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Suzuki Ignis manual available for free PDF download: Service Manual
Suzuki Ignis Service Manual (3998 pages)
RG413
Brand:
Suzuki
| Category:
Automobile
| Size: 64.6 MB
Table of Contents
Table of Contents
8
General Information
9
Table of Contents
9
How to Use this Manual
10
Diagnosis
11
Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System
11
Servicing and Handling
12
General Precautions
14
Precautions for Catalytic Converter
17
Precaution for Installing Mobile Communication Equipment
17
Precaution in Servicing Full-Time 4Wd Vehicle
18
Precautions for Electrical Circuit Service
19
Electrical Circuit Inspection Procedure
21
Open Circuit Check
21
Continuity Check
22
Voltage Check
23
Short Circuit Check (Wire Harness to Ground)
24
Intermittent and Poor Connection
24
Identification Information
26
Vehicle Identification Number
26
Engine Identification Number
26
Transmission Identification Number
26
Warning, Caution and Information Labels
27
Vehicle Lifting Points
28
When Using Frame Contact Hoist
28
When Using Floor Jack
29
Abbreviations and Symbols May be Used in this Manual
30
Symbols
32
Wire Color Symbols
32
Fastener Information
33
Metric Fasteners
33
Fastener Strength Identification
33
Standard Tightening Torque
33
Tightening Torque Chart
34
Maintenance and Lubrication
35
Maintenance Schedule under Normal Driving Conditions
36
Maintenance Recommended under Severe Driving Conditions
38
Maintenance Service
39
Engine
39
Drive Belt
39
Water Pump and Generator Drive Belt Inspection
39
A/C Compressor Drive Belt (if Equipped) Inspection
40
Valve Lash (Clearance)
40
Engine Oil and Oil Filter
40
Engine Coolant
42
Engine Oil Specification
42
Exhaust System
44
Ignition System
44
Spark Plugs
44
Fuel System
44
Air Cleaner Filter
44
Fuel Lines and Connections
45
Fuel Filter
45
Fuel Tank
46
Emission Control System
46
Fuel Evaporative Emission Control System
46
Pcv Valve
46
Brake Discs and Pads (Front)
46
Brake Drums and Shoes (Rear)
47
Brake Hoses and Pipes
47
Brake Fluid
47
Brake Lever and Cable
47
Chassis and Body
48
Clutch
48
Tires / Wheels
48
Suspension System
49
Steering System
49
Wheel Discs Inspection
49
Wheel Bearing Inspection
49
Drive Shaft (Axle) Boots Inspection
50
Propeller Shafts (4Wd) Inspection
50
Manual Transmission Oil
51
Automatic Transmission Fluid
51
Transfer Oil (4Wd) and Rear Differential Oil (4Wd)
52
All Latches, Hinges and Locks
53
Doors
53
Engine Hood
53
Final Inspection
53
Engine Start
54
Exhaust System Check
54
Clutch (for Manual Transmission)
54
Gearshift or Select Lever (Transmission)
54
Recommended Fluids and Lubricants
55
Heater and Ventilation
57
General Description
58
Diagnosis Table
59
Wiring Circuit
60
On-Vehicle Service
61
Heater Unit
61
Blower Fan Motor
63
Blower Fan Motor Resistor
64
Heater Control Assembly
65
Air Inlet Box
68
Ventilation Louver
69
Required Service Materials
70
Air Conditioning (Optional)
71
Refrigerant Circulation
73
Refrigerant Type
73
General Description
73
Major Components and Location
74
General Diagnosis Table
75
Abnormal Noise Diagnosis
77
Quickly Checking of Refrigerant Charge
79
Performance Diagnosis
80
Performance Diagnosis Condition
80
Performance Diagnosis Table
82
High Pressure Gauge
82
Low Pressure Gauge
82
Thermometer at Center Duct
82
Detail Diagnosis Table (Ambient Temperature at 30°C (86°F))
83
Compressor Drive Belt
85
Electrical Diagnosis
86
Wiring Diagram
86
A/C System Inspection of Ecm and Its Circuits
87
System Circuit
88
Terminal Arrangement of ECM Coupler (Viewed from Harness Side)
88
ECM Voltage Values Table for Relation of A/C Control
89
Refrigerant Recovery, Evacuating and Charging
90
Operation Procedure for Refrigerant Charging
90
Recovery
91
Replenishing Compressor Oil
91
When Charging Refrigerant Only
91
When Replacing Compressor
92
When Replacing Other Part
92
Evacuating Procedure
92
Checking System for Pressure Leaks
93
Charging Procedure
94
Low Side and High Side Pressure Example
95
Removing Manifold Gauge Set
96
Leak Test
96
Liquid Leak Detectors
96
Service Precaution
97
Refrigerant Line
97
On-Vehicle Service
97
HANDLING REFRIGERANT HFC-134A
98
Refrigerant Recovery
98
Refrigerant Charge
98
Condenser Assembly
98
Receiver/Dryer
100
Radiator/Condenser Cooling Fan Motor
101
Cooling Unit (Evaporator)
102
A/C Evaporator Temperature Sensor
104
Expansion Valve
104
A/C Refrigerant Pressure Switch
105
A/C Switch
106
Compressor
106
RADIATOR/CONDENSER COOLING FAN MOTOR RELAY No.1, No.2 and
106
Magnet Clutch
108
Lip Type Seal
111
Required Service Material
113
Special Tool
114
Steering, Suspension, Wheels and Tires
115
Diagnosis
116
Brakes
116
Front End Alignment
117
Tire Diagnosis
119
Irregular And/Or Premature Wear
119
Wear Indicators
119
Radial Tire Waddle
120
Equipment Manufacture’s Recommendations
120
Radial Tire Lead
121
Vibration Diagnosis
121
Front End Alignment
123
Toe Setting
124
Camber
124
Alignment Service Data (Reference)
124
General Description
124
Preliminary Checks Prior to Adjusting Front Alignment
125
Toe Adjustment
125
Diagnosis
125
Diagnosis Table
125
Camber and Caster Check and Adjustment
126
Steering Angle Check and Adjustment
126
Side Slip (Reference)
126
Manual Rack and Pinion
127
General Description
128
Steering Rack Boot Check
129
Tie Rod End Boots Check
129
Steering Shaft Joint Check
129
The Rod End Check
129
Diagnosis
129
Steering Wheel Check
130
On-Vehicle Service
130
Lubrication
130
Tie Rod End
132
Manual Rack and Pinion Assembly (Steering Gear Case)
133
Rack Boot/Tie Rod
136
Steering Rack Plunger
138
Steering Pinion
140
Steering Rack
141
Pinion Bearing
143
Rack Bushing
144
Required Service Material
145
Special Tool
146
Electrical Power Steering (P/S) System
147
System Components
148
General Description
148
Wiring Diagram
149
On-Board Diagnostic System
150
Precautions in Diagnosing Troubles
150
Diagnosis
150
System Check Flow Table
151
Malfunction Indicator Lamp ("Eps" Warning Lamp) Check
153
Dtc Check
154
Using Suzuki Scan Tool
154
Not Using Suzuki Scan Tool
154
Dtc Clearance
155
Serial Data Link Circuit Check
156
Dtc Table
157
Malfunction Indicator Lamp Flashes at Ignition Switch on
161
DTC C1113 (DTC No.13) TORQUE SENSOR MAIN and SUB CIRCUIT FAILURE
162
Dtc C1114 (Dtc No.14) Torque Sensor 5V Power Supply Circuit Failure
163
Dtc C1116 (Dtc No.16) Torque Sensor 8V Power Supply Circuit Failure
164
Dtc C1121/C1123/C1124 (Dtc No.21/23/24) Vss Circuit Failure
165
Dtc C1122 (Dtc No.22) Engine Speed Signal Circuit Failure
166
DTC C1141/C1142/C1143/C1144/C1145 (DTC No.41/42/43/44/45) MOTOR CIRCUIT FAILURE
167
DTC C1151 (DTC No.51) CLUTCH CIRCUIT FAILURE
168
DTC C1153(DTC No.53) P/S CONTROL MODULE POWER SUPPLY CIRCUIT FAILURE
170
DTC C1152/C1154/C1155 (DTC No.52/54/55) P/S CONTROL MODULE FAILURE
170
Trouble Diagnosis (for Trouble Not Indicated by on Board Diagnostic System)
171
Inspection of P/S Control Module and Its Circuits
172
Steering Wheel Play Inspection
174
Torque Sensor
175
Motor and Clutch
176
Motor and Clutch Circuit Resistance
176
Motor and Clutch Circuit Resistance (to Body Ground)
176
Motor and Clutch Circuit Current (Reference Value)
176
Steering Column Assembly
177
Steering Wheel and Column
179
Steering Column
180
Steering Wheel and Driver Air Bag (Inflator) Module
180
Inspection and Repair Required after Accident
180
General Description
180
Diagnosis
180
On-Vehicle Service
181
Service Precautions
181
Service and Diagnosis
181
Disabling Air Bag System
181
Enabling Air Bag System
181
Driver Air Bag (Inflator) Module
182
Handling and Storage
182
Disposal
182
Steering Wheel
184
Centering Contact Coil
185
Contact Coil and Combination Switch Assembly
186
Steering Column Assembly
188
Steering Lock Assembly (Ignition Switch)
194
Steering Lower Shaft
195
Checking Steering Column Assembly and Lower Shaft for Accident Damage
196
Special Tool
197
Front Suspension
199
Diagnosis
201
Stabilizer Bar And/Or Bushing Check
201
Strut Assembly Check
201
Suspension Control Arm / Steering Knuckle Check
202
Suspension Control Arm Bushing Check
202
Suspension Control Arm Joint Check
202
Front Suspension Fasteners Check
203
Wheel Disc, Nut and Bearing Check
203
Strut Assembly
204
On-Vehicle Service
204
Stabilizer Bar And/Or Bushings
207
Wheel Hub and Steering Knuckle
209
Suspension Control Arm / Bushing
214
Required Service Material
217
Special Tool
217
Rear Suspension
219
General Description
220
Rear Shock Absorber Check
222
Diagnosis
222
Trailing Arm, Lateral Rod, Rear Axle, Pear Axle Housing and Coil Spring Check
222
Bump Stopper/Spring Upper Seat Check
223
Rear Suspension Fasteners
223
Wheel Disc, Nut and Bearing Check
223
Lateral Rod
224
On-Vehicle Service
224
Rear Shock Absorber
225
Coil Spring
225
Bump Stopper
228
Spring Upper Seat
229
Trailing Arm
229
Rear Axle (2Wd Vehicle)
232
Wheel Bearing and Wheel Stud (2Wd Vehicle)
237
Rear Axle Shaft and Wheel Bearing (4Wd Vehicle)
239
Rear Axle Shaft Oil Seal (4Wd Vehicle)
243
Rear Axle Housing (4Wd Vehicle)
244
Wheels and Tires
251
Tires
252
Wheels
252
Replacement Tires
252
Replacement Wheels
252
How to Measure Wheel Runout
253
Balancing Wheels
253
General Balance Procedures
254
Off-Vehicle Balancing
254
On-Vehicle Balancing
254
Maintenance and Minor Adjustments
255
Matched Tires and Wheels
255
Tire Maintenance
255
Tire Placard
255
Inflation of Tires
256
Tire Rotation
256
Higher than Recommended Pressure Can Cause
256
Unequal Pressure on same Axle Can Cause
256
Wheel
257
Front Drive Shaft
259
Drive Shaft Boot Check
260
Drive Shaft Assembly
262
For Tripod Joint Type Drive Shaft
263
For DOJ Type Drive Shaft
264
For Center Shaft and Center Bearing Support
265
Tightening Torque Specification
274
Required Service Material
274
Special Tool
274
Propeller Shafts
275
Propeller Shaft Joint Check
276
Brakes
279
General Description
280
Road Testing Brakes
282
Brake Fluid Leaks
282
Substandard or Contaminated Brake Fluid
282
Diagnosis
282
Diagnosis Table
283
Brake Pedal Free Height Adjustment
286
Brake Pedal Play Inspection
286
Stop Light Switch Adjustment
286
Excessive Pedal Travel Inspection
287
Front Brake Pad Inspection
287
Brake Disc Inspection
287
Parking Brake Inspection and Adjustment
288
Booster Operation Inspection
289
Check Air Tightness under Load
290
Fluid Pressure Test (if Equipped with Lspv)
290
Master Cylinder and Brake Fluid Level Inspection
292
Brake Hose and Pipe Inspection
293
Air Bleeding of Brake System
293
On-Vehicle Service
293
Front Brake
295
Brake Pad
295
Caliper Assembly
297
Brake Disc
301
Rear Brake
303
Brake Drum
304
Brake Shoe
307
Wheel Cylinder
308
Brake Back Plate (for 2Wd Vehicle)
309
Brake Back Plate (for 4Wd Vehicle)
311
Master Cylinder Reservoir
311
Master Cylinder Assembly
312
Brake Booster
316
Installation Position of Push Rod
318
Clearance between Booster Piston Rod and Master Cylinder Piston
318
Front Brake Hose/Pipe
319
Rear Brake Hose/Pipe
322
Parking Brake Cable
324
Lspv (Load Sensing Proportioning Valve) Assembly (if Equipped)
326
Required Service Material
328
Special Tool
328
Antilock Brake System (Abs)
331
Components/Parts Location and Brake Hose/Pipe Routing
332
General Description
332
System Schematic
334
Abs Hydraulic Unit/Control Module Assembly
335
Self-Diagnosis Function
335
Fail-Safe Function
335
System Circuit
336
Diagnosis
338
Precaution in Diagnosing Troubles
338
Abs Diagnostic Flow Table
339
Abs Warning Lamp Check
342
Ebd Warning Lamp (Brake Warning Lamp) Check
342
Abs Warning Lamp Circuit Check
343
Lamp Does Not Come“On” at Ignition Switch on
343
Lamp Comes “On” Steady
344
Diagnostic Trouble Code
348
Lamp)
350
Diagnostic Trouble Code (Dtc) Table
350
Dtc C1013 (Dtc 13) - System Specifications Different from Abs Control Module Specifications
352
Dtc C1015 (Dtc 15) - G Sensor Circuit
352
Dtc C1055 (Dtc 55) - Left-Rear Inlet Solenoid Circuit
356
Dtc C1042 (Dtc 42) - Right-Front Outlet Solenoid Circuit
356
Dtc C1046 (Dtc 46) - Left-Front Outlet Solenoid Circuit
356
Dtc C1052 (Dtc 52) - Right-Rear Outlet Solenoid Circuit
356
Dtc C1056 (Dtc 56) - Left-Rear Outlet Solenoid Circuit
356
Dtc C1057 (Dtc 57) - Power Source Circuit
357
Dtc C1061 (Dtc 61) - Abs Pump Motor Circuit
358
Dtc C1063 (Dtc 63) - Abs Fail-Safe Relay Circuit
359
Dtc C1071 (Dtc 71) - Abs Control Module
360
On-Vehicle Service
361
Precautions
361
Abs Hydraulic Unit Operation Check (Using Suzuki Scan Tool)
361
Abs Hydraulic Unit Operation Check (Not Using Suzuki Scan Tool)
361
Abs Hydraulic Unit/Control Module Assembly
363
Front Wheel Speed Sensor
365
Sensor Roter Inspection
367
Front Wheel Speed Sensor Ring
367
Rear Wheel Speed Sensor
368
Output Voltage Inspection
368
Sensor Inspection
369
Sensor Rotor Inspection
370
Rear Wheel Speed Sensor Ring (for 2Wd Vehicle)
371
G Sensor (for 4Wd Vehicle Only)
373
Special Tool
374
Engine General Information and Diagnosis
375
Statement on Cleanliness and Care
378
General Information on Engine Service
378
Precaution on Fuel System Service
379
Fuel Pressure Relief Procedure
380
Fuel Leakage Check Procedure
380
Engine Diagnosis
380
General Description
380
On-Board Diagnostic System (Vehicle with Immobilizer Indicator Lamp)
381
Freeze Frame Data
382
Priority of Freeze Frame Data
382
Data Link Connector (Dlc)
383
Freeze Frame Data Clearance
383
Precaution in Diagnosing Trouble
385
Engine Diagnostic Flow Table
386
Customer Complaint Analysis
387
Dtc/Freeze Frame Data Check, Record and Clearance
387
Trouble Symptom Confirmation
387
Engine Basic Inspection and Engine Diagnosis Table
387
Customer Problem Inspection Form (Example)
388
Malfunction Indicator Lamp (Mil) Check
389
Diagnostic Trouble Code (Dtc) Check
389
Diagnostic Trouble Code (Dtc) Clearance
390
Diagnostic Trouble Code (Dtc) Table
391
Fail-Safe Table
394
Visual Inspection
396
Engine Basic Inspection
397
Engine Diagnosis Table
400
Scan Tool Data
405
Fuel System (Fuel System Status)
407
Calc Load (Calculated Load Value, %)
407
Short Ft B1 (Short Term Fuel Trim, %)
407
Long Ft B1 (Long Term Fuel Trim, %)
407
Ignition Advance (Ignition Timing Advance for No.1 Cylinder, °)
408
Intake Air Temp. (°C, °F)
408
MAF (MASS AIR FLOW RATE, Gm/S, Lb/Min)
408
Total Fuel Trim (%)
408
Radiator Fan
409
Electric Load
409
Fuel Tank Level
409
Pnp Signal
409
Inspection of Ecm and Its Circuits
410
Ecm Voltage Values Table
411
Terminal Resistance Table
417
Component Location
419
Malfunction Indicator Lamp Circuit Check
420
Without Immobilizer Indicator
421
With Grounding Diagnosis Switch
422
Immobilizer Indicator Lamp)
422
Cranked up
423
Dtc P0105 (Dtc No.11) Manifold Absolute Pressure (Map) Circuit Malfunction
426
Dtc P0110 (Dtc No.18) Intake Air Temp. (Iat) Circuit Malfunction
429
Dtc P0115 (Dtc No.19) Engine Coolant Temperature (Ect) Circuit Malfunction
431
Dtc P0120 (Dtc No.13) Throttle Position Circuit Malfunction
434
Dtc P0121 Throttle Position Circuit Range/Performance Problem
437
Dtc P0130 (Dtc No.14) Heated Oxygen Sensor (Ho2S) Circuit Malfunction (Sensor-1)
440
Dtc P0133 Heated Oxygen Sensor (Ho2S) Circuit Slow Response (Sensor-1)
442
Dtc P0134 Heated Oxygen Sensor (Ho2S) Circuit no Activity Detected (Sensor-1)
443
Dtc P0135 (Dtc No.14) Heated Oxygen Sensor (Ho2S) Heater Circuit Malfunction (Sensor-1)
444
Dtc P0136 Heated Oxygen Sensor (Ho2S) Circuit Malfunction (Sensor-2)
446
Dtc P0141 Heated Oxygen Sensor (Ho2S) Heater Circuit Malfunction (Sensor-2)
448
Dtc P0171 Fuel System too Lean
450
Dtc P0172 Fuel System too Rich
450
Dtc P0301 Cylinder 1 Misfire Detected
455
Dtc P0302 Cylinder 2 Misfire Detected
455
Dtc P0303 Cylinder 3 Misfire Detected
455
Dtc P0304 Cylinder 4 Misfire Detected
455
Dtc P0325 (Dtc No.17) Knock Sensor Circuit Malfunction
460
Dtc P0335 (Dtc No.23) Crankshaft Position (Ckp) Sensor Circuit Malfunction
462
Dtc P0340 (Dtc No.15) Camshaft Position (Cmp) Sensor Circuit Malfunction
465
Dtc P0400 Exhaust Gas Recirculation Flow Malfunction
468
Dtc P0420 Catalyst System Efficiency below Threshold
471
Dtc P0443 Purge Control Valve Circuit Malfunction
474
Dtc P0480 Radiator Cooling Fan Control System Malfunction
475
Dtc P0500 (Dtc No.16) Vehicle Speed Sensor (Vss) Malfunction
477
Dtc P0505 (Dtc No.26) Idle Control System Malfunction
479
Dtc P1450 Barometric Pressure Sensor Low/High Input
482
Dtc P1451 Barometric Pressure Sensor Performance Problem
482
Dtc P1500 Engine Starter Signal Circuit Malfunction
484
Dtc P1510 Ecm Back-Up Power Supply Malfunction
485
Dtc P1600 Serial Communication Problem between Ecm and Tcm
486
Dtc P1717 A/T Drive Range (Park/Neutral Position) Signal Circuit Malfunction
488
Engine Mechanical (M13 Engine)
507
General Description
508
Engine
508
Engine Lubrication
509
Compression Check
510
Diagnosis
510
Diagnosis Table
510
Engine Vacuum Check
512
Oil Pressure Check
513
Valve Lash (Clearance)
515
On-Vehicle Service
518
Air Cleaner Element
518
Air Cleaner Assembly and Resonator
519
Knock Sensor
519
Cylinder Head Cover
519
Throttle Body and Intake Manifold
522
Exhaust Manifold
525
Oil Pan and Oil Pump Strainer
527
Timing Chain Cover
531
Oil Pump
536
Timing Chain and Chain Tensioner
540
Crankshaft Timing Sprocket
541
Timing Chain Tensioner Adjuster
541
Camshaft, Tappet and Shim
545
Valves and Cylinder Head
550
Pistons, Piston Rings, Connecting Rods and Cylinders
563
Engine Mountings
573
Unit Repair Overhaul
574
Engine Assembly
574
Main Bearings, Crankshaft and Cylinder Block
579
Required Service Material
591
Tightening Torque Specification
592
Special Tool
593
Cooling System Circulation
596
General Description
596
Coolant
597
Diagnosis
598
Diagnosis Table
598
System Circuit
599
System Circuit Inspection
599
Maintenance
600
Coolant Level Check
600
Engine Cooling System Inspection and Service
601
Cooling System Flush and Refill
601
Water Pump/Generator Drive Belt Tension Inspection and Adjustment
603
On-Vehicle Service
604
System Components
604
Cooling System Draining
605
Cooling System Refill
605
Cooling Water Pipes or Hoses
606
Thermostat
606
Radiator
608
Radiator and Condenser Cooling Fan
609
Radiator and Condenser Cooling Fan Relay
609
Water Pump/Generator Drive Belt
609
Water Pump
610
Ect Sensor
612
Required Service Material
612
Tightening Torque Specification
612
Engine Fuel
613
On-Vehicle Service
614
Components
614
Precautions
615
Fuel Lines
616
Fuel Pipe
616
Fuel Filler Cap
617
Fuel Tank Inlet Valve
618
Fuel Tank
619
Fuel Pump Assembly
622
Disassembly and Reassembly
624
Special Tool
626
Tightening Torque Specification
626
Air Intake System
631
Fuel Delivery System
632
Fuel Pump
632
Electronic Control System
633
Engine & Emission Control Input/Output Table
634
Ecm Input/Output Circuit Diagram
635
Ecm Terminal Arrangement Table
639
Accelerator Cable Adjustment
641
Idle Speed/Idle Air Control (Iac) Duty Inspection
641
On-Vehicle Service
641
Idle Mixture Inspection / Adjustment (Vehicle Without Heated Oxygen Sensor)
643
Air Intake System
644
Throttle Body
644
Idle Air Control Valve (Iac Valve)
646
Fuel Delivery System
647
Fuel Pressure Inspection
647
Fuel Pump with Pressure Regulator
648
Fuel Injector
649
Electronic Control System
653
Engine Control Module (Ecm)
653
Manifold Absolute Pressure Sensor (Map Sensor)
653
Throttle Position Sensor (Tp Sensor)
654
Intake Air Temperature Sensor (Iat Sensor)
655
Engine Coolant Temperature Sensor (Ect Sensor)
656
Heated Oxygen Sensor (Ho2S-1 and Ho2S-2)
657
Camshaft Position Sensor
658
Crankshaft Position Sensor
658
Vehicle Speed Sensor (Vss)
659
Fuel Level Sensor (Gauge)
659
Knock Sensor (if Equipped)
659
Main Relay, Fuel Pump Relay and Radiator Fan Relay No.1
659
Fuel Cut Operation
660
Radiator Fan Control System
660
Radiator Fan Relay No. 2 and No.3
660
Output Signals of Throttle Valve Opening and Engine Coolant Temp. (Vehicle with A/Tonly)
662
Emission Control System
662
Egr System
662
Evaporative Emission Control System
663
Pcv System
665
Special Tool
666
General Description
669
Diagnosis
670
On-Vehicle Service
672
Ignition Spark Test
672
High-Tension Cords
672
Spark Plugs
673
Ignition Coil Assembly (Including Ignitor)
674
Crankshaft Position Sensor (Ckp Sensor)
674
Ignition Timing
675
Special Tool
676
Cranking Circuit
679
General Description
679
Diagnosis
679
Diagnosis Table
679
Performance Test
681
Pull-In Test
681
Hold-In Test
681
Plunger and Pinion Return Test 6G-4
681
No-Load Performance Test
682
On-Vehicle Service
682
Starting Motor
682
Dismounting
682
Remounting
682
Disassembly and Reassembly
683
1.0 Kw TYPE
683
Required Service Material
685
Battery
687
Carrier and Hold-Down
687
Electrolyte Freezing
687
Sulfation
687
General Description
687
Built-In Indicator (if Equipped)
687
Care of Battery
688
Generator
689
Hydrometer Test
690
Diagnosis
690
Battery
690
Visual Inspection
690
Charging Indicator Lamp Operation
691
Generator
691
Undercharged Battery
692
No-Load Check
692
Overcharged Battery
693
Jump Starting in Case of Emergency
694
With Charging Equipment
694
On-Vehicle Service
694
Battery
694
Generator Belt
695
Dismounting
695
Handling
695
Remounting
695
Dismounting and Remounting
696
Disassembly and Reassembly
696
Inspection
697
Tightening Torque Specification
699
General Description
701
Maintenance
701
On-Vehicle Service
702
Exhaust Manifold
703
Exhaust Pipe
703
Manual Transmission
704
General Description
705
Construction and Servicing
705
Transmission for 2Wd Model
706
Transmission for 4Wd Model
707
Diagnosis
708
On-Vehicle Service
708
Oil Change
709
Differential Side Oil Seal
709
Gear Shift Control Lever and Cable
711
Vehicle Speed Sensor (Vss)
713
Transmission Unit
714
Unit Repair Overhaul
714
Trasmission Case
715
Input & Counter Shaft
716
Gear Shifter & Differential
717
Transmission Unit
719
Unit Disassembly
720
Gear Shifter, Input Shaft and Counter Shaft
722
Right Case
723
Sub Assembly Service
724
Right Case
724
Left Case
724
Input Shaft Assembly
725
Counter Shaft Assembly
728
Gear Shifter
732
Differential Assembly
733
Unit Assembly
736
Differential to Left Case
736
Fifth Gears
738
Gear Shift and Select Shaft Assembly
741
Tightening Torque Specification
742
Required Service Material
743
Special Tool
743
Automatic Transmission (4 A/T)
746
General Description
748
Electronic Shift Control System .7B-6
751
Transmission Control Module (Tcm)
752
Fail Safe Function
753
Change Mechanism
755
Automatic Gear Shift Diagram
756
Diagnosis
758
Automatic Transmission Diagnostic Flow Table
758
Trouble Diagnosis Table
763
Stall Test
765
Time Lag Test
766
Line Pressure Test
767
Engine Brake Test
768
P" Range Test
768
Electronic Control System Diagnosis
769
Precautions in Diagnosing Troubles
769
Dtc Check
770
Dtc Clearance
772
Dtc Table
773
Tcm Power and Ground Circuit Check
775
Dtc P0715 (Dtc No.14) Input/Turbine Speed Sensor Circuit Malfunction
776
Dtc P0730 (Dtc No. 18) Incorrect Gear Ratio
778
Dtc P0753 (Dtc No.21/22) Shift Solenoid-A (No.1) Electrical
780
Dtc P0758 (Dtc No.23/24) Shift Solenoid-B (No.2) Electrical
780
Dtc P0743 (Dtc No.25/26) Tcc (Lock-Up Clutch) System Electrical
780
Dtc P0741 (Dtc No.29) Tcc (Lock-Up) Solenoid Performance or Stuck off
782
Dtc P0720 (Dtc No. 31) Output Shaft Speed Sensor Circuit Malfunction
783
Dtc P1700 (Dtc No.32/33) Throttle Position Signal Input Malfunction
786
Dtc P0705 (Dtc No.34) Transmission Range Sensor (Switch) Circuit Malfunction
788
Dtc P0725 (Dtc No.35) Engine Speed Input Circuit Malfunction
790
DTC P0710 (DTC No.36/38) TRANSMISSION TEMPERATURE SENSOR CIRCUIT MALFUNCTION
792
Dtc P0763 (Dtc No.43) Shift Solenoid-C (No.3) Electrical
794
Dtc P0768 (Dtc No.45) Shift Solenoid-B (No.4) Electrical
794
Dtc P0773 (Dtc No.48) Shift Solenoid-E (No.5) Electrical
794
Dtc P1709 (Dtc No.51) Engine Coolant Temperature/Barometric Pressure Signal Circuit
796
DTC P0702/P1702 (DTC No.52)Transmission CONTROL SYSTEM ELECTRICAL or INTERNAL MALFUNCTION of TCM
797
Inspection of Tcm and Its Circuits
798
Fluid Level at Normal Operating Temperature
800
On-Vehicle Service
800
Maintenance Service
800
Fluid Level at Room Temperature
801
Fluid Change
801
Selector Lever
802
Transmission Range Sensor (Shift Switch)
803
Selector Cable
805
Output Shaft Speed Sensor (A/T Vss)
807
Input Shaft Speed Sensor
808
Vehicle Speed Sensor (Vss)
808
Throttle Position Sensor
808
Engine Coolant Temp. (Ect) Sensor
809
Dropping Resistor
809
O/D off Switch
810
Shift Solenoid Valves and Transmission Temperature Sensor
810
Shift Solenoid Valves
811
Transmission Temperature Sensor
811
Differential Side Oil Seal
813
Transmission Control Module (Tcm)
814
Learning Control Initialization 7B-70
815
Brake Interlock System (if Equipped)
815
Key Interlock Cable (if Equipped)
817
Transmission Unit Repair Overhaul
820
Dismounting
821
Remounting
822
Unit Disassembly
823
Disassembly/Assembly of Subassembly
833
Oil Pump
833
Front Clutch (C2 Clutch)
836
Rear Clutch (C1 Clutch)
840
Direct Clutch (C0 Clutch)
845
Clutch Discs, Plates and Flange
846
Direct Clutch Return Spring Seat
846
Direct Clutch Piston Lip and Direct Clutch Balancer Lip
847
Planetary Set
849
Valve Body
851
Differential Assembly
857
Rear Cover (O/D Brake Piston Assembly)
860
Planetary Sun Gear No.1 Assembly
860
Torque Converter Housing
861
Transmission Case
862
Unit Assembly
863
Special Tool
882
Required Service Material
884
General Description
887
Diagnosis
888
On-Vehicle Service
889
Clutch Cable
889
Clutch Pedal and Clutch Pedal Bracket
891
Clutch Pedal Height
892
Clutch Pedal Free Travel
892
Clutch Cover, Clutch Disc and Flywheel
893
Unit Repair Overhaul
893
Clutch Release System
896
Tightening Torque Specification
899
Required Service Material
899
Special Tool
899
Transfer
902
General Description
903
Diagnosis
903
Oil Change
904
Transfer Gear Oil
904
Oil Capacity
904
On-Vehicle Service
904
Unit Repair Overhaul
905
Unit Dismounting
906
Unit Disassembly
907
Transfer Assembly
907
Reduction Driven Gear
908
Intermediate Shaft
909
Transfer Output Retainer
910
Component Inspection
911
Unit Assembly
911
Reduction Driven Gear
911
Bevel Gear Shim
912
Transfer Output Retainer
913
Right Case
917
Left Case
918
Rear Differential
926
Viscous Coupling
927
General Description
927
Diagnosis
928
On-Vehicle Service
929
Oil Change
929
Unit Repair Overhaul
930
Differential Unit
931
Unit Disassembly
932
Sub-Assembly Repair
933
Viscous Coupling
933
Rear Differential
935
Unit Assembly
945
Tightening Torque Specification
945
Required Service Material
946
Special Tool
946
Body Electrical System
948
Headlights with Leveling System (if Equipped)
950
Turn Signal and Hazard Warning Light
950
Diagnosis
950
Clearance, Tail and License Plate Light
951
Back-Up Light
951
Brake Light
951
Front Fog Light (if Equipped)
951
Speedometer and Vss
952
Fuel Meter and Fuel Level Sensor (Gauge Unit)
952
Engine Coolant Temperature (Ect) Meter and Ect Sensor
952
Oil Pressure Warning Light
952
Brake and Parking Brake Warning Light
953
Rear Window Defogger
953
Wipers and Washers
953
Front Wiper and Washer
953
Rear Wiper and Washer (if Equipped)
953
Cigarette Lighter
954
Power Window Control System (if Equipped)
954
Power Door Lock Control System (if Equipped)
954
Keyless Entry System (if Equipped)
954
Interior Light
955
Horn
955
Power Door Mirror Control System (if Equipped)
955
Ignition Key Remainder (if Equipped) and Light Remainder Warning Buzzer
955
Seat Belt Warning Light (if Equipped)
955
Headlight Switch
956
Front Seat Heater (if Equipped)
956
On-Vehicle Service
956
Cautions in Servicing
956
Headlight Assembly
957
Headlight Bulb
957
Headlight Aiming Adjustment with Screen
958
Turn Signal and Hazard Warning Lights
959
Turn Signal Light Switch
959
Headlight Leveling Switch (if Equipped)
959
Removal and Installation
959
Turn Signal and Hazard Relay
960
Hazard Switch
960
Front Fog Lights (if Equipped)
960
Rear Fog Light Switch
961
Ignition Switch
961
Rear Fog Light (if Equipped)
961
Combination Meter
962
Circuit
962
Fuel Meter and Fuel Level Sensor (Gauge Unit)
963
Fuel Level Meter
963
Fuel Level Sensor (Gauge Unit)
964
Speed Meter and Vss
964
Vss
964
Meter and Sensor
964
(Ect) Meter
964
Ect Sensor
965
Oil Pressure Warning Light
965
Oil Pressure Switch
965
Brake Fluid Level and Parking Brake Warning Light
965
Brake Fluid Level Switch
965
Parking Brake Switch
966
Rear Window Defogger
966
Defogger Wire
966
Wipers and Washers
968
Components
968
Front Wiper and Washer Switch
968
Front Wiper Motor
970
Washer Tank and Washer Pump
971
Rear Wiper and Washer Switch (if Equipped)
972
Rear Wiper Motor
972
Ignition Key Remainder (if Equipped) and Light Remainder Warning Buzzer
972
Power Window Control System
973
Power Window Sub Switch
974
Door Switch
974
Stop Lamp (Brake) Switch
974
Power Door Lock System (if Equipped)
975
Door Lock Controller
975
Driver's Door Knob Switch
975
Door Lock Actuator
976
Keyless Entry System (if Equipped)
976
Door Lock Controller
976
Receiver
977
Transmitter
977
Power Door Mirror Control System (if Equipped)
978
Mirror Switch
978
Door Mirror Actuator
979
Front Seat Heater (if Equipped)
979
Seat Heater Switch (Driver and Passenger Side)
979
Seat Heater Wire
980
General Description
983
Wiring Circuit
984
On-Board Diagnostic System (Self-Diagnosis Function)
985
Diagnosis
986
Precautions in Diagnosing Troubles
986
Precautions in Identifying Diagnostic Trouble Code
986
Diagnostic Flow Table
987
Diagnostic Trouble Code (Dtc) Check (Immobilizer Control Module)
988
Diagnostic Trouble Code (Dtc) Check (Ecm)
989
Diagnostic Trouble Code Table
990
Dtc12 Fault in Immobilizer Control Module
995
Dtc13 no Transponder Code Transmitted or Coil Antenna Opened/Shorted
996
Dtc21 Ecm/Immobilizer Control Module Code Not Matched (Immobilizer Control Module Side)
997
Dtc P1623 Ecm/Immobilizer Control Module Code Not Matched (Ecm Side)
997
Dtc P1620 Ecm/Immobilizer Control Module Code Not Registered
997
Dtc P1622 Fault in Ecm
997
Dtc22 Ignition Switch Circuit Open/Short
998
Shorted
999
Inspection of Ecm, Immobilizer Control Module and Its Circuit
1001
On-Vehicle Service
1002
Precautions in Handling Immobilizer Control System
1002
Immobilizer Control Module
1003
How to Register Ignition Key
1004
Body Service
1008
Glass, Windows and Mirrors
1009
Front Door Glass
1009
Front Door Window Regulator
1013
Door Mirror
1014
Rear Door Glass (if Equipped)
1015
Rear Door Window Regulator
1018
Window Shield
1019
Quarter Window
1024
Back Door Glass
1025
Body Structure
1026
Front Door Assembly
1026
Rear Door Assembly
1029
Back Door Assembly
1030
Hood
1032
Front Fender
1033
Front Bumper and Rear Bumper
1034
Roof Rail (if Equipped)
1035
Body Dimensions
1036
Engine Room
1036
Back Door
1037
Side Body
1038
Under Body
1041
Panel Clearance
1043
Instrumentation and Driver Information
1045
Instrument Panel
1045
Seats
1047
Front Seat
1047
Rear Seat
1048
Security and Locks
1049
Front Door Lock Assembly
1049
Rear Door Lock Assembly (if Equipped)
1051
Key Coding
1053
Key Usage and Identification
1053
Ignition Switch Lock Cylinder
1054
Exterior and Interior Trim
1054
Floor Carpet
1054
Head Lining
1055
Paint and Coatings
1057
Restraint System
1070
General Description
1071
System Specification
1072
Seat Belt Pretensioner (if Equipped)
1072
Diagnosis
1072
Inspection and Repair Required after Accident
1072
On-Vehicle Service
1073
Service Precautions
1073
Service and Diagnosis
1073
Disabling Air Bag System
1073
Enabling Air Bag System
1073
Handling and Storage
1073
Disposal
1073
Front Seat Belt
1074
Rear Seat Belt
1077
General Description
1080
System Components and Wiring Location View and Connectors
1081
System Wiring Diagram
1082
Diagnosis
1083
Diagnostic Trouble Code (Dtc)
1083
Use of Special Tool
1083
Intermittents and Poor Connections
1085
Air Bag Diagnostic System Check Flow Table
1087
Dtc Check
1088
Dtc Clearance
1089
Dtc B1021 - Driver Air Bag Initiator Circuit Resistance High
1106
Dtc B1022 - Driver Air Bag Initiator Circuit Resistance Low
1106
Dtc B1024 - Driver Air Bag Initiator Circuit Short to Ground
1106
Dtc B1032 - Power Source Voltage Low
1113
Dtc B1041 - Driver Pretensioner Initiator Circuit Resistance High
1115
Dtc B1042 - Driver Pretensioner Initiator Circuit Resistance Low
1115
Dtc B1043 - Driver Pretensioner Initiator Circuit Short to Ground
1115
Dtc B1044 - Driver Pretensioner Initiator Circuit Short to Power Circuit
1115
Dtc B1045 - Passenger Pretensioner Initiator Circuit Resistance High
1115
Dtc B1046 - Passenger Pretensioner Initiator Circuit Resistance Low
1115
Dtc B1047 - Passenger Pretensioner Initiator Circuit Short to Ground
1115
Dtc B1048 - Passenger Pretensioner Initiator Circuit Short to Power Circuit
1115
Dtc B1051 - Frontal Crash Detected (System Activation Command Outputted)
1121
Dtc B1071 - Internal Sdm Fault
1122
On-Vehicle Service
1123
Service Precautions
1123
Service and Diagnosis
1123
Disabling Air Bag System
1124
Enabling Air Bag System
1124
Handling and Storage
1125
Repairs and Inspections Required after an Accident
1130
Accident with Deployment/ Activation - Component Replacement
1130
Accident with or Without Deployment/Activation - Component Inspections
1130
Sdm
1133
Driver Air Bag (Inflator) Module
1136
Contact Coil and Combination Switch Assembly
1136
Seat Belt Pretensioner (if Equipped)
1136
Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal
1137
Deployment/Activation Outside Vehicle
1138
Deployment/Activation Inside Vehicle
1144
Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal
1147
Special Tool
1148
Precautions ................................................0A
1156
Precautions
1157
General Precautions
1157
Identification Information
1160
Vehicle Identification Number
1160
Precaution for Can Communication System
1160
Engine Identification Number
1161
Transmission Identification Number
1161
Warning, Caution and Information Labels
1162
Abbreviations
1164
Fastener Information
1166
Metric Fasteners Information
1166
(Z13DT Engine)
1174
Fuel Tank Inspection (Z13DT Engine)
1178
Clutch Inspection
1178
Automatic Transmission Fluid Level Inspection
1179
Automatic Transmission Fluid Replacement
1180
Automatic Transmission Fluid Cooler Hose Inspection
1180
Air Conditioning Filter (if Equipped) Inspection
1180
Air Conditioning Filter (if Equipped) Replacement
1180
Recommended Fluids and Lubricants
1181
General Description
1183
Heater and Ventilation Construction
1183
On-Board Diagnostic System Description (Z13DT Engine Model)
1185
Diagnosis
1186
Heater and Ventilation System Symptom Diagnosis
1186
Diagnostic Trouble Code (DTC) Check (Z13DT Engine Model)
1187
Diagnostic Trouble Code (DTC) Table (Z13DT Engine Model)
1188
Heater Unit Components
1190
Heater Unit Removal and Installation
1191
Supplementary Heater Removal and Installation (if Equipped) (Z13DT Engine)
1192
Supplementary Heater Inspection
1192
Supplementary Heater Controller Removal and Installation (if Equipped) (Z13DT Engine)
1192
Supplementary Heater Relay Inspection
1192
Equipped) (Z13DT Engine)
1192
Air Inlet Box Components
1193
Condenser Assembly Removal and Installation
1203
Receiver / Dryer Removal and Installation
1204
Cooling Unit (Evaporator) Components
1206
Cooling Unit (Evaporator) Removal and Installation
1207
(Z13DT Engine)
1209
Pressure Sensor Removal and Installation (Z13DT Engine)
1209
A/C Relay Inspection (Z13DT Engine)
1209
Installation
1209
Compressor Drive Belt Inspection and Adjustment
1211
Compressor Drive Belt Replacement
1211
Magnet Clutch Inspection
1211
Relief Valve Inspection
1212
Specifications
1212
Tightening Torque Specifications
1212
Special Tools and Equipment
1213
Required Service Material
1213
Special Tool
1213
General Description
1223
Front Suspension Construction
1223
Diagnosis
1224
Wheel Disc, Nut and Bearing Check
1224
On-Vehicle Service
1225
Strut Assembly Removal and Installation
1225
Wheel Hub and Steering Knuckle Removal and Installation
1226
Tightening Torque Specifications
1228
General Description
1231
Rear Suspension Construction
1231
Diagnosis
1233
Wheel Disc, Nut and Bearing Check
1233
On-Vehicle Service
1251
Road Test
1439
Camshaft Inspection
2591
Crankcase Ventilation System
2706
Fastener Strength
2794
Drive Belt Inspection
2824
Exhaust System Inspection
2827
Side Ventilation Louver Removal and Installation
2838
Sembly and Assembly
3002
Wheel Bolts
3044
Tire Placard
3046
Tire Rotation
3046
Tire Repair
3048
Propeller Shafts
3070
Excessive Pedal Travel Check
3085
Brake Pedal Play Check
3085
Brake Fluid Level Check
3086
Flushing Brake Hydraulic System
3089
Booster Operation Check
3091
Inspection and Adjustment
3121
Front Brake Disc Inspection
3130
Timing Chain
3438
Valve Guides
3452
Cylinder Head
3454
Piston Rings
3462
Cylinder Block
3480
Ignition Timing Inspection
3572
Clutch Disc
3663
Body Electrical System
3718
Interior Light Switch
3732
Hood Adjustment
3849
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