ENGINE ASSEMBLY WITH TRANSMISSION

(a) Set the engine lifter.
EM
A133259
(b) Remove the 4 bolts and disconnect the engine rear support
member.
A133258
(c) Remove the 6 bolts, operate the engine lifer, and then remove
Vehicle Front
the engine assembly with transaxle and the front suspension
crossmember from the vehicle.
A133256
47. REMOVE OIL COOLER TUBE (AUTOMATIC TRANSMISSION)

(a) Remove the 2 union bolts and disconnect the oil cooler tube.
(b) Remove the bolt and disconnect the clamp (A) from the trans-
mission assembly.
(c) Remove the bolt, and then remove the clamp (B) from the
engine mount bracket.
HINT:
The clamp (B) is tightened together with the ground cable.
C135146
GETtheMANUALS.org
(B)
EM (A)
C135145J01
48. REMOVE FRONT SUSPENSION CROSS MEMBER

(a) Install the engine hanger No. 1 and No. 2 to the locations shown
(b) Use an engine sling device and chain block to hold the engine
assembly with transaxle and the front suspension cross mem-
ber.
A137720
(c) Remove the 3 bolts and nuts and disconnect the engine mount-
ing insulator FR RH.
A133261
(d) Remove the 2 bolts and nut. Then disconnect the engine
mounting bracket FR RH and remove the front suspension
cross member.
A133260
GETtheMANUALS.org
EM–49
49. REMOVE STARTER ASSEMBLY

(a) Remove the terminal cap.
(b) Remove the nut, then remove terminal 30.
(c) Disconnect the connector.
(d) Remove the 2 bolts and then remove the starter assembly.
50. REMOVE TORQUE CONVERTER SET BOLT (AUTOMATIC

51. SUPPORT TRANSMISSION ASSEMBLY (AUTOMATIC TRANS-

A133263 MISSION)
52. REMOVE TRANSMISSION ASSEMBLY (AUTOMATIC TRANSMIS-

SION)
(a) Remove the 9 bolts and the transmission assembly. EM
NOTICE:
To avoid damage to the knock pin, do not pry the contact
surfaces of the automatic transmission assembly and the
engine.
C136910J01
53. REMOVE FLYWHEEL RING GEAR (AUTOMATIC TRANSMIS-

SION)
(a) Using the SST, secure the flywheel ring gear.
SST SST 09210-87701
(b) Remove the 6 bolts and the flywheel ring gear.
54. SUPPORT TRANSMISSION ASSEMBLY (MANUAL TRANSMIS-

SION)
A137592
55. REMOVE TRANSMISSION ASSEMBLY (MANUAL TRANSMIS-

SION)
(a) Remove the 9 bolts and the transmission assembly.
NOTICE:
Do not jolt the transmission assembly to avoid a damage to
the input shaft.
56. REMOVE CLUTCH COVER ASSEMBLY (MANUAL TRANSMIS-

SION) (See page CL-20)
C136911J04 57. REMOVE CLUTCH DISC ASSEMBLY (MANUAL TRANSMISSION)

(See page CL-20)
58. REMOVE FLYWHEEL (MANUAL TRANSMISSION)
(a) Using the SST, secure the flywheel.
SST 09210-87701
SST (b) Remove the 6 bolts and the flywheel.
A139357
GETtheMANUALS.org
59. REMOVE REAR END PLATE

(a) Remove the bolt and the rear end plate.
A133301
60. REMOVE ENGINE WIRE HARNESS

(a) Disconnect the connectors and the wire harness clamps from
EM the engine assembly, and remove the engine wire harness.
A133303
(b) Detach the alternator connector and then disconnect the wire
harness clamp.
A133305
(c) Remove the cam position sensor and the water temperature
sensor connectors and then disconnect the wire harness clamp
bracket.
62. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (See

page EM-150)
63. REMOVE MANIFOLD STAY (See page EM-150)
A133306
64. REMOVE EXHAUST MANIFOLD (See page EM-150)
69. REMOVE FUEL INJECTOR ASSEMBLY (See page FU-10)
70. REMOVE THROTTLE BODY ASSEMBLY (See page EM-148)
GETtheMANUALS.org
EM–51
73. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Using a deep socket wrench (24 mm), remove the engine oil
pressure switch.
A137321
74. REMOVE IDLER PULLEY NO. 1

(a) Remove the nut, then remove idler pulley No. 1.
75. REMOVE CRANK POSITION SENSOR (See page IG-14) EM

76. REMOVE FAN PULLEY (See page CO-29)
77. REMOVE ALTERNATOR ASSEMBLY (See page CH-10)
A137714

(a) Remove the nut, then remove the knock control sensor.
A109109
79. REMOVE RADIATOR HOSE NO. 4

(a) Loosen the clamp and then remove radiator hose No. 4.
A133307

(a) Loosen the clamp and then remove radiator hose No. 3.
A133408
GETtheMANUALS.org
81. REMOVE WATER BY-PASS HOSE NO. 2

(a) Loosen the clamp and then remove the water by-pass hose No.
2.
A133407

(a) Loosen the clamp and then remove the water by-pass hose No.
EM 4.
83. REMOVE WATER BY-PASS PLATE

(a) Remove the 2 bolts and the water by-pass plate.

(See page EM-152)
A133308
85. REMOVE CAM POSITION SENSOR

(a) Remove the bolt, then remove the cam position sensor.
A136155
86. REMOVE WATER INLET

(a) Remove the bolt and nut and then remove the water inlet.
A133309
87. REMOVE THERMOSTAT

(a) Remove the thermostat.
A136151
GETtheMANUALS.org
EM–53
88. REMOVE WATER TEMPERATURE SENSOR

(a) Using a 19 mm deep socket wrench, remove the water temper-
ature sensor.
A136152
89. REMOVE IGNITION COIL ASSEMBLY

(a) Remove the bolt and the ignition coil assembly.
EM
A133310
90. REMOVE COMPRESSOR MOUNTING BRACKET NO. 1

(a) Remove the 4 bolts and the compressor mounting bracket No.
1.
A133311
91. REMOVE ENGINE MOUNTING BRACKET FR NO. 1 RH

(a) Remove the 4 bolts and the engine mounting bracket FR No. 1
RH.
A133312
92. REMOVE ENGINE MOUNTING BRACKET FR NO. 2

(a) Remove the 4 bolts and the engine mounting bracket FR No. 2.
A133313
GETtheMANUALS.org
93. REMOVE OIL FILTER BRACKET

(a) Remove the 2 bolts and the oil filter bracket.
(b) Remove the oil filter bracket gasket.
INSTALLATION
A133314
1. INSTALL OIL FILTER BRACKET

(a) Install the oil filter bracket with new O-rings attached by the 2
EM bolts. to the cylinder block.
HINT:
Apply a light coat of engine oil to the oil filter bracket union
insertion part.
A133314
2. INSTALL ENGINE MOUNTING BRACKET FR NO. 2

(a) Install the engine mounting bracket FR No. 2 with the 4 bolts.
HINT:
A Tighten part A temporarily, and then tighten it fully after fully
tightening the other 3 bolts.
A139360
3. INSTALL ENGINE MOUNTING BRACKET FR NO. 1 RH

(a) Install the engine mounting bracket FR No. 1 RH with the 4
bolts.
A
HINT:
Tighten part A temporarily, and then tighten it fully after fully
A139361
GETtheMANUALS.org
EM–55
4. INSTALL COMPRESSOR MOUNTING BRACKET NO. 1

(a) Install the compressor mounting bracket No. 1 with the 3 bolts.
A133311
5. INSTALL IGNITION COIL ASSEMBLY

(a) Install the ignition coil assembly with the bolt.
Torque: 7.5 N*m (76 kgf*cm) EM
A133310
6. INSTALL WATER TEMPERATURE SENSOR

(a) Using a new gasket and a 19 mm deep socket wrench, install
the water temperature sensor.
7. INSTALL THERMOSTAT
(a) Install a new gasket to the thermostat.
A136152
(b) Align the water inlet matchmark and the thermostat jiggle valve,
and install the thermostat.
A133315
8. INSTALL WATER INLET

(a) Install the water inlet with the bolt and nut.
9. INSTALL CAM POSITION SENSOR

(a) Apply a light coat of engine oil to the O-ring.
A133309
GETtheMANUALS.org
(b) Install the cam position sensor with the bolt.

NOTICE:
Install the sensor so that the O-ring is not cut or pinched.

(See page EM-162)
11. INSTALL WATER BY-PASS PLATE

(a) Install the water by-pass plate to the cylinder head with a gasket
A136155 and 2 bolts.
(b) Install the water by-pass plate to the water valve bracket with
the bolt.
EM Torque: 7.5 N*m (76 kgf*cm)
12. INSTALL WATER BY-PASS HOSE NO. 2
(a) Install the water by-pass hose No. 2 with the clamp.
A133407

A133308
14. INSTALL RADIATOR HOSE NO. 3

(a) Install the radiator hose No. 3 with the clamp.
A133307
GETtheMANUALS.org
EM–57

A133408

shown in the illustration. EM
17. INSTALL ALTERNATOR ASSEMBLY (See page CH-10)

45°
15° 18. INSTALL FAN PULLEY (See page CO-29)
19. INSTALL CRANK POSITION SENSOR

15° (a) Apply a light coat of engine oil to the O-ring.
A107019J01
(b) Install the crank position sensor with the bolt.

A137713
20. INSTALL IDLER PULLEY NO. 1

(a) Install the idler pulley No. 1 with the nut.
21. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Apply Three Bond TB1344 to the first 2 to 3 threads of the
engine oil pressure switch assembly.
A137714
(b) Using a deep socket wrench (24 mm), install the engine oil
pressure switch assembly.
NOTICE:
Do not start the engine within 1 hour of installation.
22. INSTALL INTAKE MANIFOLD (See page EM-164)
24. INSTALL FUEL INJECTOR ASSEMBLY (See page FU-11)

A137321
GETtheMANUALS.org
25. INSTALL FUEL DELIVERY PIPE

(a) Temporarily install the fuel delivery pipe with the 2 bolts.
NOTICE:
Do not drop the fuel injector when installing the fuel deliv-
ery pipe.
(b) Check that the fuel delivery pipe rotates smoothly.
NOTICE:
If the fuel delivery pipe does not rotate smoothly, reinstall it
with a new O-ring.
A136082 (c) Tighten the 2 bolts.
26. INSTALL OIL LEVEL GAUGE GUIDE

(a) Apply engine oil to a new O-ring, then install it to the oil level
EM gauge guide.
(b) Install the oil level gauge guide with the 2 bolts.
27. INSTALL EXHAUST MANIFOLD (See page EM-162)
28. INSTALL MANIFOLD STAY (See page EM-163)
29. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (See

page EM-163)
30. INSTALL ENGINE WIRE HARNESS
(a) Install the cam position sensor and the water temperature sen-
sor connectors, and then install the wire harness clamp bracket.
A133306
(b) Install the alternator connector, and then install the wire harness
clamp.
Torque: 10 N*m (102 kgf*cm) (Terminal B)
A133305
(c) Install the sensor connectors and wire harness clamps, and
then install the engine wire harness.
A133303
GETtheMANUALS.org
EM–59
34. INSTALL REAR END PLATE

(a) Install the rear end plate with the bolt.
A133301
35. INSTALL FLYWHEEL (MANUAL TRANSMISSION)

(a) Using SST, hold the crankshaft.
SST
SST 09210-87701 EM
(b) Apply Three Bond TB1344 to the first 2 to 3 threads of the fly-
wheel installation bolt.
NOTICE:
Clean and degrease the flywheel installation bolt and bolt
hole.
A139359
(c) Temporarily install the flywheel with the 6 bolts.
A134237
(d) Tighten the 6 bolts in the order shown in the illustration.

NOTICE:
Do not start the engine within 1 hour of the installation.
3 1
36. INSTALL CLUTCH DISC ASSEMBLY (MANUAL TRANSMISSION)
5 6
(See page CL-21)
2 4
37. INSTALL CLUTCH COVER ASSEMBLY (MANUAL TRANSMIS-
A134238
SION)
39. INSTALL TRANSMISSION ASSEMBLY (MANUAL TRANSMIS-

SION)
(a) Ensure that the 2 knock pins are installed on the engine side.
(b) Using a high-mission jack, horizontally align the engine and the
automatic transmission assembly and then insert the knock pin
in the knock pin hole.
GETtheMANUALS.org
(c) Using a pri set torque wrench, temporarily install the transmis-
sion assembly with the 9 bolts.
NOTICE:
• Do not jolt the transmission unit assembly to avoid a
damage to the input shaft.
C136911J04
(d) Tighten the transmission assembly installation bolt A.

EM
C141309
(e) Tighten the transmission assembly installation bolts A, B and C

A A
in order from A to C.
B (1) Tighten bolt A.
NOTICE:
A
B Tighten bolt A together with the water by-pass pipe
No. 2 clamp.
C HINT:
Bolt A part number: 91619-61250 (Length under neck 57
C
C C C136911J03 mm)
(2) Tighten bolt B.
HINT:
Bolt B part number: 91619-61250 (Length under neck 57
mm)
(3) Tighten bolt C.
HINT:
Bolt C part number: 90119-10260 (Length under neck 40
mm)
GETtheMANUALS.org
EM–61
40. INSTALL FLYWHEEL RING GEAR (AUTOMATIC TRANSMISSION)

SST 09330-00021, 09213-54015 (91651-60855)
SST (b) Apply Three Bond TB1344 to the first 2 to 3 threads of the fly-
wheel ring gear installation bolt.
NOTICE:
Clean and degrease the flywheel ring gear installation bolt
and bolt hole.
(c) Temporarily install the flywheel ring gear with the 6 bolts.
A137593

NOTICE: EM
3 1
5 6
MISSION)
2 4
42. INSTALL TRANSMISSION ASSEMBLY (AUTOMATIC TRANSMIS-
SION)
A134236 (a) Ensure that the 2 knock pins are installed on the engine side.
(c) Temporarily install the transmission assembly with the 9 bolts.
A A
NOTICE:
Do not jolt the transmission unit assembly to avoid a dam-
A
age to the input shaft.
C139312J02
GETtheMANUALS.org
(d) Using a torque wrench (QL-100), tighten a new transmission

assembly installation bolt A.
HINT:
Bolt A part number: 91619-61250 (Length under neck 50 mm)
EM
C141308

A A
in order.
Torque: 59 N*m (602 kgf*cm) New bolt A
B 37 N*m (375 kgf*cm) Bolt B
37 N*m (375 kgf*cm) Bolt C
B HINT:
• Bolt A part number: 90041-19968 (Length under neck 57
C
mm)
• Bolt A and B part number: 90041-19968 (Length under neck
C
C C C139312J03 57 mm)
• Bolt C part number: 91612-61040 (Length under neck 40
mm)
43. INSTALL TORQUE CONVERTER SET BOLT (AUTOMATIC

44. INSTALL STARTER ASSEMBLY
(a) Install the starter assembly with 2 bolts.
(c) Install terminal 30 with the nut.
(d) Close the terminal cap.
A133263
GETtheMANUALS.org
EM–63
45. INSTALL FRONT SUSPENSION CROSS MEMBER

assembly with transmission.
EM
A137720
(c) Install the left side front suspension cross member to the engine
assembly with transmission with the 2 bolts and nut.
Torque: 48.1 N*m (490 kgf*cm) (Nut)
30.4 N*m (310 kgf*cm) (Bolt)
A133260
(d) Install the right side front suspension cross member to the
engine assembly with transmission with the 3 bolts and nut.
Torque: 48.1 N*m (490 kgf*cm) (Nut)
30.4 N*m (310 kgf*cm) (Bolt)
A133261
46. INSTALL OIL COOLER TUBE (AUTOMATIC TRANSMISSION)

(a) Temporarily install the oil cooler tube to the transmission
assembly with the 2 union bolts.
(b) Temporarily install clamp A and B with the 2 bolts.
NOTICE:
The clamp (B) is tightened together with the ground wire,
and the ground wire comes on top.
C135146
GETtheMANUALS.org
A
EM
C135145
(c) Tighten the 2 union bolts.

(d) Tighten the bolts of clamp A and B.
Torque: 7.9 N*m (80 kgf*cm) (A)
Torque: 36.8 N*m (375 kgf*cm) (B)
47. INSTALL ENGINE ASSEMBLY WITH TRANSMISSION
A133259
(b) Operate the engine lifer, and then temporarily install the engine
Vehicle Front
assembly with transmission and the front suspension cross
member to the vehicle with the 6 bolts.
(c) Tighten the bolts to the specified torque in several passes.
A133256
(d) Install the engine rear support member to the vehicle with the 4
bolts.
(e) Tighten the bolts to the specified torque in several passes.
A133258
GETtheMANUALS.org
EM–65
48. INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING

(a) Connect the front shock absorber with coil spring to the suspen-
sion knuckle assembly with the 2 bolts and nuts.
C135148
49. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY LH

(a) Connect the disc brake cylinder assembly with the 2 bolts.
50. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY RH
C139221
51. INSTALL SPEED SENSOR FR LH

(a) Install the speed sensor FR LH to the steering knuckle with the
bolt.
Torque: 18.2 N*m (185.5 kgf*cm)
NOTICE:
Tighten it together with the brake flexible hose clamp with
the bolt, with the flexible hose clamp on the top.
C133716
(b) Install the bolt and wire harness clamp to the shock absorber.
52. INSTALL SPEED SENSOR FR RH

53. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


(MANUAL TRANSMISSION) (See page MT-23)
C133715
55. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) (See
page PR-4)
56. INSTALL FRONT SUSPENSION CROSS MEMBER LWR (See page

PR-4)
57. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEM-

BLY (See page PR-7)
GETtheMANUALS.org
58. INSTALL EXHAUST PIPE ASSEMBLY FR

(a) With a new gasket inserted, install the exhaust pipe assembly
FR to the exhaust manifold with the 2 compression springs and
Tail Pipe Side 2 bolts.
NOTICE:
• Make sure the gasket is installed in the correct direc-
Gasket
tion.
• Dropping the gasket may damage it.
A031088J01 • Do not damage the sliding parts of the gasket.
(b) Using a new gasket, install the exhaust tail pipe assembly to the
exhaust pipe assembly FR with the 2 new nuts.
EM (c) Connect oxygen sensor No. 2 connector.
59. INSTALL STEERING SHAFT UNIVERSAL JOINT ASSEMBLY
A133302
60. CONNECT ENGINE WIRE HARNESS

(a) Connect the cylinder head cover ground connector, and then
install the ground wire harness with the 3 bolts.
A133250
(b) Connect the ground wire harness with the bolt.

A133248
GETtheMANUALS.org
EM–67
(c) Connect the 3 engine room R/B connecters and clamp.
A133247
(d) Install the wire harness inside the engine room.

(e) Connect the engine control computer connector, and then install
the glove compartment door assembly. EM
61. CONNECT VACUUM HOSE ASSEMBLY (See page EM-165)

page EM-165)
A133249
63. INSTALL CHARCOAL CANISTER PIPE NO. 1

(a) Install the charcoal canister pipe No. 1 with the bolt.
A133920
64. CONNECT HEATER OUTLET WATER HOSE

(a) Connect the heater outlet water hose.
A136002
65. CONNECT HEATER INLET WATER HOSE

(a) Connect the heater inlet water hose.
66. INSTALL COOLER COMPRESSOR WITH MAGNETIC CLUTCH

67. INSTALL COOLER REFRIGERANT SUCTION HOSE NO. 1

68. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO. 1

A136001
GETtheMANUALS.org
69. INSTALL VANE PUMP WITH BRACKET

(a) Install the vane pump with bracket with the 3 bolts.
70. INSTALL FAN AND ALTERNATOR V BELT (See page EM-8)
71. ADJUST FAN AND ALTERNATOR V BELT (See page EM-9)
72. CHECK FAN AND ALTERNATOR V BELT (See page EM-9)

A137622 74. CONNECT RADIATOR HOSE NO. 1 (See page CO-18)

EM 77. CONNECT OIL COOLER OUTLET HOSE NO. 1 (AUTOMATIC
TRANSMISSION)(See page CO-18)
78. CONNECT OIL COOLER INLET HOSE NO. 1 (AUTOMATIC

79. CONNECT FUEL HOSE NO. 2 (See page EM-165)

80. CONNECT RADIATOR HOSE NO. 2
(a) Connect the radiator hose No. 2 with the clamp.
81. INSTALL BATTERY

(a) Connect the negative terminal with the nut and clamp.
83. INSTALL FRONT TIRE

A136170
84. CHECK FRONT TIRES FACING STRAIGHT AHEAD
85. ADD ENGINE OIL
87. ADD AUTOMATIC TRANSMISSION FLUID (AUTOMATIC TRANS-

MISSION)
88. ADD MANUAL TRANSMISSION OIL (MANUAL TRANSMISSION)
89. ADD TRANSFER OIL (for 4WD)
92. CHECK FOR FUEL LEAKS (See page EM-167)
93. CHECK FOR EXHAUST GAS LEAKS
94. CHECK FOR OIL LEAKS
95. CHECK ENGINE OIL LEVEL (See page EM-167)
96. CHECK ENGINE IDLE SPEED (See page EM-2)
97. CHECK IGNITION TIMING (See page EM-1)
98. CHECK DENSITY OF CO AND HC (See page EM-3)
99. CHARGE REFRIGERANT HFC - 134a [R134a] (STEERING TYPE:

GETtheMANUALS.org
EM–69
100. WARM UP ENGINE (STEERING TYPE: LHD) (See page AC-28)
101. CHECK FOR REFRIGERANT LEAKS (STEERING TYPE: LHD)

(See page AC-28)
102. INITIALIZE LEARNED VALUE IN DS-II (AUTOMATIC TRANSMIS-

SION)
See page AT-15.
103. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

See page SP-4.
104. INSTALL ENGINE UNDER COVER RR LH

(a) Install the engine under cover RR LH with the 4 bolts.
105. INSTALL ENGINE UNDER COVER RR RH EM

(a) Install the engine under cover RR RH with the 7 bolts.
106. INSTALL ENGINE UNDER COVER

(a) Install the engine under cover with the 11 bolts.
107. TEST MODE INSPECTION (SPEED SENSOR)

(See page BC-9.)
(See page BC-65.)
GETtheMANUALS.org
EM–70 ENGINE MECHANICAL - PARTIAL ENGINE ASSEMBLY (K3-VE)
PARTIAL ENGINE ASSEMBLY (K3-VE)

ENGINE MECHANICAL
COMPONENTS
T=7.5{76}
T=3.5{36} ×2
EM BATTERY
CLAMP
T=18{184}
T=7.5{76}
×2
BATTERY
FUEL HOSE NO. 2

T=8.5{87} ×3
ACCELERATOR CONTROL HEATER OUTLET COOLANT HOSE

CABLE ASSEMBLY
BATTERY CARRIER
RADIATOR HOSE NO. 1
RADIATOR HOSE NO. 2
OIL COOLER OUTLET HOSE NO. 1
T=5.4{55}
×7
T=5.4{55}
×4
T=5.4{55} ×11 ENGINE UNDER COVER
GETtheMANUALS.org
ENGINE MECHANICAL - PARTIAL ENGINE ASSEMBLY (K3-VE)
EM–71
ENGINE ROOM R/B

CYLINDER HEAD
A/T COVER GROUND
TRANSMISSION CONTROL WIRE HARNESS
CHARCOAL CANISTER PIPE NO. 1
CABLE ASSEMBLY
GROUND WIRE
HARNESS
M/T
CABLE ASSEMBLY
T=7.5{76}
EM
VACUUM HOSE ASSEMBLY
T=29.4{300}
T=29.4{300}
STEERING INTERMEDIATE SHAFT ASSEMBLY

COOLER COMPRESSOR WITH
T=25{255}
SPEED SENSOR FR LH
T=10{102}
O-RING
T=8.4{86}
O-RING COOLER REFRIGERANT

DISCHARGE HOSE NO. 1 EXHAUST PIPE GASKET
T=25{225}
COOLER REFRIGERANT
SUCTION HOSE NO. 1
T=19{194}
T=10{102}
T=19{194}

EXHAUST PIPE GASKET
T=46{469}
GETtheMANUALS.org
2WD PROPELLER WITH CENTER ×4

T=60{612}
FRONT DISC BRAKE ×2

T=37{377}
VANE PUMP WITH BRACKET FRONT SHOCK ABSORBER

×2 WITH COIL SPRING
T=112.8{1150}
EM
T=97.5{976}
FRONT DISC BRAKE
×2
CYLINDER ASSEMBLY RH
T=112.8{1150}
×6 ×2
FRONT SUSPENSION
CROSS MEMBER
T=125{1275}
4WD FRONT PROPELLER SHAFT ASSEMBLY

T=60{612}
×4
×4
T=60{612}
×2
FRONT DISC BRAKE T=37{377} PROPELLER WITH CENTER
CYLINDER ASSEMBLY RH BEARING SHAFT ASSEMBLY
×2
VANE PUMP WITH BRACKET
T=112.8{1150}
FRONT SHOCK ABSORBER
WITH COIL SPRING
T=95.7{976}
×2 FRONT DISC BRAKE
T=112.8{1150}
FRONT SUSPENSION
CROSS MEMBER ×2
×6
T=125{1275}
TIGHTENING TORQUE
A137621J02
GETtheMANUALS.org
EM–73

T=7.5{76}
×4
×4
SPARK PLUG
×4
REAR END PLATE
FAN PULLEY
EM
T=7.5{76}
T=11.5{117}
T=44{449} ENGINE OIL PRESSURE

SWITCH ASSEMBLY
T=15{153}
IDLER PULLEY NO. 1
×2
T=20.6{210}
VANE PUMP OIL FILTER BRACKET

T=43.2{440} T=7.5{76}
WITH BRACKET
COMPRESSOR MOUNTING BRACKET NO. 1
A/T T=78{800}
T=27.5{280}
×2
ENGINE MOUNTING T=19{194}
×6
INSULATOR FR RH O-RING
T=37{377}
T=28{286} ×6
×4
FLYWHEEL RING GEAR
BRACKET FR NO. 2
M/T T=19.1{195}
×4
×3 T=18{184} T=78{800} ×6
T=30.4{310}
×2
ENGINE MOUNTING
BRACKET FR NO. 1 RH ×6
T=30.4{310}
CLUTCH COVER
ASSEMBLY
ENGINE MOUNTING INSULATOR FLYWHEEL
FRONT LH
GETtheMANUALS.org
4WD
×7
T=37{375}
T=36.8{375}
T=7.9{80}
OIL COOLER
HOSE
T=34.3{349}
×2
EM OIL COOLER TUBE GASKET
TRANSFER ASSEMBLY
OIL COOLER HOSE
T=58.8{596}
T=58.8{596}

ASSEMBLY
O-RING
T=84.5{85}
x6
TRANSMISSION
T=58.8{596} SENSOR

T=36.8{375}
T=68{693}
T=68{693}
T=37{375}
T=68{693}
FRONT SUSPENSION
T=68{693}
C139184J09
GETtheMANUALS.org
EM–75
T=37{375}
T=58.8{596}
EM
T=58.8{596}
T=18{185}
T=36.8{375}
T=36.8{375}
T=68{693}
T=68{693}

C140480J01
GETtheMANUALS.org
T=8.5{87}

COOLANT BYPASS HOSE O-RING
T=7.5{76}
T=21{214}
EM THROTTLE BODY
×2
ASSEMBLY T=7.5{76}
×2 THROTTLE BODY BRACKET NO. 2
T=19{194}
O-RING
×2
T=19{194} T=21{214}
×2 ×3 THROTTLE BODY BRACKET
T=7.5{76}
RADIATOR PIPE
VENTILATION HOSE INTAKE MANIFOLD

TO HEAD GASKET
INTAKE MANIFOLD
T=7.5{76}
O-RING
EXHAUST MANIFOLD
HEAT INSULATOR NO. 1
T=8.5{87}
VALVE ASSEMBLY
FANBELT ADJUSTING BAR T=8.5{87}
T=10{102}
T=19{194}
T=19{194}
T=44{449}
T=35{357}
ALTERNATOR ASSEMBLY ×2
MANIFOLD STAY ×3
T=35{357}
EXHAUST MANIFOLD TO HEAD GASKET
T=9.3{95}
EXHAUST MANIFOLD
A137041J01
GETtheMANUALS.org
EM–77
FUEL DELIVERY PIPE
COOLANT TEMPERATURE T=21{214}

SENSOR ×2
RADIATOR HOSE NO. 4

GASKET
CAMSHAFT POSITION ×4
SENSOR ×4 EM
T=7.5{76} INJECTOR VIBRATION ×4
INSULATOR
T=19.0{200} T=20{204}
GASKET
GASKET ×2
COOLANT BYPASS PLATE
T=9.0{92} FUEL INJECTOR
ASSEMBLY
T=20{204}
WATER INLET
T=8.8{90}
THERMOSTAT
×2
WATER BYPASS HOSE NO. 4
T=37{377}
STARTER ASSEMBLY
RADIATOR HOSE NO. 2
COOLANT RADIATOR HOSE NO. 3

A137074J01
GETtheMANUALS.org
REMOVAL

See page RS-164.
EM 8. REMOVE REFRIGERANT HFC - 134a (R134a) (Steering type:

11. DRAIN ENGINE OIL

(a) After draining the engine oil, install the drain plug using a new
gasket.


14. DRAIN TRANSFER OIL (for 4WD) (See page TF-7)
16. DISCONNECT FUEL HOSE NO. 2 (See page EM-175)


19. REMOVE BATTERY

(a) Remove the battery clamp.
(b) Remove the battery.
22. DISCONNECT RADIATOR HOSE NO.1(See page CO-22)
GETtheMANUALS.org
EM–79
25. REMOVE VANE PUMP WITH BRACKET

(a) Remove the 3 bolts and the vane pump with bracket.
26. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO.

1 (STEERING TYPE: LHD) (See page AC-51)

28. DISCONNECT COOLER COMPRESSOR WITH MAGNETIC

CLUTCH ASSEMBLY (See page AC-51)
A137622

(a) Detach the clamp and disconnect the heater inlet water hose.
EM
A136001

(a) Detach the clamp and disconnect the heater outlet water hose.
A136002

(a) Remove the bolt and the charcoal canister pipe No. 1.

(See page EM-175)
34. DISCONNECT ENGINE WIRE HARNESS

(a) Remove the glove compartment door assembly and then dis-
connect the connectors of the engine control computer.
A133920
(b) Pull the wire harness out through the engine room side.
A133249
GETtheMANUALS.org
(c) Remove the bolt and disconnect the ground wire harness.
A133248
(d) Remove the connectors and clamps from the engine room R/B,
and then disconnect the wire harness.
EM
A133247
(e) Disconnect the ground connector of the cylinder head cover.

(f) Remove the bolt and disconnect the ground wire harness.
(g) Disconnect all the wire harnesses and connectors, and check
that the wire harness is not connected between the body and
the engine.
35. REMOVE STEERING SHAFT UNIVERSAL JOINT ASSEMBLY (See

page PS-11)
A133250

A134988
(b) Disconnect the oxygen sensor No. 2 connector.
A133302
GETtheMANUALS.org
EM–81
(c) Remove the 2 bolts and 2 springs.

(d) Remove the exhaust support cushion, and then remove the

BLY (See page PR-6)
38. REMOVE FRONT SUSPENSION CROSS MEMBER LWR (for 4WD)

(See page PR-3)
39. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)

A134989
(See page PR-3)

41. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY EM

(a) Remove the bolt, and disconnect the speed sensor FR LH from
the steering knuckle.
C133716
(b) Remove the bolt and nut, and disconnect the wire harness
clamp from the shock absorber.

C133715
44. SEPARATE FRONT DISC BRAKE CYLINDER ASSEMBLY LH

(a) Remove the 2 bolts, and disconnect the front disc brake cylin-
der assembly LH.
(b) Hang the disconnected front disc brake cylinder assembly LH
with wire or similar.
45. SEPARATE FRONT DISC BRAKE CYLINDER ASSEMBLY RH

C139221
GETtheMANUALS.org

(a) Remove the 4 bolts and 4 nuts, and disconnect the front shock
absorber with coil spring LH and RH from the steering knuckle.
C135148
47. REMOVE ENGINE ASSEMBLY WITH TRANSMISSION

EM
A133259
member.
A133258
(c) Remove the 6 bolts, operate the engine lifer, and then remove
Vehicle Front
the engine assembly with transaxle and the front suspension
crossmember from the vehicle.
A133256
48. REMOVE OIL COOLER TUBE (AUTOMATIC TRANSMISSION)

(a) Remove the 2 union bolts and disconnect the oil cooler tube.
(b) Remove the bolt and disconnect the clamp (A) from the trans-
mission assembly.
(c) Remove the bolt, and then remove the clamp (B) from the
engine mount bracket.
HINT:
The clamp (B) is tightened together with the ground cable.
C135146
GETtheMANUALS.org
EM–83
(B)
(A) EM
C135145J01
49. REMOVE FRONT SUSPENSION CROSS MEMBER

assembly with transaxle and the front suspension cross mem-
ber.
A137720
(c) Remove the 3 bolts and nuts and disconnect the engine mount-
ing insulator FR RH.
A133261
(d) Remove the 2 bolts and nut. Then disconnect the engine
mounting bracket FR RH and remove the front suspension
cross member.
A133260
GETtheMANUALS.org

(b) Remove the nut, then remove terminal 30.
(d) Remove the 2 bolts and then remove the starter assembly.
51. REMOVE TORQUE CONVERTER SET BOLT (AUTOMATIC


A133263 MISSION)

SION)
EM (a) Remove the 9 bolts and the transmission assembly.
NOTICE:
To avoid damage to the knock pin, do not pry the contact
surfaces of the automatic transmission assembly and the
engine.
C136910J01

SION)
(a) Using the SST, secure the flywheel ring gear.
SST SST 09210-87701
(b) Remove the 6 bolts and the flywheel ring gear.

SION)
A137592

SION)
(a) Remove the 9 bolts and the transmission assembly.
NOTICE:
Do not jolt the transmission assembly to avoid a damage to
the input shaft.

C136911J04 58. REMOVE CLUTCH DISC ASSEMBLY (MANUAL TRANSMISSION)

(See page CL-20)
GETtheMANUALS.org
EM–85
59. REMOVE FLYWHEEL (MANUAL TRANSMISSION)

(a) Using the SST, secure the flywheel.
SST 09210-87701
SST (b) Remove the 6 bolts and the flywheel.
A139357
60. REMOVE REAR END PLATE

(a) Remove the bolt and the rear end plate.
EM
A133301
61. REMOVE ENGINE WIRE HARNESS

(a) Disconnect the connectors and the wire harness clamps from
the engine assembly, and remove the engine wire harness.
A133303
(b) Detach the alternator connector and then disconnect the wire
harness clamp.
A133305
(c) Remove the cam position sensor and the water temperature
sensor connectors and then disconnect the wire harness clamp
bracket.
63. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (See

page EM-177)
64. REMOVE MANIFOLD STAY (See page EM-177)
A133306
65. REMOVE EXHAUST MANIFOLD (See page EM-178)
GETtheMANUALS.org
70. REMOVE FUEL INJECTOR ASSEMBLY (See page FU-15)

74. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a) Using a deep socket wrench (24 mm), remove the engine oil
EM pressure switch.
A137321

76. REMOVE CRANK POSITION SENSOR (See page IG-16)
A137714

(a) Remove the nut, then remove the knock control sensor.
A109109
GETtheMANUALS.org
EM–87

(a) Remove the clamp and then remove radiator hose No. 4.
A133408

(a) Remove the clamp and then remove radiator hose No. 3.
EM
A133307

(a) Remove the clamp and then remove the water by-pass hose
No. 2.
A133407

(a) Remove the clamp and then remove the water by-pass hose
No. 4.
84. REMOVE WATER BY-PASS PLATE

(a) Remove the 2 bolts and the water by-pass plate.

(See page EM-180)
A133308

(a) Remove the bolt, then remove the cam position sensor.
A136155
GETtheMANUALS.org

(a) Remove the bolt and nut and then remove the water inlet.
A133309

EM
A136151
89. REMOVE WATER TEMPERATURE SENSOR

(a) Using a 19 mm deep socket wrench, remove the water temper-
ature sensor.
A136152

(a) Remove the bolt and the ignition coil assembly.
A133310
91. REMOVE COMPRESSOR MOUNTING BRACKET NO. 1

(a) Remove the 4 bolts and the compressor mounting bracket No.
1.
A133311
GETtheMANUALS.org
EM–89
92. REMOVE ENGINE MOUNTING BRACKET FR NO. 1 RH

(a) Remove the 4 bolts and the engine mounting bracket FR No. 1
RH.
A133312
93. REMOVE ENGINE MOUNTING BRACKET FR NO. 2

(a) Remove the 4 bolts and the engine mounting bracket FR No. 2.
EM
A133313
94. REMOVE OIL FILTER BRACKET

(a) Remove the 2 bolts and the oil filter bracket.
(b) Remove the oil filter bracket gasket.
INSTALLATION
A133314
1. INSTALL OIL FILTER BRACKET

(a) Install the oil filter bracket with new O-rings attached by the 2
bolts. to the cylinder block.
HINT:
Apply a light coat of engine oil to the oil filter bracket union
insertion part.
A133314
2. INSTALL ENGINE MOUNTING BRACKET FR NO. 2

(a) Install the engine mounting bracket FR No. 2 with the 4 bolts.
HINT:
A Tighten part A temporarily, and then tighten it fully after fully
A139360
GETtheMANUALS.org
3. INSTALL ENGINE MOUNTING BRACKET FR NO. 1 RH

(a) Install the engine mounting bracket FR No. 1 RH with the 4
bolts.
A
HINT:
Tighten part A temporarily, and then tighten it fully after fully
A139361
4. INSTALL COMPRESSOR MOUNTING BRACKET NO. 1

(a) Install the compressor mounting bracket No. 1 with the 3 bolts.
EM Torque: 28 N*m (286 kgf*cm)
A133311

A133310
6. INSTALL WATER TEMPERATURE SENSOR

(a) Using a new gasket and a 19 mm deep socket wrench, install
the water temperature sensor.
(a) Install a new gasket to the thermostat.
A136152
(b) Align the water inlet matchmark and the thermostat jiggle valve,
and install the thermostat.
A133315
GETtheMANUALS.org
EM–91

(a) Install the water inlet with the bolt and nut.

A133309
(b) Install the cam position sensor with the bolt.

NOTICE: EM

(See page EM-189)
11. INSTALL WATER BY-PASS PLATE

(a) Install the water by-pass plate to the cylinder head with a gasket
A136155 and 2 bolts.
(b) Install the water by-pass plate to the water valve bracket with
the bolt.
A133407

A133308
GETtheMANUALS.org

A133307

EM
A133408


45°
15° 18. INSTALL FAN PULLEY (See page CO-33)

15° (a) Apply a light coat of engine oil to the O-ring.
A107019J01

A137713

21. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Apply Three Bond TB1344 to the first 2 to 3 threads of the
engine oil pressure switch assembly.
A137714
GETtheMANUALS.org
EM–93
(b) Using a deep socket wrench (24 mm), install the engine oil
NOTICE:
24. INSTALL FUEL INJECTOR ASSEMBLY (See page FU-16)

A137321

(a) Temporarily install the fuel delivery pipe with the 2 bolts.
NOTICE: EM
Do not drop the fuel injector when installing the fuel deliv-
ery pipe.
(b) Check that the fuel delivery pipe rotates smoothly.
NOTICE:
If the fuel delivery pipe does not rotate smoothly, reinstall it
with a new O-ring.
A136082 (c) Tighten the 2 bolts.

(a) Apply engine oil to a new O-ring, then install it to the oil level
gauge guide.
(b) Install the oil level gauge guide with the 2 bolts.
27. INSTALL EXHAUST MANIFOLD (See page EM-190)
28. INSTALL MANIFOLD STAY (See page EM-191)
29. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (See

page EM-191)
30. INSTALL ENGINE WIRE HARNESS
(a) Install the cam position sensor and the water temperature sen-
sor connectors, and then install the wire harness clamp bracket.
A133306
(b) Install the alternator connector, and then install the wire harness
clamp.
Torque: 10 N*m (102 kgf*cm) (Terminal B)
A133305
GETtheMANUALS.org
(c) Install the sensor connectors and wire harness clamps, and
then install the engine wire harness.
A133303
34. INSTALL REAR END PLATE

(a) Install the rear end plate with the bolt.
A133301
35. INSTALL FLYWHEEL (MANUAL TRANSMISSION)

SST 09210-87701
wheel installation bolt.
NOTICE:
Clean and degrease the flywheel installation bolt and bolt
hole.
A139359
(c) Temporarily install the flywheel with the 6 bolts.
A134237

NOTICE:
3 1
5 6
(See page CL-21)
2 4
A134238
GETtheMANUALS.org
EM–95

SION)
39. INSTALL TRANSMISSION ASSEMBLY (MANUAL TRANSAXLE)

(a) Ensure that the 2 knock pins are installed on the engine side.
NOTICE:
• Do not jolt the transmission unit assembly to avoid a
damage to the input shaft.
EM
C136911J04
(d) Using a pri set torque wrench, tighten the transmission assem-
bly installation bolt A.
C141309

A A
in order.
B (1) Tighten bolt A.
NOTICE:
A
B Tighten bolt A together with the water by-pass pipe
No. 2 clamp.
C HINT:
Bolt A part number: 91619-61250 (Length under neck
C
C C C136911J03 57m)
(2) Tighten bolt B.
GETtheMANUALS.org
HINT:
Bolt B part number: 91619-61250 (Length under neck 57
mm)
(3) Tighten bolt C.
HINT:
Bolt C part number: 90119-10260 (Length under neck 40
mm)
SST 09330-00021, 09213-54015 (91651-60855)
wheel ring gear installation bolt.
EM NOTICE:
Clean and degrease the flywheel ring gear installation bolt
and bolt hole.
(c) Temporarily install the flywheel ring gear with the 6 bolts.
A137593

NOTICE:
3 1
5 6
MISSION)
2 4
SION)
A134236 (a) Ensure that the 2 knock pins are installed on the engine side.
A A
NOTICE:
Do not jolt the transmission unit assembly to avoid a dam-
A
age to the input shaft.
C139312J02
GETtheMANUALS.org
EM–97
(d) Using a torque wrench (QL-100), tighten a new transmission

assembly installation bolt A.
HINT:
Bolt A part number: 91619-61250 (Length under neck 50 mm)
EM
C141308

A A
in order.
Torque: 59 N*m (602 kgf*cm) New bolt A
37 N*m (375 kgf*cm) Bolt C
B HINT:
• Bolt A part number: 90041-19968 (Length under neck 57
C
mm)
• Bolt A and B part number: 90041-19968 (Length under neck
C
C C C139312J03 57 mm)
• Bolt C part number: 91612-61040 (Length under neck 40
mm)
43. INSTALL TORQUE CONVERTER SET BOLT (AUTOMATIC

(a) Install the starter assembly with 2 bolts.
(c) Install terminal 30 with the nut.
(d) Close the terminal cap.
A133263
GETtheMANUALS.org
45. INSTALL FRONT SUSPENSION CROSS MEMBER

assembly with transmission.
EM
A137720
(c) Install the left side front suspension cross member to the engine
assembly with transmission with the 2 bolts and nut.
Torque: 48.1 N*m (490 kgf*cm) (nut)
30.4 N*m (310 kgf*cm) (bolt)
A133260
(d) Install the right side front suspension cross member to the
engine assembly with transmission with the 3 bolts and nut.
30.4 N*m (310 kgf*cm) (bolt)
A133261
46. INSTALL OIL COOLER TUBE (AUTOMATIC TRANSMISSION)

(b) Temporarily install clamp A and B with the 2 bolts.
NOTICE:
The clamp (B) is tightened together with the ground wire,
and the ground wire comes on top.
C135146
GETtheMANUALS.org
EM–99
A
EM
C135145

(d) Tighten the bolts of clamp A and B.
Torque: 7.9 N*m (80 kgf*cm) (A)
Torque: 36.8 N*m (375 kgf*cm) (B)
47. INSTALL ENGINE ASSEMBLY WITH TRANSMISSION
A133259
(b) Operate the engine lifer, and then temporarily install the engine
Vehicle Front
assembly with transmission and the front suspension cross
member to the vehicle with the 6 bolts.
(c) Tighten the bolts to the specified torque in several passes.
A133256
(d) Install the engine rear support member to the vehicle with the 4
bolts.
(e) Tighten the bolts to the specified torque in several passes.
A133258
GETtheMANUALS.org

(a) Connect the front shock absorber with coil spring to the suspen-
sion knuckle assembly with the 2 bolts and nuts.
C135148
49. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY LH

(a) Connect the disc brake cylinder assembly with the 2 bolts.
50. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY RH

C139221
51. INSTALL SPEED SENSOR FR LH

(a) Install the speed sensor FR LH to the steering knuckle with the
bolt.
NOTICE:
Tighten it together with the brake flexible hose clamp with
the bolt, with the flexible hose clamp on the top.
C133716
(b) Install the bolt and wire harness clamp to the shock absorber.
52. INSTALL SPEED SENSOR FR RH



C133715
55. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) (See
page PR-4)

PR-4)

BLY (See page PR-7)
GETtheMANUALS.org
EM–101

(a) With a new gasket inserted, install the exhaust pipe assembly
FR to the exhaust manifold with the 2 compression springs and
Tail Pipe Side 2 bolts.
NOTICE:
Gasket
tion.
A031088J01 • Do not damage the sliding parts of the gasket.
(b) Using a new gasket, install the exhaust tail pipe assembly to the
exhaust pipe assembly FR with the 2 new nuts.
(c) Connect oxygen sensor No. 2 connector. EM
59. INSTALL STEERING SHAFT UNIVERSAL JOINT ASSEMBLY (See
page PS-25)
A133302
60. CONNECT ENGINE WIRE HARNESS

(a) Connect the cylinder head cover ground connector, and then
install the ground wire harness with the 3 bolts.
A133250
(b) Connect the ground wire harness with the bolt.

A133248
GETtheMANUALS.org
(c) Connect the 3 engine room R/B connecters and clamp.
A133247
(d) Install the wire harness inside the engine room.

(e) Connect the engine control computer connector, and then install
EM the glove compartment door assembly.

page EM-193)
A133249

(a) Install the charcoal canister pipe No. 1 with the bolt.
A133920

A136002




A136001
GETtheMANUALS.org
EM–103
69. INSTALL VANE PUMP WITH BRACKET

(a) Install the vane pump with bracket with the 3 bolts.
Torque: 20.6 N*m (210 kgf*cm) (Bolt A)
43.2 N*m (440 kgf*cm) (Bolt B)
A
A

B
A140646
74. CONNECT RADIATOR HOSE NO. 1 (See page CO-18)
76. INSTALL BATTERY CARRIER (See page EM-194) EM

77. CONNECT OIL COOLER OUTLET HOSE NO. 1 (AUTOMATIC

79. CONNECT FUEL HOSE NO. 2 (See page EM-193)

(a) Connect the radiator hose No. 2 with the clamp.
81. INSTALL BATTERY

(a) Connect the negative terminal with the nut and clamp.

A136170
85. ADD ENGINE OIL

MISSION)
89. ADD TRANSFER OIL (for 4WD)
90. CHARGE REFRIGERANT HFC - 134a [R134a] (STEERING TYPE:

91. WARM UP ENGINE (STEERING TYPE: LHD) (See page AC-28)
92. CHECK FOR REFRIGERANT LEAKS (STEERING TYPE: LHD)

(See page AC-28)
GETtheMANUALS.org
102. INITIALIZE LEARNED VALUE IN DS-II (AUTOMATIC TRANSMIS-

SION)
See page AT-15.

See page SP-4.

(a) Install the engine under cover RR LH with the 4 bolts.
EM 105. INSTALL ENGINE UNDER COVER RR RH
(a) Install the engine under cover RR RH with the 7 bolts.


(See page BC-9.)
(See page BC-65.)
GETtheMANUALS.org
ENGINE MECHANICAL - CHAIN (3SZ-VE)
EM–105
CHAIN (3SZ-VE)
ENGINE MECHANICAL
COMPONENTS
T=3.5{36}
BATTERY
BATTERY CLAMP T=7.5{76}
×2
EM
T=8.5{87} ×3 T=18{184}
T=7.5{76} ×2
BATTERY CARRIER
AIR CLEANER HOSE NO. 1 ACCELERATOR CONTROL CABLE ASSEMBLY
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} ×11
..... TIGHTENING TORQUE [N*m{kgf*cm}]

A136903J01
GETtheMANUALS.org
EM–106 ENGINE MECHANICAL - CHAIN (3SZ-VE)
VENTILATION HOSE IGNITION COIL ASSEMBLY
EM VENTILATION HOSE NO. 2 SPARK PLUG

T=20{204}
T=7.5{76}
×4
CAMSHAFT TIMING OIL T=7.5{76}

CONTROL VALVE ASSEMBLY ×4
×4
O-RING
T=7.5{76}
IDLER PULLEY
IDLER PULLEY NO. 1

RADIATOR PIPE
×3
T=11.5{117}
T=44{449}
T=130{1326}
×3
T=20.6{210}
O-RING
T=7.5{76}
CRANKSHAFT PULLEY VANE PUMP ASSEMBLY
..... TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PART

A136904J02
GETtheMANUALS.org
EM–107
OIL FILLER CAP

T=11{112}
CYLINDER HEAD COVER
T=9.0{92}
×11
CHAIN TENSIONER PLUNGER

EM
CYLINDER HEAD COVER GASKET
TIMING CHAIN
TENSIONER ARM
TIMING GEAR (CHAIN)
COVER GASKET
TIMING CHAIN GUIDE
T=9.0{92}
CHAIN
T=23{235}
T=12{122}
×9
×2
T=44{449} ×3
T=19{195}
T=7.5{76}
T=7.5{76}
×2
TIMING CHAIN (BELT) COVER OIL SEAL
TIMING CHAIN GUIDE NO. 2
CRANKSHAFT ANGLE SENSOR PLATE NO. 1
APPLY MP GREASE
..... TIGHTENING TORQUE [N*m{kgf*cm} NON-REUSEABLE PART A136905J03
GETtheMANUALS.org
REMOVAL
(See page SS-10.)
4. DRAIN ENGINE OIL
EM 8. REMOVE ACCELERATOR CONTROL CABLE ASSEMBLY (See

page EM-147)
11. REMOVE VANE PUMP ASSEMBLY (See page EM-44)
12. REMOVE IDLER PULLEY NO. 1 (See page EM-150)
13. DISCONNECT VENTILATION HOSE (See page EM-147)
14. DISCONNECT VENTILATION HOSE NO. 2 (See page EM-147)
19. REMOVE CRANKSHAFT PULLEY (See page EM-151)
20. REMOVE CAM POSITION SENSOR (See page EM-152)

(See page EM-152)
22. REMOVE TIMING CHAIN (BELT) COVER (See page EM-152)
23. REMOVE TIMING CHAIN (BELT) COVER OIL SEAL (See page
EM-153)
24. REMOVE CRANK ANGLE SENSOR PLATE NO. 1
(a) Remove the crank angle sensor plate No. 1.
D-MARK
25. REMOVE CHAIN TENSIONER PLUNGER
(a) Move the stopper plate downward and hold it with the lock
released.[*1]
HINT:
If it is difficult to release the stopper plate lock, use the hexagon
head portion of the camshaft and rotate the camshaft a little to
the right and left.
A135998
GETtheMANUALS.org
EM–109
(b) Under the conditions noted at [*1], use the hexagon head por-
and hold.[*2]
HINT:
plunger.
A108005
(c) Under the conditions noted at [*2], align the stopper plate and
the chain tensioner plunger hole.[*3]
HINT: EM
If the stopper plate and the chain tensioner plunger hole are dif-
ficult to align, rotate the camshaft a little to the left and then
back a little to the right again to align them.
Stopper Plate Plunger

A108555J02
(d) Under the conditions noted at [*3], insert a bar of 3 mm in diam-

eter into the stopper plate and the chain tensioner plunger hole.
(e) Remove the bolt and nut and then remove the chain tensioner
plunger.
A108556
26. REMOVE TIMING CHAIN TENSION ARM

(a) Remove the bolt and the timing chain tensioner arm.
A108557
27. REMOVE TIMING CHAIN GUIDE

(a) Remove the 2 bolts and the timing chain guide.
A108558
GETtheMANUALS.org
28. REMOVE TIMING CHAIN GUIDE NO. 2

(a) Remove the 2 bolts and the timing chain guide No. 2.
29. REMOVE CHAIN
INSTALLATION
A108559
1. INSTALL CHAIN
(a) Align the mark plate (yellow) and the timing mark as shown in
EM Mark Plate Mark Plate
the illustration and install the chain.
Timing Mark Timing Mark
Mark Plates
Timing Mark
A137742
2. INSTALL TIMING CHAIN GUIDE NO. 2

(a) Install the timing chain guide No. 2 with the 2 bolts.
A108559
GETtheMANUALS.org
EM–111
3. INSTALL TIMING CHAIN GUIDE

(a) Install the timing chain guide with the 2 bolts.
A108558
4. INSTALL TIMING CHAIN TENSION ARM

(a) Install the timing chain tension arm with the bolt.
Torque: 19 N*m (195 kgf*cm) EM
A108557
5. INSTALL CHAIN TENSIONER PLUNGER

(a) Install the chain tensioner plunger with the bolt and nut.
HINT:
Using the hexagon wrench head portion of the camshaft, rotate
the camshaft a little to the left, and with the chain slightly slack
on the chain tensioner plunger side, attach the chain tensioner
plunger.
(b) Pull the 3 mm diameter bar out from the chain tensioner
A108556 plunger.
6. INSTALL CRANK ANGLE SENSOR PLATE NO. 1

(a) Install the crank angle sensor plate No. 1 so that the D mark is
D-MARK
visible.
7. INSTALL TIMING CHAIN (BELT) COVER (See page EM-160)
8. INSTALL TIMING CHAIN (BELT) COVER OIL SEAL (See page EM-
200)
9. INSTALL CRANK POSITION SENSOR (See page EM-57)
A135998
(See page EM-162)
11. INSTALL CRANKSHAFT PULLEY (See page EM-161)
13. INSTALL SPARK PLUG (See page EM-162)
GETtheMANUALS.org
19. INSTALL IDLER PULLEY NO. 1 (See page EM-163)
20. INSTALL VANE PUMP ASSEMBLY (See page EM-68)
21. INSTALL FAN PULLEY (See page CO-29)

page EM-165)
EM 26. INSTALL RADIATOR HOSE NO. 1 (See page CO-18)
30. INSTALL BATTERY

33. ADD ENGINE OIL
35. INSPECT ENGINE OIL LEAKS
38. CHECK IDLE SPEED (See page EM-2)
GETtheMANUALS.org
ENGINE MECHANICAL - CHAIN (K3-VE)
EM–113
CHAIN (K3-VE)
ENGINE MECHANICAL
COMPONENTS
T=3.5{36}
BATTERY
×2
EM
T=8.5{87} ×3 T=18{184}
T=7.5{76} ×2
BATTERY CARRIER
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} ×11

A136903J01
GETtheMANUALS.org
EM–114 ENGINE MECHANICAL - CHAIN (K3-VE)

T=20{204}
T=7.5{76}
×4

×4
O-RING
T=7.5{76}
IDLER PULLEY
IDLER PULLEY NO. 1

RADIATOR PIPE
×3
T=11.5{117}
T=44{449}
T=130{1326}
×3
T=20.6{210}
O-RING
T=7.5{76}

A136904J02
GETtheMANUALS.org
EM–115
OIL FILLER CAP

T=11{112}
CYLINDER HEAD COVER
T=9.0{92}
×11

EM
TIMING CHAIN
TENSIONER ARM
TIMING GEAR (CHAIN)
COVER GASKET
TIMING CHAIN GUIDE
T=9.0{92}
CHAIN
T=23{235}
T=12{122}
×9
×2
T=44{449} ×3
T=19{195}
T=7.5{76}
T=7.5{76}
×2
MP GREASE
..... TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PART A136905J05
GETtheMANUALS.org
REMOVAL
(See page RS-164.)
2. REMOVE BATTERY CARRIER (See page EM-173 )
4. DRAIN ENGINE OIL
5. DRAIN ENGINE COOLANT (See page CO-11 )
6. REMOVE AIR CLEANER ASSEMBLY (See page EM-173 )
7. REMOVE RADIATOR HOSE NO. 1 (See page CO-22 )
EM 8. REMOVE ACCELERATOR CONTROL CABLE ASSEMBLY (See

page EM-175 )
9. REMOVE FAN AND ALTERNATOR V BELT (See page EM-12 )
10. REMOVE VANE PUMP WITH BRACKET (See page EM-79 )
11. REMOVE FAN PULLEY (See page CO-33 )
12. REMOVE IDLER PULLEY NO. 1 (See page EM-177 )
13. DISCONNECT VENTILATION HOSE (See page EM-174 )
14. DISCONNECT VENTILATION HOSE NO. 2 (See page EM-174 )
15. REMOVE ENGINE ROOM MAIN WIRE (See page EM-175 )
16. REMOVE RADIATOR PIPE (See page EM-174 )
17. REMOVE IGNITION COIL ASSEMBLY (See page EM-178 )
18. REMOVE CYLINDER HEAD COVER (See page EM-178 )
19. REMOVE CRANKSHAFT PULLEY (See page EM-179 )
20. REMOVE CAM POSITION SENSOR (See page EM-179 )

(See page EM-180 )
22. REMOVE TIMING CHAIN (BELT) COVER (See page EM-180 )
23. REMOVE TIMING CHAIN (BELT) COVER OIL SEAL (See page
EM-180 )
D-MARK
released.[*1]
HINT:
the right and left.
A135998
GETtheMANUALS.org
EM–117
and hold.[*2]
HINT:
plunger.
A108005
HINT: EM
Stopper Plate Plunger A108555J02

(e) Remove the bolt and nut and then remove the chain tensioner
plunger.
A108556

A108557

A108558
GETtheMANUALS.org

29. REMOVE CHAIN
INSTALLATION
A108559
1. INSTALL CHAIN
(a) Align the mark plate (yellow) and the timing mark as shown in
EM Mark Plate Mark Plate
Mark Plates
Timing Mark
A137742

A108559
GETtheMANUALS.org
EM–119

A108558

Torque: 19 N*m (195 kgf*cm) EM
A108557

HINT:
plunger.
A108556 plunger.

(a) Install the crank angle sensor plate No. 1 so that the D mark is
D-MARK
visible.
7. INSTALL TIMING CHAIN (BELT) COVER (See page EM-188 )
8. INSTALL TIMING CHAIN (BELT) COVER OIL SEAL (See page EM-
206 )
9. INSTALL CRANK POSITION SENSOR (See page EM-92 )
A135998
(See page EM-189 )
11. INSTALL CRANKSHAFT PULLEY (See page EM-189 )
12. INSTALL CYLINDER HEAD COVER (See page EM-190 )
13. INSTALL SPARK PLUG (See page EM-190 )
14. INSTALL IGNITION COIL ASSEMBLY (See page EM-190 )
15. INSTALL RADIATOR PIPE (See page EM-194 )
17. INSTALL VENTILATION HOSE (See page EM-193 )
GETtheMANUALS.org
18. INSTALL VENTILATION HOSE NO. 2 (See page EM-193 )
19. INSTALL IDLER PULLEY NO. 1 (See page EM-191 )
20. INSTALL FAN PULLEY (See page CO-33 )
21. INSTALL VANE PUMP WITH BRACKET (See page EM-103 )
22. INSTALL FAN AND ALTERNATOR V BELT (See page EM-12 )
23. ADJUST FAN AND ALTERNATOR V BELT (See page EM-13 )
24. CHECK FAN AND ALTERNATOR V BELT (See page EM-13 )

page EM-193 )
EM 26. INSTALL RADIATOR HOSE NO. 1 (See page CO-25 )
27. INSTALL AIR CLEANER ASSEMBLY (See page EM-194 )
28. INSTALL AIR CLEANER HOSE NO. 1 (See page CO-26 )
29. INSTALL BATTERY CARRIER (See page EM-194 )
30. INSTALL BATTERY

32. ADD ENGINE COOLANT (See page CO-11 )
33. ADD ENGINE OIL
34. CHECK FOR ENGINE COOLANT LEAKS (See page CO-12 )
35. CHECK FOR ENGINE OIL LEAKS
36. CHECK ENGINE OIL LEVEL (See page EM-195 )
37. CHECK IGNITION TIMING (See page EM-4 )
38. CHECK IDLE SPEED (See page EM-5 )
39. INSTALL ENGINE UNDER COVER (See page EM-104 )
GETtheMANUALS.org
ENGINE MECHANICAL - CAMSHAFT (3SZ-VE)
EM–121
CAMSHAFT (3SZ-VE)
ENGINE MECHANICAL
COMPONENTS
T=3.5{36}
BATTERY
×2
EM
T=8.5{87} ×3 T=18{184}
T=7.5{76} ×2
BATTERY CARRIER
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} ×11

A136903J01
GETtheMANUALS.org
EM–122 ENGINE MECHANICAL - CAMSHAFT (3SZ-VE)
VENTILATION HOSE VENTILATION HOSE NO. 2

T=11{112}
×4
×2 T=7.5{76}
×4
CYLINDER HEAD COVER T=7.5{76}
T=9.0{92} ×11
EM
CYLINDER HEAD COVER
GASKET
RADIATOR PIPE
CAMSHAFT BEARING CAP NO. 1 T=12.5{130}
×16
CAMSHAFT BEARING CAP NO. 2
T=12.5{130}
×4
×8
CAMSHAFT
CAMSHAFT TIMING CAMSHAFT NO. 2
SPROCKET
T=47{480}
TIMING CHAIN (BELT) COVER NO. 2
T=8.5{87}
T=17{173}
CHAIN COVER SERVICE HOLE

SCREW PLUG

A137081J01
GETtheMANUALS.org
EM–123
REMOVAL
(See page RS-164.)
2. REMOVE BATTERY CARRIER (See page EM-146 )
4. DRAIN ENGINE COOLANT (See page CO-9 )
5. REMOVE RADIATOR HOSE NO. 1 (See page CO-15 )
6. REMOVE AIR CLEANER ASSEMBLY (See page EM-146 )
7. REMOVE AIR CLEANER HOSE NO. 1 (See page CO-15 )

(See page EM-147 )
EM
9. DISCONNECT VENTILATION HOSE (See page EM-147 )
10. DISCONNECT VENTILATION HOSE NO. 2 (See page EM-147 )
12. REMOVE RADIATOR PIPE (See page EM-147 )
13. REMOVE IGNITION COIL ASSEMBLY (See page EM-150 )
14. REMOVE CYLINDER HEAD COVER (See page EM-151 )
15. REMOVE TIMING CHAIN (BELT) COVER NO. 2

(a) Remove the 2 bolts and the timing chain (belt) cover No. 2.
16. REMOVE CHAIN
(a) Rotate the crankshaft pulley clockwise to align the timing mark
(groove) so it is at 0°.Make sure that each timing mark is posi-
tioned as shown in the illustration.
HINT:
If the timing marks are not aligned, turn the crankshaft pulley
Timing Marks
clockwise again and align the marks.
Notch
A137746
GETtheMANUALS.org
(b) Place a paint mark on each plate of the chains at the points
EM Timing Marks
A107964J01
(c) Using the hexagon head portion of the camshaft, loosen the
A133812
(d) Using a 10 mm socket hexagon wrench, remove the chain

A137724
(e) Using a screwdriver, access the tensioner stopper plate through

HINT:
the right and left.
(f) Under the conditions noted at [*1], use the hexagon head por-
and hold.[*2]
HINT:
plunger.
A133813
GETtheMANUALS.org
EM–125
(g) Under the conditions noted at [*2], remove the screwdriver from
NOTICE:
head portion.
A133879 • Fix the 3 mm diameter bar using tape or similar so it
does not come out.
(h) Remove the chain from the camshaft timing sprocket.
17. REMOVE CAMSHAFT TIMING SPROCKET

(a) Remove the bolt and the camshaft timing sprocket.
EM
A133815
18. REMOVE CAMSHAFT BEARING CAP NO. 1

NOTICE:
When rotating the camshaft with the chain disconnected, rotate
it 90° clockwise with the valve fully open and check that the
90°
crankshaft pulley groove is located in the position shown in the
illustration so that it does not interfere with the piston.
A137743
(a) Remove the camshaft bearing cap No. 1 in the order indicated
2
A133124

2 10 14 6
NOTICE:
4 12 16 8
HINT:
3 11 15 7
Be sure to keep the removed parts separate according to the
installation areas.
1 9 13 5
20. REMOVE CAMSHAFT
A133125
(a) Remove the camshaft.
GETtheMANUALS.org
21. REMOVE CAMSHAFT NO. 2

(a) Remove the camshaft No. 2.
(b) After removing the camshaft, hold the chain using a bar or rope
so that it does not drop.
NOTICE:
cover.
A133818
EM Advance Angle Port

22. INSPECT CAMSHAFT TIMING SPROCKET
(a) Cover all the ports except one advance port shown in the illus-
tration with plastic tape.
(b) Secure the service hexagon wrench head portion of the cam-
shaft in a vise using an aluminum or other metal cap, and then
install the camshaft timing sprocket with the bolt.
NOTICE:
Retard Angle Port • Do not damage the camshaft.
• Do not tighten the vise too firmly.
A033448J02 • Do not press too firmly on the camshaft timing gear
assembly as the seal surface can be easily damaged by
the end of the camshaft knock pin which may cause the
seal to fail.
• Do not remove the other 3 bolts.If the bolts are
removed, replace the camshaft timing gear assembly.
(c) Using an air gun, apply an air pressure of approximately 100
kPa (1 kgf/cm2) to the advance port shown in the illustration.
NOTICE:
Cover the ports with a piece of cloth to prevent oil from
splattering when the air pressure is applied.
HINT:
Air pressure is applied to release the lock pin for the most
retarded angle.
(d) Under the above conditions, rotate the camshaft timing sprocket
A033449J01 by hand in the advance direction (direction indicated by the
arrow in the illustration).
Standard:
Must rotate
HINT:
• Applying air pressure will rotate the camshaft timing
sprocket in the advance direction without applying manual
force.Air leaking out from the ports will make it difficult to
apply air pressure, which may also make it difficult to
release the lock pin.
• Attempting to rotate the camshaft timing sprocket will make
it difficult to release the lock pin due to pressure applied
from the side.
GETtheMANUALS.org
EM–127
(e) Unless it is in the most retarded position where the lock pin
engages, rotate the camshaft timing sprocket fully 2 to 3 times
and check the movable range and slide.
Standard:
Movable in a range of approximately 30°.
(f) Rotate the camshaft timing sprocket by hand and lock it in the
most retarded position.
(g) Remove the bolt and the camshaft timing sprocket.
INSTALLATION
1. INSTALL CAMSHAFT NO. 2
Camshaft NO. 1 Camshaft NO. 2 (a) When installing camshaft No. 2, rotate the crankshaft 90° (crank
(In Side) (Ex Side) angle) in the direction that the engine rotates from cylinder No. EM
NO. 3 NO. 4 NO. 4 NO. 2 1 TDC/compression so the lifted valve does not interfere with
the piston.
(b) Apply engine oil to the cam part of camshaft No. 2 and the jour-
nal part of the cylinder head, and then install camshaft No. 2.
NOTICE:
A137596 camshaft No. 2 push down the lifter valve.
2. INSTALL CAMSHAFT
Camshaft NO. 1 Camshaft NO. 2 (a) Apply engine oil to the cam of the camshaft and the journal part
(In Side) (Ex Side) of the cylinder head, and then install the camshaft.
NO. 3 NO. 4 NO. 4 NO. 2 NOTICE:
camshaft push down the lifter valve.
3. INSTALL CAMSHAFT BEARING CAP NO. 2

(a) Confirm the front mark and number of the camshaft bearing cap
No. 2 and install it.
A137596
(b) Tighten the camshaft bearing cap No. 2 in the order shown in
the illustration.
I2
I3
I4
I5

NOTICE:
• Position the cap so the arrows on it face toward the
front of the engine, and install it so the punched num-
15 7 3 11
13 5 1 9
14 6 2 10
16 8 4 12
E2
E4
E5
E3
A133070
GETtheMANUALS.org

(a) Tighten the camshaft bearing cap No. 1 in the order shown in
the illustration.
3
1
NOTICE:
Tighten it after checking that the thrust part of the camshaft
2 is aligned with the groove on camshaft bearing cap No. 1.
4
5. INSTALL CAMSHAFT TIMING SPROCKET
(a) Apply engine oil to the installation surface to the camshaft.
A133071
(b) Install the camshaft knock pin and the camshaft timing sprocket.
NOTICE:
Knock Pin
EM Pin Hole • If the knock pin and pin hole do not align, use the hexa-
press too firmly on the camshaft timing sprocket as the
Do Not Remove knock pin which may cause the seal to fail.
A136098 replace the camshaft timing sprocket.
6. INSTALL CHAIN
(a) Install the chain so the matchmarks of the camshaft timing gear
Timing Marks
A133561
(b) Pull the 3 mm diameter bar out from the chain tensioner.
NOTICE:
A109220
GETtheMANUALS.org
EM–129
(c) Make sure that each timing mark is positioned as shown in the
illustration.
(d) Apply TB1324 to the first 2 to 3 threads of the chain cover ser-
vice hole screw plug bolt.
NOTICE:
Clean and degrease the bolt and bolt hole.
Timing Marks
EM
Notch
A137746
(e) Using a 10 mm socket hexagon wrench, install the chain cover

A137724
7. INSTALL TIMING CHAIN (BELT) COVER NO. 2

Apply Liquid Gasket (a) Apply Three Bond TB1207B to the position shown in the illustra-
tion.
CAUTION:
TB1207B.
• Do not start the engine within 2 hours of installation.
A139347
(b) Install the timing chain cover No. 2 with the 2 bolts.
8. INSTALL CYLINDER HEAD COVER (See page EM-162 )
9. INSTALL IGNITION COIL ASSEMBLY (See page EM-162 )
10. INSTALL RADIATOR PIPE (See page EM-166 )
11. INSTALL RADIATOR HOSE NO. 1 (See page CO-18 )

A107960
13. CONNECT VENTILATION HOSE NO. 2 (See page EM-166 )
GETtheMANUALS.org
14. CONNECT VENTILATION HOSE (See page EM-166 )

page EM-165 )
16. INSTALL AIR CLEANER ASSEMBLY (See page EM-167 )
17. INSTALL AIR CLEANER HOSE NO. 1 (See page CO-19 )
18. ADD ENGINE COOLANT (See page CO-9 )
20. CHECK FOR ENGINE COOLANT LEAKS (See page CO-10 )
21. CHECK COOLANT LEVEL (See page CO-10 )
EM 22. INSTALL ENGINE UNDER COVER (See page EM-69 )

24. CHECK IGNITION TIMING (See page EM-1 )
25. CHECK ENGINE IDLE SPEED (See page EM-2 )
26. CHECK DENSITY OF CO AND HC (See page EM-3 )
GETtheMANUALS.org
ENGINE MECHANICAL - CAMSHAFT (K3-VE)
EM–131
CAMSHAFT (K3-VE)
ENGINE MECHANICAL
COMPONENTS
T=3.5{36}
BATTERY
×2
EM
T=8.5{87} ×3 T=18{184}
T=7.5{76} ×2
BATTERY CARRIER
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} ×11

A136903J01
GETtheMANUALS.org
EM–132 ENGINE MECHANICAL - CAMSHAFT (K3-VE)
VENTILATION HOSE VENTILATION HOSE NO. 2

T=11{112}
×4
×2 T=7.5{76}
×4
CYLINDER HEAD COVER T=7.5{76}
T=9.0{92} ×11
EM
CYLINDER HEAD COVER
GASKET
RADIATOR PIPE
CAMSHAFT BEARING CAP NO. 1 T=12.5{130}
×16
T=12.5{130}
×4
×8
CAMSHAFT
CAMSHAFT TIMING CAMSHAFT NO. 2
SPROCKET
T=47{480}
TIMING CHAIN (BELT) COVER NO. 2
T=8.5{87}
T=17{173}
CHAIN COVER SERVICE HOLE

SCREW PLUG

A137081J01
GETtheMANUALS.org
EM–133
REMOVAL
(See page RS-164.)

(See page EM-175)
EM
9. DISCONNECT VENTILATION HOSE (See page EM-174)
10. DISCONNECT VENTILATION HOSE NO. 2 (See page EM-174)
15. REMOVE TIMING CHAIN (BELT) COVER NO. 2

(a) Remove the 2 bolts and the timing chain (belt) cover No. 2.
16. REMOVE CHAIN
HINT:
Timing Marks If the timing marks are not aligned, turn the crankshaft pulley
Notch
A140612
GETtheMANUALS.org
(b) Place a paint mark on each plate of the chains at the points
EM Timing Marks
A107964J01
(c) Using the hexagon head portion of the camshaft, loosen the
A133812
(d) Using a 10 mm socket hexagon wrench, remove the chain

A137724
(e) Using a screwdriver, access the tensioner stopper plate through

HINT:
the right and left.
(f) Under the conditions noted at [*1], use the hexagon head por-
and hold.[*2]
HINT:
plunger.
A133813
GETtheMANUALS.org
EM–135
(g) Under the conditions noted at [*2], remove the screwdriver from
NOTICE:
• Hold the camshaft in the position using the hexagonal
head portion.
A133879 • Fix the 3 mm diameter bar using tape or similar so it
does not come out.
(h) Remove the chain from the camshaft timing sprocket.

(a) Remove the bolt and the camshaft timing sprocket.
EM
A133815

NOTICE:
When rotating the camshaft with the chain disconnected, rotate
it 90° clockwise with the valve fully open and check that the
90°
crankshaft pulley groove is located in the position shown in the
illustration so that it does not interfere with the piston.
A137743
2
A133124

2 10 14 6
NOTICE:
4 12 16 8
HINT:
3 11 15 7
Be sure to keep the removed parts separate according to the
installation areas.
1 9 13 5
20. REMOVE CAMSHAFT
A133125
(a) Remove the camshaft.
GETtheMANUALS.org
21. REMOVE CAMSHAFT NO. 2

(a) Remove the camshaft No. 2.
(b) After removing the camshaft, hold the chain using a bar or rope
so that it does not drop.
NOTICE:
cover.
A133818
EM Advance Angle Port

22. INSPECT CAMSHAFT TIMING SPROCKET
(a) Cover all the ports except one advance port shown in the illus-
tration with plastic tape.
(b) Secure the service hexagon wrench head portion of the cam-
shaft in a vise using an aluminum or other metal cap, and then
install the camshaft timing sprocket with the bolt.
NOTICE:
Retard Angle Port • Do not damage the camshaft.
• Do not tighten the vise too firmly.
A033448J02 • Do not press too firmly on the camshaft timing gear
assembly as the seal surface can be easily damaged by
the end of the camshaft knock pin which may cause the
seal to fail.
• Do not remove the other 3 bolts.If the bolts are
removed, replace the camshaft timing gear assembly.
(c) Using an air gun, apply an air pressure of approximately 100
kPa (1 kgf/cm2) to the advance port shown in the illustration.
NOTICE:
Cover the ports with a piece of cloth to prevent oil from
splattering when the air pressure is applied.
HINT:
Air pressure is applied to release the lock pin for the most
retarded angle.
(d) Under the above conditions, rotate the camshaft timing sprocket
A033449J01 by hand in the advance direction (direction indicated by the
arrow in the illustration).
Standard:
Must rotate
HINT:
• Applying air pressure will rotate the camshaft timing
sprocket in the advance direction without applying manual
force.Air leaking out from the ports will make it difficult to
apply air pressure, which may also make it difficult to
release the lock pin.
• Attempting to rotate the camshaft timing sprocket will make
it difficult to release the lock pin due to pressure applied
from the side.
GETtheMANUALS.org
EM–137
(e) Unless it is in the most retarded position where the lock pin
engages, rotate the camshaft timing sprocket fully 2 to 3 times
and check the movable range and slide.
Standard:
Movable in a range of approximately 30°.
(f) Rotate the camshaft timing sprocket by hand and lock it in the
most retarded position.
(g) Remove the bolt and the camshaft timing sprocket.
INSTALLATION
Camshaft NO. 1 Camshaft NO. 2 (a) When installing camshaft No. 2, rotate the crankshaft 90° (crank
(In Side) (Ex Side) angle) in the direction that the engine rotates from cylinder No. EM
NO. 3 NO. 4 NO. 4 NO. 2 1 TDC/compression so the lifted valve does not interfere with
the piston.
nal part of the cylinder head, and then install camshaft No. 2.
NOTICE:
A137596 camshaft No. 2 push down the lifter valve.
2. INSTALL CAMSHAFT

(a) Confirm the front mark and number of the camshaft bearing cap
No. 2 and install it.
A137596
(b) Tighten the camshaft bearing cap No. 2 in the order indicated in
the illustration.
I2
I3
I4
I5

NOTICE:
• Position the cap so the arrows on it face toward the
front of the engine, and install it so the punched num-
15 7 3 11
13 5 1 9
14 6 2 10
16 8 4 12
E2
E4
E5
E3
A133070
GETtheMANUALS.org

(a) Tighten the camshaft bearing cap No. 1 in the order shown in
the illustration.
3
1
NOTICE:
Tighten it after checking that the thrust part of the camshaft
2 is aligned with the groove on camshaft bearing cap No. 1.
4
A133071
(b) Install the camshaft knock pin and the camshaft timing sprocket.
NOTICE:
Knock Pin
EM Pin Hole • If the knock pin and pin hole do not align, use the hex-
agonal head portion of the camshaft and rotate the cam-
press too firmly on the camshaft timing sprocket as the
Do Not Remove knock pin which may cause the seal to fail.
A136098 replace the camshaft timing sprocket.
6. INSTALL CHAIN
(a) Install the chain so the matchmarks of the camshaft timing gear
Timing Marks
A133561
(b) Pull the 3 mm diameter bar out from the chain tensioner.
NOTICE:
A109220
GETtheMANUALS.org
EM–139
(c) Make sure that each timing mark is positioned as shown in the
illustration.
(d) Apply TB1324 to the first 2 to 3 threads of the chain cover ser-
vice hole screw plug bolt.
NOTICE:
Timing Marks Clean and degrease the bolt and bolt hole.
EM
Notch
A140612
(e) Using a 10 mm socket hexagon wrench, install the chain cover

A137724
7. INSTALL TIMING CHAIN (BELT) COVER NO. 2

Apply Liquid Gasket (a) Apply Three Bond TB1207B to the position shown in the illustra-
tion.
CAUTION:
TB1207B.
A139347
(b) Install the timing chain cover No. 2 with the 2 bolts.

A107960
13. CONNECT VENTILATION HOSE NO. 2 (See page EM-193)
GETtheMANUALS.org
14. CONNECT VENTILATION HOSE (See page EM-193)

page EM-193)
EM 22. INSTALL ENGINE UNDER COVER (See page EM-104)

GETtheMANUALS.org
ENGINE MECHANICAL - CYLINDER HEAD GASKET (3SZ-VE)
EM–141
CYLINDER HEAD GASKET (3SZ-VE)

ENGINE MECHANICAL
COMPONENTS
T=3.5{36}
BATTERY
×2
EM
T=8.5{87} ×3 T=18{184}
T=7.5{76} ×2
BATTERY CARRIER
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} ×11

A136903J01
GETtheMANUALS.org
EM–142 ENGINE MECHANICAL - CYLINDER HEAD GASKET (3SZ-VE)

T=20{204}
T=7.5{76}
×4

×4
O-RING
T=7.5{76}
IDLER PULLEY
IDLER PULLEY NO. 1

RADIATOR PIPE
×3
T=11.5{117}
T=44{449}
T=130{1326}
×3
T=20.6{210}
O-RING
T=7.5{76}

A136904J02
GETtheMANUALS.org
EM–143

T=7.5{76}
COOLANT BYPASS HOSE
THROTTLE BODY ASSEMBLY ×2

T=21{214} EM
T=7.5{76}
×2

O-RING THROTTLE BODY
T=19{194} T=21{214}
BRACKET NO. 2
T=19{194} ×2
×2 ×3
THROTTLE BODY
T=8.5{87}
BRACKET
O-RING
GASKET EXHAUST MANIFOLD
INTAKE MANIFOLD
INSULATOR NO. 1
T=8.5{87}
T=8.5{87}
T=19{194} GASKET
T=10{102}
T=32{326}
T=44{449}
T=35{357}
×2
ALTERNATOR ASSEMBLY
×3
EXHAUST
T=9.3{95} MANIFOLD
T=35{357}
..... TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PARTA140623J01
GETtheMANUALS.org
OIL FILLER CAP

T=11{112}
CYLINDER HEAD COVER
T=9.0{92}
×11

EM

TIMING CHAIN
TENSIONER ARM
TIMING GEAR (CHAIN)
COVER GASKET
TIMING CHAIN GUIDE
T=9.0{92}
CHAIN
T=23{235}
T=12{122}
×9
×2
T=44{449} ×3
T=19{195}
T=7.5{76}
T=7.5{76}
×2
APPLY MP GREASE
GETtheMANUALS.org
EM–145

T=12.5{130}
×16
T=12.5{130}
×4
×8 CAMSHAFT
CAMSHAFT TIMING SPROCKET
EM
T=47{480}
×10
CYLINDER HEAD BOLT

CAMSHAFT NO. 2
WASHER
×10
CYLINDER HEAD
PLASTIC REGION TIGHTENING METHOD

GETtheMANUALS.org
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
(a) Procedure required when removing the F/P relay
(1) Turn the ignition switch to the LOCK position.
(2) Remove the F/P relay.
Instrument Panel J/B (3) Start up the engine.
(4) After the engine has stopped on its own, turn the ignition
switch off.
HINT:
DTC P0171/25 lean malfunction may be detected.
(5) Crank the engine again, then check that the engine does
F/P Relay not start.
EM (6) Remove the fuel tank cap to discharge pressure from the
A135986J01 fuel tank.
(7) Disconnect the negative terminal from the battery.
(8) Install the F/P relay.

(See page RS-164.)
3. REMOVE BATTERY CARRIER

(a) Remove the 3 bolts and battery carrier.
5. DRAIN ENGINE OIL (See page EM-43)
7. REMOVE RADIATOR RESERVE TANK ASSEMBLY (See page CO-

15)
8. REMOVE CHARCOAL CANISTER ASSEMBLY (See page CO-16)
10. REMOVE WITH WATER FAN ASSEMBLY (See page CO-17)
12. REMOVE AIR CLEANER ASSEMBLY

(a) Disconnect the VSV connector and 2 hoses.
(b) Disconnect the vacuum sensor connector and hose.
(c) Remove the inlet air temperature sensor.
(d) Remove the 3 bolts and the air cleaner assembly.
(a) Loosen the clip, then disconnect the heater inlet water hose
from the radiator pipe.
A136001
GETtheMANUALS.org
EM–147

(a) Loosen the clip, then disconnect the heater outlet water hose.
A136002
15. REMOVE RADIATOR PIPE

(a) Remove the 2 bolts, loosen the clip and then remove the radia-
tor pipe. EM
A133397
16. REMOVE VENTILATION HOSE

(a) Loosen the clip and remove the ventilation hose.
A134307
17. REMOVE VENTILATION HOSE NO. 2

(a) Loosen the clip and remove ventilation hose No. 2.
A134308

(a) Loosen the nut and disconnect the accelerator control cable
assembly from the throttle body assembly.
(b) Remove the bolt and bracket.
19. DISCONNECT ENGINE ROOM MAIN WIRE

(a) Disconnect the engine wire clamp from the bracket.
(b) Disconnect the sensor connectors.
(c) Disconnect the ground connector of the cylinder head cover.
A131808
GETtheMANUALS.org
(d) Remove the 2 bolts and disconnect the ground wire.
A133250
20. DISCONNECT EXHAUST PIPE ASSEMBLY FR

(a) Remove the 2 bolts and 2 springs, then disconnect the exhaust
EM pipe assembly FR from the exhaust manifold.
A134989
21. REMOVE FUEL HOSE NO. 2

(a) Loosen the clip, then disconnect fuel hose No. 2.
A133396
22. REMOVE OIL LEVEL GAUGE GUIDE

(a) Remove the bolt and nut, then remove the oil level gauge guide
and O-ring.

(a) Disconnect the vacuum hose assembly from the booster vac-
uum tube.
A136065

(a) Remove the 2 bolts and bracket.
(b) Disconnect the throttle body assembly connector and wire har-
ness clamp.
A131805
GETtheMANUALS.org
EM–149
(c) Loosen the clamp, then disconnect the water hose.

Blue Paint (d) Remove the 3 bolts and the throttle body assembly.
(e) Remove the 2 bolts and the throttle body assembly.
A131806
25. REMOVE FUEL DELIVERY PIPE

BOLT
(a) Remove the 2 bolts, then hold both sides of the fuel delivery
pipe and lift it straight up to remove. EM
A134311
26. REMOVE THROTTLE BODY BRACKET

(a) Remove the 2 bolts and the throttle body bracket.
27. REMOVE FUEL INJECTOR ASSEMBLY

(a) Remove the fuel injector assembly from the fuel delivery pipe.
NOTICE:
• The O-ring may be stuck, but even if it is, do not apply
sideways force to the fuel injector assembly.
• If re-installing the fuel injector assembly instead of
replacing it with a new one, note the cylinder number on
A109106
a tag or similar to distinguish it.
(b) Remove the O- ring and insulator from the fuel injector assem-
bly.
O-ring 28. REMOVE INTAKE MANIFOLD
(a) Disconnect the water by-pass hose from the cylinder head.
(b) Disconnect the wire harness from the intake manifold.
Insulator
A107004J02
(c) Remove the 3 bolts and 2 nuts, then remove the intake mani-
fold.
(d) Remove the gasket from the intake manifold.
29. REMOVE FAN AND ALTERNATOR V BELT (See page EM-8)
32. REMOVE VANE PUMP WITH BRACKET (See page EM-44)

A109108
GETtheMANUALS.org

A137714
34. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1

(a) Remove the 5 bolts and the exhaust manifold heat insulator No.
EM 1.
A133399
35. REMOVE MANIFOLD STAY

(a) Remove the 2 bolts and the manifold stay.
A136071
36. REMOVE EXHAUST MANIFOLD

(a) Remove the 3 bolts and 2 nuts, then remove the exhaust mani-
fold.

(a) Disconnect the ignition coil connector.
A133400
GETtheMANUALS.org
EM–151
(b) Remove the bolt and the ignition coil assembly.
A133310
38. REMOVE CYLINDER HEAD COVER

(a) Remove the 11 bolts and 2 nuts, then remove the cylinder head
cover. EM
A132251
39. REMOVE CRANKSHAFT PULLEY

HINT:
If the timing marks are not aligned, turn the crankshaft pulley
Timing Marks
Notch
A137746
(b) Using the SST, hold the crankshaft pulley and loosen the bolt.
SST 09278-87201
SST
A139349
GETtheMANUALS.org
(c) Using the SST and the crankshaft pulley bolt, remove the crank-
shaft pulley.
SST 09306-87501
NOTICE:
SST
Install the SST to the crankshaft pulley so that the fixing
bolts for the SST do not contact with the chain cover.
A137589
40. REMOVE CRANK POSITION SENSOR

(a) Remove the bolt and the crank position sensor.
EM
A137713

(a) Remove the bolt and the camshaft timing oil control valve
assembly.
A136191
42. REMOVE TIMING CHAIN (BELT) COVER

(a) Remove the 13 bolts and 2 nuts.
A133402
GETtheMANUALS.org
EM–153
(b) Using a screwdriver wrapped with protective tape, lever off and
remove the timing chain (belt) cover.
NOTICE:
Do not damage the timing chain cover, cylinder block or
cylinder head.
A133404
43. REMOVE TIMING CHAIN (BELT) COVER OIL SEAL

(a) Using a screwdriver, pry out the timing chain (belt) cover oil
seal. EM
Wooden
Protective Tape Block
A033132J01

D-MARK
A135998

released.[*1]
HINT:
the right and left.
A108005 and hold.[*2]
HINT:
plunger.
GETtheMANUALS.org
HINT:

A108555J01

EM (e) Remove the bolt and nut and then remove the water inlet.
A108556

A108557

A108558

49. REMOVE CHAIN
A108559
GETtheMANUALS.org
EM–155

Hold (a) Using the hexagon head portion of the camshaft, remove the
NOTICE:
When rotating the camshaft with the chain removed, rotate
the crankshaft 90° (crank angle) in the direction that the
engine rotates from cylinder No. 1 TDC / compression so
the valve does not interfere with the piston.
A136076

2
in the illustration. EM
4
A133124

2 10 14 6
NOTICE:
4 12 16 8
3 11 15 7
1 9 13 5
A133125
53. REMOVE CYLINDER HEAD

4 6 9 7 1 (a) Using an 8 mm double hexagon wrench, loosen the cylinder
head bolts in several passes in the order shown in the illustra-
tion, then remove the cylinder head bolt and washer.
NOTICE:
• When removing the bolt, do not drop the washer into
the head.
• Failure to remove the bolts in the specified order may
damage the cylinder head.
2 8 10 5 3
A132854 (b) Remove the cylinder head.
54. REMOVE CYLINDER HEAD GASKET
GETtheMANUALS.org
INSTALLATION
1. INSPECT CYLINDER HEAD BOLT
(a) Using vernier calipers, measure the diameter of the thread
A within the range indicated by A in the illustration.
Maximum limit:
25mm 20mm 8.75 mm
HINT:
• Measure the diameter at several locations. If the smallest
measured value is above the limit, the engine may be dam-
aged. Replace the bolt with a new one.
A108575J01 • If there is any damage to the thread on the bolt, replace the
cylinder head bolt.
EM 2. INSTALL CYLINDER HEAD GASKET
NOTICE:
Cylinder Head • Install the cylinder head gasket within 3 minutes and tighten
0-4 mm
21-27 mm the cylinder head bolts within 15 minutes after applying
2.5 mm Three Bond TB1207B.
(a) Apply Three Bond TB1207B to the locations shown in the illus-
tration.
Cylinder Head
Gasket
17-23 mm Cylinder Block
2.0 mm
A083197J02
(b) Install a new cylinder head gasket in the direction shown in the
illustration.
NOTICE:
• Check that it is installed in the correct direction.
• Do not damage the cylinder head gasket.
3. INSTALL CYLINDER HEAD

NOTICE:
Front • Clean and degrease the installation surfaces.
• Inspect and clean the cylinder head and installation hole.
A033157J01
• Tighten the cylinder head using the plastic area tightening
method.
• Do not allow oil to get on the lower surface of the cylinder
head.
(a) Install the cylinder head.
NOTICE:
• Take care not to damage the cylinder head gasket when
installing it.
• Install the cylinder head bolt to the same place it was
removed from.
GETtheMANUALS.org
EM–157
(b) Apply a light coat of engine oil to the threads and bolt-seating
surface of the cylinder head bolts.
Apply Engine Oil

A133007
(c) Using an 8 mm double hexagon wrench, temporarily install the

7 5 2 4 10 cylinder head bolts and washers in several passes in the order
shown in the illustration and then tighten the bolts with the spec- EM
ified torque.
9 3 1 6 8
A133008
(d) Put paints mark on the engine front side of heads of the cylinder
head bolts.
Paint Mark (e) Using the paint mark as a reference, tighten the cylinder head
bolts 180° in the specified order.
(f) Check all the paint marks are now moved 180°.
180° Tighten
(g) When installing the cylinder head, wipe off any Three Bond
TB1207B that is squeezed out.
NOTICE:
When wiping off the seal packing black, do not allow it to
A140645 enter the bolt hole or knock pin hole.

(a) When installing camshaft No. 2, rotate the crankshaft 90° (crank
angle) in the direction that the engine rotates from cylinder No.
1 TDC/compression so the lifted valve does not interfere with
the piston.
Camshaft NO. 1 Camshaft NO. 2 nal part of the cylinder head, and then install the camshaft No.
(In Side) (Ex Side) 2.
camshaft No. 2 push down the lifter valve.
A137596
GETtheMANUALS.org
5. INSTALL CAMSHAFT
A137596

(a) Confirm the front mark and number of camshaft bearing cap No.
EM
I2
I3
I4
I5
2 and install it.

the illustration.
15 7 3 11
NOTICE:
14 6 2 10
16 8 4 12
E2
E4
E5
E3
A133070

(a) Tighten the camshaft bearing cap No. 1 in the order indicated in
the illustration.
3
1
NOTICE:
2 camshaft is aligned with the groove on camshaft bearing
4 cap No. 1.

A133071
(b) Align the camshaft knock pin and the camshaft timing sprocket
Pin Hole Knock Pin
shaft.
NOTICE:
GETtheMANUALS.org
EM–159
(c) Apply a small amount of engine oil to the camshaft timing

(d) Using the hexagon head portion of the camshaft, tighten the
A136076
9. INSTALL CHAIN
Mark Plate Mark Plate (a) Align the mark plate (yellow) and the timing mark as shown in
the illustration and install the chain. EM
HINT:
Install so that the mark plate is on the engine front side.
Mark Plates
Timing Mark
A137742

A108559

A108558
GETtheMANUALS.org

A108557

HINT:
plunger.
A108556 plunger.

D Mark (a) Install the crank angle sensor plate No. 1 so that the D mark is
visible.
A133073
15. INSTALL TIMING CHAIN (BELT) COVER

(a) Install a new gasket to the timing chain (belt) cover.
A108562
(b) Apply Three Bond TB1207B to the locations shown in the illus-
tration.
NOTICE:
• Clean and degrease the installation surfaces using
brake cleaner and white gasoline.
• Install the timing chain (belt) cover within 3 minutes of
applying Three Bond TB1207B.
• Tighten the timing chain (belt) cover to the specified
torque within 15 minutes of applying Three Bond
Apply Liquid Gasket A108563J02 TB1207B.
GETtheMANUALS.org
EM–161
• Do not add engine oil within 2 hours of installation.

B B 6 mm Diameter
EM
6 mm Diameter
3-4 mm Diameter 3 mm Diameter

A A
Apply Liquid Gasket

3-4 mm 3-4 mm A139363
(c) Install the timing chain (belt) cover with the 13 bolts and 2 nuts.
Torque: 12 N*m (122 kgf*cm) (Bolts 1 to 9)
23 N*m (235 kgf*cm) (Nuts 11 to 12)
10 44 N*m (449 kgf*cm) (Bolts 13 to 15)
3
2 16. INSTALL TIMING CHAIN (BELT) COVER OIL SEAL (See page EM-
200)
4 12
15
11 13
14
5
1
9
6
7 8
A136081
17. INSTALL CRANKSHAFT PULLEY

(a) Using the SST, hold the crankshaft pulley and tighten the bolt.
SST 09278-87201
SST
A137588
GETtheMANUALS.org

NOTICE:
A137713

EM (b) Install the camshaft timing oil control valve assembly with the
bolt.
NOTICE:
A136191
20. INSTALL CYLINDER HEAD COVER

(a) Apply seal packing black to the position shown in the illustra-
tion.
NOTICE:
TB1207B.
• Tighten the cylinder head cover to the specified torque
within 15 minutes of applying Three Bond TB1207B.
Apply Liquid Gasket
A079650J02 • Do not start the engine within 2 hours of installation.
(b) Install the cylinder head cover with the 11 bolts and 2 nuts in
8 2 4 6
several passes in the order shown in the illustration.
Torque: 11 N*m (112 kgf*cm) (Nut)
12 13 9.0 N*m (92 kgf*cm) (Bolt)
9
21. INSTALL SPARK PLUG
10 11
5 3 1 7
A133409

23. INSTALL EXHAUST MANIFOLD

(a) Install the exhaust manifold using a new gasket.
A133310
GETtheMANUALS.org
EM–163
(b) Install the intake manifold with the 3 bolts and 2 nuts in the
order shown in the illustration.
EM
A133400
24. INSTALL MANIFOLD STAY

(a) Install the manifold stay with the bolt.
Torque: 9.3 N*m (95 kgf*cm) (Bolt)
A136071
25. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1

(a) Install the exhaust manifold heat insulator No. 1 with the 5 bolts.
A133399

29. INSTALL VANE PUMP WITH BRACKET (See page EM-68)

A137714
GETtheMANUALS.org
33. INSTALL INTAKE MANIFOLD

(a) Temporarily install the intake manifold with the 3 bolts and 2
nuts using a new gasket.
A109108
(b) Tighten the bolts and nuts in the order shown in the illustration.
EM
A079976J02

(a) Temporarily install the throttle body bracket with the 2 bolts.
(b) Temporarily install the throttle body assembly with the 3 bolts
using a new gasket.
(c) Tighten the throttle body bracket with the 2 bolts.
(d) Using a new gasket, tighten the throttle body assembly on the
throttle body bracket side and then the intake manifold side with
the 3 bolts.
A109106 Torque: 21 N*m (214 kgf*cm) Bolt throttle body bracket
side
7.5 N*m (75 kgf*cm) Bolt intake manifold side
(e) Connect the 2 water by-pass hoses.
(f) Connect the engine wire harness.
35. INSTALL FUEL INJECTOR ASSEMBLY
(a) Install a new injector vibration insulator.
O-ring (b) Apply gasoline to the new fuel injector assembly O-ring.
Insulator
A107004J01
GETtheMANUALS.org
EM–165
(c) Install the fuel delivery pipe while rotating the fuel injector
assembly to the left and right.
NOTICE:
Install the sensor so that the O-ring is not twisted or
pinched.
(d) Check that the fuel injector assembly rotates smoothly.
NOTICE:
If the fuel injector assembly does not rotate smoothly, rein-
stall it with a new O-ring.
A107005
(a) Install the fuel pipe insulator.
(b) Temporarily install the fuel delivery pipe and the fuel tube with
the 2 bolts.
NOTICE:
EM
• Do not drop the fuel injector when installing the fuel
delivery pipe.
• If the tip of the sensor is hit or dropped, replace it with a
new one.
• Make sure there is no foreign matter in or damage to the
insertion part of the injector assembly (cylinder head).
A136082 (c) Check that the fuel injectors rotate smoothly.
NOTICE:
If a fuel injector does not rotate smoothly, reinstall it with a
new O-ring.
(d) Tighten the 2 bolts.
37. CONNECT VACUUM HOSE ASSEMBLY

(a) Connect the vacuum hose assembly to the brake booster
assembly.
39. CONNECT FUEL HOSE NO. 2

(a) Connect the fuel hose No. 2.
NOTICE:
• Before proceeding, check that there is no damage to or
foreign matter on the fuel hose No. 2 or the connection
of the pipe.
40. INSTALL EXHAUST PIPE ASSEMBLY FR (See page EM-66)

41. CONNECT ENGINE ROOM MAIN WIRE
(a) Install the ground wire with the 2 bolts.
(b) Connect the cylinder head cover ground connector.
(c) Connect the connectors of the sensors.
(d) Connect the engine wire clamp to the bracket.
42. CONNECT ACCELERATOR CONTROL CABLE ASSEMBLY

(a) Connect the accelerator control cable assembly to the throttle
body assembly.
(b) Install the bracket with the bolt.
A133250
(c) Adjust the wire cable and tighten the nut.
GETtheMANUALS.org
43. INSTALL VENTILATION HOSE

(a) Install the ventilation hose.
Yellow Paint A131812
44. INSTALL VENTILATION HOSE NO. 2

White Paint
Yellow Paint (a) Install ventilation hose No. 2.
EM
A131807
45. INSTALL RADIATOR PIPE

(a) Install the radiator pipe with the 2 bolts and connect the hose.
A133397

A136002

48. INSTALL WITH WATER FAN ASSEMBLY (See page CO-29)
50. INSTALL CHARCOAL CANISTER ASSEMBLY (See page CO-18)
51. INSTALL RADIATOR RESERVE TANK ASSEMBLY (See page CO-

18)
A136001
GETtheMANUALS.org
EM–167
52. INSTALL BATTERY CARRIER

(a) Install the battery carrier with the 3 bolts.
53. INSTALL BATTERY
54. CONNECT BATTERY NEGATIVE TERMINAL

55. INSTALL AIR CLEANER ASSEMBLY
A (a) Install the air cleaner assembly with the 3 bolts.
A
B
(b) Connect the VSV connector.
(c) Connect the inlet air temperature sensor.
(d) Connect the connector of the vacuum sensor. EM
A136084 57. ADD ENGINE OIL
61. CHECK ENGINE OIL LEVEL

(a) Warm up the engine, stop the engine and wait 5 minutes. Check
that the oil level is between the F mark and L marks. If low,
check for leakage and add oil up to the F mark.
63. CHECK FOR FUEL LEAKS

(a) Check the fuel pump operation.
(2) Follow the prompts on the screen to select ACTIVE TEST
/ CIRCUIT RELAY / ON, and check the fuel pump opera-
tion.
(b) Check for fuel leaks.
(1) Check that there are no leaks in the fuel system with fuel
pressure applied.
GETtheMANUALS.org
EM–168 ENGINE MECHANICAL - CYLINDER HEAD GASKET (K3-VE)
CYLINDER HEAD GASKET (K3-VE)

ENGINE MECHANICAL
COMPONENTS
T=3.5{36}
BATTERY
×2
EM
T=8.5{87} ×3 T=18{184}
T=7.5{76} ×2
BATTERY CARRIER
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} ×11

A136903J01
GETtheMANUALS.org
ENGINE MECHANICAL - CYLINDER HEAD GASKET (K3-VE)
EM–169
VENTILATION HOSE NO. 2 SPARK PLUG EM

T=20{204}
T=7.5{76}
×4

×4
O-RING
T=7.5{76}
IDLER PULLEY
IDLER PULLEY NO. 1

RADIATOR PIPE
×3
T=11.5{117}
T=44{449}
T=130{1326}
×3
T=20.6{210}
O-RING
T=7.5{76}

A136904J02
GETtheMANUALS.org

T=7.5{76}
COOLANT BYPASS HOSE
EM ×2
T=21{214}
THROTTLE BODY ASSEMBLY T=7.5{76}

×2

O-RING
T=19{194}
T=21{214} THROTTLE BODY
T=19{194}
×2 ×3
BRACKET NO. 2
×2
THROTTLE BODY
T=8.5{87}
BRACKET
O-RING
GASKET
INTAKE MANIFOLD EXHAUST MANIFOLD HEAT
INSULATOR NO. 1
T=8.5{87}
T=8.5{87}
T=19{194} GASKET
T=10{102}
T=32{326}
T=44{449}
T=35{357}
×2
ALTERNATOR ASSEMBLY
×3
EXHAUST
T=9.3{95}
MANIFOLD
T=35{357}
GETtheMANUALS.org
EM–171
OIL FILLER CAP

T=11{112}
CYLINDER HEAD COVER
T=9.0{92}
×11

EM

TIMING CHAIN
TENSIONER ARM
TIMING GEAR (CHAIN)
COVER GASKET
TIMING CHAIN GUIDE
T=9.0{92}
CHAIN
T=23{235}
T=12{122}
×9
×2
T=44{449} ×3
T=19{195}
T=7.5{76}
T=7.5{76}
×2
APPLY MP GREASE
GETtheMANUALS.org

T=12.5{130}
×16
T=12.5{130}
×4
×8 CAMSHAFT
CAMSHAFT TIMING SPROCKET
EM
T=47{480}
×10
CYLINDER HEAD BOLT

CAMSHAFT NO. 2
WASHER
×10
CYLINDER HEAD
PLASTIC REGION TIGHTENING METHOD

GETtheMANUALS.org
EM–173
REMOVAL
NOTICE:
• Always discharge fuel system pressure before removing any
fuel system components.
• As some pressure will remain in the fuel line even after the
fuel system pressure has been discharged, cover the open-
ing with a shop rag or a similar to prevent fuel from splash-
ing.
(a) Procedure required when removing the F/P relay
(1) Turn the ignition switch to the LOCK position.
(2) Remove the F/P relay.
Instrument Panel J/B (3) Start up the engine. EM
(4) After the engine has stopped on its own, turn the ignition
switch off.
HINT:
(5) Crank the engine again, then check that the engine does
F/P Relay not start.
(6) Remove the fuel tank cap to discharge pressure from the
A135986J01 fuel tank.
(7) Disconnect the negative terminal from the battery.
(8) Install the F/P relay.

(See page RS-164.)
3. REMOVE BATTERY CARRIER

(a) Remove the 3 bolts and battery carrier.
5. DRAIN ENGINE OIL (See page EM-78)

22)
10. REMOVE WITH WATER FAN ASSEMBLY (See page CO-24)
12. REMOVE AIR CLEANER ASSEMBLY

(a) Disconnect the VSV connector and 2 hoses.
(b) Disconnect the vacuum sensor connector and hose.
(c) Remove the inlet air temperature sensor.
(d) Remove the 3 bolts and the air cleaner assembly.
GETtheMANUALS.org

(a) Loosen the clip, then disconnect the heater inlet water hose
from the radiator pipe.
A136001

(a) Loosen the clip, then disconnect the heater outlet water hose.
EM
A136002
15. REMOVE RADIATOR PIPE

(a) Remove the 2 bolts, loosen the clip and then remove the radia-
tor pipe.
A133397

A134307

(a) Loosen the clip and remove ventilation hose No. 2.
A134308
GETtheMANUALS.org
EM–175

(a) Loosen the nut and disconnect the accelerator control cable
assembly from the throttle body assembly.
(b) Remove the bolt and bracket.
19. DISCONNECT ENGINE ROOM MAIN WIRE

(a) Disconnect the engine wire clamp from the bracket.
(b) Disconnect the sensor connectors.
(c) Disconnect the ground connector of the cylinder head cover.
A131808
(d) Remove the 2 bolts and disconnect the ground wire.
EM
A133250

pipe assembly FR from the exhaust manifold.
A134989
21. REMOVE FUEL HOSE NO. 2

A133396
22. REMOVE OIL LEVEL GAUGE GUIDE

(a) Remove the bolt and nut, then remove the oil level gauge guide
and O-ring.

(a) Disconnect the vacuum hose assembly from the booster vac-
uum tube.
A136065
GETtheMANUALS.org

(b) Disconnect the throttle body assembly connector and wire har-
ness clamp.
A131805
(c) Loosen the clamp, then disconnect the water hose.

Blue Paint (d) Remove the 3 bolts and the throttle body assembly.
EM (e) Remove the 2 bolts and the throttle body assembly.
A131806

BOLT
(a) Remove the 2 bolts, then hold both sides of the fuel delivery
pipe and lift it straight up to remove.
A134311
26. REMOVE THROTTLE BODY BRACKET

(a) Remove the 2 bolts and the throttle body bracket.

(a) Remove the fuel injector assembly from the fuel delivery pipe.
NOTICE:
sideways force to the fuel injector assembly.
• If re-installing the fuel injector assembly instead of
replacing it with a new one, note the cylinder number on
A109106
a tag or similar to distinguish it.
(b) Remove the O- ring and insulator from the fuel injector assem-
bly.
O-ring 28. REMOVE INTAKE MANIFOLD
(a) Disconnect the water by-pass hose from the cylinder head.
(b) Disconnect the wire harness from the intake manifold.
Insulator
A107004J02
GETtheMANUALS.org
EM–177
(c) Remove the 3 bolts and 2 nuts, then remove the intake mani-
fold.
(d) Remove the gasket from the intake manifold.
30. REMOVE VANE PUMP WITH BRACKET (See page EM-79)

A109108

EM
A137714
34. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1

(a) Remove the 5 bolts and the exhaust manifold heat insulator No.
1.
A133399
35. REMOVE MANIFOLD STAY

(a) Remove the 2 bolts and the manifold stay.
A136071
GETtheMANUALS.org
36. REMOVE EXHAUST MANIFOLD

(a) Remove the 3 bolts and 2 nuts, then remove the exhaust mani-
fold.

(a) Disconnect the ignition coil connector.
EM
A133400
(b) Remove the bolt and the ignition coil assembly.
A133310
38. REMOVE CYLINDER HEAD COVER

(a) Remove the 11 bolts and 2 nuts, then remove the cylinder head
cover.
A132251
GETtheMANUALS.org
EM–179

HINT:
Timing Marks If the timing marks are not aligned, turn the crankshaft pulley
EM
Notch
A140612
(b) Using the SST, hold the crankshaft pulley and loosen the bolt.
SST 09278-87201
SST
A139349
(c) Using the SST and the crankshaft pulley bolt, remove the crank-
shaft pulley.
SST 09306-87501
NOTICE:
SST
A137589

(a) Remove the bolt and the crank position sensor.
A137713
GETtheMANUALS.org

(a) Remove the bolt and the camshaft timing oil control valve
assembly.
A136072
42. REMOVE TIMING CHAIN (BELT) COVER

EM
A133402
remove the timing chain (belt) cover.
NOTICE:
Do not damage the timing chain cover, cylinder block or
cylinder head.
A133404

(a) Using a screwdriver, pry out the timing chain (belt) cover oil
seal.
Wooden
Protective Tape Block
A033132J01
GETtheMANUALS.org
EM–181

D-MARK
A135998

released.[*1] EM
HINT:
the right and left.
A108005 and hold.[*2]
HINT:
plunger.
HINT:

A108555J01

(e) Remove the bolt and nut and then remove the water inlet.
A108556
GETtheMANUALS.org

A108557

EM
A108558

49. REMOVE CHAIN
A108559

Hold (a) Using the hexagon head portion of the camshaft, remove the
NOTICE:
When rotating the camshaft with the chain removed, rotate
the crankshaft 90° (crank angle) in the direction that the
engine rotates from cylinder No. 1 TDC / compression so
the valve does not interfere with the piston.
A136076

2
A133124
GETtheMANUALS.org
EM–183

2 10 14 6
NOTICE:
4 12 16 8
3 11 15 7
1 9 13 5
A133125
53. REMOVE CYLINDER HEAD

4 6 9 7 1 (a) Using an 8 mm double hexagon wrench, loosen the cylinder
head bolts in several passes in the order shown in the illustra- EM
tion, then remove the cylinder head bolt and washer.
NOTICE:
• When removing the bolt, do not drop the washer into
the head.
• Failure to remove the bolts in the specified order may
damage the cylinder head.
2 8 10 5 3 (b) Remove the cylinder head.
A132854
54. REMOVE CYLINDER HEAD GASKET
INSTALLATION
1. INSPECT CYLINDER HEAD BOLT
(a) Using vernier calipers, measure the diameter of the thread
A within the range indicated by A in the illustration.
Maximum limit:
25mm 20mm 8.75 mm
HINT:
• Measure the diameter at several locations. If the smallest
measured value is above the limit, the engine may be dam-
aged. Replace the bolt with a new one.
A108575J01 • If there is any damage to the thread on the bolt, replace the
cylinder head bolt.
2. INSTALL CYLINDER HEAD GASKET
NOTICE:
Cylinder Head • Install the cylinder head gasket within 3 minutes and tighten
0-4 mm
21-27 mm the cylinder head bolts within 15 minutes after applying
2.5 mm Three Bond TB1207B.
tration.
Cylinder Head
Gasket
17-23 mm Cylinder Block
2.0 mm
A083197J02
GETtheMANUALS.org
(b) Install a new cylinder head gasket in the direction shown in the
illustration.
NOTICE:
• Check that it is installed in the correct direction.
• Do not damage the cylinder head gasket.
3. INSTALL CYLINDER HEAD

NOTICE:
Front • Clean and degrease the installation surfaces.
• Inspect and clean the cylinder head and installation hole.
A033157J01
• Tighten the cylinder head using the plastic area tightening
method.
• Do not allow oil to get on the lower surface of the cylinder
head.
EM (a) Install the cylinder head.
NOTICE:
• Take care not to damage the cylinder head gasket when
installing it.
• Install the cylinder head bolt to the same place it was
removed from.
(b) Apply a light coat of engine oil to the threads and bolt-seating
surface of the cylinder head bolts.
Apply Engine Oil

A133007
(c) Using an 8 mm double hexagon wrench, temporarily install the

7 5 2 4 10 cylinder head bolts and washers in several passes in the order
shown in the illustration and then tighten the bolts with the spec-
ified torque.
9 3 1 6 8
A133008
(d) Put paint marks on the engine front side of heads of the cylinder
head bolts.
Paint Mark (e) Using the paint mark as a reference, tighten the cylinder head
bolts 180° in the specified order.
(f) Check all the paint marks are now moved 180°.
180° Tighten
(g) When installing the cylinder head, wipe off any Three Bond
TB1207B that is squeezed out.
NOTICE:
When wiping off the Three Bond TB1207B, do not allow it
A140645 to enter the bolt hole or knock pin hole.
GETtheMANUALS.org
EM–185

(a) When installing camshaft No. 2, rotate the crankshaft 90° (crank
angle) in the direction that the engine rotates from cylinder No.
1 TDC/compression so the lifted valve does not interfere with
the piston.
Camshaft NO. 1 Camshaft NO. 2 nal part of the cylinder head, and then install the camshaft No.
(In Side) (Ex Side) 2.
camshaft No. 2 push down the lifter valve.
EM
A137596
5. INSTALL CAMSHAFT
A137596

(a) Confirm the front mark and number of camshaft bearing cap No.
I2
I3
I4
I5
2 and install it.

the illustration.
15 7 3 11
NOTICE:
14 6 2 10
16 8 4 12
E2
E4
E5
E3
A133070

(a) Tighten the camshaft bearing cap No. 1 in the order indicated in
the illustration.
3
1
NOTICE:
2 camshaft is aligned with the groove on camshaft bearing
4 cap No. 1.

A133071
GETtheMANUALS.org
(b) Align the camshaft knock pin and the camshaft timing sprocket
Pin Hole Knock Pin
shaft.
NOTICE:
(c) Apply a small amount of engine oil to the camshaft timing
EM Hold sprocket installation bolt thread and seating surface to tempo-
(d) Using the hexagon head portion of the camshaft, tighten the
A136076
9. INSTALL CHAIN
Mark Plate Mark Plate (a) Align the mark plate (yellow) and the timing mark as shown in
HINT:
Install so that the mark plate is on the engine front side.
Mark Plates
Timing Mark
A137742
GETtheMANUALS.org
EM–187

A108559

A108558

A108557

HINT:
plunger.
A108556 plunger.

D Mark (a) Install the crank angle sensor plate No. 1 so that the D mark is
visible.
A133073
GETtheMANUALS.org
15. INSTALL TIMING CHAIN (BELT) COVER

(a) Install a new gasket to the timing chain (belt) cover.
A108562
(b) Apply Three Bond TB1207B to the locations shown in the illus-
tration.
EM NOTICE:
• Clean and degrease the installation surfaces using
brake cleaner and white gasoline.
• Install the timing chain (belt) cover within 3 minutes of
applying Three Bond TB1207B.
• Tighten the timing chain (belt) cover to the specified
torque within 15 minutes of applying Three Bond
Apply Liquid Gasket A108563J02 TB1207B.
• Do not add engine oil within 2 hours of installation.
B B 6 mm Diameter
6 mm Diameter
3-4 mm Diameter 3 mm Diameter

A A
Apply Liquid Gasket

3-4 mm 3-4 mm A139363
GETtheMANUALS.org
EM–189
(c) Install the timing chain (belt) cover with the 13 bolts and 2 nuts.
Torque: 12 N*m (122 kgf*cm) (Bolts 1 to 9)
23 N*m (235 kgf*cm) (Nuts 11 to 12)
10 44 N*m (449 kgf*cm) (Bolts 13 to 15)
3
2 16. INSTALL TIMING CHAIN (BELT) COVER OIL SEAL (See page EM-
206)
4 12
15
11 13
14
5
1
9
6
7 8 EM
A136081

SST 09278-87201
SST
A137588

NOTICE:
A137713

(b) Install the camshaft timing oil control valve assembly with the
bolt.
NOTICE:
A136072
GETtheMANUALS.org
20. INSTALL CYLINDER HEAD COVER

tration.
NOTICE:
TB1207B.
• Tighten the cylinder head cover to the specified torque
within 15 minutes of applying Three Bond TB1207B.
Apply Liquid Gasket
A079650J02 • Do not start the engine within 2 hours of installation.
(b) Install the cylinder head cover with the 11 bolts and 2 nuts in
8 2 4 6
several passes in the order shown in the illustration.
12 13
9 21. INSTALL SPARK PLUG
10 11
5 3 1 7
A133409

23. INSTALL EXHAUST MANIFOLD

(a) Install the exhaust manifold using a new gasket.
A133310
(b) Install the intake manifold with the 3 bolts and 2 nuts in the
order shown in the illustration.
A133400
GETtheMANUALS.org
EM–191
24. INSTALL MANIFOLD STAY

(a) Install the manifold stay with the bolt.
Torque: 9.3 N*m (95 kgf*cm) (bolt)
EM
A136071
25. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1

(a) Install the exhaust manifold heat insulator No. 1 with the 5 bolts.
A133399

29. INSTALL VANE PUMP WITH BRACKET (See page EM-103)

A137714 33. INSTALL INTAKE MANIFOLD
(a) Temporarily install the intake manifold with the 3 bolts and 2
nuts using a new gasket.
(b) Tighten the bolts and nuts in the order shown in the illustration.
A079976J02
GETtheMANUALS.org

(a) Temporarily install the throttle body bracket with the 2 bolts.
(b) Temporarily install the throttle body assembly with the 3 bolts
using a new gasket.
(c) Tighten the throttle body bracket with the 2 bolts.
(d) Using a new gasket, tighten the throttle body assembly on the
throttle body bracket side and then the intake manifold side with
the 3 bolts.
A109106 Torque: 21 N*m (214 kgf*cm) Bolt throttle body bracket
side
7.5 N*m (75 kgf*cm) Bolt intake manifold side
(e) Connect the 2 water by-pass hoses.
EM (f) Connect the engine wire harness.
(a) Install a new injector vibration insulator.
Insulator
A107004J01
NOTICE:
Install the sensor so that the O-ring is not twisted or
pinched.
(d) Check that the fuel injector assembly rotates smoothly.
NOTICE:
If the fuel injector assembly does not rotate smoothly, rein-
stall it with a new O-ring.
A107005
(a) Install the fuel pipe insulator.
(b) Temporarily install the fuel delivery pipe and the fuel tube with
the 2 bolts.
NOTICE:
• Do not drop the fuel injector when installing the fuel
delivery pipe.
• If the tip of the sensor is hit or dropped, replace it with a
new one.
insertion part of the injector assembly (cylinder head).
A136082 (c) Check that the fuel injectors rotate smoothly.
NOTICE:
If a fuel injector does not rotate smoothly, reinstall it with a
new O-ring.
(d) Tighten the 2 bolts.
GETtheMANUALS.org
EM–193
37. CONNECT VACUUM HOSE ASSEMBLY

(a) Connect the vacuum hose assembly to the brake booster
assembly.

(a) Connect the fuel hose No. 2.
NOTICE:
foreign matter on the fuel hose No. 2 or the connection
of the pipe.
40. INSTALL EXHAUST PIPE ASSEMBLY FR (See page EM-101)

41. CONNECT ENGINE ROOM MAIN WIRE
(a) Install the ground wire with the 2 bolts.
EM
(b) Connect the cylinder head cover ground connector.
(c) Connect the connectors of the sensors.
(d) Connect the engine wire clamp to the bracket.
42. CONNECT ACCELERATOR CONTROL CABLE ASSEMBLY

(a) Connect the accelerator control cable assembly to the throttle
body assembly.
(b) Install the bracket with the bolt.
A133250
(c) Adjust the wire cable and tighten the nut.


White Paint (a) Install ventilation hose No. 2.
Yellow Paint
A131807
GETtheMANUALS.org
45. INSTALL RADIATOR PIPE

(a) Install the radiator pipe with the 2 bolts and connect the hose.
A133397

EM
A136002

48. INSTALL WITH WATER FAN ASSEMBLY (See page CO-24)

25)
A136001 52. INSTALL BATTERY CARRIER
(a) Install the battery carrier with the 3 bolts.
53. INSTALL BATTERY

55. INSTALL AIR CLEANER ASSEMBLY
A (a) Install the air cleaner assembly with the 3 bolts.
A
B
NOTICE:
• Check that the O-ring is installed correctly to the throt-
tle body joint.
• Check that there is no foreign matter in the throttle
body opening.
• Check that there is no foreign matter on the clean side
part of the air cleaner.
A136084 Torque: 7.5 N*m (75 kgf*cm) (Bolt A)
(b) Connect the VSV connector.
(c) Connect the inlet air temperature sensor.
(d) Connect the connector of the vacuum sensor.
GETtheMANUALS.org
EM–195
57. ADD ENGINE OIL

63. Check for fuel leaks.

EM
/ CIRCUIT RELAY / ON, and check the fuel pump opera-
tion.
(1) Check that there are no leaks in the fuel system with fuel
pressure applied.
GETtheMANUALS.org
EM–196 ENGINE MECHANICAL - TIMING CHAIN (BELT) COVER OIL SEAL (3SZ-VE)
TIMING CHAIN (BELT) COVER OIL SEAL (3SZ-VE)

ENGINE MECHANICAL
COMPONENTS
EM
T=7.5{76}
×2
FRONT BUMPER COVER
ENGINE UNDER COVER
FOG LIGHT ASSEMBLY RH
T=5.4{55} ×11

A136654J01
GETtheMANUALS.org
ENGINE MECHANICAL - TIMING CHAIN (BELT) COVER OIL SEAL (3SZ-VE)
EM–197
CHARCOAL CANISTER NO. 1

RADIATOR RESERVE RADIATOR HOSE NO. 2
TANK ASSEMBLY
T=7.5{76}
RADIATOR HOSE NO. 1
T=7.5{76}
CHARCOAL CANISTER
ASSEMBLY
T=7.5{76}
RADIATOR CAP EM
RADIATOR SUPPORT UPR
×2
×2
WITH WATER
×2 FAN ASSEMBLY
T=7.5{76}
RADIATOR SUPPORT CUSHION

×4
RADIATOR ASSEMBLY
T=5.0{51}
T=5.0{51}
DRAIN COCK SUB-ASSEMBLY
×2 OIL COOLER
OUTLET HOSE NO. 1
A/T
T=5.0{51}
T=5.0{51}
CONDENSER ASSEMBLY
(WITH RESERVOIR)
SEAL PLATE

A136655J01
GETtheMANUALS.org
EM
CRANKSHAFT PULLEY
T=130{1326}
APPLY MP GREASE
A137089J02
GETtheMANUALS.org
EM–199
REMOVAL
(See page RS-164.)
4. REMOVE FOG LIGHT ASSEMBLY LH (See page CO-15)
5. REMOVE FOG LIGHT ASSEMBLY RH
6. REMOVE FRONT BUMPER COVER (See page CO-15)
8. REMOVE SEAL PLATE (See page CO-15) EM




15)
15. REMOVE RADIATOR SUPPORT UPPER (See page CO-16)
16. DISCONNECT CONDENSER ASSEMBLY (WITH RECEIVER) (See

page CO-16)
17. REMOVE RADIATOR ASSEMBLY (See page CO-17)

(a) Using the SST, hold the crankshaft pulley and loosen the bolt.
SST 09278-87201
SST
A139349
(b) Using the SST and the crankshaft pulley bolt, remove the crank-
shaft pulley.
SST 09306-87501
NOTICE:
SST

(a) Using a cutter knife, cut off the lip of the oil seal.
A137589
GETtheMANUALS.org
remove the oil seal.
Protective Tape NOTICE:
After removing the oil seal, check there are no scratches or
other damage to the crankshaft part.If there are any
scratches, remove them using sandpaper (No. 400).
INSTALLATION
1. INSTALL TIMING CHAIN (BELT) COVER OIL SEAL
A107954J01
(a) Apply a light coat of MP grease to the lip of a new timing chain
(belt) cover oil seal.
NOTICE:
EM • Keep the lip free of chips, sand and other foreign mat-
ter.
• Wipe off any grease on the crankshaft.
(b) Using the SST, drive in a new timing chain (belt) cover oil seal
to the position shown in the illustration.
SST 09223-87202
NOTICE:
• Be careful not to tap the timing chain (belt) cover oil
seal at an angle.
SST
• After installing it, check that the timing chain (belt)
cover oil seal has been driven in right to the end face of
the timing gear (chain) case.
A137591 (c) Standard
(1) Press fit margin
• Amount of protrusion from the end face of the timing
chain (belt) cover: less than 0.5 mm
• Press fit depth from the end face of the timing chain
(belt) cover: less than 1 mm
SST 09278-87201
Torque: 130 N*m (1,326 kgf*cm)

SST 5. CHECK FAN AND ALTERNATOR V BELT (See page EM-9)
A139349
6. INSTALL RADIATOR ASSEMBLY (See page CO-17)
7. INSTALL CONDENSER ASSEMBLY (WITH RECEIVER) (See page

CO-18)
8. INSTALL RADIATOR SUPPORT UPPER (See page CO-18)

18)

GETtheMANUALS.org
EM–201

15. INSTALL SEAL PLATE (See page CO-19)
17. INSTALL ENGINE UNDER COVER (See page CO-19)
18. INSTALL FRONT BUMPER COVER (See page CO-19)
19. INSTALL FOG LIGHT ASSEMBLY LH
20. INSTALL FOG LIGHT ASSEMBLY RH
21. CONNECT NEGATIVE BATTERY TERMINAL (See page CO-19)

EM
GETtheMANUALS.org
EM–202 ENGINE MECHANICAL - TIMING CHAIN (BELT) COVER OIL SEAL (K3-VE)
TIMING CHAIN (BELT) COVER OIL SEAL (K3-VE)

ENGINE MECHANICAL
COMPONENTS
EM
T=7.5{76}
×2
FRONT BUMPER COVER
ENGINE UNDER COVER
T=5.4{55} ×11

A136654J01
GETtheMANUALS.org
ENGINE MECHANICAL - TIMING CHAIN (BELT) COVER OIL SEAL (K3-VE)
EM–203

TANK ASSEMBLY
T=7.5{76}
RADIATOR HOSE NO. 1
T=7.5{76}
CHARCOAL CANISTER
ASSEMBLY
T=7.5{76}
RADIATOR CAP EM
×2
×2
WITH WATER
×2 FAN ASSEMBLY
T=7.5{76}

×4
RADIATOR ASSEMBLY
T=5.0{51}
T=5.0{51}
×2 OIL COOLER
OUTLET HOSE NO. 1
A/T
T=5.0{51}
T=5.0{51}
CONDENSER ASSEMBLY
(WITH RESERVOIR)
SEAL PLATE

A136655J01
GETtheMANUALS.org
EM
CRANKSHAFT PULLEY
T=130{1326}
APPLY MP GREASE
A137089J02
GETtheMANUALS.org
EM–205
REMOVAL
(See page RS-164.)
4. REMOVE FOG LIGHT ASSEMBLY LH (See page LI-33)
6. REMOVE FRONT BUMPER COVER (See page ET-2)
8. REMOVE SEAL PLATE (See page AC-57) EM




22)
15. REMOVE RADIATOR SUPPORT UPPER (See page CO-23)
16. DISCONNECT CONDENSER ASSEMBLY (WITH RECEIVER) (See

page CO-23)
17. REMOVE RADIATOR ASSEMBLY (See page CO-24)

(a) Using the SST, hold the crankshaft pulley and loosen the bolt.
SST 09278-87201
SST
A139349
(b) Using the SST and the crankshaft pulley bolt, remove the crank-
shaft pulley.
SST 09306-87501
NOTICE:
SST

(a) Using a cutter knife, cut off the lip of the oil seal.
A137589
GETtheMANUALS.org
remove the oil seal.
Protective Tape NOTICE:
After removing the oil seal, check there are no scratches or
other damage to the crankshaft part.If there are any
scratches, remove them using sandpaper (No. 400).
INSTALLATION
1. INSTALL TIMING CHAIN (BELT) COVER OIL SEAL
A107954J01
(a) Apply a light coat of MP grease to the lip of a new timing chain
(belt) cover oil seal.
NOTICE:
EM • Keep the lip free of chips, sand and other foreign mat-
ter.
• Wipe off any grease on the crankshaft.
(b) Using the SST, pressure fit a new timing chain (belt) cover oil
seal vertically.
SST 09223-87202
NOTICE:
• Be careful not to tap the timing chain (belt) cover oil
seal at an angle.
SST
• After installing it, check that the timing chain (belt)
cover oil seal has been driven in right to the end face of
the timing gear (chain) case.
A137591 (c) Standard
(1) Press fit margin
• Amount of protrusion from the end face of the timing
chain (belt) cover: less than 0.5 mm
• Press fit depth from the end face of the timing chain
(belt) cover: less than 1 mm
SST 09278-87201
Torque: 130 N*m (1,326 kgf*cm)

SST 5. CHECK FAN AND ALTERNATOR V BELT (See page EM-13)
A139349
6. INSTALL RADIATOR ASSEMBLY (See page CO-24)
7. INSTALL CONDENSER ASSEMBLY (WITH RECEIVER) (See page

CO-25)
8. INSTALL RADIATOR SUPPORT UPPER (See page CO-25)

25)

GETtheMANUALS.org
EM–207

15. INSTALL SEAL PLATE (See page CO-26)
18. INSTALL FRONT BUMPER COVER (See page ET-5)
19. INSTALL FOG LIGHT ASSEMBLY LH (See page LI-34)

EM
GETtheMANUALS.org
EM–208 ENGINE MECHANICAL - ENGINE REAR OIL SEAL (3SZ-VE)
ENGINE REAR OIL SEAL (3SZ-VE)

ENGINE MECHANICAL
COMPONENTS
REAR END PLATE ENGINE REAR OIL SEAL
T=7.5{76}
EM
×7
T=10{102}
ENGINE REAR OIL SEAL RETAINER
T=68{693}
×4
T=8.5{86}
×10
FRONT SUSPENSION
T=8.5{86} ×4 CROSS MEMBER LWR
OIL PAN
M/T CLUTCH DISC ASSEMBLY

T=19.1{195}
A/T ×6
T=27.5{280} T=78{800}
×6
×6
T=78{800}
×6
FLYWHEEL RING GEAR FLYWHEEL CLUTCH COVER ASSEMBLY
APPLY MP GREASE
A139030J01
GETtheMANUALS.org
ENGINE MECHANICAL - ENGINE REAR OIL SEAL (3SZ-VE)
EM–209
REMOVAL
SION)
HINT:
See IP-8 for the procedure leading up to the removal of the transmis-
sion assembly.

SION) (See page EM-49)

SION)
HINT:
sion assembly.
EM
5. REMOVE CLUTCH DISC ASSEMBLY (MANUAL TRANSMISSION)

(See page CL-20)
6. REMOVE FLYWHEEL (MANUAL TRANSMISSION) (See page EM-

49)
7. REMOVE FRONT DRIVE SHAFT ASSEMBLY (for 4WD)

HINT:
See IP-8 for the procedure leading up to the removal of the front drive
shaft assembly.
8. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for

4WD)
HINT:
See IP-8 for the procedure leading up to the removal of the front dif-
ferential carrier assembly.

(See page EM-47)
10. REMOVE REAR END PLATE (See page EM-50)
11. REMOVE OIL PAN

(b) Using an oil pan seal cutter, remove the oil pan from the cylin-
der block.
NOTICE:
• Be careful not to damage the oil pan and the cylinder
block.
• When removing, take care not to deform the oil pan
flange.
A139023
GETtheMANUALS.org
EM–210 ENGINE MECHANICAL - ENGINE REAR OIL SEAL (3SZ-VE)
12. REMOVE ENGINE REAR OIL SEAL RETAINER

(a) Remove the 7 bolts and then the engine rear oil seal retainer.
A139034
13. REMOVE ENGINE REAR OIL SEAL

(a) Using a screwdriver, pry out the engine rear oil seal.
EM
INSTALLATION
1. INSTALL ENGINE REAR OIL SEAL
(a) Apply a light coat of MP grease to the lip of a new engine rear
oil seal.
NOTICE:
Keep the lip free of chips, sand and other foreign matter.
A139035
(b) Using the SST, drive in a new engine rear oil seal to the position
NOTICE:
• Be careful not to tap the engine rear oil seal at an angle.
• After installing it, check that the engine rear oil seal has
been driven in right to the end face.
SST -0.5-1 mm
Wooden Block A139032
2. INSTALL ENGINE REAR OIL SEAL RETAINER

(a) Apply Three Bond TB1207B to the engine rear oil seal retainer
3-4 mm
as shown in the illustration (3 to 4 mm diameter).
(b) Install the engine rear oil seal retainer with the 7 bolts.
A139033
3. INSTALL OIL PAN

Liquid Gasket Thickness 3.0-4.0 mm
18 mm (a) Apply Three Bond TB1207B to the locations shown in the illus-
tration (3 to 4 mm diameter).
NOTICE:
• Install the oil pan within 3 minutes of applying Three
Bond TB1207B.
• Tighten the oil pan to the specified torque within 15
17 mm Liquid Gasket Thickness 1.3-1.5 mm minutes of applying Three Bond TB1207B.
:Apply Liquid Gasket A139022 • Do not start the engine within 2 hours of installation.
GETtheMANUALS.org
ENGINE MECHANICAL - ENGINE REAR OIL SEAL (3SZ-VE)
EM–211
(b) Install the oil pan with the 10 bolts and 4 nuts.
4. INSTALL REAR END PLATE (See page EM-59)

PR-4)
6. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)

HINT:
See IP-8 for the procedure leading up to the installation of the front
differential carrier assembly.
7. INSTALL FRONT DRIVE SHAFT ASSEMBLY (for 4WD)

HINT:
drive shaft assembly.
EM
8. INSTALL FLYWHEEL (MANUAL TRANSMISSION) (See page EM-
59)

(See page CL-21)


SION)
HINT:
See IP-8 for the procedure leading up to the installation of the trans-
mission assembly.

(See page EM-61)

SION)
HINT:
mission assembly.
GETtheMANUALS.org
EM–212 ENGINE MECHANICAL - ENGINE REAR OIL SEAL (K3-VE)
ENGINE REAR OIL SEAL (K3-VE)

ENGINE MECHANICAL
COMPONENTS
REAR END PLATE ENGINE REAR OIL SEAL
T=7.5{76}
EM
×7
T=10{102}
ENGINE REAR OIL SEAL RETAINER
T=68{693}
×4
T=8.5{86}
×10
FRONT SUSPENSION
T=8.5{86} ×4 CROSS MEMBER LWR
OIL PAN
M/T CLUTCH DISC ASSEMBLY

T=19.1{195}
A/T ×6
T=27.5{280} T=78{800}
×6
×6
T=78{800}
×6
FLYWHEEL RING GEAR FLYWHEEL CLUTCH COVER ASSEMBLY
APPLY MP GREASE
A139030J01
GETtheMANUALS.org
ENGINE MECHANICAL - ENGINE REAR OIL SEAL (K3-VE)
EM–213
REMOVAL
SION)
HINT:
sion assembly.

SION) (See page EM-84)

SION)
HINT:
sion assembly.
EM
5. REMOVE CLUTCH DISC ASSEMBLY (MANUAL TRANSMISSION)

(See page CL-20)
6. REMOVE FLYWHEEL (MANUAL TRANSMISSION) (See page EM-

85)
7. REMOVE FRONT DRIVE SHAFT ASSEMBLY (for 4WD)

HINT:
See IP-8 for the procedure leading up to the removal of the front drive
shaft assembly.
8. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for

4WD)
HINT:
See IP-8 for the procedure leading up to the removal of the front dif-
ferential carrier assembly.
9. REMOVE REAR END PLATE (See page EM-85)
10. REMOVE OIL PAN

(b) Using an oil pan seal cutter, remove the oil pan from the cylin-
der block.
NOTICE:
• Be careful not to damage the oil pan and the cylinder
block.
• When removing, take care not to deform the oil pan
flange.
A139023
GETtheMANUALS.org
EM–214 ENGINE MECHANICAL - ENGINE REAR OIL SEAL (K3-VE)
11. REMOVE ENGINE REAR OIL SEAL RETAINER

(a) Remove the 7 bolts and then the engine rear oil seal retainer.
A139034
12. REMOVE ENGINE REAR OIL SEAL

(a) Using a screwdriver, pry out the engine rear oil seal.
EM
INSTALLATION
1. INSTALL ENGINE REAR OIL SEAL
(a) Apply a light coat of MP grease to the lip of a new engine rear
oil seal.
NOTICE:
Keep the lip free of chips, sand and other foreign matter.
A139035
(b) Using the SST, drive in a new engine rear oil seal to the position
NOTICE:
• Be careful not to tap the engine rear oil seal at an angle.
• After installing it, check that the engine rear oil seal has
been driven in right to the end face.
SST -0.5-1 mm
Wooden Block A139032
2. INSTALL ENGINE REAR OIL SEAL RETAINER

3-4 mm (a) Apply Three Bond TB1207B to the engine rear oil seal retainer
as shown in the illustration (3 to 4 mm diameter).
(b) Install the engine rear oil seal retainer with the 7 bolts.
A139033
3. INSTALL OIL PAN

Liquid Gasket Thickness 3.0-4.0 mm
18 mm (a) Apply Three Bond TB1207B to the locations shown in the illus-
tration (3 to 4 mm diameter).
NOTICE:
• Install the oil pan within 3 minutes of applying Three
Bond TB1207B.
• Tighten the oil pan to the specified torque within 15
17 mm Liquid Gasket Thickness 1.3-1.5 mm minutes of applying Three Bond TB1207B.
:Apply Liquid Gasket A139022 • Do not start the engine within 2 hours of installation.
GETtheMANUALS.org
ENGINE MECHANICAL - ENGINE REAR OIL SEAL (K3-VE)
EM–215
(b) Install the oil pan with the 10 bolts and 4 nuts.
4. INSTALL REAR END PLATE (See page EM-94)
5. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)

HINT:
6. INSTALL FRONT DRIVE SHAFT ASSEMBLY (for 4WD)

HINT:
drive shaft assembly.
7. INSTALL FLYWHEEL (MANUAL TRANSMISSION) (See page EM-

94)
EM
(See page CL-21)


SION)
HINT:
mission assembly.

(See page EM-96)

SION)
HINT:
mission assembly.
GETtheMANUALS.org
TO INDEX
ENGINE
FUEL
FUEL SYSTEM (3SZ-VE)
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-1
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-3
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-4
FUEL SYSTEM (K3-VE)
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-6
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-8
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-10
FUEL INJECTOR ASSEMBLY (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-12 FU
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-13
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-15
FUEL INJECTOR ASSEMBLY (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-18
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-20
FUEL PUMP (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-23
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-24
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-25
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-26
FUEL PUMP (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-29
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-30
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-31
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-32
FUEL TANK ASSEMBLY (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-36
FUEL TANK ASSEMBLY (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-42
GETtheMANUALS.org
FU–1 FUEL − FUEL SYSTEM (3SZ-VE)
FUEL SYSTEM (3SZ-VE)

FUEL
ENGINE
PRECAUTIONS
1. PRECAUTIONS
(a) Disconnect the negative terminal from the battery before
performing work on the fuel system.
(b) Do not smoke or work near an open flame when working on the
fuel system.
(c) Keep rubber or leather parts away from gasoline.
NOTICE:
FU • As some pressure will remain in the fuel line even after the
fuel system pressure has been discharged, cover the
opening with a shop rag or similar to prevent fuel from
splashing.
(a) Turn the ignition switch to the LOCK position.
(b) Remove the F/P relay.
Instrument Panel J/B (c) After the engine has stopped on its own, turn the ignition switch
off.
HINT:
The DTC P0171/25 indicating a lean malfunction may be
detected.
(d) Crank the engine again, then check that the engine does not
F/P Relay
start.
(e) Remove the fuel tank cap to discharge pressure from the fuel
A135986J01 tank.
(f) Disconnect the negative terminal from the battery.
(g) Install the F/P relay.
3. FUEL SYSTEM
(a) Follow the procedures listed below as a large amount of
gasoline will splash when the fuel line is removed.
(1) Discharge fuel system pressure.
(2) Remove the fuel tube retaining clips.
(3) Remove the fuel tube.
(4) Remove the fuel remaining in the fuel tube.
(5) Cover the fuel tube that was removed with a plastic bag to
prevent it from being damaged and to prevent foreign
matter from entering it.
B000679J01
GETtheMANUALS.org
FUEL − FUEL SYSTEM (3SZ-VE)
FU–2
(b) Observe these precautions when removing and installing

O-ring injectors.
(1) Never reuse an O-ring.
(2) When placing a new O-ring on the injector, do not damage
it.
Injector
Delivery Pipe (3) Before installing new O-rings, apply spindle oil or gasoline
to them.Do not use engine oil, gear oil or brake oil.
A106967J01
(c) Install the injector to the delivery pipe and the cylinder head as
shown in the illustration. Before installing the injector, always
apply gasoline or spindle oil to the parts on the injector O-ring
that the delivery pipe will touch.
(d) Observe these precautions when removing the fuel tube FU
connector.
(1) Before disconnecting the fuel tube connector, check that
O-ring there is no mud or other dirt on the fuel tube connector and
Insulator
Delivery Pipe pipe. Clean if necessary.
A106968J01
(2) Disengage and push down the 2 fuel tube connector

retainer claws, then disconnect the fuel tube connector
from the pipe.
NOTICE:
Never use tools for this procedure.
Retainer
A125388J01
(3) If the fuel tube connector and pipe are stuck, pinch the
pipe, then push and pull the fuel tube connector to release
and disconnect the fuel tube connector.
NOTICE:
(4) After disconnecting the fuel tube, check that there is no
mud or other dirt on the pipe seal surface. Clean if
necessary.
A091246J01
(5) Protect the disconnected fuel tube connector and pipe with
a plastic bag.
Plastic Bag NOTICE:
Do not damage the fuel tube connector and pipe or
allow any foreign matter to get into the pipe.
A093309
GETtheMANUALS.org
FU–3 FUEL − FUEL SYSTEM (3SZ-VE)
(e) Observe these precautions when connecting the fuel tube

connector.
(1) Match the axis of the fuel tube connector with the axis of
the pipe, push in the fuel tube connector and push up the
retainer.
Retainer
A125397J01
(2) After connecting the fuel tube connector, check that the fuel
tube connector and pipe are securely connected by pulling
them.
FU (a) Always check that there are no fuel leaks after repairing the fuel
system.
OPERATION CHECK
A093435
1. CHECK FUEL PRESSURE
(a) Discharge fuel system pressure.
See page FU - 1.
(b) Disengage the fuel tube clamp and disconnect the fuel tube
(fuel tube connector).
See page FU - 1.
(c) Assemble the SST and gauge.
SST (Clip) SST 09268-41047
(d) Wipe off any spilled gasoline.
E.F.I. Pressure Gauge
(e) Start up the engine.
(f) Measure the fuel pressure at idle.
Standard:
T Joint
304 to 343 kPa (3.1 to 3.5 kgf/cm2)
(g) Stop the engine.
Fuel Tube (h) After stopping the engine, check that the fuel pressure does not
change for 5 minutes.
Standard:
147 kPa (1.5 kgf/cm2) or more
SST (Hose) HINT:
If the fuel pressure is not as specified, check the fuel pump, the
fuel pressure regulator or the injector.
(i) After measuring the pressure, take care to prevent gasoline
from splashing while removing the SST and the fuel tube
connector.
(j) Connect the fuel tube (fuel tube connector).
SST (Fuel Tube Connector)
(k) Install fuel pipe clamp No. 1.
A105669J02
2. CHECK FUEL PUMP OPERATION AND FOR FUEL LEAKS
/ FUEL PUMP / ON and check the fuel pump operation.
GETtheMANUALS.org
FUEL − FUEL SYSTEM (3SZ-VE)
FU–4

(1) Check that there are no leaks in the fuel system when fuel
pressure is applied.
LOCATION
INSTRUMENT PANEL J/B
FU
F/P RELAY
FUEL PUMP
A137725J01
GETtheMANUALS.org
FU–5 FUEL - FUEL SYSTEM (K3-VE)
FUEL SYSTEM (K3-VE)

FUEL
ENGINE
PRECAUTIONS
1. PRECAUTIONS
(a) Disconnect the negative terminal from the battery before
performing work on the fuel system.
(b) Do not smoke or work near an open flame when working on the
fuel system.
(c) Keep rubber or leather parts away from gasoline.
NOTICE:
FU • As some pressure will remain in the fuel line even after the
fuel system pressure has been discharged, cover the
opening with a shop rag or similar to prevent fuel from
splashing.
(a) Turn the ignition switch to the LOCK position.
(b) Remove the F/P relay.
Instrument Panel J/B (c) After the engine has stopped on its own, turn the ignition switch
off.
HINT:
(d) Crank the engine again, then check that the engine does not
start.
F/P Relay
(e) Remove the fuel tank cap to discharge pressure from the fuel
tank.
A135986J01 (f) Disconnect the negative terminal from the battery.
(g) Install the F/P relay.
3. FUEL SYSTEM
(a) Follow the procedures listed below as a large amount of
gasoline will splash when the fuel line is removed.
(1) Discharge fuel system pressure.
(2) Remove the fuel tube retaining clips.
(3) Remove the fuel tube.
(4) Remove the fuel remaining in the fuel tube.
(5) Cover the fuel tube that was removed with a plastic bag to
prevent it from being damaged and to prevent foreign
matter from entering it.
B000679J01
GETtheMANUALS.org
FUEL - FUEL SYSTEM (K3-VE)
FU–6
(b) Observe these precautions when removing and installing

O-ring injectors.
(1) Never reuse an O-ring.
(2) When placing a new O-ring on the injector, do not damage
it.
Injector
Delivery Pipe (3) Before installing new O-rings, apply spindle oil or gasoline
to them. Do not use engine oil, gear oil or brake oil.
A106967J01
(c) Install the injector to the delivery pipe and the cylinder head as
shown in the illustration. Before installing the injector, always
apply gasoline or spindle oil to the parts on the injector O-ring
that the delivery pipe will touch.
(d) Observe these precautions when removing the fuel tube FU
connector.
(1) Before disconnecting the fuel tube connector, check that
O-ring there is no mud or other dirt on the fuel tube connector and
Insulator
Delivery Pipe pipe. Clean if necessary.
A106968J01
(2) Disengage and push down the 2 fuel tube connector

retainer claws, then disconnect the fuel tube connector
from the pipe.
NOTICE:
Retainer
A125388J01
(3) If the fuel tube connector and pipe are stuck, pinch the
pipe, then push and pull the fuel tube connector to release
and disconnect the fuel tube connector.
NOTICE:
(4) After disconnecting the fuel tube, check that there is no
mud or other dirt on the pipe seal surface. Clean if
necessary.
A091246J01
(5) Protect the disconnected fuel tube connector and pipe with
a plastic bag.
Plastic Bag NOTICE:
Do not damage the fuel tube connector and pipe or
allow any foreign matter to get into the pipe.
A093309
GETtheMANUALS.org
FU–7 FUEL - FUEL SYSTEM (K3-VE)
(e) Observe these precautions when connecting the fuel tube

connector.
(1) Match the axis of the fuel tube connector with the axis of
the pipe, push in the fuel tube connector and push up the
retainer.
Retainer
A125397J01
(2) After connecting the fuel tube connector, check that the fuel
tube connector and pipe are securely connected by pulling
them.
FU (a) Always check that there are no fuel leaks after repairing the fuel
system.
OPERATION CHECK
A093435
1. CHECK FUEL PRESSURE
(a) Discharge fuel system pressure.
See page FU-5.
(b) Disengage the fuel tube clamp and disconnect the fuel tube
(fuel tube connector).
See page FU-5.
(c) Assemble the SST and gauge.
SST (Clip) SST 09268-41047
(d) Wipe off any spilled gasoline.
E.F.I. Pressure Gauge
(e) Start up the engine.
(f) Measure the fuel pressure at idle.
Standard:
T Joint
304 to 343 kPa (3.1 to 3.5 kgf/cm2)
(g) Stop the engine.
Fuel Tube (h) After stopping the engine, check that the fuel pressure does not
change for 5 minutes.
Standard:
147 kPa (1.5 kgf/cm2) or more
SST (Hose) HINT:
If the fuel pressure is not as specified, check the fuel pump, the
fuel pressure regulator or the injector.
(i) After measuring the pressure, take care to prevent gasoline
from splashing while removing the SST and the fuel tube
connector.
(j) Connect the fuel tube (fuel tube connector).
SST (Fuel Tube Connector)
(k) Install fuel pipe clamp No. 1.
A105669J02
2. CHECK FUEL PUMP OPERATION AND FOR FUEL LEAKS
/ FUEL PUMP / ON and check the fuel pump operation.
GETtheMANUALS.org
FUEL - FUEL SYSTEM (K3-VE)
FU–8

LOCATION
FU
F/P RELAY
FUEL PUMP
A137725J01
GETtheMANUALS.org
FU–9 FUEL - FUEL INJECTOR ASSEMBLY (3SZ-VE)
FUEL INJECTOR ASSEMBLY (3SZ-VE)

FUEL
ENGINE
COMPONENTS
FU
T=7.5{76}
×2
T=18{184}
T=7.5{76}
×2
FUEL DELIVERY PIPE
FUEL HOSE NO. 1

T=21{214} ×2

O-RING
ACCELERATOR CONTROL CABLE ASSEMBLY

INJECTOR VIBRATION
INSULATOR VENTILATION HOSE NO. 2
O-RING
×2
T=7.5{76}
VENTILATION HOSE
THROTTLE BODY BRACKET NO. 2
GETtheMANUALS.org
FUEL - FUEL INJECTOR ASSEMBLY (3SZ-VE)
FU–10
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE (See page EM - 146)

(See page RS - 164.)
3. REMOVE AIR CLEANER HOSE NO. 1 (See page CO - 15)
4. REMOVE AIR CLEANER ASSEMBLY (See page EM - 146)
5. REMOVE ACCELERATOR CONTROL CABLE ASSEMBLY (See

page EM - 147)
FU
A134307

(a) Remove ventilation hose No. 2.
8. DISCONNECT FUEL HOSE NO. 1

A134308

(a) Remove the 2 bolts and the bracket.
(b) Disconnect the connector.
(c) Remove the clamp and disconnect fuel hose No. 1 from the
pipe.
(d) Protect the connections of the fuel hose and the pipe with a
plastic bag to prevent any foreign matter from entering them.
A131805
(e) Remove the 2 bolts, then remove the fuel delivery pipe with the
BOLT
fuel injector assembly.
NOTICE:
Do not drop the fuel injector assembly.

(a) Remove the fuel injector assembly from the delivery pipe.
NOTICE:
sideways force to the injector.
A134311
GETtheMANUALS.org
• If re-installing the injector instead of replacing it with a

new one, note the cylinder number on a tag or similar to
identify it.
(b) Remove the O-ring.
(c) Remove the insulator.
O-ring
INSTALLATION
Insulator
A107004J01
FU 1. INSTALL FUEL INJECTOR ASSEMBLY

(a) Install a new insulator.
Insulator
A107004J01
NOTICE:
• Take care that the O-ring does not get twisted.
• After installing the fuel injector assembly to the fuel
delivery pipe, check that it can be rotated relatively
lightly. If it cannot be rotated, replace the O-ring with a
new one and re-install it.
A107005

BOLT
(a) Install the fuel delivery pipe with the 2 bolts.
NOTICE:
• Do not drop the fuel injector assembly when installing
the fuel delivery pipe.
• If the tips of the fuel injector assembly are hit or
dropped, replace it with a new one.
A134311 insertion part of the fuel injector assembly (cylinder
head).
• After installing the fuel delivery pipe, rotate the fuel
injector assembly by hand to check that it is correctly
and securely installed.If it does not rotate smoothly,
reinstall it with a new O-ring.
GETtheMANUALS.org
FUEL - FUEL INJECTOR ASSEMBLY (3SZ-VE)
FU–12
(c) Install the bracket with the 2 bolts.


(a) Connect fuel hose No. 1.
NOTICE:
foreign matter on the connection of the pipe or the
hose.
A131805

White Paint
FU
A131807


page EM - 165)
7. INSTALL AIR CLEANER ASSEMBLY (See page EM - 167)
8. INSTALL AIR CLEANER HOSE NO. 1 (See page CO - 19)

10. CHECK FOR FUEL LEAKS (See page FU - 3)
INSPECTION
1. INSPECT FUEL INJECTOR ASSEMBLY
(1) Using the tester, measure the resistance between the
injector terminals.
Reference value:
12 Ω (20°C)
HINT:
If the measured resistance is not as specified, replace the
terminals with normal ones.
GETtheMANUALS.org
(b) Check the injection volume.

A NOTICE:
Injector Perform the test in a well-ventilated area and watch out for
B flames.
(1) Connect the SST (injection measuring tool set) to the fuel
pipe (vehicle side).
Fuel Pipe SST 09843-97201, 09268-41047
(2) Set the injector to a graduated cylinder.
HINT:
A139327 Attach a suitable size of plastic tube or similar to prevent
the fuel from splashing.
(3) Connect the DS-II to the DLC, then operate the fuel pump.
SST 09843-97201
(5) Connect the SST to the battery, then perform fuel injection
FU (for 15 seconds) 2 or 3 times and calculate the average.
Standard
Injection Volume Difference between Injectors

46 to 59 ml 13 ml or less
NOTICE:
Always switch at the battery terminal side.
HINT:
If the measured value is not as specified, replace it with
normal one.
(c) Check for leaks.
(1) Check that there are no leaks from the fuel injector
assembly when the SST is removed from the battery
under the same conditions as above.
Standard:
B000069J01
GETtheMANUALS.org
FUEL - FUEL INJECTOR ASSEMBLY (K3-VE)
FU–14
FUEL INJECTOR ASSEMBLY (K3-VE)

FUEL
ENGINE
COMPONENTS
FU
T=7.5{76}
×2
T=18{184}
T=7.5{76}
×2
FUEL DELIVERY PIPE
FUEL HOSE NO. 1

T=21{214} ×2

O-RING

INJECTOR VIBRATION
INSULATOR VENTILATION HOSE NO. 2
O-RING
×2
T=7.5{76}
VENTILATION HOSE
THROTTLE BODY BRACKET NO. 2
GETtheMANUALS.org
FU–15 FUEL - FUEL INJECTOR ASSEMBLY (K3-VE)
REMOVAL

(See page RS - 164)
5. REMOVE ACCELERATOR CONTROL CABLE ASSEMBLY (See

page EM - 175)
FU
A134307

(a) Remove ventilation hose No. 2.
8. DISCONNECT FUEL HOSE NO. 1

A134308

(a) Remove the 2 bolts and the bracket.
(c) Remove the clamp and disconnect fuel hose No. 1 from the
pipe.
(d) Protect the connections of the fuel hose and the pipe with a
plastic bag to prevent any foreign matter from entering them.
A131805
(e) Remove the 2 bolts, then remove the fuel delivery pipe with the
BOLT
fuel injector assembly.
NOTICE:
Do not drop the fuel injector assembly.

(a) Remove the fuel injector assembly from the delivery pipe.
NOTICE:
sideways force to the injector.
A134311
GETtheMANUALS.org
FU–16
• If re-installing the injector instead of replacing it with a

new one, note the cylinder number on a tag or similar to
identify it.
(b) Remove the O-rings.
(c) Remove the insulator.
O-ring
INSTALLATION
Insulator
A107004J01

(a) Install a new insulator.
FU
Insulator
A107004J01
NOTICE:
• Take care that the O-ring does not get twisted.
• After installing the fuel injector assembly to the fuel
delivery pipe, check that it can be rotated relatively
lightly. If it cannot be rotated, replace the O-ring with a
new one and re-install it.
A107005

BOLT
(a) Install the fuel delivery pipe with the 2 bolts.
NOTICE:
• Do not drop the fuel injector assembly when installing
the fuel delivery pipe.
• If the tips of the fuel injector assembly are hit or
dropped, replace it with a new one.
A134311 insertion part of the fuel injector assembly (cylinder
head).
• After installing the fuel delivery pipe, rotate the fuel
injector assembly by hand to check that it is correctly
and securely installed.If it does not rotate smoothly,
reinstall it with a new O-ring.
GETtheMANUALS.org
FU–17 FUEL - FUEL INJECTOR ASSEMBLY (K3-VE)
(c) Install the bracket with the 2 bolts.


(a) Connect fuel hose No. 1.
NOTICE:
foreign matter on the connection of the pipe or the
hose.
A131805

White Paint
FU
A131807


page EM - 193)

INSPECTION
1. INSPECT FUEL INJECTOR ASSEMBLY
(1) Using the tester, measure the resistance between the
injector terminals.
Reference value:
12 Ω (20°C)
HINT:
If the measured resistance is not as specified, replace the
terminals with known-good ones.
GETtheMANUALS.org
FU–18
(b) Check the injection volume.

A NOTICE:
Injector Perform the test in a well-ventilated area and watch out for
B flames.
(1) Connect the SST (injection measuring tool set) to the fuel
pipe (vehicle side).
Fuel Pipe SST 09843-97201, 09268-41047
(2) Set the injector to a graduated cylinder.
HINT:
A139327 Attach a suitable size of plastic tube or similar to prevent
the fuel from splashing.
(3) Connect the DS-II to the DLC, then operate the fuel pump.
SST 09843-97201
(5) Connect the SST to the battery, then perform fuel injection
(for 15 seconds) 2 or 3 times and calculate the average. FU
Standard
Injection Volume Difference between Injectors

46 to 59 ml 13 ml or less
NOTICE:
Always switch at the battery terminal side.
HINT:
known-good parts.
(c) Check for leaks.
(1) Check that there are no leaks from the fuel injector
assembly when the SST is removed from the battery
under the same conditions as above.
Standard:
B000069J01
GETtheMANUALS.org
FU–19 FUEL – FUEL PUMP (3SZ-VE)
FUEL PUMP (3SZ-VE)

FUEL
ENGINE
COMPONENTS
REAR FLOOR SERVICE HOLE COVER
T=4.0{41}
FUEL PUMP BRACKET

FU
FUEL SUCTION TUBE
PUMP ASSEMBLY FUEL WITH FILTER
FUEL PUMP BRACKET GASKET
GETtheMANUALS.org
FUEL – FUEL PUMP (3SZ-VE)
FU–20

FU
A136378J01
GETtheMANUALS.org
REMOVAL

3. REMOVE REAR FLOOR SERVICE HOLE COVER
(a) Remove the 2 clips and roll back the rear seat carpet.
FU :Clip A134334
(b) Remove the butyl tape, then remove the rear floor service hole
cover.
A134337
(c) Disconnect the fuel pump connector.
A134335
4. DISCONNECT FUEL SUCTION TUBE

(a) Grasp both ends of the retainer and with the lock removed, pull
out the tube and the retainer together.
A134336
GETtheMANUALS.org
FU–22
(b) Pull out and disconnect the fuel suction tube.

NOTICE:
• Remove any dirt and foreign matter on the clip part
before performing this work.
• As the fuel tube joint seals the fuel pump tube and fuel
suction plate by the O-ring, make sure there is no
damage to or foreign matter on the connection part
when performing this work.
• Always install and remove by hand. Never use tools.
A134874 • Do not forcibly bend, fold or rotate the nylon tube.
• After disconnecting the fuel pump tube, protect the
connected part by covering it with a plastic bag or
similar.
• If the nylon tube and fuel suction plate are stuck, push
and pull them to release.
5. REMOVE PUMP ASSEMBLY FUEL WITH FILTER
FU
(a) Remove the 8 screws, then remove the pump assembly fuel
with filter.
6. DRAIN FUEL
DISASSEMBLY
1. REMOVE FUEL SENDER GAUGE ASSEMBLY
(a) Disconnect the fuel sender gauge assembly connector.
A134338
(b) Release the lock shown in the illustration, and slide the fuel
sender gauge assembly to remove it.
REASSEMBLY
1. INSTALL FUEL SENDER GAUGE ASSEMBLY
(a) Match the protruding part of the fuel sender gauge assembly
with the recessed part of the pump assembly fuel with filter side.
A139483
(b) Slide the fuel sender gauge assembly to install it.

(c) Install the fuel sender gauge assembly connector.
A139484
GETtheMANUALS.org
INSTALLATION
1. INSTALL PUMP ASSEMBLY FUEL WITH FILTER
(a) Align the bracket hole and the protruding part of the pump, and
then align the bracket and the fuel tank matchmarks to attach
them.
FU
A134873
(b) Install the pump assembly fuel with filter with the 8 screws.
A134338
2. CONNECT FUEL SUCTION TUBE

(a) Insert the fuel suction tube into the plug of the suction plate.
NOTICE:
• Check that the connection is not damaged or
contaminated with foreign matter.
• Check that the fuel suction tube is securely inserted all
the way in.
• After installing the tube joint clip, check that the fuel
suction tube cannot be pulled out.
A136229
3. REPLACE FUEL SUCTION TUBE
(a) Remove the connector and the corresponding fuel pipe
following the procedure listed above, and then remove the
retainer from the pump on the fuel pump side.
(b) Align the connector with the axis of the corresponding fuel pipe,
then push the connector in until the retainer makes a (click)
sound.
GETtheMANUALS.org
FU–24
(c) Pull the checker out vertically in relation to the direction in which
it is installed.
Fuel Pump Side
4. INSTALL REAR FLOOR SERVICE HOLE COVER
(a) Connect the connector.
Pull Out Checker
A134952
(b) Install the rear floor service hole cover using new butyl tape.
5. REFILL FUEL
Butyl Tape
Torque: 5.4 N*m (55 kgf*cm) FU
INSPECTION
A136230
1. INSPECT PUMP ASSEMBLY FUEL WITH FILTER

E terminals.
Reference value:
2 1 0.2 to 3.0 (20°C)
4 3 (b) Check operation.
that the motor operates.
A134990 NOTICE:
• Complete the check quickly (within 10 seconds).
• Move the pump assembly fuel with filter as far
away as possible from the battery.
• Always switch at the battery terminal side.
GETtheMANUALS.org
FU–25 FUEL - FUEL PUMP (K3-VE)
FUEL PUMP (K3-VE)

FUEL
ENGINE
COMPONENTS
T=4.0{41}
FUEL PUMP BRACKET

FU
FUEL SUCTION TUBE
GETtheMANUALS.org
FUEL - FUEL PUMP (K3-VE)
FU–26

FU
A136378J01
GETtheMANUALS.org
REMOVAL

(See page RS-164.)
3. REMOVE REAR FLOOR SERVICE HOLE COVER
FU :Clip A134334
(b) Remove the butyl tape, then remove the rear floor service hole
cover.
A134337
(c) Disconnect the fuel pump connector.
A134335

(a) Grasp both ends of the retainer and with the lock removed, pull
out the tube and the retainer together.
A134336
GETtheMANUALS.org
FU–28
(b) Pull out and disconnect the fuel suction tube.

NOTICE:
• As the fuel tube joint seals the fuel pump tube and fuel
suction plate by the O-ring, make sure there is no
damage to or foreign matter on the connection part
when performing this work.
A134874 • Do not forcibly bend, fold or rotate the nylon tube.
• After disconnecting the fuel pump tube, protect the
connected part by covering it with a plastic bag or
similar.
• If the nylon tube and fuel suction plate are stuck, push
and pull them to release.
5. REMOVE PUMP ASSEMBLY FUEL WITH FILTER
FU
(a) Remove the 8 screws, then remove the pump assembly fuel
with filter.
6. DRAIN FUEL
DISASSEMBLY
1. REMOVE FUEL SENDER GAUGE ASSEMBLY
A134338
(b) Release the lock shown in the illustration, and slide the fuel
sender gauge assembly to remove it.
REASSEMBLY
1. INSTALL FUEL SENDER GAUGE ASSEMBLY
(a) Match the protruding part of the fuel sender gauge assembly
with the recessed part of the pump assembly fuel with filter side.
A139483
(b) Slide the fuel sender gauge assembly to install it.

(c) Install the fuel sender gauge assembly connector.
A139484
GETtheMANUALS.org
INSTALLATION
1. INSTALL PUMP ASSEMBLY FUEL WITH FILTER
(a) Align the bracket hole and the protruding part of the pump, and
then align the bracket and the fuel tank matchmarks to attach
them.
FU
A134873
(b) Install the pump assembly fuel with filter with the 8 screws.
A134338

(a) Insert the fuel suction tube into the plug of the suction plate.
NOTICE:
• Check that the connection is not damaged or
contaminated with foreign matter.
• Check that the fuel suction tube is securely inserted all
the way in.
• After installing the tube joint clip, check that the fuel
suction tube cannot be pulled out.
A136229
3. REPLACE FUEL SUCTION TUBE
(a) Remove the connector and the corresponding fuel pipe
following the procedure listed above, and then remove the
retainer from the pump on the fuel pump side.
(b) Align the connector with the axis of the corresponding fuel pipe,
then push the connector in until the retainer makes a (click)
sound.
GETtheMANUALS.org
FU–30
(c) Pull the checker out vertically in relation to the direction in which
it is installed.
Fuel Pump Side
4. INSTALL REAR FLOOR SERVICE HOLE COVER
Pull Out Checker
A134952
(b) Install the rear floor service hole cover using new butyl tape.
5. REFILL FUEL
Butyl Tape
Torque: 5.4 N*m (55 kgf*cm) FU
7. CHECK FOR FUEL LEAKS (See page FU-42)
INSPECTION
A136230
1. INSPECT PUMP ASSEMBLY FUEL WITH FILTER

E terminals.
Reference value:
2 1 0.2 to 3.0 (20°C)
4 3 (b) Check operation.
that the motor operates.
A134990 NOTICE:
• Complete the check quickly (within 10 seconds).
• Move the pump assembly fuel with filter as far
away as possible from the battery.
• Always switch at the battery terminal side.
GETtheMANUALS.org
FU–31 FUEL - FUEL TANK ASSEMBLY (3SZ-VE)
FUEL TANK ASSEMBLY (3SZ-VE)

FUEL
ENGINE
COMPONENTS
T=4.0{41}
FUEL PUMP BRACKET

FU
FUEL SUCTION TUBE
GETtheMANUALS.org
FUEL - FUEL TANK ASSEMBLY (3SZ-VE)
FU–32
EVAP HOSE
FUEL SUCTION TUBE
FUEL TANK TO FILLER PIPE HOSE
FU
FUEL TANK
BRACKET HOSE
FUEL CUT OFF VALVE ASSEMBLY GASKET
FUEL TANK ASSEMBLY
×4
T=20{204}
FUEL TANK PROTECTOR NO. 2
T=8.0{81}
FUEL TANK PROTECTOR NO.1

A135990J01
GETtheMANUALS.org
REMOVAL

3. REMOVE REAR FLOOR SERVICE HOLE COVER (See page FU -

21)
4. DISCONNECT FUEL SUCTION TUBE (See page FU - 21)
5. REMOVE PUMP ASSEMBLY FUEL WITH FILTER (See page FU -

22)
6. DRAIN FUEL
7. REMOVE FUEL TANK PROTECTOR NO. 1
FU (a) Remove the 3 bolts and the fuel tank protector No. 1.
A134993
8. DISCONNECT FUEL TANK BRACKET HOSE

(a) Disconnect the fuel tank bracket hose from the fuel tank.
A136251
9. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

(a) Disconnect the fuel tank to filler pipe hose from the fuel tank.
A134992
GETtheMANUALS.org
FU–34

(a) Release the lock as shown in the illustration, then pull out the
fuel suction tube.
NOTICE:
• As the quick connector seals the pipe and connector by
the O-ring, make sure there is no damage to or foreign
matter on the connection part when performing this
A125388 work.
• Do not forcibly bend, fold or rotate the nylon tube.
• After disconnecting, protect the connected part by
covering it with a plastic bag or similar.
• If the connector and the pipe are stuck, rotate the nylon
tube by hand to release, then pull out and disconnect FU
the nylon tube.
11. DISCONNECT EVAPORATOR HOSE
(a) Loosen the clip, then disconnect the evaporator hose.
NOTICE:
A136253
12. REMOVE FUEL TANK ASSEMBLY

(a) Remove the 2 front bolts.
A134991
(b) Remove the 2 bolts, and disconnect the fuel tank assembly.

(a) Remove the 2 bolts and the fuel tank protector No. 2.
14. REMOVE FUEL CUT-OFF VALVE ASSEMBLY

(a) Remove the fuel cut-off valve assembly, then remove the
gasket.
INSTALLATION
A136252
1. INSTALL FUEL CUT-OFF VALVE ASSEMBLY
(a) Install the fuel cut-off valve assembly using the gasket.
NOTICE:
• Press the fuel cut-off valve assembly firmly in until
there is no gap between the upper face of the gasket
and the face of the cut off flange.
GETtheMANUALS.org
• Do not deform the tank.
2. INSTALL FUEL TANK PROTECTOR NO. 2

(a) Install fuel tank protector No. 2 with the 2 bolts.
3. INSTALL FUEL TANK ASSEMBLY

(a) Clean and degrease the bolt hole.
(b) Install the fuel tank assembly with the 4 bolts.
4. CONNECT EVAPORATOR HOSE
(a) Connect the hose with the clip.
FU
A136253

(a) Match the axis of the fuel suction tube with the axis of the pipe,
push in the fuel suction tube and push up the retainer.
NOTICE:
foreign matter on the connections of the pipe or the
connector.
• After connecting the fuel pump tube, pull the fuel tube
connector and fuel pump tube to check they are
A125397 securely installed.
6. CONNECT FUEL TANK TO FILLER PIPE HOSE

(a) Connect the fuel tank to filler pipe hose to the fuel tank.
A134992
7. CONNECT FUEL TANK BRACKET HOSE

(a) Connect the fuel tank bracket hose to the fuel tank.
A136251
GETtheMANUALS.org
FU–36

9. INSTALL PUMP ASSEMBLY FUEL WITH FILTER (See page FU -

23)
10. CONNECT FUEL SUCTION TUBE (See page FU - 23)
11. INSTALL REAR FLOOR SERVICE HOLE COVER (See page FU -

24)
A134993
13. REFILL FUEL

(2) Follow the prompts on the screen and check the fuel
FU
pump operation.
GETtheMANUALS.org
FU–37 FUEL - FUEL TANK ASSEMBLY (K3-VE)
FUEL TANK ASSEMBLY (K3-VE)

FUEL
ENGINE
COMPONENTS
T=4.0{41}
FUEL PUMP BRACKET

FU
FUEL SUCTION TUBE
GETtheMANUALS.org
FUEL - FUEL TANK ASSEMBLY (K3-VE)
FU–38
EVAP HOSE
FUEL SUCTION TUBE
FUEL TANK TO FILLER PIPE HOSE
FU
FUEL TANK
BRACKET HOSE
FUEL CUT OFF VALVE ASSEMBLY GASKET
FUEL TANK ASSEMBLY
×4
T=20{204}
FUEL TANK PROTECTOR NO. 2
T=8.0{81}
FUEL TANK PROTECTOR NO.1

A135990J01
GETtheMANUALS.org
REMOVAL

3. REMOVE REAR FLOOR SERVICE HOLE COVER (See page FU -

27)
4. DISCONNECT FUEL SUCTION TUBE (See page FU - 27)
5. REMOVE PUMP ASSEMBLY FUEL WITH FILTER (See page FU -

28)
6. DRAIN FUEL
FU (a) Remove the 3 bolts and the fuel tank protector No. 1.
A134993
8. DISCONNECT FUEL TANK BRACKET HOSE

(a) Disconnect the fuel tank bracket hose from the fuel tank.
A136251
9. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

(a) Disconnect the fuel tank to filler pipe hose from the fuel tank.
A134992
GETtheMANUALS.org
FU–40

(a) Release the lock as shown in the illustration, then pull out the
fuel suction tube.
NOTICE:
• As the quick connector seals the pipe and connector by
the O-ring, make sure there is no damage to or foreign
matter on the connection part when performing this
A125388 work.
• Do not forcibly bend, fold or rotate the nylon tube.
• If the connector and the pipe are stuck, rotate the nylon
tube by hand to release, then pull out and disconnect FU
the nylon tube.
11. DISCONNECT EVAPORATOR HOSE
(a) Loosen the clip, then disconnect the evaporator hose.
NOTICE:
A136253
12. REMOVE FUEL TANK ASSEMBLY

(a) Remove the 2 front bolts.
A134991
(b) Remove the 2 bolts, and disconnect the fuel tank assembly.

(a) Remove the 2 bolts and the fuel tank protector No. 2.
14. REMOVE FUEL CUT-OFF VALVE ASSEMBLY

(a) Remove the fuel cut-off valve assembly, then remove the
gasket.
INSTALLATION
A136252
1. INSTALL FUEL CUT-OFF VALVE ASSEMBLY
(a) Install the fuel cut-off valve assembly using the gasket.
NOTICE:
• Press the fuel cut-off valve assembly firmly in until
there is no gap between the upper face of the gasket
and the face of the cut off flange.
GETtheMANUALS.org
• Do not deform the tank.

3. INSTALL FUEL TANK ASSEMBLY

(a) Clean and degrease the bolt hole.
(b) Install the fuel tank assembly with the 4 bolts.
4. CONNECT EVAPORATOR HOSE
(a) Connect the hose with the clip.
FU
A136253

(a) Match the axis of the fuel suction tube with the axis of the pipe,
push in the fuel suction tube and push up the retainer.
NOTICE:
foreign matter on the connections of the pipe or the
connector.
• After connecting the fuel pump tube, pull the fuel tube
connector and fuel pump tube to check that they are
A125397 securely installed.
6. CONNECT FUEL TANK TO FILLER PIPE HOSE

(a) Connect the fuel tank to filler pipe hose to the fuel tank.
A134992
7. CONNECT FUEL TANK BRACKET HOSE

(a) Connect the fuel tank bracket hose to the fuel tank.
A136251
GETtheMANUALS.org
FU–42

9. INSTALL PUMP ASSEMBLY FUEL WITH FILTER (See page FU -

29)
10. CONNECT FUEL SUCTION TUBE (See page FU - 29)
11. INSTALL REAR FLOOR SERVICE HOLE COVER (See page FU -

30)
A134993
13. REFILL FUEL

(2) Follow the prompts on the screen and check the fuel
FU
pump operation.
GETtheMANUALS.org
TO INDEX
ENGINE
EMISSION CONTROL
EMISSION CONTROL SYSTEM (3SZ-VE)
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-1
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-3
EMISSION CONTROL SYSTEM (K3-VE)
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-4
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-6
OXYGEN SENSOR (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-8
OXYGEN SENSOR (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-9
EC
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-10
OXYGEN SENSOR NO. 2 (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-12
OXYGEN SENSOR NO. 2 (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-14
GETtheMANUALS.org
EC–1 EMISSION CONTROL - EMISSION CONTROL SYSTEM (3SZ-VE)
EMISSION CONTROL SYSTEM (3SZ-VE)

EMISSION CONTROL
ENGINE
OPERATION CHECK
1. AIR FUEL RATIO COMPENSATION DEVICE
(b) Select the following items following the prompts on the DS-II
screen: DATA LIST / FrO2 SENSOR OUTPUT VOLTAGE /
RrO2 SENSOR OUTPUT VOLTAGE . Then check that the volt-
age changes.
(1) Maintain the engine speed at 2,500 r/min for about 2 min-
utes to warm up the oxygen sensor.
(2) Keeping the engine speed at 2,500 r/min, check that the
DS-II indicates that the voltage alternates between 0 V
and 1 V.
Standard:
The voltage changes 8 times or more in 10 seconds.
EC NOTICE:
• Perform immediately after oxygen sensor warm-up
in order to ensure that the sensor does not cool
down.
• If the tester does not indicate voltage changes,
warm up the oxygen sensor again before perform-
ing this inspection.
2. DECELERATION CONTROL DEVICE

(a) Set the engine speed to about 3,500 r/min.
(b) Using a sound scope, check the operating sound of the injector.
(c) Check that the operating sound of the injector stops momen-
tarily and then resumes once again when the accelerator pedal
is released.
3. FUEL EVAPORATIVE GAS SUPPRESSION DEVICE

(b) After starting the engine, disconnect fuel vapor feed hose No. 1
as shown in the illustration.
(c) Following the prompts on the DS-II screen, select the following
items: ACTIVE TEST / PURGE VSV. Then, with the VSV set to
ON, check that a vacuum occurs at the VSV port.
(d) If the check result is abnormal, check the following items.
(1) VSV (for evap purge)
(2) Clogging in the fuel vapor feed hose No. 2 (between the
throttle body and VSV)
A136713 (3) Engine control computer PRG voltage
(e) Exit ACTIVE TEST and restore the fuel vapor feed hose No. 1.
(f) Following the prompts on the DS-II screen, display the DATA
LIST screen. Then select EVAP PURGE OUTPUT in order to
check the purge VSV operation.
(g) After sufficiently warming up the vehicle, check that the value of
the data list is 0% when at idle speed.
GETtheMANUALS.org
EMISSION CONTROL - EMISSION CONTROL SYSTEM (3SZ-VE)
EC–2
4. VISUAL INSPECTION
(a) Check that there are no cracks, leaks, or damage.
HINT:
• Removing the oil level gauge, oil filler cap, or PCV hose may
cause the engine to run improperly or stall.
• If the parts between the throttle body and the cylinder head
are dislocated, loosened, or cracked, secondary air will be
sucked in and the engine may run improperly or stall.
A109297
5. CHECK CHARCOAL CANISTER ASSEMBLY

Purge Port Tank Port (a) Using a MIGHTY VAC, perform a check following the inspection
procedures.
Atmosphere (1) With the air port covered tightly (by pressing down with a
Port finger), apply positive pressure to the tank port.
Standard:
There is air-flow between the tank port and the EC
purge port.
(2) With the air port covered tightly (by pressing down with a
A139376J01 finger), apply negative pressure to the tank port.
Standard:
There is air-flow between the tank port and the
purge port.
GETtheMANUALS.org
EC–3 EMISSION CONTROL - EMISSION CONTROL SYSTEM (3SZ-VE)
LOCATION
EC
OXYGEN SENSOR
OXYGEN SENSOR NO. 2
A137726J01
GETtheMANUALS.org
EMISSION CONTROL - EMISSION CONTROL SYSTEM (K3-VE)
EC–4
EMISSION CONTROL SYSTEM (K3-VE)

EMISSION CONTROL
ENGINE
OPERATION CHECK
1. AIR FUEL RATIO COMPENSATION DEVICE
(b) Select the following items following the prompts on the DS-II
screen: ECU DATA MONITOR / FrO2 SENSOR OUTPUT
VOLTAGE / RrO2 SENSOR OUTPUT VOLTAGE. Then check
that the voltage changes.
(1) Maintain the engine speed at 2,500 r/min for about 2 min-
utes to warm up the oxygen sensor.
(2) Keeping the engine speed at 2,500 r/min, check that the
DS-II indicates that the voltage alternates between 0 V
and 1 V.
Standard:
The voltage changes 8 times or more in 10 seconds.
NOTICE:
EC
• Perform immediately after oxygen sensor warm-up
in order to ensure that the sensor does not cool
down.
• If the tester does not indicate the changes of volt-
age, warm up the oxygen sensor again before per-
forming this inspection.
2. DECELERATION CONTROL DEVICE

(a) Set the engine speed to about 3,500 r/min.
(b) Using a sound scope, check the operating sound of the injector.
(c) Check that the operating sound of the injector stops momen-
tarily and then resumes once again when the accelerator pedal
is released.
3. FUEL EVAPORATIVE GAS SUPPRESSION DEVICE

(b) After starting the engine, disconnect the fuel vapor feed hose
No. 1 shown in the illustration.
(c) Following the prompts on the DS-II screen, select the following
items: ACTIVE TEST / PURGE VSV. Then, with the VSV set to
ON, check that a vacuum occurs at the VSV port.
(d) If the check result is abnormal, check the following items.
(1) VSV (for evap purge)
(2) Clogging in the fuel vapor feed hose No. 2 (between the
throttle body and VSV)
A136713 (3) Engine control computer PRG voltage
(e) Exit ACTIVE TEST and restore the fuel vapor feed hose No. 1.
(f) Following the prompts on the DS-II screen, display the DATA
LIST screen. Then select EVAP PURGE OUTPUT in order to
check the purge VSV operation.
(g) After sufficiently warming up the vehicle, check that the value of
the data list is 0% when at idle speed.
GETtheMANUALS.org
EC–5 EMISSION CONTROL - EMISSION CONTROL SYSTEM (K3-VE)
4. VISUAL INSPECTION
(a) Check that there are no cracks, leaks, or damage.
HINT:
• Removing the oil level gauge, oil filler cap, or PCV hose may
cause the engine to run improperly or stall.
• If the parts between the throttle body and the cylinder head
are dislocated, loosened, or cracked, secondary air will be
sucked in and the engine may run improperly or stall.
A109297
5. CHECK CHARCOAL CANISTER ASSEMBLY

Purge Port Tank Port (a) Using a MIGHTY VAC, perform a check following the inspection
procedures.
Atmosphere (1) With the air port covered tightly (by pressing down with a
Port finger), apply positive pressure to the tank port.
Standard:
EC There is air-flow between the tank port and the
purge port.
(2) With the air port covered tightly (by pressing down with a
A139376J01 finger), apply negative pressure to the tank port.
Standard:
There is air-flow between the tank port and the
purge port.
GETtheMANUALS.org
EMISSION CONTROL - EMISSION CONTROL SYSTEM (K3-VE)
EC–6
LOCATION
EC
OXYGEN SENSOR
OXYGEN SENSOR NO. 2
A137726J01
GETtheMANUALS.org
EC–7 EMISSION CONTROL - OXYGEN SENSOR (3SZ-VE)
OXYGEN SENSOR (3SZ-VE)

EMISSION CONTROL
ENGINE
COMPONENTS
OXYGEN SENSOR
T=34{367}
EC
TIGHTENING TORQUE
A135991J01
GETtheMANUALS.org
EMISSION CONTROL - OXYGEN SENSOR (3SZ-VE)
EC–8
REMOVAL
1. REMOVE OXYGEN SENSOR
(a) Remove the clamp and disconnect the connector.
(b) Using an O2 sensor socket, remove the oxygen sensor.
INSTALLATION
A139378
1. INSTALL OXYGEN SENSOR

(a) Using an O2 sensor socket, install the oxygen sensor.
Standard:
EC
T = 34 N*m [367 kgf*cm]
INSPECTION
A139378
1. CHECK OXYGEN SENSOR

(a) Check the resistance of the sensor heater.
+B HT1A (1) Using a tester, measure the resistance between terminals
2 (+B) and 1 (HT1A).
2 1 Standard:
5 to 10 (when at 20°C)
(b) Check for a short circuit in the sensor heater
4 3 (1) Using a tester, check the continuity between terminals 1
(D14-) and 4 (D13+) of the connector.
E2 A133577J03 Standard:
No continuity
GETtheMANUALS.org
EC–9 EMISSION CONTROL - OXYGEN SENSOR (K3-VE)
OXYGEN SENSOR (K3-VE)

EMISSION CONTROL
ENGINE
COMPONENTS
OXYGEN SENSOR
T=34{367}
EC
TIGHTENING TORQUE
A135991J01
GETtheMANUALS.org
EMISSION CONTROL - OXYGEN SENSOR (K3-VE)
EC–10
REMOVAL
1. REMOVE OXYGEN SENSOR
(a) Remove the clamp and disconnect the connector.
(b) Using an O2 sensor socket, remove the oxygen sensor.
INSTALLATION
A139378
1. INSTALL OXYGEN SENSOR

(a) Using an O2 sensor socket, install the oxygen sensor.
Standard:
EC
T = 34 N*m [367 kgf*cm]
INSPECTION
A139378
1. CHECK OXYGEN SENSOR

(a) Check the resistance of the sensor heater.
+B HT1A (1) Using a tester, measure the resistance between terminals
2 (+B) and 1 (HT1A).
2 1 Standard:
5 to 10 (when at 20°C)
(b) Check for a short circuit in the sensor heater
4 3 (1) Using a tester, check the continuity between terminals 1
(D14-) and 4 (D13+) of the connector.
E2 A133577J03 Standard:
No continuity
GETtheMANUALS.org
EC–11 EMISSION CONTROL - OXYGEN SENSOR NO. 2 (3SZ-VE)
OXYGEN SENSOR NO. 2 (3SZ-VE)

EMISSION CONTROL
ENGINE
COMPONENTS
Oxygen Sensor NO. 2

T=34{367
EC
Engine Under Cover RR LH
×6
T=5.4{55}
Tightening Torque
A135989J02
GETtheMANUALS.org
EMISSION CONTROL - OXYGEN SENSOR NO. 2 (3SZ-VE)
EC–12
REMOVAL
2. REMOVE OXYGEN SENSOR NO. 2
(a) Using an O2 sensor socket, remove the oxygen sensor No. 2.
INSTALLATION
A139379
1. INSTALL OXYGEN SENSOR NO. 2

(a) Using an O2 sensor socket, install the oxygen sensor No. 2.
Standard:
T = 34 N*m [367 kgf*cm]
EC
2. INSTALL ENGINE UNDER COVER RR LH (See page EM - 69)
A139379
GETtheMANUALS.org
EC–13 EMISSION CONTROL - OXYGEN SENSOR NO. 2 (K3-VE)
OXYGEN SENSOR NO. 2 (K3-VE)

EMISSION CONTROL
ENGINE
COMPONENTS
Oxygen Sensor NO. 2

T=34{367
EC
Engine Under Cover RR LH
×6
T=5.4{55}
Tightening Torque
A135989J02
GETtheMANUALS.org
EMISSION CONTROL - OXYGEN SENSOR NO. 2 (K3-VE)
EC–14
REMOVAL
2. REMOVE OXYGEN SENSOR NO. 2
(a) Using an O2 sensor socket, remove the oxygen sensor No. 2.
INSTALLATION
A139379
1. INSTALL OXYGEN SENSOR NO. 2

(a) Using an O2 sensor socket, install the oxygen sensor No. 2.
Standard:
T = 34 N*m [367 kgf*cm]
EC
A139379
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TO INDEX
ENGINE
EXHAUST
EXHAUST PIPE ASSEMBLY (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-2
EXHAUST PIPE ASSEMBLY (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-5
EX
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EX–1 EXHAUST - EXHAUST PIPE ASSEMBLY (3SZ-VE)
EXHAUST PIPE ASSEMBLY (3SZ-VE)

EXHAUST
ENGINE
COMPONENTS

EXHAUST PIPE GASKET
EXHAUST PIPE SUPPORT

BRACKET
EX
EXHAUST TAILPIPE ASSEMBLY
OXYGEN SENSOR NO.2

T=19{194}
T=19{194} ENGINE UNDER COVER RR RH
ENGINE UNDER COVER

T=46{469}
RR LH

EXHAUST PIPE ×7
GASKET T=5.4{55}
×4
T=5.4{55}
×11
T=5.4{55}
ENGINE UNDER COVER
A135486J01
GETtheMANUALS.org
EXHAUST - EXHAUST PIPE ASSEMBLY (3SZ-VE)
EX–2
REMOVAL

4. REMOVE EXHAUST TAILPIPE ASSEMBLY
(b) Remove the 3 exhaust pipe support cushions, then remove the
exhaust tailpipe assembly.
5. REMOVE OXYGEN SENSOR NO. 2 (See page EC - 12)
A134988

(a) Remove the 2 bolts and the 2 springs.
(b) Remove the exhaust pipe support cushion, then remove the
EX
INSTALLATION
A134989

(a) Using a wooden block and hammer, tap in a new gasket until it
is flush with the exhaust manifold.
NOTICE:
• Make sure the gasket is installed in the correct
Wooden
direction.
Block
• Do not re-use a gasket that has been previously
removed.
• Never push a new gasket into the exhaust manifold
Gasket when installing the exhaust pipe.
A066225J01
(b) Install the exhaust pipe assembly FR with the exhaust pipe
support cushion.
(c) Install the exhaust pipe assembly FR to the exhaust manifold
with the 2 springs and the 2 bolts.
2. INSTALL EXHAUST TAILPIPE ASSEMBLY

(a) Install the exhaust tailpipe assembly with the exhaust pipe
support cushion.
NOTICE:
Install the the exhaust pipe support cushion onto the
supports with retainers.
A134989
GETtheMANUALS.org
EX–3 EXHAUST - EXHAUST PIPE ASSEMBLY (3SZ-VE)
(b) Install the exhaust tailpipe assembly to the exhaust pipe

assembly FR with a new gasket and 2 new nuts.
NOTICE:
• Do not damage the sliding parts of the gasket.
3. INSTALL OXYGEN SENSOR NO. 2 (See page EC - 12)

A134988
6. INSTALL ENGINE UNDER COVER RR RH (See page EM - 69)
7. INSTALL ENGINE UNDER COVER (See page CO - 19)
EX
GETtheMANUALS.org
EXHAUST - EXHAUST PIPE ASSEMBLY (K3-VE)
EX–4
EXHAUST PIPE ASSEMBLY (K3-VE)

EXHAUST
ENGINE
COMPONENTS

EXHAUST PIPE GASKET

BRACKET
EX
EXHAUST TAILPIPE ASSEMBLY
OXYGEN SENSOR NO.2

T=19{194}
T=19{194} ENGINE UNDER COVER RR RH
ENGINE UNDER COVER

T=46{469}
RR LH

EXHAUST PIPE ×7
GASKET T=5.4{55}
×4
T=5.4{55}
×11
T=5.4{55}
ENGINE UNDER COVER
A135486J01
GETtheMANUALS.org
EX–5 EXHAUST - EXHAUST PIPE ASSEMBLY (K3-VE)
REMOVAL

4. REMOVE EXHAUST TAILPIPE ASSEMBLY
(a) Remove the 2 bolts.
(b) Remove the 3 exhaust pipe support cushions, then remove the
exhaust tailpipe assembly.
5. REMOVE OXYGEN SENSOR NO. 2 (See page EC - 14)
A134988

EX (a) Remove the 2 nuts and the 2 springs.
(b) Remove the exhaust pipe support cushion, then remove the
INSTALLATION
A134989

(a) Using a wooden block and hammer, tap in a new gasket until it
NOTICE:
• Make sure the gasket is installed in the correct
Wooden
direction.
Block
removed.
Gasket when installing the exhaust pipe.
A066225J01
(b) Install the exhaust pipe assembly FR with the exhaust pipe
support cushion.
(c) Install the exhaust pipe assembly FR to the exhaust manifold
2. INSTALL EXHAUST TAILPIPE ASSEMBLY

(a) Install the exhaust tailpipe assembly with the exhaust pipe
support cushion.
NOTICE:
Install the the exhaust pipe support cushion onto the
supports with retainers.
A134989
GETtheMANUALS.org
EXHAUST - EXHAUST PIPE ASSEMBLY (K3-VE)
EX–6
(b) Install the exhaust tailpipe assembly to the exhaust pipe

assembly FR with a new gasket and 2 new nuts.
NOTICE:
• Do not damage the sliding parts of the gasket.
3. INSTALL OXYGEN SENSOR NO. 2 (See page EC - 14)

A134988
6. INSTALL ENGINE UNDER COVER RR RH (See page EM - 104)
7. INSTALL ENGINE UNDER COVER (See page EM - 104)
EX
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TO INDEX
ENGINE
COOLING
COOLING SYSTEM (3SZ-VE)
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-1
COOLING SYSTEM (K3-VE)
COOLING FAN SYSTEM (3SZ-VE)
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-6
COOLING FAN SYSTEM (K3-VE)
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-8
COOLANT (3SZ-VE)
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-9
COOLANT (K3-VE)
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-11
CO
RADIATOR ASSEMBLY (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-17
RADIATOR ASSEMBLY (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-24
WATER PUMP ASSEMBLY (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-29
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-29
WATER PUMP ASSEMBLY (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-33
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-33
THERMOSTAT (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-36
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-37
THERMOSTAT (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-41
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-42
COOLING FAN RELAY (3SZ-VE)
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-45
GETtheMANUALS.org
COOLING FAN RELAY (K3-VE)
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-46
CO
GETtheMANUALS.org
COOLING - COOLING SYSTEM (3SZ-VE)
CO–1
COOLING SYSTEM (3SZ-VE)

COOLING
ENGINE
OPERATION CHECK
1. CHECK FOR COOLANT LEAKS
CAUTION:
Do not remove the radiator cap while the engine and radiator are
still hot.Pressurized fluid and steam may be released and cause
serious burns.Also be careful when applying the pressure to a
radiator cap tester, as hot engine coolant from various parts of
the cooling system may splash.
(a) Fill the radiator with coolant and attach a radiator cap tester.
(c) Using a radiator cap tester, increase the pressure inside the
radiator to 122.6 kPa (1.25 kgf/cm2), and check that the
pressure does not drop.
HINT:
If the pressure drops, check the hose, radiator and water pump
for leaks.If no external leaks are found, check the heater core,
A136066
cylinder block and head.
CO
2. CHECK COOLANT LEVEL
(a) Check that the engine coolant level in the reserve tank is
between the LOW and FULL lines when the engine is cold.
HINT:
If the engine coolant is low, check for leaks and add coolant to
the FULL line.
3. CHECK COOLANT QUALITY

(a) Remove the radiator cap.
CAUTION:
Do not remove the radiator cap while the engine and
radiator are still hot.Pressurized fluid and steam may be
released and cause serious burns.
(b) Check if there are any excessive deposits of rust or scales
around the radiator cap and water inlet.
HINT:
If excessively dirty, replace the coolant.
(c) Install the radiator cap.
4. CHECK RADIATOR CAP
(a) If there are water stairs or foreign matter on packing 1, 2 or 3,
rinse them with water.
NOTICE:
Always clean by hand.
<1> (b) Perform a visual check.
<2> (1) Check that there is no deformation, cracks or damage to
<4> the metal, resin or rubber parts.
<3>
(2) Check that there is no swelling on packing 1, 2 or 3.
A107446J01 (3) Check that packing 3 and 4 are not stuck together.
GETtheMANUALS.org
CO–2 COOLING - COOLING SYSTEM (3SZ-VE)
(c) Perform a operation check.

(1) Apply engine coolant to 2 and 3.
(2) Using a radiator cap tester, measure the maximum
opening pressure while pumping the tester several time.
Standard
More Than 30° Standard 93.3 - 122.7 kPa (0.95 - 1.25 kgf/cm2)
Minimum Standard
78.5 kPa (0.8 kgf/cm2)
Value
Measurement
A104282J01 Pumping speed is 1 turn within 1 second
Condition
NOTICE:
When using the cap tester, tilt it more than 30
degrees.
HINT:
If the maximum opening pressure is below the minimum
standard value, replace the radiator cap.
CO
GETtheMANUALS.org
COOLING - COOLING SYSTEM (K3-VE)
CO–3
COOLING SYSTEM (K3-VE)

COOLING
ENGINE
OPERATION CHECK
1. CHECK FOR COOLANT LEAKS
CAUTION:
serious burns.Also be careful when applying the pressure to a
radiator cap tester, as hot engine coolant from various parts of
the cooling system may splash.
(c) Using a radiator cap tester, increase the pressure inside the
HINT:
A136066
CO
HINT:
the FULL line.
3. CHECK COOLANT QUALITY

(a) Remove the radiator cap.
CAUTION:
Do not remove the radiator cap while the engine and
radiator are still hot.Pressurized fluid and steam may be
released and cause serious burns.
(b) Check if there are any excessive deposits of rust or scales
around the radiator cap and water inlet.
HINT:
If excessively dirty, replace the coolant.
(c) Install the radiator cap.
4. CHECK RADIATOR CAP
(a) If there are water stairs or foreign matter on packing 1, 2 or 3,
rinse them with water.
NOTICE:
Always clean by hand.
<1> (b) Perform a visual check.
<2> (1) Check that there is no deformation, cracks or damage to
<4> the metal, resin or rubber parts.
<3>
(2) Check that there is no swelling on packing 1, 2 or 3.
A107446J01 (3) Check that packing 3 and 4 are not stuck together.
GETtheMANUALS.org
CO–4 COOLING - COOLING SYSTEM (K3-VE)
(c) Perform a operation check.

(1) Apply engine coolant to 2 and 3.
(2) Using a radiator cap tester, measure the maximum
opening pressure while pumping the tester several time.
Standard
More Than 30° Standard 93.3 - 122.7 kPa (0.95 - 1.25 kgf/cm2)
Minimum Standard
78.5 kPa (0.8 kgf/cm2)
Value
Measurement
A104282J01 Pumping speed is 1 turn within 1 second
Condition
NOTICE:
When using the cap tester, tilt it more than 30
degrees.
HINT:
If the maximum opening pressure is below the minimum
standard value, replace the radiator cap.
CO
GETtheMANUALS.org
COOLING - COOLING FAN SYSTEM (3SZ-VE)
CO–5
COOLING FAN SYSTEM (3SZ-VE)

COOLING
ENGINE
OPERATION CHECK
1. CHECK OPERATION WHEN THE ENGINE IS COLD
(a) Make sure the coolant temperature is below 83°C (181.4°F).
(1) Check that the cooling fan does not rotate when turning
the ignition switch to the ON position with the A/C switch
OFF.
(2) Check that the cooling fan operates when the water
temperature sensor connector is disconnected and the
ignition switch is turned ON.
2. CHECK OPERATION WHEN ENGINE IS HOT

(a) Make sure the coolant temperature is above 96°C (204.8 °F).
(1) After the engine is warmed up, check that the A/C is
turned OFF.
(2) Check that the cooling fan starts rotating when the coolant
temperature reaches above 96°C (204.8°F) and that it
stops rotating when the temperature reaches about
94.5°C (202.1°F).
NOTICE:
CO
The coolant temperature is detected by the water
temperature sensor on the water outlet (engine outlet)
of the cylinder head.
HINT:
• The cleaning fan is controlled by the engine control
computer.
• The coolant temperature can be checked using the
ECU DATA MONITOR on the DS-II.
GETtheMANUALS.org
CO–6 COOLING - COOLING FAN SYSTEM (3SZ-VE)
LOCATION
ENGINE ROOM R/B
COOLING FAN RELAY
CO
COOLING FAN MOTOR
A137727J01
GETtheMANUALS.org
COOLING - COOLING FAN SYSTEM (K3-VE)
CO–7
COOLING FAN SYSTEM (K3-VE)

COOLING
ENGINE
OPERATION CHECK
1. CHECK OPERATION WHEN THE ENGINE IS COLD
(a) Make sure the coolant temperature is below 83°C (181.4° F).
(1) Check that the cooling fan does not rotate when turning
the ignition switch to the ON position with the A/C switch
OFF.
(2) Check that the cooling fan rotates when the water
temperature sensor connector is disconnected and the
ignition switch is turned ON.
2. CHECK OPERATION WHEN ENGINE IS HOT

(a) Make sure the coolant temperature is above 96°C (204.8°F).
(1) After the engine is warmed up, check that the A/C is
turned OFF.
(2) Check that the cooling fan starts rotating when the coolant
temperature reaches above 96°C (204.8°F) and that it
stops rotating when the temperature reaches about
94.5°C (202.1°F).
NOTICE:
CO
The coolant temperature is detected by the water
temperature sensor on the water outlet (engine outlet)
of the cylinder head.
HINT:
• The cleaning fan is controlled by the engine control
computer.
• The coolant temperature can be checked using the
ECU DATA MONITOR on the DS-II.
GETtheMANUALS.org
CO–8 COOLING - COOLING FAN SYSTEM (K3-VE)
LOCATION
ENGINE ROOM R/B
COOLING FAN RELAY
CO
COOLING FAN MOTOR
A137727J01
GETtheMANUALS.org
COOLING - COOLANT (3SZ-VE)
CO–9
COOLANT (3SZ-VE)
COOLING
ENGINE
REPLACEMENT
2. DRAIN ENGINE COOLANT

CAUTION:
serious burns.
(a) Open the radiator cap.
(b) Loosen the radiator drain cock plug and drain the coolant.
Radiator Cap
CO
Drain Cock
A133974
3. ADD ENGINE COOLANT

(a) Close the radiator drain cock plug.
(b) Loosen the cock (white) of air bleed valves A and B to remove
Valve B them.
(c) Pour coolant into the radiator inlet.
Valve A (d) If the coolant overflows from air bleed valve A, tighten the cock
to valve A.[*1]
(e) If the coolant overflows from air bleed valve B, tighten the cock
to valve B.[*2]
(f) If the coolant overflows from the radiator, tighten the radiator
cap.
A139131 (g) With the engine speed kept at 2,000 r/min, warm up the engine
until the coolant fan comes on two times. Then stop the engine.
GETtheMANUALS.org
CO–10 COOLING - COOLANT (3SZ-VE)
(h) After the engine has cooled down, pour coolant into the radiator
and reserve tanks.
HINT:
In operations [*1] and [*2], if coolant does not overflow from
either air bleed valve A or valve B, or overflows from neither
valve A nor valve B, tighten the cocks to the air bleed valves
after coolant overflows from the radiator.
4. CHECK FOR ENGINE COOLANT LEAKS

CAUTION:
serious burns.
(b) Using a radiator cap tester, increase the pressure inside the
HINT:
CO
HINT:
the FULL line.
GETtheMANUALS.org
COOLING - COOLANT (K3-VE)
CO–11
COOLANT (K3-VE)
COOLING
ENGINE
REPLACEMENT
2. DRAIN ENGINE COOLANT

CAUTION:
serious burns.
(a) Open the radiator cap.
(b) Loosen the radiator drain cock plug and drain the coolant.
Radiator Cap
CO
Drain Cock
A133974
3. ADD ENGINE COOLANT

(a) Close the radiator drain cock plug.
(b) Loosen the cock (white) of air bleed valves A and B to remove
Valve B them.
(c) Pour coolant into the radiator inlet.
Valve A (d) If the coolant overflows from air bleed valve A, tighten the cock
to valve A.[*1]
(e) If the coolant overflows from air bleed valve B, tighten the cock
to valve B.[*2]
(f) If the coolant overflows from the radiator, tighten the radiator
cap.
A139131 (g) With the engine speed kept at 2,000 r/min, warm up the engine
until the coolant fan comes on two times. Then stop the engine.
GETtheMANUALS.org
CO–12 COOLING - COOLANT (K3-VE)
(h) After the engine has cooled down, pour coolant into the radiator
and reserve tanks.
HINT:
In operations [*1] and [*2], if coolant does not overflow from
either air bleed valve A or valve B, or overflows from neither
valve A nor valve B, tighten the cocks to the air bleed valves
after coolant overflows from the radiator.
4. CHECK FOR ENGINE COOLANT LEAKS

CAUTION:
serious burns.
(b) Using a radiator cap tester, increase the pressure inside the
HINT:
CO
HINT:
the FULL line.
GETtheMANUALS.org
COOLING - RADIATOR ASSEMBLY (3SZ-VE)
CO–13
RADIATOR ASSEMBLY (3SZ-VE)

COOLING
ENGINE
COMPONENTS
CO
T=7.5{76}
×2
FRONT BUMPER COVER
ENGINE UNDER COVER
T=5.4{55} ×11

A136654J01
GETtheMANUALS.org
CO–14 COOLING - RADIATOR ASSEMBLY (3SZ-VE)

TANK ASSEMBLY
T=7.5{76}
RADIATOR HOSE NO. 1
T=7.5{76}
CHARCOAL CANISTER
ASSEMBLY
RADIATOR CAP
T=7.5{76}

×2
×2
WITH WATER
×2 FAN ASSEMBLY
CO T=7.5{76}

×4
RADIATOR ASSEMBLY
T=5.0{51}
T=5.0{51}
×2 OIL COOLER
OUTLET HOSE NO. 1
A/T
T=5.0{51}
T=5.0{51}
CONDENSER ASSEMBLY
(WITH RESERVOIR)
SEAL PLATE
A136655J01
GETtheMANUALS.org
CO–15
REMOVAL
(See page RS-164)
4. REMOVE FOG LIGHT ASSEMBLY LH (See page CO-9)
6. REMOVE FRONT BUMPER COVER (See page CO-15)

7. REMOVE AIR CLEANER HOSE NO. 1
(a) Remove the 2 bolts. Then remove the air cleaner hose No. 1.
A133317
CO
8. REMOVE SEAL PLATE
(a) Detach the 2 clips and remove the seal plate.
A133919

(a) Remove the clip. Then radiator hose No. 2 hose.

TRANSMISSION)
(a) Remove the clip and disconnect oil cooler inlet hose No. 1 from
the radiator assembly.

TRANSMISSION)
A136170 (a) Remove the clip and disconnect oil cooler outlet hose No. 1
from the radiator assembly.
12. REMOVE RADIATOR RESERVE TANK ASSEMBLY

(a) Disconnect the radiator reserve tank assembly hose.
(b) Remove the bolt and pull out the pin on the lower side of the
radiator reserve tank assembly from the bush.

(a) Remove the clip. Then remove radiator hose No. 1.
GETtheMANUALS.org
14. REMOVE CHARCOAL CANISTER ASSEMBLY

(a) Remove the bolt. Then remove the charcoal canister pipe No. 1
from the battery carrier.
A133920
(b) Disconnect the 3 hoses and remove the charcoal canister

assembly from the bracket by sliding it upward.
15. REMOVE RADIATOR SUPPORT UPPER

(a) Remove the bolt. Then remove the right and left radiator
support uppers.
CO A133921
16. REMOVE CONDENSER ASSEMBLY (WITH RECEIVER)

(a) Remove the 4 bolts and disconnect the condenser assembly
(with receiver).
A133918
(b) Secure the condenser assembly (with receiver) to the radiator

support upper with a string so that it does not fall.
A133917
GETtheMANUALS.org
CO–17
17. REMOVE RADIATOR ASSEMBLY

(a) Disconnect the cleaning fan motor connector and wire harness
clamp.
(b) Remove the radiator assembly together with the with water fan
assembly from the vehicle.
NOTICE:
When removing the radiator assembly, do not apply
unreasonable force to the condenser assembly (with
receiver) and the pipe.
A133257
18. REMOVE RADIATOR SUPPORT CUSHION
19. REMOVE WITH WATER FAN ASSEMBLY

(a) Remove the 4 bolts and the with water fan assembly.
20. REMOVE DRAIN COCK SUB-ASSEMBLY

(a) Remove the drain cock sub-assembly from the radiator
assembly.
INSTALLATION
1. INSTALL DRAIN COCK SUB-ASSEMBLY
A133318 (a) Install the drain cock sub-assembly to the radiator assembly. CO
2. INSTALL WITH WATER FAN ASSEMBLY
(a) Install the floor shift assembly with the 4 bolts.
3. INSTALL RADIATOR SUPPORT CUSHION
4. INSTALL RADIATOR ASSEMBLY

(a) Install the radiator assembly to the vehicle together with the
cleaning fan assembly.
NOTICE:
A133318 Make sure the radiator assembly does not interfere with the
cooler condenser assembly.
(b) Connect the cooling fan motor connector and the wire harness
clamp.
A133257
GETtheMANUALS.org
5. INSTALL CONDENSER ASSEMBLY (WITH RECEIVER)

(a) Install the condenser assembly (with receiver) with the 4 bolts.
6. INSTALL RADIATOR SUPPORT UPPER

(a) Install the radiator support upper with the bolt.
CO A133918
7. INSTALL CHARCOAL CANISTER ASSEMBLY

(a) Install the 3 hoses.
(b) Install the charcoal canister assembly to the bracket.
A133921
(c) Install the charcoal canister pipe No. 1 with the bolt.

(a) Install radiator hose No. 1 and fix it with the clamp.
9. INSTALL RADIATOR RESERVE TANK ASSEMBLY

(a) Install the radiator reserve tank assembly with the bolt.
(b) Install the radiator reserve tank assembly hose.
A133920
TRANSMISSION)
(a) Install oil cooler outlet hose No. 1 and fix it with the clamp.

TRANSMISSION)
(a) Install oil cooler inlet hose No. 1 and fix it with the clamp.
GETtheMANUALS.org
CO–19

A136170
13. INSTALL SEAL PLATE

(a) Install the seal plate with the 2 clips.
A133919 CO
14. INSTALL AIR CLEANER HOSE NO. 1
(a) Install the air cleaner hose No. 1 with the 2 bolts.
16. INSTALL FRONT BUMPER COVER (See page CO-19)
17. INSTALL FOG LIGHT ASSEMBLY LH

A133317 19. CONNECT NEGATIVE BATTERY TERMINAL
20. REFILL ENGINE COOLANT (See page CO-10)
GETtheMANUALS.org
CO–20 COOLING - RADIATOR ASSEMBLY (K3-VE)
RADIATOR ASSEMBLY (K3-VE)

COOLING
ENGINE
COMPONENTS
CO
T=7.5{76}
×2
FRONT BUMPER COVER
ENGINE UNDER COVER
T=5.4{55} ×11

A136654J01
GETtheMANUALS.org
COOLING - RADIATOR ASSEMBLY (K3-VE)
CO–21

TANK ASSEMBLY
T=7.5{76}
RADIATOR HOSE NO. 1
T=7.5{76}
CHARCOAL CANISTER
ASSEMBLY
RADIATOR CAP
T=7.5{76}

×2
×2
WITH WATER
×2 FAN ASSEMBLY
T=7.5{76} CO
×4
RADIATOR ASSEMBLY
T=5.0{51}
T=5.0{51}
×2 OIL COOLER
OUTLET HOSE NO. 1
A/T
T=5.0{51}
T=5.0{51}
CONDENSER ASSEMBLY
(WITH RESERVOIR)
SEAL PLATE
A136655J01
GETtheMANUALS.org
REMOVAL
(See page CO-22)
2. REMOVE ENGINE UNDER COVERó
4. REMOVE FOG LIGHT ASSEMBLY LH (WITH FOG LIGHT) (See

page LI-33)
5. REMOVE FOG LIGHT ASSEMBLY RH (WITH FOG LIGHT)

7. REMOVE AIR CLEANER HOSE NO. 1
(a) Remove the 2 bolts. Then remove the air cleaner hose No. 1.
CO
A133317
8. REMOVE SEAL PLATE

A133919


TRANSMISSION)
(a) Remove the clip and disconnect the oil cooler inlet hose No. 1

TRANSMISSION)
A136170 (a) Remove the clip and disconnect oil cooler outlet hose No. 1
12. REMOVE RADIATOR RESERVE TANK ASSEMBLY

(a) Disconnect the radiator reserve tank assembly hose.
(b) Remove the bolt and pull out the pin on the lower side of the
radiator reserve tank assembly from the bush.

GETtheMANUALS.org
CO–23
14. REMOVE CHARCOAL CANISTER ASSEMBLY

(a) Remove the bolt. Then remove the charcoal canister pipe No. 1
from the battery carrier.
A133920
(b) Disconnect the 3 hoses and remove the charcoal canister

assembly from the bracket by sliding it upward.
15. REMOVE RADIATOR SUPPORT UPPER

(a) Remove the bolt. Then remove the right and left radiator
support uppers.
A133921 CO
(a) Remove the 4 bolts and disconnect the condenser assembly
(with receiver).
A133918
(b) Secure the condenser assembly (with receiver) to the radiator

support upper with a string so that it does not fall.
A133917
GETtheMANUALS.org
17. REMOVE RADIATOR ASSEMBLY

(a) Disconnect the cleaning fan motor connector and wire harness
clamp.
(b) Remove the radiator assembly together with the with water fan
assembly from the vehicle.
NOTICE:
When removing the radiator assembly, do not apply
unreasonable force to the condenser assembly (with
receiver) and the pipe.
A133257
18. REMOVE RADIATOR SUPPORT CUSHION
19. REMOVE WITH WATER FAN ASSEMBLY

(a) Remove the 4 bolts and the with water fan assembly.
20. REMOVE DRAIN COCK SUB-ASSEMBLY

(a) Remove the drain cock sub-assembly from the radiator
assembly.
INSTALLATION
1. INSTALL DRAIN COCK SUB-ASSEMBLY
CO A133318 (a) Install the drain cock sub-assembly to the radiator assembly.
2. INSTALL WITH WATER FAN ASSEMBLY

(a) Install the floor shift assembly with the 4 bolts.
3. INSTALL RADIATOR SUPPORT CUSHION
4. INSTALL RADIATOR ASSEMBLY

(a) Install the radiator assembly to the vehicle together with the
cleaning fan assembly.
NOTICE:
A133318 Make sure the radiator assembly does not interfere with the
cooler condenser assembly.
(b) Connect the cooling fan motor connector and the wire harness
clamp.
A133257
GETtheMANUALS.org
CO–25

(a) Install the condenser assembly (with receiver) with the 4 bolts.
6. INSTALL RADIATOR SUPPORT UPPER

(a) Install the radiator support upper with the bolt.
A133918 CO
7. INSTALL CHARCOAL CANISTER ASSEMBLY
(a) Install the 3 hoses.
(b) Install the charcoal canister assembly to the bracket.
A133921
(c) Install the charcoal canister pipe No. 1 with the bolt.

9. INSTALL RADIATOR RESERVE TANK ASSEMBLY

(a) Install the radiator reserve tank assembly with the bolt.
(b) Install the radiator reserve tank assembly hose.
A133920
TRANSMISSION)
(a) Install oil cooler outlet hose No. 1 and fix it with the clamp.

TRANSMISSION)
(a) Install oil cooler inlet hose No. 1 and fix it with the clamp.
GETtheMANUALS.org

A136170

(a) Install the seal plate with the 2 clips.
CO A133919
14. INSTALL AIR CLEANER HOSE NO. 1

(a) Install the air cleaner hose No. 1 with the 2 bolts.

17. INSTALL FOG LIGHT ASSEMBLY LH (WITH FOG LIGHT) (See

A133317
page LI-34)
18. INSTALL FOG LIGHT ASSEMBLY RH (WITH FOG LIGHT)

GETtheMANUALS.org
COOLING - WATER PUMP ASSEMBLY (3SZ-VE)
CO–27
WATER PUMP ASSEMBLY (3SZ-VE)

COOLING
ENGINE
COMPONENTS
T=7.5{76} AIR CLEANER HOSE NO. 1
CO

ENGINE UNDER COVER
T=5.4{55} ×11
TIGHTENING TORQUE
A136710J01
GETtheMANUALS.org
CO–28 COOLING - WATER PUMP ASSEMBLY (3SZ-VE)
WATER PUMP ASSEMBLY

FAN PULLEY
CO
T=9.0{92}
×4
T=9.0{92}
T=11.5{117}
WATER PUMP GASKET

A136711J01
GETtheMANUALS.org
COOLING - WATER PUMP ASSEMBLY (3SZ-VE)
CO–29
REMOVAL

5. REMOVE FAN PULLEY
(a) Using a screwdriver or similar, fix the fan pulley, as shown in the
illustration to prevent it from being turned.
(b) Remove the 3 bolts. Then remove the fan pulley.
A137587
6. REMOVE WATER PUMP ASSEMBLY

(a) Remove the 3 bolts and 2 nuts. Then remove the water pump.
CO
INSPECTION
A108597
1. WATER PUMP ASSEMBLY

(a) Check that there is no looseness and abnormal sound on the
bearings.
INSTALLATION
A136267
1. INSTALL WATER PUMP ASSEMBLY

(a) Using a new gasket, install the water pump with the 3 bolts and
2 nuts.
NOTICE:
Make sure there is no oil on the bolt threads.
2. INSTALL FAN PULLEY

(a) Temporarily install the fan pulley with the 3 bolts.
A108597
GETtheMANUALS.org
CO–30 COOLING - WATER PUMP ASSEMBLY (3SZ-VE)
(b) Using a screwdriver or similar, fix the fan pulley, as shown in the
illustration to prevent it from being turned. Then install it.
(c) Tighten the 3 bolts.
A137587
CO
GETtheMANUALS.org
COOLING - WATER PUMP ASSEMBLY (K3-VE)
CO–31
WATER PUMP ASSEMBLY (K3-VE)

COOLING
ENGINE
COMPONENTS
T=7.5{76} AIR CLEANER HOSE NO. 1
CO

ENGINE UNDER COVER
T=5.4{55} ×11
TIGHTENING TORQUE
A136710J01
GETtheMANUALS.org
CO–32 COOLING - WATER PUMP ASSEMBLY (K3-VE)
WATER PUMP ASSEMBLY

FAN PULLEY
CO
T=9.0{92}
×4
T=9.0{92}
T=11.5{117}
WATER PUMP GASKET

A136711J01
GETtheMANUALS.org
COOLING - WATER PUMP ASSEMBLY (K3-VE)
CO–33
REMOVAL
2. DRAIN ENGINE COOLANT(See page CO-11)

5. REMOVE FAN PULLEY
(a) Using a screwdriver or similar, fix the fan pulley, as shown in the
illustration to prevent it from being turned.
(b) Remove the 3 bolts. Then remove the fan pulley.
A137587
6. REMOVE WATER PUMP ASSEMBLY

(a) Remove the 3 bolts and 2 nuts. Then remove the water pump.
CO
INSPECTION
A108597
1. WATER PUMP ASSEMBLY

(a) Check that there is no looseness and abnormal sound on the
bearings.
INSTALLATION
A136267
1. INSTALL WATER PUMP ASSEMBLY

(a) Using a new gasket, install the water pump with the 3 bolts and
2 nuts.
NOTICE:
Make sure there is no oil on the bolt threads.
2. INSTALL FAN PULLEY

(a) Temporarily install the fan pulley with the 3 bolts.
A108597
GETtheMANUALS.org
CO–34 COOLING - WATER PUMP ASSEMBLY (K3-VE)
(b) Using a screwdriver or similar, fix the fan pulley, as shown in the
illustration to prevent it from being turned. Then install it.
(c) Tighten the 3 bolts.
A137587
CO
GETtheMANUALS.org
COOLING – THERMOSTAT (3SZ-VE)
CO–35
THERMOSTAT (3SZ-VE)
COOLING
ENGINE
COMPONENTS
WATER INLET
THERMISTOR
T=7.5{76}
T=18{184} T=9.0{92}
T=7.5{76}
CO
ENGINE UNDER COVER
T=5.4{55}
..... TIGHTENING TORQUE [N*m {kgf*cm}]

A138914J01
GETtheMANUALS.org
CO–36 COOLING – THERMOSTAT (3SZ-VE)
REMOVAL

(a) Remove the bolt. Then remove the harness clamp.
A138814
CO
A138817
(c) Remove the bolt. Then remove the harness clamp.

(d) Disconnect the connector.
A138988
GETtheMANUALS.org
CO–37
(e) Remove the bolt and the nut. Then remove the water inlet.
INSPECTION
1. THERMOSTAT
(a) Before heating, measure the dimension with the valve fully
closed.
A138989 CO
(b) Immerse the thermostat in water and gradually heat the water.
(c) Check the valve opening temperature.
Standard:
78 - 82°C
HINT:
• The thermostat is stamped with the valve opening
temperature.
• If the valve opening temperature is not as specified, replace
the thermostat.
P000436
(d) Check the valve lift.

More Than 8.5 mm Standard:
Valve lift 8.5 mm or more
Temperature with the valve fully open 93°C
HINT:
If the valve lift is not as specified, replace the thermostat.
(e) Check that the valve is fully closed when the thermostat is at
low temperature (below 75°C/167°F).
HINT:
Length When Fully Open
A134293 If the valve is not fully closed, replace the thermostat.
INSTALLATION
(a) Install a new thermostat gasket to the thermostat.
GETtheMANUALS.org
CO–38 COOLING – THERMOSTAT (3SZ-VE)
(b) Install the thermostat, aligning the water inlet matchmark and
the thermostat jiggle valve.
A133315

(a) Using a pri set torque wrench, install the water inlet with the bolt
and nut.
CO
A138989
(c) Install the wire harness clamp with the bolt.
A138988
GETtheMANUALS.org
CO–39
(d) Install the wire harness clamp with the bolt.
A138817
(e) Install the wire harness clamp with the bolt.

(f) Connect the connector.

A138814
CO
GETtheMANUALS.org
CO–40 COOLING - THERMOSTAT (K3-VE)
THERMOSTAT (K3-VE)
COOLING
ENGINE
COMPONENTS
WATER INLET
THERMISTOR
T=7.5{76}
T=18{184} T=9.0{92}
T=7.5{76}
CO
ENGINE UNDER COVER
T=5.4{55}
..... TIGHTENING TORQUE [N*m {kgf*cm}]

A138914J01
GETtheMANUALS.org
COOLING - THERMOSTAT (K3-VE)
CO–41
REMOVAL

(a) Remove the bolt. Then remove the harness clamp.
A138814
CO
A138817
(c) Remove the bolt. Then remove the harness clamp.

A138988
GETtheMANUALS.org
(e) Remove the bolt and the nut. Then remove the water inlet.
INSPECTION
1. THERMOSTAT
(a) Before heating, measure the dimension with the valve fully
closed.
CO A138989
(b) Immerse the thermostat in water and gradually heat the water.
(c) Check the valve opening temperature.
Standard:
78 - 82°C
HINT:
• The thermostat is stamped with the valve opening
temperature.
• If the valve opening temperature is not as specified, replace
the thermostat.
P000436
(d) Check the valve lift.

More Than 8.5 mm Standard:
Valve lift 8.5 mm or more
Temperature with the valve fully open 93°C
HINT:
If the valve lift is not as specified, replace the thermostat.
(e) Check that the valve is fully closed when the thermostat is at
low temperature (below 75°C/167°F).
HINT:
Length When Fully Open
A134293 If the valve is not fully closed, replace the thermostat.
INSTALLATION
(a) Install a new thermostat gasket to the thermostat.
GETtheMANUALS.org
COOLING - THERMOSTAT (K3-VE)
CO–43
(b) Install the thermostat, aligning the water inlet matchmark and
the thermostat jiggle valve.
A133315

(a) Using a pri set torque wrench, install the water inlet with the bolt
and nut.
CO
A138989
(c) Install the wire harness clamp with the bolt.
A138988
GETtheMANUALS.org
A138817

(f) Connect the connector.

CO A138814
GETtheMANUALS.org
COOLING – COOLING FAN RELAY (3SZ-VE)
CO–45
COOLING FAN RELAY (3SZ-VE)

COOLING
ENGINE
INSPECTION
1. RADIATOR FAN RELAY
(a) Check the continuity.
Standard:
1 terminal ←→ 2 terminal: continuity
3 terminal ←→ 5 terminal: no continuity
(2) Using the tester, check the continuity between terminal 3
and 5 when battery voltage is applied to terminal 1 and 2.
A133875 Standard:
Continuity
CO
GETtheMANUALS.org
CO–46 COOLING - COOLING FAN RELAY (K3-VE)
COOLING FAN RELAY (K3-VE)

COOLING
ENGINE
INSPECTION
1. RADIATOR FAN RELAY
Standard:
and 5 when battery voltage is applied to terminal 1 and 2.
A133875 Standard:
Continuity
CO
GETtheMANUALS.org
TO INDEX
ENGINE
LUBRICATION
LUBRICATION SYSTEM (3SZ-VE)
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-1
LUBRICATION SYSTEM (K3-VE)
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-2
OIL PUMP ASSEMBLY (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-7
OIL PUMP ASSEMBLY (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-14
OIL FILTER (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-18
OIL FILTER (K3-VE) LU
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-20
GETtheMANUALS.org
LU–1 LUBRICATION - LUBRICATION SYSTEM (3SZ-VE)
LUBRICATION SYSTEM (3SZ-VE)

LUBRICATION
ENGINE
OPERATION CHECK
NOTICE:
Do not fill with engine oil above the full level mark.
2. CHECK ENGINE OIL QUALITY

(a) Check the oil for deterioration, entry of water, discoloring or
thinning. If the quality is visibly poor, replace the oil.
3. CHECK OIL PRESSURE
NOTICE:
Before and after measuring the oil pressure, clean the tools and
hoses with white gasoline.
(a) Remove the engine oil pressure switch assembly.
(1) Disconnect the oil pressure switch connector.
(2) Using a 24mm deep socket wrench, remove the oil
pressure switch.
LU
A135962
(b) Install the oil pressure gauge.

(1) Install the pressure gauge with an adapter.
(c) Warm up the engine.
(d) Check the oil pressure.
Standard
At 700 r/min 49 kPa [0.5 kgf/cm2] or more

At 3,000 r/min 206 kPa [2.1 kgf/cm2] or more
(e) Remove the oil pressure gauge.

A135963 (f) Install the engine oil pressure switch assembly.
(1) Apply Three Bond 1194J to 2 or 3 threads of the engine oil
NOTICE:
Do not start the engine within 1 hour of after the
installation.
(2) Using a 24 mm deep socket wrench, install the oil
pressure switch.
(3) Connect the oil pressure switch connector.
(g) Check for engine oil leaks.
GETtheMANUALS.org
LUBRICATION - LUBRICATION SYSTEM (K3-VE)
LU–2
LUBRICATION SYSTEM (K3-VE)

LUBRICATION
ENGINE
OPERATION CHECK
NOTICE:
Do not fill with engine oil above the full level mark.
2. CHECK ENGINE OIL QUALITY

(a) Check the oil for deterioration, entry of water, discoloring or
thinning. If the quality is visibly poor, replace the oil.
NOTICE:
Before and after measuring the oil pressure, clean the tools and
hoses with white gasoline.
(a) Remove the engine oil pressure switch assembly.
(1) Disconnect the oil pressure switch connector.
(2) Using a 24mm deep socket wrench, remove the oil
pressure switch.
LU
A135962
(b) Install the oil pressure gauge.

(1) Install the pressure gauge with an adapter.
(c) Warm up the engine.
(d) Check the oil pressure.
Standard
At 700 r/min 39 kPa [0.4 kgf/cm2] or more

At 3,000 r/min 225 kPa [2.3 kgf/cm2] or more
(e) Remove the oil pressure gauge.

A135963 (f) Install the engine oil pressure switch assembly.
(1) Apply Three Bond 1194J to 2 or 3 threads of the engine oil
NOTICE:
Do not start the engine within 1 hour of after the
installation.
(2) Using a 24 mm deep socket wrench, install the oil
pressure switch.
(3) Connect the oil pressure switch connector.
(g) Check for engine oil leaks.
GETtheMANUALS.org
LU–3 LUBRICATION – OIL PUMP ASSEMBLY (3SZ-VE)
OIL PUMP ASSEMBLY (3SZ-VE)

LUBRICATION
ENGINE
COMPONENTS
T=3.5{36}
BATTERY
×2
T=8.5{87} ×3 T=18{184}
T=7.5{76} ×2
BATTERY CARRIER
LU
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} ×11

A136903J01
GETtheMANUALS.org
LUBRICATION – OIL PUMP ASSEMBLY (3SZ-VE)
LU–4
VENTILATION HOSE NO. 2 SPARK PLUG

T=20{204}
T=7.5{76}
×4

×4 LU
O-RING
T=7.5{76}
IDLER PULLEY
IDLER PULLEY NO. 1

RADIATOR PIPE
×3
T=11.5{117}
T=44{449}
T=130{1326}
×3
T=20.6{210}
O-RING
T=7.5{76}

A136904J02
GETtheMANUALS.org
OIL FILLER CAP

T=11{112}
CYLINDER HEAD COVER
T=9.0{92}
×11

TIMING CHAIN TENSIONER ARM

TIMING GEAR (CHAIN)
COVER GASKET TIMING CHAIN GUIDE
LU T=9.0{92}
CHAIN
TIMING CHAIN (BELT) COVER
T=23{235}
T=12{122}
×9
×2
T=44{449}
×3
T=19{195}
T=7.5{76}
T=7.5{76}
×2
TIMING CHAIN GUIDE NO. 2 OIL PUMP ASSEMBLY
TIMING CHAIN (BELT)

T=7.5{76}
COVER OIL SEAL

T=9.0{92}
OIL NOZZLE NO.1
MP GREASE
A136905J04
GETtheMANUALS.org
LU–6
REMOVAL
2. REMOVE BATTERY CARRIER (See page EM - 146)
4. DRAIN ENGINE OIL (See page EM - 43)
5. DRAIN ENGINE COOLANT (See page CO - 15)
7. REMOVE RADIATOR HOSE NO. 1 (See page CO - 15)
8. REMOVE ACCELERATOR CONTROL GAUGE ASSEMBLY (See

page EM - 147)
9. REMOVE FAN AND ALTERNATOR BELT (See page EM - 8)
10. REMOVE FAN PULLEY (See page CO - 29)
11. REMOVE VANE PUMP ASSEMBLY (See page EM - 44)
12. REMOVE IDLER PULLEY NO. 1 (See page EM - 150)
13. DISCONNECT VENTILATION HOSE (See page EM - 148)

LU
14. DISCONNECT NO. 2 VENTILATION HOSE (See page EM - 147)
15. REMOVE ENGINE ROOM MAIN WIRE (See page EM - 147)
16. REMOVE RADIATOR PIPE (See page EM - 147)
17. REMOVE IGNITION COIL ASSEMBLY (See page EM - 150)
18. REMOVE CYLINDER HEAD COVER (See page EM - 151)
19. REMOVE CRANKSHAFT PULLEY (See page EM - 151)

(See page EM - 152)
21. REMOVE TIMING CHAIN (BELT) COVER (See page EM - 152)
22. REMOVE TIMING CHAIN (BELT) COVER OIL SEAL (See page EM
- 153)
23. REMOVE CRANK ANGLE SENSOR PLATE NO. 1 (See page EM -

108)
24. REMOVE CHAIN TENSIONER PLUNGER (See page EM - 108)
25. REMOVE TIMING CHAIN TENSION ARM (See page EM - 109)
26. REMOVE TIMING CHAIN GUIDE (See page EM - 109)
27. REMOVE TIMING CHAIN GUIDE NO. 2 (See page EM - 110)
28. REMOVE CHAIN
GETtheMANUALS.org
29. REMOVE OIL NOZZLE NO. 1

(a) Remove the bolt. Then remove oil nozzle No. 1.
A108584
30. REMOVE OIL PUMP ASSEMBLY

(a) Remove the 3 bolts. Then remove the oil pump assembly.
INSTALLATION
A108585
LU 1. INSTALL OIL PUMP ASSEMBLY

(a) Apply a generous amount of engine oil to the location shown in
the illustration.
HINT:
• On the oil pump assembly side, apply the oil between the
teeth of the inner and the outer rotors.
• On the cylinder block side, apply the oil to the lower outside
periphery of the rotor hole (more than 90°).
• There is no distinction between the front and back sides of
Apply Engine Oil the outer rotor.
A032062J01
• Check the positioning pin.
(b) Install the oil pump assembly with the 3 bolts.
A108585
GETtheMANUALS.org
LU–8
2. INSTALL OIL NOZZLE NO. 1

(a) Install the oil nozzle No. 1 with the bolt.
3. INSTALL CHAIN (See page EM - 110)
4. INSTALL TIMING CHAIN GUIDE NO. 2 (See page EM - 110)
5. INSTALL TIMING CHAIN GUIDE (See page EM - 111)
6. INSTALL TIMING CHAIN TENSION ARM (See page EM - 111)

A108584 7. INSTALL CHAIN TENSIONER PLUNGER (See page EM - 111)
8. INSTALL CRANK ANGLE SENSOR PLATE NO. 1 (See page EM -

111)
9. INSTALL TIMING CHAIN (BELT) COVER (See page EM - 160)
10. INSTALL TIMING CHAIN (BELT) COVER OIL SEAL (See page EM
- 200)
11. INSTALL CRANK POSITION SENSOR (See page EM - 57)

(See page EM - 162)
13. INSTALL CRANKSHAFT PULLEY (See page EM - 161)
14. INSTALL CYLINDER HEAD COVER (See page EM - 162)

LU
15. INSTALL SPARK PLUG (See page EM - 162)
16. INSTALL IGNITION COIL ASSEMBLY (See page EM - 162)
17. INSTALL RADIATOR PIPE (See page EM - 166)
18. INSTALL ENGINE ROOM MAIN WIRE (See page EM - 165)
19. INSTALL VENTILATION HOSE (See page EM - 166)
20. INSTALL VENTILATION HOSE NO. 2 (See page EM - 166)
21. INSTALL IDLER PULLEY NO. 1 (See page EM - 163)
22. INSTALL VANE PUMP ASSEMBLY (See page EM - 68)
23. INSTALL FAN PULLEY (See page CO - 29)
24. INSTALL FAN AND ALTERNATOR V BELT (See page EM - 8)
25. ADJUST FAN AND ALTERNATOR V BELT (See page EM - 9)
26. CHECK FAN AND ALTERNATOR V BELT (See page EM - 9)
27. INSTALL ACCELERATOR CONTROL GAUGE ASSEMBLY (See

page EM - 165)
28. INSTALL RADIATOR HOSE NO. 1 (See page CO - 18)
31. INSTALL BATTERY CARRIER (See page EM - 167)
32. INSTALL BATTERY
33. CONNECT NEGATIVE BATTERY TERMINAL (See page EM - 112)
34. REFILL ENGINE COOLANT (See page CO - 9)
35. REFILL ENGINE OIL
GETtheMANUALS.org
36. CHECK FOR ENGINE COOLANT LEAKS (See page CO - 10)
38. CHECK ENGINE OIL LEVEL (See page EM - 167)
40. CHECK IDLE SPEED (See page EM - 2)
LU
GETtheMANUALS.org
LUBRICATION – OIL PUMP ASSEMBLY (K3-VE)
LU–10
OIL PUMP ASSEMBLY (K3-VE)

LUBRICATION
ENGINE
COMPONENTS
T=3.5{36}
BATTERY
×2
T=8.5{87} ×3 T=18{184}
T=7.5{76} ×2
BATTERY CARRIER
LU
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} ×11

A136903J01
GETtheMANUALS.org
LU–11 LUBRICATION – OIL PUMP ASSEMBLY (K3-VE)
VENTILATION HOSE NO. 2 SPARK PLUG

T=20{204}
T=7.5{76}
×4

LU ×4
O-RING
T=7.5{76}
IDLER PULLEY
IDLER PULLEY NO. 1

RADIATOR PIPE
×3
T=11.5{117}
T=44{449}
T=130{1326}
×3
T=20.6{210}
O-RING
T=7.5{76}

A136904J01
GETtheMANUALS.org
LU–12
OIL FILLER CAP

T=11{112}
CYLINDER HEAD COVER
T=9.0{92}
×11

TIMING CHAIN TENSIONER ARM

TIMING GEAR (CHAIN)
COVER GASKET TIMING CHAIN GUIDE
T=9.0{92}
CHAIN LU
TIMING CHAIN (BELT) COVER
T=23{235}
T=12{122}
×9
×2
T=44{449}
×3
T=19{195}
T=7.5{76}
T=7.5{76}
×2
TIMING CHAIN GUIDE NO. 2 OIL PUMP ASSEMBLY
TIMING CHAIN (BELT)

T=7.5{76}
COVER OIL SEAL

T=9.0{92}
OIL NOZZLE NO.1
MP GREASE
A136905J04
GETtheMANUALS.org
REMOVAL
2. REMOVE BATTERY CARRIER (See page EM - 173)
4. DRAIN ENGINE OIL
5. DRAIN ENGINE COOLANT (See page CO - 11)
7. REMOVE RADIATOR HOSE NO. 1 (See page CO - 22)
8. REMOVE ACCELERATOR CONTROL GAUGE ASSEMBLY (See

page EM - 175)
9. REMOVE FAN AND ALTERNATOR BELT (See page EM - 12)
10. REMOVE VANE PUMP WITH BRACKET (See page EM - 79)
11. REMOVE FAN PULLEY (See page CO - 33)
12. REMOVE IDLER PULLEY NO. 1 (See page EM - 177)
13. DISCONNECT VENTILATION HOSE (See page EM - 175)

LU
14. DISCONNECT NO. 2 VENTILATION HOSE (See page EM - 174)
15. REMOVE ENGINE ROOM MAIN WIRE (See page EM - 175)
16. REMOVE RADIATOR PIPE (See page EM - 174)
17. REMOVE IGNITION COIL ASSEMBLY (See page EM - 178)
18. REMOVE CYLINDER HEAD COVER (See page EM - 178)
19. REMOVE CRANKSHAFT PULLEY (See page EM - 179)

(See page EM - 180)
21. REMOVE TIMING CHAIN (BELT) COVER (See page EM - 180)
22. REMOVE TIMING CHAIN (BELT) COVER OIL SEAL (See page EM
- 180)
23. REMOVE CRANK ANGLE SENSOR PLATE NO. 1 (See page EM -

116)
24. REMOVE CHAIN TENSIONER PLUNGER (See page EM - 116)
25. REMOVE TIMING CHAIN TENSION ARM (See page EM - 117)
26. REMOVE TIMING CHAIN GUIDE (See page EM - 117)
27. REMOVE TIMING CHAIN GUIDE NO. 2 (See page EM - 118)
28. REMOVE CHAIN
GETtheMANUALS.org
LU–14
29. REMOVE OIL NOZZLE NO. 1

(a) Remove the bolt. Then remove the oil nozzle No. 1.
A108584
30. REMOVE OIL PUMP ASSEMBLY

(a) Remove the 3 bolts. Then remove the oil pump assembly.
INSTALLATION
A108585
1. INSTALL OIL PUMP ASSEMBLY

LU
(a) Apply a generous amount of engine oil to the location shown in
the illustration.
HINT:
• On the oil pump assembly side, apply the oil between the
teeth of the inner and the outer rotors.
• On the cylinder block side, apply the oil to the lower outside
periphery of the rotor hole (more than 90°).
• There is no distinction between the front and back sides of
Apply Engine Oil the outer rotor.
A032062J01
• Check the positioning pin.
(b) Install the oil pump assembly with the 3 bolts.
A108585
GETtheMANUALS.org
2. INSTALL OIL NOZZLE NO. 1

(a) Install the oil nozzle No. 1 with the bolt.
3. INSTALL CHAIN (See page EM - 118)
4. INSTALL TIMING CHAIN GUIDE NO. 2 (See page EM - 118)
5. INSTALL TIMING CHAIN GUIDE (See page EM - 119)
6. INSTALL TIMING CHAIN TENSION ARM (See page EM - 119)

A108584 7. INSTALL CHAIN TENSIONER PLUNGER (See page EM - 119)
8. INSTALL CRANK ANGLE SENSOR PLATE NO. 1 (See page EM -

119)
9. INSTALL TIMING CHAIN (BELT) COVER (See page EM - 188)
10. INSTALL TIMING CHAIN (BELT) COVER OIL SEAL (See page EM
- 206)
11. INSTALL CRANK POSITION SENSOR (See page EM - 92)
12. INSTALL CRANKSHAFT PULLEY (See page EM - 189)
13. INSTALL CYLINDER HEAD COVER (See page EM - 190)
LU 14. INSTALL SPARK PLUG (See page EM - 190)
15. INSTALL IGNITION COIL ASSEMBLY (See page EM - 190)
16. INSTALL RADIATOR PIPE (See page EM - 194)
17. INSTALL ENGINE ROOM MAIN WIRE (See page EM - 193)
18. INSTALL VENTILATION HOSE (See page EM - 193)
19. INSTALL VENTILATION HOSE NO. 2 (See page EM - 193)
20. INSTALL IDLER PULLEY NO. 1 (See page EM - 191)
21. INSTALL FAN PULLEY (See page CO - 33)
22. INSTALL VANE PUMP WITH BRACKET (See page EM - 103)
23. INSTALL FAN AND ALTERNATOR V BELT (See page EM - 12)
24. ADJUST FAN AND ALTERNATOR V BELT (See page EM - 13)
25. CHECK FAN AND ALTERNATOR V BELT (See page EM - 13)
26. INSTALL ACCELERATOR CONTROL GAUGE ASSEMBLY (See

page EM - 193)
27. INSTALL RADIATOR HOSE NO. 1 (See page CO - 25)
30. INSTALL BATTERY CARRIER (See page EM - 194)
31. INSTALL BATTERY
32. CONNECT NEGATIVE BATTERY TERMINAL (See page EM - 120)
33. REFILL ENGINE COOLANT (See page CO - 11)
34. REFILL ENGINE OIL
35. CHECK FOR ENGINE COOLANT LEAKS (See page CO - 12)
GETtheMANUALS.org
LU–16
37. CHECK ENGINE OIL LEVEL (See page EM - 195)
39. CHECK IDLE SPEED (See page EM - 5)
LU
GETtheMANUALS.org
LU–17 LUBRICATION - OIL FILTER (3SZ-VE)
OIL FILTER (3SZ-VE)

LUBRICATION
ENGINE
COMPONENTS
OIL FILTER
LU
GASKET
T=29.5{301}
OIL PAN DRAIN PLUG
APPLY ENGINE OIL

A136969J02
GETtheMANUALS.org
LUBRICATION - OIL FILTER (3SZ-VE)
LU–18
REMOVAL
1. DRAIN ENGINE OIL
2. REMOVE OIL FILTER
(a) Before draining the oil, place a tray under the drain hose to
collect the oil drained through the drain hose and the oil filter.
HINT:
Check that the tip of the drain hose comes out from the engine
Hose under cover.
A139372
(b) Using SST, remove the oil filter.

SST 09228-87201
INSTALLATION
1. INSTALL OIL FILTER
(a) If you are using a torque wrench:
(1) Remove dirt and foreign matters from the installation
SST surface of the oil filter on the engine side. LU
(2) Apply a small amount of engine oil to the O-ring of the
A134340
new oil filter.
(3) Using SST, install the oil filter.
SST 09228-87201
(b) If you are not using a torque wrench:
surface of the oil filter on the engine side.
new oil filter.
(3) Manually install the oil filter until the O-ring touches the
installation surface.
(4) Using SST, tighten it by an additional 3/4 turn.
SST 09228-87201
2. INSTALL OIL PAN DRAIN PLUG

(a) Install the drain pan drain plug using a new gasket.
3. ADD ENGINE OIL
SST 4. CHECK ENGINE OIL LEVEL (See page EM - 167)
A134340
GETtheMANUALS.org
LU–19 LUBRICATION - OIL FILTER (K3-VE)
OIL FILTER (K3-VE)

LUBRICATION
ENGINE
COMPONENTS
OIL FILTER
LU
GASKET
T=29.5{301}
OIL PAN DRAIN PLUG
APPLY ENGINE OIL

A136969J02
GETtheMANUALS.org
LUBRICATION - OIL FILTER (K3-VE)
LU–20
REMOVAL
1. DRAIN ENGINE OIL
2. REMOVE OIL FILTER
(a) Before draining the oil, place a tray under the drain hose to
collect the oil drained through the drain hose and the oil filter.
HINT:
Check that the tip of the drain hose comes out from the engine
Hose under cover.
A139372
(b) Using SST, remove the oil filter.

SST 09228-87201
INSTALLATION
1. INSTALL OIL FILTER
(a) If you are using a torque wrench:
SST surface of the oil filter on the engine side. LU
A134340
new oil filter.
(3) Using SST, install the oil filter.
SST 09228-87201
(b) If you are not using a torque wrench:
surface of the oil filter on the engine side.
new oil filter.
(3) Manually install the oil filter until the O-ring touches the
installation surface.
(4) Using SST, tighten it by an additional 3/4 turn.
SST 09228-87201
2. INSTALL OIL PAN DRAIN PLUG

(a) Install the drain pan drain plug using a new gasket.
3. ADD ENGINE OIL
SST 4. CHECK ENGINE OIL LEVEL (See page EM - 195)
A134340
GETtheMANUALS.org
TO INDEX
ENGINE
IGNITION
IGNITION SYSTEM (3SZ-VE)
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-1
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-2
IGNITION SYSTEM (K3-VE)
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-3
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-4
CAM POSITION SENSOR (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-8
CAM POSITION SENSOR (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-12
CRANK POSITION SENSOR (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-14 IG
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-14
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-14
CRANK POSITION SENSOR (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-16
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-16
SPARK PLUG (3SZ-VE)
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-17
SPARK PLUG (K3-VE)
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IG-18
GETtheMANUALS.org
IG–1 IGNITION - IGNITION SYSTEM (3SZ-VE)
IGNITION SYSTEM (3SZ-VE)

IGNITION
ENGINE
OPERATION CHECK
1. PERFORM SPARK TEST
(a) Check for diagnostic trouble codes. (See page ES-8)
NOTICE:
If a DTC is detected, perform the troubleshooting proce-
dures for the corresponding DTC.
(b) Perform the spark test.
(1) Remove the air cleaner assembly.
(2) Disconnect the connector from the ignition coil.
(3) Remove the ignition coil.
(4) Remove the spark plug.
(5) Install the spark plug to the ignition coil and connect the
connector.
(6) Disconnect all connectors of the fuel injector assembly.
(7) Ground the spark plug.
(8) Make sure that sparks occur when the engine is cranking.
NOTICE:
• Be sure to ground the hexagonal part or the thread
of the ground electrode of the spark plug.
• If the ignition coil has been dropped or struck,
IG replace it.
• Do not crank the engine for more than 2 seconds.
(9) Connect the connector of the fuel injector assembly.
(10) Install the spark plugs.
(11) Install the ignition coils.
(12) Connect the connector to the ignition coil.
(13) Check for diagnostic trouble codes.
GETtheMANUALS.org
IGNITION - IGNITION SYSTEM (3SZ-VE)
IG–2
LOCATION
IG
CRANKSHAFT POSITION SENSOR SPARK PLUG
A137728J01
GETtheMANUALS.org
IG–3 IGNITION - IGNITION SYSTEM (K3-VE)
IGNITION SYSTEM (K3-VE)

IGNITION
ENGINE
OPERATION CHECK
1. PERFORM SPARK TEST
(a) Check for diagnostic trouble codes. (See page ES-8)
NOTICE:
If a DTC is detected, perform the troubleshooting proce-
dures for the corresponding DTC.
(b) Perform the spark test.
(1) Remove the air cleaner assembly.
(2) Disconnect the connector from the ignition coil.
(3) Remove the ignition coil.
(4) Remove the spark plug.
(5) Install the spark plug to the ignition coil and connect the
connector.
(6) Disconnect all connectors of the fuel injector assembly.
(7) Ground the spark plug.
(8) Make sure that sparks occur when the engine is cranking.
NOTICE:
• Be sure to ground the hexagonal part or the thread
of the ground electrode of the spark plug.
• If the ignition coil has been dropped or struck,
IG replace it.
• Do not crank the engine for more than 2 seconds.
(9) Connect the connector of the fuel injector assembly.
(10) Install the spark plugs.
(11) Install the ignition coils.
(12) Connect the connector to the ignition coil.
(13) Check for diagnostic trouble codes.
GETtheMANUALS.org
IGNITION - IGNITION SYSTEM (K3-VE)
IG–4
LOCATION
IG
CRANKSHAFT POSITION SENSOR SPARK PLUG
A137728J01
GETtheMANUALS.org
IG–5 IGNITION - CAM POSITION SENSOR (3SZ-VE)
CAM POSITION SENSOR (3SZ-VE)

IGNITION
ENGINE
COMPONENTS
T=7.5{76}
T=18{184}
T=7.5{76}
T=7.5{76}
IG
GETtheMANUALS.org
IGNITION - CAM POSITION SENSOR (3SZ-VE)
IG–6
REMOVAL

(a) Remove the bolt, then remove the wire harness clamp.
A138814
IG
A138817
(c) Remove the bolt, then remove the wire harness clamp.
A138988
GETtheMANUALS.org
IG–7 IGNITION - CAM POSITION SENSOR (3SZ-VE)
(e) Remove the bolt, then remove the cam position sensor.
INSTALLATION
A138990
(b) Using a priset torque wrench, install the cam position sensor
IG with the bolt.

NOTICE:
Be careful that the O-ring is not cracked or pinched when
installing it to the cylinder head.
A138990
GETtheMANUALS.org
IGNITION - CAM POSITION SENSOR (3SZ-VE)
IG–8
A138988
IG
A138817
(f) Install the wire harness clamp with the bolt.

(g) Connect the connector.
INSPECTION
A138814
1. INSPECT CAM POSITION SENSOR

(a) Using a tester, measure the resistance between the connector
terminals.
Standard:
1850 to 2450 Ω (20°C)
2 1
A105341J05
GETtheMANUALS.org
IG–9 IGNITION - CAM POSITION SENSOR (K3-VE)
CAM POSITION SENSOR (K3-VE)

IGNITION
ENGINE
COMPONENTS
T=7.5{76}
T=18{184}
T=7.5{76}
T=7.5{76}
IG
GETtheMANUALS.org
IGNITION - CAM POSITION SENSOR (K3-VE)
IG–10
REMOVAL

(a) Remove the bolt, then remove the wire harness clamp.
A138814
IG
A138817
(c) Remove the bolt, then remove the wire harness clamp.
A138988
GETtheMANUALS.org
IG–11 IGNITION - CAM POSITION SENSOR (K3-VE)
(e) Remove the bolt, then remove the cam position sensor.
INSTALLATION
A138990
(b) Using a pri set torque wrench, install the cam position sensor
IG with the bolt.

NOTICE:
A138990
GETtheMANUALS.org
IGNITION - CAM POSITION SENSOR (K3-VE)
IG–12
A138988
IG
A138817
(f) Install the wire harness clamp with the bolt.

(g) Connect the connector.

INSPECTION
A138814
1. INSPECT CAM POSITION SENSOR

(a) Using a tester, measure the resistance between the connector
terminals.
Standard:
1850 to 2450 Ω(20°C)
2 1
A105341J05
GETtheMANUALS.org
IG–13 IGNITION - CRANK POSITION SENSOR (3SZ-VE)
CRANK POSITION SENSOR (3SZ-VE)

IGNITION
ENGINE
COMPONENTS
IG
ENGINE UNDER COVER
T=7.5{76}
T=5.4{55} ×11 CRANKSHAFT POSITION SENSOR
GETtheMANUALS.org
IGNITION - CRANK POSITION SENSOR (3SZ-VE)
IG–14
REMOVAL

(b) Remove the bolt, then remove the crank position sensor.
INSTALLATION
A137749

NOTICE:
IG
INSPECTION
A137749
1. INSPECT CRANK POSITION SENSOR

(1) Using a tester, measure the resistance between the con-
nector terminals.
Standard:
2 1 1850 to 2450 Ω (20°C)
A133584
GETtheMANUALS.org
IG–15 IGNITION - CRANK POSITION SENSOR (K3-VE)
CRANK POSITION SENSOR (K3-VE)

IGNITION
ENGINE
COMPONENTS
IG
ENGINE UNDER COVER
T=7.5{76}
T=5.4{55} ×11 CRANKSHAFT POSITION SENSOR
GETtheMANUALS.org
IGNITION - CRANK POSITION SENSOR (K3-VE)
IG–16
REMOVAL

(b) Remove the bolt, then remove the crank position sensor.
INSTALLATION
A137749

NOTICE:

IG
A137749
INSPECTION
1. INSPECT CRANK POSITION SENSOR

(1) Using a tester, measure the resistance between the con-
nector terminals.
Standard:
2 1 1850 to 2450 Ω(20°C)
A133584
GETtheMANUALS.org
IG–17 IGNITION - SPARK PLUG (3SZ-VE)
SPARK PLUG (3SZ-VE)

IGNITION
ENGINE
INSPECTION
1. INSPECT SPARK PLUG
(a) Inspect spark plug gap.
NOTICE:
• Because an iridium plug is used, do not adjust the gap
of the spark plug except when using a new plug (when
the vehicle was driven 1000 km or less).
• Do not damage the iridium tip.
Standard
Specified Value
Manufacturer Type Maximum (mm)
(mm)
NGK IKR7C 0.8-0.9 1.1
(b) If the gap is larger than the maximum, replace the spark plug
because the iridium tip is worn out.
NOTICE:
Because a long-reach plug is used, be sure to replace the
plug with the specified plug.
(c) Clean the spark plug.
NOTICE:
Do not clean the spark plug as it may damage the iridium
IG tip.However, if the plug is extremely dirty due to smoke
damage or for other reasons, the spark plug may be
cleaned for very short time (less than 20 seconds) using a
spark plug cleaner. In order to prevent damage to the elec-
trode, do not exceed 20 seconds.
GETtheMANUALS.org
IGNITION - SPARK PLUG (K3-VE)
IG–18
SPARK PLUG (K3-VE)

IGNITION
ENGINE
INSPECTION
1. CHECK SPARK PLUG
(a) Inspect spark plug gap.
Standard
Manufacturer Type Specified Value (mm)

NGK BKR6EY-11 1.0-1.1
DENSO K20R-U11 1.0-1.1
(b) Inspect for smoke damage or excessive burning on the spark

plug.
(c) Check the plug gap using a plug gap gauge.
(d) If the gap is larger than the maximum, replace the spark plug
because the iridium tip is worn out.
(e) Clean the spark plug.
IG
GETtheMANUALS.org
TO INDEX
ENGINE
STARTING
STARTING SYSTEM (3SZ-VE)
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-1
STARTING SYSTEM (K3-VE)
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-2
STARTER ASSEMBLY (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-10
STARTER ASSEMBLY (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-16
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-19
STARTER RELAY ASSEMBLY (3SZ-VE)
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-21
STARTER RELAY ASSEMBLY (K3-VE)
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-22
ST
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ST–1 STARTING - STARTING SYSTEM (3SZ-VE)
STARTING SYSTEM (3SZ-VE)

STARTING
ENGINE
LOCATION
STARTER RELAY
ASSEMBLY
ST
STARTER ASSEMBLY
A137730J01
GETtheMANUALS.org
STARTING - STARTING SYSTEM (K3-VE)
ST–2
STARTING SYSTEM (K3-VE)

STARTING
ENGINE
LOCATION
STARTER RELAY
ASSEMBLY
ST
STARTER ASSEMBLY
A137730J01
GETtheMANUALS.org
ST–3 STARTING - STARTER ASSEMBLY (3SZ-VE)
STARTER ASSEMBLY (3SZ-VE)

STARTING
ENGINE
COMPONENTS
ST
ENGINE UNDER COVER

×7 T=5.4{55}
×4 ENGINE UNDER COVER RR LH
T=5.4{55}
T=60{612}
×4
×11
T=5.4{55}
×2
T=37{377}
PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

A140751J01
GETtheMANUALS.org
STARTING - STARTER ASSEMBLY (3SZ-VE)
ST–4
T=37{377}
×2
ST
T=8.8{90}
STARTER ASSEMBLY

A137005J01
GETtheMANUALS.org
REMOVAL
(See page RS-164.)

BLY (See page PR-6)
(a) Remove bolt A and bolt B. Then remove the fan belt adjusting
slider.
A138907
(b) Remove the terminal cap.

(c) Remove the nut using an extension bar (270mm). Then remove
ST terminal 30.
A138900
(e) Disconnect the oxygen sensor No. 2 connector.
A133302
GETtheMANUALS.org
ST–6
(f) Remove the 2 bolts and disconnect the exhaust pipe assembly
FR.
A134989
(g) Support the engine rear support member with a mission jack.
C141310
(h) Remove the 4 bolts and disconnect the engine rear support
member.
ST
A133258
(i) Remove the bolt and disconnect the fuel delivery pipe.
A138811
(j) Remove the 2 bolts using an extension bar (600mm). Then dis-
connect the fuel delivery pipe and the water bypass pipe No 2.
A138813
GETtheMANUALS.org
(k) Remove the 2 bolts.
A138815
(l) Remove the starter as shown in the illustration.
INSTALLATION
ST
A139036

(a) Set in the starter assembly as shown in the illustration.
A138903
GETtheMANUALS.org
ST–8
(b) Turn the starter assembly as shown in the illustration.
A138902
(c) Using an extension bar (600mm), install the starter assembly

with the 2 bolts.
A138815
(d) Using an extension bar (600mm), install the water bypass pipe
No. 2 with 2 new bolts.
ST
A138816
(e) Using an extension bar (600mm), install the fuel delivery pipe
with a new bolt.
A138812
(f) Install the fuel delivery pipe with the bolt.
A138811
GETtheMANUALS.org
(g) Support the engine rear support member with a high-mission

transmission jack.
C141310
(h) Install the engine rear support member with the 4 bolts.
A133258
(i) Using a wooden block and hammer, tap in a new gasket until it
NOTICE:
ST • Make sure the gasket is installed in the correct direc-
tion.
Wooden
Block
removed.
when installing the exhaust pipe.
Gasket
A066225J07
(j) Install the exhaust pipe assembly FR to the exhaust manifold

A134989
(k) Using an extension bar (270mm) and a preset torque wrench,

install terminal 30 with the nut.
(l) Close the terminal cap.
(m) Connect the connector.
A138901
GETtheMANUALS.org
ST–10
(n) Install the fan belt adjusting slider with bolt A and bolt B.

BLY (See page PR-7)
A138907
6. INSTALL ENGINE UNDER COVER RR LH (See page EM-69)
7. INSTALL ENGINE UNDER COVER RR RH (See page EM-69)
INSPECTION
1. CHECK STARTER ASSEMBLY
NOTICE:
Perform each test for 3 - 5 seconds.
(a) Remove the nut and disconnect the terminal C.
Terminal 30
Terminal C
ST
Terminal 50
A134304
(b) Wire the terminals as shown in the illustration, and check that
the pinion gear moves outward.
Terminal C
Body
Terminal 50
A137696
(c) With the pinion gear out and the cable to terminal C discon-
nected, check that the pinion gear remains out.
Terminal C
Body
Terminal 50
A137697
GETtheMANUALS.org
(d) With the pinion gear out and the cable to the starter body dis-
connected, check that the pinion gear returns inward.
Terminal C (e) Install terminal C with the nut.
Body Torque: 8.8 N*m (90 kgf*cm)
(f) Secure the starter in the vise with aluminum plates inserted.
Terminal 50
A137698
(g) Wire the cables and connect one of them to the positive (+) side
Tester
Body (h) Connect terminal 50 and measure the current value when the
tester indicator becomes stable.
Standard:
90 A (about 11.5 V) or less
Terminal 50
Terminal 30
A140750
ST
GETtheMANUALS.org
STARTING - STARTER ASSEMBLY (K3-VE)
ST–12
STARTER ASSEMBLY (K3-VE)

STARTING
ENGINE
COMPONENTS
ST
ENGINE UNDER COVER

×7 T=5.4{55}
×4 ENGINE UNDER COVER RR LH
T=5.4{55}
T=60{612}
×4
×11
T=5.4{55}
×2
T=37{377}
PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
GETtheMANUALS.org
ST–13 STARTING - STARTER ASSEMBLY (K3-VE)
T=37{377}
×2
ST
T=8.8{90}
STARTER ASSEMBLY

A137005J01
GETtheMANUALS.org
ST–14
REMOVAL
(See page RS-164.)

BLY (See page PR-6)
(a) Remove bolt A and bolt B. Then remove the fan belt adjusting
slider.
A138907
(b) Remove the terminal cap.

(c) Remove the nut using an extension bar (270mm). Then remove
terminal 30. ST
A138900
(e) Disconnect the oxygen sensor No. 2 connector.
A133302
GETtheMANUALS.org
(f) Remove the 2 bolts and disconnect the exhaust pipe assembly
FR.
A134989
(g) Support the engine rear support member with a mission jack.
C141310
(h) Remove the 4 bolts and disconnect the engine rear support
member.
ST
A133258
(i) Remove the bolt and disconnect the fuel delivery pipe.
A138811
(j) Remove the 2 bolts using an extension bar (600mm). Then dis-
connect the fuel delivery pipe and the water bypass pipe No 2.
A138813
GETtheMANUALS.org
ST–16
(k) Remove the 2 bolts.
A138815
(l) Remove the starter as shown in the illustration.
INSTALLATION
ST
A139036

(a) Set in the starter assembly as shown in the illustration.
A138903
(b) Turn the starter assembly as shown in the illustration.
A138902
GETtheMANUALS.org
(c) Using an extension bar (600mm), install the starter assembly

with the 2 bolts.
A138815
(d) Using an extension bar (600mm), install the water bypass pipe
No. 2 with 2 new bolts.
A138816
(e) Using an extension bar (600mm), install the fuel delivery pipe
with a new bolt.
ST
A138812
(f) Install the fuel delivery pipe with the bolt.
A138811
(g) Support the engine rear support member with a high-mission

transmission jack.
C141310
GETtheMANUALS.org
ST–18
(h) Install the engine rear support member with the 4 bolts.
A133258
(i) Using a wooden block and hammer, tap in a new gasket until it
NOTICE:
tion.
Wooden
Block • Do not re-use a gasket that has been previously
removed.
when installing the exhaust pipe.
Gasket
A066225J07
(j) Install the exhaust pipe assembly FR to the exhaust manifold

ST
A134989
(k) Using an extension bar (270mm) and a preset torque wrench,

install terminal 30 with the nut.
(l) Close the terminal cap.
(m) Connect the connector.
A138901
(n) Install the fan belt adjusting slider with bolt A and bolt B.

BLY (See page PR-7)
A138907
GETtheMANUALS.org
8. INSTALL ENGINE UNDER COVER RR LH (See page EM-104)
9. INSTALL ENGINE UNDER COVER RR RH (See page EM-104)
INSPECTION
1. CHECK STARTER ASSEMBLY
NOTICE:
Perform each test for 3 - 5 seconds.
(a) Remove the nut and disconnect the terminal C.
Terminal 30
Terminal C
Terminal 50
A134304
(b) Wire the terminals as shown in the illustration, and check that
ST Terminal C
the pinion gear moves outward.
Body
Terminal 50
A137696
(c) With the pinion gear out and the cable to terminal C discon-
nected, check that the pinion gear remains out.
Terminal C
Body
Terminal 50
A137697
GETtheMANUALS.org
ST–20
(d) With the pinion gear out and the cable to the starter body dis-
connected, check that the pinion gear returns inward.
Terminal C
(e) Install terminal C with the nut.
Body
(f) Secure the starter in the vise with aluminum plates inserted.
Terminal 50
A137698
(g) Wire the cables and connect one of them to the positive (+) side
Tester
Body (h) Connect terminal 50 and measure the current value when the
tester indicator becomes stable.
Standard:
90 A (about 11.5 V) or less
Terminal 50
Terminal 30
A140750
ST
GETtheMANUALS.org
ST–21 STARTING - STARTER RELAY ASSEMBLY (3SZ-VE)
STARTER RELAY ASSEMBLY (3SZ-VE)

STARTING
ENGINE
INSPECTION
1. CHECK STARTER RELAY ASSEMBLY
(1) Using tester, check the continuity between each terminal.
Standard
1←→2 Continuity

A133875 and 5 when battery voltage is applied to terminal 1 and 2.
Standard:
Continuity
ST
GETtheMANUALS.org
STARTING - STARTER RELAY ASSEMBLY (K3-VE)
ST–22
STARTER RELAY ASSEMBLY (K3-VE)

STARTING
ENGINE
INSPECTION
1. CHECK STARTER RELAY ASSEMBLY
(1) Using tester, check the continuity between each terminal.
Standard
1←→2 Continuity

A133875 and 5 when battery voltage is applied to terminal 1 and 2.
Standard:
Continuity
ST
GETtheMANUALS.org
TO INDEX
ENGINE
CHARGING
CHARGING SYSTEM (3SZ-VE)
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-1
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-2
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-3
CHARGING SYSTEM (K3-VE)
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-5
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-6
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-7
ALTERNATOR ASSEMBLY (3SZ-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-10
ALTERNATOR ASSEMBLY (K3-VE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-13
CH
GETtheMANUALS.org
CH–1 CHARGING - CHARGING SYSTEM (3SZ-VE)
CHARGING SYSTEM (3SZ-VE)

CHARGING
ENGINE
PRECAUTIONS
1. Check that the battery cables are correctly connected to the
terminals.
2. Disconnect the battery cables when the battery is given a quick
charge.
3. Never disconnect the battery while the engine is running.
CH
GETtheMANUALS.org
CHARGING - CHARGING SYSTEM (3SZ-VE)
CH–2
LOCATION
CH
ALTERNATOR ASSEMBLY
A137729J01
GETtheMANUALS.org
CH–3 CHARGING - CHARGING SYSTEM (3SZ-VE)
OPERATION CHECK
1. CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte level (for maintenance-free batteries).
(1) If the electrolyte level is below the lower line, replace the
battery.
(b) Check the electrolyte level in each cell (for non-maintenance-
free batteries).
(1) If the electrolyte level is below the lower line, add distilled
water.
2. CHECK BATTERY'S SPECIFIC GRAVITY (NON-MAINTENANCE-
FREE BATTERIES)
(a) Check the specific gravity of each cell in the battery.
Standard:
1.25 - 1.29 (electrolyte temperature 20°C)
HINT:
If the specific gravity values are outside the specified range,
charge the battery.
A001259J01

(a) In order to remove the surface charge, turn off the engine after
driving the vehicle. Then turn the ignition switch ON (within 20
seconds) and turn ON electrical systems (headlights, blower
motor, rear defogger, etc.).
(b) Turn the ignition switch OFF, and turn OFF the electrical
CH systems.
(c) Using a tester, measure the battery voltage between the
terminals.
A001260J01 Standard:
12.5 - 12.9 V (20° C)
HINT:
If the voltage is outside the specified range, charge the battery.
4. CHECK BATTERY TERMINAL, FUSIBLE LINK, AND FUSE
(a) Check that the battery terminals are not loose or corroded.
(b) Check that there is continuity in the fusible link and the fuse.
5. CHECK BELT
(a) Check the belt for wear and cracks.
HINT:
• Replace belts that are worn to the point where the wire is
exposed.
• Replace belts that contain cracks that reach the wire in more
than one place.
• Replace belts that contain more than one chunk that is
missing from the ribs.
B000543J01
GETtheMANUALS.org
CHARGING - CHARGING SYSTEM (3SZ-VE)
CH–4
(b) Check that the belt is fitted properly in the ribbed grooves.
HINT:
Check visually and with your hand that the belt has not slipped
out of the grooves on the bottom of the pulley.
6. CHECK ALTERNATOR WIRING
(a) Check that the wiring is in good condition.
7. CHECK FOR ABNORMAL NOISE FROM ALTERNATOR
(a) Check that the alternator does not emit any abnormal noise
while the engine is running.
B000540J01
8. CHECK CHARGE WARNING LIGHT
(a) Warm up the engine and turn the ignition switch OFF.
(b) Turn OFF all electrical systems.
(c) Turn the ignition switch to the ON position, and check that the
charge warning light goes on.
(d) Start the engine and check that the charge warning light goes
off.
HINT:
Troubleshoot the charge warning light circuit if the light does not
operate as specified above.
9. TEST WITHOUT LOAD
(a) Connect an ammeter and voltmeter to the charging circuit as
follows.
Connect to Terminal B
(1) Disconnect terminal B from the alternator.
(2) Connect the ammeter's positive (+) terminal to terminal B of
Battery the alternator.
(3) Connect the ammeter's negative (-) terminal to the battery's
Alternator
positive (+) terminal.
(4) Connect the voltmeter's positive (+) terminal to terminal B
CH
A050553J02 of the alternator.
(5) Ground the voltmeter's negative (-) terminal.
(b) Inspect the charging circuit.
(1) Using a tester, measure the battery voltage when the
engine speed is increased to 2,000 r/min.
Standard:
12.1 - 15.4 V (10 A or less)
10. TEST WITH LOAD
Electrical Current (a) Using SST (AC/DC probe 400A), with the conditions specified
Terminal B for TEST WITHOUT LOAD met, turn on the high beam
headlights and turn the heater blower switch to the HI position.
Battery Then immediately measure the current when the engine speed
is set to 2,000 r/min.
SST 09083-00300
Alternator
Standard:
SST
30 A or more
A104538J01 HINT:
If the battery is fully charged, the ammeter reading will
sometimes be less than the standard amperage. In this case,
increase the load by turning on electrical devices such as the
wiper motor and the rear window defogger. Then, remeasure
the current.
GETtheMANUALS.org
CH–5 CHARGING - CHARGING SYSTEM (K3-VE)
CHARGING SYSTEM (K3-VE)

CHARGING
ENGINE
PRECAUTIONS
1. Check that the battery cables are correctly connected to the
terminals.
2. Disconnect the battery cables when the battery is given a quick
charge.
3. Never disconnect the battery while the engine is running.
CH
GETtheMANUALS.org
CHARGING - CHARGING SYSTEM (K3-VE)
CH–6
LOCATION
CH
ALTERNATOR ASSEMBLY
A137729J01
GETtheMANUALS.org
CH–7 CHARGING - CHARGING SYSTEM (K3-VE)
OPERATION CHECK
1. CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte level (for maintenance-free batteries).
(1) If the electrolyte level is below the lower line, replace the
battery.
(b) Check the electrolyte level in each cell (for non-maintenance-
free batteries).
(1) If the electrolyte level is below the lower line, add distilled
water.
2. CHECK BATTERY'S SPECIFIC GRAVITY (NON-MAINTENANCE-
FREE BATTERIES)
(a) Check the specific gravity of each cell in the battery.
Standard:
1.25 - 1.29 (electrolyte temperature 20°C)
HINT:
If the specific gravity values are outside the specified range,
charge the battery.
A001259J01

(a) In order to remove the surface charge, turn off the engine after
driving the vehicle. Then turn the ignition switch ON (within 20
seconds) and turn ON electrical systems (headlights, blower
motor, rear defogger, etc.).
(b) Turn the ignition switch OFF, and turn OFF the electrical
CH systems.
(c) Using a tester, measure the battery voltage between the
terminals.
A001260J01 Standard:
12.5 - 12.9 V (20° C)
HINT:
If the voltage is outside the specified range, charge the battery.
4. CHECK BATTERY TERMINAL, FUSIBLE LINK, AND FUSE
(a) Check that the battery terminals are not loose or corroded.
(b) Check that there is continuity in the fusible link and the fuse.
5. CHECK BELT
(a) Check the belt for wear and cracks.
HINT:
• Replace belts that are worn to the point where the wire is
exposed.
• Replace belts that contain cracks that reach the wire in more
than one place.
• Replace belts that contain more than one chunk that is
missing from the ribs.
B000543J01
GETtheMANUALS.org
CHARGING - CHARGING SYSTEM (K3-VE)
CH–8
(b) Check that the belt is fitted properly in the ribbed grooves.
HINT:
Check visually and with your hand that the belt has not slipped
out of the grooves on the bottom of the pulley.
6. CHECK ALTERNATOR WIRING
(a) Check that the wiring is in good condition.
7. CHECK FOR ABNORMAL NOISE FROM ALTERNATOR
(a) Check that the alternator does not emit any abnormal noise
while the engine is running.
B000540J01
8. CHECK CHARGE WARNING LIGHT
(a) Warm up the engine and turn the ignition switch OFF.
(b) Turn OFF all electrical systems.
(c) Turn the ignition switch to the ON position, and check that the
charge warning light goes on.
(d) Start the engine and check that the charge warning light goes
off.
HINT:
Troubleshoot the charge warning light circuit if the light does not
operate as specified above.
9. TEST WITHOUT LOAD
(a) Connect an ammeter and voltmeter to the charging circuit as
follows.
Connect to Terminal B
(1) Disconnect terminal B from the alternator.
(2) Connect the ammeter's positive (+) terminal to terminal B of
Battery the alternator.
(3) Connect the ammeter's negative (-) terminal to the battery's
Alternator
positive (+) terminal.
(4) Connect the voltmeter's positive (+) terminal to terminal B
CH
A050553J02 of the alternator.
(5) Ground the voltmeter's negative (-) terminal.
(b) Inspect the charging circuit.
(1) Using a tester, measure the battery voltage when the
engine speed is increased to 2,000 r/min.
Standard:
12.1 - 15.4 V (10 A or less)
10. TEST WITH LOAD
Electrical Current (a) Using SST (AC/DC probe 400A), with the conditions specified
Terminal B for TEST WITHOUT LOAD met, turn on the high beam
headlights and turn the heater blower switch to the HI position.
Battery Then immediately measure the current when the engine speed
is set to 2,000 r/min.
SST 09083-00300
Alternator
Standard:
SST
30 A or more
A104538J01 HINT:
If the battery is fully charged, the ammeter reading will
sometimes be less than the standard amperage. In this case,
increase the load by turning on electrical devices such as the
wiper motor and the rear window defogger. Then, remeasure
the current.
GETtheMANUALS.org
CH–9 CHARGING - ALTERNATOR ASSEMBLY (3SZ-VE)
ALTERNATOR ASSEMBLY (3SZ-VE)

CHARGING
ENGINE
COMPONENTS
ALTERNATOR ASSEMBLY
T=19{194}
T=10{102}
T=19{194}
T=44{449}
IDLER PULLEY
×3
CHARCOAL CANISTER PIPE No.1

T=11.5{117}
CH
T=7.5{76}
GETtheMANUALS.org
CHARGING - ALTERNATOR ASSEMBLY (3SZ-VE)
CH–10
REMOVAL
(See page RS-164.)
2. REMOVE BATTERY (See page EM-43)

(a) Remove the bolt and charcoal canister pipe No. 1.
8. REMOVE ALTERNATOR ASSEMBLY

(b) Remove the nut and terminal B.
(d) Remove the wire harness clamp.
A133920
(e) Remove bolts A and B, then remove the alternator assembly.

(f) Remove bolt C and the fan belt adjusting slider.
INSTALLATION
CH
A138796
1. INSTALL ALTERNATOR ASSEMBLY

(a) Install the fan belt adjusting slider with bolt C.
(b) Temporarily install the alternator assembly with bolts A and B
using the nut.
(c) Install the wire harness clamp.
(d) Connect the connector.
(e) Install terminal B with the nut.
(f) Install the terminal cap.
(g) Temporarily install the V-ribbed belt to the alternator pulley.
Engine
Front
A138797
GETtheMANUALS.org
CH–11 CHARGING - ALTERNATOR ASSEMBLY (3SZ-VE)
(h) Turning adjusting bold C, adjust the tension of the V-ribbed belt.
Adjustment Bolt C (i) Tighten bolts A and B.
Bolt A 44 N*m (449 kgf*cm) (Bolt B)
Bolt B A108381

(a) Install charcoal canister pipe No. 1 with the bolt.
7. INSTALL AIR CLEANER HOSE NO. 1(See page CO-19)
9. CONNECT NEGATIVE BATTERY TERMINAL(See page EM-68)
A133920
CH
GETtheMANUALS.org
CHARGING - ALTERNATOR ASSEMBLY (K3-VE)
CH–12
ALTERNATOR ASSEMBLY (K3-VE)

CHARGING
ENGINE
COMPONENTS
ALTERNATOR ASSEMBLY
T=19{194}
T=10{102}
T=19{194}
T=44{449}
IDLER PULLEY
×3
CHARCOAL CANISTER PIPE No.1

T=11.5{117}
CH
T=7.5{76}
GETtheMANUALS.org
CH–13 CHARGING - ALTERNATOR ASSEMBLY (K3-VE)
REMOVAL
(See page RS-164.)
2. REMOVE BATTERY (See page EM-78)

(a) Remove the bolt and charcoal canister pipe No. 1.
8. REMOVE ALTERNATOR ASSEMBLY

(b) Remove the nut and terminal B.
(d) Remove the wire harness clamp.
A133920
(e) Remove bolts A and B, then remove the alternator assembly.

(f) Remove bolt C and the fan belt adjusting slider.
INSTALLATION
CH
A138796
1. INSTALL ALTERNATOR ASSEMBLY

(a) Install the fan belt adjusting slider with bolt C.
(b) Temporarily install the alternator assembly with bolts A and B
using the nut.
(c) Install the wire harness clamp.
(e) Install terminal B with the nut.
(f) Install the terminal cap.
(g) Temporarily install the V-ribbed belt to the alternator pulley.
Engine
Front
A108383
GETtheMANUALS.org
CHARGING - ALTERNATOR ASSEMBLY (K3-VE)
CH–14
(h) Turning adjusting bold C, adjust the tension of the V-ribbed belt.
Adjustment Bolt C (i) Tighten bolts A and B.
Bolt A 44 N*m (449 kgf*cm) (Bolt B)
Bolt B A108381

(a) Install charcoal canister pipe No. 1 with the bolt.

A133920 7. INSTALL AIR CLEANER HOSE NO. 1(See page CO-26)
10. CONNECT NEGATIVE BATTERY TERMINAL(See page EM-103)
CH
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TO INDEX
pTRANSMISSION / TRANSAXLE
ELECTRONICALLY CONTROLLED AUTOMATIC TRANSMISSION
(ECT)
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-1
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-6
DIAGNOSTIC TROUBLE CODE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . AT-7
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-7
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-8
HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . AT-9
CUSTOMER PROBLEM ANALYSIS CHECK SHEET. . . . . . . . . . . . . . . . . AT-12
CHECK / CLEAR DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-13
FREEZE FRAME DATA / DTC DETAILED INFORMATION . . . . . . . . . . . . AT-14
OPERATION SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-15
CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-16
ECU TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-17
ECU DATA LIST / ACTIVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-20
FAIL-SAFE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-22
P0705/55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-24
P0705/56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-24
P0710/38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-27
P0711/38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-27
P0715/37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-29
P0720/42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-31
P0725/86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-33
P0753/61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-35
P0758/62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-35
P0763/63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-35
P0768/64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P0773/65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AT-39
AT-41
AT
P1780/66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-41
P1703/72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-44
P1706/31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-45
P1711/41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-46
P1730/21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-47
P1731/22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-50
U0100/82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-53
U0101/85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-53
AUTOMATIC TRANSMISSION ASSEMBLY
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-54
AUTOMATIC TRANSMISSION FLUID
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-55
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-56
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-57
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-58
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-59
TORQUE CONVERTER AND DRIVE PLATE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-60
TRANSMISSION REVOLUTION SENSOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-62
GETtheMANUALS.org
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-63
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-63
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-63
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-65
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-71
TRANSMISSION FLOOR SHIFT ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-78
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-79
TRANSMISSION WIRE
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-81
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-82
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-82
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-83
TRANSMISSION VALVE BODY ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-84
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-88
AUTOMATIC TRANSMISSION THREE-WAY SOLENOID ASSEM-
BLY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-91
CLUTCH CONTROL SOLENOID NO. 1
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-92
LOCK-UP CONTROL SOLENOID
AT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-93
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-94
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-95
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-95
SHIFT LOCK DEVICE
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-96
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-97
TRANSMISSION CONTROL COMPUTER ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-98
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-98
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-99
SHIFT LOCK RELEASE CABLE ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-100
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-102
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-103
GETtheMANUALS.org
AUTOMATIC TRANSMISSION - ELECTRONICALLY CONTROLLED AUTOMATIC TRANSMISSION (ECT)
AT–1
ELECTRONICALLY CONTROLLED AUTOMATIC TRANSMIS-

TRANSMISSION
/ TRANSAXLE
SION (ECT)
OPERATION CHECK
1. INSPECT SHIFT LOCK OPERATION
(a) Move the shift lever to the P position.
(b) When operating the shift lever, check that the shift lever cannot
be moved to any position other than the P position.
(c) Check that the shift lever can be moved out of the P position
when the ignition switch is turned to the ON position and the
brake pedal is depressed.
2. CHECK KEY INTERLOCK OPERATION

(b) While depressing the brake pedal, check that the shift lever can
be moved out of the P position.
(c) Check that the ignition key cannot be turned to the LOCK posi-
tion.
(d) Move the shift lever to the P position and turn the ignition key to
the LOCK position, and check that the ignition key can be
removed.
3. CHECK TIME LAG

NOTICE:
• Be sure to check for time lag after checking and adjusting the
engine.
• Be sure to perform this check when the fluid is at its normal
driving temperature (70-90°C).
• Perform this check when the air conditioning is turned OFF. AT
(a) Apply the parking brake and use chocks.
(b) Start the engine.
(c) While depressing the brake pedal, shift from the N position to
the D or R position with the engine idling, and measure the time
until the shock can be felt.
Standard:
N → D position: 1.0 second or less
N → R position: 1.0 second or less
NOTICE:
• Take several measurements and use the average.
• Allow an interval of 1 minute between measurements..
4. CHECK STALL SPEED

NOTICE:
• Be sure to perform this check after checking and adjusting
the engine.
• Perform this check when the air conditioning is turned OFF.
• Do not perform this check continuously for more than 5 sec-
onds.
• Perform this inspection where the µ (friction coefficient) is
high, such as on the asphalt, to prevent the wheels from
spinning.
(a) Apply the parking brake and use chocks.
GETtheMANUALS.org
AT–2 AUTOMATIC TRANSMISSION - ELECTRONICALLY CONTROLLED AUTOMATIC TRANSMISSION (ECT)
(b) Using the DS-II, following the prompts on the screen, select
ECU DATA LIST and ENGINE SPEED.
(c) Start the engine.
(d) Fully depress the accelerator pedal with the left foot, shift to the
D position, then quickly read the maximum engine speed when
fully depressing the accelerator pedal with the right foot.
Standard:
2200 to 2700 r/min
5. CHECK FLUID PRESSURE

(a) Pressure gauge installation procedure
LUC ON Pressure
C2 Pressure
C3 Pressure
Modulator Pressure
B1 Pressure
AT LUC OFF Pressure
C1 Pressure
C139911
NOTICE:
• Clean the measurement gauges and hoses using a sol-
vent before and after the measurements.
• Use a new gasket for the SST and measurement
gauges.
• The test plugs are not reusable.
(1) Remove the test plug, then install an automatic transmis-
sion oil pressure gauge and adapter.
SST 09325-87201
NOTICE:
Ensure that the gauge and adapter do not interfer-
ence with the front propeller shaft assembly.
(2) Start the engine and warm-up the transmission (between
70 and 90°C), and check the volume and leaks of the
fluid.
(3) After the test is completed, install a new test plug.
(b) C2 pressure test
(1) Apply the parking brake and use chocks.
(2) Start the engine.
GETtheMANUALS.org
AT–3
(3) Firmly depress the brake pedal with the left foot and shift
to the D position. Operate the accelerator pedal with the
right foot and measure the fluid pressure.
Standard:
930 to 1130 kPa [9.4 to 11.4 kgf/cm2]
(c) C1 pressure test
(1) Apply the parking brake and use chocks.
(3) Firmly depress the brake pedal with the left foot and shift
to the R position. Operate the accelerator pedal with the
right foot and measure the fluid pressure.
Standard:
1520 to 2110 kPa [15.5 to 21.5 kgf/cm2]
(d) B1 pressure test
(1) Lift up the vehicle.
(3) Shift to the D position, gradually depress the accelerator
pedal to shift to the 2nd gear, then measure the fluid pres-
sure at engine speed of 2,000 r/min.
Standard:
930 to 1130 kPa [9.4 to 11.4 kgf/cm2]
(e) C3 pressure test
(3) Shift to the D position, gradually depress the accelerator
pedal to shift to the 3rd gear, then measure the fluid pres-
sure when releasing the accelerator pedal.
Standard:
(f)
440 to 640 kPa [4.5 to 6.5 kgf/cm2]
LUC OFF pressure test
AT
(3) Shift to the D position and measure the fluid pres-
sure.(Fluid pressure when the lock-up is OFF)
Standard:
590 to 750 kPa [6.0 to 7.6 kgf/cm2]
(4) Gradually depress the accelerator pedal to shift to the 4th
gear, and keep accelerating. Measure the fluid pressure
when the lock-up occurs.(Fluid pressure when the lock-up
is ON)
Standard:
20 kPa [0.2 kgf/cm2 or less]
6. SHIFT TABLE
NOTICE:
• Be sure to perform this check after checking and adjusting
the engine.
• Perform this test with no electrical load, air conditioning OFF,
and the brake not applied.
Standard:
GETtheMANUALS.org
Throttle Valve Opening Vehicle Speed (km/h)

Position Shift Change
Angle 2WD 4WD
1st → 2nd 41-56 38-53
2nd → 3rd 86-101 78-93
3rd → 4th 141-156 130-145
100% D Position
4th → 3rd 133-148 124-139
3rd → 2nd 77-92 71-86
2nd → 1st 30-45 27-42
4th → 3rd 23-38 20-35
0% D Position 3rd → 2nd 10-25 9-24
2nd → 1st 10-25 9-24
4th → 3rd 133-148 124-139
Inhibit D Position 3rd → 2nd 82-97 75-90
2nd → 1st 37-52 34-49
Lock-up
Vehicle Speed (km/h)
Throttle Valve Opening Angle Gear Position
2WD 4WD
3rd ON 110-125 100-115
5-100%
3rd OFF 99-114 89-104
4th ON 62-77 62-77
5-20%
4th OFF 58-73 58-73
7. ROAD TEST
CAUTION:
Ensure the safety of the road before performing this test.
NOTICE:
• Be sure to perform this test after checking and adjusting the
AT engine.
• Be sure to perform this test when the fluid is at its normal
• Perform this test when the air conditioning and cruise con-
trol are turned OFF.
HINT:
ROAD TEST CHART

Inspection Item Inspection and Check Procedures
Check that the transmission shifts from/to 1st ←→ 2nd ←→ 3rd ←→ 4th under normal driving condi-
D position shift function
tions (city driving).
Shift shock level when driving in D
During normal driving, check the shock level at each up-shift.
position
• Perform the kick-down operation at each gear, and check that the transmission downshifts nor-
Kick-down function mally.
• Check the shock level at kick-down.
• While driving in the 3 position and 3rd gear (at a vehicle speed of approximately 40 to 50 km/h),
shift into the 2 position and check the 2nd gear engine brake operation.
Engine brake operation
• While driving in the 2 position and 2nd gear (at a vehicle speed of approximately 20 to 30 km/h),
shift into the L position and check the operation of the 1st gear engine brake.
Shift point when the accelerator pedal Fully depress the accelerator pedal in the D position to start off, then check that the 1st to 2nd up-
is fully depressed shift speed meets the shift point.
Lightly depress the accelerator pedal when driving at a constant speed within the lock-up speed
Lockup function
range on a level road. Check that the engine speed does not change abruptly.
Park the vehicle on a slope with a grade of approximately 5 degree or more, shift to the P position,
P position operation
and release the parking brake. Check that the vehicle does not move.
GETtheMANUALS.org
AT–5
Inspection Item Inspection and Check Procedures

Abnormal noise, vibration Check for abnormal noise and vibration when driving and shifting.
• When driving on an uphill, check that the up-shift to 4th gear is prohibited.
Hill control function • When applying the brake while driving downhill in 4th gear with the accelerator pedal fully
depressed, check that the transmission downshifts to the 3rd gear.
Fluid leaks Check each unit for fluid leaks after the road test.
8. MANUAL ROAD TEST

(a) Disconnect the transmission wire connector.
(b) Check that the gear shifts to the appropriate position while driv-
ing.
Standard:
Shift Lever Position Position

D position 3rd
(c) Clear DTCs after the manual road test.
AT
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LOCATION
TRANSMISSION CONTROL COMPUTER
DLC
COMBINATION METER ASSEMBLY
STOP LIGHT SWITCH
AT
SOLENOID NO. 2
NEUTRAL START
SWITCH ASSEMBLY SOLENOID NO. 1
SWITCH SOLENOID
LUC SOLENOID SOLENOID NO. 3
DUTY SOLENOID
C135963J02
GETtheMANUALS.org
AT–7

P0705/55 No input from the neutral
× × AT-24
start switch
P0705/56 Multiple input from the
{ { AT-24
neutral start switch
P0710/38 Open or short in the fluid
{ { AT-27
temperature sensor circuit
P0711/38 Fluid temperature sensor
{ { AT-27
performance problem
P0715/37 No input for turbine speed { { AT-29
P0720/42 No input for output speed { { AT-31
P0725/86 No input for engine speed { { AT-33
P0753/61 Open or short in the sole-
{ { AT-35
noid No. 1 circuit
{ { AT-35
noid No. 2 circuit
{ { AT-35
noid No. 3 circuit
P0768/64 Open or short in the duty
{ { AT-39
solenoid circuit
P0773/65 Open or short in the LUC
{ { AT-41
solenoid circuit
P1703/72 Lock-up speed does not
{ { AT-44
match
P1706/31 Engine torque error { × AT-45
P1711/41 Throttle sensor signal
{ × AT-46
P1730/21
error
Battery system power
AT
{ { AT-47
source error
P1731/22 Sensor system power
{ { AT-50
source error
P1780/66 Open or short in the switch
{ { AT-41
solenoid circuit
U0100/82 EFI communication receiv-
{ { AT-53
ing error
U0101/85 EFI communication send-
{ { AT-53
ing error

1. Solenoid (No. 1) -
Does not upshift (any of the gears from 1st to 3rd gear
do not upshift)
3. Transmission control computer assembly AT-17
Does not upshift (3rd to 4th) 3. Solenoid (No. 3) -
4. Switch solenoid -
GETtheMANUALS.org

Does not downshift (4th to 3rd) 2. Solenoid (No. 2) -
Does not upshift (any of the gears from 1st to 3rd gear 2. Solenoid (No. 3) -
do not downshift) 3. Switch solenoid -
1. Duty solenoid -
2. LUC solenoid -
3. Turbine speed sensor system -
Lock-up does not occur or does not turn off
4. Engine coolant temperature sensor -
5. Fluid temperature sensor -
1. Throttle sensor system -
2. Output speed sensor system -
Shift point too high or too low
3. Neutral start switch assembly system -
1. Fluid temperature sensor system AT-27
Up-shift to 4th gear when transmission is cold
Harsh engagement (N → D)
1. Throttle sensor system -
Harsh engagement (when shifting to any gear)
AT 5. Transmission control computer assembly AT-17
1. Duty solenoid -
2. LUC solenoid -
Harsh engagement (Lock-up) 3. Engine speed -
Poor acceleration 2. Switch solenoid -
The engine stalls when the vehicle is stopped or when 1. Switch solenoid -
the shift lever is moved to the D or R position after the 2. Transmission control computer assembly AT-17
engine is started.
DESCRIPTION
1. DIAGNOSIS FUNCTION
(a) The O/D light blinks when a malfunction occurs in the AT sys-
tem.
NOTICE:
If the system returns to normal, the O/D light does not
come on.
GETtheMANUALS.org
AT–9
(b) The result of diagnosis regarding the time the malfunction

occurred is stored in the transmission control computer.
NOTICE:
Do not remove the ECUB fuse and battery terminals until
the inspection is completed as the memory of the com-
puter will be erased.
2. FAIL-SAFE FUNCTION
(a) If an open or short circuit occurs in any of the solenoid valve cir-
cuits, the transmission control computer turns the other sole-
noid valves ON or OFF.In addition, if all of the solenoid valves
are disabled, only the mechanical hydraulic circuit is available,
enabling manual shifting. (If an open or short circuit occurs, the
transmission control computer stops sending current to the
failed solenoid valve.
HOW TO PROCEED WITH TROUBLE-

SHOOTING
2 CONDUCT CUSTOMER PROBLEM ANALYSIS AND CHECK SYMPTOMS
HINT:
See page AT-12. AT
3 CHECK COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM FOR CONTROL
(a) Using the DS-II, check for DTCs by selecting DIAGNOSIS → VEHI-
CLE DIAGNOSIS/CAN BUS DIAGNOSIS → DIAGNOSIS FUNC-
TION/COMMUNICATION ERROR DTC CHECK.
HINT:
See page CA-9 for the CAN COMMUNICATION section.
DTC DETECTED (GO TO CAN COMMUNICA-

TION SECTION)
NO DTC (GO TO STEP 5)
4 CHECK FOR DTCS
HINT:
See page AT-13.
(a) CHECK DTC AND FREEZE FRAME DATA
GETtheMANUALS.org
(1) Record the DTCs and the freeze frame data.

(b) CLEAR DTCs AND FREEZE FRAME DATA
(c) RE-CHECK FOR DTCS
(1) Based on the DTCs and freeze frame data recorded, reproduce
the symptoms that caused the problem and re-check for the
DTCs.
HINT:
• If DTCs are output, see Diagnostic Trouble Code Chart (See
page AT-7).
• See page IN-30 for MALFUNCTION REPRODUCTION.
DTC DETECTED (GO TO STEP 8)
DTC NOT DETECTED, SYMPTOMS CANNOT

BE CONFIRMED AND REPRODUCED (GO
TO MALFUNCTION REPRODUCTION)
DTC NOT DETECTED, BUT SYMPTOMS CAN BE CONFIRMED AND REPRODUCED (GO
TO STEP 6)
5 PROBLEM SYMPTOMS TABLE
HINT:
See page AT-7.
AT RELATED TO PROBLEM SYMPTOM (GO TO

STEP 8)
NOT RELATED TO PROBLEM SYMPTOM (GO TO STEP 7)
6 PERFORM TROUBLESHOOTING BASED ON PROBLEM SYMPTOM
(a) DS-II ECU DATA LIST (See page AT-20).

(b) DS-II ACTIVE TEST (See page AT-20).
(c) MANUAL ROAD TEST (See AT-5).
(d) ECU TERMINALS (See page AT-17).
7 ADJUST, REPAIR OR REPLACE
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AT–11
8 CONFIRMATION TEST
END
AT
GETtheMANUALS.org

CHECK
Customer’s Name
First Registration Year Year Month
Model
VIN
Date Vehicle Brought In Odometer Reading km
Weather Clear Cloudy Rainy Snowy Others

Temperature Approximately
Road Conditions
Date Problem First Occurred

Month _____ Day _______ (Engine: ___Cold ___Warm)
Frequency Problem Occurs Continuous Intermittent ( ____times a day)
___Vehicle unable to move (__All shift positions ___A specific shift position [___Position])
__Does not shift up (___1st → 2nd ____2nd → 3rd ___ 3rd → 4th )
__Does not shift down (____4th → 3rd ____ 3rd → 2nd ____ 2nd → 1st)
__Poor lock up
AT
Symptoms __Poor gear change
__Large gear change shock ( N → D or R ___ Lock up ___During gear change(s)
__Poor acceleration (Slipping etc.)
__Abnormal sound or vibration
__Others ( )
MIL Condition ___On ( ) ___Off
First time ___ Normal Code Malfunction Code

DTC Inspection
Second time ___ Normal Code Malfunction Code
The first time a malfunction code is output, freeze frame data is also output.
Freeze Frame Data
G020628
GETtheMANUALS.org
AT–13
CHECK / CLEAR DTCs

1. CHECK DTCS (using DS-II)
(a) Using the DS-II, follow the prompts and display the DIAGNOSIS
- A/T screen, then select DTC FREEZE DATA.
(b) Check for DTCs.
HINT:
If the freeze frame data is recorded, "I" will be displayed on the
left side and the color of that column will be changed.
2. DS-II FREEZE FRAME DATA
(a) Using the DS-II, following the prompts on the screen, select
CHECK DTC and select the DTCs that have the records of the
freeze frame data (indicated by a "I" mark).
HINT:
• Check the consistency between the problem symptoms
from inquiry and the diagnostic trouble code chart.
• After completing repairs, conduct the confirmation test
based upon the driving conditions confirmed above.
3. CLEAR DTCS (using DS-II)
(a) Using the DS-II, follow the prompts and display the DIAGNOSIS
- A/T screen, then select DTC FREEZE DATA.
(b) Select CLEAR from the screen to clear the data.
NOTICE:
DTCs and freeze frame data will be cleared at the same
time.
4. CHECK DTCs (using check engine warning light)
ECUT (a) Short terminals 13 (ECUT) and 4 (E) of the DLC.
NOTICE:
Be sure to short the specified terminals correctly, or a mal-
function may occur.
AT
(c) Read the DTCs (count the number of times that the check
engine warning light blinks).
E
G100941
Normal Malfunction When Codes “21” And “31” Are Output

0.5 Sec. 1.5 Seconds
4. 0 Sec. 4 Seconds Continues
1 Sec.
2.5 Sec. To Repeat
0.25 Sec. 0.5 Seconds
Turns On Turns On
Turns Off Turns Off

Short In TC Terminal Short In TC Terminal
C104256J02
NOTICE:
When a letter is used such as [C1] of the DS-II code, it indi-
cates a hexadecimal value. These hexadecimal values use
two characters. When they are displayed, they blink 12
times, then once.(at even intervals)
Hexadecimal Conversion Table
Hexadecimal Number of Blinks
A 10
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Hexadecimal Number of Blinks

B 11
C 12
D 13
E 14
F 15
HINT:
• If the system is normal, the warning light will blink repeat-
edly at an interval of 0.25 seconds on and 0.25 off.
• When only one code is present, the same code will be out-
put again at 4-second intervals.
• When 2 or more DTCs are present, the different codes will
be output in series at 2.5-second intervals.When all the
codes have been output, the series will return to the begin-
ning and, after a 4.5 second pause, the codes will be output
again.
• When 2 or more codes are output, the code with the lower
number is indicated first.
(d) Turn the ignition switch off.
(e) Open the circuit between terminals 13 (ECUT) and 4 (E) of the
DLC.
5. DELETE DTCs FROM MEMORY (by removing a fuse)
(a) After repairing the trouble area, disconnect the ECUB fuse in
the engine compartment for more than 60 seconds, then recon-
nect it.
(b) Short terminals 13 (ECUT) and 4 (E) of the DLC.
ECUT NOTICE:
AT Be sure to short the specified terminals correctly, or a mal-
function may occur.
(c) Turn the ignition switch to the ON position.
(d) Check that the normal code is output.
NOTICE:
If any trouble codes are output, perform trouleshooting
again in accordance with the output codes.
E
G100941 (e) Turn the ignition switch off.
(f) Open the circuit between terminals 13 (ECUT) and 4 (E) of the
DLC.
FREEZE FRAME DATA / DTC

DETAILED INFORMATION
1. DS-II FREEZE DATA
CHECK DTC and select the DTCs that have the records of the
freeze frame data (indicated by a "I" mark).
HINT:
• Check the consistency between the problem symptoms
from inquiry and the diagnostic trouble code chart.
GETtheMANUALS.org
AT–15
• After completing repairs, conduct the confirmation test

based upon the driving conditions confirmed above.
FREEZE FRAME DATA LIST
Item Abbreviation Item Abbreviation
Engine Speed ESPD LUC Solenoid LUC
Turbine Speed RTBN Switch Solenoid SW
Output Speed ROPT Battery Voltage VOLT
Vehicle Speed SPD O/D OFF Switch O/D
Shift Position SHFT Throttle Opening Angle TANG
Solenoid No. 1 Current SOL1 Oil Temperature OTMP
Solenoid No. 2 Current SOL2 Gear Position GEAR
Solenoid No. 3 Current SOL3 Gear Ratio RATO
Duty Solenoid DUTY - -
OPERATION SUPPORT
1. INITIALIZATION OF DS-II AT LEANED VALUE
NOTICE:
• When replacing any of the transmission assembly, valve
body assembly, transmission wire, and transmission control
computer, perform the AT LEARNED VALUE INITIALIZATION.
• Wait at least 1 minute after connecting the battery terminal
before performing the initialization of the automatic trans-
mission learned values.
HINT:
Learned values will not be initialized (erased) by simply disconnecting
the negative (-) terminal of the battery.
(a) After confirming that the shift position is in the P position, con-
nect the DS-II to the DLC and turn the ignition switch ON and AT
the DS-II power ON.
NOTICE:
(b) Conduct AT learned value initialization
(1) To initialize learned values, follow the DS-II screen display,
select MAIN MENU [OPERATION SUPPORT] → OPERA-
TION SUPPORT CLASSIFICATION [A/T] → [AT LEARNED
VALUE INITIALIZATION] and run [AT LEARNED VALUE
INITIALIZATION].
HINT:
Initialization will complete in about 1 minute.
GETtheMANUALS.org
CIRCUIT DIAGRAM
Ignition Switch
IG1 IG1/BACK 7.5A
AM 60A
IG2 ECU IG 10A
C6
+B1
Neutral Start
Switch Assembly
ECUB 10A B2
BAT1 C15 4
Battery B1 P
BAT2 B7 1 7
R
C24 5
N
C17 3
D
Transmission Wire
C16 2
2
6 C6 C25 8 6
B1+ L
Solenoid No. 1
10 C5
B1-
Back-up Light
8 C4
C2+
Solenoid No. 2 Transmission
12 C3 Control Computer
C2-
7 C2
C3B2+
Solenoid No. 3 1
11 C1 C9
C3B2- VBTB Transmission
C10 2 Revolution Sensor
Duty Solenoid RTBN
3 C23
LUCC C20 3 (Turbine Speed Sensor)
ETBN
LUC Solenoid 2 C11
AT Switch Solenoid
LUCR
1 C12
SOLR
C7 1
VBOP
Oil Temperature Sensor Transmission
C8 2 Revolution Sensor
5 C14 ROPT
OTMP C18 3 (Output Speed Sensor)
9 C13 EOPT
ETMP
B24
E1
B6
E01
B5
E02
O/D Off Switch
B22
O/D1
B19
LCN1
EFI ECU
B9 Combination Meter
B16 HCN1
Starter Relay STR
B8
REG1 EFI ECU
B17
DLC
DLC3 SIO1
B10
CANH
ABS ECU
B20
CANL
C133165J03
GETtheMANUALS.org
AT–17
ECU TERMINALS
1. TRANSMISSION CONTROL COMPUTER ASSEMBLY
Connector A Connector B Connector C

C135997J01
HINT:
Using SST , check the voltage, pulse, and conductivity between the
terminals of the connector.
SST 09842-97215
TERMINAL LAYOUT
Terminal Symbol Input / Out-
Item Measurement Condition Standard
(Terminal No.) put
RTBN ←→ E1
Input Waveform Engine idle speed Waveform 1
[C10 ←→ B24]
ROPT ←→ E1
Input Waveform When driving at 20 km/h Waveform 2
[C8 ←→ B24]
VBTB ←→ E1
Output Voltage Engine is stopped, ignition switch ON 10 to 14 V
[C9 ←→ B24]
VBOP ←→ E1
[C7 ←→ B24]
REG1 ←→ E
[B8 ←→ B24]
Output Waveform Engine idle speed Waveform 3 AT
P ←→ E1
Input Voltage Shift lever in P position 7.5 to 14 V
[C15 ←→ B24]
P ←→ E1
Input Voltage Shift lever in any position other than P 0 to 1.5 V
[C15 ←→ B24]
R ←→ E1
Input Voltage Shift lever in R position 7.5 to 14 V
[B7 ←→ B24]
R ←→ E1
Input Voltage Shift lever in any position other than R 0 to 1.5 V
[B7 ←→ B24]
N ←→ E1
Input Voltage Shift lever in N position 7.5 to 14 V
[C24 ←→ B24]
N ←→ E1
Input Voltage Shift lever in any position other than N 0 to 1.5 V
[C24 ←→ B24]
D ←→ E1
Input Voltage Shift lever in D position 7.5 to 14 V
[C17 ←→ B24]
D ←→ E1
Input Voltage Shift lever in any position other than D 0 to 1.5 V
[C17 ←→ B24]
2 ←→ E1
Input Waveform Shift lever in 2nd position 7.5 to 14 V
[C16 ←→ B24]
2 ←→ E1
Input Waveform Shift lever in any position other than 2nd position 0 to 1.5 V
[C16 ←→ B24]
L ←→ E1
Input Voltage Shift lever in L position 7.5 to 14 V
[C25 ←→ B24]
L ←→ E1
Input Voltage Shift lever in any position other than L 0 to 1.5 V
[C25 ←→ B24]
GETtheMANUALS.org

(Terminal No.) put
OTMP ←→ ETMP
Input Voltage Transmission fluid temperature 20 C 3.4 V
[C14 ←→ C13]
OTMP ←→ ETMP
Input Voltage Transmission fluid temperature 80 C 1.1 V
[C14 ←→ C13]
B1+ ←→ B1-
Output Waveform Without electricity 0 to 1.5 V
[C6 ←→ C5]
B1+ ←→ B1-
Output Waveform With electricity Waveform 4
[C6 ←→ C5]
C2+ ←→ C2-
[C4 ←→ C3]
C2+ ←→ C2-
[C4 ←→ C3]
C3B2+ ←→ C3B2-
[C2 ←→ C1]
C3B2+ ←→ C3B2-
[C2 ←→ C1]
LUCC ←→ E01
Output Waveform Lock-up is OFF 0 to 1.5 V
C23 ←→ B6]
LUCC ←→ E01
Output Waveform When slip lock-up occurs Waveform 7
C23 ←→ B6]
LUCR ←→ E01
Output Voltage Without electricity 0 to 1.5 V
C11 ←→ B6]
LUCR ←→ E01
Output Voltage With electricity 10 to 14 V
C11 ←→ B6]
SOLR ←→ E01
Output Voltage Without electricity 0 to 1.5 V
C12 ←→ B6]
SOLR ←→ E01
Output Voltage With electricity 10 to 14 V
C12 ←→ B6]
AT +B1 ←→ E01
B3 ←→ B6]
BAT1 ←→ E01
Output Voltage Always 10 to 14 V
B2 ←→ B6]
BAT2 ←→ E01
B1 ←→ B6]
E1 ←→ Body Ground
- Continuity Always Continuity
[B24 ←→ Body Ground]
(a) Waveform 1 (turbine speed sensor)

5V 1 ms
5V 1ms Item Condition
Tester Connection RTBN ←→ E1
Tool Setting 5 V/DIV 1 ms/DIV
Measurement Condition Engine idle speed
HINT:
As turbine speed increases, the cycle becomes shorter.
C133030
GETtheMANUALS.org
AT–19
(b) Waveform 2 (output speed sensor)

5V 1 ms
Tester Connection ROPT ←→ E1
Measurement Condition Driving at approx. 20 km/h
HINT:
As output speed (vehicle speed) increases, the cycle becomes
shorter.
C133034
(c) Waveform 3 (engine speed signal)

5V 5 ms
Tester Connection REG1 ←→ E1
Measurement Condition Engine idle speed
HINT:
As engine speed increases, the cycle becomes shorter.
C133031
(d) Waveform 4 (solenoid No. 1)

5V 1 ms
Tester Connection B1+ ←→ B1-
Measurement Condition With electricity
HINT:
During the shift transition, the duty ratio decreases.
AT
C133032
(e) Waveform 5 (solenoid No. 2)

5V 1 ms
Tester Connection C2+ ←→ C2-
HINT:
During the shift transition, the duty ratio decreases.
C133032
(f) Waveform 6 (solenoid No. 3)

5V 1 ms
Tester Connection C3B2+ ←→ C3B2-
HINT:
During the shift transition and line pressure regulation, the duty
ratio decreases.
C133032
GETtheMANUALS.org
(g) Waveform 7 (duty solenoid)

5V 1 ms
Tester Connection LUCC ←→ E01-
Measurement Condition When slip lock-up occurs
HINT:
During the direct lock-up, the duty ratio becomes 100 %.
C133033
1. DS-II - DATA LIST
NOTICE:
In the event of a problem with intricate symptoms such as surge
or rough idling, collect sample data from another vehicle of the
same model operating under identical conditions in order to
reach an overall judgment by comparing all the items in the data
list.
ECU DATA LIST and read the data.
[ANALYSIS MENU:A/T → ECU DATA LIST]
Item
[Symbol]
Engine Speed Engine is stopped, igni-
Indicates the engine speed 0 r/min REG1 signal
[RENG] tion switch ON
Engine Speed
Indicates the engine speed Constant engine speed No significant fluctuation REG1 signal
[RENG]
Vehicle stopped with
Indicates the transmission
Turbine Speed shift lever in P or N posi- Almost the same as
AT [RTBN]
input speed
Display: r/min
tion
(when engine idling)
engine idle speed
RTBN signal

Turbine Speed Vehicle stopped with
input speed 0 r/min RTBN signal
[RTBN] shift lever in D position
Display: r/min
Turbine Speed When driving at a con-
input speed No significant fluctuation RTBN signal
[RTBN] stant speed
Display: r/min
Output Speed When the vehicle is
output shaft speed 0 km/h ROPT signal
[ROPT] stopped
Display: r/min
Output Speed When driving at a con-
output shaft speed No significant fluctuation ROPT signal
[ROPT] stant speed
Display: r/min
Indicates the vehicle speed
calculated from the output
Vehicle Speed When the vehicle is
speed by the A/T ECU 0 km/h CAN signal
[SPD] stopped
Display range: 0 to 255 km/
h
Indicates the vehicle speed
calculated from the output
Vehicle Speed When driving at a con-
speed by the A/T ECU No significant fluctuation CAN signal
[SPD] stant speed
Display range: 0 to 255 km/
h
GETtheMANUALS.org
AT–21
Item
[Symbol]
Indicates the electrical cur-
rent to the B1 solenoid (No.
Solenoid No. 1 Current B1 solenoid (No. 1)
1) 1,000 → 0 mA*1 B1 solenoid (No. 1)
[SOL1] ON → OFF
Display range: 0 to 1,200
mA
rent to the C2 solenoid (No.
Solenoid No. 2 Current C2 solenoid (No. 2)
2) 1,000 → 0 mA*1 C2 solenoid (No. 2)
[SOL2] ON → OFF
mA
rent to the C3 solenoid (No.
Solenoid No. 3 Current C3 solenoid (No. 3)
3) 1,000 → 0 mA*1 C3 solenoid (No. 3)
[SOL3] ON → OFF
mA
Indicates the ON duty ratio
Duty Solenoid LUC solenoid
of the LUC solenoid 100→0% Duty solenoid
[DUTY] ON → OFF
Display range: 0 to 100 %
Indicates the operating sta-
LUC Solenoid LUC solenoid
tus (ON/OFF) of the LUC ON → OFF Switch solenoid
[LUC] ON → OFF
solenoid
Switch Solenoid Switch solenoid
tus (ON/OFF) of the switch ON → OFF LUC solenoid
[SW] ON → OFF
solenoid
Battery Voltage Indicates the battery voltage BAT1 voltage
Engine idling 9 to 14 V
[VOLT] Display range: 0 to 25.5 V BAT2 voltage
O/D OFF Switch O/D OFF switch
tus (ON/OFF) of the O/D ON → OFF O/D1 voltage
[O/D] ON → OFF
OFF switch
Brake Switch
tus (ON/OFF) of the brake
Stop light switch
ON → OFF ABS ECU signal
AT
[BRKS] ON → OFF
switch
Indicates the throttle open- Accelerator pedal fully
Throttle Opening Angle
ing angle released → fully Continuously changes EFI ECU signal
[TANG]
Display range: 0 to 100 % depressed
Indicates the ATF tempera-
Oil Temperature Equal to outside air tem-
ture When cold (IG ON) OTMP voltage
[OTMP] perature
Display range: -50 to 205 °C
Oil Temperature Sensor circuit is open
ture -50°C OTMP voltage
[OTMP] (IG ON)
Oil Temperature Sensor circuit is shorted
ture 205°C OTMP voltage
[OTMP] (IG ON)
Gear Position Indicates the current gear Shift to each gear posi-
When driving Neutral start switch signal
[GEAR] position tion
Gear Ratio Indicates the gear ratio
- - -
[RATO] Display range: 0 to 3.999
Indicates the torque con-
verter slip volume calcu-
Torque Converter Slip Vol- lated from the engine speed
ume - turbine speed (During IG - - -
[SLIP] ON →OFF)
Display range: -5,120 to
5,080 r/min
GETtheMANUALS.org
HINT:
*1
: The value may exceed 1,000 mA due to the current feed-
back.
2. DS-II-ACTIVE TEST
ACTIVE TEST to perform the active test.
[DIAGNOSIS MENU SCREEN: A/T → ACTIVE TEST]
Item Test Contents Condition
Turns the B1 solenoid (No. 1) ON (electrical current 1 A)/OFF
Solenoid No.1
(electrical current 0 A) and cancels drive signals from the DS-II.
Turns the C2 solenoid (No. 2) ON (electrical current 1 A)/OFF
Solenoid No. 2
(electrical current 0 A) and cancels drive signals from the DS-II.
Turns the C3 and B2 solenoids (No. 3) ON (electricity current 1
IG ON
Solenoid No. 3 A)/OFF (electricity current 0 A) and cancels drive signals from
the DS-II. P position
Vehicle speed 0 km/h
Turns the LUC control (duty) solenoid ON (duty ratio 100%)/ Throttle opening angle 2 % or less
Duty Solenoid
OFF (duty ratio 0%) and cancels drive signals from the DS-II.
Turns the LUC shift solenoid ON/OFF (without electricity) and
LUC Solenoid
cancels drive signals from the DS-II.
Turns the switch solenoid ON/OFF (without electricity) and can-
Switch Solenoid
cels drive signals from the DS-II.
FAIL-SAFE CHART
If any of the codes below are stored in the ECU, the ECU enters fail-safe
mode.
DTC
Fail-safe Operation Fail-safe Mode Cancel Condition
SAE/ECTS
P0705/55 Performs the normal shifting control with the shift lever in
AT P0705/56 the D position
Canceled after normal conditions are restored
Shifts to the 3rd gear when the error is detected, then Canceled when the shift lever is moved to the
P0710/38
shifts between the 1st and 3rd gears according to the P or N position with the vehicle speed at 0 km/
P0711/38
vehicle speed and throttle opening angle h after normal conditions are restored
P0715/37 shifts between the 1st and 3rd gears according to the P or N position with the vehicle speed at 0 km/
• For sensor system errors, fail-safe opera-
tion will be canceled when the shift lever
• If the sensor system has some errors, the gear posi-
lever is moved to the P or N position with
tion that was selected at the time of the detection of
the vehicle speed at 0 km/h after normal
the error is retained, and the transmission will be
P0720/42 conditions are restored.
fixed at the 1st gear after the vehicle is stopped.
• For transmission assembly body errors,
• If the transmission assembly body has some errors,
the fail-safe operation will be canceled
the transmission will be fixed at the 1st gear.
when the ignition switch is turned off after
normal conditions are restored.
P0725/86 shifts between the 1st and 3rd gears according to the P or N position with the vehicle speed at 0 km/
P0753/61 • Prohibits sending current to the solenoid that is
P0758/62 determined to be defective
• If a short circuit occurs, normal solenoids are used
P0763/63
to shift between the 1st and 3rd gears.However, if Canceled when the ignition switch is turned
P0768/64 solenoid No. 3 and the switch solenoid are shorted, off after normal conditions are restored
P0773/65 the transmission will be fixed at 3rd gear.
• If an open circuit occurs or more than 1 solenoid has
P1780/66 faults, the transmission will be fixed at 3rd gear.
GETtheMANUALS.org
AT–23
DTC
Fail-safe Operation Fail-safe Mode Cancel Condition
SAE/ECTS
• Controls the engine torque at a constant value
Canceled when the shift lever is moved to the
• Shifts to the 3rd gear when the error is detected,
P1706/31 P or N position with the vehicle speed at 0 km/
then shifts between the 1st and 3rd gears according
h after normal conditions are restored
to the vehicle speed and throttle opening angle
• Controls the throttle opening angle at a constant
value Canceled when the shift lever is moved to the
P1711/41 • Shifts to the 3rd gear when the error is detected, P or N position with the vehicle speed at 0 km/
then shifts between the 1st and 3rd gears according h after normal conditions are restored
Canceled when the ignition switch is turned
P1730/21 Shifts to the 3rd gear after the error is detected
off after normal conditions are restored
Canceled when the ignition switch is turned
P1731/22 Shifts to the 3rd gear after the error is detected
off after normal conditions are restored
• Controls the throttle opening angle and engine
torque at a constant value Canceled when the shift lever is moved to the
U0100/82 • Shifts to the 3rd gear when the error is detected, P or N position with the vehicle speed at 0 km/
• Controls the throttle opening angle and engine
torque at a constant value Canceled when the shift lever is moved to the
U0101/85 • Shifts to the 3rd gear when the error is detected, P or N position with the vehicle speed at 0 km/
AT
GETtheMANUALS.org
DTC P0705/55 No Input from the Neutral Start Switch
DTC P0705/56 Multiple Input from the Neutral Start Switch

DESCRIPTION
The shift positions are detected based on the signals input from the neutral start switch assembly to the transmission control com-
puter assembly.
DTC No. Detection Item Trouble Area

• Wire harness and connector (transmission control com-
puter assembly - neutral start switch assembly)
P0705/55 No shift position signal is input.
• Neutral start switch assembly
• Transmission control computer assembly
• Wire harness and connector (transmission control com-
puter assembly - neutral start switch assembly)
P0705/56 Multiple shift position signals are input.
• Neutral start switch assembly
CIRCUIT DESCRIPTION
Neutral Start Switch Assembly Transmission Control Computer Assembly
P 4 C15
P
IG1/ BACK Fuse 7 RB R 1 B7 R
(7.5 A) N 5 C24
N
D 3 C17
AT 2 2 C16
D
2
6 E L 8 C25
L
C134807J01
1 INSPECT WIRE HARNESS AND CONNECTOR (POWER SOURCE SYSTEM)
HINT:
See page IN-38 for the inspection procedure and precautions for the wire
harness and connector.
GETtheMANUALS.org
AT–25
(a) Disconnect the neutral start switch assembly connector.

Neutral Starter Switch Assembly (b) Turn the ignition switch to the ON position, and using the tester, mea-
sure the terminal voltage of the wire harness side connector.
Standard:
Terminal No. (Terminal Symbols) Voltage [V]

7 (RB) ←→ Body Ground 9-14
RB NG INSPECT POWER SOURCE SYSTEM

C135998J01
OK
2 INSPECT NEUTRAL START SWITCH ASSEMBLY
(a) Using the tester, check the continuity between the terminals of the
neutral start switch assembly.
D 2
P R Standard:
4 3 2 1
Shift Position Terminal No. (Terminal Name) Continuity
8 7 6 5
P position 4 (P) ←→ 6 (E) Continuity
L N R position 1 (R) ←→ 7 (RB) Continuity
RB E N position 5 (N) ←→ 6( E) Continuity
D position 3 (D) ←→ 6 (E) Continuity
C133975J01
2 position 2 (2) ←→ 6 (E) Continuity
L position 6 (E) ←→ 8 (L) Continuity
NG REPLACE NEUTRAL START SWITCH AT

ASSEMBLY
OK
3 INSPECT WIRE HARNESS AND CONNECTOR (NEUTRAL START SWITCH ASSEMBLY - TRANSMIS-
SION CONTROL COMPUTER ASSEMBLY)
HINT:
(a) Connect the neutral start switch assembly connector.
(b) Disconnect connectors B and C of the transmission control computer
assembly.
SOLR LUCR
(d) Using a tester, check the voltage between the terminals from the wire
harness side.(For terminal layout, see page AT-17.)
Standard:
E1 LUCC
Connector B Connector C Shift Position Terminal No. (Terminal Symbols) Voltage [V]
C133974
P position C15 (P) ←→ B24 (E1) 9-14
Other than P position C15 (P) ←→ B24 (E1) 0-1.5
R position B7 (R) ←→ B24 (E1) 9-14
Other than R position B7 (R) ←→ B24 (E1) 0-1.5
N position C24 (N) ←→ B24 (E1) 9-14
GETtheMANUALS.org
Shift Position Terminal No. (Terminal Symbols) Voltage [V]

Other than N position C24 (N) ←→ B24 (E1) 0-1.5
D position C17 (D) ←→ B24 (E1) 9-14
D position C17 (D) ←→ B24 (E1) 0-1.5
2 position C16 (2) ←→ B24 (E1) 9-14
2 position C16 (2) ←→ B24 (E1) 0-1.5
L position C25 (L) ←→ B24 (E1) 9-14
L position C25 (L) ←→ B24 (E1) 0-1.5

CONNECTOR
OK
INSPECT AND REPLACE TRANSMISSION CONTROL COMPUTER ASSEMBLY
AT
GETtheMANUALS.org
AT–27
Open or Short in the Fluid Temperature Sensor

DTC P0710/38
Circuit
DTC P0711/38 Fluid temperature sensor performance problem

DESCRIPTION
The fluid temperature sensor attached inside the valve body detects the fluid temperature in the transmission fluid pressure con-
trol system circuit, and inputs the signal to the transmission control computer assembly according to the fluid temperature.
DTC No. 2.Error Status Suspected Area
3.Error Period
1. None • Wire harness and connector (fluid temperature sensor sys-
2. The fluid temperature sensor voltage is 0.15 V or less, or tem)
P0710/38
4.90 V or more • Transmission sensor (fluid temperature sensor)
3. 0.5 seconds or more • Transmission control computer assembly
1. None • Wire harness and connector (fluid temperature sensor sys-
2. The fluid temperature sensor voltage is 0.15 V or less, or tem)
P0711/38
4.90 V or more • Transmission sensor (fluid temperature sensor)
3. 0.5 seconds or more • Transmission control computer assembly
CIRCUIT DIAGRAM
Transmission Control Computer Assembly

Automatic Transmission Assembly
OTMP 5 C14
OTMP
AT
Transmission Wire
(Oil Temperature Sensor)
E 9 C13
ETMP
C134819
HINT:
1 INSPECT TRANSMISSION WIRE (FLUID TEMPERATURE SENSOR)
SST 09990-97201
GETtheMANUALS.org

OTMP (b) Connect SST (A/T solenoid wire check sub-harness).
(c) Using the tester, inspect the resistance between the terminals.
1 2 3 4 Standard:
5 6 7 8
9 10 11 12
Terminal No. (Terminal Sym- Fluid temperature
E Resistance [Ω]
bols) [°C]
5 (OTMP) ←→ 9 (E) 10 5.63
5 (OTMP) ←→ 9 (E) 140 0.072
C134820J01
(d) Using the tester, check the insulation between the terminal and body
ground.
Standard:
Terminal No. (Terminal Symbols) Resistance

5 (OTMP) ←→ Body Ground 1 MΩ or higher
NG REPAIR OR REPLACE TRANSMISSION

WIRE
OK
2 INSPECT WIRE HARNESS AND CONNECTOR (TRANSMISSION WIRE - TRANSMISSION CONTROL

COMPUTER ASSEMBLY)
HINT:
AT (a) Disconnect the transmission wire connector.
(b) Disconnect connector C of the transmission control computer assem-
bly, and using the tester, inspect the resistance between the termi-
nals.(For terminal layout, see page AT-17.)
ETMP Standard:
OTM
Fluid tempera-
Terminal No. (Terminal Symbols) Resistance [Ω]
ture [°C]
Connector C C14 (OTMP) ←→ C13 (ETMP) 10 5.63
C134821J01
C14 (OTMP) ←→ C13 (ETMP) 140 0.072
OK REPAIR OR REPLACE WIRE HARNESS OR

CONNECTOR
NG
GETtheMANUALS.org
AT–29
DTC P0715/37 No Input for Turbine Speed

DESCRIPTION
The transmission revolution sensor (turbine speed sensor) inputs input axis speed signals to the transmission control computer
assembly.
3.Error Period
• Wire harness and connector (transmission revolution
1. Idling with shift lever in P or N position, or driving in D posi-
sensor (turbine speed sensor) system)
tion
P0715/37 • Transmission revolution sensor (turbine speed sen-
2. Turbine speed signals are not input.
sor)
3. 2 seconds
HINT:
If P0715/37 is output, inspect the neutral start switch assembly first.(See page AT-59)
CIRCUIT DIAGRAM
Transmission Revolution Sensor

(Turbine Speed Sensor) Transmission Control Computer Assembly
1 C9
VBTB
2 C10
RTBN
3 C20
ETBN
B24
AT
E1
C134822
1 INSPECT TRANSMISSION REVOLUTION SENSOR (TURBINE SPEED SENSOR)
(a) Inspect the output waveform.

(b) Connect the DS-II between the C10 (RTBN) and B24 (E1) terminals
of the transmission control computer assembly connector.
(c) Set the DS-II to the oscilloscope function.
GETtheMANUALS.org
Transmission Control Computer Assembly 5V 1ms
E1
RTBN
Connector B Connector C C134823J01
Item Condition
Tool Setting 5 V/DIV, 1 ms/DIV.
Measurement Condition When idling after warm-up
HINT:
NG REPLACE TRANSMISSION REVOLUTION

SENSOR (TURBINE SPEED SENSOR)
OK
2 INSPECT WIRE HARNESS AND CONNECTOR (TRANSMISSION REVOLUTION SENSOR (TURBINE

SPEED SENSOR) - TRANSMISSION CONTROL COMPUTER ASSEMBLY)
HINT:
AT harness and connector.
(a) Disconnect the transmission revolution sensor (turbine speed sensor)
connector.
bly, and using the tester, inspect the continuity between the termi-
VBTB Standard:
RTBN
ETBN Terminal No. (Terminal Symbols) Standard

Connector C C20 (ETBN) ←→ 3 (E2) Continuity
C134821J02
C10 (RTBN) ←→ 2 (RTBN) Continuity
C9 (VBTB) ←→ 1 (V12) Continuity

CONNECTOR
OK
GETtheMANUALS.org
AT–31
DTC P0720/42 No Input for Output Speed

DESCRIPTION
The transmission revolution sensor (output speed sensor) inputs output axis speed signals to the transmission control computer
assembly.
3.Error Period
1. When driving
• Wire harness and connector (output speed system)
2. Output speed signals are not input.Or the ratio to the
P0720/42 • Transmission revolution sensor (output speed sensor)
turbine speed is abnormal.
3. 1 second
HINT:
If Ço0720/42 is output, inspect the neutral start switch assembly first.(See page AT-59)
CIRCUIT DIAGRAM

(Output Speed Sensor) Transmission Control Computer Assembly
1 C7
VBOP
2 C8
ROPT
3 C18
EOPT
B24
E1 AT
C134822J01
1 INSPECT TRANSMISSION REVOLUTION SENSOR (OUTPUT SPEED SENSOR)

(b) Connect the DS-II between C8 (ROPT) and B24 (E1) terminals of the
transmission control computer assembly connector.
E1 ROPT
Connector B Connector C
C134824J01
GETtheMANUALS.org
Item Condition
Measurement Condition When driving at 20 km/h
HINT:
As output speed increases, the cycle becomes shorter.
NG REPLACE TRANSMISSION REVOLUTION

SENSOR (OUTPUT SPEED SENSOR)
OK
2 INSPECT WIRE HARNESS AND CONNECTOR (TRANSMISSION REVOLUTION SENSOR (OUTPUT

SPEED SENSOR) - TRANSMISSION CONTROL COMPUTER ASSEMBLY)
HINT:
(a) Disconnect the turbine speed sensor connector.
bly, and using the tester, inspect the continuity between the termi-
ROPT Standard:
VBOP
Terminal No. (Terminal Symbols) Standard

C18 (EOPT) ←→ 3 (E2) Continuity
EOPT
Connector C C8 (ROPT) ←→ 2 (ROPT) Continuity
C134821J03
AT C7 (VBOP) ←→ 1 (V12) Continuity
OK REPAIR OR REPLACE WIRE HARNESS OR

CONNECTOR
NG
GETtheMANUALS.org
AT–33
DTC P0725/86 No Input for Engine Speed

DESCRIPTION
This DTC is output when engine speed signals are not input from the engine control computer to the transmission control com-
puter assembly.
3.Error Period
1. Engine is running
2. Engine speed signals from the engine control computer • Wire harness and connector (engine control computer -
P0725/86 are not input to the transmission control computer transmission control computer assembly)
assembly. • Engine control computer
3. 0.5 seconds
CIRCUIT DIAGRAM
Transmission Control Computer Assembly Engine Control Computer
B8 D4
REG1 ATNE
AT
C134825J01
HINT:
1 INSPECT WIRE HARNESS AND CONNECTOR (TRANSMISSION CONTROL COMPUTER ASSEMBLY

- ENGINE CONTROL COMPUTER)
HINT:
(a) Disconnect connector B8 (REG1) of the transmission control com-
puter assembly and connector D4 (ATNE) of the engine control com-
puter.
(b) Using a tester, check the continuity between the terminals.(See AT-17
for the transmission control computer assembly terminal layouts, and
see page ES-16 for the engine control computer terminal layouts.)
Standard:
Continuity
GETtheMANUALS.org

CONNECTOR
OK
INSPECT OR REPLACE ENGINE CONTROL COMPUTER
AT
GETtheMANUALS.org
AT–35
DTC P0753/61 Open or Short in the Solenoid No. 1 Circuit

DESCRIPTION
The transmission control computer assembly combines the ON-OFF states of solenoids No. 1, No. 2, and No. 3 to change the
drive position from the 1st to 4th.If an open or short circuit occurs in any of the solenoid valve circuits, the transmission control
computer assembly turns the other normal solenoid valves ON or OFF as a fail-safe function.In addition, if all of the solenoid
valves are disabled, only the mechanical hydraulic circuit is available, enabling manual shifting. (If an open or short circuit occurs,
the transmission control computer assembly stops sending current to the failed solenoid valve.)
DTC No. 2. Error Status Suspected Area
3. Error Period
• Wire harness and connector (solenoid No. 1 signal system)
1. When sending current to solenoid No. 1
P0753/61 2. Open or short in solenoid No. 1 circuit
• Solenoid No. 1
3. Continues for 0.03 sec. or more
P0758/62 2. Open or short in solenoid No. 2 circuit
• Solenoid No. 2
Ço0763/63 2. Open or short in solenoid No. 3 circuit
• Solenoid No. 3
CIRCUIT DIAGRAM
AT
Automatic Transmission Assembly Transmission Control Computer Assembly

B1+ 6 C6
B1+
Solenoid No. 1
B1- 10 C5
B1-
C2+ 8 C4
C2+
Solenoid No. 2
C2- 12 C3
C2-
C3B2+ 7 C2
C3B2+
Solenoid No. 3
C3B2- 11 C1
C3B2-
C134826J01
GETtheMANUALS.org
1 INSPECT TRANSMISSION WIRE (No. 1/No. 2/No. 3)
C3B2+
SST 09990-97201
B1+ (a) Disconnect the transmission wire connector.
C2+ (b) Connect the SST (A/T solenoid wire check sub-harness).
1 2 3 4 (c) Using the tester, inspect the resistance between the terminals.
5 6 7 8 Standard:
9 10 11 12
B1-
C2-
6 (B1+) ←→ 10 (B1-) 5.1 to 5.5 (20°C)
C3B2-
8 (C2+) ←→ 12 (C2-) 5.1 to 5.5 (20°C)
C134820J02
7 (C3B2+) ←→ 11 (C3B2-) 5.1 to 5.5 (20°C)
(d) Using the tester, inspect the insulation between each terminal and the
body ground.
Standard:

6 (B1+) ←→ Body ground 1 M or higher
8 (C2+) ←→ Body ground 1 M or higher
7 (C3B2+) ←→ Body ground 1 M or higher
Result:
Status Proceed to
AT Solenoid No. 1 error Go to step A
Solenoid No. 2 error Go to step B
Solenoid No. 3 error Go to step C
DTC is not output Go to OK
NG (A) GO TO STEP 3
NG (B) GO TO STEP 4
NG (C) GO TO STEP 5
OK
2 INSPECT WIRE HARNESS AND CONNECTOR (TRANSMISSION WIRE - TRANSMISSION CONTROL

COMPUTER ASSEMBLY)
HINT:
GETtheMANUALS.org
AT–37
(a) Connect the transmission wire connector, and disconnect connector

C of the transmission control computer assembly.
(b) Using the tester, inspect the resistance between the terminals.(For
terminal layout, see page AT-17.)
C2+ C2- C3B+ Standard:
B1-
C3B-
B1+
C6 (B1+) ←→ C5 (B1-) 5.1 to 5.5 (20 C)
Connector C C4 (C2+) ←→ C3 (C2-) 5.1 to 5.5 (20 C)

C134821J04
C2 (C3B2+) ←→ C1 (C3B2-) 5.1 to 5.5 (20 C)

CONNECTOR
OK
3 INSPECT SOLENOID NO. 1
(a) Disconnect the clutch control solenoid No. 2 (solenoid No. 1) connec-
tor.
(b) Using the tester, inspect the resistance between the terminals.
Standard:
5.1 to 5.5 Ω (20°C)
NG REPLACE SOLENOID NO. 1 AT

OK
REPAIR OR REPLACE TRANSMISSION WIRE
tor.
Standard:
5.1 to 5.5 Ω (20°C)
NG REPLACE SOLENOID NO. 2
OK
GETtheMANUALS.org
tor.
Standard:
5.1 to 5.5 Ω (20°C)
NG REPLACE SOLENOID NO. 3
OK
AT
GETtheMANUALS.org
AT–39
DTC P0768/64 Open or Short in the Duty Solenoid Circuit

DESCRIPTION
The transmission control computer assembly controls the duty solenoid at the predetermined duty ratio.
3. Error Period
• Wire harness and connector (LUCC signal system)
1. When sending current to the duty solenoid
• Transmission wire (LUCC signal system)
P0768/64 2. Open or short in solenoid LUCC circuit
• Duty solenoid
3. 0.33 seconds
CIRCUIT DIAGRAM
Duty Solenoid
3 C23
LUCC
LUC Solenoid
2 C11
LUCR
Switch Solenoid
1 C12
SOLR
B24
E1
C134827J01
AT
1 INSPECT TRANSMISSION WIRE (LUCC)
SST 09990-97201
LUCR LUCC
(b) Connect the SST (A/T solenoid wire check sub-harness).
SOLR (c) Using the tester, inspect the resistance between the terminals.
1 2 3 4 Standard:
5 6 7 8
9 10 11 12
3 (LUCC) ←→ Body ground 11 to 13 (20°C)
NG GO TO STEP 3
C134820J03
OK
GETtheMANUALS.org
2 INSPECT WIRE HARNESS OR CONNECTOR (TRANSMISSION WIRE - TRANSMISSION CONTROL

COMPUTER ASSEMBLY)
HINT:
For inspection procedures and precautions, see page IN-34
(a) Connect the transmission wire connector, and disconnect connectors
B and C of the transmission control computer assembly.
SOLR LUCR
Standard:

E1 LUCC
C23 (LUCC) ←→ B24 (E1) 11 to 13 (20°C)
C133974J01
CONNECTOR
OK
3 INSPECT DUTY SOLENOID
(a) Disconnect the duty solenoid connector.

(b) Using the tester, inspect the resistance between the solenoid terminal
AT and body.
Standard:
11 to 13 Ω (20°C)
NG REPLACE DUTY SOLENOID
OK
GETtheMANUALS.org
AT–41
DTC P0773/65 Open or Short in the LUC Solenoid Circuit
Switching solenoid circuit disconnection, short

DTC P1780/66
circuit
DESCRIPTION
The transmission control computer assembly controls the LUC solenoid at the predetermined duty ratio and performs lock-up.
3. Error Period
• Wire harness and connector (LUCR signal system)
1. When sending current to the LUC solenoid
• Transmission wire (LUCR signal system)
P0773/65 2. Open or short in solenoid LUCC circuit
• LUC solenoid
3. 0.04 seconds
• Wire harness and connector (SOLR signal system)
1. When sending current to the switch solenoid
• Transmission wire (SOLR signal system)
P1780/66 2. Open or short in solenoid SOLR circuit
• Switch solenoid
3. 0.04 seconds
CIRCUIT DIAGRAM
Duty Solenoid
3 C23
LUCC
LUC Solenoid
2 C11
LUCR AT
Switch Solenoid
1 C12
SOLR
B24
E1
C134827J01
1 INSPECT TRANSMISSION WIRE (LUCR, SOLR)
SST 09990-97201
LUCR LUCC
SOLR (b) Connect the SST (A/T solenoid wire check sub-harness).
1 2 3 4 (c) Using the tester, inspect the resistance between the terminals.
5 6 7 8 Standard:
9 10 11 12
2 (LUCR) ←→ Body ground 14 to 18 (20°C)
1 (SOLR) ←→ Body ground 14 to 18 (20°C)
C134820J03
GETtheMANUALS.org
Result
Status Proceed to
LUC solenoid Go to step A
Switch solenoid Go to step B
DTC is not output Go to OK
NG (A) GO TO STEP 3
NG (B) GO TO STEP 4
OK
2 INSPECT WIRE HARNESS OR CONNECTOR (TRANSMISSION WIRE - TRANSMISSION CONTROL

COMPUTER ASSEMBLY)
HINT:
For inspection procedures and precautions, see page IN-34
(a) Connect the transmission wire connector, and disconnect connectors
B and C of the transmission control computer assembly.
SOLR LUCR
Standard:
E1 LUCC Terminal No. (Terminal Symbols) Resistance [Ω]
Connector B Connector C C11 (LUCR) ←→ B24 (E1) 14 to 18 (20°C)

C133974J01 C12 (SOLR) ←→ B24 (E1) 14 to 18 (20°C)

CONNECTOR
AT
OK
3 INSPECT LUC SOLENOID
(a) Disconnect the LUC solenoid connector.

and body.
Standard:
14 to 18 Ω (20°C)
NG REPLACE LUC SOLENOID
OK
4 INSPECT SWITCH SOLENOID
(a) Disconnect the switch solenoid connector.
GETtheMANUALS.org
AT–43
and body.
Standard:
14 to 18 Ω (20°C)
NG REPLACE SWITCH SOLENOID
OK
AT
GETtheMANUALS.org
DTC P1703/72 Lock-up Speed does not Match

DESCRIPTION
This DTC is output when the engine speed and lock-up speed differ significantly during the direct lock-up.

DTC No. Suspected Area
2.Error Status
3.Error Period
1. During the direct lock-up
• Valve body assembly
2. The engine speed and lock-up speed dif-
P1703/72 • Torque converter assembly
fer significantly.
• Transmission assembly
3. 2 seconds
1 CHECK FLUID PRESSURE
(a) Lift up the vehicle.

(b) Start the engine.
(c) Gradually depress the accelerator pedal to shift to the 3rd gear, and
keep accelerating. Measure the LUC ON pressure and LUC OFF
pressure during the direct lock-up.
Standard:
617 - 715 kPa (6.5 - 7.3 kgf/cm) (LUC ON pressure - LUC OFF
pressure)
HINT:
To measure the fluid temperature again after the warning is dis-
AT played, stop the vehicle, shift to the N position (release the fail), and
shift to the D position again. Then start the measurements.
NG REPLACE VALVE BODY ASSEMBLY
OK
2 INSPECT TORQUE CONVERTER
HINT:
See page IN-34 for the inspection procedure of the torque converter
assembly.
NG REPLACE TORQUE CONVERTER
OK
REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY
GETtheMANUALS.org
AT–45
DTC P1706/31 Engine Torque Error

DESCRIPTION
P1706/31 Engine system error Engine system
1 INSPECT ENGINE CONTROL SYSTEM
(a) Check for DTCs of the engine system using the DS-II.(See page ES-
8 for procedures) (See page ES-3 for the DTC chart)
GO TO DIAGNOSTIC TROUBLE CODE CHART
AT
GETtheMANUALS.org
DTC P1711/41 Throttle sensor signal error

DESCRIPTION
P1711/41 Throttle sensor system errors Throttle sensor system
1 INSPECT ENGINE CONTROL SYSTEM
(a) Inspect the throttle sensor system.(See page ES-39)
GO TO THROTTLE SENSOR SYSTEM
AT
GETtheMANUALS.org
AT–47
DTC P1730/21 Battery System Power Source Error

DESCRIPTION
This DTC is output when the battery system power source (BAT1, BAT2) is abnormally cut off for a certain period of time.

DTC No. Suspected Area
2.Error Status
3.Error Period
1. Always
Wire harness or connector (battery power source
2. Battery system power source (BAT1, BAT2) is cut
P1730/21 system)
off.
3. 0.1 seconds
CIRCUIT DIAGRAM
ECUB 10A B2
BAT1
B1
BAT2
Battery
AT
C135132J01
1 INSPECT TRANSMISSION CONTROL COMPUTER ASSEMBLY (VOLTAGE INSPECTION)
(a) Measure the voltage between the terminals of the transmission con-
trol computer connector using the tester.
E01 BAT1 BAT2 Terminal (Terminal Name) Standard
B2 (BAT1) - B6 (E01) 10 to 14 V
B1 (BAT2) - B6 (E01) 10 to 14 V
OK HOW TO TROUBLESHOOT ECU CON-

Connector B
TROLLED SYSTEMS
C134828J02
NG
GETtheMANUALS.org
2 INSPECT FUSE (ECUB)
(a) Remove the ECUB fuse from the engine room R/B.
Engine Room R/B (b) Using a tester, check for continuity.
Standard:
ECUB Fuse
Continuity
NG REPLACE FUSES
C136002
OK
3 INSPECT WIRE HARNESS OR CONNECTOR (TRANSMISSION CONTROL COMPUTER ASSEMBLY -

ECUB FUSE)
HINT:
(a) Disconnect connector B of the transmission control computer assem-
bly.
(b) Remove the ECUB fuse from the engine room R/B.
(c) Using the tester, check for continuity and short between the vehicle
side connector of the transmission control computer assembly and
BAT1 BAT2 the ECUB fuse holder.(For terminal layout, see page AT-17.)
AT
Connector B
Engine Room R/B
ECUB Fuse
2
1
C136003
Standard:
Terminal (Terminal Name)
Transmission control computer assembly ←→ ECUB fuse Standard
holder
There is continuity and no short between the other terminals or body
B2 (BAT1) ←→ 2
ground.
There is continuity and no short between the other terminals or body
B1 (BAT2) ←→ 2
ground.
NOTICE:
When taking the measurement using the tester probe, do not press
the tester probes too hard as it may cause damage to the holder part.
GETtheMANUALS.org
AT–49

CONNECTOR
OK
AT
GETtheMANUALS.org
DTC P1731/22 Sensor System Power Source Error

DESCRIPTION
This DTC is output when there is no input from the speed sensor systems for a certain period of time.
3.Error Period
• CHECK WIRE HARNESS OR CONNECTOR
(SPEED SENSOR POWER SOURCE SYS-
1. Always TEM)
P1731/22 2. No input from the turbine speed sensor and output speed sensor • Transmission revolution sensor (turbine speed
3. 0.1 seconds sensor)
• Transmission revolution sensor (output speed
sensor)
CIRCUIT DIAGRAM
Transmission Revolution Sensor Transmission Control Computer Assembly

(Turbine Speed Sensor)
1 C9
VBTB
2 C10
RTBN
3 C20
ETBN

(Output Revolution Sensor)
1 C7
AT 2 C8
VBOP
ROPT
3 C18
EOPT
B24
E1
B6 E01
B5
E02
C135133J01
GETtheMANUALS.org
AT–51
1 INSPECT WIRE HARNESS OR CONNECTOR (TRANSMISSION CONTROL COMPUTER ASSEMBLY -

BODY GROUND)
HINT:
(a) Disconnect connector C of the transmission control computer assem-
VBTB bly.
(b) Using the tester, check the continuity between the terminals.(For ter-
minal layout, see page AT-17.)
VBOP Standard:
Terminal No. (measurement terminal) Standard
C134821J05 C9 (VBTB) ←→ Body ground Continuity
C7 (VBOP) ←→ Body ground Continuity

CONNECTOR
OK
2 INSPECT TRANSMISSION REVOLUTION SENSOR (TURBINE SPEED SENSOR)

(b) Turn the ignition switch to the ON position, and follow the prompts on
the DS-II screen to check for DTCs.(See page AT-13)
(c) When disconnecting the vehicle side connector of the transmission
revolution sensor (turbine speed sensor), check that P1731/22 will be
AT
cleared.
Standard:
DTC P1731/22 is cleared.
HINT:
When disconnecting the vehicle side connector of the transmission
revolution sensor (turbine speed sensor), take notice that P0715/37
will be displayed.
OK REPLACE TRANSMISSION REVOLUTION

SENSOR (TURBINE SPEED SENSOR)
NG
3 INSPECT TRANSMISSION REVOLUTION SENSOR (OUTPUT SPEED SENSOR)

(b) Turn the ignition switch to the ON position, and follow the prompts on
the DS-II screen to check for DTCs.(See page AT-13)
(c) When disconnecting the vehicle side connector of the transmission
revolution sensor (output speed sensor), check that P1731/22 will be
cleared.
Standard:
DTC P1731/22 is cleared.
GETtheMANUALS.org
HINT:
When disconnecting the vehicle side connector of the transmission
revolution sensor (output speed sensor), take notice that P0720/42
will be displayed.
NG HOW TO TROUBLESHOOT ECU CON-

TROLLED SYSTEMS
OK
REPLACE TRANSMISSION REVOLUTION SENSOR (OUTPUT SPEED SENSOR)
AT
GETtheMANUALS.org
AT–53
DTC U0100/82 EFI Communication Receiving Error
DTC U0101/85 EFI Communication Sending Error

DESCRIPTION
Cannot receive communication signals from the engine control
U0100/82 CAN communication
computer.
Cannot send communication signals from the engine control com-
U0101/85 CAN communication
puter.
1 READ DTCS
(a) Record the DTCs.

HINT:
If a CAN communication error DTC and corresponding sensor error DTC
are output at the same time, troubleshoot the sensor error codes after the
communication returns to normal.
GO TO TROUBLESHOOTING FOR CAN COMMUNICATION SYSTEM
AT
GETtheMANUALS.org
AT–54 AUTOMATIC TRANSMISSION - AUTOMATIC TRANSMISSION ASSEMBLY

TRANSMISSION
/ TRANSAXLE
PRECAUTIONS
1. Before disassembly, clean any sand or mud attached to the out-
side of the transmission to prevent it from entering the inside of
the transmission.
2. As any foreign matter remaining in the oil pan may enter the
valve body, do not place the oil pan side upward until the oil pan
is removed.
3. When removing and installing the transmission parts, perform
the operation wearing vinyl gloves or with bare hands.Do not
use cotton work gloves or waste clothes to avoid getting cotton
threads or particles in the parts.
4. Always organize and arrange the dismounted parts properly to
protect them from dust or other foreign matter.
5. Coat the sliding and rotating surfaces with ATF before installa-
tion.
6. As it will cause fluid leakage, be extremely careful not to damage
the fitting surfaces of the case.
7. Use ATF as the fluid to be added.
8. The fluid level check is not needed for the periodic mainte-
nance.However, if the bleeding or leakage can be found, check
the fluid level.
AT
GETtheMANUALS.org
AUTOMATIC TRANSMISSION - AUTOMATIC TRANSMISSION FLUID
AT–55
AUTOMATIC TRANSMISSION FLUID

TRANSMISSION
/ TRANSAXLE
INSPECTION
1. TRANSMISSION FLUID
NOTICE:
• If the fluid level is too high or too low, it may cause trouble.
• Check the idle speed before this inspection.
• Stop the vehicle on a level road.
• Perform this inspection with the transmission fully warmed-
up (ATF temperature 70 to 90°C).
• Use ATF as the fluid to be added.
(a) Apply the parking brake.
(b) Start the engine with the brake pedal depressed.
(c) With the engine idling, slowly move the shift lever from the P to
the L position, then return it to the P position.
(d) With the engine idling, pull out the level gauge and wipe off the
fluid on the gauge with a waste cloth. Re-insert the level gauge
and confirm that the fluid level is within the HOT range of the
level gauge.
H C
NOTICE:
• When the fluid temperature is low (20 to 30 °C), such as
when changing the fluid, adjust the fluid level to the
HOT COLD COOL range of the level gauge, then re-check the fluid
(70 -90 ) level with the transmission fully warmed-up.
C143536 • If the fluid levels differ between the front and back sides
of the gauge, check with the lower level.
(e) If the fluid level is low, check for fluid leaks.
AT
GETtheMANUALS.org
AT–56 AUTOMATIC TRANSMISSION - NEUTRAL START SWITCH ASSEMBLY

TRANSMISSION
/ TRANSAXLE
COMPONENTS
T=18.2{185}
T=12.8{130}
TRANSMISSION CONTROL SHAFT LEVER

T=9.2{94}
AT TRANSMISSION CONTROL CABLE

T=5.4{5.5}

C139188J04
REMOVAL
3. DISCONNECT TRANSMISSION CONTROL CABLE ASSEM-

BLY(See page AT-70)
4. REMOVE TRANSMISSION CONTROL SHAFT LEVER

(a) Move the shift lever to the neutral position.
GETtheMANUALS.org
AUTOMATIC TRANSMISSION - NEUTRAL START SWITCH ASSEMBLY
AT–57
(b) Remove the nut, and remove the transmission control shaft
lever from neutral start switch assembly.
5. REMOVE NEUTRAL START SWITCH ASSEMBLY

C137009
(b) Disconnect the wire harness clamp.

Clamp
Connector
C136922
(c) Remove the bolt and neutral start switch assembly.
INSTALLATION
AT
C136924J02
1. INSTALL NEUTRAL START SWITCH ASSEMBLY

(a) Temporarily install the neutral start switch assembly with the
bolt
(b) Temporarily install the transmission control shaft lever.
C136924
(c) Turn the transmission control shaft lever counterclockwise until

it stops (P position), and turn it clockwise 2 notches to set it to
the N position.
P
N R
C136977J01
GETtheMANUALS.org
AT–58 AUTOMATIC TRANSMISSION - NEUTRAL START SWITCH ASSEMBLY
(d) Install the SST and turn the switch part so that the gauge part of
the SST and the standard line of the neutral start switch assem-
bly match. Tighten the bolt to the specified torque.
SST 09302-87201
Reference Line Torque: 18.2 N*m (185 kgf*cm)
SST
C141978
(e) Connect the connector to the neutral start switch assembly.

Clamp 2. FULLY TIGHTEN TRANSMISSION CONTROL SHAFT LEVER
Connector (a) Tighten the transmission control shaft lever with the nut.
3. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY(See

page AT-75)
C136922
5. INSPECT NEUTRAL START SWITCH ASSEMBLY
(a) Depress the parking brake pedal and turn the ignition switch to
the ON position.
(b) Depress the brake pedal and check that the engine starts when
the shift lever is set in the N or P position, but does not start in
other positions.
(c) Check that the back-up light comes on and the reverse position
warning buzzer sounds when the shift lever is set in the R posi-
tion, but do not function in other positions.
AT 6. INSTALL ENGINE UNDER COVER RR RH
ADJUSTMENT
1. ADJUST NEUTRAL START SWITCH ASSEMBLY
(a) Move the shift lever to the neutral position.
(b) Remove the bolt and transmission control cable.
NOTICE:
Do not move the control cable end for more than 8 degrees
and do not apply load to the control cable end.
(c) Remove the nut and transmission control shaft lever.
(d) Loosen the mounting bolt of the neutral start switch assembly.
C138435
GETtheMANUALS.org
AUTOMATIC TRANSMISSION - NEUTRAL START SWITCH ASSEMBLY
AT–59
(e) Install the SST and turn the switch part so that the gauge part of
the SST and the standard line of the neutral start switch assem-
bly match.
SST 09302-87201
Reference Line (f) Tighten the mounting bolt of the neutral start switch assembly.
SST
(g) Install the transmission control shaft lever with the nut.
(h) Install the transmission control cable with the bolt.
C141978 (i) After adjustment, inspect the neutral start switch assembly.
INSPECTION
1. CHECK CONTINUITY
(a) Using the tester, check the continuity between the terminals of
D 2
P R the connector.
Standard:
4 3 2 1
8 7 6 5 Terminal No. (Terminal
Shift Position Continuity
Symbols)
L N
RB E P position 6 (E) ←→ 4 (P) Continuity
R position 1 (R) ←→ 7 (RB) Continuity
C133975J01
N position 6 (E) ←→ 5 (N) Continuity
D position 6 (E) ←→ 3 (D) Continuity
2 position 6 (E) ←→ 2 (2) Continuity
L position 6 (E) ←→ 8 (L) Continuity
AT
GETtheMANUALS.org
AT–60 AUTOMATIC TRANSMISSION - TORQUE CONVERTER AND DRIVE PLATE
TORQUE CONVERTER AND DRIVE PLATE

TRANSMISSION
/ TRANSAXLE
INSPECTION
1. INSPECT TORQUE CONVERTER ASSEMBLY
Sample of A/T Fluid particles (a) Determine the condition of the torque converter assembly.
(1) If the inspection result of the torque converter meets the
replacement standards, replace the torque converter.
Standard:
Some metallic sounds are heard from the torque
converter unit during the stall test or when the shift
lever is in the N position.
The one-way clutch is free or locked in both direc-
tions.
Fine powder exceeding the sample limit is identified
in the ATF (see the sample).
HINT:
The ATF powder sample shows approximately 25 ml of
ATF (one bottle of 35 mm film case) taken from the
removed converter.
(b) Replace the ATF in the torque converter.
(1) If the ATF is discolored and/or has a foul odor, completely
stir the ATF in the torque converter and drain it with the
Sample of Actual Item Enlarged installation face up.
C051621J01
(c) Clean and inspect the oil cooler and oil pipe line.
Example Of Scratches Inside T/C Set Block (1) If the torque converter inspection and the ATF replace-
AT Standard Part Defective Part ment are performed, clean the oil cooler and pipe line.
HINT:
• Spray compressed air of 196 kPa (2kgf/cm2) from the
inlet hose.
Contact • If a lot of fire powder is found in the ATF, add new ATF
Damage
using a bucket pump and clean it again.
(Deep Hole)
(2) If the ATF is cloudy, inspect the oil cooler (radiator).
G020455J01
(d) Prevent deformation of the torque converter and damage to the

oil pump gear.
Representative Example of Operation
(1) If there is any damage to the end of the torque converter
mounting bolt and the bottom of the torque converter
mounting hole, replace the bolt and torque converter.
(2) All of the mounting bolts should be the same length (0.5
mm or shorter).
C062941
GETtheMANUALS.org
AUTOMATIC TRANSMISSION - TORQUE CONVERTER AND DRIVE PLATE
AT–61
2. INSPECT DRIVE PLATE AND RING GEAR

(a) INSPECT DRIVE PLAGE
(1) Using a dial indicator, check the runout of the drive plate.
Standard:
0.25 mm
HINT:
If the value is not as specified, replace the drive plate and
ring gear.
(b) INSPECT RING GEAR
C081014 (1) Check the ring gear for damage.
HINT:
If the ring gear is damaged, replace the drive plate and
ring gear.
AT
GETtheMANUALS.org
AT–62 AUTOMATIC TRANSMISSION ― TRANSMISSION REVOLUTION SENSOR
TRANSMISSION REVOLUTION SENSOR

TRANSMISSION
/ TRANSAXLE
COMPONENTS
O-RING
T=8.4{85}
x7 TRANSMISSION
REVOLUTION SENSOR
O-RING (OUTPUT SPEED SENSOR)
T=5.4{55}
T=8.4{85}
TRANSMISSION REVOLUTION
SENSOR (TURBINE SPEED
SENSOR )
x4 ENGINE UNDER COVER RR LH

AT T=5.4{55}
4WD
T=68{693}
FRONT PROPELLER
SHAFT ASSEMBLY
T=68{693}
FRONT SUSPENSION CROSS

T=60.3{615} MEMBER LWR
x4
APPLY ATF
C140801J02
GETtheMANUALS.org
AUTOMATIC TRANSMISSION ― TRANSMISSION REVOLUTION SENSOR
AT–63
REMOVAL
4. DRAIN TRANSFER FLUID (FOR 4WD)(See page TF-7)
5. REMOVE FRONT SUSPENSION CROSS MEMBER LWR (FOR

4WD)(See page PR-3)
6. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (FOR

4WD)(See page PR-3)
7. REMOVE TRANSMISSION REVOLUTION SENSOR

(b) Remove the bolt, each transmission revolution sensor, and O-
ring.
INSTALLATION
1. INSTALL TRANSMISSION REVOLUTION SENSOR
(a) Coat a new O-ring with ATF and install it to the transmission
revolution sensor.
(b) Install each transmission revolution sensor with the bolt.
2. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (FOR

4WD)(See page PR-4)
3. INSTALL FRONT SUSPENSION CROSS MEMBER LWR (FOR

4WD)(See page PR-4) AT
4. ADD TRANSFER FLUID (FOR 4WD)(See page TF-6)
8. CHECK DS-II - ECU DATA LIST
INSPECTION
1. TRANSMISSION REVOLUTION SENSOR (TURBINE SPEED SEN-
SOR)
(b) Connect the DS-II between the C10 (RTBN) and B24 (E1) ter-
minals of the transmission control computer assembly connec-
tor.
GETtheMANUALS.org
AT–64 AUTOMATIC TRANSMISSION ― TRANSMISSION REVOLUTION SENSOR
E1
RTBN
C134823J01
Item Condition
Measurement Condition When idling after warm-up
HINT:
2. TRANSMISSION REVOLUTION SENSOR (OUTPUT SPEED SEN-

SOR)
(b) Connect the DS-II between C8 (ROPT) and B24 (E1) terminals
of the transmission control computer assembly connector.
AT
E1 ROPT
C134824J01
Item Condition
Measurement Condition Driving at 20 km/h
HINT:
As output speed increases, the cycle becomes shorter.
GETtheMANUALS.org
AUTOMATIC TRANSMISSION ― AUTOMATIC TRANSMISSION ASSEMBLY
AT–65

TRANSMISSION
/ TRANSAXLE
COMPONENTS
AIR CLEANER
ASSEMBLY
T=7.5{75}
×2
T=18{184}
×2×2
T=8.0{82}
BATTERY
AT
ENGINE UNDER COVER
×7
×4
T=5.4{55}
×11
T=5.4{55}
T=5.4{55}
×11
TIGHTENING TORQUE [N*m{kgf*cm}] C141337J01
GETtheMANUALS.org
AT–66 AUTOMATIC TRANSMISSION ― AUTOMATIC TRANSMISSION ASSEMBLY
T=7.5{76}
T=21{214}
×2
T=7.5{76}
×2
THROTTLE
BODY ASSEMBLY THROTTLE BODY BRACKET NO. 2
T=19{194} O-RING
THROTTLE BODY BRACKET
×3 T=21{214}
×2
T=19{194}

VENTILATION HOSE
INTAKE MANIFOLD TO HEAD GASKET
INTAKE MANIFOLD T=21{204}

FUEL DELIVERY PIPE
×2
AT
×4
×4
O-RING
×4
FUEL INJECTOR
ASSEMBLY
INJECTOR VIBRATION
INSULATOR
T=37{377}
T=37{377} ×2
STARTER ASSEMBLY
C141354J01
GETtheMANUALS.org
AT–67
EXHAUST PIPE GASKET
T=19{194}
T=19{194}
T=46{469}
EXHAUST PIPE GASKET
T=60{612}
×4
AT
T=60{612}
×4
PROPELLER WITH CENTER

×2 BEARING SHAFT ASSEMBLY
T=37{377}
NON-REUSEABLE PART TIGHTENING TORQUE [N*m{kgf*cm}]
C141353J01
GETtheMANUALS.org
4WD
×7
T=37{375}
T=36.8{375}
T=7.9{80}
OIL COOLER
HOSE
T=34.3{349}
×2
OIL COOLER TUBE GASKET
TRANSFER ASSEMBLY
OIL COOLER HOSE
T=58.8{596}
T=58.8{596}

ASSEMBLY
O-RING
T=84.5{85}
x6
AT
TRANSMISSION
T=58.8{596} SENSOR

T=36.8{375}
T=68{693}
T=68{693}
T=37{375}
T=68{693}
FRONT SUSPENSION
T=68{693}
C139184J09
GETtheMANUALS.org
AT–69
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE(See page EM-146)
5. DRAIN AUTOMATIC TRANSMISSION FLUID

(a) Remove the drain plug and gasket, and drain the fluid.
6. DRAIN TRANSFER FLUID (FOR 4WD)(See page TF-7)
7. DRAIN ENGINE COOLANT(See page CO-9)
9. REMOVE AIR CLEANER ASSEMBLY(See page EM-146)
10. REMOVE VENTILATION HOSE(See page EM-147)
12. DISCONNECT ACCELERATOR CONTROL CABLE ASSEM-

BLY(See page EM-147)
13. REMOVE FUEL HOSE NO. 2(See page EM-148)
14. DISCONNECT VACUUM HOSE ASSEMBLY(See page EM-148)
15. REMOVE FUEL DELIVERY PIPE(See page EM-149)
16. REMOVE THROTTLE BODY ASSEMBLY(See page EM-148)
17. REMOVE THROTTLE BODY BRACKET(See page EM-149)
18. REMOVE FUEL INJECTOR ASSEMBLY(See page EM-149)

AT
19. REMOVE INTAKE MANIFOLD(See page EM-149)
20. DISCONNECT EXHAUST PIPE ASSEMBLY FR(See page MT-10)

4WD)(See page PR-3)

BLY(See page PR-6)

4WD)(See page PR-3)
24. REMOVE STARTER ASSEMBLY(See page MT-10)

25. REMOVE TORQUE CONVERTER SET BOLT
(a) Remove the 6 torque converter set bolts.
26. SUSPEND ENGINE ASSEMBLY(See page MT-12)

MISSION)(See page MT-12)
C135144
GETtheMANUALS.org

(a) Remove clip and bolt, and disconnect the transmission control
cable assembly from the neutral start switch.
NOTICE:
Do not move the control cable end for more than 8 degrees
C138435
29. DISCONNECT CONNECTOR

Clamp (a) Disconnect the neutral start switch connector.
(b) Disconnect the transmission solenoid connector and the 2
Connector transmission revolution sensor connectors.
C136922
(c) Remove the bolt and earth wire.
AT
C141255
30. REMOVE OIL COOLER TUBE

(a) Remove the 2 union bolts, then disconnect the oil cooler tube
from the transmission assembly.
C141253
GETtheMANUALS.org
AT–71
(b) Remove the bolt, then disconnect the oil cooler tube clamp from
the transmission assembly.
31. REMOVE ENGINE REAR SUPPORT MEMBER(See page MT-12)
C141254

SION)
A (a) Remove the 6 bolts and automatic transmission assembly.
HINT:
When removing bolts A, use an extension bar (600 mm).
A NOTICE:
• Using a belt, secure the automatic transmission assem-
bly to the high mission jack to prevent the automatic
transmission assembly from falling.
C136910J03 • To avoid damage to the knock pin, do not pry the con-
necting portion of the automatic transmission assembly
and the engine.
33. REMOVE TORQUE CONVERTER ASSEMBLY

(a) Put matchmarks on the converter and case.
(b) Remove the torque converter assembly from the automatic
transmission assembly.
34. REMOVE ENGINE MOUNTING BRACKET RR (FOR 2WD)(See

page MT-13) AT
35. REMOVE TRANSFER ASSEMBLY (FOR 4WD)(See page TF-9)
INSTALLATION
1. INSTALL TRANSFER ASSEMBLY (FOR 4WD)(See page TF-10)
2. INSTALL ENGINE MOUNTING BRACKET RR NO. 1

(a) Install the engine mounting bracket RR No. 1 to the transmis-
sion assembly with the 3 bolts.
3. INSTALL TORQUE CONVERTER ASSEMBLY

(a) Clean the mounting hole of the converter set bolt on the drive
plate.
(b) Apply MP grease to the edge of the torque converter assembly.
(c) Aligning the matchmarks on the case and converter, engage the
spline of the input shaft with the spline of the turbine liner.
NOTICE:
Perform this operation while keeping the converter level.
GETtheMANUALS.org
(d) After installing the torque converter, measure dimension A from

the edge surface of the housing to the converter set block.
Standard:
16.5 mm or more from the T/M fitting surface
A
4. TEMPORARILY TIGHTEN TRANSMISSION ASSEMBLY (AUTO-
MATIC TRANSMISSION)
(a) Check that 2 knock pins are attached to the engine side.
(b) Using a high-mission jack, level the engine and automatic trans-
mission assembly, and engage the knock pin with the knock pin
C138322
hole.
NOTICE:
• To protect the oil pan, place the high-mission jack
attachment on the receiving stand of the high-mission
jack and perform the tasks.
• Check that the high-mission jack attachment and oil
pan are on the center of the receiving stand of the high-
mission jack.
• Do not forcibly twist the transmission assembly.
NOTICE:
• Do not shake the transmission unit assembly violently
as doing so may cause damage to the input shaft.
• Tighten the bracket of the rear O2 sensor together.
5. INSTALL ENGINE REAR SUPPORT MEMBER(See page MT-14)
6. FULLY TIGHTEN TRANSMISSION ASSEMBLY (AUTOMATIC

TRANSMISSION)
C143537 (a) Lower the vehicle.
AT
(b) Using a pri set torque wrench, tighten new mounting bolt A of
HINT:
Bolt A part number 91619-61250 (Length under bolt head 50
mm)
A
C141308
GETtheMANUALS.org
AT–73
7. INSTALL TORQUE CONVERTER SET BOLT

(a) Install the 6 torque converter set bolts.
NOTICE:
• First, tighten the standard bolt (blue silver white color
plating).
• Tighten the remaining 5 bolts uniformly.

(a) Temporarily install the starter assembly with the 2 bolts.
C135144
(b) Connect the starter assembly connector with the nut.

(c) Lift up the vehicle.
(d) Using a high-mission jack, support the engine rear support
member.
C141257
(e) Remove the 4 bolts and disconnect the engine rear support
member.
AT
A133258
(f) Using an extension bar (600 mm), tighten the 2 starter assem-
bly mounting bolts.
HINT:
Adjust the height of the transmission assembly using a high-
mission jack, and tighten the 2 starter assembly mounting bolts.
A138815
9. FULLY TIGHTEN TRANSMISSION ASSEMBLY (AUTOMATIC

A A
TRANSMISSION)
(a) Tighten the transmission assembly mounting bolts in the order
B of A, B, C.
Torque: 59 N*m (602 kgf*cm) Bolt A
HINT:
C
• Bolt A, B product number 90041-19968 (Length under bolt
head 57 mm)
C
C C C139312J03 • Bolt C product number 91612-61040 (Length under bolt
head 40 mm)
GETtheMANUALS.org
(1) Using an extension bar (600 mm), tighten the 2 new bolts
A.
A NOTICE:
When tightening bolts A, tighten the clamp of water
bypass pipe No. 2 together.
HINT:
Bolt A product number 90041-19968 (Length under bolt
head 57 mm)
C141323
(2) Using an extension bar (600 mm), tighten 2 bolts B.

NOTICE:
B Tighten the C2 sensor bracket together.
HINT:
B Bolt B product number 90041-19968 (Length under bolt
AT head 57 mm)
C143602
(3) Tighten 4 bolts C.

HINT:
Bolt C product number 90119-10260 (Length under bolt
head 40 mm)
C
C C C143601
GETtheMANUALS.org
AT–75

(a) Install the transmission control cable assembly to the neutral
start switch with the bolt.
NOTICE:
Do not move the control cable end for more than 8 degrees,
C138435
11. INSTALL OIL COOLER TUBE

C141253
(b) Temporarily install the oil cooler tube clamp with the bolt.
(d) Tighten the mounting bolt of the clamp.
AT
C141254
12. CONNECT CONNECTOR

Clamp (a) Connect the neutral start switch connector.
(b) Connect the trans solenoid connector and the 2 transmission
Connector revolution sensor connectors.
C136922
(c) Install the earth wire to the transmission body with the bolt.
C141255
GETtheMANUALS.org
(d) Install the wire harness clamp of the oxygen sensor assembly.
A133302
(e) Install the engine rear support member with the 4 bolts.
13. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (FOR

4WD)(See page PR-4)

BLY(See page PR-7)
15. INSTALL FRONT SUSPENSION CROSS MEMBER LWR(See page

PR-4)
A133258
16. INSTALL EXHAUST PIPE ASSEMBLY FR(See page EX-2)
17. INSTALL INTAKE MANIFOLD(See page EM-164)
18. INSTALL THROTTLE BODY ASSEMBLY(See page EM-164)
19. INSTALL FUEL INJECTOR ASSEMBLY(See page EM-164)
20. INSTALL FUEL DELIVERY PIPE(See page EM-165)
21. CONNECT VACUUM HOSE ASSEMBLY(See page EM-165)

AT 22. CONNECT ACCELERATOR CONTROL CABLE ASSEMBLY(See
page EM-165)
23. INSTALL VENTILATION HOSE(See page EM-166)
25. INSTALL AIR CLEANER ASSEMBLY(See page EM-167)
27. INSTALL BATTERY
29. ADD AUTOMATIC TRANSMISSION FLUID(See page AT-55)
30. ADD TRANSFER FLUID (FOR 4WD)(See page TF-6)
31. ADD ENGINE COOLANT(See page CO-9)
33. CHECK COOLANT LEVEL(See page CO-10)
34. CHECK FOR FUEL LEAKS(See page EM-167)
36. INSTALL ENGINE UNDER COVER RR RH
GETtheMANUALS.org
AT–77
39. INSPECT ENGINE IDLE SPEED(See page EM-2)
40. INITIALIZE DS-II AT LEARNED VALUE

(See page AT-15)
AT
GETtheMANUALS.org
AT–78 AUTOMATIC TRANSMISSION ― TRANSMISSION FLOOR SHIFT ASSEMBLY

TRANSMISSION
/ TRANSAXLE
COMPONENTS
CONSOLE BOX ASSEMBLY RR
CONSOLE BOX REAR COVER
CONSOLE BOX CARPET
T=18.1{185}
×4
AT
TRANSMISSION CONTROL CABLE

ASSEMBLY
CLIP
CLIP

C143659J01
GETtheMANUALS.org
AUTOMATIC TRANSMISSION ― TRANSMISSION FLOOR SHIFT ASSEMBLY
AT–79
REMOVAL
(b) Remove the 2 clips, and disconnect the transmission control
cable end from the transmission floor shift assembly.
NOTICE:
or do not apply load to the control cable end.
2. REMOVE CONSOLE BOX ASSEMBLY RR (See page IP-9)
3. DISCONNECT SHIFT LOCK RELEASE CABLE ASSEMBLY

(a) Disconnect the shift lock release cable end from the transmis-
sion floor shift assembly.
C138326
4. REMOVE TRANSMISSION FLOOR SHIFT ASSEMBLY

(a) Disconnect the wire harness clamp.
(b) Remove the 4 bolts and transmission floor shift assembly.
INSTALLATION
C138325
1. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY

(a) Install the transmission floor shift assembly with the 4 bolts. AT
(b) Install the wire harness clamp.
2. CONNECT SHIFT LOCK RELEASE CABLE ASSEMBLY

(a) Install the shift lock release cable end to the transmission floor
shift assembly.
C138325

(a) Install the transmission control cable assembly to the transmis-
sion floor shift assembly with 2 new clips.
NOTICE:
:Install the eye-end first.
:Do not move the control cable end for more than 8
degrees, and do not apply load to the control cable end.
(b) Connect the end of the control cable to the transmission floor
shift assembly.
C138326
4. INSTALL CONSOLE BOX ASSEMBLY RR(See page IP-20)
5. CHECK FUNCTION OF TRANSMISSION FLOOR SHIFT ASSEM-

BLY
GETtheMANUALS.org
AT–80 AUTOMATIC TRANSMISSION ― TRANSMISSION FLOOR SHIFT ASSEMBLY
(a) Check the operation of the shift lock.

(b) While putting the shift lever into each shift range, make sure
P that the shift lever operates as shown in the illustration. Make
sure that the shift lever moves properly and can be operated
R
smoothly. Also check that the correct shift position indicator is
N indicated when the shift lever is in each position. Make sure that
the position indicator does not flicker when the shift lever is
D
moved slightly within each shift position.
2 (c) Start the engine and check that the vehicle moves forward when
the shift lever is in the D, 2, and L positions. Also check that the
L
vehicle reverses when the shift lever is in the R position.
:Put the ignition switch into the ACC or ON position. (d) Turn the ignition switch to the ON position. Check that the
Move the shift while pressing the shift lever button
and keeping the brake pedal depressed.
backup light turns on and the warning buzzer operates when
:It should be possible to move the shift lever the shift lever is in the R position.
without pressing the shift lever button.
:The pressing the shift lever button must be pressed
6. ADJUST TRANSMISSION CONTROL CABLE ASSEMBLY
in order to move the shift lever. (a) Check for wear and damage on the joints between the control
cable and the control shaft lever assembly. Also check other
areas for wear and damage.
(b) Place identification marks on the parts to indicate up and down.
Remove the installation bolt of the control cable and control
shaft lever assembly.
Marks
AT
(c) Rotate the control shaft lever in the counterclockwise direction
until it stops. (this is the P position.) Then rotate the control
shaft lever two turns in the opposite direction. (This is the N
position.)
(d) Put the shift lever in the N position.
(e) With no slackness in the control cable, install the transmission
control shaft lever assembly.
Standard:
T=9.2 N*m (94kgf*cm)
P
N R (f) After marking the adjustments, check the operation of shift
lever.
GETtheMANUALS.org
AUTOMATIC TRANSMISSION ― TRANSMISSION WIRE
AT–81
TRANSMISSION WIRE
TRANSMISSION
/ TRANSAXLE
COMPONENTS
T=8.4{85}
TRANSMISSION WIRE
CONNECTOR
O-RING
TRANSMISSION WIRE
T=5.9{60}
AT
O-RING
OIL STRAINER
TRANSMISSION MAGNET
TRANSAXLE
OIL PAN (ATM)
GASKET
x15
DRAIN PLUG
T=8.35{85}
T=24.5{250}
APPLY ATF
C139187J06
GETtheMANUALS.org
AT–82 AUTOMATIC TRANSMISSION ― TRANSMISSION WIRE
REMOVAL
4. DRAIN AUTOMATIC TRANSMISSION FLUID(See page AT-85)
5. REMOVE TRANSAXLE OIL PAN (ATM)(See page AT-85)
6. REMOVE OIL STRAINER(See page AT-85)

7. REMOVE TRANSMISSION WIRE
(a) Disconnect the solenoid connector and solenoid wire connector.
(b) Disconnect the wire harness from the clamp.
C135076
(c) Disconnect the 6 connectors of each solenoid valve, and dis-

connect the transmission wire from the valve body.
INSTALLATION
1. INSTALL TRANSMISSION WIRE
(a) Install the transmission wire connector with the bolt.
AT
C138436
(b) Connect the transmission wire connector.
C138436
GETtheMANUALS.org
AUTOMATIC TRANSMISSION ― TRANSMISSION WIRE
AT–83
(c) Connect the solenoid connector and the solenoid wire connec-
tor.
2. INSTALL OIL STRAINER(See page AT-90)
3. INSTALL TRANSAXLE OIL PAN (ATM)(See page AT-90)
5. ADD AUTOMATIC TRANSMISSION FLUID

C135076
8. INITIALIZE AUTOMATIC TRANSMISSION LEARNED VALUE

(See page AT-15)
INSPECTION
1. CHECK RESISTANCE
OTMP (a) Using the tester, inspect the resistance between the terminals.
Standard:
1 2 3 4
5 6 7 8
9 10 11 12 Terminal No. (Terminal
Fluid temperature [°C] Resistance [Ω]
Symbols)
E
5 (OTMP) ←→ 1 (E) 0 5.63±0.56
5 (OTMP) ←→ 1 (E) 140 0.072±0.0022
C134820J01
AT
GETtheMANUALS.org
AT–84 AUTOMATIC TRANSMISSION ― TRANSMISSION VALVE BODY ASSEMBLY
TRANSMISSION VALVE BODY ASSEMBLY

TRANSMISSION
/ TRANSAXLE
COMPONENTS
SOLENOID LOCK PLATE

LOCK UP CONTROL SOLENOID
T=5.9{60}

3-WAY SOLENOID ASSEMBLY
T=5.9{60} SOLENOID
LOCK PLATE
BRAKE CYLINDER SEAL
O-RING
T=5.9{60}

T=5.9{60}
AT AUTOMATIC TRANSMISSION 3-WAY SOLENOID LOCK PLATE

SOLENOID ASSEMBLY
O-RING

x6 ASSEMBLY
T=5.9{60}
T=5.9{60}
T=8.4{85}
MANUAL DETENT SPRING
APPLY ATF

C141076J02
GETtheMANUALS.org
AUTOMATIC TRANSMISSION ― TRANSMISSION VALVE BODY ASSEMBLY
AT–85
REMOVAL
4. DRAIN AUTOMATIC TRANSMISSION FLUID

(a) Remove the drain plug and gasket, and drain the automatic
transmission fluid.
(b) Install the drain plug using a new gasket.
5. REMOVE TRANSAXLE OIL PAN (ATM)

(a) Remove the 14 bolts, and remove the oil pan.
HINT:
After removing the bolts, hold the oil pan by hand, and lightly tap
the flange of the oil pan to remove the oil pan.
6. REMOVE OIL STRAINER
(a) Disengage the 3 claws and remove the oil strainer.
NOTICE:
As the transmission fluid will be discharged, place the tray
under it.
7. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

(a) Remove the manual detent with the 2 bolts.
C138798
(b) Disconnect the solenoid connector and transmission wire.

AT
C135076
(c) Using the SST, hold the manual valve idler shaft.
SST 09350-97201
MANUAL VALVE IDLER SHAFT
SST
C143357
GETtheMANUALS.org
(d) Evenly loosen the 6 bolts to remove, then remove the transmis-
sion valve body assembly.
NOTICE:
When removing the transmission valve body assembly, pay
attention not to drop the manual valve.
C143358
8. REMOVE BRAKE CYLINDER SEAL

2nd And 4th (a) Remove the brake cylinder seal.
Brake Cylinder Seal NOTICE:
When removing the valve body, pay attention to the 2nd
and 4th brake cylinder seal as they may drop.
C135078
9. REMOVE CLUTCH CONTROL SOLENOID NO. 1

(a) Gently remove the manual valve from the body assembly.
AT
C135080
(b) Remove the 2 bolts and the 2 clutch control solenoids No. 1.
Clutch Control Solenoid NO. 1

C136841
GETtheMANUALS.org
AT–87
10. REMOVE CLUTCH CONTROL SOLENOID NO. 2

(a) Remove the bolt and clutch control solenoid No. 2.

C136840
11. REMOVE LOCK-UP CONTROL SOLENOID

(a) Remove the 2 bolts and the lock-up control solenoid.
AT
Lockup Control Solenoid
C136842
12. REMOVE AUTOMATIC TRANSMISSION THREE-WAY SOLENOID

ASSEMBLY
Automatic Transmission (a) Remove the 4 bolts and the 2 automatic transmission three-way
3-Way Solenoid Assembly solenoid assemblies.
C136843
GETtheMANUALS.org
INSTALLATION
1. INSTALL AUTOMATIC TRANSMISSION THREE-WAY SOLENOID
ASSEMBLY
Automatic Transmission (a) Install the automatic transmission three-way solenoid assembly
3-Way Solenoid Assembly with the 4 bolts.
C136843
2. INSTALL LOCK-UP CONTROL SOLENOID

(a) Install the lock-up control solenoid with the 2 bolts.
AT
Lockup Control Solenoid

C136842
3. INSTALL CLUTCH CONTROL SOLENOID NO. 2

(a) Install the clutch control solenoid No. 2 with the bolt and sole-
noid lock plate.

C136840
GETtheMANUALS.org
AT–89
4. INSTALL CLUTCH CONTROL SOLENOID NO. 1

(a) Install the clutch control solenoid No. 1 with the 2 bolts and the
solenoid lock plate.
(b) Coat the manual valve with ATF, then install it to the valve body
assembly.
HINT:
After assembling the manual valve, lightly move the manual
valve back and forth and check that the valve moves smoothly.
5. INSTALL BRAKE CYLINDER SEAL

(a) Install a new brake cylinder seal.
Clutch Control Solenoid NO. 1 C136841
6. TEMPORARILY TIGHTEN TRANSMISSION VALVE BODY ASSEM-

2nd And 4th BLY
Brake Cylinder Seal (a) Check that the brake cylinder seal is installed on the transmis-
sion case.
C135078
(b) By aligning the protrusion of the manual valve lever with the
Clamp A
groove of the manual valve, install them to the transmission
case.
AT
(c) Temporarily install the valve body assembly with the 6 bolts.
NOTICE:
Clean the bolts with air before installation.
Groove
A
Protrusion
C143358J01
7. FULLY TIGHTEN TRANSMISSION VALVE BODY ASSEMBLY

Clamp A
(a) Tighten the 2 standard bolts (labeled A) to the specified torque.
(b) Tighten the remaining bolts to the specified torque.
NOTICE:
• Be sure to install the solenoid wire connector.
• Be sure to install the solenoid wire to the clamp.
Groove
A
Protrusion
C143358J01
GETtheMANUALS.org
(c) Using SST, align the groove of the manual valve with the hole of
the valve body (N position) and install the manual detent spring.
SST 09351-87211
HINT:
First tighten bolt A then bolt B to install the manual detent
SST spring.
8. INSTALL OIL STRAINER

(a) Coat a new O-ring with ATF, and install it to the oil strainer.
A
B
Groove
Hole
C143359
(b) Install the oil strainer.
9. INSTALL TRANSAXLE OIL PAN (ATM)

(a) Clean and degrease the fitting surface, then coat the fitting sur-
face with liquid gasket.
NOTICE:
Do not apply too much liquid gasket. (If a large amount of
AT liquid gasket dissolves in the ATF, the ATF will deteriorate.)
(b) Install the oil pan to the transmission case with the 14 bolts.
C138798
14. INITIALIZE AUTOMATIC TRANSMISSION LEARNED VALUE

(See page AT-15)

(See page SS-10)
GETtheMANUALS.org
AUTOMATIC TRANSMISSION ― AUTOMATIC TRANSMISSION THREE-WAY SOLENOID ASSEMBLY
AT–91
AUTOMATIC TRANSMISSION THREE-WAY SOLENOID

TRANSMISSION
/ TRANSAXLE
ASSEMBLY
INSPECTION
1. AUTOMATIC TRANSMISSION THREE-WAY SOLENOID ASSEM-
BLY
(a) Check the operation (LUC solenoid).
(1) When connecting the battery positive lead to the auto-
matic transmission three-way solenoid assembly (LUC
solenoid ) terminal and the negative lead to the body,
check if the valve in the solenoid operates.
Standard:
The valve operates. (Operating sounds can be
heard.)
NOTICE:
The LUC solenoid valve does not have a spring. If it is
necessary to operate the valve again, shake the sole-
noid or ball to return the valve to its original position.
(To return the valve to its original position with the
valve installed on the vehicle, start the engine with the
shift lever in the P position.)
(b) Check the resistance (LUC solenoid).
(1) Using the tester, inspect the resistance between the sole-
noid terminal and body.
Standard:
14 to 18 Ω (20°C)
(c) Check the operation (switch solenoid).
(1) When connecting the battery positive lead to the auto- AT
matic transmission three-way solenoid assembly (switch
solenoid ) terminal and the negative lead to the body,
check if the valve in the solenoid operates.
Standard:
heard.)
NOTICE:
The switch solenoid valve does not have a spring. If it
is necessary to operate the valve again, shake the
solenoid or ball to return the valve to its original posi-
tion.(To return the valve to its original position with
the valve installed on the vehicle, start the engine with
the shift lever in the P position.)
(d) Check the resistance (LUC solenoid).
Standard:
14 to 18 Ω (20°C)
GETtheMANUALS.org
AT–92 AUTOMATIC TRANSMISSION ― CLUTCH CONTROL SOLENOID NO. 1

TRANSMISSION
/ TRANSAXLE
INSPECTION
1. CLUTCH CONTROL SOLENOID NO. 1
(a) Check the operation (solenoid No. 2).
(1) Using a 12 V-21 W bulb, connect the battery positive lead
to terminal 2 of the clutch control solenoid No. 1 (solenoid
No. 2) and the negative lead to terminal 1. Check that the
valve in the solenoid operates.
Standard:
heard.)
C053442J07 NOTICE:
Do not apply battery voltage directly.Be sure to use
the specified bulb (resistance) to check the operation.
(b) Check the resistance (solenoid No. 2).
(1) Using the tester, inspect the resistance between the termi-
nals.
Standard:
5.0 to 5.6 Ω (20°C)
(c) Check the operation (solenoid No. 3).
Standard:
AT heard.)
NOTICE:
C053442J07 Do not apply battery voltage directly.Be sure to use
the specified bulb (resistance) to check the operation.
(d) Check the resistance (solenoid No. 3).
nals.
Standard:
5.0 to 5.6 Ω (20°C)
GETtheMANUALS.org
AUTOMATIC TRANSMISSION ― LOCK-UP CONTROL SOLENOID
AT–93
LOCK-UP CONTROL SOLENOID

TRANSMISSION
/ TRANSAXLE
INSPECTION
1. LOCK-UP CONTROL SOLENOID
(a) Check the operation.
(1) When connecting the battery positive lead to the lock-up
control solenoid terminal and the negative lead to the
body, check if the valve in the solenoid operates.
Standard:
heard.)
(b) Check the resistance.
Standard:
11 to 13 Ω (20°C)
AT
GETtheMANUALS.org
AT–94 AUTOMATIC TRANSMISSION ― EXTENSION HOUSING OIL SEAL

TRANSMISSION
/ TRANSAXLE
COMPONENTS
EXTENSION HOUSING
OIL SEAL
T=60{612}
AUTOMATIC
REAR DIFFERENTIAL
CARRIER ASSEMBLY
AT
T=37{377}
T=5.4{55}
×7 ENGINE UNDER COVER LH
ENGINE UNDER COVER RH T=5.4{55}
×4
TIGHTENING TORQUE [N*m{kgf*cm}] APPLY MP GREASE

C139182J05
GETtheMANUALS.org
AUTOMATIC TRANSMISSION ― EXTENSION HOUSING OIL SEAL
AT–95
REMOVAL
3. DRAIN AUTOMATIC TRANSMISSION FLUID(See page AT-85)

BLY(See page PR-6)
5. REMOVE EXTENSION HOUSING OIL SEAL

SST 09308-00010
(a) Using the SST, remove the oil seal.
SST
INSTALLATION
1. INSTALL EXTENSION HOUSING OIL SEAL
SST 09309-87201
C138770
(a) Apply a small amount of MP grease to the lip of a new oil seal.
SST (b) Using the SST and a hammer, drive in the oil seal into the
extension housing.
Standard:
1.5 ± 0.5 mm (press in)
NOTICE:
• Do not tap the oil seal in too much.
• Be careful not to deform the oil seal. AT
• Make sure the oil seal is installed in the correct direc-
C138771 tion.

BLY(See page PR-7)
4. INSPECT AUTOMATIC TRANSMISSION FLUID(See page AT-55)
GETtheMANUALS.org
AT–96 AUTOMATIC TRANSMISSION ― SHIFT LOCK DEVICE
SHIFT LOCK DEVICE

TRANSMISSION
/ TRANSAXLE
1. INSPECT SHIFT LOCK OPERATION
(a) Turn the ignition switch to the ACC or ON position.
(b) Move the shift lever to the P position and release the shift lever
button.
(c) With the brake pedal not depressed, make sure that the shift
lever button cannot be depressed and the shift lever cannot be
moved to any position other than the P position.
(d) With the brake pedal depressed, make sure that the shift lever
button can be depressed and the shift lever can be moved out
of the P position.
(e) Move the shift lever to the P position and release the shift lever
button.
(f) Turn the ignition key to the LOCK position.
(g) Regardless of the condition of the brake pedal, make sure that
the shift lever button cannot be depressed and the shift lever
cannot be shifted to any position other than the P position.
AT
GETtheMANUALS.org
AUTOMATIC TRANSMISSION ― CLUTCH CONTROL SOLENOID NO. 2
AT–97

TRANSMISSION
/ TRANSAXLE
INSPECTION
1. CLUTCH CONTROL SOLENOID NO. 2
(a) Check the operation (solenoid No. 1).
Standard:
heard.)
C053442J01 (b) Check the resistance (solenoid No. 1).
nals.
Standard:
5.0 to 5.6 Ω (20°C)
AT
GETtheMANUALS.org
AT–98 AUTOMATIC TRANSMISSION ― TRANSMISSION CONTROL COMPUTER ASSEMBLY
TRANSMISSION CONTROL COMPUTER ASSEMBLY

TRANSMISSION
/ TRANSAXLE
COMPONENTS
AT GLOVE COMPARTMENT DOOR ASSEMBLY
COMPUTER ASSEMBLY
REMOVAL
2. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (See page

IP-11)
3. REMOVE TRANSMISSION CONTROL COMPUTER ASSEMBLY

(a) Remove the 2 bolts and steering shaft universal joint assembly.
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AUTOMATIC TRANSMISSION ― TRANSMISSION CONTROL COMPUTER ASSEMBLY
AT–99
(b) Disconnect the connector from the transmission control com-

puter assembly.
INSTALLATION
1. INSTALL TRANSMISSION CONTROL COMPUTER ASSEMBLY
(a) Connect the connector to the transmission control computer
assembly.
C136739
(b) Install the transmission control computer assembly with the 2

bolts.
2. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY (See page

IP-18)
C136739
AT
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AT–100 AUTOMATIC TRANSMISSION ― SHIFT LOCK RELEASE CABLE ASSEMBLY

TRANSMISSION
/ TRANSAXLE
COMPONENTS
STEERING COLUMN COVER
AT
INSTRUMENT PANEL FINISH PANEL LWR
C143661J01
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AUTOMATIC TRANSMISSION ― SHIFT LOCK RELEASE CABLE ASSEMBLY
AT–101
CONSOLE BOX CARPET
T=12{122}

T=9.2{94}
AT
T=12{122}

C143660J01
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AT–102 AUTOMATIC TRANSMISSION ― SHIFT LOCK RELEASE CABLE ASSEMBLY
REMOVAL
1. HANDLING AND WORK PRECAUTIONS
3. DISCONNECT BATTERY NEGATIVE TERMINAL

(a) Disconnect the shift lock release cable assembly from the shift
control unit assembly.
6. REMOVE STEERING COLUMN LOWER COVER (See page WW-

21)
7. REMOVE INSTRUMENT PANEL FINISH PANEL LWR (See page

IP-11)
8. REMOVE INSTRUMENT PANEL UNDER COVER NO. 1 (See page

IP-11)
9. REMOVE SHIFT LOCK RELEASE CABLE ASSEMBLY

(a) Remove the 2 bolts, and disengage the 2 clamps of the shift
lock release cable assembly.
(b) Disengage the 2 claws and disconnect the shift lock release
cable assembly from the key cylinder assembly.
AT
C136010
(c) Remove the bolt and shift lock release cable assembly.
C143662
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AUTOMATIC TRANSMISSION ― SHIFT LOCK RELEASE CABLE ASSEMBLY
AT–103
INSTALLATION
1. INSTALL SHIFT LOCK RELEASE CABLE ASSEMBLY
(a) Install the shift lock release cable assembly with the bolt.
(b) Turn the ignition key to the ACC position, and fully slide the key
lock pin toward the front of the vehicle.
C143662
(c) Install the shift lock release cable end to the key cylinder
assembly.
(d) Install the 2 clamps of the shift lock release cable assembly with
the 2 bolts.
Vehicle Front
(e) Move the shift lever to the park.position.
(f) Install the shift lock release cable end to the shift control unit
assembly.
Key Lock Pin
C136008
2. ADJUST SHIFT LOCK RELEASE CABLE ASSEMBLY

(a) Loosen the nut, and without depressing the brake pedal, adjust
the lock mechanism unit so that the protrusion becomes 0.5 to 4
mm and secure it with the nut.
m
-4m Standard:
0.5
0.5 to 4 mm (protrusion of lock mechanism) AT
NOTICE:
Do not overtighten the adjust nut, or it may change the
height of the brake pedal.
C138170J02
3. INSTALL INSTRUMENT PANEL UNDER COVER NO. 1 (See page
IP-18)
4. INSTALL INSTRUMENT PANEL FINISH PANEL LWR (See page IP-

18)
5. INSTALL STEERING COLUMN LOWER COVER (See page WW-

23)
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TO INDEX
TRANSMISSION / TRANSAXLE
CLUTCH
CLUTCH SYSTEM (MTM)
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-1
CLUTCH PEDAL (MTM)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-4
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-6
CLUTCH MASTER CYLINDER ASSEMBLY (MTM)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-9
CLUTCH RELEASE CYLINDER ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-12
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-12
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-13
CLUTCH UNIT
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-19
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-21
CL
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CL–1 CLUTCH - CLUTCH SYSTEM (MTM)
155
CLUTCH SYSTEM (MTM)
CLUTCH

Engine mounting (looseness) -
Clutch disk (runout) CL-21
Clutch disk (oily) CL-20
Clutch chatters when engaging
Clutch disk (wear) CL-21
Clutch disk (damaged) CL-21
Diaphragm spring (irregular height) CL-19
Clutch pipe line (air interfusion) -
Spongy clutch pedal Master cylinder piston (damaged) CL-9
Release cylinder piston (damaged) CL-12
Release bearing (wear, dirty, or damaged) -
Abnormal noise from clutch
Clutch disk (damaged) CL-21
Clutch pedal (free play) CL-6
Clutch slips Clutch disk (wear) CL-21
Diaphragm spring (damaged) CL-19
Flywheel (distortion) CL-21
Clutch pedal (free play) CL-6
Clutch pipe line (air interfusion) CL-13
Master cylinder piston (damaged) CL-9
Release cylinder cup (damaged) CL-12
Clutch disk (runout) CL-21
Clutch does not engage Clutch disk (damaged lining) CL-21
CL Clutch disk (dirty or burned) CL-20
Clutch disk (insufficient spline grease) CL-21
Diaphragm spring (damaged) CL-19
Diaphragm spring (irregular height) CL-19
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CLUTCH - CLUTCH PEDAL (MTM)
CL–2
CLUTCH PEDAL (MTM)

CLUTCH
COMPONENTS
CL
C139175J01
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CL–3 CLUTCH - CLUTCH PEDAL (MTM)
CLUTCH MASTER CYLINDER

PUSH ROD CLEVICE
CLIP T=13{132.5} T=18.2{185}
HOLE PIN
×4
WASHER T=18.2{185}
T=27{275.3}
T=18{185}
BRAKE PEDAL BUSH
T=15{154}
T=18{183.5}
BRAKE PEDAL
T=20{203}
T=13{132.5}
CL CLUTCH PEDAL
BUSH
TO FLEXIBLE HOSE TUBE
CLUTCH PEDAL CUSHION
CLUTCH PEDAL PAD
CLUTCH PEDAL SPRING
CLUTCH PEDAL ASSEMBLY
……NON-REUSEABLE PART
C143563J01
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CL–4
REMOVAL

IP-11)

IP-11)
4. DRAIN BRAKE FLUID
5. DISCONNECT CLUTCH HOSE NO. 1
6. DISCONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE

HOSE TUBE
SST 09023-00100
(a) Using SST, disconnect the flexible brake hose tube.
7. REMOVE BRAKE PEDAL

(a) Remove the brake pedal shaft and the brake pedal.
C138328
8. REMOVE CLUTCH PEDAL ASSEMBLY WITH BRACKET

(a) Remove the 3 bolts, 4 nuts and the clutch pedal assembly with
bracket.
9. DISCONNECT CLUTCH MASTER CYLINDER PUSH ROD CLEVIS

(a) Remove the clip, hole pin, and washer, and disconnect the
clutch master cylinder push rod clevis from the clutch pedal CL
assembly.
10. REMOVE CLUTCH PEDAL ASSEMBLY

(a) Remove the pedal shaft and the clutch pedal from the clutch
pedal support.
11. REMOVE CLUTCH PEDAL SPRING

(a) Remove the clutch pedal spring from the clutch pedal.
12. REMOVE CLUTCH PEDAL BUSHING

C140428 (a) Remove the 3 pedal bushes from the clutch pedal.
13. REMOVE CLUTCH PEDAL PAD

(a) Remove the clutch pedal pads from the clutch pedal.
INSTALLATION
1. INSTALL CLUTCH PEDAL BUSHING
(a) Apply MP grease to the inside/outside of the pedal bush.
(b) Install the 3 pedal bushes to the clutch pedal.
2. INSTALL CLUTCH PEDAL SPRING

(a) Apply MP grease to the sliding areas of the spring.
(b) Install the pedal spring.
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CL–5 CLUTCH - CLUTCH PEDAL (MTM)
3. INSTALL CLUTCH PEDAL PAD

(a) Install the clutch pedal pad to the clutch pedal.
4. INSTALL CLUTCH PEDAL ASSEMBLY

(a) Install the clutch pedal pad to the clutch pedal.
NOTICE:
Do not allow the grease to get on the threads of the pedal
shaft.
5. CONNECT CLUTCH MASTER CYLINDER PUSH ROD CLEVIS

(a) Apply MP grease to the contact surface of the push rod clevis
bush of the hole pin.
(b) Using the hoe pin, clip, and washer, connect the master cylinder
push rod clevis to the clutch pedal.
6. INSTALL CLUTCH PEDAL ASSEMBLY WITH BRACKET
(a) Install the clutch pedal assembly with bracket using the 3 bolts
A and 4 nuts.
Torque: 27 N*m (275.3 kgf*cm) Bolt A
18 N*m (183.5 kgf*cm) Bolt B
13 N*m (132.5 kgf*cm) Bolt C
B 13 N*m (132.5 kgf*cm) Nut
7. CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE

TUBE
SST 09023-00100
C140428J01
CL (a) Using SST, connect the flexible hose tube.

8. CONNECT CLUTCH HOSE NO. 1
C138328
9. INSTALL INSTRUMENT PANEL UNDER COVER NO. 1

(a) Engage the 4 innermost claws to install the instrument panel
under cover No. 1.
<D> <D> (b) Install the 2 screws <D>.
10. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER

(a) Install the DLC connector and the wire harness clamp to the
instrument panel finish panel LWR.
B136287J01
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CL–6
(b) Engage the 5 claws.

(c) Install the instrument panel finish panel LWR with the 2 <D>
bolts.

(See page SS-10.)
13. BLEED AIR FROM BRAKE SYSTEM (WITHOUT VSC)

<D> <D>
: Claw B136286J01
14. BLEED AIR FROM BRAKE SYSTEM (WITH VSC) (See page BR-7)
15. CHECK BRAKE FLUID LEAKAGE
ADJUSTMENT
1. INSPECT AND ADJUST CLUTCH PEDAL
(a) Pull up the floor carpet.
(b) Using vernier calipers, measure the height of the clutch pedal.
Standard:
176.3 ± 4 mm
(c) Loosen the clevis lock nut, and turn the push rod to adjust the
brake pedal height.
Standard:
T=20N*m [203 kgf*cm] (lock nut)
(d) Press the pedal gently with your fingers and measure the pedal
freeplay.
Standard:
3 to 20 mm (pedal freeplay)
Pedal Play
Reference value:
0.5 to 1.4 mm (push rod freeplay)
(e) Loosen the lock nut of the master cylinder push rod clevis, and
Push Rod Play

turn the master cylinder push rod to adjust the pedal freeplay.
CL
C102627J01 (f) After adjusting the pedal freeplay, check the pedal height.
(g) Install the floor carpet.
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CL–7 CLUTCH - CLUTCH MASTER CYLINDER ASSEMBLY (MTM)
CLUTCH MASTER CYLINDER ASSEMBLY (MTM)

CLUTCH
COMPONENTS
CL
C139175J01
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CLUTCH - CLUTCH MASTER CYLINDER ASSEMBLY (MTM)
CL–8
T=13{132.5} T=18.2{185}
×4
T=18.2{185}
T=27{275.3}
CLIP BRAKE PEDAL BUSH
CLUTCH HOSE NO. 1

T=18{183.5}
BRAKE PEDAL
T=20{203}
T=13{132.5}
HOLE PIN
CLUTCH PEDAL
BUSH T=15{154} CL
CLUTCH MASTER
CYLINDER ASSEMBLY T=18{185}
CLUTCH PEDAL CUSHION

CLUTCH PEDAL SPRING
CLUTCH PEDAL
NON-REUSEABLE PART
C143571J01
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CL–9 CLUTCH - CLUTCH MASTER CYLINDER ASSEMBLY (MTM)
REMOVAL

IP-11)

IP-11)

6. DISCONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE
HOSE TUBE
(a) Using a union nut wrench, disconnect the clutch tubes.
7. REMOVE CLUTCH PEDAL ASSEMBLY WITH BRACKET (See

page CL-4)
8. DISCONNECT CLUTCH MASTER CYLINDER PUSH ROD CLEVIS

(See page CL-4)
9. REMOVE CLUTCH MASTER CYLINDER ASSEMBLY

C138328
(a) Remove the bolt, nut and the master cylinder assembly.
INSTALLATION
1. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY
(a) Install the master cylinder assembly with the bolt and nut.
2. CONNECT CLUTCH MASTER CYLINDER PUSH ROD CLEVIS

(See page CL-5)
3. INSTALL CLUTCH PEDAL ASSEMBLY WITH BRACKET (See

CL page CL-5)

TUBE (See page CL-5)

(a) Install the reservoir tube No. 1 with the clip.
7. PERFORM INITIALIZATION (See page CL-6)
8. REFILL BRAKE FLUID
9. BLEED CLUTCH PIPE LINE (WITHOUT VSC) (See page BR-5)
10. BLEED CLUTCH PIPE LINE (WITH VSC) (See page BR-7)
11. CHECK FOR BRAKE FLUID LEAKS
12. INSPECT A BRAKE FLUID LEVEL
13. INSPECT AND ADJUST CLUTCH PEDAL (See page CL-6)

IP-18)
18)
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CLUTCH - CLUTCH RELEASE CYLINDER ASSEMBLY
CL–10
CLUTCH RELEASE CYLINDER ASSEMBLY

CLUTCH
COMPONENTS
CL
×7
T=5.4{55}

×4
T=5.4{55}
ENGINE UNDER COVER
×11

C139174J02
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CL–11 CLUTCH - CLUTCH RELEASE CYLINDER ASSEMBLY
T=18{185}
BLEEDER PLUG CAP
CLUTCH RELEASE CYLINDER BLEEDER PLUG

T=11{112}
CLUTCH RELEASE
CYLINDER ASSEMBLY
CLUTCH HOSE NO. 2
GASKET
T=24.5{250}
T=18{185}
CL
PUSH ROD
SPRING
BOOT PISTON
CLUTCH RELEASE CYLINDER KIT

NON-REUSEABLE PART APPLY LITHIUM SOAP BASE GLYCOL GREASE
C139164J04
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CLUTCH - CLUTCH RELEASE CYLINDER ASSEMBLY
CL–12
REMOVAL

(a) Remove the union bolt and gasket and disconnect the clutch
hose No. 2 from the clutch release cylinder assembly.
C137079
6. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY

(a) Remove the 2 bolts and the clutch release cylinder assembly.
DISASSEMBLY
1. REMOVE CLUTCH RELEASE CYLINDER KIT
(a) Remove the boot from the cylinder body.
(b) Remove the push rod from the cylinder body.
(c) Remove the piston from the cylinder body.
NOTICE:
C133718J01
Do not damage the inside of the cylinder body.
(d) Remove the spring from the cylinder body.
(e) Remove the bleeder plug cap from the bleeder plug.
CL
2. REMOVE CLUTCH RELEASE CYLINDER BLEEDER PLUG
REASSEMBLY
1. INSTALL CLUTCH RELEASE CYLINDER BLEEDER PLUG
(a) Install the clutch release cylinder bleeder plug to the cylinder
body.
2. INSTALL CLUTCH RELEASE CYLINDER KIT

(a) Apply the rubber grease to the entire surface of a new piston.
(b) Install the spring and piston to the release cylinder body.
NOTICE:
(c) Install a new boot to the push rod.
(d) Install the push rod and boot to the cylinder body.
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CL–13 CLUTCH - CLUTCH RELEASE CYLINDER ASSEMBLY
INSTALLATION
1. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY
(a) Install the clutch release cylinder assembly with the 2 bolts.
C133718J01

(a) Connect the clutch hose No. 2 with the union bolt and gasket.
3. REFILL BRAKE FLUID
4. BLEED CLUTCH PIPE LINE (WITHOUT VSC) (See page BR-5)
5. BLEED CLUTCH PIPE LINE (WITH VSC) (See page BR-7)

C137079 7. INSPECT A BRAKE FLUID LEVEL
CL
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CLUTCH - CLUTCH UNIT
CL–14
CLUTCH UNIT
CLUTCH
COMPONENTS
AIR CLEANER
ASSEMBLY
T=7.5{75}
×2
T=18{184}
×2×2
T=8.0{82}
BATTERY
CL
ENGINE UNDER COVER
×7
×4
T=5.4{55}
×11
T=5.4{55}
T=5.4{55}
×11
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CL–15 CLUTCH - CLUTCH UNIT
T=7.5{76}
T=21{214}
×2
T=7.5{76}
×2
THROTTLE
T=19{194} O-RING
×3 T=21{214}
×2
T=19{194}

VENTILATION HOSE

FUEL DELIVERY PIPE
×2
CL ×4
×4
O-RING
×4
FUEL INJECTOR
ASSEMBLY
INJECTOR VIBRATION
INSULATOR
T=37{377}
T=37{377} ×2
STARTER ASSEMBLY
C141354J01
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CL–16
EXHAUST PIPE GASKET
T=19{194}
T=19{194}
T=46{469}
EXHAUST PIPE GASKET
T=60{612}
×4

CL
T=60{612}
×4

T=37{377}
C141353J01
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T=37{375}
T=58.8{596}
T=58.8{596}
T=18{185}
CL
T=36.8{375}
T=36.8{375}
T=68{693}
T=68{693}

C140480J01
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CL–18
4WD CLIP TRANSMISSION CONTROL CABLE ASSEMBLY

T=37{377}
×2
CABLE ASSEMBLY
CLIP
CABLE BRACKET
T=37{377}
NEEDLE BEARING
TRANSFER GASKET TRANSFER ASSEMBLY
T=37{377}
ENGINE MOUNTING BRACKET RR CL

T=37{377}
ENGINE REAR SUPPORT MEMBER
×2
T=48{490}
×2
T=48{490}

C142612J01
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RELEASE ANTI-LATERAL
RELEASE BEARING HUB CLIP SPRING
T=19.1{195}
CLUTCH COVER
ASSEMBLY
×6 CLUTCH RELEASE
FORK SUPPORT
CLUTCH RELEASE FORK
CLUTCH RELEASE FORK BOOT
CLUTCH RELEASE BEARING
TIGHTENING TORQUE [N*m{kgf*cm}] APPLY RELEASE HUB GREASE

C139163J04
REMOVAL
CL 1. DISCHARGE FUEL SYSTEM PRESSURE (See pageEM-146)
5. DRAIN MANUAL TRANSMISSION OIL (See pageMT-9)
6. DRAIN ENGINE COOLANT (See pageCO-9)
7. REMOVE AIR CLEANER HOSE NO. 1 (See pageCO-15)
8. REMOVE AIR CLEANER ASSEMBLY (See pageEM-146)
9. REMOVE VENTILATION HOSE (See pageEM-147)
10. REMOVE VENTILATION HOSE NO. 2 (See pageEM-147)

(See pageEM-147)
12. REMOVE FUEL HOSE NO. 2 (See pageEM-148)
13. DISCONNECT VACUUM HOSE ASSEMBLY (See pageEM-148)
14. REMOVE FUEL DELIVERY PIPE (See pageEM-149)
15. REMOVE THROTTLE BODY ASSEMBLY (See pageEM-148)
16. REMOVE THROTTLE BODY BRACKET (See pageEM-149)
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CL–20
17. REMOVE FUEL INJECTOR ASSEMBLY (See page EM-149)
18. REMOVE INTAKE MANIFOLD (See page MT-9)
19. DISCONNECT EXHAUST PIPE ASSEMBLY FR (See page MT-10)

4WD) (See page PR-3)
21. REMOVE PROPELLER WITH CENTER BEARING SHAFT

ASSEMBLY (See page PR-6)
22. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (FOR 4WD)

(See page PR-3)
23. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY (See

page MT-10)
24. DISCONNECT CONNECTOR (See page MT-10)
25. REMOVE STARTER ASSEMBLY (See page MT-10)
26. SUSPEND ENGINE ASSEMBLY (See page MT-12)
27. SUPPORT TRANSMISSION ASSEMBLY (TRANSMISSION M/T)

(See page MT-12)

(See page MT-12)
29. REMOVE ENGINE REAR SUPPORT MEMBER (See page MT-12)
30. REMOVE TRANSMISSION ASSEMBLY (TRANSMISSION M/T)

(See page MT-13)
31. REMOVE CLUTCH RELEASE FORK

(a) Remove the release bearing, clip and clutch release fork.
32. REMOVE CLUTCH RELEASE BEARING

(a) Remove the clip and clutch release bearing from the clutch CL
release fork.
33. REMOVE CLUTCH RELEASE FORK BOOT

(a) Remove the clutch release fork boot from the transmission
assembly.
34. REMOVE CLUTCH RELEASE FORK SUPPORT

(a) Remove the clutch release fork support from the transmission
assembly.
35. REMOVE CLUTCH COVER ASSEMBLY

SST 09210-87701
(a) Use the SST to prevent the ring gear from turning.
(b) Remove the 6 bolts and the clutch cover assembly.
NOTICE:
Do not drop the clutch disk assembly.
36. REMOVE CLUTCH DISK ASSEMBLY

NOTICE:
Do not allow any lubricant or foreign matter to contaminate the
SST surface of the lining part of the clutch disk, the pressure plate
and the flywheel.
C142601
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INSPECTION
1. INSPECT CLUTCH DISC ASSEMBLY
(a) Using a vernier caliper, check the wear on the facing.
Maximum limit:
0.3 mm (rivet depth)
(b) Install the clutch disk assembly to the transaxle assembly.
NOTICE:
Make sure the clutch disk assembly is installed in the
correct direction.
(c) Using the dial indicator with roller probes, turn the clutch disk to
C062956 check the runout of the clutch disk.
Maximum limit:
1.0 mm
NOTICE:
Use a new input shaft to check the runout of the clutch
disk.
2. INSPECT CLUTCH COVER ASSEMBLY
(a) Using a vernier caliper, check the wear on the contact surface
Width
Depth with the release bearing.
Maximum limit:
0.5 mm (depth)
6.0 mm (width)
C057466
3. INSPECT FLYWHEEL
(a) Using a dial indicator, check the runout of the flywheel.
CL Maximum limit:
0.1 mm
C138497
INSTALLATION
1. INSTALL CLUTCH DISK ASSEMBLY
(a) Using SST, center the clutch disk assembly.
SST 09301-00110
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CL–22
NOTICE:
Make sure the clutch disk assembly is installed in the
correct direction.
SST
C138496
2. INSTALL CLUTCH COVER ASSEMBLY

(a) Use the SST to prevent the ring gear from turning.
SST 09210-87701
SST
SST
C143525
(b) Align the clutch cover assembly with the knock pin of the
1 flywheel to install it. Temporarily tighten it in the order of 1 →
6 3→ 5, then fully tighten in the order of 1 → 3 → 6 → 2 → 4 → 5.
2
SST Torque: 19.1 N*m (195 kgf*cm)
HINT:
Bolt 1 should be one of the 3 attaching parts close to the knock
5 3
pin.
NOTICE:
4
C138500
• Tighten it until the bottom of the bolt touches the cover
for the temporary tightening.
CL
• Uniformly tighten the bolt in several passes.
3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

SST 09333-00013, 09302-87701
(a) Using the SST, check if there is any irregular height of the
diaphragm spring.
Standard:
SST
0.5 mm or less
Minimum standard value:
0.5 mm or less
C138499
GETtheMANUALS.org
(b) If the result exceeds the limit, correct the irregularity of height in
the finger part using the SST.
SST
4. INSTALL CLUTCH RELEASE FORK SUPPORT
(a) Using a deep socket wrench (17 mm), install the release fork
support to the transaxle assembly.
5. INSTALL CLUTCH RELEASE FORK BOOT
6. INSTALL CLUTCH RELEASE FORK

C138498
(a) Apply the EP grease to the following parts of the release fork.
(1) Contact surface to the release fork support
(2) Contact surface to the release cylinder push rod
(3) Contact surface on the release bearing hub part
(b) Install the release fork to the release bearing.
(c) Install the clutch release bearing hub clip to the clutch release
fork.
7. INSTALL CLUTCH RELEASE BEARING

(a) Apply the clutch grease to the spline part of the input shaft on
the transaxle assembly.
(b) Install the release bearing and the release fork to the transaxle
assembly.
NOTICE:
After the installation, move the fork back and forth and
check if the release bearing slides smoothly.
8. TEMPORARILY TIGHTEN TRANSMISSION ASSEMBLY

(TRANSMISSION M/T) (See page MT-13)
9. INSTALL ENGINE REAR SUPPORT MEMBER (See page MT-14)
10. FULLY TIGHTEN TRANSMISSION ASSEMBLY (TRANSMISSION
CL M/T) (See page MT-14)
11. INSTALL STARTER ASSEMBLY (See page MT-14)
12. FULLY TIGHTEN TRANSMISSION ASSEMBLY (TRANSMISSION

M/T) (See page MT-15)
13. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (See

page MT-16)
14. CONNECT CONNECTOR (See pageMT-17)
15. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (See page

MT-17)
16. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (FOR 4WD)

(See page PR-4)
17. INSTALL PROPELLER WITH CENTER BEARING SHAFT


PR-4)
19. INSTALL EXHAUST PIPE ASSEMBLY FR (See page EX-2)
22. INSTALL FUEL INJECTOR ASSEMBLY (See page EM-164)
GETtheMANUALS.org
CL–24
23. INSTALL FUEL DELIVERY PIPE (See page EM-165)

page EM-165)
28. INSTALL BATTERY
32. REFILL MANUAL TRANSMISSION OIL
33. INSPECT MANUAL TRANSMISSION OIL LEVEL (See page MT-3)
42. INSPECT ENGINE IDLE SPEED (See page EM-2)

CL
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TO INDEX
MANUAL TRANSMISSION
SPEEDOMETER SENSOR (WITHOUT ABS)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-2
MANUAL TRANSMISSION SYSTEM (MTM)
BASIC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-3
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-3
TRANSMISSION UNIT ASSEMBLY (MTM)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-13
TRANSMISSION EXTENSION HOUSING OIL SEAL (MTM) (2WD)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-20
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-22
TRANSMISSION CONTROL CABLE ASSEMBLY (MTM)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-26
MT
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MT–1 MANUAL TRANSMISSION - SPEEDOMETER SENSOR (WITHOUT ABS)
SPEEDOMETER SENSOR (WITHOUT ABS)

TRANSMISSION
MANUAL TRANSMISSION
/ TRANSAXLE
COMPONENTS
T=8.4{85}
SPEED METER SENSOR
SPEED METER DRIVEN GEAR
TYPE K OIL SEAL
SPEED METER SHAFT SLEEVE
MT O RING
C143658J01
APPLY ATF APPLY MP GREASE
REMOVAL
1. REMOVE SPEEDOMETER SENSOR
SST 09201-01080
(a) Remove the bolt, then remove the speedometer sensor from
(b) Insert SST into the speedometer shaft sleeve, and make a
mark.
SST
Put a mark.
C143637
GETtheMANUALS.org
MANUAL TRANSMISSION - SPEEDOMETER SENSOR (WITHOUT ABS)
MT–2
(c) Using SST, remove the type K oil seal from the speedometer
shaft sleeve.
2. INSPECT SPEEDMETER SENSOR

(a) Check for any wear or damage to the shaft and gear parts of the
speedometer driven gear.
SST
C143638
(b) Check for any damage to the speedometer shaft sleeve.
Damage
Damage,wear
C143639
INSTALLATION
1. INSTALL SPEEDOMETER SENSOR
(a) Coat the lip of a new type K oil seal with ATF.
(b) Using SST, install the type K oil seal to the speedometer shaft
SST sleeve.
NOTICE:
By referring to the mark made at the time of removal, insert
the oil seal into the sleeve.
(c) Coat a new O-ring with ATF, and install it to the speedometer
MT
shaft sleeve.
Oil seal (d) Apply ATF to the entire circumference of the speedometer
driven gear shaft, then install it to the speedometer shaft sleeve.
C143640 (e) Install the speedometer sensor to the transmission with the bolt.
GETtheMANUALS.org
MT–3 MANUAL TRANSMISSION - MANUAL TRANSMISSION SYSTEM (MTM)
MANUAL TRANSMISSION SYSTEM (MTM)

TRANSMISSION
MANUAL TRANSMISSION
/ TRANSAXLE
BASIC INSPECTION
1. CHECK FLUID LEVEL
(a) Stop the vehicle on a level road.
(b) Remove the transmission filler plug and gasket.
(c) Using your fingers or wires, check that the fluid level is 0 to 5
mm below the bottom of the transmission filler plug hole.
Filler Plug NOTICE:
• If the fluid level is too high or too low, it may cause
Oil Level trouble.
• If the fluid is replaced, check the fluid level after driving.
0-5 mm (d) If the fluid level is low, check for fluid leaks.
Wire
(e) Install the transmission filler plug using a new gasket.
C132685
2. CHECK FOR FLUID LEAKS
(a) Visually inspect whether fluid is leaking from the oil seal parts,
plug parts, case fitting surfaces, or any other parts.

Fluid (too low) MT-3
Fluid (wrong type or deteriorated) MT-3
Abnormal noise
Gear (worn or damaged) -
Bearing (worn or damaged) -
Fluid (too high) MT-3
Gasket (damaged) -
Fluid leaks Oil seal (worn or damaged) (2WD) MT-20
MT Oil seal (worn or damaged) (4WD) TF-7
O-ring (worn or damaged) -
Control cable (defect) MT-26
Synchronizer ring (worn or damaged) -
Difficult to shift or cannot shift
Shift key spring (damaged) -
Fluid (wrong type or deteriorated) -
Locking ball spring (damaged) -
Shift fork (worn or damaged) -
Jumps to the next gear
Gear (worn or damaged) -
Bearing (worn or damaged) -
GETtheMANUALS.org
MANUAL TRANSMISSION - TRANSMISSION UNIT ASSEMBLY (MTM)
MT–4
TRANSMISSION UNIT ASSEMBLY (MTM)

TRANSMISSION
MANUAL TRANSMISSION
/ TRANSAXLE
COMPONENTS
AIR CLEANER
ASSEMBLY
T=7.5{75}
×2
T=18{184}
×2×2
T=8.0{82}
BATTERY
MT
ENGINE UNDER COVER
×7
×4
T=5.4{55}
×11
T=5.4{55}
T=5.4{55}
×11
GETtheMANUALS.org
MT–5 MANUAL TRANSMISSION - TRANSMISSION UNIT ASSEMBLY (MTM)
T=7.5{76}
T=21{214}
×2
T=7.5{76}
×2
THROTTLE
T=19{194} O-RING
×3 T=21{214}
×2
T=19{194}

VENTILATION HOSE

FUEL DELIVERY PIPE
×2
×4
×4
MT O-RING
×4
FUEL INJECTOR
ASSEMBLY
INJECTOR VIBRATION
INSULATOR
T=37{377}
T=37{377} ×2
STARTER ASSEMBLY
C141354J01
GETtheMANUALS.org
MT–6
EXHAUST PIPE GASKET
T=19{194}
T=19{194}
T=46{469}
EXHAUST PIPE GASKET
T=60{612}
×4
MT
T=60{612}
×4

T=37{377}

C141353J01
GETtheMANUALS.org
T=37{375}
T=58.8{596}
T=58.8{596}
T=18{185}
T=36.8{375}
MT
T=36.8{375}
T=68{693}
T=68{693}

C140480J01
GETtheMANUALS.org
MT–8
4WD CLIP TRANSMISSION CONTROL CABLE ASSEMBLY

T=37{377}
×2
CABLE ASSEMBLY
CLIP
CABLE BRACKET
T=37{377}
NEEDLE BEARING
TRANSFER GASKET TRANSFER ASSEMBLY
T=37{377}
ENGINE MOUNTING BRACKET RR

T=37{377} MT
ENGINE REAR SUPPORT MEMBER
×2
T=48{490}
×2
T=48{490}

C142612J01
GETtheMANUALS.org
REMOVAL
5. DRAIN MANUAL TRANSMISSION FLUID

(a) Remove the drain plug, filler plug, and gasket, and drain the
manual transmission fluid.
(b) Install the drain plug using a new gasket.

(See page EM-147)
12. REMOVE FUEL HOSE NO. 2 (See page EM-148)
14. REMOVE FUEL DELIVERY PIPE (See page EM-149)
17. REMOVE FUEL INJECTOR ASSEMBLY (See page EM-149)
18. REMOVE INTAKE MANIFOLD

MT (a) Remove the bolt and disconnect the oil level gauge guide from
the intake manifold.
(b) Disconnect the water bypass hose from the cylinder head.
(c) Disconnect the wiring harness from the intake manifold.
(d) Remove the 3 bolts and 2 nuts, then remove the intake
manifold.
(e) Remove the gasket from the intake manifold.
A109108
GETtheMANUALS.org
MT–10
(f) Remove the nut and disconnect the connector from the starter
assembly.
C141257

pipe assembly FR from the exhaust manifold.

4WD) (See page PR-3)

22. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (FOR 4WD)

A134989
(See page PR-3)
23. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

(a) Remove the 2 bolts, then disconnect the clutch release cylinder
assembly from the transmission assembly.
C133718
MT
24. DISCONNECT CONNECTOR
(a) Disconnect the backup light switch assembly connectors.
C141311
(b) Disconnect the wire harness clamp of the oxygen sensor.

(a) Using a high transmission jack, support the engine rear support
member.
A133302
GETtheMANUALS.org
member.
A133258
(c) Remove the bolt, then disconnect the fuel delivery pipe.
A138811
(d) Remove the 2 bolts, then disconnect water bypass pipe No. 2.
(e) Lower the high transmission jack so that the 2 starter assembly
mounting bolts can be removed.
A138813
MT
(f) Using an extension bar (600 mm), remove the 2 starter
assembly mounting bolts.
(g) Temporarily install the engine rear support member.
(h) Lower the vehicle and remove the starter assembly from the
engine room side.
A138815
(i) Remove transmission assembly mounting bolt A.
C141317
GETtheMANUALS.org
MT–12
26. SUSPEND ENGINE ASSEMBLY

(a) Install engine hunger No. 1 and No. 2 with the bolts to the
locations shown in the illustration.
(b) Use an engine sling device, hold the engine.
27. SUPPORT TRANSMISSION ASSEMBLY (MANUAL

TRANSMISSION)
(a) Support the transmission with a high transmission jack.
A137720
member.
A133258

(a) Remove the 4 clips, and disconnect the transmission control
cable assembly from the transmission assembly.
NOTICE:
8°
8°
or do not apply load to the control cable end. MT
C143526
29. REMOVE ENGINE REAR SUPPORT MEMBER

(a) Remove the bolt and nut, then remove the engine rear support
member.
C141256
GETtheMANUALS.org
30. REMOVE TRANSMISSION ASSEMBLY (MANUAL

TRANSMISSION)
A (a) Remove the 6 bolts and transmission assembly.
HINT:
When removing bolts A, use an extension bar (600 mm).
A NOTICE:
Do not shake the transmission unit assembly violently as
doing so may cause damage to the input shaft.
31. REMOVE ENGINE MOUNTING BRACKET RR (FOR 2WD)

C136911J05
(a) Remove the 3 bolts and engine mounting bracket RR.
32. REMOVE TRANSMISSION CONTROL CABLE BRACKET NO. 1

(FOR 2WD)
(a) Remove the 2 bolts and transmission control cable bracket No.
1.
33. REMOVE TRANSFER ASSEMBLY (FOR 4WD) (See page TF-9)
34. REMOVE BACKUP LIGHT SWITCH ASSEMBLY

(a) Remove the backup light switch assembly and gasket from the
transmission case.
INSTALLATION
1. INSTALL BACKUP LIGHT SWITCH ASSEMBLY
(a) Install the backup light switch assembly to the transmission
case using a new gasket.
2. INSTALL TRANSFER ASSEMBLY (FOR 4WD) (See page TF-10)
3. INSTALL TRANSMISSION CONTROL CABLE BRACKET NO. 1

(FOR 2WD)
(a) Install control cable bracket No. 1 with the 2 bolts.
MT 4. INSTALL ENGINE MOUNTING BRACKET RR (FOR 2WD)
(a) Install the engine mounting bracket RR with the 3 bolts.
5. TEMPORARILY TIGHTEN TRANSMISSION ASSEMBLY (MANUAL
TRANSMISSION)
(a) Clean the seal bolt hole of the engine block.
NOTICE:
The seat bolts are not reusable.
(b) Check that 2 knock pins are attached to the engine side.
(c) Using a high transmission jack, level the engine and
transmission assembly, and engage the knock pin with the
knock pin hole.
C142614J01 NOTICE:
Do not forcibly twist the transmission assembly.
GETtheMANUALS.org
MT–14
(d) Temporarily install the transmission assembly with the 3 bolts.

NOTICE:
• Do not shake the transmission unit assembly violently
as doing so may cause damage to the input shaft.
• Tighten with the oxygen sensor bracket.
C143529
6. INSTALL ENGINE REAR SUPPORT MEMBER

(a) Install the engine rear support member to the transmission
assembly with the bolt and nut.
C141256
(b) Temporarily install the engine rear support member with the 4
bolts.
7. FULLY TIGHTEN TRANSMISSION ASSEMBLY (MANUAL

TRANSMISSION)
(a) Lower the vehicle.
A133258
MT
(b) Using a preset torque wrench, tighten transmission assembly
mounting bolt A.

(a) Temporarily install the starter assembly with the 2 bolts.
A
C141309
GETtheMANUALS.org
(b) Connect the starter assembly connector with the nut.

(c) Lift up the vehicle.
C141257
(d) Using a high transmission jack, support the engine rear support
member.
(e) Remove the 4 bolts and disconnect the engine rear support
member.
(f) Using an extension bar (600 mm), tighten the 2 starter
assembly mounting bolts.
HINT:
Adjust the height of the transmission assembly using a high
C141310 transmission jack, and tighten the 2 starter assembly mounting
bolts.
9. FULLY TIGHTEN TRANSMISSION ASSEMBLY (MANUAL
A A
TRANSMISSION)
B (a) Tighten the transmission assembly mounting bolts in the order
of A, B, C.
A
B
C
C C C136911J03
MT
GETtheMANUALS.org
MT–16
(1) Using an extension bar (600 mm), tighten bolt A.

NOTICE:
A When tightening bolt A, tighten the clamp of water
bypass pipe No. 2 together.
HINT:
Bolt A part number 91619-61250 (Length under bolt head
57 mm)
C141323
(2) Using an extension bar (600 mm), tighten bolts B.

B HINT:
Bolt B part number 91619-61250 (Length under bolt head
57 mm)
B
C143527
MT
(3) Tighten bolts C.
HINT:
Bolt C part number 90119-10260 (Length under bolt head
40 mm)
C
C C C143528
10. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Using the 4 clips, install the transmission control cable
assembly to the shift control cable bracket and transmission
assembly.
8° NOTICE:
8°
or do not apply load to the control cable end.
C143526
GETtheMANUALS.org
11. CONNECT CONNECTOR

(a) Connect the backup light switch assembly and vehicle speed
sensor connectors.
C141311
(b) Install the wire harness clamp of the oxygen sensor assembly.
A133302
(c) Install the engine rear support member with the 4 bolts.
A133258
MT
12. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY
(a) Install the clutch release cylinder assembly to the transmission
assembly with the 2 bolts.
13. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (FOR 4WD)

(See page PR-4)

C133718
PR-4)
16. INSTALL EXHAUST PIPE ASSEMBLY FR (See page EX-2)
19. INSTALL FUEL INJECTOR ASSEMBLY (See page EM-164)
20. INSTALL FUEL DELIVERY PIPE (See page EM-165)
GETtheMANUALS.org
MT–18

page EM-165)
25. INSTALL BATTERY
26. CONNECT BATTERY NEGATIVE TERMINAL (See page EM-167)
29. ADD MANUAL TRANSMISSION FLUID
30. INSPECT MANUAL TRANSMISSION FLUID LEVEL (See page MT-

3)
39. INSPECT ENGINE IDLE SPEED (See page EM-2)

(See page SS-10)
MT
GETtheMANUALS.org
MT–19 MANUAL TRANSMISSION - TRANSMISSION EXTENSION HOUSING OIL SEAL (MTM) (2WD)
TRANSMISSION EXTENSION HOUSING OIL SEAL (MTM)

TRANSMISSION
MANUAL TRANSMISSION
/ TRANSAXLE
(2WD)
COMPONENTS
T=60{612}
×4
MT ×2 PROPELLER WITH CENTER BEARING

SHAFT ASSEMBLY
T=37{377}

×7
T=5.4{55}
×4
T=5.4{55}
NON-REUSEABLE PART APPLY MP GREASE C139166J05
GETtheMANUALS.org
MANUAL TRANSMISSION - TRANSMISSION EXTENSION HOUSING OIL SEAL (MTM) (2WD)
MT–20
REMOVAL
3. DRAIN MANUAL TRANSMISSION FLUID

5. REMOVE EXTENSION HOUSING OIL SEAL
(a) Using SST, remove the oil seal.
SST SST 09308-00010
INSTALLATION
6. INSTALL EXTENSION HOUSING OIL SEAL
(a) Apply a small amount of MP grease to the lip of a new oil seal.
C138770
(b) Using SST and a hammer, install the oil seal.

SST SST 09309-87201
HINT:
Press in the oil seal up to the housing surface.

8. ADD MANUAL TRANSMISSION FLUID

C138771
MT
MT
GETtheMANUALS.org
MT–21 MANUAL TRANSMISSION - SHIFT LEVER ASSEMBLY (MTM)

TRANSMISSION
MANUAL TRANSMISSION
/ TRANSAXLE
COMPONENTS
SHIFT LEVER KNOB
CONSOLE BOX
ASSEMBLY RR
T=5.0{51}
CONSOLE BOX COVER

T=18{185}
T=18{185}
MT CABLE CLAMP
T=6.4{65}
TRANSMISSION FLOOR CLIP

SHIFT ASSEMBLY
CABLE ASSEMBLY
CLIP
T=18{185}
TRANSMISSION CONTROL CABLE CLAMP

C139165J01
GETtheMANUALS.org
MANUAL TRANSMISSION - SHIFT LEVER ASSEMBLY (MTM)
MT–22
REMOVAL
1. REMOVE TRANSMISSION CONTROL CABLE CLAMP
(a) Remove the bolt, then remove the clip from the transmission
floor shift assembly.
C134967
(b) Remove the bolt and transmission control cable clamp.
2. REMOVE SHIFT LEVER KNOB

(a) Remove clip A shown in the illustration, and disconnect the
transmission control cable assembly from the transmission floor
shift assembly.
C134968
(b) Remove the 2 clips B from the transmission floor shift assembly.
B MT
B C133958J01
5. REMOVE TRANSMISSION FLOOR SHIFT ASSEMBLY

(a) Remove the 4 bolts and shift lever assembly.
INSTALLATION
1. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY
(a) Pass the transmission control cable assembly through the
transmission floor shift assembly installation hole.
C134969
GETtheMANUALS.org
MT–23 MANUAL TRANSMISSION - SHIFT LEVER ASSEMBLY (MTM)
(b) Install the transmission floor shift assembly with the 4 bolts.

(a) Install the transmission control cable assembly to the
transmission floor shift assembly with clip A shown in the
illustration.
C134969
(b) Secure the transmission control cable assembly to the

transmission floor shift assembly with 2 clips B.
NOTICE:
A
Make sure that the control cable assembly is securely
installed onto the shift lever.
3. INSTALL CONSOLE BOX ASSEMBLY RR
4. INSTALL SHIFT LEVER KNOB

B
B C133958J01
5. INSTALL TRANSMISSION CONTROL CABLE CLAMP

(a) Install the clip to the transmission floor shift assembly with the
bolt.
C134967
MT
(b) Install the transmission control cable clamp with the bolt.
C134968
GETtheMANUALS.org
MANUAL TRANSMISSION - TRANSMISSION CONTROL CABLE ASSEMBLY (MTM)
MT–24
TRANSMISSION CONTROL CABLE ASSEMBLY (MTM)

TRANSMISSION
MANUAL TRANSMISSION
/ TRANSAXLE
COMPONENTS

MT
×7
T=5.4{55}

×4
T=5.4{55}
ENGINE UNDER COVER
×11

C139174J03
GETtheMANUALS.org
MT–25 MANUAL TRANSMISSION - TRANSMISSION CONTROL CABLE ASSEMBLY (MTM)
SHIFT LEVER KNOB
CONSOLE BOX
ASSEMBLY RR
T=5.0{51}
CONSOLE BOX COVER

T=18{185}
T=18{185}
CABLE CLAMP
T=6.4{65} CLIP
CLIP
CLIP
MT CABLE ASSEMBLY
WASHER
CABLE BRACKET
T=18{185}
TRANSMISSION CONTROL CABLE CLAMP
APPLY MP GREASE
C143531J01
GETtheMANUALS.org
MANUAL TRANSMISSION - TRANSMISSION CONTROL CABLE ASSEMBLY (MTM)
MT–26
REMOVAL

(a) Remove the 4 clips, and disconnect the transmission control
cable assembly from the transmission assembly.
5. REMOVE TRANSMISSION CONTROL CABLE CLAMP (See page

MT-22)
6. REMOVE SHIFT LEVER KNOWB
8. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Expand clip A shown in the illustration, and disconnect the
transmission control cable assembly from the transmission floor
shift assembly.
(b) Remove 2 clips B shown in the illustration, then remove the
cable end from the installation hole of the floor shift assembly.
A
INSTALLATION
(a) Install the transmission control cable assembly to the
transmission floor shift assembly with clip A shown in the
illustration.
B
B C133958J01
(b) Secure the transmission control cable assembly to the

transmission floor shift assembly with 2 clips B.
A
NOTICE: MT
Make sure that the control cable assembly is securely
installed onto the shift lever.
B
B C133958J01
2. INSTALL TRANSMISSION CONTROL CABLE CLAMP

(a) Install the clip to the transmission floor shift assembly with the
bolt.
C134967
GETtheMANUALS.org
MT–27 MANUAL TRANSMISSION - TRANSMISSION CONTROL CABLE ASSEMBLY (MTM)
(b) Install the transmission control cable clamp with the bolt.
NOTICE:
TAPE • Assemble the parts so that the shift cable is positioned
at the lower side.
• Make sure that the tape is positioned as shown in the
illustration.

(a) Using the 4 clips, install the transmission control cable
C134968J01
assembly to the shift control cable bracket and transmission
assembly.
MT
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TO INDEX
DRIVE LINE / AXLE
TRANSFER
TRANSFER SYSTEM (4WD)
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TF-1
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TF-2
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TF-3
TRANSFER (4WD)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TF-4
TRANSFER OIL (4WD)
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TF-6
TRANSFER EXTENSION HOUSING OIL SEAL (4WD)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TF-7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TF-7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TF-9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TF-10
DIFFERENTIAL LOCK SWITCH (4WD)
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TF-12
TF
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TF–1 TRANSFER - TRANSFER SYSTEM (4WD)
TRANSFER SYSTEM (4WD)

DRIVE LINE / AXLE
TRANSFER
OPERATION CHECK
1. INSPECT TRANSFER ACTUATOR FUNCTION
(a) Disconnect the 2 vacuum hoses from the actuator part of the
transfer assembly.
(b) Connect a MIGHTY VAC to the (A) side in the illustration, and
(B)
(A) check if the front propeller shaft assembly turns in the reverse
direction when turning the propeller shaft assembly manually by
applying vacuum.
(c) Connect the MIGHTY VAC to the (B) side in the illustration, and
check if the front propeller shaft assembly turns in the same
direction as in the previous step when turning the propeller shaft
assembly manually by applying vacuum.
C133926
2. INSPECT VACUUM SWITCHING VALVE FUNCTION

(a) When turning OFF the differential lock switch, check that VSV1
does not have ventilation to the check valve side, but VSV2
VSV1
has.
Check Valve (b) When turning ON the differential lock switch, check that VSV1
has ventilation to the check valve side, but VSV2 does not
have.
VSV2
C133932J01
TF
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TRANSFER - TRANSFER SYSTEM (4WD)
TF–2
LOCATION
DIFFERENTIAL LOCK SWITCH
VACUUM SWITCHING VALVE
TF
TRANSFER ACTUATOR
C133931J01
GETtheMANUALS.org
TF–3 TRANSFER - TRANSFER SYSTEM (4WD)

Use the table below to help determine the causes of the problems. Check each part, and if
necessary, repair or replace these parts.
Noise from transfer Fluid level (too low) TF-6
Fluid level (too high) TF-6
Transfer fluid leaks Transfer extension housing oil seal (worn or damaged) -
Gasket (damaged) -
TF
GETtheMANUALS.org
TRANSFER - TRANSFER (4WD)
TF–4
TRANSFER (4WD)
DRIVE LINE / AXLE
TRANSFER
COMPONENTS
EXHAUST PIPE ASSEMBLY FR EXHAUST

PIPE GASKET
T=19{194}
T=46{469} T=60{612}
×4
EXHAUST PIPE GASKET

T=37{377} ×2
T=60{612}
×4
ENGINE UNDER COVER RR RH FRONT PROPELLER TF

SHAFT ASSEMBLY
T=68{693}
×7
T=68{693}
×4
×11 FRONT SUSPENSION CROSS

ENGINE UNDER COVER MEMBER LWR
C139168J04
GETtheMANUALS.org
TF–5 TRANSFER - TRANSFER (4WD)
M/T CLIP
CLIP
×2
T=37{375}
TRANSMISSION CONTROL TRANSMISSION CONTROL
CABLE ASSEMBLY CABLE BRACKET
T=37{375} ×7 TRANSFER EXTENSION

HOUSING OIL SEAL
TRANSFER ASSEMBLY
NEEDLE ROLLER
BEARING (M/T)
TRANSFER GASKET (M/T)
M/T
T=37{375}
ENGINE MOUNTING
BRACKET RR
TRANSFER EXTENSION
×3 HOUSING OIL SEAL
×3
TF T=37{375}
T=37{375}
ENGINE MOUNTING
BRACKET RR ENGINE REAR
SUPPORT MEMBER
×2
T=48{490}
×2
T=48{490}

C139169J08
GETtheMANUALS.org
TRANSFER - TRANSFER OIL (4WD)
TF–6
TRANSFER OIL (4WD)

DRIVE LINE / AXLE
TRANSFER
ADJUSTMENT
1. INSPECT AND ADJUST TRANSFER FLUID
(a) Remove the filler plug and gasket.
C136854
(b) Using your fingers or wires, check that the fluid level is 0 to 5
mm below the bottom of the transmission filler plug hole.
Filler Plug NOTICE:
• If the fluid level is too high or too low, it may cause
Oil Level trouble.
• If the fluid is replaced, check the fluid level after driving.
0-5 mm (c) If the fluid level is low, check for fluid leaks and add fluid.
Wire
(d) Install the filler plug using a new gasket.
C132685
2. ADD TRANSER FLUID
(a) Remove the filler plug and gasket.
(b) Add transmission gear fluid (API GL-4, SAE 75W-80).
Reference value:
The fluid level is 0 to 5 mm below the bottom of the filler
plug hole.
(c) Check the fluid level.
(d) Install the filler plug using a new gasket.
NOTICE: TF
Recheck the fluid level after driving
GETtheMANUALS.org
TF–7 TRANSFER - TRANSFER EXTENSION HOUSING OIL SEAL (4WD)
TRANSFER EXTENSION HOUSING OIL SEAL (4WD)

DRIVE LINE / AXLE
TRANSFER
REMOVAL
2. REMOVE ENGINE UNDER COVER RR RH (WITH ENGINE UNDER

COVER RR RH)
3. REMOVE ENGINE UNDER COVER RR LH (WITH ENGINE UNDER

COVER RR LH)
4. DRAIN TRANSFER FLUID
(a) Remove the drain plug, and drain the transfer fluid.
(b) Install the transfer case plug N (filler plug) using a new transfer
seal gasket.
5. REMOVE FRONT SUSPENSION CROSS MEMBER LWR(See page

PR-3)
6. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (See page PR-

C136854J01 3)

ASSEMBLY(See page PR-6)
8. REMOVE TRANSFER EXTENSION HOUSING OIL SEAL

SST 09308-00010
(a) Using SST, remove the transfer extension housing oil seal.
(b) Perform the same procedure for the FR side oil seal as for the
RR side oil seal.
INSTALLATION
1. INSTALL TRANSFER EXTENSION HOUSING OIL SEAL
SST 09309-87201, 09310-87301
(a) Coat the lip of the extension housing oil seal with MP grease.
TF C136781
(b) Using SST and a hammer, drive in a new extension housing oil
seal.
NOTICE:
Make sure the oil seal is installed in the correct direction.
HINT:
• Perform the same procedure for the FR side oil seal as for
the RR side oil seal.
• Press in the oil seal until the oil seal surface is flush with the
the case surface.
C136782
3. INSTALL FRONT PROPELLER SHAFT ASSEMBLY(See page PR-

4)

PR-4)
5. ADD TRANSER FLUID(See page TF-6)
GETtheMANUALS.org
TRANSFER - TRANSFER EXTENSION HOUSING OIL SEAL (4WD)
TF–8
6. INSPECT AND ADJUST TRANSFER FLUID (See page TF-6)
7. INSPECT MANUAL TRANSMISSION FLUID (MANUAL

TRANSMISSION)
8. INSTALL ENGINE UNDER COVER RR RH (WITH ENGINE UNDER

COVER RR RH)
9. INSTALL ENGINE UNDER COVER RR LH (WITH ENGINE UNDER

COVER RR LH)
TF
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TF–9 TRANSFER - TRANSFER ASSEMBLY (4WD)

DRIVE LINE / AXLE
TRANSFER
REMOVAL
6. DRAIN TRANSFER FLUID(See page TF-7)

4WD)(See page PR-3)

4WD)(See page PR-3)


(MANUAL TRANSMISSION)
(a) Remove the 2 clips, then disconnect the transmission control
cable assembly from the cable bracket.
12. SUPPORT ENGINE WITH TRANSMISSION ASSEMBLY

(a) Using a mission jack, support the engine with transmission
assembly.
13. REMOVE ENGINE REAR SUPPORT MEMBER

(a) Remove the bolt and nut, then disconnect the transfer from the
engine rear support member.
(b) Remove the 4 bolts and engine rear support member.
TF 14. REMOVE TRANSFER ASSEMBLY
(a) Remove the 7 bolts and transfer assembly.
NOTICE:
• For the transfer assembly, hit the rib part of the case
using a plastic-faced hammer, and remove it.
• Do not drop the needle roller bearing at the tip of the
output shaft of the transmission assembly.(Manual
transmission)
C136779
C136855
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TRANSFER - TRANSFER ASSEMBLY (4WD)
TF–10
15. REMOVE ENGINE MOUNTING BRACKET RR (AUTOMATIC

TRANSMISSION)
(a) Remove the 3 bolts, then remove the engine mounting bracket
RR from the transfer assembly.
16. REMOVE ENGINE MOUNTING BRACKET RR (MANUAL

TRANSMISSION)
(a) Remove the 3 nuts, then remove the engine mounting bracket
RR from the transfer assembly.
17. REMOVE TRANSMISSION CONTROL CABLE BRACKET NO. 1

(a) Remove the 2 bolts, then remove the transmission control cable
bracket No. 1 from the transfer assembly.
INSTALLATION
1. INSTALL TRANSMISSION CONTROL CABLE BRACKET NO. 1
(a) Install the transmission control cable bracket No. 1 to the
transmission assembly with the 2 bolts.
2. INSTALL ENGINE MOUNTING BRACKET RR (AUTOMATIC

TRANSMISSION)
(a) Install the engine mounting bracket RR to the transfer assembly
with the 3 bolts.
3. INSTALL ENGINE MOUNTING BRACKET RR (MANUAL

TRANSMISSION)
(a) Install the engine mounting bracket RR to the transfer assembly
with the 3 nuts.
4. INSTALL TRANSFER ASSEMBLY (MANUAL TRANSMISSION)

(a) Install the transfer assembly and gasket to the transmission
assembly with the 7 bolts.
NOTICE: TF
• Do not drop the needle roller bearing at the tip of the
output shaft of the transmission assembly.
• Pay attention that the oil supply pipe of the transfer
assembly does not come off.
C136855
5. INSTALL TRANSFER ASSEMBLY (AUTOMATIC TRANSMISSION)

(a) Using a scraper and solvent, clean the fitting surfaces between
the transfer and transmission side cover.
GETtheMANUALS.org
TF–11 TRANSFER - TRANSFER ASSEMBLY (4WD)
(b) Apply Three Bond 1216 to the transmission side cover.

NOTICE:
After applying Three Bond 1216, install the transmission
side cover within 3 minutes, and tighten within 15 minutes.
(c) Install the transfer assembly with the 7 bolts.
NOTICE:
Pay attention that the oil supply pipe of the transfer
assembly does not come off.
C142410
6. INSTALL ENGINE REAR SUPPORT MEMBER

(a) Install the engine rear support member with the 4 bolts.
(b) Connect the engine rear support member to the transfer
assembly with the bolt and nut.

(a) Install the transmission control cable assembly to the cable
bracket with the 2 clips.
A133258

4)

PR-4)
12. ADD TRANSER FLUID(See page TF-6)
13. INSPECT AND ADJUST TRANSFER FLUID (See page TF-6)
14. INSPECT MANUAL TRANSMISSION FLUID
TF 15. INSTALL ENGINE UNDER COVER RR RH
18. INSTALL FRONT TIRE(See page EM-68)
GETtheMANUALS.org
TRANSFER - DIFFERENTIAL LOCK SWITCH (4WD)
TF–12
DIFFERENTIAL LOCK SWITCH (4WD)

DRIVE LINE / AXLE
TRANSFER
INSPECTION
1. INSPECT DIFFERENTIAL LOCK SWITCH
+B (1) Using a tester, check the continuity between the
GND
terminals.
Standard:
Terminal (Terminal
Switch Position Standard
Name)
OFF +B (3) ←→ GND (4) No continuity
C133933J01
ON +B (3) ←→ GND (4) Continuity
TF
GETtheMANUALS.org
TO INDEX
DRIVE LINE / AXLE
PROPELLER SHAFT
PROPELLER SHAFT SYSTEM
BASIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PR-1
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PR-1
FRONT PROPELLER SHAFT ASSEMBLY (4WD)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PR-2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PR-3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PR-4
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PR-5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PR-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PR-7
PR
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PR–1 PROPELLER SHAFT - PROPELLER SHAFT SYSTEM
PROPELLER SHAFT SYSTEM

DRIVE LINE / SHAFT
PROPELLER AXLE
BASIC INSPECTION
1. INSPECT PROPELLER SHAFT
(a) Inspect loosened connection.
(1) Check for looseness in the installed bolts of the flange
yoke and the center support bearing bracket.
C132729

Use the table below to help determine the cause of the problem.Inspect each part and repair or
replace the parts if necessary.
1. Front propeller shaft (runout) PR - 3
2. Rear propeller shaft (runout) PR - 6
Noise and vibration from the propeller shaft. 3.Universal joint spider (loose) (2WD) PR - 6
4.Universal joint spider (loose) (4WD) PR - 3
5. Center support bearing (worn, loose) PR - 6
PR
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PROPELLER SHAFT - FRONT PROPELLER SHAFT ASSEMBLY (4WD)
PR–2
FRONT PROPELLER SHAFT ASSEMBLY (4WD)

DRIVE LINE / SHAFT
PROPELLER AXLE
COMPONENTS
T=68{693}
T=68{693}
×4
FRONT PROPELLER
T=60{612} SHAFT ASSEMBLY
ENGINE UNDER COVER RR RH PR
T=5.4{55}
×7
T=5.4{55}
×4
T=5.4{55} ENGINE UNDER COVER ASSEMBLY

×11
C139208J06
GETtheMANUALS.org
PR–3 PROPELLER SHAFT - FRONT PROPELLER SHAFT ASSEMBLY (4WD)
REMOVAL
4. DRAIN TRANSFER OIL (See page TF-7)

5. REMOVE FRONT SUSPENSION CROSS MEMBER LWR
(a) Remove the 4 bolts and the front suspension cross member
LWR.
6. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

(a) Put matchmarks on the universal joint flange yoke and the dif-
ferential flange.
C133711
(b) Remove the 4 bolts and disconnect the front propeller shaft
assembly from the front differential carrier.
HINT:
If the flange connection is tight, temporarily tighten one bolt only
and evenly tap the flange with a brass bar and hammer to
remove it.
(c) Remove the front propeller shaft assembly from the extension
housing.
NOTICE:
C137191 • Be careful not to damage the oil seal.
• When removing the propeller shaft assembly, do not
apply excessive force to the universal joint and other
parts.
7. INSPECT FRONT PROPELLER SHAFT ASSEMBLY

(a) Check that the shaft tube is not damaged.
(b) Using a dial indicator and a V-block, check the runout of the
PR shaft.
Maximum limit:
0.5 mm
NOTICE:
The dial indicator should be installed at a right angle to and
in the middle of the propeller shaft assembly.
8. INSPECT UNIVERSAL JOINT SPIDER ASSEMBLY

(a) Allow the spider to turn and check that it turns smoothly.
C133957
(b) Shake the spider hard in the axial direction and the direction
perpendicular to the axis to check that there is no looseness on
the spider.
GETtheMANUALS.org
PROPELLER SHAFT - FRONT PROPELLER SHAFT ASSEMBLY (4WD)
PR–4
INSTALLATION
1. INSTALL FRONT PROPELLER SHAFT ASSEMBLY
(a) Insert the front propeller shaft assembly into the extension
housing.
NOTICE:
• Be careful not to damage the extension housing oil
seal.
• When installing the propeller shaft assembly, do not
parts.
(b) Align the matchmarks on the universal joint flange yoke and dif-
ferential flange.
(c) Install the front propeller shaft assembly with the 4 bolts.
C137191
2. INSTALL FRONT SUSPENSION CROSS MEMBER LWR

(a) Install the front suspension cross member LWR with the 4 bolts.
3. REFILL TRANSFER OIL (See page TF-6)
4. INSPECT AND ADJUST TRANSFER OIL (See page TF-6)
5. INSPECT MANUAL TRANSMISSION OIL (See page MT-3)

C133711 7. INSTALL ENGINE UNDER COVER RR LH

PR
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PR–5 PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY

DRIVE LINE / SHAFT
PROPELLER AXLE
COMPONENTS
FOR COLD AREA SPECIFICATION VEHICLES
PROPELLER SHAFT
DUST COVER NO. 1
T=17{173}
T=60{612}
×4

×2
PR T=37{377}
C140647J03
GETtheMANUALS.org
PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY
PR–6
REMOVAL
1. DRAIN TRANSFER OIL (FOR 4WD) (See page TF-7)
2. DRAIN AUTOMATIC TRANSMISSION FLUID (2WD, TRANSMIS-

SION A/T) (See page AT-69)

BLY
(a) Put matchmarks on the universal joint flange yoke and the dif-
ferential flange.
(b) Remove the 4 bolts and disconnect the propeller with center
bearing shaft assembly from the rear differential carrier assem-
bly.
HINT:
If the flange connection is tight, temporarily tighten one bolt only
and evenly tap the flange with a brass bar and hammer to
remove it.
C135265
(c) Remove the 2 bolts and the propeller with center bearing shaft
assembly.
NOTICE:
• When removing, do not apply excessive force to the
universal joint.
• When removing from the transfer, be careful not to dam-
age the oil seal.
(d) Remove the front propeller with center bearing shaft assembly
from the extension housing.
C135266
4. REMOVE PROPELLER SHAFT DUST COVER NO. 2 (FOR VEHI-

CLES WITH COLD WEATHER SPECIFICATIONS)
(a) Remove the nut and the propeller shaft dust cover No. 1.
5. INSPECT PROPELLER WITH CENTER BEARING SHAFT ASSEM-

BLY
PR
(a) Check that the shaft tube is not damaged.
C135264
(b) Using a dial indicator and a V-block, check the runout of the
shaft.
Maximum limit:
0.5 mm
NOTICE:
The dial indicator should be installed at a right angle to and
in the middle of the propeller shaft assembly.
6. INSPECT UNIVERSAL JOINT SPIDER ASSEMBLY

(a) Allow the spider to turn and check that it turns smoothly.
C091260
GETtheMANUALS.org
PR–7 PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY
(b) Shake the spider hard in the axial direction and the direction
perpendicular to the axis to check that there is no looseness on
the spider.
7. INSPECT CENTER SUPPORT BEARING ASSEMBLY

(a) Inspect that there is no damages or cracks on the rubber part
and detached springs.
(b) Check that there are not cracks or deformation on the bracket of
the center support bearing part.
INSTALLATION
1. INSTALL PROPELLER SHAFT DUST COVER NO. 2 (FOR VEHI-
CLES WITH COLD WEATHER SPECIFICATIONS)
(a) Install the propeller shaft dust cover No. 1 with the nut.

BLY
(a) Insert the propeller shaft assembly into the extension housing.
NOTICE:
• Be careful not to damage the extension housing oil
C135264
seal.
• When installing the propeller shaft assembly, do not
parts.
HINT:
Support the propeller with center bearing shaft assembly using
a mission jack or other tools.
(b) Align matchmarks of the propeller with center bearing shaft
assembly and the differential side of the companion flange.
(c) With the 4 bolts, install the propeller with center bearing shaft
assembly to the differential companion flange.
NOTICE:
When tightening, keep the washer and nut free of oil.
PR
C135265
(d) With the 2 bolts, temporarily install the propeller with center
bearing shaft assembly.
(e) Fully tighten the 2 bolts of the center support bearing.
3. REFILL TRANSFER OIL (FOR 4WD) (See page TF-6)
4. INSPECT AND ADJUST TRANSFER OIL (FOR 4WD) (See page

TF-6)
5. REFILL MANUAL TRANSMISSION OIL (FOR 4WD) (See page MT-

C135266
3)
6. REFILL AUTOMATIC TRANSMISSION FLUID (2WD, TRANSMIS-

SION A/T)
GETtheMANUALS.org
PROPELLER SHAFT - PROPELLER SHAFT ASSEMBLY
PR–8
7. INSPECT AUTOMATIC TRANSMISSION FLUID (2WD, TRANSMIS-

SION A/T) (See page AT-55)
PR
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TO INDEX
DRIVE LINE / AXLE
DRIVE SHAFT
DRIVE SHAFT SYSTEM
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DS-1
FRONT DRIVE SHAFT (4WD)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DS-2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DS-5
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DS-6
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DS-7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DS-10
DS
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DS–1 DRIVE SHAFT - DRIVE SHAFT SYSTEM
DRIVE SHAFT SYSTEM

DRIVE SHAFT
LINE / AXLE

Abnormal noises from the front wheels Drive shaft DS-6
DS
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DRIVE SHAFT - FRONT DRIVE SHAFT (4WD)
DS–2
FRONT DRIVE SHAFT (4WD)

DRIVE SHAFT
LINE / AXLE
COMPONENTS
×7
T=5.4{55}
ENGINE UNDER COVER RR LH DS

×4
T=5.4{55}
ENGINE UNDER COVER
×11

C139174J02
GETtheMANUALS.org
DS–3 DRIVE SHAFT - FRONT DRIVE SHAFT (4WD)
FRONT DRIVE SHAFT ASSEMBLY LH
T=18.2{186}
SPEED SENSOR FR LH
(With ABS)
T=8.4{86}
TIE ROD END LH
T=46.6{475} CLIP
FRONT STABILIZER
LINK ROD
FRONT AXLE
HUB NUT LH
T=76.5{780}
T=205.8{2099}
DS
FRONT SUSPENSION T=58.1{592}
LOWER ARM NO. 1 LH
T=37.3{380}
CLIP

C140799J03
GETtheMANUALS.org
DS–4
FRONT AXLE OUTBOARD JOINT BOOT CLAMP
DRIVE SHAFT OUTBOARD JOINT BOOT
FRONT AXLE OUTBOARD JOINT

BOOT CLAMP LH NO. 2
FRONT AXLE OUTBOARD

JOINT SHAFT ASSEMBLY
FRONT DRIVE SHAFT

HOLE SNAP RING LH
FRONT DRIVE INBOARD

JOINT ASSEMBLY LH
FRONT DRIVE INNER SHAFT

SNAP RING INN LH
TRIPOD JOINT
DS
INBOARD JOINT BOOT CLAMP
NO. 2
DRIVE SHAFT INBOARD JOINT BOOT
FRONT AXLE INBOARD JOINT

BOOT CLAMP
APPLY MP GREASE NON-REUSEABLE PART

C139205J04
GETtheMANUALS.org
REMOVAL
3. DRAIN DIFFERENTIAL OIL
4. DISCONNECT SPEED SENSOR FR LH (WITH ABS)
5. REMOVE FRONT AXLE HUB NUT LH

SST 09511-87202
(a) Using a chisel and a hammer, release the staked part of the
front axle hub nut LH.
(b) Hold the front axle hub using SST, and remove the front axle
hub nut LH.
NOTICE:
• When removing the front axle hub nut LH, completely
loosen the staked part.
• Do not damage the threads of the drive shaft assembly.
6. DISCONNECT TIE ROD END LH

SST 09628-00011
SST
(a) Remove the clip and nut.
C139823
(b) Using SST, disconnect the tie rod end LH from the steering
SST knuckle.
NOTICE:
• When setting SST, install a dummy nut to the threads of
the tie rod end to prevent damage to the threads.
• Do not damage the front disc brake dust cover.
• To prevent SST from dropping, be sure to hang it with a
piece of string or other tools.
• Do not damage the ball joint dust cover.
C139824 • Do not damage the steering knuckle.
7. REMOVE FRONT STABILIZER LINK ROD(See page SP-14)
8. DISCONNECT FRONT SUSPENSION LOWER ARM NO. 1 LH

SST 09628-00011
DS (b) Using SST, disconnect the front sustention lower arm No. 1 LH
from the steering knuckle.
NOTICE:
• When setting SST, install a dummy nut to the threads of
the tie rod end to prevent damage to the threads.
• To prevent SST from dropping, be sure to hang it with a
SST • Do not damage the ball joint dust cover.
• Do not damage the steering knuckle.
C142002
9. DISCONNECT FRONT AXLE HUB LH
(a) Using a plastic hammer, lightly tap the end of the drive shaft
assembly, and disengage the shaft and front axle assembly.
HINT:
If the engagement of the spline is firm, use a brass bar and
hammer to lightly tap the end of the drive shaft assembly LH.
GETtheMANUALS.org
DS–6
(b) Push the axle assembly outward from the vehicle, and remove
the drive shaft assembly LH from the axle assembly.
NOTICE:
• Do not push the axle assembly outward from the
vehicle more than necessary.
• Do not damage the boot.
• Be sure to hang the drive shaft assembly LH with a
• Do not apply excessive force to the flexible hose.
10. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

SST 09648-87201
(a) Using SST, remove the front drive shaft assembly LH.
11. INSPECT FRONT DRIVE SHAFT ASSEMBLY LH

(a) Move the joint up and down, left and right, and in the axial
direction to check that it moves smoothly and that there is no
significant looseness.Check the boot for cracks, damage, and
grease leakage.
SST
DISASSEMBLY
C139827 1. DISCONNECT INBOARD JOINT BOOT CLAMP NO. 2
(a) Using a screwdriver, unstuck the inboard joint boot clamp No. 2.
(b) Disconnect the inboard joint boot clamp No. 2 from the drive
shaft inboard joint boot.
2. DISCONNECT FRONT AXLE INBOARD JOINT BOOT CLAMP

(a) In the same way as the inboard joint boot clamp No. 2,
disconnect the front axle inboard joint boot clamp.
3. DISCONNECT DRIVE SHAFT INBOARD JOINT BOOT

(a) Disconnect the drive shaft inboard joint boot from the inboard
joint assembly.
C138320
4. REMOVE FRONT DRIVE INBOARD JOINT ASSEMBLY LH
(a) Remove grease from the inboard joint.
(b) Put matchmarks on the front drive inboard joint assembly LH
Matchmarks and front axle outboard joint shaft assembly.
NOTICE:
Do not use a punch to put matchmarks.
DS
(c) Remove the front drive inboard joint assembly LH from the front
axle outboard joint shaft assembly.
(d) Secure the front axle outboard joint shaft assembly in the vise
between aluminum plates.
NOTICE:
C138321 Do not tighten the vise too firmly.
GETtheMANUALS.org
(e) Using a snap ring expander, remove the front drive inner shaft
snap ring INN LH.
C061822J01
(f) Put matchmarks on the tripod joint and front axle outboard joint
shaft assembly.
NOTICE:
Do not use a punch to put matchmarks.
(g) Using a brass bar and a hammer, remove the tripod joint from
the front axle outboard joint shaft assembly.
NOTICE:
• Do not hit the roller.
Matchmarks • Do not drop the tripod joint.
C061823 (h) Remove the inboard joint boot clamp No. 2, drive shaft inboard
joint boot, and front axle inboard joint boot clamp.
5. REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH
NO. 2
(a) Hold the staked part of the clamp using pliers, and pry the front
axle outboard joint boot clamp LH No. 2 as shown in the
illustration.
6. REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH

(a) In the same way as the front axle outboard joint boot clamp LH
No. 2, hold the staked part of the clamp using pliers, and pry the
front axle outboard joint boot clamp LH.
C103884
7. REMOVE DRIVE SHAFT OUTBOARD JOINT BOOT
(a) Remove the drive shaft outboard joint boot and the 2 clamps
from the front axle outboard joint shaft assembly.
REASSEMBLY
DS 1. INSTALL DRIVE SHAFT OUTBOARD JOINT BOOT
(a) Wrap protective tape around the inboard side spline of the front
axle outboard joint shaft assembly.
(b) Install a new front axle outboard joint boot clamp LH No. 2, the
drive shaft outboard joint boot, and a new front axle outboard
joint boot clamp to the front axle outboard joint shaft assembly
in order.
(c) Fill the joint part of the front axle outboard joint shaft assembly
with grease.
HINT:
Grease application volume: 100 ± 10 g
(d) Install the drive shaft outboard joint boot into the groove of the
C142657 front axle outboard joint shaft assembly.
NOTICE:
Keep the groove free of grease.
GETtheMANUALS.org
DS–8
2. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH NO.

2
SST 09648-97202
(a) Secure the drive shaft assembly in the vise between aluminum
plates.
NOTICE:
Do not tighten the vise too firmly.
(b) Using SST, squeeze the front axle outboard joint boot clamp LH
No. 2 so that its clearance is within the standard value range.
SST Standard:
1.0 to 4.0 mm
NOTICE:
• Do not squeeze the boot clamp excessively, or its
clearance will be below the specified range.
Clearance • If the measurement value is not within the specified
C142659 range, use a new front axle outboard joint boot clamp
LH No. 2 and perform the installation procedure again.
3. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP

SST 09648-97202
(a) Using SST, squeeze the front axle outboard joint boot clamp so
that its clearance is within the standard value range using the
same procedure as the front axle outboard joint boot clamp LH
No. 2.
Standard:
1.0 to 4.0 mm
NOTICE:
• Do not squeeze the boot clamp excessively, or its
clearance will be below the specified range.
• If the measurement value is not within the specified
range, use a new front axle outboard joint boot clamp
and perform the installation procedure again.
4. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY LH
Protective Tape (a) Install a new front axle inboard joint boot clamp, the drive shaft
inboard joint boot, and a new inboard joint boot clamp No. 2 to
the front axle outboard joint shaft assembly in order.
(b) Secure the drive shaft assembly in the vise between aluminum
DS
plates.
NOTICE:
(c) Align the matchmarks and install the tripod joint onto the front
C142660J02 axle outboard joint shaft assembly.
GETtheMANUALS.org
(d) Using a brass bar and a hammer, tap in a tripod joint.

Matchmarks CAUTION:
• Do not hit the roller.
• Keep the tripod joint free of foreign objects.
C062073
(e) Using a snap ring expander, install a new front drive inner shaft
snap ring INN LH.
(f) Fill the inboard joint assembly with grease.
HINT:
Grease application volume: 95 ± 10 g
C061822J02
(g) Align the matchmarks and install the front drive inboard joint
Matchmarks assembly LH onto the front axle outboard joint shaft assembly.
5. INSTALL DRIVE SHAFT INBOARD JOINT BOOT

(a) Install the drive shaft inboard joint boot in the grooves of the
front axle outboard joint shaft assembly and front drive inboard
joint assembly LH.
NOTICE:
Keep the grooves free of grease.
C138321 6. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

(a) Install the front axle inboard joint boot clamp to the drive shaft
inboard joint boot.
(b) Using pliers and a hammer or similar tools, stake the inboard
joint clamp.
7. INSTALL INBOARD JOINT BOOT CLAMP NO. 2

DS (a) Install the inboard joint boot clamp No. 2 to the drive shaft
inboard joint boot.
(b) Using pliers and a hammer or similar tools, stake the inboard
joint boot clamp No. 2.
8. INSPECT FRONT DRIVE SHAFT ASSEMBLY

(a) Move the joint up and down, left and right, and in the axial
direction to check that it operates smoothly and there is no
significant looseness.
(b) Check the joint boot for cracks, damage, and grease leakage.
NOTICE:
Keep the drive shaft assembly in a horizontal position
when carrying.
GETtheMANUALS.org
DS–10
INSTALLATION
1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
(a) Apply MP grease to the front drive shaft assembly LH as shown
(b) Align the spline of the front drive inboard joint assembly LH, and
uniformly tap in the front drive shaft assembly LH using a brass
bar and a hammer.
NOTICE:
• Do not damage the oil seal.
APPLY MP GREASE
C143572J01 • Use the injection wall of the inboard joint assembly for
tapping.
• Do not tap the edge of the outboard joint assembly with
the hammer.
HINT:
Check that the drive shaft assembly LH is completely tapped in
according to the brass bar reaction force or sound change.
2. INSTALL FRONT AXLE HUB LH

(a) Push the front axle hub LH outward from the vehicle to align the
spline of the front drive shaft assembly LH with the front axle
hub LH and insert.
NOTICE:
• Do not damage the outboard joint boot.
• Do not damage the oil seal.
3. CONNECT FRONT SUSPENSION LOWER ARM NO. 1 LH

(a) Install the front suspension lower arm No. 1 LH to the steering
knuckle, and tighten with the nut.
(b) Install a new clip.
4. INSTALL FRONT STABILIZER LINK ROD

(a) Install the front stabilizer link rod to the front suspension lower
arm No. 1 and tighten with the nut.
5. INSTALL TIE ROD END LH

(a) Install the tie rod end to the steering knuckle, and tighten with
the nut.
DS
C137246 Torque: 46.6 N*m (475 kgf*cm)
6. INSTALL FRONT AXLE HUB NUT LH

(a) Install a new front axle hub nut LH.
GETtheMANUALS.org
(b) Using a chisel and a hammer, stake the front axle hub nut LH.
7. CONNECT SPEED SENSOR FR LH (WITH ABS)(See page BC-

147)

10. ADJUST FRONT WHEEL ALIGNMENT

C135147
(See page SP-4)
11. TEST MODE INSPECTION (ABS SENSOR CHECK)

WITHOUT VSC (See page BC-9)
WITH VSC (See page BC-65.)
DS
GETtheMANUALS.org
TO INDEX
DRIVE LINE / AXLE
DIFFERENTIAL
DIFFERENTIAL SYSTEM
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-1
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-1
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-2
DIFFERENTIAL OIL
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-3
FRONT DIFFERENTIAL (4WD)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-5
FRONT DIFFERENTIAL CARRIER OIL SEAL (4WD)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-9
FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-11
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-12
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-27
REAR DIFFERENTIAL
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-30
REAR DIFFERENTIAL CARRIER OIL SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-32
REAR DIFFERENTIAL CARRIER ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-34
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-34
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-50
DF
GETtheMANUALS.org
DF–1 DIFFERENTIAL - DIFFERENTIAL SYSTEM
DIFFERENTIAL SYSTEM
DRIVE LINE / AXLE
DIFFERENTIAL
PRECAUTIONS
1. Before disassembly, clean the outside of the differential
assembly and remove any sand or mud to prevent it from
entering the inside of the assembly during disassembly or
installation.
2. When disassembling a connecting part made of light alloy such
as a differential carrier cover, lightly tap it in with a plastic
hammer. Do not attempt to pry it off with a screw driver.
3. Always organize and arrange the disassembled parts properly to
protect them from dust or other foreign matter.
4. Fully wash and dry each part before installing it, and apply
differential gear oil.Do not use alkaline cleaner for aluminum or
rubber parts or ring gear set bolts.In addition, do not clean
rubber parts such as O-rings or oil seals with cleaning oils (such
as solvent).
5. Sufficiently coat the sliding and rotating surfaces with
differential gear oil before installation.
6. When securing parts in a vise, do not place the parts directly in
the vice. Be sure to place aluminum plates between the parts
and the vice.
7. Be extremely careful not to damage the contact surfaces of the
case. Such damage may cause oil leaks.
8. Before applying sealant, remove the old adhesive or old sealant
from the seal, and clean the area with a solvent.
9. Do not fill oil immediately after installing sealed parts. Wait at
least an hour.
10. As it may cause oil leaks, do not scratch or damage the contact
surfaces of the oil seal, O-ring, or gasket.
11. When tapping the oil seal into the end of the differential carrier,
inspect the installation depth at 3 or more locations on the oil
seal circumference. To prevent oil leakage, make sure that the
difference between the maximum and minimum measurement
values is within the standard value range.
12. When press-fitting an oil seal, be extremely careful not to
DF 13.
damage the oil seal lip or its outer circumference.
When replacing a bearing, replace the outer and inner races as a
set.
OPERATION CHECK
1. INSPECT DIFFERENTIAL OIL
(a) CHECK OIL LEVEL (See page DF-3 for the procedure.)
(b) CHECK FOR OIL LEAKS
(1) Visually inspect whether oil is leaking from the oil seal,
differential carrier, plug, case fitting surface, or any other
parts.
GETtheMANUALS.org
DIFFERENTIAL - DIFFERENTIAL SYSTEM
DF–2

Oil level (low) DF-3
Ring gear or pinion gear (worn or chipped) DF-12
Misalignment of the backlash DF-13
Noise from the front differential
Misalignment of the preload DF-14
Misalignment of the tooth contact pattern DF-22
Worn bearing DF-12
Oil level (low) DF-3
Ring gear or pinion gear (worn or chipped) DF-34
Misalignment of the backlash DF-35
Noises from the rear differential
Misalignment of the preload DF-46
Misalignment of the tooth contact pattern DF-46
Worn bearing DF-34
Oil level (high) DF-3
Oil leakage from the front differential
Carrier oil seal (worn or damaged) DF-9
Oil level (high) DF-3
Oil leakage from the rear differential
Carrier oil seal (worn or damaged) DF-32
DF
GETtheMANUALS.org
DF–3 DIFFERENTIAL - DIFFERENTIAL OIL
DIFFERENTIAL OIL
DRIVE LINE / AXLE
DIFFERENTIAL
ADJUSTMENT
(a) Put an oil tray under the drain plug.
(b) Remove the drain plug, then remove the filler plug.
(c) Check that the oil has drained completely.
(d) Tighten the drain plug using the specified torque.
2. ADD DIFFERENTIAL OIL

(a) Make sure that the vehicle is level.
(b) Remove the differential filler plug and gasket.
(c) Insert the gear oil injection nozzle, and slowly fill with hypoid
gear oil (differential oil).
NOTICE:
If the oil is filled too quickly, it may flow back. This may
cause you think mistakenly that the specified amount has
been added.
(d) Leave to stand for 5 minutes after the oil overflow from the filler
plug stops.
3. INSPECT AND ADJUST DIFFERENTIAL OIL
(a) Using your fingers or a wire, inspect the oil level.
Filler Plug Standard:
Within 0 to 5 mm from the bottom edge of the filler plug
Oil Level hole
NOTICE:
0-5 mm • As it may take some time for the oil to fill into the
Wire
differential, be sure to wait before checking the oil level.
• If the oil level is too high or too low, it may cause
C132685 trouble.
• Stop the vehicle on a level road.
(b) If the oil level is low, check for oil leaks and add oil.
(c) After oil is added, re-check that the oil has been filled up to the
specified level.
(d) Install the differential filler plug and a new gasket.
Standard:
T = 49 N*m (500 kgf*cm) (front differential)
DF T = 61 N*m (625 kgf*cm) (rear differential)

(a) Remove the differential filler plug and gasket.
(b) Rear differential (with LSD)
(1) Add differential hypoid gear oil (LSD)
Standard:
Within 0 - 5 mm from the bottom edge of the filler plug opening.
Full capacity:
Approx. 1.81 liter
(c) Front and rear deferential
(1) Add hypoid gear oil (differential oil)
Standard:
Within 0 - 5 mm from the bottom edge of the filler plug opening.
GETtheMANUALS.org
DIFFERENTIAL - DIFFERENTIAL OIL
DF–4
Full capacity:
Approx. 0.45 liter
Approx. 1.81 liter (rear differential)
(d) Check the oil level.
(e) Install the differential filler plug and a new gasket.
Standard:
T = 49 N*m (500 kgf*cm) (front differential)
T = 61 N*m (625 kgf*cm) (rear differential)
NOTICE:
After adding oil, re-check the oil level after driving.
DF
GETtheMANUALS.org
DF–5 DIFFERENTIAL - FRONT DIFFERENTIAL(4WD)
FRONT DIFFERENTIAL(4WD)
DRIVE LINE / AXLE
DIFFERENTIAL
COMPONENTS
×7
T=5.4{55}

DF ×4
T=5.4{55}
ENGINE UNDER COVER
×11

C139174J02
GETtheMANUALS.org
DIFFERENTIAL - FRONT DIFFERENTIAL(4WD)
DF–6
FRONT DRIVE SHAFT ASSEMBLY LH
T=18.2{186}
SPEED SENSOR FR LH
(With ABS)
T=8.4{86}
TIE ROD END LH
T=46.6{475} CLIP
FRONT STABILIZER
LINK ROD
FRONT AXLE
HUB NUT LH
T=76.5{780}
T=205.8{2099}
FRONT SUSPENSION T=58.1{592} DF

LOWER ARM NO. 1 LH
T=37.3{380}
CLIP
C140799J01
GETtheMANUALS.org
DF–7 DIFFERENTIAL - FRONT DIFFERENTIAL(4WD)
T=76{775}
×3
T=41.7{425}
FRONT DIFFERENTIAL MOUNT CUSHION NO. 1
FRONT DIFFERENTIAL BRACKET RR
T=76{775}
×3
FRONT DIFFERENTIAL
CARRIER ASSEMBLY ×4 T=76{775}
T=76{775}
×4

T=41.7{425} SUPPORT BRACKET
DF
...... TIGHTENING TORQUE [N*m{kgf*cm}]
C136382J01
GETtheMANUALS.org
DIFFERENTIAL - FRONT DIFFERENTIAL(4WD)
DF–8
FRONT DIFFERENTIAL
PINION
FRONT DIFFERENTIAL
PINION SHAFT
DIFFERENTIAL SIDE FRONT DIFFERENTIAL DRIVE
GEAR THRUST WASHER PINION BEARING SPACER
DIFFERENTIAL
SIDE GEAR FRONT DRIVE
DIFFERENTIAL SIDE PINION NUT
GEAR THRUST WASHER FRONT DRIVE PINION
DIFFERENTIAL COMPANION FLANGE FR
SIDE GEAR FRONT DRIVE PINION
FRONT DIFFERENTIAL TAPERED ROLLER BEARING RR
PINION DIFFERENTIAL
CARRIER
FILLER PLUG T=118{1203}
DIFFERENTIAL GASKET
SIDE OIL SEAL
FRONT DIFFERENTIAL
CASE BEARING T=49{500}
T=83.4{849} T=30{306}
SHIM
DIFFERENTIAL SHIM
×8 CASE NO.1
DRAIN PLUG SHIM
GASKET
BREATHER PLUG FRONT DIFFERENTIAL
T=11.3{115} CARRIER OIL SEAL
DIFFERENTIAL
DRIVE PINION
FRONT DRIVE PINION TAPERED
ROLLER BEARING FR
×8
T=20.6{210}
DIFFERENTIAL SIDE OIL SEAL
DIFFERENTIAL CARRIER SHIM
COVER FRONT DIFFERENTIAL DF
CASE BEARING
DIFFERENTIAL
RING GEAR

C140217J01
GETtheMANUALS.org
DF–9 DIFFERENTIAL - FRONT DIFFERENTIAL CARRIER OIL SEAL (4WD)
FRONT DIFFERENTIAL CARRIER OIL SEAL (4WD)

DRIVE LINE / AXLE
DIFFERENTIAL
REMOVAL
2. REMOVE ENGINE UNDER COVER RR RH (WITH ENGINE UNDER

COVER RR RH)
3. REMOVE ENGINE UNDER COVER RR LH (WITH ENGINE UNDER

COVER RR LH)
4. DRAIN TRANSFER OIL(See page TF-7)

PR-3)

3)
7. DRAIN DIFFERENTIAL OIL(See page DF-11)
8. REMOVE FRONT DRIVE PINION COMPANION FLANGE FR

(a) Using a chisel and a hammer, unstake the companion flange
nut.
NOTICE:
• When removing the nut, completely unstake it.
• Do not damage the threads of the drive pinion.
(b) Using the SST, secure the companion flange FR.
(c) Using a deep socket wrench (0.87in), remove the companion
flange nut and plate washer.
(d) Using the SST, remove the companion flange.
NOTICE:
Apply grease to the threads and tip of the SST center bolt
before use.
9. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL

SST 09308-10010
NOTICE:
SST Apply grease to the threads and tip of the SST center bolt
before use.
DF INSTALLATION
1. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL
SST 09636-20010
C137413
GETtheMANUALS.org
DIFFERENTIAL - FRONT DIFFERENTIAL CARRIER OIL SEAL (4WD)
DF–10
(a) Using the SST and a hammer, drive in a new carrier oil seal.
Make sure that the seal is installed according to the standard
SST below.
Standard:
0.5 ± 0.5 mm (from the carrier end face)
(b) Apply MP grease to the lip of the carrier oil seal.
2. INSTALL FRONT DRIVE PINION COMPANION FLANGE FR

(a) Install the companion flange FR.
C139818
(c) Using the SST, hold the companion flange and install the plate
washer and lock nut.
(d) Using a chisel and a hammer, stake the companion flange nut.

4)

PR-4)
5. ADD TRANSFER OIL(See page TF-6)

(See page DF-3)
7. INSPECT AND ADJUST TRANSFER OIL(See page TF-6)

(See page DF-3)
9. INSTALL ENGINE UNDER COVER RR RH (WITH ENGINE UNDER

COVER RR RH)
10. INSTALL ENGINE UNDER COVER RR LH (WITH ENGINE UNDER

COVER RR LH)
DF
GETtheMANUALS.org
DF–11 DIFFERENTIAL - FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD)
FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD)

DRIVE LINE / AXLE
DIFFERENTIAL
REMOVAL
(b) Remove the drain plug and gasket and drain the oil.
(c) Install the drain plug and a new gasket.
6. REMOVE FRONT AXLE HUB NUT LH(See page DS-5)
7. REMOVE FRONT AXLE HUB NUT RH

(a) Perform the same procedure for the RH side as for the LH side.
8. REMOVE TIE ROD END LH (See page DS-5)
9. REMOVE TIE ROD END RH

HINT:
Perform the same procedure for the RH side as for the LH side.
10. REMOVE FRONT STABILIZER LINK ROD(See page SP-14)
11. DISCONNECT FRONT SUSPENSION LOWER ARM NO. 1 LH(See

page DS-5)
12. DISCONNECT FRONT SUSPENSION LOWER ARM NO. 1 RH

HINT:
13. DISCONNECT FRONT AXLE HUB LH(See page DS-5)
14. DISCONNECT FRONT AXLE RH

HINT:
15. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH(See page DS-6)
16. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

DF HINT:

PR-3)

3)
19. SUPPORT FRONT DIFFERENTIAL CARRIER ASSEMBLY

(a) Support the front differential carrier assembly with a
transmission jack.
NOTICE:
As the front differential carrier assembly is heavy, be sure
that it is securely supported with the transmission jack.
GETtheMANUALS.org
DIFFERENTIAL - FRONT DIFFERENTIAL CARRIER ASSEMBLY (4WD)
DF–12
20. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY

(a) Remove the bolt and disconnect front differential mount cushion
No. 1 from the front suspension cross member.
C137248J01
(b) Remove the 2 bolts, then remove the front differential carrier
assembly (with bracket).
NOTICE:
• Do not lose the front differential carrier assembly.
• When removing the front differential carrier assembly,
there is a possibility of leakage of residual oil.
21. REMOVE FRONT DIFFERENTIAL CARRIER SUPPORT BRACKET

(a) Remove the 4 bolts, then remove the front differential carrier
support bracket from the front differential carrier.
C136011
22. REMOVE FRONT DIFFERENTIAL MOUNT CUSHION NO. 1
(a) Remove the 3 bolts, then remove front differential mount
cushion No. 1 from front differential mount No. 1.
23. REMOVE FRONT DIFFERENTIAL BRACKET RR

(a) Remove the 7 bolts, then remove the front differential bracket
RR from the front differential carrier.
DISASSEMBLY
1. REMOVE FRONT DIFFERENTIAL CARRIER COVER BREATHER
PLUG
(a) Remove the breather plug from the carrier plug.
2. REMOVE DIFFERENTIAL SIDE OIL SEAL
(a) Using the SST, remove the right and left side gear shaft oil seal.
SST SST 09308-00010
DF
C136916
3. REMOVE FRONT DIFFERENTIAL CARRIER COVER

(b) Using a brass bar and a hammer, lightly tap on the differential
carrier cover to remove it.
NOTICE:
• Place the brass bar against the ribs of the carrier cover.
• Do not damage the contact surfaces of the differential
carrier.
4. SECURE DIFFERENTIAL CARRIER ASSEMBLY

C137249
SST 09219-87701, 09219-87202
GETtheMANUALS.org
(a) Install the SST to the front differential carrier assembly.
SST
C139756
(b) Secure the front differential carrier assembly to the SST.

SST
SST
C139757
5. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

(a) Install a dial indicator at a right-angle to the back side of the ring
gear.
(b) Check the runout of the ring gear by turning the companion
flange FR.
Maximum limit:
0.10 mm
HINT:
If the runout exceeds the specified maximum value, remove the
C137270 ring gear and check the case runout.
6. INSPECT DIFFERENTIAL RING GEAR AND DIFFERENTIAL

DRIVE PINION BACKLASH
(a) Install a dial indicator at a right-angle to the edge of the tooth
surface of the ring gear.
(b) Secure the companion flange FR by hand, and move the ring
gear to check the backlash.
DF Standard:
0.10 to 0.17 mm
NOTICE:
C137410 Check the backlash at 3 or more locations on the ring gear
circumference.
7. REMOVE DIFFERENTIAL CASE NO. 1

(a) Remove rear differential case assembly and the shim.
8. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH

(a) Secure the differential case in a vise.
NOTICE:
GETtheMANUALS.org
DF–14
(b) Install a dial indicator at a right-angle to the edge of the tooth

surface of the side gear shaft.
(c) Secure the pinion gear to the differential case, and turn the side
gear to check the side gear backlash.
Standard:
0.025 to 0.10 mm
C123386
9. INSPECT TOTAL PRELOAD

(a) Using a torque wrench and a deep socket wrench, inspect the
total preload (activation torque) while the drive pinion and ring
gear teeth are in contact.
Standard:
T = 0.69 to 1.07 N*m (7.04 to 10.9 1kgf*cm)
10. REMOVE DRIVE PINION COMPANION FLANGE NUT

SST 09330-00021, 09213-58013
(a) Using a chisel and a hammer, unstake the lock nut.
C139807
(c) Using a deep socket wrench, remove the companion flange nut.
NOTICE:
SST • Do not damage the threads of the drive pinion.

SST 09510-87301
C139755
(a) Using the SST, remove the companion flange FR.

NOTICE:
DF
before use.
C139758
GETtheMANUALS.org
12. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL

SST
SST 09308-10010
NOTICE:
before use.
C139759
13. REMOVE DIFFERENTIAL DRIVE PINION

(a) Using a press, remove the differential drive pinion.
C139760
14. REMOVE FRONT DRIVE PINION TAPERED ROLLER BEARING

RR
(a) Remove the tapered roller bearing RR (inner race) from the
differential carrier.
(b) Remove the drive pinion bearing spacer and shim.
C139761

FR
(a) Using the SST and a press, remove the tapered roller bearing
FR (inner race) from the drive pinion.
DF
C137302

FR
(a) Using a brass bar and a hammer, lightly and uniformly tap on
the tapered roller bearing FR (outer race) to remove it.
C088550
GETtheMANUALS.org
DF–16

RR
the tapered roller bearing RR (outer race) to remove it.
18. REMOVE FRONT DIFFERENTIAL CASE BEARINGS

SST O9502-10012
(a) Remove the shim.
C088551
(b) Using the SST, remove the LH side bearing and the RH side
bearing.
NOTICE:
SST As a reference for assembly, the shims should be stored
separately in for the ring gear back side and tooth side.
NOTICE:
• Apply grease to the threads and tip of the SST center
bolt before use.
19. REMOVE DIFFERENTIAL RING GEAR

C139762
(a) Secure the differential case in the vise between aluminum
plates.
NOTICE:
(b) Put match marks on the ring gear and the differential case.
(c) Remove the 8 bolts.
Matchmarks
C135701
20. DISASSEMBLE THE DIFFERENTIAL CASE ASSEMBLY

4 (a) Remove the parts listed below from the differential case
2
assembly.
NOTICE:
DF
3 • When removing the parts, identify the installation
position on the case differential.
3
• Store the gear and washer differential side gear thrust
1
as a set.(Do not mix up the gears and washer
differential side gear thrusts.)
4 2
C137301 (1) Differential pinion shaft (1 in the diagram)
(2) Differential pinion gear (2 pieces) (2 in the diagram)
(3) Front differential side gear thrust washer No. 1 (2 pieces)
(3 in the diagram)
(4) Differential side gear (2 pieces) (4 in the diagram)
GETtheMANUALS.org
21. INSPECT DIFFERENTIAL CASE ASSEMBLY

(a) Pinion differential drive, gear differential ring
A
(1) Visually inspect parts (A), (B), and (C) as shown in the
B
diagram.
Standard:
There is no notable wear or damage.
C
C135702
(b) Shaft differential pinion, pinion differential, gear differential side

A
(1) Visually inspect parts (A), (B), (C), (D), (E), and (F) as
shown in the diagram.
Standard:
F D
C B E
C135703
(c) CASE DIFFERENTIAL

C
E (1) Visually inspect parts (A), (B), (C), (D), and (E) as shown
B
in the diagram.
Standard:
REASSEMBLY
D 1. INSTALL FRONT DRIVE PINION TAPERED ROLLER BEARING
D
A FR
C135704
SST 09950-60010
(a) Using the SST and a press, press in the tapered roller bearing
FR (outer race).
2. INSTALL FRONT DRIVE PINION TAPERED ROLLER BEARING

RR
SST 09950-60010
DF
C088552
RR (outer race).
3. INSTALL DIFFERENTIAL DRIVE PINION

SST 09257-87202, 09330-87301, 09530-87504, 09350-87202
(a) Install the tapered roller bearing.
(b) Install the SST.
(c) Install the companion flange and plate washer.
C088553
GETtheMANUALS.org
DF–18
(d) Using the SST, tighten the lock nut to the specified torque.
(e) Install the SST.
SST
C139777
(f) Select the shims so that (A) in the diagram becomes the
SST
standard value.
Standard:
0.5 ± 0.05 mm
A
HINT:
PMD
PMD (pinion mounting distance)
83.0mm
HINT:
SST Shim Selection Table (for adjustment of differential drive pinion
protrusion)
Product Number Thickness (mm)

90045-64318 0.15
90045-64319 0.20
90045-64320 0.25
90045-64321 0.50
C139778
(g) Remove the lock nut.
(h) Remove the plate washer and companion flange.
(i) Using the SST, install the tapered roller bearing into the pinion.
NOTICE:
• Press in the bearing by pushing its inner side.
SST
• If either the front or rear bearing is damaged, replace
them both as a set.
• When replacing the drive pinion, replace it with the ring
gear as a set.
C139779
(j) Using the SST and a press, install the pinion to the differential DF
carrier.
NOTICE:
SST Do not install the bearing spacer and shim (for preload
adjustment).
SST
C139780
GETtheMANUALS.org
C139781
(k) Using the SST and a press, install the companion flange.
NOTICE:
Do not assemble the type T oil seal.
SST
(l) Install the plate washer and lock nut.
(m) To work in the bearing, turn the flange several times forward
and backward.
SST
4. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
SST 09330-87301
C139782
(a) Using the SST and a torque wrench, gradually tighten the lock
nut to the preload standard.
Standard:
SST 0.59 to 0.98 N*m (6.0 to 10.0 kgf*cm)
5. INSTALL FRONT DIFFERENTIAL CASE

NOTICE:
• When installing the side gear thrust washer No. 1, side gear,
pinion gear, or other parts, make sure that there is no dirt or
foreign matter on the parts, such as dust or cutting powder.
C139777
• When replacing either the side gear or the pinion gear, be
sure to replace the side gear and the pinion gear together as
a set.
• Apply gear oil to the rotating and moving parts.
(a) Install the parts listed below to the the differential case.
4 HINT:
2
• Differential pinion shaft (1 in the diagram)
• Differential pinion gear (2 pieces) (2 in the diagram)
DF 3 • Front differential side gear thrust washer No. 1 (2 pieces) (3
in the diagram)
3
• Differential side gear (2 pieces) (4 in the diagram)
1
(1) Apply oil to the differential side gear and side gear thrust
washer No. 1 and install them to the differential case.
4 2
C137301 (2) Apply oil to the differential pinion and install it to the
differential case.
(3) Apply oil to the differential pinion shaft and insert it into the
differential case.
Lubricants:
Differential hypoid gear oil SAE80W-90 (API
category GL5)
GETtheMANUALS.org
DF–20
(b) Install a dial indicator at a right-angle to the edge of the tooth

surface of the pinion gear.
(c) Secure the drive pinion against the differential case, and check
the backlash.
Standard:
0.025 to 0.10 mm
(d) Use the same-sized side gear thrust washer No. 1 in order to be
able adjust the backlash of the side gear to within the standard
value and to ensure that the gear rotates smoothly.
ZD07930 HINT:
Slide Gear Thrust Washer No. 1 Types

41361-87501 0.80
41361-87705 0.85
41361-87506 0.90
41361-87507 1.00
6. INSTALL DIFFERENTIAL RING GEAR

(a) Wipe off any grease or moisture from the ring gear contact
surface of the differential case.
(b) Secure the differential case in the vise between aluminum
plates.
NOTICE:
(c) Clean the threaded holes of the differential case.
(d) Wipe off any grease or moisture from the ring gear (contact
surface of the differential case).
(e) Align the match marks on the differential case and the ring gear,
and install the ring gear.
NOTICE:
Align the bolt holes of the differential case and the
threaded holes of the ring gear.
(f) Tighten the 8 set bolts.
NOTICE:
• Wait until the ring gear has fully cooled off before
Matchmarks
C135701 tightening the bolts.
• Tighten the bolts in cross-diagonal order. Tighten
gradually in several passes..
7. INSTALL FRONT DIFFERENTIAL CASE

DF
SST 09309-87201
(a) Using the SST and a press, press the LH and RH bearings into
the differential case.
SST CAUTION:
If the bearing is damaged, replace it with new one.
NOTICE:
• Align the SST with the center of the differential case.
8. INSTALL DIFFERENTIAL CASE ASSEMBLY

(a) Install the differential case to the differential carrier.
C139806
GETtheMANUALS.org
(b) Install using the same parts as those disassembled when

removing only the shims for the back side of the gear differential
ring.
HINT:
Check the shims. If the shims are worn or scratched, install a
new shim of the same thickness.
C137412
9. ADJUST DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE

PINION BACKLASH
(a) Set the dial indicator at a right-angle to the gear.
(b) Secure the flange S/A drive pinion companion, and move the
gear to measure the backlash.
NOTICE:
Apply hypoid gear oil to each part.
Standard:
0.10 to 0.17 mm
C137410 HINT:
Select and install a shim so that the backlash of the ring gear
falls within the range of standard values.
Front Differential Case Shim Types
90045-64598 1.30
90045-64599 1.35
90045-64600 1.40
90045-64601 1.45
90045-64602 1.50
90045-64603 1.55
90045-64604 1.60
90045-64605 1.65
90045-64606 1.70
90045-64607 1.75
90045-64608 1.80
10. DIFFERENTIAL CASE NO. 1 (PLAY ADJUSTMENT)

(a) Measure the play of the differential carrier and the radial ball
DF bearing on the differential ring gear tooth surface side.
HINT:
Select shims (for use in the direction of the differential case
thrust) so that the play is within the specified value.
Front Differential Case Shim Types
90045-64598 1.30
90045-64599 1.35
90045-64600 1.40
90045-64601 1.45
90045-64602 1.50
90045-64603 1.55
90045-64604 1.60
90045-64605 1.65
GETtheMANUALS.org
DF–22

90045-64606 1.70
90045-64607 1.75
90045-64608 1.80
11. INSPECT TOOTH CONTACT BETWEEN DIFFERENTIAL RING

GEAR AND DRIVE PINION
(a) Apply a light coat of red primer uniformly to the tooth surface
side of the ring gear, and turn the ring gear several times
forward and backward. The pattern of the red primer indicates
the tooth contact position.
Heel Contact Face Contact
Select The Front Differential Case Washer To Allow The Drive Pinion To Come Close To
The Differential Ring Gear.
Flank Contact
Toe Contact
Normal Gear Contact
Select The Front Differential Case Washer To Allow The Drive Pinion To
Avoid Contact With The Differential Ring Gear.
C089686J01
NOTICE:
Check the contact state at 4 locations on the differential
ring gear circumference.
(b) If the tooth alignment is off, use the appropriate shim selected
from the table to adjust the drive pinion protrusion and re-install.
NOTICE:
In the case of face contact or flank contact, the error may DF
be adjustable within the range of standard backlash values.
HINT:
Shim Selection Table (for differential drive pinion protrusion
adjustment)

90045-64318 0.15
90045-64319 0.20
90045-64320 0.25
90045-64321 0.50
12. REMOVE DIFFERENTIAL CASE NO.1

(a) Remove rear differential case No. 1 and the shim.

SST 09330-87301, 09510-87301
GETtheMANUALS.org
(a) Using the SST, secure the companion flange FR.

(b) Remove the lock nut and the plate washer.
SST
C139755
(c) Using the SST, remove the companion flange FR.

NOTICE:
before use.
C139758

(a) Using a press, remove the differential drive pinion.
C139760
(b) Remove the tapered roller bearing from the differential carrier.
15. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING

SPACER
(a) Install a new bearing spacer and shim (same as the one
DF removed) to the drive pinion.
HINT:
Check the shims. If the shims are worn or scratched, install a
new shim of the same thickness.
C139761 16. INSTALL DIFFERENTIAL DRIVE PINION

SST 09330-87301, 09257-87202, 09350-87202
GETtheMANUALS.org
DF–24
(a) Using SST and a press, install the differential drive pinion.
SST
SST
C139780
(b) Using SST, install the companion flange.
SST
SST
C139782
(c) Using the SST and a torque wrench, tighten the lock nut.
SST
C139777
17. MEASURE DIFFERENTIAL DRIVE PINION PRELOAD

(a) Measure the preload of the drive pinion. If the preload is not
within the specified range, select a shim (for preload
adjustment) and adjust.

90045-64533 1.65
90045-64534 1.70
DF
90045-64535 1.75
90045-64536 1.80
C139807
90045-64537 1.85
90045-64538 1.90
90045-64539 1.95
90045-64540 2.00
90045-64541 2.05
90045-64542 2.10
90045-64543 2.15
90045-64544 2.20
90045-64545 2.25
90045-64546 2.30
90045-64547 2.35
GETtheMANUALS.org

90045-64548 2.40
90045-64549 2.45

SST 09330-87301, 09510-87301
(a) Using the SST, remove the lock nut and the plate washer.
SST
C139777
(b) Using the SST, remove the companion flange.
SST
19. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL
SST 09636-20010
(a) Apply MP grease No. 2 to the lip of the carrier oil seal.
C139758
(b) Using the SST and a press, tap in a new carrier oil seal. Make
sure that the seal is installed to the standard value.
Standard:
SST 0.5 ± 0.5 mm (from the carrier end face)
20. INSTALL FRONT DRIVE PINION COMPANION FLANGE FR

SST 09257-87202, 09330-87301, 09350-87202
C139783
DF (a) Using the SST and a press, install the companion flange.
SST
SST
C139782
GETtheMANUALS.org
DF–26
(b) Using the SST and a torque wrench, tighten the lock nut.
SST
C139777
(c) Using a chisel and a hammer, stake the companion flange nut.
21. INSTALL DIFFERENTIAL CASE NO. 1

(a) Install differential case No. 1 and the shim to the differential
carrier.
22. INSTALL DIFFERENTIAL CARRIER COVER

(a) Using a scraper and wire brush, clean the liquid gasket
attached to the differential carrier and the differential carrier
cover. Then remove any oils using cleaning fluid or equivalent.
ZK07449
(b) Apply the liquid gasket to the cover, and install the cover to the
differential carrier. Make sure that there are no gaps in the liquid
gasket before installing the cover to the carrier.
NOTICE:
• If the liquid gasket dries before the cover is installed,
remove and re-apply the liquid gasket.
• After installing the cover to the differential carrier, wait
at least 1 hour before filling with oil or driving the
vehicle. In addition, avoid rapid acceleration/
C136379 deceleration for at least 12 hours.
• Before the liquid gasket dries, install the differential
side oil seal. (See procedure 23.)
(c) Using the 8 bolts, install the differential carrier cover.
23. INSTALL DIFFERENTIAL SIDE OIL SEAL

SST 09636-20010
DF
C137249
GETtheMANUALS.org
(b) Using the SST and a hammer, drive in a new carrier oil seal up
to the edge surface of the seal attachment part.
SST
C137976

(a) Using a torque wrench and a deep socket wrench, inspect the
total preload (activation torque) while the drive pinion and ring
gear teeth are in contact.
Standard:
0.69 to 1.07 N*m (7.03 to 10.9 kgf*cm)
25. INSTALL FRONT DIFFERENTIAL CARRIER COVER BREATHER

PLUG
(a) Install the breather plug to the carrier cover.
C139807
INSTALLATION
1. INSTALL FRONT DIFFERENTIAL BRACKET RR
(a) Using the 7 bolts, install the front differential bracket RR to the
front differential carrier.
2. INSTALL FRONT DIFFERENTIAL MOUNT CUSHION NO. 1

(a) Using the 3 bolts, install front differential mount cushion No. 1 to
front differential mount No. 1.
3. INSTALL FRONT DIFFERENTIAL CARRIER SUPPORT BRACKET

(a) Using the 4 bolts, install the front differential carrier support
bracket to the front differential carrier.
4. SUPPORT FRONT DIFFERENTIAL CARRIER ASSEMBLY

(a) Using the transmission to support the front differential carrier
DF assembly (with bracket), lift up to the installation position.
NOTICE:
• As the front differential carrier assembly is heavy, be
sure that it is securely supported with the transmission
jack.
• Do not damage the attachment surfaces when installing
the front differential carrier assembly.
• Do not lose the front differential carrier assembly.
GETtheMANUALS.org
DF–28
5. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY

(a) Using the 2 bolts, install the front differential carrier support
bracket to the front suspension cross member.
C136011
(b) Using the 2 bolts, install the front differential mount cushion No.
1 to the front suspension cross member.

4)

PR-4)
8. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH(See page DS-10)

C137248
9. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
HINT:
10. INSTALL FRONT AXLE HUB LH(See page DS-10)
11. INSTALL FRONT AXLE HUB RH

HINT:
12. CONNECT FRONT SUSPENSION LOWER ARM NO. 1 LH(See

page DS-10)
13. CONNECT FRONT SUSPENSION LOWER ARM NO. 1 RH

HINT:
14. INSTALL FRONT STABILIZER LINK ROD (See page SP-15)
15. CONNECT TIE ROD END LH(See page DS-10)
16. CONNECT TIE ROD END RH

HINT:
DF
17. INSTALL FRONT AXLE HUB NUT LH(See page DS-10)
18. INSTALL FRONT AXLE HUB NUT RH

HINT:
19. INSTALL FRONT DISC

(See page DF-3)
21. INSTALL ENGINE UNDER COVER RR RH (WITH ENGINE

UNDERCOVER RR RH)
22. INSTALL ENGINE UNDER COVER RR LH (WITH ENGINE

UNDERCOVER RR LH)
GETtheMANUALS.org

DF
GETtheMANUALS.org
DIFFERENTIAL - REAR DIFFERENTIAL
DF–30
REAR DIFFERENTIAL
DRIVE LINE / AXLE
DIFFERENTIAL
COMPONENTS
REAR BRAKE DRUM
REAR AXLE SHAFT RH
FILLER PLUG
T=61.2{624.5}
FILLER PLUG
GASKET REAR AXLE HOUSING ASSEMBLY
REAR DIFFERENTIAL
CARRIER ASSEMBLY
T=8.4{86}
x10
SPEED SENSOR FR LH
x4 T=32{326} T=61.2{624.5} DRAIN PLUG GASKET

DRAIN PLUG
T=60{612}‫ޓޓ‬

T=42{425.2}
DF
×4
REAR AXLE SHAFT LH
REAR AXLE BEARING

RETAINER OUT LH
REAR BRAKE DRUM

C139224J02
GETtheMANUALS.org
DF–31 DIFFERENTIAL - REAR DIFFERENTIAL
2WD
REAR DIFFERENTIAL
PINION
DIFFERENTIAL
SPIDER REAR DIFFERENTIAL
PINION SHAFT
REAR DIFFERENTIAL
PINION
BEARING CAP REAR DIFFERENTIAL BEARING

ADJUST NUT LOCK
FILLER PLUG
T=84{857} T=5.4{55}
×2
×2
×4
FILLER PLUG REAR DIFFERENTIAL
GASKET REAR DIFFERENTIAL SIDE SIDE GEAR
FRONT BEARING GEAR THRUST WASHER REAR DIFFERENTIAL

OUTER RACE PINION
REAR DIFFERENTIAL REAR DIFFERENTIAL
CASE BEARING SIDE GEAR
REAR DIFFERENTIAL BEARING OUTER
CARRIER OIL SEAL RACE REAR DIFFERENTIAL SIDE
GEAR THRUST WASHER
REAR DRIVE PINION
REAR DIFFERENTIAL
WASHER REAR DRIVE PINION PINION SHAFT
TAPERED ROLLER BEARING FR
REAR DIFFERENTIAL REAR DIFFERENTIAL
DUST DEFLECTOR PINION
REAR DRIVE PINION
COMPANION FLANGE RR DIFFERENTIAL BEARING OUTER
RACE
DF T=157{1600} RING GEAR
DIFFERENTIAL
REAR DRIVE
DRIVE PINION
PINION NUT ×8
REAR DIFFERENTIAL DRIVE
PINION BEARING SPACER
T=97{989}
REAR BEARING REAR DIFFERENTIAL
REAR DIFFERENTIAL
OUTER RACE DRIVE PINION
CASE
WASHER
REAR DIFFERENTIAL
REAR DRIVE PINION TAPERED CASE BEARING
ROLLER BEARING RR
REAR DIFFERENTIAL BEARING

ADJUST NUT
TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PART C139206J02
GETtheMANUALS.org
DIFFERENTIAL - REAR DIFFERENTIAL CARRIER OIL SEAL
DF–32
REAR DIFFERENTIAL CARRIER OIL SEAL

DRIVE LINE / AXLE
DIFFERENTIAL
REMOVAL
1. DRAIN DIFFERENTIAL OIL(See page DF-34)

3. REMOVE REAR DRIVE PINION NUT

SST 09330-87301
(a) Using a chisel and a hammer, unstake the pinion nut.
NOTICE:
(b) Using the SST, remove the lock nut and the plate washer.
(c) Using a socket wrench (24 mm), remove the pinion nut and
washer.
4. REMOVE REAR DRIVE PINION COMPANION FLANGE RR

(a) Remove the companion flange RR.
5. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

SST 09308-10010
SST
C139822
(a) Using the SST, remove the carrier oil seal.

NOTICE:
before use.
Apply Force
Hold
C137974
INSTALLATION
1. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
SST 09515-87302 DF
(b) Using the SST and a hammer, drive in a new carrier oil seal to
the standard value.
SST
Standard:
0.5±0.5 mm (from the carrier end face)
2. INSTALL REAR DRIVE PINION COMPANION FLANGE RR

SST 09330-87301
(a) Install the companion flange.
(b) Apply a light coat of gear oil to the screw part of a new pinion
nut.
C139820
(c) Using the SST, secure the companion flange RR.
GETtheMANUALS.org
DF–33 DIFFERENTIAL - REAR DIFFERENTIAL CARRIER OIL SEAL
(d) Using a torque wrench and a socket wrench (24 mm), install the
plate washer and the lock nut.
(e) Using a chisel and a hammer, stake the pinion nut.


(See page DF-3)
SST
C139821
(See page DF-3)
DF
GETtheMANUALS.org
DIFFERENTIAL - REAR DIFFERENTIAL CARRIER ASSEMBLY
DF–34
REAR DIFFERENTIAL CARRIER ASSEMBLY

DRIVE LINE / AXLE
DIFFERENTIAL
REMOVAL
1. REMOVE REAR TIRE

(b) Remove the drain plug and gasket. Drain the oil.
(c) Install the drain plug and a new gasket.
3. REMOVE REAR BRAKE DRUM(See page BR-30)

(a) Remove the bolt and speed sensor RR LH.

6. REMOVE REAR AXLE BEARING RETAINER OUT LH(See page

AH-13)
7. REMOVE REAR AXLE BEARING RETAINER OUT RH

HINT:
C133712
8. REMOVE REAR AXLE SHAFT LH (See page AH-13)
9. REMOVE REAR AXLE SHAFT RH

HINT:

11. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY

(a) Support the rear differential carrier assembly with a jack.
NOTICE:
As the differential is heavy, be sure that it is securely
supported with the jack.
(b) While supporting the rear differential carrier assembly with the
jack, remove the 10 bolts and remove the rear differential
carrier assembly.
NOTICE:
• Do not damage the attachment surfaces when removing
DF
the rear differential carrier assembly.
• When removing the front differential carrier assembly,
there is a possibility of leakage of residual oil.
C137447 DISASSEMBLY
1. SECURE REAR DIFFERENTIAL CARRIER ASSEMBLY
SST 09548-87202, 09219-87202
GETtheMANUALS.org
DF–35 DIFFERENTIAL - REAR DIFFERENTIAL CARRIER ASSEMBLY
(a) Secure the differential carrier assembly to the disassembly

SST SST stand as shown in the diagram.
2. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

(a) Install a dial indicator at a right-angle to the back side of the ring
gear.
SST
C139639
(b) Check the runout of the ring gear by turning the companion
flange RR.
Maximum limit:
0.16 mm
HINT:
If the runout exceeds the specified maximum value, remove the
ring gear and check the case runout.
3. INSPECT DIFFERENTIAL RING GEAR AND DIFFERENTIAL

DRIVE PINION BACKLASH
C137448
(b) Secure the companion flange RR by hand, and move the ring
Standard:
0.08 to 0.13 mm
NOTICE:
Measure in 3 locations on the ring gear circumference. In at
least 2 of these locations, the measurement should be
within 0.08 to 0.13 mm. In one location, however, a value as
high as 0.15 mm may be allowed.
C139640
4. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH
SST 09564-97401, 09330-87301
(a) Place the dial indicator at a right-angle against the tooth surface
edge of the differential side gear.
(b) Secure the differential pinion to the differential case, and
inspect the backlash of the differential side gear.
Standard:
DF 2WD 0.025 to 0.1 mm
4WD 0 to 0.075 mm
C139641
GETtheMANUALS.org
DF–36
(c) If the backlash is 0 mm, use the SST to measure the activation
SST
torque of the side gear.
Torque: 39.2 N*m (399 kgf*cm) or less
SST
C143343
5. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

(a) Using a socket wrench and a torque wrench, measure the
preload with the drive pinion in contact with the ring gear tooth
surface.
Standard:
T = 0.78 to 1.17 N*m (8 to 11.9 kgf*cm)
6. REMOVE REAR DRIVE PINION NUT

SST 09330-87301, O9213-31021
C139642
(a) Using a chisel and a hammer, unstake the pinion nut.

NOTICE:
• Always wear gloves and safety glasses when
performing work.
C139643
(b) Using the SST, secure the companion flange, and remove the
lock nut.
SST
SST O9213-31021
DF
C139644
(a) Using the SST, remove the companion flange RR.

NOTICE:
SST
before use.
C139645
GETtheMANUALS.org
8. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

(a) Using the SST, remove the carrier oil seal.
SST 09308-10010
SST NOTICE:
before use.
9. REMOVE REAR DIFFERENTIAL CASE

SST 09504-87501
(a) Remove the 2 bolts, then remove the 2 adjusting nut locks.
C139646
(b) Put match marks on the bearing cap and differential carrier.
HINT:
Put identification marks on one side only.
(c) Remove the 4 bolts, and remove the 2 bearing caps and 2
adjusting nuts.
NOTICE:
As the bearing cap and carrier is processed as one unit, do
not mix up the parts.
Matchmarks
C139653
(d) Using the SST, remove the adjusting nut.

(e) Remove rear differential case No. 1 together with the case
SST bearing (outer race).
C139648
(f) Put identification marks on the adjusting nut and case bearing
(outer race) or organize the parts separately.
10. REMOVE REAR DIFFERENTIAL CASE BEARING

SST 09950-97201
DF HINT:
Do not the remove the differential case bearing except when
replacing the case bearing or the differential case.
C014047
GETtheMANUALS.org
DF–38
(a) Using the SST, remove the 2 case bearings (inner race).
NOTICE:
• Apply grease to the threads and the tip of the SST
center bolt before use.
• Do not deform the gauge of the bearing (when re-using
the bearing).
• Hook the SST claw from the notch of the differential
case to the inner race of the case bearing.
HINT:
C139650 If it is difficult to hook the claw, lightly tap it using a hammer.
11. REMOVE DIFFERENTIAL RING GEAR

(a) Secure the differential case in the vise between aluminum
plates.
NOTICE:
(b) Put mach marks on the ring gear and the differential case.
(c) Remove the 10 bolts, then remove the differential ring gear.
(d) Using a plastic hammer, uniformly tap the outer circumference
of the ring gear to remove it.
HINT:
Place a rag over the tooth surface side of the ring gear to
prevent damage.
(e) Secure the differential case in the vise between aluminum
Matchmarks
plates.
NOTICE:
(f) Remove the parts listed below from the differential case.(2
4 pinion differential)
2
(1) Rear differential pinion shaft (1 in the diagram)
(2) Rear differential pinion gear (2 pieces) (2 in the diagram)
3 (3) Rear differential side gear thrust washer No. 1 (2 pieces)
(3 in the diagram)
3
(4) Rear differential side gear (2 pieces) (4 in the diagram)
1
(g) Secure the differential case in the vise between aluminum
plates.
4 2
C137301 NOTICE:
(h) Remove the parts listed below from the differential case.(4
pinion differential)
DF
1
2
5
1 2
4
4 3
1 2
5
1
C137453

(3) Spider differential (3 in the diagram)
GETtheMANUALS.org
(4) Rear differential side gear (2 pieces) (4 in the diagram)

(5) Rear differential side gear thrust washer No. 1 (2 pieces)
(5 in the diagram)
(a) Using the plastic hammer or a similar tool, tap the differential
drive pinion lightly to remove it.
NOTICE:
Do not drop the differential drive pinion.
(b) Remove the drive pinion bearing spacer from the differential
drive pinion.
C139651
13. REMOVE REAR DRIVE PINION TAPERED ROLLER BEARING RR

Recommended Tool (a) Using the bearing pulling attachment and a press, remove the
NO. 145 tapered roller bearing RR (inner race) from the drive pinion.
NOTICE:
C139652
14. REMOVE REAR DRIVE PINION TAPERED ROLLER BEARING FR

the tapered roller bearing FR (outer race) to remove it.
C091046
15. REMOVE REAR DRIVE PINION TAPERED ROLLER BEARING RR

the tapered roller bearing RR (outer race) and remove it.
DF
C091047
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DF–40
16. INSPECT REAR DRIVE PINION COMPANION FLANGE RR

(a) Check for any wear or damage on the oil contact part (A) or the
A
spline (B) of the rear drive pinion companion flange RR.
17. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

HINT:
Perform this task only if the dust deflector is damaged.
C139654
(a) Using the bearing pulling attachment and a press, remove the
dust deflector from the companion flange RR.
NOTICE:
Do not lose the companion flange.
C090136J01
18. INSPECT REAR DIFFERENTIAL CARRIER ASSEMBLY

A (a) Check for any damage to the side bearing attachment part of
B C the differential carrier (A), the outer race attachment part of the
tapered roller bearing (B), the oil seal insertion part (C), the
carrier cover attachment part (D), and the carrier body (E).
B D
E C139655
19. INSPECT FRONT DIFFERENTIAL CASE

(a) PINION DIFFERENTIAL DRIVE, GEAR DIFFERENTIAL RING
A
(1) Visually inspect parts (A), (B), and (C) as shown in the
B
diagram.
Standard:
DF
C
C135702
(b) Shaft differential pinion, pinion differential, gear differential side

A
(1) Visually inspect parts (A), (B), (C), (D), (E), and (F) as
shown in the diagram.
Standard:
F D
C B E
C135703
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(c) CASE DIFFERENTIAL

C
E
(1) Visually inspect parts (A), (B), (C), (D), and (E) as shown
B
in the diagram.
Standard:
REASSEMBLY
D 1. INSTALL REAR DRIVE PINION TAPERED ROLLER BEARING RR
D
A SST 09608-87302
C135704
RR (outer race).
NOTICE:
them both as a set.
• Check the shims. If the shims are worn or scratched,
install a new shim of the same thickness.
2. INSTALL REAR DRIVE PINION TAPERED ROLLER BEARING FR

SST 09608-87302
C092467
FR (outer race).
NOTICE:
them both as a set.
3. INSTALL REAR DRIVE PINION TAPERED ROLLER BEARING RR

SST 09310-87301, 09608-03071
C092466
(a) Using the SST and a press, press the tapered roller bearing RR
(inner race) into the drive pinion.
SST NOTICE:
them both as a set.
SST • When replacing the drive pinion, replace it with the ring
DF gear as a set.
C139724
4. INSTALL DIFFERENTIAL DRIVE PINION

TAPERED ROLLER (a) Apply hypoid gear oil to the drive pinion tapered roller bearing
BEARING FR (inner race), and temporarily install it together with the
(INNER RACE) differential drive pinion to the differential carrier.
HINT:
• Do not install the drive pinion bearing spacer and shim.
C139725
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DF–42
(b) Using the SST, press in the tapered roller bearing FR (inner
race).

SST SST 09330-87301
SST
SST
C139726
(a) Using the SST, secure companion flange RR, and gradually
tighten the plate washer and the locknut to the standard
preload.
SST NOTICE:
• As the locknut does not contain a spacer, tighten it
gradually. Do not tighten excessively.
(b) To work in the bearing, turn the flange several times forward
and backward.
C139727
(c) Using a torque wrench and a socket wrench (24 mm), measure
the preload of the drive pinion.
Standard:
0.88 to 1.27 N*m (9 to 13 kgf*cm)
NOTICE:
• For the total preload measurement, record the preload.

SST 09564-97401
C139728
(a) Install the thrust washer to the side gear.

NOTICE:
• When installing the side gear thrust washer, side gear,
pinion gear, or other parts, make sure that there is no
dirt or foreign matter on the parts, such as dust or
cutting powder.
• When replacing the side gear or pinion, be sure to DF
replace the side gear and pinion together as a set.
• Apply gear oil to the rotating and moving parts.
C137459
(b) Install the side gear (with thrust washer) and pinion, and pinion
shaft.
(c) Secure the differential case in the vise between aluminum
plates.
NOTICE:
(d) Install a dial indicator at a right-angle to the edge of the tooth
surface of the pinion gear.
C139186
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(e) Secure the pinion against the differential case, and check the
backlash.
Standard:
2WD 0.025 to 0.00 mm
4WD 0 to 0.075 mm
ZK01883
(f) If the backlash is 0 mm, use the SST to measure the activation
torque of the side gear.
SST
Standard:
Side gear activation torque of 39.2 N*m (399 kgf*cm) or
less
(g) In order to ensure that backlash of the side gear position falls
within the range of standard values, select side gear thrust
washers of the same size for both left and right sides. Then
adjust.
C143344 HINT:
Thrust Washer Types

41361-87509 1.10
41362-87407 1.15
41363-87709 1.20
41361-87408 1.25
41361-87510 1.30
41361-87409 1.35
7. INSTALL DIFFERENTIAL RING GEAR

(a) Secure the differential case in a vise between aluminum plates.
NOTICE:
(b) Align the match marks on the differential case and ring gear,
and install the ring gear.
(c) Install the 10 ring gear bolts.
NOTICE:
DF Tighten the bolts in cross-diagonal order. Tighten gradually
in several passes.
8. INSTALL REAR DIFFERENTIAL CASE BEARING

Matchmarks SST 09707-87302
C135437
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DF–44
(a) Using the SST and a press, press the left and right case
SST
bearings (inner race) into the differential case.
CAUTION:
If the bearing is damaged, replace it with new one.
NOTICE:
• When using a new bearing, do not apply the gear oil.
• Align the SST with the center of the differential case.
SST
• When replacing the case bearing (inner race), also
replace the case bearing (outer race) together as set.
C139729
(a) Install the case bearing (outer race) to the case bearing (inner
race)
NOTICE:
Be sure to install the case bearing (outer races) in the
correct left-right position.
(b) Install differential case No. 1 to the differential carrier.
C139730
10. INSTALL REAR DIFFERENTIAL DRIVE BEARING ADJUST NUT

(a) Install the 2 rear differential bearing adjust nuts.
(b) Align the match marks of the bearing cap and carrier.
C139731
(c) Tighten the bearing cap bolt 2 or 3 turns, then press down on
the bearing cap with your hand to temporarily install it.
DF
11. ADJUST DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE
PINION BACKLASH
SST 09504-87501
Matchmarks
C139653
GETtheMANUALS.org
(a) After the bearing plug is tightened with the specified torque,
loosen it to the point where the adjusting nut can be turned with
the SST.
SST (b) Using the SST, tighten the adjusting nut on the back surface
side of the side gear until the ring gear backlash is
approximately 0.15 mm.
(c) While turning the ring gear, use the SST to fully tightened the
adjusting nut of the ring gear tooth surface side to stabilize the
C139732 bearing. Then loosen the adjusting nut.
(d) Using the SST, tighten the adjusting nut of the ring gear tooth
surface side 1 or 2 notches in the direction of the ring gear axis
from the 0 clearance point.
NOTICE:
SST
The 0 clearance position in the axis direction is the point at
which the adjusting nut becomes difficult to tighten.
C139733
(e) To make the backlash of the side gear and ring gear fall within
the range of standard values, adjust the bearing by using the
left and right of adjusting nuts.(When loosening one side,
tighten the other side by the same side.)
Standard:
0.08 to 0.13 mm
NOTICE:
• Measure in 3 locations on the ring gear circumference.
In at least 2 of these locations, the measurement should
C139640 be within 0.08 to 0.13 mm. In one location, however, a
value as high as 0.15 mm may be allowed.
• Align the holes of the adjusting nut lock and the
adjusting nut.
(f) Tighten the 4 bearing cap bolts.
DF
Matchmarks
C139653
GETtheMANUALS.org
DF–46

(a) Using a socket wrench and a torque wrench, measure the
preload with the drive pinion in contact with the ring gear tooth
surface.
Standard:
0.88 to 1.27 N*m (9 to 13 kgf*cm)
NOTICE:
If the preload value is outside of the range of standard
values, adjust it using the adjusting nut of the ring gear
C139642 tooth surface side.
13. INSPECT TOOTH CONTACT BETWEEN THE DIFFERENTIAL

RING GEAR AND DRIVE PINION
(a) Apply a light coat of red primer uniformly to the tooth surface
side of the ring gear, and turn the ring gear several times
forward and backward.
NOTICE:
• Check the contact at 4 locations on the outer edge of
the ring gear.
• If the primer is applied unevenly or in too heavily a coat,
the measurement will be inaccurate. Therefore, apply
the primer to all of the gear teeth in an even coat as
thinly as possible.
HINT:
The pattern of the red primer indicates the tooth contact
position.
Heel Contact Face Contact
Select a washer that allows the drive

pinion to come close to the ring gear
Toe Contact Flank Contact
DF
Normal Tooth Contact
Select a washer to distance the drive pinion from the

ring gear. ZK03673
(b) If the tooth alignment is off, use the appropriate shim selected
from the table in order to make adjustments and re-install.
NOTICE:
• In the case of face contact or flank contact, the error
may be adjustable within the range of standard
backlash values.
GETtheMANUALS.org
• If the thickness of the drive pinion washer has been

changed, adjust the backlash and measure the total
preload.
HINT:
Drive Pinion Protrusion Adjustment Shim Types

90045-64585 0.29
90045-64586 0.32
90045-64587 0.35
90045-64588 0.38
90045-64589 0.41
90045-64590 0.44
90045-64591 0.47
90045-64592 0.50
90045-64593 0.53
90045-64594 0.56
90045-64595 0.59
90045-64596 0.62
90045-64597 0.65
(c) Remove the 4 bolts, and remove the differential cap and
differential case assembly.

SST 09330-87301, O9213-31021
(a) Using the SST, secure the companion flange, then remove the
lock nut.
SST
C139644
DF SST
C139645
GETtheMANUALS.org
DF–48

(a) Using a plastic hammer or similar tool, tap the differential drive
pinion gently to remove it.
NOTICE:

SST 09330-87301
(a) Install the drive pinion spacer and shim (same one with
disassembling) to the differential drive pinion.
C139651
NOTICE:
• When replacing the drive pinion, replace it with the ring
gear as a set.
(b) After applying gear oil to the tapered roller bearing FR (inner
race). Temporarily install the tapered roller bearing FR (inner
race) together with the differential drive pinion to the differential
carrier. Then use the SST to press in the tapered roller bearing
SST
FR (inner race)
SST
SST
C139726
(c) Using the SST, secure the companion flange, then tighten the
lock nut.
NOTICE:
SST • Do not install the oil seal.
• To work in the bearing, turn the flange several times
forward and backward.
C139727
17. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

(a) Measure the bearing preload of the drive pinion. If the preload is
out of the specified range, select a shim from the table below in
order to adjust the preload. Install the shim.
DF
HINT:
Preload Adjustment Shim Types

90045-64550 1.65
90045-64551 1.70
C139728
90045-64552 1.75
90045-64553 1.80
90045-64554 1.85
90045-64555 1.90
90045-64556 1.95
90045-64557 2.00
90045-64558 2.05
90045-64559 2.10
GETtheMANUALS.org

90045-64560 2.15
90045-64561 2.20
90045-64562 2.25
90045-64563 2.30
90045-64564 2.35
90045-64565 2.40
90045-64566 2.45

SST 09330-87301, O9213-31021
SST (a) Using the SST, fix the companion flange, then remove the lock
nut.
C139644
19. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL

SST SST 09515-87302
(a) Apply a thin coat of MP grease No. 2 to the lip of the carrier oil
seal.
C139645
(b) Using the SST and a hammer, drive in a new carrier oil seal to
the standard value.
Standard:
SST
0.5 ± 0.5 mm (from the carrier end face)
NOTICE:
Tap in the oil seal evenly so that it is straight.
DF
C139734
20. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR

(a) Using the SST and a press, press in a new dust deflector.
Iron Piece NOTICE:
When pressing in the dust deflector, check the deflector to
make sure that it is not being damaged. Apply slow,
gradual pressure and do not over-press.

SST 09330-87301
C011829
GETtheMANUALS.org
DF–50
(a) Using the SST, install the rear drive pinion companion flange
RR, the plate washer, and the lock nut.
SST
C139727

(a) Using a torque wrench and a socket wrench (24 mm), measure
the preload (activation torque) with the drive pinion in contact
with the ring gear tooth surface.
Standard:
0.88 to 1.27 N*m (9 to 13 kgf*cm)
23. INSPECT DIFFERENTIAL RING BACKLASH

C139728
(b) Secure the companion flange RR by hand, and move the ring
Standard:
0.08 to 0.13 mm
NOTICE:
Check the backlash at 3 or more locations on the ring gear
circumference.
C137464
24. INSTALL REAR DRIVE PINION COMPANION FLANGE NUT

(a) Using a chisel and a hammer, stake the pinion nut.
25. INSTALL REAR DIFFERENTIAL DRIVE BEARING ADJUST NUT

LOCK
(a) Install the 2 adjusting nut locks to the left and right side of the
bearing caps.
DF
ZK07449
(b) Install the 2 bolts.

INSTALLATION
1. INSTALL REAR DIFFERENTIAL CARRIER ASSEMBLY
(a) Support the rear differential carrier assembly with the
transmission jack.
NOTICE:
As the front differential carrier assembly is heavy, be sure
C139735
that it is securely supported with the transmission jack.
GETtheMANUALS.org
(b) Slowly lift up the transmission carrier and install the rear
NOTICE:
Do not drop the rear differential carrier assembly.
(c) Clean any dust or grease from the contact surface between the
rear differential carrier assembly and the rear axle housing .
(d) Apply liquid gasket to the differential carrier attachment part of
rear axle housing.
(e) Install the rear differential carrier assembly and tighten the 10
bolts.

3. INSTALL REAR AXLE SHAFT

C137447
5. INSTALL SPEED SENSOR RR LH

(a) Install the speed sensor RR LH with the bolt.


(See page DF-3)

(See page DF-3)
C133712
9. INSTALL REAR TIRE
10. TEST MODE INSPECTION (ABS SENSOR CHECK)
DF
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TO INDEX
DRIVE LINE / AXLE
AXLE
AXLE SYSTEM
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-1
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-1
STEERING KNUCKLE LH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-5
FRONT AXLE HUB LH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-11
REAR AXLE ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-13
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-13
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-15
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-21
AH
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AH–1 AXLE - AXLE SYSTEM
AXLE SYSTEM
DRIVE LINE / AXLE
AXLE
OPERATION CHECK
1. INSPECT WHEEL BEARING LOOSENESS
(a) Put your hands at the top and bottom of the tire and move it to
check that there is no looseness in the wheel bearing.
(b) If there is any looseness, check again with the brake pedal
depressed to make sure that the looseness occurs in the bear-
ing wheel.
C142304
(c) If necessary, use a dial indicator to check for looseness in the

axle hub and bearing.
NOTICE:
If the looseness exceeds the maximum limit, replace the
bearing with a new one.
Maximum limit:
0.05 mm (front)
0.8 mm (rear)
C142305

1. Front wheel alignment -
AH Wander / pulls
2. Steering linkage (Loose or worn) -
4. Hub bearing (Loose or worn) AH-1
5. Stabilizer bar (Bent or broken) -
1. Wheel (Out of balance) -
2. Shock absorber (Dropped) -
Front wheel shimmy 4. Wheel alignment (Incorrect) -
5. Ball joint (Loose or worn) -
6. Hub bearing (Loose or worn) AH-1
1. Wheel alignment (Incorrect) -
Abnormal noises from the front wheels
2. Shock absorber (dropped) -
Abnormal noises from the rear wheels 2. Shock absorber (dropped) -
GETtheMANUALS.org
AXLE - STEERING KNUCKLE LH
AH–2
STEERING KNUCKLE LH
DRIVE LINE / AXLE
AXLE
COMPONENTS
4WD
FRONT DRIVE SHAFT
ASSEMBLY LH
T=95.7{976} FRONT DISC BRAKE

T=95.7{976}
SPEED SENSOR FR LH
STEERING KNUCKLE SPINDLE

TIE ROD END LH FRONT AXLE HUB
T=8.4{86} BEARING LH
FRONT AXLE HUB
HOLE SNAP RING LH
T=46.6{475} STEERING KNUCKLE LH
CLIP FRONT AXLE HUB LH
T=58.1{592}
CLIP
AH
FRONT DISC BRAKE DUST
COVER LH
T=205.8{2099}
FRONT DISC
FRONT AXLE
HUB NUT LH
NON-REUSEABLE PART …… TIGHTENING TORQUE [N*m{kgf*cm}]

C140816J01
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AH–3 AXLE - STEERING KNUCKLE LH
REMOVAL
3. DISCONNECT FRONT DISC BRAKE CYLINDER ASSEMBLY LH

(See page EM-46)
4. REMOVE FRONT DISC

5. INSPECT FRONT AXLE HUB BEARING LH
(a) Set the dial indicator to the edge of the drive shaft, and check
the looseness in the axial direction of the bearing.
Maximum limit:
0.05 mm
NOTICE:
If it exceeds the maximum limit, replace the axle hub and
radial ball bearing.
C136858
6. INSPECT FRONT AXLE RUNOUT

(a) Set the dial indicator to the periphery of the axle hub, and
inspect the axle hub by turning it.
Maximum limit:
0.05 mm
NOTICE:
If it exceeds the maximum limit, replace the axle hub and
radial ball bearing.
7. REMOVE FRONT AXLE HUB NUT LH (for 4WD) (See page DS-5)
C132732
8. REMOVE FRONT AXLE HUB LH (for 4WD)
SST 09520-00031, 09950-97201
(a) Using the SST, remove the front axle hub LH.
SST 09520-00031
AH C137545
(b) Using the SST, remove the hub bearing inner race (outer side)
from the axle hub.
9. REMOVE TIE ROD END LH (for 4WD) (See page DS-5)
SST
C139829
GETtheMANUALS.org
AH–4
10. REMOVE FRONT AXLE ASSEMBLY LH

(a) Remove the 2 bolts and the 2 nuts of the shock absorber
assembly.
(b) Push the front axle assembly towards the outside of the vehicle,
and remove the front drive shaft assembly from the front axle
assembly.
NOTICE:
• Do not push the front axle assembly more than neces-
sary.
C135148 • Be careful not to damage the drive shaft outboard joint
boot.
• Be careful not to deform the speed sensor harness
clamp.
• Be careful not to damage the speed sensor rotor.
• Hang the drive shaft assembly with a piece of string or
similar.
(c) Remove the clip and nut of the suspension lower arm ball joint.
(d) Using the SST, remove the front axle assembly LH from the
lower arm.
SST 09628-00011
SST
C142002
11. REMOVE STEERING KNUCKLE SPINDLE (for 2WD)

(a) Secure the steering knuckle spindle from behind, and remove
the front axle hub nut LH.
C136381
12. REMOVE FRONT AXLE HUB LH (for 2WD)

(a) Using the SST, remove the front axle hub LH.
SST 09520-00031 AH
C137545
GETtheMANUALS.org
from the axle hub.
SST 09950-40011
SST
C139829
14. REMOVE FRONT AXLE ASSEMBLY LH (for 2WD)

(a) Remove the 2 bolts and the 2 nuts of the shock absorber
assembly.
(b) Remove the clip and nut of the suspension lower arm ball joint.
C135148
(c) Using the SST, remove the front axle assembly LH from the
lower arm.
SST 09628-00011
15. REMOVE FRONT DISC BRAKE DUST COVER LH
16. REMOVE FRONT AXLE HUB HOLE SNAP RING LH

(a) Remove the front axle hub hole snap ring LH.
SST
C142002
17. REMOVE FRONT AXLE HUB BEARING LH

(a) Using the SST and a press, remove the bearing from the steer-
SST ing knuckle.
SST 09550-10012 (09554-10010)
NOTICE:
• Check that the SST is positioned in the center of the
bearing.
• Remove the bearing slowly and carefully.
AH SST
C139828 INSTALLATION
1. INSTALL FRONT AXLE HUB BEARING LH
SST 09506-87302, 09550-10012 (09554-10010)
GETtheMANUALS.org
AH–6
(a) Using the SST and a press, press-fit a new bearing into the
steering knuckle.
NOTICE:
Bearing SST
• Do not remove the inner race because the oil seal is
built-into the axle hub bearing.
• If the inner race has been removed from a bearing, do
SST not re-use the bearing.
• Do not wipe the grease off from a new bearing.
• Press-fit the bearing in the direction that allows the
C139830 inside of the sensor encoder to face the brown side of
the oil seal.
• Keep the magnetic rotor side away from a magnet.
2. INSTALL FRONT AXLE HUB WHEEL SNAP RING LH

(a) Install the front axle hub wheel snap ring LH.
3. INSTALL FRONT DISC BRAKE DUST COVER LH

SST 09506-87302, 09718-87702
(a) Install a new brake dust cover to the steering knuckle.
C142655
(b) Using the SST and a hammer, install the brake dust cover.
NOTICE:
• By gradually sliding the SST, uniformly press-fit it.
SST
• Securely set it in the press-fit seat.

SST 09550-10012 (09554-10010)
C142656
(a) Using the SST and a press, press-fit the axle hub into the steer-
ing knuckle.
5. INSTALL FRONT AXLE ASSEMBLY LH (for 4WD)

AH
(a) Install the front assembly to the lower arm and tighten it with a
nut.
SST Torque: 58.1 N*m (592.4 kgf*cm)
NOTICE:
Keep the screws and the tapered portions free of oil or
grease.
C139831
GETtheMANUALS.org

(c) Push the front axle assembly towards the outside of the vehicle,
then align and insert the spline of the drive shaft assembly to
the axle assembly.
NOTICE:
• Do not push the axle assembly more than necessary.
• Be careful not to damage the drive shaft outboard joint
boot.
C137246
(d) Install the front axle assembly to the shock absorber, then insert
the 2 bolts and tighten the 2 nuts.
6. INSTALL FRONT AXLE ASSEMBLY LH (for 2WD)

(a) Install the front assembly to the lower arm and tighten it with a
nut.
NOTICE:
Keep the screws and the tapered areas free of oil or grease.
C135148
C137246
(c) Install the front axle assembly to the shock absorber, then insert
the 2 bolts and tighten the 2 nuts.
7. CONNECT TIE ROD END LH

(a) Connect the tie rod end to the steering knuckle, and tighten it
with a nut.
AH NOTICE:
Be careful not to damage the ball joint dust cover.
C135148
8. INSTALL FRONT AXLE HUB NUT LH

(a) Install a new front axle hub nut LH.
Torque: 205.8 N*m (2097.5 kgf*cm)
GETtheMANUALS.org
AH–8
(b) Using a chisel and a hammer, stake the front axle hub nut LH.
C135147
9. INSTALL STEERING KNUCKLE SPINDLE (for 2WD)

(a) Secure the steering knuckle spindle from behind, and tighten
the hub nut.
NOTICE:
When securing the steering knuckle spindle, do not put the
tools on the lower arm or tie rod end.
Torque: 205.8 N*m (2097.5 kgf*cm)
Using a chisel and a hammer, stake the front axle hub nut LH.
C136381
10. INSPECT LOOSENESS OF FRONT AXLE HUB AND BEARING

ASSEMBLY IN THE AXIAL DIRECTION (See page AH-3)
11. INSPECT RUNOUT OF FRONT AXLE HUB AND BEARING

ASSEMBLY (See page AH-3)

NOTICE:
Do not allow the disc surface to come into contact with lubri-
cant.
C135147
13. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY LH (See
page EM-65)
14. INSTALL SPEED SENSOR FR LH (See page EM-65)


(See page SP-4)
17. TEST MODE INSPECTION (SPEED SENSOR) AH

(a) WITHOUT VSC (See page BC-9)
(b) WITH VSC (See page BC-65)
GETtheMANUALS.org
AH–9 AXLE - FRONT AXLE HUB LH
FRONT AXLE HUB LH

DRIVE LINE / AXLE
AXLE
COMPONENTS
4WD
FRONT DRIVE SHAFT
ASSEMBLY LH
T=95.7{976} FRONT DISC BRAKE

T=95.7{976}
SPEED SENSOR FR LH
STEERING KNUCKLE SPINDLE

TIE ROD END LH FRONT AXLE HUB
T=8.4{86} BEARING LH
FRONT AXLE HUB
HOLE SNAP RING LH
T=46.6{475} STEERING KNUCKLE LH
CLIP FRONT AXLE HUB LH
T=58.1{592}
CLIP
AH
FRONT DISC BRAKE DUST
COVER LH
T=205.8{2099}
FRONT DISC
FRONT AXLE
HUB NUT LH
NON-REUSEABLE PART …… TIGHTENING TORQUE [N*m{kgf*cm}]

C140816J01
GETtheMANUALS.org
AXLE - FRONT AXLE HUB LH
AH–10
REMOVAL
2. DISCONNECT SPEED SENSOR FR LH (See page EM-46)
3. DISCONNECT FRONT DISC BRAKE CYLINDER ASSEMBLY LH
5. INSPECT FRONT AXLE HUB BEARING LH (See page AH-3)
6. INSPECT FRONT AXLE RUNOUT (See page AH-3)
7. REMOVE FRONT AXLE HUB NUT LH (for 4WD) (See page DS-5)
9. REMOVE FRONT AXLE ASSEMBLY LH (See page AH-4)
10. REMOVE STEERING KNUCKLE SPINDLE (for 2WD) (See page

AH-4)
12. REMOVE FRONT AXLE ASSEMBLY LH (for 2WD) (See page AH-
4)
13. REMOVE FRONT AXLE HUB LH

SST 09520-00031, 09950-97201
(a) Using the SST, remove the axle hub.
SST 09520-00031
C137545
from the axle hub.
14. REMOVE FRONT AXLE HUB HOLE SNAP RING LH (See page
AH-5)
15. REMOVE FRONT AXLE HUB BEARING LH (See page AH-5)

SST
AH
C139829
GETtheMANUALS.org
AH–11 AXLE - FRONT AXLE HUB LH
INSTALLATION
1. INSTALL FRONT AXLE HUB BEARING LH
(a) Using the SST and a press, press-fit a new bearing into the
steering knuckle.
Bearing SST
SST 09506-87302, 09550-10012 (09554-10010)
NOTICE:
• Do not remove the inner race because the oil seal is
SST built-into the axle hub bearing.
• If the inner race has been removed from a bearing, do
not re-use the bearing.
C139830 • Do not wipe off grease on a new bearing.
• Press-fit the bearing in the direction that allows the
inside of the sensor encoder to face the brown side of
the oil seal.
• Keep the magnetic rotor side away from a magnet.
2. INSTALL FRONT AXLE HUB WHEEL SNAP RING LH

(a) Install the front axle hub wheel snap ring LH.
(a) Using the SST and a press, press-fit the axle hub into the steer-
ing knuckle.
SST 09550-10012 (09554-10010)
4. INSTALL FRONT AXLE ASSEMBLY LH (for 4WD) (See page AH-

SST 6)
5. INSTALL FRONT AXLE ASSEMBLY LH (for 2WD) (See page AH-

7)
C139831
6. CONNECT TIE ROD END LH (See page DS-10)
7. INSTALL FRONT AXLE HUB NUT LH (See page DS-10)
8. INSTALL STEERING KNUCKLE SPINDLE (for 2WD) (See page

AH-8)
9. INSPECT LOOSENESS OF FRONT AXLE HUB AND BEARING

ASSEMBLY IN THE AXIAL DIRECTION (See page AH-3)
10. INSPECT RUNOUT OF FRONT AXLE HUB AND BEARING

ASSEMBLY (See page AH-3)
12. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY LH (See

AH page EM-65)
13. INSTALL SPEED SENSOR FR LH (See page EM-65)


(See page SP-4.)

VEHICLE WITHOUT VSC (See page BC-9)
VEHICLE WITH VSC (See page BC-65)
GETtheMANUALS.org
AXLE - REAR AXLE ASSEMBLY
AH–12
REAR AXLE ASSEMBLY

DRIVE LINE / AXLE
AXLE
COMPONENTS
SPEED SENSOR RR LH
T=8.4{86}
REAR AXLE SHAFT OIL SEAL
ABS REAR AXLE BEARING

RETAINER INNER
SKID COMTROL SENSOR ROTOR
REAR AXLE SHAFT BEARING
REAR AXLE BEARING ×4

RETAINER OUT LH
T=41.7{425}
AH
REAR AXLE SHAFT
NON-REUSEABLE PART REAR BRAKE DRUM

C143618J01
GETtheMANUALS.org
AH–13 AXLE - REAR AXLE ASSEMBLY
REMOVAL
1. REMOVE REAR TIRE
3. REMOVE REAR BRAKE DRUM (See page BR-30)
4. DISCONNECT SPEED SENSOR FR LH (WITH ABS) (See page DF-

34)
5. REMOVE REAR AXLE BEARING RETAINER OUT LH
(a) Remove the 4 nuts from the service hole, and disconnect the
bearing retainer OUT from the backing plate.
6. REMOVE REAR AXLE SHAFT

SST 09520-00031
C137753
(a) Using the SST, remove the rear axle shaft.

NOTICE:
• Immediately wipe off oil to prevent oil on the shaft from
entering the bearing.
• Do not allow the spline of the shaft edge to scratch the
oil seal.
• Be careful not to scratch the rear skid control rotor.
HINT:
SST As the differential oil may leak, place a tray under it.
C137579
7. REMOVE REAR AXLE SHAFT OIL SEAL

(a) Using the SST, remove the shaft oil seal.
SST 09308-00010
DISASSEMBLY
SST C137580
AH
1. REMOVE SKID CONTROL SENSOR ROTOR (WITH ABS)
Hand Grinder (a) Grind a part of the skid control sensor rotor with a grinder, then
break and remove it using a chisel and a hammer.
CAUTION:
Use extra caution when using a hand grinder, and be sure
to wear safety glasses.
NOTICE:
Be careful not to damage the rear axle shaft.
2. REMOVE REAR AXLE BEARING RETAINER INNER

C137600
HINT:
Perform the same procedure as for the skid control sensor rotor.
GETtheMANUALS.org
AH–14
3. REMOVE REAR AXLE SHAFT BEARING

(a) Using the SST and a press, remove the bearing.
SST SST 09527-30010
SST NOTICE:
Be careful not to drop the axle shaft.
4. REMOVE REAR AXLE BEARING RETAINER OUT LH

(a) Remove the rear axle bearing retainer OUT LH from the rear
axle shaft.
C143533 5. INSPECT REAR AXLE SHAFT LH

(a) Check the rear axle shaft for kinks and cracks.
Damage, Wear
Bending, Cracks
C137601
REASSEMBLY
1. INSTALL REAR AXLE BEARING RETAINER OUT LH
(a) Install the rear axle bearing retainer OUT LH to the rear axle
shaft.
2. INSTALL REAR AXLE SHAFT BEARING LH

SST 09608-03071
(a) Using the SST and a press, press-fit a new bearing.
SST NOTICE:
Make sure the bearing is installed in the correct direction.
SST AH
C143534
GETtheMANUALS.org
AH–15 AXLE - REAR AXLE ASSEMBLY
3. INSTALL SKID CONTROL SENSOR ROTOR (WITH ABS)

Rear Axle Bearing (a) Using the SST and a press, press-fit a new skid control sensor
Retainer INNER rotor to the standard position on the rear axle bearing retainer
INNER as shown in the illustration.
6.7±0.5
SST 09515-21010, 09608-32010
Standard:
6.7 ± 0.5 mm
Skid Control 4. INSTALL REAR AXLE BEARING RETAINER INNER

Sensor Rotor (a) Heat a new rear axle bearing retainer INNER (with the skid con-
C136547J01
trol sensor rotor) to 150 °C.
CAUTION:
As the inner retainer becomes extremely hot, be sure to
use safety gloves to perform this procedure.
NOTICE:
The retainer turns slightly yellow when reaches 150 °C. Do
not heat above 150 °C.
(b) Tap in the rear axle bearing retainer INNER (with the skid con-
trol sensor rotor) part of the way using a hammer or similar tool.
Then use the SST and a press to press-fit it before it gets cold.
INSTALLATION
1. INSTALL REAR AXLE SHAFT OIL SEAL
(a) Apply MP grease to the lip of the shaft oil seal.
(b) Using the SST and a hammer, tap in a new oil seal to the posi-
tion shown in the illustration.
SST 09517-12010
NOTICE:
• Install the oil seal slowly and uniformly.
• Be careful not to damage the oil seal.

SST 09520-00031
SST
AH 4.8±0.5mm
C142184J01
GETtheMANUALS.org
AH–16
(a) Using the SST, insert the rear axle shaft to the axle housing.
SST
C137579
(b) Using the 4 nuts, install the rear axle bearing retainer OUT LH.
NOTICE:
• Do not allow the spline of the shaft edge to scratch the
shaft oil seal.
• Be careful not to damage the speed sensor rotor.
• Check for any foreign matter on the speed sensor rotor
and insertion part.
• Check that the axle shaft is inserted firmly to the differ-
C137753 ential side by truing it.
3. INSTALL SPEED SENSOR RR LH (WITH ABS) (See page DF-51)
4. INSTALL REAR BRAKE DRUM

6. INSPECT TEST MODE (SPEED SENSOR SYSTEM) (WITH ABS)

VEHICLE WITHOUT VSC (See page BC-9)
VEHICLE WITH VSC (See page BC-65)
AH
GETtheMANUALS.org
AH–17 AXLE - REAR AXLE HOUSING ASSEMBLY

DRIVE LINE / AXLE
AXLE
COMPONENTS
REAR BRAKE BACKING PLATE LH
REAR WHEEL BRAKE CYLINDER ASSEMBLY

REAR BRAKE SHOE KIT
REAR BRAKE SHOE HOLD

DOWN SPRING
REAR BRAKE SHOE HOLD

DOWN SPRING CUP
REAR BRAKE SHOE RETURN SPRING
REAR BRAKE DRUM

AH REAR AXLE SHAFT
C139222J02
GETtheMANUALS.org
AXLE - REAR AXLE HOUSING ASSEMBLY
AH–18
T=92{938}
REAR LATERAL CONTROL ROD ASSEMBLY
REAR SHOCK ABSORBER

ASSEMBLY LH
T=87{887}
REAR BRAKE TUBE NO. 5
T=7.4{71}
REAR AXLE HOUSING
SPEED SENSOR RR LH(ABS) T=35{357}
ASSEMBLY

BEARING SHAFT ASSEMBLY T=32{326}
FILLER PLUG
T=61.2{624.5} T=7.4{71}
GASKET
REAR BRAKE TUBE NO. 6

GASKET
T=61.2{624.5}
×10
DRAIN PLUG REAR DIFFERENTIAL
T=32{326}
CARRIER ASSEMBLY
×4
T=60{612} T=97{987}
SPEED SENSOR RR LH (ABS)
UPPER CONTROL ARM
REAR SPRING SEAT LWR
ASSEMBLY RR LH
T=92{938} REAR COIL SPRING LH
T=7.4{75.5}
PARKING BRAKE CABLE

ASSEMBLY NO. 3 AH
T=92{938}
T=97{987}
TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PART C140824J01
GETtheMANUALS.org
REMOVAL
1. REMOVE REAR TIRE

4. DRAIN TRANSFER OIL (TRANSMISSION A/T, 4WD) (See page TF-

7)

6. DRAIN DIFFERENTIAL OIL (See page DF-3)

7. DISCONNECT SPEED SENSOR RR LH
(a) Remove the bolt and 4 wire harness clamps, and disconnect
the speed sensor RR LH from the rear suspension arm No. 1
and the rear axle housing assembly.
C133713J02
(b) Remove the bolt and speed sensor RR LH.
8. DISCONNECT SPEED SENSOR RR RH

9. REMOVE REAR BRAKE DRUM (See page BR-30)
10. REMOVE REAR BRAKE SHOE KIT (See page BR-30)
C133712
11. DISCONNECT PARKING BRAKE CABLE ASSEMBLY NO. 3

(a) Remove the two bolts, and disconnect the parking brake cable
from the backing plate.
AH
C135474
GETtheMANUALS.org
AH–20
(b) Remove the 2 bolts, and separate the 2 parking brake cable
clamps from the rear suspension control arm.
12. REMOVE REAR WHEEL BRAKE CYLINDER ASSEMBLY (See

page BR-31)
13. REMOVE REAR AXLE BEARING RETAINER OUT LH (See page

AH-13)
14. REMOVE REAR AXLE SHAFT (See page AH-13)
C137682
15. REMOVE REAR BRAKE BACKING PLATE LH
(a) Remove the rear brake backing plate LH from the rear axle
shaft.
16. REMOVE REAR BRAKE BACKING PLATE RH


BLY (See page PR-6)
18. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY (See page

DF-34)
19. REMOVE REAR BRAKE FLEXIBLE HOSE LH

SST 09023-00100
(a) Using the SST, disconnect the brake tube from the rear brake
flexible hose LH.
(b) Remove the clip and disconnect the rear brake flexible hose LH
from the rear axle housing assembly.
20. REMOVE REAR BRAKE FLEXIBLE HOSE RH

SST 09023-00100
21. REMOVE UPPER CONTROL ARM ASSEMBLY RR LH (See page

SP-22)
22. REMOVE UPPER CONTROL ARM ASSEMBLY RR RH

C136544
23. SUPPORT REAR AXLE HOUSING ASSEMBLY

(a) Using a mission jack, support the rear axle housing assembly
with a rag placed between the assembly and the jack.
24. REMOVE REAR LATERAL CONTROL ROD ASSEMBLY

(a) Remove the bolt, nut, and 2 washers, and remove the body side
of the rear lateral control rod.
(b) Remove the nut and 2 washers, and remove the rear axle hous-
AH
ing assembly side of the rear lateral control rod.
25. REMOVE REAR SHOCK ABSORBER ASSEMBLY LH (See page

SP-20)
26. REMOVE REAR SHOCK ABSORBER ASSEMBLY LH

27. REMOVE REAR COIL SPRING LH
C137750
28. REMOVE REAR COIL SPRING RH
29. REMOVE LOWER CONTROL ARM ASSEMBLY LH (See page SP-

24)
GETtheMANUALS.org
30. REMOVE LOWER CONTROL ARM ASSEMBLY RH

31. REMOVE REAR AXLE HOUSING ASSEMBLY

(a) Slowly lower the jack supporting the rear axle housing assem-
bly, and remove the rear axle housing.
32. REMOVE REAR SPRING SHEET LOWER

(a) Remove the rear spring sheet LWR from the rear axle housing
assembly.
33. REMOVE REAR BRAKE TUBE NO. 5

(a) Remove the bolt and the rear brake tube No. 5.
NOTICE:
Do not bend or damage the tube No. 5.
34. REMOVE REAR BRAKE TUBE NO. 6

(a) Remove the 2 bolts and rear brake tube No. 6.
NOTICE:
Do not bend or damage tube No. 6.
INSTALLATION
1. INSTALL REAR BRAKE TUBE NO. 5
(a) Install rear brake tube No. 5 with the bolt.
NOTICE:
2. INSTALL REAR BRAKE TUBE NO. 6

(a) Install rear brake tube No. 6 with the 2 bolts.
NOTICE:
3. INSTALL REAR SPRING SHEET LWR
4. INSTALL REAR AXLE HOUSING ASSEMBLY

(a) By supporting the axle with a jack, temporarily install the lower
control arm LH and RH with the bolt and nut.
5. INSTALL REAR COIL SPRING LH (See page SP-19)
6. INSTALL REAR COIL SPRING RH

7. TEMPORARILY TIGHTEN REAR SHOCK ABSORBER ASSEMBLY

AH LH (See page SP-20)

RH
9. TEMPORARILY TIGHTEN REAR LATERAL CONTROL ROD

ASSEMBLY
(a) Using the bolt, nut and 2 washers, install the rear lateral control
rod assembly to the body side.
GETtheMANUALS.org
AH–22
(b) Using the nut and 2 washers, install the rear lateral control rod
assembly to the rear axle housing assembly.
10. TEMPORARILY TIGHTEN UPPER CONTROL ARM ASSEMBLY

RR LH (See page SP-22)

RR RH
12. CONNECT REAR BRAKE FLEXIBLE HOSE LH

C137750
SST O9023-00100
(a) Using a new clip, install the rear brake flexible hose LH to the
rear axle housing assembly.
(b) Using the SST, connect the brake tube to the rear brake flexible
hose LH.
13. CONNECT REAR BRAKE FLEXIBLE HOSE RH

SST O9023-00100
14. INSTALL REAR DIFFERENTIAL CARRIER ASSEMBLY (See page

DF-50)
C136544
BLY (See page PR-7)
16. INSTALL REAR BRAKE BACKING PLATE LH
(a) Apply the Three Bond 1212 or equivalent to the brake backing
Vehicle Front plate and install the plate to the rear axle housing.
NOTICE:
Do not apply to the weep hole of the backing plate shown
Apply Bond 17. INSTALL REAR BRAKE BACKING PLATE RH
Do Not Apply Bond To (a) Perform the same procedure for the RH as for the LH.
The Water Escape Hole 18. INSTALL REAR AXLE SHAFT (See page AH-15)
C137747
19. CONNECT PARKING BRAKE CABLE ASSEMBLY NO. 3

(a) Using the two bolts, install the parking brake cable assembly
No. 3 to the backing plate.
AH
C135474
GETtheMANUALS.org
(b) Using the 2 bolts, install the 2 cable clamps to the rear suspen-
sion arm assembly No. 2.
20. INSTALL REAR WHEEL BRAKE CYLINDER ASSEMBLY (See

page BR-32)
21. INSTALL REAR BRAKE SHOE KIT (See page BR-33)
C137682
(See page BC-9)
24. BLEED AIR FROM BRAKE SYSTEM (WITH VSC)

(See page BC-65)

MISSION)
26. ADD TRANSFER OIL (AUTOMATIC TRANSMISSION, 4WD)
28. ADD DIFFERENTIAL OIL (See page DF-3)

30. STABILIZE VEHICLE (See page SP-21)
31. FULLY TIGHTEN REAR SHOCK ABSORBER ASSEMBLY LH (See

page SP-21)
32. FULLY TIGHTEN REAR SHOCK ABSORBER ASSEMBLY RH

33. FULLY TIGHTEN REAR LATERAL CONTROL ROD ASSEMBLY

(a) Tighten the bolts of the body side.
(b) Tighten the nuts of the rear axle housing side.
34. FULLY TIGHTEN UPPER CONTROL ARM ASSEMBLY RR LH (See

page SP-23)
35. FULLY TIGHTEN UPPER CONTROL ARM ASSEMBLY RR RH

36. FULLY TIGHTEN LOWER CONTROL ARM ASSEMBLY LH (See

AH page SP-25)
C137750
37. FULLY TIGHTEN LOWER CONTROL ARM ASSEMBLY RH
GETtheMANUALS.org
TO INDEX
SUSPENSION
SUSPENSION
SUSPENSION SYSTEM
BASIC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-1
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-1
FRONT SUSPENSION
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-2
FRONT WHEEL ALIGNMENT
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-4
FRONT SHOCK ABSORBER WITH COIL SPRING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. .. . .. .. . .. ......... SP-8
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. .. . .. .. . .. ......... SP-9
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. .. . .. .. . .. ......... SP-9
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. .. . .. .. . .. ......... SP-10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. .. . .. .. . .. ......... SP-10
DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. .. . .. .. . .. ......... SP-11
FRONT SUSPENSION LOWER ARM ASSEMBLY LH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-14
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-15
REAR SUSPENSION
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-17
REAR COIL SPRING LH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-19
REAR SHOCK ABSORBER ASSEMBLY LH
REMOVAL . . . . . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . SP-20
INSPECTION. . . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . SP-20
INSTALLATION .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . SP-20
DISPOSAL . . . . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . SP-21
UPPER CONTROL ARM ASSEMBLY RR LH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-24 SP
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-24
REAR STABILIZER BAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP-26
GETtheMANUALS.org
SP–1 SUSPENSION - SUSPENSION SYSTEM
SUSPENSION SYSTEM
SUSPENSION
BASIC INSPECTION
1. CHECK CONNECTING PART AND LINKAGE OF SUSPENSION
FOR LOOSENESS, WEAR, AND DAMAGE
(a) Check the connections and linkages of the suspension for
looseness, wear, and damage.
2. CHECK SHOCK ABSORBERS FOR DAMAGE AND OIL LEAKS

(a) Visually check whether oil is leaking from the tube or any other
part of the shock absorbers.

Tires (worn or improperly inflated) -
Front wheel alignment SP-4
Hub bearing -
Vehicle sways
Front shock absorber with coil spring SP-9
Rear shock absorber SP-20
Rear coil spring SP-19
Vehicle (overloaded) -
Bottoming out
Front stabilizer bar SP-14
Vehicle shimmies or tilts Front shock absorber with coil spring SP-9
Wheel alignment (incorrect) -
Front wheel shimmy
Front suspension lower arm -
Hub bearing -
Wheel alignment (incorrect) -
Rear wheel shimmy
SP Rear coil spring

Tires (worn or improperly inflated)
SP-19
-
Abnormal tire wear Wheel alignment (incorrect) -
GETtheMANUALS.org
SUSPENSION - FRONT SUSPENSION
SP–2
FRONT SUSPENSION
SUSPENSION
COMPONENTS
FRONT STABILIZER
BRACKET
T=95.7{976}
T=147{1499}

CLIP
T=58.1{592}
T=76.5{780}
T=31{316}
FRONT STABILIZER LINK ROD
T=37.3{380}
FRONT STABILIZER BAR BUSH NO. 1
T=147{1499}
FRONT SUSPENSION LOWER ARM NO. 1 LH
ENGINE UNDER COVER ×11
T=5.4{55}
SP

C140828J02
GETtheMANUALS.org
SP–3 SUSPENSION - FRONT SUSPENSION
BEARING DUST COVER
T=47.1{480}
T=26.5{270}
FRONT SUSPENSION
FRONT COIL SPRING
SUPPORT
INSULATOR UPR
BUSH
FRONT SPRING SEAT
FRONT COIL SPRING LH

DUST COVER LH NO.1

FRONT SPRING ASSEMBLY LH
BUMPER NO. 1
SP

C143629J01
GETtheMANUALS.org
SUSPENSION - FRONT WHEEL ALIGNMENT
SP–4
FRONT WHEEL ALIGNMENT

SUSPENSION
ADJUSTMENT
1. CHECK VEHICLE CONDITION
(a) Check that the vehicle is empty. (With the fuel tank full, remove
spare tires and tools.)
2. CHECK TIRE
(a) Check tire size, tire air pressure and tire wear.
3. CHECK SIDE SLIP

(a) Check for side slip with a side slip tester.
Standard:
0 ± 5 mm (per 1 m)
NOTICE:
• Put the vehicle in neutral, and, approach the tester
straight ahead at a speed no higher than that of walking
pace (4 km/h, 2.5 mph).
• Do not depress the brake while the vehicle is on the
tester.
• Do not operate the steering wheel while the vehicle is
on the tester.
(b) If the side slip values are outside the specified value, check the
wheel alignment.
4. CHECK TOE-IN
(a) Bounce the vehicle to stabilize.
(b) Physically push the vehicle and advance it 5 m (16.5 ft.).
NOTICE:
After moving the vehicle backward, always move it forward
the same distance it was moved backward.
(c) Align the needle height of the toe-in gauge with the height of the
Toe-in Gauge center of the front wheel axis and insert into the back side of the
Tread Center tire.
(d) Make a tread center mark at the rear end of both (right and left)
front tires and measure the distance between the marks (mea-
surement B).
Measurement B (e) Slowly push the vehicle forward and rotate the tire 180º to the
tire pressure bulb on the front wheels.
Toe-in Gauge NOTICE:
CA00066J04 Do not rotate the tire more than 180º . In case of over-rota-
tion, repeat the procedure from the point where the toe-in
gauge is set.
(f) Measure the distance between the tread center marks at the
SP
A front end of the tires (measurement A).
(g) Find the toe-in.
Vehicle Front Standard:
0 ± 2 mm
Measurement A HINT:
B
Toe-in = measurement B - measurement A
5. ADJUST TOE-IN
(a) Measure the thread lengths of the right and left rack ends.
Toe-in Gauge CA00067J04
Standard:
Difference in thread lengths of 1.5 mm (0.059 in) or less
GETtheMANUALS.org
SP–5 SUSPENSION - FRONT WHEEL ALIGNMENT
(b) Loosen the tie rod end nuts.

(c) Turn the right and left rack ends in the opposite directions by an
equal amount to adjust the toe-in so that it is within the specified
range.
Standard:
0 ± 2 mm
(d) Tighten the nut of the tie rod end nut.
C137748
6. CHECK WHEEL ANGLE

(a) Set the turning radius gauge.
Inside Outside Outside Inside
(b) Check the wheel angle.
Standard:
Mounted suspen- Outside Wheel

Inside Wheel
sion (Reference)
Front STD 40°32’±2° 34°05’±2°
Two Wheel Drive
C101050J01 low down sus- 40°23’±2° 33°46’±2°
215/65R16 pension
Four Wheel Drive
low down sus- 39°18’±2° 33°02’±2°
pension
Standard sus-
235/60R16 39°06’±2° 33°06’±2°
pension
NOTICE:
• Empty the vehicle (spare tires, tools, etc.)
• Remove the stop light fuse so that the stop light will not
blink while checking.
• With the vehicle empty, apply pressure to the brake
pedal that the front wheels do not rotate. Then check
that the brake pedal is working.
7. ADJUST WHEEL ANGLE

(a) Loosen the nut of the tie rod end nut.
(b) Adjust the lengths of the right and left rack ends so that they are
the same.
NOTICE:
When adjusting, do not twist the boot.
SP (c) Tighten the nut of the tie rod end nut.
8. CHECK CAMBER, CASTER AND KING PIN ANGLE

(a) Set the turning radius gauge.
(b) Set the calibration of the turning radius gauge to 0° and lock.
C137748
GETtheMANUALS.org
SUSPENSION - FRONT WHEEL ALIGNMENT
SP–6
(c) Get in the vehicle so that the center of the tire tread is aligned in
the center of the turning radius gauge.
NOTICE:
• With the vehicle empty, apply pressure to the brake
pedal so that the front wheels do not rotate. Then check
that the brake pedal is working.
• When using a portable type turning radius gauge, make
sure that the rear wheels have the same height and
evenness.
C142694 • Remove the stop light switch fuse so that the stop light
will not blink while checking.
(d) Install the computer in the disk wheel. Then install the camber
caster king pin gauge.
(e) Set the calibration of the turning radius gauge to 0°. Then
remove the lock on the turning radius gauge.
(f) Install the center rod terminal of the camber caster king pin
gauge so that it adjusts to the predefined position of the com-
puter.
(g) Check the camber.
(h) Confirm straight symptoms.
C142695
(i) Set the gauge in a horizontal position so that the horizontal bub-
ble of the gauge is in the center.
(j) Read the calibration of the center position of the bubble in the
gauge being used for camber measurements.
Standard
Mounted suspension Standard

Standard suspension 0°30'±45'
Camber
Low down suspension 0°12'±45'
C142696 (k) Check the caster angle and king pin angle (right wheel).
Caster Angle
(() (()
(') (')
C142697J01
SP
Kingpin Angle
(() (()
(') (')
C142698J01
GETtheMANUALS.org
SP–7 SUSPENSION - FRONT WHEEL ALIGNMENT
(l) Turn the steering wheel to the right until calibration of the turn-
ing radius gauge reaches 20°.
(m) Turn the adjustment screws for the caster angle and king pin
angle of the gauge so that each bubble is aligned with "0".
(n) Turn the steering wheel to the left until calibration of the turning
radius gauge reaches 20°.
(o) Read the calibration of the center position of the bubble in the
gauge being used to measure the caster angle and the king pin
angle.
Standard
Mounted suspension Standard

Standard suspension 4°53'±1°
Caster angle
Low down suspension 4°53'±1°
Standard suspension 12°25'±1°
King pin angle
Low down suspension 12°52'±1°
(p) Check the caster angle and king pin angle (left wheel).
HINT:
Since the camber, caster and king pin angle have been
adjusted to the standard values in advance, no adjustments are
needed.
(q) Remove the gauge and computer.
SP
GETtheMANUALS.org
SUSPENSION - FRONT SHOCK ABSORBER WITH COIL SPRING
SP–8

SUSPENSION
REMOVAL
2. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Remove the bolt, and disconnect the brake flexible hose and
the speed sensor FR from the front shock absorber with coil
spring.
C133716
(b) Using a flathead screwdriver wrapped in protective tape,

remove the speed sensor clamp.
(c) Remove the bolt, and disconnect the speed sensor FR from the
front shock absorber with coil spring.
C142004
(d) Remove the 2 bolts and 2 nuts, and disconnect the front shock
absorber with coil spring from the steering knuckle.
(e) Remove the bearing dust cover.
(f) Loosen the lock nut of the front shock absorber.
NOTICE:
• Only loosen the lock nut. Do not remove it.
C135148
SP
• Loosen the lock nut only when disassembling the front
shock absorber with coil spring.
C137686
GETtheMANUALS.org
SP–9 SUSPENSION - FRONT SHOCK ABSORBER WITH COIL SPRING
(g) Remove the 3 nuts. Then remove the front suspension support
No. 2 and the front shock absorber with coil spring.
NOTICE:
Cover the drive shaft boot with a rag so as not to damage it.
DISASSEMBLY
C137687
1. REMOVE FRONT SUSPENSION SUPPORT

(a) Install the SST to the front coil spring so that the top and bottom
hooks on the SST are fully extended. Compress the coil spring
until it moves freely.
SST 09727-30021
NOTICE:
• Install the SST so that there is the greatest possible dis-
tance between the hooks.
• Do not use an impact wrench.
C137689 (b) Remove the lock nut.
(c) Remove the front suspension support.
2. REMOVE FRONT SPRING SHEET
3. REMOVE FRONT SHOCK ABSORBER DUST COVER LH NO. 1
4. REMOVE FRONT SPRING BUMPER NO. 1

(a) Remove the front spring bumper No. 1 from the front shock
absorber.
5. REMOVE FRONT COIL SPRING LH
6. REMOVE FRONT COIL SPRING INSULATOR UPPER

(a) Remove the front coil spring insulator upper from the coil spring.
INSPECTION
1. CHECK FRONT SHOCK ABSORBER ASSEMBLY LH
(a) Check the shock absorber operation.
(1) Compress and extend the front shock absorber assembly
4 or more times.
(2) Check the front shock absorber assembly.
Standard:
When compressing and extending the front shock
SP absorber assembly LH at a constant speed, the
weight of all the strokes is constant and there is no
G030676J01 abnormal resistance or sound. When extending, it
returns at a constant speed and there is no abnor-
mal noise.
HINT:
If there is any abnormality, replace the front shock
absorber assembly with a new one.
GETtheMANUALS.org
SUSPENSION - FRONT SHOCK ABSORBER WITH COIL SPRING
SP–10
REASSEMBLY
1. INSTALL FRONT COIL SPRING LH
SST 09727-30021
(a) Using the SST, compress the coil spring.
NOTICE:
Do not use an impact wrench.
C137689
(b) Install the coil spring so that the end comes to the stepped por-
tion of the shock absorber.
NOTICE:
Install the spring with the smaller diameter facing up.
2. INSTALL FRONT SPOIL SPRING INSULATOR UPPER
3. INSTALL FRONT SPRING BUMPER NO. 1
4. REMOVE FRONT SHOCK ABSORBER DUST COVER LH NO. 1
C137688
5. INSTALL FRONT SPRING SHEET
(a) Install the front spring sheet so that the stepped portion of the
front spring sheet and the end of the coil spring are aligned.
6. INSTALL FRONT SUSPENSION SUPPORT

(a) Temporarily tighten a new lock nut to the front shock absorber
assembly.
(b) Release the SST and remove it from the coil spring.
NOTICE:
Do not use an impact wrench.
HINT:
After installing the front shock absorber in the vehicle, tighten
the lock nut.
INSTALLATION
(a) Install the suspension support side on the vehicle with the 3
nuts.
SP
C137687
GETtheMANUALS.org
SP–11 SUSPENSION - FRONT SHOCK ABSORBER WITH COIL SPRING
(b) Insert the 2 bolts from the front of the vehicle and tighten the
front shock absorber with coil spring and the steering knuckle
with the 2 nuts.
C135148
(c) Fully tighten the new lock nut.

C137686
(d) With the bolt and the wire harness clamp, install the flexible
hose and the speed sensor to the shock absorber.
NOTICE:
Do not twist the speed sensor or the flexible hose while
installing.

C133716 3. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

(See page SP-4.)
DISPOSAL
1. DISPOSE OF FRONT SHOCK ABSORBER ASSEMBLY LH
(a) The disposal procedure is described below.
(1) Use a vise to fix the shock absorber with the piston-rod
extended.
(2) Using a metal saw or equivalent, slowly make a cut 5 cm
(2 in.) from the upper end of the shock absorber to dis-
charge the gas inside.
SP NOTICE:
• The gas that discharges is colorless, odorless and
C099138 non-poisonous.
• Cover the metal saw with a cloth, etc. when drilling
the hole because the force of the gas may cause it
to burst out.
GETtheMANUALS.org
SUSPENSION - FRONT SUSPENSION LOWER ARM ASSEMBLY LH
SP–12
FRONT SUSPENSION LOWER ARM ASSEMBLY LH

SUSPENSION
REMOVAL
2. REMOVE FRONT STABILIZER LINK ROD (See page SP-14)

3. REMOVE FRONT SUSPENSION LOWER ARM NO. 1 LH
C137246
(b) Using the SST, remove the ball joint of the front suspension
lower arm No. 1 LH from the steering knuckle.
SST 09628-00011
SST
C142002
(c) Remove the 2 bolts and nut. Then remove the front suspension
lower arm No. 1 LH.
C134966J01 INSTALLATION
1. TEMPORARILY TIGHTEN FRONT SUSPENSION LOWER ARM
NO. 1 LH
(a) With the 2 bolts and nut, temporarily tighten the lower arm.
HINT:
SP
After stabilizing the vehicle, fully tighten the lower arm.
(b) With the nut, install the lower arm to the steering knuckle.
NOTICE:
Keep the screws and the tapered portions free of oil or
C134966J01 grease.
(c) Install a new clip.
2. INSTALL FRONT STABILIZER LINK ROD (See pageSP-15)
GETtheMANUALS.org
SP–13 SUSPENSION - FRONT SUSPENSION LOWER ARM ASSEMBLY LH
3. STABILIZE VEHICLE
(a) Install the front tire.
(b) Jack down the vehicle and bounce the vehicle at the corners up
and down to stabilize the front suspension.
(c) Remove the front tire.
(d) Jack up the front suspension lower arm assembly LH, applying
the load to the suspension so that the front suspension lower
arm assembly LH is level.
4. FULLY TIGHTEN FRONT SUSPENSION LOWER ARM NO. 1 LH
(a) Fully tighten the bolt and nut.

(See page SP-4)
C134966
SP
GETtheMANUALS.org
SUSPENSION - FRONT STABILIZER BAR
SP–14

SUSPENSION
REMOVAL

3. REMOVE FRONT STABILIZER LINK ROD
(a) Remove the nut and the front stabilizer link rod.
HINT:
If the stud bolt spins free, use a hexagon wrench.
C135141
(b) Hold the front stabilizer link rod with a wrench and remove the
nut.
(c) Remove the front stabilizer link rod.
(d) Perform the same procedure for the RH as for the LH.
C135142
4. REMOVE FRONT STABILIZER BRACKET

(a) Remove the 4 bolts. Then remove the front stabilizer bracket LH
and RH.
5. REMOVE FRONT STABILIZER BAR

(a) Remove the front stabilizer bar from the vehicle.
6. REMOVE FRONT STABILIZER BAR BUSH NO. 1

(a) Remove the 2 front stabilizer bar bush No. 1 from the front sta-
bilizer bar.
C135143
INSPECTION
1. CHECK FRONT STABILIZER LINK ASSEMBLY LH
(a) Check flipping behavior of the ball joint.
(1) Fix the front stabilizer link assembly with an aluminum SP
plate inserted.
(2) Install the nut to the stud of the front stabilizer link assem-
bly.
(3) Turn the stud 5 times in the same direction as it vibrates.
Turn it at a rate of 2 to 4 seconds per turn. Take the torque
reading on the 5th turn.
G021679 Standard:
0.98 N*m (10 kgf*cm) or less (turning torque)
HINT:
If the difference is out of the specified range, replace the
front stabilizer link assembly with a new one.
GETtheMANUALS.org
SP–15 SUSPENSION - FRONT STABILIZER BAR
(4) Rotate the stud.

Standard:
There is no dragging or looseness during the rota-
tion
(b) Check the dust cover
(1) Check the dust cover for cracks or grease leakage.
INSTALLATION
1. INSTALL FRONT STABILIZER BAR BUSH NO. 1
Front (a) Install the 2 front stabilizer bar bush No. 1 so that the bush stop-
pers on the stabilizer bar are on the inside.
Side Slippage Prevention Ring

C133029
2. INSTALL FRONT STABILIZER BAR

(a) Install the front stabilizer bracket and the front stabilizer bar with
the 4 bolts.
NOTICE:
• Install the front stabilizer bar with the identification
marks on the top.
• Install the brackets so that the notch is on the upper
vehicle side.
C135143 NOTICE:
3. INSTALL FRONT STABILIZER LINK ROD

SST 09729-97203
(a) Install the stabilizer link rod to the stabilizer with the nut.
HINT:
If the stud bolt spins free, use a hexagon wrench.
SP C135141
GETtheMANUALS.org
SUSPENSION - FRONT STABILIZER BAR
SP–16
(b) Install the stabilizer link rod to the front suspension lower arm
with the nut.
HINT:
Fix the stabilizer link rod with a wrench.
C135142
(c) Measure the dimensions of "a" in the figure.

Standard:
10 to 15 mm
NOTICE:
When tightening regulation torque, tighten to 15 mm when
the dimensions of "a" are less than 15 mm.
a 5. INSTALL FRONT TIRE

C142693 Torque: 103 N*m (1050 kgf*cm)

HINT:
(See page SP-4)
SP
GETtheMANUALS.org
SP–17 SUSPENSION - REAR SUSPENSION
REAR SUSPENSION
SUSPENSION
COMPONENTS
T=35{357}
T=96.8{987}
REAR SHOCK ABSORBER

ASSEMBLY LH
T=92{938}
REAR LATERAL CONTROL

ROD ASSEMBLY

T=20{204} ×2
REAR SHOCK ABSORBER
ASSEMBLY LH
UPPER CONTROL ARM REAR BRAKE
ASSEMBLY RR RH FLEXIBLE HOSE LH
T=97{989}
CLIP
×2 T=35{357}
T=15.2{155}
T=92{938}
T=97{989}
REAR SPRING
SEAT UPR
T=92{938}
REAR COIL SPEED SENSOR RR LH

SPRING RH UPPER CONTROL ARM
ASSEMBLY RR LH
REAR SPRING SEAT UPR
LOWER CONTROL ARM T=97{987}

ASSEMBLY RH REAR COIL SPRING LH
T=7.4{75.5}
SP REAR SPRING SEAT LWR
T=92{938}
T=92{938}
T=97{987}

C140883J01
GETtheMANUALS.org
SUSPENSION - REAR SUSPENSION
SP–18
REAR STABILIZER LINK

T=53.5{546}
T=53.5{546}
T=53.5{546}
REAR STABILIZER LINK
T=53.5{546}
REAR STABILIZER BAR
REAR STABILIZER
BUSH
REAR STABILIZER
BRACKET
T=30{306} REAR STABILIZER

BUSH
SP
REAR STABILIZER
BRACKET
T=30{306}

C143631J01
GETtheMANUALS.org
SP–19 SUSPENSION - REAR COIL SPRING LH
REAR COIL SPRING LH

SUSPENSION
REMOVAL
1. REMOVE REAR TIRE
3. REMOVE REAR BRAKE FLEXIBLE HOSE LH (See page AH-20)


6. DISCONNECT PARKING BRAKE CABLE
(a) With the 2 bolts, disconnect the 2 parking brake cable clamps
from the rear suspension control arm lower.

SP-20)
8. REMOVE REAR COIL SPRING LH

(a) Slowly lower the jack supporting the rear axle and remove the
spring.
C137682
9. REMOVE REAR SPRING SHEET UPPER
INSTALLATION
1. INSTALL REAR SPRING SHEET UPPER

3. INSTALL REAR COIL SPRING LH
(a) With the identifying mark on the underside, in the rear of the
vehicle,install the rear coil spring LH, to the spring seat part of
rear suspension arm assemble No. 2 LH.

Identification LH (See page SP-20)
Marks
5. CONNECT PARKING BRAKE CABLE (See page SP-21)
6. CONNECT REAR BRAKE FLEXIBLE HOSE LH (See page AH-22)

C142003
8. INSTALL REAR TIRE (See page SP-21)

SP 9. STABILIZE VEHICLE (See page SP-21)
10. FULLY TIGHTEN REAR SHOCK ABSORBER ASSEMBLY LH (See

page SP-21)
11. REMOVE THE BRAKE FLUID REFILL
12. Bleed air from the brake system.

(See page BR-5)
13. CHECK BRAKE FLUID LEAKS
GETtheMANUALS.org
SUSPENSION - REAR SHOCK ABSORBER ASSEMBLY LH
SP–20
REAR SHOCK ABSORBER ASSEMBLY LH

SUSPENSION
REMOVAL
1. REMOVE REAR TIRE
2. DISCONNECT PARKING BRAKE CABLE (See page SP-19)

(a) Using a jack, support the rear axle housing with a cloth inserted.
(b) Remove the nut and the washer of the body side of the rear
shock absorber assembly LH.
(c) Remove the nut and bolt of the rear shock absorber assembly
LH rear axle housing. Then remove the rear shock absorber
assembly LH.
INSPECTION
C135160
1. CHECK REAR SHOCK ABSORBER ASSEMBLY LH

(a) Check the shock absorber operation.
(1) Check the rear shock absorber assembly by compressing
and extending it.
Standard:
When compressing and extending the rear shock
absorber assembly LH at a constant speed, the
weight of all the strokes is constant and there is no
abnormal resistance or sound.
C061284 In addition, after extending, it returns at a constant
speed.
HINT:
If there is any abnormality, replace the rear shock
absorber assembly with a new one.
INSTALLATION
LH
(a) Using a washer, temporarily tighten the rear shock absorber
assembly LH to the body side with the nut. SP
(b) With a jack, lift the rear axle housing and temporarily install it
with the bold and the nut.
C135160
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SP–21 SUSPENSION - REAR SHOCK ABSORBER ASSEMBLY LH
2. INSTALL PARKING BRAKE CABLE

(a) With the 2 bolts, install the 2 parking brake cable clamps to the
suspension control arm lower.

4. STABILIZE VEHICLE
(a) With the vehicle empty, bounce the vehicle up and down sev-
C137682 eral times to stabilize the rear suspension.
5. FULLY TIGHTEN REAR SHOCK ABSORBER ASSEMBLY LH

(a) Fully tighten the nut on the body side.
(b) Fully tighten the bolt and the rear screw housing side.
C135160 DISPOSAL
(a) The disposal procedure is described below.
(1) With the piston-rod extended, slant and secure the rear
shock absorber assembly in a vise.
(2) Using a metal saw or equivalent, slowly make a cut 2 cm
(0.8 in) from the lower end of the rear shock absorber
assembly to discharge the gas inside.
NOTICE:
• The gas that discharges is colorless, odorless and
C101412J01 non-poisonous.
• Cover the metal saw with a cloth, etc. when drilling
the hole because the force of the gas may cause it
to burst out.
SP
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SUSPENSION - UPPER CONTROL ARM ASSEMBLY RR LH
SP–22
UPPER CONTROL ARM ASSEMBLY RR LH

SUSPENSION
REMOVAL
1. REMOVE REAR TIRE
2. DISCONNECT SPEED SENSOR RR LH

(a) Remove the bolt, and disconnect the speed sensor wire from
the rear axle housing.
(b) Remove the 2 clips, and disconnect the speed sensor RR LH
from the upper control arm assembly RR LH.
C137683
3. REMOVE UPPER CONTROL ARM ASSEMBLY RR LH

A (a) Remove the 2 bolts, 2 nuts and the upper control arm assembly
RR LH.
A RR LH
(a) Temporarily tighten the upper control arm assembly RR LH with
the 2 bolts and 2 nuts.
C137685
2. INSTALL SPEED SENSOR RR LH

(a) Install the 2 wire harness clamps to the upper control arm
SP
assembly RR LH.

C137683
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SP–23 SUSPENSION - UPPER CONTROL ARM ASSEMBLY RR LH
5. FULLY TIGHTEN UPPER CONTROL ARM ASSEMBLY RR LH

A (a) Fully tighten the bolt and the nut of the upper control arm
assembly RR LH.
97 N*m (989 kgf*cm) (Nut B)
B
C137685
SP
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SUSPENSION - LOWER CONTROL ARM ASSEMBLY LH
SP–24

SUSPENSION
REMOVAL
1. REMOVE REAR TIRE
3. REMOVE REAR BRAKE FLEXIBLE HOSE LH (See page AH-20)

5. DISCONNECT PARKING BRAKE CABLE

(a) Using a mission jack, support the rear axle housing assembly
with a piece of cloth inserted.

SP-20)
8. REMOVE REAR SHOCK ABSORBER ASSEMBLY RH

9. REMOVE REAR COIL SPRING LH (See page SP-19)
10. REMOVE REAR COIL SPRING RH

12. REMOVE LOWER CONTROL ARM ASSEMBLY LH

(a) Remove the bolt (A) and the nut, and remove the lower control
arm assembly LH from the body.
(b) Remove the bolt (B), nut and washer on the axle housing side.
Then remove the lower control arm assembly LH.
A
INSTALLATION
B 1. TEMPORARILY TIGHTEN LOWER CONTROL ARM ASSEMBLY
LH
C137684
(a) Temporarily tighten the body side of the lower control arm
assembly LH with the bolt (A), nut and washer.
(b) With the bolt (B) and nut, temporarily tighten the lower control
arm assembly LH to the rear axle housing side. SP
3. INSTALL REAR COIL SPRING LH (See page SP-19)

A 4. INSTALL REAR COIL SPRING RH
B 5. TEMPORARILY TIGHTEN REAR SHOCK ABSORBER ASSEMBLY
C137684
LH (See page SP-20)
6. CONNECT REAR BRAKE FLEXIBLE HOSE LH (See page AH-22)
GETtheMANUALS.org
SP–25 SUSPENSION - LOWER CONTROL ARM ASSEMBLY LH

8. CONNECT PARKING BRAKE CABLE (See page SP-21)


11. FULLY TIGHTEN LOWER CONTROL ARM ASSEMBLY LH
(a) Fully tighten the bolt and the nut of the lower control arm
assembly LH.
Torque: 92 N*m (938 kgf*cm) (Nut A)
97 N*m (987 kgf*cm) (Nut B)
A 12. REFILL THE BRAKE FLUID.
13. BLEED AIR FROM THE BRAKE SYSTEM.

B (See page BR-5)
C137684
14. CHECK BRAKE FLUID LEAKS
SP
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SUSPENSION - REAR STABILIZER BAR
SP–26
REAR STABILIZER BAR

SUSPENSION
REMOVAL
1. REMOVE REAR STABILIZER LINK
(a) Remove the 4 bolts. Then remove stabilizer link LH and stabi-
lizer link RH from the stabilizer.
C137752
2. REMOVE REAR STABILIZER BAR

(a) Remove the 4 bolts, then remove the rear stabilizer bar.
1. INSTALL REAR STABILIZER BAR
(a) Install the rear stabilizer bush so that the identification paint of
Vehicle Inner Side the rear stabilizer bar is located on the internal side.
Identification Paint
C098640
(b) Install the rear stabilizer bar and the 2 rear stabilizer brackets to
the rear axle housing with the 4 bolts.
SP
C140502
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SP–27 SUSPENSION - REAR STABILIZER BAR
2. INSTALL REAR STABILIZER LINK

(a) Install the rear stabilizer links LH and RH with the 4 bolts.
C137752
SP
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TO INDEX
SUSPENSION
TIRE AND WHEEL

WHEEL AND TIRE
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TW-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TW-1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TW-1
WHEEL AND TIRE SYSTEM
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TW-2
TW
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TW–1 TIRE AND WHEEL - WHEEL AND TIRE
WHEEL AND TIRE

TIRE AND WHEEL
SUSPENSION
COMPONENTS
WHEEL AND TIRE
×5
T=103.0{1050}

C140922J01
REMOVAL
1. REMOVE WHEEL AND TIRE
(a) Remove the wheel cap S/A.
(b) Jack up the vehicle.
(c) Remove the 5 nut hubs.
(d) Remove the wheel disk.
TW
INSTALLATION
1. INSTALL WHEEL AND TIRE
(a) Install the wheel and the tire.
(b) Install the 5 nut hubs.
(c) Jack down the vehicle.
(d) Install the wheel cap S/A.
GETtheMANUALS.org
TIRE AND WHEEL - WHEEL AND TIRE SYSTEM
TW–2
WHEEL AND TIRE SYSTEM

TIRE AND WHEEL
SUSPENSION
INSPECTION
1. CHECK TIRE
(a) Check for a size and wear.
(b) Check for cracks and damage.
(c) Check the tire pressure.
Standard
Tire Pressure (Front Tire Pressure (Rear

Tire Size Wheels) Wheels)
kPa (kgf/cm2) kPa (kgf/cm2)
215/65R16 2.0 2.0
235/60R16 2.1 2.1
(d) Check for modification of the suspension and damage to any

parts of the wheel.
(e) Check the tire runout.
Maximum tire runout:
1.4 mm (vertical)
2.0 mm (horizontal)
HINT:
Remove the wheel assembly from the vehicle, and measure the
runout of the wheel assembly when it is off the vehicle.
(f) Check that the bolts on the wheel-related parts are properly
tightened.
C050798J01 (g) Check the related parts for looseness.
2. ROTATE TIRE
(a) Rotate the tires as shown in the illustration.
Front
G023600J01
3. CHECK WHEEL BALANCE

(a) Check the wheel balance (off-the-car balance).
(b) Adjust the wheel balance (off-the-car balance).
Imbalance after adjustment:
11 g or less
(c) If tire vibration occurs even after adjusting the off-the-car TW
balance, adjust the on-the-car balance.
4. CHECK FRONT AXLE HUB BEARING
C080976J01
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TO INDEX
BRAKE
BRAKE
BRAKE SYSTEM
PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-1
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-1
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-3
BRAKE FLUID
BLEED AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-5
BRAKE PEDAL
COMPONENTS . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-10
REMOVAL . . . . . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-11
INSTALLATION .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-11
ADJUSTMENT . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-12
BRAKE MASTER CYLINDER ASSEMBLY
COMPONENTS . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-14
REMOVAL . . . . . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-15
DISASSEMBLY . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-15
ASSEMBLY . . . . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-16
INSTALLATION .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-18
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-22
FRONT DISC BRAKE
COMPONENTS . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-24
REMOVAL . . . . . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-25
DISASSEMBLY . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-26
INSPECTION. . . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-26
ASSEMBLY . . . . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-27
INSTALLATION .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-28
REAR DRUM BRAKE
COMPONENTS . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-30
DISASSEMBLY . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-31
INSPECTION. . . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-33
ASSEMBLY . . . . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . BR-33
BR
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BR–1 BRAKE – BRAKE SYSTEM
BRAKE SYSTEM
BRAKE
PRECAUTIONS
1. HANDLING AND OPERATING PRECAUTIONS
NOTICE:
This maintenance operation may affect the SRS air bag. Make
sure to read the precautionary items of the SRS air bag before
starting work. (See page RS-164)
2. Care must be taken to replace each part properly as it could
affect the performance of the brake system and result in a
driving hazard. Replace the parts with the same part or
equivalent.
3. During the maintenance of the braking system, be sure to keep
the repair parts and the surrounding environment clean.
4. If the vehicle is equipped with a radio communication system,
refer to the precaution in the INTRODUCTION section.
OPERATION CHECK
1. CHECK BRAKE BOOSTER
(a) INSPECT AIR TIGHTNESS OF BRAKE BOOSTER
(1) Start the engine, then stop it after 1 or 2 minutes of idling.
(2) Step on the brake pedal several times with the normal
Normal Defective force used for normal braking operation. Then check the
changes of the brake pedal height.
Standard:
The height of the brake pedal should be higher the
second and third times than the first time. (The
intervals between the first and second, and the
second and third should be at least 5 seconds.)
Third Time (b) INSPECT BRAKE BOOSTER OPERATION
First Time Second Time C132733 (1) Step on the brake pedal several times with the engine
stopped using the same level of force, and check that the
height of the brake pedal does not change.
(2) While stepping on the brake pedal, start the engine and
check for changes in the height of the brake pedal.
Standard:
When starting the engine with the brake pedal
depressed, the brake pedal will move back slightly.
(c) INSPECT LOAD AIR TIGHTNESS OF BRAKE BOOSTER
Engine Running Held 30 Seconds With (1) With the engine is running, step on the brake pedal. Stop
Engine Stopped the engine and let stand for 30 seconds, then check the
height of the brake pedal.
Standard:
No change in the height of the pedal
BR
C132735
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BRAKE – BRAKE SYSTEM
BR–2
2. INSPECT BRAKE BOOSTER FUNCTION

(a) PREPARE FOR INSPECTION
Negative Pressure Gauge

Pressure Gauge
Brake Pedal Pressure Gauge
Vacuum
Hose
C142008J01
(1) Connect the portable brake tester as shown in the

illustration.
(2) Bleed air from the portable brake tester.
(b) INSPECT AIR TIGHTNESS FUNCTION
(1) Start the engine, then stop it at the negative pressure of
66.7 kPa (500 mm Hg) and check for changes in
pressure.
Standard:
No reduction of the negative pressure for 15
seconds.
(c) INSPECT LOAD AIR TIGHTNESS FUNCTION
(1) Start the engine, step-on the brake pedal with a force of
196 N (20 kgf), then stop the engine at the negative
pressure of 66.7 kPa (500 mm Hg). Check for changes in
pressure.
Standard:
Within 15 seconds, the reduction of the negative
pressure is within the 3.3 kPa (25 mm Hg)
(d) INSPECT NON-BRAKE BOOSTER OPERATION
(1) Stop the engine and operate the brake pedal several
times, then check the fluid pressure without applying a
vacuum.
Standard:
For vehicles without VSC BR

Pedal Force [N (kgf)] 2
Fluid Pressure [MPa (kgf/cm )]
98{10} 0.17{1.73}
294{30} 1.78{18.2}
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BR–3 BRAKE – BRAKE SYSTEM
With VSC
Pedal Force [N (kgf)] Fluid Pressure [MPa (kgf/cm2)]
98{10} 0.24{2.45}
294{30} 1.88{19.2}
(e) INSPECT BRAKE BOOSTER OPERATION

(1) Start the engine, have the negative pressure 66.7 kPa
(500 mm Hg) inside the brake booster, then check the
fluid pressure for each pedal force.
Standard:
For vehicles without VSC

49{0} 3.11{31.7}
98{10} 5.81{59.3}
147{15} 8.81{89.9}
196{20} 9.21{93.9}
With VSC
49{0} 3.23{32.9}
98{10} 5.98{61.0}
147{15} 9.02{92.0}
196{20} 9.43{96.2}
HINT:
If the brake booster assembly is defective, inspect the
check valve; if the check valve has no error, replace the
brake booster assembly.
(f) Remove the portable brake tester.
(g) Bleed air from the braking system. (See Page BR-5.)
3. INSPECT CHECK VALVE

(a) Slide the clip, and disconnect the vacuum hose.
(b) Check that there is air flow from the brake booster side to the
engine side, and no air flow from the engine side to the brake
booster side.
HINT:
If any defect is found, replace the vacuum check valve.
(c) Connect the vacuum hose with the clip.

Brake system (fluid leaks) -
Brake system (air mixing) BR-5
The pedal drops down; feels soft when depressed Piston seals (abrasion or damage) BR-25
Wheel cylinder cup (broken) (rear drum) BR-30
BR Master cylinder (defect) BR-15
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BRAKE – BRAKE SYSTEM
BR–4

Brake pedal freeplay (minimum) BR-12
Parking brake lever clearance (out of adjustment) -
Brake shoe clearance (out of adjustment) (rear drum) BR-32
Parking brake wire (sticking) -
Pad (cracked or deformed) (front disc) BR-25
Brake shoe (cracked or deformed) (rear drum) BR-32
Dragging of the brake Piston (sticking) (front disc) BR-25
Wheel cylinder piston (sticking) (rear drum) BR-30
Piston (stuck) (front disc) BR-25
Wheel cylinder piston (stuck) (rear drum) BR-30
Tension or return spring (defect) (rear drum) BR-30
Booster system air leaks BR-1
Master cylinder (defect) BR-15
Piston (sticking) (front disc) BR-25
Pad (oily) (front disc) BR-25
Brake shoe (oily) (rear drum) BR-32
Piston (stuck) (front disc) BR-25
Brake pulling to one side
Wheel cylinder piston (stuck) (rear drum) BR-30
Front disc (scratched) BR-25
Rear drum (scratched) BR-32
Brake system (fluid leaks) -
Brake system (air mixing) BR-5
Piston (sticking) (front disc) BR-25
The pedal is hard to depress, but the braking power is
Pad (oily) (front disc) BR-25
insufficient
Brake shoe (oily) (rear drum) BR-32
Pad (burned) (front disc) BR-25
Brake shoe (burned) (rear drum) BR-32
Booster system air leaks BR-1
Installation bolt (loose) (front disc) BR-27
Installation bolt (loose) (rear drum) BR-32
Pad support plate (loose) (front disc) BR-25
Abnormal braking noise
Sliding pin (worn) (front disc)
Pad (dirty) (front disc)
BR-24
BR-25
BR
Pad (burned) (front disc) BR-25
Lining (burned) (rear drum) BR-32
Tension or return spring (defect) (rear drum) BR-30
Anti-squeal shim (front disc) BR-25
Hold down spring (rear drum) BR-30
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BR–5 BRAKE – BRAKE FLUID
BRAKE FLUID
BRAKE
BLEED AIR
NOTICE:
• When a brake system is removed or installed, or when air in the
brake line is suspected, bleed air from the brake system.
• Do get brake fluid on painted surfaces. If brake fluid comes into
contact with any painted surfaces, wash the fluid off immediately.

SST O9023-00100
(a) Refill the brake fluid.
(1) Place the brake fluid container upside-down on the
reservoir.
NOTICE:
Check that there is sufficient brake fluid in the
container.
(b) Bleed air from the master cylinder.
HINT:
When a master cylinder is removed or installed, or when the
C138736 reservoir is empty, bleed air from the master cylinder.
(1) Using the SST, disconnect the 2 brake tubes from the
master cylinder.
(2) Slowly depress the brake pedal, and keep it down.
C138737
(3) Cover the tube holes with your finger, and release the
brake pedal.
(4) Then, remove your fingers, slowly step on the brake
pedal, and hold it in that position. Cover the tube holes
with your finger, and release the brake pedal. Repeat this
action 3 or 4 times.
(5) Using the SST, connect the 2 brake tubes to the master
cylinder.
C138738 (c) Bleed air from the brake system.
(1) Connect a vinyl tube to the bleeder plug.
(2) Depress the brake pedal several times, and while holding
the pedal down, loosen the bleeder plug.
(3) When the brake fluid stops coming out, temporarily
BR tighten the bleeder plug. Then release the brake pedal.
(4) Repeat this procedure until the air in the brake fluid is
completely bled out.
GETtheMANUALS.org
BRAKE – BRAKE FLUID
BR–6
(5) Tighten the bleeder plug.

Torque: 6.9 N*m (70.4 kgf*cm) (Front disk brake
bleeder plug)
8.0 N*m (81.5 kgf*cm) (Rear drum brake
bleeder plug)
(6) Repeat the above procedure for each wheel to bleed the
air from the brake lines.
NOTICE:
Bleed air from the brake lines of all wheels until air is
(d) Inspect a brake fluid level.
(1) Check the brake fluid level. If necessary, refill the brake
fluid up to the MAX line on the reservoir.
(e) Bleed air from the actuator.
NOTICE:
• After bleeding air from the brake system, if the correct
height or feel of the brake pedal cannot be obtained and
it is possible that there is air in the fluid, perform the
following procedure for bleeding out the air.
• Use the DS-II to bleed out the air. Bleeding out the air
without using the DS-II may cause injury or serious
accident.
(1) Turn the ignition switch off (LOCK) and depress the brake
pedal at least 20 times.
(2) With the ignition switch off (LOCK), connect the DS-II to
the DLC.
NOTICE:
(4) Turn the DS-II on and depress the brake pedal with a
force of 196 N (20 kgf) and hold it.
(5) With the brake pedal depressed, following the prompts on
the DS-II screen, select the secondary repair air active
test and activate the actuator.
HINT:
• To protect the actuator, the actuator's operation will
automatically stop in approximately 5 seconds.
• During this time, the brake pedal attempts to return to
the released position. Hold the brake pedal with a
force of 196 N (20 kgf).
(6) Release brake pedal
(7) Connect the vinyl tube to the bleeder plug at the front right
wheel.
(8) Depress brake pedal several times.
(9) With the brake pedal depressed, loosen the bleeder plug.
tighten the bleeder plug. Then release the brake pedal.
completely bled out. BR
bleeder plug)
(13) Bleed the air from the front left wheel using the same
procedures.
(f) Repeat steps (d) through (m) until air is completely bled out.
GETtheMANUALS.org
(g) Bleed the braking system for all of the wheels.
2. BLEED AIR FROM BRAKE SYSTEM (WITH VSC)

SST O9023-00100
(a) Refill the brake fluid.
(1) Place the brake fluid container upside-down on the
reservoir.
NOTICE:
Check that there is sufficient brake fluid in the
container.
(b) Bleed air from the master cylinder.
HINT:
When a master cylinder is removed or installed, or when the
C138736 reservoir is empty, bleed air from the master cylinder.
(1) Using the SST, disconnect the 2 brake tubes from the
master cylinder.
(2) Slowly depress the brake pedal, and keep it down.
C138737
(3) Cover the tube holes with your finger, and release the
brake pedal.
(4) Then, remove your fingers, slowly step on the brake
pedal, and hold it in that position. Cover the tube holes
with your finger, and release the brake pedal. Repeat this
action 3 or 4 times.
(5) Using the SST, connect the 2 brake tubes to the master
cylinder.
C138738 (c) Bleed air from the brake system.
(1) Connect a vinyl tube to the bleeder plug.
(2) Depress the brake pedal several times, and while holding
the pedal down, loosen the bleeder plug.
tighten the bleeder plug. Then release the brake pedal.
bleeder plug)
bleeder plug)
BR (6) Repeat the above procedure for each wheel to bleed the
air from the brake lines.
(d) Bleed air from the actuator.
NOTICE:
• After bleeding air from the brake system, if the correct
height or feel of the brake pedal cannot be obtained and
GETtheMANUALS.org
BRAKE – BRAKE FLUID
BR–8
it is possible that there is air in the fluid, perform the

following procedure for bleeding out the air.
• Use the DS-II to bleed out the air. Bleeding out the air
without using the DS-II may cause injury or serious
accident.
(e) Bleed air from the actuator intake system.
NOTICE:
• Bleed the air from the actuator intake system at the
front wheels of the vehicle.
(1) Turn the ignition switch off (LOCK) and depress the brake
pedal at least 20 times.
(2) With the ignition switch off (LOCK), connect the DS-II to
the DLC.
NOTICE:
(4) Loosen the bleeder plug of the front right wheel.
(5) Turn the DS-II on. Following the prompts on the DS-II
screen, select the secondary repair air active test and
activate the actuator.
HINT:
• To protect the actuator, the actuator's operation will
automatically stop in approximately 5 seconds.
• Release the brake pedal.
(6) On the DS-II screen, confirm that the operation is
stopped.
(7) With the bleeder plug loosened, repeat the above
procedure, from the start operation to the stop operation
of the actuator, until the air is completely bled out.
bleeder plug)
(9) Press RETURN on the DS-II.
(10) Perform the same procedure for the left front wheel.
(f) Bleed air from the actuator pressure reduction line.
NOTICE:
Bleed air from the actuator pressure reduction lines of all 4
wheels, one at a time.
(1) Loosen the bleeder plug of the front right wheel.
(2) Following the prompts on the DS-II screen, select the
tertiary repair air active test and active the actuator. At the
same time, depress and hold the brake pedal.
NOTICE:
• Although the pedal force of the brake pedal may
be heavy, try to step on so that the brake fluid
come out from the bleeder plug.
• Keep the brake pedal depressed. Do not pump the
brakes.
HINT: BR
To protect the solenoid, the actuator will automatically
stop after approximately 5 seconds. If it is necessary to
operate the actuator repeatedly, allow at least a 20
second interval between each operation.
GETtheMANUALS.org
(3) Tighten the bleeder plug, then release the brake pedal.
bleeder plug)
bleeder plug)
(4) Press RETURN on the DS-II.
(5) For the remaining three wheels, perform the same
procedure as that for the right front wheel.
(g) Bleed air from the actuator intake system and the actuator
pressure reduction line until air is completely bled out.
(h) Repeat the standard procedure for bleeding air from the brake
system by pumping the brakes.
NOTICE:
Bleed air from the brake lines of all wheels until air is
(i) Inspect a brake fluid level.
(1) Check the brake fluid level. If necessary, refill the brake
fluid up to the MAX line on the reservoir.
BR
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BRAKE – BRAKE PEDAL
BR–10
BRAKE PEDAL
BRAKE
COMPONENTS

INSTRUMENT PANEL UNDER COVER
BRAKE PEDAL SUPPORT
GUIDE
BRAKE MASTER CYLINDER BRAKE PEDAL
PUSH ROD PIN RETURN SPRING
T=24.5{250}
BRAKE PEDAL BUSH
CUSHION
PUSH ROD CLEVICE
A/T
CLIP
BRAKE PEDAL SHAFT

T=18.2{186}
SHIFT LOCK
BRAKE PEDAL BUSH
RELEASE CABLE
BRAKE PEDAL ASSEMBLY
BRAKE PEDAL PAD BR

C139230J07
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BR–11 BRAKE – BRAKE PEDAL
REMOVAL
IP-11)

IP-11)
3. REMOVE BRAKE PEDAL PAD
4. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS

(a) Loosen the lock nut of the push rod clevis.
(b) Remove the clip.
(c) Remove the push rod pin, and separate the push rod clevis
from the brake pedal.
5. REMOVE BRAKE PEDAL

(a) Remove the brake pedal shaft, then remove the brake pedal.
C135442
(b) Remove the return spring, cushion, and bush from the brake
Return Spring pedal.
Bush
INSTALLATION
Cushion
1. INSTALL BRAKE PEDAL
(a) Apply MP grease to the inner surface and outer surface of 2
brake pedal valve bushes and to the inside and both end
contact parts of the return spring.
(b) Install the return spring, bush, and cushion to the brake pedal.
C135443
(c) Using 2 brake pedal bushes, install the brake pedal with the
brake pedal shaft.
NOTICE:
When installing the brake pedal shaft, do not apply grease
to the thread part.
2. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS

(a) Coat the push rod pin and the installation part with MP grease.
(b) Using the push rod pin, connect the push rod clevis to the brake
pedal.
(c) Install the clip to the push rod pin.
HINT:
The lock nut of push rod clevis should be tightened when
adjusting the height of the brake pedal.
(d) Using needle nose pliers, install the return spring.
BR 3. INSTALL BRAKE PEDAL PAD
C135442 4. INSPECT AND ADJUST BRAKE PEDAL(See page BR-12)

18)
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BRAKE – BRAKE PEDAL
BR–12

IP-18)
ADJUSTMENT
IP-11)

IP-11)
3. INSPECT AND ADJUST BRAKE PEDAL
(a) Inspect a brake pedal height.
Standard:
165 mm (from the floor to the pad surface)
NOTICE:
Perform inspection with the floor carpet pulled up.
(b) Adjust the brake pedal height.
Push Rod Clevis Lock Nut (1) Loosen the installation bolt of the shift lock release cable.
(2) Remove the stop lamp switch by turning it
counterclockwise.
(3) Loosen the clevis lock nut, and turn the push rod to adjust
the brake pedal height.
Standard:
165 mm (from the floor to the pad surface)
Pedal Height
NOTICE:
C139150
(4) Tighten the clevis lock nut.
(5) Insert the stop lamp switch until it touches the brake
pedal.
NOTICE:
• Do not push the brake pedal when inserting the
stop lamp switch.
• Keep the brake pedal lifted up while performing
the operation.
(6) With the stop light switch fully pressed in, turn the switch
body in the clockwise direction, and lock it.
(7) Connect the connector to the stop light switch.
(8) Check the protrusion of the shaft.
Standard:
0.2-2.8 mm 0.2 to 2.8 mm
Stop Light Switch
(9) Check that the stop light does not illuminate when the
brake pedal is not depressed.
Shaft
Brake Pedal C139122
BR
GETtheMANUALS.org
BR–13 BRAKE – BRAKE PEDAL
(c) Inspect a brake pedal freeplay.

(1) After stopping the engine, depress the brake pedal
forcefully several times so that there is no negative
pressure in the brake booster.
(2) Using your finger, gently press the brake pedal to check
the brake pedal freeplay.
Standard:
Pedal Play 0.5 to 2.0 mm
F048932J01
(d) Inspect brake pedal reserve distance.

(1) Check the reserve distance of the brake pedal while
depressing it with a pedal force of 294 N (30 kgf).
Standard:
122 mm or more
NOTICE:
Pedal Distance
HINT:
When the brake pedal is depressed with no vacuum, there
C112611J01 may be sounds and resistance. However, this is due to
the structure of the brake booster and it does not cause
any problems.

IP-18)

18)
BR
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BRAKE – BRAKE MASTER CYLINDER ASSEMBLY
BR–14
BRAKE MASTER CYLINDER ASSEMBLY

BRAKE
COMPONENTS
M/T
BRAKE MASTER
CYLINDER ASSEMBLY
CLUTCH MASTER
SYLINDER TO FLEX-
IBLE HOSE TUBE
T=12.7{130}
T=15.2{155} BRAKE TUBE
T=15.2{155}
BRAKE TUBE

RESERVOIR GROMMET
BRAKE MASTER CYLINDER PISTON

ASSEMBLY NO. 1
BRAKE MASTER CYLINDER PISTON

ASSEMBLY NO. 2
MASTER CYLINDER BODY

BR
APPLY BRAKE GREASE APPLY BRAKE FLUID(DOT3)
C139228J11
GETtheMANUALS.org
BR–15 BRAKE – BRAKE MASTER CYLINDER ASSEMBLY
REMOVAL

HOSE TUBE (MANUAL TRANSMISSION)
(a) Remove the clip, and disconnect the clutch master cylinder to
flexible hose tube.
4. REMOVE BRAKE MASTER CYLINDER ASSEMBLY

SST O9023-00100
NOTICE:
Before removing the brake master cylinder assembly, depress
the brake pedal several times and release the vacuum from the
C137907
brake booster.
(a) Disconnect the brake fluid level warning switch connector.
NOTICE:
Make sure that no brake fluid adheres to the connector
part.
(b) Using the SST, disconnect the 2 brake tubes.
C136542
(c) Remove the 2 nuts, then remove the brake master cylinder
assembly.
DISASSEMBLY
C137906
1. REMOVE BRAKE MASTER CYLINDER RESERVOIR

(a) Using a pin punch and a hammer, punch out the spring pin and
remove the brake master cylinder reservoir.
2. REMOVE BRAKE MASTER CYLINDER KIT

(a) Remove the 2 master cylinder reservoir grommets.
BR
C142607
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BR–16
(b) Keeping the piston pushed in, remove the straight pin.
NOTICE:
Pin Use a rag or similar to prevent damage.
(c) Secure the master cylinder body in the vise between aluminum
plates.
C137835J01
(d) Push in the piston, and remove the snap ring using the snap
ring pliers.
(e) Remove the No. 1 piston sub-assembly by pulling it out in a
straight line from the master cylinder body.
NOTICE:
Snap Ring Pliers

C137838J02
(f) Tap the flange lightly with a wooden block until the end face of
the No. 2 piston comes out. Then remove the No. 2 piston by
pulling it out in a straight line from the master cylinder body.
NOTICE:
REASSEMBLY
1. INSTALL BRAKE MASTER CYLINDER KIT
Wooden Blocks (a) Apply brake fluid (DOT3) to a new No. 2 piston, No. 1 piston,
C137836
and each cylinder cap.
(b) Install the No. 2 piston sub-assembly to the master cylinder
body.
NOTICE:
To avoid damaging the inside of the cylinder, insert the
piston straight.
(c) Install the No. 2 piston sub-assembly to the master cylinder
body straight.
NOTICE:
• To avoid damaging the inside of the cylinder, insert the
piston straight.
• Do not damage the lip part of the cylinder cup.
(d) Keeping the piston pushed in, insert the straight pin from the
port of the reservoir attachment part.
Pin NOTICE:
Make sure that the straight pin and piston are securely
installed. BR
C137835J01
GETtheMANUALS.org
BR–17 BRAKE – BRAKE MASTER CYLINDER ASSEMBLY
(e) With the piston pushed in, install a new snap ring using the
snap ring pliers.
2. INSTALL BRAKE MASTER CYLINDER RESERVOIR

(a) Coat the inside of 2 new brake master cylinder reservoir
grommets with brake fluid (DOT3) and coat the outside with
brake grease. Then install the grommets on the master cylinder
body.
Snap Ring Pliers (b) Install the brake master cylinder reservoir to the master cylinder
body.
C137838J02
(c) Using a pin punch and a hammer, tap in a spring pin.
3. INSPECT BRAKE BOOSTER PUSH ROD

SST 09730-87401
C142607
(a) Install the O-ring into the groove of the rod of the gauge (SST).
O-Ring Then install the attachment (SST) as shown in the
illustration.Coat the surface of the attachment (SST) with brake
grease.
Attachment
C142608
(b) Install the adapter (SST) to the booster.

HINT:
Coat the surface of the adapter (SST) with grease for easier
Adapter installation of the attachment.
C142331
(c) Set the SST so that its rod lightly touches the piston of the
master cylinder.
BR
C142332
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BR–18
(d) Install the SST to the booster side. Using the MIGHTY VAC,
Attachment apply vacuum of approximately 66.7 kpa (500 mm Hg) to the
booster and check the clearance between the SST rod and the
booster push rod.
Standard:
Push Rod
Clearance 0 mm
Adapter
C142333
(e) If the clearance does not meet the specified value, use the SST
to secure the rod and adjust the length by turning the tip of the
rod using a socket driver (7 mm).
NOTICE:
After adjusting the rod, re-inspect the push rod clearance.
INSTALLATION
1. INSTALL BRAKE MASTER CYLINDER ASSEMBLY
SST O9023-00100
C100160
(a) Install the master cylinder with the 2 nuts.

C137906
(b) Using the SST, connect the 2 brake tubes to the master
cylinder.
(c) Connect the fluid level warning switch connector.
C136542

TUBE (MANUAL TRANSMISSION)
(a) Connect the clutch master cylinder to flexible hose tube using
the clip.

BR
4. BLEED AIR FROM BRAKE SYSTEM (WITHOUT VSC) (See page
BR-5)
5. BLEED AIR FROM BRAKE SYSTEM (WITH VSC)(See page BR-7)

C137907
GETtheMANUALS.org
BR–19 BRAKE – BRAKE BOOSTER ASSEMBLY

BRAKE
COMPONENTS
BR
C139175J03
GETtheMANUALS.org
BRAKE – BRAKE BOOSTER ASSEMBLY
BR–20
RHD ENGINE ROOM R/B LHD
WINDSHIELD WASHER
JAR ASSEMBLY
T=13.5{138}
T=24.5{250}

VACUUM HOSE PUSH ROD PIN
PUSH ROD CLEVICE
BRAKE MASTER CYLINDER CLIP

ASSEMBLY
T=13.5{138}
BRAKE BOOSTER GASKET
T=12.7{130}
M/T CLUTCH MASTER CYLINDER
T=15.2{155}
T=15.2{155}
APPLY MP GREASE C143678J01 BR

REMOVAL
GETtheMANUALS.org
BR–21 BRAKE – BRAKE BOOSTER ASSEMBLY
3. REMOVE ENGINE ROOM R/B (FOR RIGHT HAND DRIVE)

(a) Remove the bolt and slide the engine room R/B.
4. REMOVE WINDSHIELD WASHER JAR ASSEMBLY (FOR LEFT

HAND DRIVE) (See page WW-26)

HOSE TUBE (MANUAL TRANSMISSION) (See page BR-15)
6. REMOVE BRAKE MASTER CYLINDER ASSEMBLY(See page BR-

15)

IP-11)

IP-11)
9. REMOVE BRAKE BOOSTER ASSEMBLY

(a) Loosen the lock nut of the clevis master cylinder push rod.
(b) Remove the clip and push rod pin, and disconnect the push rod
clevis from the brake pedal.
(c) Remove the push rod clevis from the push rod.
(d) Remove the clip and disconnect the vacuum hose from the
brake booster assembly.
C135442
(e) Remove the 4 nuts and the brake booster assembly.
10. REMOVE BRAKE BOOSTER GASKET

(a) Remove the gasket from the brake booster assembly.
INSTALLATION
1. INSTALL BRAKE BOOSTER ASSEMBLY
(a) Install a new gasket to the brake booster assembly.
C136545
(b) Install the brake booster assembly with the 4 nuts.

(c) Connect the vacuum hose to the brake booster assembly using
the clip.
2. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS

(a) Install the push rod clevis to the push rod.
(b) Coat the push rod pin and the installation part with MP grease.
BR C136545
GETtheMANUALS.org
BRAKE – BRAKE BOOSTER ASSEMBLY
BR–22
(c) Using the push rod pin, connect the push rod clevis to the brake
pedal.
HINT:
The lock nut of the brake master cylinder push rod clevis should
be tightened when adjusting the height of the brake pedal.
(d) Install the clip to the push rod pin.
3. INSTALL BRAKE MASTER CYLINDER ASSEMBLY (See page BR-

18)
C135442 4. CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE

TUBE (MANUAL TRANSMISSION) (See page BR-18)
5. INSTALL ENGINE ROOM R/B (FOR RIGHT HAND DRIVE)

(a) Install the engine room R/B with the bolt.
6. INSTALL WINDSHIELD WASHER JAR ASSEMBLY (FOR LEFT

HAND DRIVE) (See page WW-27)
8. BLEED AIR FROM BRAKE SYSTEM (WITHOUT VSC)(See page

BR-5)
11. INSPECT AND ADJUST BRAKE PEDAL(See page BR-12)

IP-18)
18)
BR
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BR–23 BRAKE - FRONT DISC BRAKE
FRONT DISC BRAKE

BRAKE
COMPONENTS
FRONT BRAKE FLEXIBLE HOSE NO. 1 FRONT DISC BRAKE
UNION BOLT BLEEDER PLUG CAP

T=30.4{310}
FRONT DISC BRAKE
FRONT DISC BRAKE PAD
T=6.8{69} BLEEDER PLUG
SUPPORT PLATE NO. 1 GASKET
FRONT DISC BRAKE
FRONT DISC
CYLINDER PISTON SEAL
BRAKE PAD KIT
FRONT DISC BRAKE

FRONT DISC BRAKE
ANTI-SQUEAL SHIM KIT FRONT DISC
BRAKE PISTON
FRONT DISC BRAKE FRONT DISC BRAKE
ANTI-SQUEAL SHIM KIT CYLINDER BOOT
FRONT DISC BRAKE PAD FRONT DISC BRAKE CYLINDER SLIDE PIN
SUPPORT PLATE NO. 2 FRONT DISC BRAKE
BUSH DUST BOOT
T=83.4{850}
FRONT DISC BRAKE FRONT DISC BRAKE

CYLINDER SLIDE PIN CYLINDER MOUNTING LH
T=49{500}
FRONT DISC BRAKE

BUSH DUST BOOT
T=112.8{1150}
FRONT DISC
BR
TIGHTENING TORQUE [N*m{kgf*cm}] APPLY BRAKE GREASE
NON-REUSEABLE PART APPLY BRAKE FRUID(DOT3)
C140644J06
GETtheMANUALS.org
BRAKE - FRONT DISC BRAKE
BR–24
REMOVAL

3. DISCONNECT FRONT BRAKE FLEXIBLE HOSE NO. 1
(a) Remove the union bolt and gasket, and disconnect the flexible
hose from the disc brake cylinder.
C137908
4. REMOVE FRONT DISC BRAKE CYLINDER ASSEMBLY LH

(a) Remove the 2 slide pins, and remove the front disk brake
cylinder assembly LH.
5. REMOVE FRONT DISC BRAKE PAD

(a) Remove the brake pad from the disc brake cylinder mounting.
6. REMOVE FRONT DISK BRAKE ANTI-SQUEAL SHIM KIT

(a) Remove anti-squeal shim No. 1, No. 2, and No. 3 from the
brake pad.
C137909
7. REMOVE FRONT DISK BRAKE PAD SUPPORT PLATE NO. 1
(a) Remove brake pad support plate No. 1 from the disc brake
cylinder mounting.
8. REMOVE FRONT DISK BRAKE PAD SUPPORT PLATE NO. 2

(a) Remove brake pad support plate No. 2 from the disc brake
cylinder mounting.
9. REMOVE FRONT DISK BRAKE BUSH DUST BOOT
(a) Remove the dust boot from the disc brake cylinder mounting.
C137910
10. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH

(a) Remove the 2 bolts, and remove the disk brake cylinder
mounting.
BR
C137911
GETtheMANUALS.org

(a) Mark the alignment of the disc and axle hub, and remove the
disc.
DISASSEMBLY
Matchmarks
C137834
1. REMOVE FRONT DISC BRAKE CYLINDER BOOT

(a) Remove the cylinder boot from the disc brake cylinder.
C108933
2. REMOVE FRONT DISC BRAKE PISTON

A Shop Rag Or A Piece Of Cloth (a) Install a wood block between the pistons of the disc brake
cylinder in order to prevent the pistons from jumping out.
(b) Using the air gun, gradually apply air, and remove the disk
brake piston from the disk brake cylinder.
CAUTION:
Be careful not to pinch your fingers.
NOTICE:
Do not spatter fluid.
G031605J01
3. REMOVE FRONT DISC BRAKE CYLINDER PISTON SEAL

(a) Using a screwdriver, remove the piston seal.
NOTICE:
Do not damage the inside of the disk brake cylinder or the
attachment groove of the piston seal.
4. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP
5. REMOVE FRONT DISC BRAKE BLEEDER PLUG

INSPECTION
C108934
6. INSPECT DISC BRAKE PISTON AND CYLINDER
(a) Check that the side surface and inside surface of the disc brake
piston are not damaged.
7. INSPECT DISC BRAKE PAD THICKNESS
BR (a) Using vernier calipers, measure the thickness of the brake pad.
Maximum limit:
1.0 mm
Reference value:
10.0 mm (when new)
GETtheMANUALS.org
BR–26
8. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE NO. 1

(a) With the brake pad still installed on the disk brake cylinder
mounting, clean the contact surface of the brake pad using
brake cleaner or similar.
(b) With brake pad support plate No. 1 still installed, check for
looseness, deformation, cracks, rust, or any foreign matter that
is difficult to remove.
(c) When attaching a disk brake pad, check that brake pad support
plate No. 1 has spring force. After installation, check that the
disk brake pad cannot fall off easily.
9. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE NO. 2

(a) With the brake pad still installed on the disk brake cylinder
mounting, clean the contact surface of the brake pad using
brake cleaner or similar.
(b) With brake pad support plate No. 1 still installed, check for
looseness, deformation, cracks, rust, or any foreign matter that
is difficult to remove.
(c) When attaching the disc brake pad, check that brake pad
support plate No. 2 has spring force. After installation, check
that the disc brake pad cannot fall off easily.
10. INSPECT DISC THICKNESS

(a) Using a micrometer, measure disc thickness.
Maximum limit:
15.0 mm (SOLID)
21.0mm (VENTI)
Reference value:
16.0 mm (SOLID, when new)
22.0 mm (VENTI, when new)
11. INSPECT DISC RUNOUT

(a) Check that the front wheel bearings do not rattle.
(b) Using a dial gauge, inspect the runout at 10 mm inside the outer
edge of the disc.
Maximum runout:
0.10 mm
NOTICE:
If the disk run exceeds the specified range, check for axle
hub run. If no abnormalities are found in the axle hub,
replace the disc.
C137846 REASSEMBLY
1. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
2. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
3. INSTALL FRONT DISC BRAKE CYLINDER PISTON SEAL

(a) Apply brake grease to the entire circumference of the new
piston seal, and securely install it to the groove of the disc brake
cylinder. BR
4. INSTALL FRONT DISC BRAKE PISTON
(a) Apply brake grease to a new cylinder boot.
GETtheMANUALS.org
(b) Install the cylinder boot to the disc brake piston.

NOTICE:
Install the cylinder boot to the groove of the disc brake
piston.
(c) Apply a thin layer of brake fluid (DOT3) to the outer edge of the
disc brake piston, and attach the disc brake piston to the disc
brake cylinder.
NOTICE:
Do not force the disk brake piston.
5. INSTALL FRONT DISC BRAKE CYLINDER BOOT

(a) Install the cylinder boot to the disc brake cylinder.
NOTICE:
Securely install the cylinder boot to the groove of the disc
brake cylinder.
APPLY BRAKE GREASE INSTALLATION

APPLY BRAKE FLUID(DOT3)
C143617

(a) Using the matchmarks, align the disc with the axle hub, and
install the disc.
NOTICE:
When replacing the disc with a new one, install the new
disc in the position with the least run.
Matchmarks
C137834
7. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH

(a) Install the disc brake cylinder mounting to the steering knuckle
with the 2 bolts.
C137911
8. INSTALL FRONT DISC BRAKE BUSH DUST BOOT

(a) Apply brake grease to the inside of a new dust boot.
(b) Install the dust boot to the disc brake cylinder mounting.
9. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE NO. 2

BR (a) Install brake pad support plate No. 2 to the disc brake cylinder
mounting.
10. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE NO. 1

(a) Install brake pad support plate No. 1 to the disc brake cylinder
C137910 mounting.
GETtheMANUALS.org
BR–28
11. INSTALL FRONT DISK ANTI-SQUEAL SHIM KIT

(a) Install the front disc anti-squeal shim kit to the brake pad.
12. INSTALL FRONT DISC BRAKE PAD KIT

(a) Install the brake pad to the disc brake cylinder mounting.
13. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN

(a) Install cylinder disk brake LH.
(b) Apply brake grease to the contact surface of the new front disc
brake bush dust boot and the front disc brake cylinder slide pin.
(c) Apply brake grease to the sliding surfaces of the front disc
brake cylinder slide pin.
(d) Install the front disc brake cylinder slide pin to the front disc
brake cylinder assembly LH.
(A)
(B)
C137909J01
14. CONNECT FRONT BRAKE FLEXIBLE HOSE NO. 1

(a) Placing a new gasket in between the parts, connect the flexible
hose to the disc brake cylinder using the union bolt.
NOTICE:
When connecting the flexible hose, check that the hose is
not twisted or bent, and make sure that the hose does not
interfere with other parts.
15. BLEED AIR FROM BRAKE SYSTEM (WITHOUT VSC)(See page

C137908
BR-5)

BR
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BR–29 BRAKE - REAR DRUM BRAKE
REAR DRUM BRAKE

BRAKE
COMPONENTS
WHEEL CYLINDER BOOT

REAR WHEEL CYLINDER
COMPRESSION SPRING
WHEEL CYLINDER PISTON
WHEEL
CYLINDER BOOT
WHEEL CYLINDER
T=15.2{155} CUP
WHEEL CYLINDER PISTON

T=9.5{97}
BRAKE TUBE REAR WHEEL BRAKE CYLINDER ASSEMBLY

BLEEDER PLUG CAP
REAR BRAKE SHOE KIT
BLEEDER PLUG
REAR BRAKE T=8.0{82} PARKING BRAKE SHOE
HOLE PLUG LEVER LH
×2
C WASHER
CLIP
REAR BRAKE SHOE
HOLD DOWN SPRING PIN
REAR BRAKE
STRUT KIT
REAR BRAKE SHOE REAR BRAKE
HOLD DOWN SPRING AUTOMATIC
ADJUST LEVER LH
REAR BRAKE SHOE KIT
REAR BRAKE SHOE HOLD REAR BRAKE AUTOMATIC

DOWN SPRING CUP ADJUST LEVER
REAR BRAKE SHOE TORSION SPRING
RETURN SPRING
BR REAR BRAKE DRUM
…… TIGHTENING TORQUE [N*m{kgf*cm}]

APPLY BRAKE GREASE NON-REUSEABLE PART
C140727J09
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BRAKE - REAR DRUM BRAKE
BR–30
DISASSEMBLY
1. REMOVE REAR TIRE

3. REMOVE REAR BRAKE DRUM
(a) Release the parking brake and remove the brake drum.
HINT:
Adjuster If the brake drum can not be removed easily, remove the hole
plug, push up the automatic adjust lever from the service hole of
the backing plate using a screwdriver. Then, use another
Retract screwdriver to turn the adjuster and retract it.
4. REMOVE REAR BRAKE SHOE KIT

Automatic Adjuster Lever SST 09703-30011
C102597J01
(a) Using the SST, disconnect the tension spring from the brake
shoe strut (front side).
NOTICE:
Do not damage the wheel cylinder boot.
(b) Remove the rear brake shoe hold down spring cup, the rear
brake shoe hold down spring, and the rear brake shoe hold
down spring pin. Then remove the brake shoe (front side).
(c) Remove the rear brake shoe return spring.
C136078
(d) Remove the tension spring from the brake shoe (rear). Then
remove the rear brake strut kit.
(e) Remove the rear brake shoe hold down spring cup, the rear
brake shoe hold down spring, and the rear brake shoe hold
down spring pin. Then remove the brake shoe (rear side).
C137755
(f) Using needle nose pliers, disconnect the parking brake cable.
C136074
BR
GETtheMANUALS.org
5. REMOVE REAR BRAKE AUTOMATIC ADJUST LEVER LH

(a) Remove the automatic adjust lever torsion spring and the clip.
Then remove the rear brake automatic adjust lever.
6. REMOVE PARKING BRAKE SHOE LEVER LH

(a) Using a screwdriver, remove the C-washer and the parking
brake shoe lever.
7. REMOVE REAR WHEEL BRAKE CYLINDER ASSEMBLY

SST O9023-00100
C136885 HINT:
Disassembly and inspection of the rear wheel cylinder can be
performed with the parking plate still installed. Therefore, do not
remove the parking plate, except when replacing the rear wheel
cylinder or similar
(a) Using the SST, disconnect the brake tube from the wheel
cylinder.
C136883
(b) Remove the bleeder plug cap.

(c) Remove the rear drum brake bleeder plug.
(d) Remove the 2 bolts, then remove the rear wheel cylinder.
C136884J05
8. REMOVE REAR WHEEL BRAKE CYLINDER CUP KIT

(a) Remove the 2 wheel cylinder boots from the wheel cylinder
piston.
(b) Remove the 2 wheel cylinder pistons.
(c) Remove the wheel cylinder cups from each wheel cylinder
piston.
(d) Remove the rear wheel cylinder compression spring.
C057785J01
BR
GETtheMANUALS.org
BR–32
INSPECTION
1. INSPECT BRAKE DRUM INSIDE DIAMETER
(a) Using a vernier caliper, measure the inside diameter of the
drum.
Maximum diameter:
229.6 mm
Reference value:
228.6 mm (when new)
2. INSPECT REAR DRUM BRAKE SHOE LINING THICKNESS

(a) Using vernier calipers, measure the thickness of the shoe lining.
C093250J01
Maximum thickness:
1.0 mm
Reference value:
5.0 mm (when new)
NOTICE:
Replacement of the brake shoe lining should not be
performed for only a single side of the vehicle. (To prevent
the vehicle from pulling to one side)
3. INSPECT BRAKE DRUM AND LINING CONTACT
(a) Apply chalk to the inside of the brake drum, and move the lining
back and forth across the chalked surface inside the drum.
Standard:
No significant contact problems
(b) If the contact is not good, shape the brake shoe lining to
improve fit.
NOTICE:
After completing the inspection, wipe off the chalk.
R001564J01
4. CHECK REAR WHEEL BRAKE CYLINDER ASSEMBLY
(a) Check that the inside surface of the wheel cylinder body is not
damaged.
HINT:
If there is any damage on the inside surface of the wheel
cylinder body, replace it with a new front disk brake cylinder
assembly LH.
REASSEMBLY
1. INSTALL REAR WHEEL CYLINDER CUP KIT
(a) Apply brake grease to 2 new wheel cylinder cups and install the
cup to each of the 2 wheel cylinder pistons.
(b) Apply brake grease to 2 new wheel cylinder pistons.
(c) Install the rear wheel cylinder compression spring and the 2
wheel cylinder pistons to the wheel cylinder body.
(d) Install 2 new wheel cylinder boots to the wheel cylinder body.
2. INSTALL REAR WHEEL BRAKE CYLINDER ASSEMBLY

‫ޓޓ‬㨯㨯㨯㨯㨯 APPLY BRAKE GREASEC057785J08 SST O9023-00100 BR
GETtheMANUALS.org
(a) Install the rear wheel cylinder with the bolt.

(b) Temporarily install the rear drum brake bleeder plug.
(c) Install the bleeder plug cap.
C136884J06
(d) Using the SST, connect the brake tubes to the wheel cylinder.
C136883
3. INSTALL PARKING BRAKE SHOE LEVER LH

(a) Using new C-washer, install the parking brake shoe lever to the
brake shoe (rear side).
C062256J01
4. INSTALL REAR BRAKE AUTOMATIC ADJUST LEVER LH

(a) Install the automatic adjust lever and torsion spring to the brake
shoe (front side).
5. INSTALL REAR BRAKE SHOE KIT

SST 09703-30011
(a) Apply brake grease to a part of the packing plate where the
shoe contacts.
C136885
(b) Using needle-nose pliers, install the parking brake cable to the
parking brake shoe lever.
(c) Install the brake shoe (rear side) with the rear brake shoe hold
down spring cup, the rear brake shoe hold down spring, and the
BR rear brake shoe hold down spring pin.
C136074
GETtheMANUALS.org
BR–34
(d) Hook the tension spring to the brake shoe (rear side), and
install the rear brake strut kit.
(e) Install the rear brake shoe return spring from the back side of
the brake shoe.
(f) Install the brake shoe (front side) with the rear brake shoe hold
down spring cup, the rear brake shoe hold down spring, and the
rear brake shoe hold down spring pin.
C137755
(g) Using the SST, install the tension spring to the brake shoe
(front).
NOTICE:
Do not damage the wheel cylinder boot.
6. INSPECT REAR DRUM BRAKE INSTALLATION

(a) Check that each part is properly installed.
NOTICE:
• Check that the wheel cylinder boot is not damaged, and
that there is no oil or grease on the part.
C136078
• Check that there is no oil or water on the surface of the
shoe lining.

8. ADJUST CLEARANCE BETWEEN BRAKE DRUM AND LINING
(a) Using a screwdriver through the service hole, extend the
adjuster by turning it. Extend the adjuster until the brake shoe
Adjuster comes into contact with the drum.
Expand
C102598J01
(b) Using another screwdriver, lift up the automatic adjust lever.

Then turn the adjuster until the drum rotates slightly.
(c) Install the hole plug.
Adjuster
Retract
Automatic Adjuster Lever

C102597J01
BR
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TO INDEX
BRAKE
PARKING BRAKE
PARKING BRAKE SYSTEM
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-1
PARKING BRAKE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-2
PARKING BRAKE CABLE ASSEMBLY NO. 2
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-6
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-11
PARKING BRAKE LEVER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-16
PB
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PB–1 PARKING BRAKE - PARKING BRAKE SYSTEM
PARKING BRAKE SYSTEM

PARKING BRAKE
BRAKE

Parking brake lever clearance (out of adjustment) -
Parking brake wire (sticking) -
Dragging of the brake Brake shoe clearance (out of adjustment) -
Brake shoe (cracked or deformed) -
Tension spring (defect) -
PB
GETtheMANUALS.org
PARKING BRAKE - PARKING BRAKE
PB–2
PARKING BRAKE
PARKING BRAKE
BRAKE
ADJUSTMENT
1. REMOVE REAR TIRE

(See page BR-34)

4. INSPECT PARKING BRAKE LEVER CLEARANCE

(a) Pull the parking brake lever hard once.
(b) Release the parking brake lever.
(c) Pull the parking brake lever slowly, and count the noises.
Standard:
4 to 7 notches [Control force 196 N (20 kgf)]
5. ADJUST PARKING BRAKE LEVER CLEARANCE

(a) Remove the console box hole cover.
(b) Turn and adjust the adjusting nut to obtain the standard
clearance value.
Standard:
4 to 7 notches [Control force 196 N (20 kgf)]
(c) Operate the parking brake lever 3 to 4 times, then check the
clearance.
(d) Check whether or not the parking brake is dragging.
(e) When operating the parking brake lever, check if the brake
warning light is lit.
C136908 Standard:
When pulling up the parking brake, check that the light is
lit when the parking brake is moved to the first notch.
PB
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PB–3 PARKING BRAKE - PARKING BRAKE CABLE ASSEMBLY NO. 2

PARKING BRAKE
BRAKE
COMPONENTS
SHIFT LEVER KNOB
C139231J03
PB
GETtheMANUALS.org
PARKING BRAKE - PARKING BRAKE CABLE ASSEMBLY NO. 2
PB–4
×2
T=8.0{82}
T=7.4{76}
T=7.4{76}
T=7.4{76}
T=7.4{76}
T=7.4{76} T=7.4{76}
×2
T=7.4{76}
×2
T=7.4{76}
T=8.0{82}

C143345J01
REMOVAL
1. REMOVE REAR TIRE
4. REMOVE SHIFT LEVER KNOB (MANUAL TRANSMISSION)

6. REMOVE PARKING BRAKE WIRE ADJUSTING NUT NO. 1
(a) Loosen the lock nut and the adjusting nut of the parking brake
cable assembly No. 1.
(b) Disconnect the cable end from the equalizer.
PB
C136908
GETtheMANUALS.org
7. REMOVE PARKING BRAKE CABLE ASSEMBLY NO. 2

(a) Remove the 2 bolts and disconnect the parking brake cable
from the backing plate.
C143306
(b) Remove 2 bolts and separate the 2 parking brake cable clamps
from the rear suspension control arm.
(c) Remove the bolt, and then remove each cable bracket of the
parking brake cable assembly No. 2 from the body.
C143307
PARKING BRAKE CABLE

ASSEMBLY NO. 2
C135698J01
PB
GETtheMANUALS.org
PB–6
INSTALLATION
1. INSTALL PARKING BRAKE CABLE ASSEMBLY NO. 2
(a) Install the parking brake cable assembly No. 2 to the backing
plate with the 2 bolts.
C143306
(b) Install the 2 cable clamps to the rear suspension control arm
with the 2 bolts.
(c) Install each cable bracket of the parking brake cable assembly
No. 2 to the body with the bolt.
NOTICE:
The clamps must be securely installed.
C143307
PARKING BRAKE CABLE

ASSEMBLY NO. 2
C135698J01
PB
(d) Connect the cable end to the equalizer.
3. INSPECT REAR DRUM BRAKE INSTALLATION (See page BR-34)
GETtheMANUALS.org

(See page BR-34)

7. INSPECT PARKING BRAKE CLEARANCE (See page PB-2)
8. ADJUST PARKING BRAKE CLEARANCE (See page PB-2)
9. INSTALL CONSOLE BOX ASSEMBLY RR (See page IP-20)
10. INSTALL SHIFT LEVER KNOB (MANUAL TRANSAXLE)
PB
GETtheMANUALS.org
PB–8

PARKING BRAKE
BRAKE
COMPONENTS
SHIFT LEVER KNOB
C139231J03
PB
GETtheMANUALS.org
×2
T=8.0{82}
T=7.4{76}
T=7.4{76}
T=7.4{76}
T=7.4{76}
T=7.4{76} T=7.4{76}
×2
T=7.4{76}
×2
T=7.4{76}
PARKING BRAKE CABLE ASSEMBLY NO. 3 T=8.0{82}

C143345J03
REMOVAL
1. REMOVE REAR TIRE

6. REMOVE PARKING BRAKE WIRE ADJUSTING NUT NO. 1
(a) Loosen the lock nut and the adjusting nut of the parking brake
cable assembly No. 1.
(b) Disconnect the cable end from the equalizer.
PB
C136908
GETtheMANUALS.org
PB–10
7. REMOVE PARKING BRAKE CABLE ASSEMBLY NO. 3

(a) Remove the 2 bolts and disconnect the parking brake cable
assembly No. 1 from the backing plate.
C135474
(b) Remove the 2 bolts and separate the 2 parking brake cable
clamps from the rear suspension control arm.
(c) Remove the bolt, and then remove each cable bracket of
parking brake cable assembly No. 3 from the body.
C137682
PARKING BRAKE CABLE

ASSEMBLY NO. 3
C135698J02
PB
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INSTALLATION
(a) Install the parking brake cable assembly No. 3 to the backing
plate with the 2 bolts.
C135474
(b) Install the 2 cable clamps to the rear suspension control arm
with the 2 bolts.
(c) Install each cable bracket of parking brake cable assembly No.
3 to the body with the bolt.
NOTICE:
The clamps must be securely installed.
C137682
PARKING BRAKE CABLE

ASSEMBLY NO. 3
PB C135698J02
(d) Connect the cable end to the equalizer.
3. INSPECT REAR DRUM BRAKE INSTALLATION (See page BR-34)
GETtheMANUALS.org
PB–12

(See page BR-34)

7. INSPECT PARKING BRAKE CLEARANCE (See page PB-2)
8. ADJUST PARKING BRAKE CLEARANCE (See page PB-2)
10. INSTALL SHIFT LEVER KNOB (MANUAL TRANSAXLE)
PB
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PB–13 PARKING BRAKE - PARKING BRAKE LEVER
PARKING BRAKE LEVER

PARKING BRAKE
BRAKE
COMPONENTS
SHIFT LEVER KNOB
C139231J01
PB
GETtheMANUALS.org
PARKING BRAKE - PARKING BRAKE LEVER
PB–14
T=18.2{186}
PARKING BRAKE LEVER PARKING BRAKE CABLE

ASSEMBLY NO.2
EQUALIZER
PARKING BRAKE CABLE

ASSEMBLY NO.3
PARKING BRAKE WIRE

ADJUSTING NUT NO. 1
BRAKE WARNING TEST SWITCH ASSEMBLY

C139227J04
REMOVAL
2. REMOVE SHIFT LEVER KNOB (MANUAL TRANSAXLE)

(a) Loosen the parking brake wire adjusting nut No. 1.
C136908
PB
GETtheMANUALS.org
(b) Separate the parking brake cable assembly No. 2 from the
equalizer part of the parking brake cable assembly No. 1.
No.2
C143311J01

(a) Separate the parking brake cable assembly No. 3 from the
No.3
C143312J01
6. REMOVE PARKING BRAKE LEVER

(a) Disconnect the connector from the brake warning test switch
assembly.
C143313
(b) Remove the 2 bolts, then remove the parking brake lever.
C136907
7. REMOVE BRAKE WARNING TEST SWITCH ASSEMBLY

(a) Remove the screw, and then remove the brake warning test
switch assembly.
PB
C143314
GETtheMANUALS.org
PARKING BRAKE - PARKING BRAKE LEVER
PB–16
INSTALLATION
1. INSTALL BRAKE WARNING TEST SWITCH ASSEMBLY
(a) Install the brake warning test switch assembly with the screw.
C143314
2. INSTALL PARKING BRAKE LEVER

(a) Install the parking brake lever with the 2 bolts.
C136907
(b) Connect the connector to the brake warning test switch

assembly.
C143313

(a) Connect the parking brake cable assembly No. 3 to the
No.3
C143317J01
PB
GETtheMANUALS.org

(a) Connect the parking brake cable assembly No. 2 to the
No.2
C143318J01
(b) Install the parking brake wire adjusting nut No. 1.
5. CHECK PARKING BRAKE CABLE ASSEMBLY NO. 2
6. ADJUST PARKING BRAKE LEVER CLEARANCE (See page PB-2)
C136908
PB
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TO INDEX
STEERING
STEERING COLUMN
STEERING SYSTEM
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SR-1
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SR-1
STEERING COLUMN ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. . SR-2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. . SR-4
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. . SR-6
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. . SR-7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. . SR-7
SR
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SR–1 STEERING COLUMN - STEERING SYSTEM
STEERING SYSTEM
STEERING COLUMN
OPERATION CHECK
1. INSPECT STEERING COLUMN NOISE
(b) With the ignition switch OFF, move the steering wheel to the
right and left, and inspect for noise.

STEERING MECHANISM HYDRAULIC PS
Front tires (improperly inflated, unevenly worn) TW-2
Front wheel alignment (incorrect) SP-4
Front suspension (lower ball joint) -
Power steering motor fluid level (low) PS-3
Steering is heavy V-ribbed belt (slack) -
Steering intermediate shaft -
Steering column assembly SR-4
Power steering vane pump PS-7
Power steering link assembly PS-23
Poor steering wheel return
Freeplay: none or excessive
Power steering link assembly -
Abnormal noise or vibration in steering Steering intermediate shaft -
wheel Steering column assembly SR-4
SR
GETtheMANUALS.org
STEERING COLUMN - STEERING COLUMN ASSEMBLY
SR–2

STEERING COLUMN
COMPONENTS

HORN BUTTON ASSEMBLY
STEERING WHEEL ASSEMBLY
T=34.3{350}
T=7.4{75}
HEADLIGHT DIMMER SWITCH
ASSEMBLY
T=7.4{75}
SHIFT LOCK RELEASE CABLE ASSEMBLY SPIRAL CABLE WITH

STEERING SENSOR
STEERING COLUMN
WINDSHIELD WIPER SWITCH ASSEMBLY
ASSEMBLY
T=23{235}
T=23{235}
T=29.4{300}
STEERING INTERMEDIATE ASSEMBLY


C142072J01
SR
GETtheMANUALS.org
SR–3 STEERING COLUMN - STEERING COLUMN ASSEMBLY
STEERING LOCK SET BOLT
STEERING COLUMN UPPER WITH SWITCH

BRACKET ASSEMBLY
IGNITION SWITCH LOCK

CYLINDER ASSEMBLY IGNITION (STARTER) SWITCH ASSEMBLY
UNLOCK WARNING SWITCH ASSEMBLY
SR NON-REUSEABLE PART
C142073J01
GETtheMANUALS.org
SR–4
C136487J01
REMOVAL
4. REMOVE HORN BUTTON ASSEMBLY
5. REMOVE STEERING WHEEL ASSEMBLY

(a) Remove the nut and put matchmarks on the steering wheel
assembly and the steering main shaft.
(b) Remove the steering wheel assembly.
Matchmarks
C136239J01
SR
GETtheMANUALS.org
6. REMOVE STEERING COLUMN COVER

(a) Remove the 3 screws and detach the 5 claws to remove the
steering column cover (lower).
: Claw C133192J04
(b) Remove the 2 steering column assembly bolts to disconnect the

steering column.
(c) Do not release the tilt lever until the installation is com-
pleted.(Because it may malfunction.)
Return Spring
(d) Remove the steering column cover (upper) from the steering
column assembly.
7. REMOVE SPIRAL CABLE WITH STEERING SENSOR (See page

RS-177)
C142074 8. REMOVE HEADLIGHT DIMMER SWITCH ASSEMBLY
9. REMOVE WINDSHIELD WIPER SWITCH ASSEMBLY
10. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER
11. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER
13. REMOVE STEERING COLUMN ASSEMBLY

(a) Disconnect the connectors and wire harness clamps from the
steering column assembly.
(b) Put matchmarks on the steering intermediate shaft assembly
and the steering column assembly.
(c) Remove bolt A.
Matchmarks
Bolt A
C136414J01
SR
GETtheMANUALS.org
SR–6
(d) Remove the 2 nuts to remove the steering column assembly.

DISASSEMBLY
14. REMOVE STEERING COLUMN UPPER WITH SWITCH BRACKET
ASSEMBLY
(a) Using a drill, drill a hole in the 2 steering lock set bolts to allow
for a screw extractor.
C142075
(b) Remove the steering lock set bolts using screw extractors and
then remove the steering column upper with switch bracket
assembly.
15. REMOVE UNLOCK WARNING SWITCH ASSEMBLY

(a) Disconnect the unlock warning switch assembly connector from
the ignition (starter) switch assembly.
C136419
(b) Disengage the 3 claws to remove the unlock warning switch

Claws
assembly.
16. REMOVE IGNITION SWITCH LOCK CYLINDER ASSEMBLY

(a) Place the ignition switch lock cylinder assembly in the ACC
position.
C136423
(b) Press down on the location shown in the illustration using a thin
flat-head screwdriver and pull out the ignition switch lock cylin-
der assembly.
17. REMOVE IGNITION (STARTER) SWITCH ASSEMBLY

(a) Remove the 2 screws and then the ignition (starter) switch
assembly from the steering column bracket assembly upper.
SR
C136424
GETtheMANUALS.org
REASSEMBLY
1. INSTALL IGNITION (STARTER) SWITCH ASSEMBLY
(a) Install the ignition (starter) switch assembly using 2 screws.
2. INSTALL IGNITION SWITCH CYLINDER ASSEMBLY

(a) Place the ignition switch lock cylinder assembly in the ACC
position.
(b) Insert the ignition switch lock cylinder assembly.
(c) Make sure that the ignition switch lock cylinder assembly is
securely fixed in place.
3. INSTALL UNLOCK WARNING SWITCH ASSEMBLY

(a) Engage the 3 claws and install the unlock warning switch
assembly.
(b) Connect the unlock warning switch assembly connector to the
ignition (starter) switch assembly.
4. INSTALL STEERING COLUMN UPPER WITH SWITCH BRACKET
ASSEMBLY
(a) Install the steering column clamp upper and steering column
upper with switch bracket assembly using new steering lock set
bolts and fully tighten down the bolts.
INSTALLATION
C136425
5. INSTALL STEERING COLUMN ASSEMBLY

(a) Align matchmarks and connect the steering column assembly to
the steering intermediate shaft assembly.
Matchmarks
Bolt A
C136414J01
SR
GETtheMANUALS.org
SR–8
(b) Install the steering column assembly with the 2 nuts.

(c) Install the steering column assembly and steering intermediate
shaft assembly using a new bolt (A).
(d) Connect the connectors and clamp the wire harness to the
steering column assembly bracket.
6. INSTALL SHIFT LOCK RELEASE CABLE ASSEMBLY
9. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY
10. INSTALL HEADLIGHT DIMMER SWITCH ASSEMBLY
11. INSTALL SPIRAL CABLE WITH STEERING SENSOR (See page

RS-178)
C142075
12. INSTALL STEERING COLUMN COVER

(a) Install the steering column cover (upper) to the steering column
assembly.
: Claw C133192J04
(b) Install the steering column assembly using 2 bolts.

(c) With the tilt lever released, make sure that the steering column
assembly moves smoothly.
Return Spring
HINT:
If the steering column assembly has been removed with the tilt
lever released, install the steering column assembly with the
holding spring removed, and then install the holding spring.
(d) Attach the 5 claws and install the steering column cover (lower).
C142074J01 (e) Install the steering column cover using the 3 screws.
13. INSTALL STEERING WHEEL ASSEMBLY

(a) Align the matchmarks and install the steering wheel assembly
to the steering column assembly.
(b) Install the nut.
Matchmarks
14. INSTALL HORN BUTTON ASSEMBLY

SR
16. CHECK AIRBAG WARNING LIGHT
C136239J01
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TO INDEX
STEERING
POWER STEERING
POWER STEERING SYSTEM
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PS-1
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PS-1
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PS-4
VANE PUMP ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PS-6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PS-7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PS-7
POWER STEERING LINK ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PS-9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PS-11
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PS-12
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PS-16
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PS-16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PS-25
PS
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PS–1 POWER STEERING - POWER STEERING SYSTEM
POWER STEERING SYSTEM

POWER STEERING
STEERING
PRECAUTIONS
1. HANDLING AND OPERATING PRECAUTIONS FOR SRS AIRBAG
SYSTEM
NOTICE:
Some service operations affect the SRS airbag. Be sure to read
the precautionary notice for the SRS airbags before servicing.
(See page RS-164)
OPERATION CHECK
1. CHECK STEERING MOUNT TORQUE
NOTICE:
Some service operations affect the SRS airbag. Be sure to read
the precautionary notice for the SRS airbags before servicing.
(a) Stop the vehicle on a level, paved road and align the front
wheels straight ahead.
(b) Check the handling and operating precautions for the SRS air-
bag system.
(c) Disconnect the negative battery terminal.
(d) Remove the horn button assembly.
(e) Using a torque wrench, check that there is no slack in the steer-
ing wheel set nut.
(f) Connect the negative battery terminal.
(g) Start the engine and idle it.
(h) Turn the steering wheel 90 degrees to the right and measure
steering torque while turning. Check in the opposite direction in
the same manner.
Reference value:
Torque = 5.5 N*m (55 kgf*cm) or less (oil temperature:
80°C)
(i) Align the front wheels straight ahead.
(j) Disconnect the negative battery terminal.
(k) Install the horn button assembly.
(l) Connect the negative battery terminal.
(m) Check the airbag warning light. (See page RS-1)

(a) Remove No.1 engine under cover.
(b) Disconnect pressure feed tube assembly. (See page PS-7)
PS
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POWER STEERING - POWER STEERING SYSTEM
PS–2
(c) Install pressure gauge.
Valve Fully Open
Oil Resevoir Vane Pump
Power Valve Fully Open

Steering Gear
Gauge
IN Side
Gauge OUT Side
C133720J01
(1) Using the attachment, install the pressure gauge IN side

to the vane pump assembly pressure port.
NOTICE:
Install the pressure gauge OUT side with the pressure
gauge valve fully opened.
(2) Using the attachment and a new gasket, install the pres-
sure gauge OUT side to the pressure feed tube assembly
(vane pump side).
NOTICE:
Install the pressure gauge OUT side with the pressure
gauge valve fully opened.
(d) Bleed power steering fluid air.
(e) Set oil temperature for oil pressure check.
(2) With the engine running at 1,000 r/min or less, move the
steering wheel from full lock on one side to full lock on the
other side to raise the temperature of the fluid.
Standard:
50°C
(f) Inspect vane pump generated oil pressure.
(1) With the engine idling, fully close the pressure gauge
Oil valve and measure the oil pressure.
Resevoir
Standard:
Power 7.4 to 7.9 MPa (75 to 80 kgf/cm2)
Steering NOTICE:
Gear
• Do not close the pressure gauge valve for more
Vane than 10 seconds.
Pump
• The fluid temperature must not exceed 85°C.
C055439
PS
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(g) Check oil temperature without load.

(1) Fully open the pressure gauge valve.
Oil (2) Measure the oil pressure with the engine idling at both
Resevoir
1,000 r/min and 3,000 r/min and check the difference in oil
Power pressure. If the difference is out of the specified range,
Steering replace the vane pump assembly with a new one.
Gear
Standard:
Vane Within 0.5 MPa (5 kgf/cm2)
Pump
NOTICE:
C055440 Do not operate the steering wheel.
(h) Check steering gear housing generated oil pressure.

(1) Fully open the pressure gauge valve.
Oil
(2) With the engine idling, turn the steering wheel fully left
Resevoir
and right and measure oil pressure.
Power Standard:
Steering
Gear 7.4 to 7.9 MPa (75 to 80 kgf/cm2)
NOTICE:
Vane
Do not hold the steering wheel in the fully turned
Pump
position for more than 10 seconds.
C055441 (i) Remove pressure gauge and attachment
(j) Connect pressure feed tube assembly. (See page PS-8)
(k) Bleed power steering fluid leakage.
(l) Check for powersteering fluid leakage.
(m) Install No.1 engine under cover.
3. CHECK STEERING WHEEL FREEPLAY

(a) Start the engine and align the wheels straight ahead.
(b) Move the steering wheel gently with your fingers and check the
steering wheel freeplay.
Maximum freeplay:
Within 30 mm
4. CHECK OIL RESERVOIR FLUID LEVEL

(a) Make sure the vehicle is level.
(b) With the engine running at 1,000 r/min or less, move the steer-
ing wheel from full lock on one side to full lock on the other side
to raise the temperature of the fluid.
Standard:
50°C
(c) Check that no bubbles or cloudy fluid come out of the mouth of
the oil reservoir.
(d) Measure the difference in the fluid level when the engine is run-
ning and stopped. If the difference is outside of the specified
range, bleed out air. If there is no improvement after bleeding
the air, check the hydraulic system for oil leakage.
Standard:
Within 5 mm
(e) Check that the fluid level is within the range of specified values.
If it is below the range of specified values, add power steering
fluid up to the maximum level of the standard range.
Standard:
Within the HOT level range (When oil temperature is
50°C)
PS
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POWER STEERING - POWER STEERING SYSTEM
PS–4
HINT:
When the oil temperature is low (0 to 20°C), check that the oil
level is within the COLD level range.
5. BLEED POWER STEERING FLUID AIR

(a) Add power steering fluid until it reaches 10-15 mm above the
upper level of the oil reservoir level gauge (COLD side).
(b) Idle the engine at 1,000 r/min or less for approximately 2 sec-
onds. When the surface of the fluid drops below the upper level,
add power steering fluid until it reaches the upper level mark.
Repeat this procedure until the surface of the fluid settles at the
upper level mark.
(c) Start the engine and turn the steering wheel from lock to lock 2
to 3 times. Repeat this procedure until the oil level no longer
changes.
NOTICE:
• Continue to add fluid to ensure that oil reservoir does
not run dry.
• When performing the lock to lock, hold the steering
wheel at the fully turned position for 2 to 3 seconds and
then turn the wheel quickly to the other side.
(d) Hold the steering wheel at the lock position for 5 to 6 seconds
repeatedly for 3 to 4 times at intervals of approximately 2 to 3
seconds.
(e) Check that there are no fine air bubbles in the oil reservoir, and
then check that the steering wheel does not stick, vibrate or
malfunction in any way when it is operated.
HINT:
If there is no improvement after bleeding the air, check the
hydraulic system for oil leakage.
(f) Check the oil reservoir fluid level.

Steering is heavy V-ribbed belt (slack) EM-1
Power steering vane pump PS-7
Poor steering wheel return
Freeplay: none or excessive
PS
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Abnormal noise or vibration in steering wheel
PS
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POWER STEERING - VANE PUMP ASSEMBLY
PS–6
VANE PUMP ASSEMBLY

POWER STEERING
STEERING
COMPONENTS
T=7.5{76}
ENGINE UNDER COVER
T=5.4{55}
T=20{203}
VANE PUMP ASSEMBLY
GASKET
PRESSURE FEED TUBE ASSEMBLY
T=43{438}
CLIP
T=54{551}
OIL RESEVOIR TO PUMP HOSE

C140212J02
PS
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PS–7 POWER STEERING - VANE PUMP ASSEMBLY
REMOVAL
1. DRAIN POWER STEERING FLUID

6. REMOVE OIL RESERVOIR TO PUMP HOSE
(a) Slide the clip and disconnect the oil reservoir to pump hose
from the vane pump assembly.
7. DISCONNECT PRESSURE FEED TUBE ASSEMBLY

(a) Remove the union bolt while holding the pressure feed tube
assembly using an adjustable wrench.
(b) Disconnect the pressure feed tube assembly from the vane
pump assembly.
C140204
(c) Remove the gasket from the pressure feed tube assembly.
8. REMOVE VANE PUMP ASSEMBLY

(a) Disconnect the connector from the oil pressure switch.
(b) Remove the 2 installation bolts from the vane pump pulley
holes.
C140205
(c) Remove the bolt and vane pump assembly.
C140206
INSTALLATION
1. INSTALL VANE PUMP ASSEMBLY
SST 09249-63010
PS
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POWER STEERING - VANE PUMP ASSEMBLY
PS–8
(a) Install the vane pump assembly with 2 bolts A and bolt B.
Torque: 43.2 N*m (440 kgf*cm) Bolt A
B
20.6 N*m (210 kgf*cm) Bolt B
(b) Connect the connector to the oil pressure switch.
A
C140210
2. CONNECT PRESSURE FEED TUBE ASSEMBLY

(a) Install a new gasket and the union bolt while holding the pres-
sure feed tube assembly using an adjustable wrench.
3. CONNECT OIL RESERVOIR TO PUMP HOSE

(a) Connect the oil reservoir to pump hose and secure it with a clip.
5. INSTALL FRONT TIRE RH

6. REFILL POWER STEERING FLUID
7. BLEED AIR FROM POWER STEERING FLUID (See page PS-4)

C140204 8. CHECK FLUID LEVEL (See page PS-3)
9. CHECK FOR FLUID LEAKAGE
PS
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PS–9 POWER STEERING - POWER STEERING LINK ASSEMBLY
POWER STEERING LINK ASSEMBLY

POWER STEERING
STEERING
COMPONENTS
STEERING INTERMEDIATE ASSEMBLY
T=29.4{300}
STEERING SHAFT UNIVERSAL JOINT ASSEMBLY

T=29.4{300}
T=90.6{923} PRESSURE
T=46.6{475} RETURN TUBE
T=35{357}
CLIP
PRESSURE FEED TUBE
T=46.6{475}
CLIP
ENGINE UNDER COVER

C139171J02
PS
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POWER STEERING - POWER STEERING LINK ASSEMBLY
PS–10
TIE ROD END RH

STEERING RACK BOOT CLAMP
STEERING RACK BOOT NO.1
STEERING RACK BOOT CLAMP NO. 1
T=47.1{480}
CYLINDER END
CYLINDER END STOPPER STOPPER OIL SEAL
T=60{612}
POWER STEERING POWER STEERING

RACK END CONTROL VALVE
CLAW WASHER ORIFICE SEAT
O-RING BUSH DUST COVER
O-RING
T=18.2{185}
PISTON RING
T=18.2{185}
POWER STEERING
CONTROL VALVE
POWER STEERING RACK UPPER OIL SEAL
POWER STEERING RACK POWER STEERING
HOUSING OIL SEAL RACK GUIDE
RACK GUIDE CONTROL VALVE
SPRING
POWER STEERING PRESSURE CONTROL
RACK GUIDE VALVE ORIFICE SEAT
SPRING CAP CONTROL HOUSING
T=83.4{850} GASKET
STEERING RIGHT TURN POWER STEERING

PRESSURE TUBE CONTROL VALVE
T=24.5{250}
BUSH UPPER BEARING
POWER STEERING
×4
CONTROL VALVE RING
CLAW WASHER
T=103{1050}
STEERING LEFT TURN
PRESSURE TUBE
STEERING
RACK END
T=47.1{480}
STEERING RACK BOOT CLAMP NO. 1
TIE ROD END LH
STEERING RACK BOOT NO.2
STEERING RACK
BOOT CLAMP
POWER STEERING FLUID
RUBBER GREASE NON-REUSEABLE PART
LONG LIFE GREASE TIGHTENING TORQUE [N*m{kgf*cm}]
C139172J03
PS
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REMOVAL

IP-11)

IP-11)
6. DISCONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

(a) Put matchmarks on the steering intermediate shaft assembly
and the steering column assembly.
(b) Remove bolt A.
7. REMOVE STEERING SHAFT UNIVERSAL JOINT ASSEMBLY

(a) Put matchmarks on the intermediate shaft and the steering
shaft universal joint assembly.
Matchmarks
Bolt A
C136414J01
(b) Remove the bolt and steering intermediate shaft assembly.

STEERING INTERMEDIATE (c) Put matchmarks on the steering shaft universal joint assembly
ASSEMBLY
and the steering gear.
Matchmarks
C136672J01
(d) Remove the bolt and steering shaft universal joint assembly.
8. REMOVE TIE ROD END LH (See page DS-5)

HINT:
Steering Gear Assy Perform the same procedure for the RH as for the LH.
Matchmarks
C136671J01
PS
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PS–12
10. DISCONNECT OIL RESERVOIR TO PUMP HOSE

(a) Using a union nut wrench, disconnect the oil reservoir to pump
hose from the rack and pinion type power steering gear assem-
bly.
C140215
11. DISCONNECT PRESSURE FEED TUBE ASSEMBLY

(a) Using a union nut wrench, disconnect the pressure feed tube
assembly from the rack and pinion type power steering gear
assembly.
C140216
12. REMOVE RACK AND PINION TYPE POWER STEERING GEAR

ASSEMBLY
(a) Remove the 4 bolts and rack and pinion type power steering
gear assembly from the suspension cross member.
(b) Remove the rack and pinion type power steering gear assembly
from the driver's seat side.
DISASSEMBLY
C136552
1. SECURE RACK AND PINION TYPE POWER STEERING GEAR

ASSEMBLY
(a) Secure the power steering link assembly in a vise using the
SST wrapped with protection tape.
SST 09612-00012
SST HINT:
Remove and reinstall the securing SST as needed.
2. REMOVE TIE ROD END LH

(a) Put matchmarks on the tie rod end LH and the steering rack
C140231
end.
(b) Loosen the lock nut, and remove the tie rod end LH and the lock
nut from the steering rack end.

HINT:
Perform the same procedure for the RH as for the LH.
Match Mark
C142403
PS
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4. REMOVE STEERING LEFT TURN PRESSURE TUBE

SST 09633-00020
(a) Using the SST, remove the steering left turn pressure tube from
the rack and pinion type power steering gear assembly.
NOTICE:
Turning the steering wheel with the tube removed may
cause residual fluid to fly out.
C142407
5. REMOVE STEERING RIGHT TURN PRESSURE TUBE

SST 09633-00020
HINT:
Remove the steering right turn pressure tube using the same proce-
dure as for the left.
NOTICE:
Turning the steering wheel with the tube removed may cause
residual fluid to fly out.
6. REMOVE STEERING RACK BOOT CLIP

C142408
(a) Remove the left and right steering rack boot clips from the left
and right steering rack boots.
7. REMOVE STEERING RACK BOOT CLAMP NO. 1

(a) Using pliers, pinch steering rack boot clamp No. 1.
(b) Using a screwdriver, lift up and remove steering rack boot
clamp No. 1 as shown in the illustration.
8. REMOVE STEERING RACK BOOT NO. 1
9. REMOVE STEERING RACK END

SST 09922-10010
(a) Secure the steering rack end ball joint in the vise between alu-
minum plates.
NOTICE:
(b) Using a screwdriver and hammer, unstake the RH and LH claw

washers.
NOTICE:
Avoid any impact to the power steering rack.
(c) Using a wrench, secure the steering rack.
C140234
PS
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PS–14
(d) Using the SST, remove the left and right steering rack ends.
NOTICE:
• Use the SST in the correct direction.
• Secure the steering rack securely with a wrench.
(e) Remove the left and right claw washers from the left and right
SST
steering rack ends.
10. REMOVE STEERING RACK GUIDE

SST 09612-10020
C142383
(a) Using the SST, remove the power steering rack guide spring
cap.
(b) Remove the rack guide spring.
(c) Remove the power steering rack guide.
11. REMOVE CYLINDER END STOPPER

SST 09631-20090
(a) Using the SST, remove the cylinder end stopper.
SST
C142402
(b) Remove the O-ring from the cylinder end stopper.
12. REMOVE POWER STEERING CONTROL VALVE ASSEMBLY

(a) Put matchmarks on the rack housing and the control valve
housing.
(b) Remove the dust cover.
(c) Remove the 2 bolts and then remove the power steering control
SST
valve from the power steering rack housing.
C140237
(d) Remove the power steering control valve housing gasket.

Matchmarks
C140238
13. REMOVE POWER STEERING RACK

(a) Using a bolt (M14 x P1.5) and a press, remove the power steer-
ing rack and oil seal.
(b) Using a screwdriver, remove the seal ring and O-ring from the
power steering rack.
NOTICE:
Do not damage the ring groove.
14. REMOVE POWER STEERING CONTROL VALVE

(a) Wrap the serrated area of the power steering control valve with
C142404
protective tape.
PS
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(b) Using a press, remove the power steering control valve.

(c) Using a screwdriver, remove the 4 control valve rings.
NOTICE:
• Do not damage the ring groove.
Protective Tape • Do not drop the power steering control valve.
• Do not damage the oil seal inside the control valve
housing.
C143363
15. REMOVE POWER STEERING CONTROL VALVE UPPER BEAR-

ING
SST 09950-60010 (09951-00180 09951-00240 09952-06010)
(a) Using the SST and a press, remove the oil seal and power
steering control valve bearing.
16. REMOVE PRESSURE CONTROL VALVE ORIFICE SEAT

NOTICE:
Replace the seat only if there is significant deformation that
could possibly result in fluid leakage.
C140240
(a) Using a screw extractor, remove the power steering control

valve spacer.
NOTICE:
• Do not turn the tap any more than necessary.
• Do not allow any chips to get into the port.
• Do not damage the inside of the port.
HINT:
The power steering control valve spacer has an inside diameter
of 5.5 mm.
C087365
17. REMOVE POWER STEERING CONTROL VALVE UNION SEAT
HINT:
• Use the same procedure as for the pressure control valve orifice
seat.
• The power steering control valve union seat has an inside diame-
ter of 6.0 mm.
18. REMOVE POWER STEERING RACK HOUSING OIL SEAL
(a) Using needle nose pliers, remove the power steering rack bush.
C142405J02
PS
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PS–16
(b) Using the SST, remove the oil seal.

NOTICE:
Do not damage the rack housing when pressing with a
Extension
press.
SST 09950-60010
(c) Thoroughly clean the inside and outside of the removed steer-
ing rack housing with cleaning oil to remove grease and dirt.
Socket NOTICE:
• Use a bamboo brush to clean the inside of the housing
C140243 to avoid damage.
• After cleaning, apply air to the inside and outside of the
housing to remove all of the oil cleaner.
19. CHECK POWER STEERING RACK

(a) Check the tooth surface for wear and damage.
(b) Using a V-block and dial indicator, check the bend of the rack.
Standard:
0.15 mm (center portion of the rack)
INSPECTION
1. INSPECT TIE ROD END LH
(a) Secure the tie rod end LH ball joint in the vise between alumi-
num plates.
NOTICE:
C140414
(b) Install the flange nut to the stud bolt.
(c) Flip the ball joint back and forth 5 times or more.
(d) Set a torque wrench to the nut, turn the ball joint continuously at
a rate of 3 to 5 seconds per turn, and check the turning torque.
2. INSPECT TIE ROD END RH

HINT:
3. INSPECT POWER STEERING RACK

(a) Check the tooth surface for wear and damage.
ZK08184J02
(b) Using a V-block and dial indicator, check the bend of the power
steering rack.
Maximum bend:
0.15 mm
REASSEMBLY
1. INSTALL POWER STEERING RACK HOUSING OIL SEAL
(a) Coat the lip of the new power steering rack housing oil seal with
power steering fluid.
C031886
PS
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(b) Using the SST, install the power steering rack housing oil seal
to the rack housing.
SST 09950-60010 (09951-00230 09951-00410)
NOTICE:
• Make sure the oil seal is installed in the correct direc-
tion.
• Install the oil seal straight.
SST
STEERING RACK
HOUSING
OIL SEAL
C140413
(c) Using needle nose pliers, install a new power steering rack
Mating Marks bush to the rack housing.
C142405
2. INSTALL POWER STEERING RACK

(a) Lightly stretch the O-ring using fingers as shown in the illustra-
tion and install the O-ring to the ring groove of the steering rack.
NOTICE:
• Before installing, coat the O-ring with power steering
fluid.
• Do not twist or damage the O-ring.
(b) Work the power piston ring and stretch it with your fingers to
make it easier to install.
C003629 (c) Install the power piston ring to the power steering rack.
NOTICE:
• Before installing, coat the seal ring with power steering
fluid.
• Do not stretch the power piston ring excessively.
• Stretch the full circumference of the power piston ring
evenly.
• Do not damage the power piston ring.
• After installing the power piston ring, coat the ring
groove with power steering fluid.
PS
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PS–18
(d) While holding the stretched seal ring with your hand, allow the
seal ring to shrink.
C140408
(e) With the rack cover tube covering the tooth surface and port,
cut the rack cover tube so it is approximately 30 mm longer than
Approx. 30 mm Air Passage Hole
the power steering rack.
NOTICE:
Width
To
As it is used to protect the cylinder tube oil seal, before
Cover using the rack cover tube, check that it has no burrs,
The Paper
cracks or other damage.
Surface
Of The
(f) Cut a piece of newspaper so it is wide enough to cover the
Teeth Rack Cover Tube power steering rack teeth and the same length as the rack
ZX09558 cover tube.
HINT:
Make sure the newspaper is large enough that the power steer-
ing rack leaves no teeth marks on the rack cover tube when the
tube is contracted.
(g) Fill the grooved sections of the power steering rack teeth with
amix long life grease.
Rack Cover Tube NOTICE:
Do not clog the ventilation hole of the steering rack with
Air Passage Hole grease.
Paper (h) Position the newspaper so that it covers the power steering rack
Rack teeth.
Tuck
(i) Insert the rack cover tube in the direction of the crease shown in
Rack Cover
Paper Tube the illustration until it covers the ports.
A-A’ Cross Section
ZX06746J02
(j) Using the rear side of the teeth, bring the dryer air outlet to the
Rack Cover Tube
power steering rack at an angle as shown in the illustration, and
Rack Cover Tube
move the dryer so that it pushes the air inside the rack cover
Paper
tube to side B and in doing so, contracts the rack cover tube
Dryer from part A to part B.
NOTICE:
If the rack cover tube is contracted by the dryer from the
Dryer
side of the power steering rack teeth, it will leave teeth
Paper marks on the rack cover tube, which will make it difficult to
C063189 remove the rack cover tube.
HINT:
Using a fine head on the dryer air outlet makes it easier to con-
tract the crease on the rack cover tube one side at a time.
PS
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(k) Turn just the rack cover tube approximately 180 degrees.
(l) Using the rear side of the power steering rack, contract the the
other side of the rack cover tube.
180° Rotation (m) Pull out the newspaper.
180° Rotation HINT:
• If the newspaper rips, pull off the rack cover tub to remove it.
• When installing the rack cover tube, be sure to insert the
Paper power steering rack until it fully covers the ports.
Paper Rack Cover
B-B’ Cross Section Tube
ZX06747J02
(n) While rotating the power steering rack, thoroughly heat just the
rack cover tube end C, and then twist it quickly while pushing it
into the steering rack end installation hole.
NOTICE:
Rack Cover Tube
The rack cover tube may become difficult to remove if heat
is also applied to the teeth.
(o) Make sure that there are no protrusions, edges or similar on the
rack cover tube end.
HINT:
If there are any protrusions or edges on the end, heat the end
Dryer Dryer
once again and push the protrusions and or edges into the rack
end installation hole using a pen or similar.
(p) Check that the surface of the rack cover tube is not scratched or
Rack End Threaded Hole Tip
otherwise damaged.
(q) Coat the rack cover tube and power steering rack power piston
ring with power steering fluid.
(r) Install the power steering rack to the rack housing and remove
the rack cover tube.
NOTICE:
• Do not damage the power piston ring.
Rack Cover Tube C030439J02
• Do not reuse the rack cover tube.
• As there is a risk that the power steering cylinder tube
oil seal may be damaged by power steering rack over-
stroke, do not move the power steering rack any more
than needed after the rack cover tube is removed until
the control valve is installed.
3. INSTALL CYLINDER END STOPPER

(a) Coat the lip of a new cylinder end stopper oil seal with power
steering fluid.
(b) Install the cylinder end stopper oil seal to the rack housing.
NOTICE:
• Make sure the cylinder end stopper oil seal is installed
in the correct direction.
• Do not damage the cylinder end stopper oil seal.
(c) Check that the bush located on the inner surface of the cylinder
end stopper is not damaged.
PS
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PS–20
(d) Coat the bush located on the inner surface of the cylinder end
stopper with long life chassis grease.
(e) Coat a new O-ring with power steering fluid and install it to the
cylinder end stopper.
Application of grease
C142406
(f) Coat the inner surface of the bush of the cylinder end stopper
Cylinder End Stopper with power steering fluid and drive in the bush to the rack hous-
ing so that the cylinder end stopper can be tightened.
C140412
(g) Using the SST, tighten the cylinder end stopper.

4. CHECK POWER STEERING RACK HOUSING AIRTIGHTNESS

SST 09631-12071
(a) Install the SST on the rack housing.
SST
C140237
(b) Install a MIGHTY VAC to the SST. Then apply a vacuum of

53.33 kPa (400 mm Hg) for 30 seconds and check that there is
no change to the vacuum pressure in that time.
SST NOTICE:
If there is any air leakage, inspect the cylinder end stopper
oil seal and cylinder tube oil seal and replace.
C140244
5. INSTALL PRESSURE CONTROL VALVE ORIFICE SEAT

(a) Using a sliding T-handle and hammer, lightly tap in a new power
steering control valve spacer.
NOTICE:
Do not allow any foreign matter to get into the port.
6. INSTALL POWER STEERING CONTROL VALVE UNION SEAT

HINT:
Use the same procedure as for the pressure control valve orifice seat.
C085426 PS
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7. INSTALL POWER STEERING CONTROL VALVE UPPER OIL

SEAL
(a) Apply power steering fluid to the lip of the new power steering
control valve upper oil seal and power steering control valve
upper bearing.
(b) Using the SST and a press, press in the power steering control
valve upper oil seal.
SST 09950-60010 (09951-00290)
Handle NOTICE:
• Make sure the power steering control valve upper oil
seal is installed in the correct direction.
Spacer
• While pressing in with the press, do not apply an exces-
Oil Seal sive force.
Oil Seal
C140241
8. INSTALL POWER STEERING CONTROL VALVE UPPER BEAR-

ING
Handle
(a) Using the SST and a press, press in the power steering control
valve upper bearing.
SST 09950-60010 (09951-00320)
Spacer NOTICE:
While pressing in with the press, do not apply an excessive
Bearing
force.
C140242
9. INSTALL POWER STEERING CONTROL VALVE

SST 09631-20070
(a) Coat 4 new power steering control valve rings with power steer-
ing fluid.
PS
GETtheMANUALS.org
PS–22
(b) Using the SST, stretch the 4 control valve rings.

HINT:
Insert the seal rings from the smaller diameter side of the SST.
Slide the rings toward the larger diameter side of the SST to
stretch them.
NOTICE:
• Do not stretch the power steering control valve rings
excessively.
• Stretch the full circumference of the power steering
SST
C140409 control valve rings evenly.
• Do not damage the power steering control valve rings.
(c) While holding the 4 power steering control valve rings and allow
them to shrink.
C140410
(d) Coat the 4 rings with power steering fluid. Using the SST, allow
the rings to shrink further.
SST (e) Wrap the serrated area of the control valve with protective tape.
(f) Coat the oil seal with power steering fluid.
(g) Using a press, install the power steering control valve to the
power steering control valve housing.
NOTICE:
• Do not damage the power steering control valve rings.
• Do not damage the power steering control valve upper
C140411 oil seal inside the power steering control valve housing.
• When the power steering control valve cannot be
pressed in easily, make sure that the control valve ring
is not pinched and that the bearing inside the control
valve housing is not tilted.
10. INSTALL POWER STEERING CONTROL VALVE ASSEMBLY

(a) Coat the grooved sections of the pinion rack teeth with long life
grease.
(b) Coat the needle roller bearing inside the rack housing with long
life grease.
(c) Install a new power steering control valve housing gasket to the
control valve housing.
(d) Align matchmarks of the control valve housing and the rack
housing, and install the power steering control valve assembly.
C057760
Apply Grease
PS
GETtheMANUALS.org
(e) Install the power steering control valve housing to the power
Matchmarks steering rack housing using 2 bolts.
11. INSTALL STEERING RACK GUIDE

(a) Coat the surface that contacts the power steering rack with long
life grease.
(b) Install the power steering rack guide to the rack housing.
(c) Clean the threaded parts of the spring cap and the rack hous-
ing.
C140238
(d) Install the rack guide spring to the rack housing.
(e) Temporarily tighten the spring cap.
(f) Engage the power steering rack and the control valve.
Apply Grease
C057761
(g) Using the SST, install the spring cap.


SST 09616-00010
(a) Temporarily install the left and right steering rack ends to the
NOTICE:
SST
Make sure to install the left and right steering rack ends
because moving the power steering rack at full stroke with-
C140236
out installing the steering rack ends may damage the oil
seal.
(b) Using the SST, move the power steering rack 1 to 2 times at full
stroke to work in the power steering rack.
SST
C140245
PS
GETtheMANUALS.org
PS–24
(c) Using the SST, inspect total preload.

Standard:
SST 0.8 to 1.5 N*m (8 to 14.8 kg*cm)
(d) Remove the right and left steering rack ends from the power
steering rack.
13. INSTALL STEERING RACK END

(a) Align the claws of 2 new claw washers with the RH and LH
steering rack end grooves to install them to the steering rack
ends.
C140415
(b) Temporarily install the left and right steering rack ends.
(c) Using the SST and a wrench, install the steering rack end to the
NOTICE:
• Use the SST in the correct direction.
SST
• When tightening, do not twist the steering rack.
• Secure the power steering rack securely with a spanner.
C142383
(d) Secure the steering rack end ball joint in the vise between alu-
minum plates.
NOTICE:
(e) Using a brass bar and a hammer, stake the 2 claw washers (RH
and LH).
NOTICE:
Avoid any impact to the power steering rack.
14. INSTALL STEERING RACK BOOT NO. 2

C035928
(a) INSTALL LEFT AND RIGHT STEERING RACK BOOTS AND
BOOT CLAMP Install the left and right steering rack boots and
boot clamp.
(b) Using the SST, rotate the control valve and check that the steer-
ing rack boot expands and contracts smoothly.
SST
15. INSTALL STEERING LEFT TURN PRESSURE TUBE
SST 09633-00020
(a) Using the SST, install the steering left turn pressure tube to the
power steering gear assembly.
16. INSTALL STEERING RIGHT TURN PRESSURE TUBE

C140245 SST 09633-00020
(a) Use the same procedure as for the steering left turn pressure
tube.
PS
GETtheMANUALS.org
17. INSTALL TIE ROD END LH

(a) Install the lock nut and the tie rod end LH to the rack end until
the matchmarks are aligned and install the lock nut.
18. INSTALL TIE ROD END RH

HINT:
Install the RH in the same way as the LH.
Match Mark
C142403
INSTALLATION
1. INSTALL RACK AND PINION TYPE POWER STEERING GEAR

ASSEMBLY
(a) Using a torque wrench , install the rack and pinion type power
steering gear assembly.
2. INSTALL STEERING SHAFT UNIVERSAL JOINT ASSEMBLY

(a) Align the matchmarks and install the steering shaft universal
joint assembly to the steering gear assembly.
NOTICE:
C136552
Insert the steering shaft universal joint assembly until the
spline part can no longer be seen.
(b) After temporarily tightening a new bolt by hand, fully tighten the
bolt.
(c) Insert the steering intermediate shaft into the column hole cover
from the cabin side.
Steering Gear Assy
(d) Align matchmarks and connect the steering column assembly to
Matchmarks the steering intermediate shaft assembly.
C136671J01
(e) Temporarily tighten bolt A by hand so that the steering interme-

diate shaft assembly slides slightly.
(f) Align the matchmarks and connect the steering intermediate
shaft and the steering shaft universal joint assembly.
NOTICE:
Matchmarks Insert the steering intermediate shaft until the serrated part
can no longer be seen.
Bolt A
C136414J01
PS
GETtheMANUALS.org
PS–26
(g) After temporarily tightening a new bolt by hand, fully tighten the
STEERING INTERMEDIATE bolt.
ASSEMBLY
NOTICE:
Make sure the bolt does not run on the notch of the steer-
ing intermediate shaft.
Matchmarks
C136672J01
(h) Fully tighten bolt A.

3. INSTALL INSTRUMENT PANEL UNDER COVER NO. 1 (See

pageIP-18)
4. INSTALL INSTRUMENT PANEL FINISH PANEL LWR (See pageIP-

18)
Bolt A
C136414J02
5. CONNECT OIL RESERVOIR TO PUMP HOSE

(a) Using a torque wrench, connect the oil reservoir to pump hose
to the rack and pinion type power steering gear assembly.
6. CONNECT PRESSURE FEED HOSE

(a) Using a torque wrench, connect the pressure feed hose to the
rack and pinion type power steering gear assembly.
7. INSTALL TIE ROD END LH (See pageDS-10)
8. INSTALL TIE ROD END RH

HINT:
9. REFILL POWER STEERING FLUID
10. BLEED AIR FROM POWER STEERING FLUID (See pagePS-4)
11. CHECK POWER STEERING FLUID LEVEL (See pagePS-3)
12. CHECK FOR POWER STEERING FLUID LEAKAGE

15. PERFORM ZERO POINT CALIBRATION
PS
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TO INDEX
HEATER AND AIR CONDITIONER / VENTILATION
AIR CONDITIONER
HEATER AND AIR CONDITIONING SYSTEM
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-1
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-10 AC
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-11
CUSTOMER PROBLEM ANALYSIS CHECK SHEET . . . . . . . . . . . . . . . . . . . . . . AC-13
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-14
ECU TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-15
BLOWER MOTOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-16
MAGNETIC CLUTCH RELAY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-19
PRESSURE SWITCH CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-22
REFRIGERANT HFC - 134a (R134a)
PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-25
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-27
REFRIGERANT LINE
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-29
AIR CONDITIONER PANEL
COMPONENTS . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . AC-30
REMOVAL . . . . . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . AC-30
DISASSEMBLY . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . AC-31
ASSEMBLY . . . . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . AC-32
INSTALLATION .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . AC-33
HEATER CONTROL NO. 1
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-34
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-35
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-36
AIR CONDITIONING RADIATOR ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. . AC-38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. . AC-41
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. . AC-44
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. . AC-45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. . AC-46
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...................... AC-50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...................... AC-51
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...................... AC-52
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...................... AC-52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...................... AC-54
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...................... AC-55
CONDENSER ASSEMBLY (WITH RECEIVER)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-56
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-57
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-57
BLOWER REGISTER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-59
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-59
GETtheMANUALS.org
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-59
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-60
COOLER THERMISTOR NO. 1
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-61
HEATER RELAY NO. 1
AC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-62
AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-63
COMPONENTS . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . . AC-64
REMOVAL . . . . . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . . AC-64
INSTALLATION. .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . . AC-64
INSPECTION . . . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . . AC-65
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC-66
GETtheMANUALS.org
AIR CONDITIONER - HEATER AND AIR CONDITIONING SYSTEM
AC–1
HEATER AND AIR CONDITIONING SYSTEM

HEATER
AIR CONDITIONER
AND AIR CONDITIONER / VENTILATION
OPERATION CHECK
1. CHECK COOLING PERFORMANCE
(a) Install the air conditioning tool set to the vehicle.
(b) Set the vehicle to the following conditions.[*1] AC
Item Condition
Vehicle body Vehicle is parked in the shade and the engine is stopped
Doors Fully open
A/C switch ON
Engine speed 2000 r/min
Air inlet control damper position Air inlet position
Air outlet damper position FACE
Temperature setting MAX COOL
Blower speed HIGH
Air inlet temperature *2 25 to 30°C
Condenser pressure (gauge high pressure side) *3 1.37 to 1.57 MPa (14 to 16 kgf/cm2)
HINT:
*2 ... If the air inlet temperature is out of the range of 25 to 30°C,
determination may be inaccurate. Postpone the inspection if
the temperature is too low.
*3 ... When the condenser pressure (gauge pressure side) is
too high, pour water on the condenser to decrease the pres-
sure. Conversely, when it is too low, cover the front side of the
condenser to increase the pressure.
(c) Place the hygrometer at the air inlet (to measure the humidity)
and insert the hygrometer bulb into the mouth of the air outlet.
(d) Operate the air conditioning system under condition [*1], and
stabilize the temperature of the air outlet. (Approximately 5 to 6
minutes)
(e) Measure the dry-bulb temperature of the air inlet and the wet-
bulb temperature of the air outlet.
GETtheMANUALS.org
AC–2 AIR CONDITIONER - HEATER AND AIR CONDITIONING SYSTEM
(f) Apply the dry and wet bulb temperatures of the air inlet to the
psychrometric diagram to determine the relative humidity.
AC Relative Humidity
Wet-bulb Temperature
Relative Humidity
Dry-bulb temperature (°C)

E103335
(1) The example shows how to determine the relative humid-

ity, In the example, the air inlet dry-bulb temperature is
Example
25°C and the wet-bulb temperature is 19.5°C. The inter-
Wet-bulb
Temperature section point on the diagram indicates the relative humid-
ity, which is 60%.
Dry-bulb Temperature(°C)
E103336
GETtheMANUALS.org
AC–3
(g) Check the cooling performance by referring to the relative

humidity on the standard performance chart and the difference
between the measured inlet and outlet temperatures.
AC
Temperature Difference
Between Inlet and Outlet (°C)
Relative Humidity (%) E103337
Standard:
Within the shaded area in the illustration
(1) The example shows how to determine the cooling perfor-
mance by using the standard performance chart. In the
example, the difference between inlet and outlet dry-bulb
Temperature
temperatures is 17°C and the relative humidity is 60%.
Difference Between
Inlet And Outlet (°C)
Meeting Point
Relative Humidity (%)
E103338
GETtheMANUALS.org
2. CHECK REFRIGERANT PRESSURE

(a) INSPECT REFRIGERANT VOLUME
(1) Check the sight glass of liquid tube A.
(2) Set the vehicle to the following conditions.[*1]
Sight Glass Item Condition

Doors Fully open
AC Temperature setting MAX COOL
Blower speed HIGH
A/C ON
(3) Under condition [*1], check the sight glass.
Symptom Amount of Refrigerant Countermeasure

• Check for gas leak-
E131260J01 age and repair if nec-
Bubbles appear in the essary
Not enough
sight glass • Pour refrigerant until
the air bubbles are
gone.
Bubbles do not appear in None, not enough, too See (*2) and (*3)
the sight glass many
• Check for gas leak-
There is no temperature age and repair if nec-
difference between the essary
Empty or nearly empty
compressor intake vent • Pour refrigerant until
and exhaust vent (*2) the air bubbles are
gone.
There is a notable tem-
perature difference
between the compressor Reasonable or too much Refer to (*4) and (*5)
intake vent and exhaust
vent (*3)
• Discharge refrigerant
The refrigerant in the
• Bleed the air, then
sight glass is transparent
Too much pour in the proper
immediately after turning
amount of new refrig-
off the air conditioner (*4)
erant
The refrigerant is bub-
bling, then becomes
transparent immediately Reasonable -
after turning off the air
conditioner (*5)
HINT:
When the room temperature is higher than normal, pre-
sume that air bubbles in the sight glass are normal when
there is sufficient cooling,
GETtheMANUALS.org
AC–5
(b) INSPECT REFRIGERANT PRESSURE USING GAUGE
Gauge Indicated Value Reference Data
Low Side Pressure

MPa{kgf/cm2} AC
0.5{5.0}
Blower HI Zone
0.4{4.0}
1.06{10.9}
0.3{3.0}
0.27{2.85}
1.2{12.3}
0.22{2.25}
0.2{2.0} 0.2{2.1} Blower LO Zone
1.25{12.8}
0.14{1.5}
1.32{13.5} High Side

Pressure
0.5{5.0} 1.0{10.0} 1.5{15.0} 2.0{20.0} MPa{kgf/cm2}
E100247J01
(1) Install the air conditioning tool set.

(2) Set the vehicle to the following conditions.[*2]
Item Condition
Engine After warm up
Doors Fully open
A/C ON
Air inlet mode switch RECIRCULATION
Temperature setting MAX COOL
Blower speed HIGH
Air inlet temperature 30°C to 35°C
(3) Under condition [*2], check the gauge reading.

Standard:
0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm2) (Low pressure
side)
1.37 to 1.57 MPa (14 to 16 kgf/cm2) (High pressure
side)
HINT:
The specified value is applicable when the refrigerant
charge volume is normal.
E100248
GETtheMANUALS.org
Condition: Periodically Cools And Then Fails To Cool
AC
E100249J02
Result
Symptom Cause Diagnosis Countermeasure
Moisture in the refrigeration sys- • Cooler dryer is overly satu-
1. Replace cooler dryer
tem freezes at the expansion rated
During operation, the pressure on 2. Remove moisture from cycle
valve orifice, causing a temporary • Moisture in refrigeration sys-
the low-pressure side cycles by repeatedly evacuating air
stop of cycle. But after the ice tem freezes at expansion
between vacuum and normal 3. Supply the appropriate vol-
melts, the system will return to valve orifice and blocks refrig-
ume of new refrigerant
normal erant gas circulation
HINT:
These gauge readings indicate that moisture is in the
cooling system
Condition:Insufficient Cooling
E100250J02
Result
• Check for refrigerant leakage
and repair if necessary
• The pressure of both high • Supply the appropriate vol-
and low side is low ume of new refrigerant
• Bubbles appear continuously There is gas leakage from the • Insufficient refrigerant • If the indicated pressure
in the sight glass refrigeration system • Refrigerant leakage value is close to 0 when con-
• Cooling performance is insuf- nected to the gauge, perform
ficient vacuum purging after inspect-
ing and repairing the location
of the leak
HINT:
These gauge readings indicate that cooling performance
is poor.
GETtheMANUALS.org
AC–7
Condition: Insufficient Cooling
AC
E100251J01
Result
• The pressure of both high
and low side is low
Refrigerant flow is obstructed by Replace the cooler condenser
• There is frost on the piping Cooler condenser core blockage
dirt in the cooler condenser core core
from the cooler condenser to
the A/C unit
HINT:
These gauge readings indicate that cooling performance
is poor.
Condition: Does Not Cool (Cools From Time To Time In Some Cases)
E100252J01
Result
1. Check the cooler expansion
valve
2. Remove dirt from the cooler
• Vacuum indicated on the low- expansion valve using an air
• Refrigerant gas flow is
pressure side, and extremely gun
obstructed by moisture or dirt
low pressure indicated on the 3. Replace the cooler con-
in the refrigeration system
high-pressure side denser core
• Refrigerant gas flow is Refrigerant does not circulate
• Frost or condensation is seen 4. After vacuum purging, supply
obstructed by refrigerant gas
on the piping on both sides of the appropriate volume of
leakage from the cooler
the cooler condenser core or refrigerant
expansion valve
cooler expansion valve 5. If there is refrigerant leakage
from the cooler expansion
valve, replace the cooler
expansion valve
HINT:
These gauge readings indicate that the refrigerant is not
circulating.
GETtheMANUALS.org
AC
E100253J01
Result
1. Clean the cooler condenser
• The pressure on both the core fins
high and low-pressure sides 2. Check the operation of the
• Excessive refrigerant • Excessive refrigerant
is too high condenser fan motor
• Insufficient cooling of the • Cooling failure of the cooler
• Bubbles do not appear in the 3. If 1 and 2 are normal, check
cooler condenser core condenser core
sight glass even when engine the amount of refrigerant and
speed is reduced supply the appropriate vol-
ume of refrigerant
HINT:
These gauge readings indicate that the amount of refrig-
erant is excessive or that there is insufficient cooling of
the cooler condenser core.
NOTE: These gauge indications are

shown when the refrigeration system
has been opened and the refrigerant
charged without vacuum purging.
E100254J01
Result
• The pressure on both the
high and low pressure sides
1. Check to see if the compres-
is too high
• Air in the refrigeration system sor oil is dirty or low
• The low-pressure piping is Air in the refrigeration system
• Insufficient vacuum purging 2. After vacuum purging, supply
too hot to touch
new refrigerant
• Bubbles appear in the sight
glass
HINT:
These gauge readings indicate that there is air in the
refrigeration system.
GETtheMANUALS.org
AC–9
AC
E100255J01
Result
• Excessive refrigerant in the
high and low-pressure sides
low pressure piping Replace the cooler expansion
is too high Cooler extension valve trouble
• The cooler expansion valve is valve
• Frost or condensation on the
open too wide
low-pressure side
HINT:
These gauge readings indicate that there is a problem
with the cooler extension valve.
E100256J01
Result
high and low pressure sides • Compression failure
Leakage in the cooler compres- Repair or replace cooler com-
is too high • Valve leakage or damage to
sor pressor
• The pressure on the high sliding parts
pressure side is too low
HINT:
These gauge readings indicate a compression failure of
the cooler compressor.
3. INSPECT COOLER CONDENSER ASSEMBLY

(a) If the fins of the cooler condenser are dirty, clean them with
water and dry them with compressed air.
NOTICE:
Do not scratch the fins of the cooler condenser assembly.
(b) If the fins of the cooler condenser are bent, straighten them
using a screwdriver or pliers.
4. CHECK FOR REFRIGERANT LEAKAGE

(a) Check for refrigerant leaks from the piping connections using a
halogen leak detector.
(b) Check the tightening torque of the joint if refrigerant leakage is
detected in a pipe joint.
GETtheMANUALS.org
LOCATION
AC ENGINE ROOM R/B

-MAGNETIC CLUTCH RELAY
AIR CONDITIONER TUBE AND

ACCESSORY ASSEMBLY

WITH MAGNETIC CLUTCH ASSEMBLY
ENGINE CONTROL
COMPUTER
HEATER RELAY NO. 1
E128422J02
GETtheMANUALS.org
AC–11
AIR CONDITIONER UNIT ASSEMBLY
AC
HEATER CORE ASSEMBLY
EVAPORATOR ASSEMBLY
BLOWER REGISTER
E131271J01

MANUAL AIR CONDITIONER
Check fuse (IG1 / BACK) -
All functions of the A/C system do not operate No. 1 heater control AC-34
Wire harness and connector -
Check fuse (HEATER) -
Check heater relay No. 1 AC-62
Check blower motor (with fan) AC-65
Blower motor (with fan) does not operate
Check heater control No. 2 AC-35
Check blower register AC-60
Check blower register AC-60
Check blower motor (with fan) AC-65
Blower motor (with fan) does not operate
Check heater control No. 2 AC-35
GETtheMANUALS.org

Check the refrigerant charge volume AC-1
Check refrigerant pressure AC-4
Cabin temperature does not decrease (does not get Check air conditioning tube and accessory assembly AC-63
cooler) Check cooler compressor assembly with magnetic clutch AC-55
assembly
AC Check the cooler expansion valve -
Check fuse (MGC) -
Check refrigerant pressure AC-4
Check cooler compressor assembly with magnetic clutch AC-55
assembly
Compressor does not turn ON
Check air conditioning tube and accessory assembly AC-63
Check cooler thermistor No. 1 (evaporator rear sensor) AC-61
Engine control computer ES-16
GETtheMANUALS.org
AC–13

CHECK
AC
Date Vehicle Brought In
Heater and Air Conditioning System Check Sheet / /
Customer’s Name License Plate No. First Registration Year
Model VIN
Written by Inspector’s Name Engine Type Odometer Reading km
Description of Symptoms
Date Problem First Occurred Date Time

Frequency Problem Occurs Constant Occasional (___times per day , ___ times per month)
Conditions (Method of use and results)
Weather Clear Cloudy Rainy Snowy Others ( ) Air Temperature Approx. ( )°C
Road City Suburb Highway Others ( ) Paved Unpaved
Blower motor does not operate

Wind Volume Control Poor Blower motor speed does not change
Always at high, medium, or low speed
Room temperature does not decrease

Temperature Control Poor Room temperature does not increase
Slow response
Problem No circulation between entering ambient air and room air
Symptoms Suction Port Control Poor
Always room air / Always ambient air
Blower port not allow air to pass
Blower Exit Control Poor
Does not enter the desired mode
Others
E074980J01
GETtheMANUALS.org
CIRCUIT DIAGRAM
AC Tail SW
ACC
IG1
AM1
IG2
ST
Rr Defogger
+B
IG
ILL-
IG
RrDEF
RrDEF SW Heater Control NO. 3
Heater Control NO. 2 TAIL
ILL+ E 10A
ILL- ILL+ 2
1
Blower Motor HTR Relay
5 3
Blower Register 1 2 HTR
HI 10 1 4 40A
HI LO
M2 6 3 M2 2 M1
M1 7
LO 9
E Heater Control NO. 1

5 6 ILL- ILL+ 5
3 E
IG1/
C11
Pressure Switch BACK
BLW 7.5A
D3 1 2 4B L 2
ACSW
A/C SW
C31 MGC
MGC Relay
E21 5 3 7.5A
2
Cooler 1 1 2
Thermistor NO. 1 MG+
Magnetic
(Sensor after EVAP)
Clutch
1
C14
ACEW
B32
E1 D16
MGC
E128400J01
GETtheMANUALS.org
AC–15
ECU TERMINALS
1. Engine control computer
connecter A connecter B connecter C connecter D
AC
27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28
106105 104103102101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 72 71 70
135134 133132 131130129 128127 126125 124123 122 121 120119 118 117 116 115 114 113 112 111 110109 108107
E133924
(a) TERMINAL LAYOUT
Terminal Symbol Input /

(Terminal No.) Output
Engine idling, blower switch LO; A/C switch is turned from
MGC ←→ E1
Output Voltage OFF to ON 10 to 14 V → 1 V or less
[D36 ←→ B125]
(Magnetic clutch ON)
ACSW ←→ E1 The engine is started; the magnetic clutch is changed from
Input Voltage 1 V or less → 10 to 14 V
[D3 ←→ B125] OFF to ON
BLW ←→ E1 Changes from 10 to 14 V to 0
Input Voltage IG ON, blower switch LO, OFF - ON
(C42 ←→ B125) to 0.5 V
ACEW ←→ E21
Input Voltage IG ON, A/C switch ON 0.15 to 4.8 V
(A24 ←→ C116)
GETtheMANUALS.org
BLOWER MOTOR CIRCUIT

DESCRIPTION
When the heater control (blower switch) is operated with 0 to 1 or more, No. 1 heater relay (HTR Relay) turns on and the current
leads the blower motor (with fan) to rotate. Speed change of the blower motor (with fan) is operated by heater control (blower
AC switch) to transit between ground ←→ blower register circuit.
CIRCUIT DIAGRAM
+B
+IG
2 3
HTR Relay
Heater Control 1 5
(Blower Switch )
C11
BLW
Blower Motor
(With Fan)
E130115
1 CHECK FUSE (IG1 / BACK, HEATER)
(a) Check fuse (IG1 / BACK 7.5A) of the instrument panel J/B.
(b) Check fusible link assembly (HEATER 40A) in the engine room R/B.
NG REPLACE FUSES
OK
GETtheMANUALS.org
AC–17
2 CHECK HEATER RELAY NO. 1 (HTR)
(a) Using the tester, check the continuity between each of the connecter
terminals.
Standard
Tester Connection Standard

AC
Terminal 1 ←→ Terminal 2 Continuity
Terminal 3 ←→ Terminal 5 No continuity
(b) Using the tester, check the continuity between terminal 3 and 5 when
battery voltage is applied to terminal 1 and 2.
E062721J01 Standard:
Continuity
NG REPLACE HEATER RELAY NO. 1
OK
3 CHECK WIRE HARNESS OR CONNECTOR (POWER SOURCE SYSTEM)

(b) Using the tester, check the voltage between the blower motor (with
BLOWER MOTOR W/H SIDE fan) vehicle wire harness side connector (+B) terminal 2 and the body
ground.
Standard
Tester Connection Measurement Condition Standard

Blower switch
1 2 2 (+B) ←→ body ground 0 V → 10 to 14 V
0→4
GND +B

E130114J01
CONNECTOR
OK
4 CHECK BLOWER MOTOR UNIT (WITH FAN)
(a) Check that the operation of the motor when connector terminal 2 is
connected to the positive battery terminal and terminal 1 is connected
$ )0&
to the negative battery terminal.
NG REPLACE BLOWER MOTOR (WITH FAN)

E108727J01
OK
GETtheMANUALS.org
5 CHECK BLOWER REGISTER
(a) Disconnect the connector of the blower register.

(b) Using the tester, check the resistance between each terminal of the
blower register.
AC Standard

Terminal 1 (HI) ←→ Terminal 4 (LO) 3.43 ± 0.24 Ω
Terminal 1 (HI) ←→ Terminal 2 (MI) 1.03 ± 0.07 Ω
Terminal 1 (HI) ←→ Terminal 3 (M2) 0.47 ± 0.03 Ω
HINT:
E032877J01 There is a thermal fuse between terminal 1 - terminal 2, 3 and 4.
NG REPLACE BLOWER REGISTER
OK
6 CHECK HEATER CONTROL (NO. 2, BLOWER SWITCH)
(a) Disconnect the connector of the heater control.

(b) Using the tester, check the continuity between each of the heater
E control terminals.
Standard
Tester Connection Measurement Condi- Continuity

tion
Terminals ←→ 5 (E) Blower switch 0 None
9 (LO) ←→ 5 (E) Blower switch 1 Continuity
HI Lo M1 M2
7 (M1) ←→ 5 (E) Blower switch 2 Continuity
6 (M2) ←→ 5 (E) Blower switch 3 Continuity
E108726J02
10 (HI) ←→ 5 (E) Blower switch 4 Continuity
NG REPLACE HEATER CONTROL (NO. 2)
OK
GETtheMANUALS.org
AC–19
MAGNETIC CLUTCH RELAY CIRCUIT

DESCRIPTION
• The heater control base sends magnetic clutch ON command signal to the ECM.
• The ECM actuates the magnetic clutch relay to turn ON the magnetic clutch.
AC
CIRCUIT DIAGRAM
Magnetic Clutch Relay Engine Control Computer
2 1 D16
Heater Blower Circuit MGC
MGC 7.5A 5
3
Battery
IG1/BACK 7.5
Cooler Compressor Assembly

MG+ 1
Heater Control Base

Pressure Switch
2 4 2 1 D3
ACSW
E130116J01
1 CHECK FUSE (MGC)
NG REPAIR OR REPLACE FUSE
OK
GETtheMANUALS.org
2 CHECK MAGNETIC CLUTCH RELAY
(a) Remove the magnetic clutch relay from the relay block assembly.
(b) Using the tester, check the continuity between the connecter termi-
nals.
AC Standard:
Continuity between terminal 1 and terminal 2
(c) Using the tester, check the continuity between terminal 3 and 5 when
battery voltage is applied to terminal 1 and 2.
Standard:
E062721
NG REPLACE MAGNETIC CLUTCH RELAY
OK
3 CHECK COOLER COMPRESSOR WITH MAGNETIC CLUTCH ASSEMBLY
(a) Disconnect the cooler compressor assembly connector.

(b) Using the tester, check the continuity between connector terminal 1
(MG+) and the ground.
Standard:
Continuity
(c) When connector terminal 1 (MG+) is connected to the positive battery
1 terminal and the body ground is connected to the negative battery ter-
minal, check that the magnetic clutch makes a sound indicating that it
is operating, and check that the magnetic clutch's hub and rotor lock.
NG REPLACE COOLER COMPRESSOR WITH

E130121
OK
4 CHECK WIRE HARNESS OR CONNECTOR (POWER SOURCE SYSTEM AND MAGNETIC CLUTCH
RELAY)

(b) Using the tester, check the voltage between terminals in the engine
Engine Room R/B Room R/B.
Standard:

3 ←→ The body ground 10 to 14 V

E130122J01
CONNECTOR
OK
GETtheMANUALS.org
AC–21
5 CHECK WIRE HARNESS OR CONNECTOR (MAGNETIC CLUTCH RELAY AND ECM)
(a) Disconnect the ECM connector.

(b) Using the tester, check for continuity and GND short between the ter-
minals of the vehicle wire harness connector.
Measuring Point AC
ECM Side Relay Block Assembly Side
Terminal No. (Terminal Symbols) Terminal No.
D36 (MGC) 1
Standard:
There is continuity between the terminals but no short to GND
MGC
Engine Room R/B CONNECTOR
E130123J01
OK
CHECK AND REPLACE ENGINE ECM
GETtheMANUALS.org
PRESSURE SWITCH CIRCUIT

DESCRIPTION
To detect malfunctions in refrigerant pressure, the pressure switch is installed on the high pressure piping block of the front of the
condenser. If an abnormal condition occurs in refrigerant pressure, the pressure switch sends a switch OFF signal to the ECM.
AC The ECM receives the signals and stops the cooler compressor control.
CIRCUIT DIAGRAM
(See page AC-19)
1 CHECK FUSE (IG1 / BACK)
NG REPLACE FUSES
OK
2 CHECK HEATER CONTROL (NO. 1, A/C SWITCH)

(1) Using the tester, check the continuity between each of the con-
A/C Switch necter terminals of the heather control knob.
Terminal No. (Terminal Measurement Condition Continuity

Name)
3 (E) ←→ 2 (L) The A/C switch is OFF. None
4 (B) ←→ 2 (L) The A/C switch is OFF. None
3(E) ←→ 4 (B) Always Continuity
3 (E) ←→ 2 (L) The A/C switch is ON Continuity
4 (B) ←→ 2 (L) The A/C switch is ON Continuity
5 (ILL+) ←→ 6 (ILL-) Always Continuity
(b) CHECK ILLUMINATION

(1) Connect the positive battery lead to terminal 5 of the connector,
ILL+ '
and the negative battery lead to terminal 6, then check that the
illumination of the heater control knob comes on.
NG HEATER CONTROL (NO. 1)
ILL- $ L
I100849J01
OK
3 CHECK WIRE HARNESS OR CONNECTOR (POWER SOURCE)
(a) Disconnect the connector of the pressure switch.
GETtheMANUALS.org
AC–23
(b) Using the tester, check the continuity between the vehicle wire har-
ness side connector terminal 1 and the body ground of the pressure
Pressure Switch W/H Side Connector switch.
Standard:
Continuity
(c) Turn IG ON and turn the A/C switch ON.
(d) Using the tester, check the voltage between the vehicle wire harness
side connector terminal 2 and terminal 1 of the pressure switch.
AC
Standard:
E130120J01
10 to 14 V

CONNECTOR
OK
4 CHECK AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY
(a) CHECK PRESSURE SWITCH

(2) Start the engine and operate the cooler.
(3) Using the tester, check the continuity between the pressure
switch terminals.
Standard:
Depending on the refrigerant pressure, the continuity
standard will be like that shown in the illustration.
NG CHECK AIR CONDITIONING TUBE AND

Continuity ACCESSORY ASSEMBLY
No
Continuity
196 225 2550 3140 [kPa]
{2.0} {2.3} {26} {32}
{kgf/cm }
2
E128435J01
OK
5 CHECK ECM
(a) Disconnect the ECM's connector D.

(b) Start the engine and turn the A/C switch ON.
(c) Using the tester, check the voltage between the vehicle side connec-
tor of the engine control connector and the body ground.
Terminal Symbol Measurement Condition Standard

(Terminal No.)
ACSW ←→ E1 Start the engine and turn the A/C 1 V or less → 10
[D3 ←→ B32] switch from OFF to ON. to 14 V

ACSW
CONNECTOR
E130147J01
GETtheMANUALS.org
OK
CHECK AND REPLACE ECM
AC
GETtheMANUALS.org
AIR CONDITIONER - REFRIGERANT HFC - 134a (R134a)
AC–25
REFRIGERANT HFC - 134a (R134a)

HEATER
AIR CONDITIONER
PRECAUTIONS
1. PRECAUTIONS FOR REFRIGERANT HFC-134a (R134a)
(a) COMPATIBILITY
HFC-134a (R134a) (1) When selecting compressor oil or component parts in the AC
A/C System refrigerant cycle, there is no compatibility between the
HFC-134a (R134a) system and the previous R12 system.
Trouble
R12
A/C System
E102505J03
(b) REFRIGERANT HFC-134a (R134a)

(1) Always use refrigerant HFC-134a (R134a).
NOTICE:
• Refrigerant is safe and non-toxic under conditons
of normal use. However, it may be hazardous if
exposed to an open flame or high temperatures
(e.g., cigarette or heater, etc.).
• Ensure that there is proper ventilation and do not
work in a closed space.
E102506 • Do not use a halide torch type leak tester to check
for refrigerant leakage.
HINT:
In order to avoid mistakes when adding refrigerant, use
only a manifold gauge to measure HFC-134a (R134a).
(c) COMPRESSOR OIL
(1) Use only ND-OIL 8 for the compressor oil.
HINT:
If R12 compressor oil is used with a HFC-134a (R134a)
system, the system may not be properly lubricated and rub-
ber parts may swell. These problems may cause compres-
sor lock-up or refrigerant leakage. Conversely, using HFC-
134a (R134a) compressor oil with an R12 System may
reduce the durability of the A/C system.
E102507 (2) Because HFC-134a (R134a) compressor oil is highly
absorbent, seal all openings with a plug or vinyl tape as
soon as A/C parts are removed
(3) Because HFC-134a (R134a) compressor oil may damage
acrylic materials, do not splash the oil.
(d) About O-Rings
(1) Be sure to use O-ring for HFC-134a (R134a).
HINT:
For the material or size of O-rings for HFC-134a (R134a)
and R12 is different, gas leakage may cause by using
wrong type.
R12 O-ring
Gas Leak
E102508J02
GETtheMANUALS.org
AC–26 AIR CONDITIONER - REFRIGERANT HFC - 134a (R134a)
(e) PRECAUTIONS FOR VACUUM PURGING

(1) To perform vacuum purging, install the vacuum pump for
R12 to the solenoid valve adapter.
HINT:
If a solenoid valve adapter is not used during and after vac-
uum purging, oil (for R12) may reflux into the HFC-134a
AC (R134a) system from the vacuum pump.
(f) CHECK REFRIGERANT LEAKAGE
Halogen Leak Detector
(1) Use a halogen gas leak detector to check for refrigerant
leaks.
HINT:
• Standard halide torch type leak testers cannot be used
because HFC-134a (R134a) does not contain chlorine.
• The standard electric gas leak tester also may be inac-
curate because it may not be sensitive enough to detect
HFC-134a (R134a), which is has smaller molecules
E102509J02 than R12.
(2) When checking for refrigerant leakage, turn IG OFF.
HINT:
• If the check is performed while the engine is running,
results may be inaccurate because leaked gas may be
diluting by fan or blower wind.
• If the check is performed when the cooler is operating,
gas may not leak because refrigerant pressure in the
cooler unit decreases when the unit is in operation.
• If the check is performed when the cooler is operating,
results may be inaccurate because the electric gas leak
tester may react to sudden humidity changes caused by
wet air coming in from the drain hose (the HFC-134a
[R134a]model is especially sensitive).
2. PRECAUTIONS FOR REMOVAL AND INSTALLATION
(a) TREATMENT IN EVENT THAT REFRIGERANT GETS IN
EYES
(1) Do not rub your eyes with your hands or with a handker-
chief.
(2) See an eye specialist for treatment.
(b) HANDLING PRECAUTIONS FOR REFRIGERANT (SERVICE
CAN)
(1) Do not heat a service can. If a service can is heated
directly or put into boiled water, the pressure inside the can
may increase to dangerous levels and there is a danegr of
explosion. If it is absolutely necessary to heat a service
can, use only water with a temperature below 40°C.
(2) Do not drop or otherwise cause impact to the service can.
(3) Do not open the high pressure valve of the manifold gauge
while the engine is running. If the high pressure valve is
opened while the engine is operating, high pressure gas
may flow in the reverse direction and may cause the ser-
vice can to explode.
(4) Do not handle the service can in close proximity to your
head or face. Always wear safety glasses.
GETtheMANUALS.org
AIR CONDITIONER - REFRIGERANT HFC - 134a (R134a)
AC–27
(c) INSTALL PIPING

(1) Be sure to use a new O-ring.
HINT:
• Be sure to use O-ring for HFC-134a (R134a).
• Use a toothpick or soft thing to remove O-ring, being
careful not to damage the piping.
(2) Sufficiently apply compressor oil (ND-OIL8) to the O-ring.
(3) Position the hose piping naturally and do not forcibly bend,
AC
twist or turn it.
E102510 (4) Do not use cotton work gloves to avoid refrigerant leakage
caused by cotton wastes or foreign objects on the O-ring.
ADJUSTMENT
1. DRAIN REFRIGERANT HFC - 134a (R134a)
(a) Turn the A/C switch ON.
(b) At an engine speed of approximately 1000 r/min, operate the
cooler compressor for 5 to 6 minutes in order to circulate the
refrigerant and collect into the cooler as much of the compres-
sor oil remaining in each component as possible.
(c) Stop the engine.
(d) Connect the refrigerant collection and recycling device to dis-
charge the refrigerant.
NOTICE:
Use the refrigerant collection and recycling device properly
in accordance with its instruction manual.
2. CHARGE REFRIGERANT HFC - 134a (R134a)

(a) Perform vacuum purging using a vacuum pump.
(b) Charge refrigerant HFC - 134a (R134a).
Charge Volume
Additional Charge 100 g Centering On Appropriate Value
rI Overcharge
High Pressure
Shelf
Bubbles Disappear
Shelf
Cooling Volume
Sub-cooling Cycle
E100257J07
Standard:
300 ± 30 g (RHD)
350 ± 30 g (LHD)
GETtheMANUALS.org
AC–28 AIR CONDITIONER - REFRIGERANT HFC - 134a (R134a)
NOTICE:
Do not operate the cooler compressor before charging it
with refrigerant. Without refrigerant, the system may burn-
out due to insufficient lubrication.
HINT:
Because the collection rate of the refrigerant collection and
AC recycling device is 90%, prepare a service can in order to add
refrigerant when reusing refrigerant gas collected using a refrig-
erant collection and recycling device.
3. WARM UP ENGINE
NOTICE:
After charging the refrigerant, warm-up the engine for at least 2
minutes, keeping the engine speed below 2000 r/min.
4. CHECK FOR REFRIGERANT LEAKS

(a) After recharging the refrigerant gas, check for refrigerant eak-
age using a halogen leak detector.
GETtheMANUALS.org
AIR CONDITIONER - REFRIGERANT LINE
AC–29
REFRIGERANT LINE
HEATER
AIR CONDITIONER
COMPONENTS
AC
COOLER REFRIGERANT DISCHARGE HOSE NO. 1
T=10{102}
T=10{102} T=9.8{100}
T=10{102} T=10{102}
AIR CONDITIONER TUBE

AND ACCESSORY ASSEMBLY
COOLER REFRIGERANT SUCTION HOSE NO. 1

E128495J01
GETtheMANUALS.org
AC–30 AIR CONDITIONER - AIR CONDITIONER PANEL
AIR CONDITIONER PANEL

HEATER
AIR CONDITIONER
COMPONENTS
AIR MIX DAMPER CONTROL CABLE

AC
AIR INLET DAMPER CONTROL CABLE

BULB HEATER CONTROL
NO. 3
DEFROSTER DAMPER CONTROL CABLE

BULB
BULB
HEATER CONTROL BASE
INSTRUMENT CLUSTER FINISH PANEL CTR
E128477J01
REMOVAL
1. DISCONNECT INSTRUMENT CLUSTER FINISH PANEL CTR (See
page IP-9)
2. DISCONNECT AIR MIX DAMPER CONTROL CABLE (See page

IP-9)
3. DISCONNECT DEFROSTER DAMPER CONTROL CABLE (See

page IP-9)
4. DISCONNECT AIR INLET DAMPER CONTROL CABLE (See page

IP-9)
GETtheMANUALS.org
AIR CONDITIONER - AIR CONDITIONER PANEL
AC–31
DISASSEMBLY
1. REMOVE HEATER CONTROL NO. 3
(a) Detach the 2 claws and then remove heater control knob No. 3.
AC
Claw E130972J01
(b) Remove the valve.
I100696
2. REMOVE HEATER CONTROL

(a) Detach the 2 claws and remove heater control No. 1.
Claw E130970J01
I100698
GETtheMANUALS.org
AC–32 AIR CONDITIONER - AIR CONDITIONER PANEL
3. REMOVE HEATER CONTROL

(a) Detach the 2 claws and remove heater control No. 2.
AC
Claw E130971J01
4. REMOVE HEATER CONTROL BASE

(a) Remove the 4 screws and the heater control base.
REASSEMBLY
1. INSTALL HEATER CONTROL BASE
(a) Install the heater control base with the 4 screws.
I100700
2. INSTALL HEATER CONTROL

(a) Install the valve.
I100700
(b) Engage the 2 claws to install heater control No. 2.
Claw E130971J01
3. INSTALL HEATER CONTROL

I100698
GETtheMANUALS.org
AIR CONDITIONER - AIR CONDITIONER PANEL
AC–33
(b) Engage the 2 claws to install heater control No. 1.
AC
Claw E130970J01
4. INSTALL HEATER CONTROL NO. 3

I100696
(b) Engage the 2 claws to install heater control knob No. 3.
INSTALLATION
1. INSTALL AIR INLET DAMPER CONTROL CABLE (See page IP-
20)
2. INSTALL DEFROSTER DAMPER CONTROL CABLE (See page IP-

20)
3. INSTALL AIR MIX DAMPER CONTROL CABLE (See page IP-21)

Claw E130972J01
4. INSTALL INSTRUMENT CLUSTER FINISH PANEL CTR (See page

IP-21)
GETtheMANUALS.org
AC–34 AIR CONDITIONER - HEATER CONTROL NO. 1

HEATER
AIR CONDITIONER
INSPECTION
1. CHECK HEATER CONTROL
AC A/C Switch (1) Using the tester, check the continuity between each of the
connecter terminals of heater control No. 1.
Standard:
Terminal No. (Terminal

Measurement Condition Continuity
Name)
3 (E) ←→ 2 (L) The A/C switch is OFF. None
4 (B) ←→ 2 (L) The A/C switch is OFF. None
3(E) ←→ 4 (B) Always Continuity
3 (E) ←→ 2 (L) The A/C switch is ON Continuity
4 (B) ←→ 2 (L) The A/C switch is ON Continuity
ILL+ ' 5 (ILL+) ←→ 6 (ILL-) Always Continuity

(1) Connect the positive battery lead to terminal 5 of the con-
nector, and the negative battery lead to terminal 6, then
check that the illumination of heater control No. 1 comes
on.
ILL- $ L
I100849J01
GETtheMANUALS.org
AIR CONDITIONER - HEATER CONTROL NO. 2
AC–35

HEATER
AIR CONDITIONER
INSPECTION
1. CHECK HEATER CONTROL
M1
LO
30° 30°
M2
(1) Using the tester, check the continuity between each of the AC
connecter terminals of heater control No. 2.
30° 30° Standard
OFF HI
Switch Continuity
Name)
OFF Terminals ←→ 5 (E) None
LO 9 (LO) ←→ 5 (E) Continuity
9 (LO) ←→ 5 (E) ←→ 7
LO ←→ M1 Continuity
(M1)
9 (LO) ←→ 5 (E) ←→ 7
M1 Continuity
(M1)
E ILL+ ILL-
9 (LO) ←→ 5 (E) - 7 (M1)
M1 ←→ M2 Continuity
←→ 6 (M2)
9 (LO) ←→ 5 (E) ←→ 6
M2 Continuity
(M2)
9 7 9 (LO) ←→ 5 (E) ←→ 6
M2 ←→ HI Continuity
(M2) ←→ 10 (HI)
HI LO M1 M2 9 (LO) ←→ 5 (E) ←→ 10
HIGH Continuity
I100852J01
(H1)

on.
GETtheMANUALS.org
AC–36 AIR CONDITIONER - HEATER CONTROL NO. 3

HEATER
AIR CONDITIONER
INSPECTION
1. CHECK HEATER CONTROL NO. 3
AC Rr Defogger
(1) Using the tester, check the continuity between each No. 3
heater control connecter terminals.
Standard:

Name)
3 (IG) ←→ 1 (E) Rr DEF switch OFF None
3 (IG) ←→ 1 (E) Rr DEF switch OFF Continuity
3 (IG) ←→ 2 (Rr DEF) Rr DEF switch OFF None
MAX COOL MAX HOT 3 (IG) ←→ 2 (Rr DEF) Rr DEF switch OFF Continuity
The dial is set to a posi-
V/B ILL+ IG 3 (IG) ←→ 6 (MAX HOT) tion other than MAX None
HOT
The dial is set to MAX
3 (IG) ←→ 6 (MAX HOT) Continuity
HOT
4 (ILL-) ←→ 5 (ILL+) Always Continuity
SG E The dial is set to MAX
7 (V/B) ←→ 8 (SG) None
HOT
MAX-HOT ILL- RrDEF
I100850J01 The dial is set to a posi-
7 (V/B) ←→ 8 (SG) tion other than MAX Continuity
HOT

on.
(c) CHECK INDICATOR ILLUMINATION
nector, and the negative battery lead to terminal 1, and
when the Rr DEF Switch is ON, check that the illumination
of heater control No. 3 comes on.
GETtheMANUALS.org
AIR CONDITIONER - HEATER CONTROL NO. 3
AC–37
(d) CHECK RESISTANCE

270° (1) Using the tester, measure the resistance between the
connecter 7 (V/B) and 8 (SG) while the dial is being
turned.
Standard:
The resistance will change in the manner shown in
the illustration AC
MAX COOL MAX HOT
V/B
SG
Resistance
0° 10° 135° 260° 270°
MAX HOT MAX COOL Rotation

Angle
I100851
GETtheMANUALS.org
AC–38 AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSEMBLY
AIR CONDITIONING RADIATOR ASSEMBLY

HEATER
AIR CONDITIONER
COMPONENTS
AC
AIR CONDITIONER UNIT ASSEMBLY
T=9.8{100}
INSTRUMENT PANEL REINFORCEMENT
DOOR CONTROL RECEIVER
INSTRUMENT PANEL BRACE NO. 1
TIGHTENING TORQUE
E132139J02
GETtheMANUALS.org
AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSEMBLY
AC–39
AC
AIR DUCT
AIR INLET DAMPER

CONTROL CABLE
LINK PLATE
DOOR ASSEMBLY
BLOWER UPPER CASE ASSEMBLY
x3
BLOWER LOWER CASE ASSEMBLY
BLOWER REGISTER
E132249J01
GETtheMANUALS.org
PIPE CLAMP HEATER OUTLET COOLANT HOSE

ACCESSORY ASSEMBLY
AC COOLER REFRIGERANT SUCTION

HEATER PIPE GROMMET
HOSE NO. 1
COOLER PIPE GROMMET

PIPE CLAMP
HEATER CASE RH
AIR MIX DAMPER

CONTROL CABLE
DOOR ASSEMBLY (FOR MODE)
HEATER CASE LH
DEFROSTER DAMPER
CONTROL CABLE
LINK PLATE
x8
LINK PLATE DOOR ASSEMBLY

(FOR AIR MIX)
HEATER CORE ASSEMBLY
T=2.0{20} AIR DUCT
EXPANSION VALVE
CLAMP
EVAPORATOR ASSEMBLY
PACKING
PACKING
T=2.0{20}
BLOWER LOWER CASE ASSEMBLY
APPLY COMPRESSOR OIL (ND-OIL8)

E134288J01
GETtheMANUALS.org
AC–41
REMOVAL
HINT:
• See page IP-2 for the instrument panel safety pad components
1. REMOVE REFRIGERANT HFC - 134a (R134a) (See page AC-27)
2. REMOVE AIR CONDITIONING TUBE AND ACCESSORY ASSEM-

BLY
AC
(a) Check the direction in which the quick joint remover (high pres-
sure use) should be inserted.
HINT:
Set the quick joint remover (high pressure use) so that the stop-
per side is on the piping clamp lock side.
(b) Insert the quick joint remover (high pressure use) into the pipe
Clamp Lock Side
clamp.
Stopper
Insert From The Side

With The Guard
Indicates Direction
quick joint remover To Insert Clamp
(high pressure use)
E015841J02
(c) Press the quick joint remover (high pressure use) with your
thumb while holding the pipe with both hands.
NOTICE:
Be careful not to bend the pipe by applying excessive force
Push to the pipe.
(d) Push the quick joint remover (high pressure use) back until the
stopper lightly touches the pipe.
E015842
(e) Lift the quick joint remover (high pressure use) stopper and
Stopper remove the piping clamp together with the quick joint remover
(high pressure use) from the pipe.
(f) Remove the piping clamp from the quick joint remover (high
Return
pressure use) .
(g) Remove the air conditioning tube and accessory assembly.
(h) Remove the 2 O-rings from the air conditioning tube & acces-
sory assembly.
Pipe(Tube) NOTICE:
E015840 • Do not apply excessive force to the air conditioning
tube and accessory assembly.
• Seal the opening of the disconnected hose using vinyl
tape to prevent moisture and foreign matter from enter-
ing.

HINT:
Using the quick joint remover (high pressure use), disconnect it using
the same procedure as that for the air conditioning tube and the
accessory assembly.
GETtheMANUALS.org
4. DISCONNECT HEATER INLET WATER HOSE (See page EM-44)
5. DISCONNECT HEATER OUTLET WATER HOSE (See page EM-44)
6. REMOVE INSTRUMENT PANEL WITH PASSENGER AIRBAG

ASSEMBLY
HINT:
AC See page IP-8 for the procedure leading up to the removal of the
instrument panel.
7. REMOVE AIR DUCT (DRIVER SIDE)
(a) Remove the screw.
(b) Disengage the claws and remove the air duct (driver side).
: Claw E131450J01
8. REMOVE AIR DUCT (PASSENGER SIDE)

(a) Disengage the claws and remove the air duct (passenger side).
9. REMOVE DOOR CONTROL RECEIVER (WITH WIRELESS DOOR

LOCK)
: Claw E131451J01
(b) Remove the bolt and the door control receiver.
10. REMOVE TRANSMISSION CONTROL COMPUTER ASSEMBLY

(TRANSMISSION A/T) (See page AT-98)
11. REMOVE ECM (See page ES-139)
E131452
12. REMOVE AIR DUCT

(a) Remove the 2 bolts and air duct.
13. REMOVE INSTRUMENT PANEL BRACE NO. 1

(a) Detach the clamps and disconnect the wire harness.
E132140
GETtheMANUALS.org
AC–43
(b) Remove the 3 bolts and nut, and then remove instrument panel
brace No. 1.
14. REMOVE STEERING COLUMN ASSEMBLY

(See page SR-4)
15. REMOVE INSTRUMENT PANEL REINFORCEMENT

(a) Remove the connectors and clamps, and then disconnect the
wire harness.
AC
(b) Remove the 6 bolts and nut, and then remove the instrument
: Clamp E132248J01 panel reinforcement.
: Clamp
E131454J01
16. REMOVE AIR CONDITIONER UNIT ASSEMBLY

(a) Remove the connectors and clamps, and then disconnect the
wire harness.
(b) Remove the 2 bolts and air conditioner unit assembly.
17. DISCONNECT TRANSPONDER KEY ECU ASSEMBLY
: Clamp E131455J01
GETtheMANUALS.org
18. DISCONNECT AIR INLET DAMPER CONTROL CABLE

(a) Disengage the 3 claws and remove the air inlet control cable.
19. REMOVE BLOWER MOTOR (WITH FAN) (See page AC-64)
20. REMOVE BLOWER REGISTER (See page AC-59)

DISASSEMBLY
AC
Claw E131461J01
21. DISCONNECT DEFROSTER DAMPER CONTROL CABLE

(a) Using a screwdriver with the tip taped, disengage the claw and
remove the defroster damper control cable.
Protective Tape
E133921J01
22. DISCONNECT AIR MIX DAMPER CONTROL CABLE

(a) Using a screwdriver with the tip taped, disengage the claw and
remove the air mix damper control cable.
Protective Tape 23. DISCONNECT HEATER CORE ASSEMBLY
(a) Disengage the 5 screws and claws, and remove the blower
case (lower) and heater case.
(b) Disengage the 3 screws and claws, and remove the blower
case assembly (upper and lower).
(c) Disengage the 8 screws and claws, and remove the heater
E133920J01
case assembly.
(d) Remove the heater core assembly from the air conditioner radi-
ator assembly.
24. REMOVE EXPANSION VALVE

(a) Remove the packing from the air conditioner tube assembly.
(b) Using a 4 mm hexagon wench, remove the 2 hexagon bolts.
Then remove the air conditioner tube assembly and the expan-
sion valve.
(c) Remove the 2 O-rings from the air conditioner tube assembly.
25. REMOVE EVAPORATOR ASSEMBLY

(a) Using a 4 mm hexagon wench, remove the 2 hexagon bolts and
the air conditioner tube assembly.
(b) Remove the 2 O-rings from the evaporator assembly.
(c) Remove cooler thermistor No. 1together with the evaporator
assembly.
GETtheMANUALS.org
AC–45
26. REMOVE COOLER THERMISTOR NO. 1

(a) Remove cooler thermistor No. 1 from cooler evaporator No. 1.
REASSEMBLY
AC
E131459
27. INSTALL COOLER THERMISTOR NO. 1

(a) Install the new cooler thermistor No. 1 in the position shown in
A [1] the illustration.
NOTICE:
• Do not insert the thermistor more than once in order to
B maintain the thermistor's durability.
• When reusing the evaporator, insert the thermistor into
a position on the left or right of the previous position.
(Within the [1] range, as shown in the illustration)
• Do not apply excessive force to the lead after inserting
the thermistor.
• Insert the resin case straight into the evaporator until
the end of the resin case (A) touches that of (B).
28. INSTALL EVAPORATOR ASSEMBLY

E131460J01 (a) Install cooler thermistor No. 1 together with the evaporator
assembly.
(b) Sufficiently apply compressor oil (ND-OIL8) to 2 new O-rings
and the evaporator assembly of the air conditioner tube assem-
bly.
(c) Install the 2 O-rings on the air conditioning tube assembly.
NOTICE:
Do not allow foreign matter to attach to the O-ring or O-ring
seal.
(d) Using a 4 mm hexagon wrench, install the air conditioning tube
assembly with the 2 hexagon bolts.
29. INSTALL EXPANSION VALVE

(a) Sufficiently apply compressor oil (ND-OIL8) to 2 new O-rings
and the expansion valve of the air conditioning tube assembly.
(b) Install the 2 O-rings on the air conditioning tube assembly.
NOTICE:
seal.
(c) Install the expansion valve to the air conditioning tube assem-
bly.
(d) Sufficiently apply compressor oil (ND-OIL8) to 2 new O-rings
and the fitting surface of the expansion valve.
(e) Install the 2 O-rings on the air conditioning tube assembly.
NOTICE:
seal.
GETtheMANUALS.org
(f) Using a 4 mm hexagon wrench, install the air conditioning tube

assembly with the 2 hexagon bolts.
30. INSTALL HEATER CORE ASSEMBLY

(a) Install the heater core assembly to the air conditioning radiator
assembly.
AC (b) Attach the claw and install the heater case with the 8 screws.
(c) Attach the claw and install the blower case assembly (upper
and lower) with the 3 screws.
(d) Attach the claw and install the blower case (lower) and heater
case with the 5 screws.
(e) When reusing the blower case (lower), use screws given for
A A repair and tighten the positions (8 locations) in the diagram.
A:
B B BLOWER CASE ASSEMBLY (UPPER AND LOWER) 4
LOCATIONS
A B:
BLOWER CASE ASSEMBLY (INSIDE AND OUTSIDE GAS
B B CASE) 4 LOCATIONS
A
E133910J01
31. INSTALL AIR MIX DAMPER CONTROL CABLE

(a) Set the temperature adjusting dial to MAX-COOL.
(b) Push the air mix door gear to the stopper pin on the MAX-COOL
side.
(c) Attach the gear on the cable side to the air mix door gear, and
HOT install the air mix damper control cable.
NOTICE:
• Do not damage the cable with metal edge or others.
COOL
• Do not bend the cable.
Stopper Pin E131485J01 • If the gear is misaligned, it may cause malfunction.
32. INSTALL DEFROSTER DAMPER CONTROL CABLE

(a) Set the air inlet control dial to the FACE mode.
(b) Push the mode door gear to the stopper pin on the FACE side.
(c) Attach the gear on the cable side to the air mix door gear, and
install the defroster damper control cable.
DEF NOTICE:
FACE • Do not bend the cable.
• If the gear is misaligned, it may cause malfunction.
Stopper Pin E131487J01
INSTALLATION
1. INSTALL BLOWER REGISTER (See page AC-59)
2. INSTALL BLOWER MOTOR (WITH FAN) (See page AC-64)
GETtheMANUALS.org
AC–47
3. INSTALL AIR INLET DAMPER CONTROL CABLE

(a) Set the air inlet control dial to the FRESH AIR mode.
Stopper Pin
(b) Install by inserting the air inlet damper control cable pin into the
air inlet door side link groove.
Inside Air NOTICE:
• Do not bend the cable.
• If the gear is misaligned, it may cause malfunction.
AC
Atmosphere
E131486J01
(c) Attach the 3 claws to install the air inlet damper control cable.
4. INSTALL TRANSPONDER KEY ECU ASSEMBLY
Claw E131461J01
5. INSTALL AIR CONDITIONER UNIT ASSEMBLY

(a) Install the air conditioner unit assembly with the 2 bolts.
(b) Install the wire harness with the clamps and connectors.
6. INSTALL INSTRUMENT PANEL REINFORMCEMENT

(a) Install the instrument panel reinforcement with the 6 bolts and
nut.
: Clamp E131455J01
GETtheMANUALS.org
(b) Install the wire harness with the clamps and connectors.
AC
: Clamp
E131454J01
7. INSTALL STEERING COLUMN ASSEMBLY

(See page SR-7)
8. INSTALL INSTRUMENT PANEL BRACE NO. 1
(a) Install instrument panel brace No. 1(transmission A/T) with the
5 bolts and nut.
(b) Install instrument panel brace No. 1(transmission A/T) with the
3 bolts and nut.
(c) Install the harness with the clamps.
: Clamp
E132248J01
GETtheMANUALS.org
AC–49
9. INSTALL AIR DUCT.

(a) Install the air duct with the 2 bolts.
10. INSTALL ECM (See page ES-139)
11. INSTALL TRANSMISSION CONTROL COMPUTER ASSEMBLY

(TRANSMISSION A/T) (See page AT-99)
12. INSTALL DOOR CONTROL RECEIVER (WITH WIRELESS DOOR AC

LOCK)
(a) Install the door control receiver with the bolts.
E132140
13. INSTALL AIR DUCT (PASSENGER SIDE)

(a) Attach the claw and install the air duct (passenger side).
14. INSTALL AIR DUCT (DRIVER SIDE)

(a) Attach the claws.
(b) Install the air duct (driver side) with the screws.
15. INSTALL INSTRUMENT PANEL WITH PASSENGER AIRBAG

ASSEMBLY
(See page IP-15.)
16. INSTALL HEATER OUTLET WATER HOSE (See page EM-67)
17. INSTALL HEATER INLET WATER HOSE (See page EM-67)

(a) Remove the attached vinyl tape from the connected part of
cooler refrigerant suction hose No. 1and the air conditioner tube
assembly.
(b) Sufficiently apply compressor oil (ND-OIL8) to 2 new O-rings
and the fitting surface of the air conditioning tube assembly .
(c) Install the 2 O-rings on the No. 1 cooler refrigerant suction
hose.
NOTICE:
Do not allow foreign objects caught on the O-ring or O-ring
seal.
(d) Press down on the seal hole until it fits with the hose joint axis
core.
(e) Install cooler refrigerant discharge hose No. 1 with the pipe
clamp.
NOTICE:
Make sure that the pipe clamp fits securely.
19. INSTALL AIR CONDITIONER TUBE AND ACCESSORY ASSEM-

BLY
HINT:
Install the air conditioner tube and accessory assembly by following
the same procedure as that used to install cooler refrigerant dis-
charge hose No. 1.
20. CHARGE REFRIGERANT HFC - 134a [R134a] (See page AC-27)
21. WARM UP ENGINE (See page AC-28)
22. CHECK FOR REFRIGERANT LEAKS (See page AC-28)
GETtheMANUALS.org
AC–50 AIR CONDITIONER - COOLER COMPRESSOR ASSEMBLY

HEATER
AIR CONDITIONER
COMPONENTS
AC
COOLER COMPRESSOR
WITH MAGNETIC CLUTCH
ASSEMBLY T=25{255}
T=9.8{100}
COOLER REFRIGERANT DISCHARGE HOSE NO. 1

O-RING
O-RING T=25{255}
COOLER REFRIGERANT SUCTION HOSE NO. 1

T=9.8{100}
COOLER COMPRESSOR
SNAP RING ASSEMBLY
SNAP RING
T=18{185}
PLATE WASHER

E131083J02
GETtheMANUALS.org
AIR CONDITIONER - COOLER COMPRESSOR ASSEMBLY
AC–51
REMOVAL

(a) Remove the bolt and disconnect cooler refrigerant discharge
AC
hose No. 1.
(b) Remove the O-ring from the No. 1 cooler refrigerant discharge
hose.
NOTICE:
Seal the opening of the disconnected cooler refrigerant
discharge hose No. 1 and cooler compressor assembly
using vinyl tape to prevent moisture and foreign matter
E131084 from entering.
5. REMOVE COOLER REFRIGERANT SUCTION HOSE NO. 1

(a) Remove the bolt and disconnect cooler refrigerant suction hose
No. 1.
(b) Remove the O-ring from the No. 1 cooler refrigerant suction
hose.
NOTICE:
6. REMOVE COOLER COMPRESSOR WITH MAGNETIC CLUTCH

ASSEMBLY
(b) Remove the 4 bolts and cooler compressor with magnetic
clutch assembly.
E131086
GETtheMANUALS.org
DISASSEMBLY
1. REMOVE MAGNETIC CLUTCH ASSEMBLY
(a) Apply current to magnetic clutch assembly and secure the hub
and rotor.
AC (b) Remove the bolt, the magnetic clutch's hub and the magnetic
clutch's washers.
HINT:
The number of washers used to adjust the magnetic clutch
clearance may vary.
E131145
(c) Using SST, remove the snap ring and clutch rotor from cooler
compressor assembly.
SST 09904-00010 (09904-00050)
NOTICE:
Do not damage the bearing seal cover when removing the
snap ring.
(d) Detach the screws and disconnect the ground wire.
(e) Disconnect the the magnetic clutch assembly connector.
E052164
(f) Using SST, remove the snap ring and the magnetic clutch stator
from the cooler compressor assembly.
SST 09904-00010 (09904-00050)
REASSEMBLY
E037448
2. INSTALL MAGNETIC CLUTCH ASSEMBLY

(a) Install the magnetic clutch stator to the cooler compressor
assembly as shown in the illustration.
E104623
GETtheMANUALS.org
AC–53
(b) Using SST, install a new snap ring at chamfered side up.
SST 09904-00010 (09904-00050)
(d) Connect the ground wire with screws.
(e) Install the magnetic clutch rotor to the cooler compressor
assembly.
Chamfered
Surface AC
← →
Inside Outside
E069084J01
(f) Using SST, install a new snap ring at chamfered side up.
SST 09904-00010 (09904-00050)
NOTICE:
• Do not expand the inside diameter more than φ30.5mm
when installing the snap ring.
• Do not damage the bearing seal cover when installing
Chamfered the snap ring.
Surface (g) Temporarily install the magnetic clutch washer and hub to the
← →
Inside Outside cooler compressor assembly using bolts.
E069085J01 NOTICE:
Use the exact combination of washers for the magnetic
clutch as that used before disassembly.
(h) Apply current to the magnetic clutch assembly and secure the
hub and rotor.
(i) Wrap the V belt around the pulley, hold the pulley securely with
your hand and tighten the bolt.
NOTICE:
• When tightening the bolt, do not allow oil or foreign
matter to come in contact with the clutch hub seating
surface, or to be caught in between the compressor
shaft edge and the screw or between the bolt seating
surface and the screw.
E131145
3. CHECK MAGNETIC CLUTCH AIR GAP

(a) Set the dial gauge so that it is perpendicular to the magnetic
clutch hub.
(b) Connect the positive battery lead to terminal 1 of the connector,
and the negative battery lead to the ground wire. Turn the mag-
netic clutch ON and OFF, and measure the air gap when the
magnetic clutch is OFF.
Standard:
0.5 (+0.15, -0.20) mm
E131146 (c) If the result is not as specified, remove the clutch hub and
adjust by changing the number of the magnetic clutch washers.
NOTICE:
Do not use more than 3 magnetic clutch washers in making
the adjustment.
GETtheMANUALS.org
INSTALLATION
1. CHECK COMPRESSOR OIL AMOUNT
(a) When replacing the cooler compressor assembly with a new
one, first gradually discharging inert gas (helium) from the ser-
vice valve, then drain the oil from the new cooler compressor
AC assembly (using the calculation shown below). When this pro-

cedure is complete, install the new cooler compressor assembly
.
Standard:
(Oil amount in the new cooler compressor assembly 80
[+20] ml) - (Remaining oil amount in the removed cooler
compressor assembly) = (Oil amount to be removed
when replacing the assembly)
NOTICE:
• Observe the precautions found in the removal/installa-
tion procedures when checking the amount of compres-
sor oil.
• Compressor oil remains in the pipes of the vehicle. Oil
is subtracted from the new cooler compressor assem-
bly in order to compensate for this oil remaining in the
pipes. If oil is not subtracted, the amount of oil will be
excessive, preventing heat exchange in the refrigerant
cycles and causing refrigeration failure.
• If the volume of oil remaining in the removed cooler
compressor assembly is too small, check for oil leak-
age.
• Use only ND-OIL 8 for the compressor oil.
ASSEMBLY
(a) Temporarily tighten the cooler compressor assembly with the
bolts.
E131143
(b) Install the cooler compressor assembly with the 3 bolts.

(4)
NOTICE:
Tighten the bolts in the order shown in the illustration.

(1)
(a) Remove the attached vinyl tape from the connecter part of
(3)
cooler refrigerant suction hose No. 1 and the air conditioner
(2) tube assembly.
E131086J01
(b) Sufficiently apply compressor oil (ND-OIL8) to new O-ring and
the fitting surface of the cooler compressor assembly.
(c) Install the O-ring on the No. 1 cooler refrigerant suction hose.
NOTICE:
seal.
GETtheMANUALS.org
AC–55
(d) Install cooler refrigerant suction hose No. 1 with the bolt.

cooler refrigerant suction hose No. 1 and the air conditioner
tube assembly.
(b) Sufficiently apply compressor oil (ND-OIL8) to new O-ring and AC
the fitting surface of the cooler compressor assembly.
(c) Install the O-ring on the No. 1 cooler refrigerant discharge hose.
E131085
NOTICE:
seal.
(d) Install the No. 1 cooler refrigerant discharge hose with bolt.
5. INSTALL FAN AND ALTERNATOR V BELT (See page CH-10)

E131084

(See page SS-10 for details.)
INSPECTION
1. CHECK COOLER COMPRESSOR WITH MAGNETIC CLUTCH
ASSEMBLY
(a) Disconnect the cooler compressor assembly connector.
(b) Using the tester, check the continuity between connector termi-
nal 1 (MG+) and the ground.
Standard:
Continuity
(c) When connector terminal 1 (MG+) is connected to the positive
1 battery terminal and the body ground is connected to the nega-
tive battery terminal, check that the magnetic clutch makes a
sound indicating that it is operating, and check that the mag-
netic clutch's hub and rotor lock.
E130121
GETtheMANUALS.org
AC–56 AIR CONDITIONER - CONDENSER ASSEMBLY (WITH RECEIVER)
CONDENSER ASSEMBLY (WITH RECEIVER)

HEATER
AIR CONDITIONER
COMPONENTS
AC
T=5.0{51}
CONDENSOR ASSEMBLY (WITH RECEIVER)
O-RING
T=5.4{55} COOLER REFRIGERANT DISCHARGE
HOSE NO. 1
T=5.0{51}
O-RING
T=5.4{55}

SEAL PLATE
ACCESSORY ASSEMBLY
T=5.4{55}
ENGINE UNDER COVER

E131067J02
GETtheMANUALS.org
AIR CONDITIONER - CONDENSER ASSEMBLY (WITH RECEIVER)
AC–57
REMOVAL
4. REMOVE SEAL PLATE AC

(a) Remove the bolt and disconnect cooler refrigerant discharge
hose No. 1.
(b) Remove the O-ring from the No. 1 cooler refrigerant discharge
hose.
NOTICE:
6. REMOVE AIR CONDITIONING TUBE AND ACCESSORY ASSEM-

BLY
(a) Remove the air conditioner tube and accessory assembly.
(b) Remove O-ring from the air conditioning tube & accessory
assembly.
NOTICE:
Seal the opening of the disconnected air conditioner tube
and accessory assembly and condenser assembly (with
receiver) using vinyl tape to prevent moisture and foreign
E131069 object from entering.

(a) Remove 4 bolts and the condenser assembly (with receiver).
NOTICE:
Do not damage the condenser assembly (with receiver) or
the radiator assembly when removing the condenser
assembly (with receiver).
INSTALLATION
(2)
(1) (a) Install the condenser assembly (with receiver) using 4 bolts.
NOTICE:
• Do not damage the condenser assembly (with receiver)
or the radiator assembly when installing condenser
• Tighten the bolts in the order shown in the illustration.
(3)
(4) 2. INSTALL AIR CONDITIONER TUBE AND ACCESSORY ASSEM-
E133923J01
BLY
(a) Remove the attached vinyl tape from the connecter part of the
air conditioner tube and accessory assembly and the condenser
GETtheMANUALS.org
AC–58 AIR CONDITIONER - CONDENSER ASSEMBLY (WITH RECEIVER)

the fitting surface of the air conditioning tube & accessory
assembly.
(c) Install O-ring to the air conditioning tube & accessory assembly.
NOTICE:
AC seal.
(d) Install the air conditioner tube and accessory assembly with the
bolt.

cooler refrigerant discharge hose No. 1 and the condenser
the fitting surface of No. 1 cooler refrigerant discharge hose.
E131069
(c) Install the O-ring on No. 1 cooler refrigerant discharge hose.
NOTICE:
seal.
(d) Install cooler refrigerant discharge hose No. 1 with the bolt.

E131068

GETtheMANUALS.org
AIR CONDITIONER - BLOWER REGISTER
AC–59
BLOWER REGISTER
HEATER
AIR CONDITIONER
COMPONENTS
AC
BLOWER REGISTER
E130974J02
REMOVAL
IP-12)
2. REMOVE BLOWER REGISTER

(b) Remove the 2 screws and the blower register.
INSTALLATION
1. INSTALL BLOWER REGISTER
(a) Install the blower register with the 2 screws.

IP-17)
GETtheMANUALS.org
AC–60 AIR CONDITIONER - BLOWER REGISTER
INSPECTION
1. CHECK BLOWER REGISTER
(a) CHECK RESISTANCE
(1) Disconnect the connector of the blower register.
(2) Using the tester, check the resistance between the con-
AC necter terminals.
Standard
Terminal No. Standard

1 (HI) ←→ 4 (LO) 3.43 ± 0.24 Ω
1 (HI) ←→ 2 (MI) 1.03 ± 0.07 Ω
1 (HI) - 3 (M2) 0.47 ± 0.03 Ω
HINT:
E032877J01 There is thermal fuse between terminals 1, 2, 3 and 4.
GETtheMANUALS.org
AIR CONDITIONER - COOLER THERMISTOR NO. 1
AC–61

HEATER
AIR CONDITIONER
INSPECTION
1. CHECK COOLER THERMISTOR NO. 1
(a) CHECK REGISTANCE OF COOLER THERMISTOR NO. 1
(1) Using a tester, measure the resistance between terminals AC
1 and 2 of the connector.
Standard:
Temperature Standard
0°C 4.79 to 4.91 kΩ
15°C 2.25 to 2.44 kΩ
HINT:
• If the temperature sensor side is touched by hand,
body temperature will confuse the measurement.
Therefore, make sure to hold the connector side when
performing the measurements.
• Wait until the sensor adjusts to a stable ambient tem-
perature before performing the inspection.
E128427
GETtheMANUALS.org
AC–62 AIR CONDITIONER - HEATER RELAY NO. 1
HEATER RELAY NO. 1

HEATER
AIR CONDITIONER
INSPECTION
1. HEATER RELAY NO. 1
(a) CHECK THE CONTINUITY OF HEATER RELAY NO. 1
AC (1) Using the tester, check the continuity between each of the
Standard
Terminals Standard
1←→2 Continuity
E062721J01 (2) Using the tester, check the continuity between terminals 3
←→ 4 and between terminals 3 ←→ 5, when battery volt-
age is applied to terminals 1 and 2.
Standard:
Continuity
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AIR CONDITIONER - AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY
AC–63
AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY

HEATER
AIR CONDITIONER
1. CHECK AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY
(a) CHECK VEHICLE WIRE HARNESS
(1) Disconnect the connector of the pressure switch. AC
(2) Using the tester, check the continuity between the vehicle
wire harness side connector terminal 1 and the body
ground of the pressure switch.
Standard:
Continuity
(3) Turn IG ON and turn the A/C switch ON.
(4) Using the tester, check the voltage between the vehicle
wire harness side connector terminal 2 and terminal 1 of
the pressure switch.
E130120 Standard:
10 to 14 V
(b) CHECK PRESSURE SWITCH
(2) Start the engine and operate the cooler.
(3) Using the tester, check the continuity between the termi-
nals in the pressure switch.
Standard:
Depending on the refrigerant pressure, the continu-
ity standard will be like that shown in the illustra-
tion.
Continuity
No
Continuity
196 225 2550 3140 [kPa]
{2.0} {2.3} {26} {32}
{kgf/cm }
2
E128435J01
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AC–64 AIR CONDITIONER - BLOWER MOTOR (WITH FAN)

HEATER
AIR CONDITIONER
COMPONENTS
AC
E131190J01
REMOVAL
IP-12)
2. BLOWER MOTOR (WITH FAN)

(b) Remove the 3 screws, then remove the blower motor (with fan).
INSTALLATION
1. INSTALL BLOWER MOTOR (WITH FAN)
(a) Install the blower motor (with fan) with the 3 screws.

IP-17)
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AIR CONDITIONER - BLOWER MOTOR (WITH FAN)
AC–65
INSPECTION
1. CHECK BLOWER MOTOR (WITH FAN)
(a) CHECK OPERATION
check that the motor rotates to the position indicated by AC
the arrow on the illustration without making any noise.

I100853
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AC–66 AIR CONDITIONER - MAGNETIC CLUTCH RELAY

HEATER
AIR CONDITIONER
INSPECTION
1. CHECK MAGNETIC CLUTCH RELAY
(a) Using the tester, check the continuity between the connecter
AC terminals.
Standard:
Inspection Terminal Standard

1←→2 Continuity
E062721 (b) Apply battery voltage between connector terminals 1 and 2.

(c) Using the tester, check the continuity between terminals 3 and
5.
Standard:
Continuity
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TO INDEX
SRS AIRBAGS AND SEAT BELTS
SRS AIRBAG
SRS AIRBAG SYSTEM
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-1
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-6
DIAGNOSTIC TROUBLE CODE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . RS-7
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-11 RS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-12
HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . RS-15
CUSTOMER PROBLEM ANALYSIS CHECK SHEET. . . . . . . . . . . . . . . . . RS-18
CHECK / CLEAR DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-19
DIAGNOSIS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-20
ECU TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-22
B1000/31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-24
B1600/15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-25
B1605/15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-25
B1620/32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-33
B1625/33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-38
B1630/23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-43
B1635/24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-48
B1800/13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-53
B1801/14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-57
B1802/11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-61
B1803/12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-65
B1805/53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-69
B1806/54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-72
B1807/51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-75
B1808/52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-78
B1820/43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-81
B1821/44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-84
B1822/41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-87
B1823/42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-90
B1825/47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-93
B1826/48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-96
B1827/45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-99
B1828/46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-102
B1830/83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-105
B1831/84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-108
B1832/81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-111
B1833/82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-114
B1835/87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-117
B1836/88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-120
B1837/85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-123
B1838/86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-126
B1900/63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-129
B1901/64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-132
B1902/61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-135
B1903/62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-138
B1905/73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-141
B1906/74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-144
B1907/71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-147
B1908/72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-150
WARNING LIGHT DOES NOT TURN ON . . . . . . . . . . . . . . . . . . . . . . . . . . RS-153
WARNING LIGHT REMAINS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-155
POWER SOURCE VOLTAGE DROP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-158
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TC TERMINAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-161
SRS AIRBAGS
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-164
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-169
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-169
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-170
RS DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-171
SPIRAL CABLE
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-176
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-177
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-177
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-178
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-179
INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-180
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-181
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-182
DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-182
CURTAIN SHIELD AIRBAG RH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-187
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-187
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-189
DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-190
FRONT SEAT AIRBAG ASSEMBLY RH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-195
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-195
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-196
DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-196
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-201
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-202
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-203
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-205
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-206
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-207
SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-208
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-209
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-209
AIRBAG CUTOFF SWITCH CYLINDER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-211
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-212
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-212
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-213
FRONT AIRBAG SENSOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-214
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-215
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-216
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SRS AIRBAG - SRS AIRBAG SYSTEM
RS–1
SRS AIRBAG SYSTEM

SRS AIRBAG
AIRBAGS AND SEAT BELTS
OPERATION CHECK
1. CHECK AIRBAG WARNING LIGHT
(a) Check that the warning light comes on when the ignition switch
is turned on (IG).
(b) Check that the warning light goes off approximately 6 seconds
after the ignition switch is turned on (IG).
RS
HINT:
• If the warning light remains on for more than approximately
6 seconds after the ignition switch is turned on (IG), there is
a malfunction in the airbag and pretensioner system.
C093955 • If the warning light continues to come on occasionally even
after approximately 6 seconds has elapsed after the ignition
switch is turned on (IG), the cause may be a short to the +B
of the airbag warning system or a short or open ground.
• If the light remains on even when the ignition switch is
turned off or to the ACC position, there may be a failure in
the power supply system or in the combination meter
assembly.
2. CHECK HORN BUTTON ASSEMBLY
(a) For vehicles that have not been involved in a collision:
(1) If there are any of the following symptoms, replace the
horn button assembly with a new one.
Standard:
There are cracks, dents or chips on the horn button
assembly pad surface.
C140196
(b) For vehicles that have been involved in a collision without the
airbags being deployed:
CAUTION:
Follow these procedures correctly when replacing the horn
button assembly.
(1) If there are any of the following symptoms when removing
the horn button assembly, replace the assembly with a
new one.
Standard:
There are cracks, dents or chips on the horn button
assembly pad surface.
There are scratches, abrasions, cracks or other
damage to the connector and wire harness.
The horn button assembly has been dropped.
C140197
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RS–2 SRS AIRBAG - SRS AIRBAG SYSTEM

horn button assembly and steering wheel assembly with
new ones as a set.
Standard:
The horn button assembly and steering wheel
assembly interfere, making installation difficult.
The clearance when the horn button assembly and
steering wheel assembly have been installed is not
RS even.
C140198 There is deformation of the steering wheel
assembly bracket.
NOTICE:
If there is any deformation of the steering wheel
assembly bracket, do not attempt to repair it. Instead,
replace it with a new one.
3. CHECK INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY

instrument panel passenger airbag assembly with a new
one.
Standard:
There are cracks, dents or chips on the instrument
panel passenger airbag assembly surface.
CAUTION:
Follow the correct instrument panel passenger airbag
assembly replacement procedure.
(1) Remove the instrument panel passenger airbag assembly
and if there are any of the following symptoms, replace
the assembly with a new one.
Standard:
C137853 There are cracks, dents or chips on the instrument
panel passenger airbag assembly surface.
The instrument panel passenger airbag assembly
has been dropped.
There is deformation of the instrument panel
passenger airbag assembly bracket and the
instrument panel reinforcement bracket.
NOTICE:
If there is any deformation of the instrument panel
passenger airbag assembly bracket and instrument
panel reinforcement bracket, do not attempt to repair
the parts. Instead, replace the parts with new ones.
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RS–3
4. CHECK FRONT SEAT AIRBAG ASSEMBLY

front seat airbag assembly with a new one.
NOTICE:
When replacing the front seat airbag assembly,
replace it with the front seat assembly.
Standard:
There are cracks, dents or chips on the front seat RS
C132554 airbag assembly surface and grooved part.
CAUTION:
Follow the correct front seat airbag assembly replacement
procedure.
(1) Remove the front seat airbag assembly and if there are
any of the following symptoms, replace the assembly with
a new one.
Standard:
C132630 There are cracks, dents or chips on the front seat
airbag assembly surface.
The front seat airbag assembly has been dropped.
There is deformation of the front seat airbag
assembly bracket.
5. CHECK CURTAIN SHIELD AIRBAG ASSEMBLY
curtain shield airbag with a new one.
Standard:
There are cracks, dents, chips on or any other
deformation of the curtain shield airbag surface.
C137854 CAUTION:
Follow the correct curtain shield airbag replacement
procedure.
(1) Remove the curtain shield airbag and if there are any of
the following symptoms, replace the airbag with a new
one.
Standard:
There are cracks, dents, chips on or any other
deformation of the curtain shield airbag surface.
6. INSPECT AIRBAG COMPUTER ASSEMBLY

(a) For vehicles that have not been involved in a collision or
vehicles that have been involved in a collision without the
(1) Check for DTCs.
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(b) For vehicles that have been involved in a collision in which the
airbags deployed:
(1) Replace the airbag computer assembly with a new one.
7. CHECK FRONT AIRBAG SENSOR

(1) Check for DTCs.
(b) For vehicles that have been involved in a collision:
RS (1) Check for DTCs.

(2) If the front grille of the vehicle or any part around the grille
has been damaged and there are any of the following
symptoms, replace the front airbag sensor with a new one
even if the airbag has not deployed.
Standard:
There is deformation of the installation part or
missing paint.
damage to the front airbag sensor and connector.
There is damage to the serial number.
8. CHECK SIDE AIRBAG SENSOR ASSEMBLY

(1) Check for DTCs.
(b) For vehicles that have not been involved in a collision:
(1) Check for DTCs.
(2) If the side pillar of the vehicle or any part around the side
pillar has been damaged and there are any of the
following symptoms, replace the side airbag sensor
assembly with a new one even if the airbag has not
deployed.
Standard:
There is deformation of the bracket or paint
missing.
There are scratches, cracks or other damage to the
side airbag sensor assembly and connector part.
There is damage to the serial number or the label is
peeled off.
9. CHECK SIDE AIRBAG SENSOR ASSEMBLY NO. 2

(a) For vehicles that have not been involved in a collision or
vehicles that have been involved in a collision without the
(1) Check for DTCs.
(1) Check for DTCs.
(2) If the C pillar of the vehicle or any part around the C pillar
has been damaged and there are any of the following
symptoms, replace the airbag sensor rear with a new one
even if the airbag has not deployed.
Standard:
There is deformation of the bracket or paint
missing.
damage to the airbag sensor rear or connector.
There is damage to the serial number or the label is
peeled off.
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RS–5
10. CHECK WIRE HARNESS AND CONNECTOR

(1) Check for DTCs.
(1) Check for DTCs.
(2) Check that there is no damage to the wire harness for the
airbag and all wire harnesses whose contact points have
been exposed.
(3) Check that there are no scratches, abrasions, cracks or RS
other damage to the connector of the wire harness for the
airbag.
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LOCATION
RS
AIRBAG WARNING
CURTAIN SHIELD AIRBAG LH
CURTAIN SHIELD AIRBAG RH FRONT SEAT

AIRBAG
ASSEMBLY LH
SPIRAL CABLE ASSEMBLY
FRONT AIRBAG
SENSOR (RHD) SIDE AIRBAG SENSOR
ASSEMBLY RH NO. 2
SIDE AIRBAG
SENSOR
ASSEMBLY LH
NO. 2
FRONT SEAT
OUTER BELT
FRONT AIRBAG SIDE AIRBAG ASSEMBLY LH
SENSOR (LHD) SENSOR SIDE AIRBAG
ASSEMBLY RH SENSOR ASSEMBLY LH
FRONT SEAT AIRBAG FRONT SEAT

ASSEMBLY RH OUTER BELT ASSEMBLY RH

C139737J01
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RS–7
Trouble area Check Mode Airbag warning Light code See Page
DTC No. Diagnostic Item
light memory
Sensor unit Airbag computer
B1000/31*4 *
1 { { RS-24
malfunction assembly
⋅ Front airbag
Right side front

sensor RH
⋅ Airbag computer
RS
mechanical assembly
B1600/15*4 *
1 { { RS-25
sensor ⋅ Instrument panel
malfunction wire
⋅ Engine room
main wire
⋅ Front airbag
sensor LH
Left side ⋅ Airbag computer
mechanical assembly
B1605/15*4 *1 { { RS-25
sensor ⋅ Instrument panel
malfunction wire
⋅ Engine room
main wire
⋅ Side airbag
sensor assembly
Right side B pillar
RH
B1620/32*4 sensor *2 { { RS-33
⋅ Airbag computer
malfunction
assembly
⋅ Floor wire No. 2
⋅ Side airbag
sensor assembly
Left side B pillar
LH
B1625/33*4 sensor *2 { { RS-38
⋅ Airbag computer
malfunction
assembly
⋅ Side airbag
sensor assembly
Right side C pillar
RH No. 2
B1630/23*4 sensor *2 { { RS-43
⋅ Airbag computer
malfunction
assembly
⋅ Side airbag
sensor assembly
Left side C pillar
LH No. 2
B1635/24*4 sensor *2 { { RS-48
⋅ Airbag computer
malfunction
assembly
⋅ Horn button
assembly
Short circuit ⋅ Spiral cable
between driver assembly
B1800/13 *2 { { RS-53
seat front collision ⋅ Airbag computer
igniter lines assembly
⋅ Instrument panel
wire
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light memory
⋅ Horn button
assembly
Open circuit in ⋅ Spiral cable
driver seat front assembly
B1801/14 *2 { { RS-57
collision igniter ⋅ Airbag computer
circuit assembly
RS wire
⋅ Horn button
assembly
Ground short ⋅ Spiral cable
circuit in driver assembly
B1802/11 *
2 { { RS-61
seat front collision ⋅ Airbag computer
igniter circuit assembly
wire
⋅ Horn button
assembly
Power supply
⋅ Spiral cable
short circuit in
assembly
B1803/12 driver seat front *
2 { { RS-65
⋅ Airbag computer
collision igniter
assembly
circuit
wire
Short circuit passenger airbag
between assembly
B1805/53 passenger seat ⋅ Airbag computer *2 { { RS-69
front collision assembly
igniter lines ⋅ Instrument Panel
Wire
passenger airbag
Open circuit in
assembly
passenger seat
B1806/54 ⋅ Airbag computer *2 { { RS-72
front collision
assembly
igniter circuit
wire Y
Ground short passenger airbag
circuit in assembly
B1807/51 passenger seat ⋅ Airbag computer *
2 { { RS-75
igniter circuit ⋅ Instrument Panel
Wire
Power supply passenger airbag
short circuit in assembly
B1808/52 passenger seat ⋅ Airbag computer *2 { { RS-78
igniter circuit ⋅ Instrument Panel
Wire
⋅ Front seat airbag
Short circuit assembly RH
B1820/43 between right side ⋅ Airbag computer *2 { { RS-81
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RS–9
light memory
assembly RH
Open circuit in
right side igniter
assembly
B1822/41
Ground short
circuit in right side
assembly RH
⋅ Airbag computer *
2 { { RS-87 RS
igniter assembly
Power supply assembly RH
B1823/42 short circuit in ⋅ Airbag computer *
2 { { RS-90
right side igniter assembly
Short circuit assembly LH
B1825/47 between left side ⋅ Airbag computer *2 { { RS-93
assembly LH
Open circuit in left
side igniter
assembly
Ground short assembly LH
B1827/45 circuit in left side ⋅ Airbag computer *2 { { RS-99
igniter assembly
Power supply assembly LH
B1828/46 short circuit in left ⋅ Airbag computer *
2 { { RS-102
side igniter assembly
⋅ Curtain shield
Short circuit airbag assembly
between right side RH
B1830/83 *2 { { RS-105
curtain igniter ⋅ Airbag computer
lines assembly
⋅ Curtain shield
airbag assembly
Open circuit in
RH
B1831/84 right side curtain *2 { { RS-108
⋅ Airbag computer
igniter
assembly
⋅ Curtain shield
airbag assembly
Ground short
RH
B1832/81 circuit in right side *2 { { RS-111
⋅ Airbag computer
curtain igniter
assembly
⋅ Curtain shield
Power supply airbag assembly
short circuit in RH
B1833/82 *2 { { RS-114
right side curtain ⋅ Airbag computer
igniter assembly
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light memory
⋅ Curtain shield
Short circuit airbag assembly
between left side LH
B1835/87 *
2 { { RS-117
curtain igniter ⋅ Airbag computer
lines assembly
⋅ Curtain shield
RS Open circuit
airbag assembly
LH
B1836/88 between left side *
2 { { RS-120
⋅ Airbag computer
curtain igniter
assembly
⋅ Curtain shield
airbag assembly
Ground short
LH
B1837/85 circuit in left side *
2 { { RS-123
⋅ Airbag computer
curtain igniter
assembly
⋅ Curtain shield
airbag assembly
Power supply
LH
B1838/86 short circuit in left *2 { { RS-126
⋅ Airbag computer
side curtain igniter
assembly
⋅ Front seat outer
belt assembly RH
Short circuit
(driver seat side
between front
B1900/63 pretensioner) *2 { { RS-129
right seat
⋅ Airbag computer
pretensioner lines
assembly
belt assembly RH
Open circuit in (driver seat side
B1901/64 front right seat pretensioner) *2 { { RS-132
pretensioner ⋅ Airbag computer
assembly
belt assembly RH
Ground short in (driver seat side
B1902/61 front right seat pretensioner) *
2 { { RS-135
assembly
belt assembly RH
Power supply
(driver seat side
short circuit in
front right seat
⋅ Airbag computer
pretensioner
assembly
belt assembly LH
Short circuit (passenger side
B1905/73 between front left pretensioner) *
2 { { RS-141
pretensioner lines ⋅ Airbag computer
assembly
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RS–11
light memory
belt assembly LH
Open circuit in (passenger side
B1906/74 front left side pretensioner) *
2 { { RS-144
assembly
⋅ Front seat outer RS
belt assembly LH
Ground short in (passenger side
B1907/71 front left seat pretensioner) *
2 { { RS-147
assembly
belt assembly LH
Power supply
(passenger side
short circuit in
front left seat
⋅ Airbag computer
pretensioner
assembly
HINT:
• *1: DTC is not corresponding to the check mode.
• *2: DTC is corresponding to the check mode.
• *3: Those code may appear not only due to a faulty airbag computer
assembly but also due to a malfunction that occurs in the igniter circuit.
• *4: Those code may appear not only due to a faulty airbag sensor but
also due to a malfunction that occurs in the ignition circuit.

The warning light remains on even after approximately Warning light system RS-155
6 seconds have elapsed after the ignition switch is
Power supply voltage system RS-158
turned on (IG).
The warning light does not come on even when the
Warning light system RS-153
ignition switch is turned on (IG).
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DESCRIPTION
1. CONNECTOR FUNCTIONS
9
25
Side Airbag Sensor Curtain Shield Airbag

Assembly LH
RS Assembly NO. 2
10
26
7
24
Side Airbag Sensor Front Seat Airbag

Assembly RH Assembly LH
8
24
5
21
Front Airbag Sensor 11 Front Seat Outer

Assembly 12 Belt Assembly LH
6
22
3
21
Front Seat Outer

Belt Assembly RH
4
22
1
23
Front Seat Airbag

Airbag Computer Assembly RH
Assembly
2
24
3
25
Curtain Shield
Airbag Assembly RH
4
26
7
17
13
Side Airbag Sensor
Assembly LH Spiral Cable Horn Button Assembly
8 14
18
9
19
15
Instrument Panel
Side Airbag Sensor
Passenger Airbag
Assembly LH NO. 2 16 Assembly
10
20
C142185
Mechanism Name Applicable Connectors

Terminal twin-lock mechanism 2, 4, 6, 8, 10, 11, 12, 13, 14, 15, 16, 17, 19, 21, 23, 25
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RS–13
Mechanism Name Applicable Connectors

Half connection prevention mechanism 6, 8, 10, 12, 13, 15, 23
Connector twin-lock mechanism 19
Terminal short circuiting mechanism 2, 4, 14, 16, 18, 20, 22, 24, 26
Connector lock mechanism (1) 17, 19, 21, 25
Half connection detection mechanism (CPA
6
connector)
(a) Terminal twin-lock mechanism RS

Spacer (Secondary Lock)
Lance (Primary Lock)
Primary Lock Secondary Lock C055220
(1) This mechanism increases the terminal holding power and

prevents the terminal from coming out.
(2) The connectors have a two-piece component consisting of
a housing and a spacer. This design enables the terminal to
be locked securely by the twin lock of the lance (primary
lock) and the spacer (secondary lock).
(b) Half connection prevention mechanism
Spring
Stopper Protrusion Slider Protruding Portion
Locking Portion Locking Arm Pushed Back By
Slider (Spring)
C054588
(1) This mechanism prevents half connection of the

connectors.
(2) If the connector is not completely connected, the spring
presses back the opposing connector (male) so that no
continuity exists.
(c) Connector twin-lock mechanism
(1) This mechanism is used in the connector of the wire
harness for ignition, and by double locking the pairs of
connectors (male, female), it improves the reliability of the
connection. The mechanism is designed so that if the
primary lock is not engaged, the protruding part prevents
the secondary lock from being engaged.
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(d) Terminal short circuiting mechanism
Open Shorted
Male Side Housing
Female Terminal
Male Side Terminal

Female Side Housing
RS
Short Spring Plate Short Spring Plate Contacts The
Male Side Terminal C138240
(1) This mechanism allows the airbag power supply terminal

and the ground terminal to automatically short circuit when
the connector is disconnected.
(2) The spring plate contained in each connector forms a
closed circuit (potential difference between the 2 terminals
does not occur) on the airbag side to prevent any mistaken
operation during servicing.
(e) Connector lock mechanism (1)
Lock The Locking Button
Claw
Groove
The Claw Of The Locking
Button Locks In The Groove
C067476
(1) This mechanism prevents the connectors from coming out.

(2) Locking the connector locking button engages the locking
button claws on both sides of the opposing connector to
connect the connector securely.
(f) Half connection detection mechanism (CPA connector)
Female Locking Portion

Secondary Lock
Connector Primary Lock
CPA Locking Portion
Male Connector G033081
(1) This mechanism detects half connection of the connectors.

(2) The CPA and female connector slide simultaneously to the
male connector side and the primary lock engages when
the female connector moves past the lock section of the
male connector. From this point, only the CPA moves on to
the male connector side, and the secondary lock engages
when the CPA stopper moves past the female connector.
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RS–15
When the connection is complete, the CPA and female

connector rear side align.
2. RELEASE TERMINAL SHORT CIRCUITING MECHANISM
Vehicle Wire Harness Side Connector Part Side Connector

(Airbag Sensor Assembly CTR) (Spiral Cable Vehicle Wire Harness Side)
Before Disconnecting After Disconnecting Before Disconnecting After Disconnecting
The Connector The Connector The Connector The Connector
RS
Inspection Paper Inspection Paper Inspection Paper Inspection Paper

C101106J01
(a) Using paper of the same thickness as the terminal (0.5 mm),
release the connector short circuiting mechanism.
NOTICE:
• Do not use paper of a different thickness to the terminal
as it may damage the terminal and short spring.
• Do not release the connector short circuiting
mechanism unless instructed to do so as part of
troubleshooting.
HINT:
A connector with a short circuiting mechanism built in is used
for the airbag system igniter circuit connector so that the
terminal on the airbag side short circuits when the connector is
disconnected. This prevents accidental airbag activation due to
static electricity and the like.
HOW TO PROCEED WITH

TROUBLESHOOTING
HINT:
(See page RS-18.)
3 CHECK FOR DTCs
HINT:
(See page RS-19.)
(a) CHECK FOR DTCs
(1) Record the DTC output.
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HINT:
When outputting DTCs, see Diagnostic Trouble Code Chart RS-
7.
DTC IS NOT OUTPUT (Go to step 8)
DTC DETECTED (GO to STEP 4)
RS 4 CHECK CONNECTOR AND CIRCUIT

(b) Disconnect the negative battery terminal, and wait for 90 seconds.
(c) Check to see if there is an error in the connection status of each
connector, the terminal and the wire harness.
5 CLEAR DTCs FROM MEMORY
HINT:
See page RS-19.
6 DTC CHECK
HINT:
See page RS-19.
DTC DETECTED (GO to STEP 9)
DTC IS NOT OUTPUT (Go to step 7)
7 PERFORM REPRODUCTION METHOD
HINT:
See page RS-19.
8 DETERMINE PROBLEM
9 REPAIR OR REPLACE
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RS–17
10 CONFIRMATION TEST
END
RS
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CHECK
SRS Airbag System Check Sheet
RS Inspector’s Name
Customer’s Name License Plate No.
First Registration Year / /
VIN
Date Vehicle Brought In Odometer Reading km
Date Problem Occured

Weather Clear Cloudy Rainy Snowy Others
Temperature Approximately
Starting Idling
Vehicle Operating Condition
Driving (Constant speed Increase Speed Reduce Speed Others)
Road Conditions
Problem Content
Before occurance of problem, vehicle inspection and repair history(including SRS airbag system)
Diagnosis System Inspection

Airbag Warning Light First Time On Occasionally turns on Does not turn on
Inspection Second Time On Occasionally turns on Does not turn on
First Time Normal Code Malfunction Code [Code ]
DTC Inspection
Second Time Normal Code Malfunction Code [Code ]
C082826J01
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RS–19
CHECK / CLEAR DTCs

1. READ DTC USING DS-II (NORMAL MODE)
(c) After turning the ignition switch on (IG), follow the prompts on
the DS-II screen to display the DTC CHECK screen. Select
NORMAL MODE to read the DTCs.
2. READ DTC USING DS-II (CHECK MODE) RS
(c) After turning the ignition switch on (IG), follow the prompts on
the DS-II screen to display the DTC CHECK screen. Select
CHECK MODE and read the DTCs.
NOTICE:
Display the DS-II DTC CHECK screen and select CHECK
MODE to clear DTCs output up until that point (present and
past).
HINT:
• Malfunctions can be detected with better sensitivity in check
mode than in normal diagnosis mode.
• The CHECK MODE should be used to output the normal
code when the DTCs are read out with the normal mode
even though a malfunction in each inflator system is
suspected.
• See the Diagnostic Trouble Code Chart (RS-7) to check
whether or not the output DTC corresponds to the check
mode.
3. Read the DTCs using the warning light.
(a) Make sure the vehicle is stopped.
(b) Turn the ignition switch on (IG) and wait 60 seconds.
(c) Using the SST, short the circuit between terminals 13 (ECUT)
ECUT and 4 (E) of the DLC and read the number of times the warning
light blinks.
SST 09843-18020
HINT:
When there are 2 or more DTCs, they are output in order
beginning with the lowest number. After all of the codes have
been output, the codes are output a second time.
CAUTION:
E
G100941 • Be sure to short circuit the DLC using the specified
SST.
• Be sure to short circuit the DLC properly, or
malfunction may occur.
(d) The airbag warning light in the combination meter blinks and the
code is displayed.
HINT:
• All codes recorded are displayed repeatedly in order from
the smallest number.
• When there is just 1 code, it is displayed once and then
again after a 4 second delay.
• When there are 2 or more codes, each code is displayed
from the smallest number 2.5 seconds apart until all the
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codes have been displayed. This process is then repeated

after a 4 second delay.
4. CLEAR DTCs WITH DS-II
(c) After turning the ignition switch on (IG), follow the DS-II's
prompts and clear the DTCs.
5. CLEAR WITH DLC
RS (a) After checking and repairing the trouble spots indicated by the
DTC output, use the following procedure to clear the DTCs
recorded.
(1) Using the DTC output display method, output and display
the DTCs via the airbag warning lights.
(2) While looking at a clock (with a second hand), alternatively
short circuit and open circuit the ECUT terminal and E
terminal 4 of the DLC 4 times for 1 second (+/- 0.4
seconds), and then on the fifth time leave the ECUT and E
terminals short circuited.
SST 09843-18020
CAUTION:
• Be sure to short circuit the DLC using the specified
SST.
• Be sure to short circuit the DLC properly, or
malfunction may occur.
(3) If the codes are properly cleared at this point, the airbag
warning light will blink quickly.
HINT:
If the warning light does not blink quickly, repeat the
procedure from the beginning.
(4) After clearing the memory, check that the airbag warning
light has gone off, then output the code again and check
that the normal code is output.
DIAGNOSIS SYSTEM
1. PRIMARY CHECK
(a) Turn the ignition switch off. Wait for at least 2 seconds, then turn
the ignition switch on (IG). The warning light comes on for
approximately 6 seconds and the diagnosis of the airbag and
pretensioner system will be performed.
NOTICE:
Turn the ignition switch off when connecting the battery.
(b) If trouble is detected during the primary check, the warning light
remains on even after approximately 6 seconds has elapsed.
2. CONSTANT CHECK
(a) After the primary check is completed (the warning light goes off
approximately 6 seconds after the ignition switch is turned on),
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RS–21
the airbag computer assembly makes the system available and

constantly monitors the airbag system for trouble.
Primary Check Check Is Normal

Warning Lights
Turn On Warning Lights
IG ON IG OFF
For Approx. 6 Sec. Turn Off
RS
C064938J06
(b) If any trouble is detected during the constant check, the airbag
computer assembly functions as follows.
(1) The warning light comes on.
HINT:
If any trouble code is output, the warning light comes on.
(2) The warning light comes on and then goes off.
HINT:
When the source voltage drops, the warning light comes on
and then goes off 10 seconds after the source voltage
returns to normal.
(3) The warning light remains on or does not come on.
HINT:
The warning light remains on or does not come on at all if
there is trouble with the combination meter assembly or the
communication system.
3. SUMMARY
(a) When the airbag system is normal:
(1) The warning light comes on only during the primary check
period (for approximately 6 seconds after the ignition switch
is turned on [IG]).
(b) When the airbag system has trouble:
(1) The warning light remains on even after the primary check
period has elapsed.
(2) After the primary check period has elapsed, the warning
light goes off once and then comes on again.
(3) The warning light remains on or does not come on at all
due to troubles with the combination meter assembly or the
communication system.
(4) The warning light is blinked by the airbag computer
assembly even after the primary check period has elapsed
if the airbag computer assembly has been activated due to
a collision.(*1)
HINT:
• (*1) Above is a function for distinguishing an airbag
computer assembly that has been activated from one
that has not been activated.
• Always replace the vehicle sensors (airbag computer
assembly, front airbag sensor, side airbag sensor
assembly RH and LH, side airbag sensor assembly RH
No. 2 and LH No. 2) with new ones if the airbags have
been deployed, as they may not function correctly.
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ECU TERMINALS
1. AIRBAG COMPUTER ASSEMBLY TERMINAL ARRANGEMENT
(VEHICLES WITHOUT CURTAIN SHIELD AIRBAGS AND SIDE
AIRBAGS)
RS B A B A
A B
C138243
Terminal No. Terminal Symbol Destination

A-5 PR+ RH pretensioner mechanism squib (+)
A-6 PR- RH pretensioner mechanism squib (-)
A-7 PL- LH pretensioner mechanism squib (-)
A-8 PL+ LH pretensioner mechanism squib (+)
B-1 AP+ Front passenger seat airbag squib (+)
B-2 AP- Front passenger seat airbag squib (-)
B-3 AD- Driver seat airbag squib (-)
B-4 AD+ Driver seat airbag squib (+)
B-9 IG1 IG power source
B-10 TC Diagnosis startup
FSSR+
B-12 Front airbag sensor (+)
(LHD: FSSL+)
FSSR-
B-13 Front airbag sensor (-)
(LHD: FSSL-)
B-17 SIL DLC
B-18 GSW2 EFI ECU
B-19 E1 Ground
B-21 LA Airbag warning light
2. AIRBAG COMPUTER ASSEMBLY TERMINAL ARRANGEMENT

(VEHICLES WITH CURTAIN SHIELD AIRBAGS AND SIDE
AIRBAGS)
A B B A B A
A B C C138244

A-1 PL- LH pretensioner mechanism squib (-)
A-2 PL+ LH pretensioner mechanism squib (+)
A-3 ICL+ LH curtain shield airbag squib (+)
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RS–23

A-4 ICL- LH curtain shield airbag squib (-)
A-5 SFL- LH side airbag squib (-)
A-6 SFL+ LH side airbag squib (+)
A-7 VUPL LH side airbag sensor power, communications
A-9 ESL LH side airbag sensor ground
A-11 CSL- LH side airbag safing rear sensor (-)
A-12 ESCL LH side airbag rear sensor ground RS
A-15 CSL+ LH side airbag safing rear sensor (+)
A-16 VUCL LH side airbag rear sensor power, communications
B-1 AP+ Front passenger seat airbag squib (+)
B-2 AP- Front passenger seat airbag squib (-)
B-3 AD- Driver seat airbag squib (-)
B-4 AD+ Driver seat airbag squib (+)
B-9 IG1 IG power source
B-10 TC Diagnosis startup
FSSR+
B-12 Front airbag sensor (+)
(LHD: FSSL+)
FSSR-
B-13 Front airbag sensor (-)
(LHD: FSSL-)
B-17 SIL DLC
B-18 GSW2 EFI ECU
B-19 E1 Ground
B-21 LA Airbag warning light
C-1 SFR+ RH side airbag squib (+)
C-2 SFR- RH side airbag squib (-)
C-3 ICR- RH curtain shield airbag squib (+)
C-41 ICR+ RH curtain shield airbag squib (-)
C-5 PR+ RH pretensioner mechanism squib (+)
C-6 PR- RH pretensioner mechanism squib (-)
C-8 ESR RH side airbag sensor ground
C-10 VUPR RH side airbag sensor power, communications
C-11 VUCR RH side airbag rear sensor power, communications
C-12 CSR+ RH side airbag safing rear sensor (+)
C-15 ESCR RH side airbag rear sensor ground
C-16 CSR- RH side airbag safing rear sensor (-)
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DTC B1000/31 Sensor unit error

DESCRIPTION
The airbag computer assembly consists of the G sensor, the safing sensor, the drive circuit, the diagnosis circuit, the ignition
control, etc. If the airbag computer assembly receives signals from the G sensor, it determines whether or not the airbags (horn
button assembly, instrument panel passenger airbag assembly, curtain shield airbag RH and LH, front seat airbag assembly RH
and LH) and pretensioners (front seat outer belt assembly RH and LH) should be activated and it detects trouble locations in the
RS airbag system.
DTC No. DTC Detection Item Trouble Area

B1000/31 • Airbag computer assembly malfunction • Airbag computer assembly
HINT:
• Before proceeding with the reproduction method, check whether or not the airbag computer assembly is applicable with the
test mode.(See page RS-7)
• Select the TEST MODE with the DS-II to perform the reproduction method. (See page RS-19.)
• After selecting TEST MODE, perform the reproduction method by shaking each of the airbag system connectors and running
the vehicle around town or on bad roads. (See page IN-33.)
1 CHECK FOR DTCs
(a) Turn the ignition switch on (IG) and wait 60 seconds.

(b) Using the DS-II, clear the DTCs and then check the DTCs again.
(See page RS-19.)
Standard:
DTC other than B1000/31 is not output.
HINT:
DTC B1000/31 may appear due to a malfunction that occurs in the igniter
circuit, such as a ground short circuit of 1kΩ, as well as airbag computer
assembly malfunction.
NG GO TO CORRESPONDING DTC
OK
REPLACE AIRBAG COMPUTER ASSEMBLY
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RS–25
Right Side Front Mechanical Sensor

DTC B1600/15
Malfunction
DTC B1605/15 Left Side Mechanical Sensor Malfunction

DESCRIPTION
The front airbag sensor circuit consists of the airbag computer assembly and the front airbag sensor. RS
The front airbag sensor detects impacts and sends the signal to the airbag computer assembly to determine airbag activation.
DTC B1600/15 is recorded if a malfunction is detected in the front airbag sensor RH circuit.
DTC B1605/15 is recorded if a malfunction is detected in the front airbag sensor LH circuit.

• Front Airbag Sensor RH
• Short circuit of wire harness +B, and ground short and
• Airbag computer assembly
open circuit between airbag computer assembly and
• Instrument panel wire (between airbag computer
B1600/15 front airbag sensor RH
assembly and joint connector)
• Front airbag sensor RH malfunction
• Engine room main wire (between joint connector and front
• Airbag computer assembly malfunction
airbag sensor RH)
• Front Airbag Sensor LH
• Short circuit of wire harness +B, and ground short and
open circuit between airbag computer assembly and
• Instrument panel wire (between airbag computer
B1605/15 front airbag sensor LH
assembly and joint connector)
• Front airbag sensor LH malfunction
• Engine room main wire (between joint connector and front
airbag sensor LH)
HINT:
The check procedure for DTC B1600/15 (Right side front mechanical sensor malfunction) is as follows.When checking for DTC
B1605/15 (Right side front mechanical sensor malfunction), substitute FSSL+ for FSSR+ and FSSL- for FSSR- and carry out the
check in the same way as listed below.
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CIRCUIT DIAGRAM
RS
FSSR+ CS+ CS+ FSSR+
FSSR- CS- CS- FSSR-
Relay Connector
Front Airbag Sensor
Airbag Computer Assembly
C138117
1 CHECK FRONT AIRBAG SENSOR RH CIRCUIT (+B SHORT CIRCUIT) (BETWEEN AIRBAG
COMPUTER ASSEMBLY AND FRONT AIRBAG SENSOR RH)
(For inspection procedures and precautions, see page IN-38.)
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RS–27
(a) Disconnect the negative battery terminal, and wait for 90 seconds.
HINT:
Front Airbag Check that the ignition switch is turned off (LOCK) before
Airbag Computer disconnecting the negative battery terminal.
Sensor Assembly (b) Disconnect the connectors from the airbag computer assembly and
the front airbag sensor RH.
(c) Connect the negative battery terminal, and turn the ignition switch on
(IG).
(d) Using a tester, check the voltage between terminals FSSR+ and RS
FSSR- of connector B, and the body ground.
Standard:
1 V or less
NG Go to step 7
FSSR- FSSR+
C138076
OK
2 CHECK FRONT AIRBAG SENSOR RH CIRCUIT (GROUND SHORT CIRCUIT) (BETWEEN AIRBAG
COMPUTER ASSEMBLY AND FRONT AIRBAG SENSOR RH)

(a) Turn the ignition switch off (LOCK).
Front Airbag (c) Using a tester, measure the resistance between terminals FSSR+
Airbag Computer and FSSR- of connector B, and the body ground.
Sensor Assembly Standard:
1 MΩ or higher
NG Go to step 8
FSSR- FSSR+
C138076
OK
3 CHECK FRONT AIRBAG SENSOR RH (BETWEEN AIRBAG COMPUTER ASSEMBLY AND FRONT
AIRBAG SENSOR RH)
GETtheMANUALS.org
(a) Using a tester, measure the resistance between terminals FSSR+

and FSSR- of connector B.
Front Airbag Standard:
Airbag Computer 1 MΩ or higher
Sensor Assembly
NG Go to step 9
RS
FSSR- FSSR+
C138076
OK
4 CHECK FRONT AIRBAG SENSOR RH CIRCUIT (OPEN CIRCUIT) (BETWEEN AIRBAG COMPUTER
ASSEMBLY AND FRONT AIRBAG SENSOR RH)
SST 09843-18020
(a) Using the SST, short the circuit between terminals FSSR+ and FSSR-
of connector E.
Front Airbag NOTICE:
Airbag Computer When short circuiting, do not insert the SST into the connector
Sensor Assembly terminals with force.
(b) Using a tester, touch terminals FSSR+ and FSSR- of connector B
with the tester probe and measure the resistance between connector
B and connector E.
Standard:
1Ω or less
NG Go to step 10
FSSR- FSSR+
C138077
OK
GETtheMANUALS.org
RS–29
5 CHECK FRONT AIRBAG SENSOR RH UNIT
(a) Using a tester, touch terminals CS+ and CS- of the front airbag
sensor RH with the tester probe and measure the resistance of the
front airbag sensor RH.
Standard:
820Ω
RS
NG REPLACE FRONT AIRBAG SENSOR RH
CS+ CS-
C138078
OK
6 INSPECT AIRBAG COMPUTER ASSEMBLY
(a) Release the short circuit between terminals CS+ and CS- of
connector E.
(b) Connect the connectors to the airbag computer assembly and front
Front Airbag airbag sensor RH.
Airbag Computer (c) Connect the negative battery terminal, turn the ignition switch on (IG)
Sensor Assembly and wait for 60 seconds.
(d) Using the DS-II, clear the DTCs and then check the DTCs again.
(See page RS-19.)
(1) When reading the code using the warning lights:
DLC DTC B1600/15 Standard:
DTC 15 is not output.
(2) When reading the code using the DS-II:
Standard:
E DTC B1600 is not output.
ECUT
C138079 NG REPLACE FRONT AIRBAG SENSOR RH
OK
PERFORM REPRODUCTION METHOD
7 CHECK ENGINE ROOM MAIN WIRE (+B SHORT CIRCUIT) (BETWEEN JOINT CONNECTOR AND
FRONT AIRBAG SENSOR RH)
GETtheMANUALS.org

Airbag (c) Disconnect connectors C and D.
Front (d) Connect the negative battery terminal, and turn the ignition switch on
Computer
Airbag (IG).
Assembly
Sensor
(e) Using a tester, check the voltage between terminals CS+ and CS- of
connector D and the body ground.
Standard:
RS 1 V or less
NG REPAIR OR REPLACE ENGINE ROOM MAIN

WIRE (BETWEEN JOINT CONNECTOR AND
CS- CS+
C138080
OK
REPAIR OR REPLACE INSTRUMENT PANEL WIRE (AIRBAG COMPUTER ASSEMBLY

AND JOINT CONNECTOR)
8 CHECK ENGINE ROOM MAIN WIRE (GROUND SHORT CIRCUIT) (BETWEEN JOINT CONNECTOR
AND FRONT AIRBAG SENSOR RH)

(a) Disconnect connectors C and D.
(b) Using a tester, measure the resistance between terminals CS+ and
CS- of connector D, and the body ground.
Airbag
Front Standard:
Computer
Airbag 1 MΩ or higher
Assembly
Sensor
CS- CS+
C138080
OK

GETtheMANUALS.org
RS–31
9 CHECK ENGINE ROOM MAIN WIRE (BETWEEN JOINT CONNECTOR AND FRONT AIRBAG
SENSOR RH)

(b) Using a tester, measure the resistance between terminals CS+ and
CS- of connector D.
Front
Airbag
Computer Standard: RS
Airbag 1 MΩ or higher
Assembly
Sensor
CS- CS+
C138080
OK

10 CHECK ENGINE ROOM MAIN WIRE (OPEN CIRCUIT) (BETWEEN JOINT CONNECTOR AND FRONT
AIRBAG SENSOR RH)
SST 09843-18020
HINT:
Airbag Connector E is short circuited at this point.
Front (b) Using a tester, touch terminals CS+ and CS- of connector D with the
Computer
Airbag
Assembly tester probe and measure the resistance between connector D and
Sensor
connector E.
Standard:
1Ω or less

CS- CS+
C138082
GETtheMANUALS.org
OK

RS
GETtheMANUALS.org
RS–33
DTC B1620/32 Right Side B Pillar Sensor Malfunction

DESCRIPTION
The side airbag sensor assembly RH circuit consists of the airbag computer assembly and the side airbag sensor assembly RH.
The side airbag sensor assembly RH detects impacts and sends the signal to determine airbag activation to the airbag computer
assembly.
DTC B1620/32 is recorded if a malfunction is detected in the side airbag sensor assembly RH circuit.

RS
• Wire harness short circuit, +B short circuit, ground
• Side airbag sensor assembly RH
short or open circuit between airbag computer
B1620/32 assembly and the side airbag sensor assembly RH
• Floor wire (between airbag computer assembly and side
• Side airbag sensor assembly RH malfunction
airbag sensor assembly RH)
CIRCUIT DIAGRAM
VUPR VUPR
ESR ESR
Side Airbag Sensor Assembly RH Airbag Computer Assembly
C138058
GETtheMANUALS.org
1 INSPECT CHECK SIDE AIRBAG SENSOR ASSEMBLY RH
(a) Connect the negative battery terminal, turn the ignition switch on (IG)
and wait for 60 seconds.
Airbag (b) Using the SST, clear the DTCs and then check the DTCs again. (See
RS Side Airbag
ࠛࠕࡃ࠶ࠢ
Computer
ࠦࡦࡇࡘ࡯࠲ page RS-19.)
#55;
Assembly (1) When reading the code using the warning lights:
Sensor
Standard:
Assembly
RH
Standard:
$ DTC B1620 is not output.
OK PERFORM REPRODUCTION METHOD
' '%76
C138059
NG
2 INSPECT AIRBAG COMPUTER ASSEMBLY CONNECTOR CONNECTION STATUS

(c) Check the connection status of the connectors that are connected to
the airbag computer assembly.
Standard:
Make sure the connector is correctly connected to the
airbag computer assembly.
NG RECONNECT CONNECTOR
OK
3 CHECK CONNECTION STATUS OF SIDE AIRBAG SENSOR CONNECTORS
(a) Check the connection status of the connectors that are connected to
the side airbag sensor assembly RH.
Standard:
side airbag sensor assembly RH.
NG REPAIR OR REPLACE FLOOR WIRE

(AIRBAG COMPUTER ASSEMBLY AND SIDE
AIRBAG SENSOR ASSEMBLY RH)
OK
GETtheMANUALS.org
RS–35
4 INSPECT SIDE AIRBAG SENSOR RH CIRCUIT (OPEN CIRCUIT) (BETWEEN AIRBAG COMPUTER
ASSEMBLY AND SIDE AIRBAG SENSOR ASSEMBLY RH)
SST 09843-18020
(a) Disconnect the connectors from the airbag computer assembly and
the side airbag sensor assembly RH.
Side
Airbag
Computer (b) Using the SST, short the circuit between terminals VUPR and ESR of RS
Airbag Assembly
Sensor connector C.
Assembly (c) Using a tester, touch terminals VUPR and ESR of connector B with
RH
the tester probe and measure the resistance between connector B
and connector C.
ESR Standard:
1Ω or less
VUPR NG REPAIR OR REPLACE FLOOR WIRE

C138060
OK
5 INSPECT SIDE AIRBAG SENSOR RH CIRCUIT (GROUND SHORT CIRCUIT) (BETWEEN AIRBAG
COMPUTER ASSEMBLY AND SIDE AIRBAG SENSOR ASSEMBLY RH)

(a) Release the short circuit between terminals VUPR and ESR of
connector C.
Airbag (b) Using a tester, measure the resistance between terminals VUPR and
Side Computer ESR of connector B and the body ground.
Airbag Assembly Standard:
Sensor 1 MΩ or higher
Assembly
RH NG REPAIR OR REPLACE FLOOR WIRE
VUPR
ESR
C138061
OK
6 INSPECT SIDE AIRBAG SENSOR RH CIRCUIT (SHORT CIRCUIT) (BETWEEN AIRBAG COMPUTER
ASSEMBLY AND SIDE AIRBAG SENSOR ASSEMBLY RH)
GETtheMANUALS.org
(a) Using a tester, measure the resistance between terminals VUPR and
ESR of connector B.
Airbag Standard:
Side Computer 1 MΩ or higher
Airbag Assembly
Sensor NG REPAIR OR REPLACE FLOOR WIRE
Assembly
RH
RS
VUPR
ESR
C138061
OK
7 INSPECT SIDE AIRBAG SENSOR RH CIRCUIT (+B SHORT CIRCUIT) (BETWEEN AIRBAG
COMPUTER ASSEMBLY AND SIDE AIRBAG SENSOR ASSEMBLY RH)

(a) Connect the negative battery terminal, and turn the ignition switch on
(IG).
Airbag (b) Using a tester, check the voltage between terminals VUPR and ESR
Side Computer of connector B, and the body ground.
Airbag Assembly Standard:
Sensor 1 V or less
Assembly
RH NG REPAIR OR REPLACE FLOOR WIRE
VUPR
ESR
C138061
OK
SST 09843-18020
GETtheMANUALS.org
RS–37

(c) Connect the connectors to the airbag computer assembly.
Airbag
(d) Switch the side airbag sensor assembly RH and LH, and securely
Side Airbag Computer
install the connectors.
Sensor Assembly
NOTICE:
Assembly
LH • When installing the connectors, do not drop the airbag
sensor assembly RH and LH or subject them to any other
DTC B1620/32
type of strong impact. RS
DLC • Replace the sensor body with a new one if it is dropped or
subject to any other type of strong impact.
(e) Connect the negative battery terminal, turn the ignition switch on (IG)
DTC B1625/33
E ECUT (f) Using the SST, clear the DTCs and then check the DTCs again. (See
page RS-19.)
C138062
Standard:
DTC 32 is not output. (A)
DTC 33 is not output. (B)
Standard:
DTC B1620 is not output. (A)
NG (A) REPLACE AIRBAG COMPUTER ASSEMBLY
NG (B) REPLACE SIDE AIRBAG SENSOR

ASSEMBLY RH
OK
GETtheMANUALS.org
DTC B1625/33 Left Side B Pillar Sensor Malfunction

DESCRIPTION
The side airbag sensor assembly LH circuit consists of the airbag computer assembly and the side airbag sensor assembly LH.
The side airbag sensor assembly LH detects impacts and sends the signal to determine airbag activation to the airbag computer
assembly.
DTC B1625/33 is recorded if a malfunction is detected in the side airbag sensor assembly LH circuit.
RS DTC No. DTC Detection Item Trouble Area
• Side airbag sensor assembly LH
B1625/33 assembly and the side airbag sensor assembly LH
• Floor wire No. 2 (between airbag computer assembly and
• Side airbag sensor assembly LH malfunction
side airbag sensor assembly LH)
CIRCUIT DIAGRAM
VUPL VUPL
ESL ESL
Side Airbag Sensor Assembly LH Airbag Computer Assembly
C138063
GETtheMANUALS.org
RS–39
1 CHECK SIDE AIRBAG SENSOR ASSEMBLY LH
SST 09843-18020
Side Airbag
Sensor
(b) Using the SST, clear the DTCs and then check the DTCs again. (See RS
Assembly page RS-19.)
Airbag
LH (1) When reading the code using the warning lights:
Computer
Standard:
Assembly
Standard:
DTC B1625/33
DLC DTC B1625 is not output.
E ECUT
C138064
NG

Standard:
OK
3 CHECK CONNECTION STATUS OF SIDE AIRBAG SENSOR CONNECTORS
the side airbag sensor assembly LH.
Standard:
side airbag sensor assembly LH.
OK
GETtheMANUALS.org
4 INSPECT SIDE AIRBAG SENSOR LH CIRCUIT (OPEN CIRCUIT) (BETWEEN AIRBAG COMPUTER
ASSEMBLY AND SIDE AIRBAG SENSOR ASSEMBLY LH)
SST 09843-18020
the side airbag sensor assembly LH.
RS Side Airbag
Sensor
(b) Using the SST, short circuit between terminals VUPR and ESR of
Assembly connector C.
Airbag
LH (c) Using a tester, touch terminals VUPL and ESL of connector B with the
Computer
Assembly tester probe and measure the resistance between connector B and
connector C.
Standard:
1Ω or less
NG REPAIR OR REPLACE FLOOR WIRE NO. 2

ESL VUPL (BETWEEN AIRBAG COMPUTER
ASSEMBLY AND SIDE AIRBAG SENSOR
ASSEMBLY LH)
C138065
OK
5 INSPECT SIDE AIRBAG SENSOR LH CIRCUIT (GROUND SHORT CIRCUIT) (BETWEEN AIRBAG
COMPUTER ASSEMBLY AND SIDE AIRBAG SENSOR ASSEMBLY LH)

(a) Release the short circuit between terminals VUPL and ESL of
connector C.
Side Airbag (b) Using a tester, measure the resistance between terminals VUPL and
Sensor
ESL of connector B and the body ground.
Assembly Airbag
LH Standard:
Computer
1 MΩ or higher
Assembly
(BETWEEN AIRBAG COMPUTER
VUPL ASSEMBLY LH)
ESL
C138066
OK
6 INSPECT SIDE AIRBAG SENSOR LH CIRCUIT (SHORT CIRCUIT) (BETWEEN AIRBAG COMPUTER
ASSEMBLY AND SIDE AIRBAG SENSOR ASSEMBLY LH)
GETtheMANUALS.org
RS–41
(a) Using a tester, measure the resistance between terminals VUPL and
ESL of connector B.
Side Airbag
Sensor Standard:
Assembly Airbag 1 MΩ or higher
LH Computer
Assembly
ASSEMBLY LH) RS
VUPL
ESL
C138066
OK
7 INSPECT SIDE AIRBAG SENSOR LH CIRCUIT (+B SHORT CIRCUIT) (BETWEEN AIRBAG
COMPUTER ASSEMBLY AND SIDE AIRBAG SENSOR ASSEMBLY LH)

(IG).
Side Airbag
(b) Using a tester, check the voltage between terminals VUPL and ESL
Sensor
Assembly of connector B, and the body ground.
Airbag
LH Standard:
Computer
Assembly 1 V or less

VUPL ASSEMBLY LH)
ESL
C138066
OK
SST 09843-18020
GETtheMANUALS.org

Side Airbag (b) Disconnect the negative battery terminal, and wait for 90 seconds.
Sensor (c) Connect the connectors to the airbag computer assembly.
Assembly Airbag (d) Switch the side airbag sensor assembly LH and RH, and securely
RH Computer install the connectors.
Assembly NOTICE:
• When installing the connectors, do not drop the airbag
sensor assembly LH and RH or subject them to any other
RS DLC DTC B1620/32
type of impact.
• Replace the sensor body with a new one if it is dropped or
B1625/33
E ECUT DTC and wait for 60 seconds.
(f) Using the SST, clear the DTCs and then check the DTCs again. (See
page RS-19.)
C138067
Standard:
Standard:
NG (A) REPLACE SIDE AIRBAG SENSOR

ASSEMBLY LH
NG (B) REPLACE AIRBAG COMPUTER ASSEMBLY
OK
GETtheMANUALS.org
RS–43
DTC B1630/23 Right Side C Pillar Sensor Malfunction

DESCRIPTION
The side airbag sensor assembly RH No. 2 circuit consists of the airbag computer assembly and the side airbag sensor assembly
RH No. 2.
The side airbag sensor assembly RH No. 2 detects impacts and sends the signal to determine airbag activation to the airbag
computer assembly.
DTC B1630/23 is recorded if a malfunction is detected in the side airbag sensor assembly RH No. 2 circuit. RS
• Side airbag sensor assembly RH No. 2
B1630/23 assembly and side airbag sensor assembly RH No. 2
• Side airbag sensor assembly RH No. 2 malfunction
side airbag sensor assembly RH No. 2)
CIRCUIT DIAGRAM
CSR+ CSR+
VUCR VUCR
ESCR ESCR
CSR- CSR-
Side Airbag Sensor Assembly RH NO. 2 Airbag Computer Assembly
C138068
GETtheMANUALS.org
1 INSPECT SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2
Airbag (b) Using the DS-II, clear the DTCs and then check the DTCs again.
RS Side Airbag
Computer (See page RS-19.)
Sensor
Standard:
Assembly
RH NO. 2
Standard:
DTC B1630/23 DTC B1630 is not output.
DLC
E ECUT
C138069
NG

Standard:
OK
3 CHECK CONNECTION STATUS OF SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2
the side airbag sensor assembly RH No. 2.
Standard:
side airbag sensor assembly RH No. 2.
OK
4 INSPECT SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2 CIRCUIT (OPEN CIRCUIT) (BETWEEN
AIRBAG COMPUTER ASSEMBLY AND SIDE AIRBAG SENSOR ASSEMBLY RH NO.2)
SST 09843-18020
GETtheMANUALS.org
RS–45

the side airbag sensor assembly RH No. 2.
(b) Using the SST, short circuit between terminals VUCR and ESCR of
Airbag
Computer connector C, and CSR+ and CSR- terminals.
Side (c) Using a tester, touch terminals VUCR and ESCR of connector B or
Airbag Assembly
Sensor CSR+ and CSR- terminals with the tester probe and measure the
Assembly resistance between connector B and connector C.
RH NO. 2 Standard: RS
1Ω or less

CSR- CSR+ (BETWEEN AIRBAG COMPUTER
ASSEMBLY RH NO. 2)
ESCR VUCR
C138070
OK
5 INSPECT SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2 CIRCUIT (GROUND SHORT CIRCUIT)
(BETWEEN AIRBAG COMPUTER ASSEMBLY AND SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2)

(a) Release the short circuit between terminals VUCR and ESCR of
connector C and CSR+ and CSR- terminals.
Airbag
Computer (b) Using a tester, measure the resistance between the body ground and
Side the VUCR, ESCR, CSR+ and CSR- terminals of connector B.
Airbag
Assembly
Sensor
Standard:
Assembly 1 MΩ or higher
RH NO. 2
ASSEMBLY RH NO. 2)
CSR- VUCR
ESCR CSR+
C138071
OK
6 INSPECT SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2 CIRCUIT (SHORT CIRCUIT) (BETWEEN
AIRBAG COMPUTER ASSEMBLY AND SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2)
GETtheMANUALS.org
(a) Using a tester, measure the resistance between terminals VUCR and
ESCR of connector B, and between terminals CSR+ and CSR-.
Airbag
Computer Standard:
Side 1 MΩ or higher
Airbag
Assembly
Sensor
Assembly
RH NO. 2 (BETWEEN AIRBAG COMPUTER
RS ASSEMBLY RH NO. 2)
CSR- VUCR
ESCR CSR+
C138071
OK
7 INSPECT SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2 CIRCUIT (+B SHORT CIRCUIT) (BETWEEN
AIRBAG COMPUTER ASSEMBLY AND SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2)

(IG).
Airbag
Computer (b) Using a tester, measure the voltage between the body ground and the
Side VUCR, ESCR, CSR+ and CSR- terminals of connector B.
Airbag
Assembly
Sensor
Standard:
RH NO. 2
ASSEMBLY RH NO. 2)
CSR- VUCR
ESCR CSR+
C138071
OK
8 INSPECT SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2
SST 09843-18020
GETtheMANUALS.org
RS–47

Airbag
(d) Switch the side airbag sensor assembly RH No. 2 and the airbag
Side Computer
Airbag Assembly sensor rear left, and securely install the connectors.
Sensor NOTICE:
Assembly • When installing the connectors, do not drop the side airbag
LH NO. 2 sensor assembly RH No. 2 or the airbag sensor rear left, and
DLC
DTC B1630/23 do not subject them to any other type of strong impact. RS
• Replace the sensor body with a new one if it is dropped or
DTC B1635/24 and wait for 60 seconds.
E ECUT
page RS-19.)
C138072
Standard:
Standard:
DTC B1635 is not output. (B)
NG (A) REPLACE AIRBAG COMPUTER ASSEMBLY
NG (B) REPLACE SIDE AIRBAG SENSOR

ASSEMBLY RH NO. 2
OK
GETtheMANUALS.org
DTC B1635/24 Left Side C Pillar Sensor Malfunction

DESCRIPTION
The side airbag sensor assembly LH No. 2 circuit consists of the airbag computer assembly and side airbag sensor assembly LH
No. 2.
The side airbag sensor assembly LH No. 2 detects impacts and sends the signal to determine airbag activation to the airbag
computer assembly.
RS DTC B1635/24 is recorded if a malfunction is detected in the side airbag sensor assembly LH No. 2 circuit.

• Side airbag sensor assembly LH No. 2
B1635/24 assembly and side airbag sensor assembly LH No. 2
• Side airbag sensor assembly LH No. 2 malfunction
side airbag sensor assembly LH No. 2)
CIRCUIT DIAGRAM
CSL+ CSL+
VUCL VUCL
ESCL ESCL
CSL- CSL-
Side Airbag Sensor Assembly NO. 2 Airbag Computer Assembly
C138073
GETtheMANUALS.org
RS–49
1 INSPECT SIDE AIRBAG SENSOR ASSEMBLY LH NO. 2
SST 09843-18020
(a) Turn the ignition switch on (IG) and wait 60 seconds.
(b) Using the SST, clear the DTCs and then check the DTCs again. (See
Side Airbag page RS-19.) RS
Sensor (1) When reading the code using the warning lights:
Assembly Airbag Standard:
LH NO. 2 Computer DTC 24 is not output.
Assembly (2) When reading the code using the DS-II:
Standard:
DTC B1635 is not output.
DLC DTC B1635/24
E ECUT
C138074
NG

Standard:
OK
3 CHECK CONNECTION STATUS OF SIDE AIRBAG SENSOR ASSEMBLY LH NO. 2
the side airbag sensor assembly LH No. 2.
Standard:
side airbag sensor assembly LH No. 2.
OK
GETtheMANUALS.org
4 INSPECT SIDE AIRBAG SENSOR ASSEMBLY LH NO. 2 CIRCUIT (OPEN CIRCUIT) (BETWEEN
AIRBAG COMPUTER ASSEMBLY AND SIDE AIRBAG SENSOR ASSEMBLY LH NO. 2)
SST 09843-18020
Side Airbag
the side airbag sensor assembly LH No. 2.
RS Sensor
Assembly (b) Using the SST, short the circuit between terminals VUCL and ESCL
LH NO. 2 Airbag of connector C and terminals CSL+ and CSL-.
Computer (c) Using a tester, touch terminals VUCL and ESCL of connector B or
Assembly CSL+ and CSL- terminals with the tester probe and measure the
resistance between connector B and connector C.
Standard:
1Ω or less

VUCL CSL- ASSEMBLY AND SIDE AIRBAG SENSOR
CSL+ ESCL ASSEMBLY LH NO. 2)
C138115
OK
5 INSPECT SIDE AIRBAG SENSOR ASSEMBLY LH NO. 2 CIRCUIT (GROUND SHORT CIRCUIT)
(BETWEEN AIRBAG COMPUTER ASSEMBLY AND SIDE AIRBAG SENSOR ASSEMBLY LH NO. 2)

(a) Release the short circuit between terminals VUCL and ESCL of
connector C, and terminals CSL+ and CSL-.
Side (b) Using a tester, measure the resistance between terminals VUCL,
Airbag
Sensor ESCL of connector B and the CSL+ and CSL- terminals, and the
Assembly Airbag body ground.
LH NO. 2
Computer Standard:

ASSEMBLY LH NO. 2)
VUCL CSL-
CSL+ ESCL
C138075
OK
6 INSPECT SIDE AIRBAG SENSOR ASSEMBLY LH NO. 2 CIRCUIT (SHORT CIRCUIT) (BETWEEN
GETtheMANUALS.org
RS–51
(a) Using a tester, measure the resistance between terminals VUCL,

ESCL of connector B and between terminals CSL+ and CSL-.
Side
Airbag
Standard:
Sensor 1 MΩ or higher
Assembly Airbag
LH NO. 2 NG REPAIR OR REPLACE FLOOR WIRE NO. 2
Computer
Assembly (BETWEEN AIRBAG COMPUTER
ASSEMBLY LH NO. 2) RS
VUCL CSL-
CSL+ ESCL
C138075
OK
7 INSPECT SIDE AIRBAG SENSOR ASSEMBLY LH NO. 2 CIRCUIT (+B SHORT CIRCUIT) (BETWEEN

(IG).
Side
(b) Using a tester, measure the voltage between the body ground and the
Airbag
Sensor VUCL, ESCL, CSL+ and CSL- terminals of connector B.
Assembly Airbag Standard:
LH NO. 2
Computer 1 V or less
Assembly
ASSEMBLY LH NO. 2)
VUCL CSL-
CSL+ ESCL
C138075
OK
8 INSPECT SIDE AIRBAG SENSOR ASSEMBLY LH NO. 2
SST 09843-18020
GETtheMANUALS.org

Side Airbag (d) Switch the side airbag sensor assembly LH No. 2 and the side airbag
Sensor
Assembly sensor assembly LRH No.2, and securely install the connectors.
RH NO. 2
Airbag
Computer NOTICE:
Assembly • When installing the connectors, do not drop the airbag
sensor assembly RH No. 2 or LH . And do not subject them to
RS DTC B1630/23
any other type of strong impact.
DLC • Replace the sensor body with a new one if it is dropped or
DTC B1635/24 and wait for 60 seconds.
E ECUT (f) Using the SST, clear the DTCs and then check the DTCs again. (See
page RS-19.)
C138116
Standard:
Standard:
DTC B1635 is not output. (B)
NG (A) REPLACE SIDE AIRBAG SENSOR

ASSEMBLY LH NO. 2
NG (B) REPLACE AIRBAG COMPUTER ASSEMBLY
OK
GETtheMANUALS.org
RS–53
Short Circuit between Driver Seat Front

DTC B1800/13
Collision Igniter Lines
DESCRIPTION
The driver seat airbag igniter circuit consists of the airbag computer assembly, the spiral cable and the horn button assembly. The
airbag will be activated when the activation conditions are met.
When a short is detected in the driver seat airbag igniter circuit (AD+, AD- line), DTC B1800/13 is recorded in the airbag computer
assembly.
RS
• Wire harness AD+, AD- line short circuit between
airbag computer assembly and horn button assembly • Horn button assembly
(driver seat side airbag) • Spiral cable
B1800/13 • Horn button assembly (driver seat side airbag) • Airbag computer assembly
malfunction • Instrument panel wire (between airbag computer
• Spiral cable malfunction assembly and spiral cable)
CIRCUIT DIAGRAM
A+ D+ D+ AD+
A- D- D- AD-
Horn Button Assembly

(Driver Side Airbag) Spiral Cable
C137857
GETtheMANUALS.org
HINT:
RS
1 CHECK AIRBAG CONNECTORS
HINT:
Check that the ignition switch is turned off (LOCK) before
disconnecting the negative battery terminal.
(b) Disconnect the connectors from the horn button assembly.
(c) Check that there is no damage to the horn button assembly (driver
seat side airbag) connectors.
Standard:
The locking button of the connector has not moved out
of position.
The claws of the locking button have no deformation or
other damage.
NG REPLACE SPIRAL CABLE
OK
2 INSPECT DRIVER SEAT AIRBAG IGNITER CIRCUIT (BETWEEN AIRBAG COMPUTER ASSEMBLY
AND HORN BUTTON ASSEMBLY)
HINT:
For inspection procedures and precautions, see page IN-38.
(a) Disconnect the connectors from the airbag computer assembly.
Horn Button Assembly Short Mechanism (b) Release the short circuiting mechanism of connector B (AD+, AD-).
(Driver Side Airbag) Release (c) Using a tester, touch terminals D+ and D- of connector E with the
tester probe and measure the resistance between connector B and
Spiral connector E.
Cable Standard:
1 MΩ or higher
Airbag
NG Go to step 5
Computer
Assembly
C095277J01
OK
GETtheMANUALS.org
RS–55
SST 09843-18020
(a) Connect the connectors to the airbag computer assembly.
(b) Connect the negative battery terminal, turn the ignition switch on (IG)
Airbag
Spiral
Cable
Computer (c) Using the SST, clear the DTCs and then check the DTCs again. (See
page RS-19.)
RS
Assembly
Horn Button Assembly Standard:
(Driver Side Airbag) DTC 13 is not output.
Standard:
DLC DTC B1800/13 DTC B1800 is not output.
NG REPLACE AIRBAG COMPUTER ASSEMBLY
E ECUT
C082259J02
OK
4 INSPECT DRIVER SEAT IGNITER (HORN BUTTON ASSEMBLY)
SST 09843-18020
Spiral Cable (b) Disconnect the negative battery terminal, and wait for 90 seconds.
(c) Connect the connectors to the horn button assembly.
Airbag
(d) Connect the negative battery terminal, turn the ignition switch on (IG)
Computer
Assembly and wait for 60 seconds.
(e) Using the SST, clear the DTCs and then check the DTCs again. (See
Horn Button Assembly page RS-19.)
(Driver Side Airbag) (1) When reading the code using the warning lights:
Standard:
DLC DTC B1800/13
Standard:
E
ECUT NG REPLACE HORN BUTTON ASSEMBLY
C082260J02
OK
5 INSPECT INSTRUMENT PANEL WIRE (BETWEEN AIRBAG COMPUTER ASSEMBLY AND SPIRAL
CABLE)
HINT:
GETtheMANUALS.org

Short Mechanism Release
HINT:
At this point, the short circuiting mechanism of connector B is in
Spiral
released.
Cable
(b) Using a tester, touch terminals D+ and D- of connector C with the
tester rod and measure the resistance between connector B and
Horn Button Assembly Airbag
(Driver Side Airbag) connector C.
Computer
Standard:
Assembly
RS 1 MΩ or higher
NG REPAIR OR REPLACE INSTRUMENT PANEL

D- WIRE (BETWEEN AIRBAG COMPUTER
D+
ASSEMBLY AND SPIRAL CABLE)
G026016J02
OK
6 INSPECT SPIRAL CABLE
(a) Release the short circuiting mechanism of connector D (D+, D-).

Horn Button Assembly Short Mechanism (b) Using a tester, touch terminals D+ and D- of connector E with the
(Driver Side Airbag) Release tester probe and measure the resistance between the spiral cables.
Standard:
Spiral 1 M Ω or higher
Cable
NG REPLACE SPIRAL CABLE
Airbag
Computer
Assembly
D+ D-
C095280J01
OK
GETtheMANUALS.org
RS–57
Open Circuit in Driver Seat Front Collision

DTC B1801/14
Igniter Circuit
DESCRIPTION
When an open circuit is detected in the driver seat airbag ignition circuit (AD+, AD- line), DTC B1801/14 is recorded in the airbag
computer assembly.
RS
• Open circuit of the AD+ and AD- lines of the wire
harness between the airbag computer assembly and • Horn button assembly
the horn button assembly (driver seat side airbag) • Spiral cable
CIRCUIT DIAGRAM
A+ D+ D+ AD+
A- D- D- AD-

C137857
GETtheMANUALS.org
HINT:
RS
HINT:
HINT:
(Driver Side Airbag)
Spiral
(b) Disconnect the connectors from the airbag computer assembly and
Cable
the horn button assembly.
(c) Using a tester, touch terminals D+ and D- of connector E with the
Airbag
Computer
connector E.
Assembly
D- D+ Standard:
1Ω or less
NG Go to step 4
C095281J01
OK
GETtheMANUALS.org
RS–59

(b) Using a wire harness (wire diameter: 0.5 mm), short the circuit
between terminals D+ and D- of connector E.
Airbag NOTICE:
Spiral
Computer
Cable
Assembly
When short circuiting, do not insert the wire harness into the
connector terminals with force.
RS
(c) Connect the negative battery terminal, turn the ignition switch on (IG)
(d) Using the SST, clear the DTCs and then check the DTCs again. (See
Twist The Stripped page RS-19.)
Section
Wire Harness Standard:
(Wire Diameter DTC 14 is not output.
0.5 mm ) (2) When reading the code using the DS-II:
Standard:
DTC B1801/14 DTC B1801 is not output.
DLC
E
ECUT
C095282J03
OK

(c) Release the short circuit between terminals D+ and D- of connector E
Airbag and connect the connector to the horn button assembly.
Spiral Computer (d) Connect the negative battery terminal, turn the ignition switch on (IG)
Cable Assembly and wait for 60 seconds.
Horn Button Assembly page IN-38.)
Standard:
DLC DTC B1801/14 DTC 14 is not output.
Standard:
ECUT
C080630J02 NG REPLACE HORN BUTTON ASSEMBLY
OK
GETtheMANUALS.org
CABLE)
HINT:
(b) Using a tester, touch terminals D+ and D- of connector C with the
RS tester rod and measure the resistance between connector B and
Spiral connector C.
Cable
Standard:
1Ω or less
Airbag
(Driver Side Airbag) NG REPAIR OR REPLACE INSTRUMENT PANEL
Computer
Assembly WIRE (BETWEEN AIRBAG COMPUTER
D- D+
G026017J01
OK
(a) Using a tester, touch terminals D+ and D- of connector E with the

Horn Button Assembly tester probe and measure the resistance between the spiral cables.
(Driver Side Airbag) Standard:
1Ω or less
Spiral
Cable NG REPLACE SPIRAL CABLE
Airbag
Computer
Assembly
C095284J01
OK
GETtheMANUALS.org
RS–61
Ground Short Circuit in Driver Seat Front

DTC B1802/11
Collision Igniter Circuit
DESCRIPTION
When a ground short is detected in the driver seat airbag ignition circuit (AD+, AD- line), DTC B1802/11 is recorded in the airbag
computer assembly.
RS
• Wire harness AD+, AD- line ground short circuit
between airbag computer assembly and horn button • Horn button assembly
assembly (driver seat side airbag) • Spiral cable
CIRCUIT DIAGRAM
A+ D+ D+ AD+
A- D- D- AD-

C137857
GETtheMANUALS.org
HINT:
RS
HINT:
(Driver Side Airbag) HINT:
Spiral
Cable
(c) Using a tester, measure the resistance between terminals D+ and D-
Airbag
of connector E, and the body ground.
Computer
Standard:
Assembly
D- D+ 1 M Ω or higher
NG Go to step 4
C095281J01
OK
GETtheMANUALS.org
RS–63

Horn Button Assembly (b) Using a wire harness (wire diameter: 0.5 mm), short circuit between
(Driver Side Airbag) terminals D+ and D- of connector E.
Airbag NOTICE:
Spiral
Cable
Computer
Assembly
RS
Twist The Stripped
Portion page RS-19.)
Wire Harness (1) When reading the code using the warning lights:
(Diameter 0.5 mm) Standard:
B1802/1 Standard:

E EC
C095285J05
OK

Spiral
Computer (d) Connect the negative battery terminal, turn the ignition switch on (IG)
Cable
page IN-38.)
Standard:
B1802/1
Standard:
EC
OK
GETtheMANUALS.org
CABLE)
HINT:
(b) Using a tester, measure the resistance between terminals D+ and D-
RS Spiral
of connector C, and the body ground.
Standard:
Cable
1 MΩ or higher
Horn Button Assembly NG
Airbag REPLACE SPIRAL CABLE
Computer
Assembly
D- D+
G026017J01
OK
(a) Using a tester, measure the resistance between terminals D+ and D-

of connector E, and the body ground.
Standard:
1 M Ω or higher
Spiral
Cable NG REPAIR OR REPLACE WIRE HARNESS OR
CONNECTOR (BETWEEN AIRBAG
Airbag COMPUTER ASSEMBLY AND SPIRAL
Computer CABLE)
Assembly
C095284J01
OK
GETtheMANUALS.org
RS–65
Power Supply Short Circuit in Driver Seat Front

DTC B1803/12
DESCRIPTION
When a +B short is detected in the driver seat airbag igniter circuit (AD+, AD- line), DTC B1803/12 is recorded in the airbag
computer assembly.
RS
• +B short circuit of the AD+ and AD- lines of the wire
harness between the airbag computer assembly and • Horn button assembly
the horn button assembly (driver seat side airbag) • Spiral cable
CIRCUIT DIAGRAM
A+ D+ D+ AD+
A- D- D- AD-

C137857
GETtheMANUALS.org
HINT:
RS
HINT:
HINT:
Spiral
Cable
Airbag
(IG).
Computer
(d) Using a tester, check the voltage between terminals D+ and D- of
Assembly
D- D+ connector E, and the body ground.
Standard:
1 V or less
NG Go to step 4
C095281J01
OK
GETtheMANUALS.org
RS–67

Horn Button Assembly (b) Disconnect the negative battery terminal, and wait for 90 seconds.
(Driver Side Airbag) (c) Connect the connectors to the airbag computer assembly.
Airbag (d) Using a wire harness (wire diameter: 0.5 mm), short the circuit
Spiral
Cable Computer
Assembly
between terminals D+ and D- of connector E.
NOTICE:
RS
Twist The Stripped (e) Connect the negative battery terminal, turn the ignition switch on (IG)
Section and wait for 60 seconds.
Wire Harness (f) Using the SST, clear the DTCs and then check the DTCs again. (See
(Wire Diameter page RS-19.)
0.5 mm) (1) When reading the code using the warning lights:
Standard:
B1802/1 DTC 12 is not output.
Standard:
E EC
C095285J03
OK

Spiral (d) Connect the negative battery terminal, turn the ignition switch on (IG)
Cable Computer
Horn Button Assembly page IN-38.)
(Driver Side Airbag) (1) When reading the code using the warning lights:
Standard:
Standard:
E EC
OK
GETtheMANUALS.org
CABLE)
HINT:
RS Spiral
(c) Disconnect connectors C and D.
(d) Connect the negative battery terminal, and turn the ignition switch on
Cable
(IG).
(e) Using a tester, check the voltage between terminals D+ and D- of
Airbag connector C, and the body ground.
Computer Standard:

WIRE (BETWEEN AIRBAG COMPUTER
D- D+
G026017J01
OK
(a) Using a tester, check the voltage between terminals D+ and D- of

connector E, and the body ground.
Standard:
1 V or less
Spiral
Cable NG REPLACE SPIRAL CABLE
Airbag
Computer
Assembly
C095284J01
OK
GETtheMANUALS.org
RS–69
Short Circuit between Passenger Seat Front

DTC B1805/53
Collision Igniter Lines
DESCRIPTION
The passenger seat airbag igniter circuit consists of the airbag computer assembly and the instrument panel passenger airbag
assembly. The instrument panel passenger airbag assembly operates when the deployment conditions are met.
When a short is detected in the passenger seat airbag igniter circuit (AP+, AP- line), DTC B1805/53 is recorded in the airbag
computer assembly.
RS
• Short circuit of the AP+ and AP- lines of the wire
harness between the airbag computer assembly and • Instrument panel passenger airbag assembly
the instrument panel passenger airbag assembly • Airbag computer assembly
B1805/53 (passenger seat side airbag) • Instrument panel wire (between airbag computer
• Instrument panel passenger airbag assembly assembly and instrument panel passenger airbag
(passenger seat side airbag) malfunction assembly)
CIRCUIT DIAGRAM
AP+
AP-
Instrument Panel Passenger Airbag

Assembly (Passenger Side Airbag)
G024724J02
GETtheMANUALS.org
HINT:
RS
1 INSPECT INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY CONNECTOR
HINT:
disconnecting the battery negative terminal.
(b) Disconnect the connectors from the instrument panel passenger
airbag assembly.
(c) Check that the instrument panel passenger airbag assembly (front
passenger seat side airbag) connectors are not damaged.
Standard:
of position.
other damage.

WIRE (INSTRUMENT PANEL PASSENGER
AIRBAG ASSEMBLY CONNECTOR)
OK
2 INSPECT INSTRUMENT PANEL WIRE (BETWEEN AIRBAG COMPUTER ASSEMBLY AND

INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY)
HINT:
Instrument Panel Short Mechanism (b) Release the short circuiting mechanism of connector B (AP+, AP-).
Passenger Airbag Release (c) Using a tester, touch terminals P+ and P- of connector C with the
Assembly (Passenger
Side Airbag)
C Airbag connector.
Computer Standard:
D
NG REPLACE INSTRUMENT PANEL WIRE

(INSTRUMENT PANEL PASSENGER AIRBAG
ASSEMBLY CONNECTOR)
G024726J01
OK
GETtheMANUALS.org
RS–71

(c) Using the SST, clear the DTCs and then check the DTCs again. (See
C Airbag
Computer
page RS-19.)
RS
D
Assembly
Standard:
B1805/5 Standard:

E EC
G024728J02
OK
4 INSPECT PASSENGER SEAT IGNITER (INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY)

(c) Connect the connectors to the instrument panel passenger airbag
assembly.
C Airbag (d) Connect the negative battery terminal, turn the ignition switch on (IG)
Computer and wait for 60 seconds.
D Assembly (e) Using the SST, clear the DTCs and then check the DTCs again. (See
page IN-38.)
B1805/53 Standard:
Standard:
E
ECUT DTC B1805 is not output.
C137813 NG REPLACE INSTRUMENT PANEL

PASSENGER AIRBAG ASSEMBLY
OK
GETtheMANUALS.org
Open Circuit in Passenger Seat Front Collision

DTC B1806/54
Igniter Circuit
DESCRIPTION
RS When an open circuit is detected in the passenger seat airbag igniter circuit (AP+, AP- line), DTC B1806/54 is recorded in the

• Open circuit of the AP+ and AP- lines of the wire
harness between the airbag computer assembly and
the instrument panel passenger airbag assembly • Instrument panel passenger airbag assembly
B1806/54 (passenger seat side airbag) • Airbag computer assembly
• Instrument panel passenger airbag assembly • Instrument panel wire
(passenger seat side airbag) malfunction
CIRCUIT DIAGRAM
AP+
AP-
Instrument Panel Passenger Airbag Assembly

(Passenger Side Airbag)
C137997
GETtheMANUALS.org
RS–73
HINT:
RS
1 INSPECT PASSENGER SEAT AIRBAG IGNITER CIRCUIT (BETWEEN AIRBAG COMPUTER
ASSEMBLY AND INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY)
HINT:
Instrument Panel Passenger Airbag HINT:
Assembly (Passenger Side Airbag) Check that the ignition switch is turned off (LOCK) before
C (b) Disconnect the connectors from the airbag computer assembly and
Airbag
the instrument panel passenger airbag assembly.
Computer
Assembly (c) Using a tester, touch terminals P+ and P- of connector C with the
D
connector C.
Standard:
1Ω or less

ASSEMBLY AND INSTRUMENT PANEL
C137998
PASSENGER AIRBAG ASSEMBLY)
OK
GETtheMANUALS.org

(b) Using a wire harness (wire diameter: 0.5 mm), short the circuit
between terminals P+ and P- of connector C.
NOTICE:
C
RS Airbag
Computer
D Assembly (c) Connect the negative battery terminal, turn the ignition switch on (IG)
Portion (1) When reading the code using the warning lights:
(Wire Diameter 0.5 mm) DTC 54 is not output.
Standard:
B1806/54
E ECUT
C137999
OK

Instrument Panel Passenger Airbag Assembly (b) Disconnect the negative battery terminal, and wait for 90 seconds.
(c) Release the short circuit between P+ and P- of connector C and
connect the connectors to the instrument panel passenger airbag
C Airbag assembly.
D
Assembly
page IN-38.)
B1806/54 Standard:
Standard:
E ECUT DTC B1806 is not output.
C138001
NG REPLACE INSTRUMENT PANEL

OK
GETtheMANUALS.org
RS–75
Ground Short Circuit in Passenger Seat Front

DTC B1807/51
DESCRIPTION
When a ground short is detected in the passenger seat airbag igniter circuit (AP+, AP- line), DTC B1807/51 is recorded in the
RS
• Ground short circuit of the AP+ and AP- lines of the
wire harness between the airbag computer assembly • Instrument panel passenger airbag assembly
and the instrument panel passenger airbag assembly • Airbag computer assembly
CIRCUIT DIAGRAM
AP+
AP-

C137997
GETtheMANUALS.org
HINT:
RS
HINT:
Airbag
Computer
(c) Using a tester, measure the resistance between terminals P+ and P-
D Assembly
Standard:
1 MΩ or higher
NG INSPECT INSTRUMENT PANEL WIRE

C137998
OK
GETtheMANUALS.org
RS–77

Instrument Panel Passenger Airbag Assembly (b) Using a wire harness (wire diameter: 0.5 mm), short the circuit
(Passenger Side Airbag) between terminals P+ and P- of connector C.
NOTICE:
C
Airbag
Computer
RS
D Assembly (c) Connect the negative battery terminal, turn the ignition switch on (IG)
page RS-19.)
Twist The Stripped
Standard:
B1807/51
E ECUT
C138003
OK

(c) Release the short circuit between P+ and P- of connector C and
Airbag connect the connectors to the instrument panel passenger airbag
C
Computer assembly.
Assembly (d) Connect the negative battery terminal, turn the ignition switch on (IG)
D
page IN-38.)
B1807/51
Standard:
E ECUT
Standard:
C138004

OK
GETtheMANUALS.org
Power Supply Short Circuit in Passenger Seat

DTC B1808/52
Front Collision Igniter Circuit
DESCRIPTION
The passenger seat airbag igniter circuit consists of the airbag sensor assembly and the instrument panel passenger airbag
RS When a +B short is detected in the passenger seat airbag igniter circuit (AP+, AP- line), DTC B1808/52 is recorded in the airbag
computer assembly.

• +B short circuit of the AP+ and AP- lines of the wire
harness between the airbag computer assembly and • Instrument panel passenger airbag assembly
the instrument panel passenger airbag assembly • Airbag computer assembly
CIRCUIT DIAGRAM
AP+
AP-

C137997
GETtheMANUALS.org
RS–79
HINT:
RS
HINT:
Airbag
Computer
Assembly (c) Connect the negative battery terminal, and turn the ignition switch on
D
(IG).
(d) Using a tester, measure the voltage between terminals P+ and P- of
connector C, and the body ground.
Standard:
1 V or less

C137998
OK
GETtheMANUALS.org

(Passenger Side Airbag) (c) Connect the connectors to the airbag computer assembly.
(d) Using a wire harness (wire diameter: 0.5 mm), short the circuit
C
RS Airbag
Computer
between terminals P+ and P- of connector C.
NOTICE:
D Assembly When short circuiting, do not insert the wire harness into the
Twist The Stripped
Portion (f) Using the SST, clear the DTCs and then check the DTCs again. (See
Wire Harness page RS-19.)
(Wire Diameter 0.5 mm) (1) When reading the code using the warning lights:
Standard:
Standard:
E ECUT NG REPLACE AIRBAG COMPUTER ASSEMBLY

C138005
OK

(Passenger Side Airbag) (c) Release the short circuit between P+ and P- of connector C and
connect the connectors to the instrument panel passenger airbag
C Airbag assembly.
D Assembly and wait for 60 seconds.
page IN-38.)
B1808/52
Standard:
E Standard:
ECUT
C138006

OK
GETtheMANUALS.org
RS–81
DTC B1820/43 Short Circuit between Right Side Igniter Lines

DESCRIPTION
The front seat airbag RH igniter circuit consists of the airbag computer assembly and the front seat airbag assembly RH. The
front seat airbag assembly RH operates when deployment conditions are met.
When a short is detected in the front seat airbag RH igniter circuit (SFR+, SFR- line), DTC B1820/43 is recorded in the airbag
computer assembly.

RS
• Short circuit of the SFR+ and SFR-lines of the wire
• Front seat airbag assembly RH
B1820/43 the front seat airbag assembly RH
• Floor wire No. 2 (between the airbag computer assembly
• Front seat airbag assembly RH malfunction
and the front seat airbag assembly RH)
CIRCUIT DIAGRAM
Front Seat Airbag Assembly RH
C138007
HINT:
GETtheMANUALS.org
1 INSPECT FRONT SEAT AIRBAG RH IGNITER CIRCUIT (BETWEEN AIRBAG COMPUTER

ASSEMBLY AND FRONT SEAT AIRBAG ASSEMBLY RH)
HINT:
RS For inspection procedures and precautions, see page IN-38.
HINT:
Front Seat Airbag Airbag disconnecting the battery negative terminal.
Assembly RH Computer (b) Disconnect the connectors from the airbag computer assembly and
Assembly the front seat airbag assembly RH.
(c) Release the short circuiting mechanism of connector B (SFR+, SFR-
).
Short Mechanism (d) Using a tester, touch terminals SFR+ and SFR- of connector C with
Release the tester probe and measure the resistance between connector B
and connector C.
Standard:
1 MΩ or higher

C138008 (BETWEEN AIRBAG COMPUTER
ASSEMBLY AND FRONT SEAT AIRBAG
ASSEMBLY RH)
OK

Front Seat Airbag (c) Using the SST, clear the DTCs and then check the DTCs again. (See
Assembly RH Airbag
Computer page RS-19.)
Standard:
Standard:
B1820/43

E ECUT
C138009
OK
GETtheMANUALS.org
RS–83
3 INSPECT FRONT SEAT AIRBAG RH IGNITER

(c) Connect the connector to the front seat airbag assembly RH.
Front Seat
Airbag (d) Connect the negative battery terminal, turn the ignition switch on (IG)
Airbag
Assembly RH Computer
(e)
Using the SST, clear the DTCs and then check the DTCs again. (See
RS
Assembly
page IN-38.)
Standard:
B1820/43
Standard:
E ECUT
NG REPLACE FRONT SEAT AIRBAG
C138010 ASSEMBLY RH
OK
GETtheMANUALS.org
DTC B1821/44 Open Circuit in Right Side Igniter

DESCRIPTION
When an open circuit is detected in the front seat airbag RH igniter circuit (SFR+, SFR- line), DTC B1821/44 is recorded in the
CIRCUIT DIAGRAM
C138007
HINT:
GETtheMANUALS.org
RS–85

HINT:
For inspection procedures and precautions, see page IN-38. RS
HINT:
Front Seat Check that the ignition switch is turned off (LOCK) before
Airbag Airbag disconnecting the battery negative terminal.
(c) Using a tester, touch terminals SFR+ and SFR- of connector C with
and connector C.
Standard:
1Ω or less

C138011
ASSEMBLY RH)
OK

(b) Using the SST, short the circuit between terminals SFR+ and SFR- of
Front Seat connector C.
Airbag NOTICE:
Airbag
Assembly RH When short circuiting, do not insert the SST into the connector
Computer
Assembly terminals with force.
page RS-19.)
Standard:
B1821/44
Standard:
E ECUT
C138012
GETtheMANUALS.org
OK

RS Front Seat
Airbag
(c) Release the short circuit between SFR+ and SFR- of connector C
and connect the connectors to the front seat airbag assembly RH.
Airbag
Assembly RH Computer (d) Connect the negative battery terminal, turn the ignition switch on (IG)
page IN-38.)
B1821/44 Standard:
Standard:
C138013 NG REPLACE FRONT SEAT AIRBAG

ASSEMBLY RH
OK
GETtheMANUALS.org
RS–87
DTC B1822/41 Ground Short Circuit in Right Side Igniter

DESCRIPTION
When a ground short is detected in the front seat airbag RH igniter circuit (SFR+, SFR- line), DTC B1822/41 is recorded in the

RS
CIRCUIT DIAGRAM
C138007
HINT:
GETtheMANUALS.org

HINT:
HINT:
(c) Using a tester, measure the resistance between terminals SFR+ and
SFR- of connector C, and the body ground.
Standard:
1 MΩ or higher

ASSEMBLY RH)
C138011
OK

(b) Using the SST, short the circuit between terminals SFR+ and SFR- of
Front Seat connector C.
Airbag NOTICE:
Airbag
Assembly RH Computer When short circuiting, do not insert the SST into the connector
page RS-19.)
Standard:
Standard:
B1822/41
E ECUT
C138014
GETtheMANUALS.org
RS–89
OK

Front Seat
Airbag Airbag
RS
Assembly RH Computer (d) Connect the negative battery terminal, turn the ignition switch on (IG)
page IN-38.)
B1822/41 (1) When reading the code using the warning lights:
Standard:
Standard:

ASSEMBLY RH
OK
GETtheMANUALS.org
DTC B1823/42 Power Supply Short Circuit in Right Side Igniter

DESCRIPTION
When a +B short is detected in the front seat airbag RH igniter circuit (SFR+, SFR- line), DTC B1823/42 is recorded in the airbag
computer assembly.
• +B Short circuit of the SFR+ and SFR- lines of the wire
CIRCUIT DIAGRAM
C138007
HINT:
GETtheMANUALS.org
RS–91

HINT:
HINT:
(IG).
(d) Using a tester, check the voltage between terminals SFR+ and SFR-
Standard:
1 V or less

C138011
ASSEMBLY RH)
OK

Front Seat (c) Connect the connectors to the airbag computer assembly.
Airbag Airbag (d) Using the SST, short the circuit between terminals SFR+ and SFR- of
Assembly RH Computer connector C.
Assembly NOTICE:
When short circuiting, do not insert the SST into the connector
terminals with force.
page RS-19.)
Standard:
B1823/42
Standard:

C138016
GETtheMANUALS.org
OK

RS Front Seat
Airbag Airbag
Assembly RH (d) Connect the negative battery terminal, turn the ignition switch on (IG)
Computer
Assembly
(e) Using the DS-II, clear the DTCs and then check the DTCs again.
(See page IN-38.)
B1823/42 Standard:
Standard:

ASSEMBLY RH
OK
GETtheMANUALS.org
RS–93
DTC B1825/47 Short in L side side ignition system wire

DESCRIPTION
The front seat airbag LH igniter circuit consists of the airbag computer assembly and the front seat airbag assembly LH. The front
seat airbag assembly LH operates when the deployment conditions are met.
When a short is detected in the front seat airbag LH igniter circuit (SFL+, SFL- line), DTC B1825/47 is recorded in the airbag
computer assembly.

RS
• Short circuit of the SFL+ and SFL-lines of the wire
• Front seat airbag assembly LH
B1825/47 the front seat airbag assembly LH
• Front seat airbag assembly LH malfunction
and the front seat airbag assembly LH)
CIRCUIT DIAGRAM
Front Seat Airbag Assembly LH
C138018
HINT:
GETtheMANUALS.org
1 INSPECT FRONT SEAT AIRBAG LH IGNITER CIRCUIT (BETWEEN AIRBAG COMPUTER ASSEMBLY
AND FRONT SEAT AIRBAG ASSEMBLY LH)
HINT:
Front Seat Airbag HINT:
Short Mechanism
Assembly LH Check that the ignition switch is turned off (LOCK) before
Release
Airbag the front seat airbag assembly LH.
Computer (c) Release the short circuiting mechanism of connector B (SFL+, SFL-).
Assembly (d) Using a tester, touch terminals SFL+ and SFL- of connector C with
and connector C.
Standard:
1 M Ω or higher

C138019
ASSEMBLY LH)
OK

Front Seat Airbag (b) Connect the negative battery terminal, turn the ignition switch on (IG)
Assembly LH and wait for 60 seconds.
page RS-19.)
Airbag (1) When reading the code using the warning lights:
Computer
Standard:
Assembly
Standard:
B1825/47 DTC B1825 is not output.

E ECUT
C138020
OK
GETtheMANUALS.org
RS–95
3 INSPECT FRONT SEAT AIRBAG LH IGNITER

Front Seat Airbag
Assembly LH
(c) Connect the connector to the front seat airbag assembly LH.
Airbag
(e)
Using the SST, clear the DTCs and then check the DTCs again. (See
RS
Computer
Assembly page IN-38.)
Standard:
B1825/47 (2) When reading the code using the DS-II:
Standard:
E ECUT
NG REPLACE FRONT SEAT AIRBAG
C138021 ASSEMBLY LH
OK
GETtheMANUALS.org
DTC B1826/48 Open Circuit in Left Side Igniter

DESCRIPTION
When an open circuit is detected in the front seat airbag LH igniter circuit (SFL+, SFL- line), DTC B1826/48 is recorded in the
• Open circuit of the SFL+ and SFL-lines of the wire
CIRCUIT DIAGRAM
C138018
HINT:
GETtheMANUALS.org
RS–97
HINT:
Computer (c) Using a tester, touch terminals SFL+ and SFL- of connector C with
Assembly the tester probe and measure the resistance between connector B
and connector C.
Standard:
1Ω or less

C138023
ASSEMBLY LH)
OK

Front Seat Airbag (b) Using SST, short the circuit between terminals SFL+ and SFL- of
Assembly LH connector C.
NOTICE:
Airbag terminals with force.
Computer
Assembly
page RS-19.)
Standard:
B1826/48 Standard:

E ECUT
C138024
GETtheMANUALS.org
OK

Front Seat Airbag (b) Disconnect the negative battery terminal, and wait for 90 seconds.
Assembly LH
RS (c) Release the short circuit between SFL+ and SFL- of connector C and
connect the connectors to the front seat airbag assembly LH.
Airbag
Computer
Assembly (e) Using the SST, clear the DTCs and then check the DTCs again. (See
page IN-38.)
B1826/48 Standard:
Standard:

ASSEMBLY LH
OK
GETtheMANUALS.org
RS–99
DTC B1827/45 Ground Short Circuit in Left Side Igniter

DESCRIPTION
When a ground short is detected in the front seat airbag LH igniter circuit (SFL+, SFL- line), DTC B1827/45 is recorded in the

RS
• Short circuit of the SFL+ and SFL-lines of the wire
CIRCUIT DIAGRAM
C138018
HINT:
GETtheMANUALS.org
HINT:
Computer (c) Using a tester, measure the resistance between terminals SFL+ and
Assembly SFL- of connector C and the body ground.
Standard:
1 M Ω or higher

ASSEMBLY LH)
C138023
OK

Front Seat Airbag (b) Using SST, short the circuit between terminals SFL+ and SFL- of
Assembly LH connector C.
NOTICE:
Airbag terminals with force.
Computer (c) Connect the negative battery terminal, turn the ignition switch on (IG)
page RS-19.)
Standard:
Standard:
B1827/45
E ECUT
C138027
GETtheMANUALS.org
RS–101
OK

Assembly LH
(c) Release the short circuit between SFL+ and SFL- of connector C and
RS
Airbag and wait for 60 seconds.
Computer
Assembly
page IN-38.)
B1827/45 Standard:
Standard:

ASSEMBLY LH
OK
GETtheMANUALS.org
DTC B1828/46 Power Supply Short Circuit in Left Side Igniter

DESCRIPTION
When a +B short is detected in the front seat airbag LH igniter circuit (SFL+, SFL- line), DTC B1828/46 is recorded in the airbag
computer assembly.
• +B short circuit of the SFL+ and SFL-lines of the wire
CIRCUIT DIAGRAM
C138018
HINT:
GETtheMANUALS.org
RS–103
HINT:
Computer (c) Connect the negative battery terminal, and turn the ignition switch on
Assembly (IG).
(d) Using a tester, check the voltage between terminals SFL+ and SFL-
Standard:
1 V or less

C138023
ASSEMBLY LH)
OK

Assembly LH (c) Connect the connectors to the airbag computer assembly.
(d) Using SST, short the circuit between terminals SFR+ and SFR- of
connector C.
Airbag NOTICE:
Computer When short circuiting, do not insert the SST into the connector
page RS-19.)
Standard:
Standard:

C138030
GETtheMANUALS.org
OK

Front Seat Airbag
RS Assembly LH (c) Release the short circuit between SFL+ and SFL- of connector C and
Computer (e) Using the SST, clear the DTCs and then check the DTCs again. (See
Assembly
page IN-38.)
B1828/46 Standard:
Standard:
E ECUT

ASSEMBLY LH
OK
GETtheMANUALS.org
RS–105
Short Circuit between Right Side Curtain Igniter

DTC B1830/83
Lines
DESCRIPTION
The curtain shield airbag RH igniter circuit consists of the airbag computer assembly and the curtain shield airbag RH. The curtain
shield airbag RH operates when the deployment conditions are met.
When a short is detected in the curtain shield airbag RH igniter circuit (ICR+, ICR- line), DTC B1830/83 is recorded in the airbag
computer assembly.
RS
• Short circuit of the ICR+ and ICR-lines of the wire
• Curtain shield airbag RH
B1830/83 the curtain shield airbag assembly RH
• Curtain shield airbag RH malfunction
and curtain shield airbag RH)
CIRCUIT DIAGRAM
Curtain Shield Door Airbag RH
C138083
GETtheMANUALS.org
HINT:
RS
1 CHECK CURTAIN SHIELD AIRBAG CONNECTORS
HINT:
(b) Disconnect the connector from the curtain shield airbag RH.
(c) Check that there is no damage to the curtain shield airbag RH
connectors.
Standard:
of position.
other damage.

(CURTAIN SHIELD AIRBAG CONNECTOR)
OK
2 INSPECT CURTAIN SHIELD AIRBAG RH IGNITER CIRCUIT (BETWEEN AIRBAG COMPUTER

ASSEMBLY AND CURTAIN SHIELD AIRBAG RH)
HINT:
Short Mechanism Release (b) Release the short circuiting mechanism of connector B (ICR+, ICR-).
Curtain Shield (c) Using a tester, touch terminals ICR+ and ICR- of connector C with the
Door Airbag RH Airbag tester probe and measure the resistance between connector B and
Computer
connector C.
Assembly
Standard:
1 MΩ or higher

ASSEMBLY AND CURTAIN SHIELD AIRBAG
RH)
C138084
OK
GETtheMANUALS.org
RS–107

Curtain Shield
Door Airbag RH Airbag
Computer page RS-19.)
RS
Assembly
Standard:
B1830/83 Standard:
E ECUT
C138085
OK
4 INSPECT CURTAIN SHIELD AIRBAG RH IGNITER

Curtain Shield (c) Connect the connector to the curtain shield airbag RH.
Door Airbag RH Airbag (d) Connect the negative battery terminal, turn the ignition switch on (IG)
Assembly
page IN-38.)
Standard:
B1830/83
Standard:
E ECUT
NG REPLACE CURTAIN SHIELD AIRBAG RH
C138086
OK
GETtheMANUALS.org
DTC B1831/84 Open Circuit in Right Side Curtain Igniter

DESCRIPTION
When an open circuit is detected in the curtain shield airbag RH igniter circuit (ICR+, ICR- line), DTC B1831/84 is recorded in the
• Open circuit of the ICR+ and ICR-lines of the wire
CIRCUIT DIAGRAM
Curtain Shield Airbag RH
C138087
HINT:
GETtheMANUALS.org
RS–109

HINT:
HINT:
Curtain Shield Check that the ignition switch is turned off (LOCK) before
Airbag
Airbag RH disconnecting the battery negative terminal.
Computer
Assembly
the curtain shield airbag RH.
(c) Using a tester, touch terminals ICR+ and ICR- of connector C with the
connector C.
Standard:
1Ω or less

C138088
RH)
OK

Curtain Shield (b) Using a wire harness (wire diameter: 0.5 mm), short circuit between
Airbag RH Airbag terminals ICR+ and ICR- of connector C.
Computer NOTICE:
Assembly When short circuiting, do not insert the wire harness into the
Twist The Stripped (d) Using the SST, clear the DTCs and then check the DTCs again. (See
(Wire Diameter 0.5 mm) Standard:
Standard:
B1831/84

E ECUT
C138089
GETtheMANUALS.org
OK

RS Curtain Shield
Airbag RH Airbag
(c) Release the short circuit between ICR+ and ICR- of connector C and
connect the connectors to the curtain shield airbag RH.
page IN-38.)
B1831/84 Standard:
Standard:
C138090 NG REPLACE CURTAIN SHIELD AIRBAG RH
OK
GETtheMANUALS.org
RS–111
Ground Short Circuit in Right Side Curtain

DTC B1832/81
Igniter
DESCRIPTION
When a ground short is detected in the curtain shield airbag RH igniter circuit (ICR+, ICR- line), DTC B1832/82 is recorded in the
RS
• Ground short circuit of the ICR+ and ICR-lines of the
wire harness between the airbag computer assembly
B1832/82 and the curtain shield airbag assembly RH
CIRCUIT DIAGRAM
C138087
GETtheMANUALS.org
HINT:
RS
HINT:
HINT:
Airbag
Airbag RH Computer disconnecting the battery negative terminal.
Assembly (b) Disconnect the connectors from the airbag computer assembly and
(c) Using a tester, measure the resistance between terminals ICR+ and
ICR- of connector C, and the body ground.
Standard:
1 MΩ or higher

RH)
C138088
OK
GETtheMANUALS.org
RS–113

Curtain Shield (b) Using a wire harness (wire diameter: 0.5 mm), short circuit between
Airbag RH Airbag terminals ICR+ and ICR- of connector C.
Computer NOTICE:
RS
Twist The Stripped
Portion
page RS-19.)
Wire Harness
Standard:
B1832/81
Standard:

E ECUT
C138091
OK

Curtain Shield
Airbag RH Airbag
page IN-38.)
B1832/81 Standard:
Standard:
E ECUT
OK
GETtheMANUALS.org
Power Supply Short Circuit in Right Side

DTC B1833/82
Curtain Igniter
DESCRIPTION
RS When a +B short is detected in the curtain shield airbag RH igniter circuit (ICR+, ICR- line), DTC B1833/82 is recorded in the

• +B short circuit of the ICR+ and ICR-lines of the wire
CIRCUIT DIAGRAM
C138087
GETtheMANUALS.org
RS–115
HINT:
RS
HINT:
HINT:
Airbag
Airbag RH disconnecting the battery negative terminal.
Computer
Assembly
(IG).
(d) Using a tester, measure the resistance between terminals ICR+ and
ICR- of connector C, and the body ground.
Standard:
1Ω or less

C138088
RH)
OK
GETtheMANUALS.org

Curtain Shield (b) Disconnect the negative battery terminal, and wait for 90 seconds.
Airbag RH Airbag (c) Connect the connectors to the airbag computer assembly.
Computer (d) Using a wire harness (wire diameter: 0.5 mm), short circuit between
RS Assembly terminals ICR+ and ICR- of connector C.

NOTICE:
Portion
Wire Harness
(Wire Diameter 0.5 mm)
page RS-19.)
Standard:
B1833/82
Standard:
E ECUT
C138093
OK

Curtain Shield
Airbag RH Airbag
page IN-38.)
B1833/82 Standard:
Standard:
E ECUT
OK
GETtheMANUALS.org
RS–117
Short Circuit between Left Side Curtain Igniter

DTC B1835/87
Lines
DESCRIPTION
The curtain shield airbag LH igniter circuit consists of the airbag computer assembly and the curtain shield airbag LH. The curtain
shield airbag LH operates when the deployment conditions are met.
When a short is detected in the curtain shield airbag LH igniter igniter (ICL+, ICL- line), DTC B1836/87 is recorded in the airbag
computer assembly.
RS
• Short circuit of the ICR+ and ICR- lines of the wire
• Curtain shield airbag LH
B1836/87 the curtain shield airbag assembly LH
• Curtain shield airbag LH malfunction
and curtain shield airbag LH)
CIRCUIT DIAGRAM
Curtain Shield Airbag LH
C138095
GETtheMANUALS.org
HINT:
RS
1 CHECK CURTAIN SHIELD AIRBAG CONNECTORS
HINT:
(b) Disconnect the connector from the curtain shield airbag LH.
(c) Check that there is no damage to the curtain shield airbag LH
connectors.
Standard:
of position.
other damage.

(CURTAIN SHIELD AIRBAG CONNECTOR)
OK
2 INSPECT CURTAIN SHIELD AIRBAG LH IGNITER CIRCUIT (BETWEEN AIRBAG COMPUTER

ASSEMBLY AND CURTAIN SHIELD AIRBAG LH)
HINT:
Curtain Shield Short Mechanism Release (b) Release the short circuiting mechanism of connector B (ICL+, ICL-).
Airbag LH (c) Using a tester, touch terminals ICL+ and ICL- of connector C with the
connector C.
Airbag Standard:
Computer
1 MΩ or higher
Assembly
LH)
C138096
OK
GETtheMANUALS.org
RS–119

Curtain Shield (b) Connect the negative battery terminal, turn the ignition switch on (IG)
Airbag LH and wait for 60 seconds.
Airbag
page RS-19.)
RS
Computer Standard:
Assembly DTC 87 is not output.
Standard:
B1835/87
E ECUT
C138097
OK
4 INSPECT CURTAIN SHIELD AIRBAG LH IGNITER

Curtain Shield (b) Disconnect the negative battery terminal, and wait for 90 seconds.
Airbag LH
(c) Connect the connector to the curtain shield airbag LH.
Airbag
Computer
page IN-38.)
Assembly
Standard:
Standard:
E ECUT NG REPLACE CURTAIN SHIELD AIRBAG LH

C138098
OK
GETtheMANUALS.org
DTC B1836/88 L side curtain ignition system open circuit

DESCRIPTION
When an open circuit is detected in the curtain shield airbag LH igniter circuit (ICL+, ICL- line), DTC B1836/88 is recorded in the
• Open circuit of the ICR+ and ICR- lines of the wire
CIRCUIT DIAGRAM
C138095
HINT:
GETtheMANUALS.org
RS–121

HINT:
Curtain Shield Airbag LH HINT:
Airbag curtain shield airbag LH.
Computer (c) Using a tester, touch terminals ICL+ and ICL- of connector C with the
Assembly
connector C.
Standard:
1Ω or less

C138099
LH)
OK

Curtain Shield Airbag LH (b) Using a wire harness (wire diameter: 0.5 mm), short circuit between
terminals ICL+ and ICL- of connector C.
NOTICE:
Airbag When short circuiting, do not insert the wire harness into the
Computer connector terminals with force.
Assembly (c) Connect the negative battery terminal, turn the ignition switch on (IG)
Twist The Stripped (d) Using the SST, clear the DTCs and then check the DTCs again. (See
(Wire Diameter 0.5 mm ) Standard:
B1836/88 Standard:

E ECUT
C138100
GETtheMANUALS.org
OK

Curtain Shield Airbag LH (b) Disconnect the negative battery terminal, and wait for 90 seconds.
RS (c) Release the short circuit between ICL+ and ICL- of connector C and
connect the connectors to the curtain shield airbag LH.
Standard:
Standard:
E ECUT
C138101 NG REPLACE CURTAIN SHIELD AIRBAG LH
OK
GETtheMANUALS.org
RS–123
DTC B1837/85 Ground Short Circuit in Left Side Curtain Igniter

DESCRIPTION
When a ground short is detected in the curtain shield airbag LH igniter circuit (ICL+, ICL- line), DTC B1837/85 is recorded in the

RS
• Short circuit of the ICR+ and ICR- lines of the wire
CIRCUIT DIAGRAM
C138095
HINT:
GETtheMANUALS.org

HINT:
Computer (c) Using a tester, measure the resistance between terminals ICL+ and
Assembly
ICL- of connector C and the body ground.
Standard:
1 M Ω or higher

LH)
C138099
OK

(b) Using a wire harness (wire diameter: 0.5 mm), short circuit between
terminals ICL+ and ICL- of connector C.
NOTICE:
Airbag
Computer
Assembly (c) Connect the negative battery terminal, turn the ignition switch on (IG)
Twist The Stripped Portion page RS-19.)
Wire Harness
Standard:
B1837/85 Standard:

E ECUT
C138102
GETtheMANUALS.org
RS–125
OK

(c) Release the short circuit between ICL+ and ICL- of connector C and
RS
Standard:
Standard:
E ECUT
OK
GETtheMANUALS.org
Power Supply Short Circuit in Left Side Curtain

DTC B1838/86
Igniter
DESCRIPTION
RS When a B+ short is detected in the curtain shield airbag LH igniter circuit (ICL+, ICL- line), DTC B1838/86 is recorded in the

• Ground short circuit of the ICR+ and ICR- lines of the
wire harness between the airbag computer assembly
B1838/86 and the curtain shield airbag assembly LH
CIRCUIT DIAGRAM
C138095
GETtheMANUALS.org
RS–127
HINT:
RS
HINT:
Assembly (IG).
(d) Using a tester, check the voltage between terminals ICL+ and ICL- of
connector C and the body ground.
Standard:
1 V or less

C138099
LH)
OK
GETtheMANUALS.org

(d) Using a wire harness (wire diameter: 0.5 mm), short circuit between
RS Airbag terminals ICL+ and ICL- of connector C.

NOTICE:
Computer
Portion and wait for 60 seconds.
Wire Harness (f) Using the SST, clear the DTCs and then check the DTCs again. (See
Wire Diameter 0.5 mm ) page RS-19.)
Standard:
Standard:
E ECUT
C138104
OK

(c) Release the short circuit between ICL+ and ICL- of connector C and
Airbag
page IN-38.)
B1838/86 Standard:
Standard:
E ECUT
OK
GETtheMANUALS.org
RS–129
Short Circuit between Front Right Seat

DTC B1900/63
Pretensioner Lines
DESCRIPTION
The front pretensioner RH igniter circuit consists of the airbag computer assembly and the front seat outer belt assembly RH
(driver seat side pretensioner). The pretensioner RH operates when the deployment conditions are met.
When a short is detected in the front pretensioner RH igniter circuit (PR+, PR- line), DTC B1900/63 is recorded in the airbag
computer assembly.
RS
• Short to the PR+ and PR- lines of the wire harness • Front seat outer belt assembly RH (driver seat side
between the airbag computer assembly and front seat pretensioner)
outer belt assembly RH (driver seat side pretensioner) • Airbag computer assembly
B1900/63
• Front seat outer belt assembly RH (driver seat side • Floor wire No. 2 (between the airbag computer assembly
pretensioner) malfunction and the front seat outer belt assembly RH [driver seat
• Airbag computer assembly malfunction side pretensioner])
CIRCUIT DIAGRAM
Front Seat Outer Belt Assembly RH

(Driver Side Pretensioner)
C138033
GETtheMANUALS.org
HINT:
RS
1 CHECK PRETENSIONER CONNECTOR
HINT:
(b) Disconnect the connector from the pretensioner RH.
(c) Check that there is no damage to the pretensioner connector.
Standard:
of position.
other damage.

(PRETENSIONER CONNECTOR)
OK
2 INSPECT FRONT PRETENSIONER RH IGNITER CIRCUIT (BETWEEN AIRBAG COMPUTER

ASSEMBLY AND FRONT SEAT OUTER BELT ASSEMBLY RH)
HINT:
(b) Release the short circuiting mechanism of connector B (PR+, PR-).
Front Seat Outer Belt
(c) Using a tester, touch terminals PR+ and PR- of connector C with the
Assembly RH Airbag
(Driver Side Pretensioner) Computer
Assembly connector C.
Standard:
1 MΩ or higher
Short Mechanism NG REPAIR OR REPLACE FLOOR WIRE NO. 2

Release (BETWEEN AIRBAG COMPUTER
ASSEMBLY AND FRONT SEAT OUTER BELT
ASSEMBLY RH)
C138034
OK
GETtheMANUALS.org
RS–131

Front Seat Outer Belt and wait for 60 seconds.
Assembly RH (c) Using the SST, clear the DTCs and then check the DTCs again. (See
(Driver Side Pretensioner) Airbag
Computer
page RS-19.)
RS
Assembly Standard:
B1900/63 Standard:
E ECUT
C138035
OK
4 INSPECT FRONT PRETENSIONER RH IGNITER

Front Seat Outer Belt (c) Connect the connector to the pretensioner RH.
Assembly RH (d) Connect the negative battery terminal, turn the ignition switch on (IG)
(Driver Side Pretensioner) and wait for 60 seconds.
Airbag
Standard:
Standard:
E NG REPLACE FRONT SEAT OUTER BELT

ECUT
C138036 ASSEMBLY RH
OK
GETtheMANUALS.org
DTC B1901/64 Open Circuit in Front Right Seat Pretensioner

DESCRIPTION
When an open circuit is detected in the front pretensioner RH igniter circuit (PR+, PR- line), DTC B1901/64 is recorded in the
• Open circuit to the PR+ and PR- lines of the wire
• Front seat outer belt assembly RH (driver seat side
pretensioner)
front seat outer belt assembly RH (driver seat side
B1901/64 pretensioner)
and the front seat outer belt assembly RH [driver seat
pretensioner) malfunction
side pretensioner])
CIRCUIT DIAGRAM

C138033
GETtheMANUALS.org
RS–133
HINT:
RS
HINT:
HINT:
Assembly RH
(Driver Side Pretensioner) disconnecting the battery negative terminal.
Airbag
Computer
Assembly the pretensioner RH.
(c) Using a tester, touch terminals PR+ and PR- of connector C with the
connector C.
Standard:
1Ω or less

C138038
ASSEMBLY RH)
OK
GETtheMANUALS.org

Front Seat Outer Belt (b) Using a wire harness (wire diameter: 0.5 mm), short the circuit
Assembly RH between terminals PR+ and PR- of connector C.
(Driver Side Pretensioner) NOTICE:
Airbag
RS Computer
Assembly
page RS-19.)
Twist The Stripped (1) When reading the code using the warning lights:
Portion Standard:
Wire Harness
Standard:
E
ECUT
C138039
OK

(c) Release the short circuit between PR+ and PR- of connector C and
Assembly RH
connect the connectors to the pretensioner RH.
page IN-38.)
B1901/64 Standard:
Standard:
C138040 NG REPLACE FRONT SEAT OUTER BELT

ASSEMBLY RH
OK
GETtheMANUALS.org
RS–135
DTC B1902/61 Ground Short in Front Right Seat Pretensioner

DESCRIPTION
When a ground short is detected in the front pretensioner RH igniter circuit (PR+, PR- line), DTC B1902/61 is recorded in the

RS
• A ground short to the PR+ and PR- lines of the wire
pretensioner)
side pretensioner])
CIRCUIT DIAGRAM

C138033
GETtheMANUALS.org
HINT:
RS
HINT:
HINT:
Assembly RH
(Driver Side Pretensioner) Airbag disconnecting the battery negative terminal.
Computer (b) Disconnect the connectors from the airbag computer assembly and
(c) Using a tester, measure the resistance between terminals PR+ and
PR- of connector C, and the body ground.
Standard:
1 MΩ or higher

ASSEMBLY RH)
C138041
OK
GETtheMANUALS.org
RS–137

Front Seat Outer Belt (b) Using a wire harness (wire diameter: 0.5 mm), short the circuit
Assembly RH
between terminals PR+ and PR- of connector C.
Airbag NOTICE:
Computer
Assembly
RS
B1902/61 Standard:
E ECUT
C138042
OK

Front Seat Outer Belt (c) Release the short circuit between PR+ and PR- of connector C and
Assembly RH connect the connectors to the pretensioner RH.
(Driver Side Pretensioner) Airbag (d) Connect the negative battery terminal, turn the ignition switch on (IG)
page IN-38.)
B1902/61 Standard:
Standard:
ECUT DTC B1902 is not output.
E
ASSEMBLY RH
OK
GETtheMANUALS.org
Power Supply Short Circuit in Front Right Seat

DTC B1903/62
Pretensioner
DESCRIPTION
RS When a +B short is detected in the front pretensioner RH igniter circuit (PR+, PR- line), DTC B1903/62 is recorded in the airbag
computer assembly.

• A ground short to the PR+ and PR- lines of the wire
pretensioner)
side pretensioner])
CIRCUIT DIAGRAM

C138033
GETtheMANUALS.org
RS–139
HINT:
RS
HINT:
HINT:
Assembly RH
(Driver Side Pretensioner) Airbag disconnecting the battery negative terminal.
Computer (b) Disconnect the connectors from the airbag computer assembly and
(IG).
(d) Using a tester, measure the voltage between terminals PR+ and PR-
Standard:
1 V or less

C138041
ASSEMBLY RH)
OK
GETtheMANUALS.org

Front Seat Outer Belt (b) Disconnect the negative battery terminal, and wait for 90 seconds.
Assembly RH (c) Connect the connectors to the airbag computer assembly.
(Driver Side Pretensioner) (d) Using a wire harness (wire diameter: 0.5 mm), short the circuit
Airbag
RS Computer
Assembly
between terminals PR+ and PR- of connector C.
NOTICE:
Twist The Stripped and wait for 60 seconds.
(Wire Diameter 0.5 mm ) (1) When reading the code using the warning lights:
Standard:
Standard:
C138044
OK

Front Seat Outer Belt (c) Release the short circuit between PR+ and PR- of connector C and
Assembly RH connect the connectors to the pretensioner RH.
(Driver Side Pretensioner) Airbag (d) Connect the negative battery terminal, turn the ignition switch on (IG)
page IN-38.)
B1903/62
Standard:
Standard:
E ECUT
ASSEMBLY RH
OK
GETtheMANUALS.org
RS–141
Short Circuit between Front Left Pretensioner

DTC B1905/73
Lines
DESCRIPTION
The front pretensioner LH igniter circuit consists of the airbag computer assembly and the front seat outer belt assembly LH
(passenger seat side pretensioner). The pretensioner LH operates when the deployment conditions are met.
When a short is detected in the front pretensioner LH igniter circuit (PL+, PL- line), DTC B1905/73 is recorded in the airbag
computer assembly.
RS
• Short to the PL+ and PL- lines of the wire harness
• Front seat outer belt assembly LH (front passenger seat
between the airbag computer assembly and front seat
side pretensioner)
outer belt assembly LH (front passenger seat side
• Floor wire (between the airbag computer assembly and
• Front seat outer belt assembly LH (front passenger
the front seat outer belt assembly LH [front passenger
seat side pretensioner) malfunction
seat side pretensioner])
CIRCUIT DIAGRAM
Front Seat Outer Belt Assembly LH

(Passenger Side Pretensioner)
C138046
GETtheMANUALS.org
HINT:
test mode.(See page IN-33)
RS
1 CHECK PRETENSIONER CONNECTOR
HINT:
(b) Disconnect the connector from the pretensioner LH.
(c) Check that there is no damage to the pretensioner connector.
Standard:
of position.
other damage.

(PRETENSIONER CONNECTOR)
OK
2 INSPECT FRONT SEAT PRETENSIONER LH IGNITER CIRCUIT (BETWEEN AIRBAG COMPUTER

ASSEMBLY AND FRONT SEAT OUTER BELT ASSEMBLY LH)
HINT:
Front Seat Outer Belt Assembly LH (b) Release the short circuiting mechanism of connector B (PL+, PL-).
(Passenger Side Pretensioner) (c) Using a tester, touch terminals PL+ and PL- of connector C with the
Short Mechanism Release tester probe and measure the resistance between connector B and
connector C.
Standard:
Airbag
1 MΩ or higher
Computer
Assembly NG REPAIR OR REPLACE FLOOR WIRE NO. 2
ASSEMBLY LH)
C138047
OK
GETtheMANUALS.org
RS–143

Airbag (c) Using the SST, clear the DTCs and then check the DTCs again. (See
Computer
Front Seat Outer Belt Assembly
page RS-19.)
RS
Assembly LH
Standard:
(Passenger Side
Pretensioner)
Standard:
B1905/73
E ECUT
C138048
OK
4 INSPECT FRONT PRETENSIONER LH IGNITER

(c) Connect the connector to the pretensioner LH.
Airbag
Computer
Front Seat Outer Assembly and wait for 60 seconds.
Belt Assembly LH (e) Using the SST, clear the DTCs and then check the DTCs again. (See
(Passenger Side page IN-38.)
Pretensioner) (1) When reading the code using the warning lights:
Standard:
Standard:
E ECUT
NG REPLACE FRONT SEAT OUTER BELT
C138049 ASSEMBLY LH
OK
GETtheMANUALS.org
DTC B1906/74 Open Circuit in Front Left Side Pretensioner

DESCRIPTION
When an open circuit is detected in the front pretensioner LH igniter circuit (PL+, PL- line), DTC B1906/74 is recorded in the
• Open circuit to the PL+ and PL- lines of the wire
side pretensioner)
front seat outer belt assembly LH (front passenger seat
B1906/74 side pretensioner)
and the front seat outer belt assembly LH [front
passenger seat side pretensioner])
CIRCUIT DIAGRAM

C138046
GETtheMANUALS.org
RS–145
HINT:
RS
HINT:
Front Seat Outer Belt Assembly LH HINT:
(Passenger Side Pretensioner) Check that the ignition switch is turned off (LOCK) before
Airbag pretensioner LH.
Computer (c) Using a tester, touch terminals PL+ and PL- of connector C with the
Assembly tester probe and measure the resistance between connector B and
connector C.
Standard:
1Ω or less

C138050
ASSEMBLY LH)
OK
GETtheMANUALS.org

Front Seat Outer Belt Assembly LH (b) Using a wire harness (wire diameter: 0.5 mm), short the circuit
(Passenger Side Pretensioner) between terminals PL+ and PL- of connector C.
NOTICE:
RS When short circuiting, do not insert the wire harness into the
Airbag (c) Connect the negative battery terminal, turn the ignition switch on (IG)
Computer
Assembly
page RS-19.)
Twist The Stripped
Portion
Standard:
Wire Harness
Standard:
E ECUT
C138051
OK

Front Seat Outer Belt Assembly LH (b) Disconnect the negative battery terminal, and wait for 90 seconds.
(Passenger Side Pretensioner) (c) Release the short circuit between PL+ and PL- of connector C and
connect the connectors to the pretensioner LH.
page IN-38.)
B1906/74 Standard:
Standard:
E ECUT
ASSEMBLY LH
OK
GETtheMANUALS.org
RS–147
DTC B1907/71 Ground Short in Front Left Seat Pretensioner

DESCRIPTION
When a ground short is detected in the front pretensioner LH igniter circuit (PL+, PL- line), DTC B1907/71 is recorded in the

RS
• Ground short to the PL+ and PL- lines of the wire
side pretensioner)
front seat outer belt assembly LH (front passenger seat
B1907/71 side pretensioner)
CIRCUIT DIAGRAM

C138046
GETtheMANUALS.org
HINT:
RS
HINT:
Computer (c) Using a tester, measure the resistance between terminals PL+ and
Assembly PL- of connector C and the body ground.
Standard:
1 M Ω or higher

ASSEMBLY LH)
C138050
OK
GETtheMANUALS.org
RS–149

Front Seat Outer Belt Assembly LH (b) Using a wire harness (wire diameter: 0.5 mm), short the circuit
(Passenger Side Pretensioner) between terminals PL+ and PL- of connector C.
NOTICE:
RS
Airbag
Computer
Assembly
page RS-19.)
Twist The Stripped
Portion
Standard:
Wire Harness
Standard:
B1907/71
E ECUT
C138053
OK

page IN-38.)
Standard:
B1907/71
Standard:

ASSEMBLY LH
OK
GETtheMANUALS.org
Power Supply Short Circuit in Front Left Seat

DTC B1908/72
Pretensioner
DESCRIPTION
RS When a +B short is detected in the front pretensioner LH igniter circuit (PL+, PL- line), DTC B1908/72 is recorded in the airbag
computer assembly.

• +B short to the PL+ and PL- lines of the wire harness
between the airbag computer assembly and front seat
side pretensioner)
outer belt assembly LH (front passenger seat side
CIRCUIT DIAGRAM

C138046
GETtheMANUALS.org
RS–151
HINT:
RS
HINT:
Assembly (IG).
(d) Using a tester, measure the voltage between terminals PL+ and PL-
Standard:
1 V or less

C138050
ASSEMBLY LH)
OK
GETtheMANUALS.org

(Passenger Side Pretensioner) (c) Connect the connectors to the airbag computer assembly.
(d) Using a wire harness (wire diameter: 0.5 mm), short the circuit
RS between terminals PL+ and PL- of connector C.

NOTICE:
Airbag
Computer
Assembly connector terminals with force.
Twist The Stripped and wait for 60 seconds.
Standard:
B1908/72
Standard:
C138055
OK

page IN-38.)
Standard:
B1908/72
Standard:
E ECUT
ASSEMBLY LH
OK
GETtheMANUALS.org
RS–153
WARNING LIGHT DOES NOT TURN ON

DESCRIPTION
The airbag warning light is built into the combination meter assembly.
If the airbag system is functioning normally, the airbag warning light will come on for approximately 6 seconds when the ignition
switch is turned on (IG) and then automatically go off. If there is any trouble with the airbag system, the airbag warning light will
remain on or blink to inform the driver of the trouble.
If there is a wire harness ground short circuit between the airbag computer assembly and the combination meter assembly or RS
trouble with the combination meter assembly, the airbag warning light (in the combination meter assembly) will not come on.
CIRCUIT DIAGRAM
Ignition Switch
F/L AM ECU IG2 IG2 Combination AIR BAG
Meter Assembly
Battery
C138106
1 CHECK POWER SOURCE VOLTAGE
(a) Using a tester, check the battery voltage.

Standard:
10 to 14 V
GETtheMANUALS.org
NG REPAIR OR REPLACE BATTERY OR

RECHARGING SYSTEM
OK
RS (a) Disconnect the negative battery terminal, and wait for 90 seconds.
(b) Disconnect the connectors from the airbag computer assembly.
(IG).
(d) Check the illumination status of the airbag warning light in the
combination meter assembly.
Standard:
The airbag warning light does not come on.
OK
3 CHECK WIRE HARNESS (BETWEEN AIRBAG COMPUTER ASSEMBLY AND COMBINATION METER
ASSEMBLY)
HINT:
(c) Remove the combination meter assembly. (See page ME-30.)
(d) Connect the negative battery terminal, and turn the ignition switch on
(IG).
(e) Using a tester, check the voltage between terminal LA+ of the
connector of the airbag computer assembly and the body ground.
Standard:
1 V or less
LA+
C138107
CONNECTOR (BETWEEN AIRBAG
COMPUTER ASSEMBLY AND COMBINATION
METER ASSEMBLY)
OK
REPLACE COMBINATION METER ASSEMBLY
GETtheMANUALS.org
RS–155
WARNING LIGHT REMAINS ON

DESCRIPTION
The airbag warning light is built into the combination meter assembly.
If the airbag system is functioning normally, the airbag warning light will come on for approximately 6 seconds when the ignition
switch is turned on (IG) and then automatically go off. If there is any trouble with the airbag system, the airbag warning light will
remain on or blink to inform the driver of the trouble.
If there is a wire harness +B short circuit or open circuit between the airbag computer assembly and the combination meter RS
assembly or trouble with the combination meter assembly, the airbag warning light (in the combination meter assembly) will
remain on.
CIRCUIT DIAGRAM
Combination Meter Assembly

Ignition Switch
IG2 AIR BAG
Battery
C138108
1 CHECK CONNECTOR CONNECTION STATUS
GETtheMANUALS.org
(b) Check the connection status of the connectors that are connected to
the airbag computer assembly and combination meter assembly.
Standard:
The connectors must be securely connected.
OK
RS
2 INSPECT COMBINATION METER ASSEMBLY

(a) Remove the combination meter assembly. (See page ME-30.)
(b) Connect the negative battery terminal, and turn the ignition switch on
(IG).
(c) Using a tester, check the resistance between the AIRBAG terminal of
the connector disconnected from the combination meter assembly,
and the body ground.
Standard:
1 MΩ or higher
AIRBAG NG REPLACE COMBINATION METER

C137814
ASSEMBLY
OK
ASSEMBLY)

(b) Disconnect the connectors from the airbag computer assembly.
(c) Using a tester, check the voltage between terminal LA+ of the
connector of the airbag computer assembly and the body ground.
Standard:
1 V or less
NG REPAIR OR REPLACE WIRE HARNESS

LA+
C138107 ASSEMBLY AND COMBINATION METER
ASSEMBLY)
OK
ASSEMBLY)
GETtheMANUALS.org
RS–157
(a) Using a tester, touch terminal LA+ of the airbag computer assembly
Airbag Computer connector and the AIR BAG terminal of the combination meter
Assembly Side assembly connector with the tester probe and measure the resistance
between the airbag computer assembly and the combination meter
assembly.
Standard:
1Ω or less
NG REPAIR OR REPLACE WIRE HARNESS RS

ASSEMBLY AND COMBINATION METER
LA+
ASSEMBLY)
Combination Meter
Assembly
AIRBAG
C138111
OK
GETtheMANUALS.org
POWER SOURCE VOLTAGE DROP

DESCRIPTION
A voltage-increase circuit (DC-DC converter) is built into the airbag computer assembly in case the power supply voltage in the
SRS airbags drops.
If the voltage of the power source drops, the voltage-increase circuit (DC-DC converter) operates to return the voltage of the
power source to normal.
RS The method by which trouble in the voltage-increase circuit is indicated differs from that used for other circuits. When the
diagnosis code indicates a normal code, the airbag warning light comes to indicate a drop in power supply voltage.
Troubles in this circuit are not recorded in the airbag computer assembly. The airbag warning light automatically goes off when
the power supply voltage returns to normal.
DTC No. DTC Detection Item

None POWER SOURCE VOLTAGE DROP
CIRCUIT DIAGRAM
Ignition Switch
Battery
TC
C138112
HINT:
GETtheMANUALS.org
RS–159
1 INSPECTION PREPARATION
HINT:
(b) Disconnect the connectors from the horn button assembly. (See page
RS-169.)
RS
(c) Disconnect the connectors from the instrument panel passenger
airbag assembly. (See page RS-181.)
(d) Disconnect the connectors from the front seat outer belt assembly RH
and LH (pretensioner). (See page SE-3.)
(e) Disconnect the connectors from the front seat airbag assembly RH
and LH. (See page RS-195.)
(f) Disconnect the connector from the curtain shield airbag RH and LH.
(See page RS-188.)
(g) Disconnect the connectors from the airbag computer assembly. (See
page RS-202.)
(h) Disconnect the connector from the front airbag sensor RH and LH.
(i) Disconnect the connectors from the side airbag sensor assembly RH
and LH. (See page RS-206.)
(j) Disconnect the connectors from the side airbag sensor assembly RH
No. 2 and side airbag sensor assembly LH No. 2. (See page RS-
207.)
2 CHECK POWER SOURCE VOLTAGE
HINT:
(IG).
(b) Using a tester, check the voltage between terminals IG1-E1 of the
airbag computer assembly connector.
Standard:
10 to 14 V
IG1
RECHARGING SYSTEM
E1
C138113
OK
3 CHECK AIRBAG WARNING LIGHT

(c) Connect the connectors to the horn button assembly.
(d) Connect the connectors to the instrument panel passenger airbag
assembly.
GETtheMANUALS.org
(e) Connect the connector to the front seat outer belt assembly RH and
LH (pretensioner).
(f) Connect the connectors to the front seat airbag assembly RH and LH.
(g) Connect the connectors to the curtain shield airbag RH and LH.
(h) Connect the connectors to the airbag computer assembly.
(i) Connect the connectors to the front airbag sensor RH and LH.
(j) Connect the connectors to the side airbag sensor assembly RH and
LH.
RS (k) Connect the connectors to the side airbag sensor assembly RH No. 2
and the side airbag sensor assembly LH No. 2.
(l) Connect the negative battery terminal, turn the ignition switch on (IG)
(m) Activate the electrical system (defogger, wipers, headlights, heater
blower, etc.) and check the airbag warning light.
Standard:
The airbag warning light does not come on.

RECHARGING SYSTEM
OK
(a) Using the SST, clear the DTCs and then check the DTCs again. (See
page RS-7.)
Standard:
DTC is not output.
Standard:
DTC is not output.
OK
GETtheMANUALS.org
RS–161
TC TERMINAL CIRCUIT
DESCRIPTION
Shorting the circuit between terminals ECUT and E of the DLC causes the DTC output mode to be selected. The airbag warning
light in the combination meter assembly will come on continuously or blink to indicate status.
CIRCUIT DIAGRAM
RS
E ECUT
C138114
1 INSPECT WIRE HARNESS OPEN CIRCUIT (BETWEEN DLC AND BODY GROUND)
HINT:
(a) Using a tester, measure the resistance between terminal E of DLC
Standard:
1Ω or less

CONNECTOR (BETWEEN DLC AND
BATTERY)
E
G100941J03
OK
GETtheMANUALS.org
2 INSPECT WIRE HARNESS OPEN CIRCUIT (BETWEEN DLC AND BODY GROUND)
HINT:
ECUT (IG).
RS (b) Using a tester, check the voltage between terminal ECUT of the DLC,
Standard:
10 to 14 V

G100941J04 BATTERY)
OK
3 INSPECT WIRE HARNESS SHORT CIRCUIT (BETWEEN DLC AND BODY GROUND)
HINT:
ECUT (b) Disconnect the negative battery terminal, and wait for 90 seconds.
(c) Using a tester, measure the resistance between terminal ECUT of the
DLC and the body ground.
Standard:
1 MΩ or higher

G100941J04 BATTERY)
OK
4 CHECK OPEN CIRCUIT IN WIRE HARNESS (BETWEEN THE DLC AND THE AIRBAG COMPUTER
ASSEMBLY)
HINT:
For inspection procedures and precautions, see page.
GETtheMANUALS.org
RS–163

ECUT (b) Disconnect the negative battery terminal, and wait for 90 seconds.
(c) Using the tester, check the resistance between the ECUT terminal of
the DLC and each connector B10 (TC) terminal of the vehicle wire
harness side of the airbag computer assembly.
Standard:
1Ω or less
Connector B NG REPAIR OR REPLACE WIRE HARNESS OR RS
CONNECTOR (BETWEEN DLC AND AIRBAG
COMPUTER ASSEMBLY)
TC
C142387
OK
GETtheMANUALS.org
RS–164 SRS AIRBAG - SRS AIRBAGS
SRS AIRBAGS
SRS AIRBAG
PRECAUTIONS
(a) Failure to carry out the service operations in the correct
sequence could cause the airbag or pretensioner to
unexpectedly deploy during servicing and lead to serious life-
RS threatening injury. Furthermore, if a mistake is made when
servicing, it is possible that the airbag or pretension may fail to
operate properly. Before performing servicing (including
removal or installation of parts, inspection or replacement), be
sure to read the following items carefully. Then follow the
correct procedures indicated in the repair manual.
(a) Check the DTC, turn the ignition switch off, disconnect the
negative battery terminal and then wait at least 90 seconds
before starting the operation.
(1) The airbag and pretensioner system is equipped with a
back-up power source. So, if work is started within 90
seconds after disconnecting the negative battery terminal,
the airbags may still be deployed.
(2) As the memory of some of the systems is cleared when the
negative battery terminal is disconnected, always record
the contents of each system memory before starting
servicing. Reset the systems after completing the work.
(b) Turn the ignition switch off and connect the negative terminal of
the battery.
3. GENERAL PRECAUTIONS
(a) Use an tester for electrical inspections.
(b) Information labels are attached to the SRS components. Follow
the instructions on the labels.
(c) Never disassemble an SRS airbag.
(d) Replace any dropped, cracked, dented, broken or otherwise
defective SRS components with new ones.
(e) Never use airbag or pretensioner parts from another vehicle.
When replacing parts, use new parts.
(f) Do not directly expose any of the SRS components to hot air or
flames.
(g) After a collision, perform a DTC check, even if the the airbag or
pretensioner have not deployed.
(h) Lubricants, oil, water, or detergents of any kind should not be
applied to any of the SRS components. If any of the SRS
components come into contact with liquid, quickly wipe them off
with a dry cloth.
(i) Store and handle the system in a location away from high
temperatures [ambient temperature: 93°C or higher
(pretensioner: 80°C or higher)] or humidity and that is not
exposed to the effects of electrical noise.
(j) When scrapping vehicles or disposing of any parts, always use
the SST to deploy the airbags and pretensioners.
HINT:
• Disposal of horn button assembly (See page RS-172.)
GETtheMANUALS.org
SRS AIRBAG - SRS AIRBAGS
RS–165
• Disposal of instrument panel passenger airbag assembly

(See page RS-182.)
• Disposal of curtain shield airbags (See page RS-190.)
• Disposal of front seat airbag assembly (See page RS-196.)
(k) Do not measure the resistance of airbag components.
CAUTION:
This may activate the airbag and the pretensioner due to
the electrical current generated by the tester, which is
extremely dangerous. RS
GETtheMANUALS.org
RS
C133038
4. AIRBAG AND PRETENSIONER DISPOSAL PRECAUTIONS

(BEFORE DEPLOYMENT)
(a) Do not dispose of an airbag or pretensioner that has not been
activated.
GETtheMANUALS.org
SRS AIRBAG - SRS AIRBAGS
RS–167
(b) Conduct work on airbags and pretensioners outside in a level

location where safety can be assured. Avoid conducting this
work in residential areas.
(c) As work on airbags and pretensioners is noisy, make it known
to all people in the surrounding areas before proceeding.
(d) When activating an airbag or pretensioner, use an SST and
stand at least 5 m away from the airbag/pretensioner.
(e) As static electricity may cause airbags and pretensioners to
operate, discharge any static electricity by touching a water RS
pipe or other steel object with a bare hand before starting work.
(f) When deploying the airbag, be careful that the airbag
deployment side is not facing downward.
Do not position the airbag unit to deploy downward
Danger
Danger
Reverse Force Reverse Force
Reverse Force
Reverse Force
Caution: There may be approximately 1 ton of

force in the direction of the arrows G032277J01
5. AIRBAG AND PRETENSIONER DISPOSAL PRECAUTIONS

(AFTER DEPLOYMENT)
(a) Leave the airbag and the pretensioner for approximately 30
minutes after it is activated as parts of the airbag and
pretensioner may reach a temperature of several hundreds of
degrees Celsius after being activated.
(b) Do not apply water, etc. to a steering pad with a deployed
airbag or pretensioner.
(c) Use dust-proof safety glasses and gloves when handling an
airbag or a pretensioner that has been activated.
(d) Place an airbag or a pretensioner that has been activated in a
strong, transparent plastic bag and seal the bag for disposal.
(e) Always wash your hands with water after completing work.
6. PRECAUTIONS FOR HORN BUTTON ASSEMBLY (DRIVER SEAT
AIRBAG), INSTRUMENT PANEL PASSENGER AIRBAG
ASSEMBLY (PASSENGER SEAT SIDE AIRBAG), FRONT SEAT
GETtheMANUALS.org
OUTER BELT ASSEMBLY (PRETENSIONER), FRONT SEAT

AIRBAG ASSEMBLY AND CURTAIN SHIELD AIRBAG ASSEMBLY
(a) Be sure to keep the deployment side facing upwards when
working, even if it is only removing the assembly momentarily.
CAUTION:
Operating the airbag, for any reason, with the deployment
side facing downward may lead to serious, life-threatening
injury.
RS (b) When storing airbags, do not place anything on top of them.
Also, do not stack airbags on top of each other.
7. PRECAUTIONS FOR SPIRAL CABLE
(a) Be sure to center the spiral cable when installing the spiral
cable and attaching or removing the steering wheel. (See page
RS-179.)
NOTICE:
If the steering wheel is operated without the spiral cable
having been centered, the spiral cable may break or
become disconnected.
8. PRECAUTIONS FOR AIRBAG ASSEMBLY, FRONT AIRBAG
SENSOR, SIDE AIRBAG SENSOR ASSEMBLY AND SIDE
AIRBAG SENSOR NO. 2
(a) Be sure to replace the sensor assembly (airbag computer
assembly, front side and rear as a set) if the vehicle has been
involved in a collision in which the airbag was deployed and the
pretensioner was activated (even if only the airbag was
deployed or only the pretensioner was activated).
9. PRECAUTIONS FOR WIRE HARNESS AND CONNECTORS
(a) All wire harnesses in the engine room are yellow with the
exception of those that are not visible.
(b) Be careful when handling the connectors, as special types of
connectors are used.
10. PROCEDURE FOR VEHICLES DAMAGED IN COLLISION
(a) When using electric welders on the vehicle, disconnect the
airbags and pretensioners before performing work.
(b) Remove the airbag computer assembly, front airbag sensor,
side airbag sensor assembly and side airbag sensor no. 2 if
there is any chance they will be subject to shock.
(c) Do not expose the airbag computer assembly, front airbag
sensor, side airbag sensor assembly or side airbag sensor no. 2
to high temperatures.
(d) As some parts of the airbag and pretensioner may reach
temperatures of several hundred degrees Celsius, check that
the surrounding wire harnesses and connectors are not melted
or otherwise damaged.
11. CASES WHEN INSPECTION OF AIRBAG AND PRETENSIONER
IS NECESSARY
(a) When the the vehicle has been damaged in a collision or
similar, even if the airbag has not been deployed and the
pretensioner has not been activated.
(b) When a DTC has been output.
GETtheMANUALS.org
RS–169
SRS AIRBAG - HORN BUTTON ASSEMBLY

SRS AIRBAG
COMPONENTS
RS
T=7.4{75} T=7.4{75}
:TIGHTENING TORQUE [N*m{kgf*cm}] C137588J01
REMOVAL
(See page RS-164.)

(See page RS-164.)
GETtheMANUALS.org
RS–170
3. REMOVE HORN BUTTON ASSEMBLY

(a) Using a T30 torx wrench, loosen the 2 torx bolts until they spin
freely.
(b) Using needle-nose pliers, pull out the 2 torx bolts.
RS
Screw Case
C140199
(c) Pull the horn button assembly out towards the rear of the vehicle.
(d) Using a screwdriver with its tip wrapped in protection tape, release
the lock of the airbag connector and then disconnect the
connector.
(e) Disconnect the horn connector and remove the horn button
assembly.
INSTALLATION
4. INSTALL HORN BUTTON ASSEMBLY
C103846 (a) Connect the horn connector to the horn button assembly.
(b) Connect the airbag connector to the horn button assembly and lock
it securely in place.
C103846J01
GETtheMANUALS.org
RS–171
(c) Using a torx socket wrench (T30), install the horn button assembly
to the steering wheel with the 2 torx bolts.
6. INSPECT AIRBAG WARNING LIGHT (See page RS-1)
(See page RS-164.) RS
DISPOSAL
1. DISPOSE OF HORN BUTTON ASSEMBLY (WHEN INSTALLED IN
VEHICLE)
Screw Case SST 09082-00780, 09082-87710
CAUTION:
• Conduct this work outside in a level location where safety can be
assured. Avoid conducting this work in residential areas.
• As this work is quite noisy, make it known to all people in the
surrounding areas before proceeding.
C140199
(a) Remove the steering column lower cover.

(1) Turn the steering wheel assembly 90 to the right and remove
the screw on the front surface of the steering column lower
cover.
E127343
(2) Turn the steering wheel assembly 90 to the left and remove
the screw on the front surface of the steering column cover
lower.
E127342
(3) Remove the screw, disengage the claw and remove the
steering column lower cover.
(4) Disconnect the negative battery terminal. (See page RS-164.)
(5) Disconnect the airbag connector from the spiral cable.
Claw E127342
GETtheMANUALS.org
RS–172
(b) Deploy the airbag (horn button assembly).

(1) Connect the following 2 SSTs at the same time.
SST 09082-00780
(2) Short circuit the SST alligator clip and terminal.
(3) Connect the SST and airbag connector (4P yellow) and lock
it securely in place.
CAUTION:
Check that there is no looseness in the steering wheel
RS Short The Connectors assembly and horn button assembly.
C133167J01
NOTICE:
Securely lock the SST connectors in place.
(4) Extend the SST as far as possible so that the battery is
placed 5 m or more away from the vehicle.
Fully Extend The SST
CAUTION:
Close all the doors and windows.
(5) Check that the interior and the surrounding area of of the
vehicle are safe and then attach the alligator clip of the SST
to the negative battery terminal.
(6) Connect the SST terminal to the positive battery terminal
Separate More Than 5 m and deploy the airbag (horn button assembly).
C133170
CAUTION:
• Before proceeding, check that no one is inside or near
the vehicle.
• Before proceeding, call out in a loud voice to warn
anyone near the vehicle for scrapping.
(c) Procedure for airbag (horn button assembly) disposal.
(1) Place the deployed airbag (horn button assembly) in a strong,
transparent plastic bag, tie it tightly and dispose of it.
CAUTION:
• As parts of the airbag (horn button assembly) may reach
a temperature of several hundreds of degrees Celsius
when it is deployed, do not touch it for at least 30
minutes after deployment.
• Never apply water to an airbag (horn button assembly)
G023054
that has been deployed.
• Use dust-proof safety glasses and gloves when handling
an airbag (horn button assembly) that has been deployed.
• Do not dispose of an airbag (horn button assembly) that
has not been deployed.
• After completing the work, always wash your hands with
water.
2. DISPOSE OF HORN BUTTON ASSEMBLY (WHEN NOT INSTALLED IN

VEHICLE)
CAUTION:
• Conduct this work outside in a level location where safety can be
assured. Avoid conducting this work in residential areas.
GETtheMANUALS.org
RS–173
(a) SECURE HORN BUTTON ASSEMBLY

(1) Insert 2 bolts with plate washers into the 2 horn button
assembly installation holes and tighten firmly by hand.
(2) Connect the following 2 SSTs at the same time.
SST 09082-00802 (09082-10801, 09082-30801)
(3) Connect the SSTs to the airbag (horn button assembly) and
More Than 35 mm
Threaded lock them securely in place.
Width
NOTICE:
6.0mm
• Match the part color of the SST connector with the color
RS
Pitch 1.0 mm C137591
of the connecting part of the horn button assembly
connector and attach them.
• Securely lock the SST connectors in place.
(4) Pass the SSTs through the disc wheel and use a wire
harness (core wire area: 1.25 mm2 or more) to fix the horn
button assembly to the disc wheel.
Secure The Deployment Side of the Airbag Facing The Center Of The Tire
Wire Harness Stripped Portion Cross Section Diameter More Than 1.25 mm²
Stripped Portion
Tire
Tie 3 Layers Of Wire Harness Wheel

(Eliminate Any Slack) C137592
CAUTION:
• Strictly adhere to the instructions for the following 2
items. If the instructions are not followed, the airbag may
deploy or the tire could be blown off, resulting in serious
injury.
• Tightly wind the wire harness 3 times and make sure that
there is no slack as the wire harness is subjected to a
force of approximately 1 ton when the airbag (horn button
assembly) is deployed.
• Always tie down the airbag (horn button assembly) with
the deployment side facing upward, as shown in the
illustration.
GETtheMANUALS.org
RS–174
(b) Deploy the airbag (horn button assembly).

Short The Connectors (1) Short circuit the SST alligator clip and terminal.
SST SST 09082-00711
(2) Connect the SST from the lower side of the disc wheel to the
SST connected to the airbag (horn button assembly).
(3) Stack 3 or more tires on top of the disc wheel that the horn
assembly is tied to and then place a tire with a disc wheel on
top, as shown in the illustration.
RS (4) Tie the tires together by tightly wrapping a wire of 1.8 mm
C137593
diameter or more (normal steel wire for general use:
equivalent to JIS SWM-B) around them 2 or more times,
making sure there is no slack.
NOTICE:
Make sure that after the tires are fixed together they are
capable of withstanding a load of 1 ton or more.
(5) Extend the SST as far as possible away from the airbag (horn
button assembly) so that the battery is placed 5 m or more
away from the tires.
Tie More Than Two Layers Of Wire

(Eliminate Any Slack)
Tire With Wheel
Tires Without Wheels

Tire With Wheel
Separate More Than 5 m

C137594
(6) Cordon off an area with a radius of 5 m from the outside edge
of the tires with pylons and rope or similar to prevent people
from getting any closer.
(7) Check that the surroundings are safe and then attach the
alligator clip of the SST to the negative battery terminal.
More Than 5 m
CAUTION:
• Conduct this work outside in a level location where
safety can be assured. Avoid conducting this work in
residential areas.
C105875J01
• As this work is quite noisy, make it known to all people in
the surrounding areas before proceeding.
and deploy the airbag (horn button assembly).
CAUTION:
• Before proceeding, check that no one is nearby.
• Before activating pretensioners, call out in a loud voice to
warn anyone in or near the work area.
GETtheMANUALS.org
RS–175
HINT:
Note that the heat generated by the inflator when the airbag
is deployed once will melt the connector of the SST (wire C)
that is directly connected to the inflator.
(c) Procedure for airbag (horn button assembly) disposal.
(1) Place the deployed airbag (horn button assembly) in a strong,
transparent plastic bag, tie it tightly and dispose of it.
CAUTION:
• As parts of the airbag (horn button assembly) may reach
RS
a temperature of several hundreds of degrees Celsius
when it is deployed, do not touch it for at least 30
• Never apply water to an airbag (horn button assembly)
G023054
• Use dust-proof safety glasses and gloves when handling
an airbag (horn button assembly) that has been deployed.
• Never dispose of an airbag (horn button assembly) that
has not been deployed.
• After completing the work, always wash your hands with
water.
GETtheMANUALS.org
RS–176 SRS AIRBAG - SPIRAL CABLE
SPIRAL CABLE
SRS AIRBAG
COMPONENTS
RS
WITH STEERING SENSOR

SPIRAL CABLE ASSEMBLY
STEERING SENSOR
ASSEMBLY
T=34.3{350}

T=7.4{75}

T=7.4{75}
:TIGHTENING TORQUE [N*m{kgf*cm}]

C137595J01
GETtheMANUALS.org
SRS AIRBAG - SPIRAL CABLE
RS–177
REMOVAL
(See page RS-164.)

(See page RS-164.)
4. REMOVE HORN BUTTON ASSEMBLY(See page RS-170) RS

5. REMOVE STEERING WHEEL ASSEMBLY (See page SR-4)
6. REMOVE STEERING COLUMN COVER (See page SR-5)
7. REMOVE SPIRAL CABLE WITH STEERING SENSOR

(a) Disengage the claws of the steering column upper cover and
slide it upwards.
(b) Disconnect each connector from the spiral cable.
(c) Disengage the 3 claws and remove the spiral cable with
steering sensor.
Claw
C133166J01
8. REMOVE SPIRAL CABLE

Pin (a) Disengage the 6 claws and remove the spiral cable from the
steering sensor.
INSPECTION
9. INSPECT SPIRAL CABLE
(a) If there are any defects that match the standards below, replace
the spiral cable with a new one.
Pin
Standard:
Claw There are scratches, abrasions, cracks or other damage
C137596J01
to the connector part.
There are cracks, dents or chips in the spiral cable.
GETtheMANUALS.org
RS–178 SRS AIRBAG - SPIRAL CABLE
INSTALLATION
1. INSTALL SPIRAL CABLE
Pin (a) Align the 2 pins of the spiral cable and the 2 holes in the
steering sensor.
(b) Engage the 6 claws and install the steering sensor to the spiral
cable.
RS 2. CHECK FRONT TIRES FACING STRAIGHT AHEAD
Pin 3. INSTALL SPIRAL CABLE WITH STEERING SENSOR

(a) Set the turn signal switch to the neutral position.
Claw C137596J01 NOTICE:
If it is not in the neutral position, the pin of the turn signal
switch may be snapped.
(b) Engage the 3 claws and install the spiral cable with the steering
sensor.
NOTICE:
When replacing the spiral cable with a new one, remove the
spiral cable lock pin before installing the steering wheel
assembly.
(c) Connect each connector.
(d) Engage the claw to install the steering column cover upper.
4. INSTALL STEERING COLUMN COVER (See page SR-8)
5. CENTER SPIRAL CABLE

(a) Check that the ignition switch is off.
(b) Check that the negative battery terminal is disconnected.
NOTICE:
Claw If the terminal has been removed, wait for at least 90
C133166J01
seconds after removing it before starting the procedure.
(c) Rotate the spiral cable counterclockwise until it locks.

NOTICE:
Rotate the spiral cable without force to prevent it from
breaking.
HINT:
Rotate the spiral cable a maximum of approximately 6 times.
Turn Until It
Slowly Locks
C137597
(d) Rotate the spiral cable with steering sensor clockwise 3 turns
Rotate Back 3 Times And Align Marks from the position at which the spiral cable locked to align the
marks shown in the illustration.
6. INSTALL STEERING WHEEL ASSEMBLY

(a) Align the matchmarks and install the steering wheel assembly
to the steering column assembly.
(b) Install the nut.
(c) Connect each connector to the spiral cable.
C133294
7. INSTALL HORN BUTTON ASSEMBLY (See page RS-170)
GETtheMANUALS.org
SRS AIRBAG - SPIRAL CABLE
RS–179

(See page SS-10)
INSPECTION
1. SPIRAL CABLE
(a) Set the spiral cable in the center position. (See page RS-178.)
(b) Using a tester, check the continuity between the terminals of the
RS
Connector A spiral cable under the following conditions.
Connector B
(1) After setting the spiral cable in the center position, check
the continuity when the spiral cable is rotated 3 turns
clockwise and again when it is rotated 3 turns
counterclockwise.
(2) Set the spiral cable at a position 3 turns in the clockwise
direction from the center position, then check the
continuity while rotating it 6 turns counterclockwise.
Connector D Standard:
Tester Connection Measurement Condition Continuity

A1 (D+) ←→ C1 (D+) Always Continuity
A2 (D-) ←→ C2 (D-) Always Continuity
Connector C B136645J01 B1 (HO) ←→ D1 (HO) Always Continuity
NOTICE:
Do not rotate the spiral cable more than the specified
number of turns as the cable may break or become
disconnected.
GETtheMANUALS.org
RS–180 SRS AIRBAG - INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY

SRS AIRBAG
COMPONENTS

AIRBAG ASSEMBLY
RS
AIRBAG PASSENGER DOOR ASSEMBLY
PLATE
T=8.4{84}
INSTRUMENT PANEL BOX NO. 2
GLOVE COMPARTMENT
DOOR STOPPER
GLOVE COMPARTMENT ASSEMBLY
GETtheMANUALS.org
SRS AIRBAG - INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY
RS–181
REMOVAL
1. HANDLING AND OPERATING PRECAUTIONS(See page IP-8)

IP-11)
4. REMOVE GLOVE COMPARTMENT DOOR STOPPER (See page

IP-12) RS
5. REMOVE INSTRUMENT PANEL BOX NO. 2 (See page IP-12)
6. REMOVE INSTRUMENT PANEL PASSENGER AIRBAG

ASSEMBLY
(b) Remove the 2 bolts.
B136292
(c) Place your hand through the opening in the instrument panel
and disengage the claws to remove the instrument panel
passenger airbag together with the airbag passenger door
assembly.
B136293
7. REMOVE AIRBAG PASSENGER DOOR ASSEMBLY

(a) Remove the 2 nuts and the plate.
(b) Lift up the airbag so that it rotates, disengage the 5 claws and
remove the airbag from the airbag passenger door assembly.
8. INSPECT INSTRUMENT PANEL PASSENGER AIRBAG

ASSEMBLY (See page RS-2)
B142021
GETtheMANUALS.org
INSTALLATION
1. INSTALL AIRBAG PASSENGER DOOR ASSEMBLY
(a) Engage the 5 claws and install the airbag in the airbag
passenger door assembly.
(b) Install the plate with the 2 nuts.
RS
B142021
2. INSTALL INSTRUMENT PANEL PASSENGER AIRBAG

ASSEMBLY
(a) Install the instrument passenger airbag assembly with the 2
bolts.
3. INSTALL INSTRUMENT PANEL BOX NO. 2
4. INSTALL GLOVE COMPARTMENT DOOR STOPPER (See page

B136292 IP-17)

IP-18)
DISPOSAL
1. DISPOSE OF INSTRUMENT PANEL PASSENGER AIRBAG
ASSEMBLY (WHEN INSTALLED IN VEHICLE)
CAUTION:
• Conduct this work outside in a level location where safety
can be assured. Avoid conducting this work in residential
areas.
• As this work is noisy, make it known to all people in the
(a) Disconnect the instrument panel passenger airbag connector.
(See page RS-181.)
(b) Activate instrument panel passenger airbag assembly.
(1) Connect the following 2 SSTs.
SST
SST 09082-00711, 09082-00780
(3) Connect the SST and the instrument panel passenger
airbag assembly connector (4P yellow) and lock it
securely in place.
CAUTION:
• Make sure there is no looseness in the instrument
Short The Connectors C133296J01 panel passenger airbag assembly.
• Check that there are no objects on the upper door
part of the instrument panel passenger airbag.
GETtheMANUALS.org
RS–183

Fully Extend The SST (5) Check that the interior and the area surrounding the
vehicle are safe and then attach the alligator clip of the
SST to the battery negative terminal.
CAUTION:
and activate the instrument panel passenger airbag RS
C137598 assembly.
CAUTION:
• Before proceeding, check that no one is inside or
near the vehicle.
(c) Procedure for disposal of the instrument panel passenger
airbag assembly
(1) Place the instrument panel passenger airbag assembly
that has been activated in a strong, transparent plastic
bag, tie it tightly and dispose of it.
CAUTION:
• As parts of the instrument panel passenger airbag
assembly may reach a temperature of several
hundreds of degrees Celsius when the airbag is
C036592 deployed, do not touch the airbag for at least 30
• Do not apply water, etc. to an instrument panel
passenger airbag assembly that has been
activated.
• Use dust-proof safety glasses and gloves when
handling an instrument panel passenger airbag
assembly that has been activated.
• Never dispose of an instrument panel passenger
airbag assembly that has not been activated.
• After completing the work, always wash your
hands with water.
2. DISPOSE OF INSTRUMENT PANEL PASSENGER AIRBAG

ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE)
CAUTION:
areas.
GETtheMANUALS.org
(a) SECURE INSTRUMENT PANEL PASSENGER AIRBAG

ASSEMBLY
(1) Using a wire harness (core wire area: 1.25 mm2 or more),
Short The fix the instrument panel passenger airbag assembly to a
Connectors tire.
CAUTION:
• Strictly adhere to the instructions for the following
2 items. If the instructions are not followed, the
RS instrument panel passenger airbag assembly may
C096825 activate or the tire could be blown off, resulting in
serious injury.
• Tightly wind the wire harness 3 times and make
sure that there is no slack as the wire harness is
subjected to a force of approximately 1 ton when
the instrument panel passenger airbag assembly
is activated.
• Always tie down the instrument panel passenger
airbag assembly with the deployment side facing
toward the center of the tire, as shown in the
illustration.
(b) Activate instrument panel passenger airbag assembly.
SST 09082-00711, 09082-00802 (09082-10801,
09082-30801)
(3) Connect the SST and the instrument panel passenger
airbag assembly connector and lock it securely in place.
NOTICE:
• Match the part color of the SST connector with the
color of the connecting part of the horn button
assembly connector and attach them.
• Make sure the SST is securely locked.
(4) Stack 2 tires and place the tire that the instrument panel
passenger airbag assembly is tied to on top of them, and
then place another tire with a disc wheel on top, as shown
(5) Tie the tires together by tightly wrapping a wire of 1.8 mm
NOTICE:
Make sure that after the tires are fixed together they
are capable of withstanding a load of 1 ton or more.
GETtheMANUALS.org
RS–185
(6) Extend the SST as far as possible away from the

instrument panel passenger airbag assembly so that the
battery is placed 5 m or more away from the tires.
Tie More Than Two Layers Of Wire (Eliminate Any Slack)
Tire With Wheel

RS
Separate More Than 5 mm) C096826
(7) Cordon off a 5 m-radius area from the outside edge of the
tire with pylons and rope or similar to prevent people from
getting any closer.
(8) Check that the surrounding area is safe and then connect
the alligator clip of the SST to the negative battery
More Than 5 m terminal.
CAUTION:
• Conduct this work outside in a level location
where safety can be assured. Do not conduct this
C069563 work in a residential area.
• Because the sound a pretensioner makes when it
is activated is rather loud, give prior notice of
activation to those around you.
and activate the instrument panel passenger airbag
assembly.
CAUTION:
• Before activating pretensioners, call out in a loud
voice to warn anyone in or near the work area.
HINT:
Note that the heat generated by the inflator when the
airbag is deployed once will melt the connector of the SST
(wire C) that is directly connected to the inflator.
(c) Procedure for disposal of the instrument panel passenger
airbag assembly
(1) Place the instrument panel passenger airbag assembly
that has been activated in a strong, transparent plastic
bag, tie it tightly and dispose of it.
CAUTION:
• As parts of the instrument panel passenger airbag
assembly may reach a temperature of several
hundreds of degrees Celsius when the airbag is
C036592 deployed, do not touch the airbag for at least 30
GETtheMANUALS.org
• Do not apply water, etc. to an instrument panel

passenger airbag assembly that has been
activated.
handling an instrument panel passenger airbag
assembly that has been activated.
• Never dispose of an instrument panel passenger
airbag assembly that has not been activated.
RS • After completing the work, always wash your
hands with water.
GETtheMANUALS.org
SRS AIRBAG - CURTAIN SHIELD AIRBAG RH
RS–187
CURTAIN SHIELD AIRBAG RH

SRS AIRBAG
COMPONENTS
RS
Roof Side Rail Bracket NO. 2
Roof Side Rail Bracket RH
T=8{81} T=8{81}
T=8{81}
:Tightening Torque [N*m{kgf*cm}]

C133417J01
REMOVAL
(See page RS-164.)
HINT:
This procedure is for the RH side. Use the same procedure for the LH
side as for the RH side, except for the special sections.
3. REMOVE ROOF HEADLINING ASSEMBLY

(See page IR-1.)
(See page IR-4.)
GETtheMANUALS.org
RS–188 SRS AIRBAG - CURTAIN SHIELD AIRBAG RH
4. REMOVE CURTAIN SHIELD AIRBAG RH

(a) Using a screwdriver with its tip wrapped in protection tape,
release the lock of the airbag connector and then disconnect
the connector.
(b) Remove the 9 bolts and the clamp, and then remove the curtain
shield airbag RH.
HINT:
Remove the bolts in order starting from the front of the vehicle.
RS
C133304
C132631
5. INSPECT CURTAIN SHIELD AIRBAG RH (See page RS-3)

6. REMOVE ROOF SIDE RAIL BRACKET RH
(a) Remove the bolt and the roof side rail bracket RH.
C133419
GETtheMANUALS.org
RS–189
7. REMOVE ROOF SIDE RAIL BRACKET NO. 2

(a) Remove the bolt, then remove the roof side rail bracket No. 2.
INSTALLATION
RS
C133420
1. INSTALL ROOF SIDE RAIL BRACKET NO. 2

(a) Insert the 2 hooks into the holes on the body, and install the roof
side rail bracket No. 2 with the bolt.
C133420
2. INSTALL ROOF SIDE RAIL BRACKET NO. 2 RH

(a) Insert the hooks into the holes on the body, and install the roof
side rail bracket RH with the bolt.
3. INSTALL CURTAIN SHIELD AIRBAG RH

(a) Temporarily install the curtain shield airbag RH with 9 new bolts
and clamp.
C133419
C132631
NOTICE:
Do not rotate any parts of the curtain shield airbag RH 360°
from the correct position by mistake when installing.
GETtheMANUALS.org
(b) Fully tighten the 9 bolts in the order shown in the illustration.
4 3 1 2 7 8 9
RS
6
C132631J01

(c) Connect the curtain shield airbag connector to the curtain shield
airbag RH and lock it securely in place.
NOTICE:
Securely lock the curtain shield airbag connector in place.
4. INSTALL ROOF HEADLINING ASSEMBLY

(See page IR-1.)
(See page IR-9.)
(See page SS-10)
DISPOSAL
6. DISPOSE OF CURTAIN SHIELD AIRBAG RH (WHEN INSTALLED
IN VEHICLE)
CAUTION:
G C137599 • Conduct this work outside in a level location where safety
areas.
HINT:
Perform the same procedure for disposing of the LH side as for the
RH.
(a) DEPLOY CURTAIN SHIELD AIRBAG RH
SST 09082-00711, 09082-00802 (09082-10801,
09082-20801)
Short The Connectors
(3) Connect the SSTs to the curtain shield airbag RH and lock
SST(Wire B)
SST them securely in place.
CAUTION:
Check that there is no looseness in the curtain shield
C119198J01 airbag RH.
GETtheMANUALS.org
RS–191

Fully Extend The SST CAUTION:
After connecting the connector, close all the doors
and windows.
SST to the negative battery terminal.
Separate From The Vehicle More Than 5 m

(6) Connect the SST terminal to the positive battery terminal RS
C137706 and activate the instrument panel passenger airbag
assembly.
CAUTION:
near the vehicle.
HINT:
Note that the heat generated by the inflator when the
(wire B) that is directly connected to the inflator.
(b) Procedure for curtain shield airbag RH disposal
(1) Place the curtain shield airbag RH that has been deployed
in a strong, transparent plastic bag, tie it tightly and
dispose of it.
CAUTION:
• As parts of the curtain shield airbag RH may get to
a temperature of several hundreds of degrees
Celsius when it is deployed, do not touch it for at
least 30 minutes after deployment.
C104590 • Do not apply water to a curtain shield airbag RH
handling a curtain shield airbag RH that has been
deployed.
• Never dispose of a curtain shield airbag RH that
has not been activated.
hands with water.
7. DISPOSE OF CURTAIN SHIELD AIRBAG RH (WHEN NOT

INSTALLED IN VEHICLE)
CAUTION:
areas.
• Before proceeding, call out in a loud voice to warn anyone
near the vehicle for scrapping.
HINT:
RH.
GETtheMANUALS.org
(a) Cut off the curtain shield airbag RH.

(1) Cut off the deployment parts of the curtain shield airbag
Cut
RH.
(b) Secure the curtain shield airbag RH.
secure the curtain shield airbag RH to a tire.
CAUTION:
RS items. If the instructions are not followed, the
C104587J02 curtain shield airbag may deploy, resulting in
serious injury.
the curtain shield airbag RH is deployed.
• Always tie down the curtain shield airbag RH with
the deployment side facing toward the center of
the tire, as shown in the illustration.
Secure The Deployment Side Of The Airbag Facing The Center Of The Tire
Wire Harness Stripped Wire Cross Section Diameter More Than1.25 mm²
Stripped Wire
Layer 3 Wire Harnesses Tire

(Eliminate any slack)
C121083J01
(c) DEPLOY CURTAIN SHIELD AIRBAG RH

SST 09082-00711, 09082-00802 (09082-10801,
Short The 09082-20801)
Connectors (2) Short circuit the SST alligator clip and terminal.
(3) Connect the SSTs to the curtain shield airbag RH and lock
SST(Wire B)
them securely in place.
SST NOTICE:
C121032J01 (4) Stack 2 tires and place the tire that the curtain shield
airbag RH is tied to on top of them, and then place
GETtheMANUALS.org
RS–193
another tire with a disc wheel on top, as shown in the

illustration.
CAUTION:
• Make sure the deployment section (tip) of the
curtain shield airbag is facing toward the center of
the tire.
• Never face the deployment section (tip) of the
curtain shield airbag toward the ground.
• Select tires of the same width so that the RS
deployment part (tip) does not get caught between
one tire and the next.
NOTICE:
(6) Extend the SST as far as possible away from the curtain
shield airbag RH so that the battery is placed 5 m or more
away from the tires.
Tire With Wheel

C121055J01
(7) Cordon off an area with a radius of 5 m from the outside

edge of the tires with pylons and rope or similar to prevent
people from getting any closer.
More Than 5 m terminal.
CAUTION:
where safety can be assured. Avoid conducting
C069563 this work in residential areas.
• As this work is noisy, make it known to all people
in the surrounding areas before proceeding.
GETtheMANUALS.org

and activate the instrument panel passenger airbag
assembly.
CAUTION:
HINT:
RS Note that the heat generated by the inflator when the
(wire B) that is directly connected to the inflator.
(d) Procedure for curtain shield airbag RH disposal
(1) Place the curtain shield airbag RH that has been deployed
in a strong, transparent plastic bag, tie it tightly and
dispose of it.
CAUTION:
• As parts of the curtain shield airbag RH may get to
C104590 • Do not apply water to a curtain shield airbag RH
handling a curtain shield airbag RH that has been
deployed.
• Never dispose of a curtain shield airbag RH that
has not been activated.
hands with water.
GETtheMANUALS.org
SRS AIRBAG - FRONT SEAT AIRBAG ASSEMBLY RH
RS–195
FRONT SEAT AIRBAG ASSEMBLY RH

SRS AIRBAG
COMPONENTS
RS
FRONT SEAT AIRBAG ASSEMBLY
FRONT SEAT ASSEMBLY RH
T=8.3{84}

C137738J01
REMOVAL
CAUTION:
Some service operations affect the SRS airbag system. Be sure to
read the precautionary notice for the SRS airbag system before
servicing. (See page RS-164)
2. REMOVE FRONT SEAT ASSEMBLY RH

(See page SE-1.)
(See page SE-3.)
(See page SE-3.)
GETtheMANUALS.org
RS–196 SRS AIRBAG - FRONT SEAT AIRBAG ASSEMBLY RH
3. REMOVE FRONT SEAT AIRBAG ASSEMBLY RH

(a) Remove the wire harness and 2 nuts, and then remove the front
seat airbag assembly RH.
INSTALLATION
RS
C137737
4. INSTALL FRONT SEAT AIRBAG ASSEMBLY RH

(a) Attach the wire harness clamp and then attach the front seat
airbag assembly RH with the 2 nuts.
5. INSTALL FRONT SEAT ASSEMBLY RH

(See page SE-1.)
(See page SE-6.)
(See page SE-8.)
C137737 6. INSPECT AIRBAG WARNING LIGHT (See page RS-1)
7. PERFORM BATTERY TERMINAL REMOVAL AND INSTALLATION

SETTINGS (See page RS-190)
DISPOSAL
1. DISPOSE OF FRONT SEAT AIRBAG ASSEMBLY RH (WHEN
CAUTION:
can be assured. Avoid conducting this work in a residential
area.
(b) Slide the slider and then disconnect the airbag connector.
(c) Activate the front seat airbag assembly RH.
Short The Connectors SST 09082-00711, 09082-00750
(3) Connect the SST and the front seat airbag assembly RH
connector (2P yellow) and lock it securely in place.
SST NOTICE:
C137735
GETtheMANUALS.org
RS–197

Fully Extend The SST placed 5 m or more away from the vehicle.
CAUTION:
SST to the negative battery terminal.
Separate More Than 5 m and activate the front seat airbag assembly RH. RS
C137736 CAUTION:
near the vehicle.
(d) Procedure for front seat airbag assembly RH disposal
(1) Place the front seat airbag assembly RH that has been
activated in a strong, transparent plastic bag, tie it tightly
and dispose of it.
CAUTION:
• As parts of the curtain shield airbag RH may reach
C081053 • Do not apply water to a front seat airbag assembly
RH that has been activated.
handling a front seat airbag assembly RH that has
been activated.
• Never dispose of a front seat airbag assembly RH
hands with water.
2. DISPOSE OF FRONT SEAT AIRBAG ASSEMBLY RH (WHEN NOT

CAUTION:
can be assured. Avoid conducting this work in a residential
area.
HINT:
RH.
(a) Remove the front seat airbag assembly RH (See page RS-195.)
HINT:
See the procedure up to the front seat airbag assembly RH
removal.
GETtheMANUALS.org
(b) Secure front seat airbag assembly RH.

(1) Install the 2 installation nuts in the front seat airbag
assembly.
RS
C119203
More Than 1.25 mm²

Wire Harness
secure the front seat airbag assembly RH to a tire.
CAUTION:
Stripped Wire Harness Section items. If the instructions are not followed, the front
seat airbag assembly may activate or the tire
could be blown off, resulting in serious injury.
the front seat airbag assembly RH is activated.
• Always tie down the front seat airbag assembly
RH with the deployment side facing toward the
center of the tire, as shown in the illustration.
Wire Harness Wrapped 3 Times

(To Hold in Position)
Deployment Side Should Face the Center
Of The Tire
Tire
Deployment Side
B108333J01
(c) Activate the front seat airbag assembly RH.

SST 09082-00711, 09082-00750
Short The
Connectors (2) Short circuit the SST alligator clip and terminal.
(3) Connect the SST to the front seat airbag assembly RH
connector (2P yellow).
SST
NOTICE:
Make sure the SST is securely locked.
(4) Stack 2 tires and place the tire that the front seat airbag
C119205J01 assembly RH is tied to on top of them, and then place
another tire with a disc wheel on top, as shown in the
illustration.
GETtheMANUALS.org
RS–199

NOTICE:
(6) Extend the SST as far as possible away from the front
seat airbag assembly RH so that the battery is placed 5 m
or more away from the tires.
RS
Tire With Wheel

C119206J01
getting any closer.
terminal.
More Than 5 m CAUTION:
where safety can be assured. Avoid conducting
C069563 this work in residential areas.
• As this work is noisy, make it known to all people
in the surrounding areas before proceeding.
and activate the front seat airbag assembly RH.
CAUTION:
anyone in or near the work area.
(d) Procedure for front seat airbag assembly RH disposal
(1) Place the front seat airbag assembly RH that has been
activated in a strong, transparent plastic bag, tie it tightly
and dispose of it.
CAUTION:
• As parts of the curtain shield airbag RH may reach
C081053 • Do not apply water to a front seat airbag assembly
RH that has been activated.
GETtheMANUALS.org

handling a front seat airbag assembly RH that has
been activated.
• Never dispose of a front seat airbag assembly RH
hands with water.
RS
GETtheMANUALS.org
SRS AIRBAG - AIRBAG COMPUTER ASSEMBLY
RS–201

SRS AIRBAG
COMPONENTS
RS
AIR INLET DAMPER

CONTROL CABLE

T=8.4{85}
SHIFT LEVER KNOB

(VEHICLES NOT EQUIPPED WITH SHIFTING HOLE BEZEL
CURTAIN SHIELD AIRBAGS ) (TRANSMISSION M/T)
CONSOLE BOX HOLE COVER

T=8.4{85}
CONSOLE BOX
CARPET

(CURTAIN SHIELD AIRBAG EQUIPPED
VEHICLES)
CONSOLE BOX FR

C139661J01
GETtheMANUALS.org
RS–202 SRS AIRBAG - AIRBAG COMPUTER ASSEMBLY
REMOVAL
(See page RS-164.)

page IP-9)
RS 4. DISCONNECT AIR MIX DAMPER CONTROL CABLE (See page IP-
9)

page IP-9)
6. DISCONNECT AIR INLET CONTROL CABLE (See page IP-9)
8. REMOVE SHIFTING HOLE BEZEL (AUTOMATIC TRANSMISSION)

(See page IP-9)
10. REMOVE CONSOLE BOX FR (See page IP-10)
11. REMOVE AIRBAG COMPUTER ASSEMBLY (VEHICLES WITH

CURTAIN SHIELD AIRBAGS)
CAUTION:
If the terminal is removed, wait for at least 90 seconds after
removing it before starting the procedure.
(c) Disconnect the connectors from the airbag computer assembly.
CAUTION:
Always check that the negative terminal of the battery is
disconnected before proceeding. If this work is performed
without disconnecting the negative terminal of the battery,
just an impact to the airbag computer assembly itself may
be enough to cause the airbag to deploy.
(d) Remove the 4 bolts and airbag computer assembly.
12. REMOVE AIRBAG COMPUTER ASSEMBLY (VEHICLES

C133345
WITHOUT CURTAIN SHIELD AIRBAGS)
CAUTION:
GETtheMANUALS.org
SRS AIRBAG - AIRBAG COMPUTER ASSEMBLY
RS–203
(c) Disconnect the connectors from the airbag computer assembly.

CAUTION:
Always check that the negative terminal of the battery is
disconnected before proceeding. If this work is performed
without disconnecting the negative terminal of the battery,
just an impact to the airbag computer assembly itself may
be enough to cause the airbag to deploy.
(d) Remove the 3 bolts and airbag computer assembly.
13. INSPECT AIRBAG COMPUTER ASSEMBLY (See page RS-3)

RS
C133346
INSTALLATION
1. INSTALL AIRBAG COMPUTER ASSEMBLY (VEHICLES WITH
CAUTION:
• Always check that the negative terminal of the battery is
disconnected before proceeding. If this work is
performed without disconnecting the negative terminal
of the battery, just an impact to the airbag computer
assembly itself may be enough to cause the airbag to
deploy.
• If the battery terminal is removed, wait for at least 90
(c) Install the airbag computer assembly with the 4 bolts.
(d) Connect the connector to the airbag computer assembly and
push in the connector lever so that it is securely locked.
NOTICE:
Make sure that it is locked securely.
(e) Check that there is no looseness in the airbag computer
assembly.
(f) After tying, press down the vehicle wire harness to prevent the
C133345 vehicle wire harness from rising up.
2. INSTALL AIRBAG COMPUTER ASSEMBLY (VEHICLES WITHOUT

CAUTION:
• Always check that the negative terminal of the battery is
disconnected before proceeding. If this work is
performed without disconnecting the negative terminal
of the battery, just an impact to the airbag computer
assembly itself may be enough to cause the airbag to
deploy.
• If the battery terminal is removed, wait for at least 90
GETtheMANUALS.org
RS–204 SRS AIRBAG - AIRBAG COMPUTER ASSEMBLY
(c) Install the airbag computer assembly with the 3 bolts.

(d) Connect the connector to the airbag computer assembly and
push in the connector lever so that it is securely locked.
NOTICE:
Make sure that it is locked securely.
(e) Check that there is no looseness in the airbag computer
assembly.
RS (f) After tying, press down the vehicle wire harness to prevent the
C133346 vehicle wire harness from rising up.
3. INSTALL CONSOLE BOX FR (See page IP-19)
4. INSTALL CONSOLE BOX ASSEMBLY RR (MANUAL

TRANSMISSION) (See page IP-20)
5. INSTALL SHIFTING HOLE BEZEL (AUTOMATIC TRANSMISSION)

(See page IP-20)
6. INSTALL SHIFT LEVER KNOB (MANUAL TRANSMISSION)
7. INSTALL AIR INLET DAMPER CONTROL CABLE (AIR

CONDITIONING MANUAL) (See page IP-20)
8. INSTALL DEFROSTER DAMPER CONTROL CABLE (AIR

9. INSTALL AIR MIX DAMPER CONTROL CABLE (AIR

10. INSTALL INSTRUMENT CLUSTER FINISH PANEL CTR (See page

IP-21)

(See page SS-10)
GETtheMANUALS.org
SRS AIRBAG - SIDE AIRBAG SENSOR ASSEMBLY RH
RS–205

SRS AIRBAG
COMPONENTS
RS
DECK FLOOR BOX RH
T=8.4{85}
CENTER PILLAR GARNISH LWR RH
FRONT DOOR SCUFF PLATE RH
REAR DOOR SCUFF PLATE RH
GETtheMANUALS.org
RS–206 SRS AIRBAG - SIDE AIRBAG SENSOR ASSEMBLY RH
REMOVAL
(See page RS-164.)

(See page RS-164.)
3. REMOVE FRONT DOOR SCUFF PLATE RH (See page IP-10)

RS 4. REMOVE DECK FLOOR BOX RH (See page IR-4)
5. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-4)
6. REMOVE CENTER PILLAR GARNISH LWR RH
7. REMOVE SIDE AIRBAG SENSOR ASSEMBLY RH

(a) Disconnect the connector from the side airbag sensor assembly
RH.
(b) Remove the 2 bolts, and then remove the side airbag sensor
assembly RH from the center pillar.
8. CHECK SIDE AIRBAG SENSOR ASSEMBLY RH (See page RS-4)
C137742
GETtheMANUALS.org
SRS AIRBAG - SIDE AIRBAG SENSOR ASSEMBLY RH
RS–207
INSTALLATION
9. INSTALL SIDE AIRBAG SENSOR ASSEMBLY RH
CAUTION:
(c) Connect the connector to the side airbag sensor assembly RH. RS
(d) Install the side airbag sensor assembly RH with the 2 bolts.
(e) Check that there is no looseness in the side airbag sensor
assembly RH.
10. INSTALL CENTER PILLAR GARNISH LWR RH
11. INSTALL FRONT DOOR SCUFF PLATE RH (See page IP-19)
12. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-12)
C137742
13. INSTALL DECK FLOOR BOX RH (See page IR-12)

(See page SS-10)
GETtheMANUALS.org
RS–208 SRS AIRBAG - SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2
SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2

SRS AIRBAG
COMPONENTS
RS DECK TRIM SIDE PANEL ASSEMBLY RH
REAR FLOOR MAT SUPPORT

DECK FLOOR BOX RH PLATE RR
BACK DOOR WEATHERSTRIP

DECK BOARD ASSEMBLY
T=8.4{85}
T=8.4{85}
SIDE AIRBAG SENSOR ASSEMBLY

RH NO. 2

C137808J02
GETtheMANUALS.org
SRS AIRBAG - SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2
RS–209
REMOVAL
(See page RS-164.)
3. REMOVE DECK BOARD ASSEMBLY (See page IR-4)
4. REMOVE DECK FLOOR BOX RH (See page IR-4)

RS
6. REMOVE BACK DOOR WEATHERSTRIP
(a) Pull out the back door weatherstrip, according to need, to
remove the rear floor mat support plate RR and the deck trim
side panel assembly RH.
7. REMOVE REAR FLOOR MAT SUPPORT PLATE RR (See page IR-

5)
8. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH (See page IR-

5)
9. REMOVE SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2
NOTICE:
(c) Remove the 2 clamps and then disconnect the wire harness.
(d) Remove the bolt and the side airbag sensor assembly RH No.
2.
C133416 (e) Disconnect the connector from the side airbag sensor assembly
RH No. 2.
10. INSPECT SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2 (See

page RS-4)
INSTALLATION
1. INSTALL SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2
CAUTION:
If the battery terminal is removed, wait for at least 90
(c) Install the side airbag sensor assembly RH No. 2 with the 2
bolts.
(d) Connect the connector to the side airbag sensor assembly RH
No. 2.
(e) Install the wire harness with a clamp.
(f) Check that there is no looseness in the side airbag sensor
assembly RH No. 2.
2. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH (See page IR-

C133416
12)
GETtheMANUALS.org
RS–210 SRS AIRBAG - SIDE AIRBAG SENSOR ASSEMBLY RH NO. 2
5. INSTALL REAR FLOOR MAT SUPPORT PLATE RR (See page IR-

13)
6. INSTALL BACK DOOR WEATHERSTRIP
7. INSTALL DECK BOARD ASSEMBLY (See page IR-13)
9. CHECK AIRBAG WARNING LIGHT (See page RS-1)

RS 10. PERFORM INITIALIZATION
(See page SS-10)
GETtheMANUALS.org
SRS AIRBAG - AIRBAG CUTOFF SWITCH CYLINDER
RS–211

SRS AIRBAG
COMPONENTS
RS
GLOVE COMPARTMENT
DOOR STOPPER
GLOVE COMPARTMENT DOOR ASSEMBLY
C138439J01
GETtheMANUALS.org
RS–212 SRS AIRBAG - AIRBAG CUTOFF SWITCH CYLINDER
REMOVAL
CAUTION:
If the negative battery terminal is removed, wait for at least 90

IP-11)
RS 3. REMOVE GLOVE COMPARTMENT DOOR STOPPER (See page
IP-12)
4. REMOVE AIRBAG CUTOFF SWITCH CYLINDER

(b) Remove the screw, then remove the airbag cutoff switch
cylinder.
INSTALLATION
LHD
RHD
C141947
5. INSTALL AIRBAG CUTOFF SWITCH CYLINDER

(a) Install the airbag cutoff switch cylinder with a screw.
6. INSTALL GLOVE COMPARTMENT DOOR STOPPER (See page

IP-17)

IP-18)
LHD
RHD
C141947
GETtheMANUALS.org
SRS AIRBAG - AIRBAG CUTOFF SWITCH CYLINDER
RS–213
INSPECTION
1. AIRBAG CUTOFF SWITCH CYLINDER
With Side Airbag (a) Check the continuity.
(1) Using the tester, check the continuity of each connector
Connector A Connector C
terminal of the airbag cutoff switch cylinder when the key
is operated.
Right hand drive vehicle
Tester Connection
Key Operation Standard
RS
Connector B Connector D (Terminal symbol)
A2 (P+) ←→ B3 (P+) Always Continuity
No continuity ← →
A1 (P-) ←→ B4 (P-) OFF ←→ ON
(Yellow Colored Tube) continuity
C1 (+) ← → D1 (+)
(Vehicles with a side Always Continuity
Cut Off Switch airbag)
Cylinder C2 (-) ← → D2 (-)
C141945J01 (Vehicles with a side Always Continuity
airbag)
C3 (SFR+) ← → D3
(SFR+)
Always Continuity
(Vehicles with a side
airbag)
C4 (SFR-) ← → D4
(SFR-) No continuity ← →
OFF ←→ ON
(Vehicles with a side continuity
airbag)
Left hand drive vehicles

Tester Connection
Key Operation Standard
(Terminal symbol)
A2 (P+) ←→ B3 (P+) Always Continuity
No continuity ← →
A1 (P-) ←→ B4 (P-) OFF ←→ ON
continuity
C3 (+) ← → D3 (+)
airbag)
C4 (-) ← → D4 (-)
airbag)
C1 (SFR+) ← → D1
(SFR+)
Always Continuity
(Vehicles with a side
airbag)
C2 (SFR-) ← → D2
(SFR-) No continuity ← →
OFF ←→ ON
(Vehicles with a side continuity
airbag)
GETtheMANUALS.org
RS–214 SRS AIRBAG - FRONT AIRBAG SENSOR
FRONT AIRBAG SENSOR

SRS AIRBAG
COMPONENTS
RHD FRONT AIRBAG SENSOR RH
RS
T=8.4{85}
GETtheMANUALS.org
SRS AIRBAG - FRONT AIRBAG SENSOR
RS–215
FRONT AIRBAG SENSOR LH

LHD
T=8.4{85}
RS

C137741J02
REMOVAL
(See page IN-5.)

(See page IN-5.)
3. REMOVE FRONT AIRBAG SENSOR RH

NOTICE:
If the battery negative terminal is removed, wait for at least
90 seconds after removing it before starting the procedure.
GETtheMANUALS.org
RS–216 SRS AIRBAG - FRONT AIRBAG SENSOR
(c) Remove the 2 bolts and front airbag sensor RH.

(d) Disconnect the connector from the front airbag sensor RH.
NOTICE:
• Do not take hold of the wire harness and pull on it.
Vehicle Front
4. INSPECT FRONT AIRBAG SENSOR RH (See page RS-4)
5. REMOVE FRONT AIRBAG SENSOR LH

RS (b) Check that the negative battery terminal is disconnected.
C133351J01 NOTICE:
If the battery negative terminal is removed, wait for at least
(c) Remove the 2 bolts and the front airbag sensor LH.
(d) Disconnect the connector from the front airbag sensor LH.
NOTICE:
• Do not take hold of the wire harness and pull on it.
6. INSPECT FRONT AIRBAG SENSOR LH (See page RS-4)

INSTALLATION
7. INSTALL FRONT AIRBAG SENSOR RH
Vehicle Front (a) Check that the ignition switch is off.
C133352J01 (b) Check that the negative battery terminal is disconnected.
CAUTION:
If the negative battery terminal is removed, wait for at least
(c) Connect the connector to the front airbag sensor RH.
(1) Push the connector in the direction of the arrow until it
makes a click sound.
NOTICE:
• When connecting the connector, push it in evenly
without tilting it.
Check Temporary
Stop Position
G031730J01
(d) Install the front airbag sensor RH with the 2 bolts.

(e) Check that there is no looseness in the front airbag sensor RH.
Vehicle Front 8. INSTALL FRONT AIRBAG SENSOR LH

CAUTION:
If the negative battery terminal is removed, wait for at least
C133351J01
GETtheMANUALS.org
SRS AIRBAG - FRONT AIRBAG SENSOR
RS–217
(c) Connect the connector to the front airbag sensor LH.

(1) Push the connector in the direction of the arrow until it
makes a click sound.
NOTICE:
• When connecting the connector, push it in evenly
without tilting it.
Check Temporary
Stop Position RS
G031730J01
(d) Install the front airbag sensor LH with the 2 bolts.

(e) Check that there is no looseness in the front airbag sensor LH.
(See page SS-10)
Vehicle Front
C133352J01
GETtheMANUALS.org
TO INDEX
SRS AIRBAGS AND SEAT BELTS
SEAT BELT
SEAT BELT WARNING SYSTEM
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-1
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-2
HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . SB-2
CUSTOMER PROBLEM ANALYSIS CHECK SHEET. . . . . . . . . . . . . . . . . SB-4
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-5
ECU TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-5 SB
FRONT SEAT CUSHION COVER AND PAD LH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-7
FRONT SEAT OUTER BELT ASSEMBLY RH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-12
DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-14
FRONT SEAT INNER BELT ASSEMBLY RH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-19
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-20
FRONT SEAT INNER BELT ASSEMBLY LH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-21
REAR SEAT 3-POINT TYPE BELT ASSEMBLY OUT RH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-24
REAR SEAT LAP TYPE BELT ASSEMBLY RH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-27
REAR SEAT LAP TYPE BELT ASSEMBLY CTR LH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-29
REAR SEAT BELT ASSEMBLY INN
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-31
REAR SEAT BELT ASSEMBLY INN RH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-33
REAR SEAT BELT ASSEMBLY INN NO. 1
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-35
GETtheMANUALS.org
REAR SEAT OUTER BELT ASSEMBLY CENTER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-38
SB
GETtheMANUALS.org
SEAT BELT - SEAT BELT WARNING SYSTEM
SB–1
SEAT BELT WARNING SYSTEM

SRS AIRBAGS
SEAT BELT AND SEAT BELTS
LOCATION
INDICATOR ASSEMBLY
DRIVER SIDE SEATBELT

WARNING LIGHT SB
PASSENGER SEATBELT COMBINATION METER ASSEMBLY

WARNING LIGHT ASSEMBLY
FRONT SEAT CUSHION COVER FRONT SEAT INNER BELT

AND PAD LH OCCUPANT SENSOR ASSEMBLY RH
B144284J01
GETtheMANUALS.org
SB–2 SEAT BELT - SEAT BELT WARNING SYSTEM

Warning indicator assembly ME-37
Driver side seat belt warning light does not blink or go Combination meter assembly ME-8
off Front seat inner belt assembly RH SB-20
Wire harness -
Warning indicator assembly ME-37
SB Passenger side seat belt warning light does not blink

Combination meter assembly
Front seat cushion cover and pad LH (occupant detection
ME-8
SB-7
or go off sensor)
Front seat inner belt assembly LH SB-21
Wire harness -
HOW TO PROCEED WITH

TROUBLESHOOTING
HINT:
See page SB-4.
(a) Refer to the problem symptoms table and check if the symptom of the
problem is listed in the table.
HINT:
See page SB-2.
Standard
Result Proceed to
Symptom is not listed in problem symptoms table A
Symptom is listed in problem symptoms table B
B GO TO INSPECTION PROCEDURE 5
4 TROUBLESHOOT BASED ON THE SYMPTOM
(a) Function check (See page SB-5.)

(b) ECU terminals (See page SB-5.)
GETtheMANUALS.org
SB–3
END
SB
GETtheMANUALS.org

CHECK

Seat Belt Warning System Problem Diagnosis Check Sheet
/ /
License
Customer’s name Plate No.
First Registration
Year 20___ / /
Model VIN
SB Written By
Inspector’s Engine Odometer
name Type Reading
Description Of Symptoms

Frequency Problem Occurs Constant Occasional (__times per day, __times per month)
Conditions (Method of use and results)

Weather Clear Cloudy Rainy Snowy Others ( ) Temperature Approx. ( )°C
Road City Suburbs Highway Others ( ) Paved Unpaved
Problem D Seat belt warning does not flash or turn off

Symptoms
P Seat belt warning does not flash or turn off
B081794J01
GETtheMANUALS.org
SB–5
OPERATION CHECK
1. INSPECT SEAT BELT WARNING LIGHT FOR DRIVER SEAT
(b) Check that the indicator assembly driver side seat belt warning
light blinks when the seat belt is not fastened.
(c) Check that the indicator assembly driver side seat belt warning
light goes off when the seat belt is fastened.
2. INSPECT SEAT BELT WARNING LIGHT FOR PASSENGER SEAT
(b) Sit in the passenger seat and check that the passenger side SB
seat belt warning light blinks when the seat belt is not fastened.
(c) Check that the passenger side seat belt warning light goes out
when the seat belt is fastened.
3. CHECK SEAT BELT WARNING BUZZER SOUNDING
(a) Start the engine.
(b) When the seat belt is not fastened, check that the combination
meter assembly buzzer sounds at 1.2 second intervals for
approximately 30 seconds when the vehicle is driven at 20 km/h
or more.
(c) Approximately 30 seconds after the buzzer has first sounded,
check that the buzzer cycle changes to 0.4 seconds for
approximately 90 seconds.
(d) Check that the buzzer stops approximately 120 seconds after it
has first sounded.
(e) After the buzzer has stopped, turn the ignition switch off and
then start the engine again. With the seat belt unfastened, drive
the vehicle at approximately 20 km/h or more and check that
the buzzer sounds again.
(f) After the buzzer has stopped, fasten the seat belt and drive the
vehicle at approximately 20 km/h or more and check that the
buzzer sounds when the seat belt is unfastened.
(g) After the buzzer has stopped, move the shift lever to R. Then
move the shift lever to D and with the seat belt unfastened,
drive the vehicle at approximately 20 km/h or more and check
that the buzzer sounds again.
ECU TERMINALS
1. COMBINATION METER ASSEMBLY (METER ECU)
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
B135640
Connector A
Terminal No. Item Measurement Condition Standard
1 (TAIL) ←→ 15 (GND) Voltage IG OFF → IG ON, light control switch ON 1 V or less → 10 to 14 V
13 (+B) ←→ 15 (GND) Voltage Always 10 to 14 V
GETtheMANUALS.org

4 (P SEAT BLT IN) ←→ 15 Sit in the passenger seat, passenger side seat belt
Continuity Continuity → No continuity
(GND) unfastened → fastened
35 (D SEAT BLT IN) ←→
Continuity Driver side seat belt unfastened → fastened Continuity → No continuity
15 (GND)
38 (P SEAT BELT OUT) IG ON, sit in passenger seat, passenger side seat belt Alternating between 10 to 14 V
Voltage
←→ 15 (GND) unfastened → fastened ←→ 0 V
39 (D SEAT BELT OUT) IG ON, sit in the driver's seat, driver side seat belt Alternating between 10 to 14 V
Voltage
←→ 15 (GND) unfastened → fastened ←→ 0 V
15 (GND) ←→ Body
SB ground
Continuity Always Continuity
GETtheMANUALS.org
SEAT BELT - FRONT SEAT CUSHION COVER AND PAD LH
SB–7
FRONT SEAT CUSHION COVER AND PAD LH

SRS AIRBAGS
INSPECTION
1. CHECK BELT WARNING OCCUPANT DETECTION SENSOR
(1) Using a tester, check for continuity between the terminals.
Standard
Tester Connection Pad State Standard

1←→2 Normal No continuity
56
1←→2 Pad load (15 kgf or more) Continuity
B141297
GETtheMANUALS.org
SB–8 SEAT BELT - FRONT SEAT OUTER BELT ASSEMBLY RH
FRONT SEAT OUTER BELT ASSEMBLY RH

SRS AIRBAGS
COMPONENTS
FRONT SHOULDER BELT

ANCHOR ADJUSTER ASSEMBLY
(ADJUSTABLE ANCHOR)
SB
REAR DOOR
T=40.7{415}
WEATHERSTRIP
RH
FRONT DOOR
WEATHERSTRIP RH
T=40.7{415}
CENTER PILLAR
SHOULDER BELT
GARNISH UPR RH
ANCHOR COVER
(ADJUSTABLE ANCHOR)
FRONT SEAT OUTER

BELT ASSEMBLY RH
(ADJUSTABLE ANCHOR)
FRONT SEAT OUTER T=40.7{415}

BELT ASSEMBLY RH
T=40.7{415}
T=40.7{415}
DECK FLOOR
BOX RH
FRONT DOOR
SCUFF PLATE RH
T=40.7{415}
T=40.7{415}
:TIGHTENING TORQUE [N*m{kgf*cm}] B148366J01
GETtheMANUALS.org
SEAT BELT - FRONT SEAT OUTER BELT ASSEMBLY RH
SB–9
REMOVAL
CAUTION:
Some of these service operations affect the SRS airbag system. Be
sure to read the precautionary notice for the SRS airbag system
before servicing. (See page RS-164)
HINT:
• This procedure is for the RH side. Use the same procedure for the LH
side as for the RH side, except for the special sections.

SB
2. REMOVE SHOULDER BELT ANCHOR COVER (VEHICLES WITH
ADJUSTABLE ANCHOR)
(a) Disengage the claws and remove the shoulder belt anchor
cover.
B135389
3. SEPARATE FRONT SEAT OUTER BELT ASSEMBLY RH

(VEHICLES WITH ADJUSTABLE ANCHOR)
(a) Remove the bolt and separate the front seat outer belt
assembly RH shoulder anchor.
B135390
4. REMOVE FRONT SEAT OUTER BELT ASSEMBLY RH

(a) Disengage the claw, open the anchor cover, and remove the
bolt. Then remove the front seat outer belt assembly RH
shoulder anchor.
5. REMOVE FRONT DOOR SCUFF PLATE RH (See page IP-10)
B148364
9. SEPARATE FRONT DOOR WEATHERSTRIP RH

(a) Separate the front door weatherstrip RH only as far as needed
to remove the center pillar garnish UPR RH.
B135391
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10. SEPARATE REAR DOOR WEATHERSTRIP RH

(a) Separate the rear door weatherstrip RH only as far as needed
to remove the center pillar garnish UPR RH.
11. REMOVE CENTER PILLAR GARNISH UPR RH (See page IR-6)
12. REMOVE FRONT SEAT OUTER BELT ASSEMBLY RH (VEHICLES

WITH ADJUSTABLE ANCHOR)
assembly RH floor anchor.
(b) Using a screwdriver with its tip wrapped in protective tape, pull
SB B141298
the locking button forward to release the lock and then
disconnect the connector.
(c) Remove the bolt and screw, and then remove the front seat
outer belt assembly RH.
Unlock
B141299
13. REMOVE FRONT SEAT OUTER BELT ASSEMBLY RH

assembly RH floor anchor.
(b) Remove the bolt, and then remove the front seat outer belt
assembly RH.
B148365
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SB–11
14. REMOVE FRONT SHOULDER BELT ANCHOR ADJUSTER

ASSEMBLY (VEHICLES WITH ADJUSTABLE ANCHOR)
(a) Remove the 2 bolts, then remove the front shoulder belt anchor
adjuster assembly.
B135610
SB
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INSTALLATION
CAUTION:
HINT:
This procedure is for the RH side. Use the same procedure for the LH side
as for the RH side, except for the special sections.
1. INSTALL FRONT SHOULDER BELT ANCHOR ADJUSTER
SB ASSEMBLY (VEHICLES WITH ADJUSTABLE ANCHOR)
(a) Install the front shoulder belt anchor adjuster assembly with the
2 bolts.
B135610
2. INSTALL FRONT SEAT OUTER BELT ASSEMBLY RH (VEHICLES

WITH ADJUSTABLE ANCHOR)
45
(a) Check ELR locking angle
(1) When the retractor is attached and gently moved, check
that the ELR does not lock if the inclination of the retractor
is 15 or less, and check that the belt remains locked if the
inclination of the retractor is over 45°.
NOTICE:
Do not disassemble the retractor.
B061488J01 (b) Insert the 2 hooks into the retractor bracket, and install the front
seat outer belt assembly RH with the bolt and screw.
Lock
B141301
GETtheMANUALS.org
SB–13
(c) Inspect the ELR lock

(1) With the seat belt installed, check that the seat belt locks
when it is pulled out quickly.
(d) Connect the connector to lock the locking button.
NOTICE:
Make sure the locking button is securely locked.
(e) Install the floor anchor with the bolt.
3. INSTALL FRONT SEAT OUTER BELT ASSEMBLY RH

SB
inclination of the retractor is over 45°.
NOTICE:
(b) Insert the 2 hooks into the retractor bracket and install the front
seat outer belt assembly RH with the bolt.
(c) Inspect the ELR lock
(1) With the seat belt installed, check that the seat belt locks
when it is pulled out quickly.
(d) Install the floor anchor with the bolt.
4. INSTALL CENTER PILLAR GARNISH UPR RH (See page IR-11)

B148365
5. INSTALL REAR DOOR WEATHERSTRIP RH (See page IR-11)
6. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH

(See page IP-17)
10. INSTALL FRONT DOOR SCUFF PLATE RH (See page IP-19)

11. CONNECT FRONT SEAT OUTER BELT ASSEMBLY RH
(VEHICLES WITH ADJUSTABLE ANCHOR)
(a) Install the shoulder anchor part of the front seat outer belt
assembly RH with the bolt.
B135390
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12. CONNECT FRONT SEAT OUTER BELT ASSEMBLY RH

(a) Install the shoulder anchor part of the front seat outer belt
assembly RH with the bolt.
(b) Engage the 2 claws and install the anchor cover.
13. INSTALL SHOULDER BELT OUTER COVER (VEHICLES WITH

ADJUSTABLE ANCHOR)
SB B148364
15. INSPECT FUNCTION OF SEAT BELT
(See page SB-5.)
DISPOSAL
CAUTION:
HINT:
as for the RH side, unless there are special sections.
1. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY RH (WHEN

SST 09082-97201, 09082-87710
(a) How to activate pretensioner
(1) Using a screwdriver with its tip wrapped in protective tape,
pull the locking button forward to release the lock and
then disconnect the connector.
Unlock CAUTION:
• Check that there is no looseness in the front seat
outer belt assembly RH installation part.
• Check that there is no slack in the seat belt.
B141302

(4) Connect the SST to lock the locking button.
HINT:
Always lock the locking button when connecting the SST
Lock to the pretensioner.
B141303
GETtheMANUALS.org
SB–15

CAUTION:
Fully Extend
The SST (6) Check that the interior and surrounds of the vehicle are
safe and then attach the alligator clip of the SST to the
negative battery terminal.
and activate the pretensioner.
Position The Battery More Than 5 m
CAUTION:
From the Vehicle B141304
• Before proceeding, check that no one is inside or SB
near the vehicle.
anyone in or near the work area.
(b) How to dispose of pretensioner
(1) Place a pretensioner that has been activated in a clean
and sturdy bag, tie the end tightly and dispose of it.
CAUTION:
• Because the temperature of the pretensioner can
reach several hundred degrees after activation,
you should not handle it for at least 30 minutes
after activation.
• Do not apply water, etc. to a pretensioner that has
B080671 been activated.
handling a pretensioner that has been activated.
• Always wash your hands with water after
completing work.
• Never dispose of a pretensioner that has not been
activated.
2. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY RH (WHEN

NOT INSTALLED IN VEHICLE)
SST 09082-87710, 09082-97201
(a) How to activate pretensioner
(1) Wind the seat belt with the retractor.
Cut
(2) When the seat belt is sufficiently wound, cut the seat belt
10cm approximately 10 cm from the retractor.
HINT:
Winding the seat belt before pretensioner activation will
increase the pulling resistance during pretensioner
activation.
B080663J01
GETtheMANUALS.org

Lock (4) Short circuit the SST alligator clip and terminal.
(5) Connect the SST to lock the locking button.
HINT:
Always lock the locking button when connecting the SST
to the pretensioner.
Short The Connectors
SB B105166J01
Wire Harness (Center Cross (6) Using a wire harness (wire cross-section: 1.25 mm2 or
Section Area 1.25 mm² ) more), secure the pretensioner to a tire fitted to a wheel
(tire width: about 185 mm) with the connector facing up.
(7) Pass the SST over the top of the tire.
NOTICE:
The SST may get damaged if passed under the tire.
B080667

Fully Stretch The SST placed 5 m or more away from the tire.
(9) Check that the surrounds are safe and then attach the
alligator clip of the SST to the negative battery terminal.
CAUTION:
where safety can be assured. In addition, avoid
activating pretensioners in a residential area.
Separate The Battery
From The Wheel More
• Because the sound a pretensioner makes when it
Than 5 m
B080669 is activated is rather loud, give prior notice of
activation to those in or near the work area.
getting any closer.
and activate the pretensioner.
CAUTION:
More Than 5 m
B070292
GETtheMANUALS.org
SB–17
(b) How to dispose of pretensioner

(1) Place a pretensioner that has been activated in a clean
and sturdy bag, tie the end tightly and dispose of it.
CAUTION:
• Because the temperature of the pretensioner can
reach several hundred degrees after activation,
you should not handle it for at least 30 minutes
after activation.
• Do not apply water, etc. to a pretensioner that has
been activated.
B080671
• Use dust-proof safety glasses and gloves when SB
handling a pretensioner that has been activated.
• Always wash your hands with water after
completing work.
• Never dispose of a pretensioner that has not been
activated.
GETtheMANUALS.org
SB–18 SEAT BELT - FRONT SEAT INNER BELT ASSEMBLY RH

SRS AIRBAGS
COMPONENTS
SB
T=33.8{345}
FRONT SEAT LEG COVER
T=33.8{345}
T=33.8{345}
T=33.8{345}
FRONT SEAT LEG COVER LH

(FOR RH SEAT )
T=40.7{415}
FRONT SEAT CUSHION SHIELD INN RH

B147933J01
GETtheMANUALS.org
SEAT BELT - FRONT SEAT INNER BELT ASSEMBLY RH
SB–19
REMOVAL
1. PRECAUTIONS WHEN OVERHAULING SEATS WITH SRS SIDE
AIRBAGS (See page SE-3)
2. REMOVE FRONT SEAT LEG COVER (See page SE-3)
3. REMOVE FRONT SEAT LEG COVER LH (FOR RH SEAT) (See

page SE-3)
4. REMOVE FRONT SEAT ASSEMBLY RH (See page SE-3)
5. REMOVE FRONT SEAT CUSHION SHIELD INN RH (See page SE- SB

4)
6. REMOVE FRONT SEAT INNER BELT ASSEMBLY RH
(a) Disconnect the connector and clamp.
(b) Remove the nut, and then remove the front seat inner belt
assembly RH.
INSTALLATION
CAUTION:
B135428
before servicing. (With front seat airbags) (See page RS-164)
HINT:
1. INSTALL FRONT SEAT INNER BELT ASSEMBLY RH
(a) Install the front seat inner belt with the bolt.
NOTICE:
Do not allow the front seat inner belt to run on the front
seat frame and adjuster locations shown in the illustration.
(b) Install the connector and clamp.
2. INSTALL FRONT SEAT CUSHION SHIELD INN RH (See page SE-

8)
:Location B141334J01
3. INSTALL FRONT SEAT ASSEMBLY RH (See page SE-8)
4. INSTALL FRONT SEAT LEG COVER LH (FOR RH SEAT) (See

page SE-9)
5. INSTALL FRONT SEAT LEG COVER (See page SE-9)
6. INSPECT AIRBAG WARNING LIGHT
7. PERFORM INITIALIZATION (See page SE-9)
GETtheMANUALS.org
SB–20 SEAT BELT - FRONT SEAT INNER BELT ASSEMBLY RH
INSPECTION
1. INSPECT FRONT SEAT INNER BELT ASSEMBLY RH
RHD Standard
Tester Connection Buckle State Standard

When seat belt(s) is/are
fastened
SB 1←→2
When seat belt(s) is/are
not fastened
Continuity
If the result is not as specified, replace the front seat inner

belt.
LHD
B146497J01
GETtheMANUALS.org
SEAT BELT - FRONT SEAT INNER BELT ASSEMBLY LH
SB–21

SRS AIRBAGS
INSPECTION
1. INSPECT FRONT SEAT INNER BELT ASSEMBLY LH
RHD Standard
Tester Connection Buckle State Standard
1←→2
When seat belt(s) is/are Continuity SB
fastened No continuity
When seat belt(s) is/are No continuity
1←→2
not fastened Continuity
If the result is not as specified, replace the front seat inner

belt.
LHD
B146497J01
GETtheMANUALS.org
SB–22 SEAT BELT - REAR SEAT 3-POINT TYPE BELT ASSEMBLY OUT RH
REAR SEAT 3-POINT TYPE BELT ASSEMBLY OUT RH

SRS AIRBAGS
COMPONENTS
SB REAR DOOR WEATHERSTRIP RH
ROOF SIDE INNER GARNISH RH
T=40.7{415}
DECK FLOOR BOX RH
REAR SEAT
T=40.7{415}
3-POINT TYPE
T=40.7{415} BELT ASSEMBLY
REAR DOOR
SCUFF PLATE RH OUT RH
BACK DOOR
WEATHERSTRIP
DECK TRIM SIDE PANEL ASSEMBLY RH
REAR SEATBELT HOLDER
DECK BOARD ASSEMBLY
REAR FLOOR MAT

..... TIGHTENING TORQUE [N*m{kgf*cm}] SUPPORT PLATE RR
B141330J01
GETtheMANUALS.org
SEAT BELT - REAR SEAT 3-POINT TYPE BELT ASSEMBLY OUT RH
SB–23
REMOVAL
4. SEPARATE BACK DOOR WEATHERSTRIP RH

(a) Separate the back door weatherstrip only as far as needed to
remove the rear floor mat support plate RR, deck trim side
panel assembly RH and roof side inner garnish RH.
SB
5)
6. SEPARATE REAR SEAT 3-POINT TYPE BELT ASSEMBLY OUT
RH
(a) Remove the bolt and separate the rear seat 3-point type belt
assembly OUT RH floor anchor.

5)
B135500
8. REMOVE REAR SEAT BELT HOLDER

(a) Using a screwdriver wrapped with protective tape, disengage
the claw and remove the rear seat belt holder from the deck trim
side panel assembly RH.
9. SEPARATE REAR DOOR WEATHERSTRIP RH

(a) Separate the rear door weatherstrip RH only as far as needed
to remove the roof side inner garnish RH.
10. REMOVE ROOF SIDE INNER GARNISH RH (WITHOUT CURTAIN

Protective Tape
Claw B135501J01 SHIELD AIRBAG) (See page IR-6)
11. REMOVE ROOF SIDE INNER GARNISH RH (WITH CURTAIN

SHIELD AIRBAG)
12. REMOVE REAR SEAT BELT RETRACTOR COVER

13. REMOVE REAR SEAT 3-POINT TYPE BELT ASSEMBLY OUT RH
(a) Remove the bolt and shoulder anchor.
B141341
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SB–24 SEAT BELT - REAR SEAT 3-POINT TYPE BELT ASSEMBLY OUT RH
(b) Remove the bolt and 2 hooks, and then remove the rear seat 3-
point type belt assembly OUT RH.
INSTALLATION
HINT:
SB B141340
1. INSTALL REAR SEAT 3-POINT TYPE BELT ASSEMBLY OUT RH

45°
inclination of the retractor is over 45×.
CAUTION:
B103773J02
(b) Insert the 2 hooks into the retractor bracket, and install the rear
seat 3-point type belt assembly OUT RH (retractor part) with the
bolt.
B141340
(c) Install the shoulder anchor part with the bolt.

(d) Inspect the ELR lock
(1) With the belt installed, check that the belt locks when it is
pulled out quickly.
2. INSTALL REAR SEAT BELT RETRACTOR COVER
3. INSTALL ROOF SIDE INNER GARNISH RH (VEHICLES WITHOUT

CURTAIN SHIELD AIRBAGS) (See page IR-11)
B141341
4. INSTALL ROOF SIDE INNER GARNISH RH (VEHICLES WITH
5. INSTALL REAR DOOR WEATHERSTRIP RH
GETtheMANUALS.org
SEAT BELT - REAR SEAT 3-POINT TYPE BELT ASSEMBLY OUT RH
SB–25
6. INSTALL REAR SEAT BELT HOLDER

(a) Engage the 2 claws to install the rear seat belt holder.

12)
Claw B109429J02
SB
8. INSTALL REAR SEAT 3-POINT TYPE BELT ASSEMBLY OUT RH
(a) Install the rear seat 3-point type belt assembly OUT RH (floor
anchor part).
NOTICE:
Do not allow the rear seat 3-point type belt assembly OUT
RH to run on the location.

13)
B135500
GETtheMANUALS.org
SB–26 SEAT BELT - REAR SEAT LAP TYPE BELT ASSEMBLY RH

SRS AIRBAGS
COMPONENTS
RECLINING RELEASE HANDLE REAR SEATBACK ASSEMBLY RH
SB
REAR SEAT RECLINING

COVER INN RH
SEPARATE TYPE REAR

SEAT CUSHION COVER RH
REAR SEAT RECLINING COVER NO. 1 RH
REAR SEAT ROCK

COVER RH
REAR SEAT LEG COVER
T=40.7{415}
[N*m{kgf*cm}]
B141372J01
GETtheMANUALS.org
SEAT BELT - REAR SEAT LAP TYPE BELT ASSEMBLY RH
SB–27
REMOVAL
1. REMOVE REAR SEAT LEG COVER (See page SE-11)
2. REMOVE REAR SEAT ASSEMBLY RH (See page SE-11)
3. REMOVE RECLINING RELEASE HANDLE (See page SE-11)
4. REMOVE REAR SEAT RECLINING COVER NO. 1 RH (See page

SE-11)
5. REMOVE REAR SEAT RECLINING COVER INN RH (See page SE-

12) SB
6. REMOVE REAR SEAT LOCK COVER RH (See page SE-12)
7. REMOVE REAR SEATBACK ASSEMBLY RH (See page SE-12)
8. REMOVE SEPARATE TYPE REAR SEAT CUSHION COVER RH

(See page SE-13)
9. REMOVE REAR SEAT LAP TYPE BELT ASSEMBLY RH
(a) Remove the bolt and rear seat lap type belt assembly RH.
INSTALLATION
B141369
10. INSTALL REAR SEAT LAP TYPE BELT ASSEMBLY RH

(a) Install the rear seat belt with the bolt.
HINT:
Cross the rear seat lap type belt assembly RH and the rear seat
belt INN RH, then pass the rear seat cushion rubber.
11. INSTALL SEPARATE TYPE REAR SEAT CUSHION COVER RH

(See page SE-14)
B141369 12. INSTALL REAR SEATBACK ASSEMBLY RH (See page SE-15)
13. INSTALL REAR SEAT LOCK COVER RH (See page SE-15)
14. INSTALL REAR SEAT RECLINING COVER INN RH (See page SE-
15)
15. INSTALL REAR SEAT RECLINING COVER NO. 1 RH (See page

SE-16)
16. INSTALL RECLINING RELEASE HANDLE LH (See page SE-16)
17. INSTALL REAR SEAT ASSEMBLY RH (See page SE-16)
GETtheMANUALS.org
SB–28 SEAT BELT - REAR SEAT LAP TYPE BELT ASSEMBLY CTR LH

SRS AIRBAGS
COMPONENTS
SB REAR SEATBACK ASSEMBLY LH
SEPARATE TYPE REAR SEAT CUSHION COVER LH
REAR SEAT
RECLINING
COVER LH
REAR SEAT RECLINING COVER INN LH

REAR SEATBELT
ASSEMBLY INN RH
T=40.7{415}
RECLINING RELEASE HANDLE LH
REAR SEAT LEG COVER

REAR SEAT ROCK
COVER LH
T=34{345}
T=34{345}
T=40.7{415}
[N*m{kgf*cm}]
B141383J01
GETtheMANUALS.org
SEAT BELT - REAR SEAT LAP TYPE BELT ASSEMBLY CTR LH
SB–29
REMOVAL
2. REMOVE REAR SEAT ASSEMBLY LH (See page SE-18)
4. REMOVE REAR SEAT RECLINING COVER LH (See page SE-18)
5. REMOVE REAR SEAT RECLINING COVER INN LH (See page SE-

19)
6. REMOVE REAR SEAT LOCK COVER LH (See page SE-19) SB

7. REMOVE REAR SEAT BELT ASSEMBLY INN RH (See page SB-
32)
8. REMOVE REAR SEATBACK ASSEMBLY LH (See page SE-19)
9. REMOVE SEPARATE TYPE REAR SEAT CUSHION COVER LH

(See page SE-21)
10. REMOVE REAR SEAT CUSHION PAD LH

11. REMOVE REAR SEAT LAP TYPE BELT ASSEMBLY CTR LH
(a) Remove the bolt and rear seat lap type belt assembly CTR LH.
INSTALLATION
B135612
1. INSTALL REAR SEAT LAP TYPE BELT ASSEMBLY CTR LH

(a) Install the rear seat lap type belt assembly CTR LH with the
bolt.
2. INSTALL REAR SEAT CUSHION PAD LH
3. INSTALL SEPARATE TYPE REAR SEAT CUSHION COVER LH

(See page SE-21)
4. INSTALL REAR SEATBACK ASSEMBLY LH (See page SE-22)

B135612
5. INSTALL REAR SEAT BELT ASSEMBLY INN RH (See page SB-33)
6. INSTALL REAR SEAT LOCK COVER LH (See page SE-22)
7. INSTALL REAR SEAT RECLINING COVER INN LH (See page SE-

22)
8. INSTALL REAR SEAT RECLINING COVER LH (See page SE-23)
10. INSTALL REAR SEAT ASSEMBLY LH (See page SE-23)
11. INSTALL REAR SEAT LEG COVER (See page SE-23)
GETtheMANUALS.org
SB–30 SEAT BELT - REAR SEAT BELT ASSEMBLY INN
REAR SEAT BELT ASSEMBLY INN

SRS AIRBAGS
COMPONENTS
RECLINING RELEASE HANDLE REAR SEATBACK ASSEMBLY RH
SB
REAR SEAT RECLINING

COVER NO. 1 RH
SEPARATE TYPE REAR

REAR SEAT RECLINING

COVER INN RH
REAR SEAT ROCK

COVER RH
REAR SEAT LEG COVER
T=40.7{415}
REAR SEATBELT ASSEMBLY INN
[N*m{kgf*cm}]
B141370J01
GETtheMANUALS.org
SEAT BELT - REAR SEAT BELT ASSEMBLY INN
SB–31
REMOVAL
NOTICE:
Use a "Torx" socket wrench (E10) to remove the rear seat.
2. REMOVE REAR SEAT ASSEMBLY RH (See page SE-11)
4. REMOVE REAR SEAT RECLINING COVER NO. 1 RH (See page

SE-11) SB
5. REMOVE REAR SEAT RECLINING COVER INN RH (See page SE-
12)
6. REMOVE REAR SEAT LOCK COVER RH (See page SE-12)
7. REMOVE REAR SEATBACK ASSEMBLY RH (See page SE-12)
8. REMOVE SEPARATE TYPE REAR SEATBACK COVER RH (See

page SE-13)
9. REMOVE REAR SEAT BELT ASSEMBLY INN
(a) Remove the bolt and rear seat belt assembly INN.
INSTALLATION
B141371
1. INSTALL REAR SEAT BELT ASSEMBLY INN

(a) Install the rear seat belt assembly INN with the bolt.
HINT:
Cross the rear seat belt assembly INN and the rear seat lap
type belt assembly RH, then pass the rear seat cushion rubber.

(See page SE-14)
B141371 3. INSTALL REAR SEATBACK ASSEMBLY RH (See page SE-15)
4. INSTALL REAR SEAT LOCK COVER RH (See page SE-15)
5. INSTALL REAR SEAT RECLINING COVER INN RH (See page SE-

15)
6. INSTALL REAR SEAT RECLINING COVER NO. 1 RH (See page

SE-16)
7. INSTALL RECLINING RELEASE HANDLE (See page SE-16)
8. INSTALL REAR SEAT ASSEMBLY RH (See page SE-16)
GETtheMANUALS.org
SB–32 SEAT BELT - REAR SEAT BELT ASSEMBLY INN RH

SRS AIRBAGS
COMPONENTS
SB
T=40.7{415}
[N*m{kgf*cm}] B141373J01
REMOVAL
1. REMOVE REAR SEAT BELT ASSEMBLY INN RH
(a) Remove the bolt and rear seat belt assembly INN RH.
B135616
GETtheMANUALS.org
SEAT BELT - REAR SEAT BELT ASSEMBLY INN RH
SB–33
INSTALLATION
1. INSTALL REAR SEAT BELT ASSEMBLY INN RH
(a) Install the rear seat belt assembly INN RH with the bolt.
SB
B135616
GETtheMANUALS.org
SB–34 SEAT BELT - REAR SEAT BELT ASSEMBLY INN NO. 1

SRS AIRBAGS
COMPONENTS
SB
REAR SEATBACK ASSEMBLY LH
REAR SEAT RECLINING COVER INN LH

SEPARATE TYPE REAR SEAT
CUSHION COVER LH
REAR SEAT RECLINING COVER LH
REAR SEAT BELT

T=40.7{415} ASSEMBLY INNER
RECLINING RELEASE HANDLE LH
REAR SEAT ROCK

COVER LH

REAR SEAT LEG COVER
T=40.7{415}
[N*m{kgf*cm}]
B141385J01
GETtheMANUALS.org
SEAT BELT - REAR SEAT BELT ASSEMBLY INN NO. 1
SB–35
REMOVAL
2. REMOVE REAR SEAT ASSEMBLY LH (See page SE-18)
3. REMOVE RECLINING RELEASE HANDLE LH (See page SE-18)

32)
5. REMOVE REAR SEAT RECLINING COVER LH (See page SE-18)
6. REMOVE REAR SEAT RECLINING COVER INN LH (See page SE- SB

19)
7. REMOVE REAR SEAT LOCK COVER LH (See page SE-19)
8. REMOVE REAR SEATBACK ASSEMBLY LH (See page SE-19)

(See page SE-20)

11. REMOVE REAR SEAT BELT ASSEMBLY INN NO. 1
(a) Remove the bolt and rear seat belt assembly INN No. 1.
INSTALLATION
B135612
1. INSTALL REAR SEAT BELT ASSEMBLY INN NO. 1

(a) Install the rear seat belt assembly INN No. 1 with the bolt.

(See page SB-35)
4. INSTALL REAR SEATBACK ASSEMBLY LH (See page SE-22)
B135612
5. INSTALL REAR SEAT LOCK COVER LH (See page SE-22)
6. INSTALL REAR SEAT RECLINING COVER INN LH (See page SE-

22)
7. INSTALL REAR SEAT RECLINING COVER LH (See page SE-23)
10. INSTALL REAR SEAT ASSEMBLY LH (See page SE-23)
GETtheMANUALS.org
SB–36 SEAT BELT - REAR SEAT OUTER BELT ASSEMBLY CENTER
REAR SEAT OUTER BELT ASSEMBLY CENTER

SRS AIRBAGS
COMPONENTS
SB
REAR SEAT BELT OUTER ANCHOR

BRACKET ASSEMBLY LH
T=40.7{415}
T=40.7{415}
REAR SEAT OUTER BELT

ASSEMBLY CENTER
T=40.7{415}
BRACKET
SEAT BELT
RETRACTOR COVER

B141331J01
GETtheMANUALS.org
SEAT BELT - REAR SEAT OUTER BELT ASSEMBLY CENTER
SB–37
REMOVAL
See page IR-1 for roof headlining assembly components.
1. REMOVE SEAT BELT RETRACTOR COVER
(a) Disengage the clip and 5 claws, and remove the seat belt
retractor cover.

(See page IR-4.)
SB
B141379
3. REMOVE BRACKET
B141380
4. REMOVE REAR SEAT OUTER BELT ASSEMBLY CENTER

(a) Remove the bolt and rear seat outer belt assembly center.
B141381
5. REMOVE REAR SEAT BELT OUTER ANCHOR BRACKET

ASSEMBLY LH
(a) Remove the 2 bolts and rear seat belt outer anchor bracket
assembly LH.
B141382
GETtheMANUALS.org
SB–38 SEAT BELT - REAR SEAT OUTER BELT ASSEMBLY CENTER
INSTALLATION
1. INSTALL REAR SEAT BELT OUTER ANCHOR BRACKET
ASSEMBLY LH
(a) Install the rear seat belt outer anchor bracket assembly LH with
the 2 bolts.
SB
B141382
2. INSTALL REAR SEAT OUTER BELT ASSEMBLY CENTER

(a) Align the hook and install the rear seat outer belt assembly
center with the bolt.
B141381
3. INSTALL BRACKET
(a) Align the hook and install the bracket with the 2 bolts.

(See page IR-9.)
B141380
5. INSTALL SEAT BELT RETRACTOR COVER

(a) Engage the claws and install the seat belt retractor cover with
the clip.
B141379
GETtheMANUALS.org
TO INDEX
BODY AND ELECTRICAL
ENGINE IMMOBILISER
ENGINE IMMOBILISER SYSTEM
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EI-1
DIAGNOSTIC TROUBLE CODE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EI-1
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EI-2
HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . EI-2
CUSTOMER PROBLEM ANALYSIS CHECK SHEET . . . . . . . . . . . . . . . . . . . . . . EI-5
CHECK / CLEAR DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EI-6
ECU TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ECU DATA LIST / ACTIVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EI-7
EI-9
EI
B2780/15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EI-10
B2788/41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EI-13
B2789/42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EI-13
B2793/23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EI-15
B2794/22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EI-16
B2795/21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EI-17
B2796/12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EI-18
B2797/24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EI-18
B2798/25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EI-18
B2797/24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EI-21
B2798/25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EI-21
GETtheMANUALS.org
EI–1 ENGINE IMMOBILISER - ENGINE IMMOBILISER SYSTEM
ENGINE IMMOBILISER SYSTEM

BODY AND
ENGINE IMMOBILISER
ELECTRICAL
LOCATION
STEERING COLUMN UPPER WITH SWITCH BRACKET ASSEMBLY

(IMMOBILISER COIL)
(NON-ROTATION SOLENOID)
EI

(ENGINE ECU )
TRANSPONDER KEY COMPUTER ASSEMBLY

(IMMOBILISER ECU)
B143124J01
DTC No. Diagnostic Item Code Memory See Page

Open in the PUSH or KEY SW
B2780/15 { EI-10
circuit
Communication Error (code does
B2788/41 { EI-13
not match)
Communication Error (no
B2789/42 { EI-13
response)
GETtheMANUALS.org
ENGINE IMMOBILISER - ENGINE IMMOBILISER SYSTEM
EI–2
DTC No. Diagnostic Item Code Memory See Page

Immobiliser: Communication
B2793/23 { EI-15
Malfunction 1
B2794/22 { EI-16
Malfunction 2
Main Key ID Code Does Not
B2795/21 { EI-17
Match
B2796/12 Main Key Or Coil Malfunction { EI-18
B2797/24 { EI-21
Malfunction 4
B2798/25 { EI-21
Malfunction 5
EI

EI-15
1. Transponder key EI-16
EI-18
2. Engine control computer (engine ECU) EI-13
EI-10
EI-13
3. Transponder key computer assembly EI-16
EI-18
EI-21
Engine does not start
EI-10
EI-16
4. Steering column upper with switch bracket assembly
EI-18
EI-21
EI-10
EI-13
5. Wire harness
EI-18
EI-21
6. Combination meter assembly EI-10
HOW TO PROCEED WITH

TROUBLESHOOTING
HINT:
(See page EI-5)
GETtheMANUALS.org
3 CHECK FOR DTCs OF EFI (engine control system)
HINT:
(See page ES-8)
(a) Check for DTCs of the EFI system using the DS-II.
Result Proceed to
DTC is not output A
DTC is output B
EI B GO TO ENGINE CONTROL SYSTEM
4 CHECK FOR DTCs OF IMB (ENGINE IMMOBILISER SYSTEM)
(a) Using the DS-II, check for DTCs (see page EI-1). Record any DTCs.
(b) Delete the DTCs.
(c) Reproduce the symptoms based on the recorded code, and check if
the same DTC is output.
Result Proceed to
DTC is not output A
DTC is output B
B GO TO TROUBLESHOOTING FOR EACH

OUTPUT DTC
(a) Check if the symptom is listed in problem symptoms table (see page
EI-2)
Result Proceed to
(a) ECU DATA LIST / ACTIVE TEST (see page EI-9)

(b) ECU terminals (See page EI-7)
GETtheMANUALS.org
EI–4
7 CHECK, REPAIR OR REPLACE
END
EI
GETtheMANUALS.org

CHECK
Date vehicle brought in

ENGINE IMMOBILISER SYSTEM Check Sheet
/ /
Customer’ s Name License Plate No. First registration year 20 __ / /
Model VIN
EI Written by
Inspector’s name Engine Type Odometer Reading
Date Problem First Occurred / / :Hour of the day ____AM/PM
Starting Trouble Security Indicator Illumination Malfunction

Problem description
Additional key registration not possible Others ( )
User ( Constant Frequent Occasional One time only )

Frequency Problem Occurs
During dealer check ( Constant Frequent Occasional One time only No longer occurs )
Temperature and weather
conditiions when problem occurred 1) Temperature : ( Approx. ( )°C , 2) Weather : Clear Cloudy Rainy Snowy
Tendency to occur Morning driving Restarting the vehicle after driving approx. ( ) hours Others
When having starting trouble

did the vehicle start with another registered key? YES NO
When IG ON, does the security indicator turn off? YES NO
Detailed check results Does the engine crank normally? YES NO

when problem occurs
Is another key attached to the key being used? YES NO
Immobiliser system DTC ( )

EFI system DTC ( )
Previous DTC ( )
History of changed problem parts
Engine starter (genuine parts / others) Smart system

Installed accessory parts
Car navigation (genuine parts / others)
Other specified items
B143390
GETtheMANUALS.org
EI–6
CHECK / CLEAR DTCs
1. PREPARE FOR INSPECTION

(a) Move the shift lever to the P position.
(b) Turn off the air conditioning.
2. CHECK DTCs (using DS-II)
(b) Following the prompts on the screen, select DIAGNOSIS / IMB /
DIAGNOSTIC CODE to check DTCs.
HINT:
EI
• If the check engine warning light remains on, wire harness
may have a short (or pinched) or the engine control
computer (engine ECU) may be malfunctioning.
• If the DS-II does not display DTCs or indicate the normal
condition, and the indicator light does not flash, there may
be an open in the TC circuit between the DLC connecter
and each ECU or the engine control computer (engine ECU)
may be malfunctioning.
3. CHECK DTCs (using the security indicator light)
NOTICE:
Turn the ignition switch to the ON position before reading the
DTCs, and check that the security indicator light is flashing.
(b) Using the diagnosis check wire, short terminals 13 (ECUT) and
ECUT 4 (E) of the DLC.
SST 09843-18040
NOTICE:
• Do not connect diagnosis check wire No. 2 to the wrong
terminals. Doing so may cause malfunctions.
• Use only dedicated diagnosis check wire.
(c) Turn the ignition switch to the ON position, and count the
E
number of flashes of the security indicator light.
B141833
Normal Abnormal (codes 21 and 41 are output)
0.5 seconds
0.5 seconds
0.25 seconds
ON ON
OFF OFF
4 seconds
4 seconds 0.5 seconds 2.5 seconds
1.5 seconds Code 41 Repeated

Code 21 B141832
HINT:
• If the indicator light does not indicate a DTC (light does not
come on), there may be an open in the TC terminal or the
computer may be malfunctioning.
• If the security indicator light remains on, the wire harness
may have a short circuit (pinched) or the computer may be
malfunctioning.
GETtheMANUALS.org
• If an irrelevant DTC is output, the computer may be

malfunctioning.
(d) Remove the diagnosis check wire.
4. CLEAR DTCs
CHECK DTC and CLEAR to clear the DTCs.
NOTICE:
• If the DTCs cannot be cleared, turn the ignition switch
off, then perform this procedure again.
• Selecting CLEAR on the ALL DTCs screen clear all
system DTCs.
EI
ECU TERMINALS
1. TRANSPONDER KEY COMPUTER ASSEMBLY (IMMOBILISER
ECU)
(a) Check immobiliser ECU.
(1) Disconnect the immobiliser ECU connector.
(2) Using the tester, measure the voltage and the continuity
between the terminals of the connector on the vehicle side.
Standard:
B142045J01
Terminal No. (Terminal Symbols) Item Measurement Condition Standard

7 (GND) ←→ Body ground Continuity Always Continuity
1 V or less → 10 to
2 (IG) ←→ 7 (GND) Voltage Ignition switch OFF → ON
14 V
HINT:
If the result is not as specified, the wire harness on the
vehicle side may be malfunctioning.
(3) Connect the connector.
(4) Measure the voltage between connecter terminals using
the tester.
(5) Using an oscilloscope, check that a pulse is generated
between terminals.
Standard:
Terminal No. (Terminal Symbols) Measurement Condition Standard

6(COL+) ←→ 13(COL-) Key is not inserted in the ignition knob → Key is inserted Pulse is generated
3 (KSW) ←→ 7 (GND) Key is not inserted in the ignition knob → Key is inserted 1 V or less → 10 to 14 V
8 (SIO2) ←→ 7 (GND) Ignition switch OFF → ON Pulse is generated
HINT:
If the result is not as specified, the transponder key
computer assembly may be malfunctioning.
(b) Oscilloscope waveform
NOTICE:
The oscilloscope waveform as shown is an example and
noise or chattering waveforms are not included.
GETtheMANUALS.org
EI–8
(1) Waveform
Tester Connection SIO2 ←→ GND

Tool Setting 2 V/DIV, 20 msec/DIV
Measurement Condition Ignition switch OFF → ON
B103170
STEERING COLUMN UPPER

2. STEERING COLUMN UPPER WITH SWITCH BRACKET ASSEM-
BLY
EI
(a) Check the immobiliser system.
WITH SWITCH BRACKET ASSEMBLY
(1) Disconnect the steering column upper with switch bracket
assembly connector.
(2) Measure the continuity between connecter terminals using
a tester.
Standard:
B143211J01

1(COL+) ←→ 2(COL-) Always Continuity
HINT:
If the result is not as specified, the steering column upper
with switch bracket assembly may be malfunctioning.
(3) Using the tester, measure the voltage between terminals of
the connector on the vehicle side.
Standard:

4(+) ←→ The body ground Key is inserted in the ignition knob → Key is not inserted 10 to 14 V → 1 V or less
HINT:
If the result is not as specified, the wire harness on the
vehicle side may be malfunctioning.
3. ENGINE CONTROL COMPUTER (ENGINE ECU)
(a) Check the immobiliser system.

7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 31 30 29 28 27 26
B141848J01
GETtheMANUALS.org
(1) Using an oscilloscope, check that a pulse is generated

between terminals.
HINT:
See page ES-16 for the procedure for checking the power
source voltage and the ground.
Standard:

C32 (SIO2) ←→ B32 (E1) Ignition switch OFF → ON Pulse is generated
(b) Oscilloscope waveform

NOTICE:
EI The oscilloscope waveform as shown is an example and
noise or chattering waveforms are not included.
(1) Waveform
Tester Connection SOL+ ←→ E1

Tool Setting 2 V/DIV, 20 msec/DIV
Measurement Condition Ignition switch OFF → ON

1. ECU DATA LIST
(a) Determine if there are any malfunctions using the ECU data list
B103170 function of DS-II.
Standard:
Transponder key computer assembly

Item (Symbols) Inspection Condition Reference value
TEST Terminal [T] T terminal circuit: short / open GND / OPEN
IG [IG] IG ON ON
KEY SW [KSW] Key: inserted in the ignition knob / not inserted in the ignition knob ON / OFF
REQ Permission Signal [REQ] Request permission signal output in SIO2 Output / Stop
Match / Does not
Transponder Communication [TP] Main key: inserted in the ignition knob / not inserted in the ignition knob
match
Immobiliser Condition [IMO] Main key: inserted in the ignition knob / not inserted in the ignition knob UNSET/ SET
Registered/
Key 4 [KKD4] -
Unregistered
Registered/
Key 3 [KKD4] -
Unregistered
Registered/
Key 2 [KKD2] -
Unregistered
Registered /
Key 1 [KKD1] -
Unregistered
GETtheMANUALS.org
EI–10
DTC B2780/15 Open in the PUSH or KEY SW circuit

DESCRIPTION
The transponder key computer assembly outputs this code when KSW signals are not received with the ignition switch on.
DTC No. DTC Detection Condition Trouble Area

• Steering column upper with switch bracket
B2780/15 KSW signal is not received with the ignition switch on. assembly
• Transponder key computer assembly
• Combination meter assembly
EI
CIRCUIT DIAGRAM
Steering Column Upper With

Combination Meter Assembly Switch Bracket Assembly
3 26 2 3
KSW KSW B -
B143378J01
(a) Insert the key to the ignition knob.

(b) Measure the voltage between terminal 4 (+) and the body ground
STEERING COLUMN UPPER using the tester.
Standard:
10 to 14 V
NG CHECK AND REPAIR POWER SOURCE

CIRCUIT
B143211J01
GETtheMANUALS.org
OK
2 READ DATA USING DS-II (KEY SW)

(b) Using the DS-II, following the prompts on the screen, select ECU
DATA LIST and KEY SW.
(c) Check any changes in the switch condition (ON or OFF) when the key
is inserted to the ignition knob.
Standard
EI Measurement Condition
Screen
Display
When the key is inserted to the ignition knob ON
When the key is not inserted to the ignition knob OFF
NG REPLACE STEERING COLUMN UPPER

OK
(a) Disconnect the steering column upper with switch bracket assembly
and combination meter assembly connectors.
(b) Using the tester, measure the continuity between terminals of the
Steering Column Upper With Switch connector on the vehicle side.
Bracket Assembly Standard
Terminal No. (Terminal Symbols)
Steering Column Upper with Switch Bracket Assembly ←→ Continuity
3 (-) ←→ 2 (B) Continuity
(-) NG REPAIR OR REPLACE WIRE HARNESS OR

CONNECTOR
B
B143230J01
OK
GETtheMANUALS.org
EI–12
(a) Disconnect the transponder key computer assembly and the

combination meter assembly connectors.
Transponder Key Computer Assembly connector on the vehicle side.

Transponder Key Computer Assembly ←→ Combination Meter Continuity
Assembly
3 (KSW) ←→ 26 (KSW) Continuity EI
KSW
CONNECTOR
KSW
B143231J01
OK
5 REPLACE TRANSPONDER KEY COMPUTER ASSEMBLY
(a) Replace the transponder key computer assembly and register the key
code.
(b) Clear DTCs using the DS-II.
6 CHECK FOR DTCs
(a) Check for DTCs using the DS-II.

Standard
Result Proceed to
DTC B2780/15 is not output A
DTC B2780/15 is output B
B REPLACE COMBINATION METER

ASSEMBLY
END
GETtheMANUALS.org
DTC B2788/41 Communication Error (code does not match)
DTC B2789/42 Communication Error (no response)

DESCRIPTION
The transponder key computer assembly outputs these codes if it receives a code unmatched signal when communicating with
the engine control computer or if signals are not received from the engine control computer.

The transponder key computer receives a • Wire harness or connector
EI B2788/41 code unmatched signal when communicating •

with the engine control computer. •
Engine control computer
The transponder key computer does not
receive signals from the engine control
B2789/42 • Engine control computer
computer when communicating with the
engine control computer.
CIRCUIT DIAGRAM

8 117
SIO2 SIO2
B141860J04
(a) Disconnect the transponder key computer assembly (immobiliser

ECU) connector and the engine control computer (engine ECU)
connector C.
GETtheMANUALS.org
EI–14
connector on the vehicle wire harness side.
Standard
Continuity
Immobilizer ECU ←→ Engine ECU
8 (SIO2) ←→ 117 (SIO2) Continuity

CONNECTOR
SIO2
Connector C
EI
SIO2
B143232J01
OK
code.
3 CHECK FOR DTCs

Standard
Result Proceed to
DTCs B2788/41 and B2789/42 are not output A
DTCs B2788/41 and B2789/42 are output B
B REPLACE ENGINE CONTROL COMPUTER
END
GETtheMANUALS.org
DTC B2793/23 Immobiliser: Communication Malfunction 1

DESCRIPTION
The transponder key computer assembly outputs this code if a problem is detected during key code registration or if the key code
is not successfully registered.

B2793/23 Trouble in key code registration • Key
EI
1 RE-REGISTRATION OF THE KEY THAT DOES NOT START ENGINE
(a) Clear DTCs using the DS-II.

(b) Re-register the key that does not start the engine.
(c) Check that the ignition switch is turned to the ON position and the
engine is started using the key.
OK NO PROBLEM
NG
REPLACE KEY THAT CAUSES B2793 TO BE OUTPUT
GETtheMANUALS.org
EI–16

DESCRIPTION
The transponder key computer assembly outputs these codes if a malfunction is detected in communication between the
transponder key computer assembly and the key.

• Key
B2794/22 Code key does not match
INSPECTION PROCEDURE EI
1 CHECK OPERATION WITH ANOTHER KEY
(a) Check if the ignition switch is turned to the ON position and the
engine is started using another key.
Standard:
The ignition switch is turned to the ON position and the engine
is started.
OK REPLACE KEY THAT DOES NOT START

ENGINE
NG
GETtheMANUALS.org
DTC B2795/21 Main Key ID Code Does Not Match

DESCRIPTION
transponder key computer assembly and the key.

• Key
B1795/21 Key ID code does not match.
EI INSPECTION PROCEDURE
1 Key re-registration

(b) Re-register the key.
(c) Check that the ignition switch is turned to the ON position and the
engine is started using the key.
NG REPLACE KEY
OK
GETtheMANUALS.org
EI–18
DTC B2796/12 Main Key or Coil Malfunction

DESCRIPTION
Those codes will be output through the transponder key computer assembly if a malfunction occurs due to a defect in the key or
the immobiliser in communication.
DTC No. DTC Detection Condition Trouble Area EI

• Key
B2796/12 ID code is not sent back • Transponder key computer assembly
• Steering column upper with switch
bracket assembly (immobiliser coil)
• Key
B2797/24 Transponder communication trouble • Transponder key computer assembly
• Key
Complete data is not received within a
B2798/25 • Transponder key computer assembly
specified time
CIRCUIT DIAGRAM
Transponder Key Computer Assembly Steering Column Upper With Switch Bracket Assembly
(Immobiliser Coil)
6 1
COL+ COL+
13 2
COL- COL-
B141956J02
GETtheMANUALS.org
(a) Disconnect the connectors from the transponder key computer

assembly (immobiliser ECU) and the steering column upper with
switch bracket assembly (immobiliser ECU).
Standard
EI Transponder Key Computer Assembly

Transponder ECU ←→ Immobiliser Coil
Continuity
6(COL+) ←→ 1(COL-) Continuity


COL- COL+ CONNECTOR
Steering Column Upper With
Switch Bracket Assembly
COL+ COL-
B143233J01
OK
2 CHECK OPERATION WITH ANOTHER KEY
(a) Check if the ignition switch is turned to the ON position and the
engine is started using another key.
Standard:
The ignition switch is turned to the ON position and the engine
is started.
OK REPLACE KEY THAT DOES NOT START

ENGINE
NG
code.
GETtheMANUALS.org
EI–20
4 CHECK FOR DTCs

Standard
Result Proceed to
DTCs B2796/12, B2797/24 and B2798/
A
25 are not output
DTCs B2796/12, B2797/24 and B2798/
B
25 are output
B REPLACE STEERING COLUMN UPPER

EI
END
GETtheMANUALS.org

DESCRIPTION
transponder key computer assembly and the steering column upper with switch bracket assembly.

EI B2797/24 Transponder communication trouble

•
•
Steering column upper with switch bracket
assembly
Complete data is not received within a • Transponder key computer assembly
B2798/25
specified time • Steering column upper with switch bracket
assembly
CIRCUIT DIAGRAM
Transponder Key Computer Assembly Steering Column Upper With Switch Bracket Assembly
(Immobiliser Coil)
6 1
COL+ COL+
13 2
COL- COL-
B141956J02
(a) Disconnect the connectors from the transponder key computer

assembly and the steering column upper with switch bracket
assembly.
GETtheMANUALS.org
EI–22
Standard
Vehicle Side Connector Terminal No. (Terminal Symbols)
Immobiliser ECU ←→ Steering column upper with switch Continuity
bracket assembly
COL- COL+ NG REPAIR OR REPLACE WIRE HARNESS OR

Steering Column Upper With CONNECTOR
Switch Bracket Assembly
EI
COL+ COL-
B143233J01
OK
code.
3 CHECK FOR DTCs

Standard
Result Proceed to
DTCs B2797/24 and B2798/25 are not
A
output
DTCs B2797/24 and B2798/25 are
B
output
B REPLACE STEERING COLUMN UPPER

END
GETtheMANUALS.org
TO INDEX
BODY AND ELECTRICAL
LIGHTING
LIGHTING SYSTEM
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-1
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-1
BASIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-2
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-4
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-6
HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . LI-9
CUSTOMER PROBLEM ANALYSIS CHECK SHEET. . . . . . . . . . . . . . . . . LI-11
CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-12
ECU TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ILLUMINATED ENTRY SYSTEM DOES NOT OPERATE . . . . . . . . . . . . .
LI-16
LI-18
LI
HEADLIGHT ASSEMBLY LH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-26
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-27
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-29
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-29
CORRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-32
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-33
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-34
SIDE TURN SIGNAL LIGHT ASSEMBLY LH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-36
TAILLIGHT (REAR COMBINATION LIGHT) ASSEMBLY LH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-39
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-41
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-42
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-42
CENTER STOP LIGHT ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-43
MAP LIGHT ASSEMBLY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-44
ROOM LIGHT ASSEMBLY NO. 1
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-45
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-46
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INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-47
GLOVE BOX LIGHT ASSEMBLY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-48
HEADLIGHT DIMMER SWITCH ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-49
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-50
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-50
HAZARD WARNING SIGNAL SWITCH ASSEMBLY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-52
LI ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-53
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-54
FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-55
REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-56
BACK DOOR COURTESY LIGHT SWITCH ASSEMBLY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-57
HEADLIGHT RELAY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-59
FOG LIGHT RELAY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LI-60
REAR FOG LIGHT SWITCH
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LIGHTING - LIGHTING SYSTEM
LI–1
LIGHTING SYSTEM
BODY AND ELECTRICAL
LIGHTING
PRECAUTIONS
1. PRECAUTIONS WHEN REPLACING HEADLIGHT BULBS
(a) Because halogen lights become extremely hot when in use, the
life of the bulb may be reduced in the event that the surface of
the bulb comes in contact with oil or another similar substance.
When replacing the bulb, hold the flange part and do not touch
the glass with your bare hands.
(b) Halogen bulbs have pressurized gas inside and can be
damaged or shattered if dropped, bumped or scratched.
(c) Because dirt and moisture can enter the lens of a bulb that is
removed and left out for a long period of time, have a new bulb LI
on hand before performing bulb replacement.
(d) When replacing a bulb, always use a bulb of the same
specification.
(e) When replacing one-sided bulbs, keep in mind that there is a
difference in the brightness and luminescent color of left and
right bulbs.
(f) If bulbs are not properly installed in their sockets, water and
mist may get inside the lens. Therefore, after replacing bulbs,
make sure that they have been securely installed.
(g) Flying glass shards can cause injury. Therefore, do not break
bulbs when disposing of them after use.
2. PRECAUTIONS WHEN ADJUSTING HEADLIGHT BEAMS
(a) Do not cover a headlight for more than 3 minutes when the
headlights are ON.
(b) Because the outer lens of the headlight is made of resin, there
is a possibility that the outer lens may melt if it is covered for too
long while the adjustments are made.
OPERATION CHECK
1. BEFORE YOU TROUBLESHOOT
(a) Basic inspection
(1) Using a tester, measure the voltage of the battery.
Standard:
10 to 14 V (during engine stop)
(b) Visually check for broken light bulbs, broken fuses,
disconnected wire harnesses, short circuits and connectors with
bad connections.
2. CHECK HEADLIGHT MANUAL LEVELING FUNCTION (VEHICLES

WITH HALOGEN HEADLIGHTS)
(a) With the ignition switch ON, turn the headlight dimmer switch
assembly to the OFF → HEAD position. When the headlight
leveling switch is re-enabled, check that the reflector is
activated and that the headlight beam changes.
3. CHECK ILLUMINATED ENTRY SYSTEM ACTIVATION

HINT:
The applicable lights are shown below.
• MAP LIGHT ASSEMBLY (VEHICLES WITH A MAP LIGHT)
• ROOM LIGHT ASSEMBLY NO. 1 (VEHICLES WITHOUT A MAP
LIGHT)
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LI–2 LIGHTING - LIGHTING SYSTEM
• ROOM LIGHT ASSEMBLY NO. 2

(a) Perform the following operations to check that the lights come
on under the appropriate conditions.
(1) With the ignition switch (IG) OFF, close all the doors and
lock the driver side door.
(2) With the doors unlocked, check that each light comes on
when any of the doors is opened, and check that the lights
go out 15 seconds after the doors are closed.
(3) With the ignition switch (IG) ON, check that when any of
the doors is opened and then closed, each light goes out
immediately.
(4) Starting with the ignition switch (IG) OFF, check that the
lights go out immediately when any of the doors is opened
LI and the ignition switch (IG) is turned on within 15 seconds
(i.e., before the time at which the lights are supposed to
go out automatically).
(5) With the ignition switch (IG) OFF, and with the doors open
and each light illuminated, check that the lights go out
immediately when the driver side door is locked within
around 15 seconds (i.e., before the time at which the
lights are supposed to go out automatically).
4. INSPECT BATTERY SAVER FUNCTION

(a) With the ignition (IG) OFF, check that each lamp that is
illuminated by the illuminated entry control (lights are
illuminated when any of the doors is opened) goes out after
about 10 minutes.
HINT:
With the ignition switch (IG) ON, or, with the doors closed, the
battery saver system is cancelled.
BASIC INSPECTION
1. CHECK OPERATION
(a) Check the operation of the lights.
(1) Visually check the operation of the vehicle's exterior
lights.
• HEADLIGHTS (HI-LO MODES)
• CLEARANCE LIGHTS
• TAILLIGHTS
• STOP LIGHTS
• BACK-UP LIGHTS
• LICENSE PLATE LIGHTS
• TURN SIGNAL LIGHTS
• HAZARD LIGHTS
• FOG LIGHTS
Standard:
Illumination is normal.
2. CONDITION OF INSTALLATION
(a) Check the installation of the lights.
(1) Wiggle the lights with your hand to check that they are
properly installed.
Standard:
The lights are not loose.
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LI–3
(2) Check that there is no damage, such as discoloration or

cracks, to the reflectors or lenses of the lights. In addition,
check for dirt and water penetration on the inside of the
lamp.
Standard:
There is no damage, such as discoloration or
cracks.
There is no dirt or water penetration.
LI
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LOCATION
TAIL LIGHT (REAR COMBINATION LIGHT) ASSEMBLY LH
TAIL LIGHT (REAR COMBINATION LIGHT)

LI ASSEMBLY RH
ENGINE COMPARTMENT FUSE BOX

-TAIL FUSE
-DOME FUSE
-HEAD LP RELAY
-STOP FUSE
SIDE TURN SIGNAL LIGHT

ASSEMBLY LH
SIDE TURN SIGNAL LIGHT ASSEMBLY RH
HEADLIGHT ASSEMBLY RH
E132125J01
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LI–5
MAP LIGHT ASSEMBLY FRONT DOOR

COURTESY LIGHT SWITCH
ASSEMBLY
MAP LIGHT ASSEMBLY NO.1
FRONT DOOR
CENTER STOP LIGHT ASSEMBLY LI
ASSEMBLY LH
REAR DOOR
ASSEMBLY LH
REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY RH
E134280J01
GETtheMANUALS.org

HAZARD WARNING
SIGNAL
SWITCH ASSEMBLY
HEADLIGHT DIMMER
SWITCH ASSEMBLY
LI
INSTRUMENT PANEL J/B ASSEMBLY

-TURN SIGNAL FLASHER ASSEMBLY
-FOG LIGHT RELAY
GLOVE COMPARTMENT LIGHT
ASSEMBLY
E132744J01

HEADLIGHTS
H-LP RH fuse, H-LP LH fuse -
None of the headlights come on (but the taillights
Headlight bulbs -
operate properly)
Wire harness -
None of the headlights come on (the taillights do not Headlight dimmer switch assembly LI-50
come on either) Wire harness -
H-LP RH fuse, H-LP LH fuse -
The headlights on one side of the vehicle does not H-LP main fuse -
come on Headlight bulbs -
Wire harness -
Clearance light bulbs -
Headlight dimmer switch assembly LI-50
The clearance lights do not come on
TAIL fuse -
Wire harness -
GETtheMANUALS.org
LI–7

Headlight bulbs -
The low beams do not come on Headlight dimmer switch assembly LI-50
Wire harness -
Headlight bulbs -
The high beams do not come on Headlight dimmer switch assembly LI-50
Wire harness -
Passing does not function
Wire harness -
Headlight leveling switch LI-53
Headlight aim cannot be adjusted
Wire harness -
TAILLIGHTS
Symptom Suspected Area See Page LI
TAIL fuse -
None of the taillights come on (but the headlights
The inoperative taillight bulbs -
operate properly)
Wire harness -
None of the taillights come on (the headlights do not
come on either)
Wire harness -
The taillights on one side of the vehicle do not come on
Wire harness -
FRONT FOG LIGHTS

The inoperative front fog light bulb -
TAIL fuse -
Even when the light control switch is set to TAIL or FR FOG fuse -
HEAD, the front fog lights still do not come on (but the
headlights operate properly) Fog light relay -
Wire harness -
The front fog light on one side of the vehicle does not The inoperative front fog light bulb -
come on Wire harness -
REAR FOG LIGHTS

Even when the fog light switch is set to ON, the rear Rear fog light bulbs -
fog lights still do not come on (but the front fog lights Rear fog light switch LI-61
operate properly) Wire harness -
BACK-UP LIGHTS
The inoperative back-up light bulb -
NEUTRAL SWITCH ASSEMBLY (AUTOMATIC -
Neither of the back-up lights come on TRANSMISSION VEHICLES)
Back-up light switch (vehicles with manual transmission) -
Wire harness -
The back-up light on one side of the vehicle does not The inoperative back-up light bulb -
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STOP LIGHTS
STOP fuse -
None of the stop lights come on STOP LIGHT SWITCH ASSEMBLY LI-54
Wire harness -
Rear combination light assembly -
Some of the stop lights do not come on
Wire harness -
CENTER STOP LIGHT

The center stop light does not come on (but the other CENTER STOP LIGHT ASSEMBLY -
stop lights operate properly) Wire harness -
TURN SIGNAL LIGHTS

LI Symptom Suspected Area See Page
Turn signal flasher assembly LI-58
None of the turn signal lights comes on Headlight dimmer switch assembly LI-50
Wire harness -
Turn signal lamps on one side of the vehicle do not The inoperative turn signal light bulbs -
HAZARD WARNING SIGNAL LIGHTS

Hazard warning switch assembly LI-52
The hazard lights do not function (but the turn signal Door control relay assembly LI-16
lights operate properly) Turn signal flasher assembly LI-58
Wire harness -
LICENSE PLATE LIGHTS

License plate light bulbs -
The license plate lights do not come on (but the TAIL fuse -
headlights operate properly) Headlight dimmer switch assembly LI-50
Wire harness -
ROOM LAMP ASSY NO.1

ROOM LAMP ASSY NO.1 -
Room light bulb No. 1 -
Room light switch base -
Front door courtesy light switch assembly -
Room light assembly no. 1 does not come on
Rear door courtesy light switch assembly -
Back door courtesy light switch -
Door control relay assembly -
Wire harness -
GETtheMANUALS.org
LI–9
MAP LIGHT ASSEMBLY

MAP LIGHT ASSEMBLY LI-44
Front door courtesy light switch assembly LI-55
The map light does not come on
Rear door courtesy light switch assembly LI-56
Back door courtesy light switch assembly LI-57
Door control relay assembly LI-16
Wire harness -
Room light assembly No. 2

Room light assembly No. 2 LI-46 LI
The room light does not come on (but the illuminated Front door courtesy light switch assembly LI-55
entry system operates properly) Rear door courtesy light switch assembly LI-56
Wire harness -
Room light assembly No. 3

Room light assembly No. 3 LI-47
Front door courtesy light switch assembly LI-55
The room light does not come on
Rear door courtesy light switch assembly LI-56
Wire harness -
ILLUMINATED ENTRY SYSTEM

See troubleshooting flowchart (ILLUMINATED ENTRY LI-18
The illuminated entry system does not operate (the
SYSTEM DOES NOT OPERATE)
room light does not come on when a door is opened)
Wire harness -
BATTERY SAVER CONTROL

Battery saver control does not operate LI-2
Battery saver control does not operate (but the other
control systems are normal)
Wire harness -
HOW TO PROCEED WITH

TROUBLESHOOTING
GETtheMANUALS.org
HINT:
See page LI-6.
A RELATED TO PROBLEM SYMPTOM (GO TO

LI STEP 5)
4 BASED ON PROBLEM SYMPTOM, PERFORM TROUBLESHOOTING USING METHOD BELOW
(a) CHECK FUNCTION (See page LI-1.)

(b) ECU terminals (See page LI-16.)
(c) ON-VEHICLE INSPECTION
(d) INSPECTION
6 CONFIRMATION TEST
END
GETtheMANUALS.org
LI–11

CHECK

Lighting Problem Diagnosis Check Sheet / /
Customer’s Name License Plate No. First registration year
Model VIN
Written By Inspector’s Name Engine Type
Odometer reading
km
LI
Date Problem First Occured
Frequency Problem Occurs Constant Occasional ( _ times per day, _ times per month)
Conditions (Method of use and results) Air temperature approx.( ) °C
Weather Clear Cloudy Rainy Snowy Others ( )
Outside light
Illumination
Malfunction
Symptoms
Switch
E052038J01
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CIRCUIT DIAGRAM
Headlight (Halogen Headlight Equipped Vehicles)
Headlight
Relay
Battery
LI TAIL H-LP RH H-LP LH

10A 10A 10A
26
+
3 3
Combination Meter
Headlight Headlight Assembly
Assembly RH Assembly LH
LO HI LO HI
1 2 1 2 -
27
5 6 10 9
B1 H HL HU Headlight Dimmer
Switch Assembly
ED T1
7 8
1 2 3 2 3 2
B T RHM+ RHT LHM+ LHT
Headlight Headlight Headlight
Leveling Switch Leveling Motor Leveling Motor
E RH E RH LH E LH
4 1 1
E133840
GETtheMANUALS.org
LI–13
Turn Signal Light
Turn Signal Flasher Assembly Headlight Assembly RH

HAZ 10A 2 1 2
To Battery 4 LR
B
Front Turn Signal Light RH
IG 1 BACK 7.5A 1
To IG IG
3 1
Headlight Assemby LH
2
LI
LL
Headlight Dimmer Switch Assembly Front Turn Signal Light LH
13 6
TR ER
11
E
12 5
TL EL
TURN R 28
7 15
E GND
TURN L 29
Hazard Warning Signal Switch Assembly

4 3 8 Side Turn Signal Light RH
HAZ- HAZ+ EHW
2 1
Side Turn Signal Light LH

2 1
Rear Combination Light Assembly RH

2 1
Rear Turn Signal Light RH
Rear Combination Light Assembly LH

2 1
Rear Turn Signal Light LH
E131478
GETtheMANUALS.org
DOME 7.5A
Illumination/Interior To Battery
BACK UP 10A
To Battery
IG1 BACK 7.5A
To Battery
H12 H10
IG ECUB
LI Headlight Dimmer Switch Assembly

TAIL 10A 5 8
To Battery B1 T1
Differential Lock Switch

2 ILL- ILL+ 1
O/D Switch
1 ILL- ILL+ 2 Map Light Assembly
Door B6
Hazard Warning Switch Assembly Control
Relay 7 E
2 ILL- ILL+ 1
2 CTY
Headlight Leveling Switch

4 E ILL+ 3
CTR H16 2 CTY B 6
Front Wiper Deicer Switch

2 - + 1 Room Light
Assembly NO. 1
Seat Heater Switch 2 CTY B 6
8 ILL- ILL+ 7 H18 GND
Room Light
Assembly NO. 2
Downhill Assist Control and TRC OFF Switch
MPX
1 ILL- ILL+ 6
H13
Rear Fog Light Switch

1 E ILL 3
Heater Control
6 ILL- ILL+ 5
E134283
GETtheMANUALS.org
LI–15
Room Light Assembly NO. 3
2 L B 1
1 37
ILL+ LIN
Front Door Courtesy Light
Switch Assembly (RH)
15 9 1
GND CTY

Switch Assembly (LH)
1
LI
Combination Meter
Rear Door Courtesy Light Switch

Assembly (RH)
1
Rear Door Courtesy Light

1
Back Door Courtesy Light Switch

Assembly (LH)
1 D+ E 2
E131481
GETtheMANUALS.org
ECU TERMINALS
1. INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY RH
GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
CRL
HZD
MPX
IG1
UKS
LI H ECUB
LKS
IND
HORN
ULM
LKM
BDR1
C
D E
25
A F
10 9
24 23 22 21 20 19
12 11 10 9 8 7
4
6
2
2
18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
3
5
8
1
7
B
3
1
6
2
5
1
10 9
4
18 17 16 15 14 13
6
G
3
5
8
4
22 21 20 19 18 17 16 30 29 28 27 26 25 24 23
3
7 6 5 4 3 2 1 15 14 13 12 11 10 9 8
2
6
2
1
5
1
4 3 2 1 2 1
2 1 10 9 8 7 6 5 6 5 4 3
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
Connector A Connector B Connector D Connector E Connector F
12 11 10 9 8 7 6 5 4 3 2 1 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
25
24 23 22 21 20 19 18 17 16 15 14 13 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
Connector C Connector G
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Connector H
B137035
GETtheMANUALS.org
LI–17
Standard
CONNECTOR - H
ECUB ←→ Body ground
(H10 ←→ Body ground)
IG ←→ Body ground
Output Voltage IG ON, IG ACC 10 to 14 V
MPX ←→ Body ground Input /
Waveform Always Pulse is generated
(H6 ←→ Body ground) Output
HZD ←→ Body ground 10 to 14 V → 1.3 V or
Output Voltage Hazard switch OFF → ON
(H14 ←→ Body ground) less
CRL ←→ Body ground Dome light assembly, room light assembly OFF →
Output Voltage 10 to 14 V → 1 V or less
(H16 ←→ Body ground) ON
LI
GETtheMANUALS.org
ILLUMINATED ENTRY SYSTEM DOES NOT OPERATE

CIRCUIT DIAGRAM
DOME 7.5A
To Battery
BACK UP 10A
To Battery
IG1 BACK 7.5A
To IG
ECU IG2 10A
H12 H10
13 12 IG ECUB
+B IG
LI Switch Assembly (RH)
1 9 CTY LIN 37 H13 MPX Map Light Assembly
B6
7 E
1 2 CTY
Rear Door Courtesy

Light Switch Assembly (RH)
CTR H16 2 CTY B 6
1
Rear Door Courtesy Room Light Assembly NO. 1

Light Switch Assembly (LH)
1 2 CTY B 6
H18 GND
GND
Room Light Assembly NO. 2
Back Door Courtesy Light 15
1
Door Control Relay
Combination Meter
:LIN E134282
1 PROBLEM SYMPTOM CONFIRMATION
(a) Confirm the conditions in which the malfunction occurs.
Conditions of Malfunction Occurrence Proceed to

Other than below A
All doors are locked → When unlocking the driver's door B
HINT:
• If the result is B, go to the problem symptoms table,
ILLUMINATED ENTRY SYSTEM FOR UNLOCK DOORS DOES
OPERATE.
GETtheMANUALS.org
LI–19
B Proceed to PROBLEM SYMPTOMS CHART

(See Page LI-6).
2 CHECK ROOM LIGHT ASSEMBLY NO. 1 (VEHICLES WITHOUT A MAP LIGHT)

(1) Using the tester, check the continuity between the terminals.
Standard
Switch Operation Positions Switch Terminal No. (Terminal Continuity
OFF
Symbols)
2 (CTY) ←→ 3 (E) No continuity
LI
1 (B) ←→ 3 (E)
DOOR 2 (CTY) ←→ 3 (E) Continuity
ON 1 (B) ←→ 3 (E) Continuity
OK GO TO STEP 3
E068342J01
NG
REPLACE ROOM LIGHT ASSEMBLY NO. 1
3 CHECK MAP LIGHT ASSEMBLY (VEHICLES WITH A MAP LIGHT)
(a) Check the continuity of the room light.

(1) Using the tester, check the continuity between the terminals
when the room light switch is operated.
CTY Standard

Switch Continuity
Symbols)
OFF 1 (CTY) ←→ 7 (E) No continuity
GND
E073293J06
OK GO TO STEP 4
NG
REPLACE MAP LIGHT ASSEMBLY
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4 CHECK ROOM LIGHT ASSEMBLY NO. 2

(1) Using the tester, check the continuity between the terminals.
Standard
Switch Operation Positions Switch Terminal No. (Terminal Continuity

Symbols)
OFF 2 (CTY) ←→ 3 (E) No continuity
1 (B) ←→ 3 (E)
ON 1 (B) ←→ 3 (E) Continuity
LI
OK GO TO STEP 5
E068342J01
NG
REPLACE ROOM LIGHT ASSEMBLY NO. 2
5 CHECK COURTESY LIGHT SWITCH

(1) Using the tester, check the continuity between the connector
terminal and the body ground (the courtesy light switch
assembly for each door) or terminal 1 and terminal 2 (the
courtesy light switch assembly for the back door).
Standard
Door Courtesy Light Switch For Each Door Condition Standard

With the shaft not depressed Continuity
With the shaft depressed No continuity
E109770J02
OK GO TO STEP 6
NG
REPLACE COURTESY LIGHT SWITCH ASSEMBLY (APPLICABLE SWITCH)
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LI–21
6 CHECK WIRE HARNESS AND CONNECTOR (BETWEEN ROOM LIGHT ASSEMBLY AND DOOR
CONTROL RELAY ASSEMBLY)
(a) Using the tester, check between the room light assembly No. 1 2
(CTY) terminal and the door control relay assembly side vehicle wire
harness connector H16 (CTR) terminal.
OK GO TO STEP 7
NG

LI
7 CHECK WIRE HARNESS AND CONNECTOR (BETWEEN MAP LIGHT ASSEMBLY AND DOOR

(1) Disconnect connector H of the door control relay assembly (at
the rear of the vehicle).
(2) Using the tester, check between the room light assembly No. 1
1 (CTY) terminal and the door control relay assembly side
vehicle wire harness connector H 16 (CTR) terminal.
Map Light Assembly Door Control Relay Side Connector
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
E132073
Standard
Terminal No. (Terminal Symbols) Item Measurement Condition Standard

2 (CTY) ← → H16 (CTR) Continuity Always Continuity
OK GO TO STEP 8
NG
8 CHECK WIRE HARNESS AND CONNECTOR (BETWEEN ROOM LIGHT ASSEMBLY NO. 2 AND
DOOR CONTROL RELAY ASSEMBLY)
(a) Using the tester, check between the room light assembly No. 2 2
(CTY) terminal and the door control relay assembly side vehicle wire
harness connector H 16 (CTR) terminal.
GETtheMANUALS.org
OK GO TO STEP 9
NG
9 CHECK WIRE HARNESS AND CONNECTOR (BETWEEN COMBINATION METER AND DOOR
COURTESY LIGHT SWITCH ASSEMBLY)

(1) Disconnect the connector of the combination meter assembly
LI and the connector of the door courtesy switch for each door.
(2) Using the tester, check between the combination meter
assembly 9 (L) on the vehicle's harness connector and each
door's courtesy switch terminal. (See page ME-16.)
Standard
Combination Meter Assembly Terminal Number

Item
(Terminal Signal)
9 (L) ←→ Each door's courtesy switch Continuity
NOTICE:
Make sure that there is continuity between each terminal,
and that the GND is not short-circuiting
OK GO TO STEP 10
NG
10 CHECK WIRE HARNESS AND CONNECTOR (BETWEEN COMBINATION METER AND DOOR
Door Control Relay Side Connector Meter Side Connector
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
E132072J01
(1) Disconnect connector A of the door control relay assembly (at

the rear of the vehicle) and disconnect the combination meter
assembly connector.
(2) Using the tester, measure between terminals of the connector
on the vehicle wire harness side.
GETtheMANUALS.org
LI–23
Standard
Terminal No. (Terminal Measurement

Item Standard
Symbols) Condition
37 (LIN) ←→ 6 (MPX) Continuity Always Continuity
NOTICE:
Make sure that there is continuity between each terminal,
and that the GND is not short-circuiting
OK REPLACE DOOR CONTROL RELAY

ASSEMBLY
NG
LI
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LI–24 LIGHTING - HEADLIGHT ASSEMBLY LH
BODY AND ELECTRICAL
LIGHTING
COMPONENTS
LI
FRONT BUMPER ASSEMBLY
E131554J01
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LIGHTING - HEADLIGHT ASSEMBLY LH
LI–25
CLEARANCE LIGHT BULB SOCKET HEADLIGHT BEARING MOTOR LH
CLEARANCE LIGHT BULB
HEADLIGHT LEVELING
MOTOR PACKING
HEADLIGHT BULB NO. 2
FRONT TURN SIGNAL LIGHT BULB
FRONT TURN SIGNAL

LIGHT BULB SOCKET
LI
HEADLIGHT
COVER NO. 1
4 LIGHT TYPE
CLEARANCE LIGHT BULB

HEADLIGHT LEVELING MOTOR LH CLEARANCE LIGHT BULB SOCKET
HEADLIGHT LEVELING MOTOR PACKING

FRONT TURN SIGNAL
LIGHT BULB
FRONT TURN SIGNAL
LIGHT BULB SOCKET
HEADLIGHT COVER NO. 1
2 LIGHT TYPE
E132719J01
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Support Bracket
Headlight Protector Retainer

Headlight Protector Retainer UPR LH UPR LH NO. 2
LI
Headlight Protector
Retainer
LWR LH
E132718J01
REMOVAL
2. REMOVE FRONT BUMPER ASSEMBLY (See Page ET-2)

3. REMOVE HEADLIGHT ASSEMBLY LH
(a) Remove the 2 bolts, screw and clip.
(b) Remove the pins of the headlight bracket. Then remove the
headlight assembly LH.
Pin E128798
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LI–27
DISASSEMBLY
1. REMOVE NO. 2 HEADLIGHT BULB
(a) Turn in the direction of the arrow shown in the illustration and
remove headlight bulb No. 2.
LI
E132270J01
2. REMOVE HEADLIGHT BULB NO. 1 (4-LIGHT HEADLIGHT

SYSTEMS)
(a) Remove the socket cover.
4 Light Type 2 Light Type
E132183J01
(b) Remove the set spring.

(c) Remove headlight bulb No. 1.
NOTICE:
Do not touch the glass part of the bulb.
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3. REMOVE FRONT TURN SIGNAL LIGHT BULB

(a) Rotate the front turn signal light socket in the direction shown in
the illustration, and remove the front turn signal light bulb
together with the front turn signal light socket.
LI
E132183J02
(b) Remove the front turn signal light bulb from the front turn signal
light socket.
4. REMOVE CLEARANCE LIGHT BULB

(a) Turn the clearance light socket in the direction shown in the
illustration, and remove the clearance light bulb together with
the and clearance socket.
E132183J03
(b) Remove the clearance light bulb from the clearance light
socket.
REASSEMBLY
1. INSTALL CLEARANCE LIGHT BULB
(a) Install the clearance light bulb in the clearance light socket.
(b) Install the clearance light bulb together with the clearance light
socket.
GETtheMANUALS.org
LI–29
2. INSTALL FRONT TURN SIGNAL LIGHT BULB

(a) Install the front turn signal light bulb in the front turn signal light
socket.
(b) Install the front turn signal light bulb together with the front turn
signal light socket.
3. INSTALL HEADLIGHT BULB NO. 1

(a) Install headlight bulb No. 1.
(b) Lock the set spring.
(c) Install the socket cover.
4. INSTALL HEADLIGHT BULB NO. 2 (4-LIGHT HEADLIGHT

SYSTEMS)
(a) Install the headlight bulb No. 2.
(b) Lock the set spring.
(c) Install the socket cover.
LI
INSTALLATION
1. INSTALL HEADLIGHT ASSEMBLY LH
2. INSTALL FRONT BUMPER ASSEMBLY
4. PREPARATION FOR HEADLIGHT ADJUSTMENT(See Page LI-29)
5. ADJUSTMENT OF HEADLIGHT AIM (See Page LI-31)
6. PREPARATION FOR ADJUSTMENT OF FOG LIGHT BEAM AIM

(See Page LI-34)
7. ADJUSTMENT OF FOG LIGHT AIM (See Page LI-34)
ADJUSTMENT
1. PREPARATION FOR HEADLIGHT ADJUSTMENT
(a) Adjust the tire air inflation pressure to the specified value.
(b) Seat a person in the driver's seat.
(c) Replenish oils to the specified levels. Fill up the tank with fuel.
(d) Mount the tools, jack and spare tire at the specified positions.
(e) Rock the vehicle in the up-and-down direction, as well as in the
right-and-left direction to settle the suspension.
(f) Set the engine speed to 1500 r/min or more. (If the engine
speed is too low, the light terminal voltage drops, making it
difficult to recognize the cut-off line.)
HINT:
Cut-off line: Boundary line between the bright zone and the dark
zone in the low beam.
(g) If the vehicle is equipped with a headlight leveling switch, adjust
the leveling switch to zero.
GETtheMANUALS.org
2. PHOTOMETRIC AXIS ADJUSTMENT

(a) Adjust the photometric axis of the low beam according to the
Upper/Lower Aiming instruction manual of the headlamp screen to be used.
Left/Right Aiming
2 Lights
LI Left/Right Aiming
(Low Beam)
Left/Right Aiming
(High Beam)
Upper/Lower
Aiming
(High Beam)
Upper/Lower Aiming
(Low Beam) 4 Lights
GETtheMANUALS.org
LI–31
3. ADJUSTMENT OF HEADLIGHT AIM (WHEN USING LOW BEAM

SCREEN)
(a) Prepare a screen for the adjustment as indicated in the figure.
1.7 1.7
Center of the headlamp
LI
Cut off line
(Reference position)
1.0 1.2 1.5
Elbow point
:Reference range of Elbow points
Unit:%
E133905
HINT:
The illustration is for RH vehicles. For LH vehicles, the
illustration is symmetrically reverse in relation to the vertical
center line.
(b) Place the screen at a distance of three meters ahead of the
light. Align point F with the center of the light.
HINT:
This normal placing can be carried out easily when a screen is
affixed to the lens of the headlamp tester (for high beam use).
(c) Turn on the low beams of the headlights. Perform the
adjustment in such a way that the elbow point comes into the
shadow section on the screen.
NOTICE:
Perform the adjustment by turning the aiming screw in the
tightening direction. (When performing the adjustment in
the loosening direction, first loosen the screw then turn it
in the tightening direction.)
HINT:
Reference position of elbow point
GETtheMANUALS.org
Vertical position Within the range between 1.0% and 1.5% below the horizontal line
that passes through the center of the light (Reference position: 1.2%
below)
Horizontal position Within 1.7% left or right of the vertical line that passes through the
center of the light (Reference position: on the vertical line that passes
through the center of the light)
CORRECTION
1. INSTALL HEADLIGHT PROTECTOR RETAINER UPPER LH
HINT:
If the headlight unit LH is the only installed part that is damaged, you
can use the repair bracket as shown in the illustration below as an
LI inexpensive workaround. However, this is limited to cases in which
the headlight assembly LH itself is not damaged.
Headlight Protector
Retainer UPR LH
Headlight Protector Retainer

2 Light UPR LH NO. 2
Type
4 Light
Type
Alternate Bracket
(Install With Screw)
E132261
(a) After disconnecting the damaged part, reshape it using

sandpaper.
NOTICE:
After shaving down the damaged spots in an approximate
way, fit the headlight protector retainer into the boss part.
Then shave down the parts that still do not fit in order to
shape the retainer so that it can be installed.
(b) Install the headlight protector retainer upper LH with the 2
screws.
HINT:
Install the other retainers using the same method.
2. INSTALL HEADLIGHT PROTECTOR RETAINER UPPER LH N0. 2
3. INSTALL HEADLIGHT PROTECTOR RETAINER LOWER LH
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LIGHTING - FOG LIGHT ASSEMBLY LH
LI–33

BODY AND ELECTRICAL
LIGHTING
COMPONENTS
LI
FOG LIGHT BULB
E130020J01
REMOVAL
2. REMOVE FRONT FENDER LINER LH (See Page ED-65)

3. REMOVE FOG LIGHT ASSEMBLY
(a) Remove the connector and the screw.
(b) Disengage the pin and remove the fog light assembly LH.
4. REMOVE FOG LIGHT BULB
INSTALLATION
1. INSTALL FOG LIGHT BULB
Pin
Screw E128799J01
GETtheMANUALS.org
LI–34 LIGHTING - FOG LIGHT ASSEMBLY LH
2. INSTALL FOG LIGHT ASSEMBLY

(a) Engage the pin.
(b) Install fog light assembly LH with the screw.
3. INSTALL FRONT FENDER LINER LH (See Page ED-66)

Pin (See PageLI-34)
Screw E128799J01
6. ADJUSTMENT OF FOG LIGHT AIM (See Page LI-34)
7. PERFORM INTIALIZATION (See page SS - 8 for details.)
LI
ADJUSTMENT
(a) Adjust the tire air inflation pressure to the specified value.
(b) Remove fender liner.
(c) Set the engine speed to 1500 r/min or more.
2. ADJUSTMENT OF FOG LIGHT BEAM AIM

(a) Prepare a screen for the adjustment as indicated in the figure.
E133906
(b) Place the screen at a distance of three meters ahead of the

light. Align line H with the center of the front fog light.
(c) Turn on the front fog light. Perform the adjustment in such a
way that the light distribution comes in the shaded section on
the screen.
HINT:
• Perform the adjustment by turning the aiming screw in the
tightening direction. (When performing the adjustment in the
loosening direction, first loosen the screw then turn it in the
tightening direction.)
Aiming Screw
• There is no screw for the horizontal direction adjustment.
GETtheMANUALS.org
LIGHTING - SIDE TURN SIGNAL LIGHT ASSEMBLY LH
LI–35

BODY AND ELECTRICAL
LIGHTING
COMPONENTS
LI

E129940J01
REMOVAL
2. REMOVE SIDE TURN SIGNAL LIGHT ASSEMBLY RH
(a) Detach the 2 claws in the order indicated by the arrows in the
illustration, and disconnect the side turn signal light assembly
LH.
(b) Disconnect the connector and remove the side turn signal light
assembly LH.
(2) (1)
Claw E128792
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LI–36 LIGHTING - SIDE TURN SIGNAL LIGHT ASSEMBLY LH
INSTALLATION
1. INSTALL SIDE TURN SIGNAL LIGHT ASSEMBLY RH
(a) Engage the 2 claws and install the side turn signal light
assembly LH.
(See page SS - 8 for details.)
(1) (2)
Claw E128793
LI
GETtheMANUALS.org
LIGHTING - TAILLIGHT (REAR COMBINATION LIGHT) ASSEMBLY LH
LI–37
TAILLIGHT (REAR COMBINATION LIGHT) ASSEMBLY LH

BODY AND ELECTRICAL
LIGHTING
COMPONENTS
LI
T=9.8{100}
TAIL AND STOP LIGHT BULB
REAR TURN SIGNAL LIGHT BULB T=9.8{100}
BACK-UP LIGHT BULB
TAIL LIGHT (REAR COMBINATION LIGHT)

ASSEMBLY LH
E130018J02
REMOVAL
2. REMOVE TAILLIGHT (REAR COMBINATION LIGHT) ASSEMBLY

LH
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LI–38 LIGHTING - TAILLIGHT (REAR COMBINATION LIGHT) ASSEMBLY LH
(b) Pulling in the direction indicated by the arrow, disengage the pin
and clip and remove the taillight (rear combination light)
assembly LH.
HINT:
• Leave the claw and clip in the vehicle body.
• With the door closed, pull the taillight (rear combination
light) assembly RH in the direction of the arrow.
: Claw
: Pin E130044J01
3. REMOVE TAILLIGHT AND STOP LIGHT BULBS

(a) Turning in the direction of the arrow in the illustration, remove
LI the tail and stop light bulbs and the stop light bulb socket as a
unit.
(b) Remove the taillight and stop light bulbs from the taillight and
stop light bulb socket.
E130102
4. REMOVE REAR TURN SIGNAL RIGHT BULB

(a) Turning in the direction shown in the illustration, remove the
rear turn signal light bulb and rear turn signal light socket as a
unit.
(b) Remove the rear turn signal light bulb from the rear turn signal
light socket.
E132563
5. REMOVE BACKUP LIGHT BULB (WITHOUT REAR FOG LIGHT)

backup light bulb from the backup light bulb socket as a unit.
(b) Remove the backup light bulb from the backup light bulb socket.
E132564
6. REMOVE REAR FOG LIGHT (WITH REAR FOG LIGHT)

rear fog light bulb and rear fog light bulb socket as a unit.
(b) Remove the rear fog light bulb from the rear fog light bulb
socket.
E132564
GETtheMANUALS.org
LIGHTING - TAILLIGHT (REAR COMBINATION LIGHT) ASSEMBLY LH
LI–39
INSTALLATION
1. INSTALL REAR FOG LIGHT (WITH REAR FOG LIGHT)
(a) Install the rear fog light bulb in the rear fog light bulb socket.
(b) Turning in the direction shown in the illustration, install the rear
fog light bulb and rear fog light bulb socket as a unit.
2. INSTALL BACKUP LIGHT BULB (WITHOUT REAR FOG LIGHT)

(a) Install the backup light bulb in the backup light bulb socket.
LI
E132569
(b) Turning in the direction shown in the illustration, install the

backup light bulb and backup light bulb socket as a unit.
3. INSTALL TAILLIGHT AND STOP LIGHT BULB

(a) Install the taillight and stop light bulbs in the taillight and stop
light bulb socket.
E132569

taillight and stop light bulb and taillight and stop light bulb socket
as a unit.
4. INSTALL REAR TURN SIGNAL LIGHT BULB

(a) Install the rear turn signal light bulb in the rear turn signal light
socket.
E132568
(b) Turning in the direction shown in the illustration, install the rear
turn signal light bulb and rear turn signal light bulb socket as a
unit.
E132567
GETtheMANUALS.org
LI–40 LIGHTING - TAILLIGHT (REAR COMBINATION LIGHT) ASSEMBLY LH
5. INSTALL TAILLIGHT (REAR COMBINATION LIGHT) ASSEMBLY

LH
(a) Engage the pin and clip and install the taillight (rear combination
light) assembly LH.
HINT:
Align the claw of the taillight (rear combination lamp) assembly
LH with the clip.
(b) Install the 2 bolts.
: Claw Torque: 9.8 N*m (100 kgf*cm)
: Pin E130044J04
LI
GETtheMANUALS.org
LIGHTING - LICENSE PLATE LIGHT ASSEMBLY
LI–41

BODY AND ELECTRICAL
LIGHTING
COMPONENTS
LI

E132257J01
REMOVAL
2. REMOVE LICENSE PLATE LIGHT ASSEMBLY
(a) Disengage the claw.
(b) Disconnect the connector and remove the license plate light
assembly.
E132259
GETtheMANUALS.org
LI–42 LIGHTING - LICENSE PLATE LIGHT ASSEMBLY
(c) Turning in the direction shown in the illustration, remove the

license plate light bulb and license plate light socket as a unit.
(d) Remove the license plate light bulb from the license plate light
bulb socket.
INSTALLATION
1. INSTALL LICENSE PLATE LIGHT ASSEMBLY
(a) Install the license plate light bulb in the license plate light
socket.
E108424

license plate light bulb and license plate light bulb socket as a
LI unit.
E108425
(d) Engage the claw and install the license plate light assembly.
1. INSPECT LICENSE PLATE LIGHT ASSEMBLY
(a) Inspect the LED light.
E132260
(1) Disconnect the connector.
(2) Using the tester, measure the voltage between the

License Plate Light Assembly terminals of the connector on the vehicle wire harness
(Vehicle Wire Harness Side) side and body ground.
E073251J01
Standard
Light Terminal No. Measurement Condition Standard

LICENSE PLATE LIGHTS 1 Headlight dimmer switch OFF → TAIL 1 V or less → 10 to 14 V
GETtheMANUALS.org
LIGHTING - CENTER STOP LIGHT ASSEMBLY
LI–43

BODY AND ELECTRICAL
LIGHTING
COMPONENTS
LI
CENTER STOP LIGHT COVER
E132122J01
REMOVAL
1. REMOVE CENTER STOP LIGHT COVER
(a) Disengage the claw and remove the center stop light cover.
2. REMOVE CENTER STOP LIGHT ASSEMBLY
(a) Remove the two screws. Then remove the center stop light
assembly.
INSTALLATION
1. INSTALL CENTER STOP LAMP ASSEMBLY
(a) Install the center stop light assembly with the 2 screws.
2. INSTALL CENTER STOP LIGHT ASSEMBLY

E130837 (a) Engage the claw, and install the center stop light cover.
GETtheMANUALS.org
LI–44 LIGHTING - MAP LIGHT ASSEMBLY
MAP LIGHT ASSEMBLY

BODY AND ELECTRICAL
LIGHTING
INSPECTION
1. INSPECT MAP LIGHT ASSEMBLY
(a) Using the tester, check the continuity between the connector
terminal when the map light switch is operated.
Standard
Switch Terminal No. (Terminal Continuity
Name)
Map light switches for 6 (+B) ←→ 7 (GND) No continuity
both the driver's and
passenger seats are OFF
LI E073293
Map light switch for the 6 (+B) ←→ 7 (GND) Continuity
driver's seat is ON
Map light switch for the 6 (+B) ←→ 7 (GND) Continuity
passenger seat is ON
(b) Check the illumination of the dome light.

(1) Connect the positive (+) battery terminal to the 6 (+B)
terminal of the connector, and connect the negative (-)
battery terminal to the 1 (CTY) terminal. Then check the
illumination condition of the dome light when the door
switch is turned from OFF to ON.
Standard:
Dome light off → dome light on
GETtheMANUALS.org
LIGHTING - ROOM LIGHT ASSEMBLY NO. 1
LI–45

BODY AND ELECTRICAL
LIGHTING
INSPECTION
1. CHECK ROOM LIGHT ASSEMBLY NO. 1
(1) Using a tester, inspect the continuity between the
Switch Operation Positions terminals.
Standard
Switch Terminal Name Standard

OFF - -
DOOR 1 (CTY) ←→ 2 (B) Continuity
ON 2 (B) ←→ body ground Continuity LI
E068342J02
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LI–46 LIGHTING - ROOM LIGHT ASSEMBLY NO. 2

BODY AND ELECTRICAL
LIGHTING
INSPECTION
(1) Using the tester, check the continuity between the
terminals.
Switch Operation Positions
Standard
Switch Terminal Name Standard

OFF - -
DOOR 1 (CTY) ←→ 2 (B) Continuity
LI ON 2 (B) ←→ body ground Continuity
E068342J01
GETtheMANUALS.org
LIGHTING - ROOM LIGHT ASSEMBLY NO. 3
LI–47

BODY AND ELECTRICAL
LIGHTING
INSPECTION
(a) Using the tester, check the continuity between the connector
terminals.
Standard:
Continuity
LI
GETtheMANUALS.org
LI–48 LIGHTING - GLOVE BOX LIGHT ASSEMBLY
GLOVE BOX LIGHT ASSEMBLY

BODY AND ELECTRICAL
LIGHTING
INSPECTION
1. CHECK INTERIOR ILLUMINATION LIGHT NO. 1 LH
(a) CHECK LIGHT ILLUMINATION
(1) Connect the positive (+) battery terminal to the 2 terminal
of the connector, and connect the negative (-) battery
terminal to the 1 terminal. Then check the illumination
condition of the light.
Standard:
The illumination comes on.
LI E068686
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LIGHTING - HEADLIGHT DIMMER SWITCH ASSEMBLY
LI–49

BODY AND ELECTRICAL
LIGHTING
COMPONENTS
LI
HEADLIGHT DIMMER
SWITCH ASSEMBLY
STEERING COLUMN UPPER COVER
STEERING COLUMN LOWER COVER
E132256J01
REMOVAL
2. REMOVE STEERING COLUMN LOWER COVER (See Page WW-

21)
3. REMOVE STEERING COLUMN UPPER COVER (See Page WW-

22)
GETtheMANUALS.org
LI–50 LIGHTING - HEADLIGHT DIMMER SWITCH ASSEMBLY
4. REMOVE HEADLIGHT DIMMER SWITCH ASSEMBLY

(b) Disengage the claw and remove the headlight dimmer switch
assembly.
INSTALLATION
: Claw E127717J01
1. INSTALL HEADLIGHT DIMMER SWITCH ASSEMBLY

(a) Insert the headlight dimmer switch assembly until the claw
LI engages.
2. INSTALL STEERING COLUMN UPPER COVER (See Page WW-23)
3. INSTALL STEERING COLUMN LOWER COVER (See Page WW-

23)

: Claw E127717J01
INSPECTION
1. CHECK HEADLIGHT DIMMER SWITCH ASSEMBLY
(a) Check the continuity of the light control switch.
Standard
4 3 2 1
13 12 11 10 9 8 7 6 5 Switch Standard
Name)
5 (T) ← → 6 (H) ← → 7
OFF No continuity
(EL) ← → 8 (ET)
E107922 TAIL 5 (T) ← → 8 (ET) Continuity
5 (T) ← → 8 (ET)
HEAD Continuity
6 (H) ← → 7 (EL)
(b) Check the continuity of the headlight dimmer switch.

Standard

Switch Standard
Name)
6 (H) ← → 7 (EL) ← → 9
FLASH Continuity
(HU)
LOW BEAM 7 (EL) ←→ 10 (HL) Continuity
HIGH BEAM 7 (EL) ←→ 9 (HU) Continuity
HINT:
Perform the LOW BEAM and the HIGH BEAM check with
the light control switch set to HEAD.
GETtheMANUALS.org
LIGHTING - HEADLIGHT DIMMER SWITCH ASSEMBLY
LI–51
(c) Check the continuity of the turn signal switch.

Standard

Switch Standard
Name)
Right 12 (TB) ←→ 13 (TR) Continuity
11 (TL) ←→ 12 (TB) ←→
Neutral No continuity
13 (TR)
Left 11(TL) ←→ 12 (TB) Continuity
(d) Check the continuity of the front fog light switch. (Vehicles with
front fog lights)
LI
Standard

Switch Standard
Name)
OFF 3 (BFG) ←→ 1 (FFG) No continuity
ON 3 (BFG) ←→ 1 (FFG) Continuity
GETtheMANUALS.org
LI–52 LIGHTING - HAZARD WARNING SIGNAL SWITCH ASSEMBLY
HAZARD WARNING SIGNAL SWITCH ASSEMBLY

BODY AND ELECTRICAL
LIGHTING
INSPECTION
1. CHECK HAZARD WARNING SIGNAL SWITCH ASSEMBLY
(1) Using the tester, check the continuity between the 4
(HAZ+) terminal and the 3 (HAZ-) terminal on the
connector when the hazard warning switch is operated.
Standard:
When the switch is ON, there is continuity.
When the switch is OFF, there is no continuity.
(b) CHECK ILLUMINATION BULB
LI E050230 (1) Using the tester, check the continuity between the 6 (B)
terminal and 5 (-) terminal of the connector.
Standard:
Continuity
GETtheMANUALS.org
LIGHTING - HEADLIGHT LEVELING SWITCH
LI–53

BODY AND ELECTRICAL
LIGHTING
1. CHECK HEADLIGHT LEVELING SWITCH
(a) Check the voltage.
(1) Using the tester, with the connectors connected, check
the voltage between the connector terminals from the
2(T) underside of the connector when the headlight leveling
4(E)
switch is operated.
Standard:
500-
800 Ω
E107910J01 Switch Position
Voltage
(when battery voltage is 12
LI
Name)
V)
8.7 to 13.0 V
0 2(T) ←→ 4(E)
(10.4 to 11.2 V)
8.2 to 12.3 V
(0.5) 2(T) ←→ 4(E)
(9.8 to 10.5 V)
7.6 to 11.5 V
1 2(T) ←→ 4(E)
(9.2 to 9.9 V)
7.1 to 10.8 V
(1.5) 2(T) ←→ 4(E)
(8.5 to 9.2 V)
6.6 to 10.0 V
2 2(T) ←→ 4(E)
(7.9 to 8.6 V)
6.0 to 9.3 V
(2.5) 2(T) ←→ 4(E)
(7.2 to 8.0 V)
5.5 to 8.5 V
3 2(T) ←→ 4(E)
(6.6 to 7.3 V)
5.0 to 7.8 V
(3.5) 2(T) ←→ 4(E)
(6.0 to 6.7 V)
4.4 to 7.0 V
4 2(T) ←→ 4(E)
(5.3 to 6.0 V)
3.9 to 6.3 V
(4.5) 2(T) ←→ 4(E)
(4.7 to 5.4 V)
3.4 to 5.6 V
5 2(T) ←→ 4(E)
(4.0 to 4.8 V)
(b) CHECK ILLUMINATION BULB

terminals.
Terminal No. (Terminal Name) Standard
43 2 1 3 (ILL+) ←→ 4 (E) Continuity
E107909
GETtheMANUALS.org
LI–54 LIGHTING ﾐ STOP LIGHT SWITCH ASSEMBLY

BODY AND ELECTRICAL
LIGHTING
INSPECTION
1. CHECK STOP LIGHT SWITCH ASSEMBLY
connector terminals when the shaft is operated.
Standard:
When the shaft is not depressed, there is continuity.
When the shaft is depressed, there is no continuity.
LI
GETtheMANUALS.org
LIGHTING - FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY
LI–55
FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY

BODY AND ELECTRICAL
LIGHTING
INSPECTION
1. CHECK COURTESY LIGHT SWITCH
connector terminal and the body ground.
Standard:
LI
GETtheMANUALS.org
LI–56 LIGHTING − REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY
REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY

BODY AND ELECTRICAL
LIGHTING
INSPECTION
Standard:
LI
GETtheMANUALS.org
LIGHTING - BACK DOOR COURTESY LIGHT SWITCH ASSEMBLY
LI–57

BODY AND ELECTRICAL
LIGHTING
INSPECTION
Standard:
LI
GETtheMANUALS.org
LI–58 LIGHTING - TURN SIGNAL FLASHER ASSEMBLY

BODY AND ELECTRICAL
LIGHTING
1. CHECK TURN SIGNAL FLASHER ASSEMBLY
(a) CHECK INPUT AND OUTPUT OPERATIONS
LL(+) LR(+) (1) Disconnect the turn signal flasher assembly.
(2) Using the tester, measure the voltage and continuity
between the terminals of the connector on the instrument
IG(+)
panel J/B side and the body ground.
HAZ(+) B(+)
LI
E ER(+) EL(+) E101506J04
Standard
Input / Terminal
Terminal No. Tester Connection Standard
Output Symbol
Input 4 B Always 10 to 14 V
Input 1 IG Ignition switch OFF → ON 1 V or less → 10 to 14 V
- 7 E Always Continuity
GETtheMANUALS.org
LIGHTING - HEADLIGHT RELAY
LI–59
HEADLIGHT RELAY
BODY AND ELECTRICAL
LIGHTING
INSPECTION
1. CHECK HEADLIGHT RELAY
Standard:
(2) Using the tester, check the continuity between terminals 3
and 5 when battery voltage is applied to terminals 1 and 2.
A035654 Standard: LI
Continuity
GETtheMANUALS.org
LI–60 LIGHTING - FOG LIGHT RELAY
FOG LIGHT RELAY

BODY AND ELECTRICAL
LIGHTING
INSPECTION
1. CHECK FOG LIGHT RELAY
Standard:
(2) Using the tester, check the continuity between terminals 3
and 5 when battery voltage is applied to terminals 1 and 2.
LI B016200 Standard:
Continuity
GETtheMANUALS.org
LIGHTING - REAR FOG LIGHT SWITCH
LI–61

BODY AND ELECTRICAL
LIGHTING
1. CHECK REAR FOG LIGHT SWITCH
(a) Using the tester, check the voltage and continuity between the
body ground and each terminal of the connector on the wire
harness side of the switch.
LI
E131599
Terminal No. Terminal Name Item Inspection Condition Standard

1 E Continuity Always Continuity
3 ILL Voltage Headlight dimmer switch 0 → 10 to 14 V
OFF → TAIL or HEAD
4 B Voltage Always 10 to 14 V
6 H/L Continuity Headlight dimmer switch No continuity → continuity
OFF → HEAD
8 - Continuity Always Continuity
(b) CHECK REAR FOG ILLUMINATION

(1) Turn the ignition switch ON.
(2) Check the illumination of the rear fog lights when each
switch is operated.
Inspection Condition Standard

Headlight dimmer switch OFF → HEAD Rear fog light illuminates
, rear fog light switch ON
Headlight dimmer switch OFF → TAIL Rear fog light illuminates
Front fog light switch ON
Rear fog light switch ON
GETtheMANUALS.org
TO INDEX
BODY AND ELECTRICAL
WIPER AND WASHER

WIPER AND WASHER SYSTEM
BASIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-1
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-2
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-2
WINDSHIELD WIPER MOTOR ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-7
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-11
WIPER RUBBER LH WW
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-13
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-15
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-17
REAR WIPER RUBBER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-19
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-23
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-23
WASHER NOZZLE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-25
WINDSHIELD WASHER JAR ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-27
WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY
REAR WASHER NOZZLE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WW-29
GETtheMANUALS.org
WW–1 WIPER AND WASHER - WIPER AND WASHER SYSTEM
WIPER AND WASHER SYSTEM

BODY AND
WIPER ANDELECTRICAL
WASHER
BASIC INSPECTION
1. CHECK WIPER AND WASHER SYSTEM
(1) CHECK OPERATION OF WIPER AND WASHER
(a)With the ignition switch (IG) ON, check the operation of the wipers.
Standard:
LO position:: Sets the speed to low.
HI position:: Sets the speed to high.
INT position:: Sets the speed to intermittent.
MIST position:: Wipes 1 time and then stops.
(b)Check the wiping status when the wipers are operating.
Standard:: Spray direction and height are good.
(c) Check the direction and height of the wiper fluid when it is sprayed.
Standard:: Spray direction and height are good.
WW (d)Visually check the amount of washer fluid in the washer tank.
Standard:: There is sufficient washer fluid in the washer tank.
GETtheMANUALS.org
WIPER AND WASHER - WIPER AND WASHER SYSTEM
WW–2
LOCATION
REAR WASHER NOZZLE
REAR WIPER ARM ASSEMBLY
WINDSHIELD WIPER
SWITCH ASSEMBLY
FRONT WIPER ARM RH
WW
WINDSHIELD
WIPER LINK ASSEMBLY
WASHER NOZZLE
FRONT WIPER ARM LH
WASHER NOZZLE
INSTRUMENT PANEL J/B ASSEMBLY
-IG FUSE WINDSHIELD WIPER MOTOR ASSEMBLY
-ACC FUSE
-WIP WSHR FUSE
E128156J02

FRONT WIPER AND WASHER
WIP WSHR fuse -
Both the wipers and the washer do not operate Windshield wiper switch assembly WW-23
Wire harness -
GETtheMANUALS.org
WW–3 WIPER AND WASHER - WIPER AND WASHER SYSTEM

WIP WSHR fuse -
Washer does not operate when in either the LO or HI Windshield wiper switch assembly WW-23
setting Windshield wiper motor assembly WW-11
Wire harness -
WIP WSHR fuse -
Windshield wiper switch assembly WW-23
Washer does not operate on the INT setting
Windshield wiper motor assembly WW-11
Wire harness -
WIP WSHR fuse -
Windshield wiper switch assembly (washer switch) WW-23
Washer motor does not operate Windshield washer motor and pump assembly (front spray WW-28
position)
Wire harness -
WW Washer hose -
Washer fluid does not spray
Washer nozzle -
WIP WSHR fuse -
With the wiper switch ON, the wipers do not operate
Windshield wiper switch assembly (washer switch) WW-23
when the washer is operated
Windshield wiper motor assembly WW-11
When the wiper switch is turned OFF, the wiper blades Windshield wiper motor assembly (automatic stop position) WW-11
do not return to the stopped position, or the stopped Vehicle wire harness and connector -
position is incorrect
REAR WIPER AND WASHER

WIP WSHR fuse -
Both the rear wiper and the rear washer do not operate Windshield wiper switch assembly WW-23
Wire harness -
WIP WSHR fuse -
Windshield wiper switch assembly WW-23
Rear wiper does not operate
Rear wiper motor assembly WW-17
Wire harness -
WIP WSHR fuse -
Windshield wiper switch assembly (rear washer switch) WW-23
Rear washer motor does not operate Windshield washer motor and pump assembly (rear spray WW-28
position)
Wire harness -
Washer hose -
Rear washer does not spray
Washer nozzle -
When the rear wiper is OFF, the rear wiper blade does Rear wiper motor assembly WW-17
not return to the stopped position. Wire harness -
GETtheMANUALS.org
WIPER AND WASHER - WINDSHIELD WIPER MOTOR ASSEMBLY
WW–4

BODY AND
WIPER ANDELECTRICAL
WASHER
COMPONENTS
FRONT WIPER ARM HEAD CAP
FRONT WIPER ARM AND BLADE ASSEMBLY LH
FRONT WIPER ARM HEAD CAP

FRONT WIPER ARM AND BLADE ASSEMBLY RH
WW
COWL TOP
VENTILATOR LOUVER
COWL TOP VENTILATOR LOUVER
BONNET (HOOD) TO
COWL TOP SEAL
WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
×3
WINDSHIELD WIPER LINK ASSEMBLY
E130099J01
GETtheMANUALS.org
WW–5 WIPER AND WASHER - WINDSHIELD WIPER MOTOR ASSEMBLY
REMOVAL
2. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
(a) Remove the front wiper arm nut. Then remove the front wiper
arm and blade assembly RH.
E127347
3. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH

WW (a) Remove the front wiper arm nut. Then remove the front wiper
arm and blade assembly RH.
4. REMOVE COWL TOP VENTILATOR LOUVER

(a) Disengage the 7 clips and remove the cowl top ventilator louver.
E127346
Clip
E127784J01
GETtheMANUALS.org
WW–6
(b) Detach the 2 clips and 10 claws, and remove the cowl top
ventilator louver as shown in the illustration.
WW
Clip
Claw
E127785J01
5. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

(FOR VEHICLES WITHOUT COLD WEATHER SPECIFICATIONS)
(b) Remove the clamp and connector. Then remove the windshield
wiper motor and link assembly.
E129775
6. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

(FOR VEHICLES WITH COLD WEATHER SPECIFICATIONS)
(a) Disconnect the connector and clamp.
E132263

(c) Remove the clamp and connector. Then remove the windshield
wiper motor and link assembly.
E129775
GETtheMANUALS.org
7. REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY

(a) Using a screwdriver covered with protective tape, remove the
arm of the windshield wiper link assembly from the crank arm
pivot of the windshield wiper motor assembly, as shown in the
illustration.
Protective Tape
E107892J01
(b) Remove the 3 bolts. Then remove the windshield wiper motor
assembly.
HINT:
If the windshield wiper motor assembly cannot easily be
WW removed from the windshield wiper link assembly, it can be
removed by turning the crank arm until the windshield wiper
motor assembly is in a position where it can be detached.
INSTALLATION
E107893

(a) Install the windshield wiper motor assembly to the windshield
wiper link assembly with the 3 bolts.
(b) Coat the pivoting part of the crank arm of the windshield wiper
motor assembly with Denso No. 50 grease.
E107893
(c) Connect the arm of the windshield wiper link assembly to the
pivoting part of the crank arm of the windshield wiper motor
assembly.
9. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

(FOR VEHICLES WITHOUT COLD WEATHER SPECIFICATIONS)
(b) Engage the rubber pin.
E107894
GETtheMANUALS.org
WW–8
(c) Install the windshield wiper motor and link assembly with the 3
bolts.
10. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

(FOR VEHICLES WITH FOR COLD WEATHER SPECIFICATIONS)
(a) Connect the connector to the wiper motor assembly.
E129775J01
(b) Engage the rubber pin.

(c) Install the windshield wiper motor and link assembly with the 3
bolts.
WW
E129775
(d) Connect the connector and clamp.
11. INSTALL COWL TOP VENTILATOR LOUVER

(a) Attach the 10 claws.
E132263J01
Clip
Claw
E127785J01
(b) Engage the 5 claws and the 2 clips, and install the cowl top
ventilator louver.
GETtheMANUALS.org
13. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH

(a) Stop the windshield wiper motor assembly at the automatic stop
Wiper ࡢࠗࡄࠕ࡯ࡓ
Arm Serrations position.
࠮࡟࡯࡚ࠪࡦㇱ
(b) Using a round file or equivalent, clean the wiper arm serration.
(when reassembling)
(c) Using a wire brush, clean the wiper pivot serration part.
(d) Install the front wiper arm and blade assembly RH with the front
wiper arm nut, so that it comes to the position shown in the
illustration.
Wire Brush
Wiper Pivot
Serrations
WW E053010J01
25 +- 0 25 +- 0
10 10
E129774J01

HINT:
While holding down the wiper arm hinge with your hand, tighten
the front wiper arm nut.
GETtheMANUALS.org
WW–10
14. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH

(a) Using a round file or equivalent, clean the wiper arm serration.
(when reassembling)
(b) Using a wire brush, clean the wiper pivot serration part.
Wiper ࡢࠗࡄࠕ࡯ࡓ
Arm Serrations
࠮࡟࡯࡚ࠪࡦㇱ (c) Install the front wiper arm and blade assembly LH with the front
wiper arm nut, so that it comes to the position shown in the
illustration.
Wire Brush
Wiper Pivot
Serrations WW
E053010J01
25 +- 0 25 +- 0
10 10
E129774J01

HINT:
(d) Operate the front wipers while spraying water or washer fluid on
the windshield glass. Make sure that the wipers function
properly and that there is no interference with the vehicle body.

(See page SS-10.)
GETtheMANUALS.org
1. CHECK WINDSHIELD WIPER MOTOR ASSEMBLY
(a) CHECK AUTOMATIC STOP POSITION
(1) Operate the windshield wiper motor assembly. Then stop
the wipers and check the automatic stop position of the
wiper arm.
Standard:
The wiper arm stops at the position shown in the
illustration
WW
25 +- 0 25 +- 0
10 10
E129774J01
INSPECTION
1. CHECK WINDSHIELD WIPER MOTOR ASSEMBLY
(a) Check LO Operation
(1) Connect the positive battery terminal to terminal 1 (+1) of
the connector, and the negative battery terminal to
terminal 5 (E). Then check that the windshield wiper motor
assembly operates at low speed (LO).
(b) CHECK HI OPERATION
(1) Connect the positive battery terminal to terminal 4 (+2) of
E034081 terminal 5 (E). Then check that the windshield wiper motor
assembly operates at high speed (HI).
GETtheMANUALS.org
WIPER AND WASHER - WIPER RUBBER LH
WW–12
WIPER RUBBER LH
BODY AND
WIPER ANDELECTRICAL
WASHER
COMPONENTS
FRONT WIPER BLADE LH
WW
FRONT WIPER WIPER RUBBER LH

BACKING PLATE
FRONT WIPER BACKING PLATE
E130802J01
REMOVAL
1. REMOVE FRONT WIPER BLADE LH
(a) Remove the front wiper blade LH from the front wiper arm LH,
NOTICE:
Do not lay the wiper arm down with the wiper blade
removed.
E127345
GETtheMANUALS.org
WW–13 WIPER AND WASHER - WIPER RUBBER LH
2. REMOVE WIPER RUBBER LH

(a) Remove the wiper rubber LH, together with the front wiper
backing plate, from the front wiper blade LH.
(b) Remove the front wiper backing plate from the wiper rubber LH.
INSTALLATION
E127348
3. INSTALL WIPER RUBBER LH

(a) Install the front wiper backing plate to the wiper rubber LH.
NOTICE:
• Align the recessed part of the backing blade with the
WW protruding part of the wiper rubber LH.
• Align the R direction of the backing plate with the R
direction on the windshield glass.
E123098
(b) Install the front wiper blade LH so that the head part (the side
that bulges) of wiper rubber LH faces the arm axle side.
NOTICE:
Firmly push the connectors on the wiper blade into the
recessed part of the wiper rubber to attach them
completely.
4. INSTALL FRONT WIPER BLADE LH

(a) Install front wiper blade LH to front wiper arm LH.
E112266
GETtheMANUALS.org
WIPER AND WASHER - REAR WIPER MOTOR ASSEMBLY
WW–14

BODY AND
WIPER ANDELECTRICAL
WASHER
COMPONENTS
WW
REAR WIPER
ARM ASSEMBLY
REAR WIPER MOTOR GROMMET

REAR WIPER ARM HEAD CAP
E130721J01
GETtheMANUALS.org
WW–15 WIPER AND WASHER - REAR WIPER MOTOR ASSEMBLY
REMOVAL
1. REMOVE REAR WIPER ARM HEAD CAP
2. REMOVE REAR WIPER ARM ASSEMBLY

(a) Remove the nut. Then remove the rear wiper arm.
3. REMOVE REAR WIPER MOTOR GROMMET
4. REMOVE BACK DOOR TRIM PANEL ASSEMBLY (See Page ED-

47)
5. REMOVE REAR WIPER MOTOR ASSEMBLY

(b) Loosen the 3 bolts. Then remove the rear wiper motor
assembly.
WW INSTALLATION
6. INSTALL REAR WIPER MOTOR ASSEMBLY
(a) Install the rear wiper motor assembly with the 3 bolts.
7. INSTALL BACK DOOR TRIM PANEL ASSEMBLY (See Page ED-

E129776 49)
8. INSTALL REAR WIPER MOTOR GROMMET

(a) Install the rear wiper motor grommet, with the positioning mark
Set Mark
shown in the illustration facing up.
Rear Wiper
Motor Grommet
E102190J01
GETtheMANUALS.org
WIPER AND WASHER - REAR WIPER MOTOR ASSEMBLY
WW–16
9. INSTALL REAR WIPER ARM

(a) Using a round file or equivalent, clean the serrated part of the
rear wiper arm. (when reassembling)
(b) Using a wire brush, clean the serrated part of the wiper pivot.
Wiper Arm Serrations (c) Stop the rear wiper motor assembly at the automatic stop
position and install the rear wiper arm as shown in the
illustration.
Wire Brush
Wiper Pivot
Serrations WW
E060224J01
±5
E130720J01

HINT:
(d) Operate the rear wipers while spraying washer fluid or water on
the windshield glass. Make sure that the wipers function
properly and there is no interference with the vehicle body.
10. INSTALL REAR WIPER ARM HEAD CAP
GETtheMANUALS.org
WW–17 WIPER AND WASHER - REAR WIPER MOTOR ASSEMBLY
1. CHECK REAR WIPER MOTOR ASSEMBLY
(a) CHECK AUTOMATIC STOP POSITION
WW
±5
E130720J01
(1) Operate the rear wiper motor assembly. Then stop the
wipers and check the automatic stop position of the wiper
arm.
Standard:
The position of the rear wiper blade is within 5mm
above or below the defogger line.
INSPECTION
1. CHECK REAR WIPER MOTOR ASSEMBLY
(a) CHECK OPERATION
(1) Connect the positive battery terminal to terminal 1 (+B) of
terminal 3 (LS). Then check that the rear wiper motor
assembly operates.
NOTICE:
The body ground must be connected.
(b) CHECK INTERMITTENT OPERATION
E101507 (1) Connect the positive battery terminal to terminal 1 (+B) of
terminal 2 (C1). Then check that the rear wiper motor
assembly operates intermittently.
NOTICE:
The body ground must be connected.
GETtheMANUALS.org
WIPER AND WASHER - REAR WIPER RUBBER
WW–18
REAR WIPER RUBBER

BODY AND
WIPER ANDELECTRICAL
WASHER
COMPONENTS
Rear Wiper Blade Assembly

WW
Rear Wiper Rubber Backing Plate
Rear Wiper Rubber Backing Plate
Rear Wiper Rubber
E107956J01
GETtheMANUALS.org
WW–19 WIPER AND WASHER - REAR WIPER RUBBER
REMOVAL
1. REMOVE REAR WIPER BLADE
(a) Lift up the rear wiper blade.
(b) Lift the rear wiper blade to the position shown in the illustration
until you hear the sound of the claws snapping out of their
engagement. [*1]
NOTICE:
Claw
Be careful not to damage the claws.
E036417J01
(c) After completing [*1] above, remove the rear wiper blade from
the rear wiper arm by pulling the blade straight away from the
WW wiper arm towards the left side of the vehicle.
NOTICE:
Do not lay the wiper arm down on the windshield with the
wiper blade removed.
E036418J01
2. REMOVE REAR WIPER RUBBER

Lightly Push (a) Squeeze the rear wiper rubber out of the stopper at the back
(Squeeze)
end of the rear wiper blade and pull it out as shown in the
illustration.
NOTICE:
Hold Up Do not pull out the wiper rubber forcibly. Doing so will
deform the backing plate or damage the blade claw.
HINT:
Stopper Lightly press around the center of the wiper blade claws until it
Pull Out
(Rear End Tip) is easy to lift and pull out the rubber.
E056794J01
(b) Remove the backing blade from the rear wiper rubber.
INSTALLATION
1. INSTALL REAR WIPER BLADE
Warpage (a) Install the rear wiper rubber backing plate as shown in the
illustration.
NOTICE:
Make sure that the curve of the backing plate is facing in
the proper direction.
E036208J01
GETtheMANUALS.org
WIPER AND WASHER - REAR WIPER RUBBER
WW–20
(b) Insert the rear wiper rubber at the second claw from the front
Second Claw end of the wiper blade and push the rubber through to the rear
end of the rear wiper blade.
(c) Pass the rear wiper rubber through the rear end side claw and
allow it to protrude from the rear end stopper.
(d) Pass the rear wiper rubber through the front end claw to install
it.
Rear End Claw E060705J01
2. INSTALL REAR WIPER RUBBER

(a) Engage the claw and install the rear wiper blade to the wiper
arm.
(b) Confirm that the claws are engaged securely and return the rear
wiper arm. WW
E107955
GETtheMANUALS.org
WW–21 WIPER AND WASHER - WINDSHIELD WIPER SWITCH ASSEMBLY

BODY AND
WIPER ANDELECTRICAL
WASHER
COMPONENTS
STEERING COLUMN UPPER COVER
WW
STEERING COLUMN LOWER COVER
E132255J01
REMOVAL
2. REMOVE STEERING COLUMN LOWER COVER
(a) Turn the steering wheel assembly to the right and remove the
screw as shown in the illustration.
E127343
GETtheMANUALS.org
WIPER AND WASHER - WINDSHIELD WIPER SWITCH ASSEMBLY
WW–22
(b) Turn the steering wheel assembly to the left and remove the
screw as shown in the illustration.
E127342
(c) Remove the screw.

(d) Disengage the 5 claws and remove the steering column lower
cover.
WW
Claw E127787J02
3. REMOVE STEERING COLUMN COVER UPPER

(a) Disengage the claw and remove the steering column upper
cover.
Clip
E127788J01
4. REMOVE WINDSHIELD WIPER SWITCH ASSEMBLY

(b) Disengage the claws and remove the windshield wiper switch
assembly.
NOTICE:
The claw will be damaged if it is pressed too hard.
: Claw E127344J01
GETtheMANUALS.org
WW–23 WIPER AND WASHER - WINDSHIELD WIPER SWITCH ASSEMBLY
INSTALLATION
(a) Insert the windshield wiper switch assembly until the claw
engages.
2. INSTALL STEERING COLUMN UPPER COVER

(a) Engage the clip and install the steering column cover upper.
3. INSTALL STEERING COLUMN LOWER COVER

(a) Engage the 5 claws and install the steering column lower cover
:Claw E128485J01 with the screw.
WW (See page SS-10 for details.)
INSPECTION
1. CHECK WINDSHIELD WIPER SWITCH ASSEMBLY
Standard:
Front wiper switch

Switch Terminal No. (Terminal Name) Continuity
MIST 7 (+1) ←→ 8 (WB) Continuity
E034353 OFF 6 (+S) ←→ 7 (+1) Continuity
INT 6 (+S) ←→ 7 (+1) Continuity
LO 7 (+1) ←→ 8 (WB) Continuity
HIGH 8 (WB) ←→ 9 (+2) Continuity
Front wiper switch

OFF 4 (W) ←→ 5 (EW) None
ON 4 (W) ←→ 5 (EW) Continuity
Rear wiper switch

WASH 3 (WR) ←→ 5 (EW) Continuity
OFF
(Vehicles with rear 3 (WR) ←→ 1 (C1R) ←→ 2 (+1R)
NEITHER
intermittent ←→ 5 (EW)
operation)
OFF
(Vehicles without
3 (WR) ←→ 5 (EW) NEITHER
rear intermittent
operation)
INT 1 (C1R) ←→ 5 (EW) Continuity
ON 2 (+1R) ←→ 5 (EW) Continuity
ON + WASH 3 (WR) ←→ 2 (+1R) ←→ 5 (EW) Continuity
(b) CHECK INTERMITTENT FUNCTION (FRONT WIPERS)

(1) Using the tester, connect the 7 (+1) terminal of the
connector to the positive (+) terminal of the tester and
GETtheMANUALS.org
WIPER AND WASHER - WINDSHIELD WIPER SWITCH ASSEMBLY
WW–24
connect the 5 (EW) terminal to the negative (-) terminal of

the tester.
(2) Connect the negative battery (-) terminal to the 5 (EW)
terminal and the 6 (+S) terminal, and connect the positive
battery (+) terminal to the 8 (B) terminal of the connector.
(3) Set the front wiper switch to INT.
(4) Connect the positive (+) battery terminal to the 6 (+S)
terminal of the connector for 5 seconds.
(5) Connect the negative (-) battery terminal to the 6 (+S)
Connect The Negative Battery Terminal terminal of the connector and check the voltage between
To The 6(+S) Terminal
the 5 (EW) terminal and the 7 (+1) terminal when the
10-14V intermittent wiper relay is operated.
Standard:
7(+1)←→5(EW)
As shown in the illustration
Voltage Between
(c) OPERATION CHECK (FRONT WASHER)
Terminals WW
0V (1) Turn front wiper switch OFF.
3.3±1 Sec.
(2) Connect the negative (-) battery terminal to the 5 (EW)
E101527J09 terminal and the 6 (+S) terminal, and connect the positive
(+) battery terminal to the 8 (+B) terminal of the connector.
(3) Using the tester, connect the negative (-) terminal of the
tester to the 5 (EW) terminal, and connect the positive (+)
Washer
Switch terminal of the tester to the 7 (+1) terminal of the
ON
connector. Then check the voltage between the 5 (EW)
OFF
7(+1)←→5(EW) terminal and the 7 (+1) terminal when the washer switch is
10 to 14V turned ON and OFF.
Voltage
0V Standard:
Between
Terminals Approx. Approx. As shown in the illustration
0.3 Sec. 2.2 Sec.
E036383J05
GETtheMANUALS.org
WW–25 WIPER AND WASHER - WASHER NOZZLE
WASHER NOZZLE
BODY AND
WIPER ANDELECTRICAL
WASHER
INSPECTION
1. CHECK WASHER NOZZLE
(a) With the engine running, check the position of the spray of the
washer fluid.
HINT:
Check the left handle using the same standard.
Standard:
Within the area shown in the illustration.
336 336
WW
120
80
285 100 285
E129772J01
GETtheMANUALS.org
WIPER AND WASHER - WINDSHIELD WASHER JAR ASSEMBLY
WW–26

BODY AND
WIPER ANDELECTRICAL
WASHER
COMPONENTS
WW
E130015J01
REMOVAL
1. REMOVE WINDSHIELD WASHER JAR ASSEMBLY
(1) Remove the 2 bolts and the connector. Then remove the
windshield washer jar assembly.
E127789
GETtheMANUALS.org
WW–27 WIPER AND WASHER - WINDSHIELD WASHER JAR ASSEMBLY
INSTALLATION
1. INSTALL WINDSHIELD WASHER JAR ASSEMBLY
(1) Temporarily install the windshield washer jar assembly to the
vehicle body and connect the connector.
(2) Install the 2 bolts.
WW
E129448
GETtheMANUALS.org
WIPER AND WASHER - WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY
WW–28

BODY AND
WIPER ANDELECTRICAL
WASHER
1. CHECK WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY
(FRONT SPRAY POSITION)
(a) CHECK OPERATION
(1) With the windshield washer motor and pump assembly
installed in the windshield washer jar assembly, add
washer fluid to the windshield washer jar assembly.
(2) Check the pressure feed of the washer liquid on the front
side when the battery minus (-) is connected to terminal 2
and the battery positive (+) is connected to terminal 1 of
the windshield washer motor & pump assembly.
2. CHECK WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY WW

(REAR SPRAY POSITION)
(a) CHECK OPERATION
(1) With the windshield washer motor and pump assembly
installed in the windshield washer jar assembly, add
E053078
washer fluid to the windshield washer jar assembly.
(2) Check the pressure feed of the washer liquid on the front
side when the battery minus (-) is connected to terminal 2
and the battery positive (+) is connected to terminal 1 of
the windshield washer motor & pump assembly.
E066244
GETtheMANUALS.org
WW–29 WIPER AND WASHER - REAR WASHER NOZZLE
REAR WASHER NOZZLE

BODY AND
WIPER ANDELECTRICAL
WASHER
INSPECTION
1. CHECK REAR WASHER NOZZLE
(1) With the engine running, check the position of the spray of the washer fluid.
Standard: Within the area shown in the illustration.
20
14
6.5
WW 5.6
100
75
E129773J01
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TO INDEX
BODY AND ELECTRICAL
DOOR LOCK
ELECTRIC DOOR LOCK SYSTEM
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-1
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-2
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-3
HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . DL-3
CUSTOMER PROBLEM ANALYSIS CHECK SHEET. . . . . . . . . . . . . . . . . DL-5
ECU TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-6
UNABLE TO LOCK OR UNLOCK ANY OF DOORS USING MASTER
SWITCH OR DRIVER SIDE DOOR KEY OPERATION . . . . . . . . . . . . . DL-9
ALL DOORS LOCK AND UNLOCK EXCEPT THE DRIVER SIDE DOOR . DL-12
ALL DOORS LOCK AND UNLOCK EXCEPT PASSENGER SIDE DOOR . DL-15
ALL DOORS LOCK AND UNLOCK EXCEPT THE RIGHT REAR DOOR. . DL-18
ALL DOORS LOCK AND UNLOCK EXCEPT THE LEFT REAR DOOR . . . DL-21
KEY LOCK-IN PREVENTION FUNCTION DOES NOT OPERATE NOR-
MALLY (UNLOCK WARNING SWITCH CIRCUIT). . . . . . . . . . . . . . . . . DL-24
DL
MALLY (COURTESY LIGHT SWITCH CIRCUIT). . . . . . . . . . . . . . . . . . DL-28
ALL DOORS LOCK AND UNLOCK EXCEPT BACK DOOR . . . . . . . . . . . . DL-32
WIRELESS DOOR LOCK CONTROL SYSTEM
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-37
ECU TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-41
NO ANSWER-BACK (HAZARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-46
ONLY WIRELESS FUNCTION (REMOTE OPERATION) IS INOPERATIVE
(PREPARE NEW OR NORMAL TRANSMITTER) . . . . . . . . . . . . . . . . . DL-48
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-54
ECU TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-57
KEY REMINDER WARNING DOES NOT WORK . . . . . . . . . . . . . . . . . . . . DL-58
DOOR CONTROL RELAY ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-62
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-63
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-63
FRONT DOOR WITH MOTOR LOCK ASSEMBLY RH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-64
FRONT DOOR WITH MOTOR LOCK ASSEMBLY LH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-65
REAR DOOR WITH MOTOR LOCK ASSEMBLY RH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-66
REAR DOOR MOTOR LOCK ASSEMBLY LH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-67
GETtheMANUALS.org
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-68
FRONT DOOR OUTSIDE HANDLE ASSEMBLY RH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-69
DOOR CONTROL TRANSMITTER MODULE SET
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-70
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-70
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-70
REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-70
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-72
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-72
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-73
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL-74
DL
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DOOR LOCK - ELECTRIC DOOR LOCK SYSTEM
DL–1
ELECTRIC DOOR LOCK SYSTEM

BODY AND
DOOR LOCKELECTRICAL
OPERATION CHECK
1. CHECK ELECTRIC DOOR LOCK
(a) Check that all of the doors lock when the door lock knob (for
manual operation) of the driver's door is turned to LOCK. Also,
check that all of the doors unlock when the door lock knob is
turned to UNLOCK.
(b) Check that the key-linked operation works from outside of the
vehicle. Do this by making sure that all of the doors lock when
the driver's side door lock is turned to LOCK, and that all of the
doors unlock when turned to UNLOCK.
(c) Check the key lock-in prevention function.
NOTICE:
In order to prevent key lock-in, perform the check with the
door window open.
(1) Have the ignition key inserted in the ignition switch lock
DL
cylinder.
(2) With any door open, perform the following lock opera-
tions. Then check immediately that the unlocking function
works as well.
• Turn the door lock knob on the driver's side door in the
LOCK direction. (immediately)
• Using the driver's side door key operation, turn the
door lock knob in the LOCK direction. (immediately)
• Lock the vehicle by holding down the door lock knob
on the driver side door to the locked side for at least
two seconds. Then shut the driver's side door. (Unlock
after 1 sec)
(d) Check illumination function
HINT:
• The room light comes on and goes off using the illumination
function.
• The room light functions when the switch is in the DOOR
position.
(1) Check that each of the lights goes on when the doors are
unlocked by using the key operation in the driver's side
door. Also check that each light goes out in about 15 sec-
onds if none of the doors are open after the door unlock
operation is completed.
GETtheMANUALS.org
DL–2 DOOR LOCK - ELECTRIC DOOR LOCK SYSTEM
LOCATION
REAR DOOR COURTESY

LIGHT SWITCH ASSEMBLY RH
FRONT DOOR MOTOR
WITH LOCK ASSEMBLY RH REAR DOOR MOTOR WITH
(DOOR CONTROL SWITCH) LOCK ASSEMBLY RH
BACK DOOR LOCK

ASSEMBLY
BACK DOOR
COURTESY
LIGHT SWITCH
INSTRUMENT PANEL JUNCTION
ASSEMBLY
DL BLOCK ASSEMBLY
FUSE BLOCK
ASSEMBLY
DOOR CONTROL
RELAY ASSEMBLY
REAR DOOR MOTOR

WITH LOCK ASSEMBLY
LH
FRONT DOOR COURTESY

FRONT DOOR MOTOR WITH

REAR DOOR COURTESY LIGHT
LOCK ASSEMBLY LH
SWITCH ASSEMBLY LH
FRONT DOOR COURTESY

LIGHT SWITCH ASSEMBLY LH
B141844J01
GETtheMANUALS.org
DL–3

ECU-IG 10 A, ECU-B 7.5 A, D/L 25 A fuse
Unable to lock or unlock any of the doors using the Front door lock assembly RH
driver's side door lock knob or the driver's side door Wire harness DL-9
key operation Fuse block assembly
Door control relay assembly
Front door lock assembly RH
All of the doors can be locked and unlocked except the Wire harness
DL-12
driver side door Fuse block assembly
Front door lock assembly LH
All of the doors lock and unlock except the passenger Wire harness
DL-15
side door Fuse block assembly
Door control relay assembly DL
Rear door lock assembly RH
Wire harness
All doors lock and unlock except the right rear door DL-18
Fuse block assembly
Rear door lock assembly LH
Wire harness
All doors lock and lock except the left rear door DL-21
Fuse block assembly
Unlock unlock warning switch
The key lock-in prevention function does not operate Fuse block assembly
DL-24
properly (unlock warning switch circuit) Wire harness
Courtesy light switch assembly
The key lock-in prevention function does not operate Fuse block assembly
DL-28
properly (unlock warning switch circuit) Wire harness
Back door lock assembly
All doors lock and unlock except back door Wire harness DL-32

SHOOTING
HINT:
(See page DL-5.)
GETtheMANUALS.org
HINT:
See page DL-3.
Result Proceed to
DL 4 TROUBLESHOOT BASED ON THE SYMPTOM
(a) CHECK FUNCTION (See page DL-1.)

(b) ECU terminals (See page DL-6.)
(c) INSPECTION
END
GETtheMANUALS.org
DL–5

CHECK

Door Lock Control System Problem Diagnosis Check Sheet / /
Customer’s Name License Plate No. First Registration Year
20___/ /
Model VIN
Written By Inspector’s Name Engine Type

Odometer Reading
DL
Date Problem First Occured Date Time
Frequency Problem Occurs Constant Occasional (____times per day, ____times per month)
Conditions
(Method of use and results)
Weather Clear Cloudy Rainy Snowy Others( ) Temperature Approx. ( )°C
Road City Suburb Highway Others( ) Paved Unpaved

Lock function does not operate Unlock function does not operate
Driver seat Driver seat
Front passenger seat Front passenger seat
Right rear seat Right rear seat
Left rear seat Left rear seat
Lock and unlock functions do not operate
Driver seat
Problem Front passenger seat
Symptoms Right rear seat
Left rear seat
Door control does not operate by the master switch
Door control does not operate by key link
Others( )
B147938
GETtheMANUALS.org
ECU TERMINALS
1. FUSE BLOCK ASSEMBLY (DOOR CONTROL RELAY ASSEMBLY)
GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
CRL
HZD
MPX
IG1
UKS
H ECUB
LKS
IND
HORN
DL ULM
LKM
BDR1
C
D E
25
A F
10 9
24 23 22 21 20 19
12 11 10 9 8 7
4
6
2
2
18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
3
5
8
1
7
B
3
1
6
2
5
1
10 9
4
18 17 16 15 14 13
6
G
3
5
8
4
22 21 20 19 18 17 16 30 29 28 27 26 25 24 23
3
7 6 5 4 3 2 1 15 14 13 12 11 10 9 8
2
6
2
1
5
1
4 3 2 1 2 1
2 1 10 9 8 7 6 5 6 5 4 3
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
12 11 10 9 8 7 6 5 4 3 2 1 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
25
24 23 22 21 20 19 18 17 16 15 14 13 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Connector H
B137035
GETtheMANUALS.org
DL–7
(a) INSPECT FUSES

(1) Check that the following fuses are normal: DOME 7.5 A,
POWER 30 A, AM1 50 A, AM2 30, BACK UP 15 A, HORN
10 A.
(b) Check the fuse block assembly (door control relay assembly).
(1) Disconnect connectors A, C and G.
(2) Using a tester, check the voltage and continuity between
the body ground and each terminal of the connector.
Standard:

A2 (BDR1) ←→ G29 (GND) Voltage Always 10 to 14 V
C10 (ECUB) ←→ G29 (GND) Voltage Always 10 to 14 V
G23 (LKS) ←→ Body
Continuity The door control switch is in the LOCK position Continuity
ground
G10 (UKS) ←→ Body
ground
Continuity The door control switch is in the UNLOCK position Continuity DL
G29 (GND) ←→ Body
ground
(3) Connect the connector.

(4) Using a tester, check the voltage between the connector
terminals.
Standard:

D14 (IG1) ←→ G29 (GND) Voltage Ignition switch OFF → ON About 0 V → 10 to 14 V
G17 (CRL) ←→ G29 (GND) Voltage All doors open → closed About 0 V → 10 to 14 V
F5 (HZD) ←→ G29 (GND) Voltage Hazard lights OFF → Blinking 10 to 14 V → About 0 V
G16 (LKM) ←→ G30 (ULM)
Door control switch (manual function, key-linked opera- About 0 → 10 to 14 V →
G1 (LKM) ←→ G11 (ULM) Voltage
tion) OFF → LOCK About 0 V
B4 (LKM) ←→ B2 (ULM)
G30 (ULM) ←→ G16 (LKM)
Door control switch (manual function, key-linked opera- About 0 → 10 to 14 V →
G11 (ULM) ←→ G1 (LKM) Voltage
tion) OFF → LOCK About 0 V
B2 (ULM) ←→ B4 (LKM)
2. Combination meter assembly
B068593
(a) CHECK INPUT / OUTPUT SIGNALS

(1) Using a tester, connect the connector and check the conti-
nuity and the voltage of each terminal by aiming the tester
needle from behind the vehicle's wire harness connector .
Standard:
GETtheMANUALS.org

The ignition key is the key cylinder → the ignition key is
2 (KEY) ←→ Body ground Voltage 1 V or less → 10 to 14 V
not in the cylinder
9 (KEY) ←→ Body ground Voltage Door indicator OFF → ON 1 V or less → 10 to 14 V
DL
GETtheMANUALS.org
DL–9
UNABLE TO LOCK OR UNLOCK ANY OF DOORS USING MASTER

SWITCH OR DRIVER SIDE DOOR KEY OPERATION
DESCRIPTION
The door control relay assembly receives the switch signal from the driver's side door lock knob and the driver's side door key.
The door control relay assembly then actuates the door lock motor of each door.
CIRCUIT DIAGRAM
Front Door Motor With

Fuse Block Assembly Lock Assembly RH
H15 UKM UKM G11 U/L+ 1

DL
Door
Control
H16 LKM LKM G1 LOK+ 4
Relay
Assembly H11 LKS LKS G23 LOK+ 6 8
H8 UKS UKS G10 U/L+ 7
B137726
1 CHECK FRONT DOOR LOCK ASSEMBLY LH
(a) CHECK CONTINUITY (DOOR LOCK CONTROL SWITCH, KEY-

LINK OPERATION)
(1) Using a tester, check the continuity between the terminals when
LOCK the switch lever in the positions shown below.
Standard:
Neutral
UNLOCK Terminal 6 ←→ Terminal
LOCK Continuity
8
Neutral - -
Terminal 7 ←→ Terminal
UNLOCK Continuity
8
NG REPLACE FRONT DOOR LOCK ASSEMBLY

LH
B056104J02
GETtheMANUALS.org
OK
2 CHECK WIRE HARNESS (BETWEEN FRONT DOOR LOCK ASSEMBLY AND FUSE BLOCK ASSEM-
BLY)
(a) Detach the front door lock assembly RH and connector G of the fuse
block assembly.
(b) Using a tester, check the continuity between each terminal of the
Front Door Lock Assembly RH vehicle side connector. (For terminal layout, see page DL-6.)
Standard:
Terminal No.
(Door lock ←→ Fuse block assem- Standard
bly)
1 (U/L+) ←→ G11 (UKM) Continuity
DL 4 (LOK+) ←→ G1 (LKM)
6 (LOK+) ←→ G23 (LKS)
Continuity
Continuity
Fuse Block Assembly 7 (U/L+) ←→ G10 (UKS) Continuity

Connector G
Standard:
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
Terminal No.
Standard
(Door lock ←→ Body ground)
8 (E) ←→ Body Ground Continuity
B141845 NG REPAIR OR REPLACE WIRE HARNESS OR

CONNECTOR
OK
GETtheMANUALS.org
DL–11
3 INSPECT FUSE BLOCK ASSEMBLY
(a) Remove the door control relay assembly from the fuse block assem-
bly.
(b) Using a tester, check the continuity between each terminal of the fuse
block assembly. (For terminal layout, see page DL-6.)
Standard:
Fuse Block Assembly
Connector G
Terminal No.
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 (Fuse block connector G ←→ Fuse Standard
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
block connector H)
G11 (UKM) ←→ H15 (UKM) Continuity
G1 (LKM) ←→ H16 (LKM) Continuity
G23 (LKS) ←→ H11 (LKS) Continuity
G10 (UKS) ←→ H8 (UKS) Continuity
Fuse Block Assembly DL
Connector H
NG REPLACE FUSE BLOCK ASSEMBLY
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B141849
OK
REPLACE DOOR CONTROL RELAY ASSEMBLY
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ALL DOORS LOCK AND UNLOCK EXCEPT THE DRIVER SIDE DOOR
DESCRIPTION
The door control relay assembly then actuates the door lock motor of the driver's door.
CIRCUIT DIAGRAM

H15 UKM UKM G11 U/L+ 1
Door
DL Control
H16 LKM LKM G1 LOK+ 4
Relay
Assembly H11 LKS LKS G23 LOK+ 6 8
H8 UKS UKS G10 U/L+ 7
B137726
1 CHECK FRONT DOOR LOCK ASSEMBLY RH
(a) Check the continuity between the door lock function and the position
switch
(1) Check the continuity between the position switch and the door
lock function when battery voltage is applied between the motor
terminals inside the door lock.
Standard:
Standard
Connection Operates
Position Switch
Positive (+) battery
terminal ←→ Termi- Terminal 6
Terminal 7 ←→ Ter-
nal 4 ←→ Terminal
LOCK minal 8
Negative (-) battery 8
No continuity
terminal ←→ Termi- Continuity
nal 1
Positive (+) battery
terminal ←→ Termi- Terminal 6
Terminal 7 ←→ Ter-
nal 1 ←→ Terminal
UNLOCK minal 8
Negative (-) battery 8
Continuity
terminal ←→ Termi- No continuity
nal 4
B081029J01
RH
GETtheMANUALS.org
DL–13
OK
2 CHECK WIRE HARNESS (BETWEEN FRONT DOOR LOCK ASSEMBLY AND FUSE BLOCK ASSEM-
BLY)
HINT:
block assembly.
Front Door Lock Assembly RH vehicle side connector. (For terminal layout, see page DL-6.)
Standard:
Terminal No.
Standard
(Door lock ←→ Fuse block)
1 (U/L+) ←→ G11 (ULM)
4 (LOK+) ←→ G1 (LKM)
Continuity
Continuity
DL
Fuse Block Assembly CONNECTOR
Connector G
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
B141845
OK
bly.
GETtheMANUALS.org
Standard:
Fuse Block Assembly Terminal No.

Connector G (Fuse block connector G ←→ Junc- Standard
tion block connector H)
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 G11 (UKM) ←→ H15 (UKM) Continuity
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
G1 (LKM+) ←→ H16 (LKM) Continuity
G23 (LKS) ←→ H11 (LKS) Continuity
G10 (UKS+) ←→ H8 (UKS) Continuity

Fuse Block Assembly
Connector H
DL 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B141849
OK
GETtheMANUALS.org
DL–15
ALL DOORS LOCK AND UNLOCK EXCEPT PASSENGER SIDE DOOR

DESCRIPTION
The door control relay assembly then actuates the door lock motor of the passenger side door.
CIRCUIT DIAGRAM

Fuse Block Assembly
Lock Assembly LH
Door H15 ULM ULM2 G30 U/L+ 1

Control DL
Relay
Assembly
H16 LKM LKM2 G16 LOK+ 4
B137758J01
1 CHECK FRONT DOOR LOCK ASSEMBLY LH
(a) CHECK DOOR LOCK FUNCTION

(1) Check the operation of the door lock when battery voltage is
applied between the terminals of the motor inside the door lock.
Standard:
Connection Operates
Positive (+) battery terminal ←→ Terminal 4
LOCK
Negative (-) battery terminal ←→ Terminal 1
UNLOCK
UNLOCK
LOCK LH
4 3 2 1
10 9 8 7 6 5
B137237
OK
GETtheMANUALS.org
2 CHECK WIRE HARNESS (BETWEEN FRONT DOOR LOCK ASSEMBLY LH AND FUSE BLOCK
ASSEMBLY)
HINT:
For inspection procedures and precautions, (see page IN-38.)
block assembly.
Front Door Lock Assembly LH vehicle side connector. (For terminal layout, see page DL-6.)
Standard:
Terminal No.
Standard
(Door lock ←→ Junction block)
1 (U/L+) ←→ G30 (ULM2) Continuity
4 (LOK+) ←→ G16 (LKM2) Continuity
DL
Fuse Block Assembly CONNECTOR
Connector G
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
B141845J01
OK
bly.
GETtheMANUALS.org
DL–17
Standard:

Connector G (Fuse block assembly connector G
Standard
←→ Fuse block assembly connector
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 H)
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
G30 (ULM2) ←→ H15 (ULM) Continuity
G16 (LKM2) ←→ H16 (LKM) Continuity
Fuse Block Assembly

Connector H
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
DL
B141849
OK
GETtheMANUALS.org
ALL DOORS LOCK AND UNLOCK EXCEPT THE RIGHT REAR DOOR
DESCRIPTION
The door control relay assembly receives the switch signal from the driver's side door unlock knob and driver side door key. The
door control relay assembly then actuates the door lock motor of the right rear door.
CIRCUIT DIAGRAM
Rear Door Motor With

Door H15 ULM ULM3 B2 U/L+ 1

DL Control
Relay
Assembly
H16 LKM LKM3 B4 LOK+ 4
B137848
1 CHECK REAR DOOR LOCK ASSEMBLY RH
(a) Check the operation of the door lock when battery voltage is applied
between the terminals of the motor inside the door lock.
Standard:
Connection Operates
LOCK
UNLOCK
NG REPLACE REAR DOOR LOCK ASSEMBLY

RH
UNLOCK LOCK
B054346J01
GETtheMANUALS.org
DL–19
OK
2 CHECK WIRE HARNESS (BETWEEN REAR DOOR LOCK ASSEMBLY RH AND FUSE BLOCK
ASSEMBLY)
HINT:
(a) Detach the front door lock assembly RH and connector B of the fuse
block assembly.
Rear Door Motor With Lock (b) Using a tester, check the continuity between each terminal of the
Assembly RH vehicle side connector.
Standard:
Terminal No.
Standard
(Door lock ←→ Junction block)
1 (U/L+) ←→ B2 (ULM3)
4 (LOK+) ←→ B4 (LKM3)
Continuity
Continuity
DL
Fuse Block Assembly
Connector B
CONNECTOR
4 3 2 1
10 9 8 7 6 5
B141851
OK
HINT:
bly.
GETtheMANUALS.org
Standard:
Fuse Block Assembly

Terminal No.
Connector B
(Fuse block assembly connector B
Standard
4 3 2 1 H)
10 9 8 7 6 5
B2 (ULM3) ←→ H15 (ULM) Continuity
B4 (LKM3) ←→ H16 (LKM) Continuity

Fuse Block Assembly
Connector H
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
DL
B141850
OK
GETtheMANUALS.org
DL–21
ALL DOORS LOCK AND UNLOCK EXCEPT THE LEFT REAR DOOR
DESCRIPTION
The door control relay assembly then actuates the motor of the left rear door.
CIRCUIT DIAGRAM
Rear Motor With Lock

Fuse Block Assembly Assembly LH
Door H15 ULM ULM3 B2 U/L+ 1 DL

Control
Relay
Assembly H16 LKM LKM3 B4 LOK+ 4
B143786
1 CHECK REAR DOOR LOCK ASSEMBLY LH
between the terminals of the motor inside the door lock.
Standard:
Connection Operates
LOCK
UNLOCK
NG REPLACE REAR DOOR LOCK ASSEMBLY

LH
LOCK UNLOCK
4 3 2 1
10 9 8 7 6 5
B137238
OK
GETtheMANUALS.org
2 CHECK WIRE HARNESS (BETWEEN REAR DOOR LOCK ASSEMBLY LH AND FUSE BLOCK
ASSEMBLY)
HINT:
For inspection procedures and precautions, see page DL-6.
(a) Detach the front door lock assembly RH and connector B of the fuse
block assembly.
Rear Door Motor With vehicle side connector.
Lock Assembly LH
Standard:
Terminal No.
(Door lock ←→ Fuse block assem- Standard
bly)
1 (U/L+) ←→ B2 (ULM3) Continuity
DL 4 (LOK+) ←→ B4 (LKM3) Continuity
Fuse Block Assembly NG REPAIR OR REPLACE WIRE HARNESS OR

Connector B CONNECTOR
4 3 2 1
10 9 8 7 6 5
B141851J01
OK
HINT:
bly.
GETtheMANUALS.org
DL–23
block assembly.
Standard:
Fuse Block Assembly

Terminal No.
Connector B
(Fuse block assembly connector B
Standard
4 3 2 1 H)
10 9 8 7 6 5
B4 (LKM3) ←→ H16 (LKM) Continuity

Fuse Block Assembly
Connector H
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
DL
B141850
OK
GETtheMANUALS.org

MALLY (UNLOCK WARNING SWITCH CIRCUIT)
DESCRIPTION
Through the unlock warning switch assembly, the combination meter assembly (meter ECU) detects the presence or absence of
a key in the ignition system switch lock cylinder. When a door is locked while any of the doors is still open and the key is in the
ignition switch lock cylinder, the door control relay assembly transmits an UNLOCK signal (after first sending a LOCK signal) to
the lock motors in all of the doors. This prevents the doors from being locked.
CIRCUIT DIAGRAM
DL Combination
Unlock Warning
Meter Assembly Fuse Block Assembly
Switch Assembly
HORN D13+ D14- 2 37 F16 ITC- H6 MPX
KEY LIN
MAIN Door Control

Relay
Assembly
Battery
B137900
1 INSPECT FUSES
(a) Check the HORN 7.5 A fuse.
NG REPLACE FUSES
OK
2 CHECK WIRE HARNESS (POWER SOURCE SYSTEM)

(1) Disconnect the connector of the unlock warning switch assem-
bly.
(2) Using a tester, check the voltage of the 2 (D13+) terminal of the
vehicle side connector of the unlock warning switch.
Standard:
GETtheMANUALS.org
DL–25
Measure-
Terminal No. Item ment Condi- Standard
tion
2 (D13+) ←→ Body ground Voltage Always 10 to 14 V
NG REPAIR OR REPLACE WIRE HARNESS

(POWER SOURCE SYSTEM)
OK
3 CHECK UNLOCK WARNING SWITCH ASSEMBLY

(1) Using a tester, check the continuity between terminal 1 (D14-)
Unlock Warning Switch Assembly
and terminal 2 (D13+) of the connector.
Standard:
DL
With the pin not depressed No continuity
With the pin depressed Continuity
Pin
E105271J03
NG REPLACE UNLOCK WARNING SWITCH
ASSEMBLY
OK
4 CHECK WIRE HARNESS (BETWEEN THE UNLOCK WARNING SWITCH AND THE COMBINATION
METER ASSEMBLY)

(1) Disconnect the connector of the combination meter assembly.
(2) Insert the key into the ignition lock cylinder.
(3) Using a tester, check the voltage between each terminal of the
vehicle side connector of the combination meter assembly.
Standard:

20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 2 (KEY) ←→ 15(GND) 10 to 14 V

B141852
CONNECTOR (BETWEEN THE UNLOCK
WARNING SWITCH AND THE COMBINATION
ASSEMBLY)
OK
GO TO METER AND GAUGE SYSTEM
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5 CHECK WIRE HARNESS (BETWEEN THE COMBINATION METER ASSEMBLY AND THE FUSE
BLOCK ASSEMBLY)
(a) Using a tester, check the continuity between each terminal of the
vehicle side connector.
(b) Disconnect the connector to the combination meter assembly and
connector F of the fuse block assembly.
Standard:
Fuse Block Assembly Terminal No. Standard

Connector F Combination meter ←→ Fuse block
37 (LIN) ←→ F16 (ITC-) Continuity
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 NG REPAIR OR REPLACE WIRE HARNESS OR
CONNECTOR (BETWEEN THE COMBINA-
DL TION METER ASSEMBLY AND THE FUSE
BLOCK ASSEMBLY)
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
B141854
OK
bly.
GETtheMANUALS.org
DL–27
block assembly.
Standard:

Connector F Fuse block assembly connector F ←→ Fuse block
assembly connector H
F16 (ITC-) ←→ H6 (MPX) Continuity
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
Fuse Block Assembly

Connector H
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
DL
B141853
OK
GETtheMANUALS.org

MALLY (COURTESY LIGHT SWITCH CIRCUIT)
DESCRIPTION
With any door open and the electric card key still in the vehicle, when the door is closed using the keyless lock, an unlock is
immediately output and the door will not lock.
NOTICE:
This occurs as the electric door lock system attempts to perform body multiplex communication. Perform a trouble
shooting according to HOW TO PROCEED WITH TROUBLE SHOOTING after checking the communication functions and
confirming there is no malfunction.
CIRCUIT DIAGRAM
DL
Combination Meter
Courtesy Light Switch Assembly Fuse Block Assembly
At Each Door
1 9 F16 ITC- H6
Courtesy LIN 37 MPX
Door Control
Relay
Assembly
B137902
1 CHECK COURTESY LIGHT SWITCH

(1) Using a tester, check the continuity between the bracket and
terminal 1 of each courtesy light switch connector.
Standard:
Operation Standard
With the switch depressed No continuity
With the switch not depressed Continuity
B032309J01
NG REPLACE COURTESY LIGHT SWITCH
ASSEMBLY
GETtheMANUALS.org
DL–29
OK
2 CHECK WIRE HARNESS (BETWEEN EACH COURTESY LIGHT SWITCH AND THE COMBINATION
METER ASSEMBLY)

(1) Disconnect the connector from each courtesy light switch
assembly, and disconnect the connector from the combination
meter assembly.
(2) Using a tester, check the continuity between the terminal of
each connector of the vehicle side wire harness.
Standard:
Front Door Courtesy Light Switch Assembly

Each courtesy ←→ Combination meter
1 (+) ←→ 9 (courtesy) Continuity
DL
CONNECTOR (BETWEEN EACH COURTESY
LIGHT SWITCH AND THE COMBINATION
METER ASSEMBLY)
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
B141855
OK
3 CHECK WIRE HARNESS (BETWEEN THE COMBINATION METER ASSEMBLY AND THE FUSE
BLOCK ASSEMBLY)

(1) Disconnect the connector to the combination meter assembly
and connector F of the fuse block assembly.
GETtheMANUALS.org
(2) Using a tester, check the continuity between the terminal of

each connector of the vehicle side wire harness.
Standard:

Connector F Combination meter←→ Fuse block assembly
37 (LIN) ←→ F16 (ITC-) Continuity
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 NG REPAIR OR REPLACE WIRE HARNESS OR
CONNECTOR (BETWEEN THE COMBINA-
TION METER ASSEMBLY AND THE INSTRU-
MENT PANEL JUNCTION BLOCK
ASSEMBLY)
DL 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
B141854
OK

(1) Remove the main door control relay assembly from the fuse
block assembly.
(2) Using a tester, check the continuity between each terminal of
the fuse block assembly.
Standard:

Connector F Fuse block assembly connector F ←→ Fuse block
assembly connector H
16 (ITC-) ←→ H6 (MPX) Continuity
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
Fuse Block Assembly

Connector H
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B141853
GETtheMANUALS.org
DL–31
OK
DL
GETtheMANUALS.org
ALL DOORS LOCK AND UNLOCK EXCEPT BACK DOOR

DESCRIPTION
The door control relay assembly then actuates the motor of the back door.
CIRCUIT DIAGRAM
Fuse Block Assembly Back Door Lock Actuator Assembly
Door H15 ULM ULM3 B2 U/L+ 2

DL Control
Relay
Assembly
H16 LKM LKM3 B4 LOK+ 1
B137856
1 CHECK BACK DOOR LOCK ASSEMBLY
between the terminals of the actuator inside the door lock.
Standard:
Connection Operates
LOCK Positive (+) battery terminal ←→ Terminal 2
UNLOCK
UNLOCK
LOCK
B137673
NG CHECK BACK DOOR LOCK ASSEMBLY
OK
2 CHECK WIRE HARNESS AND CONNECTOR (BETWEEN THE BACK DOOR ACTUATOR ASSEMBLY
AND THE FUSE BLOCK ASSEMBLY)
(a) Disconnect the connector of the back door lock actuator assembly
and the connector B of the fuse block assembly.
GETtheMANUALS.org
DL–33
Standard:
Back Door Lock Actuator Assembly

Terminal No.
Standard
(Door lock ←→ Fuse block connector B)
2 (U/L+) ←→ B2 (ULM3) Continuity
1 (LOK+) ←→ B4 (LKM3) Continuity

CONNECTOR
Fuse Block Assembly

Connector B
4 3
10 9 8 7
2 1
6 5 DL
B141856
OK
bly.
block assembly connector.
Standard:

Connector B (Fuse block connector B ←→ Fuse block con- Standard
nector H
4 3 2 1 B4 (LKM3) ←→ H16 (LKM) Continuity
10 9 8 7 6 5
Fuse Block Assembly

Connector H
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B141857
GETtheMANUALS.org
OK
DL
GETtheMANUALS.org
DOOR LOCK - WIRELESS DOOR LOCK CONTROL SYSTEM
DL–35
WIRELESS DOOR LOCK CONTROL SYSTEM

BODY AND
DOOR LOCKELECTRICAL
OPERATION CHECK
1. NOTICES WHEN CHECKING
(a) The wireless door lock remote control functions only when the
following 3 conditions are satisfied.
(1) All the doors are closed.
(2) The key plate is not inserted in the ignition switch lock cyl-
inder.
(3) The electric door lock operates normally.
(b) The operating range of the wireless door lock remote control
function may vary depending on the following conditions.
(1) The operating range may change depending on how the
remote control is held and depending on who is operating
the remote control.
(2) The operational range may decrease due to the shape of
the vehicle body and the influence of the surrounding
DL
environment. There may be places where only partial
functionality is experienced.
(3) The remote control uses weak radio waves. Therefore,
operating range may decrease, or the device may not
function at all in places where there is interference from a
strong signal or there are a number of frequencies in use,
(4) If the battery is low, the operating range may decrease, or
the device may not function at all.
HINT:
Placing the door control transmitter in direct sunlight, such
as on a dashboard, may cause the battery life to shorten
or the battery to stop functioning.
2. INITIAL VEHICLE STATE (THAT SATISFIES CONDITIONS FOR

WIRELESS OPERATION)
NOTICE:
Indicates initial settings that are not selected in the CUSTOMIZE
function by the DS-II.
(a) The key is not inserted in the ignition switch lock cylinder.
(b) All doors are closed. (door warning inside meter is not on)
3. CHECK WIRELESS DOOR LOCK CONTROL OPERATION

(a) CHECK BASIC FUNCTION
HINT:
The switches described below transmit LOCK / UNLOCK sig-
nals and are built in to the door control transmitter.
(1) Check the wireless operation within the remote control's
operating range. Note that if the key is in the ignition
switch lock cylinder, or if any of the doors is open, the
remote control will not operate.
(b) Check the chattering prevention function.
(1) If the switch is held down, check that the corresponding
operation occurs only once and does not repeatedly acti-
vate. However, if a switch is pressed and released at 1
second intervals, check that the corresponding operation
activates once for ever press of the switch.
GETtheMANUALS.org
DL–36 DOOR LOCK - WIRELESS DOOR LOCK CONTROL SYSTEM
(c) Check the automatic locking function.

(1) Check that, when all of the doors are unlocked with the
UNLOCK switch and none of the doors are opened or
locked within 30 seconds, the doors lock again automati-
cally.
(2) Under the same conditions as those described above,
check that, if any of the doors are opened or all of the
doors are locked within 30 seconds, the doors will not lock
again automatically.
(d) Check the switch operation fail-safe function.
(1) If the key is in the ignition switch lock cylinder, check that
the doors cannot be locked or unlocked by using the
LOCK switch. However, this does not apply when the sys-
tem is in the recognition code registration mode.
(2) Check that when a switch is pressed on an unregistered
transmitter, the LOCK / UNLOCK functions will not oper-
ate. Also, check that when a switch is pressed on a regis-
DL tered transmitter, these functions will operate.
(e) Check the door ajar warning function.
(1) When a door is open or not completely closed, check that
the doors cannot be locked by using the LOCK switch.
(f) Check the repeat function.
(1) Check that, when the LOCK switch is pressed with the
driver door control knob held forcibly in the UNLOCK posi-
tion, all doors will lock again about 1 second later.
(g) Check the answer-back function.
(1) When the LOCK switch is pressed, check that, when all
doors are either locked or unlocked, the hazard warning
lights also flash. They should flash once when the door is
locked and twice when the door is unlocked.
GETtheMANUALS.org
DL–37
LOCATION
FRONT DOOR COURTESY

LIGHT SWITCH RH
STEERING COLUMN UPPER WITH SWITCH

BRACKET ASSEMBLY
- UNLOCK WARNING SWITCH ASSEMBLY REAR DOOR MOTOR WITH
LOCK ASSEMBLY RH
INSTRUMENT PANEL BACK DOOR LOCK

JUNCTION BLOCK ASSEMBLY
- FUSE BLOCK ASSEMBLY
- DOOR CONTROL RELAY
ASSEMBLY BACK DOOR COURTESY
LIGHT SWITCH RH
DL
REAR DOOR MOTOR WITH

LOCK ASSEMBLY LH
FRONT DOOR MOTOR WITH REAR DOOR COURTESY

LOCK ASSEMBLY RH LIGHT SWITCH LH
FRONT DOOR COURTESY

LIGHT SWITCH LH
FRONT DOOR MOTOR WITH

LOCK ASSEMBLY LH
REAR DOOR COURTESY

LIGHT SWITCH RH
B141871J01
GETtheMANUALS.org

IG1/BACK 7.5 A, BACK UP 10 A D/L 15 A fuse
Transmitter battery
Door control transmitter
Only the wireless control function is inoperative Door control receiver DL-48
Unlock warning switch assembly
Wire harness
No Answer-back (Hazard) Lighting system DL-46
Wire harness
DL HOW TO PROCEED WITH TROUBLE-

SHOOTING
HINT:
(See page DL-40.)
HINT:
(See page DL-38.)
(a) For unrelated problem systems, go to A.
(b) For related problem systems, go to B.
(a) ECU terminals (See page DL-41.)

(b) CHECK FUNCTION (See page DL-35.)
(c) INSPECTION
GETtheMANUALS.org
DL–39
END
DL
GETtheMANUALS.org

CHECK

Wireless Door Lock Control System Problem Diagnosis Check Sheet / /
Customer’s Name License Plate No.
First Registered Year 20__/ /
Model VIN
Written By Inspector’s Name

Engine Type Odometer Reading
DL
Date Time
Date Problem First Occured
Conditions
Weather Clear Cloudy Rainy Snowy Others( ) Temperature Approx. ( )°C
DTC is output
All wireless door lock control functions do not operate

Problem
Symptoms Answer back function does not operate
Others
Condition Returns To Normal IG ON Engine Starting ( ) SW Operation
Conditions When Present

IG OFF ON ( ) SW Operation Others ( )
Problem Occurs Not Present
B105502J01
GETtheMANUALS.org
DL–41
ECU TERMINALS
1. CHECK INSTALLMENT PANEL JUNCTION LOCK ASSEMBLY
(a) INSPECT FUSES
(1) Check that the following fuses are normal: IG1/BACK 7.5A,
BACK UP 10 A, D/L15 A, HAZ 10 A.
(b) Check the fuse block assembly.
(1) Disconnect connector A of the fuse block assembly. Also
disconnect connectors C, D, F and G.
DL
GETtheMANUALS.org
(2) Using a tester, check the voltage, resistance and continuity

between the body ground and each terminal of the vehicle
side connector.
GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
CRL
HZD
MPX
IG1
UKS
H ECUB
LKS
IND
HORN
DL ULM
LKM
BDR1
C
D E
25
A F
10 9
24 23 22 21 20 19
12 11 10 9 8 7
4
6
2
2
18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
3
5
8
1
7
B
3
1
6
2
5
1
10 9
4
18 17 16 15 14 13
6
G
3
5
8
4
22 21 20 19 18 17 16 30 29 28 27 26 25 24 23
3
7 6 5 4 3 2 1 15 14 13 12 11 10 9 8
2
6
2
1
5
1
4 3 2 1 2 1
2 1 10 9 8 7 6 5 6 5 4 3
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
12 11 10 9 8 7 6 5 4 3 2 1 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
25
24 23 22 21 20 19 18 17 16 15 14 13 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Connector H
B137035
GETtheMANUALS.org
DL–43
Standard:

D4 (+) ←→ Body ground Voltage IG OFF → IG ON 0 V → 10 to 14 V
D6 (B) ←→ Body ground Voltage IG OFF ←→ ACC ON 0 V → 10 to 14 V
A2 (B) ←→ body ground Voltage Always 10 to 14 V
C10 (B/UP) ←→ Body ground Voltage Always 10 to 14 V
G29 (E) ←→ Body Ground Voltage Always Continuity
HINT:
If the results are not as specified, the problem is on the
vehicle side.
(c) Connect the connector and check the voltage of each terminal
of the connector.
Standard:
Terminal No. Item Measurement Condition Standard DL

IG OFF, no key
With all of the doors closed, transmitter switch OFF
5 (EHW) ←→ Body ground Voltage 10 to 14 V → 0 V → 10 to 14 V
→ ON
(When performing the answer-back function)
HINT:
If the results are not as specified, there is a problem with the
door control relay assembly.
2. INSPECT COMBINATION METER ASSEMBLY
(a) Disconnect the connector. Using a tester, check both the conti-
nuity and the voltage of each terminal of the connector of the
vehicle side wire harness.
B068593
Standard
Terminal No. (Terminal Name) Item Measurement Condition Standard

9 (Courtesy) ←→ 15 (GND) Voltage All doors closed → open Below 1 V → 10 V to 14 V
No key in the ignition switch
2 (KEY ←→ 15(GND) Voltage lock cylinder → key in the cyl- 1 V or less → 10 to 14 V
inder
Connect the connector and check the voltage of each terminal

of the connector.
Standard:
GETtheMANUALS.org

IG OFF, no key
33 (KLS) ←→ Body ground Voltage With all of the doors closed, transmitter switch OFF 10 to 14 V → 1 V or less
→ ON
IG OFF, no key
37 (LIN) ←→ Body ground Voltage With all of the doors closed, transmitter switch OFF Pulse is generated
→ ON
HINT:
If the result is not as specified, there is a problem with the com-
bination meter assembly.
3. CHECK DOOR CONTROL RECEIVER
(a) Disconnect the connector. Using a tester, check both the conti-
nuity and the voltage of each terminal of the connector of the
vehicle side wire harness.
DL
B143795
Standard

4 (E) ←→ Body Ground Continuity Always Continuity
HINT:
If the results are not as specified, the problem is on the vehicle
side.
(b) With the connectors connected, check the voltage of each ter-
minal.
Standard:

IG OFF, no key, all doors closed, transmitter LOCK Pulse is generated
5 (SIG) ←→ 4 (GND) Voltage
switch OFF → ON Waveform 1
IG OFF, no key, all doors closed, transmitter Pulse is generated
5 (SIG) ←→ 4 (GND) Voltage
UNLOCK switch OFF → ON Waveform 2
HINT:
If the results are not as specified, there is a problem with the
door control receiver.
4. Oscilloscope waveform
HINT:
The oscilloscope waveform shown is provided as a reference. Wave-
forms for noise and chattering are omitted.
GETtheMANUALS.org
DL–45
(a) Waveform 1
HOLD Item Condition

Tester Connection 5 (SIG) ←→ 4 (GND)
Tool Setting 5 V (voltage axis), 50 ms (time axis)
Condition When switched to LOCK
B141264
(b) Waveform 2
50mS Item Condition
HOLD
Tester Connection 5 (SIG) ←→ 4 (GND)
Tool Setting 5 V (voltage axis), 50 ms (time axis)
Condition When switched to UNLOCK
DL
B141263
GETtheMANUALS.org
NO ANSWER-BACK (HAZARD)
DESCRIPTION
The door control receiver receives a signal from the transmitter and the signal is sent to the combination meter assembly (meter
ECU).The combination meter assembly sends the door lock, unlock signals to the door control relay assembly using body multi-
plex communication (LIN). The door control relay assembly outputs a hazard light blinking signal (answer back) according to the
door lock or unlock signal.
NOTICE:
The wireless door lock control system uses the Body Electrical Area Network. Following the HOW TO PROCEED WITH
TROUBLESHOOTING section, go to CHECK COMMUNICATION FUNCTION and proceed to TROUBLESHOOTING.
CIRCUIT DIAGRAM
Fuse Block Assembly

DL
Turn Signal Flasher Assembly Door Control Assembly
H5 HAZ
EHW 8
B140180
1 CONFIRM WIRELESS DOOR LOCK OPERATION
(a) Confirm that the wireless door lock is functioning by operating the
transmitter switch.
HINT:
If the wireless door lock / unlock functions are working properly, con-
firm that the wireless indicator from the transmitter is inputting to the
door control receiver.
NG TO CIRCUIT THAT ONLY WIRELESS FUNC-

TION DOES NOT OPERATE
OK
2 CHECK HAZARD LIGHT OUTPUT
(a) Check whether the hazard lights function normally when the hazard
switch is pressed.
HINT:
If NG, see lighting system (page LI-9).
GETtheMANUALS.org
DL–47
NG GO TO LIGHTING SYSTEM
OK
3 CHECK FUSE BLOCK ASSEMBLY (TURN SIGNAL FLASHER ASSEMBLY - DOOR CONTROL RELAY
ASSEMBLY)
(a) Remove the door control relay assembly and the turn signal flasher
assembly.
(b) Using a tester, check the continuity between each terminal of the door
control relay assembly connector and the terminal to the turn signal
Turn Signal Flasher Assembly flasher connector of the fuse block assembly.
Standard:
Terminal No. (Turn signal ←→ Door

Standard
control relay assembly)
8 (EHW) ←→ H5 (HAZ) Continuity
DL
Fuse Block Assembly
Connector H
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B141873
OK
GETtheMANUALS.org
ONLY WIRELESS FUNCTION (REMOTE OPERATION) IS INOPERATIVE

(PREPARE NEW OR NORMAL TRANSMITTER)
DESCRIPTION
The signal from the door lock control transmitter is sent to the combination meter assembly via the continuous line that the door
control receiver receives. Then, via the combination meter assembly, it is changed by the Body Electrical Area Network and sent
to the fuse block assembly (door control relay assembly). The fuse block assembly (door control relay assembly) controls by
sending the door lock/unlock signal to each of the door lock actuators.
NOTICE:
The wireless door lock control system uses the Body Electrical Area Network. Following the HOW TO PROCEED WITH
TROUBLESHOOTING section, go to CHECK COMMUNICATION FUNCTION and proceed to TROUBLESHOOTING.
CIRCUIT DIAGRAM
DL
Combination Meter
Door Control Receiver Assembly Fuse Block Assembly
Door Control
Relay Assembly
+B 85 D/L 15A
SIG 52 33 KYLS
LIN 37 F16 ITC-
Unlock Warning
Switch Assembly
HORN
6 MPX
1 7.5A 2 1 2
KEY
E 4
B140220J02
1 CONFIRM WIRELESS DOOR LOCK OPERATION
OK DTC is not output
NG
GETtheMANUALS.org
DL–49
2 INSPECT TRANSMITTER
(a) Replace the transmitter with a normal or new one. Record the identi-
fication code, then check the standard functions (see page DL-35).
OK REPLACE DOOR TRANSMITTER MODULE

SET
NG
3 IDENTIFICATION CODE REGISTRATION
(a) Check that recognition code registry regrettable mode has com-
menced and that codes can be registered.
OK NORMAL (PERFORM OPERATION CHECK) DL

NG
4 CHECK DOOR CONTROL RECEIVER RESPONSE
(a) While pressing and holding the switch of a new or known good door
control transmitter for the same vehicle model, check whether there is
a diagnostic discrepancy in the identification code that is outputted.
OK REPLACE DOOR TRANSMITTER MODULE

SET
NG
5 CHECK DOOR CONTROL RECEIVER (POWER SOURCE, BODY GROUND SYSTEM)
(a) Disconnect the door control receiver connector, and, using a tester,
check the continuity and the voltage between each terminal and the
body ground.
Standard:
Measure-
Terminal No. (Terminal Name) Item ment Condi- Standard
tion
B143795 8 (+B) ←→ body ground Voltage Always 10 to 14 V
NG REPLACE DOOR CONTROL RECEIVER
OK
GETtheMANUALS.org
6 CHECK DOOR CONTROL RECEIVER (OUTPUT SYSTEM)
(a) Connect the door control receiver connector, and, using a tester,
check the voltage between terminal 5 and the body ground.
Standard:
B143795

IG OFF, no key, all doors closed, transmitter switch
5 (SIG) ←→ Body Ground 0 V → 1.2 V or less
DL Voltage
OFF → ON
NG REPLACE DOOR CONTROL RECEIVER
OK
(a) Using a tester, check the continuity between terminal 1 and terminal 2
of the connector.
Unlock Warning Switch Assembly
Standard:

Pin
NG REPLACE UNLOCK WARNING SWITCH
E105271J03
ASSEMBLY
OK
GETtheMANUALS.org
DL–51
8 CHECK WIRE HARNESS AND CONNECTOR (BETWEEN DOOR CONTROL RECEIVER AND COMBI-
NATION METER ASSEMBLY)
(a) Check the continuity of the wire harnesses.

(1) Disconnect the door control receiver connector, the unlock
Door Control Receiver
warning switch assembly connector, the combination meter
assembly connector and connector F of the fuse block assem-
bly.
(2) Using a tester, check the continuity between the vehicle side
Unlock Warning Switch connector terminal of the fuse block assembly and the vehicle
side connector of the combination meter assembly, the unlock
warning switch assembly, and the door control receiver.
Standard:
Combination Meter Assembly Measure-

Terminal No. (Receiver ←→
Combination meter assembly)
Item ment Condi-
tion
Standard DL
5 (SIG) ←→ 33 (KYLS) Continuity Always Continuity
Fuse Block Assembly Standard:

Connector F
Terminal No. (Combination meter Measure-
assembly ←→ Fuse block Item ment Condi- Standard
assembly) tion
B143855
37 (LIN) ←→ F16(ITC-) (in front of
vehicle)
Standard:
Terminal No. (Unlock warning Measure-

switch ←→ Combination meter Item ment Condi- Standard
assembly) tion
1 ←→ 2 (KEY) Continuity Always Continuity
Standard:
Door control receiver
Measure-
tion
No continu-
5 (SIG) ←→ Body Ground Continuity Always
ity
Standard:
Fuse block assembly
Measure-
tion
No continu-
F16 (ITC-) ←→ Body ground Continuity Always
ity
Standard:
Unlock warning switch assembly
GETtheMANUALS.org
Measure-
tion
No continu-
1 ←→ The body ground Continuity Always
ity

CONNECTOR
OK
(a) Disconnect connector F from the fuse block assembly.

(b) Remove the door control relay assembly.
Standard:
DL
Terminal No. (Terminal Name) Item Standard
Fuse Block Assembly F16 (ITC-) ←→ H6 (MPX) Continuity Continuity
Connector F
OK REPLACE DOOR CONTROL RELAY ASSEM-
9 8 7 6 5 4 3 2 1
BLY (IF NO IMPROVEMENT, GO TO METER
18 17 16 15 14 13 12 11 10
AND GAUGE SYSTEM)
Fuse Block Assembly

Connector H
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
I102689
NG
REPLACE FUSE BLOCK ASSEMBLY
GETtheMANUALS.org
DOOR LOCK - KEY REMINDER WARNING SYSTEM
DL–53

BODY AND
DOOR LOCKELECTRICAL
OPERATION CHECK
1. OPERATION CHECK
(a) Check the sound of the key reminder warning buzzer.
(1) With all the doors closed, insert the key in the ignition
switch lock cylinder, and put the key in the LOCK or ACC
position.
(2) Repeat the above with any of the doors open, and check
that the buzzer sounds intermittently.
(b) Check that the key reminder warning sound stops.
(1) With the buzzer sounding, perform the following and
check whether the buzzing sound stops.
• Close all the doors. (Turn each door's door courtesy
light switch assembly OFF.)
• Turn the key to the ON position.
• Remove the key from the ignition switch lock cylinder.
DL
GETtheMANUALS.org
DL–54 DOOR LOCK - KEY REMINDER WARNING SYSTEM
LOCATION
FRONT DOOR COURTESY

DL
FRONT DOOR COURTESY LIGHT

SWITCH ASSEMBLY LH
REAR DOOR COURTESY LIGHT SWITCH

ASSEMBLY RH
REAR DOOR COURTESY LIGHT

SWITCH ASSEMBLY LH
B144282J01
GETtheMANUALS.org
DL–55

Unlock warning switch assembly DL-74
Each door's door courtesy light switch assembly -
The key reminder warning does not work
Combination meter assembly ME-8
Wire harness -

SHOOTING
DL
HINT:
For customer problem analysis check, see page DL-56.
(a) Refer to the problem symptoms table and check if the symptom of the
problem is listed in the table.
HINT:
See page DL-55.
Standard
Result Proceed to

(b) ECU terminals (See page DL-57.)
(c) INSPECTION
GETtheMANUALS.org
END

CHECK
DL
Key Reminder Warning System Problem
Diagnosis Check Sheet
/ /
Customer’s Name License Plate No. Engine Type
First Registration Year 20__/ / Model
Written By
Odometer Reading VIN
Inspector’s Name

Conditions
Weather Clear Cloudy Rainy Snowy Others ( ) Temperature Approx. ( )°C
Road City Suburbs Highway Others( ) Paved Unpaved
Problem ‫ غ‬Key reminder buzzer does not operate (unlock warning switch circuit)
Symptoms
‫ غ‬Key reminder buzzer does not operate (front door courtesy switch circuit)
B101780
GETtheMANUALS.org
DL–57
ECU TERMINALS
1. COMBINATION METER ASSEMBLY
(a) CHECK INPUT / OUTPUT SIGNALS
needle from behind the vehicle's wire harness connector.
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
B141852
DL
Connector A
(Terminal No.) put
IG+ ←→ Body ground
Input Voltage Ignition switch OFF → ON 1 V or less → 10 to 14 V
(12 ←→ Body ground)
Courtesy ←→ Body
ground Input Voltage Any of the doors closed → open 1 V or less → 10 to 14 V
LIN ← Body ground Input / Out-
Waveform Engine is stopped, ignition switch ON Pulse is generated
(37 ←→ Body ground) put
GND ←→ Body ground
GETtheMANUALS.org
KEY REMINDER WARNING DOES NOT WORK

DESCRIPTION
Through the unlock warning switch assembly and each door's courtesy light switch, the combination meter assembly senses
whether each door is opened or closed and whether a key is present or absent in the ignition switch lock cylinder. Furthermore, by
sensing the open signal from each door's courtesy light switch and the signal that there is a key in the ignition, the combination
meter assembly decides to issue a key reminder and intermittently sounds the buzzer of the built-in meter.
CIRCUIT DIAGRAM
Combination
Unlock Warning
DL HORN Switch Assembly
Meter Assembly Courtesy Switch
At Each Seat
7.5A D13+ D14- 2 1 2
KEY CTY 9
MAIN
Battery
B141265
1 INSPECT FUSES
(a) Check the HORN 7.5 A fuse.
NG REPLACE FUSES
OK
2 CHECK WIRE HARNESS (POWER SOURCE SYSTEM)

(1) Disconnect the connector of the unlock warning switch assem-
bly.
(2) Using a tester, check the voltage between the body ground and
the vehicle side connector of the unlock warning switch assem-
bly.
Standard:
10 V to 14 V (when normal)
GETtheMANUALS.org
DL–59
NG REPLACE WIRE HARNESS (POWER

SOURCE SYSTEM)
OK

(1) Using a tester, check the continuity between terminal 1 and ter-
minal 2 of the connector.
Standard

E105271
NG REPLACE UNLOCK WARNING SWITCH DL
ASSEMBLY
OK
4 CHECK WIRE HARNESS (BETWEEN THE UNLOCK WARNING SWITCH AND THE COMBINATION
METER ASSEMBLY)

(1) Disconnect the connector of the combination meter assembly.
(2) Insert the key into the ignition lock cylinder.
(3) Using a tester, check the voltage between each terminal of the
Standard

2 (KEY) ←→ 15 (GND) 10 to 14 V

CONNECTOR (BETWEEN THE UNLOCK
WARNING SWITCH ASSEMBLY AND THE
COMBINATION METER ASSEMBLY)
OK
GETtheMANUALS.org
5 CHECK COURTESY LIGHT SWITCH ASSEMBLY

(1) Using a tester, operate the switch and check the continuity
between the bracket and connector 1 terminal.
Standard

With the switch depressed No continuity
With the switch not depressed Continuity
NG REPLACE COURTESY LIGHT SWITCH

E109315
ASSEMBLY
OK
DL
6 CHECK WIRE HARNESS (BETWEEN EACH DOOR COURTESY LIGHT SWITCH ASSEMBLY AND
THE COMBINATION METER ASSEMBLY)
Combination Meter Assembly Courtesy Light Switch Assembly
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 1
B141292
(1) Disconnect the connector to each door's courtesy light switch

assembly and the connector to the combination meter assem-
bly.
(2) Using a tester, check the continuity between each terminal of
the connector of the vehicle side wire harness.
Standard
Tester Connection
Terminal No. (Receiver ←→ Combination meter Standard
assembly)
1 ←→ 9 (courtesy) Continuity

CONNECTOR (BETWEEN EACH DOOR
COURTESY LIGHT SWITCH ASSEMBLY AND
THE COMBINATION METER ASSEMBLY)
GETtheMANUALS.org
DL–61
OK
DL
GETtheMANUALS.org
DL–62 DOOR LOCK - DOOR CONTROL RELAY ASSEMBLY

BODY AND
DOOR LOCKELECTRICAL
COMPONENTS
INSTRUMENT PANEL
JUNCTION BLOCK ASSEMBLY
DL
FUSE BLOCK ASSEMBLY
COIN BOX ASSEMBLY
B141468J01
GETtheMANUALS.org
DOOR LOCK - DOOR CONTROL RELAY ASSEMBLY
DL–63
REMOVAL
1. REMOVE COIN BOX ASSEMBLY (See page IP-11)

IP-11)

IP-11)
4. REMOVE FUSE BLOCK ASSEMBLY
(a) Remove 1 bolt and disengage 1 claw. Then remove the fuse
block assembly together with the door control relay assembly.
(b) Disconnect each connector.
5. REMOVE DOOR CONTROL RELAY ASSEMBLY

(a) Remove the door control relay assembly from the fuse block
assembly.
INSTALLATION
B141293 6. INSTALL DOOR CONTROL RELAY ASSEMBLY
DL
(a) Install the door control relay assembly to the fuse block assem-
bly.
7. INSTALL FUSE BLOCK ASSEMBLY

(a) Connect each connector.
(b) Engage the claw and install the fuse block assembly with the 1
bolt.

IP-18)

18)
10. INSTALL COIN BOX ASSEMBLY (See page IP-19)
B141293
GETtheMANUALS.org
DL–64 DOOR LOCK - FRONT DOOR WITH MOTOR LOCK ASSEMBLY RH
FRONT DOOR WITH MOTOR LOCK ASSEMBLY RH

BODY AND
DOOR LOCKELECTRICAL
INSPECTION
1. CHECK FRONT DOOR LOCK ASSEMBLY RH
(a) Check the continuity (door control switch, key-link operation).
(1) Using a tester, check the continuity between the terminals
when the switch lever in the positions shown below.
Standard:
Neutral

Terminal 6 ←→ Termi-
LOCK Continuity
nal 8
Neutral - -
Terminal 7 ←→ Termi-
UNLOCK Continuity
nal 8
DL
B064315J01
(b) Check the continuity between the door lock function and the
position switch.
(1) Check the operation of the door lock when battery voltage
is applied between the terminals of the motor inside the
door lock.
(2) Using a tester, check the continuity of the position switch
when the door lock is operated.
Standard:
Standard
Connection Operates
(Position Switch)
Positive (+) battery terminal
←→ Terminal 4 Terminal 7 ←→ Terminal 8
LOCK
Negative (-) battery terminal No continuity
←→ Terminal 1
Positive (+) battery terminal
←→ Terminal 1 Terminal 7 ←→ Terminal 8
UNLOCK
Negative (-) battery terminal Continuity
←→ Terminal 4
B081029J01
GETtheMANUALS.org
DOOR LOCK - FRONT DOOR WITH MOTOR LOCK ASSEMBLY LH
DL–65
FRONT DOOR WITH MOTOR LOCK ASSEMBLY LH

BODY AND
DOOR LOCKELECTRICAL
INSPECTION
1. CHECK FRONT DOOR LOCK ASSEMBLY LH
(a) Check the continuity between the door lock function and the
position switch.
(1) Using a tester, check the door lock function when battery
voltage is applied between the connectors.
Standard:
Connection Operates
LOCK
UNLOCK
DL
B081032J01
GETtheMANUALS.org
DL–66 DOOR LOCK - REAR DOOR WITH MOTOR LOCK ASSEMBLY RH
REAR DOOR WITH MOTOR LOCK ASSEMBLY RH

BODY AND
DOOR LOCKELECTRICAL
INSPECTION
1. CHECK REAR DOOR LOCK ASSEMBLY RH
(1) Check the door lock function when battery voltage is
applied between the connectors.
Standard:
Connection Operates
LOCK
UNLOCK
DL
B081044J02
GETtheMANUALS.org
DOOR LOCK - REAR DOOR MOTOR LOCK ASSEMBLY LH
DL–67
REAR DOOR MOTOR LOCK ASSEMBLY LH

BODY AND
DOOR LOCKELECTRICAL
INSPECTION
1. CHECK REAR DOOR LOCK ASSEMBLY LH
(1) Check the door lock function when battery voltage is
applied between the connectors.
Standard:
Connection Operates
LOCK
UNLOCK
DL
B081070J02
GETtheMANUALS.org
DL–68 DOOR LOCK - BACK DOOR LOCK ASSEMBLY

BODY AND
DOOR LOCKELECTRICAL
INSPECTION
1. CHECK BACK DOOR LOCK ASSEMBLY
(1) Check the operation of the door lock when battery voltage
is applied between the terminals of the motor inside the
door lock.
Standard:
LOCK
UNLOCK
Connection Operates
LOCK
B137673 Negative (-) battery terminal ←→ Terminal 2
UNLOCK
DL
GETtheMANUALS.org
DOOR LOCK - FRONT DOOR OUTSIDE HANDLE ASSEMBLY RH
DL–69
FRONT DOOR OUTSIDE HANDLE ASSEMBLY RH

BODY AND
DOOR LOCKELECTRICAL
INSPECTION
1. CHECK FRONT DOOR OUTSIDE HANDLE ASSEMBLY RH
TRG- (1) Using a tester, check the continuity between the connec-
tor 3 (TRG+) terminal and 1 (TRG-) terminal when the trig-
ger switch is operated.
Standard:
TRG+
Switch Operation Standard

When switch is not operated No continuity
E067622J13
When switch is operated Continuity
DL
GETtheMANUALS.org
DL–70 DOOR LOCK - DOOR CONTROL TRANSMITTER MODULE SET
DOOR CONTROL TRANSMITTER MODULE SET

BODY AND
DOOR LOCKELECTRICAL
COMPONENTS
TRANSMITTER HOUSING COVER
DOOR CONTROL TRANSMITTER

MODULE SET
DL
B143931J01
REMOVAL
1. REMOVE DOOR CONTROL TRANSMITTER MODULE SET
NOTICE:
Since each part consists of precise electronic parts, take suffi-
cient care when handling them.
(a) Remove the screw and cover.
NOTICE:
Do not forcibly twist.
(b) Remove the door control transmitter module set from the trans-
mitter housing case.
INSTALLATION
2. INSTALL DOOR CONTROL TRANSMITTER MODULE SET
(a) With the screw, tighten the transmitter housing cover.
B143692
REGISTRATION
1. IDENTIFICATION CODE REGISTRATION
HINT:
• Identification code registration is necessary if a transmitter is ever
lost and a new one is added.
• It is possible to register up to 2 distinct codes with the receiver. It
is also possible to use up to 2 transmitters.
• When registering a new transmitter, completely erase the old
identification code that is registered with the receiver.
• The identification code will not be lost even if the battery is
removed.
GETtheMANUALS.org
DOOR LOCK - DOOR CONTROL TRANSMITTER MODULE SET
DL–71
(a) Perform the following procedure to register.
The conditions to begin with are those conditions as follows:

1.The key is not inserted into the IG key cylinder.
2. The negative battery terminal and the receiver
connector are disconnected.
The negative battery terminal and the receiver connector are connected (power supplied to the receiver), and all
doors are closed.
Within 15 seconds after connection, simultaneously press the transmitter LOCK switch and UNLOCK switch,
which are to be registered, for more than 5 seconds.
As an operation response, a lock and unlock operation will occur automatically.
After the operation response, press the transmitter UNLOCK switch and LOCK switch, which are to be
registered, for more than 1 second within 5 seconds.
DL
A lock and unlock operation will occur automatically to indicate registration completion.
Seconds transmitter registration

Registration complete After the registration completion response, within 15 seconds, simultaneously
press the transmitter LOCK switch and UNLOCK switch for more than 5 seconds.
The transmitter will operate when it automatically locks and unlocks as a registration completion response.
After the operation response, press the transmitter UNLOCK switch and LOCK switch, which are to be
registered, for more than 1 second within 5 seconds.
A lock and unlock operation wil occur automatically to indicate registration completion.
Registration of the third and fourth transmitters.

Registration complete
B143869J01
(b) When registration is complete, perform the following.

(1) Check the wireless door lock control system operation.
See page DL-35.
NOTICE:
If the wireless function is not working, re-register the
identification code(s).
GETtheMANUALS.org
DL–72 DOOR LOCK - DOOR CONTROL RECEIVER

BODY AND
DOOR LOCKELECTRICAL
COMPONENTS
DL
GLOVE COMPARTMENT ASSEMBLY
B146672J01
REMOVAL
IP-11)
GETtheMANUALS.org
DOOR LOCK - DOOR CONTROL RECEIVER
DL–73
2. REMOVE DOOR CONTROL RECEIVER

(b) Remove the bolt. Then remove the door control receiver.
INSTALLATION
B146586
3. INSTALL DOOR CONTROL RECEIVER

(a) Align the claws and install the door control receiver with the
bolt.

IP-18) DL
B146586
GETtheMANUALS.org
DL–74 DOOR LOCK - UNLOCK WARNING SWITCH ASSEMBLY

BODY AND
DOOR LOCKELECTRICAL
INSPECTION
1. CHECK UNLOCK WARNING SWITCH ASSEMBLY
(a) Using a tester, check the continuity between the connector's ter-
minals.
Standard
Condition Standard
Pin
E105271J01
DL
GETtheMANUALS.org
TO INDEX
BODY AND ELECTRICAL
METER
METER / GAUGE SYSTEM
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-1
BASIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-3
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-4
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-6
HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . ME-8
CUSTOMER PROBLEM ANALYSIS CHECK SHEET. . . . . . . . . . . . . . . . . ME-11
DIAGNOSIS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-12
CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-13
ECU TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-16
TACHOMETER MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-19
FUEL RECEIVER GAUGE MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . ME-21
WATER TEMPERATURE RECEIVER GAUGE MALFUNCTION . . . . . . . . ME-24
SPEEDOMETER MALFUNCTION (VEHICLES WITH VSC) . . . . . . . . . . . . ME-26
SPEEDOMETER MALFUNCTION (VEHICLES WITHOUT VSC) . . . . . . . . ME-28
ME
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-30
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-31
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-31
ENGINE OIL PRESSURE SWITCH ASSEMBLY
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-33
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-34
INDICATOR ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-37
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ME-37
GETtheMANUALS.org
ME–1 METER - METER / GAUGE SYSTEM
METER / GAUGE SYSTEM

BODY AND ELECTRICAL
METER
OPERATION CHECK
1. CHECK LED
(a) Check the LED illumination status.
(1) Check that each indicator / warning light comes on for the
period of time specified below when turning the ignition
switch to the ON position.
Standard:
Indicator / Warning Illumination Condition

Brake, ABS, Slip, VSC, VSC OFF, DAC, Water Temperature Warn- When the ignition switch is turned to the ON position, the light
ing (HOT) comes on for approx. 3 seconds.
When the ignition switch is turned to the ON position, the light
Airbag
comes on for approx. 6 seconds.
When the ignition switch is turned to the ON position, the light
Check Engine, Charge, Engine Oil Pressure
comes on.
ME Water Temperature Warning (COOL)
When the ignition switch is turned to the ON position, the water
temperature warning light (HOT) comes on, then goes off after
the engine is warmed up.
HINT:
• Illumination requests are made by the relevant ECUs.
(See page ME-13 for details regarding the ECUs.)
• Check the brake warning light with the parking brake
released.
2. INSPECTION OF SPEEDOMETER
(a) Check operation
(1) Using a speedometer tester, check the indication error of
the speedometer and the operation of the odometer.
Standard:
Meter Indication Acceptable Range (km/h) Meter Indication Acceptable Range (km/h)
Tester Indication Standard Speed (km/h) (for EU) (for general export)
Values in parenthesis are for reference Values in parenthesis are for reference
20 (21-25) (21-25)
40 41.2-47.0 37.2-43.0
60 62.0-68.9 56.2-65.0
80 82.4-91.0 75.1-87.0
100 102.6-113.0 94.1-109.0
120 122.7-134.9 113.0-130.9
140 142.8-156.9 131.9-153.0
160 163.0-178.9 151.0-175.0
NOTICE:
If the tire pressure is improper, the indication error
increases.
(2) Inspect the amount of fluctuation of the speedometer.
Standard:
0.5 km/h or less
3. INSPECTION OF TACHOMETER
(a) Check operation
GETtheMANUALS.org
METER - METER / GAUGE SYSTEM
ME–2
(2) Using a tachometer (test equipment), check the indication

error of the vehicle's tachometer.
Standard:
Meter Indication Acceptable Range (r/min)

Tachometer (Test Equipment) Indication (r/min)
Values in parenthesis are for reference
700 500-700
1000 (900-1100)
2000 (1875-2125)
3000 2850-3150
4000 (3850-4150)
5000 4840-5160
6000 (5820-6180)
NOTICE:
Do not run the engine at a speed higher than its maxi-
mum permissible speed (indicated by the red zone on
the tachometer).
4. INSPECTION OF OIL PRESSURE WARNING INDICATOR ME

(a) Check operation
(1) Disconnect the engine oil pressure switch assembly con-
nector.
(3) Using a test lead wire, check the status of the oil pressure
warning indicator when creating a short circuit between
the vehicle wire harness connector terminal of the engine
oil pressure switch assembly and the body ground.
SST 09843-18040
Standard:
The engine oil pressure warning indicator comes
on.
5. Inspect engine oil pressure switch assembly

(1) Using the tester, check for continuity between the engine
oil pressure switch terminal and the body ground.
Engine Condition Standard

Engine is stopped Continuity
Engine is running No continuity
6. INSPECTION OF FUEL RECEIVER GAUGE AND WARNING

LIGHT
(a) Inspect circuit
(1) Disconnect the fuel sender gauge assembly connector.
(2) Disconnect the negative battery terminal, and reconnect
it.
(3) Check the fuel receiver gauge indication status when turn-
ing the ignition switch to the ON position.
Standard:
The gauge indication is below E.
(4) Using a test lead wire, short the circuit between the fuel
sender gauge vehicle harness side connector terminal 2
and terminal 3.
(5) Disconnect the negative battery terminal, and reconnect
it.
GETtheMANUALS.org
(6) Check the fuel receiver gauge indication status when turn-
ing the ignition switch from the OFF to the ON position.
Standard:
Points above F
7. INSPECTION OF BUZZER OPERATION

(a) Check operation
(1) Activate each warning function and check the operation of
the buzzer built into the combination meter assembly.
E110982
Warning Function Inspection Condition Buzzer Sound
Light control switch TAIL,
Taillight Reminder Warn- ignition switch OFF, (with-
Continuous sound
ing out key) → driver side
door open
Taillight OFF, ignition
Key Reminder Warning switch OFF, with key, Intermittent sound
driver side door open
BASIC INSPECTION
ME 1. INSPECTION OF BATTERY VOLTAGE
(a) Measure the battery voltage when the engine is stopped.
Standard:
10 to 14 V
GETtheMANUALS.org
ME–4
LOCATION
BRAKE LEVEL WARNING SWITCH
ME

ALTERNATOR ASSEMBLY
SKID CONTROL COMPUTER ASSEMBLY
E131139J01
GETtheMANUALS.org
INDICATOR ASSEMBLY
COMBINATION ASSEMBLY
COMPUTER ASSEMBLY
HEADLIGHT DIMMER
ENGINE CONTROL SWITCH ASSEMBLY
COMPUTER ASSEMBLY
ME
INSTRUMENT PANEL
J/B ASSEMBLY
-FLASHER RELAY
FRONT SEAT INNER

BELT ASSEMBLY RH
PARKING BRAKE SWITCH
FRONT SEAT
FRONT SEAT CUSHION COVER AND PAD LH INNER BELT ASSEMBLY LH
(OCCUPANT DETECTION SENSOR )
AIRBAG SENSOR CTR
E132254J01
GETtheMANUALS.org
ME–6
E.F.I. COOLANT TEMPERATURE

ME
E131196J02

METER / GAUGE
Speedometer operation malfunction (Vehicles without See troubleshooting flowchart (speedometer malfunction)
ME-28
VSC attachment) (Vehicles without VSC attachment)
Speedometer operation malfunction (Vehicles See troubleshooting flowchart (speedometer malfunction)
ME-26
equipped with VSC) (Vehicles equipped with VSC)
Tachometer malfunction See troubleshooting flowchart (tachometer malfunction) ME-19
See troubleshooting flowchart (fuel receiver gauge malfunc-
Fuel receiver gauge malfunction ME-21
tion)
See troubleshooting flowchart (water temperature warning
Water temperature warning light malfunction ME-24
light malfunction)
INDICATOR / WARNING LIGHTS

Check LED ME-1
Check vehicle W/H and connectors (combination meter ←→
Check engine warning light malfunction -
ECM)
Inspect engine ECU ES-16
GETtheMANUALS.org

Check LED ME-1
Check vehicle W/H and connectors (alternator ←→ combina-
-
Charge warning light malfunction tion meter)
Alternator L terminal -
Replace combination meter assembly -
Check LED ME-1
Inspect engine oil pressure switch assembly ME-33
Oil pressure warning light malfunction Check vehicle W/H and connectors (engine oil pressure switch
-
←→ combination meter)
CAN communication system CA-24
A/T shift position indicator light (P, R, N, D) malfunction
Brake warning light malfunction (vehicles without ABS Check LED ME-1
or VSC) See troubleshooting flowchart (brake warning light remains on) BC-123
Check LED ME-1
See troubleshooting flowchart (ABS warning light remains on)
BC-43
ME ABS warning light malfunction (vehicles without VSC)
See troubleshooting flowchart (ABS warning light remains on)
BC-120
(vehicles with VSC)
Check LED ME-1
Slip indicator light malfunction
See troubleshooting flowchart (VSC warning light is on but no
BC-135
VSC warning light malfunction trouble code is output) (vehicles with VSC)
Inspect combination meter assembly ME-16
Check vehicle wire harness and connectors (downhill assist
Downhill assist control OFF indicator light malfunction -
control OFF switch ←→ combination meter)
Replace combination meter -
Check LED ME-1
SRS airbag warning light malfunction See troubleshooting flowchart (warning light remains on) RS-155
High beam indicator light malfunction Check vehicle wire harness and connectors (headlight dimmer
-
switch ←→ combination meter)
Turn indicator light malfunction (lighting system oper-
ates normally) Check vehicle wire harness and connectors (flasher relay ←→
-
combination meter)
Check vehicle wire harness and connectors (front fog light
Front fog indicator light malfunction -
switch, front fog light relay ←→ combination meter)
Rear fog indicator light malfunction (front fog light Check vehicle wire harness and connectors (rear fog light
-
operates normally) switch ←→ combination meter)
Inspect indicator assembly ME-37
Door warning light malfunction (courtesy light switches
and room light assembly No. 3 operate normally)
Fuel level warning light malfunction (fuel gauge oper- Inspect combination meter assembly ME-16
ates normally) Replace combination meter assembly -
GETtheMANUALS.org
ME–8

Driver's seat belt warning light malfunction Seat belt warning system SB-2
Passenger seat belt warning light malfunction Seat belt warning system SB-2
BUZZER FUNCTION
None of the buzzers sound Replace combination meter assembly -
A/T reverse buzzer malfunction (shift position R is nor- Replace combination meter assembly
-
mal)
Light reminder buzzer malfunction (lighting system is Replace combination meter assembly
normal/door warning turns on when driver side door is -
opened)
Seat belt warning system SB-2
Seat belt buzzer malfunction (warning light is normal)
Key reminder warning buzzer malfunction

Key reminder warning system DL-58 ME
Multi information display

The clock, average fuel consumption, current fuel con- Replace combination meter assembly
sumption, possible travel distance, or altitude are very -
inaccurate (other meter functions are normal)
Check vehicle wire harness and connectors (combination
Pressing MODE switch does not change multi-display -
meter assembly ←→ MODE switch)
indication
Inspect combination meter assembly (MODE SW terminal) ME-16
OTHER FUNCTIONS
ODO /TRIP liquid crystal display malfunction (speed- Replace combination meter assembly
-
ometer function is normal)
Go to heater and air conditioning system AC-15
Ambient temperature indication malfunction
Multi-display malfunction Replace combination meter assembly -

SHOOTING
HINT:
See page ME-11.
Result Proceed to
Symptoms can be confirmed A
GETtheMANUALS.org
Result Proceed to
Symptoms cannot be confirmed B
B GO TO SYMPTOM SIMULATION (IN-33)
3 CHECK LIN COMMUNICATION SYSTEM
HINT:
See page MP-3.
Result Proceed to
No problem A
There is a problem B
B GO TO LIN COMMUNICATION SYSTEM SEC-

TION (MP-2)
ME
A
4 CHECK CAN COMMUNICATION SYSTEM
SST 09991-70300
HINT:
See page CA-10.
Result Proceed to
No problem A
There is a problem B
B GO TO CAN COMMUNICATION SYSTEM

SECTION (CA-5)
HINT:
See page ME-6.
Result Proceed to
B GO TO STEP 7
GETtheMANUALS.org
ME–10
(a) CHECK FUNCTION (See page ME-1.)

(b) ECU terminals (See page ME-16.)
(c) INSPECTION
8 CONFIRMATION TEST
ME
END
GETtheMANUALS.org

CHECK
Combination Meter System Check Sheet Inspector’s Name:
License Plate No.

Customer’s Name
First Registration Year
Frame No.
Date Vehicle Brought In / / Odometer Reading km
Date Problem First Occured / /
Frequency Problem Occurs Constant Occasionally ___times/day

ME
Weather Clear Cloudy Rainy Others ( )
Ambient Air Temperature Approximately °C
Speedometer operation malfunction

Fails to move Large discrepancy Others ( )
Tachometer operation malfunction

Fuel gauge operation malfunction
Coolant temperature gauge operation malfunction
Problem Indicator/warning light does not illuminate (___________light)

Symptoms
Indicator/warning light always illuminates (___________light)
Buzzer does not sound ( Buzzer)
Others
E058690J04
GETtheMANUALS.org
ME–12
DIAGNOSIS SYSTEM
1. DTC CHECK (read from meter LCD display) (See page MP-3)
(a) With the ignition switch in the OFF position, short the circuit
between terminals 13 (ECUT) and 4 (E) of the DLC.
(b) Turn the ignition switch to the ON position and read the DTCs
displayed on the LCD in the meter.
HINT:
The following DTCs appear on the meter LCD.
DTC No. DTC designation

0011 ITC Communication error (See page MP-8.)
0021 Short to communication line / Short to communication circuit inside
ECU
(See page MP-12.)
0045(*1) Door lock signal reception status
0046(*1) Door unlock signal reception status
0047(*1) Line registration initiation signal reception status
0048(*1) Line registration completion signal reception status
0051 EFI ECU Communication error (See page CA-30 for details) ME
0052 E-A/T communication error (See page CA-24 for details)
0053 ABS ECU Communication error (See page CA-24 for details)
0054 Helm sensor communication error (See page CA-26 for details)
0055 Yaw and G sensor communication error (See page CA-28 for details)
0056(*2) Auto air conditioner communication error (See page CA-32 for
details.)
HINT:
• *1: These DTCs are for inspection and do not indicate any
error.
• *2: The DTC for automatic air conditioner communication
error appearing on manual air conditioners does not indicate
an error.
(c) Correct the contents of each DTC.
(d) Once again short the DLC and read the DTCs. Check and
make sure that none of the above DTCs (except *1, including *2
for vehicles with manual air conditioning) are output.
GETtheMANUALS.org
CIRCUIT DIAGRAM
S-GND 15 Buzzer
EFI ECU
4P OUT 7
Buffer Circuit
Mode SW
(ODO/TRIP SW)
System 13 +B
Power
MODE SW 3
2 KEY
Adjustment SW
SENDER 8
SPEED Key SW
D BELT OUT 39
Indicator Assembly
38 TACHO
P BELT OUT
CPU
Seat D Buckle SW D BELT IN 35
FUEL
Seat P Buckle SW
P BELT IN 4
ME Seat Sensor
LCD
Odo/Trip
Multi-display
Door Control
Relay ECU
Multiple LIN 37
Load Signal (LIN)
CANH 21
EFI
A/T CAN
TEMP HOT
DVS CANL 22 IC
TEMP COLD
Terminal ECU T 10
ABS EFI ECU SLIP
VSC
Courtesy SW CTY 9
VSC OFF
TCS OFF SW DAC

TCS OFF 34
TSC OFF
DAC SW
DAC 5 LOW FUEL
With VSC
PKB SW PKB 36 O/D OFF
A/T P
CHG
31 A/T R
A/T N
IG2
A/T D
A/T 2
A/T L 12
Alternator
E132252
GETtheMANUALS.org
ME–14
W/ VSC
ABS
PKB SW
BRAKE
W/O VSC BRAKE FLUID

LEVEL SW
CHG W/O ABS OR VSC
BRAKE
BRAKE FLUID
LEVEL SW
W/O VSC
W/ VSC
BRAKE 30 W/ ABS
BRAKE
(REVERSE ROTATION)
ME
BRAKE FLUID LEVEL SW ABS 25
ABS 26 BEAM+
ABS (REVERSE ROTATION)
ECU TURN L
29
W/O VSC AIR BAG FLASHER
PARKING RELAY
W/ ABS (REVERSE ROTATION) 28
BRAKE
TURN R
BEAM T/S SW
AIRBAG 40 AIR BAG
ECU
TURN L
DIMMER SW
W/ DIODE
BEAM+ 27 TRUN R
20 F FOG
OIL
CENTER
OIL 16
DEFROST
OIL PRESSURE SW CHK E/G 32 SW
CHK E/G 24
REAR FOG
17 SW
EFI ECU F.FOG
TAIL F.FOG SW
CENTER DEFROST
F.FOG FOG LIGHT
LIGHT RELAY
REAR FOG
1 TAIL SW
TAIL
7.5A
E132253
GETtheMANUALS.org
B14 2 1
THW
Engine Coolant
Temperature Information B6
E2
C2 Crankshaft Position Sensor

HCAN
B19 1
Engine Speed N1+
C1
LCAN Information B35
N1-
2
C6
W
ME
Neutral Start Switch Assembly

C15 4
P
B7 1
R
A41 A/T Shift Point Indicator C24 5

N
Reverse Buzzer C16 2
A49 2
8
L C25
C17 3
D
E131473J01
GETtheMANUALS.org
ME–16
ABS And Traction Actuator Assembly (VSC Equipped Vehicles)
CANH [BRAKE Warning Light]

CANL [ABS Warning Light]
[SLIP Warning Light]
[Buzzer Sound Request]
ME
E133863
ECU TERMINALS
1. COMBINATION METER ASSEMBLY
(a) Check input / output signals
needle from behind the vehicle's wire harness connector .
B068593J01
Connector A
TAIL ←→ Body ground Ignition switch ON,light control switch OFF 1 V or less
Input Voltage
(1 ←→ Body ground) → TAIL, HEAD → 10 to 14 V
KEY ←→ Body ground Ignition key is not in key cylinder 1 V or less
Input Voltage
(2 ←→ Body ground) → Ignition key is in key cylinder → 10 to 14 V
GETtheMANUALS.org

MODE SW ←→ Body
Ignition switch ON, MODE switch OFF between 1 V or less and
ground Input Voltage
→ ON 10 to 14V
P BELT IN- ←→ Body 1 V or less
Ignition switch ON, passenger seat occupied, seat belt
ground Input Voltage → between 1 V or less
unfastened → fastened
(4 ←→ Body ground) and 10 to 14V
Ignition switch ON, downhill assist control system OFF
DAC ←→ Body ground 1 V or less
Input Voltage indicator OFF
(5 ←→ Body ground) → 10 to 14 V
→ ON
SPEED ←→ Body ground Wave- Pulse is generated
Input Driving at approx. 20 km/h
(6 ←→ Body ground) form (Waveform 1)
4P OUT ←→ Body ground Wave- Pulse is generated
Output Driving at approx. 20 km/h
(7 ←→ Body ground) form (Waveform 1)
FUEL ←→ Body ground
Input Voltage Ignition switch ON, fuel F (full) ←→ E (empty) 1 V or less → 4 to 7 V
CTY ←→ Body ground 1 V or less
Input Voltage Door indicator OFF ←→ ON
ME ECU-T ←→ Body ground

IG+ ←→ Body ground 1 V or less

Input Voltage Ignition switch OFF → ON
+B ←→ Body ground
- Voltage Always 10 to 14 V
GND ←→ Body ground
OIL ←→ Body ground 1 V or less
Input Voltage Ignition switch ON, oil pressure warning OFF ←→ ON
R FOG ←→ Body ground 1 V or less
Input Voltage Rear fog light indicator ON ←→ OFF
F FOG ←→ Body ground 1 V or less
Input Voltage Front fog light indicator OFF ←→ ON
CAN H
Input / Wave-
←→ Body ground Engine is stopped, ignition switch ON Pulse is generated
Output form
CAN L
Input / Wave-
←→ Body ground Engine is stopped, ignition switch ON Pulse is generated
Output form
CHK E/G
←→ Body ground Input Voltage Ignition switch ON, CHK E/G indicator ON → OFF 1 V or less → 10 to 14 V
ABS ←→ Body ground
Input Voltage Ignition switch ON, ABS indicator OFF → ON 2 V or less → 10 to 14 V
BEAM+ ←→ Body ground
Input Voltage High beam indicator light OFF → ON 1 V or less → 10 to 14 V
BEAM- ←→ Body ground
Input Voltage High beam warming ON ←→ OFF 1 V or less → 10 to 14 V
TURN R ←→ Body ground 1 V or less → between 1
Input Voltage Turn right indicator OFF → blinking
(28 ←→ Body ground) V or less and 10 to 14V
TURN L ←→ Body ground 1 V or less → between 1
Input Voltage Turn left indicator OFF → blinking
(29 ←→ Body ground) V or less and 10 to 14V
BRAKE (vehicles without
VSC) ←→ Body ground Input Voltage Ignition switch ON, parking brake ON → OFF 1 V or less → 10 to 14 V
CHG ←→ Body ground
Input Voltage CHG warning ON ←→ OFF 1 V or less → 10 to 14 V
GETtheMANUALS.org
ME–18

Center differential lock ←→
Ignition switch ON, center differential lock switch
Body ground Input Voltage 1 V or less → 10 to 14 V
OFF ←→ ON
KLS ←→ Body ground
Input Voltage Keyless switch ON ←→ OFF 1 V or less → 10 to 14 V
TCS OFF ←→ Body ground
Input Voltage Ignition switch ON, TCS OFF switch ON ←→ OFF 1 V or less → 10 to 14 V
D BELT IN ←→ Body
Ignition switch ON, driver side seat belt fastened →
ground Input Voltage 1 V or less → 10 to 14 V
unfastened
PKB (vehicles with VSC)
←→ Body ground Input d Voltage Ignition switch ON, parking brake indicator ON ←→ OFF 1 V or less → 10 to 14 V
LIN ←→ Body ground Input /
(37 ←→ Body ground) Output
P BELT OUT ←→ Body
Ignition switch ON, passenger side seat belt fastened →
ground Output Voltage 1.5 V or less → 10 to 14 V
unfastened
D BELT OUT ←→ Body
ME
Ignition switch ON, driver side seat belt fastened →
ground Output Voltage 1.5 V or less → 10 to 14 V
unfastened
AIR BAG ←→ Body ground
Input Voltage Ignition switch ON, AIR BAG warning OFF ←→ ON 1 V or less → 10 to 14 V
(2) Waveform 1
Item Condition
Tester Connection 4P, Speed input ←→ Body ground
Measurement Condition Driving at approx. 20 km/h
HINT:
As vehicle speed increases, the cycle becomes shorter.
A005135
GETtheMANUALS.org
TACHOMETER MALFUNCTION
CIRCUIT DIAGRAM
Combination Meter Assembly Engine Control Computer
Engine Speed Values

(CAN Communication)
ME
E109324J01
1 CHECK FOR DTCS (METER LCD)
SST 09843-18020
(a) Check that the meter LCD does not display CAN system DTCs (DTCs
no. 0051, 52 and 53).
(1) Check for DTC output (See page MP-3)
DTCs are not output A

DTCs 0051, 52 and 53 are output B
B GO TO TROUBLESHOOTING FOR CAN

COMMUNICATION SYSTEM
2 CHECK DTC OUTPUT (ENGINE CONTROL COMPUTER)

Standard:
DTCs P0335/13 and U1002/88 are not output
The abovementioned DTCs are not out- A

put
The abovementioned DTCs are output B
GETtheMANUALS.org
ME–20
B GO TO EFI SYSTEM (DTC SYNOPSIS)
3 CHECK POWER SYSTEM (COMBINATION METER ASSEMBLY)
(a) Using a tester, check the voltage between the combination meter
assembly vehicle side connector of the power terminal and the
ground terminal and the body ground.

CONNECTOR
OK
4 CHECK POWER SYSTEM (ENGINE CONTROL COMPUTER)
(a) Using a tester, check the engine control computer of the power sys- ME
tem. (See page ES-120.)

CONNECTOR
OK
REPLACE COMBINATION METER ASSEMBLY (IF NO IMPROVEMENT IS SEEN,

REPLACE ENGINE CONTROL COMPUTER)
GETtheMANUALS.org
FUEL RECEIVER GAUGE MALFUNCTION

HINT:
If the fuel level warning light operates properly, the combination meter assembly is malfunctioning.
CIRCUIT DIAGRAM
FUEL SENDER GAUGE

COMBINATION METER ASSEMBLY ASSEMBLY WITH FUEL PUMP
8 2 3
ME
E131187
1 INSPECT COMBINATION METER ASSEMBLY

(b) Using the tester, measure the voltage at terminal 8 (FUEL) with the
combination meter assembly connector connected.
NG REPLACE COMBINATION METER ASSEM-

BLY
OK
2 INSPECT FUEL SENDER GAUGE ASSEMBLY
(a) FUEL SENDER GAUGE ASSEMBLY

(1) Using the tester, check for continuity between the specified ter-
Fuel Sender Gauge Assembly minals on the connector of the fuel sender gauge assembly with
With Fuel Pump fuel pump.
Standard:
F Tester Connection
S
Sender gauge (main) Standard
with fuel pump
E101630J13 Terminal 2 (S) ←→ Terminal 3 (FE) Continuity
NG GO TO STEP 3
GETtheMANUALS.org
ME–22
OK
3 CHECK OPERATION AFTER SHORT CIRCUITING (FUEL SENDER VEHICLE WIRE HARNESS SIDE)
SST 09843-18020
(a) Check operation
(1) Disconnect the connector of the fuel sender gauge assembly
Fuel Sender Gauge with fuel pump.
Assembly With Fuel Pump (2) Using the SST, create a short circuit between the specified ter-
minals of the vehicle wire harness side connector.
Sender Gauge Terminals to be shorted

Fuel sender gauge assembly with fuel
Terminal 2 (S) ←→ Terminal 3 (FE)
pump
(3) Disconnect the negative battery terminal, and reconnect it.

E110982J01
(4) Check the status of the fuel receiver gauge indication when the
ignition switch is turned to the ON position.
Standard:
Points above F
ME
NG GO TO STEP 5
OK
4 CHECK WIRE HARNESS OR CONNECTOR (BETWEEN METER AND SENDER GAUGE)
HINT:
(a) Between combination meter and fuel sender assembly with fuel pump
(1) Disconnect the connectors of the combination meter assembly
and the fuel sender gauge assembly with fuel pump.
(2) Using the tester, check the wire harnesses between the combi-
nation meter assembly and the fuel sender gauge assembly
with fuel pump. (For terminal layout, see page ME-16.)
Standard:
Tester Connection Item Standard

Continu- There is continuity and there is no
A8 (FUEL) ←→ 2 (S)
ity short to +B or GND
NG REPLACE COMBINATION METER ASSEM-

BLY
OK
5 INSPECT FUEL SENDER GAUGE ASSEMBLY
GETtheMANUALS.org
CAUTION:
Be extremely careful with fire.
(1) Check that the float moves smoothly between the F level (upper
position) and E level (lower position).
Upper End
Lower End
E074278
(2) Using the tester, measure the resistance between terminals 2

(S) and 1 (FE) of the connector when the float is placed in both
the upper and lower positions. Also, check that the resistance
continuously changes.
Standard:
ME FE
Float Position Specified Value (Ω)
F (upper position) 15.0±1.5
S E (lower position) 410.0±4.5
E068605J01
NG REPLACE FUEL SENDER GAUGE ASSEM-

BLY
OK
NORMAL (POOR INSTALLATION OF THE FUEL SENDER GAUGE ASSEMBLY)
GETtheMANUALS.org
ME–24
Water Temperature Receiver Gauge Malfunction

CIRCUIT DIAGRAM
THW THW
E2 E2
Coolant Temperature Data

(CAN Communication ) E075444J02
ME
SST 09843-18040
(a) Check that the meter LCD does not display DTC s relating to CAN
system (DTCs No. 0051, 52 and 53).
(b) Check for DTCs (See page MP-3)
DTCs are not output A

DTCs 0051, 52 and 53 are not output B

2 CHECK DTC OUTPUT (ENGINE CONTROL COMPUTER)

Standard:
DTCs P0115/42 and U1002/88 are not output

put
B GO TO EFI SYSTEM (DTC SYNOPSIS)
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(a) Using the tester, inspect the voltage between the terminal of the wire
harness side connector of the combination meter assembly and the
body ground.

CONNECTOR
OK
4 CHECK POWER SYSTEM (ENGINE CONTROL COMPUTER)
(a) Using the electrical tester, check the engine control computer of the
power system. (See page ES-120.)

ME CONNECTOR
OK

REPLACE ENGINE CONTROL COMPUTER)
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ME–26
Speedmeter Malfunction (Vehicles Equipped with VSC)

CIRCUIT DIAGRAM
ABS and Traction

Actuator Assembly (VSC
Combination Meter Assembly Equipped Vehicles)
Vehicle Speed Information

(CAN Communication)
E134152
ME
SST 09843-18020
(a) Check that the meter LCD does not display DTC s relating to CAN
system (DTCs No. 0051, 52 and 53).
(1) Check for DTCs (See page MP-3)
DTCs 0051, 52 and 53 are not output A

DTCs 0051, 52 and 53 are output B

2 CHECK FOR DTCs (ABS ECU)

Standard:
DTCs C0200/21, C0205/22, C0210/23, C0215/24, C0235/25,
C0236/26, C0238/27, C0239/28, C1241/15 and C1301/79 are not
output.

put
B GO TO ABS WITH EBD & TRC & VSC & BA

SYSTEM
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(a) Using a tester, measure the voltage between the combination meter

CONNECTOR
OK
4 CHECK POWER SYSTEM (ABS AND TRACTION ACTUATOR ASSEMBLY)
(a) Using a tester, measure the voltage between the ABS / traction actu-
ator assembly vehicle side connector of the power terminal and the
ME ground terminal and the body ground.

CONNECTOR
OK

REPLACE ABS / TRACTION ACTUATOR ASSEMBLY)
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ME–28
Speedometer Malfunction (Vehicles without VSC)

CIRCUIT DIAGRAM
Brake Actuator Assembly

Combination Meter Assembly (VSC Non-equipped Vehicles)
SPEED 6 26 VOUT
Vehicle Speed Information
E134151
ME
1 CHECK VEHICLE SPEED SIGNAL INPUT
(a) CHECK VEHICLE SPEED SIGNAL OUTPUT (See page MP-3.)
NG GO TO STEP 3
OK
(a) Using a tester, check the voltage between the combination meter

CONNECTOR
OK
3 CHECK FOR DTCs (ABS ECU)

Standard:
DTCs C0200/21, C0205/22, C0210/23, C0215/24, C0235/25,
C0236/26, C0238/27, C0239/28, C1241/15 and C1301/79 are not
displayed.
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put
B ABS WITH EBD SYSTEM (See Page BC-4)
4 CHECK POWER SYSTEM (BRAKE ACTUATOR ASSEMBLY)
(a) Using a tester, check the voltage between the power terminal of the
connector of brake actuator assembly and the body terminal and the
body ground.

CONNECTOR
OK
ME
5 INSPECT WIRE HARNESS AND CONNECTOR (BETWEEN COMBINATION METER ASSEMBLY AND
BRAKE ACTUATOR ASSEMBLY)
(a) Using a tester, check the continuity between the vehicle side 6
(SPEED) connector of the combination meter assembly and the vehi-
cle side connector 26 (VOUT) of the brake actuator assembly.

CONNECTOR
OK
REPLACE BRAKE ACTUATOR ASSEMBLY
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METER - COMBINATION METER ASSEMBLY
ME–30

BODY AND ELECTRICAL
METER
COMPONENTS
ME
INSTRUMENT CLUSTER FINISH PANEL
E128790J01
REMOVAL
2. REMOVE INSTRUMENT CLUSTER FINISH PANEL
(1) Disengage the clips and claws shown in the illustration, and
remove the instrument cluster finish panel.
: Clip
: Claw E127350J02
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ME–31 METER - COMBINATION METER ASSEMBLY
3. REMOVE COMBINATION METER ASSEMBLY

(1) Remove the 2 screws and disengage the 2 clips.
E127095
(2) Pull out the combination meter assembly as shown in the illustra-
tion.
(3) Disconnect the connector and wire harness clamp, and remove
the combination meter assembly.
ME
E127096
DISASSEMBLY
1. REMOVE COMBINATION METER GLASS
(1) Disengage the 7 claws and remove the combination meter glass.
REASSEMBLY
1. INSTALL COMBINATION METER GLASS
(1) Engage the 7 claws to install the combination meter glass.
INSTALLATION
1. INSTALL COMBINATION METER ASSEMBLY
(1) Connect the connector and wire harness clamp.
(2) Temporarily install the combination meter assembly to the vehicle
E127096J01
(3) Install the combination meter assembly with the 2 clips and the 2
screws.
E127095
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METER - COMBINATION METER ASSEMBLY
ME–32
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL

(1) Engage the 4 claws and the 5 clips, and install the instrument clus-
ter finish panel.
: Clip
: Claw E127350J02

ME
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ME–33 METER - ENGINE OIL PRESSURE SWITCH ASSEMBLY

BODY AND ELECTRICAL
METER
1. INSPECT ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a) Using the tester, check for continuity between the engine oil
pressure switch terminal and the body ground.
Standard:
When the engine is stopped there is continuity.
When the engine is running there is no continuity.
ME
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METER - FUEL SENDER GAUGE ASSEMBLY
ME–34

BODY AND ELECTRICAL
METER
INSPECTION
1. INSPECT FUEL SENDER GAUGE ASSEMBLY
CAUTION:
Be extremely careful with fire.
(1) Check that the float moves smoothly between the F level
(upper position) and E level (lower position).
Upper End
Lower End
E074279
ME
(2) Using the tester, measure the resistance between termi-
nals 2 (FS) and 1 (FE) of the connector when the float is
placed in the upper and lower positions. Also, check that
the resistance continuously changes.
Standard:
Float Position Specified Value (Ω)

F (upper position) 15.0±1.5
E (lower position) 410.0±4.5
E068605
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ME–35 METER - INDICATOR ASSEMBLY
INDICATOR ASSEMBLY
BODY AND ELECTRICAL
METER
COMPONENTS
RADIO TUNER OPENING COVER
STEREO COMPONENT TUBE ASSEMBLY

ME
AIR INLET DAMPER CONTROL CABLE
E132251J01
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METER - INDICATOR ASSEMBLY
ME–36
INDICATOR ASSEMBLY
ME
E129929J01
REMOVAL
Page IP-9)
2. DISCONNECT AIR MIX DAMPER CONTROL CABLE (See Page

IP-9)

Page IP-9)
4. DISCONNECT AIR INLET CONTROL CABLE (See Page IP-9)
5. REMOVE RADIO TUNER OPENING COVER (WITHOUT RADIO

RECEIVER)
6. REMOVE INSTRUMENT CLUSTER FINISH PANEL CTR (See Page

IP-9)
7. REMOVE STEREO COMPONENT TUNER ASSEMBLY (See Page

AV-35)
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ME–37 METER - INDICATOR ASSEMBLY
8. REMOVE INDICATOR ASSEMBLY

(a) Disengage the claw, and remove the indicator assembly by
pushing it in the direction indicated by the arrow.
INSTALLATION
E127790
1. INSTALL INDICATOR ASSEMBLY

(a) Insert the indicator assembly in the direction indicated by the
arrow and engage the claw.
2. INSTALL STEREO COMPONENT TUNER ASSEMBLY (See Page

AV-36)
ME 3. INSTALL RADIO TUNER OPENING COVER (WITHOUT RADIO

RECEIVER)
E130124
4. INSTALL STEREO COMPONENT TUNER ASSEMBLY (See Page
AV-36)
5. INSTALL AIR INLET DAMPER CONTROL CABLE (See Page IP-

20)
6. INSTALL DEFROSTER DAMPER CONTROL CABLE (See Page IP-

20)
7. INSTALL AIR MIX DAMPER CONTROL CABLE (See Page IP-21)
8. INSTALL INSTRUMENT CLUSTER FINISH PANEL CTR (See Page

IP-21)
INSPECTION
1. INSPECT INDICATOR ASSEMBLY
(a) Check warning light illumination status (excluding the turn indi-
cator light)
HINT:
See page ME-13 for the wiring diagram.
(1) Check that each light (LED) comes on when connecting
the battery lead to each terminal of the connector.
Standard:
E130125
Positive Battery Negative Battery
Light Name Connection Ter- Connection Termi-
minal nal
Driver side seat belt
1 2
warning
Passenger side seat belt
1 3
warning
Security
4 5
indicator
Airbag
1 6
OFF indicator
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TO INDEX
BODY AND ELECTRICAL
AUDIO AND VISUAL

AUDIO SYSTEM
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-1
DIAGNOSTIC TROUBLE CODE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . AV-2
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-5
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-5
HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . AV-9
CUSTOMER PROBLEM ANALYSIS CHECK SHEET. . . . . . . . . . . . . . . . . AV-12
DIAGNOSIS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-13
CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-18
ECU TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-20
RADIO SIGNAL CANNOT BE RECEIVED (POOR RECEPTION) . . . . . . . AV-22
NOISE ENTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-25
AUDIO AND VISUAL
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-29
FRONT SPEAKER ASSEMBLY NO. 1
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-30 AV
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-31
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-31
SPEAKER ASSEMBLY RR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-33
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-33
STEREO COMPONENT TUNER ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-35
ANTENNA ASSEMBLY (WITH HOLDER)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-44
ANTENNA CORD NO. 2
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-53
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV-56
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AV–1 AUDIO AND VISUAL - AUDIO SYSTEM
AUDIO SYSTEM
BODY AND
AUDIO ANDELECTRICAL
VISUAL
LOCATION
ENGINE COMPARTMENT FUSE BLOCK

-TAIL FUSE
AV
ANTENNA ASSEMBLY (WITH HOLDER )

FRONT SPEAKER
ASSEMBLY NO. 1 RH
STEREO COMPONENT SPEAKER
TUNER ASSEMBLY ASSEMBLY RR RH
FRONT SPEAKER
ASSEMBLY NO. 1 LH
SPEAKER ASSEMBLY RR LH
INSTRUMENT PANEL FUSE BLOCK

-ACC FUSE
E132178J01
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AUDIO AND VISUAL - AUDIO SYSTEM
AV–2

HINT:
• The following diagnostic trouble codes may appear during a service
inspection.
• Each device is described in the following order: physical address, parts
name.
1. PHYSICAL ADDRESS: 190, PARTS NAME: RADIO RECEIVER
ASSEMBLY
HINT:
• Logical address 01: Communication Control
• Logical address 60: Radio unit
• Logical address 62: CD-P
• Logical address 64: MD-P
Logical Address
Diagnostic
- Diagnostic Description Countermeasure Remarks
Item
Trouble Code
• The device storing this code
was once disconnected from
This code may be recorded
the system while the ignition
Check the power source system and even if no failure is detected,
01 - D6 No master
switch was turned to the ACC
or ON position.
the wire harness of the AVC-LAN com-
munication system of the stereo com-
depending on the condition of
the battery or the power
AV
• The master device was once
ponent tuner assembly. source wave when the engine
disconnected from the sys-
is started.
tem while this code was
being stored.
• The component indicated by
This code is recorded 180
the sub-code was once dis-
No response seconds after the power sup-
connected from the system Check the power source system and
to connec- ply of the component indi-
after the engine was started. the wire harness of the AVC-LAN com-
01 - D8 tion confir- cated by the sub-code is
• The component indicated by munication system of the component
mation disconnected with the igni-
the sub-code was discon- indicated by the sub-code.
command tion switch in the ACC or ON
nected from the system after
position.
the engine start.
• A component (sound or
visual system) that was func-
tioning before the engine was
turned off is disconnected
from the system while the This code may be recorded
ignition switch was in the Check the power source system and even if no failure is detected,
Last mode ACC or ON position. the wire harness of the AVC-LAN com- depending on the condition of
01 - D9
error • A component (sound or munication system of the component the battery or the power
visual system) that was func- indicated by the sub-code. source wave when the engine
tioning before the engine was is started.
turned off was disconnected
from the system while the
ignition switch was in the
ACC or ON positions.
1. Check the power source system
The component indicated by the
and the wire harness of the AVC-
sub-codes does not respond
LAN communication system of the
No response when sound or visual modes are
component indicated by the sub-
01 - DA to ON / OFF changed. (This code is detected -
code.
command when the display or the sound
2. If the error still occurs, replace the
does not change when the but-
component indicated by the sub-
tons are operated.)
code.
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Logical Address
Diagnostic
Item
Trouble Code
Check the power source system and even if no failure is detected,
Echoing is detected from the
Mode status the wire harness of the AVC-LAN com- depending on the condition of
01 - DB component indicated by the sub-
error munication system of the component the battery or the power
code.
indicated by the sub-code. source wave when the engine
is started.
1. If the same sub-code is recorded
for the other components, check
the power source system and the
A transmission failure has wire harness of the AVC-LAN
occurred in relation to the compo- communication system of the
Failure in by turning the ignition switch
01 - DC nent indicated by the sub-code. component indicated by the sub-
transmission on after the engine has been
(This code does not always indi- code.
on for at least 60 seconds.
cate a failure.) 2. If the same code does not is
recorded for any other component,
delete the DTC and wait for a
while.
1. Check the power source system
and the wire harness of the AVC-
Master reset The master component was dis- LAN communication system of the This code may be recorded
AV 01 - DD (momentary connected from the system after stereo component tuner assembly. by restarting the ignition after
interruption) the engine was started. 2. If the error reoccurs frequently, the engine has been started.
replace the stereo component
tuner assembly.
Check the power source system and
Slave reset A slave component was once dis- This code may be recorded
the wire harness of the AVC-LAN com-
01 - DE (momentary connected from the system after by restarting the ignition after
munication system of the component
interruption) the engine started. the engine has been started.
indicated by the sub-code.
• A component with a display
malfunctions and the master This code is recorded 210
function is switched to an Check the power source system and seconds after the power sup-
audio device. the wire harness of the AVC-LAN comply of the stereo component
01 - DF Master error
• A communication error munication system of the stereo com- tuner assembly is turned off
occurs between a sub-mas- ponent tuner assembly. with the ignition switch in the
ter (audio) component and ACC or ON position.
the master component.
Registration even if no failure is detected,
A registration complete com- This code is for engineering purposes
complete depending on the condition of
01 - E0 mand cannot be received from and it may be detected even when it
indication the battery or the power
the master. does not indicate a failure.
error source wave when the engine
is started.
Voice pro- Check the power source system and even if no failure is detected,
The amplifier detects that its out-
cessing the wire harness of the AVC-LAN com- depending on the condition of
01 - E1 put has stopped, but the source
component munication system of the stereo com- the battery or the power
component is still operating.
ON error ponent tuner assembly. source wave when the engine
is started.
ON / OFF
An error occurred in the com-
indication Replace the stereo component tuner
01 - E2 mand controlling the ON / OFF -
parameter assembly
by the master component.
error
GETtheMANUALS.org
AV–4
Logical Address
Diagnostic
Item
Trouble Code
• A registration demand com-
mand is output from the com-
ponent indicated by the sub-
even if no failure is detected,
Registration code This code is for engineering purposes
depending on the condition of
01 - E3 demand • A registration demand com- and it may be detected even when it
the battery or the power
transmission mand is output when a con- does not indicate a failure.
source wave when the engine
nection confirmation
is started.
command is received from a
sub-master component.
even if no failure is detected,
Multiple This code is for engineering purposes
The multiple frame transmission depending on the condition of
01 - E4 frame and it may be detected even when it
is incomplete. the battery or the power
incomplete does not indicate a failure.
source wave when the engine
is started.
• Delete the DTC and check the wir-
ing of the radio antenna.
FM tuner
• Recheck the symptom after delet-
60-11 PLL lock fail- FM tuner PLL circuit malfunction -
ing the DTC, and replace the ste-
ure
reo component tuner assembly if
the same code is detected. AV
AM tuner Replace the stereo component tuner
60-43 AM tuner malfunction -
FM tuner Replace the stereo component tuner
60-44 FM tuner malfunction -
1. Check the CD (for cracks, etc.).
(Retry with another CD.)
2. Clean the CD player (the pick-up
CD disc read The CD disc signal cannot be lens).
62-42 -
error read. 3. Recheck the symptom after delet-
the same code is detected.
1. Check the CD (for cracks, etc.).
2. Check for foreign matters in the
component.
CD malfunc-
62-44 CD mechanism function failure 3. Recheck the symptom after delet- -
tion
1. Replace the CD.
2. Recheck the symptom after delet-
62-45 EJECT error The CD cannot be ejected. ing the DTC, and replace the ste- -
1. Check the CD. (Retry with another
The CD is CD.)
dirty, dam- 2. Clean the CD.
• The CD is dirty or damaged.
62-46 aged, or 3. Recheck the symptom after delet- -
• The CD is upside down.
upside ing the DTC, and replace the ste-
down. reo component tuner assembly if
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GENERAL
Fuses (DOME,ACC) -
Pressing the power switch does not turn on the system
Replace the stereo component tuner assembly -
The night light of the stereo component tuner assem- Fuse (TAIL) -
bly does not come on Replace the stereo component tuner assembly -
Check the lighting of all the elements AV-13
Liquid crystal display error
Switches
Check if there is any foreign matter jammed around the -
switches that have problems
The panel switches do not operate
Check the panel switch (all elements lighting mode) -
AUDIO GENERAL
Check front speaker assembly No. 1 AV-31
AV Check speaker assembly RR AV-33
In all modes, there is no sound, or a low volume of or a Check the wire harness and connectors of the vehicle AV-20
bad quality of sound from certain speakers (between the stereo component tuner assembly and the
speaker that has the problem)
DESCRIPTION
1. RADIO FREQUENCY BAND
(a) The table below describes the radio frequency bands currently
used for radio broadcasting.
Frequency
Name
Radio
Frequency
Modulation Type Amplitude Modulation Frequency Modulation
Low Frequency
Medium Frequency
High Frequency
Very High Frequency
E050001
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AV–6
2. SERVICE AREA
(a) FM stereo broadcasting can be unavailable even where AM
broadcasting is available without any inconvenience as there is
a significant difference in their service areas. In addition to the
smaller service area, FM stereo broadcasting can be easily
affected by noise or other interference (such as phasing noise,
FM Stereo
multi-path noise or fade out).
FM Monoaural
3. RADIO RECEPTION PROBLEMS
HINT:
E050005 Besides noise problems, there are other problems called phasing
noise, multi-path noise or fade out. These problems do not occur due
to electrical noise. They occur because of the quality of the radio
waves themselves.
(a) Phasing noise
Ionosphere
(1) In addition to electrical interference, AM broadcasts are
susceptible to another form of interference, especially at
night. At night, AM radio waves are reflected off the iono-
sphere. These reflected waves can interfere with the signal
received by the vehicle antenna directly from the transmit-
ter. This interference is called PHASING NOISE.
AV
E050006
(b) Multi-path noise

Multi-Path (1) Interference caused when radio waves are reflected off
obstructions is called MULTI-PATH. The MULTI-PATH
occurs when signals from radio broadcasting are reflected
off buildings or mountains, and interfere with the signal that
is directly received. The noise caused by this interference is
called MULTI-PATH NOISE.
E050007
(c) Fade out

Fade Out (1) FM radio waves are of a higher frequency than AM radio
waves. High frequency waves are easily deflected by
obstacles such as buildings or mountains. Therefore, the
FM signal may fade out or become weaker when obstacles
such as buildings come between the vehicle and the trans-
mitter. This interference is called fade out.
4. NOISE PROBLEMS
(a) Noise symptom questionnaire
E050008 (1) When troubleshooting noise problems, it is very important
to understand the customer's complaints. Therefore, use
the questionnaire below to diagnose the problem accu-
rately.
Broadcast Type Symptom Possible Cause

AM Noise occurs in a certain area There is a high possibility that the noise comes from outside.
The identical program is often being transmitted by multiple stations. In such
Noise occurs when listening to an inter-
AM case, there is a possibility that the appropriate program that a user should
mittent broadcast
select is not selected. This occurs especially in listening to NHK.
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Broadcast Type Symptom Possible Cause

There is a high possibility that radio waves from a distant transmitter are inter-
AM Noise occurs at night
fering.
Noise occurs while driving in a certain There is a high possibility that multi-path noise and phasing noise is occurring
FM
area because of changes in FM frequency.
HINT:
If the noise symptoms are not covered by the questionnaire
above, refer to RADIO RECEPTION PROBLEMS. Refer to
the sections regarding multi-path noise and phasing noise.
(b) Points to check when confirming noise problems
(1) Because the radio is equipped with a noise prevention
function, noise may not affect normal radio operation and
loud noise will not frequently occur. Therefore, if loud radio
noise occurs, check that the ground of the antenna mount-
ing base has been installed properly.
(2) Check that all of the specified noise prevention parts have
been installed correctly and that the wiring is correct. Also,
check that no non-specified parts have been used.
(3) To make it easier to determine the symptom, tune the radio
so that it is slightly off frequency. This will make the noise
AV easier to hear.
(c) Antenna and noise
Antenna (1) The electrical signal that is received by the antenna is
transmitted to the radio through the core wire of the co-axial
cable. If noise other than that from radio waves penetrates
Noise
Radio Receiver ASSY the cable, radio noise will occur and sound quality will
Signal worsen. To prevent such electrical noise from interfering
Noise with the radio, the core wire in the co-axial cable is wrapped
Noise
with woven mesh shielding wire. This shield wire prevents
noise interference by diverting current to the ground.
Noise E134206 HINT:
Noise occurs when the ground of the shield wire ground
has a problem.
5. CD
(a) Compatible discs
(1) This CD player is compatible with music CDs , CD-R (CD-
Recordable) and CD-RW (CD-Rewritable) discs labeled
with the marks shown in the illustration below.
E100925
(b) Precautions regarding discs and playback

NOTICE:
• Copy-control CDs are unavailable.
• Dual DISCs (discs with CD and DVD on opposite sides
of the same disc) are unavailable.
GETtheMANUALS.org
AV–8
• Occasionally CD-R or CD-RW cannot be played because

of recording or disc condition such as damage, dirt or
deterioration due to long exposure in the cabin environ-
ment.
• A CD-R or CD-RW that has not been finalized cannot be
played.
• Be careful not to get finger prints, dirt or scratches on
the discs.
• When handling discs, hold the edge and hole in the
middle with your fingers, and make sure that the labeled
side faces up.
• If a disc is left in the ejected position for a long period of
time, the disc may be damaged and become unplayable.
• If a CD is played that has tape, stickers, labels on it
(such as CD-R, rental or other labels) on its surface,
there is a possibility that the disc may not eject properly
and the component may be damaged.
• Store discs away from direct sunlight. (Direct sunlight
may be damage discs, causing them to be unplayable.)
• Only disc that is round shape and diameter 12 cm or 8
cm can be played.
• Do not use special shaped disc, because it may cause
AV
component failure.
• Do not use discs that have transparent or translucent
parts on the recordable area. These discs may not load
or eject properly.
• An adapter is not required in order to play a single CD
(8cm).
HINT:
• Low temperature or rain may condense inside the player in
the same manner as the glass fogs up. Under these condi-
tions, CDs may skip or stop playing. If so, stop the player
and allow it to air out and dehumidify before playing.
• CDs may skip if the player vibrates when driving over rough
surfaces.
(c) Cleaning
NOTICE:
Do not use lens cleaner because it may damage the pick-up
part of the player.
(1) Wipe the disc with a soft, dry cloth such as an lens cleaning
cloth for use with eye glasses. Lightly wipe the disc, work-
ing radially from the center to the edge.
NOTICE:
• The disc may be damaged if the surface is pressed
E050013 hard with fingers or rubbed with a rough cloth.
• Disc may be damaged and rendered unplayable by
the use of treated rages or solvents like record
cleaner, antistatic additive, alcohol, benzene or thin-
ner.
6. COMMUNICATION SYSTEM
(a) If components other than those available at the dealer have
been installed, the components of the audio system may not be
able to communicate with each other via the AVC-LAN.
GETtheMANUALS.org
(b) The master component of the AVC-LAN is the stereo compo-

nent tuner assembly. It has the resistance (a resistance of 60 to
80 , between terminal TX+ and terminal TX-) that is necessary
for communication with the stereo component tuner assembly.
(c) If there is an open or short circuit in the AVC-LAN, the audio
system will not function normally as communication will not be
possible.
7. DIAGNOSIS FUNCTION
(a) The audio system has diagnosis functions (displayed on the liq-
uid crystal display of the stereo component tuner assembly).
(b) A 3-digit component code (physical address) number (in hexa-
decimals) is set in each function of the components that make
up the AVC-LAN.
(c) A 2-digit component code (logical address) number (in hexa-
decimals) is set in each function of the components that make
up the AVC-LAN.

SHOOTING
AV
HINT:
For customer problem analysis check, see page AV-12.
3 BASIC INSPECTION
SST 09082-00030
(a) Basic inspection
(1) Using a tester, measure the voltage of the battery.
Standard:
10 to 14 V (when the engine is stopped)
(2) Visually check for broken fuses, disconnected wire harnesses,
short circuits and connectors with bad connections.
4 CHECK POWER SOURCE SUPPLY TO STEREO COMPONENT TUNER ASSEMBLY
(a) CHECK THAT LIQUID CRYSTAL ILLUMINATION OF STEREO

COMPONENT TUNER ASSEMBLY COMES ON
(1) Turn the ignition switch to the ACC or ON positions.
GETtheMANUALS.org
AV–10
(2) When the audio power switch is turned ON, make sure the back
light of the stereo component tuner assembly illuminates and
the liquid crystal is displayed.
LIQUID CRYSTAL ILLUMINATION DOES NOT

COME ON (PROBLEM SYMPTOMS TABLE:
PRESSING POWER SWITCH DOES NOT
TURN ON SYSTEM [See page AV-5.])
NO PROBLEM (GO TO STEP 5)
5 Check for DTCs.
HINT:
See page AV-13.
(a) Check for DTCs.
(1) Record the DTCs. AV
(b) Delete the DTCs.
(c) Recheck for DTCs.
(1) Based on the DTCs recorded, reproduce the symptoms that
caused the problem and recheck for the DTCs.
HINT:
When outputting the DTC, see DIAGNOSTIC TROUBLE CODE
CHART (AV-13).
DTC DETECTED (GO TO STEP 7)
UNABLE TO DETECT DTC AND UNABLE TO

REPRODUCE PROBLEM [PERFORM MAL-
FUNCTION SIMULATION] (SEE PAGE IN-33)
UNABLE TO DETECT DTC BUT ABLE TO REPRODUCE PROBLEM (GO TO STEP 6)
HINT:
See page AV-5.
RELATED TO PROBLEM SYMPTOM (GO TO

STEP 8)
NOT LISTED IN PROBLEM SYMPTOM TABLE (GO TO STEP 7)
GETtheMANUALS.org
(a) ECU terminals (See page AV-20.)
8 CHECK OR REPLACE
9 CONFIRMATION TEST
END
AV
GETtheMANUALS.org
AV–12

CHECK

Audio Problem Diagnosis Check Sheet / /
Customer’s name License Plate No. First Registration Year
Model VIN
Inspector’s
Written By name Engine Type Odometer Reading km

Condition (Method of use and results)
AV
Weather Clear Cloudy Rainy Snowy Others ( ) Air Temperature Approx. ( )°C
Switch
Radio
Problem
Symptoms
CD
Static
Device Name (Physical address) First DTC Second DTC

Radio Receiver Assembly (190)
DTC Check
E073773
GETtheMANUALS.org
DIAGNOSIS SYSTEM
1. INSPECT DIAGNOSIS MODE
(a) Start the diagnosis mode.
(1) When the audio is OFF and the ignition switch is in the ON
or ACC position, press the DISC switch 3 times while
pressing and holding preset buttons 1 and 6 at the same
time.
HINT:
After a beep sound sounds 3 times, start the the diagnosis
and go to the all elements lighting mode.
E130975J02 (b) All elements illumination mode
HINT:
The element display check and the panel switch operation
check are available in the all elements illumination mode.
AV
E130976
(1) Check that there are no problems with the illumination of

the elements.
(2) Make sure that a beep sound sounds when each of the
panel switches is pressed.
HINT:
Pressing the SEEK / TRACK UP switch, opens the service
inspection screen. Check the operation by changing
screens.
(c) Service inspection mode
(1) Press the SEEK / TRACK UP switch in the all elements illu-
mination mode.
HINT:
• The service inspection mode is displayed.
• It may take about 40 seconds to complete the inspec-
tion.
• When the service inspection mode is displayed, the
system inspection and the diagnosis memory inspection
starts. The results are listed in order beginning with the
lowest component code (physical address).
(d) Release diagnosis mode
(1) Press and hold DISC switch for 3 seconds or more. Or turn
the ignition switch to the OFF position.
GETtheMANUALS.org
AV–14
(e) The service inspection mode result (for inspecting current and
past system status)
(1) Use the SEEK / TRACK switch to check the result of each
Inspection component that is connected to the system.
<
results of the
<
Switch Switch
first device in
Term Contents
the system
Component Code (*1) Physical address of the target compo-
<
Switch Switch
<
nent
Inspection Inspection results (*2) After a diagnosis memory check and
results of the
<
<
Switch Switch system inspection of the target compo-

second device
in the system nent are performed, the present and
past component status inspection
<
<
Switch Switch results are displayed by the following

Devices in the system and those inspection six types: "good", "nCon (no connec-
results will bedisplayed in order
tion)", ECHn (exchange)", CHEC
<
<
Switch Switch (check)", "OLd (old)", nrES (no

response)"..
Connection check number (*3) The current connection check numbers
<
<
Switch Switch
To the first device are displayed.
in the system
From the first device in the system HINT:
• The illustration shows an example in which component
E123624
code 190 (radio receiver) and component code 360 (CD
changer) show in the system and there is a malfunction
AV
associated with component code 360.
• The inspection results are displayed in order, beginning
with the smallest component code (physical address)
followed by the inspection results for each component
code.
• In that event that components purchased at a dealer or
components that use the AVC-LAN system have not
been added, codes above component code 190 (radio
receiver assembly) will not be displayed.
Component Code (*1) Description
Term Definition
P Symbol that indicates a physical address
A 3-digit unique symbol (in hexadecimals) is set based on the functions in each component that
Physical address
makes up the AVC-LAN.
HINT:
Examples of physical addresses of connected optional com-
ponents are shown below.
• 3A0 : MD changer
• 360 : CD changer
Inspection Result (*2) Description
Displayed
Source Term Definition Countermeasure
Text
Good Neither SYSTEM CHECK CONFIRMATION nor DIAG-
good -
(normal) NOSTIC MEMORY RESPONSE is displayed.
Check the power source system and the
wire harness of the AVC-LAN communi-
No connection System is recognized during registration but the compo-
nCon cation system of the component indi-
(no connection) nent does not respond the to DIAGNOSIS ON command.
cated by the component code (physical
address).
DIAGNOSTIC ON CONFIRMATION confirms the item rele-
Go to the detailed information mode to
Exchange vant to the current diagnosis. In addition, 1 or more DTCs
ECHn check the trouble area indicated in the
(Exchange) for EXCHANGE are detected in either SYSTEM CHECK
DTC list.
RESULT MODE or DIAGNOSTIC MEMORY MODE.
GETtheMANUALS.org
Displayed
Source Term Definition Countermeasure
Text
vant to the current diagnosis. In addition, when no DTCs Go to the detailed information mode to
Check
CHEC are detected for EXCHANGE, one or more DTCs for check the trouble area indicated in the
(Check)
CHECK are detected in either SYSTEM CHECK MODE or DTC list.
DIAGNOSTIC MEMORY MODE.
Go to the detailed information mode to
Old vant to the current diagnosis. An old DTC application is
OLd check the trouble area indicated in the
(Old version) identified and a DTC is detected in either SYSTEM CHECK
DTC list.
RESULT MODE or DIAGNOSIS MEMORY MODE.
Check the power source system and the
The component gives no response to any one of SYSTEM wire harness of the AVC-LAN communi-
No response
nrES CHECK MODE ON REQUEST, SYSTEM CHECK RESULT cation system of the component indi-
(No response)
REQUEST and DIAGNOSIS MEMORY REQUEST. cated by the component code (physical
address).
(2) To restart the service check, press preset button 1.

HINT:
To restart the service check after the wire harness check,
turn the ignition switch OFF (IG) and then start from the
beginning.
AV (f) Detailed information mode (DTC codes for malfunctioning com-
ponents)
(1) When CHEC or ECHn is indicated, press preset button 2 to
Service Check Mode display the detailed information mode.
HINT:
In the detailed information mode, an underscore mark is
displayed in front of the physical address that describes the
<
<
Switch Switch component code, as shown in the illustration.
Preset Button “2”
Detailed Information
Display Mode
Preset Button “3”
E123625
GETtheMANUALS.org
AV–16
(2) Press the SEEK / TRACK switch to display SYSTEM

Detailed Information Display Mode CHECK RESULT (SyS) and DIAGNOSIS MEMORY
RESPONSE RESULT (COdE).
HINT:
• The illustration shows an example in which a system
<
check or diagnosis memory response shows that a
<
Switch Switch
component (CD changer) with device code 360 has
diagnosis codes 63-44 and 01-E4.
<
<
Switch Switch • The check result details are displayed in the following
Detailed order: SYSTEM CHECK RESULT (details are displayed
information after the characters, SyS), followed by DIAGNOSIS
for the
<
Switch
<
Switch MEMORY RESPONSE RESULT (details are displayed

first code of the
after the characters, COdE).
target device
(3) Confirm system check result.
<
<
Switch Switch HINT:

• System check results are displayed after the charac-
Displaying continues when
ters, SyS, are displayed.
there are multiple diagnosis codes
• System check results ate displayed in the following
<
<
Switch Switch order: component code → diagnostic trouble code.

System Check Result Display
Term Definition AV
<
<
Switch Switch Diagnostic trouble code A serial number that is added to the diagnosis code
number for each component code
A 2-digit code (in hexadecimals) given to each
<
<
Switch Switch Logical address function (unit) that make up the components of the
(*1) AVC-LAN device.
(L is the symbol of that it is logical address.)
Detailed
<
<
information
Switch Switch Diagnostic trouble code Diagnostic trouble code
(*2) (d indicates a diagnosis code.)
for the
second code (4) Check diagnosis memory response result.
<
<
of the Switch Switch HINT:

target device
• The diagnosis memory response result is displayed
after the characters, COdE.
<
Switch
<
Switch
• The diagnosis memory response result is displayed in
the following order: component code → diagnostic trou-
ble code → sub-code → connection check number →
<
Switch
<
Switch number of times of occurrence.

Displaying continues when
Diagnosis Memory Response Result Display
there are multiple diagnosis codes
Term Definition
<
<
Switch Switch Diagnostic trouble code A serial number that is added to the diagnosis code
Coming from number for each component code
A 2-digit code (in hexadecimals) given to each
Returning to Logical address function (unit) that make up the components of the
E123626
(*3) AVC-LAN device.
(L is the symbol of that it is logical address.)
Diagnostic trouble code Diagnostic trouble code
(*4) (d indicates a diagnosis code.)
The physical address is stored with the sub-code.
Sub-code (When there is no address information, --- is dis-
(*5) played.)
P indicates a physical address.)
The connection check number (in hexadecimals) is
displayed as a set with the diagnostic code. (When
Connection check number
there is no connection check number, -- is dis-
(*6)
played.)
(n indicates a connection check number.)
GETtheMANUALS.org
Term Definition
The number of times of occurrence is displayed as
a set with the diagnostic code. (The number of
Number of times of occur- identical occurrences is shown in multiples of ten.
rence So, for example, 0 is recorded for codes that occur
(*7) fewer than ten times. If there is no information
about the number of occurrences, -- is displayed.)
(c indicates the number of times of occurrence.)
(5) Check the trouble area referring to the diagnosis code

chart. (See page AV-2.)
(6) To return to the service check mode, press preset button 3.
(g) Clear the diagnostic trouble codes (individually).
(1) When ECHn (exchange) is displayed in the service check
mode or detail information mode, press and hold preset
button 5 for 2 seconds or more.
HINT:
• A beep sound sounds once when the memory clear
operation is complete.
• After the DTC memory is cleared, only the component
code (physical address) is displayed since the relevant
AV diagnosis information for the component has been

deleted.
• To confirm the DTC, press preset button 1 and restart
the service check.
(h) Clear the diagnostic trouble codes (all).
(1) After repair the trouble area, start the diagnosis mode.
(2) Press and hold preset button 5 for 2 seconds or more. (
CLr is displayed.)
HINT:
• A beep sound sounds once when the memory clear
operation is complete.
• After the DTC memory is cleared, only the component
code (physical address) is displayed since all of the
diagnosis information for the component has been
deleted.
(3) Press preset button 1 to restart the service check, and con-
firm that no DTCs are displayed for any of the component
codes (physical address).
GETtheMANUALS.org
AV–18
CIRCUIT DIAGRAM
1. CIRCUIT DIAGRAM
Stereo Component Tube Assembly
A
To Battery DO 1 Front Speaker
4 B FR 1 +
AC 2 Assembly NO. 1 (RH)
To IG 3 AC FR 5 -
TAIL
To Headlight 10 ILL+
Dimmer Switch 1
Assembly FL 2 + Front Speaker
2
FL- 6 - Assembly NO. 1 (LH)
GN 7
B
1 Speaker
RR 1 +
RR 3
2
- Assembly RR (RH) AV
1 Speaker
2 +
Antenna Assembly RL 2
6 - Assembly RR (LH)
RL
E133776J01
GETtheMANUALS.org
2. CONNECTOR CHART
Stereo Component Tuner Assembly
Front Speaker Assembly NO. 1 Speaker Assembly RR
AV
E131472J01
GETtheMANUALS.org
AV–20
ECU TERMINALS
1. Stereo Component Tuner Assembly
D C B A
Connector D
Connector A Connector B Connector C
AV
E130978J01
Connector A
Te
r
Tester Connec- Malfunction symptom when
mi
Terminal Input / tion Measurement Condi- the result is not as specified
na Item Standard
Symbol Output Positive (+) ←→ tion O: Open
l
Negative (-) S: Short to Body
N
o.
No sound from front speaker
Waveform synchro-
Wave- Audio system is play- assembly No. 1 (RH) and
1 FR+ Output A1←→ A7 nized with sound is
form ing speaker assembly FR No. 2
output
(RH)
Waveform synchro-
Wave- Audio system is play- assembly No. 1 (LH) and
2 FL+ Output A2 ←→ A7 nized with sound is
output
(LH)
O: System does not operate
3 ACC Input A3 ←→ A7 Voltage IG ACC 10 to 14 V
S: Blown fuse
O: System does not operate
4 B Input A4 ←→ A7 Voltage Always 10 to 14 V
S: Blown fuse
Waveform synchro-
Wave- Audio system is play- assembly No. 1 (RH) and
5 FR- Output A5 ←→ A7 nized with sound is
output
(RH)
GETtheMANUALS.org
Te
r
mi
na Item Standard
l
N
o.
Waveform synchro-
Wave- Audio system is play- assembly No. 1 (LH) and
6 FL- Output A6 ←→ A7 nized with sound is
output
(LH)
A7 ←→ Conti-
7 GND - Always Continuity O: Noise slightly increased
Body ground nuity
Headlight dimmer O: No light illuminates at night
10 ILL+ Input A10 ←→ A7 Voltage 10 to 14 V
switch TAIL S: Blown fuse
Connector B
Ter Malfunction symptom
Tester Connec-
mi when the result is not as
Terminal Input / tion Measurement Condi-
nal Item Standard specified
Symbol Output Positive (+) ←→ tion
No O: Open
Negative (-)
. S: Short to Body
AV 1 RR+ Output F1 ←→ A7
Wave-
Audio system is playing
Waveform synchro-
nized with sound is out-
No sound from speaker
form assembly RR (RH)
put
Waveform synchro-
Wave- No sound from speaker
2 RL+ Output F2 ←→ A7 Audio system is playing nized with sound is out-
form assembly RR (LH)
put
Waveform synchro-
3 RR- Output F3 ←→ A7 Audio system is playing nized with sound is out-
form assembly RR (RH)
put
Waveform synchro-
6 RL- Output F6 ←→ A7 Audio system is playing nized with sound is out-
form assembly RR (LH)
put
Connector C
Te
r
mi
na Item Standard
l
N
o.
Audio system is play- O: Popping sound
6 MUTE Input B6 ←→ A7 Voltage 3.5 V or more
ing S: No sound from speaker
GETtheMANUALS.org
AV–22
RADIO SIGNAL CANNOT BE RECEIVED (POOR RECEPTION)

1 CHECK RECEPTION AFTER CHANGING VEHICLE LOCATION
(a) Change vehicle location.

(1) Change vehicle location to be able to receive radio broadcast,
and check if it is functioning normally.
Standard:
Reception returns to normal
OK Normal (external factors like radio wave sta-

tus)
NG
2 CHECK ACCESSORY PARTS (WINDOW TINT FILM OR TELEPHONE ANTENNAS, ETC.)

AV
(a) CHECK ACCESSORY PARTS
(1) Check if any accessory parts, such as window tinting film or
telephone antennas, etc., have been installed.
Standard:
No accessory parts
NG Influence of accessory parts
OK
3 Check for antenna noise.
(a) Check for antenna noise.

(1) With the ignition switch in the ON or ACC position, turn on the
radio and set the radio to the AM mode.
(2) Remove the antenna rod.
(3) Touch a screwdriver to the screw that connects the antenna rod
of the antenna assembly, and check that noise is emitted from
the speaker.
Standard:
Noise is emitted from the speaker (scratching
sound).
OK CHECK AND REPLACE STEREO COMPO-

NENT TUNER ASSEMBLY
NG
4 CHECK ANTENNA CORD

(1) Make sure that the connection between the antenna holder and
the antenna cord is visible.
GETtheMANUALS.org
(2) Disconnect the connection between the antenna holder and the
antenna cord.
(b) Check for noise.
(1) Turn the ignition switch to the ON or ACC position while the ste-
reo component tuner assembly connector is connected.
(2) Turn on the radio and set it to the AM mode.
(3) Touch a screwdriver, thin wire, or other metal object to the
antenna jack of the antenna cord, and check that noise is emit-
ted from the speaker.
Standard:
Noise is emitted from the speaker (scratching sound).
OK REPLACE ANTENNA HOLDER
NG
5 CHECK ANTENNA CORD NO. 2

(1) Make sure that the connection between the antenna cord and
AV antenna cord No. 2 is visible.
(2) Disconnect the connector between the antenna cord and
antenna code No. 2.
antenna jack of antenna cord No. 2, and check that noise is
emitted from the speaker.
Standard:
NG REPLACE ANTENNA CORD NO. 2
OK
6 CHECK STEREO COMPONENT TUNER ASSEMBLY

(1) Prepare the stereo component tuner assembly for removal.
(2) Disconnect the antenna plug.
antenna jack of the stereo component tuner assembly No. 2,
and check that noise is emitted from the speaker.
Standard:
E120166
NG CHECK AND REPLACE STEREO COMPO-
NENT TUNER ASSEMBLY
GETtheMANUALS.org
AV–24
OK
REPLACE ANTENNA CORD
AV
GETtheMANUALS.org
NOISE ENTERS
1 CHECK NOISE CONTAMINATION MODE
(a) Check noise contamination source.

(1) Operate the stereo component tuner assembly, and check for
the source of the noise.
Standard:
Does noise occur only in radio mode or in all modes?
Result Proceed to
Noise occurs only in radio mode A
Noise occurs in all modes B
B Go To Step 8
A
AV
2 CHECK CONDITION WHEN ABNORMALITY OCCURS
(a) CHECK CONDITION WHEN ABNORMALITY OCCURS

(1) Check when (under what circumstances, location) noise occurs.
Standard:
Does noise occur only when driving in certain certain
areas or everywhere?
Result Proceed to
Noise occurs regardless of the location A
Noise sounds in only certain areas B
B Electromagnetic wave interference
3 CHECK ACCESSORY PARTS (WINDOW TINT FILM OR TELEPHONE ANTENNAS, ETC.)
(a) CHECK ACCESSORY PARTS

(1) Check if any accessory parts, such as window tinting film or
telephone antennas, etc., have been installed.
Standard:
Check that accessory parts are installed properly.
Result Proceed to
Accessory parts are installed properly. A
Accessory parts are not installed properly. B
HINT:
Noise contamination in the radio mode is partially prevented by
noise prevention in order to protect the radio from damage.
Therefore loud noise does not occur frequently. If loud noise
occurs, check the ground of the antenna connection, and check
GETtheMANUALS.org
AV–26
if the manufacturer-specified noise prevention parts have been

installed, or the wiring is connected properly.
B Influence of accessory parts
4 INSPECT ANTENNA ASSEMBLY (WITH HOLDER) (INSTALLATION CONDITION)
(a) Check the installation of the antenna holder.

(1) Check the condition of the antenna holder installation and
check that there are no loose areas, misalignment or other fail-
ures.
NG INSTALL PROPERLY
OK
5 CHECK ANTENNA PLUG REMOVAL (ANTENNA CORD)
(a) PREPARE FOR INSPECTION AV

(1) Make sure that the connection between the antenna holder and
the antenna cord is visible.
(2) Disconnect the connection between the antenna holder and the
antenna cord.
(1) Restart the stereo component tuner assembly with the antenna
plug removed from the antenna cord, and check if noise occurs.
Standard:
Noise does not occur.
OK REPLACE ANTENNA HOLDER
NG
6 CHECK ANTENNA PLUG REMOVAL (ANTENNA CORD NO. 2)

(1) Make sure that the connection between the antenna cord and
antenna cord No. 2 is visible.
(2) Disconnect the connector plug between the antenna cord and
antenna code No. 2.
(1) Restart the stereo component tuner assembly with the antenna
plug removed from antenna cord No. 2, and check if noise
occurs.
Standard:
OK REPLACE ANTENNA CORD
NG
GETtheMANUALS.org
7 CHECK ANTENNA PLUG REMOVAL (STEREO COMPONENT TUNER ASSEMBLY)

(1) Prepare the stereo component tuner assembly for removal.
(2) Remove the plug of antenna code No. 2
(1) With the antenna plug removed from stereo component tuner
assembly, restart the stereo component tuner assembly, and
check if noise occurs.
Standard:
OK REPLACE ANTENNA CORD NO. 2
NG
8 INSPECT SPEAKER INSTALLATION CONDITION
AV (a) Check the condition of the speaker installation and check that there
are no loose areas, misalignment or other failures.
(b) Check that there is no foreign matter in any of the speakers, no tears
in the speaker cones, or other abnormalities.
Standard
Result Proceed to
The speakers have no problems A
Speaker installation failure B
Foreign matter in the speaker C
Tears on the speaker cones D
B INSTALL SPEAKER CORRECTLY
C REMOVE CONTAMINANTS IN SPEAKERS
D REPLACE SPEAKER
9 IDENTIFY CAUSE OF NOISE CONTAMINATION
(a) See the diagnostic trouble code below and identify the cause of noise
contamination.
HINT:
• First make sure that the noise is not originating from outside the
vehicle. Make sure not to skip this check. If the check is not per-
formed, the source of the noise source may be unclear, resulting
in a misdiagnosis.
• Troubleshoot noise problems in order of loudness, starting with
the loudest noise.
• To make it easier to determine the symptom, tune the radio so that
it is slightly off frequency. This will make the noise easier to hear.
GETtheMANUALS.org
AV–28
Diagnostic Trouble Code Chart

Symptom Cause Of Noise Contamination
Depressing the accelerator pedal increases whine, and stopping the engine stops the noise imme-
Alternator noise
diately
The noise occurs when the air conditioning or heater is on Blower motor noise
A noise occurs when accelerating suddenly on rough road or the ignition switch is turned ON (IG) Fuel pump noise
A clicking sound when pressing and releasing the horn button, or a buzz sounding when the horn is
Horn noise
pressed and held
The noise (buzzing) stops when the ignition is turned off Ignition noise
A clattering noise when the turn signal is flashing Flasher noise
Noise when the window washer is operating Washer noise
A creaking noise that occurs when the engine is on and continues after the ignition is turned off Water temperature sensor noise
A rubbing sound when the wiper is operating Wiper noise
A popping sound when the brake pedal is depressed Stop lamp switch noise
Other Static electricity build up in the vehicle
Standard
Result Proceed to
Cause of noise contamination cannot be determined A
Cause of noise contamination can be determined B
AV
B REPLACE RELEVANT NOISE FILTERS
CHECK AND REPLACE STEREO COMPONENT TUNER ASSEMBLY
GETtheMANUALS.org
AV–29 AUDIO AND VISUAL - AUDIO AND VISUAL
AUDIO AND VISUAL

BODY AND
AUDIO ANDELECTRICAL
VISUAL
PRECAUTIONS
1. Explain to the customer that when the negative terminal is dis-
connected from the battery during this operation, the AM/FM
channel presets in the stereo component tuner assembly are
cleared. If resetting is required, record all stored channel infor-
mation and reset after connecting the negative terminal.
2. Eject all discs from the stereo component tuner assembly before
removal or installation.
HINT:
If the discs do not eject because of a malfunction, do not try to
remove them forcibly. Send the unit for repair service, as is.
3. Do not touch the cones of the speaker assembly.
AV
GETtheMANUALS.org
AUDIO AND VISUAL - FRONT SPEAKER ASSEMBLY NO. 1
AV–30

BODY AND
AUDIO ANDELECTRICAL
VISUAL
COMPONENTS

FRONT DOOR LOWER FRAME BRACKET GARNISH RH
FRONT DOOR TRIM BOARD RH
AV
DOOR ASSIST GRIP BASE
FRONT DOOR ASSIST GRIP COVER RH

E129906J01
REMOVAL
1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH
RH (See Page MI-5)
2. REMOVE FRONT DOOR ASSIST GRIP COVER RH (See Page ED-

11)
3. REMOVE DOOR ASSIST GRIP BASE (See Page ED-11)
4. REMOVE FRONT DOOR TRIM BOARD RH (See Page ED-11)
GETtheMANUALS.org
AV–31 AUDIO AND VISUAL - FRONT SPEAKER ASSEMBLY NO. 1
5. REMOVE FRONT SPEAKER ASSEMBLY NO. 1

(b) Remove the 3 bolts and the front speaker assembly No. 1.
INSTALLATION
E127786
1. INSTALL FRONT SPEAKER ASSEMBLY NO. 1

(a) Tighten the 3 bolts and install the front speaker assembly No. 1.
2. INSTALL FRONT DOOR TRIM BOARD RH
3. INSTALL DOOR ASSIST GRIP BASE
4. INSTALL FRONT DOOR ASSIST GRIP COVER RH
5. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH RH

AV E127786
INSPECTION
1. CHECK FRONT SPEAKER ASSEMBLY NO. 1
(a) Check the condition of the speaker installation and check that
there are no loose areas, misalignment or other failures.
(b) Make sure that there is no foreign matter in the speaker, no
tears on the speaker cone, or other abnormalities.
(c) Check the resistance.
(1) Remove the connector of the front speaker assembly No.
1.
speaker terminals.
Standard:
Approximately 4
HINT:
Check the resistance without removing the speakers.
GETtheMANUALS.org
AUDIO AND VISUAL - SPEAKER ASSEMBLY RR
AV–32
SPEAKER ASSEMBLY RR
BODY AND
AUDIO ANDELECTRICAL
VISUAL
COMPONENTS
REAR DOOR REAR GUIDE BRACKET GARNISH RH
REAR DOOR TRIM BOARD RH
SPEAKER
ASSEMBLY RR
AV

REAR DOOR INSIDE HANDLE RH
E129907J01
REMOVAL
1. REMOVE REAR DOOR DIVISION BAR INSIDE SEAL RH (See
Page ED-30)
2. REMOVE REAR DOOR REAR GUIDE BRACKET GARNISH RH

(See Page ED-30)
3. REMOVE REAR DOOR ASSIST GRIP COVER RH (See Page ED-

30)
4. REMOVE DOOR ASSIST GRIP BASE (See Page ED-30)
5. REMOVE REAR DOOR TRIM BOARD RH (See Page ED-30)
GETtheMANUALS.org
AV–33 AUDIO AND VISUAL - SPEAKER ASSEMBLY RR
6. REMOVE SPEAKER ASSEMBLY RR

(b) Remove the 3 bolts and the rear speaker assembly RR.
INSTALLATION
E127786
1. INSTALL SPEAKER ASSEMBLY RR)

(a) Tighten the 3 bolts and install the rear speaker assembly RR.
2. INSTALL FRONT DOOR TRIM BOARD RH (See Page ED-43)
3. INSTALL DOOR ASSIST GRIP BASE (See Page ED-43)
4. INSTALL REAR DOOR ASSIST GRIP COVER RH (See Page ED-

43)
AV E127786
5. INSTALL REAR DOOR REAR GUIDE BRACKET GARNISH RH
(See Page ED-43)
6. INSTALL REAR DOOR DIVISION BAR INSIDE SEAL RH (See

Page ED-44)
INSPECTION
1. SPEAKER ASSEMBLY RR
(a) Check the condition of the speaker installation and check that
there are no loose areas, misalignment or other failures.
(b) Make sure that there is no foreign matter in the speaker, no
tears on the speaker cone, or other abnormalities.
(c) Check the resistance.
(1) Remove the connector of the speaker assembly RR.
speaker terminals.
Standard:
Approximately 4
HINT:
Check the resistance without removing the speakers.
GETtheMANUALS.org
AUDIO AND VISUAL - STEREO COMPONENT TUNER ASSEMBLY
AV–34

BODY AND
AUDIO ANDELECTRICAL
VISUAL
COMPONENTS
AV
INSTRUMENT CLUSTER
FINISH PANEL CTR
RADIO BRACKET NO. 2
RADIO BRACKET NO. 1
E132720J01
GETtheMANUALS.org
AV–35 AUDIO AND VISUAL - STEREO COMPONENT TUNER ASSEMBLY
REMOVAL
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL CTR (See Page
IP-9)
2. REMOVE STEREO COMPONENT TUNER ASSEMBLY
)
(a) Remove the 4 screws and the stereo component tuner assem-
bly.
E129935
3. REMOVE RADIO BRACKET NO. 1

(a) Remove the 4 screws and radio bracket No. 1.
AV
E128795
4. REMOVE RADIO BRACKET NO. 2

(a) Remove the 4 screws and radio bracket No. 2.
INSTALLATION
E128796
1. INSTALL RADIO BRACKET NO. 1

(a) Install radio bracket No.1 to the stereo component tuner assem-
bly with the 4 screws.
E128796
GETtheMANUALS.org
AUDIO AND VISUAL - STEREO COMPONENT TUNER ASSEMBLY
AV–36
2. INSTALL RADIO BRACKET NO. 2

(a) Install radio bracket No. 2 to the stereo component tuner
assembly with the 4 screws.
E128795
3. INSTALL STEREO COMPONENT TUNER ASSEMBLY

(a) Install the stereo component tuner assembly with the 4 screws.

IP-21)
6. PERFORM INITIALIZATION AT BATTERY TERMINAL REMOVAL

AND INSTALLATION
E129935 AV
GETtheMANUALS.org
AV–37 AUDIO AND VISUAL - ANTENNA ASSEMBLY (WITH HOLDER)
ANTENNA ASSEMBLY (WITH HOLDER)

BODY AND
AUDIO ANDELECTRICAL
VISUAL
COMPONENTS
WITH CURTAIN SHIELD AIRBAG
CLIP
CLIP CLIP
CLIP
CLIP
FRONT PILLAR GARNISH RH

CLIP FRONT PILLAR GARNISH LH
AV
FRONT PILLAR GARNISH LH
FRONT DOOR OPENING

TRIM WEATHERSTRIP RH
FRONT DOOR OPENING TRIM WEATHERSTRIP LH
NON-REUSEABLE PART B141274J02
GETtheMANUALS.org
AUDIO AND VISUAL - ANTENNA ASSEMBLY (WITH HOLDER)
AV–38
REAR DOOR OPENING ROOF SIDE INNER

TRIM WEATHERSTRIP RH ROOF SIDE INNER GARNISH RH GARNISH RH
DECK FLOOR BOX RH
CENTER PILLAR
GARNISH UPR RH
DECK TRIM SIDE PANEL

ASSEMBLY RH AV

CENTER PILLAR GARNISH LWR LH
FRONT DOOR
SCUFF PLATE RH
ROOF SIDE INNER GARNISH LH ROOF SIDE INNER GARNISH LH
DECK FLOOR BOX LH
CENTER PILLAR
GARNISH UPR LH
REAR DOOR OPENING

TRIM WEATHERSTRIP LH
DECK TRIM SIDE PANEL ASSEMBLY LH

REAR DOOR SCUFF PLATE LH

B137694J01
GETtheMANUALS.org
ASSIST GRIP
ASSIST GRIP
ROOF HEADLINING ASSEMBLY
AV
VISOR ASSEMBLY RH ASSIST GRIP
VISOR HOLDER
VISOR ASSEMBLY LH
MAP LIGHT ASSEMBLY
VISOR HOLDER
DECK BOARD ASSEMBLY
REAR FLOOR MAT SUPPORT PLATE RR BACK DOOR WEATHERSTRIP
B137695J01
GETtheMANUALS.org
AV–40
ANTENNA POLE
ANTENNA ASSEMBLY
(WITH HOLDER )
T=2.9{30}
AV
TIGHTENING TORQUE [N*m{kgf*cm}] E131465J01
GETtheMANUALS.org
REMOVAL
1. HANDLING AND OPERATING PRECAUTIONS (See Page IR-4)
2. REMOVE FRONT DOOR SCUFF PLATE RH (See Page IR-4)
4. REMOVE DECK BOARD ASSEMBLY (See Page IR-4)
5. REMOVE DECK FLOOR BOX RH (See Page IR-4)
6. REMOVE DECK FLOOR BOX LH
7. REMOVE REAR DOOR SCUFF PLATE RH (See Page IR-4)
8. REMOVE REAR DOOR SCUFF PLATE LH
10. REMOVE REAR FLOOR MAT SUPPORT PLATE RR (See Page IR-
5)
12. REMOVE CENTER PILLAR GARNISH LWR LH
AV 13. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH (See Page IR-
5)
14. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH (See Page IR-
5)
15. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH
16. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH
17. REMOVE REAR DOOR WEATHERSTRIP
18. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH
19. REMOVE FRONT PILLAR GARNISH RH (WITHOUT CURTAIN

SHIELD AIRBAG) (See Page IR-5)
20. REMOVE FRONT PILLAR GARNISH LH (WITHOUT CURTAIN

SHIELD AIRBAG)
21. REMOVE FRONT PILLAR GARNISH RH (WITH CURTAIN SHIELD

AIRBAG) (See Page IR-5)
22. REMOVE FRONT PILLAR GARNISH LH (WITH CURTAIN SHIELD

AIRBAG)
23. REMOVE SHOULDER BELT ANCHOR COVER (See Page SB-9)
24. SEPARATE FRONT SEAT OUTER BELT ASSEMBLY RH (See

page SB-9)
25. SEPARATE FRONT SEAT OUTER BELT ASSEMBLY LH
26. REMOVE CENTER PILLAR GARNISH UPR RH (See Page IR-6)
27. REMOVE CENTER PILLAR GARNISH UPR LH

29. REMOVE ROOF SIDE INNER GARNISH LH (WITHOUT CURTAIN

SHIELD AIRBAG)
GETtheMANUALS.org
AV–42

31. REMOVE ROOF SIDE INNER GARNISH LH (WITH CURTAIN

SHIELD AIRBAG)
32. REMOVE MAP LAMP ASSEMBLY (See Page IR-6)
33. REMOVE ROOM LIGHT ASSEMBLY NO. 2 (See Page IR-7)
34. REMOVE ASSIST GRIP (See Page IR-7)
35. REMOVE VISOR ASSEMBLY RH (See Page IR-7)
36. REMOVE VISOR ASSEMBLY LH
37. REMOVE VISOR HOLDER (See Page IR-8)
38. REMOVE SEAT BELT RETRACTOR COVER (See Page SB-37)
39. REMOVE ROOF HEADLINING ASSEMBLY (See Page IR-8)

40. REMOVE ANTENNA ASSEMBLY (WITH HOLDER)
(a) Remove the nut and disconnect the antenna cable.
AV
E131466
GETtheMANUALS.org
(b) Detach the 4 clamps and remove the antenna cable.
AV
: Clamp
E131467J01
(c) Remove the antenna holder.
GETtheMANUALS.org
AV–44
INSTALLATION
1. INSTALL ANTENNA ASSEMBLY (WITH HOLDER)
(a) Install the antenna holder.
(b) Connect the 4 clamps and install the antenna cable.
AV
: Clamp
E131467J01
GETtheMANUALS.org
(c) Install the antenna cable to the antenna holder with the nut.
3. INSTALL VISOR HOLDER (See Page IR-10)
4. INSTALL VISOR ASSEMBLY RH (See Page IR-10)
5. INSTALL VISOR ASSEMBLY LH
6. INSTALL ASSIST GRIP (See Page IR-10)

E131466
7. INSTALL ROOM LIGHT ASSEMBLY NO. 2 (See Page IR-10)
8. INSTALL MAP LAMP ASSEMBLY (See Page IR-10)
9. INSTALL FRONT PILLAR GARNISH RH (WITHOUT CURTAIN

10. INSTALL FRONT PILLAR GARNISH LH (WITHOUT CURTAIN

SHIELD AIRBAG)
11. INSTALL FRONT PILLAR GARNISH RH (WITH CURTAIN SHIELD

AIRBAG) (See Page IR-10)
AV 12. INSTALL FRONT PILLAR GARNISH LH (WITH CURTAIN SHIELD

AIRBAG)
13. INSTALL CENTER PILLAR GARNISH UPR RH (See Page IR-11)
14. INSTALL CENTER PILLAR GARNISH UPR LH
15. CONNECT FRONT SEAT OUTER BELT ASSEMBLY RH (See Page

SB-13)
16. INSTALL SHOULDER BELT ANCHOR COVER
17. CONNECT FRONT SEAT OUTER BELT ASSEMBLY LH
18. INSTALL SHOULDER BELT ANCHOR COVER
19. INSTALL ROOF SIDE INNER GARNISH RH (WITHOUT CURTAIN

SHIELD AIRBAGS) (See Page IR-11)
20. INSTALL ROOF SIDE INNER GARNISH LH (WITHOUT CURTAIN

SHIELD AIRBAG)
21. INSTALL ROOF SIDE INNER GARNISH RH (WITH CURTAIN

SHIELD AIRBAG)
22. INSTALL ROOF SIDE INNER GARNISH LH (WITH CURTAIN

SHIELD AIRBAG)

(See Page IR-11)
24. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH
25. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH (See

Page IR-11)
26. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH
28. INSTALL CENTER PILLAR GARNISH LWR LH
29. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH (See Page IR-
12)
GETtheMANUALS.org
AV–46
30. INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH (See Pa)ge IR-
12)
31. INSTALL FRONT DOOR SCUFF PLATE RH (See Page IR-12)
33. INSTALL REAR DOOR SCUFF PLATE RH (See Page IR-12)
34. INSTALL REAR DOOR SCUFF PLATE LH
35. INSTALL DECK FLOOR BOX RH (See Page IR-12)
36. INSTALL DECK FLOOR BOX LH
37. INSTALL REAR FLOOR MAT SUPPORT PLATE RR (See Page IR-
13)
39. INSTALL DECK BOARD ASSEMBLY (See Page IR-13)
AV
GETtheMANUALS.org
AV–47 AUDIO AND VISUAL − ANTENNA CORD NO. 2
ANTENNA CORD NO. 2

BODY AND
AUDIO ANDELECTRICAL
VISUAL
COMPONENTS
AV INSTRUMENT CLUSTER FINISH PANEL

T=34.3{350}
WINDSHIELD WIPER ASSEMBLY
T=7.4{75}
TIGHTENING TORQUE * *
B136121J01
GETtheMANUALS.org
AUDIO AND VISUAL − ANTENNA CORD NO. 2
AV–48
STEREO COMPONENT RADIO TUNER OPENING COVER

TUNER ASSEMBLY
AV
AIR MIXTURE DAMPER INSTRUMENT CLUSTER FINISH PANEL CTR

CONTROL CABLE
AIR INLET DAMPER

CONTROL CABLE
DEFROSTER DAMPER
CONTROL
CABLE
B143235J01
GETtheMANUALS.org
COWL SIDE TRIM BOARD RH

CONSOLE BOX FR
INSTRUMENT PANEL
BRACE COVER INN NO. 3
AV
SHIFT LEVER KNOB

SHIFTING HOLE BEZEL
(TRANSMISSION A/T)

CONSOLE BOX
CARPET
B143236J01
GETtheMANUALS.org
AV–50
T=8.2{84}
COIN BOX ASSEMBLY

AV
GLOVE COMPARTMENT
DOOR STOPPER

INSTRUMENT PANEL
UNDER COVER NO. 2

B136124J01
GETtheMANUALS.org

CLIP
CLIP
CLIP

FRONT DOOR OPENING TRIM

WEATHERSTRIP RH
AV

WEATHERSTRIP LH
NON-REUSEABLE PART
E133873J01
GETtheMANUALS.org
AV–52
INSTRUMENT PANEL
AV
ANTENNA CORD NO. 2
E131195J01
GETtheMANUALS.org
REMOVAL
TABLE OF BOLTS, SCREWS AND NUTS
HINT:
• All necessary bolts, screws and nuts relevant to installing and removing
the instrument panel are shown in the text or illustration below with their
part numbers.
• In the illustration, D indicates diameter (mm) and L indicates length
(mm).
D=6 D=6 D=5

<A> L18 L14 <C> L=14
91551-80618 90109-06292 93568-55014
AV
D=5 D=5 <F> D=6
<D> <E>
L=14 L=14 L14
93567-55014 93567-15014 91551-80614
B139418J01
1. HANDLING AND OPERATING PRECAUTIONS (See Page IP-8)
4. REMOVE HORN BUTTON ASSEMBLY (See Page RS-170)
5. REMOVE STEERING WHEEL ASSEMBLY (See Page SR-4)
6. REMOVE INSTRUMENT CLUSTER FINISH PANEL (See Page ME-

30)
7. REMOVE STEERING COLUMN COVER (See Page IP-8)
8. REMOVE HEADLIGHT DIMMER SWITCH ASSEMBLY (See Page

LI-50)
9. REMOVE WINDSHIELD WIPER SWITCH ASSEMBLY (See Page

WW-22)
10. REMOVE COMBINATION METER ASSEMBLY (See Page ME-31)

Page IP-9)
12. DISCONNECT AIR MIX DAMPER CONTROL CABLE (See Page

IP-9)
GETtheMANUALS.org
AV–54

Page IP-9)
14. DISCONNECT AIR INLET CONTROL CABLE (See Page IP-9)

RECEIVER)

(See Page IP-9)
19. REMOVE CONSOLE BOX ASSEMBLY RR (See Page IP-9)
20. REMOVE CONSOLE BOX FR (See Page IP-10)
21. REMOVE FRONT DOOR SCUFF PLATE RH (See Page IP-10)
23. REMOVE COWL SIDE TRIM BOARD RH (See Page IP-10)
25. REMOVE INSTRUMENT PANEL BRACE COVER INN NO. 3 (See AV

Page IP-10)
26. REMOVE INSTRUMENT PANEL UNDERCOVER NO. 3 (See Page

IP-11)
27. REMOVE COIN BOX ASSEMBLY (See Page IP-11)
28. REMOVE INSTRUMENT PANEL FINISH PANEL LWR (See Page

IP-11)
29. REMOVE INSTRUMENT PANEL UNDER COVER NO. 1 (See Page

IP-11)
30. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (See Page

IP-11)
31. REMOVE GLOVE COMPARTMENT DOOR STOPPER (See Page

IP-12)
32. REMOVE INSTRUMENT PANEL BOX NO. 2 (See Page IP-12)
33. REMOVE INSTRUMENT PANEL UNDER COVER NO. 2 (See Page

IP-12)

(See Page IP-12)

SHIELD AIRBAG) (See Page IP-12)

SHIELD AIRBAG)

AIRBAG) (See Page IP-13)

AIRBAG)
GETtheMANUALS.org
40. REMOVE INSTRUMENT PANEL (See Page IP-14)
41. REMOVE ANTENNA CORD NO. 2

(a) Disconnect connectors and clamps, and remove antenna cord
No. 2
AV
E130361
GETtheMANUALS.org
AV–56
INSTALLATION
1. INSTALL ANTENNA CORD NO. 2
(a) Connect the connectors and clamps and install antenna cord
No. 2.
AV
E130361J01
2. INSTALL INSTRUMENT PANEL (See Page IP-16)
3. INSTALL INSTRUMENT PANEL PASSENGER AIRBAG ASSEM-

BLY (See Page IP-16)

SHIELD AIRBAG) (See Page IP-16)

SHIELD AIRBAG)

AIRBAG) (See Page IP-16)
7. INSTALL FRONT PILLAR GARNISH LH (WITH CURTAIN SHIELD

AIRBAG)

(See Page IP-17)
GETtheMANUALS.org
10. INSTALL INSTRUMENT PANEL UNDER COVER NO. 2 (See Page

IP-17)
12. INSTALL GLOVE COMPARTMENT DOOR STOPPER (See Page

IP-17)
13. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY (See Page

IP-18)

IP-18)
15. INSTALL INSTRUMENT PANEL FINISH PANEL LWR (See Page

IP-18)
16. INSTALL COIN BOX ASSEMBLY (See Page IP-19)

IP-19)
18. INSTALL INSTRUMENT PANEL BRACE COVER NO. 3 (See Page

AV IP-19)
19. INSTALL COWL SIDE TRIM BOARD RH (See Page IP-19)
21. INSTALL FRONT DOOR SCUFF PLATE RH (See Page IP-19)
23. INSTALL CONSOLE BOX FR (See Page IP-19)
24. INSTALL CONSOLE BOX ASSEMBLY RR (MANUAL TRANSMIS-

SION) (See Page IP-20)

(See Page IP-20)
27. INSTALL RADIO TUNER OPENING COVER (WITHOUT RADIO

RECEIVER)
29. INSTALL AIR INLET DAMPER CONTROL CABLE (AIR CONDI-

TIONING MANUAL) (See Page IP-20)
30. INSTALL DEFROSTER DAMPER CONTROL CABLE (AIR CONDI-

TIONING MANUAL) (See Page IP-20)
31. INSTALL AIR MIX DAMPER CONTROL CABLE (AIR CONDITION-

ING MANUAL) (See Page IP-21)

IP-21)
33. INSTALL COMBINATION METER ASSEMBLY (See Page ME-31)
34. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY (See Page

WW-23)
35. INSTALL HEADLIGHT DIMMER SWITCH ASSEMBLY (See Page

LI-50)
GETtheMANUALS.org
AV–58
36. INSTALL STEERING COLUMN COVER (See Page IP-21)
37. INSTALL INSTRUMENT CLUSTER FINISH PANEL (See Page ME-

32)
38. INSTALL STEERING WHEEL ASSEMBLY (See Page SR-8)
39. INSTALL HORN BUTTON ASSEMBLY (See Page RS-170)
41. CHECK AIRBAG WARNING LIGHT (See Page IP-21)
AV
GETtheMANUALS.org
TO INDEX
BODY AND ELECTRICAL
OTHER ELECTRICAL
HORN SYSTEM
BASIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OT-1
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OT-2
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OT-3
LOW PITCHED HORN ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OT-4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OT-4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OT-4
POWER OUTLET SOCKET
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OT-5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OT-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OT-6
HORN RELAY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OT-8
IGNITION (STARTER) SWITCH ASSEMBLY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OT-9
OT
GETtheMANUALS.org
OT–1 9OTHER ELECTRICAL - HORN SYSTEM
HORN SYSTEM
BODY AND
9OTHER ELECTRICAL
ELECTRICAL
BASIC INSPECTION
1. INSPECTION OF HORN
(a) CHECK OPERATION OF HORN
(1) Press the horn button while turning the steering wheel,
and check that the horn blows.
Standard:
The horn blows.
(2) Check that the sound volume and quality are constant.
Standard:
The sound quality is constant.
OT
GETtheMANUALS.org
9OTHER ELECTRICAL - HORN SYSTEM
OT–2
LOCATION
HORN RELAY
OT
E128157J01
GETtheMANUALS.org
OT–3 9OTHER ELECTRICAL - HORN SYSTEM

HORN Fuse (10 A) -
Low pitched horn assembly -
Vehicle horn does not sound Horn button assembly -
Wire harness or connector -
Horn relay OT-8
OT
GETtheMANUALS.org
OTHER ELECTRICAL - LOW PITCHED HORN ASSEMBLY
OT–4

BODY AND
OTHER ELECTRICAL
ELECTRICAL
COMPONENTS
OT
LOW PITCH HORN ASSEMBLY

T=19{194}

E130118J01
REMOVAL
1. REMOVE LOW PITCHED HORN ASSEMBLY
(b) Remove the bolt and the low pitched horn assembly.
INSTALLATION
1. INSTALL LOW PITCHED HORN ASSEMBLY
(a) Install the low pitched horn assembly with the bolt.
E127349
GETtheMANUALS.org
OT–5 OTHER ELECTRICAL - POWER OUTLET SOCKET
POWER OUTLET SOCKET

BODY AND
OTHER ELECTRICAL
ELECTRICAL
COMPONENTS
POWER POINT
SOCKET ASSEMBLY
CONSOLE BOX FR
POWER OUTLET SOCKET COVER SHIFT LEVER KNOB
SHIFTING HOLE BEZEL
OT
CONSOLE BOX CARPET
DECK FLOOR BOX LH
POWER OUTLET
SOCKET COVER
REAR DOOR SCUFF

PLATE LH
POWER POINT SOCKET ASSEMBLY
E132246J01
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OTHER ELECTRICAL - POWER OUTLET SOCKET
OT–6
REMOVAL

(See Page IP-9)
3. REMOVE CONSOLE BOX ASSEMBLY RR (See Page IP-9)
4. REMOVE CONSOLE BOX FR (See Page IP-10)

5. REMOVE POWER POINT SOCKET ASSEMBLY
(a) Disengage the claw, and remove the power point socket
assembly by pulling it out in the direction indicated by the arrow
Claw E105660J01
6. REMOVE POWER OUTLET SOCKET COVER

(a) Disengage the 2 claws, and remove the power outlet socket
cover by pulling it out in the direction indicated by the arrow in
the illustration.
OT
9. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH (See Page IR-

5)
Claw E105661J01
10. REMOVE POWER POINT SOCKET ASSEMBLY

(a) Disengage the claw, and remove the power point socket
assembly by pulling it out in the direction indicated by the arrow
Claw E105660J01
11. REMOVE POWER OUTLET SOCKET COVER

(a) Disengage the 2 claws, and remove the power outlet socket
cover by pulling it out in the direction indicated by the arrow in
the illustration.
INSTALLATION
1. INSTALL POWER OUTLET SOCKET COVER
(a) Attach the 2 claws and install the power outlet socket cover to
the deck trim side panel assembly LH.
Claw E105661J01
2. INSTALL POWER POINT SOCKET ASSEMBLY

(a) Attach the claw and install the power point socket assembly.
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OT–7 OTHER ELECTRICAL - POWER OUTLET SOCKET
3. INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH (See Page IR-

12)
6. INSTALL POWER OUTLET SOCKET COVER

(a) Attach the 2 claws and install the power outlet socket cover to
the console box FR.
7. INSTALL POWER POINT SOCKET ASSEMBLY

(a) Attach the claw and install the powe)r point socket assembly.
8. INSTALL CONSOLE BOX FR (See Page IP-19)

TRANSMISSION) (See Page IP-20)

(See Page IP-20)

OT (See page SS-10 for details.)
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OTHER ELECTRICAL - HORN RELAY
OT–8
BODY AND ELECTRICAL
HORN RELAY
OTHER ELECTRICAL
INSPECTION
1. INSPECT HORN RELAY
Standard:
Terminal Continuity
1-2 Continuity
3-5 No continuity
B016200
(2) Apply battery voltage and check the operation of the relay.
Standard:
Tester
Connection
When battery voltage is applied to
3-5 Continuity
terminals 1 and 2
OT
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OT–9 OTHER ELECTRICAL - IGNITION (STARTER) SWITCH ASSEMBLY
IGNITION (STARTER) SWITCH ASSEMBLY

BODY AND
OTHER ELECTRICAL
ELECTRICAL
INSPECTION
1. INPSPECTION OF IGNITION (STARTER) SWITCH ASSEMBLY
connecter terminals of the ignition (starter) switch
assembly.
Standard
Key Position Terminal No. Standard

LOCK - No continuity
ACC 1←→3 Continuity
B050489J01
1←→2←→3
ON Continuity
5←→6
1←→2
START Continuity
4←→5←→6
OT
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TO INDEX
BODY AND ELECTRICAL
GLASS AND WINDOW

POWER WINDOW SYSTEM
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-1
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-2
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-3
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-3
HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . WS-3
CUSTOMER PROBLEM ANALYSIS CHECK SHEET . . . . . . . . . . . . . . . . . . . . . . WS-5
ECU TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-6
DRIVER SIDE WINDOW DOES NOT OPERATE WITH REGULATOR SWITCH . . WS-9
WINDOW CANNOT BE OPERATED BY REGULATOR SWITCH OF PASSENGER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-13
REAR RIGHT SIDE WINDOW DOES NOT OPERATE WITH REGULATOR
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-18
REAR LEFT SIDE WINDOW DOES NOT OPERATE WITH REGULATOR SWITCH WS-23
EACH WINDOW DOES NOT OPERATE WITH MASTER SWITCH (SWITCH
INSTALLED AT EACH WINDOW IS AVAILABLE) . . . . . . . . . . . . . . . . . . . . . . WS-28
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-31
HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . WS-32 WS
WINDSHIELD DEICER DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-34
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-38
HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . WS-39
REAR WINDOW DEFOGGER DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . WS-42
POWER WINDOW REGULATOR MOTOR ASSEMBLY RH
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-44
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-44
POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-46
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-48
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-50
WINDSHIELD GLASS
COMPONENTS . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . WS-52
REMOVAL . . . . . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . WS-54
INSTALLATION .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . WS-57
INSPECTION. . . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . WS-63
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BACK WINDOW GLASS
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-64
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-65
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-66
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-70
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-71
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-72
DEICER RELAY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-76
DEFOG RELAY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WS-77
WS
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GLASS AND WINDOW - POWER WINDOW SYSTEM
WS–1
POWER WINDOW SYSTEM

BODY AND
GLASS ANDELECTRICAL
WINDOW
OPERATION CHECK
1. CHECK MANUAL OPERATION
(a) CHECK BASIC FUNCTION
(2) Check that when operating the UP modes of the remote
switches that control each of the vehicle's windows on the
power window regulator master switch assembly (driver's
seat power window SW), the power windows (door glass)
go up, and when operating the DOWN modes of the
remote switches of the power window regulator master
switch assembly (driver seat power window SW), the
power windows (door glass) go down.
(3) Check that when operating the UP side of the remote
remote switches of the power window master switch
assembly for each seat (each power window SW) the
power windows (door glass) go up. Also check that when
operating the DOWN side of the remote switches of each
power window master switch assembly for each seat
(each power window SW) the power windows (door glass)
go down.
(4) Check that when operating the LOCK button of the win-
dow lock switch of the power window regulator master
WS
switch assembly (driver's seat power window SW), the
illumination (LED) of the power window regulator switch
assembly (for each power window SW), except the one
for the driver seat, is turned off. Also check that each
power window (each door glass) does not operate.
2. CHECK AUTO OPERATION

(a) Check basic functions (driver's seat).
(2) Check that the power windows go down automatically
(AUTO DOWN) and the drivers side door glass goes to
the fully open position when the driver's seat switch of the
power window regulator master switch assembly (driver's
seat power window SW) is pushed to the DOWN position
twice.
3. CHECK POWER WINDOW REGULATOR MASTER SWITCH

ASSEMBLY
(a) CHECK ILLUMINATION
(1) Check that when the ignition switch is turned to the ON
position while the connector is connected, the illumination
(LED) on the switch of the power window regulator master
switch assembly (driver's seat power window SW) turns
on.
4. CHECK POWER WINDOW REGULATOR SWITCH ASSEMBLY

(a) CHECK ILLUMINATION
(1) Check that when the ignition switch is turned to the ON
position while the connector is connected, the illumination
(LED) on the switch of the power window regulator switch
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WS–2 GLASS AND WINDOW - POWER WINDOW SYSTEM
assembly (power window SW of passenger seat, rear

seat right side and rear seat left side) turns on.
LOCATION
POWER WINDOW REGULATOR MOTOR

POWER WINDOW MASTER SWITCH ASSEMBLY ASSEMBLY RH (REAR SEAT RH)
(DRIVER SIDE POWER WINDOW SW)
POWER WINDOW SWITCH ASSEMBLY
FRONT DOOR WINDOW (REAR SEAT RH POWER WINDOW SW)
REGULATOR RH
POWER WINDOW REAR DOOR WINDOW

REGULATOR MOTOR REGULATOR RH
ASSEMBLY RH (DRIVER SIDE)
WS
POWER WINDOW SWITCH ASSEMBLY

(PASSENGER SIDE POWER WINDOW SW) REAR DOOR WINDOW
REGULATOR LH
POWER WINDOW REGULATOR POWER WINDOW SWITCH ASSEMBLY

MOTOR ASSEMBLY LH (PASSENGER SIDE) (REAR SEAT RH POWER WINDOW SW)

MOTOR ASSEMBLY LH (REAR SEAT RH)
FRONT DOOR WINDOW REGULATOR LH
B141471J01
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WS–3

Window cannot be operated from the power window
regulator master switch assembly (driver's seat power Go to the flowchart WS-9
window SW)
regulator switch assembly (passenger seat power win- Go to the flowchart WS-13
dow SW)
regulator switch assembly (rear seat right side power Go to the flowchart WS-18
window SW)
switch regulator assembly (rear seat left side power Go to the flowchart WS-23
window SW)
The (driver's seat power window SW) power window
regulator master switch assembly does not operate the
Go to the flowchart WS-28
non-driver seat windows (although the windows can be
operated via their respective door switches)
DESCRIPTION
1. POWER WINDOW OPERATION MODE
Standard:
WS
Power Window Operation IG ON
Manual UP Operates
Manual DOWN Operates
AUTO DOWN Operates

SHOOTING
2 CONDUCT CUSTOMER PROBLEM ANALYSIS AND CHECK SYMPTOMS (See page WS-5)
3 PROBLEM SYMPTOMS TABLE (See page WS-3)
(a) Check that the symptom is listed in the problem symptoms table.
Result Proceed to
Symptom is listed in the problem symptoms table B
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(a) ECU terminals (See page WS-6.)

(b) CHECK FUNCTION (See page WS-1.)
END
WS
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WS–5

CHECK
Power Window System Problem Diagnosis Check Sheet / /
Customer’s Name License
First Registered Year 20___/ /
Plate No.
Model VIN
Inspector’s Engine Odometer Reading km / mile

Written by
Name Type
Frequency Problem Occurs Constant Occasionally (____times per day, ____times per month)
Conditions (Method of use and result)
Weather Clear Cloudy Rainy Cloudy Others( ) Air Temperature Approx. ( )°C / °F WS
Road City Suburb Highway Others ( ) Paved Unpaved
Power window switches (each seat door glass) does not operate
Driver seat Right rear seat
Passenger Seat Left rear seat
Door Glass AUTO DOWN do not operate

Master switch (D seat) cannot remotely operate other seats
(operation possible by the switch for each seat)
Problem
Symptoms
Others
Normal Operation Resume Condition IG ON Engine starting ( ) SW operation

If Condition Exists At Time
IG OFF to ON ( ) SW operation Others
Of Occurance
B146677
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ECU TERMINALS
1. POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
(DRIVER'S SEAT POWER WINDOW SW)
(a) Check the power window regulator master switch assembly
(driver's seat power window SW).
4 3 2 1 (1) Disconnect the power window regulator master switch
assembly (driver's seat power window SW).
A (2) Using the tester, check the voltage and the continuity
between the terminals of the connector on the vehicle wire
harness side of the power window regulator master switch
Standard:
B
B141544

B6 (GND) ←→ Body
ground
B1 (IG) ←→ 6 (GND) Voltage Always 10 to 14 V
WS HINT:
If the result is not as specified, the vehicle side is malfunc-
tioning.
(3) Check the voltage between the terminals of the connector
of the power window regulator master switch assembly
(driver's seat power window SW).
Standard:

• IG ON
B11 (DD) ←→ 6 (GND) Voltage • Power window regular master switch assembly (driver's seat 1 V or less → 10 to 14 V
power window SW) OFF → UP (manual operation)
• IG ON
• Driver's seat door glass fully closed → Power window regulator 1 V or less → 10 to 14 V
B11 (DD) ←→ 6 (GND) Voltage
master switch assembly (driver's seat power window SW) DOWN → 1 V or less
(auto operation) → Driver door glass fully open
• IG ON
B10 (IG) ←→ 6 (GND) Voltage • Power window master switch assembly (driver's seat power 1 V or less → 10 to 14 V
window SW) OFF → DOWN (manual operation)
• IG ON
• Driver's seat door glass fully open → Power window regulator 1 V or less → 10 to 14 V
B10 (IG) ←→ 6 (GND) Voltage
master switch assembly (driver seat power window SW) UP (auto → 1 V or less
operation) → Driver seat door glass fully closed
• IG ON
B12 (PD) ←→ 6 (GND) Voltage • Window lock switch ON 0 → 10 to 14 V
• Passenger seat power window switch OFF → DOWN
• IG ON
B7 (PU) ←→ 6 (GND) Voltage • Window lock switch ON 0 → 10 to 14 V
• Passenger seat power window switch OFF → UP
• IG ON
B3 (RRD) ←→ 6 (GND) Voltage • Window lock switch ON 0 → 10 to 14 V
• Rear seat right side power window switch OFF → DOWN
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WS–7

• IG ON
B2 (RRU) ←→ 6 (GND) Voltage • Window lock switch ON 0 → 10 to 14 V
• Rear seat right side power window switch OFF → UP
• IG ON
B4 (RLD) ←→ 6 (GND) Voltage • Window lock switch ON 0 → 10 to 14 V
• Rear seat left side power window switch OFF → DOWN
• IG ON
B5 (RLU) ←→ 6 (GND) Voltage • Window lock switch ON 0 → 10 to 14 V
• Rear seat left side power window switch OFF → UP
HINT:
If the result is not as specified, the power window regulator
master switch assembly (driver's seat power window SW)
is malfunctioning.
2. CHECK ILLUMINATION
(a) Connect the positive battery terminal to terminal 1 of the con-
nector B, and the negative battery terminal to terminal 6, then
check the illumination condition.
Standard:
The illumination comes on.
3. POWER WINDOW REGULATOR SWITCH ASSEMBLY (PASSEN-
GER SEAT POWER WINDOW SW)
(a) Check the power window regulator switch assembly (passenger
seat power window SW). WS
(1) Remove the power window regulator switch assembly (pas-
senger seat power window SW).
(2) Using the electrical tester, check the continuity between the
terminals of the connector when operating each switch of
the power window regulator switch assembly (passenger
B031201 seat power window SW).
Standard:
Switch Operation Terminal No. Standard

2←→3
UP
4←→5
1←→2
OFF Continuity
4←→5
1←→2
DOWN
3←→4
4. POWER WINDOW REGULATOR SWITCH ASSEMBLY (REAR

SEAT POWER WINDOW SW)
(a) Check the power window regulator switch assembly (rear seat
power window SW).
(1) Remove the power window regulator switch assembly (rear
seat power window SW).
B031201
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(2) Using the electrical tester, check the continuity between the
terminals of the connector when operating each switch of
the power window regulator switch assembly (rear seat
power window SW).
Standard:
Switch Operation Terminal No. Standard

2←→3
UP
4←→5
1←→2
OFF Continuity
4←→5
1←→2
DOWN
3←→4
WS
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WS–9
DRIVER SIDE WINDOW DOES NOT OPERATE WITH REGULATOR

SWITCH
DESCRIPTION
The power window regulator motor assembly RH (driver's seat) is activated when the power window regulator master switch
assembly (driver's seat power window SW) is operated while the ignition switch is the ON position. The power window regulator
motor assembly RH (driver'sseat) has a motor function and a regulator function.
CIRCUIT DIAGRAM
Power Window Master Switch Assembly Power Window Regulator Motor

(Driver Side Power Window SW) Assembly RH (Driver Side)
POWER 30A B1
IG
B6 B11 1 D
E DD
B10 2 U
DU WS
POWER 30A B9
+B
B144276J01
1 INSPECT FUSES
(a) Check the fuses in the junction block.

Inspection Parts (Cabin)
Suspected Area Inspection Fuse
Instrument panel junction block assembly (body ECU) POWER 30 A
Standard:
The fuses are not damaged.
NG REPLACE FUSES
OK
2 CHECK POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
HINT:
For inspection procedures and precautions, See page IN-38.
GETtheMANUALS.org

(1) Remove the power window regulator master switch assembly
(driver seat power window SW). (while the connector is con-
nected)
(b) CHECK POWER SOURCE VOLTAGE
(1) Using the electrical tester, check the voltage between each ter-
minal of the connecter when the driver's seat switch is oper-
ated. (For terminal layout, See page WS-6.)

B11 (DD) ←→ Volt- • IG ON 1 V or less →
DD DU E 6 (E) age • Power window regular master 10 to 14 V
switch assembly (driver's seat
B144247J05
power window SW) OFF → UP
(manual operation)
B11 (DD) ←→ Volt- • IG ON 1 V or less →
6 (E) age • Driver's seat door glass fully 10 to 14 V →
closed → Power window regula- 1 V or less
tor master switch assembly
(driver's seat power window SW)
DOWN (auto operation) →
Driver's door glass fully open
B10 (DU) ←→ Volt- • IG ON 1 V or less →
6 (E) age • Power window regulator master 10 to 14 V
WS switch assembly (driver's seat
power window SW) OFF →
DOWN (manual operation)
B10 (DU) ←→ Volt- • IG ON 1 V or less →
6 (E) age • Driver's seat door glass fully 10 to 14 V →
closed → Power window regula- 1 V or less
tor master switch assembly
(driver's seat power window SW)
UP (auto operation) → Driver's
seat door glass fully closed
OK GO TO INSPECTION PROCEDURE 5
NG
3 CHECK WIRE HARNESS OR CONNECTOR (BETWEEN POWER WINDOW FUSE AND POWER WIN-
DOW REGULATOR MASTER SWITCH ASSEMBLY)
HINT:
(1) Disconnect the connector of the power window master switch
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WS–11

B (1) Using the electrical tester, measure the continuity between ter-
minals of the connector on the vehicle wire harness side. (For
terminal layout, See page WS-6.)
1 2 3 4 5
Standard:
6 7 8 9 10 11 12
Tester Connec-
tion Measurement
Item Voltage
E (Terminal sym- Condition
B144248J03 bol)
1 (B) ←→ 6 (E) Voltage Always 10 to 14 V

CONNECTOR
OK
4 CHECK POWER WINDOW REGULATOR MOTOR ASSEMBLY RH
(a) Check the operation of the power window regulator motor assembly
RH (driver's seat).
NOTICE:
Do not apply voltage to any terminals of the motor other the ter-
minals 1 and 2. Doing so will damage the pulse sensor in the WS
motor.
(1) Check that the motor operates smoothly when battery voltage is
Activation Axis
applied to the terminals of the connector.
Standard:
Rotation
Right
Measurement Condition Operational Direction
Positive (+) battery terminal ←→ Ter-
minal 1
Turn it clockwise to the drive axis
Negative (-) battery terminal ←→ Ter-
Rotation
minal 2
Left
B117970J01 Positive (+) battery terminal ←→ Ter-
minal 2 Turn it counterclockwise to the drive
Negative (-) battery terminal ←→ Ter- axis
minal 1
(b) Check the operation of the power window motor.

NOTICE:
The operation check should be performed with the front window
regulator RH, the power window regulator motor assembly RH
(driver's seat) and the door glass installed in the vehicle.
(1) Set the probe of the electrical tester to the wire harness of con-
nector terminal 2 of the power window regulator motor assem-
bly RH (driver seat).
NOTICE:
Turn the probe arrow toward the power window regulator
motor assembly RH (driver's seat).
(2) Fully close the power window (driver's seat door glass).
(3) Wait about 60 seconds after the window is fully closed, and re-
operate (first time) the power window regulator master switch
assembly (driver's seat power window SW) by pressing and
holding the UP side of the switch. While doing so, check how
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long the current of the power window regulator motor assembly

RH (driver's seat) takes to change from about 16 - 28 A to 1 A
or less. (Cut-off check)
Standard:
About 4 to 90 seconds
(4) Wait about 60 seconds after the cut-off check, and check that
the door glass goes down by operating the power window regu-
lator master switch assembly (driver's seat power window SW).
(Recovery check)
NG REPLACE POWER WINDOW REGULATOR

MOTOR ASSEMBLY RH
OK
5 CHECK WIRE HARNESS OR CONNECTOR (BETWEEN POWER WINDOW REGULATOR MASTER

SWITCH ASSEMBLY AND POWER WINDOW REGULATOR MOTOR ASSEMBLY RH)
HINT:
(a) Disconnect the connector of the power window regulator master
Power Window Regulator Master switch assembly (driver's seat power window SW) and the power win-
Switch Assembly dow regulator motor assembly RH (driver's seat).
(Driver Side Power Window SW) (b) Using the tester, measure the continuity between terminals of the
WS connector on the vehicle wire harness side. (For terminal layout, See
page WS-6.)
1 2 3 4 5 Standard:
6 7 8 9 10 11 12
Switch ←→ Motor Measure-
Terminal Connection (Terminal Item ment Con- Standard
M/U+ M/D+
Symbol) dition
Power Window Regulator Motor There is
Assembly RH (Driver Side) continuity
between
10 (M/U+) ←→ 2 (U+) Continuity Always terminals
and no
D+ U+ short on +B
or GND
1 2
There is
3 4 5 6 continuity
between
11 (M/D+) ←→ 1 (D+) Continuity Always terminals
B144249J01
and no
short on +B
or GND
OK
REPLACE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
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WS–13
FRONT PASSENGER SIDE WINDOW DOES NOT OPERATE WITH REG-

ULATOR SWITCH
DESCRIPTION
The power window regulator motor assembly RH (passenger seat) is activated when the power window regulator switch assem-
bly (passenger seat power window SW) is operated when the window lock switch of the power window regulator master switch
assembly (driver's seat power window SW) is NORMAL and the ignition switch is the ON position.
CIRCUIT DIAGRAM
Power Window Regulator Master Switch Assembly

(Driver Side Power Window SW)
Power Window Regulator Motor
Assembly (Passenger Side)
POWER 30A
B1
IG B1 5 4 1 D
PD SD D M
B6
E B7 1 U 2 2 U
PU SU
WS
3
B
Power Window Regulator Switch Assembly

(Passenger Side)
B141710J04
NOTICE:
• Perform initialization on the power window system if the connectors of the power window regulator master switch
assembly (driver seat power window SW) are disconnected.
1 INSPECT FUSES
(a) Check the fuses in each junction block.

Instrument panel junction block assembly (driver's seat body ECU) POWER 30 A
Standard:
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NG REPLACE FUSES
OK
HINT:
(driver's seat power window SW). (while the connector is con-
nected)
(1) Using a tester, check the voltage between terminal B12 (PD)
and terminal B7 (PU) of the connector when the passenger seat
switch is operated.
Standard:
10 to 14 V

PD PU MASTER SWITCH ASSEMBLY
B144247J01
WS
OK
HINT:
(1) Disconnect connector B of the power window regulator master
switch assembly (driver's seat power window SW).
B (1) Using the tester, measure the continuity between terminals of
the connector on the vehicle wire harness side. (For terminal
layout, See page WS-6.)
1 2 3 4 5
Standard
6 7 8 9 10 11 12 Tester Connec-
tion Measurement
Item Voltage
(Terminal sym- Condition
E bol)
B144248J03 1 (B) ←→ B6 (E) Voltage Always 10 to 14 V

CONNECTOR
OK
GETtheMANUALS.org
WS–15
4 CHECK POWER WINDOW REGULATOR SWITCH ASSEMBLY
HINT:
(1) Disconnect the power window regulator switch assembly (pas-
senger seat power window SW).
(1) Using a tester, check the voltage between terminal 5 (SD) and
terminal 1 (SU) of the connector when the passenger seat
switch is operated. (For terminal layout, See page WS-6.)
Standard:
10 to 14 V
5 4 3 2 1
SD SU
SWITCH ASSEMBLY
B141749J01
OK

SWITCH ASSEMBLY AND POWER WINDOW REGULATOR SWITCH ASSEMBLY) WS
HINT:
(1) Disconnect connector B of the power window regulator switch
assembly (passenger seat) and the power window regulator
master switch assembly.
GETtheMANUALS.org

(1) Using the electrical tester, measure the continuity between ter-
minals of the connector on the vehicle wire harness side. (For
terminal layout, See page WS-6.)
Power Window Regulator (c)
Master Switch Assembly Standard:
POWER WINDOW MASTER SW

←→ POWER WINDOW SW (PAS- Measure-
SENGER SEAT) Item ment Con- Voltage
1 2 3 4 5
Terminal Connection (Terminal dition
6 7 8 9 10 11 12 Symbol)
There is
continuity
PU+ PD+
between
Power Window Regulator 12 (PD+) ←→ 5 (D+) Continuity Always terminals
Switch Assembly LH and no
(Passenger Side) short on +B
or GND
There is
continuity
between
1 2 3 4 5
7 (PD+) ←→ 1 (U+) Continuity Always terminals
and no
U+ D+ short on +B
WS or GND

B141836J01
CONNECTOR
OK
6 CHECK POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
LH (passenger seat)
NOTICE:
minals 1 and 2. Doing so will damage the pulse sensor in the
motor.
Activation Axis
Standard:
Rotation
Right
Tester Connection Operational Direction
minal 2
Rotation minal 1
Left
minal 2
GETtheMANUALS.org
WS–17
NOTICE:
The operation should be performed with front door window reg-
ulator LH, power window regulator motor assembly LH (passen-
ger seat) and front door glass (LH) installed in the vehicle.
(1) Set the DC400A probe of the electrical tester to the wire har-
ness of connector terminal 2 of the power window regulator
motor assembly LH (passenger seat).
NOTICE:
motor assembly LH (FR).
(2) Fully close the power window (passenger seat door glass).
assembly (passenger seat power window SW) by pressing and
holding the UP side of the switch. While doing so, check how
long the current of the power window regulator motor assembly
RH (passenger seat) takes to change from about 16 - 28 A to 1
A or less.(Cut-off check)
Standard:
4 to 90 sec.
lator master switch assembly (passenger seat power window
SW). (Recovery check)
WS
NG REPAIR OR REPLACE POWER WINDOW
REGULATOR MOTOR ASSEMBLY LH
OK
REPLACE WIRE HARNESS OR CONNECTOR (BETWEEN POWER WINDOW REGULA-

TOR SWITCH ASSEMBLY AND POWER WINDOW REGULATOR MOTOR MOTOR ASSEM-
BLY LH)
GETtheMANUALS.org
REAR RIGHT SIDE WINDOW DOES NOT OPERATE WITH REGULATOR

SWITCH
DESCRIPTION
The power window regulator motor assembly RH (rear seat right side) is activated when the power window regulator switch
assembly (driver's seat power window SW) is operated when the window lock switch of the power window regulator master
switch assembly (driver's seat power window SW) is NORMAL and the ignition switch is the ON position.
CIRCUIT DIAGRAM

(Driver Side Power Window SW) Power Window Regulator
Motor Assembly (Rear
Seat RH)
POWER 30A
B1
B B3 5 4 1 D
RRD SD D M
B6
E
RRU B2 1 SU 2 2 U
WS U
3
B
Power Window Switch Assembly

(Rear Seat RH)
B141710J05
1 INSPECT FUSES
(a) Check the fuses in each junction block.

Standard:
NG REPLACE FUSES
GETtheMANUALS.org
WS–19
OK
HINT:
nected)
RRD RRU
(1) Using the electrical tester, check the voltage between terminal
B2 (RRU) and terminal B3 (RRD) of the connector when the
driver's seat switch is operated. (For terminal layout, See page
WS-6.)
Standard:
10 to 14 V

B144247J03
MASTER SWITCH ASSEMBLY
OK
WS
HINT:
switch assembly (driver's seat power window SW).
the connector on the vehicle side. (For terminal layout, See
page WS-6.)
1 2 3 4 5
Standard:
6 7 8 9 10 11 12
Measure-
Tester Connection
Item ment Con- Voltage
(Terminal symbol)
E dition
B144248J03 B1 (B) ←→ B6 (E) Voltage Always 10 to 14 V

CONNECTOR
OK
HINT:
GETtheMANUALS.org
(1) Disconnect the connector of the power window regulator switch

assembly (rear seat right side power window SW).
(1) Using the electrical tester, check the voltage between terminal 5
(D+) and terminal 1 (U+) of the connector when the rear seat
right side switch is operated. (For terminal layout, See page
WS-6.)
Standard:
5 4 3 2 1
10 to 14 V

SD SU
B141749J01
SWITCH ASSEMBLY
OK

SWITCH ASSEMBLY AND POWER WINDOW REGULATOR SWITCH ASSEMBLY (REAR SEAT
RIGHT SIDE))
HINT:
(1) Disconnect the connector of the power window regulator switch
WS assembly (rear seat right side power window SW) and the
power window regulator master switch assembly RH.
(1) Using the tester, measure the continuity between terminals of
Power Window Regulator Master
Switch Assembly
(Driver Side Power Window SW) layout, See page WS-6.)
Standard:
RRU+ RRD+
POWER WINDOW MASTER SW

1 2 3 4 5
←→ POWER WINDOW SW (REAR Measure-
6 7 8 9 10 11 12 SEAT RIGHT SIDE) Item ment Con- Voltage
Symbol)
There is
Power Window Regulator Switch continuity
Assembly RH (Rear Seat RH) between
B3 (RRD+) ←→ 5 (D+) Continuity Always terminals
and no
short on +B
or GND
1 2 3 4 5 There is
continuity
between
U+ D+ B2 (RRU+) ←→ 1 (U+) Continuity Always terminals
B141836J02 and no
short on +B
or GND

CONNECTOR
OK
GETtheMANUALS.org
WS–21
6 CHECK POWER WINDOW REGULATOR MOTOR ASSEMBLY RH
RH (rear seat right side )
NOTICE:
motor.
Activation Axis
Standard:
Rotation
Right Measurement Condition Operational Direction
Positive (+) battery terminal ←→ Termi-
nal 2
Negative (-) battery terminal ←→ Termi-
Rotation nal 1
Left
B117982J01 Positive (+) battery terminal ←→ Termi-
nal 1 Turn it counterclockwise to the drive
Negative (-) battery terminal ←→ Termi- axis
nal 2

NOTICE: WS
The operation check should be performed with the front window
regulator RH, the power window regulator motor assembly RH
(driver's seat) and the door glass installed in the vehicle.
(1) Set the probe of the tester to the wire harness of connector ter-
minal 1 of the power window regulator motor assembly RH
(driver seat).
NOTICE:
motor assembly RH (driver's seat).
(2) Fully close the power window (rear seat right side door glass).
assembly (rear seat right side power window SW) by pressing
and holding the UP side of the switch. While doing so, check
how long the current of the power window regulator motor
assembly RH (rear seat right side) takes to change from about
16 - 28 A to 1 A or less. (Cut-off check)
Standard:
About 4 to 90 seconds
the power window (rear seat right side door glass) goes down
by operating the power window regulator switch assembly (rear
seat right side power window SW). (Recovery check)

MOTOR ASSEMBLY RH
GETtheMANUALS.org
OK
REPAIR OR REPLACE WIRE HARNESS OR CONNECTOR (BETWEEN POWER WINDOW

REGULATOR SW [REAR SEAT RIGHT SIDE] AND POWER WINDOW REGULATOR
MOTOR ASSEMBLY RH)
WS
GETtheMANUALS.org
WS–23
REAR LEFT SIDE WINDOW DOES NOT OPERATE WITH REGULATOR

SWITCH
DESCRIPTION
The power window regulator motor assembly LH (rear seat left side) is activated when the power window switch assembly (rear
seat left side power window SW) is operated when the window lock switch of the power window regulator master switch assembly
(driver seat power window SW) is NORMAL and the ignition switch is the ON position.
CIRCUIT DIAGRAM

Power Window Regulator Motor
Assembly (Rear Seat LH)
POWER 30A
B1
B B4 5 4 1 D
RLD SD D M
B6
E B5 1 2 2 U
RLU SU U
WS
3
B

(Rear Seat LH)
B141710J06
1 INSPECT FUSES
(a) Check the fuses in the junction block.

Standard:
NG REPLACE FUSES
GETtheMANUALS.org
OK
HINT:
nected)
RLU RLD (1) Using a tester, check the voltage between terminal B4 (RLD)
and terminal B5 (RLU) of the connector when the switch of the
rear seat left side is operated.
Standard:
10 to 14 V

B144247J04
OK
WS
HINT:
(1) Disconnect the power window regulator master switch assem-
bly (driver's seat power window SW).
layout, See page WS-6.)
1 2 3 4 5
Standard:
6 7 8 9 10 11 12
Measure-
Tester Connection
Item ment Con- Voltage
(Terminal symbol)
E dition
B144248J03 1 (B) ←→ 6 (E) Voltage Always 10 to 14 V

CONNECTOR
OK
HINT:
GETtheMANUALS.org
WS–25
(1) Disconnect the connector of the power window switch assembly

(rear seat left side power window SW).
(1) Using the electrical tester, check the voltage between terminal 5
(SD) and terminal 1 (SU) of the connector when the passenger
seat switch is operated. (For terminal layout, See page WS-6.)
Standard:
10 to 14 V
5 4 3 2 1
SD SU
SWITCH ASSEMBLY
B141749J01
OK

SWITCH ASSEMBLY AND POWER WINDOW REGULATOR SWITCH ASSEMBLY [REAR SEAT LEFT
SIDE])
HINT:
(1) Disconnect connector B of the power window SW (rear seat left
side) and the power window regulator master switch assembly. WS
Power Window Regulator Master (1) Using the electrical tester, measure the continuity between the
Switch Assembly terminals of the connector on the vehicle wire harness side and
(Driver Side Power Window SW) body ground. (For terminal layout, See page WS-6.)
RLD+ RLU+ Standard:
Power Window Regulator Master

1 2 3 4 5
Switch SW ←→ Power Window Measure-
6 7 8 9 10 11 12 SW Item ment Con- Voltage
Symbol)
There is
Power Window Regulator Switch continuity
Assembly LH (Rear Seat LH) between
B4 (RLD+) ←→ 5 (D+) Continuity Always terminals
and no
short on +B
or GND
There is
1 2 3 4 5 continuity
between
B5 (RLU+) ←→ 1 (U+) Continuity Always terminals
U+ D+ B141836J03 and no
short on +B
or GND

MOTOR ASSEMBLY LH
OK
GETtheMANUALS.org
6 CHECK POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
LH (rear seat left side)
NOTICE:
motor.
Activation Axis
Standard:
Rotation
Right
Measurement Condition Operational Direction
minal 1
Rotation
minal 2
Left
minal 1

WS NOTICE:
The operation should be performed with the rear window regula-
tor LH, the power window regulator motor assembly LH (rear
seat left side) and the door glass installed in the vehicle.
(1) Set the probe of the electrical tester to the wire harness of con-
nector terminal 1 of the power window regulator motor assem-
bly LH (passenger seat).
NOTICE:
motor assembly LH (rear seat left side).
(2) Fully close the rear seat left side door glass.
assembly (rear seat left side power window SW) by pressing
and holding the UP side of the switch. While doing so, check
how long the current of the power window regulator motor
assembly RH (rear seat left side) takes to change from about 16
- 28 A to 1 A or less. (Cut-off check)
Standard:
4 to 90 sec.
lator master switch assembly (rear seat left side power window

CONNECTOR
GETtheMANUALS.org
WS–27
OK
REPAIR OR REPLACE WIRE HARNESS OR CONNECTOR (BETWEEN POWER WINDOW

REGULATOR SWITCH ASSEMBLY (REAR SEAT LEFT SIDE) AND POWER WINDOW
REGULATOR MOTOR ASSEMBLY LH)
WS
GETtheMANUALS.org
EACH WINDOW DOES NOT OPERATE WITH MASTER SWITCH

(SWITCH INSTALLED AT EACH WINDOW IS AVAILABLE)
DESCRIPTION
The power window motor of each seat is activated when remote switch signals for the other seats are sent by the power window
regulator master switch assembly to the power window switch assemblies while the ignition switch is in the ON position.
CIRCUIT DIAGRAM

Power Window Regulator
*1:B12
Motor Assembly
*2:B3
POWER 30A
*1:PD *3:B4 5 4
(Each Seat)
B1 *2:RRD SD D
B
*3:RLD
*1:B7
B6 *2:B2
E *1:PU *3:B5 1
*2:RRU SU U
*3:RLU 2
WS 3
B

(Each Seat)
*1:P Seat
*2:RR Seat
*3:RL Seat
B141826J03
1 CHECK WIRE HARNESS OR CONNECTOR (RELEVANT AREA)
HINT:
(1) Disconnect the power window regulator switch assembly (rele-
vant seats power window SW).
switch assembly.
GETtheMANUALS.org
WS–29

Power Window Regulator (1) Using the tester, measure the continuity between terminals of
Master Switch Assembly the connector on the vehicle wire harness side. (For terminal
(Driver Side Power Window SW) layout, See page WS-6.)
RRU+ RRD+ RLD+ RLU+ Standard:
Passenger seat
1 2 3 4 5
POWER WINDOW REGULATOR MASTER SWITCH
6 7 8 9 10 11 12 ASSEMBLY ←→ POWER WINDOW REGULATOR
Continuity
SWITCH ASSEMBLY
Terminal Connection (Terminal Symbol)
PU+ PD+
12 (PD+) ←→ 5 (D+) Continuity
Power Window Regulator 7 (PU+) ←→ 1 (U+) Continuity
Switch Assembly (Each Seat)
Rear seat right side
ASSEMBLY ←→ POWER WINDOW REGULATOR
Continuity
SWITCH ASSEMBLY
1 2 3 4 5
3 (RRD+) ←→ 5 (D+) Continuity
2 (RRU+) ←→ 1 (U+) Continuity
U+ D+ B141836J04
Rear seat left side
ASSEMBLY ←→ POWER WINDOW REGULATOR
Continuity
SWITCH ASSEMBLY
WS
4 (RLD+) ←→ 5 (D+) Continuity
5 (RLU+) ←→ 1 (U+) Continuity

CONNECTOR
OK
REPLACE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
GETtheMANUALS.org
WS–30 GLASS AND WINDOW - WINDSHIELD DEICER SYSTEM

BODY AND
GLASS ANDELECTRICAL
WINDOW
OPERATION CHECK
1. CHECK WINDSHIELD DEICER OPERATION
(b) Check that when the windshield deicer switch located at the
lower right side of the driver's seat is pressed, the indicator illu-
minates and the windshield deicer starts to warm up.
(c) Check that the indicator light turns off after about 15 minutes,
and that the deicer stops operation.
WS
GETtheMANUALS.org
GLASS AND WINDOW - WINDSHIELD DEICER SYSTEM
WS–31
LOCATION
WINDSHIELD DEICER
DEICER RELAY
WS
LEFT-HAND DRIVE RIGHT-HAND DRIVE
WINDSHIELD DEICER SWITCH
B148368J01
GETtheMANUALS.org

Windshield deicer does not operate Go to the relevant flowchart (DEICER DOES NOT OPERATE) WS-34

SHOOTING
HINT:
(See page WS-33)
WS
HINT:
(See page WS-32)

STEP 7)
(a) CHECK FUNCTION (See page WS-30.)
6 CONFIRMATION TEST
END
GETtheMANUALS.org
WS–33

CHECK

Windshield Deicer System
/ /
Customer’s Name License Plate No. First Registered Year 20__/ /
Model VIN
Written By Inspector’s Name Engine Type Odometer Reading km/mile
Conditions (Method of use and
results)
WS
Weather Clear Cloudy Rainy Snowy Others( ) Temperature Approx. ( )°C/°F
Windshield deicer does not operate
Others
Problem
Symptoms
Condition Returns To Normal IG ON Engine starting ( ) SW operation

IG OFF ON ( ) SW operation Others ( )
Problem Occurs Not present
B118918
GETtheMANUALS.org
Windshield deicer does not operate

DESCRIPTION
The front deicer is activated by operating the windshield deicer switch while the ignition switch is in the ON position.
The windshield deicer is controlled by the windshield deicer switch, and when the switch ON signal is received, the DEICER relay
operates for 15 minutes. Also, the operation of the DEICER relay stops if the switch OFF signal is received within 15 minutes.
CIRCUIT DIAGRAM
Deicer Relay Windshield Deicer Switch
LH-IG 1 +S -S 2 4
IG Relay D
DEICER 5 B L 3
Battery
2
IG
Front Deicer
3 E B 1 3
E
WS
B2 2
B142930
1 CHECK FUSE (DEICER, LH-IG)
NG REPLACE FUSES
OK
2 CHECK DEICER RELAY
(a) Remove the DEICER relay.
GETtheMANUALS.org
WS–35
(b) Using the electrical tester, check the continuity between each of the
Standard:

Terminal 1 ←→ Terminal 2 Continuity
Terminal 3 ←→ Terminal 5 No continuity
(c) Apply battery voltage between terminal 1 and 2 of the connector.

B118916 (d) Using the electrical tester, check the continuity between terminal 3
and 5 of the connecter.
Standard:
Continuity
NG REPLACE DEICER RELAY
OK
3 CHECK WIRE HARNESS AND CONNECTOR (BETWEEN POWER SOURCE SYSTEM AND WIND-
SHIELD DEICER SWITCH)
(a) Connect the DEICER relay.

(b) Disconnect the windshield deicer switch connector.
(d) Using the electrical tester, check the voltage between the vehicle wire WS
harness side connector of terminal 4 (D) and terminal 3 (E).
Standard:
10 to 14 V

CONNECTOR
E D
E105444J02
OK
4 CHECK WINDSHIELD DEICER (TERMINAL D)
(a) Connect the windshield deicer switch connector.

(c) Using the electrical tester, check the voltage of each terminal of the
windshield deicer switch assembly.
Standard:
Terminal No.
Measurement
(Measurement Item Standard
Condition
Connection)
IG(+) IG ON, wind- 1 V or less → 10

D(+) E(-)
shield deicer to 14 V (15 ± after
4 (D) ←→ 3 (E) Voltage
E105443J01
switch OFF → three minutes at
ON 1 V or less)
GETtheMANUALS.org
Terminal No.
Measurement
(Measurement Item Standard
Condition
Connection)
With the ignition
switch in the ON
Windshield position, wind-
10 to 14 V → 1 V 10 to 14 V → 1 V
deicer switch shield deicer
or less or less
OFF → ON switched ON →
OFF (when
pushed)
NG REPLACE WINDSHIELD DEICER
OK
5 CHECK WIRE HARNESS AND CONNECTOR (BETWEEN POWER SOURCE SYSTEM AND WIND-
SHIELD DEICER)
HINT:
(a) Disconnect the connector of the windshield deicer.
(b) Using the electrical tester, measure the voltage between terminals of
the connector on the vehicle wire harness side.
Standard:
WS
1 2 Inspection Terminal
Standard
(Terminal symbol)
1 (L1) ←→ 3 (E) 10 to 14 V
L1 L2
2 (L2) ←→ 3 (E) 10 to 14 V
E
B101533J02
CONNECTOR
OK
6 CHECK WINDSHIELD DEICER UNIT
(a) Using the electrical tester, check the continuity between the terminals
of the connector of the windshield deicer.
Standard:
2 1 Inspection Terminal
Standard
(Terminal symbol)
B2 + 1 (+) ←→ 3 (E) Continuity
2 (B2) ←→ 3 (E) Continuity
E
B119093J02
NG REPAIR FRONT WINDOW DEICER OR
REPLACE WINDSHIELD GLASS
OK
REPLACE WINDSHIELD DEICER
GETtheMANUALS.org
GLASS AND WINDOW - REAR WINDOW DEFOGGER SYSTEM
WS–37

BODY AND
GLASS ANDELECTRICAL
WINDOW
OPERATION CHECK
1. CHECK REAR WINDOW DEFOGGER OPERATION
(b) Check that when the rear window defogger switch is pressed,
the indicator illuminates and the rear window defogger switch
starts to warm up.
(c) Check that the indicator light turns off after about 15 minutes,
and the rear window defogger stops operation.
WS
GETtheMANUALS.org
WS–38 GLASS AND WINDOW - REAR WINDOW DEFOGGER SYSTEM
LOCATION
INSTRUMENT PANEL JUNCTION

BLOCK ASSEMBLY
DEFOG RELAY
DEFOG FUSE
BACK DOOR GLASS

(PRINTED HEAT WIRE)
WS
REAR WINDOW DEFOGGER SWITCH
B148494J01
GETtheMANUALS.org
WS–39

Go to relevant flowchart (REAR WINDOW DEFOGGER DOES
Rear window defogger system does not operate WS-42
NOT OPERATE)

SHOOTING
HINT:
See page WS-41.
WS
HINT:
See page WS-39.

STEP 5)
(a) CHECK FUNCTION (See page WS-37.)
GETtheMANUALS.org
6 CONFIRMATION TEST
END
WS
GETtheMANUALS.org
WS–41

CHECK

Windshield Deicer System
/ /
Customer’s Name License Plate No. First Registered Year 20__/ /
Model VIN
Written By Inspector’s Name Engine Type Odometer Reading km / mile
Conditions
WS
Weather Clear Cloudy Rainy Snowy Others( ) Temperature Approx. ( ) °C / °F
Rear window defogger does not operate
Others
Problem
Symptoms
Condition Returns To Normal IG ON Engine starting ( ) SW operation

IG OFF ON ( ) SW operation Others ( )
Problem Occurs Not present
B118917
GETtheMANUALS.org
REAR WINDOW DEFOGGER DOES NOT OPERATE

DESCRIPTION
The rear window defogger is activated by operating the rear window defogger switch on the instrument cluster finish panel CTR
while the ignition switch is in the ON position.
The rear window defogger is controlled by heater control No. 3. When the switch ON signal is received, the DEFOG relay oper-
ates for 15 minutes. Also, the DEFOG relay operation stops if the switch OFF signal is received within 15 minutes.
CIRCUIT DIAGRAM
DEFOG Relay Heater Control No. 3
LH-IG Fuse (10A) 1 +S -S 2 2

IG Relay RrDEF
5 B L 3
Battery
Fusible Link Assembly
(DEFOG 15A)
3
IG
Rear Defogger
1 1
E
WS
B148495
1 CHECK FUSE (LH-IG, FUSIBLE LINK ASSEMBLY [DEFOG])
(a) Make sure that the LH - IG fuse or the fusible link assembly (DEFOG)
is not burned out.
NG REPLACE FUSES
OK
2 CHECK DEFOG RELAY
(a) Remove the DEICER relay.

(b) Using the electrical tester, check the continuity between the each of
terminals.
Standard:

1←→2 Continuity
(c) Apply battery voltage between terminal 1 and 2 of the connector.

B118916 (d) Using the electrical tester, check the continuity between the each of
terminals.
GETtheMANUALS.org
WS–43
NG REPLACE DEFOG RELAY
OK
3 CHECK BACK DOOR GLASS (REAR DEFOGGER AREA)
(a) Using the electrical tester, check the continuity between terminal 1 of
the power source side connector of the rear defogger and terminal 1
of the body ground side connector.
Standard:
Continuity
NG REPAIR BACK WINDOW GLASS (HEATER

ELEMENT LINES)
OK
4 CHECK REAR DEFOGGER SWITCH
(a) Using the electrical tester, check the continuity between the terminals
Rr Defogger Swich of the connector of the heater control No. 3.
Terminal No. Measurement Condition Continuity WS

3 (IG) ←→ 1 (E) Rr DEF switch OFF None
3 (IG) ←→ 1 (E) Rr DEF switch OFF Continuity
3 (IG) ←→ 2 (Rr DEF) Rr DEF switch OFF None
3 (IG) ←→ 2 (Rr DEF) Rr DEF switch OFF Continuity
NG REPLACE REAR DEFOGGER SWITCH
IG RrDEF E
I100850J04
OK
GETtheMANUALS.org
WS–44 GLASS AND WINDOW - POWER WINDOW REGULATOR MOTOR ASSEMBLY RH

BODY AND
GLASS ANDELECTRICAL
WINDOW
1. POWER WINDOW REGULATOR MOTOR ASSEMBLY RH
(INSTALLED IN FRONT SIDE)
(a) Check the operation of the power window motor.
NOTICE:
The operation should be performed with the front door win-
dow regulator RH, the power window regulator motor
assembly RH (front seat right side) and the front door glass
(RH) installed in the vehicle.
(1) Set the probe of the electrical tester to the wire harness of
connector terminal 2 of the power window regulator motor
assembly RH (front seat right side).
NOTICE:
Turn the probe arrow toward the power window regu-
lator motor assembly RH (front seat right side).
(2) Fully close the power window (front seat right side door
glass).
(3) Wait about 60 seconds after the window is fully closed,
E102972 and re-operate (first time) the power window regulator
master switch assembly (front seat right side power win-
WS dow SW) by pressing and holding the UP side of the
switch. While doing so, check how long the current of the
power window regulator motor assembly RH (front seat
right side) takes to change from about 16 - 28 A to 1 A or
less. (Cut-off check)
Standard:
4 to 90 sec.
(4) Wait about 60 seconds after the cut-off check, and check
that the power window (front seat right side door glass)
goes down by operating the power window regulator mas-
ter switch assembly (front seat right side power window
INSPECTION
(a) Check the operation of the power window regulator motor
assembly RH (front seat right side).
NOTICE:
Do not apply voltage to any terminals of the motor other
the terminals 1 and 2. Doing so will damage the pulse sen-
sor in the motor.
GETtheMANUALS.org
GLASS AND WINDOW - POWER WINDOW REGULATOR MOTOR ASSEMBLY RH
WS–45
(1) Check that the power window regulator motor assembly

Activation Axis
RH (front seat right side) operates smoothly when apply-
ing voltage to the terminals of the power window regulator
Rotation motor assembly RH (front seat right side) connector.
Right Standard:
Rotation Positive (+) battery terminal ←→ Ter-

Left minal 1
E102950J01 Negative (-) battery terminal ←→ Ter-
minal 2
minal 1
WS
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WS–46 GLASS AND WINDOW - POWER WINDOW REGULATOR MOTOR ASSEMBLY LH

BODY AND
GLASS ANDELECTRICAL
WINDOW
1. POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
NOTICE:
The operation should be performed with front door window
regulator LH, power window regulator motor assembly LH
and front door glass (LH) installed in the vehicle.
assembly LH.
NOTICE:
lator motor assembly LH.
(2) Fully close the door glass.
and re-operate (first time) the power window regulator
E102972 master switch assembly (front seat left side power window
SW) by pressing and holding the UP side of the switch.
While doing so, check how long the current of the power
WS window regulator motor assembly LH takes to change
from about 16 - 28 A to 1 A or less. (Cut-off check)
Standard:
4 to 90 sec.
that the power window (rear seat left side door glass)
goes down by operating the power window regulator
switch assembly (rear seat left side power window SW).
(Recovery check)
INSPECTION
assembly LH (front seat left side)
NOTICE:
sor in the motor.
LH (front seat left side) operates smoothly when applying
Activation Axis
voltage to the terminals of the power window regulator
Rotation
motor assembly LH (front seat left side) connector.
Right Standard:

Rotation
Left minal 2
minal 1
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GLASS AND WINDOW - POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
WS–47

minal 2
WS
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WS–48 GLASS AND WINDOW - POWER WINDOW REGULATOR MOTOR ASSEMBLY RH

BODY AND
GLASS ANDELECTRICAL
WINDOW
(INSTALLED IN REAR SIDE)
NOTICE:
The operation should be performed with the rear door win-
dow regulator RH, the power window regulator motor
assembly RH (rear seat right side) and the rear door glass
(RH) installed in the vehicle.
assembly RH (rear seat right side).
NOTICE:
lator motor assembly RH (rear seat right side).
(2) Fully close the power window (rear seat right side door
glass).
master switch assembly (rear seat right side power win-
WS dow SW) by pressing and holding the UP side of the
switch. While doing so, check how long the current of the
power window regulator motor assembly RH (rear seat
right side) takes to change from about 16 - 28 A to 1 A or
less. (Cut-off check)
Standard:
4 to 90 sec.
that the power window (rear seat right side door glass)
switch assembly (rear seat right side power window SW).
(Recovery check)
INSPECTION
assembly RH (rear seat right side )
NOTICE:
sor in the motor.
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GLASS AND WINDOW - POWER WINDOW REGULATOR MOTOR ASSEMBLY RH
WS–49

RH (rear seat right side) operates smoothly when apply-
Activation Axis
ing voltage to the terminals of the power window regulator
Rotation motor assembly RH (rear seat right side) connector.
Right Standard:

Left minal 2
minal 1
minal 2
WS
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WS–50 GLASS AND WINDOW - POWER WINDOW REGULATOR MOTOR ASSEMBLY LH

BODY AND
GLASS ANDELECTRICAL
WINDOW
NOTICE:
The operation should be performed with the rear window
regulator LH, the power window regulator motor assembly
LH (rear seat left side) and the rear door glass (LH)
installed in the vehicle.
(1) Set the DC400A probe of the electrical tester to the wire
harness of connector terminal 1 of the power window reg-
ulator motor assembly LH (passenger seat).
NOTICE:
lator motor assembly LH (rear seat left side).
(2) Fully close the power window (rear seat left side door
glass).
master switch assembly (rear seat left side power window
WS SW) by pressing and holding the UP side of the switch.
While doing so, check how long the current of the power
window regulator motor assembly RH (rear seat left side)
takes to change from about 16 - 28 A to 1 A or less. (Cut-
off check)
Standard:
4 to 90 sec.
that the power window (rear seat left side door glass)
switch assembly (rear seat left side power window SW).
(Recovery check)
INSPECTION
assembly LH (rear seat left side)
NOTICE:
sor in the motor.
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GLASS AND WINDOW - POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
WS–51

Activation Axis
LH (rear seat left side) operates smoothly when applying
voltage to the terminals of the power window regulator
Rotation motor assembly LH (rear seat left side) connector.
Right Standard:

Left minal 1
minal 2
minal 1
WS
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WS–52 GLASS AND WINDOW - WINDSHIELD GLASS
WINDSHIELD GLASS
BODY AND
GLASS ANDELECTRICAL
WINDOW
COMPONENTS
CLIP
CLIP CLIP
CLIP
CLIP

WS
FRONT DOOR OPENING

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GLASS AND WINDOW - WINDSHIELD GLASS
WS–53
MAP LIGHT EQUIPPED

VEHICLES
ASSIST GRIP
VISOR ASSEMBLY RH WS
MAP LIGHT ASSEMBLY
VISOR HOLDER
FRONT WIPER ARM HEADCAP
T=22{224}
VISOR HOLDER
T=22{224} VISOR ASSEMBLY LH
FRONT WIPER ARM

AND BLADE ASSEMBLY RH
FRONT WIPER ARM
AND BLADE ASSEMBLY LH
COWL TOP VENTILATOR LOUVER
BONNET (HOOD) TO COWL TOP SEAL

B148492J01
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WINDSHIELD GLASS STOPPER NO. 1
WINDSHIELD GLASS
STOPPER NO. 2
WS
WINDSHIELD GLASS ADHESIVE DAM
WINDSHIELD OUTSIDE MOLDING
WINDSHIELD GLASS
NON-REUSEABLE PART
B143253J01
REMOVAL
2. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (See

page WW-5)
3. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See

page WW-5)
4. REMOVE COWL TOP VENTILATOR LOUVER (See page WW-5)

(See page IP-12)

SHIELD AIRBAG) (See page IP-12)

SHIELD AIRBAG)

AIRBAG) (See page IP-13)
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WS–55

AIRBAG)
11. REMOVE MAP LIGHT ASSEMBLY (WITH MAP LIGHT) (See page
IR-6)
12. REMOVE ROOM LIGHT ASSEMBLY NO. 1 (WITHOUT MAP

LIGHT) (See page IR-7)
13. REMOVE ASSIST GRIP (See page IR-7)
14. REMOVE VISOR ASSEMBLY RH (See page IR-7)
16. REMOVE VISOR HOLDER (See page IR-8)

HINT:
Partially remove the front side of the roof headlining assembly to
allow the windshield glass to be removed or installed.
18. REMOVE WINDSHIELD OUTSIDE MOULDING
(a) Using a cutter knife, cut off the part of the windshield outside
Cut
moulding as illustrated.
NOTICE:
• Do not damage the windshield glass and body.
• If the body surface is damaged, apply an antirust treat-
ment after removing the windshield glass. WS
(b) Remove the windshield outside moulding by using your hand to
pull it out.
B127854J01
19. REMOVE WINDSHIELD GLASS

NOTICE:
• Windshield glass stoppers No. 1 and No. 2, as well as the
1 Piece Type windshield glass retainer are installed in the area of the wind-
shield glass shown in the illustration. Therefore, be sure not
to damage the windshield glass when cutting it.
• Use a windshield knife or piano wire depending on the areas
to be cut or conditions.
Stopper Stopper
• Have a helper hold the windshield glass from the outside
using rubber suction to prevent the windshield glass falling
during the operation.
HINT:
There are two types windshield glass stoppers depending on the
vehicle: a 1 piece type and a 2 piece type.
2 Piece Type
B143254J01
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(a) Put protection tape on the body surface around the outside line
For New Windshield Glass of the windshield glass.
NOTICE:
When re-using the same windshield glass, use a pen to
mark the masking tape on both the windshield glass and
the body panel areas before removing it. This will allow you
Protective Tape to be able to align the glass when reinstalling it later.
For Reused Windshield Glass
Protective Tape
Apply Packing Tape.

Place Matchmarks.
B116655J01
(b) Disconnect the connector of the windshield deicer. (For vehicles
WS (c)
with cold weather specifications)
Apply suction cups to the windshield glass.
E132177
(d) Put piano wire (0.6 mm is appropriate) through the locations

shown in the illustration, and tie each end to wood blocks or
pinch with vice pliers or a similar tool.
(e) Pull the piano wire end alternately and leave the windshield
glass stopper, then cut off adhesive.
NOTICE:
• Do not let the piano wire touch the windshield glass
edge with force.
• When working on the air bag area of the curtain shield,
B143256 make sure not to damage it with piano wire.
• When working on the instrument panel (safety pad)
area, use a plastic protective board to prevent damage
by the piano wire.
• Be careful not to cross the piano wire to prevent the
wire from snapping.
(f) Hold the suction cups, disconnect the claws of the windshield
glass stopper No. 1 and remove the windshield glass.
NOTICE:
Make sure that the windshield glass does not fall.
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WS–57
(g) Remove windshield glass stopper No. 2 (2 piece type, when

reusing windshield glass).
(1) Remove windshield glass stopper No. 2 with a scraper.
NOTICE:
• Do not damage the windshield glass.
• Make sure to replace the previously installed wind-
shield glass stopper No. 2 with a new part.
(h) Remove windshield glass stopper No. 1 (1 piece type, when
reusing windshield glass)
(1) Remove windshield glass stopper No. 1 with a scraper.
NOTICE:
Do not damage the windshield glass.
HINT:
When installing the windshield glass, use a 2 piece type
windshield glass stopper No. 1.
(i) Remove windshield glass stopper No. 1 (2 piece type)
Stopper
(1) Remove the windshield glass stopper No. 1.
NOTICE:
Make sure to replace the previously installed wind-
shield glass stopper No. 1 with a new part.
INSTALLATION
WS
B112215J01
1. CLEAN WINDSHIELD GLASS

(a) Remove any adhesive or double-sided tape that is remaining on
the windshield glass surface using a scraper or other tools.
(when reusing windshield glass)
NOTICE:
Do not damage the windshield glass.
(b) Clean the circumference of the windshield glass with a solvent.
NOTICE:
Always clean the windshield glass, even when using a part.
B112214
2. INSTALL WINDSHIELD GLASS STOPPER NO. 1

Stopper
(a) Install the new windshield glass stopper No. 1 to the body side.
HINT:
The new windshield glass stopper No. 1 comes only in a two
piece type. Therefore, even when working on a windshield with
a 1 piece type stopper, you must use a two part stopper.
3. INSTALL WINDSHIELD GLASS STOPPER NO. 2

(a) Apply a primer to the installation part of the windshield glass
stopper No. 2 of the windshield glass. Make sure to use the
B112215J01
appropriate primer.
NOTICE:
Do not apply too much primer.
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(b) Install the new windshield glass stopper No. 2 to the windshield
glass as shown in the illustration.
Ceramic Notch Ceramic Notch
10.5mm 10.5mm
Stopper Center Line Stopper Center Line
Units [mm]
B143255J01
NOTICE:
• Wait for the primer to dry. (The primer will dry in approx-
imately 3 minutes.) Then install windshield glass stop-
per No. 2.
• Be careful to install windshield glass stopper No. 2 in
WS the correct direction.
4. INSTALL WINDSHIELD GLASS ADHESIVE DAM

(a) Apply a primer to the installation part of the adhesive dam of the
windshield glass. Make sure to use the appropriate primer.
NOTICE:
(b) Install the new windshield glass adhesive dam at the location
shown in the illustration. Install the dam along the adhesion
center line of the windshield glass.
NOTICE:
A
Wait for the primer to dry. (The primer will dry in approxi-
A mately 3 minutes.) Then install the windshield glass adhe-
C C
sive dam.
5. INSTALL WINDSHIELD OUTSIDE MOULDING

(a) Apply a primer to the installation part of the outside moulding of
the windshield glass. Make sure to use the appropriate primer.
B
NOTICE:
B Do not apply too much primer.
A-A,C-C B-B
7 24.9
B143257
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WS–59
(b) Install the new windshield outside moulding to the windshield

glass as shown in the illustration.
Back Side NOTICE:
Wait for the primer to dry. (The primer will dry in approxi-
A
mately 3 minutes.) Then install the windshield glass out-
A side moulding.
B B
A-A,B-B
B143263
6. INSTALL WINDSHIELD GLASS
Adhesive Adhesive
(a) CLEAN INSTALLATION SURFACE OF BODY
(1) If the adhesive remaining on the surface of the vehicle
WS
body is rough, use a cutter knife to smooth it down.
NOTICE:
Make sure to leave a little adhesive.
(2) Clean the installation surface of the body with a solvent.
(b) PREPARATION FOR WINDSHIELD GLASS INSTALLATION
(1) Apply suction cups to the windshield glass.
B106081J01 (2) Place the windshield glass on the body, and align the top
and side of the windshield glass evenly (making sure that
the gap between the body and the windshield glass edges
is even around the circumference of the glass).
(3) Apply masking tape or a similar tape to the windshield
glass and body panel parts, and mark them with a pen to
help alignment during installation. (when using new wind-
shield glass)
NOTICE:
From inside the cabin, make sure that windshield
glass stopper No. 1 and windshield glass stopper No.
2 are securely engaged.
Apply Packing Tape. HINT:
Place Matchmarks. When reusing the windshield glass, check or correct the
B116661J01
position of the installation marks.
(4) Remove the windshield glass.
(5) Coat the exposed part of the vehicle body (places where
there is no adhesive left on the body) with primer. Make
sure to use the appropriate primer.
NOTICE:
• Do not apply too much primer.
• Do not apply primer to the adhesive.
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• Use extra care when applying primer to panel

joints or to areas that have been spot welded.
(6) Apply primer to the windshield glass as shown in the illus-
tration. Make use to use the appropriate primer.
A-A C-C 7.0

7.0
A B
A B
C C
D D-D
B-B
7.0 22.0
D
Units [mm]
B143258
NOTICE:
(c) Cut off the tip of the adhesive tube, as shown in the illustration.
WS (d) Put the adhesive tube into the sealant gun.
7.0
12.0
Units [ mm ] B106205J07
GETtheMANUALS.org
WS–61
(e) Apply a bead of adhesive along the windshield glass adhesive

dam and the windshield outside moulding, as shown in the illus-
tration below.
A-A B-B
A B
3.5 3.5
A B
C C
12.0 12.0
7.0 7.0
D
C-C D-D
3.5 7.0 14.4
12.0 12.0
WS
7.0 7.0
7.0
Units [mm]
B143259
NOTICE:
Wait for the primer dry. (The primer will dry in approxi-
mately 3 minutes.) Then apply the adhesive.
(f) INSTALL WINDSHIELD GLASS
(1) Using the appropriate suction cups to hold the windshield
glass, align the new windshield glass using the installation
marks and install.
NOTICE:
• Allow the primer on the vehicle body to dry before
installing the windshield glass. (The primer dries
in approximately 3 minutes.)
Align Matchmarks • From inside the cabin, make sure that windshield
B116661J02 glass stopper No. 1 and windshield glass stopper
No. 2 are securely engaged.
(2) Press the front surface of the windshield glass lightly and
it attach it securely.
HINT:
Pressing force: 98 N (10 kgf) or more
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(3) Using a scraper, clean away excess adhesive or add

adhesive where necessary.
Adhesive
NOTICE:
Make sure to also apply adhesive to the glass edge
surface.
(4) Remove any excess adhesive before it hardens.
(5) Press the windshield glass down with protection tape or
similar until the adhesive hardens.
HINT:
B035036J01 Follow the instructions on the adhesive regarding mini-
mum drying time or wait time required before the vehicle
can be driven.
(6) Connect the windshield deicer connector. (For vehicles
with cold weather specifications)
7. CHECK FOR WATER LEAKS AND REPAIR

(a) After the adhesive hardens, pour water on the outside of the
vehicle and check that no water leaks into the cabin.
(b) When a water leak occurs, refix the glass from the beginning
after removing the water.

E132177
9. INSTALL VISOR HOLDER (See page IR-10)
WS 10. INSTALL VISOR ASSEMBLY RH (See page IR-10)
12. INSTALL ASSIST GRIP (See page IR-10)
13. INSTALL MAP LIGHT ASSEMBLY (WITH MAP LIGHT) (See page
IR-10)
14. INSTALL ROOM LIGHT ASSEMBLY NO. 1 (WITHOUT MAP

LIGHT) (See page IR-10)

SHIELD AIRBAG) (See page IP-16)

SHIELD AIRBAG)

AIRBAG) (See page IP-16)

AIRBAG)

(See page IP-17)
21. INSTALL COWL TOP VENTILATOR LOUVER (See page WW-8)
22. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See

page WW-9)
23. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See

page WW-10)
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WS–63

INSPECTION
1. CHECK WINDSHIELD GLASS
(a) Disconnect the connector of the windshield deicer.
(b) Using the electrical tester, check the continuity between each of
the connecter terminals.
Standard:

1←→3 Continuity
2←→3 Continuity
B119093
WS
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WS–64 GLASS AND WINDOW - BACK WINDOW GLASS
BACK WINDOW GLASS

BODY AND
GLASS ANDELECTRICAL
WINDOW
COMPONENTS

BACK WINDOW MOULDING OUTSIDE
BACK WINDOW GLASS CLIP
REAR WIPER ARM HEAD CAP
WS
T=5.5{56}
T=5.5{56}
BACK DOOR GLASS
REAR WIPER ARM AND BLADE ASSEMBLY

BACK WINDOW
GLASS SPACER
BACK DOOR TRIM PANEL ASSEMBLY

B140140J02
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GLASS AND WINDOW - BACK WINDOW GLASS
WS–65
REMOVAL
1. REMOVE SPARE TIRE
2. REMOVE CENTER STOP LIGHT COVER (See page LI-43)
3. REMOVE CENTER STOP LIGHT ASSEMBLY (See page LI-43)
4. REMOVE BACK DOOR TRIM PANEL ASSEMBLY (See page ED-

47)
6. REMOVE REAR WIPER ARM (See page WW-15)
8. REMOVE REAR WIPER MOTOR ASSEMBLY (See page WW-15)
9. REMOVE BACK DOOR GLASS

NOTICE:
• When re-using the same glass, use a pen to put the match-
mark on both the glass and the body panel areas before
removing it. This will allow you to be able to align the glass
when reinstalling it later.
• Because clips and spacers are installed on the glass in the
positions shown in the illustration, take extra care not to
damage the windshield glass when the removing the adhe-
Piano Wire
sive. WS
• Use a windshield knife or piano wire depending on the areas
to be cut or conditions.
• Have a helper hold the glass from the outside using suction
cups in order to prevent the glass from falling during the
Spacer Apply Adhesive
operation.
:Clip B141878 (a) Disconnect each connector.
(b) Put protection tape on the body surface around the outside line
of the glass.
(c) Apply suction cups.
Protective Tape B141877
(d) Put piano wire (0.6 mm is appropriate) through the locations

shown in the illustration, and tie each end to wood blocks.
(e) Pull the piano wire end alternately and leave the glass spacers
and clips, then cut off adhesive.
Piano Wire NOTICE:
• Do not let the piano wire touch the glass edge with
force.
Spacer Apply Adhesive
wire from snapping.
:Clip B141878 (f) Disengage the clip, and remove the back door glass while hold-
ing it with suction cups.
10. REMOVE BACK WINDOW MOLDING OUTSIDE
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INSTALLATION
1. CLEAN BACK DOOR GLASS
(a) Using a scraper or a similar tool, remove the adhesive or dam
that is remaining on the glass. (when reusing glass)
NOTICE:
HINT:
Because the purpose of the clips is for positioning, it is not nec-
essary to reuse them when reusing the glass if they are dam-
aged.
BO03986J01 (b) Clean the outer edge of the glass with a solvent.
HINT:
Even when using new glass, clean the glass with a solvent.
2. INSTALL BACK WINDOW GLASS SPACER
(a) Install the 7 back window glass spacers, aligning the position of
the adjustment marks on the back door glass with the center.
Marking
WS
B142170
3. INSTALL BACK WINDOW GLASS CLIP

(a) Install the back window glass clip RH in the position shown in
the illustration.
:Clip B146385
4. INSTALL BACK WINDOW MOULDING OUTSIDE

Back Side (a) Install the back window molding outside in the position shown in
the illustration.
B B
A A
A-A, B-B 3mm
B146399
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WS–67
5. INSTALL BACK DOOR GLASS

Adhesive Adhesive (1) If the adhesive remaining on the surface of the vehicle
NOTICE:
(b) INSTALL BACK DOOR GLASS
(1) Apply suction cups to the back door glass.
(2) Place the glass on the body, and align the outer edge of
ZU07174J01 the windshield glass evenly (making sure that the gap
between the body and the windshield glass edges is even
around the circumference of the glass).
(3) Apply masking tape or a similar tape to the glass and
body panel parts, and mark them with a pen to help align-
ment during installation. (when using new glass)
NOTICE:
When reusing the glass, check or correct the position
of the installation marks.
(4) Remove the glass.
there is no adhesive left on the body) with primer. Make
NOTICE:
WS
• Wait for the primer to dry. (The primer will dry in
approximately 3 minutes.) Then install the wind-
shield glass adhesive dam.
A-A 15 B-B
22.6
A 23
A D
D 5.5
B B
C C-C D-D
15 22.9
C
15
Units [mm] 5.5
B141879
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(6) Cut off the tip of the adhesive tube, as shown in the illus-
tration.
(7) Put the adhesive tube into the sealant gun.
(8) Apply a bead of adhesive as shown in the illustration.
7.0
12.0
Units [ mm ] B106205J07
A-A B-B
13 38.4
30.4
A 12
12
A D
D
B B 7 7
C-C D-D
C 13 30.4
WS C
12 12
Units [mm]
7 7
B141880
(c) INSTALL GLASS

(1) Using the appropriate suction cups to hold the glass, align
the new windshield glass using the installation marks and
install.
NOTICE:
• Allow the primer on the vehicle body to dry before
installing the glass. (The primer dries in approxi-
mately 3 minutes.)
• Make sure the back door glass clips are securely
engaged.
(2) Press the front surface of the glass lightly and it attach it
securely.
HINT:
Pressing force: 98 N (10 kgf) or more
(4) Press the windshield glass down with protection tape or
similar until the adhesive hardens.
(d) Connect each connector.
6. CHECK FOR WATER LEAKS

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WS–69
7. INSTALL REAR WIPER MOTOR ASSEMBLY (See page WW-15)
8. INSTALL REAR WIPER MOTOR GROMMET (See page WW-15)
9. INSTALL REAR WIPER ARM (See page WW-16)
11. INSTALL BACK DOOR TRIM PANEL ASSEMBLY (See page ED-
49)
12. INSTALL CENTER STOP LIGHT ASSEMBLY (See page LI-43)
13. INSTALL CENTER STOP LIGHT ASSEMBLY (See page LI-43)
14. INSTALL SPARE TIRE
WS
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WS–70 GLASS AND WINDOW - QUARTER WINDOW ASSEMBLY LH

BODY AND
GLASS ANDELECTRICAL
WINDOW
COMPONENTS
WITHOUT CURTAIN SHIELD AIRBAG WITH CURTAIN SHIELD AIRBAG
QUARTER WINDOW GLASS RETAINER UPR
QUARTER WINDOW OUTSIDE

FRONT MOLDING LH
WS QUARTER WINDOW GLASS

RETAINER LWR
QUARTER WINDOW GLASS LH

QUARTER WINDOW GLASS SPACER
BACK DOOR
WEATHERSTRIP
REAR FLOOR MAT SUPPORT PLATE RR
DECK BOARD ASSEMBLY
REAR DOOR OPENING TRIM

WEATHERSTRIP LH
DECK FLOOR BOX LH

NON-REUSEABLE PART
B141367J01
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GLASS AND WINDOW - QUARTER WINDOW ASSEMBLY LH
WS–71
REMOVAL
3. REMOVE DECK FLOOR BOX LH (See page IR-4)
4. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-4)

5)
6. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH (See page IR-

5)
7. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH

SHIELD AIRBAG) (See page IR-6)
9. REMOVE ROOF SIDE INNER GARNISH LH (WITH CURTAIN

SHIELD AIRBAG) (See page IR-6)
10. REMOVE QUARTER WINDOW GLASS LH
NOTICE:
• Because clips and spacers are installed on the glass in the
positions shown in the illustration, take extra care not to
damage the glass when the removing the adhesive.
• Have a helper hold the glass from the outside using suction WS
Spacer cups in order to prevent the glass from falling during the
Retainer
operation.
(a) Put protection tape on the body surface around the outside line
of the glass.
(b) Apply suction cups.
B144191J01
(c) Put piano wire (0.6 mm is appropriate) through the locations

shown in the illustration, and tie each end to wood blocks.
(d) Pull the piano wire end alternately and leave the glass spacers
and clips, then cut off adhesive.
NOTICE:
• Do not let the piano wire touch the glass edge with
force.
wire from snapping.
B140079 (e) Disengage the retainer using pliers or other similar tool, and
remove the quarter window glass LH.
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INSTALLATION
1. CLEAN QUARTER WINDOW GLASS LH
(a) Remove the adhesive or spacer remaining on the glass using a
scraper or a similar tool. (when reusing glass)
NOTICE:
(b) Clean the outer edge of the glass with a solvent.
HINT:
Even when using new glass, clean the glass with a solvent.
2. INSTALL QUARTER WINDOW GLASS SPACER

BO03986J07
(a) Apply a primer to the installation part of the spacer. Make sure
to use the appropriate primer.
NOTICE:
imately 3 minutes.) Then install the spacer.
(b) Install the quarter window glass spacer in the position shown in
the illustration.
3. INSTALL QUARTER WINDOW GLASS RETAINER UPR
4. INSTALL QUARTER WINDOW GLASS RETAINER LWR

(a) Apply a primer to the installation part of the retainer. Make sure
WS to use the appropriate primer.
NOTICE:
4.0mm
Marking
4.0mm imately 3 minutes.) Then install the retainer.
B140086J01
(b) Install the quarter window glass retainer UPR and the quarter
window glass retainer LW in the position shown in the illustra-
24. 3 mm
tion.
5. INSTALL QUARTER WINDOW OUTSIDE FRONT MOULDING LH

(a) Apply a primer to the installation part of the moulding. Make
NOTICE:
24.7 mm
24. 5 mm
imately 3 minutes.) Then install the moulding.
Glass Retainer UPR • Do not apply primer to the surface of the moulding.
(b) Apply adhesive to the installation part of the moulding.
Glass Retainer LWR
24.4 mm
B144192J01
GETtheMANUALS.org
WS–73
(c) Install the quarter window moulding LH in the position shown in

the illustration.
(d) Remove any excess adhesive before it hardens.
NOTICE:
Do not allow any adhesive to remain on the moulding or
the surface of the glass.
HINT:
Follow the instructions on the adhesive regarding minimum dry-
ing time or wait time required before the vehicle can be driven.
B140080
6. INSTALL QUARTER WINDOW GLASS LH

Adhesive Adhesive (1) If the adhesive remaining on the surface of the vehicle
NOTICE:
(b) INSTALL QUARTER WINDOW GLASS LH
(1) Apply suction cups to the quarter window glass LH.
B060685J02 there is no adhesive left on the body) with primer. Make
NOTICE:
WS
(3) Apply a primer to the adhesive part of the quarter window
glass LH, as shown in the illustration. Make sure to use an
appropriate primer.
A-A D-D
3.0 15.0 4.6 15.0
B
F C B-B E-E
F C B 15.0 3.4
5.3 15.0
D
E
D
C-C F-F 15.0 15.0
E
20.5 23
Units [mm]
Ceramic Edge
B140081
NOTICE:
GETtheMANUALS.org
(4) Cut off the tip of the adhesive tube, as shown in the illus-
tration.
(5) Put the adhesive tube into the sealant gun.
(6) Cut off the tip of the nozzle as shown in the illustration.
(7) Apply a bead of adhesive as shown in the illustration.
8.0
12.0
Units [ mm ] B106205J05
A-A D-D
A 12.1
10.5
A 12.0
12.0
B
F C
F C B
8.0
B-B 8.0 E-E
10.9 12.8
D 12.0
12.0
E
D
E
8.0
WS C-C
8.0
F-F
28.0 8.0
22.5
12.0 12.0
Ceramic Edge
Units [mm] 8.0
B140082
(c) INSTALL GLASS

(1) Engage the retainer and Install the glass to the vehicle.
NOTICE:
Allow the primer on the vehicle body to dry before
installing the glass. (The primer dries in approxi-
mately 3 minutes.)
(2) Press the front surface of the glass lightly and it attach it
securely.
HINT:
Pressure strength: 98 N (10 kgf) or more
NOTICE:
Make sure to also apply adhesive to the glass edge
surface.
(d) Press the windshield glass down with protection tape or similar
until the adhesive hardens.
7. CHECK FOR WATER LEAKS

GETtheMANUALS.org
WS–75
8. INSTALL ROOF SIDE INNER GARNISH RH (VEHICLES WITHOUT

CURTAIN SHIELD AIRBAGS) (See page IR-11)

10. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (See

page IR-11)
11. INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH (See page IR-
12)
12. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-12)
13. INSTALL DECK FLOOR BOX LH (See page IR-12)
13)
WS
GETtheMANUALS.org
WS–76 GLASS AND WINDOW - DEICER RELAY
DEICER RELAY
BODY AND
GLASS ANDELECTRICAL
WINDOW
INSPECTION
1. CHECK DEICER RELAY
(a) Using the electrical tester, check the continuity between each of
the connecter terminals.
Standard:

1←→2 Continuity
B118916 (b) Apply battery voltage between terminal 1 and 2 of the connec-
tor.
(c) Using the electrical tester, check the continuity between termi-
nals 3 and 5 of the connecter.
Standard:
Continuity
WS
GETtheMANUALS.org
GLASS AND WINDOW - DEFOG RELAY
WS–77
DEFOG RELAY
BODY AND
GLASS ANDELECTRICAL
WINDOW
INSPECTION
1. INSPECT DEFOG RELAY
(a) Using the electrical tester, check the continuity between the
each of terminals.
Standard:

1←→2 Continuity
B118916 (b) Apply battery voltage between terminal 1 and 2 of the connec-
tor.
(c) Using the electrical tester, check the continuity between the
each of terminals.
Standard:

3←→5 Continuity
WS
GETtheMANUALS.org
TO INDEX
BODY AND ELECTRICAL
MIRROR
ELECTRIC MIRROR SYSTEM
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MI-1
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MI-2
OUTER MIRROR SWITCH ASSEMBLY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MI-3
OUTER REAR VIEW MIRROR RH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MI-4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MI-5
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MI-5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MI-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MI-6
OUTER REAR VIEW MIRROR ASSEMBLY RH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MI-7
OUTER REAR VIEW MIRROR ASSEMBLY LH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MI-8
INNER REAR VIEW MIRROR ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MI-9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MI-10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MI-10
MI
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MI–1 MIRROR - ELECTRIC MIRROR SYSTEM

BODY AND ELECTRICAL
MIRROR
LOCATION
MI
B143123J01
GETtheMANUALS.org
MIRROR - ELECTRIC MIRROR SYSTEM
MI–2

ACC (7.5 A) fuse -
Outer mirror switch assembly MI-3
Outer rear view mirror does not operate Outer rear view mirror assembly RH MI-8
Outer rear view mirror assembly LH MI-9
Outer mirror switch assembly MI-3
Outer rear view mirror operates abnormally Outer rear view mirror assembly RH MI-8
Outer rear view mirror assembly LH MI-9
MI
GETtheMANUALS.org
MI–3 MIRROR - OUTER MIRROR SWITCH ASSEMBLY

BODY AND ELECTRICAL
MIRROR
INSPECTION
1. INSPECTION OF OUTER MIRROR SWITCH ASSEMBLY
Left/Right Rocker Switch (a) Check the continuity.
(1) Change the left/right adjustment switch to the left side.
(2) Using a tester, check for continuity between the specified
L R terminals when the switch is operated.
Standard
Operation Switch Terminal No. Standard

Neutral - No continuity
MIRROR Up
4←→8
Continuity
6←→7
4←→7
Down Continuity
6←→8
5←→8
Operation Switch Left Continuity
6←→7
5←→7
Right Continuity
6←→8
10 6 8 7 6 5 4 3 2 1 (3) Change the left/right adjustment switch to the right side.

(4) Using a tester, check for continuity between the specified
terminals when the switch is operated.
Standard
MI B107836J01
Operation Switch Terminal No. Standard
Neutral - No continuity
3←→8
Up Continuity
6←→7
3←→7
Down Continuity
6←→8
2←→8
Left Continuity
6←→7
2←→7
Right Continuity
6←→8
GETtheMANUALS.org
MIRROR - OUTER REAR VIEW MIRROR RH
MI–4

BODY AND ELECTRICAL
MIRROR
COMPONENTS
OUTER MIRROR COVER RH
T=8.0{82}
FRONT DOOR LOWER FRAME

MI
BRACKET GARNISH RH
CLIP
FRONT DOOR TRIM BOARD RH
TIGHTENING TORQUE [N*m{kgf cm}]
B143210J01
GETtheMANUALS.org
MI–5 MIRROR - OUTER REAR VIEW MIRROR RH
REMOVAL
RH
(a) Disengage the 2 claws and the clip, and remove the front door
lower frame bracket garnish RH.
2. REMOVE FRONT DOOR ASSIST GRIP COVER RH (See page ED-

11)
3. REMOVE DOOR ASSIST GRIP BASE (See page ED-11)

Claw 4. REMOVE FRONT DOOR TRIM BOARD RH (See page ED-11)
: Clip B140124J01
5. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY RH

(b) Remove the 3 bolts and outer rear view mirror assembly RH.
DISASSEMBLY
1. REMOVE OUTER REAR VIEW MIRROR RH
(a) Protect the outer rear view mirror assembly RH with waste cloth
or etc., as shown in the illustration.
B135856
(b) Insert a screwdriver wrapped with protective tape into the two
MI clip areas shown in the illustration and disengage the clips
located at the lower part of the mirror.
NOTICE:
Before removal, warm the mirror using a hair dryer etc.
because the clip and claws may brake in cold tempera-
tures.
(c) Pull down the mirror and remove.
Claw (d) Disconnect the connector and remove the outer rear view mirror
: Clip B143213 RH. (Vehicles with mirror heater)
2. REMOVE OUTER MIRROR COVER RH

(a) Remove the claws through the inside of the mirror body.
B135860
GETtheMANUALS.org
MIRROR - OUTER REAR VIEW MIRROR RH
MI–6
(b) As shown in the illustration, pull the upper part of the mirror for-
ward. Remove the lower claw and then remove the outer mirror
cover RH.
REASSEMBLY
B148489
1. INSTALL OUTER MIRROR COVER RH

(a) Engage the claw of the lower part of the mirror cover.
(b) Engage the claw of the upper part of the mirror cover to install
the outer mirror cover RH.
(c) After installing the outer mirror cover, check that there is bump
between the cover and mirror body.
NOTICE:
A bump between the cover and the mirror body will cause a
wind noise or similar sound.
B148490
2. INSTALL OUTER REAR VIEW MIRROR RH
(a) Connect the connector. (Vehicles with mirror heater)
(b) Engage the 2 claws of the mirror.
(c) Engage the 2 claws to install the mirror.
MI
INSTALLATION
Claw
: Clip B143224J01
1. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY RH

(a) Install the outer rear view mirror assembly RH with the 3 bolts.
2. INSTALL FRONT DOOR TRIM BOARD RH (See page ED-25)
3. INSTALL DOOR ASSIST GRIP BASE (See page ED-26)
4. INSTALL FRONT DOOR ASSIST GRIP COVER RH (See page ED-

26)
B135856
(a) Engage the two claws and the clip, and install the front door
lower flame bracket garnish RH.
GETtheMANUALS.org
MI–7 MIRROR - OUTER REAR VIEW MIRROR ASSEMBLY RH

BODY AND ELECTRICAL
MIRROR
INSPECTION
1. INSPECTION OF OUTER REAR VIEW MIRROR ASSEMBLY RH
(a) Check actuator operation
(1) Check the operation of the actuator when battery voltage
is applied to each terminal.
Standard
Connection Operational Direction

Positive battery (+) ←→ Terminal 3 (MV)
Upward
Negative battery (-) ←→ Terminal 7 (M+)
Positive battery (+) ←→ Terminal 7 (M+)
Downward
B056297J01 Negative battery (-) ←→ Terminal 3 (MV)
Positive battery (+) ←→ Terminal 6 (MH)
Inward
Outward
Negative battery (-) ←→ Terminal 6 (MH)
2. INSPECTION OF OUTER REAR VIEW MIRROR ASSEMBLY RH

(WITH HEATER)
(a) Check mirror heater operation
(1) Measure the resistance between terminals 1 and 2 of the
connector.
MI Standard:
10.5 ± 2.1 Ω (room temperature)
check that the mirror surface is getting warmer.
(b) Check actuator operation
Standard

Upward
Downward
Negative battery (-) ←→ Terminal 3 (MV)
B056297J01 Positive battery (+) ←→ Terminal 6 (MH)
Inward
Outward
GETtheMANUALS.org
MIRROR - OUTER REAR VIEW MIRROR ASSEMBLY LH
MI–8

BODY AND ELECTRICAL
MIRROR
INSPECTION
1. INSPECT OUTER REAR VIEW MIRROR ASSEMBLY LH
(a) Check actuator operation
Standard

Upward
Downward
B056297J01 Negative battery (-) ←→ Terminal 3 (MV)
Inward
Outward
2. INSPECTION OF OUTER REAR VIEW MIRROR ASSEMBLY LH

(WITH HEATER)
(a) Check mirror heator operation
(1) Measure the resistance between terminals 1 and 2 of the
connector.
Standard: MI
10.5 ± 2.1Ω (room temperature)
check that the mirror surface is getting warmer.
(b) Check actuator operation
Standard

Upward
Downward
Negative battery (-) ←→ Terminal 3 (MV)
B056297J01 Positive battery (+) ←→ Terminal 7 (M+)
Inward
Outward
GETtheMANUALS.org
MI–9 MIRROR - INNER REAR VIEW MIRROR ASSEMBLY
INNER REAR VIEW MIRROR ASSEMBLY

BODY AND ELECTRICAL
MIRROR
COMPONENTS
MI
Inner Rear View Mirror Assembly
B137761J01
GETtheMANUALS.org
MIRROR - INNER REAR VIEW MIRROR ASSEMBLY
MI–10
REMOVAL
1. REMOVE INNER REAR VIEW MIRROR ASSEMBLY
the claw and remove the inner rear view mirror cover.
(b) Using a screwdriver wrapped with protective tape, hold down
the claw in the direction indicated by (a).
(c) Remove the inner rear view mirror assembly by pulling it out in
the direction indicated by (b) in the illustration.
Claw
Protective INSTALLATION
Tape
B065800J01
1. INSTALL INNER REAR VIEW MIRROR ASSEMBLY

(a) Install the inner rear view mirror assembly by sliding it until the MI
claw locks.
(b) Engage the claw and install the inner rear view mirror cover.
Claw
B107875J01
GETtheMANUALS.org
TO INDEX
BODY AND ELECTRICAL
INSTRUMENT PANEL
INSTRUMENT PANEL
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP-1
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP-2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP-15
IP
GETtheMANUALS.org
IP–1 INSTRUMENT PANEL - INSTRUMENT PANEL
INSTRUMENT PANEL
BODY AND ELECTRICAL
INSTRUMENT PANEL
PRECAUTIONS
1. PRECAUTIONS FOR VEHICLES WITH SRS AIRBAG AND SEAT
BELT PRETENSIONER
(a) Some operations in this section may affect the SRS airbags.
Prior to performing the corresponding servicing operations,
read the SRS airbag NOTICE. (See page RS-164.)
2. NOTICE FOR REMOVAL AND INSTALLATION
(a) When prying the clip and the claw to detach and disengage
them with a screwdriver, be sure to apply protective tape to
prevent damage to the parts.
IP
GETtheMANUALS.org
INSTRUMENT PANEL - INSTRUMENT PANEL
IP–2
COMPONENTS
INSTRUMENT CLUSTER FINISH PANEL
T=34.3{350}
IP
T=7.4{75}

B136121J05
GETtheMANUALS.org
STEREO COMPONENT RADIO TUNER OPENING COVER

TUNER ASSEMBLY
IP AIR MIXTURE DAMPER INSTRUMENT CLUSTER FINISH PANEL CTR

CONTROL CABLE
AIR INLET DAMPER

CONTROL CABLE
DEFROSTER DAMPER
CONTROL
CABLE
B143235J01
GETtheMANUALS.org
IP–4

CONSOLE BOX FR
INSTRUMENT PANEL
BRACE COVER INN NO. 3
SHIFT LEVER KNOB

IP
SHIFTING HOLE BEZEL
(TRANSMISSION A/T)

CONSOLE BOX
CARPET
B143236J01
GETtheMANUALS.org
T=8.2{84}
COIN BOX ASSEMBLY
IP INSTRUMENT PANEL UNDER COVER NO. 1
GLOVE COMPARTMENT
DOOR STOPPER

INSTRUMENT PANEL
UNDER COVER NO. 2

B136124J01
GETtheMANUALS.org
IP–6

CLIP
CLIP CLIP
CLIP
CLIP


FRONT PILLAR GARNISH LH WEATHERSTRIP RH
IP

WEATHERSTRIP LH
INSTRUMENT PANEL REGISTER NO. 1
INSTRUMENT PANEL REGISTER NO. 2

..... NON REUSEABLE PARTS
B136125J01
GETtheMANUALS.org
DEFROSTER NOZZLE
ASSEMBLY
HEATER TO REGISTER DUCT CTR
IP
INSTRUMENT PANEL
SWITCH HOLE BASE NO. 1
INDICATOR ASSEMBLY
GLOVE COMPARTMENT DOOR LOCK STRIKER

B136126J02
GETtheMANUALS.org
IP–8
REMOVAL
TABLE OF BOLTS, SCREWS AND NUTS
HINT:
• All necessary bolts, screws and nuts relevant to installing and removing
the instrument panel are shown in the text or illustration below with their
part numbers.
• In the illustration, D indicates diameter (mm) and L indicates length
(mm).
D=6 D=6 D=5

<A> L18 L14 <C> L=14
91551-80618 90109-06292 93568-55014
D=5 D=5 <F> D=6

<D> <E>
L=14 L=14 L14
93567-55014 93567-15014 91551-80614
IP
B139418J01

(See page IP-1.)
4. REMOVE HORN BUTTON ASSEMBLY(See page RS-170)
5. REMOVE STEERING WHEEL ASSEMBLY (See page SR-4)
6. REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page ME-

30)
7. REMOVE STEERING COLUMN COVER
(a) Remove the 3 <C> screws and detach the 5 claws. Then
<C>
remove the steering column cover.
<C>
8. REMOVE HEADLIGHT DIMMER SWITCH ASSEMBLY (See page
LI-50)
9. REMOVE WINDSHIELD WIPER SWITCH ASSEMBLY (See page

WW-22)
<C> 10. REMOVE COMBINATION METER ASSEMBLY (See page ME-31)
: Claw C133192J03
GETtheMANUALS.org
11. DISCONNECT INSTRUMENT CLUSTER FINISH PANEL CTR

(a) Detach the 11 clips and remove the instrument cluster finish
panel CTR.
(b) Disconnect each connector.
: Claw B136279J02
12. DISCONNECT AIR MIX DAMPER CONTROL CABLE

(a) Detach the 2 claws and disconnect the air mix control cable.
: Claw E127924J01
13. DISCONNECT DEFROSTER DAMPER CONTROL CABLE

(a) Detach the 2 claws and disconnect the defroster control cable.
IP
: Claw E127926J01
14. DISCONNECT AIR INLET DAMPER CONTROL CABLE

(a) Detach the 2 claws and disconnect the air inlet control cable.

RECEIVER)

: Claw E127927J01
(a) Detach the claw and remove the shifting hole bezel.
19. REMOVE CONSOLE BOX ASSEMBLY RR

(a) Remove the console box hole cover and detach the clip.
(b) Remove the console box carpet. Then remove the bolt.
(c) Sliding the console box assembly RR in the direction of the
arrows indicated in the arrow, detach the 8 claws and remove

the console box assembly RR.
: Claw B139421J01
GETtheMANUALS.org
IP–10
20. REMOVE CONSOLE BOX MOUNTING BRACKET NO. 1

(a) Remove the 2 <F> bolts, then remove console box mounting
<F> bracket No. 1
B147315
21. REMOVE CONSOLE BOX FR

<E> (a) Remove the 2 <E> screws.
<E> (b) Detach the 2 claws and disconnect each connector to remove
the console box FR.
: Claw
B139834J01
22. REMOVE FRONT DOOR SCUFF PLATE RH

(a) Detach the 7 claws and remove the front door scuff plate RH.
24. REMOVE COWL SIDE TRIM BOARD RH

(a) Detach the clip. IP
: Claw B136281J01
(b) Detach the 2 claws and remove the cowl side trim board RH.
: Claw B136283J01
26. REMOVE INSTRUMENT PANEL BRACE COVER INN NO. 3.

(a) Detach the 2 clips and the claw, and then remove the
instrument panel brace cover INN No. 3.
: Claw B136284J01
GETtheMANUALS.org
27. REMOVE INSTRUMENT PANEL UNDER COVER NO. 3

(a) Detach the 3 claws and remove the instrument panel under
cover No. 3.
: Claw
B139425J01
28. REMOVE COIN BOX ASSEMBLY

(a) Open the instrument panel box.
(b) With the instrument panel box open, pull the hinge side directly
above and detach the claws to remove it.
(c) Disengage the stopper to the instrument panel box from the
notch of the instrument panel finish panel LWR, and then
remove the instrument panel box.
: Hinge B136285J01
29. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER

(a) Remove the 2 <D> screws.
(b) Detach the 5 claws to the instrument panel finish panel LWR.
(c) Disconnect the DLC connector and the wire harness clamp, and
then remove the instrument panel finish panel LWR.
IP
<D> <D>
: Claw B136286J01
30. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER

(a) Detach the 2 <D> screws and the claw, and remove the
instrument panel under cover No. 1.
<D> <D>
B136287J01
31. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY

(a) Detach the claw and remove the glove compartment door
stopper.
B139530
GETtheMANUALS.org
IP–12
(b) Deform the stopper part of the glove compartment door

assembly to some extent so that the stopper can be
disengaged, and open the glove compartment door assembly to
the horizontal position.
(c) Horizontally pull the glove compartment door assembly and
disengage the hinge, and then remove the glove compartment
door assembly.
NOTICE:
Pulling the glove compartment assembly upward may
result in the loosened hinges, so be sure to pull the glove
compartment assembly horizontally when removing it.
32. REMOVE GLOVE COMPARTMENT DOOR STOPPER

(a) Detach the claw and remove the glove compartment door
stopper.
Stopper
33. REMOVE INSTRUMENT PANEL BOX NO. 2
(a) Pull open the instrument panel box No. 2 by pressing it from the
inside, and detach the claw to remove the instrument panel box
No. 2.
Hinge
B139531J01
34. REMOVE INSTRUMENT PANEL UNDER COVER NO. 2

(a) Detach the 5 claws and then remove the instrument panel
under cover No. 2.
IP
: Claw B136288J01

(a) Remove the front door opening trim weatherstrip RH.
B136289

SHIELD AIRBAG)
(a) Detach the 3 clips and 2 claws, and remove the front pillar
garnish RH.

SHIELD AIRBAG)
Clip
Claw B139532J01
GETtheMANUALS.org

AIRBAG)
NOTICE:
Install the protective cover to the curtain shield airbag
immediately after removing the front pillar garnish.
(a) Detach the 3 clips and 2 claws, and remove the front pillar
garnish RH.
NOTICE:
Be sure to install new parts for the removed special clips as
they may be damaged.
Clip
Claw B139533J01
(b) Using a rag or nylon, wrap the curtain shield airbag as shown in
the illustration and fix both ends of the rag or nylon with gum
tape.
Packing Tape 40. REMOVE FRONT PILLAR GARNISH LH (WITH CURTAIN SHIELD
AIRBAG)
IP Curtain Shield
41. REMOVE INSTRUMENT PANEL REGISTER ASSEMBLY NO. 1
Airbag
(a) Apply protective tape.
Protective Cover
(b) Remove the outer mirror switch assembly.
B139938J01
(c) As shown in the illustration, push out the instrument panel

register assembly No. 1 from the back side. Then detach the
two lower side claws.
(d) Disengage the 2 upper side claws and then remove the
instrument panel register assembly No. 1.
NOTICE:
Due to the risk of dents, damage and paint chipping, do not
forcibly bend the instrument panel register assembly No. 1.
42. REMOVE INSTRUMENT PANEL REGISTER ASSEMBLY NO. 2

(a) Apply protective tape.
Claw
B136290J01
GETtheMANUALS.org
IP–14
(b) As shown in the illustration, push out the instrument panel

register assembly No. 2 from the back side. Then detach the
two lower side claws.
(c) Detach the 2 upper side claws and then remove the instrument
register assembly No. 2.
NOTICE:
Due to the risk of dents, damage and paint chipping, do not
forcibly bend the instrument panel register assembly No. 2.
43. REMOVE INSTRUMENT PANEL PASSENGER AIRBAG

ASSEMBLY
Claw
B136291J01
IP
B136292
(c) Put your hand in the opening of the instrument panel and
detach the claw. Then remove the instrument panel passenger
airbag assembly.
44. REMOVE INSTRUMENT PANEL

(a) Disconnect each clamp and each connector.
B136293
GETtheMANUALS.org
(c) Detach the 5 claws and remove the instrument panel.
<A>
<A>
<A>
<A>
<A>
<A>
<A>
<A>
<A>
<A>
Claw B139534J01
45. REMOVE SWITCH HOLE BASE NO. 1

(a) Remove the 4 <E> screws. Then remove the switch hole base
No. 1.
IP 46. REMOVE GLOVE COMPARTMENT DOOR LOCK STRIKER

(a) Remove the <E> screw. Then remove the glove compartment
door lock striker.
47. REMOVE HEATER TO REGISTER DUCT CTR

(a) Remove the 3 <E> screws. Then remove the heater to register
duct CTR.
48. REMOVE DEFROSTER NOZZLE ASSEMBLY

(a) Remove the 5 <E> screws. Then remove the defroster nozzle
assembly.
49. REMOVE INDICATOR ASSEMBLY

(a) Detach the 2 claws and remove the indicator assembly.
INSTALLATION
1. INSTALL INDICATOR ASSEMBLY
(a) Attach the 2 claws and install the indicator assembly.
2. INSTALL DEFROSTER NOZZLE ASSEMBLY

(a) Install the defroster nozzle assembly with the 5 <E> screws.
3. INSTALL HEATER TO REGISTER DUCT CTR

(a) Install the heater to register duct CTR with the 3 <E> screws.
4. INSTALL GLOVE COMPARTMENT DOOR LOCK STRIKER

(a) Install the glove compartment door lock striker with the <E>
screw.
5. INSTALL SWITCH HOLE BASE NO. 1

(a) Install the switch hole base No. 1 with the 4 <E> screws.
GETtheMANUALS.org
IP–16
6. INSTALL INSTRUMENT PANEL

NOTICE:
Make sure they do not bite into any of the wire harnesses.
(b) Connect each connector and clamp.
(c) Install the instrument panel with the 10 <A> bolts.
<A>
<A>
<A>
<A>
<A>
<A>
<A>
<A>
<A>
<A>
Claw B139534J01
IP
7. INSTALL INSTRUMENT PANEL PASSENGER AIRBAG
ASSEMBLY
(a) Install the instrument panel passenger airbag with the 2 <A>
<A> bolts.
<A>
8. INSTALL INSTRUMENT PANEL REGISTER ASSEMBLY NO. 1

(a) Attach the 4 claws and install the indicator panel register
assembly No. 1.
B136292J01
9. INSTALL INSTRUMENT PANEL REGISTER ASSEMBLY NO. 2
SHIELD AIRBAG)
(a) Attach the 3 clips and 2 claws, and install the front pillar garnish
RH.

SHIELD AIRBAG)

Clip AIRBAG)
Claw B139532J01 (a) Remove the rag or the nylon.
GETtheMANUALS.org
(b) Install a new clip A (front pillar garnish clip) on the garnish side.
(c) Attach the 2 claws and clip to install the front pillar garnish.

AIRBAG)
Clip
Claw B139936J01

(a) Align the front side of the front door opening trim weatherstrip
and the corner of the body flange, and install the front door
opening trim weatherstrip RH.
NOTICE:
Check that the corner does not rise up after installation.
B136289J01
IP 16. INSTALL INSTRUMENT PANEL UNDER COVER NO. 2

(a) Attach the 2 innermost claws first, and then attach the other 3
claws to install the instrument panel under cover No. 2.
18. INSTALL GLOVE COMPARTMENT DOOR STOPPER

(a) Attach the claw and install the glove compartment door stopper.
: Claw B136288J01
GETtheMANUALS.org
IP–18
19. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY

(a) Attach the claw of the hinge horizontally to install the glove
compartment door assembly.
NOTICE:
Always align the hinge horizontally when installing.
Installing it upwards may result in the loosened hinge.
Stopper
Hinge
B139531J02
(b) Bend the stopper part of the glove compartment door assembly
slightly and engage the stopper.
(c) Attach the claw and connect the glove compartment door
stopper.
IP
B139530

(a) Attach the 4 innermost claws to install the instrument panel
under cover No. 1.
(b) Install the 2 <D> screws.

(a) Install the DLC connector and the wire harness clamp to the
instrument panel finish panel LWR.
B136287
(b) Attach the 5 claws.

(c) Install the instrument panel finish panel LWR with the 2 <D>
bolts.
<D> <D>
: Claw B136286J01
GETtheMANUALS.org
22. INSTALL COIN BOX ASSEMBLY

(a) Insert the coin box stopper from the notch of the instrument
panel finish panel LWR.
(b) Attach the hinge with the coin box open.
(c) Close the coin box.
: Hinge B136285J02

(a) Attach the 3 claws and install the instrument panel under cover
No. 3.
24. INSTALL INSTRUMENT PANEL BRACE COVER INN NO. 3

(a) Attach the claws.
: Claw
B139425J01
(b) Install the instrument panel brace cover INN No. 3 with the 2
clips.
IP
: Claw B136284J01
25. INSTALL COWL SIDE TRIM BOARD RH

(a) Attach the 2 claws and install the cowl side trim board RH.
(b) Attach the clip.
27. INSTALL FRONT DOOR SCUFF PLATE RH

(a) Attach the 7 claws and install the front door scuff plate RH.
: Claw B136283J01
29. INSTALL CONSOLE BOX FR

(b) Install the console box FR with the 2 screws.
: Claw
B139834J02
GETtheMANUALS.org
IP–20
30. INSTALL CONSOLE BOX MOUNTING BRACKET NO. 1

(a) Install the console box mounting bracket No. 1 with the 2 <F>
<F> bolts.
B147315

TRANSMISSION)
(b) Install the console box assembly RR with the clip and bolt .
(c) Install the console box hole cover and the console box carpet.

(a) Attach the claw and install the shifting hole bezel.

: Claw
B139421J02
34. INSTALL RADIO TUNER OPENING COVER (WITHOUT RADIO
RECEIVER)

36. INSTALL AIR INLET DUMPER CONTROL CABLE
(a) Attach the 2 claws and connect the air inlet damper control
cable.
IP
:Claw E127927
37. INSTALL DEFROSTER DUMPER CONTROL CABLE

(a) Attach the 2 claws and connect the defroster damper control
cable.
:Claw E127926
GETtheMANUALS.org
38. INSTALL AIR MIX DAMPER CONTROL CABLE

(a) Attach the 2 claws and connect the air mix damper control
cable.
39. INSTALL INSTRUMENT CLUSTER FINISH PANEL CTR

(a) Connect each connector.
:Claw E127924
(b) Attach the 11 clips and install the instrument cluster finish panel
CTR.
40. INSTALL COMBINATION METER ASSEMBLY (See page ME-31)
41. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY (See page

WW-23)
42. INSTALL HEADLIGHT DIMMER SWITCH ASSEMBLY (See page

LI-50)
: Claw B136279J02
43. INSTALL STEERING COLUMN COVER
(a) Install the steering column cover (upper) to the steering column
assembly.
(b) Attach the 5 claws and install the steering column cover (lower).
(c) Install the steering column cover with the 3 <C> screws.
44. INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page ME-

<C>
IP <C>
32)
45. INSTALL STEERING WHEEL ASSEMBLY (See page SR-8)
46. INSTALL HORN BUTTON ASSEMBLY (See page RS-170)
<C> 48. INSPECT AIRBAG WARNING LIGHT

: Claw C133192J01 (See page RS-1.)
GETtheMANUALS.org
TO INDEX
BODY AND ELECTRICAL
SEAT
FRONT SEAT ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE-3
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE-3
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE-8
REAR SEAT ASSEMBLY RH (6:4 Division, Double Fold Type)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE-10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE-11
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE-11
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE-13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE-16
REAR SEAT ASSEMBLY LH (6:4 Division, Double Fold Type)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE-17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE-18
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE-18
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE-20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE-23
SE
GETtheMANUALS.org
SE–1 SEAT - FRONT SEAT ASSEMBLY
FRONT SEAT ASSEMBLY

BODY AND ELECTRICAL
SEAT
COMPONENTS
T=33.8{345}
SE T=33.8{345}
T=33.8{345}
T=33.8{345}

(FOR RH SEAT)

B136501J02
GETtheMANUALS.org
SEAT - FRONT SEAT ASSEMBLY
SE–2
FRONT SEAT HEADREST

ASSEMBLY
SEAT CUSHION COVER ASSEMBLY
FRONT SEAT HEADREST

SUPPORT
SEAT CUSHION
ASSEMBLY
OCCUPANT SENSOR
SEPARATE TYPE FRONT SEATBACK

COVER RH
SEPARATE TYPE FRONT
SEATBACK PAD RH
FRONT SEAT AIRBAG ASSEMBLY RH HOG RING
VERTICAL ADJUSTER
COVER RH FRONT SEAT HINGE
OUTER COVER RH
T=8.3{85}
SE
RECLINING ADJUSTER
RELEASE HANDLE RH
SNAP SEAT TRACK UPPER RAIL
VERTICAL ADJUSTER RING COVER RH
LOCK LEVER
FRONT SEAT HINGE
OUTER COVER LH
FRONT SEAT INNER BELT

SEAT TRACK
ASSEMBLY RH
ADJUSING HANDLE
FRONT SEAT CUSHION
SHIELD RH T=41{418}
FRONT SEAT CUSHION FRONT SEAT CUSHION

SHIELD LH (SEAT LH) SHIELD INNER RH
B136607J02
GETtheMANUALS.org
REMOVAL
AIRBAGS
(a) For proper handling of seats equipped with SRS side airbags,
be sure to read the precautions for the SRS airbag system
before performing the work. (See page RS-164)
NOTICE:
If the side airbag of a vehicle has deployed, replace the
front seat assembly RH.
2. REMOVE FRONT SEAT LEG COVER
(a) Disengage the 3 claws and remove the front seat leg cover.
: Claw B136502J01
3. REMOVE FRONT SEAT LEG COVER LH (FOR RH SEAT)

(a) Disengage the 2 claws and remove the front seat leg cover LH.
4. REMOVE FRONT SEAT ASSEMBLY RH

(b) Operate the seat track adjusting handle to move the front seat
assembly to its rearmost position.
(c) Remove the 2 bolts from the front side.
SE (d) Operate the seat track adjusting handle to move the front seat
assembly to its frontmost position.
: Claw B136503J01
(e) Remove the 2 bolts on the rear side.
(f) Remove the front seat assembly RH from the vehicle.
DISASSEMBLY
1. REMOVE FRONT SEAT ASSEMBLY
(a) Press the lock button on the front seat headrest support, and
remove the front seat headrest.
2. REMOVE VERTICAL ADJUSTER COVER RH
the 3 claws and remove the vertical adjuster cover RH.
Protective Tape
: Claw B136608J01
GETtheMANUALS.org
SE–4
3. REMOVE VERTICAL ADJUSTER LOCK LEVER

(a) Remove the 2 screws and the vertical adjuster lock lever.
B106626
4. REMOVE RECLINING ADJUSTER RELEASE HANDLE RH

(a) Remove the snap ring using a rag or piece of cloth, and remove
the reclining adjuster release handle RH.
B136642
5. REMOVE FRONT SEAT CUSHION SHIELD RH

(a) Disengage the 3 claws and remove the front seat cushion shield
RH by sliding it out in the direction indicated by the arrow in the
illustration.
SE
: Claw B138220J01
6. REMOVE FRONT SEAT CUSHION SHIELD INN RH

(a) Disengage the claw and remove the front seat cushion shield
INN RH by sliding it out in the direction indicated by the arrow in
the illustration.
7. REMOVE FRONT SEAT CUSHION SHIELD LH (SEAT LH)
8. REMOVE FRONT SEAT INNER BELT ASSEMBLY RH (See page

SB-19)
: Claw B138221J01
9. REMOVE FRONT SEAT HEADREST SUPPORT

(a) Open the lower parts of the seatback cover and remove the hog
rings.
: Hog Ring B136657J01
GETtheMANUALS.org
(b) Disengage the claw and remove the 2 front seat headrest
supports.
10. REMOVE SEPARATE TYPE FRONT SEATBACK COVER RH

(a) Disconnect the connector of the seatback heater. (Vehicles with
seat heater)
B136658
(b) Remove the hog rings and the separate type front seatback
cover RH.
11. REMOVE SEPARATE TYPE FRONT SEATBACK PAD RH
12. REMOVE FRONT SEAT AIRBAG ASSEMBLY RH (See page RS-

196)
13. REMOVE FRONT SEAT CUSHION COVER

(a) Detach the clip.
(b) Remove the connecter clamp of the occupant detection sensor.
(Passenger seat)
(c) Disengage the J hook and the claws, and remove the seat
cushion cover with pad.
SE
: Clip B136659J01
(d) Disengage the hog rings, and remove the seat cushion cover.
14. REMOVE BELT WARNING OCCUPANT DETECTION SENSOR

(a) Remove the belt warning occupant detection sensor from the
seat cushion.
GETtheMANUALS.org
SE–6
15. REMOVE FRONT SEAT HINGE OUTER COVER RH

the 4 claws and remove the front seat hinge outer cover RH.
16. REMOVE FRONT SEAT HINGE OUTER COVER LH
: Claw B136673J01
17. REMOVE SEAT TRACK UPPER RAIL COVER RH

(a) Disengage the claw and remove the seat track upper rail cover
RH by sliding it out in the direction indicated by the arrow in the
illustration.
B136774J01
18. REMOVE SEAT TRACK ADJUSTING HANDLE

Handle Support Wire (a) Using a screwdriver, disengage the claw on the handle support
wire and remove the seat track adjusting handle.
REASSEMBLY
19. INSTALL SEAT TRACK ADJUSTING HANDLE
(a) Engage the handle support wire and install the seat track
adjusting handle. SE
B070262
20. INSTALL SEAT TRACK UPPER RAIL COVER RH

(a) Engage the claw and install the seat track upper rail cover RH.
B139043
21. INSTALL FRONT SEAT HINGE OUTER COVER RH

(a) Engage the claw and install the front seat hinge outer cover RH.
22. INSTALL FRONT SEAT HINGE OUTER COVER LH
23. INSTALL BELT WARNING OCCUPANT DETECTION SENSOR

(a) Install the belt warning occupant detection sensor in the seat
cushion.
: Claw B139042J01
GETtheMANUALS.org
24. INSTALL FRONT SEAT CUSHION COVER

(a) Using hog ring pliers, install the seat cushion cover with new
hog rings.
NOTICE:
• Do not damage or soil the seat cushion cover.
• Align the center of the cover and the center of the seat
cushion pad, making sure to avoid wrinkles, and install
hog rings.
(b) Engage the J hook and the claws, and install the seat cushion
cover with pad.
(c) Install the connecter clamp of the occupant detection sensor.
(Passenger seat)
(d) Attach the clip.
25. INSTALL FRONT SEAT AIRBAG ASSEMBLY RH (See page RS-

196)
26. INSTALL SEPARATE TYPE FRONT SEATBACK PAD RH
SE 27. INSTALL SEPARATE TYPE FRONT SEATBACK COVER RH

(a) Using hog ring pliers, install new hog rings.
: Clip B136659J01
NOTICE:
• Do not damage or soil the separate type front seatback
cover RH.
• Align the center of the cover and the center of the seat
back pad, making sure to avoid wrinkles, and install hog
rings.
GETtheMANUALS.org
SE–8
(b) Using hog ring pliers, install the separate type front seatback
cover RH with new hog rings.
(c) Connect the connector of the seatback heater. (Vehicles with

seat heater)
28. INSTALL FRONT SEAT HEADREST SUPPORT
29. INSTALL FRONT SEAT INNER BELT ASSEMBLY RH (See page

SB-19)
30. REMOVE FRONT SEAT CUSHION SHIELD LH (SEAT LH)

31. INSTALL FRONT SEAT CUSHION SHIELD INN RH
(a) Insert the front seat cushion shield INN RH in the direction
indicated by the arrow in the illustration, engage the claw and
install the front seat cushion shield INN RH.
SE
: Claw B139039J01
32. INSTALL FRONT SEAT CUSHION SHIELD RH

(a) Insert the front seat cushion shield RH in the direction indicated
by the arrow in the illustration, engage the claw and install the
front seat cushion shield RH.
33. INSTALL RECLINING ADJUSTER RELEASE HANDLE RH

(a) Engage the snap ring to the reclining adjuster release handle
RH and install it.
: Claw B139038J01
34. INSTALL VERTICAL ADJUSTER LOCK LEVER

(a) Install the vertical adjuster lock lever with the 2 screws.
35. INSTALL VERTICAL ADJUSTER COVER RH

(a) Engage the 3 claws and install the vertical adjuster cover RH.
36. INSTALL FRONT SEAT HEADREST ASSEMBLY
INSTALLATION
1. INSTALL FRONT SEAT ASSEMBLY RH
B106626
(a) Place the front seat assembly RH on the vehicle and adjust the
hole on the vehicle side.
GETtheMANUALS.org

(c) Operate the seat track adjusting handle to move the front seat
NOTICE:
Make sure that the assembly locks.
(d) Temporarily install the 2 bolts on the rear side of the seat.
(e) Operate the seat track adjusting handle to move the front seat
NOTICE:
(f) Temporarily install the 2 bolts on the front side of the seat.
(g) Operate the seat track adjusting handle to move the front seat
NOTICE:
(h) Tighten the 2 bolts on the rear side of the seat.
(i) Operate the seat track adjusting handle to move the front seat
NOTICE:
(j) Tighten the 2 bolts on the rear side of the seat.
2. INSTALL FRONT SEAT LEG COVER LH (FOR RH SEAT)
(a) Engage the 2 claws and install the front seat leg cover LH.
SE
: Claw B136503J01
3. INSTALL FRONT SEAT LEG COVER

(a) Engage the 3 claws and install the front seat leg cover.
: Claw B136502J01
GETtheMANUALS.org
SEAT - REAR SEAT ASSEMBLY RH (6:4 Division, Double Fold Type)
SE–10
REAR SEAT ASSEMBLY RH (6:4 Division, Double Fold

BODY AND ELECTRICAL
SEAT
Type)
COMPONENTS
SEPARATE TYPE REAR SEAT REAR SEAT HEADREST

BACK COVER RH ASSEMBLY
BACK PAD RH
REAR SEAT HEADREST

SUPPORT
HOG RING
T=31{316}
RECLINING RELEASE HANDLE REAR SEAT

RECLINING
SNAP RING COVER INN RH
REAR SEAT RECLINING

COVER NO. 1 RH
REAR SEAT LOCK RELEASE BAND
REAR SEAT LOCK COVER RH
SE
T=31{316}
REAR SEAT LEG COVER T=34{345} REAR SEAT BELT
ASSEMBLY INN
SEPARATE TYPE REAR
T=34{345} REAR SEAT LAP TYPE
BELT ASSEMBLY RH
T=41{418}
REAR SEAT HOLDER BAND
T=34{345}
REAR SEAT CUSHION

LOCK ASSEMBLY RH
REAR SEAT CUSHION PAD RH T=45.5{463}

T=45.5{463}

B137877J04
GETtheMANUALS.org
SE–11 SEAT - REAR SEAT ASSEMBLY RH (6:4 Division, Double Fold Type)
REMOVAL
1. REMOVE REAR SEAT LEG COVER
(a) Disengage the 4 claws and remove the rear seat leg cover.
2. REMOVE REAR SEAT ASSEMBLY RH

(a) Pull the rear seat lock release band and pull up the rear seat
assembly RH.
(b) Remove the 2 clips.
Clip B146467J01
(c) Remove the 4 bolts and the rear seat assembly RH.
DISASSEMBLY
1. REMOVE REAR SEAT HEADREST ASSEMBLY
(a) Press the lock button of the rear headrest support, and remove
the rear seat headrest assembly.
B135944
SE
2. REMOVE RECLINING RELEASE HANDLE
(a) Disengage the snap ring and remove the reclining release
handle.
B136007
3. REMOVE REAR SEAT RECLINING COVER NO. 1 RH

(a) Disengage the 2 claws and remove the rear seat reclining cover
No. 1 RH.
B138174
GETtheMANUALS.org
SE–12
4. REMOVE REAR SEAT RECLINING COVER INN RH

(a) Remove the 2 bolts and the rear seat reclining cover INN RH.
B138173
5. REMOVE REAR SEAT LOCK COVER RH

(a) Remove the screws and the rear seat lock cover RH.
B142545
6. REMOVE REAR SEATBACK ASSEMBLY RH

(a) Remove the 4 bolts and the rear seatback assembly.
SE
B136006
7. REMOVE REAR SEAT HEADREST SUPPORT

(a) Disengage the claws of the separate type rear seatback cover
RH.
(b) Open the fastener.
B136008
(c) Disengage the claw and remove the rear seat headrest support.
B136658
GETtheMANUALS.org
8. REMOVE SEPARATE TYPE REAR SEATBACK COVER RH

(a) Remove the hog rings and the separate type rear seatback
cover RH.
9. REMOVE SEPARATE TYPE REAR SEATBACK PAD RH
10. REMOVE SEPARATE TYPE REAR SEAT CUSHION COVER RH

(a) Remove the hog rings.
(b) Remove the hog rings and the separate type rear seat cushion
cover RH.
11. REMOVE REAR SEAT CUSHION PAD RH
12. REMOVE REAR SEAT LOCK RELEASE BAND
13. REMOVE REAR SEAT HOLDER BAND

(a) Remove the bolt and the rear seat holder band.
SE 14. REMOVE REAR SEAT BELT ASSEMBLY INN (See page SB-31)
: Hog Ring B136021J01 15. REMOVE REAR SEAT WRAP TYPE BELT ASSEMBLY RH (See
page SB-27)
16. REMOVE REAR SEAT CUSHION LOCK ASSEMBLY RH
(a) Remove the 4 bolts and the rear seat cushion lock assembly
RH.
REASSEMBLY
B142938
1. INSTALL REAR SEAT CUSHION ASSEMBLY RH

(a) Install the rear seat cushion lock assembly RH with the 4 bolts.
2. INSTALL REAR SEAT BELT ASSEMBLY INN (See page SB-31)
3. INSTALL REAR SEAT WRAP TYPE BELT ASSEMBLY RH (See

page SB-27)
4. INSTALL REAR SEAT HOLDER BAND

(a) Put rear seat holder band through the separate type rear seat
B142938
cushion cover RH.
GETtheMANUALS.org
SE–14
(b) Install the rear seat holder band with the bolt.
5. INSTALL REAR SEAT LOCK RELEASE BAND
6. INSTALL REAR SEAT CUSHION PAD RH

NOTICE:
• Do not damage or soil the separate type rear seat
cushion cover RH.
• Align the center of the cover and the center of the
separate type rear seat cushion cover RH, making sure
to avoid wrinkles, and attach them with the hog rings.
(b) Using hog ring pliers, install the separate type rear seat cushion
SE
8. INSTALL SEPARATE TYPE REAR SEATBACK PAD RH
9. INSTALL SEPARATE TYPE REAR SEATBACK COVER RH

(a) Using hog ring pliers, install the separate type rear seatback
GETtheMANUALS.org
NOTICE:
• Do not damage or soil the separate type front seatback
cover RH.
separate type rear seatback cover RH, making sure to
avoid wrinkles, and install hog rings.
(b) Close the fastener.
(c) Engage the claws of the separate type rear seatback cover RH.
10. INSTALL REAR SEAT HEADREST SUPPORT
B136008
11. INSTALL REAR SEATBACK ASSEMBLY RH

(a) Install the rear seat back assembly RH with the 4 bolts.
B136006
SE 12. INSTALL REAR SEAT LOCK COVER RH

(a) Install the rear seat lock cover RH with the screw.
B142545
13. INSTALL REAR SEAT RECLINING COVER INN RH

(a) Install the rear seat reclining cover INN RH with the 2 screws.
B138173
GETtheMANUALS.org
SE–16
14. INSTALL REAR SEAT RECLINING COVER NO. 1 RH

(a) Engage the claw and install the rear seat reclining cover No. 1
RH.
B138174
15. INSTALL RECLINING RELEASE HANDLE

(a) Attach the snap ring to the reclining release handle and then
install the reclining release handle.
16. INSTALL REAR SEAT HEADREST ASSEMBLY
INSTALLATION
B136007
1. INSTALL REAR SEAT ASSEMBLY RH

(a) Tighten the 4 bolts in the order shown in the illustration, and
install rear seat assembly RH.
(b) Check that both the two rear seat cushion locks lock smoothly.
SE
B135944
(c) Install the 2 clips.
2. INSTALL REAR SEAT LEG COVER

(a) Attach the 4 claws and install the rear seat leg cover.
Clip B146467J01
GETtheMANUALS.org
SE–17 SEAT - REAR SEAT ASSEMBLY LH (6:4 Division, Double Fold Type)
REAR SEAT ASSEMBLY LH (6:4 Division, Double Fold Type)

BODY AND ELECTRICAL
SEAT
COMPONENTS
REAR SEAT HEADREST

ASSEMBLY
SEPARATE TYPE REAR SEAT BACK
COVER LH
SEPARATE TYPE REAR
SEATBACK PAD LH
REAR SEAT
REAR SEATBELT HEADREST
ASSEMBLY INN RH SUPPORT
T=40.7{415}
HOG RING

CUSHION COVER LH
T=31{316}
REAR SEAT RECLINING COVER

INN LH T=31{316}
RECLINING RELEASE
REAR SEAT RECLINING
SE COVER LH
HANDLE LH
REAR SEAT CUSHION SNAP RING

PAD LH
REAR SEAT BELT ASSEMBLY
T=34{345} INN NO. 1
REAR SEAT LOCK
COVER LH
T=41{418}
REAR SEAT LOCK
RELEASE BAND
T=34{345}
REAR SEAT HOLDER BAND
REAR SEAT CUSHION LOCK ASSEMBLY LH
T=45.5{463}
T=45.5{463}
B137878J02
GETtheMANUALS.org
SEAT - REAR SEAT ASSEMBLY LH (6:4 Division, Double Fold Type)
SE–18
REMOVAL
1. REMOVE REAR SEAT LEG COVER
(a) Disengage the 4 claws and remove the rear seat leg cover.
2. REMOVE REAR SEAT ASSEMBLY LH

(a) Pull the rear seat lock release band and move the rear seat
assembly LH to the upright position.
(b) Remove the 2 clips.
Clip B146466J01
(c) Remove the 4 bolts and the rear seat assembly LH.
DISASSEMBLY
1. REMOVE REAR SEAT HEADREST ASSEMBLY
(a) Press the lock button of the rear seat headrest support, and
remove the rear seat headrest.
B136030
SE
2. REMOVE RECLINING RELEASE HANDLE LH
(a) Disengage the snap ring and remove the reclining release
handle LH.
B136032
3. REMOVE REAR SEAT RECLINING COVER LH

(a) Disengage the 2 claws and remove the rear seat reclining cover
LH.

31)
B138175
GETtheMANUALS.org
5. REMOVE REAR SEAT RECLINING COVER INN LH

(a) Remove the 2 bolts and the rear seat reclining cover INN LH.
B138176
6. REMOVE REAR SEAT LOCK COVER LH

(a) Remove the screws and the rear seat lock cover LH.
B142545
7. REMOVE REAR SEATBACK ASSEMBLY LH

(a) Remove the 4 bolts and the rear seat back assembly LH.
SE
B136031
8. REMOVE REAR SEAT HEADREST SUPPORT

(a) Disengage the claws of the separate type rear seatback cover
LH.
(b) Open the fastener.
B136033
(c) Disengage the claw and remove the rear seat headrest support.
B136658
GETtheMANUALS.org
SE–20
9. REMOVE SEPARATE TYPE REAR SEATBACK COVER LH

(a) Remove the hog rings and the separate type rear seatback
cover LH.
10. REMOVE SEPARATE TYPE REAR SEATBACK PAD LH

(a) Remove the hog rings.
(b) Remove the hog rings and the separate type rear seat cushion
cover LH.
13. REMOVE REAR SEAT LOCK RELEASE BAND
14. REMOVE REAR SEAT HOLDER BAND

(a) Remove the bolt and the rear seat holder band.
15. REMOVE REAR SEAT BELT ASSEMBLY INN NO. 1 (See page SB- SE
35)
16. REMOVE REAR SEAT CUSHION LOCK ASSEMBLY LH

(a) Remove the 4 bolts and the rear seat cushion lock assembly
LH.
REASSEMBLY
B142938
1. INSTALL REAR SEAT CUSHION LOCK ASSEMBLY LH

(a) Install the rear seat cushion lock assembly LH with the 4 bolts.
2. INSTALL REAR SEAT BELT ASSEMBLY INN NO. 1 (See page SB-
35)
3. INSTALL REAR SEAT HOLDER BAND

(a) Put the rear seat holder band through the separate type rear
seat cushion cover LH.
B142938 (b) Install the rear seat holder band with the bolt.
4. INSTALL REAR SEAT LOCK RELEASE BAND
GETtheMANUALS.org

NOTICE:
• Do not damage or soil the separate type rear seat
cushion cover LH.
separate type rear seat cushion cover LH, making sure
to avoid wrinkles, and install hog rings.
(b) Using hog ring pliers, install the separate type rear seat cushion
cover LH with new hog rings.
SE
7. INSTALL SEPARATE TYPE REAR SEATBACK PAD LH
8. INSTALL SEPARATE TYPE REAR SEATBACK COVER LH

(a) Using hog ring pliers, install the separate type rear seatback
cover LH with new hog rings.
NOTICE:
• Do not damage or soil the separate type rear seatback
cover LH.
GETtheMANUALS.org
SE–22

separate type rear seatback cover LH, making sure to
avoid wrinkles, and install hog rings.
(b) Close the fastener.
(c) Engage the claws of the separate type rear seatback cover LH.
9. INSTALL REAR SEAT HEADREST SUPPORT
B136008
10. INSTALL REAR SEATBACK ASSEMBLY LH

(a) Install the rear seat back assembly LH with the 4 bolts.
B136006
11. INSTALL REAR SEAT LOCK COVER LH

(a) Install the rear seat lock cover LH with the screw.
SE
B142545
12. INSTALL REAR SEAT RECLINING COVER INN LH

(a) Install the rear seat reclining cover INN LH with the 2 screws.
B138176
GETtheMANUALS.org
14. INSTALL REAR SEAT RECLINING COVER LH

(a) Engage the 2 claws and install the rear seat reclining cover LH.
B138175
15. INSTALL RECLINING RELEASE HANDLE LH

(a) Attach the snap ring to the reclining release handle LH, then
install the reclining release handle LH.
16. INSTALL REAR SEAT HEADREST ASSEMBLY
INSTALLATION
B136032
1. INSTALL REAR SEAT ASSEMBLY LH

(a) Tighten the 4 bolts in the order shown in the illustration, and
install the rear seat assembly LH.
(b) Check that both the two rear seat cushion locks lock smoothly.
SE
B136030
(c) Install the 2 clips.
2. INSTALL REAR SEAT LEG COVER

(a) Attach the 4 claws and install the rear seat leg cover.
Clip B146466J01
GETtheMANUALS.org
TO INDEX
BODY AND ELECTRICAL
ENGINE HOOD / DOOR

ENGINE HOOD
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-1
ENGINE HOOD INSULATOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-4
ENGINE HOOD LOCK CONTROL CABLE ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-8
FRONT DOOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-9
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-11
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-18
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-26
REAR DOOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-28
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-30
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-36
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-44
BACK DOOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-46
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-47
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-48
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-49
ED
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-52
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-58
FRONT FENDER LH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-62
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-65
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED-66
GETtheMANUALS.org
ED–1 ENGINE HOOD / DOOR - ENGINE HOOD
ENGINE HOOD
BODY AND
ENGINE HOOD
ELECTRICAL
/ DOOR
ADJUSTMENT
1. CHECK ENGINE HOOD
(a) Check that the installed fit of the rear door panel LH is within the
specified range.
A C
B D
B139062J01
Reference value
A 5.0 ± 1.5 mm
B 6.5 ± 1.5 mm
C 4.6 ± 1.5 mm
D 5.2 mm
2. REMOVE ENGINE HOOD LOCK CONTROL CABLE COVER (See

ED page ED - 6)
3. ADJUST ENGINE HOOD
(a) Adjust front to back hood alignment, as well as rear left to right
alignment.
(1) Loosen and adjust the bolt of the hood hinge assembly.
NOTICE:
Because a centering bolt is used, adjustment should
be performed after replacing the provided bolt.
B139057
(b) Adjust the height of the hood.

(1) Turn the cushion to adjust the height.
B139056
GETtheMANUALS.org
ENGINE HOOD / DOOR - ENGINE HOOD
ED–2
(c) Adjust the height and the right-left alignment of the front end of
the hood.
(1) Loosen the 3 bolts and adjust.
NOTICE:
Because a centering bolt is used, adjustment should
be performed after replacing the provided bolt.
4. INSTALL ENGINE HOOD LOCK CONTROL CABLE COVER (See

page ED - 8)
B139058
ED
GETtheMANUALS.org
ED–3 ENGINE HOOD / DOOR - ENGINE HOOD INSULATOR
ENGINE HOOD INSULATOR

BODY AND
ENGINE HOOD
ELECTRICAL
/ DOOR
COMPONENTS
ED BONNET (HOOD) INSULATOR
B139047J01
REMOVAL
1. REMOVE ENGINE HOOD INSULATOR
(a) Detach the 7 clips and remove the engine hood insulator.
Clip
B139048J01
GETtheMANUALS.org
ENGINE HOOD / DOOR - ENGINE HOOD INSULATOR
ED–4
INSTALLATION
1. INSTALL ENGINE HOOD INSULATOR
(a) Install the engine hood insulator with the 7 clips.
Clip
B139048J01
ED
GETtheMANUALS.org
ED–5 ENGINE HOOD / DOOR - ENGINE HOOD LOCK CONTROL CABLE ASSEMBLY
ENGINE HOOD LOCK CONTROL CABLE ASSEMBLY

BODY AND
ENGINE HOOD
ELECTRICAL
/ DOOR
COMPONENTS
RIGHT-HAND DRIVE
×2
T=6.2{64}
BONNET (HOOD) LOCK CONTROL CABLE ASSEMBLY
×2 COWL SIDE TRIM BOARD RH
BONNET (HOOD) LOCK ASSEMBLY
ED BONNET (HOOD) LOCK

CONTROL CABLE COVER
T=6.2{64} ×3
B141345J01
GETtheMANUALS.org
ENGINE HOOD / DOOR - ENGINE HOOD LOCK CONTROL CABLE ASSEMBLY
ED–6
LEFT-HAND DRIVE

T=6.2{64}
×2
×2
BONNET (HOOD) LOCK CONTROL CABLE ASSEMBLY
T=6.2{64} ×3
BONNET (HOOD) LOCK ASSEMBLY
BONNET (HOOD) LOCK CONTROL CABLE COVER
B141344J01
ED
REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE RH (FOR RIGHT HAND
DRIVE) (See page IP-10)
2. REMOVE FRONT DOOR SCUFF PLATE LH (FOR LEFT HAND

DRIVE)
3. REMOVE COWL SIDE TRIM BOARD RH (FOR RIGHT HAND

4. REMOVE COWL SIDE TRIM BOARD LH (FOR LEFT HAND

DRIVE)
5. REMOVE ENGINE HOOD LOCK CONTROL CABLE COVER

(a) Remove the 2 bolts and the engine hood lock control cable
cover.
GETtheMANUALS.org
ED–7 ENGINE HOOD / DOOR - ENGINE HOOD LOCK CONTROL CABLE ASSEMBLY
6. REMOVE ENGINE HOOD LOCK ASSEMBLY

(a) Remove the 3 bolts and the engine hood lock assembly.
B142274
7. REMOVE ENGINE HOOD LOCK CONTROL CABLE ASSEMBLY

(a) Disconnect the engine hood lock control cable assembly from
the engine hood lock assembly, following the procedure shown
in the illustration. (right hand drive)
B139053
(b) Disconnect the engine hood lock control cable assembly from
the engine hood lock assembly, following the procedure shown
in the illustration. (left hand drive)
ED B139052

(d) Disconnect the grommet and the clamp in the engine room, and
remove the engine hood lock control cable assembly.
B139051
GETtheMANUALS.org
ENGINE HOOD / DOOR - ENGINE HOOD LOCK CONTROL CABLE ASSEMBLY
ED–8
INSTALLATION
1. INSTALL ENGINE HOOD LOCK CONTROL CABLE ASSEMBLY
(a) Install the 2 bolts.
B139051
(b) Connect the engine hood lock control cable assembly, following
the procedure shown in the illustration. (left hand drive)
B146452
(c) Connect the engine hood lock control cable assembly, following
the procedure shown in the illustration. (right hand drive)
2. INSTALL ENGINE HOOD LOCK ASSEMBLY

(a) Install the engine hood lock assembly with the 3 bolts.
3. INSTALL ENGINE HOOD LOCK CONTROL CABLE COVER

(a) Install the engine hood lock control cable cover with the 2 bolts.
ED
4. INSTALL COWL SIDE TRIM BOARD RH (FOR RIGHT HAND
B146453
5. INSTALL COWL SIDE TRIM BOARD LH (FOR LEFT HAND DRIVE)
6. INSTALL FRONT DOOR SCUFF PLATE RH (FOR RIGHT HAND

7. INSTALL FRONT DOOR SCUFF PLATE LH (FOR LEFT HAND

DRIVE)
8. CHECK ENGINE HOOD (See page ED-1)
9. ADJUST ENGINE HOOD (See page ED-1)
GETtheMANUALS.org
ED–9 ENGINE HOOD / DOOR - FRONT DOOR
FRONT DOOR
BODY AND
ENGINE HOOD
ELECTRICAL
/ DOOR
COMPONENTS
FRONT DOOR GLASS WEATHERSTRIP

ASSEMBLY OUT RH
OUTER REAR VIEW MIRROR

ASSEMBLY RH
FRONT DOOR GLASS

RUN RH
T=4.4{45}

BRACKET GARNISH RH
FRONT DOOR GLASS WEATHERSTRIP INN RH

ED
FRONT DOOR GLASS RUN NO. 2
FRONT DOOR WEATHERSTRIP RH
FRONT DOOR
TRIM BOARD RH
FRONT ARMREST BASE PANEL
UPR RH
×2

×2
FRONT DOOR ASSIST
Clip GRIP COVER RH
B136932J01
GETtheMANUALS.org
ENGINE HOOD / DOOR - FRONT DOOR
ED–10
FRONT DOOR INSIDE LOCKING CABLE RH

FRONT DOOR LOCK CYLINDER
FRONT DOOR OUTSIDE HANDLE COVER RH
DOOR OUTSIDE
HANDLE NO. 1
FRONT DOOR OUTSIDE HANDLE PAD RR FRONT DOOR LOCK OPENROD RH

×3
FRONT DOOR OUTSIDE T=4.0{41} FRONT DOOR LOCK REMOTE
HANDLE PAD FR CONTROL CABLE RH
T=5.0{51}
T=4.0{41}
FRONT DOOR OUTSIDE DOOR LOCK

HANDLE FRAME RH WIREHARNESS SEAL
FRONT DOOR LOCK ASSEMBLY RH

FRONT DOOR INSIDE HANDLE RH
T=5.0{51}
T=31{316}
×2
PLUG HOLE
FRONT DOOR CHECK RH T=5.0{51}
FRONT DOOR FRAME ×2

RR LWR RH
T=5.0{51}
×2
T=5.0{51} ED
FRONT DOOR FRAME FRONT DOOR OUTER PANEL PAD RH
FR LWR RH Butyl Tape
FRONT DOOR FRONT DOOR

GLASS RH SERVICE
×2 HOLE COVER
T=5.0{51}
×2
FRONT DOOR WINDOW REGULATOR RH
×3
DOOR TRIM BRACKET NO. 1 RH
FRONT SPEAKER
×2 ASSEMBLY NO. 1
×4
T=5.0{51}
×3
APPLY MP GREASE
NON-REUSEABLE PART TIGHTENING TORQUE [N*m{kgf*cm}] B136933J02
GETtheMANUALS.org
DISASSEMBLY
RH
2. REMOVE FRONT DOOR ASSIST GRIP COVER RH
(a) Disengage the claws and remove the front door assist grip
cover RH.
Claw
B137087J01
3. REMOVE DOOR ASSIST GRIP BASE

(a) Remove the 2 screws and door assist grip base.
4. REMOVE FRONT DOOR TRIM BOARD RH

(a) Remove the 2 screws and the clip.
B137088
(b) Using a clip remover, disengage the 8 clips of the front door trim
board RH.
(c) Disconnect the connector from behind of the front door trim
board RH.
ED 5. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY RH
Clip
B137089J01
6. REMOVE FRONT DOOR GLASS WEATHERSTRIP INN RH

(a) Remove the front door glass weatherstrip INN RH from the front
door trip board RH.
B137092
GETtheMANUALS.org
ED–12
7. REMOVE FRONT ARMREST BASE PANEL UPR RH

(a) Disconnect the 10 claws and remove the front armrest base
panel UPR RH.
Claw
B137090J01
8. REMOVE POWER WINDOW REGULATOR MASTER SWITCH

ASSEMBLY (DRIVER'S SEAT SIDE)
(a) Remove the 2 screws and power window regulator master
switch assembly from the front armrest base panel UPR RH.
B137091
9. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY

(PASSENGER SEAT SIDE)
(a) Disengage the 2 claws and remove the power window switch
assembly.
Claw B137242J02
ED
10. REMOVE FRONT DOOR INSIDE HANDLE RH
(*1) (a) Disengage the claw of the rear side.(*1)
(b) Pull the front claw toward the rear side and disengage it. (*2)
(c) Disconnect the front door lock remote control cable RH and the
front door inside locking cable RH, and remove the front door
(*2) inside handle RH.
Claw B053166J03
11. REMOVE DOOR TRIM BRACKET NO. 1

(a) Remove the 2 screws, then remove the door trim bracket No. 1
RH.
12. REMOVE FRONT SPEAKER ASSEMBLY NO. 1
B137093
GETtheMANUALS.org
13. REMOVE FRONT DOOR SERVICE HOLE COVER RH

(a) Remove the front door service hole cover RH.
NOTICE:
Remove the butyl tape remaining on the body side.
14. REMOVE FRONT DOOR GLASS RH

(a) Connect the power window regulator master switch assembly
and move the front door glass until the installation bolt on the
front door glass is visible. (when working on the driver's seat
side)
B137094
(b) Using the remote operation of the power window regulator mas-
ter switch assembly, move the front door glass until the installa-
tion bolt on the front door glass is visible. (when working on the
passenger seat side)
B137095
(d) Remove the front door glass RH, as shown in the illustration.
(2)
NOTICE:
(1)
Do not damage the front door glass RH.
(e) Remove the power window regulator master switch assembly.
ED
B143238J01
15. REMOVE FRONT DOOR WINDOW REGULATOR RH

(a) Disconnect the connector of the power window regulator motor
Connector assembly RH.
(b) Loosen the temporary bolt.
Board With NOTICE:
Bolts
The front door window regulator RH may fall and change
its shape if the temporary bolt is removed.
(c) Remove the 5 bolts and the front door window regulator RH.
(d) Remove the temporary bolt from the front door window regula-
B137096J01 tor RH.
GETtheMANUALS.org
ED–14
16. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY

RH
(a) Using a "Torx" Socket Wrench (T25), remove the 3 screws and
the power window regulator motor assembly RH from the front
door window regulator RH.
B137097
17. REMOVE FRONT DOOR OUTER PANEL PAD RH (WITH FRONT

DOOR OUTER PANEL PAD)
(a) Remove the bolt.
(b) Heat the front door outer panel pad RH (areas attached with
double-sided tape) with a heat gun.
(c) Remove the double-sided tape and the front door outer panel
Protective
pad RH.
Tape
B137098J01
18. REMOVE FRONT DOOR GLASS RUN RH

(a) Remove the front door glass run RH.
B137099
ED
19. REMOVE FRONT DOOR GLASS RUN NO. 2
(a) Remove the front door glass run No. 2.
B143239
20. REMOVE FRONT DOOR FRAME FR LWR RH

(a) Remove the 2 bolts and the front door frame FR LWR RH.
B137100
GETtheMANUALS.org
21. REMOVE FRONT DOOR FRAME RR LWR RH

(a) Remove the 2 bolts and the front door frame RR LWR RH.
B137101
22. REMOVE FRONT DOOR OUTSIDE HANDLE COVER RH

(a) Remove the plug hole.
(b) Using a "Torx" Socket Wrench (T30), remove the screws, then
remove the front door outside handle cover RH and the front
door lock cylinder at the same time.
B118634
23. REMOVE DOOR OUTSIDE HANDLE NO. 1

(a) Disconnect the connector of the front door outside handle
assembly RH
ED B137102
(b) Pull the front door outside handle assembly RH toward the vehi-
cle rear, and disengage the claws of the front outside handle
frame RH.
(c) Pull the front door outside handle assembly RH forward and
remove it from the front door outside handle frame RH.
B107001
24. REMOVE FRONT DOOR OUTSIDE HANDLE PAD FR

(a) Disengage the 2 claws and remove the front door outside han-
dle pad FR.
Claw B137103J05
GETtheMANUALS.org
ED–16
25. REMOVE FRONT DOOR OUTSIDE HANDLE PAD RR

(a) Disengage the 2 claws and remove the front door outside han-
dle pad RR.
26. REMOVE FRONT DOOR LOCK ASSEMBLY RH

(a) Disconnect the connector of the front door lock assembly RH.
Claw B137104J02
(b) Using a "Torx" Socket Wrench (T30), remove the 3 screws.

(c) Slide down the front door lock assembly RH. Then pull off the
front door lock open rod RH, and remove the front door lock
assembly RH.
(d) Remove the door lock wire harness seal from the front door lock
assembly RH.
B137105
27. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE RH

(a) Remove the front door lock remote control cable RH from the
front door lock assembly RH, as shown in the illustration.
(3)
(1)
(2)
B137106J01
ED
28. REMOVE FRONT DOOR INSIDE LOCKING CABLE RH
the 3 claws of the front door lock assembly RH.
Claw
B137107J01
(b) Remove the front door inside locking cable RH from the front
door lock assembly RH, as shown in the illustration.
(2)
(1)
B137108J01
GETtheMANUALS.org
29. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME RH

(a) Disengage the claw of the grommet.
(b) Using a "Torx" Socket Wrench (T30), loosen the screw.
(c) Disengage the clamp and disconnect the connector.
(d) Disengage the claws by pulling it out toward the vehicle front,
remove the front door outside handle frame RH.
Grommet
Screw
Clamp
B143380J01
30. REMOVE FRONT DOOR LOCK OPEN ROD RH

(a) Disengage the claw of the front door outside handle snap, and
remove the front door lock open rod RH.
ED B129288
31. REMOVE FRONT DOOR CHECK RH

(a) Remove the 3 bolts and the front door check RH.
B137245
GETtheMANUALS.org
ED–18
32. REMOVE FRONT DOOR WEATHERSTRIP RH

(a) Using a clip remover, disengage the 29 clips and remove the
front door weatherstrip RH.
33. REMOVE FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY

OUT RH
REASSEMBLY
1. APPLY BODY GREASE
(a) Apply MP grease to the sliding areas of the front door window
regulator RH, front door outside handle frame RH, and front
door lock assembly RH.
2. INSTALL FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY

OUT RH
Clip
B137111J01
3. INSTALL FRONT DOOR WEATHERSTRIP RH

(a) Attach the 29 clips and install new front door weatherstrip RH to
the front door panel.
Clip
B137111J02
ED
4. INSTALL FRONT DOOR CHECK RH
(a) Install the front door check RH with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm) (door side)
Torque: 31 N*m (316 kgf*cm) (body side)
5. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY RH
B137245
6. INSTALL FRONT DOOR LOCK OPEN ROD RH

(a) Attach the front door outside handle snap and install the front
door lock open rod RH to the front door outside handle frame
RH.
(1)
(2)
B129289J01
GETtheMANUALS.org
7. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME RH

(a) Engage the claw on the rear of the vehicle. Then engage the
claw on the grommet and temporarily install the front door out-
side handle frame RH to the front door panel.
(b) Using a "Torx" Socket Wrench (T30), install the front door out-
side handle frame RH with the screw.
Grommet
Screw
Clamp
B143380J02
8. INSTALL FRONT DOOR INSIDE LOCKING CABLE RH

(a) Install the front door inside locking cable RH to the front door
lock assembly RH, as shown in the illustration.
(2)
(1)
ED B143240J01
9. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE RH

(a) Install the front door lock remote control cable RH to the front
(3)
(1)
(2)
B143241J01
(b) Engage the 3 claws of the front door lock assembly RH.
10. INSTALL FRONT DOOR LOCK ASSEMBLY RH

NOTICE:
• When reusing the removed front door lock assembly with
motor, replace the door lock wire harness seal of the connec-
tor area with a new part.
• Make sure no grease or dirt adheres to the door lock wire
harness seal of the connector area.
Claw • If a door lock wire harness seal is reused or if a damaged
B137107J01
door lock wire harness seal is used, there is a possibility that
GETtheMANUALS.org
ED–20
water may get into the connecter area. This may cause a mal-
function of the front door lock assembly with motor.
(a) Install a new door lock wire harness seal to the front door lock
assembly RH.
(b) Insert the front door lock open rod RH into the front door lock
assembly RH. Then engage the front door lock open rod RH
with the front door panel.
(c) Make sure that the front door lock open rod RH is securely
engaged with the front door lock assembly RH.
(d) Using a "Torx" Socket Wrench (T30), install the front door lock
assembly RH with the 3 screws.
(e) Connect the connector.
B137105
11. INSTALL FRONT DOOR OUTSIDE HANDLE PAD RR

(a) Attach the 2 claws and install the front door outside handle pad
RR.
Claw B137104J01
ED
12. INSTALL FRONT DOOR OUTSIDE HANDLE PAD FR
(a) Engage the 3 claws and install the front door outside handle
pad FR.
Claw B137103J01
13. INSTALL DOOR OUTSIDE HANDLE NO. 1

(a) Insert the tip of the door outside handle No. 1 and the connector
into the front door outside handle frame RH.
(b) Insert the rear end of the door outside handle No. 1 into the
front door outside handle frame RH, and install the door outside
handle No. 1 by sliding it toward the vehicle front.
B107002
GETtheMANUALS.org
(c) Connect the connector of the door outside handle No. 1.
B137102
14. INSTALL FRONT DOOR OUTSIDE HANDLE COVER RH

(a) With the front door lock cylinder still installed, attach the front
door outside handle cover RH to the front door panel
HINT:
Make sure that the front door lock cylinder rod is securely
inserted into the front door lock assembly RH.
B118633
(b) Using a "Torx" Socket Wrench (T30), install the front door out-
side handle cover RH with the screw.
(c) Install the plug hole.
ED B118634
15. INSTALL FRONT DOOR FRAME RR LWR RH

(a) Install the front door frame RR LWR RH with the 2 bolts.
B137101
16. INSTALL FRONT DOOR FRAME FR LWR RH

(a) Install the front door frame FR LWR RH with the 2 bolts.
B137100
GETtheMANUALS.org
ED–22
17. INSTALL FRONT DOOR GLASS RUN NO. 2

(a) Install the front door glass run No. 2.
B143239
18. INSTALL FRONT DOOR GLASS RUN RH

(a) Install the front door glass run RH to the front door panel.
19. INSTALL FRONT DOOR OUTER PANEL PAD RH (WITH FRONT

DOOR OUTER PANEL PAD)
(a) Clean the installation surface.
(1) Heat the double-sided tape on the front door panel using a
heat gun. Then wipe off the tape with a rag.
(2) Clean the surface with a solvent.
(b) Clean the front door outer panel pad RH. (when reusing)
B137099
(1) Heat the double-sided tape on the front door outer panel
pad RH using a heat gun.
(2) While heating the tape with the heat gun, use a rag to
scrub off the double-sided tape remaining on the front
door outer panel pad RH.
(4) Apply double-sided tape to the front door outer panel pad
RH.
(c) Install the front door outer panel pad RH.
(1) Install the front door outer panel pad RH with the bolt and
firmly press-fit the front door outer panel pad RH. ED
Protective
Tape
B137098J01
20. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY

RH
(a) Using a "Torx" Socket Wrench (T25), install the power window
regulator motor assembly RH to the front door window regulator
RH with the 3 screws.
HINT:
The new regulator motor does not have threads in the screw
holes, but by using self tapping screws, the threads will be cre-
ated when the new screws are installed.
B137097
21. INSTALL FRONT DOOR WINDOW REGULATOR RH
(a) Install a temporary bolt to the front door window regulator RH.
GETtheMANUALS.org
(b) Temporarily install the front door window regulator RH to the

front door panel.
Connector (c) Tighten the 6 bolts, and install the front door window regulator
RH.
Board With Torque: 5.0 N*m (51 kgf*cm)
Bolts
(d) Connect the connector of the power window regulator motor
assembly RH.
22. INSTALL FRONT DOOR GLASS RH

(a) Connect the power window regulator master switch assembly
B137096J01
and move the front door window regulator RH until the installa-
tion position of the front door glass RH is visible. (when working
on the driver's seat side)
(b) Using the remote operation of the power window regulator mas-
ter switch assembly, move the front door window regulator RH
until the installation position of the front door glass RH is visi-
ble.(when working on the passenger seat side)
(c) Temporarily install the front door glass RH to the front door win-
(1)
dow regulator RH, as shown in the illustration.
(2)
NOTICE:
Do not damage the front door glass RH.
B143238J02
(d) Install the front door glass RH with the 2 bolts.

(e) Remove the power window regulator master switch assembly.
ED 23. INSTALL FRONT DOOR SERVICE HOLE COVER RH
(a) Apply butyl tape on the door panel side.
(b) Put the front door lock remote control cable RH and rear door
inside locking cable RH through the new front door service hole
cover RH.
B137095
GETtheMANUALS.org
ED–24
(c) Attach the new front door service hole cover RH, aligning it with
the standard position of the front door panel.
NOTICE:
Attach the front door service hole cover RH, pressing it
Standard Standard
Position Position down fully to prevent winkles or bubbles.
24. INSTALL FRONT SPEAKER ASSEMBLY NO. 1
Butyl Tape
B137112J01
25. INSTALL DOOR TRIM BRACKET NO. 1

(a) Install the door trim bracket No. 1 with the 2 screws.
26. INSTALL FRONT DOOR INSIDE HANDLE RH

(a) Connect the front door inside locking cable RH and the front
door lock remote control cable RH to the front door inside han-
dle RH.
B137093
(b) Slide the front door inside handle RH toward the front of the
(*2) vehicle and attach the 2 claws.(*1)
(c) Attach the claw and install the front door inside handle RH.(*2)
ED
(*1)
Claw
B053166J04
27. INSTALL POWER WINDOW REGULATOR MASTER SWITCH

ASSEMBLY (DRIVER'S SEAT SIDE)
(a) Install the master switch to the front armrest base panel UPR
B137091
GETtheMANUALS.org
28. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY

(PASSENGER SEAT SIDE)
(a) Attach the 2 claws and install the power window switch to the
rear door armrest base panel UPR.
Claw B137242J01
29. INSTALL FRONT ARMREST BASE PANEL UPR RH

(a) Attach the 10 claws and install the front armrest base panel
UPR RH.
Claw
B137090J01
30. INSTALL FRONT DOOR GLASS WEATHERSTRIP RH

(a) Install the front door glass weatherstrip INN RH.
31. INSTALL FRONT DOOR TRIM BOARD RH

(a) Connect the connector of the power window master switch
assembly.
ED B137092
(b) Engage the 8 claws and install the front door trim board RH.
(c) Install the 2 screws and clip.
Clip
B137089J03
GETtheMANUALS.org
ED–26

(a) Install the door assist grip base with the 2 screws.
B137088
33. INSTALL FRONT DOOR ASSIST GRIP COVER RH

(a) Engage the 10 claws to install the front door assist grip cover
RH.
ADJUSTMENT
1. CHECK FRONT DOOR PANEL LH
Claw
B137087J02 specified range.
A E
F
B
C G ED
H
B138862J01
Reference value
A 4.5 ± 1.5 mm E 4.3 ± 1.5 mm

B 1.0 ± 1.5 mm F 0 ± 1.5 mm
C 4.3 ± 1.5 mm G 4.3 ± 1.5 mm
D 0 ± 1.5 mm H 0 ± 1.5 mm
GETtheMANUALS.org
2. ADJUST FRONT DOOR PANEL LH

(a) After loosening the bolt of the body side, use the SST to adjust
the up or down and front to rear position of the door panel.
SST 09812-00010
(b) To adjust the up and down position of the door and the front to
rear position of the front end of the door, first loosen the bolt on
the door side.
NOTICE:
Because a centering bolt is used, adjustment should be
performed after replacing the provided bolt.
B138863
(c) To adjust the height and horizontal position of the door rear end
and front door lock striker plate assembly, use a "Torx" Socket
Wrench (T40) to loosen the striker installation screws until the
striker starts to move. Then adjust by tapping the striker using a
brass bar.
ED B128524
GETtheMANUALS.org
ENGINE HOOD / DOOR - REAR DOOR
ED–28
REAR DOOR
BODY AND
ENGINE HOOD
ELECTRICAL
/ DOOR
COMPONENTS

ASSEMBLY OUT RH
REAR DOOR GLASS RUN RH
REAR DOOR WEATHERSTRIP RH

REAR DOOR REARGUIDE
BRACKET GARNISH RH ED
REAR DOOR GLASS RUN LWR FR Clip ×3
REAR GLASS WEATHERSTRIP INNER RH

REAR DOOR DIVISION
BAR INSIDE SEAL RH
REAR DOOR TRIM BOARD RH REAR DOOR ARMREST

BASE PANEL UPR

SWITCH ASSEMBLY

...... NON-REUSEABLE PART
B136934J01
GETtheMANUALS.org
ED–29 ENGINE HOOD / DOOR - REAR DOOR
REAR OUTSIDE HANDLE COVER RH

DOOR OUTSIDE HANDLE NO. 1
REAR DOOR OUTSIDE PAD RR

REAR DOOR OUTSIDE HANDLE PAD FR
×2
T=5.0{51}
REAR DOOR OUTSIDE
HANDLE FRAME RH
T=31{316}
×2
REAR DOOR WINDOW GUIDE RR RH
T=5.0{51} REAR DOOR CHECK
ASSEMBLY RH
REAR DOOR INSIDE LOCKING CABLE RH

×3
T=5.0{51}
T=5.0{51}
DOOR LOCK
REAR DOOR WINDOW GUIDE FR RH WIREHARNESS SEAL
REAR DOOR LOCK ASSEMBLY RH
ED REAR GLASS RH REAR DOOR LOCK REMOTE CONTROL CABLE RH
Butyl Tape
×2
DOOR TRIM BRACKET
×2 NO. 1 RH
REAR DOOR SERVICEHOLE
T=5.0{51} COVER RH
×3
T=5.0{51}
×2
×3
REAR WINDOW REGULATOR RH
×4 REAR DOOR INSIDE HANDLE RH
SPEAKER ASSEMBLY RR
T=5.0{51}
APPLY MP GREASE
B136935J02
GETtheMANUALS.org
ED–30
DISASSEMBLY
1. REMOVE REAR DOOR DIVISION BAR INSIDE SEAL RH
(a) Using a wide type handy remover, detach the 3 claws and
remove the rear door division bar inside seal RH.
Claw
B137258J01
2. REMOVE REAR DOOR REAR GUIDE BRACKET GARNISH RH

(a) Using a wide type handy remover, remove rear door rear guide
bracket garnish RH.
Clip
B137259J01
3. REMOVE REAR DOOR ASSIST GRIP COVER RH

(a) Disengage the claw and remove the front door assist grip cover
RH.
ED
Claw
B137087J01
4. REMOVE DOOR ASSIST GRIP BASE

(a) Remove the 2 screws and door assist grip base.
5. REMOVE REAR DOOR TRIM BOARD RH

(a) Remove the 2 screws.
B137088
GETtheMANUALS.org
(b) Using a clip remover, disengage the 6 clips and remove the rear
door trim board RH.
(c) Disconnect the connector from behind of the front door trim
board RH.
Clip
B137240J02
6. REMOVE REAR DOOR ARMREST BASE PANEL UPR

(a) Disconnect the 10 claws and remove the rear door armrest
base panel UPR.
Claw
B137241J02
7. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY

(a) Disengage the 2 claws and remove the power window regulator
switch assembly.
ED
Claw B137242J02
8. REMOVE REAR DOOR GLASS WEATHERSTRIP INNER RH

(a) Remove the rear door glass weatherstrip inner RH from the rear
door trim board.
B137243
GETtheMANUALS.org
ED–32
9. REMOVE REAR DOOR INSIDE HANDLE RH

(*1) (a) Detach the claw from the rear side of the rear door inside han-
dle RH. (*1)
(b) Pull the front claw toward the rear side and disengage it. (*2)
(c) Disconnect the rear door lock remote control cable RH and the
(*2) rear door inside locking cable RH. Then remove the rear door
lock remote control cable RH.
10. REMOVE SPEAKER ASSEMBLY RR
Claw B053166J03
11. REMOVE DOOR TRIM BRACKET NO. 1

(a) Remove the 2 screws and the rear door armrest bracket RH.
B143242
12. REMOVE REAR DOOR SERVICE HOLE COVER RH

(a) Remove the rear door service hole cover RH.
NOTICE:
B137244
ED
13. REMOVE FRONT DOOR WEATHERSTRIP RH
(a) Using a clip remover, disengage the 31 clips and remove the
rear door weatherstrip RH.
Clip
B137246J02
GETtheMANUALS.org
14. REMOVE REAR DOOR GLASS RUN RH

(a) Remove the rear door glass run FR.
B137247
15. REMOVE REAR DOOR GLASS RUN LWR FR

(a) Remove the rear door glass run LWR FR.
B143243
16. REMOVE REAR DOOR WINDOW GUIDE FR RH

(a) Remove the bolts and the rear door window guide FR RH.
ED B137248
17. REMOVE REAR DOOR WINDOW GUIDE RR RH

(a) Remove the screw and the 2 bolts, and remove the rear window
guide RR RH.
18. REMOVE REAR DOOR GLASS RH

(a) Connect the power window regulator switch assembly and
move the front door glass RH until the installation bolt on the
rear door glass RH is visible.
B137113
(b) Remove the 2 bolts and the rear door glass RH.
NOTICE:
Do not damage the rear door glass RH.
(c) Remove power window regulator switch assembly.
19. REMOVE REAR DOOR WINDOW REGULATOR RH

(a) Disconnect the connector of the power window regulator motor
assembly RH.
B137249
GETtheMANUALS.org
ED–34
(b) Loosen the temporary bolt.

NOTICE:
The front door window regulator RH may fall and change
its shape if the temporary bolt is removed.
(c) Remove the 5 bolts and rear door window regulator RH.
(d) Remove the temporally bolt from the rear door window regulator
Connector RH.
Board With
Bolts
B137250J01
20. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY

RH
(a) Using a "Torx" Socket Wrench (T25), remove the 3 screws and
the power window regulator motor assembly RH from the rear
door window regulator RH.
B137097
21. REMOVE REAR DOOR CHECK ASSEMBLY RH

(a) Remove the 3 bolts and the rear door check assembly RH.
ED
B137245
22. REMOVE REAR DOOR LOCK ASSEMBLY RH

(a) Using a "Torx" Socket Wrench (T30), remove the 3 screws.
(b) Slide down the rear door lock assembly RH, and pull off the
release plate of the rear door outside handle frame RH. Then
remove the rear door lock assembly RH.
(c) Remove the door lock wire harness seal from the rear door lock
assembly RH.
23. REMOVE REAR DOOR LOCK REMOTE CONTROL CABLE RH

(a) Detach the 3 claws of the rear door lock assembly RH.
B137251
GETtheMANUALS.org
(b) Remove the rear door lock remote control cable RH from the
rear door lock assembly RH, as shown in the illustration.
(3)
(1)
(2)
B137252J01
24. REMOVE REAR DOOR INSIDE LOCKING CABLE RH

(a) Detach the 3 claws of the rear door lock assembly RH.
Claw
B137253J02
(b) Remove the rear door inside locking cable RH from the rear
(1)
(2)
ED B137254J01
25. REMOVE REAR DOOR OUTSIDE HANDLE COVER RH

(a) Using a "Torx" Socket Wrench (T30), loosen the screw.
(b) Detach the claws, and remove the rear door outside handle
cover RH.
Claw B118642
26. REMOVE DOOR OUTSIDE HANDLE NO. 1

(a) Lift and hold the release plate of the outside handle frame RH,
NOTICE:
If the release plate of the rear door outside handle frame
RH is not held up, the release plate may interfere with the
the rear door outside handle assembly RH when it is
removed. If this happens, the rear door outside handle
assembly RH may be damaged.
B137255
GETtheMANUALS.org
ED–36
(b) Pull the rear door outside handle assembly RH toward the vehi-
cle rear, and disengage the claws of the rear door outside han-
dle frame RH.
(c) Pull the rear door outside handle assembly RH forward and
remove the rear door outside handle frame RH.
B107001J02
27. REMOVE REAR DOOR OUTSIDE HANDLE PAD FR

(a) Disengage the 2 claws and remove the rear door outside han-
dle pad FR.
Claw B137103J01
28. REMOVE REAR DOOR OUTSIDE PAD RR

(a) Disengage the 2 claws and remove the rear door outside pad
RR.
Claw B137104J01
ED
29. REMOVE REAR DOOR OUTSIDE HANDLE FRAME RH
(a) Using a "Torx" Socket Wrench (T30), loosen the screw.
(b) Disengage the claw of the grommet.
(c) Disengage the claw by pulling it out toward the front of the vehi-
cle. Then remove the rear door outside handle frame RH.
30. REMOVE REAR DOOR GLASS WEATHERSTRIP ASSEMBLY

Grommet
OUT RH
REASSEMBLY
1. APPLY BODY GREASE
(a) Apply MP grease to the sliding areas of the rear door window
regulator RH, rear door outside handle frame RH, and rear door
lock assembly RH.
2. INSTALL REAR DOOR GLASS WEATHERSTRIP ASSEMBLY OUT

RH
3. INSTALL REAR DOOR OUTSIDE HANDLE FRAME RH

(a) Engage the claw by pulling it toward the back of the vehicle.
B137256J01
GETtheMANUALS.org
(b) Engage the claw of the grommet, and temporarily install the
rear outside handle frame RH.
(c) Using a "Torx" Socket Wrench (T30), tighten the screw.
Grommet
B137256J02
4. INSTALL REAR DOOR OUTSIDE PAD RR

(a) Attach the 2 claws and install the rear door outside pad RR.
ED Claw B137104J01
5. INSTALL REAR DOOR OUTSIDE HANDLE PAD FR

(a) Attach the 2 claws and install the rear door outside handle pad
FR.
Claw B137103J01
6. INSTALL DOOR OUTSIDE HANDLE NO. 1

(a) Insert the tip of the door outside handle No. 1 into the rear door
outside handle frame RH.
(b) Insert the rear end of the door outside handle No. 1 into the rear
door outside handle frame RH, and install the door outside han-
dle No. 1 by sliding it toward the vehicle front.
B107001J03
GETtheMANUALS.org
ED–38
7. INSTALL REAR DOOR OUTSIDE HANDLE COVER RH

(a) Attach the claws and temporarily install the rear door outside
handle cover RH.
Claw B120693J02
(b) Using a "Torx" Socket Wrench (T30), install the rear door out-
side handle cover RH with the screw.
B120694J01
8. INSTALL REAR DOOR INSIDE LOCKING CABLE RH

(a) Install the rear door inside locking cable RH to the rear door
lock assembly RH, as shown in the illustration.
(2)
(1)
B143245J01
ED
(b) Attach the 4 claws to the rear door lock assembly RH.
Claw
B137253J01
9. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE RH

(a) Install the rear door lock remote control cable RH to the rear
(1) 10. INSTALL REAR DOOR LOCK ASSEMBLY RH

(3) NOTICE:
• When reusing a removed rear door lock assembly, replace
(2) the door lock wire harness seal of the connector with a new
part.
• Make sure no grease or dirt adheres to the door lock wire
B143244J01
harness seal of the connector area.
GETtheMANUALS.org
• If a door lock wire harness seal is reused or if a damaged

door lock wire harness seal is used, there is a possibility that
water may get into the connecter area. This may cause a mal-
function of the front door lock assembly with motor.
(a) Install a new door lock wire harness seal to the rear door lock
assembly RH.
(b) Insert the rear door lock assembly RH into the release plate of
the rear door outside handle frame RH and install it to the rear
door panel.
(c) Make sure that the link of the rear door outside handle frame
RH is securely engaged with the rear door lock assembly RH.
(d) Using a "Torx" Socket Wrench (T30), install the rear door lock
assembly RH with the 3 screws.
(e) Connect the connector.
B137251
11. INSTALL REAR DOOR CHECK ASSEMBLY RH

(a) Install the rear door check assembly RH with the 3 bolts.
5.0 N*m (51 kgf*cm) (door side)
ED
B137245
12. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY

RH
(a) Using a "Torx" Socket Wrench (T25), install the power window
regulator motor assembly RH to the rear door window regulator
HINT:
The new regulator motor does not have threads in the screw
holes, but by using self tapping screws, the threads will be cre-
ated when the new screws are installed.
B137097
GETtheMANUALS.org
ED–40
13. INSTALL REAR DOOR WINDOW REGULATOR RH

(a) Temporarily install a bolt to the rear door window regulator RH.
Connector (b) Temporarily install the rear door window regulator RH to the
rear door panel.
(c) Install the rear door window regulator RH with the 6 bolts.
Board With Torque: 5.0 N*m (51 kgf*cm)
Bolts (d) Connect the connector.
B137250J01
14. INSTALL REAR DOOR GLASS RH

(a) Install the rear door glass RH with the 2 bolts.
B137249
15. INSTALL REAR DOOR WINDOW GUIDE RR RH

(a) Install the rear door window guide RR RH with the screw and
the 2 bolts.
B137113
ED
16. INSTALL REAR DOOR WINDOW GUIDE FR RH
(a) Install the rear door window guide FR RH with the bolt.
B137248
17. INSTALL REAR DOOR GLASS RUN LWR FR

(a) Install the rear door glass run LWR FR
B143243
GETtheMANUALS.org
18. INSTALL REAR DOOR GLASS RUN RH

(a) Install the rear door glass run RH.
B137247
19. INSTALL REAR DOOR WEATHERSTRIP RH

(a) Attach the 31 clips and install the new rear door weatherstrip
RH to the rear door panel.
20. INSTALL REAR DOOR SERVICE HOLE COVER RH

(b) Put the connector, the rear door lock remote control cable RH
and rear door inside locking cable RH through the new rear
door service hole cover RH.
Clip
B137246J01
(c) Attach the new rear door service hole cover RH, aligning it with
the standard position of the front door panel.
Standard Position Standard Position
NOTICE:
ED Attach the rear door service hole cover RH, pressing it fully
to prevent winkles or bubbles.
Butyl Tape
B137257J01
21. INSTALL DOOR TRIM BRACKET NO. 1

(a) Install the door trim bracket No. 1 with the 2 screws.
22. INSTALL SPEAKER ASSEMBLY RR
23. INSTALL REAR DOOR INSIDE HANDLE RH

(a) Connect the rear door lock remote control cable RH and the
rear door inside locking cable RH.
B143242
GETtheMANUALS.org
ED–42
(b) Slide the rear door inside handle RH toward the front of the
(*2) vehicle and attach the 2 claws.(*1)
(c) Engage the claw on the rear side and install the rear door inside
handle RH.(*2)
(*1)
Claw
B053166J04
24. INSTALL REAR DOOR GLASS WEATHERSTRIP INNER RH

(a) Install the rear door glass weatherstrip inner RH to the rear door
trim board RH.
B137243
25. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY

(a) Attach the 2 claws and install the power window switch to the
rear door armrest base panel UPR.
Claw B137242J01
ED
26. INSTALL REAR DOOR ARMREST BASE PANEL UPR
(a) Attach the 10 claws and install the rear door armrest base panel
UPR to the rear door trim board RH.
Claw
B137241J01
GETtheMANUALS.org
27. INSTALL REAR DOOR TRIM BOARD RH

(a) Engage the 6 clips.
(b) Install the rear door trim board RH with the 2 screws.
Clip
B137240J01

(a) Install the door assist grip base with the 2 screws.
B137088
29. INSTALL REAR DOOR ASSIST GRIP COVER RH

(a) Engage the 10 claws to install the front door assist grip cover
RH.
ED 30. INSTALL REAR DOOR REAR GUIDE BRACKET GARNISH RH
(a) Replace the 3 clips with new ones.
Clip
B137087
(b) Attach the 3 claws and install the rear door rear guide bracket
garnish RH.
Clip
B147460J01
GETtheMANUALS.org
ED–44
31. INSTALL REAR DOOR DIVISION BAR INSIDE SEAL RH

(a) Attach the 3 claws and install the rear door division bar inside
seal RH.
ADJUSTMENT
1. CHECK REAR DOOR PANEL LH
specified range.
Claw
B143246J01
A E
B
F
C G
H
D
B138864J01
Reference value
A 4.3 ± 1.5 mm E 4.5 ± 1.5 mm

B 0 ± 1.5 mm F 0 ± 1.5 mm
4.3 ± 1.5 mm 4.3 ± 1.5 mm
C
D 0 ± 1.5 mm
G
H 0 ± 1.5 mm
ED
6. REMOVE SHOULDER BELT ANCHOR COVER (WITH ADJUST-

ABLE ANCHOR)
7. REMOVE FRONT SEAT OUTER BELT ASSEMBLY LH
GETtheMANUALS.org
8. ADJUST REAR DOOR PANEL LH

(a) After loosening the nut on the body side, use the SST to adjust
the front to rear position of the door as well its up and down
position.
SST 09812-00010
(b) To adjust the up and down position of the door and the front to
rear position of the front end of the door, first loosen the bolt on
the door side.
NOTICE:
Because a centering bolt is used, adjustment should be
performed after replacing the provided bolt.
B138865
(c) To adjust the height and horizontal position of the door rear end
and rear door lock striker plate assembly, use a "Torx" Socket
Wrench (T40) to loosen the striker installation screws until the
striker starts to move. Then adjust by tapping the striker using a
brass bar.
9. INSTALL FRONT SEAT OUTER BELT ASSEMBLY LH
ED B050237J01
10. INSTALL SHOULDER BELT ANCHOR COVER (WITH ADJUST-
ABLE ANCHOR)
GETtheMANUALS.org
ENGINE HOOD / DOOR - BACK DOOR
ED–46
BACK DOOR
BODY AND
ENGINE HOOD
ELECTRICAL
/ DOOR
COMPONENTS

CENTER STOP
LIGHT ASSEMBLY
REAR WIPER ARM HEADCAP

T=5.4{56}
REAR WIPER ARM AND

BLADE ASSEMBLY
T=8.4{86} ×3
BACK DOOR TRIM PANEL ASSEMBLY
BACK DOOR SERVICE HOLE COVER

Butyl Tape ED
BACK DOOR SIDE MALE STOPPER
×2
T=12.5{127}
T=5.5{56}
×2 T=30{306}
×2
BACK DOOR CHECK
T=12.5{127} ASSEMBLY
BACK DOOR SIDE
FEMALE STOPPER
T=5.5{56} ×2
×4
T=5.5{56}
T=13{133}
BACK DOOR OUTSIDE
HANDLE ASSEMBLY
SPARE WHEEL CARRIER

×3
ASSEMBLY
T=5.8{59}
TIGHTENING TORQUE[N*m{kgf*cm}]
BACK DOOR LOCK ASSEMBLY NON-REUSEABLE PART
B148393J01
GETtheMANUALS.org
ED–47 ENGINE HOOD / DOOR - BACK DOOR
DISASSEMBLY
1. REMOVE SPARE TIRE
2. REMOVE SPARE WHEEL CARRIER ASSEMBLY

(a) Remove the 4 bolts and the spare wheel carrier assembly.
3. REMOVE CENTER STOP LIGHT COVER

(a) Disengage the claw and remove the center stop light cover.
4. REMOVE CENTER STOP LIGHT ASSEMBLY
(a) Remove the two screws. Then remove the center stop light
assembly.
E130837
5. REMOVE BACK DOOR TRIM PANEL ASSEMBLY

(a) Disengage the 17 clips and remove the back door trim panel.
Clip
B137537J01
ED 6. REMOVE BACK DOOR SERVICE HOLE COVER

(a) Remove the back door service hole cover.
HINT:
8. REMOVE REAR WIPER ARM AND BLADE ASSEMBLY
B137539
10. REMOVE REAR WIPER MOTOR ASSEMBLY
11. REMOVE BACK DOOR OUTSIDE HANDLE ASSEMBLY

(a) Remove the 2 nuts and back door outside handle.
(b) Disconnect the open rod of the back door lock assembly and
the back door outside handle assembly.
B143267
GETtheMANUALS.org
ED–48
12. REMOVE BACK DOOR LOCK ASSEMBLY

(b) Disconnect the connector and remove the back door lock
assembly.
13. REMOVE BACK DOOR CHECK ASSEMBLY

(a) Remove the 2 nuts, the bolt and the back door check assembly.
14. REMOVE BACK DOOR SIDE FEMALE STOPPER

(a) Remove the 2 bolts and the back door side female stopper.
B143268
15. REMOVE BACK DOOR SIDE MALE STOPPER
(a) Remove the 2 bolts and the back door side male stopper.
REASSEMBLY
1. INSTALL BACK DOOR SIDE MALE STOPPER
(a) Install the back door side male stopper with the 2 bolts.
2. INSTALL BACK DOOR SIDE FEMALE STOPPER

(a) Install the back door side female stopper with the 2 bolts.
3. INSTALL BACK DOOR CHECK ASSEMBLY

(a) Install the back door check assembly with the 2 nuts and bolts.
30 N*m (306 kgf*cm) (bolt)
4. INSTALL BACK DOOR LOCK ASSEMBLY
(a) Using a "Torx" Socket Wrench (T30) and a bolt, install the back
door lock assembly with the 3 "torx" screws.
“Torx”Screw 5.8 N*m (59 kgf*cm) (Torx screw)
ED
Bolt
B143268J01
5. INSTALL BACK DOOR OUTSIDE HANDLE ASSEMBLY

(a) Install the back door outside handle assembly with the 2 nuts.
(b) Connect the connector of the open rod of the back door lock
assembly.
6. INSTALL REAR WIPER MOTOR ASSEMBLY
7. INSTALL REAR WIPER MOTOR GROMMET
8. INSTALL REAR WIPER ARM AND BLADE ASSEMBLY

B143267
GETtheMANUALS.org
10. INSTALL BACK DOOR SERVICE HOLE COVER

Standard Position
(b) Apply the new back door service hole cover adjusting to the
standard position of the back door panel.
NOTICE:
Apply the back door service hole cover thoroughly pre-
venting winkles or bubbles, and press it completely.
Butyl Tape B137543J01
11. INSTALL BACK DOOR TRIM PANEL ASSEMBLY

(a) Engage the 16 claws and install the back door trim panel
assembly.
12. INSTALL CENTER STOP LAMP ASSEMBLY
13. INSTALL CENTER STOP LIGHT ASSEMBLY
14. INSTALL SPARE WHEEL CARRIER ASSEMBLY

(a) Install the spare wheel carrier assembly with the 4 bolts.
Clip Torque: 13 N*m (133 kgf*cm)
B137537J01
15. INSTALL SPARE TIRE
ADJUSTMENT
ED 1. INSPECT BACK DOOR
(a) Check that the back door is installed within the specified range.
H
A
B
C I
E
D
J
F
K
B138866J01
GETtheMANUALS.org
ED–50
A 5.5 ± 1.5 mm G 6.5 ± 1.5 mm

B 3.2 ± 1.5 mm H 1.3 ± 1.5 mm
C 5.5 ± 1.5 mm I 5.5 ± 1.5 mm
D 5.6 ± 1.5 mm J 5.5 ± 1.5 mm
E 0.2 ± 1.5 mm K 7.1 ± 1.5 mm
F 6.0 ± 1.5 mm
2. REMOVE TAILLIGHT (REAR COMBINATION LIGHT) ASSEMBLY

RH (See page LI-37)
4. REMOVE QUARTER OUTSIDE MOLDING LH (VEHICLES WITH

OVER FENDER) (See page ET-30)
5. REMOVE QUARTER OUTSIDE MOLDING RH (VEHICLES WITH

OVER FENDER)
6. REMOVE OUTSIDE MOLDING CLIP NO. 4 (VEHICLES WITH

7. REMOVE REAR WHEEL OPENING EXTENSION PAD NO. 2 (VEHI-

CLES WITH OVER FENDER) (See page ET-30)
8. REMOVE LICENSE PLATE BRACKET BASE (See page ET-8)
9. REMOVE REAR BUMPER COVER (See page ET-8)
10. ADJUST BACK DOOR

SST 09812-00010
(a) To adjust the height and the right to left position of the back door
panel, loosen the bolt on the body side before performing the
adjustment.
(b)
72 N*m (734 kgf*cm) (door side)
To adjust the height and the rear to front position of the left edge
ED
of the back door, loosen the bolt on the door side before per-
forming the adjustment.
B138867
GETtheMANUALS.org
(c) To adjust the height and horizontal position of the left edge of
the back door and as well as the position of the back door lock
striker plate assembly, use a Torx Socket Wrench (T40) to
loosen the striker installation screws until the striker starts to
move. Then adjust by tapping the striker using a brass bar.
B070664J01
(d) To adjust the height and horizontal position of the left hand edge
of the back door panel or to adjust the position of the back door
side female stopper, first loosen the bolt.
B138868
(e) To adjust the height and horizontal position of the left hand edge
of the back door panel or to adjust the position of the back door
side male stopper, first loosen the bolt.
11. INSTALL TAILLIGHT (REAR COMBINATION LIGHT) ASSEMBLY

RH (See page LI-40)
12. INSTALL REAR BUMPER COVER (See page ET-11)
ED B138869
13. INSTALL LICENSE PLATE BRACKET BASE (See page ET-12)
14. CLEAN INSTALLATION SURFACE (See page ET-30)
15. CLEAN QUARTER OUTSIDE MOLDING AND REAR WHEEL

OPENING EXTENSION (WHEN REUSING) (See page ET-30)
16. INSTALL OUTSIDE MOLDING CLIP NO. 4 (See page ET-31)
17. INSTALL REAR WHEEL OPENING EXTENSION PAD NO. 1 (See

page ET-31)
18. INSTALL QUARTER OUTSIDE MOLDING LH (See page ET-31)
19. INSTALL QUARTER OUTSIDE MOLDING RH
GETtheMANUALS.org
ENGINE HOOD / DOOR - FUEL LID LOCK CONTROL CABLE
ED–52

BODY AND
ENGINE HOOD
ELECTRICAL
/ DOOR
COMPONENTS
T=33.8{345}
T=33.8{345}
ED
T=33.8{345}
T=33.8{345}

(FOR RH SEAT)

B136501J01
GETtheMANUALS.org
ED–53 ENGINE HOOD / DOOR - FUEL LID LOCK CONTROL CABLE
RIGHT-HAND DRIVE
DECK FLOOR BOX RH

ASSEMBLY RH
ED
DECK BOARD ASSEMBLY
FUEL LID LOCK OPEN LEVER
B141348J01
GETtheMANUALS.org
ED–54
LEFT-HAND DRIVE
DECK FLOOR BOX RH
DECK TRIM SIDE PANEL ASSEMBLY RH
DECK FLOOR BOX LH
ED
CENTER PILLAR
GARNISH LWR LH
B141346J01
GETtheMANUALS.org
LEFT-HAND DRIVE
FUEL LID LOCK DECK BOARD ASSEMBLY

CONTROL CABLE
ED
FUEL LID LOCK OPEN LEVER
B141347J01
GETtheMANUALS.org
ED–56
REMOVAL
• For right-hand drive vehicles, please refer to step 1 to step 15.
• For left-hand drive vehicles, please refer to step 16 to step 35.


page SE-3)
4. REMOVE FRONT SEAT ASSEMBLY RH (See page SE-3)
5. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-4)
6. REMOVE COWL SIDE TRIM BOARD RH (See page IP-10)
5)
5)
14. REMOVE FUEL LID LOCK OPEN LEVER
(a) Remove the bolt and the fuel lid lock open lever.
(b) Remove the fuel lid lock open lever from the fuel lid lock control
cable.
ED
B139054
15. REMOVE FUEL LID LOCK CONTROL CABLE

(a) Disconnect the fuel lid lock control cable, as shown in the illus-
tration.
(1)
(2)
B139055J01
GETtheMANUALS.org
(b) Remove the tape and the clamps from the locations shown in
the illustration, and remove the fuel lid lock control cable.
Cramp
B142175J01


page SE-3)
ED 19. REMOVE FRONT SEAT ASSEMBLY RH (See page SE-3)
20. REMOVE FRONT SEAT LEG COVER
21. REMOVE FRONT SEAT LEG COVER LH (FOR LH SEAT)
22. REMOVE FRONT SEAT ASSEMBLY LH
23. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-4)
24. REMOVE COWL SIDE TRIM BOARD LH (See page IP-10)
5)
5)
GETtheMANUALS.org
ED–58
34. REMOVE FUEL LID LOCK OPEN LEVER

(a) Remove the bolt and the fuel lid lock open lever.
(b) Remove the fuel lid lock open lever from the fuel lid lock control
cable.
B139054
35. REMOVE FUEL LID LOCK CONTROL CABLE

(a) Disconnect the fuel lid lock control cable, as shown in the illus-
tration.
(1) (b) Remove the tape and the resin band from the locations shown
in the illustration, and remove the fuel lid lock control cable.
(2)
B139055J01
Cramp
ED
B142174J01
INSTALLATION
• For right-hand drive vehicles, please refer to step 1 to step 17.
• For left-hand drive vehicles, please refer to step 18 to step 39.
1. INSTALL FUEL FILLER OPENING LID LOCK
2. INSTALL FUEL LID LOCK OPEN LEVER

(a) Connect the fuel lid lock control cable.
GETtheMANUALS.org
(b) Install the fuel lid lock open lever with the bolt.
B139054
3. INSTALL FUEL LID LOCK CONTROL CABLE

(a) Connect the fuel lid lock control cable assembly, as shown in
the illustration.
(b) Install the fuel lid lock control cable with the tape and the
clamps on the location, as shown in the illustration.
B139055
Cramp
ED
B142175J01

12)

13)
GETtheMANUALS.org
ED–60
11. INSTALL COWL SIDE TRIM BOARD RH (See page IP-19)
12. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-12)

page SE-9)
18. INSTALL FUEL FILLER OPENING LID LOCK
19. INSTALL FUEL LID LOCK OPEN LEVER

(a) Connect the fuel lid lock control cable.
(b) Install the fuel lid lock open lever with the bolt.
B139054
20. INSTALL FUEL LID LOCK CONTROL CABLE

(a) Connect the fuel lid lock control cable assembly, as shown in
the illustration.
ED
B139055
GETtheMANUALS.org
(b) Install the fuel lid lock control cable with the tape and the
clamps on the location, as shown in the illustration.
Cramp
B142174J01
12)
13)

ED 24. INSTALL REAR DOOR SCUFF PLATE LH
30. INSTALL COWL SIDE TRIM BOARD LH (See page IP-19)
31. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-12)

page SE-9)
35. INSTALL FRONT SEAT ASSEMBLY LH
36. INSTALL FRONT SEAT LEG COVER LH (FOR LH SEAT)
37. INSTALL FRONT SEAT LEG COVER
GETtheMANUALS.org
ENGINE HOOD / DOOR - FRONT FENDER LH
ED–62
FRONT FENDER LH
BODY AND
ENGINE HOOD
ELECTRICAL
/ DOOR
COMPONENTS
FRONT FENDER LINER RH
T=22{224}
×13
ED
Clip
FRONT FENDER LINER LH
FRONT WIPER ARM AND T=22{224}
BLADE ASSEMBLY RH
FRONT WIPER ARM AND BLADE ASSEMBLY LH
COWL TOP
VENTILATOR LOUVER
BONNET (HOOD) TO COWL TOP SEAL COWL TOP VENTILATOR LOUVER
B142172J02
GETtheMANUALS.org
ED–63 ENGINE HOOD / DOOR - FRONT FENDER LH
OVER FENDER EQUIPPED VEHICLES FRONT FENDER MOLDING RH
FRONT FENDER MOLDING LH
FRONT WHEEL OPENING

EXTENSION PAD NO. 2
FRONT BUMPER COVER

T=6.0{61}
ROCKER PANEL MOLDING EQUIPPED VEHICLES MOLDING TAPE NO.3

ED
MOLDING TAPE NO.2
ROCKER PANEL MOLDING LH
SIDE MUD GUARD RETAINER
NON-REUSEABLE PART
B148410J01
GETtheMANUALS.org
ED–64
FRONT FENDER TO COWL SIDE SEAL LH

SIDE TURN SIGNAL
LIGHT ASSEMBLY LH
T=8.5{87}
FRONT FENDER LH
FRONT BUMPER SIDE SUPPORT LH
FOG LIGHT COVER RH

T=6.0{61} ED
FRONT BUMPER COVER
FOG LIGHT COVER LH
FOG LIGHT EQUIPPED VEHICLES SIDE MUD GUARD EQUIPPED VEHICLES
FOG LIGHT ASSEMBLY

FOG LIGHT ASSEMBLY
FRONT FENDER MUD GUARD
NON-REUSEABLE PART
B142173J01
GETtheMANUALS.org
REMOVAL
1. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (See
page WW-5)
2. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See

page WW-5)
3. REMOVE COWL TOP VENTILATOR LOUVER (See page WW-5)
4. REMOVE FRONT FENDER MUD GUARD LH (WITH SIDE MUD

GUARD) (See page ET-13)
5. REMOVE SIDE MUD GUARD RETAINER (WITH ROCKER PANEL

MOLDING) (See page ET-20)
6. REMOVE ROCKER PANEL MOLDING LH (WITH ROCKER PANEL

7. REMOVE MOLDING TAPE NO. 2 (WITH ROCKER PANEL MOLD-

ING)
8. REMOVE MOLDING TAPE NO. 3 (WITH ROCKER PANEL MOLD-

ING)
9. REMOVE FRONT FENDER MOLDING LH (WITH OVER FENDER)

(See page ET-25)
10. REMOVE FRONT FENDER MOLDING RH (WITH OVER FENDER)
11. REMOVE FRONT WHEEL OPENING EXTENSION PAD NO. 2

(WITH OVER FENDER) (See page ET-25)
12. REMOVE FRONT FENDER LINER RH
(a) Remove the clip, then roll back the front fender liner RH.
ED
Clip B144043J01
13. REMOVE FRONT FENDER LINER LH

(a) Cut off the fender liner with a cutter knife and remove the 2
grommets.
(b) Remove the 13 clips and the front fender liner LH.
14. REMOVE FOG LIGHT ASSEMBLY LH (WITH FOG LIGHT)

Cut
16. REMOVE FOG LIGHT COVER LH (WITHOUT FOG LIGHT) (See

page ET-2)
B144044J01
17. REMOVE FOG LIGHT COVER RH (WITHOUT FOG LIGHT)
19. REMOVE FRONT BUMPER SIDE SUPPORT LH (See page ET-3)
20. REMOVE SIDE TURN SIGNAL LIGHT ASSEMBLY LH (See page

LI-35)
GETtheMANUALS.org
ED–66
21. REMOVE FRONT FENDER TO COWL SIDE SEAL LH
22. REMOVE HEADLIGHT ASSEMBLY LH (See page LI-26)

23. REMOVE FRONT FENDER LH
(a) Remove the 6 bolts and the front fender LH.
INSTALLATION
B140142
1. INSTALL FRONT FENDER LH

(a) Install the front fender LH with the 6 bolts.
2. INSTALL FRONT FENDER TO COWL SIDE SEAL LH

(a) Heat the double-sided tape on the vehicle body with a heat gun.
Then scrape off the tape using a rag.
(b) Clean the application surface on the body side with a solvent.
(c) Install a new front fender to cowl side seal LH with double-sided
tape.
3. INSTALL SIDE TURN SIGNAL LIGHT ASSEMBLY LH (See page

LI-36) ED
4. INSTALL HEADLIGHT ASSEMBLY LH
5. INSTALL FRONT BUMPER SIDE SUPPORT RH (See page ET-5)

B140142
9. REMOVE FOG LIGHT COVER LH (WITHOUT FOG LIGHT)
10. INSTALL FOG LIGHT COVER RH (WITHOUT FOG LIGHT)
11. INSTALL FRONT FENDER LINER LH

(a) Install the front fender liner LH with the 13 clips.
(b) Install 2 new grommets.(Vehicles without the rocker panel mold-
ing and side mud guard)
12. INSTALL FRONT FENDER LINER RH
13. CLEAN VEHICLE INSTALLATION SURFACE (WITH ROCKER

PANEL MOLDING) (See page ET-21)
14. CLEAN ROCKER PANEL MOLDING LH (WHEN REUSING) (See

page ET-21)
15. INSTALL MOLDING TAPE NO. 2 (WITH ROCKER PANEL MOLD-

ING) (See page ET-22)
GETtheMANUALS.org
16. INSTALL MOLDING TAPE NO. 3 (WITH ROCKER PANEL MOLD-

17. INSTALL ROCKER PANEL MOLDING LH (WITH ROCKER PANEL

18. INSTALL SIDE MUD GUARD RETAINER (WITH ROCKER PANEL

19. INSTALL FRONT FENDER MUD GUARD LH (WITH SIDE MUD

GUARD) (See page ET-14)

(WITH OUTSIDE MOLDING) (See page ET-27)
21. INSTALL FRONT FENDER MOLDING RH (WITH OUTSIDE MOLD-

ING)
22. INSTALL FRONT FENDER MOLDING LH (WITH OUTSIDE MOLD-

23. INSTALL COWL TOP VENTILATOR LOUVER (See page WW-8)
24. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See

page WW-9)
25. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See

page WW-10)
26. PERFORM INITIALIZATION (See page WW-10)
ED
GETtheMANUALS.org
TO INDEX
BODY AND ELECTRICAL
BODY EXTERIOR
FRONT BUMPER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-4
REAR BUMPER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-10
SIDE MUD GUARD LH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-14
NAME PLATE
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-15
ROOF DRIP SIDE FINISH MOULDING LH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-17
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-21
FRONT FENDER WHEEL OPENING MOULDING LH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-25
QUARTER PANEL WHEEL OPENING MOULDING LH ET
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-30
BLACKOUT TAPE NO. 2 LH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-34
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-40
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-45
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-47
FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY OUT LH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-49
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-50
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-50
GETtheMANUALS.org
REAR DOOR GLASS WEATHERSTRIP ASSEMBLY OUT LH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-51
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ET-52
ET
GETtheMANUALS.org
BODY EXTERIOR - FRONT BUMPER
ET–1
FRONT BUMPER
BODY AND
EXTERIOR
ELECTRICAL
COMPONENTS
OVER FENDER EQUIPPED VEHICLES
FRONT FENDER
MOLDING RH
FRONT WHEEL OPENING

EXTENSION PAD NO. 2
FRONT WHEEL
OPENINGEXTENSION
PAD NO. 1
FRONT BUMPER
EXTENSION RH
T=17.5{179} FRONT FENDER LINER RH
T=12.5{128}
FRONT BUMPER SIDE SUPPORT RH
FRONT BUMPER REINFORCEMENT
FRONT FENDER LINER LH
FRONT BUMPER COVER FRONT BUMPER SIDE SUPPORT LH

ET
OVER FENDER EQUIPPED
VEHICLES
FRONT WHEEL
OPENINGEXTENSION PAD NO. 2
FRONT BUMPER
FRONT WHEEL OPENING
HOLE COVER LH T=6.0{61} EXTENSION PAD NO. 1
FOG LIGHT
COVER RH FOG LIGHT COVER LH
FOG LIGHT EQUIPPED VEHICLES

FRONT BUMPER EXTENSION LH
NON-REUSEABLE PART
FOG LIGHT ASSEMBLY LH TIGHTENING TORQUE [N*m{kgf*cm}]
B141140J02
GETtheMANUALS.org
ET–2 BODY EXTERIOR - FRONT BUMPER
REMOVAL
1. REMOVE FRONT FENDER MOULDING LH (WITH OVER FENDER)
(See page ET-25)
2. REMOVE FRONT FENDER MOULDING RH (WITH OVER

FENDER)

4. REMOVE FRONT FENDER LINER LH
(a) Remove the clip, then roll back the front fender liner LH.
6. REMOVE FOG LIGHT ASSEMBLY LH (WITH FOG LIGHT) (See

page LI-33)
Clip B142168J01

(a) Disengage the 4 claws and remove the fog light cover LH.
Claw B137868J01
10. REMOVE FRONT BUMPER COVER

ET Protective Tape (a) Apply protective tape as shown in the illustration.
(b) Remove the 5 clips, the 5 bolts, and the 2 screws.
Clip B137697J01
GETtheMANUALS.org
ET–3
(c) Hold the front bumper cover with both hands as shown in the
illustration. With the front bumper cover pushed up, disengage
the 6 claws on the left and right side without damaging them.
Then remove the front bumper cover.
NOTICE:
• Disengaging the claws all at once may damage the claw
on the front bumper side support or the front bumper
cover. Be sure to disengage the claws one at a time
from the outside.
• Hold areas close to the claws when disengaging the
claws. Holding areas away from the claws may damage
the claws or the front bumper cover.
• Securely hold the front bumper cover so that it will not
fall down.
Claw B147492J01
11. REMOVE FRONT BUMPER SIDE SUPPORT RH

(a) Remove the screw and the 2 clips.
B137702
ET
(b) Turn the front bumper side support approximately 90° and
remove it, as shown in the illustration.
12. REMOVE FRONT BUMPER SIDE SUPPORT LH
B137703
13. REMOVE FRONT BUMPER HOLE COVER LH
Claw B137699J01
GETtheMANUALS.org
14. REMOVE FRONT BUMPER REINFORCEMENT

(a) Remove the bolt and 6 nuts and then remove the front bumper
reinforcement.
15. REMOVE FRONT BUMPER EXTENSION LH (WITH OVER

FENDER) (See page ET-25)
16. REMOVE FRONT BUMPER EXTENSION RH (WITH OVER

FENDER)

B137701
INSTALLATION
1. CLEAN INSTALLATION SURFACE (WITH OVER FENDER) (See
page ET-25)
2. CLEAN FRONT BUMPER EXTENSION AND FRONT FENDER

MOULDING (WHEN REUSING) (See page ET-26)
3. INSTALL FRONT WHEEL OPENING EXTENSION PAD NO. 1

4. INSTALL FRONT BUMPER EXTENSION LH (WITH OVER

FENDER) (See page ET-26)
5. INSTALL FRONT BUMPER EXTENSION RH (WITH OVER

FENDER)
6. INSTALL FRONT BUMPER REINFORCEMENT
(a) Install the front bumper reinforcement with the bolt and 6 nuts.
17.5 N*m (179 kgf*cm) (nut)
ET
B137701
7. INSTALL FRONT BUMPER HOLE COVER LH

(a) Attach the 4 claws and install the front bumper hole cover LH.
Claw B137699J01
GETtheMANUALS.org
ET–5
8. INSTALL FRONT BUMPER SIDE SUPPORT RH

(a) Insert the tip of the front bumper side support RH into the front
(*2) fender RH hole, while it is tilted at a 90°.(*1)
(b) Tilt the front bumper side support RH 90°. (*2)
(*1)
B137703J01
(c) Install the front bumper side support RH with the screw and the
2 clips.
9. INSTALL FRONT BUMPER SIDE SUPPORT LH
B137702
10. INSTALL FRONT BUMPER COVER

(a) Engage the 6 claws on the right and left side, and temporarily
install the front bumper cover.
Claw B137698J01
ET
(b) Install the front bumper cover with the 4 clips, the 5 bolts and
Protective Tape the 2 screws.
Clip B137697J01
GETtheMANUALS.org

(a) Engage the 4 claws and install the fog light cover RH.
13. INSTALL FOG LIGHT ASSEMBLY LH (WITH FOG LIGHT) (See

page LI-34)
14. INSTALL FOG LIGHT ASSEMBLY RH (WITH FOG LIGHT)
Claw B137868J01
15. INSTALL FRONT FENDER LINER LH

(a) Install the front fender liner LH with the clip.

18. INSTALL FRONT FENDER MOULDING LH (WITH OVER FENDER)

(See page ET-27)
Clip B142168J02
19. INSTALL FRONT FENDER MOULDING RH (WITH OVER FENDER)
ET
GETtheMANUALS.org
BODY EXTERIOR - REAR BUMPER
ET–7
REAR BUMPER
BODY AND
EXTERIOR
ELECTRICAL
COMPONENTS
T=13.5{137}
REAR BUMPER SIDE SUPPORT RH
T=13.5{137}
REAR BUMPER COVER
REAR BUMPER SIDE

SUPPORT LH
ET
REAR BUMPER COVER UPR RH
T=6.0{61} REFLEX REFLECTOR

ASSEMBLY RH
REFLEX REFLECTOR ASSEMBLY LH
OVER FENDER EQUIPPED VEHICLES
QUARTER OUTSIDE
QUARTER OUTSIDE
MOLDING RH
MOLDING LH
REAR WHEEL OPENING EXTENSION PAD NO. 2
..... NON-REUSEABLE PART ..... TIGHTENING TORQUE [N*m{kgf*cm}] B141141J03
GETtheMANUALS.org
ET–8 BODY EXTERIOR - REAR BUMPER
REMOVAL
2. REMOVE QUARTER OUTSIDE MOULDING LH (VEHICLES WITH

3. REMOVE QUARTER OUTSIDE MOULDING RH (VEHICLES WITH

OVER FENDER)
4. REMOVE OUTSIDE MOULDING CLIP NO. 4 (VEHICLES WITH

5. REMOVE REAR WHEEL OPENING EXTENSION PAD NO. 2 (VEHI-

CLES WITH OVER FENDER) (See page ET-30)
6. REMOVE LICENSE PLATE BRACKET BASE

(a) Remove the 2 bolts and the license plate bracket base.
7. REMOVE REAR BUMPER COVER
(a) Apply protective tape as shown in the illustration.
Clip B137912J01
(b) Remove the 4 clips and the 2 bolts on the right and left side.
ET
Clip B137913J01
B137914
GETtheMANUALS.org
ET–9
(d) With the rear bumper cover pushed up, disengage the 6 claws
on the left and right side.
NOTICE:
• Removing the rear bumper cover while pressing on the
shaded area may damage the cover. Be sure not to
press the shaded area when removing the cover.
• Disengaging the claws all at once may damage the
claws on the rear bumper side support or the rear
bumper cover. Be sure to disengage the claws one at a
Claw B146578J01 time from the outside.
• Hold the areas close to the claws when disengaging the
claws. Holding areas away from the claws may damage
the claws or the rear bumper cover.
(e) Remove the 3 claws in the center of the rear bumper cover, and
remove the rear bumper cover.
8. REMOVE REAR BUMPER SIDE SUPPORT RH

Claw B137917J01
(b) Remove the bolt and the 3 clips, then remove the rear bumper
side support RH.
9. REMOVE REAR BUMPER SIDE SUPPORT LH

ET
Clip B137919J01
(b) Remove the bolt and the 2 clips, then remove the rear bumper
side support LH.
Clip B137920J01
GETtheMANUALS.org
10. REMOVE REFLEX REFLECTOR ASSEMBLY RH

(b) Disengage the claw and install the reflex reflector assembly RH.
11. REMOVE REFLEX REFLECTOR ASSEMBLY LH
B139068
12. REMOVE REAR BUMPER COVER UPR RH

(a) Disengage the 3 claws and remove the rear bumper cover UPR
RH.
INSTALLATION
Claw B137918J01
1. INSTALL REAR BUMPER COVER UPR RH

(a) Attach the 3 claws and install the rear bumper cover UPR RH.
Claw B137918J01
ET
2. INSTALL REFLEX REFLECTOR ASSEMBLY RH
(a) Attach the claw and install the reflex reflector assembly RH with
the screw.
3. INSTALL REFLEX REFLECTOR ASSEMBLY LH
4. INSTALL REAR BUMPER SIDE SUPPORT RH

(a) Install the screw.
B139068J01
GETtheMANUALS.org
ET–11
(b) Install the rear bumper side support RH with the bolt and the 3
clips.
5. INSTALL REAR BUMPER SIDE SUPPORT LH

(a) Install the screw.
Clip B137919J01
(b) Install the rear bumper side support LH with the bolt and the 2
clips.
Clip B137920J01
6. INSTALL REAR BUMPER COVER

(a) Attach the 3 claws in the center and the 6 claws on the right and
the left, install the rear bumper cover.
Claw B137917J01
ET
Claw B137916J01
(b) Install the 4 clips on the right and the left sides and the 2 bolts.
Clip B137912J01
GETtheMANUALS.org
Clip B137913J01
(c) Install the 2 bolts.

7. INSTALL LICENSE PLATE BRACKET BASE

(a) Install the license plate bracket base with the 2 bolts.
8. CLEAN INSTALLATION SURFACE (See page ET-30)
9. CLEAN QUARTER OUTSIDE MOULDING AND REAR WHEEL

OPENING EXTENSION (WHEN REUSING) (See page ET-30)
10. INSTALL OUTSIDE MOULDING CLIP NO. 4 (See page ET-31)
11. INSTALL REAR WHEEL OPENING EXTENSION PAD NO. 1 (See

page ET-31)
12. INSTALL QUARTER OUTSIDE MOULDING LH (See page ET-31)
13. INSTALL QUARTER OUTSIDE MOULDING RH

B137914
ET
GETtheMANUALS.org
BODY EXTERIOR - SIDE MUD GUARD LH
ET–13
SIDE MUD GUARD LH

BODY AND
EXTERIOR
ELECTRICAL
COMPONENTS
QUARTER PANEL MUD GUARD RR LH
FRONT FENDER MUD GUARD LH

ET
B142171J01
REMOVAL
1. REMOVE FRONT FENDER MUD GUARD LH
(a) Remove the 3 clips and the front fender mud guard LH.
Clip B140049J01
GETtheMANUALS.org
ET–14 BODY EXTERIOR - SIDE MUD GUARD LH
2. Remove the quarter panel mud guard RR LH

(a) Remove the 3 clips and the quarter panel mud guard RR LH.
INSTALLATION
Clip B140050J01
1. INSTALL FRONT FENDER MUD GUARD LH

(a) Install the front fender mud guard LH with the 3 clips.
Clip B140049J01
2. INSTALL QUARTER PANEL MUD GUARD RR LH

(a) Install the quarter panel mud guard RR LH with the 3 clips.
Clip B140050J01
ET
GETtheMANUALS.org
BODY EXTERIOR - NAME PLATE
ET–15
NAME PLATE
BODY AND
EXTERIOR
ELECTRICAL
COMPONENTS
(1)
(2) (3) (4)
(1)BACK DOOR NAMEPLATE NO. 1 (3)BACK DOOR NAMEPLATE NO. 3
2.7
Back Door Edge Back Door Edge Body Crease
ET
Body Crease 218.5
2.4
Body Crease
Back Door Edge
Backing Paper(Template) 132
(2)BACK DOOR NAMEPLATE NO. 4 (4)BACK DOOR NAMEPLATE NO. 2
Back Door Edge
Perforated Line Body Crease Backing Paper(Template)
Units [mm]
B141317J01
GETtheMANUALS.org
ET–16 BODY EXTERIOR - ROOF DRIP SIDE FINISH MOULDING LH
ROOF DRIP SIDE FINISH MOULDING LH

BODY AND
EXTERIOR
ELECTRICAL
COMPONENTS
ROOF RACK EQUIPPED VEHICLE ROOF RACK LEG COVER RR LH

ROOF RACK LEG COVER FR LH
ROOF RACK LEG CUSHION RR LH

ROOF RACK LEG CUSHION FR LH
ROOF DRIP SIDE FINISH MOLDING FR LH

ROOF DRIP SIDE
FINISHMOLDING CLIP
ROOF DRIP SIDE FINISH MOLDING

CLIP NO. 2
ET
NON-REUSEABLE PART
TIGHTENING TORQUE [N*m{kgf*cm}] B143265J01
GETtheMANUALS.org
BODY EXTERIOR - ROOF DRIP SIDE FINISH MOULDING LH
ET–17
REMOVAL
1. REMOVE ROOF RACK LEG COVER FR LH (WITH ROOF RACK)
(See page ET-46)
2. REMOVE ROOF RACK LEG COVER RR LH (WITH ROOF RACK)

(See page ET-46)
3. REMOVE ROOF RACK ASSEMBLY LH (WITH ROOF RACK) (See

page ET-46)
4. REMOVE ROOF RACK LEG CUSHION FR LH (WITH ROOF

RACK)
5. REMOVE ROOF RACK LEG CUSHION RR LH (WITH ROOF

RACK)
6. REMOVE ROOF DRIP SIDE FINISH MOULDING FR LH
(a) Put protective tape on the body panel around the roof drip side
finish moulding outline.
(b) Disengage the 2 clips and remove the roof drip finish moulding.
NOTICE:
• Do not remove the clip.
• If the clips are damaged, replace them with extra clips.
Protective Tape INSTALLATION

HINT:
If the clips have come off or damaged, follow steps 1 to 3.
1. CLEAN INSTALLATION SURFACE

(a) Heat the double-sided tape on the body using a heat gun. Then
wipe off the tape using a rag or piece of cloth.
(b) Clean the surface with a solvent.
2. INSTALL ROOF DRIP SIDE FINISH MOULDING CLIP

(a) Put a one-to-one ratio of base compound to hardening agent of
adhesive in a plastic bag or similar container. Mix them until the ET
color of the mixture changes from clear to milky white.
Clip B140048J01
NOTICE:
• Be sure to mix the base compound and hardening agent
in a one-to-one ratio. If they are not mixed in the speci-
fied ratio, adhesion will significantly decrease.
• Thoroughly mix the base compound and hardening
agent. Failure to do so will result in poor hardening.
• Apply the mixture within 20 minutes of mixing.
(b) Coat the clip with adhesive so that the thickness of the adhesive
is 0.5 mm or more.
Standard:
When press-firring the clip, the adhesive protrudes from
the outer edge.
0.5mm or more
B147243
GETtheMANUALS.org
ET–18 BODY EXTERIOR - ROOF DRIP SIDE FINISH MOULDING LH
(c) After applying the adhesive, attach the clip to the position
shown in the illustration and firmly press-fit the clip.
C
A B HINT:
• Do not touch the adhesive surface with your fingertips, etc.
• Keep the adhesive surface away from oil, water, dirt, and
other foreign objects.
• Press-fit the clip at right angles to the body.
Symbols Specified value (mm)

A 1.2
B 1±0.5
C 1.3±1
D 5.4
E 1±0.5
F 1.3±1
D E F
(d) Harden the adhesive.
HINT:
Heating the adhesive will facilitate hardening.
Leave adhesive unattended 3 hours or more at room temperature

B140047J01 Heat adhesive 30 minutes or more at 80°C
(e) Install the roof drip side finish moulding FR LH and then remove
it. Check that the clip is securely attached.
3. INSTALL ROOF DRIP SIDE FINISH MOULDING CLIP NO. 2

4. INSTALL ROOF DRIP SIDE FINISH MOULDING FR LH
(a) Attach the 2 clips and install the roof drip side finish moulding
A
FR LH.
Symbols Specified value (mm)

A 18.5
B 18
ET (b) Remove the protective tape.
5. INSTALL ROOF RACK LEG CUSHION RR LH
6. INSTALL ROOF RACK LEG CUSHION FR LH
7. INSTALL ROOF RACK ASSEMBLY LH (See page ET-47)
8. REMOVE ROOF RACK LEG COVER RR LH (See page ET-47)

B
9. REMOVE ROOF RACK LEG COVER FR LH (See page ET-48)
B140048J02
GETtheMANUALS.org
BODY EXTERIOR - ROCKER PANEL MOULDING LH
ET–19

BODY AND
EXTERIOR
ELECTRICAL
COMPONENTS
MOLDING TAPE NO.3
MOLDING TAPE NO.2
ET
ROCKER PANEL MOLDING LH
SIDE MUD GUARD RETAINER
NON-REUSEABLE PART
B142176J01
GETtheMANUALS.org
ET–20 BODY EXTERIOR - ROCKER PANEL MOULDING LH
REMOVAL
1. REMOVE SIDE MUD GUARD RETAINER
(a) Remove the 7 side mud guard retainers using a wide type
handy remover.
B144221
2. REMOVE ROCKER PANEL MOULDING LH

(a) Remove the 3 screws.
ET
B144222
GETtheMANUALS.org
ET–21
(b) Apply protective tape as shown in the illustration.
MOLDING TAPE NO.3

Protective Tape
MOLDING TAPE NO.2
:Clip B139164J01
(c) Using a heat gun, heat the rocker panel moulding LH (double
sided adhesive area).
(d) Using a wide type handy remover, remove the 9 claws and con-
nectors (double sided tape). Then remove the locker panel
moulding LH.
3. REMOVE MOULDING TAPE NO. 2
4. REMOVE MOULDING TAPE NO. 3
INSTALLATION
(a) Heat the moulding tape on the body using a heat gun. Then
2. CLEAN ROCKER PANEL MOULDING LH (WHEN REUSING) ET

(a) CLEAN MOULDING TAPE INSTALLATION SURFACE
(1) Using a heat gun, heat the moulding tape remaining on
the rocker panel moulding LH.
(2) While heating the tape with the heat gun, use a rag or
piece of cloth to wipe off the moulding tape remaining on
the rocker panel moulding LH.
NOTICE:
• Remove as much of the moulding tape as possi-
ble. Any tape that remains may cause attachment
failure when the rocker panel moulding is
installed.
• Use a waste cloth to scrub off, because it may
cause damage and attachment failure if using a
driver.
GETtheMANUALS.org
ET–22 BODY EXTERIOR - ROCKER PANEL MOULDING LH
3. INSTALL MOULDING TAPE NO. 2

(a) Attach the moulding tape No. 2 to the rocker panel moulding LH
MOLDING TAPE NO.3 MOLDING TAPE NO.2
B147469J01
NOTICE:
Be careful not to touch the adhesive surface with your fin-
gers when removing the exfoliate paper from the moulding
tape.
4. INSTALL MOULDING TAPE NO. 3

(a) Attach the moulding tape No. 3 to the rocker panel moulding LH
NOTICE:
tape.
5. INSTALL ROCKER PANEL MOULDING LH

(a) Using a heat gun, heat the rocker panel moulding LH and the
surface of the vehicle body.
(b) Set the rocker panel moulding LH on the vehicle, and press
firmly to install it.
NOTICE:
ET Be careful not to touch the adhesive surface with your fin-

tape.
(c) Attach the 9 claws and install the rocker panel moulding LH.
MOLDING TAPE NO.3

Protective Tape
MOLDING TAPE NO.2
:Clip B139164J01
GETtheMANUALS.org
ET–23
(d) Install the 3 screws.
B144222
6. INSTALL SIDE MUD GUARD RETAINER

(a) Install the 7 side mud guard retainers.
ET
B144221
GETtheMANUALS.org
ET–24 BODY EXTERIOR - FRONT FENDER WHEEL OPENING MOULDING LH
FRONT FENDER WHEEL OPENING MOULDING LH

BODY AND
EXTERIOR
ELECTRICAL
COMPONENTS
FRONT FENDER MOLDING RH
FRONT WHEEL OPENING

EXTENSION PAD NO. 2
FRONT FENDER LINER RH
ET FRONT FENDER LINER LH
FRONT WHEEL OPENING

EXTENSION PAD NO. 2
FOG LIGHT COVER RH FRONT BUMPER COVER

T=6.0{61}
FOG LIGHT COVER LH

FRONT WHEEL OPENING
EXTENSION PAD NO. 1
FOG LAMP EQUIPPED VEHICLES

FRONT BUMPER EXTENSION LH

..... TIGHTENING TORQUE [N*m{kgf*cm}] ..... NON-REUSEABLE PART
B141277J01
GETtheMANUALS.org
BODY EXTERIOR - FRONT FENDER WHEEL OPENING MOULDING LH
ET–25
REMOVAL
1. REMOVE FRONT FENDER MOULDING LH
(a) Apply protective tape, as shown in the illustration.
(b) Remove the 3 clips and the screw.
Protective Tape (c) Using a heat gun, heat the front fender moulding LH (double
HINT:
Heat the front bumper extension for 3 to 5 minutes at a temper-
ature between 40 and 60°C.
Clip B142167J01
(d) Disengage the 5 claws and remove the front fender moulding
LH.
2. REMOVE FRONT FENDER MOULDING RH

(a) Remove the front wheel opening extension pad No. 2 from the
front fender moulding.
4. REMOVE FRONT FENDER LINER LH (See page ET-2)
Clip B137696J01

page ET-2)
10. REMOVE FRONT BUMPER COVER (See page ET-2) ET

11. REMOVE FRONT BUMPER EXTENSION LH
(a) Using a heat gun, heat the front bumper extension LH (double
HINT:
Heat the front bumper extension for 3 to 5 minutes at a temper-
ature between 40 and 60°C.
(b) Remove the 2 clips and the 3 nuts, then remove the front
bumper extension LH.

(a) Remove front wheel opening extension pad No. 1 from the front
bumper extension.
INSTALLATION
Clip B137704J01 (a) Heat the double-sided tape on the body using a heat gun. Then
GETtheMANUALS.org
ET–26 BODY EXTERIOR - FRONT FENDER WHEEL OPENING MOULDING LH
2. CLEAN FRONT BUMPER EXTENSION AND FRONT FENDER

MOULDING (WHEN REUSING)
(a) CLEAN DOUBLE SIDED TAPE INSTALLATION SURFACE
(1) Heat the double sided tape on the front bumper extension
and the front fender moulding using a heat gun.
piece of cloth to wipe off the double sided tape remaining
on the front bumper extension and the front fender mould-
ing.
NOTICE:
• Remove as much of the double sided tape as pos-
sible. Any tape that remains may cause attach-
ment failure when the front bumper extension and
front fender moulding are installed.
driver.
(a) Install the front wheel opening extension pad No. 1 to the front
FRONT WHEEL OPENING bumper extension LH with double sided tape.
EXTENSION PAD NO. 1
4. INSTALL FRONT BUMPER EXTENSION LH
(a) Using a heat gun, heat the front bumper extension LH and the
bumper cover surface.
(b) Install the front bumper extension LH to the front bumper cover
with the 2 clips and 3 nuts.
ET (c) Firmly press the front fender moulding LH to the vehicle body.
NOTICE:
gers when removing the exfoliate paper from the double
sided tape.
Clip B137704J01 6. REMOVE FOG LIGHT ASSEMBLY LH (WITH FOG LIGHT)

page ET-6)
10. INSTALL FRONT FENDER LINER LH (See page ET-6)
GETtheMANUALS.org
BODY EXTERIOR - FRONT FENDER WHEEL OPENING MOULDING LH
ET–27

fender moulding using double sided tape.
13. INSTALL FRONT FENDER MOULDING LH

(a) Using a heat gun, heat the font fender moulding LH and the sur-
face of the vehicle body.
FRONT WHEEL OPENING

EXTENSION PAD NO. 2
(b) Engage the 5 claws and temporarily install the front fender
moulding LH.
Clip B137696J01
(c) Install the front fender moulding LH with the 3 clips and the
screw.
(d) Firmly press the front fender moulding LH to the vehicle body.
NOTICE:
sided tape.
(e) Remove the protective tape.
14. INSTALL FRONT FENDER MOULDING RH

Clip B142167J02
ET
GETtheMANUALS.org
ET–28 BODY EXTERIOR - QUARTER PANEL WHEEL OPENING MOULDING LH
QUARTER PANEL WHEEL OPENING MOULDING LH

BODY AND
EXTERIOR
ELECTRICAL
COMPONENTS
REAR WHEEL
OPENING
EXTENSION
NO. 1 RH
MOULDING
COVER NO.1
QUARTER OUTER
SIDE MOLDING RH
REAR WHEEL OPENING
EXTENSION PAD NO. 1 REAR WHEEL OPENING
EXTENSION PAD NO. 1
ET OUTSIDE MOLDING RETAINER NO. 2 RH
MOUNTING
BRACKET
NO.1
MOUNTING
BRACKET
NO.2
REAR WHEEL OPENING REAR
EXTENSION NO. 1 LH OUTSIDE MOLDING RETAINER
NO. 3 LH WHEELOPENING
EXTENSION PAD
MOULDING COVER NO.1 NO. 2
OUTSIDE MOLDING CLIP NO. 4
QUARTER OUTSIDE MOLDING LH
REAR WHEEL OPENINGEXTENSION

..... NON-REUSEABLE PART PAD NO. 2
B141276J01
GETtheMANUALS.org
BODY EXTERIOR - QUARTER PANEL WHEEL OPENING MOULDING LH
ET–29
REMOVAL
1. REMOVE MOLDING COVER NO. 1
(a) Disengage the 2 claws and remove the moulding cover No. 1.
B137925
2. REMOVE REAR WHEEL OPENING EXTENSION NO. 1 LH

Protective Tape (a) Apply protective tape as shown in the illustration.
(b) Remove the rivet.
(1) Wrap tape around the drill bit leaving approximately 5 mm
from the tip of the drill bit, as shown in the illustration.
HINT:
The purpose of wrapping the tape around the drill bit is to
prevent the drill from drilling too deep.
(2) Apply and hold the drill to the rivet. Drill the rivet flange
B137922J01 area and remove the rivet.
(c) Heat the rear wheel opening extension No. 1 using a heat gun.
(d) Remove the screw, disengage the cllips, and remove the rear
wheel opening extension No. 1 LH.
ET
B137921
3. REMOVE OUTSIDE MOULDING RETAINER NO. 3 LH

(a) Remove the 3 screws and the outside moulding retainer No. 3
LH.
4. REMOVE REAR WHEEL OPENING EXTENSION PAD NO. 1

(a) Remove the rear wheel opening extension No. 1 from the rear
wheel opening extension No. 1 LH.
B137923
GETtheMANUALS.org
5. REMOVE QUARTER OUTSIDE MOULDING LH

Protective Tape (a) Apply protective tape as shown in the illustration.
(b) Remove the 2 screws and the 3 clips.
(c) Heat the quarter outside moulding RH using a heat gun.
(d) Disengage the 5 clips and remove the quarter outside moulding
RH.
:Clip B137909J01
6. REMOVE OUTSIDE MOULDING CLIP NO. 4

(a) If the outside moulding clip No. 4 remains on the vehicle side,
turn it to about 90° and remove it, as shown in the illustration.
B137911
7. REMOVE MOUNTING BRACKET NO.1

No.1 (a) Remove the 2 screws and mounting bracket No. 1.
No.2 8. REMOVE MOUNTING BRACKET NO. 2
(a) Remove the 2 screws and mounting bracket No. 2.
9. REMOVE REAR WHEEL OPENING EXTENSION PAD NO. 2

(a) Remove the rear wheel opening extension pad No. 2 from the
quarter outside moulding.
B137910J01 INSTALLATION
ET 1. CLEAN INSTALLATION SURFACE
(a) Heat the double sided tape on the body using a heat gun. Then
2. CLEAN QUARTER OUTSIDE MOULDING AND REAR WHEEL

OPENING EXTENSION (WHEN REUSING)
(a) CLEAN DOUBLE SIDED TAPE INSTALLATION SURFACE
(1) Heat the double sided tape that remains on the quarter
outside moulding and the rear wheel opening extension
using a heat gun.
piece of cloth to wipe off the double sided tape remaining
on the quarter outside moulding and the rear wheel open-
ing extension.
NOTICE:
• Remove as much of the double sided tape as pos-
sible. Any tape that remains may cause attach-
ment failure when the quarter outside moulding
and the rear wheel opening extension are
installed.
GETtheMANUALS.org
BODY EXTERIOR - QUARTER PANEL WHEEL OPENING MOULDING LH
ET–31

driver.
3. INSTALL MOUNTING BRACKET NO.1
No.1 (a) Install the 2 screws and mounting bracket No. 1.
No.2
NOTICE:
Do not confuse mounting bracket No. 1 with mounting
bracket No. 2. The parts look alike.
4. INSTALL MOUNTING BRACKET NO. 2

(a) Install the 2 screws and mounting bracket No. 2.
NOTICE:
Do not confuse mounting bracket No. 2 with mounting
B137910J01
bracket No. 1. The parts look alike.
5. INSTALL OUTSIDE MOULDING CLIP NO. 4

(a) Install the outside moulding clip No. 4 to the quarter outside
moulding LH.
6. INSTALL REAR WHEEL OPENING EXTENSION PAD NO. 1
fender moulding LH using double sided tape.
7. INSTALL QUARTER OUTSIDE MOULDING LH

(a) Using a heat gun, heat both the quarter outside moulding LH
and the surface of the body.
REAR WHEEL OPENING

EXTENSION PAD NO. 1
B147247J01
(b) Attach the 5 claws and install the quarter outside moulding LH.
Protective Tape (c) Connect the 2 screws and the 3 clips and attach it thoroughly.
NOTICE:
Be careful not to touch the adhesive surface with your fin- ET
sided tape.
:Clip B137909J01
8. INSTALL OUTSIDE MOULDING RETAINER NO. 3 LH

(a) Install the outside moulding retainer No. 3 LH with the 3 screws.
B137923
GETtheMANUALS.org
9. INSTALL REAR WHEEL OPENING EXTENSION PAD NO. 2

(a) Install the rear wheel opening extension pad No. 2 to the rear
wheel opening extension No. 1 LH with double-sided tape.
10. INSTALL REAR WHEEL OPENING EXTENSION NO. 1

(a) Using a heat gun, heat both the rear wheel opening extension
No. 1 LH and the surface of the body.
REAR WHEEL OPENING

EXTENSION PAD NO. 2
(b) Connect the 2 claws and the screw, and firmly press the exten-
sion to the vehicle body.
NOTICE:
sided tape.
(c) Install the rivet.
(1) Put nose piece No. 2 on the riveter.
B137921
(2) Using the riveter, install a new rivet. Operate the riveter
while holding it perpendicular to the rivet hole.
ET B137922
11. INSTALL MOULDING COVER NO.1

(a) Engage the 2 claws and install the moulding cover No. 1.
B137925
GETtheMANUALS.org
BODY EXTERIOR - BLACKOUT TAPE NO. 2 LH
ET–33

BODY AND
EXTERIOR
ELECTRICAL
COMPONENTS

BLACK-OUT TAPE NO. 2 LH

ASSEMBLY OUT LH
T=4.4{45}

BRACKET GARNISH LH
FRONT DOOR
FRONT DOOR GLASS RUN LH GLASS LH
T=5.0{51}
FRONT DOOR INSIDE
HANDLE LH
×2
ET
Butyl Tape
DOOR TRIM BRACKET

NO. 1 LH
×2
FRONT DOOR SERVICE

HOLE COVER LH
×3 ×2
DOOR ASSIST
GRIP BASE
Clip FRONT DOOR ASSIST
FRONT DOOR TRIM BOARD LH
GRIP COVER LH
NON-REUSEABLE PART TIGHTENING TORQUE [N*m{kgf*cm}] B141028J01
GETtheMANUALS.org
ET–34 BODY EXTERIOR - BLACKOUT TAPE NO. 2 LH
REMOVAL
RH

11)
4. REMOVE FRONT DOOR TRIM BOARD RH (See page ED-11)
5. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY RH
6. REMOVE FRONT DOOR INSIDE HANDLE RH (See page ED-12)
7. REMOVE DOOR TRIM BRACKET NO. 1 RH (See page ED-12)
8. REMOVE FRONT SPEAKER ASSEMBLY NO. 1 (See page AV-31)
9. REMOVE FRONT DOOR SERVICE HOLE COVER RH (See page

ED-13)
10. REMOVE FRONT DOOR GLASS RH (See page ED-13)
11. REMOVE FRONT DOOR GLASS RUN RH (See page ED-14)

OUT RH (See page ET-50)
13. REMOVE BLACKOUT TAPE NO. 2 LH

(a) Heat the blackout tape No. 2 LH using a heat gun.
NOTICE:
Be careful not to get burned by dryer heat or by the black-
out tape No. 2 LH while it is hot.
(b) Pry up the edge of the weatherstrip using a finger nail and
remove it by pulling it parallel to the surface.
INSTALLATION
ET 1. PRECAUTIONS FOR APPLYING BLACKOUT TAPE
(a) Appropriate temperature to paste
(1) If the ambient temperature is 15°C or lower, heat the vehi-
cle body (installation surface) and the blackout tape using
an infrared lamp until the temperature reaches between
20 and 30°C. Then begin the operation. If the ambient
temperature is 35°C or higher, cool the installation surface
and the tape to a temperature lower than 35°C.
HINT:
• When applying the blackout tape, 25°C is an appropri-
ate temperature.
• Blackout tape hardens and its adhesive strength
weakens at low temperatures. In addition, blackout
tape softens at high temperatures.
(b) PREPARATION
(1) If any paint seeds or dust are caught on the surface of the
body (installation surface) when the blackout tape is
applied, this may cause bubbling and a poor appearance.
Therefore, make sure to remove any paint seeds or dust
from the around the installation surface and the blackout
tape.
GETtheMANUALS.org
ET–35
(c) HANDLING OF BLACKOUT TAPE

(1) Because blackout tape is easily deformed, protect the
blackout tape by storing it between cardboard in a flat dry
place.
NOTICE:
Do not bend the tape or leave in a hot place.
(d) BLACKOUT TAPE APPLICATION TECHNIQUES (RUBBER
SPATULA TECHNIQUES AND APPLICATION PROCEDURES
FOR GENERAL AREAS)
NOTICE:
• To determine the initial application position, be accu-
rate within ± 1 mm. Inaccuracy will affect the appear-
ance of the tape and careless installation may cause
peeling at a later date.
• Blackout tape cannot be reused. Once it is peeled off, it
deforms and its adhesive strength is weakened.
(1) To prevent air bubbles, lift the part which is not pressed by
a rubber spatula from the base, and tilt the rubber spatula
Push
40 to 50 (by pushing) or 30 to 45 (by pulling), push the air
3-7 cm/sec. out from the inside toward the outside slowly with a pres-
40-50°
sure strength of 20 to 30 N ( 2 to 3 kgf) and a speed of 3 to
7 cm/second, then press-fit firmly.
Rubber spatula NOTICE:
When using a rubber spatula, be careful about appli-
Black-out Tape cation speed, pressure strength, and angle. If the
10-20 mm
speed or pressure of application is not constant, or if
the application is stopped in the middle, a line (called
a shock line) may be caused on the blackout surface.
Release Paper Also air bubbles may be caused if the application
speed is too fast.
HINT:
Pull • The rubber spatula can be pushed or pulled across
3-7 cm/sec.
the surface, depending on the requirements of the ET
application area.
• During this procedure, peel off the exfoliate paper of
the blackout tape, working 10 to 20 mm ahead of the
Rubber spatula 10-20 mm rubber spatula tip.
30-45°
Black-out Tape
Release Paper
GETtheMANUALS.org
(e) BLACKOUT TAPE APPLICATION TECHNIQUES (RUBBER

Rubber spatula SPATULA TECHNIQUES AND APPLICATION PROCEDURES
Second Time FOR HEMMING AREAS)
First Time (1) If it is too difficult to apply the blackout tape with one pass
Third Time
of the rubber spatula, try to press-fit the tape using multi-
ple applications of the rubber spatula. Press-fit the black-
out tape, working gradually when working in areas with
tight curves. Apply the tape in three steps, pressing with
Hemming Portion your finger or the fat part of the rubber spatula, as shown
B108310J01 in the illustration.
HINT:
For the back of the hemming area, peel off the exfoliate
paper, and press-fit with fingers or the fat side of the rub-
ber spatula.
(f) BLACKOUT TAPE APPLICATION TECHNIQUES (RUBBER
FOR CORNER AREAS)
(1) For the corner area, peel off the exfoliate paper and
press-fit carefully, using the tips of your fingers.
(2) In order to prevent poor appearance due to tape pinching,
heat the blackout tape with a heat gun, and fold the tape
around each corner, flattening each corner in order.
(g) POST-APPLICATION INSPECTION
(1) After applying the blackout tape, check to make sure that
the tape has been applied properly. If appearance is poor,
peel off the tape and repeat the procedure with new black-
out tape.
NOTICE:
• Do not reuse the blackout tape once it has been
peeled off.
• Glossy tapes, like the ones used for the outboard
panel, show scratches easily. So, do not use a
ET needle to remove air bubbles when using glossy

tapes.
HINT:
If the hemming area or corner area of the blackout tape is
slightly peeled off, fix with an instant adhesive.
2. APPLY BLACKOUT TAPE NO. 2 LH

(a) CLEAN APPLICATION SURFACE (PROCEDURE FOR USING
INFRA-RED LIGHT)
(1) Using an infrared lamp, heat the blackout tape No. 2 LH
and the adhesive remaining on the body of the vehicle.
NOTICE:
Be careful not to burn yourself with the infrared lamp
or the vehicle body while it is hot.
HINT:
Heat the front bumper extension for 3 to 5 minutes at a
temperature between 40 and 60°C.
(2) Using a rag, scrub away the blackout tape No. 2 LH and
the adhesive remaining on the body.
NOTICE:
• Use a rag or other cloth to remove the tape. Do not
use a screwdriver or similar tool. These tools may
GETtheMANUALS.org
ET–37
scratch the body of the vehicle body and make it

difficult to attach the moulding.
• Remove as much of the blackout tape as possible.
Any old tape that remains may cause attachment
failure when the new blackout tape No. 2 LH is
installed.
(3) Clean the application surface with a solvent.
(b) CLEAN APPLICATION SURFACE (PROCEDURE FOR USING
TAPE REMOVAL DISK)
(1) Set the 8 discs in the holder, and install the removal disk
to an air drill or an electric drill.
NOTICE:
Use an electric drill with a no-load speed of 2000 to
3000 r/min.
(2) Scrape off the blackout tape No. 2 LH or the adhesive
remaining on the body using the remover disc.
NOTICE:
• Use safety glasses while removing the blackout
tape.
• Be careful about the direction of the disc's rotation
and the operating direction.
• In order to avoid damaging the body of the vehi-
cle, visually check to make sure that too much
material is not shaved away.
installed.
(c) Apply the new blackout tape No. 2 LH in the position shown in
the illustration.
ET
A
A-A C-C
A
R Stop
R Stop
Unnecessary Portion
B B
4 mm B-B
C
4±1 mm
B140143J01

OUT LH
4. INSTALL FRONT DOOR GLASS RUN LH (See page ED-22)
5. INSTALL FRONT DOOR GLASS LH (See page ED-23)
GETtheMANUALS.org
6. INSTALL FRONT DOOR SERVICE HOLE COVER LH (See page

ED-23)
7. INSTALL FRONT SPEAKER ASSEMBLY NO. 1 (See page AV-31)
8. INSTALL DOOR TRIM BRACKET NO. 1 (See page ED-24)
9. INSTALL FRONT DOOR INSIDE HANDLE LH (See page ED-24)
10. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH
11. INSTALL FRONT DOOR TRIM BOARD LH (See page ED-25)
13. INSTALL FRONT DOOR ASSIST GRIP COVER LH (See page ED-
26)
14. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH
ET
GETtheMANUALS.org
ET–39

BODY AND
EXTERIOR
ELECTRICAL
COMPONENTS

ASSEMBLY OUT LH
REAR DOOR REAR GUIDE

BRACKET GARNISH LH
REAR DOOR DIVISION

BAR INSIDE SEAL LH
BLACK-OUT TAPE
REAR DOOR GLASS RUN LH
NO. 3 LH
REAR DOOR TRIM

BOARD LH
×2
ET
DOOR TRIM BRACKET

NO. 1 LH
FRONT DOOR ASSIST GRIP COVER LH ×2
×3
REAR DOOR INSIDE HANDLE LH
SPEAKER ASSEMBLY RR
REAR DOOR SERVICE HOLE COVER LH
×2
..... NON-REUSEABLE PART
REAR DOOR GLASS LH ..... TIGHTENING TORQUE [N*m{kgf*cm}]
T=5.0{51}
B141029J01
GETtheMANUALS.org
REMOVAL
1. REMOVE REAR DOOR DIVISION BAR INSIDE SEAL LH (See
page ED-30)
2. REMOVE REAR DOOR REAR GUIDE BRACKET GARNISH LH

(See page ED-30)
3. REMOVE FRONT DOOR ASSIST GRIP COVER LH (See page ED-

30)
5. REMOVE REAR DOOR TRIM BOARD LH (See page ED-30)
6. REMOVE REAR DOOR INSIDE HANDLE LH (See page ED-32)
7. REMOVE SPEAKER ASSEMBLY RR (See page AV-33)
8. REMOVE DOOR TRIM BRACKET NO. 1 LH (See page ED-32)
9. REMOVE REAR DOOR SERVICE HOLE COVER LH (See page

ED-32)
10. REMOVE REAR DOOR GLASS RUN LH (See page ED-33)
11. REMOVE REAR DOOR GLASS LH (See page ED-33)

OUT LH
13. REMOVE BLACKOUT TAPE NO. 3 LH

(a) Heat the blackout tape No. 3 LH using a heat gun.
NOTICE:
Be careful not to get burned by dryer heat or by the black-
out tape No. 3 LH while it is hot.
(b) Pry up the edge of the weatherstrip using a finger nail and
remove it by pulling it parallel to the surface.
ET INSTALLATION
1. PRECAUTIONS FOR APPLYING BLACKOUT TAPE
(a) Appropriate temperature to paste
(1) If the ambient temperature is 15°C or lower, heat the vehi-
cle body (installation surface) and the blackout tape using
an infrared lamp until the temperature reaches between
20 and 30°C. Then begin the operation. If the ambient
temperature is 35°C or higher, cool the installation surface
and the tape to a temperature lower than 35°C.
HINT:
• When applying the blackout tape, 25°C is an appropri-
ate temperature.
• Blackout tape hardens and its adhesive strength
weakens at low temperatures. In addition, blackout
tape softens at high temperatures.
(b) PREPARATION
(1) If any paint seeds or dust are caught on the surface of the
body (installation surface) when the blackout tape is
applied, this may cause bubbling and a poor appearance.
Therefore, make sure to remove any paint seeds or dust
GETtheMANUALS.org
ET–41
from the around the installation surface and the blackout

tape.
HINT:
Because the air is dry especially in the winter season,
store the blackout tape in between cardboard in a flat dry
place.
(c) HANDLING OF BLACKOUT TAPE
(1) Because blackout tape is easily deformed, protect the
blackout tape by storing it between cardboard in a flat dry
place.
NOTICE:
Do not bend the tape or leave in a hot place.
(d) BLACKOUT TAPE APPLICATION TECHNIQUES (RUBBER
FOR GENERAL AREAS)
NOTICE:
• To determine the initial application position, be accu-
rate within ± 1 mm. Inaccuracy will affect the appear-
ance of the tape and careless installation may cause
peeling at a later date.
• Blackout tape cannot be reused. Once it is peeled off, it
deforms and its adhesive strength is weakened.
(1) To prevent air bubbles, lift the part which is not pressed by
a rubber spatula from the base, and tilt the rubber spatula
Push
40 to 50 (by pushing) or 30 to 45 (by pulling), push the air
3-7 cm/sec. out from the inside toward the outside slowly with a pres-
40-50°
sure strength of 20 to 30 N (2 to 3 kgf) and a speed of 3 to
7 cm/second, then press-fit firmly.
Rubber spatula NOTICE:
When using a rubber spatula, be careful about appli-
Black-out Tape 10-20 mm cation speed, pressure strength, and angle. If the
speed or pressure of application is not constant, or if
the application is stopped in the middle, a line (called ET
a shock line) may be caused on the blackout surface.
Release Paper Also air bubbles may be caused if the application
speed is too fast.
HINT:
Pull • The rubber spatula can be pushed or pulled across
the surface, depending on the requirements of the
3-7 cm/sec. application area.
• During this procedure, peel off the exfoliate paper of
the blackout tape, working 10 to 20 mm ahead of the
Rubber spatula 10-20 mm rubber spatula tip.
30-45°
Black-out Tape
Release Paper
GETtheMANUALS.org
(e) BLACKOUT TAPE APPLICATION TECHNIQUES (RUBBER

Rubber spatula SPATULA TECHNIQUES AND APPLICATION PROCEDURES
Second Time FOR HEMMING AREAS)
(1) If it is too difficult to apply the blackout tape with one pass
First Time
Third Time of the rubber spatula, try to press-fit the tape using multi-
ple applications of the rubber spatula. Press-fit the black-
out tape, working gradually when working in areas with
tight curves. Apply the tape in three steps, pressing with
your finger or the fat part of the rubber spatula, as shown
Hemming Portion
HINT:
For the back of the hemming area, peel off the exfoliate
paper, and press-fit with fingers or the fat side of the rub-
ber spatula.
(f) BLACKOUT TAPE APPLICATION TECHNIQUES (RUBBER
FOR CORNER AREAS)
(1) For the corner area, peel off the exfoliate paper and
press-fit carefully, using the tips of your fingers.
(2) In order to prevent poor appearance due to tape pinching,
heat the blackout tape with a heat gun, and fold the tape
around each corner, flattening each corner in order.
(g) POST-APPLICATION INSPECTION
(1) After applying the blackout tape, check to make sure that
the tape has been applied properly. If appearance is poor,
peel off the tape and repeat the procedure with new black-
out tape.
NOTICE:
• Do not reuse the blackout tape once it has been
peeled off.
• Glossy tapes, like the ones used for the outboard
panel, show scratches easily. So, do not use a
ET needle to remove air bubbles when using glossy

tapes.
HINT:
If the hemming area or corner area of the blackout tape is
slightly peeled off, fix with an instant adhesive.
2. APPLY BLACKOUT TAPE NO. 3 LH

(a) CLEAN APPLICATION SURFACE (PROCEDURE FOR USING
HEAT GUN)
(1) Using a heat gun, heat the blackout tape No. 2 LH and the
adhesive remaining on the body of the vehicle.
NOTICE:
Be careful not to burn yourself with the infrared lamp
or the vehicle body while it is hot.
HINT:
Heat the front bumper extension for 3 to 5 minutes at a
temperature between 40 and 60°C.
(2) Using a rag, scrub away the blackout tape No. 3 LH and
the adhesive remaining on the body.
NOTICE:
• Use a rag or other cloth to remove the tape. Do not
use a screwdriver or similar tool. These tools may
GETtheMANUALS.org
ET–43
scratch the body of the vehicle body and make it

difficult to attach the moulding.
installed.
(3) Clean the application surface with a solvent.
(b) CLEAN APPLICATION SURFACE (PROCEDURE FOR USING
TAPE REMOVAL DISK)
(1) Set the 8 discs in the holder, and install the removal disk
to an air drill or an electric drill.
NOTICE:
Use an electric drill with a no-load speed of 2000 to
3000 r/min.
(2) Scrape off the blackout tape No. 3 LH or the adhesive
remaining on the body using remover disc.
NOTICE:
• Use safety glasses while removing the blackout
tape.
• Be careful about the direction of the disc's rotation
and the operating direction.
• In order to avoid damaging the body of the vehi-
cle, visually check to make sure that too much
material is not shaved away.
installed.
(c) Apply the new blackout tape No 3 LH in the position shown in
the illustration.
ET
A
A-A C-C
A
R Stop
R Stop
B B Unnecessary Portion
B-B
4 mm
C
4±1 mm
B140145J01

RH (See page ET-52)
4. INSTALL REAR DOOR GLASS RH (See page ED-40)
5. INSTALL REAR DOOR GLASS RUN RH (See page ED-41)
GETtheMANUALS.org
6. INSTALL REAR DOOR SERVICE HOLE COVER RH (See page ED-

41)
7. INSTALL DOOR TRIM BRACKET NO. 1 (See page ED-41)
8. INSTALL SPEAKER ASSEMBLY RR (See page AV-33)
9. INSTALL REAR DOOR INSIDE HANDLE RH (See page ED-41)
10. INSTALL FRONT DOOR TRIM BOARD RH (See page ED-43)
12. INSTALL FRONT DOOR ASSIST GRIP COVER RH (See page ED-
43)
13. INSTALL REAR DOOR REAR GUIDE BRACKET GARNISH RH

(See page ED-43)
14. INSTALL REAR DOOR DIVISION BAR INSIDE SEAL RH (See

page ED-44)
ET
GETtheMANUALS.org
BODY EXTERIOR - ROOF RACK ASSEMBLY LH
ET–45

BODY AND
EXTERIOR
ELECTRICAL
COMPONENTS
ROOF RACK LEG COVER RR LH

ROOF RACK LEG COVER FR LH

T=31{316}
x2
T=31{316}
x2
ROOF RACK END COVER NO. 2
ROOF RACK LEG COVER CTR LH

ROOF RACK LEG CUSHION RR LH
ROOF RACK LEG CUSHION FR LH
ET

B137894J01
GETtheMANUALS.org
ET–46 BODY EXTERIOR - ROOF RACK ASSEMBLY LH
REMOVAL
1. REMOVE ROOF RACK LEG COVER FR LH
(b) Using a clip remover, detach the claw, and remove the roof rack
leg cover FR LH.
Protective Tape
Claw
B137895J01
2. REMOVE ROOF RACK LEG COVER RR LH

(b) Using a clip remover, detach the claw, and remove the roof rack
leg cover RR LH.
Protective Tape
Claw
B137896J01
3. REMOVE ROOF RACK ASSEMBLY LH

(a) Remove the 4 bolts and the roof rack assembly LH.
ET
B137897
4. REMOVE ROOF RACK LEG COVER CTR LH

(a) Detach the 3 claws and remove the roof rack leg cover CTR LH.
Claw
B137898J01
GETtheMANUALS.org
BODY EXTERIOR - ROOF RACK ASSEMBLY LH
ET–47
5. REMOVE ROOF RACK END COVER NO. 2

(a) Detach the 3 claws and remove the roof rack end cover No. 2.
6. REMOVE ROOF RACK LEG CUSHION FR LH
7. REMOVE ROOF RACK LEG CUSHION RR LH
INSTALLATION
1. INSTALL ROOF RACK LEG CUSHION RR LH
Claw
B137898J01 2. INSTALL ROOF RACK LEG CUSHION FR LH
3. INSTALL ROOF RACK END COVER NO. 2

(a) Attach the 3 claws and install the roof rack end cover No. 2.
Claw
B137898J01
4. INSTALL ROOF RACK LEG COVER CTR LH

(a) Attach the 3 claws and install the roof rack leg cover CTR LH.
Claw
B137898J01
ET
5. INSTALL ROOF RACK ASSEMBLY LH
(a) Install the roof rack assembly LH with the 4 bolts.
B137897
6. INSTALL ROOF RACK LEG COVER RR LH

(a) Attach the claw and install the roof rack leg cover RR LH.
Claw
B143906J01
GETtheMANUALS.org
ET–48 BODY EXTERIOR - ROOF RACK ASSEMBLY LH
7. INSTALL ROOF RACK LEG COVER FR LH

(a) Attach the claw and install the roof rack leg cover FR LH.
Claw
B143907J01
ET
GETtheMANUALS.org
BODY EXTERIOR - FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY OUT LH
ET–49
FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY OUT LH

BODY AND
EXTERIOR
ELECTRICAL
COMPONENTS
OUTER REAR VIEW MIRROR

ASSEMBLY LH

ASSEMBLY OUT LH
T=4.4{45}

BRACKET GARNISH LH
FRONT DOOR TRIM BOARD LH

ET
×2
FRONT DOOR ASSIST GRIP COVER LH

B141144J01
GETtheMANUALS.org
ET–50 BODY EXTERIOR - FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY OUT LH
REMOVAL
RH(See page MI-5)

11)
4. REMOVE FRONT DOOR TRIM BOARD RH (See page ED-11)
5. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY RH (See

page MI-5)
OUT LH
(a) Using a clip remover from inside of the vehicle, detach the 7
claws and remove the front door glass weatherstrip assembly
OUT LH.
INSTALLATION
Claw
B142299J01

OUT LH
Standard Position (a) Install the front door glass weatherstrip assembly OUT LH
adjusting to the standard position of the front door panel.
(b) Attach the 7 claws and install the front door glass weatherstrip
assembly OUT LH.
2. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH (See page

MI-6)
ET Claw
B142299J02 3. INSTALL FRONT DOOR TRIM BOARD LH (See page ED-25)
5. INSTALL FRONT DOOR ASSIST GRIP COVER LH (See page ED-

26)
6. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH

(See page MI-6)
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BODY EXTERIOR - REAR DOOR GLASS WEATHERSTRIP ASSEMBLY OUT LH
ET–51
REAR DOOR GLASS WEATHERSTRIP ASSEMBLY OUT LH

BODY AND
EXTERIOR
ELECTRICAL
COMPONENTS
REAR DOOR REAR GUIDE

BRACKET GARNISH LH

ET
ASSEMBLY OUT LH
B141145J06
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ET–52 BODY EXTERIOR - REAR DOOR GLASS WEATHERSTRIP ASSEMBLY OUT LH
REMOVAL
1. REMOVE REAR DOOR REAR GUIDE BRACKET GARNISH LH
(See page ED-30)
OUT LH
(a) Using a clip remover from inside of the vehicle, detach the 6
claws and remove the front door glass weatherstrip assembly
OUT LH.
INSTALLATION
Claw
B142300J01

Standard Position LH
(a) Install the front door glass weatherstrip assembly OUT LH
adjusting to the standard position of the front door panel.
(b) Attach the 7 claws and install the front door glass weatherstrip
assembly OUT LH.
2. INSTALL REAR DOOR REAR GUIDE BRACKET GARNISH LH

(See page ED-43)
Claw
B142300J02
ET
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TO INDEX
BODY AND ELECTRICAL
BODY INTERIOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR-4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR-9
IR
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IR–1 BODY INTERIOR - ROOF HEADLINING ASSEMBLY

BODY AND
INTERIOR
ELECTRICAL
COMPONENTS
CLIP
CLIP CLIP
CLIP
CLIP

IR
FRONT DOOR OPENING

GETtheMANUALS.org
BODY INTERIOR - ROOF HEADLINING ASSEMBLY
IR–2
REAR DOOR OPENING ROOF SIDE INNER

TRIM WEATHERSTRIP RH ROOF SIDE INNER GARNISH RH GARNISH RH
DECK FLOOR BOX RH
CENTER PILLAR
GARNISH UPR RH

ASSEMBLY RH

CENTER PILLAR GARNISH LWR LH
FRONT DOOR
SCUFF PLATE RH

IR
DECK FLOOR BOX LH
CENTER PILLAR
GARNISH UPR LH
REAR DOOR OPENING

TRIM WEATHERSTRIP LH


B137694J01
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ROOF SILENCER PAD NO.2
ASSIST GRIP
ROOF SILENCER PAD NO.1
SEAT BELT RETRACTOR COVER
ASSIST GRIP
ASSIST GRIP
VISOR ASSEMBLY RH ROOM LIGHT ASSEMBLY NO. 2
VISOR HOLDER ROOM LIGHT ASSEMBLY NO. 1
IR
MAP LIGHT ASSEMBLY VISOR ASSEMBLY LH
VISOR HOLDER
MAP LIGHT EQUIPPED
VEHICLES
DECK BOARD ASSEMBLY
B148367J01
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IR–4
REMOVAL
(See Page RS-165)
2. REMOVE FRONT DOOR SCUFF PLATE RH(See page IP - 12)
4. REMOVE DECK BOARD ASSEMBLY

(b) Remove the 7 clips and the deck board assembly.
Clip B137763J01
5. REMOVE DECK FLOOR BOX RH

(b) Disengage the 4 claws and the clip, and remove the deck floor
box RH.
Clip IR
Claw B137764J01
7. REMOVE REAR DOOR SCUFF PLATE RH

(a) Disengage the 7 claws and remove the rear door scuff plate
RH.
Claw B137765J01
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10. REMOVE REAR FLOOR MAT SUPPORT PLATE RR

(a) Disengage the 4 clips and remove the rear floor mat support
plate RR.
Clip B137766J01
13. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH

(a) Remove the rear seat belt bolts and the 3 clips installed in the
floor.
(b) Disengage the 5 clips and 4 claws, and remove the deck trim
side panel assembly.
Clip
Claw B137767J01
14. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH

(a) Remove the rear seat belt bolts and the 3 clips installed in the
floor.
(b) Disengage the 5 clips and 4 claws, and remove the deck trim
side panel assembly.
(c) Disconnect the connector of the accessory socket and the deck
IR light on the underside of the deck trim side panel assembly,
17. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH
18. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH

SHIELD AIRBAG) (See page IP - 12)
Clip Claw B137768J01

SHIELD AIRBAG)

AIRBAG) (See page IP - 13)

AIRBAG)
23. REMOVE SHOULDER BELT ANCHOR COVER (ADJUSTABLE

ANCHOR VEHICLES) (See page SB-9)
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IR–6
24. SEPARATE FRONT SEAT OUTER BELT ASSEMBLY RH (See

page SB-9)
25. REMOVE CENTER PILLAR GARNISH UPR RH
(a) Disengage the 2 clips and remove the center pillar garnish UPR
RH.
26. REMOVE SHOULDER BELT ANCHOR COVER (ADJUSTABLE

ANCHOR VEHICLES)
27. SEPARATE FRONT SEAT OUTER BELT ASSEMBLY LH
28. REMOVE CENTER PILLAR GARNISH UPR LH
B137776

SHIELD AIRBAG)
(a) Disengage the 9 clips and remove the roof side inner garnish
RH.
(b) Remove the roof side inner garnish RH by passing the anchor
of the rear seat outer belt assembly RH through the garnish.

SHIELD AIRBAG)
Clip B137769J01

SHIELD AIRBAG)
(a) Disengage the 9 clips and remove the roof side inner garnish
RH.
Roof Side Rail Bracket NO. 2
NOTICE:
Make sure that the garnish does not get caught on the claw
to the roof side rail bracket No. 2.
(b) Remove the roof side inner garnish RH by passing the anchor
of the rear seat outer belt assembly RH through the garnish.
32. REMOVE ROOF SIDE INNER GARNISH LH (WITH CURTAIN IR

SHIELD AIRBAG)
Clip
B142304J01
33. REMOVE MAP LIGHT ASSEMBLY (WITH MAP LIGHT)

(a) Using a clip remover wrapped in protective tape, disengage the
4 clips and remove the map light assembly.
Clip B137772J01
GETtheMANUALS.org
34. REMOVE ROOM LIGHT ASSEMBLY NO. 1 (WITHOUT MAP

LIGHT)
(a) Using a clip remover wrapped in protective tape, remove the
room light lens.
(b) Remove the 2 screws and the room light assembly No. 1.
B137773
35. REMOVE ROOM LIGHT ASSEMBLY NO. 2

room light lens.
Claw B137770J01
(b) Remove the 2 screws and the room light assembly No. 2.
B137771
36. REMOVE THE ASSIST GRIP

IR (a) Using a screwdriver wrapped in protective tape, disengage the
Claws 2 claws and turn over the 2 assist grip covers.
(b) Remove the 2 screws and the assist grip.
HINT:
Remove the other two assist grips in the same manner.
B050112J02
37. REMOVE VISOR ASSEMBLY RH

(a) Remove the 2 screws and the visor assembly RH.
B137774
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IR–8
39. REMOVE VISOR HOLDER

visor holder.
HINT:
Use the same procedure to remove the LH side.
40. REMOVE SEAT BELT RETRACTOR COVER (REAR CENTER

THIRD POINT SEAT BELT)

B137775 (a) Detach the 5 clips.
Clip B140006J01
(b) Take the removed roof headlining assembly out from the back
door.
NOTICE:
Do not damage the roof headlining assembly or the body
interior.
HINT:
Remove the roof headlining with the roof wire harness attached.
42. REMOVE SEAT BELT RETRACTOR COVER IR
(a) Disengage the clip and 5 claws, and remove the seat belt
retractor cover.
43. REMOVE ROOF SILENCER PAD NO. 1

HINT:
Removal of the roof silencer pad is performed when replacing the
room headlining assembly.
B141379
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(a) Remove the roof silencer pad from the position shown in the
illustration.
Roof Silencer Pad NO. 1 Roof Silencer Pad NO. 2
5 40 7 20 5
Units [mm]
B140007J01
44. REMOVE ROOF SILENCER PAD NO. 2
45. REMOVE ROOF WIRE NO. 1

HINT:
Removal of the roof wire No. 1 is performed when replacing the room
headlining assembly.
(a) Remove the double-sided tape and then remove the roof wire
No. 1.
INSTALLATION
1. INSTALL ROOF WIRE NO. 1
2. INSTALL ROOF SILENCER PAD NO. 1

(a) Using double-sided tape, install the roof silencer pad No. 1 as
IR
Roof Silencer Pad NO. 1 Roof Silencer Pad NO. 2
5 40 7 20 5
Units [mm]
B140007J01
3. INSTALL ROOF SILENCER PAD NO. 2

(a) Using double-sided tape, install the roof silencer pad No. 2 as
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IR–10
5. INSTALL VISOR HOLDER

(a) Install the 2 visor holders.
6. INSTALL VISOR ASSEMBLY RH
(a) Install the visor assembly RH with the 2 screws.
8. INSTALL ASSIST GRIP

(a) Install the 3 assist grips with the 2 bolts.
B137774
9. INSTALL ROOM LIGHT ASSEMBLY NO. 2

(a) Install the room light assembly with the 2 screws.
(b) Install the room light lens.
B137771
10. INSTALL MAP LIGHT ASSEMBLY (WITH MAP LIGHT)

IR
B137773
(b) Engage the 4 clips and install the map light assembly.
11. INSTALL ROOM LIGHT ASSEMBLY NO. 1 (WITHOUT MAP

LIGHT)
(b) Install the room light assembly No. 1 with the 2 screws.
(c) Attach the 4 claws to install the lens.

SHIELD AIRBAG) (See page IP - 16)
Clip B137772J01
SHIELD AIRBAG)

AIRBAG) (See page IP - 16)

AIRBAG)
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16. INSTALL CENTER PILLAR GARNISH UPR RH

(a) Pass the anchor to the front seat outer belt assembly RH
through the garnish.
(b) Engage the 2 clips and install the center pillar garnish UPR RH.
17. INSTALL FRONT SEAT OUTER BELT ASSEMBLY RH (See page

SB-13)
18. INSTALL SHOULDER BELT ANCHOR COVER (ADJUSTABLE

ANCHOR VEHICLES)
19. INSTALL CENTER PILLAR GARNISH UPR LH
20. INSTALL FRONT SEAT OUTER BELT ASSEMBLY LH

B137776 21. INSTALL SHOULDER BELT ANCHOR COVER (ADJUSTABLE
ANCHOR VEHICLES)
22. INSTALL ROOF SIDE INNER GARNISH RH (WITHOUT CURTAIN
SHIELD AIRBAG)
(a) Pass the rear seat belt, engage the 9 clips, and install the roof
side inner garnish RH.
23. INSTALL ROOF SIDE INNER GARNISH LH (WITHOUT CURTAIN

SHIELD AIRBAG)

Clip B137769J01
25. INSTALL ROOF SIDE INNER GARNISH LH (WITH CURTAIN
SHIELD AIRBAG)

(See page IP - 17)

28. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH
(a) Install the weatherstrip terminal by aligning it with the protruding
part of the body.
IR 29. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH
Protruding Portion
B141390J01
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IR–12
32. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH

(a) Engage the 4 claws and the 5 clips and install the deck trim side
panel assembly RH.
(b) Install the 3 clips into the floor.
(c) Install the rear seat belt with the bolt.
Clip
Claw B137767J01
33. INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH

(a) Connect the deck light and the connector to the accessory
socket.
(b) Engage the 4 claws and the 5 clips and install the deck trim side
panel assembly LH.
(c) Install the 3 clips into the floor.
(d) Install the rear seat belt with the bolt.
34. INSTALL FRONT DOOR SCUFF PLATE RH
Clip Claw B137768J01
36. INSTALL REAR DOOR SCUFF PLATE RH

(a) Engage the 7 claws and install the rear door scuff plate RH. IR
Claw B137765J01
38. INSTALL DECK FLOOR BOX RH

(a) Engage the 4 claws and the clip and install the deck floor box
RH.
(b) Install the screw.
Clip
Claw B137764J01
GETtheMANUALS.org
40. INSTALL REAR FLOOR MAT SUPPORT PLATE RR

(a) Engage the 4 clips and install the rear floor mat support plate
RR.
Clip B137766J01
41. INSTALL DECK BOARD ASSEMBLY

(a) Install the deck board assembly with the 7 clips.
(b) Install the rear seat cover with the 4 clips.
Clip B137763J01
IR
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TO INDEX
CONTROL SYSTEM
BODY MULTIPLEX COMMUNICATION SYSTEM [LIN]

MULTIPLEX BODY COMMUNICATION SYSTEM (LIN)
HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . MP-1
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MP-2
DIAGNOSTIC TROUBLE CODE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . MP-2
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MP-3
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MP-3
CHECK / CLEAR DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MP-3
CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MP-5
ECU TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MP-5
11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MP-8
21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MP-12
MP
GETtheMANUALS.org
MP–1 BODY MULTIPLEX COMMUNICATION SYSTEM [LIN] - MULTIPLEX BODY COMMUNICATION SYSTEM (LIN)
MULTIPLEX BODY COMMUNICATION SYSTEM (LIN)

CONTROL
BODY MULTIPLEX
SYSTEMCOMMUNICATION SYSTEM [LIN]
HOW TO PROCEED WITH

TROUBLESHOOTING
2 CHECK SYMPTOMS
3 CHECK FOR DTCs
(a) Check for DTCs and note any codes that are output. (See page MP-
2.)
(b) Clear the DTCs.
(c) Reproduce the symptoms based on the recorded code, and check if
the same DTC is output.
(1) If the code does not reoccur, go to A.
(2) If the code reoccurs, go to B.
4 PROBLEM SYMPTOMS TABLE (SEE PAGE MP-3)
(a) For unrelated problem systems, go to A.

MP (b) For related problem systems, go to B.
(a) ECU terminals (See page MP-5.)
GETtheMANUALS.org
BODY MULTIPLEX COMMUNICATION SYSTEM [LIN] - MULTIPLEX BODY COMMUNICATION SYSTEM (LIN)
MP–2
END
LOCATION
Fuse Block Assembly

Door Control Relay Assembly
MP
I102694J01
DTC No. Diagnostic Item HINT See Page

ITC COMMUNICATION
11 MALFUNCTION (EXCLUDING MP-8
malfunction
SHORT)
GETtheMANUALS.org
DTC No. Diagnostic Item HINT See Page

SHORT TO COMMUNICATION
Combination meter assembly
LINE / SHORT TO
21 malfunction MP-12
COMMUNICATION CIRCUIT
INSIDE ECU

Door control relay assembly MP-8
Door control relay assembly communication
Fuse block assembly -
malfunction
Wire harness -
Combination meter assembly MP-12
Short to communication line short / Short to
Fuse block assembly -
communication circuit inside ECU
Wire harness -
DESCRIPTION
1. MULTIPLEX BODY COMMUNICATION SYSTEM (LIN)
DESCRIPTION
(a) The LIN communication line is used to control the computer
connected to the combination meter assembly. When the
communication line is unable to communicate for any reason,
the system DTC is output on the LCD (Liquid Crystal Display) in
the combination meter assembly.
CHECK / CLEAR DTCs

NOTICE:
The communication malfunction system for DTCs is displayed as
long as the communication malfunction continues. When
communication returns to normal, the communication malfunction
system is cleared. When the negative battery terminal is
disconnected during a communication malfunction, the DTCs for the
MP communication malfunction, excluding shorts, are not output again.

Therefore, it is important to record the DTCs before disconnecting the
negative battery terminal.
1. DTC CHECK (read from meter LCD display)
(a) With the ignition switch off, short the circuit between terminals
13 (ECUT) and 4 (E) of the DLC using a diagnosis check wire.
SST 09843-18043
NOTICE:
• Do not confuse the connection location of the
connector. If the connection location is wrong, it may
cause a failure.
• Use only dedicated diagnosis check wire.
(b) Turn the ignition switch to the ON position and read the DTCs
displayed on the LCD in the meter.
NOTICE:
• If the battery power supply is restored when the ECU is
in a malfunctioning communication state, or if the
battery power source is restored when the door control
GETtheMANUALS.org
MP–4
relay assembly is disconnected, the failure code will not

be displayed. The normal code, 00 00, will be displayed.
HINT:
• In addition to DTCs related to the LIN communication
system, meter and CAN communication system DTCs are
also displayed on the LCD in the meter.
• When the ignition switch is turned to the ON position, DOOR
XX (XX is a number) is displayed on the LCD in the meter
for 2 seconds. The DTCs for each system are displayed for
a 2 second interval.
• Multiple codes are output from lowest to highest code
number. Moreover, if the codes cycle, they will be output
again in intervals of 4 seconds.
• The display pattern is as follows:
Formation
DTC Output Condition
LIN Communication LIN Communication
No Formation Abnormal Code “11” Abnormal Code “12”
2 Sec. 2 Sec.
Display Display Display Display

doorXX 00 11 00 12 doorXX
LCD In Meter
2 Sec. 4 Sec. 4 Seconds
0.5 Sec. Time Turned Off (Repeated)
Time Between Node ID Turning Off

Time Turned Off Between Codes
Code Output Pattern By OD/Trip

I102696
2. CLEAR RECORDED DTCs

(a) The 2 procedures for clearing DTCs are as follows:
(1) The communication malfunction is resolved. The codes are
automatically cleared after system status returns to normal.
(2) Turn the ignition switch off and disconnect the negative
battery terminal. MP
NOTICE:
While repairing communication malfunctions other
than shorts, do not conduct the repair without
disconnecting the negative battery terminal. Do not
disconnect the negative battery terminal until
completing inspection of the connector's connection
status. (Object code No. 00 11)
GETtheMANUALS.org
CIRCUIT DIAGRAM
Fuse Block Assembly
Door Control Relay

Assembly
7 F17 H6
LIN MPX
F16
Combination Meter Assembly 37
LIN
MP
:LIN
I102681J02
ECU TERMINALS
1. Fuse block assembly (door control relay assembly)
(a) Check that the following fuses are normal: ACC 7.5A, IG1
BACK 7.5A, D/LOCK 15A, ECU IG2 7.5A.
GETtheMANUALS.org
MP–6
(b) Check the fuse block assembly (door control relay assembly).
GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
CRL
HZD
MPX
IG1
UKS
H ECUB
LKS
IND
HORN
ULM
LKM
BDR1
C
D E
25
A F
10 9
24 23 22 21 20 19
12 11 10 9 8 7
4
6
2
2
18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
3
5
8
1
7
B 3
1
6
2
5
1
10 9
4
18 17 16 15 14 13
6
G
3
5
8
4
22 21 20 19 18 17 16 30 29 28 27 26 25 24 23
3
7 6 5 4 3 2 1 15 14 13 12 11 10 9 8
2
6
2
1
5
1
4 3 2 1 2 1
2 1 10 9 8 7 6 5 6 5 4 3
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10

MP
12 11 10 9 8 7 6 5 4 3 2 1 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
25
24 23 22 21 20 19 18 17 16 15 14 13 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Connector H
B137035
(1) Disconnect fuse block assembly connectors C, D, F, G
GETtheMANUALS.org
(2) Using the tester, check the voltage and continuity between
each terminal of the vehicle side wire harness connector.
Standard

G29 (GND) ←→ Body ground Continuity Always Continuity
C10 (ECUB) ←→ G29 (GND) Voltage Always 10 to 14 V
D4 (IG1) ←→ G29 (GND) Voltage IG OFF → IG ON 0 V → 10 to 14 V
F17 (LIN) ←→ G29 (GND) Continuity Always No continuity
F16 (LIN) ←→ G29 (GND) Continuity Always No continuity
HINT:
vehicle side.
2. Combination meter assembly
(a) Inspect the combination meter assembly.
(1) Disconnect the connectors of the combination meter
assembly.
(2) Using the tester, check the voltage and continuity between
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 each terminal of the vehicle side wire harness connector.
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
B141852
Standard

12 (IG+) ←→ 15 (GND) Voltage IG OFF → IG ON 0 V → 10 to 14 V
37 (LIN) ←→ 15 (GND) Continuity Always No continuity
HINT:
vehicle side.
MP
GETtheMANUALS.org
MP–8
ITC COMMUNICATION MALFUNCTION

DTC 11
(EXCLUDING SHORT)
DESCRIPTION
• The door control relay assembly communicates with the combination meter assembly via LIN.
• 0011 is output when a malfunction occurs in communication between the door control relay assembly and the combination
meter assembly.
DTC No. DTC Detection Condition Suspected Area

• Communication malfunction between the door control
• Door control relay assembly
relay assembly and the combination meter assembly
0011 • Combination meter assembly
and communication wire malfunction (door control
• Wire harness
relay assembly malfunction)
CIRCUIT DIAGRAM
Fuse Block Assembly
D4 IG1/BACK 12
IG1
A2 D/LOCK 2
Door Control
BDR1
Relay Assembly
IG SW
ACC
AM1 E9 10 E1 MPX
ECUB
IG1
IG2 18 6
F/L AM2
ST
D3 ECU IG2
IG1
C10 G12 G3 G4 G29 F16

LIN Communication Line
12 37
BACK UP 13
+B IG+ LIN MP
Combination Meter
GND ECU-T Courtesy
15 10 9
Courtesy SW
DLC
FR Left RR Left
FR Right RR Right BACK
I102695
GETtheMANUALS.org
1 CHECK FOR DTCs
SST 09843-18020
(a) Using a diagnosis check wire, short the circuit between terminals 13
ECUT (ECUT) and 4 (E) of the DLC.
(b) With the negative battery terminal connected, move the connectors
for the door control relay assembly, the combination meter assembly
and the fuse block assembly up and down and back and forth. Check
if a DTC was output.
Result Proceed to
0011 is output A
E 0011 is not output B
B141833
2 INSPECT WIRE HARNESS (BETWEEN FUSE BLOCK ASSEMBLY AND COMBINATION METER
ASSEMBLY)
(a) Disconnect fuse block assembly connector F and combination meter

assembly connector F.
(b) Using the tester, inspect the continuity between each terminal of the
vehicle side wire harness connector between the fuse block
assembly and the combination meter assembly.
Standard:

Terminal No.
(Fuse block assembly ←→ Standard
Combination meter assembly)
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 F16 (ITC-) ←→ 37 (LIN) Continuity
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
MP NG REPAIR OR REPLACE WIRE HARNESS OR

CONNECTOR
Fuse Block Assembly
Connector F
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
I102691
OK
(a) Remove door control assembly connector F and fuse block assembly
connector F from the fuse block assembly.
GETtheMANUALS.org
MP–10
fuse block assembly.
Standard:

Connector F (Fuse Block Assembly Connector F ←→ Fuse Standard
Block Assembly Connector H)
F16 (ITC-) ←→ H6 (MPX) Continuity
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
Fuse Block Assembly

Connector H
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
I102689
OK
4 INSPECT DOOR CONTROL RELAY ASSEMBLY (POWER SYSTEM, GROUND SYSTEM)
(a) Using the tester, inspect the voltage between each terminal of fuse
block assembly connector H.
Fuse Block Assembly Standard:
Connector H
Terminal No.
(Fuse Block Assembly Measurement Condition Standard
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Connector H)
H18 (E1) ←→ Body
Always Continuity
ground
I102690 H2 (BDR1) ←→ H18 (E1) Always 10 to 14 V MP
Ignition switch OFF → Below 1 V → 10 V to 14
H12 (IG1) ←→ H18 (E1)
ON V
H10 (ECUB) ←→ H18
Always 10 to 14 V
(E1)

CONNECTION (ALSO REPLACE FUSE
BLOCK ASSEMBLY IF PROBLEM IS NOT
SOLVED)
OK
5 INSPECT COMBINATION METER ASSEMBLY (POWER SYSTEM, GROUND SYSTEM)
(a) Disconnect the connectors of the combination meter assembly.
GETtheMANUALS.org
(b) Using the tester, inspect the voltage between each terminal of the
vehicle wire harness side connectors.
Standard:
Terminal No.
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
(Combination Meter Measurement Condition Standard
Assembly)
Always Continuity
ground
B141852 13 (+B) ←→ 15 (GND) Always 10 to 14 V
Ignition switch OFF →
12 (IG+) ←→ 15 (GND) Below 1 V → 10 V to 14 V
ON

CONNECTOR
OK
REPLACE DOOR CONTROL RELAY ASSEMBLY (ALSO REPLACE FUSE BLOCK

ASSEMBLY IF PROBLEM IS NOT SOLVED)
MP
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MP–12
SHORT TO COMMUNICATION LINE / SHORT TO

DTC 21
COMMUNICATION CIRCUIT INSIDE ECU
DESCRIPTION
• The combination meter assembly communicates with the door control relay assembly via LIN communication.
• 0021 is output when the communication line and power source are shorted in the circuits or wire harnesses of the combination
meter assembly or the door control relay assembly.
DTC No. DTC Detection Condition Suspected Area

• When the communication line and power source are
shorted in the circuits of the combination meter • Door control relay assembly
0021 assembly and the door control relay assembly and • Wire harness
when the communication wire and power source are • Combination meter assembly
shorted in the wire harness.
CIRCUIT DIAGRAM
Fuse Block Assembly
D4 IG1/BACK 12
IG1
A2 D/LOCK 2
Door Control
BDR1
Relay Assembly
IG SW
ACC
AM1 E9 10 E1 MPX
ECUB
IG1
IG2 18 6
F/L AM2
ST
D3 ECU IG2
IG1
C10 G12 G3 G4 G29 F16

LIN Communication Line
BACK UP 13
12 37 MP
+B IG+ LIN
Combination Meter
GND ECU-T Courtesy
15 10 9
Courtesy SW
DLC
FR Left RR Left
FR Right RR Right BACK
I102695
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1 CHECK FOR DTCs (WHEN REMOVING DOOR CONTROL RELAY ASSEMBLY)
SST 09843-18020
(b) Remove the door control relay assembly from the fuse block
assembly.
(c) Connect the negative battery terminal.
(d) Using the diagnosis check wire, short the circuit between terminals 13
ECUT (ECUT) and 4 (E) of the DLC.
(e) Turn the ignition switch to the ON position, then check for DTCs.
Result Proceed to
0021 is not output A
0021 is output B
B Go to step 3
E
B141833
2 INSPECT DOOR CONTROL RELAY ASSEMBLY (POWER SYSTEM, GROUND SYSTEM)
SST 09843-18020
(a) Using the tester, inspect the voltage between each terminal of fuse
block assembly connector H.
Fuse Block Assembly
Terminal No. Measurement Condition Standard
Connector H
H18 (E1) ←→ Body
Always Continuity
ground
H12 (IG1) ←→ Body Ignition switch OFF ←→
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Below 1 V → 10 V to 14 V
ground ignition switch ON
H2 (BDR1) ←→ Body
Always 10 to 14 V
MP I102690
ground
H10 (ECUB) ←→ Body
Always 10 to 14 V
ground

(REPAIR OR REPLACE WIRE HARNESS OR
CONNECTOR IF PROBLEM IS NOT SOLVED)
OK
3 INSPECT WIRE HARNESS (FUSE BLOCK ASSEMBLY - COMBINATION METER ASSEMBLY)
(a) Disconnect fuse block assembly connector F and the combination

meter assembly connector.
GETtheMANUALS.org
MP–14
Standard:
Terminal No.
(Fuse block assembly - combination Standard
meter assembly)
F16 (ITC-) ←→ Body ground No continuity
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 37 (LIN) ←→ Body ground No continuity
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21

CONNECTOR
Fuse Block Assembly
Connector F
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
I102691
OK
(a) Remove the door control relay assembly from the fuse block
assembly.
Standard:

Connector F H6 (MPX) ←→ Body ground No continuity
F16 (ITC-) ←→ Body ground No continuity
MP
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
Fuse Block Assembly

Connector H
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
I102689
OK
GETtheMANUALS.org
5 INSPECT COMBINATION METER ASSEMBLY (POWER SYSTEM, GROUND SYSTEM)
(a) Disconnect the connectors of the combination meter assembly.

Standard:
Measurement
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Terminal No. Standard
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
Condition
Always Continuity
ground
1(IG+) ←→ Body Ignition switch OFF
Below 1 V → 10 V to 14 V
B141852 ground ←→ ignition switch ON
13 (+B) ←→ body
Always 10 to 14 V
ground

CONNECTOR
OK
MP
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TO INDEX
CONTROL SYSTEM
CAN COMMUNICATION
CAN COMMUNICATION SYSTEM
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CA-1
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CA-3
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CA-4
SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CA-4
HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . CA-5
DIAGNOSIS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CA-10
CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CA-14
ECU TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CA-15
FAIL-SAFE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CA-20
VSC ECU COMMUNICATION STOP MODE . . . . . . . . . . . . . . . . . . . . . . . CA-22
AT ECU COMMUNICATION STOP MODE . . . . . . . . . . . . . . . . . . . . . . . . . CA-24
STEERING ANGLE SENSOR COMMUNICATION STOP MODE. . . . . . . . CA-26
YAW RATE AND G SENSOR COMMUNICATION STOP MODE . . . . . . . . CA-28
EFI ECU COMMUNICATION STOP MODE . . . . . . . . . . . . . . . . . . . . . . . . CA-30
METER ECU COMMUNICATION STOP MODE . . . . . . . . . . . . . . . . . . . . . CA-32
OPEN IN CAN MAIN BUS LINE (DLC BRANCH LINE/MAIN BUS
LINE/TERMINATING RESISTOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CA-34
SHORT IN CAN BUS LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CA-39
SHORT TO +B IN CAN BUS LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CA-48
SHORT TO GND IN CAN BUS LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CA-57
OPEN IN ONE OF CAN BUS LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CA-66
CA
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CA–1 CAN COMMUNICATION - CAN COMMUNICATION SYSTEM
CAN COMMUNICATION SYSTEM

CONTROL
CAN COMMUNICATION
SYSTEM
PRECAUTIONS
1. HANDLING PRECAUTIONS FOR SRS AIRBAG SYSTEM (See
page RS-164)
NOTICE:
This maintenance operation may affect the SRS air bag. Make
sure to read the precautionary items of the SRS air bag before
starting work.
2. PRECAUTIONS FOR REPAIRING WIRE HARNESS
(a) After repairing the bus line with solder, wrap the repaired part
with tape.
Soldered Portion Wrapped With Tape
NOTICE:
• Be sure to twist the bus line (communication line) when
installing. Do not allow any space between CAN-H and
CAN-L.
• The difference in length of the CAN-L bus line and the
CAN-H bus line should be within 100 mm.
G033631 • Untwisted parts around the connectors should be
within 80 mm.
(b) Do not perform bypass wiring between the connectors.
NOTICE:
If you perform bypass wiring, the characteristics of the
Bypass Connection
twisted wire harness will be lost.
3. PRECAUTIONS FOR MEASURING RESISTANCE OF CAN BUS
(a) After turning the ignition off, check that warning functions, such
as the key reminder, are not operating. Wait one minute after
operating the key and switches or opening and closing the
doors before performing the measurement. If a door is required
G026704 to be opened for inspections of connectors or other items, open
the door before starting the inspections.
HINT:
Operating the key or switches or opening and closing the doors
will cause the ECU to start CAN communication, the resistance
will not be stable.
CA 4. CONTINUITY CHECK METHOD

(a) When inserting tester probes into a connector, insert them from
the back of the connector.
G024985
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CAN COMMUNICATION - CAN COMMUNICATION SYSTEM
CA–2
(b) If the tester probes cannot be inserted from the back of the
Repair Wire connector, use a repair wire.
G024986J04
CA
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LOCATION
STEERING SENSOR ASSEMBLY

YAW RATE SENSOR (CONTAINS G SENSOR)
DLC
CA
COMPUTER ASSEMBLY
BRAKE ACTUATOR ASSEMBLY
ENGINE CONTROL COMPUTER ASSEMBLY
G100997J04
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CA–4

RESULT LIST OF HOW TO PROCEED WITH TROUBLESHOOTING
The result of HOW TO PROCEED WITH
TROUBLESHOOTING indicates that there is an OPEN OPEN IN CAN MAIN BUS LINE (DLC BRANCH LINE / MAIN
CA-34
IN CAN MAIN BUS LINE (DLC BRANCH LINE / MAIN BUS LINE / TERMINATING RESISTOR)
BUS LINE / TERMINATING RESISTOR).
TROUBLESHOOTING indicates that there is a SHORT IN CAN BUS LINES CA-39
SHORT IN CAN BUS LINES.
TROUBLESHOOTING indicates that there is a SHORT TO +B IN CAN BUS LINE CA-48
SHORT TO +B IN CAN BUS LINE.
TROUBLESHOOTING indicates that there is a SHORT TO GND IN CAN BUS LINE CA-57
SHORT TO GND IN CAN BUS LINE.
TROUBLESHOOTING indicates that there is an OPEN OPEN IN ONE OF CAN BUS LINES CA-66
IN ONE OF CAN BUS LINES.
COMMUNICATION STOP MODE LIST

ABS, VSC is not displayed on the CHECK ECU
CONNECTED TO CAN BUS LINE screen of the DS-II VSC ECU COMMUNICATION STOP MODE CA-22
(vehicles with VSC).
STEERING SENSOR is not displayed on the CHECK
STEERING ANGLE SENSOR COMMUNICATION STOP
ECU CONNECTED TO CAN BUS LINE screen of the CA-26
MODE
DS-II (vehicles with VSC).
YAW RATE, G SENSOR is not displayed on the
YAW RATE AND G SENSOR COMMUNICATION STOP
CHECK ECU CONNECTED TO CAN BUS LINE CA-28
MODE
screen of the DS-II (vehicles with VSC).
EFI is not displayed on the CHECK ECU
EFI ECU COMMUNICATION STOP MODE CA-30
CONNECTED TO CAN BUS LINE screen of the DS-II.
AT is not displayed on the CHECK ECU CONNECTED
AT ECU COMMUNICATION STOP MODE CA-24
TO CAN BUS LINE screen of the DS-II.
Meter is not displayed on the CHECK ECU
METER ECU COMMUNICATION STOP MODE CA-32
CONNECTED TO CAN BUS LINE screen of the DS-II.
SYSTEM DESCRIPTION
1. DESCRIPTION
CA
(a) The CAN (Controller Area Network) is a serial data
communication system for real time applications. It is a vehicle
multiplex communication system that has a high communication
speed (500 kbps) and the ability to detect malfunctions.
(b) By pairing the CAN-H and CAN-L bus lines, the CAN performs
communication based on differential voltage.
(c) Vehicles are equipped with many ECUs (sensors). The ECUs
(sensors) operate by sharing information and communicating
with each other.
(d) The CAN has two resistors of 120 which are necessary to
communicate with the main bus line.
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2. DEFINITION OF TERMS
(a) Main bus line
(1) The main bus line is a wire harness between the two
terminus circuits on the bus (communication line). This is
the main bus in the CAN communication system.
(b) Branch line
(1) The sub bus line is a wire harness which diverges from the
main bus line to an ECU or sensor.
(c) Terminus circuit
(1) The terminus circuit, which consists of a resistor and
capacitor, is placed to convert communication current of the
CAN communication into bus voltage. Two terminus circuits
are necessary on the bus.
HOW TO PROCEED WITH

TROUBLESHOOTING
1. TROUBLESHOOTING PRECAUTIONS
(a) CAN communication DTCs are output due to malfunctions in
the ECUs, sensors, and power source of the CAN system.
Therefore, be aware that codes indicating malfunctions in
relevant ECUs, sensors and power source malfunctions can be
output and recorded at the same time.
(b) If a CAN communication DTC is detected or if there is no
response to the DS-II from the ECUs that output DTCs via CAN
communication, check that the DLC branch line and the CAN
main bus line circuits are normal.
HINT:
ECUs that output DTCs via SIL communication can output the
DTCs to the DS-II even if the DLC branch line and CAN bus are
not normal.
(c) By checking the DLC terminals using the tester, malfunctions in
the DLC branch line and the CAN bus main line circuits can be
checked.
NOTICE:
• When checking the DLC connector, do not insert the
test probes directly into the terminals. Use a diagnosis
CA check wire for checking.
• Before measuring the resistance of the CAN bus, turn
the ignition switch off and check that warning
functions, such as the key reminder, are not operating.
Wait one minute after operating the key and switches or
opening and closing the doors before performing
measurement. If a door is required to be opened for
inspections of connectors or other items, open the door
before starting the inspections.
HINT:
Although the DLC is also connected to the CAN communication
line, DTCs indicating a malfunction in the DLC branch cannot
be read using the DS-II.
(d) By checking the CAN BUS CONNECTION ECU using the DS-
II, ECUs (sensors) connected to an opened branch line that is
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CA–6
connected to the CAN bus circuit. (When CAN main bus line
circuit is normal)
HINT:
• When checking ECUs that are connected to the CAN bus
line, ECUs (sensors) ECUs (sensors) connected to an
opened branch line will not respond to the DS-II (not
displayed on the screen).
• When checking ECUs connected to the CAN bus line, if a
CAN communication DTC is output although all ECUs
respond (displayed on the screen), identify the area where
the malfunction occurred using the DTC combination table,
and confirm the malfunction using the reproduction method.
(e) If an open circuit is detected, before disconnecting the relevant
connectors, push the connector case to check for loose
engagement. In addition, check that the connectors are properly
connected.
3 CHECK FOR DTCS (ALL DTCS)
(a) Using the DS-II, perform (CHECK DTC [ALL]).

NOTICE:
• If DTCs indicating ECUs that show a communication stop,
malfunction in the sensor or its power source, it is suspected
that there might not be a malfunction in the communication
line, but the ECUs and sensors might not be able to send
signals. Therefore, troubleshoot the malfunctions in ECUs or
sensors first. CA
• If the connector that includes the CAN communication line is
disconnected when the ignition switch is ON, the ECUs of the
corresponding systems and also ECUs of the relevant
systems record a CAN communication DTC.
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4 CHECK DLC (CANH ←→ CANL)

DLC (b) Using the tester, measure the resistance between terminals 6
CANL (CANH) and 14(CANL) of the DLC.
Standard
Result Proceed to
OK (55 to 65Ω ) A
NG (66Ω or more) B
NG (54Ω or more) C
CANH
G101038J01
B GO TO OPEN IN CAN MAIN BUS LINE (DLC
BRANCH LINE / MAIN BUS LINE /
TERMINATING RESISTOR) (See page CA-34)
C GO TO SHORT IN CAN BUS LINES (See page

CA-39)
5 CHECK DLC (BAT - CANH, CANL)
(a) Using the tester, measure the resistance between the DLC connector
DLC terminals.
BAT CANL Standard

6 (CANH) ←→ 16 (IG) IG OFF 6 kΩ or more
14 (CANL) ←→ 16 (IG) IG OFF 6 kΩ or more
NG GO TO SHORT TO +B IN CAN BUS LINE (See

CANH
G101038J02
page CA-48)
OK
CA
6 CHECK DLC (E ←→ CANH, CANL)
(a) Using the tester, measure the resistance between the DLC connector
DLC terminals.
CANL Standard

6 (CANH) ←→ 4 (E) IG OFF 200Ω or more
14 (CANL) ←→ 4 (E) IG OFF 200Ω or more
NG GO TO SHORT TO GND IN CAN BUS LINE

CANH E
G101038J03
(See page CA-57)
OK
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CA–8
7 CHECK FOR INSTALLED SYSTEMS (ECUs AND SENSORS) THAT ADOPT CAN COMMUNICATION
(a) Check for the installed systems that adopt CAN communication
based on the specification of the vehicle and equipped parts. (See
page CA-10.)
8 PERFORM INSPECTION USING DS-II (CHECK ECUs CONNECTED TO CAN BUS LINE)
(a) On the DS-II screen, select the following items: CAN BUS
DIAGNOSIS / CHECK ECU CONNECTED TO CAN BUS LINE. (See
page CA-10.)
(b) Check the screen display for approximately one minute and check the
ECUs displayed on the screen.
Result
DS-II Screen Display Proceed to

All ECUs and sensors that are connected to CAN communication will be displayed on the screen. A
Some of the ECUs and sensors that are connected to CAN communication will not be displayed on the screen. B
Some of the ECUs and sensors that are connected to CAN communication will not be displayed on the screen,
C
and some that are displayed or not displayed repeatedly when checking the screen.
NOTICE:
ECUs or sensors that are not equipped are not displayed. Do not
mistake them for being in the communication stop mode.
HINT:
During checking, the connection of ECU that are displayed or not
displayed repeatedly should be considered as normal. (Signals from
other ECUs that are connected to the branch line that has an open in
one side become noise and affect the display and communication
with the DS-II.)
B GO TO COMMUNICATION STOP MODE LIST

(See page CA-4)
C GO TO OPEN IN ONE OF CAN BUS LINES

(See page CA-66) CA
A
9 CHECK COMMUNICATION ERROR DTC
(a) On the DS-II screen, select the following items: CAN BUS
DIAGNOSIS / CHECK COMMUNICATION ERROR DTC. (See page
CA-10.)
(b) Record all DTCs of the previous diagnosis items.
HINT:
• If a communication error code is stored and all ECUs and sensors
connected to the CAN communication are displayed on the
CHECK ECU CONNECTED TO CAN BUS LINE screen of the
DS-II, there may be previous malfunctions that are not occurring
at the moment.
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• As communication error codes will be detected by each ECU,

identify the malfunctioning area based on the combination of
output DTCs.
10 GO TO DTC COMBINATION TABLE
(a) From the combination of CAN communication system DTCs

combination recorded, select the ECUs and sensors that stopped
communication. (See page CA-10.)
11 SYMPTOM REPRODUCTION TEST

(b) Perform the symptom reproduction for the ECUs, sensors, their
harnesses and connectors selected from the DTC combination table.
(See page IN-33)
13 CONFIRMATION TEST
END
CA
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CA–10
DIAGNOSIS SYSTEM
1. CAN BUS DIAGNOSIS (COMMUNICATION ERROR DTC CHECK)
HINT:
The DS-II can display only DTCs regarding CAN communication by
ECUs.
(a) Select [On-Board Diagnosis] from the TOP menu of the DS-II.
D101275
(b) Select [BUS Check] from the ANALYSIS MENU screen.

(c) Select [Communication Malfunction DTC] from the CAN BUS
Function View System Bar Help
DIAGNOSIS screen.
System Select
The following vehicle profile was found.
(d) The screen will display DTCs regarding CAN communication by
ECUs.
Vehicle Bus 2. CAN BUS DIAGNOSIS (CHECK ECU CONNECTED TO CAN BUS
Information Check
LINE)
EFI HINT:
ABS The DS-II can display the ECUs and sensors connected to CAN
EPS communication normally.
A/B (a) Select [Communication Bus Check ] from the Bus Check
IMB
screen.
(b) The screen will display the ECUs and sensors currently
Data Active connected to CAN communication normally.
DTC List
View Test
Utility
HINT:
G101147
• If ECUs or sensors that are connected are not displayed,
there is a communication stop in the system of the ECUs or
sensors that are not displayed.(See page CA-4)
• If there are no ECUs or sensors that are connected to the
CAN bus,nothing is displayed. CA
(c) Check the screen display for about one minute, and check that
there are no items that are displayed or not displayed
repeatedly.
HINT:
• If there is an open in one side of the branch lines other than
the DLC, outputs from the other side of the communication
line may become noise which may affect communication
(display) of other ECUs and sensors. In this case, the
branch lines of the ECUs and sensors that are displayed
and not displayed repeatedly should be considered as
normal.
• If there are items that are displayed and not displayed
repeatedly, repair the open in one side of the branch line of
the ECUs or sensors that do not respond (not displayed on
the screen).
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3. CHECK FOR INSTALLED SYSTEMS (ECUS AND SENSORS)

THAT ADOPT CAN COMMUNICATION
(a) ECUs or sensors that are connected to the CAN bus circuit
(1) Brake actuator assembly (VSC ECU)
(2) STEERING SENSOR (STEERING ANGLE SENSOR)
(3) YAW RATE SENSOR (YAW AND G SENSOR)
(4) ENGINE CONTROL COMPUTER (EFI ECU)
(5) Transmission control computer assembly (AT ECU)
(6) COMBINATION METER ASSEMBLY (METER ECU)
(b) As the CAN communication system (ECUs or sensors) differs
depending on model and option settings, check which systems
(ECUs or sensors) are installed on the vehicle.
(1) DS-II display and how to check for ECUs and sensors that
are connected to CAN communication
DS-II (CHECK ECU CONNECTED TO CAN

ECU / Sensor Name How to check for ECUs and sensors
BUS LINE) Display
Installed on the vehicle equipped with VSC
Brake actuator assembly (VSC ECU) VSC / DVS / ABS (when the ignition is ON, the VSC warning
light in the combination meter will come on)
Steering sensor (steering angle sensor)*1 Steering angle sensor (when the ignition is ON, the VSC warning
Yaw rate sensor (yaw and G sensor)*2 Yaw / G sensor (when the ignition is ON, the VSC warning
ENGINE CONTROL COMPUTER (EFI ECU) EFI Installed on all vehicles
Transmission control computer assembly (AT
AT Installed on vehicles with A/T
ECU)
COMBINATION METER ASSEMBLY (METER
Meter Installed on all vehicles
ECU)
HINT:
• *1: If the vehicle is not equipped with VSC, the steering
sensor will not be equipped.
• *2: If the vehicle is not equipped with VSC, the yaw rate
sensor will not be equipped.
4. DIAGNOSTIC TROUBLE CODE CHART BY ECU
HINT:
• In CAN communication, DS-II can display the CAN
CA communication system DTCs by ECU.
• If a CAN communication system DTC is output, perform
troubleshooting according to HOW TO PROCEED WITH
TROUBLESHOOTING (see page CA-5) because problems that
are occurring cannot be identified by checking only the DTC.
(a) Engine control computer (EFI ECU)/EFI (DS-II display name)
DTC No. Diagnosis Item (DS-II Display Name)

U0101 EAT communication (receiving)
U0121 ABS communication (receiving)
U0156 Meter communication (receiving)
U1000 EAT communication (sending)
U1002 CAN COMMUNICATION
HINT:
DTC communication uses the CAN communication system.
GETtheMANUALS.org
CA–12
(b) Transmission control computer assembly (EAT ECU)/AT (DS-II

display name)

U0100 EFI communication receiving error
U1001 EFI communication sending error
HINT:
• DTC communication uses the CAN communication system.
• This item applies to vehicles equipped with automatic
transmission.
(c) Brake actuator assembly (VSC ECU) / VSC / DVS / ABS (DS-II
Display Name)

C1231 Open or short circuit, or communication lost in steering angle sensor
C1233 Open or short circuit in yaw rate sensor
C1301 CAN communication error
U0100 EFI communication error
HINT:
• DTC communication uses the CAN communication system.
• This item applies to vehicles equipped with VSC.
(d) COMBINATION METER ASSEMBLY (METER ECU)

0051 EFI ECU communication error
0052 E-A/T communication error
0053 ABS ECU communication error
0054 Steering angle sensor communication error
0055 Yaw and G sensor communication error
5. DTC COMBINATION TABLE

(a) For a malfunction in ECUs that are connected to the CAN bus
line that is not occurring currently, identify the branch line that
caused the malfunction based on the combination table.
Perform the problem simulation test and check for DTCs. (See
page IN-33 for how to simulate the problem symptom.)
HINT:
An open in the branch line currently occurring can be detected
by performing CHECK ECU CONNECTED TO CAN BUS LINE
using the DS-II because the ECUs and sensors connected to
CA
the opened branch line will not respond (will not be displayed on
the screen).
GETtheMANUALS.org
Diagnosis Results Content Of Trouble
EFI ECU AT ECU VSC ECU Steering Angle Yaw/G Sensor Meter ECU
Origin Of Sensor
Output DTC Communication Communication Communication Communication Communication
Output Interruption Mode Interruption Mode Interruption Mode Communication Interruption Mode Interruption Mode
Interruption Mode
UO101/82
EAT Communication
(Receiving)
○
UO121/86
EFI ECU
ABS Communication
(Receiving)
○
Outputs
UO156/87
Meter Communication
(Receiving)
○
U1000/85
EAT Communication
(Sending)
○
C1231/19
Steering Angle Sensor Open
Short/Communication Interruption
○
C1233/36
Yaw Rate Sensor
VSC ECU Open/Short
○
Outputs
C1301/79
CAN Communication Error ○
UO100/49
EFI Communication Error ○
UO100/82
EFI Communication
Receiving Error
○
AT ECU
Outputs U1001/85
EFI Communication
○
CA Sending Error
G101004
HINT:
See page CA-4 for PROBLEM SYMPTOMS TABLE
(COMMUNICATION STOP MODE LIST)
GETtheMANUALS.org
CA–14
CIRCUIT DIAGRAM
Skid Control Computer *1

(VSC ECU)
DTC Memory : Possible
DTC Communication : Possible
CANL CANH
25 11
B20 B10
CANL CANH
Transmission Control Computer Assembly *2
(A/T ECU)
LCN1 HCN1
B19 B9
C1 C2
LCAN HCAN
(EFI ECU)
CANL CANH
D6 D7
CAN J/C
14
CANL
DLC
6
CANH
9
Steering Sensor *1 CANH
DTC Memory : Not possible 2
CANL Yaw Rate Sensor *1
DTC Communication : Not possible
CANL
10
3
DTC Memory : Not possible
CANHDTC Communication : Not possible
CA
22 21
:CAN-H (Main Line)

*1 : VSC equipped vehicles Combination Meter Assembly
(Meter ECU) :CAN-L (Main Line)
*2 : A/T vehicles :CAN-H (Sub Line)
DTC Communication : Possible :CAN-L (Sub Line)
G101045
GETtheMANUALS.org
ECU TERMINALS
NOTICE:
Before measuring the resistance of the CAN bus, turn the ignition
switch off and check that warning functions, such as the key
reminder, are not operating. Wait one minute after operating the key
and switches or opening and closing the doors before performing
measurement. If a door is required to be opened for inspections of
connectors or other items, open the door before starting the
inspections.
1. WIRING HARNESS CONNECTOR (CAN J/C)
Wiring Harness Connector (a) TERMINAL LAYOUT
(CAN J/C ) Vehicle Harness Connector
7 6 5 4 3 2 1
14 1312 11 10 9 8
G101014J05
Terminal No. Terminal Symbol Connected To

11 CANH Steering angle sensor (CAN-H)
12 CANL Steering angle sensor (CANL)
3 CANH Yaw and G sensor (CANH)
6 CANL Yaw and G sensor (CANL)
10 CANH DLC (CANH)
13 CANL DLC (CANL)
9 CANH Meter ECU (CAN-H)
14 CANL Meter ECU (CANL)
4 CANH EFI ECU (CANH)
5 CANL EFI ECU (CANL)
2. DLC
DLC (a) TERMINAL LAYOUT
BAT CANL
Terminal No. Terminal Symbol
CA 4 E
6 CANH
14 CANL
16 BAT
CANH E (b) INSPECT DTC

G101038J04
(1) Turn the ignition switch off.
(2) Using tester, inspect the resistance between the terminals.
Standard

6 (CANH) ←→ 14 (CANL) Resistance IG OFF 55 to 65Ω
6 (CANH) ←→ 16 (BAT) Resistance IG OFF 6 kΩ or more
14 (CANL) ←→ 16 (BAT) Resistance IG OFF 6 kΩ or more
6 (CANH) ←→ 4 (E) Resistance IG OFF 200Ω or more
14 (CANL) ←→ 4 (G) Resistance IG OFF 200Ω or more
GETtheMANUALS.org
CA–16
3. Brake actuator assembly (VSC ECU)

HINT:
The brake actuator assembly (VSC ECU) is installed on only vehicles
equipped with VSC.
Brake Actuator Assembly (VSC ECU)

CANH
CANL
G026569J07
(a) TERMINAL LAYOUT

11 CANH
25 CANL
(b) Inspect the vehicle side connector of the brake actuator

assembly (VSC ECU).
Vehicle Harness Connector (1) Turn the ignition switch off and disconnect the brake
actuator assembly (VSC ECU) connector.
CANH
(2) Using the tester, inspect the resistance between the
terminals of the vehicle side wire harness connector.
CANL G100305J11
Standard

11 (CANH) ←→ GND Resistance IG OFF 200Ω or more
25 (CANL) ←→ GND Resistance IG OFF 200Ω or more
11 (CANH) ←→ +B Resistance IG OFF 6 kΩ or more
25 (CANL) ←→ +B Resistance IG OFF 6 kΩ or more CA
4. Transmission control computer assembly (AT ECU)
HINT:
Transmission control computer assembly (AT ECU) is installed only
on vehicles equipped with automatic transmission.

CANH HCAN
CANL LCAN
Connector A Connector B Connector C C135997J02
GETtheMANUALS.org
(a) TERMINAL LAYOUT

B10 CANH
B20 CANL
B9 HCN1
B19 LCN1
(b) Inspect the vehicle side wire harness connector of the

transmission control computer assembly (AT ECU).
(1) Turn the ignition switch off and disconnect the transmission
(Vehicle Harness Connector) control computer assembly (AT ECU) connector.
HCN1
CANH
LCN1
CANL
Connector B
G100991
Standard

B10 (CANH) ←→ B20 (CANL) Resistance IG OFF 55 to 65Ω
B10 (CANH) ←→ GND Resistance IG OFF 200Ω or more
B20 (CANL) ←→ GND Resistance IG OFF 200Ω or more
B10 (CANH) ←→ +B Resistance IG OFF 6 kΩ or more
B20(CANL) ←→ +B Resistance IG OFF 6 kΩ or more
B9 (HCN1) ←→ 19 (LCN1) Resistance IG OFF 55 to 65Ω
B19 (LCN1) ←→ GND Resistance IG OFF 200Ω or more
B19 (LCN1) ←→ GND Resistance IG OFF 200Ω or more
B9 (HCN1) ←→ +B Resistance IG OFF 6 kΩ or more
B19 (LCN1) ←→ +B Resistance IG OFF 6 kΩ or more
5. STEERING SENSOR (STEERING ANGLE SENSOR)

CA Steering Sensor (Steering Angle Sensor) HINT:
The steering sensor (steering angle sensor) is installed on only
vehicles equipped with VSC.
(a) TERMINAL LAYOUT

10 CANH
9 CANL
CANH CANL
G026566J04
GETtheMANUALS.org
CA–18
(b) Inspect the vehicle side wire harness connector of the steering
sensor (steering angle sensor).
Steering Sensor (Steering Angle Sensor)
Vehicle Harness Connector (1) Turn the ignition switch off and disconnect the steering
sensor (steering angle sensor) connector.
CANH
CANL
G100307J03
Standard

9 (CANL) ←→ +B Resistance IG OFF 6 kΩ or more
6. YAW RATE SENSOR (YAW AND G SENSOR)

Yaw Rate Sensor (Yaw/G Sensor) HINT:
The yaw rate sensor (yaw and G sensor) is installed on only vehicles
equipped with VSC.
(a) TERMINAL LAYOUT

3 CANH
2 CANL
%#0* %#0.
G100311J01
(b) Inspect the vehicle side wire harness connector of the yaw rate
Yaw Rate Sensor (Yaw/G Sensor) sensor (yaw and G sensor).
Vehicle Harness Connector (1) Turn the ignition switch off and disconnect the yaw rate CA
sensor (yaw and G sensor) connector.
CANL CANH
terminals.
G100306J05
Standard

2 (CANL) ←→ +B Resistance IG OFF 6 kΩ or more
GETtheMANUALS.org
7. ENGINE CONTROL COMPUTER (EFI ECU)

LCAN CANH
27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28
106105 104103102101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 72 71 70
135134 133132 131130129 128127 126125 124123 122 121 120119 118 117 116 115 114 113 112 111 110109 108107
HCAN CANL B146450J02
(a) TERMINAL LAYOUT

C9 HCAN
C8 LCAN
D7 CANH
D6 CANL
(b) Inspect the vehicle side wire harness connector of the engine
Engine Control Computer (EFI ECU) control computer (EFI ECU).
Vehicle Harness Connector (1) Turn the ignition switch off and disconnect the connectors C
and D of the engine control computer (EFI ECU).
CANH
HCAN LCAN CANL
G101012J01
Standard
Terminal No. Item Measurement Condition Standard (Ω)

CA D7 (CANH) ←→ D6 (CANL) Resistance IG OFF 110 to 130
D7 (CANH) ←→ GND Resistance IG OFF 200 or more
D6 (CANL) ←→ GND Resistance IG OFF 200 or more
D7 (CANH) ←→ +B Resistance IG OFF 6 k or more
D6 (CANL) ←→ +B Resistance IG OFF 6 k or more
C9 (HCAN) ←→ C8 (LCAN) Resistance IG OFF 110 to 130
C9 (HCAN) ←→ GND Resistance IG OFF 200 or more
C8 (LCAN) ←→ GND Resistance IG OFF 200 or more
C9 (HCAN) ←→ +B Resistance IG OFF 6 k or more
C8 (LCAN) ←→ +B Resistance IG OFF 6 k or more
GETtheMANUALS.org
CA–20
8. COMBINATION METER ASSEMBLY (METER ECU)

(a) TERMINAL LAYOUT
Combination Meter Assembly (Meter ECU)
21 CANH
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
22 CANL
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
CANL CANH
C133847J01
(b) Inspect the vehicle side wire harness connector of the

Combination Meter Assembly (Meter ECU) combination meter assembly (meter ECU).
Vehicle Harness Connector (1) Turn the ignition switch off and disconnect the combination
meter assembly (meter ECU) connector.
CANH
CANL
G100990
Standard
Terminal No. Item Measurement Condition Standard (Ω)

21 (CANH) ←→ 22 (CANL) Resistance IG OFF 55 to 65
21 (CANH) ←→ GND Resistance IG OFF 200 or more
22 (CANL) ←→ GND Resistance IG OFF 200 or more
21 (CANH) ←→ +B Resistance IG OFF 6 k or more
22 (CANL) ←→ +B Resistance IG OFF 6 k or more
FAIL-SAFE CHART
1. FAIL-SAFE FUNCTION
(a) The fail-safe function is designed to protect system
malfunctions by entering the fail-safe process specified in each
system if any bus line (communication line) is defective due to a
short circuit or any other reason.
(b) Effects each system when communication is impossible (For CA
further details, see the pages for each system).
GETtheMANUALS.org
Behavior when
Yaw Rate/G Steering Angle DTC Detection
Function EFI ECU VSC ECU unable to
Sensor Sensor (Driver recognition)
communicate
VSC Control
(Control of strength of
VSC function Possible
driving force during
stops (light on)
VSC operation)
VSC Control
(Control of VSC/TRC VSC function Possible
engine output ) stops (light on )
Recognizeable
Meter Display Light does not
from light
(Display of operation turn on or is
illumination
conditions and DTCs) always on
malfunction
:A system mainly involved in judging control

:Related system
G101016
CA
GETtheMANUALS.org
CA–22
VSC ECU COMMUNICATION STOP MODE

DESCRIPTION
Diagnostic Item Symptom Suspected Area
• VSC / DVS / ABS is not displayed on the
CHECK ECU CONNECTED TO CAN • Power source or internal malfunction in
BUS LINE screen of the DS-II the brake actuator assembly (VSC ECU)
VSC ECU COMMUNICATION STOP MODE
• Applicable to VSC ECU • Brake actuator assembly (VSC ECU)
COMMUNICATION STOP MODE in the main line or connector
DTC combination table
HINT:
This item applies to vehicles equipped with VSC.
CIRCUIT DIAGRAM
Possible Location Of Problem
ECU IG1 46
+IG
Skid Control Computer
32 Assembly (VSC ECU)
GND1
CANH CANL
11 25
Transmission Control
Computer Assembly
(AT ECU)
Engine Control
Computer (EFI ECU)
(Terminal Resistance)
CA
DLC
CAN J/C
:CAN-H (Main Line) Combination Meter Assembly

:CAN-L (Main Line) (Meter ECU)
:CAN-H (Sub Line) (Terminal Resistance)
:CAN-L (Sub Line)
G101000J02
GETtheMANUALS.org
NOTICE:
Before measuring the resistance of the CAN bus, turn the ignition switch off and check that warning functions, such as
the key reminder, are not operating. Wait one minute after operating the key and switches or opening and closing the
doors before performing measurement. If a door is required to be opened for inspections of connectors or other items,
open the door before starting the inspections.
1 CHECK CAN BUS LINE FOR OPEN (VSC ECU MAIN LINE)
(a) Turn the ignition switch off and disconnect the vehicle side wire
harness connector of the brake actuator assembly (VSC ECU) from
the brake actuator assembly (VSC ECU).
(b) Using the tester, measure the resistance between terminals 11
(CANH) and 25 (CANL) of the vehicle side wire harness connector of
Vehicle Harness Connector the brake actuator assembly (VSC ECU).
Standard:
CANH
55 to 65 Ω
NG REPAIR OR REPLACE BRAKE ACTUATOR

ASSEMBLY (VSC ECU) BRANCH LINE OR
CONNECTOR (CAN-H, CAN-L)
CANL G100305J11
OK
2 INSPECT WIRE HARNESS (+IG VOLTAGE, GND1 CONTINUITY)
(a) Using the tester, inspect the resistance between the terminals of the
Brake Actuator Assembly (VSC ECU) vehicle side wire harness connector of the brake actuator assembly
Vehicle Harness Connector (VSC ECU) and the body ground.
Standard
+IG Tester Connection Measurement Condition Standard

46 (+IG) ←→ Body
IG ON 10 to 14 V
ground
32 (GND1) ←→ Body
Always Continuity
CA GND1 G100305J12
ground

CONNECTOR
OK
REPLACE BRAKE ACTUATOR ASSEMBLY
GETtheMANUALS.org
CA–24
AT ECU COMMUNICATION STOP MODE

DESCRIPTION
• AT is not displayed on the CHECK ECU
• Power source or internal malfunction in
CONNECTED TO CAN BUS LINE screen
the transmission control computer
of the DS-II
AT ECU COMMUNICATION STOP MODE assembly (AT ECU)
• Applicable to AT COMMUNICATION
STOP MODE in the DTC combination
(AT ECU) main line or connector
table
HINT:
This item applies to vehicles equipped with automatic transmission.
CIRCUIT DIAGRAM
ECU IG1 46
+IG
Skid Control Computer
32 Assembly (VSC ECU)
GND1
CANH CANL
11 25
Computer Assembly
(AT ECU)
120[Ω] ± 10%
(Terminal Resistance)
Engine Control
Computer (EFI ECU)
CA
DLC
CAN J/C
:CAN-H (Main Line) Combination Meter Assembly

:CAN-L (Main Line) (Meter ECU)
:CAN-H (Sub Line) 120[Ω] ± 10%
:CAN-L (Sub Line) (Terminal Resistance)
G100998J02
GETtheMANUALS.org
NOTICE:
1 CHECK CAN BUS LINE FOR OPEN (AT ECU MAIN LINE)
harness connector of the transmission control computer assembly
(AT ECU) from the transmission control computer assembly (AT
(Vehicle Harness Connector) ECU).
(b) Using the tester, measure the resistance between terminals B10
(CANH) and B20 (CANL) of the vehicle side wire harness connector
of the transmission control computer assembly (AT ECU).
Standard:
HCN1 55 to 65 Ω
NG REPAIR OR REPLACE TRANSMISSION

CANH CONTROL COMPUTER ASSEMBLY (AT ECU)
LCN1
CANL MAIN LINE OR CONNECTOR (CAN-H, CAN-
Connector B L)
G100991
OK
2 CHECK WIRE HARNESS (BAT1 VOLTAGE, BAT2 VOLTAGE)
vehicle side wire harness connector of the transmission control
computer assembly (AT ECU) and the body ground.
Standard
(Vehicle Harness Connector)
B2 (BAT1) ←→ Body
CA ground
IG ON 10 to 14 V
B1 (BAT2) ←→ Body
IG ON 10 to 14 V
BAT1 ground
B24 (E1) ←→ Body
Always Continuity
ground
BAT2
E1 NG REPAIR OR REPLACE WIRE HARNESS OR
Connector B CONNECTOR
G100991J01
OK
REPLACE TRANSMISSION CONTROL COMPUTER ASSEMBLY
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CA–26
STEERING ANGLE SENSOR COMMUNICATION STOP MODE

DESCRIPTION
• STEERING ANGLE SENSOR is not
displayed on the CHECK ECU • Power source or internal malfunction in
CONNECTED TO CAN BUS LINE screen the steering sensor (steering angle
STEERING ANGLE SENSOR
of the DS-II sensor)
COMMUNICATION STOP MODE
• Applicable to STEERING ANGLE • Steering sensor (steering angle sensor)
SENSOR COMMUNICATION STOP branch line or connector
MODE in the DTC combination table
HINT:
CIRCUIT DIAGRAM
DLC

(Meter ECU) (EFI ECU)
120[Ω] ± 10% 120[Ω] ± 10%

CAN J/C
(Terminal Resistance) (Terminal Resistance)
10 9
CANH CANL
CA
2 1
ESS
Steering Sensor :CAN-H (Main Line)
IG ECU IG
:CAN-L (Main Line)
:CAN-H (Main Line)
:CAN-L (Main Line)
G101002J02
NOTICE:
GETtheMANUALS.org
1 CHECK CAN BUS LINE FOR OPEN (STEERING ANGLE SENSOR BRANCH LINE)
harness connector of the steering sensor (steering angle sensor)
Steering Sensor (Steering Angle Sensor) from the steering sensor (steering angle sensor).
Vehicle Harness Connector (b) Using the tester, measure the resistance between terminals 10
the steering sensor (steering angle sensor).
Standard:
55 to 65 Ω
NG REPAIR OR REPLACE STEERING SENSOR

(STEERING ANGLE SENSOR) BRANCH LINE
OR CONNECTOR (CAN-H, CAN-L)
CANH
CANL
G100307J04
OK
2 INSPECT WIRE HARNESS (IG VOLTAGE, ESS CONTINUITY)
vehicle side harness connector of the steering sensor (steering angle
Steering Sensor (Steering Angle Sensor)
sensor) and the body ground.
Vehicle Harness Connector
Standard

1 (IG) ←→ Body ground IG ON 10 to 14 V
2 (ESS) ←→ Body
Always Continuity
ground
ESS NG REPAIR OR REPLACE WIRE HARNESS OR

CA IG CONNECTOR
G100307J05
OK
REPLACE STEERING SENSOR
GETtheMANUALS.org
CA–28
YAW RATE AND G SENSOR COMMUNICATION STOP MODE

DESCRIPTION
• YAW RATE AND G SENSOR is not
displayed on the CHECK ECU
• Power source or internal malfunction in
CONNECTED TO CAN BUS LINE screen
YAW RATE AND G SENSOR the yaw rate sensor (yaw and G sensor)
of the DS-II
COMMUNICATION STOP MODE • Yaw rate sensor (yaw and G sensor)
• Applicable to YAW RATE AND G
branch line or connector
SENSOR COMMUNICATION STOP
MODE in the DTC combination table
HINT:
CIRCUIT DIAGRAM
DLC

(Meter ECU) (EFI ECU)
120[Ω] ± 10% 120[Ω] ± 10%

CAN J/C
3
CANH CANL
2
CA
1 Yaw Rate Sensor 5
GND (Yaw/G Sensor) IG :CAN-H(Mine Line)
ECU IG
:CAN-L(Mine Line)
:CAN-H(Sub Line)
:CAN-L(Sub Line)
G101003J02
NOTICE:
GETtheMANUALS.org
1 CHECK CAN BUS LINE FOR OPEN (YAW AND G SENSOR BRANCH LINE)
Yaw Rate Sensor (Yaw/G Sensor) harness connector of the yaw rate sensor (yaw and G sensor) from
Vehicle Harness Connector the yaw rate sensor (yaw and G sensor).
(CANH) and 2(CANL) of the vehicle side wire harness connector of
CANL CANH
the yaw rate sensor (yaw and G sensor).
Standard:
55 to 65Ω
NG REPAIR OR REPLACE YAW RATE SENSOR

G100306J05
(YAW AND G SENSOR) BRANCH LINE OR
OK
2 INSPECT WIRE HARNESS (IG VOLTAGE, GND CONTINUITY)
Yaw Rate Sensor (Yaw/G Sensor) vehicle side wire harness connector of the yaw rate sensor (yaw and
Vehicle Harness Connector G sensor) and the body ground.
Standard
GND Tester Connection Measurement Condition Standard

IG
5 (IG) ←→ Body ground IG ON 10 to 14 V
1 (GND) ←→ Body
Always Continuity
ground
G100306J06
CONNECTOR
OK
CA
REPLACE YAW RATE SENSOR
GETtheMANUALS.org
CA–30
EFI ECU COMMUNICATION STOP MODE

DESCRIPTION
• EFI is not displayed on the CHECK ECU
CONNECTED TO CAN BUS LINE screen • Power source or internal malfunction in
of the DS-II the engine control computer (EFI ECU)
EFI ECU COMMUNICATION STOP MODE
• Applicable to EFI ECU • Engine control computer (EFI ECU) main
COMMUNICATION STOP MODE in the line or connector
DTC combination table
CIRCUIT DIAGRAM
DLC
DLC3 Possible Location Of Problem

(Meter ECU) Engine Control Computer (EFI ECU)
D7 C120
+IG
IGSW
CANH
A27
+B
D6
C39
120[Ω] ± 10% CANL To EFI Relay
MRO
120[Ω] ± 10%
B125
CAN J/C E1
:CAN-H (Main Line)

:CAN-L (Main Line)
:CAN-H (Sub Line)
:CAN-L (Sub Line)
G101001J02
NOTICE: CA
GETtheMANUALS.org
1 CHECK CAN BUS LINE FOR OPEN (EFI ECU MAIN LINE)
Engine Control Computer (EFI ECU) harness connectors C and D of the engine control computer (EFI
Vehicle Harness Connector ECU) from the engine control computer (EFI ECU).
(b) Using the tester, measure the resistance between terminals D7
(CANH) and D6 (CANL) of the vehicle side wire harness connector of
the engine control computer (EFI ECU).
Standard:
CANH 110 to 130 Ω
NG REPAIR OR REPLACE ENGINE CONTROL

COMPUTER (EFI ECU) MAIN LINE OR
HCAN LCAN CANL
G101012J01
OK
2 INSPECT WIRE HARNESS (IGSW, +B AND MRO VOLTAGE, E1 CONTINUITY)
vehicle side wire harness connector of the engine control computer
Engine Control Computer (EFI ECU) (EFI ECU) and the body ground.
Vehicle Harness Connector Standard
A27 B125 C39
C120 (IGSW) ←→ Body
IG ON 10 to 14 V
ground
A27 (+B) ←→ body
IG ON 10 to 14 V
ground
C39 (MRO) ←→ Body
IG ON 10 to 14 V
C120 ground
Connector A Connector B Connector C B125 (E1) ←→ Body

Always Continuity
CA ground

G100993J01
CONNECTOR
OK
GETtheMANUALS.org
CA–32
METER ECU COMMUNICATION STOP MODE

DESCRIPTION
• COMBINATION METER ASSEMBLY
(METER ECU) POWER SOURCE or
METER is not displayed on the CHECK ECU
METER ECU COMMUNICATION STOP INTERNAL MALFUNCTION
CONNECTED TO CAN BUS LINE screen of
MODE • COMBINATION METER ASSEMBLY
the DS-II
(METER ECU) BRANCH LINE OR
CONNECTOR
CIRCUIT DIAGRAM
Possible Location Of Problem DLC
Combination Meter Assembly (Meter ECU) Engine Control Computer (EFI ECU)
21
12 CANH
IG+
15 22
GND
CANL
120[Ω] ± 10% 120[Ω] ± 10 %
CAN J/C
:CAN-H(Main Line)
:CAN-L(Main Line)
:CAN-H(Sub Line)
:CAN-L(Sub Line)
G101039J01
NOTICE: CA
doors before performing measurement. During the check, when the door must be opened, open the door in advance and
leave it open.
HINT:
• When inspecting each connector, pull the connector case in the connection direction before disconnecting the connector.
Check that the connector is not loose and that an opening is not generated.
• When disconnecting the connector, make sure not to damage, deform, corrode or in anyway harm the connector terminal and
the connector case.
GETtheMANUALS.org
1 CHECK CAN BUS LINE FOR OPEN (METER ECU SUPPORT LINE)
harness connector of the combination meter assembly (meter ECU)
from the combination meter assembly (meter ECU).
(b) Measure the resistance between terminals 21 (CANH) and 22
(CANL) of the vehicle side wire harness connector of the combination
meter assembly (meter ECU).
Standard:
110 to 130
CANH NG REPAIR OR REPLACE COMBINATION

METER ASSEMBLY (METER ECU) BRANCH
CANL LINE OR CONNECTOR
G100990
OK
2 INSPECT WIRE HARNESS (IG+ VOLTAGE, GND CONTINUITY)
vehicle side wire harness connector of the combination meter
assembly (meter ECU) and the body ground.
Combination Meter Assembly (Meter ECU) Standard
Vehicle Harness Connector Tester Connection Measurement Condition Standard
12(IG+) ←→ Body
When the ignition is ON 10 to 14 V
ground
IG+ Always Continuity
GND ground

CONNECTOR
CA
G100990J02
OK
GETtheMANUALS.org
CA–34
OPEN IN CAN MAIN BUS LINE (DLC BRANCH LINE/MAIN BUS LINE/
TERMINATING RESISTOR)
DESCRIPTION
If the resistance between terminals 6 (CANH) and 14 (CANL) of the DLC is 70 or more, there may be an open in the CAN main
bus line or in the DLC branch line.
Symptom Suspected Area

• Open or connector malfunction (open in the main bus line) in (1), (1'),
(2), or (2')
The resistance between terminals 6 (CANH) and 14 (CANL) of
• Engine control computer (EFI ECU) malfunction
the DLC is 70 or more.
• Combination meter assembly (meter ECU) malfunction
• Wire harness connector (CAN J/C) malfunction
CA
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CIRCUIT DIAGRAM

(VSC ECU)
Transmission Control Computer *2

(A/T ECU)

(EFI ECU)
(1) (1’)
CAN J/C
DLC
Steering Sensor *1
Yaw Rate Sensor *1
DTC Communiation : Not possible
CA
(2) (2’)
Combination Meter Assembly :CAN-H (Main Line)

(Meter ECU) :CAN-L (Main Line)
DTC Memory : Possible :CAN-H (Sub Line)
*1 : VSC equipped vehicles DTC Communication : Possible :CAN-L (Sub Line)
*2 : A/T vehicles
G101049
GETtheMANUALS.org
CA–36
NOTICE:
1 INSPECT DTC
(a) Using the tester, measure the resistance between terminals 6

DLC (CANH) and 14(CANL) of the DLC when the ignition switch is off.
CANL Standard:
A 110 to 130Ω
B 132Ω or more
NOTICE:
If a CAN communication system DTC is output when the
CANH measurement result is 132 or more, there may be another
G101038J01
malfunction in addition to an open in the DLC branch line.
Troubleshooting should be performed again from HOW TO
PROCEED WITH TROUBLESHOOTING (see page CA-5) after
repairing the malfunctioning section.
B REPAIR OR REPLACE DLC BRANCH LINE

2 CHECK CAN BUS LINES FOR OPEN (CAN MAIN BUS LINE (COMBINATION METER ASSEMBLY
(METER ECU))
(a) Turn the ignition switch off and disconnect the combination meter
assembly (meter ECU) connector from the combination meter
assembly (meter ECU).
the combination meter assembly (meter ECU). CA
Standard:
110 to 130Ω
CANH OK REPLACE COMBINATION METER

ASSEMBLY
CANL
G100990
NG
GETtheMANUALS.org
3 CHECK CAN BUS LINES FOR OPEN (CAN MAIN BUS LINE (COMBINATION METER ASSEMBLY
(METER ECU) - CAN J/C))
(a) Disconnect the CAN main bus line connector of the CAN J/C from the
Wiring Harness Connector (CAN J/C) wire harness connector (CAN J/C).
the wire harness connector (CAN J/C).
Standard:
CANL 7 6 5 4 3 2 1
CANH
110 to 130 É¹
14 1312 11 10 9 8
OK REPAIR OR REPLACE CAN MAIN BUS LINE

G101014J02
NG
4 CHECK CAN BUS LINES FOR OPEN (CAN MAIN BUS LINE (ENGINE CONTROL COMPUTER (EFI
ECU)))
(a) Turn the ignition switch off and disconnect connector D of the engine
Engine Control Computer (EFI ECU) control computer (EFI ECU) from the engine control computer (EFI
Vehicle Harness Connector ECU).
(b) Using the tester, measure the resistance between terminals D7
(CANH) and D6 (CANL) of the vehicle side wire harness connector of
the engine control computer (EFI ECU).
Standard:
110 to 130 Ω
OK REPLACE ENGINE CONTROL COMPUTER
CANH
CANL
Connector D
G101037
CA NG
5 CHECK CAN BUS LINES FOR OPEN (CAN MAIN BUS LINE (ENGINE CONTROL COMPUTER [EFI
ECU] - CAN J/C))
(a) Disconnect the CAN main bus line connector of the CAN J/C from the
Wiring Harness Connector wire harness connector (CAN J/C).
(CAN J/C) Vehicle Harness
CANH
the wire harness connector (CAN J/C).
CANL
Standard:
7 6 5 4 3 2 1
110 to 130 Ω
14 1312 11 10 9 8
NG REPLACE WIRE HARNESS CONNECTOR

G101014J04
(CAN J/C)
GETtheMANUALS.org
CA–38
OK
REPAIR OR REPLACE CAN MAIN BUS LINE OR CONNECTOR (CAN-H, CAN-L)
CA
GETtheMANUALS.org
SHORT IN CAN BUS LINES

DESCRIPTION
If the resistance between terminals 6 (CANH) and 14 (CANL) of the DLC is 54 or less, there may be a short in the CAN bus line.
Symptom Suspected Area

• Short circuit among (1), (2), (3), (4), (5), (6) and (7) lines
• Engine control computer (EFI ECU) malfunction
• Transmission control computer assembly (AT ECU) malfunction
The resistance between terminals 6 (CANH) and 14 (CANL) of • Brake actuator assembly (VSC ECU) malfunction
the DLC is 54 or less. • Steering sensor (steering angle sensor) malfunction
• Yaw rate sensor (yaw and G sensor) malfunction
• Combination meter assembly (meter ECU) malfunction
• Wire harness connector (CAN J/C) malfunction
CA
GETtheMANUALS.org
CA–40
CIRCUIT DIAGRAM

(VSC ECU)
(1)
Computer Assembly *2
(A/T ECU)
(2)

(EFI ECU)
CAN J/C (3)
(4) DLC
Steering Sensor *1
DTC Memory : Not possible (7) Yaw Rate Sensor *1
DTC Communication : Not possible DTC Memory : Not possible
(5)
CA
(6)
Combination Meter Assembly :CAN-H (Main Line)

*1 : VSC equipped vehicles (Meter ECU) :CAN-L (Main Line)
*2 : A/T vehicles DTC Memory : Possible :CAN-H (Sub Line)
DTC Communication : Possible :CAN-L (Sub Line)
G101046
GETtheMANUALS.org
NOTICE:
• Before measuring the resistance of the CAN bus, turn the ignition switch off and check that warning functions, such
as the key reminder, are not operating. Wait one minute after operating the key and switches or opening and closing
the doors before performing measurement. If a door is required to be opened for inspections of connectors or other
items, open the door before starting the inspections.
• Considering the possibility that there are short circuits in several branch lines, recheck the DLC after repairing
malfunctioning areas to see if another malfunction occurs in other areas. If a malfunction is detected, follow the
diagnosis flow and continue the inspection.
1 CHECK CAN BUS LINES FOR SHORT CIRCUIT (DLC BRANCH LINE)
DLC harness connector of the wire harness connector (Driver side CAN J/
CANL C) from the wire harness connector (Driver side CAN J/C).
(CANH) and 14(CANL) of the DLC.
Standard:
6 kÉ¹ or more
NG REPAIR OR REPLACE DLC BRANCH LINE

CANH
G101038J01
OR CONNECTOR (CANH, CANL)
OK
2 CONNECT CONNECTOR
(a) Connect the DLC branch line connector to the CAN J/C.
3 CHECK CAN BUS LINES FOR SHORT CIRCUIT (METER ECU)
harness connector of the combination meter assembly (meter ECU)
CA (b)
from the combination meter assembly (meter ECU).
Using the tester, measure the resistance between terminals 6
DLC (CANH) and 14(CANL) of the DLC.
CANL Standard:
110 to 130 Ω
OK REPLACE COMBINATION METER

ASSEMBLY
CANH
G101038J01
NG
GETtheMANUALS.org
CA–42
4 CHECK CAN BUS LINES FOR SHORT CIRCUIT (CAN J/C - METER ECU)
harness connector of the wire harness connector (CAN J/C) from the
wire harness connector (CAN J/C).
Combination Meter Assembly (Meter ECU) (CANH) and 22 (CANL) of the vehicle side wire harness connector of
Vehicle Harness Connector the combination meter assembly (meter ECU).
Standard:
6 kΩ or more
HINT:

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FOREWORD

Published in February, 2006

HOW TO USE THIS MANUAL

(b) Non-reusable parts, lubricant application areas, precoated bolts

REAR AXLE SHAFT

REAR AXLE SHAFT LH

REAR AXLE SHAFT

REAR AXLE SHAFT OIL SEAL LH

(c) Tightening torque, lubricant application areas and non-reusable

SST tighten the bolt.

Standard Refers to a range of acceptable values during checking and adjusting.

6. INTERNATIONAL SYSTEM OF UNITS

International System of Units Prefixes

VEHICLE IDENTIFICATION NUMBER, ENGINE SERIAL

NUMBER AND TRANSMISSION SERIAL NUMBER

2. Engine Serial Number and Transmission Serial Number

(b) The transmission serial number is stamped on the certification

VEHICLE OPERATION AND PRECAUTION

(d) AIRBAG AND PRETENSIONER DISPOSAL PRECAUTIONS

(h) PROCEDURE FOR VEHICLES SUBJECTED TO IMPACT IN A

• Always wear a clean uniform.

unavoidable, use fuses with a lower rating than the

IN Diagram Symbol Part Name Abbreviation

Medium Current Fuse M Fuse

High Current Fuse H Fuse

Fusible Link Assembly FL

• The pmark in the illustration refers to clips, and the

Shapes (Examples) Removal And Installation

Clip Clip Remover

Roof Molding Remover

(f) FRAMING ADJUSTMENTS

(h) REMOVAL AND INSTALLATION OF VACUUM HOSES

(2) When disconnecting vacuum hoses, use tags to identify

(i) TORQUE WHEN USING TORQUE WRENCH WITH

Reading of torque wrench (N*m

5. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS

6. HANDLING OF HOSE CLAMPS

or a chassis dynamometer, turn the TRC or VSC system

(1) Drive the rear wheels onto the roller.

(c) Tow using one of the methods shown in the illustration.

Towing Speed Less Than 30 km/h

14. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER

SUPPORT POSITIONS FOR JACK,

(c) When jacking up the vehicle, be sure to support the specified

2. NOTICE ABOUT SUPPORT POSITIONS WHEN JACKING UP

Do not jack up the vehicle by the oil

Rigid Rack, Lift Up Support Position

3. PRECAUTIONS FOR USING JACKS AND RIGID RACKS

Acceptable Range For Vehicle Center Of Gravity

Offset Weight Offset Weight

Lift Cylinder Center

(e) Always drive the vehicle onto the specified position.

5. PRECAUTIONS FOR USING SWING ARM LIFT

Vehicle Center Of Gravity (Vehicle Empty)

HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

NEW DIAGNOSTIC SYSTEM

3. COMPUTERS AND SENSORS RELATED TO DIAGNOSTIC

*: Data monitor can be used simultaneously