Honda Jazz Fit 2007 To 2014 Workshop Manual PDF
Honda Jazz Fit 2007 To 2014 Workshop Manual PDF
Honda Jazz Fit 2007 To 2014 Workshop Manual PDF
Specifications
Standards and Service Limits
Engine
Trans/Driveline
Steering
Suspension
Brakes
HVAC
Design Specification
Body Dimentions
Maintenance Schedule
Lubricants and Fluids
Maintenance
Engine
Charging System
Cooling System
Fan Controls
Cruise Control System
Cylinder Head Assembly
Camshaft
Rocker Arm Assembly
Timing/Cam Chain
Valves
VTEC System
Engine Assembly and Mounts
Engine Assembly
Engine Mounts
Engine Block Assembly
Connecting Rods
Crankshaft
Pistons
Exhaust System
Ignition System
Lubrication System
Low Engine Oil Pressure Indicator Components
Starting System
Fuel and Emissions
Catalytic Converter System
EVAP Control System
EGR System
Electronic Throttle Control System
Fuel Supply System
Fuel Injection System (PGM-FI)
Idle Control System
Intake Air System
PCV System
Trans/Driveline
Automatic Transaxle
A/T Assembly
A/T Electronic Control System
A/T Gear Position Indicator System
A/T Hydraulic Controls
A/T Countershaft Assembly
A/T Mainshaft Assembly
A/T Secondary Shaft Assembly
A/T Gearshift Mechanism
A/T Differential
A/T Idler Gear Shaft Assembly
Interlock System
Torque Converter
Valve Bodies
Driveshafts
Front Driveshaft Assembly
Intermediate Shaft Assembly
Manual Transaxle
Clutch
M/T Assembly
M/T Countershaft Assembly
M/T Gearshift Mechanism
M/T Mainshaft Assembly
M/T Differential
Synchro Assemblies
Steering
EPS Components
Suspension
Front Suspension
Rear Suspension
Wheels and Tires
Brakes
ABS-TCS Components
Conventional Brake Components
Brake System indicator Components
VSA System (includes ABS, TCS)
Parking Brake
HVAC
A/C
A/C Compressor
A/C Condenser
Evaporator-Heater Unit
Automatic Climate Control
Heating/Ventilation
Blower Unit
Evaporator-Heater Unit
Rear Window Defogger
Body
Audio/Entertainment
Communication
Cigarette Lighter
Doors
Front Doors
Rear Doors
Exterior
Bumpers
Fenders
Fuel Fill Door
Fuel Fill Door Opener
Hood
Hood Opener
Openers
Trim
Tailgate
Tailgate Opnener
Frame
Subframes
Gauges
Horns
Interior
Console
Dashboard
Trim
Indicators
Lights-on Reminder
Multi-information Display
Safety Indicator System
Lights, Exterior
Automatic Lighting Control
Back-up Lights
Brake Lights
Front Fog Lights
Headlights
Headlight Leveling System
Lights-on Reminder
Taillights
Turn Signal/Hazard Warning Lights
Lights, Interior
Cargo Area Light
Entry Light Control System
Mirrors
Outside Power Mirros
Multiplex Integrated Control System (MICS)
Seats
Front Seats
Rear Seat
Seat Heaters
Security/Keyless Entry/Locks
Immobilizer System
Keyless Entry/Security Alarm System
Sunshade
Wiring System
Accessory Power Sockets
Fuse/Relay Boxes
Ground Distribution
Power Distribution
Wire Harnesses
Wiper/Washer
Windows
Power Windows
Driving Support & Restraints
Seat Belts
SRS
DTC Troubleshooting
ABS Control Unit
Automatic Lighting/ Rain Sensor
Climate Control Unit
ECM
EPS Control Unit
Gauge Control Module
Hands Free Telephone Control Unit
Headlight Leveling Control Unit
Immobilizer-keyless Control Unit
MICU (Multiplex Integrated Control Unit)
PCM
SRS Unit
VSA Control Unit
Wiring Diagrams
Lift and Support Points
NOTE: If you are going to remove heavy components such as suspension from the rear of the vehicle, first support the
front of the vehicle with tall safety stands. When substantial weight is removed from the rear of the vehicle, the center of
gravity can change, causing the vehicle to tip forward on the lift.
Vehicle Lift
1. Position the lift blocks (A), under the vehicle's front support points (B) and rear support points (C).
2. Raise the lift a few inches, and rock the vehicle gently to be sure it is firmly supported.
3. Raise the lift to its full height, and inspect the vehicle support points for solid contact with the lift blocks.
Safety Stands
To support the vehicle on safety stands, use the same support points (B and C) as for a vehicle lift. Always use safety
stands when working on or under any vehicle that is supported only by a jack.
Floor Jack
1. When lifting the front of the vehicle, set the parking brake. When lifting the rear of the vehicle, put the shift lever in
reverse for manual transmission, or P for automatic transmission.
2. Block the wheels that are not being lifted.
3. Position the floor jack under the front jacking bracket (A) or the rear jacking bracket (B). Center the jacking bracket
on the jack lift platform (C), and jack up the vehicle high enough to fit the safety stands under it.
4. Position the safety stands under the support points, and adjust them so the vehicle is level.
5. Lower the vehicle onto the stands.
Towing
If the vehicle needs to be towed, call a professional towing service. Never tow the vehicle behind another vehicle with just a Front:
rope or chain. It is very dangerous.
Emergency Towing
There are three popular methods of towing a vehicle.
Flat-bed Equipment − The operator loads the vehicle on the back of a truck. This is the best way of transporting the
vehicle.
To accommodate flat-bed equipment, the vehicle is equipped with front towing hook (A), front tie down hook slots (B), rear
towing hook (C), and the rear tie down hook slots (D).
The towing hook can be used with a winch to pull the vehicle onto the truck, and the tie down hook slots can be used to
secure the vehicle to the truck.
NOTE: The tie down hook slots use rubber plugs (E) to cover the openings.
Towing Hook Installation
The detachable towing hook is for towing very short distance, such as freeing the car. The hook mounts to the anchor in
the front and rear bumper. Rear:
To avoid damage to the vehicle, use the towing hook for straight flat ground towing only. Do not tow on an angle.
The tow hook should not be used to tow the vehicle onto a flat-bed. Do not use it as a tie down.
Improper towing preparation will damage the transmission. Follow the above procedure exactly. If you cannot shift
the transmission or start the engine (automatic transmission), the vehicle must be transported on a flat-bed.
Trying to lift or tow the vehicle by the bumpers will cause serious damage. The bumpers are not designed to
support the vehicle's weight.
Charging System Circuit Diagram
BATTERY TERMINAL
FUSE BOX UNDER−DASH FUSE/RELAY BOX IGNITION SWITCH
BATTERY
No. 1 (100 A) T−9 No. 60 (50 A) T1 2 BAT
WHT WHT
IG1
ELD
5
W1
YEL
LT BLU
PNK BLK LT BLU YEL
LT BLU
GAUGE CONTROL MODULE 32
30
G501 29 CPU
CHARGING SYSTEM
INDICATOR
ECM/PCM A3 A4
CANH CANL
5V
A24 ELD
VOLTAGE REGULATOR
RECTIFIER
ALTERNATOR
Charging system indicator does not come on with the ignition switch in ON (II)
Diagnostic procedure
1. Troubleshoot the charging system indicator circuit.
Charging system indicator stays on
Diagnostic procedure
1. Check for PGM-FI DTCs.
2. Check the drive belt auto-tensioner.
3. Check for a broken drive belt.
4. Troubleshoot the charging system indicator circuit.
Battery discharged
Diagnostic procedure
1. Check for a poor connection at the battery terminal.
2. Test the battery.
3. Check the drive belt auto-tensioner.
4. Check for a broken drive belt.
5. Check for excessive parasitic electrical current draw.
6. Troubleshoot the alternator and regulator circuit.
Battery overcharged
Diagnostic procedure
1. Test the battery.
2. Troubleshoot the alternator and regulator circuit.
Charging System Symptom Troubleshooting Index
Symptom Diagnostic procedure Also check for
Charging system indicator does not Troubleshoot the charging system indicator circuit.
come on with the ignition switch in
ON (II)
Charging system indicator stays on 1. Check for PGM-FI DTCs.
2. Check the drive belt auto-tensioner.
3. Check for a broken drive belt.
4. Troubleshoot the charging system indicator circuit.
Battery discharged 1. Check for a poor connection at the battery terminal.
2. Test the battery.
3. Check the drive belt auto-tensioner.
4. Check for a broken drive belt.
5. Check for excessive parasitic electrical current draw.
6. Troubleshoot the alternator and regulator circuit.
Battery overcharged 1. Test the battery.
2. Troubleshoot the alternator and regulator circuit.
Alternator Removal and Installation
Removal
1. Do the battery terminal disconnection procedure.
2. Remove the drive belt.
3. Remove the intake manifold.
4. Disconnect the alternator connector (A) and BLK wire (B), then remove the harness clamp (C) from the alternator.
Installation
1. Install the alternator.
2. Connect the alternator connector (A) and BLK wire (B), then install the harness clamp (C) to the alternator.
3. Install the intake manifold.
4. Install the drive belt.
5. Do the battery terminal reconnection procedure.
Alternator Overhaul
Exploded View
Special Tools Required
Driver handle, 15 x 135L
07749-0010000
4. Heat the rear bearing seat with a heat gun for about 5 minutes (50−60 °C, 129−140 °F).
5. Separate the rear housing from the drive end housing by inserting a flat-tip screwdriver into the openings and prying
them apart.
NOTE: Be careful not to damage the stator with the tip of the screwdriver.
6. Separate the rear housing (A) and drive end housing (B) with the stator (C) attached to the rear housing.
7. If you are not replacing the front bearing and/or rear bearing, go to Step 15 . Clamp the rotor in a soft-jawed vise,
then remove the pulley locknut.
11. Use a hand press to install the new rear bearing. Apply pressure only on the inner race to avoid damaging the
bearing.
12. Remove the front bearing retainer plate.
13. Support the drive end housing in a vise, and drive out the front bearing with a brass drift and hammer.
14. With a hammer and the special tools, install a new front bearing in the drive end housing.
16. Remove the terminal insulator (A) and harness bracket (B).
17. Remove the voltage regulator/brush holder assembly (A) and the rectifier (B).
18. Check for continuity in each direction, between the B terminal (A) and P terminals (B), and between the E terminal Stator side
(C) and P terminals (B) of each diode pair. All diodes should have continuity in only one direction. Because the
rectifier diodes are designed to allow current to pass in one direction, and the rectifier is made up of six diodes (six
pairs), you must test each diode in both directions for continuity with an ohmmeter that has diode checking
capability: a total of 24 checks.
If any diode failed, replace the rectifier assembly. (Diodes are not available separately.)
If all the diodes are OK, go to Step 19 .
Rear housing side
Alternator Brush Inspection
19. Measure the length of both brushes with a vernier caliper.
If either brush is shorter than the service limit, replace the rear housing assembly.
If brush length is OK, go to Step 20 .
Alternator Brush Length
20. Unsolder the brush leads from the voltage regulator/brush holder assembly with a 100 W soldering iron (A), then
replace the brushes.
Stator Test
23. Check that there is continuity between each leads (A).
If there is continuity, go to Step 24 .
If there is no continuity, replace the stator.
24. Check for continuity between each lead and the coil core (B).
If there is no continuity, go to Step 25 .
If there is continuity, replace the stator.
Alternator Reassembly
25. If you removed the pulley, put the rotor in the drive end housing, then tighten its locknut to 110 N·m (11.2 kgf·m,
81.0 lbf·ft).
26. Remove any grease or any oil from the slip rings.
27. Install the voltage regulator/brush holder assembly and rectifier on the rear housing.
28. Install the stator on the rear housing.
29. Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.8 mm (0.07 in.) diameter) to hold them there.
30. Heat the rear bearing seat with a heat gun for about 5 minutes (50−60 °C, 129−140 °F).
31. Put the rear housing assembly (A) and drive end housing/rotor assembly (B) together, tighten the four through bolts
(C).
3. Start the engine. Hold the engine at 3,000 rpm (min −1 ) with no load (in P or N (A/T model) or neutral (M/T model)),
until the radiator fan comes on then let it idle.
4. Raise the engine speed to 2,000 rpm (min −1 ) and hold it there.
5. Turn the headlights (high beam) on, and measure the voltage at the alternator terminal.
Is the voltage within 13.9−15.1 V?
YES - Go to Step 6 .
NO - Replace the alternator, or repair the alternator. ■
6. Read the amperage at 13.5 V.
NOTE: Adjust the voltage by turning the blower motor, rear window defogger, brake lights and etc. on.
Is the amperage 60 A or more?
YES - The charging system is OK. Go to alternator control circuit troubleshooting. ■
NO - Replace the alternator, or repair the alternator. ■
Alternator Control Circuit Troubleshooting
1. Connect the Honda Diagnostic System (HDS) to the data link connector (DLC).
2. Turn the ignition switch to ON (II).
3. Make sure the HDS communicates with the vehicle and the engine control module (ECM)/powertrain control
module (PCM). If it doesn't communicate, troubleshoot the DLC circuit.
4. Check for DTCs. If a DTC is present, diagnose and repair the cause before continuing with this test.
5. Disconnect the alternator 4P connector from the alternator.
6. Start the engine, and turn on the headlights to high beam.
7. Measure the voltage between alternator 4P connector terminal No. 2 and the positive terminal of the battery.
Is there 1 V or less?
YES - Go to Step 11 .
NO - Go to Step 8 .
8. Jump the SCS line with the HDS, then turn the ignition switch to LOCK (0).
NOTE: This step must be done to protect the ECM/PCM from damage.
9. Disconnect ECM/PCM connector B (49P).
10. Check for continuity between ECM/PCM connector terminal B45 and body ground.
Is there continuity?
YES - Repair short in the wire between the alternator and the ECM/PCM.■
NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original
ECM/PCM. ■
11. Jump the SCS line with the HDS, then turn the ignition switch to LOCK (0).
NOTE: This step must be done to protect the ECM/PCM from damage.
12. Disconnect ECM/PCM connector B (49P).
13. Check for continuity between ECM/PCM connector terminal B45 and alternator 4P connector terminal No. 2.
Is there continuity?
YES - Replace the alternator, or repair the alternator. ■
NO - Repair open in the wire between the alternator and the ECM/PCM.■
Charging System Indicator Circuit Troubleshooting
1. Turn the ignition switch to ON (II).
Does the charging system indicator come on?
YES - Go to Step 2 .
NO - Go to Step 14 .
2. Start the engine. Hold the engine speed at 2,000 rpm (min −1 ) for 1 minute.
Does the charging system indicator go off?
YES - Charging system indicator circuit is OK. Go to the alternator and regulator circuit troubleshooting. ■
NO - Go to Step 3 .
3. Do the gauge control module self-diagnostic function procedure.
Does the charging system indicator flash?
YES - Go to Step 4 .
NO - Replace the gauge control module .■
4. Turn the ignition switch to LOCK (0).
5. Disconnect the alternator 4P connector.
6. Turn the ignition switch to ON (II).
NOTE: The charging system indicator may come on and then go off.
Does the charging system indicator go off?
YES - Replace the alternator, or repair the alternator. ■
NO - Go to Step 7 .
7. Turn the ignition switch to LOCK (0).
8. Connect the Honda Diagnostic System (HDS) to the data link connector (DLC).
9. Turn the ignition switch to ON (II).
10. Make sure the HDS communicates with the vehicle and the engine control module (ECM)/powertrain control
module (PCM). If it doesn't communicate, troubleshoot the DLC circuit.
11. Jump the SCS line with the HDS, then turn the ignition switch to LOCK (0).
NOTE: This step must be done to protect the ECM/PCM from damage.
12. Disconnect ECM/PCM connector B (49P).
13. Check for continuity between ECM/PCM connector terminal B46 and body ground.
Is there continuity?
YES - Repair short in the wire between the alternator and the ECM/PCM (B46).■
NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original
ECM/PCM. ■
14. Do the gauge control module self-diagnostic function procedure.
Does the charging system indicator flash?
YES - Go to Step 15 .
NO - Replace the gauge control module. ■
15. Turn the ignition switch to LOCK (0).
16. Disconnect the alternator 4P connector.
17. Connect alternator 4P connector terminal No. 3 to body ground with a jumper wire.
18. Turn the ignition switch to ON (II).
Does the charging system indicator come on?
YES - Replace the alternator, or repair the alternator. ■
NO - Disconnect the jumper wire, then go to Step 19 .
19. Connect the HDS to the DLC.
20. Turn the ignition switch to ON (II).
21. Make sure the HDS communicates with the vehicle and the ECM/PCM. If it doesn't communicate, troubleshoot the
DLC circuit.
22. Jump the SCS line with the HDS, then turn the ignition switch to LOCK (0).
NOTE: This step must be done to protect the ECM/PCM from damage.
23. Disconnect ECM/PCM connector B (49P).
24. Check for continuity between ECM/PCM connector terminal B46 and alternator 4P connector terminal No. 3.
Is there continuity?
YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original
ECM/PCM. ■
NO - Repair open in the wire between the alternator and the ECM/PCM.■
Drive Belt Inspection
1. Inspect the belt for cracks or damage. If the belt is cracked or damaged, replace it.
2. Check the position of the auto-tensioner indicator's pointer (A) is within the standard range (B) as shown. If it is out
of the standard range, replace the drive belt.
Drive Belt Auto-tensioner Removal/Installation
1. Remove the drive belt.
2. Remove the auto-tensioner
3. Install the auto-tensioner in the reverse order of removal.
Drive Belt Auto-tensioner Inspection
1. Turn the ignition switch to ON (II), and make sure to turn the A/C switch off. Turn the ignition switch to LOCK (0).
2. Check the position of the auto-tensioner indicator's pointer (A). Start the engine then check the position again with
the engine idling. If the position of the indicator moves or fluctuates very much, replace the auto-tensioner.
3. Check for abnormal noise from the tensioner pulley. If you hear abnormal noise, replace the tensioner pulley.
4. Remove the drive belt.
5. Move the auto-tensioner within its limit with a wrench in the direction shown. Check that the tensioner moves
smoothly and without any abnormal noise. If the tensioner does not move smoothly or if you hear abnormal noise,
replace the auto-tensioner.
6. Remove the auto-tensioner.
7. Clamp the auto-tensioner (A) by using two 8 mm bolts (B) and a vise (C) as shown. Do not clamp the auto-
tensioner itself.
8. Set the torque wrench (D) on the pulley bolt, and align it as shown.
9. Align the indicator (E) on the tensioner base with Max. belt position mark (F) on the tensioner arm by using the
torque wrench, and measure the torque. If the torque value is out of specification, replace the auto-tensioner.
NOTE: If the indicator exceeds the Max. belt position mark, recheck the torque.
Auto-tensioner Spring Torque:
20.6−25.2 N·m (2.10−2.25 kgf·m, 15.2−18.6 lbf·ft)
Drive Belt Auto-tensioner Pulley Replacement
1. Remove the auto-tensioner.
2. Remove the tensioner pulley.
3. Install the auto-tensioner in the reverse order of removal.
Coolant Check
1. Look at the coolant level in the coolant reservoir. Make sure it is between the MAX mark (A) and MIN mark (B).
2. If the coolant level in the coolant reservoir is at or below the MIN mark, add coolant to bring it up to the MAX mark,
then inspect the cooling system for leaks.
Radiator Test
1. Wait until the engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant to the
top of the filler neck.
2. Attach the pressure tester (A) (commercially available) to the radiator. Use a small adapter H-901122-09 (B)
(commercially available) to attach the pressure tester.
4. Disconnect the fan motor connectors (A), the hood latch switch connector (B), and the horn connector (C), then RHD model
remove the ground cable (D) and the harness clamps (E).
LHD model
5. Remove the bulkhead mounting bolts, and remove the hood opener cable clamp (A), then remove the bulkhead (B).
6. Raise the vehicle on the lift to full height.
7. Disconnect the engine coolant temperature (ECT) sensor 2 connector (A), and remove the A/C compressor clutch
connector (B) from the clamp.
8. Remove the harness clamps (C).
13. Pull up the radiator (A), then remove the coolant reservoir (B), the radiator fan shroud assembly (C), the A/C
condenser fan shroud assembly (D), the radiator cap (E), the ETC sensor 2 (F), and the drain plug (G).
14. Reassemble the radiator with new O-rings (H).
15. Install the radiator. Make sure the lower cushions (I) are set securely.
16. Install the upper radiator hose.
17. Raise the vehicle on the lift to full height.
20. Connect the ECT sensor 2 connector (A), and install the A/C compressor clutch connector (B) to the clamp.
21. Install the harness clamps (C).
22. Lower the vehicle on the lift.
23. Install the hood opener cable clamp (A), then install the bulkhead (B).
24. Apply body paint to the bulkhead mounting bolts.
25. Connect the fan motor connectors (A), the hood latch switch connector (B), and the horn connector (C), then install RHD model
the ground cable (D) and the harness clamps (E).
26. Install the front bumper.
LHD model
4. Remove the A/C compressor clutch connector (A) from the clamp, then remove the harness clamps (B).
5. Lower the vehicle on the lift.
6. Disconnect the fan motor connectors (A), the hood latch switch connector (B), and the horn connector (C), then RHD model
remove the ground cable (D) and the harness clamps (E).
LHD model
7. Remove the bulkhead mounting bolts, and remove the hood opener cable clamp (A), then remove the bulkhead (B).
Installation
1. Assemble the fan shrouds.
2. Install the radiator fan shroud assembly (A), then install the condenser fan shroud assembly (B).
3. Install the coolant reservoir (C).
4. Install the hood opener cable clamp (A), then install the bulkhead (B).
5. Apply body paint to the bulkhead mounting bolts.
6. Connect the fan motor connectors (A), the hood latch switch connector (B), and the horn connector (C), then install RHD model
the ground cable (D) and the harness clamps (E).
7. Raise the vehicle on the lift to full height.
LHD model
8. Install the A/C compressor clutch connector (A) to the clamp, then install the harness clamps (B).
9. Lower the vehicle on the lift.
10. Install the front bumper.
Standard Thermostat
Lift Height: Above 8.0 mm (0.31 in.)
Starts Opening: 76−80 °C (169−176 °F)
Fully Open: 90 °C (194 °F)
Thermostat Replacement
1. Drain the engine coolant.
2. Remove the thermostat cover (A), then remove the thermostat (B).
3. Install the new rubber seal (C) onto the thermostat, then install the thermostat with the pin (D) up, and install the
thermostat cover.
4. Refill the radiator with engine coolant, then bleed the air from the cooling system.
5. Clean up any spilled engine coolant.
Thermostat Housing Removal and Installation
Removal
1. Drain the engine coolant.
2. Remove the coolant reservoir.
3. Remove the harness holder mounting bolt, then remove the harness holder (A) from the bracket.
4. Disconnect the lower radiator hose (A), the heater hose (B), and the water bypass hoses (C).
5. Remove the thermostat housing assembly (D), then remove the thermostat (E).
Installation
1. Install the new rubber seal (A) onto the thermostat, then install the thermostat (B) with pin (C) up, and install the
thermostat cover (D).
2. Install the thermostat housing Assembly (E) with new O-ring (F).
3. Install the lower radiator hose (G), the heater hose (H), and the water bypass hoses (I).
5. Disconnect the upper radiator hose (A) and the water bypass hose (B).
6. Disconnect the engine coolant temperature (ECT) sensor 1 connector, then remove the water outlet.
7. Remove the ECT sensor 1 (A) and the water bypass hose (B).
Installation
1. Install the ECT sensor 1 (A) with new O-ring (B).
2. Install the water bypass hose (C).
3. Remove the all of the old liquid gasket from the water outlet mating surfaces, the bolts, and the bolt holes.
4. Clean and dry the water outlet mating surfaces.
5. Apply liquid gasket (P/N 08C70-K0234M, 08C70-K0334M, or 08C70-X0331S) to the cylinder head mating surface of
the water outlet and to the inner threads of the bolt holes.
NOTE:
Apply liquid gasket about 2.5 mm (0.098 in.) diameter bead along the broken line (A).
Do not install components if 5 minutes or more have passed after applying the liquid gasket. Instead, remove
the old residue and reapply the liquid gasket.
7. Install the upper radiator hose (A) and the heater hose (B).
8. Install the harness holder (A), then tighten the harness holder mounting bolt (B) and the heater hose clamp bracket
mounting bolt (C).
9. Install the water bypass hose (D).
10. Clean up any spilled engine coolant.
11. Install the air cleaner housing assembly.
12. Refill the radiator with engine coolant, and bleed the air from the cooling system with the heater valve open.
Water Pump Replacement
1. Drain the engine coolant.
2. Remove the right front wheel.
3. Remove the right side splash shield.
4. Loosen the water pump pulley mounting bolts.
5. Remove the drive belt.
6. Remove the water pump pulley.
6. Turn the water pump counterclockwise, and make sure that it turns freely. If it doesn't, replace the water pump.
NOTE: When you check the water pump, you may see a small amount of ‘‘weeping'' from the bleed holes (A). This
is normal.
7. Install the water pump pulley.
8. Install the drive belt.
9. Tighten the water pump pulley mounting bolts.
10. Install the right side splash shield.
11. Install the right front wheel.
Cooling Fan Controls Component Location Index
CONDENSER FAN
RELAY
Test,
CONDENSER FAN RELAY
Test, RADIATOR FAN RELAY
Test,
RADIATOR FAN RELAY
Test,
ENGINE COOLANT
TEMPERATURE (ECT)
SENSOR 1
Replacement,
BATTERY TERMINAL
FUSE BOX UNDER−DASH FUSE/RELAY BOX IGNITION SWITCH
BATTERY
No. 1 (100 A) T−9 No. 60 (50 A) T1 2 BAT
WHT WHT
IG2
No. 30 (30 A) No. 47 (30 A)
3
No. 10 (7.5 A) S1
ORN
RHD model: 2
LHD model: 1 4 4 2
RADIATOR CONDENSER
FAN RELAY FAN RELAY
RHD model: 1 3 3 1
LHD model: 2
2 2
RADIATOR CONDENSER
FAN MOTOR FAN MOTOR
1 1
BLK BLK
G202 G202
A6 ECM/PCM
FANC
5V
B2 B3 A1 A34
1 2 1 2
11. Check for continuity between the radiator fan relay 4P socket terminal No. 3 and ECM/PCM connector terminal A6.
Is there continuity?
YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
recheck. If the symptom goes away with a known good ECM/PCM, replace the original ECM/PCM. ■
NO - Repair open in the wire between the radiator fan relay 4P socket terminal No. 3 and ECM/PCM connector
terminal A6.■
Radiator Fan Circuit Troubleshooting
1. Check the No. 30 (30 A) fuse in the under-dash fuse/relay box.
Is the fuse OK?
YES - Go to Step 2 .
NO - Replace the fuse and recheck.■
2. Remove the radiator fan relay, and test the radiator fan relay.
Is the relay OK?
YES - RHD model: Go to Step 3 .
LHD model: Go to Step 6 .
NO - Replace the radiator fan relay and recheck.■
3. Measure the voltage between the radiator fan relay 4P socket terminal No. 2 and body ground.
Is there battery voltage?
YES - Go to Step 4 .
NO - Repair open in the wire between the under-dash fuse/relay box and the radiator fan relay 4P socket
terminal No. 2.■
4. Disconnect the radiator fan motor 2P connector.
5. Check for continuity between the radiator fan relay 4P socket terminal No. 1 and the radiator fan motor 2P
connector terminal No. 2.
Is there continuity?
YES - Go to Step 9 .
NO - Repair open in the wire between the radiator fan relay 4P socket terminal No. 1 and the radiator fan motor
2P connector terminal No. 2.■
6. Measure the voltage between the radiator fan relay 4P socket terminal No. 1 and body ground.
Is there battery voltage?
YES - Go to Step 7 .
NO - Repair open in the wire between the under-dash fuse/relay box and the radiator fan relay 4P socket
terminal No. 1.■
7. Disconnect the radiator fan motor 2P connector.
8. Check for continuity between the radiator fan relay 4P socket terminal No. 2 and the radiator fan motor 2P
connector terminal No. 2.
Is there continuity?
YES - Go to Step 9 .
NO - Repair open in the wire between the radiator fan relay 4P socket terminal No. 2 and the radiator fan motor
2P connector terminal No. 2.■
9. Check for continuity between the radiator fan motor 2P connector terminal No. 1 and body ground.
Is there continuity?
YES - Replace the radiator fan motor. ■
NO - Repair open in the wire between the radiator fan motor 2P connector terminal No. 1 and body ground. If
the wire is OK, check for a poor ground at G202.■
Cruise Control Combination Switch Test
SRS components are located in this area. Review the SRS component locations, and the precautions and procedures, in
the SRS before doing repairs or service.
1. Remove the driver's airbag.
2. Disconnect the 20P connector from the cable reel.
3. Check for continuity between the terminals in each switch position according to the table.
If there is continuity, and it matches the table, but switch failure occurred on the cruise control input test,
check and repair the wire harness on the switch circuit.
If there is no continuity in one or more positions, replace the switch.
12. If the compression is not within specifications, check the following items, then remeasure the compression.
Damaged or worn valves and seats
Damaged cylinder head gasket
Damaged or worn piston rings
Damaged or worn piston and cylinder bore
13. Select ECM/PCM reset to cancel the ALL INJECTORS STOP function on the HDS.
Cylinder Head Inspection for Warpage
1. Remove the cylinder head.
2. Inspect the camshaft.
3. Check the cylinder head for warpage. Measure along the edges, and three ways across the center.
Warpage
Standard (New): 0.07 mm (0.0028 in.)
Service Limit: 0.08 mm (0.0031 in.)
If warpage is less than 0.08 mm (0.003 in.) cylinder head resurfacing is not required.
If warpage is between 0.08 mm (0.003 in.) and 0.2 mm (0.008 in.), resurface the cylinder head.
Maximum resurface limit is 0.2 mm (0.008 in.) based on a height of 120 mm (4.72 in.).
Cylinder Head Height
Standard (New): 119.9−120.1 mm (4.720−4.728 in.)
Cylinder Head Cover Removal
1. Remove the intake manifold chamber.
2. Disconnect the four ignition coil connectors.
3. Remove the harness holder (A) and the breather hose (B).
4. Apply liquid gasket (P/N 08C70-K0234M, 08C70-K0334M, or 08C70-X0331S) to the chain case contact areas (A).
NOTE:
Apply liquid gasket about 2.5 mm (0.098 in.) diameter bead to the chain case contact areas.
Do not install components if 5 minutes or more have passed after applying the liquid gasket. Instead, remove
the old residue and reapply the liquid gasket.
5. Place the cylinder head cover (A) on the cylinder head, then slide the cover slightly back and forth to seat the head
cover gasket.
6. Tighten the bolts in three steps. In the final step tighten all bolts, in sequence, to 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft).
NOTE:
Wait at least 30 minutes before filling the engine with oil.
Do not run the engine for at least 3 hours after installing the head cover.
7. Install the harness holder (A) and the breather hose (B).
8. Connect the four ignition coil connectors.
9. Install the intake manifold chamber.
Camshaft Sprocket Removal
NOTE: Keep the cam chain away from magnetic fields.
1. Remove the cylinder head cover.
2. Make a reference mark (A) across the camshaft sprocket and cam chain.
3. Apply new engine oil to the slider surface of the cam chain tensioner slider through the oil return hole in the cylinder
head.
5. Hold the crankshaft pulley and set the socket wrench (A) on the camshaft sprocket bolt.
6. Remove the maintenance bolt (B), and turn the camshaft clockwise to compress the cam chain tensioner, then
install the 6 x 1.0 mm bolt (C) in the bolt hole (D) on the engine block through the maintenance hole and cam chain
tensioner (E).
NOTE:
Turning torque should not exceed 56 N·m (5.7 kgf·m, 41 lbf·ft), when turning the camshaft.
Do not turn the camshaft counterclockwise.
7. Hold the camshaft with a 27 mm open-end wrench, then remove the camshaft sprocket.
NOTE: Hang the cam chain with a wire.
Camshaft Sprocket Installation
NOTE: Keep the cam chain away from magnetic fields.
1. Install the cam chain to the camshaft sprocket by alignment the reference mark (A), then install the camshaft
sprocket on the camshaft.
2. Hold the camshaft with a 27 mm open-end wrench, then tighten the bolt.
Specified torque:
56 N·m (5.7 kgf·m, 41 lbf·ft)
3. Apply new engine oil to the slider surface of the cam chain tensioner slider through the oil return hole in the cylinder
head.
4. Hold the crankshaft pulley and set the socket wrench (A) on the camshaft sprocket bolt.
5. Turn the camshaft clockwise to compress the cam chain tensioner, then remove the 6 x 1.0 mm bolt (B).
NOTE:
Turning torque should not exceed 56 N·m (5.7 kgf·m, 41 lbf·ft), when turning the camshaft.
Do not turn the camshaft counterclockwise.
6. Install the maintenance bolt (C) with a new washer (D).
7. Hold the camshaft with an open-end wrench, then loosen the bolt.
Installation
1. Install the CMP pulse plate.
2. Hold the camshaft with an open-end wrench, then tighten the bolt.
Specified Torque
14 x 1.5 mm 34 N·m (3.5 kgf·m, 25 lbf·ft)
3. Install the camshaft thrust cover (A) with new O-ring (B).
4. Install the cylinder head cover.
5. Install the harness holder, then install the ground cable.
6. Install the following engine wire harness connectors and wire harness clamps from the cylinder head:
Four injector connector
Engine coolant temperature (ECT) sensor 1 connector
Camshaft position (CMP) sensor connector
Air fuel ratio (A/F) sensor connector
Secondary heated oxygen sensor (secondary HO2S) connector
7. Install the intake manifold chamber.
8. Install the air cleaner housing assembly.
Crankshaft Pulley Removal and Installation
Special Tools Required
Handle, 6-25-660L
07JAB-001020B
Installation
1. Clean the crankshaft pulley (A), the crankshaft (B), the bolt (C), and the washer (D). Lubricate with new engine oil
as shown.
2. Install the crankshaft pulley.
2. Measure the distance between the chain case surface and the oil seal.
Oil Seal Installed Height:
30.3−31.0 mm (1.19−1.22 in.)
Cylinder Head Valve, Spring, and Valve Seal Removal
Special Tools Required
Valve spring compressor
07757-0010000
Identify the valves and the valve springs as they are removed so that each item can be reinstalled in its original position.
1. Remove the cylinder head.
2. Using an appropriate-sized socket (A), and a plastic mallet (B), lightly tap the spring retainer to loosen the valve
cotters.
3. Install valve the spring compressor. Compress the spring, and remove the valve cotters.
4. Remove the valve spring compressor, then remove the spring retainer, the valve spring, the valve seal, and the valve
spring seat.
Cylinder Head Valve, Spring, and Valve Seal Installation
Special Tools Required
Stem seal driver
07PAD-0010000
7. Install the valve spring compressor. Compress the spring, and install the valve cotters.
8. Lightly tap the end of each valve stem three times with a plastic mallet (A) to ensure proper seating of the valve and
valve cotters. Tap the valve stem only along its axis so you do not bend the stem.
Cylinder Head Valve Inspection
1. Remove the valves.
2. Measure the valve in these areas.
Intake Valve Dimensions
A Standard (New): 27.85−28.15 mm (1.096−1.108 in.)
B Standard (New): 118.55−119.15 mm (4.667−4.691 in.)
C Standard (New): 5.48−5.49 mm (0.2157−0.2161 in.)
C Service Limit: 5.45 mm (0.215 in.)
Exhaust Valve Dimensions
A Standard (New): 22.85−23.15 mm (0.900−0.911 in.)
B Standard (New): 117.25−117.85 mm (4.616−4.640 in.)
C Standard (New): 5.45−5.46 mm (0.2146−0.2150 in.)
C Service Limit: 5.42 mm (0.213 in.)
Cylinder Head Valve Guide Replacement
Special Tools Required
Valve guide driver, 5.35 x 9.7
07742-0010100
4. Use a hot plate or oven to evenly heat the cylinder head to 150 °C (300 °F). Monitor the temperature with a cooking
thermometer. Do not get the head hotter than 150 °C (300 °F); excessive heat may loosen the valve seats.
5. Working from the camshaft side, use the valve guide driver and an air hammer to drive the guide about 2 mm (0.1
in.) towards the combustion chamber. This will knock off some of the carbon and make removal easier. Hold the air
hammer directly in line with the valve guide to prevent damaging the driver.
6. Turn the head over, and drive the guide out toward the camshaft side of the head.
7. If a valve guide won't move, drill it out with a 8 mm (5/16 in.) bit, then try again. Drill guides only in extreme cases;
you could damage the cylinder head if the guide breaks.
8. Remove the new guide(s) from the freezer, one at a time, as you need them.
9. Apply a thin coat of new engine oil to the outside of the new valve guide. Install the guide from the camshaft side of
the head; use the valve guide driver to drive the guide in to the specified installed height (A) of the guide (B). If you
have all 16 guides to do, you may have to reheat the head.
10. Coat both reamer and valve guide with cutting oil.
11. Rotate the reamer clockwise the full length of the valve guide bore.
12. Continue to rotate the reamer clockwise while removing it from the bore.
13. Thoroughly wash the guide in detergent and water to remove any cutting residue.
14. Check the clearances with a valve. Verify that a valve slides in the intake and exhaust valve guides without sticking.
15. Inspect the valve seat. If necessary renew the valve seat using a valve seat cutter.
Cylinder Head Valve Stem-to-Guide Clearance Inspection
1. Remove the valves.
2. Subtract the O.D. of the valve stem, measured with a micrometer, from the I.D. of the valve guide, measured with an
inside micrometer or ball gauge.
Take the measurements in three places along the valve stem and three places inside the valve guide.
The difference between the largest guide measurement and the smallest stem measurement should not exceed the
service limit.
4. Bevel the upper and lower edges at the angles shown in the illustration.Check the width of the seat and adjust
accordingly.
5. Make one more very light pass with the 45 ° cutter to remove any possible burrs caused by the other cutters.
6. After resurfacing the seat, inspect for even valve seating: Apply Prussian Blue compound (A) to the valve face.
Insert the valve in its original location in the head, then lift it and snap it closed against the seat several times.
7. The actual valve seating surface (B), as shown by the blue compound, should be centered on the seat.
If it is too high (closer to the valve stem), you must make a second cut with the 67.5 ° cutter (intake) or 60 °
cutter (exhaust) to move it down, then one more cut with the 45 ° cutter to restore seat width.
If it is too low (close to the valve edge), you must make a second cut with the 30 ° cutter to move it up, then
make one more cut with the 45 ° cutter to restore seat width.
NOTE: The final cut should always be made with the 45 ° cutter.
8. Insert the intake and exhaust valves in the head, and measure valve stem installed height (A).
9. If valve stem installed height is over the service limit, replace the valve and recheck. If it is still over the service limit,
replace the cylinder head; the valve seat in the head is too deep.
VTEC Rocker Arm Oil Control Valve Removal/Installation
1. Remove the harness holder (A).
A/T model
Engine Mount Torque Rod Bracket Replacement
1. Raise the vehicle on the lift to full height.
2. A/T model: Remove the shift cable cover.
3. Support the transmission with a jack and wood block under the transmission.
A/T model
A/T model
7. Install the torque rod (A). Install the new bolt with the tab (B) on the bolt head aligned with the guide (C) on the front M/T model
subframe, then tighten the new torque rod mounting bolt and nut in the numbered sequence shown.
A/T model
3. Remove the ground cable (A), then remove the side engine mount/bracket assembly (B).
4. Install the side engine mount/bracket assembly, then tighten the new side engine mount/bracket assembly
mounting bolts (C).
5. Loosely tighten the new side engine mount/bracket assembly mounting nuts (D) and install the ground cable.
6. Remove the air cleaner housing assembly.
7. Loosen the transmission mount bracket mounting bolts and nuts (A). M/T model
8. Raise the vehicle on the lift to full height.
A/T model
9. Loosen the torque rod mounting bolt and nut (A). M/T model
10. Lower the vehicle on the lift.
A/T model
11. Tighten the side engine mount/bracket assembly mounting nuts in the numbered sequence shown.
12. Tighten the transmission mount mounting bolts and nuts in the numbered sequence shown. M/T model
13. Raise the vehicle on the lift to full height.
A/T model
14. Tighten the torque rod mounting bolt and nut in the numbered sequence shown. M/T model
15. Lower the vehicle on the lift.
A/T model
5. With M/T model: Remove the harness clamp (A). Remove the two bolts (B) and loosen the two bolts (C), then
remove the battery base (D).
6. Support the transmission with a jack and wood block under the transmission.
7. Remove the ground cable (A), then remove the transmission mount bracket (B). M/T model
8. Install the transmission mount bracket, and loosely tighten the new transmission mount bracket mounting bolts
and nuts (C).
9. Install the ground cable.
10. Raise the vehicle on the lift to full height.
A/T model
11. Loosen the torque rod mounting bolt and nut (A). M/T model
A/T model
12. Tighten the transmission mount mounting bolts and nuts in the numbered sequence shown. M/T model
13. Raise the vehicle on the lift to full height.
A/T model
14. Tighten the torque rod mounting bolt and nut in the numbered sequence shown. M/T model
A/T model
15. With M/T model: Install the battery base (A), then install the harness clamp (B).
16. With M/T model: Install the battery cables (A) to the battery terminal fuse box.
17. With M/T model: Install the harness clamps (B).
18. Do the battery installation procedure.
19. Install the air cleaner housing assembly.
Transmission Mount Replacement
1. Remove the battery.
2. Remove the air cleaner housing assembly.
3. With M/T model: Remove the battery cables (A) from the battery terminal fuse box.
4. With M/T model: Remove the harness clamps (B).
5. With M/T model: Remove the harness clamp (A). Remove the two bolts (B) and loosen the two bolts (C), then
remove the battery base (D).
6. Support the transmission with a jack and wood block under the transmission.
7. Remove the ground cable (A), then remove the transmission mount bracket (B). M/T model
A/T model
A/T model
10. Install the transmission mount bracket (A), and loosely tighten the new transmission mount bracket mounting bolts M/T model
and nuts (B).
11. Install the ground cable (C).
12. Raise the vehicle on the lift to full height.
A/T model
13. Loosen the torque rod mounting bolt and nut (A). M/T model
A/T model
14. Tighten the transmission mount mounting bolts and nuts in the numbered sequence shown. M/T model
15. Raise the vehicle on the lift to full height.
A/T model
16. Tighten the torque rod mounting bolt and nut in the numbered sequence shown. M/T model
A/T model
17. With M/T model: Install the battery base (A), then install the harness clamp (B).
18. With M/T model: Install the battery cables (A) to the battery terminal fuse box.
19. With M/T model: Install the harness clamps (B).
20. Install the battery.
21. Install the air cleaner housing assembly.
Engine Block Cylinder Bore Honing
Only a scored or scratched cylinder bore must be honed.
1. Measure the cylinder bores.
If the engine block is to be reused, hone the cylinders and remeasure the bores.
2. Hone the cylinder bores with honing oil and a fine (400 grit) stone in a 60 degree cross-hatch pattern (A). Use only
a rigid hone with 400 grit or finer stone such as Sunnen, Ammco, or equivalent. Do not use stones that are worn or
broken.
3. When honing is complete, thoroughly clean the engine block of all metal particles. Wash the cylinder bores with
hot soapy water, then dry and oil them immediately to prevent rusting. Never use solvent, it will only redistribute the
grit on the cylinder walls.
4. If scoring or scratches are still present in the cylinder bores after honing the engine block to the service limit, rebore
the engine block. Some light vertical scoring and scratching is acceptable if it is not deep enough to catch your
fingernail and does not run the full length of the bore.
Engine Block Drain Bolt/Sealing Bolt Installation
NOTE: When installing the drain bolt and/or sealing bolt, always use new washer.
Engine Oil Pan Removal
1. If the engine is already out of the vehicle, go to Step 7 .
2. Drain the engine oil.
3. Remove the drive belt.
4. Remove the driveshaft heat shield.
5. Remove the A/C compressor without disconnecting the A/C hoses.
6. A/T model: Remove the shift cable cover.
7. M/T model: Remove the torque rod bracket.
9. Remove the crankshaft position (CKP) sensor cover (A), then disconnect the CKP sensor connector (B).
10. Remove the clutch cover/torque converter cover (A), and transmission mounting bolts (B). M/T model
11. Remove the bolts securing the oil pan.
A/T model
12. Using a flat blade screwdriver, separate the oil pan from the block in the places shown.
13. Remove the oil pan.
Engine Oil Pan Installation
1. Remove any old liquid gasket from the oil pan mating surfaces, bolts and bolt holes.
2. Clean and dry the oil pan mating surfaces.
3. Install the new oil pan gasket (A), new O-ring (B), and dowel pins (C) on the oil pan.
4. Apply liquid gasket (P/N 08C70-K0234M, 08C70-K0334M, or 08C70-X0331S) to the engine block mating surface of
the oil pan and to the inner threads of the bolt holes.
NOTE:
Apply liquid gasket about 2.5 mm (0.098 in.) diameter bead along the broken line (A).
Apply liquid gasket about 5.0 mm (0.20 in.) diameter bead to the shaded area (B).
Do not install components if 5 minutes or more have passed after applying the liquid gasket. Instead, remove
the old residue and reapply the liquid gasket.
6. Tighten the bolts in three steps. Wipe off the excess liquid gasket on the each side of crankshaft pulley and the
flywheel/drive plate.
Specified torque
(1): 24 N·m (2.4 kgf·m, 17 lbf·ft)
(2)−(13): 12 N·m (1.2 kgf·m, 8.8 lbf·ft)
7. Install the clutch cover/torque converter cover (A), and install the transmission mounting bolts (B). M/T model
A/T model
8. Connect the CKP sensor connector (A), then install the CKP sensor cover (B).
9. Install the dipstick tube (A) with new O-ring (B), then install the dipstick.
10. M/T model: Install the torque rod bracket.
11. If the engine is still in the vehicle, do Step 12 through 16.
12. A/T model: Install the shift cable cover.
13. Install the A/C compressor.
14. Install the driveshaft heat shield.
15. Install the drive belt.
16. Refill the engine with engine oil.
Connecting Rod and Crankshaft End Play Inspection
1. Remove the oil pump.
2. Measure the connecting rod end play with a feeler gauge between the connecting rod and the crankshaft.
3. If the connecting rod end play is beyond the service limit, install a new connecting rod, and recheck. If it is still
beyond the service limit, replace the crankshaft.
4. Push the crankshaft firmly away from the dial indicator, and zero the dial against the end of the crankshaft. Then
pull the crankshaft firmly back toward the indicator; the dial reading should not exceed the service limit.
5. If the end play is beyond the service limit, replace the thrust washers and recheck, if it is still beyond the service
limit, replace the crankshaft.
Connecting Rod Bolt Inspection
1. Measure the diameter of each connecting rod bolt at point A and point B with a micrometer.
2. Calculate the difference in diameter between point A and point B.
Point A−Point B = Difference in Diameter
Difference in Diameter:
Specification: 0−0.05 mm (0−0.002 in.)
3. If the difference in diameter is out of specification, replace the connecting rod bolt.
Crankshaft and Piston Removal
1. Remove the engine/transmission.
2. Remove the transmission:
Manual transmission
Automatic transmission
3. M/T model: Remove the pressure plate, clutch disc, and flywheel.
4. A/T model: Remove the drive plate.
5. Remove the crankshaft position (CKP) sensor cover (A), then disconnect the CKP sensor connector (B).
6. Remove the harness cover (C).
7. Remove the oil pan.
8. Remove the oil pump.
9. Remove the cylinder head.
10. Remove the bearing cap bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the
sequence until all bolts are loosened.
11. Remove the bearing cap bridge.
12. Remove the rod caps/bearings. Keep all caps/ bearings in order.
13. Lift crankshaft (A) out of the engine. Be careful not to damage the journals and the CKP pulse plate (B).
14. Remove the CKP pulse plate.
15. Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps.
16. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A).
Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the pistons as they are
pushed out.
17. Use the wooden handle of a hammer (A) to drive out the piston/connecting rod assembly (B). Take care not to
damage the cylinder with the connecting rod.
18. Reinstall the bearing cap bridge and bearings on the engine in the proper order.
19. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly.
20. Mark each piston/connecting rod assembly with its cylinder number to make sure they are reused in original order.
NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod
bore size.
Crankshaft/Oil Seal (Transmission End) Installation
Special Tools Required
Driver handle, 15 x 135L
07749-0010000
3. Measure the distance between the crankshaft surface and crankshaft end bushing.
Oil Seal Installed Height:
0.9−1.1 mm (0.035−0.043 in.)
8. Install the crankshaft position (CKP) pulse plate (A) on the crankshaft (B); face the marked side (C) opposite the
crankshaft, and align the tab (D) on the CKP pulse plate with the groove (E) on the crankshaft.
9. Hold the crankshaft so that rod journal No. 2 and rod journal No. 3 are straight up, and lower the crankshaft into the
engine block.
10. Apply new engine oil to the thrust washer surfaces. Install the thrust washers (A) in the No. 4 journal of the engine
block.
11. Inspect the connecting rod bolts.
12. Apply new engine oil to the threads and flange of the connecting rod bolts.
13. Seat the rod journals into connecting rod No. 1 and connecting rod No. 4. Line up the mark (A) on the connecting
rod and the cap, then install the caps and the bolts finger-tight.
14. Rotate the crankshaft clockwise, and seat the journals into connecting rod No. 2 and connecting rod No. 3. Line up
the mark on the connecting rod and the cap, then install the caps and the bolts finger-tight.
15. Tighten the connecting rod bolts to 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft).
17. With L15A7 engine: Install the bearing caps with facing the arrows (A) to the cam chain side on the bearing cap
bridge.
18. Remove old liquid gasket from the bearing cap bridge/No. 5 bearing cap mating surfaces.
19. Clean and dry the bearing cap bridge/No. 5 bearing cap mating surfaces.
20. Apply liquid gasket (P/N 08C70-K0234M, 08C70-K0334M, or 08C70-X0331S) to the engine block mating surface of
the bearing cap bridge/No. 5 bearing cap.
NOTE:
Apply liquid gasket about 2.5 mm (0.098 in.) diameter bead along the broken line (A).
Do not install components if 5 minutes or more have passed after applying the liquid gasket. Instead, remove
the old residue and reapply the liquid gasket.
21. Put the bearing cap bridge on the engine block.
22. Apply engine oil to the threads and flange of the bearing cap bolts.
23. Tighten the bearing cap bolts is sequence to 25 N·m (2.5 kgf·m, 18 lbf·ft).
26. Use the special tools to drive a new oil seal squarely into the block to the specified installed height.
27. Measure the distance between the crankshaft (A) and oil seal (B).
Oil Seal Installed Height:
7−8 mm (0.28−0.31 in.)
31. Connect the CKP sensor connector (A), then install the CKP sensor cover (B).
32. Install the harness cover (C).
33. M/T model: Install the flywheel, clutch disc, and pressure plate.
34. A/T model: Install the drive plate.
35. Install the transmission:
Manual transmission
Automatic transmission
36. Install the engine/transmission.
NOTE: Whenever any crankshaft or connecting rod bearing is replaced, run the engine at idle speed until it reaches
normal operating temperature, then continue to running it for about 15 minutes.
Crankshaft Inspection
Out-of-Round and Taper
1. Remove the crankshaft from the engine block.
2. Clean the crankshaft oil passages with pipe cleaners or a suitable brush.
3. Clean the keyway and threads.
4. Measure the out-of-round at the middle of each rod and the main journal in two places. The difference between
measurements on each journal must not be more than the service limit.
Journal Out-of-Round
Standard (New): 0.005 mm (0.0002 in.) max.
Service Limit: 0.010 mm (0.0004 in.)
5. Measure the taper at the edges of each rod and the main journal. The difference between measurements on each
journal must not be more than the service limit.
Journal Taper
Standard (New): 0.005 mm (0.0002 in.) max.
Service Limit: 0.010 mm (0.0004 in.)
Straightness
6. Place the engine block on a flat surface, crankshaft side up.
7. Clean and install the bearings on the No. 1 and No. 5 journals of the engine block.
8. Lower the crankshaft into the engine block.
9. Measure the runout on all main journals. Rotate the crankshaft two complete revolutions. The difference between
measurements on each journal must not be more than the service limit.
Crankshaft Total Runout
Standard (New): 0.03 mm (0.0012 in.) max.
Service Limit: 0.04 mm (0.0016 in.)
CKP Pulse Plate Replacement
1. Remove the crankshaft.
2. Remove the crankshaft position (CKP) pulse plate (A).
3. Install the CKP pulse plate on the crankshaft (B); face the marked side (C) opposite the crankshaft, and align the
tab (D) on the CKP pulse plate with the groove (E) on the crankshaft.
4. Install the crankshaft.
Piston, Pin, and Connecting Rod Replacement
Special Tools Required
Piston base head
07PAF-0010400
Insert adjuster
070AF-PWC0120
Pilot collar, 18 mm
070AF-PWC0130
Piston base
07973-6570500
Spring
07973-6570600
Disassembly
1. Assemble the special tool as shown.
2. Temporarily install the pilot collar over the piston pin base insert (A), and adjust the piston base head inserts as
shown, then tighten the screws (B). Remove the pilot collar.
3. Assemble and adjust the length of the piston pin driver head and shaft to 57 mm (2.2 in.).
4. With the arrow on top of the piston pointing up, place the piston assembly (A) on the special tool (B).
Be sure you position the recessed flat area of the piston against the piston base head inserts (C) as shown.
5. Press the pin (D) out with the pin driver (E), the pilot collar (F), and a hydraulic press.
Inspection
1. Measure the diameter of the piston pin.
Reassembly
1. Assemble the piston and connecting rod with the arrow (A) and the embossed mark (B) on the same side.
2. Insert the pilot collar (A) into the piston and the connecting rod.
3. With the arrow on top of the piston and the embossed mark on the connecting rod facing up, place the piston
assembly (B) on the special tool (C). Be sure you position the recessed flat area of the piston against the piston
base head inserts (D) as shown.
4. Press the pin (E) in with the pin driver (F) and a hydraulic press.
Piston Installation
If the Crankshaft is Already Installed
1. Set the crankshaft to bottom dead center (BDC) for each cylinder as its piston is installed.
2. Remove the connecting rod caps, then install the ring compressor. Check that the bearing is securely in place.
3. Apply new engine oil to the piston, inside of the ring compressor, and the cylinder bore, then attach the ring
compressor to the piston/connecting rod assembly.
4. Position the arrow (A) to face the cam chain side of the engine.
5. Position the piston in the cylinder, and tap it in using the wooden handle of a hammer (A).
Push down on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore.
6. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing
the piston into place.
7. Check the connecting rod bearing clearance with plastigage.
8. Inspect the connecting rod bolts.
9. Apply new engine oil to the bolt threads, then install the rod caps with bearings. Torque the bolts to 9.8 N·m (1.0
kgf·m, 7.2 lbf·ft).
4. Position the piston in the cylinder, and tap it in using the wooden handle of a hammer (A).
Push down on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore.
5. Position all pistons at top dead center (TDC).
Piston Ring Replacement
1. Remove the piston from the engine block.
2. Using a ring expander (A), remove the old piston rings (B).
3. Clean all the ring grooves thoroughly with a squared-off broken ring, or a ring groove cleaner with a blade to fit the
piston grooves. File down the blade, if necessary. The top and second ring grooves are 1.0 mm (0.04 in.) wide, and
the oil ring groove is 2.0 mm (0.08 in.) wide. Do not use a wire brush to clean the ring grooves, or cut the ring
grooves deeper with the cleaning tool.
NOTE: If the piston is to be separated from the connecting rod, do not install new rings yet.
4. Using a piston, push a new ring (A) into the cylinder bore 15−20 mm (0.6−0.8 in.) from the bottom.
5. Measure the piston ring end-gap (B) with a feeler gauge:
If the gap is too small, check to see if you have the proper rings for your engine.
If the gap is too large, recheck the cylinder bore diameter against the wear limits.
If the bore is over the service limit, the engine block must be rebored.
Piston Ring End-Gap
Top Ring:
Standard (New): 0.15−0.30 mm (0.006−0.012 in.)
Service Limit: 0.60 mm (0.024 in.)
Second Ring:
Standard (New): 0.30−0.42 mm (0.012−0.017 in.)
Service Limit: 0.65 mm (0.026 in.)
Oil Ring:
Standard (New): 0.20−0.70 mm (0.008−0.028 in.)
Service Limit: 0.80 mm (0.031 in.)
6. Install the top ring and the second ring as shown. The top ring (A) has a R mark, and the second ring (B) has a 2R
mark. The manufacturing marks (C) must be face upward.
7. Rotate the rings in their grooves to make sure they do not bind.
UNDER-FLOOR TWC
Fuel and Emissions System Description - EVAP Control System
Exhaust Gas Recirculation (EGR) System
Evaporative Emission (EVAP) Control System
EVAP Canister Filter Replacement
LHD model
1. Lift the vehicle, and support it with jackstands.
2. Disconnect the hose from the EVAP canister (A).
3. Remove the EVAP canister filter (B).
4. Disconnect the hose (C).
5. Install the parts in the reverse order of removal.
EVAP Canister Purge Valve Replacement
1. Disconnect the EVAP canister purge valve connector (A).
2. Disconnect the hose (B), the harness clamp (C), and the then remove the EVAP canister purge guard (D), and the
canister purge valve (E).
3. Install the parts in the reverse order of removal with a new O-ring (F).
Fuel and Emissions System Description - Electronic Throttle Control System
Electronic Throttle Control System
Fuel and Emissions System Description - Electronic Throttle Control System Diagram
Electronic Throttle Control System Diagram
Accelerator Pedal Module Removal/Installation
1. Remove the driver's dashboard lower cover.
2. Disconnect the APP sensor 6P connector (A).
3. Remove the accelerator pedal module (B).
NOTE: APP sensor is not available separately. Do not disassemble the accelerator pedal module.
4. Install the parts in the reverse order of removal.
Fuel Pressure Relieving
Before disconnecting fuel lines or hoses, relieve pressure from the system by disabling the fuel pump and then
disconnecting the fuel tube/quick connect fitting in the engine compartment.
With the HDS
1. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.
2. Turn the ignition switch to ON (II).
3. Make sure the HDS communicates with the ECM/PCM. If it doesn't, go to the DLC circuit troubleshooting.
4. Turn the ignition switch to LOCK (0).
5. Remove the fuel fill cap to relieve the pressure in the fuel tank.
6. Turn the ignition switch to ON (II).
7. From the INSPECTION MENU of the HDS, select Fuel Pump OFF, then start the engine, and let it idle until it
stalls.
NOTE:
Do not allow the engine to idle above 1,000 rpm (min −1 ) or the ECM/PCM will continue to operate the fuel
pump.
A DTC or a Temporary DTC may be set during this procedure. Check for DTCs, and clear them as needed.
8. Turn the ignition switch to LOCK (0).
9. Do the battery terminal disconnection procedure.
12. Place a rag or shop towel over the quick-connect fitting (A).
13. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand, and squeeze the retainer tabs (C)
with the other hand to release them from the locking tabs (D). Pull the connector off.
NOTE:
Be careful not to damage the line (E) or other parts.
Do not use tools.
If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the
connector until it comes off easily.
Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.
14. After disconnecting the quick-connect fitting, check it for dirt or damage.
15. Do the battery terminal reconnection procedure.
10. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand, and squeeze the retainer tabs (C)
with the other hand to release them from the locking tabs (D). Pull the connector off.
NOTE:
Be careful not to damage the line (E) or other parts.
Do not use tools.
If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the
connector until it comes off easily.
Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.
11. After disconnecting the quick-connect fitting, check it for dirt or damage.
12. Do the battery terminal reconnection procedure.
Fuel Breather Line and Suction Line Inspection
1. Remove the center console.
2. Remove the parking brake lever, then remove the access panel from the floor.
3. Disconnect the suction line (A) from the fuel tank unit, and connect a vacuum pump/gauge, 0−30 in.Hg (B) to the
hose as shown.
4. Start the engine, and check the vacuum.
If there is vacuum, go to Step 5 .
If there is no vacuum, replace the fuel filter.
5. Turn the ignition switch to LOCK (0).
6. Connect a vacuum pump/gauge, 0−30 in.Hg (A) to the suction line (B), and apply vacuum to the line.
If the line holds vacuum, check for blockage in the suction line. If there is blockage, replace the suction line.
If the line does not hold vacuum, go to Step 6 .
7. Lift the vehicle, and support it with jackstands.
9. Disconnect the breather line (A), then plug the suction joint (B) with a rubber cap (C).
10. Connect a vacuum pump/gauge, 0−30 in.Hg (A) to the suction line (B), and apply vacuum to the line.
If the line holds vacuum, check for blockage in the breather line between the fuel tank and the suction joint. If
there is blockage, replace the fuel tank.
If the line does not hold vacuum, go to Step 12 .
11. Lift the vehicle, and support it with jackstands.
12. Connect a vacuum pump/gauge, 0−30 in.Hg (A) to the filler side of the breather line (B), and apply air pressure to
the line.
If the air pressure holds, check for blockage between the suction line and the filler neck on the breather pipe,
and replace the part that is causing the blockage.
If the air pressure does not hold, go to Step 13 .
13. Remove the rubber cap from the suction line, and reconnect the breather pipe to the suction line.
14. Connect a vacuum pump/gauge, 0−30 in.Hg (A) to the suction line (B), and apply pressure to the line.
If the air pressure holds, the breather line and the suction line are OK.
If the air pressure does not hold, check for a vacuum leak in the suction line, and replace the suction line if
necessary.
Fuel Pressure Regulator Replacement
1. Remove the fuel tank unit.
2. Remove the reservoir (A).
3. Remove the clip (B), ground wire (C), then remove the bracket (D).
4. Remove the clip (E), then remove the fuel pressure regulator (F).
5. Install the parts in the reverse order of removal with new O-rings (G) and a new bracket. When installing the fuel
tank unit, align the marks on the unit and the fuel tank.
NOTE:
Coat the O-rings with clean engine oil; do not use any other oils or fluids.
Do not pinch the O-rings during installation.
Use all the new parts supplied in the pressure regulator replacement kit.
Low Fuel Indicator Test
1. Do the gauge self-diagnostic test.
If the low fuel indicator flashes, go to Step 2 .
If the low fuel indicator does not flash, replace the gauge control module.
2. Check for body electrical system DTCs.
If any DTCs are indicated, do the indicated DTC's troubleshooting.
If no DTCs are indicated, go to Step 3 .
3. Do the fuel gauge sending unit test.
Fuel and Emissions System Description - PGM-FI System
PGM-FI System
A/F Sensor Replacement
Special Tools Required
O2 sensor wrench 22 x 90
07LAA-PT50101
1. Remove the cowl cover and under cowl-cover panel.
2. Disconnect the A/F sensor connector (A).
4. Turn the under-dash fuse/relay box, then remove the ELD (A).
5. Install the parts in the reverse order of removal.
ECT Sensor 1 Replacement
1. Drain the engine coolant.
2. Remove the air cleaner.
3. Remove the hose clamp stay bolt (A).
9. Connect brake pedal position switch 4P connector terminal No. 2 to body ground with a jumper wire.
10. Check for continuity between ECM/PCM connector terminal A42 and body ground.
Is there continuity?
YES - Repair open in the wire between the brake pedal position switch and the No. 24 STOP, HORN (15 A)
fuse. Inspect the brake pedal position switch. ■
NO - Repair open in the wire between the ECM/PCM (A42) and the brake pedal position switch.■
Throttle Body Cleaning
Do not insert your fingers into the installed throttle body when you turn the ignition switch ON (II) or while the ignition
switch is ON (II). If you do, you will seriously injure your fingers if the throttle valve is activated.
6. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.
7. Turn the ignition switch to ON (II).
8. Reset the ECM/PCM with the HDS.
9. Select the ETCS TEST in the INSPECTION MENU with the HDS.
10. Select TP POSITION CHECK and clear the throttle position (TP) learned value.
11. Turn the ignition switch to LOCK (0).
12. Turn the ignition switch to ON (II), and wait 2 seconds without pressing the accelerator pedal.
13. Do the ECM/PCM idle learn procedure.
Throttle Body Disassembly/Reassembly
Fuel and Emissions System Description - PCV System
Positive Crankcase Ventilation (PCV) System
PCV System Component Location Index
PCV VALVE
Inspection,
Replacement,
2. Check the PCV valve (A), hoses (B), pipe (C), and connections for leaks or restrictions.
3. At idle, make sure there is a clicking sound from the PCV valve when the hose between the PCV valve and intake
manifold is lightly pinched (A) with your fingers or pliers.
If there is no clicking sound, check the PCV valve washer for cracks or damage. If the washer is OK, replace the
PCV valve and recheck.
Ignition System Component Location Index
8. Aim the light toward the pointer (A) on the cam chain case. Check the ignition timing under a no load condition
(headlights, blower fan, rear window defogger, and air conditioner are turned off).
Ignition Timing
M/T model: 0 °±2 ° BTDC (WHITE mark (B)) at idle in neutral
A/T model: 0 °±2 ° BTDC (WHITE mark (B)) at idle in N or P
9. If the ignition timing differs from the specification, check the cam timing. If the cam timing is OK, update the
ECM/PCM, if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the
system works properly, and the ECM/PCM was substituted, replace the original ECM/PCM.
10. Disconnect the HDS and the timing light.
Spark Plug Inspection
1. Remove the spark plugs and inspect the electrodes and ceramic insulator.
Burned or worn electrodes may be caused by these conditions:
-Advanced ignition timing
-Loose spark plug
-Plug heat range too hot
-Insufficient cooling
Fouled plugs may be caused by these conditions:
-Retarded ignition timing
-Oil in combustion chamber
-Incorrect spark plug gap
-Plug heat range too cold
-Excessive idling/low speed running
-Clogged air cleaner element
-Deteriorated ignition coils
2. If the spark plug electrode is dirty or contaminated, clean the electrode with a plug cleaner.
NOTE:
Do not use a wire brush or scrape the iridium electrode since this will damage the electrode.
When using a sand blaster spark plug cleaner, do not clean for more than 20 seconds to avoid damaging the
electrode.
3. Do not adjust the gap (A) of iridium tip plugs; replace the spark plug if the gap is out of specification.
Electrode Gap
Standard (New): 1.2−1.3 mm (0.047−0.051 in.)
4. Replace the plug at the specified interval or when the center electrode is rounded (A). Use only the listed spark
plugs.
Spark Plugs
NGK: IZFR6K13
DENSO: SKJ20DR-M13
5. Apply a small amount of anti-seize compound to the plug threads, and screw the plugs into the cylinder head,
finger-tight. Then torque them to 18 N·m (1.8 kgf·m, 13 lbf·ft).
Engine Oil Pressure Test
Special Tools Required
Oil pressure gauge attachment PT 1/8
07406-0030000
6. After the rubber seal seats, tighten the oil filter clockwise with the oil filter wrench.
Tighten: 3/4 Turn Clockwise
Tightening Torque: 12 N·m (1.2 kgf·m, 8.8 lbf·ft)
7. If four numbers or marks (1 to 4 or ▼ to ▼▼▼▼) are printed around the outside of the filter, you can use the
following procedure to tighten the filter.
Spin the filter on until its seal lightly seats against the oil pan, and note which number or mark is at the
bottom.
Tighten the filter by turning it clockwise three numbers or marks from the one you noted. For example, if
mark ▼ is at the bottom when the seal is lightly seated, tighten the filter until the mark ▼▼▼▼ comes
around to the bottom.
Number or Mark when rubber seal is 1 or ▼ 2 or ▼▼ 3 or ▼▼▼ 4 or ▼▼▼▼
seated
Number or Mark after tightening 4 or ▼▼▼▼ 1 or ▼ 2 or ▼▼ 3 or ▼▼▼
8. Refill the new engine oil, run the engine for more than 3 minutes, then check for oil leakage.
Engine Oil Filter Feed Pipe Replacement
1. Remove the filter.
2. Remove the oil filter feed pipe.
3. Install two 20 x 1.5 mm nuts (A) onto the new oil filter feed pipe. Hold one nut with a wrench, then use a second
wrench to tighten the other nut.
4. Tighten the oil filter feed pipe to 39 N·m (4.0 kgf·m, 29 lbf·ft), then remove the nuts from the oil filter feed pipe.
5. Install the oil filter.
Engine Oil Replacement
1. Warm up the engine.
2. Remove the drain bolt (A), and drain the engine oil.
3. Reinstall the drain bolt with a new washer (B).
5. Run the engine for more than 3 minutes, then check oil level and oil leakage.
Engine Oil/Air Separator Installation
1. Remove the all of the old liquid gasket from the oil/air separator mating surfaces, the bolts, and the bolt holes.
2. Clean and dry the oil/air separator mating surfaces.
3. Apply liquid gasket (P/N 08C70-K0234M, 08C70-K0334M, or 08C70-X0331S) to the engine block mating surface of
the oil/air separator and to the inner threads of the bolt holes.
NOTE:
Apply liquid gasket about 1.5 mm (0.06 in.) diameter bead along the broken line (A).
Do not install components if 5 minutes or more have passed after applying the liquid gasket. Instead, remove
the old residue and reapply the liquid gasket.
5
W1
YEL
No. 22
(7.5 A)
Q8
LT BLU
DRIVER
LOW OIL
PRESSURE
INDICATOR
WHT RED
A3 A4 ECM/PCM
CANH CANL
5V
12 V
OPSW
B7
YEL/RED
5. Disconnect the battery from the M terminal. If the pinion does not retract, the hold-in coil of the solenoid is working
properly.
6. Disconnect the battery from the starter body. If the pinion retracts immediately, it is working properly.
7. Firmly clamp the starter in a vise.
8. Reconnect the wire to the M terminal.
9. Connect the starter to the battery as shown, and confirm that the motor runs.
10. If the electric current meets the specification when the battery voltage is at 11.5 V, the starter is working properly.
Specification
Electric Current: 50 A or less
Starter Removal and Installation
Removal
1. Do the battery terminal disconnection procedure.
2. Remove the coolant reservoir.
3. Remove the intake manifold.
6. Disconnect the starter cable (A) from the B terminal and disconnect the connector (B) from the S terminal, then
remove the starter.
7. Remove the two bolts securing the starter, then remove the starter.
Installation
1. Install the starter to the engine. Connect the starter cable (A) and connector (B). Make sure the starter cable
crimped side of the ring terminal faces away from the starter when you connect it.
4. Check the commutator (A) surface. If the surface is dirty or burnt, resurface it with an emery cloth or a lathe to the
specifications in Step 5 , or recondition with #500 or #600 sandpaper (B).
5. Check the commutator diameter. If the diameter is below the service limit, replace the armature.
Commutator Diameter
Standard (New): 27.9−28.0 mm (1.098−1.102 in.)
Service Limit: 27.0 mm (1.06 in.)
Commutator Runout
Standard (New): 0.05 mm (0.002 in.) max.
Service Limit: 0.4 mm (0.02 in.)
7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth.
Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow,
or V-shaped (D).
8. Check for continuity between the segments of the commutator. If there is an open circuit between any of the
segments, replace the armature.
9. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is
attracted to the core or vibrates while the core is turned, the armature is shorted. Replace the armature.
10. Use an ohmmeter to check for continuity between the commutator (A) and the armature coil core (B), and between
the commutator and the armature shaft (C). If there is continuity, replace the armature.
Brush Length
Standard (New): 9.7−10.3 mm (0.38−0.41 in.)
Service Limit: 6 mm (0.2 in.)
19. Install the brush holder insulator (A) and end cover (B).
20. Do the starter performance test.
Starter Solenoid Test
1. Do the battery terminal disconnection procedure.
2. Remove the starter cable (A) and motor cable (B), then disconnect the connector (C).
3. Check the hold-in coil for continuity between the S terminal and the armature housing (ground). There should be
continuity.
If there is continuity, go to Step 4 .
If there is no continuity, replace the solenoid.
4. Check the pull-in coil for continuity between the S terminal and M terminal. There should be continuity.
If there is continuity, the solenoid is OK.
If there is no continuity, replace the solenoid.
5. Install in the reverse order of removal.
6. Do the battery terminal reconnecting procedure.
Ball Joint Removal
Special Tools Required
Ball joint remover, 28 mm
07MAC-SL00201
Always use a ball joint remover to disconnect a ball joint. Do not strike the housing or any other part of the ball joint
connection to disconnect it.
1. Install a hex nut (A) onto the threads of the ball joint (B). Make sure the nut is flush with the ball joint pin end to
prevent damage to the threaded end of the ball joint pin.
2. Apply grease to the ball joint remover on the areas shown (A). This will ease installation of the tool and prevent
damage to the pressure bolt (B) threads.
3. Loosen the pressure bolt (A), and install the ball joint remover as shown. Insert the jaws carefully, making sure not
to damage the ball joint boot. Adjust the jaw spacing by turning the adjusting bolt (B).
NOTE: Fasten the safety tie (C) securely to a suspension arm or the subframe (D). Do not fasten it to a brake line
or wire harness.
4. After adjusting the adjusting bolt, make sure the head of the adjusting bolt is in the position shown to allow the jaw
(E) to pivot.
5. With a wrench, tighten the pressure bolt until the ball joint pin pops loose from the ball joint connecting hole. If
necessary, apply penetrating type lubricant to loosen the ball joint pin.
NOTE: Do not use pneumatic or electric tools on the pressure bolt.
6. Remove the ball joint remover, then remove the nut from the end of the ball joint pin, and pull the ball joint out of the
ball joint connecting hole. Inspect the ball joint boot, and replace it if damaged.
Front Lower Arm Ball Joint Inspection
When inspecting the ball joint, the vehicle will be shake strongly. Make sure support the front jacking bracket correctly
with the suitable jack.
1. Raise the vehicle, and support it with safety stands in the proper locations.
2. Remove the front wheel.
3. Check all bolts, nuts, and bushings on the suspension components, and make sure that there are not looseness,
deterioration, and damage.
4. Hold the outside of lower arm (A) with your hands, and move it up and down to check for abnormal noise or
wobbling.
NOTE:
If the ball joint is abnormal, replace the lower arm.
A problem on the ball joint may be caused by an abnormal clearance (B).
5. Check the ball joint boot (A) for weakness, damage, cracks, and inner boot grease leaks.
NOTE:
If the ball joint boot is damaged with grease leaks, replace the lower arm.
If the ball joint boot is weakness and cracks without grease leaks, replace the ball joint boot.
6. Install the front wheel.
NOTE: Before installing the wheel, clean the mating surfaces of the brake disc and the inside of the wheel.
Ball Joint Boot Inspection/Replacement
Special Tools Required
Inner bearing driver attachment, 40 mm
07GAF-SE00200
1. Check the ball joint boot for weakness, damage, cracks, and inner boot grease leaks.
NOTE:
If the ball joint boot is damaged with grease leaks, replace the lower arm.
If the ball joint boot is weakness and cracks without grease leaks, go to Step 2 . Replace the ball joint boot.
2. Remove the lower arm.
3. Remove the boot.
4. Pack the interior and lip (A) of a new boot with grease. Keep the grease off of the boot-to-lower arm mating surfaces
(B).
5. Wipe the grease off the tapered portion of the ball joint pin (C), and pack fresh grease into the base (D). Do not let
dirt or other foreign materials get into the boot.
6. Install the boot on the ball joint, then squeeze it gently to force out any air.
7. Press the boot with the inner bearing driver attachment until the bottom seats (A) on the lower arm all the way
around.
8. After installing a boot, wipe any grease off the exposed portion of the ball joint pin.
9. Install the lower arm.
Damper Disposal
Front damper
The dampers contain nitrogen gas and oil under pressure.
The pressure must be relieved before disposal to prevent explosion and possible injury when scrapping.
Rear damper
Always wear eye protection to avoid getting metal shavings in your eyes when the damper pressure is relieved.
Place the damper on a level surface with its shaft extended and drill a hole of 2−3 mm (0.078−0.118 in.) diameter in the
body to release the gas.
Front Damper/Spring Removal/Installation
1. Raise the front of the vehicle, and support it with safety stands in the proper locations.
2. Remove the front wheel.
3. Remove the wheel speed sensor (A) from the knuckle. Do not disconnect the wheel speed sensor connector.
4. Disconnect the stabilizer link from the damper.
5. Remove the wheel speed sensor clip (A), the wheel speed sensor stay (B), and the brake hose bracket (C) form the
damper. Do not disconnect the wheel speed sensor connector.
6. Remove the damper pinch bolts (D) and the self-locking nuts (E) from the damper.
NOTE:
Do not allow the knuckle to rotate too far outward. This may allow the driveshaft inboard joint come apart.
During installation, install new damper pinch bolts and new self-locking nuts, then tighten the damper pinch
bolts to the specified torque value.
8. Remove the damper cap (A) from the top of the damper.
9. Hold the damper shaft (B) using a hex wrench (C), and loosen the damper mounting nut (D).
10. Remove the damper mounting nut (A) and the wave washer (B), then remove the damper mounting base (C) from
the top of the damper.
11. Remove the damper/spring (A) and the damper mounting rubber (B).
NOTE: Be careful not to damage the body.
12. Install all of the removed parts in the reverse order of removal, and note these items:
First install all the components, and lightly tighten the bolts and the nuts, then raise the suspension to load
it with the vehicle's weight before fully tightening to the specified torque values. Do not place the jack against
the ball joint of the lower arm.
Before installing the wheel, clean the mating surfaces of the brake disc and the inside of the wheel.
13. Check the wheel alignment, and adjust it if necessary.
Front Damper/Spring Disassembly, Inspection, and Reassembly
Exploded View
NOTE: When compressing the damper spring, use a commercially available strut spring compressor (Branick MST-580A
or Model 7200, or equivalent) according to the manufacturer's instructions.
Disassembly
1. Compress the damper spring, then remove the nut (A) while holding the damper shaft with a hex wrench (B). Do not
compress the damper spring more than necessary to remove the nut.
2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded
View.
Inspection
1. Install the nut on the damper shaft end, and set the socket wrench and T-handle on the nut.
2. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression
and extension. The damper should extend smoothly and constantly when compression is released. If it does not,
the gas is leaking and the damper should be replaced.
3. Check for oil leaks, abnormal noises, and binding during these tests.
Reassembly
1. Install the upper spring seat (A) to the upper spring seat clip (B).
NOTE: Make sure to securely set the upper spring seat to the hook (C) on the spring seat clip.
2. Install the bump stop rubber (D) and the dust cover (E) to the upper spring seat.
NOTE: Push the bump stop rubber and the dust cover into the dent (F) of the upper spring seat securely.
3. Install the damper spring (A) on the upper spring seat clip (B) by aligning the upper end (C) of the damper spring
with the ledge portion (D) of the upper spring seat clip.
4. Install the spring seat rubber on the damper spring.
5. Compress the damper spring.
6. Install all the parts except the nut and the damper bearing onto the damper unit (A) by referring to the Exploded
View.
7. Align the raised portion (A) of the spring seat rubber and the hole (B) of the lower spring seat on the damper unit
(C).
NOTE: After reassemble the damper/spring, install the dust cover (D) into the damper unit as shown.
8. Install the damper bearing onto the damper shaft.
9. Compress the damper spring until the position (A) of the damper shaft (B) comes in contact with the damper
bearing. Do not excessively compress the damper spring.
NOTE: Make sure the distance of the rod is 44 mm (1.73 in.) from the upper surface of the bearing.
10. Install the nut (C).
11. Hold the damper shaft with a hex wench (D), and tighten the nut to the specified torque value.
12. Remove the damper/spring from the strut spring compressor.
Front Knuckle/Hub/Wheel Bearing Replacement
Exploded View
Special Tools Required
Ball joint remover, 28 mm
07MAC-SL00201
3. Remove the brake hose mounting bolt (A) from the damper bracket.
4. Remove the brake caliper bracket mounting bolts (B), and remove the caliper assembly (C) from the knuckle. To
prevent damage to the caliper assembly or the brake hose, use a short piece of wire to hang the caliper assembly
from the undercarriage. Do not twist the brake hose excessively.
5. Raise the stake (A), then remove the spindle nut (B).
6. Remove the front brake disc.
7. Check the front hub for damage and cracks.
8. Remove the wheel speed sensor (A) from the knuckle (B). Do not disconnect the wheel speed sensor connector.
9. Remove the cotter pin (A) from the tie-rod end ball joint, then remove the nut (B).
NOTE: During installation, install the new cotter pin after tightening the nut, and bend its end as shown.
10. Disconnect the tie-rod end ball joint from the knuckle using the ball joint remover.
11. Remove the lock pin (A) from the lower arm ball joint, then remove the castle nut (B).
NOTE: During installation, install the lock pin as shown after tightening the new castle nut.
12. Disconnect the lower ball joint from the knuckle using the ball joint remover.
NOTE:
Be careful not to damage the ball joint boot when installing the remover.
Do not force or hammer on the lower arm, or pry between the lower arm and the knuckle. You could damage
the ball joint.
13. Remove the damper pinch bolts (A) and the self-locking nuts (B) from the damper.
NOTE: Use new damper pinch bolts and new self-locking nuts during reassembly.
14. Remove the driveshaft outboard joint (C) from the knuckle (D) by tapping the driveshaft end (E) with a soft face
hammer while drawing the hub outward, then remove the knuckle/hub.
NOTE:
Do not pull the driveshaft end outward. The driveshaft inboard joint may come apart.
During installation, apply grease to the mating surfaces of the wheel bearing and the driveshaft outboard
joint.
15. Install the knuckle/hub in the reverse order of removal, and note these items:
First install all the components, and lightly tighten the bolts and the nuts, then raise the suspension to load
it with the vehicle's weight before fully tightening to the specified torque values. Do not place the jack against
the ball joint of the lower arm.
Be careful not to damage the ball joint boot when connecting the knuckle.
Before connecting the ball joint, degrease the threaded section and the tapered portion of the ball joint pin,
the ball joint connecting hole, and the threaded section and the mating surfaces of the castle nut.
Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with
the ball joint pin hole. Do not align the castle nut by loosening it.
Use a new spindle nut on reassembly.
Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut. After
tightening, use a drift to stake the spindle nut shoulder against the driveshaft.
Before installing the brake disc, clean the mating surfaces of the front hub and the inside of the brake disc.
Before installing the wheel, clean the mating surfaces of the brake disc and the inside of the wheel.
16. Check the wheel alignment, and adjust it if necessary.
2. Press the wheel bearing inner race (A) off of the hub (B) using the hub dis/assembly tool, a commercially available
bearing separator (C), and a press.
3. Remove the splash guard (A) and the snap ring (B) from the knuckle (C).
4. Press the wheel bearing (A) out of the knuckle (B) using the bearing driver attachment, the driver handle, and a
press.
5. Wash the knuckle and the hub thoroughly in high flash point solvent before reassembly.
6. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the support base,
and a press.
NOTE:
Install the wheel bearing with the wheel speed sensor magnetic encoder (E) (brown color), toward the inside
of the knuckle.
Remove any oil, grease, dust, metal debris, and other foreign material from the encoder surface.
Keep any magnetic tools away from the encoder surface.
Be careful not to damage the encoder surface when you insert the wheel bearing.
9. Remove the steering gearbox mounting bolt (A) and the stiffener mounting bolt (B), and remove the gearbox stay
(C) of the passenger's side.
10. Remove the steering gearbox mounting bolt (A) and the washer (B) from the rear side of the steering gearbox.
11. Remove the flange bolts (A) and the bushing holders (B), then remove the bushings (C).
12. Move the steering gearbox toward the upper side, and remove the stabilizer bar (D) from the driver's side.
NOTE: Be careful not to damage the steering gearbox.
Installation
1. Move the steering gearbox toward the upper side, and install the stabilizer bar (A) from the driver's side.
NOTE:
Be careful not no damage the steering gearbox.
Note the right and left direction of the stabilizer bar.
Note the direction of installation for the bushings (B) and the bushing holders (C).
Align the stabilizer band or the paint marks (D) on the stabilizer bar with the side of the bushings.
2. Loosely tighten the new steering gearbox mounting bolt (A) and the washer (B) from the rear side of the steering
gearbox.
3. Loosely tighten the new steering gearbox mounting bolt (A) and the new stiffener mounting bolt (B) to the gearbox
stay (C) of the passenger's side.
4. Loosely tighten the new steering gearbox mounting bolt (A) and the new stiffener mounting bolt (B) to the gearbox
stay (C) of the driver's side.
5. Tighten the steering gearbox mounting bolts (A) and the stiffener mounting bolts (B) to the specified torque values RHD model
as shown order.
6. LHD model: Install the secondary HO2S wire clamp to the steering gearbox.
7. Connect both sides of the stabilizer link to the stabilizer bar.
8. Connect the tie-rod end ball joint to the knuckle.
9. Connect the steering joint.
LHD model
10. Install the steering wheel.
11. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the front wheels.
12. Check the wheel alignment, and adjust it if necessary.
Front Stabilizer Link Removal/Installation
1. Raise the front of the vehicle, and support it with safety stands in the proper locations.
2. Remove the front wheel.
3. Remove the self-locking nut (A) and the flange nut (B) while holding the respective joint pin (C) with a hex wrench
(D), then remove the stabilizer link (E).
4. Install the stabilizer link on the stabilizer bar (F) and the damper (G) with the joint pins set at the center of their
range of movement.
5. Install the new self-locking nut and the new flange nut, and tighten them to the specified torque values while holding
the respective joint pin with a hex wrench.
6. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the front wheel.
7. Test-drive the vehicle.
8. After 5 minutes of driving, tighten the self-locking nut again to the specified torque value.
Wheel Bearing End Play Inspection
1. Raise the vehicle, and support it with safety stands in the proper locations. Front
2. Remove the wheels.
3. Install suitable flat washers (A) and the wheel nuts. Tighten the nuts to the specified torque to hold the brake disc
securely against the hub.
4. Attach the dial gauge. Place the dial gauge against the hub flange.
5. Measure the bearing end play while moving the brake disc inward and outward.
Wheel bearing end play:
Rear
Front/Rear: 0−0.05 mm (0−0.002 in.)
6. If the bearing end play measurement is more than the standard, replace the wheel bearing or the hub bearing unit.
Rear Suspension Dynamic Damper Replacement
1. Raise the vehicle, and support it with safety stands in the proper locations.
2. Remove the dynamic damper (A) from the axle beam.
NOTE: Use new self-looking nuts (B) during reassembly.
3. Install the new dynamic damper in the reverse order of removal.
Rear Stabilizer Rubber Replacement
1. Raise the vehicle, and support it with safety stands in the proper locations.
2. Remove the dynamic damper from the axle beam.
3. Remove the stabilizer rubber (A) from the axle beam.
4. Apply osmosis preservation lubricant to the new stabilizer rubber. This will ease installation of the rubber into the
stabilizer and the axle beam.
5. Make a mark (A) near the hole (B) of the axle beam as shown. Install the stabilizer rubber (C) into the axle beam
by aligning the end face of the stabilizer rubber to the plant mark.
NOTE: Make sure the stabilizer rubber is installed into the stabilizer (D).
6. Install the dynamic damper to the axle beam.
Wheel Runout Inspection
NOTE: When measuring the front wheel runout, turn the back side of the wheel slowly by hand.
1. Raise the vehicle, and support it with safety stands in the proper locations.
2. Check for bent or deformed wheel.
3. Set up the dial gauge as shown, and measure the axial runout by turning the wheel.
Front and rear wheel axial runout:
Standard:
Steel wheel: 0−1.0 mm (0−0.04 in.)
Aluminum wheel: 0−0.7 mm (0−0.03 in.)
Service limit: 2.0 mm (0.08 in.)
4. Reset the dial gauge to the position shown, and measure the radial runout.
Front and rear wheel radial runout:
Standard:
Steel wheel: 0−1.0 mm (0−0.04 in.)
Aluminum wheel: 0−0.7 mm (0−0.03 in.)
Service limit: 1.5 mm (0.06 in.)
5. If the wheel runout is not within the specification, check the wheel bearing end play, and make sure the mating
surfaces on the brake disc and the inside of the wheel are clean.
6. If the bearing end play is within the specification but the wheel runout is more than the service limit, replace the
wheel.
Wheel Bolt Replacement
Do not use a hammer or air or electric impact tools to remove and install the wheel bolts.
Be careful not to damage the threads of the wheel bolts.
1. Remove the front hub or the rear hub bearing unit: front , rear.
2. Separate the wheel bolt (A) from the hub (B) using a hydraulic press. Support the hub with hydraulic press
attachments (C) or equivalent tools.
NOTE:
Before installing the new wheel bolt, clean the mating surfaces on the bolt and the hub.
The illustration shows a front hub.
3. Insert the new wheel bolt into the hub while aligning the splined surfaces on the hub hole with the wheel bolt.
NOTE:
Degrease all around the wheel bolt.
Make sure the wheel bolt is installed vertically in relation to the hub disc surface.
4. Install the wheel bolt using a hydraulic press until the wheel bolt shoulder is fully seated.
5. Install the front hub or the rear hub bearing unit: front , rear.
NOTE: If you cannot tighten the wheel nut to the specified torque value when installing the wheel, replace the front
hub or the rear hub bearing unit as an assembly.
ABS System Description
ABS Modulator-Control Unit Inputs and Outputs for 25P Connector
System Outline
ABS Features
EBD Features
Modulator Unit
ABS Component Location Index
RIGHT-REAR WHEEL
SPEED SENSOR
DATA LINK CONNECTOR (DLC) Replacement,
LEFT-REAR WHEEL
RIGHT-FRONT WHEEL SPEED SENSOR
SPEED SENSOR Replacement,
Replacement,
LEFT-FRONT WHEEL
WHEEL BEARING SPEED SENSOR
(MAGNETIC ENCODER) Replacement,
Replacement,
WHEEL BEARING
(MAGNETIC ENCODER)
Replacement,
ABS Circuit Diagram
BATTERY
UNDER-DASH
BATTERY TERMINAL FUSE/RELAY BOX ABS MODULATOR-CONTROL UNIT
FUSE BOX
CONTROL UNIT MODULATOR
No. 1 (100 A) T-9 No. 60 (50 A) T1 UNIT
WHT IGNITION SWITCH
6 3 VCC
W1 IG1
YEL WHT
No. 11 (7.5 A)
UNDER-DASH FUSE/RELAY BOX CONNECTOR A (36P)
A32
PUR PUR
16
IG1
5V
REGULATOR
No. 37 (30 A) A2 8
WHT WHT
FSR +B
No. 58 (30 A) A23 9 FAIL-SAFE RELAY
RED RED
No. 3 (30 A*1) ECM/PCM MR +B
No. 24 (15 A) 1 2
(20 A*2) B23 B28 A42
WHT WHT LT GRN LT GRN
PUMP MOTOR RELAY
BRAKE PEDAL A3
POSITION SWITCH WHT
Closed: Brake pedal pressed
A4
RED
SOLENOIDS
LEFT-FRONT
IN
GAUGE CONTROL
MODULE
OUT
RIGHT-FRONT
30 1
BRAKE SYSTEM
INDICATOR
29
GAUGE CONTROL MODULE 32P CONNECTOR
WHT WHT WHT
BRAKE PEDAL POSITION
WHT
CAN-H
17
CAN
CONTROLLER
IN
16
PNK +B
SWITCH IC
1 SWITCH 2P CONNECTOR
LT BLU
6
RR +B PUMP MOTOR
BLK
4
BLK
1P CONNECTOR 2
GRY
15
RR-GND
25
BLK
MR-GND
24
BLK
GND
: 12 V :5V
G301*3 G502 G203*3 *1: With trailer lighting connector *3: RHD model
G302*4 G402*4 *2: Without trailer lighting connector *4: LHD model
FRONT REAR
10. Measure the voltage between ABS modulator-control unit 25P connector terminal No. 16 and body ground.
Is there battery voltage?
YES - Go to Step 11 .
NO - Repair open in the wire between the No. 11 (7.5 A) fuse in the under-dash fuse/relay box and the ABS
modulator-control unit.■
11. Turn the ignition switch to LOCK (0).
12. Check for continuity between ABS modulator-control unit 25P connector terminal No. 24 and body ground.
Is there continuity?
YES - Go to Step 13 .
NO - RHD model: Repair open in the wire between the ABS modulator-control unit and body ground
(G203).■
LHD model: Repair open in the wire between the ABS modulator-control unit and body ground
(G402).■
14. Check for continuity between the ABS modulator-control unit 25P connector terminal and gauge control module
32P connector terminal (see table).
Sign ABS Modulator-control Unit 25P Gauge Control Module 32P
Connector Terminal Connector Terminal
CAN-L No. 17 No. 29
CAN-H No. 1 No. 30
Is there continuity?
YES - Check for loose terminals in the ABS modulator-control unit 25P connector. Clean terminal: G203 (RHD
model), G402 (LHD model) and recheck. If necessary, substitute a known-good ABS modulator-control
unit, and reset.■
NO - Repair open in the wire between the gauge control module and the ABS modulator-control unit.■
HDS does not communicate with the ABS modulator-control unit or the vehicle
Diagnostic procedure
1. Troubleshoot the DLC circuit.
ABS indicator and brake system indicator do not come on at the same time
Diagnostic procedure
1. Do the gauge control module troubleshooting.
2. Substitute a known-good ABS modulator-control unit, then retest. If it is OK, replace the original ABS modulator-control unit.
ABS indicator and brake system indicator do not go off at the same time
Diagnostic procedure
1. Check for F-CAN DTCs, and troubleshoot and repair those first.
2. Symptom Troubleshooting.
3. Do the gauge control module troubleshooting.
ABS Symptom Troubleshooting Index
When the vehicle has one of these symptoms, check for a diagnostic trouble code (DTC) with the HDS. If there is no DTC, do the diagnostic procedure
for the symptom, in the sequence listed, until you find the cause.
Symptom Diagnostic procedure
HDS does not communicate with the ABS modulator-control Troubleshoot the DLC circuit.
unit or the vehicle
ABS indicator and brake system indicator do not come on 1.Do the gauge control module troubleshooting.
at the same time 2.Substitute a known-good ABS modulator-control unit, then retest. If it is OK, replace the
original ABS modulator-control unit.
ABS indicator and brake system indicator do not go off at 1.Check for F-CAN DTCs, and troubleshoot and repair those first.
the same time 2.Symptom Troubleshooting.
3.Do the gauge control module troubleshooting.
ABS Modulator-control Unit Removal and Installation
NOTE:
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint,
wash it off immediately with water.
Be careful not to damage or deform the brake lines during removal and installation.
To prevent the brake fluid from dripping, plug and cover the hose ends and joints with a shop
towel.
Removal
1. Turn the ignition switch to LOCK (0).
2. Disconnect the ABS modulator-control unit 25P connector (A) by pulling up the lock (B); the
connector disconnects itself.
3. Disconnect the six brake lines from the ABS modulator-control unit.
NOTE: Brake lines are connected to the master cylinder (C) and to the right-front (D), the left-
rear (E), the right-rear (F), and the left-front (G) brake systems.
4. Remove the ABS modulator-control unit (H) with the bracket (I) from the body.
5. Remove the ABS modulator-control unit from the bracket.
Installation
1. Install the ABS modulator-control unit on the bracket.
2. Install the bracket with the ABS modulator-control unit to the body.
3. Reconnect the six brake lines, then tighten the flare nuts to the specified torque.
4. Align the connecting surface of the ABS modulator-control unit 25P connector to the ABS modulator-control unit.
5. Lower the lock of the ABS modulator-control unit 25P connector, then confirm the connector is fully seated.
6. Bleed the brake system.
7. Start the engine, and check that the ABS indicator goes off.
8. Test-drive the vehicle, and make sure the ABS indicator does not come on.
NOTE: If the brake pedal is spongy, there may be air trapped in the modulator which could then be induced into the
normal brake system during modulation. Bleed the brake system again.
Wheel Speed Sensor Replacement
Front
1. Turn the ignition switch to LOCK (0).
2. Remove the grommet (A), then disconnect the wheel speed sensor connector (B).
3. Remove the bracket (C), the clip (D), and the stay (E).
4. Remove the bolt and the wheel speed sensor (F).
5. Install the wheel speed sensor in the reverse order of removal, and note these items:
Install the sensor carefully to avoid twisting the wires.
If the wheel speed sensor comes in contact with the wheel bearing, it is faulty.
Make sure the grommet is installed properly.
6. Start the engine, and make sure the ABS indicator go off.
7. Test-drive the vehicle, and make sure the ABS indicator do not come on.
Rear
1. Turn the ignition switch to LOCK (0).
2. Pull back the carpet under the rear seat, then disconnect the wheel speed sensor connector
(A).
3. Remove the grommet (B), the bracket (C), the clips (D), and the stay (E).
4. Remove the bolt and the wheel speed sensor (F).
5. Install the wheel speed sensor in the reverse order of removal, and note these items:
Install the sensor carefully to avoid twisting the wires.
If the wheel speed sensor comes in contact with the hub bearing unit, it is faulty.
Make sure the grommet is installed properly.
6. Start the engine, and make sure the ABS indicator go off.
7. Test-drive the vehicle, and make sure the ABS indicator do not come on.
Rear Brake Caliper Overhaul
Exploded View
Special Tools Required
Locknut wrench, 5.5 x 30 mm
07916-6390001
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
Avoid breathing dust particles.
Never use an air hose or brush to clean brake assemblies. Use an appropriate vacuum cleaner.
NOTE: Make sure that the caliper pins are installed correctly. Upper caliper pin B and lower caliper pin A are different. If
these caliper pins are installed in the wrong location, it will cause vibration, uneven or rapid pad wear, and possibly uneven
tyre wear.
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off
immediately with water.
To prevent dripping brake fluid, cover disconnected hose joints with rags or shop towels.
Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
Before reassembling, check that all parts are free of dirt and other foreign particles.
Replace parts with new ones as specified in the illustration.
Make sure no dirt or other foreign matter gets in the brake fluid.
Make sure no grease or oil gets on the brake discs or the brake pads.
When reusing brake pads, always reinstall them in their original positions to prevent loss of braking efficiency.
Do not reuse drained brake fluid. Use only clean genuine Honda DOT 3 or DOT 4 Brake Fluid from an unopened
container. Using a non-Honda brake fluid can cause corrosion and shorten the life of the system.
Coat the piston, the piston seal groove, and the caliper bore with clean brake fluid.
Use recommended greases in the rear caliper set.
After installing the caliper, check the brake hose and line for leaks, interference, and twisting.
When you apply the silicone grease, make sure not to adhere to the terminal part of connectors and surrounding
switches. Also do not touch the switches and the terminal part of connector by hands or glove that adheres the
silicone grease.
Disassembly
1. Remove the caliper body.
2. Remove the pad spring (A) from the caliper body (B).
3. Rotate the piston (A) counterclockwise by using the locknut wrench (B), and remove the piston and piston boot (C).
NOTE: Be careful not to damage the piston.
4. Remove the piston seal (A) from the caliper body (B).
NOTE: Be careful not to damage the inner surface of the cylinder wall with the tool.
5. Install the rear caliper spring compressor (A) on the spring guide (B) inside of the caliper body.
6. Locate a locknut (C) on the top of the shaft (D) and turn the shaft clockwise until a plate (E) touches the caliper
body.
7. Turn the locknut (A) and put it on the plate. Turn the shaft for 1/4 to 1/2 clockwise and compress the adjusting
spring B.
8. Remove the circlip (C) with the snap ring pliers (D).
9. Depress the lower side of the locknut, tighten the upper side of the locknut and fix the position.
NOTE: Do not displace the position of the locknut until reassembling the circlip.
10. Remove the rear caliper spring compressor, then remove the spring guide (C), adjusting spring B, spacer (D),
bearing A, adjusting bolt (E) and the cup (F).
11. Remove the sleeve piston (A), then remove the rod (B) and the O-ring (C) from the shaft.
12. Remove the return spring (A), then remove the lever/shaft (B) from the caliper.
NOTE: Do not loosen a parking nut (C), with the shaft attached to the caliper. When disassembling the lever and
the shaft, fix the lever to the vice and loosen the nut.
13. Remove the shaft cover (D).
Reassembly
NOTE: When disassembling the lever and the shaft, assemble them according to the following procedure, referring to the
exploded view beforehand, then install them to the caliper.
Install the lever and a spring washer to the shaft.
Apply new sealant (Loctite 569) to the threads of the parking nut and install it.
Fix the lever to the vice and tighten the nut.
1. Apply silicone grease to a needle roller bearing (A) of the caliper body.
NOTE: Check if notch of the needle roller bearing faces to the cylinder.
2. Apply silicone grease to the seal of a new shaft cover (B), then install it to the caliper body.
3. Apply silicone grease to the hole (C) of the shaft. Turn the hole toward the caliper, then install the lever/shaft (D) to
the caliper body.
NOTE:
Rotate the shaft slowly when inserting so as not to damage the seal of the shaft cover.
Fix the lip of the shaft cover to the groove portion of the shaft completely.
4. Install the return spring (E).
5. Install the rod (A) to the shaft (B) so that it turns toward the center.
6. Install the new O-ring (C) to the sleeve piston (D).
7. Install two pins (E) of the sleeve piston to the two holes (F) of the caliper body, so that the rod is inserted in the
hole of the bottom side of the sleeve piston.
8. Apply rubber grease to the new cup (C) and assemble to the adjusting bolt (D). Assemble the bearing A, spacer
(E), adjusting spring B, and the spring guide (F), then install them into the caliper body.
NOTE: Install the cup with the groove facing toward the bearing A.
9. Install the rear caliper spring compressor (A) on the spring guide (B) in the caliper body and turn the shaft (C)
clockwise until the plate (D) touches the locknut (E).
10. Check that the bottom (F) of the spring guide is lower than the circlip installation groove (G) of the caliper body.
11. Install the circlip (A) with the snap ring pliers (B).
NOTE: Make sure the circlip securely fits in the groove of the caliper body.
12. Apply a thin coat of silicone grease to the new piston seal (A), then install it into the groove in the caliper body.
13. Apply a thin coat of rubber grease to the new piston boot (B), then install it into the groove in the caliper body.
14. Apply brake fluid to the outer surface of the piston, then set the piston in place on the caliper body.
15. Rotate the piston clockwise by using the locknut wrench (A) to install it. Make sure that the piston boot is properly
positioned into the groove of the piston.
NOTE: Be careful not to damage the piston boot when rotate the piston.
16. Install the pad spring (A) to the caliper body (B).
17. Install the caliper body.
18. Bleed the brake system.
Front Brake Disc Replacement
NOTE: Keep any grease off the brake disc and brake pads.
1. Raise the front of the vehicle, and support it with safety stands in the proper locations.
2. Remove the front wheel.
3. Remove the brake hose mounting bolts (A).
4. Remove the brake caliper bracket mounting bolts (B), then remove the caliper assembly (C) from the knuckle. To
prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from
the undercarriage. Do not twist the brake hose excessively.
7. If the brake disc is beyond the service limit, refinish the brake disc with a commercially available on-car brake lathe.
Max. refinishing limit: 19.0 mm (0.75 in.)
NOTE:
If the brake disc is beyond the service limit for refinishing, replace it.
A new brake disc should be refinished if its runout is greater than 0.04 mm (0.0016 in.).
8. Install the brake pads.
9. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the front wheels.
NOTE: This is the maximum allowable difference between the thickness measurements.
5. If the brake disc is beyond the service limit for parallelism, refinish the brake disc with a commercially available on-
car brake lathe.
NOTE: If the brake disc is beyond the service limit for refinishing, replace it.
6. Install the brake pads.
7. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the front wheels.
Rear Brake Disc Inspection
Runout
1. Raise the rear of the vehicle, and support it with safety stands in the proper locations.
2. Remove the rear wheels.
3. Remove the brake pads.
4. Inspect the brake disc surface for damage and cracks. Clean the brake disc thoroughly, and remove all rust.
5. Install suitable flat washers (A) and the wheel nuts (B), and tighten the wheel nuts to the specified torque to hold
the brake disc securely against the hub.
6. Set up the dial gauge against the brake disc as shown, and measure the runout at 10 mm (0.39 in.) from the outer
edge of the brake disc.
Brake disc runout:
Service limit: 0.04 mm (0.0016 in.)
7. If the brake disc is beyond the service limit, refinish the brake disc with a commercially available on-car brake lathe.
Max. refinishing limit: 8.0 mm (0.31 in.)
NOTE:
If the brake disc is beyond the service limit for refinishing, replace it.
A new brake disc should be refinished if its runout is greater than 0.04 mm (0.0016 in.).
8. Install the brake pads.
9. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the rear wheels.
NOTE: This is the maximum allowable difference between the thickness measurements.
5. If the brake disc is beyond the service limit for parallelism, refinish the brake disc with a commercially available on-
car brake lathe.
NOTE: If the brake disc is beyond the service limit for refinishing, replace it.
6. Install the brake pads.
7. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the rear wheels.
Brake Hose Replacement
NOTE:
Before reassembling, check that all parts are free of dirt and other foreign particles.
Replace parts with new ones whenever specified to do so.
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off
immediately with water.
Plug the end of a hose and joints to prevent spilling brake fluid.
Front
1. Remove the front wheel.
2. Disconnect the brake line (A) from the brake hose (B), then remove the brake hose bracket (C).
3. Remove the banjo bolt (A), and disconnect the brake hose (B) from the caliper.
4. Remove the brake hose mounting bolt (C), then remove the brake hose.
5. Install the brake hose (A) with the mounting bolt (B).
6. Connect the brake hose to the caliper with the banjo bolt (C) and new sealing washers (D).
7. Install the brake hose bracket (A) to the body, then connect the brake line (B). Do not twist the brake hose.
8. After installing the brake hose, bleed the brake system.
9. Do the following checks:
Check the brake hose and line joint for leaks, and tighten if necessary.
Check the brake hoses for interference and twisting.
10. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the front wheel.
Rear
1. Remove the rear wheel.
2. Disconnect the brake line (A) from the brake hose (B), then remove the brake hose clip (C).
3. Remove the banjo bolt (A), and disconnect the brake hose (B) from the caliper.
4. Connect the brake hose (A) to the caliper with the banjo bolt (B) and new sealing washers (C).
5. Install a new brake hose clip (A) to the brake hose (B) on the bracket, then connect the brake line (C). Do not twist
the brake hose.
6. After installing the brake hoses, bleed the brake system.
7. Do the following checks:
Check the brake hose and line joint for leaks, and tighten if necessary.
Check the brake hose for interference and twisting.
8. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the rear wheel.
Rear Brake Pad Inspection and Replacement
Special Tools Required
Locknut wrench, 5.5 x 30 mm
07916-6390001
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
Avoid breathing dust particles.
Never use an air hose or brush to clean brake assemblies. Use an appropriate vacuum cleaner.
Inspection
1. Raise the rear of the vehicle, and support it with safety stands in the proper locations.
2. Remove the rear wheels.
3. Check the thickness (A) of the inner pad (B) and outer pad (C). Do not include the thickness of the backing plate.
Brake pad thickness:
Standard: 6.8−7.5 mm (0.27−0.30 in.)
Service limit: 1.6 mm (0.06 in.)
4. If the brake pad thickness of any of the pads is less than the service limit, replace the rear brake pads as a set.
5. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the rear wheels.
Replacement
1. Remove some brake fluid from the master cylinder.
2. Raise the rear of the vehicle, and support it with safety stands in the proper locations.
3. Remove the rear wheels.
4. Remove the parking brake cable mounting nut (A).
5. Remove the flange bolts (B) while holding respective caliper pins (C) with a wrench. Be careful not to damage the
pin boot, and remove the caliper (D). Check the hose, the pin boots, and the parking brake cable boots for damage
and deterioration.
NOTE: Do not twist the brake hose and the parking brake cable to prevent damage.
6. Remove the pad shims (A) and the brake pads (B).
12. Rotate the caliper piston (A) clockwise into the cylinder by using the locknut wrench.
NOTE: Be careful when moving the piston back in the caliper; brake fluid might overflow from the master cylinder's
reservoir.
13. Apply Molykote M77 grease to the pad side of the shims (A), the back of the brake pads (B), and the other areas
indicated by the arrows. Wipe excess grease off the pad shims and the brake pads. Keep grease off the brake
discs and the brake pads. Contaminated brake discs or brake pads reduce stopping ability.
14. Install the brake pads and pad shims correctly. Install the brake pad with the wear indicator (C) on the bottom
inside. If you are reusing the brake pads, always reinstall the brake pads in their original positions to prevent a
momentary loss of braking efficiency.
15. Align the cutout (A) in the piston (B) with the tab (C) on the inner pad. Lubricate the boot with rubber grease to
avoid twisting the piston boot. If the piston boot is twisted, back it out so it is positioned properly.
16. Install the caliper. Install the flange bolts (D), and tighten it to the specified torque while holding the respective
caliper pins (E) with a wrench, being careful not to damage the pin boots and parking brake cable boots.
17. Install the parking brake cable mounting nut (F).
18. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the rear wheels.
19. Press the brake pedal several times to make sure the brakes work.
NOTE: Engagement may require a greater pedal stroke immediately after the brake pads have been replaced as a
set. Several applications of the brake pedal will restore the normal pedal stroke.
20. Add brake fluid as needed.
21. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. Test-drive the
vehicle, then recheck for leaks.
22. Adjust the parking brake.
Brake Pedal Replacement
NOTE: The illustration shows RHD model.
1. Remove the driver's dashboard undercover.
2. Disconnect the brake pedal position switch connector (A).
3. Remove the lock pin (B) and joint pin (C).
4. RHD model: Remove the brake pedal support member (D).
5. Remove the brake booster mounting nuts (E).
6. Remove the brake pedal with bracket (F).
7. Install the brake pedal in the reverse order of removal.
8. Adjust the brake pedal and the brake pedal position switch.
Brake Pedal and Brake Pedal Position Switch Adjustment
Pedal Height
1. Remove the driver's dashboard undercover.
2. Turn the brake pedal position switch (A) counterclockwise, and pull it back until it is no longer touching the brake
pedal.
3. Pull back the carpet and find the cutout (B) in the insulation. Measure the pedal height (C) at the center of the
pedal pad (D) to the floor without the insulation.
Standard pedal height (with carpet removed):
M/T: 139 mm (5.5 in.)
A/T: 138 mm (5.4 in.)
4. Loosen the pushrod locknut (A), and screw the pushrod (B) in or out with pliers until the standard pedal height from
the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod
pressed.
YAW RATE-LATERAL/LONGITUDINAL
ACCELERATION SENSOR LEFT-REAR WHEEL SPEED SENSOR
Replacement, Replacement,
HUB BEARING UNIT
(MAGNETIC ENCODER)
*: The illustration shows LHD model, RHD model is similar. Replacement,
in the Shop Manual, P/N 62TF000B
RIGHT-FRONT WHEEL SPEED SENSOR
Replacement,
WHEEL BEARING LEFT-FRONT WHEEL SPEED SENSOR
(MAGNETIC ENCODER) Replacement,
Replacement, WHEEL BEARING
in the Shop Manual, P/N 62TF000B (MAGNETIC ENCODER)
Replacement,
in the Shop Manual, P/N 62TF000B
VSA System Circuit Diagram
BATTERY
UNDER-DASH
BATTERY TERMINAL FUSE/RELAY BOX VSA MODULATOR-CONTROL UNIT
FUSE BOX
CONTROL UNIT MODULATOR UNIT
No. 1 (100 A) T-9 No. 60 (50 A) T1
WHT IGNITION SWITCH
6 3 VCC
W1 IG1
YEL WHT
WHT WHT
FSR +B
No. 58 (30 A) A23 13
RED FAIL-SAFE RELAY
RED
No. 3 (30 A*3) ECM/PCM MR +B
(20 A*4) No. 24 (10 A) 1 2
B23 B28 A42
WHT WHT LT GRN LT GRN
PUMP MOTOR RELAY
Q16 BRAKE PEDAL A3
POSITION SWITCH WHT
Closed: Brake pedal pressed
A4 VCC
RED
YAW RATE-
LATERAL/
LONGITUDINAL A44 STEERING
VSA OFF SWITCH ACCELERATION
SENSOR
RED ANGLE
SENSOR UNDER-DASH FUSE/RELAY BOX PRESSURE
SENSOR
2 11
+B GRY
4
PUR
1
CONNECTOR Q BRN
STR-A
VCC
5 3 4 27
2
WHT
4 3
GRN
STR-B
26
VSA1
WHEEL SPEED
2 VSA OFF SWITCH 5P CONNECTOR
ORN
19
IN
FL +B IG1
GEAR SHIFT SENSOR
CONTROL MODULE 1 6
GRY OUT
FL-GND LEFT-REAR
IC ELECTRIC
2 23
DATA LINK GRN CURRENT
CONNECTOR (DLC) LIMITATION IN
FR +B
6 1 10
WHT PNK +B OUT
2 PARKING 1 FR-GND RIGHT-REAR
BRAKE FLUID BRAKE SWITCH
LEVEL SWITCH 14 1 21
Closed: Parking RED YEL
Closed: Low fluid
1
GAUGE CONTROL MODULE 32P CONNECTOR
brake applied
12
WHEEL SPEED
SENSOR 2
RL +B
8
GND
IN
RR +B PUMP MOTOR
BLK
16
PNK +B
2
LONGITUDINAL ACCELERATION
GRY
RR-GND
4
4
BLK
SENSOR 5P CONNECTOR
BLK
36
MR-GND
35
BLK
GND
: 12 V :5V
G302*1 G502 G402*1
*1: LHD model *3: With trailer
lighting connector
G301*2 G203*2 *2: RHD model *4: Without trailer
lighting connector
8. Measure the voltage between VSA modulator-control unit 36P connector terminal No. 30 and body ground.
Is there battery voltage?
YES - Go to Step 9 .
NO - Repair open in the wire between the No. 11 (7.5 A) fuse in the driver's under-dash fuse/relay box and the
VSA modulator-control unit.■
9. Turn the ignition switch to LOCK (0).
10. Check for continuity between VSA modulator-control unit 36P connector terminal No. 35 and body ground.
Is there continuity?
YES - Go to Step 11 .
NO - Repair open in the wire between the VSA modulator-control unit and body ground (G402 *1 , G203 *2 ).■
*1: LHD model
*2: RHD model
11. Measure the voltage between VSA modulator-control unit 36P connector terminal No. 12 and body ground.
Is there battery voltage?
YES - Go to Step 12 .
NO - Repair open in the wire between the No. 37 (30 A) fuse in the under-hood fuse/relay box and the VSA
modulator-control unit.■
12. Disconnect the gauge control module 32P connector.
13. Check for continuity between the VSA modulator-control unit 36P connector terminal and gauge control module
32P connector terminal (see table).
Sign VSA Modulator-control Unit 36P Gauge Control Module 32P
Connector Terminal Connector Terminal
CAN-L No. 1 No. 29
CAN-H No. 14 No. 30
Is there continuity?
YES - Go to Step 14 .
NO - Repair open in the wire between the gauge control module and the VSA modulator-control unit.■
14. Reconnect all connectors.
15. Update the VSA modulator-control unit if it does not have the latest software. If the unit already has the latest
software, substitute a known-good VSA modulator-control unit.
16. Turn the ignition switch to LOCK (0), then turn it to ON (II) again.
17. Check the ABS indicator, brake system indicator and the VSA indicator for several seconds when the ignition
switch is turned to ON (II).
Do the indicators come on then go off?
YES - If the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control
unit was substituted, replace the original VSA modulator-control unit. ■
NO - Check for loose terminals in the VSA modulator-control unit 36P connector. If the VSA modulator-control
unit was updated, substitute a known-good VSA modulator-control unit, then retest. If the VSA modulator-
control unit was substituted, go to Step 1 .
HDS does not communicate with the VSA modulator-control unit or the vehicle
Diagnostic procedure
1. Troubleshoot the DLC circuit.
VSA activation indicator does not come on at start-up (bulb check)
Diagnostic procedure
1. Do the gauge control module troubleshooting.
2. Update the VSA modulator-control unit if it does not have the latest software, or substitute a known-good VSA modulator-control unit, then retest.
If it is OK, the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control unit was substituted, replace
the original VSA modulator-control unit.
VSA activation indicator does not go off, and no DTCs are stored
Diagnostic procedure
1. Symptom troubleshooting.
2. Update the VSA modulator-control unit if it does not have the latest software, or substitute a known-good VSA modulator-control unit, then retest.
If it is OK, the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control unit was substituted, replace
the original VSA modulator-control unit.
ABS indicator, brake system indicator, and VSA indicator do not come on at the same time
Diagnostic procedure
1. Do the gauge control module troubleshooting.
2. Update the VSA modulator-control unit if it does not have the latest software, or substitute a known-good VSA modulator-control unit, then retest.
If it is OK, the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control unit was substituted, replace
the original VSA modulator-control unit.
ABS indicator, brake system indicator, and VSA indicator do not go off at the same time
Diagnostic procedure
1. Check for F-CAN DTCs, and troubleshoot and repair those first.
2. Symptom troubleshooting.
3. Do the gauge control module troubleshooting.
VSA System Symptom Troubleshooting Index
When the vehicle has one of these symptoms, check for a diagnostic trouble code (DTC) with the HDS. If there is no DTC, do the diagnostic procedure
for the symptom, in the sequence listed, until you find the cause.
Symptom Diagnostic procedure
HDS does not communicate with the VSA modulator-control unit or the Troubleshoot the DLC circuit.
vehicle
VSA activation indicator does not come on at start-up (bulb check) 1.Do the gauge control module troubleshooting.
2.Update the VSA modulator-control unit if it does not have the latest
software, or substitute a known-good VSA modulator-control unit, then
retest. If it is OK, the VSA modulator-control unit was updated,
troubleshooting is complete. If the VSA modulator-control unit was
substituted, replace the original VSA modulator-control unit.
VSA activation indicator does not go off, and no DTCs are stored 1.Symptom troubleshooting.
2.Update the VSA modulator-control unit if it does not have the latest
software, or substitute a known-good VSA modulator-control unit, then
retest. If it is OK, the VSA modulator-control unit was updated,
troubleshooting is complete. If the VSA modulator-control unit was
substituted, replace the original VSA modulator-control unit.
ABS indicator, brake system indicator, and VSA indicator do not come on 1.Do the gauge control module troubleshooting.
at the same time 2.Update the VSA modulator-control unit if it does not have the latest
software, or substitute a known-good VSA modulator-control unit, then
retest. If it is OK, the VSA modulator-control unit was updated,
troubleshooting is complete. If the VSA modulator-control unit was
substituted, replace the original VSA modulator-control unit.
ABS indicator, brake system indicator, and VSA indicator do not go off at 1.Check for F-CAN DTCs, and troubleshoot and repair those first.
the same time 2.Symptom troubleshooting.
3.Do the gauge control module troubleshooting.
Steering Angle Sensor Replacement
NOTE:
Do not damage or drop the combination switch as the steering angle sensor is sensitive to
shock and vibration.
The illustration shows LHD model, RHD model is symmetrical.
1. Remove the steering wheel.
2. Remove the steering column covers and the cable reel.
3. Remove the combination switch assembly.
4. Remove the combination light switch (A) and the wiper/washer switch (B) from the combination
switch body assembly (C).
5. Install the combination switch body assembly in the reverse order of removal.
NOTE:
Do not remove the steering angle sensor from the combination switch body.
When installing the cable reel, set the turn signal canceling sleeve position.
Note that the tightening order is specified for combination switch mounting screws.
VSA Modulator-control Unit Removal and Installation
NOTE:
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint,
wash it off immediately with water.
Be careful not to damage or deform the brake lines during removal and installation.
Plug the end of a hose and joints to prevent spilling brake fluid.
Removal
1. Turn the ignition switch to LOCK (0).
2. Disconnect the VSA modulator-control unit 36P connector (A) by pushing the lock (B) and
pulling down the lever (C); the connector disconnects itself.
3. Disconnect the six brake lines from the VSA modulator-control unit.
NOTE: Brake lines are connected to the master cylinder (D) and to the left-front (E), the right-
front (F), the left-rear (G), and the right-rear (H) brake systems.
4. Remove the VSA modulator-control unit (I) with the bracket (J) from the body.
5. Remove the VSA modulator-control unit from the bracket.
Installation
1. Install the VSA modulator-control unit onto the bracket.
2. Install the bracket with the VSA modulator-control unit to the body.
3. Reconnect the six brake lines, then tighten the flare nuts to the specified torque.
4. Align the connecting surface of the VSA modulator-control unit 36P connector to the VSA modulator-control unit.
5. Pull up the lever of the VSA modulator-control unit 36P connector, then confirm the connector is fully seated.
6. Bleed the brake system.
7. Do the VSA sensor neutral position memorization procedure.
8. Start the engine, and check that the ABS and the VSA indicators go off.
9. Test-drive the vehicle, and make sure that the ABS and the VSA indicators do not come on.
NOTE: If the brake pedal is spongy, there may be air trapped in the modulator which could then be induced into the
normal brake system during modulation. Bleed the brake system again.
VSA Modulator-Control Unit Update
Special Tools Required
Honda diagnostic system (HDS)
Honda interface module (HIM)
HDS pocket tester
NOTE:
Use this procedure when you need to update the VSA modulator-control unit during troubleshooting procedures.
Make sure the HDS/HIM has the latest software version.
Before you update the VSA modulator-control unit, make sure the battery in the vehicle is fully charged, and
connect a jumper battery (not a battery charger) to maintain system voltage.
Never turn the ignition switch to LOCK (0) during the update. If there is a problem with the update, leave the ignition
switch to ON (II).
To prevent VSA modulator-control unit damage, do not operate anything electrical (headlights, audio system,
brakes, A/C, power windows, door locks, etc.) during the update.
To ensure the latest program is installed, do a VSA modulator-control unit update whenever the VSA modulator-
control unit is substituted or replaced.
You cannot update a VSA modulator-control unit with a program it already has. It will only accept a new program.
If you need to diagnose the Honda interface module (HIM) because the HIM's red (#3) light came on or was flashed
during the update, leave the ignition switch in ON (II) when you disconnect the HIM from the data link connector
(DLC). This will prevent VSA modulator-control unit damage.
DTCs stored in memory are cleared when the VSA modulator-control unit is updated.
1. Turn the ignition switch to ON (II), but do not start the engine.
2. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.
3. Make sure the HDS communicates with the vehicle and the VSA modulator-control unit. If it doesn't,
troubleshooting the DLC circuit.
4. Select the update mode, and follow the screen prompts to update the VSA modulator-control unit.
5. If the software in the VSA modulator-control unit is the latest, disconnect the HDS/HIM from the DLC. If the
software in the VSA modulator-control unit is not the latest, follow the instructions on the screen.
6. Do the VSA sensor neutral position memorization procedure.
VSA Sensor Neutral Position Memorization
NOTE: Make sure to connect and disconnect the HDS to the 16P data link connector (DLC) with the ignition switch in
LOCK (0).
1. Start the engine, let it idle.
2. Slowly drive the vehicle straight without operating the steering wheel for 3 m (10 ft) or more, then park the vehicle on
a flat surface while holding the steering wheel in the straight ahead position.
3. With the ignition switch in LOCK (0), connect the HDS to the 16P data link connector (DLC) (A) under the driver's
side of the dashboard.
4. Turn the ignition switch to ON (II).
5. Do the VSA sensor neutral position memorization with the HDS.
NOTE:
Do not press the brake pedal during this procedure.
Make sure the HDS communicates with the vehicle and the VSA modulator-control unit. If it doesn't
troubleshoot the DLC circuit.
6. Turn the ignition switch to LOCK (0).
VSA OFF Switch Test
1. Turn the ignition switch to LOCK (0).
2. Pull the fuse lid panel (A).
3. Push out the VSA OFF switch (A) from the back of the fuse lid panel.
4. Disconnect the VSA OFF switch 5P connector (B).
5. Check for continuity between the VSA OFF switch 5P connector terminals No. 1 and No. 2. There should be
continuity when the switch is pressed, and no continuity when the switch is released.
6. Check for continuity between VSA OFF switch 5P connector terminals No. 4 and No. 5. There should be continuity
at all times.
7. Install the VSA OFF switch in the reverse order of removal.
Wheel Speed Sensor Replacement
Front
1. Turn the ignition switch to LOCK (0).
2. Remove the grommet (A), then disconnect the wheel speed sensor connector (B).
3. Remove the bracket (C), the clip (D), and the stay (E).
4. Remove the bolt and the wheel speed sensor (F).
5. Install the wheel speed sensor in the reverse order of removal, and note these items:
Install the sensor carefully to avoid twisting the wires.
If the wheel speed sensor comes in contact with the wheel bearing, it is faulty.
Make sure the grommet is installed properly.
6. Start the engine, and make sure the ABS and the VSA indicator go off.
7. Test-drive the vehicle, and make sure the ABS and the VSA indicator do not come on.
Rear
1. Turn the ignition switch to LOCK (0).
2. Pull back the carpet under the rear seat, then disconnect the wheel speed sensor connector
(A).
3. Remove the grommet (B), the bracket (C), the clips (D), and the stay (E).
4. Remove the bolt and the wheel speed sensor (F).
5. Install the wheel speed sensor in the reverse order of removal, and note these items:
Install the sensor carefully to avoid twisting the wires.
If the wheel speed sensor comes in contact with the hub bearing unit, it is faulty.
Make sure the grommet is installed properly.
6. Start the engine, and make sure the ABS and the VSA indicator go off.
7. Test-drive the vehicle, and make sure the ABS and the VSA indicator do not come on.
Yaw Rate-Lateral/Longitudinal Acceleration Sensor Replacement
NOTE:
Do not damage or drop the sensor as it is sensitive.
Do not use power tools.
1. Turn the ignition switch to LOCK (0).
2. Remove the center console.
3. Remove the yaw rate-lateral/longitudinal acceleration sensor (A) mounting nuts.
4. Disconnect the yaw rate-lateral/longitudinal acceleration sensor 4P connector (B).
5. Check for deformation in the bracket (C). If necessary replace it.
6. Install the yaw rate-lateral/longitudinal acceleration sensor in the reverse order of removal.
7. Do the VSA sensor neutral position memorization.
Driveshaft Disassembly
Special Tools Required Welded type
Threaded adapter, 22 x 1.5 mm
07XAC-0010100
Puller
, commercially available
Inboard Joint Side
Low profile type
1. Remove the boot bands. Be careful not to damage the boot.
If the boot band is welded type (A), cut the boot band.
If the boot band is a double loop type (B), lift up the band end (C), and push it into the clip (D).
If the boot band is a low profile type (E), pinch the boot band using the commercially available boot band
pincers (F).
2. Make marks (A) on each roller (B) and the inboard joint (C) to identify the locations of rollers to the grooves in the
inboard joint. Then remove the inboard joint on a clean shop towel (D). Be careful not to drop the rollers when
separating them from the inboard joint.
NOTE: Do not engrave or scribe any marks on the rolling surface.
3. Make marks (A) on the rollers (B) and spider (C) to identify the locations of the rollers on the spider, then remove
the rollers.
NOTE: Do not engrave or scribe any marks on the rolling surface.
4. Remove the circlip (D).
5. Make marks (E) on the spider and driveshaft (F) to identify the position of the spider on the shaft.
6. Remove the spider.
NOTE: If necessary, use a commercially available puller.
7. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damaging the boot.
8. Remove the inboard boot. Be careful not to damage the boot.
9. Remove the vinyl tape.
2. Slide the outboard boot (A) partially to the inboard joint side. Be careful not to damage the boot.
3. Wipe off the grease to expose the driveshaft and the outboard joint inner race.
4. Make a mark (A) on the driveshaft (B) at the same level as the outboard joint rim (C).
5. Securely clamp the driveshaft in a bench vise with a shop towel.
6. Remove the outboard joint (A) using the 22 x 1.5 mm threaded adapter (B) and the sliding hammer set (C).
7. Remove the driveshaft from the bench vise.
8. Remove the stop ring from the driveshaft.
9. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damaging the boot.
10. Remove the outboard boot. Be careful not to damage the boot.
11. Remove the vinyl tape.
Driveshaft Inspection
1. Check the inboard boot (A) and the outboard boot (B) on the driveshaft (C) for cracks, damage, leaking grease, and
loose boot bands (D). If any damage is found, replace the boot and boot bands.
2. Check the driveshaft for cracks and damage. If any damage is found, replace the driveshaft.
3. Check the inboard joint (E) and the outboard joint (F) for cracks and damage. If any damage is found, replace the
inboard joint or the outboard joint as an assembly.
4. Hold the inboard joint and turn the front wheel by hand, then make sure the joint is not excessively loose. If
necessary, replace the inboard joint or the outboard joint as an assembly.
Intermediate Shaft Removal
1. Drain the transmission fluid. Reinstall the drain using a new sealing washer.
2. Remove the right driveshaft.
3. Remove the control cable cover (A).
2. Press the intermediate shaft (A) out of the intermediate shaft bearing (B) using a press. Be careful not to damage
the bearing support ring (C) on the intermediate shaft during disassembly.
3. Remove the internal snap ring (A) from the bearing support (B).
4. Press intermediate shaft bearing (A) out of the bearing support (B) using the 44.5 mm oil seal driver (C), the half
shaft base (D) and a press.
Intermediate Shaft Reassembly
Exploded View
Special Tools Required
Oil seal driver, 65 mm
07JAD-PL90100
3. Install the internal snap ring (A) into the groove (B) of the bearing support.
4. Press the intermediate shaft (A) into the new shaft bearing (B) using the 35 mm inner bearing driver attachment (C)
and a press.
5. Install the external snap ring (A) in the groove of the intermediate shaft (B).
6. Install a new outer seal (A) into the bearing support (B) using the 65 mm oil seal driver (C), and a press. Press the
seal until it is 0±0.2 mm (0±0.08 in.) below the surface of the bearing support end.
Steering Component Location Index
DRIVER'S AIRBAG
Replacement,
STEERING WHEEL
Removal,
Disassembly/Reassembly,
Installation,
STEERING COLUMN
Removal and Installation,
Inspection,
Steering Lock Replacement,
Be careful not to pull the bracket (A) on the front side of steering column out of its normal position.
If the bracket accidentally comes out, replace the steering column as an assembly.
7. Hold the lower slide shaft (A) on the column with a piece of wire (B) between the joint yoke (C) of the lower slide
shaft and joint yoke (D) of the upper shaft to prevent the lower slide shaft from pulling out.
8. Release the lock lever, and adjust the steering column to the full telescopic out position, then tighten the lock lever.
NOTE: Do not release lock lever when removing the steering column from the frame.
10. Disconnect the steering joint (A) by moving the steering joint toward the column.
NOTE:
If the center guide (B) is in place and has not moved, leave it in place.
If the center guide has moved or been removed, discard it.
11. Remove the column covers.
12. Disconnect the connectors from the ignition switch, and release the wire harness clips (A) from
the steering column.
13. Disconnect the wire harness connectors from the combination switch assembly/cable reel (B).
14. Remove the combination switch assembly from the steering column shaft by removing the three
screws (C).
15. Remove the steering column (D) by removing the attaching nuts and bolts. If the lower slide
shaft (E) is removed, slip it into the upper shaft (F) by aligning the paint or stamped marks (G).
Installation
1. Install the steering column in the reverse order of removal, and note these items:
Tighten the steering column mounting nuts and bolts to the specified torque in the following order; bolts,
then nuts.
Make sure the wires are not caught or pinched by any parts.
Take care not to let the sliding capsules fall out of position during column installation.
Tighten the three screws (A) to the sequence shown.
2. Center the steering rack within its stroke.
3. With the rack in the straight ahead driving position, then cut the wire.
4. Slip the lower end of the steering joint (A) onto the pinion shaft (B).
NOTE:
Pinion shaft with center guide; install the steering joint by aligning the center guide (C).
Pinion shaft without center guide; position the steering column by aligning the gap (D) with the angle.
5. Release the lock lever, and adjust the steering column to the full tilt down position, and to the full telescopic out
position, then tighten the lock lever.
6. Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft, then loosely install the lower
steering joint bolt (C). Be sure that the joint bolt is securely in the groove in the pinion shaft.
7. Pull on the steering joint to make sure that the steering joint is fully seated, then tighten the lower joint bolt to the
specified torque.
6. If the measurement is higher than the specified, replace the steering column as an assembly.
4. If the measurement is higher than the specified, replace the steering column as an assembly.
3. If the measurement is higher than the specified, replace the steering column as an assembly.
Steering Gearbox Mount Cushion Replacement
1. Remove the steering gearbox.
2. Position a 34 mm socket wrench (A) on the flange part of the gearbox housing with a washer (B), a 10 x 105 mm
flange bolt (C) and a 10 mm nut (D) as shown.
3. Hold the flange bolt with a wrench, and tighten the nut with a wrench. Remove the gearbox mount cushion (E).
4. Apply a mild soap and water solution to the new gearbox mount cushion surface (A), then place it on the gearbox
mounting cushion hole.
5. Position the 34 mm socket wrench on the flange part of the gearbox housing with a washer, a flange bolt, and a nut
as shown.
6. Install the gearbox mount cushion by tightening the nut until the mount cushion edges (B) contact the gearbox
flange surface.
7. Install the steering gearbox.
Steering Linkage and Gearbox Inspection
Steering Lock Replacement
1. Remove the steering column.
2. Center-punch each of the two shear bolts, and drill their heads off with a 5.0 mm (0.20 in.) drill bit. Be careful not to
damage the switch body when removing the shear bolts.
3. Remove the shear bolts from the switch body.
4. Install the switch body without the key inserted.
5. Loosely tighten the new shear bolts.
6. Insert the ignition key, and check for proper operation of the steering wheel lock and that the ignition key turns
freely.
7. Tighten the shear bolts (A) until the hex heads (B) twist off.
8. Rewrite the new immobilizer control unit-receiver , and make sure the immobilizer system works properly.
Steering Rack End Removal and Installation
RHD model
LHD model
Removal
NOTE:
Do not allow dust, dirt, or other foreign materials to enter the steering gearbox.
The illustrations show RHD model, LHD model is similar for items not shown in this section.
1. Remove the boot bands (A) and discard them. Remove the tie-rod clips (B), and pull the boots away from the ends
of the steering gearbox.
2. Hold the gearbox housing using a C-clamp (A) and wooden blocks (B) as shown. Do not clamp the cylinder part of
the gearbox housing in the vise.
4. Hold the flat surface sections (A) of the steering rack (B) with one wrench, and unscrew both rack ends (C) with
another wrench. Be careful not to damage the rack shaft surface with the wrench.
5. Remove the lock washer (D) and rubber stop (E).
Installation
1. Hold the gearbox housing using a C-clamp (A) and wooden blocks (B) as shown. Do not clamp the cylinder part of
the gearbox housing in the vise.
2. Install the new rubber stop (A) and a new lock washer (B). Align the lock washer tabs (C) with the slots (D) on the
rack end (E) while holding the lock washer in place. Repeat this step for the other side of the rack.
3. Hold the flat surface sections of the steering rack with one wrench, and tighten both rack ends with another wrench.
Be careful not to damage the rack surface with the wrench.
4. Bend the lock washer (A) back against the flat spots on the rack end joint housing.
5. Apply multipurpose grease to the circumference of the rack end joint housing (A).
6. Apply a light coat of silicone grease to the boot grooves (B) on the rack end.
7. Clean off any grease or contamination from the boot installation grooves (A) around on the gearbox housing. Install
the boots (B) on the rack ends with the tie-rod clips (C), and fit the boot end in the installation grooves in the
housing properly.
8. After installing the boots, wipe the grease off the thread section (D) of the rack end.
9. Install the new boot bands by aligning the tabs (A) with the holes (B) of the band.
10. Close the ear portion (A) of the boot band (B) with commercially available pincers, Oetiker 1098 or equivalent (C).
11. Slide the rack right and left to be certain that the boots are not deformed or twisted.
12. Install the tie-rod end to the rack end.
13. Install the steering gearbox.
Steering Rack Guide Removal/Installation
NOTE:
During removal/installation, do not allow dust, dirt, or other foreign materials to enter the steering gearbox.
The illustrations show RHD model, LHD model is similar for items not shown in this section.
1. Remove the steering gearbox.
2. Loosen the locknut (A), then remove the rack guide screw (B), the spring (C), disc washer (D), and rack guide (E).
3. Replace the O-ring (F) from the rack guide. Wipe the grease off the sliding surface of the rack guide.
4. Apply multipurpose grease to the new O-ring, then install it to the rack guide.
5. Apply multipurpose grease to the sliding surface and the circumference of the rack guide, and install it onto the
gearbox housing. Wipe the grease off the threaded section of the gearbox housing.
6. Install the disc washer onto the gearbox housing.
7. Install the spring onto the gearbox housing.
8. Remove the old sealant from the rack guide screw and apply new sealant (Three Bond 1215 or Loctite 5699) to the
middle of the threads. Loosely install the rack guide screw on the steering gearbox.
NOTE: If more than 5 minutes has passed after applying the sealant, remove the old sealant and residue, and
reapply new sealant.
9. Loosely install the locknut.
10. Adjust the rack guide screw. After adjusting, check that the rack moves smoothly by sliding the rack right and left.
Steering Rack Guide Adjustment
Special Tools Required
Locknut eye wrench, 40 mm
07MAA-SL00100
1. Set the wheels in the straight ahead position.
2. Loosen the rack guide screw locknut (A) with the locknut wrench, then remove the rack guide screw (B).
3. Remove the old sealant from the rack guide screw (A), and apply new sealant (Three Bond 1215 or Loctite 5699) to
the middle of the threads (B). Loosely install the rack guide screw on the steering gearbox.
NOTE: If more than 5 minutes has passed after applying the sealant, remove the old sealant and residue, and
reapply new sealant.
4. Tighten the rack guide screw (A) to 25 N·m (2.5 kgf·m, 18 lbf·ft), then loosen it.
5. Retighten the rack guide screw to 3.9 N·m (0.4 kgf·m, 4 lbf·ft), then back it off to the specified angle.
Specified return angle: 10±3 °
6. Hold the rack guide screw stationary with a wrench, and tighten the locknut by hand until it's fully seated.
7. Install the locknut wrench on the locknut (B), and hold the rack guide screw stationary with a wrench.
Tighten the locknut to the specified torque.
8. Check for unusual steering effort through the complete turning range.
9. Check the steering wheel rotation play and the power assist.
Steering Wheel Removal
SRS components are located in this area. Review the SRS component locations, and the precautions and procedures
before doing repairs or service.
1. Do the battery terminal disconnection procedure.
2. Align the front wheels straight ahead, then remove the driver's airbag from the steering wheel.
3. Disconnect the cable reel subharness connector (A).
4. Loosen the steering wheel bolt (B).
5. Install a commercially available steering wheel puller (A) on the steering wheel (B). Free the steering wheel from the
steering column shaft by turning the pressure bolt (C) of the puller.
Note these items when removing the steering wheel:
Do not tap on the steering wheel or the steering column shaft when removing the steering wheel.
If you thread the puller bolts (D) into the wheel hub more than five threads, the bolts will hit the cable reel
and damage it. To prevent this, install a pair of jam nuts five threads up on each puller bolt.
6. Remove the steering wheel puller, then remove the steering wheel bolt and steering wheel from the steering column.
Steering Wheel Installation
1. Before installing the steering wheel, make sure the front wheels are pointing straight ahead, then center the cable
reel (A). Do this by first rotating the cable reel clockwise until it stops. Then rotate it counterclockwise about three
full turns. The arrow mark (B) on the cable reel label should point straight up.
2. Position the two tabs (A) of the turn signal canceling sleeve (B) as shown. Install the steering wheel on to the
steering column shaft, making sure the steering wheel hub (C) engages the pins (D) of the cable reel and tabs of
the turn signal canceling sleeve. Do not tap on the steering wheel or steering column shaft when installing the
steering wheel.
3. Install the steering wheel bolt (A), and tighten it to the specified torque. Connect the cable reel subharness
connector (B). Make sure the wire harness is routed and fastened properly.
4. Install the driver's airbag.
5. Do the battery terminal reconnection procedure, and do these tasks:
Turn the ignition switch to ON (II) and check that the SRS indicator should come on for about 6 seconds and
then go off.
Make sure the horn and turn signal switches work properly.
Make sure the steering wheel switches work properly.
6. After installation, do these checks:
Check the steering wheel spoke angle. If the steering spoke angles to the right and left are not equal
(steering wheel is not centered), correct the engagement of the wheel/column shaft splines.
Set the steering column to the center tilt position, and to the center telescopic position, then do the front toe
inspection.
Steering Tie-rod Ball Joint Boot Replacement
Special Tools Required
Driver, 32.5 mm
070AD-SAA0100
1. Disconnect the tie-rod ball joint from the knuckle.
2. Remove the tie-rod end from the rack end.
3. Remove the tie-rod ball joint boot from the tie-rod end, and wipe the old grease off the ball pin.
4. Pack the lower area of the ball pin (A) with fresh multipurpose grease.
5. Pack the interior of the new tie-rod ball joint boot (B) and lip (C) with fresh multipurpose grease.
Note these items when installing new grease:
Keep grease off the boot mounting area (D) and the tapered section (E) of the ball pin.
Do not allow dust, dirt, or other foreign materials to enter the boot.
6. Install the new tie-rod ball joint boot (A) using the inner bearing driver attachment. The boot must not have a gap at
the boot installation sections (B). After installing the boot, check the ball pin tapered section for grease
contamination, and wipe it if necessary.
7. Install the tie-rod end to the rack end.
8. Connect the tie-rod ball joint to the knuckle.
9. Check the wheel alignment, and adjust it if necessary.
EPS System Description
EPS Control Unit Inputs and Outputs for Connector A (2P)
EPS Control Unit Inputs and Outputs for Connector B (2P)
EPS Control Unit Inputs and Outputs for Connector C (16P)
EPS Circuit Diagram
BATTERY
EPS CONTROL UNIT
BATTERY TERMINAL
FUSE BOX
VCC
No. 2 (60 A) POWER RELAY
A2
WHT
UNDER-DASH FUSE/RELAY WHT
+B
UNDER-DASH
FUSE/RELAY BOX
BOX CONNECTOR B (36P)
No. 1 (100 A) No. 60 (IGN) (50 A)
T-9
WHT WHT STEERING GEARBOX
TORQUE SENSOR
6 IG1 3 T1 C3 *1 1
YEL WHT YEL
VS1 VS1
*2
YEL PNK
IGNITION C2 *1 2
SWIHTCH W1 No. 11 (7. 5 A) B11 C8 PNK
YEL PUR T/S GND T/S GND
PUR IG1 *2
GAUGE CONTROL PNK BLU/RED
MODULE C1 *1 3
BLU
TEST TACHOMETER VS2 *2 VS2
CONNECTOR BLU WHT/GRN
EPS
INDICATOR 2
30 LT BLU
WHT
CAN-H
29 FAIL-SAFE
RED ECM/PCM RELAY EPS MOTOR
CAN-L B1 2
A29 C7 GRN BLK
LT BLU LT BLU LT BLU M− M−
NEP NEP
A3
WHT B2 1
CAN-H RED RED
M+ M+
A4
RED
CAN-L
A32
YEL
GAUGE CONTROL MODULE 32P CONNECTOR BLK
A1 *2
GRY
SCS PG GND
BLK
1
G402* 1
G302
G301* 2 GND
BLK
DATA LINK *1
CONNECTOR (DLC)
6 C10 G301
WHT WHT WHT WHT
CAN-H
CAN
CONTROLLER
14 C9
RED RED RED RED
CAN-L
9 C5
YEL YEL
SCS
7
BLU EPS CONTROL UNIT EPS CONTROL UNIT BLU
C16
K-LINE
EPS CONTROL UNIT
16
CONNECTOR A (2P) CONNECTOR B (2P) CONNECTOR C (16P)
PNK +B
4
BLK
: 12 V
:5V
*1: RHD model
G502 *2: LHD model
11. Measure the voltage between EPS control unit connector C (16P) terminal No. 8 and body ground.
Is there battery voltage?
YES - Go to Step 12 .
NO - Repair open in the wire between the EPS control unit and No. 11 (7.5 A) fuse in the under-dash fuse/relay
box.■
12. Turn the ignition switch to LOCK (0).
13. Disconnect the EPS control unit connector A (2P).
14. Check for continuity between EPS control unit connector A (2P) terminal No. 1 and body ground.
Is there continuity?
YES - Go to Step 15 .
NO - LHD model: Repair open in the wire between the EPS control unit and body ground (G301).■
RHD model: Repair open in the wire between the EPS control unit and body ground (G402).■
17. Check for continuity between EPS control unit connector C (16P) terminal and gauge control module 32P
connector terminal individually.
Sign EPS Control Unit Connector C Gauge Control Module 32P
(16P) Terminal Connector Terminal
CAN-L 9 29
CAN-H 10 30
Is there continuity?
YES - Check for loose terminals in the EPS control unit connectors and repair if necessary. If no poor
connections are found, replace the EPS control unit. ■
NO - Repair open in the wire between the EPS control unit and gauge control module.■
HDS does not communicate with the EPS control unit or the vehicle
Procedure(s)
1. Troubleshoot the DLC circuit
EPS indicator does not come on
Procedure(s)
1. Do the gauge control module troubleshooting
EPS indicator does not go off, and no DTCs are stored
Procedure(s)
1. Symptom Troubleshooting
2. Do the gauge control module troubleshooting
EPS Symptom Troubleshooting Index
Symptom Procedure(s) Also check for
HDS does not communicate with Troubleshoot the DLC circuit
the EPS control unit or the
vehicle
EPS indicator does not come on Do the gauge control module troubleshooting
EPS indicator does not go off, 1. Symptom Troubleshooting
and no DTCs are stored 2. Do the gauge control module troubleshooting
EPS Control Unit Removal/Installation
NOTE: The illustrations shows RHD model, LHD model is similar.
1. Do the battery terminal disconnection procedure.
2. Disconnect EPS control unit connector A (2P), connector B (2P), and connector C (16P).
3. Remove the connector clips from EPS control unit bracket (D).
4. Remove the nuts (E) from the EPS control unit bracket.
5. Remove the EPS control unit.
6. Install the EPS control unit in the reverse order of removal.
7. Do the battery terminal reconnection procedure.
8. Do the memorizing the torque sensor neutral position.
9. After installation, start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times.
Check that the EPS indicator does not come on.
EPS Torque Sensor Neutral Position Memorization
The torque sensor neutral position must be memorized whenever the steering gearbox, the EPS motor, or the EPS control
unit is replaced. Note that the torque sensor neutral position is not affected when erasing the DTC.
NOTE: The torque sensor is temperature sensitive. When memorizing the torque sensor neutral position, the ambient
temperature must be above 20 °C (68 °F).
1. With the ignition switch in LOCK (0), connect the HDS to the DLC (data link connector) (A) located under the
driver's side of the dashboard.
2. Turn the ignition switch to ON (II).
3. Make sure the HDS communicates with the vehicle and the EPS control unit. If it doesn't, troubleshoot the DLC
circuit.
4. From the EPS MENU, select MISCELLANEOUS TEST then TORQUE SENSOR LEARN and follow the screen
prompts on the HDS.
NOTE: See the HDS Help menu for specific instructions.
5. Turn the ignition switch to LOCK (0).
EPS Motor Removal and Installation
NOTE:
Do not allow dust, dirt, or other foreign materials to enter the steering gearbox.
The illustrations show RHD model, LHD model is similar for items not shown in this section.
Removal
1. Remove the steering gearbox.
2. LHD model: Remove the torque sensor 4P connector (A) from the connector bracket (B).
3. Remove the connector bracket mount bolt (A), then remove the EPS motor (B) and the O-ring (C).
Installation
1. Clean the mating surfaces of the EPS motor (A) and the steering gearbox.
2. Apply steering grease to the new O-ring (B), and carefully fit it on the EPS motor.
NOTE: When you apply the silicone grease, make sure not to adhere to the terminal part of connectors and
surrounding switches. Also do not touch the switches and the terminal part of connector by hands or glove that
adheres the silicone grease.
3. Apply steering grease to the EPS motor shaft (C).
4. Install the EPS motor on the steering gearbox by engaging the EPS motor shaft and the worm shaft (D).
5. Turn the EPS motor two or three times to the right and left about 45 degrees. Make sure the EPS motor is evenly
seated on the steering gearbox, and that the O-ring is not pinched between the mating surfaces.
6. Loosely install the EPS motor mounting bolts (E), then turn the steering wheel two or three times to the right and
left about 45 degrees.
7. Tighten the EPS motor mounting bolts to the specified torque.
8. LHD model: Install the torque sensor 4P connector to the connector bracket.
9. Install the steering gearbox.
A/C Service Tips and Precautions
Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
Be careful when connecting service equipment.
Do not breathe refrigerant or vapor.
The air conditioning system uses HFC-134a (R-134a) refrigerant and polyalkyleneglycol (PAG) refrigerant oil, which are not
compatible with CFC-12 (R-12) refrigerant and mineral oil. Do not use R-12 refrigerant or mineral oil in this system, and do
not attempt to use R-12 servicing equipment; damage to the air conditioning system or your servicing equipment will
result.
Separate the manifold gauge sets (pressure gauges, hoses, joints) for refrigerants R-12 and R-134a. Do not confuse them.
If accidental system discharge occurs, ventilate the work area before resuming service.
R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with
compressed air.
Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.
Always disconnect the negative cable from the battery whenever replacing air conditioning parts.
Keep moisture and dirt out of the system. When disconnecting any lines, plug or cap the fittings immediately; don't
remove the caps or plugs until just before you reconnect each line.
Before connecting any hose or line, apply a few drops of refrigerant oil to the O-ring.
When tightening or loosening a fitting, use a second wrench to support the matching fitting.
When discharging the system, don't let refrigerant escape too fast; it will draw the A/C compressor oil out of the
system.
A/C System Test
Performance Test
Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
Be careful when connecting service equipment.
Do not breathe refrigerant or vapor.
The performance test will help determine if the air conditioner system is operating within specifications.
Use only service equipment for refrigerant HFC-134a (R-134a).
If accidental system discharge occurs, ventilate the work area before resuming service.
R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with
compressed air.
Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.
1. Connect an R-134a refrigerant recovery/recycling/charging station to the high-pressure service port and the low-
pressure service port, following the equipment manufacturer's instructions.
2. Determine the relative humidity and air temperature.
3. Open the globe box. Release the glove box stop on each side, then let the glove box hang down.
4. Insert a thermometer (A) in the center vent.
5. Place another thermometer (B) near the blower unit's recirculation inlet duct.
6. Test conditions:
Avoid direct sunlight.
Open hood.
Open front doors.
Set the temperature control dial to Max Cool, the mode control switch to Vent, and the recirculation control
knob to Recirculate.
Turn the A/C switch ON and the fan switch to Max.
Run the engine at 1,500 rpm (min −1 ).
No driver or passengers in vehicle.
7. After running the air conditioning for 10 minutes under the above test conditions, read the delivery temperature from
the thermometer in the center vent, the intake temperature near the blower unit, and the high and low system
pressure from the A/C gauges.
10. To complete the low side (suction pressure)/ambient air (intake) temperature chart:
Mark the low side (suction pressure) temperature along the vertical line.
Mark the ambient air (intake) temperature along the bottom line.
Draw a vertical line from the ambient air (intake) temperature mark.
Draw a horizontal line from the vent (delivery) temperature mark until it intersects the
vertical line.
NOTE: The low side and intake temperatures should intersect in the shaded area within about
10 % of the measured humidity level. Any measurements outside the line may indicate the need
for further inspection.
Pressure Test
Test results Related symptoms Probable cause Remedy
Driver's and Poor A/C performance. Discharge (high) Low refrigerant charge Recover, evacuate, and recharge with
passenger's and suction (low) pressures are low. specified amount.
side vent Air mix door inoperable Repair or replace.
temperatures
vary by more
than 11 °C
Discharge After stopping A/C compressor, Air in system Recover, evacuate, and recharge with
(high) pressure drops about 196 kPa (2.0 specified amount.
pressure kgf/cm 2 , 28 psi) quickly, and then falls
abnormally gradually.
high Reduced or no airflow through A/C Clogged condenser Clean.
condenser. or radiator fins Check voltage and fan rpm.
A/C condenser or Check fan direction.
radiator fan not
working properly
Line to A/C condenser is excessively Restricted flow of Restricted lines.
hot. refrigerant in system
Discharge High and low-pressures are balanced Faulty A/C Replace the A/C compressor.
pressure soon after stopping A/C compressor. compressor
abnormally Low side is higher than normal. discharge valve
low Faulty A/C
compressor seal
Test results Related symptoms Probable cause Remedy
Outlet of expansion valve is not frosted, Faulty expansion Replace.
low-pressure gauge indicates vacuum. valve Recover, evacuate, and recharge
Moisture in system with specified amount.
Suction (low) Expansion valve is not frosted, and low- Frozen expansion Recover, evacuate, and recharge
pressure pressure line is not cold. Low-pressure valve (Moisture in with specified amount.
abnormally gauge indicates vacuum. system) Replace the expansion valve.
low Faulty expansion
valve
Discharge temperature is low, and the Frozen evaporator Run the fan with A/C compressor off,
airflow from vents is restricted. then check evaporator temperature
sensor.
Expansion valve is frosted. Clogged expansion valve Clean or replace.
Receiver/dryer outlet is cool, and inlet Clogged receiver/dryer Replace.
is warm (should be warm during
operation).
Suction Low-pressure hose and service port are Expansion valve open too Repair or replace.
pressure cooler than the temperature around long
abnormally evaporator.
high Suction pressure is lowered when A/C Excessive refrigerant in Recover, evacuate, and recharge with
condenser is cooled by water. system specified amount.
High and low-pressures are equalized Faulty gasket Replace the A/C compressor.
as soon as the A/C compressor is Faulty high-
stopped, and both gauges fluctuate pressure valve
while running. Foreign particle
stuck in high-
pressure valve
Suction and Reduced airflow through A/C Clogged A/C Clean.
discharge condenser. condenser or Check voltage and fan rpm.
pressures radiator fins Check fan direction.
abnormally A/C condenser or
high radiator fan not
working properly
Suction and Low-pressure hose and metal fittings Clogged or kinked low- Repair or replace.
discharge are cooler than evaporator. pressure hose parts
pressures Temperature around expansion valve is Clogged high-pressure line Repair or replace.
abnormally too low compared with that around
low receiver/dryer.
Refrigerant A/C compressor clutch is dirty. A/C compressor shaft seal Replace the A/C compressor.
leaks leaking
A/C compressor bolt(s) are dirty. Leaking around bolt(s) Tighten bolt(s) or replace A/C
compressor.
A/C compressor gasket is wet with oil. Gasket leaking Replace the A/C compressor.
A/C fitting is dirty. Leaking O-ring Clean the A/C fitting and replace the O-
ring.
A/C System Inspection
Before troubleshooting any problem with the air conditioning system, do the following:
1. With the ignition switch in LOCK (0), inspect the A/C components, pressure lines and hoses for stains that may
indicate a refrigerant or a compressor oil leak.
2. Check the A/C condenser (A) for material clogging the fins or for damage to the fins:
Carefully clean any material from the A/C condenser fins with water and detergent.
Be sure to dry the A/C condenser completely.
3. Inspect the drive belt.
4. Make sure no material is blocking the airflow to the A/C condenser.
5. Check the dust and pollen filter, and replace it if it is clogged.
6. Start the engine, turn the air conditioning system on, and allow it to normalize for a few minutes.
7. Check that the A/C operates at each position of the blower fan switch (except OFF).
8. Check that the A/C compressor clutch (A) is engaged. The pressure plate should be rotating at the same speed as
the pulley.
9. Check that the A/C condenser fan (B) and radiator fan (C) operate when the A/C compressor clutch is engaged.
10. Check that the engine idle speed is correct when the A/C is switched on and off, and when the A/C compressor
clutch is engaged and disengaged.
A/C Line Replacement
A/C Receiver/Dryer Desiccant Replacement
NOTE: Install the receiver/dryer as quickly as possible to prevent the system from absorbing moisture from the air.
1. Remove the A/C condenser.
2. Remove the bolts from the A/C condenser, then remove the receiver/dryer (A), the bracket (B), and the O-rings (C).
3. Install the receiver/dryer in the reverse order of removal. Replace the O-rings with new ones, and apply a thin coat of
refrigerant oil (SP-10) before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid
leakage.
A/C Refrigerant Leak Test
Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
Be careful when connecting service equipment.
Do not breathe refrigerant or vapor.
3. Check the system for leaks using an R-134a refrigerant leak detector with an accuracy of 14 g (0.5 oz) per year or
better.
4. If you find leaks that require the system to be opened (to repair or replace hoses, fittings, etc.), do a recovery of the
system.
5. After checking and repairing leaks, the system must be evacuated.
A/C Refrigerant Recovery
Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
Be careful when connecting service equipment.
Do not breathe refrigerant or vapor.
Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
Be careful when connecting service equipment.
Do not breathe refrigerant or vapor.
Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
Be careful when connecting service equipment.
Do not breathe refrigerant or vapor.
6. Remove the mounting bolts and the A/C compressor (A). Be careful not to damage the radiator fins when removing
the A/C compressor.
7. Install the compressor in the reverse order of removal, and note these items:
Inspect the A/C lines for any signs of contamination.
Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing
them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage.
Use refrigerant oil (SP-10) for HFC-134a SANDEN spiral type A/C compressor only.
To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other
refrigerant oils.
Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption.
Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint,
wash it off immediately.
Charge the system.
A/C Compressor Clutch Check
1. Check the armature plate for discoloration, peeling, or other damage. If there is damage, replace the clutch set.
2. Check the rotor pulley bearing play and drag by rotating the rotor pulley by hand. Replace the clutch set with a new
one if it is noisy or has excessive play/drag.
3. Measure the clearance between the rotor pulley (A) and the armature plate (B) all the way around. If the clearance
is not within specified limits, remove the armature plate and add or remove shims as needed to increase or
decrease clearance.
Clearance: 0.35−0.65 mm (0.014−0.026 in.)
NOTE: The shims are available in four thicknesses: 0.1 mm, 0.2 mm, 0.4 mm, and 0.5 mm.
4. Release the field coil connector from the holder, then disconnect it. Check the thermal protector for continuity. If
there is no continuity, replace the thermal protector.
NOTE: The thermal protector will have no continuity above 122 to 128 °C. When the temperature drops below 116
to 104 °C, the thermal protector will have continuity.
5. Disconnect the field coil connector (A). Check resistance of the field coil. If resistance is not within specifications,
replace the field coil.
Field Coil Resistance: 3.15−3.45 Ω 20 °C
A/C Compressor Clutch Overhaul
1. Remove the center nut while holding the armature plate (A) with a commercially available A/C clutch holder (B).
2. Remove the armature plate (A) and shim(s) (B), taking care not to lose the shim(s). If the clutch needs adjustment,
increase or decrease the number and thickness of shims as necessary, then reinstall the armature plate, and
recheck its clearance.
NOTE: The shims are available in four thicknesses: 0.1 mm, 0.2 mm, 0.4 mm, and 0.5 mm.
3. If you are replacing the field coil, remove the snap ring (A) with snap ring pliers, then remove the rotor pulley (B). Be
careful not to damage the rotor pulley and A/C compressor.
4. Remove the bolt and holder (A), then disconnect the field coil connector (B). Remove the snap ring (C) with snap
ring pliers, then remove the field coil (D). Be careful not to damage the field coil and A/C compressor.
5. Reassemble the clutch in the reverse order of disassembly, and note these items:
Install the field coil with the wire side facing down, and align the boss on the field coil with the hole in the
A/C compressor.
Clean the rotor pulley and A/C compressor sliding surfaces with contact cleaner or other non-petroleum
solvent.
Install new snap rings, note the installation direction, and make sure they are fully seated in the groove.
Make sure that the rotor pulley turns smoothly after it's reassembled.
Route and clamp the wires properly or they can be damaged by the rotor pulley.
A/C Compressor Clutch Circuit Troubleshooting
NOTE:
It is normal for the A/C compressor to turn off under certain conditions, such as low idle, high engine coolant
temperature, or hard acceleration.
Do not use this troubleshooting procedure if the fans are also inoperative with the A/C on. Refer to the symptom
troubleshooting index.
1. Check the No. 43 (7.5 A) and the No. 10 (7.5 A) fuses in the under-dash fuse/relay box.
Are the fuses OK?
YES - Go to Step 2 .
NO - Replace the fuses, and recheck. If the fuses blow again, check for a short in the No. 43 (7.5 A) and No.
10 (7.5 A) fuses circuit.■
2. Connect the HDS to the DLC.
3. Start the engine.
4. Turn on the A/C.
5. Check the A/C switch in the PGM-FI Data List with the HDS.
Is the A/C switch on?
YES - Go to Step 6 .
NO - Go to A/C pressure switch circuit troubleshooting. ■
6. Using the HDS, confirm the following values in the PGM-FI Data List at idle.
TP sensor About 0.5 V
RPM A/T 740−840
M/T 700−800
ECT SENSOR 2 80−100 °C
A/C SWITCH ON
A/C CLUTCH ON
A/C PRESSURE SENSOR 196−3,138 kPa (2−32 kgf/cm 2 ) 28−455 psi
A/C TEMPERATURE 3.0 °C or more
10. Connect the No. 1 and No. 2 terminals of the A/C compressor clutch relay 4P socket with a jumper wire.
Does the A/C compressor clutch click?
YES - Go to Step 11 .
NO - Go to Step 21 .
11. Disconnect the jumper wire.
12. Turn the ignition switch to ON (II).
13. Measure the voltage between the No. 4 terminal of the A/C compressor clutch relay 4P socket and body ground.
Is there battery voltage?
YES - Go to Step 14 .
NO - Repair open in the wire between the No. 10 (7.5 A) fuse in the under-dash fuse/relay box and the A/C
compressor clutch relay.■
14. Turn the ignition switch to LOCK (0).
15. Reinstall the A/C compressor clutch relay.
16. Make sure the A/C switch is OFF.
17. Jump the SCS line with the HDS.
NOTE: This step must be done to protect the engine control module (ECM)/powertrain control module (PCM) from
damage.
18. Disconnect ECM/PCM connector A (49P).
19. Connect the ECM/PCM connector A (49P) No. 15 terminal to body ground with a jumper wire.
20. Turn the ignition switch to ON (II).
Does the A/C compressor click?
YES - Check for loose wires or poor connections at ECM/PCM connector A (49P). If the connections are good,
substitute a known-good ECM/PCM, and recheck. If the symptom/indication goes away, replace the
original ECM/PCM. ■
NO - Repair open in the wire between the A/C compressor clutch relay and the ECM/PCM.■
21. Disconnect the jumper wire.
22. Disconnect the A/C compressor clutch 1P connector.
23. Check for continuity between the A/C compressor clutch relay 4P socket No. 2 terminal and the A/C compressor
clutch 1P connector No. 1 terminal.
Is there continuity?
YES - Check the A/C compressor clutch clearance, the thermal protector circuit, and the A/C compressor
clutch field coil. ■
NO - Repair open in the wire between the A/C compressor clutch relay and the A/C compressor clutch.■
A/C Compressor Relief Valve Replacement
1. Recover the refrigerant with a recovery/recycling/charging station.
2. Remove the relief valve cover (A), the relief valve (B), and the O-ring (C). Plug the opening to keep foreign matter
from entering the system and the A/C compressor oil from running out.
3. Clean the mating surfaces.
4. Replace the O-ring with a new one at the relief valve, and apply a thin coat of refrigerant oil before installing it.
5. Remove the plug, and install and tighten the relief valve.
6. Charge the system.
A/C Condenser Replacement
1. Recover the refrigerant with a recovery/recycling/charging station.
2. Remove the front bumper.
3. Remove the nut, then disconnect the discharge hose (A) from the A/C condenser. From the discharge hose,
remove the O-ring (B).
4. Remove the bolt, then disconnect the receiver line (A) from the A/C condenser. From the receiver line, remove the
O-ring (B).
5. Remove the bolts (A), disconnect the connector (B), and remove the horn (C). If equipped with the high horn (D),
remove it.
6. Remove the bolts (E) and the brackets (F).
4. Connect the No. 1 and No. 2 terminals of the A/C condenser fan relay 4P socket with a jumper wire.
Does the A/C condenser fan run?
YES - Go to Step 5 .
NO - Go to Step 8 .
5. Disconnect the jumper wire.
6. Turn the ignition switch to ON (II).
7. Measure the voltage between the No. 4 terminal of the A/C condenser fan relay 4P socket and body ground.
Is there battery voltage?
YES - Repair open in the GRN wire between the A/C condenser fan relay and the ECM/PCM.■
NO - Repair open in the wire between the No. 10 (7.5 A) fuse in the under-dash fuse/relay box and the A/C
condenser fan relay.■
8. Disconnect the jumper wire.
9. Disconnect the A/C condenser fan 2P connector.
10. Check for continuity between the No. 1 terminal of the A/C condenser fan relay 4P socket and the No. 2 terminal of
the A/C condenser fan 2P connector.
Is there continuity?
YES - Go to Step 11 .
NO - Repair open in the wire between the A/C condenser fan relay and the A/C condenser fan.■
11. Check for continuity between the No. 1 terminal of the A/C condenser fan 2P connector and body ground.
Is there continuity?
YES - Replace the A/C condenser fan motor.■
NO - Check for an open in the wire between the A/C condenser fan and body ground. If the wire is OK, check
for poor ground at G202. ■
Radiator and A/C Condenser Fan Common Circuit Troubleshooting
NOTE: Do not use this troubleshooting procedure if the A/C compressor is inoperative. Refer to the symptom
troubleshooting index.
1. Remove the radiator fan relay and A/C condenser fan relay from the auxiliary under-hood relay box, and test them.
Are the relays OK?
YES - Go to Step 2 .
NO - Replace the relays.■
2. Reinstall the relays.
3. Jump the SCS line with the HDS.
NOTE: This step must be done to protect the engine control module (ECM)/powertrain control module (PCM) from
damage.
4. Disconnect ECM/PCM connector A (49P).
5. Connect the ECM/PCM connector A (49P) No. 6 terminal to body ground with a jumper wire.
6. Turn the ignition switch to ON (II).
Do the fans run?
YES - Check for loose wires or poor connections at ECM/PCM connector A (49P). If the connections are good,
substitute a known-good ECM/PCM, and recheck. If the symptom/indication goes away, replace the
original ECM/PCM .■
NO - Repair open in the wire between the radiator fan relay, the A/C condenser fan relay and the ECM/PCM.■
A/C Evaporator Temperature Sensor Test
1. Remove the evaporator core and the evaporator temperature sensor.
2. Dip the sensor in ice water, and measure the resistance between its terminals.
3. Then pour warm water on the sensor, and check for a change in resistance.
4. Compare the resistance readings with the specifications shown in the graph; the resistance should be within the
specifications.
5. If the resistance is not as specified, replace the evaporator temperature sensor.
Heating and A/C System Description
The air conditioning system removes heat from the passenger compartment by transferring heat from the ambient air to the evaporator. The evaporator cools the air
with the refrigerant that is circulating through the evaporator. The refrigerant expands in the evaporator, and the evaporator becomes very cold and absorbs the heat
from the ambient air. The blower fan pushes air across the evaporator where the heat is absorbed, and then it blows the cool air into the passenger compartment.
This vehicle uses HFC-134a (R-134a) refrigerant, which does not contain chlorofluorocarbons. Pay attention to the following service items:
Do not mix refrigerants CFC-12 (R-12)
EXPANSION VALVEand HFC-134a (R-134a). They are not compatible.
Use only the recommended
(Meters polyalkyleneglycol
the required amount(PAG)
of refrigerant oil (SP-10) designed for the R-134a A/C compressor. Intermixing the recommended (PAG)
refrigerant oil with any other refrigerant
refrigerant into theoil will result in A/C compressor failure.
evaporator)
BLOWER FAN
All A/C system parts (A/C compressor, discharge line, suction line, evaporator, A/C condenser, receiver/dryer, expansion valve, O-rings for joints) are
designed for refrigerant R-134a. Do not exchange with R-12 parts.
Use a halogen gas leak detector designed for refrigerant R-134a.
R-12 and R-134a refrigerant servicing equipment are not interchangeable. Use only a recovery/recycling/charging station for refrigerant R-134a.
Always recover refrigerant R-134a with an approved recovery/recycling/charging station before EVAPORATOR
disconnecting any A/C fitting.
(Absorption of heat)
Oil Separator
RELIEF VALVE
A/C PRESSURE SWITCH (Relieves pressure at the A/C compressor
When the refrigerant is below when the pressure is too high)
196 kPa (2.0 kgf/cm2, 28 psi)
or above 3,138 kPa (32 kgf/cm2,
455 psi), the ECM/PCM turns the
A/C compressor clutch relay off
to protect the A/C compressor.
A/C COMPRESSOR
(Suction and compression)
3. Using a small brush, apply a heavy coat of silver conductive paint (commercially available) (A) extending about 3
mm (1/8'') on both sides of the break. Allow 25 minutes to dry.
4. Do the function test to confirm that the wire is repaired.
5. Apply a second coat of paint in the same way. Let it dry 3 hours before removing the tape.
Seat Belts Component Location Index
Inspection,
Inspection,
Retractor Front
1. Before installing the retractor, check that the seat belt can be pulled out freely.
2. Make sure that the seat belt does not lock when the retractor (A) is leaned slowly up to 15 ° from the mounted
position. The seat belt should lock when the retractor is leaned over 40 °. Do not attempt to disassemble the
retractor.
3. Replace the seat belt with a new assembly if there is any abnormality. Do not disassemble any part of the seat belt
for any reason. Rear
In-vehicle
1. Check that the seat belt is not twisted or caught on anything.
2. After installing the anchors, check for free movement on the anchor bolts. If necessary, remove the anchor bolts
and check that the washers and other parts are not damaged or improperly installed.
3. Check the seat belts for damage or discoloration.
Clean with a shop towel if necessary. Use only soap and water to clean.
NOTE: Dirt build-up in the loops of the upper anchors can cause the seat belts to retract slowly. Wipe the inside of
the loops with a clean cloth dampened in isopropyl alcohol.
4. Check that the seat belt does not lock when pulled out slowly. The seat belt is designed to lock only during a
sudden stop or impact.
5. Make sure that the seat belt will retract automatically when released.
6. For each rear passenger's seat belt, check the seat belt retractor locking mechanism ALR (automatic locking
retractor). This function is for securing child seats.
-1. Pull the seat belt all the way out to engage the ALR. The seat belt should retract, but not extend. This is
normal.
-2. To disengage the ALR, release the seat belt and allow it to fully retract, then pull the seat belt out part-way.
The seat belt should retract and extend normally.
7. Replace the seat belt with a new assembly if there is any abnormality. Do not disassemble any part of the seat belt
for any reason.
Front Seat Belt Replacement
SRS components are located in this area. Review the SRS component locations and the precautions and procedures
before doing repairs or service.
NOTE:
Take care not to bend or scratch the trim and panels.
When removing components, use the trim tool or equivalent.
Check the front seat belts for damage, and replace them if necessary. Be careful not to damage them during
removal and installation.
9. Install the seat belt and retractor in the reverse order of removal, and note these items: Upper anchor bolt
Apply medium strength type liquid thread lock to the anchor bolts before reinstallation. installation
Tighten the bolts by hand first, then tighten to specified torque.
Check that the retractor locking mechanism functions as described.
Assemble the washers, the collars, and the bushings on the upper anchor bolt and lower anchor bolt as
shown.
Before installing the anchor bolts, make sure there are no twists or kinks in the seat belt.
Make sure the seat belt tensioner connector is plugged in properly.
Do the battery terminal reconnection procedure. Lower anchor bolt
Check for any DTCs, and clear them using the HDS. If the DTCs will not clear, do the necessary installation
troubleshooting.
4. Detach the harness clip (A), and pull the seat belt switch harness (B) through the hole in the seat track. Remove
the center anchor bolt (C), then remove the seat belt buckle (D).
5. Install the buckle in the reverse order of removal, and note these items: Center anchor bolt
Assemble the washers and collar on the center anchor bolt as shown. installation
Apply medium strength type liquid thread lock to the anchor bolts before reinstallation.
Tighten the bolt by hand first, then tighten to specified torque.
Make sure the seat belt switch connector is plugged in properly.
Do the battery terminal reconnection procedure.
Check for any DTCs, and clear them using the HDS. If the DTCs will not clear, do the necessary
troubleshooting.
Rear Seat Belt Replacement
NOTE: Check the rear seat belts for damage, and replace them if necessary. Be careful not to damage them during
removal and installation.
Rear Seat Belt
1. Remove the cargo side trim panel.
2. Pull the carpet back as necessary, and remove the lower anchor bolt (A).
3. Remove the upper anchor cap (A), and remove the upper anchor bolt (B).
4. Disconnect the seat belt tensioner connector (A) if equipped, and remove the self-tapping ET screw (B) and the
lower retractor mounting bolt (C). Remove the rear seat belt (D) and retractor (E). The right seat belt is shown, the
left seat belt is similar.
5. Install the seat belt in the reverse order of removal, and note these items: Upper anchor bolt
Apply medium strength type liquid thread lock to the anchor bolts before reinstallation. installation
Tighten the bolts by hand first, then tighten to specification torque.
Check that the retractor locking mechanism functions as described.
Assemble the washers and the collar on the upper anchor bolt as shown.
Before installing the anchor bolts, make sure there are no twists or kinks in the seat belt.
Make sure the seat belt tensioner connector is properly plugged in.
Rear Seat Belt Buckles and Center Shoulder Seat Belt Detachable Anchor/Center Lap Seat Belt
1. Pull the rear seat belt buckles (A) and rear center seat belt detachable anchor or rear center lap seat belt (B) out
through each elastic straps (C) on both seat cushions.
2. Lift both rear seat cushions up, and slip the seat belt buckles and seat belt detachable anchor or seat belt.
3. Fold both rear seat-backs.
4. Opening the cargo floor lids (A) and remove the anchor bolts (B).
5. Lift both rear seat cushions up.
6. Remove the seat belt buckles (A) and center seat belt detachable anchor (B) or rear center lap seat belt (C). With center seat belt
and seat belt buckles
7. Install the anchor and buckle in the reverse order of removal, and note these items: Right side anchor bolt
Tighten the bolts by hand first, then tighten to specification torque. installation
Assemble the washers, and the collar on the anchor bolt as shown.
Driver's Airbag
1. Remove the access panel (A) from the steering wheel, then disconnect the driver's airbag 4P connector (B) from the
cable reel.
1. Lower the glove box, then remove the connector clip. Disconnect the front passenger's airbag 4P connector (A)
from the dashboard wire harness.
Side Airbag
1. Disconnect the side airbag 2P connector (A) from the floor wire harness.
1. Disconnect the floor wire harness 2P connector (A) from the side curtain airbag.
1. Disconnect the floor wire harness 4P connector (A) from the seat belt tensioner. Pull the seat belt out all the way
and cut it.
2. Cut off each connector, and strip the ends of the wires. Twist each pair of unlike colored wires together, and clip an
alligator clip (A) from the deployment tool to each pair. Place the deployment tool at least 10 m (30 ft) away from
the vehicle.
NOTE: The driver's and front passenger's airbags have dual inflators. Twist each pair of unlike colored wires
together, and clip an alligator clip to each pair.
3. Connect a 12 volt battery to the tool.
If the green light on the tool comes on, the igniter circuit is defective and cannot deploy the component. Go
to Disposal of Damaged Components.
If the red light on the tool comes on, the component is ready to be deployed.
4. Push the tool's deployment switch. The airbags and tensioners should deploy (deployment is both highly audible
and visible: A loud noise and rapid inflation of the bag, followed by slow deflation).
If the components deploy and the green light on the tool comes on, continue with this procedure.
If a component does not deploy, and the green light comes ON, its igniter is defective. Go to Disposal of
Damaged Components.
During deployment, the airbags can become hot enough to burn you. Wait for 30 minutes after deployment
before touching the airbags.
5. Dispose of the complete airbag. No part of it can be reused. Place it in a sturdy plastic bag (A), and seal it
securely. Dispose of the deployed airbag according to your local regulations.
11. Disconnect the floor wire harness 3P connector (A) from the front passenger's seat sitting switch.
12. Install a jumper wire between the No. 1 terminal and the No. 2 terminal of the floor wire harness 3P connector.
13. From the Main Menu on the HDS, select SRS, then PARAMETER INFORMATION. In the PARAMETER
INFORMATION Menu, select ‘‘SRS PSS'', and read the HDS indicated.
Is ON indicated on the HDS?
YES - Faulty front passenger's seat sitting switch; replace the front seat cushion cover/pad.
NO - Open in the floor wire harness; replace the faulty wire harness.■
SRS Component Replacement/Inspection After Deployment
NOTE: Front pillar trim
Before doing any SRS repairs, check the DTCs, for the less obvious deployed components (seat belt tensioners,
front impact sensors, side airbag sensors, etc.).
Do not replace the OPDS unit unless it is physically damaged or a specific fault was found during DTC
troubleshooting.
After a collision where the seat belt tensioners deployed, replace these items:
SRS unit Center pillar trim
Seat belt tensioners
Front impact sensors
After a collision where the front airbag(s) deployed, replace these items:
SRS unit
Deployed airbag(s)
Seat belt tensioners
Front impact sensors
After a collision where the side airbag(s) deployed, replace these items:
Quarter pillar trim
SRS unit
Deployed side airbag(s)
Side impact sensor(s) (first)
Side impact sensor(s) (second)
Center pillar lower trim
Complete seat frame
After a collision where a side curtain airbag has deployed, replace the items for the side(s) that deployed:
SRS unit
Deployed side curtain airbag(s)
Seat belt tensioner(s)
Side impact sensor(s) (first)
Side impact sensor(s) (second)
Front pillar trim
Center pillar upper trim
Quarter pillar trim
Headliner
Front grab handle
Rear grab handle
All related trim clips
Sunvisor
After a moderate to severe side or rear collision, inspect for any damage on the side curtain airbag or other related
components. Replace the components as needed.
During the repair process, inspect these areas:
Inspect all the SRS wire harnesses. Replace, do not repair, any damaged harnesses.
Inspect the cable reel for heat damage. If there is any damage, replace the cable reel.
After the vehicle is completely repaired, turn the ignition switch to ON (II). If the SRS indicator comes on for about 6
seconds and then goes off, the SRS is OK. If the indicator does not function properly, use the HDS to read the DTC. If you
cannot retrieve a code, do the SRS Symptom Troubleshooting.
2. Using masking tape on the headliner, mark the upper edge of each pillar trim.
3. Using a TORX T30 bit, remove the two TORX bolts (A).
4. Remove the driver's airbag (B).
Installation
1. Place the driver's airbag (A) in the steering wheel, and secure it with new TORX bolts (B).
NOTE: Make sure the clearance (C) between the steering wheel and horn pad is the specified value.
2. Connect the driver's airbag 4P connector (A) and horn switch 1P connector (B) of the cable reel, then install the
access panel (C) on the steering wheel.
3. Do the battery terminal reconnection procedure.
4. Connect the HDS, and clear the DTCs.
5. After installing the airbag, confirm proper system operation:
Turn the ignition switch to ON (II); the SRS indicator should come on for about 6 seconds and then go off.
Make sure the horn and turn signal switches work properly.
Make sure the steering wheel switches work properly.
Front Passenger's Airbag Replacement
Removal
1. Do the battery terminal disconnection procedure, then wait for 3minutes before starting work.
2. Remove these items:
The glove box is lowered
Passenger's tray lid
Passenger's side vent
Center vent
Audio unit
3. Remove the connector clip, then disconnect the front passenger's airbag 4P connector (A) from the dashboard wire
harness (B).
6. Release the hooks (A), of the front passenger's lid (B) from the Audio panel.
7. Pull up the front edges of the front passenger's lid to release the hooks (C).
8. Remove the front passenger's airbag assembly (A) out of the dashboard. If you are replacing only the front
passenger's lid, go to Step 8 .
NOTE: The front passenger's lid has pawls (B, C) on each side which attach it to the dashboard.
9. Cut the four parts (A) of the front passenger's lid (B) as shown, and remove the front passenger's airbag.
NOTE:
Always replace the front passenger's lid whenever you remove the airbag from the panel.
Replace the airbag if the airbag mounting hooks or its housing is damaged.
10. Insert the hooks (A) of the front passenger's airbag housing into the new front passenger's lid, then insert the other
hooks (B) into the panel.
NOTE:
Make sure there are no objects between the airbag and the front passenger's lid.
Make sure the airbag is fully seated, and make sure the front passenger's lid is not deformed or damaged
after the airbag is in place.
Do not use tools when detaching the front passenger's airbag in order to protect it.
Installation
1. Place the front passenger's airbag assembly (A) into the dashboard. Torque the front passenger's airbag mounting
bolts (B).
2. Install the screws (C) from the front passenger's lid.
3. Connect the front passenger's airbag 4P connector (A) to the dashboard wire harness (B), then connect the
connector clip. Reinstall the glove box.
4. Do the battery terminal reconnection procedure.
5. Connect the HDS and clear the DTCs.
6. After installing the airbag, confirm proper system operation: Turn the ignition switch to ON (II); the SRS indicator
should come on for about 6 seconds and then go off.
Cable Reel Replacement
Removal
1. Make sure the front wheels are aligned straight ahead.
2. Do the battery terminal disconnection procedure, then wait for 3 minutes.
3. Remove the driver's airbag.
4. Disconnect the connector (A) from the cable reel, then remove the steering wheel bolt (B).
5. Confirm that the front wheels point straight ahead, then remove the steering wheel with a steering wheel puller. Do
not tap on the steering wheel or steering column shaft when removing the steering wheel.
6. Remove the column cover.
7. Disconnect the dashboard wire harness 4P connector (A) from the cable reel 4P connector (B), then disconnect the
dashboard wire harness 20P connector (C) from the cable reel (D).
8. Release the lock tab (A) under the cable reel connector with a 90 ° hook shaped tool (B). Slide the tool below the
cable reel connector just above the lock tab. Release the lower lock tab (C), and slide the cable reel off the column.
Installation
1. Before installing the steering wheel, align the front wheels straight ahead.
2. If not already done, disconnect the negative cable from the battery, then wait for 3 minutes.
3. Set the turn signal canceling sleeve (A) so that the projections (B) are aligned vertically.
4. Carefully install the cable reel (A) on the steering column shaft. Then connect 20P connector (B) to the cable reel,
and connect the cable reel 4P connector (C) to the dashboard wire harness 4P connector (D).
5. Install the column covers.
6. If necessary, center the cable reel (New replacement cable reels come centered.). Do this by first rotating the cable
reel clockwise until it stops. Then rotate it counterclockwise (about three turns) until the arrow mark (A) on the
cable reel label points straight up.
7. Position the two tabs (A) of the turn signal canceling sleeve (B) as shown, and install the steering wheel on to the
steering column shaft, making sure the steering wheel hub (C) engages the pins (D) of the cable reel and tabs of
the turn signal canceling sleeve. Do not tap on the steering wheel or steering column shaft when installing the
steering wheel.
8. Install and torque a new steering wheel bolt (A), then reconnect the connectors.
9. Install the driver's airbag.
10. Do the battery terminal reconnection procedure.
11. Connect the HDS and clear any DTCs.
12. After installing the cable reel, confirm proper system operation:
Turn the ignition switch to ON (II); the SRS indicator should come on for about 6 seconds, and then go off.
After the SRS indicator has turned off, turn the steering wheel fully left and right to confirm the SRS indicator
does not come on.
Make sure the horn and turn signal switches work properly.
Make sure the steering wheel switches work properly.
Front Impact Sensor Replacement
Removal
1. Do the battery terminal disconnection procedure, then wait for 3 minutes before starting work.
2. Disconnect the driver's airbag 4P connector, the front passenger's airbag 4P connector, and both seat belt
tensioner 4P connectors.
3. Remove the front bumper.
4. Disconnect the engine compartment wire harness 2P connector (A). Using a TORX T30 bit, remove the TORX bolt
(B), then remove the front impact sensor (C).
Installation
1. Install the front impact sensor with a new TORX bolt (A), then connect the engine compartment wire harness 2P
connector (B) to the front impact sensor (C).
2. Reconnect the driver's airbag 4P connector, the front passenger's airbag 4P connector, and both seat belt tensioner
4P connectors.
3. Do the battery terminal reconnection procedure.
4. Confirm proper SRS operation: Turn the ignition switch to ON (II); the SRS indicator should come on for about 6
seconds and then go off.
5. Reinstall all removed parts.
OPDS Unit Replacement
Removal
1. Do the battery terminal disconnection procedure, then wait for 3 minutes before starting work.
2. Disconnect the front passenger's side airbag harness 2P connector.
3. Remove the front passenger's seat assembly.
4. Remove the seat-back cover/pad.
5. Remove the cover (A), then disconnect the OPDS unit 18P connector (B) and sensor connectors (C) from the
OPDS unit (D).
6. Remove the two nuts (E) and the OPDS unit.
Installation
1. Place the OPDS unit (A) on the seat-back frame. Tighten the new nuts (B), and connect the OPDS unit harness
18P connector (C) and sensor connectors (D) to the OPDS unit. Reinstall the cover (E).
2. Install the seat-back cover/pad.
3. Install the front seat assembly, then connect the front passenger's side airbag harness 2P connector.
4. Do the battery terminal reconnection procedure.
5. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat.
6. Initialize the OPDS unit.
7. Confirm proper SRS operation: Turn the ignition switch to ON (II); the SRS indicator should come on for about 6
seconds and then go off.
OPDS Unit Initialization
When a seat-back cover/pad and/or OPDS unit is replaced, initialize the OPDS by doing this procedure.
NOTE: A new (uninitialized) OPDS unit installed with a faulty OPDS sensor can cause DTC 85-71 or 85-78.
1. Clear the DTC memory.
2. Make sure the front passenger's seat is dry. Set the seat-back in a normal position, and make sure there is nothing
on the seat.
3. Make sure the ignition switch is in LOCK (0).
4. Connect the HDS to the data link connector (DLC) (A).
5. Turn the ignition switch to ON (II).
6. Make sure the HDS communicates with the vehicle and the SRS unit. If it does not communicate, troubleshoot the
DLC circuit.
7. From the HDS Main Menu, select SRS, then SRS, then Calibration. In the Calibration Menu, select OPDS UNIT
INITIALIZATION. Follow the screen prompts to initialize the OPDS unit.
8. Turn the ignition switch to LOCK (0).
9. Disconnect the HDS from the DLC.
NOTE: If the OPDS unit fails to initialize after several attempts, replace the OPDS sensor/seat-back and retry. If
the OPDS unit continues to fail to initialize, replace the OPDS unit.
Side Airbag Replacement
Removal
1. Do the battery terminal disconnection procedure, then wait for 3 minutes before starting work.
2. Remove the front seat assembly.
3. Pull out the seat-back cover/pad as needed.
4. Release the rear hooks (A) from seat-back frame (B).
5. Remove the mounting nut (C) and the side airbag (D).
Installation
NOTE:
If the side airbag lid is secured with tape, remove the tape.
Do not open the lid on the side airbag cover.
Use new mounting nut tightened to the specified torque.
Make sure that the seat-back cover/pad is installed properly. Improper installation may prevent proper deployment.
Be sure to install the harness so that they are not pinched or interfering with other parts.
1. Place the side airbag (A) on the seat-back frame. Torque the new side airbag mounting nut (B).
2. Install the rear hooks (C) in the seat-back frame (D).
3. Install the seat-back cover/pad.
4. Install the front seat assembly. then connect the floor wire harness 2P connector.
5. Move the front seat and the seat-back through their full ranges of movement, making sure the harness are not
pinched or interfering with other parts.
6. Do the battery terminal reconnection procedure.
7. Connect the HDS, and clear the DTCs.
8. After installing the side airbag, confirm proper system operation: Turn the ignition switch to ON (II); the SRS
indicator should come on for about 6 seconds and then go off.
Side Curtain Airbag Replacement
Removal
NOTE:
Review the interior trim replacement procedure before doing repair or service.
Removal of the side curtain airbag must be done according to Precaution and Procedures.
The side curtain airbag system consists of many components. When the side curtain airbag
has been deployed, go to Component Replacement/Inspection After Deployment, and replace
all of the parts listed.
1. Do the battery terminal disconnection procedure, then wait for 3 minutes before starting work.
2. Remove the cargo area side trim panel.
3. Disconnect the floor wire harness 2P connectors (A) from the side curtain airbags.
4. Remove the headliner.
5. Remove the side airbag mounting bolts (A) and mounting screws (B) from the bracket. Detach
the clip (C), then remove the side curtain airbag (D).
Installation
NOTE:
Installation of the side curtain airbag must be done according to the Precautions and
Procedures.
If the airbag is frayed, or has any other visible damage, replace it. Do not attempt to repair an
airbag.
When you install the airbag, make sure it is not twisted, and that it is not caught between the
inflator bracket by the bracket bolts.
Make sure that the side curtain airbag inflator retainer is installed properly. Otherwise the airbag
could incorrectly deploy and cause damage or injuries.
Make sure you have the slack or no cutting and peeling. If tape has slack or cutting, and peeling
side curtain airbag should be replacement.
1. Place the side curtain airbag assembly on the side of the roof, and fit its clip (A) into the holes
in the body. Tighten the new side curtain airbag mounting bolts (B) and mounting screws (C).
2. Connect the floor wire harness 2P connectors (A) to the side curtain airbags.
3. Do the battery terminal reconnection procedure.
4. Connect the HDS, and clear the DTCs.
5. After installing the side curtain airbag, confirm proper system operation: Turn the ignition switch
to ON (II); the SRS indicator should come on for about 6 seconds and then go off.
6. Install all removed parts.
7. Confirm proper headliner/pillar trim overlap.
Side Impact Sensor (Second) Replacement
Removal
1. Do the battery terminal disconnection procedure, then wait for 3 minutes before starting work.
2. Remove the cargo area side trim panel.
3. Disconnect the floor wire harness 2P connector (A) from the side impact sensor (second) (B).
4. Using a TORX T30 bit, remove the TORX bolt (C) then remove the side impact sensor (second).
Installation
1. Install the side impact sensor (second) with a new TORX bolt (A), then connect the floor wire harness 2P connector
(B) to the side impact sensor (second) (C).
2. Do the battery terminal reconnection procedure.
3. Confirm proper SRS operation: Turn the ignition switch to ON (II); the SRS indicator should come on for about 6
seconds, and then go off.
4. Reinstall all removed parts.
SRS Unit Replacement
Removal
1. Do the battery terminal disconnection procedure, then wait for 3 minutes before starting work.
2. Remove the center console.
3. Remove the rear heater joint duct.
4. Disconnect SRS unit connectors A (39P) and B (39P) from the SRS unit.
5. Remove the TORX bolts (C) using a TORX T30 bit, then pull out the SRS unit.
Installation
1. Install the SRS unit (A) with a new TORX bolts (B), then connect the connectors (C) to the SRS unit; push them
into position until they click.
NOTE: Be sure the SRS unit is sitting squarely against it's bracket before torquing the TORX bolts.
2. Do the battery terminal reconnection procedure.
3. Confirm proper SRS operation: Turn the ignition switch to ON (II); the SRS indicator should come on for about 6
seconds and then go off.
4. Reinstall all removed parts.
SRS Unit Update
Special Tools Required
Honda diagnostic system (HDS) table tester
Honda interface module (HIM) and an iN workstation with HDS and CM update software
HDS pocket tester
GNA600 and an iN workstation with HDS and CM update soft ware (Any one of the update tools above will work)
NOTE:
Use this procedure when you need to update the SRS unit at anytime.
Make sure the HDS/HIM has the latest software version.
Before you update the SRS unit, make sure the battery in the vehicle is fully charged.
Never turn the ignition switch to LOCK (0) or ACC (I) during the update. If there is a problem with the update, leave
the ignition switch in the ON (II).
To prevent SRS unit damage, do not operate anything electrical (headlights, audio system, brakes, A/C, power
windows, moonroof (if equipped), door locks, etc.) during the update.
To ensure the latest program is installed, do an SRS unit update whenever the SRS unit is replaced.
You cannot update an SRS unit with a program it already has. It will only accept a new program.
If you need to diagnose the HIM because the HIM's red (#3) light came on or was flashed during the update, leave
the ignition switch in the ON (II) position when you disconnect the HIM from the data link connector (DLC). This will
prevent SRS unit damage.
1. Connect the HDS to the DLC (A).
2. Turn the ignition switch to ON (II), but do not start the engine.
3. Make sure the HDS communicates with the vehicle and the SRS unit. If it does not communicate, troubleshoot the
DLC circuit.
4. Select the update program, and follow the screen prompts to update the SRS unit.
5. If the software in the SRS unit is the latest, disconnect the HDS/HIM from the DLC, and go back to the procedure
that you were doing. If the software in the SRS unit is not the latest, follow the instructions on the screen.
NOTE: If you run into a problem during the update procedure (programming takes over 15 minutes, status bar goes
over 100 %, D or immobilizer light flashes, HDS tablet freezes, etc.), follow these steps to minimize the chance of
damaging the SRS unit :
Leave the ignition switch in the ON (II) position.
Connect a jumper battery (do not connect a battery charger).
Shut down the HDS.
Disconnect the HDS from the DLC.
Reboot the HDS.
Reconnect the HDS to the DLC, and try the update procedure again.
6. Turn the ignition switch to LOCK (0).
7. Disconnect the HDS from the DLC.
Audio System Description
Overview
Audio Unit Connector for Inputs and Outputs
USB Adapter Connector for Inputs and Outputs
Audio System Symptom Troubleshooting - Poor AM or FM radio reception or interference
Poor AM or FM radio reception or interference
NOTE:
Check the vehicle battery condition first.
Check the connectors for poor connections or loose terminals.
Check the radio reception in an open area.
Compare it to a known-good vehicle of the same model, year, and trim level whenever possible.
If necessary, have the customer demonstrate the symptom.
Poor reception/interference can be caused by the following:
-The radio station is far away.
-Atmospheric conditions are unfavorable.
-Tall buildings, mountains, or high-voltage power lines are nearby.
-Non-standard antenna element.
1. Check if the radio reception/interference is the same as the known-good vehicle in several locations.
Is the reception/interference the same?
YES - Go to Step 2 .
NO - Multipath interference or weak station. Operation is normal.■
2. Check the reception/interference while the engine is running, and compare it to the known-good vehicle.
Is there noise (static or whine) only with the engine running?
YES - Check the antenna and radio grounds. If OK, check the charging system, fuel injection system (fuel
pump), HVAC (blower motor), and the ignition system.■
NO - Go to Step 3 .
3. Make sure turn the ignition switch to LOCK (0).
4. Check the AM/FM antenna element for cracks, or other damage. Make sure that the AM/FM antenna element isn't
loose.
NOTE: Do not use any tools to tighten the AM/FM antenna element.
Is there any damage?
YES - Replace the AM/FM antenna element. ■
NO - Go to Step 5 .
5. Disconnect AM/FM antenna 3P connector.
6. Turn the ignition switch to ON (II).
7. Turn on the audio unit.
8. Measure the voltage between the AM/FM antenna 3P connector No. 3 terminal and body ground.
Is there battery voltage?
YES - Go to Step 14 .
NO - Go to Step 9 .
9. Turn the ignition switch to LOCK (0).
10. Remove the audio unit.
11. Turn the ignition switch to ON (II).
12. Turn on the audio unit.
13. Measure the voltage between audio unit connector D (3P) No. 3 terminal and body ground with the audio unit
connectors connected.
Is there battery voltage?
YES - Repair open or short in the wire between audio unit and AM/FM antenna. Also check the AM/FM antenna
lead/sublead connector.■
NO - Replace the audio unit. ■
14. Turn the ignition switch to LOCK (0).
15. Remove the audio unit, and disconnect audio unit connector D (3P).
16. Check for continuity between audio unit connector D (3P) terminal No. 1 and body ground.
Is there continuity?
YES - Replace the AM/FM antenna lead and/or sublead.■
NO - Go to Step 17 .
17. Check for continuity between audio unit connector D (3P) No. 1 and No. 2 terminals.
Is there continuity?
YES - Replace the AM/FM antenna lead and/or sublead.■
NO - Go to Step 18 .
18. Check for continuity between audio unit connector D (3P) No. 1 terminal and the AM/FM antenna 3P connector No.
1 terminal.
Is there continuity?
YES - Go to Step 19 .
NO - Replace the AM/FM antenna lead and/or sublead.■
19. Check for continuity between audio unit connector D (3P) No. 2 terminal and the AM/FM antenna 3P connector No.
2 terminal.
Is there continuity?
YES - Substitute a known-good AM/FM antenna and recheck. If the reception is still poor, replace the audio
unit. ■
NO - Replace the AM/FM antenna lead and/or sublead.■
Audio System Symptom Troubleshooting - Volume does not change
Volume does not change
NOTE: Set the fader and balance positions to the center.
1. Turn on the audio unit, and listen for sound from the speakers.
Is the sound normal?
YES - Go to Step 2 .
NO - Go to audio system sound is weak or distorted, or no sound is heard from speakers. ■
2. Operate the volume knob to see if the volume changes.
Does the volume change?
YES - Operation is normal at this time.■
NO - Replace audio unit. ■
Audio System Symptom Troubleshooting - Audio disc does not load
Audio disc does not load
NOTE:
CD labels should not be used in the audio unit. They may damage the player mechanism.
Make sure the CD is compatible with the system (see the owner's manual for more information).
1. Insert a known-good CD to see if the symptom can be duplicated.
Does the CD load?
YES - Operation is normal. If the disc loads normally, but will not play, go to audio disc does not play. ■
NO - Go to Step 2 .
2. Insert another CD.
Does the CD load?
YES - The original CD is faulty.■
NO - Replace audio unit. ■
Audio System Symptom Troubleshooting - Audio disc does not play
Audio disc does not play
1. Try loading a known-good CD.
Does the CD load?
YES - Go to Step 2 .
NO - Go to audio disc does not load. ■
2. Insert another known-good CD to see if the symptom can be duplicated.
Does the CD play?
YES - Operation is normal.■
NO - Replace the audio unit. ■
Audio System Symptom Troubleshooting - Audio disc skips
Audio disc skips
1. Confirm the vehicle's tyres are properly inflated with no cupping or flat spots.
2. Check the customers CD for scratches, fingerprints, and marks.
NOTE: The following test should be done with audio unit bass and treble set to customers listening performance.
When comparing to known-good vehicles, the comparison should be done on same model and trim level.
3. Compare the customer's CD that is skipping in a known-good vehicle under the same conditions.
Does the CD skip in the known-good vehicle under the same conditions?
YES - Operation is normal.■
NO - Replace the audio unit. ■
AM/FM Antenna Replacement
1. Remove the AM/FM antenna element (A).
2. Remove the AM/FM antenna base (B).
-1. Remove the quarter pillar trim and disconnect the connector (C).
-2. Remove the headliner and detach the clip (D).
-3. Remove the nut (E) from the AM/FM antenna base and remove it.
3. Install the antenna in the reverse order of removal.
Audio Remote Switch Test
1. Remove the driver's airbag assembly.
2. Disconnect the cable reel 20P connector (A).
3. Measure the resistance between the No. 3 and No. 7 terminals in each switch position according to the table.
Position Resistance
No button pressed About 10 kΩ
MODE About 3.7 kΩ
CH (+) About 1.7 kΩ
CH (−) About 775 Ω
▲ About 357 Ω
(VOL.UP)
▼ About 100 Ω
(VOL.DOWN)
4. Check that the door and body edges are parallel. If necessary, adjust the door cushions (A) to make the rear of the
doors flush with the body.
5. Apply touch-up paint to the hinge mounting bolts, and around the hinges.
6. Check for water leaks.
Front Door Glass Outer Weatherstrip Replacement
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the door and related parts.
RHD model is shown; LHD model is symmetrical.
1. Lower the glass fully.
2. Remove the door sash outer trim.
3. While lifting the rear of the door glass outer weatherstrip (A), slide the weatherstrip rearward, then remove the
weatherstrip.
4. Install the weatherstrip in the reverse order of removal, and note these items:
Push the weatherstrip into place securely.
Make sure that there is no clearance between the rear edge of the weatherstrip and door sash outer trim.
Front Door Latch Replacement - Without Super Locking
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the door and related parts.
RHD model is shown; LHD model is symmetrical.
Latch Replacement
1. Raise the glass fully.
2. Remove the door panel.
3. Disconnect the power door lock actuator connector.
4. Remove the plastic cover, as needed.
5. Detach the latch cable fastener (A) from the latch cable (B).
6. Disconnect the latch cable (A) from the lock knob (B).
7. Detach the inner handle cable fastener (A) from the inner handle cable (B).
8. Disconnect the inner handle cable (A) from the lock knob (B).
9. Pull the glass run channel (A) away as needed, and remove the bolt, then remove the center lower channel (B).
10. Driver's door. Pull both side flanges (A) of the retainer (B) outward, and pull the middle flange portion (C) of the outer
casing cover (D) out, then disconnect the cylinder cable (E) from the latch.
11. If necessary, remove the front door outer handle and the special screws, then separate the door cylinder (A) and
outer handle protector (B). If the retainer (C) is damaged, release the hooks (D), and replace it.
NOTE: If removed, the special screws must be replaced.
Thailand-produced
models
3. Disconnect the latch cable (A) and inner handle cable (B). Indonesia-produced
4. Install the cables in the reverse order of removal, and note these items: models
Make sure the latch cable and inner handle cable are connected securely.
Make sure the door locks and opens properly.
When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its
outside perimeter to seal out water.
Check for water leaks.
Thailand-produced
models
Front Door Latch Replacement - With Super Locking
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the door and related parts.
6. Disconnect the latch cable (A) from the lock knob (B).
7. Detach the inner handle cable fastener (A) from the inner handle cable (B).
8. Disconnect the inner handle cable (A) from the lock knob (B).
9. Pull the glass run channel (A) away as needed, and remove the bolt, then remove the center lower channel (B) by
pulling it downward.
10. Remove the screws (A, B) securing the latch (C), then remove the latch through the hole in the door. Take care not
to bend the outer handle rod (D), the cylinder cable (E) (driver's door), the latch cable (F), and the inner handle
cable (G).
11. Driver's door: While pressing a middle flange portion (A) of the outer casing cover (B) against the latch, pull both
outside flanges (C) of the retainer (D) upward.
12. Driver's door: Pull the middle flange portion (A) of the outer casing cover (B) up, then disconnect the cylinder cable
(C) from the latch.
NOTE: As soon as the cable comes off the latch, the shutter (D) goes down into the connector (E).
13. Driver's door: If the retainer (A) of the lock cylinder cable (B) is damaged, release the hooks (C), then replace it.
14. Install the latch in the reverse order of removal, and note these items:
Make sure the actuator connector is plugged in properly and each rod is connected securely.
Make sure the door locks and opens properly.
When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its
outside perimeter to seal out water.
Cylinder cable installation: Before installing the cylinder cable (A) to the latch, hang the elbow of the shutter
(B) on the boss (C) as shown. Next install the cylinder cable fully into the connector (D), then push the
retainer (E) until it snaps to engage the latch and the door cylinder securely. Make sure the elbow of the
shutter is on the boss.
Cable Replacement
1. Remove the screw, then remove the latch protector (A) by releasing the hook (B).
2. Detach the latch cable (A) and the inner handle cable (B) from the latch (C).
3. Install the cable in the reverse order of removal.
Make sure the latch cable and inner handle cable are connected securely.
Make sure the door locks and opens properly.
When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its
outside perimeter to seal out water.
Front Door Channel Tape Replacement
NOTE:
Keep dust away from the working area.
When working at lower temperatures, heat the door channel and door channel tape with a hair
dryer.
Door channel: about 15 °C (59 °F).
Door channel tape: about 30 °C (86 °F).
When heating the door channel tape, heat it evenly and gradually to prevent deformation.
When pressing the door channel tape, slowly press it from the corner to prevent air bubbles and
wrinkles.
If there are air bubbles in the door channel tape, release the air with your finger or a plastic
squeegee.
If the air bubble is more than 10 mm (0.4 in.) in diameter, peel up the door channel tape, then
reapply it.
RHD model is shown; LHD model is symmetrical.
1. The following tools are required to replace the door channel tape:
Plastic squeegee
Isopropyl alcohol
Sponge or shop towel
Hair dryer
2. Remove these items:
Power mirror
Front door glass outer weatherstrip
Front door weatherstrip, as needed
Glass run channel, as needed
Front door sash outer trim
3. Slowly peel up the old door channel tape while heating it with a hair dryer.
4. Clean the door channel bonding surface with a sponge dampened in isopropyl alcohol. After
cleaning, keep oil, grease, and water from getting on the surface.
5. Attach the door channel tape.
-1. Peel the edge of the adhesive backing from the channel tape.
-2. Fit the door channel tape to the door channel.
-3. Apply the door channel tape to the door channel while peeling the adhesive backing from it
a little at a time. Check that the channel tape is parallel with the door channel.
-4. Push firmly on the door channel tape with a plastic squeegee (felt side).
NOTE: To prevent air bubbles, slowly press the door channel tape around the door frame
corner.
6. As necessary, repeat the preceding steps.
7. Reinstall all remaining removed parts.
8. Check that the body color on the door channel is covered by the door channel tape.
9. Check for water leaks.
5. Detach the rod fastener (A), then disconnect the outer handle rod (B) with a clip remover.
8. Remove the rod fastener (A) from the outer handle base (B), then replace it with a new one.
3. Disconnect the power window switch connector (A). Remove the screw from the grip base (B).
4. Pull the inner handle (A) forward and out half-way to release the hooks (B).
6. Remove the door panel (A) with as little bending as possible to avoid creasing or breaking it.
-1. Start at the bottom edge of the door panel, release the clips with a commercially available trim pad remover.
-2. Detach the upper clips.
-3. Starting at the rear, pull the door panel upward.
NOTE: Do not pull the door panel up too far, or the door panel will be damaged by the inner handle (B).
7. Remove the door panel (A) while pulling the inner handle (B) out through the hole in the door panel.
8. Install the door panel in the reverse order of removal, and note these items:
If the clips are damaged or stress-whitened, replace them with new ones.
Make sure the connector is plugged in properly.
Front Door Sash Outer Trim Replacement
NOTE:
Take care not to scratch the door and related parts.
RHD model is shown; LHD model is symmetrical.
1. Remove the door sash outer trim (A).
-1. Remove the screw from inside the door.
-2. Release the lower edge of the trim from the door glass outer weatherstrip (B).
-3. Pull the trim up to release the hooks (C) from the door, then remove the trim.
2. Install the trim in the reverse order of removal.
Door Striker Adjustment
Make sure the door latches securely without slamming it. If necessary, adjust the striker (A): The striker nuts are fixed,
but the striker can be adjusted slightly up or down, and in or out.
1. Loosen the screws (B).
2. Wrap the striker with a shop towel, then adjust the striker by tapping it with a plastic hammer (C). Do not tap the
striker too hard.
3. Lightly tighten the screws.
4. Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door
latches properly, tighten the screws and recheck.
Front Door Weatherstrip Replacement
NOTE:
Take care not to scratch the door and related parts.
Use a clip remover to remove the clips.
RHD model is shown; LHD model is symmetrical.
1. At the front pillar, remove the door checker mounting bolt (A).
2. Detach the clips (B, C, D, E), then remove the door weatherstrip (F).
3. Install the weatherstrip in the reverse order of removal and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Make sure the weatherstrip is installed in the holder (G) securely.
Apply medium strength type liquid thread lock to door stop mounting bolt before installation.
Check for water leaks.
Rear Door Glass Outer Weatherstrip Replacement
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the door and related parts.
RHD model is shown; LHD model is symmetrical.
1. Lower the glass fully.
2. Remove the rear door rear sash trim.
3. While lifting the rear of the door glass outer weatherstrip (A), slide the weatherstrip rearward, then remove the
weatherstrip.
4. Install the weatherstrip in the reverse order of removal, and note these items:
Push the weatherstrip into place securely.
Make sure that there is no clearance between the front edge of the weatherstrip and door sash outer trim.
Rear Door Latch Replacement
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the door and related parts.
RHD model is shown; LHD model is symmetrical.
Latch Replacement
1. Raise the glass fully.
2. Remove the door panel.
3. Detach the harness clip (A), then disconnect the power door lock actuator connector (B).
4. Remove the plug caps (C), then remove the plastic cover (D), as needed.
5. Detach the latch cable fastener (A) from the latch cable (B).
6. Disconnect the latch cable (A) from the lock knob (B).
7. Detach the inner handle cable fastener (A) from the inner handle cable (B).
8. Disconnect the inner handle cable (A) from the lock knob (B).
9. Remove the bolt, and loosen the nut, then pull the rear lower channel (A) forward.
10. Remove the screws (A, B), then remove the latch (C) through the gap between the rear lower channel and door.
NOTE: Take care not to bend the latch cable, the inner handle cable.
11. Install the latch in the reverse order of removal, and note these items:
Make sure the actuator connector is plugged in properly.
Make sure the door locks and opens properly.
When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its
outside perimeter to seal out water.
Check for water leaks.
Cable Replacement Indonesia-produced
models
1. Remove the door latch.
2. Remove the screws, then remove the latch protector (A).
Thailand-produced
models
3. Disconnect the latch cable (A) and the inner handle cable (B). Indonesia-produced
4. Install the cable in the reverse order of removal, and note these items: models
Make sure the latch cable and inner handle cable are connected securely.
Make sure the door locks and opens properly.
When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its
outside perimeter to seal out water.
Check for water leaks.
Thailand-produced
models
Rear Door Channel Tape Replacement
NOTE:
Keep dust away from the working area.
When working at lower temperatures, heat the door channel and door channel tape with a hair
dryer.
Door channel: about 15 °C (59 °F).
Door channel tape: about 30 °C (86 °F).
When heating the door channel tape, heat it evenly and gradually to prevent deformation.
When pressing the door channel tape, slowly press it from the corner to prevent air bubbles and
wrinkles.
If there are air bubbles in the door channel tape, release the air with your finger or a plastic
squeegee.
If the air bubble is more than 10 mm (0.4 in.) in diameter, peel up the door channel tape, then
reapply it.
1. The following tools are required to replace the door channel tape:
Plastic squeegee
Isopropyl alcohol
Sponge or shop towel
Hair dryer
2. Remove these items:
Rear door sash outer trim
Rear door rear sash trim
Rear door glass outer weatherstrip
Glass run channel, as needed
Rear door weatherstrip, as needed
3. Slowly peel up the old door channel tape while heating it with a hair dryer.
4. Clean the door channel bonding surface with a sponge dampened in isopropyl alcohol. After
cleaning, keep oil, grease, and water from getting on the surface.
5. Attach the door channel tape.
-1. Peel the edge of the adhesive backing from the channel tape.
-2. Fit the door channel tape to the door channel.
-3. Apply the door channel tape to the door channel while peeling the adhesive backing from it
a little at a time. Check that the channel tape is parallel with the door channel.
-4. Push firmly on the door channel tape with a plastic squeegee (felt side).
NOTE: To prevent air bubbles, slowly press the door channel tape around the door frame
corner.
6. As necessary, repeat the preceding steps.
7. Reinstall all remaining removed parts.
8. Check that the body color on the door channel is covered by the door channel tape.
9. Check for water leaks.
5. Detach the rod fastener (A), then disconnect the outer handle rod (B) with a clip remover.
7. Remove the rod fastener (A) from the outer handle base (B), then replace it with a new one.
2. Pull on the front bumper (A) at the wheel arch areas to release it from the hooks (B) on the side spacers (C).
3. With the help of an assistant, release the bumper from the hooks (A) on the upper beam (B).
2. Pull on the rear bumper (A) at the wheel arch areas to release it from the hooks (B, C) on the side spacers (D).
3. With the help of an assistant, while pulling the wheel arch portion away from the side spacer (A), pull the rear
bumper (B) to release the bumper from the hooks (C) on the body.
4. Install the bumper in the reverse order of removal, and note these items:
Make sure the rear bumper engages the hooks (of both the side spacers) on each side securely.
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips and the hooks into place securely.
Rear Bumper Lower Trim Replacement
For Some Models
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the rear bumper.
1. Remove the rear bumper (A).
2. Remove the clips and the hooks (B, C), then remove the rear bumper lower trim (D) from the rear bumper.
NOTE: To remove the clips, pry the inner clip up at the edge near the line (E) on its head.
3. Install the trim in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips and the hooks into place securely.
Front Air Spoiler Replacement
For Some Models
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the front bumper.
1. Remove the clips securing the air spoiler (A) from under the front bumper (B).
NOTE: To remove the clips, pry the inner clip up at the edge near the line (C) on its head.
2. Pull the front air spoiler back to detach the hooks (D) and remove the spoiler.
3. Install the spoiler in the reverse order of removal:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips and the hooks into place securely.
Bulkhead Under Spoiler Replacement
For Some Models
NOTE: Take care not to scratch the body.
1. Detach the clips, then remove the bulkhead under spoiler (A) from the front bulkhead.
NOTE: To remove the clips, pry the inner pin up at the edge near the line (B) on its head.
2. Install the spoiler in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips into place securely.
Rear Fender Cover Replacement
NOTE: Driver's side without
Put on gloves to protect your hands. rear splash guard
Take care not to scratch the body.
1. Remove the screws and the clips, then remove the rear fender cover (A).
2. Install the cover in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips into place securely.
Passenger's side
without rear splash
guard
4. Install the fender enclosure in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Before installing the clips, make sure the hooks (A) of the front fender enclosure (B) is installed into the
holes (C) in the front fender securely.
Push the clip into place securely.
Rear Air Outlet Replacement
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the body.
1. Remove the rear bumper.
2. Detach the hooks (A), then remove the rear air outlet (B).
3. Install the air outlet by pushing on the hook portions until the hooks snap into place.
Rear Spring Seat Lower Cover Replacement
NOTE: Take care not to scratch the body.
1. Remove the clip and detach the hooks (A), then remove the rear spring seat lower cover (B).
2. Install the cover in the reverse order of removal, and note these items:
Checki if the clip is dameged or stress-whitened, and if necessary, replace it with a new one.
Push the hook portions into place securely.
Fuel Fill Door/Adapter Replacement
NOTE: Take care not to scratch the body.
1. Remove the fuel cap (A) by turning it counterclockwise, and remove the screw.
2. Pull the fuel fill door/adapter lip (A) out from the fuel fill pipe (B).
3. While pulling the fuel fill door/adapter (A), turn the fuel fill door/adapter 90 ° clockwise with the fuel fill door partly
opened.
5. If necessary, pull out the fuel fill adapter grommet (A) and the fuel fill adapter packing (B) from the rod (C).
NOTE: When reinstalling the packing, be sure the arrow mark (D) on the packing is the upper side of the packing.
7. Install the fuel fill door/adapter in the reverse order of removal, and note these items:
Apply multipurpose grease to the sliding surfaces (A) of the fuel fill adapter grommet (B) where shown.
Make sure the adapter lip (C) is fully seated on the fuel fill pipe (D).
Hood Adjustment
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the hood, body and other related parts.
1. Remove the cowl covers.
2. Slightly loosen each bolt (A).
3. Adjust the hood (B) alignment in this sequence:
Adjust the hood right and left, as well as forward and rearward, by using the elongated
holes in the hood hinges (C).
Turn the hood edge cushions (D), as necessary, to make the hood fit flush with the body
at the front and side edges.
4. Adjust the hood latch (E) to obtain the proper height at the forward edge, and move the hood
latch right or left until the striker (F) is centered in the hood latch.
5. Tighten the bolts to the specified torque.
6. Check that the hood opens properly and closes securely.
7. Apply touch-up paint to the hinge mounting bolts and around the hinges, and let the paint dry.
8. Apply multipurpose grease to the hood latch and the hood hinges as indicated by the arrows.
9. Reinstall all of the removed parts.
Hood Insulator Replacement
1. Using a clip remover, detach the clips, then remove the hood insulator (A). Take care not to scratch the hood.
2. Install the insulator in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips into place securely.
Hood Latch Replacement
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the body and related parts.
1. For some models: Remove the clip (A), then disconnect and detach the hood switch connector (B).
2. Remove the bolts, then remove the hood latch (A) from the body.
3. Disconnect the hood opener cable (B) from the hood latch. Take care not to kink the cable.
4. Install the latch in the reverse order of removal, and note these items:
Apply multipurpose grease to each location of the hood latch indicated by the arrows.
Make sure the hood opener cable is connected properly and hood latch switch connector is plugged in
properly (for some models).
Adjust the hood latch alignment.
Make sure the hood opens properly and locks securely.
Hood Seal Replacement
1. Using a clip remover, detach the clips, then remove the hood seals (A). Take care not to scratch the hood.
2. Install the seal in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips into place securely.
Hood Release Handle Replacement
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the body.
RHD model is shown; LHD model is symmetrical.
1. Remove these items:
Kick panel, driver's side
Driver's dashboard undercover
2. Remove the bolts, then remove the hood release handle (A).
3. Disconnect the hood opener cable (B) from the hood release handle. Take care not to kink the cable.
4. Install the hood release handle in the reverse order of removal, and note there items:
Make sure the hood opener cable is connected properly.
Make sure the hood opens properly.
Front Pillar Corner Trim Replacement
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the corner trim and the body.
When removing components, use the trim tools or equivalent.
1. Carefully insert the trim tool (A) next to the grommet (B), and detach the grommet by prying on the front pillar
corner trim (C), then detach the tab (D).
NOTE: Apply protective tape (E) to the body as shown.
2. While sliding the front pillar corner trim forward in the direction shown, detach the clips (A) and the tab (B) from the
body, then remove the trim.
3. Install the trim in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips into place securely.
Front Bumper Lid Replacement
For Some Models
NOTE: Take care not to scratch the front bumper.
1. Release the hooks (A) by using a flat-tip screwdriver wrapped with the protective tape, then remove the front bumper
lid (B) from the front bumper (C).
2. Install the front bumper lid by pushing on the hook portions until the hooks snap into place.
Cowl Cover Replacement
NOTE:
Put on gloves to protect your hands.
When removing components, use the trim tools or equivalent.
Take care not to damage the body.
RHD model is shown, LHD model is symmetrical.
1. Remove the windshield wiper arms.
2. Using a clip remover, detach the clips from the cowl cover, then disconnect the windshield washer tube (A).
3. Detach the clips by carefully pulling the windshield side edge of the cowl cover (A) upward, and release the forward
hooks (B) by pulling the cowl cover forward, then remove the cover.
3. For some models: If necessary, remove the screws and the push nuts (A), then remove the upper front grille
molding (B) and the front ‘‘H'' emblem (C) from the grille base (D).
4. Install the grille in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips and the hooks into place securely.
Rear License Trim Replacement
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the body.
1. Remove these items:
Tailgate lower trim panel
Rear window wiper motor
Rear window wiper arm
2. From inside the tailgate, remove the bolt securing the rear license trim.
3. Pull out the rear license trim (A) to detach the pins (B) of the clips from the grommets (C), then remove the trim
from the tailgate.
4. Using snap ring pliers, remove the grommets from the tailgate.
5. Check if the grommets and pins are damaged or stress-whitened, and if necessary, replace grommets and pins as
an assembly with new ones.
6. Install the grommets on the pins by pushing them into place.
7. Install the trim in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Do not roll up the lip (D) of the rear window rubber dam. If necessary for proper attachment, set a plastic
plate between the lip and the trim. Install the top edge of the trim while sliding a plastic plate sideward. Be
careful not to cut the lip.
Push the clips into place securely.
Rear Strake Replacement
For Some Models
NOTE: Take care not to scratch the body.
1. Remove the clips, then remove he rear strake (A) from the body.
2. Install the strake in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips into place securely.
Roof Molding Replacement
NOTE:
Take care not to scratch the body.
Take care not to bend the roof molding.
When removing components, use the trim tools or equivalent.
1. Apply protective tape (A) to the body. Using a trim tool (B), pry up on the roof molding (C).
2. Pull up and slide the roof molding to release the front bracket (D) from the pin (E).
4. Pull up and release the rear bracket (A) from the pin (B), then remove the roof molding (C).
5. Install the molding in the reverse order of removal, and note these items:
Take care not to damage the windshield molding.
Make sure the roof molding is installed securely.
Side Sill Panel Replacement
For Some Models
1. Remove the side sill panel (A).
-1. On the back of the front wheel arch, remove the clips (B).
-2. Remove the expansion clips (C).
-3. Slide the side sill panel forward, and remove it. The side clips (D, E, F) will stay in the
body.
-4. Remove the side clips (D, E) from the body by turning them 45 °.
-5. If necessary, use a utility knife to cut the double-sided adhesive tape (G) that holds the
side clips (F) to the body. Take care not to scratch the body.
2. Check if the clips are damaged or stress-whitened, and if necessary, replace them with new
ones.
3. If the side clips (F) will be reinstalled, remove any remaining double-sided adhesive tape from
the side clips, then clean the side clip surfaces with a sponge dampened in isopropyl alcohol
where new double-sided will be attached. Apply primer to the side clips, then attach new
double-sided adhesive tape.
4. Clean the body surface with a sponge dampened in isopropyl alcohol where adhesive tape will
be attached.
5. Install the side clips (A, B, C) on the side sill panel (D).
6. Hold the panel up, and fit all the side clips into the holes in the body. Push on the panel until
the clips snap into place, and press the adhesive tape into place.
7. Install the expansion clips (E).
8. Install the clips (F) on the back of the front wheel arch.
Tailgate Adjustment
NOTE:
Have an assistant help you when adjusting the tailgate.
Take care not to scratch the tailgate, the body and other related parts.
Put on gloves to protect your hands.
1. Remove the tailgate support strut from each side.
2. Slightly loosen each bolt.
3. Adjust the tailgate (A) alignment in the following sequence:
Adjust the tailgate hinges (B) right and left, using the elongated holes.
Turn the tailgate edge cushions (C), in or out as necessary, to make the tailgate fit flush with the body at the
side edges.
Adjust the fit between the tailgate and tailgate opening by moving the striker (D), and adjust the striker right
or left until it is centered in the tailgate latch (E).
4. Tighten each bolt securely.
5. Check that the tailgate opens properly and locks securely.
6. Reinstall the support struts securely.
7. Apply touch-up paint to the hinge mounting bolts and around the hinges.
8. Apply multipurpose grease to the pivot portion of the tailgate hinges as indicated by the arrows.
9. Reinstall all of the removed parts.
Tailgate Latch Replacement - Without Super Locking
NOTE: Without tailgate key
Put on gloves to protect your hands. cylinder
Take care not to scratch the tailgate and the related parts.
If the tailgate latch doesn't be unlocked by using the keyless entry transmitter or unlocking the driver's door lock,
remove the maintenance lid (A) from the tailgate lower trim panel, then unlock the tailgate latch by turning the lock
lever counterclockwise as shown. Open the tailgate by pulling the tailgate handle.
4. Disconnet the tailgate latch actuator connector (A) and the tailgate lock switch connector (B), and detach the clip
(C), then remove the tailgate latch.
5. Using a 6 mm socket wrench, remove the bolts, then pull out the tailgate latch (D) from the tailgate.
6. Install the tailgate latch in the reverse order of removal, and note these items:
Make sure the connectors are plugged in properly and the handle cable is connected properly.
Make sure the tailgate opens properly and locks securely.
Tailgate Latch Replacement - With Super Locking
With Super Locking
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the tailgate and the related parts.
If the tailgate latch doesn't be unlocked by using the keyless entry transmitter or unlocking the driver's door lock,
remove the maintenance lid (A) from the tailgate lower trim panel, then unlock the tailgate latch by turning the lock
lever counterclockwise as shown. Open the tailgate by pulling the tailgate handle.
3. Disconnect the tailgate latch actuator connector (A) and the tailgate lock switch connector (B), and the trunk knob
switch connector (C) and detach the clip (D), then remove the tailgate latch.
4. Using a 6 mm socket wrench, remove the bolts, then pull out the tailgate latch (E) from the tailgate.
5. Install the tailgate latch in the reverse order of removal, and note these items:
Make sure the connectors are plugged in properly and the handle cable is connected properly.
Make sure the tailgate opens properly and locks securely.
Tailgate Lock Cylinder Replacement
For Some Models
NOTE: Put on gloves to protect your hands.
1. Remove the tailgate lower trim panel.
2. Disconnect the tailgate cylinder rod (A).
NOTE: Check for damaged or stress-whitened rod fastener (B).
3. Remove the bolt securing the lock cylinder (A), then remove the lock cylinder by turning it.
4. Install the lock cylinder in the reverse order of removal, and note these items:
Make sure the cylinder rod is connected properly.
Make sure the tailgate opens properly and locks securely.
Tailgate Support Strut Replacement
NOTE:
Have an assistant help you when removing and installing the support strut.
Take care not to scratch the body and tailgate.
1. Remove the pivot bolt (A) from the body.
2. Remove the bolts, then remove the support strut (B) from the tailgate.
3. Install the tailgate side bolts first, next install the body side pivot bolt, and fix the support strut correctly.
Tailgate Weatherstrip Replacement
1. Remove the tailgate weatherstrip (A) by pulling out on it.
2. Locate the painted alignment mark (B) on the tailgate weatherstrip. Align the painted mark with the alignment tab in
the center of the tailgate opening, and install the weatherstrip. Make sure it's seated completely and facing in the
direction shown. Make sure there are no wrinkles in the weatherstrip.
3. Check for water leaks.
Tailgate Handle Replacement
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the tailgate and the related parts.
1. Remove these items:
Tailgate lower trim panel
Rear license trim
2. Disconnect the tailgate opener cable (A) from the tailgate handle (B), and remove the nuts. Take care not to kink
the cable.
3. From outside of the tailgate, pull out the tailgate handle (A), then remove it.
4. Install the handle in the reverse order of removal, and note these items:
Make sure the tailgate opener cable is connected securely.
Make sure the tailgate opens properly.
Frame Repair Chart
Top View
Side View
Unit: mm (in.)
φ: Inner diameter
Unit: mm (in.)
a1 φ: Inner
For engine side mount φ15 (0.59) front
diameter g Floor center stiffener locating hole φ15 (0.59) l Front floor cross-member locating hole φ25 (0.98) p
a2 For engine side mount φ13 (0.51) outer h1 Front floor locating hole φ50 (1.97) front h2 Front floor locating hole φ25 (0.98) rear q
a1 For engine side mount φ15 (0.59) front g Floor center stiffener locating hole φ15 (0.59) l Front floor cross-member locating hole φ25 (0.98)
a3 For engine side mount φ15 (0.59) rear i1 Inside sill locating hole φ25 (0.98) front Inside sill locating hole φ25 (0.98) rear r1
a2 For engine side mount φ13 (0.51) outer h1 Front floor locating hole φ50 (1.97) front h2i2 Front floor locating hole φ25 (0.98) rear
b1 a3 For transmission mount φ15 (0.59) front j1 R Floor frame locating hole φ15 (0.59) front m Trailing arm gusset locating hole φ20 (0.79) r2
For engine side mount φ15 (0.59) rear i1 Inside sill locating hole φ25 (0.98) front i2 Inside sill locating hole φ25 (0.98) rear
b2 For transmission mount φ15 (0.59) wheelhouse side j1 L Floor frame locating hole φ15 (0.59) front n1 Rear seat guide bracket locating hole φ9 (0.35) right s
b1 For transmission mount φ15 (0.59) front j1 R Floor frame locating hole φ15 (0.59) front m Trailing arm gusset locating hole φ20 (0.79)
b3 For transmission mount φ15 (0.59) rear j2 R Floor frame locating hole φ15 (0.59) rear n2 Rear seat guide bracket locating hole φ9 (0.35) left t
b2 For transmission mount φ15 (0.59) wheelhouse side j1 L Floor frame locating hole φ15 (0.59) front n1 Rear seat guide bracket locating hole φ9 (0.35) right
b4 b3 For transmission mount φ13φ15
(0.51) j2 L Floor frame locating hole φ15 (0.59) rear o1 For trailing arm mount φ15 (0.59) inner u
For transmission mount (0.59) rear j2 R Floor frame locating hole φ15 (0.59) rear n2 Rear seat guide bracket locating hole φ9 (0.35) left
[Manual transmission model] k Front floor center locating hole φ15 (0.59) For trailing arm mount φ17 (0.67) outer v
b4 For transmission mount φ13 (0.51) j2 L Floor frame locating hole φ15 (0.59) rear o1o2 For trailing arm mount φ15 (0.59) inner
c Front[Manual
side frame locating hole
transmission φ16 (0.63)
model]
k 1291 (50.83)
Front floor center locating hole φ15 (0.59) k o2 For trailing arm mount φ17 (0.67) outer
d c FrontFront
damper 374 (14.7)
sidecenter hole φ48hole
frame locating (1.89)
φ16 (0.63) 359 (14.1)
1020 (40.16) l i2 m o2 r1 s t
e1 For front subframe mount h2 n1 o1 p q
d φ15Front damper
(0.59) front center hole φ48 (1.89) 231 (9.09) d e4 f g h1 i1 j1 R k j2 R
e2 u
e1 For front subframe mount φ15 (0.59) front
e2 For front subframe mount
e2 φ16For(0.63)
front
middle
subframe mount φ16 (0.63) middle a2
7.54 °
d
e3 Re3 R Outrigger
Outrigger locating
locating holehole φ11 (0.43)
e3 φ11 (0.43) locating hole φ11 (0.43) x 15 (0.59) slot
L Outrigger
e3 Le4 Outrigger locating hole mount φ15 (0.59) rear
For front subframe
φ11 (0.43) x 15 (0.59) slot u
f Outrigger locating hole φ25 (0.98)
e4 For front subframe
mount φ15 (0.59) rear a1
c a3 48
f Outrigger locating hole e1 (1.89) s
d
φ25 (0.98) B e3 R
[Section BB] q
b2 p
CENTER LINE B
o2
j1 R
j1 L j2 R k o1
l i2
b3 e3e2L i1 h2
h1 m
e3
b1 e4
BASE
LINE A
c b3
a2 e1
b1
[Manual transmission model] a1
b2 a3
CENTER LINE A
33 (1.30) f g r1, r2
65 (2.56) n2 64
283 (11.1) j1 L j2 L
[Manual transmission model] 76 (2.52)
BASE LINE
338 (13.3) j2 L n1, n2
(2.99) 110
409 (16.1)
138 (4.33)
425 (16.7)
b4 (5.43) 634 (25.0) 234 (9.21)
155 715 (28.2) 373 (14.7)
216 (8.50)
(6.10) 805 (31.7) 405 (15.9)
340 (13.4) 900 (35.4) 469 (18.5)
1290 (50.79) j2 R/j2 L 630 (24.8)
1450 (57.09) l 655 (25.8)
1610 (63.39) h2 862 (33.9)
155 1700 (66.93) i2
b4 (6.10) 1925 (75.79) m
BASE LINE 1935 (76.18) n1, n2
Unit: mm (in.)
φ: Inner diameter
a1 For engine side mount φ15 (0.59) front g Floor center stiffener locating hole φ15 (0.59)
a2 For engine side mount φ13 (0.51) outer h1 Front floor locating hole φ50 (1.97) front
a3 For engine side mount φ15 (0.59) rear i1 Inside sill locating hole φ25 (0.98) front
b1 For transmission mount φ15 (0.59) front j1 R Floor frame locating hole φ15 (0.59) front
b2 For transmission mount φ15 (0.59) wheelhouse side j1 L Floor frame locating hole φ15 (0.59) front
b3 For transmission mount φ15 (0.59) rear j2 R Floor frame locating hole φ15 (0.59) rear
b4 For transmission mount φ13 (0.51) j2 L Floor frame locating hole φ15 (0.59) rear
[Manual transmission model] k Front floor center locating hole φ15 (0.59)
c Front side frame locating hole φ16 (0.63)
374 (14.7)
1291 (50.83) k
d Front damper center hole φ48 (1.89) 1020 (40.16)
359 (14.1)
e1 For front subframe mount
φ15 (0.59) front
231 (9.09)
d e4 f g h1 i1 j1 R k j2 R
e2
e2 For front subframe mount
φ16 (0.63) middle a2
e3 R Outrigger locating hole
φ11 (0.43)
e3 L Outrigger locating hole
φ11 (0.43) x 15 (0.59) slot
e4 For front subframe
mount φ15 (0.59) rear a1
a3
c
f Outrigger locating hole e1
φ25 (0.98) e3 R
CENTER LINE
b3 e3 L
b1
283 (11.1) j1 L j2 L
76
338 (13.3)
(2.99)
409 (16.1)
138 425 (16.7)
(5.43)
634 (25.0)
155 715 (28.2)
216 (8.50)
(6.10) 805 (31.7)
340 (13.4) 900 (35.4)
1290 (50.79) j2 R/j2 L
1450 (57.09) l
1610 (63.39)
1700 (66.93)
b4 1925 (75.79)
1935 (76.18)
l Unit: mmfloor
Front (in.) cross-member locating hole φ25 (0.98) p Middle floor cross-member locating hole φ20 (0.79)
h2 φ: Inner
Frontdiameter
floor locating hole φ25 (0.98) rear q Rear frame A locating hole φ15 (0.59)
i2 a1InsideFor
sillengine side
locating mount
hole φ15 (0.59)
φ25 (0.98) rear front r1 gRear floor
Floor center hole
locating stiffener locating
φ25 (0.98) righthole φ15 (0.59)
m a2Trailing
Forarm
engine sidelocating
gusset mount φ13
hole(0.51) outer
φ20 (0.79) r2 h1 Front
Rear floor floor locating
locating hole φ25hole φ50
(0.98) left(1.97) front
n1 a3Rear For
seatengine side mount
guide bracket φ15 (0.59)
locating hole φ9rear
(0.35) right s i1 Inside
For spring basesill locating
mount hole
hole 15 φ25x (0.98)
(0.59) front
15 (0.59) square
n2 b1Rear For
seattransmission
guide bracketmount φ15hole
locating (0.59)
φ9front
(0.35) left t j1 R damper
Rear Floor frame
centerlocating
hole φ24hole φ15 (0.59) front
(0.94)
o1 b2For trailing
For transmission
arm mountmount φ15inner
φ15 (0.59) (0.59) wheelhouse side u j1 L frame
Rear FloorBframe locating
locating hole(0.79)
hole φ20 φ15 (0.59) front
o2 b3For trailing
For transmission
arm mountmount φ15outer
φ17 (0.67) (0.59) rear v j2 R floor
Rear Floor frame
side locating
panel hole
locating φ15
hole φ20(0.59) rear
(0.79)
b4 For transmission mount φ13 (0.51) j2 L Floor frame locating hole φ15 (0.59) rear
[Manual transmission model]
l i2 m o2 r1 s k Front floor center locating hole φ15 (0.59)
ch2 Front side t
n1 frame locating
o1 hole φ16 (0.63)p q v
d Front damper center hole φ48 (1.89) u
e1 For front subframe mount φ15 (0.59) front
e2 For front subframe mount φ16 (0.63) middle 7.54 °
b2
B
j1 R
j1 L j2 R k
e2 h1 i1
e3
e4
BASE
LINE A r2
c b3
a2 e1
b1
a1 a3
A 92.7
(3.65)
n2 64 f g
(2.52) o1
[Manual transmission model] 110
BASE LINE o2 j2 L
(4.33)
234 (9.21)
b4
373 (14.7)
405 (15.9)
469 (18.5) [Section AA]
630 (24.8)
655 (25.8)
h2 862 (33.9)
i2
m 155
(6.10)
n1, n2
BASE LINE
2000 (78.74)
BASE LINE
l Front floor cross-member locating hole φ25 (0.98) p Middle floor cross-member locating hole φ20 (0.79)
h2 Front floor locating hole φ25 (0.98) rear q Rear frame A locating hole φ15 (0.59)
i2 Inside sill locating hole φ25 (0.98) rear r1 Rear floor locating hole φ25 (0.98) right
m Trailing arm gusset locating hole φ20 (0.79) r2 Rear floor locating hole φ25 (0.98) left
n1 Rear seat guide bracket locating hole φ9 (0.35) right s For spring base mount hole 15 (0.59) x 15 (0.59) square
n2 Rear seat guide bracket locating hole φ9 (0.35) left t Rear damper center hole φ24 (0.94)
o1 For trailing arm mount φ15 (0.59) inner u Rear frame B locating hole φ20 (0.79)
o2 For trailing arm mount φ17 (0.67) outer v Rear floor side panel locating hole φ20 (0.79)
s
q t
o2
o1 v
l i2
h2 m
r1, r2
n1, n2
Subframe Replacement
Front Subframe Torque
NOTE:
After loosening the subframe mounting bolts, be sure to replace them with new ones.
When installing, align both installation reference holes in the subframe with both reference holes
in the body using a screwdriver or tapered punch as a guide.
Gauge Control Module Self-diagnostic Function
NOTE: Before doing the self-diagnostic function, make sure the No. 1 (10 A) and the No. 22 (7.5 A) fuse in the under-dash
fuse/relay box are OK.
The gauge control module has a self-diagnostic function which consists of the following checks:
The beeper drive circuit check.
The indicator drive circuit check.
The switch input test.
The LCD segment check.
The gauges drive circuit check (Tachometer, Fuel gauge, Speedometer).
The communication line check (of the body-controller area network (B-CAN) communication line and the fast-
controller area network (F-CAN) communication line between the gauges).
NOTE:
Indicators are also controlled via the communication line.
Entering the self-diagnostic function with the HDS
Using the HDS, select Body Electrical, Gauges, then Function Test and do the self-diagnostic function.
Err 1: there is a malfunction in the communication line between the gauge control module and
F-CAN. Check for DTCs in the ECM/PCM, and troubleshoot the indicated DTCs.
Err 2: there is a malfunction in the communication line between the gauge control module and
B-CAN. Check for DTCs in the body electrical system and troubleshoot the indicated DTCs.
Err 12: there is a malfunction in the communication line between the gauge control module and
F-CAN or B-CAN. Check for DTCs in the ECM/PCM first and troubleshoot the indicated DTCs. If
there is no DTCs in the ECM/PCM, check for the body electrical system DTCs and troubleshoot
the indicated DTCs.
The Communication Line Check - With multi-information display (MID) Example Indication
While in the self-diagnostic mode, the Communication Line Check starts after the LCD Segments
Check.
If ‘‘···'' come on, the communication line is OK. If faulty, the word ‘‘Error'' will be indicated on the MID
followed by number(s).
Error 1: there is a malfunction in the communication line between the gauge control module and
F-CAN. Check for DTCs in the ECM/PCM, and troubleshoot the indicated DTCs.
Error 2: there is a malfunction in the communication line between the gauge control module and
B-CAN. Check for DTCs in the body electrical system and troubleshoot the indicated DTCs.
Error 12: there is a malfunction in the communication line between the gauge control module
and F-CAN or B-CAN. Check for DTCs in the ECM/PCM first and troubleshoot the indicated
DTCs. If there is no DTCs in the ECM/PCM, check for the body electrical system DTCs and
troubleshoot the indicated DTCs.
[ ]: LHD model
*: With multi information display
Horns Component Location Index
HORN SWITCH
Test,
CABLE REEL
Replacement,
HORNS
Test,
MICU (Without security) Replacement,
(Has built-in horn relay circuit)
BATTERY
*: Ground through steering colum
*1: Without trailer lighting connector
*2: With trailer lighting connector
*3: With steering wheel switch
[ ]: LHD model
BATTERY
No. 3 TERMINAL
(20 A)*1 (30 A)*2 FUSE BOX
WHT
B23
No. 24
(10 A)
MICU
UNDER-DASH
FUSE/RELAY BOX
B28
[K3]
WHT
[PUR]
WHT WHT
[PUR] [PUR]
4 2
HORN
RELAY
3 1
ORN PUR
CABLE
REEL
11
1 1 1
HORN HORN HORN
SWITCH (Low) (High)
BATTERY
*: Ground through steering colum
*1: Without trailer lighting connector
*2: With trailer lighting connector
*3: With steering wheel switch
No. 3 BATTERY
TERMINAL
(20 A)*1 (30 A)*2 FUSE BOX
WHT
No. 24
(10 A)
MICU
Q11 A13
ORN GRN
CABLE
REEL
11
1 1 1
HORN HORN HORN
SWITCH (Low) (High)
3. Using a jumper wire, connect the dashboard wire harness 20P connector No. 1 terminal to body ground. The horns
should sound.
If the horn sounds, go to Step 4 .
If the horn do not sound, check these items:
-No. 24 (10 A) fuse in the under-dash fuse/relay box.
-Horn.
-Horn relay (with security).
-MICU (without security).
-An open in the wire.
4. Reconnect the dashboard wire harness 20P connector (A) to the cable reel (B).
5. Remove the driver's airbag assembly, and disconnect the horn switch 1P positive terminal (C) from the driver's
airbag.
7. Check for continuity between the cable reel subharness 20P connector No. 11 terminal and the horn switch 1P
positive terminal.
If there is continuity, check the installation of the driver's airbag assembly and the steering wheel. If OK,
replace the driver's airbag assembly.
If there is no continuity, repair an open in the wire.
9. Check for continuity between the steering wheel switch 20P connector No. 11 terminal and the horn switch 1P
positive terminal.
If there is continuity, check the installation of the driver's airbag assembly and the steering wheel. If OK,
replace the driver's airbag assembly.
If there is no continuity, repair an open in the wire.
Horn Test/Replacement
1. Remove the front bumper.
2. Disconnect the 1P connector (A) from each horn (B).
3. Connect the terminal (A) to the battery power, and the bracket (B) to body ground.
4. If the horn does not sound, replace it.
Carpet Replacement
SRS components are located in this area. Review the SRS component locations and the precautions and procedures
before doing repairs or service.
NOTE:
Put on gloves to protect your hands.
Take care not to damage, wrinkle or twist the carpet.
Be careful not to damage the dashboard and other interior trim pieces.
When removing components, use the trim tools or equivalent.
RHD model is shown; LHD model is symmetrical.
1. Do the battery terminal disconnection procedure, then wait at least 3 minutes before beginning work.
2. Remove these items:
Center console
Front seats, both sides
Kick panels, both sides
Front door sill trim, both sides
Center pillar lower trim, both sides:
-Without side curtain airbags
-With side curtain airbags
Rear door sill trim, both sides
Rear seat leg guide cover, both sides
3. From the bottom of the both rear seat-backs (A), detach the clips and release the Velcro fasteners (B) in the rear of
the carpet (C). Pull the rear seat belt buckles (D) out through a slit, then pull the carpet out from both cargo area
side trim panels.
4. Pry up the gap (A) detach the clips and pins (B), then remove the footrest (C). RHD model is shown, LHD model is
similar.
2. While pinching the clips (A), release the hooks (B), then remove the grab handle (C).
3. Using a pair of pliers, remove the clips (A) by pinching the hooks.
4. If the side curtain airbag has deployed, replace the grab handle with a new one.
5. If the side curtain airbag has not deployed, to prevent the side curtain airbags from deploying improperly and
possibly causing injury, inspect removed pieces and replace them if they have any of these types of damage:
Any cracks or damages in the grab handle (A).
Any cracks or stress-whitenings in the caps (B).
6. Install the clips (A) to the grab handle (B), then install the caps (C) fully into the clips.
7. Position the grab handle (A) on the bracket (B), and push on the grab handle until the clips (C) snap into place
securely.
Sunvisor Removal/Installation
NOTE:
Put on gloves to protect your hands.
Take care not to bend or scratch the headliner.
RHD model is shown; LHD model is symmetrical.
1. Insert a flat-tip screwdriver wrapped with protective tape through the hole in the front side of the bracket cover (A),
and push the hook (B). Then make sure the hook is unlocked certainly.
2. While pushing the hook (A) with a flat-tip screwdriver wrapped with protective tape, release the sunvisor (B) from the
holder (C), and rotate the sunvisor backward 45 °. Then make sure the hook slides into the bracket cover (D) as the
rotating the sunvisor.
3. Pull the sunvisor (A) down, then release the pin (B) of the bracket cover (C) from the hole in the body.
4. Turn the holder (A) 45 ° counterclockwise, and remove it from the holder grommet (B) by pulling the holder down.
5. Pry out the holder grommet (A) from the body by pinching its hooks (B).
6. If the side curtain airbag has deployed, replace the sunvisor with a new one.
7. If the side curtain airbag has not deployed, to prevent the side curtain airbags from deploying improperly and
possibly causing injury, inspect removed sunvisor and replace it, if it has any cracks or breakages:
Any cracks in the sunvisor bracket (A)
Any cracks in the sunvisor bracket cover (B)
Any bends or cracks in the sunvisor stay shaft (C)
Any cracks in the sunvisor base (D)
Any cracks in the vanity mirror base (E)
8. If the holder grommet is damaged or stress-whitened, replace it with a new one.
9. Install the holder (A) to the holder grommet (B) by turning it 45 ° clockwise, and install them to the body as an
assembly by pushing it until the hooks (C) snap into place securely.
10. Set the sunvisor (A) by inserting the bracket (B) and the pin (C) of the bracket cover (D) to the hole in the body.
11. While holding the bracket cover (A), rotate the sunvisor (B) forward until the hook (C) snaps into place. Then make
sure the sunvisor does not come off the body by pulling it down. Set the sunvisor to the holder (D).
Center Console Removal/Installation - Without Seat Heater
SRS components are located in this area. Review the SRS component locations and the precautions and procedures
before doing repairs or service.
NOTE:
Take care not to scratch the front seat, dashboard, and related parts.
When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
RHD model is shown; LHD model is symmetrical.
1. M/T model: Remove the shift knob (A).
Center Vent
NOTE:
Take care not to scratch the dashboard and its related parts.
RHD model is shown; LHD model is similar.
1. Remove the center panel:
Without audio system
With audio system
2. Remove the screws, then remove the center vent panel (A) from the center panel (B).
3. Release the hooks (C), then remove the center vent (D) from the center vent panel.
4. Install the center vent in the reverse order of removal and push the hooks into place securely.
Dashboard Center Lower Trim Removal/Installation
NOTE:
Take care not to scratch the dashboard and its related parts.
When removing components, use the trim tools or equivalent.
RHD model is shown; LHD model is symmetrical.
1. Remove the center lower cover.
2. Remove the center lower trim (A).
-1. Use the trim tool to pry the gap between the dashboard (B) and the upper side of the center lower trim
partially out and release the clips and hooks (C).
-2. Pull out the center lower trim slightly toward you and disconnect the accessory power socket connector (D)
and USB connector (E) (if equipped).
3. Install the trim in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips and the hooks into place securely.
Make sure the connectors are plugged in properly.
Dashboard Center Lower Cover Removal/Installation
NOTE:
Take care not to scratch the dashboard and its related parts.
When removing components, use the trim tools or equivalent.
RHD model is shown; LHD model is symmetrical.
1. While holding the glove box (A), release the glove box stops (B) on each side from the dashboard by pushing them
in, then lower the glove box.
3. While holding the glove box (A), release the glove box stops (B) on both sides from the dashboard by pushing them
inside, then remove the glove box.
4. Install the glove box in the reverse order of removal.
Dashboard Glove Box Cover Removal/Installation
NOTE: Center
Take care not to scratch the dashboard and its related parts.
RHD model is shown; LHD model is symmetrical.
1. Remove the dashboard/steering hanger beam.
2. Remove the screws, then remove the dashboard glove box center cover (A) and the dashboard glove box outer
cover (B).
3. Install the cover in the reverse order of removal.
Outer
Glove Box Striker Replacement
SRS components are located in this area. Review the SRS component locations and the precautions and procedures
before doing repairs or service.
NOTE:
Take care not to scratch the dashboard and its related parts.
RHD model is shown; LHD model is symmetrical.
1. Pull down the glove box.
2. Remove the screws, then remove the glove box striker (A).
3. Install the glove box striker in the reverse order of removal.
Instrument Panel Removal/Installation
NOTE:
Take care not to scratch the dashboard and its related parts.
When removing components, use the trim tools or equivalent.
RHD model is shown; LHD model is symmetrical.
1. Tilt the steering column down.
2. Remove the instrument panel (A).
-1. Pull out the select/reset knob (B).
-2. While carefully lifting the panel with the appropriate trim tool, insert the trim tool into the gap (C) between the
dashboard and the panel.
-3. Use the trim tool to gently pry the panel up partially to release the clips (D, E) and the hooks (F), then pull
the panel up to release the panel.
-4. Disconnect the power mirror switch connector (G).
3. Install the panel in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips and the hooks into place securely.
Make sure each connector is plugged in properly.
Make sure the select/reset knob operate properly.
Dashboard Driver's Knee Pad Removal/Installation
NOTE: Right
Take care not to scratch the dashboard and its related parts.
RHD model is shown; LHD model is symmetrical.
1. Remove the dashboard/steering hanger beam.
2. Remove the bolt, then remove the right driver's knee pad (A) and the left driver's knee pad (B) from the steering
hanger beam (C).
3. Install the pad in the reverse order of removal.
Left
Dashboard/Steering Hanger Beam Disassembly/Reassembly
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the dashboard, the body and the other related parts.
Take care not to bend the brackets.
When removing components, use the trim tools or equivalent.
RHD model is shown; LHD model is symmetrical.
1. Remove the dashboard/steering hanger beam.
2. Remove these items from the dashboard:
Instrument panel
Gauge control module
Driver's dashboard undercover
Center panel (without audio system)
Audio unit (with audio system)
Center lower cover
Center lower trim
Passenger's tray lid
Side vent
Passenger's airbag
3. From the front of the dashboard (A), remove the screws.
4. From the back of the dashboard (A), release the hooks (B), and remove the center joint duct (C).
5. From the back of the dashboard (A), remove the screws (B, C), then separate the dashboard from the steering
hanger beam (D).
6. Remove the screws, then remove the dashboard duct (A) from the dashboard (B).
7. If necessary, remove the screws, then remove the front def trim (A) from the dashboard (B).
8. Assemble the dashboard and steering hanger beam in the reverse order of removal. Make sure the dashboard wire
harness is not pinched.
Interior Trim Removal/Installation - Door Areas
Front Door Sill Area Driver's side
NOTE:
Put on gloves to protect your hands.
Take care not to bend or scratch the trim and panels.
When removing components, use the trim tools or equivalent.
RHD model is shown; LHD model is symmetrical.
1. Remove the driver's dashboard undercover.
2. Remove the driver's kick panel (A) or the passenger's side kick panel (B). Passenger's side
-1. Pull out the front door inner seal (C) from the kick panel hooks (D) and the front door opening flange.
-2. Pull the kick panel back by hand to detach the clips, and to release the hooks (E) from the front door sill trim
(F), then remove the panel. On the driver's side, pull the hood opener knob (G) and hold it while removing the
panel.
4. Pull out the front door inner seal (A) from the trim hooks (B) and around the front door opening flange, then remove
the seal.
5. Install the trim in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips and hooks into place securely.
2. Remove the hooks (A) from the center lower trim (B), then detach the lower clips pulling the bottom of the rear side
sill trim (C) back by hand and remove it.
3. Pull out the rear door opening seal (A) from the trim hooks (B) and around the front door opening flange, then
remove the seal.
4. Install the trim in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips and hooks into place securely.
Interior Trim Removal/Installation - Pillar Areas - Without Side Curtain Airbags
Front Pillar Trim
NOTE:
Put on gloves to protect your hands.
Take care not to bend or scratch the trim and panels.
When removing components, use the trim tools or equivalent.
RHD model is shown; LHD model is symmetrical.
1. Pull the front door opening seal away from the front pillar, as needed.
2. Pull the upper portion of the front pillar trim (A) back by hand to detach the clips and pull the trim up, then remove it
from the dashboard (B).
3. Install the trim in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips into place securely.
5. Remove the upper anchor cover (A), and remove the upper anchor bolt (B).
1. Pull the front door opening seal away from the front pillar as needed.
2. Hit the upper clip in the front pillar trim (A) with a rubber mallet. The clip is under the point (B) where the triangle
mark (C) on the edge of the trim indicates. Hitting the clip breaks the projections (D) on the pin (E) and pushes it
into the grommet (F) and against the body (G).
NOTE: The clip must be replaced with a new one when the front pillar trim is reinstalled.
3. Pull the top of the front pillar trim (A) back by hand to remove the upper clip (B) from the body (C).
4. Pull the front pillar trim (A) by hand to detach the clips. Pull the trim up from the dashboard (B), then remove it.
5. If the side curtain airbag has deployed, replace the front pillar trim with a new one.
6. If the side curtain airbag has not been deployed, check the front pillar trim (A) and note the following:
To prevent the side curtain airbags from deploying improperly and possibly causing injury, inspect the front
pillar trim and replace it if it has any of these types of damage:
-Any cracks, deformations, or stress-whitened areas in the front pillar trim
-Any cracks or stress-whitening in the clip seating surfaces (B, C)
Replace the upper clip (D) with a new one.
Check if the clips (E) are damaged or stress-whitened, replace them with new ones.
7. Before installing the front pillar trim (A), carefully remove a new upper clip (B).
8. Check the overlap between the headliner and front pillar trim, and if necessary, adjust it.
9. Carefully install a new upper clip (A) to the front pillar trim (B). Be sure that the grommet (C) is nearest to the top of
the pin (D) as shown.
10. Reinstall the front pillar trim (A).
-1. Insert the bottom of the trim into the dashboard (B).
-2. Place the trim over the front pillar (C), and fit its upper clip (D) and lower clips (E) into the holes (F) in the front
pillar, then lightly push the trim into place.
NOTE:
Make sure the side curtain airbag isn't tucked down under the clips and the ribs.
Push lightly on the upper clip. If you push too hard, the clip will be damaged, and it will not hold the
trim properly.
5. Remove the upper anchor cover (A), and remove the upper anchor bolt (B).
4. Install the trim in the reverse order of removal, and note these items:
Replace any stress-whitened or damaged clips (A) with new ones.
If the side curtain airbag has deployed, replace the quarter pillar glass trim and all clips on the trim with new
ones.
To prevent the side curtain airbags from deploying improperly and possibly causing injury, inspect the trim
and replace it, if it has any of these types of damage:
-Any cracks or deformation in the quarter pillar trim (B) and the upper hook (C), and any stress-whitened
areas in the upper part of the trim
-Any cracks or stress-whitened areas in the clips seating surfaces (D)
Replace any damaged parts with new ones.
Make sure the top of the trim overlaps with the headliner correctly.
Make sure the trim hook is installed into the body holes.
Push the clip and hooks into place securely.
Before installing the seat belt anchor bolt, make sure there are no twists or kinks in the seat belt.
Interior Trim Removal/Installation - Rear Side Areas
NOTE:
Put on gloves to protect your hands.
Take care not to bend or scratch the trim and panels.
When removing components, use the trim tools or equivalent.
RHD model is shown; LHD model is symmetrical.
1. Remove these items:
Rear door opening seal, as needed
Tailgate weatherstrip, as needed
Cargo floor
Rear trim panel
2. For some models: Release the buttons (A), then remove the rear shelf (B).
2. Pull the tailgate lower trim panel (A) back by hand, and detach the clips (B, C, D), then remove it.
3. Install the trim in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips into place securely.
Steering Column Cover Removal/Installation
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the column cover.
Do not pry the cover surface with any tools.
RHD model is shown; LHD model is symmetrical.
1. Release the tilt/telescopic lever (A), adjust the steering column to full tilt down position and to the full telescopic
pull position.
2. Release the tabs (B) of the upper column cover (C) while pushing the lower column cover (D) from the front side.
Carefully release the tabs, and note the hooks (E) may break when the upper column cover is pulled up too hard.
3. Insert a suitable sized screwdriver or equivalent tool (F) into the lever hole (G) in the lower column cover D along the
guide rib (H).
4. Release the hook (I) locating on the left side of the upper column cover C. The right side hook (J) of the upper
column cover C can't be released from the inside.
5. Remove the upper column cover C by lightly pulling it up by releasing the right side hook J of the cover.
6. Remove the screws, then remove the lower column cover (A).
7. Install the upper and lower column covers in the reverse order of removal, and push the hooks into place securely.
Reminder Systems Component Location Index
FRONT PASSENGER'S
GAUGE DOOR LOCK
CONTROL MODULE
ACTUATOR/KNOB
Input Test, SWITCH*
Acutuator Test,
Replacement,
Knob Switch Test,
FRONT PASSENGER'S
DOOR SWITCH
SRS UNIT
IGNITION KEY SWITCH
Test,
PARKING BRAKE SWITCH COMBINATION LIGHT SWITCH REAR LEFT SIDE SEAT BELT
Test, Test/Replacement, BUCKLE SWITCH*3
Q8 N1
SG PG
LT BLU PNK
M16 Q9 N2 K10 M34 M24
GAUGE CONTROL MODULE 32 16
C21 B26 E2 E9 C46 C45 C32 C33 C40 C26
BEEPER
DOOR DOOR DOOR DOOR
· PARKING BRAKE LOCK LOCK LOCK LOCK
GRN GRN GRY KNOB KNOB KNOB KNOB
REMINDER
· SEAT BELT REMINDER BRN RED WHT GRN WHT
display) 10 5 5 10
LT GRN LT GRN LT GRN
*5 *4
F-CAN TRANSCEIVER
B-CAN
TRANSCEIVER MULTI
ODO/TRIP INFORMATION
DISPLAY CAN L CAN H
DISPLAY
2.6 kΩ
18 29 30 13 17 23
3. Check for continuity between the terminals in each switch position according to the table.
4. Without cruise control: if the check is not as specified, replace the switch. If the switch is OK, but the system does
not operate, check for the cable reel.
With cruise control: if the check is not as specified, go to Step 5 . If the check is OK, but the system does not
operate, check for the cable reel.
6. Check for continuity between the terminal (B) in each switch position according to the table.
7. If the continuity is not as specified, replace the switch. If the switch is OK, but the system does not operate, check
for an open in the wire between the switch and the cable reel.
Safety Indicator System Component Location Index
SAFETY INDICATOR
MICU
(Buit into the under-dash
fuse/relay box)
Input Test,
Replacement,
BATTERY TERMINAL
FUSE BOX UNDER-DASH FUSE/RELAY BOX [ ]: LHD model
BATTERY : CAN line
No. 1 (100 A) No. 1 (10 A)
T-9 N1
WHT PNK
No. 60 (IGN) (50 A)
T1
WHT
IGNITION SWITCH
DOOR
INDICATOR
(LED)
INDICATOR
DRIVE MULTI INFORMATION
CIRCUIT DISPLAY
13 17 18
BLK BLK GRN
[LT GRN]
IG1 +B B-CAN
BACK UP
SG PG
1 1 1 1 1 1 1
LEFT REAR RIGHT REAR FRONT DRIVER'S LEFT REAR RIGHT REAR 2
DOOR SWITCH DOOR SWITCH PASSENGER'S DOOR SWITCH DOOR SWITCH DOOR SWITCH TAILGATE
(Closed: (Closed: DOOR SWITCH (Closed: (Closed: (Closed: LATCH
Door open) Door open) (Closed: Door open) Door open) Door open) SWITCH
Door open) (Closed:
Tailgate open)
BLK
10. Substitute a known-good gauge control module, and recheck the system.
If the symptom is gone, the gauge control module is faulty: replace it.
If the symptom is still present, the MICU is faulty; replace the under-dash fuse/relay box.
License Plate Light Replacement
1. Push the retaining spring, and pry out the license plate light (A).
NOTE: Be careful not to damage the tailgate.
3. Separate the license plate light lens (B) and the housing (C), then remove the bulb (D).
4. Install the light in the reverse order of removal.
Brake Pedal Position Switch Test
1. Disconnect the 4P connector (A) from the brake pedal position switch (B).
2. Check for continuity between the No. 1 and No. 2 terminals.
There should be continuity when the brake pedal is pressed.
There should be no continuity when the brake pedal is released.
3. Check for continuity between the No. 3 and No. 4 terminals.
There should be no continuity when the brake pedal is pressed.
There should be continuity when the brake pedal is released.
4. If necessary, adjust or replace the switch, or adjust the pedal height.
Headlight Replacement
1. Remove the front bumper.
2. Disconnect the connectors (A) from the headlight (B).
Headlight: 60/55 W
Front Position Light: 5 W
Front Turn Signal Light: 21 W
[ ]: LHD model
Cavity Wire Test condition Test: Desired result Possible cause if desired
result is not obtained
C33 BLU Driver's door open Check for continuity to Faulty driver's door
ground: There should be switch
continuity. An open in the wire
Driver's door closed Check for continuity to Faulty driver's door
ground: There should be switch
no continuity. A short to ground in the
wire
C32 LT GRN Front passenger's door Check for continuity to Faulty front passenger's
open ground: There should be door switch
continuity. An open in the wire
Front passenger's door Check for continuity to Faulty front passenger's
closed ground: There should be door switch
no continuity. A short to ground in the
wire
C32* LT GRN Left rear door or right rear Check for continuity to Faulty left rear door
door open ground: There should be switch
continuity. Faulty right rear door
switch
An open in the wire
Left rear door and right Check for continuity to Faulty left rear door
rear door closed ground: There should be switch
no continuity. Faulty right rear door
switch
A short to ground in the
wire
C40 GRN Left rear door open Check for continuity to Faulty left rear door
ground: There should be switch
continuity. An open in the wire
Left rear door closed Check for continuity to Faulty left rear door
ground: There should be switch
no continuity. A short to ground in the
wire
Cavity Wire Test condition Test: Desired result Possible cause if desired
result is not obtained
C26 PNK Right rear door open Check for continuity to Faulty right rear door
ground: There should be switch
continuity. An open in the wire
Right rear door closed Check for continuity to Faulty right rear door
ground: There should be switch
no continuity. A short to ground in the
wire
M34 GRY Ignition key inserted into Check for continuity to Poor ground (G501)
the ignition switch ground: There should be Faulty ignition key
continuity. switch
An open in the wire
Ignition switch LOCK (0), Check for continuity to Faulty ignition key
and the ignition key ground: There should be switch
removed from the ignition no continuity. A short to ground in the
switch wire
M8· BLU· BLK Combination light switch Check for continuity to Faulty combination light
M33 OFF ground: There should be switch
continuity. An open in the wire
Combination light switch Check for continuity to Faulty combination light
in any other position than ground: There should be switch
OFF no continuity. A short to ground in the
wire
M7· GRY· Combination light switch Check for continuity to Faulty combination light
M33 BLK (PARKING position) ON ground: There should be switch
continuity. An open in the wire
Combination light switch Check for continuity to Faulty combination light
OFF ground: There should be switch
no continuity. A short in the wire
M5· RED· Combination light switch Check for continuity to Faulty combination light
M33 BLK (Headlight position) ON ground: There should be switch
continuity. An open in the wire
Combination light switch Check for continuity to Faulty combination light
OFF ground: There should be switch
no continuity. A short in the wire
B26 GRN Transmission range Check for continuity to Poor ground (G101)
switch in R position ground: There should be Faulty transmission
continuity. range switch
An open in the wire
Transmission range Check for continuity to Faulty transmission
switch in any other ground: There should be range switch
position than R position no continuity. A short in the wire
*: Without security
9. If the lights-on reminder has a problem, substitute a known-good under-dash fuse/relay box, and
recheck the system. If the seat belt reminder has a problem, check for SRS DTCs and check
the seat belt buckle switch. If all the tests prove OK, go to Step 10 .
10. Substitute a known-good gauge control module, and recheck the system.
If the symptom is gone, the gauge control module is faulty; replace it.
If the symptom is still present, the MICU is faulty; replace the under-dash fuse/relay box.
Turn Signal/Hazard Warning Lights Component Location Index
3. Check for continuity between the terminals in each switch position according to the table.
4. If the continuity is not as specified, replace the switch (A) or bulb (B).
5. Install the switch in the reverse order of removal.
Turn Signal/Hazard Warning Lights (MICU) Input Test
NOTE: Before testing, check the No. 1 (10 A), No. 22 (7.5 A), and No. 23 (10 A) fuse in the under-dash
fuse/relay box.
1. Turn the ignition switch to LOCK (0).
2. RHD model: Remove the fuse lid panel , and remove the driver's dashboard lower cover.
LHD model: Remove the fuse lid panel.
3. Disconnect the under-dash fuse/relay box connectors A, B, C, E, K, M, N, Q, and W.
NOTE:
All connector views are shown from wire side of female terminals.
The illustration shows the RHD model and the black portion shows the lock lever. The
lock lever for LHD model is shown as the dashed lines.
4. With the connectors still disconnected, make these input tests at the appropriate connector.
If any test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, the MICU must be faulty; replace the under-dash
fuse/relay box.
Cavity
Wire Test Test: Desired result Possible cause if result
condition is not obtained
K10 BLK Under all Check for continuity to ground: Poor ground
conditions There should be continuity. (G502)
An open in the
wire
N2 BLK Under all Check for continuity to ground: Poor ground
conditions There should be continuity. (G501)
An open in the
wire
M16 BLK Under all Check for continuity to ground: Poor ground
conditions There should be continuity. (G501)
An open in the
wire
Q9 BLK Under all Check for continuity to ground: Poor ground
conditions There should be continuity. (G502)
An open in the
wire
B23 WHT Under all Measure the voltage to ground: Blown No. 3 (20 A
conditions There should be battery *4 /30 A *3 ) fuse in
voltage. the battery
terminal fuse box
An open in the
wire
W1 YEL Ignition Measure the voltage to ground: Blown No. 60 (50
switch ON (II) There should be battery A) fuse in the
voltage. under-dash
fuse/relay box
Faulty ignition
switch
An open in the
wire
A28 WHT Connect B23 Check the turn signal lights Poor ground
terminal to operation: The right front turn (G202, G301)
A28 terminal signal light and right side turn [G401, G451]
with a jumper signal light *1 should come on. Blown bulb
wire. An open in the
wire
C41 WHT Connect B23 Check the turn signal light Poor ground
terminal to operation: The right rear turn (G602)
C41 terminal signal light should come on. Blown bulb
with a jumper An open in the
wire. wire
B34 BLU Connect B23 Check the turn signal lights Poor ground
terminal to operation: The left front turn (G401) [G202,
B34 terminal signal light and left side turn G302]
with a jumper signal light *1 should come on. Blown bulb
wire. An open in the
wire
C13 BLU Connect B23 Check the turn signal light Poor ground
[WHT] terminal to operation: The left rear turn (G604)
C13 terminal signal light should come on. Blown bulb
with a jumper An open in the
wire. wire
Cavity
Wire Test Test: Desired result Possible cause if result
condition is not obtained
Q6 WHT Connect B23 Check the turn signal lights Poor ground
terminal to operation: The right side turn (G501) [G502]
Q6 termanal signal light *2 and/or right turn Faulty LED *2
with a jumper signal indicator should come Faulty gauge
wire. on. control module
Faulty indicator
An open in the
wire
M20 BLU Connect B23 Check the turn signal lights Poor ground
terminal to operation: The left side turn (G502) [G501]
M20 terminal signal light *2 and/or left turn Faulty LED *2
with a jumper signal indicator should come Faulty gauge
wire. on. control module
Faulty indicator
An open in the
wire
E11 WHT Connect B23 Check the turn signal light Poor ground
*5 terminal to operation: The right side turn (G501)
E11 terminal signal light *2 should come on. Faulty LED *2
with a jumper An open in the
wire. wire
E7 BLU Connect B23 Check the turn signal light Poor ground
*6 terminal to operation: The left side turn [G501]
E7 terminal signal light *2 should come on. Faulty LED *2
with a jumper An open in the
wire. wire
Cavity
Wire Test condition Test: Desired result Possible cause if result
is not obtained
N5 · YEL Hazard warning Check for continuity Faulty hazard
Q13 · switch pressed between N5 and Q13 warning switch
PNK terminals:There should be An open in the
continuity. wire
Hazard warning Check for continuity Faulty hazard
switch released between N5 and Q13 warning switch
terminals:There should be A short in the wire
no continuity.
M2 · LT Turn signal Check for continuity Faulty
M33 GRN switch in LEFT between M2 and M33 combination light
· position terminals: There should be switch
BLK continuity An open in the
wire
Turn signal Check for continuity Faulty
switch in RIGHT between M2 and M33 combination light
or neutral terminals: There should be switch
position no continuity. A short in the wire
M6 · BRN Turn signal Check for continuity Faulty
M33 · switch in RIGHT between M6 and M33 combination light
BLK position terminals: There should be switch
continuity. An open in the
wire
Turn signal Check for continuity Faulty
switch in LEFT between M6 and M33 combination light
or neutral terminals: There should be switch
position no continuity. A short in the wire
Side Turn Signal Light Replacement
Fender type
NOTE: Be careful not to damage the fender.
1. Push the retaining spring (A), and pry out the side turn signal light (B).
Side Turn Signal Light: 5W
2. Disconnect the 2P connector (C) from the side turn signal light.
3. Turn the bulb socket (D) counterclockwise to remove it from the bulb (E).
4. Install a new bulb in the reverse order of removal.
Mirror Type
1. Remove the mirror holder.
2. Remove the skullcap.
3. Remove the two screws (A) and remove the side turn signal light (B) from the housing (C).
4. Disconnect the 2P connector (D) from the side turn signal light.
5. Install the light in the reverse order of removal.
Ceiling Light Test/Replacement
1. Turn the ceiling light switch OFF.
2. Carefully pry the lens (A) off with a small screwdriver.
Ceiling Light: 8W
3. Remove the screws, then remove the individual map light (B).
4. Disconnect the connector (C) from the individual map light.
5. Check for continuity between the terminals.
There should be continuity between the No. 1 terminal and ground terminal with the switch in the ON
position.
There should be no continuity between the No. 1 terminal and ground terminal with the switch in the OFF
position.
6. If the continuity is not as specified, check the bulb. If the bulb is OK, replace the individual map light.
7. Install the light in the reverse order of removal.
Front Individual Map Light Test/Replacement - With Sunshade
With sunshade
1. Turn the map light switch OFF.
2. Carefully pry the lens (A) off with a small screwdriver.
Front Map Light: 8Wx 2
CEILING LIGHT
Test/Replacement,
FRONT PASSENGER'S
DOOR SWITCH
INDIVIDUAL MAP LIGHT
Test/Replacement,
LEFT REAR
DOOR SWITCH
MICU
(Built into the under-
dash fuse/relay box)
Without security
BATTERY TERMINAL
FUSE BOX UNDER-DASH FUSE/RELAY BOX [ ]: LHD model
BATTERY : CAN line
No. 1 (100 A) No. 60 (IGN) (50 A)
T-9
WHT
BATTERY TERMINAL
FUSE BOX UNDER-DASH FUSE/RELAY BOX [ ]: LHD model
BATTERY : CAN line
No. 1 (100 A) No. 60 (IGN) (50 A)
T-9
T1
WHT
WHT
IGNITION SWITCH
BAT W1
YEL T1
WHT
IG1
IGNITION SWITCH
No. 1 No. 22
(10 A) (7.5 A)
BAT W1
YEL G5 C37
IG1
No. 1 No. 22 TRANSMITTER
(10 A) (7.5 A)
PNK PNK
G5 C37
2 1
KEYLESS TRANSMITTER
RECEIVER UNIT
PNK (8 W) (Built into the
immobilizer-keyless PNK
2 control unit) 1 (5 W)
B-CAN
ON OFF KEYLESS RECEIVER UNIT
(Built into the 4 2 CARGO
(8 W) immobilizer-keyless AREA
control unit) LIGHT
(5 W)
1 CEILING B-CAN
ON OFF GRN
LIGHT [LT GRN]
BLU 4 2
PUR CARGO
AREA
LIGHT
IG1 B-CAN
G7
DRIVE CIRCUIT C18
DRIVE CIRCUIT
MICU Q3
SG PG B-CAN
IG1
DRIVE CIRCUIT DRIVE CIRCUIT
Left rear door Check for continuity to Faulty left rear door
closed ground: switch
There should be no A short to ground in
continuity the wire
Cavity
Wire Test Test: Desired result Possible cause if desired
condition result is not obtained
C26 PNK Right rear Check for continuity to Faulty right rear door
*1 door open ground: switch
There should be continuity An open in the wire
Right rear Check for continuity to Faulty right rear door
door closed ground: switch
There should be no A short to ground in
continuity the wire
C22 ORN Tailgate open Check for continuity to Poor ground (G602)
ground: Faulty tailgate latch
There should be continuity switch
An open in the wire
Tailgate Check for continuity to Faulty tailgate latch
closed ground: switch
There should be no A short to ground in
continuity the wire
*1:With security
*2:Without security
6. Reconnect the connectors to the under-dash fuse/relay box, and make these input tests at the
connector.
If any test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, replace the under dash fuse relay box.
CavityWire Test condition Test: Desired result Possible cause if
desired result is not
obtained
G7 BLU Ceiling light Connect G7 terminal and Blown No. 1 (10
switch in middle body ground with a A) fuse in the
position jumper wire: under-dash
The ceiling light should fuse/relay box
come on. Faulty ceiling
light
Blown bulb
An open in the
wire
CavityWire Test condition Test: Desired result Possible cause if
desired result is not
obtained
C18 PUR Under all Connect C18 terminal and Blown No. 1 (10
conditions body ground with a A) fuse in the
jumper wire: under-dash
The cargo area light fuse/relay box
should come on. Faulty cargo
area light
Blown bulb
An open in the
wire
Power Mirrors Function Test
1. Remove the instrument panel.
2. Disconnect the 13P connector (A) from the power mirror switch (B).
3. Choose the appropriate test based on the symptom:
Both mirrors don't work, go to Step 4 .
Right mirror doesn't work, go to Step 6 .
Left mirror doesn't work, go to Step 7 .
Retractable mirrors don't work, go to Step 8 .
Both mirrors
4. Measure the voltage between the No. 2 terminal and body ground with the ignition switch ON (II). There should be
battery voltage.
If there is no battery voltage, check for:
-Blown No. 10 (7.5 A) fuse in the under-dash fuse/relay box.
-An open in the BRN wire.
If there is battery voltage, go to Step 5 .
5. Check for continuity between the No. 6 terminal and body ground.
There should be continuity.
If there is no continuity, check for:
-An open in the BLK wire.
-Poor ground (G501).
If there is continuity, check the power mirror switch.
Right mirror
6. Connect the No. 2 terminal to the No. 11 terminal, and the No. 5 (then No. 13) terminal to the No. 6 terminal with
jumper wires, and turn the ignition switch to ON (II). The right mirror should tilt down (then swing left).
If the mirror does not tilt down (or does not swing left), check for an open in the GRN (or BLU) wire between
the right mirror and the power mirror switch 13P connector. If the wire is OK, check the right mirror actuator.
If the mirror neither tilts down nor swings left, repair an open in the LT GRN wire.
If the mirror works properly, check the power mirror switch.
Left mirror
7. Connect the No. 2 terminal to the No. 10 terminal, and the No. 5 (then No. 12) terminal to the No. 6 terminal with
jumper wires, and turn the ignition switch to ON (II). The left mirror should tilt down (then swing left).
If the mirror does not tilt down (or does not swing left), check for an open in the GRN (or PNK) wire between
the left mirror and the power mirror switch 13P connector. If the wire is OK, check the left mirror actuator.
If the mirror neither tilts down nor swings left, repair an open in the ORN wire.
If the mirror works properly, check the power mirror switch.
3. Remove the plastic cover as needed, then disconnect the connector (A).
5. While holding the mirror (A), detach the clip (B) and pull the harness (C) out through the hole in the door. Take care
not to scratch the door.
6. Install the mirror in the reverse order of removal, and note these items:
Make sure the connector is plugged in properly.
Check if the clip is damaged or stress-whitened, and if necessary, replace it with a new one.
Push the clip and hooks into place securely.
Power Mirror Actuator Test
1. Remove the door panel.
2. Disconnect the power mirror 13P (or 6P) connector (A) .
3. Check actuator operation by connecting power and ground according to the table. Power Mirror Actuator
4. If the mirror fails to work properly, replace the power mirror actuator.
Retract Actuator
Power Mirror Actuator Replacement
Removal
1. Remove the power mirror holder, and the power mirror.
2. Remove the two screws (A) and the side turn signal light (B) from the housing (C).
3. Disconnect the 2P connector (D) from the side turn signal light.
4. Record the power mirror connector terminals location and the wire harness colors.
5. Disassemble the power mirror connector (A), and remove the terminals (B) from the connector.
8. Remove the three screws and the power mirror actuator (A) from the housing (B).
9. Remove the four screws, and separate the power mirror actuator (A) and the retract actuator (B).
Installation 6P CONNECTOR
10. Route the wire harness of the new actuator through the hole in the bracket and gasket, then install the parts in the
reverse order of removal.
11. Insert the new actuator terminals into the connector in the original arrangement.
13P CONNECTOR
3. Check for continuity between the terminals in each switch position according to the table. Power Mirror Switch
4. If the continuity is not as specified, remove the screws and the covers and replacement the switch.
5. Install in the reverse order of removal.
Retract Switch
Front Seat Armrest Replacement
NOTE:
Take care not to tear the seams or damage the seat covers.
When removing components, use the trim tools or equivalent.
1. Using a trim tool, remove the cap (A).
2. Remove the center pin (B), bushing (C) and washer (D), then remove the armrest (E).
3. If necessary, remove the pins (F) from the seat-back.
4. Install the armrest in the reverse order of removal.
Front Seat Frame Replacement
Passenger's Seat
NOTE
Put on gloves to protect your hands.
Apply oil to the pivot portions of the slide locks.
Apply multipurpose grease to the sliding portions of the seat tracks.
RHD model is shown; LHD model is similar.
If the side airbag has deployed, replace the seat frame and related parts with new ones.
1. Remove the front seat.
2. Remove these items:
Front seat recline covers
Front seat belt buckle
Front seat-back cover/pad
Front seat cushion cover/pad
Recline inner covers
For some models: OPDS unit
For some models: Side airbag module
3. Install the new seat frame in the reverse order of removal.
Driver's Seat
NOTE
Put on gloves to protect your hands.
Apply oil to the pivot portions of the slide locks.
Apply multipurpose grease to the sliding portions of the seat tracks.
RHD model is shown; LHD model is similar.
If the side airbag has deployed, replace the seat frame and related parts with new ones.
1. Remove the front seat.
2. Remove these items:
Front seat recline covers
Front seat belt buckle
Front seat-back cover/pad
Front seat cushion cover/pad
Recline inner covers
For some models: Side airbag module
3. Install the new seat frame in the reverse order of removal.
Front Seat Recline Cover Removal/Installation
SRS components are located in this area. Review the SRS component locations and the precautions and procedures
before doing repairs or service.
NOTE:
Put on gloves to protect your hands.
Take care not to tear the seams or damage the seat covers.
When removing components, use the trim tools or equivalent.
RHD model is shown; LHD model is similar.
5. Open the cargo floor lids (A) and remove the bolts securing both rear seats.
6. Remove the right rear seat (A) and the left rear seat (B) through both rear door opening.
7. Install the seats in the reverse order of removal, and note these items:
Apply medium strength type liquid thread lock to the seat mounting bolts before reinstallation.
Push the clips into place securely.
After installing, fix the seat belt buckles and the detachable anchor with elastic bands on both seat
cushions.
If the clips are damage or stress-whitened, replace them with new ones.
Rear Seat Disassembly/Reassembly
NOTE:
When removing components, use the trim tools or equivalent.
Take care not to tear the seams or damage the seat covers.
Put on gloves to protect your hands.
The left rear seat is shown, the right rear seat is similar.
5. Remove the bolts and nut, then separate the rear seat-back (A) and the rear seat cushion (B).
6. If necessary, remove the bushing (C) and pivot washer (D).
7. Reassemble the seat-back and seat cushion in reverse order of disassembly, and note these items:
Apply medium strength type liquid thread lock to the bolts before reinstallation.
Apply multipurpose grease to the moving portions of the recline adjusters.
Replace any damaged or stress-whitened bushing and pivot washer with new ones.
Make sure the bushing and pivot washer are installed correctly.
Rear Seat Control Cable Replacement
NOTE:
Take care not to tear the seams or damage the seat covers.
Put on gloves to protect your hands.
Take care not to kink the cable.
The left rear seat cushion is shown, the right rear seat cushion is similar.
1. Remove the rear seat assembly.
2. Remove the rear seat cushion.
3. Remove the rear seat cushion cover/pad and the silencer.
4. Fold the leg, and remove the wire tie (A).
5. Disconnect the control cable (B) from the leg end (C) and cable bracket (D) of the seat cushion frame.
6. Install the cable in the reverse order of removal, and note these items:
Replace the wire tie you removed with new ones.
Make sure the control cable is routed properly and connected securely.
Fix at the original position in the end of the cable on the cable bracket securely. And check the rear seat tip-
up operation:
Make sure the rear seat cushion unlocks by lifting the leg. If necessary, adjust the position of the cable end.
Rear Seat Cushion Cover/Pad Replacement
NOTE:
When removing components, use the trim tools or equivalent.
Take care not to tear the seams or damage the seat covers.
Put on gloves to protect your hands.
The left rear seat cushion is shown, the right rear seat cushion is similar.
1. Remove the rear seat.
2. Remove the rear seat cushion.
3. Remove the screw and clip, then release the lib (A) and remove the recline cover (B).
4. Lift the leg (A), and remove the rear seat under cover cap (B). Left rear seat cushion
5. Remove the screws and knobs (A). Release the hook strip (B) of the seat cushion cover (C) from the edge of the Left rear seat cushion
rear seat under cover (D) all the way around.
6. Remove the rear seat under cover (A) from the seat cushion frame (B). Left rear seat cushion
8. Remove the rear seat cushion cover/pad (A) and the silencer (B) from the rear seat cushion frame (C).
9. Install the rear seat cushion cover/pad in the reverse order of removal. To prevent wrinkles when installing a seat-
back cover, make sure the material is stretched evenly over the pad before securing the hooks.
Rear Seat Cushion Leg Replacement
NOTE:
Take care not to tear the seams or damage the seat covers.
Put on gloves to protect your hands.
Take care not to kink the cable.
The left rear seat cushion is shown, the right rear seat cushion is similar.
1. Remove the rear seat assembly.
2. Remove the rear seat cushion.
3. Remove the rear seat cushion cover/pad and the silencer.
4. Remove the leg (A) from the seat cushion frame (B):
-1. Disconnect the control cable.
-2. Release the push nuts (C), then remove the set pins (D).
-3. Remove the leg.
-4. If necessary, remove the bushings (E), the cable hook (F), and the spring pins (G).
5. Install the leg in the reverse order of removal, and note these items:
Replace the push nuts and spring pins you removed with new ones.
Make sure the control cable is connected securely.
Apply multipurpose grease to the inside surfaces of the brackets (H).
Rear Seat-back Cover/Pad Replacement
NOTE:
When removing components, use the trim tools or equivalent.
Take care not to tear the seams or damage the seat covers.
Put on gloves to protect your hands.
The left rear seat is shown, the right rear seat is similar.
1. Remove the rear seat assembly.
2. Remove the seat-back.
3. Remove the these items:
Latch cover
Striker hole cover
4. If equipped, remove the shelf hooks (A) and shelf holder covers (B) from the back of the seat-back.
5. Release the hook strip (A), and unzip the seat-back cover and pull back the cover (B).
7. Pull out the seat-back cover/pad (A) from the frame, then pull out the head restraint guides (B) and center head
restraint guides (C) (for some model) while pinching the end of the guides, and remove them.
9. Remove the seat-back cover/pad (A) and the silencer (B) from the seat-back frame (C). If necessary, release the
hooks (D) and remove the latch lever inner cover (E).
10. Install the seat-back cover/pad in the reverse order of removal. To prevent wrinkles when installing a seat-back
cover, make sure the material is stretched evenly over the pad before securing the hooks.
Rear Seat-back Hinge Replacement
NOTE:
Take care not to tear the seams or damage the seat covers.
Put on gloves to protect your hands.
1. Remove the rear seat assembly.
2. Release the push nut (A) from the pivot pin (B).
3. Remove the pivot pin, pivot collars (C), and hinge (D) from the seat-back frame (E). The inside hinge of each seat-
back frame is shown. The outside hinges of them are symmetrical.
4. Reassemble the hinge in the reverse order of disassembly, and note these items:
Apply multipurpose grease to the moving portions of the hinge.
Replace any push nuts you removed with new ones.
Rear Seat-back Latch Replacement
NOTE:
When removing components, use the trim tools or equivalent.
Take care not to tear the seams or damage the seat covers.
Put on gloves to protect your hands.
The left rear seat is shown, the right rear seat is similar.
1. While pulling the latch lever (A), and remove the screw.
2. Release the hooks (B), and pull up the latch cover (C) from the rear seat-back.
3. Disconnect the control cable (A) from the latch lever (B), and remove the latch cover (C). Take care not to bend the
cable.
4. Detach the clips and hooks (A), then remove the striker hole cover (B).
2. Remove the nut and bolt, then remove the foot guide (A).
3. Install the foot guide in the reverse order of removal.
Rear Seat-back Striker Replacement
1. Remove the cargo area side trim panel.
2. Remove the bolts, then remove the rear seat-back striker (A).
3. Install the striker in the reverse order of removal, and more the striker (A) up or down until it is centered in the seat-
back latch (B).
Immobilizer System Symptom Troubleshooting Index
1. Troubleshoot the immobilizer system by the order of the priority shown:
Order of Symptom Possible cause
Priority
1 Immobilizer indicator blinks after Symptom troubleshooting.
the ignition switch turned to LOCK
(0).
2 Engine does not start with the Symptom troubleshooting.
immobilizer key.
3 Immobilizer indicator does not Check the MIL indication.
come on. If the MIL comes on, go to the Fuel and
Emission MIL circuit troubleshooting.
If the MIL does not come on, go to the gauge
control module self-diagnostic function.
4 Immobilizer indicator does not go Symptom troubleshooting.
off.
How to Troubleshoot the Immobilizer System
General Check before Troubleshooting
Before troubleshooting the immobilizer system, check the following general items and solve any if applicable:
The battery is low; charge the battery fully, then troubleshoot the immobilizer system.
The ignition key is not a genuine Honda part; use the Honda-approved key blank, register the key, then
troubleshoot the immobilizer system.
A key ring, or keys, or a key case is used; remove the key from it, and troubleshoot the immobilizer system with a
key only.
An aftermarket electrical part is attached; remove it, then troubleshoot the immobilizer system.
Normal operation
If the immobilizer code is identified, the immobilizer indicator comes on for 2 seconds, then goes off after turning the
ignition switch to ON (II).
The immobilizer indicator does not come on when the ignition switch is turned to LOCK (0).
System Check
NOTE: The HDS can be used to:
Check the state of the immobilizer key registration and the S-NET line by doing a SYSTEM CHECK.
Check the number of times the immobilizer-keyless control unit doesn't permit the engine to run by checking the
STATUS LOG.
1. Connect the HDS to the data link connector, then turn the ignition switch to ON (II) and follow the prompts to the
MAIN MENU.
NOTE: If the HDS does not communicate with the vehicle, go to the DLC circuit troubleshooting.
2. At the MAIN MENU, enter IMMOBILIZER, then select the IMMOBILIZER SETUP.
3. Do the SYSTEM CHECK. If there is a system check number, do the troubleshooting for the item indicated.
4. Check the status log using the HDS. Troubleshooting the line with the highest counts first. If all the lines are ‘‘0''
zero, the problem may not be caused by the immobilizer system, check for ignition or fuel problems.
NOTE: Once repaired, clear the status log by removing the No. 1 (10 A) fuse in the under-dash fuse/relay box or
disconnecting the immobilizer-keyless control unit.
Immobilizer System Description
The vehicle is equipped with an immobilizer system that will disable the vehicle unless a programmed ignition key is used.
This system consists of a transponder located in the ignition key, an immobilizer-keyless control unit, an indicator, and the ECM/PCM.
When the key is inserted in the ignition switch and turned to the ON (II) position, the immobilizer-keyless control unit sends power to the transponder in the ignition
key. The transponder then sends a coded signal back through the immobilizer control unit-receiver to the ECM/PCM. The code is a rolling type embedded in the
receiver instead of the ECM/PCM.
A communication agreement with the HDS is required at the ECM/PCM after repair or replacement. When replacing the immobilizer-keyless control unit, all keys
are required to be registered into the new control unit. Any keys that were not registered in the control unit will not start the vehicle.
If a programmed key has been used, the immobilizer indicator will come on for about 2 seconds, then go off.
IMMOBILIZER-KEYLESS
When the ignition switch is turned to CONTROL
LOCK (0), the indicator will blinkUNIT
for about 5 seconds to signal that the unit has been set correctly, then the indicator
will go off.
If the wrong key has been used whose code was not received or recognized by the unit, the indicator will come on for about 2 seconds, then it will blink until
the ignition switch is turned to LOCK (0).
2 sec. 5 sec.
1 Hz
PROGRAMMEDIGNITION KEY ON
KEY INSERTED INDICATOR KEY CYLINDER
(Has built-in transponder)
OFF
1 sec.
WRONG KEY ON
INSERTED INDICATOR
OFF
Immobilizer System Component Location Index
ECM/PCM
Replacement,
Substituting ECM/PCM for testing,
IMMOBILIZER INDICATOR
IGNITION KEY
[ ]: LHD model
: CAN line
BATTERY TERMINAL : Other communication line
FUSE BOX UNDER-DASH FUSE/RELAY BOX
BATTERY
No. 1 (100 A) T-9 No. 1 (10 A)
WHT
MICU
IMMOBILIZER GRN
INDICATOR [LT GRN]
(LED)
18 GRN
B-CAN [LT GRN] RED PNK
ECM/PCM MICU
1 IGNITION
KEY SWITCH
BLK BRN BRN/YEL BRN/YEL BRN/YEL (Closed:
Key inserted)
2
BLK
G101 G501
Immobilizer System Symptom Troubleshooting - Immobilizer indicator blinks
Immobilizer indicator blinks
NOTE: Before troubleshooting, check the items listed in ‘‘General Check before Troubleshooting''.
1. Turn the ignition switch to LOCK (0).
2. Connect the HDS, then turn the ignition switch to ON (II).
3. Enter the IMMOBILIZER, then select the IMMOBILIZER SETUP.
4. Select the SYSTEM CHECK.
Is the SYSTEM CHECK indicated?
YES - Troubleshoot the immobilizer system according to the result of the SYSTEM CHECK.■
NO - Go to Step 5 .
5. Turn the ignition switch to LOCK (0).
6. Enter the vehicle, and remove the ignition key from the ignition switch, then close all the doors.
7. Operate the keyless transmitter LOCK and UNLOCK several times in the vehicle.
Do the door lock actuators work normally?
YES - Go to Step 8 .
NO - Check for a poor ground (G101) and/or an open in the wire between the immobilizer-keyless control unit
7P connector No. 7 terminal and body ground (G101).■
8. Turn the ignition switch to ON (II).
9. Measure the voltage between the immobilizer-keyless control unit 7P connector No. 2 terminal and body ground.
Is there battery voltage?
YES - Go to Step 10 .
NO - Repair an open in the RED wire between the under-dash fuse/relay box and the immobilizer-keyless
control unit.■
10. Measure the voltage between the immobilizer-keyless control unit 7P connector No. 7 terminal and body ground.
Is there 0.5 V or more?
YES - Repair an open or poor connection between the immobilizer-keyless control unit 7P connector No. 7
terminal and G101.■
NO - Replace the immobilizer-keyless control unit .■
Immobilizer System Symptom Troubleshooting - Engine does not start with the immobilizer key
Engine does not start with the immobilizer key
NOTE: Before troubleshooting, check the items listed in ‘‘General Check before Troubleshooting''.
1. Turn the ignition switch to LOCK (0).
2. Turn the ignition switch to ON (II), and check the immobilizer indicator indication.
Does the indicator come on for 2 seconds, then go off?
YES - Go to the immobilizer indicator blinks troubleshooting. ■
NO - Go to Step 3 .
3. Turn the ignition switch to START (III).
Does the starter motor run?
YES - Go to Step 4 .
NO - Go to Starting System and check the starter motor.■
4. Try to start the engine with the immobilizer key.
Does the engine start?
YES - Go to Step 5 .
NO - Go to the Fuel and Emissions System Symptom Troubleshooting.■
5. Wait for a few minutes with the engine running.
Does the engine stop?
YES - Go to the Fuel and Emissions System Symptom Troubleshooting.■
NO - The system is OK at this time.■
Immobilizer System Symptom Troubleshooting - Immobilizer indicator does not go off
Immobilizer indicator does not go off
1. Turn the ignition switch to LOCK (0).
2. Connect the HDS to the data link connector.
3. Turn the ignition switch to ON (II).
4. Enter the IMMOBILIZER, then select the IMMOBILIZER INFORMATION.
5. Do the SYSTEM CHECK with the HDS.
Is N-1 OK indicated?
YES - Replace the gauge control module. ■
NO - Substitute a known-good immobilizer-keyless control unit , then register it and recheck. If the symptom
goes away, replace the original immobilizer-keyless control unit .■
Immobilizer System Check
1. Connect the HDS to the data link connector.
2. Turn the ignition switch to ON (II).
3. Monitor the System Check in the Immobilizer Info with the HDS.
4. If the HDS displays the ‘‘Immobilizer system is normal'', the immobilizer system is OK. If the HDS displays any
other messages, check as follows:
System System Check Possible Failures
Check No.
N-1 Normal ———
A-1 The key is not This key is not registered in the immobilizer-keyless control
registered unit. Try to register keys by using ‘‘KEYS''.
The communication was not good between the antenna and
the immobilizer key by influence of metal such as key chains.
The communication was not good between the antenna and
the immobilizer key by battery voltage low.
A-2 Communication Intermittent interruption between transponder and immobilizer-
error between keyless control unit.
the key and The immobilizer key type is different. It is not for this vehicle
immobilizer- but for another one or for other company's one.
keyless control Key failure (transponder failure)
unit The communication was not good between the antenna and
the immobilizer key by influence of metal such as key chains.
The communication was not good between the antenna and
the immobilizer key by battery voltage low.
A-3 No The ignition switch was turned to ON (II) with a non-immobilizer
communication key.
between the The immobilizer key type is different. It is not for this vehicle
key and but for another one or for other company's one.
immobilizer- Key failure (transponder failure)
keyless control The communication was not good between the antenna and
unit the immobilizer key by influence of metal such as key chains.
The communication was not good between the antenna and
the immobilizer key by battery voltage low.
Immobilizer-keyless control unit failure
B-1 The ECM/PCM The ECM/PCM was not registered. Try to register the
is not ECM/PCM by using ‘‘REPLACE ECM/PCM''.
registered The communication was not good between the ECM/PCM and
the immobilizer-keyless control unit by battery voltage low.
The communication was not good between the immobilizer-
keyless control unit and the ECM/PCM by influence of some
noise.
B-2 Error of The ECM/PCM was not registered. Try to register the
communication ECM/PCM by using ‘‘REPLACE ECM/PCM''.
format in The communication was not good between the ECM/PCM and
ECM/PCM the immobilizer-keyless control unit by battery voltage low.
The communication was not good between the immobilizer-
keyless control unit and the ECM/PCM by influence of some
noise.
D-1 S-net line short Harness short from the ECM/PCM to the immobilizer-keyless
control unit. (IMOCD/S-NET line short)
The communication was not good between the ECM/PCM and
the immobilizer-keyless control unit by battery voltage low.
The communication was not good between the immobilizer-
keyless control unit and the ECM/PCM by influence of some
noise.
Immobilizer-keyless control unit failure
ECM/PCM failure
[ ]: LHD model
*: If only one door is not working properly, check that door's lock actuator first, then check the
other items listed in this table.
Keyless/Power Door Locks/Security System Description
Security Alarm System
Keyless Entry System
Ultrasonic System
Door Lock System
Keyless/Power Door Locks/Security System Symptom Troubleshooting - Doors will not unlock (or lock) with the
transmitter, but will unlock (lock) with the door switch
Doors will not unlock (or lock) with the transmitter, but will unlock (lock) with the door switch
NOTE: Before troubleshooting, check the B-CAN DTCs. If any DTC is indicated, troubleshoot the indicated DTC first.
1. Turn the ignition switch to LOCK (0).
2. Remove the ignition key from the ignition switch.
3. Close and lock the doors.
4. Try to lock/unlock the doors with the keyless transmitter.
Do the door lock actuators work normally?
YES - Intermittent failure, the system is OK at this time.■
NO - Go to Step 5 .
5. Open the driver's door.
Does the key-in reminder chime sound?
YES - Faulty ignition key switch , or short to ground on the ignition switch wire. Repair as necessary.■
NO - Go to Step 6 .
6. Do the transmitter test.
Is the transmitter OK?
YES - Substitute a known-good under-dash fuse/relay box and recheck. If there is still a problem, substitute a
known-good immobilizer-keyless control unit and recheck.■
NO - Replace the transmitter.■
Keyless/Power Door Locks/Security System Symptom Troubleshooting - Doors automatically relock 30 second after
being unlocked with the transmitter even though a door has been opened
Doors automatically relock 30 seconds after being unlocked with the transmitter even though a
door has been opened
NOTE: Before troubleshooting, check the B-CAN DTCs. If any DTC is indicated, troubleshoot the indicated DTC first.
1. Place the ceiling light switch in the DOOR position.
2. Turn the ignition switch to ON (II).
3. Watch the ceiling light and the door indicators on the gauge control module.
Do the ceiling light and door indicators come on when the door is open, and go off when the door is closed?
YES - Substitute a known-good under-dash fuse/relay box and recheck. If the symptom goes away, replace the
original under-dash fuse/relay box.■
NO - Repair an open in the wire between the MICU and each door switch. If the wire is OK, replace the door
switch.■
Keyless/Power Door Locks/Security System Symptom Troubleshooting - Keyless operation does not work (LOCK,
UNLOCK)
Keyless operation does not work (LOCK, UNLOCK)
NOTE:
Before troubleshooting, check the B-CAN DTCs. If any DTC is indicated, troubleshoot the indicated DTC first.
Before troubleshooting, do the keyless transmitter test.
1. Turn the ignition switch to ON (II).
2. Try to start the engine.
Does the engine start?
YES - The immobilizer system is OK, go to Step 3 .
NO - Go to the immobilizer symptom troubleshooting. ■
3. Turn the ignition switch to LOCK (0).
4. Test the transmitter.
Is the transmitter OK?
YES - Replace the immobilizer-keyless control unit .■
NO - Replace the transmitter.■
Security Alarm Function Test
Ultrasonic sensor
1. Open the driver's window.
2. Close all doors.
3. Lock the doors with the transmitter or the key cylinder.
4. Wait 25 seconds for activate the security system.
The hazard warning lights and the security indicator blink when the security system is armed.
5. Put your hand into the cabin.
If the siren sounds and hazard warning lights blink, go to Step 6 .
If the system siren doesn't sound and the hazard warning lights don't blink, replace the ultrasonic sensor.
4. If the continuity is not as specified, replace the door lock actuator assembly.
Door Lock Actuator Test - Without Super Locking
Driver's Door
1. Remove the driver's door panel.
2. Disconnect the 10P connector (A) from the actuator (B).
3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
4. If the actuator does not operate as specified, replace it.
3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
4. If the actuator does not operate as specified, replace it.
3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
4. If the actuator does not operate as specified, replace it.
3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
4. If the actuator does not operate as specified, replace it.
Door Lock Actuator Test - With Super Locking
Driver's Door with Super Locking
1. Remove the driver's door panel.
2. Disconnect the 10P connector (A) from the actuator (B).
3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
4. If the actuator does not operate as specified, replace it.
3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
4. If the actuator does not operate as specified, replace it.
3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
4. If the actuator does not operate as specified, replace it.
3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
4. If the actuator does not operate as specified, replace it.
Door Lock Knob Switch Test
Driver's Door
1. Remove the driver's door panel.
2. Disconnect the 10P connector (A) from the actuator (B).
3. Check for continuity between the terminals.
There should be continuity between the No. 9 [No. 6] and No. 10 [No. 5] terminals when the door lock knob
switch is in the LOCK position and no continuity when the switch is in the UNLOCK position.
There should be continuity between the No. 8 [No. 7] and No. 10 [No. 5] terminals when the door lock knob
switch is in the UNLOCK position and no continuity when the switch is in the LOCK position.
[ ]: LHD model
4. If the continuity is not as specified, replace the door lock actuator.
3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
4. If the actuator does not operate as specified, replace it.
Fuel Lid Lock Actuator Replacement
1. Open the tailgate, then remove the lid cover from the left cargo area side trim panel.
2. Disconnect the 2P connector (A) from the actuator (B).
3. Loosen the mounting screws (C).
4. Move an actuator at the back, and remove the actuator.
5. Install in the reverse order or removal.
Fuel Lid Lock Actuator How to Cope in the Trouble
1. Open the tailgate, then remove the lid cover from the left cargo area side trim panel.
2. Move the rod (A) by hand in the direction that the arrow shows, and release the lock.
Security Alarm Hood Switch Test
1. Open the hood.
2. Disconnect the 2P connector (A) from the hood switch (B).
3. Check for continuity between the terminals.
There should be continuity between the No. 1 and No. 2 terminals when the hood is opened (lever released).
There should be no continuity between the No. 1 and No. 2 terminals when the hood is closed (lever pushed
down).
4. If the continuity is not as specified, replace the hood latch assembly.
Keyless Entry Transmitter Test
Special Tools Required
Keyless entry checker
07MAJ-SP00400
NOTE:
If the doors unlock or lock with the transmitter, but the LED on the transmitter does not come on, the LED is faulty;
replace the transmitter.
If any door is open, you cannot lock the doors with the transmitter.
If you unlocked the doors with the transmitter, but do not open any of the doors within 30 seconds, the doors relock
automatically.
The doors do not lock or unlock with the transmitter if the ignition key is inserted in the ignition switch.
With HDS
1. Press the lock or unlock button five or six times to reset the transmitter.
If the locks work, the transmitter is OK.
If any of the transmitter buttons do not work, replace the transmitter, then register the transmitter
programming.
If the locks don't work, go to Step 2 .
2. Connect the HDS to the data link connector.
3. Select the KEYLESS from the BODY ELECTRICAL menu, then enter the KEYLESS CHECK.
4. Press lock, unlock, trunk, or panic button and check the response on the screen of the HDS.
NOTE: The door lock actuators may or may not cycle when receiving input from the transmitter.
If KEYLESS ENTRY TRANSMITTER CODE IS RECEIVED is indicated, the transmitter is OK.
If DIFFERENT KEYLESS ENTRY TRANSMITTER CODE IS RECEIVED is indicated, the transmitter is not
registered to the vehicle. If necessary, reprogram and register the transmitter.
If KEYLESS ENTRY TRANSMITTER CODE IS NOT RECEIVED is indicated, go to Step 5 .
5. Open the transmitter and check for water damage.
If you find any water damage, replace the transmitter, then register it.
If there is no water damage, go to Step 6 .
6. Replace the transmitter battery (A) with a new one, and press lock or unlock button and check the receive
condition on the screen of the HDS.
If KEYLESS ENTRY TRANSMITTER CODE IS RECEIVED is indicated, the transmitter is OK.
If KEYLESS ENTRY TRANSMITTER CODE IS NOT RECEIVED is indicated, go to Step 7 .
7. Use a different known-good keyless transmitter assembly and repeat Step 3 and 4.
NOTE: The keyless transmitter does not need to be programmed to the vehicle for this test.
If (DIFFERENT) KEYLESS ENTRY TRANSMITTER CODE IS RECEIVED is indicated, replace the keyless
transmitter and do the immobilizer system registration.
If KEYLESS ENTRY TRANSMITTER CODE IS NOT RECEIVED is indicated, the immobilizer-keyless
control unit is faulty, replace it and do the immobilizer system registration.
NOTE: As the keyless transmitter is combined with the immobilizer transponder, so when the transponder is
registered by the HDS, the keyless transmitter is also registered automatically.
Without HDS
1. Put on the transmitter (A) behind the keyless entry checker (B).
2. Press the door lock button.
If the indicator light (C) comes on, the transmitter is OK.
If the indicator light does not come on, check for;
-A dead or low battery, go to Step 3 .
-Faulty transmitter.
3. Test the horn by connecting battery power to the terminal (A) and grounding the bracket (B). The horn should
sound.
4. If it fails to sound, replace it.
Tailgate Lock Actuator Test
With Keyless Entry
1. Open the tailgate.
2. Remove the tailgate lower trim panel.
3. Disconnect the 2P connector (A) from the tailgate lock actuator (B).
4. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
5. If the actuator does not operate as specified, replace it.
Ultrasonic Sensor Input Test
1. Carefully pry off the ultrasonic sensor cover (A) with a small screwdriver.
2. Remove the mounting screws.
3. Disconnect the 3P connector (B) from the ultrasonic sensor.
4. Inspect the connector and socket terminals to be sure they are all making good contact.
If the terminals are bend, loose or corroded, repair them as necessary, and recheck the
system.
If the terminals look OK, go to Step 5 .
5. With the connector still disconnected, make these input tests at the connector.
If any test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, the ultrasonic sensor must be faulty, replace it.
CavityWire Test Test: Desired result Possible cause if desired
condition result is not obtained
1 PNK Under all Measure the voltage to Blown No. 1 (10 A)
conditions ground: There should be fuse in the under-
battery voltage. dash fuse/relay box
An open in the wire
2 GRN Alarm Check for continuity An open in the wire
control between the No. 2 terminal
siren 6P and No. 4 terminal of the
connector alarm control siren: There
disconnected should be continuity.
Check for continuity to A short to ground in the wire
ground: There should be no
continuity.
3 BLK Under all Check for continuity to Poor ground (G602)
conditions ground: There should be An open in the wire
continuity.
Battery Test
A battery can explode if you do not follow the proper procedure, causing serious injury to anyone nearby.
Follow all procedures carefully and keep sparks and open flames away from the battery.
The battery contains sulfuric acid (electrical) which is highly corrosive and poisonous.
Getting electrolyte in your eyes or on your skin can cause serious burns.
Wear protective clothing and eye protection when working on or near battery.
Swallowing electrolyte can cause fatal poisoning if immediate action is not taken.
NOTE: To get accurate results, the temperature of the electrolyte must be between 21 and 38 °C (70 and 100 °F) before
testing.
Test Equipment Required
Battery Tester with:
Voltmeter with 0−18 V scale, ammeter with 0−100 A and 0−500 A scales, and a carbon pile with 0−300 W
12 V Battery Charger:
Fast charge capability of 50 A and slow charge capability of 5 A
Test Procedure
1. Check for damage: If the case is cracked or the terminals are loose, replace the battery.
2. Check the test indicator window:
If the test indicator window indicates the shortage of battery liquid, go to Step 3 .
If the test indicator window indicates a low, go to Step 4 .
3. Remove the tape and caps, and add distilled water. After refill the distilled water, apply the tape and caps.
4. Test battery load capacity by connecting a battery tester, and applying a load of three times the battery ampere
hour rating.
When the load has been applied for exactly 15 seconds, the battery voltage reading should stay above 9.6 V.
If the reading stays above 9.6 V, the battery is OK; clean its terminals and case, and reinstall it.
If the reading is between 6.5 and 9.6 V, connect a battery charger and charge the battery for 3 minutes at an
initial rate of 40 amps.
Since the main body of the battery is transformed or might be exploded by gas generated when
charging it, loosen the cap of each cell of the battery completely when you charged battery.
Amperage will drop as voltage increases; do not increase the amperage to compensate or you may
damage the battery.
Watch the battery voltage during the entire 3 minutes; the highest reading should stay below 15.5 V.
-If the reading stays below 15.5 V, the battery is OK; clean its terminals and case, and reinstall it.
-If the reading exceeds 15.5 V any time during the 3 minutes of fast charge, the battery is not good;
replace it.
If the reading drops below 6.5 V, slow-charge the battery by connecting a battery, and charge at 5 amps for
no more than 24 hours (or until the indicator shows full charge, or the specific gravity of the electrolyte is at
least 1.270).
Then test load capacity again.
-If the voltage stays above 9.6 V, the battery is OK; clean its terminals and case, and reinstall it.
-If the voltage still drops below 6.5 V, the battery is not good; replace it.
Battery Removal/Installation
NOTE: The battery terminal disconnection/reconnection procedure must be done before and after doing this procedure.
Some systems store data in memory that is lost when the battery is disconnected.
Removal
1. Do the battery terminal disconnection procedure.
2. Remove the two nuts (A) securing the battery setting plate (B), then remove the battery setting plate and the
battery (C).
Installation
1. Install the battery (A), then install the battery setting plate (B).
2. Tighten the two nuts (C) equally until the battery is stable.
NOTE: Do not deform the battery setting plate by tightening the nuts too much.
3. Do the battery terminal reconnection procedure.
NOTE: Make sure the positive terminal and the negative terminal are not reverse-connected.
Ignition Switch Test
SRS components are located in the area. Review the SRS component locations, and precautions and procedures before
performing repairs or servicing.
1. Do the battery terminal disconnection procedure.
2. Remove the steering column covers.
3. Disconnect the 7P connector (A) from the ignition switch (B).
4. Check for continuity between the terminals in each switch position according to the table.
5. If the continuity does not agree with the table, replace the ignition switch.
6. Do the battery terminal reconnection procedure.
Ignition Switch Replacement
SRS components are located in the area. Review the SRS component locations, and precautions and procedures before
performing repairs or servicing.
1. Do the battery terminal disconnection procedure.
2. Remove the steering column covers.
3. Disconnect the 7P connector (A) from the ignition switch (B).
4. Remove the two screws and the ignition switch.
5. Install in the reverse order of removal.
6. Do the battery terminal reconnection procedure.
Accessory Power Socket Component Location Index
BATTERY TERMINAL
FUSE BOX
BATTERY
No. 1 (100 A)
WHT
T-9
No. 60
(IGN)
(50 A)
T1
WHT
IGNITION SWITCH UNDER-DASH
FUSE/RELAY
BOX
BAT S3
RED
ACC
No. 13
(20 A)
N6
PUR
ACCESSORY
POWER
SOCKET
BLK
G502
Accessory Power Socket Test/Replacement
NOTE: If the accessory power socket does not work, check the No. 13 (20 A) fuse in the under-dash fuse/relay box and
ground (G502) first.
1. Remove the center lower trim.
2. Disconnect the 2P connector (A) from the accessory power socket (B).
3. Inspect the connector terminals to be sure they are all making good contact.
If the terminals are bent, loose, or corroded, repair them as necessary and recheck the system.
If the terminals look OK, go to Step 4 .
4. Turn the ignition switch to ACC (I).
5. Measure the voltage between the accessory power socket 2P connector No. 1 terminal and body ground. There
should be battery voltage.
If there is battery voltage, go to Step 6 .
If there is no battery voltage, check for an open in the wire.
6. Check for continuity between the accessory power socket No. 2 terminal and body ground. There should be
continuity.
If there is continuity, go to Step 7 .
If there is no continuity, check for an open in the wire.
Installation
1. Install the relays and connect the connectors to the under-dash fuse/relay box, then install the under-dash
fuse/relay box in the reverse order of removal.
2. Install the removed parts in the reverse order of removal.
3. Connect the positive cable to the battery, then connect the negative cable to the battery.
4. Set the clock (if equipped).
5. Make sure that all systems work properly.
Washer Reservoir Replacement
1. Remove the right inner fender.
2. Disconnect the 2P connector (A) and tubes (B) from the washer motor (C).
Washer Reservoir Capacity:
2.5 L (2.6 US qt, 2.2 Imp qt)
4. Remove the two bolts (A) and clip (B), then remove the washer reservoir (C).
5. Install the reservoir in the reverse order of removal. Check the washer motor operation.
Washer Motor Test
1. Remove the right inner fender.
2. Disconnect the 2P connector (A) from the washer motor (B).
3. Test the motor by connecting battery power to the No. 1 (or No. 2) terminal, and ground the No. 2 (or No. 1)
terminal of the washer motor. The motor should run.
If the motor does not run, or fails to run smoothly, replace it.
If the motor runs smoothly, but little or no washer fluid is pumped, check for a disconnected or blocked
washer hose, or a clogged washer motor outlet.
Washer Tube/Nozzle Replacement
1. Remove the right inner fender.
2. Remove the washer nozzles and clips, then remove the tubes.
3. Install in the reverse order of removal. Take care not to pinch the washer tubes. Check the
washer operation.
Wiper Arm Replacement
NOTE: Set the wiper arms to the auto-stop position before removal and installation.
Windshield
NOTE: Always pull up the driver's side wiper blade first.
1. Remove the caps, the nuts, and the wiper arms.
Rear Window
NOTE: Be careful not to damage the tailgate.
1. Remove the cover, the nut, and the wiper arm.
Wiper Motor Test
Windshield
1. Remove the wiper arms, and cowl lid (A).
2. Disconnect the 5P connector (B) from the wiper motor (C).
3. Test the motor by connecting battery power to the No. 4 [No. 3] terminal and ground the No. 5 [No. 4] terminal of
the wiper motor 5P connector. The motor should run at low speed. If the motor does not run, or fails to run
smoothly, replace the motor.
4. Test the motor by connecting battery power to the No. 1 [No. 5] terminal and ground the No. 5 [No. 4] terminal of
the wiper motor 5P connector. The motor should run at high speed. If the motor does not run, or fails to run
smoothly, replace the motor.
5. Connect an analog ohmmeter to the No. 3 [No. 1] and No. 5 [No. 4] terminals, and run the motor at low or high
speed. The needle of the ohmmeter should pulse. If it does not, replace the motor.
[ ]: LHD model
Rear Window
NOTE: If there is malfunction of the rear windshield wiper operation, and no DTCs are detected, check the rear windshield
wiper motor and an open in the ground circuit of the rear windshield wiper.
1. Open the tailgate, and remove the tailgate lower trim panel.
2. Disconnect the 4P connector (A) from the wiper motor (B).
3. Test the motor by connecting battery power to the No. 1 terminal and ground the No. 3 terminal of the wiper motor.
The motor should run. If the motor does not run or fails to run smoothly, replace the motor.
4. Connect an analog ohmmeter between the rear window wiper motor 4P connector No. 3 and No. 4 terminals. The
ohmmeter should indicate continuity and no continuity alternately. If it does not, replace the motor.
Wiper Motor Replacement
Windshield
NOTE: Be careful not to scratch or damage the hood and the body.
1. Remove the windshield wiper arms.
2. Remove the under-cowl panel and hood hinge cover.
3. Disconnect the 5P connector (A) from the windshield wiper motor (B).
4. Remove the bolts and the wiper linkage assembly (C).
5. Mark lines (A) to show the original adjustment, then remove the connection rod (B) from the linkage (C).
6. Remove the three bolts and the separate the windshield wiper motor (D) from the linkage assembly (E) through the
hole.
Installation
1. Before installing the motor, connect the 5P connector to the wiper motor, and turn the windshield wiper/washer
switch ON to LO or HI position, then OFF to return the motor shaft to the park position.
NOTE:
Do not use the windshield wiper/washer switch INT position in this step.
Apply multipurpose grease to the moving parts.
2. Install the wiper motor to the wiper linkage assembly in the reverse order of removal.
3. Install the linkage to the wiper motor shaft, then align the mark (A) of the linkage and the mark (B) of the wiper
linkage assembly.
4. After installation, adjust the wiper arms.
Rear Window
NOTE: Be careful not to scratch or damage the tailgate.
1. Remove the rear window wiper arm.
2. Open the tailgate, and remove the tailgate lower trim panel.
3. Remove the cap (A), and disconnect the 4P connector (B) from the rear window wiper motor (C).
4. Remove the three bolts and the rear window wiper motor.
5. Install in the reverse order of removal, and note these items:
Grease the moving parts.
Before reinstalling the wiper arm, turn the rear window wiper switch ON, then OFF to return the wiper shaft to
the park position.
Check the wiper motor operation.
Front Door Glass and Regulator Replacement
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the door and related parts.
RHD model is shown; LHD model is symmetrical.
1. Remove the these items:
Door panel
Speaker
2. Disconnect the power door lock actuator connector.
3. Remove the plastic cover.
4. Carefully raise the glass (A) until you can see the bolts, then remove them. Carefully pull the glass out through the
window slot.
NOTE: Take care not to drop the glass inside the door.
7. Apply multipurpose grease to all the sliding surfaces of the regulator (A) where shown.
8. Install the glass and regulator in the reverse order of removal, and note these items:
Raise and lower the glass to see if it moves freely without binding.
Make sure that there is no clearance between the glass and glass run channel when the glass is closed.
Adjust the position of the glass as necessary.
Do the power window control unit reset procedure.
When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its
outside perimeter to seal out water.
Check for water leaks.
Test-drive and check for wind noise and rattles.
Make sure the power door locks, windows and power mirror operate properly.
Door Glass Adjustment
NOTE: Check the weatherstrips and glass run channel for damage or deterioration, and replace them if necessary. Front door
1. Place the vehicle on a firm, level surface.
2. Remove these items:
Door panel:
-Front door
-Rear door
Plastic cover:
-Front door Rear door
-Rear door
3. Carefully move the glass (A) until you can see the glass mounting bolts (B), then loosen them.
4. Push the glass against the channel (C), then tighten the glass mounting bolts.
5. Check that the glass moves smoothly.
6. Raise the glass fully, and check for gaps. Also check that the glass (A) contacts the glass run channel (B) evenly.
7. Attach the plastic cover making sure it is sealed around its outside perimeter to seal out water.
8. Check for water leaks. Run water over the roof and on the sealing area as shown, and note these items:
Use a 12 mm (0.47 in.) diameter hose (A).
Adjust the rate of water flow as shown (B).
Do not use a nozzle.
Hold the hose about 300 mm (12 in.) away from the door (C).
9. Reinstall the door panel:
Front door
Rear door
Front Corner Glass Replacement
NOTE:
Put on gloves to protect your hands.
Wear eye protection while cutting the glass adhesive.
Use seat covers to avoid damaging any surfaces.
The front corner trim and the front corner glass clips will need replacement because they will be damage during
glass removal.
1. Remove these items:
Front pillar corner trim
Front pillar trim:
-Without side curtain airbags
-With side curtain airbags
2. Remove the front corner trim (A).
-1. From inside the vehicle, use a utility knife to cut through the adhesive (B) of the front corner trim.
-2. Pull out the upper edge of the front corner trim.
-3. Pull out the lower edge of the front corner trim, then remove it.
NOTE: Replace the front corner trim with a new one.
3. From inside the vehicle, use a utility knife (A) to cut through the front corner glass adhesive (B) all the way around.
Apply protective tape along the edge of the entire front corner glass opening flange.
4. From inside the vehicle, cut through the clips (A, B) of the front corner glass with a utility knife.
5. Carefully remove the front corner glass.
6. With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface
around the entire front corner glass opening flange:
Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
Remove the clips and the rubber dams from the body
7. Clean the body bonding surface with a sponge dampened in isopropyl alcohol. After cleaning, keep oil, grease and
water from getting on the surface.
8. If the old front corner glass is to be reinstalled, use a putty knife to scrape off all of the old adhesive and clips from
the front corner glass. Clean the inside face of the front corner glass and the edge of the glass with isopropyl
alcohol where new adhesive is to be applied. Make sure the bonding surface is kept free of water, oil and grease.
9. Attach the front corner trim (A) with adhesive tape to the inside face of the front corner glass (B) as shown. Before
installing the front corner trim, apply primer to the inside face of the front corner glass:
Be careful not to touch the glass where adhesive will be applied.
The front corner trim must be replaced with a new one.
Be sure the bottom edge of the front corner trim lines up with the alignment mark (C).
Be sure the top edge of the front corner trim lines up with the top edge of the glass.
Front corner trim adhesive tape:
Thickness 0.8 mm (0.03 in.)
Width 5 mm (0.197 in.)
10. Attach the clip A (A), the clip B (B, C) with adhesive tape to the inside face of the front corner glass (D) as shown:
Be careful not to touch the glass where adhesive will be applied.
Be sure the clip B (B) lines up with the inner shape of the front corner trim (E).
Be sure the side portion (F) of the clip A lines up with the front corner trim.
Clip A adhesive tape:
Thickness 1.2 mm (0.047 in.)
Width 8 mm (0.315 in.)
Clip B adhesive tape:
Thickness 1.2 mm (0.047 in.)
Width 16 mm (0.63 in.)
11. Attach the rubber dam (A, B) with adhesive tape to the inside face of the front corner glass (C) as shown.
Before installing the rubber dam, apply primer to the inside face of the front corner glass.
NOTE: Be careful not to touch the front corner glass where adhesive will be applied.
Rubber dam adhesive tape:
Thickness 0.2 mm (0.0079 in.)
Width 3 mm (0.12 in.)
12. With a sponge, apply a light coat of glass primer to the inside face of the front corner glass (A) as shown, then
lightly wipe it off with gauze or cheesecloth:
With the printed dots (B) on the front corner glass as a guide, apply the glass primer to the corner portions
of the front corner glass.
Do not apply body primer to the front corner glass, and do not get body and glass primer sponges mixed up.
Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the front corner
glass properly, causing a leak after the front corner glass is installed.
Keep water, dust, and abrasive materials away from the primed surface.
13. With a sponge, apply a light coat of body primer to any exposed paint or metal around the flange where new
adhesive will be applied. Let the body primer dry for at least 10 minutes:
Do not apply glass primer to the body, and be careful not to mix up glass and body primer sponges.
Do not apply body primer to any remaining original adhesive on the flange.
Never touch the primed surfaces with your hands.
Mask off the dashboard before painting the flange.
14. Cut a ‘‘V'' in the end of the nozzle (A) on the adhesive cartridge as shown.
15. Put the cartridge in a caulking gun, and run a bead of adhesive (A) around the edge of the front corner glass (B) and
along the rubber dam (C, D) and front corner trim (E) as shown:
With the printed dots (F) on the front corner glass as a guide, apply the adhesive to the corner portions of
the front corner glass.
Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each
corner.
16. Use suction cups (A) to hold the front corner glass (B) over the opening, align it with the clips (C, D), and set it
down on the adhesive. Lightly push on the front corner glass until its edges are fully seated on the adhesive all the
way around.
NOTE: Do not open or close any of the doors for about an hour until the adhesive is dry.
17. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or
the front corner glass, use a soft shop towel dampened with isopropyl alcohol.
18. After the adhesive has dried, spray water over the front corner glass and check for leaks. Mark the leaking areas
and let the front corner glass dry, then seal with sealant. Let the vehicle stand for at least 4 hours after front corner
glass installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly.
19. Reinstall all remaining removed parts.
NOTE: Advise the customer not to do the following things for 2 to 3 days:
Slam the doors with all the windows rolled up.
Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough,
uneven roads).
Quarter Glass Replacement
NOTE:
Put on gloves to protect your hands.
Wear eye protection while cutting the glass adhesive with a piano wire.
Use seat covers to avoid damaging any surfaces.
1. Remove the quarter pillar trim.
Without side curtain airbags
With side curtain airbags
2. Remove the rubber dam (A) from the front edge of the quarter glass (B). If necessary, cut the rubber dam with a
utility knife.
3. Apply protective tape to along the inside and outside edges of the body. Using an awl, make a hole through the
adhesive from inside the vehicle. Push a piece of piano wire through the hole, and wrap each end around a piece of
wood.
4. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close
to the quarter glass (B) as possible to prevent damage to the body, and carefully cut through the adhesive (C)
around the entire quarter glass.
5. Carefully remove the quarter glass.
6. With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface
around the entire quarter glass opening flange: Cutting positions
Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
Remove the clips and rubber dams from the body.
7. Clean the body bonding surface with a sponge dampened in isopropyl alcohol. After cleaning, keep oil, grease and
water from getting on the surface.
8. If the old quarter glass is to be reinstalled, use a putty knife to scrape off all of the old adhesive, clips and the
rubber dams from the quarter glass. Clean the inside face and the edge of the quarter glass with isopropyl alcohol
where new adhesive is to be applied. Make sure the bonding surface is kept free of water, oil and grease.
9. Set the quarter glass (A) in the opening, and center it. From inside the vehicle, make alignment mark (B) to the
quarter glass where the rear clip will be installed with a grease pencil. Be careful not to touch the glass where
adhesive will be applied.
10. Remove the quarter glass.
11. Attach the rubber dam A, rubber dam B, upper clip (C), lower clip (D), and rear clip (E) with adhesive tape to the
inside face of the quarter glass (F) as shown:
Align the center of the rear clip with the alignment mark (G) you made in step 9.
Be careful not to touch the quarter glass where adhesive will be applied.
Be sure the rubber dam B contacts the rubber dam A.
Rubber dam A adhesive tape:
Thickness 0.16 mm (0.006 in.)
Width 3 mm (0.12 in.)
Rubber dam B adhesive tape:
Thickness 0.16 mm (0.006 in.)
Width 3 mm (0.12 in.)
Upper clip adhesive tape:
Thickness 1.3 mm (0.051 in.)
Width 10 mm (0.3937 in.)
Lower clip adhesive tape:
Thickness 1.3 mm (0.051 in.)
Width 11 mm (0.433 in.)
Rear clip adhesive tape:
Thickness 0.4 mm (0.016 in.)
Width 7.5 mm (0.30 in.)
12. With a sponge, apply a light coat of glass primer along the edge of the quarter glass (A) and rubber dams (B) as
shown, then lightly wipe it off with gauze or cheesecloth:
With the printed dots (C) on the quarter glass as a guide, apply the glass primer to the corner portions of the
quarter glass.
Do not apply body primer to the quarter glass, and do not get body and glass primer sponges mixed up.
Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the quarter glass
properly, causing a leak after the quarter glass is installed.
Keep water, dust, and abrasive materials away from the primed surfaces.
13. With a sponge, apply a light coat of body primer to any exposed paint or metal around the flange where new
adhesive will be applied. Let the body primer dry for at least 10 minutes:
Do not apply body primer to any remaining original adhesive on the flange.
Be careful not to mix up the body and glass primer sponges.
Never touch the primed surfaces with your hands.
14. Cut a ‘‘V'' in the end of the nozzle (A) on the adhesive cartridge as shown.
15. Put the cartridge in a caulking gun, and run a bead of adhesive (A) around the edge of the quarter glass (B) and
along the rubber dams (C) as shown. With the printed dots on the quarter glass as a guide, apply the adhesive to
the corner portions of the quarter glass. Apply the adhesive within 30 minutes after applying the glass primer. Make
a slightly thicker bead at each corner.
16. Use suction cups (A) to hold the quarter glass (B) over the opening, align it with the clips (C) and set it down on the
adhesive. Lightly push on the quarter glass until its edges are fully seated on the adhesive all the way around.
NOTE: Do not open or close any of the doors for about an hour until the adhesive is dry.
17. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or
the quarter glass, use a soft shop towel dampened with isopropyl alcohol.
18. After the adhesive has dried, spray water over the quarter glass and check for leaks. Mark the leaking areas, let the
quarter glass dry, then seal with sealant. Let the vehicle stand for at least 4 hours after quarter glass installation. If
the vehicle has to be used within the first 4 hours, it must be driven slowly.
19. Reinstall all remaining removed parts.
NOTE: Advise the customer not to do the following things for 2 to 3 days:
Slam the doors with all the windows rolled up.
Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough,
uneven roads).
Rear Window Replacement
NOTE:
Put on gloves to protect your hands.
Wear eye protection while cutting the glass adhesive with a piano wire.
Use seat covers to avoid damaging any surfaces.
Do not damage the rear window defogger grid lines and terminals.
1. Remove these items:
Tailgate lower trim panel
High mount brake light
Rear window wiper arm
2. Remove the rubber dam (A, B) from the edge of the rear window. If necessary, cut the rubber dam with a utility
knife.
4. If the old rear window is to be reinstalled, make alignment marks (A) across the glass and body with a grease
pencil.
5. Apply protective tape along the inside and outside edges of the tailgate. Using an awl, make a hole through the
adhesive from inside the vehicle at the corner portion of the rear window. Push the piano wire through the hole, and
wrap each end around a piece of wood.
6. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close
to the rear window (B) as possible to prevent damage to the tailgate, and carefully cut through the adhesive (C)
around the entire rear window.
7. Carefully remove the rear window.
8. With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface
around the entire rear window opening flange: Cutting positions
Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
Remove the fasteners from the tailgate.
9. Clean the tailgate bonding surface with a sponge dampened in isopropyl alcohol. After cleaning, keep oil, grease
and water from getting on the surface.
10. If the old rear window is to be reinstalled, use a putty knife to scrape off all of the old adhesive, the fasteners and
the rubber dams from the rear window. Clean the inside face and the edge of the rear window with isopropyl alcohol
where new adhesive is to be applied. Make sure the bonding surface is kept free of water, oil and grease.
11. Attach the rubber dam A, the rubber dam B, the rubber dam D (C), fasteners A (D), and fasteners B (E) with
adhesive tape to the inside face of the rear window (F) as shown. Before installing the rubber dam A, the rubber
dam B, apply primer to the inside face of the rear window.
Be sure the rubber dams and fasteners line up with alignment marks (G).
Be careful not to touch the rear window where adhesive will be applied.
Before installing the rubber dam D, apply primer to the area where its adhesive tape will be stuck in the
rubber dam A.
Cut both ends of the rubber dam B as shown.
Fasteners adhesive tape:
Thickness 0.6 mm (0.024 in.)
Width 7.5 mm (0.30 in.)
Rubber dam A adhesive tape:
Thickness 0.4 mm (0.016 in.)
Width 7 mm (0.276 in.)
Rubber dam B adhesive tape:
Thickness 0.2 mm (0.008 in.)
Width 3 mm (0.12 in.)
Rubber dam D adhesive tape:
Thickness 0.2 mm (0.008 in.)
Width 3 mm (0.12 in.)
12. Attach the fasteners (A, B) with adhesive tape to the tailgate as shown.
Fasteners adhesive tape:
Thickness 0.6 mm (0.024 in.)
Width 7.5 mm (0.30 in.)
13. Set the rear window (A) in the opening, and center it. Make alignment marks (B) across the rear window and body
with a grease pencil at the four points shown. Make sure the fasteners B (C) contact with the holes of the tailgate
corner. Be careful no to touch the rear window where adhesive will be applied.
14. Remove the rear window.
15. With a sponge, apply a light coat of glass primer around the edge of the rear window (A) and along the rubber dams
(B) as shown, then lightly wipe it off with gauze or cheesecloth:
With the printed dots (C) on the rear window as a guide, apply the glass primer to both side portions of the
rear window.
Do not apply body primer to the rear window, and do not get tailgate and glass primer sponges mixed up.
Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the rear window
properly, causing a leak after the rear window is installed.
Keep water, dust, and abrasive materials away from the primed surfaces.
16. With a sponge, apply a light coat of body primer to any exposed paint or metal around the flange where new
adhesive will be applied. Let the body primer dry for at least 10 minutes:
Do not apply body primer to any remaining original adhesive on the flange.
Be careful not to mix up the body and glass primer sponges.
Never touch the primed surfaces with your hands.
17. Cut a ‘‘V'' in the end of the nozzle (A) on the adhesive cartridge as shown.
18. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking
gun, and run a bead of adhesive (A) around the edge of the rear window (B) and along the rubber dams (C) as
shown:
With the printed dots (D) on the rear window as a guide, apply the adhesive to both side portions of the rear
window.
Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each
corner.
19. Use suction cups to hold the rear window over the opening, align it with the alignment marks you made in Step 14 ,
and set it down on the adhesive. Lightly push on the rear window until its edges are fully seated on the adhesive all
the way around.
NOTE: Do not open or close any of the doors for about an hour until the adhesive is dry.
20. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or
the rear window, use a soft shop towel dampened with isopropyl alcohol.
21. After the adhesive has dried, spray water over the rear window and check for leaks. Mark the leaking areas, let the
rear window dry, then seal with sealant. Let the vehicle stand for at least 4 hours after rear window installation. If
the vehicle has to be used within the first 4 hours, it must be driven slowly.
22. Reinstall all remaining removed parts.
NOTE: Advise the customer not to do the following things for 2 to 3 days:
Slam the doors with all the windows rolled up.
Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough,
uneven roads).
Power Windows System Description
Auto Reverse Operation
Power Windows Component Location Index
IGNITION SWITCH
POWER
BAT W1 No. 22 (7.5 A) WINDOW
WHT YEL RELAY
IG1 (P/W)
F5 N4 F6 F4 C31 F3 C2
GRY BRN BRN RED RED PUR PUR
3 4
POWER WINDOW MASTER SWITCH [4] [3] 20 15 POWER WINDOW MASTER SWITCH
DRIVER'S
FRONT
PASSENGER'S LEFT REAR RIGHT REAR
UP DOWN
LIGHT (AUTO) (AUTO) OFF OFF OFF
(LED)
UP DOWN UP DOWN UP DOWN
UP DOWN VMP DR
CONTROL UNIT
UP DOWN SVCC PLSA PLSB SGND IG1
MAIN SWITCH
1 2 16 5 6 7 12 10 9 22 21 13 14 11
[10] [9] [1] [2]
ORN BLU WHT GRN PNK LT GRN BLK BRN WHT YEL PUR GRN RED LT GRN RED PUR BLK
4 1 5 6 3 2 1 3 4 1 3 4 1 3 4
FRONT
UP DOWN UP DOWN LEFT REAR UP DOWN RIGHT REAR
PULSER PASSENGER'S POWER POWER
POWER
WINDOW WINDOW
WINDOW OFF OFF OFF OFF SWITCH OFF OFF SWITCH
SWITCH
2 1 2 1 2 1
FRONT
PASSENGER'S LEFT REAR RIGHT REAR
POWER POWER POWER
WINDOW WINDOW WINDOW
MOTOR MOTOR MOTOR
G501 G501
Power Window Driver's Motor Test
1. Remove the door panel.
2. Disconnect the 6P (A) connector from the driver's power window motor.
Motor Test
3. Test the motor in each direction by connecting battery power and ground according to the table. When the motor
stops running, disconnect one lead immediately.
4. If the motor does not run or fails to run smoothly, replace it.
Pulser Test
5. Reconnect the 6P connector to the driver's power window motor.
6. Turn the ignition switch to ON (II).
7. Measure the voltage between the terminals.
There should be battery voltage between the No. 5 (+) and No. 2 (−) terminals.
Connect an analog voltmeter between the No. 6 (+) and No. 2 (−) terminals, and run the window motor down
or up. The voltmeter needle should move back and forth alternately (a digital voltmeter reads about 2.5 V).
Connect an analog voltmeter between the No. 3 (+) and No. 2 (−) terminals, and run the window motor down
or up. The voltmeter needle should move back and forth alternately (a digital voltmeter reads about 2.5 V).
8. If the voltage is not as specified, do the power window master switch input test for terminals No. 5, 6, 7, and 16.
9. If the switch is OK, replace the power window motor.
10. Reset the power window control unit.
Power Window Passenger's Motor Test
1. Remove the door panel: Front passenger's
Front passenger's
Rear
2. Disconnect the 2P connector (A) from the power window motor.
Rear
3. Test the motor by connecting battery power and ground according to the table. When the motor stops running,
disconnect one lead immediately.
4. If the motor does not run or fails to run smoothly, replace it.
Power Window Master Switch Input Test
NOTE: The power window control unit is built into the power window master switch.
1. Remove the grip cover.
2. Disconnect the 22P connector (A) from the power window master switch.
3. Inspect the connector and socket terminals to be sure they are all making good contact.
If the terminals are bent, loose or corroded, repair them as necessary, and recheck the
system.
If the terminals look OK, go to Step 4 .
4. With the connector still disconnected, make these input tests at the connector.
If any test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, go to Step 5 .
NOTE: Before testing, make sure the No. 1 (10 A), No. 22 (7.5 A), and No. 60 (50 A) fuse in the
under-dash fuse/relay.
CavityWire Test condition Test: Desired result Possible cause if desired
result is not obtained
3 [4] GRY Under all conditions Measure the voltage Blown No. 3 (20 A)
to ground: There fuse in the under-
should be battery dash fuse/relay box
voltage. Faulty under-dash
fuse/relay box
An open in the wire
4 [3] BRN Ignition switch ON Measure the voltage Blown No. 17 (20 A)
(II) to ground: There fuse in the under-
should be battery dash fuse/relay box
voltage. Faulty under-dash
fuse/relay box
Faulty power
window relay (P/W)
Faulty MICU
An open in the wire
15 PUR Ignition switch ON Measure the voltage Blown No. 18 (20 A)
(II) to ground: There fuse in the under-
should be battery dash fuse/relay box
voltage. Faulty under-dash
fuse/relay box
Faulty power
window relay (P/W)
Faulty MICU
An open in the wire
20 RED Ignition switch ON Measure the voltage Blown No. 19 (20 A)
(II) to ground: There fuse in the under-
should be battery dash fuse/relay box
voltage. Faulty under-dash
fuse/relay box
Faulty power
window relay (P/W)
Faulty MICU
An open in the wire
11 BLK Under all conditions Check for continuity Poor ground (G501)
to ground: There An open in the wire
should be continuity.
12 BLK Under all conditions Check for continuity Poor ground (G501)
to ground: There An open in the wire
should be continuity.
9 [2] YEL Ignition switch ON Connect the No. 4 Blown No. 17 (20 A)
(II) [No. 3] and the No. 9 fuse in the under-
[No. 2] terminals, dash fuse/relay box
and No. 10 [No. 1] Faulty under-dash
and No. 11 terminals fuse/relay box
momentarily with Faulty front
jumper wires: The passenger's power
front passenger's window motor
window should go Faulty front
down. passenger's power
window switch
10 WHT Ignition switch ON Connect the No. 4 Poor ground (G501)
[1] (II) [No. 3] and the No. An open in the wire
10 [No. 1] terminals,
and No. 9 [No. 2]
and No. 11 terminals
momentarily with
jumper wires: The
front passenger's
window should go
up.
CavityWire Test condition Test: Desired result Possible cause if desired
result is not obtained
13 LT Ignition switch ON Connect the No. 15 Blown No. 18 (20 A)
GRN (II) and the No. 13 fuse in the under-
terminals, and No. dash fuse/relay box
14 and No. 11 Faulty under-dash
terminals fuse/relay box
momentarily with Faulty right rear
jumper wires: The power window motor
right rear window Faulty right rear
should go up. power window
14 RED Ignition switch ON Connect the No. 15 switch
(II) and the No. 14 Poor ground (G501)
terminals, and No. An open in the wire
13 and No. 11
terminals
momentarily with
jumper wires: The
right rear window
should go down.
[ ]: LHD model
5. Reconnect the 22P connector to the power window master switch. Turn the ignition switch to
ON (II), and make these input tests at the connector.
If any test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, the control unit must be faulty; replace the power window
master switch.
CavityWire Test condition Test: Desired result Possible cause if desired
result is not obtained
7 LT Ignition switch ON Check for continuity Poor ground (G501)
GRN (II) to ground: There Faulty power
should be continuity. window master
switch
An open in the wire
16 WHT Ignition switch ON Measure the voltage Faulty power
(II) to ground: There window master
should be battery switch
voltage. A short to ground in
the wire
CavityWire Test condition Test: Desired result Possible cause if desired
result is not obtained
5 GRN Ignition switch ON Measure the voltage Faulty power
(II), and driver's between the No. 5 window master
window switch and No. 7 terminals: switch
moving up or down There should be 0 Faulty driver's power
V−about 5 V−0 V− window motor
about 5 V repeatedly An open in the wire
(a digital voltmeter A short to ground in
should reads about the wire
2.5 V while the
window moves).
6 PNK Ignition switch ON Measure the voltage
(II), and driver's between the No. 6
power window switch and No. 7 terminals:
moving up or down There should be 0
V−about 5 V−0 V−
about 5 V repeatedly
(a digital voltmeter
should reads about
2.5 V while the
window moves).
[ ]: LHD model
Power Window Master Switch Test
1. Remove the grip cover.
2. Disconnect the 22P connector (A) from the power window master switch.
3. Check for continuity between the terminals in each switch position according to the tables. Front Passenger's
Driver's Switch Switch
The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the
master switch input test procedures. If the tests are normal, the driver's switch must be faulty. Replace the switch.
4. If the continuity is not as specified, replace the switch.
Rear
3. Check for continuity between the terminals in each switch position according to the table.
4. If the continuity is not as specified, replace switch.
Power Window Passenger's Switch Replacement
NOTE: The illustration shows front passenger's power window switch.
1. Remove the door panel:
Front passenger's
Rear
2. Remove the screws and the grip base (A).
ABS Indicator
The ABS indicator comes on when the ABS function is lost. The brakes still work like a conventional system.
Self-diagnosis
Self-diagnosis can be classified into two categories:
-Initial diagnosis: Done right after the ignition switch is turned to ON (II) and until the ABS indicator goes off.
-Regular diagnosis: Done right after the initial diagnosis until the ignition switch is turned to LOCK (0).
When the system detects a problem, the ABS modulator-control unit shifts to fail-safe mode.
Kickback
The pump motor operates when the ABS modulator-control unit is functioning, and the fluid in the reservoir is forced out to
the master cylinder, causing kickback at the brake pedal.
Pump Motor
The pump motor operates when the ABS modulator-control unit is functioning.
The ABS modulator-control unit checks the pump motor operation one time after completing initial diagnosis during
regular diagnosis when the vehicle is driven over 15 km/h (10 mph).
Is there continuity?
YES - Repair short in the wires between the appropriate wheel speed sensor and the ABS modulator-control
unit.■
NO - Go to Step 9 .
9. Check for continuity between the appropriate ABS modulator-control unit 25P connector terminal and the wheel
speed sensor 2P connector terminal.
DTC ABS Modulator-control Unit 25P Appropriate Wheel Speed Sensor
Connector
11-13 No. 2 Right-front
13-13 No. 12 Left-front
15-13 No. 6 Right-rear
17-13 No. 14 Left-rear
Is there continuity?
YES - Go to Step 10 .
NO - Repair open in the wire between the appropriate wheel speed sensor and the ABS modulator-control
unit.■
10. Check for continuity between the appropriate ABS modulator-control unit 25P connector terminal and the wheel
speed sensor 2P connector terminal.
DTC ABS Modulator-control Unit 25P Appropriate Wheel Speed Sensor
Connector
11-13 No. 18 Right-front
13-13 No. 3 Left-front
15-13 No. 15 Right-rear
17-13 No. 5 Left-rear
Is there continuity?
YES - Go to Step 11 .
NO - Repair open in the wire between the appropriate wheel speed sensor and the ABS modulator-control
unit.■
11. Check for continuity between body ground and the appropriate ABS modulator-control unit 25P connector terminal
(see table).
DTC ABS Modulator-control Unit 25P Connector Terminal
11-13 No. 2 No. 18
13-13 No. 12 No. 3
15-13 No. 6 No. 15
17-13 No. 14 No. 5
Is there continuity?
YES - Repair short to body ground in the wire between the appropriate wheel speed sensor and the ABS
modulator-control unit.■
NO - Go to Step 12 .
12. Turn the ignition switch to ON (II).
13. Measure the voltage between body ground and the appropriate ABS modulator-control unit 25P connector terminal
(see table).
DTC ABS Modulator-control Unit 25P Connector Terminal
11-13 No. 2 No. 18
13-13 No. 12 No. 3
15-13 No. 6 No. 15
17-13 No. 14 No. 5
Is there continuity?
YES - Repair short in the wires between the appropriate wheel speed sensor and the ABS modulator-control
unit.■
NO - Check for loose terminals in the ABS modulator-control unit 25P connector. If necessary, substitute a
known-good ABS modulator-control unit, and retest.■
ABS DTC Troubleshooting: 12-21, 14-21, 16-21, 18-21
DTC 12-21:
Right-front Wheel Speed Sensor Installation Error
DTC 14-21:
Left-front Wheel Speed Sensor Installation Error
DTC 16-21:
Right-rear Wheel Speed Sensor Installation Error
DTC 18-21:
Left-rear Wheel Speed Sensor Installation Error
1. Test-drive the vehicle. Drive the vehicle at 10 km/h (7 mph) or more.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
2. Check the RF, LF, RR, LR WHEEL SPD in the ABS DATA LIST with the HDS.
Are all four values the same?
YES - Intermittent failure, the system is OK at this time. Check for loose terminals between the wheel speed
sensor 2P connector and the ABS modulator-control unit 25P connector. Refer to intermittent failures
troubleshooting. ■
NO - Go to Step 3 .
3. Turn the ignition switch to LOCK (0).
4. Check that the appropriate wheel speed sensor is properly mounted.
DTC Appropriate Wheel Speed Sensor
12-21 Right-front
14-21 Left-front
16-21 Right-rear
18-21 Left-rear
15. Measure the voltage between ABS modulator-control unit 25P connector terminal No. 9 and body ground.
Is there battery voltage?
YES - Check for loose terminals in the ABS modulator-control unit 25P connector. If necessary, substitute a
known-good ABS modulator-control unit, and retest.■
NO - Repair open in the wire between the No. 58 (30 A) fuse in the under-dash fuse/relay box and the ABS
modulator-control unit.■
ABS DTC Troubleshooting: 52-12
DTC 52-12:
Motor Stuck OFF
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0), then turn it to ON (II) again.
4. Operate any one of the four solenoids, as listed, in the ABS FUNCTION TEST five times with the HDS.
-LFT FT SOLENOID
-RT FT SOLENOID
-LFT REAR SOLENOID
-RT REAR SOLENOID
15. Measure the voltage between ABS modulator-control unit 25P connector terminal No. 8 and body ground.
Is there battery voltage?
YES - Check for loose terminals in the ABS modulator-control unit 25P connector. If necessary, substitute a
known-good ABS modulator-control unit, and retest.■
NO - Repair open in the wire between the No. 37 (30 A) fuse in the under-dash fuse/relay box and the ABS
modulator-control unit.■
ABS DTC Troubleshooting: 61-01, 61-21, 61-22, 61-23
DTC 61-01:
ABS Modulator-control Unit Initial IG Low Voltage
DTC 61-21:
ABS Modulator-control Unit Power Source Low Voltage 1
DTC 61-22:
ABS Modulator-control Unit Power Source Low Voltage 2
DTC 61-23:
ABS Modulator-control Unit Power Source Low Voltage 3
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0), then start the engine.
4. Check for DTCs with the HDS.
Is DTC 61-01, 61-21, 61-22, or 61-23 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose terminals at the ABS modulator-control
unit 25P connector. Refer to intermittent failures troubleshooting. ■
5. Check and note BATTERY voltage in the ABS DATA LIST with the HDS.
6. Using a voltmeter, measure and note the voltage between the battery terminals.
NOTE: If the voltage is below 9.5 V, check the battery, and troubleshoot the alternator regulator circuit.
7. Compare the voltage noted in Step 5 to the voltage in Step 6 .
Is the difference between the two voltage readings less then 3 V?
YES - Intermittent failure, the system is OK at this time. Check for loose terminals at the ABS modulator-control
unit 25P connector. Refer to intermittent failures troubleshooting. If the code resets after clearing, replace
the ABS modulator-control unit. ■
NO - Check for loose terminals in the ABS modulator-control unit 25P connector. If necessary, substitute a
known-good ABS modulator-control unit, and retest.■
ABS DTC Troubleshooting: 62-21
DTC 62-21:
ABS Modulator-control Unit IG High Voltage
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0), then start the engine.
4. Check for DTCs with the HDS.
Is DTC 62-21 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Check and note BATTERY voltage in the ABS DATA LIST with the HDS.
6. Using a voltmeter, measure and note the voltage between the battery terminals.
NOTE: If the voltage is beyond 15.1 V, troubleshoot the alternator regulator circuit.
7. Compare the voltage noted in Step 5 to the voltage in Step 6 .
Is the difference between the two voltage readings less than 3 V?
YES - Intermittent failure, the system is OK at this time. Check for loose terminals at the ABS modulator-control
unit 25P connector. Refer to intermittent failures troubleshooting. If the code resets after clearing, replace
the ABS modulator-control unit. ■
NO - Replace the ABS modulator-control unit, and retest.■
ABS DTC Troubleshooting: 71-21, 71-22, 71-23, 71-24, 71-25, 71-26
DTC 71-21:
Right-front or Left-rear Different Diameter Tyre Malfunction
DTC 71-22:
Left-front or Right-rear Different Diameter Tyre Malfunction
DTC 71-23:
Right-front and Right-rear Different Diameter Tyre Malfunction
DTC 71-24:
Left-front and Left-rear Different Diameter Tyre Malfunction
DTC 71-25:
Right-front and Left-front Different Diameter Tyre Malfunction
DTC 71-26:
Right-rear and Left-rear Different Diameter Tyre Malfunction
NOTE: The DTC will be indicated when the vehicle has a different diameter tyre(s) compared to the other tyre(s).
DTC Sectional Note
71-21 Right-front or left-rear
71-22 Left-front or right-rear
71-23 Right-front and right-rear
71-24 Left-front and left-rear
71-25 Right-front and left-front
71-26 Right-rear and left-rear
Is there continuity?
YES - Check for loose terminals in the ABS modulator-control unit 25P connector. If necessary, substitute a
known-good ABS modulator-control unit, and retest.■
NO - Repair open in the wire between the ECM/PCM and the ABS modulator-control unit.■
ABS DTC Troubleshooting: 86-24, 86-25
DTC 86-24:
F-CAN Communication with Engine Malfunction
DTC 86-25:
F-CAN Communication with Engine Malfunction
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Test-drive the vehicle. Drive the vehicle at 10 km/h (7 mph) or more.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
4. Check for DTCs with the HDS.
Is DTC 86-24 and/or 86-25 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose terminals between ECM/PCM
connector A (49P) and the ABS modulator-control unit 25P connector. Refer to intermittent failures
troubleshooting. ■
5. Turn the ignition switch to LOCK (0).
6. Short the SCS line with the HDS.
7. Disconnect ECM/PCM connector A (49P).
8. Disconnect the ABS modulator-control unit 25P connector.
9. Check for continuity between the ABS modulator-control unit 25P connector terminal and ECM/PCM connector A
(49P) terminal (see table).
Sign ABS Modulator-control Unit 25P ECM/PCM Connector A (49P)
Connector Terminal Terminal
CAN-L 17 4
CAN-H 1 3
Is there continuity?
YES - Go to Step 10 .
NO - Repair open in the wire between the ECM/PCM and the ABS modulator-control unit.■
10. Reconnect all connectors.
11. Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM.
12. Clear the DTC with the HDS.
13. Test-drive the vehicle. Drive the vehicle at 10 km/h (7 mph) or more.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
14. Check for DTCs with the HDS.
Is DTC 86-24 and/or 86-25 indicated?
YES - Replace the ABS modulator-control unit. ■
NO - If the ECM/PCM was updated, troubleshooting is complete. If the ECM/PCM was substituted, replace the
original ECM/PCM. ■
ABS DTC Troubleshooting: 86-FF
DTC 86-FF:
F-CAN Communication with ABS Malfunction
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0), then turn it to ON (II) again.
4. Check for DTCs with the HDS.
Is DTC 86-FF indicated?
YES - Replace the ABS modulator-control unit. ■
NO - Intermittent failure, the system is OK at this time.■
How to Troubleshoot the EPS
EPS Indicator
Under normal conditions, the EPS indicator (A) comes on when the ignition switch is turned to ON (II) position, then goes
off after the engine is started. This indicates that the LED and its circuit are operating correctly.
If there is a failure in the system after the engine is started, the EPS indicator will stay on, and the power assist is turned
off or restricted.
When the EPS indicator comes on, the control unit memorizes the DTC. In this case, the control unit will not activate the
EPS system after the engine starts again, but it keeps the EPS indicator on.
When DTC 51-01, 51-02, 51-03 or 51-05 is stored in the control unit, the EPS indicator will stay on until the DTC is
erased. When a problem is detected and the EPS indicator comes on, there are cases when the indicator stays on until
the ignition switch is turned to LOCK (0), and cases when the indicator goes off automatically when the system returns to
normal. Even though the system is operating normally, the EPS indicator will come on under the following conditions:
The vehicle speed is above 15 km/h (10 mph) for more than 3 seconds. When the vehicle speed decreases abruptly
(by applying the brakes) from above 20 km/h (12 mph) to less than 1 km/h (1 mph), and stay for 5 seconds, and
after abrupt deceleration, when the engine speed is above 1,840 rpm (min −1 ) (after the engine starts within 5
minutes: 4,000 rpm (min −1 )) for 5 seconds (continuously).
When the steering wheel is turned, and the engine speed is above 1,840 rpm (min −1 ) (after the engine starts within
5 minutes: 4,000 rpm (min −1 )) for 20 seconds, then the engine speed is above 2,500 rpm (min −1 ) for 10 seconds
continuously.
To determine the actual cause of the problem, question the customer about the conditions during which the problem
occurred, taking the above conditions into consideration.
Self-diagnosis
Self-diagnosis can be classified into two categories:
Initial diagnosis: Done right after the engine starts and until the EPS indicator goes off.
Regular diagnosis: Done right after the initial diagnosis until the ignition switch is turned to LOCK (0).
The EPS control unit performs the following functions when a problem is detected by self-diagnosis:
1. Turns on the EPS indicator.
2. Memorizes the DTC.
3. Stops or restricts the power assist and manual steering operation resumes.
NOTE: For DTCs 11-01, 11-02, 12-01, 21-01, 21-02, 22-01, 35-04, 36-02, 37-01, and 37-02 the EPS indicator will go
off automatically, and the system returns to normal.
20. Measure the voltage between EPS control unit connector C (16P) terminal No. 8 and body ground.
Is there battery voltage?
YES - Check for loose terminals in the EPS control unit connectors and repair if necessary. If no poor
connections are found, replace the EPS control unit. ■
NO - Repair open in the wire between the No. 11 (7.5 A) fuse in the under-dash fuse/relay box and the EPS
control unit.■
EPS DTC Troubleshooting: 12-01
DTC 12-01:
Low/High VBU Voltage (Regular Diagnosis)
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC 12-01 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals.■
6. Turn the ignition switch to LOCK (0).
7. Check and note BATTERY voltage in the EPS DATA LIST with the HDS.
Is the battery OK?
YES - Go to Step 8 .
NO - Check the battery, and troubleshoot the alternator regulator circuit. ■
8. Check the No. 2 (60 A) fuse in the battery terminal fuse box.
Is the fuse OK?
YES - Reinstall the No. 2 (60 A) fuse, then go to Step 17 .
NO - Go to Step 9 .
9. Disconnect the EPS control unit connector A (2P).
10. Check for continuity between EPS control unit connector A (2P) terminal No. 2 and body ground.
Is there continuity?
YES - Repair short to body ground in the wire between the EPS control unit and No. 2 (60 A) fuse in the battery
terminal fuse box.■
NO - Install a new No. 2 (60 A) fuse in the battery terminal fuse box, then go to Step 11 .
11. Reconnect the EPS control unit connector C (16P).
12. Turn the ignition switch to ON (II).
13. Clear the DTC with the HDS.
14. Turn the ignition switch to LOCK (0).
15. Start the engine.
16. Check for DTCs with the HDS.
Is DTC 12-01 indicated?
YES - Replace the EPS control unit. ■
NO - Troubleshooting is complete. If any other DTCs are indicated, go to the indicated DTC's troubleshooting.■
17. Disconnect the EPS control unit connector A (2P).
18. Turn the ignition switch to ON (II).
19. Measure the voltage between EPS control unit connector A (2P) terminal No. 2 and body ground.
Is there battery voltage?
YES - Check for loose terminals in the EPS control unit connectors and repair if necessary. If no poor
connections are found, replace the EPS control unit. ■
NO - Repair open in the wire between the No. 2 (60 A) fuse in the battery terminal fuse box and the EPS
control unit.■
EPS DTC Troubleshooting: 21-01, 21-02
DTC 21-01:
Excessive Change of the Vehicle Speed Signal (Regular Diagnosis)
DTC 21-02:
Comparison Between the Vehicle Speed and the Engine Speed Signal (Regular Diagnosis)
NOTE:
If the MIL stays on, or the D indicator blinks at the same time as DTC 21-01 or DTC 21-02 is indicated,
troubleshoot the PGM-FI system or A/T model: automatic transmission system, then recheck for DTC 21-01 or
DTC 21-02.
Even though the system is operating normally, the EPS indicator will come on caused by the detecting condition of
DTC 21-01 or DTC 21-02.
The ABS indicator may come on during this troubleshoot. If so, clear the DTC related to the ABS.
1. Turn the ignition switch to LOCK (0).
2. Raise the vehicle, and support it with safety stands in the proper locations, and allow all four wheels to rotate freely.
3. Connect the HDS to the data link connector (DLC).
4. Start the engine, then run the vehicle in the 4th gear (M/T), or D position (A/T).
5. Check the VEHICLE SPEED in the EPS DATA LIST with the HDS.
Is 0 km/h (0 mph) indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
ECM/PCM and the EPS control unit.■
6. Turn the ignition switch to LOCK (0).
7. Start the engine and check the tachometer.
Is the tachometer working correctly?
YES - Go to Step 8 .
NO - Troubleshoot the gauge control module. ■
8. Turn the ignition switch to LOCK (0).
9. Short the SCS line with the HDS.
10. Disconnect the ECM/PCM connector A (49P) and EPS control unit connector C (16P).
11. Check for continuity between EPS control unit connector C (16P) terminal and ECM/PCM connector A (49P)
terminal individually.
Sign EPS Control Unit Connector C (16P) ECM/PCM Connector A (49P)
Terminal Terminal
CAN-L 9 4
CAN-H 10 3
Is there continuity?
YES - Check for loose terminals in the EPS control unit connectors, and repair if necessary. If no poor
connections are found, replace the EPS control unit. ■
NO - Repair open in the wire between the EPS control unit and the ECM/PCM.■
EPS DTC Troubleshooting: 22-01
DTC 22-01:
Engine Speed Signal (Regular Diagnosis)
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Test-drive the vehicle. Drive the vehicle at 10 km/h (7 mph) for 3 seconds or more.
4. Check the ENGINE SPEED in the EPS DATA LIST with the HDS.
13. Measure the voltage between EPS control unit connector C (16P) terminal No. 7 and body ground.
Is there any voltage?
YES - Repair short to power in the wire between the EPS control unit and ECM/PCM.■
NO - Check for loose terminal in the EPS control unit connectors, and repair if necessary. If no poor
connections are found, replace the EPS control unit. ■
14. Turn the ignition switch to LOCK (0).
15. Short the SCS line with the HDS.
16. Disconnect the ECM/PCM connector A (49P).
17. Check for continuity between EPS control unit connector C (16P) terminal No. 7 and body ground.
Is there continuity?
YES - Repair short to body ground in the wire between the EPS control unit and the ECM/PCM.■
NO - Go to Step 18 .
18. Check for continuity between EPS control unit connector C (16P) terminal No. 7 and ECM/PCM connector A (49P)
terminal No. 29.
Is there continuity?
YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
go to Step 1 and recheck. If the ECM/PCM was updated and DTCs are not indicated, troubleshooting is
complete. If the ECM/PCM was substituted and DTCs are not indicated, replace the original ECM/PCM.
■
NO - Repair open in the wire between the EPS control unit and the ECM/PCM.■
EPS DTC Troubleshooting: 31-01
DTC 31-01:
No Writing the Torque Sensor Neutral Position (Regular Diagnosis)
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Do the memorizing of the torque sensor neutral position.
5. Turn the ignition switch to ON (II).
6. Check for DTCs with the HDS.
Is DTC 31-01 indicated?
YES - Replace the EPS control unit. ■
NO - Intermittent failure, the system is OK at this time.■
EPS DTC Troubleshooting: 32-01, 32-02, 32-03, 32-04, 32-05, 32-06, 34-01, 35-01, 35-02, 35-03, 35-04, 36-01, 36-02, 37-
01, 37-02
DTC 32-01:
EPS Control Unit Internal Circuit (Current Sensor) (Regular Diagnosis)
DTC 32-02:
EPS Control Unit Internal Circuit Offset (Current Sensor) (Regular Diagnosis)
DTC 32-03:
Lower Current Sensor Stuck ON (Initial Diagnosis)
DTC 32-04:
Lower Current Sensor Stuck ON (Regular Diagnosis)
DTC 32-05:
Motor Power Supply Voltage (Regular Diagnosis)
DTC 32-06:
EPS Control Unit Internal Circuit (Sub-CPU) (Regular Diagnosis)
DTC 34-01:
Power Relay Stuck ON (IG Switch is in LOCK (0))
DTC 35-01:
EPS Control Unit Internal Circuit (CPU) (Initial Diagnosis/Regular Diagnosis)
DTC 35-02:
EPS Control Unit Internal Circuit (EEPROM) (Initial Diagnosis)
DTC 35-03:
EPS Control Unit Internal Circuit (CPU Communication) (Initial Diagnosis)
DTC 35-04:
EPS Control Unit Internal Circuit (CPU Communication) (Regular Diagnosis)
DTC 36-01:
EPS Control Unit Internal Circuit (Direction Distinction) (Initial Diagnosis)
DTC 36-02:
EPS Control Unit Internal Circuit (INH Output Circuit) (Initial Diagnosis)
DTC 37-01:
EPS Control Unit Internal Circuit (Step-Up Circuit) (Initial Diagnosis)
DTC 37-02:
EPS Control Unit Internal Circuit (Step-Up Circuit) (Regular Diagnosis)
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch LOCK (0).
4. Start the engine.
5. Turn the steering wheel from lock to lock several times, and hold the steering wheel for 10 seconds or more.
6. Check for DTCs with the HDS.
Is DTC 32-01, 32-02, 32-03, 32-04, 32-05, 32-06, 34-01, 35-01, 35-02, 35-03, 35-04, 36-01, 36-02, 37-01, or 37-02
indicated?
YES - Replace the EPS control unit. ■
NO - Intermittent failure, the system is OK at this time.■
EPS DTC Troubleshooting: 33-01
DTC 33-01:
Lower FET Stuck ON (Initial Diagnosis)
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Start the engine.
5. Turn the steering wheel from lock to lock several times, and hold the steering wheel for 10 seconds or more.
6. Check for DTCs with the HDS.
Is DTC 33-01 indicated?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time.■
7. Turn the ignition switch to LOCK (0).
8. Disconnect the EPS control unit connector B (2P).
9. Check for continuity between body ground and EPS control unit connector B (2P) No. 1 terminal, and No. 2
terminal.
Is there continuity?
YES - Go to Step 10 .
NO - Check for loose terminal in the EPS control unit connectors, and repair if necessary. If no poor
connections are found, replace the EPS control unit. ■
10. Disconnect the EPS motor 2P connector.
11. On the EPS motor side, check for continuity between body ground and EPS motor 2P connector No. 1 terminal,
and No. 2 terminal.
Is there continuity?
YES - Replace the EPS motor. ■
NO - Repair short to body ground in the wire between the EPS control unit and EPS motor.■
EPS DTC Troubleshooting: 33-02, 34-02
DTC 33-02:
Upper FET Stuck ON (Initial Diagnosis)
DTC 33-07:
Fail-safe Relay Stuck ON (Initial Diagnosis)
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Start the engine.
5. Turn the steering wheel from lock to lock several times, and hold the steering wheel for 10 seconds or more.
6. Check for DTCs with the HDS.
Is DTC 33-02 or 34-02 indicated?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time.■
7. Turn the ignition switch to LOCK (0).
8. Disconnect the EPS control unit connector B (2P).
9. Turn the ignition switch to ON (II).
10. Measure the voltage between body ground and EPS control unit connector B (2P) No. 1 terminal, and No. 2
terminal.
Is there battery voltage?
YES - Repair short to power in the wire between the EPS control unit and the EPS motor.■
NO - Check for loose terminal in the EPS control unit connectors, and repair if necessary. If no poor
connections are found, replace the EPS control unit. ■
EPS DTC Troubleshooting: 33-03, 33-04, 33-05
DTC 33-03:
FET Stuck ON (Overcurrent) (Regular Diagnosis)
DTC 33-04:
FET Stuck ON (Failure) (Regular Diagnosis)
DTC 33-05:
FET Stuck ON (Overcurrent Addition) (Regular Diagnosis)
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Start the engine.
5. Turn the steering wheel from lock to lock several times, and hold the steering wheel for 10 seconds or more.
6. Check for DTCs with the HDS.
Is DTC 33-03, 33-04, or 33-05 indicated?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time.■
7. Turn the ignition switch to LOCK (0).
8. Disconnect the EPS control unit connector B (2P).
9. Check for continuity between body ground and EPS control unit connector B (2P) No. 1 terminal, and No. 2
terminal.
Is there continuity?
YES - Go to Step 10 .
NO - Go to Step 12 .
10. Disconnect the EPS motor 2P connector.
11. On the EPS motor side, check for continuity between body ground and EPS motor 2P connector No. 1 terminal,
and No. 2 terminal.
Is there continuity?
YES - Replace the EPS motor. ■
NO - Repair short to body ground in the wire between the EPS control unit and EPS motor.■
12. Disconnect the EPS motor 2P connector.
13. Turn the ignition switch to ON (II).
14. Measure the voltage between body ground and EPS control unit connector B (2P) No. 1 terminal, and No. 2
terminal.
Is there battery voltage?
YES - Repair short to power in the wire between the EPS control unit and the EPS motor.■
NO - Check for loose terminal in the EPS control unit connectors, and repair if necessary. If no poor
connections are found, replace the EPS control unit. ■
EPS DTC Troubleshooting: 51-01, 51-02, 51-03, 51-04, 51-05
DTC 51-01:
Torque Sensor (VT1 and VT2) (Regular Diagnosis)
DTC 51-02:
Torque Sensor VT3 Differential-amplification Function (Regular Diagnosis)
DTC 51-03:
Torque Sensor (VT1, VT2 Rapid-change) (Regular Diagnosis)
DTC 51-04:
Torque Sensor (Temperature) (Regular Diagnosis)
DTC 51-05:
Torque Sensor (Coil) (Regular Diagnosis)
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Start the engine.
5. Turn the steering wheel from lock to lock several times, and hold the steering wheel for 10 seconds or more.
6. Check for DTCs with the HDS.
Is DTC 51-01, 51-02, 51-03, 51-04, or 51-05 indicated?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
EPS motor and the EPS control unit.■
7. Turn the ignition switch to LOCK (0).
8. Disconnect the EPS control unit connector C (16P).
9. Measure the resistance between EPS control unit connector C (16P) terminals No. 2 and No. 3.
Is there resistance 10 Ω or less at 20 °C (68 °F)?
YES - Go to Step 10 .
NO - Go to Step 12 .
10. Disconnect the torque sensor 3P connector.
11. On the torque sensor side, measure the resistance between torque sensor 3P connector terminals No. 1 and No.
2.
Is there resistance 10 Ω or less at 20 °C (68 °F)?
YES - Replace the steering gearbox. ■
NO - Repair short in the wires between the EPS control unit and torque sensor.■
12. Measure the resistance between EPS control unit connector C (16P) terminals No. 1 and No. 2.
Is there resistance 10 Ω or less at 20 °C (68 °F)?
YES - Go to Step 13 .
NO - Go to Step 15 .
13. Disconnect the torque sensor 3P connector.
14. On the torque sensor side, measure the resistance between torque sensor 3P connector terminals No. 2 and No.
3.
Is there resistance 10 Ω or less at 20 °C (68 °F)?
YES - Replace the steering gearbox. ■
NO - Repair short in the wires between the EPS control unit and torque sensor.■
15. Measure the resistance between EPS control unit connector C (16P) terminals No. 1 and No. 3.
Is there resistance 10 Ω or less at 20 °C (68 °F)?
YES - Go to Step 16 .
NO - Go to Step 18 .
16. Disconnect the torque sensor 3P connector.
17. On the torque sensor side, measure the resistance between torque sensor 3P connector terminals No. 1 and No.
3.
Is there resistance 10 Ω or less at 20 °C (68 °F)?
YES - Replace the steering gearbox. ■
NO - Repair short in the wires between the EPS control unit and torque sensor.■
18. Check for continuity between body ground and EPS control unit connector C (16P) No. 1 terminal, and No. 3
terminal.
Is there continuity?
YES - Go to Step 17 .
NO - Go to Step 19 .
19. Disconnect the torque sensor 3P connector.
20. On the torque sensor side, check for continuity between body ground and torque sensor 3P connector No. 1
terminal, and No. 3 terminal.
Is there continuity?
YES - Replace the steering gearbox. ■
NO - Repair short to body ground in the wire between the EPS control unit and torque sensor.■
21. Disconnect the torque sensor 3P connector.
22. Check for continuity between EPS control unit connector C (16P) terminal and the torque sensor 3P connector
terminal individually.
Sign Torque Sensor 3P Connector EPS Control Unit Connector C
(16P) Terminal
VS1 1 3
T/S GND 2 2
VS2 3 1
Is there continuity?
YES - Go to Step 21 .
NO - Repair open in the wire between the EPS control unit and torque sensor.■
23. On the torque sensor side, measure the resistance between torque sensor 3P connector terminals No. 1 and No.
2, and No. 2 and No. 3 individually.
Is there resistance 10−40 Ω at 20 °C (68 °F)?
YES - Check for loose terminals in the EPS control unit connectors and repair if necessary. If no poor
connections are found, replace the EPS control unit. ■
NO - Replace the steering gearbox. ■
EPS DTC Troubleshooting: 61-01, 61-02
DTC 61-01:
EPS Motor Voltage (Initial Diagnosis)
DTC 61-02:
EPS Motor Voltage (Regular Diagnosis)
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Start the engine.
5. Turn the steering wheel from lock to lock several times, and hold the steering wheel for 10 seconds or more.
6. Check for DTCs with the HDS.
Is DTC 61-01 or 61-02 indicated?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
EPS motor and the EPS control unit.■
7. Turn the ignition switch to LOCK (0).
8. Disconnect the EPS control unit connector B (2P).
9. Check for continuity between torque sensor 3P connector terminals No. 1 and No. 2.
Is there continuity?
YES - Go to Step 10 .
NO - Go to Step 12 .
10. Disconnect the EPS motor 2P connector.
11. On the EPS motor side, check for continuity between EPS motor 2P connector terminals No. 1 and No. 2.
Is there continuity?
YES - Repair open in the wire between the EPS control unit and EPS motor.■
NO - Replace the EPS motor. ■
12. Disconnect the EPS motor 2P connector.
13. Check for continuity between body ground and EPS control unit connector B (2P) No. 1 terminal, and No. 2
terminal.
Is there continuity?
YES - Repair short to body ground in the wire between the EPS control unit and EPS motor.■
NO - Check for loose terminals in the EPS control unit connectors and repair if necessary. If no poor
connections are found, replace the EPS control unit. ■
EPS DTC Troubleshooting: 61-03
DTC 61-03:
Open the EPS Motor Harness (Regular Diagnosis)
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Start the engine.
5. Turn the steering wheel from lock to lock several times, and hold the steering wheel for 10 seconds or more.
6. Check for DTCs with the HDS.
Is DTC 61-03 indicated?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
EPS motor and the EPS control unit.■
7. Turn the ignition switch to LOCK (0).
8. Disconnect the EPS control unit connector B (2P) and the EPS motor 2P connector.
9. Check for continuity between EPS control unit connector B (2P) terminal No. 2 and EPS motor 2P connector
terminal No. 1.
Is there continuity?
YES - Go to Step 10 .
NO - Repair open in the wire between the EPS control unit and EPS motor.■
10. Check for continuity between EPS control unit connector B (2P) terminal No. 1 and EPS motor 2P connector
terminal No. 2.
Is there continuity?
YES - Go to Step 11 .
NO - Repair open in the wire between the EPS control unit and EPS motor.■
11. On the EPS motor side, check for continuity between EPS motor 2P connector terminals No. 1 and No. 2.
Is there continuity?
YES - Check for loose terminals in the EPS control unit connectors and repair if necessary. If no poor
connections are found, replace the EPS control unit. ■
NO - Replace the EPS motor. ■
DTC Troubleshooting: B1152
DTC B1152:
Gauge Control Module Internal Error (EEPROM error)
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 6 seconds or more.
4. Check for DTCs with the HDS.
Is DTC B1152 indicated?
YES - Replace the gauge control module. ■
NO - Intermittent failure, the gauge control module is OK at this time.■
DTC Troubleshooting: B1155
DTC B1155:
Gauge Control Module Lost Communication with the MICU (Headlight Switch Message)
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 6 seconds or more.
4. Check for DTCs with the HDS.
Is DTC B1155 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the gauge control module is OK at this time. Check for loose or poor connections
between the gauge control module and the MICU.■
5. Check for DTCs with the HDS.
Are DTCs B1155 and B1905 indicated?
YES - Faulty MICU; replace the under-dash fuse/relay box. ■
NO - Replace the gauge control module. ■
DTC Troubleshooting: B1156
DTC B1156:
Gauge Control Module Lost Communication with the MICU (Wiper Switch Message)
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 6 seconds or more.
4. Check for DTCs with the HDS.
Is DTC B1156 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the gauge control module is OK at this time. Check for loose or poor connections
between the gauge control module and the MICU.■
5. Check for DTCs with the HDS.
Are DTCs B1156 and B1905 indicated?
YES - Faulty MICU; replace the under-dash fuse/relay box. ■
NO - Replace the gauge control module. ■
DTC Troubleshooting: B1157
DTC B1157:
Gauge Control Module Lost Communication with the MICU (MICU Message)
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 6 seconds or more.
4. Check for DTCs with the HDS.
Is DTC B1157 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the gauge control module is OK at this time. Check for loose or poor connections
between the gauge control module and the MICU.■
5. Check for DTCs with the HDS.
Are DTCs B1157 and B1905 indicated?
YES - Faulty MICU; replace the under-dash fuse/relay box. ■
NO - Replace the gauge control module. ■
DTC Troubleshooting: B1159
DTC B1159:
Gauge Control Module Lost Communication with the MICU (Door Switch Message)
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 6 seconds or more.
4. Check for DTCs with the HDS.
Is DTC B1159 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the gauge control module is OK at this time. Check for loose or poor connections
between the gauge control module and the MICU.■
5. Check for DTCs with the HDS.
Are DTCs B1159 and B1905 indicated?
YES - Faulty MICU; replace the under-dash fuse/relay box. ■
NO - Replace the gauge control module. ■
DTC Troubleshooting: B1160
DTC B1160:
Gauge Control Module Lost Communication with the MICU (Door Lock Switch)
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 6 seconds or more.
4. Check for DTCs with the HDS.
Is DTC B1160 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the gauge control module is OK at this time. Check for loose or poor connections
between the gauge control module and the MICU.■
5. Check for DTCs with the HDS.
Are DTCs B1160 and B1905 indicated?
YES - Faulty MICU; replace the under-dash fuse/relay box. ■
NO - Replace the gauge control module. ■
DTC Troubleshooting: B1168
DTC B1168:
Gauge Control Module Lost Communication with ECM/PCM (Engine Messages)
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 6 seconds or more.
4. Check for DTCs with the HDS.
Is DTC B1168 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections.■
5. Check for Fuel and Emission system DTCs with the HDS.
Is any DTCs indicated?
YES - Go to the indicated DTCs, then recheck.
NO - Go to Step 6 .
6. Turn the ignition switch to LOCK (0).
7. Disconnect the gauge control module 32P connector.
8. Jump the SCS with the HDS.
9. Disconnect the ECM/PCM connector A (49P).
10. Connect the gauge control module 32P connector No. 29 and No. 30 terminals and body ground with jumper wires.
11. Check for continuity between ECM/PCM connector A (49P) No. 3 and No. 4 terminals and body ground individually.
Is there continuity?
YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, and
recheck. If the indication goes away, replace the original ECM/PCM. If the DTC is still present, replace
the gauge control module. ■
NO - Repair an open in the wire.■
DTC Troubleshooting: B1169
DTC B1169:
Gauge Control Module Lost Communication with the PCM (A/T Message)
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 6 seconds or more.
4. Check for DTCs with the HDS.
Is DTC B1169 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections.■
5. Check for Fuel and Emission system DTCs with the HDS.
Is any DTCs indicated?
YES - Go to the indicated DTCs, then recheck.
NO - Go to Step 6 .
6. Turn the ignition switch to LOCK (0).
7. Disconnect the gauge control module 32P connector.
8. Jump the SCS with the HDS.
9. Disconnect PCM connector A (49P).
10. Connect the gauge control module 32P connector No. 29 and No. 30 terminals and body ground with jumper wires.
11. Check for continuity between PCM connector A (49P) No. 3 and No. 4 terminals and body ground individually.
Is there continuity?
YES - Update the PCM if it does not have the latest software, or substitute a known-good PCM, and recheck. If
the indication goes away, replace the original PCM. If the DTC is still present, replace the gauge control
module. ■
NO - Repair an open in the wire.■
DTC Troubleshooting: B1175
DTC B1175:
Fuel Level Sensor (Fuel Gauge Sending Unit) Circuit Malfunction
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 30 seconds.
4. Check for DTCs with the HDS.
Is DTC B1175 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the fuel level sensor circuit is OK at this time. Check for loose or poor connections.■
5. Turn the ignition switch to LOCK (0).
6. Disconnect the fuel tank unit 4P connector and the gauge control module 32P connector.
7. Connect the fuel tank unit 4P connector No. 1 and No. 3 terminals and body ground with jumper wires.
8. Check for continuity between gauge control module 32P connector No. 27 and No. 28 terminals and body ground
individually.
Is there continuity?
YES - Go to Step 9 .
NO - Repair an open in the wire between the gauge control module and the fuel tank unit.■
9. Do the fuel gauge sending unit test.
Is the fuel gauge sending unit OK?
YES - Replace the gauge control module. ■
NO - Replace the fuel tank unit.■
DTC Troubleshooting: B1176
DTC B1176:
Fuel Level Sensor (Fuel Gauge Sending Unit) Circuit
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 30 seconds.
4. Check for DTCs with the HDS.
Is DTC B1176 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the fuel level sensor circuit is OK at this time.■
5. Turn the ignition switch to LOCK (0).
6. Disconnect the fuel tank unit 4P connector.
7. Clear the DTCs with the HDS.
8. Turn the ignition switch to LOCK (0), and then back to ON (II).
9. Wait for 30 seconds.
10. Check for DTCs with the HDS.
Is DTC B1176 indicated?
YES - Go to Step 11 .
NO - Replace the fuel gauge sending unit. ■
11. Disconnect the gauge control module 32P connector.
12. Check for continuity between the gauge control module 32P connector No. 27 terminal and body ground.
Is there continuity?
YES - Repair a short to ground in the wire between the gauge control module and the fuel tank unit.■
NO - Replace the gauge control module. ■
DTC Troubleshooting: B1178
DTC B1178:
F-CAN Communication Circuit Error
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Check for DTCs with the HDS.
Are DTCs B1168, B1169, B1170, B1178, B1183 and/or B1187 indicated?
YES - Go to the indicated DTCs troubleshooting.■
NO - Intermittent failure, the F-CAN communication line is OK at this time. Check for worn or shorted wires.■
DTC Troubleshooting: B1183
DTC B1183:
Gauge Control Module Lost Communication with EPS Control Unit (EPS Message)
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 6 seconds or more.
4. Check for DTCs with the HDS.
Is DTC B1183 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections.■
5. Check for EPS system DTCs with the HDS.
Are any DTCs indicated?
YES - Go to the indicated DTCs, then recheck.
NO - Go to Step 6 .
6. Turn the ignition switch to LOCK (0).
7. Disconnect the gauge control module 32P connector.
8. Disconnect EPS control unit connector C (16P).
9. Check for continuity between the gauge control module 32P connector No. 29 and No. 30 terminals and EPS
control unit connector C (16P) No. 9 and No. 10 terminals and body ground individually.
Is there continuity?
YES - Substitute a known-good EPS control unit, and recheck. If the indication goes away, replace the original
EPS control unit. If the DTC is still present, replace the gauge control module. ■
NO - Repair an open in the wire.■
DTC Troubleshooting: B1187
DTC B1187:
Gauge Control Module Lost Communication with SRS Unit (SRS Message)
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 6 seconds or more.
4. Check for DTCs with the HDS.
Is DTC B1187 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections.■
5. Check for SRS DTCs with the HDS.
Are any DTCs indicated?
YES - Go to the indicated DTCs troubleshooting, then recheck.■
NO - Go to Step 6 .
6. Turn the ignition switch to LOCK (0).
7. Disconnect the gauge control module 32P connector.
8. Disconnect SRS unit connector A (39P).
9. Check for continuity between the gauge control module 32P connector No. 29 and No. 30 terminals and SRS unit
connector A (39P) No. 17 and No. 16 terminals individually.
Is there continuity?
YES - Substitute a known-good SRS unit, and recheck. If the indication goes away, replace the original SRS
unit. If the DTC is still present, replace the gauge control module. ■
NO - Repair an open in the wire.■
DTC Troubleshooting: B1188
DTC B1188:
Gauge Control Module Lost Communication with MICU (RM Message)
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 6 seconds or more.
4. Check for DTCs with the HDS.
Is DTC B1188 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections between the
gauge control module and the MICU.■
5. Check for DTCs with the HDS.
Are DTCs B1188 and B1905 indicated?
YES - Faulty MICU, replace the under-dash fuse/relay box. ■
NO - Replace the gauge control module. ■
DTC Troubleshooting: B1905
DTC B1905:
Immobilizer-Keyless Control Unit Lost Communication with MICU (DRLOCKSW Message)
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 6 seconds or more.
4. Check for DTCs witch the HDS.
Is DTC B1905 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the immobilizer-keyless control unit is OK at this time. Check for loose or poor
connections between the immobilizer-keyless control unit and the MICU.■
5. Check for DTCs with the HDS.
Are DTCs B1155, B1156, B1157, B1159, B1160, and B1188 all indicated with DTC B1905 at the same time?
YES - Faulty MICU; replace the under-dash fuse/relay box. ■
NO - Replace the immobilizer-keyless control unit .■
DTC Troubleshooting: B1906
DTC B1906:
Immobilizer-Keyless Control Unit Lost Communication with Gauge Control Module (A/T Message)
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 6 seconds or more.
4. Check for DTCs with the HDS.
Is DTC B1906 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections between the
gauge control module and the immobilizer-keyless control unit.■
5. Turn the ignition switch to LOCK (0).
6. Connect the HDS to the data link connector, then turn the ignition switch to ON (II).
7. Select the BODY ELECTRICAL menu, then enter the UNIT INFORMATION.
8. Check the condition of the gauge control module from the CONNECTED UNIT list.
Is NOT AVAILABLE indicated?
YES - Go to Step 9 .
NO - Go to Step 10 .
9. Do the gauge control module input test.
Are all inputs OK?
YES - Replace the gauge control module.
NO - Repair the faulty input, then recheck the DTCs.■
10. Turn the ignition switch to LOCK (0).
11. Disconnect the gauge control module 32P connector.
12. Turn the ignition switch to ON (II).
13. Measure the voltage between the gauge control module 32P connector No. 16 and No. 32 terminals and body
ground.
Is there battery voltage?
YES - Go to Step 14 .
NO - Check the No. 1 (10 A) and the No. 20 (15 A) fuses in the under-dash fuse/relay box. If the fuse is blown,
replace the fuse and recheck the DTCs. If the fuses are OK, repair an open in the wire between the under-
dash fuse/relay box and the gauge control module.■
14. Turn the ignition switch to LOCK (0).
15. Check for continuity between the gauge control module 32P connector No. 13 and No. 17 terminals and body
ground.
Is there continuity?
YES - Go to Step 16 .
NO - Repair an open in the wire or poor ground (G501).■
16. Disconnect under-dash fuse/relay box connector Q (16P).
17. Check for continuity between under-dash fuse/relay box connector Q (16P) No. 3 terminal and the gauge control
module 32P connector No. 18 terminal.
Is there continuity?
YES - Replace the gauge control module. ■
NO - Repair an open in the wire.■
DTC Troubleshooting: B1002
DTC B1002:
MICU Internal Error (EEPROM Error)
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 6 seconds or more.
4. Check for DTCs with the HDS.
Is DTC B1002 indicated?
YES - Faulty MICU; replace the under-dash fuse/relay box.■
NO - Intermittent failure, the MICU is OK at this time. Check for loose or poor connections. If the connections
are good, check the battery condition and the charging system.■
DTC Troubleshooting: B1011
DTC B1011:
MICU Lost Communication with Gauge Control Module (VSP/NE Message)
NOTE: Before troubleshooting, check the No. 1 (10 A) fuse in the under-dash fuse/relay box and No. 22 (7.5 A) fuse in the
under-dash fuse/relay box.
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 6 seconds or more.
4. Check for DTCs with the HDS.
Is DTCs B1011 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the gauge control module is OK at this time. Check for loose or poor connections
between the gauge control module and under-dash fuse/relay box connector Q (16P). If the connections
are good, check the battery condition and the charging system.■
5. Check for DTCs with the HDS.
Are DTCs B1000 and B1011 all indicated?
YES - Go to DTC troubleshooting B1000.
NO - Go to Step 6 .
6. Select the BODY ELECTRICAL system select menu, then enter the UNIT INFORMATION menu.
7. Check the condition of the gauge control module from the CONNECTED UNIT.
Is NOT AVAILABLE indicated?
YES - Go to Step 8 .
NO - Replace the gauge control module. ■
8. Turn the ignition switch to LOCK (0).
9. Disconnect the gauge control module 32P connector.
10. Turn the ignition switch to ON (II).
11. Measure the voltage between the gauge control module 32P connector No. 16 and No. 32 terminals and body
ground individually.
Is there battery voltage?
YES - Go to Step 12 .
NO - Repair an open in the wire.■
12. Turn the ignition switch to LOCK (0).
13. Check for continuity between the gauge control module 32P connector No. 13 and No. 17 terminals and body
ground individually.
Is there battery voltage?
YES - Go to Step 14 .
NO - Repair an open in the wire poor ground (G501).■
14. Disconnect under-dash fuse/relay box connector Q (16P).
15. Disconnect the gauge control module 32P connector.
16. Check for continuity between under-dash fuse/relay box connector Q (16P) No. 3 terminal and gauge control
module 32P connector No. 18 terminal.
Is there continuity?
YES - Replace the gauge control module. ■
NO - An open in the wire between the MICU and the gauge control module.■
DTC Troubleshooting: B1028
DTC B1028:
Rear Wiper Auto Stop Switch Malfunction
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0) and then back to ON (II).
3. Operate the rear window wiper for 15 seconds or more, then turn the rear window wiper switch OFF.
4. Check for DTCs with the HDS.
Is DTC B1028 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections.■
5. Check the No. 16 (10 A) fuse in the under-dash fuse/relay box.
Is the fuse OK?
YES - Go to Step 6 .
NO - Replace the fuse and recheck the system.■
6. Disconnect the rear window wiper motor 4P connector.
7. Turn the ignition switch to ON (II).
8. Measure the voltage between the rear window wiper motor 4P connector No. 1 terminal and body ground.
Is there battery voltage?
YES - Go to Step 9 .
NO - Repair an open in the wire between the under-dash fuse/relay box and rear window wiper motor.■
9. Check for continuity between the rear window wiper motor 4P connector No. 4 terminal and body ground.
Is there continuity?
YES - Go to Step 10 .
NO - Repair an open in the wire between the No. 4 terminal of the rear window wiper motor 4P connector and
body ground (G602) [G604].■
[ ]: LHD model
10. Do the rear window wiper motor test.
Is the rear window wiper motor OK?
YES - Go to Step 11 .
NO - Replace the rear window wiper motor.■
11. Disconnect under-dash fuse/relay box connector C.
12. Measure the voltage between the rear window wiper motor 4P connector No. 3 terminal and body ground.
Is there battery voltage?
YES - Repair a short to power in the wire between the rear window wiper motor and under-dash fuse/relay box.■
NO - Go to Step 13 .
13. Check for continuity between the rear window wiper motor 4P connector No. 3 terminal and body ground.
Is there continuity?
YES - Repair a short to ground in the wire between the rear window wiper motor and under-dash fuse/relay box.■
NO - Go to Step 14 .
14. Check for continuity between under-dash fuse/relay box connector C (49P) No. 29 terminal and the rear window
wiper rear window wiper motor 4P connector No. 3 terminal.
NOTE: The illustration shows the RHD model and the black portion shows the lock lever. The lock lever for LHD
model is shown as the dashed lines.
Is there continuity?
YES - Faulty MICU, replace the under-dash fuse/relay box. ■
NO - Repair an open in the wire between the rear window wiper motor and under-dash fuse/relay box.■
DTC Troubleshooting: B1036
DTC B1036:
IG1 Power Supply Circuit Malfunction
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Wait for 6 seconds or more.
4. Check for DTCs with the HDS.
Is DTC B1036 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connection at the gauge
control module 32P connector, and at under-dash fuse/relay box connector Q (16P). If the connections
are good, check the battery condition and the charging system.■
5. Measure the voltage between the gauge control module 32P connector No. 32 terminal and body ground.
Is there battery voltage?
YES - Faulty MICU or an open in the under-dash fuse/relay box internal circuit. Substitute a known-good under-
dash fuse/relay box and recheck.■
NO - Check for No. 22 (7.5 A) in the under-dash fuse/relay box. If the fuse is OK, check for an open in the wire
between the under-dash fuse/relay box and the gauge control module, or repair a short in the wire
between the under-dash fuse/relay box and the gauge control module.■
DTC Troubleshooting: B1077
DTC B1077: RHD model
Windshield Wiper (As) Signal Error
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0) and then back to ON (II).
3. Turn the windshield wiper switch to LOW or HIGH for 15 seconds or more, then turn the switch OFF.
Does the wiper motor work? LHD model
YES - Go to Step 4 .
NO - Go to Step 13 .
4. Check for DTCs with the HDS.
Is DTC B1077 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the windshield wiper system is OK at this time. Check for loose or poor connections.■
5. Turn the ignition switch to LOCK (0).
6. Do the wiper motor test.
Does the wiper motor run and does it pulse normally?
YES - Go to Step 7 .
NO - Replace the windshield wiper motor and recheck.■
7. Disconnect the windshield wiper motor 5P connector.
8. Disconnect the under-dash fuse/relay box connector A (36P) [B (36P)].
[ ]: LHD model
9. Check for continuity between the windshield wiper motor 5P connector No. 3 [No. 1] terminal and under-dash
fuse/relay box connector A (36P) No. 19 terminal or under-dash fuse/relay box connector B (36P) No. 20 terminal.
[ ]: LHD model
Is there continuity?
YES - Go to Step 10 .
NO - Repair an open in the PNK wire.■
10. Check for continuity between the windshield wiper motor 5P connector No. 3 [No. 1] terminal and body ground. RHD model
[ ]: LHD model
Is there continuity?
YES - Repair a short to ground in the PNK wire.■
NO - Go to Step 11 .
11. Turn the ignition switch to ON (II).
LHD model
12. Measure the voltage between the windshield wiper motor 5P connector No. 3 [No. 1] terminal and body ground. RHD model
[ ]: LHD model
Is there voltage?
YES - Repair a short to ground in the PNK wire.■
NO - Faulty MICU; replace the under-dash fuse/relay box.■
13. Turn the ignition switch to LOCK (0).
LHD model
14. Check the No. 56 (30 A) fuse in the under-dash fuse/relay box.
Is the fuse OK?
YES - Go to Step 15 .
NO - Replace the fuse and recheck the system.■
15. Do the wiper motor test.
Does the wiper motor run normally?
YES - Go to Step 16 .
NO - Replace the windshield wiper motor and recheck.■
16. Disconnect under-dash fuse/relay box connector A (36P) and the windshield wiper motor 5P connector.
17. Check for continuity between under-dash fuse/relay box connector A (36P) terminals and the windshield wiper RHD model
motor 5P connector terminals as shown:
Under-dash fuse/relay box connector A Windshield wiper motor 5P connector
(36P)
7 1 [5]
14 4 [3]
Is there continuity?
YES - Go to Step 18 .
NO - Repair an open in the BLU (LOW) or GRN (HIGH) wire.■
18. Check for continuity between the windshield wiper motor 5P connector No. 5 [No. 4] terminal and body ground. RHD model
[ ]: LHD model
Is there continuity?
YES - Faulty MICU; replace the under-dash fuse/relay box. ■
NO - Repair an open in the BLK wire or poor ground (G202).■
LHD model
DTC Troubleshooting: B1127
DTC B1127:
Driver's Door Key Cylinder Switch Input Circuit Malfunction (Simultaneous input of lock and unlock signal)
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Insert the ignition key into the driver's door key cylinder switch, and turn the key to the LOCK and UNLOCK
positions 10 times.
4. Check for DTCs with the HDS.
Is DTC B1127 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the driver's door key cylinder switch system is OK at this time. Check for loose or
poor connections.■
5. With the driver's door key cylinder in the neutral position, select KEYLESS with the HDS, and enter the DATA
LIST.
6. Check the ON/OFF information of the DRIVER'S DOOR KEY CYLINDER SWITCH (LOCK) and DRIVER'S DOOR
KEY CYLINDER SWITCH (UNLOCK) in the DATA LIST.
Are both information indicators OFF?
YES - Check the wires for continuity between the under-dash fuse/relay box and driver's door key cylinder
switch. If there is continuity, the MICU is faulty. Replace the under-dash fuse/relay box. ■
NO - Go to Step 7 .
7. Disconnect the driver's door lock actuator 10P connector.
8. Check the ON/OFF information of the DRIVER'S DOOR KEY CYLINDER SWITCH (LOCK) and DRIVER'S DOOR
KEY CYLINDER SWITCH (UNLOCK) in the DATA LIST.
Are both information indicators OFF?
YES - Faulty driver's door key cylinder switch; replace the driver's door lock actuator.■
NO - Go to Step 9 .
9. Turn the ignition switch to LOCK (0).
10. Disconnect under-dash fuse/relay box connector E (12P).
11. Check for continuity between the No. 4 (UNLOCK) and No. 3 (LOCK) terminals of under-dash fuse/relay box
connector E (12P) and body ground individually.
Is there continuity?
YES - Repair a short to ground in the LOCK or UNLOCK wire.■
NO - Go to Step 12 .
12. Check for continuity between the No. 4 (UNLOCK) and No. 3 (LOCK) terminals of under-dash fuse/relay box
connector E (12P).
Is there continuity?
YES - Repair a short in the wire between the LOCK and UNLOCK wires.■
NO - Faulty MICU, replace the under-dash fuse/relay box. ■
DTC Troubleshooting: B1128
DTC B1128:
Driver's Door Remote Switch Input Circuit Malfunction (Simultaneous input of lock and unlock signal)
1. Clear the DTCs with the HDS.
2. Lock and unlock the driver's door with the driver'sdoor lock switch.
3. Check for DTCs with the HDS.
Is DTC B1128 indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the driver's door lock switch system is OK at this time. Check for loose or poor
connections.■
4. With the driver's door lock switch in the neutral position, select KEYLESS from the HDS and enter the DATA LIST.
5. Check the ON/OFF information of the DRIVER'S DOOR LOCK SWITCH (LOCK) and DRIVER'S DOOR LOCK
SWITCH (UNLOCK) in the DATA LIST.
Are both information indicators OFF?
YES - Check the wires for continuity between the under-dash fuse/relay box and driver's door key cylinder
switch. If there is continuity, the MICU is faulty. Replace the under-dash fuse/relay box.■
NO - Go to Step 6 .
6. Disconnect the power window master switch connector.
7. Check the ON/OFF information of the DRIVER'S DOOR LOCK SWITCH (LOCK) and DRIVER'S DOOR LOCK
SWITCH (UNLOCK) in the DATA LIST.
Are both information indicators OFF?
YES - Faulty door lock switch; replace the power window master switch.■
NO - Go to Step 8 .
8. Turn the ignition switch to LOCK (0).
9. Disconnect under-dash fuse/relay box connector E (12P).
10. Check for continuity between the No. 8 (LOCK) and No. 1 (UNLOCK) terminals of under-dash fuse/relay box
connector E (12P) and body ground individually.
Is there continuity?
YES - Repair a short to ground in the LOCK or UNLOCK wire.■
NO - Go to Step 11 .
11. Check for continuity between the No. 8 (LOCK) and No. 1 (UNLOCK) terminals of under-dash fuse/relay box
connector E (12P).
Is there continuity?
YES - Repair a short in the wire between the LOCK and UNLOCK wires.■
NO - Faulty MICU, replace the under-dash fuse/relay box. ■
DTC Troubleshooting: B1129
DTC B1129:
Driver's Door Lock Knob Switch Input Circuit Malfunction (Simultaneous input of lock and unlock signal)
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Operate the driver's door lock knob switch several times.
4. Check for DTCs with the HDS.
Is DTC B1129 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the driver's door lock knob switch is OK at this time. Check for loose or poor
connections.■
5. Select KEYLESS from the BODY ELECTRICAL menu, and enter the DATA LIST.
6. Check the ON/OFF information of the DRIVER'S DOOR LOCK KNOB SWITCH (LOCK) and the DRIVER'S DOOR
LOCK KNOB SWITCH (UNLOCK).
Are the DRIVER'S DOOR LOCK KNOB SWITCH (LOCK) information indicator ON and the DRIVER'S DOOR
LOCK KNOB SWITCH (UNLOCK) information indicator OFF with the driver's door lock knob switch in LOCK
position, and are the DRIVER'S DOOR LOCK KNOB SWITCH (LOCK) information indicator OFF and the
DRIVER'S DOOR LOCK KNOB SWITCH (UNLOCK) information indicator ON with the driver's door lock knob
switch in UNLOCK position?
YES - Faulty MICU, replace the under-dash fuse/relay box. ■
NO - Go to Step 7 .
7. Disconnect the driver's door lock actuator 10P connector.
8. Check the ON/OFF information of the DRIVER'S DOOR LOCK KNOB SWITCH (LOCK) and DRIVER'S DOOR
LOCK KNOB SWITCH (UNLOCK) in the DATA LIST.
Are both information indicators OFF?
YES - Check for an open in the driver's door lock knob switch (LOCK) wire or the driver's door lock knob switch
(UNLOCK) wire between the MICU and the driver's door lock knob switch. If OK, replace the driver's door
lock actuator.■
NO - Go to Step 9 .
9. Turn the ignition switch to LOCK (0).
10. Disconnect under-dash fuse/relay box connector E (12P).
11. Check for continuity between the No. 2 (UNLOCK) and No. 9 (LOCK) terminals of under-dash fuse/relay box
connector E (12P) and body ground individually.
Is there continuity?
YES - Repair a short to ground in the LOCK or UNLOCK wire.■
NO - Go to Step 12 .
12. Check for continuity between the No. 2 (UNLOCK) and No. 9 (LOCK) terminals of under-dash fuse/relay box
connector E (12P).
Is there continuity?
YES - Repair a short in the wire between the LOCK wire and UNLOCK wire.■
NO - Faulty MICU, replace the under-dash fuse/relay box. ■
DTC Troubleshooting: B1275
DTC B1275:
Headlight OFF Position Circuit Malfunction
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Operate each combination light switch position, then turn the combination light switch OFF.
4. Check for DTCs with the HDS.
Is DTC B1275 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections.■
5. Select LIGHTING from the BODY ELECTRICAL system select menu.
6. Check each combination light switch position value with the DATA LIST menu.
18. Check for continuity between under-dash fuse/relay box connector M (34P) terminals and the combination light RHD model
switch 12P connector terminals as shown:
Under-dash fuse/relay box connector M Combination light switch 12P connector
(34P)
5 9 [10]
7 8 [11]
8 10[9]
33 7[12]
LHD model
[ ]: LHD model
Is there continuity?
YES - Faulty MICU, replace the under-dash fuse/relay box. ■
NO - Repair an open in the wire.■
DTC Troubleshooting: B1276
DTC B1276:
Headlight SMALL Position Circuit Malfunction
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Operate each combination light switch position, then turn the combination light switch OFF.
4. Check for DTCs with the HDS.
Is DTC B1276 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections.■
5. Select LIGHTING from the BODY ELECTRICAL system select menu.
6. Check each combination light switch position value with the DATA LIST menu.
18. Check for continuity between under-dash fuse/relay box connector M (34P) terminals and the combination light RHD model
switch 12P connector terminals as shown:
Under-dash fuse/relay box connector M Combination light switch 12P connector
(34P)
5 9 [10]
7 8 [11]
8 10[9]
33 7[12]
LHD model
[ ]: LHD model
Is there continuity?
YES - Faulty MICU, replace the under-dash fuse/relay box. ■
NO - Repair an open in the wire.■
DTC Troubleshooting: B1278
DTC B1278:
Headlight ON Position Circuit Malfunction
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Operate each combination light switch position, then turn the combination light switch OFF.
4. Check for DTCs with the HDS.
Is DTC B1278 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections.■
5. Select LIGHTING from the BODY ELECTRICAL system select menu.
6. Check each combination light switch position value with the DATA LIST menu.
18. Check for continuity between under-dash fuse/relay box connector M (34P) terminals and the combination light RHD model
switch 12P connector terminals as shown:
Under-dash fuse/relay box connector M Combination light switch 12P connector
(34P)
5 9 [10]
7 8 [11]
8 10[9]
33 7[12]
LHD model
[ ]: LHD model
Is there continuity?
YES - Faulty MICU, replace the under-dash fuse/relay box. ■
NO - Repair an open in the wire.■
DTC Troubleshooting: B1279
DTC B1279:
Dimmer Switch Circuit Malfunction
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0) and then back to ON (II).
3. Turn the combination light (headlight) switch ON.
4. Change the dimmer switch from low beam to high beam.
5. Turn the combination light switch OFF and then to the passing position.
6. Check for DTCs with the HDS.
Is DTC B1279 indicated?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections.■
7. Select LIGHTING from the BODY ELECTRICAL system select menu, then enter the DATA LIST.
8. Check each combination light switch position value with the DATA LIST menu.
When the headlight switch is turned ON, and the dimmer switch changed from low beam to
high beam
Data List Value
Headlight Switch (PASSING) OFF
Headlight Switch (High beam) ON
Headlight Switch (HEADLIGHT) ON
20. Check for continuity between under-dash fuse/relay box connector M (34P) terminals and the combination light RHD model
switch 12P connector terminals as shown:
Under-dash fuse/relay box connector M Combination light switch 12P connector
(34P)
3 3 [4]
4 1 [6]
5 9 [10]
33 7 [12]
LHD model
[ ]: LHD model
Is there continuity?
YES - Go to Step 21 .
NO - Repair an open in the wire.■
21. Check for continuity between under-dash fuse/relay box connector M (34P) terminals as shown:
From terminal To terminal
5 3, 4, 7, 8
7 3, 4, 8
8 3, 4
Is there continuity?
YES - Repair a short between the wires.■
NO - Faulty MICU; replace the under-dash fuse/relay box. ■
DTC Troubleshooting: B1280
DTC B1280:
Turn Signal Switch Circuit Malfunction
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0) and then back to ON (II).
3. Operate the turn signal switch in left and right positions.
4. Check for DTCs with the HDS.
Is DTC B1280 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections.■
5. Select LIGHTING from the BODY ELECTRICAL system select menu, then enter the DATE LIST.
6. Check each combination light switch position value with the DATA LIST menu.
LHD model
DTC Troubleshooting: B1281
DTC B1281:
Front Wiper MIST Position Circuit Malfunction
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Operate each windshield wiper switch position, then turn the wiper/washer switch OFF.
4. Check for DTCs with the HDS.
Is DTC B1281 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections.■
5. Select WIPERS from the BODY ELECTRICAL menu.
6. Check each windshield wiper switch position value with the DATA LIST menu.
19. Check for continuity between under-dash fuse/relay box connector M (34P) terminals and the windshield RHD model
wiper/wash switch 8P connector terminals as shown:
Under-dash fuse/relay box connector M Windshield wiper/wash switch 8P connector
(34P)
10 3 [4]
11 2
12 1 [3]
[ ]: LHD model
Is there continuity?
YES - Faulty MICU, replace the under-dash fuse/relay box. ■
NO - Repair an open in the wire.■
DTC Troubleshooting: B1282
DTC B1282:
Front Wiper INT Position Circuit Malfunction
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Operate each windshield wiper switch position, then turn the wiper/washer switch OFF.
4. Check for DTCs with the HDS.
Is DTC B1282 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections.■
5. Select WIPERS from the BODY ELECTRICAL menu.
6. Check each windshield wiper switch position value with the DATA LIST menu.
19. Check for continuity between under-dash fuse/relay box connector M (34P) terminals and the windshield RHD model
wiper/washer switch 8P connector terminals as shown:
Under-dash fuse/relay box connector M Windshield wiper/washer switch 8P connector
(34P)
10 3 [4]
11 2
12 1 [3]
[ ]: LHD model
Is there continuity?
YES - Faulty MICU, replace the under-dash fuse/relay box. ■
NO - Repair an open in the wire.■
DTC Troubleshooting: B1283
DTC B1283:
Front Wiper LOW Position Circuit Malfunction
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Operate each windshield wiper switch position, then turn the wiper/washer switch OFF.
4. Check for DTCs with the HDS.
Is DTC B1283 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections.■
5. Select WIPER from the BODY ELECTRICAL menu.
6. Check each windshield wiper switch position value with the DATA LIST menu.
19. Check for continuity between under-dash fuse/relay box connector M (34P) terminals and the windshield RHD model
wiper/washer switch 8P connector terminals as shown:
Under-dash fuse/relay box connector M Windshield wiper/washer switch 8P connector
(34P)
10 3 [4]
11 2
12 1 [3]
[ ]: LHD model
Is there continuity?
YES - Faulty MICU, replace the under-dash fuse/relay box. ■
NO - Repair an open in the wire.■
DTC Troubleshooting: B1284
DTC B1284:
Front Wiper HIGH Position Circuit Malfunction
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Operate each windshield wiper switch position, then turn the wiper/washer switch OFF.
4. Check for DTCs with the HDS.
Is DTC B1284 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections.■
5. Select WIPERS from the BODY ELECTRICAL menu.
6. Check each windshield wiper switch position value with the DATA LIST menu.
19. Check for continuity between under-dash fuse/relay box connector M (34P) terminals and the windshield RHD model
wiper/washer switch 8P connector terminals as shown:
Under-dash fuse/relay box connector M Windshield wiper/washer switch 8P connector
(34P)
10 3 [4]
11 2
12 1 [3]
[ ]: LHD model
Is there continuity?
YES - Faulty MICU, replace the under-dash fuse/relay box. ■
NO - Repair an open in the wire.■
How to Troubleshoot the SRS
DTC (Diagnostic Trouble Codes)
The self-diagnostic function of the SRS system allows it to locate the causes of system problems and then store this
information in memory. For easier troubleshooting, this data can be retrieved via a data link circuit.
When you turn the ignition switch to ON (II), the SRS indicator should come on. If it goes off after 6 seconds, the
system is normal, and is not currently detecting any abnormality.
If there is an abnormality, the system locates and defines the problem, stores this information in memory, and
turns the SRS indicator on. The data remains in the memory even when the ignition switch is turned to LOCK (0) or
if the battery is disconnected.
The data is stored in memory as a diagnostic trouble code (DTC).
DTCs are either latching or resetting depending on the malfunction. With resetting DTCs, the SRS indicator goes off
the next time the ignition switch is turned to ON (II) and the system is normal, but the DTC is still stored. With
latching DTCs, the SRS indicator does not turn OFF until the malfunction is repaired and the DTC is cleared.
When you connect the HDS to the 16P data link connector (DLC), you can retrieve a more detailed DTC in the
Honda Systems ‘‘SRS'' menu.
After reading and recording the DTC, proceed with the troubleshooting procedure for that code.
Precautions
Use only a digital multimeter to check the system. Make sure its output is 10 mA (0.01 A) or less when switched
to the smallest value in the ohmmeter range. A tester with a higher output could damage the airbag circuit or cause
accidental airbag deployment and possible injury.
Whenever the ignition switch is in ON (II), or has been turned to LOCK (0) for less than 3 minutes, be careful not to
bump the SRS unit; the airbags could accidentally deploy and cause damage or injuries.
Before you remove the dashboard wire harness or floor wire harness, disconnect the driver's airbag connector, the
front passenger's airbag connector, both side airbag connectors, both side curtain airbag connectors, and both seat
belt tensioner connectors.
Make sure the battery is fully charged. If the battery is dead or low, measuring values may not be correct.
Do not touch a tester probe to the terminals in the SRS unit or harness connectors, and do not connect the SRS
unit terminals or the sensor terminals or the sensor terminals with a jumper wire. Use only the backprobe set and
the multimeter. Backprobe spring-loaded lock type connectors correctly.
16. Install a jumper wire between the No. 12 and the No. 13 terminals of SRS unit connector B (39P).
17. Check for continuity between the No. 2 and the No. 3 terminals of floor wire harness 4P connector.
Is there continuity?
YES - Faulty SRS unit or poor connection at SRS unit connector B (39P) and the SRS unit. Check the
connection between the connector and the SRS unit. If the connection is OK, replace the SRS unit. ■
NO - Open or increased resistance in the floor wire harness; replace the floor wire harness.■
SRS DTC Troubleshooting: 21-3x
DTC 21-3x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Another Wire or Decreased Resistance in the Left Side Seat Belt Tensioner
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 21-3x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect the floor wire harness 4P connector from the left side seat belt tensioner.
7. Do the battery terminal reconnection procedure.
8. Clear the DTC memory.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Read the DTC.
Is DTC 21-3x indicated?
YES - Go to Step 11 .
NO - Faulty left side seat belt tensioner; replace the left side seat belt tensioner. ■
11. Turn the ignition switch to LOCK (0).
12. Do the battery terminal disconnection procedure , then wait for 3 minutes.
13. Disconnect SRS unit connector B (39P) from the SRS unit.
14. Connect an SRS short canceller (070AZ-SAA0100) to No. 12 and No. 13 terminals of the SRS unit connector B
(39P).
15. Measure the resistance between the No. 12 and No. 13 terminals of SRS unit connector B (39P). There should be
0−1.0 Ω.
Is the resistance as specified?
YES - Short in the floor wire harness; replace the floor wire harness.■
NO - Faulty SRS unit; replace the SRS unit. ■
SRS DTC Troubleshooting: 21-8x
DTC 21-8x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Power in the Left Side Seat Belt Tensioner
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 21-8x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect SRS unit connector B (39P) from the SRS unit.
7. Connect an SRS short canceller (070AZ-SAA0100) to the No. 12 and the No. 13 terminals of SRS unit connector A
(39P).
8. Do the battery terminal reconnection procedure.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Measure the voltage between the No. 12 and the No. 13 terminals of SRS unit connector B (39P) and body ground.
There should be less than 1 V.
Is the voltage as specified?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Go to Step 11 .
11. Turn the ignition switch to LOCK (0).
12. Do the battery terminal disconnection procedure , then wait for 3 minutes.
13. Disconnect the floor wire harness 4P connector from the left side seat belt tensioner.
14. Do the battery terminal reconnection procedure.
15. Turn the ignition switch to ON (II), then wait for 10 seconds.
16. Measure the voltage between the No. 12 and the No. 13 terminals of SRS unit connector B (39P) and body ground.
There should be less than 1 V.
Is the voltage as specified?
YES - Faulty left side seat belt tensioner; replace the left side seat belt tensioner. ■
NO - Short to power in the floor wire harness; replace the floor wire harness.■
SRS DTC Troubleshooting: 21-9x
DTC 21-9x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Ground in the Left Side Seat Belt Tensioner
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 21-9x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect SRS unit connector B (39P) from the SRS unit.
7. Check for continuity between the No. 12 and the No. 13 terminals of SRS unit connector B (39P) and body ground.
Is there continuity?
YES - Go to Step 8 .
NO - Faulty SRS unit; replace the SRS unit. ■
8. Disconnect the floor wire harness 4P connector from the left side seat belt tensioner.
9. Check for continuity between the No. 12 and the No. 13 terminals of SRS unit connector B (39P) and body ground.
Is there continuity?
YES - Short to ground in the floor wire harness; replace the floor wire harness.■
NO - Faulty left side seat belt tensioner; replace the left side seat belt tensioner. ■
SRS DTC Troubleshooting: 22-1x, 22-2x
DTC 22-1x (‘‘x'' can be 0 thru 9 or A thru F):
Open in the Right Side Seat Belt Tensioner
DTC 22-2x (‘‘x'' can be 0 thru 9 or A thru F):
Increased Resistance in the Right Side Seat Belt Tensioner
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 22-1x or 22-2x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect the floor wire harness 4P connector from the right side seat belt tensioner.
7. Install a jumper wire between the No. 2 and the No. 3 terminals of the floor wire harness 4P connector.
8. Do the battery terminal reconnection procedure.
9. Clear the DTC memory.
10. Turn the ignition switch to ON (II), then wait for 10 seconds.
11. Read the DTC.
Is DTC 22-1x or 22-2x indicated?
YES - Go to Step 12 .
NO - Faulty right side seat belt tensioner; replace the right side seat belt tensioner. ■
12. Turn the ignition switch to LOCK (0).
13. Do the battery terminal disconnection procedure , then wait for 3 minutes.
14. Remove a jumper wire from the floor wire harness 4P connector.
15. Disconnect SRS unit connector B (39P) from the SRS unit.
16. Install a jumper wire between the No. 14 and the No. 15 terminals of SRS unit connector B (39P).
17. Check for continuity between the No. 2 and the No. 3 terminals of floor wire harness 4P connector.
Is there continuity?
YES - Faulty SRS unit or poor connection at SRS unit connector B (39P) and the SRS unit. Check the
connection between the connector and the SRS unit. If the connection is OK, replace the SRS unit. ■
NO - Open or increased resistance in the floor wire harness; replace the floor wire harness.■
SRS DTC Troubleshooting: 22-3x
DTC 22-3x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Another Wire or Decreased Resistance in the Right Side Seat Belt Tensioner
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 22-3x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect the floor wire harness 4P connector from the right side seat belt tensioner.
7. Read the DTC.
Is DTC 22-3x indicated?
YES - Go to Step 8 .
NO - Faulty right side seat belt tensioner; replace the right side seat belt tensioner. ■
8. Turn the ignition switch to LOCK (0).
9. Do the battery terminal disconnection procedure , then wait for 3 minutes.
10. Disconnect SRS unit connector B (39P) from the SRS unit.
11. Connect an SRS short canceller (070AZ-SAA0100) to No. 14 and No. 15 terminals of the SRS unit connector B
(39P).
12. Measure the resistance between the No. 14 and No. 15 terminals of SRS unit connector B (39P). There should be
0−1.0 Ω.
Is the resistance as specified?
YES - Short in the floor wire harness; replace the floor wire harness.■
NO - Faulty SRS unit; replace the SRS unit. ■
SRS DTC Troubleshooting: 22-8x
DTC 22-8x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Power in the Right Side Seat Belt Tensioner
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 22-8x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect SRS unit connector B (39P) from the SRS unit.
7. Connect an SRS short canceller (070AZ-SAA0100) to the No. 14 and the No. 15 terminals of SRS unit connector B
(39P).
8. Do the battery terminal reconnection procedure.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Measure the voltage between the No. 14 and the No. 15 terminals of SRS unit connector B (39P) and body ground.
There should be less than 1 V.
Is the voltage as specified?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Go to Step 11 .
11. Turn the ignition switch to LOCK (0).
12. Do the battery terminal disconnection procedure , then wait for 3 minutes.
13. Disconnect the floor wire harness 4P connector from the right side seat belt tensioner.
14. Do the battery terminal reconnection procedure.
15. Turn the ignition switch to ON (II), then wait for 10 seconds.
16. Measure the voltage between the No. 14 and the No. 15 terminals of SRS unit connector B (39P) and body ground.
There should be less than 1 V.
Is the voltage as specified?
YES - Faulty right side seat belt tensioner; replace the right side seat belt tensioner. ■
NO - Short to power in the floor wire harness; replace the floor wire harness.■
SRS DTC Troubleshooting: 22-9x
DTC 22-9x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Ground in the Right Side Seat Belt Tensioner
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 22-9x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect SRS unit connector B (39P) from the SRS unit.
7. Check for continuity between the No. 14 and the No. 15 terminals of SRS unit connector B (39P) and body ground.
Is there continuity?
YES - Go to Step 8 .
NO - Faulty SRS unit; replace the SRS unit. ■
8. Disconnect the floor wire harness 4P connector from the right side seat belt tensioner.
9. Check for continuity between the No. 14 and the No. 15 terminals of SRS unit connector B (39P) and body ground.
Is there continuity?
YES - Short to ground in the floor wire harness; replace the floor wire harness.■
NO - Faulty right side seat belt tensioner; replace the right side seat belt tensioner. ■
SRS DTC Troubleshooting: 31-1x, 31-2x
DTC 31-1x (‘‘x'' can be 0 thru 9 or A thru F):
Open in the Left Side Airbag Inflator
DTC 31-2x (‘‘x'' can be 0 thru 9 or A thru F):
Increased Resistance in the Left Side Airbag Inflator
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 31-1x or 31-2x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect the floor wire harness 2P connector from the left side airbag.
7. Install a jumper wire between the No. 1 and the No. 2 terminals of floor wire harness 2P connector.
8. Do the battery terminal reconnection procedure.
9. Clear the DTC memory.
10. Turn the ignition switch to ON (II), then wait for 10 seconds.
11. Read the DTC.
Is DTC 31-1x or 31-2x indicated?
YES - Go to Step 12 .
NO - Faulty left side airbag; replace the left side airbag. ■
12. Turn the ignition switch to LOCK (0).
13. Do the battery terminal disconnection procedure , then wait for 3 minutes.
14. Remove a jumper wire from the floor wire harness 2P connector.
15. Disconnect SRS unit connector B (39P) from the SRS unit.
16. Install a jumper wire between the No. 6 and the No. 7 terminals of SRS unit connector B (39P).
17. Check for continuity between the No. 1 and the No. 2 terminals of floor wire harness 2P connector.
Is there continuity?
YES - Faulty SRS unit or poor connection at SRS unit connector B (39P) and the SRS unit. Check the
connection between the connector and the SRS unit. If the connection is OK, replace the SRS unit. ■
NO - Open or increased resistance in the floor wire harness; replace the floor wire harness.■
SRS DTC Troubleshooting: 31-3x
DTC 31-3x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Another Wire or Decreased Resistance in the Left Side Airbag Inflator
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 31-3x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect the floor wire harness 2P connector from the left side airbag.
7. Do the battery terminal reconnection procedure.
8. Clear the DTC memory.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Read the DTC.
Is DTC 31-3x indicated?
YES - Go to Step 11 .
NO - Faulty left side airbag; replace the left side airbag. ■
11. Turn the ignition switch to LOCK (0).
12. Do the battery terminal disconnection procedure , then wait for 3 minutes.
13. Disconnect SRS unit connector B (39P) from the SRS unit.
14. Connect an SRS short canceller (070AZ-SAA0100) to No. 6 and No. 7 terminals of the SRS unit connector B
(39P).
15. Measure the resistance between the No. 6 and No. 7 terminals of SRS unit connector B (39P). There should be
0−1.0 Ω.
Is the resistance as specified?
YES - Short in the floor wire harness; replace the floor wire harness.■
NO - Faulty SRS unit; replace the SRS unit. ■
SRS DTC Troubleshooting: 31-8x
DTC 31-8x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Power in the Left Side Airbag Inflator
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 31-8x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect the SRS unit connector B (39P) from the SRS unit.
7. Connect an SRS short canceller (070AZ-SAA0100) to the No. 6 and the No. 7 terminals of SRS unit connector B
(39P).
8. Do the battery terminal reconnection procedure.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Measure the voltage between the No. 6 and the No. 7 terminals of SRS unit connector B (39P) and body ground.
There should be less than 1 V.
Is the voltage as specified?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Go to Step 11 .
11. Turn the ignition switch to LOCK (0).
12. Do the battery terminal disconnection procedure , then wait for 3 minutes.
13. Disconnect the floor wire harness 2P connector from the left side airbag.
14. Do the battery terminal reconnection procedure.
15. Turn the ignition switch to ON (II), then wait for 10 seconds.
16. Measure the voltage between the No. 6 and the No. 7 terminals of SRS unit connector B (39P) and body ground.
There should be less than 1 V.
Is the voltage as specified?
YES - Faulty left side airbag; replace the left side airbag. ■
NO - Short to power in the floor wire harness; replace the floor wire harness.■
SRS DTC Troubleshooting: 31-9x
DTC 31-9x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Ground in the Left Side Airbag Inflator
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 31-9x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect SRS unit connector B (39P) from the SRS unit.
7. Check for continuity between the No. 6 and the No. 7 terminals of SRS unit connector B (39P) and body ground.
Is there continuity?
YES - Go to Step 8 .
NO - Faulty SRS unit; replace the SRS unit. ■
8. Disconnect the floor wire harness 2P connector from the left side airbag.
9. Check for continuity between the No. 6 and the No. 7 terminals of SRS unit connector B (39P) and body ground.
Is there continuity?
YES - Short to ground in the floor wire harness; replace the floor wire harness.■
NO - Faulty left side airbag; replace the left side airbag. ■
SRS DTC Troubleshooting: 32-1x, 32-2x
DTC 32-1x (‘‘x'' can be 0 thru 9 or A thru F):
Open in the Right Side Airbag Inflator
DTC 32-2x (‘‘x'' can be 0 thru 9 or A thru F):
Increased Resistance in the Right Side Airbag Inflator
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 32-1x or 32-2x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect the floor wire harness 2P connector from the right side airbag.
7. Install a jumper wire between the No. 1 and the No. 2 terminals of the floor wire harness 2P connector.
8. Do the battery terminal reconnection procedure.
9. Clear the DTC memory.
10. Turn the ignition switch to ON (II), then wait for 10 seconds.
11. Read the DTC.
Is DTC 32-1x or 32-2x indicated?
YES - Go to Step 12 .
NO - Faulty right side airbag; replace the right side airbag. ■
12. Turn the ignition switch to LOCK (0).
13. Do the battery terminal disconnection procedure , then wait for 3 minutes.
14. Remove a jumper wire from the floor wire harness 2P connector.
15. Disconnect SRS unit connector B (39P) from the SRS unit.
16. Install a jumper wire between the No. 8 and the No. 9 terminals of SRS unit connector B (39P).
17. Check for continuity between the No. 1 and the No. 2 terminals of floor wire harness 2P connector.
Is there continuity?
YES - Faulty SRS unit or poor connection at SRS unit connector B (39P) and the SRS unit. Check the
connection between the connector and the SRS unit. If the connection is OK, replace the SRS unit. ■
NO - Open or inscreased resistance in the floor wire harness; replace the floor wire harness.■
SRS DTC Troubleshooting: 32-3x
DTC 32-3x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Another Wire or Decreased Resistance in the Right Side Airbag Inflator
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 32-3x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect the floor wire harness 2P connector from the right side airbag.
7. Do the battery terminal reconnection procedure.
8. Clear the DTC memory.
9. Turn the ignition switch to LOCK (0), then wait for 10 seconds.
10. Read the DTC.
Is DTC 32-3x indicated?
YES - Go to Step 11 .
NO - Faulty right side airbag; replace the right side airbag. ■
11. Turn the ignition switch to LOCK (0).
12. Do the battery terminal disconnection procedure , then wait for 3 minutes.
13. Disconnect SRS unit connector B (39P) from the SRS unit.
14. Connect an SRS short canceller (070AZ-SAA0100) to No. 8 and No. 9 terminals of the SRS unit connector B
(39P).
15. Measure the resistance between the No. 8 and the No. 9 terminals of SRS unit connector B (39P). There should be
0−1.0 Ω.
Is the resistance as specified?
YES - Short in the floor wire harness; replace the floor wire harness.■
NO - Faulty SRS unit; replace the SRS unit. ■
SRS DTC Troubleshooting: 32-8x
DTC 32-8x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Power in the Right Side Airbag Inflator
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 32-8x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect SRS unit connector B (39P) from the SRS unit.
7. Connect an SRS short canceller (070AZ-SAA0100) to the No. 8 and the No. 9 terminals of SRS unit connector B
(39P).
8. Do the battery terminal reconnection procedure.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Measure the voltage between the No. 8 and the No. 9 terminals of SRS unit connector B (39P) and body ground.
There should be less than 1 V.
Is the voltage as specified?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Go to Step 11 .
11. Turn the ignition switch to LOCK (0).
12. Do the battery terminal disconnection procedure , then wait for 3 minutes.
13. Disconnect the floor wire harness 2P connector from the right side airbag.
14. Do the battery terminal reconnection procedure.
15. Turn the ignition switch to ON (II), then wait for 10 seconds.
16. Measure the voltage between the No. 8 and the No. 9 terminals of SRS unit connector B (39P) and body ground.
There should be less than 1 V.
Is the voltage as specified?
YES - Faulty right side airbag; replace the right side airbag. ■
NO - Short to power in the floor wire harness; replace the floor wire harness.■
SRS DTC Troubleshooting: 32-9x
DTC 32-9x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Ground in the Right Side Airbag Inflator
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 32-9x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect SRS unit connector B (39P) from the SRS unit.
7. Check for continuity between the No. 8 and the No. 9 terminals of floor wire harness 2P connector and body
ground.
Is there continuity?
YES - Go to Step 8 .
NO - Faulty SRS unit; replace the SRS unit. ■
8. Disconnect the floor wire harness 2P connector from the right side airbag.
9. Check for continuity between the No. 8 and the No. 9 terminals of SRS unit connector B (39P) and body ground.
Is there continuity?
YES - Short to ground in the floor wire harness; replace the floor wire harness.■
NO - Faulty right side airbag; replace the right side airbag. ■
SRS DTC Troubleshooting: 33-1x, 33-2x
DTC 33-1x (‘‘x'' can be 0 thru 9 or A thru F):
Open in the Left Side Curtain Airbag Inflator
DTC 33-2x (‘‘x'' can be 0 thru 9 or A thru F):
Increased Resistance in the Left Side Curtain Airbag Inflator
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 33-1x or 33-2x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect the floor wire harness 2P connector from the left side curtain airbag.
7. Install a jumper wire between the No. 1 and the No. 2 terminals of floor wire harness 2P connector.
8. Do the battery terminal reconnection procedure.
9. Clear the DTC memory.
10. Turn the ignition switch to ON (II), then wait for 10 seconds.
11. Read the DTC.
Is DTC 33-1x or 33-2x indicated?
YES - Go to Step 12 .
NO - Faulty left side curtain airbag; replace the left side curtain airbag. ■
12. Turn the ignition switch to LOCK (0).
13. Do the battery terminal disconnection procedure , then wait for 3 minutes.
14. Remove a jumper wire from the floor wire harness 2P connector.
15. Disconnect SRS unit connector B (32P) from the SRS unit.
16. Install a jumper wire between the No. 10 and the No. 11 terminals of SRS unit connector B (39P).
17. Check for continuity between the No. 1 and the No. 2 terminals of floor wire harness 2P connector.
Is there continuity?
YES - Faulty SRS unit or poor connection at SRS unit connector B (39P) and the SRS unit. Check the
connection between the connector and the SRS unit. If the connection is OK, replace the SRS unit. ■
NO - Open or increased resistance in the floor wire harness; replace the floor wire harness.■
SRS DTC Troubleshooting: 33-3x
DTC 33-3x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Another Wire or Decreased Resistance in the Left Side Curtain Airbag Inflator
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 33-3x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect the floor wire harness 2P connector from the left side curtain airbag.
7. Do the battery terminal reconnection procedure.
8. Clear the DTC memory.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Read the DTC.
Is DTC 33-3x indicated?
YES - Go to Step 11 .
NO - Faulty left side curtain airbag; replace the left side curtain airbag. ■
11. Turn the ignition switch to LOCK (0).
12. Do the battery terminal disconnection procedure , then wait for 3 minutes.
13. Disconnect SRS unit connector B (39P) from the SRS unit.
14. Connect an SRS short canceller (070AZ-SAA0100) to No. 10 and No. 11 terminals of the SRS unit connector B
(39P).
15. Measure the resistance between the No. 10 and No. 11 terminals of the SRS unit connector B (39P). There should
be 0−1.0 Ω.
Is the resistance as specified?
YES - Short in the floor wire harness; replace the floor wire harness.■
NO - Faulty SRS unit; replace the SRS unit. ■
SRS DTC Troubleshooting: 33-8x
DTC 33-8x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Power in the Left Side Curtain Airbag Inflator
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 33-8x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect the SRS unit connector B (39P) from the SRS unit.
7. Connect an SRS short canceller (070AZ-SAA0100) to the No. 10 and the No. 11 terminals of SRS unit connector B
(39P).
8. Do the battery terminal reconnection procedure.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Measure the voltage between the No. 10 and the No. 11 terminals of SRS unit connector B (39P) and body ground.
There should be less than 1 V.
Is the voltage as specified?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Go to Step 11 .
11. Turn the ignition switch to LOCK (0).
12. Do the battery terminal disconnection procedure , then wait for 3 minutes.
13. Disconnect the floor wire harness 2P connector from the left side curtain airbag.
14. Do the battery terminal reconnection procedure.
15. Turn the ignition switch to ON (II), then wait for 10 seconds.
16. Measure the voltage between the No. 10 and the No. 11 terminals of SRS unit connector B (39P) and body ground.
There should be less than 1 V.
Is the voltage as specified?
YES - Faulty left side curtain airbag; replace the left side curtain airbag. ■
NO - Short to power in the floor wire harness; replace the floor wire harness.■
SRS DTC Troubleshooting: 33-9x
DTC 33-9x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Ground in the Left Side Curtain Airbag Inflator
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 33-9x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect SRS unit connector B (39P) from the SRS unit.
7. Check for continuity between the No. 10 and the No. 11 terminals of SRS unit connector B (39P) and body ground.
Is there continuity?
YES - Go to Step 8 .
NO - Faulty SRS unit; replace the SRS unit. ■
8. Disconnect the floor wire harness 2P connector from the left side curtain airbag.
9. Check for continuity between the No. 10 and the No. 11 terminals of SRS unit connector B (39P) and body ground.
Is there continuity?
YES - Short to ground in the floor wire harness; replace the floor wire harness.■
NO - Faulty left side curtain airbag; replace the left side curtain airbag. ■
SRS DTC Troubleshooting: 34-1x, 34-2x
DTC 34-1x (‘‘x'' can be 0 thru 9 or A thru F):
Open in the Right Side Curtain Airbag Inflator
DTC 34-2x (‘‘x'' can be 0 thru 9 or A thru F):
Increased Resistance in the Right Side Curtain Airbag Inflator
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 34-1x or 34-2x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure, then wait for 3 minutes.
6. Disconnect the floor wire harness 2P connector from the right side curtain airbag.
7. Install a jumper wire between the No. 1 and the No. 2 terminals of the floor wire harness 2P connector.
8. Do the battery terminal reconnection procedure.
9. Clear the DTC memory.
10. Turn the ignition switch to ON (II), then wait for 10 seconds.
11. Read the DTC.
Is DTC 34-1x or 34-2x indicated?
YES - Go to Step 12 .
NO - Faulty right side curtain airbag, replace the right side curtain airbag. ■
12. Turn the ignition switch to LOCK (0).
13. Do the battery terminal disconnection procedure, then wait for 3 minutes.
14. Remove a jumper wire from the floor wire harness 2P connector.
15. Disconnect SRS unit connector B (39P) from the SRS unit.
16. Install a jumper wire between the No. 24 and the No. 25 terminals of SRS unit connector B (39P).
17. Check for continuity between the No. 1 and the No. 2 terminals of the floor wire harness 2P connector.
Is there continuity?
YES - Faulty SRS unit or poor connection at SRS unit connector B (39P) and the SRS unit. Check the
connection between the connector and the SRS unit. If the connection is OK, replace the SRS unit . ■
NO - Open or increased resistance in the floor wire harness; replace the floor wire harness.■
SRS DTC Troubleshooting: 34-3x
DTC 34-3x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Another Wire or Decreased Resistance in the Right Side Curtain Airbag Inflator
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 34-3x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure, then wait for 3 minutes.
6. Disconnect the floor wire harness 2P connector from the right side curtain airbag.
7. Do the battery terminal reconnection procedure.
8. Clear the DTC memory.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Read the DTC.
Is DTC 34-3x indicated?
YES - Go to Step 11 .
NO - Faulty right side curtain airbag; replace the right side curtain airbag.
11. Turn the ignition switch to LOCK (0).
12. Do the battery terminal disconnection procedure, then wait for 3 minutes.
13. Disconnect SRS unit connector B (39P) from the SRS unit.
14. Connect an SRS short canceller (070AZ-SAA0100) to No. 24 and No. 25 terminals of the SRS unit connector B
(39P).
15. Measure the resistance between the No. 24 and No. 25 terminals of the SRS unit connector B (39P). There should
be 0−1.0 Ω.
Is the resistance as specified?
YES - Short in the floor wire harness; replace the floor wire harness.■
NO - Faulty SRS unit; replace the SRS unit. ■
SRS DTC Troubleshooting: 34-8x
DTC 34-8x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Power in the Right Side Curtain Airbag Inflator
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 34-8x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure, then wait for 3 minutes.
6. Disconnect SRS unit connector B (39P) from the SRS unit.
7. Connect an SRS short canceller (070AZ-SAA0100) to No. 24 and No. 25 terminals of the SRS unit connector B
(39P).
8. Do the battery terminal reconnection procedure.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Measure the voltage between the No. 24 and the No. 25 terminals of SRS unit connector B (39P) and body ground.
There should be less than 1 V.
Is the voltage as specified?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Go to Step 11 .
11. Turn the ignition switch to LOCK (0).
12. Do the battery terminal disconnection procedure, then wait for 3 minutes.
13. Disconnect the floor wire harness 2P connector from the right side curtain airbag.
14. Do the battery terminal reconnection procedure.
15. Turn the ignition switch to ON (II), then wait for 10 seconds.
16. Measure the voltage between the No. 24 and the No. 25 terminals of SRS unit connector B (39P) and body ground.
There should be less than 1 V.
Is the voltage as specified?
YES - Faulty right side curtain airbag; replace the right side curtain airbag. ■
NO - Short to power in the floor wire harness; replace the floor wire harness.■
SRS DTC Troubleshooting: 34-9x
DTC 34-9x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Ground in the Right Side Curtain Airbag Inflator
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 34-9x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure, then wait for 3 minutes.
6. Disconnect SRS unit connector B (39P) from the SRS unit.
7. Check for continuity between the No. 24 and the No. 25 terminals of SRS unit connector B (39P) and body ground.
Is there continuity?
YES - Go to Step 8 .
NO - Faulty SRS unit; replace the SRS unit. ■
8. Disconnect floor wire harness 2P connector from the right side curtain airbag.
9. Check for continuity between the No. 24 and the No. 25 terminals of SRS unit connector B (39P) and body ground.
Is there continuity?
YES - Short to ground in the floor wire harness; replace the floor wire harness.■
NO - Faulty right side curtain airbag; replace the right side curtain airbag. ■
SRS DTC Troubleshooting: 41-1x
DTC 41-1x (‘‘x'' can be 0 thru 9 or A thru F):
No Signal From the Left Front Impact Sensor
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 41-1x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Check the connections between SRS unit connector A (39P) and the SRS unit, between the left engine
compartment wire harness 2P connector and the left front impact sensor, and at left engine compartment wire
harness 4P connector.
Are the connections OK?
YES - Go to Step 7 .
NO - Repair the poor connections and retest.
7. Disconnect SRS unit connector A (39P) from the SRS unit.
8. Connect an SRS short canceller (070AZ-SAA0100) to the No. 36 and the No. 37 terminals of SRS unit connector A
(39P).
9. Disconnect the left engine compartment wire harness 2P connector from the left front impact sensor.
10. Measure the resistance between the No. 36 and the No. 37 terminals of SRS unit connector A (39P). There should
be an open circuit or at least 1 MΩ.
Is the resistance as specified?
YES - Go to Step 11 .
NO - Short in the left engine compartment wire harness or dashboard wire harness; replace the faulty
harness.■
11. Measure the resistance between the No. 36 terminal of SRS unit connector A (39P) and body ground, and between
the No. 37 terminal and body ground. There should be an open circuit or at least 1 MΩ.
Is the resistance as specified?
YES - Go to Step 12 .
NO - Short to ground in the left engine compartment wire harness or dashboard wire harness; replace the faulty
harness.■
12. Do the battery terminal reconnection procedure.
13. Turn the ignition switch to ON (II).
14. Measure the voltage between the No. 36 terminal of SRS unit connector A (39P) and body ground, and between the
No. 37 terminal and body ground. There should be less than 1 V.
Is the voltage as specified?
YES - Go to Step 15 .
NO - Short to power in the left engine compartment wire harness or dashboard wire harness; replace the faulty
harness.■
15. Turn the ignition switch to LOCK (0).
16. Do the battery terminal disconnection procedure.
17. Install a jumper wire between the No. 1 and the No. 2 terminals of left engine compartment wire harness 2P
connector.
18. Measure the resistance between the No. 36 and the No. 37 terminals of SRS unit connector A (39P). There should
be less than 1 Ω.
Is the resistance as specified?
YES - Go to Step 19 .
NO - Open in the left engine compartment wire harness or dashboard wire harness; replace the faulty
harness.■
19. Substitute a known-good left front impact sensor and recheck.
20. Connect SRS unit connector A (39P) to the SRS unit.
21. Clear the DTC memory.
22. Turn the ignition switch to ON (II), then wait for 10 seconds.
23. Read the DTC.
Is DTC 41-1x indicated?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Faulty left front impact sensor; replace the left front impact sensor. ■
SRS DTC Troubleshooting: 41-3x, 41-8x, 41-9x, 41-Ax, 41-Bx
DTC 41-3x, 41-8x, 41-9x, 41-Ax, 41-Bx (‘‘x'' can be 0 thru 9 or A thru F):
Internal Failure of the Left Front Impact Sensor
NOTE: Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 41-3x, 41-8x, 41-9x, 41-Ax or 41-Bx indicated?
YES - Faulty left font impact sensor; replace the left front impact sensor. ■
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
SRS DTC Troubleshooting: 42-1x
DTC 42-1x (‘‘x'' can be 0 thru 9 or A thru F):
No Signal From the Right Front Impact Sensor
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 42-1x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure, then wait for 3 minutes.
6. Check the connections between SRS unit connector A (39P) and the SRS unit, between the right engine
compartment wire harness 2P connector and the right front impact sensor, and at right engine compartment wire
harness 4P connector.
Are the connections OK?
YES - Go to Step 7 .
NO - Repair the poor connections and retest.
7. Disconnect SRS unit connector A (39P) from the SRS unit.
8. Connect an SRS short canceller (070AZ-SAA0100) to the No. 38 and the No. 39 terminals of SRS unit connector A
(39P).
9. Disconnect the right engine compartment wire harness 2P connector from the right front impact sensor.
10. Measure the resistance between the No. 38 and the No. 39 terminals of SRS unit connector A (39P). There should
be an open circuit or at least 1 MΩ.
Is the resistance as specified?
YES - Go to Step 11 .
NO - Short in the right engine compartment wire harness or dashboard wire harness; replace the faulty
harness.■
11. Measure the resistance between the No. 38 terminal of SRS unit connector A (39P) and body ground, and between
the No. 39 terminal and body ground. There should be an open circuit or at least 1 MΩ.
Is the resistance as specified?
YES - Go to Step 12 .
NO - Short to ground in the right engine compartment wire harness or dashboard wire harness; replace the
faulty harness.■
12. Do the battery terminal reconnection procedure.
13. Turn the ignition switch to ON (II).
14. Measure the voltage between the No. 38 terminal of SRS unit connector A (39P) and body ground, and between the
No. 39 terminal and body ground. There should be less than 1 V.
Is the voltage as specified?
YES - Go to Step 15 .
NO - Short to power in the right engine compartment wire harness or dashboard wire harness; replace the
faulty harness.■
15. Turn the ignition switch to LOCK (0).
16. Do the battery terminal disconnection procedure.
17. Install a jumper wire between the No. 1 and the No. 2 terminals of right engine compartment wire harness 2P
connector.
18. Measure the resistance between the No. 38 and the No. 39 terminals of SRS unit connector A (39P). There should
be less than 1 Ω.
Is the resistance as specified?
YES - Go to Step 19 .
NO - Open in the right engine compartment wire harness or dashboard wire harness; replace the faulty
harness.■
19. Substitute a known-good right front impact sensor and recheck.
20. Connect SRS unit connector A (39P) to the SRS unit.
21. Clear the DTC memory.
22. Turn the ignition switch to ON (II), then wait for 10 seconds.
23. Read the DTC.
Is DTC 42-1x indicated?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Faulty right front impact sensor, replace the right front impact sensor. ■
SRS DTC Troubleshooting: 42-3x, 42-8x, 42-9x, 42-Ax, 42-Bx
DTC 42-3x, 42-8x, 42-9x, 42-Ax, 42-Bx (''x'' can be 0 thru 9 or A thru F):
Internal Failure of the Right Front Impact Sensor
NOTE: Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 42-3x, 42-8x, 42-9x, 42-Ax, or 42-Bx indicated?
YES - Faulty right front impact sensor; replace the right front impact sensor. ■
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
SRS DTC Troubleshooting: 43-3x, 43-8x, 43-9x, 43-Ax, 43-Bx
DTC 43-3x, 43-8x, 43-9x, 43-Ax, 43-Bx (''x'' can be 0 thru 9 or A thru F):
Internal Failure of the Left Side Impact Sensor (first)
NOTE: Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 43-3x, 43-8x, 43-9x, 43-Ax, or 43-Bx indicated?
YES - Faulty left side impact sensor (first); replace the left side front impact sensor (first). ■
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
SRS DTC Troubleshooting: 44-3x, 44-8x, 44-9x, 44-Ax, 44-Bx
DTC 44-3x, 44-8x, 44-9x, 44-Ax, 44-Bx (''x'' can be 0 thru 9 or A thru F):
Internal Failure of the Right Side Impact Sensor (first)
NOTE: Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 44-3x, 44-8x, 44-9x, 44-Ax, or 44-Bx indicated?
YES - Faulty right side impact sensor (first); replace the right side front impact sensor (first). ■
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
SRS DTC Troubleshooting: 45-11
DTC 45-11:
No Signal From the Left Side Impact Sensor (second)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 45-1x indicated?
YES - If DTC 45-11 is indicated alone, go to Step 4 .
If DTC except 45-11 is indicated, faulty left side impact sensor (second); replace the left side
impact sensor (second). ■
If DTC 43-11 and 45-11 are indicated, faulty left side impact sensor (first); replace the left side
impact sensor (first). ■
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Check the connections between the floor wire harness 2P connector and the left side impact sensor (second), and
at floor wire harness 2P connector.
Are the connections OK?
YES - Go to Step 7 .
NO - Repair the poor connections and retest.
7. Disconnect the floor wire harness 4P connector from the left side impact sensor (first).
8. Disconnect the floor wire harness 2P connector from the left side impact sensor (second).
9. Measure the resistance between No. 1 and No. 2 terminals of floor wire harness 2P connector. There should be an
open circuit or at least 1 MΩ.
Is the resistance as specified?
YES - Go to Step 10 .
NO - Short in the floor wire harness; replace the floor wire harness.■
10. Measure the resistance between No. 1 terminal of floor wire harness 2P connector and body ground, and between
the No. 2 terminal and body ground. There should be an open circuit or at least 1 MΩ.
Is the resistance as specified?
YES - Go to Step 11 .
NO - Short to ground in the floor wire harness; replace the floor wire harness.■
11. Do the battery terminal reconnection procedure.
12. Turn the ignition switch to ON (II).
13. Measure the voltage between No. 1 terminal of floor wire harness 2P connector and body ground, and between the
No. 2 terminal and body ground. There should be less than 1.0 V.
Is the voltage as specified?
YES - Go to Step 14 .
NO - Short to power in the floor wire harness; replace the floor wire harness.■
14. Turn the ignition switch to LOCK (0).
15. Measure the resistance between the No. 4 terminal of the floor wire harness 4P connector and the No. 1 terminal of
the floor wire harness 2P connector, and between the No. 1 terminal of the floor wire harness 4P connector and the
No. 2 terminal of the floor wire harness 2P connector. There should be 0−1.0 Ω.
Is the resistance as specified?
YES - Go to Step 16 .
NO - Open in the floor wire harness; replace the floor wire harness.■
16. Substitute a known-good left side impact sensor (second) and recheck.
17. Connect SRS unit connector B (39P) to the SRS unit.
18. Clear the DTC memory.
19. Turn the ignition switch to ON (II), then wait for 10 seconds.
20. Read the DTC.
Is DTC 45-11 indicated?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Faulty left side impact sensor (second); replace the left side impact sensor (second). ■
SRS DTC Troubleshooting: 45-3x, 45-8x, 45-9x, 45-Ax, 45-Bx
DTC 45-3x, 45-8x, 45-9x, 45-Ax, 45-Bx (‘‘x'' can be 0 thru 9 or A thru F):
Internal Failure of the Left Side Impact Sensor (second)
NOTE: Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 45-3x, 45-8x, 45-9x, 45-Ax, or 45-Bx indicated?
YES - Faulty left side impact sensor (second); replace the left side impact sensor (second). ■
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
SRS DTC Troubleshooting: 46-11
DTC 46-11:
No Signal From the Right Side Impact Sensor (second)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 46-11 indicated?
YES - If DTC 46-11 is indicated alone, go to Step 4 .
If DTC except 46-11 is indicated, faulty right side impact sensor (second); replace the right side
impact sensor (second). ■
If DTC 44-11 and 46-11 are indicated, faulty right side impact sensor (first); replace the right side
impact sensor (first). ■
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Check the connections between the floor wire harness 2P connector and the right side impact sensor (second),
and at floor wire harness 2P connector.
Are the connections OK?
YES - Go to Step 7 .
NO - Repair the poor connections and retest.
7. Disconnect the floor wire harness 4P connector from the right side impact sensor (first).
8. Disconnect the floor wire harness 2P connector from the right side impact sensor (second).
9. Measure the resistance between the No. 1 and No. 2 terminals of floor wire harness 2P connector. There should be
an open circuit or at least 1 MΩ.
Is the resistance as specified?
YES - Go to Step 10 .
NO - Short in the floor wire harness; replace the floor wire harness.■
10. Measure the resistance between No. 1 terminal of floor wire harness 2P connector and body ground, and between
the No. 2 terminal and body ground. There should be an open circuit or at least 1 MΩ.
Is the resistance as specified?
YES - Go to Step 11 .
NO - Short to ground in the floor wire harness; replace the floor wire harness.■
11. Do the battery terminal reconnection procedure.
12. Turn the ignition switch to ON (II).
13. Measure the voltage between No. 1 terminal of floor wire harness 2P connector and body ground, and between the
No. 2 terminal and body ground. There should be less than 1 V.
Is the voltage as specified?
YES - Go to Step 14 .
NO - Short to power in the floor wire harness; replace the floor wire harness.■
14. Turn the ignition switch to LOCK (0).
15. Measure the resistance between the No. 1 terminal of the floor wire harness 4P connector and the No. 2 terminal of
the floor wire harness 2P connector, and between the No. 4 terminal of the floor wire harness 4P connector and the
No. 1 terminal of the floor wire harness 2P connector. There should be 0−1.0 Ω.
Is the resistance as specified?
YES - Go to Step 16 .
NO - Open in the floor wire harness; replace the floor wire harness.■
16. Substitute a known-good right side impact sensor (second) and recheck.
17. Connect SRS unit connector B (39P) to the SRS unit.
18. Clear the DTC memory.
19. Turn the ignition switch to ON (II), then wait for 10 seconds.
20. Read the DTC.
Is DTC 46-11 indicated?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Faulty right side impact sensor (second); replace the right side impact sensor (second). ■
SRS DTC Troubleshooting: 46-3x, 46-8x, 46-9x, 46-Ax, 46-Bx
DTC 46-3x, 46-8x, 46-9x, 46-Ax, 46-Bx (‘‘x'' can be 0 thru 9 or A thru F):
Internal Failure of the Right Side Impact Sensor (second)
NOTE: Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 46-3x, 46-8x, 46-9x, 46-Ax, or 46-Bx indicated?
YES - Faulty right side impact sensor (second); replace the right side impact sensor (second). ■
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
SRS DTC Troubleshooting: 51-xx, 52-xx, 53-xx, 54-xx, 55-xx
DTC 51-xx, 52-xx, 53-xx, 54-xx, 55-xx (‘‘x'' can be 0 thru 9 or A thru F):
Internal Failure of the SRS Unit
NOTE:
Before troubleshooting any of these DTCs, check the battery/system voltage and battery cable connections. If the
voltage is low, repair the charging system or replace the battery before troubleshooting the SRS. If the
battery/system voltage is now OK, ask the customer if the battery ever went dead or if the engine was started and
run with the battery in a low state of charge. A dead battery may trigger one or more of these DTCs.
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Check that the SRS indicator goes off.
Does the SRS indicator go off?
YES - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
NO - Replace the SRS unit. ■
SRS DTC Troubleshooting: 53-FF
DTC 53-FF:
SRS Unit Programming Error
NOTE:
This DTC is indicated when a SRS unit update is not completed properly.
Do not turn the ignition switch to ACC (I) or to LOCK (0) while updating the SRS unit. If you turn the ignition switch
to ACC (I) or to LOCK (0) before you complete the SRS unit update procedure, the SRS unit can be damaged.
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
1. Do the SRS unit update procedure.
2. Read the DTC.
Is DTC 53-FF indicated?
YES - Replace the original SRS unit. ■
NO - Update is complete.■
SRS DTC Troubleshooting: 56-31
DTC 56-31:
Lost Communication with the ECM/PCM (PGM-FI system)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Check for any F-CAN and B-CAN communication DTCs, and troubleshoot those DTCs before doing this
troubleshooting procedure.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 56-31 indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to ON (II), and see if the malfunction indicator lamp (MIL) comes on.
Does the MIL come on?
YES - Go to the MIL Circuit Troubleshooting.
NO - Go to Step 5 .
5. Turn the ignition switch to LOCK (0).
6. Do the battery terminal disconnection procedure , then wait for 3 minutes.
7. Disconnect SRS unit connector A (39P) from the SRS unit.
8. Install a jumper wire between the No. 16 and the No. 17 terminal of SRS unit connector A (39P).
9. Disconnect ECM/PCM connector A (49P) from the ECM/PCM.
10. Check for continuity between the No. 3 and the No. 4 terminals of the ECM/PCM connector A (49P).
Is there continuity?
YES - Faulty SRS unit or poor connection at SRS unit connector A (39P) and the SRS unit. Check the
connection between the connector and the SRS unit. If the connection is OK, replace the SRS unit. ■
NO - Open in the left engine compartment wire harness or the floor wire harness; replace the faulty harness.■
SRS DTC Troubleshooting: 56-32, 56-33
DTC 56-32, 56-33:
Undefined Data Received From the ECM/PCM (PGM-FI system)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Check for any F-CAN and B-CAN communication DTCs, and troubleshoot those DTCs before doing this
troubleshooting procedure.
1. Turn the ignition switch to LOCK (0), then wait for 10 seconds.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Check that the malfunction indicator lamp (MIL) comes on.
Does the MIL come on?
YES - Go to Step 4 .
NO - Go to the PGM-FI system troubleshooting.
4. Clear the DTC memory.
5. Turn the ignition switch to LOCK (0), and wait for 10 seconds.
6. Turn the ignition switch to ON (II), then wait for 10 seconds.
7. Read the DTC.
Is DTC 56-32 or 56-33 indicated?
YES - Faulty ECM/PCM; replace the ECM/PCM.
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
SRS DTC Troubleshooting: 85-4x, 85-63, 85-64
DTC 85-4x, 85-63, 85-64 (‘‘x'' can be 0 thru 9 or A thru F):
Internal Failure of the OPDS Unit
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes
off.
Does the SRS indicator go off?
YES - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
NO - Go to Step 3 .
3. Turn the ignition switch to LOCK (0).
4. Initialize the OPDS unit.
5. Turn the ignition switch to ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes
off.
Does the SRS indicator go off?
YES - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. ■
NO - Replace the OPDS unit and retest. If the problem is still present, replace the OPDS sensor/seat-back
cover/pad. ■
SRS DTC Troubleshooting: 85-61, 85-62
DTC 85-61:
No Signal From the OPDS Unit
DTC 85-62:
Non-stipulated Data From the OPDS Unit
NOTE: Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
1. Clear the DTC memory.
2. Read the DTC.
Is DTC 85-61 or 85-62 indicated?
YES - Go to Step 3 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
3. Check the No. 8 (7.5 A) fuse in the under-dash fuse/relay box.
Is the fuse OK?
YES - Go to Step 4 .
NO - Replace the fuse, then turn the ignition switch to ON (II). If the fuse blows again, check for a short in the
No. 8 (7.5 A) fuse circuit (floor wire harness, or OPDS unit harness).
4. Turn the ignition switch to LOCK (0).
5. Disconnect the OPDS unit harness 18P connector (A) from the OPDS unit.
6. Turn the ignition switch to ON (II).
7. Measure the voltage between the No. 1 terminal of the OPDS unit harness 18P connector and body ground. There
should be battery voltage.
Is there battery voltage?
YES - Go to Step 8 .
NO - Open between the No. 8 (7.5 A) fuse in the under-dash fuse/relay box and the No. 1 terminal of the OPDS
unit 18P connector (floor wire harness or OPDS unit harness); replace the faulty harness.■
8. Turn the ignition switch to LOCK (0).
9. Measure the resistance between the No. 12 terminal of the OPDS unit harness 18P connector and body ground.
There should be 0−1.0 Ω.
Is the resistance as specified?
YES - Go to Step 10 .
NO - Open between the No. 12 terminal of the OPDS unit harness 18P connector and body ground (G603) or
poor connection at G603. ■
10. Do the battery terminal disconnection procedure , then wait for 3 minutes.
11. Disconnect SRS unit connector B (39P) from the SRS unit.
12. Measure the resistance between No. 1 terminal of SRS unit connector B (39P) and body ground. There should be 1
MΩ.
Is the resistance as specified?
YES - Go to Step 13 .
NO - Short to ground between the No. 1 terminal of the SRS unit connector B (39P) and the No. 7 terminal of
the OPDS unit harness 18P connector (floor wire harness or OPDS unit harness); replace the faulty
harness.■
13. Measure the resistance between the No. 1 terminal of SRS unit connector B (39P) and the No. 7 terminal of the
OPDS unit harness 18P connector. There should be 0−1.0 Ω.
Is the resistance as specified?
YES - Go to Step 14 .
NO - Open between the No. 1 terminal of the SRS unit connector B (39P) and the No. 7 terminal of the OPDS
unit harness 18P connector (floor wire harness or OPDS unit harness); replace the faulty harness.■
14. Do the battery terminal reconnection procedure.
15. Turn the ignition switch to ON (II).
16. Measure the voltage between the No. 1 terminal of the SRS unit connector B (39P) and body ground. There should
be 1 V.
Is there battery voltage?
YES - Go to Step 17 .
NO - Short to power between the No. 1 terminal of the SRS unit connector B (39P) and the No. 7 terminal of
the OPDS unit harness 18P connector (floor wire harness or OPDS unit harness); replace the faulty
harness.■
17. Replace the OPDS unit.
18. Initialize the OPDS unit.
19. Clear the DTC.
20. Read the DTC.
Is the DTC 85-61 or 85-62 indicated?
YES - Replace the SRS unit. ■
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
SRS DTC Troubleshooting: 85-71, 85-78
DTC 85-71, 85-78:
OPDS Unit Does Not Initialized
NOTE: Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 85-71 or 85-78 indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Initialize the OPDS unit.
5. Turn the ignition switch to LOCK (0), then wait for 10 seconds.
6. Turn the ignition switch to ON (II), then wait for 10 seconds.
7. Read the DTC.
Is SRS DTC indicated?
YES - Replace the OPDS unit. ■
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
SRS DTC Troubleshooting: 85-79
DTC 85-79:
OPDS Initial Check Failure
NOTE: Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes
off.
Does the SRS indicator go off?
YES - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
NO - Go to Step 3 .
3. Turn the ignition switch to LOCK (0).
4. Make sure nothing is on the front passenger's seat.
5. Clear the DTC memory.
6. Turn the ignition switch to ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes
off.
Does the SRS indicator go off?
YES - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures.
NO - Go to Step 7 .
7. Turn the ignition switch to LOCK (0).
8. Initialize the OPDS unit.
9. Turn the ignition switch to ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes
off.
Does the SRS indicator go off?
YES - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures.
NO - Replace the OPDS unit and retest. If the problem is still present, replace the OPDS sensor/seat-back
cover/pad. ■
SRS DTC Troubleshooting: 86-1x, 86-2x
DTC 86-1x (‘‘x'' can be 0 thru 9 or A thru F):
Faulty OPDS Seat-Back Sensor
DTC 86-2x (‘‘x'' can be 0 thru 9 or A thru F):
Faulty OPDS Seat Support Sensor
NOTE: Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
1. Clear the DTC memory.
2. Read the DTC.
Is DTC 86-1x or 86-2x indicated?
YES - Go to Step 3 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
3. Check the connection at the OPDS sensor harness connectors (A) and the OPDS unit harness 18P connector (B).
Is the connection OK?
YES - Go to Step 4 .
NO - Repair the poor connection, and clear the DTC. ■
4. Replace the front passenger's seat-back cover/pad, and initialize the OPDS.
5. Clear the DTC memory.
6. Read the DTC.
Is DTC 86-1x or 86-2x indicated?
YES - Replace the OPDS unit. ■
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
SRS DTC Troubleshooting: A1-1x
DTC A1-1x (‘‘x'' can be 0 thru 9 or A thru F):
Faulty Power Supply (VA line)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC A1-1x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Check the No. 8 (7.5 A) fuse in the under-dash fuse/relay box.
Is the fuse OK?
YES - Go to Step 6 .
NO - Replace the fuse, then turn the ignition switch to ON (II). If the fuse blows again, check for a short to
ground in the dashboard wire harness or in the under-dash fuse/relay box No. 8 (7.5 A) fuse circuit;
replace the dashboard wire harness. If the problem is still there, replace the under-dash fuse/relay box. ■
6. Turn the ignition switch to LOCK (0).
7. Do the battery terminal disconnection procedure , then wait for 3 minutes.
8. Disconnect SRS unit connector A (39P) from the SRS unit.
9. Do the battery terminal reconnection procedure.
10. Turn the ignition switch to ON (II).
11. Measure the voltage between the No. 26 terminal of SRS unit connector A (39P) and body ground. There should be
battery voltage.
Is the voltage as specified?
YES - Faulty SRS unit or poor connection at SRS unit connector A (39P) and the SRS unit; check the
connection. If the connection is OK, replace the SRS unit. ■
NO - Open in the dashboard wire harness; replace the dashboard wire harness.■
SRS DTC Troubleshooting: A2-1x
DTC A2-1x (‘‘x'' can be 0 thru 9 or A thru F):
Faulty Power Supply (VB line)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC A2-1x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Check the No. 6 (10 A) fuse in the under-dash fuse/relay box.
Is the fuse OK?
YES - Go to Step 6 .
NO - Replace the fuse, then turn the ignition switch to ON (II). If the fuse blows again, check for a Short to
ground in the dashboard wire harness or in the under-dash fuse/relay box No. 6 (10 A) fuse circuit;
replace the dashboard wire harness. If the problem is still there, replace the under-dash fuse/relay box. ■
6. Turn the ignition switch to LOCK (0).
7. Do the battery terminal disconnection procedure , then wait for 3 minutes.
8. Disconnect SRS unit connector A (39P) from the SRS unit.
9. Do the battery terminal reconnection procedure.
10. Turn the ignition switch to ON (II).
11. Measure the voltage between the No. 27 terminal of SRS unit connector A (39P) and body ground. There should be
battery voltage.
Is the voltage as specified?
YES - Faulty SRS unit or poor connection at SRS unit connector A (39P) and the SRS unit; check the
connection. If the connection is OK, replace the SRS unit. ■
NO - Open in the dashboard wire harness; replace the dashboard wire harness.■
SRS DTC Troubleshooting: A3-1x
DTC A3-1x (‘‘x'' can be 0 thru 9 or A thru F):
SRS Unit Connector A Not Properly Installed
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC A3-1x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Check the connection between the SRS unit connector A (39P) and the SRS unit.
Is the connection OK?
YES - Go to Step 5 .
NO - Repair the poor connection and retest.
5. Turn the ignition switch to LOCK (0).
6. Do the battery terminal disconnection procedure , then wait for 3 minutes.
7. Disconnect SRS unit connector A (39P) from the SRS unit.
8. Check for bent or damaged terminals on the SRS unit.
Are any terminals bent or damaged?
YES - Replace the dashboard wire harness.■
NO - Replace the SRS unit. ■
SRS DTC Troubleshooting: A4-1x
DTC A4-1x (‘‘x'' can be 0 thru 9 or A thru F):
SRS Unit Connector B Not Properly Installed
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC A4-1x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Check the connection between the SRS unit connector B (39P) and the SRS unit.
Is the connection OK?
YES - Go to Step 5 .
NO - Repair the poor connection and retest.
5. Turn the ignition switch to LOCK (0).
6. Do the battery terminal disconnection procedure , then wait for 3 minutes.
7. Disconnect SRS unit connector B (39P) from the SRS unit.
8. Check for bent or damaged terminals on the SRS unit.
Are any terminals bent or damaged?
YES - Replace the floor wire harness.■
NO - Replace the SRS unit. ■
SRS DTC Troubleshooting: Ex-11
DTC Ex-11 (''x'' can be 0 thru 9 or A thru F):
Control Operation Recorded
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC Ex-11 indicated?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
How to Troubleshoot the VSA System
System Indicator
This system has four indicators:
ABS indicator (A)
Brake system indicator (B)
VSA indicator (C)
VSA activation indicator (D)
When the system is OK, each indicator comes on for about 2 seconds after turning the ignition switch to ON (II), then
goes off.
When the system detects a problem, a DTC will be set and, depending upon the failure, the VSA modulator-control unit
will determine which indicator(s) will be turned on. If the problem goes away (system returns to normal), the indicator(s)
will be controlled in the following way depending upon the DTC that was set:
The indicator(s) will come on and stay on when the ignition switch is ON (II).
The indicator(s) will automatically go off.
The indicator(s) will go off after the vehicle is driven.
ABS Indicator
The ABS indicator comes on when the ABS function is lost. The brakes still work like a conventional system.
VSA Indicator
The VSA indicator comes on when the VSA function is lost.
Self-diagnosis
Self-diagnosis can be classified into two categories:
-Initial diagnosis: Done right after the ignition switch is turned to ON (II) and until the ABS and VSA indicators go
off.
-Regular diagnosis: Done right after the initial diagnosis until the ignition switch is turned to LOCK (0).
When the system detects a problem, the VSA modulator-control unit shifts to fail-safe mode.
Kickback
The pump motor operates when the VSA modulator-control unit is functioning, and the fluid in the reservoir is forced out to
the master cylinder, causing kickback at the brake pedal.
Pump Motor
The pump motor operates when the VSA modulator-control unit is functioning.
The VSA modulator-control unit checks the pump motor operation one time after completing initial diagnosis during
regular diagnosis when the vehicle is driven over 15 km/h (10 mph).
Intermittent Failures
The term ‘‘intermittent failure'' means a system may have had a failure, but it checks OK now. If the indicator(s) of the
system does not come on, check for loose connectors or poor contacts in the terminals related to the circuit that you are
troubleshooting.
Is there continuity?
YES - Repair short in the wires between the appropriate wheel speed sensor and the VSA modulator-control
unit.■
NO - Go to Step 9 .
9. Check for continuity between the appropriate VSA modulator-control unit 36P connector terminal and the wheel
speed sensor 2P connector terminal.
DTC VSA Modulator-control Unit 36P Appropriate Wheel Speed Sensor
Connector Terminal 2P Connector Terminal
11-13 No. 23 Right-front
13-13 No. 19 Left-front
15-13 No. 18 Right-rear
17-13 No. 21 Left-rear
Is there continuity?
YES - Go to Step 10 .
NO - Repair open in the wire between the appropriate wheel speed sensor and the VSA modulator-control
unit.■
10. Check for continuity between the appropriate VSA modulator-control unit 36P connector terminal and the wheel
speed sensor 2P connector terminal.
DTC VSA Modulator-control Unit 36P Appropriate Wheel Speed Sensor
Connector Terminal 2P Connector Terminal
11-13 No. 10 Right-front
13-13 No. 6 Left-front
15-13 No. 4 Right-rear
17-13 No. 8 Left-rear
Is there continuity?
YES - Go to Step 11 .
NO - Repair open in the wire between the appropriate wheel speed sensor and the VSA modulator-control
unit.■
11. Check for continuity between the appropriate VSA modulator-control unit 36P connector terminal and the wheel
speed sensor 2P connector terminal (see table).
DTC VSA Modulator-control Unit 36P Connector Terminal
11-13 No. 23 No. 10
13-13 No. 19 No. 6
15-13 No. 18 No. 4
17-13 No. 21 No. 8
Is there continuity?
YES - Repair short to body ground in the wire between the appropriate wheel speed sensor and the VSA
modulator-control unit.■
NO - Go to Step 12 .
12. Turn the ignition switch to ON (II).
13. Measure the voltage between body ground and the appropriate VSA modulator-control unit 36P connector terminal
(see table).
DTC VSA Modulator-control Unit 36P Connector Terminal
11-13 No. 23 No. 10
13-13 No. 19 No. 6
15-13 No. 18 No. 4
17-13 No. 21 No. 8
Is there continuity?
YES - Repair short in the wires between the appropriate wheel speed sensor and the VSA modulator-control
unit.■
NO - Go to Step 8 .
8. Reconnect the VSA modulator-control unit 36P connector.
9. Update the VSA modulator-control unit if it does not have the latest software. If the unit already has the latest
software, substitute a known-good VSA modulator-control unit.
10. Test-drive the vehicle. Drive the vehicle at 20 km/h (13 mph) or more, and go a distance of 100 m (328 ft) or more.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
11. Check for DTCs with the HDS.
Is DTC 12-12, 14-12, 16-12, and/or 18-12 indicated?
YES - Check for loose terminals in the VSA modulator-control unit 36P connector. If the VSA modulator-control
unit was updated, substitute a known-good VSA modulator-control unit, then retest. If the VSA modulator-
control unit was substituted, go to Step 1 .
NO - If the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control
unit was substituted, replace the original VSA modulator-control unit. If any other DTCs are indicated, go
to the indicated DTCs troubleshooting.■
VSA DTC Troubleshooting: 12-21, 14-21, 16-21, 18-21
DTC 12-21:
Right-front Wheel Speed Sensor Installation Error
DTC 14-21:
Left-front Wheel Speed Sensor Installation Error
DTC 16-21:
Right-rear Wheel Speed Sensor Installation Error
DTC 18-21:
Left-rear Wheel Speed Sensor Installation Error
1. Test-drive the vehicle. Drive the vehicle at 10 km/h (7 mph) or more.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
2. Check the RIGHT-FRONT, LEFT-FRONT, RIGHT-REAR, LEFT-REAR WHEEL SPEED in the VSA DATA LIST with
the HDS.
Are all four values the same?
YES - Intermittent failure, the system is OK at this time. Check for loose terminals between the wheel speed
sensor 2P connector and the VSA modulator-control unit 36P connector. Refer to intermittent failures
troubleshooting. ■
NO - Go to Step 3 .
3. Turn the ignition switch to LOCK (0).
4. Check that the appropriate wheel speed sensor is properly mounted.
DTC Appropriate Wheel Speed Sensor
12-21 Right-front
14-21 Left-front
16-21 Right-rear
18-21 Left-rear
9. Check for continuity between the VSA modulator-control unit 36P connector terminal and the steering angle sensor
5P connector terminal individually.
Sign VSA Modulator-control Unit 36P Steering Angle Sensor 5P
Connector Terminal Connector Terminal
SVCC No. 9 No. 5
STR-A No. 11 No. 2
STR-D No. 26 No. 3
STR-B No. 27 No. 4
SGND No. 34 No. 1
Is there continuity?
YES - Go to Step 10 .
NO - Repair open in the wire between the steering angle sensor and the VSA modulator-control unit.■
10. Substitute a known-good steering angle sensor.
11. Reconnect all connectors.
12. Turn the ignition switch to ON (II).
13. Clear the DTC with the HDS.
14. Turn the ignition switch to LOCK (0), then turn it to ON (II) again.
15. Check for DTCs with the HDS.
Is DTC 27-11 or 27-26 indicated?
YES - Go to Step 16 .
NO - Replace the original steering angle sensor. ■
16. Update the VSA modulator-control unit if it does not have the latest software. If the unit already has the latest
software, substitute a known-good VSA modulator-control unit.
17. Turn the ignition switch to LOCK (0), then turn it to ON (II) again.
18. Check for DTCs with the HDS.
Is DTC 27-11 or 27-26 indicated?
YES - Check for loose terminals in the VSA modulator-control unit 36P connector. If the VSA modulator-control
unit was updated, substitute a known-good VSA modulator-control unit, then retest. If the VSA modulator-
control unit was substituted, go to Step 1 .
NO - If the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control
unit was substituted, replace the original VSA modulator-control unit. If any other DTCs are indicated, go
to the indicated DTCs troubleshooting.■
VSA DTC Troubleshooting: 27-21, 27-22
DTC 27-21:
Steering Angle Sensor Stuck Neutral Position
DTC 27-22:
Steering Angle Sensor Stuck Offset Position
1. Turn the ignition switch to ON (II).
2. Turn the steering wheel left and right 90 degrees or more. Check the STEERING ANGLE in the VSA DATA LIST
with the HDS.
Is there +90 ° or more, and −90 ° or less?
YES - Intermittent failure, the system is OK at this time. Check for loose terminals between the steering angle
sensor 5P connector and the VSA modulator-control unit 36P connector. Refer to intermittent failures
troubleshooting. ■
NO - Go to Step 3 .
3. Turn the ignition switch to LOCK (0).
4. Disconnect the steering angle sensor 5P connector.
5. Disconnect the VSA modulator-control unit 36P connector.
6. Turn the ignition switch to ON (II).
7. Measure the voltage between body ground and steering angle sensor 5P connector terminals No. 2, No. 3, and No.
4 individually.
Is there 0.1 V or more?
YES - Repair short to power in the wire between the steering angle sensor and the VSA modulator-control unit.■
NO - Replace the steering angle sensor. ■
VSA DTC Troubleshooting: 27-23
DTC 27-23:
Steering Angle Sensor Counter Malfunction
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Start the engine.
5. Turn the steering wheel from lock-to-lock several times.
6. Check for DTCs with the HDS.
Is DTC 27-23 indicated?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. Check for loose terminals between the steering angle
sensor 5P connector and the VSA modulator-control unit 36P connector. Refer to intermittent failures
troubleshooting. ■
7. Turn the ignition switch to LOCK (0).
8. Disconnect the steering angle sensor 5P connector.
9. Disconnect the VSA modulator-control unit 36P connector.
10. Check for continuity between steering angle sensor 5P connector terminals No. 2 and No. 4.
Is there continuity?
YES - Repair short in the wires between the steering angle sensor and the VSA modulator-control unit.■
NO - Go to Step 11 .
11. Check for continuity between steering angle sensor 5P connector terminals No. 5 and No. 2, and No. 5 and No. 4
individually.
Is there continuity?
YES - Repair short in the wires between the steering angle sensor and the VSA modulator-control unit.■
NO - Go to Step 12 .
12. Check for continuity between steering angle sensor 5P connector terminals No. 1 and No. 2, and No. 1 and No. 4
individually.
Is there continuity?
YES - Repair short in the wires between the steering angle sensor and the VSA modulator-control unit.■
NO - Replace the steering angle sensor. ■
VSA DTC Troubleshooting: 27-24
DTC 27-24:
Steering Angle Sensor Exchange Malfunction
1. Turn the ignition switch to ON (II).
2. Turn the steering wheel one turn. Check the STEERING ANGLE in the VSA DATA LIST with the HDS.
Is there about 288−432 °?
YES - Intermittent failure, the system is OK at this time.■
NO - Replace the steering angle sensor. ■
VSA DTC Troubleshooting: 28-22
DTC 28-22:
Longitudinal Acceleration Sensor Stuck
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Test-drive the vehicle. Drive the vehicle at 10 km/h (7 mph) or more.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
4. Check for DTCs with the HDS.
Is DTC 28-22 indicated?
YES - Go to Step 5 .
NO - If any other DTCs are indicated, go to the indicated DTCs troubleshooting. If DTCs are not indicated,
intermittent failure, the system is OK at this time.■
5. Test-drive the vehicle. Check the LONGITUDINAL ACCELERATION SENSOR in the VSA DATA LIST with the HDS
while driving in corners.
Does the indicated value change?
YES - Intermittent failure, the system is OK at this time.■
NO - Replace the yaw rate-lateral/longitudinal acceleration sensor. ■
VSA DTC Troubleshooting: 31-xx, 32-xx, 33-xx, 34-xx, 35-xx, 36-xx, 37-xx, 38-xx
DTC 31-xx * :
ABS Right-front Inlet Solenoid Valve Malfunction
DTC 32-xx * :
ABS Right-front Outlet Solenoid Valve Malfunction
DTC 33-xx * :
ABS Left-front Inlet Solenoid Valve Malfunction
DTC 34-xx * :
ABS Left-front Outlet Solenoid Valve Malfunction
DTC 35-xx * :
ABS Right-rear Inlet Solenoid Valve Malfunction
DTC 36-xx * :
ABS Right-rear Outlet Solenoid Valve Malfunction
DTC 37-xx * :
ABS Left-rear Inlet Solenoid Valve Malfunction
DTC 38-xx * :
ABS Left-rear Outlet Solenoid Valve Malfunction
*: Any two-character subcode (see table).
10. Measure the voltage between VSA modulator-control unit 36P connector terminal No. 13 and body ground.
Is there battery voltage?
YES - Go to Step 11 .
NO - Repair open in the wire between the No. 58 (30 A) fuse in the under-hood fuse/relay box and the VSA
modulator-control unit.■
11. Reconnect the VSA modulator-control unit 36P connector.
12. Update the VSA modulator-control unit if it does not have the latest software. If the unit already has the latest
software, substitute a known-good VSA modulator-control unit.
13. Turn the ignition switch to LOCK (0), then turn it to ON (II) again.
14. Check for DTCs with the HDS.
Is DTC 51-12 indicated?
YES - Check for loose terminals in the VSA modulator-control unit 36P connector. If the VSA modulator-control
unit was updated, substitute a known-good VSA modulator-control unit, then retest. If the VSA modulator-
control unit was substituted, go to Step 1 .
NO - If the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control
unit was substituted, replace the original VSA modulator-control unit. If any other DTCs are indicated, go
to the indicated DTCs troubleshooting.■
VSA DTC Troubleshooting: 52-12
DTC 52-12:
Motor Stuck OFF
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0), then turn it to ON (II) again.
4. Operate any one of the four solenoids, as listed, in the VSA FUNCTION TEST five times with the HDS.
-LFT FT SOLENOID
-RT FT SOLENOID
-LFT REAR SOLENOID
-RT REAR SOLENOID
10. Measure the voltage between steering angle sensor 5P connector terminal No. 5 and body ground.
Is there 0.1 V or more?
YES - Repair short to power in the wire between the steering angle sensor and the VSA modulator-control unit.■
NO - Go to Step 11 .
11. Turn the ignition switch to LOCK (0).
12. Check for continuity between VSA modulator-control unit 36P connector terminal No. 9 and steering angle sensor
5P connector terminal No. 5.
Is there continuity?
YES - Go to Step 13 .
NO - Repair open in the wire between the steering angle sensor and the VSA modulator-control unit.■
13. Reconnect all connectors.
14. Update the VSA modulator-control unit if it does not have the latest software. If the unit already has the latest
software, substitute a known-good VSA modulator-control unit.
15. Turn the ignition switch to LOCK (0), then turn it to ON (II) again.
16. Check for DTCs with the HDS.
Is DTC 66-12 indicated?
YES - Check for loose terminals in the VSA modulator-control unit 36P connector. If the VSA modulator-control
unit was updated, substitute a known-good VSA modulator-control unit, then retest. If the VSA modulator-
control unit was substituted, go to Step 1 .
NO - If the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control
unit was substituted, replace the original VSA modulator-control unit. If any other DTCs are indicated, go
to the indicated DTCs troubleshooting.■
VSA DTC Troubleshooting: 66-15
DTC 66-15:
Pressure Sensor (Inside of VSA Modulator-control Unit) Malfunction
NOTE: Brake fluid leaks from brake system can cause this DTC. Check for brake fluid leaks first.
1. Test-drive the vehicle.
2. Turn the ignition switch to LOCK (0).
3. Raise the vehicle, and support it with safety stands in the proper locations.
4. Turn all four wheels by hand.
Is there brake drag?
YES - Repair the brake drag.■
NO - Go to Step 5 .
5. Turn the ignition switch to ON (II).
6. Check the BRAKE PRESS in the VSA DATA LIST with the HDS while moving the brake pedal.
Does the indicated value change?
YES - Intermittent failure, the system is OK at this time.■
NO - Go to Step 7 .
7. Update the VSA modulator-control unit if it does not have the latest software. If the unit already has the latest
software, substitute a known-good VSA modulator-control unit.
8. Turn the ignition switch to LOCK (0), then turn it to ON (II) again.
9. Check for DTCs with the HDS.
Is DTC 66-15 indicated?
YES - Check for loose terminals in the VSA modulator-control unit 36P connector. If the VSA modulator-control
unit was updated, substitute a known-good VSA modulator-control unit, then retest. If the VSA modulator-
control unit was substituted, go to Step 1 .
NO - If the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control
unit was substituted, replace the original VSA modulator-control unit. If any other DTCs are indicated, go
to the indicated DTCs troubleshooting.■
VSA DTC Troubleshooting: 68-21
DTC 68-21:
Brake Pedal Position Switch Stuck OFF
1. Turn the ignition switch to ON (II).
2. Check the BRAKE PRESS in the VSA DATA LIST with the HDS. Do not press the brake pedal.
Is there 10 MPa or less?
YES - Go to Step 3 .
NO - Check for brake drag or a misadjusted brake pedal position switch. If they are normal, go to Step 20 .
3. Check the BRAKE SWITCH in the VSA DATA LIST with the HDS while moving the brake pedal.
Does it indicate ON when the pedal is pressed, and OFF when the pedal is released?
YES - Intermittent failure, the system is OK at this time. Check for loose terminals between the brake pedal
position switch 4P connector, ECM/PCM connector A (49P), and the VSA modulator-control unit 36P
connector. Refer to intermittent failures troubleshooting. ■
NO - Go to Step 4 .
4. Turn the ignition switch to LOCK (0).
5. Disconnect the brake pedal position switch 4P connector.
6. Connect brake pedal position switch 4P connector terminals No. 1 and No. 2 with a jumper wire.
7. Turn the ignition switch to ON (II).
8. Check the BRAKE SWITCH in the VSA DATA LIST with the HDS.
Does it indicate ON?
YES - Check the brake pedal position switch adjustment. If it is OK, replace the brake pedal position switch .■
NO - Go to Step 9 .
9. Disconnect the jumper wire.
10. Turn the ignition switch to LOCK (0).
11. Check the No. 24 (15 A) fuse in the under-hood fuse/relay box.
Is the fuse blown?
YES - Go to Step 12 .
NO - Reinstall the checked fuse, then go to Step 16 .
12. Check for continuity between brake pedal position switch 4P connector terminal No. 1 and body ground.
Is there continuity?
YES - Repair short to body ground in the wire between the No. 24 (15 A) fuse in the under-hood fuse/relay box
and the brake pedal position switch.■
NO - Go to Step 13 .
13. Short the SCS line with the HDS.
14. Disconnect ECM/PCM connector A (49P).
15. Check for continuity between brake pedal position switch 4P connector terminal No. 2 and body ground.
Is there continuity?
YES - Repair short to body ground in the wire between the brake pedal position switch and the ECM/PCM.■
NO - Install a new No. 24 (15 A) fuse in the under-hood fuse/relay box, then go to Step 18 .
16. Short the SCS line with the HDS.
17. Disconnect ECM/PCM connector A (49P).
18. Measure the voltage between brake pedal position switch 4P connector terminal No. 1 and body ground.
Is there battery voltage?
YES - Go to Step 19 .
NO - Repair open in the wire between the No. 24 (15 A) fuse in the under-hood fuse/relay box and the brake
pedal position switch.■
19. Check for continuity between brake pedal position switch 4P connector terminal No. 2 and ECM/PCM connector A
(49P) terminal No. 42.
Is there continuity?
YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
go to Step 1 and recheck. If the ECM/PCM was updated and DTCs are not indicated, troubleshooting is
complete. If the ECM/PCM was substituted and DTCs are not indicated, replace the original ECM/PCM.
NO - Repair open in the wire between the ECM/PCM and the brake pedal position switch.■
20. Update the VSA modulator-control unit if it does not have the latest software. If the unit already has the latest
software, substitute a known-good VSA modulator-control unit.
21. Test-drive the vehicle. Drive the vehicle at 10 km/h (7 mph) or more.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
22. Check for DTCs with the HDS.
Is DTC 68-21 indicated?
YES - Check for loose terminals in the VSA modulator-control unit 36P connector. If the VSA modulator-control
unit was updated, substitute a known-good VSA modulator-control unit, then retest. If the VSA modulator-
control unit was substituted, go to Step 1 .
NO - If the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control
unit was substituted, replace the original VSA modulator-control unit. If any other DTCs are indicated, go
to the indicated DTCs troubleshooting.■
VSA DTC Troubleshooting: 68-22
DTC 68-22:
Brake Pedal Position Switch Stuck ON
1. Turn the ignition switch to ON (II).
2. Check the BRAKE PRESS in the VSA DATA LIST with the HDS. Do not press the brake pedal.
Is there 10 MPa or more?
YES - Check the brake pedal height. If the brake pedal height is OK, go to Step 10 .
NO - Go to Step 3 .
3. Check the BRAKE SWITCH in the VSA DATA LIST with the HDS while moving the brake pedal.
Does it indicate ON when the pedal is pressed, and OFF when the pedal is released?
YES - Intermittent failure, the system is OK at this time.■
NO - Go to Step 4 .
4. Check the BRAKE SWITCH in the VSA DATA LIST with the HDS, and disconnect the brake pedal position switch
4P connector.
Does the indicator change from ON to OFF?
YES - Replace the brake pedal position switch. ■
NO - Go to Step 5 .
5. Turn the ignition switch to LOCK (0).
6. Short the SCS line with the HDS.
7. Disconnect ECM/PCM connector A (49P).
8. Turn the ignition switch to ON (II).
9. Measure the voltage between brake pedal position switch 4P connector terminal No. 2 and body ground.
Is there 0.1 V or more?
YES - Repair short to power in the wire between the ECM/PCM and the brake pedal position switch.■
NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
go to Step 1 and recheck. If the ECM/PCM was updated and DTCs are not indicated, troubleshooting is
complete. If the ECM/PCM was substituted and DTCs are not indicated, replace the original ECM/PCM.
10. Update the VSA modulator-control unit if it does not have the latest software. If the unit already has the latest
software, substitute a known-good VSA modulator-control unit.
11. Turn the ignition switch to LOCK (0), then turn it to ON (II) again.
12. Check for DTCs with the HDS.
Is DTC 68-22 indicated?
YES - Check for loose terminals in the VSA modulator-control unit 36P connector. If the VSA modulator-control
unit was updated, substitute a known-good VSA modulator-control unit, then retest. If the VSA modulator-
control unit was substituted, go to Step 1 .
NO - If the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control
unit was substituted, replace the original VSA modulator-control unit. If any other DTCs are indicated, go
to the indicated DTCs troubleshooting.■
VSA DTC Troubleshooting: 71-21, 71-22, 71-23, 71-24, 71-25, 71-26, 71-27, 71-28, 71-29, 71-2A, 71-2B, 71-2C
DTC 71-21:
Right-front or Left-rear Different Diameter Tyre Malfunction
DTC 71-22:
Left-front or Right-rear Different Diameter Tyre Malfunction
DTC 71-23:
Right-front and Right-rear Different Diameter Tyre Malfunction
DTC 71-24:
Left-front and Left-rear Different Diameter Tyre Malfunction
DTC 71-25:
Right-front and Left-front Different Diameter Tyre Malfunction
DTC 71-26:
Right-rear and Left-rear Different Diameter Tyre Malfunction
DTC 71-27:
Right-front or Left-rear Different Diameter Tyre Malfunction
DTC 71-28:
Left-front or Right-rear Different Diameter Tyre Malfunction
DTC 71-29:
Right-front and Right-rear Different Diameter Tyre Malfunction
DTC 71-2A:
Left-front and Left-rear Different Diameter Tyre Malfunction
DTC 71-2B:
Right-front and Left-front Different Diameter Tyre Malfunction
DTC 71-2C:
Right-rear and Left-rear Different Diameter Tyre Malfunction
NOTE: The DTC will be indicated when the vehicle has a different diameter tyre(s) compared to the other tyres.
DTC Sectional Note
71-21 Right-front or left-rear
71-22 Left-front or right-rear
71-23 Right-front and right-rear
71-24 Left-front and left-rear
71-25 Right-front and left-front
71-26 Right-rear and left-rear
71-27 Right-front or left-rear
71-28 Left-front or right-rear
71-29 Right-front and right-rear
71-2A Left-front and left-rear
71-2B Right-front and left-front
71-2C Right-rear and left-rear
1. Check the tyres for proper inflation and the correct size.
2. Turn the ignition switch to ON (II).
3. Clear the DTC with the HDS.
4. Test-drive the vehicle.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
5. Check for DTCs with the HDS.
Is DTC 71-21, 71-22, 71-23, 71-24, 71-25, 71-26, 71-27, 71-28, 71-29, 71-2A, 71-2B, or 71-2C indicated?
YES - Replace tyres as needed until all their diameters match.■
NO - Intermittent failure, the system is OK at this time.■
VSA DTC Troubleshooting: 81-07
DTC 81-07:
Central Processing Unit (CPU) Internal Circuit Malfunction
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0), then turn it to ON (II) again.
4. Check for DTCs with the HDS.
Is DTC 81-07 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Turn the ignition switch to LOCK (0).
6. Disconnect the steering angle sensor 5P connector.
7. Disconnect the VSA modulator-control unit 36P connector.
8. Turn the ignition switch to ON (II).
9. Measure the voltage between steering angle sensor 5P connector terminal No. 5 and body ground.
Is there 0.1 V or more?
YES - Repair short to power in the wire between the steering angle sensor and the VSA modulator-control unit.■
NO - Go to Step 10 .
10. Turn the ignition switch to LOCK (0).
11. Reconnect all connectors.
12. Update the VSA modulator-control unit if it does not have the latest software. If the unit already has the latest
software substitute a known-good VSA modulator-control unit.
13. Turn the ignition switch to LOCK (0), then turn it to ON (II) again.
14. Check for DTCs with the HDS.
Is DTC 81-07 indicated?
YES - Check for loose terminals in the VSA modulator-control unit 36P connector. If the VSA modulator-control
unit was updated, substitute a known-good VSA modulator-control unit, then retest. If the VSA modulator-
control unit was substituted, go to Step 1 .
NO - If the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control
unit was substituted, replace the original VSA modulator-control unit. If any other DTCs are indicated, go
to the indicated DTCs troubleshooting.■
VSA DTC Troubleshooting: 81-11, 81-52, 81-54, 81-56, 81-58
DTC 81-11:
Central Processing Unit (CPU) Internal Circuit Malfunction
DTC 81-52:
Central Processing Unit (CPU) Internal Circuit Malfunction
DTC 81-54:
Central Processing Unit (CPU) Internal Circuit Malfunction
DTC 81-56:
Central Processing Unit (CPU) Internal Circuit Malfunction
DTC 81-58:
Central Processing Unit (CPU) Internal Circuit Malfunction
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Test-drive the vehicle.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
4. Check for DTCs with the HDS.
Is DTC 81-11, 81-52, 81-54, 81-56, or 81-58 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Update the VSA modulator-control unit if it does not have the latest software. If the unit already has the latest
software, substitute a known-good VSA modulator-control unit.
6. Test-drive the vehicle.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
7. Check for DTCs with the HDS.
Is DTC 81-11, 81-52, 81-54, 81-56, or 81-58 indicated?
YES - Check for loose terminals in the VSA modulator-control unit 36P connector. If the VSA modulator-control
unit was updated, substitute a known-good VSA modulator-control unit, then retest. If the VSA modulator-
control unit was substituted, go to Step 1 .
NO - If the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control
unit was substituted, replace the original VSA modulator-control unit. If any other DTCs are indicated, go
to the indicated DTCs troubleshooting.■
VSA DTC Troubleshooting: 81-3D, 81-3E, 81-59
DTC 81-3D:
Central Processing Unit (CPU) Internal Circuit Malfunction
DTC 81-3E:
Central Processing Unit (CPU) Internal Circuit Malfunction
DTC 81-59:
Central Processing Unit (CPU) Internal Circuit Malfunction
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Start the engine.
4. Turn the steering wheel from lock-to-lock several times.
5. Check for DTCs with the HDS.
Is DTC 81-3D, 81-3E, or 81-59 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Update the VSA modulator-control unit if it does not have the latest software. If the unit already has the latest
software, substitute a known-good VSA modulator-control unit.
7. Start the engine.
8. Turn the steering wheel from lock-to-lock several times.
9. Check for DTCs with the HDS.
Is DTC 81-3D, 81-3E, or 81-59 indicated?
YES - Check for loose terminals in the VSA modulator-control unit 36P connector. If the VSA modulator-control
unit was updated, substitute a known-good VSA modulator-control unit, then retest. If the VSA modulator-
control unit was substituted, go to Step 1 .
NO - If the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control
unit was substituted, replace the original VSA modulator-control unit. If any other DTCs are indicated, go
to the indicated DTCs troubleshooting.■
VSA DTC Troubleshooting: 81-51, 81-53, 81-55, 81-57
DTC 81-51:
Central Processing Unit (CPU) Internal Circuit Malfunction
DTC 81-53:
Central Processing Unit (CPU) Internal Circuit Malfunction
DTC 81-55:
Central Processing Unit (CPU) Internal Circuit Malfunction
DTC 81-57:
Central Processing Unit (CPU) Internal Circuit Malfunction
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Test-drive the vehicle.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
4. Check for DTCs with the HDS.
Is DTC 81-51, 81-53, 81-55, or 81-57 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Turn the ignition switch to LOCK (0).
6. Disconnect the VSA modulator-control unit 36P connector.
7. Turn the ignition switch to ON (II).
8. Measure the voltage between body ground and the appropriate VSA modulator-control unit 36P connector terminals
(see table).
DTC VSA Modulator-control Unit 36P Connector Terminal
81-51 No. 23
81-53 No. 19
81-55 No. 18
81-57 No. 21
Is there continuity?
YES - Go to Step 10 .
NO - Repair open in the wire between the ECM/PCM and the VSA modulator-control unit.■
10. Reconnect all connectors.
11. Update the VSA modulator-control unit if it does not have the latest software. If the unit already has the latest
software, substitute a known-good VSA modulator-control unit.
12. Turn the ignition switch to LOCK (0), then turn it to ON (II) again.
13. Check for DTCs with the HDS.
Is DTC 86-01 indicated?
YES - Check for loose terminals in the VSA modulator-control unit 36P connector. If the VSA modulator-control
unit was updated, substitute a known-good VSA modulator-control unit, then retest. If the VSA modulator-
control unit was substituted, go to Step 1 .
NO - If the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control
unit was substituted, replace the original VSA modulator-control unit. If any other DTCs are indicated, go
to the indicated DTCs troubleshooting.■
VSA DTC Troubleshooting: 86-11, 86-21, 86-22, 86-23, 86-24, 86-25, 84-41
DTC 86-11:
F-CAN Communication with ECM/PCM Malfunction
DTC 86-21:
F-CAN Communication with Engine Malfunction
DTC 86-22:
F-CAN Communication with Engine Malfunction
DTC 86-23:
F-CAN Communication with Engine Malfunction
DTC 86-24:
F-CAN Communication with Engine Malfunction
DTC 86-25:
F-CAN Communication with Engine Malfunction
DTC 86-41:
F-CAN Communication with EAT/TCM Malfunction
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Test-drive the vehicle. Drive the vehicle at 10 km/h (7 mph) or more.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
4. Check for DTCs with the HDS.
Is DTC 86-11, 86-21, 86-22, 86-23, 86-24, 86-25, and/or 86-41 indicated?
YES - If the DTC 86-01 is indicated at the same time, do the DTC 86-01 troubleshooting. If the DTC 86-01 is not
indicated, go to Step 5 .
NO - If any other DTCs are indicated, go to the indicated DTCs troubleshooting. If DTCs are not indicated,
intermittent failure, the system is OK at this time. Check for loose terminals between ECM/PCM
connector A (49P) and the VSA modulator-control unit 36P connector. Refer to intermittent failures
troubleshooting. ■
5. Turn the ignition switch to LOCK (0).
6. Short the SCS line with the HDS.
7. Disconnect ECM/PCM connector A (49P).
8. Disconnect the VSA modulator-control unit 36P connector.
9. Check for continuity between the VSA modulator-control unit 36P connector terminal and ECM/PCM connector A
(49P) terminal (see table).
Sign VSA Modulator-control Unit 36P ECM/PCM Connector A (49P)
Connector Terminal Terminal
CAN-L No. 1 No. 4
CAN-H No. 14 No. 3
Is there continuity?
YES - Go to Step 10 .
NO - Repair open in the wire between the ECM/PCM and the VSA modulator-control unit.■
10. Reconnect all connectors.
11. Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM.
12. Clear the DTC with the HDS.
13. Test-drive the vehicle. Drive the vehicle at 10 km/h (7 mph) or more.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
14. Check for DTCs with the HDS.
Is DTC 86-11, 86-21, 86-22, 86-23, 86-24, 86-25, and/or 86-41 indicated?
YES - Go to Step 15 .
NO - If the ECM/PCM was updated, troubleshooting is complete. If the ECM/PCM was substituted, replace the
original ECM/PCM. ■
15. Update the VSA modulator-control unit if it does not have the latest software. If the unit already has the latest
software, substitute a known-good VSA modulator-control unit.
16. Test-drive the vehicle. Drive the vehicle at 10 km/h (7 mph) or more.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
17. Check for DTCs with the HDS.
Is DTC 86-11, 86-21, 86-22, 86-23, 86-24, 86-25, and/or 86-41 indicated?
YES - Check for loose terminals in the VSA modulator-control unit 36P connector. If the VSA modulator-control
unit was updated, substitute a known-good VSA modulator-control unit, then retest. If the VSA modulator-
control unit was substituted, go to Step 1 .
NO - If the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control
unit was substituted, replace the original VSA modulator-control unit. If any other DTCs are indicated, go
to the indicated DTCs troubleshooting.■
VSA DTC Troubleshooting: 86-31
DTC 86-31:
F-CAN Communication with Gauge Control Module Malfunction
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0), then turn it to ON (II) again.
4. Check for DTCs with the HDS.
Is DTC 86-31 indicated?
YES - If the DTC 86-01 is indicated at the same time, do the DTC 86-01 troubleshooting. If the DTC 86-01 is not
indicated, go to Step 5 .
NO - If any other DTCs are indicated, go to the indicated DTCs troubleshooting. If DTCs are not indicated,
intermittent failure, the system is OK at this time. Check for loose terminals between the gauge control
module 32P connector and the VSA modulator-control unit 36P connector. Refer to intermittent failures
troubleshooting. ■
5. Turn the ignition switch to ON (II).
Do the gauge indicators come on?
YES - Go to Step 6 .
NO - Do the gauge control module troubleshooting. ■
6. Turn the ignition switch to LOCK (0).
7. Disconnect the gauge control module 32P connector.
8. Disconnect the VSA modulator-control unit 36P connector.
9. Check for continuity between the VSA modulator-control unit 36P connector terminal and gauge control module
32P connector terminal (see table).
Sign VSA Modulator-control Unit 36P Gauge Control Module 32P
Connector Terminal Connector Terminal
CAN-L No. 1 No. 29
CAN-H No. 14 No. 30
Is there continuity?
YES - Check for loose terminals in the gauge control module 32P connector. If necessary, substitute a known-
good gauge control module, then go to Step 1 and recheck. If no DTCs are indicated, replace the original
gauge control module. If DTC 86-31 resets, go to Step 10 .
NO - Repair open in the wire between the gauge control module and the VSA modulator-control unit.■
10. Reconnect all connectors.
11. Update the VSA modulator-control unit if it does not have the latest software. If the unit already has the latest
software, substitute a known-good VSA modulator-control unit.
12. Turn the ignition switch to LOCK (0), then turn it to ON (II) again.
13. Check for DTCs with the HDS.
Is DTC 86-31 indicated?
YES - Check for loose terminals in the VSA modulator-control unit 36P connector. If the VSA modulator-control
unit was updated, substitute a known-good VSA modulator-control unit, then retest. If the VSA modulator-
control unit was substituted, go to Step 1 .
NO - If the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control
unit was substituted, replace the original VSA modulator-control unit. If any other DTCs are indicated, go
to the indicated DTCs troubleshooting.■
VSA DTC Troubleshooting: 86-71
DTC 86-71:
F-CAN Communication with Yaw Rate-Lateral/Longitudinal Acceleration Sensor Malfunction
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Check for DTCs with the HDS.
Is DTC 86-71 indicated?
YES - If the DTC 86-01 is indicated at the same time, do the DTC 86-01 troubleshooting. If the DTC 86-01 is not
indicated, go to Step 4 .
NO - If any other DTCs are indicated, go to the indicated DTCs troubleshooting. If DTCs are not indicated,
intermittent failure, the system is OK at this time. Check for loose terminals at the yaw rate-
lateral/longitudinal acceleration sensor 5P connector and the VSA modulator-control unit 36P connector.
Refer to intermittent failures troubleshooting. ■
4. Turn the ignition switch to LOCK (0).
5. Disconnect the yaw rate-lateral/longitudinal acceleration sensor 5P connector.
6. Disconnect the VSA modulator-control unit 36P connector.
7. Check for continuity between the VSA modulator-control unit 36P connector terminal and the yaw rate-
lateral/longitudinal acceleration sensor 5P connector terminal (see table).
Sign VSA Modulator-control Unit 36P Yaw Rate-lateral/Longitudinal
Connector Terminal Acceleration Sensor 5P Connector
Terminal
CAN-L No. 1 No. 4
CAN-H No. 14 No. 3
Is there continuity?
YES - Go to Step 8 .
NO - Repair open in the wire between the yaw rate-lateral acceleration sensor and the VSA modulator-control
unit.■
8. Turn the ignition switch to ON (II).
9. Measure the voltage between yaw rate-lateral/longitudinal acceleration sensor 5P connector terminal No. 1 and
body ground.
Is there battery voltage?
YES - Go to Step 10 .
NO - Repair open in the wire between the No. 11 (7.5 A) fuse in the driver's under-dash fuse/relay box and the
yaw rate-lateral/longitudinal acceleration sensor.■
10. Turn the ignition switch to LOCK (0).
11. Reconnect the yaw rate-lateral/longitudinal acceleration sensor 5P connector.
12. Turn the ignition switch to ON (II).
13. Measure the voltage between yaw rate-lateral/longitudinal acceleration sensor 5P connector terminal No. 5 and
body ground.
Is there 0.1 V or less?
YES - Replace the yaw rate-lateral/longitudinal acceleration sensor. ■
NO - Repair open in the wire between the yaw rate-lateral/longitudinal acceleration sensor and body ground
(G503).■
VSA DTC Troubleshooting: 107-22
DTC 107-22:
Central Processing Unit (CPU) Internal Circuit Malfunction
1. Turn the ignition switch to LOCK (0) to cool the VSA modulator-control unit, and wait 1 hour or more.
2. Turn the ignition switch to ON (II).
3. Clear the DTC with the HDS.
4. Turn the ignition switch to LOCK (0), then turn it to ON (II) again.
5. Check for DTCs with the HDS.
Is DTC 107-22 indicated?
YES - Go to Step 6 .
NO - The system is OK at this time.■
6. Update the VSA modulator-control unit if it does not have the latest software. If the unit already has the latest
software, substitute a known-good VSA modulator-control unit.
7. Turn the ignition switch to LOCK (0), then turn it to ON (II) again.
8. Check for DTCs with the HDS.
Is DTC 107-22 indicated?
YES - Check for loose terminals in the VSA modulator-control unit 36P connector. If the VSA modulator-control
unit was updated, substitute a known-good VSA modulator-control unit, then retest. If the VSA modulator-
control unit was substituted, go to Step 1 .
NO - If the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control
unit was substituted, replace the original VSA modulator-control unit. If any other DTCs are indicated, go
to the indicated DTCs troubleshooting.■
VSA DTC Troubleshooting: 108-21
DTC 108-21:
Steering Angle Sensor Malfunction
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Test-drive the vehicle.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
4. Check for DTCs with the HDS.
Is DTC 108-21 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Turn the ignition switch to LOCK (0).
6. Substitute a known-good steering angle sensor.
7. Turn the ignition switch to ON (II).
8. Clear the DTC with the HDS.
9. Test-drive the vehicle.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
10. Check for DTCs with the HDS.
Is DTC 108-21 indicated?
YES - Go to Step 11 .
NO - Replace the original steering angle sensor. ■
11. Update the VSA modulator-control unit if it does not have the latest software. If the unit already has the latest
software, substitute a known-good VSA modulator-control unit.
12. Test-drive the vehicle.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
13. Check for DTCs with the HDS.
Is DTC 108-21 indicated?
YES - Check for loose terminals in the VSA modulator-control unit 36P connector. If the VSA modulator-control
unit was updated, substitute a known-good VSA modulator-control unit, then retest. If the VSA modulator-
control unit was substituted, go to Step 1 .
NO - If the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control
unit was substituted, replace the original VSA modulator-control unit. If any other DTCs are indicated, go
to the indicated DTCs troubleshooting.■
VSA DTC Troubleshooting: 116-11
DTC 116-11:
The Functional Abnormalities of i-SHIFT System
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Test-drive the vehicle.
NOTE: Drive the vehicle on a straight section of road, not a lift.
4. Check for DTCs with the HDS.
Is DTC 116-11 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for loose terminals in the VSA modulator-control
unit 36P connector. Refer to intermittent failures troubleshooting.
5. Check for i-SHIFT system DTCs with the HDS.
Are any i-SHIFT system DTCs indicated?
YES - Do the applicable troubleshooting for the i-SHIFT system, then go to Step 6 .
NO - Go to Step 9 .
6. Clear the DTC with the HDS.
7. Test-drive the vehicle.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
8. Check for DTCs with the HDS.
Is DTC 116-11 indicated?
YES - Go to Step 9 .
NO - Troubleshooting is complete.■
9. Update the VSA modulator-control unit if it does not have the latest software. If the unit already has the latest
software, substitute a known-good VSA modulator-control unit.
10. Test-drive the vehicle.
NOTE: Drive the vehicle on a straight section of road, not on a lift.
11. Check for DTCs with the HDS.
Is DTC 116-11 indicated?
YES - Check for loose terminals in the VSA modulator-control unit 36P connector. If the VSA modulator-control
unit was updated, substitute a known-good VSA modulator-control unit, then retest. If the VSA modulator-
control unit was substituted, go to Step 1 .
NO - If the VSA modulator-control unit was updated, troubleshooting is complete. If the VSA modulator-control
unit was substituted, replace the original VSA modulator-control unit. If any other DTCs are indicated, go
to the indicated DTCs troubleshooting.■
VSA DTC Troubleshooting: 121-xx, 122-xx, 123-xx, 124-xx
DTC 121-xx * :
VSA Solenoid Valve Malfunction
DTC 122-xx * :
VSA Solenoid Valve Malfunction
DTC 123-xx * :
VSA Solenoid Valve Malfunction
DTC 124-xx * :
VSA Solenoid Valve Malfunction
*: Any two-character subcode (see table).
Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note that this manual does
contain warnings and cautions against some specific service methods which could cause PERSONAL INJURY, damage a vehicle, or make it unsafe.
Please understand that these warnings cannot cover all conceivable ways in which service, whether or not recommended by Honda, might be done or of
the possible hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools,
whether or not recommended by Honda, must satisfy himself thoroughly that neither personal safety or vehicle safety will be jeopardized.
All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes
at any time without notice. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form by any means,
electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables.
HONDA MOTOR CO., LTD.
Service Publication Office
4-Plate spot
welding
Detail
Sketch 2-Plate spot
welding
C DetailF
Sketch
Fillet welding
Butt welding
RIGHT FRONT
IMPACT SENSOR
FRONT PASSENGER'S
AIRBAG
Reconnection
NOTE: Some system store data in memory is lost when the battery is disconnected.
A
Do the following procedures to restore the systems back to normal
operation.
1. Clean the battery terminals.
2. Test the battery; refer to the appropriate Fit/Jazz Shop Manual.
3. Reconnect the positive cable (A) to the battery (B) first, then reconnect the negative cable (C) to the battery.
B
NOTE: Always connect the positive cable to the battery first.
4. Apply multipurpose grease to the terminals to prevent corrosion.
5. Install the terminal cover (D).
2.9−5.9 N·m
D (0.3−0.6 kgf·m, 2.1−4.4 lbf·ft)
6. Enter the anti-theft code(s) for the audio system and/or the navigation system (if equipped).
7. Enter the audio presets (if applicable).
8. Set the clock (for vehicles without navigation).
B
Identification Number Locations
NOTE: The illustration shows the RHD model, LHD model is similar.
Front Left doorjamb
Vehicle Identification Vehicle ldentification Number
Number (VIN) (Except KP model)(VIN) (KP model)
Vehicle Identification
Number (VIN)
C
A
A
B
C
Body Specifications/Wheel Alignment
Unit: mm (in.)
Unit: mm (in.)
Round
FRONT FENDER end
6 x 1.0 mm [SECTION: ZZ]
18 N·m 8 x 1.25 mm
(1.8 kgf·m, 13 lbf·ft) 22 N·m
(2.2 kgf·m, 16 lbf·ft)
8 x 1.25 mm
22 N·m
(2.2 kgf·m, 16 lbf·ft) 10 x 1.25 mm
38 N·m
(3.9 kgf·m, 28 lbf·ft)
BATTERY BASE
HOOD
UPPER REAR
HOOD HINGE DOOR HINGE
6 x 1.0 mm
18 N·m REAR BUMPER
(1.8 kgf·m, EXTENSION
13 lbf·ft) (KQ model)
REAR DOOR
6 x 1.0 mm
9.8 N·m
(1.0 kgf·m, 7.2 lbf·ft) UPPER FRONT
DOOR HINGE
(A)
8 x 1.25 mm
LOWER REAR 29 N·m
DOOR HINGE (3.0 kgf·m,
22 lbf·ft)
FRONT FENDER (B) 8 x 1.25 mm
29 N·m
(3.0 kgf·m, 22 lbf·ft)
FRONT DOOR
8 x 1.25 mm
LOWER FRONT 29 N·m (3.0 kgf·m, 22 lbf·ft)
FRONT BUMPER DOOR HINGE
BEAM
(B) 8 x 1.25 mm
6 x 1.0 mm 8 x 1.25 mm 29 N·m (3.0 kgf·m, 22 lbf·ft)
9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
22 N·m
(2.2 kgf·m, 16 lbf·ft)
Front Body Construction
NOTE: Confirm that the sold as repair parts, refer to the appropriate Parts Catalog.
NOTE:
The parts marked with numbers are sold as repair parts.
The parts marked with letters are not sold separately and are shown only for reference.
[ ]: Thickness unit: mm (in.) (1) (7)
High-tension steel sheet: Tensioner strength 340 to 590 MPa.
No. Part Name Tensioner strength (MPa) Zinc-plating
(1) Hood Skin [0.6] (0.024) 340
Frame [0.5] (0.020) 270
a
(2) Front Fender [0.8] (0.031) 270
(3) Front Bulkhead Comp. b
-1 Front Bulkhead Upper Frame Set [0.6] (0.024) 270
(8)
-2 Front Bulkhead Side Stay Set [0.6] (0.024) 270
-3 Front Bulkhead Lower Cross-member Set [0.6] (0.024) 270 c
-4 Front Bulkhead (6)
Lower Cross-member Plate [0.6] (0.024) 270
(4) Front Wheelhouse Upper Member [0.7] (0.028) 590
(5) Front Damper Housing Comp.
a: Front Damper Housing [0.8] (0.031) e 270 ○
Rear d
b: Front Damper Base [2.0] (0.079) 270
-1 L. side: Wheelhouse Sub Set [0.8] Front(0.031) 270
R. side: Wheelhouse Gusset [0.8] (0.031) 270
-2 Front Dumper Extension [0.8] (0.031) 590
-3 Front Wheelhouse Lower Extension Set
c: Wheelhouse Lower Member [0.8] (0.031) b 590
d: Wheelhouse Lower Extension [0.8] (0.031) a 590
(6) Front Side Frame Comp. b c -2
a: Front Side Frame [1.8] (0.071)/Backplate, front a
-4 [1.4] (0.055)/ Rear [1.6] (0.063) 590
-3 (0.079)-5
b: Side Frame Extension [2.0] 590
-2 -1
c: Side Cross-member [1.8] (0.071) 440 ○
d: Outrigger [1.2] (0.047) 440 ○
-1 (4)
e: Inside Sill Front Extension [1.6] (0.063) 590
-1 Bumper Extension Bracket [1.8] (0.031) (5) 590
-2 Side Frame Gusset Plate [1.6] (0.063) (3) 590
-3 Side Frame Gusset [0.8] (0.031) 590
d -3
-4 Side Frame Support [1.0] (0.039) 270
-5 Bumper Beam Extension Outer Bracket [1.6] (0.063) 590 ○
(7) Dashboard Upper Comp.
a: Dashboard Upper [0.8] (0.031) 270
b: Windshield Lower [0.7] (0.028) 270
c: Dashboard Upper Side Driver's side [2.0] (0.079) c 590
Member Passenger's
-1 side [1.2] (0.047) 590
(8) Dashboard Lower [0.9] (0.035)/Extension [1.4] (0.055) 440
-2
-3
(2)
-4
Roof and Side Panel Construction
NOTE: Confirm that the sold as repair parts, refer to the appropriate Parts Catalog.
NOTE:
The parts marked (1)
with numbers are sold as repair parts.
The parts marked with letters are not sold separately and are shown only for reference.
[ ]: Thickness unit: mm (in.)
High-tension steel sheet: Tensioner strength 340 to 590 MPa.
C
No. Part Name Tensioner strength Zinc-plating
(11)
(MPa)
(1) Roof Panel [0.65] (0.026) f -1 270
(2) Side Sill Outer Panel [0.65] (0.026) e 270
(3) Front Side(9)Outer Panel Set [0.65] (0.026) 270
(4) Rear Side Outer Panel Set 270
-2
(5) Front Pillar Upper StiffenerDriver's side [1.8] (0.071)/Passenger's side [1.0] (0.039) 590
(6) Center Pillar Stiffener Set
a: Roof Side Stiffener [0.9] (0.035) 590
b: Center Pillara Upper Stiffener [1.6] (0.063) b 590
b a (8)
c: Center Pillar Lower Stiffener [0.9] (0.035) 590
(7) Side Sill Stiffener Set
a: Front Pillar Lower StiffenerDriver's side [1.6] (0.063)/Passenger's side [1.0] (0.039) 590
b: Front Pillar Lower Corner Stiffener [1.4] (0.055) 440
c: Side Sill Stiffener [1.6] (0.063) 590 a
(10)
d: Side Sill Rear Stiffener [1.2] (0.047) 590
(8) Rear Pillar Gutter Comp. (4)
c Upper Gutter [1.0] (0.039) d b
a: Rear Pillar 270
b: Rear Pillar Middle Gutter [0.65] (0.026) (3) 270
(6)
c: Rear Pillar Lower Gutter/Lower Gutter Extension [0.65] (0.026) 270
d: Rear Pillar Gutter c
d Upper Stiffener [0.7] (0.028) 270
(9) Front Pillar Inner Comp.
a: Front Pillar Inner Upper Driver's side [2.0] (0.079) *1 /Passenger's side [1.0] (0.039) *2 590 *1
a 440 *2
b: Front
(5) Pillar Inner Upper Extension [1.0] (0.039) 270
c: Front Pillar Inner Lower [1.4] (0.055) 590
d: Front Jack-up Base [1.6] (0.063) 590
b side [0.8] (0.031)
e: Roof Side RairDriver's side [1.4] (0.055)/Passenger's 590
f: Roof Side Rear Rail [0.8] (0.031) 440
(10) Center Inner Pillar [0.9] (0.035) 590
(11) Rear Inner Panel Comp.
-1 Rear Inner Panel [0.6] (0.024) 270
a: Side Sill Rear End Plate [1.0] (0.039) c 270
(7)
b: Rear Inner Stiffener [2.0] (0.079) 270
c: Rear Inner Upper Panel [0.75] (0.030) 270
-2 Rear Wheelhouse [0.7] (0.028) 270
(12) FrontaDoor Skin [0.7] (0.028) 270
Panel, Front [1.2] (0.047)/Rear [0.65] (0.026) 270
(13) Rear Door Skin [0.7] (0.028) 270
Panel, Front [1.2] (0.047)/Rear [0.65] (0.026) 270
(2)
d
b (13)
Rear
(12) Front
Front Rear
Floor and Rear Body Construction
NOTE: Confirm that the sold as repair parts, refer to the appropriate Parts Catalog.
NOTE:
The parts marked with numbers are sold as repair parts.
The parts marked with letters are not sold separately and are shown only for reference.
[ ]: Thickness unit: mm (in.)
High-tension steel sheet: Tensioner strength 340 to 590 MPa. (8)
-1
c d
b
Door and Bumper Reinforcement Beams
The door and bumper reinforcement beams used on Fit/Jazz vehicles are made from a metal equivalent to high-strength steel.
If high-strength steel is heated, the strength of the steel will be reduced. If high-strength steel is damaged, for example. In an accident, and the door and bumper
reinforcement beams are bent, the beams may crack when attempting to straighten them. If a door beam is damaged, the whole door panel assembly should be
replaced.
For this reason, the door and bumper reinforcement beams should NEVER be replaced; they should be replaced if they are damaged.
REAR DOOR
FRONT BUMPER REINFORCEMENT BEAM
REINFORCEMENT BEAM Do not repair.
Do not repair.
FRONT DOOR
REINFORCEMENT BEAM
Do not repair.
Zinc-plated Steel Plate Repair
The zinc-plated steel plate used in some panels of the Fit/Jazz require different repair techniques than ordinary steel plate. Refer to ‘‘Front Body Construction'' ,
‘‘Roof and Side Panel Construction'' , ‘‘Floor and Rear Body Construction'' for the location of the zinc-plated panels.
1. Before spot welding the zinc-plated steel plate, remove the paint from both sides of the flange to be welded. Apply sealer to the flange after welding.
NOTE: Seal the sandedZINC
surfaces thoroughly
PLATING to prevent rust.
(5−6 microns)
2. The electric continuity properties for zinc-plated steel plates differ from ordinary steel plates. When spot welding, increase the current by 10 to 20 %, or
increase the resistance welding time. Also increase the number of weld spots by 10 to 20 %.
NOTE: The MIG welding procedures for zinc-plated steel plates are similar to ordinary steel plates.
STEEL PLATE
3. Before applying putty or body filler to the zinc-plated steel plates, sand the zinc plating thoroughly to promote adhesion and prevent blistering.
NOTE: Use only epoxy-based putties and fillers on zinc-plated steel plates, and follow the manufacturer's specifications.
4. When doing paint work, protect the ground wire and the ground wire mounting hole threads with a bolt or a plug.
GROUND
WIRE
SPECIAL BOLT
GROUND WIRE
MOUNTING HOLE
PLUG
High-tension Steel Sheet Framed Area
The new high-tension steel sheet has greater tensioner strength than the conventional high-tension steel sheet. Although it's a thinner sheet, it maintains the same
strength capacity as the previous thicker ones. Because the manufacturing press process has improved, the usage area has expanded. For this vehicle, the new
high-tension steel sheet is used for its main frame and its cabin construction part to make the new model lightweight and to strengthen the safety capacity of the
high-crush absorption frame.
INSIDE SILL
FRONT PILLAR
INNER UPPER
FRONT PILLAR
INNER LOWER
INSIDE SILL
EXTENSION
REAR FRAME A
The new high-tension steel parts of the frame are all spot welded together. In order to disassemble, drill a hole in the sections that are spot welded
together with a very sharp spot weld bit.
The new high-tension steel sheet is more rigid than previous steel sheets, making it difficult to strengthen. When an automobile's frame is partially
constructed with the new high-tension steel sheet, it should be strengthened using an accurate frame straightening system. Inspect the body and
frame once the repair is complete for stress-related damage to the sections that are not made from the new high-tension steel.
High-tension steel has more memory than normal steel, and it is necessary to monitor the body dimensions closely during the straightening
process.
Spot welding is a acceptable for replacement parts as long as the proper number of welds is used in the repair. For replacement part welding
locations, refer to ‘‘Replacement'' in this manual. If spot welding does not provide acceptable repairs, plug the welds using an MIG welder.
AIR DRILL
SPOT CUTTER
Front Bracket
A Bracket
Upper
Lower Bracket
A
B repair bracket (B) and/or the lower repair bracket (C) on the bosses of the headlight housing (D), then
4. Install the front repair bracket (A), the upper
fasten it with the screws (E) provided with the repair bracket. C
E
E E
E
D
C
D
E D D
Paint Safety Precautions
Most paints contain substances that are harmful if inhaled or swallowed. Read the paint label before opening the container.
Intermediate coat
The intermediate coat is applied to the prepared surface to further protect against damage.
Top coat
Enamel paint and either polyester or acrylic resin paint are used in the top coat for higher solidity, smoothness, brightness, and weather resistance.
UNDERCOAT
(Electrodeposition)
BASE METAL
Color Chart Paint Specifications
Paint code NH-578 NH-700M NH-630M B-92P Y-66P R-513 BG-53M
Color Name Taffeta White Alabaster Silver M. Silver Stone M. Nighthawk Black P. Helios Yellow P. Rallye Red Brilliant Sky M.
DOOR PROTECTOR
MOLDINGS
Body color
DOOR MIRROR
· MIRROR HOUSING COVER:
Body color
· Housing:
Black (NH-70 Gloss 20)
REAR BUMPER
Body color
Check each of the plastic parts for solvent resistance and heat resistance before you do any repair work.
Select the repair material according to materials of the plastic parts.
Alcohol can be used for degreasing in small amounts, and for short periods of time. Do not soak.
Contact your paint and material supplier for other recommended cleaners for the type of plastic you are working on.
Standard Symbol Name Heat Resistance Note
Temperature °F (°C)
AAS Acrylonitrile acrylic styrene 176 (80)
ABS Acrylonitrile butadiene styrene 176 (80)
AES Acrylonitrile ethylene styrene 176 (80)
A/EPDM/S Acrylonitrile/ethylene propylene diene 176 (80)
rubber/styrene
ASA Acrylonitrile styrene acrylate 176 (80)
CAB Cellulose acetate butylate 176 (80)
E/VAC Ethylene-vinyl acetate 176 (80)
PA Polyamide 176 (80) Battery acid (sulfuric acid) can damage the material.
PBT Polybutylene terephtalate 320 (160) Solvent can damage the material.
PC Polycarbonate plastics 248 (120) Brake fluid, wax, and grease remover can damage the
material.
PE Polyethylene 176 (80) Solvent can damage the material.
PF Phenol form aldehyde 176 (80)
PMMA Polymethyl methacrylate 176 (80) Wash remover off with water thoroughly.
POM Polyoxymethylene polyacetal 212 (100) Solvent can damage the material.
PP Polypropylene 176 (80) Solvent can damage the material.
PPO (PPE) Polyphenylene oxide 212 (100)
PS Polystyrene 140 (60)
PUR Polyurethane 176 (80)
FRONT GRILLE
· MOLDING:
(ABS)
· BASE:
(AES)
DOOR PROTECTOR
MOLDINGS
(PP)
DOOR MIRROR
· MIRROR HOUSING COVER:
(ABS)
· Housing:
(AAS)
REAR BUMPER
(PP)
A soft chipping guard primer coat is then applied to the most susceptible area.
Spray the primer surface (2-part urethane primer surfacer) on the soft chipping guard primer coating areas when you replace parts using soft
chipping guard primer coat.
Coating Procedures
HOOD SKIN
250 (9.84)
[Section AA]
OUTER PANEL
D
A C
B B
A REAR
C 150 INNER
(5.91) PANEL
250 (9.84)
[Section DD]
FRONT FENDER
FRONT FENDER
[Section CC]
Floor Insulator Locations
Cut new insulators, and apply as indicated.
NOTE: Before applying, clean and degrease the floor.
(1) RIGHT DASHBOARD (3) FRONT FLOOR (4) RIGHT FRONT FLOOR (6) FRONT FLOOR REAR
LOWER INSULATOR FRONT INSULATOR MIDDLE INSULATOR CENTER INSULATOR
[X]
[Z]
[Y]
[VIEW: Z]
(2) LEFT DASHBOARD (5) LEFT FRONT FLOOR (9) REAR FLOOR
LOWER INSULATOR MIDDLE INSULATOR INSULATOR
[VIEW: X]
[VIEW: Y]
Floor Insulator Sizes
Unit: mm
Unit:
Unit: mmmm (in.)
(in.)(in.)
φ:
φ: Inner diameter
R: Round
inner diameter
R: Round
(1) RIGHT DASHBOARD LOWER INSULATOR (2) LEFT DASHBOARD LOWER INSULATOR
(4)RIGHT
(6) FRONTFRONTFLOORFLOOR MIDDLE INSULATOR
REAR CENTER (7) RIGHT REAR WHEELHOUSE INSULATOR
20 20
90 (0.8) (0.8) 186 324
(7.32)
(12.8)
(3.5) 190 (7.48)
225 (8.86) 50 400 (15.7) 160
54 (2.1)
(2.0) 90 (3.5) 96(6.30)
(3.8) 140 (5.51)
136 (5.35) 90 (3.5)
140 (5.51)
φ70 (2.8)
94 60
(3.7) (2.4) R300 (11.8)
46 (1.8)
φ100
71 (2.8) (3.94)
R40 (1.6)
120 (4.72) 116 (4.57)
53
(2.1) 35 (1.4)
137 (5.39) (8)LEFT REAR WHEELHOUSE INSULATOR
68 39 130 (5.12)
(2.7) (1.5) 240 (9.45) 400 (15.7)
117 (4.61) 112 (4.41)
128 (5.04) 87 (3.4)
204 (8.04)
49 63
320(1.9)
(12.6) (2.5)
150 (5.91) R15 (0.6) R15 (0.6)
865 (34.1)
(3) FRONT FLOOR FRONT INSULATOR
1015 (39.96)
168 (6.61)
190 (7.48) 140 (5.51)
315 (12.4)
(5)LEFT
(9) REARFRONT
FLOORFLOOR MIDDLE INSULATOR
INSULATOR
437 (17.2)
1015 (39.96)
150 (5.91) 865 (34.1)
60
φ60 (2.4) 240 (9.45) 130 (2.4)
(5.12) 400 (15.7)
90 125
(3.5) R30
(4.92) (1.2) 68
(2.7) 330 (12.99)
305 (12.0) 320 (12.6) 160 (6.30) 140 (5.51)
192 (7.56) 177 (6.97)
Front Bulkhead Removal
NOTE: This section explains the procedures after removal of all accessories and related parts.For accessories' and related parts' removal procedure, refer to the
appropriate Shop Manual.
Mass production body welding position and number
NOTE:
Welding symbols
: 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ : MIG welding L= Welding length Unit: mm (in.)
( ): The number of welds
Construction
FRONT
Replace the front bulkhead side stay and the lower cross-member stiffener as BULKHEAD
an assembly.
If necessary, replace the bulkhead lower cross member. SIDE STAY
LOWER CROSS-MEMBER STIFFENER
FRONT BULKHEAD
SIDE STAY
GUSSET PLATE
FRONT SIDE
FRAME
(9)
BULKHEAD LOWER
CROSS-MEMBER PLATE
WHEELHOUSE LOWER
BULKHEAD LOWER CROSS-MEMBER MEMBER
Front Wheelhouse/Damper Housing Removal
NOTE: This section explains the procedures after removal of all accessories and related parts.For accessories' and related parts' removal procedure, refer to the
appropriate Shop Manual.
Mass production body welding position and number [Wheelhouse upper member, lower member, and damper extension]
NOTE:
Welding symbols
: 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ : MIG welding L= Welding length Unit: mm (in.)
( ): The number of welds
Mass production body welding position and number [Damper housing]
NOTE:
WHEELHOUSE UPPER
Welding symbols MEMBER
: 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ : MIG welding L= Welding length Unit: mm (in.)
( ): The number of welds
(5) L=10 (0.4)
Construction
Remove the wheelhouse upper member.
Replace the wheelhouse lower member and the wheelhouse lower extension(2) DAMPER HOUSING
as an assembly.
Check the gusset plate and the side frame gusset. If necessary, replace them.
(12)
Construction
Check the front damper extension and the damper housing position for damage. If necessary, replace them.
NOTE: When(1) replacing the front damper extension, drill the position shown in [DETAIL X] and [DETAIL Z] from the outside of the dashboard upper side
(1) L=10 (0.4)
member, and drill the two spot welded points (A) at the joint for the front damper extension and the damper housing with a φ10 mm (0.4 in.) spot cutter.
Drill the two spot welded points (B) at the damper housing and the dashboard upper from under side of the damper housing.
(10) (3)
DASHBOARD UPPER
(B) Inside of the dashboard SIDE MEMBER
WHEELHOUSE upper side member.
GUSSET DAMPER HOUSING DASHBOARD UPPER
SIDE MEMBER
FRONT DAMPER
EXTENSION
DAMPER
(1) HOUSING
(1) DASHBOARD
UPPER
(7)
(11)FRAME EXTENSION
SIDE
SIDE FRAME FRONT SIDE FRAME WHEELHOUSE LOWER
EXTENSION MEMBER
SIDE FRAME GUSSET
(7)
WHEELHOUSE
L=10 (0.4)
LOWER MEMBER FRONT SIDE FRAME
DAMPER HOUSING
FRONT FLOOR FRAME
SIDE FRAME
Left side (3) EXTENSION
OUTRIGGER Right side (2) SIDE FRAME GUSSET
(3) (3)
A (5) OUTRIGGER
TIE DOWN STIFFENER DASHBOARD
LOWER
INSIDE SILL
EXTENSION
SIDE FRAME (8) (6)
EXTENSION
FRONT SIDE CROSS-MEMBER
FRONT SIDE FRAME
(5)
[Z] A+B+C= (11) : Inside sill extension, tie down stiffener, and outrigger
FLOOR FRAME
Front Pillar Outer Panel Removal
NOTE: This section explains the procedures after removal of all accessories and related parts.For accessories' and related parts' removal procedure, refer to the
appropriate Shop Manual.
Mass production body welding position and number [Outer panel and front pillar lower stiffener]
NOTE:
Welding symbols
: 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ : MIG welding L= Welding length Unit: mm (in.)
( ): The number of welds
Construction
Remove the wheelhouse upper member.
Cut and pry off the outer panel at the front pillar and side sill portion.
NOTE: Select the cutting positions in consideration of the front side outer panel repair part.
Replace the front pillar outer separator. (22)
Check the front pillar lower stiffener position for damage. If necessary, replace it.
Replace the front pillar inner separator.
OUTER PANEL
FRONT PILLAR
Without outer panel
UPPER STIFFENER
FRONT PILLAR
UPPER STIFFENER
FRONT PILLAR
(20) UPPER STIFFENER
(3) INNER
(8)PANEL
OUTER PANEL
FRONT PILLAR
LOWER STIFFENER (24)
FRONT INNER
(11) PILLAR
FRONT PILLAR
OUTER SEPARATOR
CENTER INNER PILLAR
SIDE SILL
FRONT PILLAR LOWER (19) (8) STIFFENER (6)
CORNER STIFFENER
FRONT PILLAR
OUTER SEPARATOR
Rear edge position of the side sill
outer repair part
CENTER PILLAR
STIFFENER
CENTER PILLAR
OUTER SEPARATOR
INSIDE SILL
OUTER PANEL
OUTER PANEL
(B)
Front side outer panel
repair part rear edge
CENTER PILLAR ROOF SIDE
STIFFENER (2) STIFFENER
CENTER INNER PILLAR WHEEL ARCH
Without outer panel OUTER SEPARATOR
(3) CENTER4-plate welding
INNER PILLAR
(A) CENTER PILLAR
OUTER SEPARATOR
(3)
CENTER PILLAR
INNER SEPARATOR CENTER PILLAR STIFFENER
(13)
(13) (5)
OUTER PANEL
Reuse.
Roof Panel Removal
NOTE: This section explains the procedures after removal of all accessories and related parts.For accessories' and related parts' removal procedure, refer to the
appropriate Shop Manual.
Mass production body welding position and number
NOTE:
Welding symbols
: 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ : MIG welding L= Welding length Unit: mm (in.)
( ): The number of welds
Construction
Remove the rear roof rail mount bolts, drill the welded flange of the front roof rail, and the roof panel. Without roof panel
(4)
FRONT ROOF RAIL REAR ROOF RAIL
ROOF PANEL
OUTER PANEL
(2)
REAR INNER UPPER
FRONT ROOF EXTENSION
RAIL
[Z]
(17) (17)
ROOF PANEL
6 x 1.0 mm
18 N·m
(1.8 kgf·m, 13 lbf·ft)
[VIEW: Z] (5)
REAR ROOF
[Z] RAIL
6 x 1.0 mm
18 N·m (1.8 kgf·m, 13 lbf·ft) [VIEW: Z]
Rear Side Outer Panel Removal
NOTE: This section explains the procedures after removal of all accessories and related parts.For accessories' and related parts' removal procedure, refer to the
appropriate Shop Manual.
Mass production body welding position and number [Outer panel and rear gutter]
NOTE:
Welding symbols
: 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ : MIG welding L= Welding length Unit: mm (in.)
( ): The number of welds
Construction
(22)
Cut and pry off the rear side outer panel, and replace it.
NOTE: Select the cutting positions in consideration of the rear side outer panel repair part.
Check the rear pillar gutter position for damage. If necessary, replace the rear pillar gutter lower.
Replace the wheel arch outer separator.
(8)
OUTER PANEL
QUARTER PILLAR STIFFENER (7) REAR PILLAR
OUTER PANEL GUTTER MIDDLE
Rear side outer panel
repair part front edge
(15) [Z]
(5) INNER UPPER
EXTANSION
WHEEL ARCH OUTER
SEPARATOR INNER UPPER (9)
PANEL
4-plate welding
(5) REARREAR PILLAR
PILLAR
GUTTER
GUTTER UPPERUPPER
STIFFENER
(7)
(13)
WHEEL ARCH OUTER REAR PILLAR
SEPARATOR (4) GUTTER MIDDLE
INNER PANEL REAR PILLAR
(4) (3) GUTTER MIDDLE
70 ° REAR PILLAR
GUTTER LOWER
(4)
REAR INNER PANEL
(2)
OUTER PANEL
Rear Panel Removal
NOTE: This section explains the procedures after removal of all accessories and related parts.For accessories' and related parts' removal procedure, refer to the
appropriate Shop Manual.
Mass production body welding position and number
NOTE:
Welding symbols
: 2-Plate spot welding/ : 3-Plate spot welding/ : 4-Plate spot welding/ : MIG plug welding/ : MIG welding L= Welding length Unit: mm (in.)
( ): The number of welds
Construction
Cut and pry off the rear panel,
REARand replace
PANEL SIDEit.
STIFFENER
REAR FLOOR
(8)
REAR FRAME
REAR PILLAR
REAR PILLAR
GUTTER LOWER
GUTTER LOWER (2) L=10 (0.4) (37)
REAR PANEL
REAR FRAME B
(6)
REAR WHEELHOUSE
MIDDLE FLOOR
CROSS-MEMBER
REAR FLOOR SIDE
(Right side shape)
REAR FLOOR
REAR FRAME B
REAR FLOOR SIDE
Outside: (3)
Left and right side (8) inside: (2)
REAR FRAME A Rear floor extesion and rear floor Rear frame A and rear frame B
Front Bulkhead Installation
NOTE:
Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MIG plug welding
: MIG welding
L= Welding length Unit: mm (in.)
( ): The number of welds
1. Set the new bulkhead parts, and measure the front compartment diagonally.
2. Check the body dimensions.
Engine compartment
Front wheelhouse lower member position
Engine compartment and front floor under view
Repair chart, top view
Repair chart, side view
3. Tack weld the new parts into position.
4. Temporarily install the front fender, the hood, and the door, then check for differences in level and clearance. Check the external parts fitting
position. If necessary, check the headlight and the front bumper positions. Make sure the body lines flow smoothly.
5. Do the main welding.
Weld the front side frame (A) and the bulkhead side stay (B).
Weld the bulkhead lower cross-member (C) to the wheelhouse lower member (D), the bulkhead side stay, and the lower cross-member
stiffener (E).
6. Install the bulkhead upper frame (A).
[VIEW: Z] B A
A
[Z]
(2)
(2)
A B
(3)
D
(3)
D
(1) E
C
E
C (4) (6)
Front Wheelhouse/Damper Housing Installation
NOTE:
Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MIG plug welding
: MIG welding
L= Welding length Unit: mm (in.)
( ): The number of welds
1. Clamp the new damper housing, the front damper extension, the side frame gusset, the gusset plate, the wheelhouse lower extension, and the
bulkhead, and measure the front compartment diagonally.
2. Check the body dimensions.
Engine compartment
Engine/transmission mount position
Front wheelhouse lower member position
Engine compartment and front floor under view
Repair chart, top view
Repair chart, side view
3. Tack weld the new parts and the front bulkhead into position.
4. Temporarily install the front subframe, and check the front side frame position.
5. Temporarily install the front fender, the hood, and the door, then check for differences in level and clearance. Check the external parts fitting
position. If necessary, check the headlight and the front bumper positions. Make sure the body lines flow smoothly.
6. Do the main welding.
Weld the damper housing (A), to the front side frame (B), and the dashboard upper (C).
7. From the passenger's side, plug weld the holes in the dashboard lower (A) and the damper housing (B).
8. Drill the holes for welding
(2) the new front damperAextension (A). Weld the damper housing (B), the front damper extension, and the dashboard upper
side member (C).
9. Weld the damper housing (A) and wheelhouse gusset (B) to the front damper extension (C). Weld the front damper extension and the wheelhouse
lower extension (D).
B C
10. Weld the side frame gusset (A) and the gusset plate (B) to the front side frame (C), and the wheelhouse lower extension (D).
11. Weld the front A
bulkhead.
A
(9) the wheelhouse
12. Weld (2) (A). When
C upper member A reusing the wheelhouse upper member, weld it with a MIG plug welding.
B
(1)
(5)
B
A
C(3) (5) L=10 (0.4)
(2) B
(3)
B
D
Front [Z](3)
(2) A A
(12) (7) (2)
B A
(7)
(4) (4)
D (4) C
(8) C
(2)
A
[VIEW: Z] (4)
D
(5)
(2)
(1)
Front Side Frame/Outrigger Installation
NOTE:
Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MIG plug welding
: MIG welding
L= Welding length Unit: mm (in.)
( ): The number of welds
1. Clamp the new side frame, and the front bulkhead, and measure the front compartment diagonally.
2. Check the body dimensions.
Engine compartment
Engine/transmission mount position
Front wheelhouse lower member position
Engine compartment and front floor under view
Repair chart, top view
Repair chart, side view
3. Tack weld the new parts and front bulkhead into position.
4. Temporarily install the front subframe, and check the front side frame position.
5. Temporarily install the front fender, the hood, and the door, then check for differences in level and clearance. Check the external parts fitting
position. If necessary, check the headlight and the front bumper positions. Make sure the body lines flow smoothly.
6. Do the main welding.
Weld the side frame extension (A), the front side cross-member (B), and the outrigger (C).
Weld the front side frame (D) and the side frame extension.
7. From the passenger's side, plug weld the holes in the dashboard lower (A), and the front floor (B).
8. Weld the Dfront side frame (A) to the damper housing (B) and the front wheelhouse gusset (C).
A the wheelhouse, lower member (A), and the side frame gusset D
9. Weld (B).
10.
LeftWeld the front bulkhead.
side (10) (2)
Right side (11)
(11)
(6)
(8)
(4)
(8)
A
A
(2)
C
B [Z]
C
(3)
A B (4)
(1)
(4)
(4) A B
B
Left side (11)
Right side (10) (7)
(3)
(3)
(3)
(1)
A
(4)
B
(1)
[VIEW: Z] A
Front
C
Front Pillar Outer Panel Installation
NOTE:
Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MIG plug welding
: MIG welding
L= Welding length Unit: mm (in.)
( ): The number of welds
1. Install the new front pillar inner separator (A) on the front pillar lower corner stiffener (B).
NOTE: Apply the sealer (C) all the way around the separator and inside the front pillar inner lower (D) without gaps.
2. Set the front pillar lower stiffener, and tack weld it into position.
3. Rough-cut the front side outer panel repair part, clamp it to the body, and check the dimensions.
Front wheelhouse lower member position
Door hinge position
Windshield and door opening. A
4. Temporarily install the windshield, the door, the hood, and the front fender, then check for differences in level and clearance.
Check the external parts fitting position. Make sure the body lines flow smoothly.
C
5. Trim the cut and joint areas of the outer panel repair part as needed, and prepare the butt-welding connections.
6. Remove the outer panel repair part, and weld the front pillar lower stiffener (A) to the upper stiffener (B) and the side sill stiffener (C).
7. Weld the patch (A) at the cut section of the body side outer panel (B).
8. Install the new front pillar outer separator
B (A) on the (1)
front pillar lower corner stiffener (B).
(3)NOTE: Apply the sealer (C) all the way around the separator and inside the outer panel repair part (D) without gaps.
[Front pillar section] [Side sill section]
9. Clamp the outer panel repair part, and recheck the clearance and alignment of the door, the front fender, and the windshield.
40 mm
10.ADo the(1.6
main
in.) welding. Weld the(4)
outer panel repair part (A) and the
(7) patch (B).
D
11. Weld
D the wheelhouse upper member. A B
[Windshield opening]
[Side sill portion]
A
L=190 (7.48)
A
B B
(7)
(7) C
B
(18) A
B 40 mm (1.6 in.) B
C
A
L=330
(13.0)
(4)
(6) (5)
A C
(8) (3)
(3)
(7)
(4)
(7)
(12)
(16)
(1)
(2)
(11)
Side Sill Outer Panel Installation
NOTE:
Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MIG plug welding
: MIG welding
L= Welding length Unit: mm (in.)
( ): The number of welds
1. Rough-cut the side sill outer panel repair part, and clamp it to the body.
2. Check the dimensions.
Front wheelhouse lower member position
Door hinge position
Windshield and door opening
3. Temporarily install the door, the hood, and the front fender, then check for differences in level and clearance. Check the external parts fitting
position. Make sure the body lines flow smoothly.
4. Trim the cut and joint areas of the outer panel repair part as needed, and prepare the butt-welding connections.
5. Weld the patch (A) at the cut section of the body side outer panel (B).
6. Install the new front pillar outer separator (A), the center pillar outer separator (B) on the front pillar lower stiffener (C), and the center pillar stiffener
(D).
[Front
[Side
NOTE:sill
pillar
section]
section]
Apply the sealer (E) all the
(5) way around the separator and inside the outer panel repair part (F) without gaps.
(2)
7. Clamp the outer panel repair part,Band
B recheck the clearance and alignment of the door and the front fender.
40 mm
8. Do the main welding. Weld the outer
A panel repair part (A) and the patch (B).
40 mm
40 mm (1.6 in.)
(1.6 in.)
BB F
L=270 (10.6)
A A
(7) (14)
(2) (2) A
(7)
[Center pillar section]
C (2)
B
E (2)
40 mm (2)
(1.6 in.)
L=310 (12.2) D (2)
40 mm
E (1.6 in.)
(21)
A B
A
B
(6)
(7)
(6) A
(5)
(1)
(11)
B
F
(8)
A (6)
A
L=330 (13.0)
Center Pillar Outer Panel Installation
NOTE:
Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MIG plug welding
: MIG welding
L= Welding length Unit: mm (in.)
( ): The number of welds
1. Clamp the side sill stiffener, and check the body dimensions.
Passenger compartment
Engine compartment and front floor under view
Front floor and rear floor, under view
Repair chart, top view
Repair chart, side view
2. Tack weld the side sill stiffener (A) and the side sill rear stiffener (B).
3. Install the new center pillar inner separator (A) on the side sill stiffener (B).
NOTE: Apply the sealer (C) all the way around the separator and inside the center pillar stiffener (D) without gaps.
4. Install the new wheel arch outer separator
(5)(A) on the rear inner panel (B).
NOTE: Apply the sealer (C) all the way around the separator and inside the outer panel reuse part (D) without gaps.
A
5. Weld the patch (A) at the cut section of the body side outer panel (B) and weld the outer panel reuse part (C).
6. Rough-cut the front side outer panel repair part, and clamp it to the body.
B
7. Check the dimensions. B A
Front wheelhouse lower
L=260 (10.2) member position
Door hinge position
Windshield and door opening
8. Temporarily install the door, the hood, and the front fender, then check for differences in level and clearance.
Check the external parts fitting position. Make sureAthe body lines flow(4)
smoothly.
C
9. Trim the cut and joint areas of the outer panel repair part as needed, and prepare the butt-welding connections.
A
10. From inside the passenger's compartment, weld the side sill stiffener (A)Cto the center pillar inner (B) and the inside sill (C).
11. Remove the outer panel repair part, and weld the center pillar stiffener (A) to the roof side stiffener (B) and the side sill stiffener (C).
(4)
B
12. Weld the patch (A) at the cut section of the body side outerBpanel (B).
D C B
13. Install the new center pillar outer separator (A) on the center
(2) pillar stiffener (B).
NOTE: Apply the sealer (C) all the way around the separator and inside the outer panel repair part (D) without gaps.
[Side sill rear
frontsection]
section]
[Z] alignment
14. Clamp the outer panel repair part , and recheck the clearance and B of the door, and the front fender.
40 mm (1.6 in.)
B
40 mm
15. Do the main welding. Weld the outer
B panel repair part (A) and the patch (B).
A (1.6 in.)
16. Weld the side Csill area.
A
B L=260 (10.2) (3)
(1)
(3)
D B
B (13)
B
(1)(2) (5)
L=170 (6.69)
A
(3)
C
L=160 (6.3)
A (7) L=160 (6.3)
L=330 (13.0) A
[VIEW: Z] (7) (29)
(25) (28) [Z]
[Center pillar section] (24)
A
40 mm (1.6 in.)
(3)In case of outer panel replacement only 40 mm (1.6 in.)C (3)
(2) D
(7)
A A
A
A B
(4)
A
(11)
C[VIEW: Z]
40 mm
(1.6 in.) B
(9)
(3)
A
In case of outer panel replacement only
(5)
(2)
Roof Panel Installation
NOTE:
Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MIG plug welding
: MIG welding
L= Welding length Unit: mm (in.)
( ): The number of welds
1. Clamp the new roof panel.
2. Check the body dimensions.
Windshield and door opening
Tailgate opening
Rear pillar gutter position
Passenger's compartment
Door hinge position
3. Tack weld the front and rear corner edge of the roof panel.
4. Temporarily install the roof molding, the windshield, the tailgate and the door, then check for differences in level and clearance.
Check the external parts fitting position. Make sure the body lines flow smoothly.
5. Do the main welding.
From inside the vehicle, weld the front roof rail (A) and the inner upper extension (B).
Fix the rear roof rail (C) with the mounting bolts (D).
Weld the front, rear, and side flange of the roof panel (E).
The roof area must be free of burrs and/or sharp edges to prevent damage to the side curtain airbag during deployment.
C E [Z] A
(2)
D
B
(6)
(5)
(1)
(5)
(4) E
[VIEW: Z]
E (2)
(4)
Rear Side Outer Panel Installation
NOTE:
Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MIG plug welding
: MIG welding
L= Welding length Unit: mm (in.)
( ): The number of welds
1. Clamp the new rear pillar gutter, rough-cut the rear side outer panel repair part, clamp it to the body.
2. Check the body dimensions.
Front wheelhouse lower member position
Door hinge position
Rear pillar gutter position
Windshield and door opening
Tailgate opening
3. Temporarily install the door, the tailgate, and the quarter glass, then check for differences in level and clearance.
Check the external parts fitting position. Make sure the body lines flow smoothly.
4. Trim the cut and joint areas of the outer panel repair part as needed, and prepare the butt-welding connections. Remove the outer panel repair part.
5. Weld the patch (A) at the cut section of the body side outer panel (B).
6. Install the new wheel arch outer separator (A) on the rear inner panel (B).
NOTE: Apply the sealer (C) all the way around the separator and inside the outer panel repair part (D) without gaps.
[Side sillglass
[Quarter section]
section]
7. Clamp the outer panel repair part, and recheck the clearance
B and alignment of the door, the quarter glass, and the tailgate.
B A
8. Do the main welding. Weld the outer panel repair part (A), and the patch (B).
(4)
9. Weld the rear pillar gutter lower (A), the outer panel (B), and the rear panel (C).
10.[Wheel
Weldopening,
[Door the outer
arch panel
portion
quarter (A)
rearand
andglass the rear
opening
end] andgutter middle
side sill area](B).
B
B L=230 (9.06)
40 mm
A (1.6 in.)
(7)
(5)
(4)
A 40 mm
(1.6 in.) (4)
L=153 (6.02)
(7) (12)
(4) A (3)
40 mm (1.6 in.)
A B
(8)
(5) (10) (11)
(3) D
(7)
4-plateC
welding (5)
A B
(13)
A
(2)
(7)
A
B
A
(3) A (10) C
(8)
L=330 (13.0) (11)
Rear Panel Installation
NOTE:
Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MIG plug welding
: MIG welding
L= Welding length Unit: mm (in.)
( ): The number of welds
1. Clamp the new rear panel.
2. Check the body dimensions.
Front floor and rear floor, under view
Rear panel position
Rear pillar gutter position
Tailgate opening
Repair chart, top view
Repair chart, side view
3. Tack weld the rear panel into position.
4. Temporarily install the tailgate, then check for differences in level and clearance.
Check the external parts fitting position. If necessary, check the taillight and the rear bumper positions. Make sure the body lines flow smoothly.
5. Do the main welding.
Weld the rear panel side stiffener (A) to the rear pillar gutter lower (B), and the rear pillar gutter upper stiffener (C).
6. Weld the rear panel (A) to the rear pillar gutter lower (B), the rear frame (C), and the rear floor (D).
(2) L=10 (0.4)
(2) C B
4-plate welding (9)
D
(5) A
C
B
(15)
(1)
A
(6)
(2) L=10 (0.4)
4-plate welding
D
(5)
(10)
C
A (2)
Rear Floor/Rear Frame Installation
NOTE:
Welding symbols
: 2-Plate spot welding
: 3-Plate spot welding
: 4-Plate spot welding
: MIG plug welding
: MIG welding
L= Welding length Unit: mm (in.)
( ): The number of welds
1. Set the new rear frame B, and measure the rear frame diagonally.
2. Check the body dimensions.
Passenger's compartment
Front floor and rear floor, under view
Repair chart, top view
Repair chart, side view
3. Tack weld the rear frame B into position.
4. Temporarily install the trailing arm, check the rear suspension position.
5. Set the new rear floor side, and the rear floor.
6. Clamp the rear panel, check the body dimensions.
Rear panel position
Rear pillar gutter position
Tailgate opening
7. Remove the rear panel, the rear floor, and B
the rear floor side. Plug weld the rear frame B, and the rear frame A.
8. Set the rear floor side, the rear floor, and recheck the alignment of the rear panel.
9. Do the main welding. Weld(3)
the rear floor side (A) and the floor side extension (B).
10. From the rear wheelhouse side, plug weld the rear frame B, the rear frame A, the rear floor side (C), and the floor side extension (D).
11.(4)Plug
L=10weld
(0.4)the rear floor (A). A
(5)
C (4)
(9) A
(2)
(2)
(12)
B A
[Z]
(6) (6)
A
A
A B
C (4)
(5) B
(3)
(5)
A
D
B
B
A
Unit: mm (in.)
A, a B, b
Bulkhead Upper Frame Front Fender Mount Bolt (Center of the bolt)
Locating Hole φ15 (0.59)
C
C F
b 1329 B
(52.32)
1077
(42.40) 569
(22.4)
630
(24.8)
a A
Upper Body Measuring Dimensions - Engine Compartment
Unit: mm (in.)
A, a B, b C, c
Bumper Beam Bulkhead Upper Frame Hood Hinge
Mount Hole φ12 (0.47) Mount Hole φ7 (0.28) Mount Hole φ7 (0.28) front
C F
C C F
F D, d
Front Damper Base
Locating Hole φ48 (1.89)
E, e F
Front Fender Windshield Lower
Mount Hole φ7 (0.28) Locating Hole φ7 (0.28) center
C
F
e 1356
(53.39) E
1348
(53.07) C
c
1324
(52.13)
d 1126 D
e (44.33) E
F
576
d (22.7) D
c
673 662 1208 150
(26.5) (26.1) (47.56) C (5.91)
552
(21.7)
533
1138 (21.0)
(44.80)
1062
667 (41.81)
(26.3)
749
b (29.5) B
a
1077 A
(42.40)
Upper Body Measuring Dimensions - Engine/Transmission Mount Position
Unit: mm (in.)
C, c G
Hood Hinge Engine Side Mount
Mount Hole φ7 (0.28) front Hole φ15 (0.59)
F
C
C F
D, d
Front Damper Base
Locating Hole
φ48 (1.89)
H
Transmission Mount Hole φ15 (0.59)
C
F
I
Transmission Mount Hole φ15 (0.59)
d D
c 1221 C
(48.07)
G
Upper Body Measuring Dimensions - Front Wheelhouse Lower Member Position
Unit: mm (in.)
J K L
Wheelhouse Lower Member Front Fender Upper Mount Front Fender Lower Mount
Locating Hole φ11 (0.43) Hole φ8 (0.32) Hole φ7 (0.28)
F
F
864
(34.0)
905
(35.6)
912
(35.9)
L
Upper Body Measuring Dimensions - Door Hinge Positon
Unit: mm (in.)
M N O
Upper Front Door Hinge Lower Front Door Hinge Upper Rear Door Hinge
Mount Hole φ13 (0.51) front Mount Hole φ13 (0.51) upper Mount Hole φ13 (0.51) upper
P Q
Lower Rear Door Hinge Rear Door Switch
Mount Hole φ13 (0.51) front Mount Hole φ8 (0.32)
F
F
M
1095 O
(43.11)
1092 1134 782
(42.99) (44.65) (30.8)
Q
N 858
1021
(40.20) (33.8)
P
Upper Body Measuring Dimensions - Passenger's Compartment
Unit: mm (in.)
R, r S, s
Front Seat Mount Hole φ15 (0.59) rear Seat Belt Anchor Plate Mount Hole φ16 (0.63)
C
F F
T, t U, u
Rear Damper Mount Hole φ24 (0.94) Rear Floor Side Locating Hole φ20 (0.79)
F
C
F
C
1116
(43.94)
1722 u
(67.80) T
s 970
1318 1797 (38.2) U
(51.89) (70.75)
746
(29.4)
1200
1370 (47.24)
(53.94) S
r
1470
1100 (57.87)
(43.31)
R
Upper Body Measuring Dimensions - Rear Panel Position
Unit: mm (in.)
S, s T, t
Seat Belt Anchor Plate Mount hole φ16 (0.63) Rear Damper Mount Hole φ24 (0.94)
C C
F
V, v
Rear Trim Panel Clip Mount Hole φ8.5 (0.34)
F C
t
439 v
(17.3)
923 934
(36.3) (36.8) V
1259
(49.57)
s T
S
Upper Body Measuring Dimensions - Rear Pillar Gutter Position
Unit: mm (in.)
W, w X, x
Tailgate Support Strut Rear Bumper Mount Hole φ7 (0.28) upper
Mount Hole φ11 (0.43)
F
C
Y, y
Rear Bumper
Mount Hole φ7 (0.28) lower
1258
(49.53)
1184 390
(46.61) (15.4)
W 1185
(46.65) x
996
(39.2) 191
581 (7.52)
(22.9) y
X 938
(36.9)
846
(33.3)
Y
Opening Repair Chart - Windshield and Door Opening
Unit: mm (in.)
A B, C
Windshield Outer Panel and Roof
Lower Locating Hole Panel Windshield
center Opening Flange Notch
(3 places)
D, E, F, G, H, I, J, K
Outer Panel Door
Opening Flange Notch
(16 places)
1400.5
(55.138)
B C
H
970
1275 (38.2) D 1371
(50.20) (53.98)
649.5
(25.57)
1051
1201 (41.38)
A (47.28) K
G I
1162
(45.75)
926.5 J
727.5 (36.48)
(28.64)
F
E 601.5
1398.5 (23.68)
(55.059)
515
(20.3)
370.5
(14.59)
Opening Repair Chart - Tailgate Opening
Unit: mm (in.)
L M
Rear Roof Rail Rear Inside Upper
Flange Notch Extension Flange End
(2 places)
N
Rear Panel Upper
Stiffener Flange
Notch
1104.5
(43.484)
622.5
(24.51)
860
(33.9)
M
796.5
(31.36)
N
Upper Body Measuring Dimensions - External Parts Fitting Positon
Rear Door
Rear Side
Outer Panel
Rear Door
4.0
Front Door (0.16)
3.5
(0.14)
3.5 Front
(0.14) Door
Front Fender
Front/Rear Door
5.0
(0.20)
Side Sill
Outer Panel
5.0 (0.20)
Under Body Measuring Dimensions - Front Subframe Positon
Unit: mm (in.)
A, a B, b
Front Bumper Mount Front Subframe Mount Bolt
Clip (Center of the clip) (Center of the bolt) front
F
F
C C
C, c D, d
Front Subframe Mount Bolt Front Floor Frame Mount Bolt
(Center of the bolt) rear (Center of the bolt)
F
C
a A
500
(19.7)
905
(35.6)
940
(37.0) 627
(24.7)
1123
(44.21)
b
B
854
(33.6)
1647
(64.84)
c 755 C
(29.7)
1620
1341 (63.78) 1357
1355 (52.80) 1310
(53.35) 1009 1014 (53.43)
(39.72) (51.57) (39.92)
972
(38.3)
d D
Under Body Measuring Dimensions - Engine Compartment and Front Floor Under View
Unit: mm (in.)
A, a B, b C, c
Front Bulkhead Cross-member Front Side Frame Front Subframe Mount
Locating Hole φ20 (0.79) Locating Hole φ16 (0.63) Hole φ15 (0.59) Front
F
C
C
F
F
D, d E, e
Front Subframe Mount Front Floor Frame
Hole φ15 (0.59) rear Mount Hole φ15 (0.59)
F
F
C
C
792
(31.2)
1357 E
B (53.43)
C
A 1014
D (39.92)
1163
(45.73)
1310 1647
1206 854 (51.57) (64.84)
(47.48) (33.6)
887 1620
(34.9) (63.78) 972
866 755 (38.3)
(34.1) 960 (29.7)
(37.8) 1341
1029 (52.80)
(40.51)
998
(39.3)
419 1009
d (39.72)
a (16.5) c
b 564 e
376
(22.2) (14.8) 1355
(53.35)
895
(35.2)
Under Body Measuring Dimensions - Front Floor and Rear Floor, Under View
Unit: mm (in.)
E, e F, f G, g
Front Floor Frame Trailing Arm Bracket Rear Frame A Locating
Mount Hole φ15 (0.59) Locating Hole φ20 (0.79) Hole φ11 (0.43) front
F
C
C F
C F
H, h I, i
Rear Frame A Locating Rear Frame B Locating
Hole φ11 (0.43) rear Hole φ 25 (0.98)
F
F 689
E 514 G H (27.1) I
(20.2) 485
(19.1)
1163
(45.79)
1163
(45.79) 970
1239 (38.2)
972 1167
(45.94) (48.78) 1094
(38.3) 984
1175 (43.07)
(46.26) (38.7)
1091
1206 (42.95)
(47.48) 1059
(41.69)
523 h
e (20.6)
g i
f 211
481 (8.31)
(18.9)
275
(10.8)
Frame Repair Chart - Top View
Unit: mm (in.)
φ: Inner diameter
a1 For engine side mount φ15 (0.59) front g Floor center stiffener locating hole φ15 (0.59) l Front floor cross-member locating hole φ25 (0.98) p
a2 For engine side mount φ13 (0.51) outer h1 Front floor locating hole φ50 (1.97) front h2 Front floor locating hole φ25 (0.98) rear q
a3 For engine side mount φ15 (0.59) rear i1 Inside sill locating hole φ25 (0.98) front i2 Inside sill locating hole φ25 (0.98) rear r1
b1 For transmission mount φ15 (0.59) front j1 R Floor frame locating hole φ15 (0.59) front m Trailing arm gusset locating hole φ20 (0.79) r2
b2 For transmission mount φ15 (0.59) wheelhouse side j1 L Floor frame locating hole φ15 (0.59) front n1 Rear seat guide bracket locating hole φ9 (0.35) right s
b3 For transmission mount φ15 (0.59) rear j2 R Floor frame locating hole φ15 (0.59) rear n2 Rear seat guide bracket locating hole φ9 (0.35) left t
b4 For transmission mount φ13 (0.51) j2 L Floor frame locating hole φ15 (0.59) rear o1 For trailing arm mount φ15 (0.59) inner u
[Manual transmission model] k Front floor center locating hole φ15 (0.59) For trailing arm mount φ17 (0.67) outer v
o2
c Front side frame locating hole φ16 (0.63)
1291 (50.83) k
d Front damper center hole φ48 (1.89) 374 (14.7)
1020 (40.16) l i2 m o2 r1 s
359 (14.1) p q t
e1 For front subframe mount h2 n1 o1
φ15 (0.59) front 231 (9.09) d e4 f g h1 i1 j1 R k j2 R
e2 u
e2 For front subframe mount
φ16 (0.63) middle a2
e3 R Outrigger locating hole
φ11 (0.43)
e3 L Outrigger locating hole
φ11 (0.43) x 15 (0.59) slot
e4 For front subframe
mount φ15 (0.59) rear a1
c a3
f Outrigger locating hole e1
φ25 (0.98) e3 R
CENTER LINE
b3 e3 L
b1
Unit: mm (in.)
φ: Inner diameter
a1 For engine side mount φ15 (0.59) front g Floor center stiffener locating hole φ15 (0.59)
a2 For engine side mount φ13 (0.51) outer h1 Front floor locating hole φ50 (1.97) front
a3 For engine side mount φ15 (0.59) rear i1 Inside sill locating hole φ25 (0.98) front
b1 For transmission mount φ15 (0.59) front j1 R Floor frame locating hole φ15 (0.59) front
b2 For transmission mount φ15 (0.59) wheelhouse side j1 L Floor frame locating hole φ15 (0.59) front
b3 For transmission mount φ15 (0.59) rear j2 R Floor frame locating hole φ15 (0.59) rear
b4 For transmission mount φ13 (0.51) j2 L Floor frame locating hole φ15 (0.59) rear
[Manual transmission model] k Front floor center locating hole φ15 (0.59)
c Front side frame locating hole φ16 (0.63)
1291 (50.83) k
374 (14.7)
d Front damper center hole φ48 (1.89) 1020 (40.16)
359 (14.1)
e1 For front subframe mount
φ15 (0.59) front
231 (9.09)
d e4 f g h1 i1 j1 R k j2 R
e2
e2 For front subframe mount
φ16 (0.63) middle a2
CENTER LINE
b3 e3 L
b1
283 (11.1) j1 L j2 L
76
338 (13.3)
(2.99)
409 (16.1)
138 425 (16.7)
(5.43)
634 (25.0)
155 715 (28.2)
216 (8.50)
(6.10) 805 (31.7)
340 (13.4) 900 (35.4)
1290 (50.79) j2 R/j2 L
1450 (57.09) l
1610 (63.39)
1700 (66.93)
b4 1925 (75.79)
1935 (76.18)
n2 Rear seat guide bracket locating hole φ9 (0.35) left t Rear damper center hole φ24 (0.94)
o1 For trailing arm mount φ15 (0.59) inner u Rear frame B locating hole φ20 (0.79)
o2 For trailing arm mount φ17 (0.67) outer v Rear floor side panel locating hole φ20 (0.79)
l i2 m o2 r1 s
p q t
h2 n1 o1 v
u
A r2
A 92.7
(3.65)
n2 64
(2.52) o1
110
(4.33)
o2
234 (9.21)
373 (14.7)
405 (15.9)
469 (18.5) [Section AA]
630 (24.8)
655 (25.8)
h2 862 (33.9)
i2
m
n1, n2
2000 (78.74)
Frame Repair Chart - Side View
Unit: mm (in.)
φ: Inner diameter
a1 For engine side mount φ15 (0.59) front g Floor center stiffener locating hole φ15 (0.59) l Front floor cross-member locating hole φ25 (0.98)
a2 For engine side mount φ13 (0.51) outer h1 Front floor locating hole φ50 (1.97) front h2 Front floor locating hole φ25 (0.98) rear
a3 For engine side mount φ15 (0.59) rear i1 Inside sill locating hole φ25 (0.98) front i2 Inside sill locating hole φ25 (0.98) rear
b1 For transmission mount φ15 (0.59) front j1 R Floor frame locating hole φ15 (0.59) front m Trailing arm gusset locating hole φ20 (0.79)
b2 For transmission mount φ15 (0.59) wheelhouse side j1 L Floor frame locating hole φ15 (0.59) front n1 Rear seat guide bracket locating hole φ9 (0.35) right
b3 For transmission mount φ15 (0.59) rear j2 R Floor frame locating hole φ15 (0.59) rear n2 Rear seat guide bracket locating hole φ9 (0.35) left
b4 For transmission mount φ13 (0.51) j2 L Floor frame locating hole φ15 (0.59) rear o1 For trailing arm mount φ15 (0.59) inner
[Manual transmission model]
k Front floor center locating hole φ15 (0.59) o2 For trailing arm mount φ17 (0.67) outer
c Front side frame locating hole φ16 (0.63)
d Front damper center hole φ48 (1.89)
e1 For front subframe mount φ15 (0.59) front
e2 For front subframe mount φ16 (0.63) middle 7.54 °
d
e3 R Outrigger locating hole φ11 (0.43)
e3 L Outrigger locating hole φ11 (0.43) x 15 (0.59) slot
e4 For front subframe mount φ15 (0.59) rear
u
f Outrigger locating hole φ25 (0.98)
48
(1.89) s
d
B
[Section BB] q
b2 p
B
o2
j1 R
j1 L j2 R k o1
l i2
e2 h1 i1 h2 m
e3
e4
BASE
LINE
c b3
a2 e1
b1
a1 a3
f g r1, r2
b4
155
(6.10)
BASE LINE
BASE LINE
Frame Repair Chart - Side View
Unit: mm (in.)
φ: Inner diameter
a1 For engine side mount φ15 (0.59) front g Floor center stiffener locating hole φ15 (0.59)
a2 For engine side mount φ13 (0.51) outer h1 Front floor locating hole φ50 (1.97) front
a3 For engine side mount φ15 (0.59) rear i1 Inside sill locating hole φ25 (0.98) front
b1 For transmission mount φ15 (0.59) front j1 R Floor frame locating hole φ15 (0.59) front
b2 For transmission mount φ15 (0.59) wheelhouse side j1 L Floor frame locating hole φ15 (0.59) front
b3 For transmission mount φ15 (0.59) rear j2 R Floor frame locating hole φ15 (0.59) rear
b4 For transmission mount φ13 (0.51) j2 L Floor frame locating hole φ15 (0.59) rear
[Manual transmission model]
k Front floor center locating hole φ15 (0.59)
c Front side frame locating hole φ16 (0.63)
d Front damper center hole φ48 (1.89)
e1 For front subframe mount φ15 (0.59) front
e2 For front subframe mount φ16 (0.63) middle 7.54 °
d
e3 R Outrigger locating hole φ11 (0.43)
e3 L Outrigger locating hole φ11 (0.43) x 15 (0.59) slot
e4 For front subframe mount φ15 (0.59) rear
f Outrigger locating hole φ25 (0.98)
48
(1.89)
d
B
[Section BB]
b2
B
j1 R
j1 L j2 R k
e2 h1 i1
e3
e4
BASE
LINE
c b3
a2 e1
b1
a1 a3
f g
b4
155
(6.10)
BASE LINE
BASE LINE
l Front floor cross-member locating hole φ25 (0.98) p Middle floor cross-member locating hole φ20 (0.79)
h2 Front floor locating hole φ25 (0.98) rear q Rear frame A locating hole φ15 (0.59)
i2 Inside sill locating hole φ25 (0.98) rear r1 Rear floor locating hole φ25 (0.98) right
m Trailing arm gusset locating hole φ20 (0.79) r2 Rear floor locating hole φ25 (0.98) left
n1 Rear seat guide bracket locating hole φ9 (0.35) right s For spring base mount hole 15 (0.59) x 15 (0.59) square
n2 Rear seat guide bracket locating hole φ9 (0.35) left t Rear damper center hole φ24 (0.94)
o1 For trailing arm mount φ15 (0.59) inner u Rear frame B locating hole φ20 (0.79)
o2 For trailing arm mount φ17 (0.67) outer v Rear floor side panel locating hole φ20 (0.79)
s
q t
o2
o1 v
l i2
h2 m
r1, r2
n1, n2
Cross Section of Body and Sealants - General
NOTE: Follow the sealer manufacturer's instructions, and apply the sealer. Note the following items:
Clean the areas to be sealed with wax and grease remover.
Wipe off any excess spot sealer with thinner. After the primer is sprayed, sealer will fill the area where the spot sealer was wiped.
Make sure you can see the sealant when the sealed part is in its proper location. For the details, refer to engine compartment and damper
housing, dashboard upper and dashboard lower, front floor, rear floor, roof panel/rear pillar gutter and rear panel, and rear wheelhouse.
When applying sealant to the engine compartment, the door opening, and the trunk lid gutter, try to match the appearance of the factory sealer.
Wipe off any excess sealer.
Apply sealer to any area that a replacement part will cover. Smooth the sealer with a brush if necessary.
Cross Section of Body and Sealants - Engine Compartment and Damper Housing
DAMPER
EXTENSION
DASHBOARD LOWER
WHEELHOUSE GUSSET DASHBOARD LOWER
[VIEW: Z]
BACKPLATE
OUTER
PANEL CORNER
STIFFENER
[Z] INNER LOWER
OUTRIGGER
INNER UPPER
WINDSHIELD
DASHBOARD LOWER
UPPER
DASHBOARD LOWER
INNER LOWER
DASHBOARD LOWER
INSIDE SILL
FRONT FLOOR
INSIDE SILL
TRAILING ARM BRACKET
LOWER GUSSET
INSIDE SILL
CENTER INNER
FRONT FLOOR
MIDDLE FLOOR
CROSS-MEMBER
FRONT FLOOR
INSIDE SILL
INSIDE SILL TRAILING ARM BRACKET
EXTENSION LOWER GUSSET
FRONT FLOOR
MIDDLE FLOOR
FRONT FLOOR CROSS-MEMBER
FLOOR CAP
FLOOR CAP
FRONT FLOOR
FLOOR CAP
FRONT FLOOR FRONT FLOOR
FLOOR CAP FRONT FLOOR
FRONT FLOOR
FLOOR CENTER
FRONT FLOOR TUNNEL
FLOOR FRAME
FLOOR FRAME
UPPER STIFFENER
Cross Section of Body and Sealants - Rear Floor
REAR DAMPER REAR FLOOR SIDE REAR FLOOR SIDE LOWER GUTTER
EXTENSION REAR WHEELHOUSE EXTENSION EXTENSION
REAR INNER OUTER PANEL
SIDE SILL REAR REAR PANEL UPPER
FLOOR SIDE REAR FLOOR SIDE STIFENER
EXTENSION EXTENSION
REAR PANEL
REAR FLOOR
SIDEGUSSET
REAR FRAME
JACK-UP BASE
REAR INNER STIFFENER
FLOOR CAP
REAR FLOOR
Cross Section of Body and Sealants - Roof Panel/Rear Pillar Gutter and Rear Panel
ROOF PANEL
OUTER PANEL
MIDDLE GUTTER
UPPER GUTTER
OUTER PANEL
LOWER GUTTER
[VIEW:Z]
LOWER GUTTER
EXTENSION TAILGATE HINGE
MIDDLE GUTTER
ROOF PANEL
UPPER GUTTER
OUTER PANEL LOWER GUTTER
LOWER GUTTER
MIDDLE GUTTER
[Z]
LOWER GUTTER LOWER GUTTER
EXTENSION EXTENSION
LOWER GUTTER
OUTER PANEL
OUTER PANEL
OUTER PANEL LOWER GUTTER
OUTER PANEL
REAR INNER
REAR WHEELHOUSE
REAR DAMPER BASE REAR DAMPER BASE
REAR DAMPER REAR
EXTENSION DAMPER REAR WHEELHOUSE
BASE
REAR DAMPER
EXTENSION
OUTER PANEL
REAR INNER
REAR WHEELHOUSE
REAR INNER
SIDE SILL
END PLATE
TRAILING ARM
BRACKET
JACK-UP BASE
OUTER PANEL SIDE SILL REAR
END PLATE WHEELHOUSE
NUT
REAR WHEELHOUSE
INNER PANEL
REAR DAMPER
EXTENSION
REAR FRAME
Rust-preventive Treatments - General
Undercoat
NOTE:
Mask the exhaust system, oxygen sensors, and suspension mount areas to protect them from undercoat overspray.
Follow the undercoating manufacturer's instructions.
Clean the body with wax and grease remover before the undercoat is sprayed.
Apply the undercoat to the front wheelhouse, rear wheelhouse, and undersides of the front floor and rear floor, refer to undercoating diagram.
Coat the bottom of the fuel tank.
Anti-rust Agents
Anti-rust agents contain substances that are harmful if you breathe or swallow them, or get them on your skin. Wear coveralls, gloves, eye
protection, and an approved respirator while using such agents.
Ventilate when spraying an anti-rust agent as it contains a small amount of organic solvent. Keep sparks, flames and cigarettes away.
NOTE:
Do not spray an anti-rust agent on the brake system components, exhaust system components and related parts, emission control devices in the
engine compartment, ball joint covers, the fuel strainer, or exterior and interior parts.
Wipe the excess agent with a clean rag dampened with light oil.
Follow the anti-rust agent manufacturer's instructions.
Before applying an anti-rust agent, thoroughly clean the area to be coated with a steam cleaner, etc., and let it dry. Waxoyl may be applied to a
wet surface.
Apply the anti-rust agent from the installation hole and the access hole to parts in the outer panel and the frame. Spray the anti-rust agent
sufficiently until the excess amount oozes out when filling the side sill.
Rust-preventive Treatments - Undercoating Area
Apply undercoat to the areas shown.
NOTE:
Coating thickness: 0.4 mm (0.016 in.) MIN.
Front wheelhouse, rear wheelhouse, and dashboard lower coating thickness 0.5 mm (0.02 in.).
Apply the undercoat 10 mm (0.4 in.) from the edge of the welded flanges.
REAR
FRAME
FRONT SIDE FRAME
REAR FLOOR SIDE 246 mm
40 mm (9.69 in.)
FRONT DAMPER (1.6 in.)
EXTENSION
10 mm
(0.4 in.) REAR
BACKPLATE FLOOR
268 mm
[SIDE SILL Section] REAR FRAME (10.6 in.)
OUTER PANEL
INSIDE SILL
FRONT FLOOR
REAR FRAME
INSIDE SILL
EXTENSION
HOOD JACK-UP
STIFFENER
HOOD HINGE
FLOOR CENTER
CROSS-MEMBER
MIDDLE SEAT
CROSS-MEMBER
FRONT FLOOR FRAME REAR
DASHBOARD UPPER
FLOOR TUNNEL
CROSS-MEMBER
REAR WHEEL
ARCH
SIDE SILL
FRONT SIDE
FRAME
WHEELHOUSE
UPPER MEMBER REAR DOOR
BULKHEAD LOWER OUTRIGGER
CROSS-MEMBER
REAR DOOR HINGE
SIDE FRAME GUSSET WHEELHOUSE
LOWER MEMBER
FRONT DOOR
FRONT FENDER
Service Precautions
General
Protect all painted surfaces and seats against dirt and scratches with a clean cloth or vinyl cover.
Work safety and give your work your undivided attention. When either the front or rear wheels are to be raised,
block the remaining wheels securely. Communicate at frequently as possible when work involves two or more
workers. Do not run the engine unless the shop or working area is well ventilated.
Before removing or disassembling parts, they must be inspected carefully to isolate the cause for which service is
necessary. Observe all safety notes and precautions and follow the proper procedures as described in this manual.
Mark or place all removed parts in order in a parts rack so they can be reassembled in their original places.
Parts must be assembled with the proper torque according to the maintenance standards established.
When tightening a series of bolts or nuts, begin with the center or large diameter bolts and tighten them in
crisscross pattern in two or more steps.
Use new packings, gaskets, O-rings, and cotter pins whenever reassembling.
Do not reuse parts that must be required to replace. Always replace them.
Use Honda parts and lubricants or those equivalent. When parts are to be reused, they must be inspected carefully
to make sure they are not damaged or deteriorated and are in good usable condition.
Coat or fill parts with specified grease as specified. Clean all removed parts with solvent upon disassembly.
Before Troubleshooting
Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will
damage the alternator diodes.
Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely
damage the wiring.
3. Check the drive belt tension.
Handling Connectors
Make sure the connectors are clean and have no loose wire terminals.
Make sure multiple cavity connectors are packed with grease (except watertight connectors).
All connectors have push-down release type locks (A).
Some connectors have a clip on their side used to attach them to a mounting bracket on the body or on another
component. This clip has a pull type lock.
Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector
from its mount bracket (A).
Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead.
Always reinstall plastic covers.
Before connecting connectors, make sure the terminals (A) are in place and not bent.
The backs of some connectors are packed with grease. Add grease if necessary. If the grease is contaminated,
replace it.
Insert the connector all the way and make sure it is securely locked.
Position wires so that the open end of the cover faces down.
Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations.
Remove clips carefully; don't damage their locks (A).
Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the
clip.
After installing harness clips, make sure the harness doesn't interfere with any moving parts.
Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and
from exposed screws and bolts.
Seat grommets in their grooves properly (A). Do not leave grommets distorted (B).
Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with
electrical tape.
After installing parts, make sure that no wires are pinched under them.
When using electrical test equipment, follow the manufacturer's instructions and those described in this manual.
If possible, insert the probe of the tester from the wire side (except waterproof connector).
Puncturing the insulation on a wire can cause poor or intermittent electrical connections.
For testing at connectors, bring the tester probe into contact with the terminal from the connector side of wire
harness connectors in the engine compartment.
For female connectors, just tough lightly with the tester probe and do not insert the probe.
When checking any control module(s) or unit(s) connector terminals, gently slide the sharp tester probe from the wire side
into the connector until it comes in contact with the terminal end of the wire.
Five-step Troubleshooting
1. Verify The Complaint
Turn on all the components in the problem circuit to verify the customer complaint. Note the symptoms. Do not
begin disassembly or testing until you have narrowed down the problem area.
2. Analyze The Schematic
Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current
paths from the power feed through the circuit components to ground. If several circuits fail at the same time, the
fuse or ground is a likely cause.
Based on the symptoms and your understanding of the circuit operation, identify one or more possible causes of
the problem.
3. Isolate The Problem By Testing The Circuit
Make circuit tests to check the diagnosis you made in Step 2 . Keep in mind that a logical, simple procedure is the
key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are
easily accessible.
4. Fix The Problem
Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures.
5. Make Sure The Circuit Works
Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the
problem was a blown fuse, be sure to test all of the circuits on the fuse. Make sure no new problems turn up and
the original problem does not recur.
Wire Color Codes
The following abbreviations are used to identify wire colors in the circuit schematics:
WHT. White
YEL. Yellow
BLK. Black
BLU. Blue
GRN. Green
RED. Red
ORN. Orange
PNK. Pink
BRN. Brown
GRY. Gray
PUR. Purple
LT BLU. Light Blue
LT GRN. Light Green
The wire insulation has one color or one color with another color stripe. The second color is the stripe.
Dashboard Fuse Lid Panel Removal/Installation
LHD Model
NOTE:
Take care not to scratch the dashboard and its related parts.
When removing components, use the trim tools or equivalent.
1. Pull the fuse lid panel (A) back by hand to release the hooks (B) and the clips.
16. Install a jumper wire between the No. 5 and the No. 6 terminals of SRS unit connector A (39P).
17. Check for continuity between the No. 2 and the No. 3 terminals of the dashboard wire harness 4P connector.
Is there continuity?
YES - Faulty SRS unit or poor connection at SRS unit connector A (39P) and the SRS unit. Check the
connection between the connector and the SRS unit. If the connection is OK, replace the SRS unit. ■
NO - Open or increased resistance in the dashboard wire harness; replace the dashboard wire harness.■
SRS DTC Troubleshooting: 12-3x
DTC 12-3x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Another Wire or Decreased Resistance in the Passenger's Airbag Inflator (LHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 12-3x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect the dashboard wire harness 4P connector from the front passenger's airbag.
7. Do the battery terminal reconnection procedure.
8. Clear the DTC memory.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Read the DTC.
Is DTC 12-3x indicated?
YES - Go to Step 10 .
NO - Faulty front passenger's airbag; replace the front passenger's airbag. ■
11. Turn the ignition switch to LOCK (0).
12. Do the battery terminal disconnection procedure , then wait for 3 minutes.
13. Disconnect SRS unit connector A (39P) from the SRS unit.
14. Connect an SRS short canceller (070AZ-SAA0100) to the No. 5 and the No. 6 terminals of the SRS unit connector
A (39P).
15. Measure the resistance between the No. 5 and the No. 6 terminals of the SRS unit connector A (39P). There
should be 0−1.0 Ω.
Is the resistance as specified?
YES - Short in the dashboard wire harness; replace the dashboard wire harness.■
NO - Faulty SRS unit; replace the SRS unit. ■
SRS DTC Troubleshooting: 12-8x
DTC 12-8x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Power in the Front Passenger's Airbag Inflator (LHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 12-8x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect SRS unit connector A (39P) from the SRS unit.
7. Connect an SRS short canceller (070AZ-SAA0100) to the No. 5 and the No. 6 terminals of the SRS unit connector
A (39P).
8. Do the battery terminal reconnection procedure.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Measure the voltage between the No. 5 and the No. 6 terminals of the SRS unit connector A (39P) and body
ground. There should be less than 1 V.
Is the voltage as specified?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Go to Step 11 .
11. Turn the ignition switch to LOCK (0).
12. Do the battery terminal disconnection procedure , then wait for 3 minutes.
13. Disconnect the dashboard wire harness 4P connector from the front passenger's airbag.
14. Do the battery terminal reconnection procedure.
15. Turn the ignition switch to ON (II), then wait for 10 seconds.
16. Measure the voltage between the No. 5 and the No. 6 terminals of SRS unit connector A (39P) and body ground.
There should be less than 1 V.
Is the voltage as specified?
YES - Faulty front passenger's airbag; replace the front passenger's airbag. ■
NO - Short to power in the dashboard wire harness; replace the dashboard wire harness.■
SRS DTC Troubleshooting: 12-9x
DTC 12-9x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Ground in the Front Passenger's Airbag Inflator (LHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 12-9x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect SRS unit connector A (39P) from the SRS unit.
7. Check for continuity between the No. 5 and the No. 6 terminals of SRS unit connector A (39P) and body ground.
Is there continuity?
YES - Go to Step 8 .
NO - Faulty SRS unit; replace the SRS unit. ■
8. Disconnect the dashboard wire harness 4P connector from the front passenger's airbag.
9. Check for continuity between the No. 5 and the No. 6 terminals of SRS unit connector A (39P) and body ground.
Is there continuity?
YES - Short to ground in the dashboard wire harness: replace the dashboard wire harness.■
NO - Faulty front passenger's airbag; replace the front passenger's airbag. ■
Fuel and Emissions Systems Connector and Harness Locations
LHD model
G101 2 3
ECM/PCM Circuit Diagram (cont'd) 1
ROCKER ARM
OIL CONTROL ENGINE 4 EVAP CANISTER
SOLENOID WIRE HARNESS
24P JUNCTION CONNECTOR 12P JUNCTION CONNECTOR MAP SENSOR PURGE VALVE
LHD model
(1) (2) (A/T) (2) (M/T) 5 (3) (4)
7
ENGINE
ECM/PCM Circuit Diagram (cont'd) WIRE HARNESS SECONDARY
No. 1 No. 2 No. 3 No. 4 ENGINE 8
A/F SENSOR HO2S
INJECTOR INJECTOR INJECTOR INJECTOR WIRE(SENSOR
HARNESS 1) (SENSOR 2)
(1) (2) OUTPUT
(3) SHAFT 5 (4)6 67 OUTPUT SHAFT
(5) (6)
LHD model (COUNTERSHAFT)
4 MAF SENSOR/ (COUNTERSHAFT)
24P JUNCTION CONNECTOR SPEED SENSOR IAT SENSOR SPEED SENSOR LEFT
10P ENGINE
CONNECTOR
31
(5) (6) (M/T) (7) (8) (A/T) 9 COMPARTMENT
(9)
3 WIRE HARNESS
DASHBOARD WIRE HARNESS 8
CABLE REEL SUBHARNESS
ECM/PCM Circuit Diagram (cont'd) 6 7 8 9 10
2 11
5
12P JUNCTION No. 4 No. 3 10
LHD model 13P CONNECTOR TEST CONNECTOR (2) 14P CONNECTOR IGNITION ESP12
CONTROL UNITIGNITION
THROTTLE
13P CONNECTOR
(1)
BODY TACHOMETER
CMP SENSOR ECT SENSOR
ECM/PCM
1 A (□) (12)*
CKP SENSOR
(3) COIL (11) ECM/PCM
(4) COIL (12)
B ( ) (13)*
(7)
(10) 1 CONNECTOR
(8) (9) (10) 13 9
(11) DASHBOARD WIRE HARNESS CABLE REEL SUBHARNESS
4
11
RIGHT ENGINE 10
UNDER-DASH
COMPARTMENT UNDER-DASH UNDER-DASH UNDER-DASH
FUSE/RELAY BOX
WIRE HARNESS FUSE/RELAY BOX FUSE/RELAY FUSE/RELAY ELD (5)
(K) (1) (N) (2) BOX (S) (3) BOX (T) (4) RIGHT ENGINE
30
No. 2 No. 1 ABS MODULATOR-
12P JUNCTION 12P JUNCTION COMPARTMENT
IGNITION GAUGE CONTROL MODULE
IGNITION(5) ECT SENSOR 2 APP SENSOR CONTROL
CONNECTOR
UNIT (7) CONNECTOR
3P CONNECTOR
(8)RIGHT 12
WIRE HARNESS
COIL (13) COIL (14) (15) (6) (16) (17) ENGINE
LEFT ENGINE COMPARTMENT
ECM/PCM
COMPARTMENT WIRE C (○) (14)*
HARNESS 14ENGINE
WIRE HARNESS
WIRE
17 3 13HARNESS
LEFT ENGINE 2ND CLUTCH A/T CLUTCH A/T CLUTCH 3ND CLUTCH
TRANSMISSION PRESSURE PRESSURE TRANSMISSION
COMPARTMENT 29WIRE HARNESS FLUID CONTROL CONTROL FLUID
PRESSURE UNDER-DASH FUSE/RELAY
TRANSMISSION SOLENOID BOX (A) (8) SOLENOID PRESSURE 15
UNDER-DASH UNDER-DASH SWITCH (15) RANGE SWITCH VALVE A VALVE C 14
SWITCH
FUSE/RELAY2 FUSE/RELAY BOX (A/T) (16) (A/T) (17) (A/T) (18) (A/T) (19) (A/T)11
NOTE: 28 PADDLE PADDLE
BOX (W) (6) (Q) (7)
· Connector with male terminals (double outline): view from terminal side 15
SHIFTER− SHIFTER+
· Connector with female terminals (single outline): view from wire side (DOWNSHIFT (UPSHIFT 16
27 SWITCH)
*: Connector with female terminals (single outline): view from terminal side (11) EVAPORATOR SWITCH) (13) 12
12P JUNCTION
1
(A/T with 17
TEMPERATURE (A/T with
26 paddle shifter 19 paddle
CONNECTOR (9) CABLE REEL (10)
model)
SENSOR (12) 16 shifter
model)
13P CONNECTOR 17
(14)
25 18
20
AUXILIARY UNDER-HOOD TRANSMISSION RANGE
SHIFT SHIFT SHIFT RELAY BOX21(23) SWITCH SUBHARNESS SHIFT
(A/T)
CONTROL CONTROL CONTROL24 ATF CONTROL
SOLENOID SOLENOID SOLENOID 23 TEMPERATURE SOLENOID
VALVE C SHIFT
VALVE A SOLENOID VALVE D 22 SENSOR VALVE B
(20) (A/T) WIRE HARNESS (A/T)(22) (A/T)
(21) (A/T) (24) (A/T) (25) (A/T)
13
22
UNDER-DASH FUSE/RELAY BOX (B) (9)
CRANK SENSOR 21
SUBHARNESS TEMPERATURE
14 LOCK
SHIFT
CABLE REEL (15) IGNITION SWITCH CONTROL DIAL A/CFUEL PUMP
CONDENSER SOLENOID
23 16 A/C COMPRESSOR
(16) (17) (KP model) FAN(18)
RELAY (19) (A/T)
CLUTCH RELAY 18
1RADIATOR FAN RELAY
A/T CLUTCH
PRESSURE 19
CONTROL
SOLENOID
8P CONNECTOR VALVE B INPUT SHAFT (MAINSHAFT) OIL PRESSURE 15KNOCK SENSOR
20 ALTERNATOR
(26) (27) (A/T) SPEED SENSOR (28) (A/T) SWITCH (29) (30) (31)
M/T
2
BRAKE PEDAL CLUTCH PEDAL
M/T DATA LINK POSITION POSITION
NOTE: SRS UNIT A (20) CONNECTOR (21)* SWITCH (22) SWITCH (23)
(M/T)
· Connector with male terminals (double outline): view from terminal side
9 from wire side
· Connector with female terminals (single outline): view
*: Connector with female terminals (single outline): view from terminal side 3
NOTE:
· Connector with male terminals (double outline): view from terminal side 4
· Connector with female terminals (single outline): view from wire side
*: Connector with female terminals (single outline): view from terminal side
5
NOTE:
· Connector with male terminals (double outline): view from terminal side 6
· Connector with female terminals (single outline): view from wire side
*: Connector with female terminals (single outline): view from terminal side 7
UNDER-DASH FUSE/RELAY
8 BOX
UNDER-DASH FUSE/RELAY BOX
Fuel and Emissions Systems Connector and Harness Locations
LHD model
G101 2 3
ECM/PCM Circuit Diagram (cont'd)
ROCKER ARM 4
OIL CONTROL 12P JUNCTION 1 EVAP CANISTER
SOLENOID CONNECTOR (2) MAP SENSOR PURGE VALVE 24P 5
JUNCTION CONNECTOR
LHD model
(1)
ENGINE (M/T, i-SHIFT System) (3) (4) (5)
WIRE HARNESS
G101 1 6
ECM/PCM Circuit Diagram (cont'd) 2ND CLUTCH
ENGINE OUTPUT SHAFT TRANSMISSION
WIREOUTPUT
HARNESS
SHAFT (COUNTERSHAFT) FLUID
(COUNTERSHAFT) SPEED SENSOR 10P CONNECTOR PRESSURE 2 TEST TRANSMISSION
7
RANGE SWITCH
24P
MAF JUNCTION
SENSOR/ CONNECTOR 6P JUNCTION TACHOMETER
LHD model
(1)SENSOR
IAT (A/T) SPEED SENSOR (2) (A/T) (3) (A/T) CONNECTOR
SWITCH (4) (5) (A/T)
(7) 13P CONNECTOR (A/T) (9) CONNECTOR
(6) (M/T, i-SHIFT System) (8) (i-SHIFT System) (10) LEFT ENGINE
ENGINE COMPARTMENT
ECM/PCM Circuit Diagram (cont'd) WIRE HARNESS 5 6 WIRE
LEFTHARNESS
ENGINE
SECONDARY
No. 1 No. 2 No. 3 No. 4 7 ENGINE HO2S
IGNITION
A/F SENSOR
WIRE HARNESS COMPARTMENT
IGNITION IGNITION IGNITION (SENSOR 1) (SENSOR 2)
COIL (1) COIL (2) 4 COIL (3) COIL (4) (5) (6)WIRE HARNESS
LHD model21A/T CLUTCH A/T CLUTCH 3ND CLUTCH
8
PRESSURE PRESSURE TRANSMISSION SHIFT SHIFT SHIFT
CONTROL CONTROL
3 FLUID CONTROL CONTROL CONTROL
ECM/PCM A (□) (11)* SOLENOID
SOLENOID PRESSURE SOLENOID ECM/PCM B (SOLENOID
) (12)* 8
SOLENOID
VALVE A VALVE C SWITCH 3 4
VALVE C 5 VALVE A VALVESUBHARNESS
D
ECM/PCM Circuit
(6) (A/T) Diagram (cont'd)
(7) (A/T) 2 (8) (A/T) (9) (A/T)
6 7(10) (A/T) CABLE REEL
(11) (A/T) 3 9
8
2
1 9
9
LHD model No. 4
10
No. 3
12P JUNCTION
410
ESP CONTROL UNIT APP SENSOR
THROTTLE
(1) BODY CMP SENSOR GAUGE CONTROL ECT MODULE
SENSOR (2)
1 CKP A/T
SENSOR (3) INJECTOR INJECTOR
CONNECTOR (4)
CLUTCH
(7)DASHBOARD
20 1 HARNESS(8)SHIFT
WIRE (9) (10) PRESSURE (11)
RIGHT ENGINE
(12)
ATF CONTROL CONTROL CABLE REEL SUBHARNESS COMPARTMENT
TEMPERATURE SOLENOID SOLENOID 11
SENSOR VALVE B 8P CONNECTOR VALVE B INPUT SHAFT (MAINSHAFT) WIRE
10 HARNESS
19(12) (A/T) (13) (A/T) (14) (A/T) (15) (A/T) RIGHT ENGINE
SPEED SENSOR (16) (A/T)
RIGHT ENGINE 10P CONNECTOR (14) AUXILIARY UNDER-HOOD COMPARTMENT WIRE HARNESS
ECM/PCM C (○) (13)*DASHBOARD WIRE HARNESS (i-SHIFT System) RELAY BOX (15) PADDLE
COMPARTMENT 13P CONNECTOR 12P JUNCTION 14P CONNECTOR SHIFTER− 2P CONNECTOR (4) 12
WIRE HARNESS 18(1) CONNECTOR (2) (3) (DOWNSHIFT (i-SHIFT System)
No. 1 EGR VALVE SWITCH) (8) ABS MODULATOR-
EVAPORATOR
No. 2 12P JUNCTION (A/T with CONTROL
TEMPERATURE
UNIT 11
12P JUNCTION
INJECTOR INJECTOR (15) ECT SENSOR 2 13 (9)
ENGINE OIL
CONNECTOR (5) (14) CONNECTOR (6) (KE, KG models) CABLE REEL (7) (16) paddle shifter (17) SENSOR
LEFT ENGINE
(13)
LEVEL SENSOR 5 model)
COMPARTMENT
SUBHARNESSWIRE HARNESS
NOTE:
· Connector ENGINE
LEFT ENGINE with male terminals (double outline): view from terminal side
· ENGINE
Connector
COMPARTMENT with female terminals (single outline): view from wire side A/C CONDENSERWIRE
OIL
AUXILIARY 17
UNDER-DASH TRANSMISSION RANGE HARNESS
SWITCH
12
*:LEVEL
WIREConnector
HARNESS with female terminals (single outline): view from terminal sideA/C COMPRESSOR CLUTCHFAN RELAY
PEDAL
SENSOR
FUSE/RELAY16BOX (5) CLUTCH RELAY SUBHARNESS
POSITION (A/T)
SUBHARNESS CLUTCH PEDAL ATRANSMISSION
SWITCHRADIATOR FAN RELAY
4 BRAKE PEDAL POSITION (8) RANGE SWITCH 11 13
VSAACTUATOR
MODULATOR-15 POSITION SWITCH B (7) (KE, KG models)
SUBHARNESS (A/T)
CLUTCH
CONTROL UNIT 16 ENGINE OIL SWITCH (6) 5 (M/T)
PADDLE(TCM) (16) 3P CONNECTOR (M/T) OIL PRESSURE KNOCK SENSOR 14
LEVEL SENSOR (17) 3P CONNECTOR (18) CLUTCH
SHIFTER+ (17) System)
(i-SHIFT (KE, KG models)
(18)
(KE, KG models) SWITCH (19) ACTUATOR (20)
(UPSHIFT 14 14 SUBHARNESS (i-SHIFT System)
CLUTCH
SWITCH) (10) ACTUATOR SHIFT SOLENOID
13P CONNECTOR 20P CONNECTOR 12
(A/T with
SUBHARNESS
18 (11) (WithWIRE
ABS) HARNESS (A/T) 15 (11) (With VSA) 6 CABLE REEL (12)
paddle3shifter 13 12 7
model) 9 8
SHIFT SOLENOID 11 10
STARTER RELAY 2 15
WIRE HARNESS (A/T)
2 13
UNDER-DASH UNDER-DASH UNDER-DASH UNDER-DASH UNDER-DASH
NOTE: ALTERNATORCRANK SENSOR
FUSE/RELAY BOX FUSE/RELAY BOX FUSE/RELAY 21 FUSE/RELAY ELD (13) FUSE/RELAY
· Connector(21)
(K)with
(9) male terminals (double outline):
SUBHARNESS (N) (10) view from terminal side
BOX (S) (11) 20
BOX (T) (12) 19 BOX
14(X) (14)
1 female terminals (single outline): view from wire side
· Connector with
*: Connector with female terminals (single
INERTIA 17 outline): view from terminal side 6 SHIFT LOCK GEAR SHIFT
IGNITION SWITCH SWTITCH (14) 12P JUNCTION FUEL PUMP SOLENOID CONTROL MODULE (18)
(13) (KE, KG models) CONNECTOR (15) (16) (17) (A/T) (i-SHIFT System) 16
15
16 17
22
18
NOTE:
· Connector with male terminals (double outline):M/T
view from terminal side
· Connector with female terminalsUNDER-DASH
(single outline): view from wire side 9 BOX (A) (17)
UNDER-DASH FUSE/RELAY
UNDER-DASH
*: Connector with female8terminalsFUSE/RELAY
FUSE/RELAY (single outline):
BOX view from terminal side
BOX (W) (15) (Q) (16) AUXILIARY
YAW RATE-LATERAL/
LONGITUDINAL UNDER-DASH
ACCELERATION 10 FUSE HOLDER
DATA LINK (22)
SRS UNIT A (19) 7 CONNECTOR (20)* SENSOR (21) (With VSA)
(i-SHIFT System)
M/T
11
7.5A 7.5A
18
12
17
UNDER-DASH FUSE/RELAY BOX (B) (18)
NOTE: UNDER-DASH FUSE/RELAY BOX 13
· Connector with male terminals (double outline): view from terminal side
· Connector with female terminals (single outline): view from wire side 14
*: Connector with female terminals (single outline): view from terminal side
NOTE:
· Connector with male terminals (double outline): view from terminal side
· Connector with female terminals (single outline): view from wire side
*: Connector with female terminals (single outline): view from terminal side
Brake Booster Replacement
LHD Model
1. Remove the air cleaner cover, and the air cleaner case.
2. Remove the master cylinder.
3. Disconnect the brake booster vacuum hose (A) from the brake booster.
7. Remove the lock pin (A) and the joint pin (B), then disconnect the yoke from the brake pedal.
8. Remove the brake booster mounting nuts (C).
Be careful not to damage the booster surfaces and threads of the booster stud bolts.
Be careful not to bend or damage the brake lines or other components hoses and lines.
NOTE:
Use new booster gasket (B) reassembly.
KG ABS model: Install the brake booster bracket (C) between brake booster and new gasket reassembly.
10. Install the brake booster in the reverse order of removal, and note these items:
Install the master cylinder after installing the brake booster.
Check the brake pedal height and free play after installing the master cylinder, and adjust it if necessary.
Bleed the brake system.
KG ABS model: Check the brake assist.
Relay and Control Unit Locations - Dashboard 1
LHD model
DAYTIME RUNNING
LIGHTS RELAY
Wire colors: BRN, WHT,
RED, GRY, and LT GRN
POWER WINDOW
RELAY (P/W)
BLOWER MOTOR
RELAY
LIGHTING RELAY 1
LHD model
G451
RIGHT ENGINE COMPARTMENT
WIRE HARNESS
G401
SRS DTC Troubleshooting: 11-1x, 11-2x
DTC 11-1x (‘‘x'' can be 0 thru 9 or A thru F):
Open in the Driver's Airbag First Inflator (LHD model)
DTC 11-2x (‘‘x'' can be 0 thru 9 or A thru F):
Increased Resistance in the Driver's Airbag First Inflator (LHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures , General Troubleshooting
Information , and Battery Terminal Disconnection/Reconnection.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 11-1x or 11-2x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.■
4. Turn the ignition switch to LOCK (0).
5. Disconnect the negative cable from the battery, then wait at least 3 minutes.
6. Disconnect the driver's airbag 4P connector from the cable reel.
7. Install a jumper wire between the No. 2 [No. 4] and the No. 3 terminals of the cable reel 4P connector.
[ ]: KG model
8. Reconnect the negative cable to the battery.
9. Clear the DTC memory.
10. Turn the ignition switch to ON (II), then wait for 10 seconds.
11. Read the DTC.
Is DTC 11-1x or 11-2x indicated?
YES - Go to Step 12 .
NO - Faulty driver's airbag; replace the driver's airbag. ■
12. Turn the ignition switch to LOCK (0).
13. Disconnect the negative cable from the battery, then wait at least 3 minutes.
14. Remove the column cover , then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
15. Install a jumper wire between the No. 2 [No. 4] and the No. 3 terminals of the dashboard wire harness 4P
connector.
[ ]: KG model
16. Reconnect the negative cable to the battery.
17. Read the DTC.
Is DTC 11-1x or 11-2x indicated?
YES - Go to Step 18 .
NO - Open or increased resistance in the cable reel; replace the cable reel. ■
18. Turn the ignition switch to LOCK (0).
19. Disconnect the negative cable from the battery, then wait at least 3 minutes.
20. Remove a jumper wire from the dashboard wire harness 4P connector.
21. Disconnect SRS unit connector A (39P) from the SRS unit.
22. Install a jumper wire between the No. 3 and the No. 4 terminals of SRS unit connector A (39P).
23. Measure the resistance between the No. 2 [No. 4] and the No. 3 terminals of the dashboard wire harness 4P
connector. There should be less than 1.0 Ω.
[ ]: KG model
Is the resistance as specified?
YES - Faulty SRS unit or poor connection at SRS unit connector A (39P) and the SRS unit. Check the
connection between the connector and the SRS unit. If the connection is OK, replace the SRS unit. ■
NO - Open or increased resistance in the dashboard wire harness; replace the dashboard wire harness.■
SRS DTC Troubleshooting: 11-3x
DTC 11-3x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Another Wire or Decreased Resistance in the Driver's Airbag First Inflator (LHD model)
Special Tools Required
SRS short canceller
070AZ-SAA0100
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures , General Troubleshooting
Information , and Battery Terminal Disconnection/Reconnection.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 11-3x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.■
4. Turn the ignition switch to LOCK (0).
5. Disconnect the negative cable from the battery, then wait at least 3 minutes.
6. Disconnect the driver's airbag 4P connector from the cable reel.
7. Reconnect the negative cable to the battery.
8. Clear the DTC memory.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Read the DTC.
Is DTC 11-3x indicated?
YES - Go to Step 11 .
NO - Faulty driver's airbag; replace the driver's airbag. ■
11. Turn the ignition switch to LOCK (0).
12. Disconnect the negative cable from the battery, then wait at least 3 minutes.
13. Remove the column cover , then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
14. Reconnect the negative cable to the battery.
15. Clear the DTC memory.
16. Turn the ignition switch to ON (II), then wait for 10 seconds.
17. Read the DTC.
Is DTC 11-3x indicated?
YES - Go to Step 18 .
NO - Short in the cable reel; replace the cable reel. ■
18. Turn the ignition switch to LOCK (0).
19. Disconnect the negative cable from the battery, then wait at least 3 minutes.
20. Disconnect SRS unit connector A (39P) from the SRS unit.
21. Connect an SRS short canceller (070AZ-SAA0100) to the No. 3 and the No. 4 terminals of the SRS unit connector
A (39P).
22. Measure the resistance between the No. 3 and the No. 4 terminals of SRS unit connector A (39P). There should be
less than 1.0 Ω.
Is the resistance as specified?
YES - Short in the dashboard wire harness; replace the dashboard wire harness.■
NO - Faulty SRS unit; replace the SRS unit. ■
SRS DTC Troubleshooting: 11-4x, 11-5x
DTC 11-4x (‘‘x'' can be 0, 2 thru 9 or A thru F):
Open in the Driver's Airbag Second Inflator (LHD model)
DTC 11-5x (‘‘x'' can be 0, 2 thru 9 or A thru F):
Increased Resistance in the Driver's Airbag Second Inflator (LHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures , General Troubleshooting
Information , and Battery Terminal Disconnection/Reconnection.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 11-4x or 11-5x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.■
4. Turn the ignition switch to LOCK (0).
5. Disconnect the negative cable from the battery, then wait at least 3 minutes.
6. Disconnect the driver's airbag 4P connector from the cable reel.
7. Install a jumper wire between the No. 1 and the No. 2 terminals of the cable reel 4P connector.
8. Reconnect the negative cable to the battery.
9. Read the DTC.
Is DTC 11-4x or 11-5x indicated?
YES - Go to Step 10 .
NO - Faulty driver's airbag; replace the driver's airbag. ■
10. Turn the ignition switch to LOCK (0).
11. Disconnect the negative cable from the battery, then wait at least 3 minutes.
12. Remove the column cover , then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
13. Install a jumper wire between the No. 1 and the No. 2 terminals of the dashboard wire harness 4P connector.
14. Reconnect the negative cable to the battery.
15. Read the DTC.
Is DTC 11-4x or 11-5x indicated?
YES - Go to Step 16 .
NO - Open in the cable reel; replace the cable reel. ■
16. Turn the ignition switch to LOCK (0).
17. Remove the jumper wire from the dashboard wire harness 4P connector.
18. Disconnect the negative cable from the battery, then wait at least 3 minutes.
19. Disconnect SRS unit connector A (39P) from the SRS unit.
20. Install a jumper wire between the No. 7 and the No. 8 terminals of SRS unit connector A (39P).
21. Check for continuity between the No. 1 and the No. 2 terminals of the dashboard wire harness 4P connector.
Is there continuity?
YES - Faulty SRS unit or poor connection at SRS unit connector A (39P) and the SRS unit. Check the
connection between the connector and the SRS unit. If the connection is OK, replace the SRS unit. ■
NO - Open in the dashboard wire harness; replace the dashboard wire harness.■
SRS DTC Troubleshooting: 11-6x
DTC 11-6x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Another Wire or Decreased Resistance in the Driver's Airbag Second Inflator (LHD model)
Special Tools Required
SRS short canceller
070AZ-SAA0100
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures , General Troubleshooting
Information , and Battery Terminal Disconnection/Reconnection.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 11-6x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.■
4. Turn the ignition switch to LOCK (0).
5. Disconnect the negative cable from the battery, then wait at least 3 minutes.
6. Disconnect the driver's airbag 4P connector from the cable reel.
7. Read the DTC.
Is DTC 11-6x indicated?
YES - Go to Step 8 .
NO - Faulty driver's airbag; replace the driver's airbag. ■
8. Turn the ignition switch to LOCK (0).
9. Disconnect the negative cable from the battery, then wait at least 3 minutes.
10. Remove the column cover , then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
11. Read the DTC.
Is DTC 11-6x indicated?
YES - Go to Step 12 .
NO - Short in the cable reel; replace the cable reel. ■
12. Turn the ignition switch to LOCK (0).
13. Disconnect the negative cable from the battery, then wait at least 3 minutes.
14. Disconnect SRS unit connector A (39P) from the SRS unit.
15. Connect an SRS short canceller (070AZ-SAA0100) to No. 7 and the No. 8 terminals of the SRS unit connector A
(39P).
16. Measure the resistance between the No. 7 and the No. 8 terminals of the SRS unit connector A (39P). There
should be less than 1.0 Ω.
Is the resistance as specified?
YES - Short in the dashboard wire harness; replace the dashboard wire harness.■
NO - Faulty SRS unit; replace the SRS unit. ■
SRS DTC Troubleshooting: 11-8x
DTC 11-8x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Power in the Driver's Airbag First Inflator (LHD model)
Special Tools Required
SRS short canceller
070AZ-SAA0100
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures , General Troubleshooting
Information , and Battery Terminal Disconnection/Reconnection.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 11-8x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Disconnect the negative cable from the battery, then wait at least 3 minutes.
6. Disconnect SRS unit connector A (39P) from the SRS unit.
7. Connect an SRS short canceller (070AZ-SAA0100) to the No. 3 and the No. 4 terminals of SRS unit connector A
(39P).
8. Reconnect the negative cable to the battery.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Measure the voltage between the No. 3 and the No. 4 terminals of SRS unit connector A (39P) and body ground.
There should be less than 1.0 V.
Is the voltage as specified?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Go to Step 11 .
11. Turn the ignition switch to LOCK (0).
12. Disconnect the negative cable from the battery, then wait at least 3 minutes.
13. Disconnect the driver's airbag 4P connector from the cable reel.
14. Reconnect the negative cable to the battery.
15. Turn the ignition switch to ON (II), then wait for 10 seconds.
16. Measure the voltage between the No. 3 and the No. 4 terminals of SRS unit connector A (39P) and body ground.
There should be less than 1.0 V.
Is the voltage as specified?
YES - Faulty driver's airbag; replace the driver's airbag. ■
NO - Go to Step 17 .
17. Turn the ignition switch to LOCK (0).
18. Disconnect the negative cable from the battery, then wait at least 3 minutes.
19. Remove the column cover , then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
20. Reconnect the negative cable to the battery.
21. Turn the ignition switch to ON (II), then wait for 10 seconds.
22. Measure the voltage between the No. 3 and the No. 4 terminals of SRS unit connector A (39P) and body ground.
There should be less than 1.0 V.
Is the voltage as specified?
YES - Short to power in the cable reel; replace the cable reel. ■
NO - Short to power in the dashboard wire harness; replace the dashboard wire harness.■
SRS DTC Troubleshooting: 11-9x
DTC 11-9x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Ground in the Driver's Airbag First Inflator (LHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 11-9x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.■
4. Turn the ignition switch to LOCK (0).
5. Disconnect the negative cable from the battery, then wait at least 3 minutes.
6. Disconnect SRS unit connector A (39P) from the SRS unit.
7. Measure the resistance between the No. 3 and the No. 4 terminals of SRS unit connector A (39P) and body
ground. There should be less than 1.0 Ω.
Is the resistance as specified?
YES - Go to Step 8 .
NO - Faulty SRS unit; replace the SRS unit. ■
8. Disconnect the driver's airbag 4P connector from the cable reel.
9. Measure the resistance between the No. 3 and the No. 4 terminals of SRS unit connector A (39P) and body
ground. There should be less than 1.0 Ω.
Is the resistance as specified?
YES - Go to Step 10 .
NO - Faulty driver's airbag; replace the driver's airbag. ■
10. Remove the column cover , then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
11. Measure the resistance between the No. 3 and the No. 4 terminals of SRS unit connector A (39P) and body
ground. There should be less than 1.0 Ω.
Is the resistance as specified?
YES - Short to ground in the dashboard wire harness: replace the dashboard wire harness.■
NO - Short to ground in the cable reel; replace the cable reel. ■
SRS DTC Troubleshooting: 11-Ax
DTC 11-Ax (‘‘x'' can be 0 thru 9 or A thru F):
Short to Power in the Driver's Airbag Second Inflator (LHD model)
Special Tools Required
SRS short canceller
070AZ-SAA0100
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures , General Troubleshooting
Information , and Battery Terminal Disconnection/Reconnection.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 11-Ax indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.■
4. Turn the ignition switch to LOCK (0).
5. Disconnect the negative cable from the battery, then wait at least 3 minutes.
6. Disconnect SRS unit connector A (39P) from the SRS unit.
7. Connect an SRS short canceller (070AZ-SAA0100) to the No. 7 and the No. 8 terminals of SRS unit connector A
(39P).
8. Reconnect the negative cable to the battery.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Measure the voltage between the No. 7 and the No. 8 terminals of the SRS unit connector A (39P) and body
ground. There should be less than 1.0 V.
Is the voltage as specified?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Go to Step 11 .
11. Turn the ignition switch to LOCK (0).
12. Disconnect the negative cable from the battery, then wait at least 3 minutes.
13. Disconnect the driver's airbag 4P connector from the cable reel.
14. Reconnect the negative cable to the battery.
15. Turn the ignition switch to ON (II), then wait for 10 seconds.
16. Measure the voltage between the No. 7 and the No. 8 terminals of SRS unit connector A (39P) and body ground.
There should be less than 1.0 V.
Is the voltage as specified?
YES - Faulty driver's airbag; replace the driver's airbag. ■
NO - Go to Step 17 .
17. Turn the ignition switch to LOCK (0).
18. Disconnect the negative cable from the battery, then wait at least 3 minutes.
19. Remove the column cover , then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
20. Reconnect the negative cable to the battery.
21. Turn the ignition switch to ON (II), then wait for 10 seconds.
22. Measure the voltage between the No. 7 and the No. 8 terminals of SRS unit connector A (39P) and body ground.
There should be less than 1.0 V.
Is the voltage as specified?
YES - Short to power in the cable reel; replace the cable reel. ■
NO - Short to power in the dashboard wire harness; replace the dashboard wire harness.■
SRS DTC Troubleshooting: 11-Bx
DTC 11-Bx (‘‘x'' can be 0 thru 9 or A thru F):
Short to Ground in the Driver's Airbag Second Inflator (LHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 11-Bx indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.■
4. Turn the ignition switch to LOCK (0).
5. Disconnect the negative cable from the battery, then wait at least 3 minutes.
6. Disconnect SRS unit connector A (39P) from the SRS unit.
7. Check for continuity between the No. 7 and the No. 8 terminals of SRS unit connector A (39P) and body ground.
Is there continuity?
YES - Go to Step 8 .
NO - Faulty SRS unit; replace the SRS unit. ■
8. Disconnect the driver's airbag 4P connector from the cable reel.
9. Check for continuity between the No. 7 and the No. 8 terminals of SRS unit connector A (39P) and body ground.
Is there continuity?
YES - Go to Step 10 .
NO - Faulty driver's airbag; replace the driver's airbag. ■
10. Remove the column cover , then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
11. Check for continuity between the No. 7 and the No. 8 terminals of SRS unit connector A (39P) and body ground.
Is there continuity?
YES - Short to ground in the dashboard wire harness: replace the dashboard wire harness.■
NO - Short to ground in the cable reel; replace the cable reel. ■
Left Engine Compartment Wire Harness Locations
LHD model
G301
G302
G201
G202
Right Engine Compartment Wire Harness Locations
LHD model
G451
RIGHT ENGINE COMPARTMENT
WIRE HARNESS
G402
G401
Dashboard Fuse Lid Panel Removal/Installation
RHD Model
NOTE:
Take care not to scratch the dashboard and its related parts.
When removing components, use the trim tools or equivalent.
1. Pull out the fuse lid panel (A) to detach the clips.
2. Gently pull down the bottom edge of the fuse lid panel (A) to detach the hooks (B).
3. Install the panel in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips and the hooks into place securely.
Dashboard Driver's Lower Cover Removal/Installation
RHD Model
NOTE:
Take care not to scratch the dashboard and its related parts.
When removing components, use the trim tools or equivalent.
1. Remove the driver's dashboard lower cover (A).
-1. Use the trim tool to pry the bottom side of the panel partially out.
-2. Pry the front bottom of the panel slightly toward you and release the clips and the hooks (B).
2. Install the lower cover in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips and the hooks into place securely.
SRS DTC Troubleshooting: 11-1x, 11-2x
DTC 11-1x (‘‘x'' can be 0 thru 9 or A thru F):
Open in the Front Passenger's Airbag Inflator (RHD model)
DTC 11-2x (‘‘x'' can be 0 thru 9 or A thru F):
Increased Resistance in the Front Passenger's Airbag Inflator (RHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 11-1x or 11-2x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect the dashboard wire harness 4P connector from the front passenger's airbag.
7. Install a jumper wire between the No. 2 and the No. 3 terminals of the dashboard wire harness 4P connector.
8. Do the battery terminal reconnection procedure.
9. Clear the DTC memory.
10. Turn the ignition switch to ON (II), then wait for 10 seconds.
11. Read the DTC.
Is DTC 11-1x or 11-2x indicated?
YES - Go to Step 12 .
NO - Faulty front passenger's airbag; replace the front passenger's airbag. ■
12. Turn the ignition switch to LOCK (0).
13. Do the battery terminal disconnection procedure , then wait for 3 minutes.
14. Remove a jumper wire from the dashboard wire harness 4P connector.
15. Disconnect SRS unit connector A (39P) from the SRS unit.
16. Install a jumper wire between the No. 3 and the No. 4 terminals of SRS unit connector A (39P).
17. Check for continuity between the No. 2 and the No. 3 terminals of the dashboard wire harness 4P connector.
Is there continuity?
YES - Faulty SRS unit or poor connection at SRS unit connector A (39P) and the SRS unit. Check the
connection between the connector and the SRS unit. If the connection is OK, replace the SRS unit. ■
NO - Open or increased resistance in the dashboard wire harness; replace the dashboard wire harness.■
SRS DTC Troubleshooting: 11-3x
DTC 11-3x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Another Wire or Decreased Resistance in the Front Passenger's Airbag Inflator (RHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 11-3x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect the dashboard wire harness 4P connector from the front passenger's airbag.
7. Clear the DTC memory.
8. Turn the ignition switch to ON (II), then wait for 10 seconds.
9. Read the DTC.
Is DTC 11-3x indicated?
YES - Go to Step 10 .
NO - Faulty front passenger's airbag; replace the front passenger's airbag. ■
10. Turn the ignition switch to LOCK (0).
11. Do the battery terminal disconnection procedure , then wait for 3 minutes.
12. Disconnect SRS unit connector A (39P) from the SRS unit.
13. Connect an SRS short canceller (070AZ-SAA0100) to No. 3 and No. 4 terminals of the SRS unit connector A
(39P).
14. Measure the resistance between the No. 3 and No. 4 terminal of the SRS unit connector A (39P). There should be
0−1.0 Ω.
Is the resistance as specified?
YES - Short in the dashboard wire harness; replace the dashboard wire harness.■
NO - Faulty SRS unit; replace the SRS unit. ■
SRS DTC Troubleshooting: 11-8x
DTC 11-8x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Power in the Front Passenger's Airbag Inflator (RHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 11-8x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect SRS unit connector A (39P) from the SRS unit.
7. Connect an SRS short canceller (070AZ-SAA0100) to the No. 3 and the No. 4 terminals of the SRS unit connector
A (39P).
8. Do the battery terminal reconnection procedure.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Measure the voltage between the No. 3 and the No. 4 terminals of the SRS unit connector A (39P) and body
ground. There should be less than 1 V.
Is the voltage as specified?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Go to Step 11 .
11. Turn the ignition switch to LOCK (0).
12. Do the battery terminal disconnection procedure , then wait for 3 minutes.
13. Disconnect the dashboard wire harness 4P connector from the cable reel.
14. Do the battery terminal reconnection procedure.
15. Turn the ignition switch to ON (II), then wait for 10 seconds.
16. Measure the voltage between the No. 3 and the No. 4 terminals of SRS unit connector A (39P) and body ground.
There should be less than 1 V.
Is the voltage as specified?
YES - Faulty front passenger's airbag; replace the front passenger's airbag. ■
NO - Short to power in the dashboard wire harness; replace the dashboard wire harness.■
SRS DTC Troubleshooting: 11-9x
DTC 11-9x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Ground in the Front Passenger's Airbag Inflator (RHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 11-9x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect SRS unit connector A (39P) from the SRS unit.
7. Check for continuity between the No. 3 and the No. 4 terminals of SRS unit connector A (39P) and body ground.
Is there continuity?
YES - Go to Step 8 .
NO - Faulty SRS unit; replace the SRS unit. ■
8. Disconnect the dashboard wire harness 4P connector from the front passenger's airbag.
9. Check for continuity between the No. 3 and the No. 4 terminals of SRS unit connector A (39P) and body ground.
Is there continuity?
YES - Short to ground in the dashboard wire harness; replace the dashboard wire harness.■
NO - Faulty front passenger's airbag; replace the front passenger's airbag. ■
SRS DTC Troubleshooting: Fx-11
DTC Fx-11 (''x'' can be 0 thru 9 or A thru F):
Airbags and/or Tensioners Deployment Recorded
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Refer to the DTCs shown:
-DTC F1-11: Driver's airbag and/or driver's seat belt tensioner deployed.
-DTC F2-11: Front passenger's airbag and/or front passenger's seat belt tensioner deployed.
-DTC F3-11: Driver's side airbag, left side curtain airbag, and/or driver's seat belt tensioner deployed.
-DTC F4-11: Front passenger's side airbag, right side curtain airbag, and/or front seat belt tensioner deployed.
When any airbags or tensioners have deployed, go to Component Replacement/Inspection After Deployment. ■
Fuel and Emissions Systems Connector and Harness Locations
RHD model
G101 2 3
ECM/PCM Circuit Diagram (cont'd) 1
ROCKER ARM
OIL CONTROL ENGINE 4
SOLENOID 24P JUNCTION CONNECTOR
WIRE HARNESS 12P JUNCTION CONNECTOR MAP SENSOR
(1)
RHD model (2) (A/T) (2) (M/T)
5 (3)
7
ENGINE
ECM/PCM Circuit Diagram (cont'd) WIRE HARNESS SECONDARY
No. 1 No. 2 No. 3 No. 4 ENGINE 8
A/F SENSOR HO2S
INJECTOR INJECTOR INJECTOR INJECTOR WIRE(SENSOR
HARNESS 1) (SENSOR 2)
(1) (2) (3) 5 6
OUTPUT
(4) 67
SHAFT (5) (6) OUTPUT SHAFT
RHD model
EVAP CANISTER 4 (COUNTERSHAFT) MAF SENSOR/ (COUNTERSHAFT)
LEFT ENGINE
PURGE VALVE 24P JUNCTION CONNECTOR SPEED SENSOR IAT SENSOR SPEED SENSOR
(4) 30 (5) (6) (M/T) (7) 9 COMPARTMENT
(8) (A/T)
3 WIRE HARNESS
CABLE REEL SUBHARNESS LEFT ENGINE COMPARTMENT
ECM/PCM Circuit Diagram (cont'd) 7 8
2 5 6 PADDLE SHIFTER− WIRE HARNESS
(DOWNSHIFT SWITCH) 12P JUNCTION 8
EPS CONTROL UNIT 16P CONNECTOR (2) (3) (A/T with 9 CONNECTOR (4)
No. 4 No. 3
10
(1) 4 paddle shifter model)
RHD model TEST
IGNITION IGNITION
THROTTLE COIL (11) COIL (12)
10P BODY
CONNECTOR 1
CMP SENSOR ECT SENSOR 1 CKP SENSOR
TACHOMETER ECM/PCM A (□) (12)*
(7) (9) 3 (8) (9)(10)
13P CONNECTOR (10)
CONNECTOR 9
CABLE REEL SUBHARNESS (11) LEFT ENGINE COMPARTMENT
10
WIRE HARNESS
BRAKE PEDAL CLUTCH PEDAL 11
RIGHT ENGINE
POSITION POSITION 12P JUNCTION 12P JUNCTION 10
SWITCH (1)
COMPARTMENT SWITCH (2) CONNECTOR (3) PADDLE SHIFTER+ CONNECTOR (3) IGNITION SWITCH
WIRE HARNESS (M/T) EVAPORATOR (UPSHIFT SWITCH) (5)
CABLE REEL (5) TEMPERATURE (7) (A/T with CABLE REEL 11
(8)
29 2 SENSOR (6) paddle shifter model)
No. 2 No. 1
IGNITION
IGNITION ECM/PCM B ( ) (13)* AUXILIARY
RIGHT ENGINE
12
COIL (13) COIL (14) ECM/PCM C (○) (14)*
UNDER-HOOD RELAY BOX
1 COMPARTMENT
ECT SENSOR 2
(15) (16) WIRE HARNESS
ENGINE
28 WIRE
1 2ND CLUTCH TRANSMISSIONHARNESS
13
TRANSMISSION A/CRANGE SWITCH
DATA LINK 12P JUNCTION FLUID PRESSURE (16) (A/T)
CONDENSER
CONNECTOR (6)* CONNECTOR12P(3) JUNCTION SWITCH (15)A (8)
SRS UNIT FAN RELAY RIGHT ENGINE
GAUGE CONTROL MODULE (9) CONNECTOR 12P CONNECTOR
(A/T) 16P CONNECTOR (12)
COMPARTMENT
(10) (11) 14 HARNESS
12
WIRE
11
27 A/C 15
18
COMPRESSOR
26 CLUTCH RELAY
11 17 12
25 19 16
18
A/T
ABS CLUTCH
MODULATOR- A/T CLUTCH 3ND CLUTCH24 SHIFT 20 SHIFT SHIFTTRANSMISSION RANGE
RADIATOR
PRESSURE
CONTROL UNIT UNDER-DASH 3P CONNECTOR
PRESSURE TRANSMISSION UNDER-DASH 22CONTROL UNDER-DASH
CONTROL UNDER-DASH
CONTROL ATF (A/T)
SWITCH SUBHARNESS
FAN RELAY
DASHBOARD WIRE HARNESS FUSE/RELAY BOX 23 21
CONTROL
(17) CONTROL (18) FLUID PRESSURE FUSE/RELAY BOX
SOLENOID FUSE/RELAY
SOLENOID FUSE/RELAY
SOLENOID TEMPERATURE
APPSOLENOID
SENSOR (13) (K) (14)
SOLENOID SWITCH (N) (15) VALVE C BOX (S)
VALVE A (16) BOXD(T) (17)
VALVE SENSOR ELD
13 (18)
VALVE
DASHBAORD WIRE A HARNESS VALVE C SHIFT SOLENOID (19) (A/T) (20) (A/T) (21) (A/T) (22) (A/T) (23) (A/T)
(17)SHIFT
(A/T) LOCK (18) (A/T) WIRE HARNESS (A/T) TEMPERATURE 13
SOLENOID FUEL PUMP (10) CONTROL DIAL (11) 2
(9) (A/T) (KZ model)
3
CRANK SENSOR
SUBHARNESS 14
NOTE: 17 4
· Connector
UNDER-DASH with male terminals (double outline): view from terminal side
UNDER-DASH 5 UNDER-DASH FUSE/RELAY BOX (A) (21)
FUSE/RELAY
· Connector FUSE/RELAY
with female terminals outline): viewA/T
(singleBOX fromCLUTCH
wire side
SHIFT(W) (19)
BOX 10 (Q) (20) (single outline): viewPRESSURE 14
*: Connector
NOTE:
CONTROL with female terminals 9 from
CONTROL terminal16side INPUT SHAFT OIL
SOLENOID
· Connector with male terminals (double outline): view 8 from
SOLENOID
terminal side (MAINSHAFT) PRESSURE KNOCK
VALVE B 8P CONNECTOR VALVE B SPEED SENSOR SWITCH SENSOR ALTERNATOR
· Connector
(24) (A/T) with female terminals
M/T
(single outline): view 7 side
from(A/T)
(26) wire 15
(25) (A/T) 6 (27) (A/T) (28) (29) (30)
*: Connector with female terminals (single outline): view from terminal side
15
M/T
22 16
NOTE:
UNDER-DASH
· Connector with male terminals (double FUSE/RELAY
outline): viewBOX
from(B)terminal
(22) side 17
· Connector with female terminals (single outline): view from wire side
*: Connector with female terminals (single outline): view from terminal side
18
19
20
21
UNDER-DASH FUSE/RELAY BOX
7. Disconnect the brake lines (A) from the ABS modulator-control unit (B).
8. Remove the driver's dashboard undercover.
9. Remove the lock pin (A) and the joint pin (B), then disconnect the yoke from the brake pedal.
10. Remove the brake booster mounting nuts (C).
11. Pull the brake booster (A) forward, then rotate it so the yoke (B) toward the driver's side.
Be careful not to damage the booster surfaces and threads of the booster stud bolts.
Be careful not to bend or damage the brake lines or other components hoses and lines.
12. Remove the brake booster from the engine compartment.
NOTE: Use new booster gasket (C) reassembly.
13. Install the brake booster in the reverse order of removal, and note these items:
Install the master cylinder after installing the brake booster.
Check the brake pedal height and free play after installing the master cylinder, and adjust it if necessary.
Bleed the brake system.
Left Engine Compartment Wire Harness Locations
RHD model
G402
G401
Right Engine Compartment Wire Harness Locations
RHD model
G203
G201
G301
G202
SRS DTC Troubleshooting: 12-1x, 12-2x
DTC 12-1x (‘‘x'' can be 0 thru 9 or A thru F):
Open in the Driver's Airbag Inflator (RHD model)
DTC 12-2x (‘‘x'' can be 0 thru 9 or A thru F):
Increased Resistance in the Driver's Airbag Inflator (RHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 12-1x or 12-2x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect the driver's airbag 4P connector from the cable reel.
7. Install a jumper wire between the No. 2 and No. 3 terminals of the cable reel 4P connector.
8. Do the battery terminal reconnection procedure.
9. Clear the DTC memory.
10. Turn the ignition switch to ON (II), then wait for 10 seconds.
11. Read the DTC.
Are DTC 12-1x or 12-2x indicated?
YES - Go to Step 12 .
NO - Faulty driver's airbag; replace the driver's airbag. ■
12. Turn the ignition switch to LOCK (0).
13. Do the battery terminal disconnection procedure , then wait for 3 minutes.
14. Remove the column cover , then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
15. Install a jumper wire between the No. 2 and the No. 3 terminals of the dashboard wire harness 4P connector.
16. Do the battery terminal reconnection procedure.
17. Read the DTC.
Is DTC 12-1x or 12-2x indicated?
YES - Go to Step 18 .
NO - Open or increased resistance in the cable reel; replace the cable reel. ■
18. Turn the ignition switch to LOCK (0).
19. Do the battery terminal disconnection procedure , then wait for 3 minutes.
20. Remove a jumper wire from the dashboard wire harness 4P connector.
21. Disconnect SRS unit connector A (39P) from the SRS unit.
22. Install a jumper wire between the No. 5 and the No. 6 terminals of SRS unit connector A (39P).
23. Measure the resistance between the No. 2 and the No. 3 terminals of the dashboard wire harness 4P connector.
There should be 0−1.0 Ω.
Is the resistance as specified?
YES - Faulty SRS unit or poor connection at SRS unit connector A (39P) and the SRS unit. Check the
connection between the connector and the SRS unit. If the connection is OK, replace the SRS unit. ■
NO - Open or increased resistance in the dashboard wire harness; replace the dashboard wire harness.■
SRS DTC Troubleshooting: 12-3x
DTC 12-3x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Another Wire or Decreased Resistance in the Driver's Airbag Inflator (RHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 12-3x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect the driver's airbag 4P connector from the cable reel.
7. Do the battery terminal reconnection procedure.
8. Clear the DTC memory.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Read the DTC.
Is DTC 12-3x indicated?
YES - Go to Step 11 .
NO - Faulty driver's airbag; replace the driver's airbag. ■
11. Turn the ignition switch to LOCK (0).
12. Do the battery terminal disconnection procedure , then wait for 3 minutes.
13. Remove the column cover , then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
14. Do the battery terminal reconnection procedure.
15. Clear the DTC memory.
16. Turn the ignition switch to ON (II), then wait for 10 seconds.
17. Read the DTC.
Is DTC 12-3x indicated?
YES - Go to Step 18 .
NO - Short in the cable reel; replace the cable reel. ■
18. Turn the ignition switch to LOCK (0).
19. Do the battery terminal disconnection procedure , then wait for 3 minutes.
20. Disconnect SRS unit connector A (39P) from the SRS unit.
21. Connect an SRS short canceller (070AZ-SAA0100) to No. 5 and the No. 6 terminals of the SRS unit connector A
(39P).
22. Measure the resistance between the No. 5 and the No. 6 terminals of the SRS unit connector A (39P). There
should be 0−1.0 Ω.
Is the resistance as specified?
YES - Short in the dashboard wire harness; replace the dashboard wire harness.■
NO - Faulty SRS unit; replace the SRS unit. ■
SRS DTC Troubleshooting: 12-8x
DTC 12-8x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Power in the Driver's Airbag Inflator (RHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 12-8x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal reconnection procedure , then wait for 3 minutes.
6. Disconnect SRS unit connector A (39P) from the SRS unit.
7. Connect an SRS short canceller (070AZ-SAA0100) to the No. 5 and the No. 6 terminals of the SRS unit connector
A (39P).
8. Do the battery terminal reconnection procedure.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Measure the voltage between the No. 5 and the No. 6 terminals of the SRS unit connector A (39P) and body
ground. There should be less than 1 V.
Is the voltage as specified?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Go to Step 11 .
11. Turn the ignition switch to LOCK (0).
12. Do the battery terminal disconnection procedure , then wait for 3 minutes.
13. Disconnect the driver's airbag 4P connector from the cable reel.
14. Do the battery terminal reconnection procedure.
15. Turn the ignition switch to ON (II), then wait for 10 seconds.
16. Measure the voltage between the No. 5 and the No. 6 terminals of SRS unit connector A (39P) and body ground.
There should be less than 1 V.
Is the voltage as specified?
YES - Faulty driver's airbag; replace the driver's airbag. ■
NO - Go to Step 17 .
17. Turn the ignition switch to LOCK (0).
18. Do the battery terminal disconnection procedure , then wait for 3 minutes.
19. Remove the column cover , then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
20. Do the battery terminal reconnection procedure.
21. Turn the ignition switch to ON (II), then wait for 10 seconds.
22. Measure the voltage between the No. 5 and the No. 6 terminals of SRS unit connector A (39P) and body ground.
There should be less than 1 V.
Is the voltage as specified?
YES - Short to power in the cable reel; replace the cable reel. ■
NO - Short to power in the dashboard wire harness; replace the dashboard wire harness.■
SRS DTC Troubleshooting: 12-9x
DTC 12-9x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Ground in the Driver's Airbag Inflator (RHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 12-9x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure , then wait for 3 minutes.
6. Disconnect SRS unit connector A (39P) from the SRS unit.
7. Measure the resistance between the No. 5 and the No. 6 terminals of SRS unit connector A (39P) and body
ground. There should be 0−1.0 Ω.
Is the resistance as specified?
YES - Go to Step 8 .
NO - Faulty SRS unit; replace the SRS unit. ■
8. Disconnect the driver's airbag 4P connector from the cable reel.
9. Measure the resistance between the No. 5 and the No. 6 terminals of SRS unit connector A (39P) and body
ground. There should be 0−1.0 Ω.
Is the resistance as specified?
YES - Go to Step 10 .
NO - Faulty driver's airbag; replace the driver's airbag. ■
10. Remove the column cover , then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
11. Measure the resistance between the No. 5 and the No. 6 terminals of SRS unit connector A (39P) and body
ground. There should be 0−1.0 Ω.
Is the resistance as specified?
YES - Short to ground in the dashboard wire harness: replace the dashboard wire harness.■
NO - Short to ground in the cable reel; replace the cable reel. ■
Fuel and Emissions Systems Connector and Harness Locations
RHD model
2 3
ECM/PCM Circuit Diagram (cont'd) G101 4
ROCKER ARM
OIL CONTROL 5 EVAP CANISTER
SOLENOID 1
12P JUNCTION CONNECTOR MAP SENSOR PURGE VALVE
(1)
RHD model (2) (M/T, i-SHIFT System) (3) (4)
ENGINE
WIRE HARNESS
ECM/PCM Circuit Diagram (cont'd) G101 1 6
2ND CLUTCH
2 TRANSMISSION
OUTPUT SHAFT
(COUNTERSHAFT)
OUTPUT SHAFT 3FLUID PRESSURE TRANSMISSION
24P JUNCTION CONNECTOR 10P CONNECTOR SPEED SENSOR
(COUNTERSHAFT) SWITCH (4) 7 RANGE SWITCH
RHD model
(1) (A/T) (2) MAF
(A/T) SENSOR/ (3) (A/T) SPEED SENSOR (A/T) (5) (A/T)
24P JUNCTION CONNECTOR IAT SENSOR (7)
(5) ENGINE (6) (M/T, i-SHIFT System) 13P CONNECTOR (8)
17 HARNESS
WIRE ENGINE
ECM/PCM
No. 1
Circuit Diagram (cont'd) WIRE HARNESS
No. 3 No. 4 SECONDARY
No. 2
IGNITION IGNITION IGNITION5 6 7
IGNITION ENGINE A/F SENSOR ENGINELEFT ENGINE
LEFTHO2S
COIL (1) COIL (2) COIL (3) COIL (4) (SENSOR 1) (SENSORCOMPARTMENT
COMPARTMENT 2)
WIRE HARNESS WIRE HARNESS
4
(5) WIRE(6)HARNESS
RHD model
A/T CLUTCH A/T CLUTCH 3ND CLUTCH SHIFT SHIFT SHIFT 8
PRESSURE PRESSURE
3 TRANSMISSION CONTROL CONTROL CONTROL ATF 8
CONTROL CONTROL FLUID PRESSURE SOLENOID SOLENOID SOLENOID 9 TEMPERATURE
SOLENOID
TEST
CABLE REEL
SOLENOID SUBHARNESS SWITCH A (□) (10)*
ECM/PCM VALVE C LEFTVALVE
ENGINE A COMPARTMENT
VALVE
ECM/PCM B ( ) (11)* SENSOR
D
ECM/PCM
VALVECircuit
A Diagram 2 VALVE
(cont'd) C (8) (A/T) 8 (9) 9
(A/T) WIRE(10) (A/T)
HARNESS (11) (A/T) (12) (A/T)
TACHOMETER
(6)CONNECTOR
(A/T) (7) (A/T) 7 PADDLE10 SHIFTER−
6 (DOWNSHIFT SWITCH)
(9)
INERTIA SWITCH EPS CONTROL UNIT (4) (A/T with 9
1
(1) (KE, KG models)
10 paddle shifter model)
(2) 16P CONNECTOR (3)
RHD model 5 10P CONNECTOR
THROTTLE BODY CMP SENSOR ECT SENSOR 1 CKP SENSOR 11 (11)
(7) 16 (8) (9) (10) (i-SHIFT System)
LEFT ENGINE 12
CABLE REEL SUBHARNESS
A/T CLUTCH COMPARTMENT WIRE HARNESS 10
11
RIGHT
SHIFTENGINE PRESSURE 13
CONTROL
COMPARTMENT 4 CONTROL INPUT SHAFT PADDLE
15 SOLENOID
SHIFT LOCK GEARSHIFTER+
SHIFT
SOLENOID
WIRE HARNESS
IGNITION SWITCH DATA LINK (MAINSHAFT) SOLENOID
EVAPORATOR (UPSHIFT
CONTROLSWITCH)
MODULE (5)
VALVE B VALVE B 12P JUNCTION
(1) 12P 8P CONNECTOR
JUNCTION CONNECTOR (2)* (15) (A/T) SPEED SENSOR(3)
CONNECTOR (4) (A/T)
TEMPERATURE (8) (A/T
(i-SHIFT CLUTCH
with System)
(13) (A/T) (14) (A/T) (16) (A/T) paddle shifter11 ACTUATOR
model)
CONNECTOR (5) CABLE REEL (6) SENSOR (7)
No.4 No. 3 No. 2 No. 1 14 SUBHARNESS
CLUTCHECM/PCM
ACTUATORC (○) (12)*
(TCM) (12) 14 INJECTOR ENGINE OIL INJECTOR INJECTOR OIL INJECTOR (i-SHIFT System)
(i-SHIFT (13) (14) (15) PRESSURE
(16) KNOCK
3 System) LEVEL SENSOR 3P CONNECTOR
(14) SWITCH
RIGHT ENGINE
SENSOR
ENGINE OIL (13) 12 COMPARTMENT
(KE, KG models) (KE, KG models) (15) 12(16)
LEVEL SENSOR WIRE HARNESS
SUBHARNESS 2 13
ENGINE OIL 12P JUNCTION ENGINE
NOTE: LEVEL SENSOR
16 CONNECTOR WIRE
CABLE
· Connector with SUBHARNESS REEL (9)
male terminals (double outline): view GAUGE CONTROL MODULE (10) (11)
SRS from terminal
UNIT A (7) side YAW RATE-LATERATERAL/
TRANSMISSION RANGE SWITCH 4UNDER-DASH13 HARNESS
1
· Connector with female terminals (single outline): view from wire side LONGITUDINAL 15
15 SUBHARNESS (A/T)
ACCELERATION FUSE/RELAY BOX
*: Connector with female terminals (single outline): viewSHIFT
22 PUMP
FUEL from terminal
SOLENOIDside TRANSMISSION (9)RANGE SWITCH
EGR VALVE(6) AUXILIARY SENSOR (8) (With VSA) 6P(K)
JUNCTION
(17) ECT SENSOR 2 WIRE HARNESS (A/T)
UNDER-HOOD FUSE/RELAY SUBHARNESS (A/T) (20)16
CONNECTOR
BOX (19) 5 (i-SHIFT System)
(KE, KG model) (18) 14 14
6 RIGHT ENGINE
ALTERNATOR
13 8 7
(17)8 A/C
12P JUNCTION 12P JUNCTION 12 11 10 9 CONDENSER 20P CONNECTOR (14) COMPARTMENT
CONNECTOR CONNECTOR FAN RELAY (With seurity alarm15 WIRE HARNESS
system)
(12) (13) SHIFT SOLENOID 16P CONNECTOR (14)
WIRE HARNESS (A/T)
7 17
CRANK SENSOR
A/C
SUBHARNESS
UNDER-DASH UNDER-DASH
COMPRESSOR UNDER-DASH UNDER-DASH 16 UNDER-DASH
FUSE/RELAY BOX FUSE/RELAY
CLUTCH RELAY FUSE/RELAY FUSE/RELAY FUSE/RELAY
ELD (13) BOX (X) (14)
NOTE: (N) (10) BOX (S) (11) BOX (T) (12) BOX (W) (15)
18
· Connector with male terminals (double outline): view from terminal
AUXILIARY
side 17
· Connector withBRAKE PEDAL
female
POSITION terminals (single outline): viewUNDER-DASH
from wire side 12P CONNECTOR
*: ConnectorWIRE
DASHBOARD with female terminals (single outline):
HARNESS
SWITCH (15) 21viewFUSE/RELAY
from terminal side (17) RADIATOR
18 APP SENSOR (18)
DASHBOARD WIRE HARNESS
ABS MODULATOR- BOX (16) VSA MODULATOR- FAN RELAY
CONTROL UNIT 20CONTROL UNIT 19 3P CONNECTOR
(21) 21 (21) (With VSA model) (22)
20 1
UNDER-DASH UNDER-DASH FUSE/RELAY BOX (A) (17)
FUSE/RELAY BOX CLUTCH PEDAL
(16) 6
(Q) AUXILIARY
19 2
3 CLUTCH PEDAL POSITION 9
UNDER-DASH 5 M/T POSITION SWITCH A
FUSE HOLDER 4 SWITCH B (21)
(19) (20) (KE, KG models)
(i-SHIFT System) (M/T) (M/T) 10
NOTE: STARTER RELAY 2
· Connector with male terminals (double outline): view from terminal side
· Connector with female terminals (single outline): view from wire side
*: Connector with female terminals (single outline): view from terminal side 11
7.5 A 7.5 A
M/T
12
18
UNDER-DASH FUSE/RELAY BOX (B) (18)
NOTE: 17
· Connector with male terminals (double outline): view from terminal side
· Connector with female terminals (single outline): view from wire side 13
*: Connector with female terminals (single outline): view from terminal side
NOTE:
· Connector with male terminals (double outline): view from terminal side
· Connector with female terminals (single outline): view from wire side
*: Connector with female terminals (single outline): view from terminal side
Brake Booster Replacement
RHD Model
1. Remove the front wiper arms.
2. Remove the cowl cover and hood hinge covers.
3. Remove the wiper linkage assembly.
4. Remove the under cowl panel.
5. Remove the master cylinder.
6. Disconnect the brake booster vacuum hose (A) from the brake booster.
7. Disconnect the brake lines (A) from the ABS/VSA modulator-control unit (B).
8. Remove the driver's dashboard undercover.
9. Remove the lock pin (A) and the joint pin (B), then disconnect the yoke from the brake pedal.
10. Remove the brake booster mounting nuts (C).
11. Pull the brake booster (A) forward, then rotate it so the yoke (B) toward the driver's side.
Be careful not to damage the booster surfaces and threads of the booster stud bolts.
Be careful not to bend or damage the brake lines or other components hoses and lines.
12. Remove the brake booster from the engine compartment.
NOTE:
Use new booster gasket (C) reassembly.
KE ABS model: Install the brake booster bracket (D) between brake booster and new gasket reassembly.
13. Install the brake booster in the reverse order of removal, and note these items:
Install the master cylinder after installing the brake booster.
Check the brake pedal height and free play after installing the master cylinder, and adjust it if necessary.
Bleed the brake system.
KE ABS model: Check the brake assist.
Relay and Control Unit Locations - Dashboard 1
RHD model
GAUGE CONTROL MODULE REAR SUPER LOCKING RELAY DRIVER'S DOOR UNLOCK RELAY*1
Wire colors: BRN, BLU, Wire colors: LT GRN, BLU,
ORN, BLK, and BLU BRN, BLK, and BLU
FRONT SUPER LOCKING RELAY*2
Wire colors: LT GRN, BLU,
GRY, BLK, and BLU
HEADLIGHT LEVELING
CONTROL UNIT
(With HID)
AUXILIARY
UNDER-DASH
SRS UNIT FUSE HOLDER
IMMOBILIZER-KEYLESS HORN RELAY
CONTROL UNIT (With security)
Wire colors: PUR,
WHT, ORN, and WHT
REAR WINDOW
DEFOGGER RELAY
POWER WINDOW
RELAY (P/W)
BLOWER MOTOR
RELAY
LIGHTING RELAY 2
RHD model
G402
G401
Right Engine Compartment Wire Harness Locations
RHD model
G203
G201
G301
G202
SRS DTC Troubleshooting: 12-1x, 12-2x
DTC 12-1x (‘‘x'' can be 0 thru 9 or A thru F):
Open in the Driver's Airbag First Inflator (RHD model)
DTC 12-2x (‘‘x'' can be 0 thru 9 or A thru F):
Increased Resistance in the Driver's Airbag First Inflator (RHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures , General Troubleshooting
Information , and Battery Terminal Disconnection/Reconnection.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 12-1x or 12-2x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.■
4. Turn the ignition switch to LOCK (0).
5. Disconnect the negative cable from the battery, then wait at least 3 minutes.
6. Disconnect the driver's airbag 4P connector from the cable reel.
7. Install a jumper wire between the No. 2 [No. 4] and No. 3 terminals of the cable reel 4P connector.
[ ]: KE model
8. Reconnect the negative cable to the battery.
9. Clear the DTC memory.
10. Turn the ignition switch to ON (II), then wait for 10 seconds.
11. Read the DTC.
Are DTC 12-1x or 12-2x indicated?
YES - Go to Step 12 .
NO - Faulty driver's airbag; replace the driver's airbag. ■
12. Turn the ignition switch to LOCK (0).
13. Disconnect the negative cable from the battery, then wait at least 3 minutes.
14. Remove the column cover , then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
15. Install a jumper wire between the No. 2 [No. 4] and the No. 3 terminals of the dashboard wire harness 4P
connector.
[ ]: KE model
16. Reconnect the negative cable to the battery.
17. Read the DTC.
Is DTC 12-1x or 12-2x indicated?
YES - Go to Step 18 .
NO - Open or increased resistance in the cable reel; replace the cable reel. ■
18. Turn the ignition switch to LOCK (0).
19. Disconnect the negative cable from the battery, then wait at least 3 minutes.
20. Remove a jumper wire from the dashboard wire harness 4P connector.
21. Disconnect SRS unit connector A (39P) from the SRS unit.
22. Install a jumper wire between the No. 5 and the No. 6 terminals of SRS unit connector A (39P).
23. Measure the resistance between the No. 2 [No. 4] and the No. 3 terminals of the dashboard wire harness 4P
connector. There should be less than 1.0 Ω.
[ ]: KE model
Is the resistance as specified?
YES - Faulty SRS unit or poor connection at SRS unit connector A (39P) and the SRS unit. Check the
connection between the connector and the SRS unit. If the connection is OK, replace the SRS unit. ■
NO - Open or increased resistance in the dashboard wire harness; replace the dashboard wire harness.■
SRS DTC Troubleshooting: 12-3x
DTC 12-3x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Another Wire or Decreased Resistance in the Driver's Airbag First Inflator (RHD model)
Special Tools Required
SRS short canceller
070AZ-SAA0100
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures , General Troubleshooting
Information , and Battery Terminal Disconnection/Reconnection.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 12-3x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.■
4. Turn the ignition switch to LOCK (0).
5. Disconnect the negative cable from the battery, then wait at least 3 minutes.
6. Disconnect the driver's airbag 4P connector from the cable reel.
7. Reconnect the negative cable to the battery.
8. Clear the DTC memory.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Read the DTC.
Is DTC 12-3x indicated?
YES - Go to Step 11 .
NO - Faulty driver's airbag; replace the driver's airbag. ■
11. Turn the ignition switch to LOCK (0).
12. Disconnect the negative cable from the battery, then wait at least 3 minutes.
13. Remove the column cover , then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
14. Reconnect the negative cable to the battery.
15. Clear the DTC memory.
16. Turn the ignition switch to ON (II), then wait for 10 seconds.
17. Read the DTC.
Is DTC 12-3x indicated?
YES - Go to Step 18 .
NO - Short in the cable reel; replace the cable reel. ■
18. Turn the ignition switch to LOCK (0).
19. Disconnect the negative cable from the battery, then wait at least 3 minutes.
20. Disconnect SRS unit connector A (39P) from the SRS unit.
21. Connect an SRS short canceller (070AZ-SAA0100) to No. 5 and the No. 6 terminals of the SRS unit connector A
(39P).
22. Measure the resistance between the No. 5 and the No. 6 terminals of the SRS unit connector A (39P). There
should be less than 1.0 Ω.
Is the resistance as specified?
YES - Short in the dashboard wire harness; replace the dashboard wire harness.■
NO - Faulty SRS unit; replace the SRS unit. ■
SRS DTC Troubleshooting: 12-4x, 12-5x
DTC 12-4x (‘‘x'' can be 0 thru 9 or A thru F):
Open in the Driver's Airbag Second Inflator (RHD model)
DTC 12-5x (‘‘x'' can be 0, 2 thru 9 or A thru F):
Increased Resistance in the Driver's Airbag Second Inflator (RHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures , General Troubleshooting
Information , and Battery Terminal Disconnection/Reconnection.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 12-4x or 12-5x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.■
4. Turn the ignition switch to LOCK (0).
5. Disconnect the negative cable from the battery, then wait at least 3 minutes.
6. Disconnect the driver's airbag 4P connector from the cable reel.
7. Install a jumper wire between the No. 1 and the No. 2 terminals of the cable reel 4P connector.
8. Reconnect the negative cable to the battery.
9. Read the DTC.
Is DTC 12-4x or 12-5x indicated?
YES - Go to Step 10 .
NO - Faulty driver's airbag; replace the driver's airbag. ■
10. Turn the ignition switch to LOCK (0).
11. Disconnect the negative cable from the battery, then wait at least 3 minutes.
12. Remove the column cover, then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
13. Install a jumper wire between the No. 1 and No. 2 terminals of dashboard wire harness 4P connector.
14. Reconnect the negative cable to the battery.
15. Read the DTC.
Is DTC 12-4x or 12-5x indicated?
YES - Go to Step 16 .
NO - Open in the cable reel; replace the cable reel. ■
16. Turn the ignition switch to LOCK (0).
17. Remove the jumper wire from the dashboard wire harness 4P connector.
18. Disconnect the negative cable from the battery, then wait at least 3 minutes.
19. Disconnect SRS unit connector A (39P) from the SRS unit.
20. Install a jumper wire between the No. 9 and the No. 10 terminals of SRS unit connector A (39P).
21. Check for continuity between the No. 1 and the No. 2 terminals of dashboard wire harness 4P connector.
Is the continuity?
YES - Faulty SRS unit or poor connection at SRS unit connector A (39P) and the SRS unit. Check the
connection between the connector and the SRS unit. If the connection is OK, replace the SRS unit. ■
NO - Open in the dashboard wire harness; replace the dashboard wire harness.■
SRS DTC Troubleshooting: 12-6x
DTC 12-6x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Another Wire or Decreased Resistance in the Driver's Airbag Second Inflator (RHD model)
Special Tools Required
SRS short canceller
070AZ-SAA0100
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures , General Troubleshooting
Information , and Battery Terminal Disconnection/Reconnection.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 12-6x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.■
4. Turn the ignition switch to LOCK (0).
5. Disconnect the negative cable from the battery, then wait at least 3 minutes.
6. Disconnect the driver's airbag 4P connector from the cable reel.
7. Read the DTC.
Is DTC 12-6x indicated?
YES - Go to Step 8 .
NO - Faulty driver's airbag; replace the driver's airbag. ■
8. Turn the ignition switch to LOCK (0).
9. Disconnect the negative cable from the battery, then wait at least 3 minutes.
10. Remove the column cover, then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
11. Read the DTC.
Is DTC 12-6x indicated?
YES - Go to Step 12 .
NO - Short in the cable reel; replace the cable reel. ■
12. Turn the ignition switch to LOCK (0).
13. Disconnect the negative cable from the battery, then wait at least 3 minutes.
14. Disconnect SRS unit connector A (39P) from the SRS unit.
15. Connect an SRS short canceller (070AZ-SAA0100) to No. 7 and No. 8 terminals of the SRS unit connector A
(39P).
16. Measure the resistance between the No. 9 and the No.10 terminal of the SRS unit connector A (39P). There should
be less than 1.0 Ω.
Is the resistance as specified?
YES - Short in the dashboard wire harness; replace the dashboard wire harness.■
NO - Faulty SRS unit: replace the SRS unit. ■
SRS DTC Troubleshooting: 12-8x
DTC 12-8x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Power in the Driver's Airbag First Inflator (RHD model)
Special Tools Required
SRS short canceller
070AZ-SAA0100
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures , General Troubleshooting
Information , and Battery Terminal Disconnection/Reconnection.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 12-8x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.■
4. Turn the ignition switch to LOCK (0).
5. Reconnect the negative cable to the battery.
6. Disconnect SRS unit connector A (39P) from the SRS unit.
7. Connect an SRS short canceller (070AZ-SAA0100) to the No. 5 and the No. 6 terminals of the SRS unit connector
A (39P).
8. Reconnect the negative cable to the battery.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Measure the voltage between the No. 5 and the No. 6 terminals of the SRS unit connector A (39P) and body
ground. There should be less than 1.0 V.
Is the voltage as specified?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Go to Step 11 .
11. Turn the ignition switch to LOCK (0).
12. Disconnect the negative cable from the battery, then wait at least 3 minutes.
13. Disconnect the driver's airbag 4P connector from the cable reel.
14. Reconnect the negative cable to the battery.
15. Turn the ignition switch to ON (II), then wait for 10 seconds.
16. Measure the voltage between the No. 5 and the No. 6 terminals of SRS unit connector A (39P) and body ground.
There should be less than 1.0 V.
Is the voltage as specified?
YES - Faulty driver's airbag; replace the driver's airbag. ■
NO - Go to Step 17 .
17. Turn the ignition switch to LOCK (0).
18. Disconnect the negative cable from the battery, then wait at least 3 minutes.
19. Remove the column cover , then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
20. Reconnect the negative cable to the battery.
21. Turn the ignition switch to ON (II), then wait for 10 seconds.
22. Measure the voltage between the No. 5 and the No. 6 terminals of SRS unit connector A (39P) and body ground.
There should be less than 1.0 V.
Is the voltage as specified?
YES - Short to power in the cable reel; replace the cable reel. ■
NO - Short to power in the dashboard wire harness; replace the dashboard wire harness.■
SRS DTC Troubleshooting: 12-9x
DTC 12-9x (‘‘x'' can be 0 thru 9 or A thru F):
Short to Ground in the Driver's Airbag First Inflator (RHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 12-9x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.■
4. Turn the ignition switch to LOCK (0).
5. Disconnect the negative cable from the battery, then wait at least 3 minutes.
6. Disconnect SRS unit connector A (39P) from the SRS unit.
7. Measure the resistance between the No. 5 and the No. 6 terminals of SRS unit connector A (39P) and body
ground. There should be less than 1.0 Ω.
Is the resistance as specified?
YES - Go to Step 8 .
NO - Faulty SRS unit; replace the SRS unit. ■
8. Disconnect the driver's airbag 4P connector from the cable reel.
9. Measure the resistance between the No. 5 and the No. 6 terminals of SRS unit connector A (39P) and body
ground. There should be less than 1.0 Ω.
Is the resistance as specified?
YES - Go to Step 10 .
NO - Faulty driver's airbag; replace the driver's airbag. ■
10. Remove the column cover , then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
11. Measure the resistance between the No. 5 and the No. 6 terminals of SRS unit connector A (39P) and body
ground. There should be less than 1.0 Ω.
Is the resistance as specified?
YES - Short to ground in the dashboard wire harness: replace the dashboard wire harness.■
NO - Short to ground in the cable reel; replace the cable reel. ■
SRS DTC Troubleshooting: 12-Ax
DTC 12-Ax (‘‘x'' can be 0 thru 9 or A thru F):
Short to Power in the Driver's Airbag Second Inflator (RHD model)
Special Tools Required
SRS short canceller
070AZ-SAA0100
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures , General Troubleshooting
Information , and Battery Terminal Disconnection/Reconnection.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 12-Ax indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.■
4. Turn the ignition switch to LOCK (0).
5. Disconnect the negative cable from the battery, then wait at least 3 minutes.
6. Disconnect SRS unit connector A (39P) from the SRS unit.
7. Connect an SRS short canceller (070AZ-SAA0100) to No. 9 and No. 10 terminals of the SRS unit connector A
(39P).
8. Reconnect the negative cable to the battery.
9. Turn the ignition switch to ON (II), then wait for 10 seconds.
10. Measure the voltage between the No. 9 and the No. 10 terminals of SRS unit connector A (39P) and body ground.
There should be less than 1.0 V.
Is the voltage as specified?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Go to Step 11 .
11. Turn the ignition switch to LOCK (0).
12. Disconnect the negative cable from the battery, then wait at least 3 minutes.
13. Disconnect the driver's airbag 4P connector from the cable reel.
14. Reconnect the negative cable to the battery.
15. Turn the ignition switch to ON (II), then wait for 10 seconds.
16. Measure the voltage between the No. 9 and the No. 10 terminals of SRS unit connector A (39P) and body ground.
There should be less than 1.0 V.
Is the voltage as specified?
YES - Faulty driver's airbag: replace driver's airbag. ■
NO - Go to Step 17 .
17. Turn the ignition switch to LOCK (0).
18. Disconnect the negative cable from the battery, then wait at least 3 minutes.
19. Remove the column cover, then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
20. Reconnect the negative cable to the battery.
21. Turn the ignition switch to ON (II), then wait for 10 seconds.
22. Measure the voltage between the No. 9 and the No. 10 terminals of SRS unit connector A (39P) and body ground.
There should be less than 1.0 V.
Is the voltage as specified?
YES - Short to power in the cable reel; replace the cable reel. ■
NO - Short to power in the dashboard wire harness; replace the dashboard wire harness.■
SRS DTC Troubleshooting: 12-Bx
DTC 12-Bx (‘‘x'' can be 0 thru 9 or A thru F):
Short to Ground in the Driver's Airbag Second Inflator (RHD model)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 12-9x indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.■
4. Turn the ignition switch to LOCK (0).
5. Disconnect the negative cable from the battery, then wait at least 3 minutes.
6. Disconnect SRS unit connector A (39P) from the SRS unit.
7. Check for continuity between the No. 9 and the No. 10 terminals of SRS unit connector A (39P) and body ground.
Is there continuity?
YES - Go to Step 8 .
NO - Faulty SRS unit; replace the SRS unit. ■
8. Disconnect the driver's airbag 4P connector from the cable reel.
9. Check for continuity between the No. 9 and the No. 10 terminals of SRS unit connector A (39P) and body ground.
Is there continuity?
YES - Go to Step 10 .
NO - Faulty driver's airbag; replace the driver's airbag. ■
10. Remove the column cover, then disconnect the dashboard wire harness 4P connector (A) from the cable reel.
11. Check for continuity between the No. 9 and the No. 10 terminals of SRS unit connector A (39P) and body ground.
Is there continuity?
YES - Short to ground in the dashboard wire harness; replace the dashboard wire harness.■
NO - Short to ground in the cable reel; replace the cable reel. ■
ECM/PCM Idle Learn Procedure
The idle learn procedure must be done so the ECM/PCM can learn the engine idle characteristics.
Do the idle learn procedure whenever you do any of these actions:
Replace the ECM/PCM.
Reset the ECM/PCM.
Update the ECM/PCM.
Replace or clean the throttle body.
When the engine or transmission is disassembled.
NOTE: Clearing the DTCs with the HDS does not require you to do the idle learn procedure.
Procedure
1. Make sure all electrical items (A/C, audio, lights, etc.) are off.
2. Reset the ECM/PCM with the HDS.
3. Turn the ignition switch to ON (II), and wait 2 seconds.
4. Start the engine. Hold the engine speed at 3,000 rpm (min −1 ) without load (A/T in P or N, M/T in neutral) until the
radiator fan comes on, or until the engine coolant temperature reaches 90 °C (194 °F).
5. Let the engine idle for about 5 minutes with the throttle fully closed.
NOTE: If the radiator fan comes on, do not include its running time in the 5 minutes.
6. Verify on the HDS data list that the idle learn procedure is complete.
Clutch Hydraulic System Bleeding
NOTE:
Do not reuse the drained fluid. Use only clean genuine Honda DOT 3 or DOT 4 Brake Fluid from an unopened
container. Fluid from an unopened container. Using a non-Honda brake fluid can cause corrosion and shorten the
life of the system.
Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid does contact the paint or
plastic, wash it off immediately with water.
If may be necessary to limit the movement of the release fork with a block of wood to remove all the air from the
system.
Use fender covers to avoid damaging painted surfaces.
1. Make sure the brake fluid level in the clutch reservoir (A) is at the MAX (upper) level line (B).
2. Attach one end of a clear tube to the bleeder screw (A), and put the other end into a container. Loosen the bleeder
screw to allow air to escape from the system.
3. Make sure there is an adequate supply of fluid in the reservoir, then slowly push the clutch pedal all the way down.
Before releasing the pedal, have an assistant temporarily tighten the bleeder screw. Loosen the bleeder screw and
push the clutch pedal down again. Repeat this step until no more bubbles appear at the clear tube.
NOTE: Make sure the fluid level on the reservoir does not go below MIN.
4. Tighten the bleeder screw securely.
5. Refill the brake fluid in the reservoir to the MAX (upper) level line.
Clutch Hose Replacement
NOTE:
Replace the clutch hose it is twisted, cracked, or if it leaks.
Use fender covers to avoid damaging painted surfaces.
Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid does contact the paint or
plastic, wash it off immediately water.
1. Do the battery removal procedure.
2. Remove the air cleaner housing.
3. Disconnect the clutch hose (A) from the clutch lines (B).
4. Remove and discard the clutch hose clips (A) from the clutch hose (B).
5. Install the clutch hose (A) with the new clutch hose clips (B).
Exploded View
NOTE:
Refer to the Exploded View, as needed during this procedure.
Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid does contact the paint or
plastic, wash it off immediately with water.
Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
Before reassembling, check that all part are free of dust and other foreign particles.
Replace parts with new ones whenever specified to do so.
Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
Do not reuse the drained fluid. Use only clean genuine Honda DOT 3 or DOT 4 brake fluid.
1. Remove the clutch master cylinder, then disconnect the reservoir hose and clutch line connector from the master
cylinder.
2. Pry the circlip off the clutch master cylinder.
3. Remove the pushrod with the stopper plate and the york.
4. Carefully remove the piston by applying air pressure through the clutch line hole.
5. Remove the piston assembly (A), the connector (B), and the O-ring (C).
6. Apply the rubber grease to the piston, and slide the piston assembly into the clutch master cylinder, then install
the pushrod with the stopper plate, and the circlip in the groove of the clutch master cylinder while pushing the
piston.
7. Install the connector with a new O-ring.
8. Connect the clutch line connector and the reservoir hose to the master cylinder, then install the clutch master
cylinder.
Clutch Slave Cylinder Replacement
NOTE:
Use fender covers to avoid damaging painted surfaces.
Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid does contact the paint or
plastic, wash it off immediately with water.
1. Do the battery removal procedure.
2. Remove the air cleaner housing.
3. Remove the mounting bolts (A), clutch line bracket (B), and clutch line clip (C), then remove the slave cylinder (D).
4. Disconnect the clutch line (A). Plug the end of the clutch line with a shop towel to prevent brake fluid from coming
out.
NOTE: Loosen the flare nut (B) while holding the clutch line connector (C) with a wrench.
6. Apply a light coat of molybdenum to the push rod (A) of the slave cylinder.
7. Install the clutch line clip (B), clutch line bracket (C), and mounting bolts (D).
8. Bleed the clutch hydraulic system.
9. Check the clutch operation, and check for leaks.
10. Install the air cleaner housing.
11. Do the battery installation procedure.
12. Test-drive the vehicle.
Clutch Slave Cylinder Overhaul
M/T Gearshift Mechanism Replacement
NOTE: When you apply the silicone grease, make sure not to adhere to the terminal part of connectors
and surrounding switches. Also do not touch the switches and the terminal part of connector by hands
or glove that adheres the silicone grease.
M/T Shift Lever Housing Replacement
NOTE:
When removing components, use the trim tool or equivalent.
Take care not to scratch the center console, dashboard, and related parts.
1. Remove the center console.
2. Remove the harness clamps.
3. Remove the lock pin (A), washer (B), and shift cable clip (C), shift cables (D) from the shift lever housing assembly
(E).
4. Remove the shift lever assembly (A) from bolts (B) and the shift cables (C).
5. Install the shift lever housing in the reverse order of removal.
DTC Troubleshooting: P0134 (41)
DTC P0134:
A/F Sensor (Sensor 1) Heater System Malfunction
NOTE:
Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
If the vehicle was out of fuel and the engine stalled before this DTC was stored, refuel and clear the DTC with the
HDS.
If DTC P0135 is stored at the same time as DTC P0134, troubleshoot DTC P0135 first, then recheck for DTC
P0134.
1. Turn the ignition switch ON (II).
2. Clear the DTC with the HDS.
3. Start the engine, and let it idle without load (A/T in P or N, M/T in neutral) until the radiator fan comes on.
4. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0134 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
A/F sensor (Sensor 1), the A/F sensor relay, and the ECM/PCM.■
5. Turn the ignition switch to LOCK (0).
6. Replace the A/F sensor (Sensor 1).
7. Turn the ignition switch to ON (II).
8. Reset the ECM/PCM with the HDS.
9. Do the ECM/PCM idle learn procedure.
10. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0134 indicated?
YES - Check for poor connections or loose terminals at the A/F sensor (Sensor 1), the A/F sensor relay, and
the ECM/PCM, then go to Step 1 .
NO - Go to Step 11 .
11. Monitor the OBD STATUS for DTC P0134 in the DTCs MENU with the HDS.
Does the screen indicate PASSED?
YES - Troubleshooting is complete. If any other Temporary DTCs or DTCs were indicated in Step 10 , go to the
indicated DTC's troubleshooting.■
NO - If the screen indicates FAILED, check for poor connections or loose terminals at the A/F sensor (Sensor
1), the A/F sensor relay, and the ECM/PCM, then go to Step 1 . If the screen indicates NOT
COMPLETED, go to Step 8 .
DTC Troubleshooting: P0339 (4)
DTC P0339:
CKP Sensor Intermittent Interruption
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Start the engine, and let it idle for 10 seconds.
4. Check the CKP NOISE in the DATA LIST with the HDS.
Are 0 counts indicated?
YES - Go to Step 7 .
NO - Go to Step 5 .
5. Test-drive the vehicle for several minutes in the range of these recorded freeze data parameters:
ENGINE SPEED
VSS
6. Check the CKP NOISE in the DATA LIST with the HDS.
Are 0 counts indicated?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
CKP sensor and the ECM/PCM.■
7. Check for poor or loose connections and terminals at these locations:
CKP sensor
ECM/PCM
Engine ground
Body ground
Are the connections and terminals OK?
YES - Go to Step 8 .
NO - Repair the connectors or terminals, then go to Step 11 .
8. Check for damage on the CKP sensor pulser plate.
Is the pulser plate damaged?
YES - Replace the CKP sensor pulser plate, then go to Step 11 .
NO - Go to Step 9 .
9. Turn the ignition switch to LOCK (0).
10. Replace the CKP sensor.
11. Turn the ignition switch to ON (II).
12. Reset the ECM/PCM with the HDS.
13. Clear the CKP pattern with the HDS.
14. Do the ECM/PCM idle learn procedure.
15. Do the CKP pattern learn procedure.
16. Start the engine, and let it idle for 10 seconds.
17. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0339 indicated?
YES - Check for poor connections or loose terminals at the CKP sensor and the ECM/PCM, then go to Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
DTC Troubleshooting: P0369 (8)
DTC P0369:
CMP Sensor Intermittent Interruption
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Start the engine, and let it idle for 10 seconds.
4. Check the CMP B NOISE in the DATA LIST with the HDS.
Are 0 counts indicated?
YES - Go to Step 7 .
NO - Go to Step 5 .
5. Test-drive the vehicle for several minutes in the range of these recorded freeze data parameters:
ENGINE SPEED
VSS
6. Check the CMP B NOISE in the DATA LIST with the HDS.
Are 0 counts indicated?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
CMP sensor and the ECM/PCM.■
7. Check for poor or loose connections and terminals at these locations:
CMP sensor
ECM/PCM
Engine ground
Body ground
Are the connections and terminals OK?
YES - Go to Step 8 .
NO - Repair the connectors or terminals, then go to Step 11 .
8. Check for damage on the CMP sensor pulser plate.
Is the pulser plate damaged?
YES - Replace the CMP sensor pulser plate, then go to Step 11 .
NO - Go to Step 9 .
9. Turn the ignition switch to LOCK (0).
10. Replace the CMP sensor.
11. Turn the ignition switch to ON (II).
12. Reset the ECM/PCM with the HDS.
13. Do the ECM/PCM idle learn procedure.
14. Start the engine, and let it idle for 10 seconds.
15. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0369 indicated?
YES - Check for poor connections or loose terminals at the CMP sensor and the ECM/PCM, then go to Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
DTC Troubleshooting: P0562
DTC P0562:
Charging System Low Voltage
NOTE:
Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
If any high current load accessories are installed, this DTC can be set.
If DTC P16BB and/or P16BC is stored at the same time as DTC P0562, troubleshoot DTC P16BB and/or P16BC
first, then recheck for DTC P0562.
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Start the engine.
4. Check under these conditions:
A/C on
Temperature control at maximum cool
Blower fan at maximum speed
Rear window defogger on
Headlights on high beam
5. Hold the engine speed at 2,000 rpm (min −1 ) (A/T in P or N, M/T in neutral) for 1 minute.
6. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0562 indicated?
YES - Check for poor connections or loose terminals at the alternator and the under-hood fuse/relay box,
then go to Step 7 .
Replace the alternator, then go to Step 7 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
alternator and the under-hood fuse/relay box, and check the battery performance. ■
7. Turn the ignition switch to ON (II).
8. Reset the ECM/PCM with the HDS.
9. Do the ECM/PCM idle learn procedure.
10. Start the engine.
11. Check under these conditions:
A/C on
Temperature control at maximum cool
Blower fan at maximum speed
Rear window defogger on
Headlights on high beam
12. Hold the engine speed at 2,000 rpm (min −1 ) (A/T in P or N, M/T in neutral) for 1 minute.
13. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0562 indicated?
YES - Check for poor connections or loose terminals at the alternator and the under-hood fuse/relay box, then
go to Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
DTC Troubleshooting: P1549
DTC P1549:
Charging System High Voltage
NOTE:
Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
If a high voltage battery (24 V, etc.) is connected to the vehicle, this DTC can be stored.
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Start the engine.
4. Check under these conditions:
A/C off
Headlights off
Rear window defogger off
5. Hold the engine speed at 2,000 rpm (min −1 ) (A/T in P or N, M/T in neutral) for 1 minute.
6. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P1549 indicated?
YES - Replace the alternator, then go to Step 7 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
alternator and the battery terminal fuse box.■
7. Turn the ignition switch to ON (II).
8. Reset the ECM/PCM with the HDS.
9. Do the ECM/PCM idle learn procedure.
10. Start the engine.
11. Check under these conditions:
A/C off
Headlights off
Rear window defogger off
12. Hold the engine speed at 2,000 rpm (min −1 ) (A/T in P or N, M/T in neutral) for 1 minute.
13. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P1549 indicated?
YES - Check for poor connections or loose terminals at the alternator and the battery terminal fuse box, then go
to Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
DTC Troubleshooting: P16BB
DTC P16BB:
Alternator B Terminal Circuit Low Voltage
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
1. Turn the ignition switch to ON (II).
2. Clear the DTC with HDS.
3. Start the engine.
4. Check under these conditions:
A/C on
Temperature control at maximum cool
Blower fan at maximum speed
Rear window defogger on
Headlights on high beam
5. Hold the engine speed at 2,000 rpm (min −1 ) (A/T in P or N, M/T in neutral) for 1 minute.
6. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P16BB indicated?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
alternator and the battery terminal fuse box, and check the battery performance. ■
7. Check for poor connections or loose terminals at the alternator and the battery terminal fuse box (+B line).
Are the connections and terminals OK?
YES - Go to Step 8 .
NO - Repair the connectors or terminals, then go to Step 9 .
8. Check for an open in the wire between the alternator and battery terminal fuse box at the engine wire harness.
Is the harness OK?
YES - Replace the alternator, then go to Step 9 .
NO - Repair open in the wire between the alternator and the battery terminal fuse box, then go to Step 9 .
9. Turn the ignition switch to ON (II).
10. Reset the ECM/PCM with the HDS.
11. Do the ECM/PCM idle learn procedure.
12. Start the engine.
13. Check under these conditions:
A/C on
Temperature control at maximum cool
Blower fan at maximum speed
Rear window defogger on
Headlights on high beam
14. Hold the engine speed at 2,000 rpm (min −1 ) (A/T in P or N, M/T in neutral) for 1 minute.
15. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P16BB indicated?
YES - Check for poor connections or loose terminals at the alternator and the battery terminal fuse box, then go
to Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
DTC Troubleshooting: U0155 (126)
DTC U0155:
F-CAN Malfunction (ECM/PCM-Gauge Control Module)
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Check for Temporary DTCs or DTCs with the HDS.
Is DTC U0155 indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
gauge control module and the ECM/PCM.■
4. Check for body electrical DTCs in the DTCs MENU with the HDS.
Is DTC B1168, B1169, and/or B1178 indicated?
YES - Go to Step 5 .
NO - Do the gauge control module input test. ■
5. Turn the ignition switch to LOCK (0).
6. Jump the SCS line with the HDS.
7. Remove the gauge control module.
8. Disconnect the gauge control module 32P connector.
9. Disconnect ECM/PCM connector A (49P).
10. Connect gauge control module 32P connector terminal No. 30 to body ground with a jumper wire.
11. Check for continuity between ECM/PCM connector terminal A3 and body ground.
Is there continuity?
YES - Go to Step 12 .
NO - Repair open in the wire between the ECM/PCM (A3) and the gauge control module, then go to Step 14 .
12. Connect gauge control module 32P connector terminal No. 29 to body ground with a jumper wire.
13. Check for continuity between ECM/PCM connector terminal A4 and body ground.
Is there continuity?
YES - Substitute a known-good gauge control module, then go to Step 14 and recheck. If DTC U0155 is not
indicated after substitution, replace the original gauge control module, then go to Step 14 .
NO - Repair open in the wire between the ECM/PCM (A4) and the gauge control module, then go to Step 14 .
14. Reconnect all connectors.
15. Turn the ignition switch to ON (II).
16. Reset the ECM/PCM with the HDS.
17. Do the ECM/PCM idle learn procedure.
18. Check for Temporary DTCs or DTCs with the HDS.
Is DTC U0155 indicated?
YES - Check for poor connections or loose terminals at the gauge control module and the ECM/PCM, then go to
Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
Manual Transmission and M/T Differential
Item Measurement Qualification Standard or New Service Limit
Manual Capacity Fluid change 1.5 L (1.6 US qt, 1.3 Imp qt)
transmission fluid Use genuine Honda MTF Overhaul 1.6 L (1.7 US qt, 1.4 Imp qt)
Mainshaft End play 0.11−0.18 mm (0.004−0.007 in.) Adjust
Diameter of ball bearing contact area 25.987−26.000 mm (1.0231−1.0236 in.) 25.93 mm (1.020 in.)
(transmission housing side)
Diameter of distance collar contact area 28.992−29.005 mm (1.1414−1.1419 in.) 28.93 mm (1.139 in.)
Diameter of needle bearing contact area 34.984−35.000 mm (1.3773−1.3780 in.) 34.93 mm (1.375 in.)
Diameter of ball bearing contact area (clutch 25.977−25.990 mm (1.0227−1.0232 in.) 25.92 mm (1.020 in.)
housing side)
Diameter of pilot bearing contact area 14.870−14.890 mm (0.5854−0.5862 in.) ———
Runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.)
Mainshaft 3rd and I.D. 39.009−39.025 mm (1.5358−1.5364 in.) 39.07 mm (1.538 in.)
4th gear Clearance 2nd-3rd 0.06−0.21 mm (0.002−0.008 in.) 0.33 mm (0.013 in.)
Endplay 4th 0.06−0.19 mm (0.002−0.007 in.) 0.31 mm (0.012 in.)
Thickness 3rd 27.92−27.97 mm (1.099−1.101 in.) 27.85 mm (1.096 in.)
4th 27.02−27.07 mm (1.064−1.066 in.) 26.65 mm (1.049 in.)
Mainshaft 5th I.D. 39.009−39.025 mm (1.5358−1.5364 in.) 39.07 mm (1.538 in.)
gear End play 0.06−0.19 mm (0.002−0.007 in.) 0.31 mm (0.012 in.)
Thickness 28.92−28.97 mm (1.139−1.141 in.) 28.95 mm (1.140 in.)
Mainshaft 4th and I.D. 29.014−29.024 mm (1.1423−1.1427 in.) 29.06 mm (1.144 in.)
5th gear distance O.D. 34.989−35.000 mm (1.3775−1.3780 in.) 34.93 mm (1.375 in.)
collar Length A 51.97−52.03 mm (2.046−2.048 in.) ———
B 24.03−24.06 mm (0.946−0.947 in.) ———
Mainshaft MBS I.D. 26.02−26.17 mm (1.024−1.030 in.) ———
distance collar Length 12.00−12.05 mm (0.472−0.474 in.) ———
Service Information
Periodically, new ECM/PCM software or new service procedures may become available. Always check online for the latest
software or service information related to the DTCs or symptoms you are troubleshooting.
MIL indication
If you turn the ignition switch to the ON (II) position, without starting the engine, the malfunction indicator lamp (MIL) (A)
will come on for about 20 seconds. It then goes off or brinks 5 times under various conditions. This is normal: it shows the
self-testing condition of the diagnostics for the emissions control systems.
If the MIL in the gauge assembly will come on, go to how to use the HDS.
2. If the MIL stays on, connect the HDS to the data link connector (DLC) (A) located under the driver's side of the
dashboard.
3. Turn the ignition switch to ON (II).
4. Make sure the HDS communicates with the ECM/PCM and other vehicle systems. If it doesn't, go to the DLC
circuit troubleshooting.
5. Check the diagnostic trouble code (DTC) and note it. Also check the freeze data and/or on-board snapshot data,
and download any data found. Then refer to the indicated DTC's troubleshooting, and begin the appropriate
troubleshooting procedure.
NOTE:
Freeze data indicates the engine conditions when the first system malfunction, misfire, or fuel trim
malfunction that activated the MIL was detected.
The HDS can read the DTC, freeze data, on-board snapshot, current data, and other engine control module
(ECM) or powertrain control module (PCM) data.
For specific operations, refer to the user's manual that came with the HDS.
6. If no DTCs are found, go to MIL troubleshooting.
DTC Clear
1. Clear the DTC with the HDS while the engine is stopped.
2. Turn the ignition switch to LOCK (0).
3. Turn the ignition switch to ON (II), and wait 30 seconds.
4. Turn the ignition switch to LOCK (0), and disconnect the HDS from the DLC.
ECM/PCM Reset
1. Reset the ECM/PCM with the HDS while the engine is stopped.
2. Turn the ignition switch to LOCK (0).
3. Turn the ignition switch to ON (II), and wait 30 seconds.
4. Turn the ignition switch to LOCK (0), and disconnect the HDS from the DLC.
5. Do the ECM/PCM idle learn procedure.
3. When diagnosis/troubleshooting is done at the ECM/PCM connector, use the terminal test port (A) above the
terminal you need to check.
4. Connect one side of the patch cord (A) terminals to a commercially available digital multimeter (B), and connect the
other side of the patch cord terminals to a commercially available banana jack (Pomona Electronics Tool No. 3563
or equivalent) (C).
5. Gently contact the pin probe (male) at test port from the terminal side. Do not force the tips into the terminals.
OBD Status
The OBD status shows the current system status of each DTC and all of the parameters. This function is used to see if
the repair was successfully completed. The results of diagnostic tests for the DTC are displayed as:
PASSED: The on board diagnosis is successfully finished.
FAILED: The on board diagnosis has finished but failed.
EXECUTING: The vehicle is in enable criteria conditions for the DTC and the on board diagnosis is running.
NOT COMPLETED: The on board diagnosis was running but is out for the enable conditions for the DTC.
OUT OF CONDITION: The vehicle has stayed out of the enable conditions for the DTC.
DTC Troubleshooting: P0171 (45), P0172 (45)
DTC P0171:
Fuel System Too Lean
DTC P0172:
Fuel System Too Rich
NOTE:
Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
If some of the DTCs listed below are indicated at the same time as DTC P0171 and/or P0172, troubleshoot those
DTCs first, then recheck for P0171 and/or P0172.
P0102, P0103: Mass air flow (MAF) sensor
P0107, P0108: Manifold absolute pressure (MAP) sensor
P0133, P1157, P2238, P2252, P2A00: Air fuel ratio (A/F) sensor (Sensor 1)
P0134, P0135: Air fuel ratio (A/F) sensor (Sensor 1) heater
P0137, P0138, P0139: Secondary HO2S (Sensor 2)
P0141: Secondary HO2S (Sensor 2) heater
P2648, P2649: VTEC system
P0443: EVAP canister purge valve
1. Check the fuel pressure.
Is the fuel pressure OK?
YES - Go to Step 2 .
NO - If the pressure is too high, replace the fuel pressure regulator, then go to Step 10 .
If the pressure is too low, check the fuel pump, the fuel feed pipe, and the fuel filter. If they are OK,
replace the fuel pressure regulator, then go to Step 10 .
6. Start the engine. Hold the engine speed at 3,000 rpm (min −1 ) without load (A/T in P or N, M/T in neutral) until the
radiator fan comes on, then let it idle.
7. Check for these conditions:
Engine coolant temperature (ECT SENSOR 1) above 70 °C (158 °F)
A/T in P or N (M/T in neutral)
All electrical loads off
8. Monitor the ENGINE SPEED in the DATA LIST with the HDS, and hold the engine speed at 2,500 rpm (min −1 ).
Once the engine speed is met, hold the accelerator pedal steady for more than 10 seconds.
Did the engine speed vary more than 100 rpm (min −1 ) from 2,500 rpm (min −1 )?
YES - Repeat Step 8 .
NO - Go to Step 9 .
9. While holding the engine speed at 2,500 rpm (min −1 ), check the MAF SENSOR in the DATA LIST with the HDS.
Is there about 4.3−5.3 gm/s (L12B1 engine) or 4.5−5.5 gm/s (L13Z1 engine) or 4.6−5.7 gm/s (L15A7 engine)?
YES - Check the engine valve clearances and adjust them if needed. If the valve clearances are OK, replace the
injectors, then go to Step 10 .
NO - Replace the MAF sensor/IAT sensor, then go to Step 10 .
10. Turn the ignition switch to ON (II).
11. Reset the ECM/PCM with the HDS.
12. Do the ECM/PCM idle learn procedure.
13. Start the engine. Hold the engine speed at 3,000 rpm (min −1 ) without load (A/T in P or N, M/T in neutral) until the
radiator fan comes on, then let it idle.
14. Test-drive under these conditions:
Engine coolant temperature (ECT SENSOR 1) above 70 °C (158 °F)
A/T in D, M/T in 4th
Drive at a steady speed between 24−120 km/h (15−75 mph) for 15 minutes
NOTE: DTC P0171 and/or P0172 may take up to 80 minutes of test driving to set. Using the HDS, monitor the long
term fuel trim (LT FUEL TRIM) or the air fuel feed back average (AF FB AVE). If the long term fuel trim/air fuel feed
back average stays within 0.80−1.25, there is no problem at this time.
15. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0171 or P0172 indicated?
YES - Check for poor connections or loose terminals at the MAF sensor/IAT sensor, the injectors, the EVAP
canister purge valve, and the ECM/PCM, then go to Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
DTC Troubleshooting: P0300 (75) and any combination of P0301 (71), P0302 (72), P0303 (73), P0304 (74)
DTC P0300:
Random Misfire and Any Combination of the Following:
DTC P0301:
No. 1 Cylinder Misfire Detected
DTC P0302:
No. 2 Cylinder Misfire Detected
DTC P0303:
No. 3 Cylinder Misfire Detected
DTC P0304:
No. 4 Cylinder Misfire Detected
Special Tools Required
Oil pressure gauge attachment
07NAJ-P070100
15. Start the engine. Hold the engine speed at 3,000 rpm (min −1 ) without load (A/T in P or N, M/T in neutral) until the
radiator fan comes on, then let it idle.
16. Check for these conditions:
Engine coolant temperature (ECT SENSOR 1) above 80 °C (176 °F)
A/T in P or N, M/T in neutral
All electrical loads off
17. Monitor the ENGINE SPEED in the DATA LIST with the HDS, and hold the engine speed at 2,500 rpm (min −1 ).
Once the engine speed is met, hold the accelerator pedal steady for more than 10 seconds.
Did the engine speed vary more than 100 rpm (min −1 ) from 2,500 rpm (min −1 )?
YES - Repeat Step 17 .
NO - Go to Step 18 .
18. While holding the engine speed at 2,500 rpm (min −1 ), check the MAF SENSOR in the DATA LIST with the HDS.
Is there about 4.3−5.3 gm/s (L12B1 engine), 4.5−5.5 gm/s (L13Z1 engine), 4.6−5.7 gm/s (L15A7 engine)?
YES - Go to Step 19 .
NO - Replace the MAF sensor/IAT sensor, then go to Step 24 .
19. Turn the ignition switch to LOCK (0).
20. Remove rocker arm oil pressure switch.
21. Attach the bolt (A) from the rocker arm oil control valve and connect the special tool as shown, the install the bolt
that was removed to the pressure gauge joint attachment.
22. Start the engine. Hold the engine speed at 3,000 rpm (min −1 ) without load (A/T in P or N, M/T in neutral) until the
radiator fan comes on, then let it idle.
23. Check the oil pressure at engine speeds of 1,000 rpm (min −1 ) and 2,000 rpm (min −1 ).
3. Start the engine. Hold the engine speed at 3,000 rpm (min −1 ) without load (in neutral) until the radiator fan comes
on, then let it idle.
4. Do the EGR TEST in the INSPECTION MENU with the HDS.
Is the result OK?
YES - Go to Step 5 .
NO - Go to Step 7 .
5. Test-drive under these conditions:
Engine coolant temperature (ECT SENSOR 1) above 70 °C (158 °F)
M/T in 4th
Drive the vehicle at a steady speed between 24−60 km/h (15−38 mph)
During the drive, decelerate (with the throttle fully closed) for 4 seconds
6. Monitor the OBD STATUS for DTC P0401 in the DTCs MENU with the HDS.
Does the screen indicate FAILED?
YES - Clean the intake manifold EGR port and EGR pipe with throttle plate and induction cleaner. Also, clean
the passage inside the EGR valve with throttle plate and induction cleaner, then go to Step 9 .
NO - If the screen indicates PASSED, intermittent failure, the system is OK at this time. Check for poor
connections or loose terminals at the EGR valve and the ECM. If the screen indicates EXECUTING, keep
driving until a result comes on. If the screen indicates OUT OF CONDITION or NOT COMPLETED, go to
Step 5 and recheck.
7. Turn the ignition switch to LOCK (0).
8. Replace the EGR valve.
9. Turn the ignition switch to ON (II).
10. Reset the ECM with the HDS.
11. Do the ECM idle learn procedure.
12. Test-drive under these conditions:
Engine coolant temperature (ECT SENSOR 1) above 70 °C (158 °F)
M/T in 4th
Drive the vehicle at a steady speed between 24−60 km/h (15−38 mph)
During the drive, decelerate (with the throttle fully closed) for 4 seconds
13. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0401 indicated?
YES - Check for poor connections or loose terminals at the EGR valve and the ECM. If the connections are OK,
go to Step 15 .
NO - Go to Step 14 .
14. Monitor the OBD STATUS for DTC P0401 in the DTCs MENU with the HDS.
Does the screen indicate PASSED?
YES - Troubleshooting is complete. If any other Temporary DTCs or DTCs were indicated in Step 13 , go to the
indicated DTC's troubleshooting.■
NO - If the screen indicates FAILED, check for poor connections or loose terminals at the EGR valve and the
ECM, then go to Step 1 . If the screen indicates EXECUTING, keep driving until a result comes on. If the
screen indicates OUT OF CONDITION or NOT COMPLETED, go to Step 12 .
15. Update the ECM if it does not have the latest software, or substitute a known-good ECM.
16. Test-drive under these conditions:
Engine coolant temperature (ECT SENSOR 1) above 70 °C (158 °F)
M/T in 4th
Drive the vehicle at a steady speed between 24−60 km/h (15−38 mph)
During the drive, decelerate (with the throttle fully closed) for 4 seconds
17. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0401 indicated?
YES - Check for poor connections or loose terminals at the EGR valve and the ECM. If the ECM was updated,
substitute a known-good ECM, then go to Step 16 . If the ECM was substituted, go to Step 1 .
NO - Go to Step 18 .
18. Monitor the OBD STATUS for DTC P0401 in the DTCs MENU with the HDS.
Does the screen indicate PASSED?
YES - If the ECM was updated, troubleshooting is complete. If the ECM was substituted, replace the original
ECM. If any other Temporary DTCs or DTCs were indicated in Step 17 , go to the indicated DTC's
troubleshooting.■
NO - If the screen indicates FAILED, check for poor connections or loose terminals at the EGR valve and the
ECM. If the ECM was updated, substitute a known-good ECM, then go to Step 16 . If the ECM was
substituted, go to Step 1 . If the screen indicates EXECUTING, keep driving until a result comes on. If the
screen indicates OUT OF CONDITION or NOT COMPLETED, go to Step 16 .
DTC Troubleshooting: P0404 (12)
DTC P0404:
EGR Control Circuit Range/Performance Problem
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Start the engine. Hold the engine speed at 3,000 rpm (min −1 ) without load (in neutral) until the radiator fan comes
on, then let it idle.
4. Do the EGR TEST in the INSPECTION MENU with the HDS.
Is the result OK?
YES - Intermittent failure, the system is OK at this time. Clean any carbon build-up on the EGR valve with
throttle plate and induction cleaner.■
NO - Go to Step 5 .
5. Turn the ignition switch to LOCK (0).
6. Disconnect the EGR valve 5P connector.
7. At the EGR valve side, measure the resistance between EGR valve 5P connector terminals No. 2 and No. 3.
Is there 100 kΩ or more?
YES - Go to Step 25 .
NO - Go to Step 8 .
8. Measure the resistance between EGR valve 5P connector terminals No. 2 and No. 4.
Is there 100 kΩ or more?
YES - Go to Step 25 .
NO - Go to Step 9 .
9. Check for continuity between EGR valve 5P connector terminal No. 5 and body ground.
Is there continuity?
YES - Go to Step 10 .
NO - Repair open in the wire between the EGR valve and G101, then go to Step 26 .
10. Jump the SCS line with the HDS.
11. Disconnect ECM connector B (49P).
12. Check for continuity between ECM connector terminal B2 and body ground.
Is there continuity?
YES - Repair short in the wire between the ECM (B2) and the EGR valve, then go to Step 26 .
NO - Go to Step 13 .
13. Check for continuity between ECM connector terminal B2 and EGR valve 5P connector terminal No. 1.
Is there continuity?
YES - Go to Step 14 .
NO - Repair open in the wire between the ECM (B2) and the EGR valve, then go to Step 26 .
14. Remove the EGR valve.
15. Clean the intake manifold EGR port and the EGR pipe with throttle plate and induction cleaner. Also, clean the
passage inside the EGR valve with throttle plate and induction cleaner.
16. Install the EGR valve.
17. Reconnect the EGR valve 5P connector.
18. Reconnect ECM connector B (49P).
19. Turn the ignition switch to ON (II).
20. Reset the ECM with the HDS.
21. Do the ECM idle learn procedure.
22. Start the engine. Hold the engine speed at 3,000 rpm (min −1 ) without load (in neutral) until the radiator fan comes
on, then let it idle.
23. Do the EGR TEST in the INSPECTION MENU with the HDS.
Is the result OK?
YES - Go to Step 32 .
NO - Go to Step 24 .
24. Turn the ignition switch to LOCK (0).
25. Replace the EGR valve.
26. Reconnect all connectors.
27. Turn the ignition switch to ON (II).
28. Reset the ECM with the HDS.
29. Do the ECM idle learn procedure.
30. Start the engine. Hold the engine speed at 3,000 rpm (min −1 ) without load (in neutral) until the radiator fan comes
on, then let it idle.
31. Do the EGR TEST in the INSPECTION MENU with the HDS.
32. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0404 indicated?
YES - Check for poor connections or loose terminals at the EGR valve and the ECM, then go to Step 1 . If the
connections and terminals are OK, go to Step 34 .
NO - Go to Step 33 .
33. Monitor the OBD STATUS for DTC P0404 in the DTCs MENU with the HDS.
Does the screen indicate PASSED?
YES - Troubleshooting is complete. If any other Temporary DTCs or DTCs were indicated in Step 32 , go to the
indicated DTC's troubleshooting.■
NO - If the screen indicates FAILED, check for poor connections or loose terminals at the EGR valve and the
ECM, then go to Step 1 . If the screen indicates EXECUTING, keep testing until a result comes on. If the
screen indicates OUT OF CONDITION or NOT COMPLETED, go to Step 30 .
34. Reconnect all connectors.
35. Update the ECM if it does not have the latest software, or substitute a known-good ECM.
36. Do the EGR TEST in the INSPECTION MENU with the HDS.
37. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0404 indicated?
YES - Check for poor connections or loose terminals at the EGR valve and the ECM. If the ECM was updated,
substitute a known-good ECM, then go to Step 36 . If the ECM was substituted, go to Step 1 .
NO - Go to Step 38 .
38. Monitor the OBD STATUS for DTC P0404 in the DTCs MENU with the HDS.
Does the screen indicate PASSED?
YES - If the ECM was updated, troubleshooting is complete. If the ECM was substituted, replace the original
ECM. If any other Temporary DTCs or DTCs were indicated in Step 37 , go to the indicated DTC's
troubleshooting.■
NO - If the screen indicates FAILED, check for poor connections or loose terminals at the EGR valve and the
ECM. If the ECM was updated, substitute a known-good ECM, then go to Step 36 . If the ECM was
substituted, go to Step 1 . If the screen indicates EXECUTING, keep testing until a result comes on. If the
screen indicates OUT OF CONDITION or NOT COMPLETED, go to Step 36 .
DTC Troubleshooting: P0406 (12)
DTC P0406:
EGR Valve Position Sensor Circuit High Voltage
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
1. Turn the ignition switch to ON (II).
2. Check the EGR VLS in the DATA LIST with the HDS.
Is 4.88 V or more indicated?
YES - Go to Step 3 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
EGR valve and the ECM.■
3. Turn the ignition switch to LOCK (0).
4. Disconnect the EGR valve 5P connector.
5. Turn the ignition switch to ON (II).
6. Measure the voltage between EGR valve 5P connector terminals No. 3 and No. 4.
Is there about 5 V?
YES - Go to Step 11 .
NO - Go to Step 7 .
7. Turn the ignition switch to LOCK (0).
8. Jump the SCS line with the HDS.
9. Disconnect ECM connector B (49P).
10. Check for continuity between ECM connector terminal B34 and EGR valve 5P connector terminal No. 3.
Is there continuity?
YES - Go to Step 18 .
NO - Repair open in the wire between the EGR valve and the ECM (B34), then go to Step 13 .
11. Turn the ignition switch to LOCK (0).
12. Replace the EGR valve.
13. Reconnect all connectors.
14. Turn the ignition switch to ON (II).
15. Reset the ECM with the HDS.
16. Do the ECM idle learn procedure.
17. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0406 indicated?
YES - Check for poor connections or loose terminals at the EGR valve and the ECM, then go to Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
18. Reconnect all connectors.
19. Update the ECM if it does not have the latest software, or substitute a known-good ECM.
20. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0406 indicated?
YES - Check for poor connections or loose terminals at the EGR valve and the ECM. If the ECM was updated,
substitute a known-good ECM, then recheck. If the ECM was substituted, go to Step 1 .
NO - If the ECM was updated, troubleshooting is complete. If the ECM was substituted, replace the original
ECM. If any other Temporary DTCs or DTCs are indicated, go to the indicated DTC's troubleshooting.■
DTC Troubleshooting: P2413 (12)
DTC P2413:
EGR System Malfunction
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Start the engine. Hold the engine speed at 3,000 rpm (min −1 ) without load (in neutral) until the radiator fan comes
on, then let it idle.
4. Do the EGR TEST in the INSPECTION MENU with the HDS.
Is the result OK?
YES - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
EGR valve and the ECM.■
NO - Go to Step 5 .
5. Turn the ignition switch to LOCK (0).
6. Turn the ignition switch to ON (II).
7. Check the EGR VLS in the DATA LIST with the HDS.
Is about 0 V indicated?
YES - Go to Step 8 .
NO - Go to Step 21 .
8. Turn the ignition switch to LOCK (0).
9. Disconnect the EGR valve 5P connector.
10. Turn the ignition switch to ON (II).
11. Measure the voltage between EGR valve 5P connector terminal No. 4 and body ground.
Is there about 5 V?
YES - Go to Step 16 .
NO - Go to Step 12 .
12. Turn the ignition switch to LOCK (0).
13. Jump the SCS line with the HDS.
14. Disconnect ECM connector B (49P).
15. Check for continuity between ECM connector terminal B19 and EGR valve 5P connector terminal No. 4.
Is there continuity?
YES - Go to Step 51 .
NO - Repair open in the wire between the EGR valve and the ECM (B19), then go to Step 44 .
16. Turn the ignition switch to LOCK (0).
17. Jump the SCS line with the HDS.
18. Disconnect ECM connector B (49P).
19. Check for continuity between ECM connector terminal B30 and body ground.
Is there continuity?
YES - Repair short in the wire between the ECM (B30) and the EGR valve, then go to Step 44 .
NO - Go to Step 20 .
20. Check for continuity between ECM connector terminal B30 and EGR valve 5P connector terminal No. 2.
Is there continuity?
YES - Go to Step 21 .
NO - Repair open in the wire between the ECM (B30) and the EGR valve, then go to Step 44 .
21. Turn the ignition switch to LOCK (0).
22. If not already done, disconnect the EGR valve 5P connector.
23. At the EGR valve side, measure the resistance between EGR valve 5P connector terminals No. 2 and No. 3.
Is there 100 kΩ or more?
YES - Go to Step 43 .
NO - Go to Step 24 .
24. At the EGR valve side, measure the resistance between EGR valve 5P connector terminals No. 2 and No. 4.
Is there 100 kΩ or more?
YES - Go to Step 43 .
NO - Go to Step 25 .
25. If not already done, jump the SCS line with the HDS.
26. If not already done, disconnect ECM connector B (49P).
27. Check for continuity between ECM connector terminal B2 and body ground.
Is there continuity?
YES - Repair short in the wire between the ECM (B2) and the EGR valve, then go to Step 44 .
NO - Go to Step 28 .
28. Check for continuity between ECM connector terminal B2 and EGR valve 5P connector terminal No. 1.
Is there continuity?
YES - Go to Step 29 .
NO - Repair open in the wire between the ECM (B2) and the EGR valve, then go to Step 44 .
29. Check for continuity between EGR valve 5P connector terminal No. 5 and body ground.
Is there continuity?
YES - Go to Step 30 .
NO - Repair open in the wire between the EGR valve and G101, then go to Step 44 .
30. Reconnect ECM connector B (49P).
31. At the EGR valve side, connect the battery positive terminal to EGR valve 5P connector terminal No. 1 with a
jumper wire.
32. Start the engine, and let it idle. Then connect the battery negative terminal to EGR valve 5P connector terminal No.
5 with a jumper wire.
Does the engine stall or run roughly?
YES - Go to Step 51 .
NO - Go to Step 33 .
33. Turn the ignition switch to LOCK (0).
34. Remove the EGR valve.
35. Clean the intake manifold EGR port and the EGR pipe with throttle plate and induction cleaner. Also, clean the
passage inside the EGR valve with throttle plate and induction cleaner.
36. Install the EGR valve.
37. Reconnect all connectors.
38. Turn the ignition switch to ON (II).
39. Reset the ECM with the HDS.
40. Do the ECM idle learn procedure.
41. Do the EGR TEST in the INSPECTION MENU with the HDS.
Is the result OK?
YES - Go to Step 49 .
NO - Go to Step 42 .
42. Turn the ignition switch to LOCK (0).
43. Replace the EGR valve.
44. Reconnect all connectors.
45. Turn the ignition switch to ON (II).
46. Reset the ECM with the HDS.
47. Do the ECM idle learn procedure.
48. Do the EGR TEST in the INSPECTION MENU with the HDS.
49. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P2413 indicated?
YES - Check for poor connections or loose terminals at the EGR valve and the ECM, then go to Step 1 .
NO - Go to Step 50 .
50. Monitor the OBD STATUS for DTC P2413 in the DTCs MENU with the HDS.
Does the screen indicate PASSED?
YES - Troubleshooting is complete. If any other Temporary DTCs or DTCs were indicated in Step 49 , go to the
indicated DTC's troubleshooting.■
NO - If the screen indicates FAILED, check for poor connections or loose terminals at the EGR valve and the
ECM, then go to Step 1 . If the screen indicates EXECUTING, keep testing until a result comes on. If the
screen indicates OUT OF CONDITION or NOT COMPLETED, go to Step 47 .
51. Reconnect all connectors.
52. Update the ECM if it does not have the latest software, or substitute a known-good ECM.
53. Do the EGR TEST in the INSPECTION MENU with the HDS.
54. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P2413 indicated?
YES - Check for poor connections or loose terminals at the EGR valve and the ECM. If the ECM was updated,
substitute a known-good ECM, then go to Step 52 . If the ECM was substituted, go to Step 1 .
NO - Go to Step 55 .
55. Monitor the OBD STATUS for DTC P2413 in the DTCs MENU with the HDS.
Does the screen indicate PASSED?
YES - If the ECM was updated, troubleshooting is complete. If the ECM was substituted, replace the original
ECM. If any other Temporary DTCs or DTCs were indicated in Step 54 , go to the indicated DTC's
troubleshooting.■
NO - If the screen indicates FAILED, check for poor connections or loose terminals at the EGR valve and the
ECM. If the ECM was updated, substitute a known-good ECM, then go to Step 53 . If the ECM was
substituted, go to Step 1 . If the screen indicates EXECUTING, keep testing until a result comes on. If the
screen indicates OUT OF CONDITION or NOT COMPLETED, go to Step 53 .
DTC Troubleshooting: P250A
DTC P250A:
Engine Oil Level Sensor Circuit Malfunction
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Wait 5 seconds.
4. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P250A indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
engine oil level sensor and the ECM.■
5. Turn the ignition switch to LOCK (0).
6. Disconnect the engine oil level sensor 3P connector.
7. Turn the ignition switch to ON (II).
8. Measure the voltage between engine oil level sensor 3P connector terminal No. 3 and body ground.
Is there battery voltage?
YES - Go to Step 9 .
NO - Repair open in the wire between the engine oil level sensor and the No. 31 OIL LVL (7.5 A) fuse then go
to Step 19 .
9. Check for continuity between engine oil level sensor 3P connector terminal No. 2 and body ground.
Is there continuity?
YES - Go to Step 10 .
NO - Repair open in the wire between the engine oil level sensor and G101, then go to Step 19 .
10. Measure the voltage between engine oil level sensor 3P connector terminal No. 1 and body ground.
Is there battery voltage?
YES - Go to Step 17 .
NO - Go to Step 11 .
11. Turn the ignition switch to LOCK (0).
12. Jump the SCS line with the HDS.
13. Disconnect ECM connector C (49P).
14. Check for continuity between ECM connector terminal C41 and body ground.
Is there continuity?
YES - Repair short in the wire between the ECM (C41) and the engine oil level sensor, then go to Step 19 .
NO - Go to Step 15 .
15. Connect engine oil level sensor 3P connector terminal No. 1 to body ground with a jumper wire.
16. Check for continuity between ECM connector terminal C41 and body ground.
Is there continuity?
YES - Go to Step 24 .
NO - Repair open in the wire between the ECM (C41) and the engine oil level sensor, then go to Step 19 .
17. Turn the ignition switch to LOCK (0).
18. Replace the engine oil level sensor.
19. Reconnect all connectors.
20. Turn the ignition switch to ON (II).
21. Reset the ECM with the HDS.
22. Do the ECM idle learn procedure.
23. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P250A indicated?
YES - Check for poor connections or loose terminals at the engine oil level sensor and the ECM, then go to
Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
24. Reconnect all connectors.
25. Update the ECM if it does not have the latest software, or substitute a known-good ECM.
26. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P250A indicated?
YES - Check for poor connections or loose terminals at the engine oil level sensor and the ECM. If the ECM was
updated, substitute a known-good ECM, then recheck. If the ECM was substituted, go to Step 1 .
NO - If the ECM was updated, troubleshooting is complete. If the ECM was substituted, replace the original
ECM. If any other Temporary DTCs or DTCs are indicated, go to the indicated DTC's troubleshooting.■
DTC Troubleshooting: P250B
DTC P250B:
Engine Oil Level Sensor Range/Performance Problem
NOTE:
Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
When you check this DTC troubleshooting, carry out in a flat place.
Check the engine oil level and condition, before checking this DTC troubleshooting.
1. Start the engine. Hold the engine speed at 3,000 rpm (min −1 ) without load (in neutral) until the radiator fan comes
on, then let it idle.
2. Check the ENGINE OIL TEMPERATURE in the DATA LIST with the HDS.
Is 50 °C (122 °F) or more indicated?
YES - Go to Step 3 .
NO - Keep idling until the value of ENGINE OIL TEMPERATURE becomes 50 °C (122 °F) or more, then go to
Step 3 .
3. Check the ENGINE OIL LEVEL MONITOR CONDITION in the DATA LIST with the HDS.
Is it OK?
YES - Go to Step 4 .
NO - Keep idling until the screen indicates ‘‘OK'', then go to Step 4 .
4. Maintain idling for 2 minutes.
5. Note the value of ENGINE OIL LEVEL in the DATA LIST with the HDS.
6. Stop the engine, but stop the ignition switch with ON (II) position.
7. Wait 5 minutes.
8. Check the ENGINE OIL LEVEL in the DATA LIST with the HDS.
9. Compare the value of ENGINE OIL LEVEL and the recorded value of ENGINE OIL LEVEL.
Does the value of ENGINE OIL LEVEL differ 2 mm (0.08 in.) or more?
YES - Intermittent failure, the system is OK at this time. Check the engine oil level and condition.■
NO - Go to Step 10 .
10. Replace the engine oil level sensor.
11. Turn the ignition switch to ON (II).
12. Reset the ECM with the HDS.
13. Do the ECM idle learn procedure.
14. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P250B indicated?
YES - Check for poor connections or loose terminals at the engine oil level sensor and the ECM, then go to
Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
DTC Troubleshooting: P250E
DTC P250E:
Engine Oil Level Sensor Intermittent Interruption
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Start the engine, and let it idle for 1 minute.
4. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P250E indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
engine oil level sensor and the ECM.■
5. Turn the ignition switch to LOCK (0).
6. Check for poor or loose connections and terminals at these locations:
Oil level sensor
ECM
Engine ground (G101)
Body ground
Are the connections and terminals OK?
YES - Go to Step 7 .
NO - Repair the connectors or terminals, then go to Step 12 .
7. Substitute a known-good engine oil level sensor.
8. Turn the ignition switch to ON (II).
9. Clear the DTC with the HDS.
10. Start the engine, and let it idle for 1 minute.
11. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P250E indicated?
YES - Go to Step 16 .
NO - Replace the original engine oil level sensor, then go to Step 12 .
12. Turn the ignition switch to ON (II).
13. Reset the ECM with the HDS.
14. Do the ECM idle learn procedure.
15. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P250E indicated?
YES - Check for poor connections or loose terminals at the engine oil level sensor and the ECM, then go to
Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
16. Update the ECM if it does not have the latest software, or substitute a known-good ECM.
17. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P250E indicated?
YES - Check for poor connections or loose terminals at the engine oil level sensor and the ECM. If the ECM was
updated, substitute a known-good ECM, then recheck. If the ECM was substituted, go to Step 1 .
NO - If the ECM was updated, troubleshooting is complete. If the ECM was substituted, replace the original
ECM. If any other Temporary DTCs or DTCs are indicated, go to the indicated DTC's troubleshooting.■
DTC Troubleshooting: U0122
DTC U0122:
F-CAN Malfunction (ECM-VSA Modulator-Control Unit)
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
1. Turn the ignition switch to ON (II).
2. Check for Temporary DTCs or DTCs with the HDS.
Are DTC U0029 and U0122 indicated at the same time?
YES - Go to troubleshooting for DTC U0029. ■
NO - Go to Step 3 .
3. Clear the DTC with the HDS.
4. Check for Temporary DTCs or DTCs with the HDS.
Is DTC U0122 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
gauge control module, the VSA modulator-control unit, and the ECM.■
5. Check for communication to the VSA system with the HDS.
Does the HDS communicate with the VSA modulator-control unit?
YES - Go to Step 6 .
NO - Go to the DLC circuit troubleshooting. ■
6. Turn the ignition switch to LOCK (0).
7. Jump the SCS line with the HDS.
8. Disconnect the VSA modulator-control unit 36P connector.
9. Disconnect ECM connector A (49P).
10. Check for continuity between ECM connector terminal A3 and VSA modulator-control unit 36P connector terminal
No. 14.
Is there continuity?
YES - Go to Step 11 .
NO - Repair open in the wire between the ECM (A3) and the VSA modulator-control unit, then go to Step 12 .
11. Check for continuity between ECM connector terminal A4 and VSA modulator-control unit 36P connector terminal
No. 1.
Is there continuity?
YES - Update the VSA modulator-control unit if it does not have the latest software, or substitute a known-good
VSA modulator-control unit, then go to Step 12 and recheck. If DTC U0122 is not indicated after
substitution, replace the original VSA modulator-control unit, then go to Step 12 .
NO - Repair open in the wire between the ECM (A4) and the VSA modulator-control unit, then go to Step 12 .
12. Reconnect all connectors.
13. Turn the ignition switch to ON (II).
14. Reset the ECM with the HDS.
15. Do the ECM idle learn procedure.
16. Check for Temporary DTCs or DTCs with the HDS.
Is DTC U0122 indicated?
YES - Check for poor connections or loose terminals at the gauge control module, the VSA modulator unit, and
the ECM, then go to Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
Engine Wire Harness and CKP Sensor Subharness Locations
M/T
G101
BATTE RY TE RMINAL
Circuit Diagram - PCM A/T Control System - Five-position Transmission
FUS E BOX UNDE R−DAS H FUS E /RE LAY BOX *1
*2
: W ith trailer lighting connector
: W ithout trailer lighting connector
BATTE RY
No. 1 (100 A) No. 39 (15 A)
No. 60 (50 A)
P OW E RTRAINECONTROL
MULTI−FUS
MODULE
BLOCK(P CM) P GM−FI
MAIN RE LAY 1
BATTE RY TE RMINAL
FUS E BOX BAT IG1 UNDE R−DASNo. 7 (10E /RE
H FUS A) LAYToBOX
5V To 12 V
*1 : W ith trailer lighting connector
*2 : W ithout trailer lighting connector
BATTE RY
No. 1 (100 A) No.
No.3920(15
(15A)A)
1 C13 V CC1 LS A B40 1 A/T CLUTCH
Y E L/RE D RE D/BLK P RE S S URE
IGNITION S W ITCH No. 22 (7.5 A)
CONTROL
OUTP UT S HAFT No. 3 (30 A)* 1 No. 60 (50 A) S OLE NOID
2 B38 NC V ALV E A
(COUNTE RS HAFT) BLK/W HT 2
S P E E D S E NS OR (20 A)* 2 No. 24 (15 A) P OW EMULTI−FUS
RTRAIN CONTROL
E BLK
MODULE (P CM)
BLOCK P GM−FI
MAIN RE LAY 1
3 C14 S G1
To 5 V P ADDLE S HIFTE R +
GRN/W
BAT HT IG1 No. 7 (10 A) (UP S HIFT S W ITCH)
LS B B48 CABLE RE E L
1
S UP P A47 BRN/W HT 2 A/T CLUTCH
1 C13
No. 20 V(15
CC1
A) P RE S S URE
Y E L/RE D YEL YEL GRN/ORN CONTROL
S OLE NOID
GAUGE CONTROL MODULE IGNITION S W ITCH No. 22 (7.5 A) 2 V ALV E B RIGHT
OUTP UT S HAFT 2 B38 NC
(COUNTE RS HAFT) BLK S UP
BLK/W HT
S P E E D S E NS OR No. 3 (30 A)* 1 1 B19 V CC2 1
(20 A)* 2 Y E L/BLU 32 No. 24 (15 A)
LT GRN
3 LT BLU C14 S G1
GRN/W HT LS C B26 1
INTP UT S HAFT 2 B18 NM BLU/Y E L A/T CLUTCH
(MAINS HAFT) P P OW E RTRAIN P ADDLE PSRE
HIFTE
SSRURE−
W HT/RE D (DOW NS HIFT S W ITCH)
S P E E D S E NS OR CONTROL CONTROL
MODULE (P CM) To 12 V S OLE NOID
R S DN P A48 2 V ALV E C
3 B34 S G2 2
GRN/Y E L LT BLU LT BLU BLK/W HT
BLK
To 5 V
GAUGE CONTROL MODULE
A/T GE AR N LE FT
A/T IG1 C10
1
P OS ITION DIMMING B19 V CC2 S DN
Y E L/BLU BLK/RE D RE D
INDICATOR CIRCUIT 32
DRIV E R D LT BLU 1
CIRCUIT GRN/Y E L
INTP UT S HAFT V B S OL A1 BLK LT GRN
2 B18
A3 NM H
CAN
(MAINS HAFT) WPHT/RE
D3 D P OW E RTRAIN CONTROL
BRN
S P E E D S E NS OR MODULE (P CM) G101 2ND CLUTCH TRANS MIS S ION
FLUID P RE S S URE S W ITCH
CAN A/T GE AR 3 R B34 S G2 To 5 V MRLY A7
CONTROLLE R P OS ITION 2 E LA/T
GRN/Y 7 W HT To 12 V BLU
G501
DIMMING
INDICATOR W HT
CIRCUIT OP 2S W B8
DRIV E R N To 12 V BLU/RE D
ATF IGP A9
TE MP E RATURE CIRCUIT 1
A4 CAN L LT GRN
S E NS OR IG1 C10
D GRN/Y E L W HT LS A B40 BLK/RE D RE D 13RD CLUTCH TRANS MIS S ION
6 A3 B28
CAN H ATFT A/T CLUTCH
RE D/BLK FLUID P RE S S URE
W HT RE D/Y E LRE D ATP RV S B23 P RESSWSITCH
URE
30 YEL CONTROL
S V B S OL A1
ATP FW D B29 BRN S OLE NOID
OP 3S W B9 BLU/Y E L V ALV E A
F−CAN A4 CAN L BLU/W HT 2
S HIFT S OLE NOIDCE IV E R
TRANS ATP 2−1 B17 BLK
CAN V ALV E A 7 RE D
MRLY A7 BLU
CONTROLLE R W HT 29 BLU
ATF S E QUE NTIAL W HT RE D ATP D3 B16
TE MP E RATURE S HIFT MODE 5 B11 SH A RE D
LS B B48 1
S E NS OR S HIFT INDICATOR BLU SG 13 BLU/BLK IGP D
ATP A9B22 A/T CLUTCH
CIRCUIT 6 B28 ATFT LTBRN/W
P NK HT
GRN P RE S S URE
S TARTE R
CONTROL
W HT PG RE
17 D/Y E L ATP N B13 CUT RE LAYNOID
W HT RE D RE D/BLK S OLE
2 V ALV E B
S HIFT S OLE NOID 30 ATP R P G1
B15 B10
V ALV E B BLK BLK BLK BLK
S HIFT S OLE NOID ATP RV S B23
F−CAN ATP P B14 YEL
V ALV E A TRANS CE IV E R
229 B27 SH B ATP FW D PB29
G2 B1
ORN GRN/W HT LS C B26 BLU/Y E L BRN 1
1 5 B11 SH A BLU/BLK W HT LTA/T
GRN CLUTCH
RE D ATP S B16 BLU/Y EL
BLU LT BLU SG 13 BLU/BLK RE D
P RE S S URE
S HIFT LOCK
LG1 C445 4 9 3 8 2 6 10 7CONTROL 1 BLK
G501 ATP D B22 BRN/Y E L S OLE NOID
S OLE NOID S HIFT S OLE NOID PG 17RHD P NK V ALV E C
V ALV E C A28 S LS 2 S TARTE R
3 BLK
S HIFT S OLE NOIDBLU P NK P NK ATP N B13 CUT RE LAY
LG2 C48 RE D/BLK
BLK/BLU RE D/BLK BLU Y E L/RE D BLU/W HT
V ALV E B BLK BLK BRN/Y E L
1 B21 SH C ATP R B15 W HT P NK BRN W HT/RE D BLK
GRN LHD GRN
2 B27 SH B G101
ATP P B14 6 7 2 8 3 9 5 1 4 10
BRAKE P E DAL ORN GRN/W HT
P OS ITION S W ITCH
S HIFT S OLE NOID 1 BLU/BLK W HT FWLTDGRN RV S ST E
V ALV E D RE D A42 BK S W G101
NG101 D 2ND CLUTCH TRANS MIS S ION
LT BLU G501 FLUID P RE S S URE S W ITCH
W HT
S HIFT S OLE NOID LT GRN LT GRN R 9 D3 6
5 4 3 8 10 7 1 BLK
S HIFT LOCK V ALV E C
S OLE NOID B12 SH D 8RHD
OP 2S W B8
3 GRN/REA28
D S LS
YEL P 2
BLU P NK P NK BLU/RE D
1 B21 SH C
GRN GRN 1
MULTIP LE X INTE GRATE D BLK/BLU RE D/BLK BLU W HT/RE D BLK
LHD
CONTROL UNIT (MICU) G101
3RD CLUTCH TRANS MIS S ION
DATA LINK A32 S CS W HT P NK Y E L/RE D FLUID PBLU/W
RE S S URE
HT S W ITCH
CONNE
S HIFT BRAKE
S OLE NOID P E DAL
CTOR YEL YEL
E D P OS ITION S W ITCH
(DLC)
V ALV 1 A26 V CC4 6 7 2 8 3 5 1 4 10
BRNA42 OP 3S W B9
BK S W BLU/W HT
W HT 3 LT GRN LT GRN A18 AP S 1
8 ORN B12 S H D FW D RV S ST E
YEL GRN/RE D N D
2 A36 S G4 TRANS MIS S ION RANGE S W ITCH
BLU R S
P CM Harness Connector Terminal Locations
ACCE LE RATOR
P E DAL P
P OS ITION MULTIP LE X INTE GRATE D
S E NS OR 4 CONTROL UNIT (MICU) A25 V CC5
GRYA32 S CS
DATA LINK
CONNE CTOR1 13 64 6 Y E7L 9 10 A26 A191V CC4AP S32 4 7 8 9 10 P G1 B10 1 2 3 4 5 6 7 8 9 10
Y E L BRN BLK
(DLC) LT BLU
3 15 16 18 19 20 21 A18 A35AP11S 1
12 13 14 15 16 17 18 19 21 11 12 13 14 15 16 17 18 20 21
5 S G5
ORNW HT
22 24 25 26 28 22 23 24 26 27 28 P G2 B1 23
2 A36 S G4 BRN
BLU
29 30 32 34 35 36 37 38 29 31 32 33 34 35 36 38 TRANS MIS S ION 29 30 31S W32ITCH
RANGE
ACCE LE RATOR
P E DAL 42 44 46 P CM
40Harness Connector Terminal
45 46 Locations
47 48 LG1 C44 43 44 46 48
P OS ITION BRN/Y E L
S E NS OR 4 A25 V CC5
GRY P CM Harness Connector Terminal Locations
A (49P ) B (49P ) C (49P )
6 A19 AP S 2 LG2 C48
LT BLU BRN/Y E L
1 3 4 6 7 9 10 1 3 4 side of female
Terminal 7 terminals
8 9 10 1 2 3 4 5 6 7 8 9 10
5 A35 S G5
W HT
1 315 16
4 186 19 720 21 9 10 11 121 13 14 315 16
4 18 19 7 21
8 9 10 11 121 13 2 14 315 16
4 175 186 720 21
8 9 10
2942 30 44
32 3446 35 4736 48
37 38 40 29 31 32 45 3446 35 4736 48
33 38 29 30 4331 44
32 46 48
42 44 46
P CM Harness
40
Connector Terminal
45 46
Locations
47 48 43 44 46 48
A (49P ) B (49P ) C (49P )
A (49P ) B (49PTerminal
) side of female terminals C (49P )
1 3 4 6 7 9 10 1 Terminal
3 4 side of female
7 terminals
8 9 10 1 2 3 4 5 6 7 8 9 10
15 16 18 19 20 21 11 12 13 14 15 16 18 19 21 11 12 13 14 15 16 17 18 20 21
22 24 25 26 28 22 23 24 26 27 28
29 30 32 34 35 36 37 38 29 31 32 33 34 35 36 38 29 30 31 32
42 44 46 47 48 40 45 46 47 48 43 44 46 48
Downshifting in D (Reference)
Accelerator pedal position sensor A voltage: 1.26 V
Lock-up OFF 41−45 km/h (25−28 mph)
5th → 4th 39−45 km/h (24−28 mph)
4th → 3rd 32−36 km/h (20−22 mph)
3rd → 1st 8−12 km/h (5−7 mph)
Accelerator pedal position sensor A voltage: 2.53 V
Lock-up OFF 116−122 km/h (72−76 mph)
Fully-opened throttle
Accelerator pedal position sensor A voltage: 4.50 V
Lock-up OFF 170−176 km/h (106−109 mph)
5th → 4th 178−184 km/h (111−114 mph)
4th → 3rd 118−124 km/h (73−77 mph)
3rd → 2nd 72−78 km/h (45−48 mph)
2nd → 1st 29−35 km/h (18−22 mph)
Downshifting in D (Reference)
Accelerator pedal position sensor A voltage: 1.26 V
Lock-up OFF 41−45 km/h (25−28 mph)
5th → 4th 41−47 km/h (25−29 mph)
4th → 3rd 32−36 km/h (20−22 mph)
3rd → 1st 8−12 km/h (5−7 mph)
Accelerator pedal position sensor A voltage: 2.53 V
Lock-up OFF 116−122 km/h (72−76 mph)
Fully-opened throttle
Accelerator pedal position sensor A voltage: 4.50 V
Lock-up OFF 170−176 km/h (106−109 mph)
5th → 4th 178−184 km/h (111−114 mph)
4th → 3rd 124−130 km/h (77−81 mph)
3rd → 2nd 79−85 km/h (49−53 mph)
2nd → 1st 36−42 km/h (22−26 mph)
Shift lever cannot be Accelerator pedal position sensor circuit Inspect the APP sensor signal.
moved from P while you Accelerator pedal position sensor defective Troubleshoot the shift lock system circuit.
are pressing on the brake Brake pedal position switch circuit Test the shift lock solenoid.
pedal Brake pedal position switch defective Inspect the transmission range switch.
Shift lock solenoid defective
Shift lock solenoid control circuit
Shift lock mechanism defective
Throttle body defective
Transmission range switch ATP P switch
stuck OFF
Transmission range switch ATP P switch
line opened
Ignition switch cannot be Interlock control system circuit Troubleshoot the key interlock system circuit.
moved from ACCESSORY Key interlock solenoid stuck ON Inspect the transmission range switch.
(I) to LOCK (0) (key is Park pin switch stuck ON
pushed in, the shift lever in Transmission range switch
P)
HDS does not DLC circuit error Troubleshoot the DLC circuit.
communicate with the
PCM or the vehicle
Shift indicator does not F-CAN communication line error Check the F-CAN communication line for a DTC.
work on five-position Gauge control module defective Check the F-CAN communication line by using the gauge control
transmission PCM defective module self-diagnostic function.
Transmission range switch defective Check the indicator drive circuit in the gauge control module by
gauge control module self-diagnostic function.
When you press the A problem in the paddle shifter + (upshift switch) Check the paddle shifter + (upshift switch) circuit.
paddle shifter + (upshift circuit
switch) in D and S, the
transmission does not
upshift on five-position
transmission
When you press the A problem in the paddle shifter − (downshift switch) Check the paddle shifter − (downshift switch) circuit.
paddle shifter − (downshift circuit
switch) in D and S, the
transmission does not
downshift on five-position
transmission
M indicator does not come F-CAN communication line error Check the F-CAN communication line for a DTC.
on even though the paddle Gauge control module defective Check the indicator drive circuit in the gauge control module by
shifter + (upshift switch) or PCM defective using the gauge control module self-diagnostic function.
paddle shifter − (downshift
switch) is operated in
sequential shift mode on
five-position transmission
Symptom Probable cause(s) Notes
Engine runs, but vehicle 1. Low ATF level Check the ATF level, and check the ATF cooler lines for leakage
does not move in any gear 2. Shift cable broken or out of adjustment and loose connections. If necessary, clean the ATF cooler lines.
3. Connection between shift cable and Check for a loose shift cable at the shift lever and the
4. transmission or body is worn transmission control lever.
5. ATF pump worn or binding Check the stall speed.
6. Regulator valve stuck or spring worn Check the line pressure.
7. ATF strainer clogged Improper alignment of ATF pump and torque converter housing
8. Mainshaft worn or damaged may cause the ATF pump to seize. The symptoms are mostly an
9. Final gears worn or damaged rpm-related ticking noise or a high pitched squeak.
10. Transmission-to-engine assembly error Be careful not to damage the torque converter housing when
Axle disengaged replacing the main ball bearing. You may also damage the ATF
pump when you torque down the main valve body. This will cause
the ATF pump seize.
Install the main seal flush with the torque converter housing when
replacing the main seal. If you push it into the torque converter
housing until it bottoms out, it will block the fluid return passage
and result in damage.
Check the regulator valve in the regulator valve body for free
movement, and check the valve spring for wear and damage.
Check the ATF strainer for debris. If the strainer is clogged, find
the damaged components that caused the debris. If no cause for
contamination is found, replace the torque converter.
Inspect the differential pinion gears for wear. If the differential
pinion gears are worn, replace the differential assembly, replace
the ATF strainer, thoroughly clean the transmission, and clean
the ATF cooler and cooler lines.
Replace the torque converter.
Inspect the countershaft and secondary shaft for wear and
damage.
Check for a misinstalled transmission.
Poor acceleration; flares 1. Shift cable broken or out of adjustment Check for a loose shift cable at the shift lever and the
when starting off in D, D3, 2. 5th clutch defective transmission control lever.
S, 2, 1, and R; stall speed Check the 5th clutch pressure.
high in R Inspect the mainshaft and 5th clutch for wear and damage.
Inspect the clutch piston, clutch piston check valve, and O-rings.
Check the spring retainer for wear and damage. Inspect the
clearance between the clutch end-plate and the top disc. If the
clearance is out of tolerance, inspect the clutch discs and plates
for wear and damage, and inspect the clutch wave-plate height. If
the discs and plates are worn or damaged, replace them as a set.
If the wave-plate height is out of tolerance, replace the wave-plate.
If they are OK, adjust the clearance with the clutch end-plate.
Poor acceleration; flares 1. Shift solenoid valve D defective Check for a stored DTC, and check for loose connections.
when starting off in D, D3, 2. Torque converter one-way clutch defective Test the shift solenoid valve function with the HDS.
S, 2, 1, and R; stall speed 3. Engine output low Inspect the O-rings, and check the shift solenoid valve for seizure.
low in D, 2, and 1 4. Torque converter clutch piston defective Replace the torque converter assembly.
5. Lock-up shift valve defective Check the lock-up shift valve in the regulator valve body for free
movement, and check the valve spring for wear and damage.
Check the engine control system.
Symptom Probable cause(s) Notes
Poor acceleration; flares 1. Torque converter one-way clutch defective Check the engine control system.
when starting off in D, D3, 2. Engine output low Replace the torque converter assembly.
S, 2, 1, and R; stall speed 3. Torque converter clutch piston defective Check the lock-up shift valve in the regulator valve body for free
low in R 4. Lock-up shift valve defective movement, and check the valve spring for wear and damage.
Engine idle vibration 1. Low ATF level Check the ATF level and check the ATF lines for leakage and
2. Shift solenoid valve D defective loose connections. If necessary, clean the ATF lines.
3. Drive plate defective or transmission Check for a stored DTC, and check for loose connections.
4. misassembled Test the shift solenoid valve function with the HDS.
5. Engine output low Inspect the O-rings, and check the shift solenoid valve for seizure.
6. Torque converter clutch piston defective Check for a misinstalled/damaged drive plate, replace the drive
7. ATF pump worn or damaged plate if it is worn or damaged.
8. Lock-up shift valve defective Check the engine control system.
Misassembled engine or transmission mount Replace the torque converter assembly.
Check the line pressure.
Improper alignment of ATF pump and torque converter housing
may cause the ATF pump to seize. The symptoms are mostly an
rpm-related ticking noise or a high pitched squeak.
Check the lock-up shift valve in the regulator valve body for free
movement, and check the valve spring for wear and damage.
Adjust the transmission and engine mounts.
Excessive shock or flares 1. A/T clutch pressure control solenoid valve B Check for a stored DTC, and check for loose connections.
on 3-4 upshift or 4-3 2. defective Test the solenoid valve function with the HDS.
downshift 3. A/T clutch pressure control solenoid valve C Inspect the A/T clutch pressure control solenoid valve body
4. defective gasket, ATF feed pipes, and O-rings for wear and damage.
5. Foreign material in separator plate orifice Check for clogged orifice in the separator plate. If the orifice is
6. 3rd accumulator defective clogged, remove it and clean the separator plate orifice.
7. 4th accumulator defective Check the 3rd and 4th clutch pressures.
3rd clutch defective Inspect the 3rd and 4th accumulator pistons, O-rings, and springs
4th clutch defective for wear and damage in the servo body.
Inspect the mainshaft, secondary shaft, 3rd clutch, and 4th clutch
for wear and damage.
Inspect the clutch piston, clutch piston check valve, and O-rings.
Check the spring retainer for wear and damage. Inspect the
clearance between the clutch end-plate and the top disc. If the
clearance is out of tolerance, inspect the clutch discs and plates
for wear and damage, and inspect the clutch wave-plate height. If
the discs and plates are worn or damaged, replace them as a set.
If the wave-plate height is out of tolerance, replace the wave-plate.
If they are OK, adjust the clearance with the clutch end-plate.
Inspect the 3rd and 4th clutch feed pipes.
If the 3rd clutch feed pipe is scored, replace it and the O-rings
under the feed pipe flange.
If the 4th clutch feed pipe is scored, replace it and the O-rings
under the feed pipe flange.
Replace the secondary shaft if the bushing for the 4th clutch feed
pipe is loose or damaged.
Replace the mainshaft if the bushing for the 3rd clutch feed pipe
is loose or damaged.
Symptom Probable cause(s) Notes
Excessive shock or flares 1. A/T clutch pressure control solenoid valve B Check for a stored DTC, and check for loose connections.
on 4-5 upshift or 5-4 2. defective Test the solenoid valve function with the HDS.
downshift 3. A/T clutch pressure control solenoid valve C Inspect the A/T clutch pressure control solenoid valve body
4. defective gasket, ATF feed pipes, and O-rings for wear and damage.
5. Foreign material in separator plate orifice Check for clogged orifice in the separator plate. If the orifice is
6. 4th accumulator defective clogged, remove it and clean the separator plate orifice.
7. 5th accumulator defective Check the 4th and 5th clutch pressures.
4th clutch defective Inspect the 4th and 5th accumulator pistons, O-rings, and springs
5th clutch defective for wear and damage in the servo body.
Inspect the mainshaft, secondary shaft, 4th clutch, and 5th clutch
for wear and damage.
Inspect the clutch piston, clutch piston check valve, and O-rings.
Check the spring retainer for wear and damage. Inspect the
clearance between the clutch end-plate and the top disc. If the
clearance is out of tolerance, inspect the clutch discs and plates
for wear and damage, and inspect the clutch wave-plate height. If
the discs and plates are worn or damaged, replace them as a set.
If the wave-plate height is out of tolerance, replace the wave-plate.
If they are OK, adjust the clearance with the clutch end-plate.
Inspect the 4th clutch feed pipes. If the 4th clutch feed pipe is
scored, replace it and the O-rings under the feed pipe flange.
Replace the secondary shaft if the bushing for the 4th clutch feed
pipe is loose or damaged.
Noise from transmission in 1. ATF pump worn or damaged Check the line pressure.
all shift lever positions 2. Mainshaft bearing, countershaft bearing, or Improper alignment of ATF pump and torque converter housing
secondary shaft bearing defective may cause the ATF pump to seize. The symptoms are mostly an
rpm-related ticking noise or a high pitched squeak.
Be careful not to damage the torque converter housing when
replacing the main ball bearing. Not torquing the valve body to
specification could also damage the ATF pump. This could cause
the pump to seize.
Install the main seal flush with the torque converter housing when
replacing the main seal. If you push it into the torque converter
housing until it bottoms out, it will block the fluid return passage
and result in damage.
Inspect the mainshaft, countershaft, and secondary shaft bearing
for wear and damage.
Vehicle does not Torque converter one-way clutch defective Replace the torque converter assembly.
accelerate above 50 km/h
(31 mph)
Vibration in all shift lever Drive plate defective or transmission misassembled Check for a misinstalled/damaged drive plate, replace the drive
positions plate if it is worn or damaged.
Check the engine control system.
Shift lever does not 1. Transmission range switch defective or out of Check for a stored DTC, and check for loose connections.
operate smoothly 2. adjustment Inspect the transmission range switch. If the transmission range
3. Shift cable broken or out of adjustment switch is faulty, replace it. If the transmission range switch is out
Connection between shift cable and of adjustment, adjust it and shift cable.
transmission or body is worn Check for a loose shift cable at the shift lever and the
transmission control lever.
Transmission does not 1. Shift cable broken or out of adjustment Check for a loose shift cable at the shift lever and the
shift into P 2. Connection between shift cable and transmission control lever.
3. transmission or body is worn Check the park pawl spring installation and the park lever spring
Park mechanism defective installation. If installation is incorrect, install the spring correctly.
Make sure that the park lever stop is not installed upside down.
Check the distance between the park pawl shaft and park lever
pin. If the distance is out of tolerance, adjust the distance with the
park lever stop.
Torque converter clutch 1. Shift solenoid valve D defective Check for a stored DTC, and check for loose connections.
does not disengage 2. A/T clutch pressure control solenoid valve A Test the solenoid valve function with the HDS.
3. defective Inspect the A/T clutch pressure control solenoid valve body
4. Torque converter clutch piston defective gasket, ATF feed pipes, and O-rings for wear and damage.
5. Lock-up shift valve defective Inspect the O-rings, and check the shift solenoid valve for seizure.
Lock-up control valve defective Replace the torque converter assembly.
Check the lock-up shift valve in the regulator valve body for free
movement, and check the valve spring for wear and damage.
Check the lock-up control valve in the main valve body for free
movement, and check the valve spring for wear and damage.
Symptom Probable cause(s) Notes
Torque converter clutch 1. Shift solenoid valve D defective Check for a stored DTC, and check for loose connections.
does not operate smoothly 2. A/T clutch pressure control solenoid valve A Test the solenoid valve function with the HDS.
3. defective Inspect the A/T clutch pressure control solenoid valve body
4. Torque converter clutch piston defective gasket, ATF feed pipes, and O-rings for wear and damage.
5. Torque converter check valve defective Inspect the O-rings, and check the shift solenoid valve for seizure.
6. Lock-up shift valve defective Replace the torque converter assembly.
Lock-up control valve defective Check the torque converter check valve in the regulator valve body
for free movement, and check the valve spring for wear and
damage.
Check the lock-up shift valve in the regulator valve body for free
movement, and check the valve spring for wear and damage.
Check the lock-up control valve in the main valve body for free
movement, and check the valve spring for wear and damage.
Torque converter clutch 1. Shift solenoid valve D defective Check for a stored DTC, and check for loose connections.
does not engage 2. A/T clutch pressure control solenoid valve A Test the solenoid valve function with the HDS.
3. defective Inspect the A/T clutch pressure control solenoid valve body
4. Input shaft (mainshaft) speed sensor defective gasket, ATF feed pipes, and O-rings for wear and damage.
5. Output shaft (countershaft) speed sensor Inspect the O-rings, and check the shift solenoid valve for seizure.
6. defective Check the input shaft (mainshaft) speed sensor and output shaft
7. Torque converter clutch piston defective (countershaft) speed sensor installation.
8. Torque converter check valve defective Inspect the sensor O-ring for wear and damage.
Lock-up shift valve defective Replace the torque converter assembly.
Lock-up control valve defective Check the torque converter check valve in the regulator valve body
for free movement, and check the valve spring for wear and
damage.
Check the lock-up shift valve in the regulator valve body for free
movement, and check the valve spring for wear and damage.
Check the lock-up control valve in the main valve body for free
movement, and check the valve spring for wear and damage.
A/T gear position indicator 1. Transmission range switch defective or out of Check for a stored DTC, and check for loose connections.
does not indicate shift 2. adjustment Inspect the transmission range switch. If the transmission range
lever positions 3. Shift cable broken or out of adjustment switch is faulty, replace it. If the transmission range switch is out
Connection between shift cable and of adjustment, adjust it and shift cable.
transmission or body worn Check for a loose shift cable at the shift lever and the
transmission control lever.
Speedometer and Output shaft (countershaft) speed sensor defective Check for a stored DTC, and check for loose connections.
odometer do not work Check the output shaft (countershaft) speed sensor installation.
Inspect the sensor O-ring.
Engine does not rev to Engine rocker arm defective Check the engine rocker arms.
high rpm, and the Check for a restricted or damaged exhaust system.
transmission upshifts at
low rpm (engine at normal
operating temperature)
ATF Replacement
NOTE: Keep all foreign particles out of the transmission.
1. Warm up the engine to normal operating temperature (the radiator fan comes on), and turn the engine off.
2. Raise the vehicle on a lift, or apply the parking brake, block both rear wheels, and raise the front of the vehicle.
Make sure it is securely supported.
3. Remove the splash shield.
4. Remove the drain plug (A), and drain the automatic transmission fluid (ATF).
5. Reinstall the drain plug with a new sealing washer (B).
6. Remove the dipstick, and refill the transmission with the recommended fluid into the dipstick guide opening (A).
Always use genuine Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect shift
quality.
Automatic Transmission Fluid Capacity:
2.5 L (2.6 US qt, 2.2 lmp qt) at change
5.85 L (6.18 US qt, 5.15 lmp qt) at overhaul
5. Remove the dipstick and check the fluid level. It should be between the upper mark (A) and lower mark (B).
6. If the level is below the lower mark, check for fluid leaks at the transmission, and hose and line joints. If a problem
is found, fix it before filling the transmission.
NOTE: If the vehicle is driven when the ATF level is below the lower mark, one or more of these symptoms may
occur:
Transmission damage.
Vehicle does not move in any gear.
Vehicle accelerates poorly, and flares when starting off in the forward and reverse positions.
The engine vibrates at idle.
7. If the level is above the upper mark, drain the ATF to proper level.
NOTE: If the vehicle is driven when the ATF level is above the upper mark, the vehicle may creep forward while in N,
or have shifting problems.
8. If necessary, fill the transmission with the ATF through the dipstick guide opening (A) to bring the fluid level midway
between the upper mark and lower mark of the dipstick. Do not fill past the upper mark. Always use genuine Honda
ATF-Z1 Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect shift quality.
9. Insert the dipstick back into the transmission.
ATF Cooler Hose Replacement
1. Slide the ATF cooler hose (A) on the ATF filter (B) until the hose end contacts the filter housing, and secure the
hose with the clip (C) at 6−8 mm (0.24−0.31 in.) (D) from the filter housing. Install the cooler hose on the other side
of the ATF filter in the same manner.
2. Slide the ATF cooler hoses (E) over the ATF lines (F) until the hose ends contact the bulge (G), and secure the
hoses with the clip (H) at 6−8 mm (0.24−0.31 in.) (I) from the hose end.
3. Slide the ATF cooler hose (J) over the ATF line (K) until the hose end contacts the line bracket (L), and secure the
hose with the clip (M) at 6−8 mm (0.24−0.31 in.) (N) from the hose end.
4. Slide the ATF cooler hose (O) over the ATF cooler line (P) until the hose end contacts the bulge (Q), and secure
the hose with the clip (R) at 2−4 mm (0.08−0.16 in.) (S) from the hose end.
ATF Filter Replacement
1. Remove the air cleaner assembly.
2. Disconnect the ATF cooler hoses (A) from the ATF filter (B).
3. Remove the ATF filter holder (C).
4. Remove the ATF filter, and replace it.
5. Install the new ATF filter on the filter mounting bracket (D), and secure it with its holder and bolt.
6. Slide the ATF cooler hose on the ATF filter until the hose end contacts the filter housing, and secure the hose with
the clip (E) at 6−8 mm (0.24−0.31 in.) (F) from the filter housing. Install the cooler hose on the other side of the
ATF filter in the same manner.
7. Install the air cleaner assembly.
A/T Drive Plate Removal and Installation
1. Remove the transmission assembly.
2. Remove the drive plate (A) and washer (B) from the engine crankshaft.
3. Install the drive plate and washer on the engine crankshaft, and tighten the six bolts in a crisscross pattern in at
least two steps.
4. Install the transmission assembly.
A/T Housing Reverse Idler Gear Removal
1. Remove the bolts (A) securing the reverse idler gear shaft holder (B).
2. Install a 5 x 0.8 mm bolt (C) in the reverse gear shaft, and pull it to remove the reverse idler gear shaft (D) and the
gear shaft holder together.
3. Install the reverse idler gear in the transmission housing in the direction shown.
4. Install the reverse idler gear shaft/holder assembly in the reverse idler gear.
5. Secure the holder with the bolts.
A/T End Cover Air Check Valve Inspection and Replacement
1. Check the air check valve filter for clogging. If the filter is clogged, remove the air check valve (A), and clean the
filter thoroughly by pouring clean ATF. Do not blow out the filter with compressed air. Replace the air check valve, if
the filter or check valve (ball) is clogged or damaged.
2. Install the air check valve and a new sealing washer (B).
A/T End Cover ATF Feed Pipe Replacement
1. Remove the snap ring (A), 3rd clutch feed pipe (B), and feed pipe flange (C) from the end cover (D).
2. Install the new O-ring (E) over the 3rd clutch feed pipe.
3. Install the 3rd clutch feed pipe in the end cover by aligning the feed pipe tabs (F) with the indentations in the end
cover.
4. Install the new O-ring (G) in the end cover, then install the feed pipe flange over the 3rd clutch feed pipe.
5. Secure the 3rd clutch feed pipe and feed pipe flange with the snap ring.
6. Remove the snap ring (H) and feed pipe flange (I).
7. Check the 4th clutch feed pipe (J) and 2nd clutch feed pipe (K) for scoring and damage. Replace the end cover, if
the feed pipe is scored or damaged.
8. Install the new O-ring (L) over the 4th clutch feed pipe.
9. Install the new O-ring (M) in the end cover, then install the feed pipe flange over the 4th clutch feed pipe.
10. Secure the 4th clutch feed pipe and feed pipe flange with the snap ring.
A/T End Cover Selector Control Shaft Bearing Replacement
Special Tools Required
Driver handle 15 x 135L
07749-0010000
Driver attachment, 22 x 24 mm
07746-0010800
1. Remove the oil seal from the end cover.
3. Install the new bearing flush to the end cover with the special tools.
4. Install the new oil seal flush to the end cover with the special tools.
A/T End Cover Selector Control Shaft Oil Seal Replacement
Special Tools Required
Driver handle 15 x 135L
07749-0010000
Driver attachment, 22 x 24 mm
07746-0010800
1. Remove the oil seal from the end cover.
2. Install the new oil seal flush to the end cover with the special tools.
Torque Converter Housing Selector Control Shaft Oil Seal Replacement
Special Tools Required
Driver handle 15 x 135L
07749-0010000
2. Install the new oil seal (A) in the torque converter housing in depth (B) of 0.5−1.5 mm (0.02−0.06 in.) below the
housing surface with the special tools.
A/T End Cover Removal
Special Tools Required
Mainshaft holder set
07PAB-0010001
1. Remove the bolts securing the ATF inlet line (A) and ATF filter holder (B), line bolt and sealing
washers, and remove the ATF inlet line, ATF hose, and ATF filter. Remove the ATF filter bracket
(C).
2. Remove the ATF outlet line bolt, line mounting bolt, sealing washers, and ATF outlet line (D).
3. Remove the transmission hanger (E) and breather hose clamp bracket (F).
4. Remove the A/T clutch pressure control solenoid valve A (G), ATF joint pipes, O-rings, ATF
pipe, and gasket.
5. Remove the A/T clutch pressure control solenoid valve B and C (H), O-rings, ATF pipe, ATF joint
pipes, and gasket.
6. Remove the input shaft (mainshaft) speed sensor (I) and output shaft (countershaft) speed
sensor (J).
7. Remove the transmission range switch cover (K).
8. Remove the transmission range switch harness clamps (L) from the clamp bracket (M), then
remove the transmission range switch (N).
9. Remove the clamp bracket from the end cover (O).
10. Remove the connector bracket (P) from the transmission housing.
11. Remove the end cover, dowel pins, O-rings, and end cover gasket.
12. Remove the ATF lubrication pipe (Q) from the idler gear shaft.
15. Cut the lock tab (A) of the each shaft locknut (B) using a chisel (C). Then remove the locknuts and conical spring
washers from each shaft.
NOTE:
Countershaft and secondary shaft locknuts have left-hand threads.
Keep all of the chiseled particles out of the transmission.
Clean the old locknuts; they are used to install the press fit idler gears and park gear.
16. Remove the snap ring securing the idler gear to the idler gear shaft.
17. Install 6 x 1.0 mm bolts (A) on the idler gear shaft idler gear (B). Set a puller (C) on the idler gear shaft (D) with
putting a spacer (E) between the puller and idler gear shaft, then remove idler gear shaft idler gear.
18. Set the puller, 6 x 1.0 mm bolts, and spacer on the secondary shaft idler gear (F), and remove the secondary shaft
idler gear from the secondary shaft in the same manner as the removal of idler gear shaft idler gear.
19. Set the puller, 6 x 1.0 mm bolts, and spacer on the mainshaft idler gear (G), and remove the mainshaft idler gear
from the mainshaft in the same manner as the removal of idler gear shaft idler gear.
20. Set the puller, 6 x 1.0 mm bolts, and spacer on the park gear (H), and remove the park gear from the countershaft
in the same manner as the removal of idler gear shaft idler gear.
21. Remove the park pawl, park pawl spring, park pawl shaft, and stop shaft.
22. Remove the park lever from the selector control shaft.
A/T End Cover Installation
Special Tools Required
Mainshaft holder set
07PAB-0010001
3. Install the mainshaft idler gear (A), old conical spring washer (B), and old locknut (C) on the mainshaft (D), and
tighten the locknut to 216 N·m (22.0 kgf·m, 159 lbf·ft).
NOTE:
Do not tap the idler gear to install.
Use a torque wrench to tighten the locknut. Do not use an impact wrench.
4. Lubricate the following parts with ATF:
Splines and threads of the secondary shaft and idler gear shaft.
Splines of the secondary shaft idler gear.
Old conical spring washer and old locknut.
5. Install the secondary shaft idler gear (A) on the secondary shaft (B), and install the idler gear shaft idler gear (C) on
the idler gear shaft (D).
6. Set the special tool on the idler gear shaft and idler gear, and tighten the installer nut to install the idler gear part-
way.
NOTE: The installer nut has left-hand threads.
7. Install the old conical spring washer (A) and old locknut (B) on the secondary shaft (C), and tighten the locknut to
226 N·m (23.0 kgf·m, 166 lbf·ft).
NOTE:
Do not tap the idler gear to install.
Use a torque wrench to tighten the locknut. Do not use an impact wrench.
Secondary shaft locknut has left-hand threads.
8. Retighten the installer nut to seat the idler gear in the idler gear shaft until it stops. Remove the special tool from
the idler gear shaft.
9. Install the new snap ring (A) on the idler gear shaft (B), and verify that the snap ring is seated securely into the
groove.
10. Install the park lever (A) and the park lever stop (B) on the selector control shaft (C), then install the lock bolt and
the new lock washer (D). Do not bend the lock tab of the lock washer until Step 23 .
11. Install the park pawl shaft (E), the park pawl spring (F), the park pawl (G), and the stop shaft (H) on the
transmission housing.
12. Lubricate the following parts with ATF:
Threads and splines of the countershaft.
Old conical spring washer and old locknut.
Areas where the park gear contacts the conical spring washer.
13. Install the park gear (I), the old conical spring washer (J), and the old locknut (K) on the countershaft.
14. Lift the park pawl up, and engage it with the park gear, then tighten the locknut to 226 N·m (23.0 kgf·m, 166 lbf·ft).
NOTE:
Do not tap the park gear to install.
Use a torque wrench to tighten the locknut. Do not use an impact wrench.
Countershaft locknut has left-hand threads.
15. Remove the locknuts and the conical spring washers from the mainshaft, the countershaft, and the secondary
shaft.
16. Lubricate the threads of the shafts, the new locknuts and the new conical spring washers with ATF.
17. Install the new conical spring washers (A) (B) with facing stamped mark side up in the direction shown, and install
the new mainshaft locknut (C), the new countershaft locknut (D), and the new secondary shaft locknut (E).
18. Tighten the countershaft locknut and the secondary shaft locknut to 167 N·m (17.0 kgf·m, 23 lbf·ft), and tighten the
mainshaft locknut to 155 N·m (15.8 kgf·m, 114 lbf·ft).
NOTE:
Be sure to install the conical spring washers in the direction shown.
Use a torque wrench to tighten the locknut. Do not use an impact wrench.
Countershaft and secondary shaft locknuts have left-hand threads.
19. Remove the special tool from the mainshaft.
20. Stake the locknuts into the shafts in depth (A) of 0.7−1.3 mm (0.03−0.05 in.) using a 3.5 mm punch (B).
21. Set the park pawl (A) in the P position, then verify that the park pawl engages with the park gear (B).
22. If the park pawl does not engage fully, check the distance (C) between the pawl shaft and the extension line
connected centers of the park lever roller pin and the selector control shaft.
23. Tighten the lock bolt (D), and bend the lock tab of the lock washer (E) against the bolt head.
24. Install the ATF lubrication pipe (A) into the idler gear shaft (B).
25. Install the new gasket (C) on the transmission housing, and install the two dowel pins (D) and new O-rings (E) over
the top of the ATF feed pipes (F).
26. Install the end cover (G), and tighten the 17 bolts.
27. Using the selector control shaft end on the torque converter housing side, turn the control shaft (A) fully clockwise
(view from end cover) to the P position. Turn the control shaft back two click-stopped positions so that it is in the N
position.
NOTE: Do not squeeze the end of the selector control shaft tips together when turning the shaft. If the control shaft
tips are squeezed together it will cause a faulty signal or position due to play between the selector control shaft
and the switch.
28. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch
(C), then put a 2.0 mm (0.08 in.) feeler gauge blade (D) in the cutouts to hold the switch in the N position.
NOTE: Be sure to use a 2.0 mm (0.08 in.) blade or equivalent to hold the switch in the N position.
29. Install the transmission range switch (A) gently on the selector control shaft (B) while holding it in the N position
with the 2.0 mm (0.08 in.) blade (C).
30. Tighten the bolts on the transmission range switch while you continue to hold it in the N position. Do not move the
transmission range switch while tightening the bolts. Remove the feeler gauge.
31. Install the harness clamp bracket (A) on the end cover (B).
32. Install the connector bracket (C) on the transmission housing.
33. Connect the transmission range switch connector (D) securely, then install the harness clamps (E) on the clamp
bracket.
34. Install the transmission range switch cover (F).
35. Install the new O-ring (A) on the input shaft (mainshaft) speed sensor (B), then install the input shaft (mainshaft)
speed sensor.
36. Install the new O-ring (C) on the output shaft (countershaft) speed sensor (D), then install the output shaft
(countershaft) speed sensor.
37. Install the new gasket (B) on the transmission housing, and install the ATF pipe (C) and the ATF joint pipes (D).
38. Install the new O-rings (E) over the ATF joint pipes, and install the A/T clutch pressure control solenoid valve A.
39. Install the new gasket (A) with the blue side facing the transmission housing and the white side facing the A/T
clutch pressure control solenoid valve body.
40. Install the ATF pipe (D) and the ATF joint pipes (E), and install the new O-rings (F) over the ATF joint pipes.
41. Install A/T clutch pressure control solenoid valve B and C.
42. Install the ATF outlet line (A) on the torque converter housing, and secure it with the line bolt (B) and new sealing
washers (C).
43. Secure the ATF outlet line with the bracket bolt.
44. Install the transmission hanger.
45. Install the breather hose clamp bracket, and install the clamp on the bracket.
3. If the measurement is out of standard, select and install the appropriate park lever stop (A) from the table.
4. After replacing the park lever stop, make sure the distance is within tolerance.
A/T End Cover Transmission Fluid Pressure Switch Replacement
1. Remove the 2nd clutch transmission fluid pressure switch (A).
2. Make sure there is no water, oil, dust, or foreign particles inside the connector.
3. Install the new 2nd clutch transmission fluid pressure switch and a new sealing washer (B), and tighten the metal
part of the switch.
4. Remove the 3rd clutch transmission fluid pressure switch (C).
5. Make sure there is no water, oil, dust, or foreign particles inside the connector.
6. Install the new 3rd clutch transmission fluid pressure switch and a new sealing washer (D), and tighten the metal
part of the switch.
A/T Housing and Shaft Assembly Removal
Special Tools Required
Housing puller
07HAC-PK40102
1. Remove the Dipstick (A).
2. Remove the shift solenoid valve cover (B), dowel pins (C), and gasket (D).
3. Disconnect the connectors from the shift solenoid valves, and remove the solenoid harness
connector (E).
4. Remove the transmission housing mounting bolts (F) (19).
5. Align the spring pin (A) on the selector control shaft (B) with the transmission housing groove (C) by turning the
control shaft with the detent plate.
NOTE: Do not squeeze the end of the selector control shaft tips together when turning the control shaft.
6. Install the special tool over the mainshaft, then remove the transmission housing, dowel pins, and gasket.
NOTE: If the top arm of your housing puller is too short, replace it with housing puller arm, 205 mm 07SAC-
P0Z0101.
7. Remove the countershaft reverse gear and needle bearing.
8. Remove the lock bolt securing the shift fork, then remove the shift fork with the reverse selector together.
9. Remove the mainshaft subassembly (A), the countershaft subassembly (B), and the secondary shaft subassembly
(C) together.
If the reverse selector hub is removed by hand, remove the 4th-5th gear and needle bearings, and remove the
mainshaft subassembly, then the countershaft subassembly and secondary shaft subassembly together.
10. Remove the baffle plate.
11. Remove the differential assembly.
A/T Shaft Assembly and Housing Installation
1. Install the differential assembly in the torque converter housing.
2. Install the baffle plate.
3. Assemble the mainshaft, countershaft, and secondary shaft.
Countershaft reverse selector hub is press-fitted type, go to Step 4 .
Countershaft reverse selector hub is not press-fitted type, go to Step 5 .
4. Join the mainshaft subassembly (A), countershaft subassembly (B), and secondary shaft subassembly (C)
together, and install them in the torque converter housing.
5. Join the countershaft subassembly and secondary shaft subassembly together, then install them in the torque
converter housing, and install the mainshaft subassembly. Install the needle bearings, 4th-5th gear, and reverse
selector hub over the countershaft.
6. Turn the shift fork shaft (A) so the large chamfered hole (B) is facing the fork bolt hole (C) of the shift fork (D).
7. Install the shift fork and reverse selector together on the shift fork shaft and countershaft. Secure the shift fork to
the shift fork shaft with the lock bolt and a new lock washer (E), then bend the lock tab of the lock washer against
the bolt head.
8. Install the needle bearing and countershaft reverse gear on the countershaft.
9. Install the reverse idler gear in the transmission housing.
10. Install the three dowel pins (A) and a new gasket (B) on the torque converter housing (C).
11. Align the spring pin (D) of the control shaft (E) with the transmission housing groove (F) by turning the control shaft
detent plate. Do not squeeze the end of the control shaft tips together when turning the shaft. If the tips are
squeezed together, it will causes a faulty shift position signal or position due to the play between the control shaft
and the switch.
12. Place the transmission housing (G) on the torque converter housing. Do not install the input shaft (mainshaft)
speed sensor and output shaft (countershaft) speed sensor before installing the transmission housing on the torque
converter housing.
13. Wrap a screwdriver tip with tape to prevent damage to the reverse idler gear teeth. Engage the reverse idler gear
with reverse gears by rotating the idler gear using the screwdriver.
14. Install the transmission housing mounting bolts, and tighten the bolts to 44 N·m (4.5 kgf·m, 33 lbf·ft) in at least two
steps in a crisscross pattern.
15. Install the shift solenoid harness connector (E) in the transmission housing with the new O-ring (F).
16. Connect the WHT and ORN wires connector to shift solenoid valve B. The ATF temperature sensor is assembled in
the WHT wires connector.
17. Connect the harness terminals to the solenoids:
BLU wire connector to shift solenoid valve A.
GRN wire connector to shift solenoid valve C.
YEL wire connector to shift solenoid valve D.
18. Install the shift solenoid valve cover (A), two dowel pins (B), and a new gasket (C).
19. Install the ATF dipstick.
A/T System Description - Electronic Control System
Electronic Control System
Electronic Control System (cont'd)
Electronic Control System (cont'd)
Electronic Control System (cont'd)
Electronic Control System (cont'd)
Electronic Control System (cont'd)
Electronic Control System (cont'd)
Electronic Control System (cont'd)
A/T 2nd Clutch Transmission Fluid Pressure Switch Replacement
1. Remove the air cleaner assembly.
2. Disconnect the 2nd clutch transmission fluid pressure switch connector, and remove the 2nd clutch transmission
fluid pressure switch (A).
3. Install the new 2nd clutch transmission fluid pressure switch with a new sealing washer (B), and tighten the metal
part of the switch.
4. Make sure there is no water, oil, dust, or foreign particles inside the connectors.
5. Connect the connector securely.
6. Install the air cleaner assembly.
A/T 3rd Clutch Transmission Fluid Pressure Switch Replacement
1. Raise the vehicle on a lift, or apply the parking brake, block rear wheels, and raise the front of the vehicle. Make
sure it is securely supported.
2. Remove the splash shield.
3. Disconnect the 3rd clutch transmission fluid pressure switch connector, then remove the 3rd clutch transmission
fluid pressure switch (A).
4. Install the new 3rd clutch transmission fluid pressure switch with a new sealing washer (B), and tighten the metal
part of the switch.
5. Make sure there is no water, oil, dust, or foreign particles inside the connector.
6. Connect the connector securely.
7. Install the splash shield.
A/T Clutch Pressure Control Solenoid Valve A Test
1. Connect the HDS to the DLC (A).
2. Select Clutch Pressure Control (Linear) Solenoid A in Miscellaneous Test Menu on the HDS.
NOTE: If the HDS does not communicate with the PCM, troubleshoot the DLC circuit.
3. Test A/T clutch pressure control solenoid valve A with the HDS.
If the valve tests OK, the test is complete. Disconnect the HDS.
If the valve does not test OK, follow the instructions on the HDS.
If the valve does not test OK, and the HDS does not determine the cause, go to Step 4 .
4. Remove the air cleaner assembly.
If the resistance is out of standard, replace A/T clutch pressure control solenoid valve A.
If the resistance is within the standard, go to Step 7 .
7. Connect a jumper wire from the negative battery terminal to the solenoid valve A connector terminal No. 2, and
connect another jumper wire from the positive battery terminal to the connector terminal No. 1.
If a clicking sound is heard, the valve is OK. Reconnect the connector, and install all removed parts.
If no clicking sound is heard, go to Step 8 .
11. Remove the mounting bolts and A/T clutch pressure control solenoid valve A.
12. Remove the ATF pipe (B), ATF joint pipes (C), O-rings (D), and gasket (E).
13. Check the fluid passage of the solenoid valve for contamination.
14. Connect a jumper wire from the negative battery terminal to A/T clutch pressure control solenoid valve A connector
terminal No. 2, and connect another jumper wire from the positive battery terminal to the connector terminal No. 1.
Make sure A/T clutch pressure control solenoid valve A moves.
15. Disconnect one of the jumper wires, and check valve movement at the fluid passage in the valve body mounting
surface. If the valve binds or moves sluggishly, or if the solenoid valve does not operate, replace A/T clutch pressure
control solenoid valve A.
16. Clean the mounting surfaces and fluid passages of the solenoid valve body and transmission housing.
17. Install the new gasket with blue side down; white side up on the transmission housing.
18. Install the ATF pipe and ATF joint pipes, and install the new O-rings over the ATF joint pipes.
19. Install A/T clutch pressure control solenoid valve A.
20. Install the transmission hanger/air cleaner housing bracket, and secure the ATF cooler line/hose bracket and
harness cover with the bolts.
21. Check the connector for rust, dirt, or oil, clean or repair if necessary, then connect the connector securely.
22. Install the air cleaner assembly.
A/T Clutch Pressure Control Solenoid Valve B Test
1. Connect the HDS to the DLC (A).
2. Select Clutch Pressure Control (Linear) Solenoid B in Miscellaneous Test Menu on the HDS.
NOTE: If the HDS does not communicate with the PCM, troubleshoot the DLC circuit.
3. Test A/T clutch pressure control solenoid valve B with the HDS.
If the valve tests OK, the test is complete. Disconnect the HDS.
If the valve does not test OK, follow the instructions on the HDS.
If the valve does not test OK, and the HDS does not determine the cause, go to Step 4 .
4. Remove the air cleaner assembly.
If the resistance is out of standard, replace A/T clutch pressure control solenoid valve B.
If the resistance is within the standard, go to Step 7 .
7. Connect a jumper wire from the negative battery terminal to the solenoid valve B connector terminal No. 2, and
connect another jumper wire from the positive battery terminal to the connector terminal No. 1.
If a clicking sound is heard, the valve is OK. Reconnect the connector, and install all removed parts.
If no clicking sound is heard, go to Step 8 .
8. Remove the breather hose (A) from its clamp (B), and remove the breather hose clamp bracket (C).
12. Connect a jumper wire from the negative battery terminal to A/T clutch pressure control solenoid valve B connector
terminal No. 2, and connect another jumper wire from the positive battery terminal to the connector terminal No. 1.
Make sure A/T clutch pressure control solenoid valve B moves.
13. Disconnect one of the jumper wires, and check valve movement at the fluid passage in the valve body mounting
surface. If the valve binds or moves sluggishly, or if the solenoid valve does not operate, replace A/T clutch pressure
control solenoid valve B and C.
14. Clean the mounting surfaces and fluid passages of the solenoid valve body and transmission housing.
15. Install the new gasket with blue side down; white side up on the transmission housing.
16. Install the ATF pipe and ATF joint pipes, and install the new O-rings over the ATF joint pipes.
17. Install A/T clutch pressure control solenoid valve B and C.
18. Check the connectors for rust, dirt, or oil, clean or repair if necessary, then connect the connectors securely.
19. Install the breather hose clamp bracket, and install the breather hose on its clamp at the dot.
20. Install the air cleaner assembly.
A/T Clutch Pressure Control Solenoid Valve C Test
1. Connect the HDS to the DLC (A).
2. Select Clutch Pressure Control (Linear) Solenoid valve C in Miscellaneous Test Menu on the HDS.
NOTE: If the HDS does not communicate with the PCM, troubleshoot the DLC circuit.
3. Test A/T clutch pressure control solenoid valve C with the HDS.
If the valve tests OK, the test is complete. Disconnect the HDS.
If the valve does not test OK, follow the instructions on the HDS.
If the valve does not test OK, and the HDS does not determine the cause, go to Step 4 .
4. Remove the air cleaner assembly.
If the resistance is out of standard, replace A/T clutch pressure control solenoid valve C.
If the resistance is within the standard, go to Step 7 .
7. Connect a jumper wire from the negative battery terminal to the solenoid valve C connector terminal No. 2, and
connect another jumper wire from the positive battery terminal to the connector terminal No. 1.
If a clicking sound is heard, the valve is OK. Reconnect the connector, and install all removed parts.
If no clicking sound is heard, go to Step 8 .
8. Remove the breather hose (A) from its clamp (B), and remove the breather hose clamp bracket (C).
12. Connect a jumper wire from the negative battery terminal to A/T clutch pressure control solenoid valve C connector
terminal No. 2, and connect another jumper wire from the positive battery terminal to the connector terminal No. 1.
Make sure A/T clutch pressure control solenoid valve C moves.
13. Disconnect one of the jumper wires, and check valve movement at the fluid passage in the valve body mounting
surface. If the valve binds or moves sluggishly, or if the solenoid valve does not operate, replace A/T clutch pressure
control solenoid valve B and C.
14. Clean the mounting surfaces and fluid passages of the solenoid valve body and transmission housing.
15. Install the new gasket with blue side down; white side up on the transmission housing.
16. Install the ATF pipe and ATF joint pipes, and install the new O-rings over the ATF joint pipes.
17. Install A/T clutch pressure control solenoid valve B and C.
18. Check the connectors for rust, dirt, or oil, clean or repair if necessary, then connect the connectors securely.
19. Install the breather hose clamp bracket, and install the breather hose on its clamp at the dot.
20. Install the air cleaner assembly.
A/T Clutch Pressure Control Solenoid Valve A Replacement
1. Remove the air cleaner assembly.
2. Remove the bolt (A) securing the harness cover.
3. Remove the bolt (B) securing the ATF cooler line/hose bracket.
4. Remove the transmission hanger/air cleaner housing bracket (C).
3. Disconnect the connectors (A) from A/T clutch pressure control solenoid valve B and C.
4. Remove A/T clutch pressure control solenoid valve B and C.
5. Remove the ATF pipe (D), ATF joint pipes (E), O-rings (F), and gasket (G).
6. Clean the mounting surface and fluid passages of the transmission housing.
7. Install the new gasket with blue side down; white side up on the transmission housing.
8. Install the ATF pipe and ATF joint pipes, and install the new O-rings over the ATF joint pipes.
9. Install A/T clutch pressure control solenoid valve B and C.
10. Check the connectors for rust, dirt, or oil, clean or repair if necessary, then connect the connectors securely.
11. Install the breather hose clamp bracket, and install the breather hose on its clamp at the dot.
12. Install the air cleaner assembly.
ATF Temperature Sensor Test/Replacement
1. Raise the vehicle on a lift, or apply the parking brake, block both rear wheels, and raise the front of the vehicle.
Make sure it is securely supported.
2. Remove the splash shield.
3. Disconnect the shift solenoid harness connector.
4. Measure the ATF temperature sensor resistance between shift solenoid harness connector terminals No. 6 and No.
7.
Standard: 50 Ω−25 kΩ
5. If the resistance is out of standard, replace the ATF temperature sensor and the solenoid harness; go to Step 6 .
The ATF temperature sensor is not available separately from the shift solenoid harness. If the resistance is within
the standard, connect the connector securely, and install the splash shield.
6. Remove the drain plug (A), and drain the automatic transmission fluid (ATF).
7. Reinstall the drain plug with a new sealing washer (B).
8. Remove the shift solenoid valve cover (A), dowel pins (B), and gasket (C).
9. Disconnect the connectors, remove the shift solenoid harness connector (E), and replace it.
10. Install the new O-ring (F) on the new shift solenoid harness connector, and install the connector in the transmission
housing.
11. Connect the WHT and ORN wires connector to shift solenoid valve B. The ATF temperature sensor is assembled in
the WHT wires connector.
12. Connect the harness terminals to the solenoids:
BLU wire connector to shift solenoid valve A.
GRN wire connector to shift solenoid valve C.
YEL wire connector to shift solenoid valve D.
13. Install the shift solenoid valve cover, dowel pins, and a new gasket.
14. Check the connector for rust, dirt, or oil, then connect it securely.
15. Refill the transmission with ATF.
16. Install the splash shield.
A/T Input Shaft (Mainshaft) Speed Sensor Replacement
1. Remove the air cleaner assembly.
2. Disconnect the input shaft (mainshaft) speed sensor connector, and remove the input shaft (mainshaft) speed
sensor (A).
3. Install the new O-ring (B) on the new input shaft (mainshaft) speed sensor, then install the input shaft (mainshaft)
speed sensor.
4. Check the connector for rust, dirt, or oil, then connect the connector securely.
5. Install the air cleaner assembly.
A/T Output Shaft (Countershaft) Speed Sensor Replacement
1. Remove the air cleaner assembly.
2. Disconnect the output shaft (countershaft) speed sensor connector, and remove the output shaft (countershaft)
speed sensor (A).
3. Install the new O-ring (B) on the new output shaft (countershaft) speed sensor, then install the output shaft
(countershaft) speed sensor.
4. Check the connector for rust, dirt, or oil, then connect the connector securely.
5. Install the air cleaner assembly.
A/T Shift Solenoid Valve Test
1. Connect the HDS to the DLC (A).
2. Select Shift Solenoid A, B, C, and D Test in Miscellaneous Test Menu on the HDS.
NOTE: If the HDS does not communicate with the PCM, troubleshoot the DLC circuit.
3. Check that the shift solenoid valve A, B, C, and D operate with the HDS. A clicking sound should be heard.
If a clicking sound is heard, the valves are OK. The test is complete, disconnect the HDS.
If no clicking sound is heard, go to Step 4 , and test the solenoid valve.
4. Raise the vehicle on a lift, or apply the parking brake, block both rear wheels, and raise the front of the vehicle.
Make sure it is securely supported.
5. Remove the splash shield.
If the resistance is within the standard, go to Step 8 and check solenoid valve for a clicking sound.
If the resistance is out of standard, go to Step 9 .
8. Connect a jumper wire from the negative battery terminal to the body ground, and connect another jumper wire from
the positive battery terminal to each shift solenoid harness connector terminal individually. A clicking sound should
be heard.
If a clicking sound is heard, the valves are OK. The test is complete, connect the connector.
If no clicking sound is heard, go to Step 9 and test shift solenoid valves.
9. Remove the drain plug (A), and drain the automatic transmission fluid (ATF).
10. Reinstall the drain plug with a new sealing washer (B).
11. Remove the shift solenoid valve cover (A), dowel pins (B), and gasket (C).
12. Disconnect the connectors from shift solenoid valve A, shift solenoid valve B, shift solenoid valve C, and shift
solenoid valve D.
13. Measure the resistance of each solenoid valve between the connector terminal and body ground.
Standard: 12−25 Ω
If the resistance is out of standard, go to Step 16 and replace shift solenoid valve.
If the resistance is within the standard, go to Step 14 and check solenoid valve for a clicking sound.
14. Connect a jumper wire from the negative battery terminal to the body ground, and connect another jumper wire from
the positive battery terminal to each solenoid valve terminal individually.
If a clicking sound is heard, go to Step 15 and replace the shift solenoid harness.
If no clicking sound is heard, go to Step 16 and replace shift solenoid valve.
15. Remove the shift solenoid harness connector (A), and replace it. Install the new O-ring (B) on the shift solenoid
harness connector, and install the connector in the transmission housing, then go to Step 21 .
16. Remove the mounting bolts, then hold the solenoid valve body and remove the solenoid valves. Do not hold the
connector to remove the solenoid valve.
17. Install new O-rings (two O-rings per solenoid valve) (E) on the reused solenoid valve.
NOTE: A new solenoid valve comes with new O-rings. If you install a new solenoid valve, use the O-rings provided
on it.
18. Install shift solenoid valve D (black connector) and shift solenoid valve C (brown connector) by holding the shift
solenoid valve body; make sure the mounting bracket contacts the servo body.
NOTE: Do not hold the solenoid valve connector to install the solenoid valve. Be sure to hold the solenoid valve
body.
19. Install shift solenoid valve B (black connector) by holding the solenoid valve body; make sure the mounting bracket
contacts the servo body.
20. Install shift solenoid valve A (brown connector) by holding the shift solenoid valve body; make sure the mounting
bracket contacts the bracket of shift solenoid valve B.
NOTE: Do not install shift solenoid valve A before installing shift solenoid valve B. If shift solenoid valve A is installed
before installing shift solenoid valve B, it may damage to hydraulic control system.
21. Connect the harness terminals to the solenoids:
BLU wire connector to shift solenoid valve A.
ORN wire connector to shift solenoid valve B.
GRN wire connector to shift solenoid valve C.
YEL wire connector to shift solenoid valve D.
22. Install the shift solenoid valve cover, dowel pins, and a new gasket.
23. Check the connector for rust, dirt, or oil, then connect the connector securely.
24. Refill the transmission with ATF.
25. Install the splash shield.
A/T Shift Solenoid Valve Replacement, and Shift Solenoid Harness Replacement
1. Raise the vehicle on a lift, or apply the parking brake, block rear wheels, and raise the front of the vehicle. Make
sure it is securely supported.
2. Remove the splash shield.
3. Remove the drain plug (A), and drain the automatic transmission fluid (ATF).
4. Reinstall the drain plug with a new sealing washer (B).
8. Remove the mounting bolts, then hold the solenoid valve body and remove the solenoid valves. Do not hold the
connector to remove the solenoid valve.
9. Install new O-rings (two O-rings per solenoid valve) (E) on the reused solenoid valve.
NOTE: A new solenoid valve comes with new O-rings. If you install a new solenoid valve, use the O-rings provided
on it.
10. Install shift solenoid valve D (black connector) and shift solenoid valve C (brown connector) by holding the shift
solenoid valve body; make sure the mounting bracket contacts the servo body.
NOTE: Do not hold the solenoid valve connector to install the solenoid valve. Be sure to hold the solenoid valve
body.
11. Install shift solenoid valve B (black connector) by holding the solenoid valve body; make sure the mounting bracket
contacts the servo body.
12. Install shift solenoid valve A (brown connector) by holding the shift solenoid valve body; make sure the mounting
bracket contacts the bracket of shift solenoid valve B.
NOTE: Do not install shift solenoid valve A before installing shift solenoid valve B. If shift solenoid valve A is installed
before installing shift solenoid valve B, it may damage to hydraulic control system.
13. Connect the harness terminals to the solenoids:
BLU wire connector to shift solenoid valve A.
ORN wire connector to shift solenoid valve B.
GRN wire connector to shift solenoid valve C.
YEL wire connector to shift solenoid valve D.
14. Install the shift solenoid valve cover, dowel pins, and a new gasket.
15. Check the connector for rust, dirt, or oil, then connect the connector
16. Refill the transmission with ATF.
17. Install the splash shield.
A/T Gear Position Indicator Component Location Index
Seven-position Transmission
Five-position Transmission
A/T GEAR POSITION INDICATOR
Gauge
A/T GEARControl Module
POSITION Self-diagnostic Function
INDICATOR
Indicator Drive Circuit
Gauge Control ModuleCheck,
Self-diagnostic Function POWERTRAIN
Indicator Drive Circuit Check, CONTROL
POWERTRAIN
MODULE
CONTROL(PCM)
MODULE (PCM)
PADDLE SHIFTER +
(UPSHIFT SWITCH)
Circuit Troubleshooting,
TRANSMISSION RANGE
Replacement,
SWITCH
Test,
TRANSMISSION RANGE SWITCH
Replacement,
Test,
Replacement,
*: This illustration shows RHD model.
*: This illustration shows RHD model.
Five-position Transmission
BATTE RY TE RMINAL FUS E BOX UNDE R−DAS H FUS E /RE LAY BOX
BATTE RY
No. 1 (100 A) No. 39 (15 A)
No. 60 (50 A)
BATTE RY TE RMINAL FUS E BOX UNDE R−DAS H FUS E /RE LAY BOX
MULTI−FUS E
BATTE RY BLOCK P GM−FI
No. 1 (100 A) No. 39 (15 A) MAIN RE LAY 1
No. 7 (10 A)
BAT IG1
No. 20 (15 A)
No. 60 (50 A)
No. 20 (15 A)
MULTIP LE X INTE GRATE D
IGINITION S W ITCH CONTROL UNITNo.(MICU)
22 (7.5 A)
32
A/T GE AR R
A/T
P OS ITION DIMMING 32
LT BLU
LT BLU
INDICATOR CIRCUIT
DRIV E R N
CIRCUIT P
P OW E RTRAIN CONTROL To 12 V
D MODULE (P CM)
R
To 5 V IG1 C10
S BLK/RE D RE D
A/T GE AR N A/T
P OS ITION DIMMING
CAN INDICATOR
D
CIRCUIT To 12 VV B S OL A1
BRN
CONTROLLE R DRIV E R
CIRCUIT
S E QUE NTIAL P OW E RTRAIN CONTROL
A3 CANMODULE
H IG1 C10
S HIFT MODE D3
(P CM) MRLY A7 BLK/RE D RE D
S HIFT INDICATOR BLU
CIRCUIT V B S OL A1
CAN
CONTROLLE R 2 W HT BRN
IGP A9
30 MRLY A7 LT GRN
1 BLU
F−CAN A4 CAN L
TRANS CE IV E R ATP RV
IGPS B23
A9
29 W HT LTYGRN
EL
RE D ATP FW D B29
30 BLU/Y E L
RE D W HT ATP RV S B23
ATP 2−1 B17 YBLU
EL
F−CAN ATP FWD3
D B29
TRANS CE IV E R RE D ATP B16 BLU/Y E L
RE D
29 ATP
ATP S
D B16
B22
RE D
P NK S TARTE R
SG 13RE D W HT ATP
ATP DN B22
B13 CUT RE LAY
REPD/BLK
NK
S TARTE R
A3 CAN H ATP
PG 17 ATP NR B13
B15 CUT RE LAY
RE D/BLK
To 5 V ATP
A4 CAN L ATP RP B15
B14
BLK BLK
ATP P B14
SG 13 BLU/BLK W HT LT GRN
2 BLU/BLK
5 W
4 HT 9 3 8 2 6 LT
10GRN 7 1 BLK
PG 17
A/T GE AR RE D/BLK GRY
P OS ITION 5 4 9 3 8 6 10 7 1 BLK
INDICATOR BLK BLK
P ANE L LIGHT G501 BLK/BLU RE D/BLK BLU Y E L/RE D BLU/W HT
6
RE D/BLK BLK BLK/BLU W HT RE D/BLK P NK BLU BRN W HT/RE DW HT/RE D BLK BLK
G101
6 7 2 8 3 9 5 1 4 10
W HT P NK Y E L/RE D BLU/W HT G101
2
A/T GE AR RE D/BLK GRY
6 7 2 8 3 5 1 FW 4D RV10S ST E
P OS ITION N D
INDICATOR DATA LINK G502 G501 A32 S CS
P ANE L LIGHT CONNE CTOR YEL YEL R N D D3 FW D RV S ST E
6
(DLC) RE D/BLK BLK
P R S 2
B10 P G1
BLK P 1
P ADDLE S HIFTE R +
(UP S HIFT S W ITCH) CABLE RE E L G502
B1 P G2
1 BRN A47 S UP P
GRN/ORN YEL YEL
42 44 46 40 45 46 47 48 43 44 46 48
1 3 4 6 7 9 10 1 3 4 7 8 9 10 1 2 3 4 5 6 7 8 9 10
22 24 25 26 28 22 23 24
Terminal 26 27 28
side of female terminals
29 30 32 34 35 36 37 38 29 31 32 33 34 35 36 38 29 30 31 32
42 44 46 47 48 40 45 46 47 48 43 44 46 48
4. Check for continuity between paddle shifter − (downshift switch) connector terminals while pressing the paddle
shifter − and when the paddle shifter − is released.
Is there continuity while pressing the paddle shifter − and no continuity when the paddle shifter − is released?
YES - Replace the steering switch harness.■
NO - Replace the paddle shifter −. ■
5. Remove the cable reel.
6. Check for continuity between cable reel 20P connector terminal No. 2 and body ground.
Is there continuity?
YES - Go to Step 7 .
NO - Repair open in the wire between cable reel 20P connector terminal No. 2 and ground (G501), or repair
poor ground (G501).■
7. Jump the SCS line with the HDS.
8. Disconnect PCM connector A (49P).
9. Check for continuity between cable reel 20P connector terminal No. 5 and body ground.
Is there continuity?
YES - Repair short in the wire between cable reel 20P connector terminal No. 5 and PCM connector terminal
A48.■
NO - Go to Step 10 .
10. Check for continuity between PCM connector terminal A48 and cable reel 20P connector terminal No. 5.
Is there continuity?
YES - Replace the cable reel. ■
NO - Repair open in the wire between PCM connector terminal A48 and the cable reel 20P connector.■
Paddle Shifter + (Upshift Switch) Circuit Troubleshooting
SRS components are located in this area. Review the SRS component locations and the precautions and procedures
before doing repairs or service.
1. Remove the steering wheel.
2. Check for continuity between steering switch harness 20P connector terminals No. 7 and No. 12 while pressing the
paddle shifter + (upshift switch) and when the paddle shifter + is released.
Is there continuity while pressing the paddle shifter + and no continuity when the paddle shifter + is released?
YES - Go to Step 5 .
NO - Go to Step 3 .
3. Disconnect the paddle shifter + (upshift switch) connector.
4. Check for continuity between paddle shifter + (upshift switch) connector terminals while pressing the paddle shifter
+ and when the paddle shifter + is released.
Is there continuity while pressing the paddle shifter + and no continuity when the paddle shifter + is released?
YES - Replace the steering switch harness.■
NO - Replace the paddle shifter +. ■
5. Remove the cable reel.
6. Check for continuity between cable reel 20P connector terminal No. 2 and body ground.
Is there continuity?
YES - Go to Step 7 .
NO - Repair open in the wire between cable reel 20P connector terminal No. 2 and ground (G501), or repair
poor ground (G501).■
7. Jump the SCS line with the HDS.
8. Disconnect PCM connector A (49P).
9. Check for continuity between cable reel 20P connector terminal No. 6 and body ground.
Is there continuity?
YES - Repair short in the wire between cable reel 20P connector terminal No. 6 and PCM connector terminal
A47.■
NO - Go to Step 10 .
10. Check for continuity between PCM connector terminal A47 and cable reel 20P connector terminal No. 6.
Is there continuity?
YES - Replace the cable reel. ■
NO - Repair open in the wire between PCM connector terminal A47 and the cable reel 20P connector.■
Paddle Shifter - (Downshift Switch) Replacement
SRS components are located in this area. Review the SRS component locations and the precautions and procedures
before doing repairs or service.
1. Remove the steering wheel.
2. Remove the four screws (A) securing the steering wheel rear cover (B), then remove the steering wheel rear cover.
3. Remove the paddle shifter − (downshift switch) connector (A) from its holder, and disconnect the connector.
4. Remove the screws (B) securing the paddle shifter − (C), remove the paddle shifter −, and replace it with a new
one.
5. Install the new paddle shifter − on the steering wheel, and secure it with the screws.
6. Connect the paddle shifter − connector securely, and install the connector in the connector holder.
7. Install the steering wheel rear cover, and secure the rear cover with the four screws.
8. Install the steering wheel.
Paddle Shifter + (Upshift Switch) Replacement
SRS components are located in this area. Review the SRS component locations and the precautions and procedures
before doing repairs or service.
1. Remove the steering wheel.
2. Remove the four screws (A) securing the steering wheel rear cover (B), then remove the steering wheel rear cover.
3. Remove the paddle shifter + (upshift switch) connector (A) from its holder, and disconnect the connector.
4. Remove the screws (B) securing the paddle shifter + (C), remove the paddle shifter +, and replace it with a new
one.
5. Install the new paddle shifter + on the steering wheel, and secure it with the screws.
6. Connect the paddle shifter + connector securely, and install the connector in the connector holder.
7. Install the steering wheel rear cover, and secure the rear cover with the four screws.
8. Install the steering wheel.
Transmission Range Switch Test
1. Remove the air cleaner assembly.
2. Disconnect the transmission range switch harness connector (A).
3. Check for continuity between terminals at the harness connector. There should be continuity between the terminals Transmission Range
in the following table for each switch position. Switch Harness
4. Transmission range switch test has finished if the test results are OK. Connector Seven-
If there is no continuity between any terminals, go to Step 5 . position Transmission
5. Raise the vehicle on a lift, or apply the parking brake, block rear wheels, and raise the front of the vehicle. Make
sure it is securely supported.
Transmission Range
Switch Harness
Connector Five-
position Transmission
8. Check for continuity between terminals at the switch connector. There should be continuity between the terminals Transmission Range
in the following table for each switch position. Switch Connector
Seven-position
Transmission
Transmission Range
Switch Connector
Five-position
Transmission
9. If the transmission range switch continuity check is OK, replace the faulty transmission range switch harness;
remove the harness clamps (A) from the clamp bracket (B), remove the transmission range switch harness (C).
10. If there is no continuity between any terminals, remove the transmission range switch, and check the end of the
selector control shaft (A).
Selector Control Shaft Specifications:
Width (B): 6.1−6.2 mm (0.240−0.244 in.)
End Gap (C): 1.8−2.0 mm (0.07−0.08 in.)
11. The measurement of the selector control shaft end is within the standard, replace the transmission range switch. If
the measurement is out of the standard, repair the selector control shaft end, and recheck the transmission range
switch continuity.
Transmission Range Switch Replacement
1. Raise the vehicle on a lift, or apply the parking brake, block the rear wheels, and raise the front of the vehicle. Make
sure it is securely supported.
2. Shift to N.
3. Remove the transmission range switch cover.
6. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch
(C), then put a 2.0 mm (0.08 in.) feeler gauge blade (D) in the cutouts to hold the switch in the N position.
NOTE: Be sure to use a 2.0 mm (0.08 in.) blade or equivalent to hold the switch in the N position.
7. Install the transmission range switch (A) gently on the selector control shaft (B) while holding it in the N position
with the 2.0 mm (0.08 in.) blade (C).
8. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the
transmission range switch when tightening the bolts. Remove the feeler gauge.
9. Check the connectors for rust, dirt, or oil, clean or repair if necessary, then connect the connector securely.
10. Turn the ignition switch to ON (II). Move the shift lever through all positions, and check the transmission range
switch synchronization with the A/T gear position indicator.
11. Check that the engine starts in P and N, and does not start in any other shift lever position.
12. Check that the back-up lights come on when the shift lever is in R.
13. Allow the front wheels to rotate freely, then start the engine, and check the shift lever operation.
6. Connect the oil pressure gauge to the line pressure inspection port (A). Do not allow dust or other foreign particles
to enter the hole while connecting the gauge.
7. Start the engine, and warm it up to normal operating temperature (the radiator fan comes on).
8. Measure the line pressure at the line pressure inspection port in P or N while holding the engine speed at 2,000
rpm (min −1 ).
NOTE: Higher pressure may be indicated if measurements are made in the shift lever position other than P or N.
Pressure Fluid Pressure
Standard Service Limit
Line (A) 900−960 kPa (9.2−9.8 kgf/cm 2 , 850 kPa (8.7 kgf/cm 2 , 120 psi)
130−140 psi)
9. Turn the engine off, then disconnect the oil pressure gauge from the line pressure inspection port.
10. Install the sealing bolt to the line pressure inspection port with a new sealing washer, and tighten the bolt to 18 N·m
(1.8 kgf·m, 13 lbf·ft). Do not reuse the old sealing washer.
11. Remove the air cleaner assembly.
12. Connect the oil pressure gauge to the 1st clutch pressure inspection port (B), then temporarily install the air
cleaner assembly.
13. Connect the oil pressure gauge to the 2nd clutch pressure inspection port (C).
14. For seven-position transmission: Measure the 1st and 2nd clutch pressure.
-1. Start the engine, and shift to 1.
-2. Measure the 1st clutch pressure at the 1st clutch pressure inspection port while holding the engine speed at
2,000 rpm (min −1 ).
-3. Shift to 2, and measure the 2nd clutch pressure at the 2nd clutch pressure inspection port while holding the
engine speed at 2,000 rpm (min −1 ).
15. For five-position transmission: Measure the 1st and 2nd clutch pressure.
-1. Start the engine, and shift to S.
-2. Pull the paddle shifter + (upshift switch), make sure the transmission is in 1st gear, and measure the 1st
clutch pressure at the 1st clutch pressure inspection port while holding the engine speed at 2,000 rpm (min
−1 ).
-3. Upshift to 2nd gear by pulling the paddle shifter +, and measure the 2nd clutch pressure at the 2nd clutch
pressure inspection port while holding the engine speed at 2,000 rpm (min −1 ).
Pressure Fluid Pressure
Standard Service Limit
1st clutch (B) 890−970 kPa (9.1−9.9 kgf/cm 2 , 840 kPa (8.6 kgf/cm 2 , 120
2nd clutch (C) 130−140 psi) psi)
16. Turn the engine off, remove the air cleaner assembly, then disconnect the oil pressure gauges from the 1st clutch
pressure and 2nd clutch pressure inspection ports.
17. Install the sealing bolts to the 1st clutch pressure and 2nd clutch pressure inspection ports with the new sealing
washers, and tighten the bolts to 18 N·m (1.8 kgf·m, 13 lbf·ft). Do not reuse old sealing washer.
18. Install the air cleaner assembly.
19. Connect the oil pressure gauge to the 3rd clutch pressure inspection port (D) and the 4th clutch pressure
inspection port (E).
20. Connect the oil pressure gauge to the 5th clutch pressure inspection port (F).
21. For seven-position transmission: Measure the 3rd, 4th, and 5th clutch pressures.
-1. Start the engine, and shift to D3, then press the accelerator pedal slowly until reaching 3rd gear.
-2. Measure the 3rd clutch pressure at the 3rd clutch pressure inspection port while holding the engine speed at
2,000 rpm (min −1 ).
-3. Shift to D, and measure the 4th clutch pressure at the 4th clutch pressure inspection port.
-4. Measure the 5th clutch pressure at the 5th clutch pressure inspection port while holding the engine speed at
2,000 rpm (min −1 ).
22. For five-position transmission: Measure the 3rd, 4th, and 5th clutch pressures.
-1. Start the engine, and shift to S.
-2. Upshift to 3rd gear by pulling the paddle shifter +, and measure the 3rd clutch pressure at the 3rd clutch
pressure inspection port while holding the engine speed at 2,000 rpm (min −1 ).
-3. Upshift to 4th gear by pulling the paddle shifter +, and measure the 4th clutch pressure at the 4th clutch
pressure inspection port while holding the engine speed at 2,000 rpm (min −1 ).
-4. Upshift to 5th gear by pulling the paddle shifter +, and measure the 5th clutch pressure at the 5th clutch
pressure inspection port while holding the engine speed at 2,000 rpm (min −1 ).
Pressure Fluid Pressure
Standard Service Limit
3rd clutch (D) 890−970 kPa (9.1−9.9 kgf/cm 2 , 840 kPa (8.6 kgf/cm 2 , 120
4th clutch (E) 130−140 psi) psi)
5th clutch (F)
23. Bring the engine back to an idle, then press the brake pedal to stop the wheels from rotating.
24. Shift to R, then release the brake pedal. Raise the engine speed to 2,000 rpm (min −1 ), and measure the 5th clutch
pressure at the 5th clutch pressure inspection port.
Pressure Fluid Pressure
Standard Service Limit
5th clutch (F) in R 890−970 kPa (9.1−9.9 kgf/cm 2 , 840 kPa (8.6 kgf/cm 2 , 120 psi)
130−140 psi)
25. Turn the engine off, then disconnect the oil pressure gauges from the 3rd, 4th, and 5th clutch pressure inspection
ports.
26. Install the sealing bolts in the 3rd, 4th, and 5th clutch pressure inspection ports with the new sealing washers, and
tighten the bolts to 18 N·m (1.8 kgf·m, 13 lbf·ft). Do not reuse the old sealing washer.
27. If any of the pressures are out of the service limit, refer to the problems and probable causes listed in the table.
Problem Probable causes
No or low line pressure Torque converter
ATF pump
Regulator valve
Torque converter check valve
Clogged ATF strainer
No or low 1st clutch pressure 1st clutch
O-rings
No or low 2nd clutch pressure 2nd clutch
O-rings
No or low 3rd clutch pressure 3rd clutch
O-rings
No or low 4th clutch pressure 4th clutch
O-rings
No or low 5th clutch pressure 5th clutch
O-rings
No or low 5th clutch pressure in R Servo valve
5th clutch
O-rings
3. Install the wave spring (A) in the 1st clutch drum (B). Starting with the clutch wave-plate, alternately install the
wave-plates (C) (6) and discs (D) (6). Install the clutch end-plate (E) with the flat side down on the top disc.
4. Install the wave spring (A) in the 2nd clutch drum (B). Starting with the clutch flat-plate, alternately install the flat-
plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.
5. Install the wave spring (A) in the 4th clutch drum (B). Starting with the clutch flat-plate, alternately install the flat-
plates (C) (4) and the discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
6. Install the wave spring (A) in the 3rd clutch drum (B). Starting with the clutch wave-plate, alternately install the
wave-plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.
7. Install the wave spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the
wave-plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.
8. Install the snap ring with a screwdriver to secure the clutch end-plate.
14. If the clearance of the 1st, 3rd, or 5th clutch is out of the service limit, select a new clutch end-plate from the
following table.
AM-AV Plates
Mark Part Number Thickness
AM 22561-RPC-004 2.1 mm (0.083 in.)
AN 22562-RPC-004 2.2 mm (0.087 in.)
AP 22563-RPC-004 2.3 mm (0.091 in.)
AQ 22564-RPC-004 2.4 mm (0.094 in.)
AR 22565-RPC-004 2.5 mm (0.098 in.)
AS 22566-RPC-004 2.6 mm (0.102 in.)
AT 22567-RPC-004 2.7 mm (0.106 in.)
AU 22568-RPC-004 2.8 mm (0.110 in.)
AV 22569-RPC-004 2.9 mm (0.114 in.)
16. Install the new clutch end-plate and recheck the clearance. If the thickest clutch end-plate is installed but the
clearance is still over the service limit, replace the clutch discs and plates.
A/T Clutch Wave-plate Phase Difference Inspection
1. Place the clutch wave-plate (A) on a surface plate, and set a dial indicator (B) on the wave-plate.
2. Find the bottom (C) of a phase difference of the wave-plate, zero the dial indicator, and make a reference mark on
the bottom of the wave-plate.
3. Rotate the 1st clutch wave-plate 5 or 6 tooth of angles apart from the bottom while holding the wave-plate by its
circumference, and rotate the 3rd and 5th clutch wave-plate about 60-degrees apart from the bottom while holding
the wave-plate by its circumference. The dial indicator should be at the top (D) of a phase difference. Do not rotate
the wave-plate while holding its surface, always rotate it by holding its circumference.
4. Read the dial indicator. The dial indicator reads the phase difference (E) of the wave-plate between the bottom and
top.
Standard: 0.07−0.20 mm (0.003−0.008 in.)
5. Rotate the 1st clutch wave-plate 5 or 6 tooth of angles from the top, and rotate the 3rd and 5th clutch wave-plate
about 60-degrees. The dial indicator should be at the bottom of a phase difference (F and G). Zero the dial indicator.
6. Measure the phase difference at the other two tops (H and I) of the wave-plate by following Step 3 thru 5.
7. If two of the three measurements are within the standard, the wave-plate is OK. If two of the three measurements
are out of the standard, replace the wave-plate.
A/T Mainshaft 3rd Gear Axial Clearance Inspection
1. Remove the mainshaft transmission housing bearing.
2. Install the thrust needle bearing (A), the 3rd gear (B), the needle bearing (C), the thrust needle bearing (D), the 40 x
63 mm thrust washer (E), the 3rd/5th clutch (F), the 5th gear collar (G), and the transmission housing bearing (H)
on the mainshaft (I). Do not install the O-rings during inspection.
3. Install the idler gear (J) on the mainshaft by a press, then install the conical spring washer (K) and the locknut (L).
4. Tighten the locknut to 29 N·m (3.0 kgf·m, 22 lbf·ft).
6. Lift 3rd gear (A) up while holding the mainshaft, and use the dial indicator (B) to read the 3rd gear axial clearance.
7. Measure the 3rd gear axial clearance in at least three places while moving 3rd gear. Use the average as the actual
clearance.
Standard: 0.04−0.10 mm (0.002−0.004 in.)
8. If the clearance is out of standard, remove the 40 x 63 mm thrust washer and measure its thickness (A).
9. Select and install a new thrust washer, then recheck.
THRUST WASHER, 40 x 63 mm
No. Part Number Thickness
1 90414-RPC-000 3.750 mm (0.1476 in.)
2 90415-RPC-000 3.775 mm (0.1486 in.)
3 90416-RPC-000 3.800 mm (0.1496 in.)
4 90417-RPC-000 3.825 mm (0.1506 in.)
5 90418-RPC-000 3.850 mm (0.1516 in.)
6 90419-RPC-000 3.875 mm (0.1526 in.)
7 90420-RPC-000 3.900 mm (0.1535 in.)
8 90421-RPC-000 3.925 mm (0.1545 in.)
9 90422-RPC-000 3.950 mm (0.1555 in.)
10 90423-RPC-000 3.975 mm (0.1565 in.)
11 90424-RPC-000 4.000 mm (0.1575 in.)
10. After replacing the thrust washer, make sure the clearance is within standard.
11. Disassemble the installed parts from the mainshaft.
12. Reinstall the bearing in the transmission housing.
A/T Housing Bearing Removal
Special Tools Required
Driver attachment, 72 x 75 mm
07746-0010600
Driver attachment, 78 x 80 mm
07NAD-PX40100
Driver attachment, 62 x 68 mm
07746-0010500
2. To remove the mainshaft bearing (A), countershaft bearing (B), secondary shaft bearing (C), and idler gear shaft
bearing (D) from the transmission housing, expand each snap ring with the snap ring pliers, then push the bearing
out.
NOTE: Do not remove the snap ring unless it's necessary to clean the grooves in the housing.
A/T Housing Bearing Installation
Special Tools Required
Driver attachment, 72 x 75 mm
07746-0010600
Driver attachment, 78 x 80 mm
07NAD-PX40100
Driver attachment, 62 x 68 mm
07746-0010500
4. After installing the bearings verify that the snap rings (A) are seated in the bearing and housing grooves, and that
the ring end gaps (B) are 0−7 mm (0−0.28 in.)
5. Install the idler gear shaft (A) in the idler gear shaft bearing.
6. Install the cotters (B) and cotter retainer (C), and secure the idler gear shaft with the snap ring (D).
Torque Converter Housing Mainshaft Bearing and Oil Seal Replacement
Special Tools Required
Adjustable bearing remover set
07JAC-PH80000
Driver attachment, 72 x 75 mm
07746-0010600
1. Remove the mainshaft bearing and oil seal with the special tool.
2. Install the new mainshaft bearing until it bottoms in the torque converter housing with the special tools.
3. Install the new oil seal flush with the housing with the special tools.
A/T Secondary Shaft Disassembly, Inspection, and Reassembly
1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
2. Inspect the splines for excessive wear and damage.
3. Check the shaft bearing surface for scoring and excessive wear.
4. Before installing the O-rings, wrap the shaft splines with tape to prevent O-ring damage.
5. Lubricate all parts with ATF during assembly.
6. Install the conical spring washer, idler gear, and 31 x 50 mm thrust washer in the direction
shown.
7. Replace the locknut and conical spring washer with new ones when assembling the
transmission. The locknut has left-hand threads.
8. Check the axial clearance of the 1st gear and 2nd gear.
9. Inspect the condition of the sealing rings. If the sealing rings are worn, distorted, or damaged,
replace them.
A/T System Description - Clutches and Gears
Clutches and Gears
Clutches and Gears (cont'd)
A/T Clutch Disassembly
Special Tools Required
Clutch spring compressor set
07LAE-PX40000
2. Remove the clutch end-plate (A), the clutch discs (B) (6), the clutch wave-plates (C) (6), and the wave spring (D)
from the 1st clutch drum (E).
3. Remove the clutch end-plate (A), the clutch discs (B) (3), the clutch flat-plates (C) (3), and the wave spring (D) from
the 2nd clutch drum (E).
4. Remove the clutch end-plate (A), the clutch discs (B) (4), the clutch flat-plates (C) (4), and the wave spring (D) from
the 4th clutch drum (E).
5. Remove the clutch end-plate (A), the clutch discs (B) (3), the clutch wave-plates (C) (3), and the wave spring (D)
from the 3rd clutch drum (E).
6. Remove the clutch end-plate (A), the clutch discs (B) (3), the clutch wave-plates (C) (3), and the wave spring (D)
from the 5th clutch drum (E).
7. Install the clutch spring compressor attachments and the clutch spring compressor bolt assembly.
8. Set the clutch spring compressor attachment (A) on the 1st clutch spring retainer (B) so the clutch spring
compressor attachment works on the clutch return spring (C).
9. If either end of the clutch spring compressor attachment is not set over the clutch return spring end, the spring
retainer may be tilted and damaged. If the retainer is tilted when compressing the return spring, reset the clutch
spring compressor attachment on the retainer at another angle.
10. Be sure the clutch spring compressor attachment (A) is adjusted to have full contact with the spring retainer (B) on
the 2nd, 3rd, 4th, and 5th clutches.
11. If either end of the clutch spring compressor attachment is set over an area of the spring retainer that is
unsupported by the return spring, reset the clutch spring compressor attachment over the proper position.
12. Compress the return spring until the snap ring can be removed.
15. Remove the snap ring (A), the spring retainer (B), and the return spring (C).
16. Wrap a shop rag around the clutch drum, and apply air pressure to the fluid passage to remove the piston. Place a
finger tip on the other passage while applying air pressure.
17. Remove the clutch piston (A) from the clutch drum (B) of the 1st, 2nd, and 4th clutches. Remove the O-ring (C)
from the clutch piston, and O-ring (D) from the drum.
18. Remove the clutch piston (A) from the clutch drum of the 3rd and 5th clutches, and remove the outer O-ring (B) and
inner O-ring (C) from the piston.
A/T 1st Clutch Reassembly
Special Tools Required
Clutch spring compressor set
07LAE-PX40000
3. Coat the piston O-ring with ATF, and install the clutch piston (A) in the clutch drum (B) while applying pressure and
rotating to ensure proper seating. Do not pinch the O-ring.
4. Install the return spring (A), and install the spring retainer (B) can be adjusted (center of tolerance) to prevent
damaging the retainer oil seal.
5. Position the snap ring (C) on the spring retainer.
6. Install the clutch spring compressor attachments and the clutch spring compressor bolt assembly.
7. Set the clutch spring compressor attachment (A) on the spring retainer (B), and over the clutch return spring end,
so the clutch spring compressor attachment works on the clutch return spring (C).
8. If either end of the clutch spring compressor attachment is not set over the clutch return spring end, reset the
clutch spring compressor attachment over the return spring end.
9. Coat between the mating areas of the spring retainer oil seal and the clutch piston with ATF. Compress the return
spring (A) carefully until the snap ring (B) can be installed, and install the spring retainer (C) to ensure proper
seating in the clutch piston, and over the clutch hub (D). Do not pinch the spring retainer oil seal.
10. Install the snap ring with the snap ring pliers.
11. Remove the clutch spring compressor attachments and the clutch spring compressor bolt assembly.
12. Check that the spring retainer oil seal (A) is properly seated in the clutch piston (B).
13. If improperly seated, remove the spring retainer, and check the oil seal. If the oil seal is worn, damaged, or peeling,
replace the spring retainer, and reinstall the new retainer in the clutch piston.
14. Install the wave spring (A) in the 1st clutch drum (B). Starting with the clutch wave-plate, alternately install the
wave-plates (C) (6) and discs (D) (6). Install the clutch end-plate (E) with the flat side down on the top disc.
15. Install the snap ring with a screwdriver to secure the clutch end-plate.
16. Check that the clutch piston moves by applying air pressure into the fluid passage.
A/T Clutch Inspection
1. Inspect the clutch pistons and the clutch piston check valves (A).
2. If the clutch piston check valve is loose or damaged, replace the clutch piston.
3. Check the spring retainer for wear and damage.
4. If the spring retainer is worn or damaged, replace it.
5. Check the oil seal (A) on the 1st clutch spring retainer for wear, damage, and peeling.
6. If the oil seal is worn, damaged, or peeling, replace the spring retainer.
7. Inspect the clutch discs, the clutch plates, and the clutch end-plate for wear, damage, and discoloration.
Clutch Discs Standard Thickness
1st clutch: 1.94 mm (0.076 in.)
2nd clutch: 1.96 mm (0.077 in.)
3rd clutch: 1.94 mm (0.076 in.)
4th clutch: 1.96 mm (0.077 in.)
5th clutch: 1.94 mm (0.076 in.)
8. If the clutch discs are worn or damaged, replace them as a set. If the clutch discs are replaced, inspect the
clearance between the clutch end-plate and the top disc.
9. If any flat-plate is worn, damaged, or discolored, replace them as a set. If the clutch flat-plates are replaced,
inspect the clearance between the clutch end-plate and the top disc.
10. If any wave-plate is worn, damaged, or discolored, replace the damaged plate with a new plate, and inspect the
other wave-plates for a phase difference. If the clutch wave-plate is replaced, inspect the clearance between the
clutch end-plate and the top disc.
11. If the clutch end-plate is worn, damaged, or discolored, inspect the clearance between the clutch end-plate and the
top disc, then replace the clutch end-plate.
A/T 2nd, 3rd, 4th, and 5th Clutch Reassembly
Special Tools Required
Clutch spring compressor set
07LAE-PX40000
3. Install the new O-rings (A) on the piston (B) of the 3rd and 5th clutches.
4. Install the clutch piston (A) in the clutch drum (B) while applying pressure and rotating to ensure proper seating. Do
not pinch the O-ring.
5. Install the return spring (A) and the spring retainer (B), and position the snap ring (C) on the spring retainer.
6. Install the clutch spring compressor attachments and the clutch spring compressor bolt assembly.
7. Be sure the clutch spring compressor attachment (A) is adjusted to have full contact with the spring retainer (B).
8. If either end of the clutch spring compressor attachment is set over an area of the spring retainer that is
unsupported by the return spring, reset the clutch spring compressor attachment over the proper position.
9. Compress the return spring until the snap ring can be installed.
10. Install the snap ring with the snap ring pliers.
11. Remove the clutch spring compressor attachments and the clutch spring compressor bolt assembly.
12. Install the wave spring (A) in the 2nd clutch drum (B). Starting with the clutch flat-plate, alternately install the flat-
plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.
13. Install the wave spring (A) in the 4th clutch drum (B). Starting with the clutch flat-plate, alternately install the flat-
plates (C) (4) and the discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
14. Install the wave spring (A) in the 3rd clutch drum (B). Starting with the clutch wave-plate, alternately install the
wave-plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.
15. Install the wave spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the
wave-plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.
16. Install the snap ring with a screwdriver to secure the clutch end-plate.
17. Check that the clutch piston moves by applying air pressure into the fluid passage.
A/T Secondary Shaft 1st Gear Axial Clearance Inspection
1. Install the thrust needle bearing (A), 1st gear (B), needle bearing (C), thrust needle bearing (D), 31 x 50 mm thrust
washer (E), and 1st clutch (F) on the secondary shaft (G), then secure them with the snap ring (H).
2. Measure the clearance between the snap ring (A) and the 1st clutch guide (B) with a feeler gauge (C), in at least
three places. Use the average as the actual clearance.
Standard: 0.04−0.12 mm (0.002−0.005 in.)
3. If the clearance is out of standard, remove the 31 x 50 mm thrust washer and measure its thickness (A).
4. Select and install a new thrust washer, then recheck.
THRUST WASHER, 31 x 50 mm
No. Part Number Thickness
1 90521-RG5-000 3.925 mm (0.1545 in.)
2 90522-RG5-000 3.950 mm (0.1555 in.)
3 90523-RG5-000 3.975 mm (0.1565 in.)
4 90524-RG5-000 4.000 mm (0.1575 in.)
5 90525-RG5-000 4.025 mm (0.1585 in.)
6 90526-RG5-000 4.050 mm (0.1594 in.)
7 90527-RG5-000 4.075 mm (0.1604 in.)
8 90528-RG5-000 4.100 mm (0.1614 in.)
9 90529-RG5-000 4.125 mm (0.1624 in.)
10 90530-RG5-000 4.150 mm (0.1634 in.)
11 90531-RG5-000 4.175 mm (0.1644 in.)
12 90532-RG5-000 4.200 mm (0.1654 in.)
13 90533-RG5-000 4.225 mm (0.1663 in.)
14 90534-RG5-000 4.250 mm (0.1673 in.)
15 90535-RG5-000 4.275 mm (0.1683 in.)
16 90536-RG5-000 4.300 mm (0.1693 in.)
17 90537-RG5-000 4.325 mm (0.1703 in.)
5. After replacing the thrust washer, make sure the clearance is within standard.
6. Disassemble the installed parts from the secondary shaft.
A/T Secondary Shaft 2nd Gear Axial Clearance Inspection
1. Install the thrust needle bearing (A), the needle bearing (B), the 2nd gear (C), the thrust needle bearing (D), the 43 x
54.5 mm thrust washer (E), the 39 mm cotters (F), and the cotter retainer (G) on the secondary shaft (H), then
secure them with the snap ring (I).
3. Lift the 2nd gear (A) up while holding the secondary shaft (B), and use the dial indicator (C) to read the 2nd gear
axial clearance.
4. Measure the 2nd gear axial clearance in at least three places while moving the 2nd gear. Use the average as the
actual clearance.
Standard: 0.04−0.12 mm (0.002−0.005 in.)
5. If the clearance is out of standard, remove the 43 x 54.5 mm thrust washer and measure its thickness.
6. Select and install a new thrust washer, then recheck.
7. After replacing the thrust washer, make sure the clearance is within standard.
8. Disassemble the installed parts from the secondary shaft.
Torque Converter Housing Secondary Shaft Bearing Replacement
Special Tools Required
Driver handle 15 x 135L
07749-0010000
Driver attachment, 62 x 68 mm
07746-0010500
1. Remove the bolt, then remove the lock washer (A) and bearing set plate (B).
2. Remove the secondary shaft bearing (A) by heating the housing to about 100 °C (212 °F) with a heat gun (B). Do
not heat the housing in excess 100 °C (212 °F).
NOTE: Let the housing cool to normal temperature before installing the bearing.
3. Install the new O-rings (A) on the ATF guide collar (B), then install the ATF guide collar in the housing.
4. Install the new secondary shaft bearing (C) in the direction shown.
5. Drive the secondary shaft bearing with the special tools, and install it securely in the housing.
6. Check that the bearing groove aligns with the housing surface, then install the bearing set plate with aligning the
bearing groove.
7. Install the new lock washer and bolt, then bend the lock tab of the lock washer against the bolt head.
A/T Secondary Shaft Sealing Ring Replacement
The sealing rings are synthetic resin with chamfered ends. Check the condition of the sealing rings, and replace them only
if they are worn, distorted, or damaged.
1. For a better fit, squeeze sealing rings together slightly before installing them.
2. Apply ATF to the new sealing rings, then install them on the mainshaft.
3. After installing the sealing rings, verify the following:
The rings are fully seated in the groove.
The rings are not twisted.
The chamfered ends of the rings are properly joined.
A/T Shift Cable Adjustment
1. Remove the center console.
2. Shift the transmission to N.
3. Remove the nut securing the shift cable end.
4. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the corner (C) on the socket holder will be in the
opening (D) of the shift lever bracket base (E). Then slide the holder to remove the shift cable from the bracket. Do
not remove the shift cable by twisting the shift cable guide (F).
5. Push the shift cable (A) until it stops, then release it. Pull the shift cable back two steps so that the shift position is
in N. Do not hold the shift cable guide (B) to adjust the shift cable.
6. Turn the ignition switch to ON (II), and check that the N indicator comes on.
7. Turn the ignition switch to LOCK (0).
8. Insert a 6.0 mm (0.24 in.) pin (A) through the positioning holes (B) on the shift lever bracket base and into the
positioning hole on the shift lever. Use only the 6.0 mm pin.
9. Check that the shift lever is secured in N.
10. Rotate the socket holder (A) on the shift cable (B) to place the corner (C) on the holder opposite the opening (D) in
the shift lever bracket base (E). Align the holder with the opening in the bracket, then slide the holder into the
bracket. Install the shift cable end (F) over the mounting stud (G) by aligning its square hole with the square fitting
(H) at the bottom of the stud. Rotate the holder a quarter turn until the holder stops to secure the shift cable. Do not
install the shift cable by twisting the shift cable guide (I).
11. Check that the shift cable end is properly installed on the mounting stud.
12. If the cable end is out of position on the mounting stud, remove the shift cable from the bracket, and reinstall the
shift cable. Do not install the shift cable end on the mounting stud while the shift cable in on the bracket. If the
cable end rides on the bottom of the mounting stud, rotate the stud and align the square fitting with the hole.
13. Secure the shift cable end with the nut (A).
14. Remove the 6.0 mm (0.24 in.) pin (B) that was installed to hold the shift lever.
15. Turn the ignition switch to ON (II). Move the shift lever to each position, and check that the A/T gear position
indicator follows the transmission range switch.
16. Shift to P, and check that the shift lock works properly. Push the shift lock release, and check that the shift lever
releases, and also check that the shift lever locks when it is shifted back into P.
17. Reinstall the center console.
A/T Shift Lever Removal
1. Remove the center console.
2. Shift the transmission to N.
3. Remove the nut securing the shift cable end.
4. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the corner (C) on the socket holder will be in the
opening (D) of the shift lever bracket base (E). Then slide the holder to remove the shift cable from the bracket. Do
not remove the shift cable by twisting the shift cable guide (F).
5. Disconnect the shift lock solenoid/park pin switch/A/T gear position indicator panel light connector (A), and remove
the harness clamps (B) from the shift lever bracket base.
6. Remove the mounting bolts, then remove the shift lever assembly.
A/T Shift Lever Installation
1. Install the shift lever assembly (A).
2. Connect the shift lock solenoid/park pin switch/A/T gear position indicator panel light connector (B), and install the
harness clamps (C) on the shift lever bracket base.
3. Turn the ignition switch to ON (II), and check that the N indicator comes on.
4. If necessary, push the shift cable (A) until it stops, then release it. Pull the shift cable back two steps so that the
shift position is in N. Do not hold the shift cable guide (B) to adjust the shift cable.
5. Turn the ignition switch to LOCK (0).
6. Insert a 6.0 mm (0.24 in.) pin (A) through the positioning holes (B) on the shift lever bracket base and into the
positioning hole on the shift lever. Use only the 6.0 mm pin.
7. Check that the shift lever is secured in N.
8. Rotate the socket holder (A) on the shift cable (B) to place the corner (C) on the holder opposite the opening (D) in
the shift lever bracket base (E). Align the holder with the opening in the bracket, then slide the holder into the
bracket. Install the shift cable end (F) over the mounting stud (G) by aligning its square hole with the square fitting
(H) at the bottom of the stud. Rotate the holder a quarter turn until the holder stops to secure the shift cable. Do not
install the shift cable by twisting the shift cable guide (I).
9. Check that the shift cable end is properly installed on the mounting stud.
10. If the cable end is out of position on the mounting stud, remove the shift cable from the bracket, and reinstall the
shift cable. Do not install the shift cable end on the mounting stud while the shift cable in on the bracket. If the
cable end rides on the bottom of the mounting stud, rotate the stud and align the square fitting with the hole.
11. Secure the shift cable end with the nut (A).
12. Remove the 6.0 mm (0.24 in.) pin (B) that was installed to hold the shift lever.
13. Turn the ignition switch to ON (II). Move the shift lever to each position, and check that the A/T gear position
indicator follows the transmission range switch.
14. Shift to P, and check that the shift lock works properly. Push the shift lock release, and check that the shift lever
releases, and also check that the shift lever locks when it is shifted back into P.
15. Reinstall the center console.
A/T Shift Lever Disassembly/Reassembly
Apply silicone grease to movable joints of the shift lock mechanism, shift lever, and lock pin rod. Keep
the connector terminals free of silicone grease.
A/T Differential Component Location Index
THRUST SHIM, 76 mm
Preload Inspection,
SPACER, 76.2mm
CARRIER BEARING
Replacement,
DIFFERENTIAL CARRIER
Backlash Inspection,
Replacement,
CARRIER BEARING
Replacement,
SPACER, 80mm
A/T Differential Backlash Inspection
1. Install the driveshaft and intermediate shaft into the differential assembly, and place the axles on V-blocks (A).
2. Measure the backlash of the pinion gears (B) with a dial indicator (C).
Standard: 0.05−0.15 mm (0.002−0.006 in.)
Driver attachment, 78 x 90 mm
07GAD-SD40101
Driver attachment, 72 x 75 mm
07746-0010600
NOTE:
Replace the bearing with a new one whenever the outer race is replaced.
Do not use shim(s) on the toque converter housing side.
Adjust the preload after replacing the bearing and the outer race.
Coat all parts with ATF during installation.
1. Remove the bearing outer race (A), 76.2 mm spacer (B), and 76 mm thrust shim (C) from the transmission housing
(D) by heating the housing to about 100 °C (212 °F) with a heat gun (E). Do not heat the housing more than 100 °C
(212 °F).
2. Install the 76 mm thrust shim (A), 76.2 mm spacer (B), and outer race (C) in the transmission housing (D).
3. Using the special tools, drive the outer race securely in the housing so there is no clearance between the outer
race, spacer, shim, and housing.
4. Remove the bearing outer race (A) and 80 mm spacer (B) from the torque converter housing (C).
5. Install the spacer and the new outer race in the torque converter housing.
6. Drive the bearing outer race securely in the housing with the special tools.
A/T Differential Carrier Bearing Preload Inspection
Special Tools Required
Driver handle 15 x 135L
07749-0010000
Driver attachment, 72 x 75 mm
07746-0010600
Diff preload inspection attachment
07HAJ-PK40201
NOTE: If the transmission housing, torque converter housing, differential carrier, tapered roller bearing, bearing outer race,
or thrust shim were replaced, the bearing preload must be adjusted.
1. Remove the bearing outer race (A), 76.2 mm spacer (B), and 76 mm thrust shim (C) from the transmission housing
(D) by heating the housing to about 100 °C (212 °F) with a heat gun (E). Do not heat the housing more than 100 °C
(212 °F).
NOTE: Let the transmission housing cool to room temperature before adjusting the bearing preload.
2. Replace the tapered roller bearing when the outer race is to be replaced.
3. Do not use a shim on the torque converter housing side.
4. Install the 76 mm thrust shim (A) in the transmission housing (B). If you replace the 76 mm thrust shim with a new
one, use the same thickness shim as the old one.
5. Install the 76.2 mm spacer (C) and the bearing outer race (D) in the transmission housing.
6. Drive the outer race securely in the housing with the special tools so there is no clearance between the outer race,
spacer, shim, and housing.
7. Install the differential assembly (A) in the torque converter housing (B), and install the gasket (C) and the three
dowel pins (D) on the housing.
8. Install the transmission housing (E), and install the transmission housing mounting bolts. Tighten the 19 bolts to 44
N·m (4.5 kgf·m, 33 lbf·ft) in at least two steps in a crisscross pattern.
9. Rotate the differential assembly in both directions to seat the bearings.
10. Measure the starting torque of the differential assembly with the special tool, a torque wrench (A), and a socket (B).
Measure the staring torque at normal room temperature in both directions.
Standard
New Bearing:
2.7−3.9 N·m (28−40 kgf·cm, 24−35 lbf·in.)
Reused Bearing:
2.5−3.6 N·m (25−37 kgf·cm, 22−32 lbf·in.)
11. If the starting torque is out of the standard, remove the thrust shim and measure its thickness.
12. Select a new thrust shim. To increase the starting torque, increase thickness of the thrust shim. To decrease the
starting torque, decrease the thickness of the thrust shim.
Changing the shim to the next size will increase or decrease the starting torque about 0.5−0.6 N·m (5−6 kgf·m,
5−5 lbf·in.)
THRUST SHIM, 76 mm
No. Part Number Thickness
0A 41428-PRP-000 1.55 mm (0.0610 in.)
0B 41429-PRP-000 1.60 mm (0.0630 in.)
(cont'd)
13. Install the new thrust shim, then recheck the staring torque.
A/T Differential Carrier Bearing Replacement
Special Tools Required
Bearing Separator
07KAF-PS30200
Attachment, 40
07LAD-PW50601
NOTE:
The bearing and outer race should be replaced as a set.
Inspect and adjust the carrier bearing preload whenever the bearing is replaced.
Check the bearing for wear and rough rotation. If the bearing is OK, removal is not necessary.
1. Remove the final driven gear from the differential carrier when replacing the carrier bearing on the final driven gear
side. When only replacing the carrier bearing on opposite side of the final driven gear, final driven gear removal is no
needed.
2. Set a commercially available bearing separator (A) or the special tool (07KAF-PS30200) under the carrier bearing
(B).
3. Place a collar (C) on the differential carrier, and set a commercially available bearing puller (D), then remove the
carrier bearing.
4. Install the new bearing with the special tool and a press. Press the bearing on securely until it bottoms so there is
no clearance between the bearing and the differential carrier.
5. Install the final driven gear if the gear was removed.
A/T Differential Carrier, Final Driven Gear Replacement
1. Remove the final driven gear (A) from the differential carrier (B). The final driven gear bolts have left-hand threads.
2. Install the final driven gear on the differential carrier in the direction shown.
3. Tighten the bolts to 101 N·m (10.3 kgf·m, 74.5 lbf·ft) in a crisscross pattern in at least two steps.
A/T Differential Oil Seal Replacement
Special Tools Required
Driver handle 15 x 135L
07749-0010000
3. Install the new oil seal in the transmission housing in between 0.2 mm-deep and 0.5 mm-high from the housing
surface with the special tools.
4. Install the new oil seal in the torque converter housing in between 0.2 mm-deep and 0.5 mm-high from the housing
surface with the special tools.
A/T Idler Gear Shaft Removal and Installation
1. Remove the snap ring (A), cotter retainer (B), and cotters (C) from the idler gear shaft (D), then remove the idler
gear shaft. Do not distort the snap ring.
2. Check the snap ring and cotter retainer for wear and damage. Replace the snap ring and/or cotter retainer if the
snap ring or cotter retainer is worn, distorted, or damaged.
3. Install the idler gear shaft in the idler gear shaft bearing.
4. Install the cotters and cotter retainer, and secure the idler gear shaft with the snap ring.
A/T End Cover Idler Gear Shaft Bearing Replacement
Special Tools Required
Adjustable bearing remover set
07JAC-PH80000
2. Install the new bearing in the end cover with the special tools.
A/T Interlock System Component Location Index
POWERTRAIN
CONTROL
MODULE (PCM)
Five-position Transmission
BATTE RY TE RMINAL FUS E BOX *1 : W ith trailer lighting connector
UNDE R−DAS H FUS E /RE LAY BOX
*2 : W ithout trailer lighting connector
BATTE RY No. 3 (30 A)* 1
(20 A)* 2 No. 24 (15 A)
MULTI−FUS E
IGNITION S W ITCH No. 22 (7.5 A) BLOCK P GM−FI
MAIN RE LAY 1
No. 7 (10 A)
BAT IG1
BRAKE W HT
P E DAL
1 No. 20 (15 A) P OS ITION
RE D LT BLU S W ITCH
S HIFT LOCK IGNITION S W ITCH No. 22 (7.5 A)
S OLE NOID RHD P OW E RTRAIN
3 A28 S LS CONTROL
BLU P NK P NK MODULE (P CM)
To 12 V
BRAKE
P E DAL
1 LHD P OS ITION
2 RE D 5 LT BLU S W ITCH
GRN GRN
IG1 C10 LT GRN
S HIFT LOCK BLK/RE D RE D
P ARK P IN
S OLE NOID BLK RHD P OW E RTRAIN
S W ITCH 3 A28 S LS CONTROL
1 BLU 4 P NK P NK MODULE (P CM)
GRN GRN V BVS OL
To 12 A1
BRN
LHD
2 5
GRN GRN G502 MRLY A7
IG1 C10 BLU LT GRN
P ARK P IN ACCE LEBLK
RATOR P E DAL BLK/RE D RE D
S W ITCH P OS ITION S E NS OR
1 4 To 5 V IGP A9
GRN GRN V B S OL A1 LT GRN
BRN
1 A26 V CC4
BRN
BK S W A42
G502 3 A18 AP S 1 MRLY A7 LT GRN
ORN BLU
ACCE LE RATOR P E DAL2 A36 S G4
P OS ITION S E NS OR BLU
To 5 V S CSIGP A32A9 DATA LINK
LT GRN
YEL YEL CONNE CTOR
1 A26 V CC4 (DLC)
4 BRN A25 V CC5
GRY ATP RV
BKS S W B23A42
3 A18 AP S 1 YLT
E LGRN
6 ORN A19 AP S 2
LT BLU ATP FW D B29
2 A36 S G4 BLU/Y E L
5 BLU A35 S G5
W HT ATP 2−1 B17
S CS A32 BLU DATA LINK
YEL YEL CONNE CTOR
ATP D3 B16 (DLC)
4 B10A25 P G1
V CC5 RE D
BLK
GRY
ATP D B22
6 A19 AP S 2 P NK LT GRN
LT BLU ATP RV S B23 S TARTE R
ATP N B13 YEL CUT RE LAY
5 B1
A35 P G2
S G5 RE D/BLK
BRN
W HT ATP FW D B29
ATP R B15 BLU/Y E L
ATP S B16
B10 P G1 ATP P B14 RE D
BLK C44 LG1
BRN/Y E L ATP D B22
P NK LT GRN
BLU/BLK W HT S TARTELT
R GRN
ATP N B13 CUT RE LAY
C48 B1 LG2P G2 BLU/BLK RE D/BLK
BRN/YBRN
EL 5 4 9 3 8 2 6 10 7 1 BLK
ATP R B15
ATP P B14
C44 LG1 BLK/BLU RE D/BLK BLU Y E L/RE D BLU/W HT
BRN/Y E L
G101 LT BLU W HT P NK BRN W HT/RE D BLK
MULTIP LE X INTE GRATE D BLU/BLK W HT LT GRN
RE D P −P IN G101
C48 LG2 CONTROL UNIT (MICU) ATP P BLU/BLK 6 7 2 8 3 9 5 1 4 10
BRN/Y E L 5 4 9 3 8 6 10 7 1 BLK
FW D RV S ST E
N D
4 UNDE R−DAS H
P UR FUS E /RE LAY BOX R D3
KE Y G101 No. 14 (7.5 A) LT BLU BLK/BLU RE D/BLK BLU W HT/RE D BLK
MULTIP LE X INTE GRATE D P 2 G101
INTE RLOCK RE D P −P IN
S OLE NOID CONTROL UNIT (MICU) ATP P W HT P NK Y E L/RE D BLU/W HT
3
LT BLU KE Y S OL− 1
6 7 2 8 3 5 1 4 10
4 UNDE R−DAS H
P UR FUS E /RE LAY BOX FW D RV S ST E
1 N D
KE Y No. 14 (7.5 A)
GRY KE Y S W R S
INTE RLOCK
S OLE NOID
IGNITION 3 P
KE Y LT BLU KE Y S OL−
S W ITCH TRANS MIS S ION RANGE S W ITCH
2
BLK BK S W
1
GRY KE Y S W
15 16 18 19 20 21 11 12 13 14 15 16 17 18 19 21 11 12 13 14 15 16 17 18 20 21
G501 P CM Harness Connector Terminal Locations
22 24 25 26 28 22 23 24 26 27 28
29 30 32 34 35 36 37 38 29 31 32 33 34 35 36 38 29 30 31 32
42 44 46 40 45 46 47 48 43 44 46 48
1 3 4 6 7 9 10 1 3 4 7 8 9 10 1 2 3 4 5 6 7 8 9 10
22 24 25 26 28 22 23 24 26 27 28
Terminal side of female terminals
29 30 32 34 35 36 37 38 29 31 32 33 34 35 36 38 29 30 31 32
42 44 46 47 48 40 45 46 47 48 43 44 46 48
12. Check for continuity between park pin switch 2P connector terminal No. 1 and No. 2.
Is there no continuity while the shift lever is in P, and continuity when the shift lever is shifted out of P?
YES - Go to Step 13 .
NO - Replace the park pin switch. ■
13. Disconnect the shift lock solenoid/park pin switch/A/T gear position indicator panel light connector.
14. Check for continuity between shift lock solenoid/park pin switch/A/T gear position indicator panel light connector
terminal No. 4 and body ground.
Is there continuity?
YES - Repair short in the wire between shift lock solenoid/park pin switch/A/T gear position indicator panel light
connector terminal No. 4 and the MICU.■
NO - There is short in the wires between shift lock solenoid/park pin switch/A/T gear position indicator panel
light connector and the 2P connector. Replace the shift lock solenoid; the shift lock solenoid is combined
with the park pin switch harness and the indicator panel light harness/socket, and supplied as an
assembly.■
15. Turn the ignition switch to LOCK (0).
16. Disconnect under-dash fuse/relay box connector B (36P).
17. Turn the ignition switch to ON (II).
18. Measure the voltage between under-dash fuse/relay box connector B (36P) terminal No. 31 and body ground.
Is there voltage?
YES - Substitute a known-good MICU and recheck.■
NO - Repair open or short in the wire between under-dash fuse/relay box connector B (36P) and the
transmission range switch.■
A/T Interlock System - Park Pin Switch Test
1. Connect the HDS to the DLC (A).
2. Check the Park Pin Switch signal with the HDS in the A/T data list while the shift lever is in P, and when the shift
lever is shifted to any position other than P.
NOTE: If the HDS does not communicate with the PCM, troubleshoot the DLC circuit.
3. Check that the park pin switch signal is OFF while the shift lever is in P, and signal is ON when the shift lever is
shifted out of P.
4. If the park pin switch signal is OK, test is complete, disconnect the HDS. If the signal is incorrect, go to Step 5 .
5. Turn the ignition switch to LOCK (0).
6. Remove the center console.
7. Remove the shift lock solenoid/park pin switch/A/T gear position indicator panel light connector from the shift lever
bracket base, then disconnect the connector.
8. Shift into P, and check for continuity between shift lock solenoid/park pin switch/A/T gear position indicator panel
light connector terminals No. 4 and No. 5. Do not press the shift lever button. There should be no continuity.
9. Shift out of P, and check for continuity between connector terminals No. 4 and No. 5. There should be continuity.
10. If the park pin switch tests OK, repair open or short in the wire between the shift lock solenoid/park pin switch/A/T
gear position indicator panel light connector terminal No. 4 and the MICU.
11. If the park pin switch tests incorrectly, test the park pin switch at the park pin switch 2P connector.
12. Disconnect the park pin switch 2P connector, and remove it from the bracket base.
13. Shift into P, and check for continuity between park pin switch 2P connector terminals No. 1 and No. 2. Do not
press the shift lever button. There should be no continuity.
14. Shift out of P, and check for continuity between connector terminals No. 1 and No. 2. There should be continuity.
15. If the park pin switch tests OK at the 2P connector, there is a break or short in the wire between shift lock
solenoid/park pin switch/A/T gear position indicator panel light connector and the 2P connector. Replace the shift
lock solenoid; the shift lock solenoid is combined with the park pin switch harness and the indicator panel light
harness/socket, and supplied as an assembly.
16. If the park pin switch fails the test, replace the park pin switch.
17. Install the center console.
A/T Interlock System - Park Pin Switch Replacement
NOTE: The park pin switch is installed in the shift lever bracket base, and not available separately from the shift lever
bracket base; replace the park pin switch and the shift lever bracket base as an assembly.
1. Remove the shift lever.
2. Disassemble the shift lever.
3. Replace the park pin switch and shift lever bracket base assembly.
4. Assemble the shift lever.
5. Install the shift lever.
A/T Interlock System - Shift Lock Release and Release Spring Replacement
1. Remove the center console.
2. Release the lock tab retaining the A/T gear position indicator panel, and move the indicator panel up.
3. Remove the shift lock release (A) and release spring (B).
4. Apply silicone grease to the pin (C) on the shift lever bracket base, and install the shift lock release and release
spring over the pin. Keep the connector terminals free of silicone grease.
5. Install the indicator panel on the shift lever bracket base.
6. Install the center console.
A/T Interlock System - Shift Lock Solenoid Test
1. Connect the HDS to the DLC (A).
2. Select Shift Lock Solenoid Test in the Miscellaneous Test Menu, and check that the shift lock solenoid operates
with the HDS.
NOTE: If the HDS does not communicate with the PCM, troubleshoot the DLC circuit.
3. Make sure that the shift lever can be moved out of P when Shift Lock Solenoid: ON. Move the shift lever back in P,
and make sure it locks with Shift Lock Solenoid: OFF.
4. Make sure that the shift lock releases when the shift lock release is pushed, and make sure it locks when the shift
lock release is released.
5. If the shift lock solenoid does not work properly, troubleshoot shift lock system.
A/T Interlock System - Shift Lock Solenoid Replacement
1. Remove the center console.
2. Remove the A/T gear position indicator panel light socket (A) from the indicator panel (B), then remove the bulb (C)
from the socket.
3. Remove the shift lock solenoid/park pin switch/A/T gear position indicator panel light connector (D) from the shift
lever bracket base (E), then disconnect the connector.
4. Disconnect the park pin switch 2P connector (F).
5. Release the lock tab (G) retaining the shift lock solenoid using thin blade screwdriver, and remove the shift lock
solenoid (H).
6. Replace the shift lock solenoid, solenoid plunger (I), and plunger spring (J) assembly.
7. Apply silicone grease to the tip of the shift lock stop and solenoid plunger. Keep the connector terminals free of
silicone grease.
8. Install the shift lock solenoid by aligning the joint (K) of the shift lock solenoid plunger with the tip of the shift lock
stop (L), then push the shift lock solenoid into the shift lever bracket base securely.
9. Install the A/T gear position indicator panel light bulb in the panel light socket, then install the socket in the A/T
gear position indicator panel.
10. Route the harness (M) through the harness clamp, and connect the park pin switch 2P connector.
11. Install the shift lock solenoid/park pin switch/A/T gear position indicator panel light connector on the bracket base,
and connect the connector.
12. Test the shift lock solenoid.
13. Install the center console.
A/T Interlock System - Shift Lock Stop/Shift Lock Stop Cushion Replacement
1. Remove the center console.
2. Remove the shift lock solenoid assembly (A).
3. Remove the shift lock stop/stop cushion (B), and replace them as an assembly.
4. Apply silicone grease to the pin (C) on the shift lever bracket base, and install the shift lock stop over the pin. Keep
the connector terminals free of silicone grease.
5. Install the shift lock solenoid assembly.
6. Install the center console.
A/T Interlock System - Shift Lock System Circuit Troubleshooting
1. Connect the HDS to the DLC.
2. Select Shift Lock Solenoid Test in the Miscellaneous Test Menu, and check that the shift lock solenoid operates
with the HDS.
NOTE: If the HDS does not communicate with the PCM, troubleshoot the DLC circuit.
Does the shift lock solenoid work properly?
YES - Go to Step 3 .
NO - Go to Step 6 .
3. Check the Brake Switch signal with the HDS in the A/T data list while pressing the brake pedal, and when the
brake pedal is released.
Does the brake pedal position switch work properly?
YES - Go to Step 4 .
NO - Troubleshoot the brake pedal position switch signal circuit. ■
4. Check the ATP Switch signal with the HDS in the A/T data list. The shift lever must be in P.
Is the ATP Switch ON?
YES - Go to Step 5 .
NO - Go to Step 19 .
5. Check the accelerator pedal position (APP) sensor A with the HDS in the A/T data list. Do not press the
accelerator.
Is the APP sensor A opening 5 % or more, or the APP sensor A voltage 1.16 V or higher?
YES - Check the APP Sensor. ■
NO - Update the PCM if it does not have the latest software, or substitute a known-good PCM, and recheck. If
the symptom goes away with a known-good PCM, replace the original PCM. ■
6. Turn the ignition switch to LOCK (0).
7. Remove the center console.
8. Disconnect the shift lock solenoid/park pin switch/A/T gear position indicator panel light connector.
9. Turn the ignition switch to ON (II).
10. Measure the voltage between shift lock solenoid/park pin switch/A/T gear position indicator panel light connector
terminal No. 1 and body ground.
Is there battery voltage?
YES - Go to Step 11 .
NO - Check for a blown No. 22 (7.5 A) fuse in the under-dash fuse/relay box. If the fuse is OK, repair open or
short in the wire between the shift lock solenoid/park pin switch/A/T gear position indicator panel light
connector and the under-dash fuse/relay box.■
11. Shift to P, and press the brake pedal. Do not press the accelerator.
12. Measure the voltage between shift lock solenoid/park pin switch/A/T gear position indicator panel light connector
terminals No. 1 and No. 3 while pressing the brake pedal.
Is there battery voltage?
YES - Go to Step 13 .
NO - Go to Step 15 .
13. Release the brake pedal, and measure the voltage between shift lock solenoid/park pin switch/A/T gear position
indicator panel light connector terminals No. 1 and No. 3. The shift lever must be in P.
Is there battery voltage?
YES - Repair short in the wire between PCM connector terminal A28 and the shift lock solenoid/park pin
switch/A/T gear position indicator panel light connector.■
NO - Go to Step 14 .
14. Connect a jumper wire from the negative battery terminal to shift lock solenoid/park pin switch/A/T gear position
indicator panel light connector terminal No. 3, and connect another jumper wire from the positive battery terminal to
connector terminal No. 1, then check that the shift lock solenoid operates.
NOTE: Do not connect the positive battery terminal to the connector terminal No. 3 or you will damage the diode
inside the shift lock solenoid.
Does the shift lock solenoid operate properly?
YES - Check the shift lock mechanism. Replace the shift lock stop and stop cushion, if the shift lock stop is
worn or stuck.■
NO - Replace the shift lock solenoid. ■
15. Turn the ignition switch to LOCK (0).
16. Jump the SCS line with the HDS.
17. Disconnect PCM connector A (49P).
18. Check for continuity between PCM connector terminal A28 and shift lock solenoid/park pin switch/A/T gear position
indicator panel light connector terminal No. 3.
Is there continuity?
YES - Update the PCM if it does not have the latest software, or substitute a known-good PCM, and recheck. If
the symptom goes away with a known-good PCM, replace the original PCM. ■
NO - Repair open in the wire between PCM connector terminal A28 and shift lock solenoid connector.■
19. Turn the ignition switch to LOCK (0).
20. Disconnect the transmission range switch connector.
21. Check for continuity between transmission range switch connector terminal No. 10 and body ground.
Is there continuity?
YES - Go to Step 22 .
NO - Repair open in the wire between transmission range switch connector terminal No. 10 and ground (G101),
or repair poor ground (G101).■
22. Turn the ignition switch to ON (II).
23. Measure the voltage between transmission range switch connector terminals No. 6 and No. 10.
Is there battery voltage?
YES - Go to Step 24 .
NO - Repair open in the wire between PCM connector terminal B14 and the transmission range switch.■
24. Check for continuity between transmission range switch connector terminals No. 6 and No. 10.
Is there continuity while the shift lever is in P, and no continuity when the shift lever is shifted to any position other
than P?
YES - Update the PCM if it does not have the latest software, or substitute a known-good PCM, and recheck. If
the symptom goes away with a known-good PCM, replace the original PCM. ■
NO - Replace the transmission range switch. ■
A/T System Description - Lock-up System
Lock-up System
Lock-up System (cont'd)
A/T Stall Speed Test
1. Make sure the transmission fluid is filled to the proper level.
2. Apply the parking brake, and block all four wheels.
3. Connect the HDS to the DLC (A), and go to the A/T data list. If the HDS does not communicate with the PCM,
troubleshoot the DLC circuit.
4. Make sure the A/C switch OFF.
5. After the engine has warmed up to normal operating temperature (the radiator fan comes on), shift to D.
6. Firmly press and hold the brake pedal then, while still holding the brake pedal, press the accelerator pedal for six to
eight seconds, and note maximum engine speed. Do not move the shift lever while raising engine speed.
7. Allow 2 minutes for cooling, repeat the test for the seven-position transmission in 2, and allow 2 minutes, then
repeat test in 1.
8. Allow 2 minutes for cooling, then repeat the test in R.
NOTE:
Do not test stall speed for more than 10 seconds at a time.
Stall speed tests should be used for diagnostic purposes only.
The stall speed should be the same in D, 2, 1, and R.
Do not test stall speed with the A/T pressure gauges installed.
Stall Speed rpm
Specification: 2,200 rpm (min −1 )
Service Limit: 2,050−2,350 rpm (min −1 )
9. If any of the stall speeds are out of the service limit, refer to the problems and probable causes listed in the table.
Seven-position Transmission
Problem Probable Causes
Stall speed rpm high in D, 2, 1, and R ATF pump output low
Clogged ATF strainer
Regulator valve stuck
Slipping clutch
Stall speed rpm high in 2 Slippage of 2nd clutch
Stall speed rpm high in 1 Slippage of 1st clutch
Stall speed rpm high in R Slippage of 5th clutch
Stall speed rpm low in D, 2, 1, and R Engine output low
Engine throttle valve closed
Torque converter one-way clutch slipping
Five-position Transmission
Problem Probable Causes
Stall speed rpm high in D and R ATF pump output low
Clogged ATF strainer
Regulator valve stuck
Slipping clutch
Stall speed rpm high in R Slippage of 5th clutch
Stall speed rpm low in D and R Engine output low
Engine throttle valve closed
Torque converter one-way clutch slipping
A/T Valve Body Repair
NOTE: Valve body repair is only necessary if one or more of the valves in a valve body do not slide smoothly in their bores.
Use this procedure to free the valves.
1. Soak a sheet of #600 abrasive paper in ATF for about 30 minutes.
2. Carefully tap the valve body so the sticking valve drops out of its bore. It may be necessary to use a small
screwdriver to pry the valve free. Be careful not to scratch the bore with the screwdriver.
3. Inspect the valve for any scuff marks. Use the ATF-soaked #600 paper to polish off any burrs that are on the valve,
then wash the valve in solvent and dry it with compressed air.
4. Roll up half of the ATF-soaked #600 paper and insert it in the valve bore of the sticking valve. Twist the paper
slightly, so that it unrolls and fits the bore tightly, then polish the bore by twisting the paper as you push it in and
out.
NOTE: The valve body is aluminum and doesn't require much polishing to remove any burrs.
5. Remove the #600 paper. Thoroughly wash the entire valve body in solvent, then dry it with compressed air.
6. Coat the valve with ATF, then drop it into its bore. It should drop to the bottom of the bore under its own weight. If
not, repeat steps 4 and 5, then retest. If the valve still sticks, replace the valve body.
7. Remove the valve, and thoroughly clean it and the valve body with solvent. Dry all parts with compressed air, then
reassemble using ATF as a lubricant.
ATF Pump Inspection
1. Install the ATF pump drive gear (A), the driven gear (B), and the ATF pump driven gear shaft (C) in the main valve
body (D). Lubricate all parts with ATF, and install the ATF pump driven gear with its grooved and chamfered side
facing up.
2. Measure the side clearance of the ATF pump drive gear (A) and the driven gear (B).
3. Remove the ATF pump driven gear shaft. Measure the thrust clearance between the ATF pump driven gear (A) and
the valve body (B) with a straight edge (C) and a feeler gauge (D).
4. Unhook the detent spring (G) from the detent arm (H), and remove the control shaft (I).
5. Remove the regulator valve body (10 bolts).
6. Remove the stator shaft (J) and stator shaft stop (K), then remove the regulator separator plate (L) and two dowel
pins (M).
7. Remove the servo body (11 bolts), then remove the separator plate (N) and two dowel pins (O).
8. Remove the ATF joint pipes (P) (Q).
9. Remove the cooler check valve spring (R) and cooler check valve (S), then remove the main valve body (T) (three
bolts). Do not let the check balls (U) fall out.
10. Remove the ATF pump driven gear shaft (V), then remove the ATF pump gears (W).
11. Remove the main separator plate (X) and two dowel pins (Y).
12. Remove the ATF magnet (Z), clean and reinstall it in the torque converter housing (AA).
13. Remove the O-ring (BB) from the stator shaft, and remove the O-ring (CC) from the ATF strainer. Install the new
ones when installing the valve bodies.
14. Clean the inlet opening (A) of the ATF strainer (B) thoroughly with compressed air, then check that it is in good
condition and that the inlet opening is not clogged.
15. Test the ATF strainer by pouring clean ATF through the inlet opening, and replace it if it is clogged or damaged.
A/T Valve Body and ATF Strainer Installation
1. Make sure that the ATF magnet is cleaned and installed in the torque converter housing.
Torque Specifications;
6 x 1.0 12 N·m (1.2 kgf·m, 8.7 lbf·ft)
mm:
8 x 1.25 18 N·m (1.8 kgf·m, 13 lbf·ft)
mm:
2. Install the main separator plate and two dowel pins on the torque converter housing.
3. Install the ATF pump drive gear (A), ATF pump driven gear (B), and ATF pump driven gear shaft (C). Install the ATF
pump driven gear with its grooved and chamfered side facing down.
4. Install the main valve body.
5. Make sure the ATF pump drive gear (A) rotates smoothly in the normal operating direction, and the ATF pump
driven gear shaft (B) moves smoothly in the axial and normal operating direction.
6. If the ATF pump drive gear and ATF pump driven gear shaft do not move smoothly, loosen the main valve body
bolts. Realign the ATF pump driven gear shaft, and retighten the bolts to the specified torque, then recheck. Failure
to align the ATF pump driven gear shaft correctly will result in a seized ATF pump drive gear or ATF pump driven
gear shaft.
7. Make sure that the three check balls and the cooler check valve are in the main valve body, then install the cooler
check valve spring in the cooler check valve.
8. Install the ATF joint pipes between the main valve body and the torque converter housing.
9. Install the regulator separator plate and two dowel pins on the main valve body.
10. Install the new O-ring on the stator shaft, and install the stator shaft and stator shaft stop.
11. Install the regulator valve body (10 bolts).
12. Install the servo separator plate and two dowel pins on the main valve body.
13. Install the servo body (11 bolts). Install the ATF strainer with the two bolts in the bolt holes (A) in step 17, and
install the baffle plate with the two bolts in the bolt holes (B) in step 4 in shaft assembly and housing installation.
14. If the detent arm was removed, install the detent arm (A) with arm collar (B) on the servo body (C), and install the
new lock washer (D) by aligning its cutout (E) with the projection (F) of the servo body. Install and tighten the bolt,
then bend the lock tab (G) of the lock washer against the bolt head.
15. Install the control shaft (A) in the torque converter housing while aligning the manual valve lever pin (B) on the
control shaft with the guide of the manual valve (C).
16. Hook the detent arm spring (A) to the detent arm (B).
17. Install the new O-ring on the ATF strainer, and install the ATF strainer (two bolts).
18. Install the 8 x 180.5 mm ATF feed pipe in the regulator valve body.
19. Install the 8 x 192.5 mm ATF feed pipe and 8 x 180.5 mm ATF feed pipe in the servo body.
A/T Main Valve Body Disassembly, Inspection, and Reassembly
1. Clean all parts thoroughly in solvent, and dry them with compressed air. Blow out all passages.
2. Do not use a magnet to remove the check balls, it may magnetize the check balls.
3. Inspect the main valve body for scoring and damage.
4. Check all valves for free movement. If any fail to slide freely, refer to valve body repair.
5. Coat all parts with ATF during assembly.
3. Install the valve and the valve spring (A) in the valve body (B). Push the valve spring in with a screwdriver, then
install the spring seat (C).
How to Troubleshoot the A/T System
How to Check for DTCs with the Honda Diagnostic System (HDS)
When the powertrain control module (PCM) senses an abnormality in the input or output system, the D indicator (A) in the
gauge assembly (B) will usually blink.
When the Honda Diagnostic System (HDS) is connected to the data link connector (DLC) (A) (located under the driver's
dashboard lower cover), it will indicate the diagnostic trouble code (DTC) when the ignition switch is turned to ON (II) and
the appropriate menu is selected.
If the D indicator or malfunction indicator lamp (MIL) has been reported on, or if a driveability problem is suspected, follow
this procedure:
1. Connect the HDS to the DLC. (See the HDS user's manual for specific instructions.)
2. Turn the ignition switch to ON (II), select A/T system, and observe the DTC in the DTCs MENU on the HDS screen.
If the HDS does not communicate with the PCM, go to the DLC circuit troubleshooting.
3. Record the freeze data and the on-board snapshots for all fuel and emissions DTCs and A/T DTCs.
4. If there is a fuel and emissions DTC, first check the fuel and emissions system as indicated by the DTC.
5. Clear the DTC and data.
6. Drive the vehicle for several minutes under the same conditions as those indicated by the freeze data, and then
recheck for a DTC. If the A/T DTC returns, go to the indicated DTC's troubleshooting. If the DTC does not return,
there was an intermittent problem within the circuit. Make sure all pins and terminals in the circuit are tight.
3. Connect one side of the patch cord (A) terminal to a digital multimeter (B), and connect the other side of the patch
cord terminals to a commercially available banana jack (Pomona Electronics Tool No. 3563 or equivalent) (C).
4. Gently slide the pin probe into the inspection port (D) at the connector terminal side. Always use the inspection
port. Do not slide the probe into the connector terminals.
26. Measure the voltage between transmission range switch connector terminals No. 5 and No. 10.
Is there voltage?
YES - Go to Step 27 .
NO - Repair open in the wire between the transmission range switch and PCM connector terminal B29, then go
to Step 37 .
27. Measure the voltage between transmission range switch connector terminals No. 8 and No. 10.
Is there voltage?
YES - Seven-position transmission: Go to Step 28 .
Five-position transmission: Go to Step 30 .
NO - Repair open in the wire between the transmission range switch and PCM connector terminal B22, then go
to Step 37 .
28. Measure the voltage between transmission range switch connector terminals No. 3 and No. 10.
Is there voltage?
YES - Go to Step 29 .
NO - Repair open in the wire between the transmission range switch and PCM connector terminal B16, then go
to Step 37 .
29. Measure the voltage between transmission range switch connector terminals No. 9 and No. 10.
Is there voltage?
YES - Go to Step 31 .
NO - Repair open in the wire between the transmission range switch and PCM connector terminal B17, then go
to Step 37 .
30. Measure the voltage between transmission range switch connector terminals No. 3 and No. 10.
Is there voltage?
YES - Go to Step 31 .
NO - Repair open in the wire between the transmission range switch and PCM connector terminal B16, then go
to Step 37 .
31. Connect the transmission range switch connector.
32. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
33. Raise the front of the vehicle, make sure it is securely supported, and allow the front wheels to rotate freely. Or
raise the vehicle on a lift.
34. Start the engine, and run it in D until the vehicle speed reaches 48 km/h (30 mph). Slow down and stop the wheels.
35. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0706 indicated?
YES - Check for poor connections and loose terminals at the transmission range switch and the PCM. If the
PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to Step
1.
NO - Go to Step 36 .
36. Monitor the OBD status for P0706 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 35 , go to the indicated DTC's troubleshooting.■
NO - Check for poor connections and loose terminals at the transmission range switch and the PCM. If the
PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to Step
1 . If the HDS indicates NOT COMPLETED, return to Step 34 and recheck.
37. Connect the transmission range switch connector.
38. Clear the DTC with the HDS.
39. Raise the front of the vehicle, make sure it is securely supported, and allow the front wheels to rotate freely. Or
raise the vehicle on a lift.
40. Start the engine, and run it in D until the vehicle speed reaches 48 km/h (30 mph). Slow down and stop the wheels.
41. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0706 indicated?
YES - Check for poor connections and loose terminals at the transmission range switch and the PCM, then go
to Step 1 .
NO - Go to Step 42 .
42. Monitor the OBD status for P0706 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete. If any other DTCs were indicated on Step 41 , go to the indicated DTC's
troubleshooting.■
NO - Check for poor connections and loose terminals at the transmission range switch and the PCM, then go
to Step 1 . If the HDS indicates NOT COMPLETED, return to Step 40 and recheck.
DTC Troubleshooting: P0711 (28)
DTC P0711:
ATF Temperature Sensor (Range/Performance)
NOTE:
Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
This code is caused by an electrical circuit problem and cannot be caused by a mechanical problem in the
transmission.
1. Turn the ignition switch to ON (II), and wait for 20 seconds.
2. Check the ATF temperature with the HDS in the A/T data list.
Does the ATF temperature exceed the ambient air temperature?
YES - Record the ATF temperature. Leave the engine off for at least 30 minutes, and go to Step 3 .
NO - Record the ATF temperature. Test the stall speed RPM three times. Go to Step 3 after stall speed
testing.
3. Check the ATF temperature with the HDS.
Does the ATF temperature change?
YES - Leave the engine off for at least 30 minutes, and go to Step 4 .
NO - Replace the ATF temperature sensor, then go to Step 13 .
4. Check the ECT SENSOR with the HDS.
Is the ECT SENSOR equal to the ambient air temperature?
YES - Go to Step 5 .
NO - Leave the engine off until the ECT SENSOR reads the same as ambient air temperature, then go to Step
5.
5. Check the ATF TEMP SENSOR with the HDS.
Does the ATF temperature read about the same as the ECT SENSOR?
YES - Check for poor connections and loose terminals at the ATF temperature sensor and the PCM. If the
connection is OK, go to Step 6 .
NO - Replace the ATF temperature sensor, then go to Step 13 .
6. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
7. Turn the ignition switch to ON (II), and wait for 20 seconds, then start the engine. Warm the engine up to normal
operating temperature (the radiator fan comes on).
8. Turn the engine off, and leave it off until the engine coolant cools to the ambient air temperature (the ECT SENSOR
reads the same as the ambient air temperature).
9. Raise the front of the vehicle, make sure it is securely supported, and allow the front wheels to rotate freely. Or
raise the vehicle on a lift.
10. Turn the ignition switch to ON (II), and wait for 20 seconds, then start the engine. Warm the engine up to normal
operating temperature (the radiator fan comes on). Start off in D, accelerate with the throttle opened at least 4
degrees, and run the vehicle at speeds over 30 km/h (19 mph) for at least 5 minutes. Or test-drive the vehicle in D
for at least 20 seconds while the ATF temperature reads −10 °C to 110 °C (14 °F to 230 °F) by monitoring with the
HDS. Slow down and stop the wheels.
11. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0711 indicated?
YES - If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to
Step 1 .
NO - Go to Step 12 .
12. Monitor the OBD status for P0711 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 11 , go to the indicated DTC's troubleshooting.■
NO - Check for poor connections and loose terminals at the ATF temperature sensor and the PCM. If the PCM
was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to Step 1 . If
the HDS indicates NOT COMPLETED, go to Step 7 and recheck.
6. Measure the voltage between shift solenoid harness connector terminals No. 6 and No. 7.
Is there about 5 V?
YES - Replace the ATF temperature sensor, then go to Step 17 .
NO - Repair open in the wire between PCM connector terminal B34 and the shift solenoid harness connector,
then go to Step 17 .
7. Turn the ignition switch to LOCK (0).
8. Jump the SCS line with the HDS.
9. Disconnect PCM connector B (49P).
10. Check for continuity between PCM connector terminal B28 and shift solenoid harness connector terminal No. 6.
Is there continuity?
YES - Go to Step 11 .
NO - Repair open in the wire between PCM connector terminal B28 and the shift solenoid harness connector,
then go to Step 16 .
11. Reconnect all connectors.
12. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
13. Start the engine in P, and wait for at least 20 seconds.
14. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0713 indicated?
YES - If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to
Step 1 .
NO - Go to Step 15 .
15. Monitor the OBD status for P0713 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 14 , go to the indicated DTC's troubleshooting.■
NO - Check for poor connections and loose terminals at the ATF temperature sensor and the PCM. If the PCM
was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to Step 1 . If
the HDS indicates NOT COMPLETED, return to Step 13 and recheck.
13. Measure the voltage between input shaft (mainshaft) speed sensor connector terminal No. 1 and body ground.
Is there about 5 V?
YES - Go to Step 18 .
NO - Go to Step 14 .
14. Turn the ignition switch to LOCK (0).
15. Jump the SCS line with the HDS.
16. Disconnect PCM connector B (49P).
17. Check for continuity between PCM connector terminal B19 and input shaft (mainshaft) speed sensor connector
terminal No. 1.
Is there continuity?
YES - Go to Step 34 .
NO - Repair open in the wire between PCM connector terminal B19 and the input shaft (mainshaft) speed
sensor, then go to Step 39 .
18. Turn the ignition switch to LOCK (0).
19. Jump the SCS line with the HDS.
20. Disconnect PCM connector B (49P).
21. Check for continuity between input shaft (mainshaft) speed sensor connector terminal No. 2 and body ground.
Is there continuity?
YES - Repair short in the wire between PCM connector terminal B18 and the input shaft (mainshaft) speed
sensor connector, then go to Step 39 .
NO - Go to Step 22 .
22. Check for continuity between PCM connector terminal B34 and input shaft (mainshaft) speed sensor connector
terminal No. 3.
Is there continuity?
YES - Go to Step 23 .
NO - Repair open in the wire between PCM connector terminal B34 and the input shaft (mainshaft) speed
sensor connector, then go to Step 39 .
23. Connect PCM connector B (49P).
24. Turn the ignition switch to ON (II).
25. Measure the voltage between input shaft (mainshaft) speed sensor connector terminals No. 2 and No. 3.
Is there about 5 V?
YES - Go to Step 26 .
NO - Go to Step 30 .
26. Connect the input shaft (mainshaft) speed sensor connector.
27. Clear the DTC with the HDS.
28. Start the engine, and run the vehicle in D at speeds over 20 km/h (12 mph) for at least 10 seconds. Slow down and
stop the wheels.
29. Monitor the OBD status for P0716 or P0717 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Replace the input shaft (mainshaft) speed sensor, then go to Step 40 .
NO - Go to Step 35 .
30. Turn the ignition switch to LOCK (0).
31. Jump the SCS line with the HDS.
32. Disconnect PCM connector B (49P).
33. Check for continuity between PCM connector terminal B18 and input shaft (mainshaft) speed sensor connector
terminal No. 2.
Is there continuity?
YES - Go to Step 34 .
NO - Repair open in the wire between PCM connector terminal B18 and the input shaft (mainshaft) speed
sensor, then go to Step 39 .
34. Reconnect all connectors.
35. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
36. Start the engine, and run the vehicle in D at speeds over 20 km/h (12 mph) for at least 10 seconds. Slow down and
stop the wheels.
37. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0716 or P0717 indicated?
YES - If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to
Step 1 .
NO - Go to Step 38 .
38. Monitor the OBD status for P0716 or P0717 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 37 , go to the indicated DTC's troubleshooting.■
NO - Check for poor connections and loose terminals at the input shaft (mainshaft) speed sensor and the
PCM. If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted,
go to Step 1 . If the HDS indicates NOT COMPLETED, return to Step 36 and recheck.
39. Reconnect all connectors.
40. Clear the DTC with the HDS.
41. Start the engine, and run the vehicle in D at speeds over 20 km/h (12 mph) for at least 10 seconds. Slow down and
stop the wheels.
42. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0716 or P0717 indicated?
YES - Check for poor connections and loose terminals at the input shaft (mainshaft) speed sensor and the
PCM, then go to Step 1 .
NO - Go to Step 43 .
43. Monitor the OBD status for P0716 or P0717 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete. If any other DTCs were indicated on Step 42 , go to the indicated DTC's
troubleshooting.■
NO - Check for poor connections and loose terminals at the input shaft (mainshaft) speed sensor and the
PCM, then go to Step 1 . If the HDS indicates NOT COMPLETED, go to Step 41 and recheck.
DTC Troubleshooting: P0718 (15)
DTC P0718:
Input Shaft (Mainshaft) Speed Sensor (Intermittent Failure)
NOTE:
Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
This code is caused by an electrical circuit problem and cannot be caused by a mechanical problem in the
transmission.
1. Clear the DTC with the HDS.
2. Test-drive the vehicle with the shift lever in D, and let the transmission shift through all five gears at speeds over 20
km/h (12 mph). Slow down and stop the wheels.
3. Monitor the OBD status for P0718 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
input shaft (mainshaft) speed sensor and the PCM. If the HDS indicates NOT COMPLETED, return to
Step 2 and recheck.
4. Turn the ignition switch to LOCK (0).
5. Disconnect the input shaft (mainshaft) speed sensor connector, and inspect the connector and connector terminals
to be sure they are making good contact.
Are the connector terminals OK?
YES - Go to Step 6 .
NO - Repair the connector terminals, then go to Step 6 .
6. Connect the input shaft (mainshaft) speed sensor connector.
7. Test-drive the vehicle with the shift lever in D, and let the transmission shift through all five gears at speeds over 20
km/h (12 mph). Slow down and stop the wheels.
8. Monitor the OBD status for P0718 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 9 .
NO - Troubleshooting is complete. If the HDS indicates NOT COMPLETED, return to Step 7 and recheck.■
9. Turn the ignition switch to LOCK (0).
10. Jump the SCS line with the HDS.
11. Disconnect PCM connector C (49P).
12. Check for continuity between PCM connector terminals C44 and body ground, and between C48 and body ground.
Is there continuity?
YES - Go to Step 13 .
NO - Repair open in the wires between PCM connector terminals C44, C48 and ground (G101), or repair poor
ground (G101), then go to Step 37 .
13. Connect PCM connector C (49P).
14. Disconnect the input shaft (mainshaft) speed sensor connector.
15. Turn the ignition switch to ON (II).
16. Measure the voltage between input shaft (mainshaft) speed sensor connector terminal No. 1 and body ground.
Is there about 5 V?
YES - Go to Step 17 .
NO - Go to Step 28 .
17. Turn the ignition switch to LOCK (0).
18. Jump the SCS line with the HDS.
19. Disconnect PCM connector B (49P).
20. Check for continuity between input shaft (mainshaft) speed sensor connector terminal No. 2 and body ground.
Is there continuity?
YES - Repair short in the wire between PCM connector terminal B18 and the input shaft (mainshaft) speed
sensor connector, then go to Step 37 .
NO - Go to Step 21 .
21. Connect PCM connector B (49P).
22. Turn the ignition switch to ON (II).
23. Measure the voltage between input shaft (mainshaft) speed sensor connector terminal No. 2 and body ground.
Is there about 5 V?
YES - Replace the input shaft (mainshaft) speed sensor, then go to Step 37 .
NO - Go to Step 24 .
24. Turn the ignition switch to LOCK (0).
25. Jump the SCS line with the HDS.
26. Disconnect PCM connector B (49P).
27. Check for continuity between PCM connector terminal B18 and input shaft (mainshaft) speed sensor connector
terminal No. 2.
Is there continuity?
YES - Go to Step 32 .
NO - Repair open in the wire between PCM connector terminal B18 and the input shaft (mainshaft) speed
sensor, then go to Step 37 .
28. Turn the ignition switch to LOCK (0).
29. Jump the SCS line with the HDS.
30. Disconnect PCM connector B (49P).
31. Check for continuity between PCM connector terminal B19 and input shaft (mainshaft) speed sensor connector
terminal No. 1.
Is there continuity?
YES - Go to Step 32 .
NO - Repair open in the wire between PCM connector terminal B19 and the input shaft (mainshaft) speed
sensor, then go to Step 37 .
32. Reconnect all connectors.
33. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
34. Test-drive the vehicle with the shift lever in D, and let the transmission shift through all five gears at speeds over 20
km/h (12 mph). Slow down and stop the wheels.
35. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0718 indicated?
YES - If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to
Step 1 .
NO - Go to Step 36 .
36. Monitor the OBD status for P0718 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 35 , go to the indicated DTC's troubleshooting.■
NO - Check for poor connections and loose terminals at the input shaft (mainshaft) speed sensor and the
PCM. If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted,
go to Step 1 . If the HDS indicates NOT COMPLETED, return to Step 34 and recheck.
37. Reconnect all connectors.
38. Clear the DTC with the HDS.
39. Test-drive the vehicle with the shift lever in D, and let the transmission shift through all five gears at speeds over 20
km/h (12 mph). Slow down and stop the wheels.
40. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0718 indicated?
YES - Check for poor connections and loose terminals at the input shaft (mainshaft) speed sensor and the
PCM, then go to Step 1 .
NO - Go to Step 41 .
41. Monitor the OBD status for P0718 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete. If any other DTCs were indicated on Step 40 , go to the indicated DTC's
troubleshooting.■
NO - Check for poor connections and loose terminals at the input shaft (mainshaft) speed sensor and the
PCM, then go to Step 1 . If the HDS indicates NOT COMPLETED, return to Step 39 and recheck.
DTC Troubleshooting: P0721 (9), P0722 (9)
DTC P0721:
Output Shaft (Countershaft) Speed Sensor (Range/Performance)
DTC P0722:
Output Shaft (Countershaft) Speed Sensor (No Signal Input)
NOTE:
Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
This code is caused by an electrical circuit problem and cannot be caused by a mechanical problem in the
transmission.
1. Clear the DTC with the HDS.
2. Check for proper output shaft (countershaft) speed sensor installation. If the sensor is installed improperly, correct
the problem, then go to Step 42 .
3. Raise the front of the vehicle, make sure it is securely supported, and allow the front wheels to rotate freely. Or
raise the vehicle on a lift.
4. Start the engine, and run the vehicle in D with the engine speed at 2,000 rpm (min −1 ) or higher, for at least 10
seconds. Slow down and stop the wheels.
5. Monitor the OBD status for P0721 or P0722 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections at the PCM and
output shaft (countershaft) speed sensor connectors. If the HDS indicates NOT COMPLETED, return to
Step 4 and recheck.
6. Turn the ignition switch to LOCK (0).
7. Jump the SCS line with the HDS.
8. Disconnect PCM connector C (49P).
9. Check for continuity between PCM connector terminals C44 and body ground, and between C48 and body ground.
Is there continuity?
YES - Go to Step 10 .
NO - Repair open in the wires between PCM connector terminals C44, C48 and ground (G101), or repair poor
ground (G101), then go to Step 41 .
10. Connect PCM connector C (49P).
11. Disconnect the output shaft (countershaft) speed sensor connector.
12. Turn the ignition switch to ON (II).
13. Measure the voltage between output shaft (countershaft) speed sensor connector terminal No. 1 and body ground.
Is there about 5 V?
YES - Go to Step 18 .
NO - Go to Step 14 .
14. Turn the ignition switch to LOCK (0).
15. Jump the SCS line with the HDS.
16. Disconnect PCM connector C (49P).
17. Check for continuity between PCM connector terminal C13 and output shaft (countershaft) speed sensor connector
terminal No. 1.
Is there continuity?
YES - Go to Step 36 .
NO - Repair open in the wire between PCM connector terminal C13 and the output shaft (countershaft) speed
sensor, then go to Step 41 .
18. Turn the ignition switch to LOCK (0).
19. Jump the SCS line with the HDS.
20. Disconnect PCM connector B (49P).
21. Check for continuity between output shaft (countershaft) speed sensor connector terminal No. 2 and body ground.
Is there continuity?
YES - Repair short in the wire between PCM connector terminal B38 and output shaft (countershaft) speed
sensor connector, then go to Step 41 .
NO - Go to Step 22 .
22. Disconnect PCM connector C (49P).
23. Check for continuity between PCM connector terminal C14 and output shaft (countershaft) speed sensor connector
terminal No. 3.
Is there continuity?
YES - Go to Step 24 .
NO - Repair open in the wire between PCM connector terminal C14 and output shaft (countershaft) speed
sensor connector, then go to Step 41 .
24. Connect PCM connectors B (49P) and C (49P).
25. Turn the ignition switch to ON (II).
26. Measure the voltage between output shaft (countershaft) speed sensor connector terminals No. 2 and No. 3.
Is there about 5 V?
YES - Go to Step 27 .
NO - Go to Step 32 .
27. Connect the output shaft (countershaft) speed sensor connector.
28. Clear the DTC with the HDS.
29. Raise the front of the vehicle, make sure it is securely supported, and allow the front wheels to rotate freely. Or
raise the vehicle on a lift.
30. Start the engine, and run the vehicle in D with the engine speed at 2,000 rpm (min −1 ) or higher, for at least 10
seconds. Slow down and stop the wheels.
31. Monitor the OBD status for P0721 or P0722 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Replace the output shaft (countershaft) speed sensor , then go to Step 42 .
NO - Go to Step 37 .
32. Turn the ignition switch to LOCK (0).
33. Jump the SCS line with the HDS.
34. Disconnect PCM connector B (49P).
35. Check for continuity between PCM connector terminal B38 and output shaft (countershaft) speed sensor connector
terminal No. 2.
Is there continuity?
YES - Go to Step 36 .
NO - Repair open in the wire between PCM connector terminal B38 and the output shaft (countershaft) speed
sensor, then go to Step 41 .
36. Reconnect all connectors.
37. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
38. Start the engine, and run the vehicle in D at speeds over 20 km/h (12 mph) for at least 10 seconds. Slow down and
stop the wheels.
39. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0721 or P0722 indicated?
YES - If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to
Step 1 .
NO - Go to Step 40 .
40. Monitor the OBD status for P0721 or P0722 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 39 , go to the indicated DTC's troubleshooting.■
NO - Check for poor connections and loose terminals at the output shaft (countershaft) speed sensor and the
PCM. If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted,
go to Step 1 . If the HDS indicates NOT COMPLETED, return to Step 38 and recheck.
41. Reconnect all connectors.
42. Clear the DTC with the HDS.
43. Start the engine, and run the vehicle in D at speeds over 20 km/h (12 mph) for at least 10 seconds. Slow down and
stop the wheels.
44. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0721 or P0722 indicated?
YES - Check for poor connections and loose terminals at the output shaft (countershaft) speed sensor and the
PCM, then go to Step 1 .
NO - Go to Step 45 .
45. Monitor the OBD status for P0721 or P0722 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete. If any other DTCs were indicated on Step 44 , go to the indicated DTC's
troubleshooting.■
NO - Check for poor connections and loose terminals at the output shaft (countershaft) speed sensor and the
PCM, then go to Step 1 . If the HDS indicates NOT COMPLETED, go to Step 43 and recheck.
DTC Troubleshooting: P0723 (9)
DTC P0723:
Output Shaft (Countershaft) Speed Sensor (Intermittent Failure)
NOTE:
Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
This code is caused by an electrical circuit problem and cannot be caused by a mechanical problem in the
transmission.
1. Clear the DTC with the HDS.
2. Test-drive the vehicle with the shift lever in D, and let the transmission shift through all five gears with the engine
speed at 2,000 rpm (min −1 ) or higher, for several minutes. Slow down and stop the wheels.
3. Monitor the OBD status for P0723 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections and loose terminals at the
output shaft (countershaft) speed sensor and the PCM. If the HDS indicates NOT COMPLETED, return to
Step 2 and recheck.
4. Turn the ignition switch to LOCK (0).
5. Disconnect the output shaft (countershaft) speed sensor connector, and inspect the connector and connector
terminals to be sure they are making good contact.
Are the connector terminals OK?
YES - Go to Step 6 .
NO - Repair the connector terminals, then go to Step 6 .
6. Connect the output shaft (countershaft) speed sensor connector.
7. Test-drive the vehicle with the shift lever in D, and let the transmission shift through all five gears with the engine
speed at 2,000 rpm (min −1 ) or higher, for several minutes. Slow down and stop the wheels.
8. Monitor the OBD status for P0723 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 9 .
NO - Troubleshooting is complete. If the HDS indicates NOT COMPLETED, return to Step 7 and recheck.■
9. Turn the ignition switch to LOCK (0).
10. Jump the SCS line with the HDS.
11. Disconnect PCM connector C (49P).
12. Check for continuity between PCM connector terminals C44 and body ground, and between C48 and body ground.
Is there continuity?
YES - Go to Step 13 .
NO - Repair open in the wires between PCM connector terminals C44, C48 and ground (G101), or repair poor
ground (G101), then go to Step 37 .
13. Connect PCM connector C (49P).
14. Disconnect the output shaft (countershaft) speed sensor connector.
15. Turn the ignition switch to ON (II).
16. Measure the voltage between output shaft (countershaft) speed sensor connector terminal No. 1 and body ground.
Is there about 5 V?
YES - Go to Step 17 .
NO - Go to Step 28 .
17. Turn the ignition switch to LOCK (0).
18. Jump the SCS line with the HDS.
19. Disconnect PCM connector B (49P).
20. Check for continuity between output shaft (countershaft) speed sensor connector terminal No. 2 and body ground.
Is there continuity?
YES - Repair short in the wire between PCM connector terminal B38 and the output shaft (countershaft) speed
sensor connector, then go to Step 37 .
NO - Go to Step 21 .
21. Connect PCM connector B (49P).
22. Turn the ignition switch to ON (II).
23. Measure the voltage between output shaft (countershaft) speed sensor connector terminal No. 2 and body ground.
Is there about 5 V?
YES - Replace the output shaft (countershaft) speed sensor, then go to Step 37 .
NO - Go to Step 24 .
24. Turn the ignition switch to LOCK (0).
25. Jump the SCS line with the HDS.
26. Disconnect PCM connector B (49P).
27. Check for continuity between PCM connector terminal B38 and output shaft (countershaft) speed sensor connector
terminal No. 2.
Is there continuity?
YES - Go to Step 32 .
NO - Repair open in the wire between PCM connector terminal B38 and the output shaft (countershaft) speed
sensor, then go to Step 37 .
28. Turn the ignition switch to LOCK (0).
29. Jump the SCS line with the HDS.
30. Disconnect PCM connector C (49P).
31. Check for continuity between PCM connector terminal C13 and output shaft (countershaft) speed sensor connector
terminal No. 1.
Is there continuity?
YES - Go to Step 32 .
NO - Repair open in the wire between PCM connector terminal C13 and the output shaft (countershaft) speed
sensor, then go to Step 37 .
32. Reconnect all connectors.
33. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
34. Test-drive the vehicle with the shift lever in D, and let the transmission shift through all five gears at speeds over 20
km/h (12 mph). Slow down and stop the wheels.
35. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0723 indicated?
YES - If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to
Step 1 .
NO - Go to Step 36 .
36. Monitor the OBD status for P0723 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 35 , go to the indicated DTC's troubleshooting.■
NO - Check for poor connections and loose terminals at the output shaft (countershaft) speed sensor and the
PCM. If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted,
go to Step 1 . If the HDS indicates NOT COMPLETED, return to Step 34 .
37. Reconnect all connectors.
38. Clear the DTC with the HDS.
39. Test-drive the vehicle with the shift lever in D, and let the transmission shift through all five gears at speeds over 20
km/h (12 mph). Slow down and stop the wheels.
40. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0723 indicated?
YES - Check for poor connections and loose terminals at the output shaft (countershaft) speed sensor and the
PCM, then go to Step 1 .
NO - Go to Step 41 .
41. Monitor the OBD status for P0723 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete. If any other DTCs were indicated on Step 40 , go to the indicated DTC's
troubleshooting.■
NO - Check for poor connections and loose terminals at the output shaft (countershaft) speed sensor and the
PCM, then go to Step 1 . If the HDS indicates NOT COMPLETED, return to Step 39 and recheck.
DTC Troubleshooting: P0746 (76)
DTC P0776:
A/T Clutch Pressure Control Solenoid Valve A Stuck OFF
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
1. Warm up the engine to normal operating temperature (the radiator fan comes on).
2. Make sure that the transmission is filled to the proper level, and check for fluid leaks.
3. Drain the ATF through a strainer. Inspect the strainer for metal debris or excessive clutch material.
Does the strainer have metal debris or excessive clutch material?
YES - Replace the transmission, then go to Step 10 .
NO - Replace the ATF, then go to Step 4 .
4. Clear the DTC with the HDS.
5. Test-drive the vehicle with the shift lever in D, and let the transmission shift through all five gears. Then slow down
to a stop. Shift to N, wait for at least 3 seconds, then shift into R. Move the vehicle in reverse for at least 3
seconds, then slow down and stop the wheels.
6. Monitor the OBD status for P0746 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. If the HDS indicates NOT COMPLETED, return to Step
5 and recheck.■
7. Clear the DTC with the HDS.
8. Select Clutch Pressure Control (Linear) Solenoid Valve A in the Miscellaneous Test Menu, and test A/T clutch
pressure control solenoid valve A with the HDS.
Does the HDS indicate NORMAL?
YES - Intermittent failure, the system is OK at this time.■
NO - Follow the instructions indicated on the HDS by the test result, but if the HDS has not determined the
cause of the failure, go to Step 9 . If any part is replaced, go to Step 10 .
9. Inspect A/T clutch pressure control solenoid valve A.
Does A/T clutch pressure control solenoid valve A work properly?
YES - Repair the hydraulic system related with shift valve A, or replace the transmission, then go to Step 10 .
NO - Replace A/T clutch pressure control solenoid valve A, then go to Step 10 .
10. Clear the DTC with the HDS.
11. Test-drive the vehicle with the shift lever in D, and let the transmission shift through all five gears. Then slow down
to a stop. Shift to N, wait for at least 3 seconds, then shift into R. Move the vehicle in reverse for at least 3
seconds, then slow down and stop the wheels.
12. Monitor the OBD status for P0746 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete.■
NO - Return to Step 10 and recheck. If the HDS indicates NOT COMPLETED, return to Step 11 and recheck.
DTC Troubleshooting: P0747 (76)
DTC P0747:
A/T Clutch Pressure Control Solenoid Valve A Stuck ON
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
1. Warm up the engine to normal operating temperature (the radiator fan comes on).
2. Make sure that the transmission is filled to the proper level, and check for fluid leaks.
3. Drain the ATF through a strainer. Inspect the strainer for metal debris or excessive clutch material.
Does the strainer have metal debris or excessive clutch material?
YES - Replace the transmission, then go to Step 10 .
NO - Replace the ATF, then go to Step 4 .
4. Clear the DTC with the HDS.
5. Test-drive the vehicle with the shift lever in D for at least 12 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
6. Monitor the OBD status for P0747 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. If the HDS indicates NOT COMPLETED, return to Step
5 and recheck.
7. Clear the DTC with the HDS.
8. Select Clutch Pressure Control (Linear) Solenoid Valve A in the Miscellaneous Test Menu, and test A/T clutch
pressure control solenoid valve A with the HDS.
Does the HDS indicate NORMAL?
YES - Intermittent failure, the system is OK at this time.■
NO - Follow the instructions indicated on the HDS by the test result, but if the HDS has not determined the
cause of the failure, go to Step 9 . If any part is replaced, go to Step 10 .
9. Inspect A/T clutch pressure control solenoid valve A.
Does A/T clutch pressure control solenoid valve A work properly?
YES - Repair the hydraulic system related with shift valve A, or replace the transmission, then go to Step 10 .
NO - Replace A/T clutch pressure control solenoid valve A, then go to Step 10 .
10. Clear the DTC with the HDS.
11. Test-drive the vehicle with the shift lever in D for at least 12 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
12. Monitor the OBD status for P0747 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete.■
NO - Return to Step 10 and recheck. If the HDS indicates NOT COMPLETED, return to Step 11 and recheck.
DTC Troubleshooting: P0751 (70), P0752 (70)
DTC P0751:
Shift Solenoid Valve A Stuck OFF
DTC P0752:
Shift Solenoid Valve A Stuck ON
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
1. Warm up the engine to normal operating temperature (the radiator fan comes on).
2. Make sure that the transmission is filled to the proper level, and check for fluid leaks.
3. Drain the ATF through a strainer. Inspect the strainer for metal debris or excessive clutch material.
Does the strainer have metal debris or excessive clutch material?
YES - Replace the transmission, then go to Step 11 .
NO - Replace the ATF, then go to Step 4 .
4. Clear the DTC with the HDS.
5. Test-drive the vehicle with the shift lever in D for at least 12 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
6. Monitor the OBD status for P0751 or P0752 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. If the HDS indicates NOT COMPLETED, return to Step
5 and recheck.■
7. Clear the DTC with the HDS.
8. Select Shift Solenoid A in the Miscellaneous Test Menu, and check that shift solenoid valve A operates with the
HDS.
Is a clicking sound heard?
YES - Go to Step 9 .
NO - Replace shift solenoid valve A, then go to Step 11 .
9. Test-drive the vehicle with the shift lever in D for at least 12 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
10. Monitor the OBD status for P0751 or P0752 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Repair the hydraulic system related with shift valve A, or replace the transmission, then go to Step 11 .
NO - Intermittent failure, the system is OK at this time. If the HDS indicates NOT COMPLETED, return to Step
9 and recheck.■
11. Clear the DTC with the HDS.
12. Test-drive the vehicle with the shift lever in D for at least 12 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
13. Monitor the OBD status for P0751 or P0752 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete.■
NO - Return to Step 11 and recheck. If the HDS indicates NOT COMPLETED, return to Step 12 and recheck.
DTC Troubleshooting: P0756 (71), P0757 (71)
DTC P0756:
Shift Solenoid Valve B Stuck OFF
DTC P0757:
Shift Solenoid Valve B Stuck ON
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
1. Warm up the engine to normal operating temperature (the radiator fan comes on).
2. Make sure that the transmission is filled to the proper level, and check for fluid leaks.
3. Drain the ATF through a strainer. Inspect the strainer for metal debris or excessive clutch material.
Does the strainer have metal debris or excessive clutch material?
YES - Replace the transmission, then go to Step 11 .
NO - Replace the ATF, then go to Step 4 .
4. Clear the DTC with the HDS.
5. Test-drive the vehicle with the shift lever in D for at least 12 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
6. Monitor the OBD status for P0756 or P0757 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. If the HDS indicates NOT COMPLETED, return to Step
5 and recheck.■
7. Clear the DTC with the HDS.
8. Select Shift Solenoid B in the Miscellaneous Test Menu, and check that shift solenoid valve B operates with the
HDS.
Is a clicking sound heard?
YES - Go to Step 9 .
NO - Replace shift solenoid valve B, then go to Step 11 .
9. Test-drive the vehicle with the shift lever in D for at least 12 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
10. Monitor the OBD status for P0756 or P0757 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Repair the hydraulic system related with shift valve B, or replace the transmission, then go to Step 11 .
NO - Intermittent failure, the system is OK at this time. If the HDS indicates NOT COMPLETED, return to Step
9 and recheck.■
11. Clear the DTC with the HDS.
12. Test-drive the vehicle with the shift lever in D for at least 12 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
13. Monitor the OBD status for P0756 or P0757 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete.■
NO - Return to Step 11 and recheck. If the HDS indicates NOT COMPLETED, return to Step 12 and recheck.
DTC Troubleshooting: P0761 (72), P0762 (72)
DTC P0761:
Shift Solenoid Valve C Stuck OFF
DTC P0762:
Shift Solenoid Valve C Stuck ON
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
1. Warm up the engine to normal operating temperature (the radiator fan comes on).
2. Make sure that the transmission is filled to the proper level, and check for fluid leaks.
3. Drain the ATF through a strainer. Inspect the strainer for metal debris or excessive clutch material.
Does the strainer have metal debris or excessive clutch material?
YES - Replace the transmission, then go to Step 11 .
NO - Replace the ATF, then go to Step 4 .
4. Clear the DTC with the HDS.
5. Test-drive the vehicle with the shift lever in D for at least 12 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
6. Monitor the OBD status for P0761 or P0762 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. If the HDS indicates NOT COMPLETED, return to Step
5 and recheck.■
7. Clear the DTC with the HDS.
8. Select Shift Solenoid C in the Miscellaneous Test Menu, and check that shift solenoid valve C operates with the
HDS.
Is a clicking sound heard?
YES - Go to Step 9 .
NO - Replace shift solenoid valve C, then go to Step 11 .
9. Test-drive the vehicle with the shift lever in D for at least 12 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
10. Monitor the OBD status for P0761 or P0762 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail
Does the HDS indicate FAILED?
YES - Repair the hydraulic system related with shift valve C, or replace the transmission, then go to Step 11 .
NO - Intermittent failure, the system is OK at this time. If the HDS indicates NOT COMPLETED, return to Step
9 and recheck.■
11. Clear the DTC with the HDS.
12. Test-drive the vehicle with the shift lever in D for at least 12 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
13. Monitor the OBD status for P0761 or P0762 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete.■
NO - Return to Step 11 and recheck. If the HDS indicates NOT COMPLETED, return to Step 12 and recheck.
DTC Troubleshooting: P0766 (73)
DTC P0766:
Shift Solenoid Valve D Stuck OFF
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
1. Warm up the engine to normal operating temperature (the radiator fan comes on).
2. Make sure that the transmission is filled to the proper level, and check for fluid leaks.
3. Drain the ATF through a strainer. Inspect the strainer for metal debris or excessive clutch material.
Does the strainer have metal debris or excessive clutch material?
YES - Replace the transmission, then go to Step 11 .
NO - Replace the ATF, then go to Step 4 .
4. Clear the DTC with the HDS.
5. Start the engine, shift to N, then into R. Move the vehicle in reverse for at least 2 seconds, and stop the wheels.
Shift to D, and test-drive the vehicle for at least 2 seconds, and let the transmission shift through all five gears, then
slow down to a stop.
6. Monitor the OBD status for P0766 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. If the HDS indicates NOT COMPLETED, return to Step
5 and recheck.■
7. Clear the DTC with the HDS.
8. Select Shift Solenoid D in the Miscellaneous Test Menu, and check that shift solenoid valve D operates with the
HDS.
Is a clicking sound heard?
YES - Go to Step 9 .
NO - Replace shift solenoid valve D, then go to Step 11 .
9. Start the engine, shift to N, then into R. Move the vehicle in reverse for at least 2 seconds, and stop the wheels.
Shift to D, and test-drive the vehicle for at least 2 seconds, and let the transmission shift through all five gears, then
slow down to a stop.
10. Monitor the OBD status for P0766 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Repair the hydraulic system related with shift valve D, or replace the transmission, then go to Step 11 .
NO - Intermittent failure, the system is OK at this time. If the HDS indicates NOT COMPLETED, return to Step
9 and recheck.■
11. Clear the DTC with the HDS.
12. Start the engine, shift to N, then into R. Move the vehicle in reverse for at least 2 seconds, and stop the wheels.
Shift to D, and test-drive the vehicle for at least 2 seconds, and let the transmission shift through all five gears, then
slow down to a stop.
13. Monitor the OBD status for P0766 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete.■
NO - Return to Step 11 and recheck. If the HDS indicates NOT COMPLETED, return to Step 12 and recheck.
DTC Troubleshooting: P0767 (73)
DTC P0767:
Shift Solenoid Valve D Stuck ON
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
1. Warm up the engine to normal operating temperature (the radiator fan comes on).
2. Make sure that the transmission is filled to the proper level, and check for fluid leaks.
3. Drain the ATF through a strainer. Inspect the strainer for metal debris or excessive clutch material.
Does the strainer have metal debris or excessive clutch material?
YES - Replace the transmission, then go to Step 11 .
NO - Replace the ATF, then go to Step 4 .
4. Clear the DTC with the HDS.
5. Test-drive the vehicle with the shift lever in D for at least 2 seconds, and let the transmission shift through all five
gears. Then slow down to a stop. With the brake pedal pressed, shift into to R, and wait for at least 3 seconds.
6. Monitor the OBD status for P0767 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. If the HDS indicates NOT COMPLETED, return to Step
5 and recheck.■
7. Clear the DTC with the HDS.
8. Select Shift Solenoid D in the Miscellaneous Test Menu, and check that shift solenoid valve D operates with the
HDS.
Is a clicking sound heard?
YES - Go to Step 9 .
NO - Replace shift solenoid valve D, then go to Step 11 .
9. Test-drive the vehicle with the shift lever in D for at least 2 seconds, and let the transmission shift through all five
gears. Then slow down to a stop. With the brake pedal pressed, shift into to R, and wait for at least 3 seconds.
10. Monitor the OBD status for P0767 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Repair the hydraulic system related with shift valve D, or replace the transmission, then go to Step 11 .
NO - Intermittent failure, the system is OK at this time. If the HDS indicates NOT COMPLETED, return to Step
9 and recheck.■
11. Clear the DTC with the HDS.
12. Test-drive the vehicle with the shift lever in D for at least 2 seconds, and let the transmission shift through all five
gears. Then slow down to a stop. With the brake pedal pressed, shift into to R, and wait for at least 3 seconds.
13. Monitor the OBD status for P0767 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete.■
NO - Return to Step 11 and recheck. If the HDS indicates NOT COMPLETED, return to Step 12 and recheck.
DTC Troubleshooting: P0776 (77), P0777 (77)
DTC P0776:
A/T Clutch Pressure Control Solenoid Valve B Stuck OFF
DTC P0777:
A/T Clutch Pressure Control Solenoid Valve B Stuck ON
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
1. Warm up the engine to normal operating temperature (the radiator fan comes on).
2. Make sure that the transmission is filled to the proper level, and check for fluid leaks.
3. Drain the ATF through a strainer. Inspect the strainer for metal debris or excessive clutch material.
Does the strainer have metal debris or excessive clutch material?
YES - Replace the transmission, then go to Step 10 .
NO - Replace the ATF, then go to Step 4 .
4. Clear the DTC with the HDS.
5. Test-drive the vehicle with the shift lever in D for at least 3 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
6. Monitor the OBD status for P0776 or P0777 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. If the HDS indicates NOT COMPLETED, return to Step
5 and recheck.
7. Clear the DTC with the HDS.
8. Select Clutch Pressure Control (Linear) Solenoid Valve B in the Miscellaneous Test Menu, and test A/T clutch
pressure control solenoid valve B with the HDS.
Does the HDS indicate NORMAL?
YES - Intermittent failure, the system is OK at this time.■
NO - Follow the instructions indicated on the HDS by the test result, but if the HDS has not determined the
cause of the failure, go to Step 9 . If any part is replaced, go to Step 10 .
9. Inspect A/T clutch pressure control solenoid valve A.
Does A/T clutch pressure control solenoid valve B work properly?
YES - Repair the hydraulic system related with shift valve B, or replace the transmission, then go to Step 11 .
NO - Replace A/T clutch pressure control solenoid valve B, then go to Step 10 .
10. Clear the DTC with the HDS.
11. Test-drive the vehicle with the shift lever in D for at least 3 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
12. Monitor the OBD status for P0776 or P0777 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete.■
NO - Return to Step 10 and recheck. If the HDS indicates NOT COMPLETED, return to Step 11 and recheck.
DTC Troubleshooting: P0796 (78), P0797 (78)
DTC P0796:
A/T Clutch Pressure Control Solenoid Valve C Stuck OFF
DTC P0797:
A/T Clutch Pressure Control Solenoid Valve C Stuck ON
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
1. Warm up the engine to normal operating temperature (the radiator fan comes on).
2. Make sure that the transmission is filled to the proper level, and check for fluid leaks.
3. Drain the ATF through a strainer. Inspect the strainer for metal debris or excessive clutch material.
Does the strainer have metal debris or excessive clutch material?
YES - Replace the transmission, then go to Step 10 .
NO - Replace the ATF, then go to Step 4 .
4. Clear the DTC with the HDS.
5. Test-drive the vehicle with the shift lever in D for at least 3 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
6. Monitor the OBD status for P0796 or P0797 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. If the HDS indicates NOT COMPLETED, return to Step
5 and recheck.■
7. Clear the DTC with the HDS.
8. Select Clutch Pressure Control (Linear) Solenoid Valve C in the Miscellaneous Test Menu, and test A/T clutch
pressure control solenoid valve C with the HDS.
Does the HDS indicate NORMAL?
YES - Intermittent failure, the system is OK at this time.■
NO - Follow the instructions indicated on the HDS by the test result, but if the HDS has not determined the
cause of the failure, go to Step 9 . If any part is replaced, go to Step 10 .
9. Inspect A/T clutch pressure control solenoid valve C.
Does A/T clutch pressure control solenoid valve C work properly?
YES - Repair the hydraulic system related with shift valve C, or replace the transmission, then go to Step 10 .
NO - Replace A/T clutch pressure control solenoid valve C, then go to Step 10 .
10. Clear the DTC with the HDS.
11. Test-drive the vehicle with the shift lever in D for at least 3 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
12. Monitor the OBD status for P0796 or P0797 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete.■
NO - Return to Step 10 and recheck. If the HDS indicates NOT COMPLETED, return to Step 11 and recheck.
DTC Troubleshooting: P0812 (65)
DTC P0812:
Transmission Range Switch ATP R Switch (Open)
NOTE:
Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
This code is caused by an electrical circuit problem and cannot be caused by a mechanical problem in the
transmission.
1. Turn the ignition switch to ON (II).
2. Shift to R, and verify the A/T R Switch signal with the HDS in the A/T data list.
Is the A/T R Switch ON?
YES - Intermittent failure, the system is OK at this time.■
NO - Go to Step 3 .
3. Turn the ignition switch to LOCK (0).
4. Disconnect the transmission range switch connector.
5. Check for continuity between transmission range switch connector terminal No. 10 and body ground.
Is there continuity?
YES - Go to Step 6
NO - Repair open in the wire between transmission range switch connector terminal No. 10 and ground (G101),
or repair poor ground (G101), then go to Step 14 .
6. Turn the ignition switch to ON (II).
7. Measure the voltage between transmission range switch connector terminals No. 7 and No. 10.
Is there voltage?
YES - Go to Step 8 .
NO - Repair open in the wire between PCM connector terminal B15 and the transmission range switch, then go
to Step 14 .
8. Check for continuity between transmission range switch connector terminals No. 7 and No. 10 while the shift lever
is in R, and when the shift lever is shifted to any position other than R.
Is there continuity while the shift lever is in R, and no continuity when the shift lever is shifted to any position other
than R?
YES - Go to Step 9
NO - Replace the transmission range switch, then go to Step 14 .
9. Connect the transmission range switch connector.
10. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
11. Start the engine, shift to R while pressing the brake pedal, and wait for at least 2 seconds. Move the vehicle in
reverse at speeds below 5 km/h (3 mph) for at least 2 seconds, then increase the speed and move at speeds over 5
km/h (3 mph) for at least 2 seconds. Slow down and stop the wheels.
12. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0812 indicated?
YES - If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to
Step 1 .
NO - Go to Step 13 .
13. Monitor the OBD status for P0812 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 12 , go to the indicated DTC's troubleshooting.■
NO - Check for poor connections and loose terminals at the transmission range switch and the PCM. If the
PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to Step
1 . If the HDS indicates NOT COMPLETED, return to Step 11 and recheck.
9. Check for continuity between A/T clutch pressure control solenoid valve A connector terminal No. 2 and body
ground.
Is there continuity?
YES - Go to Step 10 .
NO - Repair open in the wire between A/T clutch pressure control solenoid valve A and ground (G101), or repair
poor ground (G101), then go to Step 19 .
10. Jump the SCS line with the HDS.
11. Disconnect PCM connector B (49P).
12. Check for continuity between PCM connector terminal B40 and A/T clutch pressure control solenoid valve A
connector terminal No. 1.
Is there continuity?
YES - Go to Step 13 .
NO - Repair open in the wire between PCM connector terminal B40 and A/T clutch pressure control solenoid
valve A, then go to Step 19 .
13. Check for continuity between A/T clutch pressure control solenoid valve A connector terminal No. 1 and body
ground.
Is there continuity?
YES - Repair short in the wire between PCM connector terminal B40 and A/T clutch pressure control solenoid
valve A, then go to Step 19 .
NO - Go to Step 14 .
9. Check for continuity between A/T clutch pressure control solenoid valve B connector terminal No. 2 and body
ground.
Is there continuity?
YES - Go to Step 10 .
NO - Repair open in the wire between A/T clutch pressure control solenoid valve B and ground (G101), or repair
poor ground (G101), then go to Step 19 .
10. Jump the SCS line with the HDS.
11. Disconnect PCM connector B (49P).
12. Check for continuity between PCM connector terminal B48 and A/T clutch pressure control solenoid valve B
connector terminal No. 1.
Is there continuity?
YES - Go to Step 13 .
NO - Repair open in the wire between PCM connector terminal B48 and A/T clutch pressure control solenoid
valve B, then go to Step 19 .
13. Check for continuity between A/T clutch pressure control solenoid valve B connector terminal No. 1 and body
ground.
Is there continuity?
YES - Repair short in the wire between PCM connector terminal B48 and A/T clutch pressure control solenoid
valve B, then go to Step 19 .
NO - Go to Step 14 .
9. Check for continuity between A/T clutch pressure control solenoid valve C connector terminal No. 2 and body
ground.
Is there continuity?
YES - Go to Step 10 .
NO - Repair open in the wire between A/T clutch pressure control solenoid valve C and ground (G101), or repair
poor ground (G101), then go to Step 19 .
10. Jump the SCS line with the HDS.
11. Disconnect PCM connector B (49P).
12. Check for continuity between PCM connector terminal B26 and A/T clutch pressure control solenoid valve C
connector terminal No. 1.
Is there continuity?
YES - Go to Step 13 .
NO - Repair open in the wire between PCM connector terminal B26 and A/T clutch pressure control solenoid
valve C, then go to Step 19 .
13. Check for continuity between A/T clutch pressure control solenoid valve C connector terminal No. 1 and body
ground.
Is there continuity?
YES - Repair short in the wire between PCM connector terminal B26 and A/T clutch pressure control solenoid
valve C, then go to Step 19 .
NO - Go to Step 14 .
12. Check for continuity between PCM connector terminals B11 and C44 or C48.
Is there continuity?
YES - Repair short in the wire between PCM connector terminal B11 and the shift solenoid harness connector,
then go to Step 22 .
NO - Go to Step 13 .
13. Inspect shift solenoid valve A.
Is shift solenoid valve A OK?
YES - Go to Step 14 .
NO - Replace shift solenoid valve A or the shift solenoid harness, then go to Step 22 .
14. Disconnect PCM connector A (49P).
15. Turn the ignition switch to ON (II).
16. Measure the voltage between PCM connector terminals A9 and C44 or C48.
Is there battery voltage?
YES - Go to Step 17 .
NO - Check for a blown No. 39 (15 A) fuse in the under-dash fuse/relay box. If the fuse is OK, check the PGM-
FI main relay, and repair open or short in the wire between PCM connector terminal A9 and the under-
dash fuse/relay box, then go to Step 22 .
12. Check for continuity between PCM connector terminal B11 and shift solenoid harness connector terminal No. 5.
Is there continuity?
YES - Go to Step 13 .
NO - Repair open in the wire between PCM connector terminal B11 and the shift solenoid harness connector,
then go to Step 25 .
13. Remove the shift solenoid harness.
14. Check for continuity between shift solenoid harness connector terminal No. 5 and the shift solenoid valve A
connector terminal.
Is there continuity?
YES - Replace shift solenoid valve A, then go to Step 25 .
NO - Replace the shift solenoid harness, then go to Step 25 .
15. Disconnect PCM connector A (49P).
16. Turn the ignition switch to ON (II).
17. Measure the voltage between PCM connector terminals A9 and C44 or C48.
Is there battery voltage?
YES - Go to Step 20 .
NO - Go to Step 18 .
18. Turn the ignition switch to LOCK (0).
19. Check for continuity between PCM connector terminals C44 and body ground, and between C48 and body ground.
Is there continuity?
YES - Check for a blown No. 39 (15 A) fuse in the under-dash fuse/relay box. If the fuse is OK, check the PGM-
FI main relay, and repair open or short in the wire between PCM connector terminal A9 and the under-
dash fuse/relay box, then go to Step 25 .
NO - Repair open in the wires between PCM connector terminals C44, C48 and ground (G101), or repair poor
ground (G101), then go to Step 25 .
20. Connect PCM connectors.
21. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
22. Test-drive the vehicle:
Seven-position transmission: Drive the vehicle in 2nd gear in D, D3, or 2 for at least 1 second. Slow down to
a stop, and wait for at least 1 second.
Five-position transmission: Drive the vehicle in 2nd gear in the sequential shift mode in S for at least 1
second, or in D. Slow down to a stop, and wait for at least 1 second.
23. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0974 indicated?
YES - If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to
Step 1 .
NO - Go to Step 24 .
24. Monitor the OBD status for P0974 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 23 , go to the indicated DTC's troubleshooting.■
NO - Check for poor connections and loose terminals at shift solenoid valve A and the PCM. If the PCM was
updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to Step 1 . If the
HDS indicates NOT COMPLETED, return to Step 22 and recheck.
25. Reconnect all connectors.
26. Clear the DTC with the HDS.
27. Test-drive the vehicle:
Seven-position transmission: Drive the vehicle in 2nd gear in D, D3, or 2 for at least 1 second. Slow down to
a stop, and wait for at least 1 second.
Five-position transmission: Drive the vehicle in 2nd gear in the sequential shift mode in S for at least 1
second, or in D. Slow down to a stop, and wait for at least 1 second.
28. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0974 indicated?
YES - Check for poor connections and loose terminals at shift solenoid valve A and the PCM, then go to Step 1
.
NO - Go to Step 29 .
29. Monitor the OBD status for P0974 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete. If any other DTCs were indicated on Step 28 , go to the indicated DTC's
troubleshooting.■
NO - Check for poor connections and loose terminals at shift solenoid valve A and the PCM, go to Step 1 . If
the HDS indicates NOT COMPLETED, return to Step 27 and recheck.
DTC Troubleshooting: P0976 (8)
DTC P0976:
Shift Solenoid Valve B (Short)
NOTE:
Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
This code is caused by an electrical circuit problem and cannot be caused by a mechanical problem in the
transmission.
1. Clear the DTC with the HDS.
2. Start the engine, and test-drive the vehicle:
Seven-position transmission: Drive the vehicle in 1st gear in D, D3, or 1 for at least 1 second, then slow
down to a stop.
Five-position transmission: Drive the vehicle in 1st gear in the sequential shift mode in S for at least 1
second, or in D, then slow down to a stop.
3. Check that DTC P0976 recurs.
Is DTC P0976 indicated?
YES - Go to Step 7 .
NO - Go to Step 4 .
4. Select Shift Solenoid B in the Miscellaneous Test Menu, and test shift solenoid valve B with the HDS.
Is a clicking sound heard?
YES - Go to Step 5 .
NO - Go to Step 7 .
5. Start the engine, and test-drive the vehicle:
Seven-position transmission: Drive the vehicle in 1st gear in D3 for at least 1 second, then press the
accelerator pedal so that the transmission upshifts into 3rd gear, and drive in 3rd gear for at least 1 second.
Slow down and stop the wheels.
Five-position transmission: Drive the vehicle in 1st gear in the sequential shift mode in S for at least 1
second, then upshift to 3rd gear by pulling the paddle shifter + (upshift switch), and drive in 3rd gear for at
least 1 second. Slow down and stop the wheels.
6. Monitor the OBD status for P0976 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. Check the SH B wire for an intermittent short to ground
between shift solenoid valve B and the PCM. If the HDS indicates NOT COMPLETED, return to Step 4
and recheck.
7. Turn the ignition switch to LOCK (0).
8. Jump the SCS line with the HDS.
9. Disconnect PCM connectors B (49P) and C (49P).
10. Measure the resistance between PCM connector terminals B27 and C44 or C48.
Is there less than 12 Ω?
YES - Go to Step 11 .
NO - Go to Step 17 .
11. Disconnect the shift solenoid harness connector.
12. Check for continuity between PCM connector terminals B27 and C44 or C48.
Is there continuity?
YES - Repair short in the wire between PCM connector terminal B27 and the shift solenoid harness connector,
then go to Step 22 .
NO - Go to Step 13 .
13. Inspect shift solenoid valve B.
Is shift solenoid valve B OK?
YES - Go to Step 14 .
NO - Replace shift solenoid valve B or the shift solenoid harness, then go to Step 22 .
14. Disconnect PCM connector A (49P).
15. Turn the ignition switch to ON (II).
16. Measure the voltage between PCM connector terminals A1 and C44 or C48.
Is there battery voltage?
YES - Go to Step 17 .
NO - Check for a blown No. 7 (10 A) fuse in the under-hood fuse/relay box. If the fuse is OK, repair open or
short in the wire between PCM connector terminal A1 and the under-hood fuse/relay box, then go to Step
22 .
17. Reconnect all connectors.
18. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
19. Test-drive the vehicle:
Seven-position transmission: Drive the vehicle in 1st gear in D3 for at least 1 second, then press the
accelerator pedal so that the transmission upshifts into 3rd gear, and drive in 3rd gear for at least 1 second.
Slow down and stop the wheels.
Five-position transmission: Drive the vehicle in 1st gear in the sequential shift mode in S for at least 1
second, then upshift to 3rd gear by pulling the paddle shifter + (upshift switch), and drive in 3rd gear for at
least 1 second. Slow down and stop the wheels.
20. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0976 indicated?
YES - If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to
Step 1 .
NO - Go to Step 21 .
21. Monitor the OBD status for P0976 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 20 , go to the indicated DTC's troubleshooting.■
NO - Check for an intermittent short in the wire between shift solenoid valve B and the PCM. If the PCM was
updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to Step 1 . If the
HDS indicates NOT COMPLETED, return to Step 19 and recheck.
22. Reconnect all connectors.
23. Clear the DTC with the HDS.
24. Test-drive the vehicle:
Seven-position transmission: Drive the vehicle in 1st gear in D3 for at least 1 second, then press the
accelerator pedal so that the transmission upshifts into 3rd gear, and drive in 3rd gear for at least 1 second.
Slow down and stop the wheels.
Five-position transmission: Drive the vehicle in 1st gear in the sequential shift mode in S for at least 1
second, then upshift to 3rd gear by pulling the paddle shifter + (upshift switch), and drive in 3rd gear for at
least 1 second. Slow down and stop the wheels.
25. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0976 indicated?
YES - Check for an intermittent short in the wire between shift solenoid valve B and the PCM, then go to Step 1
.
NO - Go to Step 26 .
26. Monitor the OBD status for P0976 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete. If any other DTCs were indicated on Step 25 , go to the indicated DTC's
troubleshooting.■
NO - Check for an intermittent short in the wire between shift solenoid valve B and the PCM, then go to Step 1
. If the HDS indicates NOT COMPLETED, return to Step 24 and recheck.
DTC Troubleshooting: P0977 (8)
DTC P0977:
Shift Solenoid Valve B (Open)
NOTE:
Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
This code is caused by an electrical circuit problem and cannot be caused by a mechanical problem in the
transmission.
1. Clear the DTC with the HDS.
2. Start the engine, and test-drive the vehicle:
Seven-position transmission: Drive the vehicle in D3, and let the transmission shift through all three gears.
Drive the vehicle in 3rd gear for at least 1 second, then slow down to a stop.
Five-position transmission: Drive the vehicle in 1st thru 3rd gears in the sequential shift mode in S. Drive the
vehicle in 3rd gear for at least 1 second, then slow down to a stop.
3. Check that DTC P0977 recurs.
Is DTC P0977 indicated?
YES - Go to Step 7 .
NO - Go to Step 4 .
4. Select Shift Solenoid B in the Miscellaneous Test Menu, and test shift solenoid valve B with the HDS.
Is a clicking sound heard?
YES - Go to Step 5 .
NO - Go to Step 7 .
5. Start the engine, and test-drive the vehicle:
Seven-position transmission: Drive the vehicle in 1st gear in D3 for at least 1 second, then press the
accelerator pedal so that the transmission upshifts into 3rd gear, and drive in 3rd gear for at least 1 second.
Slow down and stop the wheels.
Five-position transmission: Drive the vehicle in 1st gear in the sequential shift mode in S for at least 1
second, then upshift to 3rd gear by pulling the paddle shifter + (upshift switch), and drive in 3rd gear for at
least 1 second. Slow down and stop the wheels.
6. Monitor the OBD status for P0977 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at shift
solenoid valve B and the PCM. If the HDS indicates NOT COMPLETED, return to Step 4 and recheck.
7. Turn the ignition switch to LOCK (0).
8. Jump the SCS line with the HDS.
9. Disconnect PCM connectors B (49P) and C (49P).
10. Measure the resistance between PCM connector terminals B27 and C44 or C48.
Is there 12−25 Ω?
YES - Go to Step 15 .
NO - Go to Step 11 .
11. Disconnect the shift solenoid harness connector.
12. Check for continuity between PCM connector terminal B27 and shift solenoid harness connector terminal No. 2.
Is there continuity?
YES - Go to Step 13 .
NO - Repair open in the wire between PCM connector terminal B27 and the shift solenoid harness connector,
then go to Step 25 .
13. Remove the shift solenoid harness.
14. Check for continuity between shift solenoid harness connector terminal No. 2 and the shift solenoid valve B
connector terminal.
Is there continuity?
YES - Replace shift solenoid valve B, then go to Step 25 .
NO - Replace the shift solenoid harness, then go to Step 25 .
15. Disconnect PCM connector A (49P).
16. Turn the ignition switch to ON (II).
17. Measure the voltage between PCM connector terminals A1 and C44 or C48.
Is there battery voltage?
YES - Go to Step 20 .
NO - Go to Step 18 .
18. Turn the ignition switch to LOCK (0).
19. Check for continuity between PCM connector terminals C44 and body ground, and between C48 and body ground.
Is there continuity?
YES - Check for a blown No. 7 (10 A) fuse in the under-hood fuse/relay box. If the fuse is OK, repair open or
short in the wire between PCM connector terminal A1 and the under-hood fuse/relay box, then go to Step
25 .
NO - Repair open in the wires between PCM connector terminals C44, C48 and ground (G101), or repair poor
ground (G101), then go to Step 25 .
20. Connect PCM connectors.
21. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
22. Test-drive the vehicle:
Seven-position transmission: Drive the vehicle in 1st gear in D3 for at least 1 second, then press the
accelerator pedal so that the transmission upshifts into 3rd gear, and drive in 3rd gear for at least 1 second.
Slow down and stop the wheels.
Five-position transmission: Drive the vehicle in 1st gear in the sequential shift mode in S for at least 1
second, then upshift to 3rd gear by pulling the paddle shifter + (upshift switch), and drive in 3rd gear for at
least 1 second. Slow down and stop the wheels.
23. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0977 indicated?
YES - If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to
Step 1 .
NO - Go to Step 24 .
24. Monitor the OBD status for P0977 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 23 , go to the indicated DTC's troubleshooting.■
NO - Check for poor connections and loose terminals at shift solenoid valve B and the PCM. If the PCM was
updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to Step 1 . If the
HDS indicates NOT COMPLETED, return to Step 22 and recheck.
25. Reconnect all connectors.
26. Clear the DTC with the HDS.
27. Test-drive the vehicle:
Seven-position transmission: Drive the vehicle in 1st gear in D3 for at least 1 second, then press the
accelerator pedal so that the transmission upshifts into 3rd gear, and drive in 3rd gear for at least 1 second.
Slow down and stop the wheels.
Five-position transmission: Drive the vehicle in 1st gear in the sequential shift mode in S for at least 1
second, then upshift to 3rd gear by pulling the paddle shifter + (upshift switch), and drive in 3rd gear for at
least 1 second. Slow down and stop the wheels.
28. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0977 indicated?
YES - Check for poor connections and loose terminals at shift solenoid valve B and the PCM, then go to Step 1
.
NO - Go to Step 29 .
29. Monitor the OBD status for P0977 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete. If any other DTCs were indicated on Step 28 , go to the indicated DTC's
troubleshooting.■
NO - Check for poor connections and loose terminals at shift solenoid valve B and the PCM, then go to Step 1
. If the HDS indicates NOT COMPLETED, return to Step 27 and recheck.
DTC Troubleshooting: P0979 (22)
DTC P0979:
Shift Solenoid Valve C (Short)
NOTE:
Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
This code is caused by an electrical circuit problem and cannot be caused by a mechanical problem in the
transmission.
1. Clear the DTC with the HDS.
2. Start the engine, and test-drive the vehicle:
Seven-position transmission: Drive the vehicle in D3, and let the transmission shift through all three gears.
Drive the vehicle in 3rd gear for at least 1 second, then slow down to a stop.
Five-position transmission: Drive the vehicle in 1st thru 3rd gears in the sequential shift mode in S. Drive the
vehicle in 3rd gear for at least 1 second, then slow down to a stop.
3. Check that DTC P0979 recurs.
Is DTC P0979 indicated?
YES - Go to Step 7 .
NO - Go to Step 4 .
4. Select Shift Solenoid C in the Miscellaneous Test Menu, and test shift solenoid valve C with the HDS.
Is a clicking sound heard?
YES - Go to Step 5 .
NO - Go to Step 7 .
5. Start the engine, and test-drive the vehicle:
Seven-position transmission: Drive the vehicle in D3, and let the transmission shift through all three gears,
then slow down to a stop. Shift into P, and wait for at least 1 second.
Five-position transmission: Drive the vehicle in 1st thru 3rd gears in the sequential shift mode in S, then slow
down to a stop. Shift into P, and wait for at least 1 second.
6. Monitor the OBD status for P0979 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. Check the SH C wire for an intermittent short to ground
between shift solenoid valve C and the PCM. If the HDS indicates NOT COMPLETED, return to Step 4
and recheck.
7. Turn the ignition switch to LOCK (0).
8. Jump the SCS line with the HDS.
9. Disconnect PCM connectors B (49P) and C (49P).
10. Measure the resistance between PCM connector terminals B21 and C44 or C48.
Is there less than 12 Ω?
YES - Go to Step 11 .
NO - Go to Step 17 .
11. Disconnect the shift solenoid harness connector.
12. Check for continuity between PCM connector terminals B21 and C44 or C48.
Is there continuity?
YES - Repair short in the wire between PCM connector terminal B21 and the shift solenoid harness connector,
then go to Step 22 .
NO - Go to Step 13 .
13. Inspect shift solenoid valve C.
Is shift solenoid valve C OK?
YES - Go to Step 14 .
NO - Replace shift solenoid valve C or the shift solenoid harness, then go to Step 22 .
14. Disconnect PCM connector A (49P).
15. Turn the ignition switch to ON (II).
16. Measure the voltage between PCM connector terminals A1 and C44 or C48.
Is there battery voltage?
YES - Go to Step 17 .
NO - Check for a blown No. 7 (10 A) fuse in the under-hood fuse/relay box. If the fuse is OK, repair open or
short in the wire between PCM connector terminal A1 and the under-hood fuse/relay box, then go to Step
22 .
12. Check for continuity between PCM connector terminal B21 and shift solenoid harness connector terminal No. 1.
Is there continuity?
YES - Go to Step 13 .
NO - Repair open in the wire between PCM connector terminal B21 and the shift solenoid harness connector,
then go to Step 25 .
13. Remove the shift solenoid harness.
14. Check for continuity between shift solenoid harness connector terminal No. 1 and the shift solenoid valve C
connector terminal.
Is there continuity?
YES - Replace shift solenoid valve C, then go to Step 25 .
NO - Replace the shift solenoid harness, then go to Step 25 .
15. Disconnect PCM connector A (49P).
16. Turn the ignition switch to ON (II).
17. Measure the voltage between PCM connector terminals A1 and C44 or C48.
Is there battery voltage?
YES - Go to Step 20 .
NO - Go to Step 18 .
18. Turn the ignition switch to LOCK (0).
19. Check for continuity between PCM connector terminals C44 and body ground, and between C48 and body ground.
Is there continuity?
YES - Check for a blown No. 7 (10 A) fuse in the under-hood fuse/relay box. If the fuse is OK, repair open or
short in the wire between PCM connector terminal A1 and the under-hood fuse/relay box, then go to Step
25 .
NO - Repair open in the wires between PCM connector terminals C44, C48 and ground (G101), or repair poor
ground (G101), then go to Step 25 .
20. Connect PCM connectors.
21. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
22. Test-drive the vehicle:
Seven-position transmission: Drive the vehicle in D3, and let the transmission shift through all three gears.
Drive the vehicle in 3rd gear for at least 1 second, then slow down to a stop. Shift into P, and wait for at least
1 second.
Five-position transmission: Drive the vehicle in 1st thru 3rd gears in the sequential shift mode in S. Drive the
vehicle in 3rd gear for at least 1 second, then slow down to a stop. Shift into P, and wait for at least 1
second.
23. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0980 indicated?
YES - If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to
Step 1 .
NO - Go to Step 24 .
24. Monitor the OBD status for P0980 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 23 , go to the indicated DTC's troubleshooting.■
NO - Check for poor connections and loose terminals at shift solenoid valve C and the PCM. If the PCM was
updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to Step 1 . If the
HDS indicates NOT COMPLETED, return to Step 22 and recheck.
25. Clear the DTC with the HDS.
26. Test-drive the vehicle:
Seven-position transmission: Drive the vehicle in D3, and let the transmission shift through all three gears.
Drive the vehicle in 3rd gear for at least 1 second, then slow down to a stop. Shift into P, and wait for at least
1 second.
Five-position transmission: Drive the vehicle in 1st thru 3rd gears in the sequential shift mode in S. Drive the
vehicle in 3rd gear for at least 1 second, then slow down to a stop. Shift into P, and wait for at least 1
second.
27. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0980 indicated?
YES - Check for poor connections and loose terminals at shift solenoid valve C and the PCM, then go to Step 1
.
NO - Go to Step 28 .
28. Monitor the OBD status for P0980 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete. If any other DTCs were indicated on Step 27 , go to the indicated DTC's
troubleshooting.■
NO - Check for poor connections and loose terminals at shift solenoid valve C and the PCM, then go to Step 1
. If the HDS indicates NOT COMPLETED, return to Step 26 and recheck.
DTC Troubleshooting: P0982 (60)
DTC P0982:
Shift Solenoid Valve D (Short)
NOTE:
Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
This code is caused by an electrical circuit problem and cannot be caused by a mechanical problem in the
transmission.
1. Clear the DTC with the HDS.
2. Start the engine in P, and wait for at least 1 second.
3. Check that DTC P0982 recurs.
Is DTC P0982 indicated?
YES - Go to Step 7 .
NO - Go to Step 4 .
4. Select Shift Solenoid D in the Miscellaneous Test Menu, and test shift solenoid valve D with the HDS.
Is a clicking sound heard?
YES - Go to Step 5 .
NO - Go to Step 7 .
5. Start the engine in P, and wait for at least 1 second. With the brake pedal pressed, shift to N, and wait for at least
1 second.
6. Monitor the OBD status for P0982 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. Check the SH D wire for an intermittent short to ground
between shift solenoid valve E and the PCM. If the HDS indicates NOT COMPLETED, return to Step 4
and recheck.
7. Turn the ignition switch to LOCK (0).
8. Jump the SCS line with the HDS.
9. Disconnect PCM connectors B (49P) and C (49P).
10. Measure the resistance between PCM connector terminals B12 and C44 or C48.
Is there less than 12 Ω?
YES - Go to Step 11 .
NO - Go to Step 16 .
11. Disconnect the shift solenoid harness connector.
12. Check for continuity between PCM connector terminals B12 and C44 or C48.
Is there continuity?
YES - Repair short in the wire between PCM connector terminal B12 and the shift solenoid harness connector,
then go to Step 21 .
NO - Go to Step 13 .
13. Inspect shift solenoid valve D.
Is shift solenoid valve D OK?
YES - Go to Step 14 .
NO - Replace shift solenoid valve D or the shift solenoid harness , then go to Step 21 .
14. Turn the ignition switch to ON (II).
15. Measure the voltage between PCM connector terminals C10 and C44 or C48.
Is there battery voltage?
YES - Go to Step 16 .
NO - Check for a blown No. 20 (15 A) fuse in the under-dash fuse/relay box. If the fuse is OK, repair open or
short in the wire between PCM connector terminal C10 and the under-dash fuse/relay box, then go to
Step 21 .
16. Reconnect all connectors.
17. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
18. Start the engine in P, and wait for at least 1 second. With the brake pedal pressed, shift to N, and wait for at least
1 second.
19. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0982 indicated?
YES - If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to
Step 1 .
NO - Go to Step 20 .
20. Monitor the OBD status for P0982 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 19 , go to the indicated DTC's troubleshooting.■
NO - Check for an intermittent short in the wire between shift solenoid valve D and the PCM. If the PCM was
updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to Step 1 . If the
HDS indicates NOT COMPLETED, return to Step 18 and recheck.
21. Reconnect all connectors.
22. Clear the DTC with the HDS.
23. Start the engine in P, and wait for at least 1 second. With the brake pedal pressed, shift to N, and wait for at least
1 second.
24. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0982 indicated?
YES - Check for an intermittent short in the wire between shift solenoid valve D and the PCM, then go to Step 1
.
NO - Go to Step 25 .
25. Monitor the OBD status for P0982 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete. If any other DTCs were indicated on Step 24 , go to the indicated DTC's
troubleshooting.■
NO - Check for an intermittent short in the wire between shift solenoid valve D and the PCM, then go to Step 1
. If the HDS indicates NOT COMPLETED, return to Step 23 and recheck.
DTC Troubleshooting: P0983 (60)
DTC P0983:
Shift Solenoid Valve D (Open)
NOTE:
Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
This code is caused by an electrical circuit problem and cannot be caused by a mechanical problem in the
transmission.
1. Clear the DTC with the HDS.
2. Start the engine in P. With the brake pedal pressed, shift to N, and wait for at least 1 second.
3. Check that DTC P0983 recurs.
Is DTC P0983 indicated?
YES - Go to Step 7 .
NO - Go to Step 4 .
4. Select Shift Solenoid D in the Miscellaneous Test Menu, and test shift solenoid valve D with the HDS.
Is a clicking sound heard?
YES - Go to Step 5 .
NO - Go to Step 7 .
5. Start the engine in P, and wait for at least 1 second. With the brake pedal pressed, shift to N, and wait for at least
1 second.
6. Monitor the OBD status for P0983 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at shift
solenoid valve D and the PCM. If the HDS indicates NOT COMPLETED, return to Step 4 and recheck.
7. Turn the ignition switch to LOCK (0).
8. Jump the SCS line with the HDS.
9. Disconnect PCM connectors B (49P) and C (49P).
10. Measure the resistance between PCM connector terminals B12 and C44 or C48.
Is there 12−25 Ω?
YES - Go to Step 15 .
NO - Go to Step 11 .
11. Disconnect the shift solenoid harness connector.
12. Check for continuity between PCM connector terminal B12 and shift solenoid harness connector terminal No. 8.
Is there continuity?
YES - Go to Step 13 .
NO - Repair open in the wire between PCM connector terminal B12 and the shift solenoid harness connector,
then go to Step 24 .
13. Remove the shift solenoid harness.
14. Check for continuity between shift solenoid harness connector terminal No. 8 and the shift solenoid valve D
connector terminal.
Is there continuity?
YES - Replace shift solenoid valve D, then go to Step 24 .
NO - Replace the shift solenoid harness, then go to Step 24 .
15. Turn the ignition switch to ON (II).
16. Measure the voltage between PCM connector terminals C10 and C44 or C48.
Is there battery voltage?
YES - Go to Step 19 .
NO - Go to Step 17 .
17. Turn the ignition switch to LOCK (0).
18. Check for continuity between PCM connector terminals C44 and body ground, and between C48 and body ground.
Is there continuity?
YES - Check for a blown No. 20 (15A) fuse in the under-dash fuse/relay box. If the fuse is OK, repair open or
short in the wire between PCM connector terminal C10 and the under-dash fuse/relay box, then go to
Step 24 .
NO - Repair open in the wires between PCM connector terminals C44, C48 and ground (G101), or repair poor
ground (G101), then go to Step 24 .
19. Connect PCM connectors.
20. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
21. Start the engine in P, and wait for at least 1 second. With the brake pedal pressed, shift to N, and wait for at least
1 second.
22. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0983 indicated?
YES - If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to
Step 1 .
NO - Go to Step 23 .
23. Monitor the OBD status for P0983 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 22 , go to the indicated DTC's troubleshooting.■
NO - Check for poor connections and loose terminals at shift solenoid valve D and the PCM. If the PCM was
updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to Step 1 . If the
HDS indicates NOT COMPLETED, return to Step 21 and recheck.
24. Reconnect all connectors.
25. Clear the DTC with the HDS.
26. Start the engine in P, and wait for at least 1 second. With the brake pedal pressed, shift to N, and wait for at least
1 second.
27. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0983 indicated?
YES - Check for poor connections and loose terminals at shift solenoid valve D and the PCM, then go to Step 1
.
NO - Go to Step 28 .
28. Monitor the OBD status for P0983 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete. If any other DTCs were indicated on Step 27 , go to the indicated DTC's
troubleshooting.■
NO - Check for poor connections and loose terminals at shift solenoid valve D and the PCM, then go to Step 1
. If the HDS indicates NOT COMPLETED, return to Step 26 and recheck.
DTC Troubleshooting: P16C0
DTC P16C0:
PCM A/T Control System Incomplete Update
NOTE:
Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
This code is indicated when PCM updating is incomplete.
1. Update the A/T software in the PCM.
2. Check whether the DTC P16C0 is indicated in the DTCs/Freeze Data in A/T Mode Menu with the HDS.
Is DTC P16C0 indicated?
YES - Replace the original PCM. ■
NO - PCM updating is complete.■
DTC Troubleshooting: P1717 (62)
DTC P1717:
Transmission Range Switch ATP RVS Switch (Open)
NOTE:
Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
This code is caused by an electrical circuit problem and cannot be caused by a mechanical problem in the
transmission.
1. Turn the ignition switch to ON (II).
2. Shift to R, and verify the A/T R Switch signal with the HDS in the A/T data list.
Is the A/T R Switch ON?
YES - Go to Step 3 .
NO - Check for proper transmission range switch installation, and adjust the shift cable, then recheck.■
3. Check the Reverse Switch (ATP RVS) signal with the HDS.
Is the Reverse Switch (ATP RVS) ON?
YES - Intermittent failure, the system is OK at this time.■
NO - Go to Step 4 .
4. Turn the ignition switch to LOCK (0).
5. Disconnect the transmission range switch connector.
6. Check for continuity between transmission range switch connector terminal No. 10 and body ground.
Is there continuity?
YES - Go to Step 7 .
NO - Repair open in the wire between transmission range switch connector terminal No. 10 and ground (G101),
or repair poor ground (G101), then go to Step 15 .
7. Turn the ignition switch to ON (II).
8. Measure the voltage between transmission range switch connector terminals No. 1 and No. 10.
Is there voltage?
YES - Go to Step 9 .
NO - Repair open in the wire between PCM connector terminal B23 and the transmission range switch, then go
to Step 15 .
9. Check for continuity between transmission range switch connector terminals No. 1 and No. 10 while the shift lever
is in R, and when the shift lever is shifted to any position other than R.
Is there continuity while the shift lever is in R, and no continuity when the shift lever is shifted to any position other
than R?
YES - Go to Step 10 .
NO - Replace the transmission range switch, then go to Step 15 .
10. Connect the transmission range switch connector.
11. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
12. Start the engine, and shift to R. Move the vehicle in reverse at speeds below 5 km/h (3 mph) for at least 2 seconds,
then increase the speed and move at speeds over 5 km/h (3 mph) for at least 2 seconds. Slow down and stop the
wheels.
13. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P1717 indicated?
YES - If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to
Step 1 .
NO - Go to Step 14 .
14. Monitor the OBD status for P1717 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 13 , go to the indicated DTC's troubleshooting.■
NO - Check for poor connections and loose terminals at the transmission range switch and the PCM. If the
PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to Step
1 . If the HDS indicates NOT COMPLETED, return to Step 12 and recheck.
15. Connect the transmission range switch connector.
16. Clear the DTC with the HDS.
17. Start the engine, and shift to R. Move the vehicle in reverse at speeds below 5 km/h (3 mph) for at least 2 seconds,
then increase the speed and move at speeds over 5 km/h (3 mph) for at least 2 seconds. Slow down and stop the
wheels.
18. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P1717 indicated?
YES - Check for poor connections and loose terminals at the transmission range switch and the PCM, then go
to Step 1 .
NO - Go to Step 19 .
19. Monitor the OBD status for P1717 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete. If any other DTCs were indicated on Step 18 , go to the indicated DTC's
troubleshooting.■
NO - Check for poor connections and loose terminals at the transmission range switch and the PCM, then go
to Step 1 . If the HDS indicates NOT COMPLETED, return to Step 17 and recheck.
DTC Troubleshooting: P1746 (45)
DTC P1746:
Hydraulic Control System (Cut A Valve Stuck OFF or Cut B Valve Stuck ON)
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
1. Warm up the engine to normal operating temperature (the radiator fan comes on).
2. Make sure that the transmission is filled to the proper level, and check for fluid leaks.
3. Drain the ATF through a strainer. Inspect the strainer for metal debris or excessive clutch material.
Does the strainer have metal debris or excessive clutch material?
YES - Replace the transmission, then go to Step 7 .
NO - Replace the ATF, then go to Step 4 .
4. Clear the DTC with the HDS.
5. Test-drive the vehicle with the shift lever in D for at least 3 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
6. Monitor the OBD status for P1746 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Repair cut A valve in the servo body, repair cut B valve in the main valve body, replace the main valve body
or servo body, then go to Step 7 , or replace the transmission.
NO - Intermittent failure, the system is OK at this time. If the HDS indicates NOT COMPLETED, return to Step
5 and recheck.■
7. Clear the DTC with the HDS.
8. Test-drive the vehicle with the shift lever in D for at least 3 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
9. Monitor the OBD status for P1746 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete.■
NO - Return to Step 7 and recheck. If the HDS indicates NOT COMPLETED, return to Step 8 and recheck.
DTC Troubleshooting: P1747 (45)
DTC P1747:
Hydraulic Control System (Cut A Valve Stuck ON or Cut B Valve Stuck OFF)
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
1. Warm up the engine to normal operating temperature (the radiator fan comes on).
2. Make sure that the transmission is filled to the proper level, and check for fluid leaks.
3. Drain the ATF through a strainer. Inspect the strainer for metal debris or excessive clutch material.
Does the strainer have metal debris or excessive clutch material?
YES - Replace the transmission, then go to Step 7 .
NO - Replace the ATF, then go to Step 4 .
4. Clear the DTC with the HDS.
5. Test-drive the vehicle with the shift lever in D for at least 3 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
6. Monitor the OBD status for P1747 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate FAILED?
YES - Repair cut A valve in the servo body, repair cut B valve in the main valve body, replace the main valve body
or servo body, then go to Step 7 , or replace the transmission.
NO - Intermittent failure, the system is OK at this time. If the HDS indicates NOT COMPLETED, return to Step
5 and recheck.■
7. Clear the DTC with the HDS.
8. Test-drive the vehicle with the shift lever in D for at least 3 seconds, and let the transmission shift through all five
gears. Then slow down to a stop.
9. Monitor the OBD status for P1747 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - Troubleshooting is complete.■
NO - Return to Step 7 and recheck. If the HDS indicates NOT COMPLETED, return to Step 8 and recheck.
DTC Troubleshooting: P1780 (49)
DTC P1780:
Shift Control System (Transmission Default Mode)
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
1. Clear the DTC with the HDS.
2. Test-drive the vehicle with the shift lever in D, and let the transmission shift through all five gears. Then slow down
to a stop.
3. Check for other DTCs indicated simultaneously with DTC P1780.
NOTE: DTC P1780 means there is one or more A/T DTCs about the shift control system.
Are there other DTCs?
YES - Troubleshoot the problem indicated by the DTC.■
NO - Go to Step 4 .
4. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
5. Test-drive the vehicle with the shift lever in D, and let the transmission shift through all five gears. Then slow down
to a stop.
6. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P1780 indicated?
YES - If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to
Step 1 .
NO - Go to Step 7 .
7. Monitor the OBD status for P1780 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 6 , go to the indicated DTC's troubleshooting.■
NO - Check for poor connections and loose terminals at the PCM. If the PCM was updated, substitute a
known-good PCM, then recheck. If the PCM was substituted, go to Step 1 . If the HDS indicates NOT
COMPLETED, return to Step 5 and recheck.
DTC Troubleshooting: U0029 (107) - A/T
DTC U0029:
F-CAN Malfunction (F-CAN bus OFF)
Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
1. Clear the DTC with the HDS.
2. Start the engine, and run it at idle for at least 2 minutes.
3. Check whether DTC U0029 is indicated in the DTCs/Freeze Data in PGM-FI Mode Menu with the HDS.
Is DTC U0029 indicated in the PGM-FI system?
YES - Troubleshoot DTC U0029 in the PGM-FI system. ■
NO - Go to Step 4 .
4. Check whether DTC U0029 is indicated in the DTCs/Freeze Data in A/T Mode Menu with the HDS.
Is DTC U0029 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
6. Check for Temporary DTCs or DTCs with the HDS.
Is DTC U0029 indicated?
YES - If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to
Step 1 .
NO - Go to Step 7 .
7. Monitor the OBD status for U0029 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 6 , go to the indicated DTC's troubleshooting.■
NO - Check for poor connections and loose terminals at the PCM. If the PCM was updated, substitute a
known-good PCM, then recheck. If the PCM was substituted, go to Step 1 . If the HDS indicates NOT
COMPLETED, return to Step 7 and recheck.
DTC Troubleshooting: U0121 (107) - A/T System
DTC U0121:
F-CAN Malfunction (PCM-ABS Modulator-Control Unit)
Before you troubleshoot, record all freeze data and any on-board snapshot with the HDS, and review General
Troubleshooting Information.
1. Clear the DTC with the HDS.
2. Start the engine, and run it at idle for at least 2 minutes.
3. Check whether DTC U0121 is indicated in the DTCs/Freeze Data in PGM-FI Mode Menu with the HDS.
Is DTC U0121 indicated in the PGM-FI system?
YES - Troubleshoot DTC U0121 in the PGM-FI system. ■
NO - Go to Step 4 .
4. Check whether DTC U0121 is indicated in the DTCs/Freeze Data in A/T Mode Menu with the HDS.
Is DTC U0121 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Update the A/T software in the PCM if it does not have the latest software, or substitute a known-good PCM.
6. Check for Temporary DTCs or DTCs with the HDS.
Is DTC U0121 indicated?
YES - If the PCM was updated, substitute a known-good PCM, then recheck. If the PCM was substituted, go to
Step 1 .
NO - Go to Step 7 .
7. Monitor the OBD status for U0121 in the DTCs/Freeze Data in A/T Mode Menu for a pass/fail.
Does the HDS indicate PASSED?
YES - If the PCM was updated, troubleshooting is complete. If the PCM was substituted, replace the original
PCM. If any other DTCs were indicated on Step 6 , go to the indicated DTC's troubleshooting.■
NO - Check for poor connections and loose terminals at the PCM. If the PCM was updated, substitute a
known-good PCM, then recheck. If the PCM was substituted, go to Step 1 . If the HDS indicates NOT
COMPLETED, return to Step 7 and recheck.
Automatic Transmission and A/T Differential
Item Measurement Qualification Standard or New Service Limit
Automatic Capacity Fluid change 2.5 L (2.6 US qt, 2.2 Imp qt)
transmission fluid Use genuine Honda ATF-Z1 Overhaul 5.85 L (6.18 US qt, 5.15 Imp qt)
Pressure (Seven- Line pressure At 2,000 rpm (min −1 ) in 900−960 kPa (9.2−9.8 kgf/cm 2 , 130−140 850 kPa (8.7 kgf/cm 2 ,
position P or N psi) 120 psi)
transmission) 1st clutch pressure At 2,000 rpm (min ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140
−1 840 kPa (8.6 kgf/cm 2 ,
1 psi) 120 psi)
2nd clutch pressure At 2,000 rpm (min −1 ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 840 kPa (8.6 kgf/cm 2 ,
2 psi) 120 psi)
3rd clutch pressure At 2,000 rpm (min −1 ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 840 kPa (8.6 kgf/cm 2 ,
3rd gear in D3 psi) 120 psi)
4th clutch pressure At 2,000 rpm (min −1 ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 840 kPa (8.6 kgf/cm 2 ,
4th gear in D psi) 120 psi)
5th clutch pressure At 2,000 rpm (min ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140
−1 840 kPa (8.6 kgf/cm 2 ,
5th gear in D psi) 120 psi)
Pressure (Five- Line pressure At 2,000 rpm (min −1 ) in 900−960 kPa (9.2−9.8 kgf/cm 2 , 130−140 850 kPa (8.7 kgf/cm 2 ,
position P or N psi) 120 psi)
transmission) 1st clutch pressure At 2,000 rpm (min −1 ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 840 kPa (8.6 kgf/cm 2 ,
1st gear in S psi) 120 psi)
2nd clutch pressure At 2,000 rpm (min ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140
−1 840 kPa (8.6 kgf/cm 2 ,
2nd gear in S psi) 120 psi)
3rd clutch pressure At 2,000 rpm (min −1 ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 840 kPa (8.6 kgf/cm 2 ,
3rd gear in S psi) 120 psi)
4th clutch pressure At 2,000 rpm (min −1 ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 840 kPa (8.6 kgf/cm 2 ,
4th gear in S psi) 120 psi)
5th clutch pressure At 2,000 rpm (min ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140
−1 840 kPa (8.6 kgf/cm 2 ,
5th gear in S psi) 120 psi)
Torque converter Stall speed 2,200 rpm (min −1 ) 2,050−2,350 rpm (min
Check with vehicle on level ground −1 )
BATTERY TERMINAL
FUSE BOX UNDER−DASH FUSE/RELAY BOX IGNITION SWITCH
BATTERY
No. 1 (100 A) T−9 No. 60 (50 A) T1 2 BAT
WHT WHT
ST
1
No. 44 (7.5 A) X3
PNK
STARTER
CUT RELAY
B16 B33
BLK/WHT LT GRN
BLU/WHT
B S
M SOLENOID
4
TRANSMISSION
RANGE SWITCH
(ON: P, N)
10
STARTER
BLK
G101
Automatic transmission fluid
Item Measurement Qualification Standard or New Service Limit
Automatic Capacity Fluid change 2.5 L (2.6 US qt, 2.2 Imp qt)
transmission fluid Use genuine Honda ATF-Z1 Overhaul 5.85 L (6.18 US qt, 5.15 Imp qt)
A/T Assembly Removal
Special Tools Required
Hanger plate
07MAK-PY30100
12. Remove the drain plug (A), and drain the automatic transmission fluid (ATF).
13. Reinstall the drain plug with a new sealing washer (B).
14. Disconnect the A/T clutch pressure control solenoid valve A connector (A), A/T clutch pressure control solenoid
valve B connector (B), and A/T clutch pressure control solenoid valve C connector (C).
15. Remove the bolt securing the harness cover (D), and remove the harness cover from its bracket (E).
18. Disconnect the input shaft (mainshaft) speed sensor connector (A) and 2nd clutch transmission fluid pressure
switch connector (B).
19. Remove the ATF cooler hoses (A) from the ATF cooler lines (B). Turn the ends of the cooler hoses up to prevent
ATF from flowing out, then plug the cooler hoses and lines.
20. Check for any signs of leakage at the hose joints.
21. Remove the bolt securing the harness clamp bracket (A).
22. Disconnect the shift solenoid harness connector (B) and 3rd clutch transmission fluid pressure switch connector
(C), and remove the harness clamps (D) from the clamp brackets (E).
23. Remove the air cleaner housing mounting bracket from the transmission hanger.
24. Install the hanger plate (07MAK-PY30100) (A) to the air cleaner housing mounting bracket (B) with the 8 x 1.25 mm
bolt (C).
25. Remove the harness clamp (A) from its clamp bracket (B) located in front of the left damper top.
26. Set up the engine support hanger (AAR-T1256-J00). Carefully position the engine support hanger to the vehicle;
position both cross-arm foot bases (C) over the harness clamp brackets on both sides, and position both front
stands on the front bulkhead. Attach the hook to the hanger plate, tighten the wing nut by hand, and lift and support
the engine.
27. Insert a 5 mm Allen wrench (A) in the top of the ball joint pin (B), and remove the nuts (C), then separate the
stabilizer link (D) from the stabilizer ends (E).
28. With HID lamp model: If removing the left side lower arm, disconnect the suspension stroke sensor, and the lower
arm.
29. Remove the lock pin (F) and castle nuts (G), and separate the lower arms (H) from the knuckles (I).
30. Remove the steering gearbox mounting bolt (A), bolt (B), and stiffener (C) on the right.
31. Remove the steering gearbox mounting bolt (A), bolt (B), and stiffener (C) on the left.
36. Support the front subframe with a wood piece and a jack.
40. Pry up the lock tab of the lock washer (A), and remove the lock bolt (B) and lock washer.
41. Remove the bolts securing the shift cable holder (C), and separate the shift cable (D) from the selector control shaft
end (E). Do not bend the shift cable excessively.
42. Remove the lower torque rod mounting bracket (A) and shift cable holder bracket (B).
43. Remove the torque converter cover (A), and remove the drive plate bolts (B) (eight bolts) while rotating the
crankshaft pulley.
44. Pry out the driveshafts from the differential and the intermediate shaft.
45. Coat all precision machined surfaces with clean engine oil, then put plastic bags over driveshaft ends.
46. Remove the bolts securing the heat shield (A).
47. Remove the intermediate shaft (B) and heat shield.
48. Coat all precision finished surfaces with clean engine oil, then put plastic bags over intermediate shaft ends.
49. Remove the front and upper transmission housing mounting bolts.
50. Remove the transmission ground cable terminal (A) from the transmission mount bracket (B).
51. Place a jack under the transmission, raise it just enough to take it off of the mount, and remove the transmission
mount and mount bracket.
52. Remove the jack.
4. Attach the transmission to the engine, and install the lower transmission housing mounting bolts.
7. Place a jack under the transmission, raise it and secure the transmission mount and mount bracket (A) on the
body and transmission housing with the new mounting bolts and new nuts loose.
8. Tighten the transmission mount bolts to the specified torque in the following order; on the middle (B), on the front
(C), and on the rear (D).
9. Remove the jack, and tighten the bolt (E) and nuts (F) on the transmission mount bracket to the specified torque.
10. Install the transmission ground cable terminal (G).
11. Install the new set ring (A) on the intermediate shaft (B).
12. Clean the areas where the intermediate shaft contacts the transmission (differential) with solvent, and dry with
compressed air. Apply ATF to the intermediate shaft splines, put the heat shield (C) on the intermediate shaft, then
install the intermediate shaft; be sure not to allow dust or other foreign particles to enter the transmission.
13. Secure the heat shield with the mounting bolts.
14. Install the new set ring (A) on the left driveshaft (B).
15. Clean the areas where the left driveshaft contacts the transmission (differential) with solvent, and dry with
compressed air. Then install the left driveshaft; be sure not to allow dust or other foreign particles to enter the
transmission. Turn the steering knuckle fully outward, and slide the driveshaft into the differential until you feel its
set ring fully engage the side gear.
16. Apply right driveshaft inboard-joint splines with the recommended grease.
17. Slide the right driveshaft over the intermediate shaft splines until you feel the driveshaft fully engage the
intermediate shaft set ring.
18. Attach the torque converter to the drive plate with eight bolts (A). Rotate the crankshaft pulley as necessary to
tighten the bolts to 1/2 of the specified torque, then to the final torque, in a crisscross pattern. After tightening the
last bolt, check that the crankshaft rotate freely.
19. Install the torque converter cover (B).
20. Install the shift cable holder bracket (A) and lower torque rod mounting bracket (B) on the transmission.
21. Install the control lever (A) over the control shaft (B). Do not twist the boot (C).
22. Secure the shift cable bracket (D) with the bolts.
23. Secure the control lever with the new lock washer (E) and the lock bolt (F); install the flange (G) of the lock washer
with facing to transmission housing, then bend the lock tab (H) of the lock washer against the bolt head securely.
25. Support the front subframe with a wood piece and a jack.
26. Lift the front subframe (A) up to body, and secure it with the new mounting bolts loose.
27. Tighten the right middle mounting bolt (B) first, then the left middle bolt (C), and the four remaining bolts (D) to the
specified torque.
28. Place a jack under the transmission, raise it and attach the lower torque rod (A) in the mounting bracket and front
subframe.
29. Install the new mounting bolt (B), and set the bolt tongue (C) into the stop (D) through the guide (E), then loosely
install the new nut (F).
30. Loosely install the new mounting bolt (G).
31. Remove the jack, and tighten the bolt and nut to the specified torque.
32. On the right side of the steering gearbox, secure the steering gear box (A) and stiffener (B) with the new mounting
bolt (C) and the new bolt (D) loose.
33. On the left side of the steering gearbox, secure the steering gear box (A) and stiffener (B) with the new mounting
bolt (C) and the new bolt (D) loose.
34. Loosely install the steering gearbox mounting bolt (A) and washer (B) on the middle.
35. Tighten the steering gearbox mounting bolts to the specified torque in the following order; on the right side, on the
left side, and on the middle.
36. Tighten the bolts to the specified torque securing the right side stiffener, then left side stiffener.
37. Connect the ball joints (A) to both knuckles (B), and install the new ball joint nuts (C). Tighten the nuts, then
secure the nuts with the lock pin (D).
38. Connect the stabilizer links (E) to the stabilizer ends (F), and install the nuts (G). Insert a 5 mm Allen wrench (H) in
the top of the ball joint pins (I), and tighten the nuts.
39. With HID lamp model: If the left side lower arm was removed, connect the suspension stroke sensor, to the lower
arm.
40. Remove the engine support hanger, and install the harness clamp in its bracket located in front of the left damper
top.
41. Remove the hanger plate (07MAK-PY30100) (A) and bolt (B).
42. Install the air cleaner housing mounting bracket on the transmission hanger.
43. Secure the harness clamp bracket (A) with the bolt.
44. Connect the shift solenoid harness connector (B) and 3rd clutch transmission fluid pressure switch connector (C),
and install the harness clamps (D) in the clamp brackets (E).
45. Connect the ATF cooler hoses (A) to the ATF cooler lines (B), and secure the hoses with the clips (C).
46. Connect the input shaft (mainshaft) speed sensor connector (A) and 2nd clutch transmission fluid pressure switch
connector (B).
47. Connect the output shaft (countershaft) speed sensor connector (A), and install the harness clamp (B) on its
bracket (C).
48. Connect the transmission range switch connector (D).
49. Install the harness cover (A) on its bracket (B), and secure the cover with the bolt.
50. Connect the A/T clutch pressure control solenoid valve A connector (C), A/T clutch pressure control solenoid valve
C connector (D), and A/T clutch pressure control solenoid valve B connector (E).
51. Install the air cleaner assembly.
52. Install the windshield wiper motor and center-front cowl cover (A), and install the cowl cover stiffener (B).
53. Install the cowl cover.
54. Install the windshield wiper arms.
55. Refill the transmission with ATF.
56. Install the battery base.
57. Do the battery installation procedure.
58. Install the splash shield.
59. Install the wheels.
60. Set the parking brake. Start the engine, and shift the transmission through all positions three times. Check the shift
lever operation, A/T gear position indicator operation, and shift cable adjustment.
61. Check and adjust the front wheel alignment.
62. Check the ATF level.
63. With HID lamp model: If the left side lower arm was removed, do the headlight initial position learning procedure.
64. Do the road test.
Reverse idler gear
Item Measurement Qualification Standard or New Service Limit
Reverse idler gear Reverse idler gear shaft O.D. at needle 14.99−15.00 mm (0.590−0.591 in.) When worn or damaged
bearing contact area
I.D. 20.001−20.014 mm (0.7874−0.7880 in.) When worn or damaged
I.D. of reverse idler gear shaft contact area 14.800−14.818 mm (0.5827−0.5834 in.) ———
on transmission housing
I.D. of reverse idler gear shaft holder 14.800−14.824 mm (0.5827−0.5836 in.) When worn or damaged
Reverse shift fork
Item Measurement Qualification Standard or New Service Limit
Reverse shift fork Fork finger thickness 5.90−6.00 mm (0.232−0.236 in.) 5.40 mm (0.213 in.)
Park gear and pawl
Item Measurement Qualification Standard or New Service Limit
Park gear and ——— When worn or damaged
pawl
Pressure (Seven-position transmission)
Item Measurement Qualification Standard or New Service Limit
Pressure (Seven- Line pressure At 2,000 rpm (min −1 ) in 900−960 kPa (9.2−9.8 kgf/cm 2 , 130−140 850 kPa (8.7 kgf/cm 2 ,
position P or N psi) 120 psi)
transmission) 1st clutch pressure At 2,000 rpm (min −1 ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 840 kPa (8.6 kgf/cm 2 ,
1 psi) 120 psi)
2nd clutch pressure At 2,000 rpm (min ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140
−1 840 kPa (8.6 kgf/cm 2 ,
2 psi) 120 psi)
3rd clutch pressure At 2,000 rpm (min −1 ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 840 kPa (8.6 kgf/cm 2 ,
3rd gear in D3 psi) 120 psi)
4th clutch pressure At 2,000 rpm (min −1 ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 840 kPa (8.6 kgf/cm 2 ,
4th gear in D psi) 120 psi)
5th clutch pressure At 2,000 rpm (min −1 ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 840 kPa (8.6 kgf/cm 2 ,
5th gear in D psi) 120 psi)
Pressure (Five-position transmission)
Item Measurement Qualification Standard or New Service Limit
Pressure (Five- Line pressure At 2,000 rpm (min −1 ) in 900−960 kPa (9.2−9.8 kgf/cm 2 , 130−140 850 kPa (8.7 kgf/cm 2 ,
position P or N psi) 120 psi)
transmission) 1st clutch pressure At 2,000 rpm (min −1 ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 840 kPa (8.6 kgf/cm 2 ,
1st gear in S psi) 120 psi)
2nd clutch pressure At 2,000 rpm (min ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140
−1 840 kPa (8.6 kgf/cm 2 ,
2nd gear in S psi) 120 psi)
3rd clutch pressure At 2,000 rpm (min −1 ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 840 kPa (8.6 kgf/cm 2 ,
3rd gear in S psi) 120 psi)
4th clutch pressure At 2,000 rpm (min −1 ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 840 kPa (8.6 kgf/cm 2 ,
4th gear in S psi) 120 psi)
5th clutch pressure At 2,000 rpm (min −1 ) in 890−970 kPa (9.1−9.9 kgf/cm 2 , 130−140 840 kPa (8.6 kgf/cm 2 ,
5th gear in S psi) 120 psi)
Countershaft
Item Measurement Qualification Standard or New Service Limit
Countershaft Diameter of needle bearing contact area At torque 33.504−33.517 mm (1.3191−1.3196 in.) When worn or damaged
converter housing
At 5th gear 32.986−32.999 mm (1.2987−1.2991 in.) When worn or damaged
Reverse selector 35.983−35.999 mm (1.4167−1.4173 in.) When worn or damaged
hub
I.D. of gears 5th gear 39.000−39.016 mm (1.5354−1.5361 in.) When worn or damaged
Reverse gear 42.000−42.016 mm (1.6535−1.6542 in.) When worn or damaged
End play 5th gear 0.04−0.27 mm (0.002−0.011 in.) ———
Reverse gear 0.10−0.25 mm (0.004−0.010 in.) ———
Reverse selector hub width 29.25−29.45 mm (1.152−1.160 in.) ———
Collar, 33.2 x 40 x 26 mm length 25.95−26.00 mm (1.022−1.024 in.) ———
Reverse selector hub O.D. 51.87−51.90 mm (2.042−2.043 in.) When worn or damaged
Mainshaft
Item Measurement Qualification Standard or New Service Limit
Mainshaft Diameter of needle bearing contact area At stator shaft 22.984−23.000 mm (0.9049−0.9055 in.) When worn or damaged
At 5th gear collar 32.975−32.991 mm (1.2982−1.2989 in.) When worn or damaged
At 3rd gear 46.986−46.999 mm (1.8498−1.8503 in.) When worn or damaged
I.D. of gears 5th gear 37.000−37.016 mm (1.4567−1.4573 in.) When worn or damaged
3rd gear 52.000−52.013 mm (2.0472−2.0478 in.) When worn or damaged
End play 5th gear 0.15−0.27 mm (0.006−0.106 in.) ———
3rd gear 0.04−0.10 mm (0.002−0.004 in.) ———
40 x 63 mm thrust washer thickness No. 1 3.750 mm (0.1476 in.) When worn or damaged
No. 2 3.775 mm (0.1486 in.) When worn or damaged
No. 3 3.800 mm (0.1496 in.) When worn or damaged
No. 4 3.825 mm (0.1506 in.) When worn or damaged
No. 5 3.850 mm (0.1516 in.) When worn or damaged
No. 6 3.875 mm (0.1526 in.) When worn or damaged
No. 7 3.900 mm (0.1535 in.) When worn or damaged
No. 8 3.925 mm (0.1545 in.) When worn or damaged
No. 9 3.950 mm (0.1555 in.) When worn or damaged
No. 10 3.975 mm (0.1565 in.) When worn or damaged
No. 11 4.000 mm (0.1575 in.) When worn or damaged
5th gear collar length 60.4−60.5 mm (2.380−2.381 in.) ———
5th gear collar flange thickness 3.70−3.85 mm (0.146−0.152 in.) When worn or damaged
Sealing ring thickness 1.91−1.97 mm (0.0752−0.0776 in.) 1.86 mm (0.0732 in.)
Width of sealing ring groove 2.025−2.060 mm (0.0797−0.0811 in.) 2.080 mm (0.0819 in.)
3rd clutch feed pipe O.D. 7.97−7.98 mm (0.3138−0.3142 in.) 7.95 mm (0.313 in.)
Feed pipe bushing I.D. 8.000−8.015 mm (0.3150−0.3156 in.) 8.030 mm (0.3161 in.)
Secondary shaft - 1/2
Item Measurement Qualification Standard or New Service Limit
Secondary shaft - Diameter of needle bearing contact area 1st gear 30.986−30.999 mm (1.2199−1.2204 in.) When worn or damaged
1/2 2nd gear 42.986−42.999 mm (1.6924−1.6929 in.) When worn or damaged
4th gear collar 34.975−34.991 mm (1.3770−1.3776 in.) When worn or damaged
I.D. of gears 1st gear 38.000−38.016 mm (1.4961−1.4967 in.) When worn or damaged
2nd gear 49.000−49.016 mm (1.9291−1.9298 in.) When worn or damaged
4th gear 41.000−41.016 mm (1.6142−1.6148 in.) When worn or damaged
End play 1st gear 0.04−0.12 mm (0.002−0.005 in.) ———
2nd gear 0.04−0.12 mm (0.002−0.005 in.) ———
4th gear 0.10−0.22 mm (0.004−0.009 in.) ———
31 x 50 mm thrust washer thickness No. 1 3.925 mm (0.1545 in.) When worn or damaged
No. 2 3.950 mm (0.1555 in.) When worn or damaged
No. 3 3.975 mm (0.1565 in.) When worn or damaged
No. 4 4.000 mm (0.1575 in.) When worn or damaged
No. 5 4.025 mm (0.1585 in.) When worn or damaged
No. 6 4.050 mm (0.1594 in.) When worn or damaged
No. 7 4.075 mm (0.1604 in.) When worn or damaged
No. 8 4.100 mm (0.1614 in.) When worn or damaged
No. 9 4.125 mm (0.1624 in.) When worn or damaged
No. 10 4.150 mm (0.1634 in.) When worn or damaged
No. 11 4.175 mm (0.1644 in.) When worn or damaged
No. 12 4.200 mm (0.1654 in.) When worn or damaged
No. 13 4.225 mm (0.1663 in.) When worn or damaged
No. 14 4.250 mm (0.1673 in.) When worn or damaged
No. 15 4.275 mm (0.1683 in.) When worn or damaged
No. 16 4.300 mm (0.1693 in.) When worn or damaged
No. 17 4.325 mm (0.1703 in.) When worn or damaged
43 x 54.5 mm thrust washer thickness No. 1 2.900 mm (0.114 in.) When worn or damaged
No. 2 2.925 mm (0.115 in.) When worn or damaged
No. 3 2.950 mm (0.116 in.) When worn or damaged
No. 4 2.975 mm (0.117 in.) When worn or damaged
No. 5 3.000 mm (0.118 in.) When worn or damaged
No. 6 3.025 mm (0.119 in.) When worn or damaged
No. 7 3.050 mm (0.120 in.) When worn or damaged
No. 8 3.075 mm (0.121 in.) When worn or damaged
No. 9 3.100 mm (0.122 in.) When worn or damaged
No. 10 3.125 mm (0.123 in.) When worn or damaged
No. 11 3.150 mm (0.124 in.) When worn or damaged
No. 12 3.175 mm (0.125 in.) When worn or damaged
No. 13 3.200 mm (0.126 in.) When worn or damaged
Secondary shaft - 2/2
Item Measurement Qualification Standard or New Service Limit
Secondary shaft - 4th gear collar length 32.9−33.0 mm (1.295−1.299 in.) ———
2/2 4th gear collar flange thickness 3.75−3.90 mm (0.148−0.154 in.) When worn or damaged
Sealing ring thickness 1.87−1.97 mm (0.074−0.078 in.) 1.82 mm (0.072 in.)
Width of sealing ring groove 2.025−2.060 mm (0.0797−0.0811 in.) 2.080 mm (0.0819 in.)
Clutch feed pipe O.D. 2nd clutch 6.97−6.98 mm (0.2744−0.2748 in.) 6.95 mm (0.2736 in.)
4th clutch 11.47−11.48 mm (0.4516−0.4520 in.) 11.45 mm (0.4508 in.)
Clutch feed pipe bushing O.D. 2nd clutch 7.018−7.030 mm (0.2763−0.2768 in.) 7.045 mm (0.2774 in.)
4th clutch 11.500−11.518 mm (0.4528−0.4553 in.) 11.530 mm (0.4539 in.)
ATF guide collar I.D. at sealing ring contact 21.200−21.221 mm (0.8346−0.8355 in.) 21.25 mm (0.8366 in.)
area
Clutch
Item Measurement Qualification Standard or New Service Limit
Clutch Clutch between clutch end-plate and top 1st ——— 1.62−1.82 mm
disc (0.064−0.072 in.)
2nd ——— 0.5−0.7 mm
(0.020−0.028 in.)
3rd ——— 0.73−0.93 mm
(0.029−0.037 in.)
4th ——— 0.7−0.9 mm
(0.028−0.035 in.)
5th ——— 0.73−0.93 mm
(0.029−0.037 in.)
Clutch return spring free length 1st 35.2 mm (1.39 in.) 34.5 mm (1.36 in.)
2nd 39.5 mm (1.56 in.) 37.4 mm (1.47 in.)
3rd 45.15 mm (1.778 in.) 43.0 mm (1.69 in.)
4th 39.5 mm (1.56 in.) 37.4 mm (1.47 in.)
5th 45.15 mm (1.778 in.) 43.0 mm (1.69 in.)
Clutch disc thickness 1st 1.94 mm (0.076 in.) ———
2nd 1.96 mm (0.077 in.) ———
3rd 1.94 mm (0.076 in.) ———
4th 1.96 mm (0.077 in.) ———
5th 1.94 mm (0.076 in.) ———
Clutch plate thickness 1st 1.6 mm (0.063 in.) When discolored
2nd 2.3 mm (0.091 in.) When discolored
3rd 2.0 mm (0.079 in.) When discolored
4th 1.6 mm (0.063 in.) When discolored
5th 2.0 mm (0.079 in.) When discolored
Clutch waved-plate height 1st, 3rd, and 0.07−0.20 mm (0.003−0.008 in.) 0.05 mm (0.002 in.)
5th clutches
1st, 3rd, and 5th clutch end-plate Mark 1 2.1 mm (0.083 in.) When discolored
thickness Mark 2 2.2 mm (0.087 in.) When discolored
Mark 3 2.3 mm (0.091 in.) When discolored
Mark 4 2.4 mm (0.094 in.) When discolored
Mark 5 2.5 mm (0.098 in.) When discolored
Mark 6 2.6 mm (0.102 in.) When discolored
Mark 7 2.7 mm (0.106 in.) When discolored
Mark 8 2.8 mm (0.110 in.) When discolored
Mark 9 2.9 mm (0.114 in.) When discolored
2nd and 4th clutch end-plate thickness Mark AC or AM 2.1 mm (0.083 in.) When discolored
Mark AD or AN 2.2 mm (0.087 in.) When discolored
Mark AE or AP 2.3 mm (0.091 in.) When discolored
Mark AF or AQ 2.4 mm (0.094 in.) When discolored
Mark AG or AR 2.5 mm (0.098 in.) When discolored
Mark AH or AS 2.6 mm (0.102 in.) When discolored
Mark AJ or AT 2.7 mm (0.106 in.) When discolored
Mark AK or AU 2.8 mm (0.110 in.) When discolored
Mark AL or AV 2.9 mm (0.114 in.) When discolored
A/T Shift Cable Replacement
1. Raise the vehicle on a lift, or apply the parking brake, block rear wheels, and raise the front of the vehicle. Make
sure it is securely supported.
2. Remove the splash shield.
3. Remove the center console.
4. Shift the transmission to N.
5. Remove the nut securing the shift cable end.
6. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the corner (C) on the socket holder will be in the
opening (D) of the shift lever bracket base (E). Then slide the holder to remove the shift cable from the bracket.
8. Pry up the lock tab of the lock washer (A), and remove the lock bolt (B) and lock washer.
9. Remove the bolts securing the shift cable holder (C), and separate the shift cable (D) from the selector control shaft
end (E).
10. Remove the heat shield under the body.
11. Remove the nut securing the shift cable bracket (A).
12. Remove the shift cable grommet (B), and pull out the shift cable (C).
13. Insert the new shift cable through the grommet hole (D), and install the grommet in its hole. Do not bend the shift
cable excessively.
14. Secure the shift cable bracket with the nut.
15. Install the heat shield.
16. Install the control lever (A) over the control shaft (B). Do not twist the boot (C).
17. Secure the shift cable bracket (D) with the bolts.
18. Secure the control lever with the new lock washer (E) and the lock bolt (F); install the flange (G) of the lock washer
with facing to the transmission housing, then bend the lock tab (H) of the lock washer against the bolt head
securely.
20. Turn the ignition switch to ON (II), and check that the N indicator comes on.
21. If necessary, push the shift cable (A) until it stops, then release it. Pull the shift cable back two steps so that the
shift position is in N. Do not hold the shift cable guide (B) to adjust the shift cable.
22. Turn the ignition switch to LOCK (0).
23. Insert a 6.0 mm (0.24 in.) pin (A) through the positioning holes (B) on the shift lever bracket base and into the
positioning hole on the shift lever. Use only the 6.0 mm pin.
24. Check that the shift lever is secured in N.
25. Rotate the socket holder (A) on the shift cable (B) to place the corner (C) on the holder opposite the opening (D) in
the shift lever bracket base (E). Align the holder with the opening in the bracket, then slide the holder into the
bracket. Install the shift cable end (F) over the mounting stud (G) by aligning its square hole with the square fitting
(H) at the bottom of the stud. Rotate the holder a quarter turn until the holder stops to secure the shift cable. Do not
install the shift cable by twisting the shift cable guide (I).
26. Check that the shift cable end is properly installed on the mounting stud.
27. If the cable end is out of position on the mounting stud, remove the shift cable from the bracket, and reinstall the
shift cable. Do not install the shift cable end on the mounting stud while the shift cable in on the bracket. If the
cable end rides on the bottom of the mounting stud, rotate the stud and align the square fitting with the hole.
28. Secure the shift cable end with the nut (A).
29. Remove the 6.0 mm (0.24 in.) pin (B) that was installed to hold the shift lever.
30. Turn the ignition switch to ON (II). Move the shift lever to each position, and check that the A/T gear position
indicator follows the transmission range switch.
31. Shift to P, and check that the shift lock works properly. Push the shift lock release, and check that the shift lever
releases, and also check that the shift lever locks when it is shifted back into P.
32. Reinstall the center console.
A/T differential carrier
Item Measurement Qualification Standard or New Service Limit
A/T differential Pinion shaft contact area I.D. 18.010−18.028 mm (0.709−0.710 in.) ———
carrier Clearance between carrier and pinion shaft 0.023−0.057 mm (0.001−0.002 in.) 0.1 mm (0.004 in.)
Driveshaft contact area I.D. 26.025−26.045 mm (1.024−1.025 in.) ———
Clearance between carrier and driveshaft 0.045−0.086 mm (0.002−0.003 in.) 0.12 mm (0.005 in.)
Intermediate shaft contact area I.D. 26.025−26.045 mm (1.024−1.025 in.) ———
Clearance between carrier and Intermediate 0.045−0.086 mm (0.002−0.003 in.) 0.12 mm (0.005 in.)
shaft
Tapered roller bearing starting torque For new bearing 2.7−3.9 N·m(28−40 kgf·cm, 24−35 lbf·in.) Adjust
(preload) For reused 2.5−3.6 N·m(25−37 kgf·cm, 22−32 lbf·in.) Adjust
bearing
Final driven gear backlash Reference 0.085−0.144 mm (0.003−0.006 in.) 0.2 mm (0.008 in.)
A/T differential pinion gear
Item Measurement Qualification Standard or New Service Limit
A/T differential Backlash 0.05−0.15 mm (0.002−0.006 in.) ———
pinion gear I.D. 18.042−18.066 mm (0.7103−0.7113 in.) ———
Clearance between pinion gear and pinion 0.055−0.095 mm (0.002−0.004 in.) 0.12 mm (0.005 in.)
shaft
Idler gear shaft
Item Measurement Qualification Standard or New Service Limit
Idler gear shaft End cover bearing contact area 30.003−30.013 mm (1.1812−1.1816 in.) When worn or damaged
Cotters thickness 1.39−1.42 mm (0.055−0.056 in.) ———
Torque converter
Item Measurement Qualification Standard or New Service Limit
Torque converter Stall speed 2,200 rpm (min −1 ) 2,050−2,350 rpm (min
Check with vehicle on level ground −1 )
ATF pump
Item Measurement Qualification Standard or New Service Limit
ATF pump ATF pump thrust clearance 0.03−0.06 mm (0.001−0.002 in.) 0.07 mm (0.003 in.)
Clearance between ATF pump gear and Drive gear 0.210−0.265 mm (0.0083−0.0104 in.) ———
body Driven gear 0.070−0.125 mm (0.0028−0.0049 in.) ———
ATF pump driven gear I.D. 14.016−14.034 mm (0.5518−0.5525 in.) When worn or damaged
ATF pump driven gear shaft O.D. 13.980−13.990 mm (0.5504−0.5508 in.) When worn or damaged
Main valve body spring
Item Measurement Qualification Standard or New
Wire Diameter O.D. Free Length No. of Coils
Main valve body Cut valve B spring 0.8 mm (0.031 9.9 mm (0.290 27.3 mm (1.075 8.0
spring in.) in.) in.)
Shift valve A spring 0.8 mm (0.031 7.1 mm (0.280 23.7 mm (0.933 9.7
in.) in.) in.)
Shift valve C spring 0.8 mm (0.031 7.1 mm (0.280 23.7 mm (0.933 9.7
in.) in.) in.)
Relief valve spring 1.0 mm (0.039 9.6 mm (0.378 34.1 mm (1.343 10.2
in.) in.) in.)
Lock-up control valve spring 0.6 mm (0.024 7.1 mm (0.280 29.6 mm (1.165 11.2
in.) in.) in.)
Cooler check valve spring 0.85 mm (0.033 6.6 mm (0.260 27.0 mm (1.063 11.3
in.) in.) in.)
Shift valve D spring 0.8 mm (0.031 5.6 mm (0.220 28.1 mm (1.106 15.9
in.) in.) in.)
Servo control valve spring 0.8 mm (0.031 9.9 mm (0.290 27.3 mm (1.075 8.0
in.) in.) in.)
Regulator valve body
Item Measurement Qualification Standard or New Service Limit
Regulator valve Sealing ring contact I.D. 29.000−29.021 mm (1.1417−1.1426 in.) 29.05 mm (1.144 in.)
body
Regulator valve body spring
Item Measurement Qualification Standard or New
Wire Diameter O.D. Free Length No. of Coils
Regulator valve Stator reaction spring 4.5 mm (0.177 35.4 mm 30.3 mm (1.193 1.92
body spring in.) (1.394 in.) in.)
Regulator valve spring A 1.9 mm (0.075 14.7 mm 80.6 mm (3.173 16.1
in.) (0.579 in.) in.)
Regulator valve spring B 1.6 mm (0.063 9.2 mm (0.362 44.0 mm (1.732 12.5
in.) in.) in.)
Torque converter check valve spring 1.2 mm (0.047 8.6 mm (0.339 33.8 mm (1.331 12.2
in.) in.) in.)
Lock-up shift valve spring 1.0 mm (0.039 6.6 mm (0.260 35.5 mm (1.398 18.2
in.) in.) in.)
1st accumulator spring B 2.4 mm (0.094 12.2 mm 35.0 mm (1.378 7.7
in.) (0.480 in.) in.)
1st accumulator spring A 2.4 mm (0.094 18.6 mm 50.1 mm (1.972 6.7
in.) (0.732 in.) in.)
4th accumulator spring 2.5 mm (0.098 14.6 mm 29.9 mm (1.177 4.9
in.) (0.575 in.) in.)
Servo body
Item Measurement Qualification Standard or New Service Limit
Servo body Shift fork shaft bore I.D. 14.000−14.010 mm (0.5512−0.5526 in.) When worn or damaged
Shift fork shaft valve bore I.D. 37.000−37.039 mm (1.4567−1.4582 in.) 37.045 mm (1.4585 in.)
Servo body spring
Item Measurement Qualification Standard or New
Wire Diameter O.D. Free Length No. of Coils
Servo body spring Cut valve A spring 0.9 mm (0.035 9.9 mm (0.390 22.3 mm (0.878 6.9
in.) in.) in.)
Shift valve B spring 0.8 mm (0.031 7.1 mm (0.280 23.7 mm (0.933 9.7
in.) in.) in.)
5th accumulator spring A 2.5 mm (0.098 16.6 mm 46.9 mm (1.846 7.8
in.) (0.654 in.) in.)
5th accumulator spring B 1.9 mm (0.075 10.0 mm 38.5 mm (1.516 10.6
in.) (0.394 in.) in.)
2nd accumulator spring A 1.8 mm (0.071 14.6 mm 43.8 mm (1.724 7.9
in.) (0.575 in.) in.)
2nd accumulator spring B 1.85 mm (0.073 9.4 mm (0.370 32.5 mm(1.280 8.7
in.) in.) in.)
3rd accumulator spring A 1.8 mm (0.071 14.6 mm 43.8 mm (1.724 7.9
in.) (0.575 in.) in.)
3rd accumulator spring B 1.85 mm (0.073 9.4 mm (0.370 32.5 mm (1.280 8.7
in.) in.) in.)
Stator shaft
Item Measurement Qualification Standard or New Service Limit
Stator shaft Needle bearing contact I.D. Torque converter 27.000−27.021 mm (1.063−1.064 in.) When worn or damaged
side
ATF pump side 29.000−29.021 mm (1.1417−1.1426 in.) ———
Sealing ring contact area I.D. 29.000−29.021 mm (1.1417−1.1426 in.) 29.05 mm (1.144 in.)
Engine Wire Harness, CKP Sensor Subharness, Transmission Range Switch Subharness Locations
A/T
TRANSMISSION RANGE
ENGINE WIRE HARNESS SWITCH SUBHARNESS
G101
WATER OUTLET
Removal/Installation,
VALVE COTTERS
CAM CHAIN CMP PULSE PLATE in the Shop Manual,
VALVE
TENSIONER COTTERS
SLIDER Replacement,
CMP PULSE PLATE P/N 62TF000A
in the Shop
Replacement,Manual, P/N 62TF000A
in the Shop Manual, P/N 62TF000A
CYLINDER HEAD
CAMSHAFT
Removal,
Removal,
CAMSHAFT
Inspection for Warpage,
Inspection,
Removal,
in the Shop Manual, P/N 62TF000A
Installation,
Inspection,
Installation,
O-RING Installation,
SPRING RETAINER CAMSHAFT POSITION
COOLANT SEPARATOR (CMP) SENSOR
CAMSHAFT POSITION
SPRING RETAINER
CYLINDER HEAD PLUG (CMP) SENSOR
O-RING VALVE COTTERS
CYLINDER HEAD
EXHAUST VALVE
SPRING O-RING VALVE COTTERS
GASKET
EXHAUST VALVE
SPRING SPRING RETAINER
SPRING RETAINER
EXHAUST VALVE DOWEL PINS
SEAL
EXHAUST VALVE INTAKE VALVE SPRING
SEAL INTAKE VALVE SPRING
VALVE SPRING ROCKER ARM OIL
SEAT CONTROL SOLENOID
VALVE SPRING ROCKER ARM OIL FILTER
SEAT CONTROL SOLENOID FILTER
EXHAUST VALVE
GUIDE VALVE
EXHAUST
GUIDE
6. Disconnect the upper radiator hose (A), the heater hose (B), and the water bypass hose (C).
7. Remove the heater hose from the clamps (D).
8. Remove the intake manifold bracket C.
9. Remove the subfuel feed line.
10. Remove the intake manifold/chamber assembly.
11. Remove the warm up three way catalytic converter (WU-TWC).
12. Remove the following engine wire harness connectors and wire harness clamps from the cylinder head:
Four injector connector
Engine coolant temperature (ECT) sensor 1 connector
Camshaft position (CMP) sensor connector
Secondary heated oxygen sensor (secondary HO2S) connector
Rocker arm oil control solenoid connector
14. Remove the harness holder mounting bolt (A) and the ground cable (B), then remove the harness holder (C) from
the bracket.
15. Remove the cylinder head cover.
16. Remove the cam chain.
17. Remove the cylinder head bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the
sequence until all bolts are loosened.
18. Remove the cylinder head.
Cylinder Head Installation
1. Clean the cylinder head and the block surface.
2. Install a new coolant separator (A) in the engine block whenever the engine block is replaced.
3. Install the new cylinder head gasket (B) and the dowel pins (C) on the engine block. Always use a new cylinder
head gasket.
4. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B)
on the oil pump.
5. Set the camshaft TDC. The ‘‘UP'' mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B)
on the camshaft sprocket should line up with the top edge of the head.
6. Install the cylinder head on the engine block.
7. Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts.
8. Tighten the cylinder head bolts in sequence to 29 N·m (3.0 kgf·m, 22 lbf·ft). Using a beam-type torque wrench.
When using a preset-type torque wrench, be sure to tighten slowly and do not overtighten. If a bolt makes any
noise while you are torquing it, loosen the bolt and retighten it from the first step.
12. Install the harness holder (A), then install the ground cable (B).
19. Install the upper radiator hose (A), the heater hose (B), and the water bypass hose (C).
20. Install the heater hose to the clamps (D).
21. Connect the fuel feed hose (A), then install the quick-connect fitting cover (B) and the fuel feed hose clamp (C).
22. Install the air cleaner housing assembly.
23. Do the battery installation procedure.
24. Inspect for fuel leaks. Turn the ignition switch to ON (II) (do not operate the starter) so the fuel pump runs for about
2 seconds and pressurizes the fuel line. Repeat this operation three times, then check for fuel leakage at any point
in the fuel line.
25. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
26. Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure.
27. Inspect the idle speed.
28. Inspect the ignition timing.
Camshaft Removal
1. Remove the air cleaner housing assembly.
2. Remove the intake manifold chamber.
3. Remove the following engine wire harness connectors and wire harness clamps from the cylinder head:
Four injector connector
Engine coolant temperature (ECT) sensor 1 connector
Camshaft position (CMP) sensor connector
Air fuel ratio (A/F) sensor connector
Secondary heated oxygen sensor (secondary HO2S) connector
4. Remove the harness holder mounting bolt and the ground cable, then remove the harness holder from the bracket.
5. Remove the camshaft sprocket.
6. Remove the rocker arm assembly.
7. Remove the CMP sensor.
8. Remove the camshaft thrust cover (A), then remove the camshaft (B).
Camshaft Installation
1. Install the camshaft (A), then install the camshaft thrust cover (B) with new O-ring (C).
2. Install the camshaft position (CMP) sensor.
3. Install the rocker arm assembly.
4. Install the camshaft sprocket.
5. Install the harness holder, then install the ground cable.
6. Install the following engine wire harness connectors and wire harness clamps to the cylinder head:
Four injector connector
Engine coolant temperature (ECT) sensor 1 connector
CMP sensor connector
Air fuel ratio (A/F) sensor connector
Secondary heated oxygen sensor (secondary HO2S) connector
7. Install the intake manifold chamber.
8. Install the air cleaner housing assembly.
Camshaft Inspection
1. Remove the camshaft sprocket. L15A8 engine
2. Remove the rocker arm assembly, then disassemble the rocker arm.
3. Put the rocker shaft holder bridge/rocker shaft holders on the cylinder head, then tighten the bolts to the specified
torque.
Specified Torque
6 x 1.0 mm
(1)−(10): 15 N·m (1.5 kgf·m, 11 lbf·ft) L13Z3 engine
(11): 10 N·m (1.0 kgf·m, 7.2 lbf·ft)
4. Seat the camshaft by pushing it toward the rear of the cylinder head.
5. Zero the dial indicator against the end of the camshaft. Push the camshaft back and forth, and read the end play. If
the end play is beyond the service limit, replace the thrust cover and recheck. If it is still beyond the service limit,
replace the camshaft.
Camshaft End Play
Standard (New): 0.05−0.25 mm (0.002−0.010 in.)
Service Limit: 0.5 mm (0.02 in.)
10. Clean the camshaft bearing surfaces in the cylinder head. Measure the inside diameter of each camshaft bearing
surface, and check for an out-of-round condition.
If the camshaft-to-holder clearance is within limits, go to Step 12 .
If the camshaft-to-holder clearance is beyond the service limit, and the camshaft has been replaced, replace
the cylinder head.
If the camshaft-to-holder clearance is beyond the service limit, and the camshaft has not been replaced, go
to Step 11 .
Camshaft-to-Holder Oil Clearance
Standard (New): 0.045−0.084 mm (0.0018−0.0033 in.)
Service Limit: 0.100 mm (0.004 in.)
11. Check the total runout with the camshaft supported on V-blocks.
If the total runout of the camshaft is within the service limit, replace the cylinder head.
If the total runout is beyond the service limit, replace the camshaft, and recheck the oil clearance. If the oil
clearance is still out of tolerance, replace the cylinder head.
Camshaft Total Runout
Standard (New): 0.03 mm (0.001 in.) max.
Service Limit: 0.04 mm (0.002 in.)
12. Measure the cam lobe height.
4. Check that the air pressure on the shop air compressor gauge indicates over 400 kPa (4 kgf/cm 2 , 57 psi).
5. Inspect the valve clearance.
6. Install the air adapter (A) to the inspection hole, then connect the valve inspection set (B). L15A8, L13Z3 engines
7. Loosen the valve on the regulator, and apply the specified air pressure.
Specified Air Pressure:
340 kPa (3.5 kgf/cm 2 , 50 psi)
8. With the specified air pressure applied, rotate the crankshaft clockwise, and visually check that all the primary L15A8, L13Z3 engines
rocker arms (A) and secondary rocker arms (B) move together.
If the primary rocker arm and secondary rocker arm move freely and independently of each other, remove the
primary and secondary rocker arms as an assembly, and check that the pistons in the primary and secondary
rocker arms move smoothly. If any rocker arm needs replacing, replace the primary and secondary rocker arms as
an assembly, and test.
9. Remove the air supply and the VTEC adapter.
10. Install the cylinder head cover.
Cylinder Head Rocker Arm Assembly Removal
1. Remove the cylinder head cover. L15A8 engine
2. Loosen the rocker arm adjusting screws (A).
L13Z3 engine
3. Unscrew the rocker shaft mounting bolts two turns at a time, in sequence below. L15A8 engine
NOTE: Bundle the intake rocker arms with rubber bands (A) to keep them together as a set.
L13Z3 engine
4. Remove the rocker shaft mounting bolts, then remove the rocker arm assembly. L15A8 engine
L13Z3 engine
Cylinder Head Rocker Arm Assembly Installation
1. Install the rocker arm assembly (A). L15A8 engine
L13Z3 engine
L13Z3 engine
3. Adjust the valve clearance.
4. Install the cylinder head cover.
Cylinder Head Rocker Arm and Shaft Inspection
1. Remove the rocker arm assembly.
2. Disassemble the rocker arm assembly.
3. Measure the diameter of the shaft at the first rocker location.
5. Measure the inside diameter of the rocker arm, and check it for an out-of-round condition.
6. Repeat for all rockers and shaft. If the clearance is beyond the service limit, replace the rocker shaft and all out of
service limit rocker arms. If any VTEC rocker arm needs replacement, replace the rocker arms as an assembly.
L13Z3 engine
NOTE:
Identify each part as it is removed so that each item can be reinstalled in its original position.
Inspect the rocker arm shaft and the rocker arms.
If reused, the rocker arms must be installed in the their original location.
Remove the rocker shaft bolt before removing the rocker shaft from the No. 5 rocker shaft holder.
Prior to reassembling, clean all the parts in solvent, dry them, and apply new engine oil to any
contact points.
When replacing the rocker arm assembly, remove the fastening hardware from the new rocker
arm assembly.
When reassembling the rocker arm and shaft assembly, position the arrows on the rocker shaft
holders facing the cam chain side.
Cam Chain Removal
NOTE: Keep the cam chain away from magnetic fields.
1. Remove the cylinder head cover.
2. Set the No. 1 piston at top dead center (TDC). The ‘‘UP'' mark (A) on the camshaft sprocket should be at the top,
and the TDC grooves (B) on the camshaft sprocket should line up with the top edge of the head.
3. Remove the right front wheel.
4. Remove the right side splash shield.
5. Loosen the water pump pulley mounting bolts.
6. Remove the drive belt.
12. Remove the ground cable (A), then remove the side engine mount/bracket assembly (B).
14. Measure the cam chain separation. If the distance is less than the service limit, replace the cam chain and cam
chain tensioner.
Standard Distance: 19 mm (0.75 in.)
Service Limit: 15 mm (0.59 in.)
15. Apply new engine oil to the sliding surface of the cam chain tensioner slider (A).
16. Hold the cam chain tensioner slider with the screwdriver, then remove the bolt (B), and loosen the bolt (C).
3. Set the camshaft to TDC. The ‘‘UP'' mark (A) on the camshaft sprocket should be at the top, and the TDC grooves
(B) on the camshaft sprocket should line up with the top edge of the head.
4. Install the cam chain on the crankshaft sprocket with the colored piece (A) aligned with the TDC mark (B) on the
crankshaft sprocket, then install the crankshaft sprocket to the crankshaft.
5. With L15A8 engine: Install the cam chain on the camshaft sprocket with the pointers (A) aligned with the three
colored pieces (B) as shown.
6. With L13Z3 engine: Install the cam chain on the camshaft sprocket with the pointer (A) aligned with the center of
the two colored pieces (B).
7. Install the cam chain tensioner (A) and the cam chain guide (B).
8. Install the cam chain tensioner slider, and tighten the bolt loosely.
9. Apply new engine oil to the sliding surface of the cam chain tensioner slider (A).
10. Rotate the cam chain tensioner slider clockwise to compress the cam chain tensioner, and install the remaining
bolt, then tighten the bolts.
11. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal.
12. Remove the all of the old liquid gasket from the chain case mating surfaces, the bolts, and the bolt holes.
13. Clean and dry the chain case mating surfaces.
14. Apply liquid gasket (P/N 08C70-K0234M, 08C70-K0334M, or 08C70-X0331S) to the engine block mating surface of
the chain case and to the inner threads of the bolt holes.
NOTE: Apply liquid gasket about 2.5 mm (0.098 in.) diameter bead along the broken line (A).
15. Apply liquid gasket (P/N 08C70-K0234M, 08C70-K0334M, or 08C70-X0331S) to the oil pan mating surface of the
chain case and to the inner threads of the bolt holes.
NOTE:
Apply liquid gasket about 2.5 mm (0.098 in.) diameter bead along the broken line (A).
Apply liquid gasket about 5.0 mm (0.20 in.) diameter bead to the shaded area (B).
Do not install components if 5 minutes or more have passed after applying the liquid gasket. Instead, remove
the old residue and reapply the liquid gasket.
16. Set the edge of the chain case (A) to the edge of the oil pan (B), then install the chain case on the engine block
(C).
NOTE:
When installing the chain case, do not slide the bottom surface onto the oil pan mounting surface.
Wait at least 30 minutes before filling the engine with oil.
Do not run the engine for at least 3 hours after installing the chain case.
17. Tighten the chain case mounting bolts. Wipe off the excess liquid gasket on the oil pan and the chain case mating L15A8, L13Z3 engines
area.
18. Install the side engine mount/bracket assembly (A), then tighten the new side engine mount/bracket assembly
mounting bolts (B).
19. Loosely tighten the new side engine mount/bracket assembly mounting nuts (C).
20. Install the ground cable (D).
21. Remove the air cleaner housing assembly.
22. Loosen the transmission mount bracket mounting bolts and nuts (A). M/T model
23. Raise the vehicle on the lift to full height.
A/T model
24. Loosen the torque rod mounting bolt and nut (A). M/T model
25. Lower the vehicle on the lift.
A/T model
26. Tighten the side engine mount/bracket assembly mounting nuts in the numbered sequence shown.
27. Tighten the transmission mount mounting bolts and nuts in the numbered sequence shown. M/T model
28. Raise the vehicle on the lift to full height.
A/T model
29. Tighten the torque rod mounting bolt and nut in the numbered sequence shown. M/T model
30. Lower the vehicle on the lift.
31. Install the air cleaner housing assembly.
A/T model
3. Select the correct thickness feeler gauge for the valves you are going to check. L15A8, L13Z3 engines
Valve Clearance
Intake: 0.15−0.19 mm (0.006−0.007 in.)
Exhaust: 0.26−0.30 mm (0.010−0.012 in.)
4. Insert the feeler gauge (A) between the adjusting screw and the end of the valve stem on No. 1 cylinder and slide it L15A8, L13Z3 engines
back and forth; you should feel a slight amount of drag.
5. If you feel too much or too little drag, loosen the locknut, and turn the adjusting screw (A) until the drag on the L15A8, L13Z3 engines
feeler gauge is correct.
6. Tighten the locknut and recheck the clearance. Repeat the adjustment, if necessary.
7. Tighten the locknut to the specified torque, and recheck the valve clearance. Repeat the adjustment if necessary.
Specified Torque
7 x 0.75 mm 14 N·m (1.4 kgf·m, 10 lbf·ft)
Apply new engine oil to the nut threads.
8. Rotate the crankshaft clockwise. Align the No. 3 piston TDC groove (A) on the camshaft sprocket with the top edge
of the head.
9. Check, and if necessary, adjust the valve clearance on the No. 3 cylinder.
10. Rotate the crankshaft clockwise. Align the No. 4 piston TDC groove (A) on the camshaft sprocket with the top edge
of the head.
11. Check, and if necessary, adjust the valve clearance on the No. 4 cylinder.
12. Rotate the crankshaft clockwise. Align the No. 2 piston TDC groove (A) on the camshaft sprocket with the top edge
of the head.
13. Check, and if necessary, adjust the valve clearance on the No. 2 cylinder.
14. Install the cylinder head cover.
Fuel and Emissions System Description - VTEC System
VTEC System (L13Z3 engine)
Operation (L13Z3 engine)
VTEC System (L15A8 engine)
Operation (L15A8 engine)
VTEC Component Location Index
ENGINE CONTROL
MODULE (ECM)/
POWERTRAIN CONTROL
MODULE (PCM)
General Troubleshooting
Information,
Substituting,
ROCKER ARM OIL CONTROL VALVE Update,
Removal/Installation, Replacement,
in the Shop Manual, P/N 62TF000A
VTEC System Oil Pressure Troubleshooting
Special Tools Required
Oil pressure gauge joint attachment
07NAJ-P070100
7. Remove the bolt (A) from the rocker arm oil control valve and connect the special tool as shown, the install the bolt
(A) that was removed to the oil pressure gauge joint attachment.
8. Start the engine. Hold the engine speed at 3,000 rpm (min −1 ) without load (A/T in P or N, M/T in neutral) until the
radiator fan comes on.
9. Check the oil pressure at the engine speed of 1,000 to 2,000 rpm (min −1 ).
NOTE: Keep the measuring time as short as possible (less than 1 minute).
12. Connect the battery positive terminal (+) to terminal No. 1, and the negative terminal (−) with a wire.
13. Start the engine.
14. Check the oil pressure at the engine speed of 3,500 rpm (min −1 ).
NOTE: Keep the measuring time as short as possible (less than 1 minute).
Is the oil pressure above 392 kPa (4.0 kgf/cm 2 , 56.9 psi)?
YES - The VTEC system oil pressure is normal.■
NO - Go to Step 15 .
15. Turn the ignition switch to LOCK (0).
16. Remove the rocker arm oil control valve.
17. Check the rocker arm oil control solenoid filter for dirt and clogging.
Is the rocker arm oil control solenoid filter dirty or clogged?
YES - Replace the engine oil, engine oil filter, and the rocker arm oil control solenoid filter, then go to Step 18 .
NO - Go to Step 22 .
18. Remove the bolt (A) from the rocker arm oil control valve and connect the special tool as shown, the install the bolt
that was removed to the oil pressure gauge joint attachment.
19. Connect the battery positive terminal (+) to terminal No. 1, and the negative terminal (−) with a wire.
20. Start the engine.
21. Check the oil pressure at the engine speed of 3,500 rpm (min −1 ).
NOTE: Keep the measuring time as short as possible (less than 1 minute).
Is the oil pressure above 392 kPa (4.0 kgf/cm 2 , 56.9 psi)?
YES - Troubleshooting is complete.■
NO - Go to Step 22 .
22. Replace the rocker arm oil control valve.
23. Remove the bolt (A) from the rocker arm oil control valve and connect the special tool as shown, the install the bolt
that was removed to the oil pressure gauge joint attachment.
24. Connect the battery positive terminal (+) to terminal No. 1, and the negative terminal (−) with a wire.
25. Start the engine.
26. Check the oil pressure at the engine speed of 3,500 rpm (min −1 ).
NOTE: Keep the measuring time as short as possible (less than 1 minute).
Is the oil pressure above 392 kPa (4.0 kgf/cm 2 , 56.9 psi)?
YES - Troubleshooting is complete.■
NO - Clean the oil passage of the cylinder block or replace the cylinder block.■
Engine Removal
Special Tools Required
Engine tilt hanger set
07KAK-SJ40101
6. Remove the battery cables (A) from the battery terminal fuse box.
7. Remove the harness clamps (B).
8. With M/T model: Remove the harness clamp (A). Remove the two bolts (B) and loosen the two bolts (C), then
remove the battery base (D).
9. Disconnect the engine control module (ECM)/ powertrain control module (PCM) connectors (A) and the engine wire
harness connector (B).
10. Remove the harness clamp (C) and harness holder (D).
11. Disconnect the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).
12. Remove the fuel feed hose clamp (A) and the quick-connect fitting cover (B), then disconnect the fuel feed hose (C).
13. Disconnect the secondary heated oxygen sensor (secondary HO2S) connector (A), then remove the secondary
HO2S harness from the clamps (B).
14. M/T model: Remove the shift cable.
15. M/T model: Remove the clutch slave cylinder, and clutch line bracket mounting bolt.
16. Remove the radiator cap.
17. Remove the subfuel fill cap, then retighten the subfuel cap.
18. Remove the bolt, then disconnect the subfuel feed line from the subfuel solenoid holder.
19. Raise the vehicle on the lift to full height.
20. Remove the front wheels.
26. Remove the under-floor three way catalytic converter (under-floor TWC).
27. A/T model: Remove the shift cable.
28. Remove the stabilizer links from the stabilizer.
29. Separate the knuckles from the lower arms.
32. Remove the bolts (A) securing the steering gearbox, then remove the steering gearbox stiffeners (B).
33. Remove the A/C compressor without disconnecting the A/C hoses.
34. Lower the vehicle on the lift.
35. Remove the radiator.
A/T model
45. Remove the ground cable (A), then remove the transmission mount bracket (B). M/T model
A/T model
46. Remove the ground cable (A), then remove the side engine mount/bracket assembly (B).
47. Check that the engine/transmission is completely free of vacuum hoses, fuel and coolant hoses, and electrical
wiring.
48. Slowly lower the engine/transmission about 150 mm (6 in.). Check once again that all hoses and electrical wiring
are disconnected and free from the engine/transmission, then lower it all the way.
49. Disconnect the chain hoist from the engine/transmission.
50. Raise the vehicle, and remove the engine/ transmission from under the vehicle.
Engine Installation
Special Tools Required
Engine tilt hanger set
07KAK-SJ40101
2. Install the side engine mount/bracket assembly (A), then tighten the new side engine mount/bracket assembly
mounting bolts (B) and nuts (C).
3. Loosely tighten the new side engine mount/bracket assembly mounting nuts (C).
4. Install the ground cable (D).
5. Install the transmission mount bracket (A), and loosely tighten the new transmission mount bracket mounting bolts M/T model
and nuts (B).
6. Install the ground cable (C).
7. Remove the engine tilt hanger set from the engine/transmission.
A/T model
10. Install the front subframe, then tighten the new front subframe mounting bolts in the numbered sequence shown.
11. Install the torque rod (A). Install the new bolt with the tab (B) on the bolt head aligned with the guide (C) on the front M/T model
subframe, then loosely tighten the new torque rod mounting bolt and nut (D).
12. Lower the vehicle on the lift.
A/T model
13. Tighten the side engine mount/bracket assembly mounting nuts in the numbered sequence shown.
14. Tighten the transmission mount mounting bolts and nuts in the numbered sequence shown. M/T model
15. Raise the vehicle on the lift to full height.
A/T model
16. Tighten the torque rod mounting bolt and nut in the numbered sequence shown. M/T model
A/T model
17. Install the securing the steering gearbox and the steering gearbox stiffeners, then tighten the new bolts in the
numbered sequence shown.
18. Install a new set ring on the end of each driveshaft, then install the driveshafts. Make sure each ring ‘‘clicks'' into
place in the differential and the intermediate shaft.
19. Install the driveshaft heat shield.
20. Connect the lower arms to the knuckles.
21. Install the stabilizer links to the stabilizer.
22. A/T model: Install the shift cable.
25. Install the under-floor three way catalytic converter (under-floor TWC) (A). Use new gaskets (B) and new self locking
nuts (C).
34. Connect the secondary heated oxygen sensor (secondary HO2S) connector (A), then install the secondary HO2S
harness to the clamps (B).
35. Connect the fuel feed hose (A) , then install the quick-connect fitting cover (B) and the fuel feed hose clamp (C).
36. Install the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).
37. Install the harness holder (A), then install the harness clamp (B).
38. Connect the engine wire harness connector (C) and the engine control module (ECM)/powertrain control module
(PCM) connectors (D).
39. With M/T model: Install the battery base (A), then install the harness clamp (B).
40. Install the battery cables (A) to the battery terminal fuse box.
41. Install the harness clamps (B).
42. Install the front wheels.
43. Install the under-cowl panel.
44. Do the battery installation procedure.
45. Refill the transmission with fluid:
Manual transmission
Automatic transmission
46. Install the air cleaner housing assembly.
47. A/T model: Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission
range switch.
48. M/T model: Check that the transmission shifts into all gear smoothly.
49. Inspect for fuel leaks. Turn the ignition switch to ON (II) (do not operate the starter) so the fuel pump runs for about
2 seconds and pressurizes the fuel line. Repeat this operation three times, then check for fuel leakage at any point
in the fuel line.
50. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
51. Refill the engine with engine oil.
52. Do the ECM/PCM reset procedure.
53. Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure.
54. Inspect the idle speed.
55. Inspect the ignition timing.
Engine Block Component Location Index
L15A8 engine
L13Z3 engine
PISTON RINGS
Replacement,
in the Shop Manual, P/N 62TF000A
PISTON
Removal, BEARING CAP BRIDGE
in the Shop Manual, P/N 62TF000A
Measurement,
DOWEL PIN
ENGINE BLOCK
Cylinder Bore Inspection,
Warpage Inspection,
Cylinder Bore Honing,
in the Shop Manual, P/N 62TF000A
Ridge Removal,
in the Shop Manual, P/N 62TF000A
4. Measure wear and taper in direction Y at three levels in each cylinder as shown. If measurements in any cylinder
are beyond the Oversize Bore Service Limit, replace the engine block. If the engine block is to be rebored, refer to
Step 7 after reboring.
Oversize
0.25: 73.250−73.265 mm (2.8839−2.8844 in.)
Bore Taper
Limit: (Difference between first and third measurement) 0.05 mm (0.002 in.)
6. Check the top of the engine block for warpage. Measure along the edges and across the center as shown.
7. Calculate the difference between the cylinder bore diameter and the piston diameter. If the clearance is near or
exceeds the service limit, inspect the piston and engine block for excessive wear.
Piston-to-Cylinder Clearance
L15A8 engine:
Standard (New): 0.010−0.035 mm (0.0004−0.0014 in.)
Service Limit: 0.05 mm (0.002 in.)
L13Z3 engine:
Standard (New): 0.018−0.043 mm (0.0007−0.0017 in.)
Service Limit: 0.05 mm (0.002 in.)
Connecting Rod Bearing Replacement
Rod Bearing Clearance Inspection
1. To check rod bearing-to-journal oil clearance, remove the bearing cap bridge.
2. Remove the connecting rod cap and bearing half.
3. Clean the crankshaft rod journal and bearing half with a clean shop towel.
4. Place plastigage across the rod journal.
5. Reinstall the bearing half and cap, and torque the bolts to 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft) +90 °.
NOTE: Do not rotate the crankshaft during inspection.
6. Remove the rod cap and bearing half, and measure the widest part of the plastigage.
Connecting Rod Bearing-to-Journal Oil Clearance
L15A8 engine:
Standard (New): 0.020−0.038 mm (0.0008−0.0015 in.)
Service Limit: 0.050 mm (0.0020 in.)
L13Z3 engine:
Standard (New): 0.026−0.044 mm (0.0010−0.0017 in.)
Service Limit: 0.050 mm (0.0020 in.)
7. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete
bearing with the same color code(s), and recheck the clearance. Do not file, shim, or scrape the bearings or the
caps to adjust clearance.
8. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above
or below the current one), and check clearance again. If the proper clearance cannot be obtained by using the
appropriate larger or smaller bearing, replace the crankshaft and start over.
4. Use the big end bore codes and rod journal codes to select appropriate replacement bearings from the following L15A8 engine
table.
NOTE: Color code is on the edge of the bearing.
L13Z3 engine
Crankshaft Main Bearing Replacement
Main Bearing Clearance Inspection
1. To check main bearing-to-journal oil clearance, remove the bearing cap bridge and bearing halves.
2. Clean each main journal and bearing half with a clean shop towel.
3. Place one strip of plastigage across each main journal.
4. Reinstall the bearings and bearing cap bridge, then tighten the bearing cap bolts to 25 N·m (2.5 kgf·m, 18 lbf·ft) in
the proper sequence.
NOTE: Do not rotate the crankshaft during inspection.
5. Tighten the bearing cap bolts an additional 40 °.
6. Remove the bearing cap bridge and bearings again, and measure the widest part of the plastigage.
7. If the plastigage measures too wide or too narrow, remove the crankshaft, and remove the upper half of the bearing.
Install a new, complete bearing with the same color code(s), and recheck the clearance. Do not file, shim, or
scrape the bearings or the caps to adjust clearance.
8. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above
or below the current one), and check again. If the proper clearance cannot be obtained by using the appropriate
larger or smaller bearings, replace the crankshaft and start over.
3. Use the crank bore codes and crank journal codes to select the appropriate replacement bearings from the L15A8 engine
following table.
NOTE: Color code is on the edge of the bearing.
L13Z3 engine
Exhaust Pipe and Muffler Replacement
NOTE: Use new gaskets and self-locking nuts when reassembling.
Fuel and Emissions Systems Connector and Harness Locations
G101 2 3
ECM/PCM Circuit Diagram (cont'd) 1
ROCKER ARM ENGINE
OIL CONTROL 4 EVAP CANISTER
SOLENOID WIRE HARNESS
24P JUNCTION CONNECTOR 12P JUNCTION CONNECTOR MAP SENSOR PURGE VALVE
(1) (2) (A/T) (2) (M/T) 5 (3) (4)
ENGINE 7
ECM/PCM Circuit Diagram (cont'd) WIRE HARNESS SECONDARY
No. 1 No. 2 No. 3 No. 4 ENGINE HO2S
IGNITION IGNITION IGNITION IGNITION A/F SENSOR
32 COIL (2) WIRE(SENSOR
HARNESS1) (SENSOR 2)
COIL (1) COIL (3) 5 6COIL (4) 7 (5) 8 (6)
OUTPUT 4 SHAFT 6 OUTPUT SHAFT
DASHBOARD WIRE(COUNTERSHAFT)
HARNESS MAF SENSOR/ (COUNTERSHAFT) LEFT ENGINE
24P JUNCTION
ECM/PCM CONNECTOR 3 SPEED SENSOR 6 7
IAT SENSOR 8 SPEEDCABLE REEL SUBHARNESS
SENSOR 10PCOMPARTMENT
CONNECTOR
31 Circuit Diagram (cont'd)
(5) (6) (M/T) (7)
9 10(8) (A/T)
11 9 8
(9)
5 WIRE HARNESS
2
12P JUNCTION
13P CONNECTOR CONNECTOR (2) 14P CONNECTOR ESP12
CONTROL UNIT
(1) (3) No. 4 (4) No. 3 FUEL SUBHARNESS
DASHBOARD WIRE HARNESS CABLE REEL SUBHARNESS
INJECTOR INJECTOR
13
THROTTLE BODY CMP SENSOR ECT SENSOR 1 CKP SENSOR (11) (12) 10
(7) 1 TEST4
(8) (9) (10) 10 9
13P CONNECTOR TACHOMETER ECM/PCM A (□) (12)* ECM/PCM B ( ) (13)*
(10) CONNECTOR
UNDER-DASH (11) UNDER-DASH UNDER-DASH UNDER-DASH FUEL
FUSE/RELAY BOX FUSE/RELAY BOX FUSE/RELAY FUSE/RELAY ELD (5) SUBHARNESS
(K) (1)
RIGHT ENGINE (N) (2) BOX (S) (3) BOX (T) (4)
10
COMPARTMENT 11
RIGHT
RIGHTENGINE
ENGINE
WIRE HARNESS 12P JUNCTION 12P JUNCTION COMPARTMENT
GAUGE CONTROL MODULE (5) CONNECTOR (7)
COMPARTMENT
CONNECTOR (8)WIRE HARNESS
APP SENSOR
No. 2 No. 1 SUBFUEL (6) AUXILIARY WIRE HARNESS
30 INJECTOR
LEFT ENGINE INJECTOR SOLENOID ECT SENSOR 2 UNDER-HOOD 11 14
COMPARTMENT WIRE HARNESS (14)
(13) (15) (16) RELAY BOX (17) 12
LEFT ENGINE ENGINE
COMPARTMENT WIRE 3HARNESS WIRE
ECM/PCM C (○) (14)* HARNESS
UNDER-DASH FUSE/RELAY BOX (A) (8)
19
UNDER-DASH UNDER-DASH 13
FUSE/RELAY FUSE/RELAY BOX 2ND CLUTCH A/T CLUTCH A/T CLUTCH 3ND CLUTCH 15
BOX (W) (6) (Q) (7) TRANSMISSION PRESSURE PRESSURE 12
TRANSMISSION
29 2 FLUID PADDLE SUBFUEL
CONTROL
PUMP
PADDLE CONTROL FLUID
PRESSURE SHIFTER− TRANSMISSION RELAY
SOLENOID
SHIFTER+ SOLENOID PRESSURE 11
ABS MODULATOR- 3P CONNECTOR
SWITCH (15) RANGE SWITCH VALVE A VALVE C 14
SWITCH
(19) (DOWNSHIFT
CONTROL UNIT (UPSHIFT
(18) 28 (A/T) SWITCH) (11) (16) (A/T) EVAPORATOR (17) (A/T)SWITCH) (13) (18) (A/T) (19) (A/T) 16
(A/T with TEMPERATURE (A/T with 15
12P JUNCTION
1
CONNECTOR (9) CABLE REEL (10) paddle shifter SENSOR (12) paddle shifter 13P CONNECTOR 12
model) model) (14)
27
17
26 19 16
18
25 20
AUXILIARY UNDER-HOOD TRANSMISSION RANGE
SHIFT
NOTE: CONTROL
SHIFT
UNDER-DASH FUSE/RELAY
SHIFT
BOX (B) (9) RELAY BOX21
(23) SWITCH SUBHARNESS SHIFT
(A/T)
CONTROL CONTROL24 terminal side 21 ATF CONTROL
· Connector with male terminals
SOLENOID (double outline):SOLENOID
SOLENOID view from 23 TEMPERATURE SOLENOID
VALVE
· Connector C female terminals
with VALVE
SHIFT A
(single outline):VALVE D
view from wire side 22 SENSOR 13
VALVE B
(20) (A/T)
*: Connector (21) (A/T)SOLENOID
with female terminals (22) (A/T)
(single outline): 20 (24) (A/T) (25) (A/T)
WIRE HARNESS (A/T) view from terminal side SHIFT LOCK
CRANKCABLE
SENSORREEL (15) IGNITION SWITCH FUEL PUMP SOLENOID
SUBHARNESS (17) (18) (A/T) 14
22 (16) 1
18 17
13 A/C CONDENSER
A/C COMPRESSOR FAN RELAY
CLUTCH RELAY 18
17 RADIATOR FAN RELAY
15
A/T CLUTCH 19
PRESSURE 2
CONTROL M/T 16
M/T
SOLENOID BRAKE PEDAL CLUTCH PEDALROCKER ARM
8P CONNECTOR VALVE B INPUT SHAFT (MAINSHAFT) OIL PRESSURE KNOCKPOSITION
SENSOR ALTERNATOR
POSITION OIL PRESSURE
SPEED SENSOR (28) (A/T) DATA LINK
SWITCH (29)
(26) SUBFUEL A(27)
SRS UNITPUMP(19)(A/T) FUEL INDICATOR 4P CONNECTOR
CONNECTOR (20)* (30)AUXILIARY
SWITCH (21) (31) SWITCH (22) SWITCH
(10) UNIT 9 (12) UNDER-DASH (M/T) (32)
(11) FUSE HOLDER
(13) 3
4
NOTE: 5
· Connector with male terminals (double outline): view from terminal side 15A
· Connector with female terminals (single outline): view from wire side
*: Connector with female terminals (single outline): view from terminal side
NOTE: 6
· Connector with male terminals (double outline): view from terminal side 7
· Connector with female terminals (single outline): view from wire side
*: Connector with female terminals (single outline): view from terminal side 8
NOTE: UNDER-DASH FUSE/RELAY BOX
· Connector with male terminals (double outline): view from terminal
UNDER-DASH
side FUSE/RELAY BOX
· Connector with female terminals (single outline): view from wire side
*: Connector with female terminals (single outline): view from terminal side
Fuel and Emissions Systems Circuit Diagram
ECM/PCM Circuit Diagram
24P JUNCTION
ECM/PCM Circuit Diagram (cont'd) CONNECTOR*1
(12P JUNCTION
CONNECTOR*2)E F
C19 2
BLK/RED
SINJ 7
B31 3 1
RED/GRN 3 2 1 4 5 6 7 YEL YEL/BLK
VG+ 13 K 4 1 MAF
YEL/BLK YEL/BLK SUBFUEL
SENSOR
ECM/PCM Circuit Diagram (cont'd)
B33
C5
13P CONNECTOR 13P CONNECTOR
5 2
SOLENOID
BLK/RED 13P 10
BLK/YEL
BRN *3 CONNECTOR BLK/YEL
VG−
INJ1 YEL
12 V 1 No. 1 INJECTOR
*1 9 8
GRN/YEL IAT
YEL BLK/YEL
2 2 JUNCTION
24P SENSOR
B RED/YEL
11 CONNECTOR*1
13P K H BLK/YEL 1
B35 YEL/BLK (12P JUNCTION1
*1
B32 GRN/YEL CONNECTOR
VTS 12 CONNECTOR)*2
ECM/PCM Circuit Diagram (cont'd)RED/YEL
RED
C6
IAT
8P CONNECTOR
BLK/YEL BRN
2 2
INJ2
B28 N
RED/YEL LT O
GRN BLK/YEL
6
WHT
9 No. 2 INJECTORROCKER ARM
ATFT 8 2 OIL CONTROL
A47 6 7 2 7
YEL GRN/YEL
YEL WHTGRN/YEL
B24
C29 YEL 1 1 SOLENOID
SUPP RED/WHT
RED A RED RED/WHT
ATFSHIFTER+
TEMPERATURE
1
ECT1
AFS+ PADDLE
YEL/BLK G101 (UPSHIFTSENSORSWITCH)2
1 RED/YEL ECT SENSOR 1
C7
C30
B11 *1 *2 BLK 21 3
BLU 5 BLK/YEL
B3 RED/YEL GRN
ECM/PCM Circuit Diagram (cont'd) INJ3
AFS−
SHA
BLU/BLK
YEL/BLU YEL/BLU
BLU 2
No. 4 3 INJECTOR
24P JUNCTION CONNECTOR
PCS
A48 7 5 824P JUNCTION CONNECTOR 2 WHT/BLK
SHIFT SOLENOID
C9
B10 LT BLU R O 10 LT BLU LT GRN/ EVAP CANISTER
SDNP GRN
BLK RED PADDLEVALVE SHIFTER− AA/F SENSOR
PURGE VALVE
AFSHTC
PG1 13P CONNECTOR 2 (DOWNSHIFT 1 (SENSOR 1)
B27 14P P
GRN/WHT UNDER-DASH FUSE/RELAY YEL/BLKBOX ORN SWITCH)
CONNECTOR 2 12 1
SHB
B1
C8 PURA BLK BLK
BRN YEL T Q 2
20 19 21 23 24 22 13 15 14 16 18 17
PG2
INJ4 L P G SHIFT1 SOLENOID
AK CABLE REEL BLK/YEL VALVE B4 INJECTOR
3 A9B46
C13
C2 1
(1) No. 3 1
WHT B21 BRN YEL/RED T 13P CONNECTOR YEL/RED
IG1 6 IGPVCC1
B36 GRNWHT/BLU G501 WHT/BLUGRN
YEL PGMETCS
ALTL
SHC
A34 PUR 11 B12 MICU 2 2
YEL WHT/REDGRN/RED 42
*4 IG2 4 A46 LT GRN LT GRN
C11
SHO2S
ECT2 B22 WHT/RED A/F 3
SHIFT11SOLENOID
ORN GRN/RED GRN 3 12P JUNCTION GRN/YELGRN/WHT
1 J YEL
+B ST S-NET5V
MAP
B4 B2 24P JUNCTION
CONNECTOR AD AE AFVALVE AG C AH
24SENSOR AI AJ
PNK A10 PUR CONNECTOR WHT/GRN AB
BLK/WHT RELAY
A22B12
B47
SO2SHTC
C14 YEL B5
8 G101 ECTMAP SENSOR
SENSOR 2
SG6 GRN/RED ORN 17 16 13 15 YEL 3
C44
SUBRLY
SHD WHT/RED GRN/WHT BLK/YEL
IGNITION SWITCH ALTF
SG1 BRN/YEL B6 C D
A7LG1 V
BLU *2 BLU/24P JUNCTION *1 SHIFT SOLENOID ALTERNATOR
B8 CONNECTOR WHT SECONDARY
BLK U 10 BRAKE PEDAL VALVE D HO2S
MRLY
B14
B45 LT GRN 4 5 6 11 12
5V C48 BLU/BLK POSITION24PSWITCH (2)BLU 16
BATTERY C1
ATPP WHT BRN/YEL 4
WHT/GRN
WHT
24P B9
JUNCTION CONNECTOR BRN/YEL JUNCTION
3 CONNECTOR(SENSOR 2)
ALTC
A42
A3
LG2 YEL/BLK
2
10P CONNECTOR K-LINE
(14) IGIETCS
WHT LT GRN WHT B14 LT GRN Brake pedal pressed: closed
BKSW
CANH
B7
B40 RED 7 1 4 Brake 10
1 released:
pedal
*5 C10C31 BLK/ YEL/RED
RED/BLK 3 12 8 9 10 11
LT GRN WHT BLU/WHT 1 WHT 1 PGM-FI open
(15) B15
OPSW
LSA RED GRN WHT CANH MAIN
WHT
IG1CMP WHT 6 B17 22 21 23 24 (6) 5 3 3 6
A4
ATPR 13P YEL BLU/BLK YEL (5) BLK/YEL20 BLK/BLU 19 21 Brake 222 pedal P24RELAY
9 23
pressed: 1 open To
C15
A41 24PRED 3 RED RED pedal OIL PRESSURE
BATTERY A21CANLCONNECTORWHT
BRN B18 4 4 1 2 BLK 7 Brake released: closed
SWITCH
CANL
SPARK
B34 JUNCTION RED Y1 WHT BRN/YELWHT R PLUG
G1 TERMINAL IGPLS1
BKSWNC
ETCSRLY GRN/YEL
CONNECTOR 1 A/TICM
CLUTCH PRESSUREEPS
FUSE BOX LT BLU B31 9 2 2
SG2
B13
A44 N 2 BRN Y3 RED/BLK BRN RED/BLK CONTROL CMP SOLENOID
N
SENSOR VALVE
CONTROL A
RED BRN/YEL B GRN/ G101 GRN/ GRN/
B48 PNK B24 ELD3 8 1 IGNITION
No. 1 COIL UNIT YEL
ATPN
WEN BRN/WHT GRY PNK PNK YEL YEL D PGM-FI
A16LSB
A26 BLK B33 Y2 GRN/ 1 GRN/ MAIN
ORN
13P CONNECTOR YEL 2 128 11 BRN
IMOFPR 3 14P 1 YEL 3 2 D 3 *5YEL 2
RELAY A
VCC4
A33 G501 10 YEL/BLK RED YEL BLU 3 BLK
B22
A18 GRN BLK/YEL CONNECTOR GRN (S)*4
3
3 To
A1C16 B25 T1 (7) SPARK
FPR2
C32
ATPD
APSA WHT/GRN BRN WHT 2
(12) 1 ORN
3
A/T CLUTCH PRESSURE 4 PLUG
VBSOL
IGPLS2 BLU WHT
CONTROL
FICM G SOLENOID 2 H VALVE I B
BLU L M 2 E 7 (3)
A36
CKP
B26 W1 BRN 1 2 1
*1 B23 RED BLU YEL 1
LSC
SG4
BLU/YEL
WHT YEL
(8) 1 29 No.
B16 2 9 2 IGNITION COIL 2
A25 U B27 S1 BRN/YEL BLU BRN BRN RED WHT 2 4
12P JUNCTIONATPD3*5 BLU ORN GRY IGNITION B
CONNECTOR C12 B28
6 10BLK 5 2
VCC5
(ATPS)*4 BLU/YEL 13P
3P CONNECTOR RED
YEL/RED
3 CKP SENSOR *1COIL SUBFUEL
A19 BLU WHT X3 CONNECTORBLK/YEL
10 A/T1 CLUTCH (13)
6PRESSURE
RELAYPUMP RELAY To
VCC3
C17 PNK B21 13 7 1 11 BLU 1
B17
APSB WHT/BLK YEL YEL WHT/RED
RED LT CONTROL SOLENOID 1 VALVE CSPARK
Z A24
IGPLS3 K7 1 WHT
10 A PLUGB
C20
A35 1 4 2 8 ICM 312P
ATP2-1 PNKRED/BLK ORN I BLK BRN
BLKRED 5
6 4 A32
ELD
TPSA
12 11
24P 5 Q1 G101 WHT
4
(4)
JUNCTION 2
C46
SG5 JUNCTION YEL 1 YEL1 CONNECTOR
SCS 14P
RED/BLU
CONNECTOR 3 Q2 WHT
RED/BLU No. 3 IGNITION APPCOIL
TRANSMISSION SENSOR A/B
PNK C21
B19
KS 3 2 CONNECTOR BLU BRN/YEL UNDER-DASH 1 RANGE AUXILIARY
SWITCH
*6 B29 YEL/BLU
RED YEL/BLU 3 UNDER-DASH
Q8 (9) FUSE/RELAY
AK BOX WHT 6
VCC2
TPSB LT BLU ETCSHOLDER (15 A)
ATPFWD CONNECTOR 3
4PBLK/YEL 4 KNOCK5 SENSOR
FUSE
CONTROL To
B18
C18 11J G101 WHT1 2 2ND SPARK
C43
12P WHT/RED
WHT/BLU 1 2 CLUTCH RELAY
A43
NM A25 YEL 1 YEL 5 THROTTLE PLUG
JUNCTION GRN
IGPLS4 PUR BLU 13P CONNECTOR WHT2 ICMTRANSMISSION
Clutch pedal pressed: FLUID
open
SG3
B23
CRMTCLS
CONNECTOR ClutchPRESSURE ACTUATOR
SWITCH
2 P
*1: A/T G101 (10) BLK BRN2 2 2 3 4pedal released: closed
X S BLK
ATPRVS *1: A/T ORN BLK GRN/YEL
WHT
C4 *2:YEL/RED
M/T 1 P THROTTLE BODY
A15 *2: M/T BLK/ BLU/RED No. 4 IGNITION COIL 4
PNK YEL 3 4 CLUTCH PEDAL INPUT SHAFT SUBFUEL PUMP
ETCSM+
ACC N1 (11) POSITION SWITCH (MAINSHAFT)
B8 PNK AC SPEEDSTARTER SENSOR
BLK
G302 LT BLU CUT
*1 A29
OP2SW 8 G502 8 13P 2 3RD CLUTCH RELAY
C3 CONNECTOR FUEL PUMP
TRANSMISSION
TEST TACHOMETER FLUID
A6 LT BLU
NEP YEL 13P 12P PRESSURE
BLUCONNECTOR SWITCH
ETCSM− GRN JUNCTION D 10 C
FANC
B9 CONNECTOR 10
8 7
CONNECTOR BRN 1
M A28 4 7 BLU/WHT 3
K-LINE
W
OP3SW PNK LT BLU PNK G502
SLS GRY 7 1 1 1
BLU *1
G101 YEL/REDLT BLU WHT
14P
K-LINE CANH
12P JUNCTION CONNECTOR
FUSES: B38 CONNECTOR 2 SHIFT LOCK
BLK/WHT 9 17SOLENOID
A30 YEL
UNDER-DASH FUSE/RELAY BOX: NC*1: A/TBLU Y
RED
To AUDIOCANL UNIT
(1)No. 26 A/F SENSOR5(10 A)13P VSSOUT
*2: M/T Q WHT
6
3
CONNECTOR CANH AD AE AF AG GRN/WHT
AH AJ ABS
(2)No.
BARO 39 IGP (15 A) *3: With cruise control R
AI
MODULATOR-
SENSOR
(3)No. 33 IGNITION COIL (15 A)*1:
A38 A/T 14 5 PUR OUTPUT 1 SHAFT CONTROL UNIT
RED ORN
RED DATA LINK ORN
(Built into
(4)No. 52 ETCS (15 A) *1:*6:
TAC M/T
A/T (with cruise CANL 3 CONNECTOR
A/C
(COUNTERSHAFT)
2
the ECM/PCM) 4S COMPRESSOR
(5)No. 20 FUEL PUMP (15 A) *4:control)
*1:A/T
A/T(with paddle shifter model) YEL YEL SPEED SENSOR
CLUTCH RELAY
12
(6)No. 12 ALTERNATOR (105 *5:
14PA/T (without paddle shifter
A) RED 13P CONNECTOR PNK 3 EVAPORATOR
CONNECTOR 16 TEMPERATURE
(10 A) *3: With cruise control
(7)No. 7 MISSION SOLENOIDmodel) PNK
SENSOR
(8)No. 24 STOP, HORN (15 A) BRN
5
A/C
(9)No. 22 METER (7.5 A) 4 CONDENSER
4
(10)No. 10 A/C (7.5 A) BLK FAN RELAY
(11)No. 1 BACK UP (7.5 A) 3
GRN
(12)No. 60 IG SW (50 A) V W X Y
(13)No. 44 STARTER (7.5 A)
AA G502
12P JUNCTION *1: A/T 18
RADIATOR
BATTERY TERMINAL FUSE BOX:
CONNECTOR AB AA AC Z 4 FAN RELAY
K-LINE
(14)20 A
(15)100 A 4 3 17
BLU GRN
3 CANH
*1:1A/T 16
BLU
AUXILIARY CANL
30 UNDER-HOOD RELAY BOX SRS UNIT
WHT
CANH
GAUGE CONTROL
29 MODULE
RED
CANL
Engine will not start (MIL works OK, no DTCs set)
Diagnostic procedure
1. Test the battery.
2. Test the starter.
3. Check the fuel pressure.
4. Troubleshoot the fuel pump circuit.
Also check for
Low compression
No ignition spark
Intake vacuum leaks
Locked up engine
Broken cam chain
Fuel contamination
Engine will not start (MIL comes on and stays on, no DTCs set)
Diagnostic procedure
1. Troubleshoot the DLC circuit.
Also check for
Low compression
No ignition spark
Intake vacuum leaks
Locked up engine
Broken cam chain
Fuel contamination
No power to ECM/PCM
No ground to ECM/PCM
Shorted reference voltage
MIL comes on and stays on, or never comes on at all, no DTCs set
Diagnostic procedure
1. Troubleshoot the MIL circuit.
Engine will not start (MIL works OK, no DTCs set, immobilizer indicator stays on or flashes)
Diagnostic procedure
1. Check the immobilizer system.
Engine starts but stalls immediately (MIL works OK, no DTCs set, immobilizer indicator stays on or flashes)
Diagnostic procedure
1. Check the immobilizer system.
Also check for
Camshaft timing
Low compression
Intake vacuum leaks
Fuel contamination
Weak spark
Engine is hard start (MIL works OK, no DTCs set)
Diagnostic procedure
1. Test the battery.
2. Check the fuel pressure.
3. Test the throttle body.
Also check for
Low compression
Intake air leaks
Fuel contamination
Weak spark
Engine is hard to start (engine coolant temperature below 20 °C (68 °F) and/or fuel grade (alcohol contained level)
above 61 %)
Diagnostic procedure
1. Troubleshoot the subfuel pump circuit.
2. Test the subfuel pressure.
3. Test the subfuel solenoid.
Cold fast idle too low (MIL works OK, no DTCs set)
Diagnostic procedure
1. Do the ECM/PCM idle learn procedure.
2. Check the idle speed.
3. Throttle body cleaning.
Also check for
Incorrect valve adjustment
Cold fast idle too high (MIL works OK, no DTCs set)
Diagnostic procedure
1. Do the ECM/PCM idle learn procedure.
2. Check the idle speed.
3. Test the throttle body.
Also check for
Incorrect valve adjustment
After warming up, idle speed is below specifications without load (MIL works OK, no DTCs set)
Diagnostic procedure
1. Troubleshoot the alternator FR signal circuit.
2. Test the throttle body.
Also check for
Intake vacuum leaks
Incorrect valve adjustment
After warming up, idle speed is above specifications without load (MIL works OK, no DTCs set)
Diagnostic procedure
1. Troubleshoot the alternator FR signal circuit.
2. Inspect the APP sensor.
Also check for
Intake vacuum leaks
Idle speed fluctuates (MIL works OK, no DTCs set)
Diagnostic procedure
1. Do the ECM/PCM idle learn procedure.
2. Test the fuel pressure.
3. Test the injectors.
4. Troubleshoot the alternator FR signal circuit.
5. Inspect the PCV valve.
6. Test the throttle body.
7. Troubleshoot the A/C signal circuit.
8. Troubleshoot the VTEC system oil pressure.
Also check for
Fuel contamination
Intake vacuum leaks
Misfire or rough running (MIL works OK, no DTCs set)
Diagnostic procedure
1. Check the spark plugs.
2. Test the fuel pressure.
3. Test the injectors.
4. Troubleshoot the fuel pump circuit.
5. Troubleshoot the VTEC system oil pressure.
Also check for
Low compression
Valve clearance
Fuel contamination
Fails emission test (MIL works OK, no DTCs set)
Diagnostic procedure
1. Inspect the three way catalytic converter (TWC).
2. Check the spark plugs.
3. Test the fuel pressure.
4. Test the injectors.
5. Check the EVAP system.
6. Troubleshoot the VTEC system oil pressure.
Also check for
Fuel contamination
Low compression
Broken cam chain
Low power (MIL works OK, no DTCs set)
Diagnostic procedure
1. Test the fuel pressure.
2. Check the air cleaner element.
3. Test the throttle body.
4. Inspect the three way catalytic converter (TWC).
5. Test the injectors.
6. Troubleshoot the VTEC system oil pressure.
Also check for
Fuel contamination
Low compression
Camshaft timing
Engine oil level
Engine stalls (MIL works OK, no DTCs set)
Diagnostic procedure
1. Do the ECM/PCM idle learn procedure.
2. Test the fuel pressure.
3. Check the idle speed.
4. Troubleshoot the brake pedal position switch signal circuit.
5. Check the spark plugs.
6. Troubleshoot the VTEC system oil pressure.
Also check for
Intake vacuum leaks
Faulty harness and sensor connections
Fuel contamination
Difficult to refuel
Diagnostic procedure
1. Inspect the breather line and the suction line.
HDS does not communicate with the ECM/PCM or the vehicle
Diagnostic procedure
1. Troubleshoot the DLC circuit.
Low subfuel indicator does not come on
Diagnostic procedure
1. Troubleshoot the low fuel indicator unit circuit.
Low subfuel indicator stays on
Diagnostic procedure
1. Troubleshoot the low fuel indicator unit circuit.
Fuel and Emissions Systems Symptom Troubleshooting Index
When the vehicle has one of these symptoms, check for a diagnostic trouble code (DTC) with the HDS. If there is no DTC, do the diagnostic procedure
for the symptom, in the sequence listed, until you find the cause.
Symptom Diagnostic procedure Also check for
Engine will not start (MIL works OK, no 1.Test the battery. Low compression
DTCs set) 2.Test the starter. No ignition spark
3.Check the fuel pressure. Intake vacuum leaks
4.Troubleshoot the fuel pump circuit. Locked up engine
Broken cam chain
Fuel contamination
Engine will not start (MIL comes on and Troubleshoot the DLC circuit. Low compression
stays on, no DTCs set) No ignition spark
Intake vacuum leaks
Locked up engine
Broken cam chain
Fuel contamination
No power to ECM/PCM
No ground to ECM/PCM
Shorted reference voltage
MIL comes on and stays on, or never Troubleshoot the MIL circuit.
comes on at all, no DTCs set
Engine will not start (MIL works OK, no Check the immobilizer system.
DTCs set, immobilizer indicator stays
on or flashes)
Engine starts but stalls immediately Check the immobilizer system. Camshaft timing
(MIL works OK, no DTCs set, Low compression
immobilizer indicator stays on or Intake vacuum leaks
flashes) Fuel contamination
Weak spark
Engine is hard start (MIL works OK, no 1.Test the battery. Low compression
DTCs set) 2.Check the fuel pressure. Intake air leaks
3.Test the throttle body. Fuel contamination
Weak spark
Engine is hard to start (engine coolant 1.Troubleshoot the subfuel pump circuit.
temperature below 20 °C (68 °F) and/or 2.Test the subfuel pressure.
fuel grade (alcohol contained level) 3.Test the subfuel solenoid.
above 61 %)
Cold fast idle too low (MIL works OK, 1.Do the ECM/PCM idle learn procedure. Incorrect valve adjustment
no DTCs set) 2.Check the idle speed.
3.Throttle body cleaning.
Cold fast idle too high (MIL works OK, 1.Do the ECM/PCM idle learn procedure. Incorrect valve adjustment
no DTCs set) 2.Check the idle speed.
3.Test the throttle body.
After warming up, idle speed is below 1.Troubleshoot the alternator FR signal circuit. Intake vacuum leaks
specifications without load (MIL works 2.Test the throttle body. Incorrect valve adjustment
OK, no DTCs set)
After warming up, idle speed is above 1.Troubleshoot the alternator FR signal circuit. Intake vacuum leaks
specifications without load (MIL works 2.Inspect the APP sensor.
OK, no DTCs set)
Idle speed fluctuates (MIL works OK, no 1.Do the ECM/PCM idle learn procedure. Fuel contamination
DTCs set) 2.Test the fuel pressure. Intake vacuum leaks
3.Test the injectors.
4.Troubleshoot the alternator FR signal circuit.
5.Inspect the PCV valve.
6.Test the throttle body.
7.Troubleshoot the A/C signal circuit.
8.Troubleshoot the VTEC system oil pressure.
Misfire or rough running (MIL works OK, 1.Check the spark plugs. Low compression
no DTCs set) 2.Test the fuel pressure. Valve clearance
3.Test the injectors. Fuel contamination
4.Troubleshoot the fuel pump circuit.
5.Troubleshoot the VTEC system oil pressure.
Fails emission test (MIL works OK, no 1.Inspect the three way catalytic converter (TWC). Fuel contamination
DTCs set) 2.Check the spark plugs. Low compression
3.Test the fuel pressure. Broken cam chain
4.Test the injectors.
5.Check the EVAP system.
6.Troubleshoot the VTEC system oil pressure.
Symptom Diagnostic procedure Also check for
Low power (MIL works OK, no DTCs 1.Test the fuel pressure. Fuel contamination
set) 2.Check the air cleaner element. Low compression
3.Test the throttle body. Camshaft timing
4.Inspect the three way catalytic converter (TWC). Engine oil level
5.Test the injectors.
6.Troubleshoot the VTEC system oil pressure.
Engine stalls (MIL works OK, no DTCs 1.Do the ECM/PCM idle learn procedure. Intake vacuum leaks
set) 2.Test the fuel pressure. Faulty harness and sensor
3.Check the idle speed. connections
4.Troubleshoot the brake pedal position switch signal circuit. Fuel contamination
5.Check the spark plugs.
6.Troubleshoot the VTEC system oil pressure.
Difficult to refuel Inspect the breather line and the suction line.
HDS does not communicate with the Troubleshoot the DLC circuit.
ECM/PCM or the vehicle
Low subfuel indicator does not come on Troubleshoot the low fuel indicator unit circuit.
Low subfuel indicator stays on Troubleshoot the low fuel indicator unit circuit.
Fuel and Emissions System Description - Vacuum Lines
Vacuum Hose Routing
Vacuum Distribution
Fuel and Emissions System Description - EVAP Control Diagram
Evaporative Emission (EVAP) Control Diagram
EVAP System Component Location Index
ENGINE CONTROL
MODULE (ECM)/
POWERTRAIN CONTROL
MODULE (PCM)
General Troubleshooting
EVAPORATIVE
EMISSIONInformation,
(EVAP)
CANISTER Substituting,
FILTER
Update,
Replacement,
Replacement,
in the Shop Manual, P/N 62TF000A
EVAPORATIVE
EMISSION (EVAP)
TWO WAY VALVE (MAINFUEL)
Test,
Replacement,
EVAP System Troubleshooting
1. Disconnect the vacuum hose (A) from the EVAP canister purge valve (B) and connect a vacuum pump/gauge (C) to
the hose.
2. Start the engine, and let it idle.
NOTE: Engine coolant temperature must be below 60 °C (140 °F).
Is there vacuum?
YES - Inspect vacuum hose routing. If OK, replace the EVAP canister purge valve.■
NO - Go to Step 3 .
3. Hold the engine speed at 3,000 rpm (min −1 ) without load (A/T in N or P, M/T in neutral) until the radiator fan
comes on, then hold the engine speed to 3,000 rpm (min −1 ).
Is there vacuum?
YES - Go to Step 4 .
NO - Inspect vacuum hose routing. If OK, replace the EVAP canister purge valve. ■
4. Turn the ignition switch to LOCK (0).
5. Reconnect the vacuum hose to the EVAP canister purge valve.
6. Remove the fuel fill cap.
7. Lift the vehicle, and support it with jackstands.
8. Disconnect drain tube (A) from the EVAP canister and connect the combination gauge kit and tube joint adapter to
EVAP canister (B).
9. Lower the vehicle.
10. Start the engine and raise speed to 3,000 rpm (min −1 ).
Does vacuum appear on gauge within 1 minute?
YES - See EVAP two way valve test to complete. Evaporative emission controls are OK.■
NO - Replace the EVAP canister. ■
EVAP Canister Replacement
1. Lift the vehicle, and support it with jackstands.
2. Disconnect the hoses (A) and tube (B).
3. Remove the EVAP canister (C).
4. Install the parts in the reverse order of removal.
NOTE: Align the marks (D) on the hose as shown, then insert the hose. Make sure the clamp is positioned as
shown.
EVAP Two Way Valve Test
Special Tools Required
Combination gauge kit 20/−100 kPa
07YAJ-0010610
5. Move the vacuum pump from the vacuum fitting to the pressure fitting (A) as shown.
6. Slowly pressurize the vapor line while watching the gauge. The valve should open above 5.07 kPa (38 mmHg, 1.5
in.Hg).
If the pressure hold below 5.07 kPa (38 mmHg, 1.5 in.Hg), the valve is OK.
If the pressure doesn't hold, replace the EVAP two way valve.
EVAP Two Way Valve Replacement
MAINFUEL
1. Lift the vehicle, and support with jackstands.
2. Remove the bolt (A).
3. Pull the EVAP two way valve (A) and the hoses (B) out of the frame.
4. Disconnect the hoses (B) from the EVAP two way valve (A).
5. Remove the EVAP two way valve lower stay (A) and EVAP two way valve cover (B).
6. Install the parts in the reverse order of removal.
Subfuel
1. Remove the EVAP two way valve cover (A).
ELECTRONIC THROTTLE
CONTROL SYSTEM (ETCS)
CONTROL RELAY
4. Place a rag or shop towel over the subfuel feed line (A) and (B).
5. Install the parts in the reverse order of removal, with a new O-ring (C).
6. Do the battery terminal reconnection procedure.
7. Turn the ignition switch to ON (II), but do not operate the starter. After the subfuel pump runs for about 2 seconds,
the fuel pressure in the line rises. Repeat this two or three times, then check for fuel leakage.
Fuel and Emissions System Description - Fuel Supply System
Fuel Supply System
Fuel and Emissions System Description - Subfuel Supply System
Subfuel Supply System
Fuel Supply System Component Location Index
SUBFUEL TANK
FUEL LINE/ Draining,
QUICK-CONNECT FITTING Replacement,
Precautions,
Removal, FUEL RAIL
Installation,
FUEL TANK
SUBFUEL PUMP Draining,
Circuit Troubleshooting, Replacement,
PGM-FI MAIN RELAY 1
Replacement, BREATHER LINE and
SUCTION LINE
Inspection,
ENGINE CONTROL
MODULE (ECM)/
POWERTRAIN CONTROL
MODULE (PCM)
General Troubleshooting
Information,
Substituting,
Update,
Replacement,
FUEL PUMP
Circuit Troubleshooting,
Replacement,
FUEL GAUGE SENDING UNIT
FUEL NOZZLE Test,
Replacement, Replacement,
FUEL LINE/
QUICK-CONNECT FITTING
FUEL LINE/ Precautions,
QUICK-CONNECT FITTING Removal,
Precautions, Installation,
Removal,
Installation, FUEL FEED LINE FUEL FILTER
Replacement,
FUEL VAPOR LINE FUEL LINE/
QUICK-CONNECT FITTING
Precautions,
Removal,
Installation,
Fuel Pressure Test
Special Tools Required
Fuel gauge assy. 600 kPa
07406-0040004
4. Read the fuel pressure gauge. The pressure should be 200−250 kPa (2.0−2.5 kgf/cm 2 , 28−36 psi).
If the pressure is OK, the test is complete.
If the pressure is out of specification, replace the subfuel pump, then recheck the subfuel pressure.
Subfuel pressure
Item Measurement Qualification Standard or New
Subfuel pressure Pressure with fuel pressure gauge 200−250 kPa (2.0−2.5 kgf/cm 2 , 28−36 psi)
connected
Fuel Breather Line and Suction Line Inspection
1. Remove the center console.
2. Remove the parking brake lever, then remove the access panel from the floor.
3. Disconnect the fuel vapor hose (A) from the fuel tank unit and let the fuel tank pressure out of a fuel tank.
4. Reconnect the fuel vapor hose (A).
5. Disconnect the suction line (A) from the fuel tank unit, and connect a vacuum pump/gauge, 0−30 in.Hg (B) to the
hose as shown.
6. Start the engine, and check the vacuum.
If there is vacuum, go to Step 7 .
If there is no vacuum, replace the fuel filter.
7. Turn the ignition switch to LOCK (0).
8. Connect a vacuum pump/gauge, 0−30 in.Hg (A) to the suction line (B), and apply vacuum to the line.
If the line holds vacuum, check for blockage in the suction line. If there is blockage, replace the suction line.
If the line does not hold vacuum, go to Step 9 .
9. Lift the vehicle, and support it with jackstands.
11. Disconnect the breather line (A), then plug the suction joint (B) with a rubber cap (C).
12. Connect a vacuum pump/gauge, 0−30 in.Hg (A) to the suction line (B), and apply vacuum to the line.
If the line holds vacuum, check for blockage in the breather line between the fuel tank and the suction joint. If
there is blockage, replace the fuel tank.
If the line does not hold vacuum, go to Step 14 .
13. Lift the vehicle, and support it with jackstands.
14. Connect a vacuum pump/gauge, 0−30 in.Hg (A) to the filler side of the breather line (B), and apply air pressure to
the line.
If the air pressure holds, check for blockage between the suction line and the filler neck on the breather pipe,
and replace the part that is causing the blockage.
If the air pressure does not hold, go to Step 15 .
15. Remove the rubber cap from the suction line, and reconnect the breather pipe to the suction line.
16. Connect a vacuum pump/gauge, 0−30 in.Hg (A) to the suction line (B), and apply pressure to the line.
If the air pressure holds, the breather line and the suction line are OK.
If the air pressure does not hold, check for a vacuum leak in the suction line, and replace the suction line if
necessary.
Fuel Filter Replacement
1. Relieve the fuel pressure.
2. Lift the vehicle, and support it with jackstands.
3. Remove the bolt (A).
4. Disconnect the quick-connect fittings (A).
5. Remove the fuel filter (C), and the fuel filter band (D).
8. Measure the voltage between fuel tank unit 4P connector terminals No. 1 and No. 3 with the ignition switch to ON
(II). There should be battery voltage.
If the voltage is OK, go to Step 9 .
If the voltage is not as specified, check for:
-a short in the LT GRN wire to ground.
-an open in the LT GRN or BLK wire.
9. Turn the ignition switch to LOCK (0).
10. Remove the fuel tank unit from the fuel tank.
11. Measure the resistance between fuel tank unit 4P connector terminals No. 1 and No. 3 with the float at E (EMPTY),
LOW (LOW FUEL INDICATOR), 1/2 (HALF FULL), and F (FULL) positions.
If you do not get the following readings, replace the fuel gauge sending unit.
Float Position F 91.2 mm (3.6 in.) 1/2 46 mm (1.8 in.) LOW 13.7 mm (0.5 E 6 mm (0.2 in.)
in.)
Resistance (Ω) 18.5 to 21.5 203.3 to 213.3 569.1 to 583.1 772 to 788
3. Check the fuel quick-connect fittings (A) for dirt, and clean them if needed.
4. Place a rag or shop towel over the quick-connect fitting. Hold the connector (A) with one hand, and squeeze the
retainer tabs (B) with the other hand to release them from the locking tabs (C). Pull the connector off.
NOTE:
Be careful not to damage the line (D) or other parts. Do not use tools.
If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the
connector until it comes off easily.
Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.
5. Check the contact area (A) of the line (B) for dirt or damage.
If it is dirty, clean the connector with a pressure washer, and dry it with the compressed air.
If it is rusty or damaged, replace the fuel filter, or the fuel feed line.
6. To prevent damage and keep foreign matter out, cover the disconnected connector and line ends with plastic bags
(A).
NOTE: The retainer cannot be reused once it has been removed from the line.
Replace the retainer when:
replacing the fuel rail.
replacing the fuel feed line.
replacing the fuel pump.
replacing the fuel filter.
replacing the fuel gauge sending unit.
replacing the subfuel tank.
replacing the subfuel pump.
it has been removed from the line.
it is damaged.
Fuel Line/Quick-Connect Fitting Installation
NOTE: Before you work on fuel lines and fittings, read the ‘‘Fuel Line/Quick-Connect Fitting Precautions''.
1. Check the contact area (A) of the line (B) for dirt or damage, and clean it if needed.
2. Insert a new retainer (A) into the connector (B) if the retainer is damaged, or after:
replacing the fuel rail.
replacing the fuel feed line.
replacing the fuel pump.
replacing the fuel filter.
replacing the fuel gauge sending unit.
replacing the subfuel tank.
replacing the subfuel pump.
removing the retainer from the line.
Use the same manufacturer retainer and the same size retainer when the replacing the retainer.
3. Before connecting a new fuel tube/quick-connect fitting assembly (A), remove the old retainer (B) from the mating
line.
NOTE:
When replacing the fuel tube/quick-connect fitting assembly at the engine compartment, remove the air
cleaner, and the cover (C).
When installing the fuel tube/quick-connect fitting assembly at the engine compartment, align the mark (D)
on the fuel tube.
4. Align the quick-connect fittings with the line (A), and align the retainer locking tabs (B) with the connector grooves Connection with new
(C). Then press the quick-connect fittings onto the line until both retainer tabs lock with a clicking sound. retainer
NOTE: If it is hard to connect, put a small amount of new engine oil on the line end.
Reconnection to
existing retainer
7. If equipped, install the quick-connect fitting cover. Set the groove of the cover (A) on the fuel line (B) as shown, then
install it. Make sure the cover is firmly locked in place.
Fuel Line Inspection
Fuel Nozzle Replacement
1. Relieve subfuel pressure.
2. Remove the subfuel solenoid.
3. Push the engine wire harness holder lock (A).
4. Remove the engine wire harness holder (B) from the injector pipe, and put it on the injector pipe.
5. Remove the subfuel pipe mounting bolts (C).
6. Pull out the subfuel pipe from the intake manifold, then rotate it forward 180° and pull it out in the direction shown.
NOTE: Do not scratch or damage the surface of the subfuel nozzle.
4. Measure the voltage between PGM-FI main relay 2 4P connector terminal No. 4 and body ground.
Is there battery voltage?
YES - Go to Step 5 .
NO - Replace the under-dash fuse/relay box. ■
Replace the PGM-FI main relay 1 .■
5. Measure the voltage between PGM-FI main relay 2 4P connector terminal No. 2 and body ground.
Is there battery voltage?
YES - Go to Step 6
NO - Check the No. 20 FUEL PUMP (15 A) fuse in the under-dash fuse/relay box.■
If the fuse is OK, replace the under-dash fuse/relay box. ■
7. Connect PGM-FI main relay 2 4P connector terminal No. 3 to body ground with a jumper wire.
8. Jump the SCS line with the HDS.
9. Disconnect ECM/PCM connector A (49P).
10. Check for continuity between body ground and ECM/PCM connector terminal A16.
Is there continuity?
YES - Go to Step 11 .
NO - Repair open in the wire between PGM-FI main relay 2 and the ECM/PCM (A16).■
11. Reinstall PGM-FI main relay 2.
12. Connect ECM/PCM connector terminal A7 to body ground with a jumper wire.
13. Turn the ignition switch to ON (II).
14. Measure the voltage between ECM/PCM connector terminal A16 and body ground.
Is there battery voltage?
YES - Go to Step 15 .
NO - Repair open in the wire between the under-dash fuse/relay box and the ECM/PCM (A7, A16).■
Replace PGM-FI main relay 2. ■
17. Turn the ignition switch to ON (II), and measure the voltage between under-dash fuse/relay box connector B (36P)
terminal No. 31 and body ground within 2 seconds.
Is there battery voltage?
YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original
ECM/PCM. ■
NO - Go to Step 18 .
18. Turn the ignition switch to ON (II), and measure the voltage between under-dash fuse/relay box connector B (36P)
terminal No. 31 and body ground after 2 seconds.
Is there battery voltage?
YES - Go to Step 19 .
NO - If needed, replace the under-dash fuse/relay box, then go to Step 19 .
19. Turn the ignition switch to LOCK (0).
20. Remove the center console.
21. Remove the parking brake lever, then remove the access panel from the floor.
22. Turn the ignition switch to ON (II), and measure the voltage between fuel tank unit 4P connector terminal No. 2 and
body ground within 2 seconds.
Is there battery voltage?
YES - Go to Step 27 .
NO - Go to Step 23 .
23. Turn the ignition switch to LOCK (0).
24. Remove PGM-FI main relay 2.
25. Connect PGM-FI main relay 2 4P connector terminals No. 1 and No. 2 with a jumper wire.
26. Turn the ignition switch to ON (II), and measure the voltage between fuel tank unit 4P connector terminal No. 2 and
body ground.
Is there battery voltage?
YES - Replace PGM-FI main relay 2 .■
NO - Repair open in the wire between PGM-FI main relay 2 and the fuel tank unit 4P connector.■
27. Turn the ignition switch to LOCK (0).
28. Check for continuity between fuel tank unit 4P connector terminal No. 4 and body ground.
Is there continuity?
YES - Replace the fuel pump. ■
NO - Repair open in the wire between the fuel tank unit 4P connector and G502. ■
Fuel Tank Draining
1. Remove the fuel tank unit.
2. Using a hand pump, a hose, and a container suitable for fuel, draw the fuel from the fuel tank.
3. Reinstall the fuel tank unit.
Fuel Tank Replacement
1. Drain the fuel tank, then disconnect the fuel tank unit 4P connector (A), the fuel vapor hose (B),
and the quick-connect fittings (C).
2. Lift the vehicle, and support it with jackstands.
3. Remove the fill neck tube cover (D), then disconnect the fuel fill tube (E) and the suction hose
(F). Slide back the clamps, then twist the hoses as you pull to avoid damaging them.
4. Remove the fuel tank guard bracket (G) and the fuel tank protector (H).
5. Place a jack or other support under the tank (I).
6. Remove the strap bolts and the straps (J).
7. Remove the fuel tank.
8. Install the parts in the reverse order of removal.
Fuel tank
Item Measurement Qualification Standard or New
Fuel tank Capacity 42 L (11.0 US gal, 9.2 Imp gal)
Fuel Tank Unit Removal and Installation
Special Tools Required
Fuel sender wrench
07AAA-S0XA100
Removal
1. Relieve the fuel pressure.
2. Remove the center console.
3. Remove the bolts (A), the wire harness (B), the remove the parking brake lever (C).
8. Remove the locknut (A) and the fuel tank unit (B).
Installation
1. Temporarily attach a new base gasket (A) to the fuel tank unit (B), then insert the fuel tank unit partially into the
fuel tank.
NOTE:
Be careful not to damage the new base gasket.
Be careful not to bend the fuel gauge sending unit.
Do not coat the base gasket with oil.
2. Transfer the base gasket (A) from the fuel tank unit to the fuel tank.
3. Align the marks (B) on the fuel tank and fuel tank unit, then insert the fuel tank unit into the fuel tank until the fuel
tank unit rests on top of the base gasket.
NOTE: To avoid a fuel leak, check the base gasket, visually or by hand, to make sure it is not pinched.
4. Using the special tool, tighten a new locknut (A) to the specified torque.
NOTE:
After tightening, make sure the marks are still aligned.
After installation, check the base gasket, visually or by hand, to make sure it is not pinched.
5. Connect the fuel tank unit 4P connector, then connect the quick-connect fitting, the suction hose, and the fuel
vapor hose.
6. Reconnect the negative cable to the battery, and turn the ignition switch to ON (II) (but do not operate the starter
motor). The fuel pump will run for about 2 seconds, and fuel pressure rises. Repeat this two or three times, then
check that there is no leakage in the fuel supply system.
7. Install the access panel, the parking brake lever, and the center console.
Subfuel Pump Replacement
Special Tools Required
Fuel sender wrench, clysler fuel pump module wrench
No. 7998
6. Connect subfuel pump relay 4P connector terminal No. 3 to body ground with a jumper wire.
7. Jump the SCS line with the HDS.
8. Disconnect ECM/PCM connector A (49P).
9. Check for continuity between ECM/PCM connector terminal A33 and body ground.
Is there continuity?
YES - Go to Step 10 .
NO - Repair open in the wire between the subfuel pump relay and the ECM/PCM (A33).■
10. Test the subfuel pump relay.
Is the subfuel pump relay OK?
YES - Go to Step 11 .
NO - Replace the subfuel pump relay .■
11. Reinstall the subfuel pump relay.
12. Reconnect ECM/PCM connector A (49P).
13. Turn the ignition switch to ON (II), and measure the voltage between subfuel pump relay 4P connector terminal No.
1 and body ground within 2 seconds.
Is there battery voltage?
YES - Go to Step 14 .
NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original
ECM/PCM. ■
14. Turn the ignition switch to LOCK (0).
15. Remove the glove box.
16. Disconnect the fuel subharness 4P connector (A) from the dashboard wire harness.
17. Turn the ignition switch to ON (II), and measure the voltage between dashboad wire harness 4P connector terminals
No. 1 and No. 2 within 2 seconds.
Is there battery voltage?
YES - Go to Step 20 .
NO - Go to Step 18 .
18. Turn the ignition switch to LOCK (0).
19. Check for continuity between body ground and dashboad wire harness 4P connector terminal No. 2.
Is there continuity?
YES - Repair open in the wire between the subfuel pump relay and the fuel subharness 4P connector.■
NO - Repair open in the wire between the fuel subharness 4P connector and G502. ■
20. Remove the right front fender.
21. Disconnect the subfuel pump 4P connector.
22. Connect subfuel pump 4P connector terminal No. 2 to body ground with a jumper wire.
23. Check for continuity between body ground and fuel subharness 4P connector terminal No. 1.
Is there continuity?
YES - Go to Step 24 .
NO - Repair open in the wire between the subfuel pump and the fuel subharness 4P connector.■
24. Connect subfuel pump 4P connector terminal No. 4 to body ground with a jumper wire.
25. Check for continuity between body ground and fuel subharness 4P connector terminal No. 2.
Is there continuity?
YES - Replace the subfuel pump. ■
NO - Repair open in the wire between the subfuel pump and the fuel subharness 4P connector.■
Subfuel Tank Draining
1. Remove the subfuel fill cap.
2. Using a hand pump, a hose, and a container suitable for fuel, draw the fuel from the subfuel tank.
Subfuel Tank Replacement
1. Relieve the subfuel pressure.
2. Remove the front bumper.
3. Remove the right headlight.
4. Remove the front pillar corner trim.
5. Remove the right side front inner fender clips.
6. Remove the right front fender.
7. Disconnect the subfuel feed pump 4P connector (A).
8. Remove the bolt (B) from the subfuel pump subharness holder (C).
9. Remove the bolt (D) and nut (E) from the fuel subtank (F).
10. Remove the subfuel feed pipe protector (A) and (B).
10. Measure the voltage between fuel indicator unit 5P connector terminal No. 1 and body ground.
Is there battery voltage?
YES - Go to Step 11 .
NO - Repair open in the wire between the fuel indicator unit and the No. 22 METER (7.5 A) fuse in the under-
dash fuse/relay box.■
11. Measure the voltage between fuel indicator unit 5P connector terminals No. 1 and No. 5.
Is there battery voltage?
YES - Replace the fuel indicator unit .■
NO - Repair open in the wire between the fuel indicator unit and G502. ■
12. Turn the ignition switch to LOCK (0).
13. Remove the gauge control module.
14. Connect gauge control module 32P connector terminal No. 15 to body ground with a jumper wire.
15. Turn the ignition switch to ON (II).
16. Check the subfuel tank low fuel indicator.
Is the subfuel tank low fuel indicator indicated?
YES - Repair open in the wire between the fuel indicator unit and the gauge control module.■
NO - Replace the original gauge control module. ■
8. Measure the voltage between dashboard wire harness 4P connector terminal No. 4 and body ground.
Is there battery voltage?
YES - Go to Step 9 .
NO - Repair open in the wire between the fuel indicator unit (sensor out line) and the fuel subharness.■
9. Measure the voltage between dashboard wire harness 4P connector terminals No. 3 and No. 4.
Is there battery voltage?
YES - Go to Step 10 .
NO - Repair open in the wire between the fuel indicator unit (sensor in line) and the fuel subharness.■
10. Turn the ignition switch to LOCK (0).
11. Reconnect the fuel subharness 4P connector to the dashboard wire harness.
12. Remove the right front fender.
13. Disconnect the subfuel pump 4P connector.
14. Turn the ignition switch to ON (II).
15. Measure the voltage between subfuel pump 4P connector terminal No. 3 and body ground.
Is there battery voltage?
YES - Go to Step 16 .
NO - Repair open in the wire between the dashboard wire harness (sensor out line) and the subfuel pump.■
16. Measure the voltage between subfuel pump 4P connector terminals No. 1 and No. 3.
Is there battery voltage?
YES - Replace the subfuel pump. ■
NO - Repair open in the wire between the fuel subharness (sensor in line) and the subfuel pump.■
17. Turn the ignition switch to LOCK (0).
18. Disconnect the fuel indicator unit 5P connector.
19. Turn the ignition switch to ON (II), and watch the subfuel tank low fuel indicator.
Does the subfuel tank low fuel indicator stay on for more than 2 seconds after turning the ignition switch to ON
(II)?
YES - Repair short in the wire between the fuel indicator unit and the gauge control module.■
NO - Go to Step 20 .
20. Turn the ignition switch to LOCK (0).
21. Remove the glove box.
22. Disconnect the fuel subharness 4P connector (A) from the dashboard wire harness.
23. Check for continuity between dashboard wire harness 4P connector terminal No. 4 and body ground.
Is there continuity?
YES - Repair short in the wire between the fuel indicator unit (sensor out line) and the fuel subharness.■
NO - Go to Step 24 .
24. Remove the right front fender.
25. Disconnect the subfuel pump 4P connector.
26. Check for continuity between subfuel pump 4P connector terminal No. 3 and body ground.
Is there continuity?
YES - Repair short in the wire between the dashboard wire harness (sensor out line) and the subfuel pump.■
NO - Replace the fuel indicator unit .■
PGM-FI System Component Location Index
MAINFOLD ABSOLUTE
PRESSURE (MAP) SENSOR
Replacement,
PGM-FI MAIN RELAY 1 in the Shop Manual, P/N 62TF000A
CAMSHAFT POSITION (CMP) SENSOR
Replacement,
in the Shop Manual, P/N 62TF000A
IGNITION COIL RELAY
ENGINE COOLANT
TEMPERATURE (ECT)
SENSOR 1
Replacement,
in the Shop Manual, P/N 62TF000A
IGNITION COILS
A/F SENSOR RELAY
MASS AIR FLOW (MAF)
SENSOR/
INTAKE AIR TEMPERATURE
(IAT) SENSOR
Replacement,
in the Shop Manual,
P/N 62TF000A
SECONDARY HEATED OXYGEN
SENSORENGINE CONTROL
MODULE
(SECONDARY (ECM)/
HO2S) (SENSOR 2)
POWERTRAIN CONTROL
Replacement,
MODULE
in the Shop (PCM)
Manual, P/N 62TF000A
AIR FUEL RATIO (A/F) General Troubleshooting
SENSOR (SENSOR 1) Information,
Replacement, Substituting,
in the Shop Manual, P/N 62TF000A Update,
Replacement,
19. Connect DLC terminal No. 7 to body ground with a jumper wire.
20. Check for continuity between body ground and these connector terminals:
Connector Terminal
SRS unit A (39P) No. 18 (BLU)
ABS control unit 25P No. 10 (BLU)
EPS control unit C (16P) No. 16 (BLU)
Immobilizer-keyless control unit 7P No. 5 (BLU)
Audio unit 24P No. 3 (BLU)
Under-dash fuse/relay box Q (16P) No. 2 (BLU)
Is there continuity between the DLC terminal and each of the terminals in the chart?
YES - Replace the part that does not communicate with the HDS.■
NO - Repair open in the wire between the DLC (K-line) and the appropriate connector.■
21. Check for B-CAN system DTCs without the HDS.
Is DTC U0029 and/or U0100 indicated?
YES - Go to Step 34 .
NO - Go to Step 22 .
22. Turn the ignition switch to LOCK (0).
23. Disconnect the HDS from the DLC.
24. Measure the voltage between DLC terminal No. 16 and body ground.
Is there battery voltage?
YES - Go to Step 25 .
NO - Repair open in the wire between DLC terminal No. 16 and the No. 1 BACK UP (7.5 A) fuse in the under-
dash fuse/relay box.■
25. Measure the voltage between DLC terminals No. 4 and No. 16.
Is there battery voltage?
YES - Go to Step 26 .
NO - Repair open in the wire between DLC terminal No. 4 and body ground (G502).■
26. Connect the HDS to the DLC.
27. Jump the SCS line with the HDS.
28. Disconnect ECM/PCM connector A (49P).
29. Disconnect the HDS from the DLC.
30. Connect DLC terminal No. 6 to body ground with a jumper wire.
31. Check for continuity between ECM/PCM connector terminal A3 and body ground.
Is there continuity?
YES - Go to Step 32 .
NO - Repair open in the wire between the ECM/PCM (A3) and DLC terminal No. 6.■
32. Connect DLC terminal No. 14 to body ground with a jumper wire.
33. Check for continuity between ECM/PCM connector terminal A4 and body ground.
Is there continuity?
YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original
ECM/PCM. ■
NO - Repair open in the wire between the ECM/PCM (A4) and DLC terminal No. 14.■
34. Try to start the engine.
Does the engine start and idle smoothly?
YES - Go to F-CAN circuit troubleshooting. ■
NO - Go to Step 35 .
35. Turn the ignition switch to LOCK (0).
36. Check the No. 60 IGSW (50 A) fuse in the under-dash fuse/relay box.
Is the fuse OK?
YES - Repair open in the wire the No. 60 IGSW (50 A) fuse and the ignition switch. If the wire is OK go to Step
37 .
NO - Repair short in the wire the No. 60 IGSW (50 A) fuse and the under-dash fuse/relay box. Also replace the
No. 60 IGSW (50 A) fuse.■
37. Inspect the No. 39 IGP (15 A) fuse in the under-dash fuse/relay box.
Is the fuse OK?
YES - Go to Step 44 .
NO - Go to Step 38 .
38. Remove the blown No. 39 IGP (15 A) fuse from the under-dash fuse/relay box.
39. Open the fuse lid (A), then remove the PGM-FI main relay 1 (B) from the under-dash fuse/relay box.
40. Check for continuity between body ground and PGM-FI main relay 1 4P connector terminals No. 2 and No. 3
individually.
Is there continuity?
YES - Replace the under-dash fuse/relay box. ■
NO - Go to Step 41 .
41. While disconnecting each of the parts or connectors below, one at a time, check for continuity between PGM-FI
main relay 1 4P connector terminal No. 1 and body ground.
PGM-FI main relay 2
ECM/PCM connector A (49P)
Each injector 2P connector
Camshaft position (CMP) sensor 3P connector
Crankshaft position (CKP) sensor 3P connector
Electronic throttle control system (ETCS) control relay
Does continuity go away when one of the above components is disconnected?
YES - Replace the part that made the short to body ground go away when disconnected. If the part is the
ECM/PCM, update the ECM/PCM if it does not have the latest software, or substitute a known-good
ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace
the original ECM/PCM. Also replace the No. 39 IGP (15 A) fuse.■
NO - Go to Step 42 .
42. Disconnect these parts or connectors:
PGM-FI main relay 2
ECM/PCM connector A
Injectors
Camshaft position (CMP) sensor
Crankshaft position (CKP) sensor
Electronic throttle control system (ETCS) control relay
43. Check for continuity between PGM-FI main relay 1 4P connector terminal No. 1 and body ground.
Is there continuity?
YES - Repair short in the wire between PGM-FI main relay 1 and each item. Also replace the No. 39 IGP (15 A)
fuse.■
NO - Replace PGM-FI main relay 1. Also replace the No. 39 IGP (15 A) fuse.■
44. Inspect the No. 20 FUEL PUMP (15 A) fuse in the under-dash fuse/relay box.
Is the fuse OK?
YES - Go to Step 54 .
NO - Go to Step 45 .
45. Remove the blown No. 20 FUEL PUMP (15 A) fuse from the under-dash fuse/relay box.
46. Open the fuse lid (A), then remove the PGM-FI main relay 2 (B) from the under-dash fuse/relay box.
47. Test PGM-FI main relay 2.
Is the fuse OK?
YES - Go to Step 48 .
NO - Replace PGM-FI main relay 2. Also replace the No. 20 FUEL PUMP (15 A) fuse.■
48. Check for continuity between PGM-FI main relay 2 4P connector terminal No. 2 and body ground.
Is there continuity?
YES - Go to Step 49 .
NO - Go to Step 52 .
49. Jump the SCS line with the HDS.
50. Disconnect ECM/PCM connector C (49P).
51. Check for continuity between ECM/PCM connector terminal C10 and body ground.
Is there continuity?
YES - Repair short in the wire between the No. 20 FUEL PUMP (15 A) fuse and the ECM/PCM (C10), or PGM-
FI main relay 2. Also replace the No. 20 FUEL PUMP (15 A) fuse.■
NO - Go to Step 52 .
52. Disconnect the fuel pump 4P connector.
53. Check for continuity between fuel pump 4P connector terminal No. 2 and body ground.
Is there continuity?
YES - Repair short in the wire between the fuel pump and PGM-FI main relay 2. Also replace the No. 20 FUEL
PUMP (15 A) fuse.■
NO - Check the fuel pump, and replace it if necessary. Also replace the No. 20 FUEL PUMP (15 A) fuse.■
54. Jump the SCS line with the HDS.
55. Disconnect ECM/PCM connectors A (49P) and C (49P).
56. Turn the ignition switch to ON (II).
57. Measure the voltage between ECM/PCM connector terminal C10 and body ground.
Is there battery voltage?
YES - Go to Step 58 .
NO - Repair open in the wire between the No. 20 FUEL PUMP (15 A) fuse and the ECM/PCM (C10).■
58. Measure the voltage between ECM/PCM connector terminal A7 and body ground.
Is there battery voltage?
YES - Go to Step 64 .
NO - Go to Step 59 .
59. Turn the ignition switch to LOCK (0).
60. Open the fuse lid (A), then remove the PGM-FI main relay 1 (B) from the under-dash fuse/relay box.
61. Measure the voltage between PGM-FI main relay 1 4P connector terminal No. 3 and body ground.
Is there battery voltage?
YES - Go to Step 62 .
NO - Replace the under-dash fuse/relay box.
62. Connect PGM-FI main relay 1 4P connector terminal No. 4 to body ground with a jumper wire.
63. Check for continuity between ECM/PCM connector terminal A7 and body ground.
Is there battery voltage?
YES - Test PGM-FI main relay 1. If the relay is OK, update the ECM/PCM if it does not have the latest software,
or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-
good ECM/PCM, replace the original ECM/PCM. ■
NO - Repair open in the wire between the ECM/PCM (A7) and PGM-FI main relay 1.■
64. Turn the ignition switch to LOCK (0).
65. Open the fuse lid (A), then remove the PGM-FI main relay 1 (B) from the under-dash fuse/relay box.
66. Measure the voltage between PGM-FI main relay 1 4P connector terminal No. 2 and body ground.
Is there battery voltage?
YES - Go to Step 67 .
NO - Replace the under-dash fuse/relay box. ■
67. Connect PGM-FI main relay 1 4P connector terminal No. 1 to body ground with a jumper wire.
68. Check for continuity between ECM/PCM connector terminal A9 and body ground.
Is there continuity?
YES - Go to Step 69 .
NO - Repair open in the wire between the ECM/PCM (A9) and PGM-FI main relay 1.■
69. Test PGM-FI main relay 1.
Is PGM-FI main relay 1 OK?
YES - Go to Step 70 .
NO - Replace the PGM-FI main relay 1 .■
70. Disconnect ECM/PCM connector B (49P).
71. Check for continuity between body ground and ECM/PCM connector terminals B1, B10, C2, C44, and C48
individually.
Is there continuity?
YES - Go to Step 72 .
NO - Repair open in the wire between the ECM/PCM (B1, B10, C2, C44, C48) and G101.■
72. Check for continuity between ECM/PCM connector terminal C13 and body ground.
Is there continuity?
YES - Go to Step 73 .
NO - Go to Step 74 .
73. Continue to check for continuity between ECM/PCM connector terminal C13 and body ground, while disconnecting
these parts, one at a time:
MAP sensor 3P connector
Output shaft (countershaft) speed sensor 3P connector
Does continuity go away when one of the above components is disconnected?
YES - Repair the part that caused an open when it was disconnected.■
NO - Repair short in the between the ECM/PCM (C13) and the MAP sensor or the output shaft (countershaft)
speed sensor.■
74. Check for continuity between ECM/PCM connector terminal B19 and body ground.
Is there continuity?
YES - Go to Step 75 .
NO - Go to Step 76 .
75. Continue to check for continuity between ECM/PCM connector terminal B19 and body ground, while disconnecting
the input shaft (mainshaft) speed sensor 3P connector.
Is there continuity?
YES - Repair short in the wire between the ECM/PCM (B19) and the input shaft (mainshaft) speed sensor.■
NO - Replace the input shaft (mainshaft) speed sensor. ■
76. Check for continuity between ECM/PCM connector terminal C12 and body ground.
Is there continuity?
YES - Go to Step 77 .
NO - Go to Step 78 .
77. Continue to check for continuity between ECM/PCM connector terminal C12 and body ground, while disconnecting
the throttle body 6P connector.
Is there continuity?
YES - Repair short in the wire between the ECM/PCM (C12) and the throttle body.■
NO - Replace the throttle body. ■
78. Check for continuity between ECM/PCM connector terminal A26 and body ground.
Is there continuity?
YES - Go to Step 79 .
NO - Go to Step 80 .
79. Continue to check for continuity between ECM/PCM connector terminal A26 and body ground, while disconnecting
the APP sensor 6P connector.
Is there continuity?
YES - Repair short in the wire between the ECM/PCM (A26) and APP sensor A.■
NO - Replace the accelerator pedal module. ■
80. Check for continuity between ECM/PCM connector terminal A25 and body ground.
Is there continuity?
YES - Go to Step 81 .
NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original
ECM/PCM. ■
81. Continue to check for continuity between ECM/PCM connector terminal A25 and body ground, while disconnecting
the APP sensor 6P connector.
Is there continuity?
YES - Repair short in the wire between the ECM/PCM (A25) and APP sensor B.■
NO - Replace the accelerator pedal module. ■
F-CAN Circuit Troubleshooting
NOTE: Information marked with an asterisk ( * ) applies to the CANL line.
1. Turn the ignition switch to LOCK (0).
2. Jump the SCS line with the HDS.
3. Disconnect ECM/PCM connector A (49P), then disconnect the HDS.
4. Measure the resistance between ECM/PCM connector terminals A3 and A4.
Is there about 95−116 Ω?
YES - Go to Step 27 .
NO - Go to Step 5 .
5. Disconnect these connectors:
Gauge control module 32P
ABS modulator-control unit 25P
EPS control unit C (16P)
SRS unit A (39P)
8. Check for continuity between gauge control module 32P connector terminal No. 30 and body ground.
Is there continuity?
YES - With ABS: Go to Step 9 .
Without ABS: Go to Step 10 .
NO - Repair open in the wire between the ECM/PCM (A3) and the gauge control module.■
9. Check for continuity between ABS modulator-control unit 25P connector terminal No. 1 and body ground.
Is there continuity?
YES - Go to Step 10 .
NO - Repair open in the wire between the ECM/PCM (A3) and the ABS modulator-control unit.■
10. Check for continuity between EPS control unit connector C (16P) terminal No. 10 and body ground.
Is there continuity?
YES - Go to Step 11 .
NO - Repair open in the wire between the ECM/PCM (A3) and the EPS control unit.■
11. Remove the jumper wire from ECM/PCM connector A (49P).
12. Connect ECM/PCM connector terminal A4 to body ground with a jumper wire.
13. Check for continuity between gauge control module 32P connector terminal No. 29 and body ground.
Is there continuity?
YES - With ABS: Go to Step 14 .
Without ABS: Go to Step 15 .
NO - Repair open in the wire between the ECM/PCM (A4) and the gauge control module.■
14. Check for continuity between ABS modulator-control unit 25P connector terminal No. 17 and body ground.
Is there continuity?
YES - Go to Step 15 .
NO - Repair open in the wire between the ECM/PCM (A4) and the ABS modulator-control unit.■
15. Check for continuity between EPS control unit connector C (16P) terminal No. 9 and body ground.
Is there continuity?
YES - Go to Step 16 .
NO - Repair open in the wire between the ECM/PCM (A4) and the EPS control unit.■
16. Reconnect the gauge control module 32P connector.
17. Measure the resistance between ECM/PCM connector terminals A3 and A4.
Is there about 108−132 Ω?
YES - With ABS: Go to Step 18 .
Without ABS: Go to Step 21 .
NO - Substitute a known-good gauge control module, If the HDS identifies the vehicle, replace the original
gauge control module. ■
18. Disconnect the gauge control module 32P connector.
19. Reconnect the ABS modulator-control unit 25P connector.
20. Measure the resistance between ECM/PCM connector terminals A3 and A4.
Is there about 2.34−2.86 kΩ?
YES - Go to Step 21 .
NO - Substitute a known-good ABS modulator-control unit, If the HDS identifies the vehicle, replace the original
ABS modulator-control unit. ■
21. Disconnect the ABS modulator-control unit 46P connector (with ABS) or the gauge control module 32P connector
(without ABS).
22. Reconnect EPS control unit connector C (16P).
23. Measure the resistance between ECM/PCM connector terminals A3 and A4.
Is there about 2.34−2.86 kΩ?
YES - Go to Step 24 .
NO - Substitute a known-good EPS control unit, If the HDS identifies the vehicle, replace the original EPS
control unit. ■
24. Disconnect EPS control unit connector C (16P).
25. Reconnect SRS unit connector A (39P).
26. Measure the resistance between ECM/PCM connector terminals A3 and A4.
Is there about 2.34−2.86 kΩ?
YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original
ECM/PCM. ■
NO - Substitute a known-good SRS unit. If the HDS identifies the vehicle, replace the original SRS unit. ■
27. Disconnect these connectors:
Gauge control module 32P
ABS modulator-control unit 25P
EPS control unit C (16P)
SRS unit A (39P)
28. Check for continuity between ECM/PCM connector terminal A3 and body ground.
Is there continuity?
YES - Repair short in the wire between ECM/PCM terminals A3 and the gauge control module, the ABS
modulator-control unit, the EPS control unit, the SRS unit, or the DLC.■
NO - Go to Step 29 .
29. Check for continuity between ECM/PCM connector terminal A4 and body ground.
Is there continuity?
YES - Repair short in the wire between ECM/PCM terminals A4 and the gauge control module, the ABS
modulator-control unit, the EPS control unit, the SRS unit, or the DLC.■
NO - Go to Step 30 .
30. Reconnect all connectors.
31. Connect the HDS to the DLC.
32. Disconnect the gauge control module 32P connector.
33. Turn the ignition switch to ON (II), and read the HDS.
Does the HDS identify the vehicle?
YES - Replace the gauge control module. ■
NO - With ABS: Go to Step 34 .
Without ABS: Go to Step 38 .
11. Measure the resistance between injector (A) terminals No. 1 and No. 2. There should be 10−13 Ω.
If the resistance is OK, go to Step 12 .
If the resistance is not as specified, replace the injector.
12. Check the fuel pressure.
If the fuel pressure is as specified, check the following:
-Whether there is wire breakage, or poor connection in the YEL/BLK wire between the PGM-FI main relay
1 and the junction connector.
-Whether the junction connector is open or corroded.
-Whether there is wire breakage, or poor connection in the YEL/BLK wire between the junction connector
and the injector.
-Whether there is any short-circuiting, wire breakage or poor connection in the wire between the injector
and the ECM/PCM.
If the fuel pressure is not as specified, recheck the fuel pressure.
Injector Replacement
1. Relieve the fuel pressure.
2. Remove the intake manifold, and intake manifold chamber.
3. Remove the cover (A), then disconnect the quick-connect fitting (B).
4. Disconnect the injector connectors (C).
5. Remove the fuel rail mounting nuts (D) from the fuel rail (E).
6. Remove the fuel rail and the injectors from the cylinder head.
7. Remove the injector clips (F) from the fuel rail.
8. Remove the injectors (G) from the fuel rail.
9. Coat the new O-rings (black) (A) with clean engine oil, and insert the injectors (B) into the fuel
rail (C).
10. Install the injector clips (D).
11. Coat the new injector O-rings (brown) (E) with clean engine oil.
12. Install the fuel rail and the injectors in the cylinder head (F).
13. Install the fuel rail mounting nuts (G).
14. Connect the injector connectors (H).
15. Connect the quick-connect fitting (I).
16. Turn the ignition switch to ON (II), but do not operate the starter. After the fuel pump runs for
about 2 seconds, the fuel rail will be pressurized. Repeat this two or three times, then check for
fuel leakage.
17. Reinstall the intake manifold, and intake manifold chamber.
MIL Circuit Troubleshooting
1. Turn the ignition switch to ON (II).
2. Do the gauge self-diagnostic function.
Does the MIL indicator flash?
YES - Go to Step 3 .
NO - Substitute a known-good gauge control module, and recheck. If the symptom/indication goes away with a
known-good gauge control module, replace the original gauge control module. ■
3. Connect the HDS to the DLC.
4. Check the SCS in the DATA LIST with the HDS.
Is a short indicated?
YES - Go to Step 5 .
NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original
ECM/PCM. ■
5. Turn the ignition switch to LOCK (0).
6. Disconnect ECM/PCM connector A (49P), then disconnect the HDS.
7. Check for continuity between ECM/PCM connector terminal A32 and body ground.
Is there continuity?
YES - Repair short in the wire between the ECM/PCM (A32) and the DLC.■
NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original
ECM/PCM. ■
Subfuel Solenoid Test
1. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.
2. Make sure the HDS communicates with the ECM/PCM. If it doesn't, go to the DLC circuit troubleshooting.
3. Select the SUBFUEL SOLENOID ON and OFF in the INSPECTION MENU with the HDS.
4. Check the clicking sound of subfuel solenoid by means of a stethoscope.
If any subfuel solenoid fails to make the typical clicking sound, check the sound again after replacing the
subfuel solenoid.
If clicking sound is still absent, check the following.
-Whether there is wire breakage or poor connection in the YEL/BLK, YEL wire between subfuel pump relay
and the subfuel solenoid.
-Whether there is wire breakage or poor connection in the WHT wire between subfuel pump relay and the
auxiliary under-dash fuse holder (15 A) fuse.
-Whether there is any short-circuiting, wire breakage or poor connection in the wire between the subfuel
solenoid and the ECM/PCM.
5. Turn the ignition switch to LOCK (0).
6. Disconnect the subfuel solenoid 2P connector.
7. Measure the resistance between subfuel solenoid (A) terminals No. 1 and No. 2. There should be 10.3 Ω.
If the resistance is OK, go to Step 8 .
If the resistance is not as specified, replace the subfuel solenoid.
8. Remove the subfuel solenoid.
9. Check the subfuel solenoid for dirt or rusty.
If it is dirty or rusty, replace the subfuel solenoid, and the fuel nozzle.
Subfuel Solenoid Replacement
1. Relieve the subfuel pressure.
2. Remove the bolt (A).
3. Remove the intake manifold stay (B).
4. Disconnect the connector (C) from the subfuel solenoid.
5. Remove the harness band (D) from the subfuel solenoid holder (E).
8. Coat the new O-ring (A) with clean engine oil, and insert the subfuel solenoid (B) into the subfuel solenoid holder
(C).
9. Install the injector clip (D).
10. Coat the injector O-ring (E) with clean engine oil, and insert the subfuel solenoid into the subfuel pipe (F).
11. Place the wrench (G), then tighten the bolts (H).
A/C COMPRESSOR
CLUTCH RELAY
Signal Circuit
Troubleshooting,
4. Start the engine. Hold the engine speed at 3,000 rpm (min −1 ) without load (A/T in P or N, M/T in neutral) until the
radiator fan comes on, then let it idle.
5. Check the idle speed without load conditions: headlights, blower fan, radiator fan, and air conditioner off.
Idle speed should be:
L13Z3 engine
M/T 700±50 rpm (min −1 )
A/T 700±50 rpm (min −1 ) (in N or P)
L15A8 engine
M/T 700±50 rpm (min −1 )
A/T 700±50 rpm (min −1 ) (in N or P)
6. Let the engine idle for 1 minute with high electric load (A/C switch on, temperature set to max cool, blower fan on
High, and headlights on high beam).
Idle speed should be:
NOTE: If the idle speed is not within specification, do the ECM/PCM idle learn procedure. If the idle speed is still
not within specification, go to symptom troubleshooting.
7. Reconnect the EVAP canister purge valve connector.
Engine idle
Item Measurement Qualification Standard or New
Engine idle Idle speed without load M/T (in neutral) 700±50 rpm
A/T (in N or P)
Idle speed with high electrical load (A/C M/T (in neutral), 790±50 rpm
switch ON, temperature set to max cool, A/T (in N or P)
blower fan on High, rear window defogger
ON, and headlights on high beam)
Idle CO 0.1 % max
A/C Signal Circuit Troubleshooting
1. Start the engine, and let it idle.
2. Turn the blower switch on.
3. Turn the A/C switch on.
4. Check the A/C CLUTCH in the DATA LIST with the HDS.
Does it indicate ON?
YES - Go to Step 5 .
NO - Do the A/C system test. ■
5. Check the A/C system.
Does the A/C system operate?
YES - The air conditioning system circuit is OK.■
NO - Go to Step 6 .
6. Turn the ignition switch to LOCK (0).
7. Turn the ignition switch to ON (II).
8. Activate the A/C CLUTCH in the INSPECTION MENU with the HDS.
Is there a clicking noise from the A/C compressor clutch?
YES - Do the A/C system test. ■
NO - Go to Step 9 .
9. Turn the ignition switch to LOCK (0).
10. Jump the SCS line with the HDS.
11. Disconnect ECM/PCM connector A (49P).
12. Turn the ignition switch to ON (II).
13. Momentarily connect ECM/PCM connector terminal A15 to body ground with a jumper wire several times.
Is there a clicking noise from the A/C compressor clutch?
YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original
ECM/PCM. ■
NO - Check for poor connections or loose terminals at the A/C compressor clutch relay and the ECM/PCM. If
the connections are OK, check the A/C compressor clutch relay, repair open in the wire between the
ECM/PCM (A15) and the A/C compressor clutch relay and the other A/C systems.■
Alternator FR Signal Circuit Troubleshooting
1. Start the engine, and let it idle.
2. Monitor the ALTERNATOR in the DATA LIST with the HDS.
3. Check if the indicated percentage varies when the headlight switch is turned on.
Does the percentage vary?
YES - The alternator signal circuit is OK.■
NO - Go to Step 4 .
4. Turn the headlight switch off and the ignition switch to LOCK (0).
5. Jump the SCS line with the HDS.
6. Disconnect the alternator 4P connector.
7. Disconnect ECM/PCM connector B (49P).
8. Check for continuity between body ground and ECM/PCM connector terminal B47.
Is there continuity?
YES - Repair short in the wire between the ECM/PCM (B47) and the alternator.■
NO - Troubleshoot the alternator and regulator circuit. ■
Update the ECM/PCM if it does not have the latest software, or substitute a known-good
ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM,
replace the original ECM/PCM. ■
Intake Air System Component Location Index
THROTTLE BODY
Test,
Cleaning,
in the Shop Manual, P/N 62TF000A
Removal/Installation,
Disassembly/Reassembly,
in the Shop Manual, P/N 62TF000A
AIR CLEANER
Removal/Installation,
Exploded View
Removal
1. Remove the harness holder mounting bolt, then remove the harness holder (A) from the bracket.
2. Remove the positive crankcase ventilation (PCV) hose (B).
3. Disconnect the exhaust gas recirculation (EGR) valve connector.
4. Remove the dipstick.
5. Remove the intake manifold.
6. Remove the intake manifold bracket C.
Installation
1. Install the subfuel pipe (A) to the intake manifold.
2. Install the intake manifold bracket C (B).
3. Install the intake manifold (C) with new gaskets (D), and tighten the bolts and nuts in a crisscross pattern in three
steps, beginning with the inner bolt.
4. Install the dipstick.
5. Connect the EGR valve connector.
Exploded View
Removal
1. Remove the under-cowl panel.
2. Remove the air cleaner housing assembly.
3. Remove the engine wire harness connectors and wire harness clamps from the intake manifold chamber.
Throttle actuator connector
Manifold absolute pressure (MAP) sensor connector
4. Remove the brake booster vacuum hose (A) and the harness clamp (B).
5. Remove the water bypass hose from the clamp (C).
6. Remove the throttle body without disconnecting the water bypass hoses.
Installation
1. Install the intake manifold chamber (A) with a new gaskets (B), and tighten the bolts in a crisscross pattern in three
steps, beginning with the inner bolt.
2. Loosen the intake manifold bracket mounting bolt (A). Tighten the mounting bolts (B), then tighten the mounting
bolt (A).
Exploded View
Removal
1. Remove the under-cowl panel.
2. Remove the air cleaner housing assembly.
3. Remove the engine wire harness connectors and wire harness clamps from the intake manifold chamber.
Throttle actuator connector
Manifold absolute pressure (MAP) sensor connector
Exhaust gas recirculation (EGR) valve connector
4. Remove the brake booster vacuum hose (A) and the harness clamp (B).
5. Remove the water bypass hose from the clamp (C).
6. Remove the throttle body without disconnecting the water bypass hoses.
7. Remove the harness holder mounting bolt, then remove the harness holder (A) from the bracket.
8. Remove the positive crankcase ventilation (PCV) hose (B).
9. Remove the dipstick.
Installation
1. Install the intake manifold/chamber assembly (A) with a new gasket (B), and tighten the bolts and nuts in a
crisscross pattern in three steps, beginning with the inner bolt.
2. Loosen the intake manifold bracket mounting bolt (A). Tighten the mounting bolts (B), then tighten the mounting
bolt (A).
4. Start the engine. Hold the engine speed at 3,000 rpm (min −1 ) without load (A/T in P or N, M/T in neutral) until the
radiator fan comes on, then let it idle.
5. Check REL TP SENSOR in the DATA LIST the HDS. The reading should be below 2.46 deg. If it is not, clean the
throttle body.
Throttle Body Removal/Installation
Do not insert your fingers into the installed throttle body when you turn the ignition switch to ON (II) or
while the ignition switch is ON (II). If you do, you will seriously injure your fingers if the throttle valve is
activated.
8. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.
9. Turn the ignition switch to ON (II).
10. Reset the ECM/PCM with the HDS.
11. Select the ETCS TEST in the INSPECTION MENU with the HDS.
12. Select TP POSITION CHECK and clear the throttle position (TP) learned value.
13. Turn the ignition switch to LOCK (0).
14. Turn the ignition switch to ON (II), and wait 2 seconds without pressing the accelerator pedal.
15. Do the ECM/PCM idle learn procedure.
Engine Lubrication Component Location Index
DRAIN BOLT
WASHER
OIL PAN
Removal,
in the Shop Manual,
P/N 62TF000A
Installation,
in the Shop Manual,
P/N 62TF000A
OIL SCREEN
(L13Z3 engine)
OIL FILTER
Replacement,
DIPSTICK TUBE
OIL SCREEN
(L15A8 engine)
GASKET
OIL PUMP
Overhaul,
O-RING
OIL PRESSURE SWITCH
Circuit Diagram,
in the Shop Manual, P/N 62TF000A
OIL/AIR SEPARATOR Test,
Installation, in the Shop Manual, P/N 62TF000A
in the Shop Manual, P/N 62TF000A Replacement,
in the Shop Manual, P/N 62TF000A
Oil Pressure Test,
in the Shop Manual, P/N 62TF000A
Engine Oil Pump Overhaul
Exploded View
Special Tools Required
Sub hanger stay
07MAK-PY30100
Removal
1. Remove the cam chain.
2. Remove the alternator mounting bolt, then install the sub hanger stay.
3. Attach the chain to the sub hanger stay. Lift and support the engine with the chain.
4. Remove the oil pan.
5. Remove the oil screen (A), then remove the oil pump (B). L15A8 engine
L13Z3 engine
Inspection
1. Remove the screws from the oil pump housing, then separate the pump housing and pump cover.
2. Check the inner-to-outer rotor radial clearance between the inner rotor (A) and the outer rotor (B). If the inner-to-
outer rotor clearance exceeds the service limit, replace the oil pump assembly.
3. Check the pump housing-to-rotor axial clearance between the rotors (A) and pump housing (B). If the pump
housing-to-rotor axial clearance exceeds the service limit, replace the oil pump assembly.
4. Check the pump housing-to-outer rotor radial clearance between the outer rotor (A) and the pump housing (B). If the
pump housing-to-outer rotor radial clearance exceeds the service limit, replace the oil pump assembly.
5. Inspect both rotors and the pump housing for scoring or other damage. Replace the parts, if necessary.
6. Check that the oil pump turns freely.
Installation L15A8 engine
1. Clean the O-ring groove and the mating surface of the engine block.
2. Install the oil pump (A) with a new O-ring (B).
3. Install the oil screen (C) with a new gasket (D).
4. Install the oil pan.
5. Support the engine with a jack and wood block under the oil pan.
L13Z3 engine
6. Remove the chain and sub hanger stay, then tighten the alternator mounting bolt.
7. Install the cam chain.
Right Front Fender Removal/Installation
FFV Model
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the front fender and body.
1. Remove these items:
Front bumper
Headlight
Front pillar corner trim
2. Remove the front inner fender.
3. Remove the fuel filler cap (A).
4. Remove the fuel fill door trim.
6. From back of the front fender (A), remove the fuel fill door opener cable (B) from the fuel filler lid (C), take care not to
scratch the front fender.
7. Install the front fender in the reverse order of removal, and note these items:
Make sure the fuel fill door latch is installed properly.
Make sure the fuel fill door opens properly and locks securely.
If the clips are damaged or stress-whitened, replace them with new ones.
Apply touch-up paint to the front fender installation bolts, and around the front fender.
Front fender in or out until it's flush with the door, and up or down as necessary to equalize the gaps.
Apply multipurpose grease to the fuel fill door latch.
Front Fender Fairing Replacement - Supplement
Right Front Fender Fairing - FFV Model
1. Remove the front right fender.
2. Remove the hooks (A), then remove the front fender fairing (B) from the front right fender (C).
3. Install the front fender fairing in the reverse order of removal.
Front Inner Fender Replacement
FFV Model
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the body.
1. For some models: Remove the side sill panel.
2. Remove the front inner fender (A).
-1. On the back of the wheel arch, remove the screws (B), and remove the front splash guard
(C) (for some models).
-2. From under the front bumper (D), remove the screw (E) securing the front bumper, the
splash shield (F), and the front inner fender.
-3. Remove the clip (G) securing the front bumper and the front inner fender.
-4. From the wheel arch, remove the screw (H), clips (I, J, K), clips (L).
-5. Release the hook (M) of the splash shield, then remove the front inner fender.
NOTE: To remove the clips G, I, pry the inner the clip up at the edge near the line (N) on
its head.
3. Install the inner fender in the reverse order of removal, and note these items:
Pull the lower end of the drain tube (A) down fully, then the inner fender (B) fasten the tube with the clips (C).
And make sure that water is drained through the tube.
If the clips are damaged or stress-whitened, replace them with new ones.
Push the clips into place securely.
Fuel Fill Door Adjustment
FFV Model
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the front fender.
1. Remove the fuel fill door trim.
2. Slightly loosen the hinge mounting bolts (A).
3. Adjust the fuel fill door (B) in or out until it's flush with the front fender, and up or down as necessary to equalize the
gaps.
4. Tighten the hinge mounting bolts.
5. Check that the fuel fill door opens properly and locks securely, and check that the rear of the door is flush with the
front fender.
3. Remove the fuel fill door trim (A) with the drain tube (B) from the front fender (C).
4. Disconnect the drain tube (A) from the fuel fill door trim (B).
5. Install the trim in the reverse order of removal and make sure the drain tube is connected securely.
Fuel Fill Door Opener Replacement
FFV Model
1. Remove the driver's side kick panel.
2. Remove the bolt, then remove the fuel fill door opener handle (A).
3. Disconnect the fuel fill door cable (B) from the fuel fill door release handle. Take care not to bend the cable.
4. Install the fuel fill door release handle in the reverse order of removal, and note these items:
Make sure the fuel fill door opener cable is connected properly.
Make sure the fuel fill door opens properly.
Fuel Fill Door Opener Cable Replacement
FFV Model
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the body and related parts.
1. Remove the right front fender.
2. Remove these items:
Left front inner fender
Driver's side kick panel
3. Disconnect the fuel fill door opener cable (A) from the fuel fill door opener (B). Take care not to
kink the cable.
4. Using a clip remover, detach the clips (C, D). Release the fuel fill door opener cable from the
clips (E, F, G) being wound onto the opener cable off, then remove the fuel fill door opener cable
from the grommet (H). Take care not to kink the cable.
5. Install the cable in the reverse order of removal, and note these items:
If the clips are damaged or stress-whitened, replace them with new ones.
Make sure the fuel fill door opens properly and locks securely.
Hood Opener Cable Replacement
FFV Model
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the body and the related parts.
1. Remove these items:
Left front inner fender
Kick panel, driver's side
2. Disconnect the hood opener cable (A) from the hood latch (B), and disconnect the hood opener
cable from the hood release handle (C). Take care not to kink the cable.
3. Using a clip remover, detach the clips (D, E), release the cable from the clips (F, G, H) being
wound onto the opener cable off, then remove the hood opener cable from the grommet (I). Take
care not to kink the cable.
4. Install the cable in the reverse order of removal, and note these items:
If the clips are damaged or stress-whitened, replace them with new ones.
Make sure the cable is connected properly.
Make sure the hood opens properly and locks securely.
Fuse to Components Index - Auxiliary Under-dash Fuse Holder
AUXILIARY UNDER-DASH
FUSE HOLDER
*
1 2
*: Not used
A/C Compressor Thermal Protector Replacement
1. Remove the bolt and the holder (A). Disconnect the field coil connector (B), then remove the thermal protector (C).
2. Replace the thermal protector (A) with a new one, and apply silicone sealant (B) to the bottom of the thermal
protector.
3. Install the thermal protector in the reverse order of removal.
SRS Precautions and Procedures
General Precautions
Please read the following precautions carefully before servicing the airbag system. Observe the instructions described in
this manual, or the airbags could accidentally deploy and cause damage or injuries.
Except when doing electrical inspections, always turn the ignition switch to LOCK (0), disconnect the negative
cable from the battery, then wait for 3 minutes before starting work.
NOTE: The SRS memory is not erased even if the ignition switch is turned to LOCK (0) or the battery cables are
disconnected from the battery.
Use replacement parts which are manufactured to the same standards and quality as the original parts. Do not
install used SRS parts. Use only new parts when making SRS repairs.
Carefully inspect any SRS part before you install it.
Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or
deformation.
Before disconnecting the SRS unit connectors, always disconnect the appropriate SRS parts connectors.
Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA
(0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could
cause accidental deployment and possible injury.
Do not put objects on the front passenger's airbag.
Steering-Related Precautions
Misalignment of the cable reel could cause an open in the wiring, making the SRS system, remote steering wheel
controls, and the horn inoperative. Center the cable reel whenever you do the following.
-Installation of the steering wheel
-Installation of the cable reel
-Installation of the steering column
-Other steering-related adjustment or installation
Do not disassemble the cable reel.
Do not apply grease to the cable reel.
If the cable reel shows any signs of damage, replace it with a new one. For example, if it does not rotate smoothly,
replace the cable reel.
To prevent damage to the airbag, keep it away from any oil, grease, detergent, or water.
Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200 °F/93 °C).
Never do electrical tests on the airbags, such as measuring resistance.
Do not position yourself in front of the airbag during removal, inspection, or replacement.
For proper disposal of a damaged airbag , refer to airbag disposal.
The side curtain airbag module assembly is a long, jointed part containing an inflator (A), a flexible bag (B), and
brackets (C). When removing or installing the side curtain airbag inflator assembly, never do these things:
-Drop the curtain airbag.
-Cut, tear, or real the tape.
-Handle the flexible bag (B).
SRS Unit, Front and Side Impact Sensors
Turn the ignition switch to LOCK (0), disconnect the negative cable from the battery, then wait at least 3 minutes
before beginning installation or replacement of the SRS unit or disconnecting the connectors from the SRS unit.
Be careful not to bump or impact the SRS unit, front impact sensors or side impact sensors when the ignition
switch is at ON (II), or for at least 3 minutes after the ignition switch is turned to LOCK (0).
During installation or replacement, be careful not to bump (by impact wrench, hammer, etc.) the area around the
SRS unit, front impact sensors or side impact sensors. The airbags could accidentally deploy and cause damage
or injury.
After a collision where a front airbag, side airbags, side curtain airbags, or a seat belt tensioner deployed, go to
Component Replacement/Inspection after Deployment. After a collision where the airbags or the side airbags did
not deploy, inspect for any damage or any deformation on the SRS unit, front impact sensors and side impact
sensors. Replace all damaged parts.
Do not disassemble the SRS unit, front impact sensors and side impact sensors.
Be sure the SRS unit, front impact sensors and side impact sensors are installed securely with the mounting bolts
torqued to 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft) whenever you remove or replace the SRS unit, all impact sensors, always
install the components with new TORX bolts.
Do not spill water or oil on the SRS unit or the side impact sensors.
Wiring Precautions
Some of the SRS wiring can be identified by special yellow outer covering, and the SRS connectors can be identified by
their yellow color. Observe the instructions.
Never attempt to modify, splice, or repair SRS wiring.
If there is an open or damage in SRS wiring, replace the harness.
Be sure to install the harness wires so they do not get pinched or interfere with other parts.
Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal
contact. Poor grounds can cause intermittent problems that are difficult to diagnose.
Do not use any silicone based cleaners or lubricants on any SRS connectors or terminals.
To reconnect the connector, push in on the connector sleeve (A). As the connector is pressed in, the lever (B) moves to
the locked position.
To reconnect, hold the pawl-side connector, and press on the back of the sleeve-side connector in the direction shown. As
the two connector halves are pressed together, the sleeve (A) is pushed back by the pawl (C). Do not touch the sleeve.
1. Turn the ignition switch to LOCK (0). Disconnect the negative cable from the battery, then wait for 3 minutes.
Driver's Airbag
2. Remove the access panel (A) from the steering wheel, then disconnect the driver's airbag 4P connector (B) from the
cable reel.
Side Airbag
4. Disconnect both side airbag 2P connectors (A) from the floor wire harness.
SRS Unit
9. Remove the center console.
10. Remove the heater joint duct.
11. Disconnect SRS unit connectors A (39P) and B (39P) from the SRS unit.
Audio System Symptom Troubleshooting - Audio unit power switch will not turn on (No information display and no
sound)
Audio unit power switch will not turn on (No information display and no sound)
NOTE:
Check the vehicle battery condition first.
Check the connectors for poor connections or loose terminals.
1. Turn the ignition switch to ON (II).
2. Push the power button on to see if audio unit turns on.
Does the audio unit display operate properly, and does the audio unit sound normal?
YES - Intermittent failure, the system is OK at this time.■
NO - Go to Step 3 .
3. Turn off the audio unit, then turn the ignition switch to LOCK (0).
4. Check the No. 1 (10 A) and No. 14 (7.5 A) fuses in the under-dash fuse/relay box.
Are the fuses OK?
YES - Go to Step 5 .
NO - Replace the fuse(s), and recheck.■
5. Remove the audio unit. Check that the audio unit connectors are properly connected.
NOTE: Eject the CD before removing the audio unit to prevent damaging the CD player′s load mechanism.
Are they connected properly?
YES - Go to Step 6 .
NO - Repair poor connections and reconnect the connectors, and recheck the function.■
6. Disconnect audio unit connector A (24P).
7. Turn the ignition switch to ON (II).
8. Measure the voltage between body ground and audio unit connector A (24P) No. 14 and No. 24 terminals
individually.
Is there battery voltage?
YES - Go to Step 9 .
NO - Repair open or short in the wire(s) between the No. 1 (10 A) and No. 14 (7.5 A) fuse in the under-dash
fuse/relay box and the audio unit.■
9. Turn the ignition switch to LOCK (0).
10. Reconnect audio unit connector A (24P).
11. Turn the ignition switch to ON (II).
12. Measure the voltage between audio unit connector A (24P) terminal No. 12 and body ground.
Is there less than 0.1 V?
YES - Substitute a known-good audio unit, and recheck. If the symptom/indication goes away, replace the
original audio unit.■
NO - Repair open in the wire between the audio unit and body ground (G503).■
Audio System Symptom Troubleshooting - Audio unit power switch will not turn off
Audio unit power will not turn off
NOTE:
Check for aftermarket accessories plugged into the vehicle's accessory power sockets.
Check the connectors for poor connections or loose terminals.
1. Turn the ignition switch to ON (II).
2. Push the power switch to see if the audio unit turn off.
Does the audio unit turn off?
YES - Operation is normal.■
NO - Go to Step 3 .
3. Turn the ignition switch to LOCK (0).
Does the audio unit turn off?
YES - Replace the audio unit. ■
NO - Go to Step 4 .
4. Remove the audio unit. and disconnect audio unit connector A (24P).
NOTE: Eject the CD before removing the audio unit to prevent damaging the CD player's load mechanism.
5. Measure the voltage between audio unit connector A (24P) No. 14 terminal and body ground.
Is there battery voltage?
YES - Check for short to power on the PUR wire.
NO - Substitute a known-good audio unit, and recheck. If the symptom/indication goes away, replace the
original audio unit.■
Audio System Symptom Troubleshooting - No sound is heard from speaker(s) (display is normal)
No sound is heard from the speaker(s) (display is normal)
NOTE:
Check the vehicle battery condition first.
Check the connectors for poor connections or loose terminals.
Set the fader and balance positions to the center.
Set the VOL knob except MIN position.
1. Do the speaker check mode with the self-diagnostic function.
Do any or all of the speakers fail to sound?
YES - If at least one speaker is OK, go to Step 6 .
If all speakers fail to sound, go to Step 2 .
NO - System is OK at this time. Check for poor connections at the audio unit and speakers.■
2. Make sure the ignition switch to LOCK (0).
3. Remove the audio unit and disconnect audio unit connector A (24P).
NOTE: Eject the CD before removing the audio unit to prevent damaging the CD player's load mechanism.
4. Check for continuity between audio unit connector A (24P) No. 14 terminal and body ground according to the table.
Speaker Audio unit connector Wire color
Left front door speaker A23 (+) LT BLU
A22 (−) LT GRN
Right front door speaker A19 (+) BRN
A18 (−) RED
Left rear door speaker A11 (+) GRY
A10 (−) BRN
Right rear door speaker A7 (+) BLU
A6 (−) ORN
Is there continuity?
YES - Repair short to body ground in the wire(s) between the audio unit and the faulty speaker(s).
NO - Go to Step 5 .
5. Test the speaker(s).
Is the speaker OK?
YES - Go to Step 13 .■
NO - Replace the speaker(s) and recheck.■
6. Make sure the ignition switch to LOCK (0).
7. Check the faulty speaker(s) face for damage.
Is there any damage?
YES - Replace the speaker(s) and recheck.■
NO - Go to Step 8 .
8. Test the speaker(s) with no sound.
Is the speaker OK?
YES - Go to Step 9 .
NO - Replace the speaker(s) and recheck.■
9. Remove the audio unit and disconnect audio unit connector A (24P).
NOTE: Eject the CD before removing the audio unit to prevent damaging the CD player's load mechanism.
10. Connect the speaker connector terminal (+) and (−) with a jumper wire.
11. Check for continuity between both pairs of speaker wires (+) and (−) at audio unit connector A (24P) according to
the table.
Speaker Audio unit connector Wire color
Left front door speaker A23 (+) LT BLU
A22 (−) LT GRN
Right front door speaker A19 (+) BRN
A18 (−) RED
Left rear door speaker A11 (+) GRY
A10 (−) BRN
Right rear door speaker A7 (+) BLU
A6 (−) ORN
Is there continuity?
YES - Go to Step 12 .
NO - Repair open in the wires between the audio unit and the faulty speaker(s).■
12. Disconnect the jumper wire.
13. While disconnecting the speaker connector(s), check for continuity between both pairs of speaker wires (+) and (−)
at audio unit connector A (24P) according to the table.
Speaker Audio unit connector Wire color
Left front door speaker A23 (+) LT BLU
A22 (−) LT GRN
Right front door speaker A19 (+) BRN
A18 (−) RED
Left rear door speaker A11 (+) GRY
A10 (−) BRN
Right rear door speaker A7 (+) BLU
A6 (−) ORN
Is there continuity?
YES - Repair short in the wire(s) between the audio unit and the faulty speaker(s).■
NO - Replace the audio unit. ■
Audio System Symptom Troubleshooting - Audio system sound is weak or distorted (display is normal)
Audio system sound is weak or distorted (display is normal)
NOTE:
Check the vehicle battery condition first.
Check the connectors for poor connections or loose terminals.
1. Turn the ignition switch to ON (II).
2. Turn on the audio unit and check for sound in each mode (AM, FM, and CD).
Is there sound from the speakers, and is the sound quality normal in each mode?
YES - Intermittent failure. The system is OK at this time. Check for loose connections at the audio unit and
each speaker.■
NO - Speakers all work, sound quality is poor.■
If the sound quality is poor only with AM or FM, go to poor AM or FM radio reception or
interference.
If the sound is poor in all modes, go to no sound is heard from speaker(s).
Audio System Symptom Troubleshooting - Audio unit button illumination does not work
Audio unit button illumination does no work
NOTE:
Check the vehicle battery condition first.
Check the connectors for poor connections or loose terminals.
1. Check the No. 29 (10 A) fuse in the under-dash fuse/relay box.
Is the fuse OK?
YES - Go to Step 2 .
NO - Replace the fuse, and recheck.■
2. Turn the ignition switch to ON (II).
3. Turn the combination lighting switch to the parking light position.
4. Check the illumination of the audio unit buttons.
Are the buttons illuminated?
YES - Intermittent failure: the audio unit is OK at this time. Check for loose or poor connections at the audio unit
connector A (24P).■
NO - Go to Step 5 .
5. Check the illumination of several other buttons not related to the audio system.
Are the buttons illuminated?
YES - Go to Step 6 .
NO - Troubleshoot the dashboard illumination circuit.■
6. Turn the ignition switch to LOCK (0).
7. Disconnect audio unit connector A (24P).
NOTE: Eject the CD before removing the audio unit to prevent damaging the CD player's load mechanism.
8. Turn the ignition switch to ON (II).
9. With the headlight switch still on, measure the voltage between audio unit connector A (24P) terminal No. 13 and
body ground.
Is there battery voltage?
YES - Check the connections at audio unit connector A (24P). If all connections are OK, replace the audio unit.
■
NO - Repair open in the wire between the under-dash fuse/relay box and the audio unit.■
Audio System Symptom Troubleshooting - Audio disc does not eject
Audio disc does not eject
NOTE:
Check the vehicle battery condition first.
Disc labels should not be used in the audio unit. They may damage the player mechanism.
Check the connectors for poor connections or loose terminals
1. Turn the ignition switch to ON (II).
2. Turn on the audio unit.
Does the system turn on?
YES - Go to Step 3 .
NO - Go to Audio unit power switch will not turn on. ■
3. Check to see if the disc ejects correctly with no binding when you push the EJECT button.
Does the disc eject properly?
YES - Operation is normal.■
NO - Go to Step 4 .
4. Turn the ignition switch to LOCK (0).
5. Substitute a known-good center panel
Is the symptom still present?
YES - Replace the original center unit.■
NO - Replace the audio unit. ■
Audio System Symptom Troubleshooting - Volume does not increase with speed
Volume does not increase with speed
NOTE:
Check the vehicle battery condition first.
Check the connectors for poor connections or loose terminals.
1. Test-drive the vehicle at highway speeds and monitor if the volume increases.
Does the volume increase?
YES - Intermittent failure, the system is OK at this time.■
NO - Go to Step 2 .
2. Verify SVC mode setting in audio unit sound adjustment set-up.
Is the SVC set to off?
YES - Change setting to MID and retest.■
NO - Go to Step 3 .
3. Turn the ignition switch to LOCK (0).
4. Remove the audio unit , and disconnect audio unit connector A (24P).
NOTE: Eject the CD before removing the audio unit to prevent damaging the CD player's load mechanism.
5. Turn the ignition switch to ON (II).
6. Drive the vehicle and have an assistant measure the voltage at audio unit connector A (24P) terminal No. 15.
Is there a 0−5 V pulse?
YES - Substitute a known-good audio unit, and recheck. If the symptom/indication goes away, replace the
original audio unit.■
NO - Repair opens or shorts in the wire between audio unit connector A (24P) No. 15 terminal and ECM/PCM
connector A (49P) No. 30 terminal. If no opens are found, substitute a known-good ECM/PCM and
recheck. If the symptom/indicated goes away, replace the original ECM/PCM. ■
Audio System Symptom Troubleshooting - Volume is too high or too low when driving at freeway speeds
Volume is too high or too low when driving at freeway speeds
1. Test-drive the vehicle at highway speeds and monitor volume level.
Is the volume level too high or too low?
YES - Go to Step 2 .
NO - internal failre, the system is OK at this time.■
2. Change SVC mode setting in sound adjustment set-up to MID and retest.
Is the volume level still too high, or too low?
YES - Replace the audio unit. ■
NO - Improper (SVC) setting for the customer's sound preference, Advise the customer to try different SVC
settings.■
Audio System Symptom Troubleshooting - Audio remote switch does not work properly
Audio remote switch does not work properly
NOTE:
Check the vehicle battery condition first.
Check the connectors for poor connections or loose terminals.
1. Turn the ignition switch to ON (II).
2. Turn on the audio unit and check the audio unit operation (volume up, volume down, CH (UP), CH (DOWN),
MODE).
Is the audio unit operation OK?
YES - Go to Step 3 .
NO - Go to audio unit button does not work. ■
3. Turn the ignition switch to LOCK (0).
4. Do the audio remote switch test.
Is the audio remote switch OK?
YES - Go to Step 5 .
NO - Replace the audio remote switch.
5. Remove the audio unit.
6. Disconnect audio unit connector A (24P).
NOTE: Eject the CD before removing the audio unit to prevent damaging the CD player's load mechanism.
7. Reconnect the audio remote switch, and measure the resistance between audio unit connector A (24P) terminals
No. 5 and No. 16 as specified in the table.
8. Check for continuity between body ground and the No. 5 and No. 16 terminals of audio unit connector A (24P)
individually.
Is there continuity?
YES - Repair short to body ground in the circuit between the audio unit and the audio remote switch. If the wires
are OK, replace the cable reel. ■
NO - Substitute a known-good audio unit, and recheck. If the symptom/indication goes away, replace the
original audio unit. ■
Audio System Symptom Troubleshooting - Audio unit button does not work
Audio unit button does not work
NOTE:
Check the vehicle battery condition first.
Check the connectors for poor connections or loose terminals.
If the audio unit does not turn on, go to audio unit power switch will not turn on.
1. Turn the ignition switch to ON (II).
2. Using the owner's manual, check if the symptom is duplicated that uses the faulty button.
Is the symptom duplicated?
YES - Go to Step 3 .
NO - The system is OK. There is a possibility of doing an improper operation.■
3. Turn the ignition switch to LOCK (0).
4. Substitute a known-good center panel. and recheck.
Is the symptom still present?
YES - Replace the original center panel.■
NO - Replace the audio unit.
Audio System Symptom Troubleshooting - Audio unit disc indicator does not work
Audio unit disc indicator does not work
NOTE: CD with labels should not be used in the audio unit. They may damage the player mechanism.
1. Turn on the audio system.
2. Insert a known-good disc or press the EJECT button.
Is the DISC indicator (LED) indicated?
YES - The audio unit is OK at this time. Check for loose or poor connections at audio unit and center panel.■
NO - Substitute a known-good audio unit, and recheck. If the symptom/indication goes away, replace the
original audio unit. If the symptom is still present, substitute a known-good center panel, and recheck. If
the symptom/indication goes away, replace the original center panel.■
Audio System Symptom Troubleshooting - USB audio device input sound is low or cannot be heard
USB audio device input sound is low or cannot be heard
NOTE:
Check the vehicle battery condition first.
Check the connectors for poor connections or loose terminals.
1. Turn the ignition switch to ON (II).
2. Do the speaker check mode with the self-diagnostic mode.
Do all speakers make a sound?
YES - Go to Step 3 .
NO - Go to no sound is heard from speaker(s).■
3. Turn the ignition switch to LOCK (0).
4. Connect the customer′ s USB device to a known-good vehicle that equipped with the USB adapter and check the
USB device operation.
Is the USB device working properly?
YES - Go to Step 5 .
NO - USB device is faulty. Also check the USB cable and USB adapter connector condition.■
5. On the customer′s vehicle, connect the customer′s USB device to the USB adapter.
6. Turn the ignition switch to ON (II) and turn on the audio unit.
7. Check if the USB device can be operated with the audio unit (Folders or Files UP/DOWN, etc.).
Can the USB device be operated but no sound is heard?
YES - Go to Step 8 .
NO - If the sound is normal, USB device is OK at this time. If the USB device cannot be operated, Go to USB
audio device does not work. ■
8. Turn the ignition switch to LOCK (0).
9. Disconnect audio unit connector C (14P).
10. Disconnect USB adapter unit connector A (14P).
11. Check for continuity between the terminals of audio unit connector C (14P) according to the table.
From terminal(wire color) To terminals(wire color)
C4 (PNK) C5 (BRN), C6 (WHT), C13 (RED), C14 (LT BLU)
C5 (BRN) C6 (WHT), C13 (RED), C14 (LT BLU)
C6 (WHT) C13 (RED), C14 (LT BLU)
C13 (RED) C14 (LT BLU)
12. Check for continuity between audio unit connector C (14P) and USB adapter unit connector A (14P) according to
the table.
Audio unit connector USB adapter unit connector Wire color
C5 A5 BRN
C6 A6 WHT
C13 A13 RED
C14 A14 LT BLU
Is there continuity?
YES - Substitute a known-good USB adapter unit, then reconnect all of the connectors and recheck. If the
symptom/indication goes away, replace the original USB adapter unit. If the symptom/indication is still
present, replace the audio unit.■
NO - Open in the wire(s) between the audio unit and the USB adapter unit. Replace the affected shielded
harness.■
Audio System Symptom Troubleshooting - USB audio device does not work
USB audio device does not work
NOTE:
Check the vehicle battery condition first.
Check the connectors for poor connections or loose terminals.
Check the USB device requirement:
-Mass-storage class ready digital audio player with USB 2.0 port
-More than 256 MB of RAM
-Supports MP3, WMA, and AAC (encorded with the i-Tunes) files, DRM files are not supported
1. Turn the ignition switch to ON (II) and turn on the audio unit.
2. Push the AUX button to select USB mode.
Is USB NO DATA displayed?
YES - Go to Step 3 .
NO - Go to Step 8 .
3. Turn the ignition switch to LOCK (0).
4. Connect the customer's USB device to a known-good vehicle that equipped with the USB adapter and check the
USB device operation.
Is the USB device working properly?
YES - Go to Step 5 .
NO - USB device is faulty. Also check the USB cable and USB adapter connector condition.■
5. On the customer′s vehicle, remove the USB adapter.
6. Disconnect USB adapter unit connector B (5P).
7. Check for continuity between the terminals of USB adapter unit connector B (5P) and USB adapter 5P connector
according to the table.
USB adapterunit connector USB adapterconnector
B1 1
B2 2
B3 3
B4 4
Is there continuity?
YES - Substitute a known-good USB adapter cable and recheck. If the symptom/indication goes away, replace
the original USB adapter cable. If the symptom/indication still present, go to Step 9 .
NO - Open in the wire(s) between the USB adapter unit and the USB adapter. Replace the affected shielded
harness.■
8. Turn the ignition switch to LOCK (0).
9. Remove the audio unit. Check that the audio unit connectors and the USB adapter unit connectors properly
connected.
Is the connectors properly connected?
YES - Go to Step 10 .
NO - Connect the connectors and recheck.■
10. Disconnect USB adapter unit connector A (14P).
11. Turn the ignition switch to ON (II).
12. Measure the voltage between body ground and USB adapter unit connector A (14P) No. 1 and No. 2 terminals
individually.
Is there battery voltage?
YES - Go to Step 14 .
NO - Go to Step 13 .
13. Measure the voltage between body ground and audio unit connector C (14P) No.1 and No.2 terminals individually.
Is there battery voltage?
YES - Repair open or short in the wire(s) between the audio unit and the USB adapter unit.■
NO - Replace the audio unit.■
14. Turn the ignition switch to LOCK (0).
15. Disconnect audio unit connector C (14P).
16. Check for continuity between audio unit connector C (14P) No. 11 terminal and USB adapter unit connector A (14P)
No. 11 terminal.
Is there continuity?
YES - Go to Step 17 .
NO - Repair open in the wire between the audio unit and the USB adapter unit.■
17. Check for continuity between the terminals of audio unit connector C (14P) according to the table.
From terminal(wire color) To terminals(wire color)
C3 (GRY) C9 (YEL), C10 (GRN)
C9 (YEL) C10 (GRN)
18. Check for continuity between the terminals of audio unit connector C (14P) and USB adapter unit connector A
(14P) according to the table.
Audio unit connector USB adapter unit connector Wire color
C9 A9 YEL
C10 A10 GRN
Is there continuity?
YES - Substitute a known-good USB adapter unit, then reconnect all of the connectors and recheck. If the
symptom/indication goes away, replace the original USB adapter unit. If the symptom/indication is still
present, replace the audio unit. ■
NO - Open in the wire(s) between the audio unit and the USB adapter unit. Replace the affected shielded
harness.■
Poor AM or FM radio reception or interference
Diagnostic procedure
1. Symptom Troubleshooting
Also check for
Antenna lead and/or sublead short or open in the wire
Audio unit power switch will not turn on (No information display and no sound)
Diagnostic procedure
1. Symptom Troubleshooting
Audio unit power switch will not turn off
Diagnostic procedure
1. Symptom Troubleshooting
No sound is heard from the speaker(s) (display is normal)
Diagnostic procedure
1. Symptom Troubleshooting
Audio system sound is weak or distorted (display is normal)
Diagnostic procedure
1. Symptom Troubleshooting
Audio unit button illumination does not work
Diagnostic procedure
1. Symptom Troubleshooting
Audio disc does not eject
Diagnostic procedure
1. Symptom Troubleshooting
Volume does not change
Diagnostic procedure
1. Symptom Troubleshooting
Volume does not increase with speed
Diagnostic procedure
1. Symptom Troubleshooting
Volume is too high or too low when driving at freeway speeds
Diagnostic procedure
1. Symptom Troubleshooting
Audio disc does not load
Diagnostic procedure
1. Symptom Troubleshooting
Audio disc does not play
Diagnostic procedure
1. Symptom Troubleshooting
Audio disc skips
Diagnostic procedure
1. Symptom Troubleshooting
Also check for
Tyre pressure (over-inflated), disc smudged, dirty, or scratched
Audio remote switch does not work properly
Diagnostic procedure
1. Symptom Troubleshooting
Audio unit button does not work
Diagnostic procedure
1. Symptom Troubleshooting
Audio unit disc indicator does not work
Diagnostic procedure
1. Symptom Troubleshooting
USB audio device input sound is low or cannot be heard
Diagnostic procedure
1. Symptom Troubleshooting
Also check for
Requirement of the USB devices (see Owner's manual)
USB audio device does not work
Diagnostic procedure
1. Symptom Troubleshooting
Also check for
Requirement of the USB devices (see Owner's manual)
Audio System Symptom Troubleshooting Index
Symptom Diagnostic procedure Also check for
Poor AM or FM radio reception or interference Symptom Troubleshooting Antenna lead and/or sublead short or open in
the wire
Audio unit power switch will not turn on (No information display Symptom Troubleshooting
and no sound)
Audio unit power switch will not turn off Symptom Troubleshooting
No sound is heard from the speaker(s) (display is normal) Symptom Troubleshooting
Audio system sound is weak or distorted (display is normal) Symptom Troubleshooting
Audio unit button illumination does not work Symptom Troubleshooting
Audio disc does not eject Symptom Troubleshooting
Volume does not change Symptom Troubleshooting
Volume does not increase with speed Symptom Troubleshooting
Volume is too high or too low when driving at freeway speeds Symptom Troubleshooting
Audio disc does not load Symptom Troubleshooting
Audio disc does not play Symptom Troubleshooting
Audio disc skips Symptom Troubleshooting Tyre pressure (over-inflated), disc smudged,
dirty, or scratched
Audio remote switch does not work properly Symptom Troubleshooting
Audio unit button does not work Symptom Troubleshooting
Audio unit disc indicator does not work Symptom Troubleshooting
USB audio device input sound is low or cannot be heard Symptom Troubleshooting Requirement of the USB devices (see Owner's
manual)
USB audio device does not work Symptom Troubleshooting Requirement of the USB devices (see Owner's
manual)
Audio System Self-diagnostic Function
Audio Unit Self-diagnostic Mode
1. Turn the ignition switch to ON (II). Make sure turn off the audio unit.
2. Push and hold the preset No. 1 and No. 6 buttons. While holding the buttons, push the power
button (A). Release the buttons and the self-diagnostic mode begins.
3. Each time you press the preset button, the diagnostic state is displayed according to the table.
Button Desired result Diagnostic procedure
operation
Pressing the The audio unit (center panel) Audio unit button does
preset No. 2 buttons or audio remote switch not work.
button name and/or value should be Audio remote switch
displayed (Except power does not work properly.
button)
APressing the The all of display segments If all of display segments does
preset No. 3 should become on/go off not come on, replace the audio
button unit.
BPressing the When the parking light switch Audio unit button
preset No. 4 is on, the illumination steps illumination does not
button should be changed from − work.
step to 22 step while adjusting Gauge control module
the dash brightness control (Lighting)
knob
CPressing the When you drive the vehicle, Volume does not increase with
preset No. 5 the VSP indicates the vehicle speed.
button speed in km/h.
4. If the diagnosis result is not matching the desired result, do the affected system
troubleshooting.
5. The self-diagnostic mode ends when you turn off the audio unit or turn the ignition switch to
LOCK (0).
Order of Speakers
( ) is (1)→(2)→(3)→(4)→(5)
pressed:
( ) is (1)→(5)→(4)→(3)→(2)
pressed:
4. Open the dashboard upper tray lid. Insert a flat-tip screwdriver in the groove (A), then pull the screwdriver shaft up
slightly.
5. Pull the center panel (A) out and disconnect the connectors, then remove the center panel.
NOTE: When you disconnect audio unit connector A, while pushing the tab (B), pull the lever (C) up and disconnect
the connector.
6. With USB adapter, remove the USB adapter unit.
7. Remove the mounting screws and bolts from the audio unit (A), then remove the bracket (B).
8. Remove the screws and the audio unit (A) from the center panel (B).
9. Install the audio unit in the reverse order of removal, and note these items:
Make sure all connectors are secure.
If needed, enter the anti-theft codes for the audio system.
Set the clock.
Cylinder Head Removal
NOTE:
Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
To avoid damaging the cylinder head, wait until the engine coolant temperature drops below 38 °C (100 °F) before
loosening the cylinder head bolts.
Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or
interfere with other parts.
1. Relieve fuel pressure.
2. Drain the engine coolant.
3. Do the battery removal procedure.
4. Remove the air cleaner housing assembly.
5. Remove the fuel feed hose clamp (A) and the quick-connect fitting cover (B), then disconnect the fuel feed hose (C).
6. Disconnect the upper radiator hose (A), the heater hose (B), and the water bypass hose (C).
7. Remove the heater hose from the clamps (D).
8. Remove the intake manifold/chamber assembly.
9. Remove the warm up three way catalytic converter (WU-TWC).
10. Remove the following engine wire harness connectors and wire harness clamps from the cylinder head:
Four injector connector
Engine coolant temperature (ECT) sensor 1 connector
Camshaft position (CMP) sensor connector
Secondary heated oxygen sensor (secondary HO2S) connector
Rocker arm oil control solenoid connector
12. Remove the harness holder mounting bolt (A) and the ground cable (B), then remove the harness holder (C) from
the bracket.
13. Remove the cylinder head cover.
14. Remove the cam chain.
15. Remove the cylinder head bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the
sequence until all bolts are loosened.
16. Remove the cylinder head.
Cylinder Head Installation
1. Clean the cylinder head and the block surface.
2. Install a new coolant separator (A) in the engine block whenever the engine block is replaced.
3. Install the new cylinder head gasket (B) and the dowel pins (C) on the engine block. Always use a new cylinder
head gasket.
4. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B)
on the oil pump.
5. Set the camshaft TDC. The ‘‘UP'' mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B)
on the camshaft sprocket should line up with the top edge of the head.
6. Install the cylinder head on the engine block.
7. Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts.
8. Tighten the cylinder head bolts in sequence to 29 N·m (3.0 kgf·m, 22 lbf·ft). Using a beam-type torque wrench.
When using a preset-type torque wrench, be sure to tighten slowly and do not overtighten. If a bolt makes any
noise while you are torquing it, loosen the bolt and retighten it from the first step.
12. Install the harness holder (A), then install the ground cable (B).
17. Install the upper radiator hose (A), the heater hose (B), and the water bypass hose (C).
18. Install the heater hose to the clamps (D).
19. Connect the fuel feed hose (A), then install the quick-connect fitting cover (B) and the fuel feed hose clamp (C).
20. Install the air cleaner housing assembly.
21. Do the battery installation procedure.
22. Inspect for fuel leaks. Turn the ignition switch to ON (II) (do not operate the starter) so the fuel pump runs for about
2 seconds and pressurizes the fuel line. Repeat this operation three times, then check for fuel leakage at any point
in the fuel line.
23. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
24. Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure.
25. Inspect the idle speed.
26. Inspect the ignition timing.
Camshaft Removal
1. Remove the air cleaner housing assembly.
2. Remove the intake manifold chamber.
3. Remove the following engine wire harness connectors and wire harness clamps from the cylinder head:
Four injector connector
Engine coolant temperature (ECT) sensor 1 connector
Camshaft position (CMP) sensor connector
Air fuel ratio (A/F) sensor connector
Secondary heated oxygen sensor (secondary HO2S) connector
4. Remove the harness holder mounting bolt and the ground cable, then remove the harness holder from the bracket.
5. Remove the camshaft sprocket.
6. Remove the rocker arm assembly.
7. Remove the CMP sensor.
8. Remove the camshaft thrust cover (A), then remove the camshaft (B).
Camshaft Installation
1. Install the camshaft (A), then install the camshaft thrust cover (B) with new O-ring (C).
2. Install the camshaft position (CMP) sensor.
3. Install the rocker arm assembly.
4. Install the camshaft sprocket.
5. Install the harness holder, then install the ground cable.
6. Install the following engine wire harness connectors and wire harness clamps to the cylinder head:
Four injector connector
Engine coolant temperature (ECT) sensor 1 connector
CMP sensor connector
Air fuel ratio (A/F) sensor connector
Secondary heated oxygen sensor (secondary HO2S) connector
7. Install the intake manifold chamber.
8. Install the air cleaner housing assembly.
Fuel and Emissions System Description - VTEC System
VTEC System (L13Z1 engine)
Operation (L13Z1 engine)
VTEC System (L15A7 engine)
Operation (L15A7 engine)
VTEC Component Location Index
ENGINE CONTROL
MODULE (ECM)/
POWERTRAIN CONTROL
MODULE (PCM)
General Troubleshooting
Information,
Substituting,
Update,
ROCKER ARM OIL CONTROL VALVE Replacement,
Removal/Installation,
7. Remove the bolt (A) from the rocker arm oil control valve and connect the special tool as shown, the install the bolt
(A) that was removed to the oil pressure gauge joint attachment.
8. Start the engine. Hold the engine speed at 3,000 rpm (min −1 ) without load (A/T in P or N, M/T in neutral) until the
radiator fan comes on.
9. Check the oil pressure at the engine speed of 1,000 to 2,000 rpm (min −1 ).
NOTE: Keep the measuring time as short as possible (less than 1 minute).
12. Connect the battery positive terminal (+) to terminal No. 1, and the negative terminal (−) with a wire.
13. Start the engine.
14. Check the oil pressure at the engine speed of 3,500 rpm (min −1 ).
NOTE: Keep the measuring time as short as possible (less than 1 minute).
Is the oil pressure above 392 kPa (4.0 kgf/cm 2 , 56.9 psi)?
YES - The VTEC system oil pressure is normal.■
NO - Go to Step 15 .
15. Turn the ignition switch to LOCK (0).
16. Remove the rocker arm oil control valve.
17. Check the rocker arm oil control solenoid filter for dirt and clogging.
Is the rocker arm oil control solenoid filter dirty or clogged?
YES - Replace the engine oil, engine oil filter, and the rocker arm oil control solenoid filter, then go to Step 18 .
NO - Go to Step 22 .
18. Remove the bolt (A) from the rocker arm oil control valve and connect the special tool as shown, the install the bolt
that was removed to the oil pressure gauge joint attachment.
19. Connect the battery positive terminal (+) to terminal No. 1, and the negative terminal (−) with a wire.
20. Start the engine.
21. Check the oil pressure at the engine speed of 3,500 rpm (min −1 ).
NOTE: Keep the measuring time as short as possible (less than 1 minute).
Is the oil pressure above 392 kPa (4.0 kgf/cm 2 , 56.9 psi)?
YES - Troubleshooting is complete.■
NO - Go to Step 22 .
22. Replace the rocker arm oil control valve.
23. Remove the bolt (A) from the rocker arm oil control valve and connect the special tool as shown, the install the bolt
that was removed to the oil pressure gauge joint attachment.
24. Connect the battery positive terminal (+) to terminal No. 1, and the negative terminal (−) with a wire.
25. Start the engine.
26. Check the oil pressure at the engine speed of 3,500 rpm (min −1 ).
NOTE: Keep the measuring time as short as possible (less than 1 minute).
Is the oil pressure above 392 kPa (4.0 kgf/cm 2 , 56.9 psi)?
YES - Troubleshooting is complete.■
NO - Clean the oil passage of the cylinder block or replace the cylinder block.■
Fuel and Emissions System Description - EVAP Control Diagram
Evaporative Emission (EVAP) Control Diagram
EVAP System Component Location Index
RHD model
LHD model EVAPORATIVE EMISSION (EVAP)
CANISTER PURGE VALVE
Replacement, FUEL FILL CAP
EVAPORATIVE
EMISSION (EVAP) CANISTER
EVAP System Troubleshooting,
Replacement,
EVAPORATIVE
EMISSION (EVAP)
TWO WAY VALVE
Test,
Replacement,
EVAPORATIVE
EMISSION (EVAP)
CANISTER FILTER
Replacement,
ENGINE CONTROL
MODULE (ECM)/
POWERTRAIN CONTROL
MODULE (PCM)
General Troubleshooting
EVAPORATIVE EMISSION Information,
(EVAP) CANISTER Substituting,
EVAP System Troubleshooting, Update,
Replacement, Replacement,
*: This illustration shows RHD model.
EVAPORATIVE
EMISSION (EVAP)
TWO WAY VALVE
Test,
Replacement,
EVAP System Troubleshooting
Special Tools Required
Combination gauge kit 20/−100 kPa
07YAJ-0010610
3. Hold the engine speed at 3,000 rpm (min −1 ) without load (A/T in P or N, M/T in neutral) until the radiator fan
comes on, then hold the engine speed to 3,000 rpm (min −1 ).
Is there vacuum?
YES - Go to Step 4 .
NO - Inspect vacuum hose routing. If OK, replace the EVAP canister purge valve. ■
4. Turn the ignition switch to LOCK (0).
5. Reconnect the vacuum hose to the EVAP canister purge valve.
6. Remove the fuel fill cap.
7. Remove the air cleaner.
8. Disconnect the drain tube joint (A) from the EVAP canister and connect the combination gauge kit and tube joint
adapter to EVAP canister (B).
9. Install the air cleaner.
10. Start the engine and raise speed to 3,000 rpm (min −1 ).
Does vacuum appear on gauge within 1 minute?
YES - See EVAP two way valve test to complete. Evaporative emission controls are OK.■
NO - Replace the EVAP canister. ■
LHD model
1. Disconnect the vacuum hose (A) from the EVAP canister purge valve (B) and connect a vacuum pump/gauge (C) to
the hose.
2. Start the engine, and let it idle.
NOTE: Engine coolant temperature must be below 60 °C (140 °F).
Is there vacuum?
YES - Inspect vacuum hose routing. If OK, replace the EVAP canister purge valve.■
NO - Go to Step 3 .
3. Hold the engine speed at 3,000 rpm (min −1 ) without load (A/T in N or P, M/T in neutral) until the radiator fan
comes on, then hold the engine speed to 3,000 rpm (min −1 ).
Is there vacuum?
YES - Go to Step 4 .
NO - Inspect vacuum hose routing. If OK, replace the EVAP canister purge valve. ■
4. Turn the ignition switch to LOCK (0).
5. Reconnect the vacuum hose to the EVAP canister purge valve.
6. Remove the fuel fill cap.
7. Lift the vehicle, and support it with jackstands.
8. Disconnect drain tube (A) from the EVAP canister and connect the combination gauge kit and tube joint adapter to
EVAP canister (B).
9. Lower the vehicle.
10. Start the engine and raise speed to 3,000 rpm (min −1 ).
Does vacuum appear on gauge within 1 minute?
YES - See EVAP two way valve test to complete. Evaporative emission controls are OK.■
NO - Replace the EVAP canister. ■
EVAP Canister Replacement
RHD model
1. Remove the air cleaner.
2. Disconnect the hoses (A).
3. Remove the EVAP canister (B).
4. Remove the EVAP two way valve (C) from the EVAP canister.
5. Install the parts in the reverse order of removal.
NOTE: Align the marks (D) on the hose as shown, then insert the hose. Make sure the clamp is positioned as
shown.
LHD model
1. Lift the vehicle, and support it with jackstands.
2. Disconnect the hoses (A) and tube (B).
3. Remove the EVAP canister (C).
4. Remove the EVAP two way valve (D) from the EVAP canister.
5. Install the parts in the reverse order of removal.
NOTE: Align the marks (E) on the hose as shown, then insert the hose. Make sure the clamp is positioned as
shown.
EVAP Two Way Valve Test
Special Tools Required
Combination gauge kit 20/−100 kPa
07YAJ-0010610
5. Move the vacuum pump from the vacuum fitting to the pressure fitting (A) as shown.
6. Slowly pressurize the vapor line while watching the gauge. The valve should open above 5.07 kPa (38 mmHg, 1.5
in.Hg).
If the pressure hold below 5.07 kPa (38 mmHg, 1.5 in.Hg), the valve is OK.
If the pressure doesn't hold, replace the EVAP two way valve.
EVAP Two Way Valve Replacement
1. Remove the EVAP canister. RHD model
2. Disconnect the hose (A).
3. Remove the EVAP two way valve (B).
4. Install the parts in the reverse order of removal.
LHD model
Electronic Throttle Control System Component Location Index
ELECTRONIC THROTTLE
CONTROL SYSTEM (ETCS)
CONTROL RELAY
ACCELERATOR
PEDAL POSITION
(APP) SENSOR
Signal Inspection,
ENGINE CONTROL
MODULE (ECM)/
POWERTRAIN CONTROL
MODULE (PCM)
General Troubleshooting
Information,
Substituting,
Update,
Replacement,
ACCELERATOR PEDAL MODULE
*:
*: This
This illustration
illustration shows
shows RHD
RHD model.
model. Removal/Installation,
APP Sensor Signal Inspection
NOTE:
This procedure checks the APP sensor in this fully closed position. In any other position, the APP sensor stores
DTCs which are covered in other troubleshooting procedures.
Check for Temporary DTCs or DTCs with the HDS before doing this procedure. If any DTCs are indicated,
troubleshoot them first, then do this procedure.
Press the accelerator pedal several times to check its operation. If it does not operate smoothly, check the pedal. If
you find a problem, replace the accelerator pedal module.
1. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.
2. Turn the ignition switch to ON (II).
3. Make sure the HDS communicates with the ECM/PCM. If it doesn't, go to the DLC circuit troubleshooting.
4. Make sure the accelerator pedal is not pressed, then check the APP SENSOR in the DATA LIST with the HDS.
If it is 0 %, the APP sensor is OK.
If it is not 0 %, update the ECM/PCM if it does not have the latest software, or substitute a known-good
ECM/PCM, then go to Step 5 .
5. Make sure the accelerator pedal is not pressed, then check the APP SENSOR in the DATA LIST with the HDS.
If it is 0 %, the APP sensor is OK.
If it is not 0 %, replace the accelerator pedal module, then go to Step 1 .
Fuel Pressure Test
Special Tools Required
Fuel gauge assy. 600 kPa
07406-0040004
8. Measure the voltage between fuel tank unit 4P connector terminals No. 1 and No. 3 with the ignition switch to ON
(II). There should be battery voltage.
If the voltage is OK, go to Step 9 .
If the voltage is not as specified, check for:
-a short in the LT GRN wire to ground.
-an open in the LT GRN or BLK wire.
9. Turn the ignition switch to LOCK (0).
10. Remove the fuel tank unit from the fuel tank.
11. Measure the resistance between fuel tank unit 4P connector terminals No. 1 and No. 3 with the float at E (EMPTY),
LOW (LOW FUEL INDICATOR), 1/2 (HALF FULL), and F (FULL) positions.
If you do not get the following readings, replace the fuel gauge sending unit.
Float Position F 109.5 mm (4.3 1/2 61 mm (2.4 in.) LOW 24.7 mm (1.0 E 16 mm (0.6 in.)
in.) in.)
Resistance (Ω) 19 to 21 203.3 to 213.3 529.8 to 714.1 772 to 788
3. Check the fuel quick-connect fittings (A) for dirt, and clean them if needed.
4. Place a rag or shop towel over the quick-connect fitting. Hold the connector (A) with one hand, and squeeze the
retainer tabs (B) with the other hand to release them from the locking tabs (C). Pull the connector off.
NOTE:
Be careful not to damage the line (D) or other parts. Do not use tools.
If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the
connector until it comes off easily.
Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.
5. Check the contact area (A) of the line (B) for dirt or damage.
If it is dirty, clean the connector with a pressure washer, and dry it with the compressed air.
If it is rusty or damaged, replace the fuel filter or the fuel feed line.
6. To prevent damage and keep foreign matter out, cover the disconnected connector and line ends with plastic bags
(A).
NOTE: The retainer cannot be reused once it has been removed from the line.
Replace the retainer when:
replacing the fuel rail.
replacing the fuel line.
replacing the fuel pump.
replacing the fuel filter.
replacing the fuel tank.
it has been removed from the line.
it is damaged.
Fuel Line/Quick-Connect Fitting Installation
NOTE: Before you work on fuel lines and fittings, read the ‘‘Fuel Line/Quick-Connect Fitting Precautions''.
1. Check the contact area (A) of the line (B) for dirt or damage, and clean it if needed.
2. Insert a new retainer (A) into the connector (B) if the retainer is damaged, or after:
replacing the fuel rail.
replacing the fuel line.
replacing the fuel pump.
replacing the fuel filter.
replacing the fuel tank.
removing the retainer from the line.
Use the same manufacturer retainer and the same size retainer when replacing the retainer.
3. Before connecting a new fuel tube/quick-connect fitting assembly (A), remove the old retainer (B) from the mating
line.
NOTE:
When replacing the fuel tube/quick-connect fitting assembly at the engine compartment, remove the air
cleaner, and the cover (C).
When installing the fuel tube/quick-connect fitting assembly at the engine compartment, align the mark (D)
on the fuel tube.
4. Align the quick-connect fittings with the line (A), and align the retainer locking tabs (B) with the connector grooves Connection with new
(C). Then press the quick-connect fittings onto the line until both retainer tabs lock with a clicking sound. retainer
NOTE: If it is hard to connect, put a small amount of new engine oil on the line end.
Reconnection to
existing retainer
5. When you reconnect the connector with the old retainer, make sure the connection is secure and the tabs (A) are Reconnection to
firmly locked into place; check visually and also by pulling the connector (B). When you replace the fuel line with a existing retainer
new one, make sure you remove the ring pull (C) upwards after you confirm the connection is secure.
NOTE: Before you remove the ring pull, make sure the fuel line connection is secure. If the connection is not
secure, the ring pull could break when you try to remove it.
6. Reconnect the negative cable to the battery, and turn the ignition switch to ON (II) (but do not operate the starter
motor). The fuel pump will run for about 2 seconds, and fuel pressure will rise. Repeat two or three times, and
check that there is no leakage in the fuel supply system.
Connection to new fuel
line
7. If equipped, install the quick-connect fitting cover. Set the groove of the cover (A) on the fuel line (B) as shown, then
install it. Make sure the cover is firmly locked in place.
Fuel Line Inspection
RHD model
LHD model
Fuel Pump/Fuel Gauge Sending Unit Replacement
1. Remove the fuel tank unit.
2. Remove the fuel level sensor (fuel sending unit) (A) from the fuel tank unit (B).
3. Check these items before installing the fuel tank unit:
When connecting the wire harness, make sure the connection is secure and the connector (C) is firmly
locked into place.
When installing the fuel gauge sending unit, make sure the connection is secure. Be careful not to bend or
twist it excessively.
4. Install the parts in the reverse order of removal. When installing the fuel tank unit, align the marks on the unit and
the fuel tank.
Fuel Tank Draining
1. Remove the fuel tank unit.
2. Using a hand pump, a hose, and a container suitable for fuel, draw the fuel from the fuel tank.
3. Reinstall the fuel tank unit.
Fuel Tank Unit Removal and Installation
Special Tools Required
Fuel sender wrench
07AAA-S0XA100
Removal
1. Relieve the fuel pressure.
2. Remove the center console.
3. Remove the bolts (A), the wire harness (B), the remove the parking brake lever (C).
8. Remove the locknut (A) and the fuel tank unit (B).
Installation
1. Temporarily attach a new base gasket (A) to the fuel tank unit (B), then insert the fuel tank unit partially into the
fuel tank.
NOTE:
Be careful not to damage the new base gasket.
Be careful not to bend the fuel gauge sending unit.
Do not coat the base gasket with oil.
2. Transfer the base gasket (A) from the fuel tank unit to the fuel tank.
3. Align the marks (B) on the fuel tank and fuel tank unit, then insert the fuel tank unit into the fuel tank until the fuel
tank unit rests on top of the base gasket.
NOTE: To avoid a fuel leak, check the base gasket, visually or by hand, to make sure it is not pinched.
4. Using the special tool, tighten a new locknut (A) to the specified torque.
NOTE:
After tightening, make sure the marks are still aligned.
After installation, check the base gasket, visually or by hand, to make sure it is not pinched.
5. Connect the fuel tank unit 4P connector, then connect the quick-connect fitting, the suction hose, and the fuel
vapor hose.
6. Reconnect the negative cable to the battery, and turn the ignition switch to ON (II) (but do not operate the starter
motor). The fuel pump will run for about 2 seconds, and fuel pressure rises. Repeat this two or three times, then
check that there is no leakage in the fuel supply system.
7. Install the access panel, the parking brake lever, and the center console.
Injector Test
NOTE: Check the following items before testing; idle speed, ignition timing, and idle CO%.
1. Try to start the engine.
If the engine starts, go to Step 2 .
If the engine does not start, go to Step 8 .
2. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.
3. Make sure the HDS communicates with the ECM/PCM. If it doesn't, go to the DLC circuit troubleshooting.
4. Select ONE INJECTOR in INSPECTION MENU with the HDS.
5. Disable each injector at a time by selecting number of an injector which you want to step.
6. Inspect the change in the idle speed.
If the idle speed drop is almost the same for each cylinder, the fuel injectors are normal.
If the idle speed or quality remains the same when you disconnect a particular injector, faulty injector is
suspected. Replace the injector and retest.
7. Check the clicking sound of each injector by means of a stethoscope when the engine is idling.
If any fuel injector fails to make the typical clicking sound, check the sound again after replacing the
injector.
If clicking sound is still absent, check the following.
-Whether there is wire breakage or poor connection in the YEL/BLK wire between the PGM-FI main relay 1
and the junction connector.
-Whether the junction connector is open or corroded.
-Whether there is wire breakage or poor connection in the YEL/BLK wire between the junction connector
and the injector.
-Whether there is any short-circuiting, wire breakage or poor connection in the wire between the injector
and the ECM/PCM.
If all is OK, the test is complete.
8. Turn the ignition switch to LOCK (0).
9. Remove the intake manifold.
10. Disconnect the injector connector.
11. Measure the resistance between injector (A) terminals No. 1 and No. 2. There should be 10−13 Ω.
If the resistance is OK, go to Step 12 .
If the resistance is not as specified, replace the injector.
12. Check the fuel pressure.
If the fuel pressure is as specified, check the following:
-Whether there is wire breakage, or poor connection in the YEL/BLK wire between the PGM-FI main relay
1 and the junction connector.
-Whether the junction connector is open or corroded.
-Whether there is wire breakage, or poor connection in the YEL/BLK wire between the junction connector
and the injector.
-Whether there is any short-circuiting, wire breakage or poor connection in the wire between the injector
and the ECM/PCM.
If the fuel pressure is not as specified, recheck the fuel pressure.
Injector Replacement
1. Relieve the fuel pressure.
2. Remove the intake manifold, and intake manifold chamber.
3. Remove the cover (A), then disconnect the quick-connect fitting (B).
4. Disconnect the injector connectors (C).
5. Remove the fuel rail mounting nuts (D) from the fuel rail (E).
6. Remove the fuel rail and the injectors from the cylinder head.
7. Remove the injector clips (F) from the fuel rail.
8. Remove the injectors (G) from the fuel rail.
9. Coat the new O-rings (black) (A) with clean engine oil, and insert the injectors (B) into the fuel
rail (C).
10. Install the injector clips (D).
11. Coat the new injector O-rings (brown) (E) with clean engine oil.
12. Install the fuel rail and the injectors in the cylinder head (F).
13. Install the fuel rail mounting nuts (G).
14. Connect the injector connectors (H).
15. Connect the quick-connect fitting (I).
16. Turn the ignition switch to ON (II), but do not operate the starter. After the fuel pump runs for
about 2 seconds, the fuel rail will be pressurized. Repeat this two or three times, then check for
fuel leakage.
17. Reinstall the intake manifold, and intake manifold chamber.
MIL Circuit Troubleshooting
1. Turn the ignition switch to ON (II).
2. Do the gauge self-diagnostic function.
Does the MIL indicator flash?
YES - Go to Step 3 .
NO - Substitute a known-good gauge control module, and recheck. If the symptom/indication goes away with a
known-good gauge control module, replace the original gauge control module. ■
3. Connect the HDS to the DLC.
4. Check the SCS in the DATA LIST with the HDS.
Is a short indicated?
YES - Go to Step 5 .
NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original
ECM/PCM. ■
5. Turn the ignition switch to LOCK (0).
6. Disconnect ECM/PCM connector A (49P), then disconnect the HDS.
7. Check for continuity between ECM/PCM connector terminal A32 and body ground.
Is there continuity?
YES - Repair short in the wire between the ECM/PCM (A32) and the DLC.■
NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original
ECM/PCM. ■
Idle Control System Component Location Index
ENGINE CONTROL
MODULE (ECM)/
A/C COMPRESSOR POWERTRAIN CONTROL
CLUTCH RELAY (RHD model) MODULE
BRAKE (PCM)
PEDAL POSITION
Signal Circuit General Troubleshooting
SWITCH
Troubleshooting, Information,
Signal Circuit
Substituting,
Troubleshooting,
ALTERNATOR A/C COMPRESSOR Update,
A/C COMPRESSOR Signal Circuit CLUTCH RELAY (LHD model) Replacement,
Troubleshooting, Signal Circuit
*: This illustration shows RHD model. Troubleshooting,
*: This illustration shows RHD model.
A/C Signal Circuit Troubleshooting
1. Start the engine, and let it idle.
2. Turn the blower switch on.
3. Turn the A/C switch on.
4. Check the A/C CLUTCH in the DATA LIST with the HDS.
Does it indicate ON?
YES - Go to Step 5 .
NO - Do the A/C system test. ■
5. Check the A/C system.
Does the A/C system operate?
YES - The air conditioning system circuit is OK.■
NO - Go to Step 6 .
6. Turn the ignition switch to LOCK (0).
7. Turn the ignition switch to ON (II).
8. Activate the A/C CLUTCH in the INSPECTION MENU with the HDS.
Is there a clicking noise from the A/C compressor clutch?
YES - Do the A/C system test. ■
NO - Go to Step 9 .
9. Turn the ignition switch to LOCK (0).
10. Jump the SCS line with the HDS.
11. Disconnect ECM/PCM connector A (49P).
12. Turn the ignition switch to ON (II).
13. Momentarily connect ECM/PCM connector terminal A15 to body ground with a jumper wire several times.
Is there a clicking noise from the A/C compressor clutch?
YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then
recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original
ECM/PCM. ■
NO - Check for poor connections or loose terminals at the A/C compressor clutch relay and the ECM/PCM. If
the connections are OK, check the A/C compressor clutch relay, repair open in the wire between the
ECM/PCM (A15) and the A/C compressor clutch relay and the other A/C systems.■
Alternator FR Signal Circuit Troubleshooting
1. Start the engine, and let it idle.
2. Monitor the ALTERNATOR in the DATA LIST with the HDS.
3. Check if the indicated percentage varies when the headlight switch is turned on.
Does the percentage vary?
YES - The alternator signal circuit is OK.■
NO - Go to Step 4 .
4. Turn the headlight switch off and the ignition switch to LOCK (0).
5. Jump the SCS line with the HDS.
6. Disconnect the alternator 4P connector.
7. Disconnect ECM/PCM connector B (49P).
8. Check for continuity between body ground and ECM/PCM connector terminal B47.
Is there continuity?
YES - Repair short in the wire between the ECM/PCM (B47) and the alternator.■
NO - Troubleshoot the alternator and regulator circuit. ■
Update the ECM/PCM if it does not have the latest software, or substitute a known-good
ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM,
replace the original ECM/PCM. ■
Intake Manifold Removal and Installation
Exploded View
Removal
1. Remove the harness holder mounting bolt, then remove the harness holder (A) from the bracket.
2. Remove the positive crankcase ventilation (PCV) hose (B).
3. Disconnect the exhaust gas recirculation (EGR) valve connector.
4. Remove the dipstick.
Installation
1. Install the intake manifold (A) with new gaskets (B), and tighten the bolts and nuts in a crisscross pattern in three
steps, beginning with the inner bolt.
2. Install the dipstick.
3. Connect the EGR valve connector.
4. Start the engine. Hold the engine speed at 3,000 rpm (min −1 ) without load (A/T in P or N, M/T in neutral) until the
radiator fan comes on, then let it idle.
5. Check REL TP SENSOR in the DATA LIST the HDS. The reading should be below 2.46 deg. If it is not, clean the
throttle body.
Throttle Body Removal/Installation
Do not insert your fingers into the installed throttle body when you turn the ignition switch ON (II) or
while the ignition switch is ON (II). If you do, you will seriously injure your fingers if the throttle valve is
activated.
8. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.
9. Turn the ignition switch ON (II).
10. Reset the ECM/PCM with the HDS.
11. Select the ETCS TEST in the INSPECTION MENU with the HDS.
12. Select TP POSITION CHECK and clear the throttle position (TP) learned value.
13. Turn the ignition switch to LOCK (0).
14. Turn the ignition switch to ON (II), and wait 2 seconds without pressing the accelerator pedal.
15. Do the ECM/PCM idle learn procedure.
Front Inner Fender Replacement
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the body.
1. For some models: Remove the side sill panel.
2. Remove the front inner fender (A).
-1. On the back of the wheel arch, remove the screws (B), and remove the front splash guard
(C) (for some models).
-2. From under the front bumper (D), remove the screw (E) securing the front bumper, the
splash shield (F), and the front inner fender.
-3. Remove the clip (G) securing the front bumper and the front inner fender.
-4. From the wheel arch, remove the screw (H), clip (I, J, K), clip (L).
-5. Release the hook (M) of the splash shield, then remove the front inner fender.
NOTE: To remove the clips G, I, pry the inner the clip up at the edge near the line (N) on
its head.
3. Install the inner fender in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with
new ones.
Push the clips and the hook into place securely.
Hood Opener Cable Replacement
NOTE:
Put on gloves to protect your hands.
Take care not to scratch the body and the related parts.
1. Remove these items:
Front inner fender
Kick panel, driver's side
2. Disconnect the hood opener cable (A) from the hood latch (B), and disconnect the hood opener
cable from the hood release handle (C). Take care not to kink the cable.
3. Using a clip remover, detach the clips (D, E), and peel the vinyl tapes (F) being wound onto the
opener cable off, then remove the hood opener cable from the grommet (G). Take care not to
kink the cable.
4. Install the cable in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with
new ones.
Make sure the cable is connected properly.
Make sure the hood opens properly and locks securely.
A/C Switch Test
1. Remove the A/C switch.
2. Check for continuity between the terminals in each switch position according to the table.
3. If the continuity is not as specified, replace the bulbs or the switch.
A/C Switch Replacement
1. Remove the heater control panel.
2. Disconnect the 5P connector (A) and push out the A/C switch (B) from behind the heater control panel.
5. Open the clamp (A), then remove the A/C lines (B).
6. Remove the blower unit.
7. Remove the bolt, then disconnect the A/C line (A) from the evaporator core and remove the O-rings (B).
8. Disconnect the connectors (A) from the evaporator temperature sensor and the blower resistor, then remove the
connector clip (B). Remove the self-tapping screws, the expansion valve cover (C), and the seal (D).
9. Carefully pull out the evaporator core assembly (A) without bending the lines, then remove the plate (B).
10. Pull out the evaporator temperature sensor (A) from the evaporator core.
11. Install the evaporator temperature sensor in the evaporator core, and note these items:
When the evaporator temperature sensor (A) is installed into the new evaporator core, set the sensor into
the factory-preset position (B, C).
When the evaporator temperature sensor is reinstalled into the original evaporator core, set the sensor into
the new position (D, E) because the fin may be deforming by the previous installation.
12. Install the core in the reverse order of removal and note these items:
If you're installing a new evaporator core, add refrigerant oil (SP-10).
Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing
them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage.
Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption.
Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint,
wash it off immediately.
Make sure that there is no air leakage.
Charge the system.
Heater Fan Switch Test
1. Remove the heater control panel.
2. Check for continuity between the terminals in each switch position according to the table.
3. If the continuity is not as specified, replace the heater fan switch.
Heater Control Cable Removal/Installation
Mode Control Cable
1. Open the globe box. Release the glove box stop on each side, then let the glove box hang down.
2. Set the mode control dial to VENT ( ).
3. Detach the mode control cable housing from the clamp (A), and disconnect the inner cable (B) from the mode
control linkage (C).
4. Install the cable in the reverse order of removal, and note these items:
Make sure insert the ring (D) in the groove (E).
After installation, operate the control panel controls to see whether it works properly.
4. Remove the mounting nut from the heater unit. Take care not to damage or bend the fuel lines or brake lines, etc.
5. Remove the dashboard.
6. Disconnect the connector (A) from the evaporator sensor. Remove the wire harness (B).
7. Remove the duct (A) and the drain hose (B). Remove the mounting nuts and blower-heater unit (C).
8. Remove the self-tapping screws and the heater core cover (A).
9. Except KZ, KP, and MA models; Remove the stay (B), grommet (C), and carefully pull out the heater core (D).
10. Install the heater core, and the evaporator core in the reverse order of removal.
11. Install the heater unit in the reverse order of removal, and note these items:
Except KZ, KP, and MA models:
-Do not interchange the inlet and outlet heater hoses, and install the hose clamps securely.
-Refill the cooling system with engine coolant.
-Make sure that there is no coolant leakage.
Make sure that there is no air leakage.
Refer to the evaporator core replacement.
12. Do the battery terminal reconnection procedure.
Manual Transmission and M/T Differential (i-SHIFT)
Item Measurement Qualification Standard or New Service Limit
Manual Capacity Fluid change 1.4 L (1.5 US qt, 1.2 Imp qt)
transmission Use genuine Honda MTF Overhaul 1.6 L (1.7 US qt, 1.4 Imp qt)
fluid
Mainshaft End play 0.11−0.18 mm (0.004−0.007 in.) Adjust
Diameter of bushing surface 14.870−14.890 mm (0.5854−0.5862 in.) 14.77 mm (0.5815 in.)
Diameter of distance collar 28.992−29.005 mm (1.1414−1.1419 in.) 28.93 mm (1.139 in.)
Diameter of ball bearing contact area 25.977−25.990 mm (1.0227−1.0232 in.) 25.92 mm (1.020 in.)
(clutch housing side)
Diameter of needle bearing contact area 34.984−35.000 mm (1.3773−1.3780 in.) 34.93 mm (1.375 in.)
Diameter of ball bearing contact area 24.987−25.000 mm (0.9837−0.9843 in.) 24.93 mm (0.981 in.)
(transmission housing side)
Runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.)
Mainshaft 3rd, I.D. 3rd/4th/5th 39.009−39.025 mm (1.5358−1.5364 in.) 38.95 mm (1.533 in.)
4th, 5th, and 6th 6th 35.009−35.025 mm (1.3783−1.3789 in.) 34.95 mm (1.376 in.)
gears Clearance 2nd-3rd 0.06−0.21 mm (0.002−0.008 in.) 0.30 mm (0.012 in.)
End play 4th 0.06−0.19 mm (0.002−0.007 in.) 0.28 mm (0.011 in.)
5th 0.06−0.14 mm (0.002−0.006 in.) 0.23 mm (0.009 in.)
6th 0.06−0.16 mm (0.002−0.006 in.) 0.25 mm (0.010 in.)
Thickness 3rd 27.02−27.07 mm (1.064−1.066 in.) 26.95 mm (1.061 in.)
4th 25.52−25.57 mm (1.005−1.007 in.) 25.45 mm (1.002 in.)
5th 22.42−22.47 mm (0.883−0.885 in.) 22.35 mm (0.880 in.)
6th 23.92−23.97 mm (0.942−0.944 in.) 23.85 mm (0.939 in.)
Mainshaft I.D. 29.014−29.024 mm (1.1423−1.1427 in.) 29.03 mm (1.143 in.)
4th/5th gears O.D. 34.989−35.000 mm (1.3775−1.3780 in.) 34.94 mm (1.376 in.)
distance collar Length A 48.97−49.03 mm (1.9279−1.9303 in.) ———
B 22.53−22.56 mm (0.887−0.888 in.) ———
Mainshaft 6th I.D. 25.00−25.01 mm (0.984−0.985 in.) 25.12 mm (0.989 in.)
gear distance Length 24.03−24.08 mm (0.946−0.948 in.) ———
collar
Countershaft Diameter of ball bearing contact area 26.020−26.033 mm (1.0244−1.0249 in.) 25.97 mm (1.022 in.)
(transmission housing side)
Diameter of needle bearing contact area 34.000−34.015Bmm (1.3386−1.3392 in.) 33.95 mm (1.337 in.)
(clutch housing side)
Diameter of distance collar contact area 38.987−39.000 mm (1.5349−1.5354 in.) 38.94 mm (1.533 in.)
Runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.)
32 mmA shim-to-bearing inner race 0.04−0.10 mm (0.0016−0.0039 in.) Adjust
clearance
Countershaft 1st I.D. 48.509−48.525 mm (1.9098−1.9104 in.) 48.58 mm (1.913 in.)
gear End play 0.06−0.16 mmB(0.002−0.006 in.) 0.25 mm (0.010 in.)
Thickness 21.42−21.47 mm (0.843−0.845 in.) ———
Countershaft I.D. 48.509−48.525 mm (1.9098−1.9104 in.) 48.52 mm (1.910 in.)
2nd gear End play 0.06−0.14 mm (0.002−0.006 in.) 0.23 mm (0.009 in.)
Thickness 26.42−26.47 mm (1.040−1.042 in.) ———
BATTERY
Test,
BATTERY TERMINAL
FUSE BOX
No. 24 (10 A)
B17
1 3
STATER
CUT RELAY 1
2 4
X2
B16 B33 B4
GRN PNK
GRN PUR
PUR AUXILIARY
BLK
UNDER−DASH
1 4 FUSE HOLDER
STATER
CUT RELAY 2
No. 1 No. 2
(7.5 A) (7.5 A)
2 3
BLU BLK
3 1
BRAKE
PEDAL
M SOLENOID POSITION
SWITCH
4 2
BRN LT GRN
STARTER
G401 (RHD)
G302 (LHD)
BLU
TCM A10
STEN
Starter System Circuit Troubleshooting
i-SHIFT model
NOTE:
Air temperature must be between 15 and 38 °C (59 and 100 °F) during this procedure.
After this inspection, you must reset engine control module (ECM), otherwise the ECM will continue to stop the fuel
injectors from functioning. Select ECM reset using the Honda Diagnostic System (HDS).
The battery must be in good condition and fully charged.
1. Check the No. 24 (10 A) fuse in the under-hood fuse/relay box.
Is the fuse OK?
YES - Go to Step 2 .
NO - Replace the fuse and recheck.■
2. Connect the HDS to the data link connector (DLC).
3. Turn the ignition switch to ON (II).
4. Make sure the HDS communicates with the vehicle and the ECM. If it does not, troubleshoot the DLC circuit.
5. Check the BRAKE SWITCH in the DATA LIST with the HDS.
Dose it indicate OFF?
YES - Go to Step 6 .
NO - Inspect the brake pedal position switch.
6. Press the brake pedal, and check the BRAKE SWITCH in the DATA LIST with the HDS.
Dose it indicate ON?
YES - Go to Step 13 .
NO - Go to Step 7 .
7. Turn the ignition switch OFF.
8. Disconnect the brake pedal position switch 4P connector.
9. Measure the voltage between brake pedal position switch 4P connector terminal No. 1 and body ground.
Is there battery voltage?
YES - Go to Step 10 .
NO - Repair open in the wire between the brake pedal position switch 4P connector terminal No. 1 and under-
hood fuse/relay box.■
10. Turn the ignition switch to ON (II).
11. Jump the SCS line with the HDS, then turn the ignition switch OFF.
NOTE: This step must be done to protect the ECM from damage.
12. Check for continuity between ECM connector terminal A42 and the brake pedal position switch 4P connector
terminal No. 2.
Is there continuity?
YES - Inspect the brake pedal position switch. ■
NO - Repair open in the wire between ECM (A42) and the brake pedal position switch 4P connector terminal
No. 2.■
13. Hook up the following equipment:
Ammeter, 0−400 A
Voltmeter, 0−20 V (accurate within 0.1 V)
14. Turn the ignition switch to ON (II).
15. Select PGM-FI, INSPECTION, then ALL INJECTORS OFF on the HDS.
16. With the shift lever in N position, the brake pedal pressed, turn the ignition switch ON (II), and press the engine
start switch.
Did the starter crank the engine normally?
YES - The starting system is OK. Go to Step 21 .
NO - Go to Step 17 .
17. Check the battery condition. Check electrical connections at the battery, the negative battery cable to body, the
engine ground cables, and the starter for looseness and corrosion. Then try cranking the engine again.
Did the starter crank the engine?
YES - Repairing the loose connection corrected the problem. The starting system is OK. Go to Step 23 .
NO - Check the following:
If the starter will not crank the engine at all, go to Step 18 .
If the starter cranks the engine erratically or too slowly, go to Step 20 .
If the starter does not disengage from the flywheel ring gear when you release the switch, replace
the starter, or remove and disassemble it and check for the following:
-Solenoid plunger and switch malfunction
-Dirty drive gear or damaged overrunning clutch
18. Make sure the transmission is in Neutral, and set the parking brake. Disconnect the connector (A) from the starter
solenoid S terminal. Connect a jumper wire from the battery positive terminal to the solenoid terminal.
Did the starter crank the engine?
YES - Go to Step 19 .
NO - Remove the starter, and repair or replace as necessary.■
19. Check the following items in the order listed until you find the open circuit:
The BLK wire and connectors between the under-dash fuse/relay box and the starter cut relay 2.
The BLU wire and connectors between the starter cut relay 2 and the starter.
20. While cranking the engine, check the cranking voltage and the current draw.
Is the cranking voltage greater than or equal to 8.0 V (KQ, KZ models), 9.0 V (Except KQ, KZ models) and the
current draw less than or equal to 200 A (KQ, KZ models), 150 A (Except KQ, KZ models)?
YES - Go to Step 21 .
NO - Replace the starter, or remove and disassemble it, and check for the following:
Drag in the starter armature
Shorted armature winding
Excessive drag in the engine
22. Remove the starter, and inspect its drive gear and the flywheel ring gear for damage. Replace any damaged parts.
23. Select ECM reset to cancel ALL INJECTORS OFF on the HDS.
M/T Component Location Index
DIFFERENTIAL
CHANGE LEVER
ASSEMBLY
Disassembly/Reassembly,
SHIFT FORK
Clearance
Inspection,
TRANSMISSION
TRANSMISSION FLUID Removal, Disassembly/
Inspection and Installation, Reassembly,
Replacement, BACK-UP LIGHT SWITCH Disassembly,
Test, Reassembly,
MAINSHAFT ASSEMBLY
Clearance Inspection,
COUNTERSHAFT ASSEMBLY
MAINSHAFT Clearance Inspection,
Disassembly, Countershaft Disassembly,
Inspection,
REVERSE Reassembly, Inspection,
IDLER GEAR Thrust Clearance Adjustment, Reassembly,
Bearing and Oil Seal Replacement, Bearing Replacement,
Hard to shift into 1st gear
Diagnostic procedure
1. Check and/or replace the MTF.
2. Check the clutch.
3. Check the change lever assembly.
4. Check the 1st synchro ring and the 1st gear.
5. Check the 1st/2nd synchro sleeve and hub.
Hard to shift into 2nd gear
Diagnostic procedure
1. Check and/or replace the MTF.
2. Check the change lever assembly.
3. Check the 2nd synchro ring and the 2nd gear.
4. Check the 1st/2nd synchro sleeve and hub.
Hard to shift into 3rd gear
Diagnostic procedure
1. Check and/or replace the MTF.
2. Check the change lever assembly.
3. Check the 3rd synchro ring and the 3rd gear.
4. Check the 3rd/4th synchro sleeve and hub.
Hard to shift into 4th gear
Diagnostic procedure
1. Check and/or replace the MTF.
2. Check the change lever assembly.
3. Check the 4th synchro ring and the 4th gear.
4. Check the 3rd/4th synchro sleeve and hub.
Hard to shift into 5th gear
Diagnostic procedure
1. Check and/or replace the MTF.
2. Check the change lever assembly.
3. Check the 5th synchro ring and the 5th gear.
4. Check the 5th/6th synchro sleeve and hub.
Hard to shift into 6th gear
Diagnostic procedure
1. Check and/or replace the MTF.
2. Check the change lever assembly.
3. Check the 6th synchro ring and the 6th gear.
4. Check the 5th/6th synchro sleeve and hub.
Hard to shift into reverse
Diagnostic procedure
1. Check and/or replace the MTF.
2. Check the clutch.
3. Check the change lever assembly.
4. Check the reverse shift fork and reverse idler gear.
5. Check reverse gears.
HDS does not communicate with the ECM or the vehicle
Diagnostic procedure
1. Troubleshoot the DLC circuit.
Noise from the transmission
Diagnostic procedure
1. Check and/or replace the MTF.
2. Check the MTF level (unfilled or in surplus the transmission with the MTF).
3. Check the transmission gears.
4. Check the transmission bearings.
5. Check the differential carrier, the final driven gear, and the carrier bearings.
Transmission jumps out of gear
Diagnostic procedure
1. Check and/or replace the MTF.
2. Check the detent ball springs.
3. Check the teeth of the synchro rings and the gears.
4. Check for bent, deform, or damage of the shift forks.
M/T System Symptom Troubleshooting
Symptom Diagnostic procedure
Hard to shift into 1st gear 1.Check and/or replace the MTF.
2.Check the clutch.
3.Check the change lever assembly.
4.Check the 1st synchro ring and the 1st gear.
5.Check the 1st/2nd synchro sleeve and hub.
Hard to shift into 2nd gear 1.Check and/or replace the MTF.
2.Check the change lever assembly.
3.Check the 2nd synchro ring and the 2nd gear.
4.Check the 1st/2nd synchro sleeve and hub.
Hard to shift into 3rd gear 1.Check and/or replace the MTF.
2.Check the change lever assembly.
3.Check the 3rd synchro ring and the 3rd gear.
4.Check the 3rd/4th synchro sleeve and hub.
Hard to shift into 4th gear 1.Check and/or replace the MTF.
2.Check the change lever assembly.
3.Check the 4th synchro ring and the 4th gear.
4.Check the 3rd/4th synchro sleeve and hub.
Hard to shift into 5th gear 1.Check and/or replace the MTF.
2.Check the change lever assembly.
3.Check the 5th synchro ring and the 5th gear.
4.Check the 5th/6th synchro sleeve and hub.
Hard to shift into 6th gear 1.Check and/or replace the MTF.
2.Check the change lever assembly.
3.Check the 6th synchro ring and the 6th gear.
4.Check the 5th/6th synchro sleeve and hub.
Hard to shift into reverse 1.Check and/or replace the MTF.
2.Check the clutch.
3.Check the change lever assembly.
4.Check the reverse shift fork and reverse idler gear.
5.Check reverse gears.
HDS does not communicate with the ECM or the Troubleshoot the DLC circuit.
vehicle
Noise from the transmission 1.Check and/or replace the MTF.
2.Check the MTF level (unfilled or in surplus the transmission with the MTF).
3.Check the transmission gears.
4.Check the transmission bearings.
5.Check the differential carrier, the final driven gear, and the carrier bearings.
Transmission jumps out of gear 1.Check and/or replace the MTF.
2.Check the detent ball springs.
3.Check the teeth of the synchro rings and the gears.
4.Check for bent, deform, or damage of the shift forks.
MTF Inspection and Replacement
1. Park the vehicle on level ground, and turn the engine OFF.
2. Raise the vehicle on a lift and make sure it is securely supported.
3. Remove the splash shield.
4. Remove the filler plug (A) and sealing washer (B), check the condition of the MTF and make sure it is at the proper
level (C).
5. If the MTF is dirty, remove the drain plug (A) and drain the MTF.
6. Reinstall the drain plug with a new sealing washer (B), and refill the transmission with MTF to the proper level.
Always use Genuine Honda Manual Transmission Fluid (MTF).
Fluid Capacity
1.4 L (1.5 US qt, 1.2 Imp qt) at fluid change
1.6 L (1.7 US qt, 1.4 Imp qt) at overhaul
7. Install the filler plug (C) with a new sealing washer (D).
8. Install the splash shield.
9. Lower the vehicle on the lift.
10. Without service reminder system, this procedure is complete.
CLUTCH DISC
Inspection and Removal,
Installation,
PRESSURE PLATE
Inspection and Removal,
Installation,
RELEASE BEARING
Removal,
Inspection,
Installation,
FLYWHEEL
Inspection,
Replacement,
Clutch Replacement
Special Tools Required
Stop collar
070AF-SMGC150
Center shaft
070AF-SMGC140
You must use the pressure plate compressor, the center shaft, and the stop collar required to remove and install the
clutch pressure plate or you will damage it.
Pressure Plate Inspection and Removal
1. Remove the transmission.
2. Remove the transmission mount.
3. Check the evenness of the height of the diaphragm spring fingers using the center shaft, the stop collar (A), and a
feeler gauge (B). If the height difference is more than the service limit, replace the pressure plate and clutch disc as
a set.
Standard (New): 0.8 mm (0.03 in.) max.
Service Limit: 1.0 mm (0.04 in.)
4. Install the center shaft (A), the stop collar (B), the pressure plate compressor (C), and the ring gear holder (D).
5. Turn the center screw (E) clockwise by hand to apply pressure on the diaphragm spring. Continue turning the
center screw until it stops.
6. Loosen the pressure plate mounting bolts (A) in the pattern shown in several steps, then remove the bolts.
7. Turn the center screw (B) on the pressure plate compressor counterclockwise by hand to release the pressure,
then install two pressure plate mounting bolts by finger-tight to hold the pressure plate (C).
8. Remove the stop collar, the pressure plate compressor, then remove the finger-tightened bolts and the pressure
plate.
9. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.
10. Inspect the pressure plate surface (A) for wear, cracks, and burning.
11. Inspect for warpage using a straight edge (A) and a feeler gauge (B). Measure across the pressure plate (C). If the
most measurement difference is more than the service limit, replace the pressure plate and clutch disc as a set.
Standard (New): 0.03 mm (0.001 in.) max.
Service Limit: 0.15 mm (0.006 in.)
14. Measure clutch disc thickness. If the measurement is less than the service limit, replace the clutch disc and
pressure plate as a set.
Standard (New): 7.6−8.0 mm (0.299−0.315 in.)
Service Limit: 6.0 mm (0.236 in.)
15. Measure the rivet depths from the clutch disc lining surface (A) to the rivets (B) on both sides. If the measurement
is less than the service limit, replace the clutch disc and pressure plate as a set.
Standard (New): 1.1 mm (0.043 in.) min.
Service Limit: 0.3 mm (0.012 in.)
Flywheel Inspection
16. Remove the ring gear holder.
17. Inspect the ring gear teeth for wear and damage.
18. Inspect the clutch disc mating surface on the flywheel for wear, cracks and burning.
19. Measure the flywheel (A) runout using a dial indicator (B). Through at least two full turns with pushing against the
flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the measurement is not within
the standard, replace the flywheel, and recheck the runout. Go to Step 20 .
Standard (New): 0.05 mm (0.002 in.) max.
Flywheel Replacement
20. Install the ring gear holder.
21. Loosen the flywheel mounting bolts in a crisscross pattern in several steps. Remove the bolts, then remove the
flywheel and the ring gear holder.
22. Install the flywheel on the crankshaft, and install the mounting bolts finger-tight.
23. Install the ring gear holder (A), then torque the flywheel mounting bolts (B) in a crisscross pattern in several steps.
27. Install the new pilot bearing (A) into the crankshaft using the 15 x 135L driver handle (B) and 28 x 30 mm bearing
driver attachment (C). Apply a light coat of molybdenum grease to the bearing surface.
31. Align point marks (A) across the pressure plate (B) and flywheel (C).
32. Install the pressure plate and the mounting bolts (D) by finger-tight.
33. Install the stop collar (A) and the pressure plate compressor (B).
34. Turn the center screw (C) clockwise by hand to apply pressure on the diaphragm spring. Continue turning the
center screw until it stops.
35. Be careful not to damage the pressure plate (D). Tighten (180 degrees apart) the pressure plate mounting bolts (E)
in the pattern as shown in several steps.
Specified Torque: 25 N·m (2.6 kgf·m, 19 lbf·ft)
36. Turn the center screw on the pressure plate compressor counterclockwise by hand to release the pressure.
Remove the pressure plate compressor, the stop collar, the center shaft, and the ring gear holder.
37. Make sure the diaphragm spring fingers are all the same height.
38. Do the release bearing inspection, and replace if it necessary.
39. Install the transmission mount.
40. Install the transmission.
Transmission Side
Release Bearing Removal
1. Remove the transmission.
2. Remove the release fork boot (A) from the clutch housing (B).
3. Remove the release fork (C) from the clutch housing by squeezing the release fork set spring (D). Remove the
release bearing (E).
6. With the release fork (A) slide between the release bearing pawls (B), install the release bearing on the mainshaft
while inserting the release fork through the hole (C) in the clutch housing.
7. Align the detent (D) of the release fork with the release fork bolt (E), then press the detent of the release fork over
the release fork bolt squarely.
8. Install the release fork boot (F). Make sure the boot seals around the release fork and clutch housing.
9. Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B) and that the
release bearing slides smoothly. Wipe off any excess grease.
10. Install the transmission.
Clutch disc
Item Measurement Qualification Standard or New Service Limit
Clutch disc Rivet head depth 1.1 mm (0.043 in.) 0.3 mm (0.012 in.)
Thickness 7.6−8.0 mm (0.299−0.315 in.) 6.0 mm (0.236 in.)
Pressure plate
Item Measurement Qualification Standard or New Service Limit
Pressure plate Warpage 0.03 mm (0.001 in.) max. 0.15 mm (0.006 in.)
Height of diaphragm spring fingers measured 0.8 mm (0.03 in.) 1.0 mm (0.04 in.)
with feeler gauge and special tool
Flywheel
Item Measurement Qualification Standard or New Service Limit
Flywheel Runout on clutch mating surface 0.05 mm (0.002 in.) max. ———
i-SHIFT System Fail Safe Action Index
SAE Fault Code Malfunction Criteria Fail Safe Action
(DTC)
P0504 Diagnosis by the brake information in the F-CAN Driving in manual mode is impossible.
signal.
Received brake signal did not change for 3 drive
cycles or more.
i-SHIFT drive cycle is established under these
conditions (Once all of these conditions
mentioned are satisfied, 1 drive cycle is
established.):
-Two minutes elapsed after the ignition switch
is turned ON.
-Gear is shifted to the 3rd gear or higher.
-Speed has reached 16 km/h or more.
P0780 Diagnosis by shift position while shifting gears. i-SHIFT indicator comes on.
Even if synchro position is not reached, but
reaching the connecting part in the gear has
failed at least three times.
P0810 Diagnosis by the value from the clutch actuator i-SHIFT indicator comes on.
position sensor. When vehicle speed exceedes a certain
speed (varies with the speed gear
When the position sensor value does not retained), the clutch actuator position
change even if the clutch actuator has been when the malfunction occurred is
commanded to operate. retained, and control is performed.
When vehicle speed is below a certain
speed, the mode becomes Neutral.
Although the engine can be restarted,
the time elapsed to start the engine after
pressing the starter switch is longer
than usual (about 1 sec).
P0882 Diagnosis by input voltage value and F-CAN signal i-SHIFT indicator comes on (If the F-CAN signal
value. from the ECM is sent continuously, control
continues until the IG1 in the ECM turns OFF).
When voltage input value in the TCM is almost
0 V, even if the IG1 signal (received F-CAN
value) of the ECM is ON.
SAE Fault Code Malfunction Criteria Fail Safe Action
(DTC)
P0883 Diagnosis by input voltage value and F-CAN signal i-SHIFT indicator comes on.
value.
When voltage input value in the TCM is almost
equal or more than the battery voltage, even if
the IG1 signal (received F-CAN value) of the
ECM is OFF.
P0904 Diagnosis by sensor signal. i-SHIFT indicator comes on.
Fixed at the speed gear when a
Monitors PULSES SELECT signal. malfunction has been confirmed
When the line for PULSES SELECT signal is (connects or disconnects the clutch by
open. vehicle speed).
When the line for PULSES SELECT signal is
about 0 V (GND short).
When the line for PULSES SELECT signal is
almost equal to the battery voltage (BATT
short).
U0404 Diagnosis using CAN signal. Fail safe action is classified according to
malfunction mode.
If the data received by the TCM from the gear
shift control module contains an abnormal or Auto/Manual range abnormality: i-SHIFT
INVALID value. indicator comes on. However, shifting
between Automatic and manual is not
possible.
For abnormality in other range and
abnormality in the data received: i-SHIFT
indicator comes on.
If vehicle speed is over 5 km/h, the
position at malfunction is retained, and
control is done. When vehicle speed is
below 5 km/h, the mode becomes
Neutral.
U1400 Diagnosis using CAN signal. When vehicle speed exceedes a certain
speed (varies with the speed gear
Abnormality exists in the ECM data received by retained), the clutch actuator position
TCM. when the malfunction occurred is
retained, and control is performed.
When vehicle speed is below a certain
speed, the mode becomes Neutral.
Although the engine can be restarted,
the time elapsed to start the engine after
pressing the starter switch is longer
than usual (about 1 sec).
U1401 Diagnosis using CAN signal. None
TCM received a shift down request, but when
gear is shifted, maximum engine speed is
exceeded.
GEAR SHIFT
CONTROL MODULE
Replacement,
PADDLE SHIFTER −
(DOWNSHIFT SWITCH)
Circuit Troubleshooting,
Test,
Replacement,
CLUTCH ACTUATOR (TCM)
Function Test,
Learning,
The illustration shows the LHD model; RHDBleeding,
model is similar.
Removal/Installation,
Replacement,
i-SHIFT System Circuit Diagram
BLK BLK
G502 G501
i-SHIFT System Symptom Troubleshooting - Engine doesn't crank
Engine Doesn't Crank
1. Turn the ignition switch to ON (II).
2. Press the brake pedal, and change the shift lever to the N position.
3. Check the MECHANICAL GEAR STACK FOR STARTER ENABLE in the DATA LIST with the HDS.
Is the starter enable signal OK?
YES - Test the starter. ■
NO - Go to Step 4 .
4. Check the FOOTBRAKE ON SIGNAL FOR STARTER ENABLE in the DATA LIST with the HDS.
Is the starter enable signal OK?
YES - Go to Step 5 .
NO - Do the brake pedal position switch signal circuit troubleshooting. ■
5. Check the CLUTCH OPEN SIGNAL FOR STARTER ENABLE in the DATA LIST with the HDS.
Is the starter enable signal OK?
YES - Go to Step 7 .
NO - Go to Step 6 .
6. Check the CLUTCH POSITION in the DATA LIST with the HDS.
Is there more 15 mm (0.6 in.)?
YES - Check for these conditions, and repair if necessary:■
Clutch disc and pressure plate
Diaphragm spring
Release bearing
NO - Check for these conditions, and repair if necessary:■
Slave cylinder
Release fork
7. Check the NEUTRAL SHIFTER SIGNAL FOR STARTER ENABLE in the DATA LIST with the HDS.
Is the starter enable OK?
YES - Go to Step 9 .
NO - Go to Step 8 .
8. Move the shift lever in N, then check the SHIFT VALID N FROM SHIFTER in the DATA LIST with the HDS.
It is OK?
YES - Go to Step 9 .
NO - Replace the gear shift control module. ■
9. Check the ENGAGE GEAR NEUTRAL in the DATA LIST with the HDS.
Does the gear change into the N position?
YES - Go to Step 11 .
NO - Repair the transmission internal failure.■
10. Make sure the battery is fully charged.
11. Try to start the engine.
Does the engine start?
YES - Troubleshooting is complete.■
NO - Substitute a known-good TCM, then recheck. If the symptom/indication goes away with a known-good
TCM, replace the original TCM . ■
i-SHIFT System Symptom Troubleshooting - No transmission power to wheels
No Transmission Power to Wheels
1. Start the engine.
2. Press the brake pedal, and change the shift lever to the A/M position.
3. Check the BRAKE SWITCH in the DATA LIST with the HDS.
Is the brake switch OK?
YES - Go to Step 4 .
NO - Do the brake pedal position switch signal circuit troubleshooting. ■
4. Check that the gear position indicator is displayed in 1st gear while in Auto mode.
NOTE: When all the doors are closed, the gear position indicator should not flash. If the gear position indicator
flashes, go to Step 5 .
Is the gear position displayed?
YES - Go to Step 8 .
NO - Go to Step 5 .
5. Check for these conditions:
Leaks at hoses and line joints and connections, and repair if necessary.
Clutch lines for damage and leaks. Also check for bent clutch lines.
Reservoir level.
Are they OK?
YES - Go to Step 6 .
NO - Repair the problems, then go through Step 1 to 4 and make sure it is normal.■
6. Do the i-SHIFT system learning (static mode).
7. Check that the gear position indicator is displayed in 1st gear while in Auto mode.
Is the 1st gear position displayed?
YES - Go to Step 9 .
NO - Update the TCM if it does not have the latest software, or substitute a known-good TCM, then recheck. If
the symptom/indication goes away with a known-good TCM, replace the original TCM. ■
8. Read out error memory and remove errors if present.
9. Check the clutch, concentric slave cylinder.
It is OK?
YES - Go to Step 10 .
NO - Repair the problems, then go through Step 1 to 4 and make sure it is normal.■
10. Do the ENGAGE GEARS in the FUNCTIONAL TEST MENU with the HDS, and try to shift the position that cannot
be shifted.
Does the actuator move normally?
YES - Update the TCM if it does not have the latest software, or substitute a known-good TCM, then recheck. If
the symptom/indication goes away with a known-good TCM, replace the original TCM. ■
NO - Repair the transmission internal failure, then go through Step 1 to 4 and make sure it is normal.■
i-SHIFT System Symptom Troubleshooting - Non-Creep
Non-creep
NOTE: The creep function is only supported in gears, 1, 2, and R.
1. Turn the ignition switch to ON (II).
2. Check these parameters in the DATA LIST with the HDS (check signal change inactive/active):
IDLE SWITCH
BRAKE SWITCH
PARKING BRAKE SWITCH
CLUTCH TEMPERATURE (with a clutch temperature increased to higher degrees, creeping torque is
reduced linearly. With a clutch temperature of 300 °C creeping function is inactive).
Do they show the proper valve?
YES - Go to Step 3 .
NO - Repair the items that did not show the proper valve.■
3. Press the brake pedal, and change the shift lever to the A/M position.
4. Compare the TARGET GEAR and the ACTUAL GEAR in the DATA LIST with the HDS.
Is the gear position OK?
YES - Go to Step 5 .
NO - Update the TCM if it does not have the latest software, or substitute a known-good TCM, then recheck. If
the symptom/indication goes away with a known-good TCM, replace the original TCM. ■
5. Do the i-SHIFT system learning (static mode).
Is the i-SHIFT system learning OK?
YES - Go to Step 6 .
NO - Repeat the i-SHIFT system learning (static mode) and the i-SHIFT system bleeding. ■
6. Test-drive, under these conditions:
Full load start at least five times.
Shift to every gear.
NOTE: During test drive, read out the actual clutch temperature with the HDS. Do not start test drive with clutch
temperature of 100 °C.
7. Clear any DTCs with the HDS.
8. Check the creep condition.
Is it OK?
YES - Vehicle is normal.■
NO - Go to Step 1 and recheck.
i-SHIFT System Symptom Troubleshooting - Engine stalls when stopping
Engine Stalls When Stopping
1. Check the clutch line for leaks and low fluid level.
Is there any problems?
YES - Repair the problem part, then go to Step 2 .
NO - Go to Step 3 .
2. Clear the DTCs with the HDS (invoked due to repair).
3. Bleed hydraulic system to remove any air bubbles.
4. Do the i-SHIFT system learning (static mode).
Was the i-SHIFT system learning (static mode) successfully completed?
YES - Go to Step 6 .
NO - Go to Step 5 .
5. Check for DTCs with the HDS.
Are any DTCs indicated?
YES - Go to the indicated DTC's troubleshooting.■
NO - Bleed hydraulic system to remove any air bubbles, then do the i-SHIFT system learning (static mode). ■
6. Test-drive the vehicle for 10 minutes with at least 5 full load start.
NOTE: During the test-drive, read out the actual clutch temperature with the HDS. Do not start test-drive with clutch
temperature above 100 °C (212 °F).
Was the test successfully completed?
YES - Troubleshooting is complete.■
NO - Go to Step 7 .
7. Check for DTCs with the HDS.
Are any DTCs indicated?
YES - Go to the indicated DTC's troubleshooting.■
NO - Bleed the hydraulic system to remove any air bubbles, then do the i-SHIFT system learning (static
mode). ■
i-SHIFT System Symptom Troubleshooting - i-SHIFT indicator stay on, but no DTCs are stored
i-SHIFT indicator stay on, but no DTCs are stored
1. Turn the ignition switch to ON (II).
2. Do the gauge self-diagnostic function.
Does the i-SHIFT indicator flash?
YES - Go to Step 3 .
NO - Update the TCM if it does not have the latest software, or substitute a known-good gauge control module,
and recheck. If the i-SHIFT indicator circuit is OK, replace the original gauge control module. ■
3. Connect the HDS to the DLC.
4. Make sure the HDS communicates with the vehicle and the TCM. If it does not, troubleshoot the DLC circuit.
5. Check for DTCs with the HDS.
Is DTC U0155 indicated?
YES - Go to the troubleshooting DTC U0155. ■
NO - Update the TCM if it does not have the latest software, or substitute a known-good TCM, then recheck. If
the symptom/indication goes away with a known-good TCM, replace the original TCM. ■
i-SHIFT System Functional Test
Clutch Actuator Full Stroke Operation
By the command from the HDS, the master cylinder in the clutch actuator is moved to full stroke position.
This functional test can be done under these conditions:
IG switch on.
Engine not running.
N position.
Drivers side door closed.
Engage Gears
By the command from the HDS, the clutch actuator and transmission shift change actuator operates, and shifts to any
gear.
This functional test can be done under these conditions:
IG switch on.
Engine not running.
N position.
Synchronizing position learning has been completed.
NOTE:
Specify a gear, and forcibly shift to that gear (usual paddle shifter is until 2nd).
When diagnosing malfunction of the TCM or Motor, use it depending on the cause of malfunction.
HDS does not communicate with the TCM or the vehicle
Diagnostic procedure
1. Troubleshoot the DLC circuit.
i-SHIFT indicator does not come on
Diagnostic procedure
1. Do the gauge control module troubleshooting.
2. Check the i-SHIFT INDICATOR LIGHT F-CAN in the DATA LIST with the HDS. If it is NG, replace the TCM.
i-SHIFT indicator stays on, but no DTCs are stored
Diagnostic procedure
1. Symptom troubleshooting.
i-SHIFT position indicator does not come on
Diagnostic procedure
1. Do the gauge control module troubleshooting.
2. Substitute a known-good TCM, then recheck. If it is OK, replace the original TCM.
i-SHIFT position indicator does not change or a gear position does not match
Diagnostic procedure
1. Do the gauge control module troubleshooting.
2. Move the shift lever to all position then check the SHIFT VALID N or D or A/M or + or − or R FROM SHIFTER in the DATA LIST with the HDS. If it
is NG, replace the gear shift control module.
Paddle shifter + (upshift switch) does not gear change
Diagnostic procedure
1. Paddle shifter + (upshift switch) circuit troubleshooting.
2. Paddle shifter + (upshift switch) test.
3. Substitute a known-good TCM, then recheck. If it is OK, replace the original TCM.
Paddle shifter − (downshift switch) does not gear change
Diagnostic procedure
1. Paddle shifter − (downshift switch) circuit troubleshooting.
2. Paddle shifter − (downshift switch) test.
3. Substitute a known-good TCM, then recheck. If it is OK, replace the original TCM.
Manual mode does not gear change of gear shift control module
Diagnostic procedure
1. Move the shift lever to all positions then check the SHIFT VALID N or D or A/M or + or − or R FROM SHIFTER in the DATA LIST with the HDS. If
it is NG, replace the gear shift control module.
Engine doesn't crank
Diagnostic procedure
1. Symptom troubleshooting.
No transmission power to wheels
Diagnostic procedure
1. Symptom troubleshooting.
Non-creep
Diagnostic procedure
1. Symptom troubleshooting.
Engine stalls when stopping
Diagnostic procedure
1. Symptom troubleshooting.
All segments of the gear position indicator turn on. (When starting the engine, N is not indicated on the gear position
indicator although the shift lever is at N position)
Diagnostic procedure
1. Make sure the shift lever is at N position, press the brake pedal and keep it pressed.
2. Turn the ignition switch to ON (II).
3. Keep the brake pedal pressed until the gear position indicator indicates N. If the gear position indicator does not change to N, inspect the battery.
i-SHIFT System Symptom Troubleshooting
When the vehicle has one of these symptoms, check for a diagnostic trouble code (DTC) with the HDS. If there is no DTC, do the diagnostic procedure
for the symptom, in the sequence listed, until you find the cause.
Symptom Diagnostic procedure
HDS does not communicate with the TCM or the vehicle Troubleshoot the DLC circuit.
i-SHIFT indicator does not come on 1.Do the gauge control module troubleshooting.
2.Check the i-SHIFT INDICATOR LIGHT F-CAN in the DATA LIST with the HDS. If it is NG,
replace the TCM.
i-SHIFT indicator stays on, but no DTCs are stored Symptom troubleshooting.
i-SHIFT position indicator does not come on 1.Do the gauge control module troubleshooting.
2.Substitute a known-good TCM, then recheck. If it is OK, replace the original TCM.
i-SHIFT position indicator does not change or a gear 1.Do the gauge control module troubleshooting.
position does not match 2.Move the shift lever to all position then check the SHIFT VALID N or D or A/M or + or − or
R FROM SHIFTER in the DATA LIST with the HDS. If it is NG, replace the gear shift
control module.
Paddle shifter + (upshift switch) does not gear change 1.Paddle shifter + (upshift switch) circuit troubleshooting.
2.Paddle shifter + (upshift switch) test.
3.Substitute a known-good TCM, then recheck. If it is OK, replace the original TCM.
Paddle shifter − (downshift switch) does not gear change 1.Paddle shifter − (downshift switch) circuit troubleshooting.
2.Paddle shifter − (downshift switch) test.
3.Substitute a known-good TCM, then recheck. If it is OK, replace the original TCM.
Manual mode does not gear change of gear shift control Move the shift lever to all positions then check the SHIFT VALID N or D or A/M or + or − or
module R FROM SHIFTER in the DATA LIST with the HDS. If it is NG, replace the gear shift control
module.
Engine doesn't crank Symptom troubleshooting.
No transmission power to wheels Symptom troubleshooting.
Non-creep Symptom troubleshooting.
Engine stalls when stopping Symptom troubleshooting.
All segments of the gear position indicator turn on. (When 1.Make sure the shift lever is at N position, press the brake pedal and keep it pressed.
starting the engine, N is not indicated on the gear position 2.Turn the ignition switch to ON (II).
indicator although the shift lever is at N position) 3.Keep the brake pedal pressed until the gear position indicator indicates N. If the gear
position indicator does not change to N, inspect the battery.
i-SHIFT System Bleeding
NOTE:
Do not reuse the drained fluid. Use only clean genuine Honda DOT 4 Brake Fluid from an unopened container.
Using a non-Honda brake fluid can cause corrosion and shorten the life of the system.
Make sure dirt or other foreign matter is allowed to contaminate the brake fluid.
Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off
immediately with water.
1. Make sure the brake fluid level in the reservoir (A) is at the MAX (upper) level line (B).
2. Remove the bleeder screw cap. Attach a hose to the bleeder (A), and suspend the hose in a container of brake
fluid.
3. Do the CLUTCH FILLING in the ADJUSTMENT MENU with the HDS.
4. Tighten the bleeder screw securely.
5. Do the CLUTCH FLUID AIR BLEEDING in the ADJUSTMENT MENU with the HDS.
6. Refill the brake fluid in the reservoir to the MAX (upper) level line.
7. Check the clutch operation and check for leaking fluid.
i-SHIFT System Learning
The i-SHIFT learning must be done so the TCM can learn characteristic information of the system. There are two learning
modes, ‘‘Dynamic mode'' and ‘‘Static mode'', and the learning information is different between these two. It can only be
done by doing the DYNAMIC MODE LEARNING or the STATIC MODE LEARNING in the ADJUSTMENT MENU with the
HDS. The ‘‘Dynamic mode'' requires driving procedures, and the ‘‘Static mode'' does not require any driving procedures.
i-SHIFT System Learning (Dynamic Mode)
i-SHIFT system learning (Dynamic Mode) is learned through the following steps with the HDS.
1. Shift change actuator position learning.
2. Synchronizing position learning.
3. Clutch contact position 1 learning.
4. Clutch contact position 2 learning.
5. Clutch friction learning.
6. Clutch contact position 3 learning.
Tasks necessary in the learning process.
Replace the clutch actuator (TCM).
Replace the clutch disc.
Replace the pressure plate.
Replace the flywheel.
6. Remove the bolts (A) from the slave cylinder (B) so as not to bend the clutch line.
7. Remove the clutch reservoir tank (A) from the bulkhead (B).
NOTE:
Do not spill brake fluid from the reservoir tank.
When remove the reservoir tank, fix the reservoir tank by hand.
8. Disconnect the clutch actuator connector (A) and the ground cable (B).
9. Release the lock and remove the transmission shift change actuator connector (A), then remove the transmission
shift change actuator harness cover (B) and the harness clip (C).
13. Loosen the bolts (A), then remove the clutch actuator (B) with the clutch pipe comp (C) and the clutch fluid tube
assembly (D).
14. Install the clutch actuator in the reverse order of removal.
15. Do the battery installation procedure.
16. Bleed the clutch hydraulic system.
17. Do the i-SHIFT system learning (dynamic mode).
18. Test-drive the vehicle.
i-SHIFT Clutch Fluid Tube Assembly Replacement
NOTE:
Use fender covers to avoid damaging painted surfaces.
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off
immediately with water.
1. Raise the vehicle, and make sure it is securely supported.
2. Remove the splash shield.
3. Disconnect the clutch fluid tube (A) from the clutch actuator (B). Plug the end of the clutch fluid with a shop towel
to prevent brake fluid from coming out.
4. Lower the vehicle, and make sure it is securely supported.
5. Remove the clutch reservoir tank (A) from the bulkhead (B), then remove the reservoir tube (C) from the clips (D).
Replace to the new clutch fluid tube assembly.
6. Install the clutch reservoir tank (A) on the bulkhead (B), then install the reservoir tube (C), from the clips (D).
NOTE:
Make a mark (E) on this side and insert the tube into the clip.
When install the reservoir tank, fix the reservoir tank by hand.
7. Raise the vehicle, and make sure it is securely supported.
8. Connect the clutch fluid tube (A) on to the clutch actuator (B).
NOTE:
Match the mark of tube (C) with the mark of grommet (D).
Install the tube till the mark is matched to the protrusion of tube.
Application of oil is not allowed.
9. Install the splash shield.
10. Bleed the clutch hydraulic system.
11. Do the i-SHIFT system learning (static mode).
12. Check the clutch operation and check for leaking fluid.
13. Test-drive the vehicle.
i-SHIFT Clutch Pipe Assembly Replacement
NOTE:
Use fender covers to avoid damaging painted surface.
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off
immediately with water.
1. Remove the slave cylinder (A) from the transmission housing (B), so as not to bend the clutch line.
2. Raise the vehicle, and make sure it is securely supported.
3. Remove the splash shield.
4. Remove the clip (A) then Disconnect the clutch pipe comp (B) from the clutch actuator (C). Plug the end of the
clutch line with a shop towel to prevent brake fluid from coming out.
5. Connect the clutch pipe comp (A) with the new O-ring (B) then install the clip (C) from the clutch actuator (D).
NOTE:
No clip protrude after install.
Confirm the connector being set certainly.
Application of oil is not allowed.
6. Install the splash shield.
7. Lower the vehicle, and make sure it is securely supported.
8. Pull the boot (A) back, and apply grease to the boot and slave cylinder rod (B). Reinstall the boot.
9. Apply a light coat of molybdenum grease to the tip of the push rod the slave cylinder and the release fork.
10. Install the slave cylinder (C) on the transmission housing (D).
11. Bleed the clutch hydraulic system.
12. Do the i-SHIFT system learning (static mode).
13. Check the clutch operation and check for leaking fluid.
14. Test-drive the vehicle.
i-SHIFT Gear Shift Control Module Replacement
NOTE: LHD model is shown, RHD model is similar.
1. Remove the center console.
2. Disconnect the connector (A), then remove the gear shift control module (B).
NOTE: If the gear shift control module needs to be replaced, remove the shift lever knob (C) from the gear shift
control module.
3. Install the gear shift control module (A), then connect the connector (B).
NOTE: If the gear shift control module was replaced, install the shift lever knob (C) to the gear shift control module
(turn the shift lever knob clockwise for 11 to 13 times, and make sure the shift pattern on the knob is at the right
place).
4. Install the center console.
5. Test-drive the vehicle.
Paddle Shifter - (Downshift Switch) Circuit Troubleshooting
SRS components are located in this area. Review the SRS component locations, and the precautions and procedures
before doing repair or service.
1. Remove the steering wheel.
2. Check for continuity between steering switch harness 20P connector terminals No. 8 and No. 12 while pressing
paddle shifter − (downshift switch) and when the switch is released.
Is there continuity while pressing paddle shifter − (downshift switch) and no continuity when the switch released?
YES - Go to Step 5 .
NO - Go to Step 3 .
3. Disconnect the paddle shifter − (downshift switch) connector.
4. Check for continuity between paddle shifter − (downshift switch) connector terminals while pressing the switch and
when the switch is released.
Is there continuity while pressing the switch and no continuity when the switch released?
YES - Replace the steering switch harness.■
NO - Replace the paddle shifter − (downshift switch).
5. Remove the cable reel.
6. Check for continuity cable reel 20P connector terminal No. 2 and body ground.
Is there continuity?
YES - Go to Step 7 .
NO - Repair open in the wire between cable reel 20P connector terminal No. 2 and ground (G501), or repair
poor ground (G501).■
7. Check for continuity between cable reel 20P connector terminal No. 5 and body ground.
Is there continuity?
YES - Repair short to ground in the wire between cable reel 20P connector terminal No. 5 and gear shift control
module 12P connector terminal No. 1.■
NO - Go to Step 8 .
8. Turn the ignition switch to ON (II), and shift to the A position.
9. Measure voltage between cable reel 20P connector terminal No. 2 and No. 5.
Is there battery voltage in neutral position and no voltage while pressing shift − (minus) switch?
YES - Replace the cable reel. ■
NO - Go to Step 10 .
10. Turn the ignition switch to LOCK (0).
11. Jump the SCS line with the HDS.
12. Disconnect gear shift control module 12P connector.
13. Check for continuity between gear shift control module 12P connector terminal No. 1 and cable reel 20P connector
terminal No. 5.
Is there continuity?
YES - Check for loose or poor connections at gear shift control module 12P connector terminal No. 1. If the
connection is OK, substitute a known-good gear shift control module and recheck.■
NO - Repair open in the wire between gear shift control module 12P connector terminal No. 1 and cable reel
20P connector.■
Paddle Shifter - (Downshift Switch) Test
SRS components are located in this area. Review the SRS component locations and the precautions and procedures
before doing repairs or service.
1. Remove the steering wheel.
2. Check the paddle shifter − (downshift switch) for continuity between steering switch harness 20P connector
terminals No. 8 and No. 12.
There should be continuity while pressing the paddle shifter − (downshift switch), and no continuity when the switch
is released.
3. Paddle shifter − (downshift switch) test has finished if the test result is OK.
If the switch works incorrectly at the 20P connector, test the switch at the switch connector.
4. Remove paddle shifter − (downshift switch) connector from its holder, and disconnect the connector.
5. Check the paddle shifter − (downshift switch) for continuity between the switch connector terminals while pressing
the switch and when the switch is released.
There should be continuity while pressing the switch, and no continuity when the switch is released.
6. Replace the paddle shifter − (downshift switch) if the switch works incorrectly.
7. Replace the steering switch harness if the switch is OK.
Paddle Shifter - (Downshift Switch) Replacement
SRS components are located in this area. Review the SRS component locations and the precautions and procedures
before doing repairs or service.
1. Remove the steering wheel.
2. Remove the four screws (A) securing the steering wheel rear cover (B), then remove the steering wheel rear cover.
3. Remove the paddle shifter − (downshift switch) connector (A) from its holder, and disconnect the connector.
4. Remove the screws (B) securing the paddle shifter − (C), remove the paddle shifter −, and replace it with a new
one.
5. Install the new paddle shifter − on the steering wheel, and secure it with the screws.
6. Connect the paddle shifter − connector securely, and install the connector in the connector holder.
7. Install the steering wheel rear cover, and secure the rear cover with the four screws.
8. Install the steering wheel.
Paddle Shifter + (Upshift Switch) Circuit Troubleshooting
SRS components are located in this area. Review the SRS component locations, and the precautions and procedures
before doing repair or service.
1. Remove the steering wheel.
2. Check for continuity between steering switch harness 20P connector terminals No. 7 and No. 12 while pressing
paddle shifter + (upshift switch) and when the switch is released.
Is there continuity while pressing paddle shifter + (upshift switch) and no continuity when the switch released?
YES - Go to Step 5 .
NO - Go to Step 3 .
3. Disconnect the paddle shifter + (upshift switch) connector.
4. Check for continuity between paddle shifter + (upshift switch) connector terminals while pressing the switch and
when the switch is released.
Is there continuity while pressing the switch and no continuity when the switch released?
YES - Replace the steering switch harness.■
NO - Replace the paddle shifter + (upshift switch).
5. Remove the cable reel.
6. Check for continuity cable reel 20P connector terminal No. 2 and body ground.
Is there continuity?
YES - Go to Step 7 .
NO - Repair open in the wire between cable reel 20P connector terminal No. 2 and ground (G501), or repair
poor ground (G501).■
7. Check for continuity between cable reel 20P connector terminal No. 6 and body ground.
Is there continuity?
YES - Repair short to ground in the wire between cable reel 20P connector terminal No. 6 and gear shift control
module 12P connector terminal No. 7.■
NO - Go to Step 8 .
8. Turn the ignition switch to ON (II), and shift to the A position.
9. Measure voltage between cable reel 20P connector terminal No. 2 and No. 6.
Is there about 5 V in neutral position and no voltage while pressing paddle shifter + (upshift switch)?
YES - Replace the cable reel. ■
NO - Go to Step 10 .
10. Turn the ignition switch to LOCK (0).
11. Jump the SCS line with the HDS.
12. Disconnect gear shift control module 12P connector.
13. Check for continuity between gear shift control module 12P connector terminal No. 7 and cable reel 20P connector
terminal No. 6.
Is there continuity?
YES - Check for loose or poor connections at gear shift control module 12P connector terminal No. 7 If the
connection is OK, substitute a known-good gear shift control module and recheck.■
NO - Repair open in the wire between gear shift control module 12P connector terminal No. 7 and cable reel
20P connector.■
Paddle Shifter + (Upshift Switch) Test
SRS components are located in this area. Review the SRS component locations and the precautions and procedures
before doing repairs or service.
1. Remove the steering wheel.
2. Check the paddle shifter + (upshift switch) for continuity between steering switch harness 20P connector terminals
No. 7 and No. 12.
There should be continuity while pressing the paddle shifter + (upshift switch), and no continuity when the switch is
released.
3. Paddle shifter + (upshift switch) test has finished if the test result is OK.
If the switch works incorrectly at the 20P connector, test the switch at the switch connector.
4. Remove paddle shifter + (upshift switch) connector from its holder, and disconnect the connector.
5. Check the paddle shifter + (upshift switch) for continuity between the switch connector terminals while pressing the
switch and when the switch is released.
There should be continuity while pressing the switch, and no continuity when the switch is released.
6. Replace the paddle shifter + (upshift switch) if the switch works incorrectly.
7. Replace the steering switch harness if the switch is OK.
Paddle Shifter + (Upshift Switch) Replacement
SRS components are located in this area. Review the SRS component locations and the precautions and procedures
before doing repairs or service.
1. Remove the steering wheel.
2. Remove the four screws (A) securing the steering wheel rear cover (B), then remove the steering wheel rear cover.
3. Remove the paddle shifter + (upshift switch) connector (A) from its holder, and disconnect the connector.
4. Remove the screws (B) securing the paddle shifter + (C), remove the paddle shifter +, and replace it with a new
one.
5. Install the new paddle shifter + on the steering wheel, and secure it with the screws.
6. Connect the paddle shifter + connector securely, and install the connector in the connector holder.
7. Install the steering wheel rear cover, and secure the rear cover with the four screws.
8. Install the steering wheel.
i-SHIFT Transmission Shift Change Actuator Replacement
NOTE: Use fender covers to avoid damaging painted surface.
1. Do the battery terminal disconnection procedure.
2. Remove the air cleaner housing.
3. Remove the transmission shift change actuator harness cover (A) and the harness clip (B).
4. Disconnect the transmission shift change actuator connectors (A). Remove the cotter pin (B) and select wire
washer (C).
5. Disconnect the select actuator rod (D) and shift actuator rod (E) with joint covers (F) from the change lever
assembly (G).
6. Remove the transmission shift change actuator (H), then remove the dowel pins (I) from the top of the transmission
housing.
7. Install the transmission shift change actuator in the reverse order of removal with the new cotter pin.
NOTE:
Be careful of assemble direction of joint cover.
Application of grease is not allowed at installation to the rods.
Install the select wire washer certainly.
8. Do the battery terminal reconnection procedure.
9. Do the i-SHIFT system learning (static mode).
10. Test-drive the vehicle.
TCM Replacement
NOTE:
Take care not to scratch the body.
Use fender covers to avoid damaging painted surfaces.
1. Remove the clutch actuator from the body.
2. Remove the clip (A) then remove the clutch pipe comp (B) and the clutch fluid tube assembly (C) from the clutch
actuator (D). Plug the end of the clutch line with a shop towel to prevent brake fluid from coming out.
3. Remove the clutch actuator cover cap (A) and bolt (B). Remove the harness clips (C).
4. Remove the clutch actuator (D) from the clutch actuator bracket (E).
5. Remove the bolts (A) then remove the clutch actuator cover (B) from the clutch actuator case (C). Remove the
clutch actuator case with the clutch actuator collar (D) and the O-ring (E) from the clutch actuator (F).
NOTE: Do not damage the wire harness.
6. Pull the fixtures (A) then disconnect the clutch actuator connectors (B). Remove the clutch actuator grommet (C)
from the clutch actuator (D). Replace to the new clutch actuator.
7. Connect the clutch actuator connectors (A) on the new clutch actuator (B), then fix the connectors by pushing the
fixtures (C). Install the clutch actuator grommet (D) on the clutch actuator.
8. Install the clutch actuator (A) on the clutch actuator case (B) with the clutch actuator collar (C) and the O-ring (D).
NOTE:
Do not damage the wire harness.
Match the mark of harness grommet with the mark of case at the angle shown.
Install the O-ring in the ditch of the collar certainly.
9. Install the clutch actuator cover (E) on the clutch actuator case.
10. Install the clutch actuator (A) from the clutch actuator bracket (B).
11. Install the bolt (C) and new clutch actuator cover cap (D). Install the harness clips (E).
12. Install the clutch fluid tube assembly (A) to the clutch actuator (B). Install the clutch pipe comp (C) with the new O-
ring (D) then install the clip (E) to the clutch actuator.
NOTE:
Match the mark of tube (F) with the mark of grommet (G).
Install the tube till the mark is matched to the protrusion of tube.
No clip protrude after install.
Confirm the connector being set certainly.
Application of oil is not allowed.
Apply industrial alcohol to the clutch tube assembly is allowed of installation.
13. Install the clutch actuator on the body.
14. Bleed the clutch hydraulic system.
15. Do the i-SHIFT system learning (dynamic mode).
16. Test-drive the vehicle.
M/T Assembly Removal
Special Tools Required
Engine support hanger
AAR-T-1256-J00
NOTE: Use fender covers to avoid damaging painted surfaces.
1. Secure the hood in the wide open position (support rod in the lower hole).
2. Remove the windshield wiper arms.
3. Remove the cowl covers and hood hinge cover.
4. Remove the wiper motor.
5. Remove under-cowl panel.
6. Do the battery terminal disconnection procedure.
7. Do the battery removal procedure.
8. Remove the clutch actuator (TCM).
9. Remove the transmission shift change actuator.
10. Remove the air cleaner stay.
11. Disconnect the back-up light switch connector (A), then remove the harness clips (B).
12. Disconnect the vehicle speed sensor (VSS) connector (A), then remove the harness clamp bracket (B).
13. Remove the purge control SOL.V. hose (A). Install the hanger plate (B) to the air cleaner housing mounting bracket
(C) with the 8 x 1.25 mm bolt (D).
14. Install the engine support hanger (A) with the hook (B) to the vehicle. Tighten the wing nut (C) by hand, and lift and
support the engine.
16. Remove the ground cable (A), transmission mount nuts (B), and transmission mount bolts (C), from the
transmission bracket (D).
17. Raise the vehicle on a lift, and make sure it is securely supported.
18. Remove the splash shield.
19. Drain the transmission fluid. Reinstall the drain plug using a new sealing washer.
20. Remove the right and left driveshafts.
21. Remove the heat cover.
5. Install the torque rod bracket with new bolt (A) and bolts (B).
6. Loosely install the torque rod new bolt (A), new nut (B) and new bolt (C), then remove the transmission jack.
12. Install the transmission mount bracket (A), and loosely tighten the new transmission mount bracket mounting bolts
and nuts (B).
13. Install the ground cable (C).
14. Loosen the wing nut (A). Remove the hook (B) and engine support hanger (C) from the vehicle.
15. Remove the hanger plate (A) to the air cleaner housing mounting bracket (B) with the 8 x 1.25 mm bolt (C). Install
the purge control SOL.V. hose (D).
16. Tighten the transmission mount mounting bolts and nuts in the numbered sequence shown.
17. Tighten the torque rod with the bolts and nut to the specified torque value.
19. Connect the vehicle speed sensor (VSS) connector (A), then install the harness clamp bracket (B).
20. Connect the back-up light switch connector (A), then install the harness clips (B).
21. Install the air cleaner stay.
22. Install the transmission shift change actuator.
23. Install the clutch actuator (TCM).
24. Do the battery installation procedure.
25. Refill the transmission fluid to the proper level.
26. Install the splash shield.
27. Install the under-cowl panel.
28. Install the wiper motor.
29. Install the hood hinge cover and cowl cover.
30. Install the windshield wiper arms.
31. Do the i-SHIFT system learning (static mode).
32. Check the clutch operation.
33. Check the wheel alignment and adjust it if necessary.
34. Test-driver the vehicle.
M/T Assembly Disassembly
3. Remove the change lever assembly (A) and the 8 x 10 mm dowel pins (B).
4. Remove the transmission hanger (A) and back-up light switch (B).
5. Remove the drain plug (A), filler plug (B) and the speed sensor (C), then remove the O-ring (D).
11. Remove the reverse idler gear (A) and reverse gear shaft (B).
12. Apply tape to the mainshaft splines to protect the seal, then remove the mainshaft assembly (A) and countershaft
assembly (B) with the shift forks (C) from the clutch housing (D).
13. Remove the 36 mm spring washer (E) and 26 mm washer (F).
14. Remove the differential assembly (A) and magnet (B).
15. Remove the oil gutter plate (A), 52 x 62 mm shim (B), and oil guide plate M.
M/T Assembly Reassembly
NOTE: Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces.
1. Install the magnet (A) and differential assembly (B).
2. Install the 36 mm spring washer (A) and 26 mm washer (B) over the ball bearing (C). Note the installation direction
of the spring washer.
3. Apply tape on the mainshaft spline (D) to protect the seal. Install the mainshaft and countershaft (E) into the shift
forks (F), and install them as an assembly.
4. Install the reverse idler gear (A) and the reverse gear shaft (B).
6. Select the proper size 52 x 62 mm shim (A) according to the measurements made during the mainshaft thrust
clearance adjustment. Install the oil gutter plate (B), oil guide plate M, and the 52 x 62 mm shim into the
transmission housing (C).
7. Remove any dirt and oil from the transmission housing sealing surface. Apply liquid gasket (P/N 08C70-K0234M,
08C70-K0334M, or 08C70-X0331S) to the sealing surface. Make sure you seal the entire circumference of the bolt
holes to prevent oil leakage.
NOTE: Do not install components if too much time has passed after applying the liquid gasket. Instead, remove the
old residue and reapply the liquid gasket.
12. Apply liquid gasket (P/N 08C70-K0234M, 08C70-K0334M, or 08C70-X0331S) to the threads of the 32 mm sealing
cap (C), and install it on the transmission housing.
15. Remove any dirt and oil from the change lever cover sealing surface. Apply liquid gasket (P/N 08C70-K0234M,
08C70-K0334M, or 08C70-X0331S) to the sealing surface.
NOTE: Do not install components if too much time has passed after applying the liquid gasket. Instead, remove the
old residue and reapply the liquid gasket.
16. Install the 8 x 14 mm dowel pins (A), and change lever assembly (B).
17. Install the drain plug (A), filler plug (B), speed sensor (C), and new O-ring (D).
18. Install the detent bolts (A), the springs, and the steel balls with new washers.
19. Install the 20 mm bolt (B) and a new 20 mm washer (C).
20. Install the new washer (A), the back-up light switch (B), and the transmission hanger (C).
Back-up Light Switch Test
1. Disconnect the back-up light switch 2P connector (A).
2. Check for continuity between the back-up light switch 2P connector terminals No. 1 and No. 2. There should be
continuity when the shift lever is in reverse. If the result is faulty, go to Step 3 .
3. Remove the back-up light switch (A). Check for continuity between the back-up light switch 2P connector terminals
No. 1 and No. 2. There should be continuity when the switch end (B) is pressed, and no continuity when the switch
end is released. If the result is faulty, replace the back-up light switch. If the switch is OK, check the reverse shift
piece in the transmission.
4. Install the removed or the new back-up light switch and new washer.
5. Connect the back-up light switch 2P connector.
M/T Clutch Housing Countershaft Bearing Replacement
Special Tools Required
Adjustable bearing remover head, 20−40 mm
07JAC-PH80100
2. Position the oil guide plate C and new needle bearing (A) in the bore of the clutch housing (B).
3. Install the needle bearing using the special tools.
M/T Clutch Housing Differential Thrust Clearance Adjustment
Special Tools Required
Inner driver handle, 40 mm
07746-0030100
1. Install the 80 mm shim that's the same size as the one you removed.
4. Use the special tool to bottom the differential assembly in the clutch housing.
5. Measure clearance between 80 mm shim and bearing outer race in transmission housing.
Standard: 0.01−0.10 mm (0.0004−0.0039 in.)
6. If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in
step 5 is within the standard, go to Step 9 .
80 mm Shim
Type Part Number Thickness
A 41441-PL3-B00 1.00 mm (0.039 in.)
B 41442-PL3-B00 1.10 mm (0.043 in.)
C 41443-PL3-B00 1.20 mm (0.047 in.)
D 41444-PL3-B00 1.30 mm (0.051 in.)
E 41445-PL3-B00 1.40 mm (0.055 in.)
F 41446-PL3-B00 1.50 mm (0.059 in.)
G 41447-PL3-B00 1.60 mm (0.063 in.)
H 41448-PL3-B00 1.70 mm (0.067 in.)
J 41449-PL3-B00 1.80 mm (0.071 in.)
K 41450-PL3-B00 1.05 mm (0.041 in.)
L 41451-PL3-B00 1.15 mm (0.045 in.)
M 41452-PL3-B00 1.25 mm (0.049 in.)
N 41453-PL3-B00 1.35 mm (0.053 in.)
P 41454-PL3-B00 1.45 mm (0.057 in.)
Q 41455-PL3-B00 1.55 mm (0.061 in.)
R 41456-PL3-B00 1.65 mm (0.065 in.)
S 41457-PL3-B00 1.75 mm (0.069 in.)
2. Remove the oil seal (A) from the clutch side. Be careful when removing the seal so the clutch housing is not
damaged.
3. Drive the new oil seal in from the transmission side using the special tools.
4. Drive the new ball bearing in from the transmission side using the special tools.
M/T Clutch Housing Mainshaft Thrust Clearance Adjustment
Special Tools Required
Catch adapter
07GAJ-PG20110
Base collar
07GAJ-PG20120
Base adapter
07GAJ-PG20130
2. Thoroughly clean the spring washer (A) and washer (B) before installing them on the ball bearing (C). Note the
installation direction of the spring washer.
3. Install the 3rd/4th synchro hub, the distance collar, the 5th synchro hub, the distance collar, and ball bearing on the
mainshaft.
NOTE: Refer to the mainshaft reassembly Exploded View.
4. Install the mainshaft in the clutch housing.
5. Place the transmission housing over the mainshaft and onto the clutch housing.
6. Secure the clutch and transmission housings with several 8 mm bolts.
NOTE: It is not necessary to use sealing agent between the housings for this procedure.
7. Light tap the mainshaft with a plastic hammer.
(Example)
Measure reading: 1.93 mm (0.0759 in.)
Subtract the middle of the clearance standard 0.14 mm (0.0055 in.) from the total clearance measurement.
1.93 − 0.14 = 1.79 mm (0.0705 in.)
Select the shim closest to the amount calculated, for example the 1.78 mm (0.0701 in.) shim.
14. With oil guide plate M and the appropriate size shim installed in the transmission housing, check the thrust
clearance again to verify the clearance is within the standard.
52 x 62 mm Shim
Type Part Number Thickness
A 23931-PZ9-000 0.85 mm (0.0335 in.)
B 23932-PZ9-000 0.88 mm (0.0346 in.)
C 23933-PZ9-000 0.91 mm (0.0358 in.)
D 23934-PZ9-000 0.94 mm (0.0370 in.)
E 23935-PZ9-000 0.97 mm (0.0382 in.)
F 23936-PZ9-000 1.00 mm (0.0394 in.)
G 23937-PZ9-000 1.03 mm (0.0406 in.)
H 23938-PZ9-000 1.06 mm (0.0417 in.)
I 23939-PZ9-000 1.09 mm (0.0429 in.)
J 23940-PZ9-000 1.12 mm (0.0441 in.)
K 23941-PZ9-000 1.15 mm (0.0453 in.)
L 23942-PZ9-000 1.18 mm (0.0465 in.)
M 23943-PZ9-000 1.21 mm (0.0476 in.)
N 23944-PZ9-000 1.24 mm (0.0488 in.)
O 23945-PZ9-000 1.27 mm (0.0500 in.)
P 23946-PZ9-000 1.30 mm (0.0512 in.)
Q 23947-PZ9-000 1.33 mm (0.0524 in.)
R 23948-PZ9-000 1.36 mm (0.0535 in.)
S 23949-PZ9-000 1.39 mm (0.0547 in.)
T 23950-PZ9-000 1.42 mm (0.0559 in.)
U 23951-PZ9-000 1.45 mm (0.0571 in.)
V 23952-PZ9-000 1.48 mm (0.0583 in.)
W 23953-PZ9-000 1.51 mm (0.0594 in.)
X 23954-PZ9-000 1.54 mm (0.0606 in.)
Y 23955-PZ9-000 1.57 mm (0.0618 in.)
Z 23956-PZ9-000 1.60 mm (0.0630 in.)
AA 23957-PZ9-000 1.63 mm (0.0642 in.)
AB 23958-PZ9-000 1.66 mm (0.0654 in.)
AC 23959-PZ9-000 1.69 mm (0.0665 in.)
AD 23960-PZ9-000 1.72 mm (0.0677 in.)
AE 23987-PZ9-000 1.75 mm (0.0689 in.)
AF 23988-PZ9-000 1.78 mm (0.0701 in.)
AG 23989-PZ9-000 1.81 mm (0.0713 in.)
AH 23990-PZ9-000 1.84 mm (0.0724 in.)
AI 23991-PZ9-000 1.87 mm (0.0736 in.)
AJ 23992-PZ9-000 1.90 mm (0.0748 in.)
AK 23993-PZ9-000 1.93 mm (0.0760 in.)
AL 23994-PZ9-000 1.96 mm (0.0772 in.)
AM 23995-PZ9-000 1.99 mm (0.0783 in.)
AN 23996-PZ9-000 2.02 mm (0.0795 in.)
AO 23997-PZ9-000 2.05 mm (0.0807 in.)
AP 23998-PZ9-000 2.08 mm (0.0819 in.)
AQ 23999-PZ9-000 2.11 mm (0.0831 in.)
M/T Countershaft Disassembly
1. Securely clamp the countershaft assembly in a bench vise with wood blocks.
2. Remove the special bolt (left-hand threads).
3. Support ball bearing (A) 6th gear (B) on steel blocks (C), then use a press (D) and an attachment (E) to press the
countershaft out of the ball bearing.
4. Remove the 32 mm shim and distance collar.
5. Support 4th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E)
out of the 5th gear.
6. Support 2nd gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E)
out of 3rd gear.
7. Support 1st gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E)
out of the 1st/2nd synchro.
M/T Countershaft Reassembly
Exploded View
Special Tools Required
Inner driver handle, 40 mm
07746-0030100
4. Install the 1st/2nd synchro hub (A) by aligning the synchro cone fingers (B) with the grooves in the 1st/2nd synchro
hub (C).
5. Install the reverse gear.
9. Install 2nd gear (A) by aligning the synchro cone fingers (B) with the grooves in 2nd gear (C).
10. Support the countershaft (A) on the steel blocks, then install 3rd gear (B) using the special tool and a press (C). Do
not exceed the maximum pressure.
11. Install the 4th gear (A) using the special tool and a press (B). Do not exceed the maximum pressure.
12. Install the 5th gear (A) using the special tool and a press (B). Do not exceed the maximum pressure.
13. Install 6th gear (A) using the special tools and a press (B). Do not exceed the maximum pressure.
14. Install the 32 mm shim and the old ball bearing (A) using the special tools and a press.
15. Measure the clearance between the old bearing (A) and the 32 mm shim (B) with a feeler gauge (C).
Standard: 0.04−0.10 mm (0.0016−0.0039 in.)
16. If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in
Step 17 is within the standard, replace only the new ball bearing.
32 mm Shim
Type Part Number Thickness
A 23971-RPF-000 1.56 mm (0.061 in.)
B 23972-RPF-000 1.60 mm (0.063 in.)
C 23973-RPF-000 1.64 mm (0.065 in.)
D 23974-RPF-000 1.68 mm (0.066 in.)
E 23975-RPF-000 1.72 mm (0.068 in.)
F 23976-RPF-000 1.76 mm (0.069 in.)
G 23977-RPF-000 1.80 mm (0.071 in.)
H 23978-RPF-000 1.84 mm (0.072 in.)
J 23979-RPF-000 1.88 mm (0.074 in.)
K 23980-RPF-000 1.92 mm (0.076 in.)
L 23981-RPF-000 1.96 mm (0.077 in.)
M 23982-RPF-000 2.00 mm (0.079 in.)
N 23983-RPF-000 2.04 mm (0.080 in.)
P 23984-RPF-000 2.08 mm (0.082 in.)
Q 23985-RPF-000 2.12 mm (0.083 in.)
R 23986-RPF-000 2.16 mm (0.085 in.)
S 23987-RPF-000 2.20 mm (0.087 in.)
T 23988-RPF-000 2.24 mm (0.088 in.)
U 23989-RPF-000 2.28 mm (0.090 in.)
V 23990-RPF-000 2.32 mm (0.091 in.)
17. Support 6th gear (A) on steel blocks (B) then use a press (C) and an attachment (D) to press the countershaft out
of the ball bearing.
18. If necessary, install the 32 mm shim selected in step 15, then recheck the clearance.
19. Install 6th gear (A) using the special tools and a press (B). Do not exceed the maximum pressure.
20. Install the new ball bearing (A) using the special tools and a press.
21. Tighten the new special bolt (A) (left-hand threads).
M/T Countershaft Assembly Clearance Inspection
1. Measure the clearance between the 1st gear (A) and the distance collar (B) with a feeler gauge (C). If the clearance
is more than the service limit, go to Step 2 .
Standard: 0.06−0.16 mm (0.002−0.006 in.)
Service Limit: 0.25 mm (0.010 in.)
4. Measure the clearance between the 2nd gear (A) and 3rd gear (B) with a feeler gauge (C). If the clearance is more
than the service limit, go to Step 5 .
Standard: 0.06−0.14 mm (0.02−0.006 in.)
Service Limit: 0.23 mm (0.009 in.)
Standard:
A Ball Bearing Surface (Transmission Housing Side):
26.020−26.033 mm (1.0244−1.0249 in.)
B Distance Collar Surface:
38.987−39.000 mm (1.5349−1.5354 in.)
C Needle Bearing Surface (Clutch Housing Side):
34.000−34.015 mm (1.3386−1.3392 in.)
Service Limit:
A: 25.97 mm (1.022 in.)
B: 38.94 mm (1.533 in.)
C: 33.95 mm (1.337 in.)
2. Inspect the runout by supporting both ends of the countershaft. Rotate the countershaft two complete revolutions
when measuring the runout. If the runout exceeds the service limit, replace the countershaft with a new one.
Standard: 0.02 mm (0.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)
Countershaft 1st gear
Item Measurement Qualification Standard or New Service Limit
Countershaft 1st I.D. 48.509−48.525 mm (1.9098−1.9104 in.) 48.58 mm (1.913 in.)
gear End play 0.06−0.16 mm (0.002−0.006 in.) 0.25 mm (0.010 in.)
Thickness 21.42−21.47 mm (0.843−0.845 in.) ———
Countershaft 2nd gear
Item Measurement Qualification Standard or New Service Limit
Countershaft I.D. 48.509−48.525 mm (1.9098−1.9104 in.) 48.52 mm (1.910 in.)
2nd gear End play 0.06−0.14 mm (0.002−0.006 in.) 0.23 mm (0.009 in.)
Thickness 26.42−26.47 mm (1.040−1.042 in.) ———
Countershaft 1st gear distance collar
Item Measurement Qualification Standard or New Service Limit
Countershaft 1st I.D. 39.00−39.01 mm (1.5354−1.5358 in.) 39.02 mm (1.536 in.)
gear distance O.D. 44.489−44.500 mm (1.7515−1.7520 in.) 44.44 mm (1.750 in.)
collar Length 21.53−21.58 mm (0.848−0.850 in.) ———
Countershaft 2nd gear distance collar
Item Measurement Qualification Standard or New Service Limit
Countershaft I.D. 39.00−39.01 mm (1.5354−1.5358 in.) 39.02 mm (1.536 in.)
2nd gear O.D. 44.489−44.5 mm (1.7515−1.7520 in.) 44.44 mm (1.750 in.)
distance collar Length 26.53−26.56 mm (1.044−1.046 in.) ———
M/T Change Lever Assembly Disassembly/Reassembly
Exploded View
Special Tools Required
Bearing driver attachment, 24 x 26 mm
07746-0010700
5. Remove the spring pins (A) from the select lever (B).
NOTE: Install the spring pins into the interlock with the groove of the spring pins at the angle shown.
6. Remove the select lever from the shift arm cover (C), then remove the shift piece (D) and the interlock (E).
7. Remove the oil seal (F).
8. Install in the reverse order of removal.
9. Remove the dirt and oil from the sealing surface. Apply liquid gasket (P/N 08C70-K0234M, 08C70-K0334M, or
08C70-X0331S) to the sealing surface.
NOTE: Do not install components if too much time has passed after applying the liquid gasket. Instead, remove the
old residue and reapply the liquid gasket.
10. Install the oil seal (A) using the special tools.
Inter lock
Item Measurement Qualification Standard or New Service Limit
Inter lock I.D. 14.000−14.077 mm (0.5512−0.5542 in.) ———
Inter lock to select lever 0.032−0.136 mm (0.0013−0.0054 in.) ———
Select lever
Item Measurement Qualification Standard or New Service Limit
Select lever O.D. 13.941−13.968 mm (0.5489−0.5499 in.) ———
Shift arm cover clearance 0.032−0.127 mm (0.0013−0.0050 in.) ———
M/T Reverse Shift Fork Clearance Inspection
1. Measure the clearance between the reverse idler gear (A) and the reverse shift fork (B) with a feeler gauge (C). If the
clearance is more than the service limit, go to Step 2 .
Standard: 0.20−0.60 mm (0.007−0.024 in.)
Service Limit: 1.2 mm (0.047 in.)
3. Measure the clearance between the shift fork (A) and the shift piece (B). If the clearance exceeds the service limit,
go to Step 4 .
Standard: 0.2−0.5 mm (0.008−0.020 in.)
2. Support the 3rd gear (A) on steel blocks, and press the mainshaft out of the 3rd/4th synchro hub (B). Use of a jaw-
type puller can damage the gear teeth.
M/T Mainshaft Reassembly
Exploded View
Special Tools Required
Inner driver handle, 40 mm
07746-0030100
6. Install the 3rd/4th synchro sleeve (A) by aligning the stops (B) with the 3rd/4th synchro sleeve and hub. After
installing, check the operation of the 3rd/4th synchro hub set.
7. Install the 4th gear synchro spring and ring, 4th gear and needle bearing, the distance collar, and 5th gear and its
needle bearing on the shaft.
8. Install the 5th gear synchro ring and synchro spring on the shaft.
9. Install the 5th/6th synchro hub (A) using the special tool.
10. Install the 5th/6th synchro sleeve.
11. Install the distance collar and the 6th gear.
12. Install the new ball bearing (A) using the special tools.
M/T Mainshaft Assembly Clearance Inspection
NOTE: If replacement is required, always replace the synchro sleeve and hub as a set.
1. Support the bearing inner race with an appropriate sized socket (A), and push down on the mainshaft (B).
2. Measure the clearance between 2nd (C) and 3rd (D) gears with a feeler gauge (E).
If the clearance is more than the service limit, go to Step 3 .
If the clearance is within the service limit, go to Step 4 .
Standard: 0.06−0.21 mm (0.002−0.008 in.)
Service Limit: 0.30 mm (0.012 in.)
4. Measure the clearance between 4th gear (A) and the distance collar (B) with a dial indicator (C). If the clearance is
more than the service limit, go to Step 5 .
Standard: 0.06−0.19 mm (0.002−0.007 in.)
Service Limit: 0.28 mm (0.011 in.)
7. Measure the clearance between the distance collar (A) and 5th gear (B) with a dial indicator (C). If the clearance is
more than the service limit, go to Step 8 .
Standard: 0.06−0.14 mm (0.002−0.006 in.)
Service Limit: 0.23 mm (0.009 in.)
10. Measure the clearance between the 6th gear (A) and angular ball bearing (B) with a feeler gauge (C). If the
clearance is more than the service limit, go to Step 11 .
Standard: 0.06−0.16 mm (0.002−0.006 in.)
Service Limit: 0.25 mm (0.010 in.)
11. Measure the thickness of the distance collar.
If the thickness is not within the standard, replace the distance collar.
If the thickness is within the standard, go to Step 12 .
Standard: 24.03−24.08 mm (0.946−0.948 in.)
B
Mainshaft 6th gear distance collar
Item Measurement Qualification Standard or New Service Limit
Mainshaft 6th I.D. 25.00−25.01 mm (0.984−0.985 in.) 25.12 mm (0.989 in.)
gear distance Length 24.03−24.08 mm (0.946−0.948 in.) ———
collar
M/T Mainshaft Inspection
1. Inspect the gear surface and bearing surface for wear and damage, then measure the mainshaft at points A, B, C,
D, and E. If any part of the mainshaft is less than the service limit, replace it with a new one.
Standard:
A Ball Bearing Surface (Transmission Housing Side):
24.987−25.000 mm (0.9837−0.9843 in.)
B Distance Collar Surface:
28.992−29.005 mm (1.1414−1.1419 in.)
C Needle Bearing Surface:
34.984−35.000 mm (1.3773−1.3780 in.)
D Ball Bearing Surface (Clutch Housing Side):
25.977−25.990 mm (1.0227−1.0232 in.)
E Bushing Surface:
14.870−14.890 mm (0.5854−0.5862 in.)
Service Limit:
A: 24.93 mm (0.981 in.)
B: 28.93 mm (1.139 in.)
C: 34.93 mm (1.375 in.)
D: 25.92 mm (1.020 in.)
E: 14.77 mm (0.5815 in.)
2. Inspect the runout by supporting both ends of the mainshaft. Rotate the mainshaft two complete revolutions when
measuring the runout. If the runout is more than the service limit, replace the mainshaft with a new one.
Standard: 0.02 mm (0.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)
Mainshaft 3rd, 4th, 5th, and 6th gears
Item Measurement Qualification Standard or New Service Limit
Mainshaft 3rd, I.D. 3rd/4th/5th 39.009−39.025 mm (1.5358−1.5364 in.) 38.95 mm (1.533 in.)
4th, 5th, and 6th 6th 35.009−35.025 mm (1.3783−1.3789 in.) 34.95 mm (1.376 in.)
gears Clearance 2nd-3rd 0.06−0.21 mm (0.002−0.008 in.) 0.30 mm (0.012 in.)
End play 4th 0.06−0.19 mm (0.002−0.007 in.) 0.28 mm (0.011 in.)
5th 0.06−0.14 mm (0.002−0.006 in.) 0.23 mm (0.009 in.)
6th 0.06−0.16 mm (0.002−0.006 in.) 0.25 mm (0.010 in.)
Thickness 3rd 27.02−27.07 mm (1.064−1.066 in.) 26.95 mm (1.061 in.)
4th 25.52−25.57 mm (1.005−1.007 in.) 25.45 mm (1.002 in.)
5th 22.42−22.47 mm (0.883−0.885 in.) 22.35 mm (0.880 in.)
6th 23.92−23.97 mm (0.942−0.944 in.) 23.85 mm (0.939 in.)
M/T Differential Component Location Index
CARRIER BEARING
Replacement,
DIFFERENTIAL CARRIER
Backlash Inspection,
Replacement,
CARRIER BEARING
Replacement,
M/T Differential Backlash Inspection
1. Place the differential assembly on V-blocks (A), and install both axles.
2. Measure the backlash of both pinion gears (B) with a dial indicator (C). If the backlash is not within the standard,
replace the differential carrier.
Standard (New): 0.05−0.15 mm (0.002−0.006 in.)
M/T Differential Carrier Bearings Replacement
Special Tools Required
Commercially available
bearing puller
3. Install the new bearing (A) with the 40 mm inner driver handle and a press. Press each bearing on until it bottoms.
There should be no clearance between the bearings and the carrier.
NOTE: Turn the seal (B) part of the bearing to the outside of differential, and install it.
M/T differential 80 mm shim
Item Measurement Qualification Standard or New Service Limit
M/T differential 80 mm shim-to-bearing outer race 0.01−0.10 mm (0.0004−0.0039 in.) Adjust
80 mm shim clearance in transmission housing
M/T Differential Oil Seal Replacement
Special Tools Required
Driver handle, 15 x 135L
07749-0010000
2. Remove the oil seal (A) from the clutch housing (B).
3. Install the new oil seal in the transmission housing with the special tools.
4. Install the new oil seal in the clutch housing with the special tools.
M/T differential pinion gear
Item Measurement Qualification Standard or New Service Limit
M/T differential Backlash 0.05−0.15 mm (0.002−0.006 in.) ———
pinion gear
M/T Differential Final Driven Gear/Carrier Replacement
1. Remove the bolts in a crisscross pattern in several steps, then remove the final driven gear from the differential
carrier.
2. Install the final driven gear with the chamfer on the inside diameter facing the carrier. Tighten the bolts in a
crisscross pattern in several steps.
M/T Synchro Ring and Gear Inspection
1. Inspect the inside of each synchro ring (A) for wear.
Inspect the teeth (B) on each synchro ring for wear (rounded off).
2. Inspect the teeth (A) on each synchro sleeve and matching teeth on each gear for wear (rounded off).
3. Inspect the thrust surface (A) on each gear hub for wear.
4. Inspect the cone surface (B) on each gear hub for wear and roughness.
5. Inspect the teeth on all gears (C) for uneven wear, scoring, and cracks.
6. Coat the cone surface of each gear with MTF, and place its synchro ring on it. Rotate the synchro ring, making
sure that it does not slip.
7. Measure the clearance between each gear (A) and its synchro ring (B) all around the gear. Hold the synchro ring
against the gear evenly while measuring the clearance. If the clearance is less than the service limit, replace the
synchro ring and gear.
Synchro Ring-to-Gear Clearance
Standard: 0.655−1.334 mm (0.026−0.053 in.)
Service Limit: 0.4 mm (0.016 in.)
Double Cone Synchro and Triple Cone Synchro-to-Gear Clearance Synchro ring-to-gear
Standard:
(1): Outer Synchro Ring (B) to Synchro Cone (C) 0.70−1.19 mm (0.028−0.047 in.)
(2): Synchro Cone (C) to Gear (A) 0.50−1.04 mm (0.020−0.041 in.)
(3): Outer Synchro Ring (B) to Gear (A) 0.95−1.68 mm (0.037−0.066 in.)
Service Limit:
(1): 0.3 mm (0.012 in.) Double cone synchro
(2): 0.3 mm (0.012 in.) and triple cone
(3): 0.6 mm (0.024 in.) synchro-to-gear
Synchro ring
Item Measurement Qualification Standard or New Service Limit
Synchro ring Ring-to-gear clearance Ring pushed 0.655−1.334 mm (0.026−0.053 in.) 0.4 mm (0.016 in.)
against gear
M/T Synchro Sleeve and Hub Inspection and Reassembly
1. Inspect the gear teeth on all synchro hubs and synchro sleeves for wear (rounded off corners).
2. Install each synchro hub (A) in its mating synchro sleeve (B), and check for free movement. Make sure to match
the three sets of longer teeth (C) (120 degrees apart) on the synchro sleeve with the three sets of deeper grooves
(D) in the synchro hub.
NOTE:
Do not install the synchro sleeve with its longer teeth in the 1st/2nd and 5th/6th synchro hub slots (E)
because it will damage the spring ring.
If replacement is required, always replace the synchro sleeve and synchro hub as a set.
Engine Wire Harness, CKP Sensor Subharness, Change Actuator Subharness A/B, Clutch Actuator Subharness, and Engine
Oil Level Sensor Subharness Locations
i-SHIFT system
G101 G151
10. Connect starter relay 1 4P connector terminal No. 2 to body ground with a jumper wire.
11. Check for continuity between ECM connector terminal A14 and body ground.
Is there continuity?
YES - Go to Step 17 .
NO - Repair open in the wire between the ECM (A14) and starter relay 1, then go to Step 12 .
12. Reconnect all connectors.
13. Turn the ignition switch to ON (II).
14. Reset the ECM with the HDS.
15. Do the ECM idle learn procedure.
16. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0615 indicated?
YES - Check for poor connections or loose terminals at starter relay 1, starter relay 2, and the ECM, then go to
Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
17. Reconnect all connectors.
18. Update the ECM if it does not have the latest software, or substitute a known-good ECM.
19. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0615 indicated?
YES - Check for poor connections or loose terminals at starter relay 1, starter relay 2, and the ECM. If the ECM
was updated, substitute a known-good ECM, then recheck. If the ECM was substituted, go to Step 1 .
NO - If the ECM was updated, troubleshooting is complete. If the ECM was substituted, replace the original
ECM. If any other Temporary DTCs or DTCs are indicated, go to the indicated DTC's troubleshooting.■
DTC Troubleshooting: P0616
DTC P0616: RHD model
Starter Relay 2 Malfunction
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
1. Turn the ignition switch to ON (II).
2. Check the STARTER CUT RELAY in the DATA LIST with the HDS.
LHD model
Is the 2.2 V or less indicated?
YES - Go to Step 3 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at
starter relay 1, starter relay 2, and the ECM.■
3. Start the engine.
Does the engine start?
YES - Go to Step 4 .
NO - Go to Step 7 .
4. Turn the ignition switch to LOCK (0).
5. Open the fuse lid (A), then remove starter relay 1 (B) for the under-dash fuse/relay box.
6. Test start relay 1.
Is start relay 1 OK?
YES - Replace starter relays 2, then go to Step 23 .
NO - Replace starter relay 1, then go to Step 23 .
7. Turn the ignition switch to LOCK (0).
8. Open the fuse lid (A), then remove starter relay 1 (B) for the under-dash fuse/relay box. RHD model
9. Turn the ignition switch to ON (II).
10. Check the STARTER CUT RELAY in the DATA LIST with the HDS.
Is the 2.2 V or less indicated?
YES - Go to Step 11 .
NO - Replace starter relay 1, then go to Step 23 . LHD model
11. Turn the ignition switch to LOCK (0).
12. Remove the starter relay 2 for the auxiliary under-dash fuse/relay box.
13. Turn the ignition switch to ON (II).
14. Check the STARTER CUT RELAY in the DATA LIST with the HDS.
Is the 2.2 V or less indicated?
YES - Go to Step 15 .
NO - Replace starter relay 2, then go to Step 23 .
15. Turn the ignition switch to LOCK (0).
16. Jump the SCS line with the HDS.
17. Disconnect ECM connector A (49P).
18. Check for continuity starter relay 1 4P connector terminal No. 2 to body ground.
Is the 1 MΩ or more?
YES - Go to Step 28 .
NO - Go to Step 19 .
19. Disconnect under-dash fuse/relay box connector X (3P).
20. Check for continuity under-dash fuse/relay box connector X (3P) terminal No. 2 and body ground.
Is there continuity?
YES - Repair short in the wire between the ECM (A14) and the under-dash fuse/relay box, then go to Step 23 .
NO - Go to Step 21 .
21. Disconnect under-dash fuse/relay box connector B (36P).
22. Check for continuity under-dash fuse/relay box connector B (36P) terminal No. 16 and body ground.
Is there continuity?
YES - Repair short in the wire between the under-dash fuse/relay box and starter relay 2, then go to Step 23 .
NO - Replace the under-dash fuse/relay box, then go to Step 23 .
23. Reconnect all connectors.
24. Turn the ignition switch to ON (II).
25. Reset the ECM with the HDS.
26. Do the idle learn procedure.
27. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0615 indicated?
YES - Check for poor connection or loose terminals at starter relay 1, starter relay 2, and the ECM, then go to
Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
28. Reconnect all connectors.
29. Update the ECM if it does not have the latest software, or substitute a known-good ECM.
30. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0615 indicated?
YES - Check for poor connections or loose terminals at starter relay 1, starter relay 2, and the ECM, If the ECM
was updated, substitute a known-good ECM, then recheck. If the ECM was substituted, go to Step 1 .
NO - If the ECM was updated, troubleshooting is complete. If the ECM was substituted, replace the original
ECM. If any other Temporary DTCs or DTCs are indicated, go to the indicated DTC's troubleshooting.■
DTC Troubleshooting: P0617
DTC P0617: RHD model
Starter Relay 1 Malfunction
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
1. Turn the ignition switch to ON (II).
2. Check the STARTER CUT RELAY in the DATA LIST with the HDS.
LHD model
Is the 3.2 V or more indicated?
YES - Go to Step 3 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at
starter relay 1, starter relay 2, and the ECM.■
3. Turn the ignition switch to LOCK (0).
4. Open the fuse lid (A), then remove starter relay 1 (B) for the under-dash fuse/relay box.
5. Turn the ignition switch to ON (II).
6. Check the STARTER CUT RELAY in the DATA LIST with the HDS.
Is the 3.2 V or more indicated?
YES - Go to Step 7 .
NO - Replace starter relay 1, then go to Step 12 .
7. Turn the ignition switch to LOCK (0).
8. Jump the SCS line with the HDS.
9. Disconnect ECM connector A (49P).
10. Turn the ignition switch to ON (II).
11. Measure the voltage between ECM connector terminal A14 and body ground.
Is there any voltage?
YES - Repaire short to power in the wire between the ECM (A14) and starter relay 1, then go to Step 12 .
NO - Go to Step 17 .
12. Reconnect all connectors.
13. Turn the ignition switch to ON (II).
14. Reset the ECM with the HDS.
15. Do the ECM idle learn procedure .
16. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0615 indicated?
YES - Check for poor connections or loose terminals at starter relay 1 and the ECM, then go to Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
17. Reconnect all connectors.
18. Update the ECM if it does not have the latest software, or substitute a known-good ECM.
19. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P0617 indicated?
YES - Check for poor connections or loose terminals at starter relay 1 and the ECM. If the ECM was updated,
substitute a known-good ECM, then recheck. If the ECM was substituted, go to Step 1 .
NO - If the ECM was updated, troubleshooting is complete. If the ECM was substituted, replace the original
ECM. If any other Temporary DTCs or DTCs are indicated, go to the indicated DTC's troubleshooting.■
DTC Troubleshooting: P15B7
DTC P15B7:
Starter Control System Low Input
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II), and wait 5 seconds.
5. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P15B7 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
TCM and the ECM.■
6. Turn the ignition switch to LOCK (0).
7. Jump the SCS line with the HDS.
8. Disconnect ECM connector A (49P).
9. Turn the ignition switch to ON (II).
10. Measure the voltage between ECM connector terminal A43 and body ground.
Is there voltage?
YES - Substitute a known-good TCM, then go to Step 14 . If DTC P15B7 is not indicated, replace the original
TCM, then go to Step 14 .
NO - Go to Step 11 .
11. Turn the ignition switch to LOCK (0).
12. Disconnect TCM connector A (37P).
13. Check for continuity between ECM connector terminal A43 and body ground.
Is there continuity?
YES - Repair short in the wire between the ECM (A43) and the TCM, then go to Step 14 .
NO - Go to Step 22 .
14. Turn the ignition switch to LOCK (0).
15. Reconnect all connectors and the battery.
16. Turn the ignition switch to ON (II).
17. Reset the ECM with the HDS.
18. Do the ECM idle learn procedure.
19. Turn the ignition switch to LOCK (0).
20. Turn the ignition switch to ON (II), and wait 5 seconds.
21. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P15B7 indicated?
YES - Check for poor connections or loose terminals at the TCM and the ECM, then go to Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
22. Reconnect all connectors.
23. Update the ECM if it does not have the latest software, or substitute a known-good ECM.
24. Turn the ignition switch to LOCK (0).
25. Turn the ignition switch to ON (II), and wait 5 seconds.
26. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P15B7 indicated?
YES - Check for poor connections or loose terminals at the TCM and the ECM. If the ECM was updated,
substitute a known-good ECM, then recheck. If the ECM was substituted, go to Step 1 .
NO - If the ECM was updated, troubleshooting is complete. If the ECM was substituted, replace the original
ECM. If any other Temporary DTCs or DTCs are indicated, go to the indicated DTC's troubleshooting.■
DTC Troubleshooting: P15B8
DTC P15B8:
Starter Control System High Input
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II), and wait 5 seconds.
5. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P15B8 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
TCM and the ECM.■
6. Turn the ignition switch to LOCK (0).
7. Jump the SCS line with the HDS.
8. Disconnect ECM connector A (49P).
9. Turn the ignition switch to ON (II).
10. Measure the voltage between ECM connector terminal A43 and body ground.
Is there voltage?
YES - Substitute a known-good TCM, then go to Step 14 . If DTC P15B8 is not indicated, replace the original
TCM, then go to Step 14 .
NO - Go to Step 11 .
11. Turn the ignition switch to LOCK (0).
12. Disconnect TCM connector A (37P).
13. Check for continuity between ECM connector terminal A43 and TCM connector A (37P) terminal No. 10.
Is there continuity?
YES - Go to Step 22 .
NO - Repair open in the wire between the ECM (A43) and the TCM, then go to Step 14 .
14. Turn the ignition switch to LOCK (0).
15. Reconnect all connectors.
16. Turn the ignition switch to ON (II).
17. Reset the ECM with the HDS.
18. Do the ECM idle learn procedure.
19. Turn the ignition switch to LOCK (0).
20. Turn the ignition switch to ON (II), and wait 5 seconds.
21. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P15B8 indicated?
YES - Check for poor connections or loose terminals at the TCM and the ECM, then go to Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
22. Reconnect all connectors.
23. Update the ECM if it does not have the latest software, or substitute a known-good ECM.
24. Turn the ignition switch to LOCK (0).
25. Turn the ignition switch to ON (II), and wait 5 seconds.
26. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P15B8 indicated?
YES - Check for poor connections or loose terminals at the TCM and the ECM. If the ECM was updated,
substitute a known-good ECM, then recheck. If the ECM was substituted, go to Step 1 .
NO - If the ECM was updated, troubleshooting is complete. If the ECM was substituted, replace the original
ECM. If any other Temporary DTCs or DTCs are indicated, go to the indicated DTC's troubleshooting.■
DTC Troubleshooting: P15BF
DTC P16BF:
Starter Relay Circuit Malfunction
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS and wait 5 seconds.
3. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P16BF indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
starter cut relay and the ECM.■
4. Turn the ignition switch to LOCK (0).
5. Jump the SCS line with the HDS.
6. Remove starter relay 1.
7. Disconnect ECM connector A (49P).
8. Check for continuity between ECM connector terminal A13 and body ground.
Is there continuity?
YES - Repair short in the wire between the ECM (A13) and starter relay 1, then go to Step 9 .
NO - Go to Step 14 .
9. Reconnect all connectors.
10. Turn the ignition switch to ON (II).
11. Reset the ECM with the HDS.
12. Do the ECM idle learn procedure.
13. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P16BF indicated?
YES - Check for poor connections or loose terminals at starter relay 1 and the ECM, then go to Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
14. Reconnect all connectors.
15. Update the ECM if it does not have the latest software, or substitute a known-good ECM.
16. Check for Temporary DTCs or DTCs with the HDS.
Is DTC P16BF indicated?
YES - Check for poor connections or loose terminals at the starter cut relay and the ECM. If the ECM was
updated, substitute a known-good ECM, then recheck. If the ECM was substituted, go to Step 1 .
NO - If the ECM was updated, troubleshooting is complete. If the ECM was substituted, replace the original
ECM. If any other Temporary DTCs or DTCs are indicated, go to the indicated DTC's troubleshooting.■
DTC Troubleshooting: U0101
DTC U0101:
F-CAN Malfunction (ECM-TCM)
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Check for Temporary DTCs or DTCs in the DTCs MENU with the HDS.
Is DTC U0101 indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
gauge control module, the TCM, and the ECM.■
4. Turn the ignition switch to LOCK (0).
5. Check the No. 60 AMT (40 A) fuse in the under-dash fuse/relay box.
Is the fuse OK?
YES - Go to Step 6 .
NO - Repair short in the wire between the No. 60 AMT +B (40 A) fuse and the TCM. Also replace the No. 60
AMT +B (40 A) fuse, then go to Step 19 .
6. Remove the TCM.
7. Check for poor connections at TCM connector A (37P).
Are the connections OK?
YES - Go to Step 8 .
NO - Repair the poor connections or loose terminals at TCM connector A (37P), then go to Step 19 .
8. Disconnect TCM connector A (37P).
9. Reconnect the engine compartment wire harness 10P connector; LHD model, RHD model.
10. Reconnect the ground cable of the TCM to the body ground.
11. Turn the ignition switch to ON (II).
12. Measure the voltage between TCM connector A (37P) terminal No. 28 and body ground.
Is there battery voltage?
YES - Go to Step 13 .
NO - Repair open in the wire between the No. 60 AMT (40 A) fuse and the TCM, then go to Step 19 .
13. Turn the ignition switch to LOCK (0).
14. Check for continuity between TCM connector A (37P) terminal No. 29 and body ground.
Is there continuity?
YES - Go to Step 15 .
NO - Repair open in the wire between the TCM and body ground (G151), then go to Step 19 .
15. Jump the SCS line with the HDS.
16. Disconnect ECM connector A (49P).
17. Check for continuity between ECM connector terminal A3 and TCM connector A (37P) terminal No. 33.
Is there continuity?
YES - Go to Step 18 .
NO - Repair open in the wire between the ECM (A3) and the TCM, then go to Step 19 .
18. Check for continuity between ECM connector terminal A4 and TCM connector A (37P) terminal No. 31.
Is there continuity?
YES - Update the TCM if it does not have the latest software, or substitute a known-good TCM, then go to Step
20 and recheck. If DTC U0101 is not indicated with a known-good TCM, replace the original TCM, then go
to Step 20 .
NO - Repair open in the wire between the ECM (A4) and the TCM, then go to Step 20 .
19. Turn the ignition switch to LOCK (0).
20. Install the TCM.
21. Reconnect all connectors and the battery.
22. Turn the ignition switch to ON (II).
23. Reset the ECM with the HDS.
24. Do the ECM idle learn procedure.
25. Check for Temporary DTCs or DTCs with the HDS.
Is DTC U0101 indicated?
YES - Check for poor connections or loose terminals at the gauge control module, the TCM, and the ECM, then
go to Step 1 .
NO - Troubleshooting is complete. If any other Temporary DTCs or DTCs are indicated, go to the indicated
DTC's troubleshooting.■
DTC Troubleshooting: U0103
DTC U0103:
F-CAN Malfunction (ECM-TCM)
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general troubleshooting
information.
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Check for Temporary DTCs or DTCs in the DTCs MENU with the HDS.
Is DTC U0103 indicated?
YES - Go to the i-SHIFT system's general troubleshooting information. ■
NO - Intermittent failure, the system is OK at this time. Check for poor connections or loose terminals at the
gauge control module, the TCM, and the ECM.■
How to Troubleshoot the i-SHIFT System
i-SHIFT Indicator
Under normal conditions, the i-SHIFT indicator (A) comes on when the ignition switch is turned to the ON (II) position, then
goes off after the engine is started. This indicates that the LED and its circuit are operating correctly.
If there is a failure in the system after the engine is started, the i-SHIFT indicator will stay on.
The i-SHIFT indicator comes on under certain conditions even if the i-SHIFT system is working normally. Here are some
examples:
When you use high-powered wireless equipment in the vehicle.
When the battery voltage suddenly drops below 9 volts or rises above 16 volts.
Self-diagnosis
When a problem is detected by self-diagnosis, the system does the following:
Turns the i-SHIFT indicator on.
Memorizes the DTC.
When the system detects a problem, the TCM shifts to fail-safe mode.
NOTE: If the malfunction indicator lamp (MIL) comes on at the same time as the i-SHIFT indicator, check for i-SHIFT
system DTCs and troubleshoot them first.
Intermittent Failures
The term ‘‘intermittent failure'' means a system may have had a failure, but it checks OK now. If the i-SHIFT indicator does
not come on, check for poor connections or loose terminals at all connectors related to the circuit that you are
troubleshooting. If the indicator comes ON, but then went out, the original problem may have been intermittent.
How to Check for DTCs with the Honda Diagnostic System (HDS)
If the i-SHIFT indicator has been reported on, or if a driveability problem is suspected, follow this procedure:
1. If the i-SHIFT indicator stays on, connect the HDS to the DLC (A).
2. Turn the ignition switch to ON (II).
3. Check the diagnostic trouble code (DTC) and note it.
NOTE: For specific operations, refer to the user's manual that came with the HDS.
4. After recording the DTCs, clear all DTCs.
5. Recheck the system under the same conditions as the problem has been reported on. If the DTC returns, go to the
DTC troubleshooting index. If the DTC does not return, there was an intermittent problem within the circuit. Make
sure all pins and terminals in the circuit are tight.
13. Check for continuity between clutch actuator subharness 10P connector terminal No. 2 and body ground.
Is there continuity?
YES - Repair a short in the wire between the No. 12 (10 A) fuse in the under-dash fuse/relay box and the clutch
actuator subharness 10P connector, and replace the No. 12 (10 A) fuse.■
NO - Remove the clutch actuator assembly, and check for clutch actuator subharness. If the wire harness is
OK, substitute a known-good TCM, then recheck. If the symptom/indication goes away with a known-
good TCM, replace the original TCM. ■
DTC Troubleshooting: P0883 (139-4)
DTC P0883:
TCM Power Input Voltage Higher than ECM Power Input Signal
NOTE: If there is communication error between the ECM and TCM, DTC P0883 is not stored.
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC P0883 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Check the IGNITION SWITCH ON SIGNAL in the DATA LIST with the HDS.
Does it indicate ON?
YES - Remove the clutch actuator assembly, then check for the clutch actuator subharness, if the wire harness
is OK, substitute a known-good TCM, then recheck. If the symptom/indication goes away with a known-
good TCM, replace the original TCM. ■
NO - Update the ECM if it does not have the latest software, or substitute a known-good ECM . If the ECM was
updated, check for IG1 line between the ignition switch and the ECM.■
DTC Troubleshooting: P0904 (162-2)
DTC P0904:
Select Actuator Motor Rotating Pulse Sensor Signal Circuit Malfunction
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Start the engine.
4. Change the shift lever in D, N, D, and N.
5. Check for DTCs with the HDS.
Is DTC P0904 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Turn the ignition switch to LOCK (0).
7. Disconnect the select actuator motor 6P connector.
8. Turn the ignition switch to ON (II).
9. Check for DTCs with the HDS.
Is DTC P0904 indicated?
YES - Go to Step 10 .
NO - Replace the transmission shift change actuator. ■
10. Turn the ignition switch to LOCK (0).
11. Disconnect the change actuator subharness B 10P connector.
12. Check for continuity between select actuator motor 6P connector terminal No. 5 and body ground.
Is there continuity?
YES - Repair a short to ground in the wire of the change actuator subharness B.■
NO - Go to Step 13 .
13. Turn the ignition switch to ON (II).
14. Measure voltage between select actuator motor 6P connector terminal No. 5 and body ground.
Is there battery voltage?
YES - Repair a short to power in the wire of the change actuator subharness B.■
NO - Go to Step 15 .
15. Check for continuity between select actuator motor 6P connector terminal No. 5 and change actuator subharness
B 10P connector terminal No. 5.
Is there continuity?
YES - Remove the clutch actuator assembly, and check for change actuator subharness A. If the wire harness
is OK, substitute a known-good TCM, then recheck. If the symptom/indication goes away with a known-
good TCM, replace the original TCM. ■
NO - Repair an open in the wire of the change actuator subharness B.■
DTC Troubleshooting: P0909 (162-3)
DTC P0909:
Transmission Shift Change Actuator Neutral Position Learned Value Out of Range
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Do the i-SHIFT System Learning (Static Mode).
4. Check for DTCs with the HDS.
Is DTC P0909 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Turn the ignition switch to LOCK (0).
6. Remove the transmission shift change actuator.
7. Check the shift actuator and select actuator rods.
Are they good condition?
YES - Replace the transmission shift change actuator. ■
NO - Repair the transmission internal failure.■
DTC Troubleshooting: P0910 (162-4)
DTC P0910:
Select Actuator Motor System Malfunction
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Do the i-SHIFT System Learning (Static Mode).
4. Check for DTCs with the HDS.
Is DTC P0910 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Turn the ignition switch to LOCK (0).
6. Remove the transmission shift change actuator.
7. Reconnect the 6P connectors to the transmission shift change actuator.
8. Turn the ignition switch to ON (II).
9. Change the shift lever from D to N, then from N to D, and check the select actuator rod (A) operation.
Does the select actuator rod move smoothly?
YES - Repair the transmission internal failure.■
NO - Go to Step 10 .
10. Turn the ignition switch to LOCK (0).
11. Disconnect the select actuator motor 6P connector.
12. Change the shift lever from D to N, then from N to D, and measure voltage between select actuator motor 6P
connector terminals No. 1 and No. 6.
Does the battery voltage change from positive (or negative) to negative (or positive) depending by the shift lever
operation?
YES - Replace the transmission shift change actuator. ■
NO - Go to Step 13 .
13. Change the shift lever from D to N, then from N to D, and measure voltage between select actuator motor 6P
connector terminal No. 1 and body ground.
Does the voltage change from 0 V (or battery voltage) to battery voltage (or 0 V) depending by the shift lever
operation?
YES - Go to Step 14 .
NO - Repair an open in the wire between the TCM and the transmission shift change actuator.■
14. Change the shift lever from D to N, then from N to D, and measure voltage between select actuator motor 6P
connector terminal No. 6 and body ground.
Does the voltage change from 0 V (or battery voltage) to battery voltage (or 0 V) depending by the shift lever
operation?
YES - Remove the clutch actuator assembly, and check for change actuator subharness A. If the wire harness
is OK, substitute a known-good TCM, then recheck. If the symptom/indication goes away with a known-
good TCM, replace the original TCM. ■
NO - Repair an open in the wire between the TCM and the transmission shift change actuator.■
DTC Troubleshooting: P0914 (162-5)
DTC P0914:
Shift Actuator Motor Rotating Pulse Sensor Signal Circuit Malfunction
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Start the engine.
4. Change the shift lever in D, then operate the shift lever between + and − positions.
5. Check for DTCs with the HDS.
Is DTC P0914 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Turn the ignition switch to LOCK (0).
7. Disconnect the shift actuator motor 6P connector.
8. Turn the ignition switch to ON (II).
9. Check for DTCs with the HDS.
Is DTC P0914 indicated?
YES - Go to Step 10 .
NO - Replace the transmission shift change actuator. (A few DTCs related with open circuit will be stored at
this time.)■
10. Turn the ignition switch to LOCK (0).
11. Remove the clutch actuator assembly.
12. Disconnect TCM connector B (40P).
13. Check for continuity between shift actuator motor 6P connector terminal No. 5 and body ground.
Is there continuity?
YES - Repair a short to ground in the wire of the change actuator subharness A.■
NO - Go to Step 14 .
14. Turn the ignition switch to ON (II).
15. Measure voltage between shift actuator motor 6P connector terminal No. 5 and body ground.
Is there battery voltage?
YES - Repair a short to power in the wire of the change actuator subharness A.■
NO - Go to Step 16 .
16. Turn the ignition switch to LOCK (0).
17. Check for continuity between shift actuator motor 6P connector terminal No. 5 and TCM connector terminal B9.
Is there continuity?
YES - Substitute a known-good TCM, then recheck. If the symptom/indication goes away with a known-good
TCM, replace the original TCM. ■
NO - Repair an open in the wire of the change actuator subharness A.■
DTC Troubleshooting: P0919 (162-6)
DTC P0919:
Transmission Shift Change Actuator Neutral Position Learning Time Out
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Do the i-SHIFT System Learning (Static Mode).
4. Check for DTCs with the HDS.
Is DTC P0919 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Turn the ignition switch to LOCK (0).
6. Remove the transmission shift change actuator.
7. Check if the shift arm (A) moves smoothly.
Does the shift arm move smoothly?
YES - Replace the transmission shift change actuator. ■
NO - Repair the transmission internal failure.■
DTC Troubleshooting: P0920 (162-7)
DTC P0920:
Shift Actuator Motor System Malfunction
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Do the i-SHIFT System Learning (Static Mode).
4. Check for DTCs with the HDS.
Is DTC P0920 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Turn the ignition switch to LOCK (0).
6. Remove the transmission shift change actuator.
7. Reconnect the 6P connectors to the transmission shift change actuator.
8. Turn the ignition switch to ON (II).
9. Change the shift lever from D to N, then from N to D, and check the shift actuator rod (A) operation.
Does the shift actuator rod move smoothly?
YES - Repair the transmission internal failure.■
NO - Go to Step 10 .
10. Turn the ignition switch to LOCK (0).
11. Disconnect the shift actuator motor 6P connector.
12. Change the shift lever from D to N, then from N to D, and measure voltage between shift actuator motor 6P
connector terminals No. 1 and No. 6.
Does the battery voltage change from positive (or negative) to negative (or positive) depending by the shift lever
operation?
YES - Replace the transmission shift change actuator. ■
NO - Go to Step 13 .
13. Change the shift lever from D to N, then from N to D, and measure voltage between shift actuator motor 6P
connector terminal No. 1 and body ground.
Does the voltage change from 0 V (or battery voltage) to battery voltage (or 0 V) depending by the shift lever
operation?
YES - Go to Step 14 .
NO - Repair an open in the wire between the TCM and the transmission shift change actuator.■
14. Change the shift lever from D to N, then from N to D, and measure voltage between shift actuator motor 6P
connector terminal No. 6 and body ground.
Does the voltage change from 0 V (or battery voltage) to battery voltage (or 0 V) depending by the shift lever
operation?
YES - Update the TCM if it does not have the latest software, or substitute a known-good TCM, then recheck. If
the symptom/indication goes away with a known-good TCM, replace the original TCM. ■
NO - Repair an open in the wire between the TCM and the transmission shift change actuator.■
DTC Troubleshooting: P0942 (163-4)
DTC P0942:
Clutch Hydraulic System Malfunction
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Change the shift lever in D.
4. Check for DTCs with the HDS.
Is DTC P0942 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Turn the ignition switch to LOCK (0).
6. Make sure the clutch fluid is full in the reservoir, then check the clutch hose and line joint for leaks.
Is it OK?
YES - Go to Step 7 .
NO - Replace the hose or tighten the joint if necessary.■
7. Turn the ignition switch to ON (II).
8. Change the shift lever in N.
9. Do the CLUTCH ACTUATOR FULL STROKE OPERATION in the FUNCTIONAL TEST MENU with the HDS.
10. Check the CLUTCH POSITION ACTUAL in the DATA LIST with the HDS.
Is there more than 15 mm (0.6 in.)?
YES - Check for these conditions, and repair if necessary:■
Clutch disc and pressure plate
Diaphragm spring
Release bearing
NO - Check for these conditions, and repair if necessary:■
Slave cylinder
Release fork
DTC Troubleshooting: P16C0 (99-1)
DTC P16C0:
TCM Programming Error
NOTE:
DTC P16C0 is stored when the i-SHIFT system update is not completed.
Do not turn the ignition switch to LOCK (0) while updating the i-SHIFT system. If you turn the ignition switch to
LOCK (0) before completion, the i-SHIFT system can be damaged.
1. Do the i-SHIFT system update procedure.
2. Check for DTCs with the HDS.
Is DTC P16C0 indicated?
YES - Replace the TCM. ■
NO - Update is complete.■
DTC Troubleshooting: P19E4 (162-8)
DTC P19E4:
Gear Shift Actuator Temperature Out of Range
NOTE: DTC P19E4 is stored when the gear change motor is protection mode. This can be caused due to frequent
UP/DOWN operation. In this case, it is not a malfunction.
1. Check whether the driver changed gears excessively while driving.
Did the driver change gears excessively while driving?
YES - Not failure, just a rise of the transmission shift change actuator temperature due to excessive gear
changes.■
NO - Go to Step 2 .
2. Turn the ignition switch to ON (II).
3. Clear the DTCs with the HDS.
4. In order to cool the system, wait for at least 1 hour.
5. Test-drive the vehicle for at least 10 minutes.
6. Check for DTCs with the HDS.
Is DTC P19E4 indicated?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time.■
7. Turn the ignition switch to LOCK (0).
8. Remove the transmission shift change actuator.
9. Check if the shift arm (A) moves smoothly.
Does the shift arm move smoothly?
YES - Replace the transmission shift change actuator. ■
NO - Repair the transmission internal failure.■
DTC Troubleshooting: P19E5 (163-2)
DTC P19E5:
Clutch Actuator Stroke Sensor Signal Out of Range
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC P19E5 indicated?
YES - Update the TCM if it does not have the latest software, or substitute a known-good TCM, then recheck. If
the symptom/indication goes away with a known-good TCM, replace the original TCM. ■
NO - Intermittent failure, the system is OK at this time.■
DTC Troubleshooting: P19E6 (164-1)
DTC P19E6:
Clutch Temperature Too High (Over 300 °C (572 °F))
NOTE:
DTC P19E6 is stored when the clutch temperature is higher than 300 °C (572 °F).
If the DTC P19E6 is stored, the system stops the creep control.
The value of the clutch temperature is reset when the DTC is cleared with the HDS.
The clutch temperature is high when the UP/DOWN operation is done frequently at a short time.
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Test-drive the vehicle for at least 10 minutes.
4. Check for DTCs with the HDS.
Is DTC P19E6 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Turn the ignition switch to LOCK (0).
6. Do the CLUTCH FLUID AIR BLEEDING in the ADJUSTMENT MENU with the HDS.
7. Check for DTCs with the HDS.
Is DTC P19E6 indicated?
YES - Update the TCM if it does not have the latest software, or substitute a known-good TCM, then recheck. If
the symptom/indication goes away with a known-good TCM, replace the original TCM. ■
NO - The system is OK at this time (Failure by air in the fluid).■
DTC Troubleshooting: P19E7 (160-27)
DTC P19E7:
Clutch Contact Position 3 Learning Not Completed
NOTE: If the Clutch Contact Position 3 Learning is incomplete after replacing the clutch disc, repeat the Clutch Contact
Position 3 Learning several times. If the Clutch Contact Position 3 Learning is still incomplete, check the clutch disc
installation.
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Start the engine. Hold the engine speed at 3,000 rpm (min −1 ) without load until the radiator fan comes on, then let
it idle.
4. Turn the headlight switch to ON.
5. Do the i-SHIFT System Learning (Dynamic Mode).
6. Check for DTCs with the HDS.
Is DTC P19E7 indicated?
YES - Go to Step 7 .
NO - Intermittent failure, the system is OK at this time.■
7. Turn the ignition switch to LOCK (0).
8. Do the CLUTCH FLUID AIR BLEEDING in the ADJUSTMENT MENU with the HDS.
9. Do the i-SHIFT System Learning (Dynamic Mode).
10. Check for DTCs with the HDS.
Is DTC P19E7 indicated?
YES - Go to Step 8 and repeat the steps.
NO - Clutch Contact Position 3 Learning is complete.■
DTC Troubleshooting: P19E8 (130-1)
DTC P19E8:
Vehicle Speed Signal Malfunction (from ECM by Signal Line)
1. Turn the ignition switch to LOCK (0).
2. Raise the vehicle, and make sure it is securely supported.
3. Start the engine, and change the shift lever in D.
4. Compare the speedometer indication and the VEHICLE SPEED in the DATA LIST with the HDS.
Does the HDS indication match with the speedometer?
YES - Intermittent failure, the system is OK at this time.■
NO - Go to Step 5 .
5. Check the VEHICLE SPEED in the DATA LIST with the HDS.
Is 0 km/h (0 mph) indicated?
YES - Repair a short to ground in the wire between the ECM (A33) and the TCM (A3).■
NO - Go to Step 6 .
6. Turn the ignition switch to LOCK (0).
7. Disconnect the clutch actuator subharness 10P connector from the engine compartment wire harness.
8. Turn the ignition switch to ON (II).
9. Measure voltage between clutch actuator subharness 10P connector terminal No. 5 and body ground.
Is there battery voltage?
YES - Repair a short to power in the wire between the ECM (A33) and the clutch actuator subharness.■
NO - Go to Step 10 .
10. Turn the ignition switch to LOCK (0).
11. Jump the SCS line with the HDS.
12. Disconnect ECM connector A (49P).
13. Check for continuity between ECM connector terminal A33 and clutch actuator subharness 10P connector terminal
No. 5.
Is there continuity?
YES - Remove the clutch actuator assembly, and check for clutch actuator subharness. If the wire harness is
OK, substitute a known-good TCM, then recheck. If the symptom/indication goes away with a known-
good TCM, replace the original TCM. ■
NO - Repair an open in the wire between the ECM (A33) and the clutch actuator subharness.■
DTC Troubleshooting: P19E9 (131-1)
DTC P19E9:
Brake Pedal Position Signal Malfunction (from ECM by Signal Line)
1. Turn the ignition switch to ON (II).
2. Press and release the brake pedal continuously for at least 2 minutes.
3. With the brake pedal released, check the BRAKE PEDAL POSITION SWITCH AND SIGNAL in the DATA LIST with
the HDS.
Does it indicate ON?
YES - Repair a short to ground in the wire between the ECM (A28) and the TCM (A35).■
NO - Go to Step 4 .
4. Turn the ignition switch to LOCK (0).
5. Disconnect the clutch actuator subharness 10P connector from the engine compartment wire harness.
6. Turn the ignition switch to ON (II).
7. Measure voltage between clutch actuator subharness 10P connector terminal No. 3 and body ground.
Is there battery voltage?
YES - Repair a short to power in the wire between the ECM (A28) and the TCM (A35).■
NO - Go to Step 8 .
8. Turn the ignition switch to LOCK (0).
9. Jump the SCS line with the HDS.
10. Disconnect ECM connector A (49P).
11. Check for continuity between ECM connector terminal A28 and clutch actuator subharness 10P connector terminal
No. 3.
Is there continuity?
YES - Remove the clutch actuator assembly, and check for clutch actuator subharness. If the wire harness is
OK, substitute a known-good TCM, then recheck. If the symptom/indication goes away with a known-
good TCM, replace the original TCM. ■
NO - Repair an open in the wire between the ECM (A28) and the clutch actuator subharness.■
DTC Troubleshooting: P19EA (132-1)
DTC P19EA:
Starter Signal Malfunction (from ECM by Signal Line)
1. Turn the ignition switch to ON (II).
2. With the shift lever in N and the brake pedal pressed, check the STARTER ENABLE SIGNAL in the DATA LIST
with the HDS.
Does it indicate ON?
YES - Repair a short to ground in the wire between the ECM (A43) and the TCM (A10).■
NO - Go to Step 3 .
3. Turn the ignition switch to LOCK (0).
4. Disconnect the clutch actuator subharness 10P connector from the engine compartment wire harness.
5. Turn the ignition switch to ON (II).
6. Measure voltage between clutch actuator subharness 10P connector terminal No. 1 and body ground.
Is there battery voltage?
YES - Repair a short to power in the wire between the ECM (A43) and the TCM (A10).■
NO - Go to Step 7 .
7. Turn the ignition switch to LOCK (0).
8. Jump the SCS line with the HDS.
9. Disconnect ECM connector A (49P).
10. Check for continuity between ECM connector terminal A43 and clutch actuator subharness 10P connector terminal
No. 1.
Is there continuity?
YES - Remove the clutch actuator assembly, and check for clutch actuator subharness. If the wire harness is
OK, substitute a known-good TCM, then recheck. If the symptom/indication goes away with a known-
good TCM, replace the original TCM. ■
NO - Repair an open in the wire between the ECM (A43) and the clutch actuator subharness.■
DTC Troubleshooting: P19EB (133-1)
DTC P19EB:
TCM initialization with Tester Error
NOTE: If DTC P19EB is indicated, replace the TCM.
DTC Troubleshooting: P19EC (150-21)
DTC P19EC:
Shift Actuator Motor Rotating Pulse/Rotating Direction Sensor Supply Signal Circuit Low Voltage
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC P19EC indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Turn the ignition switch to LOCK (0).
7. Disconnect the shift actuator motor 6P connector.
8. Turn the ignition switch to ON (II).
9. Clear the DTCs with the HDS.
10. Turn the ignition switch to LOCK (0).
11. Turn the ignition switch to ON (II).
12. Check for DTCs with the HDS.
Is DTC P19EC indicated?
YES - Repair a short to ground in the wire between the TCM (B20) and the shift actuator motor.■
NO - Replace the transmission shift change actuator. (A few DTCs related with open circuit will be stored at
this time.)■
DTC Troubleshooting: P19ED (150-22)
DTC P19ED:
Shift Actuator Motor Rotating Pulse/Rotating Direction Sensor Supply Signal Circuit High Voltage
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC P19ED indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Turn the ignition switch to LOCK (0).
7. Disconnect the shift actuator motor 6P connector.
8. Connect the shift actuator motor 6P connector terminal No. 3 and body ground with a jumper wire.
9. Turn the ignition switch to ON (II).
10. Clear the DTCs with the HDS.
11. Turn the ignition switch to LOCK (0).
12. Turn the ignition switch to ON (II).
13. Check for DTCs with the HDS.
Is DTC P19ED indicated?
YES - Repair an open in the wire between the TCM (B20) and the shift actuator motor.■
NO - Replace the transmission shift change actuator. (A few DTCs related with open circuit will be stored at
this time.)■
DTC Troubleshooting: P19EE (150-23)
DTC P19EE:
Shift Actuator Motor Rotating Pulse/Rotating Direction Sensor Supply Signal Circuit High Voltage
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC P19EE indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Turn the ignition switch to LOCK (0).
7. Disconnect the shift actuator motor 6P connector.
8. Turn the ignition switch to ON (II).
9. Measure voltage between the shift actuator motor 6P connector terminal No. 3 and body ground.
Is there battery voltage?
YES - Repair a short to power in the wire between the TCM (B20) and the shift actuator motor.■
NO - Replace the transmission shift change actuator. ■
DTC Troubleshooting: P19EF (151-22)
DTC P19EF:
Shift Actuator Motor Position Sensor Ground Line Open
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC P19EF indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Turn the ignition switch to LOCK (0).
7. Disconnect the shift actuator motor 6P connector.
8. Remove the clutch actuator assembly.
9. Disconnect TCM connector B (40P).
10. Check for continuity between TCM connector terminal B1 and shift actuator motor 6P connector terminal No. 2.
Is there continuity?
YES - Replace the transmission shift change actuator. ■
NO - Repair an open in the wire of the change actuator subharness A.■
DTC Troubleshooting: P19F0 (152-21)
DTC P19F0:
Shift Actuator Motor Rotating Direction Sensor Signal Circuit Low Voltage
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC P19F0 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Turn the ignition switch to LOCK (0).
7. Disconnect the shift actuator motor 6P connector.
8. Turn the ignition switch to ON (II).
9. Clear the DTCs with the HDS.
10. Turn the ignition switch to LOCK (0).
11. Turn the ignition switch to ON (II).
12. Check for DTCs with the HDS.
Is DTC P19F0 indicated?
YES - Repair a short to ground in the wire between the TCM (B8) and the shift actuator motor.■
NO - Replace the transmission shift change actuator. (A few DTCs related with open circuit will be stored at
this time.)■
DTC Troubleshooting: P19F2 (152-23)
DTC P19F2:
Shift Actuator Motor Rotating Direction Sensor Signal Circuit High Voltage
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC P19F2 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Turn the ignition switch to LOCK (0).
7. Disconnect the shift actuator motor 6P connector.
8. Connect shift actuator motor 6P connector terminal No. 4 and body ground with a jumper wire.
9. Turn the ignition switch to ON (II).
10. Clear the DTCs with the HDS.
11. Turn the ignition switch to LOCK (0).
12. Turn the ignition switch to ON (II).
13. Check for DTCs with the HDS.
Is DTC P19F2 indicated?
YES - Repair an open in the wire between the TCM (B8) and the shift actuator motor.■
NO - Go to Step 14 .
14. Turn the ignition switch to LOCK (0).
15. Remove the clutch actuator assembly.
16. Disconnect the TCM connector B (40P).
17. Turn the ignition switch to ON (II).
18. Measure voltage between shift actuator motor 6P connector terminal No. 4 and body ground.
Is there battery voltage?
YES - Repair a short to power in the wire of the change actuator subharness A.■
NO - Replace the transmission shift change actuator. ■
DTC Troubleshooting: P19F3 (153-21)
DTC P19F3:
Select Actuator Motor Rotating Pulse/Rotating Direction Sensor Supply Signal Circuit Low Voltage
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC P19F3 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Turn the ignition switch to LOCK (0).
7. Disconnect the select actuator motor 6P connector.
8. Turn the ignition switch to ON (II).
9. Clear the DTCs with the HDS.
10. Turn the ignition switch to LOCK (0).
11. Turn the ignition switch to ON (II).
12. Check for DTCs with the HDS.
Is DTC P19F3 indicated?
YES - Repair a short to ground in the wire between the TCM (B2) and the select actuator motor.■
NO - Replace the transmission shift change actuator. (A few DTCs related with open circuit will be stored at
this time.)■
DTC Troubleshooting: P19F4 (153-22)
DTC P19F4:
Select Actuator Motor Rotating Pulse/Rotating Direction Sensor Supply Signal Circuit High Voltage
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC P19F4 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Turn the ignition switch to LOCK (0).
7. Disconnect the select actuator motor 6P connector.
8. Connect select actuator motor 6P connector terminal No. 3 and body ground with a jumper wire.
9. Turn the ignition switch to ON (II).
10. Clear the DTCs with the HDS.
11. Turn the ignition switch to LOCK (0).
12. Turn the ignition switch to ON (II).
13. Check for DTCs with the HDS.
Is DTC P19F4 indicated?
YES - Repair an open in the wire between the TCM (B3) and the select actuator motor.■
NO - Replace the transmission shift change actuator. (A few DTCs related with open circuit will be stored at
this time.)■
DTC Troubleshooting: P19F5 (153-23)
DTC P19F5:
Select Actuator Motor Rotating Pulse Sensor Signal Circuit High Voltage
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC P19F5 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Turn the ignition switch to LOCK (0).
7. Disconnect the select actuator motor 6P connector.
8. Turn the ignition switch to ON (II).
9. Measure voltage between select actuator motor 6P connector terminal No. 3 and body ground.
Is there battery voltage?
YES - Repair a short to power in the wire of the change actuator subharness B.■
NO - Remove the clutch actuator assembly, and check for change actuator subharness A. If the wire harness
is OK, replace the transmission shift change actuator. ■
DTC Troubleshooting: P19F6 (154-22)
DTC P19F6:
Select Actuator Motor Position Sensor Ground Line Open
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC P19F6 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Turn the ignition switch to LOCK (0).
7. Disconnect the select actuator motor 6P connector.
8. Disconnect the change actuator subharness B 10P connector.
9. Check for continuity between change actuator subharness B 10P connector terminal No. 8 and select actuator
motor 6P connector terminal No. 2.
Is there continuity?
YES - Remove the clutch actuator assembly, and check for change actuator subharness A. If the wire harness
is OK, replace the transmission shift change actuator. ■
NO - Repair an open in the wire of the change actuator subharness B.■
DTC Troubleshooting: P19F7 (155-21)
DTC P19F7:
Select Actuator Motor Rotating Direction Sensor Signal Circuit Low Voltage
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC P19F7 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Turn the ignition switch to LOCK (0).
7. Disconnect the select actuator motor 6P connector.
8. Turn the ignition switch to ON (II).
9. Clear the DTCs with the HDS.
10. Turn the ignition switch to LOCK (0).
11. Turn the ignition switch to ON (II).
12. Check for DTCs with the HDS.
Is DTC P19F7 indicated?
YES - Repair a short to ground in the wire between the TCM (B10) and the select actuator motor.■
NO - Replace the transmission shift change actuator. (A few DTCs related with open circuit will be stored at
this time.)■
DTC Troubleshooting: P19F9 (155-23)
DTC P19F9:
Select Actuator Motor Rotating Direction Sensor Signal Circuit High Voltage
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC P19F9 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Turn the ignition switch to LOCK (0).
7. Disconnect the select actuator motor 6P connector.
8. Connect select actuator motor 6P connector terminal No. 4 and body ground with a jumper wire.
9. Turn the ignition switch to ON (II).
10. Clear the DTCs with the HDS.
11. Turn the ignition switch to LOCK (0).
12. Turn the ignition switch to ON (II).
13. Check for DTCs with the HDS.
Is DTC P19F9 indicated?
YES - Repair an open in the wire between the TCM (B10) and the select actuator motor.■
NO - Go to Step 14 .
14. Turn the ignition switch to LOCK (0).
15. Disconnect the change actuator subharness B 10P connector.
16. Turn the ignition switch to ON (II).
17. Measure voltage between select actuator motor 6P connector terminal No. 4 and body ground.
Is there battery voltage?
YES - Repair a short to power in the wire of the change actuator subharness B.■
NO - Remove the clutch actuator assembly, and check for change actuator subharness A. If the wire harness
is OK, replace the transmission shift change actuator. ■
DTC Troubleshooting: P19FA (160-21)
DTC P19FA:
Clutch Contact Position Adaptation Condition Error
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Start the engine, and wait for at least 1 second.
4. Check for DTCs with the HDS.
Is DTC P19FA indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Check the ENGINE TORQUE DISTURBANCE SIGNAL in the DATA LIST with the HDS.
Does it indicate ACTIVE more than 10 minutes?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Check for Fuel and Emissions systems DTCs with the HDS.
Are any Temporary DTCs or DTCs indicated?
YES - Go to the indicated DTC's troubleshooting.
NO - Electrical load change is continuing. Do the i-SHIFT System Learning (Static Mode) and the i-SHIFT
System Learning (Dynamic Mode). ■
DTC Troubleshooting: P19FB (160-22)
DTC P19FB:
Clutch Contact Position 1 and 2 Learning Not Completed
NOTE: If the Clutch Contact Position 1, 2 Learning is incomplete after replacing the clutch disc, repeat the Clutch Contact
Position 1, 2 Learning several times. If the Clutch Contact Position 1, 2 Learning is still incomplete, check the clutch disc
installation.
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Do the i-SHIFT System Learning (Static Mode).
4. Check for DTCs with the HDS.
Is DTC P19FB indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Turn the ignition switch to LOCK (0).
6. Do the CLUTCH FLUID AIR BLEEDING in the ADJUSTMENT MENU with the HDS.
7. Do the i-SHIFT System Learning (Static Mode).
8. Check for DTCs with the HDS.
Is DTC P19FB indicated?
YES - Go to Step 7 and repeat the steps.
NO - Clutch Contact Position 1, 2 Learning is complete.■
DTC Troubleshooting: P19FC (160-23)
DTC P19FC:
Shift Change Actuator Position Learning Not Completed
NOTE:
DTC P19FC is stored when the Shift Change Actuator Position Learning is incomplete.
Make sure the battery is fully charged.
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Do the i-SHIFT System Learning (Static Mode).
4. Check for DTCs with the HDS.
Is DTC P19FC indicated?
YES - Go to Step 3 , and repeat the steps. If DTC P19FC is stored again after doing the i-SHIFT System
Learning (Static Mode), check the repair error, or there is a problem in a replacement part.
NO - Intermittent failure, the system is OK at this time.■
DTC Troubleshooting: P19FD (160-24)
DTC P19FD:
Shift Change Actuator Position Learning Value Out of Range
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Do the i-SHIFT System Learning (Static Mode).
4. Check for DTCs with the HDS.
Is DTC P19FD indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Clear the DTCs with the HDS.
6. Test-drive the vehicle for at least 10 minutes.
7. Check for DTCs with the HDS.
Is DTC P19FD indicated?
YES - Do the i-SHIFT System Learning (Static Mode), and recheck. If DTC P19FD is stored again, replace the
transmission shift change actuator. ■
NO - The system is OK at this time.■
DTC Troubleshooting: P19FE (160-25)
DTC P19FE:
Clutch Contact Position Adaptation Learning Value Out of Range
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Do the i-SHIFT System Learning (Static Mode).
4. Check for DTCs with the HDS.
Is DTC P19FE indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Turn the ignition switch to LOCK (0).
6. Do the CLUTCH FLUID AIR BLEEDING in the ADJUSTMENT MENU with the HDS.
7. Do the i-SHIFT System Learning (Static Mode).
8. Turn the ignition switch to LOCK (0).
9. Check for DTCs with the HDS.
Is DTC P19FE indicated?
YES - Go to Step 10 .
NO - The system is OK at this time.■
10. Turn the ignition switch to LOCK (0).
11. Remove the clutch pipe assembly from the clutch actuator.
12. Do the CLUTCH FLUID FILLING in the ADJUSTMENT MENU with the HDS.
13. Turn the ignition switch to ON (II).
14. Check for DTCs with the HDS.
Is DTC P19FE indicated?
YES - Replace the TCM. ■
NO - Check for these conditions, and repair if necessary:■
Slave cylinder
Release system
DTC Troubleshooting: P19FF (160-26)
DTC P19FF:
Clutch Friction Coefficient Learning Value Out of Range
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Test-drive the vehicle and change the shift lever from 1st to 6th gear.
4. Check for DTCs with the HDS.
Is DTC P19FF indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Turn the ignition switch to LOCK (0).
6. Do the CLUTCH FLUID AIR BLEEDING in the ADJUSTMENT MENU with the HDS.
7. Do the i-SHIFT System Learning (Static Mode).
8. Turn the ignition switch to LOCK (0).
9. Check for DTCs with the HDS.
Is DTC P19FF indicated?
YES - Go to Step 10 .
NO - The system is OK at this time.■
10. Turn the ignition switch to LOCK (0).
11. Remove the clutch pipe assembly from the clutch actuator.
12. Do the CLUTCH FLUID FILLING in the ADJUSTMENT MENU with the HDS.
13. Turn the ignition switch to ON (II).
14. Check for DTCs with the HDS.
Is DTC P19FF indicated?
YES - Replace the TCM. ■
NO - Check for these conditions, and repair if necessary:■
Slave cylinder
Release system
DTC Troubleshooting: P2785 (163-1)
DTC P2785:
Clutch Actuator Temperature Too High
NOTE: DTC P2785 is stored when the clutch motor is protection mode. This can be caused due to frequent UP/DOWN
operation. In this case, it is not a malfunction.
1. Check whether the driver changed gears excessively while driving.
Did the driver change gears excessively while driving?
YES - Not failure, just a rise of the clutch actuator temperature due to excessive gear changes.■
NO - Go to Step 2 .
2. Check the CLUTCH ACTUATOR TEMPERATURE and the TRANSMISSION SHIFT CHANGE ACTUATOR
TEMPERATURE in the DATA LIST with the HDS.
Is the clutch actuator temperature about 195 °C (383 °F) or more, or the transmission shift change actuator
temperature about 118 °C (244 °F) or more?
YES - Go to Step 3 .
NO - Go to Step 6 .
3. Turn the ignition switch to LOCK (0).
4. In order to cool the system, wait for at least 1 hour.
5. Check the CLUTCH ACTUATOR TEMPERATURE and the TRANSMISSION SHIFT CHANGE ACTUATOR
TEMPERATURE in the DATA LIST with the HDS.
Is the clutch actuator temperature about 195 °C (383 °F) or more, or the transmission shift change actuator
temperature about 118 °C (244 °F) or more?
YES - Update the TCM if it does not have the latest software, or substitute a known-good TCM, then recheck. If
the symptom/indication goes away with a known-good TCM, replace the original TCM. ■
NO - Go to Step 6 .
6. Test-drive the vehicle with changing gears frequently for at least 15 minutes.
7. Check the CLUTCH ACTUATOR TEMPERATURE and the TRANSMISSION SHIFT CHANGE ACTUATOR
TEMPERATURE in the DATA LIST with the HDS.
Is the clutch actuator temperature about 195 °C (383 °F) or more, or the transmission shift change actuator
temperature about 118 °C (244 °F) or more?
YES - Go to Step 8 .
NO - Intermittent failure, the system is OK at this time.■
8. Check the release fork moves smoothly.
Does the release fork move smoothly?
YES - Replace the TCM. ■
NO - Replace the release bearing. ■
DTC Troubleshooting: P2786 (162-1)
DTC P2786:
Transmission Shift Change Actuator Temperature Too High
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. In order to cool the system, wait for at least 1 hour.
4. Test-drive the vehicle for at least 10 minutes.
5. Check for DTCs with the HDS.
Is DTC P2786 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Turn the ignition switch to LOCK (0).
7. Remove the transmission shift change actuator.
8. Check if the shift arm (A) moves smoothly.
Does the shift arm move smoothly?
YES - Replace the transmission shift change actuator.■
NO - Repair the transmission internal failure.■
DTC Troubleshooting: P2787 (164-2)
DTC P2787:
Clutch Temperature Too High (Over 400 °C (752 °F))
NOTE: DTC P2787 is stored when the clutch is protection mode. This can be caused due to frequent UP/DOWN
operation. In this case, it is not a malfunction.
1. Check whether the driver changed gears excessively while driving.
Did the driver change gears excessively while driving?
YES - Not failure, just a rise of the clutch temperature due to excessive gear changes.■
NO - Go to Step 2 .
2. Test-drive the vehicle for at least 15 minutes with the Auto mode, then repeat a start and a stop several times.
Does the clutch slip?
YES - Replace the clutch. ■
NO - Go to Step 3 .
3. Turn the ignition switch to LOCK (0).
4. In order to cool the system, wait for at least 1 hour.
5. Check the CLUTCH TEMPERATURE in the DATA LIST with the HDS.
Is the clutch temperature about 400 °C (752 °F) or more?
YES - Update the TCM if it does not have the latest software, or substitute a known-good TCM, then recheck. If
the symptom/indication goes away with a known-good TCM, replace the original TCM. ■
NO - Intermittent failure, the system is OK at this time.■
DTC Troubleshooting: U0100 (107-11)
DTC U0100:
F-CAN Malfunction (TCM Lost Communication with ECM)
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC U0100 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Check for DTCs with the HDS.
Are DTC U0103, U0155, and U1261 indicated?
YES - Go to Step 7 .
NO - Go to Step 13 .
7. Turn the ignition switch to LOCK (0).
8. Wait for at least 30 seconds.
9. Jump the SCS line with the HDS.
10. Disconnect ECM connector A (49P).
11. Disconnect the clutch actuator subharness 10P connector from the engine compartment wire harness.
12. Check for continuity between ECM connector terminal A3 (A4) * and clutch actuator subharness 10P connector
terminal No. 7 (No. 6) * .
*: CANL
Is there continuity?
YES - Remove the clutch actuator assembly, and check for change actuator subharness. If the wire harness is
OK, substitute a known-good TCM, then recheck. If the symptom/indication goes away with a known-
good TCM, replace the original TCM. ■
NO - Repair an open in the wire between the clutch actuator subharness 10P connector and the ECM (A3 (A4)
* ).■
*: CANL
13. Turn the ignition switch to LOCK (0).
14. Wait for at least 30 seconds.
15. Jump the SCS line with the HDS.
16. Disconnect ECM connector A (49P).
17. Disconnect the clutch actuator subharness 10P connector from the engine compartment wire harness.
18. Check for continuity between ECM connector terminal A3 (A4) * and clutch actuator subharness 10P connector
terminal No. 7 (No. 6) * .
*: CANL
Is there continuity?
YES - Update the ECM if it does not have latest software. If the ECM was updated, substitute a known-good
ECM, and recheck. If the symptom/indication goes away with a known-good ECM, replace the original
ECM. ■
NO - Repair an open in the wire between the clutch actuator subharness 10P connector and the ECM (A3 (A4)
* ).■
*: CANL
DTC Troubleshooting: U0103 (107-9)
DTC U0103:
F-CAN Malfunction (TCM Lost Communication with Gear Shift Control Module)
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC U0103 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Check for DTCs with the HDS.
Are DTC U0100, U0155, and U1261 indicated?
YES - Go to Step 7 .
NO - Go to Step 13 .
7. Turn the ignition switch to LOCK (0).
8. Wait for at least 30 seconds.
9. Disconnect the gear shift control module 12P connector.
10. Disconnect the clutch actuator subharness 10P connector from the engine compartment wire harness.
11. Connect gear shift control module 12P connector terminal No. 3 (No. 9) * and body ground with jumper wires.
*: CANL
12. Check for continuity between clutch actuator subharness 10P connector terminal No. 7 (No. 6) * and body ground.
*: CANL
Is there continuity?
YES - Remove the clutch actuator assembly, and check for change actuator subharness. If the wire harness is
OK, substitute a known-good TCM, then recheck. If the symptom/indication goes away with a known-
good TCM, replace the original TCM. ■
NO - Repair an open in the wire between the clutch actuator subharness 10P connector and the gear shift
control module.■
13. Turn the ignition switch to LOCK (0).
14. Wait for at least 30 seconds.
15. Disconnect the gear shift control module 12P connector.
16. Disconnect the clutch actuator subharness 10P connector from the engine compartment wire harness.
17. Connect gear shift control module 12P connector terminal No. 3 (No. 9) * and body ground with jumper wires.
*: CANL
18. Check for continuity between clutch actuator subharness 10P connector terminal No. 7 (No. 6) * and body ground.
*: CANL
Is there continuity?
YES - Substitute a known-good gear shift control module, then recheck. If the symptom/indication goes away
with a known-good gear shift control module, replace the original gear shift control module. ■
NO - Repair an open in the wire between the clutch actuator subharness 10P connector and the gear shift
control module.■
DTC Troubleshooting: U0155 (107-3)
DTC U0155:
F-CAN Malfunction (TCM Lost Communication with Gauge Control Module)
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC U0155 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Check for DTCs with the HDS.
Are DTC U0100, U0103, and U1261 indicated?
YES - Go to Step 7 .
NO - Go to Step 13 .
7. Turn the ignition switch to LOCK (0).
8. Wait for at least 30 seconds.
9. Disconnect the gauge control module 32P connector.
10. Disconnect the clutch actuator subharness 10P connector from the engine compartment wire harness.
11. Connect gauge control module 32P connector terminal No. 30 (No. 29) * and body ground with jumper wires.
*: CANL
12. Check for continuity between clutch actuator subharness 10P connector terminal No. 7 (No. 6) * and body ground.
*: CANL
Is there continuity?
YES - Remove the clutch actuator assembly, and check for change actuator subharness. If the wire harness is
OK, substitute a known-good TCM, then recheck. If the symptom/indication goes away with a known-
good TCM, replace the original TCM. ■
NO - Repair an open in the wire between the clutch actuator subharness 10P connector and the gauge control
module.■
13. Turn the ignition switch to LOCK (0).
14. Wait for at least 30 seconds.
15. Disconnect the gauge control module 32P connector.
16. Disconnect the clutch actuator subharness 10P connector from the engine compartment wire harness.
17. Connect gauge control module 32P connector terminal No. 30 (No. 29) * and body ground with jumper wires.
*: CANL
18. Check for continuity between clutch actuator subharness 10P connector terminal No. 7 (No. 6) * and body ground.
*: CANL
Is there continuity?
YES - Substitute a known-good shift lever, then recheck. If the symptom/indication goes away with a known-
good shift lever, replace the original shift lever. ■
NO - Repair an open in the wire between the clutch actuator subharness 10P connector and the gauge control
module.■
DTC Troubleshooting: U0401 (134-2)
DTC U0401:
F-CAN Malfunction (TCM Received Invalid Data from ECM)
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Start the engine.
4. Change the engine speed from idle to 4,000 rpm (min −1 ) twice.
5. Check for DTCs with the HDS.
Is DTC U0401 indicated?
YES - Check for Fuel and Emissions systems DTCs with the HDS.■
NO - Intermittent failure, the system is OK at this time.■
DTC Troubleshooting: U0404 (134-7)
DTC U0404:
F-CAN Malfunction (TCM Received Invalid Data from Gear Shift Control Module)
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Change the shift lever in all positions.
4. Check for DTCs with the HDS.
Is DTC U0404 indicated?
YES - Substitute a known-good gear shift control module, then recheck. If the symptom/indication goes away
with a known-good gear shift control module, replace the original gear shift control module. ■
NO - Intermittent failure, the system is OK at this time.■
DTC Troubleshooting: U1261 (107-21)
DTC U1261:
F-CAN Malfunction (TCM Lost Communication with ABS/VSA Modulator-Control Unit)
NOTE: If DTC U1261 is stored at the same time as DTC U1405, troubleshoot DTC U1261 first, then recheck for DTC
U1405.
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC U1261 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Check for DTCs with the HDS.
Are DTC U0100, U0103, and U0155 indicated?
YES - Go to Step 7 .
NO - Go to Step 13 .
7. Turn the ignition switch to LOCK (0).
8. Wait for at least 30 seconds.
9. Disconnect the ABS modulator-control unit 25P connector (or the VSA modulator-control unit 36P connector).
10. Disconnect the clutch actuator subharness 10P connector from the engine compartment wire harness.
11. With ABS: Connect ABS modulator-control unit 25P connector terminal No. 1 (No. 17) * and body ground with
jumper wires.
With VSA: Connect VSA modulator-control unit 36P connector terminal No. 14 (No. 1) * and body ground with
jumper wires.
*: CANL
12. Check for continuity between clutch actuator subharness 10P connector terminal No. 7 (No. 6) * and body ground.
*: CANL
Is there continuity?
YES - Remove the clutch actuator assembly, and check for change actuator subharness. If the wire harness is
OK, substitute a known-good TCM, then recheck. If the symptom/indication goes away with a known-
good TCM, replace the original TCM. ■
NO - Repair an open in the wire between the clutch actuator subharness 10P connector and the ABS (or VSA)
modulator-control unit.■
13. Turn the ignition switch to LOCK (0).
14. Wait for at least 30 seconds.
15. Disconnect the ABS modulator-control unit 25P connector (or the VSA modulator-control unit 36P connector).
16. Disconnect the clutch actuator subharness 10P connector from the engine compartment wire harness.
17. With ABS: Connect ABS modulator-control unit 25P connector terminal No. 1 (No. 17) * and body ground with
jumper wires.
With VSA: Connect VSA modulator-control unit 36P connector terminal No. 14 (No. 1) * and body ground with
jumper wires.
*: CANL
18. Check for continuity between clutch actuator subharness 10P connector terminal No. 7 (No. 6) * and body ground.
*: CANL
Is there continuity?
YES - Substitute a known-good VSA modulator-control unit, then recheck. If the symptom/indication goes away
with a known-good VSA modulator-control unit, replace the original VSA modulator-control unit. ■
NO - Repair an open in the wire between the clutch actuator subharness 10P connector and the VSA
modulator-control unit.■
DTC Troubleshooting: U1400 (135-2)
DTC U1400:
F-CAN Malfunction (TCM Received Out of Range Data from ECM)
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Turn the ignition switch to LOCK (0).
4. Turn the ignition switch to ON (II).
5. Check for DTCs with the HDS.
Is DTC U1400 indicated?
YES - Go to Step 6 .
NO - Intermittent failure, the system is OK at this time.■
6. Check for Fuel and Emissions systems DTCs with the HDS.
Are any DTCs indicated?
YES - Go to the Fuel and Emissions systems indicated DTCs troubleshooting.
NO - Go to Step 7 .
7. Check these parameters in the DATA LIST with the HDS:
ENGINE SPEED
ENGINE COOLANT TEMPERATURE
INTAKE AIR TEMPERATURE
Is the value 10,001 rpm (min −1 ), 151 °C (304 °F), and 151 °C (304 °F) or more?
YES - Remove the clutch actuator assembly, and substitute a known-good TCM, then recheck. If the
symptom/indication goes away with a known-good TCM, replace the original TCM. ■
NO - Update the ECM if it does not have the latest software. If the ECM was updated, substitute a known-good
ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original
ECM. ■
DTC Troubleshooting: U1401 (161-21)
DTC U1401:
F-CAN Malfunction (TCM Received Invalid Shift Down Command While Cruise Control from ECM)
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Test-drive the vehicle with cruise control.
4. Check for DTCs with the HDS.
Is DTC U1401 indicated?
YES - Check for Fuel and Emissions systems.■
NO - Intermittent failure, the system is OK at this time.■
DTC Troubleshooting: U1402 (161-22)
DTC U1402:
F-CAN Malfunction (TCM Received Invalid Shift Down Command While Cruise Control from ECM)
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Test-drive the vehicle with cruise control.
4. Check for DTCs with the HDS.
Is DTC U1402 indicated?
YES - Check for Fuel and Emissions systems DTCs with the HDS.■
NO - Intermittent failure, the system is OK at this time.■
DTC Troubleshooting: U1403 (134-21)
DTC U1403:
F-CAN Malfunction (TCM Received Invalid Data from ABS/VSA Modulator-Control Unit)
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Test-drive the vehicle for at least 10 km/h (6.2 mph).
4. Check for DTCs with the HDS.
Is DTC U1403 indicated?
YES - Check for ABS (VSA) system DTCs with the HDS.■
NO - Intermittent failure, the system is OK at this time.■
DTC Troubleshooting: U1404 (135-21)
DTC U1404:
F-CAN Malfunction (TCM Received Out of Range Data from ABS/VSA Modulator-Control Unit)
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Test-drive the vehicle for several minutes.
4. Check for DTCs with the HDS.
Is DTC U1404 indicated?
YES - Go to Step 5 .
NO - Intermittent failure, the system is OK at this time.■
5. Check for ABS (VSA) system DTCs with the HDS.
Are any ABS (VSA) system DTCs indicated?
YES - Go to the VSA system indicated DTC's troubleshooting. ■
NO - Go to Step 6 .
6. Test-drive the vehicle for at least 10 km/h (6.2 mph).
7. Check each WHEEL SENSOR in the DATA LIST with the HDS.
Does any of wheel speeds indicate 2,594 rpm?
YES - Substitute a known-good VSA modulator-control unit, then recheck. If the symptom/indication goes away
with a known-good VSA modulator-control unit, replace the original VSA modulator-control unit. ■
NO - Remove the clutch actuator assembly, and substitute a known-good TCM, then recheck. If the
symptom/indication goes away with a known-good TCM, replace the original TCM. ■
DTC Troubleshooting: U1405 (134-22)
DTC U1405:
F-CAN Malfunction (TCM Received Invalid Data from ABS/VSA Modulator-Control Unit)
NOTE: If DTC U1261 is stored at the same time as DTC U1405, troubleshoot DTC U1261 first, then recheck for DTC
U1405.
1. Turn the ignition switch to ON (II).
2. Clear the DTCs with the HDS.
3. Test-drive the vehicle for at least 10 km/h (6.2 mph).
4. Check for DTCs with the HDS.
Is DTC U1405 indicated?
YES - Check for ABS (VSA) system DTCs with the HDS.■
NO - Intermittent failure, the system is OK at this time.■
Starting System Component Location Index
BATTERY
Test,
12. Remove the starter, and inspect its drive gear and the flywheel ring gear (M/T model) or torque converter ring gear
(A/T model) for damage. Replace any damaged parts.
13. Select ECM/PCM reset to cancel ALL INJECTORS STOP on the HDS.
M/T System Description
Reverse Lockout System
Hard to shift into 1st gear
Probable cause(s)
1. Worn or incorrect MTF.
2. Clutch defective.
3. 1st synchro ring defective.
4. 1st/2nd synchro sleeve and hub defective.
5. 1st gear defective.
6. Change lever assembly defective.
Diagnostic procedure
Check and/or replace the MTF.
Check the clutch.
Check the 1st synchro ring.
Check the 1st/2nd synchro sleeve and hub.
Check 1st gear.
Check the change lever assembly.
Hard to shift into 2nd gear
Probable cause(s)
1. Worn or incorrect MTF.
2. 2nd synchro ring defective.
3. 1st/2nd synchro sleeve and hub defective.
4. 2nd gear defective.
5. Change lever assembly defective.
Diagnostic procedure
Check and/or replace the MTF.
Check the 2nd synchro ring.
Check the 1st/2nd synchro sleeve and hub.
Check 2nd gear.
Check the change lever assembly.
Hard to shift into 3rd gear
Probable cause(s)
1. Worn or incorrect MTF.
2. 3rd synchro ring defective.
3. 3rd/4th synchro sleeve and hub defective.
4. 3rd gear defective.
5. Change lever assembly defective.
Diagnostic procedure
Check and/or replace the MTF.
Check the 3rd synchro ring.
Check the 3rd/4th synchro sleeve and hub.
Check 3rd gear.
Check the change lever assembly.
Hard to shift into 4th gear
Probable cause(s)
1. Worn or incorrect MTF.
2. 4th synchro ring defective.
3. 3rd/4th synchro sleeve and hub defective.
4. 4th gear defective.
5. Change lever assembly defective.
Diagnostic procedure
Check and/or replace the MTF.
Check the 4th synchro ring.
Check the 3rd/4th synchro sleeve and hub.
Check 4th gear.
Check the change lever assembly.
Hard to shift into 5th gear
Probable cause(s)
1. Worn or incorrect MTF.
2. 5th synchro ring defective.
3. 5th synchro sleeve defective.
4. 5th gear defective.
5. Change lever assembly defective.
Diagnostic procedure
Check and/or replace the MTF.
Check the 5th synchro ring.
Check the 5th synchro sleeve and hub.
Check 5th gear.
Check the change lever assembly.
Hard to shift into reverse
Probable cause(s)
1. Worn or incorrect MTF.
2. Clutch defective.
3. Reverse shift fork defective.
4. Reverse idler gear defective.
5. Reverse gear defective.
6. Change lever assembly defective.
Diagnostic procedure
Check and/or replace the MTF.
Check the clutch.
Check the reverse shift fork.
Check the reverse idler gear.
Check reverse gear.
Check the change lever assembly.
Noise from the transmission
Probable cause(s)
1. Worn or incorrect MTF.
2. Low MTF level.
3. Worn or damaged transmission gears.
4. Worn or damaged transmission bearings.
Diagnostic procedure
Check and/or replace the MTF.
Check the MTF level.
Check the transmission gears.
Check the transmission bearings.
Shift lever does not operate smoothly
Probable cause(s)
1. Worn or incorrect MTF.
2. Shift cable defective.
3. Joint in shift cable and transmission or body.
Diagnostic procedure
Check and/or replace the MTF.
Check the shift cable.
Check joint in the shift cable.
Transmission jumps out of gear
Probable cause(s)
1. Worn or incorrect MTF.
2. Detent ball springs defective.
3. Worn gear dogs.
Diagnostic procedure
Check and/or replace the MTF.
Check the detent ball springs.
Check the gear dogs.
M/T Symptom Troubleshooting Index
Symptom Probable cause(s) Diagnostic procedure
Hard to shift into 1st 1. Worn or incorrect MTF. Check and/or replace the MTF.
gear 2. Clutch defective. Check the clutch.
3. 1st synchro ring defective. Check the 1st synchro ring.
4. 1st/2nd synchro sleeve and hub defective. Check the 1st/2nd synchro sleeve and hub.
5. 1st gear defective. Check 1st gear.
6. Change lever assembly defective. Check the change lever assembly.
Hard to shift into 2nd 1. Worn or incorrect MTF. Check and/or replace the MTF.
gear 2. 2nd synchro ring defective. Check the 2nd synchro ring.
3. 1st/2nd synchro sleeve and hub defective. Check the 1st/2nd synchro sleeve and hub.
4. 2nd gear defective. Check 2nd gear.
5. Change lever assembly defective. Check the change lever assembly.
Hard to shift into 3rd 1. Worn or incorrect MTF. Check and/or replace the MTF.
gear 2. 3rd synchro ring defective. Check the 3rd synchro ring.
3. 3rd/4th synchro sleeve and hub defective. Check the 3rd/4th synchro sleeve and hub.
4. 3rd gear defective. Check 3rd gear.
5. Change lever assembly defective. Check the change lever assembly.
Hard to shift into 4th 1. Worn or incorrect MTF. Check and/or replace the MTF.
gear 2. 4th synchro ring defective. Check the 4th synchro ring.
3. 3rd/4th synchro sleeve and hub defective. Check the 3rd/4th synchro sleeve and hub.
4. 4th gear defective. Check 4th gear.
5. Change lever assembly defective. Check the change lever assembly.
Hard to shift into 5th 1. Worn or incorrect MTF. Check and/or replace the MTF.
gear 2. 5th synchro ring defective. Check the 5th synchro ring.
3. 5th synchro sleeve defective. Check the 5th synchro sleeve and hub.
4. 5th gear defective. Check 5th gear.
5. Change lever assembly defective. Check the change lever assembly.
Hard to shift into 1. Worn or incorrect MTF. Check and/or replace the MTF.
reverse 2. Clutch defective. Check the clutch.
3. Reverse shift fork defective. Check the reverse shift fork.
4. Reverse idler gear defective. Check the reverse idler gear.
5. Reverse gear defective. Check reverse gear.
6. Change lever assembly defective. Check the change lever assembly.
Noise from the 1. Worn or incorrect MTF. Check and/or replace the MTF.
transmission 2. Low MTF level. Check the MTF level.
3. Worn or damaged transmission gears. Check the transmission gears.
4. Worn or damaged transmission bearings. Check the transmission bearings.
Shift lever does not 1. Worn or incorrect MTF. Check and/or replace the MTF.
operate smoothly 2. Shift cable defective. Check the shift cable.
3. Joint in shift cable and transmission or body. Check joint in the shift cable.
Transmission jumps out 1. Worn or incorrect MTF. Check and/or replace the MTF.
of gear 2. Detent ball springs defective. Check the detent ball springs.
3. Worn gear dogs. Check the gear dogs.
Clutch Replacement
Special Tools Required
Clutch alignment tool set
07PAF-0020000
3. Install the ring gear holder (A) and the clutch alignment tool set (B).
4. To prevent warping, unscrew the pressure plate mounting bolts (C) in a crisscross pattern in several steps, then
remove the pressure plate (D).
5. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.
6. Inspect the pressure plate (A) surface for wear, cracks, and burning.
7. Inspect for warpage using a straight edge (A) and feeler gauge (B). Measure across the pressure plate (C). If the
warpage is more than the service limit, replace the pressure plate.
Standard (New): 0.03 mm (0.001 in.) max.
Service Limit: 0.15 mm (0.006 in.)
11. Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B) on both sides. If the measurement is
less than the service limit, replace the clutch disc.
Standard (New): 1.00−1.50 mm (0.039−0.059 in.) max.
Service Limit: 0.2 mm (0.008 in.)
Flywheel Inspection
12. Remove the ring gear holder.
13. Inspect the ring gear teeth for wear and damage.
14. Inspect the clutch disc mating surface on the flywheel for wear, cracks and burning.
15. Measure the flywheel (A) runout using a dial indicator (B). Through at least two full turns with pushing against the
flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the measurement is not within
the standard, replace the flywheel, and recheck the runout. Go to Step 16 .
Standard (New): 0.05 mm (0.002 in.) max.
Service Limit: 0.15 mm (0.006 in.)
Flywheel Replacement
16. Install the ring gear holder.
17. Loosen the flywheel mounting bolts in a crisscross pattern in several steps. Remove the bolts, then remove the
flywheel and the ring gear holder.
18. Install the flywheel on the crankshaft, and install the mounting bolts finger-tight.
19. Install the ring gear holder (A), then torque the flywheel mounting bolts (B) in a crisscross pattern in several steps.
23. Install the new pilot bearing (A) into the crankshaft using the 15 x 135L driver handle (B) and 28 x 30 mm bearing
driver attachment (C). Apply a light coat of molybdenum grease to the bearing surface.
Clutch Disc and Pressure Plate Installation
24. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides
freely on the mainshaft.
25. Apply a light coat of molybdenum to the crankshaft pilot bearing (A).
26. Apply molybdenum grease to the splines (B) of the clutch disc (C), then install the clutch disc using the clutch
alignment tool set (D).
27. Install the pressure plate (A) and the mounting bolts (B) finger-tight.
28. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the
diaphragm spring.
PRESSURE PLATE MOUNTING BOLT TORQUE:
25 N·m (2.6 kgf·m, 19 lbf·ft)
29. Remove the ring gear holder (A), and the clutch alignment tool set (B).
30. Make sure the diaphragm spring fingers are all the same height.
31. Do the release bearing inspection, and replace if it necessary.
32. Install the transmission.
Transmission Side
Release Bearing Removal
1. Remove the transmission.
2. Remove the release fork boot (A) from the clutch housing (B).
3. Remove the release fork (C) from the clutch housing by squeezing the release fork set spring (D) with pliers.
Remove the release bearing (E).
9. Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B), and that the
release bearing slides smoothly. Wipe off any excess grease.
10. Install the transmission.
M/T Assembly Removal
Special Tools Required
Engine support hanger
AAR-T-1256-J00
NOTE: Use fender covers to avoid damaging painted surfaces.
1. Secure the hood in the wide open position (support rod in the lower hole).
2. Remove the windshield wiper arms.
3. Remove the cowl covers and hood hinge cover.
4. Remove the wiper motor.
5. Remove under-cowl panel.
6. Do the battery removal procedure.
7. Remove the air cleaner housing.
8. Remove the air cleaner stay.
9. Remove the battery base bolts (A), loosen the two bolts (B), remove the battery harness clamp (C) and the bracket
bolt (D) then remove the battery base (E).
10. Remove the clutch hose bracket (A) and the slave cylinder (B). Remove the clutch line from the clip (C), then
carefully move the slave cylinder out of the way to avoid bending the clutch line.
NOTE:
Do not disconnect the clutch line joints.
Do not press the clutch pedal after the slave cylinder has been removed.
11. Disconnect the back-up light switch connector (A), then remove the harness clip (B).
12. Remove the lock pins (A), shift cable bracket bolts (B), and harness clip (C), then disconnect the shift cables (D),
from the change lever assembly (E). Carefully remove both cables and the shift cable bracket (F) together to avoid
bending the cables.
14. Remove the purge control SOL.V. hose (A). Install the hanger plate (B) to the bolt hole (C) at the air cleaner
housing mounting bracket with the 8 x 1.25 mm bolt.
15. Install the engine support hanger (A) with the hook (B) to the vehicle. Tighten the wing nut (C) by hand, and lift and
support the engine.
17. Remove the ground cable (A), transmission mount nuts (B), and transmission mount bolt (C), from the transmission
bracket (D).
18. Raise the vehicle on a lift, and make sure it is securely supported.
19. Remove the splash shield.
20. Drain the transmission fluid. Reinstall the drain plug using a new sealing washer.
21. Remove the right and left driveshafts.
6. Install the torque rod bracket with new bolt (A) and bolts (B).
7. Loosely install the torque rod new bolt (A), new nut (B) and new bolt (C), then remove the transmission jack.
11. Tighten the new transmission mount bolts (A), three new engine mount nuts (B), and ground cable (C) to the
specified torque value.
12. Loosen the wing nut (A). Remove the hook (B) and engine support hanger (C) from the vehicle.
13. Remove the hanger plate (A) to the air cleaner stay (B) with the 8 x 1.25 mm bolt (C). Install the purge control
SOL.V. hose (D).
14. Tighten the torque rod with the bolts and nut to the specified torque value.
17. Apply a light coat of silicone grease to the cable ends (A), and connect the cable end to the change lever assembly
(B), then install the shift cable bracket (C), harness clip (D) and the lock pins (E). Do not bend or damage the shift
cables.
NOTE: When you apply the silicone grease, make sure not to adhere to the terminal part of connectors and
surrounding switches. Also do not touch the switches and the terminal part of connector by hands or glove that
adheres the silicone grease.
18. Connect the back-up light switch connector (A), then install the harness clip (B).
19. Apply a light coat of molybdenum grease to the end of the slave cylinder rod (A). Install the slave cylinder (B) and
clutch line bracket (C). Install the clutch line in the clip (D). Take care not to bend the clutch line.
20. Install the battery base (A) and harness clip (B).
3. Remove the change lever assembly (A) and 8 x 10 mm dowel pins (B).
4. Remove the drain plug (A), filler plug (B), the sealing washers (C), and the vehicle speed sensor (VSS) (D), the O-
rings (E).
5. Remove the 8 mm flange bolts (A) and transmission hanger (B) in a crisscross pattern in several steps.
9. Remove the reverse idler gear (A) and the reverse gear shaft (B).
12. Tape the mainshaft splines, then remove the mainshaft assembly (A) and the countershaft assembly (B) with the
shift forks (C) from the clutch housing (D).
13. Remove the 8 mm special bolt (E) and the 8 mm spring washer (F).
14. Remove the 36 mm spring washer (G) and the 26 mm washer (H).
15. Remove the differential assembly (A), and the magnet (B).
16. Remove the oil gutter plate (A), the oil guide plate M (B), and the 72 mm shim (C).
M/T Assembly Reassembly
NOTE: Prior to reassembly, clean all the parts in solvent, dry them, and apply MTF to any contact surfaces.
1. Install the magnet (A) and differential assembly (B).
2. Install the 8 mm spring washer (A) and the 8 mm special bolt (B).
3. Install the 36 mm spring washer (C) and 26 mm washer (D) over the ball bearing (E). Note the installation direction
of the spring washer.
4. Tape the mainshaft splines (F) with vinyl tape to protect the seal. Install the mainshaft and countershaft (G) into the
shift forks (H), and install them as an assembly.
7. Install the reverse idler gear (A) and reverse gear shaft (B).
8. Select the proper size 72 mm shim (A) according to the measurements made during the Mainshaft Thrust
Clearance Adjustment. Install the oil gutter plate (B), oil guide plate M (C) and 72 mm shim into the transmission
housing (D).
9. Clean any dirt or oil from the transmission housing and clutch housing mating surface. Apply liquid gasket (P/N
08C70-K0234M, 08C70-K0334M, or 08C70-X0331S) to the sealing surface as shown.
NOTE: Do not install components if too much time has passed after applying the liquid gasket. Instead, remove the
old residue and reapply the liquid gasket.
14. Apply liquid gasket (P/N 08C70-K0234M, 08C70-K0334M, or 08C70-X0331S) to the threads of the 32 mm sealing
screw (E), and install it on the transmission housing.
15. Install the transmission hanger (A) and the 8 mm flange bolts finger-tight.
17. Clean any dirt or oil from the change lever assembly sealing surface. Apply liquid gasket (P/N 08C70-K0234M,
08C70-K0334M, or 08C70-X0331S) to the sealing surface.
NOTE: Do not install components if too much time has passed after applying the liquid gasket. Instead, remove the
old residue and reapply the liquid gasket.
18. Install the 8 x 10 mm dowel pins (A) and change lever assembly (B).
19. Install the set screws (A), new 12 mm washers (B), springs (C), and steel balls (D).
20. Install the new washer (E) and back-up light switch (F).
21. Install the new washers (A), drain plug (B), filler plug (C), new O-ring (D), and vehicle speed sensor (VSS) (E).
Back-up Light Switch Test
1. Disconnect the back-up light switch 2P connector (A).
2. Check for continuity between the back-up light switch 2P connector terminals No. 1 and No. 2. There should be
continuity when the shift lever is in reverse. If the result is faulty, go to Step 3 .
3. Remove the back-up light switch (A). Check for continuity between the back-up light switch 2P connector terminals
No. 1 and No. 2. There should be continuity when the switch end (B) is pressed, and no continuity when the switch
end is released. If the result is faulty, replace the back-up light switch. If the switch is OK, check the reverse shift
piece in the transmission.
4. Install the removed or the new back-up light switch and new washer.
5. Connect the back-up light switch 2P connector.
M/T Clutch Housing Countershaft Bearing Replacement
Special Tools Required
Adjustable bearing remover head, 20−40 mm
07JAC-PH80100
2. Position the oil guide plate C (A) and new needle bearing (B) in the bore of the clutch housing (C).
3. Press in the needle bearing using the 15 x 135L driver handle (D), 52 x 55 mm bearing driver attachment (E).
M/T Clutch Housing Mainshaft Bearing and Oil Seal Replacement
Special Tools Required
Adjustable bearing remover head, 20−40 mm
07JAC-PH80100
4. Drive the new oil seal in from the transmission side using the 15 x 135L driver handle (A) and 37 x 40 mm bearing
driver attachment (B).
5. Drive the new ball bearing (A) in from the transmission side using the 15 x 135L driver handle (B) and 52 x 55 mm
bearing driver attachment (C).
M/T Clutch Housing Mainshaft Thrust Clearance Adjustment
Special Tools Required
Base adapter
07GAJ-PG20130
Base collar
07GAJ-PG20120
Catch adapter
07GAJ-PG20110
1. Remove the 72 mm shim (A) and oil guide plate M (B) from the transmission housing (C).
2. Install the 3rd/4th synchro hub (A), the distance collar (B), the 5th synchro hub (C), distance collar (D), and ball
bearing (E) on the mainshaft (F), then install the assembled mainshaft in the transmission housing (G).
3. Install the washer (H) on the mainshaft.
4. Measure distance (1) between the end of the transmission housing and washer with a straight edge and vernier
caliper. Measure at three locations and average the reading.
5. Measure distance (2) between the end of the clutch housing (A) and bearing inner race (B) with a straight edge and
depth gauge. Measure at three locations and average the readings.
(Basic Formula)
(1) + (2) − (0.75 + 0.11) = shim thickness (maximum)
(1) + (2) − (0.75 + 0.18) = shim thickness (minimum)
(For example)
2.41 + 0.22 − (0.75 + 0.11) = 1.77 mm (0.070 in.)
2.41 + 0.22 − (0.75 + 0.18) = 1.70 mm (0.067 in.)
7. Take the middle value of the minimum value and the maximum value, and select shim of 1.74 mm (0.069 in).
72 mm Shim
Type Part Number Thickness
A 23931-P21-000 0.60 mm (0.0236 in.)
B 23932-P21-000 0.63 mm (0.0248 in.)
C 23933-P21-000 0.66 mm (0.0260 in.)
D 23934-P21-000 0.69 mm (0.0271 in.)
E 23935-P21-000 0.72 mm (0.0283 in.)
F 23936-P21-000 0.75 mm (0.0295 in.)
G 23937-P21-000 0.78 mm (0.0307 in.)
H 23938-P21-000 0.81 mm (0.0319 in.)
I 23939-P21-000 0.84 mm (0.0331 in.)
J 23940-P21-000 0.87 mm (0.0343 in.)
K 23941-P21-000 0.90 mm (0.0354 in.)
L 23942-P21-000 0.93 mm (0.0366 in.)
M 23943-P21-000 0.96 mm (0.0378 in.)
N 23944-P21-000 0.99 mm (0.0390 in.)
O 23945-P21-000 1.02 mm (0.0402 in.)
P 23946-P21-000 1.05 mm (0.0413 in.)
Q 23947-P21-000 1.08 mm (0.0425 in.)
R 23948-P21-000 1.11 mm (0.0437 in.)
Type Part Number Thickness
S 23949-P21-000 1.14 mm (0.0449 in.)
T 23950-P21-000 1.17 mm (0.0461 in.)
U 23951-P21-000 1.20 mm (0.0472 in.)
V 23952-P21-000 1.23 mm (0.0484 in.)
W 23953-P21-000 1.26 mm (0.0496 in.)
X 23954-P21-000 1.29 mm (0.0508 in.)
Y 23955-P21-000 1.32 mm (0.0520 in.)
Z 23956-P21-000 1.35 mm (0.0531 in.)
AA 23957-P21-000 1.38 mm (0.0543 in.)
AB 23958-P21-000 1.41 mm (0.0555 in.)
AC 23959-P21-000 1.44 mm (0.0567 in.)
AD 23960-P21-000 1.47 mm (0.0579 in.)
AE 23961-P21-000 1.50 mm (0.0591 in.)
AF 23962-P21-000 1.53 mm (0.0602 in.)
AG 23963-P21-000 1.56 mm (0.0614 in.)
AH 23964-P21-000 1.59 mm (0.0626 in.)
AI 23965-P21-000 1.62 mm (0.0638 in.)
AJ 23966-P21-000 1.65 mm (0.0650 in.)
AK 23967-P21-000 1.68 mm (0.0661 in.)
AL 23968-P21-000 1.71 mm (0.0673 in.)
AM 23969-P21-000 1.74 mm (0.0685 in.)
AN 23970-P21-000 1.77 mm (0.0697 in.)
AO 23971-P21-000 1.80 mm (0.0709 in.)
8. Install the 72 mm shim (A) selected and oil guide plate M (B) in the transmission housing (C).
9. Throughly clean the spring washer (A) and washer (B) before installing them on the clutch housing side ball bearing
(C). Note the installation direction of the spring washer.
10. Install the mainshaft in the clutch housing.
11. Place the transmission housing over the mainshaft and onto the clutch housing.
12. Tighten the clutch and transmission housings with several 8 mm bolts.
NOTE: It is not necessary to use sealing agent between the housings.
13. Tap the mainshaft with a plastic hammer.
14. Slide the base collar (B), and base adapter (C) over the mainshaft (A).
15. Attach the catch adapter (A), base collar (B), and base adapter (C) to the mainshaft as follows:
Back-out the mainshaft holder bolt (D) and loosen the two hex bolts (E).
Fit the holder over the mainshaft so its lip is towards the transmission.
Align the mainshaft holder's lip around the groove at the inside of the mainshaft splines, then tighten the hex
bolts.
16. Seat the mainshaft fully by tapping its end with a plastic hammer.
17. Thread the mainshaft holder bolt in until it just contacts the wide surface of the mainshaft base.
3. Remove the locknut (left-hand threads) (A) and the spring washer (B).
4. Support 5th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E)
out of the ball bearing * (F).
*L15A7 engine: Needle bearing
5. Support 4th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E)
out of the 4th gear.
6. Support 3rd gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E)
out of the 3rd gear.
M/T Countershaft Assembly Clearance Inspection
1. Measure the clearance between the 1st gear (A) and the countershaft (B) with a feeler gauge (C). If the clearance is
more than the service limit, go to Step 2 .
If the clearance is more than the service limit, go to Step 2 .
If the clearance is within the service limit, go to Step 4 .
Standard: 0.03−0.12 mm (0.001−0.005 in.)
Service Limit: 0.24 mm (0.009 in.)
4. Measure the clearance between the 2nd gear (A) and 3rd gear (B) with a feeler gauge (C). If the clearance is more
than the service limit, go to Step 4 .
Standard: 0.04−0.12 mm (0.002−0.005 in.)
Service Limit: 0.24 mm (0.009 in.)
2. Inspect the runout by supporting both ends of the countershaft. Rotate the countershaft two complete revolutions
when measuring the runout. If the runout exceeds the service limit, replace the countershaft with a new one.
Standard: 0.02 mm (0.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)
M/T Change Lever Clearance Inspection
1. Measure the clearance between change lever (A) and the select lever (B) with a feeler gauge (C). If the clearance is
more than the service limit, go to Step 2 .
Standard: 0.05−0.35 mm (0.002−0.014 in.)
Service Limit: 0.55 mm (0.022 in.)
3. Measure the clearance between the shift forks (A) and the shift arm (B). If the clearance exceeds the service limit,
go to Step 4 .
Standard: 0.2−0.5 mm (0.008−0.020 in.)
Service Limit: 0.62 mm (0.024 in.)
3. Support 5th gear (A) on steel blocks, and press the mainshaft out of the 5th synchro hub (B).
NOTE: Do not use a jaw-type puller; it can damage the gear teeth.
4. Support the 3rd gear (A) on steel blocks, and press the mainshaft out of the 3rd/4th synchro hub (B).
NOTE: Do not use a jaw-type puller; it can damage the gear teeth.
M/T Mainshaft Reassembly
Exploded View
Special Tools Required
Inner driver handle, 40 mm
07746-0030100
4. Install the 3rd/4th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 3rd/4th
synchro hub.
NOTE: Make sure the installing direction of the 3rd/4th synchro hub.
5. Press in the 3rd/4th synchro hub (A) using the 40 mm inner driver handle (B) and 30 mm inner bearing driver
attachment (C).
6. Install the 3rd/4th synchro sleeve (A) by aligning the stops (B) of the 3rd/4th synchro sleeve and 3rd/4th synchro
hub. After installing, check the operation of the 3rd/4th synchro hub set.
7. Install the synchro ring (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the grooves (D)
in the 3rd/4th synchro hub.
8. Install 4th gear (E) onto the synchro ring.
9. Install the 4th/5th gear distance collar (A) with the needle bearings (B) and 5th gear (C).
10. Install the synchro ring (D) with the synchro spring (E) onto the 5th gear.
11. Install the 5th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 5th synchro hub.
12. Press in the 5th synchro hub (A) using the 40 mm inner driver handle (B) and 30 mm inner bearing driver
attachment (C).
13. Install the 5th synchro sleeve (A) by aligning the slots of the 5th synchro sleeve and the 5th synchro hub (B). After
installing, check the operation of the 5th synchro hub set.
NOTE: The slots layout is inequable. Set correctly them.
14. Install the synchro ring (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the grooves (D)
in the 5th synchro hub.
15. Install the distance collar (E) and tapered cone ring (F).
16. Press in the new angular ball bearing (A) using the 40 mm inner driver handle (B) 30 mm inner bearing driver
attachment (C) and press (D).
M/T Mainshaft Assembly Clearance Inspection
NOTE: If replacement is required, always replace the synchro sleeve and hub as a set.
1. Support the bearing inner race with a socket (A), and push down on the mainshaft (B).
2. Measure the clearance between 2nd (C) and 3rd (D) gears with a feeler gauge (E).
If the clearance is more than the service limit, go to Step 3 .
If the clearance is within the service limit, go to Step 4 .
Standard: 0.06−0.21 mm (0.002−0.008 in.)
Service Limit: 0.33 mm (0.013 in.)
4. Measure the clearance between 4th gear (A) and the distance collar (B) with a dial indicator (C). If the clearance is
more than the service limit, go to Step 5 .
Standard: 0.06−0.19 mm (0.002−0.007 in.)
Service Limit: 0.31 mm (0.012 in.)
7. Measure the clearance between the distance collar (A) and 5th gear (B) with a dial indicator (C). If the clearance is
more than the service limit, go to Step 8 .
Standard: 0.06−0.19 mm (0.002−0.007 in.)
Service Limit: 0.31 mm (0.012 in.)
2. Inspect the runout by supporting both ends of the mainshaft. Rotate the mainshaft two complete revolutions when
measuring the runout. If the runout is more than the service limit, replace the mainshaft with a new one.
Standard: 0.02 mm (0.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)
M/T Differential Component Location Index
CARRIER BEARING
Replacement,
DIFFERENTIAL CARRIER
Backlash Inspection,
Replacement,
CARRIER BEARING
Replacement,
M/T Differential Backlash Inspection
1. Place the differential assembly on V-blocks (A), and install both axles.
2. Measure the backlash of both pinion gears (B) with a dial indicator (C). If the backlash is not within the standard,
replace the differential carrier.
Standard (New): 0.05−0.15 mm (0.002−0.006 in.)
M/T Differential Carrier Bearings Replacement
Special Tools Required
Commercially available
bearing puller
3. Install the new bearing (A) with the 40 mm inner driver handle and a press. Press each bearing on until it bottoms.
There should be no clearance between the bearings and the carrier.
NOTE: Turn the seal (B) part of the bearing to the outside of differential, and install it.
M/T Differential Oil Seal Replacement
Special Tools Required
Driver handle, 15 x 135L
07749-0010000
3. Remove the oil seal (A) from the clutch housing (B).
4. Install the new oil seal (A) in the transmission housing (B) with the 15 x 135L driver handle (C) and the 64 x 72 mm
oil seal driver attachment (D).
5. Install the new oil seal (A) in the clutch housing (B) with the 15 x 135L driver handle (C) and the 64 x 72 mm oil
seal driver attachment (D).
M/T Differential Final Driven Gear/Carrier Replacement
1. Remove the bolts in a crisscross pattern in several steps, then remove the final driven gear from the differential
carrier.
2. Install the final driven gear with the chamfer on the inside diameter facing the carrier. Tighten the bolts in a
crisscross pattern in several steps.
M/T Synchro Ring and Gear Inspection
1. Inspect the inside of each synchro ring (A) for wear. Inspect the teeth (B) of each synchro ring for wear (rounded
off).
2. Inspect the teeth (A) on each synchro sleeve and matching teeth on each gear for wear (rounded off).
3. Inspect the thrust surface (A) on each gear hub for wear.
4. Inspect the cone surface (B) on each gear hub for wear and roughness.
5. Inspect the teeth on all gears (C) for uneven wear, scoring, and cracks.
6. Coat the cone surface of each gear with transmission fluid, and place its synchro ring on it. Rotate the synchro
ring, making sure that it does not slip.
7. Measure the clearance between each gear (A) and its synchro ring (B) all the way round. Hold the synchro ring
against the gear evenly while measuring the clearance. If the clearance is less than the service limit, replace the
synchro ring and gear.
WHT
BAT IGNITION
ST SWITCH
BLK PNK
BLK/WHT
B S
M SOLENOID
STARTER
M/T Component Location Index
GEARSHIFT MECHANISM
Replacement,
in the Shop Manual, P/N 62TF000A
TRANSMISSION
CHANGE LEVER
ClearanceRemoval,
Inspection,
in the ShopinManual,
the ShopP/NManual, P/N 62TF000A
62TF000A
Installation,
in the Shop Manual, P/N 62TF000A
BACK-UP LIGHT SWITCH Disassembly,
SHIFT FORK
Test, in the Shop Manual,Inspection,
Clearance P/N 62TF000A
TRANSMISSION FLUID in the Shop Manual, Reassembly,
Inspection and Replacement, P/N 62TF000A in the Shop Manual,
in the Shop P/N 62TF000A
Manual,
P/N 62TF000A
REVERSE Disassembly/ Reassembly,
IDLER GEAR
in the Shop Manual,
P/N 62TF000A
MAINSHAFT ASSEMBLY
Clearance Inspection, COUNTERSHAFT ASSEMBLY
Clearance Inspection,
in the Shop Manual, P/N 62TF000A in the Shop Manual, P/N 62TF000A
REVERSE SHIFT FORK MAINSHAFT COUNTERSHAFT
Clearance Inspection, Disassembly, Disassembly,
in the Shop Manual, P/N 62TF000A in the Shop Manual, P/N 62TF000A
in the Shop Manual, Inspection, Inspection,
P/N 62TF000A in the Shop Manual, P/N 62TF000A in the Shop Manual, P/N 62TF000A
Reassembly, Reassembly (L13Z1, L15A7),
in the Shop Manual, P/N 62TF000A in the Shop Manual, P/N 62TF000A
Thrust Clearance Adjustment, Reassembly (L12B1),
in the Shop Manual, P/N 62TF000A Bearing Replacement,
Bearing and Oil Seal Replacement, in the Shop Manual, P/N 62TF000A
in the Shop Manual, P/N 62TF000A
MTF Inspection and Replacement
1. Park the vehicle on level ground, and turn the engine OFF.
2. Raise the vehicle on a lift and make sure it is securely supported.
3. Remove the splash shield.
4. Remove the filler plug (A) and sealing washer (B), check the condition of the MTF and make sure it is at the proper
level (C).
5. If the MTF is dirty, remove the drain plug (A) and drain the MTF.
6. Reinstall the drain plug with a new sealing washer (B), and refill the transmission with MTF to the proper level.
Always use Genuine Honda Manual Transmission Fluid (MTF).
Fluid Capacity
1.5 L (1.6 US qt, 1.3 Imp qt) at fluid change
1.6 L (1.7 US qt, 1.4 Imp qt) at overhaul
7. Install the filler plug (C) with a new sealing washer (D).
8. Install the splash shield.
9. Lower the vehicle on the lift.
10. Without service reminder system, this procedure is complete.
CLUTCH PEDAL
POSITION SWITCH A
(With SHIFT INDICATOR LAMP)
CLUTCH LINE Test,
CONNECTOR Adjustment,
CLUTCH
PILOT BEARING LINE CLUTCH HOSE CLIPS
Inspection, BRACKET Replace.
in the Shop Manual, B
P/N 62TF000A
Replacement, RELEASE BEARING
in the Shop Manual, Removal,
P/N 62TF000A in the Shop Manual,
P/N 62TF000A
CLUTCH DISC Inspection,
Inspection and Removal, in the Shop Manual,
in the Shop Manual, P/N 62TF000A P/N 62TF000A
Installation, Installation,
in the Shop Manual, P/N 62TF000A in the Shop Manual,
P/N 62TF000A
SLAVE CYLINDER
Replacement,
in the Shop Manual, P/N 62TF000A PRESSURE PLATE
Overhaul, CLUTCH LINE Inspection and Removal,
in the Shop Manual, P/N 62TF000A in the Shop Manual, P/N 62TF000A
Installation,
in the Shop Manual, P/N 62TF000A
Clutch disc
Item Measurement Qualification Standard or New Service Limit
Clutch disc Rivet head depth 1.00−1.50 mm (0.039−0.059 in.) 0.2 mm (0.008 in.)
Thickness 7.25−7.95 mm (0.285−0.313 in.) 5.0 mm (0.20 in.)
Clutch Master Cylinder Replacement
NOTE:
Use fender covers to avoid damaging painted surfaces.
Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid does contact the paint or
plastic, wash it off immediately with water.
Without cruise control: Clutch pedal adjusting bolt is substituted as clutch pedal position switch B.
Put on gloves to protect your hands.
1. Secure the hood in the wide open position (support rod in the lower hole).
2. Remove the windshield wiper arms.
3. Remove the cowl cover and hood hinge cover.
4. Remove the wiper motor.
5. Remove the under-cowl panel.
6. LHD model: Remove the air cleaner housing.
7. Remove the brake fluid from the clutch master cylinder reservoir with a syringe.
8. Remove the driver's dashboard under cover.
9. Pry out the lock pin (A), and pull the pedal pin (B) out of the yoke. Remove the master cylinder mounting nuts (C).
10. LHD model: Remove the clutch pipe bracket bolts (A).
11. LHD model: Remove the reservoir hose from two clips.
12. Disconnect the reservoir hose (A), then remove the clutch line (B) from the clutch master cylinder (C). Plug or wrap
the end of the reservoir hose and clutch line with a shop towel to prevent brake fluid from coming out.
NOTE:
Loosen the flare nut (D) while holding the clutch line connector (E) with a wrench.
Inspect the hose. If the hose has damage, leaks interference, or twisting, replace it.
13. Remove the clutch master cylinder seal (F) from the clutch master cylinder.
14. Remove the retaining clip (A), then remove the clutch line connector (B) and the O-ring (C) from the master cylinder
(D).
15. Install the clutch line connector (A) with a new O-ring (B), then set in a new retaining clip (C) to the master cylinder
(D).
NOTE: Apply the rubber grease on the O-ring and joint part (E) of the clutch line connector.
16. To prevent the retaining clip (A) from coming off, pry apart the tip (B) of the clip with a screwdriver.
17. Install the new clutch master cylinder seal (A) to the clutch master cylinder (B).
18. Connect the clutch line (C), and reservoir hose (D).
NOTE: Tighten the flare nut (E) while holding the clutch line connector (F) with a wrench.
19. LHD model: Install the two reservoir hose clips.
20. LHD model: Install the clutch pipe bracket bolts (A).
21. Make sure the hose clamps (A) are positioned on the master cylinder (B) and reservoir (C) as shown. LHD model
22. LHD model: Install the air cleaner housing.
RHD model
7. Loosely install clutch pedal position switch A and clutch pedal position switch B.
10. While holding clutch pedal position switch A, tighten the locknut.
11. Check the clutch operation.
12. Connect the clutch pedal position switch A and the clutch pedal position switch B connectors, then check the
cruise control and the shift indicator lamp operation.
Clutch pedal
Item Measurement Qualification Standard or New Service Limit
Clutch pedal Height from the floor RHD 145 mm (5.71 in.) ———
LHD 150 mm (5.91 in.) ———
Stroke 120−130 mm (4.72−5.12 in.) ———
Pressure plate
Item Measurement Qualification Standard or New Service Limit
Pressure plate Warpage 0.03 mm (0.001 in.) max. 0.15 mm (0.006 in.)
Height difference of diaphragm spring fingers 0.6 mm (0.02 in.) max. 1.0 mm (0.04 in.)
measured with dial indicator
Flywheel
Item Measurement Qualification Standard or New Service Limit
Flywheel Runout on clutch mating surface 0.05 mm (0.002 in.) max. 0.15 mm (0.006 in.)
M/T Clutch Housing Differential Thrust Clearance Adjustment
Special Tools Required
Inner driver handle, 40 mm
07746-0030100
1. Remove the left driveshaft side oil seal.
2. Install the 72 mm shim (A) that's the same size as the one you removed.
5. Use the 40 mm inner driver handle to bottom the differential assembly in the clutch housing.
6. Measure clearance between 72 mm shim and bearing outer race in transmission housing.
Standard: 0.01−0.1 mm (0.0004−0.004 in.)
7. If the clearance is more than the standard, select a new 72 mm shim from the following table. If the clearance
measured in Step 6 is within the standard, go to Step 10 .
Exploded View
Countershaft
Item Measurement Qualification Standard or New Service Limit
Countershaft Diameter of needle bearing contact area 34.000−34.015 mm (1.3386−1.3392 in.) 33.95 mm (1.337 in.)
(transmission housing side)
Diameter of ball bearing contact area (clutch 24.980−24.993 mm (0.9835−0.9840 in.) 24.93 mm (0.981 in.)
housing side)
Diameter of distance collar contact area 36.487−36.500 mm (1.4365−1.4370 in.) 36.44 mm (1.4346 in.)
Runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.)
Countershaft 1st gear
Item Measurement Qualification Standard or New Service Limit
Countershaft 1st I.D. 48.509−48.525 mm (1.9098−1.9104 in.) 48.580 mm (1.9126 in.)
gear End play 0.03−0.12 mm (0.001−0.005 in.) 0.24 mm (0.009 in.)
Thickness 27.42−27.47 mm (1.080−1.081 in.) 27.39 mm (1.078 in.)
Countershaft 2nd gear
Item Measurement Qualification Standard or New Service Limit
Countershaft 2nd I.D. 45.009−45.025 mm (1.7720−1.7726 in.) 45.07 mm (1.774 in.)
gear End play 0.04−0.12 mm (0.002−0.005 in.) 0.24 mm (0.009 in.)
Thickness 27.41−27.46 mm (1.079−1.081 in.) 27.36 mm (1.077 in.)
Countershaft 1st gear distance collar
Item Measurement Qualification Standard or New Service Limit
Countershaft 1st I.D. 36.50−36.51 mm (1.4370−1.4373 in.) 36.52 mm (1.4378 in.)
gear distance O.D. 44.489−45.000 mm (1.7515−1.7717 in.) 44.44 mm (1.7500 in.)
collar Length A 30.50−30.54 mm (1.2007−1.2023 in.) ———
B 26.53−26.58 mm (1.044−1.046 in.) ———
Countershaft 2nd gear distance collar
Item Measurement Qualification Standard or New Service Limit
Countershaft 2nd I.D. 34.000−34.010 mm (1.3386−1.3390 in.) 34.04 mm (1.340 in.)
gear distance O.D. 39.989−40.000 mm (1.5744−1.5748 in.) 39.93 mm (1.572 in.)
collar Length 27.53−27.56 mm (1.084−1.085 in.) 27.51 mm (1.083 in.)
Change lever
Item Measurement Qualification Standard or New Service Limit
Change lever Shaft-to-select lever clearance 0.05−0.35 mm (0.002−0.014 in.) 0.55 mm (0.022 in.)
Groove width 13.00−13.15 mm (0.512−0.518 in.) ———
Shaft-to-shift arm clearance 0.013−0.070 mm (0.0005−0.0028 in.) 0.1 mm (0.004 in.)
Select lever
Item Measurement Qualification Standard or New Service Limit
Select lever Finger width 12.80−12.95 mm (0.504−0.510 in.) ———
Reverse shift fork
Item Measurement Qualification Standard or New Service Limit
Reverse shift fork Finger width 13.5−13.8 mm (0.53−0.54 in.) ———
Fork-to-reverse idler gear clearance 1.30−1.90 mm (0.051−0.075 in.) 2.5 mm (0.098 in.)
Shift fork
Item Measurement Qualification Standard or New Service Limit
Shift fork Finger thickness 1st-2nd and 3rd- 7.4−7.6 mm (0.29−0.30 in.) ———
4th forks
5th fork 6.7−6.9 mm (0.26−0.27 in.) ———
Fork-to-synchro sleeve clearance 0.35−0.65 mm (0.014−0.026 in.) 1.0 mm (0.04 in.)
Shift arm
Item Measurement Qualification Standard or New Service Limit
Shift arm I.D. 13.973−14.000 mm (0.5501−0.5512 in.) ———
Finger width 12.9−13.0 mm (0.508−0.512 in.) ———
Shift arm-to-shift fork clearance 0.2−0.5 mm (0.008−0.020 in.) 0.62 mm (0.024 in.)
Mainshaft
Item Measurement Qualification Standard or New Service Limit
Mainshaft End play 0.11−0.18 mm (0.004−0.007 in.) Adjust
Diameter of ball bearing contact area 25.987−26.000 mm (1.0231−1.0236 in.) 25.93 mm (1.020 in.)
(transmission housing side)
Diameter of distance collar contact area 28.992−29.005 mm (1.1414−1.1419 in.) 28.93 mm (1.139 in.)
Diameter of needle bearing contact area 34.984−35.000 mm (1.3773−1.3780 in.) 34.93 mm (1.375 in.)
Diameter of ball bearing contact area (clutch 25.977−25.990 mm (1.0227−1.0232 in.) 25.92 mm (1.020 in.)
housing side)
Diameter of pilot bearing contact area 14.870−14.890 mm (0.5854−0.5862 in.) ———
Runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.)
Mainshaft 4th/5th gear distance collar
Item Measurement Qualification Standard or New Service Limit
Mainshaft 4th/5th I.D. 29.014−29.024 mm (1.1423−1.1427 in.) 29.06 mm (1.144 in.)
gear distance O.D. 34.989−35.000 mm (1.3775−1.3780 in.) 34.93 mm (1.375 in.)
collar Length A 51.97−52.03 mm (2.046−2.048 in.) ———
B 24.03−24.06 mm (0.946−0.947 in.) ———
MBS distance collar
Item Measurement Qualification Standard or New Service Limit
MBS distance I.D. 26.02−26.17 mm (1.024−1.030 in.) ———
collar Length 12.00−12.05 mm (0.472−0.474 in.) ———
Mainshaft 3rd and 4th gear
Item Measurement Qualification Standard or New Service Limit
Mainshaft 3rd and I.D. 39.009−39.025 mm (1.5358−1.5364 in.) 39.07 mm (1.538 in.)
4th gear Clearance 2nd-3rd 0.06−0.21 mm (0.002−0.008 in.) 0.33 mm (0.013 in.)
Endplay 4th 0.06−0.19 mm (0.002−0.007 in.) 0.31 mm (0.012 in.)
Thickness 3rd 27.92−27.97 mm (1.099−1.101 in.) 27.85 mm (1.096 in.)
4th 27.02−27.07 mm (1.064−1.066 in.) 26.65 mm (1.049 in.)
Mainshaft 5th gear
Item Measurement Qualification Standard or New Service Limit
Mainshaft 5th I.D. 39.009−39.025 mm (1.5358−1.5364 in.) 39.07 mm (1.538 in.)
gear End play 0.06−0.19 mm (0.002−0.007 in.) 0.31 mm (0.012 in.)
Thickness 28.92−28.97 mm (1.139−1.141 in.) 28.85 mm (1.136 in.)
M/T differential pinion gear
Item Measurement Qualification Standard or New Service Limit
M/T differential Backlash 0.05−0.15 mm (0.002−0.006 in.) ———
pinion gear
Synchro ring
Item Measurement Qualification Standard or New Service Limit
Synchro ring Ring-to-gear clearance Ring pushed 0.85−1.10 mm (0.033−0.043 in.) 0.4 mm (0.02 in.)
against gear
Fuel and Emissions System Description - VTEC System
VTEC System (L12B1 engine)
Operation (L12B1 engine)
M/T differential 72 mm shim
Item Measurement Qualification Standard or New Service Limit
M/T differential 72 72 mm shim-to-bearing outer race clearance 0.01−0.1 mm (0.0004−0.004 in.) Adjust
mm shim in transmission housing
(L12B1, L13Z1)
Safety Messages
Safety Messages
Your safety, and the safety of others, is very important. To help you make informed decisions, we have provided safety
messages, and other safety information throughout this manual. Of course, it is not practical or possible to warn you
about all the hazards associated with servicing this vehicle. You must use your own good judgment.
You will find important safety information in a variety of forms including:
Safety Labels − on the vehicle.
Safety Messages − preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or
CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don't follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don't follow instructions.
You CAN be HURT if you don't follow instructions.
Gauges
Under−dash
Auxiliary
ECM/PCM
MICU
Audio
Immobilizer
ABS, System
Battery,
A/T
Power
SRS Gear
Heating/Air
EPS Fuse/Relay
Under−hood
System,
Windows,
Battery
Position
Terminal
Power Box
Ignition
Relay
Indicator
Conditioning,
Wipers/Washers, Box,
Key
Mirrors
Fuse
Panel
Rear
Combination Box,Charging
Switch,
Light, Accessory
System,
Under−dash
Window
Light Interior
Defogger
Switch, Starting
Power
Lights,
Fuse/Relay
Cable Reel, Socket,
System,
Back−up
Box
Steering Door
FuelLock
Lights,
Wheel Pump,
BrakeActuators
Horns
lights,
Switches, FrontWarning
Hazaed PositionSwitch
Lights, Taillights, License Plate lights, Turn Signal Lights, Headlights
A AA
AA *5 B BB CC
CC
C
11
10
13
12
15
14
16987654321 No . 1 (10 A)*2
F USE
(1− C)
15 PNK
*7
PNK
AL ARM CO NT RO L SIREN
UL T RASO NIC
1 SENSO R
IG NIT IO N SW IT CH
OFF
*6 (RHD mo d el) *7 *5 (L HD mo d el)
*: Only severe schedule is required in some countries, refer to local warranty booklet.
Service at the indicated distance or time whichever comes first km x 1,000 20 40 60 80 100 120 140 160 180 200
miles x 1,000 12.5 25.0 37.5 50.0 62.5 75.0 87.5 100.0112.5125.0
months 12 24 36 48 60 72 84 96 108 120
Check front and rear brakes Every 10,000 km (6,250 miles)
Check the brake pad and disc thickness. Check for damage.
Check the calipers for damage, leaks, and tightness.
Replace brake fluid Every 3 years
Use only DOT 3 or DOT 4 brake fluid. We recommend genuine Honda Brake Fluid.
Check the brake fluid level is between upper and lower marks on the reservoir.
Exhaust system
Check the exhaust pipe and muffler for damage, leaks, and tightness.
Fuel lines, and connections
Check fuel lines for loose connections, cracks, and deterioration.
Retighten loose connections and replace any damaged parts.
Maintenance Schedule for Normal and Severe Conditions - Except Australia
This maintenance schedule outlines the minimum required maintenance that you should perform to ensure the trouble-free operation of the vehicle. Due
to regional and climatic differences, some additional service may be required. Please consult the warranty booklet for a more detailed description.
The following items must be used for ‘‘severe conditions'' indicated on schedule, if the vehicle is driven MAINLY under the specified conditions A to F.
Engine oil and engine oil filter: A/B/C/D/E
Transmission fluid
M/T: B/D
A/T: B/C/D/F
A: Driving less than 8 km (5 miles) per trip or, in freezing temperatures, driving less than 16 km (10 miles) per trip.
B: Driving in extremely hot over 35 °C (95 °F) conditions.
C: Extensive idling, or long periods of stop-and-go driving.
D: Towing trailer, driving with a loaded roof rack, or driving in mountainous conditions.
E: Driving on muddy, dusty, or de-iced roads.
F: Driving more than 20,000 km (12,500 miles) per year, or driving at high speed frequently.
Service at the indicated distance or time whichever comes first km x 1,000 20 40 60 80 100 120 140 160 180 200
miles x 1,000 12.5 25.0 37.5 50.0 62.5 75.0 87.5 100.0112.5125.0
months 12 24 36 48 60 72 84 96 108 120
Replace engine oil * Normal Conditions Every 10,000 km (6,250 miles) or 1 year
Severe Conditions Every 5,000 km (3,125 miles) or 6 months
Replace engine oil filter * Normal Conditions ● ● ● ● ● ● ● ● ● ●
Severe Conditions Every 10,000 km (6,250 miles) or 6 months
Replace air cleaner element Every 30,000 km (18,750 miles)
Inspect valve clearance Every 40,000 km (25,000 miles)
Replace fuel filter ● ●
Replace spark plugs Every 100,000 km (62,500 miles)
Inspect and adjust drive belt ● ● ● ● ●
Look for cracks and damage, then check the deflection and tension.
Inspect idle speed ●
Replace engine coolant At 200,000 km (120,000 miles) or 10 years, then
Use genuine Honda All Season Antifreeze/Coolant Type 2. every 100,000 km (60,000 miles) or 5 years
Replace Manual Transmission Fluid Normal Conditions ●
Use genuine Honda MTF. Severe Conditions ● ● ●
Replace Automatic Transmission Fluid Normal Conditions ● ●
Use genuine Honda ATF-Z1. Severe Conditions ● ● ● ●
*: Only severe schedule is required in some countries, refer to local warranty booklet.
Service at the indicated distance or time whichever comes first km x 1,000 20 40 60 80 100 120 140 160 180 200
miles x 1,000 12.5 25.0 37.5 50.0 62.5 75.0 87.5 100.0112.5125.0
months 12 24 36 48 60 72 84 96 108 120
Check front and rear brakes Every 10,000 km (6,250 miles)
Check the brake pad and disc thickness. Check for damage.
Check the calipers for damage, leaks, and tightness.
Replace brake fluid Every 3 years
Use only DOT 3 or DOT 4 brake fluid. We recommend genuine Honda Brake Fluid.
Check the brake fluid level is between upper and lower marks on the reservoir.
Exhaust system
Check the exhaust pipe and muffler for damage, leaks, and tightness.
Fuel lines, and connections
Check fuel lines for loose connections, cracks, and deterioration.
Retighten loose connections and replace any damaged parts.
Mileage / Year
km mile
20,000km/1year
Mileage / Year
km mile
20,000km/1year
Design Specifications
Item Measurement Qualification Specification
DIMENSION Overall length 3,900−3,920 mm (153.5−154.3 in.)
Overall width 1,695 mm (66.7 in.)
Overall height 1,525 mm (60.0 in.)
Wheelbase 2,500 mm (98.4 in.)
Track 15 inch wheel Front 1,490 mm (58.7 in.)
model Rear 1,475 mm (58.1 in.)
16 inch wheel Front 1,475 mm (58.1 in.)
model Rear 1,460 mm (57.5 in.)
Ground clearance 150 mm (5.9 in.)
Seating capacity Five (5)
WEIGHT (except KQ) Curb weight M/T 1,045 kg (2,304 lbs)
A/T 1,070 kg (2,359 lbs)
WEIGHT (KQ) Curb weight M/T 1,025−1,040 kg (2,260−2,293 lbs)
(L13Z1) A/T 1,070−1,093 kg (2,359−2,410 lbs)
Curb weight M/T 1,048−1,060 kg (2,310−2,337 lbs)
(L15A7) A/T 1,075−1,085 kg (2,370−2,392 lbs)
ENGINE Type Water-cooled, 4-stroke SOHC i-VTEC engine
Cylinder arrangement Inline 4-cylinder, transverse
Bore and stroke L13Z1 73 x 80 mm (2.87 x 3.15 in.)
ABS . 13
Accessory Power Socket . 10
Audio System . 16
Auxiliary Under-hood Relay Box . 3
A/T Gear Position Indicator Panel Light . 9
Back-up Lights . 9
Battery Terminal Fuse Box . 1
Battery . 1
Brake Lights . 9
Cable Reel . 8
Charging system . 3
Combination Light Switch . 8
Data Link Connector . 4
Door Lock Actuators . 10
ECM/PCM . 4, 5
EPS . 13
Front Position Lights . 9
Fuel Pump . 3
Gauges . 6, 7
Hazard Warning Switch . 8
Headlights . 9
Heating/Air Conditioning . 15
Horns . 3
Ignition Key Switch . 10
Immobilizer System . 10
Interior Lights . 9
License Plate Lights . 9
MICU . 12
Power Mirrors . 11
Power Windows . 11
Rear Window Defogger . 15
SRS . 14
Starting System . 3
Steering Wheel Switches . 8
Taillights . 9
Turn Signal Lights . 9
Under-dash Fuse/Relay Box . 1, 2
Wipers/Washers . 8
Engine Electrical
Item Measurement Qualification Standard or New Service Limit
Ignition coil Rated voltage 12 V
Firing order 1−3−4−2
Spark plug Type NGK: IZFR6K13
DENSO: SKJ20DR-M13
Gap 1.2−1.3 mm (0.047−0.051 in.) ———
Ignition timing At idle (check the M/T (in neutral): 0±2 ° BTDC
white mark) A/T (in N or P): 0±2 ° BTDC
Drive belt Tension Auto-tensioner
Alternator Output At 13.5 V and 95 A
normal engine
temperature
Coil (rotor) resistance At 20 °C (68 °F) 2.1−2.3 Ω
Slip ring O.D. 22.7 mm (0.89 in.) 21.2 mm (0.83 in.)
Brush length 23.0 mm (0.91 in.) 18.0 mm (0.71 in.)
Brush spring tension 4.1−5.3 N (0.42−0.54 kgf, 0.93−1.19 lbs)
Starter Output Except L13Z1 0.7 kw
KP, KQ
L13Z1 KP, KQ 0.6 kw, 0.7 kw
Commutator mica depth 0.45−0.75 mm (0.018−0.030 in.) 0.20 mm (0.008 in.)
Commutator runout 0.05 mm (0.002 in.) max. 0.4 mm (0.02 in.)
Commutator O.D. 27.9−28.0 mm (1.098−1.102 in.) 27.0 mm (1.06 in.)
Brush length 9.7−10.3 mm (0.38−0.41 in.) 6.0 mm (0.20 in.)
Engine Assembly
Item Measurement Qualification Standard or New Service Limit
Compression Pressure check at 250 rpm (min −1 ) with Minimum 980 kPa (10.0 kgf/cm 2 , 142 psi) ———
wide open throttle. (See Design Specs for Maximum 200 kPa (2.0 kgf/cm 2 , 28 psi) ———
ratio) variation
Cylinder Head
Item Measurement Qualification Standard or New Service Limit
Head Warpage 0.07 mm (0.0028 in.) 0.08 mm (0.003 in.)
Height 119.9−120.1 mm (4.720−4.728 in.) ———
Camshaft End play 0.05−0.25 mm (0.002−0.010 in.) 0.5 mm (0.02 in.)
Camshaft-to-holder oil clearance 0.045−0.084 mm (0.0018−0.0033 in.) 0.100 mm (0.004 in.)
Total runout 0.03 mm (0.001 in.) max. 0.04 mm (0.002 in.)
Cam lobe height L13Z1 Intake, primary 34.290 mm (1.3500 in.) ———
Intake, secondary 30.529 mm (1.2019 in.) ———
Exhaust 35.047 mm (1.3798 in.) ———
L15A7 Intake, primary 35.241 mm (1.3874 in.) ———
Intake, secondary 36.173 mm (1.4241 in.) ———
Exhaust 35.471 mm (1.3964 in.) ———
Valve Clearance (cold) Intake 0.15−0.19 mm (0.006−0.007 in.) ———
Exhaust 0.26−0.30 mm (0.010−0.012 in.) ———
Stem O.D. Intake 5.48−5.49 mm (0.216−0.216 in.) 5.45 mm (0.215 in.)
Exhaust 5.45−5.46 mm (0.215−0.215 in.) 5.42 mm (0.213 in.)
Stem-to-guide clearance Intake 0.020−0.050 mm (0.0008−0.0020 in.) 0.08 mm (0.003 in.)
Exhaust 0.050−0.080 mm (0.0020−0.0031 in.) 0.11 mm (0.004 in.)
Valve seat Width Intake 0.850−1.150 mm (0.0335−0.0453 in.) 1.60 mm (0.063 in.)
Exhaust 1.250−1.550 mm (0.0492−0.0610 in.) 2.00 mm (0.079 in.)
Stem installed height Intake 46.1−46.5 mm (1.815−1.831 in.) 46.8 mm (1.843 in.)
Exhaust 46.2−46.6 mm (1.819−1.835 in.) 46.9 mm (1.846 in.)
Valve spring Free length L13Z1 Intake 51.17 mm (2.014 in.) ———
Exhaust 57.26 mm (2.254 in.) ———
L15A7 Intake 48.55 mm (1.911 in.) ———
Exhaust 54.52 mm (2.146 in.) ———
Valve guide I.D. Intake 5.51−5.53 mm (0.217−0.218 in.) 5.55 mm (0.219 in.)
Exhaust 5.51−5.53 mm (0.217−0.218 in.) 5.55 mm (0.219 in.)
Installed height Intake 15.85−16.35 mm (0.624−0.644 in.) ———
Exhaust 15.85−16.35 mm (0.624−0.644 in.) ———
Rocker arm Arm-to-shaft clearance Intake 0.019−0.058 mm (0.0007−0.0023 in.) 0.08 mm (0.003 in.)
Item Measurement Qualification Standard or New Service Limit
Exhaust 0.019−0.058 mm (0.0007−0.0023 in.) 0.08 mm (0.003 in.)
Engine Block
Item Measurement Qualification Standard or New Service Limit
Block Warpage of deck 0.07 mm (0.003 in.) max. 0.10 mm (0.004 in.)
Bore diameter 73.000−73.015 mm (2.8740−2.8746 in.) 73.065 mm (2.8776 in.)
Bore taper ——— 0.05 mm (0.002 in.)
Reboring limit ——— 0.25 mm (0.01 in.)
Piston Skirt O.D. at 16 mm (0.6 in.) from bottom of L13Z1 72.972−72.982 mm (2.8729−2.8733 in.) 72.97 mm (2.8728 in.)
skirt L15A7 72.980−72.990 mm (2.8732−2.8736 in.) 72.97 mm (2.8728 in.)
Clearance in cylinder L13Z1 0.018−0.043 mm (0.007−0.0017 in.) 0.05 mm (0.002 in.)
L15A7 0.010−0.035 mm (0.0004−0.0014 in.) 0.05 mm (0.002 in.)
Ring groove width Top 1.050−1.060 mm (0.0413−0.0417 in.) 1.080 mm (0.0425 in.)
Second 1.020−1.030 mm (0.0401−0.0405 in.) 1.050 mm (0.0413 in)
Oil 2.005−2.020 mm (0.0789−0.0795 in.) 2.050 mm (0.0807 in.)
Piston ring Ring-to-groove clearance Top 0.065−0.090 mm (0.0026−0.0035 in.) 0.15 mm (0.006 in.)
Second 0.030−0.055 mm (0.0012−0.0022 in.) 0.12 mm (0.005 in.)
Ring end gap Top 0.15−0.30 mm (0.006−0.012 in.) 0.60 mm (0.024 in.)
Second 0.30−0.42 mm (0.012−0.017 in.) 0.65 mm (0.026 in.)
Oil 0.20−0.70 mm (0.008−0.028 in.) 0.80 mm (0.031 in.)
Piston pin O.D. 17.996−18.000 mm (0.7085−0.7087 in.) ———
Engine Lubrication
Item Measurement Qualification Standard or New Service Limit
Engine oil Capacity Engine overhaul 4.2 L (4.4 US qt, 3.7 Imp qt) ———
Oil change including oil filter 3.6 L (3.8 US qt, 3.2 Imp qt) ———
Oil change without oil filter 3.4 L (3.6 US qt, 3.0 Imp qt) ———
Oil pump Inner rotor-to-outer rotor clearance 0.06−0.16 mm (0.002−0.006 in.) 0.20 mm (0.008 in.)
Pump housing-to-outer rotor 0.100−0.175 mm (0.0039−0.0069 in.) 0.20 mm (0.008 in.)
clearance
Pump housing-to-rotor axial 0.02−0.06 mm (0.001−0.002 in.) 0.15 mm (0.006 in.)
clearance
Relief valve Relief valve, oil pressure with oil At idle 70 kPa (0.7 kgf/cm 2 , 10 psi) min. ———
temperature at 80°C (176°F)
At 3,000 rpm (min −1 ) 340 kPa (3.5 kgf/cm 2 , 50 psi) min. ———
Cooling
Item Measurement Qualification Standard or New
Radiator Coolant capacity (Includes engine, L13Z1 M/T With heater Engine overhaul 5.02 L (1.326 US gal, 1.104 Imp gal)
heater, hoses, and reservoir) Coolant change 4.53 L (1.197 US gal, 0.997 Imp gal)
Use genuine Honda All Season Without heater Engine overhaul 4.59 L (1.213 US gal, 1.010 Imp gal)
Antifreeze/Coolant Type 2
Coolant change 4.10 L (1.083 US gal, 0.902 Imp gal)
A/T With heater Engine overhaul 4.94 L (1.305 US gal, 1.087 Imp gal)
Coolant change 4.45 L (1.176 US gal, 0.979 Imp gal)
Without heater Engine overhaul 4.51 L (1.192 US gal, 0.992 Imp gal)
Coolant change 4.02 L (1.062 US gal, 0.884 Imp gal)
L15A7 M/T With heater Engine overhaul 5.03 L (1.329 US gal, 1.107 Imp gal)
Coolant change 4.54 L (1.199 US gal, 0.999 Imp gal)
Without heater Engine overhaul 4.60 L (1.215 US gal, 1.012 Imp gal)
Item Measurement Qualification Standard or New
Coolant change 4.11 L (1.086 US gal, 0.904 Imp gal)
A/T With heater Engine overhaul 4.95 L (1.308 US gal, 1.089 Imp gal)
Coolant change 4.46 L (1.178 US gal, 0.981 Imp gal)
Without heater Engine overhaul 4.52 L (1.195 US gal, 0.994 Imp gal)
Coolant change 4.03 L (1.065 US gal, 0.887 Imp gal)
Coolant Coolant capacity 0.44 L (0.116 US qt, 0.097 Imp qt)
reservoir
Radiator cap Opening pressure 93−123 kPa (0.95−1.25 kgf/cm 2 , 14−18 psi)
Thermostat Opening temperature Begins to open 76−80 °C (169−176 °F)
Fully open 90 °C (194 °F)
Valve lift at fully open 8.0 mm (0.31 in.) min.
Clutch
Item Measurement Qualification Standard or New Service Limit
Clutch pedal Height from the floor RHD 145 mm (5.71 in.) ———
LHD 150 mm (5.91 in.) ———
Stroke 120−130 mm (4.72−5.12 in.) ———
Flywheel Runout on clutch mating surface 0.05 mm (0.002 in.) max. 0.15 mm (0.006 in.)
Clutch disc Rivet head depth 1.00−1.50 mm (0.039−0.059 in.) 0.2 mm (0.008 in.)
Thickness 7.25−7.95 mm (0.285−0.313 in.) 5.0 mm (0.20 in.)
Pressure plate Warpage 0.03 mm (0.001 in.) max. 0.15 mm (0.006 in.)
Height difference of diaphragm spring fingers 0.6 mm (0.02 in.) max. 1.0 mm (0.04 in.)
measured with dial indicator
Steering
Item Measurement Qualification Standard or New
Steering wheel Rotational play measured at outside edge 0−10 mm (0−0.39 in.)
with engine running
Initial load measured at outside edge with 29 N (3.0 kgf, 6.6 lbf)
engine running
Gearbox Angle of rack guide screw loosened from 10±3 °
locked position
Suspension
Item Measurement Qualification Standard or New Service Limit
Wheel alignment Camber Front 0 ° 00 ′±1 °
Rear −1 ° 00 ′±1 °
Caster Front 3 ° 20 ′±1 °
Total toe-in Front 0±3 mm (0±0.12 in.)
Rear 2.5±2.5 mm (10±0.10 in.)
Front wheel turning angle Inward 40 ° 19 ′±2 °
Outward 33 ° 19 ′±1 °
(reference)
Wheel Steel wheel runout Axial 0−1.0 mm (0−0.04 in.) 2.0 mm (0.08 in.)
Radial 0−1.0 mm (0−0.04 in.) 1.5 mm (0.06 in.)
Aluminium wheel runout Axial 0−0.7 mm (0−0.03 in.) 2.0 mm (0.08 in.)
Radial 0−0.7 mm (0−0.03 in.) 1.5 mm (0.06 in.)
Wheel bearing End play Front 0−0.05 mm (0−0.002 in.)
Rear 0−0.05 mm (0−0.002 in.)
Brakes
Item Measurement Qualification Standard or New Service Limit
Parking brake Distance traveled when lever pulled with 196 6 to 8 clicks
N (20 kgf, 44 lbf) of force
Brake pedal Pedal height (carpet moved aside) M/T 139 mm (5.5 in.)
A/T 138 mm (5.4 in.)
Free play 1−5 mm (0.04−0.20 in.)
Brake disc Thickness Front 20.9−21.1 mm (0.82−0.83 in.) 19.0 mm (0.75 in.)
Rear 8.9−9.1 mm (0.35−0.36 in.) 8.0 mm (0.31 in.)
Runout ——— 0.04 mm (0.0016 in.)
Parallelism ——— 0.015 mm (0.0006 in.)
Brake pad Thickness Front 9.5−10.2 mm (0.37−0.41 in.) 1.6 mm (0.06 in.)
Rear 6.8−7.5 mm (0.27−0.30 in.) 1.6 mm (0.06 in.)
Brake booster Master cylinder oil pressure Vacuum booster Brake pedal Master cylinder oil pressure kPa (kgf/cm 2 , psi)
Vacuum kPa pressure N (kgf,
(mmHg, in.Hg) lbf)
0 (0, 0) 98 (10, 22) 0 (0, 0)
196 (20, 44) Except LHD (M/T) 577 (5.9, 84)
LHD (M/T) 501 (5.1, 73)
66.7 (500, 19.7) 98 (10, 22) Except LHD (M/T) 4,523 (46.1, 656)
LHD (M/T) 4,235 (43.2, 614)
196 (20, 44) Except LHD (M/T) 9,538 (97.3, 1.383)
LHD (M/T) 9,468 (96.5, 1.373)
Air Conditioning
Item Measurement Qualification Standard or New
Refrigerant Type HFC-134a (R-134a)
Capacity of system 370−420 g (13.1−14.8 oz)
Refrigerant oil Type SP-10 (P/N 38897-P13-A01, 38898-P13-003, or 38899-P13-A01)
Capacity of components Condenser 25 mL (5/6 fl·oz, 0.9 Imp·oz)
Evaporator 35 mL (1 1/6 fl·oz, 1.2 Imp·oz)
Each line and 10 mL (1/3 fl·oz, 0.4 Imp·oz)
hose
Receiver/Dryer 10 mL (1/3 fl·oz, 0.4 Imp·oz)
Compressor 80−90 mL (2 2/3−3 fl·oz, 2.8−3.2 Imp·oz)
Compressor Field coil resistance At 20 °C (68 °F) 3.15−3.45 Ω
Item Measurement Qualification Standard or New
Pulley-to-armature plate clearance 0.35−0.65 mm (0.014−0.026 in.)
VIN, Engine, and Transmission Numbers
Vehicle Identification Number
a. Manufacturer, Make, and Type of Vehicle
MRH: Honda Automobile (Thailand) Co., Ltd.
MHR:GE6
MRH P.T. Honda
7 3Prospect
0 9 Motor, Indonesia
P 000001
b. Line, Body and Engine Type
GE6: Jazz/L13Z1
GE8: Jazz/L15A7
c.a BodybType and
c dTransmission
e f g Typeh
7: 4-door Hatchback/5-speed Manual
8: 4-door Hatchback/5-speed Automatic
d. Vehicle Grade (Series)
3: S (except IN model)
4: S (IN model)
5: 1.3GLI, 1.5VTI, V
6: 1.5VTIS, SV, E
8: S-MA
9: V-MA
e. Fixed Code or Check Digit
f. Model Year
9: '09
Production Year (IN model)
g. Factory Code
P: AYUTTHAYA Factory in Thailand
J: KARAWANG Factory in Indonesia
h. Serial Number
Engine Number
a. Engine Type
L13Z1: 1.3 L SOHC i-VTEC Sequential Multiport Fuel-injected engine
L15A7:
L13Z1 1.5 L SOHC i-VTEC Sequential Multiport Fuel-injected engine
- 1700001
b. Serial Number
Transmission Number
a.a Transmission
b Type
F1R4: 5-speed Manual (L13Z1)
F1S4:
F1R4 5-speed Manual (L15A7 except IN model)
- 8000001
F1S5: 5-speed Manual (L15A7 for IN model)
SG0A: 5-speed Automatic
b. Serial Number
a b
Applicable Area Code List
MODEL APPLICABLE GRADE NAME ENGINE TRANSMISSION MANUFACTURER NAME
AREA CODE TYPE TYPE
Jazz KQ 1.3GLI L13Z1 5MT Honda Automobile (Thailand)
5AT Co.,Ltd.
1.5VTI, 1.5VTIS L15A7 5MT
5AT
KZ S, V, SV L15A7 5MT
5AT
S-MA, V-MA
KP S L13Z1 5MT
5AT
V L15A7 5MT
5AT
IN S, E L15A7 5MT P.T. Honda Prospect Motor,
5AT Indonesia
VIN, Engine, and Transmission Number Locations
NOTE: The illustration shows the RHD model, LHD model is similar.
NOTE: The illustration shows the RHD model, the LHD model is similar.
Driver's doorjamb:
NOTE: The illustration shows the RHD model, the LHD model is symmetrical.
Abbreviations
List of automotive abbreviations which may be used in shop manual.
ABS Anti-lock Brake System
A/C Air Conditioning, Air Conditioner
ACEA Association des Constructeurs Europeens d' Automobiles
ACL Air Cleaner
A/F Air Fuel Ratio
AHB Advanced Hydraulic Booster
ALR Automatic Locking Retractor
ALT Alternator
AMP Ampere(s)
ANT Antenna
API American Petroleum Institute
APP Accelerator Pedal Position
APPROX. Approximately
ASSY Assembly
A/T Automatic Transmission
ATDC After Top Dead Center
ATF Automatic Transmission Fluid
ATT Attachment
AUTO Automatic
AUX Auxiliary
BARO Barometric
BAT Battery
BCM Battery Condition Monitor
BDC Bottom Dead Center
BTDC Before Top Dead Center
CARB Carburetor
CAT or CATA Catalytic Converter
CD Compact Disc
CHG Charge
CKF Crankshaft Speed Fluctuation
CKP Crankshaft Position
CLV Calculated Load Value
CMBS Collision Mitigation Brake System
CMP Camshaft Position
CO Carbon Monoxide
COMP Complete
CPB Clutch Pressure Back up
CPC Clutch Pressure Control
CPU Central Processing Unit
CVT Continuously Variable Transmission
CVTF Continuously Variable Transmission Fluid
CYL Cylinder
CYP Cylinder Position
DIFF Differential
DLC Data Link Connector
DLI Distributor Less Ignition
DOHC Double Overhead Camshaft
DOT Department of Transportation
DPF Diesel Particulate Filter
DPI Dual Point Injection
DPSF Dual Pump System Fluid
DTC Diagnostic Trouble Code
EBD Electronic Brake Distribution
ECM Engine Control Module
ECT Engine Coolant Temperature
EGR Exhaust Gas Recirculation
EGT Exhaust Gas Temperature
ELD Electrical Load Detector
EPR Evaporator Pressure Regulator
EPS Electrical Power Steering
ETCS Electronic Throttle Control System
EVAP Evaporative Emission
EX Exhaust
F Front
FIA Fuel Injection Air
FL Front Left
FP Fuel Pump
FR Front Right
FRP Fuel Rail Pressure
FSR Fail Safe Relay
FWD Front Wheel Drive
GAL Gallon
GND Ground
GPS Global Positioning System
H/B Hatchback
HBA Hydraulic Brake Assist
HC Hydrocarbons
HDS Honda Diagnostic System
HFT Hands Free Telephone
HID High Intensity Discharge
HIM Honda Interface Module
HO2S Heated Oxygen Sensor
HPS Hydraulic Power Steering
HVAC Heating, Ventilation, and Air Conditioning
IAB Intake Air Bypass
IAC Idle Air Control
IACV Idle Air Control Valve
IAR Intake Air Resonator
IAT Intake Air Temperature
ICM Ignition Control Module
ID Identification
ID or I.D. Inside Diameter
i-DSI Intelligent-Dual & Sequential Ignition
IG or IGN Ignition
IMA Idle Mixture Adjustment
Integrated Motor Assisted
IMMOBI. Immobilizer (Immobiliser)
IMRC Intake Manifold Runner Control
IMT Intake Manifold Tuning
IN Intake
INJ Injection
INT Intermittent
IQA Injector Quantity Adjustment (Diesel model)
ISV Intake Shutter Valve
KS Knock Sensor
L Left
L/C Lock-up Clutch
LCD Liquid Crystal Display
LED Light Emitting Diode
LEV Low Emission Vehicle
LF Left Front
LH Left Handle
LHD Left Handle Drive
LR Left Rear
LSD Limited Slip Differential
L4 In-line Four Cylinder (engine)
MAF Mass Air Flow
MAP Manifold Absolute Pressure
MAX. Maximum
MBS Mainshaft Brake System
MCK Motor Check
MCM Motor Control Module
MCU Moment Control Unit
MICS Multiplex Integrated Control System
MICU Multiplex Integrated Control Unit
MIL Malfunction Indicator Lamp
MIN. Minimum
MPI Multi Point Injection
M/S Manual Steering
M/T Manual Transmission
MTF Manual Transmission Fluid
NOx Oxides of Nitrogen
OBD On-board Diagnostic
OD or O.D. Outside Diameter
OPDS Occupant Position Detection System
O2S Oxygen Sensor
PAIR Pulsed Secondary Air Injection
PCM Powertrain Control Module
PCV Positive Crankcase Ventilation
Proportioning Control Valve
PDU Power Drive Unit
PGM-FI Programmed-fuel Injection
PGM-IG Programmed Ignition
PH Pressure High
PL Pilot Light or Pressure Low
PMR Pump Motor Relay
P/N Part Number
PRI Primary
P/S Power Steering
PSF Power Steering Fluid
PSP Power Steering Pressure
PSW Pressure Switch
Qty Quantity
R Right
REF Reference
RH Right Handle
RHD Right Handle Drive
RL Rear Left
RON Research Octane Number
RR Rear Right
SAE Society of Automotive Engineers
SCS Service Check Signal
SEC Second, Secondary
SOHC Single Overhead Camshaft
SOL Solenoid
SPEC Specification
S/R Sun Roof
SRS Supplemental Restraint System
STD Standard
SW Switch
T Torque
TB Throttle Body
T/B Timing Belt
TC Torque Converter
TCM Transmission Control Module
TCS Traction Control System
TDC Top Dead Center
TFT Thin Film Transistor
T/N Tool Number
TP Throttle Position
TPMS Tyre Pressure Monitoring System
TWC Three Way Catalytic Converter
VC Viscous Coupling
VCM Variable Cylinder Management
VIN Vehicle Identification Number
VSA Vehicle Stability Assist
VSS Vehicle Speed Sensor
VTEC Variable Valve Timing & Valve Lift Electronic Control
VVIS Variable Volume Intake System
V6 V-engine Six Cylinder (engine)
W With
W/O Without
WOT Wide Open Throttle
2WD Two Wheel Drive
4WD Four Wheel Drive
4AT 4-speed Automatic Transmission
5AT 5-speed Automatic Transmission
5MT 5-speed Manual Transmission
6MT 6-speed Manual Transmission
P Park
R Reverse
N Neutral
D4 Drive (1st through 4th gear)
D3 Drive (1st through 3rd gear)
D Drive
M Manual mode
S Second
L Low
O/D Over Drive
1ST Low (gear)
2ND Second (gear)
3RD Third (gear)
4TH Fourth (gear)
5TH Fifth (gear)
6TH Sixth (gear)
Lubricants and Fluids
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods.
Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly
wash your hands with soap and water as soon as possible after handling used oil.
For the details of the lubrication points and the type of lubricants to be applied, refer to the illustrated
index and the various work procedures (such as Assembly/Reassembly, Replacement, Overhaul,
Installation, etc.) contained in each section.
Application Lubricant or Fluid
A Engine Always use API service grade SL or higher SAE
viscosity: See chart.
B Manual transmission Honda Manual Transmission Fluid (MTF)
Always use genuine Honda MTF * . Using motor oil
can cause stiffer shifting because it does not
contain the proper additives.
Automatic transmission Honda ATF-Z1
Always use genuine Honda ATF-Z1. Using a non-
Honda ATF can affect shift quality.
C Brake system (including ABS lines) Brake Fluid DOT 3 or DOT 4
D Clutch system (manual transmission) We recommend genuine Honda Brake Fluid. Using
a non-Honda brake fluid can cause corrosion and
decrease the life of the system.
E Release fork (manual transmission) Multipurpose Grease
F Battery terminals
G Brake booster clevis pin
H Clutch master cylinder clevis pin (manual
I transmission)
J Fuel fill door
K Hood hinges and hood latch
Tailgate hinges
L Caliper piston boot Rubber Grease
M Caliper piston seal, caliper pins and boots Silicone Grease
N Shift cable ends (manual transmission)
O Air conditioning compressor Compressor Oil:SP-10 (P/N 38897-P13-A01 or
38899-P13-A01)
for refrigerant HFC-134a (R-134a)
P Cooling system Always use genuine Honda All Season
Antifreeze/Coolant Type 2
If genuine Honda MTF is not available, use API service SL or higher grade motor oil with a viscosity
of SAE 10W-30 or 10W-40 as a temporary replacement.
NOTE:
Lubricate the following grease using the recommended lubricants and fluids.
In corrosive area, more frequent lubrication is necessary.
The illustration shows the RHD model, the LHD model is symmetrical.
Alternator
Item Measurement Qualification Standard or New Service Limit
Alternator Output At 13.5 V and 95 A
normal engine
temperature
Coil (rotor) resistance At 20 °C (68 °F) 2.1−2.3 Ω
Slip ring O.D. 22.7 mm (0.89 in.) 21.2 mm (0.83 in.)
Brush length 23.0 mm (0.91 in.) 18.0 mm (0.71 in.)
Brush spring tension 4.1−5.3 N (0.42−0.54 kgf, 0.93−1.19 lbs)
Drive belt
Item Measurement Qualification Standard or New Service Limit
Drive belt Tension Auto-tensioner
Coolant reservoir
Item Measurement Qualification Standard or New
Coolant Coolant capacity 0.44 L (0.116 US qt, 0.097 Imp qt)
reservoir
Radiator
Item Measurement Qualification Standard or New
Radiator Coolant capacity (Includes engine, L13Z1 M/T With heater Engine overhaul 5.02 L (1.326 US gal, 1.104 Imp gal)
heater, hoses, and reservoir) Coolant change 4.53 L (1.197 US gal, 0.997 Imp gal)
Use genuine Honda All Season Without heater Engine overhaul 4.59 L (1.213 US gal, 1.010 Imp gal)
Antifreeze/Coolant Type 2
Coolant change 4.10 L (1.083 US gal, 0.902 Imp gal)
A/T With heater Engine overhaul 4.94 L (1.305 US gal, 1.087 Imp gal)
Coolant change 4.45 L (1.176 US gal, 0.979 Imp gal)
Without heater Engine overhaul 4.51 L (1.192 US gal, 0.992 Imp gal)
Coolant change 4.02 L (1.062 US gal, 0.884 Imp gal)
L15A7 M/T With heater Engine overhaul 5.03 L (1.329 US gal, 1.107 Imp gal)
Coolant change 4.54 L (1.199 US gal, 0.999 Imp gal)
Without heater Engine overhaul 4.60 L (1.215 US gal, 1.012 Imp gal)
Coolant change 4.11 L (1.086 US gal, 0.904 Imp gal)
A/T With heater Engine overhaul 4.95 L (1.308 US gal, 1.089 Imp gal)
Coolant change 4.46 L (1.178 US gal, 0.981 Imp gal)
Without heater Engine overhaul 4.52 L (1.195 US gal, 0.994 Imp gal)
Coolant change 4.03 L (1.065 US gal, 0.887 Imp gal)
Radiator cap
Item Measurement Qualification Standard or New
Radiator cap Opening pressure 93−123 kPa (0.95−1.25 kgf/cm 2 , 14−18 psi)
Thermostat
Item Measurement Qualification Standard or New
Thermostat Opening temperature Begins to open 76−80 °C (169−176 °F)
Fully open 90 °C (194 °F)
Valve lift at fully open 8.0 mm (0.31 in.) min.
Head
Item Measurement Qualification Standard or New Service Limit
Head Warpage 0.07 mm (0.0028 in.) 0.08 mm (0.003 in.)
Height 119.9−120.1 mm (4.720−4.728 in.) ———
Camshaft
Item Measurement Qualification Standard or New Service Limit
Camshaft End play 0.05−0.25 mm (0.002−0.010 in.) 0.5 mm (0.02 in.)
Camshaft-to-holder oil clearance 0.045−0.084 mm (0.0018−0.0033 in.) 0.100 mm (0.004 in.)
Total runout 0.03 mm (0.001 in.) max. 0.04 mm (0.002 in.)
Cam lobe height L13Z1 Intake, primary 34.290 mm (1.3500 in.) ———
Intake, secondary 30.529 mm (1.2019 in.) ———
Exhaust 35.047 mm (1.3798 in.) ———
L15A7 Intake, primary 35.241 mm (1.3874 in.) ———
Intake, secondary 36.173 mm (1.4241 in.) ———
Exhaust 35.471 mm (1.3964 in.) ———
Rocker arm
Item Measurement Qualification Standard or New Service Limit
Rocker arm Arm-to-shaft clearance Intake 0.019−0.058 mm (0.0007−0.0023 in.) 0.08 mm (0.003 in.)
Exhaust 0.019−0.058 mm (0.0007−0.0023 in.) 0.08 mm (0.003 in.)
Valve
Item Measurement Qualification Standard or New Service Limit
Valve Clearance (cold) Intake 0.15−0.19 mm (0.006−0.007 in.) ———
Exhaust 0.26−0.30 mm (0.010−0.012 in.) ———
Stem O.D. Intake 5.48−5.49 mm (0.216−0.216 in.) 5.45 mm (0.215 in.)
Exhaust 5.45−5.46 mm (0.215−0.215 in.) 5.42 mm (0.213 in.)
Stem-to-guide clearance Intake 0.020−0.050 mm (0.0008−0.0020 in.) 0.08 mm (0.003 in.)
Exhaust 0.050−0.080 mm (0.0020−0.0031 in.) 0.11 mm (0.004 in.)
Valve guide
Item Measurement Qualification Standard or New Service Limit
Valve guide I.D. Intake 5.51−5.53 mm (0.217−0.218 in.) 5.55 mm (0.219 in.)
Exhaust 5.51−5.53 mm (0.217−0.218 in.) 5.55 mm (0.219 in.)
Installed height Intake 15.85−16.35 mm (0.624−0.644 in.) ———
Exhaust 15.85−16.35 mm (0.624−0.644 in.) ———
Valve spring
Item Measurement Qualification Standard or New Service Limit
Valve spring Free length L13Z1 Intake 51.17 mm (2.014 in.) ———
Exhaust 57.26 mm (2.254 in.) ———
L15A7 Intake 48.55 mm (1.911 in.) ———
Exhaust 54.52 mm (2.146 in.) ———
Valve seat
Item Measurement Qualification Standard or New Service Limit
Valve seat Width Intake 0.850−1.150 mm (0.0335−0.0453 in.) 1.60 mm (0.063 in.)
Exhaust 1.250−1.550 mm (0.0492−0.0610 in.) 2.00 mm (0.079 in.)
Stem installed height Intake 46.1−46.5 mm (1.815−1.831 in.) 46.8 mm (1.843 in.)
Exhaust 46.2−46.6 mm (1.819−1.835 in.) 46.9 mm (1.846 in.)
Compression
Item Measurement Qualification Standard or New Service Limit
Compression Pressure check at 250 rpm (min −1 ) with Minimum 980 kPa (10.0 kgf/cm 2 , 142 psi) ———
wide open throttle. (See Design Specs for Maximum 200 kPa (2.0 kgf/cm 2 , 28 psi) ———
ratio) variation
Block
Item Measurement Qualification Standard or New Service Limit
Block Warpage of deck 0.07 mm (0.003 in.) max. 0.10 mm (0.004 in.)
Bore diameter 73.000−73.015 mm (2.8740−2.8746 in.) 73.065 mm (2.8776 in.)
Bore taper ——— 0.05 mm (0.002 in.)
Reboring limit ——— 0.25 mm (0.01 in.)
Connecting rod
Item Measurement Qualification Standard or New Service Limit
Connecting rod Pin-to-rod interferemce 0.019−0.036 mm (0.007−0.0014 in.) ———
Small-end bore diameter 17.964−17.977 mm (0.707−0.708 in.) ———
Large-end bore diameter Nominal 43.0 mm (1.69 in.) ———
End play installed on crankshaft 0.15−0.35 mm (0.006−0.014 in.) 0.40 mm (0.016 in.)
Crankshaft
Item Measurement Qualification Standard or New Service Limit
Crankshaft Main journal diameter 49.976−50.000 mm (1.9676−1.9685 in.) ———
Rod journal diameter 39.976−40.000 mm (1.5739−1.5748 in.) ———
Rod/main journal taper 0.005 mm (0.0002 in.) 0.010 mm (0.0004 in.)
Rod/main journal out-of-round 0.005 mm (0.0002 in.) 0.010 mm (0.0004 in.)
End play 0.10−0.35 mm (0.004−0.014 in.) 0.45 mm (0.018 in.)
Runout 0.03 mm (0.0012 in.) max. 0.04 mm (0.0016 in.)
Crankshaft bearing
Item Measurement Qualification Standard or New Service Limit
Crankshaft Main bearing-to-journal oil clearance 0.018−0.036 mm (0.0007−0.0014 in.) 0.050 mm (0.0020 in.)
bearing Rod bearing clearance L15A7 0.020−0.038 mm (0.0008−0.0015 in.) 0.050 mm (0.0020 in.)
L13Z1 0.026−0.044 mm (0.0010−0.0017 in.) 0.050 mm (0.0020 in.)
Piston
Item Measurement Qualification Standard or New Service Limit
Piston Skirt O.D. at 16 mm (0.6 in.) from bottom of L13Z1 72.972−72.982 mm (2.8729−2.8733 in.) 72.97 mm (2.8728 in.)
skirt L15A7 72.980−72.990 mm (2.8732−2.8736 in.) 72.97 mm (2.8728 in.)
Clearance in cylinder L13Z1 0.018−0.043 mm (0.007−0.0017 in.) 0.05 mm (0.002 in.)
L15A7 0.010−0.035 mm (0.0004−0.0014 in.) 0.05 mm (0.002 in.)
Ring groove width Top 1.050−1.060 mm (0.0413−0.0417 in.) 1.080 mm (0.0425 in.)
Second 1.020−1.030 mm (0.0401−0.0405 in.) 1.050 mm (0.0413 in)
Oil 2.005−2.020 mm (0.0789−0.0795 in.) 2.050 mm (0.0807 in.)
Piston pin
Item Measurement Qualification Standard or New Service Limit
Piston pin O.D. 17.996−18.000 mm (0.7085−0.7087 in.) ———
Pin-to-piston clearance 0.010−0.017 mm (0.0004−0.0007 in.) ———
Piston ring
Item Measurement Qualification Standard or New Service Limit
Piston ring Ring-to-groove clearance Top 0.065−0.090 mm (0.0026−0.0035 in.) 0.15 mm (0.006 in.)
Second 0.030−0.055 mm (0.0012−0.0022 in.) 0.12 mm (0.005 in.)
Ring end gap Top 0.15−0.30 mm (0.006−0.012 in.) 0.60 mm (0.024 in.)
Second 0.30−0.42 mm (0.012−0.017 in.) 0.65 mm (0.026 in.)
Oil 0.20−0.70 mm (0.008−0.028 in.) 0.80 mm (0.031 in.)
Fuel and Emissions Systems Circuit Diagram
ECM/PCM Circuit Diagram
24P JUNCTION
ECM/PCM Circuit Diagram (cont'd) CONNECTOR*1
(12P JUNCTION
CONNECTOR*2)E F
B31 3
RED/GRN 3 2 1 4 5 6 7
VG+ K 4 1 MAF
YEL/BLK YEL/BLK SENSOR
ECM/PCM Circuit Diagram (cont'd)
B33
C5 5 2
BLK/RED 13P 10
BLK/YEL
BRN *5 CONNECTOR BLK/YEL
VG−
INJ1
12 V 1 No. 1 INJECTOR
*1 9 8
GRN/YEL IAT
YEL BLK/YEL
2 2 JUNCTION
24P SENSOR
RED/YEL
11 CONNECTOR*1
13P K H BLK/YEL 1
B35 YEL/BLK (12P JUNCTION1
*1
B32 GRN/YEL CONNECTOR
VTS 12 CONNECTOR)*2
ECM/PCM Circuit Diagram (cont'd)RED/YEL
RED
C6
IAT
8P CONNECTOR
BLK/YEL BRN
2 2
INJ2
B28 N
RED/YEL LT O
GRN *3 BLK/YEL
6 9
WHT No. 2 INJECTOR
ROCKER ARM
ATFT 1 2 OIL CONTROL
A47 6 7 2 7
YEL GRN/YEL
YEL WHTGRN/YEL
B24
C29 YEL 1 1 SOLENOID
SUPP RED/WHT
RED A RED RED/WHT ATFSHIFTER+
TEMPERATURE
1
ECT1
AFS+ PADDLE
YEL/BLK G101 (UPSHIFT SENSORSWITCH)2
1 RED/YEL ECT SENSOR 1
C7
C30
B11 *1 *2 BLK 21 3
BLU 5 BLK/YEL
B3 RED/YEL
*3 GRN
ECM/PCM Circuit Diagram (cont'd) INJ3
AFS−
SHA
BLU/BLK
YEL/BLU *10 13P CONNECTOR
YEL/BLU
BLU 2
No.4 3 INJECTOR
24P JUNCTION CONNECTOR
PCS
A48 12P JUNCTION 2 5 824P JUNCTION CONNECTOR 2 11 WHT/BLK
SHIFT SOLENOID
C9
B10 LT BLU R CONNECTOR O 10 LT GRN/ LT GRN/ EVAP CANISTER
SDNP GRN
BLK RED RED 3 PADDLEVALVE SHIFTER− AA/F SENSOR
PURGE VALVE
AFSHTC
PG1 13P CONNECTOR 2 (DOWNSHIFT 1 (SENSOR 1)
B27 16P P
GRN/WHT UNDER-DASH FUSE/RELAY YEL/BLK BOX ORN SWITCH)
CONNECTOR 2 12 1
SHB
B1
C8 14P PURA WHT BLK
BRN YEL
CONNECTOR T Q 2
20 19 21 23 24 22 13 15 14 16 18 17
PG2
INJ4 6 5 11 12 L P G SHIFT1 SOLENOID
8 CABLE REEL BLK/YEL VALVE B4 INJECTOR
3 A9B46
C13
C2
16P CONNECTOR
*10 1
(1) No. 3 1
*8 WHT B21 BRN YEL/RED T (20P CONNECTOR)*6 YEL/RED
IG1 6 IGPVCC1
B36 GRNWHT/BLU G501 WHT/BLU GRN
YEL PGMETCS
ALTL
SHC
A34 PUR B12 MICU 2 2
LT GRN WHT/RED GRN/RED 42
IG2 4 A46C11
SHO2S B22 WHT/RED LT GRN
ORN ECT2
GRN/RED GRN 14 12P JUNCTION GRN/YEL GRN/WHT A/F 3
SHIFT11SOLENOID
1 (18)*6 J YEL
+B ST S-NET5V
MAP
B4 B2 24P JUNCTION
CONNECTOR AD AE AFVALVE AG C AH
24SENSOR AI AJ
PNK A10 PUR YEL CONNECTOR WHT/GRN AB
BLK/WHT RELAY
A22B12
B47
SO2SHTC
C14
7
YEL B5
8 G101 ECTMAP SENSOR
SENSOR 2
SG6 GRN/RED ORN 17 12 16 13 15 YEL 3
C44
SUBRLY
SHD WHT/RED GRN/WHT BLK/YEL
IGNITION SWITCH ALTF
SG1 BRN/YEL *10 B6
(16)*6 C D
A7LG1 V
BLU BLU/24P JUNCTION *1 SHIFT SOLENOID ALTERNATOR
B8 CONNECTOR WHT SECONDARY
BLK 4 3 2 U 9 BRAKE
10 8 PEDAL VALVE D HO2S
MRLY
B14
B45 LT GRN
5V C48 BLU/BLK (5)BRN/YEL(6) (11) POSITION
(12) 24PSWITCH (2)BLU 16
BATTERY C1
ATPP WHT BRN/YEL 4
WHT/GRN
WHT
B9 JUNCTION
3 CONNECTOR(SENSOR 2)
ALTC
A42
A3
LG2 *10 *10 *10
YEL/BLK
2
10P CONNECTOR *10 K-LINE
(14) IGIETCS
WHT LT GRN WHT B14 LT GRN Brake pedal pressed: closed
BKSW
CANH
B7
B40 RED 7 1 4 Brake pedal 10
1 released:
*5 C10C31 BLK/ YEL/RED
RED/BLK 3 12 8 9 10 11
LT GRN WHT BLU/WHT 1 WHT 1 PGM-FI open
(15) B15
OPSW
LSA RED GRN WHT CANH MAIN
WHT
IG1CMP WHT 6 B17 (6) 5 3 3 6
A4
ATPR 13P YEL BLU/BLK YEL (5) BLK/YEL 20 BLK/BLU19 21 22
Brake 2 pedal P24RELAY
9 23
pressed: 1 open To
C15 24PRED 3 RED (21) OIL PRESSURE
BATTERY A21A41
CANLCONNECTOR WHT
BRN B18 4 4(22) 1 2 BLK
(23) RED pedal
7 (24)
Brake released: closed
SWITCH
CANL
SPARK
B34 JUNCTION RED Y1 WHT BRN/YEL
*2 WHT *2 *2 *2 R PLUG
G1 TERMINAL IGPLS1
BKSWNC
ETCSRLY GRN/YEL
CONNECTOR 1 A/TICMCLUTCH PRESSUREEPS
FUSE BOX LT BLU B32 9 2 2
SG4
B13
A44 N 2 BRN Y3 RED/BLK BRN RED/BLK *3 CONTROL CMP SOLENOIDN
SENSOR VALVE
CONTROL A
RED BRN/YEL GRN/ G101 GRN/ GRN/
B48 PNK B25 ELD3 8 1 IGNITION
No. 1 COIL UNIT YEL
ATPN
WEN BRN/WHT GRY 14P CONNECTOR PNK PNK YEL YEL D PGM-FI
A16 Y2
LSB
A26 2 ORN12BLK11 B34 14 14 12 4 GRN/ 1 GRN/ MAIN
3 8 16P3 BRN
1 YEL 3 2 D *9YEL 2
RELAY A
IMOFPR
VCC4 14P YEL/BLK RED YEL BLU
3
G501 BLK/YEL CONNECTOR BLK To
B22
A18 *10 CONNECTOR (S)*8
3
A1C16 B26 T1 (7) 9 1 SPARK
C32
ATPD
APSA WHT/GRN BRN WHT 2
(12) ORN
3
A/T CLUTCH PRESSURE PLUG
VBSOL
IGPLS2 1 *10 BLU CONTROL
FICM G SOLENOID 2 H VALVE I B
BLU L M 2 E 7 (3)
A36
CKP
B26 W1 9 BRN 1 2
*1 B24 RED BLU 1
LSC
SG4
BLU/YEL
WHT YEL
(8) 1 29 No.
*7 12P JUNCTIONB16 2 9 2 IGNITION COIL
A25 U B28 S1 BRN/YEL BLU BRN BRN RED 4 TEMPERATURE
CONNECTOR 14P BLU ORN 13P CONNECTOR 2
ATPD3*9 CONNECTOR 6 GRY
10BLK 5 IGNITION B
C12
VCC5
(ATPS)*8 B29 RED *3 2 SENSOR CONTROL
BLU/YEL
3P CONNECTOR YEL/RED CKP COIL
A19 BLU WHT X3 *10 BLK/YEL
10
3
A/T CLUTCH(13) 6
DIAL
PRESSURE
RELAY To
VCC3
C17 PNK B21 11 BLU1
A20 YEL YEL 6 WHT/REDRED 1 LT CONTROL 1SOLENOID
5 VALVE CSPARK
Z B17
APSB WHT/BLK GRN GRN PLUG
A24
IGPLS3
VCC6
C20 4 K7 1 10
8 ICM A B
A35 ORN I BLK BLK RED 2 312P
5
ATP2-1*3PNKRED/BLK BRN 8
6 4 A32A37
ELD
TPSA
11 12
24P 15 5 Q1 G101 WHT (4)
4
JUNCTION
C46
SG5 PURJUNCTION YEL 1 1 PUR 4CONNECTOR
SCSACTEMP
(12) (11) RED/BLU
CONNECTOR 3 Q2 WHT
RED/BLU No. 3 IGNITION APPCOIL
TRANSMISSION SENSOR A/B
PNK C21
B19
KS*10 *10 16P BLU BRN/YEL UNDER-DASH7 1 RANGE
*4 B29 YEL/BLU
RED CONNECTOR YEL/BLU 3 6 SWITCH
YEL Q8 (9) FUSE/RELAY BOX WHT YEL 6
VCC2
TPSB LT BLU 3 ETCS
ATPFWD 4
B18
C18 *3 G101 BLK/YEL
WHT 2 2ND KNOCK 5 SENSOR CONTROL To
*10
C43 11J 16P CONNECTOR 1 CLUTCH RELAY SPARK
A43 WHT/RED
WHT/BLU 1
NM GRN A26 5 THROTTLE PLUG
IGPLS4 PUR *3 BLU 13P CONNECTOR WHT 2 ICMTRANSMISSION
Clutch pedal pressed: FLUID
open
SG3
B23
CRMTCLS *3 Clutch PRESSURE ACTUATOR
SWITCH
2
3 2 *1:*11A/T A34 G101 (10) BRN2 2 3 pedal released: closed
X S
ATPRVS *1: A/T 15 BRN GRN BLK GRN/YEL
WHT 21
C4
A29
A15 *2:YEL/RED
*2: M/T
M/T
LT BLU (19)*6 *3 BLK/ BLU/RED No. 4 IGNITION P
TEST THROTTLE
COIL 4
TACHOMETER BODY
PNK 3 YEL4 4 3 CLUTCH PEDAL INPUT SHAFT
NEP
ETCSM+ CONNECTOR
ACC N1 (11) POSITION SWITCH (MAINSHAFT)
12PB8 PNK AC SPEEDSTARTER SENSOR
BLK
13P G401 LT BLU12P 3RD CLUTCH CUT
*1 JUNCTION 4 8 CONNECTOR 8
OP2SW
C3
CONNECTOR 8 7 CONNECTOR FUEL PUMP RELAY
TRANSMISSION FLUID
A6 YEL (6)*6 12P PRESSURE SWITCH
13P *3 D 10 C BLU
ETCSM− GRN CONNECTOR JUNCTION
FANC
B9 1 10
A28 16P CONNECTOR *10 9 7 BRN *3 BLU/WHT 3
M W LT BLU PNK K-LINE G502
OP3SW PNK CONNECTOR
SLS (20P GRY 7 12P JUNCTION 1 1 1
BLU *1
G101 YEL/REDLT BLU WHT
CONNECTOR)*6 16PK-LINE CONNECTOR CANH
CONNECTOR
*10 SHIFT LOCK
FUSES: B38
BLK/WHT 9 2 17SOLENOID
A30 YEL
UNDER-DASH FUSE/RELAY BOX: NC*1: A/TBLU Y
RED
To AUDIO CANL UNIT
(1)No. 26 A/F SENSOR5(10 A)13P VSSOUT
*2: M/T Q WHT
6
3
CONNECTOR *10 CANH AD AE AF AG GRN/WHTAH AJ ABS
(2)No.
BARO 39 IGP (15 A) *5: With cruise control R
AI
MODULATOR-
SENSOR
(3)No. 33 IGNITION COIL (15 A)*1:
A38 A/T 414 BRN OUTPUT 1 SHAFT CONTROL UNIT
RED RED DATA LINK ORN
(Built into
(4)No. 52 ETCS (15 A) *1:*3:
TAC
*3 RHD
A/T model CANL
(PUR)*10
CONNECTOR
A/C
(COUNTERSHAFT)
2
the ECM/PCM) 4S COMPRESSOR
(5)No. 20 FUEL PUMP (15 A) 16P *3:*4:
*1: M/T
RHD
A/T (with
model cruise YEL SPEED SENSOR
CLUTCH RELAY
14P 12
(6)No. 12 ALTERNATOR (10 *8:CONNECTOR
A)
control)
A/T(with paddle shifter model) RED CONNECTOR PNK 3 EVAPORATOR
13 *9: 16 TEMPERATURE
(7)No.
*10 7 MISSION SOLENOID (10
*10:
A/T *3:model
A)LHD RHDpaddle
(without model shifter PNK
SENSOR
(8)No. 24 STOP, HORN (15 A)model) *5: With cruise control BRN
5
A/C
(9)No.
5 22 METER (7.5 A) *10: LHD*6: With headlight adjuster
model 4 CONDENSER
*7: KZ, KP models 4
(10)No.
14P 10 A/C (7.5 A) BLK FAN RELAY
CONNECTOR *10: LHD model
(11)No. 1 BACK UP (7.5 A) 3
GRN
(12)No. 60 IG SW (50 A) V W X Y
(13)No. 44 STARTER (7.5 A)
AA G502
12P JUNCTION *1: A/T 18
RADIATOR
BATTERY TERMINAL FUSE BOX:
CONNECTOR AB AA AC Z 4 FAN RELAY
*3: RHD model K-LINE
(14)20 A (with trailer lighting connecter: 30 A)
(15)100 A 4
BLU
*10: LHD model 3 17
3 GRN CANH
*1:1A/T 16
*3: RHDBLU
model AUXILIARY CANL
*6: With headlight adjuster 30 UNDER-HOOD RELAY BOX SRS UNIT
*3: RHD model
*10: LHD model WHT
CANH
GAUGE CONTROL
*10: LHD model MODULE
29
*11: With SRS RED
CANL
Engine will not start (MIL works OK, no DTCs set)
Diagnostic procedure
1. Test the battery.
2. Test the starter.
3. Check the fuel pressure.
4. Troubleshoot the fuel pump circuit.
Also check for
Low compression
No ignition spark
Intake vacuum leaks
Locked up engine
Broken cam chain
Fuel contamination
Engine will not start (MIL comes on and stays on, no DTCs set)
Diagnostic procedure
1. Troubleshoot the DLC circuit.
Also check for
Low compression
No ignition spark
Intake vacuum leaks
Locked up engine
Broken cam chain
Fuel contamination
No power to ECM/PCM
No ground to ECM/PCM
Shorted reference voltage
MIL comes on and stays on, or never comes on at all, no DTCs set
Diagnostic procedure
1. Troubleshoot the MIL circuit.
Engine will not start (MIL works OK, no DTCs set, immobilizer indicator stays on or flashes)
Diagnostic procedure
1. Check the immobilizer system.
Engine starts but stalls immediately (MIL works OK, no DTCs set, immobilizer indicator stays on or flashes)
Diagnostic procedure
1. Check the immobilizer system.
Engine is hard starting (MIL works OK, no DTCs set)
Diagnostic procedure
1. Test the battery.
2. Check the fuel pressure.
3. Test the throttle body.
Also check for
Low compression
Intake air leaks
Fuel contamination
Weak spark
Cold fast idle too low (MIL works OK, no DTCs set)
Diagnostic procedure
1. Do the ECM/PCM idle learn procedure.
2. Check the idle speed.
3. Throttle body cleaning.
Also check for
Incorrect valve adjustment
Cold fast idle too high (MIL works OK, no DTCs set)
Diagnostic procedure
1. Do the ECM/PCM idle learn procedure.
2. Check the idle speed.
3. Test the throttle body.
Also check for
Incorrect valve adjustment
After warming up, idle speed is below specifications without load (MIL works OK, no DTCs set)
Diagnostic procedure
1. Troubleshoot the alternator FR signal circuit.
2. Test the throttle body.
Also check for
Intake vacuum leaks
Incorrect valve adjustment
After warming up, idle speed is above specifications without load (MIL works OK, no DTCs set)
Diagnostic procedure
1. Troubleshoot the alternator FR signal circuit.
2. Inspect the APP sensor.
Also check for
Intake vacuum leaks
Idle speed fluctuates (MIL works OK, no DTCs set)
Diagnostic procedure
1. Do the ECM/PCM idle learn procedure.
2. Test the fuel pressure.
3. Except KQ model: Test the injectors.
4. Troubleshoot the alternator FR signal circuit.
5. Inspect the PCV valve.
6. Test the throttle body.
7. Troubleshoot the A/C signal circuit.
8. Troubleshoot the VTEC system oil pressure.
Also check for
Fuel contamination
Intake vacuum leaks
Misfire or rough running (MIL works OK, no DTCs set)
Diagnostic procedure
1. Check the spark plugs.
2. Test the fuel pressure.
3. Test the injectors.
4. Troubleshoot the fuel pump circuit.
5. Troubleshoot the VTEC system oil pressure.
Also check for
Low compression
Valve clearance
Fuel contamination
Fails emission test (MIL works OK, no DTCs set)
Diagnostic procedure
1. Except KQ model: Inspect the three way catalytic converter (TWC).
2. Except KQ model: Check the spark plugs.
3. Test the fuel pressure.
4. Except KQ model: Test the injectors.
5. Check the EVAP system.
6. Troubleshoot the VTEC system oil pressure.
Also check for
Fuel contamination
Low compression
Broken cam chain
Low power (MIL works OK, no DTCs set)
Diagnostic procedure
1. Test the fuel pressure.
2. Check the air cleaner element.
3. Test the throttle body.
4. Except KQ model: Inspect the three way catalytic converter (TWC).
5. Except KQ model: Test the injectors.
6. Troubleshoot the VTEC system oil pressure.
Also check for
Fuel contamination
Low compression
Camshaft timing
Engine oil level
Engine stalls (MIL works OK, no DTCs set)
Diagnostic procedure
1. Do the ECM/PCM idle learn procedure.
2. Test the fuel pressure.
3. Check the idle speed.
4. Troubleshoot the brake pedal position switch signal circuit.
5. Except KQ model: Check the spark plugs.
6. Troubleshoot the VTEC system oil pressure.
Also check for
Intake vacuum leaks
Faulty harness and sensor connections
Fuel contamination
Difficult to refuel
Diagnostic procedure
1. Inspect the breather line and the suction line.
HDS does not communicate with the ECM/PCM or the vehicle
Diagnostic procedure
1. Troubleshoot the DLC circuit.
Fuel and Emissions Systems Symptom Troubleshooting Index
When the vehicle has one of these symptoms, check for a diagnostic trouble code (DTC) with the HDS. If there is no DTC, do the diagnostic procedure
for the symptom, in the sequence listed, until you find the cause.
Symptom Diagnostic procedure Also check for
Engine will not start (MIL works OK, no 1.Test the battery. Low compression
DTCs set) 2.Test the starter. No ignition spark
3.Check the fuel pressure. Intake vacuum leaks
4.Troubleshoot the fuel pump circuit. Locked up engine
Broken cam chain
Fuel contamination
Engine will not start (MIL comes on and Troubleshoot the DLC circuit. Low compression
stays on, no DTCs set) No ignition spark
Intake vacuum leaks
Locked up engine
Broken cam chain
Fuel contamination
No power to ECM/PCM
No ground to ECM/PCM
Shorted reference voltage
MIL comes on and stays on, or never Troubleshoot the MIL circuit.
comes on at all, no DTCs set
Engine will not start (MIL works OK, no Check the immobilizer system.
DTCs set, immobilizer indicator stays
on or flashes)
Engine starts but stalls immediately Check the immobilizer system.
(MIL works OK, no DTCs set,
immobilizer indicator stays on or
flashes)
Engine is hard starting (MIL works OK, 1.Test the battery. Low compression
no DTCs set) 2.Check the fuel pressure. Intake air leaks
3.Test the throttle body. Fuel contamination
Weak spark
Cold fast idle too low (MIL works OK, 1.Do the ECM/PCM idle learn procedure. Incorrect valve adjustment
no DTCs set) 2.Check the idle speed.
3.Throttle body cleaning.
Cold fast idle too high (MIL works OK, 1.Do the ECM/PCM idle learn procedure. Incorrect valve adjustment
no DTCs set) 2.Check the idle speed.
3.Test the throttle body.
After warming up, idle speed is below 1.Troubleshoot the alternator FR signal circuit. Intake vacuum leaks
specifications without load (MIL works 2.Test the throttle body. Incorrect valve adjustment
OK, no DTCs set)
After warming up, idle speed is above 1.Troubleshoot the alternator FR signal circuit. Intake vacuum leaks
specifications without load (MIL works 2.Inspect the APP sensor.
OK, no DTCs set)
Idle speed fluctuates (MIL works OK, no 1.Do the ECM/PCM idle learn procedure. Fuel contamination
DTCs set) 2.Test the fuel pressure. Intake vacuum leaks
3.Except KQ model: Test the injectors.
4.Troubleshoot the alternator FR signal circuit.
5.Inspect the PCV valve.
6.Test the throttle body.
7.Troubleshoot the A/C signal circuit.
8.Troubleshoot the VTEC system oil pressure.
Misfire or rough running (MIL works OK, 1.Check the spark plugs. Low compression
no DTCs set) 2.Test the fuel pressure. Valve clearance
3.Test the injectors. Fuel contamination
4.Troubleshoot the fuel pump circuit.
5.Troubleshoot the VTEC system oil pressure.
Fails emission test (MIL works OK, no 1.Except KQ model: Inspect the three way catalytic converter (TWC). Fuel contamination
DTCs set) 2.Except KQ model: Check the spark plugs. Low compression
3.Test the fuel pressure. Broken cam chain
4.Except KQ model: Test the injectors.
5.Check the EVAP system.
6.Troubleshoot the VTEC system oil pressure.
Low power (MIL works OK, no DTCs 1.Test the fuel pressure. Fuel contamination
set) 2.Check the air cleaner element. Low compression
3.Test the throttle body. Camshaft timing
4.Except KQ model: Inspect the three way catalytic converter (TWC). Engine oil level
5.Except KQ model: Test the injectors.
6.Troubleshoot the VTEC system oil pressure.
Engine stalls (MIL works OK, no DTCs 1.Do the ECM/PCM idle learn procedure. Intake vacuum leaks
set) 2.Test the fuel pressure. Faulty harness and sensor
3.Check the idle speed. connections
4.Troubleshoot the brake pedal position switch signal circuit. Fuel contamination
5.Except KQ model: Check the spark plugs.
6.Troubleshoot the VTEC system oil pressure.
Symptom Diagnostic procedure Also check for
Difficult to refuel Inspect the breather line and the suction line.
HDS does not communicate with the Troubleshoot the DLC circuit.
ECM/PCM or the vehicle
Fuel pressure regulator
Item Measurement Qualification Standard or New
Fuel pressure Pressure with fuel pressure gauge 320−370 kPa (3.3−3.8 kgf/cm 2 , 47−54 psi)
regulator connected
Fuel tank
Item Measurement Qualification Standard or New
Fuel tank Capacity 42 L (11.0 US gal, 9.2 Imp gal)
Engine idle
Item Measurement Qualification Standard or New
Engine idle Idle speed without load (L13Z1) M/T (in neutral) 650±50 rpm
A/T (in N or P) 700±50 rpm
Idle speed without load (L15A7) M/T (in neutral), 700±50 rpm
A/T (in N or P)
Idle speed with high electrical load (A/C M/T (in neutral), 790±50 rpm
switch ON, temperature set to max cool, A/T (in N or P)
blower fan on High, rear window defogger
ON, and headlights on high beam)
Idle CO 0.1 % max.
Ignition timing
Item Measurement Qualification Standard or New Service Limit
Ignition timing At idle (check the M/T (in neutral): 0±2 ° BTDC
white mark) A/T (in N or P): 0±2 ° BTDC
Ignition coil
Item Measurement Qualification Standard or New Service Limit
Ignition coil Rated voltage 12 V
Firing order 1−3−4−2
Spark plug
Item Measurement Qualification Standard or New Service Limit
Spark plug Type NGK: IZFR6K13
DENSO: SKJ20DR-M13
Gap 1.2−1.3 mm (0.047−0.051 in.) ———
Oil pump
Item Measurement Qualification Standard or New Service Limit
Oil pump Inner rotor-to-outer rotor clearance 0.06−0.16 mm (0.002−0.006 in.) 0.20 mm (0.008 in.)
Pump housing-to-outer rotor 0.100−0.175 mm (0.0039−0.0069 in.) 0.20 mm (0.008 in.)
clearance
Pump housing-to-rotor axial 0.02−0.06 mm (0.001−0.002 in.) 0.15 mm (0.006 in.)
clearance
Relief valve
Item Measurement Qualification Standard or New Service Limit
Relief valve Relief valve, oil pressure with oil At idle 70 kPa (0.7 kgf/cm 2 , 10 psi) min. ———
temperature at 80°C (176°F)
At 3,000 rpm (min −1 ) 340 kPa (3.5 kgf/cm 2 , 50 psi) min. ———
Engine oil
Item Measurement Qualification Standard or New Service Limit
Engine oil Capacity Engine overhaul 4.2 L (4.4 US qt, 3.7 Imp qt) ———
Oil change including oil filter 3.6 L (3.8 US qt, 3.2 Imp qt) ———
Oil change without oil filter 3.4 L (3.6 US qt, 3.0 Imp qt) ———
Starter
Item Measurement Qualification Standard or New Service Limit
Starter Output Except L13Z1 0.7 kw
KP, KQ
L13Z1 KP, KQ 0.6 kw, 0.7 kw
Commutator mica depth 0.45−0.75 mm (0.018−0.030 in.) 0.20 mm (0.008 in.)
Commutator runout 0.05 mm (0.002 in.) max. 0.4 mm (0.02 in.)
Commutator O.D. 27.9−28.0 mm (1.098−1.102 in.) 27.0 mm (1.06 in.)
Brush length 9.7−10.3 mm (0.38−0.41 in.) 6.0 mm (0.20 in.)
Wheel alignment
Item Measurement Qualification Standard or New Service Limit
Wheel alignment Camber Front 0 ° 00 ′±1 °
Rear −1 ° 00 ′±1 °
Caster Front 3 ° 20 ′±1 °
Total toe-in Front 0±3 mm (0±0.12 in.)
Rear 2.5±2.5 mm (10±0.10 in.)
Front wheel turning angle Inward 40 ° 19 ′±2 °
Outward 33 ° 19 ′±1 °
(reference)
Wheel bearing
Item Measurement Qualification Standard or New Service Limit
Wheel bearing End play Front 0−0.05 mm (0−0.002 in.)
Rear 0−0.05 mm (0−0.002 in.)
Wheel
Item Measurement Qualification Standard or New Service Limit
Wheel Steel wheel runout Axial 0−1.0 mm (0−0.04 in.) 2.0 mm (0.08 in.)
Radial 0−1.0 mm (0−0.04 in.) 1.5 mm (0.06 in.)
Aluminium wheel runout Axial 0−0.7 mm (0−0.03 in.) 2.0 mm (0.08 in.)
Radial 0−0.7 mm (0−0.03 in.) 1.5 mm (0.06 in.)
Parking Brake Inspection and Adjustment
Inspection
1. Pull the parking brake lever (A) with 196 N (20 kgf, 44 lbf) of force to fully apply the parking brake. The parking
brake lever should be locked within the specified number of clicks.
Lever locked clicks: 6 to 8
2. If the number of lever clicks is not as specified, adjust the parking brake.
Adjustment
1. Release the parking brake lever fully.
2. Press the brake pedal several times.
3. Remove the center console.
4. Loosen the parking brake adjusting nut (A).
5. Raise the rear of the vehicle, and support it with safety stands in the proper locations.
6. Remove the rear wheels.
7. Make sure the lever (A) on the rear brake caliper contacts the stop pin (B).
NOTE: The parking brake lever will contact the stop pin when the parking brake adjusting nut is loosened.
8. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the rear wheels.
9. Pull the parking brake lever 1 click.
10. Tighten the parking brake adjusting nut until the parking brakes drag slightly when the rear wheels are turned.
11. Release the parking brake lever fully, and check that the parking brakes do not drag when the rear wheels are
turned. Readjust if necessary.
12. Make sure the parking brake lever within the specified number of clicks (6 to 8 clicks).
13. Install the center console.
Parking brake
Item Measurement Qualification Standard or New Service Limit
Parking brake Distance traveled when lever pulled with 196 6 to 8 clicks
N (20 kgf, 44 lbf) of force
Parking Brake Cable Replacement
Exploded View
NOTE:
The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature cable failure.
Refer to the Exploded View as needed during this procedure.
1. Release the parking brake lever fully.
2. Loosen the parking brake cable adjustment nut.
3. Remove the parking brake cable clip (A) from the brake cable (B).
4. Disconnect the parking brake cable from the lever (C).
5. Remove the parking brake cable mounting hardware, then remove the cable.
6. Install the parking brake cable in the reverse order of removal, and note these items:
Be careful not to bend or distort the cable.
Make sure the parking brake cable clip is fully seated on the cable housing.
Adjust the parking brake.
Brake System Bleeding
NOTE:
Do not reuse the drained fluid. Use only clean genuine Honda DOT 3 or DOT 4 Brake Fluid from an unopened
container. Using a non-Honda brake fluid can cause corrosion and shorten the life of the system.
Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off
immediately with water.
The reservoir connected to the master cylinder must be at the MAX (upper) level mark at the start of the bleeding
procedure and checked after bleeding each wheel location. Add fluid as required.
1. Make sure the brake fluid level in the reservoir (A) is at the MAX (upper) level line (B).
2. Have someone slowly pump the brake pedal several times, then apply steady pressure.
3. Start the bleeding at the driver's side of the front brake system.
NOTE: Bleed the calipers or the wheel cylinders in the sequence shown.
4. Attach a length of clear drain tube (A) to the bleed screw (B), then, loosen the bleed screw to allow air to escape Front
from the system. Then tighten the bleed screw securely.
5. Refill the master cylinder reservoir to the MAX (upper) level line.
6. Repeat the procedure for each brake circuit until there are no air bubbles are in the fluid.
Rear
Conventional Brake Component Location Index
MASTER CYLINDER
Brake System Bleeding,
Replacement,
Disassembly,
Reassembly,
BRAKE BOOSTER
Inspection,
Replacement,
REAR BRAKE
Pad Inspection and
Replacement,
Disc Inspection,
Disc Replacement,
Caliper Overhaul,
PARKING BRAKE
Inspection and Adjustment,
Cable Replacement,
Exploded View
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
Avoid breathing dust particles.
Never use an air hose or brush to clean brake assemblies. Use an appropriate vacuum cleaner.
NOTE: Make sure that the caliper pins are installed correctly. Upper caliper pin B and lower caliper pin A are different. If
these caliper pins are installed in the wrong location, it will cause vibration, uneven or rapid pad wear, and possibly uneven
tyre wear.
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off
immediately with water.
To prevent dripping brake fluid, cover disconnected hose joints with rags or shop towels.
Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
Before reassembling, check that all parts are free of dirt and other foreign particles.
Replace parts with new ones as specified in the illustration.
Make sure no dirt or other foreign matter gets in the brake fluid.
Make sure no grease or oil gets on the brake discs or the brake pads.
When reusing brake pads, always reinstall them in their original positions to prevent loss of braking efficiency.
Do not reuse drained brake fluid. Use only clean genuine Honda DOT 3 or DOT 4 Brake Fluid from an unopened
container. Using a non-Honda brake fluid can cause corrosion and shorten the life of the system.
Coat the piston, the piston seal groove, and the caliper bore with clean brake fluid.
Use recommended greases in the front caliper set.
After installing the caliper, check the brake hose and line for leaks, interference, and twisting.
When you apply the silicone grease, make sure not to adhere to the terminal part of connectors and surrounding
switches. Also do not touch the switches and the terminal part of connector by hands or glove that adheres the
silicone grease.
Disassembly
1. Remove the caliper body.
2. Set the wooden block (A) or several shop towels to the caliper body (B) as shown. Blow out the piston with
compressed air gradually, and remove the piston from the caliper body.
NOTE: Do not put the hand into the caliper body because the piston will come out hardly from the caliper body.
3. Remove the piston boot (A) and the piston seal (B) from the caliper body (C).
NOTE: Be careful not to damage the inner surface of the cylinder wall with the tool.
Reassembly
1. Apply a thin coat of silicone grease to the new piston seal (A), then install it into the groove in the caliper body.
2. Apply a thin coat of rubber grease to the new piston boot (B), then install it into the groove in the caliper body.
3. Apply the brake fluid to the outer surface of the piston, then set the piston in place on the caliper body.
4. Mount the commercially available brake caliper piston compressor tool (A) on the caliper body (B).
5. Press in the piston with the brake caliper piston compressor tool. Make sure that the piston boot is properly
positioned into the groove of the piston.
NOTE:
Do not press the piston diagonally, and do not press it forcibly.
Be careful not to damage the piston boot when press the piston.
6. Install the caliper body.
7. Bleed the brake system.
Brake disc
Item Measurement Qualification Standard or New Service Limit
Brake disc Thickness Front 20.9−21.1 mm (0.82−0.83 in.) 19.0 mm (0.75 in.)
Rear 8.9−9.1 mm (0.35−0.36 in.) 8.0 mm (0.31 in.)
Runout ——— 0.04 mm (0.0016 in.)
Parallelism ——— 0.015 mm (0.0006 in.)
Brake Hose and Line Inspection
1. Inspect the brake hoses for damage, deterioration, leaks, interference, and twisting.
2. Check the brake lines for damage, rusting, and leaks. Also check for bent brake lines.
3. Check for leaks at hose and line joints and connections, and retighten if necessary.
4. Check the master cylinder and the ABS modulator-control unit for damage and leaks.
Connection Component Connected Specified Torque Note
Point to Value
A Front brake caliper Brake hose 34 N·m (3.5 kgf·m, 25 Banjo
lbf·ft) bolt
Bleed screw 8 N·m (0.8 kgf·m, 6
lbf·ft)
B Rear brake caliper Brake hose 34 N·m (3.5 kgf·m, 25 Banjo
lbf·ft) bolt
Bleed screw 9 N·m (0.9 kgf·m, 7
lbf·ft)
C Brake hose Brake line 15 N·m (1.5 kgf·m, 11 Flare nut
lbf·ft)
D Master cylinder Brake line 15 N·m (1.5 kgf·m, 11 Flare nut
lbf·ft)
E ABS modulator-control Brake line 15 N·m (1.5 kgf·m, 11 Flare nut
unit lbf·ft)
Front Brake Pad Inspection and Replacement
Inner pad
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
Avoid breathing dust particles.
Never use an air hose or brush to clean brake assemblies. Use an appropriate vacuum cleaner.
4. If the brake pad thickness of any of the pads is less than the service limit, replace the front brake pads as a set.
5. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the front wheels.
Replacement
1. Remove some brake fluid from the master cylinder.
2. Raise the front of the vehicle, and support it with safety stands in the proper locations.
3. Remove the front wheels.
4. Remove the brake hose mounting bolt (A).
5. Remove the flange bolt (B) while holding the caliper pin (C) with a wrench. Be careful not to damage the pin boot,
and pivot the caliper (D) up out of the way. Check the hose and the pin boots for damage and deterioration.
6. Remove the pad shims (A) and the brake pads (B).
11. Mount a commercially available brake caliper piston compressor tool (A) on the caliper body (B).
12. Press in the piston with the brake caliper piston compressor tool so the caliper will fit over the brake pads. Make
sure the piston boot is in position to prevent damaging it when pivoting the caliper down.
NOTE: Be careful when pressing in the piston; brake fluid might overflow from the master cylinder's reservoir. If
brake fluid gets on any painted surface, wash it off immediately with water.
13. Remove the brake caliper piston compressor tool.
14. Apply Molykote M77 grease to the pad side of the shims (A), the back of the brake pads (B) and the other areas
indicated by the arrows. Wipe excess grease off the pad shims and the brake pads. Keep grease off the brake
discs and the brake pads. Contaminated brake discs or brake pads reduce stopping ability.
15. Install the brake pads and the pad shims correctly. Install the brake pad with the wear indicator (C) on the upper
inside. If you are reusing the brake pads, always reinstall the brake pads in their original positions to prevent a
momentary loss of braking efficiency.
16. Pivot the caliper down into position. Install the flange bolt (A), and tighten it to the specified torque while holding the
caliper pin (B) with a wrench being careful not to damage the pin boot.
17. Install the brake hose mounting bolt (C).
18. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the front wheels.
19. Press the brake pedal several times to make sure the brakes work.
NOTE: Engagement may require a greater pedal stroke immediately after the brake pads have been replaced as a
set. Several applications of the brake pedal will restore the normal pedal stroke.
20. Add brake fluid as needed.
21. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.
Test-drive the vehicle, then check for leaks.
Brake pad
Item Measurement Qualification Standard or New Service Limit
Brake pad Thickness Front 9.5−10.2 mm (0.37−0.41 in.) 1.6 mm (0.06 in.)
Rear 6.8−7.5 mm (0.27−0.30 in.) 1.6 mm (0.06 in.)
Brake pedal
Item Measurement Qualification Standard or New Service Limit
Brake pedal Pedal height (carpet moved aside) M/T 139 mm (5.5 in.)
A/T 138 mm (5.4 in.)
Free play 1−5 mm (0.04−0.20 in.)
Gearbox
Item Measurement Qualification Standard or New
Gearbox Angle of rack guide screw loosened from 10±3 °
locked position
Steering wheel
Item Measurement Qualification Standard or New
Steering wheel Rotational play measured at outside edge 0−10 mm (0−0.39 in.)
with engine running
Initial load measured at outside edge with 29 N (3.0 kgf, 6.6 lbf)
engine running
A/C condenser fan does not run at all (but radiator fan runs with the A/C on)
Diagnostic procedure
1. A/C condenser fan circuit troubleshooting
Also check for
Blown fuse No. 47 (30 A) in the under-dash fuse/relay box
Poor ground at G202
Cleanliness and tightness of all connectors
Both fans do not run with the A/C on (but the A/C compressor runs with the A/C on)
Diagnostic procedure
1. Radiator and A/C condenser fan common circuit troubleshooting
Also check for
Blown fuse No. 30 (30 A) and No. 47 (30 A) in the under-dash fuse/relay box
Poor ground at G202
Cleanliness and tightness of all connectors
The A/C compressor clutch does not engage (but both fans run with the A/C on)
Diagnostic procedure
1. A/C compressor clutch circuit troubleshooting
Also check for
Blown fuse No. 43 (7.5 A) in the under-dash fuse/relay box
Cleanliness and tightness of all connectors
A/C system does not come on (both fans and the A/C compressor do not work); heater is OK
Diagnostic procedure
1. A/C pressure switch circuit troubleshooting
Also check for
Poor ground at G502
Cleanliness and tightness of all connectors
A/C Pressure Switch Circuit Troubleshooting
NOTE:
Do not use this troubleshooting procedure if any of these items are working properly with the A/C switch ON;
condenser fan, radiator fan, A/C compressor, or if the heater does not work. Refer to the symptom troubleshooting
index.
Check the A/C high-side pressure.
1. Disconnect the A/C pressure switch 2P connector.
2. Turn the ignition switch to ON (II).
3. Measure the voltage between the A/C pressure switch 2P connector No. 2 terminal and body ground.
Is there battery voltage?
YES - Go to Step 4 .
NO - Go to Step 23 .
4. Turn the ignition switch to LOCK (0).
5. Check for continuity between the No. 1 and No. 2 terminals of the A/C pressure switch.
Is there continuity?
YES - Go to Step 6 .
NO - Replace the A/C pressure switch.■
6. Reconnect the A/C pressure switch 2P connector.
7. Disconnect the A/C switch 5P connector.
8. Turn the ignition switch to ON (II).
9. Measure the voltage between the A/C switch 5P connector No. 2 terminal and body ground.
Is there battery voltage?
YES - Go to Step 10 .
NO - Repair open in the wire between the A/C pressure switch and the A/C switch.■
10. Turn the ignition switch to LOCK (0).
11. Test the A/C switch.
Is the A/C switch OK?
YES - Go to Step 12 .
NO - Replace the A/C switch.■
12. Disconnect the heater fan switch 8P connector.
13. Check for continuity between the A/C switch 5P connector No. 1 terminal and the heater fan switch 8P connector
No. 6 terminal.
Is there continuity?
YES - Go to Step 14 .
NO - Repair open in the wire between the A/C switch and the heater fan switch.■
14. Test the heater fan switch.
Is the heater fan switch OK?
YES - Go to Step 15 .
NO - Replace the heater fan switch. ■
15. Remove the evaporator temperature sensor and test it.
Is the evaporator temperature sensor OK?
YES - Go to Step 16 .
NO - Replace the evaporator temperature sensor. ■
16. Jump the SCS line with the HDS.
NOTE: This step must be done to protect the engine control module (ECM)/powertrain control module (PCM) from
damage.
17. Disconnect ECM/PCM connector A (49P).
18. Check for continuity between the following terminals of ECM/PCM connector A (49P) and the evaporator
temperature sensor 2P connector.
49P: 2P:
No. 10 No. 2
No. 38 No. 1
Is there continuity?
YES - KZ, KP, and MA models: Go to Step 19 .
Except KZ, KP, and MA models: Go to Step 22 .
NO - Repair open in the wire(s) between the ECM/PCM and the evaporator temperature sensor.■
19. Test the temperature control dial.
Is the temperature control dial OK?
YES - Go to Step 20 .
NO - Replace the temperature control dial. ■
20. Check for continuity between the following terminals of ECM/PCM connector A (49P) and the heater control panel
6P connector.
49P: 6P:
No. 10 No. 6
No. 20 No. 5
No. 37 No. 4
Is there continuity?
YES - Go to Step 21 .
NO - Repair open in the wire(s) between the ECM/PCM and the heater control panel. Also check the heater
control panel harness.■
21. Check for continuity between ECM/PCM connector A (49P) No. 37 terminal and body ground.
Is there continuity?
YES - Repair short to body ground in the wire between the ECM/PCM and the temperature control dial.■
NO - Go to Step 22 .
22. Check for continuity between ECM/PCM connector A (49P) No. 38 terminal and body ground.
Is there continuity?
YES - Repair short to body ground in the wire between the ECM/PCM and the evaporator temperature sensor.■
NO - Check for loose wires or poor connections at ECM/PCM connector A (49P), the evaporator temperature
sensor 2P connector, the A/C pressure switch 2P connector, the A/C switch 5P connector and at the
heater fan switch 8P connector. If the connections are good, substitute a known-good ECM/PCM, and
recheck. If the symptom/indication goes away, replace the original ECM/PCM.■
23. Turn the ignition switch to LOCK (0).
24. Reconnect the A/C pressure switch 2P connector.
25. Make sure the A/C switch is OFF.
26. Turn the ignition switch to ON (II).
27. Measure the voltage between under-dash fuse/relay box connector A (36P) No. 21 terminal and body ground with
the under-dash fuse/relay box connectors connected.
Is there battery voltage?
YES - Repair open in the wire between the A/C pressure switch and the MICU.■
NO - Check for loose wires or poor connections at the under-dash fuse/relay box. If the connections are OK,
substitute a known-good MICU and recheck. If the symptom goes away, replace the original MICU .■
Refrigerant
Item Measurement Qualification Standard or New
Refrigerant Type HFC-134a (R-134a)
Capacity of system 370−420 g (13.1−14.8 oz)
Refrigerant oil
Item Measurement Qualification Standard or New
Refrigerant oil Type SP-10 (P/N 38897-P13-A01, 38898-P13-003, or 38899-P13-A01)
Capacity of components Condenser 25 mL (5/6 fl·oz, 0.9 Imp·oz)
Evaporator 35 mL (1 1/6 fl·oz, 1.2 Imp·oz)
Each line and 10 mL (1/3 fl·oz, 0.4 Imp·oz)
hose
Receiver/Dryer 10 mL (1/3 fl·oz, 0.4 Imp·oz)
Compressor 80−90 mL (2 2/3−3 fl·oz, 2.8−3.2 Imp·oz)
Compressor
Item Measurement Qualification Standard or New
Compressor Field coil resistance At 20 °C (68 °F) 3.15−3.45 Ω
Pulley-to-armature plate clearance 0.35−0.65 mm (0.014−0.026 in.)
Heating and A/C Component Location Index
BLOWER RESISTOR
Test,
EVAPORATOR
RADIATOR FAN RELAY
Test, TEMPERATURE
SENSOR
Test,
MODE CONTROL CABLE
Removal/Installation,
SIGHT GLASS RECEIVER/DRYER
(For some models) RADIATOR FAN DESICCANT
RECIRCULATION Replacement,
CONTROL CABLE A/C CONDENSER FAN
Removal/Installation, A/C CONDENSER
A/C PRESSURE SWITCHReplacement,
A/C COMPRESSOR
Replacement, HEATER CORE
Clutch Check, AUXILIARY UNDER-HOOD (Except KZ, KP, and MA models)
Clutch Overhaul, RELAY BOX (RHD model) Removal/Installation,
Thermal Protector Replacement,
Relief Valve Replacement,AIR MIX CONTROL CABLE
A/C COMPRESSOR (Except KZ, KP, and MA models)
RHD model is shown, LHD modelRELAY
CLUTCH is similar. Removal/Installation,
RADIATOR FAN RELAY
Test, Test,
A/C SWITCH HEATER FAN SWITCH
Test, A/C CONDENSER Test,
Replacement, FAN RELAY
Test, TEMPERATURE CONTROL DIAL
Test,
RHD model is shown, LHD model is HEATER
similar. CONTROL PANEL
Removal/Installation,
Disassembly and Reassembly,
3 4
BLOWER
1 3 1* 1 3 2 3 4 2 MOTOR
1 2
2* 2 S2
WHT WHT BLU
EVAPORATER
TEMPERATURE YEL HEATER FAN 1 6
SENSOR SWITCH
SG6 A10 6 4 SG
YEL YEL YEL
ENGINE COOLANT
TEMPERATURE YEL
HEATER CONTROL PANEL 1
(ETC) SENSOR 2
TW2 A34 2 1 BLK BLK
LT GRN
ECM/PCM
G202 G502 G502 G502
Blower motor runs, but one or more speeds are inoperative
Diagnostic procedure
1. Blower motor circuit troubleshooting
Also check for
Cleanliness and tightness of all connectors
Blower motor does not run at all
Diagnostic procedure
1. Blower motor circuit troubleshooting
Also check for
Blown fuse No. 10 (7.5 A) and No. 57 (30 A) in the under-dash fuse/relay box
Poor ground at G501
Cleanliness and tightness of all connectors
Heating and A/C Symptom Troubleshooting
Symptom Diagnostic procedure Also check for
Blower motor runs, but one or more speeds are Blower motor circuit troubleshooting Cleanliness and tightness of all connectors
inoperative
Blower motor does not run at all Blower motor circuit troubleshooting Blown fuse No. 10 (7.5 A) and No. 57 (30 A) in
the under-dash fuse/relay box
Poor ground at G501
Cleanliness and tightness of all connectors
A/C condenser fan does not run at all (but A/C condenser fan circuit troubleshooting Blown fuse No. 47 (30 A) in the under-dash
radiator fan runs with the A/C on) fuse/relay box
Poor ground at G202
Cleanliness and tightness of all connectors
Both fans do not run with the A/C on (but the Radiator and A/C condenser fan common circuit Blown fuse No. 30 (30 A) and No. 47 (30 A) in
A/C compressor runs with the A/C on) troubleshooting the under-dash fuse/relay box
Poor ground at G202
Cleanliness and tightness of all connectors
The A/C compressor clutch does not engage A/C compressor clutch circuit troubleshooting Blown fuse No. 43 (7.5 A) in the under-dash
(but both fans run with the A/C on) fuse/relay box
Cleanliness and tightness of all connectors
A/C system does not come on (both fans and A/C pressure switch circuit troubleshooting Poor ground at G502
the A/C compressor do not work); heater is OK Cleanliness and tightness of all connectors
Heater Control Panel Removal/Installation
1. Remove the audio unit.
2. Remove the control cables from the blower/heater unit.
3. Remove the screw and pull the heater control panel (A).
4. Disconnect the connectors and remove the heater control panel.
5. Install the control panel in the reverse order of removal. After installation, operate the control panel controls to see
whether it works properly.
Heater Control Panel Disassembly/Reassembly
1. Remove the heater control panel.
2. Using a snap ring pliers, widen the cable stops (A) in the cable holder (B), then pull out the
recirculation control cable (C), mode control cable (D), and air mix control cable (E).
3. Hook the tip of the new control cables to the dial or slider, then push the cable housing into the
cable holder until it locks into place.
4. After assembly, check that the lever slides or the dial turns smoothly through the full stroke
from right to left.
Blower Unit Removal/Installation
1. Remove the passenger's dashboard undercover and the glove box.
2. Remove the recirculation control cable from the blower unit.
3. Cut the plastic cross brace (A) in the glove box opening with diagonal cutters in the area (B). Retain plastic cross
brace to be reinstalled later.
5. Disconnect the connector (A) from the blower motor. Remove the clips (B).
6. Remove the self-tapping screws and the passenger's heater duct (A).
7. Remove the self-tapping screws and the mounting nuts, and pull the blower unit (A) out.
8. Install the unit in the reverse order of removal. Make sure that there is no air leakage.
Blower Unit Component Replacement
NOTE: The these items when overhauling the blower unit.
The blower motor (A) and the dust and pollen filter (B) can be placed without removing the blower unit.
Before reassembly, make sure that the recirculation control linkage and door move smoothly.
Emblem/Sticker Replacement
NOTE: When removing the emblems, take care not to scratch the body.
1. To remove the front ‘‘H'' emblem, remove the upper front grille.
2. To remove the rear ‘‘H'' emblem, remove the rear license trim.
3. Clean the body surface with a sponge dampened in isopropyl alcohol. After cleaning, keep oil,
grease, and water from getting on the surface.
4. Apply the emblems where shown.
Lower Front Grille Replacement
NOTE: With front air spoiler
Put on gloves to protect your hands.
Take care not to scratch the front bumper.
1. Remove the front bumper.
2. Detach the clips and the hooks (A) by using a flat-tip screwdriver wrapped with the protective tape, then remove the
front bumper lower grille (B) from the front bumper (C).
NOTE: To remove the clips, pry the inner clip up at the edge near the line (D) on its head.
3. Install the grille in the reverse order of removal, and note these items:
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Push the clips and the hooks into place securely. Without front air spoiler
Gauges Circuit Diagram
[ ]: LHD model
*1: With security
*2: With paddle shifter +/−
*3: With cruise control
BATTERY TERMINAL *4: With multi information display
FUSE BOX UNDER-DASH FUSE RELAY BOX : CAN line
BATTERY IGNITION SWITCH
[ ]: LHD model *4: Without multi information display
No. 1 (100 A) T-9 No. 1 (10 A) *1: A/T *5: With SRS
WHT No. 60 (IGN) (50 A) T1 BAT *2: With cruise control *6: With side airbag
WHT *3: With multi information display *7: With side turn signal light (Mirror type)
IG1
No. 22 (7.5 A) W1
YEL
(RHD model) (LHD model)
Q8 N1 LEFT SIDE RIGHT SIDE
TURN SIGNAL MICU TURN SIGNAL
LT BLU PNK (MIRROR TYPE) (MIRROR TYPE)
24 23
ORN GRY
1 10
CABLE
1 REEL
CRUISE CRUISE CRUISE GRY 11 ORN 3
· ECM/PCM · MICU CONTROL CONTROL CONTROL
· EPS CONTROL UNIT FUEL 5*3 6*3
· IMMOBILIZER-KEYLESS FUEL MAIN RESET SET
· SRS UNIT CONTROL UNIT GAUGE SWITCH SWITCH SWITCH BLK BLK
TANK
· ABS MODULATOR- UNIT SENDING
CONTROL UNIT UNIT
· DATA LINK CONNECTOR *3
(DLC) SELECT/RESET/
3 INFORMATION SELECT/
INFORMATION
SWITCH RESET SWITCH
SWITCH LIGHT LIGHT
(LED) (LED)
2 BRAKE FLUID
1
LEVEL SWITCH PARKING
2*3 3*3 1*3
(Closed:10 BRAKE
9 SWITCH 4
CABLE Float down) (Closed:
REEL (Open: Lever pulled)
1 Float up)3 4 9
PUR GRN BLK
BLK
G301
[G302]
Headliner Removal/Installation
SRS components are located in this area. Review the SRS component locations and the precautions and procedures
before doing repairs or service.
NOTE:
Put on gloves to protect your hands.
When removing components, use the trim tools or equivalent.
Take care not to bend or scratch the trim and panels.
RHD model is shown; LHD model is symmetrical.
1. Do the battery terminal disconnection procedure, then wait at least 3 minutes before beginning work.
2. Remove these items:
Driver's dashboard undercover
Front pillar trim, both sides:
-Without side curtain airbags
-With side curtain airbags
Center pillar upper/lower trim, both sides:
-Without side curtain airbags
-With side curtain airbags
Quarter pillar trim, both sides:
-Without side curtain airbags
-With side curtain airbags
Individual map light
Ceiling light
Sunvisors, both sides
Grab handles, four places
Rear center seat belt (for some model)
Ultrasonic sensor (for some model)
3. Remove the roof wire harness (A) by detaching the harness clips (B, C, D) and disconnect the roof wire harness
connector (E) from the driver's side front pillar.
4. Remove the antenna lead (A) by detaching the harness clips (B) and disconnect the antenna lead connector (C)
from the passenger's side front pillar.
5. Disconnect the tailgate sub lead connectors (A, B) by detaching the harness clips (C, D).
6. Lower the headliner (A). With child seat tether
-1. Remove the front door inner seals (B), rear door inner seals (C), and tailgate weatherstrip (D) from each roof anchor model
portion.
-2. Release the clips (E, F) from the headliner.
-3. Lower the headliner.
7. With the help of an assistant, pull the headliner (A) out through the tailgate opening. Do not bend the headliner.
Bending the headliner will crease and damage it.
8. For some model: Remove the screws, and release the hooks (A), then remove the retractor cover bracket (B) and
retractor cover (C) from the headliner (D).
9. Remove the cushion tapes, then remove the roof wire harness (A) and antenna lead (B) from the headliner (C). RHD model
LHD model
10. Without side curtain airbags: If necessary, detach the hooks, then remove the front roof side pad (A).
11. Without side curtain airbags: If necessary, remove the hooks and screws, and remove the center roof side pad (A)
with a glove rail bracket (B), then release the hooks (C) and remove the bracket from the pad.
12. With side curtain airbags: If necessary, remove the grab handle bracket mounting bolts (A) and the side curtain
airbag mounting screw (B), then remove the grab handle bracket (C) from each side by releasing the hooks (D).
13. Install the headliner in the reverse order of removal, and note these items: Headliner
If the side curtain airbag has deployed, replace the headliner and removed trim pieces with new ones.
To prevent the side curtain airbags from deploying improperly and possibly causing injury, inspect removed
pieces and replace them if they have any of these types of damage:
-Any crease or tears in the headliner (A)
-Any cracks or breakages in the grab handle (B)
-Any damages around the grab handle holes (C) or sunvisor holes in the headliner
-Any cracks in the sunvisor stay base (D)
-Any bends or cracks in the sunvisor stay shaft (E) Grab handle
-Any cracks in the sunvisor base (F)
-Any cracks or breakages in the vanity mirror base (G)
-Any clip bases (H) which have come off the headliner
When installing the grab handle, push on the handle against the bracket (I) until the clips (J) snap into place
securely.
Check if the clips are damaged or stress-whitened, and if necessary, replace them with new ones.
Replace the removed cushion tape with new ones. Sunvisor
Check that both sides of the headliner are securely attached to the trim.
Make sure the headliner overlaps the trim pieces correctly.
When reinstalling the headliner through the tailgate opening, be careful not to fold or bend it. Also, be careful
not to scratch the body.
Dashboard/Steering Hanger Beam Removal/Installation
SRS components are located in this area. Review the SRS component locations and the precautions and procedures
before doing repairs or service.
NOTE:
Put on gloves to protect your hands.
Have an assistant help you when removing and installing the dashboard/steering hanger beam.
Take care not to scratch the dashboard, body and other related parts.
RHD model is shown; LHD model is symmetrical.
1. Do the battery terminal disconnection procedure, then wait at least 3 minutes before beginning work.
2. Remove these items:
Front seats, both sides
Driver's dashboard undercover
Kick panels, both sides
Center console
Glove box
Fuse lid panel:
-RHD model
-LHD model
Passenger's dashboard undercover
Front pillar trim, both sides:
-Without side curtain airbags
-With side curtain airbags
Steering column
AC control cables
Driver's side
3. From under the dash, disconnect the right engine compartment wire harness connector (A), the left engine
compartment wire harness connector (B), the driver's door wire harness connectors (C), the interior wire harness
connectors (D), floor wire harness connector (E), and remove the bolt (F), then release the battery cable (G) from
the driver's under-dash fuse/relay box (H).
Center
4. Disconnect the sub harness connectors (A).
5. Release the harness clips (A), then disconnect the blower motor connector (B).
7. From under dash, disconnect SRS control unit connector A and remove the bolt (B). Remove the ground bolt (C)
using a TORX T30 bit.
8. Detach the wire harness clips (A), then disconnect the parking brake switch connector (B), fuel pump connector
(C), and A/T position switch connector (D) (A/T model).
Passenger's side
9. From under the dash, disconnect the passenger's floor wire harness connectors (A), passenger's door wire harness
connector (B), the left engine compartment wire harness connectors (RHD model)/the right engine compartment
wire harness connectors (LHD model) (C), and SRS sensor sub harness connector (D).
10. Detach all of the harness and the connector clips.
11. Remove the special bolts (A, B) from outside the passenger's door. RHD model is shown; LHD model is
symmetrical.
-1. Remove the caps (C).
-2. Loosen the special bolts until its threads have come off the side bracket (D) of the steering hanger beam. The
bolt will be screwed into the inside threads of the collar bolt (E) by loosening the bolt. Because of the thread
lock on the threads of the bolt, the bolt and the collar bolt will be fixed.
-3. Loosen the bolt again to screw the collar bolt into the fixed space adjuster (F) until it is stopped by the
stopper (G). This will provide a gap (H) between the collar bolt and the body.
-4. Remove the bolts.
12. If the collar bolts (A) are not screwed fully into the fixed space adjuster when removing the special bolts, slightly
screw the collar bolt into the space adjuster with a 21 mm open-end wrench (B). In this case, the special bolt
should be replaced with a new one because its thread locks were worn out.
13. From outside the driver's door, remove the caps (A), then remove the bolts (B, C, D, E, F).
14. Lift up on the dashboard (A) to release it from the guide pins (B, C). Carefully remove the dashboard through the
front door opening. Take care not to scratch the body with the collar nuts on the passenger's side.
NOTE: Do not rest the dashboard on its lower center cover opening, or it may be damaged. Lay it on its front or
back.
15. Install the dashboard in the reverse order of removal, and note these items: Special bolt tightening
Make sure the dashboard fits onto the guide pins correctly. on passenger's side
Before tightening the bolts, make sure the wire harnesses are not pinched.
Make sure the connectors are plugged in properly.
Before reinstalling the dashboard, be sure the collar bolt (A) on passenger's side can be screwed/unscrewed
lightly by hand, and then screw all of them into the fixed space adjuster (B) until they contact the stoppers
(C) by hand. Do not tighten them fully with any tools.
Before reinstalling the dashboard, try to screw the special bolt (D) into the loosened collar bolt. If the collar
bolt is not unscrewed by screwing the special bolt, replace this special bolt with a new one.
After setting the dashboard on the body, reinstall all of the mounting bolts to the dashboard, tighten the
driver's side bracket to the specified torque, then torque the special bolt D on the passenger's side. First
screw the special bolt into the collar bolt A, they will be fixed because of the thread lock on the bolt.
Continue tightening the bolt with the collar bolt, they are loosened from the fixed space adjuster B until the
collar bolt contacts the inside face of the body. Then tighten the bolts again to the specified torque.
Apply medium strength type liquid thread lock to the bolts securing the center joint bracket and the
dashboard before reinstallation.
After tightening the dashboard mounting bolts, tighten the center joint bracket mounting bolts, and then
tighten the center frame mounting bolts.
Do the battery terminal reconnection procedure.
Check for any DTCs that may have been set during repairs, and clear them.
Exterior Lights Component Location Index
LHD model
4. Inspect the connector terminals to be sure they are all making good contact.
If the terminals are bent, loose or corroded, repair them as necessary, and recheck the
system.
If the terminals look OK, check for continuity between the terminals in each switch
position according to the tables.
-If the continuity is not as specified, replace the switch.
Exterior Lights (MICU) Input Test
NOTE:
Before performing the input tests, check the No. 1, No. 5, No. 22, No. 24, No. 32, No. 34, No.
48, and No. 51 fuses in the under-dash fuse/relay box.
The illustration shows the RHD model and the black portion shows the lock lever. The lock lever
for LHD model is shown as the dashed lines.
1. Turn the ignition switch to LOCK (0).
2. RHD model: Remove the fuse lid panel , and remove the driver's dashboard lower cover.
LHD model: Remove the fuse lid panel.
3. Disconnect under-dash fuse/relay box connectors A, B, C, K, M, N, Q, and W.
NOTE: All connector views are wire side of female terminals.
4. Inspect the connector and socket terminals to be sure they are all making good contact.
If the terminals are bent, loose or corroded, repair them as necessary and recheck the
system.
If the terminals look OK, go to Step 5 .
5. With the connectors still disconnected, make these input tests at the connectors.
If any test indicates a problem, find and correct the cause, then recheck the system.
If all the input tests prove OK, the MICU must be faulty; replace the under-dash
fuse/relay box.
CavityWire Test condition Test: Desired result Possible cause if
result is not obtained
N2 BLK Under all Check for continuity to Poor ground
conditions ground: There should be (G501)
continuity. An open in the
wire
K10 BLK Under all Check for continuity to Poor ground
conditions ground: There should be (G502)
continuity. An open in the
wire
M16 BLK Under all Check for continuity to Poor ground
conditions ground: There should be (G501)
continuity. An open in the
wire
Q9 BLK Under all Check for continuity to Poor ground
conditions ground: There should be (G502)
continuity. An open in the
wire
W1 YEL Ignition switch ON Measure the voltage to Blown No. 60
(II) ground: There should be (IGN) (50 A) fuse
battery voltage. in the under-dash
fuse/relay box
Faulty ignition
switch
An open in the
wire
A24 PNK Ignition switch ON Connect W1 terminal and Blown bulb
(II) A24 terminal with a Poor ground
jumper wire: The right (G202) [G401]
headlight (low beam) An open in the
should come on. wire
A30 GRNIgnition switch ON Connect W1 terminal and Blown bulb
(II) A30 terminal with a Poor ground
jumper wire: The right (G202) [G401]
headlight (high beam) An open in the
should come on. wire
B29 BRN Ignition switch ON Connect W1 terminal and Blown bulb
(II) B29 terminal with a Poor ground
jumper wire: The left (G401) [G202]
headlight (low beam) An open in the
should come on. wire
B13 GRYIgnition switch ON Connect W1 terminal and Blown bulb
(II) B13 terminal with a Poor ground
jumper wire: The left (G401) [G202]
headlight (high beam) An open in the
should come on. wire
A8 GRYIgnition switch ON Connect W1 terminal and Blown bulb
(II) A8 terminal with a jumper Poor ground
wire: The right front (G202) [G401]
position light should An open in the
come on. wire
CavityWire Test condition Test: Desired result Possible cause if
result is not obtained
B30 GRYIgnition switch ON Connect W1 terminal and Blown bulb
(II) B30 terminal with a Poor ground
jumper wire: The left front (G401) [G202]
position light should An open in the
come on. wire
C42 GRYIgnition switch ON Connect W1 terminal and Blown bulb
(II) C42 terminal with a Poor ground
jumper wire: The taillights (G602, G604)
and license plate lights An open in the
should come on. wire
C21 GRNIgnition switch ON Connect W1 terminal and Blown bulb
(II) C21 terminal with a Poor ground
jumper wire: The back-up (G602, G604)
lights should come on. An open in the
wire
[ ]: LHD model
[ ]: LHD model
Brake Lights Circuit Diagram
No. 24
(15 A)
1
BRAKE PEDAL
POSITION SWITCH
(Closed: Pedal pressed)
2
LT GRN
ECM/PCM
3 3 3
LEFT HIGH MOUNT RIGHT
BRAKE LIGHT BRAKE LIGHT BRAKE LIGHT
(21 W) (21 W) (21 W)
2 2 2
BATTERY TERMINAL
FUSE BOX UNDER-DASH FUSE/RELAY BOX UNDER-DASH FUSE/RELAY BOX
BATTERY
No. 1 (100 A) T-9 No. 60 (IGN) (50 A)
WHT
IGNITION SWITCH
IG1 T1
YEL WHT
BAT GAUGE CONTROL MODULE COMBINATION LIGHT SWITCH
SG PG
M16 Q9 N2 K10
1 3 1 3
2 2
1 1 4 4 1 1
G501 G502 G501 G502 G401 G202 G401 G202 G604 G602 G602 G602
[G202] [G401] [G202] [G401] [G604] [G604]
Taillight Replacement
1. Open the tailgate and remove the maintenance lid.
2. Disconnect the connectors (A) from the taillights (B).
3. Remove the mounting nuts from the taillight.
4. Install the taillight in the reverse order of removal.
Interior Lights Circuit Diagram
BATTERY TERMINAL
FUSE BOX UNDER-DASH FUSE/RELAY BOX
BATTERY
No. 1 (100 A) T-9 No. 1 (10 A) C37
WHT PNK
G5
PNK
(8 W)
(8 W) (8 W)
BLU PUR
MICU
LEFT REAR RIGHT REAR FRONT DRIVER'S LEFT REAR RIGHT REAR 2 TAILGATE
DOOR SWITCH DOOR SWITCH PASSENGER'S DOOR SWITCH DOOR SWITCH DOOR SWITCH LATCH SWITCH
(Closed: (Closed: DOOR SWITCH (Closed: (Closed: (Closed: (Closed:
Door open) Door open) (Closed: Door open) Door open) Door open) Tailgate open)
Door open)
BLK
G602
(Without security) (With security)
Mirrors Component Location Index
MOUNT
POWER MIRROR
Replacement,
SKULL CAP
MIRROR HOLDER
Replacement,
REARVIEW MIRROR
Replacement,
Rearview Mirror Replacement
1. Release the hooks (A), then pull the mirror base cover (B) down.
2. Pull the hook (A) down to release it from the mount (B), and slide the mirror base (C) rearward, then remove the
rearview mirror (D).
3. Install the mirror base cover on the mirror base securely.
4. Fit the mirror base (A) over the mount (B), and secure the rearview mirror with the spring (C) and hook (D).
MICS Self-diagnostic Function
NOTE: Use only if the HDS is unavailable.
Test Mode 1
Special Tools Required
MPCS short connector
07WAZ-0010100
1. Turn the ignition switch to LOCK (0).
2. RHD model: Remove the fuse lid panel, and remove the driver's dashboard lower cover. LHD
model: Remove the fuse lid panel.
3. Check the No. 1 (10 A) fuse in the under-dash fuse/relay box and the No. 22 (7.5 A) fuse in the
under-dash fuse/relay box. If the fuse is blown, find and correct the cause, then replace the
fuse.
4. Turn the ceiling light switch in ‘‘DOOR'' (middle) position. Close all doors. Turn the ignition
switch to ON (II).
NOTE: If the driver's seat belt is unbuckled, the beeper will beep.
5. Connect the MPCS short connector (A) to the MICU service check connector (B), and turn the
switch (C) on.
6. After 5 seconds, the ceiling light should come on for 2 seconds, go out, then blink once for 0.2
second. This means that you are in Test Mode 1 of the self-diagnostic function.
7. About 1 second after step 5, the ceiling light will blink and indicate the DTC, and repeat it every
3 seconds. If there is more than one DTC, the system will indicate them in ascending order,
beginning from the DTC with the lowest numerical value. Troubleshoot the DTCs as indicated
below:
DTC Cause and Troubleshooting
1 The MICU cannot receive signals sent from the MICU itself (for checking the
sending signals), or the MICU cannot receive signals from the gauge control
module. If DTC 1 only indicates, substitute a known-good gauge control
module and an MICU one at a time, in that order, and recheck for the DTC
after each substitution.
5 The MICU cannot receive signals (VSP/NE message) from the gauge
control module. If DTC 5 only indicates, substitute a known-good gauge
control module, and recheck for the DTC.
*: With security
[ ]: LHD model
: CAN line
: Other communication line
BATTERY TERMINAL
FUSE BOX UNDER-DASH FUSE/RELAY BOX UNDER-DASH FUSE/RELAY BOX
BATTERY
No. 1 (100 A) T-9 No. 1 (10 A)
WHT
PNK PNK
BLU BLU BLU BLU
GRN GRN
LT BLU PNK [LT BLU] RED PNK BLU [LT BLU] PNK BLU PNK PUR BLU PUR BLU PUR BLU WHT PUR BLU
BRN/YEL
Before Troubleshooting
Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will
damage the alternator diodes.
Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely
damage the wiring.
Handling Connectors
Make sure the connectors are clean and have no loose wire terminals.
Make sure multiple cavity connectors are packed with dielectric grease (except watertight connectors).
All connectors have push-down release type locks (A).
Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another
component. This clip has a pull type lock.
Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector
from its mount bracket (A).
Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead.
Always reinstall plastic covers.
Before connecting connectors, make sure the terminals (A) are in place and not bent.
The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is
contaminated, replace it.
Insert the connector all the way and make sure it is securely locked.
Position wires so that the open end of the cover faces down.
Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations.
Remove clips carefully; don't damage their locks (A).
After installing harness clips, make sure the harness doesn't interfere with any moving parts.
Keep wire harnesses away from exhaust components and other hot parts, from sharp edges of brackets and holes,
and from exposed screws and bolts.
Seat grommets in their grooves properly (A). Do not leave grommets distorted (B).
Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with
electrical tape.
Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage is SRS wiring or terminals,
replace the harness.
After installing parts, make sure that no wires are pinched under them.
When using electrical test equipment, follow the manufacturer's instructions and those described in this manual.
If possible, insert the probe of the tester from the wire side (except waterproof connector).
Five-step Troubleshooting
1. Verify The Complaint:
Turn on all the components in the problem circuit to verify the customer complaint. Note the symptoms. Do not
begin disassembly or testing until you have narrowed down the problem area.
2. Analyze The Schematic:
Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current
paths from the power feed through the circuit components to ground. If several circuits fail at the same time, the
fuse or a ground is a likely cause.
Based on the symptoms and your understanding of the circuit operation, identify one or more possible causes of
the problem.
3. Isolate The Problem By Testing The Circuit:
Make circuit tests to check the diagnosis you made in Step 2 . Keep in mind that a logical, simple procedure is the
key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are
easily accessible.
4. Fix The Problem:
Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures.
5. Make Sure The Circuit Works:
Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the
problem was a blown fuse, be sure to test all of the circuits on the fuse. Make sure no new problems turn up and
the original problem does not recur.
The wire insulation has one color or one color with another color stripe. The second color is the stripe.
Troubleshoot the B-CAN Circuit Related Problems
How to check for DTCs with the HDS (preferred method)
The HDS can check the F-CAN and B-CAN communication status, read and clear the DTCs, display
the data list, and perform function test.
Check for DTCs
1. Connect the HDS to the data link connector (A) located under the driver's side of the dashboard.
2. Turn the ignition switch to ON (II).
3. Make sure the HDS communicates with vehicle.
NOTE: If the HDS does not communicate with the vehicle, troubleshoot the DLC circuit.
4. Select the BODY ELECTRICAL, then select the desired TEST MODE menu, and check the
DTCs. If the DTCs do not pertain to the select menu, select the All DTC Check icon to view all
Body DTCs.
NOTE: For specific operations, refer to the HDS user's manual.
5. If any DTCs are indicated, go to the indicated DTCs troubleshooting.
NOTE: If the DTC B1000, B1150, B1178, and/or B1900 are stored, troubleshoot these DTCs first
(beginning with the lowest number).
How to check for DTCs without the HDS (Use only if the HDS is unavailable)
Special Tools Required
MPCS short connector
07WAZ-0010100
If the HDS is unavailable, using the following method, you can check the B-CAN communication
status, DTCs, and some F-CAN communication status related with the gauge control module.
3. After 5 to 10 seconds, the DTCs which have been detected and stored individually by various B-
CAN unit, will be indicated one by one on the odo/trip display if the communication line between
the MICU and the gauge control module is OK. To scroll through the DTCs, press the
select/reset button.
The unit that has stored the code can be identified by the number shown on the odo/trip display.
Control Unit Control Unit I.D. Number
MICU 10
Gauge control module 50
Immobilizer-keyless control unit 96
NOTE: Also you can check the B-CAN communication status by following methods:
The MICU self-diagnostic function Test Mode 1 and Test Mode 2 can check some
communication status and some switch circuits.
The gauge control module self-diagnostic function can check the communication status.
Input
System Menu Data List Data List Indication
Lighting Driver's Door Switch OFF/ON
Hazard Switch OFF/ON
Headlight Switch (OFF) OFF/ON
Headlight Switch (PARKING) OFF/ON
Headlight Switch (HEADLIGHT) OFF/ON
Headlight Switch (High Beam) OFF/ON
Headlight Switch (PASSING) OFF/ON
Turn Signal Switch (LEFT) OFF/ON
Turn Signal Switch (RIGHT) OFF/ON
Interior Light Command OFF/ON
Left Turn Signal Command OFF/ON
Right Turn Signal Command OFF/ON
Cargo Light Command OFF/ON
Headlight Command OFF/ON
Headlight High Beam Command OFF/ON
Parking Light Command OFF/ON
Input
System Menu Data List Data List Indication
Gauges Cruise Control Main Switch (ACC switch) OFF/ON
Cruise Control Set Switch OFF/ON
Cruise Control Resume Switch OFF/ON
Engine Oil Pressure Switch OFF/ON
Gauge Select/Reset Switch OFF/ON
Parking Brake Switch OFF/ON
Brake Fluid Level Switch OFF/ON
Select/Reset Switch OFF/ON
INFO Next Switch OFF/ON
Fuel Sending Unit Input 2 v
ABS Indicator OFF/ON
EBD Indicator (Electronic Brake Distribution) OFF/ON
Cruise Control Main Switch Indicator OFF/ON
MIL Indicator OFF/ON
Low Oil Pressure Indicator OFF/ON
Charging System Indicator OFF/ON
Cruise Main Switch ON Indicator OFF/ON
High Beam Indicator OFF/ON
Parking Light ON Indicator OFF/ON
Low Fuel Warning Indicator OFF/ON
Security Indicator OFF/ON
Seat Belt Indicator OFF/ON
Door Open Indicator OFF/ON
A/T Indicator OFF/ON
SRS Indicator OFF/ON
Side Airbag Cutoff Indicator OFF/ON
Driver's Seat Belt Buckle Switch OFF/ON
A/T Gear Position Switch (R) OFF/ON
A/T Gear Position Switch (P) OFF/ON
Input
System Menu Data List Data List Indication
Door Locks Driver's Door Switch OFF/ON
Front Passenger's Door Switch OFF/ON
Driver's Rear Door Switch OFF/ON
System Menu Data List Data List Indication
Passenger's Rear Door Switch OFF/ON
Front Passenger's Door Lock Knob Switch (UNLOCK) OFF/ON
Driver's Rear Door Lock Knob Switch (UNLOCK) OFF/ON
Passenger's Rear Door Lock Knob Switch (UNLOCK) OFF/ON
Driver's Door Key Cylinder Switch (LOCK) OFF/ON
Driver's Door Key Cylinder Switch (UNLOCK) OFF/ON
Driver's Door Lock Switch (LOCK) OFF/ON
Driver's Door Lock Switch (UNLOCK) OFF/ON
Driver's Door Lock Knob Switch (LOCK) OFF/ON
Driver's Door Lock Knob Switch (UNLOCK) OFF/ON
Door LOCK Command OFF/ON
Door UNLOCK Command OFF/ON
Wipers Brake Pedal Position Switch OFF/ON
Windshield Wiper Switch (LOW) OFF/ON
Windshield Wiper Switch (HIGH) OFF/ON
Windshield Wiper Switch (MIST) OFF/ON
Windshield Wiper Switch (INT) OFF/ON
Windshield Washer Switch OFF/ON
Rear Wiper Switch ON/OFF
Windshield Wiper Motor PARK Switch OFF/ON
Rear Wiper Command ON/OFF
Rear Washer Command ON/OFF
Windshield Wiper Motor HI Command OFF/ON
Windshield Wiper Motor LO Command OFF/ON
Windshield Washer Motor Command OFF/ON
Rear Wiper Auto Stop Switch OFF/ON
Input
System Menu Data List Data List Indication
Keyless Driver's Door Switch OFF/ON
Front Passenger's Door Switch OFF/ON
Driver's Rear Door Switch OFF/ON
Passenger's Rear Door Switch OFF/ON
Trunk Lid/Tailgate Switch OFF/ON
Front Passenger's Door Lock Knob Switch (UNLOCK) OFF/ON
Driver's Rear Door Lock Knob Switch (UNLOCK) OFF/ON
Passenger's Rear Door Lock Knob Switch (UNLOCK) OFF/ON
Driver's Door Key Cylinder Switch (LOCK) OFF/ON
Input
System Menu Data List Data List Indication
Security Ignition Key Cylinder Switch OFF/ON
Driver's Door Switch OFF/ON
Front Passenger's Door Switch OFF/ON
Driver's Rear Door Switch OFF/ON
Passenger's Rear Door Switch OFF/ON
Trunk Lid/Tailgate Switch OFF/ON
Front Passenger's Door Lock Knob Switch (UNLOCK) OFF/ON
Driver's Rear Door Lock Knob Switch (UNLOCK) OFF/ON
Passenger's Rear Door Lock Knob Switch (UNLOCK) OFF/ON
Trunk Knob Switch (UNLOCK) OFF/ON
Hazard Switch OFF/ON
Hood Switch OFF/ON
Driver's Door Key Cylinder Switch (LOCK) OFF/ON
Driver's Door Key Cylinder Switch (UNLOCK) OFF/ON
Driver's Door Lock Switch (LOCK) OFF/ON
Driver's Door Lock Switch (UNLOCK) OFF/ON
Driver's Door Lock Knob Switch (LOCK) OFF/ON
Driver's Door Lock Knob Switch (UNLOCK) OFF/ON
Door LOCK Command OFF/ON
Door UNLOCK Command OFF/ON
Security Hazard Signal Command OFF/ON
Headlight Command OFF/ON
Headlight High Beam Command OFF/ON
Parking Light Command OFF/ON
Horn Command ON/OFF
A/C A/C Pressure Switch/Thermal Protector OFF/ON
Output
System Menu HDS Description Note
Door locks LOCK all doors Outputs LOCK signal 1 time (0.6 sec) to all
door
UNLOCK all doors Outputs UNLOCK signal 1 time (0.6 sec) to
all door
Lighting Interior Light Command Illuminates for 30 seconds
Hazard flasher Blinks turn signal (left and right) for 15
seconds
LEFT Turn Signal Command Blinks for 5 seconds
RIGHT Turn Signal Command Blinks for 5 seconds
Headlight Command Operates headlight (low) for 15 seconds
Headlight HIGH Beam Command Operates headlight (high) for 15 seconds
Parking Light Command Operates small lights for 15 seconds
Cargo Area Light Illuminates for 30 seconds
Security Horn Command Operates horn for 1 second
Wipers/washers Windshield Wiper Motor LOW Command Operates windshield wiper for 5 seconds (low
speed)
Windshield Wiper Motor HIGH Command Operates windshield wiper for 5 seconds
(high speed)
Windshield Washer Command Operates windshield washer for 5 seconds
Rear window washer motor command Operates for 5 seconds
Rear Wiper motor Operates for 5 seconds
Loss of Communication DTC cross-reference chart
When an ECU is unable to communicate with the other ECUs on the CAN circuit, the other control units will set loss of
communication DTCs. Use this chart to find the control unit that is not communicating.
1. Find the Transmitting Control Unit that is in the same row as all of the loss of communication DTCs retrieved.
2. Perform the input test for the transmitting control unit.
POWER WINDOW
RELAY (P/W)
BLOWER MOTOR
RELAY
Normally-open type
Check for continuity between the terminals:
There should be continuity between the No. 1 and No. 2 terminals when battery power is connected to the No. 4
terminal, and body ground is connected to the No. 3 terminal.
There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected.
Under-dash Fuse/Relay Box Connector Locations
3 4 5 6
7
2 8
1 9
10
20
11
12
13
14
19
18 17 16 15
22 23
21
24
31 25
26
30
27
29
28
(view of back side)
Ground Circuit Identification
BLK B Battery
RHD model
*1: RHD model
BRN E No. 1 ignition coil *2: LHD model
G1
RHD model No. 2 ignition coil
BLK C No. 3 ignition
Engine mount coil
bracket
No. 4 ignition coil
ECM/PCM (PG2)
LHD model BLK I
ECM/PCM (PG2)
G2 Rocker arm oil control solenoid
BLK D
BRN/YEL E Transmission
ECM/PCM (LG2)mount bracket
LHD model
G201 BLK I Right side turn signal light (fender type)
BLK E ECM (PG1)
G3 BLK I Brake fluid level switch
BLK E BLK E PCM (PG1)
BLK J Steering gearheadlight
box
BLK I Right
BLK E BLK F Transmission range switch
BLK I Hood switch (with security)
BLK
BLK K
BLK
K I Ignition key switch
MICURadiator
(SG) fan motor *: RHD model
G301 BRN/YEL E
BLK MBLK J Left front
Right brake position light
light/taillight *: RHD model
BLK
BLK KK Steering wheel
Radiator
Databack-up
Right link switches
fan motor
connector
light (DLC)
BLK BLK
K I (Via cable
Audio reel)
unitcondenser
A/C fan motor
G401 BLK
BLKMK
BLK BLK
K J Steering
Leftwheel
Fuelrear
Right pump turn switches
frontsignal
turn signal
light light
BLK J (ILLMI)Windshield
(Via cable reel)*
wiper motor
Left headlight
BLK K BLK K BRN/YELBLK
E O Front ECM/PCM (LG1) rear/left rear power window motors
passenger's/right
A/C switch
BLK BLK
J J (Via
Left power
front windowlight
A/C position
condenser main
fan switch)
motor
BLK M BLK N Right license plate light
Power
Left window
license platemaster
light switch
G202 BLK K HeaterCKP fan switch
BRN/YEL E BRN H High sensorlight
BLK K BLK J BLK O Left mount
Driver's
frontdoor brake
turn lock knob
signal switch/
light
key window
Rear
Left cylinder switch
side turndefogger (−) terminal
signal light (fender type)
G503 BLK K Heater
Tailgate control
latchside
Right [Left] panel
switch light
turn signal light (mirror type)
BRN/YEL E CMP sensor
BLK KBLK I Rear
Powerwindow
ABS
mirror wiper motor
modulator-control
switch unit (GND)
G202 BLK IJ Clutch
ABS pedal position switch
modulator-control unit (GND) *1
BLK K Audio
(M/T with unit
cruise control)
BLK K SRS unit (VA)
BLK K MICU (PG)
JUNCTION
BLK M BLK T Rear center seat
CONNECTOR BLK BLK
BRN/YEL
K I E BRN J BRN K Parkrear link belt
Dataswitch
ABS
pin
buckle (DLC)
connector
modulator-control switch
unit (MR-GND)
(with seat belt reminder)*
Immobilizer-keyless control unit
BLK
BLK K
IK MICU
ABS (SG)
modulator-control
SRS unit (VB) unit (MR-GND)
BLK K A/T gear position indicator panel light
BLK M BLK U Ultrasonic sensor (with ultrasonic)
BLK K ELD
G203 BLK BLK
K J Hazard EPS controlswitch
warning unit *2
UNDER-DASH
G401 FUSE/RELAY BOX
G504 BLK K Rear window
Data linkdefogger switch
connector (DLC)
BRN K
(Internal connection)
G402 BLK K BlowerImmobilizer-keyless
motor relay control unit
G602
BLK K Rear window defogger switch (ILLMI)
BLK M Driver's seat belt buckle switch
BLK J EPS
Rearcontrol unitbelt buckle switch
right seat
BLK U Front
(withpassenger's
rear seat seat
belt belt buckle switch
reminder)*
I BLK BRN/YEL
: Right engine compartment wire harness K E Accessory
(with power
passenger's socket
seat belt reminder)*
G301
BLK M BLK Q Rear leftrear
Right seatdoor
belt buckle switch
lock knob switch
BLK K BLK P (with
Leftrear
(with seatside
belt turn
security)*
[Right] reminder)*
signal light (mirror type)
BLK U BLK U Front passenger's seat belt sitting
Front passenger's door lock knob switch
switch (with security)
G501 Secondary HO2S WHT/RED E (with passenger's
ECM/PCM seat belt reminder)*
G402
(Sensor 2)
G101 BLK I Right side turn signal light (fender type)
G601 BLK
Knock U
sensor BLK V RED/BLU E OPDS unit (with side airbag)
ECM/PCM
G603
K : Dashboard wire harness M : Floor wire harness Q : Right rear door wire harness
G302
I : Right engine compartment wire harness BLK
J : MLeft engine compartment wire harness Left brake light/taillight
Left back-up light
I : Right engine compartment wire harness
G604
M : Floor wire harness N : Tailgate wire harness R : Left rear door wire harness
A No. 1 (100 A)
UNDER-DASH FUSE/RELAY BOX BLK Alternator
G1 B
No. MULTI
2 (60 A)FUSE/RELAY
UNDER-DASH FUSE BLOCKBOX
WHT EPS control unit
C
No. 25 (NotNo. 60 (IGN) (50 A)
used)
UNDER-DASH FUSE/RELAY BOX WHT 2 [ ]: LHD model
IGNITION SWITCH
No. 3 (30 A)*1 (20 A)*2
D 1
WHT UNDER-DASH FUSE/RELAY BOX
No. 60 (IGN) (50 A) UNDER-DASH FUSE/RELAY BOX [ ]: LHD model
FUSE No. 60 (AMT) (40 A) IGNITION
No. 30 (30 A) *1: A/T
(UNDER-DASH COIL RELAY
FUSE/RELAY BOX) E LT BLU 3 Radiator fan relay*2: M/T
POWER WINDOW
UNDER-DASH FUSE/RELAYRELAYNo.BOX
PGM-FI 28 (Not
(P/W) H
WHTuesd)
2 UNDER-DASH FUSE/RELAY BOX
MAIN RELAY1
(FI-MAIN) (Internal connection)
No.
No.43 (7.5A)A)
1 (10 MICU (P/W RLY)
No. 39 (15 A) FUSE/RELAY BOX
UNDER-DASH (Internal connection) *1: With trailer lighting connector
No. 27 LT GRN 4MICU A/C
(+B compressor
BACK clutch relay
IGNITION SWITCH (30 A) BLU *2: Without
ECM/PCM trailerUP)
(MRLY) lighting connector
WHT *3: LHD model
F
[ ]: LHD model
No. 10OFF
(7.5 A) MICU [ ]: LHD model
No. 47 (30 A) LT GRN LT GRN ECM/PCM (IGP)
FUSE G No. 37 (ABS FSR) (30 A) (With ultrasonic)
(UNDER-DASH RED 5 A/C condenser fan relay
WHT ABS modulator-control unit (FSR +B)
FUSE/RELAY PNK YEL/BLK YEL CKP sensor
ACCBOX) No.MICU
35 (15 A) Alarm control siren
No. 11 (7.5 A) LT BLU Front passenger's door lock actuator
No. 43 (7.5 A) 6 YEL/BLK Ultrasonic
sensorsensor
CMPmodulator-control
No. 20 (15 A) No. 10
AUXILIARY UNDER-HOOD RELAY (7.5 A) BOX PUR ABS unit (IG1)
FUSE BAT IG2 FUSE No. 58 (ABS MTR) (30 A) BRN No. 1 injector
(UNDER-DASH ORN
No. 45 (Not
(UNDER-DASH used) [PUR] Cargo 6area light
AUXILIARY UNDER-HOOD
LT
REDBLU Left
Windshield/rear
[Right]
ABS rear door window
modulator-control lock actuator
washer motor
FUSE/RELAY BOX)
IG1
No. 21 (15 A)
FUSE/RELAY BOX) PGM-FI DRIVE
LT
PURBLU No.
EPS 2control
injectorRELAY BOX unit (MTR +B)
unit (IG1)
BRN IGNITION Tailgate
No. 3 injector
lock actuator
YELNo. 17 (20 A) MAIN RELAY2
CIRCUIT
COIL RELAY PNK Individual map light
4 [PUR] L A/C COMPRESSOR
(FUELNo.
PUMP) No. 4 injector
36 (15 A) ORN Windshield/rear
Ceiling light master window washer motor
33 (15 A)CLUTCH RELAY
No.DRIVE BRN Power window switch
CIRCUIT PNK Driver's door lock actuator
ST GRY
BRN BLK/YEL ECM/PCM (IMOFPR)
No. 1 ignition coil
No. BRN A/C switch power window motor
No. 12
46 (10
(20 A)
A) 1 2 BRN WHT Front
No.A/Cpassenger's
2 ignition coil clutch
LT GRN Power
(Via sensor
front compressor
mirror switch
passenger's power window switch)
No. 1856
(20(30
A) A) YEL GRN YEL
PNK BLK/YEL MAF
Right
No.[Left]
Windshield rear
3 ignition door
wiper lock
coildefogger
motor actuator
(HI)relay
No. ORN Fuel Rear
pump window
DRIVE I J PNK
PUR Gauge
EVAP
Power
Fuel canister
control
No.lidwindow
4 actuator
ignitionpurge
module
coilvalve
master switch
PNK RED CIRCUIT Audio Rear
Secondary window defogger switch
unit HO2S
No. 10 (7.5 A) FUSE No. 49 (15 A) indicatorwiper
lightmotor (LO)
No. 5 (10(UNDER-DASH
A) BLOWER REAR PURBLU Windshield
Immobilizer-keyless
Alternator
Right rear power control
window unit
motor
FUSE FUSE/RELAY BOX) 4 ELECTRONIC3 HMOTOR WINDOWYEL YEL BRN Front
(Via
ECM/PCM
Datarightpassenger's
link rear
(BKSWNC)
power
connector door lock actuator
window
(DLC) switch)
8 BRN9 No. 19 (20 A)
No. 47 (30 A) (UNDER-DASH
[PUR] THROTTLE RELAY DEFOGGER PNK ECM/PCM (ACC)
(Via brake pedal position switch)
FUSE FUSE/RELAY BOX) J CONTROL SYSTEM RELAY RED Power window master switch
(ETCS) ECM/PCM (MRLY)
REAR WINDOW YEL Left [Right] rear door lock actuator
3 (30 A)*1 (20 A)*
(UNDER-DASH
No. · 2UNDER-DASH UNDER-DASH No. 16 (10 A)
FUSE/RELAY BOX) FUSE/RELAY
FUSE K
FUSE/RELAY No. 10 (7.5 A)CONTROL
FUSE
DEFOGGER RELAY
RELAY RED Left rear
Tailgate
Rear lock
windowpower actuator
window
wiper motor motor
(UNDER-DASH A/F SENSOR RELAY PUR
(BATTERY TERMINALBOX*1 BRN
No. 22 (7.5 BOX No.FUSE/RELAY
26 (10 A) BOX)
(Via left rear power window switch)
FUSE 5 A) FUSE
BOX) [PUR]
· STARTER* 2 No. 20 (15 A) A/C CONDENSERused)
No. 15 (Not
No. 50 (15 A) PUR
RED Rear window
ECM/PCM defogger switch
(ETCSRLY)
(UNDER-DASH No. 29 ORN ECM/PCM
Driver's door (SUBRLY)
FUSE/RELAY BOX) (10 A) I FAN RELAY
YEL
RED BLK/RED ECM/PCM (IG1)lock actuator
1 No. 52 (15 A)
DRIVE
7 2 1
CIRCUIT GRN
WHT WHT Back-up(IG1ETCS)
ECM/PCM light (A/T)
RED MICU
No. 59 (20 A) PUR
YEL WHT/BLK A/F A/C
Right sensor
[Left] rear doorfanlock actuator
No. 5 MOTOR
BLOWER (10 A) RED BLU condenser
Immobilizer-keyless motor
control
Trailer lighting connector* 1
unit
No. 31 (Not used) RELAY Fuel lid actuator
LT GRN RED Back-up light (M/T)
WHT (Via back-up light switch)
No. 57 (30 A)
LIGHTING
LT BLU No.RELAY1
23 (10 A) L TURN SIGNAL/ GRY Right front position light
WHT Blower motor
4 HAZARD3
BRN WARNING YEL(Internal connection) Hazard warning switch
No. 30 (30 A) [PUR] PGM-FI BLU Rear
MICUwindow defogger
No. 2DRIVE
(10 A) CIRCUIT GRY Left front position light
FUSE MAIN
(UNDER-DASH CIRCUIT RELAY2No. 32 (10 A)
FUSE/RELAY BOX) K PNK
BLK Right headlight (LO)
No. 5424
No. (Not
(15used)
A) GRY Right taillight
3 No.
RADIATOR
ELD 34 (10 A)
HORN Left taillight
No.
No.22 (7.5A)A)
3 (20 CIRCUITMICU GRN HORN (Low)
FAN RELAY BRN Left
Rightheadlight (LO) light
license plate
No. 40 (Not used) LT GRN 7 HORN ELD (High)* 3
GRY Power
Left license
windowplate
master (With
light security)
switch
LIGHTING G501
1 [2]
IGNITION SWITCH
LT BLU No. 55 (Not2 [1]
RELAY2 used) PNK RED ECM/PCM
Radiator
Security (ELD)
horn fan motor
(ACC) Gauge control module
(Internal connection) Shift lock solenoid
9BLK G No. 4 (Not used) WHT(Internal connection) MICU
No. 41 (Not used) Horn
MICU relay
(IG1 METER)
[PUR]
No. 48 (10 A) Horn warning
(Low) (Via horn light
relay)
GRY Hazard switch
GRYBrake pedal Left headlight (HI) relay)*3
BRN A 4 3 position A/THorn
gear(Hi) (Via
position horn
indicator
IGNITION GRN switch ECM/PCM (FANC)
RED SWITCH [PUR] No. 51 (10 A) panel light (A/T)
(ST) G501
No. 42 (Not used) GRN
WHT LT GRN Right
Rightheadlight
brake (HI)
8 B No. 13 (20 A) GRY Steering wheellight
switch light
No. 6 (10 A) Left brake
Accessory light
power socketswitch light
No. 38 (Not used) PUR Rear window deffoger
PUR HighSRS unitbrake
mount (VB) light
No.14
No. 9 (20
(7.5A)A)
C (Internal connection) ECM/PCM (BKSW)
MICU (ACC)
PNK STARTER CUT
No. 7(ST
RELAY (10CUT)
A) (A/T)
No. 53
No.(Not uesd)
44 (7.5 A) PUR Key inter lock solenoid (A/T)
D BRN PCM (VBSOL)
PNK ORN LT GRN BLU/WHT Audio unit
Transmission range switch (N, P)
GRY Audio unit light
E No. 8 (7.5 A) A/C switch light
PNK HVAC control
WHT SRS unitunit
(VA)light
GRN BLK/WHT Starter
WHT GRN OPDS unit
(With side airbag/
side curtain airbag)
F
(M/T)
Fuse to Components Index - Under-dash Fuse/Relay Box
[ ]: LHD model
52 15 A ECM/PCM (IG1ETCS) (via electronic throttle control system (ETCS) control relay)
53 ——— Not used
54 ——— Not used
55 ——— Not used
56 30 A MICU (IG1 FR WIPER)
57 30 A Blower motor (via blower motor relay)
58 30 A ABS modulator-control unit (MTR)
59 20 A Rear window defogger (via rear window defogger relay)
60 (IGN)50 A Ignition switch
(AMT)40 A Not used
[ ]: LHD model
10
56 57 58 59
1 11
2 12 *
20 26 32 38
3 13
* 21 27 33 39
4 14 *
* 22 28 34 40* 44 48 52
5 15 * *
23 29 35 41 45 49 53
6 16 *
24 30 36 42* 46 50 54
7 17 * * *
25 31 37 43 47 51 55
8 18
9* 19
60
*: Not used
Roof Wire Harness, Reminder Wire Harness, and Ultrasonic Sensor Subharness Locations
8. Check for continuity between under-dash fuse/relay box connector C (49P) No. 25 terminal and body ground.
NOTE: The illustration shows the RHD model and the black portion shows the lock lever. The lock lever for LHD
model is shown as the dashed lines.
Is there continuity?
YES - Go to Step 9 .
NO - Repair an open in the wire between the MICU and the alarm control siren.■
9. Disconnect the jumper wire from the alarm control siren 6P connector.
10. Check for continuity between under-dash fuse/relay box connector C (49P) No. 25 terminal and body ground.
NOTE: The illustration shows the RHD model and the black portion shows the lock lever. The lock lever for LHD
model is shown as the dashed lines.
Is there continuity?
YES - Repair a short to ground in the wire between the MICU and the alarm control siren.■
NO - Faulty alarm control siren, replace it.■
DTC Troubleshooting: B1030
DTC B1030:
Ultrasonic System Malfunction
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Check for DTCs with the HDS.
Is DTC B1030 indicated?
YES - Faulty alarm control siren, replace it.■
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections.■
DTC Troubleshooting: B1031
DTC B1031:
Ultrasonic Sensor Malfunction
1. Clear the DTCs with the HDS.
2. Turn the ignition switch to LOCK (0), and then back to ON (II).
3. Check for DTCs with the HDS.
Is DTC B1031 indicated?
YES - Go to Step 4 .
NO - Intermittent failure, the system is OK at this time. Check for loose or poor connections.■
4. Do the ultrasonic sensor input test, and check power supply and ground for ultrasonic sensor.
Do all of the input tests prove OK?
YES - Go to Step 5 .
NO - If any input tests indicate a problem, find and correct them, then recheck the system■
5. Do the alarm control siren input test, and check power supply and ground for alarm control siren.
Do all of the input tests prove OK?
YES - Faulty alarm control siren, replace it.■
NO - If any input tests indicate a problem, find and correct them, then recheck the system.■
Brake System Symptom Troubleshooting - Rapid brake pad wear, vehicle vibration (after a long drive), or high, hard
brake pedal
Rapid brake pad wear, vehicle vibration (after a long drive), or high, hard brake pedal
NOTE: Make sure that the caliper pins are installed correctly.
Upper caliper pin B and lower caliper pin A are different. If the pins are installed in the wrong location, it will cause
vibration, uneven or rapid brake pad wear, and possibly uneven tyre wear. For proper caliper pin location.
1. Drive the vehicle until the brakes drag or until the pedal is high and hard. This can take 20 or more brake pedal
applications during an extended test-drive.
2. With the engine running, raise the vehicle on a lift, and spin all four wheels by hand.
Is there brake drag at any of the wheels?
YES - Go to Step 3 .
NO - Look for other causes of pad wear, high pedal, or vehicle vibration.■
3. Turn the ignition switch to LOCK (0), press the brake pedal several times to deplete the vacuum in the brake
booster, and then spin the wheels again to check for brake drag.
Is there brake drag at any of the wheels?
YES - Go to Step 4 .
NO - Replace the brake booster.
RHD model. ■
LHD model. ■
4. Without removing the brake lines, unbolt and separate the master cylinder from the booster, then spin the wheels
to check for brake drag.
Is there brake drag at any of the wheels?
YES - Go to Step 5 .
NO - Check the brake pedal position switch adjustment and pedal free play. ■
5. Loosen the hydraulic lines at the master cylinder, then spin the wheels to check for brake drag.
Is there brake drag at any of the wheels?
YES - Go to Step 6 .
NO - Check the master cylinder reservoir for contamination in the brake fluid. If you find contamination, flush
the entire brake system of all contaminated fluid. If the brake fluid is OK, replace the master cylinder.
RHD model. ■
LHD model. ■
6. Loosen the bleed screws at each caliper, then spin the wheels to check for brake drag.
Is there brake drag at any of the wheels?
YES - Check the master cylinder reservoir for contamination in the brake fluid. If you find contamination, flush
the entire brake system of all contaminated fluid. If the brake fluid is OK, disassemble and repair the
caliper on the wheel(s) with brake drag.■
NO - Look for and replace any damaged brake lines. If all brake lines are OK, replace the ABS modulator-
control unit. ■
Brake System Inspection and Test
Inspect the brake system components listed. Repair or replace any parts that are leaking or damaged.
Component Inspections:
Component Procedure Also check for
Master Cylinder Look for damage or signs of fluid leakage at: Bulging seal at reservoir cap. This is a sign
of fluid contamination.
Reservoir tank, subreservoir or master
cylinder body.
Lines, reservoir tank hose and grommets,
and their joints.
Between master cylinder and booster.
Brake Hoses Look for damage or signs of fluid leakage at: Bulging, twisted, or bent lines.
Line joints and banjo bolt connections.
Hoses and lines, also inspect for twisting or
damage.
Caliper Look for damage or signs of fluid leakage at: Seized or sticking caliper pins.
Piston seal.
Banjo bolt connections.
Bleed screw.
ABS Modulator-control Look for damage or signs of fluid leakage at:
Unit
Line joints.
Modulator-control unit.
SIDELEFT
AIRBAG CUTOFF
FRONT INDICATOR
IMPACT SENSOR
Replacement,
SRS INDICATOR
FRONT PASSENGER'S
AIRBAG
Replacement,
RIGHT SIDE IMPACT SENSOR
Disposal, (FIRST)
Replacement,
UNDER-DASH
BATTERY TAERMINAL FUSE/RELAY BOX
BATTERY FUSE BOX
No. 60 (IGN) (50 A)
*: Wire color may be substitued
for SRS circuits
C *1: With side airbag and
BAT No. 8 (7.5 A) 4 side curtain airbag
*: Wire color may: beCANsubstitued
line
IG1 for SRS circuits: Other communication line
3 *1: With side airbag and
FLOOR : Shielding
IGNITION SWITCH No. 6 (10 A) side curtain airbag
2 WIRE
HARNESS
No. 22 (7.5 A)
P (LHD) (RHD)
Q *1 FRONT FRONT
*1 8 PASSENGER'S DRIVER'S PASSENGER'S DRIVER'S
LT BLU FLOOR AIRBAG AIRBAG AIRBAG AIRBAG
INFLATOR
32P 32
WIRE INFLATOR INFLATOR INFLATOR
GAUGE CONTROL MODULE LEFT
LTSIDE
BLU HARNESS RIGHT SIDE
IMPACT WHT IMPACT
SENSOR 4 1 2 SENSOR
*1 (SECOND) 4P (SECOND)
OPDS
2P 2 JUNCTION 2P 1 UNIT 2
1 CONNECTOR 4P 4P
HARNESS 3 2 2 3
GRY* BLU GRN YEL BLK BLK *1
SIDE FRONT ORN* GRN* LT GRN* PUR*
AIRBAG SEAT BELT SRS
CUTOFF REMINDER INDICATOR 18P 7 1 12 17 LEFT SIDE CABLE CABLE
REEL RIGHT
SIDE
INDICATOR INDICATOR REEL
COMPULSORY CURTAIN CURTAIN LEFT SIDE RIGHT SIDE
TURNING-ON CIRCUIT PUR* WHT* AIRBAG AIRBAG AIRBAG AIRBAG
OPDS UNIT INFLATOR INFLATOR INFLATOR INFLATOR
LEFT SIDE RIGHT SIDE
DRIVE CIRCUIT IMPACT IMPACT
SENSORFAIL-SAFE
(FIRST) CIRCUIT DASHBOAD SENSOR (FIRST) 4P 4P 4P 4P
WIRE 3 2 3 2 2 3 2 3
HARNESS
4P 4P 3
MAIN3 CIRCUIT
2 4 1 2 1 4 2P 2P 2P 2P
OPDS FLOOR 2
LT BLU* 1 DASHBOAD
BRN* 2 1
YEL* ORN* 2 1 2 1
ORN* YEL*
DASHBOAD
BRN* LT BLU*
SENSOR WIRE WIRE WIRE
GRY* PNK* GRN* ORN* LT GRN* BRN* PUR* LT GRN* FLOOR HARNESS HARNESS
F-CAN TRANSCEIVER HARNESS
FLOOR WIRE RED* WHT* BLU* YEL*
WIRE G603 HARNESS
HARNESS 27 26
B 1 3 4 6 5 3 4 4 3
FLOOR 3 4 5 6
32P O FLOOR A A ORN* PUR* LT GRN* PNK*
30 29 WIRE 4P 4P 4P 4P WIRE
HARNESS 2 1 VB VA ODS RA1+ 1 RA1−
2 LA1+ HARNESS
LA1− LA1− LA1+ RA1− RA1+
WHT RED SRS SRS SRS UNIT SRS UNIT
CAN LO CAN HI GND1 GND2 K-LINE WEN LFS− LFS+ RFS− RFS+ FLBC FRBC RLBO RRBO RCBO
FLOOR FLOOR
A WIRE B WIRE 19RED* WHT* BLU* YEL*
16 17 28 29 18 31 36 37 38 39 21 16 18 17
HARNESS HARNESS
FLOOR FLOOR FLOOR BLU*
DASHBOAD DASHBOAD WIRE YEL* WIRE GRN* WIRE RED* WHT*
DASHBOAD
WIRE B 36RED* 37
WHT* BLK* BLK* WIRE BLU* RED* 38 39
WIRE BRN* RED* LT BLU* GRN* HARNESS 10
B
11 24HARNESS
25 6 7 HARNESS
8 9 2P
2
HARNESS HARNESS RIMINDER
HARNESS BLU WIRE
LBS1− LBS1+ RBS1− RBS1+ LCA1− LCA1+ RCA1− RCA1+ LSA− LSA+ RSA− RSA+
2 2 SRS UNIT 2 2 1 HARNESS
SRS UNIT 2 3 2P 2P 2P 2P 2P
LRP− LRP+ RRP− RRP+ SS+
4P 4P
B LEFT ENGINE 2 3
RIGHT ENGINE BLU BLU BLU BLU BLU
12 13 14 15 23
COMPARTMENT COMPARTMENT
FLOOR FLOOR WIRE WIRE REAR REAR REAR
LEFT SIDE RIGHT SIDE LEFT SIDE RIGHT SIDE CENTER
WIRE WIRE HARNESS HARNESS SEAT BELT SEAT BELT
HARNESS HARNESS BRN* RED* LT BLU* GRN* SEAT BELT SEAT BELT SEAT BELT
BUCKLE BUCKLE BUCKLE BUCKLE BUCKLE
SWITCH SWITCH SWITCH SWITCH SWITCH
JUNCTION JUNCTION 2 1 2 1 GRN GRN BLK BLK BLK
CONNECTOR
LT GRN*LT BLU* CONNECTOR
LT BLU* 2P 2P
BRN* PNK* 1
LEFT RIGHT 2P 2P 2P 2P 2P
FRONT FRONT 1 1 1 1
IMPACT IMPACT
BLU RED SENSOR
BLK SENSOR BLK BLK BLK BLK BLK
2 3 2 3 2 1
JUNCTION
4P 4P 3P
CONNECTOR
FRONT G603 G601 G603 G601 G602
DATA LINK PASSENGER'S
CONNECTOR SEAT SITTING G603
(DLC) SWITCH
LEFT SIDE RIGHT
G504 SIDE
SEAT BELT SEAT BELT (With front seat belt reminder) (With rear seat belt reminder)
(With front seat belt reminder)
TENSIONER TENSIONER
Side Impact Sensor (First) Replacement
Removal
1. Do the battery terminal disconnection procedure, then wait for 3 minutes before starting work.
2. Remove the front seat assembly.
3. Remove the center pillar lower trim:
Without side curtain airbag
With side curtain airbag
4. Disconnect the floor wire harness 4P connector (A) from the side impact sensor (first) (B).
5. Using a TORX T30 bit, remove the TORX bolt (C), then remove the side impact sensor (first).
Installation
1. Install the side impact sensor (first) with a new TORX bolt (A), then connect the floor wire harness 4P connector (B)
to the side impact sensor (first) (C).
2. Do the battery terminal reconnection procedure.
3. After installing the side impact sensor (first) confirm proper system operation: Turn the ignition switch to ON (II); the
SRS indicator should come on for 6 seconds and then go off.
4. Reinstall all removed parts.
Audio System Error Codes
The audio system displays error codes when a problem is detected with the disc player or the disc.
CD Error Codes
Error Code Possible Cause Solution
Displayed
CD Track/File format not supported. Current track will skipped. The next supported track or
UNSUPPORTED file plays automatically.
Verify that CD file names end in CDA.
Verify that CD-R or CD-RW with compressed
music formats end in MP3 or WMA.
Other file formats like i-Tunes (AAC) or Ogg are
not recognized.
WMA files may have (DRM) copy protection
and cannot be read.
BAD DISC/PLEASE CD label jammed in the mechanism. Eject CD and insert a known-good CD.
CHECK/OWNERS The wrong type disc is inserted. If flashing the PUSH EJECT, press the EJECT
MANUAL/PUSH CD eject mechanism or motor is button and hold it for 5 seconds. If the disc
EJECT inoperative. does not eject, try again. If the disc still won′t
CD spindle motor won′t spin up the eject, replace the unit.
CD.
HEAT ERROR Disc player is hot. This error can happen if Park the vehicle in a cooler place for a while and play
the vehicle is parked out in the hot sun all the disc again. If the error code is still present, try
day. another disc. If the error code is still present, replace
the audio unit.
Audio System Component Location Index
AUDIO UNIT
Connector Inputs and Outputs,
Removal/Installation,
AM/FM ANTENNA LEAD
AM/FM ANTENNA SUBLEAD
RIGHT FRONT
DOOR SPEAKER
Test/Replacement,
AUDIO REMOTE
SWITCH
Test,
No. 1 (10 A)
(W ith security
system)
MICU
3
AM/FM
M23 Q2 N1 M18 ANTE NNA
BLU
AM/FM ANTE NNA LE AD
AUDIO UNIT
FR FR FR FR RR RR RR RR
GND ILL− L+ L− R+ R− L+ L− R+ R−
BLK BLK
LT BLU LT GRN BRN RE D GRY BRN BLU ORN
2 1 2 1 2 1 2 1
G503 G502
Audio System Circuit Diagram - With Audio
With Audio
No. 1 (10 A)
(With security
system)
3 2 1 2 1 2 1 2 1
AM/FM
M23 Q2 N1 M18 ANTENNA
ECM/PCM
No. 29 (10 A) FUSE BLU LT BLU LT GRN BRN RED GRY BRN BLU ORN
2 1 VSS OUT
(In the under-dash
fuse/relay box) A30
BLU
AM/FM ANTENNA LEAD
BLU
GRY GRN DATA LINK BLU PNK PUR AM/FM ANTENNA SUBLEAD
CONNECTOR
(DLC)
A13 A4 A3 A24 A14 D3 D2 D1 A15 A23 A22 A19 A18 A11 A10 A7 A6
ILL+ SCTY K-LINE +B ACC ANT+B RF SH RF IN VSS OUT FR FR FR FR RR RR RR RR
L+ L− R+ R− L+ L− R+ R−
9 10 8 CABLE REEL 7 YEL GRN WHT LT BLU BRN RED ORN BLU BLK
GRY* PNK*
4 3 5 6
A3 A9 A10 A4 A6 A14 A5 A13 A1 A2 A11
BLK GRY BLK GRN RED/BLK GRN/RED BRN GA-NET GA-NET GA-NET GA-NET GA-NET GA-NET GA-NET GA-NET GA-NET SYS GA-NET
BUS SH BUS+ BUS− AUDIO AUDIO AUDIO AUDIO AUDIO +B ACC GND
AUDIO REMOTE SWITCH SH L+ L− R+ R−
USB ADAPTER UNIT
USB USB USB USB USB
SH VBUS DATA− DATA+ GND
100 Ω
270 Ω 470 Ω 1.2 kΩ 3.9 kΩ 10 kΩ B5 B1 B2 B3 B4
No. 29 (10 A) FUSE
(In the under-dash
fuse/relay box) VOL VOL
DOWN UP CH CH MODE
( ) ( ) (−) (+)
5 1 2 3 4
USB ADAPTER
G503 G501
10. Measure the resistance between No. 36 terminal of SRS unit connector B (39P) and body ground, and between the
No. 37 terminal and body ground. There should be an open circuit or at least 1 MΩ.
Is the resistance as specified?
YES - Go to Step 11 .
NO - Short to ground in the floor wire harness; replace the floor wire harness.■
11. Do the battery terminal reconnection procedure.
12. Turn the ignition switch to ON (II).
13. Measure the voltage between No. 36 terminal of SRS unit connector B (39P) and body ground, and between the
No. 37 terminal and body ground. There should be less than 1.0 V.
Is the voltage as specified?
YES - Go to Step 14 .
NO - Short to power in the floor wire harness; replace the floor wire harness.■
14. Turn the ignition switch to LOCK (0).
15. Measure the resistance between the No. 2 terminal of the floor wire harness 4P connector and the No. 37 terminal
of the SRS unit connector B (39P), and between the No. 3 terminal of the floor wire harness 4P connector and the
No. 36 terminal of the SRS unit connector B (39P). There should be 0−1.0 Ω.
Is the resistance as specified?
YES - Go to Step 16 .
NO - Open in the floor wire harness; replace the floor wire harness.■
16. Substitute a known-good left side impact sensor (first) and recheck.
17. Connect SRS unit connector B (39P) to the SRS unit.
18. Clear the DTC memory.
19. Turn the ignition switch to ON (II), then wait for 10 seconds.
20. Read the DTC.
Is DTC 43-11 indicated?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Faulty left side impact sensor (first); replace the left side impact sensor (first). ■
SRS DTC Troubleshooting: 44-11
DTC 44-11:
No Signal From the Right Side Impact Sensor (first)
NOTE:
Before doing this troubleshooting procedure, review SRS Precautions and Procedures and General Troubleshooting
Information.
Before replacing the SRS unit, check the SRS unit software version with the HDS. If the software version is not the
latest, update the SRS unit software and retest.
1. Clear the DTC memory.
2. Turn the ignition switch to ON (II), then wait for 10 seconds.
3. Read the DTC.
Is DTC 44-11 indicated?
YES - If DTC 44-11 is indicated alone, go to Step 4 .
If DTC 44-11 and 46-11 are indicated, faulty right side impact sensor (first); replace the right side
impact sensor (first). ■
NO - Intermittent failure, the system is OK at this time. Go to Troubleshooting Intermittent Failures. If another
DTC is indicated, troubleshoot the DTC.
4. Turn the ignition switch to LOCK (0).
5. Do the battery terminal disconnection procedure, then wait for 3 minutes.
6. Check the connections between SRS unit connector B (39P) and the SRS unit, between the floor wire harness 4P
connector and the right side impact sensor (first), and at floor wire harness 4P connector.
Are the connections OK?
YES - Go to Step 7 .
NO - Repair the poor connections and retest.
7. Disconnect SRS unit connector B (39P) from the SRS unit.
8. Disconnect the floor wire harness 4P connector from the right side impact sensor (first).
9. Measure the resistance between the No. 38 and No. 39 terminals of SRS unit connector B (39P). There should be
an open circuit or at least 1 MΩ.
Is the resistance as specified?
YES - Go to Step 10 .
NO - Short in the floor wire harness; replace the floor wire harness.■
10. Measure the resistance between No. 38 terminal of SRS unit connector B (39P) and body ground, and between the
No. 39 terminal and body ground. There should be an open circuit at least 1 MΩ.
Is the resistance as specified?
YES - Go to Step 11 .
NO - Short to ground in the floor wire harness; replace the floor wire harness.■
11. Do the battery terminal reconnection procedure.
12. Turn the ignition switch to ON (II).
13. Measure the voltage between No. 38 terminal of SRS unit connector B (39P) and body ground, and between the
No. 39 terminal and body ground. There should be less than 1.0 V.
Is the voltage as specified?
YES - Go to Step 14 .
NO - Short to power in the floor wire harness; replace the floor wire harness.■
14. Turn the ignition switch to LOCK (0).
15. Measure the resistance between the No. 2 terminal of the floor wire harness 4P connector and the No. 39 terminal
of the SRS unit connector B (39P), and between the No. 3 terminal of the floor wire harness 4P connector and the
No. 38 terminal of the SRS unit connector B (39P). There should be 0−1.0 Ω.
Is the resistance as specified?
YES - Go to Step 16 .
NO - Open in the floor wire harness; replace the floor wire harness.■
16. Substitute a known-good right side impact sensor (first) and recheck.
17. Connect SRS unit connector B (39P) to the SRS unit.
18. Clear the DTC memory.
19. Turn the ignition switch to ON (II), then wait for 10 seconds.
20. Read the DTC.
Is DTC 44-11 indicated?
YES - Faulty SRS unit; replace the SRS unit. ■
NO - Faulty right side impact sensor (first); replace the right side impact sensor (first). ■
Safety Messages
Safety Messages
Your safety, and the safety of others, is very important. To help you make informed decisions, we have provided safety
messages, and other safety information throughout this manual. Of course, it is not practical or possible to warn you
about all the hazards associated with servicing this vehicle. You must use your own good judgement.
You will find important safety information in a variety of forms including:
Safety Labels − on the vehicle.
Safety Messages − preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or
CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don't follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don't follow instructions.
You CAN be HURT if you don't follow instructions.
Heating/Air
A/T
Headlights,Headlight
Immobilizer
MICUGear
Charging
ECM/PCM
ECM/PCM,
Audio
Data
EPS, Position
Under−dash
GaugesSystem
Battery,
Power
ABS,
SRS VSA
Climate
Seat Conditioning
System,
System,
Heater
Link i−SHIFT
Windows,
Battery
Sunshade
Control, Indicator
Connector,
Wipers/Washers,
Cable Reel Ignition
Fuse/RelayLeveling
Box
Starting
Terminal
Power
RearECM/PCM Panel
Box, Key
System,
System,
Mirrors
Fuse
Window
Steering Light,
Switch,
Auxiliary
Box, FuelCombination
Interior
Door
Pump,
Under−dash
Defogger
Wheel Switches, Lock
Under−hoodLights,
HornsLight
Actuators,
Back
Relay
Fuse/Relay
Hazard WarningSwitch,
BoxupAccessory
Box Lights,
SwitchAutomatic
Brake
Power
Lighting
lights,
Socket,
Front
System,
Cigarette
Position
Turnlighter
Signal
Lights,Lights
Taillights, License Plate lights, Fog lights
A AA B BB
B CC
CC
C
18
16
19
13
14
15
17
21
22
24
20
23
11
10
12987654321 DRIVER'S *1 No.40 (20 A)*2
(M/T o r i− SHIF T system)
No.10 (25 A)*2
IG NIT IO N SW IT CH
RIG HT T URN
(W ith cru ise co n tro l)
RIG HT T URN
IG NIT IO N SW IT CH DO O R UNL O CK F RO NT SUPER REAR SUPER No . 1 (10 A) *1 No . 1 (10 A) A) *1 SIG NAL
OFF
INDICAT O R (17− D) SIG NAL L IG HTNo . 24 (15 A) *1
(ACC) F USE No . F23 ( 10A ) *1
USE FUSARD
HAZ E W ARNING No . 5 (10
T URN FUS E SIG NAL L IG HT SIG NAL L IG HT No . 12 (10 A) *1 INDICAT O R SIG NAL L IG HT
(2− B) REL AY L O CKING REL AY L O CKING REL AY F USE(1− B) IT CH (11− D) F USE SW IT CH (14−
(1−B)
SW (2−C)
B) No(14−. 10C) (7.5 A) *2 MICU (10− C) (14− D) F USE (14− C) F USE (10− C) (14− D)
(15− C) (15− C) (15− C) (1− B) (2− C) F USE (17− B) 201
(3− A)
(2− C) No . 1 (10 A) *2ACC (In tern al co n n ectio n ) (2− D) (3− A)
77BAT TUNDER− DASH 163 17 19 84 78 ·IMMO BIL IZ R− KEYL ESS 196 16 MICU90 (+ B BACK UP) (17− A)
ERY No . 10 (7.5 A) *2 161 162 107 33 143 110
(W ith o u t VSA) F USE/REL AY BO X F USE
(W ith VSA)
164 *1 165 166
CO NT RO L UNIT
*2 167 BAT 168 80 169 IG 2 170 171 No . 45172 (20A) *1 No . 10
173 (7.5 A) *2
174 167 168 169 · DRIVER'S 170 SEAT HEAT 171
ER SW IT CH(24− 172B) 173 174
(1− C) No . 60 (IG N)(15− (50A)A) AUXIL IARY COUNDER−
MBINATFHO IO NO LDIG HT SW IT CH
No . 20 (15A) *1 (2−No C) . 1 (10A) *1 G AUG E CO NT RL
MO DUL E BL K 1 ST ART ER (4− B) No . 14 (7.5A)
F USE F USE ·MICU 14 W HT*7 REL AY O RN BO X (1−
USE
B) BRN 78 · F RO NT PASSENG ER'S SEAT HEAT ER SW IT CH
T H: T HERMO ST AT F[O N:25− 35°C(77− 95°F )] F USE
USE
36 44°C(97− 111°F
[O FD)F :36−
(2− )] (1− B) 79 (8− B) (3− A) (1− A) (17− D) L T BL U*5 17 ·· INDIVIDUAL MAP L IG HT (13− A) (24− B)
No .RED
BR: BREAKER 34 (10A) *1[O N:25− 35°C(77− No . 48 95°F (10A))]*1 *2 No . 32 (10A) *1 No . 51 (10A) *1 No . 48 (15A) *1 No . 34 (10A) *1 No . 32 (15A) *1 No . 51 (10A) *1 IG 1
YEL PNK*6 30 CEIL ING L IG HT (13− A)
F USE [O F93 F USEBRN 129°F
F :46− 54°C(114− No . )]13 (20 18 A) F USE *1 139G RY F USE O RN F USE (In tern al F USE YEL BRN PNK 102 L T G RNL T G RN BRN BRN F USE 158 BLF USE
U BL U
BRN BL U G RN BL U W HTG RY W HT W HT W HT YEL(In tern al co W
n n ectio n )
HT BL U BL
79 W HT
U BL U W HT W HT W HT W HT ith SUNSHADE)
(W
No . 2 (60
(1− D) A) (1− D) GPUR (1− D) (1− D) A/C CO MPRESSO R · BL O W ER MO T O R REL AY (1− B)
BL K (1− D) (1− D)
No . 58 (30 A) *2 No . 37 (30 A) *2 No . 11 (7.5 A) *2 DAT A L INK AUG E CO NT RO L 100 · ACCESSO (1−RYD) POco WnER
A) *2 ERn
SO CKET
ectio n ) (30 (1−(15− D) D)
A) *2 (19− A) [PUR] A) *2 CL UT CH REL AY T URN SIG NAL SW IT CH L IG HT A LING INK SW CO IT CH O R (DL C) (5− D) · REAR W INDO W DEF O GMICU F RO NT /REAR F O G L IG HT SW IT CH
MO DUL E (8− W HT B) L T BL U*2 · CIG ARRET No .258L(30 IGEPS HT CO No NT
(15− . 37RO
D) L UNIT No . 11 (7.5ST
18 RAT· E− DAT NNECT G ER REL AY (2− A)
39
PNK F USE 41F USE F USE 38CO NNECT O R
L TD)BL U 42 F USE 48 PNKF USE 44 DIMMING 46 43 F USE G EAR SHIF TPNK YAW · G AUG L AT ERALE CO NT / LRO O NG L ITMO UDINAL
DUL E (8− C)
G AUG E
(17− C)
(1− A) (1− A) (2− C) (5− PNK*3 (1− A)*3 56(1− A)CL IMAT E*4CO NT RO L UNIT (22− B) (2− C) 1 CO NT RO L MO DUL (Climate E ACCEL ERAT IO NBIL SENSO R KEYL ESS CO NT RO L UNIT (15− CO NT RO L
(In tern al co n n ectio n ) (In tern al co n n ectio COnMPUL ) SO RY
PUR
(W ith CL IMAT E CO NT RO L )
ST EERING CIRCUIT ANG NoL. E43SENSO (7.5 A)R*2 27 No . 16 (10 A)2*2 co n tro l) · IMMO BLIZ U ER− MO A) DUL E No .1 (10A) *2 No .22 (7.5A) *2 L IG HT ING REL AY 1
6 4 89 137 138 7 5 MICU (17− B) F USE G RN *289 L TBRN G RN F USE MICU W HT · AUDIO UNIT 111
BRN(23− A/CA,MICU
CO (17− A) R CL UT CH (21−
B) MPRESSO
80 A) 200 F(3−
USE F USE
T URNING − O F F *2 BRN *2 HO RN *2 BL U (2−CAND) H CAN BLLU (17− B) BRN · HANDS F REE
[PUR]CAN LT EL EPHO NE
CAN H CO NT RO L AUXIL
UNIT IARY
(23− B) UNDER− HO O D REL AY BO XW(1−HTB)B) (2− D)
RED No .AUDIO14 (7.5
PNKUNIT A) *2 REAR
CIRCUIT
(23− WC) INDO W L
159 No . 3 (20(In
T G RN F USE
A)
tern al co n n ectio n )
No . 17 (20 A)
F USE MICU HVACREL AY CO NT RO L UNIT
G AUG
No . 19 (20 A)
F (21−
USE
EPUR D)
CO NT RO L MO DUL E (9− B)
(1− B)
G RY 10 V ST ABIL IZ
No . 18 (20 A)
ING
F USE MICU PCM (6− B) G AUG E CO NT RO L MO DUL E (9− A)
No . 10 (7.5 A )
F USE
(9− B) PUR 57 179 180n typ e)) 181 PNK 178 O AREA L IG HT4 (13− B) 177 21 20 99
G1 INDIVIDUAL DEF NoO. G
INDIVIDUAL 3G *1,*3
ER REL AY (1− B) 101CEIL (1−MICU
ING
D) (17− (ACC)C) (17− A) CARG(W (4− ithO C)HVACAREACO NT RO L(1− (Pu D)sh b u2tto 4 3 CIRCUIT 5 1(1− D) (17− C) RED 4
91
3 6 3PNK 9 E11 1 *2 19 CARG 5 *2 3 *2(2− C)
W IPER/W ASHER 217 SW1IT CH MAP L IG HT R18 MAP L IGCHT R7 P R R8 N2 L IG HT D D3 L IG HT 2 N5 DAT
Q 131A L INK M2 M6 (8− D) C13 B34 BRNM20 Q 142 No . A28 22 (7.5 A)C41 No . 1 (10 A) C13 B34 E7 M20 Q6 A28 C41
1 23(L ED) (L ED) W HT (L ED) 53 207 (L ED) 3 UNDER− (L1ED) DASH REAR F USE/REL
125 W INDO (L ED)W AY DEF BO XOCO (3−
G G(LA)
NNECT
ED)
55*4SW
ER
YEL OIT R CH (DL(22−C) C) *5 (i− SHIFGTRN System) 54 (i−[PUR]
SHIFGTRN 200
System)
G AUG E CO NT RO L HVAC129 co n tro l (lever typFe)USE PNK F130 USE 112 ECM/PCM (ACC) (6− A) L T G RN DIMMER140 L T G RN
No . 11 (7.5 A) *2 No . 2 (60 A) *1 ECM/PCM PUR PUR 58 (W ith HVAC CO NTHAZ RO(5− L (L C,D)
ever typ T e))URN146 T URN A PUR MO DUL E (8− B)
BL U (2− BL D)U BL K (1− B) BL U BL U BL K REAR
F USENo .59(20 A) *2,*11 F USE (NEP) 144 +B SW
ST ART ER
145 L SW *11 R SW ST AT ER T URN L BLWOHT W ER 2 LMOT BL
RED
TO UT RURN R 20 AUT O MAT IC L IG HT ING /RAIN T SENSO
URN W (W
LRithith
(14− · sid D)eW
PO airb
ERag
210/
MIRRO R SW IT CH (16− D)211 T URN R FOG
(5− A) REL e AY
airb(1− B)L EF T5 o u t sid e cu rtain airb ag ) L T BL U
(2− C)
(30 A) *2,*10
(1− A) PUR 102 · KEY INT ERL O CK SO L ENO HAZ ARD *7 CUT REL AY IG NIT IO N CUT REL AYBRN *6 (WPG ith
M− sid
F INDENSO ag )R 298
RIG HT 4 (W ith sid 18 e cu rtain airb ag ) MICU81(17− C)· A/C YEL
CH INDICAT O R*13 (21−
G RY 5 2 4 HI(W ith sid e airbPASSING ag an d sid e cu rtain airb ag )
ID*3 (15− B) (ST AT ER 2
A/C CO BRN () O F FSW IT
1· REAR W INDO W DEF O G G ER SW IT CH
C)
(8 W ) No . 1RED (100(8A)W*1) 89 2 No . 1 (100 A) *1 126 No BL . 12URED *2
(10 A)DRIVER'S (8 W ) · BRN AUDIO DRIVER'S UNIT (ACC) 59 (23− A,WREAR C) BL O W ER SW IT CH (ST ART ER [PUR] PNK
PNK PUR
137 138MAIN
F AN REL RELAY AY 2
No . 24 (10 A)*2 BRNO F F
3 BL O W ER
W HT PUR (8 W ) BL U F RO NT (8 W GW )RNHT ORED HT T G W INDO W DEF REL OG AY G ERRED
1) BRN(22− D) BACK− G RNUP (STL) IG L THTBL DRIVER'S
UPNK PUR REL BLAY 1)PUR No . 2 (10BRN
U DRIVER'S A) *2 (F UEL PUMP)31 A/T G EAR
OREDR REL AY W HT
RAIN FBRN AL L F USE(Po w er d o oGrRY lo cks 2 mo tio n ) PNK ECM/PCM (5− B) F USE
(W A/T
ith
BL su KGpEAR loPO
er AIRBAG ckin SIT g )IO N INDICAT AIRBAG R120
DRIVE
BRN AL TCIRCUITERNAT OBAT R (4− ERY RY MO T O R 153F RO NT
A) A) REL AY (3− A)PASSENG ER'S
159 (3−2A) PNK ECM/PCM PO SIT IOFNUSE · REAR F O MO LTIG 170 · INDICAT
171 O R L IG HT *13 (22− C) ( ) L T BL UMICU
(1− A) PASSENG ER'S (2− D) (1− SW IT CH(2− B) AIRBAG AIRBAG 2 RIG PNK HT (2− A)
1PNK
(1.4 W ) RIG 21 G
REL AY HT (13− D) (17− 3 C) REAR L O 3
SENSIT IVIT Y G RY
AIRBAG W ASH F IRST SECO ND W ASH (1− B) AIRBAG th e tran smissioF NonIRST. 47PNK (30 A) *2 LSECO
EF T ND (7− A) 2 L EF T SIDE INDICATHT SIDE O
(3−
R A) F EF
L ROTNTSIDE
L T· LBL
REAR (O F
UBrake
pOenG : RIG
L(IG )HTHTSIDE (13− D) · (O CL p en : E CO( NT ) RO L) AUT
BRAKE
O*14 (22− A,D) LSUPER
EF T L O CKING RIG HT
ADJUSTPNK ER*3 INF L AT OW R HT GBLRN U G RN(O n 75 28 BACK− UP *11 76 RED G RY BACK− 77UP BL K PUR L T BL U MICUBRN
AIRBAG AIRBAG
PANEL L IG HT BL WU HT CURT
SUPER
YEL AIN OAIRBAG
CKING 113(1− edC)alA/C
pCURT pAIN
ressed
CO AIRBAG)
NDENSO R F AN MO · Brake
T OIMAT
RO(21−pRNed
BLalA)Ureleased UNITPEDAL
90 INF L AT O RW ASH O RNINF L AT O R*10 O1RN INF
103 L AT O R(10A) oPUR
h*10 u sin g ) 76No . 12INF F USE L AT O R 104LINF L AT O R 131 L IG HT 68 INF L AT O R INF L AT 109 se:CO NT RO L UNIT *15PO
RED 208BRAKE
L O CK REL AY PNK BRAKE BL K
or 120O2FSW
W ASHER
1 121 4 122 123 BRNW ASH No
RED
4
. 53
(Clo sed :
(10A)
(1− B)
1
IGPURHT
No . No
2 .
(7.5A)3 (20 *5A) *2 (21W ) W HT L TO R BL U L O CK
INF LPNK
ATREL O RAY(Clo se: INF L AT O R
Brake 3 p ed al released DAT ) A L INK (Clo
HVAC
SW
SITD,22−
(21−
IT CH
IO N D) L IG HTYEL L EFSUNSHADE
T F RO NT MO TL OIG R HT/LCOEF T NTFRO ROLNT UNIT
O FTFINT O
L EF N
ERMIT TO ENTN F IT CH MIST BLU RIG HT HI ON O F F L EF T O F F O N (5 W ) 31 F USE
In R p o RIG sitioHT
F USE (21W ) *2 ECM (7− A)No . 14 (7.5 A) RED *2 23 25 AM/FCOM NNECT O R(16− A)Brake RECIRCUL p ed alAT p ressed
IO N CO ) NT RO L MO T O R*15 (21− D) (21 W ) T W EET ER (21
L IG WDO HT
) O ING SPEAKER
REL AY 2
O N IG HTO F1F LT GRN O N3No . 543 (20 A) *2 BLU 4GRN (1− D) n(2−) D) 1 F USE
UNDER− DASH1 MICU
No . 1 (10 G A)RY PO W ER W INDO W MAST ANT ER ENNA SW IT CH LT· RGRN VSA MO DUL AT O R− CO NT RO L
HEADL
PO WDW ERIGEL HT
WL INDOT1IME W MAST IG 1ER SWNT IT CH 3 +B HEADL B−O FF
CAN [4] HEADL [3] IG HT 2 3 20
HEADL IG HT 2 AUXIL IARY 3 (3− · B) UNDER− DASH4 F USE 6 3 F USE (5− D)
BL U DR LWEF HTT SIDEPO W ER MIRRO DR R SW IT CH 2 2
CO NT RO L8L ER*4UNL O CK
GSIL
AUG DRE CO RO
SILL DR MO DUL E OKC
BACK
FF
UP DR *3 WKC HT DR LO SILRED AS YEL SIL RA 59 REAR W INDO W DEF O G G RN G ER SIL D)
(22− RD HO UNDER−
OD DASH 15 F USE/REL PUR
BRNAY (17− SIL
F USE/REL
D)T /G AY (1−
W B)
HT 2 RED3RADIO No . (3− 15 A) (7.5 1A) *2 DR DR
IMPACT 3 L EF T SIDE 1 REM DR REM DR L EF T SIDE UNIT T /G *7(18− B)
L O CK UNL O CK 7 1 51 1 PNK 90 118 [PUR] SW RA SW RD SW AS SW DR UNL O CK IMPACT 2· IMO
SENSO SWBIL R IZ ER− KEYL ESS
CO NT RO L MO DUL EWAUT O LoOr CK UNL O CK UNL O CK 44 UNL O CK 1 3 SW F USE HO L DER
BO X
*8 UNL
BO
10 XO CK 9 132 5 SW 6 4
L T G2RN 1 14 13
*12IMPACT SENSO R (F IRSTL) O CK 15
G AUG E PUR
9 8 HT *516 L/RED
T BL10 U HT /BL U W HT /G 1 17
KEY
13 12 W HT YEL [3] 11 [5] BL U 27 26 9 (3− B) *6
34 (2− C) 30 W HT(2− 202C) RED 18
1
14 1 1 : 53 1021 : 6 1 : 10 W HT 1:8 1 : 9 9 82 2DAYT SENSO 6 1 :RRUNNING
IME 10 2 1 : 8L IG HT S REL 4 AY 1:9 BRN 1:3 1 : 1 (SECO ND) CO NT RO 7 L UNIT (15− A)
BL K INT W HT W RN *2 BL K *3 133 BL O W ER 134 W HT L T G RN 135 213 (13− B) G RN ·
IG NIT IO NGCO AUDIO
AUG IL E CO NTE2 A E9
E BIL IZ ER− KEYLE4 E3 No . 55 AUDIO (10 A) M24 HO RN C46 HIG H/L O KEY W BEAM INF O C45 SET / HID UNITKEY A29 IG · NIT
HIG H/LIOONW
. 27PUR (30BEAM
*9A) *2 IL M (+ C28 ) IL M (− ) PADDLMOnTnEO 2R: M23 C4016 E 2 : 9
PADDL : C26 2:W 10HT C32 2 : 9 RESUME C33 SET E1
2 : 42 1
E8 2MAIN 2G
· ND MICU C22 (17− 1 D)
REL AY DO O REMO T E RO L MO DUL IMMO ESS CO NT RO *2 L UNIT R REMO T E O RN O RNDO O R + BHIDBUNIT RIG HT PO WSW ERDO ITMIRRO
CHING INT RERLG RN/W O CKHT RESET SWST
KEY No ART
IT CHING ER (In tern al co ectio 2n ) 32
2:1 2 RED 11 2 : 11 O RN 2 : 10 2 : (IN)6 ABS MO DUL AT O R− CO NT RO L
IG NIT IO N SW R IT MR+
CH B C F SR+ B DDRIVER'S IG No 1. 37 (30 A) K− L INE DO OCAN H BL K/YEL CAN L MR+ ABS61MO DUL
F SR+ ATB OG R− GCO NT RO OBL
D)LCK
R
UNIT ST R− A ST R− BBL K/W STHT R− D SVCC
SW IT CH SG ND RIG 1 RADIAT CANOHR DOCAN WGNRY L G RN UP 1
(1− A)
1 :(ST 5 ) GLAUG O CKE CO NT 1:L 4 1:1 *21 : 3 2 L O CK G ND W HT*9 3 1 1 : 7 3L: O4CK*10 14 21+2B)
DEF
: 6(19− A)*13
O ERSO (16−LL1ENO
O SO
IDE K/W L ENOHTL OID *3 APP SENSO SW
SO L (4−
IT CH
ENO B)A/B
1 IDE RED CO MPUL SO 2RYAY 24G RN 2 MICUBL K (+1B DO O RAM/F 12L O CK) (17− D) WLHT 2P L T G 2RN L T G RN UNIT L LEFT(18− G RN
T A)
BRN RO
M− FNo
RED
. 6 (10 A) *24 NoG RN
2. M− 8 (7.5 F I A)
PUR W HT
KNO B HI G RN
1 : 8 PUR 103 ST
KNO ART (FGSR
B ER3(4− B) (W ith o u t VSA)
RN
KNO B
W HT F AIL − SAF E 5 : 4 PUR3 2 BEEPERT URNING *4F AN−REL O F F 1 L T G RN
1 2 1 W HT PNK M ANT 1 ENNA EAD 1 BL U L IG HT 3 2 · HEADL
VSA G RY 4IG HT LLTEVEL BRN
1BL UING 2 · EPS
· *55 PUR
1OBRN RN
CO NT RO L UNIT (19− B)
2 :(2− 8 B) MO KNO L OB E (8− B)B2 :PG
DUL I HI PG
USE REL AY 21:L4O4 3
5 1 *3,*4 PNK CIRCUITYEL 6 : 2 YEL PUR GBRNRY L T BL BLU.U12 (10
No G RYA) *2 RED RED BL U G RY RED (0.56W ) O F F CO NTLRO T BL L U UNIT W HT O PEN
9 (55W *2
)
B1
MAIN F USE
REL AY 1) 2 : 3
(60W
FMAIN
(55W )
3 2 2 ): 5 IMMO BIL
(60W 1 IZ ER− 2 : 6 4 : 2 F RO NT PG 2M− : 7F I MAIN BL O W ER HI L EF T RIG HT L T G RN *7 CIRCUIT ECM/PCM F USE BL O W ER *6 *3SW IT(14− CH B) REL AY · SRS UNIT (20− A)
No . 20 (15 A) 8(F[7]I MAIN) (2− C) 9 [6] (2−
(F I C) 7MAIN)[8] 6 [9]G AUG E CO NT RO L 7 [8]ESS O A/C
RN CO PASSENG ER'SCKP 7 AY
62 SENSO L2EF TR PO W ER MIRRO MO T RO R CMP CL SENSO 8 REREAR DIMMING No . 30 (30 B
IMAT A) *2 BL26 REAR 2 [1] 1 [2] (6− D) REAR1 MO T O R *5 · EPS*3REAR CO19NT RO T LBL17UNIT
U1 AUT O SECO
LMATT BLNDARY
ICUAUDIO3 UNIT (23− A, C)
KEY F S−
USE NET 76
138 137 (2− A) L G 86 (2− A) IG KEY SW MO
88 DUL
*5 E S EK−AT L INE CL UT CH ACT
KEYL
UAT O R(T CM) *2 MPRESSO SE RATREL
VSA PUR
MO DUL (i−
DEF AT SHIFO R−T
G G COSystem)
ER NT ROC)
(16− L UNIT G RNCO NT RO L CIRCUIT F USE 3 K L T BL BL UKA G RY
PADO L E
BL SHIF
K T ER PNK
BL BLK U G RN PUR RED *6 BRN (2− D)W
W INDO 114 RADIAT O RBRN/YEL F AN MO3LTTO G R RN (21− A) BRN/YEL BRN/YEL (19− W INDOLW
B) L IG HT
HO ING
2S /
(2− D) ST ART ER IL INAT No .IO 1 N(7.5A) *5 NoIL . 2L UMINAT
(7.5(8− F R IO N HE
A)B)
L CO ATE MPUL
IL(7− CSO RY IO
RL UMINAT
B)
CO
(15−NW NTHT RO L UNIT
IG
A). 10 (7.5CO
GILRNL UMINAT
*2 CLIO UTNCH REL 5 AYHE IL(FLATE
SR (F+UEL
UMINAT
(2−
B) (19−
RA) PUMP)
IO NB) ILAUDIO
L UMINAT UNIT IOEVAPO
N UNIT RAT O R REAR(1− W INDO[1] W
B) (12− B, C)
*2 *3 DEF O G*3G 90ER AM/F
DRIVER'S *3 M YEL ANT *3
*2
ENNA SUB L EAD
L T G RN
FGRO NT*3 PNK*3 *3 *3 DEF*3O G G ER *3 RIG HT RAIN*2 (SENSO
SENSO
*3 GRRRN 2) *3 No . 12 (10 A)
3 5 (W ith oREL u t B)AY2 (In
su n sh tern 7al co
CO n
NT
F n ectio
USE
RO L n& ) M F USE
6 CO NT WRO HTL &
CUT RECIRCUIT T URNING
LAY 5
CO NT −ROO FL F & No A) *3
NT RO (3−
L & B) RECO(W
AYLAY ith
NT 1 RO VSA) LCABL
& 3 E 2 CO (23−
NT C)
RO L 3& T 3
EMPERAT (22−
1 B) URE 2 (35W2 ) No . 29 (10
CABL A) E YEL PO W O ER
RN (In tern al co n n ectio n ) RED REL W HT
AY BL
No U. 10 (7.5 A) RY G RY PNK G RN
REL AY O RN No . 10 (7.5 A)
O RN
(5− C)
92 L IG HT(4− UN− 66adC8 e) L O CKDO W N A2 64(3−DIMMING ST ART ERC7
B) UP MICU 6 UN− G RN F USE F RO
BL U 104 ST ARTMICU ER11 RELUN− (35W 2) (4− B)REEL 2 C5SENSOUN−
9
F R (6− B) C16
10 DEF O G G ER 2G AUG G RN E CO
M/T NT RO L PUR M/T C10
3
2 T AIL
4G AT E
C9
T RANSIST O R 48 A/T G EAR PO WSIT IO NPUT 127 71 L(2− EF T SUPER 2 RIG HT MICUPASSENG 1 F ROER'S NT114 1 5DO DRIVER'S 13 153 F USE REAR15 12MICU 159
PNK (LPURED) L O CK
DIMMING
G RN (3−(AUTB) O CIRCUIT
)ER (RED) RED REL AY CIRCUIT VO
O
(AUT RN LOT)(LOW
AG E (17− REG)DIMMING
BLUL KL AT OO CKCIRCUIT
R DIMMING
BL UNT CIRCUIT
OFF DIMMING
B)L O(HIGH)
CK YEL CIRCUIT L EF T DIMMING CIRCUIT OO
L F CK EVAPO
RIG HT REL RAT AY O10
4R (2− V ST A) ABIL6IZMO ING HO O DE O(8−
5F F 1 REEL 3 L O2CK KNO B
HT O UT 25 SHAF MICU
REARW A)
T HT
(+ B SMAL LBL
F USE
O L L1T ) REAR
CKING (17− C) SUPERPASSENG ER'S L TRED INPUT
G RN SHAF OTR RED (2− A) DRIVER'S
SUPER 1
2 IG 1 F O R PO ABS INTMO +DUL PG AT
BMAIN M−O FR I F(ST
O RCO
− SCAL
ART
137
NTER9ROEVSA
L(AMBER)
REL AY 1)(9−
UNIT 138B) F OD) R DIAL VSA(AMBER)
(2−157C) F O R L CD
PASSENG LER'S
IG (WHT HITO112
(17−
E)
1 *5 FO YEL R L CDi−67 (WSHIF HITREAR BRN2 FBL
TE) O RU YEL L CD /BL
(AMBER)K
E 214 K−
BRN/YEL
VSA TREAR
MO EMPERAT
LDUL
O WAT 1FAS OR URE
CIRCUIT
− CO NT RO L OLW ECT
UNIT
DUL SHIF
ILSENSO 2 TRB) 2 SEAT BRN SHIF T AS CHARG 4 CH DO O RMAP 3 C SENSO INDICAT
R BRAKE O R DRIVE (CO UNT ERSHAF DO O TR) (2−EG C)R DO OEG
UUAT R R VAL VE (17− D)
DO O RCK SECURIT (MAINSHAF Y SWTIT ) CH HIG H BEAM DOLO
(2− C)
ORCKING L T 127 BL U(17− D) L T GIMMO RN BIL IZ ER
PNK 116 REL 117AY 21 NEP DRIVER'S 133 RN MASSEG
SCS L INE UEL OSW
UP (CloUP
IT CH BELDO TCAN W NH SW ING
3CANIT L CIRCUIT (8− A) G RN 115 ACTVAL O R 1PO SITABS IO(5− 2 L O CKING
N SENSO R SW KNO SIDE AIRBAG
DRIVER'S UN−(F . 58 L O CK
A) *2 DO INDICAT
O RED) O R 202 C ACT IVAT IO N134 81 DO P UP O R 135 CO NTRRO L 197 DO WNN INDICAT DO ODR UP128INDICAT S OTR DO WSENSO DO O R R O R(8−
NINDICAT 56 D) PRESSURE sed
139 OREMAINDER DO [PUR]W N 129
RSYST (Clo
EM 130 sed : INDICAT O R SYST EM SPEED SENSO SW RIT 58 MAL
CH YEL F UNCT *6ECM/PCM
138
IOVENSW IT(F
3R81 (Clo4sed
CH137
ANC)
D1: INDICAT202
D) ACT UAT OIT
SENSORCH EPS R INDICAT SPEED O R SENSO (Clo sed SRSR: 3 UN− HIGINDICAT 57H 5L O CK O R L OACT CK UAT
81 O RO 2 F FA23 202 INDICAT O R
DO ORED R W HT 131 No I MAIN) (30 L
(LOED) CK KNO INDICAT
B (L ED) OR ABS (L ED) MO(L DULED)AT L OOCK R−
(L KNO CO NT
ED) B RO L (L UNIT(L ED) L (LO CKED)KNO B
INDICAT R INDICAT OA13 A24 A14 O R G RN/YEL G D3sed
502
(Clo L:T BL UO
INDICAT D2
L T GORN R (Clo sedINDICAT : (L ED)O R Do o rINDICAT p en ) O R
o 155 L O CK T EMPERAT
(L ED) URE SW IT CHCUT 1 A22
(L ED)
L O CK KNO B *2 1L O CK YEL /BL K KEY(L RED3CYL INDERSW IT CH(L
INDICAT
132
ED) RED2
OR
SW IT CH (L ED) AUXIL IARY 64 UNDER− (MR +DASH B) (19− SW A) IT CH ED) 214 SW IT CH
INDICAT
A (L ED) 1
Ho OoRd o p en ) INDICAT O R
1 (L ED) 4
INDICAT T ailg
(L3ED)u n1lo cked ) 2
O Rate (L ED) INDICAT
Do o r oL2pBL enK) *7(MILG) AUG
AMP Do oCO r oNT p en(L ) ED) Do o r o p (Len ED) ) (L ED) INDICAT O R(20 A) *2 INDICAT O R 3
No . 39 (15 A)SEQ
BRN UENT IAL G RN 105 F USE YEL(W ith /BLoKu t VSA) 1 2 1 2 1 165 2215 3(L ED) 4 1 2
ANT +192
3B (L ED)RF BLSH 1951ERF IN3 RO L2 D/ 4 192 195 1 2 3 No . 28 (L ED) BL U
SW BL IT CH K RECT IFEIER SHIF *3T MO DO DE W N BL UP K 3
VMPDR 1412 BL U BLHO K L DER (3− B) 63 ECM/PCM BL K (MRL BL UY) (5−WA)INDSHIEL 2 D 3 BL5 K G RY L T BL U BL W KHT No BRN. 30 (30 A) *2O4 RN IL L +
BL CO
U MPUL SO RY +B REAR W INDO W 166ACC
1 BL 22 K/YEL 191 UMO5 DUL EW(8− INDSHIEL
B) 4
1 191 (L193ED)
2
194 FR
L + O
189
PEN
FR
L 4−
5 [10] 3 K 1 2 5 BL OW (WTER OithR 10 HANDSF REE L TTG EL EPHO
5 :ST 4 NEARTSYST ER 3 EM) SHIF T URNING − O NF UEL W IPER REAR
BL O WWER INDO W YEL
188 185 10 [5]184 CO NT RO SHIF T INDICAT
L*2UNIT L182 OR
TO GYEL
RN /BL K 183 YEL YEL /BL K BL U YEL G RN /BL 187
147 BRN3YEL : 4 /BL K
RED 186148
VSA MO DUL AT O R− CO NT RO
W IPER
L UNIT RESIST
W MOHT
O RN OR O RN
[4] RN
YEL CUT REL AY YEL INDICAT
2 T UP/DO W
L T G RN O R
1N
L T BL YEL U MAIN YEL CIRCUIT BL U YEL L T/REDBL U UNIT AUDIO
GMICU
MO T ORN
RN/WG HT
R
YEL /RED 26 1 GRADIAT RN/W BRNHTO R 3F AN BRN REL AY G (3− PNK B)
RY/YEL
W ASHER
RESIST L EFOTMO YEL
R O RU RED
T/BL RIGBL HTINKING YEL /BLW U HT GAUT RN/YEL O MAT IC BL K BL K
PO W ER G RN/YEL
G RNMR− CIRCUIT F F DO O R 3 [1] SW IT CH PUMP 149 MICUHO RN3 [1] 150 MICU DIMMING INDICAT O R
BLK BL KNo . 44 (7.5 BRNA) (L ED) G RY BLK (L ED) BL U (L ED)K
RED
ORN BL A/TBG EAR POBLK
(L4ED) :2 7MR− (MT RBL+OKB) INDICAT
(19− (LA) ED)O R ORN DRIVE CIRCUIT L T(LBL ED)U BL
6 :(ST
K2 ARTBL ERK DRIVE CIRCUIT BL K 2 T URNOSIG NAL TCIRCUIT URN SIG NAL L IG HT ING / BL K AUDIOWUNIT INDO W G NDDRIVE BL K
ST ARTG ER
PG ND1CUTUP G ND RLL− DO WRN N RL +SVCC PL SA /BL KPLIG SBNITBIO SGNYEL
ND SIT IO N INDICAT
G2ND R DRIVE· INJECT CIRCUIT O RS EPS (5− A)LT GRN BL K BRN (23− A,C)
(17− B) SECO NDARY BLPUR K (17− 2 A,B)
REL AY BRN INDICAT BL K RG
INDICAT ODRIVE
RY
R INDICATCIRCUIT
(17−OA,B) R RAIN SENSO R CIRCUIT PUR G RN BL K MAST BRN BLKG5RY CIRCUIT
BL KRED/W HT
REL BLAY K/RED
RED W HT TGGND PUR
B RR− YEL
W HT
G ND RR+
CO IL RELL7MICU
F
AY
L −/BL
T BL U
G ND KL TB)G RN
(17−
F L + BYEL /BL
BRN O RN YEL /BL K
F R− K G ND FYELR+ 106/BL
YEL K /BL
T RANSMISSIO
K N(W RANGithNDVSA)
G
64 E SW · IT CMP
K−
CHLSENSO INE
(6− A) R RL − G NT
CO
(5− A)O RN
NDRO L RL UNIT
A28 +B
YEL
RR− G ND A9RR+REL B AYF L2)− G ND FL+B F R− G ND HFFTR+ B
A4 HF T *3
A10
W EN
T*3EL EM T EL
*3 EM A35*3 T EL EMHO*3 2S T URN A3 *3SIG NAL*3/ A20
(L ED) BRN/YEL (L ED) A31(14− REMO D) T EBRN/YEL
ER
BRN G A− NET No . 16 (10 A)
(ST
ST ATART ER ERCUT REL AY BRN/YEL
F INDIVIDUAL
MICU *436A/CL T PRESSURE
MICUBL UBRN· *12 CKP SENSO RBL (5−UA) L T BL U MUTO E RN ICO N O4RN BL KPUR SIG
G RN/RED L+T G RN SIG PNK − SIG BLSHRED
K/W
(SENSOHT HAZ W RHT 2)ARD
G NDREL BL UAY BL U/RED YEL *3 W HT /BL YK
A33 RET RACT
K− L INE W HT /REDG ND
EXT END
REMO T E DRIVE SW IT CH
VSS O UT BUS SH MICU
25REL AY 24 5 BL K G14 MAP L15IG 1BLHTK RED 6 L13T W G HT
RN 12 1 G18RN YEL O1 RN LPNKT G RN *118 VBU . BRN 18 )L T BL U6 PUR 19 G RN ECM/PCM SCT ECM/PCM (17− A,B)
REL
(ST ARTAY 1)ER MICUPUR
2) MICU RY (17− D) 2 SW IT(17− CH35 D) 3 BRN/YEL 21 4 NoIG 1 ( 7.5A
14 2 310 *2ST S 23 ST EN 25
No . 5BKAND A) *2
VSSAMT (SO1UNDER) W EN CANH () CANL DIMMING () CIRCUIT
(3−
(4−A) B) (17− D) (17− D) No . 33 (15SW A) *2 IT CH G RN *3 F USE CPU/PO No . W 43ER (7.5SUPPULA) Y CIRCUIT
B11 / B6 161 B10
(10B9 3 B5 (5− C) (In tern al A12co n n ectio n ) (5− A4C) MICU A3 162 CIRCUIT A5 A16 A15 C3
CANH
(Bu ilit in to th e G 603 CPU/POG W ERGSUPPUL Y CIRCUIT (3− A)/ MICU
CO NT RO L L ER AREA G 502 Y CIRCUIT 4 G RN/YEL G RN/YEL
12A/C 1 G 501 2 16A1 su n sh5ad e No sw.itch16 ) 7 NoA/C. 2 G RY GNo
BL K
502A2
. 3 BL K/YEL 10No . 4 8 19 IG NIT
[G
IO NBLCO
601]
U IL S (5− C)
CO 22NT RO LRN L ER
601 BRN/YEL
21
AREA NET W O RK CO NT RO L G
L 301
ER 13 (17−C) 14 PURNET G 602W O RK CPU/PO CO NTWRO ERL SUPPUL
11
L ER
L T G RN / 27 BLA/C K/W CO HT MPRESSO R CL UT CHWREL HT /RED
83
AYMICU (3− B) MICURED/BL
(17−C) (IG 1 BACK U L T ) *8 (17− B) BRN/YEL (8− D) LGT501 G RN
L IG HT ING
G 602
REL AY 1
106 124 [10]
198 [9]199 1 [2] [G 603] [G 302]G 604 CO NT RO L L ER AREA NET W O RK CO NT RO L L ER (17− D) BL K BL K 2 602 [G 604]
G 401 CO NDENSER RADIAT O R G 202 CO MPRESSO
G CHRY REL PUR R G RY
BRN L T[1]BL U G 401BL U G 401 O RN G 301102 PUR ST ART BL
L TG UER 201
G RN CUT REL AY NoG. 602 *2 BL K O RN PUR G 604 G REAR NoW . INDO
20 (15WA)
16 F AN REL17 AY 27 26 2 [G 401] L6
2 T GCLRN UT 5 AY 2 4 2 3 8 7 3 4 O RN 5 6 G 9202 10 10 ( 7.5 A ) 6 7 8 9 10 G 501 11 24 25 G 502 200 G 501 7 B36 8
37 G 6015 GDEF603O
A [G 202]100 G601 F AN REL AY (In tern al co n n ectio n ) G601 MICU HO RN YEL (W ithMICU secu rity(ST o rART
su pER er loREL 200AYg )1)
ckin (W ith su p er lo ckin
MICU g ) YEL /RED N CO(W NTG ithRN/Wsecu HTrity) G 101 36 37 MICU (W ith*3d river's d o o r MICU lo ck G RN/YEL
*3B)sw itch ). 29 (10REL *1AYG G ER
(3−ΩB) G 502(3− B) BRN GG601
502 (W RED
(3− B)
ith su n sh ad e) BL U YEL 9 SW
(17− D) ITUNDER−
CH DASH F USE/REL AY BO X (2− A) (17− B) (3− A)
F USE
(2− C) 124
TBRANSMISSIO
(17− D) G 502 MICU
RO L MO DUL E (T CM)G RY
L T G RN 84 (17− D) *9 (17− MICU BL K 7 (17−
17 NoG603 A) *3
18 (2− A)
(17− A) *7 A)
157CANBL K KL270CAN ΩBL K
RNH PURA13
470
RED Ω
PG VB 1.2 YEL kΩ
14W HT
3.9 GGVA
kΩ
RY
RN158
10
L TkΩ
36 LBL
OW A4
UL T BL RA1+GURY A8159 LA3IGRA1−HTO RNS−(W O Nith o uPNK t HID) A4617
CRUISE
L A1+ A28G RN WL
L T G RNT /SA15
A1−
CRUISE G ND
BL26 K VS1 LBL
66 KFRO
FBRN VS2
NTA16ECM/PCM BL U (IGREAR P) (5−A30 A)
LM−
RED A1− YEL LGA1+ GM+101 G RY A38 RA1− LA10
T 7BL U RA1+ G RY RA2−
RN 6OA35 RNA34 RA2+PNK T /S 15 G(W NDith
A48G VS1RN 34 VS2
HID) A47 C13 M−RED C11 C14 RSA+ M+ B38
L CA1−(W ith oLuCA1+ t au2 to matic RCA1− lig3h NoB2. g55(10
RCA1+
tin system)A ) *2B30 BACK− UP L IG HT SW (W ithIT CH G
B19
101
au to(13− B18B)
matic lig h tinLgYEL system) 4*4 G RN BL U(Bu 7*4197
F USE
lb typ e)(1− B) B34 G RY *4
BLC10 O113 BL U
A9 A14 114 C5 PNKT EMPERAT C6 INDICAT
URE 11118 O R A43C7 CO NT RO LG W401
HT A33 L A2+
C8MAIN
INDSHIEL D/
YEL202 A2− − CAN
F O G LC32 IG HT
T RANSCEIVER PUR
F O G L IGREAR HT
160
C31
23RN
B− CAN T RANSCEIVER
RED A25 SEL 197 ECTA19 /
L T G105
5V No . 47
REDA26
(30 A) *281 A18
PUR A36BLIARY
AUXIL K 202L SA−
UNDER− L SA+
DASH(A/T )RSA− L EF T B4 BL K RIG HT
F USE B36G RN
L4BS− L BS+
C46 BL U202 G RY
L BS1− HT BS1+PNK
WC48 2 57
A1 G NDST RL D C2 NT RO L BL WSDNP C3− GSUPP F USE C1 HO L DER VCC1 S− DN B2 S−EG UP EG RP
O RN *2 L TST BLRL U Y G RN PG M− F ILI L − CANINDICATL O R CAN(L
ST S RE HIL
ED) D
L + ST EN S− INDICAT
NET IG 2
BKAND O[G RVSSAMT
REAR 302]INDICAT
W INDO ACC O R C2
WACS IMO FLPR
C3INDICAT
CAN C1OR CAN VSSO
INDICAT
H UT OWRINDO B1 W T eva T AC
B2 SG
Rr 6DEFRESET INFCAN
B−
SW
ETCO
O
IT CH
ST
−C2
CUT VART REL
ER
BL AY W RED MAP B1SRSSG 1
UNIT SEL ECT / 28 NC A/C CO NDENSER FFRONT AN(2−RRELA) AY (3− F B) NT
RO REAR
VCC2 NM Rr DEF IG 2 SG
25 2 ILBREAK
L + PEDAL
No . 20 (15 IGSRS1A) VO L SRS VOIG LG
*1
P 101
*1MAIN
INJ1REL AY (L
N )2*1
ED) INJ2 INJ3
A )L*1INKNo . 21 ( 15A ) *1
(L ED) INJ4
W ASHER (L ED)MO T O R (L ED) CKP (L ED) W IPERCMP
MICU VCC5
RLalGY501SW ITAPSB CH SG CIRCUIT
5 GRYVCC4
ECM/PCM
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