Nissan X Trail Model t31 Series 2007 Service Repair Manual

QUICK REFERENCE INDEX
Publication Number:
A GENERAL INFORMATION GI General Information
SM7E00-1T31E0E
B ENGINE EM
LU
Engine Mechanical
Engine Lubrication System
A
CO Engine Cooling System
EC
FL
Engine Control System
Fuel System
B
EX Exhaust System
STR
ACC
Starting System
Accelerator Control System
C
D TRANSMISSION CL Clutch
& DRIVELINE
TM
DLN
Transaxle & Transmission
Driveline D
FAX Front Axle
E SUSPENSION
RAX
FSU
RSU
Rear Axle
Front Suspension
Rear Suspension
E
F BRAKES
WT
BR
PB
Road Wheels & Tires
Brake System
Parking Brake System
F
G STEERING
BRC
ST
STC
Brake Control System
Steering System
Steering Control System
G
H
H RESTRAINTS SB Seat Belt
MODEL T31 SERIES SBC Seat Belt Control System
SR SRS Airbag
SRC SRS Airbag Control System
I VENTILATION, HEATER
& AIR CONDITIONER
VTL
HA
Ventilation System
Heater & Air Conditioning System
I
HAC Heater & Air Conditioning Control System
J BODY INTERIOR INT
IP
Interior
Instrument Panel
J
SE Seat
K BODY EXTERIOR, DOOR,
ROOF & VEHICLE SECURITY
DLK
SEC
Door & Lock
Security Control System
K
GW Glass & Window System
PWC
RF
Power Window Control System
Roof
L
EXT Exterior
L DRIVER CONTROLS MIR
EXL
Mirrors
Exterior Lighting System M
INL Interior Lighting System
WW
DEF
HRN
Wiper & Washer
Defogger
Horn
N
M ELECTRICAL &
POWER CONTROL
PWO
BCS
Power Outlet
Body Control System O
LAN LAN System
LNL
LNR
PCS
LAN System (LHD)
LAN System (RHD)
Power Control System
P
CHG Charging System
PG Power Supply, Ground & Circuit Elements
N DRIVER INFORMATION MWI Meter, Warning Lanp & Indicator
& MULTIMEDIA
WCS Warning Chime System
AV Audio, Visual & Navigation System
P MAINTENANCE MA Maintenance
© 2007 NISSAN EUROPE S.A.S.
All rights reserved. No part of this Electronic Service Manual may be reproduced or stored in a retrieval system, or transmitted in any form,
or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Nissan Europe
S.A.S., Paris, France.
FOREWORD
This manual contains maintenance and repair procedures for the NISSAN
X-TRAIL, model T31 series.
In order to assure your safety and the efficient functioning of the vehicle,
this manual should be read thoroughly. It is especially important that the
PRECAUTIONS in the GI section be completely understood before starting
any repair task.
All information in this manual is based on the latest product information
at the time of publication. The right is reserved to make changes in speci-
fications and methods at any time without notice.
IMPORTANT SAFETY NOTICE

The proper performance of service is essential for both the safety of the
technician and the efficient functioning of the vehicle.
The service methods in this Service Manual are described in such a man-
ner that the service may be performed safely and accurately.
Service varies with the procedures used, the skills of the technician and the
tools and parts available. Accordingly, anyone using service procedures,
tools or parts which are not specifically recommended by NISSAN must
first be completely satisfied that neither personal safety nor the vehicle’s
safety will be jeopardized by the service method selected.
NISSAN EUROPE S.A.S.

Service Engineering Section
Paris, France
GENERAL INFORMATION
GI
GENERAL INFORMATION
SECTION GI B
E
CONTENTS
HOW TO USE THIS MANUAL ...................... 3 PRECAUTIONS ................................................. 27 F
Description ...............................................................27
HOW TO USE THIS MANUAL ............................ 3 Precaution for Supplemental Restraint System
Description ................................................................ 3 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN- G
Terms ........................................................................ 3 SIONER" .................................................................27
Units .......................................................................... 3 Precautions For Xenon Headlamp Service .............27
Contents .................................................................... 3 Precaution Necessary for Steering Wheel Rota- H
Relation between Illustrations and Descriptions ...... 4 tion After Battery Disconnect ...................................27
Components .............................................................. 4 Procedures without Cowl Top Cover .......................28
General Precautions ................................................28
HOW TO FOLLOW TROUBLE DIAGNOSES ..... 6 Three Way Catalyst .................................................30 I
Description ................................................................ 6 Multiport Fuel Injection System or Engine Control
How to Follow Test Groups in Trouble Diagnosis...... 6 System .....................................................................30
Key to Symbols Signifying Measurements or Pro- Turbocharger (If Equipped) .....................................30 J
cedures ..................................................................... 7
Hoses ......................................................................30
HOW TO READ WIRING DIAGRAMS ................ 9 Engine Oils ..............................................................31
Connector symbols ................................................... 9 Air Conditioning .......................................................32 K
Sample/wiring diagram -example- ........................... 10 FUEL ..........................................................................32
Description .............................................................. 11 FUEL : Unleaded Premium Gasoline ......................32
FUEL : Diesel Engine Fuel ......................................32 L
ABBREVIATIONS ..............................................13
Abbreviation List ...................................................... 13 LIFTING POINT ................................................. 33
TIGHTENING TORQUE OF STANDARD Commercial Service Tools .......................................33
M
Garage Jack and Safety Stand and 2-Pole Lift .......33
BOLTS ................................................................14
Board-On Lift ...........................................................34
Description .............................................................. 14
Tightening Torque Table (New Standard Includ- TOW TRUCK TOWING ..................................... 35 N
ed) ........................................................................... 14 Tow Truck Towing ...................................................35
Vehicle Recovery (Freeing a Stuck Vehicle) ...........36
TERMINOLOGY .................................................17
SAE J1930 Terminology List ................................... 17 BASIC INSPECTION ................................... 38 O
FEATURES OF NEW MODEL ..................... 21 SERVICE INFORMATION FOR ELECTRICAL

IDENTIFICATION INFORMATION .....................21 INCIDENT .......................................................... 38 P
Work Flow ................................................................38
Model Variation ....................................................... 21
Control Units and Electrical Parts ............................38
Information About Identification or Model Code ...... 22
Intermittent Incident .................................................39
Dimensions ............................................................. 25
Circuit Inspection .....................................................41
Wheels&Tires .......................................................... 26
CONSULT-III/GST CHECKING SYSTEM ......... 47
PRECAUTION .............................................. 27
Description ...............................................................47
GI-1
CONSULT-III Function and System Application*2... 47 Wiring Diagram - CONSULT-III/GST CHECKING
CONSULT-III/GST Data Link Connector (DLC) SYSTEM - ............................................................... 49
Circuit ..................................................................... 48
GI-2
HOW TO USE THIS MANUAL
< HOW TO USE THIS MANUAL >
HOW TO USE THIS MANUAL GI
Description INFOID:0000000001316093
B
This volume explains “Removal, Disassembly, Installation, Inspection and Adjustment” and “Trouble Diag-
noses”.
C
Terms INFOID:0000000001316094
• The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury
and/or damage to some part of the vehicle. D
WARNING indicates the possibility of personal injury if instructions are not followed.
CAUTION indicates the possibility of component damage if instructions are not followed.
BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information. E
Standard value: Tolerance at inspection and adjustment.
Limit value: The maximum or minimum limit value that should not be exceeded at inspection and adjust-
ment.
F
Units INFOID:0000000001316095
• The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), and G
alternatively expressed in the metric system and in the yard/pound system.
Also with regard to tightening torque of bolts and nuts, there are descriptions both about range and about the
standard tightening torque.
H
“Example”
Range
I
Outer Socket Lock Nut : 59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)
Standard J
Drive Shaft Installation Bolt : 44.3 N·m (4.5 kg-m, 33 ft-lb)

K
Contents INFOID:0000000001316096
• ALPHABETICAL INDEX is provided at the end of this manual so that you can rapidly find the item and page
you are searching for. L
• A QUICK REFERENCE INDEX, a black tab (e.g. ) is provided on the first page. You can quickly find the
first page of each section by matching it to the section's black tab.
• THE CONTENTS are listed on the first page of each section. M
• THE TITLE is indicated on the upper portion of each page and shows the part or system.
• THE PAGE NUMBER of each section consists of two or three letters which designate the particular section
and a number (e.g. “BR-5”). N
• THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks of
work and hidden or tricky steps which are not shown in the previous large illustrations.
Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle
or transmission, etc. are presented in a step-by-step format where necessary. O
GI-3
Relation between Illustrations and Descriptions INFOID:0000000001316097
The following sample explains the relationship between the part description in an illustration, the part name in
the text and the service procedures.
SAIA0519E
Components INFOID:0000000001316098
• THE LARGE ILLUSTRATIONS are exploded views (see the following) and contain tightening torques, lubri-
cation points, section number of the PARTS CATALOG (e.g. SEC. 440) and other information necessary to
perform repairs.
The illustrations should be used in reference to service matters only. When ordering parts, refer to the appro-
priate PARTS CATALOG.
Components shown in an illustration may be identified by a circled number. When this style of illustration is
used, the text description of the components will follow the illustration.
GI-4
GI
SFIA2959E F
1. Union bolt 2. Copper washer 3. Brake hose

4. Cap 5. Bleed valve 6. Sliding pin bolt
G
7. Piston seal 8. Piston 9. Piston boot
10. Cylinder body 11. Sliding pin 12. Torque member mounting bolt
13. Washer 14. Sliding pin boot 15. Bushing H
16. Torque member 17. Inner shim cover 18. Inner shim
19. Inner pad 20. Pad retainer 21. Pad wear sensor
22. Outer pad 23. Outer shim 24. Outer shim cover I
1: PBC (Poly Butyl Cuprysil) grease 2: Rubber grease : Brake fluid
or silicone-based grease
Refer to GI section for additional symbol definitions.
J
SYMBOLS
SAIA0749E O
GI-5
HOW TO FOLLOW TROUBLE DIAGNOSES
NOTICE:
Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following
instructions before diagnosing.
• Before performing trouble diagnoses, read the “Work Flow” in each section.
• After repairs, re-check that the problem has been completely eliminated.
• Refer to Component Parts and Harness Connector Location for the Systems described in each section for
identification/location of components and harness connectors.
• When checking circuit continuity, ignition switch should be OFF.
• Refer to the Circuit Diagram for quick pinpoint check.
If you need to check circuit continuity between harness connectors in more detail, such as when a sub-har-
ness is used, refer to Wiring Diagram in each individual section and Harness Layout in PG section for identi-
fication of harness connectors.
• Before checking voltage at connectors, check battery voltage.
• After accomplishing the Diagnosis Procedures and Electrical Components Inspection, make sure that all
harness connectors are reconnected as they were.
How to Follow Test Groups in Trouble Diagnosis INFOID:0000000001316100
JPAIA0021GB
1. Test group number and test group title

• Test group number and test group title are shown in the upper portion of each test group.
2. Work and diagnosis procedure
• Start to diagnose a problem using procedures indicated in enclosed test groups.
3. Questions and results
• Questions and required results are indicated in test group.
4. Action
• Next action for each test group is indicated based on result of each question.
GI-6
Key to Symbols Signifying Measurements or Procedures INFOID:0000000001316101
GI
I
SAIA1539E
GI-7
SAIA1540E
GI-8
HOW TO READ WIRING DIAGRAMS
GI
Connector symbols INFOID:0000000001316102
Most of connector symbols in wiring diagrams are shown from the terminal side. B
• Connector symbols shown from the terminal side are enclosed by
a single line and followed by the direction mark.
• Connector symbols shown from the harness side are enclosed by
a double line and followed by the direction mark. C
• Certain systems and components, especially those related to
OBD, may use a new style slide-locking type harness connector.
For description and how to disconnect, refer to PG section, D
“Description”, “HARNESS CONNECTOR”.
SAIA0257E
I
• Male and female terminals
Connector guides for male terminals are shown in black and
female terminals in white in wiring diagrams. J
SGI363
P
GI-9
Sample/wiring diagram -example- INFOID:0000000001316103
• For detail, refer to following GI-11, "Description".
JCAWA0005GB
GI-10
GI
Number Item Description

1 Power supply • This means the power supply of fusible link or fuse. B
2 Fusible link • “X” means the fusible link.
Number of fusible link/
3 • This means the number of fusible link or fuse location. C
fuse
4 Fuse • “/” means the fuse.
Current rating of fus-
5 • This means the current rating of the fusible link or fuse. D
ible link/fuse
6 Optional splice • The open circle shows that the splice is optional depending on vehicle application.
• The letter shows which harness the connector is located in.
E
7 Connector number • Example “M”: main harness. For detail and to locate the connector, refer to PG-88, "LHD
: How To Read Harness Layout", PG-90, "LHD : Main Harness".
8 Splice • The shaded circle “ ” means the splice.

F
9 Page crossing • This circuit continues to an adjacent page.
10 Option abbreviation • This means the vehicle specifications which layouts the circuit between “ ”.
11 Relay • This shows an internal representation of the relay. G
12 Option description • This shows a description of the option abbreviation used on the page.
• This shows that continuity exists between terminals 1 and 2 when the switch is in the A H
13 Switch
position. Continuity exists between terminals 1 and 3 when the switch is in the B position.
14 Circuit (Wiring) • This means the wiring.
15 System branch • This shows that the circuit is branched to other systems. I
16 Shielded line • The line enclosed by broken line circle shows shield wire.
17 Component name • This shows the name of a component.
18 Ground (GND) • This shows the ground connection.
J
• This means the connector information.

19 Connector
• This unit-side is described by the connector symbols.
K
20 Connectors • This means that a transmission line bypasses two connectors or more.
• This shows a code for the color of the wire.
BR = Brown L
B = Black
OR or O = Orange
W = White
P = Pink
R = Red
PU or V (Violet) = Purple
G = Green
21 Wire color L = Blue
GY or GR = Gray M
SB = Sky Blue
Y = Yellow
CH = Dark Brown
LG = Light Green
DG = Dark Green
N
• When the wire color is striped, the base color is given first, followed by the stripe color as
shown below:
Example: L/W = Blue with White Stripe
22 Terminal number • This means the terminal number of a connector. O
SWITCH POSITIONS
Switches are shown in wiring diagrams as if the vehicle is in the “normal” condition. P
A vehicle is in the “normal” condition when:
GI-11
• ignition switch is “OFF”,
• doors, hood and trunk lid/back door are closed,
• pedals are not depressed, and
• parking brake is released.
SGI860
MULTIPLE SWITCH
The continuity of multiple switch is described in two ways as shown below.
• The switch chart is used in schematic diagrams.
• The switch diagram is used in wiring diagrams.
JSAIA0017GB
GI-12
ABBREVIATIONS
ABBREVIATIONS
GI
Abbreviation List INFOID:0000000001316105
The following ABBREVIATIONS are used: B
ABBREVIATION DESCRIPTION
A/C Air Conditioner C
A/T Automatic Transaxle/Transmission
ATF Automatic Transmission Fluid
D1 Drive range 1st gear D
D2 Drive range 2nd gear
D3 Drive range 3rd gear
E
D4 Drive range 4th gear
FR, RR Front, Rear
LH, RH Left-Hand, Right-Hand F
M/T Manual Transaxle/Transmission
OD Overdrive
G
P/S Power Steering
SAE Society of Automotive Engineers, Inc.
SDS Service Data and Specifications H
SST Special Service Tools
2WD 2-Wheel Drive
I
22 2nd range 2nd gear
21 2nd range 1st gear
12 1st range 2nd gear J
11 1st range 1st gear
GI-13
TIGHTENING TORQUE OF STANDARD BOLTS
This vehicle has both new standard based on ISO* and previous standard bolts/nuts. There are some differ-
ences between these two types of bolts/ nuts; shape of the head, grade of strength, hexagonal width across
flats and the standard tightening torque.
• For guidance in discriminating, refer to GI-14, "Tightening Torque Table (New Standard Included)".
• The new standard machine screws and tapping screws have a head of ISO standard torx recess.
• If the tightening torque is not described in the description or figure, refer to GI-14, "Tightening Torque Table
(New Standard Included)".
*ISO: International Organization for Standardization
Tightening Torque Table (New Standard Included) INFOID:0000000001316107
CAUTION:
• The special parts are excluded.
• The bolts/nuts in these tables have a strength (discrimination) number/symbol assigned to the head
or the like. As to the relation between the strength grade in these tables and the strength (discrimi-
nation) number/symbol, refer to “DISCRIMINATION OF BOLTS AND NUTS”.
PREVIOUS STANDARD
Hexagonal Tightening torque (Without lubricant)

Grade Bolt di-
Bolt width Pitch
(Strength ameter Hexagon head bolt Hexagon flange bolt
size across flats mm
grade) mm
mm N·m kg-m ft-lb in-lb N·m kg-m ft-lb in-lb
M6 6.0 10 1.0 5.5 0.56 4 49 7 0.71 5 62
1.25 13.5 1.4 10 — 17 1.7 13 —
M8 8.0 12
1.0 13.5 1.4 10 — 17 1.7 13 —
1.5 28 2.9 21 — 35 3.6 26 —
4T M10 10.0 14
1.25 28 2.9 21 — 35 3.6 26 —
1.75 45 4.6 33 — 55 5.6 41 —
M12 12.0 17
1.25 45 4.6 33 — 65 6.6 48 —
M14 14.0 19 1.5 80 8.2 59 — 100 10 74 —
M6 6.0 10 1.0 9 0.92 7 80 11 1.1 8 97
1.25 22 2.2 16 — 28 2.9 21 —
M8 8.0 12
1.0 22 2.2 16 — 28 2.9 21 —
1.5 45 4.6 33 — 55 5.6 41 —
7T M10 10.0 14
1.25 45 4.6 33 — 55 5.6 41 —
1.75 80 8.2 59 — 100 10 74 —
M12 12.0 17
1.25 80 8.2 59 — 100 10 74 —
M14 14.0 19 1.5 130 13 96 — 170 17 125 —
M6 6.0 10 1.0 11 1.1 8 — 13.5 1.4 10 —
1.25 28 2.9 21 — 35 3.6 26 —
M8 8.0 12
1.0 28 2.9 21 — 35 3.6 26 —
1.5 55 5.6 41 — 80 8.2 59 —
9T M10 10.0 14
1.25 55 5.6 41 — 80 8.2 59 —
1.75 100 10 74 — 130 13 96 —
M12 12.0 17
1.25 100 10 74 — 130 13 96 —
M14 14.0 19 1.5 170 17 125 — 210 21 155 —
CAUTION:
GI-14
The parts with aluminum or the cast iron washer surface/screw surface are excluded.
GI
NEW STANDARD BASED ON ISO
Hexagonal Tightening torque

Grade Bolt di- B
Bolt width Pitch
(Strength ameter Hexagon head bolt Hexagon flange bolt
size across flats mm
grade) mm
mm N·m kg-m ft-lb in-lb N·m kg-m ft-lb in-lb
M6 6.0 10 1.0 5.5 0.56 4 49 7 0.71 5 62 C
1.25 13.5 1.4 10 — 17 1.7 13 —
M8 8.0 13
1.0 13.5 1.4 10 — 17 1.7 13 —
4.8 D
1.5 28 2.9 21 — 35 3.6 26 —
(Without M10 10.0 16
lubricant) 1.25 28 2.9 21 — 35 3.6 26 —
1.75 45 4.6 33 — 55 5.6 41 — E
M12 12.0 18
1.25 45 4.6 33 — 65 6.6 48 —
M14 14.0 21 1.5 80 8.2 59 — 100 10 74 —
M6 6.0 10 1.0 4 0.41 3 35 5.5 0.56 4 49 F
1.25 11 1.1 8 — 13.5 1.4 10 —
M8 8.0 13
1.0 11 1.1 8 — 13.5 1.4 10 —
G
4.8 1.5 22 2.2 16 — 28 2.9 21 —
(With lu- M10 10.0 16
bricant) 1.25 22 2.2 16 — 28 2.9 21 —
1.75 35 3.6 26 — 45 4.6 33 — H
M12 12.0 18
1.25 35 3.6 26 — 45 4.6 33 —
M14 14.0 21 1.5 65 6.6 48 — 80 8.2 59 —
I
M6 6.0 10 1.0 8 0.82 6 71 10 1.0 7 89
1.25 21 2.1 15 — 25 2.6 18 —
M8 8.0 13
1.0 21 2.1 15 — 25 2.6 18 — J
8.8 1.5 40 4.1 30 — 50 5.1 37 —
(With lu- M10 10.0 16
bricant) 1.25 40 4.1 30 — 50 5.1 37 —
K
1.75 70 7.1 52 — 85 8.7 63 —
M12 12.0 18
1.25 70 7.1 52 — 85 8.7 63 —
M14 14.0 21 1.5 120 12 89 — 140 14 103 — L
M6 6.0 10 1.0 10 1.0 7 89 12 1.2 9 106
1.25 27 2.8 20 — 32 3.3 24 —
M8 8.0 13 M
1.0 27 2.8 20 — 32 3.3 24 —
10.9 1.5 55 5.6 41 — 62 6.3 46 —
(With lu- M10 10.0 16
bricant) 1.25 55 5.6 41 — 62 6.3 46 —
N
1.75 95 9.7 70 — 105 11 77 —
M12 12.0 18
1.25 95 9.7 70 — 105 11 77 —
M14 14.0 21 1.5 160 16 118 — 180 18 133 — O
CAUTION:
1. Use tightening torque with lubricant for the new standard bolts/nuts in principle. Friction coeffi-
cient stabilizer is applied to the new standard bolts/nuts. P
2. However, use tightening torque without lubricant for the following cases. Friction coefficient stabi-
lizer is not applied to the following bolts/nuts.
- Grade 4.8, M6 size bolt, Conical spring washer installed
- Paint removing nut (Size M6 and M8) for fixing with weld bolt
GI-15
DISCRIMINATION OF BOLTS AND NUTS
SAIA0453E
GI-16
TERMINOLOGY
TERMINOLOGY
GI
SAE J1930 Terminology List INFOID:0000000001316108
All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly, new B
terms, new acronyms/abbreviations and old terms are listed in the following chart.
NEW ACRONYM /
NEW TERM OLD TERM C
ABBREVIATION
Air cleaner ACL Air cleaner
Barometric pressure BARO ***
D
Barometric pressure sensor-BCDD BAROS-BCDD BCDD
Camshaft position CMP ***
Camshaft position sensor CMPS Crank angle sensor E
Canister *** Canister
Carburetor CARB Carburetor
F
Charge air cooler CAC Intercooler
Closed loop CL Closed loop
Closed throttle position switch CTP switch Idle switch G
Clutch pedal position switch CPP switch Clutch switch
Continuous fuel injection system CFI system ***
H
Continuous trap oxidizer system CTOX system ***
Crankshaft position CKP ***
Crankshaft position sensor CKPS *** I
Data link connector DLC ***
Diagnostic test mode DTM Diagnostic mode
Diagnostic test mode selector DTM selector Diagnostic mode selector J
Diagnostic test mode I DTM I Mode I
Diagnostic test mode II DTM II Mode II
K
Diagnostic trouble code DTC Malfunction code
Direct fuel injection system DFI system ***
Distributor ignition system DI system Ignition timing control L
Early fuel evaporation-mixture heater EFE-mixture heater Mixture heater
Early fuel evaporation system EFE system Mixture heater control
M
Electrically erasable programmable read
EEPROM ***
only memory
Electronic ignition system EI system Ignition timing control
N
Engine control EC ***
Engine control module ECM ECCS control unit
Engine coolant temperature ECT Engine temperature O
Engine coolant temperature sensor ECTS Engine temperature sensor
Engine modification EM ***
P
Engine speed RPM Engine speed
Erasable programmable read only memory EPROM ***
Evaporative emission canister EVAP canister Canister
Evaporative emission system EVAP system Canister control solenoid valve
Exhaust gas recirculation valve EGR valve EGR valve
GI-17
TERMINOLOGY
NEW ACRONYM /
NEW TERM OLD TERM
ABBREVIATION
Exhaust gas recirculation control-BPT
EGRC-BPT valve BPT valve
valve
Exhaust gas recirculation control-solenoid
EGRC-solenoid valve EGR control solenoid valve
valve
Exhaust gas recirculation temperature sen-
sor EGRT sensor Exhaust gas temperature sensor
EGR temperature sensor
Flash electrically erasable programmable
FEEPROM ***
read only memory
Flash erasable programmable read only
FEPROM ***
memory
Flexible fuel sensor FFS ***
Flexible fuel system FF system ***
Fuel pressure regulator *** Pressure regulator
Fuel pressure regulator control solenoid
*** PRVR control solenoid valve
valve
Fuel trim FT ***
Heated Oxygen sensor HO2S Exhaust gas sensor
Idle air control system IAC system Idle speed control
Idle air control valve-air regulator IACV-air regulator Air regulator
Idle air control valve-auxiliary air control
IACV-AAC valve Auxiliary air control (AAC) valve
valve
Idle air control valve-FICD solenoid valve IACV-FICD solenoid valve FICD solenoid valve
Idle air control valve-idle up control sole-
IACV-idle up control solenoid valve Idle up control solenoid valve
noid valve
Idle speed control-FI pot ISC-FI pot FI pot
Idle speed control system ISC system ***
Ignition control IC ***
Ignition control module ICM ***
Indirect fuel injection system IFI system ***
Intake air IA Air
Intake air temperature sensor IAT sensor Air temperature sensor
Knock *** Detonation
Knock sensor KS Detonation sensor
Malfunction indicator lamp MIL Check engine light
Manifold absolute pressure MAP ***
Manifold absolute pressure sensor MAPS ***
Manifold differential pressure MDP ***
Manifold differential pressure sensor MDPS ***
Manifold surface temperature MST ***
Manifold surface temperature sensor MSTS ***
Manifold vacuum zone MVZ ***
Manifold vacuum zone sensor MVZS ***
Mass air flow sensor MAFS Air flow meter
Mixture control solenoid valve MC solenoid valve Air-fuel ratio control solenoid valve
Multiport fuel injection System MFI system Fuel injection control
GI-18
TERMINOLOGY
NEW ACRONYM /
NEW TERM OLD TERM
ABBREVIATION GI
Nonvolatile random access memory NVRAM ***
On board diagnostic system OBD system Self-diagnosis
B
Open loop OL Open loop
Oxidation catalyst OC Catalyst
Oxidation catalytic converter system OC system *** C
Oxygen sensor O2S Exhaust gas sensor
Park position switch *** Park switch
D
Park/neutral switch
Park/neutral position switch PNP switch Inhibitor switch
Neutral position switch
Periodic trap oxidizer system PTOX system *** E
Positive crankcase ventilation PCV Positive crankcase ventilation
Positive crankcase ventilation valve PCV valve PCV valve
F
Powertrain control module PCM ***
Programmable read only memory PROM ***
Pulsed secondary air injection control sole-
PAIRC solenoid valve AIV control solenoid valve
G
noid valve
Pulsed secondary air injection system PAIR system Air induction valve (AIV) control
Pulsed secondary air injection valve PAIR valve Air induction valve H
Random access memory RAM ***
Read only memory ROM ***
I
Scan tool ST ***
Secondary air injection pump AIR pump ***
Secondary air injection system AIR system *** J
Sequential multiport fuel injection system SFI system Sequential fuel injection
Service reminder indicator SRI ***
K
Simultaneous multiport fuel injection sys-
*** Simultaneous fuel injection
tem
Smoke puff limiter system SPL system ***
L
Supercharger SC ***
Supercharger bypass SCB ***
System readiness test SRT *** M
Thermal vacuum valve TVV Thermal vacuum valve
Three way catalyst TWC Catalyst
N
Three way catalytic converter system TWC system ***
Three way + oxidation catalyst TWC + OC Catalyst
Three way + oxidation catalytic converter O
TWC + OC system ***
system
Throttle chamber
Throttle body TB
SPI body
P
Throttle body fuel injection system TBI system Fuel injection control
Throttle position TP Throttle position
Throttle position sensor TPS Throttle sensor
Throttle position switch TP switch Throttle switch
Lock-up cancel solenoid
Torque converter clutch solenoid valve TCC solenoid valve
Lock-up solenoid
GI-19
TERMINOLOGY
NEW ACRONYM /
NEW TERM OLD TERM
ABBREVIATION
Transmission control module TCM A/T control unit
Turbocharger TC Turbocharger
Vehicle speed sensor VSS Vehicle speed sensor
Volume air flow sensor VAFS Air flow meter
Warm up oxidation catalyst WU-OC Catalyst
Warm up oxidation catalytic converter sys-
WU-OC system ***
tem
Warm up three way catalyst WU-TWC Catalyst
Warm up three way catalytic converter sys-
WU-TWC system ***
tem
Wide open throttle position switch WOTP switch Full switch
***: Not applicable
GI-20
IDENTIFICATION INFORMATION
< FEATURES OF NEW MODEL >
FEATURES OF NEW MODEL GI
Model Variation INFOID:0000000001316109
B
Destination Discrimination of
WVTA
C
Body Engine Axle Transaxle Grade Equip- LHD for South-
RHD for Europe ern/Central (Whole Vehicle
ment
Europe Type Approval)
Comfort TDRARAY-EEA TDRALAY-EGA

D
2WD
Sports TDRARFY-EEA TDRALFY-EGA
6MT Comfort TDRNRAY-EEA TDRNLAY-EGA E
MR20D Sports TDRNRFY-EEA TDRNLFY-EGA With WVTA
E
Flagship TDRNRJY-EEA TDRNLJY-EGA (EURO 4*1)
Comfort TDRNRAZ-EEA TDRNLAZ-EGA F
CVT Sports TDRNRFZ-EEA TDRNLFZ-EGA
4WD
Flagship TDRNRJZ-EEA TDRNLJZ-EGA
G
Sports Standard TDBNRFY-EEA TDBNLFY-EGA
6MT With (EURO 4*1)
Flagship TDBNRJY-EEA TDBNLJY-EGA /without
QR25DE
5-door Sports TDBNRFW-EEA TDBNLFW-EGA (EURO 2*1) H
M-CVT WVTA*2
wagon Flagship TDBNRJW-EEA TDBNLJW-EGA
Comfort TTYARAY-UEA TTYALAY-UGA
2WD I
Sports TTYARFY-UEA TTYALFY-UGA
Comfort TTYNRAY-UEA TTYNLAY-UGA
6MT
Sports TTYNRFY-UEA TTYNLFY-UGA J
Flagship TTYNRJY-UEA TTYNLJY-UGA
M9R With WVTA
Sports High TTYNRFY-UEK TTYNLFY-UGK
4WD K
Comfort TTYNRAM-UEA TTYNLAM-UGA
Sports Standard TTYNRFM-UEA TTYNLFM-UGA
6AT
Flagship TTYNRJM-UEA TTYNLJM-UGA L
Flagship High TTYNRJY-UEK TTYNLJY-UGK
*1: EURO 4: With OBD, EURO 2: Without OBD
*2: Regarding how to discriminate between models with WVTA and without WVTA, refer to column 1 of “IDENTIFICATION PLATE”. M
GI-21
Model variation code (Prefix and suffix designations) :
JPAIA0049GB
Information About Identification or Model Code INFOID:0000000001316110
IDENTIFICATION NUMBER
JPAIA0050ZZ
Vehicle identification number (Chas- Vehicle identification number plate

1. Vehicle identification plate 2. 3.
sis number) (RHD only)
4. Tire placard (driver's side) 5. Air conditioner specification label
VEHICLE Identification Number ARRANGEMENT
GI-22
For Europe
GI
H
JPAIA0051GB
For Israel
I
JPAIA0052GB
N
IDENTIFICATION PLATE
JPAIA0053ZZ
GI-23
Type approval number (Models

Vehicle identification number (Chassis
1. with WVTA) 2. 3. Gross vehicle weight
number)
Blank (Models without WVTA)
Gross combination weight
4. Gross vehicle weight 5. Gross axle weight (Front) 6. Gross axle weight (Rear)
+ Gross trailing capacity (Weight)
7. Vehicle type 8. Body color code 9. Trim color code
10. Model variation code
ENGINE SERIAL NUMBER

MR ENGINE
: Vehicle front
SAIA1341E
QR ENGINE
: Vehicle front
JPAIA0054ZZ
M9R ENGINE
: Vehicle front
JPAIA0068ZZ
AUTOMATIC TRANSAXLE NUMBER

CVT Unit
GI-24
: Vehicle front GI
SAIA1496E
D
6AT (RE6F01A)
: Vehicle front E
JPAIA0055ZZ
H
MANUAL TRANSAXLE NUMBER
6MT (RS6F94R)
I
: Vehicle front
SAIA1338E L
6MT (RS6F52A)
: Vehicle front M
JPAIA0046ZZ
P
Dimensions INFOID:0000000001316111
Unit: mm (in)
Overall length 4,630 (182.3)

Overall width 1,785 (70.3)
GI-25
1,685 (66.3)
Overall height
1,770 (69.7)*
Front tread 1,530 (60.2)
Rear tread 1,535 (60.4)
Wheelbase 2,630 (103.5)
*: Roof rail (with driving lights) equipped models
Wheels&Tires INFOID:0000000001316112
Conventional Spare
16 × 6 1/2 J Aluminum/45 (1.77)
Road wheel/offset mm (in) 16 × 6 1/2 JJ Steel /45 (1.77) 16 × 6 1/2JJ Steel/45 (1.77)
17 × 6 1/2 J Aluminum/45 (1.77)
215/65R16 98H
Tire size 215/65R16 98M
215/60R17 96H
GI-26
PRECAUTIONS
< PRECAUTION >
PRECAUTION GI
PRECAUTIONS
B
Observe the following precautions to ensure safe and proper servicing. These precautions are not
described in each individual section.
C
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000001412553
D
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIRBAG” and
“SEAT BELT” of this Service Manual. E
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by F
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag G
Module, see the “SRS AIRBAG”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors. H
Precautions For Xenon Headlamp Service INFOID:0000000001316115
I
WARNING:
Comply with the following warnings to prevent any serious accident.
• Disconnect the battery cable (negative terminal) or the power supply fuse before installing, remov-
ing, or touching the xenon headlamp (bulb included). The xenon headlamp contains high-voltage J
generated parts.
• Never work with wet hands.
• Check the xenon headlamp ON-OFF status after assembling it to the vehicle. Never turn the xenon K
headlamp ON in other conditions. Connect the power supply to the vehicle-side connector.
(Turning it ON outside the lamp case may cause fire or visual impairments.)
• Never touch the bulb glass immediately after turning it OFF. It is extremely hot.
CAUTION: L
Comply with the following cautions to prevent any error and malfunction.
• Install the xenon bulb securely. (Insufficient bulb socket installation may melt the bulb, the connec-
tor, the housing, etc. by high-voltage leakage or corona discharge.) M
• Never perform HID circuit inspection with a tester.
• Never touch the xenon bulb glass with hands. Never put oil and grease on it.
• Dispose of the used xenon bulb after packing it in thick vinyl without breaking it.
N
• Never wipe out dirt and contamination with organic solvent (thinner, gasoline, etc.).
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
INFOID:0000000001316116
O
NOTE:
• This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYS-
TEM). P
• Remove and install all control units after disconnecting both battery cables with the ignition knob in the
″LOCK″ position.
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.
If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech-
anism is adopted on the key cylinder.
GI-27
PRECAUTIONS
< PRECAUTION >
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-III.
Procedures without Cowl Top Cover INFOID:0000000001316117
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
PIIB3706J
General Precautions INFOID:0000000001316118
• Do not operate the engine for an extended period of time without

proper exhaust ventilation.
Keep the work area well ventilated and free of any inflammable
materials. Special care should be taken when handling any inflam-
mable or poisonous materials, such as gasoline, refrigerant gas,
etc. When working in a pit or other enclosed area, be sure to prop-
erly ventilate the area before working with hazardous materials.
Do not smoke while working on the vehicle.
SGI285
• Before jacking up the vehicle, apply wheel chocks or other tire

blocks to the wheels to prevent the vehicle from moving. After jack-
ing up the vehicle, support the vehicle weight with safety stands at
the points designated for proper lifting before working on the vehi-
cle.
These operations should be done on a level surface.
• When removing a heavy component such as the engine or tran-
saxle/transmission, be careful not to lose your balance and drop
them. Also, do not allow them to strike adjacent parts, especially
the brake tubes and master cylinder.
SGI231
GI-28
PRECAUTIONS
< PRECAUTION >
• Before starting repairs which do not require battery power:
Turn off ignition switch. GI
Disconnect the negative battery terminal.
• If the battery terminals are disconnected, recorded memory of
radio and each control unit is erased.
B
SEF289H
D
• To prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot. E
• Dispose of drained oil or the solvent used for cleaning parts in an
appropriate manner.
• Do not attempt to top off the fuel tank after the fuel pump nozzle
shuts off automatically. F
Continued refueling may cause fuel overflow, resulting in fuel spray
and possibly a fire.
• Clean all disassembled parts in the designated liquid or solvent G
prior to inspection or assembly.
SGI233
• Replace oil seals, gaskets, packings, O-rings, locking washers,
cotter pins, self-locking nuts, etc. with new ones. H
• Replace inner and outer races of tapered roller bearings and needle bearings as a set.
• Arrange the disassembled parts in accordance with their assembled locations and sequence.
• Do not touch the terminals of electrical components which use microcomputers (such as ECM).
Static electricity may damage internal electronic components. I
• After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.
• Use only the fluids and lubricants specified in this manual.
• Use approved bonding agent, sealants or their equivalents when required. J
• Use hand tools, power tools (disassembly only) and recommended
special tools where specified for safe and efficient service repairs.
• When repairing the fuel, oil, water, vacuum or exhaust systems,
check all affected lines for leaks. K
M
PBIC0190E
• Before servicing the vehicle: N

Protect fenders, upholstery and carpeting with appropriate covers.
Take caution that keys, buckles or buttons do not scratch paint.
O
SGI234
WARNING:
To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness
connectors which are related to the engine control system and TCM (transmission control module)
GI-29
PRECAUTIONS
< PRECAUTION >
system. The connectors should be disconnected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC and AT sections.
Three Way Catalyst INFOID:0000000001316119
If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To
prevent this, follow the instructions.
• Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst.
• When checking for ignition spark or measuring engine compression, make tests quickly and only when nec-
essary.
• Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to the
catalyst.
Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three
way catalyst.
Multiport Fuel Injection System or Engine Control System INFOID:0000000001316120
• Before connecting or disconnecting any harness connector for the

multiport fuel injection system or ECM:
Turn ignition switch to “OFF” position.
Disconnect negative battery terminal.
Otherwise, there may be damage to ECM.
• Before disconnecting pressurized fuel line from fuel pump to injec-
tors, be sure to release fuel pressure.
• Be careful not to jar components such as ECM and mass air flow
sensor.
SGI787
Turbocharger (If Equipped) INFOID:0000000001316121
The turbocharger turbine revolves at extremely high speeds and

becomes very hot. Therefore, it is essential to maintain a clean sup-
ply of oil flowing through the turbocharger and to follow all required
maintenance instructions and operating procedures.
• Always use the recommended oil. Follow the instructions for
proper time to change the oil and proper oil level.
• Avoid accelerating engine to a high rpm immediately after starting.
• If engine had been operating at high rpm for an extended period of
time, let it idle for a few minutes prior to shutting if off.
SGI292
Hoses INFOID:0000000001316122
HOSE REMOVAL AND INSTALLATION

• To prevent damage to rubber hose, do not pry off rubber hose with
tapered tool or screwdriver.
SMA019D
GI-30
PRECAUTIONS
< PRECAUTION >
• To reinstall the rubber hose securely, make sure that hose insertion
length and orientation is correct. (If tube is equipped with hose GI
stopper, insert rubber hose into tube until it butts up against hose
stopper.)
B
SMA020D
D
HOSE CLAMPING
• If old rubber hose is re-used, install hose clamp in its original posi-
tion (at the indentation where the old clamp was). If there is a trace
of tube bulging left on the old rubber hose, align rubber hose at E
that position.
• Discard old clamps; replace with new ones.
F
SMA021D
H
• After installing plate clamps, apply force to them in the direction of
the arrow, tightening rubber hose equally all around.
I
K
SMA022D
Engine Oils INFOID:0000000001316123
L
Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin contact
with used oil.
If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.
M
HEALTH PROTECTION PRECAUTIONS
• Avoid prolonged and repeated contact with oils, particularly used engine oils.
• Wear protective clothing, including impervious gloves where practicable. N
• Do not put oily rags in pockets.
• Avoid contaminating clothes, particularly underpants, with oil.
• Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regu-
larly. O
• First aid treatment should be obtained immediately for open cuts and wounds.
• Use barrier creams, applying them before each work period, to help the removal of oil from the skin.
• Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Prepara- P
tions containing lanolin replace the natural skin oils which have been removed.
• Do not use gasoline, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin.
• If skin disorders develop, obtain medical advice without delay.
• Where practical, degrease components prior to handling.
• Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face
shields; in addition an eye wash facility should be provided.
ENVIRONMENTAL PROTECTION PRECAUTIONS
GI-31
PRECAUTIONS
< PRECAUTION >
Dispose of used oil and used oil filters through authorized waste disposal contractors to licensed waste dis-
posal sites, or to the waste oil reclamation trade. If in doubt, contact the local authority for advice on disposal
facilities.
It is illegal to pour used oil on to the ground, down sewers or drains, or into water sources.
The regulations concerning pollution vary between regions.
Air Conditioning INFOID:0000000001316124
Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to
HA section “REFRIGERATION SYSTEM” for specific instructions.
FUEL
FUEL : Unleaded Premium Gasoline INFOID:0000000001316125
Use unleaded premium gasoline with an octane rating of at least 95 RON (research octane number). If pre-
mium unleaded gasoline is not available, unleaded regular gasoline with an octane rating of at least 91 RON
(research octane number) can be used. However, for maximum vehicle performance, the use of premium
unleaded gasoline is recommended.
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel
other than that specified could adversely affect the emission control devices and systems, and could
also affect the warranty coverage validity.
FUEL : Diesel Engine Fuel INFOID:0000000001316126
Diesel fuel of at least 50 cetane.

If two types of diesel fuel are available, use summer or winter fuel properly according to the following temper-
ature conditions.
• Above −7°C...Summer type diesel fuel.
• Below −7°C...Winter type diesel fuel.
CAUTION:
• Do not use home heating oil, gasoline or other alternate fuels in your diesel engine. The use of those
can cause engine damage.
• Do not use summer fuel at temperatures below −7°C (20°F). The cold temperatures will cause wax to
form in the fuel. As a result, it may prevent the engine from running smoothly.
• Do not add gasoline or other alternate fuels to diesel fuel.
GI-32
LIFTING POINT
< PRECAUTION >
LIFTING POINT
GI
Commercial Service Tools INFOID:0000000001316127
B
Tool name Description
Board on attachment
D
S-NT001
Safety stand attachment F
S-NT002 G
CAUTION:
• Every time the vehicle is lifted up, maintain the complete vehicle curb condition.
• Since the vehicle's center of gravity changes when removing main parts on the front side (engine, H
transmission, suspension etc.), support a jack up point on the rear side garage jack with a mission
jack or equivalent.
• Since the vehicle's center of gravity changes when removing main parts on the rear side (rear axle,
I
suspension, etc.), support a jack up point on the front side garage jack with a mission jack or equiv-
alent.
• Be careful not to smash or do not do anything that would affect piping parts.
J
Garage Jack and Safety Stand and 2-Pole Lift INFOID:0000000001316128
WARNING: K
• Park the vehicle on a level surface when using the jack. Make sure to avoid damaging pipes, tubes,
etc. under the vehicle.
• Never get under the vehicle while it is supported only by the jack. Always use safety stands when
you have to get under the vehicle. L
• Place wheel chocks at both front and back of the wheels on the ground.
• When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of
the vehicle are well balanced. M
• When setting the lift arm, do not allow the arm to contact the brake tubes, brake cable, fuel lines and
sill spoiler.
N
GI-33
LIFTING POINT
< PRECAUTION >
JMAIA0026ZZ
1. Safety stand point and lift up point (front) 2. Safety stand point and lift up point 3. Garage jack point (front)
(rear)
4. Garage jack point (rear) (2WD) 5. Garage jack point (rear) (4WD)
CAUTION:
There is canister just behind Garage jack point rear. Jack up be carefully.
Board-On Lift INFOID:0000000001316129
CAUTION:
Make sure vehicle is empty when lifting.
• The board-on lift attachment (A) set at front end of vehicle
should be set on the front of the sill under the front door
opening.
• Position attachments at front and rear ends of board-on lift.
: Vehicle front
JMAIA0004ZZ
GI-34
TOW TRUCK TOWING
< PRECAUTION >
TOW TRUCK TOWING
GI
Tow Truck Towing INFOID:0000000001316130
CAUTION: B
• All applicable local laws regarding the towing operation must be obeyed.
• It is necessary to use proper towing equipment to avoid possible damage to the vehicle during tow-
ing operation. Towing is in accordance with Towing Procedure Manual at dealer.
• Always attach safety chains before towing. C
• When towing, make sure that the transmission, steering system and powertrain are in good order. If
any unit is damaged, dollies must be used.
• Never tow an automatic transmission model and CVT model from the rear (that is backward) with D
four wheels on the ground. This may cause serious and expensive damage to the transmission.
2WD MODELS
E
JMAIA0022ZZ J
NISSAN recommends that vehicle be towed with the driving (front) wheels off the ground or that a dolly be
used as illustrated. K
CAUTION:
• Never tow automatic transmission model and CVT models with the front wheels on the ground or
four wheels on the ground (forward or backward), as this may cause serious and expensive damage
L
to the transmission.
If it is necessary to tow the vehicle with the rear wheels raised, always use towing dollies under the
front wheels.
• When towing automatic transmission model and CVT models with the front wheels on towing dol- M
lies:
- Turn the ignition key to the OFF position, and secure the steering wheel in a straight ahead position
with a rope or similar device.Never secure the steering wheel by turning the ignition key to the LOCK
N
position. This may damage the steering lock mechanism.
- Move the selector lever to the N (Neutral) position.
• When towing two wheel drive automatic transmission model and CVT model with the rear wheels on
the ground (if you do not use towing dollies): Always release the parking brake. O
GI-35
TOW TRUCK TOWING
< PRECAUTION >
4WD MODELS
JMAIA0023ZZ
NISSAN recommends that a dolly be used as illustrated when towing 4WD models.
CAUTION:
Never tow 4WD models with any of the wheels on the ground as this may cause serious and expensive
damage to the drive train.
Vehicle Recovery (Freeing a Stuck Vehicle) INFOID:0000000001316131
FRONT
1. Remove the hook cover from the bumper using a remover tool.
2. Securely install the vehicle recovery hook stored with jacking
tools.
Make sure that the hook is properly secured in the stored place after
use.
WARNING:
• Stand clear of a stuck vehicle.
• Do not spin your tires at high speed. This could cause them to
explode and result in serious injury. Parts of your vehicle
could also overheat and be damaged.
CAUTION:
• Tow chains or cables must be attached only to the vehicle JMAIA0024ZZ
recovery hooks or main structural members of the vehicle.

Otherwise, the vehicle body will be damaged.
• Do not use the vehicle tie downs to free a vehicle stuck in sand, snow, mud, etc. Never tow the vehi-
cle using the vehicle tie downs or recovery hooks.
• Always pull the cable straight out from the front of the vehicle. Never pull on the hook at an angle.
• Pulling devices should be routed so they do not touch any part of the suspension, steering, brake or
cooling systems.
• Pulling devices such as ropes or canvas straps are not recommended for use in vehicle towing or
recovery.
REAR
WARNING:
GI-36
TOW TRUCK TOWING
< PRECAUTION >
• Rear hook is not available.
GI
JMAIA0025ZZ
GI-37
SERVICE INFORMATION FOR ELECTRICAL INCIDENT
< BASIC INSPECTION >
BASIC INSPECTION
Work Flow INFOID:0000000001316132
WORK FLOW
SGI838
STEP DESCRIPTION
Get detailed information about the conditions and the environment when the incident occurred.
The following are key pieces of information required to make a good analysis:
WHAT Vehicle Model, Engine, Transmission/Transaxle and the System (i.e. Radio).
STEP 1 WHEN Date, Time of Day, Weather Conditions, Frequency.
WHERE Road Conditions, Altitude and Traffic Situation.
System Symptoms, Operating Conditions (Other Components Interaction).
HOW
Service History and if any After Market Accessories have been installed.
Operate the system, road test if necessary.
STEP 2 Verify the parameter of the incident.
If the problem cannot be duplicated, refer to “Incident Simulation Tests”.
Get the proper diagnosis materials together including:
• Power Supply Routing
• System Operation Descriptions
STEP 3
• Applicable Service Manual Sections
• Check for any Service Bulletins
Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments.
Inspect the system for mechanical binding, loose connectors or wiring damage.
STEP 4 Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness Lay-
outs.
STEP 5 Repair or replace the incident circuit or component.
Operate the system in all modes. Verify the system works properly under all conditions. Make sure you have not inad-
STEP 6
vertently created a new incident during your diagnosis or repair steps.
Control Units and Electrical Parts INFOID:0000000001316133
PRECAUTIONS
• Never reverse polarity of battery terminals.
• Install only parts specified for a vehicle.
• Before replacing the control unit, check the input and output and functions of the component parts.
• Do not apply excessive force when disconnecting a connector.
GI-38
• Do not apply excessive shock to the control unit by dropping or hit-
ting it. GI
• Be careful to prevent condensation in the control unit due to rapid
temperature changes and do not let water or rain get on it. If water
is found in the control unit, dry it fully and then install it in the vehi-
B
cle.
• Be careful not to let oil to get on the control unit connector.
• Avoid cleaning the control unit with volatile oil.
• Do not disassemble the control unit, and do not remove the upper C
and lower covers.
SAIA0255E
D
• When using a DMM, be careful not to let test probes get close to
each other to prevent the power transistor in the control unit from
damaging battery voltage because of short circuiting. E
• When checking input and output signals of the control unit, use the
specified check adapter.
F
SEF348N
K
Intermittent Incident INFOID:0000000001316134
DESCRIPTION L
Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create the
conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The fol-
lowing section illustrates ways to simulate the conditions/environment under which the owner experiences an M
electrical incident.
The section is broken into the six following topics:
• Vehicle vibration N
• Heat sensitive
• Freezing
• Water intrusion O
• Electrical load
• Cold or hot start up
Get a thorough description of the incident from the customer. It is important for simulating the conditions of the
problem. P
VEHICLE VIBRATION
The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with
A/C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustra-
tion.
Connector & Harness
GI-39
Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently
shake each connector and harness while monitoring the system for the incident you are trying to duplicate.
This test may indicate a loose or poor electrical connection.
Hint
Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector termi-
nals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs inter-
mittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the
terminals on related connectors in the system.
Sensor & Relay
Gently apply a slight vibration to sensors and relays in the system you are inspecting.
This test may indicate a loose or poorly mounted sensor or relay.
SGI839
Engine Compartment
There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the
things to check for are:
• Connectors not fully seated.
• Wiring harness not long enough and is being stressed due to engine vibrations or rocking.
• Wires laying across brackets or moving components.
• Loose, dirty or corroded ground wires.
• Wires routed too close to hot components.
To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to Ground
Inspection described later.) First check that the system is properly grounded. Then check for loose connection
by gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect the
wiring for continuity.
Behind the Instrument Panel
An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehi-
cle vibration can aggravate a harness which is routed along a bracket or near a screw.
Under Seating Areas
An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides)
during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage or
pinching.
HEAT SENSITIVE
• The customer's concern may occur during hot weather or after car
has sat for a short time. In such cases you will want to check for a
heat sensitive condition.
• To determine if an electrical component is heat sensitive, heat the
component with a heat gun or equivalent.
CAUTION:
Do not heat components above 60°C (140°).
• If incident occurs while heating the unit, either replace or properly
insulate the component.
SGI842
FREEZING
GI-40
• The customer may indicate the incident goes away after the car
warms up (winter time). The cause could be related to water freez- GI
ing somewhere in the wiring/electrical system.
• There are two methods to check for this. The first is to arrange for
the owner to leave his car overnight. Make sure it will get cold
B
enough to demonstrate his complaint. Leave the car parked out-
side overnight. In the morning, do a quick and thorough diagnosis
of those electrical components which could be affected.
• The second method is to put the suspect component into a freezer C
long enough for any water to freeze. Reinstall the part into the car
and check for the reoccurrence of the incident. If it occurs, repair or
SGI843
replace the component. D
WATER INTRUSION
The incident may occur only during high humidity or in rainy/snowy
weather. In such cases the incident could be caused by water intru- E
sion on an electrical part. This can be simulated by soaking the car
or running it through a car wash.
CAUTION:
Do not spray water directly on any electrical components. F
SGI844
H
ELECTRICAL LOAD
The incident may be electrical load sensitive. Perform diagnosis with
all accessories (including A/C, rear window defogger, radio, fog
lamps) turned on. I
K
SGI845
COLD OR HOT START UP L

On some occasions an electrical incident may occur only when the car is started cold, or it may occur when
the car is restarted hot shortly after being turned off. In these cases you may have to keep the car overnight to
make a proper diagnosis.
M
Circuit Inspection INFOID:0000000001316135
DESCRIPTION N
• In general, testing electrical circuits is an easy task if it is approached in a logical and organized method.
Before beginning it is important to have all available information on the system to be tested. Also, get a thor-
ough understanding of system operation. Then you will be able to use the appropriate equipment and follow O
the correct test procedure.
• You may have to simulate vehicle vibrations while testing electrical components. Gently shake the wiring
harness or electrical component to do this.
P
OPEN A circuit is open when there is no continuity through a section of the circuit.
There are two types of shorts.
When a circuit contacts another circuit and causes the normal resistance to
SHORT • SHORT CIRCUIT
change.
• SHORT TO GROUND When a circuit contacts a ground source and grounds the circuit.
GI-41
TESTING FOR “OPENS” IN THE CIRCUIT
Before you begin to diagnose and test the system, you should rough sketch a schematic of the system. This
will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your work-
ing knowledge of the system.
SGI846-A
Continuity Check Method

The continuity check is used to find an open in the circuit. The digital multimeter (DMM) set on the resistance
function will indicate an open circuit as over limit (no beep tone or no ohms symbol). Make sure to always start
with the DMM at the highest resistance level.
To help in understanding the diagnosis of open circuits, please refer to the previous schematic.
• Disconnect the battery negative cable.
• Start at one end of the circuit and work your way to the other end. (At the fuse block in this example)
• Connect one probe of the DMM to the fuse block terminal on the load side.
• Connect the other probe to the fuse block (power) side of SW1. Little or no resistance will indicate that por-
tion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over
limit or infinite resistance condition. (point A)
• Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of the circuit
has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resis-
tance condition. (point B)
• Connect the probes between the relay and the solenoid. Little or no resistance will indicate that portion of the
circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infi-
nite resistance condition. (point C)
Any circuit can be diagnosed using the approach in the previous example.
Voltage Check Method
To help in understanding the diagnosis of open circuits please refer to the previous schematic.
In any powered circuit, an open can be found by methodically checking the system for the presence of voltage.
This is done by switching the DMM to the voltage function.
• Connect one probe of the DMM to a known good ground.
• Begin probing at one end of the circuit and work your way to the other end.
• With SW1 open, probe at SW1 to check for voltage.
voltage; open is further down the circuit than SW1.
no voltage; open is between fuse block and SW1 (point A).
• Close SW1 and probe at relay.
voltage; open is further down the circuit than the relay.
no voltage; open is between SW1 and relay (point B).
• Close the relay and probe at the solenoid.
voltage; open is further down the circuit than the solenoid.
no voltage; open is between relay and solenoid (point C).
Any powered circuit can be diagnosed using the approach in the previous example.
TESTING FOR “SHORTS” IN THE CIRCUIT
GI-42
To simplify the discussion of shorts in the system, please refer to the following schematic.
GI
SGI847-A
Resistance Check Method D

• Disconnect the battery negative cable and remove the blown fuse.
• Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the fuse.
• Connect one probe of the DMM to the load side of the fuse terminal. Connect the other probe to a known E
good ground.
• With SW1 open, check for continuity.
continuity; short is between fuse terminal and SW1 (point A).
F
no continuity; short is further down the circuit than SW1.
• Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good ground.
Then, check for continuity.
continuity; short is between SW1 and the relay (point B). G
no continuity; short is further down the circuit than the relay.
• Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and a
known good ground. Then, check for continuity. H
continuity; short is between relay and solenoid (point C).
no continuity; check solenoid, retrace steps.
Voltage Check Method I
• Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid discon-
nected) powered through the fuse.
• Turn the ignition key to the ON or START position. Verify battery voltage at the battery + side of the fuse ter-
minal (one lead on the battery + terminal side of the fuse block and one lead on a known good ground). J
• With SW1 open and the DMM leads across both fuse terminals, check for voltage.
voltage; short is between fuse block and SW1 (point A).
no voltage; short is further down the circuit than SW1. K
• With SW1 closed, relay and solenoid disconnected and the DMM leads across both fuse terminals, check for
voltage.
voltage; short is between SW1 and the relay (point B).
no voltage; short is further down the circuit than the relay. L
• With SW1 closed, relay contacts jumped with fused jumper wire check for voltage.
voltage; short is down the circuit of the relay or between the relay and the disconnected solenoid (point C).
no voltage; retrace steps and check power to fuse block. M
GROUND INSPECTION
• Ground connections are very important to the proper operation of electrical and electronic circuits. Ground
connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can N
become an unwanted resistance. This unwanted resistance can change the way a circuit works.
• Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can
drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. O
Even when the ground connection looks clean, there can be a thin film of rust on the surface.
• When inspecting a ground connection follow these rules:
- Remove the ground bolt or screw.
- Inspect all mating surfaces for tarnish, dirt, rust, etc. P
- Clean as required to assure good contact.
- Reinstall bolt or screw securely.
- Inspect for “add-on” accessories which may be interfering with the ground circuit.
- If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the
wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eye-
let make sure no ground wires have excess wire insulation.
GI-43
• For detailed ground distribution information, refer to “Ground Distribution” in PG section.
SGI853
VOLTAGE DROP TESTS

• Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage
drop in a circuit is caused by a resistance when the circuit is in operation.
• Check the wire in the illustration. When measuring resistance with DMM, contact by a single strand of wire
will give reading of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand
of wire is not able to carry the current. The single strand will have a high resistance to the current. This will
be picked up as a slight voltage drop.
• Unwanted resistance can be caused by many situations as follows:
- Undersized wiring (single strand example)
- Corrosion on switch contacts
- Loose wire connections or splices.
• If repairs are needed always use wire that is of the same or larger gauge.
Measuring Voltage Drop — Accumulated Method
• Connect the DMM across the connector or part of the circuit you want to check. The positive lead of the
DMM should be closer to power and the negative lead closer to ground.
• Operate the circuit.
• The DMM will indicate how many volts are being used to “push” current through that part of the circuit.
Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb.
SGI974
Measuring Voltage Drop — Steb-by-Step

• The step-by-step method is most useful for isolating excessive drops in low voltage systems (such as those
in “Computer Controlled Systems”).
• Circuits in the “Computer Controlled System” operate on very low amperage.
GI-44
• The (Computer Controlled) system operations can be adversely affected by any variation in resistance in the
system. Such resistance variation may be caused by poor connection, improper installation, improper wire GI
gauge or corrosion.
• The step by step voltage drop test can identify a component or wire with too much resistance.
B
SAIA0258E
G
CONTROL UNIT CIRCUIT TEST
System Description
• When the switch is ON, the control unit lights up the lamp. H
CASE 1
K
MGI034A
INPUT-OUTPUT VOLTAGE CHART

Terminal No. Description L
In case of high resistance such as single
Input/ Condition Value (Approx.)
+ − Signal name strand (V) *
Output
Lower than battery voltage Approx. 8 (Ex- M
Body Switch ON Battery voltage
1 Switch Input ample)
ground
Switch OFF 0V Approx. 0
Switch ON Battery voltage Approx. 0 (Inoperative lamp)
N
Body
2 Lamp Output
ground Switch OFF 0V Approx. 0
• The voltage value is based on the body ground. O
• *: If high resistance exists in the switch side circuit (caused by a single strand), terminal 1 does not detect battery voltage. Control unit
does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not supply power to light up the
lamp.
P
GI-45
CASE 2
MGI035A
INPUT-OUTPUT VOLTAGE CHART

Terminal No. Description
In case of high resistance such as single
Input/ Condition Value (Approx.)
+ − Signal name strand (V) *
Output
Body Switch ON 0V Battery voltage (Inoperative lamp)

1 Lamp Output
ground Switch OFF Battery voltage Battery voltage
Body Switch ON 0V Higher than 0 Approx. 4 (Example)

2 Switch Input
ground Switch OFF 5V Approx. 5
• The voltage value is based on the body ground.
• *: If high resistance exists in the switch side circuit (caused by a single strand), terminal 2 does not detect approx. 0V. Control unit
does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not control ground to light up the
lamp.
GI-46
CONSULT-III/GST CHECKING SYSTEM
GI
• When CONSULT-III/GST is connected with a data link connector B

(A) equipped on the vehicle side, it will communicate with the con-
trol unit equipped in the vehicle and then enable various kinds of
diagnostic tests.
C
1 : Instrument driver lower panel
• Refer to CONSULT-III Operation Manual for more information.
D
JPAIA0056ZZ E
CONSULT-III Function and System Application*2 INFOID:0000000001316137
HEAD LAMP LEVELIZER

ALL MODE AWD/4WD
ABS (Including ESP)
INTELLIGENT KEY
TRANSMISSION
METER/M&A
METER/M&A
G
MULTI AV
IPDM E/R
AIR BAG
ENGINE
BCM
ABS
EPS
Diagnostic test
Function
mode
H
This mode enables a technician to adjust I

Work support some devices faster and more accurately by x x*1 - - x - x - - x - - x -
following the indications on CONSULT-III.
Self-diagnostic Self-diagnostic results can be read and J
x x x x x x x x x x x x x x
results erased quickly.
Current self-diagnostic results and all trouble
Trouble diagnos-
diagnostic records previously stored can be - - x - - - - - - - - - - -
tic record K
read.
Data monitor Input/Output data in the ECU can be read. x x - x x x x x x x x x x x
The condition of CAN communication line can
CAN diagnosis
be indicated by a topology.
x x - x x x x x x*3 - x x x x L
CAN diagnosis The condition of CAN communication line can

support monitor be read.
x x - x x x x x x*3 - x x x x
M
Diagnostic Test Mode in which CONSULT-III
drives some actuators apart from the ECUs
Active test x - - - x x x x x x - - x -
and also shifts some parameters in a speci-
fied range. N
The results of SRT (System Readiness Test)
DTC & SRT con-
firmation
and the self-diagnosis status/result can be x*1 - - - - - - - - - - - - -
confirmed.
O
This mode enables a technician to monitor
DTC work sup-
the status/results of self-diagnosis performed - - - - - - - - - - - - - -
port
by the ECU.
P
ECU (ECM/TCM)
ECU (ECM/TCM) part number can be read. x x - - x x x - x - x x x -
part number
Classification number of a replacement ECU
ECU discriminat-
can be read to prevent an incorrect ECU from - - x - - - - - - x - - - -
ed No.
being installed.
GI-47
HEAD LAMP LEVELIZER

ALL MODE AWD/4WD
ABS (Including ESP)
INTELLIGENT KEY
TRANSMISSION
METER/M&A
METER/M&A
MULTI AV
IPDM E/R
AIR BAG
ENGINE
BCM
ABS
EPS
Diagnostic test
Function
mode
This mode can show results of self-diagnosis

of ECU with either 'OK' or 'NG'. For engines,
Function test
more practical tests regarding sensors/ x*1 x*1 x - - x x - - - - - - -
switches and/or actuators are available.
Function to READ/WRITE vehicle configura-
Configration - - - - x - - - - x - - - -
tion on BCM.
AV COMM moni- The condition of AV communication can be in-
- - - - - - - - - - x - - -
tor dicated.
Characteristic information for TCM and CVT
CALIB data
assembly can be read.
- x*1 - - - - - - - - - - - -
x: Applicable
*1 : Petrol engine models
*2 : If GST application is equipped, functions in accordance with SAE J1979 and ISO 15031-5 can be used.
*3 : ABS models only.
CONSULT-III/GST Data Link Connector (DLC) Circuit INFOID:0000000001316138
INSPECTION PROCEDURE
If the CONSULT-III/GST cannot diagnose the system properly, check the following items.
Symptom Check item

CONSULT-III cannot access
• CONSULT-III DLC power supply circuit (Terminal 8 and 16) and ground circuit (Terminal 4 and 5)
any system.
• Power supply and ground circuit for the control unit of the system (For detailed circuit, refer to wiring
CONSULT-III cannot access in- diagram for each system.)
dividual system. (Other sys- • Open or short circuit between the system and CONSULT-III DLC (For detailed circuit, refer to wiring
tems can be accessed.) diagram for each system.)
• Open or short circuit CAN communication line. Refer to LAN-13, "Trouble Diagnosis Flow Chart".
NOTE:
The DDL1 and DDL2 circuits from DLC pins 12, 13, 14 and 15 may be connected to more than one system. A
short in a DDL circuit connected to a control unit in one system may affect CONSULT-III access to other sys-
tems.
If the GST cannot operate properly, check the circuit based on the information of SAE J1962 and ISO 15031-
3.
GI-48
Wiring Diagram - CONSULT-III/GST CHECKING SYSTEM - INFOID:0000000001316139
GI
JCAWA0019GB
P
GI-49
JCAWA0020GB
GI-50
GI
JCAWA0021GB
GI-51
JCAWA0022GB
GI-52
ENGINE
SECTION
ENGINE MECHANICAL
EM EM
E
CONTENTS
MR20DE SPARK PLUG ................................................... 18 F
Exploded View .........................................................18
SYMPTOM DIAGNOSIS ............................... 6 Removal and Installation .........................................18
Inspection ................................................................19 G
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................. 6 CAMSHAFT VALVE CLEARANCE .................. 20
NVH troubleshooting Chart ....................................... 6 Inspection and Adjustment ......................................20
H
PRECAUTION ............................................... 8 COMPRESSION PRESSURE ........................... 23
Inspection ................................................................23
PRECAUTIONS ................................................... 8 I
Precaution for Procedure without Cowl Top Cover...... 8 ON-VEHICLE REPAIR ................................. 24
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect ..................................... 8 DRIVE BELT AUTO-TENSIONER .................... 24
Precaution for Supplemental Restraint System Exploded View .........................................................24 J
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Removal and Installation .........................................24
SIONER" ................................................................... 8
AIR CLEANER AND AIR DUCT ....................... 25
Draining Engine Coolant ........................................... 9 K
Exploded View .........................................................25
Disconnecting Fuel Piping ......................................... 9
Removal and Installation .........................................25
Removal and Disassembly ........................................ 9
Inspection ................................................................26
Inspection, Repair and Replacement ........................ 9 L
Assembly and Installation ......................................... 9 INTAKE MANIFOLD ......................................... 27
Parts Requiring Angle Tightening ............................. 9 Exploded View .........................................................27
Liquid Gasket .......................................................... 10 Removal and Installation .........................................27 M
PREPARATION ........................................... 11 EXHAUST MANIFOLD ...................................... 30
Exploded View .........................................................30
PREPARATION ..................................................11 Removal and Installation .........................................30 N
Special Service Tools .............................................. 11
Inspection ................................................................31
Commercial Service Tools ...................................... 12
OIL PAN (LOWER) ........................................... 33
ON-VEHICLE MAINTENANCE .................... 15 Exploded View .........................................................33
O
DRIVE BELTS ....................................................15 Removal and Installation .........................................34

Inspection ................................................................35
Exploded View ........................................................ 15
P
Checking ................................................................. 15 FUEL INJECTOR AND FUEL TUBE ................ 36
Tension Adjustment ................................................ 15 Exploded View .........................................................36
Removal and Installation ......................................... 15 Removal and Installation .........................................36
AIR CLEANER FILTER ......................................17 Inspection ................................................................40
Removal and Installation ......................................... 17 IGNITION COIL, SPARK PLUG AND ROCK-
ER COVER ........................................................ 41
EM-1
Exploded View ........................................................ 41 HOW TO SELECT PISTON AND BEARING .. 112
Removal and Installation ........................................ 41 Description ............................................................ 112
Piston .................................................................... 112
TIMING CHAIN .................................................. 43 Connecting Rod Bearing ..................................... 113
Exploded View ........................................................ 43 Main Bearing ........................................................ 115
Removal and Installation ........................................ 44
Inspection ............................................................... 52 SERVICE DATA AND SPECIFICATIONS
CAMSHAFT ....................................................... 54 (SDS) ......................................................... 119
Exploded View ........................................................ 54 SERVICE DATA AND SPECIFICATIONS
Removal and Installation ........................................ 54 (SDS) ................................................................ 119
Inspection ............................................................... 58
General Specification ............................................ 119
OIL SEAL ........................................................... 63 Drive Belt .............................................................. 119
Spark Plug ............................................................ 119
VALVE OIL SEAL ..................................................... 63 Exhaust Manifold .................................................. 120
VALVE OIL SEAL : Removal and Installation ......... 63 Camshaft ............................................................... 120
Cylinder Head ....................................................... 121
FRONT OIL SEAL ..................................................... 63 Cylinder Block ....................................................... 124
FRONT OIL SEAL : Removal and Installation ........ 64 Connecting Rod Bearing ....................................... 127
REAR OIL SEAL ....................................................... 64 Main Bearing ......................................................... 128
REAR OIL SEAL : Removal and Installation .......... 64 QR25DE
CYLINDER HEAD .............................................. 66 SYMPTOM DIAGNOSIS ........................... 129
Exploded View ........................................................ 66
Removal and Installation ........................................ 67 NOISE, VIBRATION AND HARSHNESS
Disassembly and Assembly .................................... 68 (NVH) TROUBLESHOOTING ........................... 129
Inspection ............................................................... 72 NVH Troubleshooting Chart .................................. 129
REMOVAL AND INSTALLATION ............... 75 PRECAUTION ........................................... 131
ENGINE ASSEMBLY ......................................... 75 PRECAUTIONS ................................................ 131

Procedures without Cowl Top Cover ................. 131
M/T ............................................................................. 75 Precaution Necessary for Steering Wheel Rota-
M/T : Exploded View ............................................... 75 tion After Battery Disconnect ................................ 131
M/T : Removal and Installation ............................... 76 Precaution for Supplemental Restraint System
M/T : Inspection ...................................................... 80 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................... 131
CVT ............................................................................ 80
Draining Engine Coolant ..................................... 132
CVT : Exploded View .............................................. 81
Disconnecting Fuel Piping ................................... 132
CVT : Removal and Installation .............................. 81
Removal and Disassembly .................................. 132
CVT : Inspection ..................................................... 85
Inspection, Repair and Replacement ................. 132
DISASSEMBLY AND ASSEMBLY ............. 86 Assembly and Installation .................................... 132
Parts Requiring Angle Tightening ....................... 132
ENGINE STAND SETTING ................................ 86 Liquid Gasket ....................................................... 133
Setting .................................................................... 86
PREPARATION ......................................... 134
ENGINE UNIT .................................................... 88
Disassembly ........................................................... 88 PREPARATION ................................................ 134
Assembly ................................................................ 88 Special Service Tools .......................................... 134
Commercial Service Tools .................................. 135
OIL PAN (UPPER) ............................................. 89
Exploded View ........................................................ 89 ON-VEHICLE MAINTENANCE ................. 138
DRIVE BELTS .................................................. 138
Inspection ............................................................... 92
Exploded View ...................................................... 138
CYLINDER BLOCK ........................................... 93 Checking ............................................................... 138
Exploded View ........................................................ 93 Tension Adjustment ............................................. 138
Disassembly and Assembly .................................... 94 Removal and Installation ....................................... 138
Inspection ..............................................................102
AIR CLEANER FILTER .................................... 140
EM-2
Removal and Installation ....................................... 140 VALVE OIL SEAL .................................................... 179
VALVE OIL SEAL : Removal and Installation ........ 179 A
SPARK PLUG .................................................. 141
Exploded View ...................................................... 141 FRONT OIL SEAL .................................................... 179
Removal and Installation ....................................... 141 FRONT OIL SEAL : Removal and Installation ....... 180
Inspection .............................................................. 141 EM
REAR OIL SEAL ...................................................... 180
CAMSHAFT VALVE CLEARANCE ................. 143 REAR OIL SEAL : Removal and Installation ......... 180
Inspection and Adjustment .................................... 143 C
REMOVAL AND INSTALLATION ............. 182
COMPRESSION PRESSURE .......................... 146
Inspection .............................................................. 146 ENGINE ASSEMBLY ...................................... 182
Exploded View ....................................................... 182 D
ON-VEHICLE REPAIR ............................... 148 Removal and Installation ....................................... 182
Inspection .............................................................. 187
DRIVE BELT AUTO-TENSIONER ................... 148
E
Exploded View ...................................................... 148 DISASSEMBLY AND ASSEMBLY ............ 189
Removal and Installation ....................................... 148
ENGINE STAND SETTING ............................. 189
AIR CLEANER AND AIR DUCT ...................... 150 Setting ................................................................... 189 F
Exploded View ...................................................... 150
Removal and Installation ....................................... 150 ENGINE UNIT .................................................. 191
Inspection .............................................................. 151 Disassembly .......................................................... 191
Assembly ............................................................... 191 G
INTAKE MANIFOLD ......................................... 152
Exploded View ...................................................... 152 TIMING CHAIN ................................................ 192
Removal and Installation ....................................... 152 Exploded View ....................................................... 192 H
Inspection .............................................................. 154 Removal and Installation ....................................... 193
Inspection .............................................................. 199
EXHAUST MANIFOLD AND THREE WAY
CYLINDER HEAD ........................................... 201 I
CATALYST ....................................................... 155
Exploded View ....................................................... 201
Exploded View ...................................................... 155
Disassembly and Assembly ................................... 203 J
Inspection .............................................................. 156
Inspection .............................................................. 207
OIL PAN (LOWER) ........................................... 158
Exploded View ...................................................... 158
CYLINDER BLOCK ......................................... 210
Exploded View ....................................................... 210 K
Inspection .............................................................. 160 Disassembly and Assembly ................................... 211
Inspection .............................................................. 218
OIL PAN (UPPER) AND OIL STRAINER ........ 161 L
Exploded View ...................................................... 161
HOW TO SELECT PISTON AND BEARING .. 228
Description ............................................................. 228
Piston ..................................................................... 228
Inspection .............................................................. 163 M
Connecting Rod Bearing ....................................... 229
IGNITION COIL, SPARK PLUG AND ROCK- Main Bearing ......................................................... 231
ER COVER ....................................................... 164
Exploded View ...................................................... 164
SERVICE DATA AND SPECIFICATIONS N
Removal and Installation ....................................... 164 (SDS) .......................................................... 235
FUEL INJECTOR AND FUEL TUBE ............... 166 SERVICE DATA AND SPECIFICATIONS O
Exploded View ...................................................... 166 (SDS) ............................................................... 235
Removal and Installation ....................................... 166 General Specification ............................................ 235
Inspection .............................................................. 169 Drive belt ............................................................... 235
Spark Plug ............................................................ 235 P
CAMSHAFT ...................................................... 170 Intake Manifold ...................................................... 236
Exploded View ...................................................... 170 Exhaust Manifold .................................................. 236
Removal and Installation ....................................... 170 Camshaft ............................................................... 236
Inspection .............................................................. 175 Cylinder Head ....................................................... 238
Cylinder Block ....................................................... 240
OIL SEAL ......................................................... 179 Main Bearing ......................................................... 243
Connecting Rod Bearing ...................................... 244
EM-3
M9R CHARGE AIR COOLER ................................... 266
Exploded View ...................................................... 266
SYMPTOM DIAGNOSIS ............................ 246 Removal and Installation ....................................... 266
Inspection .............................................................. 267
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING .......................... 246 EGR SYSTEM ................................................... 268
NVH Troubleshooting - Engine Noise ....................246 Exploded View ...................................................... 268
Use the Chart Below to Help You Find the Cause Removal and Installation ....................................... 268
of the Symptom .....................................................247
INTAKE MANIFOLD ......................................... 270
PRECAUTION ............................................ 248 Exploded View ...................................................... 270
PRECAUTIONS ............................................... 248 Inspection .............................................................. 272
Precaution for Procedure without Cowl Top Cover..248
Precaution Necessary for Steering Wheel Rota- CATALYST ....................................................... 273
tion After Battery Disconnect .................................248 Exploded View ...................................................... 273
Precaution for Drain Coolant .................................248 Removal and Installation ....................................... 273
Precaution for Disconnecting Fuel Piping ..............248 Inspection .............................................................. 274
Precaution for Removal and Disassembly .............248
Precaution for Inspection, Repair and Replace- TURBOCHARGER ........................................... 275
ment .......................................................................249 Exploded View ...................................................... 275
Precaution for Assembly and Installation ..............249 Removal and Installation ....................................... 275
Parts Requiring Angular Tightening .......................249 Inspection .............................................................. 276
Precaution for Liquid Gasket .................................249 EXHAUST MANIFOLD ..................................... 278
Precaution for Diesel Equipment ...........................250
Exploded View ...................................................... 278
PREPARATION .......................................... 254 Removal and Installation ....................................... 278
Inspection .............................................................. 279
PREPARATION ............................................... 254
Special Service Tools ............................................254
OIL PAN (LOWER) AND OIL STRAINER ........ 280
Commercial Service Tools .....................................255 Exploded View ...................................................... 280
ON-VEHICLE MAINTENANCE .................. 257 Inspection .............................................................. 282
DRIVE BELTS .................................................. 257 GLOW PLUG .................................................... 283

Exploded View .......................................................257 Exploded View ...................................................... 283
Checking ................................................................257 Removal and Installation ....................................... 283
Tension Adjustment ...............................................257
VACUUM PUMP ............................................... 284
Removal and Installation .......................................257
Exploded View ...................................................... 284
AIR CLEANER FILTER ................................... 259 Removal and Installation ....................................... 284
OIL SEPARATOR ............................................. 286
COMPRESSION PRESSURE .......................... 260 Exploded View ...................................................... 286
Inspection ..............................................................260 Removal and Installation ....................................... 286
ON-VEHICLE REPAIR ............................... 261 INJECTION TUBE AND FUEL INJECTOR ...... 288
Exploded View ...................................................... 288
DRIVE BELT AUTO TENSIONER AND IDLER Removal and Installation ....................................... 288
PULLEY ........................................................... 261 Inspection .............................................................. 290
Exploded View .......................................................261
FUEL PUMP ..................................................... 291
Exploded View ...................................................... 291
AIR CLEANER AND AIR DUCT ...................... 263 Removal and Installation ....................................... 291
Exploded View .......................................................263 Inspection .............................................................. 292
Inspection ..............................................................264
TIMING CHAIN ................................................. 293
Exploded View ...................................................... 293
ENGINE COVER .............................................. 265 Removal and Installation ....................................... 294
Exploded View .......................................................265 Inspection .............................................................. 303
CAMSHAFT ...................................................... 304
EM-4
Exploded View ...................................................... 304 Assembly ............................................................... 319
Removal and Installation ....................................... 304 A
Inspection .............................................................. 308 OIL PAN (UPPER) .......................................... 320
Exploded View ....................................................... 320
OIL SEAL ......................................................... 310 Removal and Installation ....................................... 320
EM
FRONT OIL SEAL ................................................... 310 CYLINDER HEAD ........................................... 323
FRONT OIL SEAL : Removal and Installation ...... 310 Exploded View ....................................................... 323
Disassembly and Assembly ................................... 323 C
REAR OIL SEAL ..................................................... 310
Inspection .............................................................. 327
REAR OIL SEAL : Removal and Installation ......... 310
SERVICE DATA AND SPECIFICATIONS
REMOVAL AND INSTALLATION ............. 312 D
(SDS) .......................................................... 329
ENGINE ASSEMBLY ....................................... 312
Exploded View ...................................................... 312
Removal and Installation ....................................... 312 (SDS) ............................................................... 329 E
Inspection .............................................................. 316 General Specification ............................................ 329
Drive Belts ............................................................. 329
DISASSEMBLY AND ASSEMBLY ............ 318 Intake Manifold ...................................................... 329 F
Exhaust Manifold ................................................... 329
ENGINE STAND SETTING .............................. 318 Turbocharger ......................................................... 330
Setting ................................................................... 318 Camshaft ............................................................... 330
Cylinder Head ........................................................ 330 G
ENGINE UNIT ................................................... 319
Disassembly .......................................................... 319
H
EM-5
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS > [MR20DE]
SYMPTOM DIAGNOSIS
NVH troubleshooting Chart INFOID:0000000001160509
PBIC3932E
1. Locate the area where noise occurs.

2. Confirm the type of noise.
3. Specify the operating condition of engine.
EM-6
4. Check specified noise source.
If necessary, repair or replace these parts. A
Operating condition of engine

Location Type of Before After When Source of
Check item
Refer- EM
of noise noise When When While noise ence page
warm- warm- start-
idling racing driving
up up ing
Top of en- Ticking or Tappet C
C A — A B — Valve clearance EM-20
gine clicking noise
Rocker
cover Camshaft Camshaft journal oil
EM-120
Cylinder Rattle C A — A B C bearing clearance D
EM-120
head noise Camshaft runout
Piston to piston pin oil

Slap or Piston pin clearance EM-124 E
— A — B B —
knock noise Connecting rod bushing EM-124
oil clearance
Piston to cylinder bore
clearance
F
Crank- EM-124
shaft pul- Piston ring side clear-
Slap or Piston EM-124
ley A — — B B A ance
rap slap noise EM-124
Cylinder Piston ring end gap G
EM-124
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod bushing
Oil pan ing rod oil clearance EM-124 H
Knock A B C B B B
bearing Connecting rod bearing EM-127
noise oil clearance
Main bearing oil clear- I
Main bear- EM-128
Knock A B — A B C ance
ing noise EM-128
Crankshaft runout
Timing J
Front of Timing chain cracks
chain and
engine Tapping or and wear EM-52
A A — B B B chain ten-
Front cov- ticking Timing chain tensioner EM-44
sioner
er operation
noise K
Drive belt
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belt deflection
or slip- L
ing EM-15
ping)
Front of
Drive belt Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
M
Water
Squall
A B — B A B pump Water pump operation CO-25
Creak
noise
N
A: Closely related B: Related C: Sometimes related —: Not related
EM-7
PRECAUTIONS
< PRECAUTION > [MR20DE]
PRECAUTION
PRECAUTIONS
Precaution for Procedure without Cowl Top Cover INFOID:0000000001160510
PIIB3706J

INFOID:0000000001160511
NOTE:
TEM).
OPERATION PROCEDURE
NOTE:
rotated.
“SEAT BELT” of this Service Manual.
WARNING:
the event of a collision which would result in air bag inflation, all maintenance must be performed by
EM-8
PRECAUTIONS
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag A
EM
ness connectors.
Draining Engine Coolant INFOID:0000000001160512
C
Drain engine coolant and engine oil when the engine is cooled.
Disconnecting Fuel Piping INFOID:0000000001160513
D
• Before starting work, check no fire or spark producing items are in the work area.
• Release fuel pressure before disconnecting and disassembly.
• After disconnecting pipes, plug openings to stop fuel leakage.
E
Removal and Disassembly INFOID:0000000001160514
• When instructed to use SST, use specified tools. Always be careful to work safely, avoid forceful or unin- F
structed operations.
• Exercise maximum care to avoid damage to mating or sliding surfaces.
• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
check that dowel pins are installed in the original position. G
• Cover openings of engine system with a tape or equivalent, if necessary, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally H
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
in the step.
Inspection, Repair and Replacement INFOID:0000000001160515 I
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
J
Assembly and Installation INFOID:0000000001160516
• Use torque wrench to tighten bolts or nuts to specification. K

• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring. L
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. M
Before assembly, oil sliding surfaces well.
• Release air within route when refilling after draining engine coolant.
• After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage. N
Parts Requiring Angle Tightening INFOID:0000000001160517
O
• Use the angle wrench [SST: KV10112100] for the final tightening of the following engine parts:
- Camshaft sprocket (INT) bolt
- Cylinder head bolts
- Main bearing cap bolts P
- Connecting rod cap bolts
- Crankshaft pulley bolt (No the angle wrench is required as bolt flange is provided with notches for angle
tightening)
• Do not use a torque value for final tightening.
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil.
EM-9
PRECAUTIONS
Liquid Gasket INFOID:0000000001160518
REMOVAL OF LIQUID GASKET SEALING

• After removing mounting nuts and bolts, separate the mating sur-
face using the seal cutter (SST) and remove old liquid gasket seal-
ing.
CAUTION:
Be careful not to damage the mating surfaces.
• Tap the seal cutter to insert it (1), and then slide it (2) by tapping on
the side as shown in the figure.
• In areas where the seal cutter (SST) is difficult to use, use a plastic
hammer to lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reason tool such as a screwdriver is
PBIC0275E
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove old liquid gasket adhering to the liquid
gasket application surface and the mating surface.
• Remove liquid gasket completely from the groove of the liquid
gasket application surface, mounting bolts, and bolt holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
PBIC0003E
3. Attach liquid gasket tube to the tube presser (commercial ser-

vice tool).
Use Genuine Liquid Gasket or equivalent.
4. Apply liquid gasket without breaks to the specified location with
the specified dimensions.
• If there is a groove for liquid gasket application, apply liquid
gasket to the groove.
EMA0622D
• As for bolt holes, normally apply liquid gasket inside the holes.
Occasionally, it should be applied outside the holes. Check to
read the text of this manual.
• Within five minutes of liquid gasket application, install the mat-
ing component.
• If liquid gasket protrudes, wipe it off immediately.
• Do not retighten mounting bolts or nuts after the installation.
• After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
CAUTION:
If there are specific instructions in this manual, observe
SEM159F
them.
EM-10
PREPARATION
< PREPARATION > [MR20DE]
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000001160519
EM
Tool number
Description C
Tool name
KV10111100 Removing oil pan (upper and lower) etc.
Seal cutter
D
E
S-NT046
KV10116200 Disassembling and assembling valve mecha-

Valve spring compressor nism F
1. KV10115900 Part (1) is a component of KV10116200, but
Attachment Part (2) is not so.
2. KV10109220
G
Adapter
PBIC1650E
H
KV10112100 Tightening bolts for main bearing cap, cylinder
Angle wrench head, etc.
J
S-NT014
KV10117100 Loosening or tightening heated oxygen sen-

Heated oxygen sensor wrench sor 1
K
For 22 mm (0.87 in) width hexagon nut
NT379
KV10107902 Removing valve oil seal M

Valve oil seal puller
1. KV10116100
Valve oil seal puller adapter
N
S-NT605 O
KV10115600 Installing valve oil seal
Valve oil seal drift Use side A.
a: 20 (0.79) dia. d: 8 (0.31) dia. P
b: 13 (0.51) dia. e: 10.7 (0.421)
c: 10.3 (0.406) dia. f: 5 (0.20)
Unit: mm (in)
S-NT603
EM-11
PREPARATION
Tool number
Description
Tool name
EM03470000 Installing piston assembly into cylinder bore
Piston ring compressor
S-NT044
ST16610001 Removing pilot converter (A/T models)

Pilot bushing puller
S-NT045
KV11103000 Removing crankshaft pulley

Pulley puller
NT676
KV11105210 Fixing drive plate and flywheel

Stopper plate
ZZA0009D
Quick connector release Removing fuel tube quick connectors in en-

gine room
(Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210)
PBIC0198E
EM-12
PREPARATION
A
Spark plug wrench Removing and installing spark plug
EM
C
PBIC2982E
Pulley holder Crankshaft pulley removing and installing
ZZA1010D
Valve seat cutter set Finishing valve seat dimensions F
S-NT048
H
Piston ring expander Removing and installing piston ring
J
S-NT030
Valve guide drift Removing and installing valve guide

K
PBIC4012E
Valve guide reamer 1: Reaming valve guide inner hole M

2: Reaming hole for oversize valve guide
PBIC4013E
O
Oxygen sensor thread cleaner Reconditioning the exhaust system threads
before installing a new heated oxygen sensor
(Use with anti-seize lubricant shown below.) P
a = 18 mm (0.71 in) dia. for zirconia heated
oxygen sensor
b = 12 mm (0.47 in) dia. for titania heated
oxygen sensor
AEM488
EM-13
PREPARATION
Anti-seize lubricant (Permatex 133AR Lubricating oxygen sensor thread cleaning
or equivalent meeting MIL specifica- tool when reconditioning exhaust system
tion MIL-A-907) threads
AEM489
Manual lift table caddy Removing and installing engine
ZZA1210D
Tube presser Pressing the tube of liquid gasket
S-NT052
EM-14
DRIVE BELTS
< ON-VEHICLE MAINTENANCE > [MR20DE]
ON-VEHICLE MAINTENANCE A
DRIVE BELTS
Exploded View INFOID:0000000001160521
EM
E
PBIC3137J
1. Alternator 2. Drive belt auto-tensioner 3. Crankshaft pulley F

A/C compressor (with A/C models)
4. 5. Water pump 6. Drive belt
Idler pulley (without A/C models)
A. Possible use range B. Range when new drive belt is installed C. Indicator G
Checking INFOID:0000000001160522
H
WARNING:
Perform this step when engine is stopped.
• Check that the indicator (notch on fixed side) of drive belt auto-tensioner is within the possible use range (A)
in the figure. I
NOTE:
• Check the drive belt auto-tensioner indication when the engine is cold.
• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (B) in the fig- J
ure.
• Visually check entire drive belt for wear, damage or cracks.
• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.
K
Tension Adjustment INFOID:0000000001160523
L
Refer to : EM-119, "Drive Belt".
Removal and Installation INFOID:0000000001160524

M
REMOVAL
1. Hold the hexagonal part (A) of drive belt auto-tensioner (1) with
N
a wrench securely. Then move the wrench handle in the direc-
tion of arrow (loosening direction of tensioner).
CAUTION:
Avoid placing hand in a location where pinching may occur O
if the holding tool accidentally comes off.
2. Insert a rod approximately 6 mm (0.24 in) in diameter such as
short-length screwdriver into the hole (B) of the retaining boss to P
fix drive belt auto-tensioner.
• Keep drive belt auto-tensioner pulley arm locked after drive
belt is removed. PBIC3936E
3. Remove drive belt.

INSTALLATION
1. Install drive belt.
EM-15
DRIVE BELTS
CAUTION:
• Confirm drive belt is completely set to pulleys.
• Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each
pulley groove.
2. Release drive belt auto-tensioner, and apply tension to drive belt.
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
4. Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to
EM-15, "Exploded View".
EM-16
AIR CLEANER FILTER
AIR CLEANER FILTER
A
REMOVAL EM
1. Unhook clips (A) and remove holder (2) from air cleaner case
(1).
C
E
JPBIA0464ZZ
2. Remove air cleaner filter (1) from air cleaner case (2). F
JPBIA0465ZZ I
INSTALLATION
Note the following, and install in the reverse order of removal. J
• Install the air cleaner filter by aligning the seal with the notch of air cleaner case.
EM-17
SPARK PLUG
SPARK PLUG
PBIC3536J
1. PCV hose 2. Rocker cover 3. Spark plug

4. Ignition coil 5. PCV hose 6. PCV valve
7. O-ring 8. Gasket
A. To air duct B. Refer to EM-41 C. To intake manifold
Refer to GI-4, "Components" for symbols in the figure.
REMOVAL
1. Remove ignition coil. Refer to EM-41, "Exploded View".
2. Remove spark plug with a spark plug wrench (commercial ser-
vice tool).
CAUTION:
Never drop or shock spark plug.
PBIC3871E
INSTALLATION
Installation is the reverse order of removal.
EM-18
SPARK PLUG
Inspection INFOID:0000000001160528
A
INSPECTION AFTER REMOVAL
Use the standard type spark plug for normal condition.
EM
Spark plug (standard) : Refer to EM-119, "Spark Plug".
CAUTION:
• Never drop or shock spark plug. C
• Never use a wire brush for cleaning.
• If plug tip is covered with carbon, spark plug cleaner may be
used. D
Cleaner air pressure : Less than 588 kPa (6 kg/cm2, 85

psi) E
Cleaning time : Less than 20 seconds
SMA773C
F
• Checking and adjusting plug gap is not required between

change intervals. G
JPBIA0031ZZ
J
EM-19
CAMSHAFT VALVE CLEARANCE
Inspection and Adjustment INFOID:0000000001160529
INSPECTION
Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if
there is unusual engine conditions regarding valve clearance.
1. Remove rocker cover. Refer to EM-41, "Exploded View".
2. Measure the valve clearance with the following procedure:
a. Set No. 1 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley (1) clockwise and align TDC mark (no
paint) (B) to timing indicator (A) on front cover.
C : White paint mark (Not use for service)
PBIC3960E
• At the same time, check that both intake and exhaust cam
noses of No. 1 cylinder face inside ( ) as shown in the figure.
1 : Camshaft (INT)
2 : Camshaft (EXH)
: Engine front
• If they do not face inside, rotate crankshaft pulley once more

(360 degrees) and align as shown in the figure.
PBIC3359J
b. Use a feeler gauge, measure the clearance between valve lifter

and camshaft.
Valve clearance : Refer to EM-120, "Camshaft".
PBIC3192J
• By referring to the figure, measure the valve clearances at

locations marked “×” as shown in the table below [locations
indicated with black arrow ( ) in the figure] with a feeler
gauge.
A : Exhaust side
B : No. 1 cylinder
C : No. 2 cylinder
D : No. 3 cylinder
E : No. 4 cylinder
PBIC3193J
EM-20
F : Intake side
: Engine front A
Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.
EM
EXH × ×
No. 1 cylinder at compression TDC
INT × ×
C
c. Set No. 4 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley (1) one revolution (360 degrees) and
align TDC mark (no paint) (B) to timing indicator (A) on front
cover. D

E
F
PBIC3960E
• By referring to the figure, measure the valve clearance at loca- G

tions marked “×” as shown in the table below [locations indi-
cated with black arrow ( ) in the figure] with a feeler gauge.
H
A : Exhaust side
B : No. 1 cylinder
C : No. 2 cylinder I
D : No. 3 cylinder
E : No. 4 cylinder
F : Intake side J
PBIC3194J
: Engine front
Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL. K
EXH × ×
No. 4 cylinder at compression TDC
INT × ×
L
3. If out of standard, perform adjustment. Refer to “ADJUSTMENT”.
ADJUSTMENT M
• Perform adjustment depending on selected head thickness of valve lifter.
1. Remove camshaft. Refer to EM-54, "Exploded View".
2. Remove valve lifters at the locations that are out of the standard. N
3. Measure the center thickness of the removed valve lifters with a
micrometer (A).
O
PBIC3195J
4. Use the equation below to calculate valve lifter thickness for replacement.
EM-21
Valve lifter thickness calculation: t = t1 + (C1 – C2)

t = Valve lifter thickness to be replaced
t1 = Removed valve lifter thickness
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake : 0.30 mm (0.012 in)
Exhaust : 0.33 mm (0.013 in)
• Thickness of new valve lifter (B) can be identified by stamp
mark (A) on the reverse side (inside the cylinder).
• Stamp mark “302” indicates 3.02 mm (0.1189 in) in thickness.
PBIC3196J
NOTE:
Available thickness of valve lifter: 26 sizes range 3.00 to 3.50 mm (0.1181 to 0.1378 in) in steps of 0.02
mm (0.0008 in) (when manufactured at factory). Refer to EM-120, "Camshaft".
5. Install the selected valve lifter.
6. Install camshaft. Refer to EM-54, "Exploded View".
7. Install timing chain and related parts. Refer to EM-43, "Exploded View".
8. Manually rotate crankshaft pulley a few rotations.
9. Check that the valve clearances is within the standard. Refer to “INSPECTION”.
10. Install remaining parts in the reverse order of removal.
11. Warm up the engine, and check for unusual noise and vibration.
EM-22
COMPRESSION PRESSURE
A
1. Warm up engine thoroughly. Then, stop it. EM

2. Release fuel pressure. Refer to ECM-349, "Inspection".
3. Remove ignition coil and spark plug from each cylinder. Refer to EM-41, "Exploded View".
4. Connect engine tachometer (not required in use of CONSULT-III). C
5. Install compression gauge (B) with an adapter (A) (commercial
service tool) onto spark plug hole.
D
F
PBIC3541J
G
• Use the adapter whose picking up end inserted to spark plug
hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it
may be caught by cylinder head during removal.
H
J
SBIA0533E
6. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each K
cylinder.
Compression pressure : Refer to EM-119, "General Specification". L

CAUTION:
Always use a fully changed battery to obtain the specified engine speed.
• If the engine speed is out of the specified range, check battery liquid for proper gravity. Check the M
engine speed again with normal battery gravity.
• If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure compression pressure again. N
• If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole
of the cylinder to re-check it for compression.
- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check pis- O
ton rings and replace if necessary.
- If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly.
P
• If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cyl-
inder head gaskets.
7. After inspection is completed, install removed parts.
8. Start the engine, and check that the engine runs smoothly.
9. Perform trouble diagnosis. If DTC appears, erase it. Refer to ECM-96, "Description".
EM-23
DRIVE BELT AUTO-TENSIONER
< ON-VEHICLE REPAIR > [MR20DE]
ON-VEHICLE REPAIR
PBIC3937E
1. Front cover 2. Drive belt auto-tensioner
Removal
1. Remove drive belt. Refer to EM-15, "Exploded View".
• Keep drive belt auto-tensioner pulley arm locked after drive belt is removed.
2. Remove front fender protector (RH). Refer to EXT-21, "Exploded View".
3. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting
stay and the engine mounting insulator (RH). Refer to EM-75, "M/T : Exploded View" (M/T models) or EM-
81, "CVT : Exploded View" (CVT models).
4. Loosen mounting bolt and remove drive belt auto-tensioner.
• Lift the front side of the engine with a jack sustaining engine base to remove mounting bolt.
NOTE:
Use TORX socket (size T50).
Installation
CAUTION:
When installing drive belt auto-tensioner, be careful not to interfere with water pump pulley.
EM-24
AIR CLEANER AND AIR DUCT
A
EM
J
JPBIA0695GB
1. Air cleaner filter 2. Holder 3. Air cleaner case K

4. Mass air flow sensor 5. Clamp 6. Air duct and resonator assembly
7. Clamp 8. PCV hose 9. Cover
10. Air duct (inlet) 11. Air duct 12. Resonator L
13. Grommet
A. To electric throttle control actuator B. To rocker cover
Refer to GI-4, "Components" for symbols in the figure. M
N
REMOVAL
1. Remove air duct (inlet).
2. Remove engine cover. Refer to EM-27, "Exploded View". O
3. Disconnect mass air flow sensor harness connector.
4. Disconnect PCV hose.
P
5. Remove the battery stay, and then move the battery.
6. Remove air cleaner case and mass air flow sensor assembly and air duct and resonator assembly discon-
necting their joints.
• Add marks as necessary for easier installation.
7. Remove mass air flow sensor from air cleaner case, if necessary.
CAUTION:
• Never shock mass air flow sensor.
EM-25
• Never disassemble mass air flow sensor.
• Never touch its sensor.
INSTALLATION
Note the following, and install in the reverse order of removal.
• Align marks. Attach each joint. Screw clamps firmly.

Inspect air duct and resonator assembly for crack or tear.
• If anything found, replace air duct and resonator assembly.
EM-26
INTAKE MANIFOLD
INTAKE MANIFOLD
A
EM
L
JPBIA0282GB
1. Clamp 2. Harness bracket 3. PCV hose M

4. Gasket 5. Vacuum hose 6. Intake manifold
7. Bracket 8. Engine cover 9. EVAP hose
EVAP canister purge volume control N
10. 11. O-ring 12. Water hose
solenoid valve
13. Water hose 14. Electric throttle control actuator 15. Gasket
A. To water outlet B. To centralized under-floor piping C. To brake booster
O

P
REMOVAL
1. Remove engine cover.
2. Pull out oil level gauge.
CAUTION:
Cover the oil level gauge guide openings to avoid entry of foreign materials.
3. Disconnect PCV hose from intake manifold and rocker cover.
EM-27
INTAKE MANIFOLD
4. Remove air duct and resonator assembly. Refer to EM-25, "Exploded View".
5. Disconnect vacuum hose from intake manifold. Refer to EM-27, "Exploded View".
6. Disconnect water hoses from electric throttle control actuator, attach blind plug to prevent engine coolant
leakage.
CAUTION:
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belts.
7. Remove electric throttle control actuator.
CAUTION:
• Handle carefully to avoid any shock to electric throttle control actuator.
• Never disassemble electric throttle control actuator.
8. Remove intake manifold (1) with the following procedure:
: Engine front
a. Loosen and remove intake manifold mounting bolts (A) and (B).
PBIC3939E
b. Loosen mounting bolts in reverse order as shown in the figure.
: Engine front
CAUTION:
Cover engine openings to avoid entry of foreign materials.
PBIC3527J
9. Remove brackets from intake manifold, if necessary.

10. Remove EVAP canister purge volume control solenoid valve from intake manifold, if necessary.
INSTALLATION
Intake Manifold
1. Check if gasket is not dropped from the installation groove of intake manifold.
2. Install intake manifold with the following procedure:
EM-28
INTAKE MANIFOLD
a. Tighten in numerical order as shown in the figure.
A
: Engine front
EM
b. Tighten No. 1 bolt again.
PBIC3527J
D
c. Tighten intake manifold mounting bolt (A). Then tighten intake
manifold mounting bolt (B).
E
1 : Intake manifold
: Engine front
PBIC3939E
K
Electric Throttle Control Actuator
• Tighten bolts of electric throttle control actuator equally and diagonally in several steps.
• Perform “Throttle Valve Closed Position Learning” after repair when removing harness connector of the elec- L
tric throttle control actuator. Refer to ECM-14, "THROTTLE VALVE CLOSED POSITION LEARNING :
Description".
• Perform “Throttle Valve Closed Position Learning” and “Idle Air Volume Learning” after repair when replacing M
electric throttle control actuator. Refer to ECM-14, "THROTTLE VALVE CLOSED POSITION LEARNING :
Description" and ECM-15, "IDLE AIR VOLUME LEARNING : Description".
EM-29
EXHAUST MANIFOLD
EXHAUST MANIFOLD
JPBIA0283GB
1. Harness bracket 2. Stud bolt 3. Gasket

4. Exhaust manifold 5. Heated oxygen sensor 1 6. Exhaust manifold cover
7. Exhaust manifold stay (2WD models) 8. Exhaust manifold stay (4WD models)
: Engine front
REMOVAL
1. Remove exhaust front tube. Refer to EX-5, "Exploded View".
2. Remove exhaust manifold cover.
3. Remove the heated oxygen sensor 1.
• Using heated oxygen sensor wrench [SST: KV10117100], remove heated oxygen sensor 1.
CAUTION:
Handle heated oxygen sensor 1 carefully and avoid impacts.
NOTE:
The exhaust manifold can be removed and installed without removing the heated oxygen sensor 1 (Disas-
sembly of harness connector is necessary)
4. Remove drive shaft (RH) and drive shaft support bearing bracket. Refer to FAX-19, "MR20DE : Exploded
View" (2WD models) or FAX-52, "MR20DE : Exploded View" (4WD models).
5. Remove exhaust manifold stay.
6. Remove exhaust manifold.
EM-30
EXHAUST MANIFOLD
• Loosen nuts in reverse order as shown in the figure
A
: Engine front
EM
JPBIA0284ZZ
D
7. Remove gasket.
CAUTION:
E
INSTALLATION
1. Install gasket to cylinder head as shown in the figure.
F
: Engine front
PBIC3943E
I
2. Install exhaust manifold with the following procedure:
a. Tighten nuts in numerical order as shown in the figure.
J
: Engine front
b. Tighten nuts in numerical order as shown in the figure again.

K
JPBIA0284ZZ
M
c. Install exhaust manifold stay (2) in the direction as shown in the
figure.
1 : Exhaust manifold
N
A : Upper mark
: Engine front
O
NOTE:
This figure shows 2WD models as an example.
P
JPBIA0286ZZ

EM-31
EXHAUST MANIFOLD
Surface Distortion
• Using straightedge (B) and feeler gauge (A), check the surface dis-
tortion of exhaust manifold mating surface in each exhaust port
and entire part.
Limit : Refer to EM-120, "Exhaust Manifold".

• If it exceeds the limit, replace exhaust manifold.
JPBIA0285ZZ
EM-32
OIL PAN (LOWER)
OIL PAN (LOWER)
A
EM
PBIC5120J
N
1. Oil level gauge 2. Oil level gauge guide 3. Rear oil seal
4. O-ring 5. O-ring 6. Oil pan (upper)
7. Balancer unit timing chain 8. Crankshaft sprocket 9. Balancer unit sprocket O
10. Balancer unit timing chain tensioner 11. Drain plug 12. Drain plug washer
13. Oil pan (lower) 14. Oil filter 15. Connector bolt
16. Oil cooler 17. O-ring 18. Oil level sensor P
A. Refer to LU-9
: Oil pan side
EM-33
OIL PAN (LOWER)
REMOVAL
1. Remove engine undercover.
2. Drain engine oil. Refer to LU-7, "Draining".
3. Remove oil pan (lower) with the following procedure:
a. Loosen mounting bolts in reverse order as shown in the figure.
: Engine front
PBIC3946E
b. Insert seal cutter (SST) between oil pan (upper) and oil pan
(lower).
CAUTION:
Be careful not to damage the mating surface.
SEM365EA
INSTALLATION
1. Install oil pan (lower) with the following procedure:
a. Use a scraper (A) to remove old liquid gasket from mating sur-
faces.
• Also remove old liquid gasket from mating surface of oil pan
(upper).
• Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Never scratch or damage the mating surface when cleaning
off old liquid gasket.
PBIC3953E
EM-34
OIL PAN (LOWER)
b. Apply a continuous bead of liquid gasket (A) with a tube presser
(commercial service tool) as shown in the figure. A
1 : Oil pan (lower)

: Engine front EM
: Engine outside

CAUTION: C
Attaching should be done within 5 minutes after liquid gas-
ket application.
D
G
JPBIA0289ZZ
c. Tighten bolts in numerical order as shown in the figure.

H
: Engine front
PBIC3946E
K
L
Clean oil strainer portion [part of the oil pan (upper)] if any object attached.
M
INSPECTION AFTER INSTALLATION
1. Check the engine oil level and adjust engine oil. Refer to LU-6, "Inspection".
2. Start engine, and check there is no leak of engine oil. N
3. Stop engine and wait for 10 minutes.
4. Check the engine oil level again. Refer to LU-6, "Inspection".
O
EM-35
FUEL INJECTOR AND FUEL TUBE
PBIC3537J
1. Fuel feed tube 2. Bracket 3. Quick connector cap

4. Fuel tube 5. O-ring (black) 6. Clip
7. Injector 8. O-ring (green)
A. To centralized under-floor piping
CAUTION:
Never remove or disassemble parts unless instructed in the figure.
WARNING:
• Put a “CAUTION: FLAMMABLE” sign in the workshop.
• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
REMOVAL
1. Release the fuel pressure. Refer to ECM-349, "Inspection".
2. Remove intake manifold. Refer to EM-27, "Exploded View".
EM-36
3. Disconnect quick connector with the following procedure. Dis-
connect fuel feed hose (1) from fuel tube (3). A
NOTE:
There is no fuel return path.
a. Remove quick connector cap (2) from quick connector connec- EM
tion.
PBIC3157J
D
b. Disconnect fuel feed hose from hose clamp.
c. With the sleeve side of quick connector release facing quick connector, install quick connector release
E
onto fuel tube.
d. Insert quick connector release into quick connector until sleeve
contacts and goes no further. Hold quick connector release on
that position. F
CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it G
contacts and goes no further.
e. Draw and pull out quick connector straight from fuel tube.
CAUTION: H
• Pull quick connector holding “A” position in the figure.
• Never pull with lateral force applied. O-ring inside quick KBIA0702E
connector may be damaged.
• Prepare container and cloth beforehand as fuel will leak out. I
• Avoid fire and sparks.
• Keep parts away from heat source. Especially, be careful when welding is performed around
them. J
• Never expose parts to battery electrolyte or other acids.
• Never bend or twist connection between quick connector and fuel feed hose during installation/
removal.
• To keep clean the connecting portion and to avoid dam- K
age and foreign materials, cover them completely with
plastic bags or something similar.
L
PBIC2205E
N
4. Disconnect harness connector from fuel injector.

5. Remove fuel tube and fuel injector assembly. O
EM-37
• Loosen mounting bolts in reverse order as shown in the figure.
: Engine front
CAUTION:
• When removing, be careful to avoid any interference with fuel
injector.
• Use a shop cloth to absorb any fuel leaks from fuel tube.
PBIC3154J
6. Remove fuel injector (3) from fuel tube (1) with the following pro-
cedure:
a. Open and remove clip (2).
b. Remove fuel injector from fuel tube by pulling straight.
CAUTION:
• Be careful with remaining fuel that may go out from fuel
tube.
• Be careful not to damage fuel injector nozzle during
removal.
• Never bump or drop fuel injector.
• Never disassemble fuel injector. JPBIA0290ZZ
INSTALLATION
1. Note the following, and install O-rings to fuel injector.
CAUTION:
• Upper and lower O-rings are different. Be careful not to confuse them.
Fuel tube side : Black

Nozzle side : Green
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign material.
• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to
twist or stretch O-ring. If O-ring is stretched while installing, never insert it quickly into fuel tube.
• Insert O-ring straight into fuel tube. Never decenter or twist it.
EM-38
2. Install fuel injector (4) to fuel tube (1) with the following proce-
dure: A
3 : O–ring (black)
5 : O–ring (green) EM
a. Insert clip (2) into clip mounting groove (F) on fuel injector.
• Insert clip so that protrusion (G) of fuel injector matches cut-
out (D) of clip. C
CAUTION:
• Never reuse clip. Replace it with a new one.
• Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring. D
b. Insert fuel injector into fuel tube with clip attached.
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion (B) of fuel tube matches E
cut-out (C) of clip.
• Check that fuel tube flange (A) is securely fixed in flange fixing
groove (E) on clip.
F
c. Check that installation is complete by making sure that fuel
injector does not rotate or come off.
G
PBIC3155J
3. Set fuel tube and fuel injector assembly at its position for installation on cylinder head.
CAUTION: H
For installation, be careful not to interfere with fuel injector nozzle.
4. Install fuel tube and injector assembly onto cylinder.
• Tighten mounting bolts in numerical order as shown in the fig- I
ure.
: Engine front J
PBIC3154J L
5. Connect harness connector to fuel injector.

6. Connect fuel feed hose with the following procedure. M
a. Check for damage or foreign material on the fuel tube and quick connector.
b. Apply new engine oil lightly to area around the top of fuel tube.
c. Align center to insert quick connector straightly into fuel tube. N
• Insert quick connector to fuel tube until the top spool on fuel
tube is inserted completely and the 2nd level spool is posi-
tioned slightly below quick connector bottom end. O
CAUTION:
• Hold “A” position in the figure when inserting fuel tube
into quick connector.
• Carefully align center to avoid inclined insertion to pre- P
vent damage to O-ring inside quick connector.
• Insert until you hear a “click” sound and actually feel
the engagement.
KBIA0272E
• To avoid misidentification of engagement with a similar
sound, be sure to perform the next step.
d. Before clamping fuel feed hose with hose clamp, pull quick connector hard by hand holding “A” position.
Check it is completely engaged (connected) so that it does not come out from fuel tube.
EM-39
e. Install quick connector cap (2) to quick connector connection.
1. Fuel feed hose

3. Fuel tube
• Install quick connector cap with the side arrow facing quick
connector side (fuel feed hose side).
CAUTION:
• Check that the quick connector and fuel tube are
securely engaged with the quick connector cap mount-
ing groove.
• Quick connector may not be connected correctly if PBIC3157J
quick connector cap cannot be installed easily. Remove

the quick connector cap, and then check the connection of quick connector again.
f. Install fuel feed hose to hose clamp.


Check on Fuel Leakage
1. Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check there
are no fuel leaks at connection points.
NOTE:
Use mirrors for checking at points out of clear sight.
2. Start the engine. With engine speed increased, check again that there are no fuel leaks at connection
points.
CAUTION:
Never touch the engine immediately after stopped, as the engine becomes extremely hot.
EM-40
IGNITION COIL, SPARK PLUG AND ROCKER COVER
A
EM
J
PBIC3536J
1. PCV hose 2. Rocker cover 3. Spark plug K

4. Ignition coil 5. PCV hose 6. PCV valve
7. O-ring 8. Gasket
A. To air duct B. Refer to EM-41 C. To intake manifold L
Removal and Installation INFOID:0000000001160548 M
REMOVAL
1. Remove intake manifold. Refer to EM-27, "Removal and Installation". N
2. Remove ignition coil.
CAUTION:
• Never drop or shock ignition coil. O
• Never disassemble ignition coil.
3. Remove rocker cover.
P
EM-41
• Loosen bolts in reverse order shown in the figure.
: Engine front
PBIC3151J
4. Remove rocker cover gasket from rocker cover.

5. Use scraper to remove all traces of liquid gasket from cylinder head and front cover.
CAUTION:
Never scratch or damage the mating surface when cleaning off old liquid gasket.
INSTALLATION
1. Install the rocker cover gasket to rocker cover.
CAUTION:
Check the gasket is not dropped.
2. Install rocker cover.
• Tighten bolts in two steps separately in numerical order as
shown in the figure.
: Engine front
1st step : 1.96 N·m (0.20 kg-m, 17 in-lb)

2nd step : 8.33 N·m (0.85 kg-m, 74 in-lb)
3. Install in the reverse order of removal, for the rest of parts.
PBIC3151J
EM-42
TIMING CHAIN
TIMING CHAIN
A
EM
PBIC3538J
P
1. Timing chain slack guide 2. Timing chain tensioner 3. Camshaft sprocket (EXH)
4. Timing chain 5. Oil filler cap 6. Front cover
Intake valve timing control solenoid
7. O-ring 8. 9. Crankshaft pulley bolt
valve
10. Crankshaft pulley 11. Front oil seal 12. Drive belt auto-tensioner
Timing chain tension guide
13. 14. Crankshaft sprocket 15. Balancer unit sprocket
(front cover side)
EM-43
TIMING CHAIN
16. Balancer unit timing chain 17. Camshaft sprocket (INT) 18. Timing chain tension guide
19. O-ring 20. Balancer unit timing chain tensioner
A. Refer to EM-44 B. Refer to EM-54
REMOVAL
CAUTION:
The rotating direction in the text indicates all directions seen from the engine front.
1. Remove front wheel (RH). Refer to WT-3, "Adjustment".
CAUTION:
Perform this step when engine is cold.
4. Remove the following parts.
• Intake manifold: Refer to EM-27, "Exploded View".
• Rocker cover: Refer to EM-41, "Exploded View".
• Drive belt: Refer to EM-15, "Removal and Installation".
5. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
a. Rotate crankshaft pulley (1) clockwise and align TDC mark (no
paint) (B) to timing indicator (A) on front cover.
PBIC3960E
b. At the same time, check that the cam noses of the No. 1 cylinder
are located ( ) as shown in the figure.
1 : Camshaft (INT)
2 : Camshaft (EXH)
: Engine front
• If not, rotate crankshaft pulley one revolution (360 degrees)

and align as shown in the figure.
PBIC3359J
6. Remove crankshaft pulley with the following procedure:

a. Fix crankshaft pulley (1) with a pulley holder (A) (commercial
service tool), loosen crankshaft pulley bolt, and locate bolt seat-
ing surface at 10 mm (0.39 in) from its original position.
CAUTION:
Never remove the crankshaft pulley bolt as they will be
used as a supporting point for the pulley puller [SST:
KV11103000].
PBIC3961E
EM-44
TIMING CHAIN
b. Attach a pulley puller (A) [SST: KV11103000] in the M6 thread
hole on crankshaft pulley (1), and remove crankshaft pulley. A
EM
PBIC3962E
D
7. Remove rear torque rod. Refer to EM-75, "M/T : Exploded View" (M/T models) or EM-81, "CVT : Exploded
View" (CVT models).
8. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting E
stay and the engine mounting insulator (RH). Refer to EM-75, "M/T : Exploded View" (M/T models) or EM-
81, "CVT : Exploded View" (CVT models).
9. Remove oil pan (lower). Refer to EM-33, "Exploded View".
F
NOTE:
If crankshaft sprocket and balancer unit component are not removed, this step is unnecessary.
10. Remove intake valve timing control solenoid valve.
G
11. Remove drive belt auto-tensioner.
12. Remove front cover with the following procedure:
a. Loosen mounting bolts in reverse order as shown in the figure. H
N
PBIC3164J
b. Cut liquid gasket by prying the position ( ) shown in the figure, O

and then remove the front cover.
CAUTION:
• Be careful not to damage the mating surface. P
• A more adhesive liquid gasket is applied compared to pre-
vious types when shipped, so it should not be forced off
the position not specified.
PBIC3357J
EM-45
TIMING CHAIN
13. Remove front oil seal from front cover.
CAUTION:
Be careful not to damage front cover.
• Lift up front oil seal using a screwdriver.
14. Remove timing chain tensioner with the following procedure:
a. Push in timing chain tensioner plunger.
b. Insert a stopper pin (A) into the body hole, and then fix it with the
plunger pushed in.
NOTE:
Use approximately 1.5 mm (0.059 in) diameter. hard metal pin
as a stopper pin.
c. Remove timing chain tensioner (1).
PBIC3165J
15. Remove timing chain slack guide (2), timing chain tension guide
(3) and timing chain (1).
CAUTION:
Never rotate each crankshaft and camshaft individually
while timing chain is removed. It causes interference
between valve and piston.
PBIC3166J
16. Remove crankshaft sprocket and balancer unit drive component with the following procedure:
EM-46
TIMING CHAIN
a. Press stopper tab (A) in the direction shown in the figure to push
the timing chain slack guide (B) toward timing chain tensioner A
(for oil pomp) (1).
• The slack guide is released by pressing the stopper tab. As
the result, the slack guide can be moved.
EM
b. Insert a stopper pin (D) into tensioner body hole (C) to secure
the timing chain slack guide.
NOTE:
Use a hard metal pin with the diameter of approximately 1.2 mm C
(0.047 in) as a stopper pin.
c. Remove balancer unit timing chain tensioner.
• When the holes on lever and tensioner body cannot be D
aligned, align these holes by slightly moving the slack guide.
G
PBIC5314E
d. Hold the WAF part of balancer shaft [WAF:19.0 mm (0.75 in)]

(A), and then loosen the balancer unit sprocket bolt. H
1 : Oil pan (upper)

: Engine front I
CAUTION:
• Secure the balancer unit shaft with the WAF part.
• Never loosen the balancer unit sprocket bolt by tightening J
the balancer unit drive chain.
e. Remove crankshaft sprocket, balancer unit sprocket and bal-
ancer unit timing chain as a set. K
N
PBIC3168J
17. Remove timing chain tension guide (front cover side) from front cover, if necessary. O
INSTALLATION
NOTE:
P
EM-47
TIMING CHAIN
The figure shows the relationship between the matching mark on
each timing chain and that on the corresponding sprocket, with the
components installed.
1. Check that crankshaft key points straight up.
1 : Timing chain
2 : Camshaft sprocket (EXH)
3 : Timing chain slack guide
4 : Timing chain tensioner
5 : Balancer unit sprocket
6 : Balancer unit drive chain
7 : Balancer unit timing chain tensioner
8 : Crankshaft sprocket
9 : Timing chain tension guide
10 : Camshaft sprocket (INT)
A : Matching mark (dark blue link)
B : Matching mark (stamping)
C : Crankshaft key position (straight up)
D : Matching mark (stamping)
E : Matching mark (orange link)
PBIC3167J
F : Matching mark (outer groove*)
*: There are two outer grooves in camshaft sprocket (INT). The wider one is a matching mark.
2. If the timing chain tension guide (front cover side) is removed, install it to the front cover.
CAUTION:
Check the joint condition by sound or feeling.
3. Install crankshaft sprocket (2), balancer unit sprocket (3) and
balancer unit timing chain (1).
A : Matching mark (stamping)

B : Matching mark (orange link)
C : Matching mark (dark blue link)
• Install it by aligning matching marks on each sprocket and bal-
ancer unit timing chain.
• If these matching marks are not aligned, rotate the balancer
shaft slightly to correct the position.
CAUTION: PBIC3171J
Check matching mark position of each sprocket after

installing the balancer unit timing chain.
EM-48
TIMING CHAIN
4. Hold the WAF part of balancer unit shaft [WAF: 19.0 mm (0.75
in)] (A), and then tighten the balancer shaft sprocket bolt. A
1 : Oil pan (upper)

: Engine front EM
CAUTION:
• Secure the balancer unit shaft with the WAF part.
• Never loosen the balancer shaft sprocket bolt by tighten- C
ing the balancer unit timing chain.
G
PBIC3168J
H
5. Install balancer unit timing chain tensioner (1).
• Fix the plunger at the most compressed position using a stop-
per pin (A), and then install it.
• Securely pull out ( ) the stopper pin after installing the bal- I
ancer unit timing chain tensioner.
• Check matching mark position of balancer unit timing chain
and each sprocket again. J
K
PBIC5315E
EM-49
TIMING CHAIN
6. Align the matching marks of each sprocket with the matching
marks of timing chain.
1 : Camshaft sprocket (EXH)

3 : Timing chain
A : Matching mark (dark blue link)
B : Matching mark (stamping)
C : Matching mark (outer groove*)
D : Matching mark (orange link)
E : Matching mark (stamping)
*: There are 2 outer grooves in camshaft sprocket (INT). The wider one is a
matching mark.
• If these matching marks are not aligned, rotate the camshaft
slightly by holding the hexagonal portion to correct the posi-
tion.
CAUTION:
Check matching mark position of each sprocket and timing
chain again after installing the timing chain.
PBIC3172J
7. Install the timing chain tension guide (3) and the timing chain
slack guide (2).
1 : Timing chain
PBIC3166J
8. Install timing chain tensioner (1).

• Fix the plunger at the most compressed position using a stop-
per pin (A), and then install it.
• Securely pull out the stopper pin after installing the timing
chain tensioner.
PBIC3165J
EM-50
TIMING CHAIN
9. Check matching mark position of timing chain and each sprocket again.
10. Install front oil seal. Refer to EM-64, "FRONT OIL SEAL : Removal and Installation". A
11. Install front cover with the following procedure:
a. Install new O-ring to cylinder block.
CAUTION: EM
Never misalign O-ring.
b. Apply a continuous bead of liquid gasket (B) with a tube presser
(commercial service tool) to front cover as shown in the figure. C
A : Liquid gasket application area

: Engine outside D
I
JPBIA0291ZZ
c. Check that matching marks of timing chain and each sprocket are still aligned. Then install front cover.
CAUTION: J
• Check O-ring on cylinder block is correctly installed.
• Be careful not to damage front oil seal by interference with front end of crankshaft.
d. Install front cover, and tighten mounting bolts in numerical order K
as shown in the figure.
• Refer to the following for the installation position of bolts.
L
M6 : No. 1
M10 : No. 6, 7, 10, 11, 14
M12 : No. 2, 4, 8, 12 M
M8 : Except the above
CAUTION:
N
ket application.
e. After all bolts are tightened, retighten them to specified torque in
numerical order as shown in the figure. O
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking.
P
PBIC3164J
12. Install crankshaft pulley with the following procedure:
EM-51
TIMING CHAIN
a. When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
CAUTION:
Never damage front oil seal lip section.
b. Secure crankshaft pulley (1) with a pulley holder (A) (commer-
cial service tool).
c. Apply new engine oil to thread and seat surfaces of crankshaft
pulley bolt.
d. Tighten crankshaft pulley bolt.
: 68.6 N·m (7.0 kg-m, 51 ft-lb)

e. Completely loosen.
PBIC3961E
: 0 N·m (0 kg-m, 0 ft-lb)

f. Tighten crankshaft pulley bolt.
: 29.4 N·m (3.0 kg-m, 22 ft-lb)

g. Put a paint mark (B) on crankshaft pulley (2), matching with any
one of six easy to recognize angle marks (A) on crankshaft pul-
ley bolt (1) flange.
h. Turn another 60 degrees clockwise (angle tightening).
• Check the tightening angle with movement of one angle mark.
PBIC3963E
i. Check that crankshaft rotates clockwise smoothly.


Timing Chain
Check for cracks (A) and any excessive wear (B) at link plates and
roller links of timing chain. Replace timing chain as necessary.
PBIC3169J

Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-22, "Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
EM-52
TIMING CHAIN
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points. A
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE:
EM
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate an unusualness. Noise
will stop after hydraulic pressure rises.
• Warm up engine thoroughly to check there is no leakage of fuel, or any oil/fluids including engine oil and C
engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the D
specified level, if necessary.
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
E
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level F
Fuel Leakage Leakage Leakage
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
G
EM-53
CAMSHAFT
CAMSHAFT
JPBIA0292GB
1. O-ring 2. Camshaft position sensor (PHASE) 3. Camshaft bracket

4. Camshaft sprocket (EXH) 5. Camshaft sprocket (INT) 6. Camshaft (EXH)
7. Camshaft (INT) 8. Signal plate 9. Valve lifter (EXH)
10. Valve lifter (INT)
A. Refer to EM-54
CAUTION:
The rotating direction in the text indicates all directions seen from the engine front.
REMOVAL
• Front cover and timing chain related parts: Refer to EM-43, "Exploded View".
NOTE:
EM-54
CAMSHAFT
Removal of balancer unit related part is not necessary.
2. Remove camshaft position sensor (PHASE) from camshaft bracket. A
CAUTION:
• Handle camshaft position sensor (PHASE) carefully and avoid impacts.
• Never disassemble camshaft position sensor (PHASE). EM
• Never place sensor where it is exposed to magnetism.
3. Put the matching mark (A) on the camshaft sprocket (INT) (2)
and the camshaft bracket (1) as shown in the figure.
C
: Engine front
NOTE: D
It prevents the knock pin of the camshaft (INT) from engaging
with the incorrect pin hole when installing the camshaft sprocket
(INT).
E
PBIC3992J
F
4. Remove camshaft sprockets (INT) (1) and (EXH) (2).
• Secure hexagonal part (A) of camshaft with a wrench. Loosen
camshaft sprocket mounting bolts and remove camshaft
sprocket. G
CAUTION:
• Never rotate crankshaft or camshaft while timing chain
is removed. It causes interference between valve and H
piston.
• Never loosen the mounting bolts with securing anything
other than the camshaft hexagonal part or with tension-
ing the timing chain. I
PBIC3454J
5. Remove camshaft bracket with the following procedure:

a. Loosen mounting bolts in reverse order as shown in the figure. J
: Engine front
K
M
PBIC3176J
b. Cut liquid gasket by prying the position ( ) shown in the figure,

and then remove the camshaft bracket. N
: Engine front
CAUTION: O
• Be careful not to damage the mating surface.
• A more adhesive liquid gasket is applied compared to pre-
vious types when shipped, so it should not be forced off P
the position not specified.
PBIC3358J
6. Remove camshafts.
7. Remove valve lifters.
• Identify installation positions, and store them without mixing them up.
EM-55
CAMSHAFT
8. Remove signal plate from camshaft (INT), if necessary.
INSTALLATION
1. Install valve lifters.
• Install them in the original positions.
2. Install camshafts.
• Clean camshaft journal to remove any foreign material.
• Distinguish between the intake and the exhaust by looking at
the different shapes of the front and rear ends of the camshaft
or using the identification colors (A) and (B).
1 : Camshaft (EXH)
2 : Camshaft (INT)
Identification color A B
Camshaft (EXH) — White
Camshaft (INT) White — PBIC3188J
• Install camshafts so that camshaft dowel pins (A) on the front

side are positioned as shown in the figure.
1 : Camshaft (EXH)
2 : Camshaft (INT)
NOTE:
Though camshaft does not stop at the positions as shown in
the figure, for the placement of cam nose, it is generally
accepted camshaft is placed for the same direction of the fig-
ure.
PBIC3189J
3. Install camshaft bracket with the following procedure:

a. Remove foreign material completely from camshaft bracket backside and from cylinder head installation
face.
b. Apply liquid gasket (A) to camshaft bracket as shown in the fig-
ure.
B : Plug hole inner wall

: Engine front
: Engine outside
PBIC3964E
EM-56
CAMSHAFT
c. Tighten mounting bolts of camshaft brackets in the following
steps, in numerical order as shown in the figure. A
: Engine front
• There are two types of mounting bolts. Refer to the following EM

for locating bolts.
M6 bolts [thread length: 57.5 mm (2.264 in)] C

: 13, 14 and 15 in the figure
M6 bolts [thread length: 35.00 mm (1.378 in)] PBIC3176J
D
: Except the above
i. Tighten mounting bolts in numerical order.
E
: 1.96 N·m (0.20 kg-m, 17 in-lb)
ii. Tighten mounting bolts in numerical order.
F
: 5.88 N·m (0.60 kg-m, 52 in-lb)

iii. Tighten mounting bolts in numerical order. G
: 9.5 N·m (0.97 kg-m, 84 in-lb)

H
CAUTION:
After tightening mounting bolts of camshaft brackets, be sure to wipe off excessive liquid gasket
from the mating surface of cylinder head.
I
4. Install the camshaft sprocket (INT) to the camshaft (INT) with the following procedure.
a. When the camshaft sprocket (INT) (2) is removed, refer to the
paint mark (A) put according to step “3”. Securely align the
J
knock pin and the pin hole, and then install them.
1 : Camshaft bracket
: Engine front
K
PBIC3992J
M
b. Tighten bolts in the following steps.
• Secure the hexagonal part of camshaft (INT) using wrench to tighten mounting bolt.
i. Tighten camshaft (INT) mounting bolt.
N
: 35.0 N·m (3.6 kg-m, 26 ft-lb)

ii. Turn 67 degrees clockwise (angle tightening). O

A : Camshaft (INT) hexagonal part P
CAUTION:
Check the tightening angle by using an angle wrench [SST:
KV10112100] (B) or protractor. Never judge by visual
inspection without an angle wrench.
PBIC3455J
EM-57
CAMSHAFT
5. Install camshaft sprocket (EXH) (2).

• Secure the hexagonal part (A) of camshaft (EXH) using
wrench to tighten mounting bolt.
PBIC3454J
6. Install timing chain and related parts. Refer to EM-43, "Exploded View".
7. Inspect and adjust valve clearance. Refer to EM-20, "Inspection and Adjustment".

Camshaft Runout
1. Put V-block on a precise flat table, and support No. 2 and 5 jour-
nal of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft
sprocket) because it has a different diameter from the other
four locations.
2. Set dial indicator (A) vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the
camshaft runout on dial indicator. (Total indicator reading)
PBIC3177J
Standard and Limit : Refer to EM-120, "Camshaft".
4. If it exceeds the limit, replace camshaft.
Camshaft Cam Height
1. Measure the camshaft cam height with a micrometer (A).
PBIC3178J

Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL OUTER DIAMETER
EM-58
CAMSHAFT
Measure the outer diameter of camshaft journal with a micrometer
(A). A
Standard : Refer to EM-120, "Camshaft".

EM
PBIC3179J
D
CAMSHAFT BRACKET INNER DIAMETER
• Tighten camshaft bracket bolts with specified torque. Refer to EM-54, "Removal and Installation".
• Measure the inner diameter of camshaft bracket with a bore gauge E
(A).
B : Measuring direction of inner diameter

F
PBIC3180J H
CAMSHAFT JOURNAL OIL CLEARANCE

• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter)
I
• If it exceeds the limit, replace camshaft or cylinder head, or both. J
NOTE:
Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head.
Replace whole cylinder head assembly.
K
Camshaft End Play
1. Install camshaft in cylinder head. Refer to EM-54, "Removal and Installation".
2. Install dial indicator in thrust direction on front end of camshaft. L
Read the end play of dial indicator (A) when camshaft is moved
forward/backward (in direction to axis).
M
PBIC3181J O
EM-59
CAMSHAFT
• Measure the following parts if out of the standard.
- Dimension “A” for groove of cylinder head No. 1 journal
Standard : 4.000 - 4.030 mm (0.1575 - 0.1587 in)

- Dimension “B” for camshaft flange
Standard : 3.877 - 3.925 mm (0.1526 - 0.1545 in)

• Refer to the standards above, and then replace camshaft and/
or cylinder head.
PBIC3183J
Camshaft Sprocket Runout

1. Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations.
2. Measure the camshaft sprocket runout with a dial indicator (A).
(Total indicator reading)
Limit : Refer to EM-120, "Camshaft".

• If it exceeds the limit, replace camshaft sprocket.
PBIC3182J
Valve Lifter
Check if surface of valve lifter has any wear or cracks.
• If anything above is found, replace valve lifter. Refer to EM-120,
"Camshaft".
KBIA0182E
Valve Lifter Clearance

VALVE LIFTER OUTER DIAMETER
• Measure the outer diameter of valve lifter with a micrometer (A).
PBIC3185J
VALVE LIFTER HOLE DIAMETER
EM-60
CAMSHAFT
Measure the diameter of valve lifter hole of cylinder head with an
inside micrometer (A). A

VALVE LIFTER CLEARANCE EM
• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter
outer diameter)
C
• If out of the standard, referring to the each standard of valve lifter PBIC3184J
outer diameter and valve lifter hole diameter, replace either or both D
valve lifter and cylinder head.
E
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION:
• Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-III
and it is directed according to inspection procedure of EC section. Refer to ECM-111, "Diagnosis F
Procedure".
• Check when engine is cold so as to prevent burns by the splashing engine oil.
1. Check engine oil level. Refer to LU-6, "Inspection". G
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking.
a. Release the fuel pressure. Refer to ECM-349, "Inspection". H
b. Remove intake manifold. Refer to EM-27, "Exploded View".
c. Disconnect ignition coil and injector harness connectors.
3. Remove intake valve timing control solenoid valve. Refer to EM-43, "Exploded View". I
4. Clean the mounting area of intake valve timing control solenoid
valve, and then insert a clean waste with no oil adhesion into the
oil hole (A) of the cylinder head. J
1 : Front cover
B : Service hole K
C : Member on RH side
: Engine front
L
5. Install engine mounting insulator (RH). (After the removal of
intake valve timing control solenoid valve and insertion of a PBIC3191J
waste into the oil hole.) M

6. Perform cranking to check that engine oil comes out from the oil hole (mounting hole of intake valve timing
control solenoid valve) of cylinder head.
• Regarding the engine oil check, judge it by the amount of oil adhered to the wasted inserted into the oil
hole. N
WARNING:
• Never insert fingers into the oil hole from the service hole of the member on the RH side.
• Be careful not to touch rotating parts (drive belt, idler pulleys and crankshaft pulley, etc.). O
CAUTION:
• Never perform cranking without installing the engine mounting insulator (RH).
• Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil P
and so as to prevent engine oil contamination.
• Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to
engine and vehicle. Especially, be careful not to apply engine oil to rubber parts of drive belt,
engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
7. Perform the following inspection if engine oil does not come out from intake valve timing control solenoid
valve oil hole of the cylinder head.
EM-61
CAMSHAFT
• Remove oil filter (for intake valve timing control solenoid), and then clean it. Refer to EM-43, "Exploded
View".
• Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-3,
"Engine Lubrication System" and LU-3, "Engine Lubrication System Schematic".
8. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
• Clean oil groove if necessary. Refer to LU-3, "Engine Lubrication System" and LU-3, "Engine Lubrica-
tion System Schematic".
9. After inspection, install removed parts in the reverse order.
EM-62
OIL SEAL
OIL SEAL
A
VALVE OIL SEAL
VALVE OIL SEAL : Removal and Installation INFOID:0000000001160555
EM
REMOVAL
1. Remove camshafts. Refer to EM-54, "Exploded View".
C
2. Remove valve lifters. Refer to EM-54, "Exploded View".
3. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
D
CAUTION:
When rotating crankshaft, be careful to avoid scarring front cover with timing chain.
4. Remove valve collet.
• Compress valve spring with the valve spring compressor, the E
attachment and the adapter [SST: KV10116200] (A).
CAUTION:
Be careful not to damage valve lifter holes. F
H
PBIC3209J
5. Remove valve spring retainer and valve spring (with valve spring seat).
CAUTION: I
Never remove valve spring seat from valve spring.
6. Remove valve oil seal with the valve oil seal puller [SST:
KV10107902] (A). J
PBIC3210J
M
INSTALLATION
1. Apply new engine oil to valve oil seal joint surface and seal lip.
2. Press in valve oil seal to the height “H” shown in the figure with N
the valve oil seal drift [SST: KV10115600] (A).
Height “H” : 15.1 - 15.7 mm (0.594 - 0.618 in) O
PBIC3211J

FRONT OIL SEAL
EM-63
OIL SEAL
FRONT OIL SEAL : Removal and Installation INFOID:0000000001160556
REMOVAL
• Front fender protector (RH): Refer to EXT-21, "Exploded View".
• Drive belt: Refer to EM-15, "Exploded View".
• Crankshaft pulley: Refer to EM-43, "Exploded View".
2. Remove front oil seal with a suitable tool.
CAUTION:
Be careful not to damage front cover and crankshaft.
INSTALLATION
1. Apply new engine oil to new front oil seal joint surface and seal lip.
2. Install front oil seal so that each seal lip is oriented as shown in
the figure.
A : Dust seal lip

B : Oil seal lip
: Engine outside
: Engine inside
PBIC3485J
• Press-fit front oil seal using a suitable drift with outer diameter 57 mm (2.24 in) and inner diameter 45
mm (1.77 in).
Within 0.3 mm (0.012 in) toward engine front (crankshaft pulley side)
Within 0.5 mm (0.020 in) toward engine rear (crankshaft sprocket side)
CAUTION:
• Be careful not to damage front cover and crankshaft.
• Press-fit oil seal straight to avoid causing burrs or tilting.

REAR OIL SEAL
REAR OIL SEAL : Removal and Installation INFOID:0000000001160557
REMOVAL
1. Remove transaxle assembly. Refer to following.
• TM-26, "Exploded View" [M/T(2WD models)]
• TM-85, "Exploded View" [M/T(4WD models)]
• TM-546, "MR20DE : Exploded View" (CVT models)
2. Remove clutch cover and clutch disk (M/T models). Refer to CL-18, "MR20DE, QR25DE : Exploded
View".
3. Remove drive plate (CVT models) or flywheel (M/T models). Refer to EM-93, "Exploded View".
4. Remove rear oil seal with a suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
INSTALLATION
1. Apply the liquid gasket lightly to entire outside area of new rear oil seal.
EM-64
OIL SEAL
2. Install rear oil seal so that each seal lip is oriented as shown in
the figure. A
A : Dust seal lip

B : Oil seal lip EM
: Engine outside
: Engine inside
C
PBIC3485J
D
• Press-fit rear oil seal with a suitable drift (A) outer diameter
115 mm (4.53 in) and inner diameter 90 mm (3.54 in).
CAUTION: E
• Be careful not to damage crankshaft and cylinder block.
• Press-fit oil seal straight to avoid causing burrs or tilt-
ing.
• Never touch grease applied onto oil seal lip. F
G
PBIC3951E
• Press in rear oil seal (1) to the position as shown in the figure. H
A : Rear end surface of cylinder block

I
K
PBIC3952E

L
EM-65
CYLINDER HEAD
CYLINDER HEAD
REMOVAL
PBIC3542J
1. Cylinder head assembly 2. Cylinder head bolt 3. Cylinder head gasket

A. Refer to EM-67
DISSASEMBLY
PBIC3543J
EM-66
CYLINDER HEAD
Valve spring (EXH) A

1. Valve collet 2. Valve spring retainer 3.
(with valve spring seat)
4. Valve oil seal 5. Valve guide (EXH) 6. Valve seat (EXH)
7. Valve (EXH) 8. Valve (INT) 9. Valve seat (INT)
EM
10. Cylinder head 11. Valve guide (INT) 12. Spark plug
Valve spring (INT)
13.
(with valve spring seat)
C
Removal and Installation INFOID:0000000001160559 D
REMOVAL
1. Release fuel pressure. Refer to ECM-349, "Inspection". E
2. Drain engine coolant and engine oil. Refer to CO-10, "Draining" and LU-7, "Draining".
3. Remove the following components and related parts.
• Exhaust manifold: Refer to EM-30, "Exploded View". F
• Fuel tube and fuel injector assembly: Refer to EM-36, "Exploded View".
• Water outlet: Refer to CO-30, "Exploded View". G
• Front cover, timing chain: Refer to EM-43, "Exploded View".
• Camshaft: Refer to EM-54, "Exploded View". H
4. Remove cylinder head.
I
: Engine front
• Using TORX socket (size E18), loosen cylinder head bolts.

J
K
PBIC3206J
5. Remove cylinder head gasket. L

INSTALLATION
1. Install cylinder head gasket.
M
2. Install cylinder head, and tighten cylinder head bolts in numeri-
cal order as shown in figure with the following procedure.
: Engine front N
CAUTION:
If cylinder head bolts are re-used, check their outer diame-
ters before installation. Refer to EM-72, "Inspection". O
a. Apply new engine oil to threads and seating surface of mounting
bolts.
P
b. Tighten all bolts. PBIC3206J
: 40.0 N·m (4.1 kg-m, 30 ft-lb)
EM-67
CYLINDER HEAD
c. Turn all bolts 100 degrees clockwise (angle tightening).
CAUTION:
Check and confirm the tightening angle by using an angle
wrench [SST: KV10112100] (A) or protractor. Never judge by
visual inspection without the tool.
d. Completely loosen.
: 0 N·m (0 kg-m, 0 ft-lb)

CAUTION:
In this step, loosen bolts in reverse order that indicated in PBIC3208J
the figure.
e. Tighten all bolts.
: 40.0 N·m (4.1 kg-m, 30 ft-lb)
f. Turn all bolts 100 degrees clockwise (angle tightening).

g. Turn all bolts 100 degrees clockwise again (angle tightening).
Disassembly and Assembly INFOID:0000000001160560
DISASSEMBLY
1. Remove spark plug with spark plug wrench (commercial service tool).
2. Remove valve lifter.
• Compress valve spring with valve spring compressor, attach-
ment and adapter [SST: KV10116200] (A). Remove valve col-
let with a magnet hand.
CAUTION:
Be careful not to damage valve lifter holes.
PBIC3209J
CAUTION:
5. Push valve stem to combustion chamber side, and remove valve.
6. Remove valve oil seal with a valve oil seal puller [SST:
KV10107902] (A).
PBIC3210J
7. When valve seat must be replaced.
EM-68
CYLINDER HEAD
• Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat
recess in cylinder head. Set the machine depth stop to ensure this. Refer to EM-121, "Cylinder Head". A
CAUTION:
Never bore excessively to prevent cylinder head from scratching.
8. When valve guide must be replaced. EM
a. To remove valve guide, heat cylinder head to 110 to 130°C (230
to 266°F) by soaking in heated oil (A).
C
E
PBIC3214J
b. Drive out valve guide with a hammer and valve guide drift (com-
F
mercial service tool).
CAUTION:
Cylinder head contains heat, wear protective equipment to
avoid getting burned. G
SEM931C
I
ASSEMBLY
1. When valve guide is removed, install it. J
CAUTION:
Replace with oversize [0.2 mm (0.008 in)] valve guide.
a. Ream cylinder head valve guide hole with a valve guide reamer K
(commercial service tool) (A).
For service parts: Oversize [0.2 mm (0.008 in)]

L
Refer to EM-121, "Cylinder Head".
PBIC3215J
N
b. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil (A).
O
PBIC3214J
EM-69
CYLINDER HEAD
c. Press valve guide (1) from camshaft side to dimensions as
2 : Cylinder head
Projection “H” : Refer to EM-121, "Cylinder Head".

CAUTION:
Cylinder head contains heat, wear protective equipment to
avoid getting burned.
PBIC3217J
d. Apply reamer finish to valve guide with a valve guide reamer

Standard : Refer to EM-121, "Cylinder Head".
PBIC3215J
2. When valve seat is removed, install it.

CAUTION:
Replace with oversize [0.5 mm (0.020 in)] valve seat.
a. Ream cylinder head (1) recess diameter for service valve seat.
2 : Valve seat
For service parts: Oversize [0.5 mm (0.020 in)]

• Be sure to ream in circles concentric to the valve guide center.
This will enable valve seat to fit correctly.
PBIC3218J

heated oil (A).
PBIC3214J
c. Provide valve seats cooled well with dry ice. Press-fit valve seat into cylinder head.
CAUTION:
• Never touch cold valve seats directly.
• Cylinder head contains heat, wear protective equipment to avoid getting burned.
EM-70
CYLINDER HEAD
d. Using valve seat cutter set (commercial service tool) or valve
seat grinder, finish valve seat to the specified dimensions. For A
dimensions, refer to EM-121, "Cylinder Head".
CAUTION:
When using valve seat cutter, firmly grip the cutter handle
EM
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with the cutter or cutting many different times
may result in stage valve seat. C
SEM934C
D
e. Using compound, grind to adjust valve fitting.
f. Check again for normal contact. Refer to EM-72, "Inspection".
3. Install valve oil seal. E
• Install with a valve oil seal drift [SST:KV10115600] (A) to
match dimension in the figure.
NOTE:
F
Dimension “H” is height that measured before installing valve
spring (with valve spring seat).
Height “H” : 15.1 - 15.7 mm (0.594 - 0.618 in) G
H
PBIC3211J
4. Install valve.
• Install larger diameter to intake side. I
5. Install valve spring (with valve spring seat).

• Install smaller pitch (valve spring seat side) to cylinder head J
side (B).
1 : Valve spring seat (Do not remove from valve spring.) K

• Confirm identification color (A) of valve spring.
Intake : Green L
Exhaust : Purple
PBIC3462J
M
6. Install valve spring retainer.

7. Install valve collet. N
• Compress valve spring with a valve spring compressor, attach-
ment and adapter [SST: KV10116200] (A). Install valve collet
with a magnet hand.
CAUTION: O
Be careful not to damage valve lifter holes.
• Tap valve stem edge lightly with a plastic hammer after instal-
lation to check its installed condition. P
PBIC3209J
8. Install valve lifter.

• Install it in the original position.
EM-71
CYLINDER HEAD
9. Install spark plug with spark plug wrench (commercial service tool).

Cylinder Head Bolts Outer Diameter
• Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between “d1” and “d2”
exceeds the limit, replace them with a new one.
Limit (“d1”–“d2”): 0.15 mm (0.0059 in)

• If reduction of outer diameter appears in a position other than “d2”,
use it as “d2” point.
PBIC3994E
Cylinder Head Distortion

NOTE:
When performing this inspection, cylinder block distortion should be also checked. Refer to EM-124, "Cylinder
Block".
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.
CAUTION:
Never allow gasket debris to enter passages for engine oil or water.
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions using straightedge (A)
and feeler gauge (B).
Limit: Refer to EM-121, "Cylinder Head".

• If it exceeds the limit, replace cylinder head.
PBIC3207J
INSPECTION AFTER DISASSEMBLY

VALVE DIMENSIONS
• Check the dimensions of each valve. For the dimensions, refer to EM-121, "Cylinder Head".
• If dimensions are out of the standard, replace valve and check valve seat contact.
VALVE GUIDE CLEARANCE
Valve Stem Diameter

• Measure the diameter of valve stem with micrometer (A).
Valve Guide Inner Diameter

• Measure the inner diameter of valve guide with bore gauge.
Valve Guide Clearance

• (Valve guide clearance) = (Valve guide inner diameter) – (Valve
stem diameter) PBIC3213J
Standard and Limit : Refer to EM-121, "Cylinder Head".
EM-72
CYLINDER HEAD
• If the calculated value exceeds the limit, replace valve and/or valve guide. When valve guide must be
replaced. Refer to EM-68, "Disassembly and Assembly". A
VALVE SEAT CONTACT
• After confirming that the dimensions of valve guides and valves are within the specifications, perform this
procedure. EM
• Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve
contact on the surface.
• Check if the contact area band is continuous all around the circum- C
ference.
A : OK
B : NG D
• If not, grind to adjust valve fitting and check again. If the contacting
surface still has “NG” conditions even after the re-check, replace
valve seat. Refer to EM-68, "Disassembly and Assembly". E
JPBIA0187ZZ
F
VALVE SPRING SQUARENESS
• Set a try square (A) along the side of valve spring and rotate
spring. Measure the maximum clearance between the top of spring G
and try square.
B : Contact
H
Limit : Refer to EM-121, "Cylinder Head".

• If it exceeds the limit, replace valve spring. I
PBIC3219J
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD J

• Check valve spring pressure with valve spring seat installed at the
specified spring height.
CAUTION: K
Standard : Refer to EM-121, "Cylinder Head". L

• If the installation load or load with valve open is out of the stan-
dard, replace valve spring (with valve spring seat).
M
SEM113
INSPECTION AFTER INSTALLATION N

• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required O
age at connection points. P
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
EM-73
CYLINDER HEAD
Other oils and fluid* Level Leakage Level
Exhaust gases — Leakage —
EM-74
ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION > [MR20DE]
REMOVAL AND INSTALLATION A

ENGINE ASSEMBLY
M/T
EM
M/T : Exploded View INFOID:0000000001160562
2WD models C
JPBIA0696GB
N
1. Engine mounting stay 2. Engine mounting insulator (RH) 3. Rear engine mounting bracket
Engine mounting bracket support
4. Rear torque rod 5. Engine mounting bracket (LH) 6.
(LH) O
7. Engine mounting insulator (LH)
4WD models P
EM-75
ENGINE ASSEMBLY
JPBIA0700GB
Engine mounting bracket support
4. Rear torque rod 5. Engine mounting bracket (LH) 6.
(LH)
M/T : Removal and Installation INFOID:0000000001160563
WARNING:
• Situate the vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
• Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped.
CAUTION:
• Always be careful to work safely, avoid forceful or uninstructed operations.
• Never start working until exhaust system and coolant are cool enough.
• If items or work required are not covered by the engine section, refer to the applicable sections.
• Always use the support point specified for lifting.
• Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid-
able reasons, support at the rear axle jacking point with a transmission jack or similar tool before
starting work, in preparation for the backward shift of center of gravity.
• For supporting points for lifting and jacking point at rear axle, refer to GI-33, "Garage Jack and
Safety Stand and 2-Pole Lift".
EM-76
ENGINE ASSEMBLY
REMOVAL
A
Outline
Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the tran-
saxle.
EM
Preparation
2. Drain engine coolant from radiator. Refer to CO-10, "Draining". C
CAUTION:
• Never spill engine coolant on drive belt.
D
• Engine undercover
• Front road wheels and tires: Refer to WT-3, "Adjustment".
• Front fender protector (RH and LH): Refer to EXT-21, "Exploded View". E
• Engine cover: Refer to EM-27, "Exploded View".
• Battery and battery tray: Refer to PG-133, "Exploded View".
• Air duct and air cleaner case assembly: Refer to EM-25, "Exploded View". F
• Radiator hose (upper and lower) and cooling fan assembly: Refer to CO-16, "Exploded View".
• Exhaust front tube: Refer to EX-5, "Exploded View".
Engine Room LH G
1. Disconnect all connections of engine harness around the engine mounting insulator (LH), and then tem-
porarily secure the engine harness into the engine side.
CAUTION: H
Protect connectors using a resin bag against foreign materials during the operation.
2. Disconnect fuel feed hose at engine side. Refer to EM-36, "Exploded View".
3. Disconnect heater hoses. Refer to CO-30, "Exploded View". I
4. Disconnect control linkage from transaxle. Refer to TM-21, "Exploded View".
Engine Room RH
1. Disconnect vacuum hose from intake manifold. Refer to EM-27, "Exploded View". J
2. Remove A/C compressor without disconnecting A/C piping, and temporarily fasten it on vehicle with a
rope (with A/C models). Refer to HA-44, "MR20DE : Exploded View".
3. Disconnect reservoir tank hoses. Refer to CO-16, "Exploded View". K
Vehicle inside
• Disconnect steering lower joint at steering gear assembly side, and release steering lower shaft. Refer to L
ST-13, "Exploded View".
Vehicle Underbody
1. Remove ground cable at transaxle side. M
2. Remove front wheel sensor (LH and RH) for ABS from steering knuckle. Refer to BRC-67, "FRONT
WHEEL SENSOR : Exploded View".
3. Remove brake caliper assembly with piping connected from steering knuckle. Temporarily secure it on the N
vehicle side with a rope to avoid load on it. Refer to BR-42, "BRAKE CALIPER ASSEMBLY : Exploded
View" (LHD models) or BR-89, "BRAKE CALIPER ASSEMBLY : Exploded View" (RHD models).
4. Disconnect steering outer sockets from steering knuckle. Refer to ST-13, "Exploded View". O
5. Remove rear torque rod.
6. Remove drive shafts (LH and RH). Refer to FAX-19, "MR20DE : Exploded View" (2WD models) or FAX-
52, "MR20DE : Exploded View" (4WD models). P
7. Disconnect csc tube. Refer to CL-14, "Exploded View".
8. Remove propeller shaft (4WD models). Refer to DLN-121, "Exploded View".
9. Remove stabilizer connecting rod. Refer to FSU-16, "Exploded View".
10. Remove front suspension member. Refer to FSU-18, "Exploded View".
11. Preparation for the separation work of transaxle is as follows:
EM-77
ENGINE ASSEMBLY
• Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to EM-33, "Exploded
View".
Removal
1. Use a manual lift table caddy (commercial service tool) or equiv-
alently rigid tool such as a transmission jack. Securely support
bottom of the engine and the transaxle assembly.
CAUTION:
Put a piece of wood or an equivalent as the supporting sur-
face, secure a completely stable condition.
PBIC1190E
2. Remove engine mounting bolts on engine mounting insulator

(RH) (2).
1 : Engine mounting stay

3 : Engine mounting insulator (LH)
3. Remove engine mounting through bolt-securing nut (A).
PBIC5123J
4. Carefully lower jack, or raise lift to remove the engine and the transaxle assembly. When performing work,
observe the following caution.
CAUTION:
• Check that no part interferes with the vehicle side.
• Before and during this lifting, always check if any harnesses are left connected.
• During the removal, always be careful to prevent the vehicle from falling off the lift due to
changes in the center of gravity.
• If necessary, support the vehicle by setting jack or suitable tool at the rear.
Separation
1. Install engine slinger to front cover front left side and cylinder
head rear right side.
: Engine front
Slinger bolts
Front cover side: : 32.9 N·m (3.4 kg-m, 24 ft-lb)
Cylinder head side: : 25.0 N·m (2.6 kg-m, 18 ft-lb)
PBIC3222J
2. Remove starter motor. Refer to STR-27, "MR20DE MODELS : Exploded View".

3. Lift with a hoist and separate the engine from the transaxle assembly. Refer to TM-26, "Exploded View"
(2WD models) or TM-85, "Exploded View" (4WD models).
INSTALLATION
CAUTION:
• Never allow engine oil to get on engine mounting insulator. Be careful not to damage engine mount-
ing insulator.
• Check that each mounting insulator is seated properly, and tighten mounting nuts and bolts.
EM-78
ENGINE ASSEMBLY
Preparation
1. Install the engine mounting bracket (LH) to the engine. A
a. Tighten the bolt No. 1 as shown in the figure. (temporarily)
EM
: Vehicle front
b. Tighten the bolt No. 2, 3 in numerical order as shown in the fig-

ure. (specified torque) C
c. Tighten the bolt No. 1 as shown in the figure. (specified torque)
D
JPBIA0697ZZ
2. Install the engine mounting insulator (RH) to the body temporarily. E

3. Install the engine mounting bracket support (LH) to the body as follows:
F
: Vehicle front
b. Tighten the bolts No. 6, 7 in numerical order as shown in the fig- G

ure. (specified torque)
c. Tighten the bolts No. 2, 3, 4, 5 in numerical order as shown in
the figure. (specified torque) H
d. Tighten the bolt No. 1 as shown in the figure. (specified torque)
L
JPBIA0698ZZ
Installation
1. Install the rear bracket to the transaxle, and then tighten mounting bolts. (specified torque) M
2. Install the rear torque rod to the suspension member and transaxle, and then tighten mounting bolts.
(specified torque)
3. Tighten the engine mounting insulator (LH) to the specified torque. N
4. Install the engine mounting insulator (RH) to the engine and tighten as follows:
O
: Vehicle front
b. Tighten the bolts No. 2, 3, 4 in numerical order as shown in the P

figure. (specified torque)
JPBIA0699ZZ
EM-79
ENGINE ASSEMBLY
5. Tighten engine mounting through bolt-securing nut (A) to the
specified torque.
: Vehicle front
6. Tighten the engine mounting insulator bolts (RH) to the body.

(specified torque)
JPBIA0780ZZ
M/T : Inspection INFOID:0000000001160564

age at connection points.
CVT
EM-80
ENGINE ASSEMBLY
CVT : Exploded View INFOID:0000000001160565
EM
JPBIA0702GB
L
4. Rear torque rod 5. Engine mounting insulator (LH)
CVT : Removal and Installation INFOID:0000000001160566
N
WARNING:
• Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped. O
CAUTION:
• Never start working until exhaust system and coolant are cool enough. P
EM-81
ENGINE ASSEMBLY
REMOVAL
Outline
saxle.
Preparation
2. Drain engine coolant from radiator. Refer to CO-10, "Draining".
CAUTION:
• Front fender protector (RH and LH): Refer to EXT-21, "Exploded View".
• Air duct and air cleaner case assembly: Refer to EM-25, "Exploded View".
• Radiator hose (upper and lower), CVT fluid cooler hose and cooling fan assembly: Refer to CO-16,
"Exploded View".
Engine Room LH
porarily secure the engine harness into the engine side.
CAUTION:
2. Disconnect fuel feed hose at engine side. Refer to EM-36, "Exploded View".
3. Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to CO-30,
"Exploded View".
4. Disconnect control cable from transaxle. Refer to TM-519, "MR20DE : Exploded View".
Engine Room RH
1. Disconnect vacuum hose from intake manifold. Refer to EM-27, "Exploded View".
rope (with A/C models). Refer to HA-44, "MR20DE : Exploded View".
3. Disconnect reservoir tank hoses. Refer to CO-16, "Exploded View".
Vehicle inside
• Disconnect steering lower joint at steering gear assembly side, and release steering lower shaft. Refer to
ST-13, "Exploded View".
Vehicle Underbody
1. Remove ground cable at transaxle side.
3. Remove brake caliper assembly with piping connected from steering knuckle. Temporarily secure it on the
4. Disconnect steering outer sockets from steering knuckle. Refer to ST-13, "Exploded View".
6. Remove drive shafts (LH and RH). Refer to FAX-52, "MR20DE : Exploded View".
7. Remove propeller shaft. Refer to DLN-121, "Exploded View" .
EM-82
ENGINE ASSEMBLY
View". A
Removal
alently rigid tool such as a transmission jack. Securely support EM
CAUTION:
Put a piece of wood or an equivalent as the supporting sur- C
PBIC1190E
E
2. Remove four mounting bolts on engine mounting insulator (RH) (front cover side).
3. Remove two mounting bolts (A) on engine mounting insulator
(LH) (transaxle side). F
:Vehicle front
CAUTION: G
Never remove the bolt (B) coupling insulator and bracket.
(part not for disassembly)
H
JPBIA0463ZZ
I
CAUTION: J
• During the removal, always be careful to prevent the vehicle from falling off the lift due to K
Separation L
1. Install engine slinger to front cover front left side and cylinder
head rear right side.
M
: Engine front
Slinger bolts N
Front cover side: : 32.9 N·m (3.4 kg-m, 24 ft-lb)
Cylinder head side: : 25.0 N·m (2.6 kg-m, 18 ft-lb)
O
PBIC3222J
2. Remove starter motor. Refer to STR-27, "MR20DE MODELS : Exploded View".

P
3. Lift with a hoist and separate the engine from the transaxle assembly. Refer to TM-546, "MR20DE :
Exploded View".
INSTALLATION
CAUTION:
ing insulator.
EM-83
ENGINE ASSEMBLY
Preparation
1. Install the engine mounting insulator (RH) to the body temporarily.
2. Install the engine mounting insulator (LH) to the body as follows:
: Vehicle front
b. Tighten the bolts No. 6, 7 in numerical order as shown in the fig-

ure. (specified torque)
c. Tighten the bolts No. 2, 3, 4, 5 in numerical order as shown in
the figure. (specified torque)
JPBIA0701ZZ
Installation
1. Install the rear bracket to the transaxle, and then tighten mounting bolts. (specified torque)
2. Install the rear torque rod to the suspension member and transaxle, and then tighten mounting bolts.
(specified torque)
3. Install the engine mounting insulator bolts (LH) to the transaxle and tighten as follows:
a. Tighten the bolt (A) as shown in the figure. (temporarily)
: Vehicle front
b. Tighten the bolt (B) as shown in the figure. (temporarily)

c. Tighten the bolt (A) to the specified torque.
d. Tighten the bolt (B) to the specified torque.
JPBIA0462ZZ
4. Install the engine mounting insulator bolts (RH) to the engine and tighten as follows:
: Vehicle front
b. Tighten the bolts No. 2, 3, 4 in numerical order as shown in the

5. Tighten the engine mounting insulator bolts (RH) to the body
side. (temporarily)
JPBIA0699ZZ
EM-84
ENGINE ASSEMBLY
CVT : Inspection INFOID:0000000001160567
A
EM
• Use procedure below to check for fuel leakage. C
- Start engine. With engine speed increased, check again for fuel leakage at connection points. D
• Bleed air from lines and hoses of applicable lines, such as in cooling system. E
Summary of the inspection items: F
G
Fuel Leakage Leakage Leakage H
I
EM-85
ENGINE STAND SETTING
< DISASSEMBLY AND ASSEMBLY > [MR20DE]
DISASSEMBLY AND ASSEMBLY

Setting INFOID:0000000001160568
NOTE:
Explained here is how to disassemble with engine stand supporting transaxle surface. When using different
type of engine stand, note with difference in steps and etc.
1. Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the
engine. Refer to EM-75, "M/T : Exploded View" (M/T models) or EM-81, "CVT : Exploded View" (CVT
models).
2. Install engine to engine stand with the following procedure:
a. Remove flywheel (M/T models) or drive plate (1) (CVT models).
• Secure flywheel or drive plate with a stopper plate [SST:
KV11105210] (A), and remove mounting bolts.
CAUTION:
• Never disassemble them.
• Never place them with signal plate facing down.
• When handling signal plate, take care not to damage or
scratch them.
• Handle signal plate in a manner that prevents them from
becoming magnetized.
NOTE:
PBIC3226J
This figure shows CVT models as an example.
b. Remove pilot converter (1) using pilot bushing puller [SST:
ST16610001] (A) or suitable tool. (CVT models)
NOTE:
M/T models have no pilot converter.
PBIC3229J
c. Lift the engine with a hoist to install it onto widely use engine stand.
CAUTION:
• Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large
enough for supporting the engine weight.
• If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the poten-
tial risk of overturning stand.
- Intake manifold: Refer to EM-27, "Exploded View".
- Exhaust manifold: Refer to EM-30, "Exploded View".
- Rocker cover: Refer to EM-41, "Exploded View".
NOTE:
The figure shows an example of widely used engine stand (A)
that can support mating surface of transaxle with flywheel (M/T
models) or drive plate (CVT models) removed.
CAUTION:
Before removing the hanging chains, check the engine
stand is stable and there is no risk of overturning.
PBIC3227J
EM-86
CAUTION: A
Be sure to clean drain plug and install with new washer.
4. Drain engine coolant by removing water drain plug (1) from
inside of the engine. EM
: Engine front
C
Tightening torque : Refer to EM-94, "Disassembly and
Assembly".
Use Genuine Liquid Gasket or equivalent. D
PBIC3228J
EM-87
ENGINE UNIT
ENGINE UNIT
Disassembly INFOID:0000000001160569

2. Remove exhaust manifold. Refer to EM-30, "Exploded View".
4. Remove oil cooler. Refer to LU-10, "Exploded View".
5. Remove ignition coil, spark plug and rocker cover. Refer to EM-41, "Exploded View".
6. Remove fuel injector and fuel tube. Refer to EM-36, "Exploded View".
7. Remove timing chain. Refer to EM-43, "Exploded View".
9. Remove water inlet. Refer to CO-27, "Exploded View".
10. Remove water outlet. Refer to CO-30, "Exploded View".
11. Remove cylinder head. Refer to EM-66, "Exploded View".
Assembly INFOID:0000000001160570
Assembly is the reverse order of disassembly.
EM-88
OIL PAN (UPPER)
OIL PAN (UPPER)
A
EM
PBIC5120J
N
1. Oil level gauge 2. Oil level gauge guide 3. Rear oil seal
4. O-ring 5. O-ring 6. Oil pan (upper)
7. Balancer unit timing chain 8. Crankshaft sprocket 9. Balancer unit sprocket O
10. Balancer unit timing chain tensioner 11. Drain plug 12. Drain plug washer
13. Oil pan (lower) 14. Oil filter 15. Connector bolt
16. Oil cooler 17. O-ring 18. Oil level sensor P
A. Refer to LU-9
: Oil pan side
EM-89
OIL PAN (UPPER)
REMOVAL
2. Remove oil cooler and oil filter. Refer to LU-10, "Exploded View".
NOTE:
For reference when installing, put a matching mark on oil cooler and oil pan (upper).
3. Remove front cover, timing chain, balancer unit timing chain and other related parts. Refer to EM-43,
"Exploded View".
4. Remove oil level gauge and oil level gauge guide.
5. Remove oil level sensor, if necessary.
CAUTION:
Never drop or shock oil level sensor.
6. Remove oil pan (upper) with the following procedure:
a. Loosen bolts in reverse order as shown in the figure.
: Engine front
JPBIA0287ZZ
b. Insert a screwdriver shown by the arrow ( ) in the figure and

open up a crack between oil pan (upper) and cylinder block.
: Engine front
CAUTION:
A more adhesive liquid gasket is applied compared to previ-
ous types when shipped, so it should not be forced off the
position not specified.
PBIC3948E
c. Insert seal cutter [SST: KV10111100] between oil pan (upper) and cylinder block, and slide it by tapping on
the side of the tool with a hammer.
CAUTION:
7. Remove O-ring between cylinder block and oil pan (upper).

INSTALLATION
1. Install oil pan (upper) with the following procedure:
EM-90
OIL PAN (UPPER)
faces. A
• Remove the old liquid gasket from mating surface of cylinder
block.
EM
CAUTION:
Never scratch or damage the mating surfaces when clean-
ing off old liquid gasket.
C
PBIC3949E
D
b. Apply a continuous bead of liquid gasket (C) with a tube presser
(commercial service tool) as shown in the figure.
E
1 : Oil pan (upper)
A : 2 mm protruded to outside
B : 2 mm protruded to rear oil seal mounting side
F
: Engine front
: Engine outside
Use Genuine Liquid Gasket or equivalent. G

CAUTION:
• Apply liquid gasket to outside of bolt hole for the posi-
tions shown by marks. H
• Attaching should be done within 5 minutes after liquid
gasket application.
I
JPBIA0288ZZ
K
c. Install new O-ring at cylinder block side.
CAUTION:
Install avoiding misalignment of O-ring. L
d. Tighten bolts in numerical order as shown in the figure.
: Engine front M
O
JPBIA0287ZZ
2. Install rear oil seal with the following procedure. P

CAUTION:
• The installation of rear oil seal should be completed within 5 minutes after installing oil pan
(upper).
• Always replace rear oil seal with new one.
• Never touch oil seal lip.
a. Wipe off liquid gasket protruding to the rear oil seal mounting part of oil pan (upper) and cylinder block
using a scraper.
EM-91
OIL PAN (UPPER)
b. Apply engine oil to entire outside area of rear oil seal.
c. Press-fit the rear oil seal using a suitable drift (A) with outer
diameter 115 mm (4.53 in) and inner diameter 90 mm (3.54 in).
PBIC3951E
• Press-fit to the specified dimensions as shown in the figure.
1 : Rear oil seal

A : Cylinder block rear end surface
CAUTION:
• Never touch the grease applied to the oil seal lip.
• Be careful not to damage the rear oil seal mounting part of
oil pan (upper) and cylinder block or the crankshaft.
• Press-fit straight, making sure that rear oil seal does not
curl or tilt.
NOTE: PBIC3952E
The standard surface of the dimension is the rear end surface of

cylinder block.

Clean oil strainer portion (part of the oil pump) if any object attached.
EM-92
CYLINDER BLOCK
CYLINDER BLOCK
A
EM
JPBIA0293GB
1. Cylinder block 2. O-ring 3. Crankshaft position sensor (POS)

4. Crankshaft position sensor (POS) cover 5. Oil filter (for intake valve timing control) 6. Knock sensor
7. Oil pressure switch 8. Top ring 9. Second ring
EM-93
CYLINDER BLOCK
10. Oil ring 11. Snap ring 12. Piston
13. Piston pin 14. Connecting rod 15. Thrust bearing
16. Connecting rod bearing (upper) 17. Main bearing (upper) 18. Crankshaft key
19. Main bearing (lower) 20. Connecting rod bearing (lower) 21. Connecting rod cap
22. Connecting rod cap bolt 23. Main bearing cap 24. Main bearing cap bolt
25. Crankshaft 26. Pilot converter (CVT models) 27. Signal plate
28. Rear oil seal 29. Drive plate (CVT models) 30. Reinforcement plate (CVT models)
31. Flywheel (M/T models)
A. Refer to EM-94 B. Chamfered
: Crankshaft side
DISASSEMBLY
1. Remove oil pan (upper). Refer to EM-89, "Exploded View".
2. Remove thermostat housing. Refer to CO-27, "Exploded View".
3. Remove knock sensor.
CAUTION:
Handle it carefully and avoid impacts.
4. Remove crankshaft position sensor (POS) cover and crankshaft position sensor (POS).
CAUTION:
• Handle it carefully and avoid impacts.
• Never disassemble.
• Never place sensor in a location where it is exposed to magnetism.
5. Remove oil filter (for intake valve timing control).
6. Remove piston and connecting rod assembly with the following procedure:
• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
EM-102, "Inspection".
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod cap.
c. Using a hammer handle or similar tool, push piston and connect-
ing rod assembly out to the cylinder head side.
CAUTION:
• Be careful not to damage matching surface with connect-
ing rod cap.
• Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod
big end.
PBIC0259E
7. Remove connecting rod bearings.

CAUTION:
When removing them, note the installation position. Keep them in the correct.
8. Remove piston rings form piston.
• Before removing piston rings, check the piston ring side clearance. Refer to EM-102, "Inspection".
EM-94
CYLINDER BLOCK
• Use a piston ring expander (commercial service tool) (A).
CAUTION: A
• When removing piston rings, be careful not to damage
the piston.
• Be careful not to damage piston rings by expanding
EM
them excessively.
PBIC3233J
D
9. Remove piston from connecting rod with the following procedure:
a. Using snap ring pliers (A), remove snap rings.
E
PBIC3230J
H
b. Heat piston to 60 to 70°C (140 to 158°F) with an industrial use
drier (A) or equivalent.
I
K
PBIC3231J
c. Push out piston pin with stick of outer diameter approximately 18 L

mm (0.71 in).
PBIC0262E O
10. Remove main bearing cap mounting bolts.

• Measure crankshaft end play before loosening main bearing cap mounting bolts. Refer to EM-102, P
"Inspection".
EM-95
CYLINDER BLOCK
• Loosen and remove bolts in reverse order as shown in the fig-
ure.
: Engine front
• Use TORX socket (size E14).
PBIC3235J
11. Remove main bearing caps.

• Tap main bearing caps lightly with a plastic hammer for removal.
CAUTION:
Be careful not to damage the mounting surface.
12. Remove crankshaft.
CAUTION:
• Be careful not to damage or deform signal plate (1)
mounted on rear end of crankshaft (A).
• When setting crankshaft on a flat floor surface, use a
block of wood to avoid interference between signal plate
and the floor surface.
• Never remove signal plate unless it is necessary to do so.
NOTE:
When removing or installing signal plate, use TORX socket (size
T30).
PBIC3234J
13. Pull rear oil seal out from rear end of crankshaft.
14. Remove main bearings and thrust bearings from cylinder block and main bearing caps.
CAUTION:
Identify installation positions, and store them without mixing them up.
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.
CAUTION:
Use a goggles to protect your eye.
2. Install each plug to cylinder block as shown in the figure.
2 : Washer
: Engine front
• Apply liquid gasket to the thread of water drain plug (4).

• Apply sealant to the thread of plug (1).
Use Thread Locking Sealant or equivalent.
NOTE:
Do not apply liquid gasket or thread locking sealant to the plug
PBIC3999E
(3).
• Tighten each plug as specified below.
Part Washer Tightening torque

1 Yes 54.0 N·m (5.5 kg-m, 40 ft-lb)
EM-96
CYLINDER BLOCK
A
3 No 19.6 N·m (2.0 kg-m, 14 ft-lb)
4 No 9.8 N·m (1.0 kg-m, 87 in-lb)
3. Install main bearings and thrust bearings with the following procedure: EM
a. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block and main bearing cap.
b. Install thrust bearings to the both sides of the No. 3 journal hous-
ing (B) on cylinder block. C
: Engine front
• Install thrust bearings with the oil groove (A) facing crankshaft D
arm (outside).
PBIC3258J
F
c. Install the main bearings paying attention to the direction.
• Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not apply new
engine oil to the back surface, but thoroughly clean it.
G
• When installing, align main bearing to the center position of cylinder block and main bearing cap.
• The difference (A) between main bearing upper (1) and main
bearing lower (3) should be 0.85 mm (0.0335 in) or less when
installing. H
2 : Cylinder block
4 : Main bearing cap I
J
PBIC3237J
• Ensure the oil holes on cylinder block and oil holes (A) on the K
main bearings (1) are aligned.
PBIC3236J
N
4. Install signal plate to crankshaft if removed.

O
a. Set the signal plate with the flange facing toward the counter weight side (engine front side) to the crank-
shaft rear surface.
b. Apply new engine oil to threads and seat surfaces of mounting bolts.
P
EM-97
CYLINDER BLOCK
c. Position crankshaft (2) and signal plate (1) using a dowel pin
(service part), and tighten mounting bolts in numerical order as
shown in the figure using TORX socket.
A : Dowel pin hole

NOTE:
Dowel pin of crankshaft and signal plate is provided as a set for
each.
d. Tighten mounting bolts in numerical order as shown in the figure
again.
PBIC3238J
e. Remove dowel pin. (service parts)
CAUTION:
Be sure to remove dowel pin.
5. Install crankshaft to cylinder block.
• While turning crankshaft by hand, check that it turns smoothly.
6. Install main bearing caps with the following procedure:
a. Install main bearing caps referring to the journal No. stamp (A)
and front mark (B) as shown in the figure.
: Engine front
NOTE:
Main bearing cap cannot be replaced as a single part, because it
is machined together with cylinder block.
PBIC3239J
b. Tighten main bearing cap bolts in numerical order as shown in

the figure with the following procedure:
: Engine front
i. Apply new engine oil to threads and seat surfaces of mounting

bolts.
ii. Tighten main bearing cap bolts.
: 34.3 N·m (3.5 kg-m, 25 ft-lb)

PBIC3235J
iii. Turn main bearing cap bolts 60 degrees clockwise (angle tight-
ening) in order from No. 1 to 10 in the figure.
CAUTION:
Confirm the tightening angle by using an angle wrench
[SST: KV10112100] (A) or protractor. Never judge by visual
inspection without the tool.
PBIC3240J
• After installing mounting bolts, check that crankshaft can be rotated smoothly by hand.
• Check crankshaft end play. Refer to EM-102, "Inspection".
7. Install piston to connecting rod with the following procedure:
a. Using snap ring pliers, install new snap ring to the groove of the piston rear side.
• Insert it fully into groove to install.
b. Assemble piston to connecting rod.
EM-98
CYLINDER BLOCK
• Using an industrial use drier or similar tool, heat the piston until the piston pin can be pushed in by hand
without excess force [approximately 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston A
pin into piston and connecting rod.
• Assemble so that the front mark (A) on the piston head and
the oil hole (B) and the cylinder number (D) on connecting rod
EM
are positioned as shown in the figure.
C : Management code
C
E : Big end diameter grade
F : Small end diameter grade
G : Front mark (connecting rod cap)
D
c. Install new snap ring to the groove of the piston front side.
• Insert it fully into groove to install. PBIC4002E
• After installing, check that connecting rod moves smoothly.
E
8. Using a piston ring expander (commercial service tool), install piston rings.
CAUTION:
• Be careful not to damage piston.
• Be careful not to damage piston rings by expanding them excessively. F
• Position each ring with the gap as shown in the figure referring
to the piston front mark.
G
A : Oil ring upper or lower rail gap
B : Front mark
C : Second ring and oil ring spacer gap H
D : Top ring gap
E : Stamped mark
CAUTION: I
Never contact the rail end gap under the oil ring with the PBIC4000E
oil drain cast groove of piston.
• Install second ring with the stamped surface facing upward.
J
9. Install connecting rod bearing upper (2) and lower (3) to con-
necting rod (1) and connecting rod cap (4).
K
C : Oil hole (connecting rod)
D : Arrow view
L
: Engine front
• Install the connecting rod in the dimension shown in the figure.

• Check that connecting rod bearing oil hole (A) is completely in M
the inside of connecting rod oil hole chamfered area (B).
• When installing connecting rod bearings, apply new engine oil
to the bearing surface (inside). Do not apply new engine oil to
the back surface, but thoroughly clean it. N
NOTE:
• There is no positioning tab.
• Install the connecting rod bearings in the center of connect- O
ing rod and connecting rod cap as shown in the figure. For
service operation, the center position can be checked, visu-
ally.
P
PBIC4541E
10. Install piston and connecting rod assembly to crankshaft.

• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
EM-99
CYLINDER BLOCK
• Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
• Match the cylinder position with the cylinder number (D) on
connecting rod to install.
B : Oil hole
C : Management code
• Install so that front mark (A) on the piston head faces the front
of engine. PBIC4002E
• Using a piston ring compressor [SST: EM03470000] (A) or

suitable tool, install piston with the front mark on the piston
head facing the front of the engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
big end.
PBIC3244J
11. Install connecting rod cap.

• Match the stamped cylinder number marks (D) on connecting
rod with those on connecting rod cap to install.
A : Front mark (piston)

B : Oil hole
C : Management code
PBIC4002E
12. Tighten connecting rod bolt with the following procedure:

CAUTION:
• Check that there is no gap in the thrust surface (A) of the
joint between connecting rod (1) and connecting rod cap
(2) and that these parts are in the correct position. And
then, tighten the connecting rod cap bolts.
• If the connecting rod bolts are reused, measure the outer
diameter. Refer to EM-102, "Inspection".
a. Apply new engine oil to the threads and seats of connecting rod
cap bolts.
b. Tighten bolts.
PBIC3510J
: 27.4 N·m (2.8 kg-m, 20 ft-lb)
c. Completely loosen bolts.
: 0 N·m (0 kg-m, 0 ft-lb)

d. Tighten bolts.
EM-100
CYLINDER BLOCK
: 19.6 N·m (2.0 kg-m, 14 ft-lb) A
e. Then turn all bolts 60 degrees clockwise (Angle tightening).

CAUTION:
Check and confirm the tightening angle by using an angle EM
wrench [SST: KV10112100] (A) or protractor. Never judge by
visual inspection without the tool.
C
PBIC3245J
• After tightening connecting rod cap bolt, check that crankshaft rotates smoothly. E
• Check the connecting rod side clearance. Refer to EM-102, "Inspection".
13. Install oil pan (upper). Refer to EM-89, "Exploded View".
NOTE: F
Install the rear oil seal after installing the oil pan (upper).
14. Install rear oil seal. Refer to EM-64, "REAR OIL SEAL : Removal and Installation".
15. Install drive plate (1) (CVT models) or flywheel (M/T models). G
Drive plate
• Secure crankshaft with a stopper plate [SST: KV11105210]
H
(A), and tighten mounting bolts crosswise over several times.
PBIC3226J
J
• Install drive plate (1), reinforcement plate (2) and pilot con-
verter (3) as shown in figure. K
A : Crankshaft rear end

B : Rounded L
C : Chamfered
• Using a drift of 33 mm (1.30 in) in diameter, press-fit pilot con-
verter into the end of crankshaft until it stops. M
PBIC3259J
N
Flywheel
• Secure crankshaft with a stopper plate [SST: KV11105210], and tighten mounting bolts crosswise over
several times. O
NOTE:
M/T models have no pilot bushing and reinforcement plate.
16. Install knock sensor. P
EM-101
CYLINDER BLOCK
• Install knock sensor (1) with harness connector facing toward
the rear of engine.
A : Cylinder block left side

: Engine front
CAUTION:
• Never tighten mounting bolts while holding the harness
connector.
• If any impact by dropping is applied to knock sensor,
replace it with a new one.
PBIC3246J
NOTE:
• Check that there is no foreign material on the cylinder block mating surface and the back surface of
knock sensor.
• Check that knock sensor does not interfere with other parts.
17. Install crankshaft position sensor (POS) and crankshaft position sensor (POS) cover.
CAUTION:
• Handle it carefully and avoid impacts.
18. Install oil filter (for intake valve timing control) (1) in the direction
• Check that the oil filter does not protrude from the upper sur-
face of cylinder block (2) after installation.
PBIC3260J
19. Assemble in the reverse order of disassembly.

CRANKSHAFT END PLAY

• Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with a dial
indicator (A).
Standard and Limit : Refer to EM-124, "Cylinder

Block".
• If the measured value exceeds the limit, replace thrust bearings,
and measure again. If it still exceeds the limit, replace crankshaft
also.
PBIC3252J
CONNECTING ROD SIDE CLEARANCE
EM-102
CYLINDER BLOCK
• Measure the side clearance between connecting rod and crank-
shaft arm with a feeler gauge (A). A

Block". EM
• If the measured value exceeds the limit, replace connecting rod,
also. C
PBIC3251J
D
PISTON TO PISTON PIN OIL CLEARANCE
Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole with an inside E
micrometer (A).
Standard : Refer to EM-124, "Cylinder Block".

F
PBIC3265J H
Piston Pin Outer Diameter
Measure the outer diameter of piston pin with a micrometer (A).
I
PBIC3266J
L
Piston to Piston Pin Oil Clearance
(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)
M
• If oil clearance is out of the standard, replace piston and piston pin assembly.
• When replacing piston and piston pin assembly. Refer to EM-112, "Description".
N
NOTE:
• Piston is available together with piston pin as assembly.
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
grades can be selected. (Only grade “0” is available.) O
PISTON RING SIDE CLEARANCE
P
EM-103
CYLINDER BLOCK
• Measure the side clearance of piston ring and piston ring groove
with a feeler gauge (A).

Block".
• If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, replace piston also.
PBIC3280J
PISTON RING END GAP

• Check that cylinder bore inner diameter is within specification. Refer to “PISTON TO CYLINDER BORE
CLEARANCE”.
• Lubricate with new engine oil to piston (1) and piston ring (2), and
then insert (A) piston ring until middle of cylinder (B) with piston,
and measure piston ring end gap with a feeler gauge (C).

Block".
measure again. If it still exceeds the limit, re-bore cylinder and use
oversized piston and piston rings.
PBIC3267J
CONNECTING ROD BEND AND TORSION

• Check with a connecting rod aligner.
A : Bend
B : Torsion
C : Feeler gauge
Limit : Refer to EM-124, "Cylinder Block".

• If it exceeds the limit, replace connecting rod assembly.
PBIC3268J
CONNECTING ROD BIG END DIAMETER
EM-104
CYLINDER BLOCK
• Install connecting rod cap (1) without connecting rod bearing
installed, and tightening connecting rod cap bolts to the specified A
torque. Refer to EM-94, "Disassembly and Assembly".
2 : Connecting rod
EM
A : Example
• Measure the inner diameter of connecting rod big end with an C
inside micrometer.
PBIC3269J
D
• If out of the standard, replace connecting rod assembly.
CONNECTING ROD BUSHING OIL CLEARANCE
E
Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing with an inside
micrometer (A).
F
PBIC3270J
Piston Pin Outer Diameter I

Standard : Refer to EM-124, "Cylinder Block". J
L
PBIC3266J
Connecting Rod Bushing Oil Clearance

(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame- M
ter)
Standard and Limit : Refer to EM-124, "Cylinder Block". N

• If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin
assembly.
• If replacing piston and piston pin assembly. Refer to EM-112, "Piston". O
• If replacing connecting rod assembly. Refer to EM-113, "Connecting Rod Bearing".
CYLINDER BLOCK TOP SURFACE DISTORTION P

• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
EM-105
CYLINDER BLOCK
• Measure the distortion on the cylinder block upper face at some
different points in six directions with a straight edge (A) and feeler
gauge (B).

• If it exceeds the limit, replace cylinder block.
PBIC3250J
MAIN BEARING HOUSING INNER DIAMETER

• Install main bearing cap without main bearings installed, and tighten main bearing cap mounting bolts to the
specified torque. Refer to EM-94, "Disassembly and Assembly".
• Measure the inner diameter of main bearing housing with a bore gauge.
• Measure the position shown in the figure [5 mm (0.20 in)] back-
ward from main bearing housing front side in the 2 directions as
shown in the figure. The smaller one is the measured value.
1 : Cylinder block
2 : Main bearing cap
: Engine front

• If out of the standard, replace cylinder block and main bearing PBIC4005E
caps assembly.
NOTE:
Main bearing caps cannot be replaced as a single, because it is machined together with cylinder block.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
• Using a bore gauge (A), measure the cylinder bore for wear, out-
of-round and taper at six different points on each cylinder. (“X” and
“Y” directions at “A”, “B” and “C”) (“Y” is in longitudinal direction of
engine)
NOTE:
When determining cylinder bore grade, measure the cylinder bore
“X” direction at “B” position.
Standard:
Cylinder bore inner diameter
: Refer to EM-124, "Cylinder Block".
Limit:
Out-of-round (Difference between“X”and“ Y”)
Taper (Difference between“ A”and“ B”)
• If the measured value exceeds the limit, or if there are scratches
and/or seizure on the cylinder inner wall, replace cylinder block.
NOTE:
Oversize piston is not provided.
PBIC4014E
Piston Skirt Diameter
EM-106
CYLINDER BLOCK
Measure the outer diameter of piston skirt with a micrometer (A).
A
EM
PBIC3272J
D
Piston to Cylinder Bore Clearance
Calculate by piston skirt diameter and cylinder bore inner diameter (direction “X”, position “B”).
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter) E
Standard and Limit : Refer to EM-124, "Cylinder Block".

• If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block. Refer to EM-112, "Pis- F
ton".
CRANKSHAFT MAIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft main journals with a G
micrometer (A).
Standard : Refer to EM-124, "Cylinder Block". H

• If out of the standard, measure the main bearing oil clearance.
Then use undersize bearing. Refer to EM-128, "Main Bearing".
I
PBIC3457J
J
CRANKSHAFT PIN JOURNAL DIAMETER

• Measure the outer diameter of crankshaft pin journal with a micrometer. K

L
• If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer
to EM-127, "Connecting Rod Bearing".
OUT-OF-ROUND AND TAPER OF CRANKSHAFT M
• Measure the dimensions at four different points as shown in the
figure on each main journal and pin journal with a micrometer.
• Out-of-round is indicated by the difference in dimensions between
“X” and “Y” at “A” and “B”. N
• Taper is indicated by the difference in dimension between “A” and
“B” at “X” and “Y”.
O
Limit:
Out-of-round (Difference between“X”and“Y”)
Taper (Difference between“A”and“B”) P
PBIC3459J
• If the measured value exceeds the limit, correct or replace crankshaft.
• If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select
main bearing and/or connecting rod bearing. Refer to EM-127, "Connecting Rod Bearing" and/or EM-128,
"Main Bearing".
CRANKSHAFT RUNOUT
EM-107
CYLINDER BLOCK
• Place a V-block on a precise flat table to support the journals on
the both end of the crankshaft.
• Place a dial indicator (A) straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on the
dial indicator. (Total indicator reading)

Block".
• If it exceeds the limit, replace crankshaft.
PBIC3458J
CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation
• Install connecting rod bearings (2) to connecting rod (3) and con-
necting rod bearing cap (1), and tighten connecting rod cap bolts to
the specified torque. Refer to EM-94, "Disassembly and Assem-
bly".
A : Example
B : Inner diameter measuring direction
• Measure the inner diameter of connecting rod bearing with an
inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
– (Crankshaft pin journal diameter) PBIC3275J

• If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end
diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to EM-113,
"Connecting Rod Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod cap bolts to the speci-
fied torque. Refer to EM-94, "Disassembly and Assembly".
CAUTION:
Never rotate crankshaft.
• Remove connecting rod cap and bearing, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
PBIC3276J
MAIN BEARING OIL CLEARANCE

EM-108
CYLINDER BLOCK
• Install main bearings (3) to cylinder block (1) and main bearing cap
(2), and tighten main bearing cap mounting bolts to the specified A
torque. Refer to EM-94, "Disassembly and Assembly".
A : Example
EM
• Measure the inner diameter of main bearing with a bore gauge.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank- C
shaft main journal diameter)
Standard and Limit : Refer to EM-124, "Cylinder Block". PBIC3277J
D
• If clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and
crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to EM-115, "Main Bearing".
Method of Using Plastigage E
• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
holes.
F
• Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap mounting bolts to
the specified torque. Refer to EM-94, "Disassembly and Assembly".
CAUTION:
Never rotate crankshaft. G
• Remove main bearing cap and bearings, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE: H
J
PBIC3278J
MAIN BEARING CRUSH HEIGHT

• When main bearing cap is removed after being tightened to the K
specified torque with main bearings (1) installed, the tip end of
bearing must protrude (B). Refer to EM-94, "Disassembly and
Assembly". L
A : Example
M
Standard : There must be crush height.
• If the standard is not met, replace main bearings.
N
PBIC3279J
CONNECTING ROD BEARING CRUSH HEIGHT

• When connecting rod cap is removed after being tightened to the O
specified torque with connecting rod bearings (1) installed, the tip
end of bearing must protrude (B). Refer to EM-94, "Disassembly
and Assembly".
P
A : Example

• If the standard is not met, replace connecting rod bearings.
PBIC3279J
EM-109
CYLINDER BLOCK
MAIN BEARING CAP BOLT OUTER DIAMETER
• Measure the outer diameters (“d1”, “d2”) at two positions as shown
in the figure.
A : “d1” measuring position

B : “d2” measuring position
• If reduction appears in places other than “B” range, regard it as
“d2”.
Limit (“d1”–“d2”): 0.15 mm (0.0059 in)

• If it exceeds the limit (a large difference in dimensions), replace PBIC4015E
main bearing cap mounting bolt with a new one.
CONNECTING ROD CAP BOLT OUTER DIAMETER
• Measure the outer diameter “d” at position as shown in the figure.
• If reduction appears in a position other than “d”, regard it as “d”.
Limit: 7.75 mm (0.3051 in)

• When “d” exceeds the limit (when it becomes thinner), replace
connecting rod cap bolt with a new one.
PBIC4016E
CLOGGED OR DAMAGED OIL FILTER (FOR INTAKE VALVE TIMING CONTROL)

• Check that there is no foreign material on the oil filter and check it
for clogging.
- Clean it if necessary.
• Check the oil filter for damage.
- Replace it if necessary.
PBIC3273J
FLYWHEEL DEFLECTION (M/T MODELS)

• Measure the deflection of flywheel contact surface to torque with a
dial indicator (A).
• Measure the deflection at 210 mm (8.27 in) diameter.
Limit : 0.45 mm (0.0177 in) or less.

• If measured value is out of the standard, replace flywheel.
• If a trace of burn or discoloration is found on the surface, repair it
with sandpaper.
CAUTION:
When measuring, keep magnetic fields (such as dial indicator
stand) away from signal plate of the rear end of crankshaft. PBIC4006E
MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)

CAUTION:
Never disassemble double mass flywheel.
Movement Amount of Thrust (Fore-and-Aft) Direction
• Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is added
at the portion of 125 mm (4.92 in) radius from the center of flywheel.
EM-110
CYLINDER BLOCK
Standard : 1.8 mm (0.071 in) or less A

Movement Amount in Radial (Rotation) Direction
EM
Check the movement amount of radial (rotation) direction with the following procedure:
1. Install clutch cover mounting bolt (1) to clutch cover mounting
hole, and place a torque wrench (A) on the extended line of the
flywheel (2) center line. C
• Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it
from loosening.
2. Put a mating mark on circumferences of the two flywheel D
masses without applying any load (Measurement standard
points).
3. Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction, E
and mark the movement amount on the mass on the transaxle
side. PBIC4007E
4. Measure the dimensions of movement amounts “A” and “B” on F

circumference of the flywheel on the transaxle side.
Limit : 33.2 mm (1.307 in) or less. G

DRIVE PLATE DEFLECTION (CVT MODELS)
H
• Measure the deflection of drive plate contact surface to torque con-
verter with a dial indicator (A).
• Measure the deflection at the area limited between 12.4 mm
(0.488 in) dia and 20.0 mm (0.787 in) dia around hole (B). I
Limit : 0.35 mm (0.0138 in) or less.

• If measured value is out of the standard, replace drive plate. J
K
PBIC4008E
EM-111
HOW TO SELECT PISTON AND BEARING
Selection points Selection parts Selection items Selection methods

Determined by match of cylin-
der block bearing housing
Between cylinder block and Main bearing grade (bearing grade (inner diameter of hous-
Main bearing
crankshaft thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Combining service grades for
connecting rod big end diame-
Between crankshaft and con- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
necting rod (bearing thickness)
ameter determine connecting
rod bearing selection.
Piston and piston pin assembly
Between cylinder block and pis- Piston grade (piston outer diam- Piston grade = cylinder bore
(piston is available together with
ton eter) grade (inner diameter of bore)
piston pin as an assembly.)
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
Piston INFOID:0000000001160578
WHEN NEW CYLINDER BLOCK IS USED

• Check the cylinder bore grade on rear left side of cylinder block (L),
and select piston of the same grade.
A : Correction stamp
B : Standard stamp
C : Cylinder No. 1 bore grade
D : Cylinder No. 2 bore grade
E : Cylinder No. 3 bore grade
F : Cylinder No. 4 bore grade
G : No. 1 main bearing housing grade
H : No. 2 main bearing housing grade
I : No. 3 main bearing housing grade
J : No. 4 main bearing housing grade
K : No. 5 main bearing housing grade
: Engine front
• If there is a correction stamp mark on the cylinder block, use it as a

correct reference.
PBIC3264J
WHEN CYLINDER BLOCK IS REUSED

1. Measure the cylinder bore inner diameter. Refer to EM-124, "Cylinder Block".
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner
diameter of the “Piston Selection Table”.
EM-112
3. Select piston of the same grade.
A
A : Identification code
B : Front mark
C : Sub grade number EM
D : Piston grade number
PBIC4004E
D
PISTON SELECTION TABLE
Unit: mm (in)
Grade number (Mark) 1 2 [or no mark (piston only)]
E
Cylinder bore Inner diameter 84.000 - 84.010 (3.3071 - 3.3075) 84.010 - 84.020 (3.3075 - 3.3079)
Piston skirt diameter 83.970 - 83.980 (3.3059 - 3.3063) 83.980 - 83.990 (3.3063 - 3.3067)
NOTE: F
Piston is available together with piston pin as an assembly.
Connecting Rod Bearing INFOID:0000000001160579
G
WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED

1. Apply connecting rod big end diameter grade stamped on con- H
necting rod side face to the row in the “Connecting Rod Bearing
Selection Table”.
I
A : Oil hole
B : Management code
C : Cylinder number
J
D : Big end diameter grade
E : Small end diameter grade
F : Front mark
PBIC4003E K
2. Apply crankshaft pin journal diameter grade stamped on crank-

L
shaft front side to the column in the “Connecting Rod Bearing
Selection Table”.
A : No. 1 pin journal diameter grade M

B : No. 2 pin journal diameter grade
C : No. 3 pin journal diameter grade
D : No. 4 pin journal diameter grade N
E : No. 1 main journal diameter grade
F : No. 2 main journal diameter grade PBIC3261J
G : No. 3 main journal diameter grade O
H : No. 4 main journal diameter grade
I : No. 5 main journal diameter grade
P
3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection
Table”.
4. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.
WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED
1. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter indi-
vidually. Refer to EM-102, "Inspection".
EM-113
2. Apply the measured dimension to the “Connecting Rod Bearing Selection Table”.
Table”.
CONNECTING ROD BEARING SELECTION TABLE
PBIC4077E
CONNECTING ROD BEARING GRADE TABLE
Connecting rod bearing grade table : Refer to EM-127, "Connecting Rod Bear-
ing".
UNDERSIZE BEARINGS USAGE GUIDE

• When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod
bearings, use undersize (US) bearings.
• When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.
CAUTION:
EM-114
In grinding crankshaft pin to use undersize bearings, keep the
fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)] (A). A
Bearing undersize table

: Refer to EM-127, "Connecting Rod Bearing". EM
PBIC3263J
D
Main Bearing INFOID:0000000001160580
WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED E

1. “Main Bearing Selection Table” rows correspond to main bearing
housing grade on rear left side of cylinder block (L).
F
A : Correction stamp
B : Standard stamp
C : Cylinder No. 1 bore grade
G
D : Cylinder No. 2 bore grade
E : Cylinder No. 3 bore grade
F : Cylinder No. 4 bore grade
H
G : No. 1 main bearing housing grade
H : No. 2 main bearing housing grade
I : No. 3 main bearing housing grade
I
J : No. 4 main bearing housing grade
K : No. 5 main bearing housing grade
: Engine front J
• If there is a correction stamp mark on cylinder block, use it as
a correct reference.
K
PBIC3264J
L
2. Apply main journal diameter grade stamped on crankshaft front

side to column in the “Main Bearing Selection Table”.
M
A : No. 1 pin journal diameter grade
B : No. 2 pin journal diameter grade
N
C : No. 3 pin journal diameter grade
D : No. 4 pin journal diameter grade
E : No. 1 main journal diameter grade
O
F : No. 2 main journal diameter grade
G : No. 3 main journal diameter grade PBIC3261J
H : No. 4 main journal diameter grade

P
I : No. 5 main journal diameter grade
3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.
CAUTION:
There are two main bearing selection tables. One is for No. 1, 4 and 5 journals and the other is for
No. 2 and 3 journals. Make certain to use the appropriate table. This is due to differences in the
specified clearances.
EM-115
4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.
NOTE:
Service part is available as a set of both upper and lower.
WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED
1. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main
journal diameter individually. Refer to EM-102, "Inspection".
2. Apply the measured dimension to the “Main Bearing Selection Table”.
CAUTION:
There are two main bearing selection tables. One is for No. 1, 4 and 5 journals and the other is for
No. 2 and 3 journals. Make certain to use the appropriate table. This is due to differences in the
specified clearances.
4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.
NOTE:
MAIN BEARING SELECTION TABLE (No. 1, 4 AND 5 JOURNAL)
PBIC4078E
EM-116
MAIN BEARING SELECTION TABLE (No. 2 AND 3 JOURNAL)
A
EM
L
PBIC4079E
MAIN BEARING GRADE TABLE (ALL JOURNALS) M
Main bearing grade table (All journals) : Refer to EM-128, "Main Bearing".
N
UNDERSIZE BEARING USAGE GUIDE
• When the specified main bearing oil clearance is not obtained with standard size main bearings, use under-
size (US) bearing.
• When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and O
grind main journal so that the main bearing oil clearance satisfies the standard.
CAUTION:
P
EM-117
In grinding crankshaft main journal to use undersize bearings,
keep the fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)] (A).
Bearing undersize table:

Refer to EM-128, "Main Bearing".
PBIC3263J
EM-118
SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [MR20DE]
SERVICE DATA AND SPECIFICATIONS (SDS) A

General Specification INFOID:0000000001160581
EM
GENERAL SPECIFICATIONS
C
Engine type MR20DE
Cylinder arrangement In-line 4
Displacement cm3 (cu in) 1,997 (121.86) D
Bore and stroke mm (in) 84.0 x 90.1 (3.307 x 3.547)
Valve arrangement DOHC
E
Firing order 1-3-4-2
Compression 2
Number of piston rings
Oil 1 F
Compression ratio 10.2
Standard 1,390 (13.9, 14.2, 202)
Compression pressure G
Minimum 1,140 (11.4, 11.6, 165)
kPa (bar, kg/cm2, psi)/250 rpm
Differential limit between cylinders 100 (1.0, 1.0, 15)
H
Valve timing
I
( ) : Valve timing control “ON”
: Intake valve
: Exhaust valve J
K
PBIC5304E
Unit: degree
a b c d e f L
13 (−27) 65 (25)
220 232 7 33
ATDC ABDC
M
Drive Belt INFOID:0000000001160582
DRIVE BELT N
Tension of drive belt Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
Spark Plug INFOID:0000000001160583

O
SPARK PLUG
Unit: mm (in) P
Make NGK
Standard type PLZKAR6A-11
Gap (Nominal) 1.1 (0.043)
EM-119
Exhaust Manifold INFOID:0000000001160584
EXHAUST MANIFOLD
Unit: mm (in)
Items Limit
Each exhaust port 0.3 (0.012)
Surface distortion
Entire part 0.7 (0.028)
Camshaft INFOID:0000000001160585
CAMSHAFT
Unit: mm (in)
Items Standard Limit

No. 1 0.045 - 0.086 (0.0018 - 0.0034)
Camshaft journal oil clearance 0.15 (0.0059)
No. 2, 3, 4, 5 0.030 - 0.071 (0.0012 - 0.0028)
No. 1 28.000 - 28.021 (1.1024 - 1.1032) —
Camshaft bracket inner diameter
No. 2, 3, 4, 5 25.000 - 25.021 (0.9843 - 0.9851) —
No. 1 27.935 - 27.955 (1.0998 - 1.1006) —
Camshaft journal diameter
No. 2, 3, 4, 5 24.950 - 24.970 (0.9823 - 0.9381) —
Camshaft end play 0.075 - 0.153 (0.0030 - 0.0060) 0.24 (0.0094)
Intake 45.265 - 45.455 (1.7821 - 1.7896) 45.065 (1.7742)
Camshaft cam height “A”
Exhaust 43.775 - 43.965 (1.7234 - 1.7309) 43.575 (1.7155)
Camshaft runout [TIR*] Less than 0.02 (0.0008) 0.05 (0.0020)
Camshaft sprocket runout [TIR*] — 0.15 (0.0059)
SEM671
*: Total indicator reading
VALVE LIFTER
Unit: mm (in)
Items Standard
Intake 33.977 - 33.987 (1.3377 - 1.3381)
Valve lifter outer diameter
Exhaust 29.977 - 29.987 (1.1802 - 1.1806)
Intake 34.000 - 34.021 (1.3386 - 1.3394)
Valve lifter hole diameter
Exhaust 30.000 - 30.021 (1.1811 - 1.1819)
Valve lifter clearance 0.013 - 0.044 (0.0005 - 0.0017)
VALVE CLEARANCE
Unit: mm (in)
Items Cold Hot* (reference data)
EM-120
Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016)
A
Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017)
*: Approximately 80°C (176°F)
AVAILABLE VALVE LIFTER EM
Thickness mm (in) Identification mark

C
F
KBIA0119E
3.00 (0.1181) 300

3.02 (0.1189) 302
G
3.04 (0.1197) 304
3.06 (0.1205) 306 H
3.08 (0.1213) 308
3.10 (0.1220) 310
3.12 (0.1228) 312 I
3.14 (0.1236) 314
3.16 (0.1244) 316
J
3.18 (0.1252) 318
3.20 (0.1260) 320
3.22 (0.1268) 322 K
3.24 (0.1276) 324
3.26 (0.1283) 326
L
3.28 (0.1291) 328
3.30 (0.1299) 330
3.32 (0.1307) 332 M
3.34 (0.1315) 334
3.36 (0.1323) 336
N
3.38 (0.1331) 338
3.40 (0.1339) 340
3.42 (0.1346) 342 O
3.44 (0.1354) 344
3.46 (0.1362) 346
3.48 (0.1370) 348 P
3.50 (0.1378) 350
Cylinder Head INFOID:0000000001160586
CYLINDER HEAD
EM-121
Unit: mm (in)

Head surface distortion — 0.1 (0.004)
Normal cylinder head height “H” 130.9 (5.15) —
PBIC0924E
VALVE DIMENSIONS
Unit: mm (in)
SEM188A
Intake 33.8 - 34.1 (1.331 - 1.343)

Valve head diameter “D”
Exhaust 27.6 - 27.9 (1.087 - 1.098)
Intake 106.27 (4.18)
Valve length “L”
Exhaust 105.26 (4.14)
Intake 5.465 - 5.480 (0.2152 - 0.2157)
Valve stem diameter “d”
Exhaust 5.455 - 5.470 (0.2148 - 0.2154)
Valve seat angle “α” 45°15′ - 45°45′
Intake 1.1 (0.043)
Valve margin “T”
Exhaust 1.2 (0.047)
VALVE GUIDE
EM-122
Unit: mm (in)
A
EM
D
PBIC2187E
Items Standard Oversize (service) [0.2 (0.008)]

E
Outer diameter 9.523 - 9.534 (0.3749 - 0.3754) 9.723 - 9.734 (0.3828 - 0.3832)
Valve guide
Inner diameter (Finished size) 5.500 - 5.518 (0.2165 - 0.2172)
Cylinder head valve guide hole diameter 9.475 - 9.496 (0.3730 - 0.3739) 9.675 - 9.696 (0.3809 - 0.3817)
F
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Intake 0.020 - 0.053 (0.0008 - 0.0021) G
Valve guide clearance 0.1 (0.004)
Exhaust 0.030 - 0.063 (0.0012 - 0.0025)
Projection length “H” 13.35 - 13.65 (0.5256 - 0.5374)
H
VALVE SEAT
Unit: mm (in)
I
L
PBIC2745E
Items Standard Oversize (service) [0.5 (0.02)]

M
Intake 34.700 - 34.727 (1.3661 - 1.3672) 35.200 - 35.227 (1.3858 - 1.3869)
Cylinder head seat recess diameter “D”
Exhaust 28.700 - 28.727 (1.1299 - 1.1310) 29.200 - 29.227 (1.1496 - 1.1507)
Intake 34.808 - 34.824 (1.3704 - 1.3710) 35.308 - 35.324 (1.3901 - 1.3907) N
Valve seat outer diameter “d”
Exhaust 28.808 - 28.824 (1.1342 - 1.1348) 29.308 - 29.324 (1.1539 - 1.1545)
Valve seat interference fit 0.081 - 0.124 (0.0032 - 0.0049)
Intake 31.8 (1.252) O
Diameter “d1”*1
Exhaust 25.3 (0.996)
Intake 33.1 - 33.6 (1.303 - 1.323)
Diameter “d2”*2 P
Exhaust 26.9 - 27.4 (1.059 - 1.079)
Intake 60°
Angle “α1”
Exhaust 45°
Angle “α2” 88°45′ - 90°15′
Angle “α3” 120°
EM-123
Intake 1.0 - 1.4 (0.039 - 0.055)
Contacting width “W”*3
Exhaust 1.2 - 1.6 (0.047 - 0.063)
Intake 5.03 - 5.13 (0.1980 - 0.2020)
Height “h” 5.9 - 6.0 (0.232 - 0.236)
Exhaust 4.95 - 5.05 (0.1949 - 0.1988)
Intake 6.04 (0.2378)
Depth “H”
Exhaust 6.05 (0.2382)
*1: Diameter made by intersection point of conic angles “α1” and “α2”
*3: Machining data
VALVE SPRING
Standard
Items
Intake Exhaust
Free height 46.18 - 46.68 mm (1.8181 - 1.8378 in) 45.67 - 46.17 mm (1.7980 - 1.8177 in)
Installation height 35.30 mm (1.390 in) 35.30 mm (1.390 in)
Installation load 151 - 175 N (15.4 - 17.9 kg, 34 - 39 lb) 140 - 162 N (14.3 - 16.5 kg, 31 - 36 lb)
Height during valve open 25.70 mm (1.0118 in) 26.88 mm (1.0583 in)
Load with valve open 333 - 379 N (34.0 - 38.7 kg, 75 - 85 lb) 283 - 323 N (28.9 - 32.9 kg, 64 - 73 lb)
Identification color Green Purple
Items Limit
Valve spring squareness 2.0 mm (0.079 in)
Cylinder Block INFOID:0000000001160587
CYLINDER BLOCK
Unit: mm (in)
PBIC4017E
Cylinder block top surface distortion Limit 0.1 (0.004)

Grade No. 1 84.000 - 84.010 (3.3071 - 3.3075)
Cylinder bore inner diameter Standard
Grade No. 2 84.010 - 84.020 (3.3075 - 3.3079)
EM-124
Out-of-round 0.015 (0.0006)
Limit A
Taper 0.010 (0.0004)
Grade No. A 55.997 - 55.998 (2.2046 - 2.2046)
Grade No. B 55.998 - 55.999 (2.2046 - 2.2047)
Grade No. C 55.999 - 56.000 (2.2047 - 2.2047) EM
Grade No. D 56.000 - 56.001 (2.2047 - 2.2048)
Grade No. E 56.001 - 56.002 (2.2048 - 2.2048)
Grade No. F 56.002 - 56.003 (2.2048 - 2.2048)
Grade No. G 56.003 - 56.004 (2.2048 - 2.2049)
C
Grade No. H 56.004 - 56.005 (2.2049 - 2.2049)
Grade No. J 56.005 - 56.006 (2.2049 - 2.2050)
Grade No. K 56.006 - 56.007 (2.2050 - 2.2050) D
Main bearing housing inner diameter grade
Grade No. L 56.007 - 56.008 (2.2050 - 2.2050)
Grade No. M 56.008 - 56.009 (2.2050 - 2.2051)
Grade No. N 56.009 - 56.010 (2.2051 - 2.2051)
Grade No. P 56.010 - 56.011 (2.2051 - 2.2052) E
Grade No. R 56.011 - 56.012 (2.2052 - 2.2052)
Grade No. S 56.012 - 56.013 (2.2052 - 2.2052)
Grade No. T 56.013 - 56.014 (2.2052 - 2.2053)
Grade No. U 56.014 - 56.015 (2.2053 - 2.2053) F
Grade No. V 56.015 - 56.016 (2.2053 - 2.2053)
Grade No. W 56.016 - 56.017 (2.2053 - 2.2054)
AVAILABLE PISTON G
Unit: mm (in)
PBIC0188E
K
Grade No. 1 83.970 - 83.980 (3.3059 - 3.3063)
Piston skirt diameter “A” Standard
Grade No. 2 83.980 - 83.990 (3.3063 - 3.3067)
L
Measure point “H” 39.9 (1.571)
Piston pin hole diameter 19.993 - 19.999 (0.7871 - 0.7874)
Standard 0.020 - 0.040 (0.0008 - 0.0016) M
Piston to cylinder bore clearance
Limit 0.08 (0.0031)
PISTON RING N
Unit: mm (in)
Top 0.04 - 0.08 (0.0016 - 0.0031) 0.11 (0.0043) O
Piston ring side clearance 2nd 0.03 - 0.07 (0.0012 - 0.0028) 0.10 (0.004)
Oil ring 0.015 - 0.185 (0.006 - 0.0073) —
Top 0.20 - 0.30 (0.008 - 0.012) 0.51 (0.0201)
P
Piston ring end gap 2nd 0.50 - 0.65 (0.020 - 0.0256) 0.83 (0.0327)
Oil (rail ring) 0.15 - 0.45 (0.0059 - 0.0177) 0.78 (0.0307)
PISTON PIN
EM-125
Unit: mm (in)

Piston pin outer diameter 19.989 - 19.995 (0.7870 - 0.7872) —
Piston to piston pin oil clearance 0.002 - 0.006 (0.0001 - 0.0002) —
CONNECTING ROD
Unit: mm (in)
Center distance 138.97 - 139.07 (5.47 - 5.48)
Bend [per 100 (3.94)] Limit 0.15 (0.0059)
Torsion [per 100 (3.94)] Limit 0.30 (0.012)
Connecting rod bushing inner diameter* Standard 20.000 - 20.012 (0.7874 - 0.7879)
Standard 0.005 - 0.023 (0.0002 - 0.0009)
Connecting rod bushing oil clearance
Limit 0.03 (0.0012)
Standard 0.20 - 0.35 (0.008 - 0.0138)
Connecting rod side clearance
Limit 0.4 (0.016)
Grade No. A 47.000 - 47.001 (1.8504 - 1.8504)
Grade No. B 47.001 - 47.002 (1.8504 - 1.8505)
Grade No. C 47.002 - 47.003 (1.8505 - 1.8505)
Grade No. D 47.003 - 47.004 (1.8505 - 1.8505)
Grade No. E 47.004 - 47.005 (1.8505 - 1.8506)
Grade No. F 47.005 - 47.006 (1.8506 - 1.8506)
Connecting rod big end diameter Grade No. G 47.006 - 47.007 (1.8506 - 1.8507)
Grade No. H 47.007 - 47.008 (1.8507 - 1.8507)
Grade No. J 47.008 - 47.009 (1.8507 - 1.8507)
Grade No. K 47.009 - 47.010 (1.8507 - 1.8508)
Grade No. L 47.010 - 47.011 (1.8508 - 1.8508)
Grade No. M 47.011 - 47.012 (1.8508 - 1.8509)
Grade No. N 47.012 - 47.013 (1.8509 - 1.8509)
*: After installing in connecting rod
CRANKSHAFT
Unit: mm (in)
SEM645 PBIC3459J
Center distance “r” 44.89 - 44.97 (1.7673 - 1.7705)

Out-of-round Limit
0.0035 (0.0001)
Taper Limit
Standard 0.05 (0.0020)
Runout [TIR*]
Limit 0.1 (0.004)
Standard 0.10 - 0.26 (0.004 - 0.0102)
Crankshaft end play
Limit 0.3 (0.012)
EM-126
Grade No. A 43.970 - 43.971 (1.7311 - 1.7311)
Grade No. B 43.969 - 43.970 (1.7311 - 1.7311) A
Grade No. C 43.968 - 43.969 (1.7310 - 1.7311)
Grade No. D 43.967 - 43.968 (1.7310 - 1.7310)
Grade No. E 43.966 - 43.967 (1.7309 - 1.7310)
Grade No. F 43.965 - 43.966 (1.7309 - 1.7309) EM
Grade No. G 43.964 - 43.965 (1.7309 - 1.7309)
Grade No. H 43.963 - 43.964 (1.7308 - 1.7309)
Grade No. J 43.962 - 43.963 (1.7308 - 1.7308)
Crankshaft pin journal diameter grade. “Dp”
Grade No. K 43.961 - 43.962 (1.7307 - 1.7308)
C
Grade No. L 43.960 - 43.961 (1.7307 - 1.7307)
Grade No. M 43.959 - 43.960 (1.7307 - 1.7307)
Grade No. N 43.958 - 43.959 (1.7306 - 1.7307) D
Grade No. P 43.957 - 43.958 (1.7306 - 1.7306)
Grade No. R 43.956 - 43.957 (1.7305 - 1.7306)
Grade No. S 43.955 - 43.956 (1.7305 - 1.7305)
Grade No. T 43.954 - 43.955 (1.7305 - 1.7305) E
Grade No. U 43.953 - 43.954 (1.7304 - 1.7305)
Grade No. A 51.978 - 51.979 (2.0464 - 2.0464)
Grade No. B 51.977 - 51.978 (2.0463 - 2.0464)
F
Grade No. C 51.976 - 51.977 (2.0463 - 2.0463)
Grade No. D 51.975 - 51.976 (2.0463 - 2.0463)
Grade No. E 51.974 - 51.975 (2.0462 - 2.0463)
Grade No. F 51.973 - 51.974 (2.0462 - 2.0462) G
Grade No. G 51.972 - 51.973 (2.0461 - 2.0462)
Grade No. H 51.971 - 51.972 (2.0461 - 2.0461)
Grade No. J 51.970 - 51.971 (2.0461 - 2.0461)
Grade No. K 51.969 - 51.970 (2.0460 - 2.0461) H
Crankshaft main journal diameter grade. “Dm”
Grade No. L 51.968 - 51.969 (2.0460 - 2.0460)
Grade No. M 51.967 - 51.968 (2.0459 - 2.0460)
Grade No. N 51.966 - 51.967 (2.0459 - 2.0459)
Grade No. P 51.965 - 51.966 (2.0459 - 2.0459) I
Grade No. R 51.964 - 51.965 (2.0458 - 2.0459)
Grade No. S 51.963 - 51.964 (2.0458 - 2.0458)
Grade No. T 51.962 - 51.963 (2.0457 - 2.0458)
Grade No. U 51.961 - 51.962 (2.0457 - 2.0457)
J
Grade No. V 51.960 - 51.961 (2.0457 - 2.0457)
Grade No. W 51.959 - 51.960 (2.0456 - 2.0457)
*: Total indicator reading K
L
Grade number Thickness mm (in) Identification color Remarks

M
0 1.494 - 1.497 (0.0588 - 0.0589) Black
1 1.497 - 1.500 (0.0589 - 0.0591) Brown
Grade and color are the same N
2 1.500 - 1.503 (0.0591 - 0.0592) Green
for upper and lower bearings.
3 1.503 - 1.506 (0.0592 - 0.0593) Yellow
4 1.506 - 1.509 (0.0593 - 0.0594) Blue
O
UPR 1.494 - 1.497 (0.0588 - 0.0589) Black
01
LWR 1.497 - 1.500 (0.0589 - 0.0591) Brown
UPR 1.497 - 1.500 (0.0589 - 0.0591) Brown P
12
LWR 1.500 - 1.503 (0.0591 - 0.0592) Green Grade and color are different
between upper and lower bear-
UPR 1.500 - 1.503 (0.0591 - 0.0592) Green ings.
23
LWR 1.503 - 1.506 (0.0592 - 0.0593) Yellow
UPR 1.503 - 1.506 (0.0592 - 0.0593) Yellow
34
LWR 1.506 - 1.509 (0.0593 - 0.0594) Blue
EM-127
UNDERSIZE TABLE
Unit: mm (in)
Items Thickness Crank pin journal diameter

US 0.25 (0.0098) 1.623 - 1.631 (0.0639 - 0.0642) Grind so that bearing clearance is the specified value.

Unit: mm (in)
Standard 0.037 - 0.047 (0.0015 - 0.0019)

Connecting rod bearing oil clearance
Limit 0.07 (0.0028)
MAIN BEARING GRADE TABLE (ALL JOURNALS)

Unit: mm (in)
Grade number Thickness Identification color Remarks

0 1.996 - 1.999 (0.0786 - 0.0787) Black
1 1.999 - 2.002 (0.0787 - 0.0788) Brown
2 2.002 - 2.005 (0.0788 - 0.0789) Green
3 2.005 - 2.008 (0.0789 - 0.0791) Yellow Grade and color are the same
4 2.008 - 2.011 (0.0791 - 0.0792) Blue for upper and lower bearings.
5 2.011 - 2.014 (0.0792 - 0.0793) Pink

6 2.014 - 2.017 (0.0793 - 0.0794) Purple
7 2.017 - 2.020 (0.0794 - 0.0795) White
UPR 1.996 - 1.999 (0.0786 - 0.0787) Black
01
LWR 1.999 - 2.002 (0.0787 - 0.0788) Brown
UPR 1.999 - 2.002 (0.0787 - 0.0788) Brown
12
LWR 2.002 - 2.005 (0.0788 - 0.0789) Green
UPR 2.002 - 2.005 (0.0788 - 0.0789) Green
23
LWR 2.005 - 2.008 (0.0789 - 0.0791) Yellow
UPR 2.005 - 2.008 (0.0789 - 0.0791) Yellow Grade and color are different
34 between upper and lower bear-
LWR 2.008 - 2.011 (0.0791 - 0.0792) Blue ings.
UPR 2.008 - 2.011 (0.0791 - 0.0792) Blue
45
LWR 2.011 - 2.014 (0.0792 - 0.0793) Pink
UPR 2.011 - 2.014 (0.0792 - 0.0793) Pink
56
LWR 2.014 - 2.017 (0.0793 - 0.0794) Purple
UPR 2.014 - 2.017 (0.0793 - 0.0794) Purple
67
LWR 2.017 - 2.020 (0.0794 - 0.0795) White
UNDERSIZE TABLE
Unit: mm (in)
Items Thickness Main journal diameter

US 0.25 (0.0098) 2.126 - 2.134 (0.0837 - 0.0840) Grind so that bearing clearance is the specified value.

Unit: mm (in)
No. 1, 4 and 5 0.024 - 0.034 (0.0009 - 0.0013)

Standard
Main bearing oil clearance No. 2 and 3 0.012 - 0.022 (0.0005 - 0.0009)
Limit 0.065 (0.0026)
EM-128
< SYMPTOM DIAGNOSIS > [QR25DE]
SYMPTOM DIAGNOSIS A
NVH Troubleshooting Chart INFOID:0000000001157935
EM
JPBIA0561GB

3. Specify the operating condition of engine.
EM-129
If necessary, repair or replace these parts.

Location Type of Before After When Source of Refer-
When When While Check item
of noise noise warm- warm- start- noise ence page
up up ing
Top of en- Ticking or Tappet
C A — A B — Valve clearance EM-143
gine clicking noise
Rocker
cover Camshaft Camshaft journal oil
Cylinder Rattle C A — A B C bearing clearance EM-175
head noise Camshaft runout

Slap or Piston pin clearance
— A — B B — EM-218
knock noise Connecting rod bushing
oil clearance
Piston to cylinder bore
Crank- clearance
EM-240
shaft pul- Piston ring side clear-
Slap or Piston EM-240
ley A — — B B A ance
rap slap noise EM-240
Cylinder Piston ring end gap
EM-240
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod bushing
Oil pan ing rod oil clearance EM-240
Knock B A C B B B
bearing Connecting rod bearing EM-244
noise oil clearance
Main bearing oil clear-
Main bear- EM-243
Knock B A — A B C ance
ing noise EM-240
Crankshaft runout
Timing
chain and
engine Tapping or and wear EM-199
A A — B B B chain ten-
Front cov- ticking Timing chain tensioner EM-193
sioner
er operation
noise
Drive belt
Squeak-
(Sticking
ing or fizz- A B — B B B Drive belt deflection
or slip-
ing EM-138
ping)
Front of
Drive belt Idler pulley bearing op-
(Slipping) eration
Water CO-55,
Squall
A B — B A B pump Water pump operation "Exploded
Creak
noise View"
EM-130
PRECAUTIONS
< PRECAUTION > [QR25DE]
PRECAUTION A
PRECAUTIONS
Procedures without Cowl Top Cover INFOID:0000000001157924
EM
C
PIIB3706J
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect F

INFOID:0000000001279179
NOTE:
• This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYS- G
TEM).
″LOCK″ position. H
anism is adopted on the key cylinder. I
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before J
OPERATION PROCEDURE
1. Connect both battery cables. K
NOTE:
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the L
rotated. M
the battery cables. (At this time, the steering lock mechanism will engage.) N
O
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain P
WARNING:
EM-131
PRECAUTIONS
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
ness connectors.
Draining Engine Coolant INFOID:0000000001157926
Drain engine coolant and engine oil when the engine is cooled.
Disconnecting Fuel Piping INFOID:0000000001157927
• Release fuel pressure before disconnecting and disassembly.
Removal and Disassembly INFOID:0000000001157928
• When instructed to use (SST), use specified tools. Always be careful to work safely, avoid forceful or unin-
structed operations.
• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
check that dowel pins are installed in the original position.
• Cover openings of engine system with a tape or equivalent, if necessary, to seal out foreign materials.
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
in the step.
Inspection, Repair and Replacement INFOID:0000000001157929
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
Assembly and Installation INFOID:0000000001157930
• Use torque wrench to tighten bolts or nuts to specification.

do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
• Release air within route when refilling after draining engine coolant.
• After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.
Parts Requiring Angle Tightening INFOID:0000000001157931
• Use the angle wrench [SST: KV10112100] for the final tightening of the following engine parts:
- Main bearing cap bolts
- Connecting rod cap bolts
- Crankshaft pulley bolt (No the angle wrench is required as bolt flange is provided with notches for angle
tightening)
• Ensure thread and seat surfaces are clean and coated with engine oil.
EM-132
PRECAUTIONS
A
REMOVAL OF LIQUID GASKET SEALING
face using the seal cutter (SST) and remove old liquid gasket seal- EM
ing.
CAUTION:
Be careful not to damage the mating surfaces. C
• Tap the seal cutter to insert it (1), and then slide it (2) by tapping on
the side as shown in the figure.
• In areas where the seal cutter (SST) is difficult to use, use a plastic
hammer to lightly tap the parts, to remove it. D
CAUTION:
If for some unavoidable reason tool such as a screwdriver is
PBIC0275E
used, be careful not to damage the mating surfaces. E
1. Using a scraper, remove old liquid gasket adhering to the liquid
gasket application surface and the mating surface. F
• Remove liquid gasket completely from the groove of the liquid
gasket application surface, mounting bolts, and bolt holes.
2. Wipe the liquid gasket application surface and the mating sur- G
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
H
PBIC0003E
I
3. Attach liquid gasket tube to the tube presser (commercial ser-
vice tool).
Use Genuine Liquid Gasket or equivalent. J
4. Apply liquid gasket without breaks to the specified location with
the specified dimensions.
• If there is a groove for liquid gasket application, apply liquid K
L
EMA0622D
• As for bolt holes, normally apply liquid gasket inside the holes. M
Occasionally, it should be applied outside the holes. Check to
read the text of this manual.
• Within five minutes of liquid gasket application, install the mat- N
ing component.
• After 30 minutes or more have passed from the installation, fill O
CAUTION:
If there are specific instructions in this manual, observe P
SEM159F
them.
EM-133
PREPARATION
< PREPARATION > [QR25DE]
PREPARATION
PREPARATION
Tool number
Description
Tool name
KV10111100 Removing oil pan and timing chain case
Seal cutter
S-NT046
KV10116200 Disassembling and assembling valve mecha-

Valve spring compressor nism
1. KV10115900 Part (1) is a component of KV10116200, but
Attachment Part (2) is not so.
2. KV10109220
Adapter
PBIC1650E
KV10112100 Tightening bolts for bearing cap, cylinder

Angle wrench head, etc.
S-NT014
KV10117100 Loosening or tightening heated oxygen sen-

Heated oxygen sensor wrench sors with 22 mm (0.87 in) hexagon nut
NT379
KV10107902 Removing valve oil seal

Valve oil seal puller
1. KV10116100
Valve oil seal puller adapter
S-NT605
KV10115600 Installing valve oil seal

Valve oil seal drift Use side A.
a: 20 (0.79) dia. d: 8 (0.31) dia.
b: 13 (0.51) dia. e: 10.7 (0.421) dia.
c: 10.3 (0.406) dia. f: 5 (0.20) dia.
Unit: mm (in)
S-NT603
EM-134
PREPARATION
Tool number
Description
Tool name A
EM
C
S-NT044
ST16610001 Removing pilot converter

Pilot bushing puller D
S-NT045
F
KV11103000 Removing crankshaft pulley
Pulley puller
H
NT676
KV11105210 Fixing drive plate and flywheel

Stopper plate
I
ZZA0009D
Quick connector release Removing fuel tube quick connectors in en- K

gine room
(Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210)
L
PBIC0198E M
EM-135
PREPARATION
Spark plug wrench Removing and installing spark plug
PBIC2982E
Pulley holder Crankshaft pulley removing and installing
ZZA1010D
Valve seat cutter set Finishing valve seat dimensions
S-NT048
TORX socket Removing and installing flywheel

Size: T55
PBIC1113E
S-NT030
Valve guide drift Removing and installing valve guide

Intake & Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
S-NT015
Valve guide reamer 1: Reaming valve guide inner hole

2: Reaming hole for oversize valve guide
Intake & Exhaust:
d1: 6.0 mm (0.236 in) dia.
d2: 10.2 mm (0.402 in) dia.
S-NT016
EM-136
PREPARATION
A
Oxygen sensor thread cleaner Reconditioning the exhaust system threads
before installing a new air fuel ratio sensor and
heated oxygen sensor (Use with anti-seize lu-
bricant shown below.) EM
a = 18 mm (0.71 in) dia. for zirconia heated
oxygen sensor and air fuel ratio sensor
b = 12 mm (0.47 in) dia. for titania heated
oxygen sensor C
AEM488
Anti-seize lubricant i.e.: (PermatexTM Lubricating oxygen sensor thread cleaning

133AR or equivalent meeting MIL tool when reconditioning exhaust system
specification MIL-A-907) threads D
AEM489
Manual lift table caddy Removing and installing engine F
ZZA1210D
H
J
S-NT052
EM-137
DRIVE BELTS
< ON-VEHICLE MAINTENANCE > [QR25DE]
ON-VEHICLE MAINTENANCE
DRIVE BELTS
JPBIA0562GB
1. Alternator 2. Water pump 3. Idler pulley

4. Crankshaft pulley 5. A/C compressor 6. Drive belt auto-tensioner
7. Drive belt
Range when new drive belt is in-
A. View A B. Indicator (notch on the fixed side) C.
stalled
D. Possible use range
: Engine front
WARNING:
Be sure to perform this step when the engine is stopped.
• Check that the indicator (notch on fixed side) of drive belt auto-tensioner is within the possible use range
(between four line notches on moving side).
NOTE:
• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (C) in the fig-
ure.
• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.
Refer to : EM-235, "Drive belt".
REMOVAL
1. Remove front wheel and tire (RH).
EM-138
DRIVE BELTS
3. Hold the hexagonal part in center of drive belt auto-tensioner
pulley with a box wrench securely. Then move the wrench han- A
dle in the direction of arrow (loosening direction of tensioner).
CAUTION:
• Avoid placing hand in a location where pinching may
EM
occur if the holding tool accidentally comes off.
• Never loosen the hexagonal part in center of drive belt
auto-tensioner pulley (Do not turn it counterclockwise). If
turned counterclockwise, the complete drive belt auto- C
tensioner must be replaced as a unit, including the pulley.
4. Insert a rod approximately 6 mm (0.24 in) in diameter such as PBIC2169E
short-length screwdriver into the hole of the retaining boss to fix D
drive belt auto-tensioner pulley.
5. Loosen drive belt from water pump pulley in sequence, and remove it.
INSTALLATION E
1. Hold the hexagonal part in center of drive belt auto-tensioner
pulley with a box wrench securely. Then move the wrench han-
dle in the direction of arrow (loosening direction of tensioner). F
CAUTION:
• Avoid placing hand in a location where pinching may
occur if the holding tool accidentally comes off. G
• Never loosen the hexagonal part in center of drive belt
auto-tensioner pulley (Do not turn it counterclockwise). If
turned counterclockwise, the complete drive belt auto-
tensioner must be replaced as a unit, including the pulley. H
2. Insert a rod approximately 6 mm (0.24 in) in diameter such as PBIC2627E
short-length screwdriver into the hole of retaining boss to fix
drive belt auto-tensioner pulley. I
3. Hook drive belt onto all pulleys except for water pump, and then onto water pump pulley finally.
CAUTION:
• Confirm drive belt is completely set to pulleys. J
pulley groove.
4. Release drive belt auto-tensioner, and apply tension to drive belt. K
6. Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to
EM-138, "Exploded View". L
EM-139
AIR CLEANER FILTER
AIR CLEANER FILTER
REMOVAL
1. Push the tabs (A) of both ends of the air cleaner cover (1) into
the inside (B).
2. Pull up the air cleaner cover forward (C) and remove it.
PBIC3557J
3. Remove the air cleaner filter (1) and holder (2) assembly from
the air cleaner case.
4. Remove the air cleaner filter from the holder.
PBIC3558J
INSTALLATION
EM-140
SPARK PLUG
SPARK PLUG
A
EM
G
JPBIA0666GB
1. Rocker cover 2. Ignition coil 3. Spark plug

4. Gasket
H
A. Refer to EM-164
I
REMOVAL J
1. Remove ignition coil. Refer to EM-164, "Removal and Installation".
2. Remove spark plug with spark plug wrench (commercial service
tool). K
CAUTION:
Never drop or shock spark plug.
L
PBIC3871E
N
INSTALLAITON
O
INSPECTION AFTER REMOVAL P

Use standard type spark plug for normal condition.
Spark plug (standard) : Refer to EM-235, "Spark Plug".

CAUTION:
• Never drop or shock spark plug.
EM-141
SPARK PLUG
• Never use wire brush for cleaning.
• If plug tip is covered with carbon, spark plug cleaner may be
used.
Cleaner air pressure: Less than 588 kPa (6 kg/cm2, 85

psi)
Cleaning time: Less than 20 seconds
SMA773C
• Checking and adjusting plug gap is not required between

change intervals.
JPBIA0031ZZ
EM-142
A
INSPECTION EM
Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if
there is unusual engine conditions regarding valve clearance.
1. Strart the engine and warm it up. C
2. Stop the engine.
3. Remove rocker cover. Refer to EM-164, "Exploded View".
4. Remove splash guard on RH fender protector. D
5. Measure the valve clearance with the following procedure:
a. Set No. 1 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley clockwise and align TDC mark to tim- E
ing indicator on front cover.
H
KBIA0190E
• At the same time, check that both intake and exhaust cam
noses of No. 1 cylinder face outside as shown in the figure. I
• If they do not face outside, rotate crankshaft pulley once more
(360 degrees) and align as shown in the figure.
J
KBIA0400J
L
b. Use a feeler gauge, measure the clearance between valve lifter
and camshaft.
M
Valve clearance : Refer to EM-236, "Camshaft".
O
SEM139D
EM-143
• By referring to the figure, measure the valve clearances at
locations marked “×” as shown in the table below (locations
indicated with black arrow in the figure) with a feeler gauge.
• No. 1 cylinder compression TDC
No. 1 cylinder at INT × ×

compression TDC EXH × ×
PBIC2624E
c. Rotate crankshaft pulley one revolution (360 degrees) and align

TDC mark to timing indicator on front cover.
KBIA0190E
• By referring to the figure, measure the valve clearance at loca-

tions marked “×” as shown in the table below (locations indi-
cated with black arrow in the figure) with a feeler gauge.
• No. 4 cylinder compression TDC
No. 4 cylinder at INT × ×

compression TDC EXH × ×
PBIC2625E
6. If out of standard, perform adjustment. Refer to “ADJUSTMENT”.

ADJUSTMENT
• Perform adjustment depending on selected head thickness of valve lifter.
2. Remove valve lifters at the locations that are out of the standard.
3. Measure the center thickness of the removed valve lifters with a
micrometer (A).
PBIC3195J
4. Use the equation below to calculate valve lifter thickness for replacement.
Valve lifter thickness calculation: t = t1 + (C1 – C2)

t = Valve lifter thickness to be replaced
EM-144
t1 = Removed valve lifter thickness
A
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake : 0.28 mm (0.011 in) EM
Exhaust : 0.30 mm (0.012 in)
• Thickness of new valve lifter (B) can be identified by stamp
mark (A) on the reverse side (inside the cylinder). C
Stamp mark “788” indicates 7.88 mm (0.3102 in) in thickness.
PBIC3196J
F
NOTE:
Available thickness of valve lifter: 26 sizes range 7.88 to 8.38 mm (0.3102 to 0.3299 in) in steps of 0.02
mm (0.0008 in) (when manufactured at factory). Refer to EM-236, "Camshaft". G
5. Install the selected valve lifter.
6. Install camshaft. Refer to EM-170, "Exploded View".
H
7. Manually rotate crankshaft pulley a few rotations.
8. Check that valve clearances for cold engine are within specifications by referring to the specified values.
Refer to “INSPECTION”.
I
9. Install all removed parts in the reverse order of removal.
10. Warm up the engine, and check for unusual noise and vibration.
J
EM-145
1. Warm up engine thoroughly. Then, stop it.

2. Release fuel pressure. Refer to ECQ-356, "Inspection".
3. Disconnect fuel pump fuse to avoid fuel injection during measurement. Refer to ECQ-22,
"Component Parts Location".
4. Remove ignition coil and spark plug from each cylinder. Refer to EM-164, "Exploded View".
5. Connect engine tachometer (not required in use of CONSULT-III).
6. Install compression tester with adapter onto spark plug hole.
KBIA0130E
• Use the adapter whose picking up end inserted to spark plug

hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it
may be caught by cylinder head during removal.
SBIA0533E
7. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and engine rpm. Perform these steps to check each cyl-
inder.
Compression pressure : Refer to EM-235, "General Specification".

CAUTION:
Always use a fully changed battery to obtain specified engine speed.
• If the engine speed is out of specified range, check battery liquid for proper gravity. Check engine speed
again with normal battery gravity.
combustion chamber (Valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure the compression pressure again.
• If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole
- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check
piston rings and replace if necessary.
• If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, gaskets are leaking. In such a case, replace cylinder head gas-
kets.
9. Start engine, and confirm that engine runs smoothly.
EM-146
10. Perform trouble diagnosis. If DTC appears, erase it. Refer to ECQ-98, "Description".
A
EM
EM-147
< ON-VEHICLE REPAIR > [QR25DE]
ON-VEHICLE REPAIR
JPBIA0563GB
1. Idler pulley 2. Drive belt auto-tensioner

Removal
CAUTION:
The complete drive belt auto-tensioner must be replaced as a unit, including the pulley.
1. Remove front wheel and tire (RH).
2. Remove front fender protector (RH).
3. Remove drive belt. Refer to EM-138, "Removal and Installation".
4. Support the bottom surface of engine using a transmission jack, and loosen engine mounting insulator
bolts (RH). Refer to EM-182, "Exploded View".
CAUTION:
Never remove the bolts (No. 4, 5) as shown in the figure.
: Engine front
JPBIA0694ZZ
5. Remove idler pulley.

6. Release the fixed drive belt auto-tensioner pulley.
7. Remove drive belt auto-tensioner.
CAUTION:
EM-148
Never loosen the hexagonal part in center of drive belt auto-tensioner pulley (Do not turn it counter-
clockwise). If turned counterclockwise, the complete drive belt auto-tensioner must be replaced as a A
unit, including the pulley.
Installation
Note the following, and install in the reverse order of removal. EM
CAUTION:
• When installing drive belt auto-tensioner, be careful not to interfere with water pump pulley.
• If there is damage greater than peeled paint, replace drive belt auto-tensioner. C
• Never swap the pulley between new and old drive belt auto-tensioner.
EM-149
JPBIA0564GB
1. Air cleaner filter 2. Air cleaner cover 3. Holder

4. Mass air flow sensor 5. Air cleaner case 6. Clamp
7. Air duct and resonator assembly 8. Grommet 9. Collar
10. Bracket 11. Grommet 12. Bracket
13. Air duct (inlet) 14. Air duct 15. Resonator
A. To electric throttle control actuator
REMOVAL
1. Remove air duct (inlet).
2. Remove battery. Refer to PG-133, "Exploded View".
EM-150
3. Disconnect harness connectors (A) and then remove bracket
(1). A
4. Disconnect mass air flow sensor harness connector.
6. Remove air cleaner case and mass air flow sensor assembly EM
and air duct and air duct and resonator assembly disconnecting
their joints.
• Add marks as necessary for easier installation. C
7. Remove mass air flow sensor from air cleaner case, if neces-
sary. JPDIA0240ZZ
CAUTION: D
Handle mass air flow sensor with the following cares.
• Never touch its sensor. E
INSTALLATION
• Align marks. Attach each joint. Screw clamps firmly. F
G
Inspect air duct and resonator assembly for crack or tear.
• If anything found, replace air duct and resonator assembly. H
EM-151
INTAKE MANIFOLD
INTAKE MANIFOLD
JPBIA0565GB
EVAP canister purge volume control

1. Bracket 2. 3. Clamp
solenoid valve
4. EVAP hose 5. EVAP hose assembly 6. Clamp
7. PCV hose 8. Fresh air hose 9. Clamp
10. Gasket 11. Intake manifold adapter 12. Gasket
13. Bracket 14. Clamp 15. Water hose
16. Water hose 17. Electric throttle control actuator 18. Gasket
19. Intake manifold support 20. Gasket 21. Vacuum hose
22. Clamp 23. Intake manifold
A. To air duct B. To heater pipe C. To water outlet
D. To brake booster E. To vacuum pipe (canister)
REMOVAL
2. Remove cowl top cover. Refer to EXT-19, "Exploded View".
3. Remove air cleaner case, mass air flow sensor and air duct and resonator assembly. Refer to EM-150,
"Exploded View".
4. Remove electric throttle control actuator with the following procedure:
a. Disconnect harness connector.
EM-152
INTAKE MANIFOLD
b. Loosen mounting bolts in reverse order as shown in the figure,
and remove electric throttle control actuator and gasket. A
CAUTION:
• Handle carefully to avoid any shock to electric throttle
control actuator.
EM
NOTE:
• When removing only intake manifold, move electric throttle
control actuator without disconnecting the water hose. C
JPBIA0882ZZ
D
5. Disconnect harness, vacuum hose and PCV hose from intake manifold, and move them aside.
6. Remove intake manifold support.
E
7. Loosen mounting bolts and nuts in reverse order as shown in
the figure, and remove intake manifold and gasket.
: Engine front F
CAUTION:
NOTE: G
Disregard No. 6 when loosening.
H
JPBIA0570ZZ
8. Disconnect sub-harness from fuel injector. Refer to EM-166, "Exploded View".

9. Remove fuel tube and fuel injector assembly from intake manifold adaptor. Refer to EM-166, "Exploded I
View".
10. Remove EVAP canister purge volume control solenoid valve from intake manifold, if necessary.
J
INSTALLATION
Intake Manifold K
• If stud bolts were removed, install them and tighten to the specified torque below.
: 9.4 N·m (0.96 kg-m, 83 in-lb) L

• Tighten in numerical order as shown in the figure.
: Engine front M
NOTE:
No. 6 means double tightening of bolt No. 1.
N
O
JPBIA0570ZZ
P
EM-153
INTAKE MANIFOLD
• Tighten mounting bolts equally and diagonally in several steps and
in numerical order as shown in the figure.
• Perform the “Throttle Valve Closed Position Learning” when har-
ness connector of electric throttle control actuator is disconnected.
Refer to ECQ-19, "THROTTLE VALVE CLOSED POSITION
LEARNING : Description".
• Perform the “Idle Air Volume Learning” and “Throttle Valve Closed
Position Learning” when electric throttle control actuator is
replaced. Refer to ECQ-17, "IDLE SPEED : Description" or ECQ-
19, "THROTTLE VALVE CLOSED POSITION LEARNING :
Description".
JPBIA0882ZZ

Surface Distortion
• Using straightedge (A) and feeler gauge (B), check the surface dis-
tortion of both the intake manifold adaptor mating surface.
Limit : Refer to EM-236, "Intake Manifold".

• If it exceeds the limit, replace intake manifold and/or intake mani-
fold adaptor.
JPBIA0883ZZ
EM-154
EXHAUST MANIFOLD AND THREE WAY CATALYST
A
EM
I
JPBIA0568GB
Exhaust manifold and three way cat- J

1. Heated oxygen sensor 1 2. Gasket 3.
alyst assembly
4. Three way catalyst cover 5. Exhaust manifold cover (lower) 6. Heated oxygen sensor 2
7. Exhaust manifold cover (upper)
K

L
Removal
1. Remove heated oxygen sensors with the following procedure:
M
a. Disconnect harness connector of each heated oxygen sensor, and harness from bracket and middle
clamp.
b. Using heated oxygen sensor wrench (SST), remove heated oxy-
N
gen sensors.
CAUTION:
• Be careful not to damage heated oxygen sensor.
• Discard any heated oxygen sensor which has been O
dropped onto a hard surface such as a concrete floor.
Replace with a new one.
P
KBIA0094E

3. Remove alternator. Refer to CHG-30, "QR25DE MODELS : Exploded View".
4. Remove exhaust manifold cover (upper).
EM-155
5. Loosen nuts in reverse order as shown in the figure to remove exhaust manifold and three way catalyst
assembly.
: Engine front
NOTE:
Disregard No. 6 to 10 when loosening.
JPBIA0569ZZ
6. Remove gasket.
CAUTION:
7. Remove exhaust manifold cover (lower) and three way catalyst cover from exhaust manifold and three
way catalyst assembly.
Installation
EXHAUST MANIFOLD
• If stud bolts were removed, install them and tighten to the specified torque below.
: 14.7 N·m (1.5 kg-m, 11 ft-lb)

• Tighten nuts in numerical order as shown in the figure.
: Engine front
NOTE:
No. 6 to 10 mean double tightening of bolts No. 1 and 5.
JPBIA0569ZZ
HEATED OXYGEN SENSOR

CAUTION:
• Before installing a new heated oxygen sensor, clean exhaust system threads using heated oxygen
sensor thread cleaner and apply anti-seize lubricant (commercial service tool).
• Never over torque the heated oxygen sensor. Doing so may cause damage to the heated oxygen
sensor, resulting in the “MI” coming on.

Surface Distortion
EM-156
• Check the surface distortion of the exhaust manifold mating sur-
face with a straightedge and a feeler gauge. A
Limit : Refer to EM-236, "Exhaust Manifold".

• If it exceeds the limit, replace exhaust manifold. EM
KBIA0046E
EM-157
OIL PAN (LOWER)
OIL PAN (LOWER)
JPBIA0571GB
1. Oil level gauge 2. Oil level gauge guide 3. O-ring

4. Oil pan (upper) 5. Cylinder block 6. O-ring
7. Oil filter 8. O-ring 9. Oil strainer
10. Drain plug 11. Drain plug washer 12. Oil pan (lower)
13. Oil level sensor (with WVTA) 14. Rear plate cover
A. Refer to LU-19 B. Oil pan side
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain the engine oil when the engine is hot.
: Engine front
JPBIA0572ZZ
EM-158
OIL PAN (LOWER)
b. Insert seal cutter (SST) between oil pan (upper) and oil pan
(lower). A
CAUTION:
EM
SEM365EA
D
INSTALLATION
E
a. Use a scraper to remove old liquid gasket from mating surfaces.
• Also remove old liquid gasket from mating surface of oil pan
(upper).
• Remove old liquid gasket from the bolt holes and threads. F
CAUTION:
Never scratch or damage the mating surface when cleaning
off liquid gasket.
G
H
SEM958F
b. Apply a continuous bead of liquid gasket with a tube presser

(commercial service tool) as shown in the figure. I
: Engine front
J
a : 4.0 – 5.0 mm (0.157 – 0.197 in)
CAUTION: K
ket application. JPBIA0575ZZ
L
c. Tighten bolts in numerical order as shown in the figure.
: Engine front M
O
JPBIA0572ZZ
2. Install oil pan drain plug. P

• Refer to the figure of components of former page for installation direction of washer. Refer to EM-158,
"Exploded View".
3. Install in the reverse order of removal after this step.
NOTE:
Pour engine oil at least 30 minutes after oil pan is installed.
Inspection
EM-159
OIL PAN (LOWER)
INSPECTION AETER INSTALLATION
1. Check engine oil level and adjust engine oil. Refer to LU-16, "Inspection".
2. Start engine, and check there is no leaks of engine oil.
4. Check engine oil level again. Refer to LU-16, "Inspection".

2. Start engine, and check there is no leaks of engine oil.
EM-160
OIL PAN (UPPER) AND OIL STRAINER
A
EM
I
JPBIA0571GB
1. Oil level gauge 2. Oil level gauge guide 3. O-ring J

4. Oil pan (upper) 5. Cylinder block 6. O-ring
7. Oil filter 8. O-ring 9. Oil strainer
10. Drain plug 11. Drain plug washer 12. Oil pan (lower) K
13. Oil level sensor (with WVTA) 14. Rear plate cover
A. Refer to LU-19 B. Oil pan side
Refer to GI-4, "Components" for symbols in the figure. L
M
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain the engine oil when the engine is hot. N
1. Remove undercover.
3. Remove oil pan (lower).EM-158, "Removal and Installation". O
4. Remove oil level gauge and guide.
5. Disconnect steering lower joint at steering gear assembly side, and release steering lower shaft. Refer to
ST-13, "Exploded View". P
6. Disconnect steering outer sockets from steering knuckle. Refer to ST-13, "Exploded View".
7. Remove rear torque rod. Refer to EM-182, "Exploded View".
rope. Refer to HA-45, "QR25DE : Exploded View".
EM-161
11. Remove oil strainer.
a. Loosen bolts in reverse order as shown in the figure.
: Engine front
JPBIA0573ZZ
b. Insert seal cutter (SST) between oil pan (upper) and lower cylin-
der block, and slide it by tapping on the side of the tool with a
hammer.
CAUTION:
SEM365EA
13. Remove O-rings at front cover side.

INSTALLATION
1. Install oil pan (upper) with the following procedure:
a. Use a scraper to remove old liquid gasket from mating surfaces.
• Also remove the old liquid gasket from mating surface of cylin-
der block.
CAUTION:
MEM108A

: Engine front
a : 4.0 – 5.0 mm (0.157 – 0.197 in)

CAUTION:
• For bolt holes with marks (3 locations), apply liquid
gasket out side the holes. JPBIA0574ZZ
• Attaching should be done within 5 minutes after liquid
gasket application.
c. Install new O-rings at front cover side.

CAUTION:
EM-162
Install avoiding misalignment of O-rings.
d. Tighten bolts in numerical order as shown in the figure. A
: Engine front
EM
NOTE:
Refer to the following for locating bolts.
M6 × 20 mm (0.79 in) : No. 16, 17 C

M8 × 25 mm (0.98 in) : No. 4, 6, 11, 13, 14, 15
M8 × 60 mm (2.36 in) : No. 7, 8, 9, 10
D
M8 × 100 mm (3.97 in) : No. 1, 2, 3, 5, 12 JPBIA0573ZZ
Tightening torque : Refer to EM-161, "Exploded View". E

2. Install oil strainer.
3. Install front suspension member. Refer to FSU-18, "Exploded View".
F
4. Install oil pan (lower). Refer to EM-158, "Removal and Installation".
5. Install oil pan drain plug.
• Refer to the figure of components of former page for installation direction of washer. Refer to EM-161,
G
"Exploded View".
NOTE:
Pour engine oil at least 30 minutes after oil pan is installed. H
I
2. Start engine, and check there is no leaks of engine oil. J
K
EM-163
JPBIA0666GB
1. Rocker cover 2. Ignition coil 3. Spark plug

4. Rocker cover gasket
A. Refer to EM-164
REMOVAL
1. Remove air duct and resonator assembly. Refer to EM-150, "Exploded View".
2. Remove electric throttle control actuator without disconnecting water hose. Refer to EM-152, "Exploded
View".
3. Loosen intake manifold mounting bolts and nuts.
4. Remove intake manifold. Refer to EM-152, "Removal and Installation".
5. Disconnect harness connector from ignition coil.
6. Support the bottom surface of engine using a transmission jack.
7. Remove ground cable and harness from engine mounting bracket (RH).
8. Remove ignition coil.
CAUTION:
• Never drop or shock ignition coil.
• Never disassemble ignition coil.
9. Disconnect PCV hose from rocker cover.
10. Remove engine mounting bracket (RH). Refer to EM-192, "Exploded View".
11. Remove PCV valve and O-ring from rocker cover, if necessary.
12. Remove oil filler cap from rocker cover, if necessary.
EM-164
13. Loosen bolts in reverse order shown in the figure.
A
: Engine front
EM
JPBIA0667ZZ
D
14. Remove rocker cover gasket from rocker cover.
15. Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket (No. 1).
CAUTION:
E
Never scratch or damage the mating surface when cleaning off old liquid gasket.
INSTALLATION
1. Apply liquid gasket to the position shown in the figure (4 places F
of cylinder head front and back) with the following procedure:
a. Refer to figure “a” to apply liquid gasket to joint part of camshaft
bracket (No. 1) and cylinder head. G
b. Refer to figure “b” to apply liquid gasket in 90 degrees to figure
“a”.
Use Genuine Liquid Gasket or equivalent. H
CAUTION:
ket application.
I
WBIA0164E
2. Install rocker cover gasket to rocker cover. M

3. Install rocker cover.
• Check if rocker cover gasket is not dropped from the installation groove of rocker cover.
N
4. Tighten bolts in two steps separately in numerical order as
O
: Engine front
: 1.96 N·m (0.2 kg-m, 17 in-lb) P

1st step
2nd step : 8.33 N·m (0.85 kg-m, 74 in-lb)
JPBIA0667ZZ
EM-165
JPBIA0668GB
1. Fuel feed hose 2. Quick connector cap 3. Fuel tube

4. Fuel tube protector 5. O-ring (blue) 6. Clip
7. Fuel injector 8. O-ring (brown) 9. Intake manifold suppport
: Engine front
CAUTION:
Never remove or disassemble parts unless instructed in the figure.
REMOVAL
WARNING:
• Put a “CAUTION: FLAMMABLE” sign in the work shop.
• Be sure to work in a well ventilated area and furnish work shop with a CO2 fire extinguisher.
• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
2. Remove air cleaner case, mass air flow sensor and air duct assembly. Refer to EM-150, "Exploded View".
3. Disconnect quick connector (A) with the following procedure:
1 : Fuel feed hose

: Vehicle front
CAUTION:
Disconnect quick connector by using quick connector
release, not by picking out retainer tabs.
JPBIA0858ZZ
EM-166
a. Remove quick connector cap.
A
EM
PBIC2348E
D
b. With the sleeve side of quick connector release facing quick connector, install quick connector release
onto fuel tube.
c. Insert quick connector release into quick connector until sleeve E
contacts and goes no further. Hold quick connector release on
that position.
CAUTION:
Inserting quick connector release hard will not disconnect F
quick connector. Hold quick connector release where it
contacts and goes no further.
d. Draw and pull out quick connector straight from fuel tube. G
CAUTION:
• Pull quick connector holding “A” position in the figure.
• Never pull with lateral force applied. O-ring inside quick KBIA0702E H
connector may be damaged.
• Prepare container and cloth beforehand as fuel will leak out.
• Avoid fire and sparks.
• Keep parts away from heat source. Especially, be careful when welding is performed around I
them.
• Never expose parts to battery electrolyte or other acids.
• Never bend or twist connection between quick connector and fuel feed hose during installation/ J
removal.
• To keep clean the connecting portion and to avoid dam-
age and foreign materials, cover them completely with
plastic bags or something similar. K
PBIC2205E
N
4. Remove intake manifold. Refer to EM-152, "Removal and Installation".
5. Disconnect sub-harness for fuel injector.
6. Remove fuel tube and fuel injector assembly. O
: Engine front
P
CAUTION:
• When removing, be careful to avoid any interference with
fuel injector.
• Use a shop cloth to absorb any fuel leaks from fuel tube.
JPBIA0669ZZ
EM-167
7. Remove fuel injector from fuel tube with the following procedure:
a. Open and remove clip (1).
b. Remove fuel injector (2) from fuel tube (3) by pulling straight.
CAUTION:
• Be careful with remaining fuel that may go out from fuel
tube.
• Be careful not to damage fuel injector nozzle during
removal.
• Never bump or drop fuel injector.
• Never disassemble fuel injector.
JPBIA0885ZZ
INSTALLATION
1. Note the following, and install O-rings to fuel injector.
CAUTION:
• Upper and lower O-rings are different. Be careful not to confuse them.
Fuel tube side : Blue

Nozzle side : Brown
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign material.
• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to
twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly
into fuel tube.
• Insert O-ring straight into fuel tube. Never decenter or twist it.
2. Install fuel injector to fuel tube with the following procedure:
2 : O-ring (Blue)
4 : O-ring (Brown)
a. Insert clip (3) into clip mounting groove (F) on fuel injector (5).
• Insert clip so that protrusion (E) of fuel injector matches cutout
(C) of clip.
CAUTION:
• Never reuse clip. Replace it with a new one.
• Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube with clip attached.
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion (A) of fuel tube (1)
matches cutout (B) of clip.
• Check that fuel tube flange (G) is securely fixed in flange fixing
groove (D) on clip.
c. Check that installation is complete by making sure that fuel
injector does not rotate or come off.
JPBIA0683ZZ
3. Install fuel tube and fuel injector assembly with the following procedure:
a. Insert the tip of each fuel injector into intake manifold support.
EM-168
b. Tighten mounting bolts in numerical order as shown in the fig-
ure. A
: Engine front
EM
4. Connect sub-harness for fuel injector.
JPBIA0669ZZ
D
5. Install intake manifold. Refer to EM-152, "Exploded View".
6. Note the following, and connect quick connector to install fuel feed hose.
E
a. Check the connection for foreign material and damage.
b. Align center to insert quick connector straightly into fuel tube.
NOTE:
The figure shows engine side as an example. F
• Insert fuel tube into quick connector until the top spool on fuel
tube is inserted completely and the second level spool is posi-
tioned slightly below quick connector bottom end. G
CAUTION:
• Hold “A” position in the figure when inserting fuel tube
into quick connector.
• Carefully align center to avoid inclined insertion to pre- H
vent damage to O-ring inside quick connector.
KBIA0272E
• Insert until you hear a “click” sound and actually feel
the engagement. I
• To avoid misidentification of engagement with a similar sound, be sure to perform the next
step.
c. Before clamping fuel feed hose with hose clamps, pull quick connector hard by hand holding “A” position. J
Check it is completely engaged (connected) so that it does not come out from fuel feed tube.
d. Install quick connector cap to quick connector connection.
• Install so that the arrow mark on the side faces up.
K
CAUTION:
• Check that quick connector and fuel tube are securely fit
into quick connector cap installation groove.
• If quick connector cap cannot be installed smoothly, L
quick connector may have not been installed correctly.
Check connection again.
7. Install fuel feed hose to hose clamp. M
PBIC2348E
N

O
Check on Fuel Leakage
1. Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check there
are no fuel leaks at connection points. P
NOTE:
Use mirrors for checking at points out of clear sight.
2. Start the engine. With engine speed increased, check again that there are no fuel leaks at connection
points.
CAUTION:
Never touch the engine immediately after stopped, as the engine becomes extremely hot.
EM-169
CAMSHAFT
CAMSHAFT
JPBIA0670GB
1. Camshaft position sensor (PHASE) 2. O-ring 3. Camshaft position sensor bracket

4. Seal washer 5. Camshaft bracket (No. 1) 6. Camshaft sprocket (INT)
7. Camshaft sprocket (EXH) 8. Valve lifter 9. Camshaft (EXH)
10. Signal plate 11. Camshaft (INT) 12. Camshaft bracket (No. 2 to 5)
A. Refer to EM-170
REMOVAL
NOTE:
This section describes removal/installation procedure of camshaft without removing front cover. If front cover
is removed or installed, removal of camshaft bracket (No. 1) is easier before step 9 and installation is easier
after step 4. Regarding removal and installation of front cover, refer to EM-192, "Exploded View".
• Rocker cover: Refer to EM-164, "Removal and Installation".
3. Remove camshaft position sensor (PHASE).
CAUTION:
• Handle carefully to avoid dropping and shocks.
• Never allow metal powder to adhere to magnetic part at sensor tip.
EM-170
CAMSHAFT
4. Remove camshaft position sensor bracket. A
: Engine front EM
5. Remove intake valve timing control cover with the following pro-
cedure:
C
a. Disconnect intake valve timing control solenoid valve harness
connector.
b. Remove intake valve timing control solenoid valve, if necessary.
D
JPBIA0671ZZ
c. Loosen bolts in reverse order as shown in the figure. E

d. Use a seal cutter [SST: KV10111100] or equivalent tool to cut liq-
uid gasket for removal.
F
JPBIA0675ZZ H
6. Pull chain guide between camshaft sprockets out through front cover.
7. Set No. 1 cylinder at TDC on its compression stroke with the following procedure: I
a. Open splash guard on RH undercover.
b. Rotate crankshaft pulley clockwise and align TDC mark to timing
indicator on front cover. J
KBIA0190E
M
c. At the same time, check that the mating marks on camshaft
sprockets are located as shown in the figure.
• If not, rotate crankshaft pulley one more turn to align mating
marks to the positions in the figure. N
P
PBIC2351E
8. Remove camshaft sprockets with the following procedure:

a. Line up the mating marks on camshaft sprockets, and paint indelible mating marks on timing chain link
plate.
EM-171
CAMSHAFT
b. Push in chain tensioner plunger. Insert a stopper pin into hole on
chain tensioner body to secure chain tensioner plunger and
remove chain tensioner.
NOTE:
Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a
stopper pin.
KBIA0048E
c. Secure hexagonal part of camshaft with a wrench. Loosen cam-

shaft sprocket mounting bolts and remove camshaft sprockets.
CAUTION:
Never rotate crankshaft or camshaft while timing chain is
removed. It causes interference between valve and piston.
NOTE:
Chain tension holding work is not necessary. Crankshaft
sprocket and timing chain do not disconnect structurally while
front cover is attached.
KBIA0049E
9. Loosen mounting bolts in reverse order as shown in the figure,

and remove camshaft brackets and camshafts.
• Remove camshaft bracket (No. 1) by slightly tapping it with a
plastic hammer.
SBIA0255E
10. Remove valve lifters.

INSTALLATION
1. Install valve lifters.
• Install them in the original positions.
2. Install camshafts.
• Distinction between intake and exhaust camshafts is per-
formed with the different shapes of rear end.
1 : Camshaft (EXH)
2 : Camshaft (INT)
JPBIA0808ZZ
EM-172
CAMSHAFT
• Install camshafts so that camshaft dowel pins on the front side
are positioned as shown in the figure. A
EM
KBIA0051E
D
3. Install camshaft brackets with the following procedure:
a. Remove foreign material completely from camshaft bracket backside and from cylinder head installation
face. E
b. Install camshaft brackets (No. 2 to 5) aligning the identification
marks on upper surface as shown in the figure.
NOTE:
F
Install so that identification mark can be correctly read when
viewed from the exhaust side.
H
SBIA0256E
c. Install camshaft bracket (No. 1) with the following procedure: I

i. Apply liquid gasket to camshaft bracket (No. 1) as shown in the
figure.
CAUTION: J
After installation, be sure to wipe off any excessive liquid
gasket leaking from part “A”.
K
L
PBIC2579E
ii. Apply liquid gasket to camshaft bracket (No. 1) contact surface

on the front cover backside. M
1 : Front cover
a : 3.4 – 4.4 mm (0.134 – 0.173 in) N
• Apply liquid gasket to the outside of bolt hole on front cover.
O
JPBIA0881ZZ
P
EM-173
CAMSHAFT
iii. For camshaft bracket (No. 1) near installation position, and
install it without disturbing the liquid gasket applied to the sur-
faces.
PBIC2641E
4. Tighten mounting bolts of camshaft brackets in the following

steps, in numerical order as shown in the figure.
a. Tighten No. 9 to 11 in numerical order.
: 2.0 N·m (0.2 kg-m, 1 in-lb)

b. Tighten No. 1 to 8 in numerical order.
: 2.0 N·m (0.2 kg-m, 1 in-lb)

c. Tighten all bolts in numerical order. SBIA0255E
: 5.9 N·m (0.6 kg-m, 4 in-lb)

d. Tighten all bolts in numerical order.
: 10.4 N·m (1.1 kg-m, 8 ft-lb)

CAUTION:
After tightening mounting bolts of camshaft brackets, be sure to wipe off excessive liquid gasket
from the parts listed below.
• Mating surface of rocker cover.
• Mating surface of front cover. (When installed without front cover)
5. Install camshaft sprockets.
• Install them by aligning the mating marks on each camshaft
sprocket with the ones painted on timing chain link plate dur-
ing removal.
CAUTION:
• Aligned mating marks could slip. Therefore, after match-
ing them, hold the timing chain in place by hand.
• Before and after installing chain tensioner, check again
that mating marks have not slipped.
NOTE:
Before installation of chain tensioner, it is possible to re-match
the marks on timing chain with the ones on each sprocket.
PBIC2351E
6. Install chain tensioner.
CAUTION:
After installation, pull the stopper pin off completely, and check that chain tensioner plunger is
released.
7. Install chain guide.
8. Install intake valve timing control cover with the following procedure:
a. Install intake valve timing control solenoid valve to intake valve timing control cover if removed.
b. Install oil rings to the camshaft sprocket (INT) insertion points on backside of intake valve timing control
cover.
c. Install new O-ring to front cover.
EM-174
CAMSHAFT
d. Apply liquid gasket with a tube presser (Commercial Service
Tool) to intake valve timing control cover as shown in the figure. A
a : 3.4 – 4.4 mm (0.134 – 0.173 in)

Use Genuine Liquid Gasket or equivalent. EM
CAUTION:
ket application. C
JPBIA0679ZZ
D
e. Tighten mounting bolts in numerical order as shown in the fig-
ure.
E
G
JPBIA0675ZZ
9. Install camshaft position sensor bracket.

H
a. Apply liquid gasket with a tube presser (commercial service tool)
to camshaft position sensor bracket as shown in the figure.
I
: Engine front
a : 2.0 – 3.0 mm (0.079 – 0.118 in) J

b : 10.5 mm (0.413 in)
CAUTION: K
• After installation, be sure to wipe off any excessive liquid JPBIA0672ZZ
gasket leaking from part “b”

• Attaching should be done within 5 minutes after liquid gasket application. L
b. Tighten mounting bolts in numerical order as shown in the fig-
ure.
M
: Engine front
10. Install camshaft position sensor (PHASE).

11. Inspect and adjust valve clearance. Refer to EM-143, "Inspec- N
tion and Adjustment".
O
JPBIA0671ZZ
P
Camshaft Runout
EM-175
CAMSHAFT
1. Put V-block on a precise flat table, and support No. 2 and 5 jour-
nal of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft
sprocket) because it has a different diameter from the other
four locations.
2. Set dial indicator (A) vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the
camshaft runout on dial indicator. (Total indicator reading)
PBIC3177J
Standard: Refer to EM-236, "Camshaft".
4. If out of the standard, replace camshaft.
Camshaft Cam Height
1. Measure the camshaft cam height with a micrometer (A).

PBIC3178J
Camshaft Journal Oil Clearance

CAMSHAFT JOURNAL DIAMETER
Measure the outer diameter of camshaft journal with a micrometer
(A).
PBIC3179J
CAMSHAFT BRACKET INNER DIAMETER

• Tighten camshaft bracket bolts with specified torque. Refer to EM-170, "Removal and Installation".
• Measure the inner diameter of camshaft bracket with an inside
micrometer.
PBIC0041E

• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter)
EM-176
CAMSHAFT
• If out of the standard, replace either or both camshaft and cylinder head.
NOTE: A
Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head.
Replace whole cylinder head assembly.
Camshaft End Play EM
1. Install camshaft in cylinder head. Refer to EM-170, "Removal and Installation".
2. Install dial indicator in thrust direction on front end of camshaft.
Read the end play of dial indicator when camshaft is moved for- C
ward/backward (in direction to axis).
Standard : Refer to EM-236, "Camshaft". D
PBIC2446E
F
• Measure the following parts if out of the standard.
- Dimension “A” for camshaft No. 1 journal
G
Standard : 25.800 - 25.848 mm (1.0157 - 1.0176 in)
- Dimension “B” for cylinder head No. 1 journal
H
Standard : 25.660 - 25.685 mm (1.0102 - 1.0112 in)
• Refer to the standards above, and then replace camshaft and/
or cylinder head. I
KBIA2426J
Camshaft Sprocket Runout

J
1. Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations. K
2. Measure the camshaft sprocket runout with a dial indicator.
(Total indicator reading)
L
Limit : Refer to EM-236, "Camshaft".
• If it exceeds the limit, replace camshaft sprocket. M
N
PBIC0930E
Valve Lifter O
Check if surface of valve lifter has any wear or cracks.
• If anything above is found, replace valve lifter. Refer to EM-236,
"Camshaft".
P
KBIA0182E
EM-177
CAMSHAFT
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER
• Measure the outer diameter of valve lifter with a micrometer (A).
PBIC3185J
VALVE LIFTER HOLE DIAMETER

Measure the diameter of valve lifter hole of cylinder head with an
inside micrometer.

VALVE LIFTER CLEARANCE
• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter
outer diameter)

• If out of the standard, referring to the each standard of valve lifter PBIC0043E
outer diameter and valve lifter hole diameter, replace either or both
valve lifter and cylinder head.
Inspection of camshaft sprocket (INT) oil Groove.
CAUTION:
EM-178
OIL SEAL
OIL SEAL
A
VALVE OIL SEAL
VALVE OIL SEAL : Removal and Installation INFOID:0000000001157972
EM
REMOVAL
1. Remove camshafts. Refer to EM-170, "Exploded View".
C
2. Remove valve lifters. Refer to EM-170, "Exploded View".
3. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
D
CAUTION:
When rotating crankshaft, be careful to avoid scarring front cover with timing chain.
• Compress valve spring with valve spring compressor, attach- E
let with a magnet hand.
CAUTION: F
When working, be careful not to damage valve lifter holes.
H
PBIC3209J
5. Remove valve spring retainer and valve spring.

CAUTION: I
6. Remove valve oil seal with a valve oil seal puller (SST).
J
SEM093F
M
INSTALLATION
1. Apply new engine oil to valve oil seal joint surface and seal lip.
2. Press in valve oil seal to the height “H” shown in the figure with a N
valve oil seal drift (SST).
Height “H” : 11.8 - 12.4 mm (0.465 - 0.488 in) O
KBIA1999J

FRONT OIL SEAL
EM-179
OIL SEAL
REMOVAL
• Under cover
• Front fender protector: Refer to EXT-21, "Exploded View".
2. Remove front oil seal with a suitable tool.
CAUTION:
Be careful not to damage front cover and crankshaft.
SEM829E
INSTALLATION
1. Apply new engine oil to new front oil seal joint surface and seal lip.
2. Install front oil seal so that each seal lip is oriented as shown in
the figure.
A : Dust seal lip

B : Oil seal lip
: Engine outside
: Engine inside
PBIC3485J
• Press-fit front oil seal until it is flush with front end surface of
front cover using a suitable drift with outer diameter 56 mm
(2.20 in) and inner diameter 48 mm (1.89 in).
CAUTION:
• Be careful not to damage front cover and crankshaft.
• Press-fit oil seal straight to avoid causing burrs or tilt-
ing.
SBIA0266E

REAR OIL SEAL
REMOVAL
1. Remove transaxle assembly. Refer to TM-85, "Exploded View" (M/T models) or TM-550, "QR25DE :
Exploded View" (CVT models).
2. Remove clutch cover and clutch disc (M/T models). Refer to CL-18, "MR20DE, QR25DE : Exploded
View".
3. Remove drive plate (CVT models) or flywheel (M/T models). Refer to EM-210, "Exploded View".
EM-180
OIL SEAL
4. Remove rear oil seal with a suitable tool.
CAUTION: A
INSTALLATION
1. Apply new engine oil to new rear oil seal joint surface and seal lip. EM
2. Install rear oil seal so that each seal lip is oriented as shown in
the figure.
C
A : Dust seal lip
B : Oil seal lip
: Engine outside D
: Engine inside
PBIC3485J
• Press in rear oil seal (1) to the position as shown in the figure. F
A : Rear end surface of cylinder block

G
I
PBIC3952E
• Press-fit rear oil seal with a suitable drift [outer diameter 102
mm (4.02 in), inner diameter 86 mm (3.39 in)]. J
CAUTION:
• Be careful not to damage crankshaft and cylinder block.
• Press-fit oil seal straight to avoid causing burrs or tilt- K
ing.
• Never touch grease applied onto oil seal lip.
L
SBIA0280E
M
EM-181
ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION > [QR25DE]
REMOVAL AND INSTALLATION

ENGINE ASSEMBLY
JPBIA0691GB
1. Upper torque rod 2. Washer 3. Engine mounting insulator (RH)

4. Engine mounting insulator (LH) 5. Rear engine mounting bracket 6. Rear torque rod
7. Engine mounting bracket 8. Engine mounting stay 9. Engine mounting insulator (LH)
A. CVT models
WARNING:
• Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped.
CAUTION:
EM-182
ENGINE ASSEMBLY
Safety Stand and 2-Pole Lift". A
REMOVAL
Outline EM
saxle.
Preparation C
CAUTION: D
3. Remove the following parts. E
• Air duct and air cleaner case assembly: Refer to EM-150, "Exploded View".
• Radiator hose (upper and lower) and cooling fan assembly: Refer to CO-47, "Exploded View". F
• Exhaust front tube: Refer to EX-10, "Exploded View". G
Engine Room LH
porarily secure the engine harness into the engine side. H
CAUTION:
2. Disconnect fuel feed hose at engine side. Refer to EM-36, "Exploded View". I
3. Disconnect heater hoses. Refer to CO-57, "Exploded View".
4. Disconnect control linkage (M/T models) or control cable (CVT models) from transaxle. Refer to TM-79,
"Exploded View" (M/T models) or TM-520, "QR25DE : Exploded View" (CVT models). J
5. Remove ground cable at transaxle side.
6. Disconnect CVT fluid cooler hose. Refer to TM-550, "QR25DE : Exploded View".
K
Engine Room RH
1. Remove alternator. Refer to CHG-30, "QR25DE MODELS : Exploded View".
2. Disconnect vacuum hose from intake manifold. Refer to EM-27, "Exploded View". L
rope (with A/C models). Refer to HA-45, "QR25DE : Exploded View".
Vehicle inside M
Disconnect steering lower joint at steering gear assembly side, and release steering lower shaft. Refer to ST-
13, "Exploded View".
Vehicle Underbody N
2. Remove brake caliper assembly with piping connected from steering knuckle. Temporarily secure it on the O
3. Disconnect steering outer sockets from steering knuckle. Refer to ST-13, "Exploded View". P
4. Remove transverse link from steering knuckle. Refer to FSU-13, "Exploded View".
5. Remove drive shafts (LH and RH). Refer to FAX-60, "QR25DE : Exploded View".
6. Remove propeller shaft. Refer to DLN-121, "Exploded View".
EM-183
ENGINE ASSEMBLY
View".
Removal
CAUTION:
PBIC1190E
2. Remove upper torque rod.

3. Remove engine mounting insulator bolts (RH).
• Loosen the mounting bolts in the reverse order as shown in
the figure.
: Engine front
JPBIA0694ZZ
4. Remove engine mounting through bolt-securing nut (A). (M/T

models)
: Engine front
JPBIA0780ZZ
5. Remove engine mounting insulator bolts (LH). (CVT models)

• Loosen the mounting bolts in the reverse order as shown in
the figure.
: Engine front
JPBIA0781ZZ
CAUTION:
EM-184
ENGINE ASSEMBLY
• Before and during this lifting, always check if any harnesses are left connected. A
EM
Separation
1. Install engine slingers into front left of cylinder head and rear right of cylinder head.
• Use alternator bracket mounting bolt holes for the front side. C
: Engine front
D
Slinger bolts
Cylinder head side (A) : : 28.0 N·m (2.9 kg-m, 21 ft-lb)
E
Front cover side (B) : : 45.0 N·m (4.6 kg-m, 33 ft-lb)
JPBIA0798ZZ F
2. Remove starter motor. Refer to STR-32, "QR25DE (M/T) MODELS : Exploded View" (M/T models) or
STR-37, "QR25DE (CVT) MODELS : Exploded View" (CVT models).
3. Lift with a hoist and separate the engine from the transaxle assembly. Refer to TM-85, "Exploded View" G
(M/T models) or TM-550, "QR25DE : Exploded View" (CVT models).
INSTALLATION (M/T models) H
CAUTION:
ing insulator. I
Preparation
J
1. Install the engine mounting bracket (LH) to the engine.
K
: Vehicle front

ure. (specified torque) L
JPBIA0692ZZ
N
3. Install the upper torque rod to the body side bracket temporarily.
4. Install the engine mounting stay (LH) to the body, and tighten.(specified torque) O
5. Install the engine mounting insulator (LH) to the engine mounting bracket support (LH) temporarily.
6. Install the engine mounting bracket support (LH) to the body as follows:
P
EM-185
ENGINE ASSEMBLY
: Vehicle front

c. Tighten the bolts No. 5, 6, 7 in numerical order as shown in the
e. Tighten the bolt No. 8 as shown in the figure. (specified torque)
7. Install the rear bracket to the transaxle and tighten. (specified
torque)
JPBIA0693ZZ
Installation
1. Tighten the engine mounting insulator (LH) to the specified torque.
: Vehicle front
b. Tighten the bolts No. 2, 3, 4, 5 in numerical order as shown in

JPBIA0694ZZ
3. Tighten engine mounting through bolt-securing nut (A) to the

specified torque.
: Vehicle front
4. Install the rear torque rod and tighen. (specified torque)

5. Tighten the upper torque rod. (specified torque)
JPBIA0780ZZ
INSTALLATION (CVT models)

CAUTION:
ing insulator.
Preparation
EM-186
ENGINE ASSEMBLY
2. Install the upper torque rod to the body side bracket temporarily. A
3. Install the engine mounting stay (LH) to the body and tighten. (specified torque)
4. Install the engine mounting insulator (LH) to the body as follows:
a. Tighten the bolt No. 1 as shown in the figure. (temporarily) EM
: Vehicle front
C
c. Tighten the bolts No. 5, 6, 7 in numerical order as shown in the
figure. (specified torque) D
e. Tighten the bolt No. 8 as shown in the figure. (specified torque)
E
5. Install the rear bracket to the transaxle and tighten. (specified
torque)
F
JPBIA0782ZZ
Installation I
1. Install the engine mounting insulator bolts (LH) to the transaxle and tighten as follows:
J
: Vehicle front
b. Tighten the bolts No. 2, 3, 4 in numerical order as shown in the K

L
JPBIA0781ZZ
M
N
: Vehicle front
b. Tighten the bolts No. 2, 3, 4, 5 in numerical order as shown in O

3. Install the rear torque rod and tighten. (specified torque) P
4. Tighten the upper torque rod. (specified torque)
JPBIA0694ZZ
EM-187
ENGINE ASSEMBLY
EM-188
< DISASSEMBLY AND ASSEMBLY > [QR25DE]
DISASSEMBLY AND ASSEMBLY A

EM
NOTE:
type of engine stand, note with difference in steps and etc. C
engine. Refer to EM-75, "M/T : Exploded View" (M/T models) or EM-81, "CVT : Exploded View" (CVT
models). D
a. Remove flywheel (M/T models) or drive plate (CVT models).
• Secure flywheel or drive plate with a stopper plate (SST) and E
use a suitable tool to remove mounting bolts.
Flywheel (M/T models) : size T55 (commercial ser- F

vice tool)
Drive plate (CVT models) : size E20
CAUTION: G
• Never disassemble them.
• Never place them with signal plate facing down. PBIC4642J
• When handling signal plate, take care not to damage or H
scratch them.
• Handle signal plate in a manner that prevents them from becoming magnetized.
NOTE:
The flywheel, two block construction, allows movement in response to transaxle side pressure, or when I
twisted in its rotation direction. Therefore, some amount of noise is normal.
b. Remove pilot converter using pilot bushing puller (SST) or suit-
able tool. (CVT models) J
NOTE:
M/T models have no pilot bushing.
K
SBIA0274E
M
c. Lift the engine with a hoist to install it onto widely use engine stand.
CAUTION:
• Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large N
- Intake manifold: Refer to EM-152, "Exploded View". O
- Rocker cover: Refer to EM-164, "Exploded View".
NOTE: P
EM-189
models) or drive plate (CVT models) removed.
CAUTION:
PBIC3227J

CAUTION:
4. Drain engine coolant by removing water drain plug from inside of
the engine.
Tightening torque : Refer to EM-210, "Exploded

View".
PBIC2716E
EM-190
ENGINE UNIT
ENGINE UNIT
A
1. Remove intake manifold. Refer to EM-152, "Exploded View". EM

4. Remove oil cooler. Refer to LU-20, "Exploded View". C
5. Remove ignition coil, spark plug and rocker cover. Refer to EM-164, "Exploded View".
6. Remove fuel injector and fuel tube. Refer to EM-166, "Exploded View".
D
9. Remove water inlet. Refer to CO-57, "Exploded View". E
10. Remove water outlet. Refer to CO-57, "Exploded View".
F

G
EM-191
TIMING CHAIN
TIMING CHAIN
JPBIA0673GB
1. Camshaft sprocket (INT) 2. Camshaft sprocket (EXH) 3. Engine mounting bracket (RH)
4. Front cover 5. Chain guide 6. Intake valve timing control cover
7. Intake valve timing control solenoid 8. O-ring 9. O-ring
10. O-ring 11. Crankshaft pulley bolt 12. Crankshaft pulley
13. Front oil seal 14. O-ring 15. O-ring
16. O-ring 17. Timing chain tension guide 18. Balancer unit sprocket
19. Balancer unit timing chain 20. Balancer unit 21. Oil pump drive spacer
22. Balancer unit timing chain tensioner 23. Crankshaft sprocket 24. Timing chain
25. O-ring 26. O-ring 27. Timing chain slack guide
28. Chain tensioner plunger 29. Spring 30. Chain tensioner
A. Refer to EM-193
EM-192
TIMING CHAIN
A
REMOVAL
• PCV hose: Refer to EM-152, "Exploded View". EM
• Ignition coil: Refer to EM-164, "Exploded View".
• Drive belt: Refer to EM-138, "Removal and Installation". C
• Drive belt auto-tensioner: Refer to EM-138, "Exploded View".
2. Remove engine mounting bracket (RH).
3. Remove rocker cover. Refer to EM-164, "Removal and Installation". D
5. Remove oil pan (upper), and oil strainer. Refer to EM-161, "Exploded View".
6. Remove intake valve timing control cover. E
• Loosen bolts in reverse order as shown in the figure.
• Use a seal cutter [SST: KV10111100] or equivalent tool to cut
liquid gasket for removal. F
CAUTION:
Be careful not to damage mounting surface.
G
H
JPBIA0675ZZ
7. Pull chain guide between camshaft sprockets out through front cover. I
8. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
a. Rotate crankshaft pulley clockwise and align TDC mark to timing
indicator on front cover. J
KBIA0190E
M
b. At the same time, check that the mating marks on camshaft
sprockets are located as shown in the figure.
• If not, rotate crankshaft pulley one more turn to align mating
N
marks to the positions in the figure.
P
PBIC2351E
EM-193
TIMING CHAIN
a. Fix crankshaft pulley with a pulley holder (commercial service
tool), loosen crankshaft pulley bolt, and locate bolt seating sur-
face at 10 mm (0.39 in) from its original position.
PBIC2434E
b. Attach a pulley puller (SST) in the M 6 thread hole on crankshaft

pulley, and remove crankshaft pulley.
PBIC2413E

a. Loosen mounting bolts in reverse order as shown in the figure,
and remove them.
A : Dowel pin
B : Dowel pin hole
b. Use a seal cutter [SST: KV10111100] or equivalent tool to cut liq-
uid gasket for removal.
CAUTION:
Be careful not to damage mounting surface.
JPBIA0674ZZ
11. If front oil seal needs to be replaced, lift it with a suitable tool, and remove it.
CAUTION:
Be careful not to damage front cover.
12. Remove timing chain and camshaft sprockets with the following procedure:
EM-194
TIMING CHAIN
a. Push in chain tensioner plunger. Insert a stopper pin into hole on
chain tensioner body to secure chain tensioner plunger and A
remove chain tensioner.
NOTE:
Use approx. 0.5 mm (0.02 in) dia. hard metal pin as a stopper
EM
pin.
KBIA0048E
D
b. Secure hexagonal part of camshaft with a wrench. Loosen cam-
shaft sprocket mounting bolts and remove timing chain and
camshaft sprockets.
E
CAUTION:
Never rotate crankshaft or camshaft while timing chain is
removed. It causes interference between valve and piston.
F
G
KBIA0049E
13. Remove timing chain slack guide, timing chain tension guide and oil pump drive spacer.
H
14. Remove balancer unit timing chain tensioner with the following procedure:
a. Press stopper tab (A) in the direction shown in the figure to push
the timing chain slack guide (B) toward timing chain tensioner I
(for oil pomp) (1).
• The slack guide is released by pressing the stopper tab. As
the result, the slack guide can be moved. J
b. Insert a stopper pin (D) into tensioner body hole (C) to secure
the timing chain slack guide.
NOTE: K
Use a hard metal pin with the diameter of approximately 1.2 mm
(0.047 in) as a stopper pin.
c. Remove balancer unit timing chain tensioner.
L
• When the holes on lever and tensioner body cannot be
aligned, align these holes by slightly moving the slack guide.
O
PBIC5314E
15. Remove balancer unit timing chain and crankshaft sprocket.

P
EM-195
TIMING CHAIN
16. Loosen mounting bolts in reverse order as shown in the figure,
and remove balancer unit.
: Engine front
CAUTION:
Never disassemble balancer unit.
NOTE:
Use TORX socket (size E14).
JPBIA0676ZZ
INSTALLATION
NOTE:
The figure shows the relationship between the mating mark on each
timing chain and that on the corresponding sprocket, with the com-
ponents installed.
1. Check that crankshaft key points straight up.
PBIC3029E
2. Tighten mounting bolts in numerical order as shown in figure

with the following procedure, and install balancer unit.
: Engine front
CAUTION:
If mounting bolts are re-used, check their outer diameter
before installation. Refer to EM-199, "Inspection".
a. Apply new engine oil to threads and seat surfaces of mounting
bolts.
b. Tighten No. 1 to 5 bolts. JPBIA0676ZZ
: 42.0 N·m (4.3 kg-m, 35 ft-lb)
c. Tighten No. 6 bolt.
: 36.0 N·m (3.7 kg-m, 27 ft-lb)
EM-196
TIMING CHAIN
d. Turn No. 1 to 5 bolts 120 degrees clockwise (angle tightening).
CAUTION: A
Use the angle wrench [SST: KV10112100] (A) to check tight-
ening angle. Never make judgment by visual inspection.
e. Turn No. 6 bolt 90 degrees clockwise (angle tightening). EM
f. Completely loosen all bolts.
: 0 N·m (0 kg-m, 0 ft-lb) C

CAUTION:
In this step, loosen bolts in reverse order as shown in the JPBIA0806ZZ
figure. D
g. Repeat step b to e.
3. Install crankshaft sprocket and balancer unit timing chain. E

• Check that crankshaft sprocket is positioned with mating
marks on cylinder block and crankshaft sprocket meeting at
the top. F
• Install it by aligning mating marks on each sprocket and bal-
ancer unit timing chain.
G
H
PBIC2183E
4. Install balancer unit timing chain tensioner.

• Be careful not to let mating marks of each sprocket and timing chain slip. I
• After installation, check the mating marks have not slipped, then remove stopper pin and release ten-
sioner sleeve.
J
5. Install timing chain and related parts.
• Install by aligning mating marks on each sprocket and timing
chain. K
• Before and after installing chain tensioner, check again to
check that mating marks have not slipped.
• After installing chain tensioner, remove stopper pin, and check
L
that tensioner moves freely.
CAUTION:
• For the following note, after the mating marks are
aligned, keep them aligned by holding them with a hand. M
• To avoid skipped teeth, never rotate crankshaft and
camshaft until front cover is installed.
NOTE:
N
Before installing chain tensioner, it is possible to change the
position of mating mark on timing chain for that on each
sprocket for alignment.
O
PBIC3029E
6. Install front oil seal to front cover. Refer to EM-180, "FRONT OIL SEAL : Removal and Installation".
a. Install O-rings to cylinder head and cylinder block.
EM-197
TIMING CHAIN
(commercial service tool) to front cover as shown in the figure.
a : 35.7 mm (1.406 in)

b : 4.8 – 5.8 mm (0.189 – 0.228 in)
c : 3.4 – 4.4 mm (0.134 – 0.173 in)
d : 179.6 mm (7.07 in)
e : 35.5 mm (1.398 in)
f : 31.3 mm (1.232 in)
G : Dowel pin hole
CAUTION:
• For bolt holes with marks (5 locations), apply liquid
gasket out side the holes.
• Attaching should be done within 5 minutes after coating.
NOTE:
Application instruction differs depending on the position.
JPBIA0678ZZ
c. Check that mating marks of timing chain and each sprocket are still aligned. Then install front cover.
CAUTION:
Be careful not to damage front oil seal by interference with front end of crankshaft.
d. Tighten mounting bolts in numerical order as shown in the fig-
ure.
e. After all bolts are tightened, retighten them to specified torque in
numerical order as shown in the figure.
A : Dowel pin
B : Dowel pin hole
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking to
surface for fitting oil pan.
Tightening torque
M10 bolt : 49.0 N·m (5.0 kg-m, 36 ft-lb)
M6 bolt : 12.8 N·m (1.3 kg-m, 9 ft-lb)
JPBIA0674ZZ
8. Install chain guide between camshaft sprockets.

9. Install intake valve timing control cover with the following procedure:
a. Install intake valve timing control solenoid valves to intake valve timing control cover if removed.
b. Install new oil rings to the camshaft sprocket (INT) insertion points on backside of intake valve timing con-
trol cover.
c. Install new O-ring to front cover.
EM-198
TIMING CHAIN
d. Apply a continuous bead of liquid gasket with a tube presser
(commercial service tool) to intake valve timing control cover as A
a : 3.4 – 4.4 mm (0.134 – 0.173 in) EM

CAUTION:
Attaching should be done within 5 minutes after liquid gas- C
ket application.
JPBIA0679ZZ
D
e. Tighten mounting bolts in numerical order as shown in the fig-
ure.
E
G
JPBIA0675ZZ
10. Insert crankshaft pulley by aligning with crankshaft key.

H
• When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
CAUTION:
Install protecting front oil seal lip section from any damage.
11. Tighten crankshaft pulley bolt. I
• Secure crankshaft pulley with a pulley holder (commercial service tool), and tighten crankshaft pulley
bolt.
• Perform angle tightening with the following procedure: J
a. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
b. Tighten crankshaft pulley bolt.
K
: 42.1 N·m (4.3 kg-m, 31 ft-lb)
c. Put a paint mark on crankshaft pulley, mating with any one of six L
easy to recognize angle marks on bolt flange.
d. Turn another 60 degrees clockwise (angle tightening).
• Check the tightening angle with movement of one angle mark. M
SEM751G O
12. Install all removed parts in the reverse order of removal.

Inspection INFOID:0000000001321927 P

Timing Chain
EM-199
TIMING CHAIN
Check timing chain for cracks and any excessive wear at the roller
links of timing chain. Replace timing chain if necessary.
PBIC0282E
Balancer Unit Mounting Bolt Outer Diameter

in the figure.
• If reduction appears in “A” range, regard it as “d2 ”.
Limit (“d1”–“d2”) : 0.15 mm (0.0059 in)

• If it exceeds the limit (large difference in dimensions), replace it
with a new one.
PBIC1137E

The following are procedures for checking fluids leak, lubricates leak.
• Warm up engine thoroughly to check there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
Fuel — Leakage —
EM-200
CYLINDER HEAD
CYLINDER HEAD
A
REMOVAL EM
JPBIA0680GB
H
1. Cylinder head assembly 2. Cylinder head gasket 3. Engine rear lower slinger
4. Cylinder head bolt
A : Refer to EM-202
I
DISASSEMBLY
J
JPBIA0681GB
EM-201
CYLINDER HEAD
1. Valve collet 2. Valve spring retainer 3. Valve spring (with valve spring seat)
4. Valve oil seal 5. Valve guide 6. Cylinder head
7. Valve seat (INT) 8. Valve (INT) 9. Valve (EXH)
10. Valve seat (EXH) 11. Spark plug tube
: Apply thread locking sealant.
REMOVAL
2. Drain engine coolant and engine oil. Refer to CO-41, "Draining" and LU-17, "Draining".
• Exhaust manifold and three way catalyst assembly: Refer to EM-155, "Removal and Installation".
• Intake manifold and fuel tube assembly: Refer to EM-152, "Removal and Installation".
• Water control valve and water control valve housing (water outlet): Refer to CO-57, "Exploded View".
NOTE:
Can be removed and installed even when assembled with cylinder head.
4. Remove front cover and timing chain. Refer to EM-192, "Exploded View".
5. Remove camshafts. Refer to EM-170, "Removal and Installation".
6. Securely support bottom of cylinder block with a jack or equivalent tool, and release the hoist that was
supporting it.
7. Remove cylinder head loosening bolts in reverse order as
• Using TORX socket (size E20), loosen cylinder head bolts.
8. Remove cylinder head gasket.
KBIA0058E
INSTALLATION
1. Install cylinder head gasket.
2. Tighten cylinder head bolts in numerical order as shown in figure
with the following procedure, and install cylinder head.
CAUTION:
If cylinder head bolts are re-used, check their outer diame-
ters before installation. Refer to EM-207, "Inspection".
a. Apply new engine oil to threads and seating surface of mounting
bolts.
b. Tighten all bolts.
: 50.0 N·m (5.1 kg-m, 37 ft-lb) KBIA0058E

d. Completely loosen.
: 0 N·m (0 kg-m, 0 ft-lb)

CAUTION:
In this step, loosen bolts in reverse order of that indicated in the figure.
e. Tighten all bolts.
EM-202
CYLINDER HEAD
: 39.2 N·m (4.0 kg-m, 29 ft-lb) A
f. Turn all bolts 75 degrees clockwise (angle tightening).

g. Turn all bolts 75 degrees clockwise again (angle tightening). EM
CAUTION:
wrench (SST) or protractor. Avoid judgment by visual
inspection without the tool. C
KBIA0059E
E
F
DISASSEMBLY
1. Remove spark plug with spark plug wrench (commercial service tool).
G
2. Remove spark plug tube, if necessary.
• Using pliers, remove it from cylinder head.
CAUTION:
• Be careful not to damage cylinder head. H
• Never remove spark plug tube if not necessary. Once removed, spark plug tube cannot be
reused because of deformation.
3. Remove valve lifter. I
• Compress valve spring with valve spring compressor, attach- J
let with a magnet hand (B).
CAUTION:
When working, be careful not to damage valve lifter holes. K
PBIC3727E M
CAUTION:
Never remove valve spring seat from valve spring. N
7. Remove valve oil seal with a valve oil seal puller (SST). O
SEM093F
EM-203
CYLINDER HEAD
8. Remove valve seat, if valve seat must be replaced.
• Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat
recess in cylinder head. Set the machine depth stop to ensure this. Refer to EM-238, "Cylinder Head".
CAUTION:
Prevent to scratch cylinder head by excessive boring.
9. Remove valve guide, if valve guide must be replaced.
a. To remove valve guide, heat cylinder head to 110 to 130°C (230
to 266°F) by soaking in heated oil (A).
PBIC3214J
b. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US

ton, 2.0 lmp ton) pressure] or hammer and suitable tool.
CAUTION:
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.
SEM931C
ASSEMBLY
1. Install valve guide if removed.
CAUTION:
Replace with oversize [0.2 mm (0.008 in)] valve guide.
a. Ream cylinder head valve guide hole with a valve guide reamer
For service parts : Oversize [0.2 mm (0.008 in)]

PBIC3215J

heated oil (A).
PBIC3214J
EM-204
CYLINDER HEAD
c. Press valve guide from camshaft side to dimensions as shown
in the figure. A
Projection “H” : Refer to EM-238, "Cylinder Head".

CAUTION: EM
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.
C
PBIC2187E
D
d. Apply reamer finish to valve guide with a valve guide reamer
E
G
PBIC3215J
2. Install valve seat if removed.

CAUTION: H
Replace with oversize [0.5 mm (0.020 in)] valve seat.
a. Ream cylinder head (1) recess diameter for service valve seat.
I
2 : Valve seat
For service parts : Oversize [0.5 mm (0.020 in)] J

• Be sure to ream in circles concentric to the valve guide center.
K
This will enable valve seat to fit correctly.
PBIC3218J
L
heated oil (A).
M
O
PBIC3214J
c. Provide valve seats cooled well with dry ice. Press-fit valve seat into cylinder head. P
CAUTION:
• Avoid directly to touching cold valve seats.
• Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.
EM-205
CYLINDER HEAD
d. Using valve seat cutter set (commercial service tool) or valve
seat grinder, finish valve seat to the specified dimensions. For
dimensions, refer to EM-238, "Cylinder Head".
CAUTION:
When using valve seat cutter, firmly grip the cutter handle
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with the cutter or cutting many different times
may result in stage valve seat.
SEM934C
e. Using compound, grind to adjust valve fitting.

f. Check again for normal contact. Refer to EM-207, "Inspection".
3. Install valve oil seal.
• Install with a valve oil seal drift (SST) to match dimension in
the figure.
NOTE:
Dimension “H” is height that measured before installing valve
spring (with valve spring seat).
Height “H” : 11.8 - 12.4 mm (0.465 - 0.488 in)
KBIA1999J
4. Install valve.
• Install larger diameter to intake side.
5. Install valve spring (with valve spring seat).

• Install smaller pitch (valve spring seat side) to cylinder head
side.
• Confirm identification color of valve spring.
Intake : Pink
Exhaust : Yellowish green
PBIC0525E

7. Install valve collet.
• Compress valve spring with a valve spring compressor, attach-
ment and adapter [SST: KV10116200] (A). Install valve collet
with a magnet hand (B).
CAUTION:
When working, be careful not to damage valve lifter holes.
lation to check its installed condition.
PBIC3727E
8. Install valve lifter.

• Install it in the original position.
EM-206
CYLINDER HEAD
9. Install spark plug tube if removed.
• Press-fit it into cylinder head with the following procedure: A
a. Remove old thread locking sealant from cylinder head side
installation hole.
b. Apply thread locking sealant all round on spark plug tube within EM
approximately 12 mm (0.47 in) width from edge of spark plug
tube on the press-fit side.
Use Genuine Thread Locking Sealant or equivalent.
C
c. Using a drift, press-fit spark plug tube so that height is as same
as “H” shown in figure.
PBIC2636E
D
Standard press-fit height “H”:
41.2 - 42.2 mm (1.622 - 1.661 in)
CAUTION: E
• When press-fitting, be careful not to deform spark plug tube.
• After press-fitting, wipe off any protruding thread locking sealant on top surface of cylinder
head.
F
10. Install spark plug with spark plug wrench (commercial service tool).
G
Cylinder Head Bolts Outer Diameter
H
• Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between “A” and “B”
exceeds the limit, replace them with new one.
I
c : 55.0 mm (2.17 in)
d : 12.0 mm (0.47 in)
J
Limit (“B”–“A”) : 0.23 mm (0.0091 in)
• If reduction of outer diameter appears in a position other than “d2”,
use it as “d2” point. K
JPBIA0884ZZ
Cylinder Head Distortion

NOTE: L
When performing this inspection, cylinder block distortion should be also checking. Refer to EM-218, "Inspec-
tion".
1. Using a scraper, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head.
M
CAUTION:
Never allow gasket fragments to enter engine oil or engine coolant passages.
measure the distortion in six directions. N

• If it exceeds the limit, replace cylinder head. O
SEM861E
VALVE DIMENSIONS
• Check dimensions of each valve. For dimensions, refer to EM-238, "Cylinder Head".
• If dimensions are out of the standard, replace valve.
EM-207
CYLINDER HEAD
Valve Stem Diameter
Measure the diameter of valve stem with a micrometer (A).
JPBIA0183ZZ

Measure the inner diameter of valve guide with a bore gauge.

(Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).
Standard and Limit : Refer to EM-238, "Cylinder Head".

• If it exceeds the limit, replace valve guide and/or valve. When valve guide must be replaced. Refer to EM-
203, "Disassembly and Assembly".
VALVE SEAT CONTACT
• After confirming that the dimensions of valve guides and valves are within specifications, perform this proce-
dure.
• Check if the contact area band is continuous all around the circum-
ference.
A : OK
B : NG
surface still has NG conditions even after the re-check, replace
valve seat. Refer to EM-203, "Disassembly and Assembly".
JPBIA0187ZZ
VALVE SPRING SQUARENESS

• Set try square (A) along the side of valve spring and rotate the
spring. Measure the maximum clearance between the top of valve
spring and try square.
B : Contact
CAUTION:

• If it exceeds the limit, replace valve spring (with valve spring seat). PBIC3219J
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD
EM-208
CYLINDER HEAD
specified spring height. A
CAUTION:
EM
SEM113
D
• If the installation load or load with valve open is out of the standard, replace valve spring (with valve spring
seat).
INSPECTION AFTER INSTALLATION E
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak. F
• Use procedure below to check for fuel leakage. G
• Run engine to check for unusual noise and vibration. H
• Bleed air from lines and hoses of applicable lines, such as in cooling system. I
Summary of the inspection items: J
Engine oil Level Leakage Level K
L
M
EM-209
CYLINDER BLOCK
CYLINDER BLOCK
JPBIA0684GB
1. Cylinder block 2. O-ring 3. Crankshaft position sensor (POS)

4. Knock sensor 5. Water drain plug 6. Lower cylinder block
7. Lower cylinder block mounting bolt 8. Snap ring 9. Connecting rod
10. Connecting rod bearing 11. Connecting rod bearing cap 12. Connecting rod bolt
13. Piston 14. Oil ring 15. Second ring
16. Top ring 17. Piston pin 18. Thrust bearing
19. Main bearing upper 20. Crankshaft 21. Crankshaft key
22. Main bearing lower 23. Drive plate (CVT models) 24. Reinforce plate (CVT models)
25. Signal plate 26. Pilot converter (CVT models) 27. Rear oil seal
28. Flywheel (M/T models)
A : Refer to EM-211
EM-210
CYLINDER BLOCK
A
DISASSEMBLY
EM
2. Remove knock sensor.
CAUTION:
Carefully handle knock sensor avoiding shocks.
3. Remove crankshaft position sensor (POS). C
CAUTION:
• Avoid impacts such as a dropping.
• Never disassemble. D
• Keep it away from metal particles.
• Never place sensor in a location where it is exposed to
magnetism.
E
F
PBIC2191E
4. Remove piston and connecting rod assembly with the following procedure:
• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to G
EM-218, "Inspection".
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod cap. H
c. Using a hammer handle or similar tool, push piston and connect-
ing rod assembly out to the cylinder head side.
CAUTION: I
Be careful not to damage the cylinder wall, resulting from
an interference of the connecting rod big end.
J
K
PBIC0259E
5. Remove connecting rod bearings. L

CAUTION:
When removing them, note the installation position. Keep them in the correct order.
6. Remove piston rings form piston. M
• Use a piston ring expander (commercial service tool) (A).
CAUTION:
• When removing piston rings, be careful not to damage
the piston. N
• Be careful not to damage piston rings by expanding
them excessively.
O
P
PBIC3233J
7. Remove piston from connecting rod with the following procedure:
EM-211
CYLINDER BLOCK
a. Using snap ring pliers (A), remove snap ring.
PBIC3230J
b. Heat piston to 60 to 70°C (140 to 158°F) with an industrial use

drier (A) or equivalent.
PBIC3231J
c. Push out piston pin with stick of outer diameter approximately 19

mm (0.75 in).
PBIC0262E
8. Remove lower cylinder block mounting bolts.

• Loosen them in reverse order as shown in the figure, and
remove them.
: Engine front
• Use TORX socket (size E14) for bolts No. 1 to 10.

• Before loosening lower cylinder block mounting bolts, mea-
sure crankshaft end play. Refer to EM-218, "Inspection".
JPBIA0904ZZ
9. Remove lower cylinder block.

• Use a seal cutter [SST: KV10111100] or equivalent tool to cut liquid gasket for removal.
CAUTION:
Be careful not to damage the mounting surface.
10. Remove crankshaft.
CAUTION:
EM-212
CYLINDER BLOCK
• Be careful not damage or deform signal plate mounted on
crankshaft. A
• When setting crankshaft on a flat floor surface, use a
block of wood to avoid interference between signal plate
and the floor surface.
EM
• Never remove signal plate unless it is necessary to do so.
NOTE:
When removing or installing signal plate, use TORX socket (size
T30). C
11. Pull rear oil seal out from rear end of crankshaft.
NOTE: SBIA0275E
When replacing rear oil seal without removing lower cylinder D
block, use a screwdriver to pull it out from between crankshaft and cylinder block.
CAUTION:
E
12. Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
CAUTION:
Identify installation positions, and store them without mixing them up. F
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material. G
CAUTION:
Use a goggles to protect your eye.
2. Install each plug to cylinder block as shown in the figure. H
• Apply liquid gasket to the thread of water drain plug “A”.
NOTE: I
Do not apply liquid gasket to the thread of plug “B”.
PBIC2770E
K
• Tighten each plug as specified below.

L
A No 9.8 N·m (1.0 kg-m, 87 in-lb)
M
B Yes 53.9 N·m (5.5 kg-m, 40 ft-lb)
3. Install oil jet.
• Insert oil jet dowel pin (A) into cylinder block dowel pin hole, N
and tighten mounting bolts.
: Engine front
O
JPBIA0686ZZ
4. Install main bearings and thrust bearings with the following procedure:
a. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block and lower cylinder
block.
EM-213
CYLINDER BLOCK
b. Install thrust bearings to the both sides of the No. 3 journal hous-
ing on cylinder block.
• Install thrust bearings with the oil groove facing crankshaft arm
(outside).
PBIC0264E
c. Install the main bearings paying attention to the direction.

• Main bearing with an oil hole and groove goes on cylinder
block. The one without them goes on lower cylinder block.
• Only main bearing (on cylinder block) for No. 3 journal has dif-
ferent specifications.
• Before installing main bearings, apply new engine oil to the
bearing surface (inside). Do not apply new engine oil to the
back surface, but thoroughly clean it.
• When installing, align main bearing stopper to the notch.
• Ensure the oil holes on cylinder block and those on the corre-
sponding bearing are aligned.
PBIC2193E
5. Install signal plate to crankshaft if removed.

a. Position crankshaft and signal plate using a dowel pin, and
tighten mounting bolts.
1 : Signal plate
2 : Crankshaft
A : Dowel pin (used to position the signal plate)
b. Remove dowel pin.
CAUTION:
Be sure to remove dowel pin.
NOTE: JPBIA0796ZZ
Dowel pin of crankshaft and signal plate is provided as a set for
each. If dowel pin is not available (when reusing crankshaft and signal), use M6 bolt [length 10 mm (0.39
in) or more] as a substitute.
6. Install crankshaft to cylinder block.
• While turning crankshaft by hand, check that it turns smoothly.
7. Install lower cylinder block with the following procedure:
a. Apply liquid gasket with a tube presser (commercial service tool)
to lower cylinder block as shown in the figure.
a : 3.5 - 4.0 mm (0.138 - 0.157 in)

B : Apply liquid gasket to an end
CAUTION:
After liquid gasket is applied, rear oil seal installation must
be finished within 5 minutes. Therefore, the following pro-
cedure must be performed quickly.
NOTE: JPBIA0905ZZ
Lower cylinder block cannot be replaced as a single part,

because it is machined together with cylinder block.
b. Tighten lower cylinder block mounting bolts with the following procedure:
i. Apply new engine oil to threads and seat surfaces of mounting bolts.
EM-214
CYLINDER BLOCK
ii. Tighten M8 bolts in numerical order from No. 11 to 22 in the fig-
ure. A
: Engine front
EM
: 25.1 N·m (2.6 kg-m, 19 ft-lb)
NOTE:
There are more processes to complete the tightening of mount- C
ing bolts. However stop procedure here to install rear oil seal.
JPBIA0904ZZ
D
c. Install rear oil seal. Refer to EM-180, "REAR OIL SEAL : Removal and Installation".
d. Restart tightening of lower cylinder block mounting bolts with the following procedure:
i. Tighten M10 bolts in numerical order from No. 1 to 10. E
: Engine front
F
: 39.2 N·m (4.0 kg-m, 29 ft-lb)
JPBIA0904ZZ H
ii. Turn M10 bolts 60 degrees clockwise (angle tightening) in order

from No. 1 to 10 in the figure.
CAUTION: I
wrench [SST: KV10112100] (A) or protractor. Avoid judg-
ment by visual inspection without the tool. J
JPBIA0687ZZ
• After installing mounting bolts, check that crankshaft can be rotated smoothly by hand. L
• Wipe off completely any protruding liquid gasket on front side of engine.
• Check crankshaft end play. Refer to EM-218, "Inspection".
8. Install piston to connecting rod with the following procedure: M
a. Using snap ring pliers, install new snap ring to the groove of the piston rear side.
b. Assemble piston to connecting rod. N
• Using an industrial use drier or similar tool, heat the piston until the piston pin can be pushed in by hand
without excess force [approx. 60 to 70 °C (140 to 158 °F)]. From the front to the rear, insert piston pin
into piston and connecting rod. O
• Assemble so that the front mark on the piston head and the oil
holes and the cylinder number on connecting rod are posi-
tioned as shown in the figure.
P
c. Install new snap ring to the groove of the piston front side.
• After installing, check that connecting rod moves smoothly.
PBIC2194E
EM-215
CYLINDER BLOCK
9. Using a piston ring expander (commercial service tool), install piston rings.
CAUTION:
Be careful not to damage piston.
• Position each ring with the gap as shown in the figure referring
to the piston front mark.
• Install second ring with the stamped surface facing upward.
Stamped mark:
Top ring :—
Second ring :2K
NOTE:
If there is no stamped mark on piston ring, no specific orienta-
tion is required for installation. PBIC2195E
10. Install connecting rod bearings to connecting rod and connecting rod cap.
• When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not
apply new engine oil to the back surface, but thoroughly clean it.
• When installing, align the connecting rod bearing stopper pro-
trusion with the cutout of connecting rod and connecting rod
cap to install.
• Ensure the oil hole on connecting rod and that on the corre-
sponding bearing are aligned.
PBIC0266E
11. Install piston and connecting rod assembly to crankshaft.

• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
• Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
• Match the cylinder position with the cylinder number on connecting rod to install.
• Using a piston ring compressor [SST: EM03470000] (A) or
suitable tool, install piston with the front mark on the piston
head facing the front of the engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
big end.
PBIC3244J
12. Install connecting rod cap.

• Match the stamped cylinder number marks on connecting rod
with those on connecting rod cap to install.
PBIC2196E
EM-216
CYLINDER BLOCK
13. Tighten connecting rod bolt with the following procedure: A

a. Apply new engine oil to the threads and seats of connecting rod bolts.
b. Tighten bolts.
EM
: 27.4 N·m (2.8 kg-m, 20 ft-lb)
c. Completely loosen bolts.
C
: 0 N·m (0 kg-m, 0 ft-lb)
d. Tighten bolts. D
: 19.6 N·m (2.0 kg-m, 14 ft-lb)

e. Then turn all bolts 90 degrees clockwise (Angle tightening). E
CAUTION:
wrench [SST: KV10112100] (A) or protractor. Avoid judg- F
ment by visual inspection without the tool.
H
JPBIA0688ZZ
• After tightening connecting rod bolt, check that crankshaft rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-218, "Inspection". I
14. Install flywheel (M/T models) or drive plate (CVT models).

CAUTION: J
Check that dowel pin is installed at the rear end of crankshaft.
• When installing flywheel (M/T models) or drive plate (CVT models) to crankshaft, check that align crank-
shaft side dowel pin with flywheel/drive-plate side dowel pin hole correctly.
K
CAUTION:
If these are not aligned correctly, engine runs roughly and “MI” turns on.
• Secure crankshaft with a stopper plate, and tighten mounting bolts crosswise over several times.
• Install drive plate (1), reinforcement plate (2) and pilot con- L
verter (3) as shown in figure (CVT models).
A : Crankshaft rear end

M
B : Rounded
C : Chamfered
• Using a drift of 33 mm (1.30 in) in diameter, press-fit pilot con- N
verter into the end of crankshaft until it stops (CVT models).
PBIC3259J O
15. Install knock sensor.

P
EM-217
CYLINDER BLOCK
• Install knock sensor with harness connector facing lower left
as shown in the figure.
CAUTION:
• Never tighten mounting bolts while holding the harness
connector.
• If any impact by dropping is applied to knock sensor,
replace it with a new one.
NOTE:
• Check that there is no foreign material on the cylinder block
mating surface and the back surface of knock sensor.
• Check that knock sensor does not interfere with other parts.
PBIC3020E
16. Install crankshaft position sensor (POS).
17. Assemble in the reverse order of disassembly after this step.
CRANKSHAFT END PLAY

• Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with a dial
indicator.
Standard and Limit : Refer to EM-240,

"Cylinder Block".
• If the measured value exceeds the limit, replace thrust bearings,
also.
PBIC2377E
CONNECTING ROD SIDE CLEARANCE

• Measure the side clearance between connecting rod and crank-
shaft arm with a feeler gauge (A).

• If the measured value exceeds the limit, replace connecting rod,
also.
JPBIA0689ZZ
PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole with an inside
micrometer (A).
PBIC3265J
EM-218
CYLINDER BLOCK
A
EM
PBIC3266J
D
Piston to Piston Pin Oil Clearance
(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)
Standard : Refer to EM-240, "Cylinder Block". E
• If oil clearance is out of the standard, replace piston and piston pin assembly.
• When replacing piston and piston pin assembly, refer to "PISTON TO CYLINDER BORE CLEARANCE".
NOTE: F
• Piston is available together with piston pin as assembly.
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
grades can be selected. (Only grade “0” is available.) G
PISTON RING SIDE CLEARANCE
• Measure the side clearance of piston ring and piston ring groove
with a feeler gauge. H

• If the measured value exceeds the limit, replace piston ring, and I
measure again. If it still exceeds the limit, replace piston also.
SEM024AA
K
PISTON RING END GAP
• Check that cylinder bore inner diameter is within specification. Refer to "Cylinder Bore Inner Diameter".
• Lubricate with new engine oil to piston (1) and piston ring (2), and
L
then insert (A) piston ring until middle of cylinder (B) with piston,
and measure piston ring end gap with a feeler gauge (C).
Standard and Limit : Refer to EM-240, "Cylinder Block". M

measure again. If it still exceeds the limit, re-bore cylinder and use
oversized piston and piston rings. N
PBIC3267J
O
CONNECTING ROD BEND AND TORSION
• Check with a connecting rod aligner.
P
EM-219
CYLINDER BLOCK
A : Bend
B : Torsion
C : Feeler gauge
Bend and Torsion : Refer to EM-240, "Cylinder Block".

• If it exceeds the limit, replace connecting rod assembly.
PBIC3268J
CONNECTING ROD BIG END DIAMETER

• Install connecting rod cap (1) without connecting rod bearing
installed, and tightening connecting rod bolts to the specified
torque. Refer to EM-211, "Disassembly and Assembly" for the
tightening procedure.
2 : Connecting rod
A : Example
• Measure the inner diameter of connecting rod big end with an
inside micrometer.
PBIC3269J

• If out of the standard, replace connecting rod assembly.
CONNECTING ROD BUSHING OIL CLEARANCE
Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing with an inside
micrometer (A).
PBIC3270J
EM-220
CYLINDER BLOCK
A
EM
PBIC3266J
D
Connecting Rod Bushing Oil Clearance
(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)
E
• If the measured value is out of the standard. Replace connecting rod assembly and/or piston and piston pin
assembly. F
• If replacing piston and piston pin assembly. Refer to EM-228, "Piston".
• If replacing connecting rod assembly. Refer to EM-229, "Connecting Rod Bearing" to select connecting rod
bearing. G
CYLINDER BLOCK DISTORTION

• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or H
other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages. I
• Measure the distortion on the cylinder block upper face at some
different points in six directions with a straight edge and feeler
gauge.
J
• If it exceeds the limit, replace cylinder block.
K
L
PBIC0121E
MAIN BEARING HOUSING INNER DIAMETER

• Install lower cylinder block without main bearings installed, and M
tighten lower cylinder block mounting bolts to the specified torque.
Refer to EM-211, "Disassembly and Assembly" for the tightening
procedure.
N
• Measure the inner diameter of main bearing housing with a bore
gauge.
Standard : Refer to EM-240, "Cylinder Block". O

• If out of the standard, replace cylinder block and lower cylinder
block assembly.
NOTE: PBIC2012E P
Cylinder block cannot be replaced as a single, because it is
machined together with lower cylinder block.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
EM-221
CYLINDER BLOCK
• Using a bore gauge, measure the cylinder bore for wear, out-of-
round and taper at six different points on each cylinder. (“X” and
“Y” directions at “A”, “B” and “C”) (“Y” is in longitudinal direction of
engine)
NOTE:
When determining cylinder bore grade, measure the cylinder bore
at “B” position.
Standard :
Cylinder bore inner diameter
: Refer to EM-240, "Cylinder Block". SBIA0284E
Limit :
Out-of-round (Difference between “X” and “Y”)
Taper (Difference between “A” and “B”)
• If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
hone or re-bore the cylinder inner wall.
• Oversize piston is provided. When using oversize piston, re-bore the cylinder so that the clearance of the
piston to cylinder bore satisfies the standard.
CAUTION:
When using oversize piston, use it for all cylinders with oversize piston rings.
Oversize (OS): 0.2 mm (0.008 in)

Piston Skirt Diameter
Measure the outer diameter of piston skirt with a micrometer (A).
PBIC3272J
Piston to Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter (direction “X”, position “B”).
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter)

• If it exceeds the limit, replace piston and piston pin assembly. Refer to EM-228, "Piston".
Re-boring Cylinder Bore
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.
Re-bored size calculation: D = A + B - C

where,
D: Bored diameter
A: Piston diameter as measured
B: Piston - to - cylinder bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in)
EM-222
CYLINDER BLOCK
2. Install lower cylinder block, and tighten mounting bolts to the specified torque. Otherwise, cylinder bores
may be distorted in final assembly. Refer to EM-211, "Disassembly and Assembly" for the tightening pro- A
cedure.
3. Cut cylinder bores.
NOTE: EM
• When any cylinder needs boring, all other cylinders must also be bored.
• Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a
time.
C
4. Hone cylinders to obtain specified piston to cylinder bore clearance.
5. Measure the finished cylinder bore for out-of-round and taper.
NOTE:
Measurement should be done after cylinder bore cools down. D
CRANKSHAFT MAIN JOURNAL DIAMETER

• Measure the outer diameter of crankshaft main journals with a E
micrometer.

F
• If out of the standard, measure the main bearing oil clearance.
Then use undersize bearing. Refer to EM-243, "Main Bearing".
G
PBIC0270E
H
CRANKSHAFT PIN JOURNAL DIAMETER

• Measure the outer diameter of crankshaft pin journal with a micrometer. I

• If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer J
to EM-244, "Connecting Rod Bearing".
OUT-OF-ROUND AND TAPER OF CRANKSHAFT
• Measure the dimensions at four different points as shown in the K
figure on each main journal and pin journal with a micrometer.
• Out-of-round is indicated by the difference in dimensions between
“X” and “Y” at “A” and “B”. L
• Taper is indicated by the difference in dimension between “A” and
“B” at “X” and “Y”.
M
Limit:
Out-of-round (Difference between “X” and “Y”)
Taper (Difference between “A” and “B”) N
PBIC3459J
• If the measured value exceeds the limit, correct or replace crankshaft.
• If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select O
main bearing and/or connecting rod bearing. Refer to EM-244, "Connecting Rod Bearing" and/or EM-243,
"Main Bearing".
CRANKSHAFT RUNOUT P
EM-223
CYLINDER BLOCK
• Place a V-block on a precise flat table to support the journals on
the both end of the crankshaft.
• Place a dial indicator straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on the
dial indicator. (Total indicator reading)

• If it exceeds the limit, replace crankshaft.
PBIC2541E

• Install connecting rod bearings (2) to connecting rod (3) and cap,
and tighten connecting rod bolts to the specified torque. Refer to
EM-211, "Disassembly and Assembly" for tightening procedure.
1 : Connecting rod bearing cap

A : Example
PBIC3275J
• Measure the inner diameter of connecting rod bearing with an inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter) – (Crankshaft pin journal diameter)

• If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end
diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to EM-229,
"Connecting Rod Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
holes.
• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified
torque. Refer toEM-211, "Disassembly and Assembly" for the tightening procedure.
CAUTION:
• Remove connecting rod cap and bearing, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
PBIC1149E

EM-224
CYLINDER BLOCK
• Install main bearings (3) to cylinder block (1) and lower cylinder
block (2), and tighten lower cylinder block mounting bolts to the A
specified torque. Refer to EM-211, "Disassembly and Assembly"
for the tightening procedure.
EM
A : Example
• Measure the inner diameter of main bearing with a bore gauge. C
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter)
PBIC3277J

• If clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and E
crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to EM-211, "Disassembly
and Assembly".
Method of Using Plastigage F
• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
holes. G
• Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block mounting
bolts to the specified torque. Refer to EM-211, "Disassembly and Assembly" for the tightening procedure.
CAUTION: H
• Remove lower cylinder block and bearings, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE: I
J
K
PBIC1149E
MAIN BEARING CRUSH HEIGHT L

• When lower cylinder block is removed after being tightened to the
specified torque with main bearings (1) installed, the tip end of
bearing must protrude (B). Refer to EM-211, "Disassembly and
M
Assembly" for the tightening procedure.
A : Example
N
Standard: There must be crush height.
• If the standard is not met, replace main bearings.
O
PBIC3279J
CONNECTING ROD BEARING CRUSH HEIGHT

P
EM-225
CYLINDER BLOCK
• When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings (1) installed,
the tip end of bearing must protrude (B). Refer to EM-211, "Disas-
sembly and Assembly" for the tightening procedure.
A : Example

• If the standard is not met, replace connecting rod bearings.
PBIC3279J
LOWER CYLINDER BLOCK MOUNTING BOLT OUTER DIAMETER

• Perform only with M10 bolts.
in the figure.
• If reduction appears in “A” range, regard it as “d2”.
Limit (“d1”–“d2”): 0.13 mm (0.0051 in)

• If it exceeds the limit (a large difference in dimensions), replace
lower cylinder block mounting bolt with a new one.
PBIC0911E
CONNECTING ROD BOLT OUTER DIAMETER

• Measure the outer diameter “d” at position as shown in the figure.
• If reduction appears in a position other than “d”, regard it as “d”.
Limit: 7.75 mm (0.3051 in)

• When “d ” exceeds the limit (when it becomes thinner), replace
connecting rod bolt with a new one.
PBIC0912E
FLYWHEEL DEFLECTION (M/T MODELS)

• Measure the deflection of flywheel contact surface to clutch with a
dial indicator.
• Measure the deflection at 210 mm (8.27 in) dia.
Standard : 0.45 mm (0.0177 in) or less.

CAUTION:
When measuring, keep magnetic fields (such as dial indicator
stand) away from signal plate of the rear end of crankshaft.
PBIC2168E
MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)

CAUTION:
Do not disassemble double mass flywheel.
Movement Amount of Thrust (Fore-and-Aft) Direction
• Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is added
at the portion of 125 mm (4.92 in) radius from the center of flywheel.
Standard : 1.3 mm (0.051 in) or less.
EM-226
CYLINDER BLOCK
Movement Amount in Radial (Rotation) Direction A
Check the movement amount of radial (rotation) direction with the following procedure:
1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel
center line. EM
• Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it from loosening.
2. Put a mating mark on circumferences of the two flywheel
masses without applying any load (Measurement standard C
points).
3. Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction,
and mark the movement amount on the mass on the transaxle D
side.
4. Measure the dimensions of movement amounts “A” and “B” on
circumference of the flywheel on the transaxle side. E
Standard: 33.0 mm (1.299 in) or less.

PBIC1263E
• If measured value is out of the standard, replace flywheel. F
EM-227
Selection points Selection parts Selection items Selection methods

Determined by match of cylin-
der block bearing housing
Between cylinder block and Main bearing grade (bearing grade (inner diameter of hous-
Main bearing
crankshaft thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Combining service grades for
connecting rod big end diame-
Between crankshaft and con- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
necting rod (bearing thickness)
ameter determine connecting
rod bearing selection.
Piston and piston pin assembly
Between cylinder block and pis- Piston grade (piston outer diam- Piston grade = cylinder bore
(piston is available together with
ton eter) grade (inner diameter of bore)
piston pin as an assembly.)
Between piston and connecting
— — —
rod*
*For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only grade “0” is available.) The
information at the shipment from the plant is described as a reference.
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
Piston INFOID:0000000001208152
WHEN NEW CYLINDER BLOCK IS USED

• Check the cylinder bore grade on rear left side of cylinder block,
and select piston of the same grade.
• If there is a corrected stamp mark on the cylinder block, use it as a
correct reference.
SBIA0283E
WHEN CYLINDER BLOCK IS REUSED

1. Measure the cylinder bore inner diameter. Refer to EM-218, "Inspection".
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner
diameter of the “Piston Selection Table”.
EM-228
3. Select piston of the same grade.
A
A : Identification code
B : Piston grade number
C : Front mark EM
D : Piston pin bore grade number
JPBIA0690ZZ
D
PISTON SELECTION TABLE
Unit: mm (in)
Grade number (Mark) 2 (or no mark) 3
E
Cylinder bore Inner diameter 89.010 - 89.020 (3.5043 - 3.5047) 89.020 - 89.030 (3.5047 - 3.5051)
Piston skirt diameter 88.990 - 89.000 (3.5035 - 3.5039) 89.000 - 89.010 (3.5039 - 3.5043)
NOTE: F
• There is no piston grade “1”.
• Piston is available together with piston pin as an assembly.
• The piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no G
grades can be selected. (Only grade “0” is available.)
H
WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED
1. Apply connecting rod big end diameter grade stamped on con-
I
necting rod side face to the row in the “Connecting Rod Bearing
Selection Table”.
PBIC2196E
L
2. Apply crankshaft pin journal diameter grade stamped on crank-

shaft front side to the column in the “Connecting Rod Bearing
M
Selection Table”.
PBIC2198E
P
Table”.
WHEN CRANKSHAFT AND CONNECTING ROD ARE REUSED
1. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter indi-
vidually. Refer to EM-218, "Inspection".
EM-229
2. Apply the measured dimension to the “Connecting Rod Bearing Selection Table”.
Table”.
CONNECTING ROD BEARING SELECTION TABLE
JPBIA0797GB
UNDERSIZE BEARINGS USAGE GUIDE

• When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod
bearings, use undersize (US) bearings.
• When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft pin to use undersize bearings, keep the
fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)].
Bearing under- : Refer to EM-244,

size table "Connecting Rod Bearing".
PBIC2200E
EM-230
A
Connecting rod bearing grade table : Refer to EM-244, "Connecting Rod Bearing".

EM
WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED

1. “Main Bearing Selection Table” rows correspond to main bearing C
housing grade on rear left side of cylinder block.
• If there is a corrected stamp mark on cylinder block, use it as a
correct reference.
D
SBIA0283E F
2. Apply main journal diameter grade stamped on crankshaft front

side to column in the “Main Bearing Selection Table”. G
PBIC2198E
J
CAUTION:
There are two main bearing selection tables. One is for odd-numbered journals (No. 1, 3 and 5) and K
the other is for even-numbered journals (No. 2 and 4). Make certain to use the appropriate table.
This is due to differences in the specified clearances.
4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing. L
NOTE:
WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED M
1. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main
journal diameter individually. Refer to EM-218, "Inspection".
2. Apply the measured dimension to the “Main Bearing Selection Table”. N
CAUTION:
There are two main bearing selection tables. One is for odd-numbered journals (No. 1, 3 and 5) and O
the other is for even-numbered journals (No. 2 and 4). Make certain to use the appropriate table.
This is due to differences in the specified clearances.
4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing. P
NOTE:
EM-231
MAIN BEARING SELECTION TABLE (No. 1, 3 and 5 journals)
PBIC2201E
EM-232
MAIN BEARING SELECTION TABLE (No. 2 and 4 journals)
A
EM
K
PBIC2202E
MAIN BEARING GRADE TABLE (ALL JOURNALS)

L
Main bearing grade table (All journals) : Refer to EM-243, "Main Bearing".
USE UNDERSIZE BEARING USAGE GUIDE

• When the specified main bearing oil clearance is not obtained with standard size main bearings, use under- M
size (US) bearing.
• When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard. N
CAUTION:
In grinding crankshaft main journal to use undersize bearings,
keep fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)].
O
PBIC2200E
EM-233
Bearing undersize table : Refer to EM-243, "Main Bearing".
EM-234
< SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE]

EM
C
Displacement cm3 (cu in) 2,488 (151.82)
Bore and stroke mm (in) 89.0 x 100.0 (3.504 x 3.937) D
E
Compression 2
Oil 1
Compression ratio 9.6 F
Standard 1,412 (14.1, 14.4, 204.7)
Compression pressure
Minimum 1,216 (12.2, 12.1, 176.3)
kPa (bar, kg/cm2, psi)/250 rpm G
Differential limit between cylinders 100 (1.0, 1.0, 14)
Unit: degree
Valve timing
J
: Intake valve
: Exhaust valve
K
PBIC5304E
a b c d e f
12 (−28) 64 (24) L
220 232 10 30
ATDC ABDC
( ): Valve timing control “ON”
M
Drive belt INFOID:0000000001157998
DRIVE BELT N
Tension of drive belt Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
Spark Plug INFOID:0000000001157999

O
SPARK PLUG
Unit: mm (in) P
Make NGK
Standard type DILKAR6A-11
Spark plug gap (Nominal) 1.1 (0.043)
EM-235
Intake Manifold INFOID:0000000001158000
INTAKE MANIFOLD
Unit: mm (in)
Items Limit
Surface distortion Intake manifold adaptor 0.1 (0.004)
EXHAUST MANIFOLD
Unit: mm (in)
Items Limit
Surface distortion Exhaust manifold 0.3 (0.012)
CAMSHAFT
Unit: mm (in)

Camshaft journal oil clearance 0.045 - 0.086 (0.0018 - 0.0034) —
No. 1 28.000 - 28.021 (1.1024 - 1.1032) —
Camshaft bracket inner diameter
No. 2, 3, 4, 5 23.500 - 23.521 (0.9252 - 0.9260) —
No. 1 27.935 - 27.955 (1.0998 - 1.1006) —
Camshaft journal diameter
No. 2, 3, 4, 5 23.435 - 23.455 (0.9226 - 0.9234) —
Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) —
Intake 44.815 - 45.005 (1.7644 - 1.7718)
Camshaft cam height “A” 0.2 (0.008)*1
Exhaust 43.975 - 44.165 (1.7313 - 1.7388)
Camshaft runout [TIR*2] Less than 0.02 mm (0.0008) —
Camshaft sprocket runout [TIR*2] — 0.15 (0.0059)
SEM671
*1: Cam wear limit

*2: Total indicator reading
VALVE LIFTER
Unit: mm (in)
Items Standard
Valve lifter outer diameter 33.977 - 33.987 (1.3377 - 1.3381)
Valve lifter hole diameter 34.000 - 34.021 (1.3386 - 1.3394)
Valve lifter clearance 0.013 - 0.044 (0.0005 - 0.0017)
VALVE CLEARANCE
EM-236
Unit: mm (in)
Items Cold Hot* (reference data) A

Intake 0.24 - 0.32 (0.094 - 0.0126) 0.304 - 0.416 (0.0120 - 0.0164)
Exhaust 0.26 - 0.34 (0.0102 - 0.0134) 0.308 - 0.432 (0.0121 - 0.0170)
EM
*: Approximately 80°C (176°F)
AVAILABLE VALVE LIFTER

Unit: mm (in) C
Thickness Identification (stamped) mark
7.88 (0.3102) 788J or 788T
D
7.90 (0.3110) 790J or 790T
7.92 (0.3118) 792J or 792T
7.94 (0.3126) 794J or 794T E
7.96 (0.3134) 796J or 796T
7.98 (0.3142) 798J or 798T
F
8.00 (0.3150) 800J or 800T
8.02 (0.3157) 802J or 802T
8.04 (0.3165) 804J or 804T G
8.06 (0.3173) 806J or 806T
8.08 (0.3181) 808J or 808T
H
8.10 (0.3189) 810J or 810T
8.12 (0.3197) 812J or 812T
8.14 (0.3205) 814J or 814T I
8.16 (0.3213) 816J or 816T
8.18 (0.3220) 818J or 818T
8.20 (0.3228) 820J or 820T J
8.22 (0.3236) 822J or 822T
8.24 (0.3244) 824J or 824T
K
8.26 (0.3252) 826J or 826T
8.28 (0.3260) 828J or 828T
8.30 (0.3268) 830J or 830T L
8.32 (0.3276) 832J or 822T
8.34 (0.3283) 834J or 834T
M
8.36 (0.3291) 836J or 836T
8.38 (0.3299) 838J or 838T
N
SEM758G
EM-237
CYLINDER HEAD
Unit: mm (in)

Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)
Normal cylinder head height “H” 129.3 - 129.5 (5.091 - 5.098) —
PBIC0924E
VALVE DIMENSIONS
Unit: mm (in)
SEM188
Valve head diameter “D” Intake 35.5 - 35.8 (1.398 - 1.409)

Exhaust 30.3 - 30.6 (1.193 - 1.205)
Intake 96.84 (3.8126)
Valve length “L”
Exhaust 97.9 (3.854)
Intake 5.965 - 5.980 (0.2348 - 0.2354)
Exhaust 5.955 - 5.970 (0.2344 - 0.2350)
Intake
Valve seat angle “α” 45°15′ - 45°45′
Exhaust
Intake 1.1 (0.043)
Exhaust 1.4 (0.055)
Valve margin “T” limit 0.5 (0.020)
Valve stem end surface grinding limit 0.2 (0.008)
VALVE GUIDE
EM-238
Unit: mm (in)
A
EM
D
SEM950E
Items Standard Oversize (Service) [0.2 (0.008)]

E
Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)
Valve guide
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)
F
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.003) G
Valve guide clearance
Exhaust 0.030 - 0.063 (0.0012 - 0.0025) 0.09 (0.0035)
Projection length “L” Intake 10.1– -10.3 (0.398 - 0.405)

H
Exhaust 10.0 - 10.4 (0.394 - 0.409)
VALVE SEAT
Unit: mm (in) I
PBIC2745E
M
Items Standard Oversize (Service) [0.5 (0.02)]
Intake 36.500 - 36.516 (1.4370 - 1.4376) 37.000 - 37.016 (1.4567 - 1.4573)
Exhaust 31.500 - 31.516 (1.2402 - 1.2408) 32.000 - 32.016 (1.2598 - 1.2408) N
Intake 36.597 - 36.613 (1.4408 - 1.4415) 37.097 - 37.113 (1.4605 - 1.4611)
Exhaust 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644)
Intake 0.081 - 0.113 (0.0032 - 0.0044) O
Valve seat interference fit
Exhaust 0.084 - 0.116 (0.0034 - 0.0046)
Intake 33.5 (1.319)
Diameter “d1”*1 P
Exhaust 28.0 (1.102)
Intake 34.8 - 35.3 (1.370 - 1.390)
Diameter “d2”*2
Exhaust 29.6 - 30.1 (1.165 - 1.185)
Intake 60°
Angle “α1”
Exhaust 60°
EM-239
Intake 88°45′ - 90°15′
Angle “α2”
Exhaust 88°45′ - 90°15′
Intake 120°
Angle “α3”
Exhaust 120°
Intake 0.99 - 1.35 (0.0390 - 0.0531)
Exhaust 1.19 - 1.55 (0.0469 - 0.0610)
Intake 5.9 - 6.0 (0.232 - 0.236) 5.0 - 5.1 (0.197 - 0.201)
Height “h”
Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.91 - 5.01 (0.1933 - 0.1972)
Depth “H” 6.0 (0.236)
*3: Machining data
VALVE SPRING
Items Intake Exhaust

Free height 43.72 – 43.92 (1.7213 – 1.7291) 45.29 - 45.49 (1.7831 – 1.7909)
Installation height 35.30 mm (1.3890 in) 35.30 mm (1.3890 in)
Installation load 151 – 175 N (15.4 – 17.8 kg, 34 – 39 lb) 151 – 175 N (15.4 – 17.8 kg, 34 – 39 lb)
Height during valve open 25.30 mm (0.9961 in) 26.76 mm (1.0535 in)
Load with valve open 351 – 394 N (35.8 – 40.2 kg, 79 – 89 lb) 318 – 362 N (22.4 – 36.9 kg, 71 – 81 lb)
Identification color Pink Yellowish green
Out- of- Square 1.9 mm (0.075 in)
Cylinder Block INFOID:0000000001158004
CYLINDER BLOCK
Unit: mm (in)
PBIC0281E
Surface distortion Limit 0.1 (0.004)

Grade No. 2 89.010 - 89.020 (3.5043 - 3.5047)
Standard
Cylinder bore Inner diameter Grade No. 3 89.020 - 89.030 (3.5047 - 3.5051)
Wear limit 0.2 (0.008)
Out-of-round (Difference between “X” and “Y”) 0.015 (0.0006)
Limit
Taper (Difference between “A” and “C”) 0.01 (0.0004)
EM-240
Grade No. A 58.944 - 58.945 (2.3206 - 2.3207)
Grade No. B 58.945 - 58.946 (2.3207 - 2.3207) A
Grade No. C 58.946 - 58.947 (2.3207 - 2.3207)
Grade No. D 58.947 - 58.948 (2.3207 - 2.3208)
Grade No. E 58.948 - 58.949 (2.3208 - 2.3208)
Grade No. F 58.949 - 58.950 (2.3208 - 2.3209) EM
Grade No. G 58.950 - 58.951 (2.3209 - 2.3209)
Grade No. H 58.951 - 58.952 (2.3209 - 2.3209)
Grade No. J 58.952 - 58.953 (2.3209 - 2.3210)
Grade No. K 58.953 - 58.954 (2.3210 - 2.3210)
C
Grade No. L 58.954 - 58.955 (2.3210 - 2.3211)
Grade No. M 58.955 - 58.956 (2.3211 - 2.3211)
Main bearing housing inner diameter grade
Grade No. N 58.956 - 58.957 (2.3211 - 2.3211) D
Grade No. P 58.957 - 58.958 (2.3211 - 2.3212)
Grade No. R 58.958 - 58.959 (2.3212 - 2.3212)
Grade No. S 58.959 - 58.960 (2.3212 - 2.3213)
Grade No. T 58.960 - 58.961 (2.3213 - 2.3213) E
Grade No. U 58.961 - 58.962 (2.3213 - 2.3213)
Grade No. V 58.962 - 58.963 (2.3213 - 2.3214)
Grade No. W 58.963 - 58.964 (2.3214 - 2.3214)
Grade No. X 58.964 - 58.965 (2.3214 - 2.3215) F
Grade No. Y 58.965 - 58.966 (2.3215 - 2.3215)
Grade No. 4 58.966 - 58.967 (2.3215 - 2.3215)
Grade No. 7 58.967 - 58.968 (2.3215 - 2.3216)
G
Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)
AVAILABLE PISTON
Unit: mm (in) H
PBIC0188E
L
Grade No. 2 88.990 - 89.000 (3.5035 - 3.5039)
Piston skirt diameter “A” Standard Grade No. 3 89.000 - 89.010 (3.5039 - 3.5043)
Oversize (Service) [0.20 (0.008)] 89.180 - 89.210 (3.5110 - 3.5122) M
Piston height “H” dimension 37.5 (1.476)
Grade No. 0 19.993 - 19.999 (0.7871 - 0.7874)
Piston pin hole diameter
Grade No. 1 19.999 - 20.005 (0.7874 - 0.7876) N
Standard 0.010 - 0.030 (0.0004 - 0.0012)
Piston to cylinder bore clearance
Limit 0.08 (0.0031)
O
PISTON RING
Unit: mm (in)
Items Standard Limit P
Top 0.040 - 0.080 (0.0016 - 0.0031) 0.11 (0.0043)
Side clearance 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.1 (0.004)
Oil ring 0.045 - 0.125 (0.0018 - 0.0049) —
EM-241
Top 0.23 - 0.33 (0.0091 - 0.0130) 0.54 (0.0213)
End gap 2nd 0.33 - 0.48 (0.0130 - 0.0189) 0.80 (0.0315)
Oil (rail ring) 0.20 - 0.45 (0.008 - 0.0177) 0.90 (0.0354)
PISTON PIN
Unit: mm (in)

Grade No. 0 19.989 - 19.995 (0.7870 - 0.7872) —
Piston pin outer diameter
Grade No. 1 19.995 - 20.001 (0.7872 - 0.7874) —
Piston to piston pin oil clearance 0.002 - 0.006 (0.0001 - 0.0002) —
Connecting rod bushing oil clearance 0.005 - 0.017 (0.0002 - 0.0007) 0.030 (0.0012)
CONNECTING ROD
Unit: mm (in)
Center distance 143.00 – 143.10 (5.63 – 5.63)
Bend [per 100 (3.94)] Limit 0.15 (0.0059)
Torsion [per 100 (3.94)] Limit 0.3 (0.012)
Grade No. 0 20.000 – 20.006 (0.7874 – 0.7876)
Connecting rod bushing inner diameter*
Grade No. 1 20.006 – 20.012 (0.7876 – 0.7879)
Standard 0.20 – 0.35 (0.008 – 0.0138)
Side clearance
Limit 0.5 (0.020)
Grade No. 0 48.000 – 48.001 (1.8898 – 1.8898)
Grade No. 1 48.001 – 48.002 (1.8898 – 1.8898)
Grade No. 2 48.002 – 48.003 (1.8898 – 1.8899)
Grade No. 3 48.003 – 48.004 (1.8899 – 1.8899)
Grade No. 4 48.004 – 48.005 (1.8899 – 1.8900)
Grade No. 5 48.005 – 48.006 (1.8900 – 1.8900)
Connecting rod big end diameter Grade No. 6 48.006 – 48.007 (1.8900 – 1.8900)
Grade No. 7 48.007 – 48.008 (1.8900 – 1.8901)
Grade No. 8 48.008 – 48.009 (1.8901 – 1.8901)
Grade No. 9 48.009 – 48.010 (1.8901 – 1.8902)
Grade No. A 48.010 – 48.011 (1.8902 – 1.8902)
Grade No. B 48.011 – 48.012 (1.8902 – 1.8902)
Grade No. C 48.012 – 48.013 (1.8902 – 1.8903)
*: After installing in connecting rod
CRANKSHAFT
Unit: mm (in)
SEM645 SBIA0535E
Center distance “r” 49.96 - 50.04 (1.9669 - 1.9701)

Out-of-round (Difference between “X” and “Y”) Limit 0.005 (0.0002)
Taper (Difference between “A” and “B”) Limit 0.005 (0.0002)
Runout [TIR*] Limit 0.05 (0.0020)
EM-242
Standard 0.10 - 0.26 (0.004 - 0.0102)
Crankshaft end play A
Limit 0.3 (0.012)
Grade No. A 44.974 - 44.973 (1.7706 - 1.7706)
Grade No. B 44.973 - 44.972 (1.7706 - 1.7705)
Grade No. C 44.972 - 44.971 (1.7705 - 1.7705) EM
Grade No. D 44.971 - 44.970 (1.7705 - 1.7705)
Grade No. E 44.970 - 44.969 (1.7705 - 1.7704)
Grade No. F 44.969 - 44.968 (1.7704 - 1.7704)
Grade No. G 44.968 - 44.967 (1.7704 - 1.7704)
C
Grade No. H 44.967 - 44.966 (1.7704 - 1.7703)
Grade No. J 44.966 - 44.965 (1.7703 - 1.7703)
Pin journal diameter grade. “Dp”
Grade No. K 44.965 - 44.964 (1.7703 - 1.7702) D
Grade No. L 44.964 - 44.963 (1.7702 - 1.7702)
Grade No. M 44.963 - 44.962 (1.7702 - 1.7702)
Grade No. N 44.962 - 44.961 (1.7702 - 1.7701)
Grade No. P 44.961 - 44.960 (1.7701 - 1.7701) E
Grade No. R 44.960 - 44.959 (1.7701 - 1.7700)
Grade No. S 44.959 - 44.958 (1.7700 - 1.7700)
Grade No. T 44.958 - 44.957 (1.7700 - 1.7700)
Grade No. U 44.957 - 44.956 (1.7700 - 1.7699) F
Grade No. A 54.979 - 54.978 (2.1645 - 2.1645)
Grade No. B 54.978 - 54.977 (2.1645 - 2.1644)
Grade No. C 54.977 - 54.976 (2.1644 - 2.1644) G
Grade No. D 54.976 - 54.975 (2.1644 - 2.1644)
Grade No. E 54.975 - 54.974 (2.1644 - 2.1643)
Grade No. F 54.974 - 54.973 (2.1643 - 2.1643)
Grade No. G 54.973 - 54.972 (2.1643 - 2.1642) H
Grade No. H 54.972 - 54.971 (2.1642 - 2.1642)
Grade No. J 54.971 - 54.970 (2.1642 - 2.1642)
Grade No. K 54.970 - 54.969 (2.1642 - 2.1641)
Grade No. L 54.969 - 54.968 (2.1641 - 2.1641) I
Grade No. M 54.968 - 54.967 (2.1641 - 2.1641)
Main journal diameter grade. “Dm”
Grade No. N 54.967 - 54.966 (2.1641 - 2.1640)
Grade No. P 54.966 - 54.965 (2.1640 - 2.1640)
Grade No. R 54.965 - 54.964 (2.1640 - 2.1639)
J
Grade No. S 54.964 - 54.963 (2.1639 - 2.1639)
Grade No. T 54.963 - 54.962 (2.1639 - 2.1639)
Grade No. U 54.962 - 54.961 (2.1639 - 2.1638) K
Grade No. V 54.961 - 54.960 (2.1638 - 2.1638)
Grade No. W 54.960 - 54.959 (2.1638 - 2.1637)
Grade No. X 54.959 - 54.958 (2.1637 - 2.1637)
Grade No. Y 54.958 - 54.957 (2.1637 - 2.1637) L
Grade No. 4 54.957 - 54.956 (2.1637 - 2.1636)
Grade No. 7 54.956 - 54.955 (2.1636 - 2.1636)
*: Total indicator reading
M
MAIN BEARING N
EM-243
Unit: mm (in)
SEM685D
Grade number Thickness Identification color Remarks

0 1.973 - 1.976 (0.0777 - 0.0778) Black
1 1.976 - 1.979 (0.0778 - 0.0779) Brown
2 1.979 - 1.982 (0.0779 - 0.0780) Green
3 1.982 - 1.985 (0.0780 - 0.0781) Yellow Grade and color are the same
4 1.985 - 1.988 (0.0781 - 0.0783) Blue for upper and lower bearings.
5 1.988 - 1.991 (0.0783 - 0.0784) Pink

6 1.991 - 1.994 (0.0784 - 0.0785) Purple
7 1.994 - 1.997 (0.0785 - 0.0786) White
UPR 1.973 - 1.976 (0.0777 - 0.0778) Black
01
LWR 1.976 - 1.979 (0.0778 - 0.0779) Brown
UPR 1.976 - 1.979 (0.0778 - 0.0779) Brown
12
LWR 1.979 - 1.982 (0.0779 - 0.0780) Green
UPR 1.979 - 1.982 (0.0779 - 0.0780) Green
23
LWR 1.982 - 1.985 (0.0780 - 0.0781) Yellow
Grade and color are different
UPR 1.982 - 1.985 (0.0780 - 0.0781) Yellow for upper and lower bearings.
34
LWR 1.985 - 1.988 (0.0781 - 0.0783) Blue
UPR 1.985 - 1.988 (0.0781 - 0.0783) Blue
45
LWR 1.988 - 1.991 (0.0783 - 0.0784) Pink
UPR 1.988 - 1.991 (0.0783 - 0.0784) Pink
56
LWR 1.991 - 1.994 (0.0784 - 0.0785) Purple
UPR 1.991 - 1.994 (0.0784 - 0.0785) Purple
67
LWR 1.994 - 1.997 (0.0785 - 0.0786) White
UNDERSIZE
Unit: mm (in)
Items Thickness Main journal diameter

0.25 (0.0098) 2.106 - 2.114 (0.0829 - 0.0832) Grind so that bearing clearance is the specified value.

Unit: mm (in)
No. 1, 3 and 5 0.012 - 0.022 (0.0005 - 0.0009)

Standard
Main bearing oil clearance No. 2 and 4 0.018 - 0.028 (0.0007 - 0.0011)
Limit 0.1 (0.004)
CONNECTING ROD BEARING
EM-244
Unit: mm (in)
Grade number Thickness Identification color Remarks A

0 1.493 - 1.496 (0.0588 - 0.0589) Black
1 1.496 - 1.499 (0.0589 - 0.0590) Brown
Grade and color are the same EM
2 1.499 - 1.502 (0.0590 - 0.0591) Green
for upper and lower bearings.
3 1.502 - 1.505 (0.0591 - 0.0593) Yellow
4 1.505 - 1.508 (0.0593 - 0.0594) Blue C
UPR 1.493 - 1.496 (0.0588 - 0.0589) Black
01
LWR 1.496 - 1.499 (0.0589 - 0.0590) Brown
D
UPR 1.496 - 1.499 (0.0589 - 0.0590) Brown
12 Grade and color are different
LWR 1.499 - 1.502 (0.0590 - 0.0591) Green for upper and lower bearings.
UPR 1.499 - 1.502 (0.0590 - 0.0591) Green E
23
LWR 1.502 - 1.505 (0.0591 - 0.0593) Yellow
UPR 1.502 - 1.505 (0.0591 - 0.0593) Yellow
34 F
LWR 1.505 - 1.508 (0.0593 - 0.0594) Blue
UNDERSIZE
Unit: mm (in)
G
Items Thickness Crank pin journal diameter
0.25 (0.0098) 1.622 - 1.630 (0.0639 - 0.0642) Grind so that bearing clearance is the specified value.
H
Unit: mm (in)
Items Standard Limit I

Connecting rod bearing oil clearance 0.035 - 0.045 (0.0014 - 0.0018) 0.1 (0.004)
EM-245
< SYMPTOM DIAGNOSIS > [M9R]
SYMPTOM DIAGNOSIS
NVH Troubleshooting - Engine Noise INFOID:0000000001160590
JPBIA0854GB
EM-246
Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000001160591
A
3. Specify the operating condition of engine. EM
If necessary, repair or replace these parts.
C
Location Type of Before After When Source of Refer-
When When While Check item D
of noise noise warm- warm- start- noise ence page
up up ing
Hydraulic
Ticking or E
Top of en- A C — B B — tappet Out of oil EM-323
clicking
gine noise
Cylinder Camshaft
head Camshaft journal oil
Rattle C A — A B C bearing EM-308 F
clearance
noise
Slap or Piston pin clearance
knock
— A — B B —
noise Connecting rod bushing
G
oil clearance
Crank- Piston to cylinder bore

shaft pul- clearance H
Slap or Piston
ley A — — B B A Piston ring side clear-
rap slap noise
Cylinder ance
block Piston ring end gap
I
(Side of Connect- Connecting rod bushing
engine) ing rod oil clearance
Oil pan Knock A B C B B B
bearing Connecting rod bearing
noise oil clearance J
Main bearing oil clear-
Main bear-
Knock A B — A B C ance
ing noise
Crankshaft runout K
Timing
chain and
engine Tapping or and wear
A A — B B B chain ten- EM-293
Front cov- ticking
sioner
Timing chain tensioner L
er operation
noise
Drive belt
Squeak- M
(Sticking
ing or fizz- A B — B — C Drive belt deflection
or slip-
ing EM-257
ping)
Front of
Drive belt Idler pulley bearing op- N
(Slipping) eration
Water
Squall
A B — B A B pump Water pump operation CO-87
Creak
noise
O
EM-247
PRECAUTIONS
< PRECAUTION > [M9R]
PRECAUTION
PRECAUTIONS
PIIB3706J

INFOID:0000000001298309
NOTE:
TEM).
OPERATION PROCEDURE
NOTE:
rotated.
Precaution for Drain Coolant INFOID:0000000001160592
Drain coolant when engine is cooled.

Precaution for Disconnecting Fuel Piping INFOID:0000000001160593
Precaution for Removal and Disassembly INFOID:0000000001160594
• When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid
forceful or uninstructed operations.
EM-248
PRECAUTIONS
• Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials. A
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
EM
Precaution for Inspection, Repair and Replacement INFOID:0000000001160595
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and C
Precaution for Assembly and Installation INFOID:0000000001160596
D
• Use torque wrench to tighten bolts or nuts to specified value.
E
do exactly same as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage. F
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, spread the oil on sliding surfaces well.
• Release air within route when refilling after draining coolant.
G
• After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for
leakage.
Parts Requiring Angular Tightening INFOID:0000000001160597
H
• Use an angle wrench for the final tightening of the following engine parts.
- Main bearing cap bolts I
- Timing sprocket bolts
- Crankshaft pulley bolt
- Wear compensation gear bolt J
- Camshaft sprocket (for fuel pump) bolt
• Ensure thread and seat surfaces are clean and coated with engine oil. K
Precaution for Liquid Gasket INFOID:0000000001160598
L
REMOVAL OF LIQUID GASKET
face using the seal cutter [SST:KV10111100 ( — )] (A) and remove
M
old liquid gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces.
• Tap the seal cutter to insert it (B), and then slide it (C) by tapping N
on the side as shown in the figure.
• In areas where the seal cutter is difficult to use, use a plastic ham-
mer to lightly tap the parts, to remove it. O
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
JPBIA0052ZZ
screwdriver is used, be careful not to damage the mating sur-
faces. P
EM-249
PRECAUTIONS
1. Using a scraper (A), remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
• Remove the liquid gasket completely from the groove of the
gasket application surface, mounting bolts and bolt holes.
2. Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
JPBIA0053ZZ
3. Attach the liquid gasket to the tube presser (commercial service

tool).
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
• If there is a groove for the liquid gasket application, apply the
EMA0622D
• As for the bolt holes, normally apply the gasket inside the
holes. If specified, it should be applied outside the holes.
Check to read the instruction in this manual.
A : Groove
B : Bolt hole
: Inside
• Within five minutes of gasket application, install the mating

component.
• If the liquid gasket protrudes, wipe it off immediately. JPBIA0010ZZ
• Do not retighten after the installation.
• After 30 minutes or more have passed from the installation, fill the engine oil and coolant.
CAUTION:
If there are instructions in this manual, observe them.
Precaution for Diesel Equipment INFOID:0000000001160599
CLEANLINESS
CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRES-
SURE DIRECT INJECTION SYSTEM
Risks relating to contamination
The system is very sensitive to contamination. The risks caused by the introduction of contamination are:
• Damage or destruction of the high pressure injection system and the engine
• Seizing or leaking of a component
All After-Sales operations must be performed under very clean conditions. This means that no impurities (par-
ticles a few microns in size) get into the system during dismantling or into the circuits via the fuel unions.
The cleanliness principle must be applied from the fuel filter to the fuel injectors.
WHAT ARE THE SOURCES OF CONTAMINATION?
Contamination is caused by:
• Metal or plastic chips
• Paint
• Fibers:
- Boxes
- Brushes
EM-250
PRECAUTIONS
- Paper
- Clothing A
- Cloths
• Foreign bodies such as hair
• Ambient air
EM
• Etc.
WARNING:
It is not possible to clean the engine using a high pressure fuel pump because of the risk of damaging
connections. In addition, moisture may collect in the connectors and create electrical connection mal- C
functions
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYS-
TEM D
• Check that you have the plugs for the unions to be opened (bag of plugs sold at the Parts Stores - Nissan
part No. 16609 00Q0A, Renault part No. 77 01 209 062). Plugs are to be used once only. After use, they
must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable).
Unused plugs must be thrown away. E
• Check that you have hermetically resealable plastic bags for storing removed parts. Stored parts will there-
fore be less subject to the risk of impurities. The bags must be used only once, and after use they must be
thrown away. F
• Lint-free towelettes to be used for fuel pump related service purpose. The use of a normal cloth or paper for
cleaning purposes is forbidden. These are not lint-free and may contaminate the fuel circuit of the system.
Each lint-free cloth should only be used once.
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT G
• For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle.
• For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).
• Use a brush and thinners to clean the connections to be opened. H
• Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and
injection system zone). Check that no bristles remain adhered.
• Wash your hands before and during the operation if necessary.
I
• When wearing leather protective gloves, cover these with latex gloves.
INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION
• As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system.
The plugs to be used are available from the Parts Stores - Nissan part No. 16609 00Q0A, Renault part No. J
77 01 209 062. They must not, under any circumstances, be reused.
• Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries con-
tamination. K
• All components of the injection system that are removed must be stored in a hermetically sealed plastic bag
once the plugs have been inserted.
• The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been
opened. These items are likely to allow impurities to enter the system. L
• A new component replacing an old one must not be removed from its packaging until it is to be fitted to the
vehicle.
Instructions for Fitting the Plugs M
Nissan part No. 16609 00Q0A
EM-251
PRECAUTIONS
(Renault part No. 77 01 209 062)
JPBIA0585ZZ
SPECIAL FEATURES
CAUTION:
• The engine must not operate with:
- Use diesel fuel required by the regulations for cetane number. Refer to GI-32, "FUEL : Diesel Engine
Fuel".
- Petrol, even in tiny quantities
EM-252
PRECAUTIONS
• Before carrying out any work, check that the fuel rail is not under pressure and that the fuel temper-
ature is not too high. [The system can inject the diesel into the engine at a pressure up to 160,000 A
kPa (1,600 bar, 1,632 kg/cm2, 23,200 psi)].
• Respect the cleaning and safety advice specified in this document for any work on the high pressure
injection system. EM
• Remove of the interior of the fuel pump and fuel injectors is prohibited.
• For safety reasons, it is strictly forbidden to slacken an injection tube union when the engine is run-
ning.
• It is not possible to remove the fuel pressure sensor from the fuel rail because this may cause circuit C
contamination malfunctions. If the fuel pressure sensor fails, the fuel pressure sensor, the fuel rail
and the fuel injection tubes must be replaced.
• It is strictly forbidden to remove the fuel pump pulley. D
• Applying 12 volts directly to any component in the system is prohibited.
• Ultrasonic carbon removal and cleaning are prohibited.
• Never start the engine without the battery being connected correctly.
CHECKING SEALING AFTER REPAIR E
CAUTION:
After any operation, check that there is no diesel leakage.
• Start the engine and check for fuel leak for one minute after starting. F
• Apply tracing fluid around the high pressure connections of the pipe that has been replaced.
• Once the engine coolant temperature is above 50°C (122F) and provided there are no malfunctions present,
carry out a road test, taking the engine speed up to 4,000 rpm at least once to check that there is no leak-
age. G
• Perform a visual inspection after the road test to check that there is no high pressure leakage.
• Clean off the tracing fluid.
H
EM-253
PREPARATION
< PREPARATION > [M9R]
PREPARATION
PREPARATION
NISSAN tool number

(RENAULT tool No.) Description
Tool name
( — )
NT044
KV10111100 Removing oil pan and front cover. etc

( — )
Seal cutter
NT046
KV10112100 Tightening bolts for bearing cap, cylinder

( — ) head, etc. in angle
Angle wrench
NT014
KV10114400 Loosening or tightening air fuel ratio sensor

( — ) a: 22 mm (0.87 in)
Heated oxygen sensor wrench
JPBIA0397ZZ
— To lock engine at TDC

(Mot. 1766)
TDC set pin
JPBIA0629ZZ
— To lock camshaft when changing timing chain

(Mot. 1769)
Camshaft timing tool
JPBIA0628ZZ
EM-254
PREPARATION
NISSAN tool number
(RENAULT tool No.) Description A
Tool name
— To lock crankshaft pulley
(Mot. 1770) EM
Crankshaft pulley locking tool
JPBIA0630ZZ
— Connecting compression gauge and glow D

(Mot. 1772) plug hole
Compression gauge adapter
E
JPBIA0626ZZ F
— To position the gear and apply for the right
(Mot. 1773) clearance (wear compensation gear)
Positioning tool G
H
JPBIA0625ZZ
Commercial Service Tools INFOID:0000000001160602 I
NISSAN tool number

J
Tool name
KV113B0040 Gauge stand used with KV113B0050 (Mot.
(Mot. 251-01) 252-01) K
Dial indicator stand set
MBIB0360E
M
KV113B0050 Thrust plate for measuring the protrusion of
(Mot. 252-01) piston used with KV113B0040 (Mot. 251-01)
Dial indicator stand set
N
O
MBIB0361E
KV113B0090 Tool for removing valve oil seals

(Mot. 1335)
Valve seal remover P
MBIB0370E
EM-255
PREPARATION
NISSAN tool number
Tool name
KV113B0180 Tool for installing valve oil seals
(Mot. 1511-01)
Valve seal drift
MBIB0378E
KV113B0200 Cylinder head and cylinder head housing sup-

(Mot. 1573) port
Cylinder head stand
MBIB0380E
NT052
Valve spring compressor Disassembling valve mechanism
JPBIA0770ZZ
Manual lift table caddy Removing and installing engine
ZZA1210D
NT030
EM-256
DRIVE BELTS
< ON-VEHICLE MAINTENANCE > [M9R]
DRIVE BELTS
EM
G
JPBIA0649ZZ
1. Water pump 2. Crankshaft pulley 3. Drive belt auto-tensioner

4. Drive belt 5. A/C compressor 6. Alternator
H
7. Idler pulley
A. Range when new drive belt is installed B. Possible use range C. Indicator
D. View
I
J
WARNING:
Be sure to perform this step when the engine is stopped.
• Check that the indicator (C) (notch on fixed side) of drive belt auto-tensioner is within the possible use range K
(B).
NOTE:
• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (A) in the fig- L
ure.
• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt. M
CAUTION:
Drive belt auto-tensioner and idler pulley must be replaced with new ones when the drive belt is
replaced.
N
Refer to EM-329, "Drive Belts".

O
CAUTION: P
• Replace the drive belt that has been removed with a new one.
• Drive belt auto-tensioner and idler pulley must be replaced with new ones when the drive belt is
replaced.
• Never run the engine without the drive belt to avoid damaging the crankshaft pulley.
REMOVAL
EM-257
DRIVE BELTS
2. Hold the TORX part of drive belt auto-tensioner pulley with a
TORX socket (A) securely. Then move the wrench handle in the
direction of arrow (loosening direction of tensioner).
CAUTION:
Never place hand in a location where pinching may occur if
the holding tool accidentally comes off.
JPBIA0662ZZ
3. Insert a stopper pin (A) in diameter such as short-length screw-

driver into the hole of the retaining boss to fix drive belt auto-ten-
sioner pulley.
• Keep drive belt auto-tensioner pulley arm locked after drive
belt is removed.
NOTE:
stopper pin.
JPBIA0661ZZ
4. Remove drive belt.

INSTALLATION
1. Install drive belt.
CAUTION:
• Check that drive belt is completely set to pulleys.
pulley groove.
2. Release drive belt auto-tensioner, and apply tension to drive belt.
4. Check that the indicator (notch on fixed side) of drive belt auto-tensioner is within the range when new
drive belt is installed. Refer to EM-257, "Checking".
EM-258
AIR CLEANER FILTER
AIR CLEANER FILTER
A
REMOVAL EM
1. Unhook clips (A) and remove holder (2) from air cleaner case
(1).
C
E
JPBIA0464ZZ
2. Remove air cleaner filter (1) from air cleaner case (2). F
JPBIA0465ZZ I
INSTALLATION
Install in the reverse order of removal.
J
EM-259
1. Warm up engine thoroughly. Then stop it.

2. Disconnect the battery cable from the negative terminal.
3. Remove glow plugs from all the cylinders.
CAUTION:
• Before removal, clean the surrounding area to prevent entry of any foreign materials into engine.
• Carefully remove glow plugs to prevent any damage or breakage.
• Handle with care to avoid applying any shock to glow plugs.
4. Disconnect fuel injector harness connectors to avoid fuel injection during measurement.
5. Install compression gauge (commercial service tool) with compression gauge adapter [SST: — (Mot.
1772)] to the hole for glow plug.
6. Turn ignition switch to START for cranking. When the gauge pointer stabilizes, read the compression
pressure and engine rpm. Perform these steps to check each cylinder.
Compression pressure : Refer to EM-329, "General Specification".

CAUTION:
Always use a fully-charged battery to obtain specified engine speed.
• When engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.
combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure compression pressure again.
• If some cylinder has low compression pressure, pour small amount of engine oil into the glow plug hole
- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check pis-
ton rings and replace if necessary.
• If two adjacent cylinders have respectively low compression pressure and their compression remain
slow even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cyl-
inder head gaskets.
8. Start the engine, and check that the engine runs smoothly.
9. Perform trouble diagnosis. If DTC appears, erase it. Refer to ECR-97, "Diagnosis Description".
EM-260
DRIVE BELT AUTO TENSIONER AND IDLER PULLEY
< ON-VEHICLE REPAIR > [M9R]
ON-VEHICLE REPAIR A
EM
JPBIA0650GB J
1. Harness bracket 2. Multifunction support bracket 3. Drive belt auto-tensioner

4. Cover 5. Idler pulley
K

L
CAUTION:
• Replace the drive belt that has been removed with a new one.
• Drive belt auto-tensioner and idler pulley must be replaced with new ones when the drive belt is M
replaced.
• Never run the engine without the drive belt to avoid damaging the crankshaft pulley.
REMOVAL N
1. Remove drive belt. Refer to EM-257, "Removal and Installation".
• Keep drive belt auto-tensioner pulley arm locked after drive belt is removed.
2. Remove drive belt auto-tensioner. O
3. Remove cover and idler pulley.
4. Remove multifunction support bracket with the following procedure:
a. Disconnect the battery cable from the negative terminal. P
b. Remove alternator. Refer to CHG-23, "M9R MODELS : Exploded View".
c. Remove A/C compressor with piping connected from the engine. Temporarily secure it on the vehicle side
with a rope to avoid putting load on it. Refer to HA-47, "M9R : Exploded View".
d. Remove multifunction support bracket.
EM-261
: Engine front
JPBIA0619ZZ
INSTALLATION
Multifunction support bracket
• Tighten mounting bolts in numerical order as shown in the figure.
: Engine front
JPBIA0619ZZ
EM-262
A
EM
J
JPBIA0773GB
1. Air cleaner filter 2. Holder 3. Retainer K

4. Air cleaner case 5. Mass air flow sensor 6. Clamp
7. Air duct assembly 8. Clamp 9. PCV hose
10. Air duct (inlet) 11. Grommet 12. Bracket L
A. To oil separator B. To turbocharger
M
REMOVAL N
2. Disconnect ECM harness connectors and remove ECM and ECM bracket. Refer to ECR-329, "General
Precautions". O
3. Remove engine cover. Refer to EM-265, "Exploded View".
5. Remove air duct (inlet). P
6. Remove air cleaner case/mass air flow sensor assembly and air duct assembly disconnecting their joints.
7. Remove mass air flow sensor from air cleaner case, if necessary.
CAUTION:
EM-263
• Never touch mass air flow sensor.
INSTALLATION

Inspect air duct assembly for crack or tear.
• If anything found, replace air duct assembly.
EM-264
ENGINE COVER
ENGINE COVER
A
EM
G
JPBIA0814GB
1. Engine cover 2. Air inlet tube cover 3. Mounting rubber (brown)

4. Mounting rubber (black) 5. Fuel injection cover
H
Removal and Installation INFOID:0000000001301420 I
REMOVAL
1. Remove engine cover. J
CAUTION:
• Never damage or scratch cover when installing or removing.
• When detaching, hold the engine cover nearby the fixing point, and remove the pins one by one. K
2. Remove air inlet hose and air inlet tube. Refer to EM-266, "Exploded View".
3. Move aside harness located above fuel injection cover.
4. Remove fuel injection cover and air inlet tube cover. L
INSTALLATION
CAUTION: M
When installing, push the engine cover at the position on the pins.
EM-265
CHARGE AIR COOLER
CHARGE AIR COOLER
JPBIA0735GB
1. Bracket 2. Air inlet tube 3. Clamp

4. Air inlet hose 5. Air inlet tube 6. Gasket
7. Charge air cooler 8. Mounting rubber 9. Gasket
10. Air inlet tube 11. Air inlet hose 12. Air inlet tube
13 Air inlet tube bracket 14. Air inlet hose 15. Air inlet tube
16. Clip
A. To electric throttle control actuator B. To turbocharger
REMOVAL
2. Remove air duct (inlet). Refer to EM-263, "Exploded View".
3. Remove air inlet hoses and air inlet tubes.
CAUTION:
When removing air inlet hose and air inlet tube, close opening on turbocharger and electric throt-
tle control actuator with shop cloth or other suitable material.
4. Remove front bumper. Refer to EXT-12, "Exploded View".
5. Remove charge air cooler.
INSTALLATION
EM-266
CHARGE AIR COOLER
• Apply a neutral detergent (fluid) to the joint between air inlet hoses and air inlet tubes (oil is not permissible). A
EM
1. Check that the charge air cooler is not full of oil. In that case, clean it with cleaning agent and then let it
dry. C
2. Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler if necessary.
• Do not deform core fins. D
• For cleaning procedure of charge air cooler core, refer to CO-71, "RADIATOR : Inspection".
EM-267
EGR SYSTEM
EGR SYSTEM
JPBIA0657GB
1. Gasket 2. EGR volume control valve 3. Gasket

4. EGR tube (front) 5. Gasket 6. Water hose
7. Clamp 8. EGR cooler tube 9. Clamp
10. Gasket 11. EGR tube (rear) 12. EGR tube insulator
EGR cooler bypass valve control sole-
13. Vacuum hose 14. 15. Bracket
noid valve
16. Engine slinger (rear)
A. To intake manifold B. To turbocharger boost sensor housing C. To water suction pipe
D. To water pipe E. To exhaust manifold F. To vacuum pump
REMOVAL
1. Drain engine coolant. Refer to LU-29, "Draining".
CAUTION:
Perform this step when the engine is cold.
EM-268
EGR SYSTEM
3. Remove electric throttle control actuator and turbocharger boost sensor housing. Refer to EM-270, A
"Exploded View".
4. Disconnect water hoses from EGR cooler tube.
5. Remove EGR tube (front) and EGR volume control valve assembly. EM
CAUTION:
• Handle carefully to avoid any shock to EGR volume control valve.
• Never disassemble EGR volume control valve. C
• Cover engine openings to avoid entry of foreign materials.
6. Remove EGR tube (front) from EGR volume control valve.
7. Remove EGR cooler bypass valve control solenoid valve and vacuum hose. D
8. Remove EGR tube insulator.
9. Remove water outlet and thermostat assembly. Refer to CO-83, "Exploded View"
10. Remove water pipe, bracket and heater pipe. Refer to CO-83, "Exploded View" E
11. Remove EGR tube (rear).
12. Remove starter motor. Refer to STR-22, "M9R MODELS : Exploded View".
F
13. Remove EGR cooler tube.
G
: Engine front
I
JPBIA0950ZZ
INSTALLATION J
CAUTION:
Clean each joint surface before installation.
K
EGR Cooler Tube
L
: Engine front
JPBIA0950ZZ
EGR Volume Control Valve O

Perform “EGR Volume Control Valve Closed Position Learning Value Clear” and “EGR Volume Control Valve
Closed Position Learning” after repair when removing or replacing EGR volume control valve. Refer to ECR-
15, "EGR VOLUME CONTROL VALVE CLOSED POSITION LEARNING VALUE CLEAR : Description" or P
ECR-15, "EGR VOLUME CONTROL VALVE CLOSED POSITION LEARNING : Description".
EM-269
INTAKE MANIFOLD
INTAKE MANIFOLD
JPBIA0658GB
1. Gasket 2. Intake manifold 3. Electric throttle control actuator stay

4. Electric throttle control actuator 5. Gasket 6. Turbocharger boost sensor
7. Turbocharger boost sensor housing 8. Gasket 9. EGR volume control valve
10. Gasket
A. Refer to EM-270
REMOVAL
3. Remove air inlet hose and air inlet tube. Refer to EM-266, "Exploded View".
4. Remove oil level gauge and oil level gauge guide.
5. Remove electric throttle control actuator stay.
6. Remove electric throttle control actuator.
CAUTION:
• Handle carefully to avoid any shock to electric throttle control actuator.
• Never disassemble electric throttle control actuator.
7. Remove turbocharger boost sensor and turbocharger boost sensor housing assembly.
CAUTION:
Handle carefully to avoid any shock to turbocharger boost sensor.
EM-270
INTAKE MANIFOLD
8. Loosen water pipe mounting bolts from intake manifold. Refer to CO-83, "Exploded View".
9. Remove EGR volume control valve and EGR tube (front) assembly. Refer to EM-268, "Removal and A
Installation".
CAUTION:
• Handle carefully to avoid any shock to EGR volume control valve. EM
• Never disassemble EGR volume control valve.
10. Remove multifunction support bracket. Refer to EM-261, "Exploded View".
11. Remove bracket from intake manifold. Refer to CO-83, "Exploded View". C
12. Remove intake manifold with the following procedure:
a. Loosen mounting bolts and nuts in reverse order as shown in
the figure. D
: Engine front
E
b. Remove intake manifold and gasket.
CAUTION:
F
JPBIA0603ZZ
G
INSTALLATION
CAUTION:
Clean each joint surface before installation. H
Intake Manifold
I
: Engine front
JPBIA0659ZZ
L
2. Install intake manifold.
• Tighten mounting bolts and nuts in two steps separately in
numerical order as shown in the figure. M
: Engine front
N
1st step: 15.0 N·m (1.5 kg-m, 11 ft-lb)

2nd step: 25.0 N·m (2.6 kg-m, 18 ft-lb) O
JPBIA0603ZZ
P
• Tighten mounting bolts of electric throttle control actuator equally and diagonally in several steps.
• Perform “Throttle Valve Closed Position Learning” and “Throttle Valve Closed Position Learning Value Clear”
after repair when removing or replacing electric throttle control actuator. Refer to ECR-16, "THROTTLE
VALVE CLOSED POSITION LEARNING VALUE CLEAR : Description" and ECR-16, "THROTTLE VALVE
CLOSED POSITION LEARNING : Description".
EM-271
INTAKE MANIFOLD

Surface Distortion
• Check the surface distortion of the intake manifold mating surface with a straightedge and a feeler gauge.
Standard : Refer to EM-329, "Intake Manifold".

• If it exceeds the standard, replace intake manifold.
EM-272
CATALYST
CATALYST
A
EM
L
JPBIA0651GB
1. Air fuel ratio sensor 2. Gasket 3. Turbocharger M

4. Catalyst support (upper) 5. Catalyst insulator 6. Bracket (2WD models)
7. Catalyst bracket 8. Gusset (4WD models) 9. Catalyst support (lower)
10. Catalyst N
A. To exhaust manifold B. To exhaust front tube
O
REMOVAL
P
2. Remove cowl top cover and extension cowl top. Refer to EXT-19, "Exploded View".
3. Disconnect air fuel ratio sensor harness connector.
EM-273
CATALYST
4. Remove air fuel ratio sensor (1) if necessary.
• Using heated oxygen sensor wrench [SST: KV10114400] (A),
remove air fuel ratio sensor.
CAUTION:
Be careful not to impact or damage air fuel ratio sensor.
JPBIA0866ZZ
5. Remove turbocharger insulator. Refer to EM-275, "Exploded View".

6. Loosen mounting nuts and remove stud bolts from turbocharger.
8. Remove right side drive shaft and support bearing bracket. Refer to FAX-26, "M9R : Exploded View"
9. Remove catalyst bracket.
10. Remove bracket (2WD models) or gusset (4WD models).
11. Remove catalyst insulator.
12. Remove catalyst support (upper).
13. Move catalyst in a rearward position of the vehicle to remove catalyst support (lower).
14. Remove mounting nut on the upper side of the stabilizer connecting rod. Refer to FSU-20, "Exploded
View".
15. Pull out catalyst from the right side of the vehicle.
INSTALLTION
Air Fuel Ratio Sensor
CAUTION:
• Before installing a air fuel ratio sensor, clean catalyst thread.
• When installing, never use such tools as an air impact wrench.

Start engine and raise engine speed to check no exhaust emission leaks.
EM-274
TURBOCHARGER
TURBOCHARGER
A
EM
L
JPBIA0655GB
1. Bracket 2. Exhaust gas temperature sensor 1 3. Vacuum hose M

4. Turbocharger boost control solenoid valve 5. Clamp 6. Water hose (M/T models)
7. Water hose 8. Turbocharger insulator 9. Water pipe
10. Water hose (A/T models) 11. Bracket 12. Clip N
13. Turbocharger cooling pump 14. Water hose 15. Water hose
16. O-ring 17. Gasket 18. Oil tube
19. Gasket 20. Exhaust gas pressure tube 21. Exhaust gas pressure sensor O
22. Clip 23. Water tube 24. Gasket
25. Water hose 26. Turbocharger
To EGR cooler bypass valve con- P
A. To heater pipe B. To vacuum pump C.
trol solenoid valve
D. To A/T fluid cooler E. To cylinder block F. To exhaust manifold
REMOVAL
EM-275
TURBOCHARGER
1. Drain engine coolant. Refer to LU-29, "Draining".
CAUTION:
2. Remove air inlet tube from turbocharger. Refer to EM-266, "Exploded View".
3. Remove air duct assembly. Refer to EM-263, "Exploded View".
4. Remove cowl top cover and extension cowl top. Refer to EXT-19, "Exploded View".
5. Disconnect vacuum hose from turbocharger.
6. Disconnect water hose from water tube of turbocharger.
8. Remove catalyst. Refer to EM-273, "Exploded View".
9. Remove oil tube from turbocharger.
10. Disconnect exhaust gas temperature sensor 1 harness connector.
11. Remove exhaust gas pressure sensor and exhaust gas pressure tube assembly.
CAUTION:
Be careful not to impact or damage exhaust gas pressure sensor.
12. Remove turbocharger from exhaust manifold.
CAUTION:
Never disassemble or adjust the turbocharger body.
13. Remove turbocharger cooling pump.
14. Remove exhaust gas temperature sensor 1, if necessary.
CAUTION:
Never remove exhaust gas temperature sensors except for replacing with new parts.
INSTALLTION
Exhaust Gas Temperature Sensor 1
CAUTION:
• Before installing a new exhaust gas temperature sensor, clean turbocharger thread.
• Be careful not to impact or damage exhaust gas temperature sensor 1.
• When installing, never use such tools as an air impact wrench.

Turbocharger
JPBIA0652ZZ
CAUTION:
When the compressor wheel, turbine wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary malfunction:
EM-276
TURBOCHARGER
Suction side: Between turbocharger and air cleaner A

Between turbocharger and charge air cleaner
Exhaust side: Between turbocharger and catalyst
EM
Between turbocharger and exhaust manifold
Turbocharger Boost Control
• Connect the handy vacuum pump (A) to the actuator, and check C
that the rod strokes smoothly in compliance with the following
pressure.
D
Standard (value of vacuum/value of rod moving):
Refer to EM-330, "Turbocharger".
E
JPBIA0665ZZ F
G
EM-277
EXHAUST MANIFOLD
EXHAUST MANIFOLD
JPBIA0654GB
1. Gasket 2. Spacer 3. Exhaust manifold

4. Gasket
A. To turbocharger B. Refer to EM-278 C. To EGR tube (rear)
REMOVAL
1. Drain engine coolant. Refer to CO-68, "Draining".
CAUTION:
2. Remove catalyst. Refer to EM-273, "Exploded View".
3. Remove turbocharger. Refer to EM-275, "Exploded View".
4. Remove air cleaner case. Refer to EM-263, "Exploded View".
5. Remove EGR tube (rear) from exhaust manifold. Refer to EM-268, "Exploded View".
6. Remove exhaust manifold and spacers.
EM-278
EXHAUST MANIFOLD
• Loosen mounting nuts in the reverse order as shown in the fig-
ure. A
: Engine front
EM
JPBIA0613ZZ
D
7. Remove gasket.
CAUTION:
E
INSTALLATION
F
: Engine front
JPBIA0653ZZ
I
2. Install exhaust manifold.
• Tighten the mounting nuts in two steps separately in numerical
order as shown in the figure.
J
: Engine front
K
L
2nd step: 30.0 N·m (3.1 kg-m, 22 ft-lb)
JPBIA0613ZZ
3. Install in the reverse order of removal, for the rest of parts. M
N
Surface Distortion
• Check the surface distortion of the exhaust manifold mating surface with a straightedge and a feeler gauge. O
Standard : Refer to EM-329, "Exhaust Manifold".

• If it exceeds the standard, replace exhaust manifold. P
EM-279
OIL PAN (LOWER) AND OIL STRAINER
JPBIA0644GB
1. Baffle plate 2. Oil pan (upper) 3. O-ring

4. Oil strainer 5. Oil pan drain plug 6. Gasket
7. Oil pan (lower)
REMOVAL
CAUTION:
a. Loosen mounting bolts in reverse order shown in the figure.
: Engine front
JPBIA0622ZZ
EM-280
b. Insert the seal cutter [SST:KV10111100 ( — )] (A) between oil
pan (upper) and oil pan (lower). Slide tool by tapping on the side A
of the tool with a hammer.
CAUTION:
• Be careful not to damage mating surface.
EM
• Never insert screwdriver, or oil pan flange will be
deformed.
JPBIA0276ZZ
D
c. Remove oil pan (lower).
4. Remove oil strainer.
• Loosen mounting bolts in the reverse order as shown in the E
figure.
: Engine front F
JPBIA0623ZZ H
INSTALLATION
1. Install oil strainer.
• Tighten mounting bolts in numerical order as shown in the fig- I
ure.
: Engine front J
L
JPBIA0623ZZ

a. Use a scraper (A) to remove old liquid gasket from mating sur- M
faces.
CAUTION:
N
JPBIA0025ZZ P
EM-281
b. Apply a continuous bead of liquid gasket with the tube presser
a : 3.0 - 7.0 mm (0.118 - 0.276 in)

: Engine front
Use Genuine Liquid Gasket or equivalent

CAUTION:
Attaching should be done within 5 minutes after coating.
JPBIA0648ZZ
c. Tighten mounting bolts in two steps separately in numerical

: Engine front

JPBIA0622ZZ

NOTE:
At least 30 minutes after oil pan is installed, pour engine oil.

Clean oil strainer if any object attached.
1. Check the engine oil level and adjust engine oil. Refer to LU-28, "Inspection".
2. Start engine, and check there is no leak of engine oil.
4. Check the engine oil level again. Refer to LU-28, "Inspection".
EM-282
GLOW PLUG
GLOW PLUG
A
EM
G
JPBIA0656GB
1. Glow plug
H
I
REMOVAL
CAUTION:
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken. J
3. Disconnect harness connector from glow plug. K
4. Remove glow plug.
CAUTION:
• When removing or installing, never use such tools as an air impact wrench. L
• Handle it carefully without giving any impact, even after removal.
INSTALLATION
1. Remove adhered carbon from glow plug installation hole with a reamer. M
2. Install glow plug.
N
EM-283
VACUUM PUMP
VACUUM PUMP
JPBIA0660GB
1. Vacuum hose 2. Vacuum hose 3. Vacuum pump

4. Gasket
To turbocharger boost control sole- To EGR cooler bypass valve control
A. To brake booster B. C.
noid valve solenoid valve
REMOVAL
3. Disconnect vacuum hoses.
4. Remove vacuum pump.
JPBIA0988GB
INSTALLATION
Vacuum pump
EM-284
VACUUM PUMP
CAUTION: A
Be sure to check that the vacuum pump is in contact with the
cylinder head before tightening the mounting bolts.
EM
JPBIA0988GB
EM-285
OIL SEPARATOR
OIL SEPARATOR
JPBIA0724GB
1. Oil separator insulator 2. Oil separator 3. Gasket

4. Gasket 5. PCV hose 6. Clamp
A. Refer to EM-286 B. To air duct assembly
REMOVAL
1. Remove engine cover and fuel injection cover. Refer to EM-265, "Exploded View".
2. Remove PCV hose.
3. Disconnect harness connector of fuel injector (No. 1).
4. Loosen oil separator insulator mounting bolts.
5. Remove oil separator.
EM-286
OIL SEPARATOR
• Loosen mounting bolts in the reverse order as shown in the
figure. A
: Engine front
EM
JPBIA0600ZZ
D
6. Remove oil separator insulator.
INSTALLATION
1. Install gaskets to oil separator. E
CAUTION:
Check the gasket is not dropped.
2. Install oil separator. F
• Tighten mounting bolts in two steps separately in numerical
G
: Engine front
1st step: 5.0 N·m (0.51 kg-m, 44 in-lb) H
2nd step: 10.0 N·m (1.0 kg-m, 89 in-lb) I

JPBIA0600ZZ

J
EM-287
INJECTION TUBE AND FUEL INJECTOR
JPBIA0722GB
1. Injection tube No.4 2. Injection tube No.3 3. Injection tube No.2

4. Injection tube No.1 5. Spill hose 6. Fuel injector support
7. O-ring 8. Fuel injector 9. Fuel injector spacer
10. Fuel rail seal 11. Fuel rail 12. Fuel hose
13. Fuel pump 14. Mounting rubber 15. Injection tube (center)
16. Diesel drain tube (lower) 17. Diesel drain hose 18. Diesel drain hose
19. Diesel drain tube (upper) 20. Diesel drain hose 21. Diesel collector
A. To fuel filter B. To cylinder head housing C. To centralized under-floor piping
REMOVAL
CAUTION:
• Be sure to read “Precautions for Diesel Equipment”. Refer to EM-250, "Precaution for Diesel Equip-
ment".
• Wait until the fuel temperature drops before carrying out any work.
• Order the special high pressure injection circuit plug kit.
• It is forbidden to open an fuel injector. If you open an fuel injector by mistake, you will have to
change it.
NOTE:
It is possible to replace a single injection tube.
1. Remove the battery. Refer to PG-133, "Exploded View".
EM-288
2. Remove oil separator. Refer to EM-286, "Exploded View".
3. Disconnect fuel hose from spill hose. A
• Pinch quick connector square-part with your fingers, and pull out the quick connector by hand.
4. Remove spill hose (1).
• Lift the movable sections of the injector unions away from the EM
spill hose.
JPBIA0601ZZ
E
5. Disconnect fuel hoses from fuel pump.
• Pinch quick connector square-part with your fingers, and pull out the quick connector by hand.
6. Remove diesel collector and injection tube (center). F
7. Remove injection tube (No. 1, 2, 3, 4).
• Put a paint mark or tag on injection tubes to identify each cylinder.
8. Remove fuel injectors with the following procedure: G
a. Remove fuel injector support.
b. Remove fuel injector. While rotating it to left and right, raise it to remove.
• If fuel injector spacer remains in cylinder head, hook it with tip of a flat-bladed screwdriver and pull it out. H
CAUTION:
• Handle fuel injector carefully without giving an impact.
• Never disassemble fuel injector.
I
9. Remove EGR volume control valve. Refer to EM-268, "Exploded View".
10. Remove fuel rail and fuel rail seal.
11. Plug all the holes in the injection circuit. J
12. Remove drain hose and diesel drain tube (upper and lower), if necessary.
INSTALLATION
K
1. Record “INJECTOR ADJUSTMENT VALUE” on the top surface when replacing fuel injector. Refer to
ECR-205, "Description".
L
JMBIA0556ZZ
O
Example: Injector adjustment value = 68HBLWH
2. Install fuel injector, injection tubes and fuel rail with the following procedure:
P
a. Install fuel injector spacer to fuel injector, and insert them into cylinder head.
CAUTION:
• Completely remove any foreign material among fuel injector and cylinder head.
EM-289
• Never mix ring (B) location. Upper location is mandatory.
1 :Fuel injector spacer

A :Fuel injector guide
JPBIA0984ZZ
b. Install fuel rail, fuel rail seal, injection tube (center) and mounting rubber (temporarily).
• Finger tighten until contact the injection tube nuts.
c. Install fuel injector support. Tighten mounting bolt (specified torque).
CAUTION:
Be sure to fit fuel injector support without looseness.
d. Install injection tube (No. 1, 2, 3, 4) in the original position (temporarily).
CAUTION:
Never put injection tubes under stress.
e. Tighten fuel rail mounting bolts and all injection tube nuts (specified torque).
3. Install spill hose onto fuel injectors.
• Align center to insert spill hose straightly into fuel injector.
• Before starting engine, bleed air from fuel piping. Refer to FL-17, "Air Bleeding".
NOTE:
Fill the fuel of at least 60 m (2.11 Imp fl oz).

• Input “INJECTOR ADJUSTMENT VALUE” to ECM after installing to the vehicle when replacing fuel injector.
Refer to ECR-205, "Description".
JMBIA0556ZZ
Example: Injector adjustment value = 68HBLWH
• Start the engine and check for fuel leak for one minute after starting.
CAUTION:
After any operation, check that there are no diesel leaks. Refer to EM-250, "Precaution for Diesel
Equipment".
EM-290
FUEL PUMP
FUEL PUMP
A
EM
I
JPBIA0985GB
1. Fuel pump J
A. Refer to EM-291
K
REMOVAL L
CAUTION:
• Be sure to read “Precautions for Diesel Equipment”. Refer to EM-250, "Precaution for Diesel Equip-
ment".
• Wait until the fuel temperature drops before carrying out any work. M
• Order the special high pressure injection circuit plug kit.
• Never disassemble or adjust the fuel pump body.
1. Remove the battery. Refer to PG-133, "Exploded View". N
2. Remove engine cover and fuel injection cover. Refer to EM-265, "Exploded View".
3. Remove air duct assembly and air cleaner case. Refer to EM-263, "Exploded View".
4. Remove diesel collector. Refer to EM-288, "Exploded View". O
5. Disconnect fuel hoses from fuel pump. Refer to EM-288, "Exploded View".
6. Remove the injection tube (center). Refer to EM-288, "Exploded View".
P
7. Plug all the holes of the injection circuit.
8. Remove the fuel pump.
EM-291
FUEL PUMP
• Loosen mounting bolts in the reverse order as shown in the
figure.
JPBIA0843ZZ
INSTALLATION
1. Install fuel pump.
CAUTION:
Be sure to check that the fuel pump is in contact with the cylinder head before tightening the
mounting bolts.
• Tighten mounting bolts in two steps separately in numerical
JPBIA0843ZZ
2. Install the injection tube (center) and mounting rubber. Refer to EM-288, "Exploded View".
• Before starting engine, bleed air from fuel piping. Refer to FL-17, "Air Bleeding".
NOTE:
Fill the fuel of at least 60 m (2.11 Imp fl oz).

• Start the engine and check for fuel leak for one minute after starting.
CAUTION:
After any operation, check that there are no diesel leaks. Refer to EM-250, "Precaution for Diesel
Equipment".
EM-292
TIMING CHAIN
TIMING CHAIN
A
EM
JPBIA0734GB
N
1. Timing chain slack guide 2. Timing chain tensioner 3. Engine mounting stay (front)
4. Engine mounting stay (rear) 5. Engine mounting bracket 6. Front cover
7. Front oil seal 8. Crankshaft pulley bolt 9. Crankshaft spacer O
10. Crankshaft pulley 11. Crankshaft sprocket 12. Timing chain
13. Oil pump drive chain 14. Oil pump 15. Oil pump baffle plate
16. Oil pump sprocket 17. Timing chain tension guide 18. Wear compensation gear spacer P
19. Wear compensation gear 20. Timing sprocket (rear) 21. Timing sprocket (front)
22. Timing sprocket spacer
NOTE:
EM-293
TIMING CHAIN
Oil pump related parts cannot be removed with an onboard condition. Refer to EM-320, "Removal and Instal-
lation".
REMOVAL
CAUTION:
Never turn the engine in the direction opposite to that of normal operation.
CAUTION:
3. Remove the following parts:
• Load wheel tire (RH)
• Fender protector (RH): Refer to EXT-21, "Exploded View".
• Fuel filter: Refer to FL-16, "Exploded View".
a. Set the crankshaft pulley locking tool [SST: — (Mot. 1770)] (A)
and loosen crankshaft pulley bolt.
JPBIA0730ZZ
b. Remove crankshaft pulley and spacer.

• Pull crankshaft pulley with both hands to remove it.
CAUTION:
Be careful not to damage front oil seal lip.
5. Remove front oil seal.
• Set logs of the service tool (A) the front oil seal notches. Turn
counterclockwise until it locks.
NOTE:
The service tool is supplied in the new front oil seal parts kit.
JPBIA0765ZZ
6. Remove the through bolt between lower torque rod and engine mounting bracket (rear), and hold the
engine mounting bracket (rear) with a transmission jack. Refer to EM-312, "Exploded View".
CAUTION:
Never hold the oil pan (lower).
7. Remove the upper torque rod and the engine mounting insulator (RH). Refer to EM-312, "Exploded View".
8. Remove engine mounting bracket and engine mounting stay (front and rear).
9. Remove water pump pulley. Refer to CO-86, "Exploded View".
EM-294
TIMING CHAIN
a. Loosen mounting bolts in the reverse of the order shown in the
figure. A
EM
G
JPBIA0772ZZ
b. Use the seal cutter [SST: KV10111100 ( — )] to cut liquid gasket for removal.
CAUTION: H
Never use a screwdriver or something similar.
NOTE:
Unstick the front cover by hand, using a jerking motion to ensure it is not damaged. I
11. Obtain No. 1 cylinder at TDC of its compression. Rotate crankshaft to set it in the position shown in the fig-
ure.
• Parallelize the groove of camshaft (right side) to face the offset J
side upward.
• Fit the matching mark (B) of wear compensation gear (1) and
boss (A) of cylinder head housing.
K
JPBIA0844ZZ
M
12. Remove the timing chain with the following procedure:
a. Set the camshaft timing tool [SST: — (Mot.1769)] (A), and
tighten mounting bolt [M6 × 50 mm (1.97 in)] (B). N
b. Loosen timing sprocket mounting bolts (C) and wear compensa-
tion gear mounting bolt (D).
O
c. Remove the camshaft timing tool.
JPBIA0728ZZ
d. Remove the timing chain tensioner.
EM-295
TIMING CHAIN
• Compress the timing chain tensioner (1) with timing chain
slack guide (2), and then insert a stopper pin (A) into hole on
timing chain tensioner.
NOTE:
stopper pin
JPBIA0727ZZ
e. Remove timing chain slack guide and timing chain tension guide.
f. Remove timing sprocket spacer, timing sprocket (front), crankshaft sprocket and timing chain.
CAUTION:
Never rotate crankshaft or camshaft while timing chain is removed. It causes interference between
valve and piston.
g. Insert a screwdriver (A) and lift it up to move the gear of wear
compensation gear (2).
NOTE:
To align two gear teeth of wear compensation gear.
h. Remove timing sprocket (rear) (1) under the condition shown in
Step “g”.
i. Remove wear compensation gear and spacer.
JPBIA0614ZZ
13. Remove oil pump related parts. Refer to EM-320, "Removal and Installation".
INSTALLATION
1. Obtain No.1 cylinder at TDC of its compression stroke with the following procedure:
a. Align the crankshaft groove (A) with the cylinder block hole (B).
NOTE:
This is for the purpose of preventing interferences of valve and
piston head.
JPBIA0610ZZ
b. Check that camshafts are located as shown in the figure.

• Parallelize the groove of camshaft (right side) (1) to face the
offset side upward.
• Fit the matching mark of camshaft (left side) (2) and boss of
cylinder head housing.
JPBIA0729ZZ
EM-296
TIMING CHAIN
c. Remove TDC pin plug (1).
A
EM
JPBIA0646ZZ
D
d. Screw in the TDC set pin [SST: — (Mot. 1766)] (A). Turn the
engine counterclockwise until the crankshaft touches the TDC
set pin.
E
: Engine front
G
JPBIA0615ZZ
2. Install wear compensation gear with the following procedure:

H
a. Set the wear compensation gear (1) on base plate of positioning
tool [SST: — (Mot. 1773)] (A).
I
K
JPBIA0766ZZ
b. Set the lever (B) in the lower gear teeth (A). Pivot the lever
counterclockwise until the two gear teeth are aligned. L
1 : Wear compensation gear

M
JPBIA0594ZZ
O
EM-297
TIMING CHAIN
c. Set a stopper pin (A) in the gear hole.
1 : Wear compensation gear

NOTE:
• Use approximately 4.0 mm (0.157 in) dia. hard metal pin as a
stopper pin
JPBIA0595ZZ
d. Install wear compensation gear (1) and wear compensation gear

spacer (2) to the camshaft (left side).
e. Align matching mark (B) on wear compensation gear and boss
(A) of cylinder head housing.
C : Stopper pin
f. Temporarily tighten mounting bolt.
JPBIA0616ZZ
3. Install timing sprocket (rear) with the following procedure:

a. Center the timing sprocket (rear) openings on the camshaft
(right side) hub mounting holes (A).
b. Set the timing sprocket (rear) fully onto the camshaft (right side)
hub.
c. Remove stopper pin (B).
JPBIA0607ZZ
EM-298
TIMING CHAIN
4. Install timing chain tension guide (2).
A
A : Matching mark
B : Matching mark (punched)
C : Matching mark (notched) EM
D : Matching mark
• Tighten timing chain tension guide mounting bolts in two steps.
C
D
5. Install timing sprocket (front) (1), crankshaft sprocket (4) and
timing chain (3). E
• Align matching marks on each sprocket and timing chain.
G
JPBIA0617ZZ
6. Install timing sprocket spacer (1) on the timing sprocket (front)

and temporarily tighten mounting bolt. H
• Allow the timing sprocket to rotate freely.
JPBIA0618ZZ
K
7. Install timing chain slack guide (2).
8. Install timing chain tensioner (1).
• Check that the timing chain tensioner makes contact with the L
cylinder block before tightening the bolts.
• Pull out stopper pin (A) after installing, and the release
plunger. M
N
JPBIA0727ZZ
9. Tighten mounting bolts (timing sprockets and wear compensation gear) with the following procedure: O
EM-299
TIMING CHAIN
a. Set the tool collet (A) of the timing adjustment tool [SST: —
(Mot. 1769)] (D) in the camshaft groove (right side).
C : Tool pin
b. Pivot the camshaft timing tool to align the axes of the spacer (B)
and the bolt hole.
JPBIA0598ZZ
c. Set tool pins (C) into the wear compensation gear holes.
d. Pivot the camshaft timing tool [SST: — (Mot. 1769)] (D) to align
the axes of the spacer (B) and the bolt hole.
e. Set the tool collet (A), without force, into the camshaft groove
(right side).
JPBIA0597ZZ
f. Set the mounting bolt [M6 × 50 mm (1.97 in)] (B) onto spacer of
the timing adjustment tool [SST: — (Mot. 1769)] (A).
g. Tighten timing sprocket mounting bolts (C).
: 10.0 N·m (1.0 kg-m, 7 ft-lb)

h. Turn 40 degrees clockwise (angle tightening).
i. Tighten wear compensation gear mounting bolt (D).
: 20.0 N·m (2.0 kg-m, 15 ft-lb) JPBIA0728ZZ
j. Turn 35 degrees clockwise (angle tightening).

CAUTION:
Check the tightening angle by using an angle wrench [SST: KV10112100 ( — )] or protractor. Never
judge by visual inspection without an angle wrench.
k. Remove timing adjustment tool.
10. Remove the TDC set pin [SST: — (Mot.1766)].
11. Apply liquid gasket to TDC pin plug, and tighten it.
Tightening torque : 25.0 N·m (2.6 kg-m, 18 ft-lb)

EM-300
TIMING CHAIN
a. Apply liquid gasket to the front cover side, referring to the appli-
cation point shown in the figure. A
A (upper side):
2.5 - 4.5 mm (0.098 - 0.177 in) in diameter EM
B (lower side):
3.0 - 7.0 mm (0.118 - 0.276 in) in diameter
C
C area:
9.0 - 13.0 mm (0.354 - 0.512 in) in diameter and
10.0 - 15.0 mm (0.394 - 0.591 in) long
D
NOTE:
Liquid gasket should be applied to the front cover side because E
the workspace is narrow.
G
JPBIA0590ZZ
b. Tighten mounting bolts in the following steps in numerical order

as shown in the figure. H
i. Tighten No. 1 to 23 in numerical order as shown.
• Apply liquid gasket to No. 23 bolt.
Use Genuine Liquid Gasket or equivalent. I
: 5.0 N·m (0.51 kg-m, 4 ft-lb)

J
ii. Tighten No. 1 to 22 in numerical order as shown.
: 16.0 N·m (1.6 kg-m, 12 ft-lb) K
iii. Tighten No. 23 bolt.

L
: 18.0 N·m (1.8 kg-m, 13 ft-lb)
• Refer to the following for the installation position of bolts.
M
M8: No. 23
M6: Except the above
N
JPBIA0772ZZ
13. Install front oil seal with the following procedure: O
EM-301
TIMING CHAIN
a. Fit the protector (A) to front oil seal (1).
• Align the front oil seal notches with front cover notches.
NOTE:
The protector is supplied in the new front oil seal parts kit.
JPBIA0778ZZ
b. Tighten to front oil seal (1) using service tool (A).

NOTE:
The service tool is supplied in the new front oil seal parts kit.
JPBIA0591ZZ
c. Remove the protector.

14. Install crankshaft pulley with the following procedure:
a. Secure crankshaft pulley with a crankshaft pulley locking tool
[SST: — (Mot. 1770)] (A).
JPBIA0730ZZ
b. Tighten crankshaft pulley bolt.
: 50.0 N·m (5.1 kg-m, 37 ft-lb)

c. Turn 85 degrees clockwise (angle tightening).
CAUTION:
Check the tightening angle by using an angle wrench [SST: KV10112100 ( — )] or protractor. Never
judge by visual inspection without an angle wrench.
d. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns
smoothly.
15. Install engine mounting bracket and engine mounting stay (front and rear) with the following procedure:
a. Temporarily tighten engine mounting bracket bolts.
b. Temporarily tighten engine mounting stay (front and rear) bolts.
EM-302
TIMING CHAIN
c. Tighten engine mounting stay (front and rear) bolts in numerical
order as shown in the figure. A
EM
JPBIA0775ZZ
D
d. Tighten engine mounting bracket bolts in numerical order as
E
G
JPBIA0774ZZ
H
INSPECTION AFTER INSTALLATION I

quantity, fill to the specified level. Refer to MA-22, "Fluids and Lubricants". J
• Run engine to check for unusual noise and vibration. K
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the L
Item Before starting engine Engine running After engine stopped
M
N
Exhaust gases — Leakage — O
EM-303
CAMSHAFT
CAMSHAFT
JPBIA0725GB
1. Camshaft position sensor 2. O-ring 3. Cylinder head housing

4. Timing sprocket spacer 5. Timing sprocket (front) 6. Timing sprocket (rear)
7. Wear compensation gear spacer 8. Wear compensation gear 9. Camshaft (right side)
10. Camshaft sprocket (for fuel pump) 11. Camshaft (left side) 12. Camshaft bracket
13. Camshaft bracket 14. Camshaft bracket 15. Camshaft bracket
Refer to GI-4, "Components" for symbols shown in the figure.
CAUTION:
• This engine has a different valve arrangement from normal DOHC 4-valve type engines. As both
camshafts on this engine have intake and exhaust camshafts.
• Refer to the figure for intake and exhaust valve arrangement.
(The camshafts have, alternately, either intake valve or an
exhaust valve.)
1. Camshaft (right side)

2. Camshaft (left side)
A. Intake cam
B. Exhaust cam
: Engine front
JPBIA0642ZZ
EM-304
CAMSHAFT
REMOVAL
1. Remove the following parts. A
• Oil separator: Refer to EM-286, "Exploded View".
• Fuel injector: Refer to EM-288, "Exploded View".
• Engine slinger (front side): Refer to EM-323, "Exploded View". EM
• Front cover and timing chain related parts: Refer to EM-293, "Exploded View".
• Fuel pump: Refer to EM-291, "Exploded View".
• Vacuum pump: Refer to EM-284, "Exploded View".
C
2. Remove camshaft position sensor.
CAUTION:
• Handle camshaft position sensor carefully and avoid impacts.
• Never disassemble camshaft position sensor. D
• Never place sensor where it is exposed to magnetism.
3. Remove cylinder head housing with the following procedure:
a. Loosen mounting bolts in reverse order as shown in the figure. E
JPBIA0596ZZ
M
: Engine front
b. Remove the cylinder head housing (1) using a flat-blade screw-

driver (A). N
B : Protective shim (suitable tool)
CAUTION: O
JPBIA0606ZZ
4. Remove camshafts with the following procedure:
EM-305
CAMSHAFT
a. Install cylinder head housing (1) to cylinder head stand [com-
mercial service tool: KV113B0200 (Mot.1573)] (A).
b. Loosen mounting bolts, and remove camshaft brackets and
camshafts.
• Mark camshafts and camshaft brackets so they are placed in
the same position and direction for installation.
JPBIA0641ZZ
5. Remove camshaft sprocket (for fuel pump) from camshaft (right side), if necessary.
INSTALLATION
1. When camshaft sprocket (for fuel pump) is removed, install it.
a. Tighten mounting bolt.
: 40.0 N·m (4.1 kg-m, 30 ft-lb)

b. Turn 34 degrees clockwise (angle tightening).
2. Install camshaft to cylinder head housing with the following procedure:
a. Clean camshaft journal to remove any foreign material.
b. Install camshafts.
c. Refer to the figure to install camshaft bracket in its original.
A. : Part marking ADM1

B. : Part marking ADM2
C. : Part marking ECH1
D. : Part marking ECH2
: Engine front
JPBIA0761ZZ
d. Tighten camshaft bracket mounting bolts.

• Finger tighten the camshaft bracket mounting bolts, until they just make contact.
3. Install cylinder head housing with the following procedure:
a. Align the crankshaft groove (A) with the cylinder block hole (B).
NOTE:
This is for the purpose of preventing interferences of valve and
piston head.
JPBIA0610ZZ
b. Remove foreign material completely from cylinder head housing backside and cylinder head installation
face.
EM-306
CAMSHAFT
c. Apply liquid gasket to cylinder head as shown in the figure.
A
a : 0.5 - 2.5 mm (0.020 - 0.098 in)
: Engine front
Use Genuine Liquid Gasket or equivalent. EM
JPBIA0609ZZ
D
d. Install so that camshafts are positioned in the directions shown
in the figure.
• Parallelize the groove of camshaft (right side) (1) to face the
E
offset side upward.
• Fit the groove of camshaft (left side) (2) and boss of cylinder
head housing.
F
G
JPBIA0729ZZ
e. Tighten mounting bolts of cylinder head housing in the following steps. H
O
JPBIA0596ZZ
: Engine front P
i. Tighten in order and successively, the cylinder head housing bolts No. 2, 7, 14 and 20 to gradually fit the
cylinder head housing on the cylinder head.
ii. Tighten the remaining bolts (temporarily).
iii. Loosen bolts No. 2, 7, 14 and 20.
iv. Tighten the bolts No. 2, 7, 14 and 20 (temporarily).
v. Tighten bolts in numerical order.
EM-307
CAMSHAFT
: 5.0 N·m (0.51 kg-m, 4 ft-lb)

vi. Tighten bolts in numerical order.
: 12.0 N·m (1.2 kg-m, 9 ft-lb)

CAUTION:
After tightening mounting bolts of cylinder head housing, be sure to wipe off excessive liquid gas-
ket from the mating surface of cylinder head.
4. Install timing chain and related parts. Refer to EM-294, "Removal and Installation".
5. Install in the reverse order of removal, for the rest of parts

Camshaft Journal oil clearance
CAMSHAFT JOURNAL
• Measure the camshaft journal with a micrometer (A).
JPBIA0122ZZ
CYLINDER HEAD HOUSING AND CAMSHAFT BRACKET INNER DIAMETER

• Measure the inner diameter (A) of cylinder head housing and cam-
shaft bracket with a bore gauge.
PBIC1645E

• (Oil clearance) = (Bracket inner diameter) – (Camshaft journal diameter)

• If it exceeds the standard, replace camshaft or/and cylinder head housing and cylinder head assembly.
NOTE:
Cylinder head housing cannot be replaced as a single part, because it is machined together with cylinder
head. Replace whole cylinder head housing and cylinder head assembly.
EM-308
CAMSHAFT
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including A
EM
C
Other oils and fluid* Level Leakage Level D
E
EM-309
OIL SEAL
OIL SEAL
FRONT OIL SEAL
REMOVAL
• Front fender protector (RH): Refer to EXT-19, "Exploded View".
2. Remove front oil seal using service tool (A).
NOTE:
The service tool is supplied in the new seal parts kit.
JPBIA0765ZZ
INSTALLATION
1. Install front oil seal with the following procedure:
a. Fit the protector (A) to front oil seal (1).
• Align the front oil seal notches with front cover notches.
NOTE:
The protector is supplied in the new seal parts kit.
JPBIA0778ZZ
b. Tighten to front oil seal (1) using service tool (A).
Tightening torque: Refer to EM-293, "Exploded View".

NOTE:
The service tool is supplied in the new seal parts kit.
JPBIA0591ZZ
c. Remove the protector.

REAR OIL SEAL
REMOVAL
EM-310
OIL SEAL
1. Remove transaxle assembly. Refer to TM-85, "Exploded View" (M/T models) or TM-351, "Exploded View"
(A/T models). A
2. Remove clutch cover and clutch disk (M/T models). Refer to CL-20, "M9R : Exploded View".
3. Remove drive plate (A/T models) or flywheel (M/T models).
4. Remove rear oil seal retainer. EM
INSTALLATION
1. Install rear oil seal retainer with the following procedure: C
a. Set guide bolt (A) and protector (B) to rear oil seal retainer (1).
NOTE:
The protector is supplied in the new seal parts kit. D
b. Move the rear oil seal retainer evenly by hand until it makes con-
tact with the cylinder block.
E
F
JPBIA0777ZZ
c. Remove guide bolts and protector.

G
d. Tighten mounting bolts in two steps separately in numerical
i. Tighten bolts No. 1and 5. H
: 5.0 N·m (0.51 kg-m, 44 in-lb)

I
ii. Tighten No. 1 to 8 in numerical order as shown.
: 10.0 N·m (1.0 kg-m, 89 in-lb) J

JPBIA0645ZZ

K
EM-311
ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION > [M9R]

ENGINE ASSEMBLY
JPBIA0731GB
1. Upper torque rod 2. Washer 3. Engine mounting insulator (RH)

Engine mounting bracket (LH)
4. Rear engine mounting bracket 5. Rear torque rod 6.
(M/T models)
Engine mounting bracket (LH)
7. 8. Engine mounting insulator (LH)
(A/T models)
A. A/T models
WARNING:
CAUTION:
EM-312
ENGINE ASSEMBLY
REMOVAL
A
Outline
saxle.
EM
Preparation
CAUTION: C
• Engine undercover D
• Road wheels tire (RH and LH): Refer to WT-4, "Road Wheel". E
• Air inlet tubes and air inlet hoses: Refer to EM-266, "Exploded View".
• Air duct (inlet) and air duct/air cleaner case assembly: Refer to EM-263, "Exploded View".
• Radiator hose (upper and lower) and cooling fan assembly: Refer to CO-73, "Exploded View". F
Engine Room LH
G
1. Remove ECM (1) and bracket (2) as a set.
2. Remove harness bracket (A) from engine mounting insulator
(LH). H
J
JPDIA0372ZZ
porarily secure the engine harness into the engine side. K
CAUTION:
4. Disconnect fuel hoses from fuel pump. Refer to EM-288, "Exploded View". L
5. Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to CO-83,
"Exploded View".
6. Disconnect control cable (A/T models) or shift cable/select cable (M/T models) from transaxle. Refer to M
TM-343, "Exploded View"(A/T models) or TM-21, "Exploded View" (M/T models).
7. Remove ground cable from transaxle side.
8. Disconnect vacuum hose from brake booster. Refer to EM-284, "Exploded View". N
Engine Room RH
1. Remove fuel filter. Refer to FL-16, "Exploded View". O
2. Remove ground cable.
3. Disconnect reservoir tank hose (lower) from water suction pipe. Refer to CO-73, "Exploded View".
4. Remove alternator. Refer to CHG-23, "M9R MODELS : Exploded View". P
5. Remove A/C compressor with piping connected from the engine. Temporarily secure it on the vehicle side
with a rope to avoid putting load on it. Refer to HA-47, "M9R : Exploded View".
Vehicle Underbody
EM-313
ENGINE ASSEMBLY
2. Remove brake caliper assembly with piping connected from steering knuckle. Temporarily secure it on the
View".
3. Remove two mounting bolts which fix steering knuckle and strut. Refer to FSU-20, "Exploded View".
5. Remove propeller shaft (4WD models). Refer to DLN-121, "Exploded View".
6. Remove drive shaft (LH and RH). Refer to FAX-26, "M9R : Exploded View" (2WD models) or FAX-68,
"M9R : Exploded View" (4WD models).
7. Remove stabilizer connecting rod mounting nut and cap at strut side (RH and LH). Refer to FSU-20,
"Exploded View".
8. Disconnect intermediate shaft to steering column assembly. Refer to ST-10, "Exploded View".
9. Remove turbocharger cooling pump and bracket assembly. Refer to EM-275, "Exploded View".
10. Remove differential exhaust pressure sensor and bracket assembly. Refer to EX-14, "Exploded View".
11. Disconnect clutch pipe. Refer to CL-14, "Exploded View".
View".
Removal
CAUTION:
PBIC1190E
2. Remove upper torque rod (1).
:Vehicle front
3. Remove three mounting bolts (A) on engine mounting insulator

(RH) (2).
4. Remove two mounting bolts (B) on engine mounting insulator
(LH) (3).
JPBIA0815ZZ
EM-314
ENGINE ASSEMBLY
observe the following caution. A
CAUTION:
EM
C
Separation
1. Set a hoist to engine slinger (rear side) (1) and engine slinger
(front side) (2).
D
: Engine front
JPBIA0719ZZ
2. Remove starter motor. Refer to STR-22, "M9R MODELS : Exploded View". G

3. Lift with a hoist and separate the engine from the transaxle assembly. Refer to TM-85, "Exploded View"
(M/T models) or TM-351, "Exploded View" (A/T models).
H
INSTALLATION
CAUTION:
• Never allow engine oil to get on engine mounting insulator. Be careful not to damage engine mount- I
ing insulator.
Preparation J
1. Install the engine mounting bracket (rear) to the engine with the
following procedure:
K
a. Tighten the bolt No. 1 as shown in the figure (temporarily).
ure (specified torque).
L
c. Tighten the bolt No. 1 as shown in the figure (specified torque).
JPBIA0717ZZ
2. Install the engine mounting bracket (LH) to the transaxle with the N
following procedure:
A : M/T models O
B : A/T models
: Vehicle front
a. Tighten the bolt No. 1 as shown in the figure (temporarily). P

ure (specified torque).
c. Tighten the bolt No. 1 as shown in the figure (specified torque). JPBIA0718ZZ
3. Install the engine mounting insulator (LH) to the body with the following procedure:
EM-315
ENGINE ASSEMBLY
:Vehicle front
b. Tighten the bolts in numerical order as shown in the figure

(specified torque).
JPBIA0716ZZ
4. Install the engine mounting insulator (RH) and upper torque rod to the body (temporarily).
Installation
1. Tighten the mounting bolt of rear torque rod (specified torque).
2. Install the engine mounting insulator (LH) to the transaxle side
with the following procedure:
:Vehicle front
a. Tighten the bolt No. 1 as shown in the figure (temporary).

b. Tighten the bolt No. 2 as shown in the figure (temporary).
c. Tighten the bolt No. 1 to the specified torque.
d. Tighten the bolt No. 2 to the specified torque.
JPBIA0811ZZ
3. Install the engine mounting insulator (RH) to the engine side.

:Vehicle front
b. Tighten the bolts in numerical order as shown in the figure

(specified torque).
JPBIA0715ZZ
4. Tighten mounting bolts of engine mounting insulator (RH) to the body (specified torque).
5. Tighten mounting bolts of upper torque rod (specified torque).
EM-316
ENGINE ASSEMBLY
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required A
EM
• Bleed air from lines and hoses of applicable lines, such as in cooling system. C
Summary of the inspection items: D
Engine oil Level Leakage Level E
F
G
EM-317
< DISASSEMBLY AND ASSEMBLY > [M9R]

NOTE:
type of engine stand, note with difference in steps and etc.
engine. Refer to EM-312, "Exploded View".
a. Remove flywheel (M/T models) or drive plate (A/T models).
• Secure crankshaft using a crankshaft pulley locking tool [SST: — (Mot.1770)], and remove mounting
bolts.
CAUTION:
Never disassemble them.
b. Lift the engine with a hoist to install it onto widely use engine stand.
CAUTION:
Use the engine stand that has a load capacity [approximately 225 kg (496 lb) or more] large
- Intake manifold: Refer to EM-270, "Exploded View".
- Oil separator: Refer to EM-286, "Exploded View".
NOTE:
models) or drive plate (A/T models) removed.
CAUTION:
PBIC3227J

CAUTION:
Be sure to clean drain plug and install with new gasket.
EM-318
ENGINE UNIT
ENGINE UNIT
A
1. Remove multifunction support bracket. Refer to EM-261, "Exploded View". EM

4. Remove oil pan (lower). Refer to EM-280, "Exploded View". C
5. Remove oil cooler. Refer to LU-31, "Exploded View".
6. Remove vacuum pump. Refer to EM-284, "Exploded View".
D
7. Remove fuel pump. Refer to EM-291, "Exploded View".
9. Remove cylinder head housing. Refer to EM-304, "Exploded View". E
10. Remove water suction pipe. Refer to CO-81, "Exploded View".
11. Remove water outlet and thermostat assembly. Refer to CO-83, "Exploded View".
F

G
EM-319
OIL PAN (UPPER)
OIL PAN (UPPER)
JPBIA0644GB
1. Baffle plate 2. Oil pan (upper) 3. O-ring

4. Oil strainer 5. Oil pan drain plug 6. Gasket
7. Oil pan (lower)
REMOVAL
1. Remove oil pan (lower) and oil strainer. Refer to EM-280, "Removal and Installation".
2. Remove rear oil seal retainer. Refer to EM-310, "REAR OIL SEAL : Removal and Installation".
: Engine front
JPBIA0602ZZ
EM-320
OIL PAN (UPPER)
b. Set two stud bolts (A), two washers (B) and two nuts (C) in place
of the oil pan (upper) mounting bolts. A
1 : Oil pan (upper)

2 : Cylinder block EM
NOTE:
Use M8 × 90 mm (3.54 in) long stud bolt.
c. Detach the oil pan (upper) from the cylinder block by gradually C
tightening the nuts. Remove oil pan (upper).
G
JPBIA0635ZZ
4. Remove oil pump related parts.

H
INSTALLATION
1. Install oil pump and oil pump baffle plate with the following procedure:
a. Install oil pump (1), oil pump baffle plate (2), oil pump drive chain I
and oil pump sprocket.
b. Tighten oil pump mounting bolts (A) in two steps.
J
K
c. Tighten oil pump baffle plate mounting bolt (B).
JPBIA0764ZZ L
: 8.0 N·m (0.82 kg-m, 71 in-lb)

2. Install oil pan (upper) with the following procedure: M
faces.
CAUTION: N
• Also remove old liquid gasket from mating surface of cylinder
block. O
P
JPBIA0027ZZ
EM-321
OIL PAN (UPPER)
b. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to areas shown in the figure.
a : 3.0 - 7.0 mm (0.118 - 0.276 in)

: Engine front
Use Genuine Liquid Gasket or equivalent

CAUTION:
• At the 5 bolt holes marked ( ), liquid gasket should be
applied inside holes.
• Attaching should be done within 5 minutes after coating. JPBIA0647ZZ
c. Tighten mounting bolts in two steps separately in numerical

: Engine front

JPBIA0602ZZ
3. Install rear oil seal retainer. Refer to EM-310, "REAR OIL SEAL : Removal and Installation".
NOTE:
At least 30 minutes after oil pan is installed, pour engine oil.
EM-322
CYLINDER HEAD
CYLINDER HEAD
A
EM
J
JPBIA0998GB
1. Valve collet 2. Valve spring retainer 3. Valve spring K

4. Valve oil seal 5. Hydraulic tappet 6. Engine slinger (front side)
7. Cylinder head 8. Valve 9. Cylinder head gasket
10. Engine slinger (rear side) 11. Cylinder head bolt L
A. Refer to EM-323
M
DISASSEMBLY N
• Turbocharger: Refer to EM-275, "Exploded View".
• Intake manifold: Refer to EM-270, "Exploded View". O
• Exhaust manifold: Refer to EM-278, "Exploded View".
• Water outlet and thermostat assembly: Refer to CO-83, "Exploded View".
• Front cover, timing chain: Refer to EM-293, "Exploded View".
• Cylinder head housing: Refer to EM-304, "Exploded View". P
EM-323
CYLINDER HEAD
2. Remove cylinder head.
: Engine front
JPBIA0605ZZ
3. Remove cylinder head gasket.

4. Set the cylinder head assembly to the cylinder head support [commercial service tool: KV113B0200
(Mot.1573)].
5. Remove hydraulic tappet.
CAUTION:
Be sure to immerse the hydraulic tappets in a bath of engine oil to ensure no air enters.
6. Remove valve collet (1).
• Compress valve spring with valve spring compressor (com-
mercial service too) (A).
JPBIA0643ZZ
7. Remove valve spring retainer and valve spring.

8. Check dimension of valve oil seal mounting position before removing valve and valve oil seal with the fol-
lowing procedure:
a. Install the push rod (A) of valve seal drift [commercial service
tool: KV113B0180 (Mot.1511-01)] on the valve oil seal.
NOTE:
The inner diameter of the push rod must be identical to that of
the valve. In addition, the bottom of the push rod must come into
contact with the metal upper section of the valve oil seal.
JPBIA0783ZZ
b. Install the guide tube (B) over the push rod (A) until the guide
tube comes into contact with the cylinder head, locking the push
rod with the knurled wheel.
• Remove the guide tube assembly plus push rod, being careful
not to loosen the knurled wheel.
JPBIA0790ZZ
EM-324
CYLINDER HEAD
10. Remove valve oil seal (1) with a valve oil seal puller [commercial A
service tool: KV113B0090 (Mot.1335)] (A).
EM
JPBIA0663ZZ
D
ASSEMBLY
E
1. Install valve.
NOTE:
Install larger diameter to intake side.
2. Install valve oil seal with the following procedure: F
a. Position the protector (A) of valve seal drift [commercial service
tool: KV113B0180 (Mot.1511-01)] on the valve.
G
I
JPBIA0714ZZ
b. Position a valve oil seal on the protector. Move the valve oil seal past the protector. J
CAUTION:
Never lubricate valve oil seal.
c. Remove the protector. K
d. Push in the push rod (A) of valve seal drift [commercial service
tool: KV113B0180 (Mot. 1511-01)] with palm of the hand until the
guide tube (B) makes contact with the cylinder head. L
N
JPBIA0790ZZ
3. Install valve spring. O

NOTE:
The intake and exhaust valve springs are identical.
P
5. Install valve collet (1).
EM-325
CYLINDER HEAD
• Compress valve spring with a valve spring compressor (com-
mercial service tool) (A).
lation to check its installed condition.
JPBIA0643ZZ
6. Install hydraulic tappet.

• Check that the tappets are filled with oil before refitting them.
7. Install cylinder head gasket with the following procedure:
CAUTION:
Before installing cylinder head, inspect piston protrusion.
a. Apply liquid gasket to position (A) shown in the figure.
: Engine front
JPBIA0612ZZ
b. Install cylinder head gasket (1), and apply liquid gasket to posi-
tion (A) shown in the figure.
: Engine front
JPBIA0611ZZ
8. Install cylinder head, and tighten mounting bolts in numerical

order as shown in figure with the following procedure:
: Engine front
a. Tighten all bolts.
: 5.0 N·m (0.51 kg-m, 4 ft-lb)

b. Tighten all bolts.
JPBIA0605ZZ
: 30.0 N·m (3.1 kg-m, 22 ft-lb)
EM-326
CYLINDER HEAD
CAUTION: A
wrench [SST: KV10112100 ( — )] (A) or protractor. Never
judge by visual inspection without the tool.
EM
JPBIA0867ZZ
D
9. Assemble in the reverse order of disassembly, for the rest of parts.
E
Cylinder Head Distortion F
NOTE:
When performing this inspection, cylinder block distortion should be also checked.
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.
G
CAUTION:
Never allow gasket debris to enter passages for engine oil or water.
measure the distortion in six directions (A - F). H
Standard: Refer to EM-330, "Cylinder Head".

I
• If it exceeds the standard, replace cylinder head and cylinder
head housing.
NOTE:
Cylinder head cannot be replaced as a single part, because it is J
machined together with cylinder head housing. Replace whole
cylinder head housing and cylinder head assembly.
JPBIA0176ZZ
K
VALVE DIMENSIONS
• Check the dimensions of each valve. For the dimensions, refer to EM-330, "Cylinder Head".
• If dimensions are out of the standard, replace valve and check valve seat contact. L
Valve Stem Diameter M

• Measure the diameter of valve stem with micrometer (A).
Standard : Refer to EM-330, "Cylinder Head". N

• Measure the inner diameter of valve guide with bore gauge.
O

• (Valve guide clearance) = (Valve guide inner diameter) – (Valve P
stem diameter) JPBIA0183ZZ

• If it exceeds the standard, replace valve and/or cylinder head and cylinder head housing.
VALVE SEAT CONTACT
EM-327
CYLINDER HEAD
• After confirming that the dimensions of valve guides and valves are within the specifications, perform this
procedure.
• Check if the contact area band is continuous all around the circum-
ference.
A : OK
B : NG
surface still has “NG” conditions even after the re-check, replace
cylinder head and cylinder head housing.
JPBIA0187ZZ
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD

specified spring height.

• If the pressure height is out of the standard, replace valve spring.
SEM113
EM-328
< SERVICE DATA AND SPECIFICATIONS (SDS) [M9R]

EM
C
Engine type M9R
Displacement cm3 (cu in) 1,995 (121.73) D
Bore and stroke mm (in) 84.0 x 90.0 (3.307 x 3.543)
E
Compression 2
Oil 1 F
Compression ratio 15.6
Standard
Compression pressure G
Minimum
kPa (bar, kg/cm2, psi) / 250 rpm
Differential limit between cylinders
H
Valve timing
J
K
EM120
Unit: degree
a b c d e f L
198 187 - 11 18 - 17 35
Drive Belts INFOID:0000000001277891 M
DRIVE BELT
N
Tension of drive belt Belt tensioning is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
Intake Manifold INFOID:0000000001585764

O
INTAKE MANIFOLD
Unit: mm (in)
P
Items Standard
Surface distortion 0.05 (0.0020)
EXHAUST MANIFOLD
EM-329
Unit: mm (in)
Items Standard
Surface distortion 0.7 (0.028)
Turbocharger INFOID:0000000001277912
Valve rod moving length

25 kPa (250 mbar, 187.525 mmHg, 7.3825 inHg) 2.95 - 5.95 mm (0.1161 - 0.2343 in)
Value of vacuum
More than 60 kPa (600 mbar, 450.06 mmHg, 17.718 inHg) The rod should not move
CAMSHAFT
Unit: mm (in)
Items Standard
Camshaft journal diameter 24.979 - 25.000 (0.9834 - 0.9843)
Cylinder head housing and camshaft bracket inner diameter 25.040 - 25.061 (0.9858 - 0.9867)
Camshaft journal oil clearance 0.040 - 0.082 (0.0016 - 0.0032)
CYLINDER HEAD
Unit: mm (in)
Items Standard
Head surface distortion 0.05 (0.0020)
JPBIA0791ZZ
Cylinder head gasket thickness “a” 1.116 - 1.184 (0.0439 - 0.0466)
JPBIA0792ZZ
Normal cylinder head height “a” 133.6 (5.26)
VALVE DIMENSIONS
EM-330
Unit: mm (in)
A
EM
D
E1BIA0064ZZ
Item Standard
Intake 27.58 - 27.82 (1.0858 - 1.0953) E
Valve head diameter “D”
Exhaust 25.88 - 26.12 (1.0189 - 1.0283)
Intake 103.737 - 104.037 (4.08 - 4.10)
Valve length “L” F
Exhaust 103.630 - 103.930 (4.08 - 4.09)
Intake 5.970 - 5.985 (0.2350 - 0.2356)
Exhaust 5.955 - 5.970 (0.2344 - 0.2350) G
Measuring point “X1” 35.0 (1.378)
Valve seat angle “α” 45°- 45°15′
H
Intake 1.1 (0.043)
Exhaust 0.94 (0.037)
Valve lift amount 8.0 (0.315) I
VALVE GUIDE
Unit: mm (in)
J
JPBIA0586ZZ
Items Standard N
Outer diameter 11.033 - 11.044 (0.4344 - 0.4348)
Valve guide
Cylinder head valve guide hole diameter 10.987 - 11.013 (0.4326 - 0.4336) O
Intake 0.015 - 0.048 (0.0006 - 0.0019)
Valve guide clearance P
Exhaust 0.030 - 0.063 (0.0012 - 0.0025)
Valve guide angle “a” 90°
Projection length “b” 14.0 (0.551)
VALVE SEAT
EM-331
Unit: mm (in)
JPBIA0787ZZ
Items Standard
Intake 28.163 - 28.191 (1.1088 - 1.1099)
Exhaust 26.986 - 27.014 (1.0624 - 1.0635)
Intake 28.276 - 28.292 (1.1132 - 1.1139)
Exhaust 27.076 - 27.092 (1.0660 - 1.0666)
Intake 0.085 - 0.129 (0.0033 - 0.0051)
Valve seat interference fit
Exhaust 0.062 - 0.106 (0.0024 - 0.0042)
Angle “α” 89°30′
Intake 1.40 (0.0551)
Exhaust 1.544 (0.0608)
Intake 4.56 - 4.64 (0.1795 -0.1827)
Height “h”
Exhaust 4.905 - 4.985 (0.1931 - 0.1963)
Intake 6.95 (0.2736)
Depth “H”
Exhaust 7.25 (0.2854)
*1: Machining data
VALVE SPRING
Free height 46.90 mm (1.8465 in)

200 - 220 N (20.4 - 22.4 kg, 45 - 49 lb) 34.90 mm (1.3740 in)
Pressure height
353 - 387 N (36.0 - 39.5 kg, 79 - 87 lb) 26.90 mm (1.0591 in)
Full pressed height 24.40 mm (0.9606 in)
Diameter of the wire 2.78 - 2.82 mm (0.1094 - 0.1110 in)
Inner diameter 13.90 - 14.30 mm (0.5472 - 0.5630 in)
Outer diameter 19.50 - 19.90 mm (0.7677 - 0.7835 in)
Valve spring squareness 1.4 mm (0.055 in)
EM-332
ENGINE
ENGINE LUBRICATION SYSTEM

SECTION LU LU
E
CONTENTS
MR20DE Engine Oil Pressure .................................................12 F
QR25DE
FUNCTION DIAGNOSIS ............................... 3
FUNCTION DIAGNOSIS .............................. 13 G
DESCRIPTION .................................................... 3
Engine Lubrication System ....................................... 3 DESCRIPTION .................................................. 13
Engine Lubrication System Schematic ...................... 3 Engine Lubrication System ....................................13
Engine Lubrication System Schematic ..................13 H
PRECAUTION ............................................... 4
PRECAUTION .............................................. 14
PRECAUTIONS ................................................... 4
I
Liquid Gasket ............................................................ 4 PRECAUTIONS ................................................. 14
Liquid Gasket ..........................................................14
PREPARATION ............................................ 5
PREPARATION ........................................... 15 J
PREPARATION ................................................... 5
Special Service Tools ................................................ 5 PREPARATION ................................................. 15
Commercial Service Tools ........................................ 5 Special Service Tools ............................................15
K
Commercial Service Tools .....................................15
ON-VEHICLE MAINTENANCE ..................... 6
ON-VEHICLE MAINTENANCE .................... 16
ENGINE OIL ........................................................ 6 L
Inspection .................................................................. 6 ENGINE OIL ...................................................... 16
Draining ..................................................................... 7 Inspection ................................................................16
Refilling ..................................................................... 8 Draining ...................................................................17
M
Refilling ....................................................................18
OIL FILTER ......................................................... 9
Removal and Installation ........................................... 9 OIL FILTER ....................................................... 19
Inspection .................................................................. 9 Removal and Installation .........................................19 N
Inspection ................................................................19
ON-VEHICLE REPAIR ................................. 10
ON-VEHICLE REPAIR ................................. 20
OIL COOLER ......................................................10 O
Exploded View ........................................................ 10 OIL COOLER .................................................... 20
Removal and Installation ......................................... 10 Exploded View .........................................................20
Inspection ................................................................ 11 Removal and Installation .........................................20 P
Inspection ................................................................20
(SDS) ............................................................ 12 DISASSEMBLY AND ASSEMBLY .............. 22
SERVICE DATA AND SPECIFICATIONS OIL PUMP ......................................................... 22
(SDS) ..................................................................12 Exploded View .........................................................22
Periodical Maintenance Specification ..................... 12 Removal and Installation .........................................22
LU-1
Disassembly and Assembly .................................... 22 ON-VEHICLE MAINTENANCE .................. 28
Inspection ............................................................... 23
ENGINE OIL ...................................................... 28
SERVICE DATA AND SPECIFICATIONS Inspection ................................................................ 28
(SDS) ........................................................... 25 Draining ................................................................... 29
Refilling ................................................................... 29
(SDS) .................................................................. 25 OIL FILTER ........................................................ 30
Periodical Maintenance Specification ................... 25 Removal and Installation ......................................... 30
Engine Oil Pressure .............................................. 25 Inspection ................................................................ 30
Oil Pump ................................................................ 25
Regulator Valve ..................................................... 25 ON-VEHICLE REPAIR ............................... 31
M9R OIL COOLER ..................................................... 31
Exploded View ........................................................ 31
FUNCTION DIAGNOSIS ............................. 26 Removal and Installation ......................................... 31
DESCRIPTION ................................................... 26 Inspection ................................................................ 32
Engine Lubrication System ..................................... 26
Engine Lubrication System Schematic ................... 26
(SDS) .......................................................... 33
PREPARATION ........................................... 27
PREPARATION ................................................. 27 (SDS) ................................................................. 33
Special Service Tools ............................................. 27 Periodical Maintenance Specification ..................... 33
Engine Oil Pressure ................................................ 33
LU-2
DESCRIPTION
< FUNCTION DIAGNOSIS > [MR20DE]
FUNCTION DIAGNOSIS A
DESCRIPTION
Engine Lubrication System INFOID:0000000001160921
LU
I
PBIC3912E
J
Engine Lubrication System Schematic INFOID:0000000001160922
PBIC3913E
LU-3
PRECAUTIONS
PRECAUTION
PRECAUTIONS

1. Remove old liquid gasket adhering to the liquid gasket application surface and the mating surface.
• Remove liquid gasket completely from the liquid gasket application surface, mounting bolts, and bolt
holes.
2. Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating
use) to remove adhering moisture, grease and foreign materials.
3. Apply liquid gasket to the liquid gasket application surface.
• Within five minutes of liquid gasket application, install the mating component.
• After 30 minutes or more have passed from the installation, fill engine oil and engine coolant.
LU-4
PREPARATION
PREPARATION A
PREPARATION
LU
Tool number
Description C
Tool name
ST25051001 Measuring oil pressure
Oil pressure gauge Maximum measuring range:
2,452 kPa (24.52 bar, 25 kg-cm2, 356 psi) D
E
NT050
ST25052000 Adapting oil pressure gauge to cylinder block

Hose F
S-NT559
H
KV10115801 Removing and installing oil filter
Oil filter wrench a: 64.3 mm (2.531 in)
J
S-NT375

K

Deep socket Removing and installing oil pressure switch L
a: 27 mm (1.06 in)
PBIC4066E N
LU-5
ENGINE OIL
ENGINE OIL
ENGINE OIL LEVEL

NOTE:
Before starting engine, put vehicle horizontally and check the engine oil level. If engine is already started, stop
it and allow 10 minutes before checking.
1. Pull out oil level gauge and wipe it clean.
2. Insert oil level gauge and check that the engine oil level is within
the range (A) shown in the figure.
3. If it is out of range, adjust it.
PBIC3309J
ENGINE OIL APPEARANCE

• Check engine oil for white turbidity or heavy contamination.
• If engine oil becomes turbid and white, it is highly probable that it is contaminated with engine coolant.
Repair or replace damaged parts.
ENGINE OIL LEAKAGE
Check for engine oil leakage around the following area.
• Oil pan (upper and lower)
• Oil pan drain plug
• Oil pressure switch
• Oil level sensor
• Oil filter
• Oil cooler
• Intake valve timing control solenoid valve
• Front cover
• Mating surface between cylinder head and camshaft bracket
• Mating surface between cylinder block and cylinder head
• Mating surface between cylinder head and rocker cover
• Crankshaft oil seals (front and rear)
OIL PRESSURE CHECK
WARNING:
• Be careful not to get burned, as engine oil may be hot.
• When checking engine oil pressure, shift position should be “Parking” (CVT models) or “Neutral”
(M/T models), and apply parking brake securely.
1. Check engine oil level. Refer to LU-6, "Inspection".
LU-6
ENGINE OIL
2. Disconnect harness connector at oil pressure switch (1), and
remove oil pressure switch using a deep socket (commercial A
service tool).
2 : Oil filter
LU
3 : Oil pan (lower)
: Engine front
CAUTION: C
Never drop or shock oil pressure switch.
PBIC3914E
3. Install oil pressure gauge [SST: ST25051001] (A) and hose

[SST: ST25052000] (B). E
JPBIA0074ZZ
H
4. Start engine and warm it up to normal operating temperature.
5. Check oil pressure with engine running under no-load.
NOTE:
When engine oil temperature is low, engine oil pressure becomes high. I
Engine oil pressure : Refer to LU-12, "Engine Oil Pressure".

J
If difference is extreme, check oil passage and oil pump for oil leakage.
6. After the inspections, install oil pressure switch as follows:
a. Remove old liquid gasket adhering to oil pressure switch and engine. K
b. Apply liquid gasket and tighten oil pressure switch to specification.
L
Tightening torque : Refer to EM-93, "Exploded View".
c. Check engine oil level. Refer to LU-6, "Inspection".
d. After warming up engine, check that there is no leakage of engine oil with running engine. M
Draining INFOID:0000000001160927
N
WARNING:
• Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin
contact with used engine oil. If skin contact is made, wash thoroughly with soap or hand cleaner as O
soon as possible.
1. Warm up the engine, and check for engine oil leakage from engine components. Refer to LU-6, "Inspec-
tion". P
2. Stop the engine and wait for 10 minutes.
3. Loosen oil filler cap.
4. Remove drain plug and then drain engine oil.
LU-7
ENGINE OIL
Refilling INFOID:0000000001160928
1. Install drain plug with new washer. Refer to EM-33, "Exploded View".
CAUTION:

2. Refill with new engine oil.
Engine oil specification and viscosity: Refer to MA-22, "Fluids and Lubricants".
Engine oil capacity : Refer to LU-12, "Periodical Maintenance Specification".

CAUTION:
• The refill capacity depends on the engine oil temperature and drain time. Use these specifica-
tions for reference only.
• Always use oil level gauge to determine the proper amount of engine oil in the engine.
3. Warm up engine and check area around drain plug and oil filter for engine oil leakage.
5. Check the engine oil level. Refer to LU-6, "Inspection".
LU-8
OIL FILTER
OIL FILTER
A
REMOVAL LU
• Using oil filter wrench [SST: KV10115801] (A), remove oil filter.
1 : Oil pan (lower) C

: Engine front
CAUTION:
• Oil filter is provided with relief valve. Use Genuine NISSAN D
Oil Filter or equivalent.
• Be careful not to get burned when engine and engine oil
may be hot. E
• When removing, prepare a shop cloth to absorb any engine
PBIC3916E
oil leakage or spillage.
• Completely wipe off any engine oil that adheres to engine and vehicle.
F
INSTALLATION
1. Remove foreign materials adhering to the oil filter installation surface.
2. Apply new engine oil to the oil seal contact surface of new oil fil- G
ter.
SMA010 J
3. Screw oil filter manually until it touches the installation surface,

then tighten it by 2/3 turn (A). Or tighten to specification. K
Oil filter:
: 17.7 N·m (1.8 kg-m, 13 ft-lb) L
JPBIA0077ZZ
N
INSPECTION AFTER INSTALLATION O

2. Start the engine, and check there is no leak of engine oil.
3. Stop the engine and wait for 10 minutes. P
4. Check the engine oil level, and adjust the level. Refer to LU-6, "Inspection".
LU-9
OIL COOLER
ON-VEHICLE REPAIR
OIL COOLER
JPBIA0576GB
1. Clamp 2. Water hose 3. Water hose

4. Oil cooler 5. Connector bolt 6. Oil filter
A. Refer to LU-9
REMOVAL
WARNING:
Be careful not to get burn yourself, as engine oil and engine coolant may be hot.
1. Drain engine coolant from radiator and cylinder block. Refer to CO-16, "Exploded View" and EM-94, "Dis-
assembly and Assembly".
2. Using oil filter wrench [SST: KV10115801], remove oil filter. Refer to LU-9, "Removal and Installation".
3. Disconnect water hoses from oil cooler.
• When removing oil cooler only, pinching water hoses near oil cooler to prevent engine coolant from spill-
ing out.
• Remaining engine coolant in piping will come out. Use a tray to collect it.
CAUTION:
4. Remove connector bolt, and remove oil cooler.
INSTALLATION
LU-10
OIL COOLER
• Tighten the connecting bolt (2) after aligning the stopper (A) on the A
oil pan (upper) side with protrusion of oil cooler (1).
: Engine front
LU
PBIC3918E D
E
Oil Cooler
Check oil cooler for cracks. Check oil cooler for clogging by blowing through engine coolant inlet. If necessary, F
replace oil cooler.
1. Check the engine oil level and the engine coolant level and add engine oil and engine coolant. Refer to G
LU-6, "Inspection" and CO-10, "Inspection".
2. Start the engine, and check that there is no leakage of engine oil or engine coolant.
H
4. Check the engine oil level and the engine coolant level again. Refer to LU-6, "Inspection" and CO-10,
"Inspection".
I
LU-11

Periodical Maintenance Specification INFOID:0000000001160934
ENGINE OIL CAPACITY (APPROXIMATE)

Unit: (lmp qt)
With oil filter change 4.4 (3-7/8)

Drain and refill
Without oil filter change 4.2 (3-3/4)
Dry engine (Overhaul) 5.2 (4-5/8)
Engine Oil Pressure INFOID:0000000001160935
Unit: kPa (bar, kg/cm2, psi)
Engine speed Approximate discharge pressure*

Idle speed More than 80 (0.80, 0.8, 12)
2,000 rpm More than 450 (4.50, 4.6, 65)
*: Engine oil temperature at 80°C (176°F)
LU-12
DESCRIPTION
< FUNCTION DIAGNOSIS > [QR25DE]
DESCRIPTION
LU
I
JPBIA0685GB
J
JPBIA0818GB
LU-13
PRECAUTIONS
PRECAUTION
PRECAUTIONS

1. Remove old liquid gasket adhering to the liquid gasket application surface and the mating surface.
• Remove liquid gasket completely from the liquid gasket application surface, mounting bolts, and bolt
holes.
2. Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating
use) to remove adhering moisture, grease and foreign materials.
3. Apply liquid gasket to the liquid gasket application surface.
• Within five minutes of liquid gasket application, install the mating component.
• After 30 minutes or more have passed from the installation, fill engine oil and engine coolant.
LU-14
PREPARATION
PREPARATION A
PREPARATION
LU
Tool number
Description C
Tool name
ST25051001 Measuring oil pressure
Oil pressure gauge Maximum measuring range: 2,452 kPa
(24.52 bar, 25 kg-cm2, 356 psi) D
E
NT050
ST25052000 Adapting oil pressure gauge to oil pan (upper)

Hose F
S-NT559
H
KV10115801 Removing and installing oil filter
Oil filter wrench a: 64.3 mm (2.531 in)
J
S-NT375

K

Deep socket Removing and installing oil pressure switch L
a: 27 mm (1.06 in)
PBIC4066E N
Tube presser Pressing tube of liquid gasket
P
NT052
LU-15
ENGINE OIL
ENGINE OIL
ENGINE OIL LEVEL

NOTE:
Before starting engine, put vehicle horizontally and check the engine oil level. If engine is already started, stop
it and allow 10 minutes before checking.
2. Insert oil level gauge and make sure the engine oil level is within
PBIC3309J

• Check engine oil for white turbidity or heavy contamination.
ENGINE OIL LEAKAGE
Check for engine oil leakage around the following areas:
• Oil pans (lower and upper)
• Oil filter
• Oil cooler
• Intake valve timing control cover and intake valve timing control solenoid valve
• Front cover
• Mating surface between cylinder head and rocker cover
• Mating surface between cylinder block and lower cylinder block
• Crankshaft oil seals (front and rear)
OIL PRESSURE CHECK
WARNING:
• Be careful not to get burn yourself, as engine oil may be hot.
• When checking engine oil pressure, shift position should be “Parking” (CVT models) or “Neutral”
(M/T models), and apply parking brake securely.
2. Remove engine under cover with power tool.
LU-16
ENGINE OIL
3. Disconnect harness connector at oil pressure switch (1), and
remove oil pressure switch using deep socket (commercial ser- A
vice tool).
2 : Oil cooler
LU
: Engine front
CAUTION:
Never drop or shock oil pressure switch. C
JPBIA0888ZZ
D
4. Install the oil pressure gauge [SST: ST25051001] (A) and hose
[SST: ST25052000] (B).
E
G
JPBIA0074ZZ
5. Start the engine and warm it up to normal operating temperature.

H
6. Check the engine oil pressure with engine running under no-load.
NOTE:
When the engine oil temperature is low, the engine oil pressure becomes high.
I
Engine oil pressure : Refer to LU-25, "Engine Oil Pressure".
If difference is extreme, check engine oil passage and oil pump for engine oil leakage.
J
7. After the inspections, install oil pressure switch as follows:
a. Remove old liquid gasket adhering to oil pressure switch and the mating surface.
b. Apply liquid gasket and tighten oil pressure switch to the specification. K
Tightening torque : Refer to LU-20, "Exploded View". L

c. After warming up engine, check that there is no leakage of engine oil with running engine.
M
WARNING:
• Be careful not to get burn yourself, as engine oil may be hot.
• Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin N
contact with used engine oil. If skin contact is made, wash thoroughly with soap or hand cleaner as
soon as possible.
1. Warm up the engine, and check for engine oil leakage from engine components. Refer to LU-16, "Inspec- O
tion".
3. Loosen oil filler cap. P
LU-17
ENGINE OIL
4. Remove drain plug (1) and then drain engine oil.
: Vehicle front
JPBIA0889ZZ
1. Install drain plug with new washer. Refer to EM-158, "Exploded View".
CAUTION:
Tightening torque : Refer to EM-XX, "Exploded View".

2. Refill with new engine oil.
Engine oil specification and viscosity:
Refer to MA-22, "Fluids and Lubricants".

CAUTION:
• Always use oil level gauge to determine the proper amount of engine oil in engine.
3. Warm up the engine and check area around drain plug and oil filter for engine oil leakage.
LU-18
OIL FILTER
OIL FILTER
A
REMOVAL LU
1. Remove splash guard. Refer to EXT-21, "Exploded View".
2. Using oil filter wrench [SST: KV10115801] (A), remove oil filter.
C
: Vehicle front
CAUTION:
D
• Oil filter is provided with relief valve. Use Genuine NIS-
SAN Oil Filter or equivalent.
• Be careful not to get burned when engine and engine oil
may be hot. E
• When removing, prepare a shop cloth to absorb any
engine oil leakage or spillage.
• Never allow engine oil to adhere to drive belts. JPBIA0890ZZ
F
• Completely wipe off any engine oil that adheres to engine
and vehicle.
G
INSTALLATION
1. Remove foreign materials adhering to oil filter installation surface.
H
2. Apply new engine oil to the oil seal contact surface of new oil fil-
ter.
K
SMA010
3. Screw oil filter manually until it touches the installation surface,

then tighten it by 2/3 turn (A). Or tighten to the specification. L
Oil filter:
M
: 17.6 N·m (1.8 kg-m, 13 ft-lb)
JPBIA0077ZZ
O
INSPECTION AFTER INSTALLATION P

2. Start the engine, and check there is no leak of engine oil.
4. Check the engine oil level, and adjust the level. Refer to LU-16, "Inspection".
LU-19
OIL COOLER
ON-VEHICLE REPAIR
OIL COOLER
JPBIA0578GB

4. Oil pressure switch 5. Oil cooler 6. Gasket
A. To water outlet B. To heater pipe
REMOVAL
WARNING:
1. Remove RH front road wheel and tire.
2. Drain engine coolant by removing water drain plug on cylinder block and radiator drain plug. Refer to EM-
210, "Exploded View" and CO-47, "Exploded View".
3. Remove oil cooler mounting bolts.
4. Disconnect water hoses from oil cooler.
5. Remove oil cooler.
INSTALLATION

Oil Cooler
LU-20
OIL COOLER
Check oil cooler for cracks. Check oil cooler for clogging by blowing through engine coolant inlet. If necessary,
replace oil cooler. A
1. Check the engine oil level and the engine coolant level and add engine oil and engine coolant. Refer to
LU-16, "Inspection" and CO-41, "Inspection". LU
C
4. Check the engine oil level and the engine coolant level again. Refer to LU-16, "Inspection" and CO-41,
"Inspection".
D
LU-21
OIL PUMP

OIL PUMP
JPBIA0577GB
1. Front cover (Oil pump body united) 2. Outer rotor 3. Inner rotor
4. Oil pump cover 5. Regulator valve 6. Regulator valve spring
7. Regulator valve plug
REMOVAL
Remove front cover. Refer to EM-192, "Exploded View".
NOTE:
Oil pump is built into front cover.
INSTALLATION
• When installing, align crankshaft flat faces with inner rotor flat faces.
DISASSEMBLY
1. Remove oil pump cover.
2. Remove oil pump inner rotor and oil pump outer rotor from front cover.
3. After removing regulator valve plug, remove regulator valve spring and regulator valve.
ASSEMBLY
Note the following, and assemble in the reverse order of disassembly.
LU-22
OIL PUMP
• Install oil pump inner rotor with the groove faced to oil pump cover
side. A
LU
PBIC0255E
D
INSPECTION AFTER DISASSEMBLY E
Oil Pump Clearance

• Measure the clearance with feeler gauge. F
- Clearance between outer rotor and front cover (Position “1”)
Standard : Refer to LU-25, "Oil Pump".

G
- Tip clearance between inner rotor and outer rotor (Position “2”)

H
PBIC0251E
I
• Measure the clearance with feeler gauge and straightedge.

- Side clearance between inner rotor and front cover (Position “3”)
J
- Side clearance between outer rotor and front cover (Position “4”) K
L
PBIC3465E
M
• Calculate the clearance between oil pump inner rotor and oil pump body as follows:
FRONT COVER INNER DIAMETER
- Measure the outer diameter of protruded portion of inner rotor with N
micrometer. (Position “5”)
PBIC3466E
OIL PUMP INNER ROTOR OUTER DIAMETER
LU-23
OIL PUMP
- Measure the inner diameter of front cover with in side micrometer.
(Position “6”)
PBIC3467E
OIL PUMP INNER ROTOR TO FRONT COVER CLEARANCE

- (Clearance) = (Front cover inner diameter) – (Oil pump inner rotor outer diameter)

• If measured/calculated values are out of the standard, replace front cover.
Regulator Valve Clearance
(Clearance) = (Regulator valve hole diameter) – (Regulator valve
outer diameter)

• If the calculated value is out of the standard, replace front cover.
CAUTION:
• Coat regulator valve with engine oil.
• Make sure that it falls smoothly into valve hole by its own
weight.
PBIC0822E

2. Start the engine, and check that there is no leakage of engine oil.
4. Check the engine oil level and adjust the level. Refer to LU-16, "Inspection".
LU-24

LU

Unit: (lmp qt) C
Destination With WVTA Without WVTA
With oil filter change 5.1 (4-1/2) 4.6 (4)
Drain and refill D
Without oil filter change 4.8 (4-1/4) 4.3 (3-3/4)
Dry engine (Overhaul) 5.9 (5-1/4) 5.4 (4-3/4)

E
Engine speed Approximate discharge pressure* F

Idle speed More than 98 (0.98, 1.0, 14)
2,000 rpm More than 294 (2.94, 3.0, 43)
G
*: Engine oil temperature at 80°C (176°F)
Oil Pump INFOID:0000000001160919

H
Unit: mm (in)
Clearance between outer rotor and front cover 0.114 - 0.179 (0.0045 - 0.0070)
I
Tip clearance between inner rotor and outer rotor 0.170 - 0.220 (0.0067 - 0.0087)
Side clearance between inner rotor and front cover 0.030 - 0.070 (0.0012 - 0.0028)
Side clearance between outer rotor and front cover 0.060 - 0.110 (0.0024 - 0.0043) J
Oil pump inner rotor to front cover clearance 0.045 - 0.091 (0.0018 - 0.0036)
Regulator Valve INFOID:0000000001160920

K
Unit: mm (in)
Regulator valve to oil pump cover clearance 0.040 - 0.097 (0.0016 - 0.0038)
L
LU-25
DESCRIPTION
< FUNCTION DIAGNOSIS > [M9R]
FUNCTION DIAGNOSIS
DESCRIPTION
JPBIA0855GB
JPBIA0760GB
LU-26
PREPARATION
PREPARATION A
PREPARATION
LU
NISSAN tool number

(RENAULT tool number) Description C
Tool name
KV113E0020 Measuring oil pressure
(Mot.836-05) D
Oil pressure gauge set
JPBIA0949ZZ
LU-27
ENGINE OIL
ENGINE OIL
ENGINE OIL LEVEL

NOTE:
Before starting engine, put vehicle horizontally and check that the engine oil level. If engine is already started,
stop it and allow 10 minutes before checking.
2. Insert oil level gauge and check that the engine oil level is within
JPBIA0756ZZ

• Check that engine oil for white turbidity or heavy contamination.
ENGINE OIL LEAKAGE
Check for engine oil leakage around the following area.
• Oil pan (upper and lower)
• Oil level sensor
• Oil filter body
• Oil cooler
• Fuel pump
• Vacuum pump
• Turbocharger
• Crankshaft position sensor
• Camshaft position sensor
• Front cover
• Mating surface between cylinder head and cylinder head housing
• Mating surface between cylinder head housing and oil separator
• Front oil seal
• Rear oil seal retainer
OIL PRESSURE CHECK
WARNING:
• When checking engine oil pressure, shift position should be “Parking” (A/T models) or “Neutral” (M/
T models), and apply parking brake securely.
1. Check engine oil level. Refer to LU-28, "Inspection".
2. Disconnect harness connector at oil pressure switch, and remove oil pressure switch using a deep socket.
CAUTION:
Handle oil pressure switch carefully and avoid impacts.
3. Install oil pressure gauge set [SST:KV113E0020 (Mot.836-05)].
4. Start engine and warm it up to normal operating temperature.
LU-28
ENGINE OIL
5. Check oil pressure with engine running under no-load.
NOTE: A
When engine oil temperature is low, engine oil pressure becomes high.
Engine oil pressure : Refer to LU-33, "Periodical Maintenance Specification". LU

If difference is extreme, check oil passage and oil pump for oil leakage.
6. After the inspections, install oil pressure switch with the following procedure:
a. Tighten oil pressure switch to specification. C
Tightening torque : Refer to LU-31, "Exploded View".

D
b. Check engine oil level. Refer to LU-28, "Inspection".
c. After warming up engine, check that there is no leakage of engine oil with running engine.
Draining INFOID:0000000001308943 E
WARNING:
• Be careful not to get burned, as engine oil may be hot. F
• Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin
contact with used engine oil. If skin contact is made, wash thoroughly with soap or hand cleaner as
soon as possible.
G
1. Warm up the engine, and check for engine oil leakage from engine components. Refer to LU-28, "Inspec-
tion".
2. Stop the engine and wait for 10 minutes. H
4. Loosen oil level gauge.
5. Remove oil pan drain plug (1) using a square driver [8 mm I
(0.315 in)]. Drain engine oil.
: Vehicle front
J
JPBIA0621ZZ L
M
1. Install drain plug with new washer.
CAUTION:
N

2. Refill with new engine oil. O
Engine oil specification and viscosity: Refer to MA-22, "Fluids and Lubricants".

P
CAUTION:
• Always use oil level gauge to determine the proper amount of engine oil in the engine.
3. Warm up engine and check area around drain plug and oil filter body for engine oil leakage.
LU-29
OIL FILTER
OIL FILTER
REMOVAL
WARNING:
Be careful not to get burned when engine and engine oil may be hot.
CAUTION:
• When removing, prepare a shop cloth to absorb any engine oil leakage or spillage.
• Completely wipe off any engine oil that adheres to engine and vehicle.
2. Loosen oil filter body assembly using a socket [27 mm (1.06 in)].
3. Remove oil filter body, and then remove oil filter and O-ring.
CAUTION:
Completely wipe clean any engine oil remaining on oil filter body or vehicle.
INSTALLATION
1. Completely remove all foreign objects adhering to the inside of oil filter body or O-ring mounting area.
2. Install oil filter and O-ring to oil filter body.
3. Install oil filter body assembly to oil cooler.
Tightening torque: Refer to LU-31, "Exploded View".

1. Check that the engine oil level. Refer to LU-28, "Inspection".
2. Start the engine, and check that there is no leak of engine oil.
4. Check that the engine oil level, and adjust the level. Refer to LU-28, "Inspection".
LU-30
OIL COOLER
ON-VEHICLE REPAIR A
OIL COOLER
LU
JPBIA0757GB K
1. Oil cooler 2. Oil pressure switch 3. Oil filter

4. O-ring 5. Oil filter body 6. Gasket L
A. To water suction pipe B. To radiator C. Refer to LU-31
M
REMOVAL N
WARNING:
1. Drain engine coolant from radiator. Refer to CO-68, "Draining". O
CAUTION:
2. Disconnect water hose and radiator hose (lower). Refer to CO-73, "Exploded View" and CO-81,
P
"Exploded View".
CAUTION:
Never adhere the engine coolant to electronic equipments. (alternator etc.)
3. Remove oil pressure switch, if necessary.
CAUTION:
Handle oil pressure switch carefully and avoid impacts.
4. Remove oil cooler.
LU-31
OIL COOLER
JPBIA0758ZZ
INSTALLATION
Oil Cooler
• Tighten mounting bolts in the following steps in numerical order as
1. Tighten mounting bolts No.2 and 4.
: 5.0 N·m (0.51 kg-m, 4 ft-lb)

2. Tighten all mounting bolts.
: 25.0 N·m (2.6 kg-m, 18 ft-lb)

JPBIA0758ZZ

Oil Cooler
Check that oil cooler for cracks. Check that oil cooler for clogging by blowing through engine coolant inlet. If
necessary, replace oil cooler.
1. Check that the engine oil level and the engine coolant level and add engine oil and engine coolant. Refer
to LU-28, "Inspection" and CO-68, "Inspection".
4. Check that the engine oil level and the engine coolant level again. Refer to LU-28, "Inspection" and CO-
68, "Inspection".
LU-32

LU

Unit: (lmp qt) C
With oil filter change 7.4 (6-1/2)
Drain and refill
Without oil filter change 7.0 (6-1/8)
D
Dry engine (Overhaul) 8.4 (7-3/8)
E
Engine speed Approximate discharge pressure*

Idle speed More than 88 (0.9, 0.9, 13) F
3,000 rpm More than 402 (4, 4.1, 58)
*: Engine oil temperature at 80°C (176°F) G
LU-33
ENGINE
ENGINE COOLING SYSTEM

SECTION CO CO
E
CONTENTS
MR20DE RADIATOR CAP ........................................................14 F
RADIATOR CAP : Inspection ..................................14
FUNCTION DIAGNOSIS ............................... 4
RADIATOR .................................................................14
G
DESCRIPTION .................................................... 4 RADIATOR : Inspection ...........................................14
M/T ............................................................................... 4 ON-VEHICLE REPAIR ................................. 16

M/T : Engine Cooling System .................................... 4 H
M/T : Engine Cooling System Schematic .................. 4 RADIATOR ........................................................ 16
Exploded View .........................................................16
CVT .............................................................................. 5 Removal and Installation .........................................18
CVT : Engine Cooling System ................................... 5 Disassembly and Assembly .....................................18 I
CVT : Engine Cooling System Schematic ................. 5 Inspection ................................................................21
SYMPTOM DIAGNOSIS ............................... 6 COOLING FAN .................................................. 23 J
Exploded View .........................................................23
OVERHEATING CAUSE ANALYSIS .................. 6 Removal and Installation .........................................23
Troubleshooting Chart ............................................... 6 Disassembly and Assembly .....................................24
K
Inspection ................................................................24
PRECAUTION ............................................... 8
WATER PUMP .................................................. 25
PRECAUTIONS ................................................... 8
Exploded View .........................................................25 L
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect ..................................... 8
Inspection ................................................................25
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- M
THERMOSTAT .................................................. 27
SIONER" ................................................................... 8 Exploded View .........................................................27
PREPARATION ............................................ 9 Inspection ................................................................28 N
PREPARATION ................................................... 9 WATER OUTLET .............................................. 30
Special Service Tools ................................................ 9
Exploded View .........................................................30
Commercial Service Tools ....................................... 9 O
ON-VEHICLE MAINTENANCE .................... 10 Inspection ................................................................31
ENGINE COOLANT ...........................................10 SERVICE DATA AND SPECIFICATIONS P

Inspection ................................................................ 10 (SDS) ............................................................ 32
Draining ................................................................... 10
Refilling ................................................................... 11
Flushing ................................................................... 12 (SDS) ................................................................. 32
Periodical Maintenance Specification ......................32
RADIATOR .........................................................14 Radiator ...................................................................32
CO-1
Thermostat ............................................................. 32 Removal and Installation ......................................... 53
Heater Thermostat (CVT models) .......................... 32 Disassembly and Assembly .................................... 54
Water Control Valve ............................................... 32 Inspection ................................................................ 54
QR25DE
WATER PUMP ................................................... 55
FUNCTION DIAGNOSIS ............................. 33 Exploded View ........................................................ 55
Removal and Installation ......................................... 55
DESCRIPTION ................................................... 33 Inspection ................................................................ 56
M/T ............................................................................. 33 THERMOSTAT AND WATER CONTROL

M/T : Engine Cooling System ................................. 33 VALVE ............................................................... 57
M/T : Engine Cooling System Schematic ............... 34 Exploded View ........................................................ 57
CVT ............................................................................ 34
Inspection ................................................................ 59
CVT : Engine Cooling System ................................ 35
CVT : Engine Cooling System Schematic .............. 36 SERVICE DATA AND SPECIFICATIONS
SYMPTOM DIAGNOSIS ............................. 37 (SDS) .......................................................... 61
OVERHEATING CAUSE ANALYSIS ................ 37 SERVICE DATA AND SPECIFICATIONS

Troubleshooting Chart ........................................... 37 (SDS) ................................................................. 61
Periodical Maintenance Specification ..................... 61
PRECAUTION ............................................. 39 Radiator .................................................................. 61
Thermostat .............................................................. 61
PRECAUTIONS ................................................. 39 Water control valve ................................................. 61
Precaution Necessary for Steering Wheel Rota- M9R
tion After Battery Disconnect .................................. 39
Precaution for Supplemental Restraint System FUNCTION DIAGNOSIS ............................ 62
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................. 39 DESCRIPTION ................................................... 62
PREPARATION ........................................... 40 M/T ............................................................................. 62

M/T : Engine Cooling System ................................. 62
PREPARATION ................................................. 40 M/T : Engine Cooling System Schematic ................ 62
Special Service Tools ........................................... 40
Commercial Service Tools .................................... 40 A/T ............................................................................. 63
A/T : Engine Cooling System .................................. 63
ON-VEHICLE MAINTENANCE ................... 41 A/T : Engine Cooling System Schematic ................ 63
ENGINE COOLANT ........................................... 41 SYMPTOM DIAGNOSIS ............................ 64

Inspection ............................................................... 41
Draining .................................................................. 41 OVERHEATING CAUSE ANALYSIS ................ 64
Refilling ................................................................... 42 Troubleshooting Chart ............................................ 64
Flushing .................................................................. 43
PRECAUTION ............................................ 66
RADIATOR ........................................................ 45
PRECAUTIONS ................................................. 66
RADIATOR CAP ....................................................... 45 Precaution Necessary for Steering Wheel Rota-
RADIATOR CAP : Inspection ................................. 45 tion After Battery Disconnect .................................. 66
RADIATOR ................................................................ 45 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
RADIATOR : Inspection .......................................... 45 SIONER" ................................................................. 66
ON-VEHICLE REPAIR ................................ 47 PREPARATION .......................................... 67
RADIATOR ........................................................ 47 PREPARATION ................................................. 67
Exploded View ........................................................ 47 Special Service Tools ............................................. 67
Removal and Installation ........................................ 48 Commercial Service Tools .................................... 67
Disassembly and Assembly .................................... 49
Inspection ............................................................... 51 ON-VEHICLE MAINTENANCE .................. 68
COOLING FAN .................................................. 53 ENGINE COOLANT ........................................... 68
Exploded View ........................................................ 53 Inspection ................................................................ 68
CO-2
Draining ................................................................... 68 Exploded View .........................................................81
Refilling ................................................................... 69 Removal and Installation .........................................81 A
Flushing ................................................................... 70 Inspection ................................................................82
RADIATOR .........................................................71 WATER OUTLET AND THERMOSTAT AS-

SEMBLY ............................................................ 83 CO
RESERVOIR TANK CAP .......................................... 71 Exploded View .........................................................83
RESERVOIR TANK CAP : Inspection ..................... 71 Removal and Installation .........................................84
RADIATOR ................................................................ 71 Inspection ................................................................85 C
RADIATOR : Inspection .......................................... 71
DISASSEMBLY AND ASSEMBLY .............. 86
ON-VEHICLE REPAIR ................................. 73 D
WATER PUMP .................................................. 86
RADIATOR .........................................................73 Exploded View .........................................................86
Exploded View ........................................................ 73 Disassembly and Assembly .....................................86
Removal and Installation ......................................... 74 Inspection ................................................................87 E
Inspection ................................................................ 77
(SDS) ............................................................ 88 F
COOLING FAN ...................................................79
Exploded View ........................................................ 79 SERVICE DATA AND SPECIFICATIONS
Removal and Installation ......................................... 79 (SDS) ................................................................. 88
Periodical Maintenance Specification ......................88 G
Inspection ................................................................ 80 Radiator ...................................................................88
Water Outlet and Thermostat Assembly ..................88
WATER PIPING ..................................................81 H
CO-3
DESCRIPTION
FUNCTION DIAGNOSIS
DESCRIPTION
M/T
M/T : Engine Cooling System INFOID:0000000001160768
JPBIA0703GB
M/T : Engine Cooling System Schematic INFOID:0000000001160769
JPBIA0704GB
CO-4
DESCRIPTION
CVT
A
CVT : Engine Cooling System INFOID:0000000001160770
CO
JPBIA0705GB
I
CVT : Engine Cooling System Schematic INFOID:0000000001160771
JPBIA0706GB
CO-5
OVERHEATING CAUSE ANALYSIS
SYMPTOM DIAGNOSIS
Troubleshooting Chart INFOID:0000000001160772
Symptom Check items

Water pump malfunction Worn or loose drive belt
Thermostat and water con-
—
trol valve stuck closed
Dust contamination or pa-
Poor heat transfer —
Damaged fins per clogging
Physical damage
Clogged radiator cooling Excess foreign material
tube (rust, dirt, sand, etc.)
Cooling fan does not oper-
ate
Reduced air flow High resistance to fan rota- Fan assembly —
tion
Damaged fan blades
Damaged radiator shroud — — —
Cooling sys- Improper engine coolant

— — —
tem parts mixture ratio
malfunction Poor engine coolant quality — Engine coolant viscosity —
Loose clamp
Cooling hose
Cracked hose
Water pump Poor sealing
Loose
Reservoir tank cap
Poor sealing
Engine coolant leakage
O-ring for damage, deterio-
Insufficient engine coolant ration or improper fitting
Radiator
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Cylinder head deterioration
Exhaust gas leaks into cool-
Overflowing reservoir tank Cylinder head gasket deteri-
ing system
oration
CO-6
Symptom Check items
A
High engine rpm under no
load
Driving in low gear for ex-
Abusive driving CO
tended time
Driving at extremely high
speed
— Overload on engine C
Power train system mal-
function
Installed improper size
Except cool- —
wheels and tires D
ing system
parts mal- Dragging brakes
function
Improper ignition timing
E
Blocked bumper —
Installed car brassiere
Blocked radiator grille Mud contamination or paper F
Blocked or restricted air clogging —
flow
Blocked radiator —
Blocked condenser G
Blocked air flow
Installed large fog lamp
CO-7
PRECAUTIONS
PRECAUTION
PRECAUTIONS
INFOID:0000000001297938
NOTE:
TEM).
OPERATION PROCEDURE
NOTE:
rotated.
WARNING:
ness connectors.
CO-8
PREPARATION
PREPARATION A
PREPARATION
CO
Tool number
Description C
Tool name
KV99103510 Installing radiator upper and lower tanks
Radiator plate pliers A
D
E
S-NT224
KV99103520 Removing radiator upper and lower tanks

Radiator plate pliers B F
S-NT225
H
I
Radiator cap tester Checking radiator and radiator cap
J
PBIC1982E
Radiator cap tester adapter Adapting radiator cap tester to radiator cap L
and water outlet (front) filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia. M
Unit: mm (in)
S-NT564 N
CO-9
ENGINE COOLANT
ENGINE COOLANT
LEVEL
• Check that the reservoir tank engine coolant level is within the
“MIN” to “MAX” when the engine is cool.
A : MAX
B : MIN
• Adjust the engine coolant level if necessary.
JPBIA0102ZZ
LEAKAGE
• To check for leakage, apply pressure to the cooling system with the
radiator cap tester (commercial service tool) (A) and the radiator
cap tester adapter (commercial service tool) (B).
Testing pressure: Refer to CO-32, "Radiator".

WARNING:
Never remove radiator cap when engine is hot. Serious burns
may occur from high-pressure engine coolant escaping from
radiator.
CAUTION:
Higher test pressure than specified may cause radiator dam- PBIC5121J
age.
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.
• If anything is found, repair or replace damaged parts.
WARNING:
• Never remove radiator cap when engine is hot. Serious burns may occur from high-pressure engine
coolant escaping from radiator.
• Wrap a thick cloth around the radiator cap. Slowly turn it a quarter of a turn to release built-up pres-
sure. Then turn it all the way.
1. Remove engine under cover.
2. Open radiator drain plug (1) at the bottom of radiator, and then
remove radiator cap.
: Vehicle front
CAUTION:
• When draining all of engine coolant in the system, open water
drain plugs on cylinder block. Refer to CO-16, "Exploded
View".
JPBIA0795ZZ
3. Remove reservoir tank if necessary, and drain engine coolant and clean reservoir tank before installing.
• Removal of engine mounting insulator (RH) is necessary. Refer to EM-75, "M/T : Exploded View" (M/T
models) or EM-81, "CVT : Exploded View" (CVT models).
CO-10
ENGINE COOLANT
• Move reservoir tank (3), and then remove it numerical order as
shown in the figure. A
: Vehicle front
CO
JPBIA0891ZZ
D
4. Check drained engine coolant for contaminants such as rust, corrosion or discoloration. If contaminated,
flush the engine cooling system. Refer to CO-12, "Flushing".
Refilling INFOID:0000000001160777 E
1. Install reservoir tank if removed, and radiator drain plug.

CAUTION: F
Be sure to clean drain plug and install with new O-ring.
Radiator drain plug : Refer to CO-16, "Exploded View".

G
• If water drain plugs on cylinder block are removed, close and tighten them. Refer to EM-94, "Disassem-
bly and Assembly".
2. Check that each hose clamp has been firmly tightened. H
3. Remove air duct and resonator assembly, and move electric throttle control actuator to aside. Refer to
EM-25, "Exploded View" and EM-27, "Exploded View".
4. Disconnect heater hose (1) at position ( ) in the figure. I
: Vehicle front
• Enhance heater hose as high as possible. J
PBIC3802E L
5. Fill radiator (1) to specified level.

CAUTION:
Never adhere the engine coolant to electronic equipments M
(alternator etc.).
• Pour coolant slowly of less than 2 (1-3/4 Imp qt) a minute to
allow air in system to escape. N
• When coolant from heater unit starts to drain, connect heater
hose and continue filling the engine coolant.
• Use Genuine NISSAN Engine Coolant or equivalent in its
O
quality mixed with water (distilled or demineralized). Refer to
MA-22, "Fluids and Lubricants". JPBIA0819ZZ
Engine coolant capacity P

(With reservoir tank at “MAX” level)
Refer to CO-32, "Periodical Maintenance Specification".
CO-11
ENGINE COOLANT
6. Refill reservoir tank to “MAX” level line with engine coolant.
A : MAX
B : MIN
Reservoir tank engine coolant capacity

(At “MAX” level)
JPBIA0102ZZ
7. Install radiator cap.

8. Install electric throttle control actuator and air duct and resonator assembly. Refer to EM-27, "Exploded
View" and EM-25, "Exploded View".
9. Warm up engine until opening thermostat. Standard for warming-up time is approximately 10 minutes at
3,000 rpm.
• Check thermostat opening condition by touching radiator hose (lower) to see a flow of warm water.
CAUTION:
Watch water temperature gauge so as not to overheat engine.
10. Stop the engine and cool down to less than approximately 50°C (122°F).
• Cool down using fan to reduce the time.
• If necessary, refill radiator up to filler neck with engine coolant.
CAUTION:
Never adhere the engine coolant to electronic equipments (alternator etc.).
12. Repeat steps 5 through 10 two or more times with radiator cap installed until engine coolant level no
longer drops.
13. Check cooling system for leakage with engine running.
14. Warm up the engine, and check for sound of engine coolant flow while running engine from idle up to
3,000 rpm with heater temperature controller set at several position between “COOL” and “WARM”.
• Sound may be noticeable at heater unit.
15. Repeat step 14 three times.
16. If sound is heard, bleed air from cooling system by repeating step 5 through 10 until reservoir tank level no
longer drops.
Flushing INFOID:0000000001160778
1. Install reservoir tank if removed and radiator drain plug.

CAUTION:

• If water drain plugs on cylinder block are removed, close and tighten them. Refer to EM-94, "Disassem-
bly and Assembly".
2. Remove air duct and resonator assembly and move electric throttle control actuator to aside. Refer to EM-
25, "Exploded View" and EM-27, "Exploded View".
CO-12
ENGINE COOLANT
3. Disconnect heater hose (1) at position ( ) in the figure.
A
: Vehicle front
• Enhance heater hose as high as possible.

CO
PBIC3802E
D
4. Fill radiator and reservoir tank with water and reinstall radiator cap.
• When engine coolant over flows disconnected heater hose, connect heater hose, and continue filling the
engine coolant.
E
5. Install electric throttle control actuator and air duct and resonator assembly. Refer to EM-27, "Exploded
View" and EM-25, "Exploded View".
6. Run the engine and warm it up to normal operating temperature.
F
7. Rev the engine two or three times under no-load.
8. Stop the engine and wait until it cools down.
9. Drain water from the system. Refer to CO-10, "Draining". G
10. Repeat steps 1 through 9 until clear water begins to drain from radiator.
CO-13
RADIATOR
RADIATOR
RADIATOR CAP
RADIATOR CAP : Inspection INFOID:0000000001193706
• Check valve seat of radiator cap.
A : Valve seat
B : Metal plunger
- Check that valve seat is swollen to the extent that the edge of the
plunger cannot be seen when watching it vertically from the top.
- Check that valve seat has no soil and damage.
JPBIA0108ZZ
• Pull negative-pressure valve to open it, and check that it closes

completely when released.
- Check that there is no dirt or damage on the valve seat of radiator
cap negative-pressure valve.
- Check that there are no unusualness in the opening and closing
conditions of negative-pressure valve.
SMA967B
• Check radiator cap relief pressure.
Standard and Limit : Refer to CO-32, "Radiator".

- When connecting radiator cap to the radiator cap tester (commer-
cial service tool) (A) and the radiator cap tester adapter (commer-
cial service tool) (B), apply engine coolant to the cap seal surface.
PBIC5122J
• Replace radiator cap if there is an unusualness related to the above three.

CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue
or foreign material.
RADIATOR
RADIATOR : Inspection INFOID:0000000001160780
Check radiator for mud or clogging. If necessary, clean radiator as follows.

CAUTION:
• Be careful not to bend or damage radiator fins.
• When radiator is cleaned without removal, remove all surrounding parts such as radiator cooling fan
assembly and horns. Then tape harness and harness connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downward.
2. Apply water again to all radiator core surfaces once per minute.
3. Stop washing if any stains no longer flow out from radiator.
CO-14
RADIATOR
4. Blow air into the back side of radiator core vertically downward.
• Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2, 71 psi) and keep distance more than 30 cm A
(11.8 in).
5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.
CO
CO-15
RADIATOR
ON-VEHICLE REPAIR
RADIATOR
REMOVAL
M/T models (Except for Russia)
JPBIA0737GB
1. Reservoir tank cap 2. Reservoir tank 3. Clamp

4. Reservoir tank hose 5. Mounting rubber (upper) 6. Mounting bracket (RH)
7. Radiator cap 8. Mounting bracket (LH) 9. Radiator
10. Mounting rubber (lower) 11. O-ring 12. Drain plug
13. Water drain hose 14. Clamp 15. Radiator hose (lower)
16. Cooling fan assembly 17. Radiator hose (upper)
A. To water outlet B. To water inlet
CO-16
RADIATOR
M/T models (for Russia) and CVT models
A
CO
I
JPBIA0738GB
1. Reservoir tank cap 2. Reservoir tank 3. Clamp

J
10. Mounting rubber (lower) 11. O-ring 12. Drain plug
K
A. To water outlet B. To water inlet
L
DISASSEMBLY
M
CO-17
RADIATOR
JPBIA0579GB
1. Upper tank 2. Sealing rubber 3. Core

4. Lower tank
REMOVAL
WARNING:
CAUTION:
4. Remove air guide (upper). Refer to HA-59, "MR20DE (M/T) : Exploded View". (M/T models)
5. Disconnect harness connector from fan motor, and move harness to aside.
6. Remove radiator hose (upper) and reservoir tank hose.
7. Remove mounting bracket (RH and LH) and mounting rubber (upper) to tilt radiator frontward.
8. Remove radiator hose (lower).
9. Remove radiator and cooling fan assembly/
CAUTION:
Be careful not to damage or scratch radiator core.
10. Remove cooling fan assembly from radiator.
CAUTION:
Be careful not to damage radiator core when removing.
INSTALLATION
PREPARATION
CO-18
RADIATOR
1. Attach the spacer to the tip of radiator plate pliers A (SST).
Spacer specification: 1.5 mm (0.059 in) thick × 18 mm (0.71 in) A
wide × 8.5 mm (0.335 in) long.
CO
SLC655C
D
2. Check that when radiator plate pliers A [SST: KV99103510] are closed dimension H′′ is approx. 7.6 mm
(0.299 in).
3. Adjust dimension H′′ with the spacer thickness, if necessary. E
DISASSEMBLY
1. Remove upper and lower tanks with a radiator plate pliers B
(SST). F
SLC903
I
• Grip the crimped edge and bend it upwards so that radiator
plate pliers B [SST: KV99103520] slips off.
CAUTION: J
Never bend excessively.
SLC893
M
• In areas where radiator plate pliers B [SST: KV99103520] can-
not be used, use screwdriver to bend the edge up.
CAUTION:
Be careful not to damage tank. N
P
SLC930
2. Remove sealing rubber.
CO-19
RADIATOR
3. Check the edge stands straight up.
SLC931
ASSEMBLY
1. Clean contact portion of tank.
SLC932
2. Install sealing rubber while pressing it in with fingers.

CAUTION:
Be careful not to twist sealing rubber.
SLC917A
3. Caulk tank in numerical order as shown in the figure with radia-

tor plate pliers A (SST).
SLC904
CO-20
RADIATOR
CO
JPBIA0903ZZ
D
B. Keep tool perpendicular to the radiator C. Grip is insufficient
a. 90°
E
• Use pliers in the locations where radiator plate pliers A [SST:
KV99103510] cannot be used.
F
H
SLC897
4. Check that the rim is completely crimped down.

I
Standard height “H” : 8.0 - 8.4 mm (0.315 - 0.331 in)
SLC554A
L
5. Check that there is no leakage.
Refer to CO-21, "Inspection".
M
INSPECTION AFTER ASSEMBLY

N
1. Apply pressure with the radiator cap tester adapter (commercial
service tool) (A) and the radiator cap tester (commercial service
tool).
O
WARNING:
To prevent the risk of hose coming undone while under P
pressure, securely fasten it down with hose clamp.
JPBIA0736ZZ
CO-21
RADIATOR
2. Check for leakage by soaking radiator in water container with
the testing pressure applied.
SLC934

• Check for leakage of engine coolant using the radiator cap tester adapter (commercial service tool) and the
radiator cap tester (commercial service tool). Refer to CO-10, "Inspection".
• Start and warm up the engine. Check visually that there is no leakage of engine coolant.
CO-22
COOLING FAN
COOLING FAN
A
CO
I
JPBIA0793GB
1. Fan motor (LH) 2. Fan motor (RH) 3. Fan shroud J

4. Cooling fan (RH) 5. Cooling fan (LH)
A. Apply on fan motor shaft
: Apply thread locking sealant. K
: Vehicle front
Refer to GI-4, "Components" for symbols not described on the above.
L
REMOVAL M
CAUTION: N
4. Remove air guide upper. Refer to HA-59, "MR20DE (M/T) : Exploded View". (M/T models) O
5. Disconnect harness connector from resistor and fan motor, and move harness to aside.
6. Remove radiator hose (upper) and reservoir tank hose. Refer to CO-16, "Exploded View".
P
7. Remove mounting bracket (RH and LH) and mounting rubber (upper) to tilt radiator frontward. Refer to
CO-16, "Exploded View".
8. Remove cooling fan assembly.
CAUTION:
Be careful not to damage or scratch on radiator core when removing.
INSTALLATION
CO-23
COOLING FAN
CAUTION:
Only use genuine parts for fan shroud mounting bolt and observe the specified torque (to prevent
radiator from being damaged).
NOTE:
Cooling fan is controlled by ECM. For details, refer to ECM-287, "Description".
DISASSEMBLY
1. Remove cooling fan mounting nuts, and then remove the cooling fans (RH and LH).
2. Remove fan motors (RH and LH).
ASSEMBLY
CAUTION:
RH and LH cooling fans are different. Be careful not to misassemble them.
• Install each fan in the following position.
Right side : 11 blades

Left side : 9 blades
• Apply thread locking sealant on fan motor shaft.

Cooling Fan
Inspect cooling fan for crack or unusual bend.
• If anything is found, replace cooling fan.
CO-24
WATER PUMP
WATER PUMP
A
CO
G
KBIA4510J
1. Water pump 2. Gasket

H
I
REMOVAL
CAUTION: J
3. Remove drive belt. Refer to EM-15, "Removal and Installation". K
4. Remove water pump.
• Engine coolant leaks from cylinder block, so have a receptacle ready below.
CAUTION: L
• Handle water pump vane so that it does not contact any other parts.
• Water pump cannot be disassembled and should be replaced as a unit.
INSTALLATION M
N
• Check visually that there is no significant dirt or rusting on water
pump body and vane (A). O
• Check that there is no looseness in vane shaft, and that it turns
smoothly when rotated by hand.
• Replace water pump, if necessary. P
PBIC3313J
CO-25
WATER PUMP
CO-26
THERMOSTAT
THERMOSTAT
A
CO
L
JPBIA0580GB
1. Thermostat housing 2. Clamp (CVT models) 3. Water hose (CVT models) M

4. Heater thermostat (CVT models) 5. Water hose (CVT models) 6. Radiator hose (lower)
7. Clamp 8. Water inlet 9. Thermostat
10. Rubber ring 11. Gasket N
A. To CVT fluid cooler B. To radiator C. To oil cooler
: Engine front
Refer to GI-4, "Components" for symbols in the figure. O
P
REMOVAL
CAUTION:
2. Disconnect the battery cable from the negative terminal. Refer to PG-133, "Exploded View".
3. Add paint mark, then disconnect radiator hose (lower) from water inlet. Refer to CO-16, "Exploded View".
CO-27
THERMOSTAT
4. Remove water inlet and thermostat.
• Engine coolant leaks from cylinder block, so have a receptacle ready below.
5. Remove thermostat housing with the following procedure:
a. Remove water pump. Refer to CO-25, "Exploded View".
b. Remove alternator. Refer to CHG-27, "MR20DE MODELS : Exploded View".
c. Disconnect water hoses.
INSTALLATION
Thermostat
• Install thermostat with making rubber ring (1) groove fit to thermo-
stat flange (A) with the whole circumference.
PBIC3315J
• Install thermostat (1) with jiggle valve (A) facing upwards.
2 : Thermostat housing
PBIC3548J

Thermostat
• Place a thread (A) so that it is caught in the valves of thermostat
(1). Immerse fully in a container (B) filled with water. Heat while
stirring.
• The valve opening temperature is the temperature at which the
valve opens and falls from the thread.
• Continue heating. Check the full open valve lift amount.
• After checking the maximum valve lift amount, lower the water
temperature and check the valve closing temperature.
Standard: Refer to CO-32, "Thermostat".

• If out of the standard, replace thermostat. PBIC3314J
Heater Thermostat (CVT models)
CO-28
THERMOSTAT
• Fully immerse the heater thermostat (1) in a container (A) filled
with water. Continue heating the water while stirring. A
• Continue heating the heater thermostat for 5 minutes or more after
bringing the water to a boil.
• Quickly take the heater thermostat out of the hot water, measure
CO
the heater thermostat within 10 seconds.
JPBIA0318ZZ
D
• Place dial indicator (A) on the pellet (B) and measure the elonga-
tion from the initial state.
E
Standard
: Refer to CO-32, "Heater Thermostat (CVT models)".
• If out of the standard, replace heater thermostat. F
G
JPBIA0319ZZ
INSPECTION AFTER INSTALLATION H

I
CO-29
WATER OUTLET
WATER OUTLET
JPBIA0581GB
1. Engine coolant temperature sensor 2. Washer 3. Water hose

4. Clamp 5. Water hose 6. Gasket
7. Water control valve 8. Rubber ring 9. Clamp
10. Water hose 11. Clamp 12. Radiator hose (upper)
13. Water hose (CVT models) 14. Clamp (CVT models) 15. Clamp
16. Heater hose 17. Water outlet 18. Heater hose
A. To heater B. To electric throttle control actuator C. To oil cooler
D. To radiator E. To CVT fluid cooler
: Engine front
REMOVAL
CAUTION:
2. Disconnect radiator hose (upper). Refer to CO-16, "Exploded View".
3. Disconnect harness connector from engine coolant temperature sensor.
4. Remove water hoses and heater hoses.
5. Remove water outlet.
6. Remove engine coolant temperature sensor from water outlet, if necessary.
CO-30
WATER OUTLET
INSTALLATION
Note the following, and install in the reverse order of removal. A
Water Control Valve
• Install water control valve with making rubber ring (1) groove fit to
water control valve flange (A) with the whole circumference. CO
PBIC4682E
E
• Install water control valve (2) with the arrow (A) facing up and the
frame center part (B) facing upwards.
F
1 : Water outlet
PBIC3319J
Inspection INFOID:0000000001160796 I

J
Water Control Valve
• Place a thread (A) so that it is caught in the valves of water control
valve (1). Immerse fully in a container (B) filled with water. Heat
while stirring. K
• Continue heating. Check the continuous valve lifting toward maxi- L
mum valve lift.
NOTE:
The maximum valve lift amount standard temperature for water
control valve is the reference value. M
• After checking the maximum valve lift amount, lower the water
PBIC3314J
temperature and check the valve closing temperature.
N
Standard: Refer to CO-32, "Water Control Valve".
• If out of the standard, replace water control valve.
O
• Start and warm up the engine. Check visually that there is no leakage of engine coolant. P
CO-31

ENGINE COOLANT CAPACITY (APPROXIMATE)

Unit: (Imp qt)
M/T models (2WD) 7.0 (6 - 1/8)
Engine coolant capacity (With reservoir tank at “MAX” level) M/T models (4WD) 7.1 (6 - 1/4)
CVT models 7.4 (6 - 1/2)
Reservoir tank engine coolant capacity (At “MAX” level) 0.75 (5/8)
Radiator INFOID:0000000001160798
Standard 78.4 - 98.0 (0.78 - 0.98, 0.80 - 1.00, 11.4 - 14.2)

Cap relief pressure
Limit 59 (0.59, 0.60, 8.6)
Leakage testing pressure 157 (1.57, 1.60, 22.8)
Thermostat INFOID:0000000001160799
Standard
Valve opening temperature 80.5 - 83.5°C (177 - 182°F)

Maximum valve lift 8.0 mm/95°C (0.315 in/203°F)
Valve closing temperature 77°C (171°F)
Heater Thermostat (CVT models) INFOID:0000000001160800
Standard
Valve lift More than 4.5 mm (0.177 in)
Reference value
Valve opening temperature 82°C (180°F)

Water Control Valve INFOID:0000000001160801
Standard

CO-32
DESCRIPTION
DESCRIPTION
M/T
CO
JPBIA0707GB
M
CO-33
DESCRIPTION
JPBIA0708GB
CVT
CO-34
DESCRIPTION
CVT : Engine Cooling System INFOID:0000000001202915
CO
K
JPBIA0709GB
CO-35
DESCRIPTION
CVT : Engine Cooling System Schematic INFOID:0000000001202916
JPBIA0710GB
CO-36
SYMPTOM DIAGNOSIS A
CO
Symptom Check items

C
Thermostat and water con-
—
trol valve stuck closed
D
Poor heat transfer —
Damaged radiator fins per clogging
Physical damage E
Cooling fan does not oper- F
ate
tion
G
Damaged fan blades
Cooling sys- Improper engine coolant H

— — —
tem parts mixture ratio
malfunction Poor engine coolant quality — Engine coolant density —
Loose clamp I
Cooling hose
Cracked hose
J
Loose
Radiator cap
Poor sealing
O-ring for damage, deterio- K
Radiator
Cracked radiator core L
Exhaust gas leaks into cool- M
ing system
oration
CO-37
Symptom Check items
load
Abusive driving
tended time
speed
— Overload on engine
Powertrain system malfunc-
tion
Except cool- —
wheels and tires
ing system
function
Blocked bumper —
Blocked radiator grille Mud contamination or paper
flow
Blocked condenser
Blocked air flow
CO-38
PRECAUTIONS
PRECAUTION A
PRECAUTIONS
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect CO
INFOID:0000000001570494
NOTE:
• This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYS- C
TEM).
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work. D
anism is adopted on the key cylinder. E
F
OPERATION PROCEDURE
1. Connect both battery cables. G
NOTE:
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the H
rotated. I
the battery cables. (At this time, the steering lock mechanism will engage.) J
K
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain L
WARNING: M
N
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this O
ness connectors.
P
CO-39
PREPARATION
PREPARATION
PREPARATION
Tool number
Description
Tool name
S-NT224

Radiator plate pliers B
S-NT225

Radiator cap tester Checking radiator and radiator cap
PBIC1982E
Radiator cap tester adapter Adapting radiator cap tester to radiator cap
and radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
S-NT564
CO-40
ENGINE COOLANT
ENGINE COOLANT
CO
LEVEL
• Check that the reservoir tank engine coolant level is within the C
A : MAX
B : MIN
D
• Adjust the engine coolant level if necessary.

E
JPBIA0102ZZ
F
LEAKAGE
• To check for leaks, apply pressure to the cooling system with the
radiator cap tester (commercial service tool) (A) and the radiator G
Testing pressure: Refer to CO-61, "Radiator". H

WARNING:
Never remove radiator cap when engine is hot. Serious burns
may occur from high-pressure engine coolant escaping from I
radiator.
CAUTION:
age. J
NOTE:
• If anything is found, repair or replace damaged parts. K
WARNING: L
• Wrap a thick cloth around the radiator cap. Slowly turn it a quarter of a turn to release built-up pres- M
2. Open radiator drain plug at the bottom of radiator, and then N
remove radiator cap.
A : Radiator drain plug hole

O
: Vehicle front
CAUTION:
Perform this step when engine is cold. P
• When draining all of engine coolant in the system, open water
drain plugs on cylinder block. Refer to EM-210, "Exploded
View". JPBIA0892ZZ
CO-41
ENGINE COOLANT
• Move reservoir tank (3), and then remove it numerical order as
: Vehicle front
JPBIA0891ZZ
4. Check drained engine coolant for contaminants such as rust, corrosion or discoloration.
If contaminated, flush the engine cooling system. Refer to CO-43, "Flushing".

CAUTION:
Radiator drain plug: Refer to CO-47, "Exploded View".

• If water drain plugs on cylinder block are removed, close and tighten them. Refer to EM-210, "Exploded
View".
2. Check that each hose clamp has been firmly tightened.
3. Remove air duct assembly, and move electric throttle control actuator to aside. Refer to EM-150,
"Exploded View" and EM-152, "Exploded View".
4. Disconnect heater hose (1) at the position ( ) in the figure.
: Vehicle front
• Lift up the heater hose end approximately 100 mm (3.94 in) (a)
higher than the height at installation.
JPBIA0817ZZ
CO-42
ENGINE COOLANT
5. Fill radiator (1) to specified level.
CAUTION: A
Never adhere the engine coolant to electronic equipments
(alternator etc.).
• Pour engine coolant through engine coolant filler neck slowly
CO
of less than 2 (2-1/8 US qt, 1-3/4 lmp qt) a minute to allow
air in system to escape.
• When engine coolant overflows disconnected heater hose,
connect heater hose, and continue filling the engine coolant. C
quality mixed with water (distilled or demineralized). Refer to JPBIA0819ZZ
MA-22, "Fluids and Lubricants". D
Engine coolant capacity
E

F
A : MAX
B : MIN
G
H
JPBIA0102ZZ
8. Install air duct assembly and electric throttle control actuator. I
Refer to EM-150, "Exploded View" and EM-152, "Exploded View".
3,000 rpm. J
• Check thermostat opening condition by touching radiator hose (lower) to see a flow of warm water.
CAUTION:
K
CAUTION: L
Never adhere the engine coolant to electronic equipments (alternator etc.).
12. Repeat steps 5 through 10 two or more times with radiator cap installed until engine coolant level no M
longer drops.
14. Warm up the engine, and check for sound of engine coolant flow while running engine from idle up to N
15. Repeat step 14 three times. O
16. If sound is heard, bleed air from cooling system by repeating step 5 through 10 until engine coolant level
no longer drops.
P

CAUTION:
CO-43
ENGINE COOLANT
• If water drain plugs on cylinder block are removed, close and tighten them. Refer to EM-210, "Exploded
View".
2. Remove air duct assembly and move electric throttle control actuator to aside. Refer to EM-150,
"Exploded View" and EM-152, "Exploded View".
3. Disconnect heater hose (1) at the position ( ) in the figure.
: Vehicle front
• Lift up the heater hose end approximately 100 mm (3.94 in) (a)
higher than the height at installation.
JPBIA0817ZZ
4. Fill radiator and reservoir tank with water and reinstall radiator cap.
• When engine coolant overflows disconnected heater hose, connect heater hose, and continue filling the
engine coolant.
5. Install air duct assembly and electric throttle control actuator. Refer to EM-150, "Exploded View" and EM-
152, "Exploded View".
9. Drain water from the system. Refer to CO-41, "Draining".
CO-44
RADIATOR
RADIATOR
A
RADIATOR CAP
RADIATOR CAP : Inspection INFOID:0000000001160734
CO
• Check valve seat of radiator cap.
A : Valve seat C
B : Metal plunger
plunger cannot be seen when watching it vertically from the top. D
E
JPBIA0108ZZ
• Pull negative-pressure valve to open it, and check that it close F

- Check that there is no dirt or damage on the valve seat of radiator
cap negative-pressure valve. G
H
SMA967B
I
• Check radiator cap relief pressure.

J
Standard and Limit: Refer to CO-61, "Radiator".
- When connecting radiator cap to the radiator cap tester (commer-
cial service tool) (A) and the radiator cap tester adapter (commer- K
cial service tool) (B), apply engine coolant to the cap seal surface.
PBIC5122J
M
• Replace radiator cap if there is an unusualness related to the above three.
CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue N
or foreign material.
RADIATOR
O

CAUTION: P
assembly and horns. Then tape harness and harness connectors to prevent water from entering.
CO-45
RADIATOR
• Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2, 71 psi) and keep distance more than 30 cm
(11.8 in).
CO-46
RADIATOR
ON-VEHICLE REPAIR A
RADIATOR
CO
REMOVAL
C
K
JPBIA0739GB
1. Reservoir tank cap 2. Reservoir tank 3. Clamp L

10. Mounting rubber (lower) 11. O-ring 12. Drain plug M
A. To water outlet B. To water inlet N
DISASSEMBLY O
CO-47
RADIATOR
JPBIA0579GB

4. Lower tank
REMOVAL
WARNING:
CAUTION:
4. Disconnect harness connector from fan motor, and move it aside.
5. Remove radiator hose (upper) and reservoir tank hose.
6. Remove mounting bracket (RH and LH) and mounting rubber (upper) to tilt radiator frontward.
7. Remove cooling fan assembly (1). Refer to CO-53, "Exploded
View".
CAUTION:
KBIA3587J
8. Removal radiator hose (lower).

9. Remove radiator.
CAUTION:
INSTALLATION
CO-48
RADIATOR
A
PREPARATION
CO
1. Attach spacer to tip of the radiator plate pliers A (SST).
Spacer specification: 1.5 mm (0.059 in) thick × 18 mm (0.71 in)
C
E
SLC655C
2. Check that when the radiator plate pliers A [SST: KV99103510] are closed dimension H′′ is approx. 7.6
mm (0.299 in). F
3. Adjust dimension H′′ with spacer, if necessary.
DISASSEMBLY G
1. Remove upper and lower tanks with the radiator plate pliers B
(SST).
H
J
SLC903
• Grip the crimped edge and bend it upwards so that the radiator K
CAUTION:
Never bend excessively. L
SLC893
N
• In areas where the radiator plate pliers B [SST: KV99103520]

cannot be used, use a screwdriver to bend the edge up. O
CAUTION:
Be careful not to damage tank.
P
SLC930
CO-49
RADIATOR
SLC931
ASSEMBLY
SLC932
2. Install new sealing rubber while pressing it with fingers.

CAUTION:
SLC917A
3. Caulk tank in numerical order as shown in the figure with the

radiator plate pliers A (SST).
SLC904
CO-50
RADIATOR
CO
JPBIA0903ZZ
D
a. 90°
E
• Use pliers in the locations where the radiator plate pliers A
[SST: KV99103510] cannot be used.
F
H
SLC897

I
SLC554A
L
5. Check that there is no leakage. Refer to CO-51, "Inspection".
M
1. Apply pressure with the radiator cap tester adapter (commercial N
tool).
Testing pressure: Refer to CO-61, "Radiator". O
WARNING:
To prevent the risk of hose coming undone while under
pressure, securely fasten it down with hose clamp. P
JPBIA0736ZZ
CO-51
RADIATOR
SLC934

CO-52
COOLING FAN
COOLING FAN
A
CO
I
JPBIA0794GB
1. Fan motor cover 2. Fan motor (LH) 3. Fan motor (RH) J

4. Fan shroud 5. Cooling fan (RH) 6. Cooling fan (LH)
A. Apply on fan motor shaft.
: Vehicle front

L
REMOVAL
M
CAUTION:
Perform this step when the engine is cold. N
4. Disconnect harness connector from fan motor, and move harness to aside.
O
5. Remove radiator hose (upper) and reservoir tank hose. Refer to CO-47, "Exploded View".
6. Remove mounting bracket (RH and LH) and mounting rubber (upper) to tilt radiator frontward. Refer to
CO-47, "Exploded View".
P
CAUTION:
Be careful not to damage or scratch on radiator core when removing.
INSTALLATION
CAUTION:
CO-53
COOLING FAN
Only use genuine parts for radiator shroud and cooling fan mounting bolt and observe the specified
torque (to prevent radiator from being damaged).
NOTE:
Cooling fan is controlled by ECM. For details, refer to ECQ-300, "Description".
DISASSEMBLY
2. Remove fan motor cover and fan motors (RH and LH).
ASSEMBLY
CAUTION:


Cooling Fan
CO-54
WATER PUMP
WATER PUMP
A
CO
G
JPBIA0582GB
1. Water pump 2. Gasket 3. Gasket

4. Water pump housing 5. Gasket 6. Water pipe
H
7. O-ring
I
REMOVAL J
CAUTION:
Perform this step when engine is cold. K
• Drive belt auto-tensioner: Refer to EM-148, "Exploded View". L
• Alternator: Refer to CHG-30, "QR25DE MODELS : Exploded View".
• Engine coolant leaks from cylinder block, so have a receptacle ready below. M
CAUTION:
• Handle water pump vane so that it does not contact any other parts.
• Water pump cannot be disassembled and should be replaced as a unit.
4. Remove water pump housing with the following procedure: N
a. Remove exhaust manifold cover. Refer to EM-155, "Exploded View".
b. Remove oil level gauge and oil level gauge guide. Refer to EM-161, "Exploded View".
CAUTION: O
Plug the oil level gauge guide opening to prevent oil pan from entering foreign materials.
c. Remove mounting bolts for water pipe.
P
d. Remove water pump housing.
5. Remove exhaust manifold and three way catalyst assembly. Refer to EM-155, "Exploded View".
6. Remove water pipe.
INSTALLATION
• When inserting water pipe end into cylinder block, apply a neutral detergent to O-ring. Then insert it immedi-
ately.
CO-55
WATER PUMP

• Check visually that there is no significant dirt or rusting on water
pump body and vane.
• Check that there is no looseness in vane shaft, and that it turns
• Replace water pump, if necessary.
KBIA0155E

• Start and warm up engine. Check visually that there is no leakage of engine coolant.
CO-56
THERMOSTAT AND WATER CONTROL VALVE
A
M/T models CO
JPBIA0583GB
K
1. Thermostat 2. O-ring 3. Water inlet
4. Clamp 5. Radiator hose (lower) 6. Water control valve
L
7. O-ring 8. Gasket 9. Radiator hose (upper)
10. Water control valve housing (water outlet) 11. Heater hose 12. Clamp
M
Engine coolant temperature
16. Clamp 17. 18. Washer
sensor
19. Heater pipe 20. O-ring 21. Heater hose
22. Water hose 23. Water hose N
A. To radiator B. To heater C. To electric throttle control actuator
D. To oil cooler
: Engine front
O
CVT models P
CO-57
JPBIA0584GB
1. Thermostat 2. O-ring 3. Water inlet

4. Clamp 5. Radiator hose (lower) 6. Clamp
7. Water hose 8. Water control valve 9. O-ring
Water control valve housing (water
10. Gasket 11. Radiator hose (upper) 12.
outlet)
13. Water hose 14. Heater hose 15. Clamp
Engine coolant temperature
19. Clamp 20. 21. Washer
sensor
22. Heater pipe 23. O-ring 24. Water hose
25. Heater hose 26. Water hose
A. To CVT fluid cooler B. To radiator C. To heater
D. To electric throttle control actuator E. To oil cooler
: Engine front
REMOVAL
2. Disconnect engine room harness connectors at unit sides TCM and ECM, and then move it to aside.
3. Remove battery tray.
4. Remove air duct and air cleaner case assembly. Refer to EM-150, "Exploded View".
CAUTION:
CO-58
6. Disconnect radiator hose (lower) at water inlet side. Refer to CO-47, "Exploded View".
7. Disconnect water hose at water inlet side. (CVT models) A
8. Remove water inlet and thermostat.
9. Remove water control valve with the following procedure:
CO
a. Disconnect radiator hose (upper) at water control valve housing (water outlet) side.
b. Disconnect harness connector from engine coolant temperature sensor.
c. Remove CVT fluid level gauge and CVT fluid charging pipe. Refer to TM-550, "QR25DE : Exploded C
View". (CVT models)
d. Disconnect water hoses.
e. Disconnect heated oxygen sensor harness connectors, and remove harness clips from heater pipe. D
f. Remove heater pipe and heater hose.
g. After removing water control valve housing (water outlet), remove water control valve.
INSTALLATION E
Thermostat and Water Control Valve
F
• Install thermostat and water control valve with making rubber ring
groove fit to thermostat flange and water control valve flange with
the whole circumference. (The example in the figure shows ther-
mostat.) G
NOTE:
Same procedure is applied for installation of water control valve.
H
I
PBIC0157E
• Install thermostat with jiggle valve facing upwards. (The position J

deviation may be within the range of 20 degrees as shown in the
figure.)
• Install water control valve with the arrow facing up and the frame
center part facing upwards. (The position deviation may be within K
the range of 20 degrees as shown in the figure.)
PBIC0158E
M
Heater Pipe Installation
Apply a neutral detergent to O-ring, then quickly insert the insertion part of heater pipe into cylinder block.
N

• Place a thread (A) so that it is caught in the valves of thermostat O
(1) and water control valve. Immerse fully in a container (B) filled
with water. Heat while stirring. (The example in the figure shows
thermostat.) P
• Continue heating. Check the maximum valve lift amount.
NOTE:
The maximum valve lift amount standard temperature for water
control valve is the reference value.
PBIC3314J
CO-59
• After checking the maximum valve lift amount, lower the water temperature and check the valve closing tem-
perature.
Standard
Thermostat : Refer to CO-61, "Thermostat".
Water control valve : Refer to CO-61, "Water control valve".
• If out of the standard, replace either or both thermostat and water control valve.
• Start and warm up engine. Check visually that there is no leakage of engine coolant.
CO-60

CO

Unit: (lmp qt) C
M/T models 6.8 (6)
Engine coolant capacity (With reservoir tank at “MAX” level)
CVT models 7.1 (6 - 1/4)
Reservoir tank 0.75 (5/8) D
E
Standard 78.4 - 98.0 (0.78 - 0.98, 0.8 - 1.0, 11- 14)

Cap relief pressure
Limit 59 (0.59, 0.6, 9) F
Leakage test pressure 157 (1.57, 1.60, 22.8)
Thermostat INFOID:0000000001303608 G
Standard
Valve opening temperature 80.5 - 83.5°C (177 - 182°F) H
Maximum valve lift 8 mm/95°C (0.315 in/203°F)
I
Water control valve INFOID:0000000001303609
Standard
J
Maximum valve lift 8 mm/108°C (0.315 in/226°F)*
Valve closing temperature 90°C (194°F) K
*: Reference data
CO-61
DESCRIPTION
FUNCTION DIAGNOSIS
DESCRIPTION
M/T
JPBIA0740GB
JPBIA0741GB
CO-62
DESCRIPTION
A/T
A
A/T : Engine Cooling System INFOID:0000000001308710
CO
JPBIA0804GB
I
A/T : Engine Cooling System Schematic INFOID:0000000001308711
JPBIA0805GB
CO-63
SYMPTOM DIAGNOSIS
Symptom Check items

Thermostat stuck closed —
Poor heat transfer Damaged radiator fins per clogging —
Physical damage
Cooling fan does not oper-
ate
tion
Damaged fan blades
Improper engine coolant
Cooling sys- — — —
mixture ratio
tem parts
malfunction Poor engine coolant quality — Engine coolant viscosity —
Loose clamp
Cooling hose
Cracked hose
Loose
Reservoir tank cap
Poor sealing
O-ring for damage, deterio-
Radiator
Cracked radiator core
Exhaust gas leakage into
cooling system
oration
CO-64
Symptom Check items
A
load
Abusive driving CO
tended time
speed
— Overload on engine C
Power train system mal-
function
Except cool- —
wheels and tires D
ing system
function
E
Blocked bumper —
Blocked radiator grille Mud contamination or paper F
flow
Blocked condenser G
Blocked air flow
CO-65
PRECAUTIONS
PRECAUTION
PRECAUTIONS
INFOID:0000000001308749
NOTE:
TEM).
OPERATION PROCEDURE
NOTE:
rotated.
WARNING:
ness connectors.
CO-66
PREPARATION
PREPARATION A
PREPARATION
CO
Tool number
Description C
Tool name
D
E
S-NT224

Radiator plate pliers B F
S-NT225
H
I
Radiator cap tester Checking radiator and reservoir tank cap
J
PBIC1982E
Radiator cap tester adapter Adapting radiator cap tester to reservoir tank L
cap and radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia. M
Unit: mm (in)
S-NT564 N
CO-67
ENGINE COOLANT
ENGINE COOLANT
LEVEL
• Check that the reservoir tank engine coolant level is within the
A : MAX
B : MIN
• Regarding engine coolant level check, perform it with engine at
idle.
NOTE:
Engine coolant level rises approximately 15 mm (0.59 in) in the
engine stop.
• Adjust the engine coolant level if necessary. JPBIA0102ZZ
WARNING:
Never remove radiator cap and reservoir tank cap when engine is hot. Serious burns may occur from
high-pressure engine coolant escaping from radiator and reservoir tank.
LEAKAGE
• To check for leakage, apply pressure to the cooling system with the
radiator cap tester (commercial service tool) (A) and the radiator

WARNING:
Never remove radiator cap and reservoir tank cap when
engine is hot. Serious burns may occur from high-pressure
engine coolant escaping from radiator and reservoir tank.
CAUTION:
age.
NOTE:
• If anything is found, repair or replace damaged parts.
WARNING:
• Never remove radiator cap and reservoir tank cap when engine is hot. Serious burns may occur from
• Wrap a thick cloth around the caps. Slowly turn it a quarter of a turn to release built-up pressure.
Then turn it all the way.
2. Open radiator drain plug at the bottom of radiator, and then
remove reservoir tank cap.
A : Radiator drain plug hole

: Vehicle front
CAUTION:
JPBIA0892ZZ
CO-68
ENGINE COOLANT
• Removal of fuel filter is necessary. Refer to FL-16, "Exploded View". A
4. Check drained engine coolant for contaminants such as rust, corrosion or discoloration. If contaminated,
flush the engine cooling system. Refer to CO-70, "Flushing".
CO

CAUTION: C
Radiator drain plug: Refer to CO-73, "Exploded View". D
2. Check that each hose clamp has been firmly tightened.

3. Remove air duct assembly. Refer to EM-263, "Exploded View". E
: Vehicle front F
H
JPBIA0816ZZ
5. When engine coolant from heater hose starts to drain, install

I
heater hose, and continue filling with engine coolant until radia-
tor (1) gets full.
CAUTION:
• Prevent engine coolant overflowing from reservoir tank. J
• Never adhere the engine coolant to electronic equip-
ments. (alternator etc.)
• Pour coolant slowly of less than 2 (1-3/4 Imp qt) a minute to K
allow air in system to escape.
• Start engine without closing reservoir tank cap. Keep engine
racing at 1,500 rpm for about 2-3 minutes.
JPBIA0819ZZ
L
quality mixed with water (distilled or demineralized). Refer to MA-22, "Fluids and Lubricants"
Engine coolant capacity M

Refer to :CO-88, "Periodical Maintenance Specification".
N
7. Fill the reservoir tank approximately 15 mm (0.59 in) above the
“MAX” level of engine coolant.
O
A : MAX
B : MIN
P
NOTE:
Engine coolant level rises approximately 15 mm (0.59 in) in the
engine stop.

JPBIA0102ZZ
CO-69
ENGINE COOLANT
8. Install air duct assembly. Refer to EM-263, "Exploded View".
3,000 rpm.
• Check thermostat opening condition by touching radiator hose (upper) to see a flow of warm water.
CAUTION:
CAUTION:
11. Fill the reservoir tank approximately 15 mm (0.59 in) above the “MAX” level of engine coolant.
NOTE:
Engine coolant level rises approximately 15 mm (0.59 in) in the engine stop.
12. Repeat steps 5 through 10 two or more times with cap (radiator and reservoir tank) installed until engine
coolant level no longer drops.
14. Warm up the engine, and check for sound of engine coolant flow while running engine from idle up to
15. Repeat step 14 three times.
16. If sound is heard, bleed air from cooling system by repeating step 5 through 10 until reservoir tank level no
longer drops.

CAUTION:
Radiator drain plug: Refer to CO-73, "Exploded View".

2. Remove air duct assembly. Refer to EM-263, "Exploded View".
: Vehicle front
JPBIA0816ZZ
4. Fill radiator and reservoir tank with water and reinstall radiator cap and reservoir tank cap.
• When engine coolant over flows disconnected heater hose, connect heater hose, and continue filling the
engine coolant.
5. Install air duct assembly. Refer to EM-263, "Exploded View".
9. Drain water from the system. Refer to CO-68, "Draining".
CO-70
RADIATOR
RADIATOR
A
RESERVOIR TANK CAP
RESERVOIR TANK CAP : Inspection INFOID:0000000001308721
CO
• Check valve seat of reservoir tank cap.
A : Valve seat C
B : Metal plunger
plunger cannot be seen when watching it vertically from the top. D
E
JPBIA0108ZZ
• Pull negative-pressure valve to open it, and check that it closes F

- Check that there is no dirt or damage on the valve seat of reservoir
tank cap negative-pressure valve. G
H
SMA967B
I
• Check reservoir tank cap relief pressure.

J
Standard and Limit : Refer to CO-88, "Radiator".
- When connecting reservoir tank cap to the radiator cap tester
(commercial service tool) (A) and the radiator cap tester adapter K
(commercial service tool) (B), apply engine coolant to the cap seal
surface.
L
PBIC5122J
M
• Replace reservoir tank cap if there is an unusualness related to the above three.
CAUTION:
When installing radiator cap and reservoir tank cap, thoroughly wipe out the radiator filler neck to N
remove any waxy residue or foreign material.
RADIATOR
O

CAUTION: P
assembly and horns. Then tape harness and connectors to prevent water from entering.
CO-71
RADIATOR
• Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2, 71 psi) and keep distance more than 30 cm
(11.8 in).
CO-72
RADIATOR
ON-VEHICLE REPAIR A
RADIATOR
CO
REMOVAL
C
K
JPBIA0742GB
1. Reservoir tank cap 2. Reservoir tank 3. Clamp L

4. Reservoir tank hose (upper) 5. Mounting bracket 6. Mounting rubber (upper)
7. Radiator cap 8. Radiator 9. Mounting rubber (lower)
10. O-ring 11. Radiator drain plug 12. Water drain hose M
13. Clamp 14. Radiator hose (lower) 15. Radiator hose pipe (M/T models)
16. Clamp 17. Water hose (M/T models) 18. Radiator hose pipe (A/T models)
19. Water hose (A/T models) 20. Water hose (A/T models) 21. Radiator hose (lower) N
22. Radiator hose (upper) 23. Reservoir tank hose (lower) 24. Cooling fan assembly
A. To A/T fluid cooler B. To turbocharger cooling pump C. To EGR cooler tube
D. To water outlet E. To oil cooler F. To water suction pipe O
DISASSENBLY P
CO-73
RADIATOR
JPBIA0579GB

4. Lower tank
REMOVAL
WARNING:
• Never remove radiator cap and reservoir tank cap when engine is hot. Serious burns may occur from
• Wrap a thick cloth around the caps. Slowly turn it a quarter of a turn to release built-up pressure.
Then turn it all the way.
CAUTION:
4. Remove air inlet hose, air inlet pipe and bracket. Refer to EM-266, "Exploded View".
5. Remove mounting bracket and mounting rubber (upper).
6. Disconnect harness connector from fan motors, and move harness to aside.
7. Disconnect radiator hose (upper).
CAUTION:
9. Disconnect reservoir tank hose (upper) from radiator.
10. Disconnect radiator hose (lower).
11. Remove radiator.
CAUTION:
INSTALLATION
PREPARATION
CO-74
RADIATOR
1. Attach the spacer to the tip of radiator plate pliers A (SST).
Spacer specification: 1.5 mm (0.059 in) thick × 18 mm (0.71 in) A
CO
SLC655C
D
2. Check that when radiator plate pliers A [SST: KV99103510] are closed dimension H′′ is approximately 7.6
mm (0.299 in).
3. Adjust dimension H′′ with the spacer thickness, if necessary. E
DISASSEMBLY
1. Remove upper and lower tanks with a radiator plate pliers B
(SST). F
SLC903
I
• Grip the crimped edge and bend it upwards so that radiator
CAUTION: J
Never bend excessively.
SLC893
M
• In areas where radiator plate pliers B [SST: KV99103520] can-
not be used, use screwdriver to bend the edge up.
CAUTION:
Be careful not to damage tank. N
P
SLC930
CO-75
RADIATOR
SLC931
ASSEMBLY
SLC932
2. Install sealing rubber while pressing it in with fingers.

CAUTION:
SLC917A
3. Caulk tank in numerical order as shown in the figure with radia-

tor plate pliers A (SST).
SLC904
CO-76
RADIATOR
CO
JPBIA0903ZZ
D
a. 90°
E
• Use pliers in the locations where radiator plate pliers A [SST:
KV99103510] cannot be used.
F
H
SLC897

I
SLC554A
L
5. Check that there is no leakage. Refer to CO-68, "Inspection".
M
radiator cap tester (commercial service tool). Refer to CO-68, "Inspection". N
• Start and warm up the engine. Visually check that there is no leakage of engine coolant.
O
1. Apply pressure with the radiator cap tester adapter (commercial
tool).
P
WARNING:
To prevent the risk of hose coming undone while under
pressure, securely fasten it down with hose clamp.
JPBIA0736ZZ
CO-77
RADIATOR
SLC934
CO-78
COOLING FAN
COOLING FAN
A
CO
I
JPBIA0793GB
1. Fan motor (LH) 2. Fan motor (RH) 3. Fan shroud J

4. Cooling fan (RH) 5. Cooling fan (LH)
A. Apply on fan motor shaft.
: Vehicle front
L
REMOVAL M
CAUTION: N
4. Remove air inlet hose, air inlet pipe and bracket. Refer to EM-266, "Exploded View". O
5. Remove mounting bracket and mounting rubber (upper).
6. Disconnect harness connector from fan motors, and move harness to aside.
P
7. Disconnect radiator hose (upper).
CAUTION:
INSTALLATION
CAUTION:
CO-79
COOLING FAN
Only use genuine parts for fan shroud mounting bolt and observe the specified torque (to prevent
radiator from being damaged).
NOTE:
Cooling fan is controlled by ECM. For details, refer to ECR-284, "Description".
DISASSEMBLY
2. Remove fan motors (RH and LH).
ASSEMBLY
CAUTION:


Cooling Fan
CO-80
WATER PIPING
WATER PIPING
A
CO
I
JPBIA0745GB
1. Clamp 2. Water hose 3. Reservoir tank hose (lower) J

4. O-ring 5. Water suction pipe 6. Clamp
7. Water hose
A. To EGR cooler tube B. To reservoir tank C. To oil cooler K

L
REMOVAL
1. Drain engine coolant from radiator. Refer to CO-68, "Draining". M
CAUTION:
2. Disconnect water hoses and reservoir tank hose (lower).
N
CAUTION:
3. Remove EGR cooler tube. Refer to EM-268, "Exploded View".
O
4. Remove multifunction support bracket. Refer to EM-261, "Exploded View".
5. Remove water suction pipe.
• Engine coolant will leak from cylinder block, so have a receptacle ready below.
P
INSTALLATION
• When inserting water suction pipe end into cylinder block, apply a neutral detergent to O-ring. Then insert it
immediately.
CO-81
WATER PIPING

CO-82
WATER OUTLET AND THERMOSTAT ASSEMBLY
A
M/T models CO
JPBIA0749GB
K
1. Heater pipe 2. Clamp 3. Heater hose
4. Water outlet and thermostat assembly 5. Rubber ring 6. Bracket
L
7. Water pipe 8. Clamp 9. Water hose
10. Water hose 11. Heater hose 12. Heater pipe
13. Mounting bracket 14. Engine coolant temperature sensor 15. O-ring
M
16. Clip
A. To heater core B. To turbocharger C. To turbocharger cooling pump
D. To radiator E. To EGR cooler tube
N
A/T models
O
CO-83
JPBIA0748GB
1. Heater pipe 2. Clamp 3. Heater hose

4. Water outlet and thermostat assembly 5. Rubber ring 6. Bracket
7. Water pipe 8. Clamp 9. Water hose
10. Water hose 11. Heater hose 12. Heater pipe
13. Mounting bracket 14. Engine coolant temperature sensor 15. O-ring
16. Clip
A. To heater core B. To turbocharger C. To radiator
D. To EGR cooler tube
REMOVAL
CAUTION:
3. Remove air duct assembly and air cleaner case. Refer to EM-263, "Exploded View".
4. Disconnect radiator hose (upper). Refer to CO-74, "Removal and Installation".
5. Disconnect harness connector from engine coolant temperature sensor.
6. Disconnect water hoses and heater hoses.
7. Remove heater pipes.
8. Remove water outlet and thermostat assembly.
9. Remove engine coolant temperature sensor from water outlet and thermostat assembly, if necessary.
CAUTION:
Handle carefully to avoid any shock to engine coolant temperature sensor.
CO-84
INSTALLATION
Note the following, and install in the reverse order of removal. A
Water outlet and thermostat assembly
• Check that installation of the thermostat (1) and the rubber ring (2)
to the cylinder head. CO
A : Air relief plug

C
JPBIA0750ZZ
E
INSPECTION AFTER REMOVAL F
Water outlet and thermostat assembly

1. Check valve seating condition at ordinary room temperatures. It should seat tightly. G
2. Check valve operation.
• If the malfunctioning condition, when valve seating at ordinary
room temperature, or measured values are out of the stan- H
dard, replace water outlet and thermostat assembly.
Standard: I
Refer to CO-88, "Water Outlet and Thermostat Assem-
bly".
J
E1BIA0038ZZ

K
L
CO-85
WATER PUMP

WATER PUMP
JPBIA0744GB
1. Water pump pulley 2. Water pump 3. O-ring

REMOVAL
1. Remove engine assembly. Refer to EM-312, "Exploded View".
NOTE:
Water pump cannot be removed with an onboard condition.
2. Remove water pump pulley.
CAUTION:
• Handle water pump vane so that it does not contact any
other parts.
• Water pump cannot be disassembled and should be
replaced as a unit.
JPBIA0746ZZ
INSTALLATION
CO-86
WATER PUMP
Water pump
• Tighten mounting bolts in numerical order as shown in the figure. A
• When inserting water pump end into cylinder block, apply a neutral
detergent to O-ring. Then insert it immediately.
CO
JPBIA0746ZZ D
E
• Visually check if there is no significant dirt or rusting on water
pump body and vane (A).
• Check that there is no looseness in vane shaft, and that it turns F
• Replace water pump, if necessary.
G
JPBIA0747ZZ
INSPECTION AFTER INSTALLATION I

• Start and warm up the engine. Visually check that there is no leakage of engine coolant. J
CO-87


Unit: (Imp qt)
M/T models 8.4 (7-3/8)
Engine coolant capacity (With reservoir tank at “MAX” level)
A/T models 8.9 (7-7/8)
Reservoir tank engine coolant capacity (At “MAX” level) 0.7 (5/8)
RESERVOIR TANK CAP

Standard 127 - 147 (1.27 - 1.47, 1.3 - 1.5, 18.5 - 21.3)

Cap relief pressure
Limit 108 (1.08, 1.1, 15.6)
RADIATOR
Leakage testing pressure 157 (1.57, 1.6, 22.8)
Water Outlet and Thermostat Assembly INFOID:0000000001308743
Standard
Valve opening temperature 86 - 89°C (187 - 192°F)

CO-88
ENGINE
ACCELERATOR CONTROL SYSTEM

SECTION ACC ACC
E
CONTENTS
PRECAUTION ............................................... 2 ON-VEHICLE REPAIR .................................. 3 F
PRECAUTIONS ................................................... 2 ACCELERATOR CONTROL SYSTEM .............. 3

Precaution for Supplemental Restraint System Exploded View .......................................................... 3 G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Removal and Installation .......................................... 3
SIONER" ................................................................... 2 Inspection ................................................................. 4
H
ACC-1
PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
WARNING:
ness connectors.
ACC-2
< ON-VEHICLE REPAIR >
ON-VEHICLE REPAIR A
ACC
JPBIA0893GB J
1. Accelerator pedal assembly (LHD models) 2. Accelerator pedal assembly (RHD models)
A. Locating pin
K
: Vehicle front
L
REMOVAL
M
LHD models
1. Loosen accelerator pedal assembly mounting nuts, and remove accelerator pedal assembly.
CAUTION: N
• Never disassemble accelerator lever. Never remove accelerator pedal position sensor from
accelerator lever.
• Avoid impact from dropping etc. during handling.
O
• Be careful to keep accelerator lever away from water.
2. Disconnect accelerator pedal position sensor harness connector.
RHD models P
2. Remove accelerator pedal assembly mounting nuts.
3. Loosen brake pedal assembly mounting nuts. Refer to BR-67, "Exploded View".
NOTE:
Brake pedal assembly does not have to be removed from the vehicle.
4. Remove accelerator pedal assembly.
ACC-3
CAUTION:
• Never disassemble accelerator lever. Never remove accelerator pedal position sensor from
accelerator lever.
• Avoid impact from dropping etc. during handling.
• Be careful to keep accelerator lever away from water.
INSTALLATION
• Insert locating pin into vehicle side to position accelerator pedal assembly. Tighten mounting nuts to acceler-
ator pedal assembly.

• Check that accelerator pedal moves smoothly within the whole operation range when it is depressed fully
and released.
• Check that accelerator pedal returns securely to the fully released position.
• For the electrical inspection of accelerator pedal position sensor. Refer to ECM-268, "Description"
(MR20DE), ECQ-275, "Description" (QR25DE) or ECR-242, "Description" (M9R).
ACC-4
DRIVER INFORMATION & MULTIMEDIA
AUDIO, VISUAL & NAVIGATION SYSTEM

SECTION AV B
E
CONTENTS
AUDIO WITHOUT NAVIGATION Component Inspection .............................................18 F
BASIC INSPECTION .................................... 6 ECU DIAGNOSIS ......................................... 19

AUDIO UNIT ...................................................... 19 G
DIAGNOSIS AND REPAIR WORKFLOW .......... 6
Work Flow ................................................................. 6 Reference Value ......................................................19
Wiring Diagram—AUDIO WITHOUT NAVIGA-
FUNCTION DIAGNOSIS ............................... 7 TION SYSTEM (LHD MODELS)— ..........................21 H
Wiring Diagram—AUDIO WITHOUT NAVIGA-
AUDIO SYSTEM .................................................. 7 TION SYSTEM (RHD MODELS)— .........................27
System Diagram ........................................................ 7
I
System Description ................................................... 7 SYMPTOM DIAGNOSIS .............................. 33
Component Parts Location ........................................ 9
Component Description ........................................... 10 MULTI AV SYSTEM SYMPTOMS .................... 33
Symptom Table .......................................................33 J
DIAGNOSIS SYSTEM (AUDIO UNIT) ................11
Diagnosis Description (With Hands-free Phone NORMAL OPERATING CONDITION ............... 34
System) ................................................................... 11 Description ...............................................................34
K
COMPONENT DIAGNOSIS ......................... 12 PRECAUTION .............................................. 36
POWER SUPPLY AND GROUND CIRCUIT ......12 PRECAUTIONS ................................................. 36 L
AUDIO UNIT .............................................................. 12 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
AUDIO UNIT : Diagnosis Procedure ....................... 12 SIONER" .................................................................36
M
MICROPHONE SIGNAL CIRCUIT .....................13 ON-VEHICLE REPAIR ................................. 37
Description .............................................................. 13
Diagnosis Procedure ............................................... 13 AUDIO UNIT ...................................................... 37 AV
Exploded View .........................................................37
STEERING SWITCH SIGNAL A CIRCUIT .........14 Removal and Installation .........................................37
Description .............................................................. 14
Diagnosis Procedure ............................................... 14 FRONT DOOR SPEAKER ................................ 38 O
Component Inspection ............................................ 14 Exploded View .........................................................38
STEERING SWITCH SIGNAL B CIRCUIT .........16 P
Description .............................................................. 16 REAR DOOR SPEAKER .................................. 39
Diagnosis Procedure ............................................... 16 Exploded View .........................................................39
Component Inspection ............................................ 16 Removal and Installation .........................................39
STEERING SWITCH SIGNAL GND CIRCUIT....18 TWEETER ......................................................... 40

Description .............................................................. 18 Exploded View .........................................................40
Diagnosis Procedure ............................................... 18 Removal and Installation .........................................40
AV-1
STEERING SWITCH .......................................... 41 System Diagram ..................................................... 57
Exploded View ........................................................ 41 System Description ................................................. 57
Removal and Installation ........................................ 41 Component Parts Location ..................................... 58
Component Description .......................................... 59
MICROPHONE ................................................... 42
Exploded View ........................................................ 42 AUDIO SYSTEM ................................................ 60
Removal and Installation ........................................ 42 System Diagram ..................................................... 60
System Description ................................................. 60
RADIO ANTENNA ............................................. 43 Component Parts Location ..................................... 61
Exploded View ........................................................ 43 Component Description .......................................... 62
DIAGNOSIS SYSTEM (NAVI CONTROL
ANTENNA FEEDER (RADIO) ........................... 44 UNIT) .................................................................. 63
Harness Layout ...................................................... 44 Diagnosis Description ............................................. 63
AUDIO WITH NAVIGATION CONSULT - III Function (MULTI AV) ...................... 74
BASIC INSPECTION ................................... 45 COMPONENT DIAGNOSIS ....................... 78

DIAGNOSIS AND REPAIR WORKFLOW ......... 45 U1000 CAN COMM CIRCUIT ............................ 78
Work Flow ............................................................... 45 Description .............................................................. 78
DTC Logic ............................................................... 78
INSPECTION AND ADJUSTMENT ................... 47 Diagnosis Procedure .............................................. 78
ADDITIONAL SERVICE WHEN REMOVING BAT- U1010 CONTROL UNIT (CAN) ......................... 79
TERY NEGATIVE TERMINAL .................................. 47
Description .............................................................. 79
ADDITIONAL SERVICE WHEN REMOVING
DTC Logic ............................................................... 79
BATTERY NEGATIVE TERMINAL : Description ... 47
Diagnosis Procedure ............................................... 79
ADDITIONAL SERVICE WHEN REMOVING
BATTERY NEGATIVE TERMINAL : Special Re- U1310 NAVI CONTROL UNIT ........................... 80
pair Requirement .................................................... 47 Description .............................................................. 80
DTC Logic ............................................................... 80
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT ........................................................ 47 U1200 NAVI CONTROL UNIT ........................... 81
ADDITIONAL SERVICE WHEN REPLACING Description .............................................................. 81
CONTROL UNIT : Description ................................ 47 DTC Logic ............................................................... 81
CONTROL UNIT : Special Repair Requirement ..... 47 U1201 NAVI CONTROL UNIT ........................... 82
Description .............................................................. 82
REAR VIEW MONITOR POSSIBLE ROUTE LINE DTC Logic ............................................................... 82
CENTER POSITION ADJUSTMENT ........................ 47
REAR VIEW MONITOR POSSIBLE ROUTE LINE U1216 NAVI CONTROL UNIT ........................... 83
CENTER POSITION ADJUSTMENT : Description Description .............................................................. 83
... 47 DTC Logic ............................................................... 83
REAR VIEW MONITOR POSSIBLE ROUTE LINE
CENTER POSITION ADJUSTMENT : Special Re- U1217 NAVI CONTROL UNIT ........................... 84
pair Requirement .................................................... 47 Description .............................................................. 84
DTC Logic ............................................................... 84
FUNCTION DIAGNOSIS ............................. 48
U1204 GPS ........................................................ 85
MULTI AV SYSTEM ........................................... 48 Description .............................................................. 85
System Diagram ..................................................... 48 DTC Logic ............................................................... 85
System Description ................................................. 48 Diagnosis Procedure ............................................... 85
Component Parts Location ..................................... 50
Component Description .......................................... 51 U1205 GPS ........................................................ 86
Description .............................................................. 86
NAVIGATION SYSTEM ..................................... 52 DTC Logic ............................................................... 86
System Diagram ..................................................... 52 Diagnosis Procedure ............................................... 86
Component Parts Location ..................................... 55 U1206 GPS ........................................................ 87
Component Description .......................................... 56 Description .............................................................. 87
DTC Logic ............................................................... 87
REAR VIEW MONITOR SYSTEM ..................... 57 Diagnosis Procedure ............................................... 87
AV-2
U1207 GPS .........................................................88 DTC Logic .............................................................. 100
Description .............................................................. 88 Diagnosis Procedure ............................................. 100 A
DTC Logic ............................................................... 88
Diagnosis Procedure ............................................... 88 U1215 NAVI CONTROL UNIT ........................ 101
Description ............................................................. 101
B
U1208 NAVI CONTROL UNIT ............................89 DTC Logic .............................................................. 101
Description .............................................................. 89 Diagnosis Procedure ............................................. 101
DTC Logic ............................................................... 89
Diagnosis Procedure ............................................... 89 U1243 DISPLAY UNIT .................................... 102 C
Description ............................................................. 102
U1209 NAVI CONTROL UNIT ............................90 DTC Logic .............................................................. 102
D
DTC Logic ............................................................... 90
Diagnosis Procedure ............................................... 90 U1244 GPS ANTENNA ................................... 104
Description ............................................................. 104
U120A NAVI CONTROL UNIT ...........................91 DTC Logic .............................................................. 104 E
DTC Logic ............................................................... 91
Diagnosis Procedure ............................................... 91 U1250 CAMERA CONTROL UNIT ................. 105
Description ............................................................. 105 F
U120C NAVI CONTROL UNIT ...........................92 DTC Logic .............................................................. 105
DTC Logic ............................................................... 92 G
Diagnosis Procedure ............................................... 92 U1300 AV COMM CIRCUIT ............................ 106
Description ............................................................. 106
U120D NAVI CONTROL UNIT ...........................93 H
Description .............................................................. 93 POWER SUPPLY AND GROUND CIRCUIT .. 107
DTC Logic ............................................................... 93 NAVI CONTROL UNIT ............................................. 107
Diagnosis Procedure ............................................... 93 NAVI CONTROL UNIT : Diagnosis Procedure ...... 107 I
U120E NAVI CONTROL UNIT ...........................94 AUDIO UNIT ............................................................. 107
Description .............................................................. 94 AUDIO UNIT : Diagnosis Procedure ..................... 107
DTC Logic ............................................................... 94 J
Diagnosis Procedure ............................................... 94 DISPLAY UNIT ......................................................... 108
DISPLAY UNIT : Diagnosis Procedure .................. 108
U120F NAVI CONTROL UNIT ...........................95
Description .............................................................. 95 CAMERA CONTROL UNIT ...................................... 108 K
DTC Logic ............................................................... 95 CAMERA CONTROL UNIT : Diagnosis Procedure
Diagnosis Procedure ............................................... 95 .. 108
L
U1210 NAVI CONTROL UNIT ............................96 RGB (R: RED) SIGNAL CIRCUIT ................... 110
Description .............................................................. 96 Description ............................................................. 110
DTC Logic ............................................................... 96 Diagnosis Procedure ............................................. 110
Diagnosis Procedure ............................................... 96 M
RGB (G: GREEN) SIGNAL CIRCUIT ............. 111
U1211 NAVI CONTROL UNIT ............................97 Description ............................................................. 111
Description .............................................................. 97 Diagnosis Procedure ............................................. 111 AV
DTC Logic ............................................................... 97
RGB (B: BLUE) SIGNAL CIRCUIT ................. 112
Description ............................................................. 112
U1212 NAVI CONTROL UNIT ............................98 Diagnosis Procedure ............................................. 112 O
Description .............................................................. 98
DTC Logic ............................................................... 98
RGB SYNCHRONIZING SIGNAL CIRCUIT ... 113
Description ............................................................. 113
Diagnosis Procedure ............................................... 98 P
Diagnosis Procedure ............................................. 113
U1213 NAVI CONTROL UNIT ............................99
Description .............................................................. 99
RGB AREA (YS) SIGNAL CIRCUIT ............... 114
DTC Logic ............................................................... 99 Description ............................................................. 114
Diagnosis Procedure ............................................... 99 Diagnosis Procedure ............................................. 114
U1214 NAVI CONTROL UNIT .......................... 100 HORIZONTAL SYNCHRONIZING (HP) SIG-
Description ............................................................ 100 NAL CIRCUIT .................................................. 115
AV-3
Description .............................................................115 AUDIO UNIT ..................................................... 161
Diagnosis Procedure .............................................115 Reference Value ................................................... 161
Wiring Diagram—AUDIO WITH NAVIGATION
VERTICAL SYNCHRONIZING (VP) SIGNAL SYSTEM (LHD MODELS)— ................................. 164
CIRCUIT ........................................................... 116 Wiring Diagram—AUDIO WITH NAVIGATION
Description .............................................................116 SYSTEM (RHD MODELS)— ................................ 177
Diagnosis Procedure .............................................116
DISPLAY UNIT ................................................. 190
MICROPHONE SIGNAL CIRCUIT .................. 117 Reference Value ................................................... 190
Description .............................................................117 Wiring Diagram—AUDIO WITH NAVIGATION
Diagnosis Procedure .............................................117 SYSTEM (LHD MODELS)— ................................. 193
CAMERA IMAGE SIGNAL CIRCUIT (REAR
SYSTEM (RHD MODELS)— ................................ 206
VIEW CAMERA TO CAMERA CONTROL
UNIT) ................................................................ 118 CAMERA CONTROL UNIT .............................. 219
Description .............................................................118 Reference Value ................................................... 219
Diagnosis Procedure .............................................118 Wiring Diagram—AUDIO WITH NAVIGATION
SYSTEM (LHD MODELS)— ................................. 222
CAMERA IMAGE SIGNAL CIRCUIT (CAM- Wiring Diagram—AUDIO WITH NAVIGATION
ERA CONTROL UNIT TO DISPLAY UNIT) .... 119 SYSTEM (RHD MODELS)— ................................ 235
Description .............................................................119
Diagnosis Procedure .............................................119 SYMPTOM DIAGNOSIS ........................... 248
CAMERA ON SIGNAL CIRCUIT ..................... 120 MULTI AV SYSTEM SYMPTOMS .................... 248
Description .............................................................120 Symptom Table ..................................................... 248
NORMAL OPERATING CONDITION ............... 251
STEERING ANGLE SENSOR SIGNAL 1, 2 Description ............................................................ 251
CIRCUIT ........................................................... 121
Description .............................................................121 PRECAUTION ........................................... 255
PRECAUTIONS ................................................ 255
STEERING ANGLE SENSOR SIGNAL 3 CIR- Precaution for Supplemental Restraint System
CUIT ................................................................. 123 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
Description .............................................................123 SIONER" ............................................................... 255
Diagnosis Procedure .............................................123 Precaution for Trouble Diagnosis .......................... 255
Precaution for Harness Repair .............................. 255
STEERING SWITCH SIGNAL A CIRCUIT ...... 124
Description .............................................................124 ON-VEHICLE REPAIR .............................. 256
Component Inspection ...........................................124
AUDIO UNIT ..................................................... 256
Exploded View ...................................................... 256
STEERING SWITCH SIGNAL B CIRCUIT ...... 126 Removal and Installation ....................................... 256
Description .............................................................126
NAVI CONTROL UNIT ..................................... 257
Exploded View ...................................................... 257
STEERING SWITCH SIGNAL GND CIRCUIT . 128
Description .............................................................128
DISPLAY UNIT ................................................. 258
Exploded View ...................................................... 258
FRONT DOOR SPEAKER ................................ 259
ECU DIAGNOSIS ....................................... 130
Exploded View ...................................................... 259
NAVI CONTROL UNIT ..................................... 130 Removal and Installation ....................................... 259
Reference Value ....................................................130
REAR DOOR SPEAKER .................................. 260
Exploded View ...................................................... 260
SYSTEM (LHD MODELS)— .................................134
SYSTEM (RHD MODELS)— .................................147 TWEETER ......................................................... 261
DTC Index .............................................................159 Exploded View ...................................................... 261
AV-4
Removal and Installation ....................................... 261 Removal and Installation ....................................... 265
Adjustment ............................................................. 265 A
STEERING SWITCH ........................................ 262
Exploded View ...................................................... 262 STEERING ANGLE SENSOR ......................... 267
Removal and Installation ....................................... 262 Exploded View ....................................................... 267
Removal and Installation ....................................... 267 B
MICROPHONE ................................................. 263
Exploded View ...................................................... 263 RADIO ANTENNA ........................................... 268
Removal and Installation ....................................... 263 Exploded View ....................................................... 268 C
CAMERA CONTROL UNIT .............................. 264
Exploded View ...................................................... 264 GPS ANTENNA ............................................... 269
Removal and Installation ....................................... 264 Harness Layout ..................................................... 269 D
Adjustment ............................................................ 264 Removal and Installation ....................................... 269
REAR VIEW CAMERA ..................................... 265 ANTENNA FEEDER ........................................ 270 E

Exploded View ...................................................... 265 Harness Layout ..................................................... 270
AV
AV-5
DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION > [AUDIO WITHOUT NAVIGATION]
BASIC INSPECTION
DETAILED FLOW
1.CHECK SYMPTOM
Check the malfunction symptoms by performing the following items.
• Interview the customer to obtain the malfunction information (conditions and environment when the malfunc-
tion occurred).
• Check the symptom.
>> GO TO 2.
2.PERFORM DIAGNOSIS BY SYMPTOM
Perform the relevant diagnosis referring to the diagnosis chart by symptom. Refer to AV-33, "Symptom Table".
>> GO TO 3.
3.REPAIR OR REPLACE MALFUNCTIONING PARTS
Repair or replace the malfunctioning parts.
>> GO TO 4.
4.FINAL CHECK
Perform the operation to check that the malfunction symptom is solved or any other symptoms are present.
Is there any symptom?
YES >> GO TO 2.
NO >> INSPECTION END
AV-6
AUDIO SYSTEM
< FUNCTION DIAGNOSIS > [AUDIO WITHOUT NAVIGATION]
AUDIO SYSTEM
System Diagram INFOID:0000000001092893
B
WITH HANDS-FREE PHONE SYSTEM

C
JPNIA0249GB
H
WITHOUT HANDS-FREE PHONE SYSTEM
JPNIA0250GB
AV
System Description INFOID:0000000001092894
The audio system is equipped with following function. Each function is operated with audio switch or steering
switch (with hands-free phone system). O
Function
AM/FM radio P
CD
HANDS-FREE PHONE (WITH HANDS-FREE PHONE SYSTEM)
FUNCTION DESCRIPTION
Operating signal
AV-7
AUDIO SYSTEM
Audio system operation can be performed with audio switch or steering switch (with hands-free phone sys-
tem).
AM/FM Radio Mode
• AM/FM radio tuner is built into audio unit.
• Audio signal is received by antenna, next it is amplified by antenna amp., and finally it is input to audio unit.
Audio unit outputs the audio signal to each speaker.
CD Mode
• CD function is built into audio unit.
• Audio unit outputs audio signal to each speaker when CD is inserted to audio unit.
Hands-free Phone System (with hands-free phone system)
• Hands-free communication can be operated by connecting using Bluetooth® with cellular phone.
• Operation is performed by steering switch.
When a call is originated
• Spoken voice sound output from the microphone (mic. signal) is input to audio unit. Audio unit outputs to cel-
lular phone with Bluetooth® communication as a TEL voice signal. Voice sound is then heard at the other
party.
When receiving a call
• Voice sound is input to own cellular phone from the other party. TEL voice signal is output to front speaker,
and the signal is input to audio unit by establishing Bluetooth® communication from cellular phone.
SPEED SENSITIVE VOLUME
Volume level of this system gone up and down automatically in proportion to the vehicle speed. And the con-
trol level can be selected by the customer.
NATS AUDIO LINK
Description
The link with the NATS IMMU implies that the audio unit can basically only be operated if connected to the
matching NATS IMMU to which the audio unit was initially fitted on the production line.
Since radio operation is impossible after the link with the NATS is disrupted, theft of the audio unit is basically
useless since special equipment is required to reset the audio unit.
Initialization Process for Audio Units That Are Linked to the NATS IMMU
New audio units will be delivered to the factories in the “NEW” state, i.e. ready to be linked with the vehicle's
NATS. When the audio unit in “NEW” state is first switched on at the factory, it will start up communication with
the vehicle's immobilizer control unit (IMMU) and send a code (the “Audio Unit Code”) to the IMMU. The IMMU
will then store this code, which is unique to each audio unit, in its (permanent) memory.
Upon receipt of the code by the IMMU, the NATS will confirm correct receipt of the audio unit code to the audio
unit. Hereafter, the audio unit will operate as normal.
During the initialization process, “NEW” is displayed on the audio unit display. Normally though, communica-
tion between audio unit and IMMU takes such a short time (300 ms) that the audio unit seems to switch on
directly without showing “NEW” on its display.
Normal Operation
Each time the audio unit is switched on afterwards, the audio unit code will be verified between the audio unit
and the NATS before the audio unit becomes operational. During the code verification process, “WAIT” is
shown on the audio unit display. Again, the communication takes such a short time (300 ms) that the audio
unit seems to switch on directly without showing “WAIT” on its display.
When The Radio Is Locked
In case of the audio unit being linked with the vehicle's NATS (immobilizer system), disconnection of the link
between the audio unit and the IMMU will cause the audio unit to switch into the lock (“SECURE”) mode in
which the audio unit is fully inoperative. Hence, repair of the audio unit is basically impossible, unless the
audio unit is reset to the “NEW” state for which special decoding equipment is required.
Clarion has provided their authorized service representatives with so called “decoder boxes” which can bring
the audio unit back to the “NEW” state, enabling the audio unit to be switched on after which repair can be per-
formed. Subsequently, when the repaired audio unit is delivered to the final user again, it will be in the “NEW”
state to enable re-linking the audio unit to the vehicle's immobilizer system. As a result of the above, repair of
the audio unit can only be done by an authorized Clarion representative (when the owner of the vehicle
requests repair and can show personal identification).
AV-8
AUDIO SYSTEM
Service Procedure
A
Item Service procedure Description
Battery disconnection No additional action required. –
Radio needs repair Repair needs to be done by authorized rep- B
resentative of radio manufacturer since ra-
dio cannot be operated unless it is reset to –
NEW state, using special decoding equip-
C
ment.
Replacement of radio by new part No additional action required. Radio is delivered in “NEW” state.
Transferring radio to another vehicle/re- Radio needs to be reset to NEW state by D
placement of radio by an old part authorized representative of radio manu- –
facturer.
Replacement of IMMU Radio needs to be reset to NEW state by After switching on the radio, it will display
authorized representative of Clarion. “SECURE” after 1 minute.
E
No communication from IMMU to radio 1. Check NATS system if NATS is mal- The radio will display “SECURE” after 1
functioning. minute after switching on the radio. Further
2. Reset radio to “NEW” state by autho- use of radio is impossible until communica- F
rized representative of Clarion after tion is established again, or after radio is re-
NATS is repaired. set by authorized representative of Clarion.
When initialized between ECM and IMMU. Radio needs to be reset to “NEW” status by It will display “SECURE” after 1 minute after G
authorized representative of Clarion. switching on the radio.
Component Parts Location INFOID:0000000001092895
JPNIA0316ZZ
AV
1. Tweeter RH 2. Tweeter LH 3. Front door speaker LH
4. Rear door speaker LH 5. Rear door speaker RH 6. Front door speaker RH
7. Radio antenna 8. Microphone* 9. Steering switch*
O
10. Audio unit
*: With hands-free phone system

P
AV-9
AUDIO SYSTEM
Component Description INFOID:0000000001092896
Part name Description

• Operational switch of audio system is integrated.
• Receiving function of AM/FM radio, replaying function of CD and hands-free
AUDIO UNIT
phone function are integrated.
• Audio signals are output to each speaker.
• Outputs sound signal from audio unit.
FRONT DOOR SPEAKER
• Outputs high, mid and low range sounds.
REAR DOOR SPEAKER
TWEETER
• Outputs high range sound.
• Operations for audio and hands-free phone are possible.
STEERING SWITCH*
• Steering switch signal (operation signal) is output to audio unit.
• Used for hands-free phone operation.
MICROPHONE* • Mic. signal is sent to audio unit.
• Power (Mic. VCC) is supplied from audio unit.
• Radio signal received by radio antenna is amplified and sent to audio unit.
RADIO ANTENNA (Built-in antenna amp.)
• Power (antenna amp ON signal) is supplied from audio unit.
AV-10
DIAGNOSIS SYSTEM (AUDIO UNIT)
DIAGNOSIS SYSTEM (AUDIO UNIT)
A
Diagnosis Description (With Hands-free Phone System) INFOID:0000000001178860
AUDIO UNIT ON BOARD DIAGNOSIS FUNCTION B

Audio unit can perform a test for the microphone used for the hands-free phone system.
ON BOARD DIAGNOSIS
C
Description
• Speaker's voice is output from the speaker by speaking into the microphone in the microphone test mode.
This allows function validation of the microphone.
D
• If no voice can be output from the speaker for a microphone test even when audio functions other than
Hands-free Phone System are normal, check the microphone.
STARTING PROCEDURE E
1. Start the engine.
2. Turn the audio system OFF.
3. With both “ ” button and “ ” button pressed, turn ON the F
audio system.
4. Audio unit display shows “TEST”, and microphone test mode
starts. G
5. Speak into the microphone to check functions of microphone.
6. Microphone test mode exits when the audio system is turned
OFF. H
NOTE:
Volume can be adjusted during microphone tests.
JSNIA0422GB I
AV
AV-11
POWER SUPPLY AND GROUND CIRCUIT
< COMPONENT DIAGNOSIS > [AUDIO WITHOUT NAVIGATION]
COMPONENT DIAGNOSIS
AUDIO UNIT
AUDIO UNIT : Diagnosis Procedure INFOID:0000000001092897
1.CHECK FUSE
Check for blown fuses.
Power source Fuse No.

Battery 35
Ignition switch ACC or ON 20
Is inspection result normal?
YES >> GO TO 2.
NO >> Be sure to eliminate cause of malfunction before installing new fuse.
2.CHECK POWER SUPPLY CIRCUIT
Check voltage between audio unit harness connectors and ground.
Signal name Connector No. Terminal No. Ignition switch position Value (Approx.)
Battery power supply M46 19 OFF 12 V
ACC power supply M46 7 ACC 12 V
YES >> INSPECTION END
NO >> Check harness between audio unit and fuse.
AV-12
MICROPHONE SIGNAL CIRCUIT
A
Supply power from audio unit to microphone. The microphone transmits the sound voice to the audio unit. B
Diagnosis Procedure INFOID:0000000001092899
1.CHECK CONTINUITY BETWEEN AUDIO UNIT AND MICROPHONE CIRCUIT C

1. Turn ignition switch OFF.
2. Disconnect audio unit connector and microphone connector.
3. Check continuity between audio unit harness connector terminals 35, 36, 37 and microphone harness D
connector terminals 1, 2, 4.
35 - 1 : Continuity should exist. E

36 - 2 : Continuity should exist.
F
4. Check continuity between audio unit harness connector terminals 35, 37 and ground.
35, 37 - Ground : Continuity should not exist.

G
YES >> GO TO 2.
NO >> Repair harness or connector. H
2.CHECK VOLTAGE MICROPHONE VCC
1. Connect audio unit connector.
2. Turn ignition switch ON. I
3. Check voltage between audio unit harness connector terminal 37 and ground.
37 - ground : Approx. 5 V J
YES >> GO TO 3.
NO >> Replace audio unit. K
3.CHECK MICROPHONE SIGNAL
1. Connect microphone connector. L
2. Check signal between audio unit harness connector terminals 35 and 36.
35 - 36 AV
PKIB5037J
O
YES >> Replace audio unit.
NO >> Replace microphone. P
AV-13
STEERING SWITCH SIGNAL A CIRCUIT
Transmits the steering switch signal to audio unit.

1.CHECK STEERING SWITCH SIGNAL A CIRCUIT

2. Disconnect audio unit connector and spiral cable connector.
3. Check continuity between audio unit harness connector terminal 6 and spiral cable harness connector ter-
minal 24.

4. Check continuity between audio unit harness connector terminal 6 and ground.
6 - Ground : Continuity should not exist.

YES >> GO TO 2.
NO >> Repair harness or connector.
2.CHECK SPIRAL CABLE
Check spiral cable.
YES >> GO TO 3.
NO >> Replace spiral cable.
3.CHECK AUDIO UNIT VOLTAGE
1. Connect audio unit connector and spiral cable connector.
2. Turn ignition switch ON.
3. Check voltage between audio unit harness connector terminals 6 and 15.
6 - 15 : Approx. 5 V
YES >> GO TO 4.
NO >> Replace audio unit.
4.CHECK STEERING SWITCH
2. Check steering switch. Refer to AV-14, "Component Inspection".
NO >> Replace steering switch.
Component Inspection INFOID:0000000001092902
Measure the resistance between the steering switch connector terminals 20 to 17 and 16 to 17.
AV-14
Standard
Between terminals 20 and 17 A
VOL UP switch ON : 634 – 665 Ω
MENU UP switch ON : 162 – 168 Ω
B
switch ON :0Ω
Between terminals 16 and 17 C

VOL DOWN switch ON : 634 – 665 Ω
MENU DOWN switch ON : 162 – 168 Ω JSNIA0396GB
SOURCE switch ON :0Ω D
AV
AV-15
STEERING SWITCH SIGNAL B CIRCUIT

1.CHECK STEERING SWITCH SIGNAL B CIRCUIT

3. Check continuity between audio unit harness connector terminal 16 and spiral cable harness connector
terminal 32.


YES >> GO TO 2.
Check spiral cable.
YES >> GO TO 3.
16 - 15 : Approx. 5 V
YES >> GO TO 4.
AV-16
Standard
Between terminals 20 and 17 A
B
switch ON :0Ω
Between terminals 16 and 17 C

SOURCE switch ON :0Ω D
AV
AV-17
STEERING SWITCH SIGNAL GND CIRCUIT

1.CHECK STEERING SWITCH SIGNAL GND CIRCUIT

terminal 31.

YES >> GO TO 2.
Check spiral cable.
YES >> GO TO 3.
3.CHECK GROUND CIRCUIT
15 - Ground : Continuity should exist.

YES >> GO TO 4.
Standard
Between terminals 20 and 17
switch ON :0Ω
Between terminals 16 and 17

SOURCE switch ON :0Ω
AV-18
AUDIO UNIT
< ECU DIAGNOSIS > [AUDIO WITHOUT NAVIGATION]
ECU DIAGNOSIS A
AUDIO UNIT
Reference Value INFOID:0000000001092909
B
TERMINAL LAYOUT
C
JPNIA0230ZZ
F
PHYSICAL VALUES
Terminal
Description G
(Wire color) Reference value
Condition
Input/ (Approx.)
+ – Signal name
Output
H
Ignition
2 3
Sound signal front LH Output switch Voice output
I
(W) (P)
ON
J
SKIB3609E
K
Ignition
4 5
Sound signal rear LH Output switch Voice output
(LG) (R)
ON
L
SKIB3609E
Keep pressing switch. 0V M

Keep pressing MENU UP
Ignition 1.7 V
6* 15* switch.
Steering switch signal A Input switch
(V) (GR) Keep pressing VOL UP AV
ON 3.3 V
switch.
Except for above. 5V
Ignition O
7
Ground ACC power supply Input switch − Battery voltage
(SB)
ACC
P
Ignition
11 12
Sound signal front RH Output switch Voice output
(G) (R)
ON
SKIB3609E
AV-19
AUDIO UNIT
Terminal
Description
Condition
Input/ (Approx.)
+ – Signal name
Output
Ignition
13 14
Sound signal rear RH Output switch Voice output
(BR) (Y)
ON
SKIB3609E
Ignition
15*
Ground Steering switch signal GND — switch — 0V
(GR)
ON
Keep pressing SOURCE
0V
switch.
Ignition Keep pressing MENU

16* 15* 1.7 V
Steering switch signal B Input switch DOWN switch.
(O) (GR)
ON Keep pressing VOL DOWN
3.3 V
switch.
17
— Immobilizer — — — —
(B)
Ignition
18 Vehicle speed signal (8- When vehicle speed is ap-
Ground Input switch
(V) pulse) prox. 40 km/h (25MPH)
ON
SKIA6649J
Ignition
19
Ground Battery power supply Input switch — Battery voltage
(BR)
OFF
Ignition
32
Ground Control signal — switch — 0V
(B)
ON
Ignition
35*
36* Microphone signal Input switch Sounds
(G)
ON
PKIB5037J
Ignition
36* Ground Mic. GND — switch — 0V
ON
Ignition
37*
36* Microphone VCC Output switch — 5V
(R)
ON
Ignition
41 Ground Antenna amp. ON signal Output switch — 12 V
ACC
42 — Antenna signal Input — — —
AV-20
AUDIO UNIT
Wiring Diagram—AUDIO WITHOUT NAVIGATION SYSTEM (LHD MODELS)—
INFOID:0000000001092910 A
AV
JCNWA0283GB
P
AV-21
AUDIO UNIT
JCNWA0284GB
AV-22
AUDIO UNIT
AV
JCNWA0285GB
AV-23
AUDIO UNIT
JCNWA0286GB
AV-24
AUDIO UNIT
AV
JCNWA0287GB
AV-25
AUDIO UNIT
JCNWA0288GB
AV-26
AUDIO UNIT
Wiring Diagram—AUDIO WITHOUT NAVIGATION SYSTEM (RHD MODELS)—
INFOID:0000000001537472 A
AV
JCNWA0289GB
P
AV-27
AUDIO UNIT
JCNWA0290GB
AV-28
AUDIO UNIT
AV
JCNWA0291GB
AV-29
AUDIO UNIT
JCNWA0292GB
AV-30
AUDIO UNIT
AV
JCNWA0293GB
AV-31
AUDIO UNIT
JCNWA0294GB
AV-32
MULTI AV SYSTEM SYMPTOMS
< SYMPTOM DIAGNOSIS > [AUDIO WITHOUT NAVIGATION]
SYMPTOM DIAGNOSIS A
Symptom Table INFOID:0000000001092911
B
RELATED TO AUDIO
C
Symptom Check items Possible malfunction location / Action to take
No sound from all speakers Audio unit (AV-37, "Exploded View")
Audio sound is not heard. Sound is not heard only from the specif- D
ic places (front RH, rear RH, front LH Sound signal circuit of suspect system
and rear LH).
RELATED TO HANDS-FREE PHONE (WITH HANDS-FREE PHONE SYSTEM) E

• Check that the cellular phone is corresponding type (Bluetooth® enabled) when the hands free related mal-
function vehicle is in service before performing a diagnosis.
• There is a case that malfunction occurs due to the version change of the phone type, etc. even though it is a F
corresponding type. Therefore, confirm it by changing the cellular phone to another corresponding type
phone, and check that it operates normally. It is necessary to distinguish whether the cause is the vehicle or
cellular phone. Check to ensure the customer's phone is supported by checking the phone compatibility for G
the hands free system.
Trouble diagnosis chart by symptom
H
Symptoms Check items Possible malfunction location / Action to take
Does not recognize cellular
Repeat the registration of cellular phone. Audio unit (AV-37, "Exploded View")
phone connection. I
• Hands-free phone operation can be
made, but the communication cannot
be established.
Hands-free phone cannot be
• Hands-free phone operation can be Audio unit (AV-37, "Exploded View")
J
activated.
performed, however, voice between
each other cannot be heard during the
conversation.
K
The other party's voice cannot
be heard by hands-free phone. Sound is not heard only from the specific
Sound signal circuit (TEL voice)
places (front RH or front LH). L
Originating sound is not heard Microphone test is normal. Audio unit (AV-37, "Exploded View")
by the other party with hands- A microphone is not usable on a micro- Microphone signal circuit (AV-13, "Diagnosis Proce-
free phone communication. phone test. dure") M
NOTE:
Regarding microphone test, refer to AV-11, "Diagnosis Description (With Hands-free Phone System)".
AV
RELATED TO STEERING SWITCH (WITH HANDS-FREE PHONE SYSTEM)
Symptoms Possible malfunction location / Action to take

O
All steering switches are not operated. Steering switch signal ground circuit (AV-18, "Diagnosis Procedure")
Only specified switch cannot be operated. Steering switch (AV-41, "Exploded View")
“MENU UP”, “VOL UP” and “ ” switches are not operated. Steering switch signal A circuit (AV-14, "Diagnosis Procedure") P
“SOURCE”, “MENU DOWN” and “VOL DOWN” switches are
Steering switch signal B circuit (AV-16, "Diagnosis Procedure")
not operated.
AV-33
NORMAL OPERATING CONDITION
RELATED TO AUDIO
• The majority of the audio malfunctions are the result of outside causes (bad CD, electromagnetic interfer-
ence, etc.). Check the symptoms below to diagnose the malfunction.
• The vehicle itself can be a source of noise if noise prevention parts or electrical equipment is malfunctioning.
Check that noise is caused and/or changed by engine speed, ignition switch turned to each position, and
operation of each piece of electrical equipment. Then determine the cause.
NOTE:
• CD-R is not guaranteed to play because they can contain compressed audio (MP3, WMA) or could be incor-
rectly mastered by the customer on a computer.
• Check that the CDs carry the Compact Disc Logo. If not, the disc is not mastered to the red book Compact
Disc Standard and may not play.
Symptoms Cause and counter measure

Check that the CD was inserted correctly.
Check that the CD is scratched or dirty.
Check that there is condensation inside the player, and if there is, wait until the condensation is
gone (about 1 hour) before using the player.
Cannot play The player will play correctly after it returns to the normal temperature if there is a temperature
increase error.
Only the music CD files (CD-DA data) will be played if there is a mixture of music CD files (CD-
DA data) and MP3/WMA files on a CD.
Files with extensions other than “.MP3”, “.WMA”, “.mp3”, or “.wma” cannot be played.
Check that the finalization process, such as session close and disc close, is done for the disc.
Check that the CD is protected by copyright.
Poor sound quality Check that the CD is scratched or dirty.
It takes a relatively long time before If there are many folder or file levels on the MP3/WMA CD, or if it is a multisession disc, some
the music starts playing. time may be required before the music starts playing.
The songs do not play back in the The playback order is the order in which the files were written by the software, so the files might
desired order. not play in the desired order.
Noise resulting from variations in field strength, such as fading noise and multi-path noise, or external noise from trains and other
sources, is not a malfunction.
NOTE:
• Fading noise: This noise occurs because of variations in the field strength in a narrow range due to mountains or buildings blocking
the signal.
• Multi-path noise: This noise results from a time difference between the broadcast waves directly from the station arriving at the
antenna and the waves reflected by mountains or buildings.
RELATED TO TELEPHONE (WITH HANDS-FREE PHONE SYSTEM)

Intermittent voice turbulence occurs be- Surrounded by buildings, cell phones may have a poor reception due to radio waves
tween buildings. irregular reflection or interception.
Noise interference occurs under the rail-
road overpass or near high-tension wires, Noise waves from these may be mixed into radio waves.
traffic lights, or neon signs.
Booming noises are mixed into audio. Radio waves from the cell phone may be mixed into audio.
• Check that the key switch is not set to ON or ACC.
No sound can be heard: • Check that sound volume (VOL) is not set to minimum.
• Voice from the party on the other end of
the line cannot be heard. • Check that the connection of Bluetooth® is normal.
• No ring tone. • Adjust cell phone ring tone and volume. Volume levels of ring tone and voice on the
phone depend on the volume setting of the cell phone, according to the model.
AV-34
A
Voice cannot be transmitted to the party on
the other end of the line. Check that the connection of Bluetooth® is normal.
• Check that the cell phone is not locked.

• Check that the connection of Bluetooth® is normal.
B
Telephone call does not get through. • Check that the telephone call is made in the area within the telecommunications car-
rier service area.
• Check that the area is not a blind area. C
The party on the other end of the line hears
The party on the other end of the line may hear noises depending on where the cell
noises while talking on a hand-held cell
phone is placed.
phone.
D
Bluetooth® has a slow connection after ig- Some models take time for standby.
nition switch ON.
Sound level of voice is different from that of This model allows separate settings for sound levels of ringing sounds, ring tone, and E
ringing sounds or ring tone. voice.
The number of electric field reception bars
of the audio unit is different from that of the
Specifications regarding the number of electric field reception bars differ from cell F
cell phone. Or telephone call does not get
phone to cell phone. (Reception bar of the audio unit is the guideline.)
through even when transmitting with the re-
ception bar displayed.
The party on the other end of the line hears Ambient sounds through the microphone make muffled sounds after conversion pe- G
muffled sounds while talking on the phone. culiar to digital devices.
AV
AV-35
PRECAUTIONS
< PRECAUTION > [AUDIO WITHOUT NAVIGATION]
PRECAUTION
PRECAUTIONS
WARNING:
ness connectors.
AV-36
AUDIO UNIT
< ON-VEHICLE REPAIR > [AUDIO WITHOUT NAVIGATION]
ON-VEHICLE REPAIR A
AUDIO UNIT
B
REMOVAL
Refer to IP-11, "Exploded View". C
DISASSEMBLY
H
JPNIA0319ZZ
1. Audio unit 2. Bracket LH 3. Pocket deck

I
4. Bracket RH

J
REMOVAL
1. Remove cluster lid C. Refer to IP-11, "Exploded View".
K
2. Remove audio unit with a pocket deck as a single unit from the body.
3. Remove bracket screws, and then remove audio unit.
INSTALLATION L
AV
AV-37
FRONT DOOR SPEAKER
FRONT DOOR SPEAKER
JPNIA0321ZZ
1. Front door speaker
REMOVAL
1. Remove front door finisher. Refer to INT-10, "FRONT DOOR FINISHER : Exploded View".
2. Remove front door speaker.
INSTALLATION
AV-38
REAR DOOR SPEAKER
REAR DOOR SPEAKER
A
D
JPNIA0322ZZ
E
1. Rear door speaker

F
REMOVAL
1. Remove rear door finisher. Refer to INT-13, "REAR DOOR FINISHER : Exploded View". G
2. Remove rear door speaker.
INSTALLATION
Install in the reverse order of removal. H
AV
AV-39
TWEETER
TWEETER
JPNIA0323ZZ
1. Tweeter
REMOVAL
1. Remove speaker grille. Refer to IP-11, "Exploded View".
2. Remove tweeter.
INSTALLATION
AV-40
STEERING SWITCH
STEERING SWITCH
A
Refer to SR-5, "Exploded View". B

REMOVAL C
Refer to SR-5, "Removal and Installation".
INSTALLATION
D
AV
AV-41
MICROPHONE
MICROPHONE
REMOVAL
Refer to INT-22, "NORMAL ROOF : Exploded View" (Normal roof), INT-25, "SUNROOF : Exploded View"
(Sunroof).
DISASSEMBLY
JPNIA0324ZZ
1. Microphone
2. Microphone cover
REMOVAL
1. Remove headlining assembly. Refer to INT-22, "NORMAL ROOF : Exploded View" (Normal roof), INT-25,
"SUNROOF : Exploded View" (Sunroof).
2. Remove microphone.
INSTALLATION
AV-42
RADIO ANTENNA
RADIO ANTENNA
A
JPNIA0325ZZ
1. Antenna rod 2. Antenna base 3. Nut G

Removal and Installation INFOID:0000000001092927 H
REMOVAL
1. Remove headlining assembly. Refer to INT-22, "NORMAL ROOF : Exploded View" (Normal roof), INT-25, I
2. Remove antenna base and antenna rod.
J
INSTALLATION
K
AV
AV-43
ANTENNA FEEDER (RADIO)
ANTENNA FEEDER (RADIO)
Harness Layout INFOID:0000000001092928
JPNIA0326GB
AV-44
< BASIC INSPECTION > [AUDIO WITH NAVIGATION]
BASIC INSPECTION A
B
OVERALL SEQUENCE
C
JSNIA0039GB M
• Reference 1··· Refer to AV-74, "CONSULT - III Function (MULTI AV)".
• Reference 2··· Refer to AV-248, "Symptom Table".
DETAILED FLOW AV
1.CHECK SYMPTOM
Check the malfunction symptoms by performing the following items. O
• Interview the customer to obtain the malfunction information (conditions and environment when the malfunc-
tion occurred).
• Check the symptom.
P
>> GO TO 2.
2.SELF-DIAGNOSIS (CONSULT-III)
1. Connect CONSULT-III and perform a self-diagnosis for “MULTI AV”.
NOTE:
Skip to step 4 of the diagnosis procedure if “MULTI AV” is not displayed.
2. Check that any DTC No. is displayed in the self-diagnosis results.
AV-45
Is any DTC No. displayed?
YES >> GO TO 3.
NO >> GO TO 4.
3.CHECK SELF-DIAGNOSIS RESULTS (CONSULT-III)
1. Check the DTC No. indicated in the self-diagnosis results.
2. Perform the relevant diagnosis referring to the DTC Index. Refer to AV-159, "DTC Index".
NOTE:
Start with the diagnosis for the CAN communication system if “CAN COMM CIRCUIT [U1000] and CONTROL
UNIT CAN [U1010]” is displayed.
>> GO TO 5.
4.PERFORM DIAGNOSIS BY SYMPTOM
Perform the relevant diagnosis referring to the diagnosis chart by symptom. Refer to AV-248, "Symptom
Table".
>> GO TO 5.
5.REPAIR OR REPLACE MALFUNCTIONING PARTS
Repair or replace the identified malfunctioning parts.
NOTE:
Erase the stored self-diagnosis results after repairing or replacing the relevant components if any DTC No. has
been indicated in the self-diagnosis results.
>> GO TO 6.
6.CHECK AFTER REPAIR
1. Perform a self-diagnosis for “MULTI AV” with CONSULT-III after repairing or replacing the malfunctioning
parts.
2. Check that any DTC No. is displayed in the self-diagnosis results.
Is any DTC No. displayed?
YES >> GO TO 3.
NO >> GO TO 7.
7.FINAL CHECK
Perform the operation to check that the malfunction symptom is solved or any other symptoms are present.
Is there any symptom?
YES >> GO TO 4.
AV-46
INSPECTION AND ADJUSTMENT
A
ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL
ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : De-
B
scription INFOID:0000000001094790
Always correct the center position of the rear view monitor's possible route line after disconnecting the battery
negative terminal. C
ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Spe-

cial Repair Requirement INFOID:0000000001094791
D
1.CORRECTION OF CENTER POSITION OF REAR VIEW MONITOR'S POSSIBLE ROUTE LINE

Refer to the following for details. E
>> Refer to AV-47, "REAR VIEW MONITOR POSSIBLE ROUTE LINE CENTER POSITION
ADJUSTMENT : Special Repair Requirement". F
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Description G
INFOID:0000000001094792
When camera control unit is replaced, the center position of rear view monitor possible route line shall be cor-
rected. H
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Special Repair Re-
quirement INFOID:0000000001115045
I
1.CORRECTION OF CENTER POSITION OF REAR VIEW MONITOR'S POSSIBLE ROUTE LINE
Refer to the following for details. J
>> Refer to AV-47, "REAR VIEW MONITOR POSSIBLE ROUTE LINE CENTER POSITION
ADJUSTMENT : Special Repair Requirement". K
REAR VIEW MONITOR POSSIBLE ROUTE LINE CENTER POSITION ADJUST-
MENT
L
MENT : Description INFOID:0000000001094794
M
Adjust the center position of the possible route line of the rear view monitor if it is shifted.
AV
MENT : Special Repair Requirement INFOID:0000000001094795
1.STEERING OPERATION O
Steer the steering wheel to the leftmost and rightmost ends.
>> GO TO 2 P
2.DRIVING
Drive the vehicle straight ahead 100 m (328.1 ft) or more at a speed of 30 km/h (18.6 MPH) or more.
>> END
AV-47
MULTI AV SYSTEM
< FUNCTION DIAGNOSIS > [AUDIO WITH NAVIGATION]
FUNCTION DIAGNOSIS
MULTI AV SYSTEM
JPNIA0241GB
Multi AV system means that the following systems are integrated.
System name System explanation

NAVIGATION SYSTEM AV-52, "System Description"
AUDIO SYSTEM AV-60, "System Description"
REAR VIEW MONITOR SYSTEM AV-57, "System Description"
• Status of audio, maintenance and navigation is displayed.
• NAVI control unit displays the maintenance information while
VEHICLE INFORMATION SYSTEM
receiving data signal through CAN communication from com-
bination meter.
HANDS-FREE PHONE SYSTEM Refer to the following “HANDS-FREE PHONE SYSTEM”.
This system verifies the immobilizer ID by CAN communication
between NAVI control unit and BCM every time the ignition
ANTI-THEFT SYSTEM switch is turned to “ACC” position. Multi AV system can be per-
mitted to operate only when the verification has successfully pro-
cessed.
• Two AV communication lines (H, L) connect between units that configure MULTI AV system. NAVI control
unit controls by sending/receiving data one by one with each unit (slave unit) that configures them com-
pletely as a master unit.
• Two AV communication lines (H, L) adopt a twisted pair line that is resistant to noise.
• NAVI control unit is connected by CAN communication, and it receives data signal from ECM, combination
meter It computes and displays fuel economy information value with the obtained information. Sending/
receiving of data signal is performed by BCM. Also, it sends the required signal of vehicle setting and
receives the response signal.
AV-48
MULTI AV SYSTEM
• NAVI control unit is connected with display and serial communication, and it sends the required signal of dis-
play and display control and receives the response signal from front display. A
NOTE:
NAVI control unit can perform CONSULT-III self-operating function and on board self-diagnosis.
• CONSULT-III self diagnosis: Refer to AV-74, "CONSULT - III Function (MULTI AV)".
B
• On board self diagnosis: Refer to AV-63, "Diagnosis Description".
HANDS-FREE PHONE SYSTEM
• Hands-free communication can be operated by connecting using Bluetooth® with cellular phone. C
• Operation is performed by steering switch or audio switch, and operating condition is indicated on display.
JPNIA0243GB
H
When a call is originated
Spoken voice sound output from the microphone (mic. signal) is input to NAVI control unit. NAVI control unit
outputs to cellular phone with Bluetooth® communication as a TEL voice signal. Voice sound is then heard at I
the other party.
When receiving a call
Voice sound is input to own cellular phone from the other party. TEL voice signal is output to front speaker, and J
the signal is input to audio unit via NAVI control unit by establishing Bluetooth® communication from cellular
phone.
K
AV
AV-49
MULTI AV SYSTEM
JPNIA0315ZZ

4. Rear door speaker LH 5. Rear view camera 6. Camera control unit
7. Rear door speaker RH 8. Front door speaker RH 9. Radio antenna
10. Microphone 11. Display unit 12. Steering angle sensor
13. Steering switch 14. Audio unit 15. NAVI control unit
16. GPS antenna
A. Inside glove box B. Trunk room RH C. Back of a display unit
D. Spiral cable part
AV-50
MULTI AV SYSTEM

• Map data can be read from the Map DVD-ROM by installing Map DVD-ROM. B
• It is the master unit of the MULTI AV system, and it is connected to each con-
trol unit by means of communication. It operates each system according to
communication signals from the NAVI control unit.
• The NAVI control unit includes the audio, hands-free phone, navigation, and C
vehicle information functions.
NAVI CONTORL UNIT
• The NAVI control unit displays the maintenance information while receiving
data signal through CAN communication from combination meter.
• It inputs the illumination signals that are required for the display dimming con-
D
trol.
• It inputs the signals for driving status recognition (vehicle speed, reverse and
parking brake). E
MAP DVD-ROM A collection of Map data.
• Display image is controlled by the serial communication from NAVI control
unit. F
DISPLAY UNIT • RGB image signal is input from NAVI control unit (RGB, RGB area and RGB
synchronizing). Camera image signal is input from camera control unit.
• Synchronize signal (HP, VP) is output to NAVI control unit.
G
• Operational switch of MULTI AV system is integrated.
• Audio unit are connected to NAVI control unit with AV communication via
AUDIO UNIT
camera control unit. Operating signals of the switch are sent to the NAVI con-
trol unit. H
FRONT DOOR SPEAKER
• Outputs sound signal from audio unit. I
REAR DOOR SPEAKER
TWEETER
• Outputs high range sound. J
• Camera image signal is input from rear view camera, and camera image is
indicated on the display.
• Power (camera ON signal) is sent to rear view camera.
CAMERA CONTROL UNIT K
• Controlled by AV communication sent from NAVI control unit.
• NAVI control unit recognizes the presence of camera system with camera
connection recognition signal.
REAR VIEW CAMERA The image of vehicle rear view is sent to camera control unit. L
STEERING ANGLE SENSOR Sensor signal (steering angle) is sent to camera control unit.
• Operations for audio, hands-free phone and navigation, etc. are possible.
STEERING SWITCH M
• Used for hands-free phone operation.
MICROPHONE • Mic. signal is sent to NAVI control unit.
• Power (Mic. VCC) is supplied from NAVI control unit. AV
GPS ANTENNA GPS signal is received and sent to NAVI control unit.
• Power (antenna amp. ON signal) is supplied from audio unit. O
AV-51
NAVIGATION SYSTEM
NAVIGATION SYSTEM
JPNIA0245GB
NAVIGATION SYSTEM
Location Detection Principle
The navigation system periodically calculates the vehicle's current
position according to the following three signals:
• Travel distance of the vehicle as determined by the vehicle speed
sensor
• Turning angle of the vehicle as determined by the gyroscope
(angular velocity sensor)
• Direction of vehicle travel as determined by the GPS antenna
(GPS information)
The current position of the vehicle is then identified by comparing the
calculated vehicle position with map data read from the map DVD-
ROM, which is stored in the DVD-ROM drive (map-matching), and
SKIB1058E
indicated on the screen as a vehicle mark. More accurate data is
judged and used by comparing vehicle position detection results found by the GPS with the result by map-
matching.
The current vehicle position will be calculated by detecting the dis-

tance the vehicle moved from the previous calculation point and its
direction.
• Travel distance
Travel distance calculations are based on the vehicle speed sen-
sor input signal. Therefore, the calculation may become incorrect
as the tires wear down. To prevent this, an automatic distance cor-
rection function has been adopted.
• Travel direction
Change in the travel direction of the vehicle is calculated by a gyro-
scope (angular velocity sensor) and a GPS antenna (GPS informa-
SEL684V
tion). They have both advantages and disadvantages.
AV-52
NAVIGATION SYSTEM
Type Advantage Disadvantage A

Gyroscope Can detect the vehicle's turning angle quite Direction errors may accumulate when vehicle is
(angular velocity sensor) accurately. driven for long distances without stopping.
GPS antenna Can detect the vehicle's travel direction Correct direction cannot be detected when vehicle B
(GPS information) (North/South/East/West). speed is low.
More accurate traveling direction is detected because priorities are set for the signals from these two
devices according to the situation. C
Map-Matching
Map-matching compares a current location detected by the method
in the “Location Detection Principle” with a road map data from Map D
DVD-ROM stored in DVD-ROM drive.
NOTE:
The road map data is based on data stored in the map DVD-ROM. E
SEL685V
G
The vehicle position may not be corrected under the following circumstances and after driving for a certain
time when GPS information is difficult to receive. In this case, the vehicle mark on the display must be cor-
rected manually. H
• In map-matching, alternative routes to reach the destination will be
shown and prioritized, after the road on which the vehicle is cur-
rently driven has been judged and the vehicle mark has been repo- I
sitioned.
Alternative routes will be shown in different order of priority, and
the incorrect road can be avoided if there is an error in distance
J
and/or direction.
They are of the same priority if two roads are running in parallel.
Therefore, the vehicle mark may appear on either of them alter-
nately, depending on maneuvering of the steering wheel and con- K
figuration of the road.
SEL686V
L
• Map-matching does not function correctly when a road on which
the vehicle is driving is new and not recorded in the map DVD-
ROM, or when road pattern stored in the map data and the actual
road pattern are different due to repair. M
The map-matching function may find another road and position the
vehicle mark on it when driving on a road not present in the map.
Then, the vehicle mark may change to it when the correct road is
AV
detected.
• Effective range for comparing the vehicle position and travel direc-
tion calculated by the distance and direction with the road data
read from the map DVD-ROM is limited. Therefore, correction by O
SKIA0613E
map-matching is not possible when there is an excessive gap
between current vehicle position and the position on the map.
GPS (Global Positioning System) P
AV-53
NAVIGATION SYSTEM
GPS (Global Positioning System) was developed for and is con-
trolled by the US Department of Defense. The system utilizes GPS
satellites (NAVSTAR), sending out radio waves while flying on an
orbit around the earth at an altitude of approximately 21,000 km
(13,100miles).
The GPS receiver calculates the vehicle's position in three dimen-
sions (latitude/longitude/altitude) according to the time lag of the
radio waves received from four or more GPS satellites (three-dimen-
sional positioning). The GPS receiver calculates the vehicle's posi-
tion in two dimensions (latitude/longitude), utilizing the altitude data
calculated previously with radio waves from four or more GPS satel-
SEL526V
lites (two-dimensional positioning) if radio waves were received only
from three GPS satellites.
Position correction by GPS is not available while the vehicle is stopped.
Accuracy of GPS will deteriorate under the following conditions:
• In two-dimensional positioning, GPS accuracy will deteriorate when altitude of the vehicle position changes.
• The accuracy can be even lower depending on the arrangement of the GPS satellites utilized for the posi-
tioning.
• Position detection is not possible when vehicle is in an area where radio waves from the GPS satellite do not
reach, such as in a tunnel, parking lot in a building, and under an elevated highway. Radio waves from the
GPS satellites may not be received when some object is located over the GPS antenna.
NOTE:
• Even a high-precision three dimensional positioning, the detection result has an error about 10 m (30ft).
• Because the signals of GPS satellite is controlled by the Tracking and Control Center in the United States,
the accuracy may be degraded lower intentionally or the radio waves may stop.
Traffic Information (RDS-TMC)
NOTE: RDS-TMC tuner is built-in audio unit.
The traffic information broadcast allows to you to avoid delays due to traffic incidents.
Traffic jams, roadwork, closed roads around your current location, etc. are represented graphically on the map
by icons depicting the nature of the event.
Incidents on the route are automatically brought to your attention when they are approached.
The Traffic Information feature gives you the opportunity to forecast traffic incidents, determine how serious
they are, via the guidance mode, and allows you to detour around traffic incidents.
The navigation system receives traffic information from best available sources and enables the RDS-TMC
(Radio Data System-Traffic Information Channel) to inform and guide you.
The RDS-TMC broadcast is fed by an audio unit so that you can still tune your radio station while Traffic Infor-
mation is being broadcasted.
AV-54
NAVIGATION SYSTEM
JPNIA0315ZZ
M

4. Rear door speaker LH 5. Rear view camera 6. Camera control unit AV
13. Steering switch 14. Audio unit 15. NAVI control unit O
16. GPS antenna
D. Spiral cable part P
AV-55
NAVIGATION SYSTEM

• The master unit controls each operation of the Navigation system.
• Map data can be read from the Map DVD-ROM by installing Map DVD-ROM.
NAVI CONTORL UNIT
• The RGB signal (map information) is output to the display.
• The voice guidance signal is output to the audio unit.
MAP DVD-ROM A collection of Map data
Map image signal is input from NAVI control unit, and it is indicated on the dis-
DISPLAY UNIT
play.
• Voice guidance signal is input from NAVI control unit, and voice guidance is
AUDIO UNIT output to front LH/RH speakers.
• Each operation of navigation can be performed.
FRONT DOOR SPEAKER
Voice guidance signal from audio unit is output.
TWEETER
• Each operation of navigation, etc. can be performed.
STEERING SWITCH • Switch operating signal is output to NAVI control unit via audio unit and cam-
era control unit with AV communication.
GPS ANTENNA GPS signal is received and is output to NAVI control unit.
AV-56
REAR VIEW MONITOR SYSTEM
A
JPNIA0244GB F
G
Camera image operation principle
• Power is supplied to rear view camera from camera control unit and outputs camera image signal to camera
control unit when shift position is set to R position and the reverse signal on camera control unit is input. H
• Camera control unit synthesizes guide lines and possible route lines with camera image signal from rear
view camera, and transmits camera image signal to the display. In this case, since the reverse signal is also
input to NAVI control unit, the NAVI control unit recognizes the shift position as in R position, and it switches I
communication signal between NAVI control unit and display unit, and image that is displayed on the display
unit by RGB signal with rear view monitor image. In addition, possible route lines are controlled by original
sensor signal from steering angle sensor.
• The NAVI control unit determines whether rear view camera is equipped or not, based on the presence of J
camera connection recognition signal. It switches to rear view monitor image at the time of reverse signal
input when it is not equipped.
• Warning message under the rear view monitor display is described by NAVI control unit. K
• NAVI control unit is connected in communication with camera control unit and display unit, and it controls
operation of rear view monitor system.
L
AV
AV-57
JPNIA0315ZZ

4. Rear door speaker LH 5. Rear view camera 6. Camera control unit
13. Steering switch 14. Audio unit 15. NAVI control unit
16. GPS antenna
D. Spiral cable part
AV-58

• Image on display is changed to rear view monitor with the communication for B
NAVI CONTORL UNIT camera control unit and display unit.
• Warning displayed in rear view monitor image is illustrated.
• Camera image signal is sent from camera control unit, and RGB signal for C
warning display is sent from NAVI control unit.
DISPLAY UNIT
• Rear view monitor image is changed with the communication for NAVI control
unit.
• Camera image signal is input from rear view camera, and camera image is
D
indicated on the display.
CAMERA CONTROL UNIT
• Controlled by AV communication sent from NAVI control unit. E
• NAVI control unit recognizes the presence of camera system with camera
connection recognition signal.
REAR VIEW CAMERA The image of vehicle rear view is sent to camera control unit.
F
Steering signal necessary for possible route line control is sent to camera con-
STEERING ANGLE SENSOR
trol unit.
AV
AV-59
AUDIO SYSTEM
AUDIO SYSTEM
JPNIA0242GB
The audio system is equipped with following function. Each function is operated with audio switch or steering switch. Operation status of AUDIO
is indicated at display.
Function
AM/FM radio
CD
FUNCTION DESCRIPTION
Operating signal
Audio system operation can be performed with audio switch or steering switch.
Screen display
• Switching of display is performed with serial communication between display and NAVI control unit.
• The image signal to display operating condition is performed with RGB signal, RGB area signal and RGB
image synchronizing signal.
AM/FM Radio Mode
• AM/FM radio tuner is built into audio unit.
• Audio signal is received by antenna, next it is amplified by antenna amp., and finally it is input to audio unit.
Audio unit outputs the audio signal to each speaker.
CD Mode
• CD function is built into audio unit.
• Audio unit outputs audio signal to each speaker when CD is inserted to audio unit.
SPEED SENSITIVE VOLUME
• Volume level of this system gone up and down automatically in proportion to the vehicle speed. And the con-
trol level can be selected by the customer.
• The audio unit inputs the vehicle signal that is sent from combination meter via CAN communication through
NAVI control unit.
AV-60
AUDIO SYSTEM
JPNIA0315ZZ
M

4. Rear door speaker LH 5. Rear view camera 6. Camera control unit AV
13. Steering switch 14. Audio unit 15. NAVI control unit O
16. GPS antenna
D. Spiral cable part P
AV-61
AUDIO SYSTEM

• Operational switch of audio system is integrated.
AUDIO UNIT • Receiving function of AM/FM radio, replaying function of CD are integrated.
• Audio signals are output to each speaker.
• Display image is controlled by the serial communication from NAVI control
DISPLAY UNIT unit.
• RGB image signal (audio operation condition) is input from NAVI control unit.
FRONT DOOR SPEAKER
REAR DOOR SPEAKER
TWEETER
• Outputs high range sound.
• Each audio operation can be operated.
STEERING SWITCH
• Power (antenna amp. ON signal) is supplied from audio unit.
AV-62
DIAGNOSIS SYSTEM (NAVI CONTROL UNIT)
A
Diagnosis Description INFOID:0000000001092946
MULTI AV SYSTEM on board diagnosis function B

• The NAVI control unit diagnosis function starts up with audio switch operation and the NAVI control unit per-
forms a diagnosis for each unit in the system during the on board diagnosis.
• Perform a CONSULT-III diagnosis if the on board diagnosis does not start, e.g., the screen does not display C
anything, the multifunction switch does not function. etc.
On board diagnosis
Description D
• The trouble diagnosis function has a self-diagnosis mode for conducting trouble diagnosis automatically and
a confirmation/adjustment mode for operating manually.
• The self-diagnosis mode performs diagnoses on the NAVI control unit, connections between system compo- E
nents as well as connections between NAVI control unit and GPS antenna. Then it displays the diagnosis
results on the display.
• The confirmation/adjustment mode allows the technician to check, modify or adjust the vehicle signals and
F
set values, as well as to monitor the system error records and system communication status. The check,
modify or adjust actions generally require human intervention and judgment (the system cannot make judg-
ment automatically).
G
On board diagnosis item
Mode Description
H
• NAVI control unit diagnosis
Self Diagnosis • Diagnoses the connections across system components, between
NAVI control unit and GPS antenna.
The following check functions are available: color tone check by color
I
Display Diagnosis
bar display, light and shade check by gray scale display.
Diagnosis of signals can be performed for vehicle speed, parking
Vehicle Signals J
brake, lights, ignition, and reverse.
Speaker Test The connection of a speaker can be confirmed by test tone.
Steering Angle Ad- A difference can be adjusted between the actual turning angle and the
justment vehicle mark turning angle. K
Navigation
A difference can be adjusted between the current location mark and the
Speed Calibration
actual location.
L
The system malfunction and the frequency when occurred in the past
Error History are displayed. The time and place that the selected malfunction last oc-
curred are displayed when the malfunctioning item is selected.
Confirmation/
Adjustment Vehicle CAN Diagnosis The transmitting/receiving of CAN communication can be monitored. M
The communication condition of each unit of Multi AV system can be
AV COMM Diagnosis
monitored.
The received volume adjustment of hands-free phone, microphone AV
Handsfree Phone
speaker check, and erase memory can be performed.
The signal connected to camera control unit can be checked and the
Camera Cont. guiding line position that overlaps rear view camera image can be ad- O
justed.
Bluetooth The passkey and the device name can be checked and changed.
Delete Unit Connection Log Erase the connection history of unit and error history. P
Operations of navigation system while driving can be restricted by us-
Feature Restriction Setting
ing this function.
STARTING PROCEDURE
1. Start the engine.
2. Turn the audio system OFF.
AV-63
3. Turn the volume control dial clockwise or counterclockwise for
40 clicks or more while pushing the “SETTING” button. (A short
beep will be heard when the self-diagnosis mode is started.)
• Shifting from current screen to previous screen is performed
by pushing “BACK” button.
JSNIA0525GB
4. The trouble diagnosis initial screen is displayed, and then the

items of “Self Diagnosis” and “Confirmation / Adjustment” can be
selected.
SKIB3961E
Self-diagnosis mode
1. Start the self-diagnosis function. Then select “Self Diagnosis”.
- Self-diagnosis subdivision screen is displayed, and the self-
diagnosis mode starts.
- The bar graph visible on the center of the self-diagnosis subdivi-
sion screen indicates progress of the trouble diagnosis.
SKIB3657E
2. Diagnosis results are displayed after the self-diagnosis is com-

pleted. The unit names and the connection lines are color-coded
according to the diagnostic results.
Diagnosis results Unit Connection

line
Normal Green Green
Connection malfunction Gray Yellow
DVD drive undiagnosed Gray Green
DVD-ROM and DVD-ROM Yellow Green SKIB9021E
drive malfunction
Unit malfunction Note Red Green
NOTE:
• Only the control unit (NAVI control unit) is displayed in red.
- The screen switch colors are determined according to the following order of priority: red > yellow > gray if
multiple errors occur at the same time for a single unit.
AV-64
- The comments of the self-diagnosis results can be viewed with a
component in the diagnosis result screen. A
JPNIA0168GB
D
Detection range of self-diagnosis mode
• The self-diagnosis mode allows the technician to diagnose the connection in the communication line
between NAVI control unit and each unit and the internal operation of the NAVI control unit.
• Because the start condition of diagnosis function is a switch operation, the on board diagnosis function can- E
not be started up if any malfunction is detected in a switch.
JPNIA0247GB
M
Self-diagnosis results
Check the applicable display at the following table, and then repair the malfunctioning parts.
AV
Self-diagnosis result chart
AV-65
Possible malfunction location / Action

Area with yellow connection lines Description
to take
NAVI control unit malfunction is de-

NAVI control unit
tected.
SKIB9022E
• Malfunction is detected on DVD-

ROM drive pickup lens in NAVI con-
• Map disc
trol unit.
• NAVI control unit
• There is dirt and damage on the
map disc.
JSNIA0380GB
DVD-ROM not inserted is detected. Insert map disc
SKIB9024E
• Malfunction is detected on commu-

nication circuit between NAVI con-
trol unit and display unit. Communication circuit between NAVI
• Malfunction is detected on commu- control unit and display unit.
nication signal between NAVI con-
trol unit and display unit.
JSNIA0381GB
AV-66
Possible malfunction location / Action
Area with yellow connection lines Description
to take A
• A malfunction is detected in Cam-

B
era-connection recognition signal
• Camera connection recognition sig-
circuit.
nal circuit
• Camera control unit power supply
and ground circuit malfunction is C
and ground circuit
detected
• Malfunction is detected on commu-
• Camera control unit
nication signal between NAVI con-
trol unit and camera control unit. D
JSNIA0445GB
F
GPS antenna connection malfunction • GPS antenna
is detected. • GPS antenna feeder
SKIB9028E H
Malfunction is detected on communi-

cation signal between NAVI control
• Audio unit J
unit and audio unit.
K
SKIB9025E
COMFIRMATON/ADJUSTMENT MODE L
1. Start the diagnosis function and select “Confirmation / Adjustment”. The confirmation/adjustment mode
indicates where each item can be checked or adjusted.
2. Select each switch on the “Confirmation / Adjustment Mode” M
screen to display the relevant trouble diagnosis screen. Press
the “BACK” switch to return to the initial “Confirmation / Adjust-
ment Mode” screen.
AV
SKIB4658E P
AV-67
Display Diagnosis
JSNIA0531GB
The tint of the color bar indication is as per the following list if RGB signal error is detected.
R (red) signal error : Light blue (Cyan) tint

G (green) signal error : Purple (Magenta) tint
B (blue) signal error : Yellow tint
Vehicle Signals
A comparison check can be made of each actual vehicle signal and
the signals recognized by the system.
SKIB3663E
Diagnosis item Display Vehicle status Remarks

ON Vehicle speed > 0 km/h (0 MPH)
Vehicle speed OFF Vehicle speed = 0 km/h (0 MPH)
— Ignition switch ACC Changes in indication may be delayed. This is normal.
ON Parking brake is applied.
Parking brake
OFF Parking brake is released.
ON Light switch ON
Lights —
OFF Light switch OFF
ON Ignition switch ON
Ignition —
OFF Ignition switch in ACC position
ON Selector lever in R position
Selector lever in any position other
Reverse OFF Changes in indication may be delayed. This is normal.
than R
— Ignition switch ACC
Speaker Test
AV-68
Select “SPEAKER TEST” to display the Speaker Diagnosis screen.
Press “START and NEXT” to generate a test tone in a speaker. A
Press “Start” to generate a test tone in the next speaker. Press
“Stop” to stop the test tones.
NOTE:
B
The frequency of test tone emitted from each speaker is as follows.
Tweeter : 3 kHz
C
Front door speaker : 300 Hz
Rear door speaker : 1 kHz
SKIB4686E
D
Navigation
STEERING ANGLE ADJUSTMENT
The steering angle output value detected with the gyroscope is
adjusted. E
SKIB3684E
H
SPEED CALIBRATION
During normal driving, distance error caused by tire wear and tire
pressure change is automatically adjusted for by the automatic dis- I
tance correction function. This function, on the other hand, is for
immediate adjustment, in cases such as driving with tire chain fitted
on tires. J
SKIB3685E
L
ERROR HISTORY
The diagnostic results of “Self-diagnosis” determine if any malfunction occurred between selecting “Self-diag-
nosis” and displaying “Self-diagnostic Results”.
The trouble diagnosis result will be judged normal if an error occurred before the ignition switch was turned M
ON and does not occur again until “Self-diagnosis” is completed. Therefore, errors in the past which cannot be
found by “Self-diagnosis”, must be found by checking the “Error record”.
The error history shows the error occurrence frequency in past. The frequency of occurrence is displayed by 2 AV
types: the count down type and the count up type. Select either type according to the error item.
In “Error History” of models with NAVI, time and place that the selected error last occurred are displayed. Be
careful about the following.
• The correct date of occurrence may not be able to be displayed if there is a malfunction with the GPS O
antenna circuit board in the NAVI control unit.
• Place of the error occurrence is represented by the position of the current location mark at the time an error
occurred. If current location mark has deviated from the correct position, then the place of the error occur- P
rence cannot be located correctly.
AV-69
Transition Screen
SKIB3687E
Count Down Type

• Set the counter to 40 when the error is detected. The counter decreases by 1 if the system is normal when
turning the ignition switch ON.
• The lower limit of the counter is 1. It can be reset to 0 by “Delete log” switch or CONSULT-III.
Count Up Type
• The counter increases 1 when the ignition switch is turned ON and the error is detected. The counter does
not decrease even if it is normal when the ignition switch is turned ON the next time.
• The upper limit of the counter is 50. 51 or more is displayed as 50. It can be reset to 0 by “Delete log” switch
or CONSULT-III.
Display type of occur-

Error history display item
rence frequency
Count down type CAN_COMM_CIRCUIT, CONTROL UNIT (CAN), AV COMM CIRCUIT, CONTROL UNIT (AV)
Count up type Other than the above
Error Item
• Some error items may be displayed simultaneously according to the cause. The detection of the cause can
be performed by the combination of display items if some error items are displayed simultaneously.
Error item Description Possible cause/Action to take

Perform the diagnosis using CONSULT-III,
and then repair the malfunctioning parts
CAN communication malfunction is de-
CAN_COMM_CIRCUIT based on diagnostic results.
tected.
Refer to AV-74, "CONSULT - III Function
(MULTI AV)".
CAN initial diagnosis malfunction is de-
CONTROL UNIT (CAN) NAVI control unit
tected.
AV communication circuit initial diagno-
CONTROL UNIT (AV) NAVI control unit
sis malfunction is detected.
• Audio unit power supply and ground
circuit malfunction is detected. • Audio unit power supply and ground cir-
• AV COMM CIRCUIT
• Malfunction is detected on communi- cuit
• Switches Connection Error
cation circuit between audio unit and • Communication circuit between audio
• Audio Unit Connection Error
camera control unit. unit and camera control unit
• Amplifier Connection Error
• Malfunction is detected on communi- • NAVI control unit
• RDS-TMC Error
cation signal between audio unit and • Audio unit
NAVI control unit.
AV-70
A
• AV COMM CIRCUIT
• Switches Connection Error
• Malfunction is detected on communi-
• Audio Unit Connection Error Communication circuit between camera
cation circuit between camera con-
• Amplifier Connection Error control unit and NAVI control unit B
trol unit and NAVI control unit.
• RDS-TMC Error
• Rear view Camera Connection Error
and ground circuit malfunction is de- • Camera control unit power supply and
C
• AV COMM CIRCUIT tected. ground circuit
• Rear view Camera Connection Error • Malfunction is detected on communi- • NAVI control unit
cation signal between camera con- • Camera control unit D
• Display unit power supply and
ground circuit malfunction is detect-
ed. E
• Display unit power supply and ground
circuit
Front Display Connection Error cation circuit between display unit
• Communication circuit between display
and NAVI control unit.
unit and NAVI control unit F
cation signal between display unit
GPS antenna connection malfunction • GPS antenna feeder G
GPS Antenna Error
is detected. • GPS antenna
Camera and connection recognition Camera-connection recognition signal cir-
Camera Control Unit Connection Error
signal circuit malfunction is detected. cuit H
NAVI control unit malfunction is detect-
FLASH-ROM Error Of Control Unit NAVI control unit
ed.
NAVI control unit malfunction is detect- I
Connection Of Gyro NAVI control unit
ed.
GPS Communication Error Intermittent malfunction caused by strong
radio interference may be detected if the J
GPS ROM Error
symptoms such as the GPS receipt mal-
GPS malfunction is detected.
GPS RAM Error function occur.
Replace NAVI control unit if the malfunc-
GPS RTC Error tion always occurs. K
DVD-ROM Communication Error
DVD-ROM Read Error
L
DVD-ROM Disc Error
DVD-ROM Mechanism not Detected
DVD-ROM Mechanism Error M
DVD-ROM Focus Error ROM drive pickup lens in NAVI con-
trol unit. • Map disc
DVD-ROM TOC Error
• There is dirt and damage on the map • NAVI control unit
DVD-ROM Seek Error
AV
disc.
DVD-ROM Error Correction Error
DVD-ROM Data Transfer Error O
DVD-ROM Data Error
DVD-ROM Time-out
DVD-ROM Loading / Eject Error P
CAN Controller Memory Error NAVI control unit malfunction is detect-
NAVI control unit
Bluetooth Module Connection Error ed.
Vehicle CAN Diagnosis
AV-71
• CAN communication status and error counter is displayed.
• Error counter displays 0 if any malfunction is not detected in the
past. It displays 40 if the malfunction is detected. It displays 39
when turning the ignition switch ON and it is normal. The lower
limit of the counter is 1.
• The error counter displays 0 if it resets.
Malfunction counter
Items Display (Current)
(Past)
Rx (ECM) OK / ??? 0 – 40
JSNIA0448GB
Rx (Cluster) — —
NOTE:
“???” indicates UNKWN.
AV COMM Diagnosis
• Displays the communication status between NAVI control unit
(master unit) and each unit.
• The error counter displays 0 if any malfunction was not detected in
the past. It displays 40 if the malfunction is detected. It displays 39
when turning the ignition switch ON and it is normal. The lower
limit of the counter is 1.
• The error counter is erased if it resets.
Status Counter
Items
(Current) (Past)
JSNIA0446GB
C Tx(ITM–PrimarySW) OK / ??? 0 – 40
C Rx(PrimarySW–ITM) OK / ??? 0 – 40
C Rx(STRG SW–ITM) OK / ??? 0 – 40
C Rx (Audio–ITM) OK / ??? 0 – 40
C Rx(Amp–ITM) OK / ??? 0 – 40
C Rx(RearCamera–ITM) OK / ??? 0 – 40
C Rx(RDS–ITM) OK / ??? 0 – 40
ITM: NAVI control unit
NOTE:
“???” indicates UNKWN.
Handsfree Phone
The hands-free phone reception volume adjustment, microphone
and speaker test, and memory erase functions are also available.
SKIB3668E
Camera Cont.
The two functions of “Connection Confirmation” and “Adjust offset of rear view camera” are available.
CONNECTION CONFIRAMATION
AV-72
The steering angle sensor, reverse signal and vehicle speed sensor
can be inspected. A
JSNIA0447GB
Diagnosis item Display Vehicle status

When steering the vehicle with ignition switch ON (remains ON until connection E
ON
mode is stopped when it is turned ON)
Steer. Angle Sensor • Ignition switch at ACC
OFF
• No steering with ignition switch ON F
— Malfunction detected in camera-connection recognition signal
ON Selector lever is in “R” with ignition switch ON.
G
• Ignition switch at ACC
Reverse Sensor OFF
• Selector lever is in position other than “R” with ignition switch ON.
H
ON Vehicle speed is more than 0 km/h with ignition switch ON
• Ignition switch at ACC
Vehicle Speed Sensor OFF
• Vehicle speed is 0 km/h with ignition switch ON
I
Side View Switch — —
ADJUST OFFSET OF REAR VIEW CAMERA J
Use this mode to adjust the guide line display position of the rear view monitor if necessary after removing the
rear view monitor camera.
NOTE: K
The number on the top left of the screen has no relation to diagnosis
and adjustment.
L
AV
SKIB3689E
Bluetooth
Confirmation/Change Passkey O
AV-73
• The passkey of Bluetooth can be confirmed and changed.
• The passkey can be changed by four digits within 0 to 9.
SKIB3669E
Confirmation/Change Device Name

• The device name of Bluetooth can be confirmed and changed.
• The device name can be changed by sixteen digits within A to Z
(small character can be used) and - (hyphen).
JSNIA0526GB
Delete Unit Connection Log

Deletes any unit connection records and error records from the NAVI
control unit memory. (Clear the records of the unit that has been
removed.)
JPNIA0172GB
Feature Restriction Setting

Operations of navigation system that are performed while driving
can be restricted by using this function.
CAUTION:
Once operational restrictions are imposed, they can not be can-
celled even when the software is updated or the language-
switching program is loaded.
JSNIA0345GB
CONSULT - III Function (MULTI AV) INFOID:0000000001092947
CONSULT-III functions
CONSULT-III performs the following functions via the communication with the NAVI control unit.
AV-74
Diagnosis mode Description A

Ecu Identification The part number of NAVI control unit can be checked.
Performs a diagnosis on the NAVI control unit and a connection diagnosis for the communica-
Self Diagnostic Result
tion circuit of the Multi AV system, and displays the current and past malfunctions collectively. B
Data Monitor The diagnosis of vehicle signal that is input to the NAVI control unit can be performed.
AV COMMUNICATION C
When “AV communication” of “CAN Diag Support Monitor” is selected, the following function will be performed.
Displays the communication status from NAVI control unit to each unit as well as the er-
AV&NAVI C/U D
AV communication ror counter.
AUDIO Displays the NAVI control unit communication status and the error counter.
ECU IDENTIFICATION E
The part number of NAVI control unit is displayed.
SELF DIAGNOSIS RESULT
• In CONSULT-III self-diagnosis, self-diagnosis results and error history are displayed collectively. F
• The current malfunction indicates “CRNT”. The past malfunction indicates “PAST”.
• The timing is displayed as “0” if any of the error codes [U1000], [U1010], [U1300] and [U1310] is detected.
The counter increases by 1 if the condition is normal at the next ignition switch ON cycle. G
Self-diagnosis detection range
AV
JPNIA0248GB
O
Self-diagnosis results display item
Error item Description Possible cause/Action to take P

CAN communication malfunction is de-
CAN COMM CIRCUIT[U1000] Refer to AV-78, "Diagnosis Procedure".
tected.
CAN initial diagnosis malfunction is de-
CONTROL UNIT (CAN) [U1010] NAVI control unit
tected.
AV communication circuit initial diagno-
CONTROL UNIT (AV) [U1310] NAVI control unit
sis malfunction is detected.
AV-75
• Audio unit power supply and ground
circuit malfunction is detected. • Audio unit power supply and ground cir-
• AV COMM CIRCUIT [U1300]
• Malfunction is detected on communi- cuit
• SWITCH CONN [U1240]
cation circuit between audio unit and • Communication circuit between audio
• AUDIO H/U CONN [U1249]
camera control unit. unit and camera control unit
• AMP CONN [U124E]
• Malfunction is detected on communi- • NAVI control unit
• RDS CONN [U124F]
cation signal between audio unit and • Audio unit
NAVI control unit.
• AV COMM CIRCUIT [U1300]
• SWITCH CONN [U1240]
Malfunction is detected on communica-
• AUDIO H/U CONN [U1249] Communication circuit between camera
tion circuit between camera control unit
• AMP CONN [U124E] control unit and NAVI control unit
• REAR-CAMERA LAN CONN [U1252]
and ground circuit malfunction is de- • Camera control unit power supply and
• AV COMM CIRCUIT [U1300] tected. ground circuit
• REAR-CAMERA LAN CONN [U1252] • Malfunction is detected on communi- • NAVI control unit
cation signal between camera con- • Camera control unit
• Display unit power supply and
ground circuit malfunction is detect-
ed.
• Display unit power supply and ground
circuit
FRONT DISP CONN [U1243] cation circuit between display unit
• Communication circuit between display
unit and NAVI control unit
cation signal between display unit
GPS antenna connection malfunction • GPS antenna feeder
GPS ANTENNA CONN [U1244]
is detected. • GPS antenna
Camera and connection recognition Camera-connection recognition signal cir-
CAMERA CONT. CONN [U1250]
signal circuit malfunction is detected. cuit
Control Unit FLASH-ROM [U1200] NAVI control unit
ed.
Gyro NO CONN [U1201] NAVI control unit
ed.
GPS COMM [U1204] Intermittent malfunction caused by strong
radio interference may be detected if the
GPS ROM [U1205]
symptoms such as the GPS receipt mal-
GPS malfunction is detected.
GPS RAM [U1206] function occur.
Replace NAVI control unit if the malfunc-
GPS RTC [U1207] tion always occurs.
AV-76
A
DVD-ROM COMM [U1208]
DVD-ROM READ [U1209]
DVD-ROM DISC [U120A] B
DVD-ROM MECHA DETECT [U120C]
DVD-ROM DRIVE MECHA [U120D]
DVD-ROM FOCUS [U120E] ROM drive pickup lens in NAVI con- C
trol unit. • Map disc
DVD-ROM TOC [U120F]
• There is dirt and damage on the map • NAVI control unit
DVD-ROM SEEK [U1210] disc.
D
DVD-ROM ERR CORRECTION [U1211]
DVD-ROM DATA FORWARD [U1212]
DVD-ROM DATA [U1213] E
DVD-ROM TIMEOUT [U1214]
DVD-ROM LOAD [U1215]
F
CAN CONT [U1216] NAVI control unit malfunction is detect-
NAVI control unit
BLUETOOTH CONN [U1217] ed.
G
DATA MONITOR
ALL SIGNALS
• Displays the status of the following vehicle signals inputted to the NAVI control unit. H
• For each signal, actual signal can be compared with the condition recognized on the system.
I
Dis-
Display Item Vehicle status Remarks
play
ON Vehicle speed >0 km/h (0 MPH) Changes in indication may be delayed. This is
VHCL SPD SIG J
OFF Vehicle speed =0 km/h (0 MPH) normal.
ON Parking brake is applied. Changes in indication may be delayed. This is

PKB SIG
OFF Parking brake is released. normal. K
ON Lighting switch ON
ILLUM SIG —
OFF Lighting switch OFF
L
IGN SIG —
ON Selector lever in R position M
Changes in indication may be delayed. This is
REV SIG Selector lever in any position other
OFF normal.
than R
SELECTION FROM MENU AV

Allows the technician to select which vehicle signals should be displayed and displays the status of the
selected vehicle signals.
O
Item to be selected Description
VHCL SPD SIG
P
PKB SIG
The same as when “ALL SIGNALS”
ILLUM SIG
is selected.
IGN SIG
REV SIG
AV-77
U1000 CAN COMM CIRCUIT
< COMPONENT DIAGNOSIS > [AUDIO WITH NAVIGATION]
COMPONENT DIAGNOSIS
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
CAN Communication Signal Chart. Refer to LAN-25, "CAN Communication Signal Chart".
DTC Logic INFOID:0000000001092950
DTC DETECTION LOGIC
Display contents of CON-

DTC Diagnostic item is detected when... Probable malfunction location
SULT-III
When NAVI control unit is not transmit or re-
CAN COMM CIRCUIT
U1000 ceive CAN communication signal for 2 sec- CAN communication system
[U1000]
onds or more.
1.PERFORM SELF DIAGNOSTIC

1. Turn ignition switch ON and wait for 2 seconds or more.
2. Check “Self Diagnostic Result” of “MULTI AV”.
Is “CAN COMM CIRCUIT” displayed?
YES >> Refer to “LAN system”. Refer to LAN-13, "Trouble Diagnosis Flow Chart".
NO >> Refer to GI section. Refer to GI-39, "Intermittent Incident".
AV-78
U1010 CONTROL UNIT (CAN)
A
Initial diagnosis of NAVI control unit. B

DTC DETECTION LOGIC C
Display contents of CON-

DTC Diagnostic item is detected when... Probable malfunction location
SULT-III D
CONTROL UNIT (CAN)
U1010 CAN initial diagnosis malfunction is detected. NAVI control unit
[U1010]
E
1.REPLACE NAVI CONTROL UNIT F

Replace NAVI control unit when DTC U1010 is detected.
>> INSPECTION END G
AV
AV-79
U1310 NAVI CONTROL UNIT
Replace the NAVI control unit if this DTC is displayed. Refer to AV-257, "Exploded View".

• It is the master unit of the MULTI AV system, and it is connected to each control
unit by means of communication. It operates each system according to com-
munication signals from the NAVI control unit.
• The NAVI control unit includes the audio, hands-free phone, navigation, and
NAVI CONTORL UNIT
trol.
parking brake).
Display contents of
DTC DTC Detection Condition Action to take
CONSULT-III
CONTROL UNIT (AV) AV communication circuit initial diagnosis malfunction is
U1310 Replace NAVI control unit.
[U1310] detected.
AV-80
A
Replace the NAVI control unit if this DTC is displayed. Refer to AV-257, "Exploded View". B

• Map data can be read from the Map DVD-ROM by installing Map DVD-ROM. C
• The NAVI control unit includes the audio, hands-free phone, navigation, and D
NAVI CONTORL UNIT
• It inputs the illumination signals that are required for the display dimming con- E
trol.
parking brake).
F
G
Display contents of
CONSULT-III
Cont Unit H
An internal malfunction is detected in NAVI control unit
U1200 FLASH- ROM Replace NAVI control unit.
(FLASH-ROM).
[U1200]
AV
AV-81

NAVI CONTORL UNIT
trol.
parking brake).
Display contents of
CONSULT-III
GYRO NO CONN Internal malfunction of NAVI control unit (gyrocompass
[U1201] disconnection) is detected.
AV-82
A
Replace the NAVI control unit if this DTC is displayed. Refer to AV-257, "Exploded View". B

• Map data can be read from the Map DVD-ROM by installing Map DVD-ROM. C
• The NAVI control unit includes the audio, hands-free phone, navigation, and D
NAVI CONTORL UNIT
• It inputs the illumination signals that are required for the display dimming con- E
trol.
parking brake).
F
G
Display contents of
CONSULT-III
CAN CONT Internal malfunction of NAVI control unit (CAN controller) H
[U1216] is detected.
AV
AV-83

NAVI CONTORL UNIT
trol.
parking brake).
Display contents of
CONSULT-III
BLUETOOTH MODULE
Internal malfunction of NAVI control unit (Bluetooth mod-
U1217 CONN Replace NAVI control unit.
ule connection malfunction) is detected.
[U1217]
AV-84
U1204 GPS
U1204 GPS
A
An intermittent error caused by strong radio interference may be detected unless any symptoms (GPS recep- B
tion error, etc.) occur. Replace the NAVI control unit if the malfunction occurs constantly. Refer to AV-257,
"Exploded View".
Part name Description C

unit by means of communication. It operates each system according to com- D
NAVI CONTORL UNIT E
trol.
F
parking brake).
DTC Logic INFOID:0000000001092966 G
Display contents of
DTC DTC Detection Condition Action to take H
CONSULT-III
GPS CONN Internal malfunction of NAVI control unit (GPS malfunc-
[U1204] tion) is detected.
I
1.PERFORM THE SELF-DIAGNOSIS J

1. Delete the self-diagnosis results. Turn ignition switch OFF.
2. Turn ignition switch ON. Perform the self-diagnosis again.
3. Check that the DTC is detected again. K
Is any DTC detected?
YES >> Replace NAVI control unit.
NO >> The intermittent malfunction caused by strong radio interference can be detected. L
AV
AV-85
U1205 GPS
U1205 GPS
An intermittent error caused by strong radio interference may be detected unless any symptoms (GPS recep-
"Exploded View".

NAVI CONTORL UNIT
trol.
parking brake).
Display contents of
CONSULT-III
GPS ROM Internal malfunction of NAVI control unit (GPS malfunc-
1.PERFORM THE SELF-DIAGNOSIS

3. Check that the DTC is detected again.
NO >> The intermittent malfunction caused by strong radio interference can be detected.
AV-86
U1206 GPS
U1206 GPS
A
An intermittent error caused by strong radio interference may be detected unless any symptoms (GPS recep- B
"Exploded View".
Part name Description C

unit by means of communication. It operates each system according to com- D
NAVI CONTORL UNIT E
trol.
F
parking brake).
DTC Logic INFOID:0000000001092972 G
Display contents of
DTC DTC Detection Condition Action to take H
CONSULT-III
GPS RAM Internal malfunction of NAVI control unit (GPS malfunc-
I
1.PERFORM THE SELF-DIAGNOSIS J

NO >> The intermittent malfunction caused by strong radio interference can be detected. L
AV
AV-87
U1207 GPS
U1207 GPS
An intermittent error caused by strong radio interference may be detected unless any symptoms (GPS recep-
"Exploded View".

NAVI CONTORL UNIT
trol.
parking brake).
Display contents of
CONSULT-III
GPS RTC Internal malfunction of NAVI control unit (GPS malfunc-

NO >> The intermittent malfunction caused by strong radio interference can be detected.
AV-88
A
B
C
vehicle information functions. D
NAVI CONTORL UNIT
trol. E
parking brake).
MAP DVD-ROM A collection of Map data. F
G
Display contents of
DTC DTC Detection Condition Probable malfunction location
CONSULT-III
• Malfunction is detected on DVD-ROM drive pickup lens H
DVD-ROM COMM • Map disc
U1208 in NAVI control unit.
[U1208] • NAVI control unit
• There is dirt and damage on the map disc.

I

J
2. Turn ignition switch ON. Replace map DVD-ROM with a normal one.
3. Perform the self-diagnosis again.
NO >> Replace Map disc. L
AV
AV-89

NAVI CONTORL UNIT
trol.
parking brake).
Display contents of
CONSULT-III
• Malfunction is detected on DVD-ROM drive pickup lens
DVD-ROM READ • Map disc

NO >> Replace Map disc.
AV-90
U120A NAVI CONTROL UNIT
U120A NAVI CONTROL UNIT
A
B
C
NAVI CONTORL UNIT
trol. E
parking brake).
G
Display contents of
CONSULT-III
DVD-ROM DISC • Map disc
U120A in NAVI control unit.
[U120A] • NAVI control unit

I

J
AV
AV-91
U120C NAVI CONTROL UNIT
U120C NAVI CONTROL UNIT

NAVI CONTORL UNIT
trol.
parking brake).
Display contents of
CONSULT-III
DVD-ROM MECHA DE- • Map disc
U120C in NAVI control unit.
TECT [U120C] • NAVI control unit

AV-92
U120D NAVI CONTROL UNIT
U120D NAVI CONTROL UNIT
A
B
C
NAVI CONTORL UNIT
trol. E
parking brake).
G
Display contents of
CONSULT-III
DVD-ROM DRIVE • Map disc
U120D in NAVI control unit.
MECHA [U120D] • NAVI control unit

I

J
AV
AV-93
U120E NAVI CONTROL UNIT
U120E NAVI CONTROL UNIT

NAVI CONTORL UNIT
trol.
parking brake).
Display contents of
CONSULT-III
DVD-ROM FOCUS • Map disc
U120E in NAVI control unit.
[U120E] • NAVI control unit

AV-94
U120F NAVI CONTROL UNIT
U120F NAVI CONTROL UNIT
A
B
C
NAVI CONTORL UNIT
trol. E
parking brake).
G
Display contents of
CONSULT-III
DVD-ROM TOC • Map disc
U120F in NAVI control unit.
[U120F] • NAVI control unit

I

J
AV
AV-95

NAVI CONTORL UNIT
trol.
parking brake).
Display contents of
CONSULT-III
DVD-ROM SEEK • Map disc

AV-96
A
B
C
NAVI CONTORL UNIT
trol. E
parking brake).
G
Display contents of
CONSULT-III
DVD-ROM ERR COR- • Map disc
RECTION [U1211] • NAVI control unit

I

J
AV
AV-97

NAVI CONTORL UNIT
trol.
parking brake).
Display contents of
CONSULT-III
DVD-ROM DATA FOR- • Map disc
WARD [U1212] • NAVI control unit

AV-98
A
B
C
NAVI CONTORL UNIT
trol. E
parking brake).
G
Display contents of
CONSULT-III
DVD-ROM DATA • Map disc

I

J
AV
AV-99

NAVI CONTORL UNIT
trol.
parking brake).
Display contents of
CONSULT-III
DVD-ROM TIMEOUT • Map disc

AV-100
A
B
C
NAVI CONTORL UNIT
trol. E
parking brake).
G
Display contents of
CONSULT-III
DVD-ROM LOAD • Map disc

I

J
AV
AV-101
U1243 DISPLAY UNIT
U1243 DISPLAY UNIT

• Display image is controlled by the serial communication from NAVI control unit.
• RGB image signal is input from NAVI control unit (RGB, RGB area and RGB
DISPLAY UNIT
synchronizing). Camera image signal is input from camera control unit.
• Synchronize signal (HP, VP) is output to NAVI control unit.
Display contents of
DTC DTC Detection Condition Possible causes
CONSULT-III
• Display unit power supply and ground circuit malfunc-
tion is detected. • Display unit power supply and
FRONT DISP CONN • Malfunction is detected on communication circuit be- ground circuit
U1243
[U1243] tween display unit and NAVI control unit. • Communication circuit between
• Malfunction is detected on communication signal be- display unit and NAVI control unit
tween display unit and NAVI control unit.
1.CHECK DISPLAY UNIT POWER SUPPLY AND GROUND CIRCUIT

Check display unit power supply and ground circuit. Refer to AV-108, "DISPLAY UNIT : Diagnosis Procedure".
YES >> GO TO 2.
NO >> Repair malfunctioning parts.
2.CHECK CONTINUITY COMMUNICATION CIRCUIT
2. Disconnect display unit connector and NAVI control unit connector.
3. Check continuity between display unit harness connector terminals 17, 19 and NAVI control unit harness
connector terminals 54, 53.

4. Check continuity between display unit harness connector terminals 17, 19 and ground.

YES >> GO TO 3.
3.CHECK COMMUNICATION SIGNAL
1. Connect display unit connector and NAVI control unit connector.
3. Check signal between display unit harness connector terminal 17 and ground.
AV-102
U1243 DISPLAY UNIT
17 - Ground B
PKIB5039J C
YES >> GO TO 4.
D
NO >> Replace NAVI control unit.
4.CHECK COMMUNICATION SIGNAL
Check signal between display unit harness connector terminal 19 and ground. E
19 - Ground
G
PKIB5039J
H
NO >> Replace display unit.
I
AV
AV-103
U1244 GPS ANTENNA
U1244 GPS ANTENNA

GPS ANTENNA GPS signal is received and sent to NAVI control unit.
Display contents of
CONSULT-III
GPS ANTENNA CONN
U1244 GPS antenna connection malfunction is detected GPS antenna disconnection
[U1244]
1.CHECK GPS ANTENNA

Visually check GPS antenna and antenna feeder.
YES >> GO TO 2.
NO >> Repair malfunctioning parts.
2.CHECK NAVI CONTROL UNIT VOLTAGE
1. Disconnect GPS antenna connector.
3. Check voltage between NAVI control unit terminal 73 and ground.
73 - Ground : Approx. 5 V
AV-104
U1250 CAMERA CONTROL UNIT
U1250 CAMERA CONTROL UNIT
A
B
• Camera image signal is input from rear view camera, and camera image is in-
dicated on the display.
C
CAMERA CONTROL UNIT
• Controlled by AV communication sent from NAVI control unit.
• NAVI control unit recognizes the presence of camera system with camera con-
nection recognition signal. D
E
Display contents of
CONSULT-III
CAMERA CONT. CONN A malfunction is detected in camera-connection recogni- Camera-connection recognition sig- F
U1250
[U1250] tion signal circuit. nal circuit

G
1.CHECK CAMERA-CONNECTION RECOGNITION SIGNAL CIRCUIT
1. Disconnect NAVI control unit connector and camera control unit connector. H
2. Check continuity between NAVI control unit harness connector terminal 67 and camera control unit har-
ness connector terminal 14.
67 - 14 : Continuity should exist. I

YES >> GO TO 2. J
2.CHECK NAVI CONTROL UNIT VOLTAGE
1. Connect NAVI control unit connector. K
3. Check voltage between NAVI control unit harness connector terminal 67 and ground.
L
YES >> Replace camera control unit. M
AV
AV-105
U1300 AV COMM CIRCUIT
U1300 AV COMM CIRCUIT
U1300 is indicated when malfunction occurs in communication signal of multi AV system. It is indicated simul-
taneously, without fail, with the malfunction of control units connected to NAVI control unit with communication
line. It determines the possible malfunction cause from the table below.
SELF-DIAGNOSIS RESULTS DISPLAY ITEM
Display contents of Possible malfunction factor/Action to

DTC Description
CONSULT-III take
• AV COMM CIRCUIT
• Audio unit power supply and
[U1300] • Audio unit power supply and ground circuit malfunction
U1300 ground circuits
• SWITCH CONN is detected.
U1240 Refer to AV-107, "AUDIO UNIT : Di-
[U1240] • Malfunction is detected on communication circuit be-
U1249 agnosis Procedure".
• AUDIO H/U CONN tween audio unit and camera control unit.
U124E • Communication circuit between au-
[U1249] • Malfunction is detected on communication signal be-
U124F dio unit and camera control unit
• AMP CONN [U124E] tween audio unit and NAVI control unit.
• AV COMM CIRCUIT
[U1300]
U1300 • SWITCH CONN
U1240 [U1240]
U1249 • AUDIO H/U CONN Malfunction is detected on communication circuit between Communication circuit between cam-
U124E [U1249] camera control unit and NAVI control unit. era control unit and NAVI control unit
U124F • AMP CONN [U124E]
U1252 • RDS CONN [U124F]
• REAR-CAMERA LAN
CONN [U1252]
• AV COMM CIRCUIT • Camera control unit power supply and ground circuit • Camera control unit power supply
U1300 [U1300] malfunction is detected. and ground circuit
U1252 • REAR-CAMERA LAN • Malfunction is detected on communication signal be- • NAVI control unit
CONN [U1252] tween camera control unit and NAVI control unit. • Camera control unit
AV-106
A
NAVI CONTROL UNIT
NAVI CONTROL UNIT : Diagnosis Procedure INFOID:0000000001093026
B
1.CHECK FUSE
C
Battery 35
D
Ignition switch ON or START 1
Is inspection result normal? E
YES >> GO TO 2.
2.CHECK POWER SUPPLY CIRCUIT F
Check voltage between NAVI control unit harness connectors and ground.
G
ACC power supply M71 5 ACC 12 V H
Ignition signal M72 63 ON 12 V
YES >> GO TO 3. I
NO >> Check harness between NAVI control unit and fuse.
3.CHECK GROUND CIRCUIT J
2. Disconnect NAVI control unit connectors.
3. Check continuity between NAVI control unit harness connector and ground.
K
Signal name Connector No. Terminal No. Ignition switch position Continuity
Ground M71 1 OFF Continuity should exist.
L
NO >> Repair harness or connector. M
AUDIO UNIT
AUDIO UNIT : Diagnosis Procedure INFOID:0000000001093027
AV
1.CHECK FUSE
Check for blown fuses. O

Battery 35 P
YES >> GO TO 2.
Check voltage between audio unit harness connectors and ground.
AV-107
NO >> Check harness between audio unit and fuse.
DISPLAY UNIT
DISPLAY UNIT : Diagnosis Procedure INFOID:0000000001093028
1.CHECK FUSE

Battery 35
YES >> GO TO 2.
Check voltage between display unit harness connectors and ground.
YES >> GO TO 3.
NO >> Check harness between display unit and fuse.
2. Disconnect display unit connector.
3. Check continuity between display unit harness connector and ground.
Ground M49 23 OFF Continuity should exist.
CAMERA CONTROL UNIT
CAMERA CONTROL UNIT : Diagnosis Procedure INFOID:0000000001093029
1.CHECK FUSE

Battery 35
AV-108
YES >> GO TO 2.
NO >> Be sure to eliminate cause of malfunction before installing new fuse. A
Check voltage between camera control unit harness connectors and ground.
B
Battery power supply B60 32 OFF 12 V
C
ACC power supply B60 30 ACC 12 V
YES >> GO TO 3. D
NO >> Check harness between camera control unit and fuse.
E
2. Disconnect camera control unit connector.
3. Check continuity between camera control unit harness connector and ground.
F
Control signal 13
B60 OFF Continuity should exist. G
Ground 31
YES >> INSPECTION END H
AV
AV-109
RGB (R: RED) SIGNAL CIRCUIT
RGB (R: RED) SIGNAL CIRCUIT
Transmits the image displayed with NAVI control unit with RGB signal to the display unit.
1.CHECK CONTINUITY RGB (R: RED) SIGNAL CIRCUIT

3. Check continuity between display unit harness connector terminal 1 and NAVI control unit harness con-
nector terminal 44.

4. Check continuity between display unit harness connector terminal 1 and ground.

YES >> GO TO 2.
2.CHECK RGB (R: RED) SIGNAL
3. Start “Confirmation / Adjustment Mode”, and then display color bar by selecting“Color Spectrum Bar” on
DISPLAY DIAGNOSIS screen.
4. Check signal between display unit harness connector terminal 1 and 8.
1-8
JPNIA0221ZZ

YES >> Replace display unit.
AV-110
RGB (G: GREEN) SIGNAL CIRCUIT
RGB (G: GREEN) SIGNAL CIRCUIT
A
Transmits the image displayed with NAVI control unit with RGB signal to the display unit. B
1.CHECK CONTINUITY RGB (G: GREEN) SIGNAL CIRCUIT C

3. Check continuity between display unit harness connector terminal 3 and NAVI control unit harness con- D
nector terminal 45.
3 - 45 : Continuity should exist. E

3 - Ground : Continuity should not exist. F

YES >> GO TO 2.
NO >> Repair harness or connector. G
2.CHECK RGB (G: GREEN) SIGNAL

1. Connect display unit connector and NAVI control unit connector. H
3. Start “Confirmation / Adjustment Mode”, and then display color bar by selecting “Color Spectrum Bar” on
4. Check signal between display unit harness connector terminal 3 and 8. I
3-8
K
JPNIA0222ZZ
L
NO >> Replace NAVI control unit. M
AV
AV-111
RGB (B: BLUE) SIGNAL CIRCUIT
RGB (B: BLUE) SIGNAL CIRCUIT
Transmits the image displayed with NAVI control unit with RGB signal to the display unit.
1.CHECK CONTINUITY RGB (B: BLUE) SIGNAL CIRCUIT

nector terminal 46.


YES >> GO TO 2.
2.CHECK RGB (B: BLUE) SIGNAL
3. Start “Confirmation / Adjustment Mode”, and then display color bar by selecting “Color Spectrum Bar” on
4. Check signal between display unit harness connector terminal 5 and 8.
5-8
JPNIA0223ZZ

AV-112
RGB SYNCHRONIZING SIGNAL CIRCUIT
RGB SYNCHRONIZING SIGNAL CIRCUIT
A
Transmits the RGB synchronizing signal to the display unit so as to synchronize the RGB image displayed B
with NAVI control unit.
C
1.CHECK CONTINUITY RGB SYNCHRONIZING SIGNAL CIRCUIT
2. Disconnect display unit connector and NAVI control unit connector. D
nector terminal 48.
E
F
YES >> GO TO 2. G
2.CHECK RGB SYNCHRONIZING SIGNAL H
I
7 - Ground
SKIB0825E
Is inspection result normal? L

M
AV
AV-113
RGB AREA (YS) SIGNAL CIRCUIT
RGB AREA (YS) SIGNAL CIRCUIT
Transmits the display area of RGB image displayed by NAVI control unit with RGB area (YS) signal to display
unit.
1.CHECK CONTINUITY RGB AREA (YS) SIGNAL CIRCUIT

nector terminal 50.


YES >> GO TO 2.
2.CHECK RGB SYNCHRONIZING SIGNAL
At RGB image displayed : Approx. 5 V
2 - Ground
At rear view camera image displayed
PKIB4948J

AV-114
HORIZONTAL SYNCHRONIZING (HP) SIGNAL CIRCUIT
HORIZONTAL SYNCHRONIZING (HP) SIGNAL CIRCUIT
A
In composite image (camera image), it transmits the vertical synchronizing (VP) signal and horizontal synchro- B
nizing (HP) signal from display unit to NAVI control unit so as to synchronize the RGB images displayed with
NAVI control unit such as the image quality adjusting menu, etc.
Diagnosis Procedure INFOID:0000000001093041 C
1.CHECK CONTINUITY HORIZONTAL SYNCHRONIZING (HP) SIGNAL CIRCUIT

1. Turn ignition switch OFF. D
nector terminal 51. E

4. Check continuity between display unit harness connector terminal 4 and ground. F

Is inspection result normal? G
YES >> GO TO 2.
2.CHECK HORIZONTAL SYNCHRONIZING (HP) SIGNAL H

3. Check signal between display unit harness connector terminal 4 and ground. I
4 - Ground
K
SKIB0825E
L
NO >> Replace display unit. M
AV
AV-115
VERTICAL SYNCHRONIZING (VP) SIGNAL CIRCUIT
VERTICAL SYNCHRONIZING (VP) SIGNAL CIRCUIT
In composite image (camera image), it is transmits the vertical synchronizing (VP) signal and horizontal syn-
chronizing (HP) signal from display unit to NAVI control unit so as to synchronize the RGB images displayed
with NAVI control unit such as the image quality adjusting menu, etc.
1.CHECK CONTINUITY VERTICAL SYNCHRONIZING (VP) SIGNAL CIRCUIT

nector terminal 52.


YES >> GO TO 2.
2.CHECK VERTICAL SYNCHRONIZING (VP) SIGNAL
6 - Ground
SKIB0823E

NO >> Replace display unit.
AV-116
A
Supplies power from NAVI control unit to microphone. The microphone transmits the sound voice to the NAVI B
control unit.
C
1.CHECK CONTINUITY BETWEEN NAVI CONTROL UNIT AND MICROPHONE CIRCUIT
2. Disconnect NAVI control unit connector and microphone connector. D
3. Check continuity between NAVI control unit harness connector terminals 6, 7, 8 and microphone harness
connector terminals 4, 2, 1.
E
6-4 : Continuity should exist.
8-1 : Continuity should exist. F
4. Check continuity between NAVI control unit harness connector terminals 6, 8 and ground.
6, 8 - Ground : Continuity should not exist. G

YES >> GO TO 2. H
2.CHECK VOLTAGE MICROPHONE VCC
1. Connect NAVI control unit connector. I
3. Check voltage between NAVI control unit harness connector terminals 6 and 7.
J
6-7 : Approx. 5 V
YES >> GO TO 3. K
3.CHECK MICROPHONE SIGNAL
L
1. Connect microphone connector.
2. Check signal between NAVI control unit harness connector terminals 8 and 7.
M
AV
8-7
O
PKIB5037J

YES >> Replace NAVI control unit. P
NO >> Replace microphone.
AV-117
CAMERA IMAGE SIGNAL CIRCUIT (REAR VIEW CAMERA TO CAMERA CON-
TROL UNIT)
CAMERA IMAGE SIGNAL CIRCUIT (REAR VIEW CAMERA TO CAMERA
CONTROL UNIT)
• Camera control unit outputs camera ON signal to rear view camera and inputs rear view camera image sig-
nal from rear view camera when the reverse signal is input.
• The camera control unit that inputs the camera image signal transmits the camera image signal to the dis-
play unit.
1.CHECK CONTINUITY CAMERA IMAGE SIGNAL CIRCUIT

2. Disconnect camera control unit connector and rear view camera connector.
3. Check continuity between camera control unit harness connector terminal 6 and rear view camera har-

4. Check continuity between camera control unit harness connector terminal 6 and ground.

YES >> GO TO 2.
2.CHECK CAMERA IMAGE SIGNAL
1. Connect camera control unit connector and rear view camera connector.
3. Check signal between camera control unit harness connector terminal 6 and ground.
6 - Ground At rear view camera image displayed
SKIB0827E

YES >> Replace camera control unit.
NO >> Replace rear view camera.
AV-118
CAMERA IMAGE SIGNAL CIRCUIT (CAMERA CONTROL UNIT TO DISPLAY
UNIT)
CAMERA IMAGE SIGNAL CIRCUIT (CAMERA CONTROL UNIT TO DIS-
A
PLAY UNIT)
B
• The camera control unit that inputs the camera image signal transmits the camera image signal to the dis- C
play unit.
D
1.CHECK CONTINUITY CAMERA IMAGE SIGNAL CIRCUIT
2. Disconnect camera control unit connector and display unit connector. E
3. Check continuity between camera control unit harness connector terminal 12, 11 and display unit harness
connector terminal 11, 12.
F
4. Check continuity between camera control unit harness connector terminal 12 and ground. G

H
YES >> GO TO 2.
I
2.CHECK CAMERA IMAGE SIGNAL
1. Connect camera control unit connector and display unit connector.
2. Turn ignition switch ON. J
12 - Ground At rear view camera image displayed

L
SKIB0827E
M
NO >> Replace camera control unit. AV
AV-119
CAMERA ON SIGNAL CIRCUIT
CAMERA ON SIGNAL CIRCUIT
• The camera control unit that inputs the camera image signal transmits the camera image signal to the dis-
play unit.
1.CHECK CONTINUITY CAMERA ON SIGNAL CIRCUIT

2. Disconnect camera control unit connector and rear view camera connector.
3. Check continuity between camera control unit harness connector terminal 8 and rear view camera har-


YES >> GO TO 2.
2.CHECK VOLTAGE CAMERA ON SIGNAL
1. Connect camera control unit connector and rear view camera connector.
3. Shift the selector lever to “R” position.
YES >> Replace rear view camera.
NO >> Replace camera control unit.
AV-120
STEERING ANGLE SENSOR SIGNAL 1, 2 CIRCUIT
A
• Steering angle sensor signal 1, 2 detects the turning direction and quantity of the steering and transmits it to B
the camera control unit.
• Steering angle sensor signal 3 detects the neutral position of the steering and transmits it to the camera con-
trol unit.
• Camera control unit performs the correction of neutral position with sensor signal 1, 2, 3 and vehicle speed C
signal.
D
1.CHECK CONTINUITY STEERING ANGLE SENSOR SIGNAL 1, 2 CIRCUIT
1. Turn ignition switch OFF. E
2. Disconnect camera control unit connector and steering angle sensor connector.
3. Check continuity between camera control unit harness connector terminals 23, 24 and steering angle sen-
sor harness connector terminals 7, 6.
F
G
4. Check continuity between camera control unit harness connector terminals 23, 24 and ground.

H
YES >> GO TO 2.
NO >> Repair harness or connector. I
2.CHECK SIGNAL SENSOR SIGNAL 1, 2
1. Connect camera control unit connector.
2. Turn ignition switch ON. J
3. Check voltage between camera control unit harness connector terminals 23, 24 and ground.
23 - Ground : Approx. 5 V K
L
YES >> GO TO 3.
3.CHECK SIGNAL SENSOR SIGNAL 1, 2 M
1. Connect steering angle sensor connector.
2. Check signal between camera control unit harness connector terminal 23, 24 and ground.
AV
AV-121
Turn the steering to the right
SKIB3827E
A: Sensor signal 1
B: Sensor signal 2
23, 24 - Ground
Turn the steering to the left
SKIB3828E
A: Sensor signal 1
B: Sensor signal 2
NO >> Replace steering angle sensor.
AV-122
STEERING ANGLE SENSOR SIGNAL 3 CIRCUIT
STEERING ANGLE SENSOR SIGNAL 3 CIRCUIT
A
• Steering angle sensor signal 1, 2 detects the turning direction and quantity of the steering and transmits it to B
the camera control unit.
• Steering angle sensor signal 3 detects the neutral position of the steering and transmits it to the camera con-
trol unit.
• Camera control unit performs the correction of neutral position with sensor signal 1, 2, 3 and vehicle speed C
signal.
D
1.CHECK CONTINUITY STEERING ANGLE SENSOR SIGNAL 3 CIRCUIT
1. Turn ignition switch OFF. E
2. Disconnect camera control unit connector and steering angle sensor connector.
3. Check continuity between camera control unit harness connector terminal 25 and steering angle sensor
harness connector terminal 5.
F
G
Is inspection result normal? H
YES >> GO TO 2.
2.CHECK SIGNAL SENSOR SIGNAL 3 I
1. Connect camera control unit connector.
3. Check voltage between camera control unit harness connector terminal 25 and ground. J
Is inspection result normal? K
YES >> GO TO 3.
3.CHECK SIGNAL SENSOR SIGNAL 3 L
1. Connect steering angle sensor connector.

2. Check signal between camera control unit harness connector terminal 25 and ground. M
AV
25 - Ground Turn the steering around the neutral position

O
SKIB3829E
A: Sensor signal 3
B: Sensor signal 1 P
NO >> Replace steering angle sensor.
AV-123

1.CHECK STEERING SWITCH SIGNAL A CIRCUIT

3. Check continuity between audio unit harness connector terminal 6 and spiral cable harness connector ter-
minal 24.

4. Check continuity between audio unit harness connector terminals 6 and ground.

YES >> GO TO 2.
Check spiral cable.
YES >> GO TO 3.
6 - 15 : Approx. 5 V
YES >> GO TO 4.
AV-124
Standard
Between terminals 20 and A
17
ENTER switch ON : 990 – 1030 Ω
MENU DOWN switch ON : 324 – 336 Ω B
C
Between terminals 16 and JPNIA0166GB

17 D
switch ON : 990 – 1030 Ω
switch ON : 324 – 336 Ω
E
VOL DOWN switch ON :0Ω
F
AV
AV-125

1.CHECK STEERING SWITCH SIGNAL B CIRCUIT

terminal 32.


YES >> GO TO 2.
Check spiral cable.
YES >> GO TO 3.
16 - 15 : Approx. 5 V
YES >> GO TO 4.
AV-126
Standard
Between terminals 20 and A
17
MENU DOWN switch ON : 324 – 336 Ω B
C

17 D
switch ON : 990 – 1030 Ω
switch ON : 324 – 336 Ω
E
VOL DOWN switch ON :0Ω
F
AV
AV-127

1.CHECK STEERING SWITCH SIGNAL GND CIRCUIT

terminal 31.

YES >> GO TO 2.
Check spiral cable.
YES >> GO TO 3.
15 - Ground : Continuity should exist.

YES >> GO TO 4.
Standard
Between terminals 20 and
17
MENU DOWN switch ON : 324 – 336 Ω

17
AV-128
switch ON : 990 – 1030 Ω

A
switch ON : 324 – 336 Ω
VOL DOWN switch ON :0Ω B
AV
AV-129
NAVI CONTROL UNIT
< ECU DIAGNOSIS > [AUDIO WITH NAVIGATION]
ECU DIAGNOSIS
NAVI CONTROL UNIT
VALUES ON THE DIAGNOSIS TOOL

CONSULT-III data monitor item
Dis-
Display Item Vehicle status Remarks
play
ON Vehicle speed >0 km/h (0 MPH) Changes in indication may be delayed. This is
VHCL SPD SIG
OFF Vehicle speed =0 km/h (0 MPH) normal.
ON Parking brake is applied. Changes in indication may be delayed. This is

PKB SIG
OFF Parking brake is released. normal.
ON Lighting switch ON
ILLUM SIG —
OFF Lighting switch OFF
IGN SIG —
ON Selector lever in R position
Changes in indication may be delayed. This is
REV SIG Selector lever in any position other
OFF normal.
than R
TERMINAL LAYOUT
JPNIA0226ZZ
PHYSICAL VALUES
Terminal
Description
Condition
Input/ (Approx.)
+ – Signal name
Output
Ignition
1
Ground GND — switch — 0V
(B)
ON
Ignition
2
(BR)
OFF
Ignition
5
Ground ACC power supply Input switch — Battery voltage
(SB)
ACC
Ignition
6
7 Microphone VCC Output switch — 5V
(R)
ON
Ignition
7 Ground Mic. GND — switch — 0V
ON
AV-130
NAVI CONTROL UNIT
Terminal
Description
(Wire color) Reference value A
Condition
Input/ (Approx.)
+ – Signal name
Output
B
Ignition
8 C
7 Microphone signal Input switch Sounds
(G)
ON
PKIB5037J D
9 — Shield — — — —
Ignition
10 11
TEL voice signal Output switch TEL voice output
(G) (R) F
ON
SKIB3609E
G
Ignition H
12 14
Voice guidance signal Output switch Voice guidance output
(L) (P)
ON
I
SKIB3609E
13 — Shield — — — —
J
Start “Confirmation / Adjust-
ment Mode”, and then dis-
Ignition
44 47 play color bar by selecting
RGB signal (R: red) Output switch K
(G) (B) “Color Spectrum Bar” on
ON
DISPLAY DIAGNOSIS
screen.
JPNIA0221ZZ L

ment Mode”, and then dis- M
Ignition
45 47 play color bar by
RGB signal (G: green) Output switch
(R) (B) selecting“Color Spectrum
ON
Bar” on DISPLAY DIAGNO-
SIS screen. AV
JPNIA0222ZZ

O
Ignition
46 47 play color bar by
RGB signal (B: blue) Output switch
(W) (B) selecting“Color Spectrum P
ON
Bar” on DISPLAY DIAGNO-
SIS screen.
JPNIA0223ZZ
Ignition
47
Ground RGB ground — switch — 0V
(B)
ON
AV-131
NAVI CONTROL UNIT
Terminal
Description
Condition
Input/ (Approx.)
+ – Signal name
Output
Ignition
48
Ground RGB synchronizing signal Output switch —
(L)
ON
SKIB0825E
Ignition
49 Ground GND — switch — 0V
ON
At RGB image displayed 5V
Ignition
50
Ground RGB area (YS) signal Output switch At rear view camera image
(G)
ON displayed
PKIB4948J
Ignition
51 Horizontal synchronizing
Ground Input switch —
(W) (HP) signal
ON
SKIB0825E
Ignition
52 Vertical synchronizing (VP)
Ground Input switch —
(R) signal
ON
SKIB0823E
Ignition
53 Communication signal When adjusting display
Ground Output switch
(L) (CONT→DISP) brightness.
ON
PKIB5039J
Ignition
Ground Input switch
(P) (DISP→CONT) brightness.
ON
PKIB5039J
55 — Shield — — — —
AV-132
NAVI CONTROL UNIT
Terminal
Description
Condition
Input/ (Approx.)
+ – Signal name
Output
61 Lighting switch is OFF. 0V B

Ground Illumination signal Input OFF
(R) Lighting switch is ON. 12 V
Ignition
63 C
Ground Ignition signal Input switch — Battery voltage
(W)
ON
Ignition Parking brake ON 0V
64
Ground Parking brake signal Input switch D
(GR) Parking brake OFF 12 V
ON
Ignition R position 12 V
65
Ground Reverse signal Input switch E
(G) Other than R position 0V
ON
F
Ignition
66 Vehicle speed signal (8- When vehicle speed is ap-
Ground Input switch
(V) pulse) prox. 40 km/h (25MPH)
ON
G
SKIA6649J
Connected to camera con-

0V
H
Ignition trol unit connector
67 Camera-connection recog-
Ground Input switch
(L) nition signal Not connected to camera
ON 5V
control unit connector I
69 AV communication signal Input/
— — — —
(L) (H) Output
70 AV communication signal Input/ J
— — — —
(P) (L) Output
71 Input/
— CAN–H — — —
(L) Output
K
72 Input/
— CAN–L — — —
(P) Output
Ignition L
Not connected to GPS an-
73 — GPS antenna signal Input switch 5V
tenna connector
ACC
74 — Shield — — — —
M
AV
AV-133
NAVI CONTROL UNIT
Wiring Diagram—AUDIO WITH NAVIGATION SYSTEM (LHD MODELS)— INFOID:0000000001093062
JCNWA0295GB
AV-134
NAVI CONTROL UNIT
AV
JCNWA0296GB
AV-135
NAVI CONTROL UNIT
JCNWA0297GB
AV-136
NAVI CONTROL UNIT
AV
JCNWA0298GB
AV-137
NAVI CONTROL UNIT
JCNWA0299GB
AV-138
NAVI CONTROL UNIT
AV
JCNWA0300GB
AV-139
NAVI CONTROL UNIT
JCNWA0301GB
AV-140
NAVI CONTROL UNIT
AV
JCNWA0302GB
AV-141
NAVI CONTROL UNIT
JCNWA0303GB
AV-142
NAVI CONTROL UNIT
AV
JCNWA0304GB
AV-143
NAVI CONTROL UNIT
JCNWA0305GB
AV-144
NAVI CONTROL UNIT
AV
JCNWA0306GB
AV-145
NAVI CONTROL UNIT
JCNWA0307GB
AV-146
NAVI CONTROL UNIT
Wiring Diagram—AUDIO WITH NAVIGATION SYSTEM (RHD MODELS)—
INFOID:0000000001537499 A
AV
JCNWA0308GB
P
AV-147
NAVI CONTROL UNIT
JCNWA0309GB
AV-148
NAVI CONTROL UNIT
AV
JCNWA0310GB
AV-149
NAVI CONTROL UNIT
JCNWA0311GB
AV-150
NAVI CONTROL UNIT
AV
JCNWA0312GB
AV-151
NAVI CONTROL UNIT
JCNWA0313GB
AV-152
NAVI CONTROL UNIT
AV
JCNWA0314GB
AV-153
NAVI CONTROL UNIT
JCNWA0315GB
AV-154
NAVI CONTROL UNIT
AV
JCNWA0316GB
AV-155
NAVI CONTROL UNIT
JCNWA0317GB
AV-156
NAVI CONTROL UNIT
AV
JCNWA0318GB
AV-157
NAVI CONTROL UNIT
JCNWA0319GB
AV-158
NAVI CONTROL UNIT
AV
JCNWA0320GB
DTC Index INFOID:0000000001093063 P
Self-diagnosis results display item
DTC Error item Refer to

U1000 CAN COMM CIRCUIT [U1000] AV-78, "Diagnosis Procedure"
U1010 CONTROL UNIT (CAN) [U1010] AV-79, "Diagnosis Procedure"
AV-159
NAVI CONTROL UNIT
DTC Error item Refer to
U1310 CONTROL UNIT (AV) [U1310] AV-80, "DTC Logic"
U1300 AV COMM CIRCUIT [U1300]
U1240 SWITCH CONN [U1240]
U1249 AUDIO H/U CONN [U1249] AV-106, "Description"
U124E AMP CONN [U124E]
U124F RDS CONN [U124F]
U1240 SWITCH CONN [U1240]
U1249 AUDIO H/U CONN [U1249]
AV-106, "Description"
U124E AMP CONN [U124E]
U124F RDS CONN [U124F]
U1252 REAR-CAMERA LAN CONN [U1252]
AV-106, "Description"
U1252 REAR-CAMERA LAN CONN [U1252]
U1243 FRONT DISP CONN [U1243] AV-102, "Diagnosis Procedure"
U1244 GPS ANTENNA CONN [U1244] AV-104, "Diagnosis Procedure"
U1250 CAMERA CONT. CONN [U1250] AV-105, "Diagnosis Procedure"
U1200 Control Unit FLASH-ROM [U1200] AV-81, "DTC Logic"
U1201 Gyro NO CONN [U1201] AV-82, "DTC Logic"
U1204 GPS COMM [U1204] AV-85, "Diagnosis Procedure"
U1205 GPS ROM [U1205] AV-86, "Diagnosis Procedure"
U1206 GPS RAM [U1206] AV-87, "Diagnosis Procedure"
U1207 GPS RTC [U1207] AV-88, "Diagnosis Procedure"
U1208 DVD-ROM COMM [U1208] AV-89, "Diagnosis Procedure"
U1209 DVD-ROM READ [U1209] AV-90, "Diagnosis Procedure"
U120A DVD-ROM DISC [U120A] AV-91, "Diagnosis Procedure"
U120C DVD-ROM MECHA DETECT [U120C] AV-92, "Diagnosis Procedure"
U120D DVD-ROM DRIVE MECHA [U120D] AV-93, "Diagnosis Procedure"
U120E DVD-ROM FOCUS [U120E] AV-94, "Diagnosis Procedure"
U120F DVD-ROM TOC [U120F] AV-95, "Diagnosis Procedure"
U1210 DVD-ROM SEEK [U1210] AV-96, "Diagnosis Procedure"
U1211 DVD-ROM ERR CORRECTION [U1211] AV-97, "Diagnosis Procedure"
U1212 DVD-ROM DATA FORWARD [U1212] AV-98, "Diagnosis Procedure"
U1213 DVD-ROM DATA [U1213] AV-99, "Diagnosis Procedure"
U1214 DVD-ROM TIMEOUT [U1214] AV-100, "Diagnosis Procedure"
U1215 DVD-ROM LOAD [U1215] AV-101, "Diagnosis Procedure"
U1216 CAN CONT [U1216] AV-83, "DTC Logic"
U1217 BLUETOOTH CONN [U1217] AV-84, "DTC Logic"
AV-160
AUDIO UNIT
AUDIO UNIT
A
TERMINAL LAYOUT B
JPNIA0227ZZ E
PHYSICAL VALUES
F
Terminal
Description
Condition
Input/ (Approx.)
+ – Signal name G
Output
H
Ignition
2 3
Sound signal front LH Output switch Voice output
(W) (P)
ON
I
SKIB3609E
Ignition
4 5
Sound signal rear LH Output switch Voice output K
(LG) (R)
ON
SKIB3609E L
Keep pressing SOURCE
0V
switch.
Keep pressing MENU UP
1.27 V
M
switch.
Ignition
6 15
Steering switch signal A Input switch Keep pressing MENU
(V) (GR) 2.53 V
ON DOWN switch. AV
Keep pressing ENTER
3.8 V
switch.
Except for above. 5V O
Ignition
7
Ground ACC power supply Input switch − Battery voltage
(SB)
ACC
P
AV-161
AUDIO UNIT
Terminal
Description
Condition
Input/ (Approx.)
+ – Signal name
Output
Ignition
11 12
Sound signal front RH Output switch Voice output
(G) (R)
ON
SKIB3609E
Ignition
13 14
Sound signal rear RH Output switch Voice output
(BR) (Y)
ON
SKIB3609E
Ignition
15
Ground Steering switch signal GND — switch — 0V
(GR)
ON
Keep pressing VOL DOWN
0V
switch.
Keep pressing VOL UP
1.27 V
Ignition switch.
16 15
Steering switch signal B Input switch
(O) (GR) Keep pressing 2.53 V
ON
switch.
Keep pressing switch. 3.8 V

Ignition
19
(BR)
OFF
— — — —
(L) (H) Output
— — — —
(P) (L) Output
Ignition
30 31
TEL voice signal Input switch TEL voice output
(G) (R)
ON
SKIB3609E
Ignition
32 33
Voice guidance signal Input switch Voice guidance output
(L) (P)
ON
SKIB3609E
37 — Shield — — — —
38 — Shield — — — —
AV-162
AUDIO UNIT
Terminal
Description
Condition
Input/ (Approx.)
+ – Signal name
Output
Ignition B
41 Ground Antenna amp. ON signal Output switch — 12 V
ACC
42 — Antenna signal Input — — — C
AV
AV-163
AUDIO UNIT
JCNWA0295GB
AV-164
AUDIO UNIT
AV
JCNWA0296GB
AV-165
AUDIO UNIT
JCNWA0297GB
AV-166
AUDIO UNIT
AV
JCNWA0298GB
AV-167
AUDIO UNIT
JCNWA0299GB
AV-168
AUDIO UNIT
AV
JCNWA0300GB
AV-169
AUDIO UNIT
JCNWA0301GB
AV-170
AUDIO UNIT
AV
JCNWA0302GB
AV-171
AUDIO UNIT
JCNWA0303GB
AV-172
AUDIO UNIT
AV
JCNWA0304GB
AV-173
AUDIO UNIT
JCNWA0305GB
AV-174
AUDIO UNIT
AV
JCNWA0306GB
AV-175
AUDIO UNIT
JCNWA0307GB
AV-176
AUDIO UNIT
INFOID:0000000001537513 A
AV
JCNWA0308GB
P
AV-177
AUDIO UNIT
JCNWA0309GB
AV-178
AUDIO UNIT
AV
JCNWA0310GB
AV-179
AUDIO UNIT
JCNWA0311GB
AV-180
AUDIO UNIT
AV
JCNWA0312GB
AV-181
AUDIO UNIT
JCNWA0313GB
AV-182
AUDIO UNIT
AV
JCNWA0314GB
AV-183
AUDIO UNIT
JCNWA0315GB
AV-184
AUDIO UNIT
AV
JCNWA0316GB
AV-185
AUDIO UNIT
JCNWA0317GB
AV-186
AUDIO UNIT
AV
JCNWA0318GB
AV-187
AUDIO UNIT
JCNWA0319GB
AV-188
AUDIO UNIT
AV
JCNWA0320GB
AV-189
DISPLAY UNIT
DISPLAY UNIT
TERMINAL LAYOUT
JPNIA0228ZZ
PHYSICAL VALUES
Terminal
Description
Condition
Input/ (Approx.)
+ – Signal name
Output

Ignition
RGB signal (R: red) Input switch
(G) (B) “Color Spectrum Bar” on
ON
DISPLAY DIAGNOSIS
screen.
JPNIA0221ZZ
At RGB image displayed 5V
Ignition
2
Ground RGB area (YS) signal Input switch At rear view camera image
(G)
ON displayed
PKIB4948J

Ignition
RGB signal (G: green) Input switch
(R) (B) “Color Spectrum Bar” on
ON
DISPLAY DIAGNOSIS
screen.
JPNIA0222ZZ
Ignition
4 Horizontal synchronizing
Ground Output switch —
(W) (HP) signal
ON
SKIB0825E
AV-190
DISPLAY UNIT
Terminal
Description
Condition
Input/ (Approx.)
+ – Signal name
Output
B
Ignition
5 8 play color bar by selecting C
RGB signal (B: blue) Input switch
(W) (B) “Color Spectrum Bar” on
ON
DISPLAY DIAGNOSIS
screen.
JPNIA0223ZZ D
E
Ignition
6 Vertical synchronizing (VP)
Ground Output switch —
(R) signal
ON
F
SKIB0823E
Ignition
7
Ground RGB synchronizing signal Input switch —
(L)
ON
H
SKIB0825E
I
Ignition
8
Ground RGB ground — switch — 0V
(B)
ON
J
Ignition
10 Ground GND — switch — 0V
ON
K
Ignition
11 At rear view camera image L
12 Camera image signal Input switch
(Y) displayed
ON
SKIB0827E
M
AV
Ignition
Ground Output switch
(P) (DISP→CONT) brightness.
ON
O
PKIB5039J
18 — Shield — — — —
P
AV-191
DISPLAY UNIT
Terminal
Description
Condition
Input/ (Approx.)
+ – Signal name
Output
Ignition
Ground Input switch
(L) (CONT→DISP) brightness.
ON
PKIB5039J
Ignition
20
(SB)
ACC
Ignition
21
(BR)
OFF
Ignition
23
(B)
ON
AV-192
DISPLAY UNIT
AV
JCNWA0295GB
P
AV-193
DISPLAY UNIT
JCNWA0296GB
AV-194
DISPLAY UNIT
AV
JCNWA0297GB
AV-195
DISPLAY UNIT
JCNWA0298GB
AV-196
DISPLAY UNIT
AV
JCNWA0299GB
AV-197
DISPLAY UNIT
JCNWA0300GB
AV-198
DISPLAY UNIT
AV
JCNWA0301GB
AV-199
DISPLAY UNIT
JCNWA0302GB
AV-200
DISPLAY UNIT
AV
JCNWA0303GB
AV-201
DISPLAY UNIT
JCNWA0304GB
AV-202
DISPLAY UNIT
AV
JCNWA0305GB
AV-203
DISPLAY UNIT
JCNWA0306GB
AV-204
DISPLAY UNIT
AV
JCNWA0307GB
AV-205
DISPLAY UNIT
INFOID:0000000001537515
JCNWA0308GB
AV-206
DISPLAY UNIT
AV
JCNWA0309GB
AV-207
DISPLAY UNIT
JCNWA0310GB
AV-208
DISPLAY UNIT
AV
JCNWA0311GB
AV-209
DISPLAY UNIT
JCNWA0312GB
AV-210
DISPLAY UNIT
AV
JCNWA0313GB
AV-211
DISPLAY UNIT
JCNWA0314GB
AV-212
DISPLAY UNIT
AV
JCNWA0315GB
AV-213
DISPLAY UNIT
JCNWA0316GB
AV-214
DISPLAY UNIT
AV
JCNWA0317GB
AV-215
DISPLAY UNIT
JCNWA0318GB
AV-216
DISPLAY UNIT
AV
JCNWA0319GB
AV-217
DISPLAY UNIT
JCNWA0320GB
AV-218
CAMERA CONTROL UNIT
CAMERA CONTROL UNIT
A
TERMINAL LAYOUT B
JPNIA0007ZZ E
PHYSICAL VALUES
F
Terminal
Description
Condition
Input/ (Approx.) G
+ – Signal name
Output
5 — Shield — — — —
H
Ignition
6 At rear view camera image I
Ground Camera image signal Input switch
(Y) displayed
ON
SKIB0827E
J
Ignition
7
(L)
ON K
Ignition R position 6V
8
Ground Camera ON signal Output switch
(G) Other than R position 0V
ON L
11 — Shield — — — —
M
Ignition
12 At rear view camera image
Ground Camera image signal Output switch
(Y) displayed
ON AV
SKIB0827E
Ignition O
13
Ground Control signal — switch — 0V
(B)
ON
Connected to camera con-
0V
P
Ignition trol unit connector
14 Camera-connection recog-
Ground — switch
(GR) nition signal Not connected to camera
ON 5V
control unit connector
— — — —
(P) (L) Output
AV-219
CAMERA CONTROL UNIT
Terminal
Description
Condition
Input/ (Approx.)
+ – Signal name
Output
— — — —
(L) (H) Output
— — — —
(P) (L) Output
— — — —
(L) (H) Output
Ignition R position 12 V
22
Ground Reverse signal Input switch
(R) Other than R position 0V
ON
Turn the steering to the

right
SKIB3827E
A: Sensor signal 1
Ignition B: Sensor signal 2
23
Ground Sensor signal 1 Input switch
(V)
ON
SKIB3828E
A: Sensor signal 1
B: Sensor signal 2
Turn the steering to the

right
SKIB3827E
A: Sensor signal 1
Ignition B: Sensor signal 2
24
(LG)
ON
SKIB3828E
A: Sensor signal 1
B: Sensor signal 2
AV-220
CAMERA CONTROL UNIT
Terminal
Description
Condition
Input/ (Approx.)
+ – Signal name
Output
B
Ignition C
25 Turn the steering around
(O) the neutral position
ON
SKIB3829E D
A: Sensor signal 3
B: Sensor signal 1
E
Ignition
26 Vehicle speed signal When vehicle speed is ap-
Ground Input switch F
(SB) (8-pulse) prox. 40 km/h (25 MPH)
ON
SKIA6649J G
Ignition
30
(W)
ACC H
Ignition
31
(B)
ON
I
Ignition
32
(R)
OFF
J
AV
AV-221
CAMERA CONTROL UNIT
JCNWA0295GB
AV-222
CAMERA CONTROL UNIT
AV
JCNWA0296GB
AV-223
CAMERA CONTROL UNIT
JCNWA0297GB
AV-224
CAMERA CONTROL UNIT
AV
JCNWA0298GB
AV-225
CAMERA CONTROL UNIT
JCNWA0299GB
AV-226
CAMERA CONTROL UNIT
AV
JCNWA0300GB
AV-227
CAMERA CONTROL UNIT
JCNWA0301GB
AV-228
CAMERA CONTROL UNIT
AV
JCNWA0302GB
AV-229
CAMERA CONTROL UNIT
JCNWA0303GB
AV-230
CAMERA CONTROL UNIT
AV
JCNWA0304GB
AV-231
CAMERA CONTROL UNIT
JCNWA0305GB
AV-232
CAMERA CONTROL UNIT
AV
JCNWA0306GB
AV-233
CAMERA CONTROL UNIT
JCNWA0307GB
AV-234
CAMERA CONTROL UNIT
INFOID:0000000001537517 A
AV
JCNWA0308GB
P
AV-235
CAMERA CONTROL UNIT
JCNWA0309GB
AV-236
CAMERA CONTROL UNIT
AV
JCNWA0310GB
AV-237
CAMERA CONTROL UNIT
JCNWA0311GB
AV-238
CAMERA CONTROL UNIT
AV
JCNWA0312GB
AV-239
CAMERA CONTROL UNIT
JCNWA0313GB
AV-240
CAMERA CONTROL UNIT
AV
JCNWA0314GB
AV-241
CAMERA CONTROL UNIT
JCNWA0315GB
AV-242
CAMERA CONTROL UNIT
AV
JCNWA0316GB
AV-243
CAMERA CONTROL UNIT
JCNWA0317GB
AV-244
CAMERA CONTROL UNIT
AV
JCNWA0318GB
AV-245
CAMERA CONTROL UNIT
JCNWA0319GB
AV-246
CAMERA CONTROL UNIT
AV
JCNWA0320GB
AV-247
< SYMPTOM DIAGNOSIS > [AUDIO WITH NAVIGATION]
SYMPTOM DIAGNOSIS
RELATED TO NAVIGATION
NOTE:
Combined part of AV switch and audio unit.
Symptoms Check items Possible malfunction location/Action to take

“MULTI AV” is displayed on “SELECT Perform the self-diagnosis using CONSULT-III.
SYSTEM” screen of CONSULT-III. (AV-74, "CONSULT - III Function (MULTI AV)")
• NAVI control unit power supply and ground circuit
AV switch cannot be operated. (AV-107, "NAVI CONTROL UNIT : Diagnosis Proce-
(All switches cannot be operated.) “MULTI AV” is not displayed on “SE- dure")
LECT SYSTEM” screen of CON- • Perform CAN diagnosis when “Please wait” is indi-
SULT-III. cated on the screen for approximately 120 seconds
after ignition switch ON. (LAN-13, "Trouble Diagnosis
Flow Chart")
CONSULT-III self-diagnosis detects Perform the self-diagnosis using CONSULT-III.
AV switch cannot be operated. a malfunction. (AV-74, "CONSULT - III Function (MULTI AV)")
(Only specified switch cannot be
operated.) CONSULT-III self-diagnosis does not
Audio unit (AV-256, "Exploded View")
detect a malfunction.
Map screen is not displayed.
Perform the self-diagnosis using CONSULT-III.
(RGB image other than map is –
(AV-74, "CONSULT - III Function (MULTI AV)")
normal.)
Voice guidance is not heard. – Voice guidance signal circuit
Traffic information (RDS-TMC) is • Radio antenna (AV-268, "Exploded View")
Radio broadcasts are not received.
not received. • Antenna feeder (AV-270, "Harness Layout")
RELATED TO REAR VIEW MONITOR

• Horizontal synchronizing (HP) signal circuit (AV-115,
"Diagnosis Procedure")
Warning message under the dis-
• Vertical synchronizing (VP) signal circuit (AV-116,
play is not displayed at rear view –
"Diagnosis Procedure")
monitor image.
• RGB area (YS) signal circuit (AV-114, "Diagnosis
Procedure")
• Camera image signal circuit
(Between camera control unit and display unit)
(AV-119, "Diagnosis Procedure")
Only warning message under the dis-
• Camera control unit power supply and ground circuit
play is displayed.
(AV-108, "CAMERA CONTROL UNIT : Diagnosis
Procedure")
• Camera control unit reverse signal circuit.
Camera image is not shown.
• Camera ON signal circuit
Only warning message under the dis- (AV-120, "Diagnosis Procedure")
play, guide lines and possible route • Camera image signal circuit
lines are displayed. (Between camera control unit and rear view camera)
(AV-118, "Diagnosis Procedure")
Warning message under the display Perform the self-diagnosis using CONSULT-III.
is rolling. (AV-74, "CONSULT - III Function (MULTI AV)")
AV-248
A
steering angle sensor signal circuit. (Sensor signal 1 or
Possible route line does not move. 2)
Possible route line are incorrect. (AV-121, "Diagnosis Procedure")
Center position of possible route line steering angle sensor signal circuit. (Sensor signal 3) B
is incorrect. (AV-123, "Diagnosis Procedure")
CONSULT-III self-diagnosis detects Perform the self-diagnosis using CONSULT-III (MULTI
It cannot be switched to rear view a malfunction. AV) (AV-74, "CONSULT - III Function (MULTI AV)"). C
monitor. CONSULT-III self-diagnosis does not
NAVI control unit reverse signal circuit
detect a malfunction.
D
RELATED TO AUDIO
Symptom Check items Possible malfunction location / Action to take

E
Audio sound is not heard. Sound is not heard only from the specif-
ic places (Front RH, rear RH, front LH Sound signal circuit of suspect system
and rear LH).
F
RELATED TO RGB IMAGE

G
RGB signal (R: red) circuit (AV-110, "Diagnosis Proce-
Light blue (Cyan) tint
dure") H
Purple (Magenta) tint and image is RGB signal (G: green) circuit (AV-111, "Diagnosis Pro-
Color of RGB image is not proper.
rolling. cedure")
RGB signal (B: blue) circuit (AV-112, "Diagnosis Proce- I
Screen looks yellowish.
dure")
• RGB image is too dark.
– RGB ground circuit
• RGB image is too fuzzy. J
“MULTI AV” is displayed on “SELECT Perform the self-diagnosis using CONSULT-III (AV-74,
RGB image is not displayed. SYSTEM” screen of CONSULT-III. "CONSULT - III Function (MULTI AV)").
(Nothing is displayed on the “MULTI AV” is not displayed on “SE- K
screen.) NAVI control unit power supply and ground circuit (AV-
LECT SYSTEM” screen of CON-
107, "NAVI CONTROL UNIT : Diagnosis Procedure")
SULT-III.
RELATED TO VOICE ACTIVATED CONTROL L

Voice sounds at “Speaker Test” and M
“Voice Microphone Test” of “Confir- NAVI control unit (AV-257, "Exploded View")
The voice cannot be controlled mation / Adjustment Mode”.
even if the voice control screen is • MIC. power supply circuit (AV-117, "Diagnosis Proce- AV
displayed. Voice does not sound at “Speaker
dure")
Test” and “Voice Microphone Test” of
• Shield (MIC.) circuit (AV-117, "Diagnosis Procedure")
“Confirmation / Adjustment Mode”.
• MIC. signal circuit (AV-117, "Diagnosis Procedure")
O
AV-249
TEL operation screen is displayed by
pressing and holding “ ” switch NAVI control unit (AV-257, "Exploded View")
of steering switch.
• TEL operation screen is not dis-
played by pressing and holding
The voice cannot be controlled. “ ” switch of steering switch. Steering switch (AV-262, "Exploded View")
(Voice control screen is not dis- • Other steering switches are nor-
played.) mal.
“BACK”, “VOL UP”, “VOL DOWN”
Steering switch signal B circuit (AV-126, "Diagnosis
and “ ” switches of steering Procedure")
switch are not operated.
All steering switches are not operat- Steering switch signal ground circuit (AV-128, "Diagno-
ed. sis Procedure")
RELATED TO HANDS FREE PHONE

• Check that the cellular phone is corresponding type (Bluetooth® enabled) when the hands free related mal-
function vehicle is in service before performing a diagnosis.
• There is a case that malfunction occurs due to the version change of the phone type, etc. even though it is a
corresponding type. Therefore, confirm it by changing the cellular phone to another corresponding type
phone, and check that it operates normally. It is necessary to distinguish whether the cause is the vehicle or
cellular phone. Check to ensure the customer's phone is supported by checking the phone compatibility for
the hands free system.
Trouble diagnosis chart by symptom

Does not recognize cellular
Repeat the registration of cellular phone. NAVI control unit (AV-257, "Exploded View")
phone connection.
• Hands free phone operation can be
made, but the communication cannot
be established.
Hands free phone cannot be
• Hands free phone operation can be NAVI control unit (AV-257, "Exploded View")
established.
performed, however, voice between
each other cannot be heard during the
conversation.
Check the “Voice Microphone Test”in
Confirmation/Adjustment Mode if sound NAVI control unit (AV-257, "Exploded View")
The other party's voice cannot is heard.
be heard by hands free phone. Check the “Voice Microphone Test”in
Confirmation/Adjustment Mode if sound TEL voice signal circuit
is not heard.
Originating sound is not heard Sound operation function is normal. NAVI control unit (AV-257, "Exploded View")
by the other party with hands Microphone signal circuit (AV-117, "Diagnosis Proce-
free phone communication. Sound operation function does not work.
dure")
RELATED TO STEERING WHEEL SWITCH
Symptoms Possible malfunction location/Action to take

All steering switches are not operated. Steering switch signal ground circuit (AV-128, "Diagnosis Procedure")
Only specified switch cannot be operated. Steering switch (AV-262, "Exploded View")
“ENTER”, “MENU UP”, “MENU DOWN” and “SOURCE”
Steering switch signal A circuit (AV-124, "Diagnosis Procedure")
switches are not operated.
“BACK”, “ ”, “VOL UP” and “VOL DOWN” switches are Steering switch signal B circuit (AV-126, "Diagnosis Procedure")
not operated.
AV-250
A
NOTE: B
For Navigation system operation information, refer to Navigation system Owner's Manual.
BASIC OPERATION
C
Symptoms Possible cause Possible solution
The brightness is at the lowest setting. Adjust the brightness of the display.
No image is displayed. D
The display is turned off. Push and hold to turn on the display.
The volume is not set correctly, or it is turned off. Adjust the volume of voice guidance.
No voice guidance is available.
The volume is too high or too low. Volume guidance is not provided for narrow streets E
This is not a malfunction.
(roads displayed in gray).
The map DVD-ROM is not inserted, or it is inserted
Insert the map DVD-ROM correctly.
No map is displayed on the screen. upside down.
F
A screen other than map screen is displayed. Push “MAP”.
The screen is too dim. Wait until the interior of the vehicle has
The temperature in the interior of the vehicle is low.
The movement is slow. warmed up.
G
Some pixels in the display are dark- This condition is an inherent characteristic of liquid
er or brighter than others. crystal displays.
Some menu items cannot be se- Some menu items become unavailable while the ve- Park the vehicle in a safe location, and H
lected. hicle is driven. then operate the navigation system.
NOTE:
Locations stored in the Address Book and other memory functions may be lost if the vehicle's battery is disconnected or becomes dis-
I
charged. Service the vehicle's battery as necessary and re-enter the information in the Address Book If this occurs.
VEHICLE ICON
J
This is because the quantity of the displayed informa-
tion is reduced so that the screen does not become K
Names of roads and locations differ too crowded. There is also a chance that names of
between Plan view and Birdview™. the roads or locations may be displayed multiple
times, and the names appearing on the screen may
be different because of a processing procedure. L
The vehicle was transported after the ignition switch
Drive the vehicle for a while on a road
was turned off, for example, by a ferry or car trans-
where GPS can be received.
porter. M
The vehicle icon is not displayed in
the correct position. The position and direction of the vehicle may be in-
This is not a malfunction. Drive the vehicle
correct depending on the driving environments and
for a while to automatically correct the po-
the levels of positioning accuracy of the navigation
system.
sition and direction of the vehicle icon. AV
When the vehicle is traveling on a Because the new road is not stored in the map data,
Updated road information will be included
new road, the vehicle icon is locat- the system automatically places the vehicle ion on
in the next version of the map DVD-ROM.
ed on another road nearby. the nearest road available. O
The screen does not switch to the
The daytime screen was set the last time the head- Set the screen to the night screen mode
night screen even after turning on
lights were turned on. using when turning on the headlights.
the headlights. P
The map does not scroll even when
The current location map screen is not displayed. Push “MAP”.
the vehicle is moving.
The vehicle icon is not displayed. The current location map screen is not displayed. Push “MAP”.
AV-251
GPS signals cannot be received depending on the
vehicle location, such as in a parking garage, on a Drive on an open, straight road for a while.
road that has numerous tall buildings, etc.
The GPS indicator on the screen
GPS signals cannot be received because objects are Remove the objects from top of the dis-
remains gray.
placed on top of the display. play.
A sufficient amount of GPS satellites are not avail- Wait for the satellites to move locations
able. available for navigation system.
Drive the vehicle for a while (at approxi-
mately 30 km/h (19 MPH) for about 30
Speed calculations based on the speed sensor may minutes) to automatically correct the vehi-
be incorrect when using tire chains or replacing the cle icon position.
The location of vehicle icon is mis- tires. Contact an NISSAN / INFINITI dealer if
aligned from the actual position. this does not correct the vehicle icon posi-
tion.
The map data has mistake or is incomplete (the vehi-
Updated road information will be included
cle icon position is always misaligned in the same ar-
in the next version of the map DVD-ROM.
ea).
MAP DVD-ROM
Symptom Possible cause Possible solution

Check the DVD-ROM and wipe it clean
with a soft cloth.
The message “Error” appears. Map DVD-ROM is dirty or partially damaged.
Replace the DVD-ROM if there is any
damage.
ROUTE CALCULATION AND VISUAL GUIDANCE

In the auto reroute calculation, way- Waypoints already passed are not included in the In case of going to that waypoints again,
points are not included. auto reroute calculation. edit the route.
Set the destination and perform route calcu-
Route calculation has not yet been performed.
lation.
The vehicle is not driven on the suggested route. Drive on the suggested route.
Route information is not displayed.
Route guidance is set to off. Turn on route guidance.
Route information is not provided for narrow streets
(roads displayed in gray).
The auto reroute calculation (or de-
tour calculation) suggests the same Route calculation took priority conditions into con-
route as the one previously sug- sideration, but the same route was calculated.
gested.
A maximum of 5 waypoints can be set on
Five waypoints are already set on the route, includ- the route. In case of going to 6 or more way-
A waypoint cannot be added.
ing ones that already passed. points, perform route calculations multiple
times as necessary.
Reset the destination to a main or ordinary
Roads near the destination cannot be calculated.
road, and recalculate the route.
The starting point and destination are too close. Set a more distant destination.
The suggested route is not dis- Divide the way by selecting one or two inter-
played. The starting point and destination are too far away. mediate destinations, and perform route
calculations multiple times.
There are time restricted roads (by day of week, by
time) near the current vehicle location or destina- Set Use Time Restricted Roads to off.
tion.
The suggested route includes narrow streets (roads
A part of the route is not displayed. This is not a malfunction.
displayed in gray).
AV-252
A
A route is managed by sections between waypoints.
The part of the route already The section between the starting point and the way-
passed is deleted. point is deleted if you passed the first waypoint. (It
may not be deleted depending on the area.) B
The system may suggest an indirect route if there
Adjust the location of the starting point or
are restrictions (such as one way streets) on roads
destination.
close to the starting point or destination.
An indirect route is suggested. C
The system may suggest an indirect route because
Reset the destination to a main or ordinary
route calculation does not take into consideration
road, and recalculate the route.
some areas such as narrow streets (gray roads).
D
The landmark information does not
This may be caused by insufficient or incorrect data
correspond to the actual informa- This is not a malfunction.
on the DVD-ROM.
tion.
The suggested route does not ex- Set the starting point, waypoints and desti- E
There is no data for route calculation closer to these
actly connect to the starting point, nation on main road, and perform route cal-
locations.
waypoints, or destination. culation.
VOICE GUIDANCE F

Voice guidance is only available at certain intersec-
G
tions. In some cases, voice guidance is not avail- This is not a malfunction.
able even when the vehicle should make a turn.
The voice guidance is not available. Go back to the suggested route or request H
The vehicle has deviated from the suggested route.
route calculation again.
Voice guidance is set to off. Turn on the voice guidance.
Route guidance is set to off. Turn on the voice guidance. I
The content of the voice guidance may vary, de-
The guidance content does not cor-
pending on the types of intersections at which turns Follow all traffic rules and regulations.
respond to the actual condition.
are made. J
VOICE RECOGNITION
K
Symptom Possible cause Possible solution
Close the windows or have other occupants
The interior of the vehicle is too noisy.
be quiet.
L
The volume of the voice is too low. Speak louder.
Pronunciation is unclear. Speak clearly.
The system does not recognize the Push the release “ ” on the steering M
command. Voice recognition mode is not yet ready to speak. switch, and speak a command after the
The system recognizes the com- tone sounds.
mand incorrectly.
Make sure to speak a command within 5 AV
5 seconds or more have passed after pushed and
seconds after push and release “ ” on
released “ ” on the steering switch.
the steering switch.
Only a limited range of voice commands is usable Use a correct voice command appropriate O
for each screen. for the current screen.
REAR VIEW MONITOR

P
Rear view monitor image is not dis- Shift lever (M/T models) or selector lever (CVT or A/ Shift lever (M/T models) or selector lever
played T models) is not in R position. (CVT or A/T models) is in R position.
AV-253
Dip a soft cloth into water and wipe the glass
Front glass of camera lens is dirty.
softly.
Rear view monitor image is not
There are raindrops, snow, etc. Wipe it with a soft cloth softly.
clear
The sunlight or the headlight of following vehicle is It returns to the original condition if the light
shining directly to the camera lens. applied to the lens disappears.
AV-254
PRECAUTIONS
< PRECAUTION > [AUDIO WITH NAVIGATION]
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
WARNING: D
an authorized NISSAN/INFINITI dealer. E
F
ness connectors.
G
Precaution for Trouble Diagnosis INFOID:0000000001093073
AV COMMUNICATION SYSTEM H
• Do not apply voltage of 7.0 V or higher to the measurement terminals.
• Use the tester with its open terminal voltage being 7.0 V or less.
• Be sure to turn ignition switch OFF and disconnect the battery cable from the negative terminal before
checking the circuit. I
Precaution for Harness Repair INFOID:0000000001093074
J
AV COMMUNICATION SYSTEM
• Solder the repaired parts, and wrap with tape. [Frays of twisted line
must be within 110 mm (4.33 in).]
K
PKIA0306E
AV
• Do not perform bypass wire connections for the repair parts. (The
spliced wire will become separated and the characteristics of
twisted line will be lost.)
O
PKIA0307E
AV-255
AUDIO UNIT
< ON-VEHICLE REPAIR > [AUDIO WITH NAVIGATION]
ON-VEHICLE REPAIR
AUDIO UNIT
REMOVAL
Refer to IP-11, "Exploded View".
DISASSEMBLY
JPNIA0328ZZ
1. Display unit 2. Bracket LH 3. Audio unit

4. Bracket RH
REMOVAL
2. Remove audio unit with a display unit as a single unit from body.
3. Remove bracket screws, and then remove audio unit.
INSTALLATION
AV-256
NAVI CONTROL UNIT
NAVI CONTROL UNIT
A
JPNIA0327ZZ
1. NAVI control unit G
H
REMOVAL
1. Remove grove box. Refer to IP-11, "Exploded View".
2. Remove bracket screws, and then remove NAVI control unit with bracket. I
3. Remove bracket screws, and then remove NAVI control unit.
INSTALLATION J
AV
AV-257
DISPLAY UNIT
DISPLAY UNIT
REMOVAL
Refer to IP-11, "Exploded View".
DISASSEMBLY
JPNIA0328ZZ
1. Display unit 2. Bracket LH 3. Audio unit

4. Bracket RH
REMOVAL
2. Remove display unit with an audio unit as a single unit from body.
3. Remove bracket screws, and then display unit.
INSTALLATION
AV-258
FRONT DOOR SPEAKER
FRONT DOOR SPEAKER
A
D
JPNIA0321ZZ
E
1. Front door speaker

F
REMOVAL
1. Remove front door finisher. Refer to INT-10, "FRONT DOOR FINISHER : Exploded View". G
2. Remove front door speaker.
INSTALLATION
AV
AV-259
REAR DOOR SPEAKER
REAR DOOR SPEAKER
JPNIA0322ZZ
1. Rear door speaker
REMOVAL
1. Remove rear door finisher. Refer to INT-13, "REAR DOOR FINISHER : Exploded View".
2. Remove rear door speaker.
INSTALLATION
AV-260
TWEETER
TWEETER
A
D
JPNIA0323ZZ
E
1. Tweeter

F
REMOVAL
1. Remove speaker grille. Refer to IP-11, "Exploded View". G
2. Remove tweeter.
INSTALLATION
AV
AV-261
STEERING SWITCH
STEERING SWITCH
Refer to SR-5, "Exploded View".

REMOVAL
Refer to SR-5, "Removal and Installation".
INSTALLATION
AV-262
MICROPHONE
MICROPHONE
A
REMOVAL B
Refer to INT-22, "NORMAL ROOF : Exploded View" (Normal roof), INT-25, "SUNROOF : Exploded View"
(Sunroof).
DISASSEMBLY C
JPNIA0324ZZ
F
1. Microphone
2. Microphone cover G
H
REMOVAL
"SUNROOF : Exploded View" (Sunroof). I
2. Remove microphone.
INSTALLATION
Install in the reverse order of removal. J
AV
AV-263
CAMERA CONTROL UNIT
CAMERA CONTROL UNIT
JPNIA0333ZZ
1. Camera control unit
REMOVAL
1. Remove luggage side upper finisher (RH). Refer to INT-28, "Exploded View".
2. Remove camera control unit.
INSTALLATION
Adjustment INFOID:0000000001117280
ADJUSTMENT
There may be a misalignment of possible route line center position of rear view monitor after removing camera
control unit. Therefore, correct neutral position with the following procedure.
1. Steer the steering wheel to the leftmost and rightmost ends.
2. Drive vehicle at 30 km/h (18.6 MPH) min. speed at least 100 m (328.1 ft).
AV-264
REAR VIEW CAMERA
REAR VIEW CAMERA
A
JPNIA0334ZZ
1. Rear view camera 2. Plate 3. Seal G

Removal and Installation INFOID:0000000001117276 H
REMOVAL
1. Remove back door finisher. Refer to EXT-34, "Exploded View". I
2. Remove back door trim finisher lower. Refer to INT-31, "Exploded View".
3. Remove nuts, and then remove rear view camera.
J
INSTALLATION
NOTE: K
Adjust the guide line position if the guide line position is shifted after installing the rear view camera.
Adjustment INFOID:0000000001117281
L
Adjust the guide line position if the guide line position is shifted after installing the rear view camera.
AV
AV-265
REAR VIEW CAMERA
1. Draw lines on rearward area of the vehicle passing through the
following points: 20 cm (7.87 in) from both sides of the vehicle,
and 0.5 m (1.64 ft), 1.0 m (3.28 ft) from the rear end of the
bumper.
2. Set into “Adjust offset of rear view camera” mode of Confirma-
tion / Adjustment mode.
SKIB3691E
3. Rotate the center dial, and then select the guiding line pattern so
that its angle is aligned with the correction line of the rear of the
vehicle.
Selected pattern :7
4. Make fine adjustment to the correction line of the rear of the
vehicle with up/down/left/right switches so that its position is
aligned with the guiding line. Press “ENTER”switch and record
the adjusted guiding line position to the camera control unit.
SKIB3689E
Up/Down adjustment range : −20 – 20
Left/Right adjustment range : −20 – 20
CAUTION:
Never operate other function such as pressing BACK while writing index data.
If Confirmation/Adjustment mode does not function in the above procedure, perform one of the
following service to adjust the index again.
• Remove battery for five min. Then reconnect battery.
• Remove camera control unit connector for five min. Then reconnect camera control unit connec-
tor.
AV-266
A
REMOVAL B
Refer to SR-7, "Exploded View".
DISASSEMBLY
C
JSNIA0135ZZ
F
1. Spiral cable
2. Steering angle sensor
G
REMOVAL H
1. Remove spiral cable. Refer to SR-7, "Exploded View".
2. Remove steering angle sensor from spiral cable.
I
INSTALLATION
J
AV
AV-267
RADIO ANTENNA
RADIO ANTENNA
JPNIA0325ZZ
1. Antenna rod 2. Antenna base 3. Nut

REMOVAL
2. Remove antenna base and antenna rod.
INSTALLATION
AV-268
GPS ANTENNA
GPS ANTENNA
A
JPNIA0331GB F
G
REMOVAL
1. Remove NAVI control unit. Refer to AV-257, "Exploded View".
H
2. Remove pocket assy. Refer to IP-11, "Exploded View".
3. Remove screw and clip. and then remove GPS antenna.
I
JPNIA0332ZZ
INSTALLATION L
AV
AV-269
ANTENNA FEEDER
ANTENNA FEEDER
NOTE:
RHD models GPS antenna is mirror image.
JPNIA0335GB
AV-270
ELECTRICAL & POWER CONTROL
SECTION
BODY CONTROL SYSTEM
BCS B
E
CONTENTS
BASIC INSPECTION .................................... 3 COMMON ITEM : CONSULT-III Function (BCM - F
COMMON ITEM) .....................................................19
INSPECTION AND ADJUSTMENT ..................... 3
DOOR LOCK ..............................................................19
ADDITIONAL SERVICE WHEN REPLACING G
DOOR LOCK : CONSULT-III Function (BCM -
CONTROL UNIT .......................................................... 3 DOOR LOCK) ..........................................................19
CONTROL UNIT : Description .................................. 3 REAR WINDOW DEFOGGER ...................................21 H
ADDITIONAL SERVICE WHEN REPLACING REAR WINDOW DEFOGGER : CONSULT-III
CONTROL UNIT : Special Repair Requirement ...... 3 Function (BCM - REAR DEFOGGER) .....................21
CONFIGURATION (BCM) ........................................... 3 BUZZER .....................................................................21 I

CONFIGURATION (BCM) : Description .................... 3 BUZZER : CONSULT-III Function (BCM - BUZZ-
CONFIGURATION (BCM) : Special Repair Re- ER) ..........................................................................21
quirement .................................................................. 4 J
INT LAMP ...................................................................21
CONFIGURATION (BCM) : Configuration list ........... 4
INT LAMP : CONSULT-III Function (BCM - INT
FUNCTION DIAGNOSIS ............................... 9 LAMP) ......................................................................22
K
MULTIREMOTE ENT .................................................23
BODY CONTROL SYSTEM ................................ 9
MULTIREMOTE ENT : CONSULT-III Function
System Description ................................................... 9
(BCM - MULTIREMOTE ENT) .................................23 L
Component Parts Location ...................................... 10
HEADLAMP ...............................................................24
COMBINATION SWITCH READING SYSTEM HEADLAMP : CONSULT-III Function (BCM -
....11 HEAD LAMP) ...........................................................24 BCS
System Diagram ...................................................... 11
System Description ................................................. 11 WIPER ........................................................................26
Component Parts Location ...................................... 14 WIPER : CONSULT-III Function (BCM - WIPER)....26
N
SIGNAL BUFFER SYSTEM ...............................15 FLASHER ...................................................................27
System Diagram ...................................................... 15 FLASHER : CONSULT-III Function (BCM -
System Description ................................................. 15 FLASHER) ...............................................................27 O
POWER CONSUMPTION CONTROL SYS- AIR CONDITIONER ...................................................28
TEM ....................................................................16 AIR CONDITIONER : CONSULT-III Function
System Diagram ...................................................... 16 (BCM - AUTO AIR CONDITIONER) ........................28 P
INTELLIGENT KEY ....................................................28
INTELLIGENT KEY : CONSULT-III Function
DIAGNOSIS SYSTEM (BCM) ............................19 (BCM - INTELLIGENT KEY) ....................................28
COMMON ITEM ......................................................... 19 COMB SW ..................................................................28
BCS-1
COMB SW : CONSULT-III Function (BCM - COMBINATION SWITCH OUTPUT CIRCUIT ... 38
COMB SW) ............................................................. 28 Diagnosis Procedure ............................................... 38
BCM ........................................................................... 29 COMBINATION SWITCH .................................. 39
BCM : CONSULT-III Function (BCM - BCM) .......... 29 Description .............................................................. 39
IMMU ......................................................................... 29
IMMU : CONSULT-III Function (BCM - IMMU) ....... 29 ECU DIAGNOSIS ....................................... 40
BATTERY SAVER .................................................... 30 BCM (BODY CONTROL MODULE) .................. 40
BATTERY SAVER : CONSULT-III Function (BCM
Reference Value ..................................................... 40
- BATTERY SAVER) .............................................. 30
Wiring Diagram - BCM - .......................................... 57
TRUNK ...................................................................... 31 Fail Safe ................................................................. 63
TRUNK : CONSULT-III Function (BCM - TRUNK)... 31 DTC Inspection Priority Chart ............................... 64
DTC Index .............................................................. 65
THEFT ALM .............................................................. 31
THEFT ALM : CONSULT-III Function (BCM - PRECAUTION ............................................ 66
THEFT ALM) .......................................................... 31
PRECAUTIONS ................................................. 66
SIGNAL BUFFER ...................................................... 32 Precaution for Supplemental Restraint System
SIGNAL BUFFER : CONSULT-III Function (BCM (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
- SIGNAL BUFFER) ................................................ 32 SIONER" ................................................................. 66
COMPONENT DIAGNOSIS ........................ 33 SYMPTOM DIAGNOSIS ............................ 67

U1000 CAN COMM CIRCUIT ............................ 33 COMBINATION SWITCH SYSTEM SYMP-
Description .............................................................. 33 TOMS ................................................................. 67
DTC Logic ............................................................... 33 Symptom Table ....................................................... 67
Diagnosis Procedure .............................................. 33
ON-VEHICLE REPAIR ............................... 68
U1010 CONTROL UNIT (CAN) ......................... 34
DTC Logic ............................................................... 34 BCM (BODY CONTROL MODULE) .................. 68
Diagnosis Procedure .............................................. 34 Exploded View ........................................................ 68
POWER SUPPLY AND GROUND CIRCUIT ..... 35
Diagnosis Procedure .............................................. 35 COMBINATION SWITCH .................................. 69
Exploded View ........................................................ 69
COMBINATION SWITCH INPUT CIRCUIT ....... 36 Removal and Installation ......................................... 69
BCS-2
BASIC INSPECTION A
B
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Description
INFOID:0000000001451318
C
BEFORE REPLACEMENT
When replacing BCM, save or print current vehicle specification with CONSULT-III configuration before
replacement. D
NOTE:
If “READ CONFIGURATION” can not be used, use the “WRITE CONFIGURATION - Manual selection” after
replacing BCM.
E
AFTER REPLACEMENT
CAUTION:
• When replacing BCM, you must perform “WRITE CONFIGURATION” with CONSULT-III.
- Complete the procedure of “WRITE CONFIGURATION” in order. F
- If you set incorrect “WRITE CONFIGURATION”, incidents might occur.
- Configuration is different for each vehicle model. Confirm configuration of each vehicle model.
• When replacing BCM, perform the system initialization (NATS). G
H
1.SAVING VEHICLE SPECIFICATION

CONSULT-III Configuration I
Perform “READ CONFIGURATION” to save or print current vehicle specification. Refer to BCS-3, "CONFIGU-
RATION (BCM) : Description".
NOTE:
J
If “READ CONFIGURATION” can not be used, use the “WRITE CONFIGURATION - Manual selection” after
replacing BCM.
K
>> GO TO 2.
2.REPLACE BCM
Replace BCM. refer to BCS-68, "Exploded View". L
>> GO TO 3.
BCS
3.WRITING VEHICLE SPECIFICATION
CONSULT-III Configuration
Perform “WRITE CONFIGURATION - Config file” or “WRITE CONFIGURATION - Manual selection” to write N
vehicle specification. Refer to BCS-4, "CONFIGURATION (BCM) : Special Repair Requirement".
>> GO TO 4. O
4.INITIALIZE BCM (NATS)
Perform BCM initialization. (NATS)
P
>> WORK END

CONFIGURATION (BCM)
CONFIGURATION (BCM) : Description INFOID:0000000001451320
Vehicle specification needs to be written with CONSULT-III because it is not written after replacing BCM.
BCS-3
Configuration has three functions as follows
Function Description
• Reads the vehicle configuration of current BCM.
READ CONFIGURATION
• Saves the read vehicle configuration.
WRITE CONFIGURATION - Manual selection Writes the vehicle configuration with manual selection.
WRITE CONFIGURATION - Config file Writes the vehicle configuration with saved data.
NOTE:
Manual setting item: Items which need selection by vehicle specifications
Automatic setting item: Items which are written in automatically (Setting can not be changed)
CAUTION:
• When replacing BCM, you must perform “WRITE CONFIGURATION” with CONSULT-III.
• Complete the procedure of “WRITE CONFIGURATION” in order.
• If you set incorrect “WRITE CONFIGURATION”, incidents might occur.
• Configuration is different for each vehicle model. Confirm configuration of each vehicle model.
• Never perform “WRITE CONFIGURATION” except for new BCM.
CONFIGURATION (BCM) : Special Repair Requirement INFOID:0000000001451321
1.WRITING MODE SELECTION

Select “CONFIGURATION” of BCM.
When writing saved data>>GO TO 2.

When writing manually>>GO TO 3.
2.PERFORM “WRITE CONFIGURATION - CONFIG FILE”
Perform “WRITE CONFIGURATION - Config file”.
>> WORK END

3.PERFORM “WRITE CONFIGURATION - MANUAL SELECTION”
1. Select "WRITE CONFIGURATION - Manual selection".
2. Identify the correct model and configuration list. Refer to BCS-4, "CONFIGURATION (BCM) : Configura-
tion list".
3. Confirm and/or change setting value for each item.
4. Select "Setting change".
CAUTION:
Make sure to select “Setting change” even if the indicated configuration of brand new BCM is
same as the desirable configuration. If not, configuration which is set automatically by selecting
vehicle model can not be memorized.
5. When "COMMAND FINISHED", select "END".
>> WORK END

CONFIGURATION (BCM) : Configuration list INFOID:0000000001403874
RHD MODELS WITHOUT I-KEY
MANUAL SETTING ITEM

NOTE
Items Setting value
RAIN SENSOR WITH ⇔ WITHOUT —
H/L BULB H4 HALOGEN H4 HALOGEN: Halogen headlamp
BCS-4
MANUAL SETTING ITEM
NOTE A
Items Setting value
AUTO LIGHT WITH ⇔ WITHOUT —
HANDLE RHD — B
KEYLESS ENTRY WITH —
I-KEY WITHOUT —
DTRL WITHOUT — C
THEFT ALARM WITH —
H/L WASHER WITHOUT —
D
⇔: Items which confirm vehicle specifications
AUTO SETTING ITEM E

NOTE
Items Setting value
H/L WSR SWTRG FR WSR SW —
FR FOG LAMP WITH Even on a vehicle without front fog lamp. it displays “WITH”. F
DONGLE WITH —
SUPER LOCK WITH —
G
DOOR/L SPEED WITH —
KEY WARNING MODE1 —
R LAMP LOGIC MODE2 — H
RR SPEED WIPER MODE1 —
ROOM LAMP TIMER MODE3 —
I
R/L ON TIME MODE2 —
R/L OFF TIME MODE2 —
HLW TIME 1 MODE1 — J
HLW TIME 2 MODE1 —
RAIN SEN TYPE MODE1 —
K
REVERSE LINK WITHOUT —
TRUNK ACT OUTPUT MODE1 —
RR WIPER GND MODE1 — L
HLW ACT STEP MODE1 —
RHD MODELS WITH I-KEY

BCS
MANUAL SETTING ITEM
NOTE
Items Setting value
N
RAIN SENSOR WITH —
• H4 HALOGEN: Halogen headlamp
H/L BULB H4 HALOGEN ⇔ DEFAULT
• DEFAULT: Xenon headlamp O
AUTO LIGHT WITH —
HANDLE RHD —
KEYLESS ENTRY WITHOUT — P
I-KEY WITH —
DTRL WITHOUT —
THEFT ALARM WITH —
H/L WASHER WITH ⇔ WITHOUT H/L WASHER: Headlamp washer system
BCS-5
AUTO SETTING ITEM

NOTE
Items Setting value
FR FOG LAMP WITH Even on a vehicle without front fog lamp. it displays “WITH”.
DONGLE WITH —
SUPER LOCK WITH —
R LAMP LOGIC MODE2 —
RR WIPER GND MODE1 —
LHD MODELS WITHOUT I-KEY
MANUAL SETTING ITEM

NOTE
Items Setting value
RAIN SENSOR WITH ⇔ WITHOUT —
H/L BULB H4 HALOGEN H4 HALOGEN: Halogen headlamp
AUTO LIGHT WITH ⇔ WITHOUT —
HANDLE LHD —
KEYLESS ENTRY WITH —
I-KEY WITHOUT —
DTRL WITH ⇔ WITHOUT DTRL: Daytime running light system
THEFT ALARM WITHOUT —
AUTO SETTING ITEM

NOTE
Items Setting value
DONGLE WITHOUT —
SUPER LOCK WITHOUT —
BCS-6
AUTO SETTING ITEM
NOTE A
Items Setting value
R/L ON TIME MODE2 — B
HLW TIME 2 MODE1 — C
D
HLW ACT STEP MODE1 — E
LHD MODELS WITH I-KEY

F
MANUAL SETTING ITEM
NOTE
Items Setting value
RAIN SENSOR WITH — G
• H4 HALOGEN: Halogen headlamp
H/L BULB H4 HALOGEN ⇔ DEFAULT
• DEFAULT: Xenon headlamp
AUTO LIGHT WITH — H
HANDLE LHD —
KEYLESS ENTRY WITHOUT —
I
I-KEY WITH —
DTRL WITH ⇔ WITHOUT DTRL: Daytime running light system
THEFT ALARM WITHOUT — J
K
AUTO SETTING ITEM
NOTE
Items Setting value
L
DONGLE WITHOUT — BCS
SUPER LOCK WITHOUT —
N
RR SPEED WIPER MODE1 — O
R/L OFF TIME MODE2 — P
BCS-7
AUTO SETTING ITEM
NOTE
Items Setting value
BCS-8
BODY CONTROL SYSTEM
< FUNCTION DIAGNOSIS >
BODY CONTROL SYSTEM
B
OUTLINE
• BCM (Body Control Module) controls various electrical components.It receives the information required from C
CAN communication and the signals received from each switch and sensor.
• BCM has a combination switch reading function for reading the status of combination switches (light, turn
signal, wiper and washer) in addition to functions for controlling the operation of various electrical compo-
nents. It also has a signal transmission function, for other systems, and a power consumption control func- D
tion that reduces the power consumption with the ignition switch OFF.
• BCM is equipped with a diagnosis function that operates with CONSULT-III and allows for various settings to
be changed. E
BCM FUNCTION LIST
System Reference page F

Combination switch reading system BCS-11, "System Diagram"
Signal buffer system BCS-15, "System Diagram"
G
Power consumption control system BCS-16, "System Diagram"
Auto light system EXL-19, "System Diagram"
Turn signal and hazard warning lamp system EXL-26, "System Diagram" H
• XENON TYPE: EXL-13, "System Diagram"
Headlamp system
• HALOGEN TYPE: EXL-237, "System Diagram"
Front fog lamp system EXL-24, "System Diagram" I
Rear fog lamp system EXL-32, "System Diagram"
Daytime running light system EXL-16, "System Diagram"
J
Interior room lamp control system INL-5, "System Diagram"
Interior room lamp battery saver system INL-8, "System Diagram"
Front wiper and washer system WW-6, "System Diagram" K
Rear wiper and washer system WW-11, "System Diagram"
Headlamp washer system WW-14, "System Diagram"
L
Warning chime system WCS-4, "WARNING CHIME SYSTEM : System Diagram"
• WITH I-KEY, WITHOUT SUPER LOCK: DLK-26, "DOOR LOCK AND UN-
LOCK SWITCH : System Diagram"
• WITH I-KEY & SUPER LOCK: DLK-307, "DOOR LOCK AND UNLOCK BCS
SWITCH : System Diagram"
Door lock system
• WITHOUT I-KEY & SUPER LOCK: DLK-601, "DOOR LOCK AND UN-
• WITHOUT I-KEY, WITH SUPER LOCK: DLK-760, "DOOR LOCK AND UN-
N
• WITH INTELLIGENT KEY SYSTEM: SEC-16, "System Diagram"
Nissan anti-theft system O
• WITHOUT INTELLIGENT KEY SYSTEM: SEC-235, "System Diagram"
• WITH INTELLIGENT KEY SYSTEM: SEC-21, "System Diagram"
Vehicle security system
• WITHOUT INTELLIGENT KEY SYSTEM: SEC-239, "System Diagram"
Rear window defogger system DEF-4, "System Diagram" P
• WITHOUT I-KEY & SUPER LOCK: DLK-604, "KEYFOB : System Dia-
gram"
Multi-remote control system
• WITHOUT I-KEY, WITHOUT SUPER LOCK: DLK-763, "KEYFOB : System
Diagram"
BCS-9
BODY CONTROL SYSTEM
System Reference page
• WITH I-KEY, WITHOUT SUPER LOCK: DLK-30, "INTELLIGENT KEY :
System Diagram"
Intelligent Key system
• WITH I-KEY & SUPER LOCK: DLK-311, "INTELLIGENT KEY : System Di-
agram"
Power window system PWC-6, "System Diagram"
JSMIA0033ZZ
1. BCM
A. Over the glove box
BCS-10
COMBINATION SWITCH READING SYSTEM
A
JPMIA0120GB
G
OUTLINE H
• BCM reads the status of the combination switch (light, turn signal, wiper and washer) and recognizes the
status of each switch.
• BCM has a combination of 5 output terminals (OUTPUT 1 - 5) and 5 input terminals (INPUT 1 - 5). It reads a I
maximum of 20 switch status.
COMBINATION SWITCH MATRIX
J
Combination switch circuit
BCS
O
JPMIA0121GB
Combination switch INPUT-OUTPUT system list P

System OUTPUT 1 OUTPUT 2 OUTPUT 3 OUTPUT 4 OUTPUT 5
INPUT 1 — FR WASHER FR WIPER LOW TURN LH TURN RH
INPUT 2 FR WIPER HI — FR WIPER INT PASSING HEADLAMP 1
INPUT 3 INT VOLUME 1 RR WASHER — HEADLAMP 2 HI BEAM
BCS-11
System OUTPUT 1 OUTPUT 2 OUTPUT 3 OUTPUT 4 OUTPUT 5
INPUT 4 RR WIPER INT INT VOLUME 3 AUTO LIGHT — TAIL LAMP
INPUT 5 INT VOLUME 2 RR WIPER RR FOG FR FOG —
NOTE:
Headlamp has a dual system switch.
COMBINATION SWITCH READING FUNCTION

Description
• BCM reads the status of the combination switch at 10 ms interval normally.
JPMIA0067GB
NOTE:
BCM reads the status of the combination switch at 20 ms interval when BCM is controlled at low power con-
sumption control mode.
• BCM operates as follows and judges the status of the combination switch.
- INPUT 1 - 5 outputs the voltage waveforms of 5 systems simultaneously.
- It operates the transistor on OUTPUT side in the following order: OUTPUT 5 → 4 → 3 → 2 → 1.
- The voltage waveform of INPUT corresponding to the formed circuit changes according to the operation of
the transistor on OUTPUT side if any (1 or more) switches are ON.
- It reads this change of the voltage as the status signal of the combination switch.
JPMIA0068GB
Operation Example
In the following operation example, the combination of the status signals of the combination switch is replaced
as follows: INPUT 1 - 5 to “1 - 5” and OUTPUT 1 - 5 to “A - E”.
Example 1: When a switch (TURN RH switch) is turned ON
BCS-12
• The circuit between INPUT 1 and OUTPUT 5 is formed when the TURN RH switch is turned ON.
A
JPMIA0122GB F
• BCM detects the combination switch status signal “1E” when the signal of OUTPUT 5 is input to INPUT 1.
• BCM judges that the TURN RH switch is ON when the signal “1E” is detected.
Example 2: When some switches (turn RH switch, front wiper LO switch) are turned ON G
• The circuits between INPUT 1 and OUTPUT 5 and between INPUT 1 and OUTPUT 3 are formed when the
TURN RH switch and FR WIPER LOW switch are turned ON.
H
JPMIA0123GB
BCS
• BCM detects the combination switch status signal “1CE” when the signals of OUTPUT 3 and OUTPUT 5 are
input to INPUT 1.
• BCM judges that the TURN RH switch and FR WIPER LOW switch are ON when the signal “1CE” is
detected. N
WIPER INTERMITTENT DIAL POSITION SETTING (FRONT WIPER INTERMITTENT OPERATION)
BCM judges the wiper intermittent dial 1 - 7 by the status of INT VOLUME 1, 2 and 3 switches.
O
BCS-13
Intermittent INT VOLUME switch ON/OFF status

Wiper intermittent
operation delay
dial position INT VOLUME 1 switch INT VOLUME 2 switch INT VOLUME 3 switch
interval
1 ON ON ON
Short
2 ON ON OFF
3 ON OFF OFF
↑
4 OFF OFF OFF
↓
5 OFF OFF ON
6 OFF ON ON
Long
7 OFF ON OFF
JSMIA0034ZZ
1. Combination switch 2. BCM

A. Over the glove box
BCS-14
SIGNAL BUFFER SYSTEM
SIGNAL BUFFER SYSTEM
A
JSMIA0032GB F
G
OUTLINE
BCM has the signal transmission function that outputs/transmits each input/received signal to each unit.
H
SIGNAL TRANSMISSION FUNCTION LIST
Signal name Input Output Description

I
• Combination meter (CAN)
Inputs the door switch signal
• IPDM E/R (CAN)
Door switch signal Any door switch and transmits it with CAN com-
• Intelligent Key unit (CAN)
munication.
• NAVI control unit (CAN) J
Inputs the stop lamp switch sig-
Stop lamp switch signal Stop lamp switch TCM (CAN) nal and transmits it with CAN
communication. K
Transmits the received oil pres-
Oil pressure switch signal IPDM E/R (CAN) Combination meter (CAN) sure switch signal with CAN
communication.
L
Inputs the A/C switch signal and
A/C switch signal transmits it with CAN communi-
cation.
Auto amp. ECM (CAN) BCS
Inputs the Blower fan motor
Blower fan motor switch signal switch signal and transmits it
with CAN communication.
N
BCS-15
POWER CONSUMPTION CONTROL SYSTEM
JPMIA0125GB
OUTLINE
• BCM incorporates a power consumption control function that reduces the power consumption according to
the vehicle status.
• BCM switches the status (control mode) by itself with the power saving control function. It performs the sleep
request to each unit (IPDM E/R, combination meter and Intelligent Key unit) that operates with the ignition
switch OFF.
Normal mode (wake-up)
- CAN communication is normally performed with other units
- Each control with BCM is operating properly
CAN communication sleep mode (CAN sleep)
- CAN transmission is stopped
- Control with BCM only is operating
Low power consumption mode (BCM sleep)
- Low power consumption control is active
- CAN transmission is stopped
LOW POWER CONSUMPTION CONTROL WITH BCM
BCM reduces the power consumption with the following operation in the low power consumption mode.
• The reading interval of the each switches changes from 10 ms interval to 20 ms interval.
SLEEP OPERATION
• BCM receives the sleep-ready signal (ready) from IPDM E/R, combination meter and Intelligent Key unit with
CAN communication.
• BCM transmits the sleep wake up signal (sleep) to each unit when all of the CAN sleep conditions are ful-
filled.
• Each unit stops the transmission of CAN communication with the sleep wake up signal. BCM is in CAN com-
munication sleep mode.
• BCM is in the low power consumption mode and perform the low power consumption control when all of the
BCM sleep conditions are fulfilled with CAN sleep condition.
BCS-16
Sleep condition
CAN sleep condition BCM sleep condition A
• Receiving the sleep-ready signal (ready) from all units
• Ignition switch: OFF
• Vehicle security system alarm: Not operation
B
• Warning lamp: Not operation
• Warning chime: Not operation
• Stop lamp switch: OFF The controls only BCM are completed.
• Key switch status: No change for 2 seconds (Interior room lamp battery saver: Time out etc.) C
• Hazard warning lamp: Not operation
• Exterior lamp: OFF
• Door lock status: No change for 2 seconds
• CONSULT-III communication status: Not communication D
• Door switch status: No change for 2 seconds
WAKE-UP OPERATION
• BCM transmits sleep wake up signal (wake up) to each unit when any condition listed below is established, E
and then goes into normal mode from low power consumption mode.
• Each unit starts transmissions with CAN communication by receiving sleep wake up signals. Each unit trans-
mits wake up signals to BCM with CAN communication to convey the start of CAN communication. F
Wake-up condition
BCM wake-up condition
• Ignition switch: OFF → ACC or ON G
• Stop lamp switch: ON (Depress brake pedal)
• Any door switch: OFF → ON
• Lighting switch: OFF → 1ST or PASS
• Hazard switch: OFF → ON H
• Back door opener switch OFF → ON
• Remote keyless entry receiver: Receiving
I
BCS
JSMIA0035ZZ
BCS-17
1. Combination meter 2. BCM 3. IPDM E/R

4. Intelligent Key unit
A. Over the glove box B. Engine room (left side) C. Over the instrument lower panel
(driver side)
BCS-18
DIAGNOSIS SYSTEM (BCM)
A
COMMON ITEM
COMMON ITEM : CONSULT-III Function (BCM - COMMON ITEM) INFOID:0000000001158227
B
APPLICATION ITEM
CONSULT-III can display each diagnostic item using the diagnostic test modes shown following.
C
Diagnosis mode Function description
ECU Identification BCM part number is displayed.
D
Self-Diagnostic Results Displays the diagnosis results judged by BCM. Refer to BCS-65, "DTC Index".
Data Monitor BCM input/output signals are displayed.
Active Test The signals used to activate each device are forcibly supplied from BCM. E
Work Support Changes the setting for each system function.
• Read and save the vehicle specification.
Configuration
• Write the vehicle specification when replacing BCM. F
CAN Diag Support Monitor Monitors the reception status of CAN communication viewed from BCM.
SYSTEM APPLICATION G
BCM can perform the following functions for each system.
NOTE:
It can perform the diagnosis modes except the following for all sub system selection items.
×: Applicable item
H
CONSULT-III Diagnosis mode

System
sub system selection item WORK SUPPORT DATA MONITOR ACTIVE TEST
I
— BCM ×
Door lock DOOR LOCK × × ×
Rear window defogger REAR DEFOGGER × × × J
Warning chime BUZZER × ×
Interior room lamp control INT LAMP × × ×
K
Remote keyless entry system MULTI REMOTE ENT × × ×
Exterior lamp HEAD LAMP × × ×
Wiper and washer WIPER × × × L
Turn signal and hazard warning lamps FLASHER × ×
Air conditioner AIR CONDITONER ×
BCS
Intelligent Key system INTELLIGENT KEY ×
Combination switch COMB SW ×
Immobilizer IMMU × × N
Interior room lamp battery saver BATTERY SAVER × × ×
Back door open TRUNK × ×
O
Vehicle security system THEFT ALM × × ×
Signal buffer system SIGNAL BUFFER × ×
— PTC HEATER* P
*: This item is displayed, but is not function.
DOOR LOCK
DOOR LOCK : CONSULT-III Function (BCM - DOOR LOCK) INFOID:0000000001509115
BCM CONSULT-III FUNCTION

CONSULT-III performs the following functions via CAN communication with BCM.
BCS-19
Diagnosis mode Function Description

WORK SUPPORT Changes the setting for each system function.
DATA MONITOR The BCM input/output signals are displayed.
ACTIVE TEST The signals used to activate each device are forcibly supplied from BCM.
DATA MONITOR
Monitor Item Condition

IGN ON SW Indicates [ON/OFF] condition of ignition switch in ON position.
ACC ON SW Indicates [ON/OFF] condition of ignition switch in ACC position.
PUSH SW*1 Indicates [ON/OFF] condition of ignition knob switch.

KEY ON SW Indicates [ON/OFF] condition of key switch.
CDL LOCK SW Indicates [ON/OFF] condition of door lock and unlock switch.
CDL UNLOCK SW Indicates [ON/OFF] condition of door lock and unlock switch.
DOOR SW-DR Indicates [ON/OFF] condition of front door switch (driver side).
DOOR SW-AS Indicates [ON/OFF] condition of front door switch (passenger side).
DOOR SW-RR Indicates [ON/OFF] condition of rear door switch RH.
DOOR SW-RL Indicates [ON/OFF] condition of rear door switch LH.
BACK DOOR SW Indicates [ON/OFF] condition of back door switch.
KEYLESS LOCK*2 Indicates [ON/OFF] condition of lock signal from key fob.
KEYLESS UNLOCK*2 Indicates [ON/OFF] condition of unlock signal from key fob.
I-KEY LOCK*1 Indicates [ON/OFF] condition of lock signal from Intelligent Key.
I-KEY UNLOCK*1 Indicates [ON/OFF] condition of unlock signal from Intelligent Key.
UNLOCK WITH DR This item is indicated, but not monitored.
Indicates [ON/OFF] condition of signal from air bag diagnosis unit.
UNLOCK SHOCK • ON: During the unlock operation interlock with air bag.
• OFF: Other than above.
Indicates [NOMAL/ON/OFF] condition of circuit between BCM and air bag diagnosis sen-
sor unit.
• NORMAL: Ignition switch ON. (BCM is receiving normal condition signal from air bag di-
SHOCK SENSOR agnosis sensor unit.)
• ON: During the receiving of air bag deployment signal from air bag diagnosis sensor
unit.
• OFF: After the receiving of air bag deployment signal from air bag diagnosis sensor unit.
Displays the vehicle speed signal received from combination meter by numerical value
VEHICLE SPEED
[km/h].
*1
: For the Intelligent key equipped vehicle.
*2: For the multi remote control system equipped vehicle.
ACTIVE TEST
Test item Description
SUPER LOCK*1 This test is able to check super lock operation [LOCK (SET)/UNLOCK (RELEASE)].
This test is able to check door lock indicator (built in door lock and unlock switch on center
DOOR LOCK IND
console) operation [ON/OFF].
This test is able to check door lock operation [ALL LOCK/ALL UNLOCK/DR UNLOCK/
DOOR LOCK
OTHER UNLOCK].
:*1 For the super lock equipped vehicle.
WORK SUPPORT
BCS-20
Test item Description A

Anti hijack function mode can be changed in this mode.
SECURITY DOOR LOCK SET • ON: Anti hijack mode is active.
• OFF: Anti hijack mode is inactive.
B
REAR WINDOW DEFOGGER
REAR WINDOW DEFOGGER : CONSULT-III Function (BCM - REAR DEFOGGER) C
INFOID:0000000001510606
Data monitor
D
Monitor Item Description
REAR DEF SW Displays “Press (ON)/other (OFF)” status determined with the rear window defogger switch.
E
F
ACTIVE TEST
Test Item Description

G
REAR DEFOGGER Give a drive signal to the rear window defogger relay to activate it.
BUZZER
H
BUZZER : CONSULT-III Function (BCM - BUZZER) INFOID:0000000001510620
CONSULT-III FUNCTION (BCM – BUZZER) I
Test item Diagnosis mode Description

Data Monitor Displays BCM input data in real time. J
Buzzer
Active Test Operation of electrical loads can be checked by sending driving signal to them.
DATA MONITOR K
Display item
Description
[Unit]
L
IGN ON SW
Ignition switch (ON) status judged by ignition power supply input.
[On/Off]
KEY ON SW
Key switch status. BCS
[On/Off]
DOOR SW -DR
Front door switch (driver side) status judged by BCM.
[On/Off]
N
TAIL LAMP SW Lighting switch status judged by the lighting switch signal read with combination switch reading func-
[On/Off] tion.
ACTIVE TEST O
Display item Description

LIGHT WARN ALM The light reminder warning operation can be checked by operating the relevant function (On/Off). P
ANTI KEY LOCK IN The anti key lock in warning operation can be checked by operating the relevant function (On/Off).
KEY REMINDER WARN The key reminder warning operation can be checked by operating the relevant function (On/Off).
INT LAMP
BCS-21
INT LAMP : CONSULT-III Function (BCM - INT LAMP) INFOID:0000000001510593
WORK SUPPORT
JPLIA0093GB
Service item Setting item Setting

MODE 2 7.5 sec.
ROOM LAMP TIMER SET MODE 3* 15 sec. Sets the interior room lamp ON time. (Timer operating time)
MODE 4 30 sec.
On* With the interior room lamp timer function
SET I/L D-UNLCK INTCON
Off Without the interior room lamp timer function
MODE 1 0.5 sec.
MODE 2* 1 sec.
MODE 3 2 sec.
MODE 4 3 sec.
ROOM LAMP ON TIME SET MODE 5 4 sec. Sets the interior room lamp gradual brightening time.
MODE 6 5 sec.
MODE 7 0 sec.
1 sec.
MODE 8
linear
MODE 1 0.5 sec.
MODE 2* 1 sec.
MODE 3 2 sec.
MODE 4 3 sec.
ROOM LAMP OFF TIME SET MODE 5 4 sec. Sets the interior room lamp gradual dimming time.
MODE 6 5 sec.
MODE 7 0 sec.
1 sec.
MODE 8
linear
MODE 1* Interior room lamp timer activates with synchronizing all doors.
R LAMP TIMER LOGIC SET Interior room lamp timer activates with synchronizing the driver door
MODE 2
only.
*: Initial setting
DATA MONITOR
BCS-22
Monitor item A
Description
[Unit]
IGN ON SW
Ignition switch (ON) status judges from IGN signal (ignition power supply)
[On/Off]
B
ACC SW
Ignition switch (ACC) status judges from ACC signal (ACC power supply)
[On/Off]
KEY ON SW C
The switch status input from key switch
[On/Off]
PUSH SW
Push switch status received from Intelligent Key unit by CAN communication
[On/Off]
D
DOOR SW-DR
The switch status input from front door switch (driver side)
[On/Off]
DOOR SW-AS
The switch status input from front door switch (passenger side) E
[On/Off]
DOOR SW-RR
The switch status input from rear door switch RH
[On/Off]
F
DOOR SW- RL
The switch status input from rear door switch LH
[On/Off]
BACK DOOR SW
The switch status input from back door switch G
[On/Off]
CDL LOCK SW
Lock switch status input from door lock and unlock switch
[On/Off]
H
CDL UNLOCK SW
Unlock switch status input from door lock and unlock switch
[On/Off]
I-KEY LOCK
Lock signal status received from Intelligent Key unit by CAN communication I
[On/Off]
I-KEY UNLOCK
Unlock signal status received from Intelligent Key unit by CAN communication
[On/Off]
KEYLESS LOCK Lock signal status received from remote keyless entry receiver (integrated in the
J
[On/Off] BCM)
KEYLESS UNLOCK Unlock signal status received from remote keyless entry receiver (integrated in the
[On/Off] BCM) K
ACTIVE TEST
L
Test item Operation Description
Outputs the interior room lamp control signal to turn the interior room lamps ON.
On [Map lamp, personal lamp, room lamp, luggage room lamp (when applicable lamps
INT LAMP BCS
switch is in DOOR position.)]
Off Stops the interior room lamp control signal to turn the interior room lamps.
MULTIREMOTE ENT N
MULTIREMOTE ENT : CONSULT-III Function (BCM - MULTIREMOTE ENT)

INFOID:0000000001509193
O
P
DATA MONITOR
BCS-23

KEYKESS LOCK Indicates [ON/OFF] condition of lock signal from key fob.
KEYLESS UNLOCK Indicates [ON/OFF] condition of unlock signal from key fob.
RKE LOCK AND UNLOCK This item is indicated, but not monitored.
MEMORY 1 Indicates [ON/OFF] condition of remote controller ID code registration.
ACTIVE TEST

This test is able to check warning chime in combination meter operation. [ALL LOCK/ALL UN-
DOOR LOCK
LOCK/DR UNLOCK/OTHER UNLOCK]
INT LAMP This test is able to check interior lamp operation [ON/OFF].
FLASHER This test is able to check flasher operation [LH/RH/OFF].
WORK SUPPORT

Answer back function (hazard) mode can be changed in this mode.
HAZARD LAMP SET
For the detail of the setting, refer to DLK-620, "System Description".
Auto door lock time can be changed in this mode.
• MODE 1: 1 minute
• MODE 2: 2 minutes
AUTO LOCK SET
HEADLAMP
HEADLAMP : CONSULT-III Function (BCM - HEAD LAMP) INFOID:0000000001510591
WORK SUPPORT

MODE 1 10 sec.
HEAD LIGHT TIMER Sets follow me home function activating time.
MODE 2* 30 sec.
*: Initial setting
DATA MONITOR
BCS-24
Monitor item A
Description
[Unit]
IGN ON SW
Ignition switch (ON) status judged from IGN signal (ignition power supply)
[On/Off]
B
ACC SW
Ignition switch (ACC) status judged from ACC signal (ACC power supply)
[On/Off]
HI BEAM SW C
[On/Off]
HEAD LAMP SW1
[On/Off]
D
HEAD LAMP SW2
[On/Off]
TAIL LAMP SW
E
[On/Off]
Each switch status that BCM judges from the combination switch reading function
AUTO LIGHT SW
[On/Off]
F
PASSING SW
[On/Off]
FR FOG SW
[On/Off] G
RR FOG SW
[On/Off]
H
DOOR SW-DR
[On/Off]
DOOR SW-AS
The switch status input from front door switch (passenger side) I
[On/Off]
DOOR SW-RR
[On/Off]
DOOR SW- RL
J
[On/Off]
BACK DOOR SW
The switch status input from back door switch
[On/Off] K
TURN SIGNAL R
[On/Off]
Each switch status that BCM judges from the combination switch reading function
TURN SIGNAL L L
[On/Off]
ENGINE RUNNING
The engine status received from ECM with CAN communication
[On/Off] BCS
LIT-SEN FAIL • The sensor status received from light & rain sensor with serial link
[OK/NOTOK] • The serial link condition that BCM judges
AUT LIGHT SYS N
Auto light system status received from light & rain sensor with serial link
[On/Off]
HD LIGHT TIME
Setting time of the follow me home function set by the work support
[Sec] O
ACTIVE TEST

P
Transmits the position light request signal to IPDM E/R with CAN com-
On
TAIL LAMP munication to turn the tail lamp ON.
Off Stops the tail lamp request signal transmission.
BCS-25
Transmits the high beam request signal with CAN communication to turn
Hi
the headlamp (HI).
HEAD LAMP Transmits the low beam request signal with CAN communication to turn
Lo
the headlamp (LO).
Off Stops the high & low beam request signal transmission.
Transmits the front fog lights request signal to IPDM E/R with CAN com-
On
FR FOG LAMP munication to turn the front fog lamp ON.
Off Stops the front fog lights request signal transmission.
• Outputs the voltage to turn the rear fog lamp ON.
On • Transmits the rear fog lamp status signal to the combination meter with
RR FOG LAMP CAN communication to turn the rear fog lamp indicator lamp ON.
• Stops the voltage to turn the rear fog lamp OFF.
Off
• Stops the rear fog lamp status signal transmission.
Transmits the day time running light request signal to IPDM E/R with
On
DAYTIME RUNNING LIGHT CAN communication to turn the each lamps ON.
Off Stops the day time running light request signal transmission.
WIPER
WIPER : CONSULT-III Function (BCM - WIPER) INFOID:0000000001510603
WORK SUPPORT
Service item Setting item Description

With vehicle speed
ON*
WIPER SPEED (Front wiper intermittent time linked with the vehicle speed and wiper intermittent dial position)
SETTING Without vehicle speed
OFF
(Front wiper intermittent time linked with the wiper intermittent dial position)
*:Factory setting
DATA MONITOR
Monitor Item
Description
[Unit]
VEHICLE SPEED
The value of the vehicle speed signal received from combination meter with CAN communication.
[km/h]
IGN ON SW Ignition switch ON status judged from ignition power supply.
IGN SW CAN Ignition switch ON status received from IPDM E/R with CAN communication.
FR WIPER HI
[OFF/ON]
FR WIPER LOW
[OFF/ON]
Each switch status that BCM judges from the combination switch reading function.
FR WIPER INT
[OFF/ON]
FR WASHER SW
[OFF/ON]
INT VOLUME
[1 − 7]
FR WIPER STOP
Front wiper motor (stop position) status received from IPDM E/R with CAN communication.
[OFF/ON]
BCS-26
Monitor Item
Description
[Unit] A
RR WIPER ON
[OFF/ON]
RR WIPER INT B
[OFF/ON]
RR WASHER SW
[OFF/ON] C
RR WIPER STOP
Rear wiper motor (stop position) status input from the rear wiper motor.
[OFF/ON]
REVERSE SW CAN NOTE: D
[OFF/ON] The item is indicated, but not monitored.
H/L WASH SW
Switch status input from headlamp washer switch.
[OFF/ON] E
ACTIVE TEST

F
Transmits the front wiper request signal (HI) to IPDM E/R with CAN communication to
HI
operate the front wiper HI operation.
G
Transmits the front wiper request signal (LO) to IPDM E/R with CAN communication
LO
FR WIPER to operate the front wiper LO operation.
Transmits the front wiper request signal (INT) to IPDM E/R with CAN communication
INT H
to operate the front wiper INT operation.
OFF Stops transmitting the front wiper request signal to stop the front wiper operation.
ON Outputs the voltage to operate the rear wiper motor.
RR WIPER I
OFF Stops the voltage to stop.
Transmits the headlamp washer request signal to IPDM E/R with CAN communication
HEADLAMP WASHER ON
to operate the headlamp washer operation. J
FLASHER
FLASHER : CONSULT-III Function (BCM - FLASHER) INFOID:0000000001510592 K
DATA MONITOR
L
Monitor item
Description
[Unit]
IGN ON SW BCS
Ignition switch (ON) status judged from IGN signal (ignition power supply)
[On/Off]
HAZARD SW
The switch status input from the hazard switch
[On/Off]
N
TURN SIGNAL R
[On/Off]
Each switch condition that BCM judges from the combination switch reading function
TURN SIGNAL L
O
[On/Off]
BRAKE SW
The switch status input from the stop lamp switch
[On/Off]
P
ACTIVE TEST

RH Outputs the voltage to blink the right side turn signal lamps.
FLASHER LH Outputs the voltage to blink the left side turn signal lamps.
Off Stops the voltage to turn the turn signal lamps OFF.
BCS-27
AIR CONDITIONER
AIR CONDITIONER : CONSULT-III Function (BCM - AUTO AIR CONDITIONER)
INFOID:0000000001510618
DATA MONITOR
Display Item List
Monitor Item [Unit] Contents

Displays [ignition switch position (On)/(Off), ACC position (Off)] status as judged form ignition
IGN SW [On/Off]
switch signal.
FAN ON SIG [On/Off] Displays [FAN (On)/FAN (Off)] status as judged form blower fan motor switch signal.
AIR COND SW [On/Off] Displays [COMP (On)/COMP (Off)] status as judged form air conditioner switch signal.
INTELLIGENT KEY
INTELLIGENT KEY : CONSULT-III Function (BCM - INTELLIGENT KEY) INFOID:0000000001510610


DATA MONITOR

PUSH SW Indicates [ON/OFF] condition of ignition knob switch.
I-KEY LOCK Indicates [ON/OFF] condition of lock signal from Intelligent Key.
I-KEY UNLOCK Indicates [ON/OFF] condition of unlock signal from Intelligent Key.
COMB SW
COMB SW : CONSULT-III Function (BCM - COMB SW) INFOID:0000000001158239
DATA MONITOR
Monitor item [UNIT] Description

TURN SIGNAL R Displays the status of “TURN RH” switch in combination switch judged by the combination switch reading
[Off/On] function.
TURN SIGNAL L Displays the status of the “TURN LH” switch in combination switch judged by the combination switch reading
[Off/On] function.
HI BEAM SW Displays the status of “HI BEAM” switch in combination switch judged by the combination switch reading func-
[Off/On] tion.
HEAD LAMP SW 1 Displays the status of “HEADLAMP 1” switch in combination switch judged by the combination switch reading
[Off/On] function.
HEAD LAMP SW 2 Displays the status of “HEADLAMP 2” switch in combination switch judged by the combination switch reading
[Off/On] function.
TAIL LAMP SW Displays the status of “TAIL LAMP” switch in combination switch judged by the combination switch reading
[Off/On] function.
PASSING SW Displays the status of “PASSING” switch in combination switch judged by the combination switch reading
[Off/On] function.
BCS-28
A
AUTO LIGHT SW Displays the status of “AUTO LIGHT” switch in combination switch judged by the combination switch reading
[Off/On] function.
FR FOG SW Displays the status of “FR FOG” switch in combination switch judged by the combination switch reading func-
[Off/On] tion. B
RR FOG SW Displays the status of “RR FOG” switch in combination switch judged by the combination switch reading func-
[Off/On] tion.
FR WIPER HI Displays the status of “FR WIPER HI” switch in combination switch judged by the combination switch reading C
[Off/On] function.
FR WIPER LOW Displays the status of “ FR WIPER LOW” switch in combination switch judged by the combination switch read-
[Off/On] ing function. D
FR WIPER INT Displays the status of “FR WIPER INT” switch in combination switch judged by the combination switch read-
[Off/On] ing function.
FR WASHER SW Displays the status of “ FR WASHER” switch in combination switch judged by the combination switch reading E
[Off/On] function.
INT VOLUME
Displays the status of wiper intermittent dial position judged by the combination switch reading function.
[1 - 7] F
RR WIPER ON Displays the status of “RR WIPER” switch in combination switch judged by the combination switch reading
[Off/On] function.
RR WIPER INT Displays the status of “RR WIPER INT” switch in combination switch judged by the combination switch read- G
[Off/On] ing function.
RR WASHER SW Displays the status of “RR WASHER” switch in combination switch judged by the combination switch reading
[Off/On] function. H
BCM
BCM : CONSULT-III Function (BCM - BCM) INFOID:0000000001158228 I
WORK SUPPORT
J
Item Description
RESET SETTING VALUE Return a value set with WORK SUPPORT of each system to a default value in factory shipment.
K
IMMU
IMMU : CONSULT-III Function (BCM - IMMU) INFOID:0000000001509194
L
APPLICATION ITEM
BCS
ACTIVE TEST The signals used to activate each device are forcibly supplied from Intelligent Key unit.
N
DATA MONITOR
O
Monitor item Content
KEY ON SW Indicates [ON/OFF] condition of key switch. P

*1: For the vehicle Intelligent key is equipped.
ACTIVE TEST
BCS-29

THEFT IND This test is able to check security indicator operation [ON/OFF].
BATTERY SAVER
BATTERY SAVER : CONSULT-III Function (BCM - BATTERY SAVER) INFOID:0000000001510594
WORK SUPPORT

MODE 1* 30 min. Sets the interior room lamp battery saver timer operating
ROOM LAMP TIMER SET
MODE 2 60 min. time.
*: Initial setting
DATA MONITOR
Monitor item
Description
[Unit]
IGN ON SW
Ignition switch (ON) status judges from IGN signal (ignition power supply)
[On/Off]
ACC SW
Ignition switch (ACC) status judges from ACC signal (ACC power supply)
[On/Off]
KEY ON SW
The switch status input from key switch
[On/Off]
PUSH SW
Push switch status received from Intelligent Key unit by CAN communication
[On/Off]
DOOR SW-DR
[On/Off]
DOOR SW-AS
The switch status input from front door switch (passenger side)
[On/Off]
DOOR SW-RR
[On/Off]
DOOR SW- RL
[On/Off]
BACK DOOR SW
The switch status input from back door switch
[On/Off]
CDL LOCK SW
Lock switch status input from door lock and unlock switch
[On/Off]
CDL UNLOCK SW
Unlock switch status input from door lock and unlock switch
[On/Off]
I-KEY LOCK
Lock signal status received from Intelligent Key unit by CAN communication
[On/Off]
I-KEY UNLOCK
Unlock signal status received from Intelligent Key unit by CAN communication
[On/Off]
KEYLESS LOCK Lock signal status received from remote keyless entry receiver (integrated in the
[On/Off] BCM)
KEYLESS UNLOCK Unlock signal status received from remote keyless entry receiver (integrated in the
[On/Off] BCM)
ACTIVE TEST

Off Cuts the interior room lamp power supply to turn interior room lamps OFF.
BATTERY SAVER
On Outputs the interior room lamp power supply to turn interior room lamps ON.*
BCS-30
*: Each lamp switch is in ON position.
TRUNK A
TRUNK : CONSULT-III Function (BCM - TRUNK) INFOID:0000000001509116
B
APPLICATION ITEM
C
ACTIVE TEST The signals used to activate each device are forcibly supplied from Intelligent Key unit. D
DATA MONITOR
E
KEY ON SW Indicates [ON/OFF] condition of key switch. F
TRNK OPNR SW Indicates [ON/OFF] condition of back door opener switch.
G
VEHICLE SPEED
[km/h].
*1
H
*2: For the remote keyless entry system equipped vehicle.
ACTIVE TEST
I
TRUNK/GLASS HATCH This test is able to check back door opener operation [ON/OFF].
J
THEFT ALM
THEFT ALM : CONSULT-III Function (BCM - THEFT ALM) INFOID:0000000001509195
K
APPLICATION ITEM
L
BCS
DATA MONITOR N

O
KEY ON SW Indicates [ON/OFF] condition of key switch. P
*2 Indicates [ON/OFF] condition of lock signal from key fob.
KEYKESS LOCK
I-KEY LOCK*1 Indicates [ON/OFF] condition of lock signal from Intelligent Key.
HOOD SW Indicates [ON/OFF] condition of hood switch.
BCS-31
*1: For vehicle equipped with Intelligent Key.
*2
: For the vehicle equipped with remote key less entry system.
ACTIVE TEST

THEFT IND This test is able to check security indicator operation [ON/OFF].
VEHICLE SECURITY HORN This test is able to check horn operation [ON].
FLASHER This test is able to check flasher operation [LH/RH/OFF].
WORK SUPPORT

Vehicle security function mode can be changed in this mode.
SECURITY ALARM SET • ON: Vehicle security function is ON.
• OFF: Vehicle security function is OFF.
The switch which triggered vehicle security system is recorded. This mode can be able to con-
THEFT ALM TRG
firm and erase the record of vehicle security system.
SIGNAL BUFFER
SIGNAL BUFFER : CONSULT-III Function (BCM - SIGNAL BUFFER) INFOID:0000000001158244
DATA MONITOR

OIL PRESS SW
Displays the status of oil pressure switch received from IPDM E/R with CAN communication.
[Off/On]
BRAKE SW
Displays the status of stop lamp switch.
[Off/On]
ACTIVE TEST

Transmits the oil pressure switch signal with CAN communication to illuminate the oil
On
OIL PRESSURE SW pressure warning lamp in the combination meter.
Off Stops the oil pressure switch signal transmission.
BCS-32
< COMPONENT DIAGNOSIS >
COMPONENT DIAGNOSIS A
B
CAN (Controller Area Network) is a serial communication line for real time applications. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Modern
vehicle is equipped with many electronic control unit, and each control unit shares information and links with C
other control units during operation (not independent). In CAN communication, control units are connected
with 2 communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less
wiring. Each control unit transmits/receives data but selectively reads required data only. D
E
DTC DETECTION LOGIC
DTC DTC Detection Condition Possible cause F

Any item (or items) of the following listed below is
malfunctioning in CAN communication system.
• Transmission G
When BCM cannot communicate CAN com- • Receiving (ECM)
U1000: CAN COMM CIRCUIT munication signal continuously for 2 sec- • Receiving (METER/M&A)
onds or more. • Receiving (TCM)
• Receiving (MULTI AV) H
• Receiving (IPDM E/R)
• Receiving (I-KEY)

I

J
2. Check “Self Diagnostic Result” of BCM.
K
YES >> Refer to LAN-13, "Trouble Diagnosis Flow Chart".
NO >> Refer to GI-39, "Intermittent Incident".
L
BCS
BCS-33
DTC DETECTION LOGIC
DTC DTC Detection Condition Possible cause

When detecting error during the initial diagnosis of CAN control-
U1010: CONTROL UNIT (CAN) BCM
ler of BCM.
1.REPLACE BCM
When “DTC:U1010” is detected, replace BCM.
>> Replace BCM. Refer to BCS-68, "Exploded View".
BCS-34
A
1.CHECK FUSES AND FUSIBLE LINK B

Check that the following fuses and fusible link are not fusing.
Terminal No. Signal name Fuses and fusible link No.

C
41 10
Battery power supply
57 J D
4 ACC power supply 20
3 Ignition power supply 1
Is the fuse fusing? E
YES >> Replace the blown fuse or fusible link after repairing the affected circuit if a fuse or fusible link is
blown.
NO >> GO TO 2. F
1. Turn ignition switch OFF. G
2. Disconnect BCM connectors.
3. Check voltage between BCM harness connector and ground.
H
Terminals
Ignition switch position
(+)
BCM (−) I
OFF ACC ON
Connector Terminal
M67 57 Battery Battery Battery
voltage voltage voltage J
M66 41
Ground Approx. Battery Battery

4
0V voltage voltage
M65 K
Approx. Approx. Battery
3
0V 0V voltage
Is the measurement value normal? L
YES >> GO TO 3.
3.CHECK GROUND CIRCUIT BCS
Check continuity between BCM harness connector and ground.
BCM
N
Continuity
Connector Terminal Ground
M67 55 Existed
O
Does continuity exist?
NO >> Repair harness or connector. P
BCS-35
COMBINATION SWITCH INPUT CIRCUIT
1.CHECK INPUT 1 - 5 CIRCUIT FOR OPEN

2. Disconnect BCM and combination switch connectors.
3. Check continuity between BCM harness connector and combination switch harness connector.
BCM Combination switch

System Continuity
Connector Terminal Connector Terminal
INPUT 1 8 1
INPUT 2 9 2
INPUT 3 M65 6 M27 3 Existed
INPUT 4 7 4
INPUT 5 10 5
YES >> GO TO 2.
NO >> Repair harnesses or connectors.
2.CHECK INPUT 1 - 5 CIRCUIT FOR SHORT
Check for continuity between BCM harness connector and ground.
BCM
System Continuity
Connector Terminal
INPUT 1 8
INPUT 2 9 Ground
INPUT 3 M65 6 Not existed
INPUT 4 7
INPUT 5 10
YES >> Repair harnesses or connectors.
NO >> GO TO 3.
3.CHECK BCM OUTPUT VOLTAGE
1. Connect BCM connector.
Terminals
(+) (−) Voltage
System
BCM (Approx.)
Connector Terminal
INPUT 1 8
Ground
INPUT 2 9
Refer to BCS-
INPUT 3 M65 6 40, "Refer-
ence Value".
INPUT 4 7
INPUT 5 10
Is the measurement value normal?
YES >> GO TO 4.
NO >> Replace BCM. Refer to BCS-68, "Exploded View".
BCS-36
4.CHECK COMBINATION SWITCH A
Check combination switch. Refer to BCS-39, "Description".
Is the check result normal?
YES >> Replace BCM. Refer to BCS-68, "Exploded View". B
NO >> Replace the combination switch (applicable parts).
BCS
BCS-37
COMBINATION SWITCH OUTPUT CIRCUIT
COMBINATION SWITCH OUTPUT CIRCUIT
1.CHECK OUTPUT 1 - 5 CIRCUIT FOR OPEN

2. Disconnect BCM and combination switch connectors.
3. Check continuity between BCM harness connector and combination switch harness connector.
BCM Combination switch

System Continuity
OUTPUT 1 40 6
OUTPUT 2 37 7
OUTPUT 3 M65 38 M27 10 Existed
OUTPUT 4 39 9
OUTPUT 5 36 8
YES >> GO TO 2.
NO >> Repair harnesses or connectors.
2.CHECK OUTPUT 1 - 5 CIRCUIT FOR SHORT
Check for continuity between BCM harness connector and ground.
BCM
System Continuity
Connector Terminal
OUTPUT 1 40
OUTPUT 2 37 Ground
OUTPUT 3 M65 38 Not existed
OUTPUT 4 39
OUTPUT 5 36
YES >> Repair harnesses or connectors.
NO >> GO TO 3.
3.CHECK COMBINATION SWITCH
Check combination switch. Refer to BCS-39, "Description".
Is the check result normal?
YES >> Replace BCM. Refer to BCS-68, "Exploded View".
NO >> Replace combination switch (applicable parts).
BCS-38
COMBINATION SWITCH
COMBINATION SWITCH
A
COMBINATION SWITCH MATRIX B

Combination switch consists of INPUT circuit and OUTPUT circuit.
Combination switch circuit
C
JPMIA0121GB
H
Combination switch INPUT-OUTPUT system list

System OUTPUT 1 OUTPUT 2 OUTPUT 3 OUTPUT 4 OUTPUT 5 I
INPUT 1 — FR WASHER FR WIPER LOW TURN LH TURN RH
INPUT 2 FR WIPER HI — FR WIPER INT PASSING HEADLAMP 1
J
INPUT 3 INT VOLUME 1 RR WASHER — HEADLAMP 2 HI BEAM
INPUT 4 RR WIPER INT INT VOLUME 3 AUTO LIGHT — TAIL LAMP
INPUT 5 INT VOLUME 2 RR WIPER RR FOG FR FOG — K
NOTE:
Headlamp has a dual system switch.
L
1.CHECK LIGHT & TURN SIGNAL SWITCH BCS

Check operation with normal light & turn signal switch installed.
Does it operate normally?
YES >> Replace light & turn signal switch. N
NO >> GO TO 2.
2.CHECK WIPER & WASHER SWITCH
O
Check operation with normal wiper & washer switch installed.
YES >> Replace wiper & washer switch. P
NO >> GO TO 3.
3.CHECK SWITCH BASE (SPIRAL CABLE)
Check operation with normal switch base (spiral cable) installed.
YES >> Replace switch base (spiral cable).
NO >> Combination switch is normal.
BCS-39
BCM (BODY CONTROL MODULE)
< ECU DIAGNOSIS >
ECU DIAGNOSIS
Monitor Item Condition Value/Status

VEHICLE SPEED While driving Equivalent to speedometer reading
Ignition switch OFF or ACC Off
IGN ON SW
Ignition switch ON On
Mechanical key is removed from key cylinder Off
KEY ON SW
Mechanical key is inserted to key cylinder On
Door lock/unlock switch does not operate Off
CDL LOCK SW
Press door lock/unlock switch to the lock side On
CDL UNLOCK SW
Press door lock/unlock switch to the unlock side On
Driver's door closed Off
DOOR SW-DR
Driver's door opened On
Passenger door closed Off
DOOR SW-AS
Passenger door opened On
Rear RH door closed Off
DOOR SW-RR
Rear RH door opened On
Rear LH door closed Off
DOOR SW-RL
Rear LH door opened On
Back door closed Off
BACK DOOR SW
Back door opened On
“LOCK” button of Intelligent Key or door request switch are not
Off
I-KEY LOCK pressed
“LOCK” button of Intelligent Key or door request switch are pressed On
“UNLOCK” button of Intelligent Key or door request switch are not
Off
pressed
I-KEY UNLOCK
“UNLOCK” button of Intelligent Key or door request switch are
On
pressed
Return to ignition switch to “LOCK” position Off
PUSH SW
Press ignition switch On
“LOCK” button of key fob is not pressed Off
KEYLESS LOCK
“LOCK” button of key fob is pressed On
“UNLOCK” button of key fob is not pressed Off
KEYLESS UNLOCK
“UNLOCK” button of key fob is pressed On
Ignition switch ON NOMAL
After the reception of air bag deployment signal from air bag diag-
Off
SHOCK SENSOR nosis sensor unit
During the reception of air bag deployment signal from air bag diag-
On
nosis sensor unit
Other than the following Off
UNLOCK SHOCK
During the unlock operation interlocked with air bag On
BCS-40
< ECU DIAGNOSIS >
A
NOTE: On
UNLOCK WITH DR
The item is indicated, but not monitored Off
Vehicle speed sensing auto door lock function does not operate Off B
LOCK WITH SPEED
Vehicle speed sensing auto door lock function is operating On
Ignition switch OFF Off
ACC ON SW
Ignition switch ACC or ON On C
Rear window defogger switch OFF Off
REAR DEF SW
Rear window defogger switch ON On
D
Lighting switch OFF Off
TAIL LAMP SW
Lighting switch 1ST On
Turn signal switch OFF Off E
TURN SIGNAL R
Turn signal switch RH On
Turn signal switch OFF Off
TURN SIGNAL L F
Turn signal switch LH On
HI BEAM SW
Lighting switch HI On G
HEAD LAMP SW 1
Lighting switch 2ND On
H
HEAD LAMP SW 2
Other than lighting switch PASS Off I
PASSING SW
Lighting switch PASS On
AUTO LIGHT SW J
Lighting switch AUTO On
Front fog lamp switch OFF Off
FR FOG SW
Front fog lamp switch ON On
K
Rear fog lamp switch OFF Off
RR FOG SW
Rear fog lamp switch ON On
Engine stopped Off L
ENGINE RUN
Engine running On
Light & rain sensor is in normal condition OK
LIT-SEN FAIL BCS
Light & rain sensor is with error NOTOK
Outside of the room is dark On
AUT LIGHT SYS
Outside of the room is bright Off N
Displays a setting time of the follow
HD LIGHT TIME — me home function set by the work
support O
IGN SW CAN
Front wiper switch OFF Off P
FR WIPER HI
Front wiper switch HI On
Front wiper switch OFF Off
FR WIPER LOW
Front wiper switch LO On
FR WIPER INT
Front wiper switch INT On
BCS-41
< ECU DIAGNOSIS >
Front washer switch OFF Off
FR WASHER SW
Front washer switch ON On
INT VOLUME Wiper intermittent dial is in a dial position 1 - 7 1-7
Any position other than front wiper stop position Off
FR WIPER STOP
Front wiper stop position On
Rear wiper switch OFF Off
RR WIPER ON
Rear wiper switch ON On
RR WIPER INT
Rear wiper switch INT On
Rear wiper stop position Off
RR WIPER STOP
Other than rear wiper stop position On
Rear washer switch OFF Off
RR WASHER SW
Rear washer switch ON On
NOTE: Off
REVERSE SW CAN
The item is indicated, but not monitored On
When headlamp washer switch is not pressed Off
H/L WASH SW
When headlamp washer switch is pressed On
Blower fan motor switch OFF Off
FAN ON SIG
Blower fan motor switch ON (other than OFF) On
Compressor ON is not requested from auto amp.
Off
(A/C indicator OFF, blower fan motor switch OFF or etc.)
AIR COND SW
Compressor ON is requested from auto amp.
On
(A/C indicator ON and blower fan motor switch ON).
Hazard switch OFF Off
HAZARD SW
Hazard switch ON On
Brake pedal is not depressed Off
BRAKE SW
Brake pedal is depressed On
When back door opener switch is not pressed Off
TRNK OPNR SW
When back door opener switch is pressed On
Close the hood
NOTE: Off
HOOD SW Vehicles without theft warning system are OFF-fixed
Open the hood On
Auto lock function does not operate Off
AUTO RELOCK
Auto lock function is operating On
The vehicle without glass break sensor Off
GLS BREAK SEN
The vehicle with glass break sensor On
• Ignition switch OFF or ACC
Off
OIL PRESS SW • Engine running
BCS-42
< ECU DIAGNOSIS >
TERMINAL LAYOUT
A
BCS
N
JSMIA0031GB
PHYSICAL VALUES O
CAUTION:
• Check combination switch system terminal waveform under the loaded condition with lighting
switch, turn signal switch and wiper switch OFF is not to be fluctuated by being overloaded.
• Turn wiper intermittent dial position to 4 except when checking waveform or voltage of wiper inter- P
mittent dial position. Wiper intermittent dial position can be confirmed on CONSULT-III. Refer to
BCS-28, "COMB SW : CONSULT-III Function (BCM - COMB SW)".
• BCM reads the status of the combination switch at 10 ms internal normally. Refer to BCS-9, "System
Description".
BCS-43
< ECU DIAGNOSIS >

(Wire color) Value
Input/ Condition
Signal name (Approx.)
+ − Output
Just after Insert mechanical key
1 Input/ Insert mechanical key into ignition key cylin-
Ground NATS antenna amp. into ignition key cylinder. Pointer
(W) Output der
of tester should move
(G) Output der
3 Ignition power sup- Ignition switch OFF or ACC 0V

Ground Input
(W) ply Ignition switch ON or START Battery voltage
4 Ignition switch OFF 0V

Ground ACC power supply Input
(SB) Ignition switch ON or ACC Battery voltage
Insert mechanical key into ignition key cylin-
5 Battery voltage
der
*1
(LG) Ground Key switch Input
Remove mechanical key from ignition key
(R)*2 0V
cylinder
BCS-44
< ECU DIAGNOSIS >
(Wire color) Value A
Input/ Condition
+ − Output
All switch OFF

(Wiper intermittent dial 4) C
JPMIA0165GB
1.4 V D
E
Lighting switch HI
(Wiper intermittent dial 4)
F
JPMIA0166GB
1.3 V
G
6 Combination switch Combination Lighting switch 2ND

H
Ground Input
(L) INPUT 3 switch (Wiper intermittent dial 4)
JPMIA0167GB
I
1.3 V
Rear washer switch ON

K
JPMIA0169GB
1.3 V L
Any of the condition below BCS

with all switch OFF
• Wiper intermittent dial 1
• Wiper intermittent dial 3 N
JPMIA0196GB
1.3 V
O
BCS-45
< ECU DIAGNOSIS >
(Wire color) Value
Input/ Condition
+ − Output
All switch OFF

JPMIA0165GB
1.4 V
Lighting switch 1ST

JPMIA0166GB
1.3 V
7 Combination switch Combination Lighting switch AUTO

Ground Input
(GR) INPUT 4 switch (Wiper intermittent dial 4)
JPMIA0168GB
1.3 V
Any of the condition below

with all switch OFF
JPMIA0169GB
1.3 V
Rear wiper INT

JPMIA0196GB
1.3 V
BCS-46
< ECU DIAGNOSIS >
Input/ Condition
+ − Output
All switch OFF C
JPMIA0165GB
1.4 V D
Turn signal switch RH
F
JPMIA0166GB
1.3 V
G
Combination
8 Combination switch switch
H
Ground Input Turn signal switch LH
(V) INPUT 1 (Wiper intermit-
tent dial 4)
JPMIA0167GB
I
1.3 V
Front wiper switch LO

K
JPMIA0168GB
1.3 V L
BCS
Front washer switch ON
N
JPMIA0196GB
1.3 V
O
BCS-47
< ECU DIAGNOSIS >
(Wire color) Value
Input/ Condition
+ − Output
All switch OFF
JPMIA0165GB
1.4 V
Lighting switch 2ND
JPMIA0166GB
1.3 V
9 Combination
Combination switch switch
(G)*3 Ground Input Lighting switch PASS
INPUT 2 (Wiper intermit-
(B)*4 tent dial 4)
JPMIA0167GB
1.3 V
Front wiper switch INT
JPMIA0168GB
1.3 V
Front wiper switch HI
JPMIA0196GB
1.3 V
BCS-48
< ECU DIAGNOSIS >
Input/ Condition
+ − Output
All switch OFF

JPMIA0165GB
1.3 V D
E
Front fog lamp switch ON
F
JPMIA0167GB
1.3 V
G
10 Combination switch Combination Rear fog lamp switch ON

H
Ground Input
(BR) INPUT 5 switch (Wiper intermittent dial 4)
JPMIA0168GB
I
1.3 V
Rear wiper switch ON

(Wiper intermittent dial 4) K
JPMIA0169GB
1.3 V L

BCS
with all switch OFF
JPMIA0196GB
1.3 V
11 Input/ O
Ground Audio link — — —
(B) Output
BCS-49
< ECU DIAGNOSIS >
(Wire color) Value
Input/ Condition
+ − Output
OFF
(When rear door RH
12 Rear door closed)
Ground Rear door switch RH Input
(LG) switch RH
PKID0924E
11.2 V
ON
(When rear door RH 0V
opened)
OFF
13 Back door (When back door closed)
Ground Back door switch Input
(V) switch
PKID0924E
11.2 V
ON
0V
(When back door opened)
OFF
(When passenger door
14
Passenger door Passenger door closed)
(P)*3 Ground Input
switch switch
(BR)*4 PKID0924E
11.2 V
ON
(When passenger door 0V
opened)
OFF
15 (When driver door closed)
Driver door
(BR)*3 Ground Driver door switch Input
*4
switch
(P) PKID0924E
11.2 V
ON
(When driver door 0V
opened)
BCS-50
< ECU DIAGNOSIS >
Input/ Condition
+ − Output
OFF
(When rear door LH C
Ground Rear door switch LH Input
(GR) switch LH
PKID0924E
11.2 V D
ON
(When rear door LH 0V
opened) E
17 Door lock status indi- Door lock status ON 12 V
Ground Output
(L) cator indicator OFF 0V
F
G
20 Rear window defog- Rear window Not pressed
Ground Input
(SB) ger switch defogger switch
H
JPMIA0154GB
1.1 V
While pressing 0V
I
21 Input/
— CAN-L — —
(P) Output
22 Input/
(L)
— CAN-H
Output
— — J
ON 0V
23 Security indica- L
Ground Security indicator Output Blinking
(V) tor
JPMIA0014GB
BCS
10.3 V
OFF 12 V
Ignition switch OFF or ACC 12 V N
24 Light & rain sensor Input/

O
Ground
(GR) serial link Output Ignition switch ON
P
JPMIA0156GB
8.7 V
25
Ground Alarm link Output — —
(G)
BCS-51
< ECU DIAGNOSIS >
(Wire color) Value
Input/ Condition
+ − Output
26
Blower fan motor Blower fan mo- OFF
(GR)*5 Ground Input
switch tor switch
(LG)*6
PKID0924E
11.2 V
ON (other than OFF) 0V
Compressor ON is not re-

quested from auto amp.
(A/C indicator OFF, blow-
er fan motor switch OFF
27
Ignition switch or etc.)
(P)*5 Ground A/C switch Input
*6
ON PKID0924E
(Y) 11.2 V
Compressor ON is re-
(A/C indicator ON and 0V
blower fan motor switch
ON).
Ignition switch OFF or ACC 0V
28
(LG)*7 Ground Shock detect sensor Input
Ignition switch ON
(R)*8
JPMIA0155GB
6.0 V
29
Back door opener Back door Not pressed
(LG)*3 Ground Input
switch opener switch
(O)*4
JPMIA0154GB
1.2 V
Pressed 0V
32 Door lock/unlock Door lock/un- Not pressed

Ground
(BR) switch (Unlock) Input lock switch
JPMIA0154GB
1.2 V
Pressed to the unlock side 0 V
BCS-52
< ECU DIAGNOSIS >
Input/ Condition
+ − Output
33
OFF C
(W)*9 Ground Hazard switch Input Hazard switch
(Y)*10
JPMIA0154GB
1.3 V D
ON 0V
34
Door lock/unlock Door lock/un- Not pressed F
(SB)*3 Ground
switch (Lock) Input lock switch
(P)*4
JPMIA0154GB
1.2 V G
Pressed to the lock side 0V
35 Headlamp washer Headlamp Not pressed I

Ground
(G) switch Input washer switch
JPMIA0154GB
J
1.2 V
All switch OFF 0V K
Lighting switch 2ND
Combination
Lighting switch HI
L
Ground Output
(G) OUTPUT 5 (Wiper intermit-
tent dial 4)
Lighting switch 1ST BCS
JPMIA0164GB
9.1 V
All switch OFF N
0V
O
37 Combination switch Combination
Ground Output
(R) OUTPUT 2 switch Any of the condition below P
with all switch OFF
• Wiper intermittent dial 6 JPMIA0161GB
9.1 V
BCS-53
< ECU DIAGNOSIS >
(Wire color) Value
Input/ Condition
+ − Output
All switch OFF 0V
Front wiper switch MIST
Combination
38 Combination switch switch Front wiper switch INT
Ground Output
(W) OUTPUT 3 (Wiper intermit- Lighting switch AUTO
tent dial 4)
Rear fog lamp switch ON JPMIA0162GB
9.3 V
All switch OFF 0V
Turn signal switch LH
Lighting switch PASS
Combination
39 Combination switch switch Lighting switch 2ND
Ground Output
(Y) OUTPUT 4 (Wiper intermit-
tent dial 4)
JPMIA0163GB
9.3 V
All switch OFF
0V
40 Combination switch Combination with all switch OFF
Ground Output • Wiper intermittent dial 1
(P) OUTPUT 1 switch
Rear wiper switch INT 9.1 V

41 Battery power sup-
Ground Input Ignition switch OFF Battery voltage
(LG) ply
42 Interior room lamp Interior room lamp battery saver activation 0V

Ground Output
(V) power supply Interior room lamp battery saver no activation 12 V
43 Rear wiper switch OFF 0V

Ground Rear wiper motor Output
(SB) Rear wiper switch ON 12 V
Rear wiper stop position

44 Ignition switch
Ground Rear wiper auto stop Input
(B) ON
JPMIA0197GB
Any position other than

0V
rear wiper stop position
BCS-54
< ECU DIAGNOSIS >
Input/ Condition
+ − Output
45 Back door lock actu- Back door Pressed

(V)
Ground
ator
Output
opener switch
C
SKIA9232E
D
Not pressed 0V
Turn signal switch OFF 0V
E
47 Ignition switch
Ground Turn signal LH Output
(BR) ON Turn signal switch LH F
PKID0926E G
6.5 V
H
48 Ignition switch
Ground Turn signal RH Output I
(GR) ON Turn signal switch RH
PKID0926E J
6.5 V
49 OFF 0V
Ground Rear fog lamp Output Rear fog lamp
(Y) ON 12 V K
50 Unlock 5V
Ground Unlock sensor Input Driver's door
(G) lock 0V
L
51 Depress the brake pedal Battery voltage
Ground Stop lamp switch Input
(R) Release the brake pedal 0V
52 Room lamp timer Interior room OFF 12 V BCS

Ground Output
(R) control lamp ON 0V
53 Power window pow- OFF or ACC 0V

(L)
Ground
er supply (IGN)
Output Ignition switch N
ON 12 V
O
Door unlock Pressed to the unlock side
54 Door lock/un-
Ground (All other than driv- Output
(O) lock switch
er's door) P
SKIA9232E
Not pressed 0V
55
Ground Ground — Ignition switch ON 0V
(B)
BCS-55
< ECU DIAGNOSIS >
(Wire color) Value
Input/ Condition
+ − Output
Not pressed 0V
56 Door lock (All) and Door lock/un-

Ground Output
(V) fuel lid lock lock switch Pressed to the lock side
SKIA9232E

(Y) ply
58 Power window pow-
Ground Output Ignition switch OFF 12 V
(P) er supply (BAT)
When lock button of key fob or Intelligent Key
0V
59 is not pressed
Ground Super lock Output
(R) When lock button of key fob or Intelligent Key
12 V
is pressed
60 Driver's door unlock Door lock/un- Pressed to the unlock side

Ground Output
(G) and fuel lid unlock lock switch
SKIA9232E
Not pressed 0V
*1: With Intelligent Key
*2: Without Intelligent Key
*3: RHD models
*4: LHD models
*5: With gasoline engine
*6: With diesel engine
*7: RHD models with side air bag
*8: LHD models with side air bag
*9: With xenon headlamp and daytime light system
*10: Except with xenon headlamp and daytime light system
BCS-56
< ECU DIAGNOSIS >
Wiring Diagram - BCM - INFOID:0000000001158260
BCS
JCMWA0500GB
P
BCS-57
< ECU DIAGNOSIS >
JCMWA0501GB
BCS-58
< ECU DIAGNOSIS >
BCS
JCMWA0502GB
BCS-59
< ECU DIAGNOSIS >
JCMWA0503GB
BCS-60
< ECU DIAGNOSIS >
BCS
JCMWA0504GB
BCS-61
< ECU DIAGNOSIS >
JCMWA0505GB
BCS-62
< ECU DIAGNOSIS >
BCS
JCMWA0506GB
P
Fail Safe INFOID:0000000001158261
FAIL-SAFE CONTROL BY DTC

BCM performs fail-safe control when any DTC is detected.
BCS-63
< ECU DIAGNOSIS >
DTC Fail-safe Cancellation

• Inhibits engine cranking
B2190: NATS ANTENNA AMP • Inhibits steering lock unlocking (Intelligent Key unit) Erase DTC
• Fuel cut (ECM)
B2191: DIFFERENCE OF KEY • Inhibits steering lock unlocking (Intelligent Key unit) Erase DTC
• Fuel cut (ECM)
B2192: ID DISCORD BCM-ECM Fuel cut (ECM) Erase DTC
B2193: CHAIN OF BCM-ECM Fuel cut (ECM) Erase DTC
B2194: DISCORD BCM-I-KEY • Inhibits steering lock unlocking (Intelligent Key unit) Erase DTC
• Fuel cut (ECM)
B2195: ANTI SCANNING • Inhibits steering lock unlocking (Intelligent Key unit) Erase DTC
• Fuel cut (ECM)
B2196: DONGLE NG • Inhibits steering lock unlocking (Intelligent Key unit) Erase DTC
• Fuel cut (ECM)
REAR WIPER MOTOR PROTECTION

BCM detects the rear wiper stopping position according to the rear wiper auto stop signal.
When the rear wiper auto stop signal does not change more than 5 seconds while driving the rear wiper, BCM
stops power supply to protect the rear wiper motor.
Condition of cancellation
2. Pass more than 1 minute after the rear wiper stop.
4. Operate the rear wiper switch.
HIGH FLASHER OPERATION
BCM detects the turn signal lamp circuit status from the terminal voltage.
BCM increases the turn signal lamp blinking speed if the bulb or harness open is detected with the turn signal
lamp operating.
NOTE:
The blinking speed is normal while activating the hazard warning lamp.
FAIL-SAFE CONTROL BY LIGHT & RAIN SENSOR MALFUNCTION
BCM detects the light & rain sensor serial link error and the light & rain sensor malfunction.
BCM controls the following fail-safe when light & rain sensor has a malfunction.
Fail-safe Control
• Auto light control: Headlamp is turned ON.
• Front wiper control: The condition just before the activation of fail-safe is maintained until the front wiper
switch is turned OFF.
DTC Inspection Priority Chart INFOID:0000000001158262
Priority DTC
• U1000: CAN COMM CIRCUIT
1
• U1010: CONTROL UNIT (CAN)
• B2190: NATS ANTENNA AMP
• B2191: DIFFERNCE OF KEY
• B2192: ID DISCORD BCM-ECM
2 • B2193: CHAIN OF BCM-ECM
• B2194: DISCORD BCM-I-KEY
• B2195: ANTI SCANNING
• B2196: DONGLE NG
BCS-64
< ECU DIAGNOSIS >
DTC Index INFOID:0000000001158263
A
NOTE:
Details of time display
• CRNT: Displays when there is a malfunction now or after returning to the normal condition until turning igni- B
tion switch OFF → ON again.
• PAST: Displays when there is a malfunction that is detected in the past and stored.
• 1 - 39: Displayed if any previous malfunction is present when current condition is normal. It increases like 1
→ 2 → 3...38 → 39 after returning to the normal condition whenever ignition switch OFF → ON. The counter C
remains at 39 even if the number of cycles exceeds it. It is counted from 1 again when turning ignition switch
OFF → ON after returning to the normal condition if the malfunction is detected again.
D
DTC TIME Fail-safe Reference
U1000: CAN COMM CIRCUIT 0 1 - 39 — BCS-33
U1010: CONTROL UNIT (CAN) 0 1 - 39 — BCS-34 E
• With Intelligent Key system: SEC-41
B2190: NATS ANTENNA AMP CRNT PAST × • Without Intelligent Key system: SEC-
254 F
B2191: DIFFERENCE OF KEY CRNT PAST × • Without Intelligent Key system: SEC-
256
G
B2192: ID DISCORD BCM-ECM CRNT PAST × • Without Intelligent Key system: SEC-
251
H
B2193: CHAIN OF BCM-ECM CRNT PAST × • Without Intelligent Key system: SEC-
253
B2194: DISCORD BCM-I-KEY CRNT PAST × SEC-53 I
B2195: ANTI SCANNING CRNT PAST × • Without Intelligent Key system: SEC-
264 J
B2196: DONGLE NG CRNT PAST × • Without Intelligent Key system: SEC-
265 K
BCS
BCS-65
PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
WARNING:
ness connectors.
BCS-66
COMBINATION SWITCH SYSTEM SYMPTOMS
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS A
COMBINATION SWITCH SYSTEM SYMPTOMS
B
1. Perform “Data Monitor” of CONSULT-III to check for any malfunctioning item.

2. Check the malfunction combinations. C
Malfunction item: ×
Data monitor item

D
HEAD LAMP SW 1
HEAD LAMP SW 2
RR WASHER SW
AUTO LIGHT SW
FR WASHER SW
TURN SIGNAL R
TURN SIGNAL L
FR WIPER LOW
TAIL LAMP SW
RR WIPER INT
RR WIPER ON
FR WIPER INT
PASSING SW
FR WIPER HI
INT VOLUME
HI BEAM SW
RR FOG SW
FR FOG SW
Malfunction combi-
nation
E
× × × × A F
× × × × B
× × × × C
G
× × × × D
× × × × E
× × × × F H
× × × G
× × × × H
I
× × × × I
× × × × J
Combinations other than those above K J
All Items L
If only one item is detected or the item is not applicable to the combinations A to L M
K
3. Identify the malfunctioning part from the agreed combination and repair or replace the part.
Malfunction
Malfunctioning part Repair or replace L
combination
A Combination switch “INPUT 1” circuit
B Combination switch “INPUT 2” circuit BCS
Inspect the combination switch input circuit applicable to the malfunctioning
C Combination switch “INPUT 3“ circuit
part. Refer to BCS-36, "Diagnosis Procedure".
D Combination switch “INPUT 4” circuit
E Combination switch “INPUT 5” circuit N
F Combination switch “OUTPUT 1” circuit
G Combination switch “OUTPUT 2” circuit
Inspect the combination switch output circuit applicable to the malfunction- O
H Combination switch “OUTPUT 3” circuit
ing part. Refer to BCS-38, "Diagnosis Procedure".
I Combination switch “OUTPUT 4” circuit
J Combination switch “OUTPUT 5” circuit P
Light & turn signal switch or wiper &
K Inspect the combination switch. Refer to BCS-39, "Description".
washer switch
L BCM Replace BCM.
Light & turn signal switch or wiper &
M Replace the applicable switch that cannot be operated.
washer switch
BCS-67
ON-VEHICLE REPAIR
CAUTION:
Before replacing BCM, perform “READ CONFIGURATION” to save or print current vehicle specifica-
tion. Refer to BCS-3, "ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Description".
JSMIA0036ZZ
1. BCM
CAUTION:
Before replacing BCM, perform “READ CONFIGURATION” to save or print current vehicle specifica-
tion. Refer to BCS-3, "ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Description".
REMOVAL
1. Remove glove box assembly. Refer to IP-11, "Exploded View".
2. Remove NAVI control unit (if equipped). Refer to AV-257, "Exploded View".
3. Disconnect 4WD control unit connector (if equipped).
4. Remove BCM bracket mounting screws.
5. Remove BCM and disconnect the connector.
INSTALLATION
CAUTION:
• Be sure to perform “WRITE CONFIGURATION” when replacing BCM.
• Be sure to perform the system initialization (NATS) when replacing BCM.
Refer to BCS-3, "ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Special Repair Require-
ment".
BCS-68
COMBINATION SWITCH
COMBINATION SWITCH
A
JSMIA0037ZZ
1. Wiper & washer switch 2. Switch base (Spiral cable) 3. Light & turn signal switch G
H
Refer to the spiral cable removal and installation SR-7, "Exploded View".
BCS
BCS-69
BRAKES
SECTION
BRAKE SYSTEM
BR B
E
CONTENTS
LHD BRAKE PAD ..............................................................15 BR
BRAKE PAD : Inspection .........................................15
SYMPTOM DIAGNOSIS ............................... 4
DISC ROTOR .............................................................15
G
NOISE, VIBRATION AND HARSHNESS DISC ROTOR : Inspection .......................................15
(NVH) TROUBLESHOOTING ............................. 4
NVH Troubleshooting Chart ...................................... 4
REAR DISC BRAKE ......................................... 16
H
BRAKE PAD ..............................................................16
PRECAUTION ............................................... 5 BRAKE PAD : Inspection .........................................16
PRECAUTIONS ................................................... 5 DISC ROTOR .............................................................16 I
Precaution for Supplemental Restraint System DISC ROTOR : Inspection .......................................16
SIONER" ................................................................... 5 ON-VEHICLE REPAIR ................................. 17
Precaution Necessary for Steering Wheel Rota- J
tion After Battery Disconnect ..................................... 5 BRAKE PEDAL ................................................. 17
Precaution for Procedure without Cowl Top Cover...... 6 Exploded View .........................................................17
Precaution for Brake System .................................... 6 Removal and Installation .........................................17 K
Inspection and Adjustment ......................................18
PREPARATION ............................................ 7
BRAKE PIPING ................................................. 19
PREPARATION ................................................... 7 L
Commercial Service Tool .......................................... 7 FRONT (WITHOUT ESP) ...........................................19
FRONT (WITHOUT ESP) : Exploded View .............19
ON-VEHICLE MAINTENANCE ..................... 8 FRONT (WITHOUT ESP) : Hydraulic Piping ...........20 M
FRONT (WITHOUT ESP) : Removal and Installa-
BRAKE PEDAL ................................................... 8 tion ...........................................................................20
Inspection and Adjustment ........................................ 8 FRONT (WITHOUT ESP) : Inspection ....................21
N
BRAKE FLUID ....................................................11 FRONT (WITH ESP) ..................................................21
Inspection ................................................................ 11 FRONT (WITH ESP) : Exploded View .....................22
Draining ................................................................... 11 FRONT (WITH ESP) : Hydraulic Piping ..................23 O
Refilling ................................................................... 11 FRONT (WITH ESP) : Removal and Installation ....24
Bleeding Brake System ........................................... 12 FRONT (WITH ESP) : Inspection ............................25
BRAKE MASTER CYLINDER ............................13 REAR .........................................................................25 P
Inspection ................................................................ 13 REAR : Exploded View ............................................26
REAR : Hydraulic Piping ..........................................26
BRAKE BOOSTER ............................................14 REAR : Removal and Installation ............................27
Inspection ................................................................ 14 REAR : Inspection ...................................................28
FRONT DISC BRAKE ........................................15 BRAKE MASTER CYLINDER .......................... 29
Exploded View .........................................................29
BR-1
Removal and Installation ........................................ 29 SERVICE DATA AND SPECIFICATIONS
Disassembly and Assembly .................................... 30 (SDS) ................................................................. 52
Inspection ............................................................... 31 General Specifications ............................................ 52
Brake Pedal ............................................................ 52
BRAKE BOOSTER ............................................ 32 Brake Booster ......................................................... 52
Exploded View ........................................................ 32
Front Disc Brake ..................................................... 52
Removal and installation ........................................ 32
Rear Disc Brake ...................................................... 52
Inspection and Adjustment ..................................... 33
RHD
VACUUM LINES ................................................ 35
SYMPTOM DIAGNOSIS ............................ 54
MR20DE .................................................................... 35
MR20DE : Exploded View ...................................... 35 NOISE, VIBRATION AND HARSHNESS
MR20DE : Removal and Installation ....................... 35 (NVH) TROUBLESHOOTING ............................ 54
MR20DE : Inspection .............................................. 35 NVH Troubleshooting Chart .................................... 54
QR25DE .................................................................... 36 PRECAUTION ............................................ 55

QR25DE : Exploded View ...................................... 36
QR25DE : Removal and Installation ....................... 36 PRECAUTIONS ................................................. 55
QR25DE : Inspection .............................................. 37 Precaution for Supplemental Restraint System
M9R ........................................................................... 37 SIONER" ................................................................. 55
M9R : Exploded View ............................................. 38 Precaution Necessary for Steering Wheel Rota-
M9R : Removal and Installation .............................. 38 tion After Battery Disconnect .................................. 55
M9R : Inspection ..................................................... 38 Precaution for Procedure without Cowl Top Cover... 56
Precaution for Brake System .................................. 56
FRONT DISC BRAKE ........................................ 40
PREPARATION .......................................... 57
BRAKE PAD ............................................................. 40
BRAKE PAD : Exploded View ................................ 40 PREPARATION ................................................. 57
BRAKE PAD : Removal and Installation ................. 40 Commercial Service Tool ........................................ 57
BRAKE PAD : Inspection and Adjustment .............. 41
ON-VEHICLE MAINTENANCE .................. 58
BRAKE CALIPER ASSEMBLY ................................ 41
BRAKE CALIPER ASSEMBLY : Exploded View ... 42 BRAKE PEDAL ................................................. 58
BRAKE CALIPER ASSEMBLY : Removal and In- Inspection and Adjustment ...................................... 58
stallation ................................................................. 42
BRAKE CALIPER ASSEMBLY : Disassembly and BRAKE FLUID ................................................... 61
Assembly ................................................................ 43 Inspection ................................................................ 61
BRAKE CALIPER ASSEMBLY : Inspection and Draining ................................................................... 61
Adjustment .............................................................. 44 Refilling ................................................................... 61
Bleeding Brake System ........................................... 62
REAR DISC BRAKE .......................................... 46
BRAKE MASTER CYLINDER ........................... 63
BRAKE PAD ............................................................. 46 Inspection ................................................................ 63
BRAKE PAD : Exploded View ................................ 46
BRAKE PAD : Removal and Installation ................. 46 BRAKE BOOSTER ............................................ 64
BRAKE PAD : Inspection and Adjustment .............. 47 Inspection ................................................................ 64
BRAKE CALIPER ASSEMBLY ................................ 47 FRONT DISC BRAKE ....................................... 65

BRAKE CALIPER ASSEMBLY : Exploded View ... 48
BRAKE CALIPER ASSEMBLY : Removal and In- BRAKE PAD .............................................................. 65
stallation ................................................................. 48 BRAKE PAD : Inspection ........................................ 65
BRAKE CALIPER ASSEMBLY : Disassembly and
DISC ROTOR ............................................................ 65
Assembly ................................................................ 49
DISC ROTOR : Inspection ...................................... 65
BRAKE CALIPER ASSEMBLY : Inspection and
Adjustment .............................................................. 50 REAR DISC BRAKE .......................................... 66
SERVICE DATA AND SPECIFICATIONS BRAKE PAD .............................................................. 66
(SDS) ........................................................... 52 BRAKE PAD : Inspection ........................................ 66
DISC ROTOR ............................................................ 66

DISC ROTOR : Inspection ...................................... 66
BR-2
ON-VEHICLE REPAIR ................................. 67 M9R ............................................................................85
M9R : Exploded View ..............................................85 A
BRAKE PEDAL ..................................................67 M9R : Removal and Installation ...............................85
Exploded View ........................................................ 67 M9R : Inspection ......................................................86
FRONT DISC BRAKE ....................................... 87 B
Inspection and Adjustment ...................................... 68
BRAKE PIPING ..................................................69 BRAKE PAD ..............................................................87

BRAKE PAD : Exploded View .................................87 C
FRONT (WITHOUT ESP) .......................................... 69 BRAKE PAD : Removal and Installation ..................87
FRONT (WITHOUT ESP) : Exploded View ............. 69 BRAKE PAD : Inspection and Adjustment ...............88
FRONT (WITHOUT ESP) : Hydraulic Piping .......... 70
FRONT (WITHOUT ESP) : Removal and Installa- BRAKE CALIPER ASSEMBLY .................................88 D
tion .......................................................................... 70 BRAKE CALIPER ASSEMBLY : Exploded View ....89
FRONT (WITHOUT ESP) : Inspection .................... 71 BRAKE CALIPER ASSEMBLY : Removal and In-
stallation ..................................................................89 E
FRONT (WITH ESP) .................................................. 71 BRAKE CALIPER ASSEMBLY : Disassembly and
FRONT (WITH ESP) : Exploded View .................... 72 Assembly .................................................................90
FRONT (WITH ESP) : Hydraulic Piping .................. 73 BRAKE CALIPER ASSEMBLY : Inspection and
FRONT (WITH ESP) : Removal and Installation .... 73 BR
Adjustment ...............................................................91
FRONT (WITH ESP) : Inspection ............................ 74
REAR DISC BRAKE ......................................... 93
REAR ......................................................................... 74 G
REAR : Exploded View ........................................... 74 BRAKE PAD ..............................................................93
REAR : Hydraulic Piping ......................................... 75 BRAKE PAD : Exploded View .................................93
REAR : Removal and Installation ............................ 75 BRAKE PAD : Removal and Installation ..................93
BRAKE PAD : Inspection and Adjustment ...............94 H
REAR : Inspection ................................................... 76
BRAKE MASTER CYLINDER ............................77 BRAKE CALIPER ASSEMBLY .................................94

Exploded View ........................................................ 77 BRAKE CALIPER ASSEMBLY : Exploded View ....95 I
Removal and Installation ......................................... 77 BRAKE CALIPER ASSEMBLY : Removal and In-
Disassembly and Assembly .................................... 78 stallation ..................................................................95
Inspection ................................................................ 79 BRAKE CALIPER ASSEMBLY : Disassembly and
Assembly .................................................................96 J
BRAKE BOOSTER ............................................80 BRAKE CALIPER ASSEMBLY : Inspection and
Exploded View ........................................................ 80 Adjustment ...............................................................97
Removal and installation ......................................... 80 K
Inspection and Adjustment ...................................... 81 SERVICE DATA AND SPECIFICATIONS
(SDS) ............................................................ 99
VACUUM LINES .................................................83
L
MR20DE ..................................................................... 83 (SDS) ................................................................. 99
MR20DE : Exploded View ....................................... 83
General Specifications .............................................99
MR20DE : Removal and Installation ....................... 83 M
Brake Pedal .............................................................99
MR20DE : Inspection .............................................. 83
Brake Booster ..........................................................99
QR25DE ..................................................................... 84 Front Disc Brake ......................................................99
QR25DE : Exploded View ....................................... 84 Rear Disc Brake ......................................................99 N
QR25DE : Removal and Installation ....................... 84
QR25DE : Inspection .............................................. 85
O
BR-3
Symptom
×: Applicable
Reference page
Possible cause and
BRAKE
SUSPECTED PARTS
Noise
Shake
Shimmy, Judder
NVH Troubleshooting Chart
Pads - damaged BR-15, BR-16
×
SYMPTOM DIAGNOSIS
Pads - uneven wear BR-15, BR-16
×
Shims damaged BR-41, BR-47
×
Rotor imbalance BR-15, BR-16
×
×
Rotor damage BR-15, BR-16
BR-4
Rotor runout BR-15, BR-16
×
Rotor deformation BR-15, BR-16
×
Rotor deflection BR-15, BR-16
×
Rotor rust BR-15, BR-16
×
Rotor thickness variation BR-15, BR-16
×
PROPELLER SHAFT NVH in DLN section
×
×
×
DIFFERENTIAL NHV in DLN section
AXLE AND SUSPENSION NVH in FAX, RAX, FSU and RSU section
×
×
×
TIRE NVH in WT section

×
×
×
Use the chart below to find the cause of the symptom. If necessary, repair or replace these parts.
ROAD WHEEL NVH in WT section

×
×
×
× × DRIVE SHAFT NVH in FAX and/or RAX section
STEERING NVH in ST section

×
×
×
[LHD]
INFOID:0000000001116104
PRECAUTIONS
< PRECAUTION > [LHD]
PRECAUTION A
PRECAUTIONS
WARNING: D
BR
ness connectors.
G
INFOID:0000000001148907
NOTE: H
TEM).
I
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech- J
steering wheel rotation will become impossible. K
OPERATION PROCEDURE L
NOTE:
Supply power using jumper cables if battery is discharged. M
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be N
rotated.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting O
P
BR-5
PRECAUTIONS
< PRECAUTION > [LHD]
PIIB3706J
Precaution for Brake System INFOID:0000000001116107
WARNING:
Clean any dust from the front brake and rear brake with a vacuum dust collector. Never blow with com-
pressed air.
CAUTION:
• Only use “DOT 3” brake fluid. Refer to MA-22, "Fluids and Lubricants".
• Never reuse drained brake fluid.
• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with water if it gets on a painted surface.
• Always clean with new brake fluid when cleaning the master cylinder, brake caliper and other com-
ponents.
• Never use mineral oils such as gasoline or light oil to clean. They may damage rubber parts and
cause improper operation.
• Always loosen the brake tube flare nut with a flare nut wrench.
• Tighten the brake tube flare nut to the specified torque with
flare nut torque wrench (A).
• Always confirm the specified tightening torque when install-
ing the brake pipes.
• Turn the ignition switch OFF and disconnect the ABS actuator
and electric unit (control unit) connector or the battery nega-
tive terminal before performing the work.
• Check that no brake fluid leakage is present after replacing
the parts.
• Burnish the brake contact surfaces after refinishing or replac-
ing rotors, after replacing pads, or if a soft pedal occurs at
JPFIA0061ZZ
very low mileage. Refer to BR-41, "BRAKE PAD : Inspection
and Adjustment" (front brake pad), BR-44, "BRAKE CALIPER ASSEMBLY : Inspection and Adjust-
ment" (front disc rotor), BR-47, "BRAKE PAD : Inspection and Adjustment" (rear brake pad), BR-50,
"BRAKE CALIPER ASSEMBLY : Inspection and Adjustment" (rear disc rotor).
BR-6
PREPARATION
< PREPARATION > [LHD]
PREPARATION A
PREPARATION
Commercial Service Tool INFOID:0000000001116108
B

C
Pin punch Removing and installing reservoir tank D

a: 4 mm (0.16 in) dia. pin
E
NT410
BR
BR-7
BRAKE PEDAL
< ON-VEHICLE MAINTENANCE > [LHD]
BRAKE PEDAL
INSPECTION
Brake Pedal Height
Check the height (H1) between the accelerator pedal stopper (1) and
the brake pedal upper surface.
Standard
Brake pedal height (H1) : Refer to BR-52, "Brake
Pedal".
CAUTION:
Remove the floor trim.
JPFIA0119ZZ
Stop Lamp Switch and/or ASCD Brake Switch (Except For M9R) or Brake Pedal Position Switch (For M9R)
Check the clearance (C) among stopper rubber (1) and stop lamp
switch and/or ASCD brake switch (except for M9R) or brake pedal
position switch (for M9R) (2) threaded end.
Standard
Clearance (C) between stop- : Refer to BR-52, "Brake
per rubber and stop lamp Pedal".
switch and/or ASCD brake
switch (except for M9R) or
brake pedal position switch
JPFIA0122ZZ
(for M9R) threaded end
CAUTION:
The stop lamp must be turned off when the brake pedal is released.
NOTE:
Pull the brake pedal pad to make the clearance between stopper rubber and stop lamp switch and/or ASCD
brake switch (except for M9R) or brake pedal position switch (for M9R) threaded end.
Brake Pedal Play
Press the brake pedal. Check the brake pedal play (A).
Standard
Pedal play (A) : Refer to BR-52, "Brake
Pedal".
JPFIA0121ZZ
Depressed Brake Pedal Height
BR-8
BRAKE PEDAL
Check the height between the accelerator pedal stopper (1) and the
brake pedal upper surface (H2) when depressing the brake pedal at A
490 N (50 kg, 110 lb) while turning engine ON.
Standard B
Depressed brake pedal : Refer to BR-52, "Brake
height (H2) Pedal".
CAUTION: C
JPFIA0120ZZ
D
ADJUSTMENT
Brake Pedal Height
1. Disconnect the stop lamp switch and/or ASCD brake switch (except for M9R) or brake pedal position E
switch (for M9R) harness connector.
2. Turn the stop lamp switch and/or ASCD brake switch (except for M9R) or brake pedal position switch (for
M9R) 45° counterclockwise. BR
3. Loosen the input rod lock nut (1). Adjust the brake pedal to the
specification. Tighten the input rod lock nut to the specification.
Refer to BR-32, "Exploded View". G
CAUTION:
The threaded end of the input rod (2) must project to the
inner side (L) of the clevis (3).
H
I
JPFIA0003ZZ
J
Standard
Pedal". K
JPFIA0119ZZ
M
1. Disconnect the stop lamp switch and/or ASCD brake switch (except for M9R) or brake pedal position N
M9R) 45° counterclockwise.
O
3. Press-fit stop lamp switch and/or ASCD brake switch (except for
M9R) or brake pedal position switch (for M9R) (2) until stop
lamp switch and/or ASCD brake switch (except for M9R) or
brake pedal position switch (for M9R) hits the stopper rubber (1) P
45° clockwise.
CAUTION:
• The clearance (C) between the stopper rubber and stop
lamp switch and/or ASCD brake switch (except for M9R)
or brake pedal position switch (for M9R) threaded end
must be the specified value. Refer to BR-52, "Brake
Pedal".
JPFIA0122ZZ
BR-9
BRAKE PEDAL
• The stop lamp must be turned off when the brake pedal is released.
Brake Pedal Play
1. Disconnect the stop lamp switch and/or ASCD brake switch (except for M9R) or brake pedal position
brake pedal position switch (for M9R) hits the stopper rubber (1)
45° clockwise.
CAUTION:
Pedal".
JPFIA0122ZZ
• The stop lamp must be turned off when the brake pedal is
released.
BR-10
BRAKE FLUID
BRAKE FLUID
A
BRAKE FLUID LEVEL B

• Check that the fluid level in the reservoir tank is within the specified
range (MAX – MIN lines).
• Visually check for any brake fluid leakage around the reservoir C
tank.
• Check the brake system for any leakage if the fluid level is
extremely low (lower than MIN).
• Check the brake system for fluid leakage if the warning lamp D
remains illuminated even after the parking brake is released.
E
JPFIA0007ZZ
BRAKE LINE
BR
1. Check brake line (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged
parts.
2. Check for fluid leakage by fully depressing brake pedal while
G
engine is running.
CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts. H
SBR389C
J
CAUTION: K
• Turn the ignition switch OFF and disconnect the ABS actuator and electric unit (control unit) con-
nector or the battery negative terminal before draining. L
1. Connect a vinyl tube to the bleed valve.
2. Depress the brake pedal and loosen the bleeder valve to gradu-
ally discharge brake fluid. M
O
BRA0007D
Refilling INFOID:0000000001116113 P
CAUTION:
Turn the ignition switch OFF and disconnect the ABS actuator and electric unit (control unit) connec-
tor or the battery negative terminal before refilling.
BR-11
BRAKE FLUID
1. Check that there is no foreign material in the reservoir tank, and
refill with new brake fluid.
CAUTION:
Never reuse drained brake fluid.
2. Loosen the bleeder valve, slowly depress the brake pedal to the
full stroke, and then release the pedal. Repeat this operation at
intervals of 2 or 3 seconds until all brake fluid is discharged.
Then close the bleeder valve with the brake pedal depressed.
Repeat the same work on each wheel.
3. Perform the air bleeding. Refer to BR-12, "Bleeding Brake Sys-
tem". PFIA0403J
Bleeding Brake System INFOID:0000000001116114
CAUTION:
nector or the battery negative terminal before performing the work.
• Monitor the fluid level in the reservoir tank during the air bleeding.
• Always use new brake fluid for refilling. Never reuse the drained brake fluid.
1. Connect a vinyl tube to the bleeder valve of the rear right brake.
2. Fully depress the brake pedal 4 to 5 times.
3. Loosen the bleeder valve and bleed air with the brake pedal depressed, and then quickly tighten the
bleeder valve.
4. Repeat steps 2 and 3 until all of the air is out of the brake line.
5. Tighten the bleeder valve to the specified torque. Refer to BR-42, "BRAKE CALIPER ASSEMBLY :
Exploded View" (front disc brake), BR-48, "BRAKE CALIPER ASSEMBLY : Exploded View" (rear disc
brake).
6. Perform steps 1 to 5 for the rear right brake → front left brake → rear left brake → and front right brake in
order.
7. Check that the fluid level in the reservoir tank is within the specified range after air bleeding. Refer to BR-
11, "Inspection".
BR-12
BRAKE MASTER CYLINDER
A
FLUID LEAK B
Check for brake fluid leakage from the master cylinder mounting face, reservoir tank mounting face and brake
tube connections.
C
BR
BR-13
BRAKE BOOSTER
BRAKE BOOSTER
OPERATION
Depress the brake pedal several times at 5-second intervals with the
engine stopped. Start the engine with the brake pedal fully
depressed. Check that the clearance between brake pedal and dash
lower panel decreases.
NOTE:
A slight impact with a small click may be felt on the pedal when the
brake pedal is fully depressed. This is a normal phenomenon due to
the brake system operation.
BRA0037D
AIR TIGHT
• Idle the engine for 1 minute to apply vacuum to the brake booster,
and stop the engine. Then depress the brake pedal several times
at 5-second intervals until the accumulated vacuum is released to
atmospheric pressure. Check that the clearance between brake
pedal and dash lower panel gradually increases (A → B → C) each
time the brake pedal is depressed during this operation.
JPFIA0043ZZ
• Depress the brake pedal with the engine running. Then stop the
engine while holding down the brake pedal. Check that the brake
pedal stroke does not change after holding down the brake pedal
for 30 seconds or more.
NOTE:
brake pedal is fully depressed. This is a normal phenomenon due
to the brake system operation.
JPFIA0044ZZ
BR-14
FRONT DISC BRAKE
FRONT DISC BRAKE
A
BRAKE PAD
BRAKE PAD : Inspection INFOID:0000000001116120
B
PAD WEAR
Check pad thickness from an inspection hole on cylinder body.
Check using a scale if necessary. C
Standard thickness : Refer to BR-52, "Front

Disc Brake". D
Wear limit thickness : Refer to BR-52, "Front

Disc Brake". E
BRA0010D
BR
DISC ROTOR
DISC ROTOR : Inspection INFOID:0000000001116121
G
APPEARANCE
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace if there are.
H
RUNOUT
1. Fix the disc rotor to the wheel hub and bearing assembly with
wheel nuts (2 points at least). I
2. Inspect the runout with a dial gauge. [Measured at 10 mm (0.39
in) inside the disc edge.]
J
Runout limit : Refer to BR-52, "Front
Disc Brake".
NOTE: K
Check the wheel bearing axial end play before the inspection.
Refer to FAX-7, "Inspection" (2WD), FAX-40, "Inspection"
SBR019B
(4WD).
L
3. Find the installation position with a minimum runout by shifting the disc rotor-to-wheel hub and bearing
assembly installation position by one hole at a time if the runout exceeds the limit value.
4. Replace or lathe the disc rotor if the runout exceeds the limit even after the above operation.
M
THICKNESS
Check the thickness of the disc rotor using a micrometer. Replace
the disc rotor if the thickness is below the wear limit. N

Disc Brake".
O
SBR020B
BR-15
REAR DISC BRAKE
REAR DISC BRAKE
BRAKE PAD
PAD WEAR
Check using a scale if necessary.
Standard thickness : Refer to BR-52, "Rear

Disc Brake".
Wear limit thickness : Refer to BR-52, "Rear

Disc Brake".
BRA0010D
DISC ROTOR
APPEARANCE
RUNOUT
wheel nuts (2 points at least).
in) inside disc edge.]
Runout limit : Refer to BR-52, "Rear

Disc Brake".
NOTE:
SBR019B
(4WD).
THICKNESS
the disc rotor if the thickness is below the wear limit.

Disc Brake".
SBR020B
BR-16
BRAKE PEDAL
< ON-VEHICLE REPAIR > [LHD]
ON-VEHICLE REPAIR A
BRAKE PEDAL
B
BR
JPFIA0123GB J
1. Clevis pin 2. Brake pedal assembly 3. Brake pedal pad

4. Brake switch (with ESP)*1 *2 5. Stop lamp switch 6. Clip
K
7. Snap pin
*1: ASCD brake switch (except for M9R)
*2: Brake pedal position switch (for M9R) L
: Apply multi-purpose grease.
M
REMOVAL
N
1. Remove instrument driver lower panel. Refer to IP-11, "Exploded View".
2. Remove foot duct. Refer to VTL-43, "FOOT DUCTS : Exploded View".
3. Remove mode door motor. Refer to VTL-25, "Exploded View". O
switch (for M9R) harness connectors.
5. Disconnect accelerator pedal position sensor harness connector. P
6. Remove steering member stay.
7. Remove snap pin and clevis pin from clevis of brake booster.
8. Remove the brake pedal assembly and the accelerator pedal.
9. Remove the accelerator pedal from brake pedal assembly. Refer to ACC-3, "Exploded View".
INSTALLATION
Note the following, and installation is the reverse order of removal.
BR-17
BRAKE PEDAL
• Apply the multi-purpose grease to the clevis pin and the mating faces. (Not necessary if grease has been
already applied.)
NOTE:
The clevis pin may be inserted in either direction.

• Check the following items and replace the brake pedal assembly if
necessary.
- Check the brake pedal upper rivet (A) for deformation.
- Check the brake pedal for bend, damage, and cracks on the
welded parts.
- Check the lapping length (X) of sub-bracket (B) and slide plate (C).
Standard
Lapping length : 5.0 – 6.0 mm (0.197 – 0.236 in)
PFIA0755J
• Check clevis pin and plastic stopper (A) for damage and deforma-
tion. If any is found, replace clevis pin.
PFIA0756J
ADJUSTMENT AFTER INSTALLATION

• Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-8, "Inspection
and Adjustment".
• Perform the accelerator pedal check after installing the accelerator pedal. Refer to ACC-4, "Inspection".
BR-18
BRAKE PIPING
BRAKE PIPING
A
FRONT (WITHOUT ESP)
FRONT (WITHOUT ESP) : Exploded View INFOID:0000000001116128
B
BR
JPFIA0142GB
K
1. Brake tube 2. ABS actuator and electric unit (con- 3. Connector
trol unit)
4. Connector bracket 5. Master cylinder assembly 6. Brake booster L
7. Lock plate 8. Brake hose 9. Union bolt
A. To front brake hose B. To rear brake tube
BR-19
BRAKE PIPING
FRONT (WITHOUT ESP) : Hydraulic Piping INFOID:0000000001116129
JPFIA0078ZZ
1. ABS actuator and electric unit (con- 2. Front disc brake 3. Master cylinder assembly
trol unit)
4. Brake booster 5. Connector 6. Rear disc brake
A. Brake tube B. Brake hose
: Flare nut
: Union bolt
: Connector
FRONT (WITHOUT ESP) : Removal and Installation INFOID:0000000001116130
REMOVAL
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
1. Remove tires.
2. Drain brake fluid. Refer to BR-11, "Draining".
3. Loosen the flare nut with a flare nut wrench and separate the brake tube from the hose.
CAUTION:
• Never scratch the flare nut and the brake tube.
• Never bend sharply, twist or strongly pull out the brake hoses and tubes.
• Cover open end of brake tubes and hoses when disconnecting to prevent entrance of dirt.
4. Remove the union bolt and remove the brake hose from the brake caliper assembly.
5. Remove the lock plate and remove the brake hose.
INSTALLATION
CAUTION:
1. Assemble the union bolt and the copper washer to the brake hose.
CAUTION:
Never reuse the copper washer.
BR-20
BRAKE PIPING
2. Align the brake hose pin to the projection (A) of the brake caliper
assembly and tighten the union bolt (1) to the specified torque. A
3. Install the brake tube to the brake hose, temporarily tighten the
flare nut by hand until it does not rotate further, and fix the brake
hose to the bracket with the lock plate. B
CAUTION:
Check that all brake hoses and tubes are not twisted and
bent.
C
4. Tighten the flare nut to the specified torque with a flare nut
torque wrench.
CAUTION: JPFIA0099ZZ
Never scratch the flare nut and the brake tube. D

5. Refill with new brake fluid and perform the air bleeding. Refer to BR-12, "Bleeding Brake System".
CAUTION:
Never reuse drained brake fluid. E
6. Install tires.
FRONT (WITHOUT ESP) : Inspection INFOID:0000000001116131
BR
INSPECTION AFTER INSTALLATOIN
1. Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no interfer- G
ence with other components when steering the steering wheel; no looseness at connections.
2. Depress the brake pedal with a force of 785 N (80 kg, 176 lb) and hold down the pedal for approximately
5 seconds with the engine running. Check for any fluid leakage.
H
CAUTION:
Retighten the applicable connection to the specified torque and repair any abnormal (damaged,
worn or deformed) part if any brake fluid leakage is present.
FRONT (WITH ESP) I
BR-21
BRAKE PIPING
FRONT (WITH ESP) : Exploded View INFOID:0000000001116132
MR20DE AND QR25DE
JPFIA0124GB
1. Brake tube 2. Connector 3. Pressure sensor

4. ABS actuator and electric unit (con- 5. Connector bracket 6. Master cylinder assembly
trol unit)
7. Brake booster 8. Lock plate 9. Brake hose
10. Union bolt
BR-22
BRAKE PIPING
M9R
A
BR
I
JPFIA0143GB
1. Brake tube 2. ABS actuator and electric unit (con- 3. Connector

trol unit) J
4. Connector bracket 5. Master cylinder assembly 6. Brake booster
A. To front brake hose B. To rear brake tube K
FRONT (WITH ESP) : Hydraulic Piping INFOID:0000000001125471 L
MR20DE AND QR25DE

M
JPFIA0125ZZ
BR-23
BRAKE PIPING
trol unit)
: Flare nut
: Union bolt
: Connector
M9R
JPFIA0078ZZ
trol unit)
: Flare nut
: Union bolt
: Connector
FRONT (WITH ESP) : Removal and Installation INFOID:0000000001125472
REMOVAL
CAUTION:
1. Remove tires.
CAUTION:
INSTALLATION
CAUTION:
BR-24
BRAKE PIPING
CAUTION: A
assembly and tighten the union bolt (1) to the specified torque. B
hose to the bracket with the lock plate.
C
CAUTION:
bent.
4. Tighten the flare nut to the specified torque with a flare nut D
torque wrench.
Never scratch the flare nut and the brake tube. E

CAUTION:
Never reuse drained brake fluid. BR
6. Install tires.
FRONT (WITH ESP) : Inspection INFOID:0000000001125778
G
1. Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no interfer-
H
CAUTION: I
REAR J
BR-25
BRAKE PIPING
REAR : Exploded View INFOID:0000000001116136
JPFIA0149GB
1. Brake tube 2. Lock plate 3. Brake hose

4. Brake hose bracket 5. Union bolt
A. To front brake tube B. To rear brake hose C. Floor side
D. Caliper side
REAR : Hydraulic Piping INFOID:0000000001116137
MR20DE (WITHOUT ESP), QR25DE (WITHOUT ESP) AND M9R
JPFIA0078ZZ
BR-26
BRAKE PIPING
1. ABS actuator and electric unit (con- 2. Front disc brake 3. Master cylinder assembly A
trol unit)
B
: Flare nut
: Union bolt
: Connector
C
MR20DE (WITH ESP) AND QR25DE (WITH ESP)

D
BR
JPFIA0125ZZ
I
trol unit)
4. Brake booster 5. Connector 6. Rear disc brake J
: Flare nut
K
: Union bolt
: Connector
L
REAR : Removal and Installation INFOID:0000000001116138
REMOVAL M
CAUTION:
N
1. Remove tires.
O
CAUTION:
• Never sharply bend, twist or strongly pull the brake hoses and tubes.
• Cover the open end of brake tubes and hoses when disconnecting to prevent entrance of dirt. P
5. Remove the lock plate and remove the brake hose from the vehicle.
INSTALLATION
CAUTION:
BR-27
BRAKE PIPING
CAUTION:
Never reuse copper washer.
2. Install the brake hose L-pin by aligning it with the brake caliper
assembly positioning hole, and tighten the union bolt (1) to the
specified torque.
3. Connect the hose to the brake tube, temporarily tighten the flare
nut by hand until it does not rotate further, and fix the brake hose
to the bracket with the lock plate.
CAUTION:
Check that the brake hoses and tubes are not twisted and
bent.
torque wrench. JPFIA0012ZZ
CAUTION:
Never scratch the flare nut and the brake tube.
CAUTION:
6. Install tires.
REAR : Inspection INFOID:0000000001125779

CAUTION:
BR-28
A
BR
I
JPFIA0126GB
1. Reservoir cap 2. Oil strainer 3. Reservoir tank J

4. Cylinder body 5. Pin 6. O-ring
7. Grommet
: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease. K
: Apply brake fluid.

L
REMOVAL M
CAUTION:
off immediately and wash with water if it gets on a painted surface. N
1. Remove battery and bracket.
2. Remove air duct and air cleaner case. Refer to EM-25, "Exploded View" (MR20DE), EM-150, "Exploded
View" (QR25DE), EM-263, "Exploded View" (M9R). O
4. Separate the brake fluid level switch harness connector.
5. Separate the brake tubes from the master cylinder assembly with a flare nut wrench. P
CAUTION:
6. Remove the master cylinder assembly.
CAUTION:
• Depress the brake pedal several times to release the vacuum pressure from the brake booster.
Then remove the master cylinder assembly.
• Never depress the brake pedal after the master cylinder assembly is removed.
BR-29
• The piston of the master cylinder assembly is exposed. Never damage it when removing the
master cylinder.
• The piston may drop off when pulled out strongly. Never hold the piston. Hold the cylinder body
when handling the master cylinder assembly.
INSTALLATION
CAUTION:
• Note the following, and installation is the reverse order of removal.
CAUTION:
• Apply PBC (Poly Butyl Cuprysil) silicone-based grease to
the brake booster [see (A) in the figure] when installing the
master cylinder assembly to the brake booster.
• The piston of the master cylinder assembly is exposed.
Never damage it when handling the master cylinder and
check that no dirt and dust are present on the piston before
installation. Clean it with new brake fluid if necessary.
• The piston may drop off when pulled strongly. Never hold
the piston. Hold the cylinder body when handling the master
cylinder assembly.
• Temporarily tighten the brake tube flare nut to the master cylinder
JPFIA0013ZZ
assembly by hand. Then tighten it to the specified torque with a
flare nut torque wrench. Refer to BR-19, "FRONT (WITHOUT ESP) : Exploded View" (without ESP), BR-22,
"FRONT (WITH ESP) : Exploded View" (with ESP).
CAUTION:
• After installation, perform the air bleeding. Refer to BR-12, "Bleeding Brake System".
CAUTION:
DISASSEMBLY
CAUTION:
• Never disassemble the cylinder body.
• Remove the reservoir tank if necessary.
1. Fix the master cylinder assembly to a vise.
CAUTION:
Always set copper plates or cloth between vise when fixing the cylinder body to a vise. Never
overtighten the vise.
2. Remove the reservoir tank mounting pin with a pin punch.
3. Remove the reservoir tank and grommet from the cylinder body.
CAUTION:
Never drop the removed parts. The parts must not be
reused if they are dropped.
JPFIA0015ZZ
ASSEMBLY
1. Apply new brake fluid to the grommet and install it to the cylinder body.
CAUTION:
• Never use mineral oil such as gasoline or light oil.
• Never reuse the grommets.
2. Install the reservoir tank to the cylinder body.
BR-30
CAUTION:
• Never drop the parts when installing. The parts must not be reused if they are dropped. A
• Never reuse reservoir tank.
3. Fix the cylinder body to a vise.
CAUTION: B
• Place the reservoir tank with the chamfered pin hole ( )
facing up.
• Always set copper plates or cloth between vise when fix-
ing the cylinder body to a vise. Never overtighten the vise. C
JPFIA0016ZZ
E
4. Tilt the reservoir tank so that a mounting pin can be inserted.
Insert a mounting pin. Return the reservoir tank to the horizontal
position. Insert another mounting pin into the pin hole on the BR
opposite side in the same manner after the mounting pin passes
through the cylinder body pin hole.
CAUTION:
Never reuse the mounting pin. G
H
JPFIA0015ZZ
I

Fluid Leak J
Check for brake fluid leakage from the cylinder body-to-brake booster mounting face, reservoir tank mounting
face and brake tube connections.
K
BR-31
BRAKE BOOSTER
BRAKE BOOSTER
JPFIA0082GB
1. Master cylinder assembly 2. Brake booster 3. Lock nut

4. Gasket 5. Spacer
Removal and installation INFOID:0000000001116145
REMOVAL
1. Remove battery and bracket.
2. Remove air duct and air cleaner case. Refer to EM-25, "Exploded View" (MR20DE), EM-150, "Exploded
View" (QR25DE), EM-263, "Exploded View" (M9R).
3. Remove brake master cylinder assembly. Refer to BR-29, "Removal and Installation".
CAUTION:
master cylinder.
4. Remove vacuum hose from brake booster. Refer to BR-35, "MR20DE : Exploded View" (MR20DE), BR-
36, "QR25DE : Exploded View" (QR25DE), BR-38, "M9R : Exploded View" (M9R).
5. Remove snap pin (1) and clevis pin (2) from inside vehicle.
6. Remove nuts on brake booster and brake pedal assembly. Refer
to BR-17, "Exploded View".
7. Remove brake booster from dash panel in engine room side.
CAUTION:
Never deform or bend the brake tubes.
8. Remove the spacer from brake booster.
JPFIA0019ZZ
INSTALLATION
BR-32
BRAKE BOOSTER
CAUTION:
• Be careful not to damage brake booster stud bolt threads. If brake booster is tilted during installa- A
tion, the dash panel may damage the threads.
• Never deform or bend the brake tubes when installing the brake booster.
• Always use a new gasket between the brake booster and the spacer.
B
• Replace the clevis pin if it is damaged. Refer to BR-18, "Inspection and Adjustment".
CAUTION:
Never reuse drained brake fluid. C
D
Output Rod Length Inspection
1. With a handy vacuum pump, apply vacuum pressure of −66.7 E
kPa (−500 mmHg, −19.70 inHg, −0.667 bar) to the brake
booster.
2. Check the output rod length (A). BR
Standard
Output rod length (A) : Refer to BR-52, "Brake G
Booster".
JPFIA0021ZZ H
Input Rod Length Inspection
1. Loosen the lock nut (1) and adjust the input rod (2) to the speci-
I
fied length (B).
Standard
J
Input rod length (B) : Refer to BR-52, "Brake
Booster".
2. Tighten the lock nut to the specified torque. K
JPFIA0020ZZ
L
Operation
M
lower pane decreases. N
NOTE:
O
P
BRA0037D
Air Tight
BR-33
BRAKE BOOSTER
JPFIA0043ZZ
NOTE:
JPFIA0044ZZ
ADJUSTMENT AFTER INSTALLTION

Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-8, "Inspection and
Adjustment".
BR-34
VACUUM LINES
VACUUM LINES
A
MR20DE
MR20DE : Exploded View INFOID:0000000001116147
B
BR
JPFIA0144ZZ
H
1. Clamp 2. Vacuum hose 3. Vacuum tube
4. Clip 5. Vacuum hose (built in check valve)
A. To intake manifold B. To brake booster C. Paint mark
I
D. Stamp indicating engine direction
MR20DE : Removal and Installation INFOID:0000000001116148

J
REMOVAL
K
2. Remove the vacuum hose and tube.
INSTALLATION
Note the following, and installation is the reverse order of removal. L
CAUTION:
• Because vacuum hose contains a check valve, it must be
installed in the correct position. Refer to the stamp to confirm
M
correct installation. Brake booster will not operate normally if
the hose is installed in the wrong direction.
• Insert vacuum hose at least 24 mm (0.94 in) (A).
• Never use lubricating oil during assembly. N
• Face the marking side up when assembling of vacuum hose.
• Face the marking side vehicle front when assembling of vac-
uum hose (built in check valve).
O
JPFIA0023ZZ
MR20DE : Inspection INFOID:0000000001116149 P

Appearance
Check for correct assembly, damage and deterioration.
Check Valve Airtightness
BR-35
VACUUM LINES
• Use a handy vacuum pump (A) to check.
When connected to the brake booster side (B):

Vacuum should decrease within 1.3 kPa (10 mm-
Hg, 0.39 inHg, 0.013 bar) for 15 seconds under a
vacuum of −66.7 kPa (−500 mmHg, −19.70 inHg, −
0.667 bar).
When connected to the engine side (C):
Vacuum should not exist.
JPFIA0024ZZ
• Replace vacuum hose assembly if vacuum hose and check valve
are malfunctioning.
QR25DE
QR25DE : Exploded View INFOID:0000000001116308
JPFIA0127ZZ
1. Clamp 2. Vacuum hose 3. Vacuum tube

4. Clip 5. Vacuum hose (built in check valve)
QR25DE : Removal and Installation INFOID:0000000001116309
REMOVAL
Remove the vacuum hose and tube.
INSTALLATION
Install the vacuum hose and tube.
CAUTION:
BR-36
VACUUM LINES
installed in the correct position. Refer to the stamp to confirm A
B
• Never use lubricating oil during assembly.
uum hose (built in check valve). C
JPFIA0023ZZ
D
QR25DE : Inspection INFOID:0000000001125780
INSPECTION AFTER REMOVAL E

Appearance
Check Valve Airtightness BR
When connected to the brake booster side (B): G

vacuum of −66.7 kPa (−500 mmHg, −19.70 inHg, − H
0.667 bar).
Vacuum should not exist. I
JPFIA0024ZZ
are malfunctioning.
J
M9R
BR-37
VACUUM LINES
M9R : Exploded View INFOID:0000000001116150
JPFIA0147ZZ
1. Vacuum hose (built in check valve) 2. Clip 3. Clamp

4. Vacuum hose connector
A. Stamp indicating engine direction B. Paint mark C. To vacuum pump
D. To brake booster
M9R : Removal and Installation INFOID:0000000001116151
REMOVAL
2. Remove the vacuum hose.
INSTALLATION
CAUTION:
• Face the marking side up when assembling (vacuum pump
side).
• Face the marking side vehicle front when assembling (brake
booster side).
JPFIA0023ZZ
M9R : Inspection INFOID:0000000001125781
BR-38
VACUUM LINES
Appearance
Check for correct assembly, damage and deterioration. A
B
Hg, 0.39 inHg, 0.013 bar) for 15 seconds under a C
0.667 bar).
When connected to the engine side (C): D
JPFIA0024ZZ
• Replace vacuum hose assembly if vacuum hose and check valve E
are malfunctioning.
BR
BR-39
FRONT DISC BRAKE
FRONT DISC BRAKE
BRAKE PAD
BRAKE PAD : Exploded View INFOID:0000000001127959
JPFIA0090GB
1. Brake hose 2. Union bolt 3. Copper washer

4. Cap 5. Bleeder valve 6. Cylinder body
7. Sliding pin 8. Sliding pin boot 9. Bushing
16. Inner pad 17. Pad retainer 18. Outer pad
19. Outer shim 20. Outer shim cover
1: Apply rubber grease.
2: Apply copper based brake grease.

BRAKE PAD : Removal and Installation INFOID:0000000001116154
REMOVAL
WARNING:
Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with
compressed air.
CAUTION:
• Never depress the brake pedal while removing the brake pads because the piston may pop out.
• Never spill or splash brake fluid on the disc rotor.
1. Remove tires.
2. Remove lower sliding pin bolt.
3. Suspend the cylinder body with suitable wire so that the brake hose will not stretch. Then remove the
brake pad from the torque member.
CAUTION:
• Never deform the pad retainer when removing the pad retainer from the torque member.
• Never damage the piston boot.
• Never drop the brake pads, shims, and the shim covers.
INSTALLATION
BR-40
FRONT DISC BRAKE
WARNING:
Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with A
compressed air.
CAUTION:
• Never depress the brake pedal while removing the brake pads or the cylinder body because the pis-
B
ton may pop out.
1. Install the pad retainer to the torque member if the pad retainers has been removed.
CAUTION: C
• Securely assemble the pad retainers so that it will not be lifted up from the torque member.
• Never deform the pad retainers.
2. Apply copper based brake grease to the mating faces between the pads, shims and shim covers, and D
install them to the brake pad.
CAUTION:
Always replace the shims together with the shim covers when replacing the brake pad. E
3. Install the cylinder body and brake pads to the torque member.
CAUTION:
• When replacing a pad with new one, check a brake fluid level in the reservoir tank because brake BR
fluid returns to master cylinder reservoir tank when pressing piston in.
NOTE:
Use a disc brake piston tool to easily press piston. G
4. Install the lower sliding pin bolt and tighten it to the specified torque.
5. Depress the brake pedal several times to check that no drag feel is present for the front disc brake.
6. Install tires. H
BRAKE PAD : Inspection and Adjustment INFOID:0000000001116155
I
Replace the shims and the shim covers if rust is excessively attached.
ADJUSTMENT AFTER INSTALLATION J
Brake Burnishing Procedure
Burnish contact surfaces between pads according to following procedure after refinishing or replacing pads, or
if a soft pedal occurs at very low mileage. K
CAUTION:
• Be careful of vehicle speed because the brake does not operate easily until pads and disc rotor are
securely fitted. L
• Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive vehicle on straight, flat road.
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops. M
3. Drive without depressing brake for a few minutes to cool the brake.
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted.
N
BRAKE CALIPER ASSEMBLY
BR-41
FRONT DISC BRAKE
BRAKE CALIPER ASSEMBLY : Exploded View INFOID:0000000001116156
JPFIA0090GB


BRAKE CALIPER ASSEMBLY : Removal and Installation INFOID:0000000001116157
REMOVAL
WARNING:
compressed air.
CAUTION:
Never depress the brake pedal. Brake fluid may splash while removing the brake hose.
1. Remove tires.
2. Fix the disc rotor using wheel nuts.
CAUTION:
Never spill or splash brake fluid on the disc rotor.
4. Remove union bolt, and then disconnect brake hose from caliper assembly.
BR-42
FRONT DISC BRAKE
5. Remove torque member mounting bolts, and remove brake cali-
per assembly. A
CAUTION:
Never drop brake pads and caliper assembly.
6. Remove disc rotor. B
CAUTION:
• Put matching marks on the wheel hub and bearing assem-
bly and the disc rotor before removing the disc rotor.
• Never drop disc rotor. C
JPFIA0030ZZ
D
INSTALLATION
WARNING:
E
compressed air.
CAUTION:
1. Install disc rotor. BR
CAUTION:
Align the matching marks made during removal when reusing the disc rotor.
2. Install the brake caliper assembly to the vehicle and tighten the torque member mounting bolts to the G
specified torque.
CAUTION:
Never spill or splash any grease and moisture on the brake caliper assembly mounting face, H
threads, mounting bolts and washers. Wipe out any grease and moisture.
3. Install brake hose to brake caliper assembly, and tighten union bolts to the specified torque.
4. Refill with new brake fluid and perform the air bleeding. Refer to BR-12, "Bleeding Brake System". I
CAUTION:
J
5. Check that no drag feel is present for the front disc brake.
6. Install tires.
BRAKE CALIPER ASSEMBLY : Disassembly and Assembly INFOID:0000000001116158 K
DISASSEMBLY
NOTE: L
Never remove the torque member, brake pads, shims, shim covers and pad retainers when disassembling and
assembling the cylinder body.
1. Remove the sliding pin bolts, and remove the cylinder body from the torque member. M
CAUTION:
Never drop pads, shims, shim covers and pad retainers from torque member.
2. Remove sliding pins and sliding pin boots from torque member. N
3. Remove bushing from sliding pin.
4. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove piston and piston boot. O
CAUTION:
Never get fingers caught in the piston.
P
MAA0272D
BR-43
FRONT DISC BRAKE
5. Remove piston seal from cylinder body using suitable tool.
CAUTION:
Be careful not to damage a cylinder inner wall.
JPFIA0038ZZ
ASSEMBLY
1. Apply rubber grease to piston seal (1), and install to cylinder
body.
CAUTION:
Never reuse piston seal.
JPFIA0039ZZ
2. Apply rubber grease to piston boot (1). Cover the piston (2) end
with piston boot, and then install cylinder side lip on piston boot
securely into a groove on cylinder body.
CAUTION:
Never reuse piston boot.
JPFIA0040ZZ
3. Apply brake fluid to piston (1). Push piston into cylinder body by
hand and push piston boot (2) piston-side lip into the piston
groove.
CAUTION:
Press the piston evenly and vary the pressing point to pre-
vent cylinder inner wall from being rubbed.
4. Apply rubber grease to bushing, install bushing to sliding pin.
5. Apply rubber grease to sliding pins and sliding pin boots, install
sliding pins and sliding pin boots to torque member.
6. Install the cylinder body to the torque member and tighten the
sliding pin bolts to the specified torque. JPFIA0034ZZ
BRAKE CALIPER ASSEMBLY : Inspection and Adjustment INFOID:0000000001116159

Cylinder Body
Check the inner wall of the cylinder for rust, wear, cracks or damage. Replace the cylinder if any abnormal
condition is detected.
CAUTION:
Always clean with new brake fluid. Never clean with mineral oil such as gasoline and light oil.
BR-44
FRONT DISC BRAKE
Torque Member
Check the torque member for rust, wear, cracks or damage. Replace the member if any abnormal condition is A
detected.
Piston
Check the surface of the piston for rust, wear, cracks or damage. Replace the piston if any abnormal condition B
is detected.
CAUTION:
A piston sliding surface is plated. Never polish with sandpaper. C
Sliding Pin and Sliding Pin Boot
Check the sliding pins and sliding boots for rust, wear, cracks or damage. Replace the parts if any abnormal
condition is detected. D
E
Burnish contact surfaces between disc rotors and pads according to following procedure after refinishing or
replacing disc rotor, or if a soft pedal occurs at very low mileage.
CAUTION:
• Be careful of vehicle speed because the brake does not operate easily until pad and disc rotor are BR
securely fitted.
1. Drive vehicle on straight, flat road. G
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops.
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted. H
BR-45
REAR DISC BRAKE
REAR DISC BRAKE
BRAKE PAD
JPFIA0129GB

4. Cap 5. Bleeder valve 6. Sliding pin bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Retaining ring 12. Sliding pin boot
13. Bushing 14. Torque member 15. Inner shim cover
16. Inner shim 17. Inner pad 18. Pad wear sensor (RH inner pad
only)
19. Pad retainer 20. Outer pad 21. Outer shim
3: Apply polyglycol ether based lubricant.

REMOVAL
WARNING:
compressed air.
CAUTION:
ton may pop out.
BR-46
REAR DISC BRAKE
1. Remove tires.
2. Remove the lower sliding pin bolt. A
3. Suspend the cylinder body with suitable wire so that the brake hose will not stretch. Remove the brake
pads from the torque member.
CAUTION: B
• Never deform the pad retainers if removing the pad retainers.
• Never drop the brake pad, shims, and the shim covers.
C
INSTALLATION
WARNING:
Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with D
compressed air.
CAUTION:
• Never depress the brake pedal while removing the brake pads or the cylinder body because the pis- E
ton may pop out.
1. Install the pad retainers to the torque member if the pad retainers has been removed.
CAUTION: BR
• Securely assemble the pad retainers not to be lifted up from the torque member.
2. Apply copper based brake grease to the mating faces between the brake pads, the shims and pawls part G
of cylinder body, and install them to the brake pad.
CAUTION:
Always replace the shims together with the shim covers when replacing the brake pad. H
3. Install cylinder body and brake pads to torque member.
CAUTION:
I
• When replacing a pads with new one, check a brake fluid level in the reservoir tank because
brake fluid returns to master cylinder reservoir tank when pressing piston in.
NOTE:
Use a disc brake piston tool to easily press piston. J
5. Depress the brake pedal several times to check that no drag feel is present for the rear disc brake.
6. Install tires. K
L
ADJUSTMENT AFTER INSTALLATION M

if a soft pedal occurs at very low mileage. N
CAUTION:
• Be careful of vehicle speed because the brake does not operate easily until pad and disc rotor are
securely fitted. O
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops. P
BR-47
REAR DISC BRAKE
JPFIA0129GB

7. Cylinder body 8. Piston seal 9. Piston
16. Inner shim 17. Inner pad 18. Pad wear sensor (RH inner pad
only)

REMOVAL
WARNING:
compressed air.
CAUTION:
1. Remove tires.
CAUTION:
BR-48
REAR DISC BRAKE
4. Remove union bolt (1) and then disconnect brake hose (2) from
caliper assembly. A
per assembly.
CAUTION: B
6. Remove disc rotor.
CAUTION:
C
• Never drop disc rotor. JPFIA0036ZZ
D
INSTALLATION
WARNING:
Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with E
compressed air.
CAUTION:
1. Install disc rotor. BR
CAUTION:
2. Install the brake caliper assembly to the vehicle and tighten the torque member mounting bolts to the G
specified torque.
CAUTION:
Never spill or splash any grease and moisture on the brake caliper assembly mounting face, H
threads, mounting bolts, and washers. Wipe out any grease and moisture.
4. Refill with new brake fluid and perform the air bleeding. Refer to BR-12, "Bleeding Brake System". I
CAUTION:
J
5. Check that no drag feel is present for the rear disc brake.
6. Install tires.
BRAKE CALIPER ASSEMBLY : Disassembly and Assembly INFOID:0000000001116165 K
DISASSEMBLY
NOTE: L
Never remove the torque member, brake pads, shims, shim covers and pad retainers disassembling and
1. Remove the sliding pin bolts and remove the cylinder body from the torque member. M
CAUTION:
2. Remove sliding pin boots from torque member. N
3. Remove bushing from sliding pin bolt.
union bolt mounting hole to remove piston and piston boot. O
CAUTION:
P
BRD0041D
BR-49
REAR DISC BRAKE
CAUTION:
JPFIA0038ZZ
ASSEMBLY
1. Apply polyglycol ether based lubricant to piston seal (1), and
install to cylinder body.
CAUTION:
JPFIA0039ZZ
with the piston boot, and then install cylinder side lip on the pis-
ton boot securely into the groove on cylinder body.
CAUTION:
JPFIA0040ZZ
3. Apply brake fluid to piston (1). Push piston into cylinder body by
hand and push piston boot (2) piston side lip into the piston
groove.
CAUTION:
Press the piston evenly and vary the pressing point to pre-
4. Apply polyglycol ether based lubricant to bushing, install bush-
ing to sliding pin bolt.
5. Apply rubber grease to the sliding pin bolts and the sliding pin
boots, install sliding pin boot to torque member.
6. Install the cylinder body to the torque member and tighten the JPFIA0041ZZ
sliding pin bolts to the specified torque.


Cylinder Body
CAUTION:
BR-50
REAR DISC BRAKE
Torque Member
Check the torque member for rust, wear, cracks or damage. Replace the member if any abnormal condition is A
detected.
Piston
Check the piston for rust, wear, cracks or damage. Replace the piston if any abnormal condition is detected. B
CAUTION:
A piston sliding surface is plated. Never polish with sandpaper.
Sliding Pin Bolt and Sliding Pin Boot C
Check the sliding pin bolts and sliding pin boots for rust, wear, cracks or damage. Replace the parts if any
abnormal condition is detected.
ADJUSTMENT AFTER INSTALLATION D

Burnish contact surfaces between disc rotors and pads according to the following procedure after refinishing E
or replacing disc rotor, or if a soft pedal occurs at very low mileage.
CAUTION:
securely fitted. BR
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops. G
H
BR-51
< SERVICE DATA AND SPECIFICATIONS (SDS) [LHD]

General Specifications INFOID:0000000001116167
Unit: mm (in.)
Cylinder bore diameter 60.33 (2.375)

Front brake Pad length × width × thickness 123.6 × 47.5 × 11.0 (4.87 × 1.870 × 0.433)
Rotor outer diameter × thickness 296 × 26.0 (11.65 × 1.024)
Cylinder bore diameter 34.93 (1.375)
Rear brake Pad length × width × thickness 83.0 × 31.9 × 8.5 (3.268 × 1.256 × 0.335)
Master cylinder Cylinder bore diameter 23.8 (15/16)
Control valve Valve type Electric brake force distribution
Brake booster Diaphragm diameter 178 (7.01)
Recommended brake fluid DOT 3 or DOT 4
Brake Pedal INFOID:0000000001116168
Unit: mm (in.)
Brake pedal height (H1) 183.7 – 193.7 (7.23 – 7.63)

Clearance (C) between stopper rubber and stop lamp switch and/or ASCD brake switch (except
0.74 – 1.96 (0.0291 – 0.0772)
for M9R) or brake pedal position switch (for M9R) threaded end
Brake pedal play (A) 3.0 – 11.0 (0.12 –0.43)
Depressed brake pedal height (H2) MR20DE and QR25DE 65 (2.56) or more
[Depressing 490 N (50 kg, 110 lb) while turning the engine ON] M9R 60 (2.36) or more
Brake Booster INFOID:0000000001116169
Vacuum type
Unit: mm (in.)
Output rod length (A) 30.5 (1.201)

Input rod length (B) 153.2 – 154.2 (6.03 – 6.07)
Front Disc Brake INFOID:0000000001116170
Unit: mm (in.)
Standard thickness 11.0 (0.433)
Brake pad
Wear limit thickness 2.0 (0.079)
Disc rotor
Thickness variation (measured at 8 positions) 0.020 (0.0008)
Runout limit (with it attached to the vehicle) 0.035 (0.0014)
Rear Disc Brake INFOID:0000000001116171
Unit: mm (in.)

Brake pad
BR-52
< SERVICE DATA AND SPECIFICATIONS (SDS) [LHD]
A
Disc rotor
Runout limit (with it attached to the vehicle) 0.070 (0.0028) B
BR
BR-53
Symptom
×: Applicable
Reference page
Possible cause and
BRAKE
SUSPECTED PARTS
Noise
Shake
Shimmy, Judder
Pads - damaged BR-65, BR-66
×
SYMPTOM DIAGNOSIS
Pads - uneven wear BR-65, BR-66
×
Shims damaged BR-88, BR-94
×
Rotor imbalance BR-65, BR-66
×
×
Rotor damage BR-65, BR-66
BR-54
Rotor runout BR-65, BR-66
×
Rotor deformation BR-65, BR-66
×
Rotor deflection BR-65, BR-66
×
Rotor rust BR-65, BR-66
×
Rotor thickness variation BR-65, BR-66
×
PROPELLER SHAFT NVH in DLN section
×
×
×
DIFFERENTIAL NHV in DLN section
AXLE AND SUSPENSION NVH in FAX, RAX, FSU and RSU section
×
×
×
TIRE NVH in WT section

×
×
×
Use the chart below to find the cause of the symptom. If necessary, repair or replace these parts.
ROAD WHEEL NVH in WT section

×
×
×
× × DRIVE SHAFT NVH in FAX and/or RAX section
STEERING NVH in ST section

×
×
×
[RHD]
INFOID:0000000001125782
PRECAUTIONS
< PRECAUTION > [RHD]
PRECAUTION A
PRECAUTIONS
WARNING: D
BR
ness connectors.
G
INFOID:0000000001148910
NOTE: H
TEM).
I
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech- J
steering wheel rotation will become impossible. K
OPERATION PROCEDURE L
NOTE:
Supply power using jumper cables if battery is discharged. M
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be N
rotated.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting O
P
BR-55
PRECAUTIONS
< PRECAUTION > [RHD]
PIIB3706J
WARNING:
Clean any dust from the front brake and rear brake with a vacuum dust collector. Never blow with com-
pressed air.
CAUTION:
• Only use “DOT 3” brake fluid. Refer to MA-22, "Fluids and Lubricants".
• Always clean with new brake fluid when cleaning the master cylinder, brake caliper and other com-
ponents.
• Never use mineral oils such as gasoline or light oil to clean. They may damage rubber parts and
cause improper operation.
• Tighten the brake tube flare nut to the specified torque with
flare nut torque wrench (A).
• Always confirm the specified tightening torque when install-
ing the brake pipes.
• Turn the ignition switch OFF and disconnect the ABS actuator
and electric unit (control unit) connector or the battery nega-
tive terminal before performing the work.
• Check that no brake fluid leakage is present after replacing
the parts.
• Burnish the brake contact surfaces after refinishing or replac-
ing rotors, after replacing pads, or if a soft pedal occurs at
JPFIA0061ZZ
very low mileage. Refer to BR-88, "BRAKE PAD : Inspection
and Adjustment" (front brake pad), BR-91, "BRAKE CALIPER ASSEMBLY : Inspection and Adjust-
ment" (front disc rotor), BR-94, "BRAKE PAD : Inspection and Adjustment" (rear brake pad), BR-97,
"BRAKE CALIPER ASSEMBLY : Inspection and Adjustment" (rear disc rotor).
BR-56
PREPARATION
< PREPARATION > [RHD]
PREPARATION A
PREPARATION
Commercial Service Tool INFOID:0000000001125784
B

C
Pin punch Removing and installing reservoir tank D

a: 4 mm (0.16 in) dia. pin
E
NT410
BR
BR-57
BRAKE PEDAL
< ON-VEHICLE MAINTENANCE > [RHD]
BRAKE PEDAL
INSPECTION
Brake Pedal Height
Check the height (H1) between the accelerator pedal stopper (1) and
the brake pedal upper surface.
Standard
Pedal".
CAUTION:
JPFIA0119ZZ
Check the clearance (C) among stopper rubber (1) and stop lamp
switch and/or ASCD brake switch (except for M9R) or brake pedal
position switch (for M9R) (2) threaded end.
Standard
Clearance (C) between stop- : Refer to BR-99, "Brake
per rubber and stop lamp Pedal".
switch and/or ASCD brake
switch (except for M9R) or
brake pedal position switch
JPFIA0122ZZ
(for M9R) threaded end
CAUTION:
The stop lamp must be turned off when the brake pedal is released.
NOTE:
Pull the brake pedal pad to make the clearance between stopper rubber and stop lamp switch and/or ASCD
brake switch (except for M9R) or brake pedal position switch (for M9R) threaded end.
Brake Pedal Play
Press the brake pedal. Check the brake pedal play (A).
Standard
Pedal play (A) : Refer to BR-99, "Brake
Pedal".
JPFIA0121ZZ
Depressed Brake Pedal Height
BR-58
BRAKE PEDAL
Check the height between the accelerator pedal stopper (1) and the
brake pedal upper surface (H2) when depressing the brake pedal at A
490 N (50 kg, 110 lb) while turning engine ON.
Standard B
Depressed brake pedal : Refer to BR-99, "Brake
height (H2) Pedal".
CAUTION: C
JPFIA0120ZZ
D
ADJUSTMENT
Brake Pedal Height
1. Disconnect the stop lamp switch and/or ASCD brake switch (except for M9R) or brake pedal position E
M9R) 45° counterclockwise. BR
3. Loosen the input rod lock nut (1). Adjust the brake pedal to the
specification. Tighten the input rod lock nut to the specification.
Refer to BR-80, "Exploded View". G
CAUTION:
The threaded end of the input rod (2) must project to the
inner side (L) of the clevis (3).
H
I
JPFIA0003ZZ
J
Standard
Pedal". K
JPFIA0119ZZ
M
1. Disconnect the stop lamp switch and/or ASCD brake switch (except for M9R) or brake pedal position N
O
brake pedal position switch (for M9R) hits the stopper rubber (1) P
45° clockwise.
CAUTION:
Pedal".
JPFIA0122ZZ
BR-59
BRAKE PEDAL
• The stop lamp must be turned off when the brake pedal is released.
Brake Pedal Play
brake pedal position switch (for M9R) hits the stopper rubber (1)
45° clockwise.
CAUTION:
Pedal".
JPFIA0122ZZ
• The stop lamp must be turned off when the brake pedal is
released.
BR-60
BRAKE FLUID
BRAKE FLUID
A
BRAKE FLUID LEVEL B

• Visually check for any brake fluid leakage around the reservoir C
tank.
• Check the brake system for any leakage if the fluid level is
• Check the brake system for fluid leakage if the warning lamp D
remains illuminated even after the parking brake is released.
E
JPFIA0007ZZ
BRAKE LINE
BR
1. Check brake line (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged
parts.
2. Check for fluid leakage by fully depressing brake pedal while
G
engine is running.
CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts. H
SBR389C
J
CAUTION: K
nector or the battery negative terminal before draining. L
1. Connect a vinyl tube to the bleed valve.
2. Depress the brake pedal and loosen the bleeder valve to gradu-
ally discharge brake fluid. M
O
BRA0007D
Refilling INFOID:0000000001125788 P
CAUTION:
Turn the ignition switch OFF and disconnect the ABS actuator and electric unit (control unit) connec-
tor or the battery negative terminal before refilling.
BR-61
BRAKE FLUID
1. Check that there is no foreign material in the reservoir tank, and
refill with new brake fluid.
CAUTION:
2. Loosen the bleeder valve, slowly depress the brake pedal to the
full stroke, and then release the pedal. Repeat this operation at
intervals of 2 or 3 seconds until all brake fluid is discharged.
Then close the bleeder valve with the brake pedal depressed.
Repeat the same work on each wheel.
3. Perform the air bleeding. Refer to BR-62, "Bleeding Brake Sys-
tem". PFIA0403J
Bleeding Brake System INFOID:0000000001116184
CAUTION:
nector or the battery negative terminal before performing the work.
• Monitor the fluid level in the reservoir tank during the air bleeding.
• Always use new brake fluid for refilling. Never reuse the drained brake fluid.
1. Connect a vinyl tube to the bleeder valve of the rear left brake.
2. Fully depress the brake pedal 4 to 5 times.
3. Loosen the bleeder valve and bleed air with the brake pedal depressed, and then quickly tighten the
bleeder valve.
4. Repeat steps 2 and 3 until all of the air is out of the brake line.
5. Tighten the bleeder valve to the specified torque. Refer to BR-89, "BRAKE CALIPER ASSEMBLY :
Exploded View" (front disc brake), BR-95, "BRAKE CALIPER ASSEMBLY : Exploded View" (rear disc
brake).
6. Perform steps 1 to 5 for the rear left brake →front right brake → rear right brake → and front left brake in
order.
7. Check that the fluid level in the reservoir tank is within the specified range after air bleeding. Refer to BR-
61, "Inspection".
BR-62
A
FLUID LEAK B
Check for brake fluid leakage from the master cylinder mounting face, reservoir tank mounting face and brake
tube connections.
C
BR
BR-63
BRAKE BOOSTER
BRAKE BOOSTER
OPERATION
lower panel decreases.
NOTE:
BRA0037D
AIR TIGHT
JPFIA0043ZZ
NOTE:
JPFIA0044ZZ
BR-64
FRONT DISC BRAKE
FRONT DISC BRAKE
A
BRAKE PAD
B
PAD WEAR
Check using a scale if necessary. C
Standard thickness : Refer to BR-99, "Front

Disc Brake". D

Disc Brake". E
BRA0010D
BR
DISC ROTOR
G
APPEARANCE
H
RUNOUT
wheel nuts (2 points at least). I
in) inside the disc edge.]
J
Runout limit : Refer to BR-99, "Front
Disc Brake".
NOTE: K
SBR019B
(4WD).
L
M
THICKNESS
the disc rotor if the thickness is below the wear limit. N

Disc Brake".
O
SBR020B
BR-65
REAR DISC BRAKE
REAR DISC BRAKE
BRAKE PAD
PAD WEAR
Check using a scale if necessary.
Standard thickness : Refer to BR-99, "Rear

Disc Brake".

Disc Brake".
BRA0010D
DISC ROTOR
APPEARANCE
RUNOUT
wheel nuts (2 points at least).
in) inside disc edge.]
Runout limit : Refer to BR-99, "Rear

Disc Brake".
NOTE:
Refer to RAX-3, "Inspection" (2WD), RAX-9, "Inspection"
SBR019B
(4WD).
THICKNESS
the disc rotor if the thickness is below the wear limit.

Disc Brake".
SBR020B
BR-66
BRAKE PEDAL
< ON-VEHICLE REPAIR > [RHD]
ON-VEHICLE REPAIR A
BRAKE PEDAL
B
BR
JPFIA0130GB J
1. Clevis pin 2. Brake pedal assembly 3. Brake pedal pad

4. Brake switch (with ESP)*1*2 5. Stop lamp switch 6. Clip
K
7. Snap pin
*1: ASCD brake switch (except for M9R)
*2: Brake pedal position switch (for M9R) L
: Apply multi-purpose grease.
M
REMOVAL
N
1. Remove instrument driver lower panel. Refer to IP-11, "Exploded View".
2. Disconnect stop lamp switch and/or ASCD brake switch (except for M9R) or brake pedal position switch
(for M9R) harness connectors.
O
4. Remove steering member stay.
5. Remove snap pin and clevis pin from clevis of brake booster. P
6. Remove the brake pedal assembly and the accelerator pedal.
7. Remove the accelerator pedal from brake pedal assembly. Refer to ACC-3, "Exploded View".
INSTALLATION
• Apply the multi-purpose grease to the clevis pin and the mating faces. (Not necessary if grease has been
already applied.)
BR-67
BRAKE PEDAL
NOTE:
The clevis pin may be inserted in either direction.

• Check the following items and replace the brake pedal assembly if
necessary.
- Check the brake pedal upper rivet (A) for deformation.
- Check the brake pedal for bend, damage, and cracks on the
welded parts.
- Check the lapping length (X) of sub-bracket (B) and slide plate (C).
Standard
Lapping length : 5.0 – 6.0 mm (0.197 – 0.236 in)
PFIA0755J
• Check clevis pin and plastic stopper (A) for damage and deforma-
tion. If any is found, replace clevis pin.
PFIA0756J

• Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-58, "Inspection
and Adjustment".
• Perform the accelerator pedal check after installing the accelerator pedal. Refer to ACC-4, "Inspection".
BR-68
BRAKE PIPING
BRAKE PIPING
A
FRONT (WITHOUT ESP)
FRONT (WITHOUT ESP) : Exploded View INFOID:0000000001116198
B
BR
JPFIA0145GB
K
1. Brake tube 2. Brake booster 3. Master cylinder assembly
4. Connector 5. Connector bracket 6. ABS actuator and electric unit (con-
trol unit) L
BR-69
BRAKE PIPING
FRONT (WITHOUT ESP) : Hydraulic Piping INFOID:0000000001116199
JPFIA0079ZZ
1. Brake booster 2. Master cylinder assembly 3. Front disc brake

4. ABS actuator and electric unit (con- 5. Connector 6. Rear disc brake
trol unit)
: Flare nut
: Union bolt
: Connector
FRONT (WITHOUT ESP) : Removal and Installation INFOID:0000000001125797
REMOVAL
CAUTION:
1. Remove tires.
CAUTION:
INSTALLATION
CAUTION:
CAUTION:
BR-70
BRAKE PIPING
assembly and tighten the union bolt (1) to the specified torque. A
hose to the bracket with the lock plate. B
CAUTION:
bent.
C
torque wrench.
Never scratch the flare nut and the brake tube. D

CAUTION:
Never reuse drained brake fluid. E
6. Install tires.
FRONT (WITHOUT ESP) : Inspection INFOID:0000000001125798
BR
1. Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no interfer- G
H
CAUTION:
FRONT (WITH ESP) I
BR-71
BRAKE PIPING
FRONT (WITH ESP) : Exploded View INFOID:0000000001116202
JPFIA0146GB
1. Brake tube 2. Brake booster 3. Master cylinder assembly

4. Connector 5. Connector bracket 6. ABS actuator and electric unit (con-
trol unit)
BR-72
BRAKE PIPING
FRONT (WITH ESP) : Hydraulic Piping INFOID:0000000001116203
BR
JPFIA0079ZZ
G
trol unit)
A. Brake tube B. Brake hose H
: Flare nut
: Union bolt I
: Connector
FRONT (WITH ESP) : Removal and Installation INFOID:0000000001125799

J
REMOVAL
CAUTION: K
1. Remove tires.
L
CAUTION:
M
4. Remove the union bolt and remove the brake hose from the brake caliper assembly. N
INSTALLATION O
CAUTION:
P
CAUTION:
BR-73
BRAKE PIPING
assembly and tighten the union bolt (1) to the specified torque.
hose to the bracket with the lock plate.
CAUTION:
bent.
torque wrench.

CAUTION:
6. Install tires.
FRONT (WITH ESP) : Inspection INFOID:0000000001125800

CAUTION:
REAR
JPFIA0149GB
BR-74
BRAKE PIPING
1. Brake tube 2. Lock plate 3. Brake hose A

4. Brake hose bracket 5. Union bolt
A. To front brake tube B. To rear brake hose C. Floor side
D. Caliper side B
REAR : Hydraulic Piping INFOID:0000000001125802

C
BR
JPFIA0079ZZ
I
trol unit)
J
: Flare nut
: Union bolt K
: Connector
REAR : Removal and Installation INFOID:0000000001125803 L
REMOVAL
CAUTION: M
1. Remove tires. N
CAUTION: O
• Never sharply bend, twist or strongly pull the brake hoses and tubes.
• Cover the open end of brake tubes and hoses when disconnecting to prevent entrance of dirt.
P
5. Remove the lock plate and remove the brake hose from the vehicle.
INSTALLATION
CAUTION:
BR-75
BRAKE PIPING
CAUTION:
Never reuse copper washer.
2. Install the brake hose L-pin by aligning it with the brake caliper
assembly positioning hole, and tighten the union bolt (1) to the
specified torque.
3. Connect the hose to the brake tube, temporarily tighten the flare
nut by hand until it does not rotate further, and fix the brake hose
to the bracket with the lock plate.
CAUTION:
Check that the brake hoses and tubes are not twisted and
bent.
torque wrench. JPFIA0012ZZ
CAUTION:
CAUTION:
6. Install tires.
REAR : Inspection INFOID:0000000001125804

CAUTION:
BR-76
A
BR
I
JPFIA0133GB
1. Reservoir cap 2. Oil strainer 3. Reservoir tank J

4. Cylinder body 5. Pin 6. O-ring
7. Grommet
: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease. K

L
REMOVAL M
CAUTION:
off immediately and wash with water if it gets on a painted surface. N
2. Remove engine room insulator.
3. Remove engine cover. Refer to EM-27, "Exploded View" (MR20DE), EM-265, "Exploded View" (M9R). O
5. Separate the brake fluid level switch harness connector.
P
6. Separate the brake tubes from the master cylinder assembly with a flare nut wrench.
CAUTION:
7. Remove the master cylinder assembly.
CAUTION:
BR-77
master cylinder.
INSTALLATION
CAUTION:
CAUTION:
• Apply PBC (Poly Butyl Cuprysil) silicone-based grease to
the brake booster [see (A) in the figure] when installing the
master cylinder assembly to the brake booster.
• The piston of the master cylinder assembly is exposed.
Never damage it when handling the master cylinder and
check that no dirt and dust are present on the piston before
installation. Clean it with new brake fluid if necessary.
• The piston may drop off when pulled strongly. Never hold
the piston. Hold the cylinder body when handling the master
cylinder assembly.
• Temporarily tighten the brake tube flare nut to the master cylinder
JPFIA0013ZZ
assembly by hand. Then tighten it to the specified torque with a
flare nut torque wrench. Refer to BR-69, "FRONT (WITHOUT ESP) : Exploded View" (without ESP), BR-72,
"FRONT (WITH ESP) : Exploded View" (with ESP).
CAUTION:
CAUTION:
DISASSEMBLY
CAUTION:
• Never disassemble the cylinder body.
• Remove the reservoir tank if necessary.
1. Fix the master cylinder assembly to a vise.
CAUTION:
Always set copper plates or cloth between vise when fixing the cylinder body to a vise. Never
overtighten the vise.
2. Remove the reservoir tank mounting pin with a pin punch.
3. Remove the reservoir tank and grommet from the cylinder body.
CAUTION:
Never drop the removed parts. The parts must not be
reused if they are dropped.
JPFIA0015ZZ
ASSEMBLY
1. Apply new brake fluid to the grommet and install it to the cylinder body.
CAUTION:
• Never use mineral oil such as gasoline or light oil.
• Never reuse the grommets.
BR-78
2. Install the reservoir tank to the cylinder body.
CAUTION: A
• Never drop the parts when installing. The parts must not be reused if they are dropped.
• Never reuse reservoir tank.
3. Fix the cylinder body to a vise. B
CAUTION:
• Place the reservoir tank with the chamfered pin hole ( )
facing up.
• Always set copper plates or cloth between vise when fix- C
ing the cylinder body to a vise. Never overtighten the vise.
JPFIA0016ZZ E
4. Tilt the reservoir tank so that a mounting pin can be inserted.

Insert a mounting pin. Return the reservoir tank to the horizontal BR
position. Insert another mounting pin into the pin hole on the
opposite side in the same manner after the mounting pin passes
through the cylinder body pin hole.
CAUTION: G
Never reuse the mounting pin.
JPFIA0015ZZ
I

J
Fluid Leak
Check for brake fluid leakage from the cylinder body-to-brake booster mounting face, reservoir tank mounting
face and brake tube connections. K
BR-79
BRAKE BOOSTER
BRAKE BOOSTER
JPFIA0083GB
1. Master cylinder assembly 2. Brake booster 3. Lock nut

4. Gasket
Removal and installation INFOID:0000000001116215
REMOVAL
2. Remove engine room insulator.
3. Remove engine cover. Refer to EM-27, "Exploded View" (MR20DE), EM-265, "Exploded View" (M9R).
4. Remove brake master cylinder assembly. Refer to BR-77, "Removal and Installation".
CAUTION:
master cylinder.
5. Remove vacuum hose from brake booster. Refer to BR-83, "MR20DE : Exploded View" (MR20DE), BR-
84, "QR25DE : Exploded View" (QR25DE), BR-85, "M9R : Exploded View" (M9R).
6. Remove snap pin (1) and clevis pin (2) from inside vehicle.
7. Remove nuts on brake booster and brake pedal assembly. Refer
to BR-80, "Exploded View".
8. Remove brake booster from dash panel in engine room side.
CAUTION:
Never deform or bend the brake tubes.
9. Remove the spacer from brake booster.
JPFIA0019ZZ
INSTALLATION
BR-80
BRAKE BOOSTER
CAUTION: A
• Be careful not to damage brake booster stud bolt threads. If brake booster is tilted during installa-
tion, the dash panel may damage the threads.
• Never deform or bend the brake tubes when installing the brake booster.
B
• Always use a new gasket between the brake booster and the spacer.
• Replace the clevis pin if it is damaged. Refer to BR-68, "Inspection and Adjustment".
CAUTION: C
D
Output Rod Length Inspection E
1. With a handy vacuum pump, apply vacuum pressure of −66.7
kPa (−500 mmHg, −19.70 inHg, −0.667 bar) to the brake
booster. BR
2. Check the output rod length (A).
Standard G
Output rod length (A) : Refer to BR-99, "Brake
Booster".
H
JPFIA0021ZZ
Input Rod Length Inspection

I
1. Loosen the lock nut (1) and adjust the input rod (2) to the speci-
fied length (B).
J
Standard
Input rod length (B) : Refer to BR-99, "Brake
Booster".
K
2. Tighten the lock nut to the specified torque.
L
JPFIA0020ZZ

Operation M
depressed. Check that the clearance between brake pedal and dash N
lower pane decreases.
NOTE:
O
P
BRA0037D
Air Tight
BR-81
BRAKE BOOSTER
JPFIA0043ZZ
NOTE:
JPFIA0044ZZ
ADJUSTMENT AFTER INSTALLTION

Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-58, "Inspection and
Adjustment".
BR-82
VACUUM LINES
VACUUM LINES
A
MR20DE
MR20DE : Exploded View INFOID:0000000001116217
B
BR
JPFIA0087ZZ
H
1. Clamp 2. Vacuum hose (built in check valve)
I
MR20DE : Removal and Installation INFOID:0000000001116218
REMOVAL J
2. Remove the vacuum hose.
K
INSTALLATION
CAUTION: L
the hose is installed in the wrong direction. M
• Face the marking side up when assembling of vacuum hose. N
O
JPFIA0023ZZ
MR20DE : Inspection INFOID:0000000001125808
P
Appearance
BR-83
VACUUM LINES

0.667 bar).
JPFIA0024ZZ
are malfunctioning.
QR25DE
QR25DE : Exploded View INFOID:0000000001116311
JPFIA0134ZZ
1. Clamp 2. Vacuum hose (built in check valve)

QR25DE : Removal and Installation INFOID:0000000001116312
REMOVAL
Remove the vacuum hose.
INSTALLATION
Install the vacuum hose.
CAUTION:
JPFIA0023ZZ
BR-84
VACUUM LINES
QR25DE : Inspection INFOID:0000000001125809
A
Appearance
B
• Use a handy vacuum pump (A) to check. C

Vacuum should decrease within 1.3 kPa (10 mm- D
0.667 bar). E
JPFIA0024ZZ BR
are malfunctioning.
M9R
G
M
JPFIA0148GB
1. Clamp 2. Vacuum hose (built in check valve) 3. vacuum tube

4. Clip 5. Bracket 6. Vacuum hose N
7. Vacuum hose connector
A. To vacuum pump B. To brake booster C. Paint mark
D. Stamp indicating engine direction O
P
REMOVAL
2. Remove the vacuum hose and tube.
INSTALLATION
CAUTION:
BR-85
VACUUM LINES
installed the correct position. Refer to the stamp to confirm
uum hose (vacuum pump side of a built in check valve).
JPFIA0023ZZ

Appearance

0.667 bar).
JPFIA0024ZZ
are malfunctioning.
BR-86
FRONT DISC BRAKE
FRONT DISC BRAKE
A
BRAKE PAD
B
BR
JPFIA0090GB
H
I
J
2: Apply copper based brake grease. K

L
REMOVAL M
WARNING:
compressed air. N
CAUTION:
• Never depress the brake pedal while removing the brake pads because the piston may pop out.
• Never spill or splash brake fluid on the disc rotor. O
1. Remove tires.
2. Remove lower sliding pin bolt.
3. Suspend the cylinder body with suitable wire so that the brake hose will not stretch. Then remove the P
brake pad from the torque member.
CAUTION:
• Never deform the pad retainer when removing the pad retainer from the torque member.
• Never drop the brake pads, shims, and the shim covers.
INSTALLATION
BR-87
FRONT DISC BRAKE
WARNING:
compressed air.
CAUTION:
ton may pop out.
1. Install the pad retainer to the torque member if the pad retainers has been removed.
CAUTION:
• Securely assemble the pad retainers so that it will not be lifted up from the torque member.
2. Apply copper based brake grease to the mating faces between the pads, shims and shim covers, and
install them to the brake pad.
CAUTION:
Always replace the shims together with the shim covers when replacing the brake pad.
3. Install the cylinder body and brake pads to the torque member.
CAUTION:
• When replacing a pad with new one, check a brake fluid level in the reservoir tank because brake
fluid returns to master cylinder reservoir tank when pressing piston in.
NOTE:
Use a disc brake piston tool to easily press piston.
5. Depress the brake pedal several times to check that no drag feel is present for the front disc brake.
6. Install tires.

if a soft pedal occurs at very low mileage.
CAUTION:
• Be careful of vehicle speed because the brake does not operate easily until pads and disc rotor are
securely fitted.
BR-88
FRONT DISC BRAKE
BR
JPFIA0090GB
G
H
I
2: Apply copper based brake grease. J
K
REMOVAL L
WARNING:
compressed air. M
CAUTION:
1. Remove tires. N
CAUTION: O
4. Remove union bolt, and then disconnect brake hose from caliper assembly.
P
BR-89
FRONT DISC BRAKE
per assembly.
CAUTION:
CAUTION:
• Never drop disc rotor.
JPFIA0030ZZ
INSTALLATION
WARNING:
compressed air.
CAUTION:
1. Install disc rotor.
CAUTION:
2. Install the brake caliper assembly to the vehicle and tighten the torque member mounting bolts to the
specified torque.
CAUTION:
Never spill or splash any grease and moisture on the brake caliper assembly mounting face,
threads, mounting bolts and washers. Wipe out any grease and moisture.
CAUTION:
5. Check that no drag feel is present for the front disc brake.
6. Install tires.
BRAKE CALIPER ASSEMBLY : Disassembly and Assembly INFOID:0000000001125816
DISASSEMBLY
NOTE:
Never remove the torque member, brake pads, shims, shim covers and pad retainers when disassembling and
1. Remove the sliding pin bolts, and remove the cylinder body from the torque member.
CAUTION:
2. Remove sliding pins and sliding pin boots from torque member.
3. Remove bushing from sliding pin.
union bolt mounting hole to remove piston and piston boot.
CAUTION:
MAA0272D
BR-90
FRONT DISC BRAKE
CAUTION: A
JPFIA0038ZZ
D
ASSEMBLY
1. Apply rubber grease to piston seal (1), and install to cylinder
body. E
CAUTION:
BR
JPFIA0039ZZ
H
with piston boot, and then install cylinder side lip on piston boot
securely into a groove on cylinder body. I
CAUTION:
J
K
JPFIA0040ZZ
3. Apply brake fluid to piston (1). Push piston into cylinder body by L
hand and push piston boot (2) piston-side lip into the piston
groove.
CAUTION:
Press the piston evenly and vary the pressing point to pre- M
4. Apply rubber grease to bushing, install bushing to sliding pin.
5. Apply rubber grease to sliding pins and sliding pin boots, install N
sliding pins and sliding pin boots to torque member.
6. Install the cylinder body to the torque member and tighten the
sliding pin bolts to the specified torque. JPFIA0034ZZ O
P
Cylinder Body
CAUTION:
BR-91
FRONT DISC BRAKE
Torque Member
Check the torque member for rust, wear, cracks or damage. Replace the member if any abnormal condition is
detected.
Piston
Check the surface of the piston for rust, wear, cracks or damage. Replace the piston if any abnormal condition
is detected.
CAUTION:
Sliding Pin and Sliding Pin Boot
Check the sliding pins and sliding boots for rust, wear, cracks or damage. Replace the parts if any abnormal
Burnish contact surfaces between disc rotors and pads according to following procedure after refinishing or
replacing disc rotor, or if a soft pedal occurs at very low mileage.
CAUTION:
securely fitted.
BR-92
REAR DISC BRAKE
REAR DISC BRAKE
A
BRAKE PAD
B
BR
JPFIA0129GB
J
7. Cylinder body 8. Piston seal 9. Piston K
16. Inner shim 17. Inner pad 18. Pad wear sensor (RH inner pad L
only)
1: Apply rubber grease. M
N
O
REMOVAL P
WARNING:
compressed air.
CAUTION:
ton may pop out.
BR-93
REAR DISC BRAKE
1. Remove tires.
2. Remove the lower sliding pin bolt.
3. Suspend the cylinder body with suitable wire so that the brake hose will not stretch. Remove the brake
pads from the torque member.
CAUTION:
• Never deform the pad retainers if removing the pad retainers.
• Never drop the brake pad, shims, and the shim covers.
INSTALLATION
WARNING:
compressed air.
CAUTION:
ton may pop out.
1. Install the pad retainers to the torque member if the pad retainers has been removed.
CAUTION:
• Securely assemble the pad retainers not to be lifted up from the torque member.
2. Apply copper based brake grease to the mating faces between the brake pads, the shims and pawls part
of cylinder body, and install them to the brake pad.
CAUTION:
Always replace the shims together with the shim covers when replacing the brake pad.
3. Install cylinder body and brake pads to torque member.
CAUTION:
• When replacing a pads with new one, check a brake fluid level in the reservoir tank because
brake fluid returns to master cylinder reservoir tank when pressing piston in.
NOTE:
Use a disc brake piston tool to easily press piston.
5. Depress the brake pedal several times to check that no drag feel is present for the rear disc brake.
6. Install tires.

if a soft pedal occurs at very low mileage.
CAUTION:
securely fitted.
BR-94
REAR DISC BRAKE
BR
JPFIA0129GB
I
7. Cylinder body 8. Piston seal 9. Piston J
16. Inner shim 17. Inner pad 18. Pad wear sensor (RH inner pad K
only)
1: Apply rubber grease. L
M
N
REMOVAL O
WARNING:
compressed air. P
CAUTION:
1. Remove tires.
CAUTION:
BR-95
REAR DISC BRAKE
4. Remove union bolt (1) and then disconnect brake hose (2) from
caliper assembly.
per assembly.
CAUTION:
CAUTION:
• Never drop disc rotor. JPFIA0036ZZ
INSTALLATION
WARNING:
compressed air.
CAUTION:
1. Install disc rotor.
CAUTION:
2. Install the brake caliper assembly to the vehicle and tighten the torque member mounting bolts to the
specified torque.
CAUTION:
Never spill or splash any grease and moisture on the brake caliper assembly mounting face,
threads, mounting bolts, and washers. Wipe out any grease and moisture.
CAUTION:
5. Check that no drag feel is present for the rear disc brake.
6. Install tires.
BRAKE CALIPER ASSEMBLY : Disassembly and Assembly INFOID:0000000001125823
DISASSEMBLY
NOTE:
Never remove the torque member, brake pads, shims, shim covers and pad retainers disassembling and
1. Remove the sliding pin bolts and remove the cylinder body from the torque member.
CAUTION:
2. Remove sliding pin boots from torque member.
3. Remove bushing from sliding pin bolt.
union bolt mounting hole to remove piston and piston boot.
CAUTION:
BRD0041D
BR-96
REAR DISC BRAKE
CAUTION: A
JPFIA0038ZZ
D
ASSEMBLY
1. Apply polyglycol ether based lubricant to piston seal (1), and
install to cylinder body. E
CAUTION:
BR
JPFIA0039ZZ
H
with the piston boot, and then install cylinder side lip on the pis-
ton boot securely into the groove on cylinder body. I
CAUTION:
J
K
JPFIA0040ZZ
3. Apply brake fluid to piston (1). Push piston into cylinder body by L
hand and push piston boot (2) piston side lip into the piston
groove.
CAUTION:
Press the piston evenly and vary the pressing point to pre- M
4. Apply polyglycol ether based lubricant to bushing, install bush-
ing to sliding pin bolt. N
5. Apply rubber grease to the sliding pin bolts and the sliding pin
boots, install sliding pin boot to torque member.
6. Install the cylinder body to the torque member and tighten the JPFIA0041ZZ O
sliding pin bolts to the specified torque.
P
Cylinder Body
CAUTION:
BR-97
REAR DISC BRAKE
Torque Member
Check the torque member for rust, wear, cracks or damage. Replace the member if any abnormal condition is
detected.
Piston
Check the piston for rust, wear, cracks or damage. Replace the piston if any abnormal condition is detected.
CAUTION:
Sliding Pin Bolt and Sliding Pin Boot
Check the sliding pin bolts and sliding pin boots for rust, wear, cracks or damage. Replace the parts if any
abnormal condition is detected.
Burnish contact surfaces between disc rotors and pads according to the following procedure after refinishing
or replacing disc rotor, or if a soft pedal occurs at very low mileage.
CAUTION:
securely fitted.
BR-98
< SERVICE DATA AND SPECIFICATIONS (SDS) [RHD]

General Specifications INFOID:0000000001116237
B
Unit: mm (in.)
Cylinder bore diameter 60.33 (2.375) C

Front brake Pad length × width × thickness 123.6 × 47.5× 11.0 (4.87 × 1.870× 0.433)
Cylinder bore diameter 34.93 (1.375) D
Rear brake Pad length × width × thickness 83.0 × 31.9 × 8.5 (3.268 × 1.256 × 0.335)
E
Master cylinder Cylinder bore diameter 23.8 (15/16)
Control valve Valve type Electric brake force distribution
Brake booster Diaphragm diameter 255 (10.4) BR
Recommended brake fluid DOT 3 or DOT 4
Brake Pedal INFOID:0000000001116238

G
Unit: mm (in.)
Brake pedal height (H1) 130.2 – 140.2 (5.13 – 5.52)
H
Clearance (C) between stopper rubber and stop lamp switch and/or ASCD brake switch (except for
0.74 – 1.96 (0.0291 – 0.0772)
M9R) or brake pedal position switch (for M9R) threaded end
Brake pedal play (A) 3.0 – 11.0 (0.12 – 0.43)
I
Depressed brake pedal height (H2) MR20DE and QR25DE 15 (0.59) or more
[Depressing 490 N (50 kg, 110 lb) while turning the engine ON] M9R 10 (0.39) or more
J
Brake Booster INFOID:0000000001125825
Vacuum type
Unit: mm (in.)
K
Output rod length (A) 30.5 (1.201)

Input rod length (B) 124.5 – 125.5 (4.90 – 4.94) L
Front Disc Brake INFOID:0000000001125826
Unit: mm (in.) M
Brake pad
N
Disc rotor
Thickness variation (measured at 8 positions) 0.020 (0.0008) O
Rear Disc Brake INFOID:0000000001125827

P
Unit: mm (in.)

Brake pad
BR-99
< SERVICE DATA AND SPECIFICATIONS (SDS) [RHD]
Disc rotor
BR-100
BRAKES
SECTION
BRAKE CONTROL SYSTEM
BRC B
E
CONTENTS
ABS C1109 POWER AND GROUND SYSTEM ........ 26 BRC
Description ...............................................................26
BASIC INSPECTION .................................... 6 DTC Logic ................................................................26
Diagnosis Procedure ...............................................26 G
DIAGNOSIS AND REPAIR WORKFLOW .......... 6
Work Flow ................................................................. 6 C1110 ABS ACTUATOR AND ELECTRIC
Diagnostic Work Sheet .............................................. 8 UNIT (CONTROL UNIT) .................................... 28
H
Description ...............................................................28
FUNCTION DIAGNOSIS ............................... 9 DTC Logic ................................................................28
ABS ..................................................................... 9 Diagnosis Procedure ...............................................28
I
System Diagram ........................................................ 9 C1111 ABS MOTOR, MOTOR RELAY SYS-
System Description ................................................... 9 TEM ................................................................... 29
Description ...............................................................29 J
Component Description ........................................... 11
DTC Logic ................................................................29
EBD ....................................................................13 Diagnosis Procedure ...............................................29
System Diagram ...................................................... 13 Component Inspection .............................................30
K
System Description ................................................. 13 C1113 G SENSOR ............................................ 31
Component Parts Location ...................................... 14 Description ...............................................................31
Component Description ........................................... 15 DTC Logic ................................................................31 L
DIAGNOSIS SYSTEM [ABS ACTUATOR Diagnosis Procedure ...............................................31
AND ELECTRIC UNIT (CONTROL UNIT)] ........17 Component Inspection .............................................32
CONSULT-III Function (ABS) ................................. 17 C1115 WHEEL SENSOR .................................. 34 M
Description ...............................................................34
COMPONENT DIAGNOSIS ......................... 20
DTC Logic ................................................................34
C1101, C1102, C1103, C1104 WHEEL SEN- Diagnosis Procedure ...............................................34 N
SOR-1 .................................................................20 Component Inspection .............................................35
Description .............................................................. 20 C1120, C1122, C1124, C1126 IN ABS SOL ..... 37
DTC Logic ............................................................... 20 O
Description ...............................................................37
DTC Logic ................................................................37
Component Inspection ............................................ 22 Diagnosis Procedure ...............................................37
C1105, C1106, C1107, C1108 WHEEL SEN- Component Inspection .............................................38 P
SOR-2 .................................................................23 C1121, C1123, C1125, C1127 OUT ABS SOL... 39
Description .............................................................. 23 Description ...............................................................39
DTC Logic ............................................................... 23 DTC Logic ................................................................39
Diagnosis Procedure ............................................... 23 Diagnosis Procedure ...............................................39
Component Inspection ............................................ 25 Component Inspection .............................................40
BRC-1
C1140 ACTUATOR RELAY SYSTEM ............... 41 PEDAL VIBRATION OR ABS OPERATION
Description .............................................................. 41 SOUND OCCURS .............................................. 63
DTC Logic ............................................................... 41 Diagnosis Procedure ............................................... 63
Component Inspection ............................................ 42 NORMAL OPERATING CONDITION ................ 64
Description .............................................................. 64
U1000 CAN COMM CIRCUIT ............................ 43
Description .............................................................. 43 PRECAUTION ............................................ 65
DTC Logic ............................................................... 43
Diagnosis Procedure .............................................. 43 PRECAUTIONS ................................................. 65
U1010 CONTROL UNIT (CAN) ......................... 44 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
Description .............................................................. 44 SIONER" ................................................................. 65
DTC Logic ............................................................... 44 Precaution for Brake System .................................. 65
Diagnosis Procedure .............................................. 44 Precaution for Brake Control ................................... 65
BRAKE FLUID LEVEL SWITCH ....................... 45 PREPARATION .......................................... 66

Description .............................................................. 45
Component Function Check ................................... 45 PREPARATION ................................................. 66
Diagnosis Procedure .............................................. 45 Special Service Tool ............................................... 66
Component Inspection ............................................ 46
PARKING BRAKE SWITCH .............................. 47
Description .............................................................. 47
WHEEL SENSOR .............................................. 67
Component Function Check ................................... 47 FRONT WHEEL SENSOR ........................................ 67
Diagnosis Procedure .............................................. 47 FRONT WHEEL SENSOR : Exploded View ........... 67
Component Inspection ............................................ 47 FRONT WHEEL SENSOR : Removal and Instal-
lation ....................................................................... 67
ABS WARNING LAMP ...................................... 49
Description .............................................................. 49 REAR WHEEL SENSOR ........................................... 67
Component Function Check ................................... 49 REAR WHEEL SENSOR : Exploded View ............. 68
Diagnosis Procedure .............................................. 49 REAR WHEEL SENSOR : Removal and Installa-
tion .......................................................................... 68
BRAKE WARNING LAMP ................................. 50
Description .............................................................. 50 SENSOR ROTOR .............................................. 69
Component Function Check ................................... 50
Diagnosis Procedure .............................................. 50 FRONT SENSOR ROTOR ........................................ 69
FRONT SENSOR ROTOR : Exploded View ........... 69
ECU DIAGNOSIS ........................................ 51 FRONT SENSOR ROTOR : Removal and Instal-
lation ....................................................................... 69
ABS ACTUATOR AND ELECTRIC UNIT
(CONTROL UNIT) .............................................. 51 REAR SENSOR ROTOR ........................................... 69
Reference Value ..................................................... 51 REAR SENSOR ROTOR : Exploded View ............. 69
Wiring Diagram -BRAKE CONTROL SYSTEM- ..... 54 REAR SENSOR ROTOR : Removal and Installa-
Fail-Safe ................................................................. 57 tion .......................................................................... 69
DTC No. Index ........................................................ 58
SYMPTOM DIAGNOSIS ............................. 59 (CONTROL UNIT) .............................................. 70
Exploded View ........................................................ 70
EXCESSIVE ABS FUNCTION OPERATION Removal and Installation ......................................... 71
FREQUENCY ..................................................... 59
Diagnosis Procedure .............................................. 59 G SENSOR ........................................................ 73
Exploded View ........................................................ 73
UNEXPECTED PEDAL REACTION .................. 60 Removal and Installation ......................................... 73
Diagnosis Procedure .............................................. 60 ESP/TCS/ABS
THE BRAKING DISTANCE IS LONG ............... 61 BASIC INSPECTION .................................. 74
DIAGNOSIS AND REPAIR WORKFLOW ......... 74
ABS FUNCTION DOES NOT OPERATE .......... 62 Work Flow ............................................................... 74
Diagnosis Procedure .............................................. 62 Diagnostic Work Sheet ........................................... 77
BRC-2
INSPECTION AND ADJUSTMENT ....................78 C1105, C1106, C1107, C1108 WHEEL SEN-
SOR-2 .............................................................. 112 A
ADJUSTMENT OF STEERING ANGLE SENSOR
Description ............................................................. 112
NEUTRAL POSITION ................................................ 78
DTC Logic .............................................................. 112
Diagnosis Procedure ............................................. 112 B
NEUTRAL POSITION : Description ........................ 78
Component Inspection ........................................... 114
NEUTRAL POSITION : Special Repair Require- C1109 POWER AND GROUND SYSTEM ...... 115
ment ........................................................................ 78 Description ............................................................. 115 C
DTC Logic .............................................................. 115
FUNCTION DIAGNOSIS .............................. 80 Diagnosis Procedure ............................................. 115
ESP .....................................................................80 D
C1110 ABS ACTUATOR AND ELECTRIC
System Diagram ...................................................... 80 UNIT (CONTROL UNIT) .................................. 117
Description ............................................................. 117
Component Parts Location ...................................... 81 E
DTC Logic .............................................................. 117
TCS .....................................................................84 C1111 ABS MOTOR, MOTOR RELAY SYS- BRC
System Diagram ...................................................... 84
TEM ................................................................. 118
Description ............................................................. 118
DTC Logic .............................................................. 118 G
ABS ....................................................................88 Component Inspection ........................................... 119
System Diagram ...................................................... 88 H
C1113 G SENSOR .......................................... 120
Description ............................................................. 120
DTC Logic .............................................................. 120
Diagnosis Procedure ............................................. 120 I
EBD ....................................................................92 Component Inspection ........................................... 122
System Diagram ...................................................... 92
C1115 WHEEL SENSOR ................................ 123
System Description ................................................. 92 J
Description ............................................................. 123
DTC Logic .............................................................. 123
HDC ....................................................................96 Component Inspection ........................................... 124 K
System Diagram ...................................................... 96
C1116 STOP LAMP SWITCH ......................... 126
Description ............................................................. 126
Component Parts Location ...................................... 97 L
DTC Logic .............................................................. 126
HSA .................................................................. 100 Component Inspection ........................................... 127
System Diagram .................................................... 100 M
C1118 4WD SYSTEM ..................................... 128
System Description ............................................... 100
Description ............................................................. 128
Component Parts Location .................................... 101
DTC Logic .............................................................. 128
Component Description ......................................... 103 N
DIAGNOSIS SYSTEM [ABS ACTUATOR
C1120, C1122, C1124, C1126 IN ABS SOL ... 129
AND ELECTRIC UNIT (CONTROL UNIT)] ...... 104 Description ............................................................. 129 O
CONSULT-III Function (ABS) ............................... 104
DTC Logic .............................................................. 129
COMPONENT DIAGNOSIS ....................... 109 Diagnosis Procedure ............................................. 129
Component Inspection ........................................... 130 P
C1101, C1102, C1103, C1104 WHEEL SEN-
C1121, C1123, C1125, C1127 OUT ABS SOL. 132
SOR-1 ............................................................... 109
Description ............................................................. 132
Description ............................................................ 109
DTC Logic .............................................................. 132
DTC Logic ............................................................. 109
Component Inspection ........................................... 133
Component Inspection .......................................... 111
C1130 ENGINE SIGNAL ................................. 135
BRC-3
Description .............................................................135 DTC Logic ............................................................. 159
DTC Logic ..............................................................135 Diagnosis Procedure ............................................. 159
Diagnosis Procedure .............................................135 Component Inspection .......................................... 160
C1140 ACTUATOR RELAY SYSTEM ............. 136 U1000 CAN COMM CIRCUIT ........................... 161
Description .............................................................136 Description ............................................................ 161
DTC Logic ..............................................................136 DTC Logic ............................................................. 161
Diagnosis Procedure .............................................136 Diagnosis Procedure ............................................. 161
U1010 CONTROL UNIT (CAN) ........................ 162
C1142 PRESS SENSOR ................................. 138 Description ............................................................ 162
Description .............................................................138 DTC Logic ............................................................. 162
Component Inspection ...........................................140 PARKING BRAKE SWITCH ............................. 163
Description ............................................................ 163
C1143, C1144 STEERING ANGLE SENSOR . 141 Component Function Check ................................. 163
Description .............................................................141 Diagnosis Procedure ............................................. 163
DTC Logic ..............................................................141 Component Inspection .......................................... 163
Component Inspection ...........................................142 ESP OFF SWITCH ............................................ 165
Special Repair Requirement ..................................142 Description ............................................................ 165
Component Function Check ................................. 165
C1145 YAW RATE SENSOR .......................... 143 Diagnosis Procedure ............................................. 165
Description .............................................................143 Component Inspection .......................................... 166
DTC Logic ..............................................................143
Diagnosis Procedure .............................................143 HDC SWITCH ................................................... 167
Component Inspection ...........................................145 Description ............................................................ 167
C1146 SIDE G SENSOR ................................. 146 Diagnosis Procedure ............................................. 167
DTC Logic ..............................................................146
Diagnosis Procedure .............................................146 ABS WARNING LAMP ..................................... 169
Component Inspection ...........................................148 Description ............................................................ 169
C1154 PNP SWITCH ....................................... 149 Diagnosis Procedure ............................................. 169
Description .............................................................149
DTC Logic ..............................................................149 BRAKE WARNING LAMP ................................ 170
Diagnosis Procedure .............................................149 Description ............................................................ 170
Component Inspection ...........................................151 Component Function Check ................................. 170
C1155 BRAKE FLUID LEVEL SWITCH .......... 152
Description .............................................................152 ESP OFF INDICATOR LAMP ........................... 171
DTC Logic ..............................................................152 Description ............................................................ 171
Diagnosis Procedure .............................................152 Component Function Check ................................. 171
Component Inspection ...........................................153 Diagnosis Procedure ............................................. 171
C1164, C1165 CV SYSTEM ............................ 155 SLIP INDICATOR LAMP .................................. 172
Description .............................................................155 Description ............................................................ 172
DTC Logic ..............................................................155 Component Function Check ................................. 172
Diagnosis Procedure .............................................155 Diagnosis Procedure ............................................. 172
HDC INDICATOR LAMP .................................. 173
C1166, C1167 SV SYSTEM ............................. 157 Description ............................................................ 173
Description .............................................................157 Component Function Check ................................. 173
ECU DIAGNOSIS ...................................... 174
C1176 STOP LAMP SW2 ................................ 159 ABS ACTUATOR AND ELECTRIC UNIT
Description .............................................................159 (CONTROL UNIT) ............................................. 174
Reference Value ................................................... 174
BRC-4
Wiring Diagram -BRAKE CONTROL SYSTEM- .. 179 PREPARATION ............................................... 197
Fail-Safe ................................................................ 185 Special Service Tool .............................................. 197 A
DTC No. Index ...................................................... 186
SYMPTOM DIAGNOSIS ............................ 188
WHEEL SENSOR ............................................ 198 B
EXCESSIVE ABS FUNCTION OPERATION
FREQUENCY ................................................... 188 FRONT WHEEL SENSOR ....................................... 198
Diagnosis Procedure ............................................. 188 FRONT WHEEL SENSOR : Exploded View ......... 198 C
FRONT WHEEL SENSOR : Removal and Instal-
UNEXPECTED PEDAL REACTION ................ 189 lation ...................................................................... 198
REAR WHEEL SENSOR ......................................... 198 D
THE BRAKING DISTANCE IS LONG .............. 190 REAR WHEEL SENSOR : Exploded View ............ 199
Diagnosis Procedure ............................................. 190 REAR WHEEL SENSOR : Removal and Installa-
tion ......................................................................... 199 E
ABS FUNCTION DOES NOT OPERATE ......... 191
Diagnosis Procedure ............................................. 191 SENSOR ROTOR ............................................ 200
PEDAL VIBRATION OR ABS OPERATION FRONT SENSOR ROTOR ....................................... 200 BRC
SOUND OCCURS ............................................ 192 FRONT SENSOR ROTOR : Exploded View ......... 200
Diagnosis Procedure ............................................. 192 FRONT SENSOR ROTOR : Removal and Instal-
lation ...................................................................... 200
G
VEHICLE JERKS DURING ESP/TCS/ABS
REAR SENSOR ROTOR ......................................... 200
CONTROL ........................................................ 193
REAR SENSOR ROTOR : Exploded View ............ 200
REAR SENSOR ROTOR : Removal and Installa- H
NORMAL OPERATING CONDITION ............... 194 tion ......................................................................... 200
Description ............................................................ 194
(CONTROL UNIT) ........................................... 201 I
PRECAUTION ............................................ 195
Exploded View ....................................................... 201
PRECAUTIONS ................................................ 195 Removal and Installation ....................................... 202
Precaution for Supplemental Restraint System J
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- G SENSOR ...................................................... 204
SIONER" ............................................................... 195 Exploded View ....................................................... 204
Precaution for Brake System ................................ 195 Removal and Installation ....................................... 204
K
Precaution for Brake Control ................................. 195
STEERING ANGLE SENSOR ......................... 205
PREPARATION ......................................... 197 Exploded View ....................................................... 205
Removal and Installation ....................................... 205 L
BRC-5
< BASIC INSPECTION > [ABS]
BASIC INSPECTION
OVERALL SEQUENCE
JSFIA0010GB
DETAIED FLOW
BRC-6
1.COLLECT THE INFORMATION FROM THE CUSTOMER A

Get the detailed information from the customer about the symptom (the condition and the environment when
the incident/malfunction occurred) using the diagnosis worksheet. Refer to BRC-8, "Diagnostic Work Sheet".
B
>> GO TO 2.
C
Check the DTC display with the self-diagnosis function. Refer to BRC-17, "CONSULT-III Function (ABS)".
Is there any DTC displayed?
YES >> GO TO 3. D
NO >> GO TO 4.
3.PERFORM THE SYSTEM DIAGNOSIS
Perform the diagnosis applicable to the displayed DTC. Refer to BRC-58, "DTC No. Index". E
>> GO TO 7.
BRC
4.CHECK THE SYMPTOM THAT IS NOT CONSIDERED A SYSTEM MALFUNCTION
Check that the symptom is a normal operation that is not considered a system malfunction. Refer to BRC-64,
"Description". G
Is the symptom is a normal operation?
NO >> GO TO 5. H
5.CHECK THE WARNING LAMP FOR ILLUMINATION
Check that the warning lamp illuminate.
• ABS warning lamp: Refer to BRC-49, "Description". I
• Brake warning lamp: Refer to BRC-50, "Description".
Is ON/OFF timing normal?
YES >> GO TO 6. J
NO >> GO TO 2.
6.PERFORM THE DIAGNOSIS BY SYMPTOM K
Perform the diagnosis applicable to the symptom.
>> GO TO 7. L
7.REPAIR OR REPLACE THE MALFUNCTIONING PARTS
Repair or replace the specified malfunctioning parts.
M
>> GO TO 8.
8.FINAL CHECK N
Perform the self-diagnosis again, and check that the malfunction is repaired completely. After checking, erase
the self-diagnosis memory. Refer to BRC-17, "CONSULT-III Function (ABS)".
Is no other DTC present and the repair completed? O
YES >> INSPACTION END
NO >> GO TO 3.
P
BRC-7
Diagnostic Work Sheet INFOID:0000000001115422
SFIA3264E
BRC-8
ABS
< FUNCTION DIAGNOSIS > [ABS]
ABS
B
BRC
JSFIA0097GB J
• Anti-Lock Braking System is a function that detects wheel revolution while braking, electronically controls K
braking force, and prevents wheel locking during sudden braking. It improves handling stability and maneu-
verability for avoiding obstacles.
• Electrical system diagnosis by CONSULT-III is available. L
BRC-9
ABS
LHD models
JSFIA0081ZZ
1. ABS warning lamp 2. Brake warning lamp 3. ABS actuator and electric unit (con-
trol unit)
4. Front wheel sensor 5. G sensor 6. Rear wheel sensor (2WD models)
7. Rear wheel sensor (4WD models)
A. Combination meter B. Engine room (right side) C. Steering knuckle

D. Center console E. Rear axle
BRC-10
ABS
RHD models
A
BRC
L
JSFIA0082ZZ
1. ABS warning lamp 2. Brake warning lamp 3. ABS actuator and electric unit (con- M
trol unit)
7. Rear wheel sensor (4WD models) N
A. Combination meter B. Engine room (left side) C. Steering knuckle
O
P
Component parts Reference
Pump
BRC-29, "Description"
Motor
ABS actuator and electric unit (control unit)
Actuator relay (Main relay) BRC-41, "Description"
Solenoid valve BRC-37, "Description"
Wheel sensor BRC-20, "Description"
BRC-11
ABS
ABS warning lamp BRC-49, "Description"
Brake warning lamp BRC-50, "Description"
BRC-12
EBD
EBD
A
BRC
I
JSFIA0097GB

J
• Electric Brake force Distribution is a following function. ABS actuator and electric unit (control unit) detects
subtle slippages between the front and rear wheels during braking. Then is electronically controls the rear
braking force (brake fluid pressure) to reducing and reduces rear wheel slippage. Accordingly it improves K
vehicle stability.
• Electrical system diagnosis by CONSULT-III is available.
L
BRC-13
EBD
LHD models
JSFIA0081ZZ
1. ABS warning lamp 2. Brake warning lamp 3. ABS actuator and electric unit (con-
trol unit)
A. Combination meter B. Engine room (right side) C. Steering knuckle

BRC-14
EBD
RHD models
A
BRC
L
JSFIA0082ZZ
1. ABS warning lamp 2. Brake warning lamp 3. ABS actuator and electric unit (con- M
trol unit)
7. Rear wheel sensor (4WD models) N
A. Combination meter B. Engine room (left side) C. Steering knuckle
O
P
Pump
Motor
Solenoid valve BRC-37, "Description"
BRC-15
EBD
Brake warning lamp BRC-50, "Description"
BRC-16
DIAGNOSIS SYSTEM [ABS ACTUATOR AND ELECTRIC UNIT (CONTROL
UNIT)]
A
UNIT)]
CONSULT-III Function (ABS) INFOID:0000000001115431
B
FUNCTION
C
Diagnostic test mode Function
Self-diagnostic results Self-diagnostic results can be read and erased quickly.
D
Data monitor Input/Output data in the ABS actuator and electric unit (control unit) can be read.
Diagnostic test mode is which CONSULT-III drives some actuators apart from the ABS actuator
Active test
and electric unit (control unit) and also shifts some parameters in a specified range.
E
ECU part number ABS actuator and electric unit (control unit) part number can be read.
Performed by CONSULT-III instead of a technician to determine whether each system is “OK”
Function test
or “NG”.
BRC
CAN diagnostic support monitor The results of transmit/receive diagnosis of CAN communication can be read.
SELF-DIAG RESULTS MODE

G
Operation Procedure
1. Before performing the self-diagnosis, start engine and drive vehicle at 30 km/h (19 MPH) or more for
approximately 1 minute. H
How to Erase Self-diagnosis Results
1. After erasing DTC memory, start engine and drive vehicle at 30 km/h (19 MPH) or more for approximately
1 minute as the final inspection, and make sure that the ABS warning lamp and brake warning lamp turn I
OFF.
CAUTION:
If memory cannot be erased, perform applicably diagnosis. J
NOTE:
• When the wheel sensor malfunctions, after inspecting the wheel sensor system, the ABS warning lamp
and brake warning lamp will not turn OFF even when the system is normal unless the vehicle is driving
at approximately 30 km/h (19 MPH) or more for approximately 1 minute. K
• Brake warning lamp will turn ON in case of parking brake operation (when switch is ON) or of brake fluid
level switch operation (when brake fluid is insufficient).
Display Item List L
Refer to BRC-58, "DTC No. Index".
DATA MONITOR MODE
M
Display Item List
×: Applicable : Optional item
SELECT MONITOR ITEM N

Monitor item (Unit) ECU INPUT SIG- Remarks
MAIN SIGNLAS
NALS
FR LH SENSOR O
× ×
[km/h (MPH)]
FR RH SENSOR
× ×
[km/h (MPH)] P
Wheel speed
RR LH SENSOR
× ×
[km/h (MPH)]
RR RH SENSOR
× ×
[km/h (MPH)]
STOP LAMP SW
× × Stop lamp switch signal status
(On/Off)
BRC-17
UNIT)]
SELECT MONITOR ITEM
MAIN SIGNLAS
NALS
BATTERY VOLT Battery voltage supplied to the ABS actuator and electric
× ×
(V) unit (control unit)
DECEL G SENSOR 1
× ×
(G) (4WD models)
Vehicle on level surface or on slope
DECEL G SENSOR 2
× ×
(G) (4WD models)
FR RH IN SOL
×
(On/Off)
FR RH OUT SOL
×
(On/Off)
FR LH IN SOL
×
(On/Off)
FR LH OUT SOL
×
(On/Off)
Operation status of each solenoid valve
RR RH IN SOL
×
(On/Off)
RR RH OUT SOL
×
(On/Off)
RR LH IN SOL
×
(On/Off)
RR LH OUT SOL
×
(On/Off)
MOTOR RELAY
× Motor and motor relay operation
(On/Off)
ACTUATOR RLY
× Actuator relay operation
(On/Off)
ABS WARN LAMP
× ABS warning lamp
(On/Off)
EBD SIGNAL
EBD operation
(On/Off)
ABS SIGNAL
ABS operation
(On/Off)
EBD FAIL SIG
EBD fail-safe signal
(On/Off)
ABS FAIL SIG
ABS fail-safe signal
(On/Off)
ACTIVE TEST MODE

CAUTION:
• Do not perform active test while driving vehicle.
• Make sure to completely bleed air from brake system.
• The active test cannot be performed with the ABS warning lamp and brake warning lamp are on.
• ABS warning lamp and brake warning lamp are on during active test.
NOTE:
• When active test is performed while depressing the pedal, the pedal depression amount will change. This is
normal. (Only solenoid valve and ABS motor.)
• “TEST IS STOPPED” is displayed 10 seconds after operation start.
• After “TEST IS STOPPED” is displayed, to perform test again, touch BACK and repeat step 3.
Test Item
ABS SOLENOID VALVE

• For ABS solenoid valve, touch “UP”, “KEEP”, and “DOWN”. Then use screen monitor to check that solenoid
valve operates as shown in solenoid valve operation chart.
BRC-18
UNIT)]
Display A
Test item Display item
UP KEEP DOWN
FR RH IN SOL OFF ON ON
FR RH SOL B
FR RH OUT SOL OFF OFF ON*
FR LH IN SOL OFF ON ON
FR LH SOL
FR LH OUT SOL OFF OFF ON* C
RR RH IN SOL OFF ON ON
RR RH SOL
RR RH OUT SOL OFF OFF ON*
RR LH IN SOL OFF ON ON D
RR LH SOL
RR LH OUT SOL OFF OFF ON*
*: ON for 1 to 2 seconds after the touch, and then OFF.
E
ABS MOTOR
• Touch “ON” and “OFF” on screen. Make sure motor relay and actuator relay operates as shown in table
below. BRC
Display
ON OFF G
MOTOR RELAY ON OFF
ABS MOTOR
ACTUATOR RLY (Note) ON ON
H
NOTE:
A brief moment of ON/OFF condition occurs every 20 seconds after ignition switch turned ON. This is not malfunction because it is an
operation for checking.
I
BRC-19
C1101, C1102, C1103, C1104 WHEEL SENSOR-1
< COMPONENT DIAGNOSIS > [ABS]
COMPONENT DIAGNOSIS
When the sensor rotor rotates, the magnetic field changes. It converts the magnetic field changes to current
signals (rectangular wave) and transmits them to the ABS actuator and electric unit (control unit).
DTC DETECTION LOGIC
DTC Display item Malfunction detected condition Possible cause

Circuit of rear RH wheel circuit is open or short circuit.
C1101 RR RH SENSOR-1
Current signal from sensor is outside limits.
Circuit of rear LH wheel circuit is open or short circuit. • Harness or connector
C1102 RR LH SENSOR-1
Current signal from sensor is outside limits. • Wheel sensor
Circuit of front RH wheel circuit is open or short circuit. • ABS actuator and electric unit
C1103 FR RH SENSOR-1 (control unit)
Circuit of front LH wheel circuit is open or short circuit.
C1104 FR LH SENSOR-1
DTC CONFIRMATION PROCEDURE

1.CHECK SELF-DIAGNOSIS RESULTS
Check the self-diagnosis results.
RR RH SENSOR-1
RR LH SENSOR-1
FR RH SENSOR-1
FR LH SENSOR-1
Is above displayed on the self-diagnosis display?
YES >> Proceed to diagnosis procedure. Refer to BRC-20, "Diagnosis Procedure".
CAUTION:
Do not check between wheel sensor terminals.
1.CHECK SENSOR AND SENSOR ROTOR
• Check that there is no damage or adherence of foreign matter on the sensor rotor surface.
• Check sensor rotor for damage.
• Check wheel sensor for damage, disconnection or looseness.
• Check that there is no deformation the wheel sensor mounting surface.
Are the sensor and sensor rotor normal?
YES >> GO TO 2.
NO >> Repair wheel sensor mount or replace sensor rotor. Then perform the self-diagnosis.
2.CHECK CONNECTOR
2. Disconnect ABS actuator and electric unit (control unit) connector.
3. Disconnect malfunctioning wheel sensor connector.
4. Check terminal to see if it is deformed, disconnected, loose, etc., Repair or replace it if any malfunction
condition is found.
BRC-20
5. Reconnect connectors and then perform the self-diagnosis.
Is any item indicated on the self-diagnosis display? A
YES >> GO TO 3.
NO >> Poor connection of connector terminal. Repair or replace connector.
3.CHECK WHEEL SENSOR HARNESS B

C
4. Check continuity between terminals. (Also check continuity when steering wheel is turned right and left
and when sensor harness inside the wheel house is moved.)
D
Measurement terminal for signal circuit
ABS actuator and electric unit (control unit) Wheel sensor
Continuity
E
12 E39 (Front RH) 4
27 E22 (Front LH) 2
E34 Existed
15 B41 (Rear RH) 8 BRC
30 B44 (Rear LH) 6
Measurement terminal for power supply circuit G

Continuity
H
21 E39 (Front RH) 3
23 E22 (Front LH) 1
E34 Existed
11 B41 (Rear RH) 7 I
26 B44 (Rear LH) 5
Measurement terminal for ground circuit J

Continuity
12, 21 K
27, 23
E34 E34 3, 4 Not existed
15, 11 L
30, 26
5. Reconnect ABS actuator and electric unit (control unit) connector.
Is the inspection result normal? M
YES >> GO TO 4.
NO >> Repair or replace malfunctioning components.
4.CHECK WHEEL SENSOR POWER SUPPLY CIRCUIT N

2. Check voltage between wheel sensor harness connector power supply terminal and ground.
O
Wheel sensor
— Voltage
Connector Terminal P
E39 (Front RH) 3
E22 (Front LH) 1
Ground Approx. 8 V or more
B41 (Rear RH) 7
B44 (Rear LH) 5
Is the inspection result normal?
BRC-21
YES >> Replace applicable wheel sensor.
NO >> Replace ABS actuator and electric unit (control unit).
1.CHECK DATA MONITOR

On “DATA MONITOR”, select “FR LH SENSOR”, “FR RH SENSOR”, “RR LH SENSOR”, and “RR RH SEN-
SOR”, and check the vehicle speed.
Wheel sensor Vehicle speed (DATA MONITOR)

FR LH SENSOR
FR RH SENSOR Nearly matches the speedometer dis-
RR LH SENSOR play (±10% or less)
RR RH SENSOR
NO >> Go to diagnosis procedure. Refer to BRC-20, "Diagnosis Procedure".
BRC-22
A
ABS unit continually monitors wheel speed sensors to detect abnormal signals. B

Signal from rear RH wheel sensor does not match other D
C1105 RR RH SENSOR-2 • Sensor not installed currently
3 wheel speed signals. • Sensor rotor or encoder dam-
Signal from rear LH wheel sensor does not match other aged
C1106 RR LH SENSOR-2 • Sensor rotor loose on axle
3 wheel speed signals. E
• Electrical interference
Signal from front RH wheel sensor does not match other • Wheel not turning - e.g. vehi-
C1107 FR RH SENSOR-2
3 wheel speed signals. cle driven on 2WD dyno
Signal from front LH wheel sensor does not match other • Sensor damaged BRC
C1108 FR LH SENSOR-2 • ABS unit damaged
3 wheel speed signals.

G
H
RR RH SENSOR-2
I
RR LH SENSOR-2
FR RH SENSOR-2
FR LH SENSOR-2 J
NO >> INSPECTION END K
CAUTION: L
1.CHECK SENSOR AND SENSOR ROTOR M
N
YES >> GO TO 2.
O
2.CHECK CONNECTOR
1. Turn ignition switch OFF. P
condition is found.
Is any item indicated on the self-diagnosis display?
YES >> GO TO 3.
BRC-23
3.CHECK WHEEL SENSOR HARNESS
Continuity
12 E39 (Front RH) 4
27 E22 (Front LH) 2
E34 Existed
15 B41 (Rear RH) 8
30 B44 (Rear LH) 6
Measurement terminal for power supply circuit

Continuity
21 E39 (Front RH) 3
23 E22 (Front LH) 1
E34 Existed
11 B41 (Rear RH) 7
26 B44 (Rear LH) 5
Measurement terminal for ground circuit

Continuity
12, 21
27, 23
15, 11
30, 26
YES >> GO TO 4.
4.CHECK WHEEL SENSOR POWER SUPPLY CIRCUIT
Wheel sensor
— Voltage
Connector Terminal
E39 (Front RH) 3
E22 (Front LH) 1
B41 (Rear RH) 7
B44 (Rear LH) 5
BRC-24
A
SOR”, and check the vehicle speed. B

C
FR LH SENSOR
RR LH SENSOR play (±10% or less) D
RR RH SENSOR
E
BRC
BRC-25
C1109 POWER AND GROUND SYSTEM
Supplies electric power to the ABS actuator and electric unit (control unit).
DTC DETECTION LOGIC

• Harness or connector
When the ABS actuator and electric unit (control unit) • ABS actuator and electric unit
BATTERY VOLTAGE power supply is lower than normal and vehicle speed is (control unit)
C1109
[ABNORMAL] greater than 6km/h (4 MPH). Power supply is greater • Fuse
than normal limits. • Vehicle electrical power sys-
tem

BATTERY VOLTAGE [ABNORMAL]
1.CHECK CONNECTOR
3. Check terminal for deformation, disconnection, looseness, and so on. If any malfunction is found, repair or
replace terminal.
4. Reconnect connector and then perform the self-diagnosis.
YES >> GO TO 2.
2.CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) POWER SUPPLY CIRCUIT
3. Turn ignition switch ON or OFF and check voltage between ABS actuator and electric unit (control unit)
harness connector terminal and ground.

— Condition Voltage
Connector Terminal
Ignition switch: ON Battery voltage
E34 16 Ground
Ignition switch: OFF Approx. 0 V
YES >> GO TO 3.
3.ABS POWER SUPPLY CHECK (UNDER LOAD CONDITIONS)
BRC-26
1. Use 12 V lamp (normal rating 10 to 20 W) connected between E34 terminals 16 and 4. With ignition
switch ON check bulb illuminates correctly. A
2. Check ABS motor supply under loaded condition (connector E34 terminals 1 and 2).
YES >> GO TO 4. B
NO >> Check both power supply and ground circuit.
4.CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) GROUND CIRCUIT
C
3. Check continuity between ABS actuator and electric unit (control unit) harness connector terminals and
ground. D

— Continuity E
Connector Terminal
E34 3, 4 Ground Existed
Is the inspection result normal? BRC
YES >> Check battery for terminal looseness, low voltage, etc. it any malfunction is found, repair malfunc-
tioning parts.
NO >> Repair or replace malfunctioning components (check ABS earth bolt for tightness and corrosion).
G
BRC-27
C1110 ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)
ABS unit is continuously monitoring ECU hardware and software for correct operation.
DTC DETECTION LOGIC

Internal failure of control unit
components. ABS solenoid
C1110 CONTROLLER FAILURE Possible internal failure of control unit components.
valve or motor power supply/
ground abnormality.

1. Check both ABS solenoid valve and motor supply and ground circuits using a suitable electrical load.
2. Check wheel speed sensor inputs.
3. Check the self-diagnosis results.
CONTROLLER FAILURE
1.REPLACE ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)

CAUTION:
Replace ABS actuator and electric unit (control unit) when self-diagnostic result shows items other
than those applicable.
>> Replace ABS actuator and electric unit (control unit).
BRC-28
C1111 ABS MOTOR, MOTOR RELAY SYSTEM
A
PUMP B
The pump returns the brake fluid stored in the reservoir to the master cylinder by reducing the pressure.
MOTOR
The motor drives the pump according to the signals transmitted by the ABS actuator and electric unit (control C
unit).
D
DTC DETECTION LOGIC

E
During the actuator motor operating with ON, when the
actuator motor turns OFF, or when the control line for ac-
tuator motor relay is open. • Harness or connector BRC
C1111 PUMP MOTOR • ABS actuator and electric unit
During the actuator motor operating with OFF, when the (control unit)
actuator motor turns ON, or when the control line for relay
is shorted to ground. G

1.CHECK SELF-DIAGNOSIS RESULTS H
I
PUMP MOTOR
Is above displayed on the self-diagnosis display? J
K
1.CHECK CONNECTOR
L
3. Check terminal for deformation, disconnect, looseness, and so on. If any malfunction is found, repair or
replace terminal. M
YES >> GO TO 2. N
NO >> Poor connection of connector terminal. Replace or repair connector.
2.CHECK ABS MOTOR AND MOTOR RELAY POWER SUPPLY CIRCUIT
O
3. Check voltage between the ABS actuator and electric unit (control unit) harness connector terminal and
ground. P

— Voltage
Connector Terminal
E34 1 Ground Battery voltage
BRC-29
YES >> GO TO 3.
Use 12 V lamp (normal rating 10 to 20 W) connected between E34 terminals 1 and 2. With ignition switch ON
check bulb illuminates correctly.
YES >> GO TO 4.
ground.

— Continuity
Connector Terminal
YES >> Replace ABS actuator and electric unit (control unit).
NO >> Repair or replace malfunctioning components. (Check ABS each bolt for tightness and corrosion).
1.CHECK ACTIVE TEST

1. On “ACTIVE TEST”, select “ABS MOTOR”.
2. Touch “ON” and “OFF” on screen. Make sure motor relay and actuator relay operates as shown in table
below.
Display
ON OFF
MOTOR RELAY ON OFF
ABS MOTOR
ACTUATOR RLY ON ON
BRC-30
C1113 G SENSOR
C1113 G SENSOR
A
G sensor detects G affecting the vehicle, and transmits the data to the ABS actuator and electric unit (control B
unit) as an analog voltage signal.
C
DTC DETECTION LOGIC
DTC Display item Malfunction detected condition Possible cause D

• ABS actuator and electric unit
(control unit) E
G sensor is malfunctioning, or signal line of G sensor is
C1113 G SENSOR • G sensor
open or shorted.
• Vehicle driven on 4WD rolling
road BRC
1.CHECK SELF-DIAGNOSIS RESULTS G
Self-diagnosis results H
G SENSOR
Is above displayed on the self-diagnosis display? I
Diagnosis Procedure INFOID:0000000001117008 J
1.CHECK CONNECTOR
1. Turn ignition switch OFF. K
3. Disconnect G sensor connector.
4. Check terminal for deformation, disconnection, looseness, and so on. If any malfunction is found, repair or L
replace terminal.
Is any item indicated on the self-diagnosis display? M
YES >> GO TO 2.
2.CHECK G SENSOR HARNESS N
3. Disconnect G sensor connector. O
4. Check continuity between G sensor harness connector terminals and ABS actuator and electric unit (con-
trol unit) harness connector terminals.
P
ABS actuator and electric unit (control unit) G sensor
Continuity
13 2
29 3
E34 B32 Existed
14 4
28 5
BRC-31
C1113 G SENSOR
YES >> GO TO 3.
3.CHECK G SENSOR POWER SUPPLY CIRCUIT
2. Check voltage between G sensor harness connector terminal and ground.
G sensor
Connector Terminal
B32 5 Ground
YES >> GO TO 4.
4.CHECK G SENSOR
1. Remove G sensor from the vehicle. Refer to BRC-73, "Exploded View".
2. Connect the following terminals between G sensor and connector.
G sensor Harness connector

Terminal Connector Terminal
1 1
2 2
3 B32 3
4 4
5 5
4. Check voltage between G sensor terminals.
G sensor
Condition
Terminals 4 – 5 Terminals 3 – 5
Horizontal 1.50 – 1.95 V 1.50 – 1.95 V
Longitudinally 20° 3.51 – 4.14 V 3.51 – 4.14 V
Longitudinally 40° 1.50 – 1.95 V 3.51 – 4.14 V
NO >> Replace G sensor.

Select “DECEL G-SENSOR1” and “DECEL G-SENSOR2”, in “DATA MONITOR” and check G sensor signal.
Monitor item Condition DATA MONITOR

Changes according to an On
DECEL G-SENSOR1 indication shown by the
decel G sensor Off
Changes according to an On
DECEL G-SENSOR2 indication shown by the
decel G sensor Off

BRC-32
C1113 G SENSOR
NO >> Go to diagnosis procedure. Refer to BRC-31, "Diagnosis Procedure". A
BRC
BRC-33
C1115 WHEEL SENSOR
C1115 WHEEL SENSOR
DTC DETECTION LOGIC

Harness or connector not a pos-
ABS SENSOR sible cause. Other possible
C1115 Miss-match between the 4 wheel speed sensor signals.
[ABNORMAL SIGNAL] causes tire radius (due to wrong
size or pressure) interference.

ABS SENSOR [ABNORMAL SIGNAL]
CAUTION:
1.CHECK TIRES
Check air pressure, wear and size.
Are air pressure, wear and size within standard?
YES >> GO TO 2.
NO >> Adjust air pressure, or replace tire.
• Check that there is no deformation, misalignment, float, and backlash on the wheel sensor and wheel sensor
mounting surface.
• Check that the wheel sensor in installed with no misalignment and backlash.
YES >> GO TO 3.
BRC-34
C1115 WHEEL SENSOR
ABS actuator and electric unit (control unit) Wheel sensor A
Continuity
12 E39 (Front RH) 4
27 E22 (Front LH) 2
B
E34 Existed
15 B41 (Rear RH) 8
30 B44 (Rear LH) 6 C

ABS actuator and electric unit (control unit) Wheel sensor D
Continuity
21 E39 (Front RH) 3
23 E22 (Front LH) 1 E
E34 Existed
11 B41 (Rear RH) 7
26 B44 (Rear LH) 5
BRC

Continuity G
12, 21
27, 23 H
15, 11
30, 26
I
YES >> GO TO 4. J
1. Turn ignition switch ON. K
Wheel sensor
L
— Voltage
Connector Terminal
E39 (Front RH) 3
M
E22 (Front LH) 1
B41 (Rear RH) 7
B44 (Rear LH) 5 N
NO >> Replace ABS actuator and electric unit (control unit). O
P
BRC-35
C1115 WHEEL SENSOR

FR LH SENSOR
RR RH SENSOR
BRC-36
C1120, C1122, C1124, C1126 IN ABS SOL
C1120, C1122, C1124, C1126 IN ABS SOL
A
The solenoid valve increases, holds or decreases the fluid pressure of each brake caliper according to the sig- B
nals transmitted by the ABS actuator and electric unit (control unit).
C
DTC DETECTION LOGIC

When the control unit detects a malfunction in the front
C1120 FR LH IN ABS SOL
LH inlet solenoid circuit.
When the control unit detects a malfunction in the front E
C1122 FR RH IN ABS SOL
RH inlet solenoid circuit. ABS actuator and electric unit
When the control unit detects a malfunction in the rear LH (control unit)
C1124 RR LH IN ABS SOL
inlet solenoid circuit. BRC
When the control unit detects a malfunction in the rear
C1126 RR RH IN ABS SOL
RH inlet solenoid circuit.
DTC CONFIRMATION PROCEDURE G

Check the self-diagnosis results. H
FR LH IN ABS SOL I
FR RH IN ABS SOL
RR LH IN ABS SOL
J
RR RH IN ABS SOL
YES >> Proceed to diagnosis procedure. Refer to BRC-37, "Diagnosis Procedure". K
L
• Check that there is no damage or adherence of foreign matter on the sensor rotor surface. M
N
YES >> GO TO 2.
O
2.CHECK CONNECTOR
2. Disconnect ABS actuator and electric unit (control unit) connector. P
replace terminal.
YES >> GO TO 3.
BRC-37
C1120, C1122, C1124, C1126 IN ABS SOL
3.CHECK ACTUATOR RELAY POWER SUPPLY CIRCUIT

3. Check voltage between ABS actuator and electric unit (control unit) harness connector terminal and
ground.

— Voltage
Connector Terminal
YES >> GO TO 4.
4.CHECK ACUATOR RELAY GROUND CIRCUIT
Check continuity between ABS actuator and electric unit (control unit) harness connector terminals and
ground.

— Continuity
Connector Terminal
1.CHECK ACTIVE TEST

1. Select each test menu item on ”ACTIVE TEST“.
2. On the display, touch “UP”, “KEEP”, and “DOWN”, and check that the system operates as shown in the
table below.
Display
UP KEEP DOWN
FR RH SOL
FR LH SOL
FR LH OUT SOL OFF OFF ON*
RR RH SOL
RR LH IN SOL OFF ON ON
RR LH SOL
BRC-38
C1121, C1123, C1125, C1127 OUT ABS SOL
C1121, C1123, C1125, C1127 OUT ABS SOL
A
C
DTC DETECTION LOGIC

C1121 FR LH OUT ABS SOL
LH outlet solenoid circuit.
C1123 FR RH OUT ABS SOL
RH outlet solenoid circuit. ABS actuator and electric unit
C1125 RR LH OUT ABS SOL
outlet solenoid circuit. BRC
C1127 RR RH OUT ABS SOL
RH outlet solenoid circuit.

FR LH OUT ABS SOL I
FR RH OUT ABS SOL
RR LH OUT ABS SOL
J
RR RH OUT ABS SOL
L
N
YES >> GO TO 2.
O
2.CHECK CONNECTOR
replace terminal.
YES >> GO TO 3.
BRC-39
C1121, C1123, C1125, C1127 OUT ABS SOL

ground.

— Voltage
Connector Terminal
YES >> GO TO 4.
4.CHECK ACUATOR RELAY GROUND CIRCUIT
ground.

— Continuity
Connector Terminal
1.CHECK ACTIVE TEST

table below.
Display
UP KEEP DOWN
FR RH SOL
FR LH SOL
RR RH SOL
RR LH SOL
BRC-40
C1140 ACTUATOR RELAY SYSTEM
A
Activates or deactivates each solenoid valve according to the signals transmitted by the ABS actuator and B
electric unit (control unit).
C
DTC DETECTION LOGIC

During the actuator relay operating with OFF, when the
actuator relay turns ON, or when the control line for the
relay is shorted to the ground. • Harness or connector
C1140 ACTUATOR RLY • ABS actuator and electric unit
E
During the actuator relay operating with ON, when the (control unit)
relay is open.
BRC
G
Self-diagnosis results H
ACTUATOR RLY
YES >> Proceed to diagnosis procedure. Refer to BRC-41, "Diagnosis Procedure". I
J
1.CHECK CONNECTOR
replace terminal.
L
YES >> GO TO 2.
M
1. Turn ignition switch OFF. N
ground.
O

— Voltage
YES >> GO TO 3.
BRC-41

YES >> GO TO 4.
ground.

— Continuity
Connector Terminal
NO >> Repair or replace malfunctioning components. (Check ABS each bolt for tightness and corrosion).
1.CHECK ACTIVE TEST

2. Touch “ON” and “OFF” on screen. Make sure motor relay and actuator relay operates as shown in table
below.
Display
ON OFF
MOTOR RELAY ON OFF
ABS MOTOR
ACTUATOR RLY ON ON
BRC-42
A
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul- B
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. C
D
DTC DETECTION LOGIC

E
When ABS actuator and electric unit (control unit) is not • CAN communication line
U1000 CAN COMM CIRCUIT transmitting or receiving CAN communication signal for 2 • ABS actuator and electric unit
seconds or more. (control unit) BRC
G
1.CHECK CONNECTOR
2. Disconnect ABS actuator and electric unit (control unit) connector. H
replace terminal.
4. Reconnect connector and perform self-diagnosis.
I
CAN COMM CIRCUIT J
YES >> Go to LAN-13, "Trouble Diagnosis Flow Chart".
BRC-43
DTC DETECTION LOGIC
DTC Items Diagnostic item is detected when... Possible cause

When detecting error during the initial diagnosis of CAN
ABS actuator and electric
U1010 CONTROL UNIT (CAN) controller of ABS actuator and electric unit (control
unit (control unit) error
unit).

1.RECHECK DTC
1. Turn the ignition switch OFF to ON.
2. Perform ABS actuator and electric unit (control unit) self-diagnosis.
Is DTC “U1010” detected?
1.ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)

Check that there is no malfunction in ABS actuator and electric unit (control unit) harness connector or discon-
nection.
NO >> Repair or replace the harnesses and connectors.
BRC-44
BRAKE FLUID LEVEL SWITCH
A
The brake fluid level switch converts the brake fluid level to an electric signal and transmits it to the ABS actu- B
ator and electric unit (control unit).
Component Function Check INFOID:0000000001117034
C
1.CHECK BRAKE FLUID LEVEL SWITCH OPERATION
Operate the brake fluid level switch. Then check that the brake warning lamp in the combination meter turns
on/off correctly. D
NO >> Go to diagnosis procedure. Refer to BRC-47, "Diagnosis Procedure". E
BRC
1.CHECK CONNECTOR
2. Disconnect brake fluid level switch connector and combination meter connector. G
replace terminal.
4. Reconnect connectors and then perform component function check. Refer to BRC-45, "Component Func-
tion Check". H
YES >> Poor connection of connector terminal. Replace or repair connector.
NO >> GO TO 2. I
2.CHECK BRAKE FLUID LEVEL SWITCH

1. Turn ignition switch OFF. J
2. Disconnect brake fluid level switch connector.
3. Check continuity between brake fluid level switch connector terminals.
K
Brake fluid level switch
Condition Continuity
Connector Terminal
When brake fluid is full in the reservoir tank. Not existed L
E37 1–2
When brake fluid is empty in the reservoir tank. Existed
YES >> GO TO 3. M
NO >> Brake fluid level switch is malfunction. Replace reservoir tank.
3.CHECK BRAKE FLUID LEVEL SWITCH CIRCUIT N
1. Disconnect combination meter connector.
2. Check continuity between brake fluid level switch harness connector terminals and combination meter
harness connector terminal and/or ground.
O
Combination meter Brake fluid level switch

Continuity
Connector Terminal Connector Terminal P
M34 27 E37 1 Existed
Combination meter
— Continuity
Connector Terminal
M34 27 Ground Not existed
BRC-45

— Continuity
Connector Terminal
E37 2 Ground Existed


Connector Terminal
When brake fluid is full in the reservoir tank. Not existed
E37 1–2
When brake fluid is empty in the reservoir tank. Existed
NO >> Replace reservoir tank.
BRC-46
PARKING BRAKE SWITCH
A
The parking brake switch converts the status of the parking brake pedal to an electric signal and transmits it to B
the ABS actuator and electric unit (control unit).
C
1.CHECK PARKING BRAKE SWITCH OPERATION
Operate the parking brake pedal. Then check that the brake warning lamp in the combination meter turns on/
off correctly. D
Condition Brake warning lamp illumination status

E
When the parking brake switch is opera-
ON
tion
When the parking brake switch is not oper-
OFF BRC
ation.
G
H
1.CHECK PARKING BRAKE SWITCH
2. Disconnect parking brake switch connector. I
3. Check continuity between parking brake switch connector terminal and ground.
Parking brake switch J

Connector Terminal
When the parking brake switch is operated. Existed
M103 1 – Ground
When the parking brake switch is not operated. Not existed K
YES >> GO TO 2.
L
NO >> Replace parking brake switch.
2.CHECK COMBINATION METER
Check if the indication and operation of combination meter are normal. Refer to MWI-24, "Diagnosis Descrip- M
tion".
YES >> INSPECTION END N
NO >> Repair or replace combination meter.
O
P
2. Disconnect parking brake switch connector.
BRC-47
Parking brake switch

Connector Terminal
When the parking brake switch is operated. Existed
M103 1 – Ground
When the parking brake switch is not operated. Not existed
BRC-48
ABS WARNING LAMP
ABS WARNING LAMP
A
×: ON –: OFF B
Condition ABS warning lamp
Ignition switch OFF –
For 1 second after turning ON ignition switch × C
1 second later after turning ON ignition switch –
ABS function is malfunctioning. ×
D
EBD function is malfunctioning. ×

E
1.CHECK ABS WARNING LAMP OPERATION
Check that the lamp illuminates for approximately 1 second after the ignition switch is turned ON. BRC
NO >> Go to diagnosis procedure. Refer to BRC-49, "Diagnosis Procedure". G
1.CHECK SELF-DIAGNOSIS H
Perform ABS actuator and electric unit (control unit) self-diagnosis.
I
YES >> GO TO 2.
NO >> Check items displayed by self-diagnosis.
2.CHECK COMBINATION METER J
Check if the indication and operation of combination meter are normal. Refer to MWI-24, "Diagnosis Descrip-
tion".
Is the inspection result normal? K
L
BRC-49
BRAKE WARNING LAMP
BRAKE WARNING LAMP
×: ON –: OFF
Condition Brake warning lamp (Note 1)

For 1 second after turning ON ignition switch × (Note 2)
1 second later after turning ON ignition switch × (Note 2)
NOTE:
• 1: Brake warning lamp will turn on in case of parking brake operation (when switch is ON) or of brake fluid level switch operation
(when brake fluid is insufficient).
• 2: After starting engine, brake warning lamp is turned off.
1.BRAKE WARNING LAMP OPERATION CHECK 1

Check that the lamp illuminates for approximately 1 second after the ignition switch is turned ON.
YES >> GO TO 2.
Check that the brake warning lamp in the combination meter turns ON/OFF correctly when operating the park-
ing brake pedal.
NO >> Check parking brake switch. Refer to BRC-47, "Diagnosis Procedure".

ing brake pedal.
YES >> GO TO 2.
2.CHECK SELF-DIAGNOSIS
YES >> GO TO 3.
tion".
BRC-50
ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)
< ECU DIAGNOSIS > [ABS]
ECU DIAGNOSIS A
B

CAUTION: C
The display shows the control unit calculation data, so a normal value might be displayed even in the
event the output circuit (harness) is open or short-circuited.
Data monitor D
Monitor item Display content Reference value in
Condition
normal operation
E
Vehicle stopped 0 [km/h (MPH)]
FR LH SENSOR Wheel speed Nearly matches the

Vehicle running
speed meter display
(Note 1) BRC
(± 10% or less)
FR RH SENSOR Wheel speed Nearly matches the

Vehicle running G
speed meter display
(Note 1)
(± 10% or less)
H
RR LH SENSOR Wheel speed Nearly matches the
Vehicle running
speed meter display
(Note 1)
(± 10% or less)
Vehicle stopped 0 [km/h (MPH)] I
RR RH SENSOR Wheel speed Nearly matches the

Vehicle running
speed meter display
(Note 1)
(± 10% or less) J
When brake pedal is depressed On
STOP LAMP SW Stop lamp switch signal status
When brake pedal is not depressed Off
K
Battery voltage supplied to the ABS actuator
BATTERY VOLT Ignition switch ON 10 – 16 V
and electric unit (control unit)
DECEL G SENSOR1 Changes according to an indication On

Decel G detected by decel G sensor L
(Note 2) shown by the decel G sensor Off
DECEL G SENSOR2 Changes according to an indication On

Decel G detected by decel G sensor
(Note 2) shown by the decel G sensor Off M
Actuator (solenoid valve) is active (“AC-
TIVE TEST” with CONSULT-III) or actu- On
ator relay is inactive (in fail-safe mode)
FR RH IN SOL Operation status of each solenoid valve N
When the actuator (solenoid valve) is
not active and actuator relay is active Off
(ignition switch ON)
O
FR RH OUT SOL Operation status of each solenoid valve P
BRC-51
Data monitor
Condition
normal operation
FR LH IN SOL Operation status of each solenoid valve
FR LH OUT SOL Operation status of each solenoid valve
RR RH IN SOL Operation status of each solenoid valve
RR RH OUT SOL Operation status of each solenoid valve
RR LH IN SOL Operation status of each solenoid valve
RR LH OUT SOL Operation status of each solenoid valve
When the motor relay and motor are op-
On
erating
MOTOR RELAY Motor and motor relay operation
When the motor relay and motor are not
Off
operating
ACTUATOR RLY When the actuator relay is operating On

Actuator relay operation
(Note 3) When the actuator relay is not operating Off
ABS warning lamp When ABS warning lamp is ON On

ABS WARN LAMP
(Note 4) When ABS warning lamp is OFF Off
EBD is active On
EBD SIGNAL EBD operation
EBD is inactive Off
ABS is active On
ABS SIGNAL ABS operation
ABS is inactive Off
In EBD fail-safe On
EBD FAIL SIG EBD fail-safe signal
EBD is normal Off
BRC-52
Data monitor
Monitor item Display content A
Reference value in
Condition
normal operation
In ABS fail-safe On
ABS FAIL SIG ABS fail-safe signal B
ABS is normal Off
NOTE:
• 1: Confirm tire pressure is normal. C
• 2: Only 4WD models.
• 3: Every 20 seconds momentary switch to OFF.
• 4: On and off timing for warning lamp and indicator lamp. D
- ABS warning lamp: Refer to BRC-49, "Description".
BRC
BRC-53
Wiring Diagram -BRAKE CONTROL SYSTEM- INFOID:0000000001115492
JCFWA0042GB
BRC-54
BRC
JCFWA0043GB
BRC-55
JCFWA0044GB
BRC-56
BRC
JCFWA0045GB
P
Fail-Safe INFOID:0000000001115493
ABS, EBD SYSTEM

In case of electrical malfunctions with the ABS, ABS warning lamp will turn ON. In case of electrical malfunc-
tions with the EBD, brake warning lamp, ABS warning lamp will turn ON. Simultaneously, the ABS become
one of the following conditions of the fail-safe function.
BRC-57
• For malfunction of ABS, only the EBD is activated and the condition of vehicle is the same condition of vehi-
cles without ABS system.
NOTE:
ABS self-diagnosis sound may be heard. That is a normal condition because a self-diagnosis for “Ignition
switch ON” and “The first starting” are being performed.
• For malfunction of EBD, EBD and ABS become inoperative, and the condition of vehicle is the same as the
condition of vehicles without ABS, EBD system.
DTC No. Index INFOID:0000000001115494
Items (CONSULT screen terms) DTC Reference

RR RH SENSOR-1 C1101
RR LH SENSOR-1 C1102
FR RH SENSOR-1 C1103
FR LH SENSOR-1 C1104
RR RH SENSOR-2 C1105
RR LH SENSOR-2 C1106
FR RH SENSOR-2 C1107
FR LH SENSOR-2 C1108
BATTERY VOLTAGE [ABNORMAL] C1109 BRC-26, "Description"
CONTROLLER FAILURE C1110 BRC-28, "Description"
PUMP MOTOR C1111 BRC-29, "Description"
G SENSOR C1113 BRC-31, "Description"
ABS SENSOR [ABNORMAL SIGNAL] C1115 BRC-34, "Description"
FR LH IN ABS SOL C1120 BRC-37, "Description"
FR LH OUT ABS SOL C1121 BRC-39, "Description"
FR RH IN ABS SOL C1122 BRC-37, "Description"
FR RH OUT ABS SOL C1123 BRC-39, "Description"
RR LH IN ABS SOL C1124 BRC-37, "Description"
RR LH OUT ABS SOL C1125 BRC-39, "Description"
RR RH IN ABS SOL C1126 BRC-37, "Description"
RR RH OUT ABS SOL C1127 BRC-39, "Description"
ACTUATOR RLY C1140 BRC-41, "Description"
CAN COMM CIRCUIT U1000 BRC-43, "Description"
CONTROL UNIT (CAN) U1010 BRC-44, "Description"
BRC-58
EXCESSIVE ABS FUNCTION OPERATION FREQUENCY
< SYMPTOM DIAGNOSIS > [ABS]
SYMPTOM DIAGNOSIS A
B
1.CHECK START
Check front and rear brake force distribution using a brake tester. C
• LHD models: Refer to BR-52, "General Specifications".
• RHD models: Refer to BR-99, "General Specifications".
Is the inspection result normal? D
YES >> GO TO 2.
NO >> Check brake system.
2.CHECK FRONT AND REAR AXLE E
Make sure that there is no excessive play in the front and rear axles.
• Front
- 2WD models: Refer to FAX-7, "Inspection". BRC
- 4WD models: Refer to FAX-40, "Inspection".
• Rear
- 2WD models: Refer to RAX-3, "Inspection". G
- 4WD models: Refer to RAX-9, "Inspection".
YES >> GO TO 3. H
3.CHECK WHEEL SENSOR AND SENSOR ROTOR
Check the following. I
• Wheel sensor installation for damage.
• Sensor rotor installation for damage.
• Wheel sensor connector connection. J
• Wheel sensor harness inspection.
YES >> GO TO 4. K
NO >> • Replace wheel sensor or sensor rotor.
• Repair harness.
4.CHECK ABS WARNING LAMP DISPLAY L
Make sure that the ABS warning lamp is turned off after the ignition switch is turned ON or when driving.
Is the ABS warning lamp illuminated?
M
YES >> Perform self-diagnosis.
NO >> Normal
BRC-59
UNEXPECTED PEDAL REACTION
1.CHECK BRAKE PEDAL STROKE

Check brake pedal stroke.
• LHD models: Refer to BR-8, "Inspection and Adjustment".
• RHD models: Refer to BR-58, "Inspection and Adjustment".
Is the stroke too large?
YES >> • Bleed air from brake tube and hose.
- LHD models: Refer to BR-12, "Bleeding Brake System".
- RHD models: Refer to BR-62, "Bleeding Brake System".
• Check brake pedal, brake booster, and master cylinder for mount play, looseness, brake system
fluid leakage, etc.
- Brake pedal
- Master cylinder
• LHD models: Refer to BR-13, "Inspection".
• RHD models Refer to BR-63, "Inspection".
- Brake booster
• RHD models: Refer to BR-64, "Inspection".
NO >> GO TO 2.
2.CHECK FUNCTION
Disconnect ABS actuator and electric unit (control unit) connector to deactivate ABS. Check if braking force is
normal in this condition. Connect connector after inspection.
YES >> Normal
BRC-60
THE BRAKING DISTANCE IS LONG
A
CAUTION: B
The stopping distance on slippery road surfaces might be longer with the ABS operating than when
the ABS is not operating.
1.CHECK FUNCTION C
Turn ignition switch OFF and disconnect ABS actuator and electric unit (control unit) connector to deactivate
ABS. In this condition, check stopping distance. After inspection, connect connector.
YES >> Normal
E
BRC
BRC-61
ABS FUNCTION DOES NOT OPERATE
CAUTION:
ABS does not operate when speed is 10 km/h (6 MPH) or lower.
1.CHECK ABS WARNING LAMP DISPLAY
Make sure that the ABS warning lamp turns OFF after ignition switch is turned ON or when driving.
YES >> Normal
NO >> Perform self-diagnosis.
BRC-62
PEDAL VIBRATION OR ABS OPERATION SOUND OCCURS
A
CAUTION: B
Under the following conditions, ABS is activated and vibration is felt when brake pedal is lightly
depressed (just place a foot on it).However, this is normal.
• When shifting gears
• When driving on slippery road C
• During cornering at high speed
• When passing over bumps or grooves [at approximately 50 mm (1.97 in) or more]
• When pulling away just after starting engine [at approximately 10 km/h (6 MPH) or higher] D
1.SYMPTOM CHECK 1
Check that there are pedal vibrations when the engine is started.
E
Do vibrations occur?
YES >> GO TO 2.
NO >> Inspect the brake pedal.
BRC
2.SYMPTOM CHECK 2
Check that there are ABS operation noises when the engine is started.
Do the operation noises occur? G
YES >> GO TO 3.
NO >> Perform self -diagnosis.
3.SYMPTOM CHECK 3 H
Check symptoms when electrical component (headlamps, etc.) switches are operated.
Do symptoms occur? I
YES >> Check if there is a radio, antenna, antenna lead wire, or wiring close to the control unit. If there is,
move it farther away.
NO >> Normal J
BRC-63
Symptom Result
Slight vibrations are felt on the brake pedal and the operation noises occur, when ABS is activated. This is a normal condi-
Stopping distance is longer than that of vehicles without ABS when the vehicle drives on rough, gravel, or tion due to the ABS acti-
snow-covered (fresh, deep snow) roads. vation.
This is a normal, and it is

The brake pedal vibrates and motor operation noises occur from the engine room, after the engine starts and
caused by the ABS op-
just after the vehicle starts.
eration check.
BRC-64
PRECAUTIONS
< PRECAUTION > [ABS]
PRECAUTION A
PRECAUTIONS
WARNING: D
BRC
ness connectors.
G
WARNING: H
Clean brake pads and shoes with a waste cloth, then wipe with a dust collector.
• Only use DOT 4 brake fluid. Refer to MA-22, "Fluids and Lubricants".
• Never to reuse drained brake fluid.
• Never to spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it off I
immediately and wash with water if it gets on a painted surface.
• Never to use mineral oils such as gasoline or light oil. They may damage rubber parts and cause improper
operation. J
• Tighten the brake tube flare nut to the specified torque with a flare
nut torque wrench.
• Always conform the specified tightening torque when installing the K
brake pipes.
• Brake system is an important safety part. If a brake fluid leak is
detected, always disassemble the affected part. If a malfunction is L
detected, replace part with a new one.
• Turn the ignition switch OFF and disconnect the ABS actuator and
electric unit (control unit) connector or the battery negative terminal
before performing the work. M
SBR820BA
Precaution for Brake Control INFOID:0000000001115503 N
• Just after starting vehicle after ignition switch ON, brake pedal may vibrate or motor operating noise may be
heard from engine compartment. This is normal condition.
• When an error is indicated by ABS or another warning lamp, collect all necessary information from customer O
(what symptoms are present under what conditions) and check for simple causes before starting diagnostic
servicing. Besides electrical system inspection, check brake booster operation, brake fluid level, and oil
leaks. P
• If tire size and type are used in an improper combination, or brake pads are not Genuine NISSAN parts,
stopping distance or steering stability may deteriorate.
• ABS might be out of order or malfunctions by putting a radio (wiring inclusive), an antenna and a lead-in wire
near the control unit.
• If aftermarket parts (car stereo, CD player, etc.) have been installed, check for incidents such as harness
pinches, open circuits, and improper wiring.
BRC-65
PREPARATION
< PREPARATION > [ABS]
PREPARATION
PREPARATION
Special Service Tool INFOID:0000000001115504
Tool number
Description
Tool name
GG94310000
Flare nut torque wrench Installing each brake piping
a: 10 mm (0.39 in)/ 12 mm (0.47 in)
S-NT406
BRC-66
WHEEL SENSOR
< ON-VEHICLE REPAIR > [ABS]
ON-VEHICLE REPAIR A
WHEEL SENSOR
FRONT WHEEL SENSOR
B
FRONT WHEEL SENSOR : Exploded View INFOID:0000000001115505
BRC
H
JSFIA0039GB
1. Front LH wheel sensor

I
A. White line (slant line)
Refer to GI-4, "Components" for symbol in the figure.
NOTE: J
The above figure (front side) shows left side. Right side is the mirror image.
FRONT WHEEL SENSOR : Removal and Installation INFOID:0000000001115506
K
REMOVAL
Pay attention to the following when removing sensor. L
CAUTION:
• Do not twist sensor harness as much as possible, when removing it. Pull sensors out without pulling
on sensor harness.
• Take care to avoid damaging sensor edges or rotor teeth. Remove wheel sensor first before remov- M
ing front or rear wheel hub. This is to avoid damage to sensor wiring and loss of sensor function.
• When you see the harness of the wheel sensor from the front side of the vehicle ensure that the
white lines (A) are not twisted. N
INSTALLATION
Pay attention to the following when installing wheel sensor. Tighten installation bolts to the specified torques.
Refer to "COMPONENT". O
• When installing, make sure there is no foreign material such as iron chips on and in the mounting hole of the
wheel sensor. Make sure no foreign material has been caught in the sensor rotor. Remove any foreign mate-
rial and clean the mount.
• When installing wheel sensor, be sure to press rubber grommets in until they lock at locations shown above P
in the figure. When installed, harness must not be twisted.
REAR WHEEL SENSOR
BRC-67
WHEEL SENSOR
REAR WHEEL SENSOR : Exploded View INFOID:0000000001115507
JSFIA0040GB
1. Rear LH wheel sensor
A. 2WD models B. 4WD models

NOTE:
REAR WHEEL SENSOR : Removal and Installation INFOID:0000000001115508
REMOVAL
Pay attention to the following when removing sensor.
CAUTION:
on sensor harness.
• Take care to avoid damaging sensor edges or rotor teeth. Remove wheel sensor first before remov-
INSTALLATION
Refer to "COMPONENT".
• When installing wheel sensor, be sure to press rubber grommets in until they lock at locations shown above
BRC-68
SENSOR ROTOR
SENSOR ROTOR
A
FRONT SENSOR ROTOR
FRONT SENSOR ROTOR : Exploded View INFOID:0000000001115509
B
Refer to FAX-9, "Exploded View" (2WD models), FAX-42, "Exploded View" (4WD models).
FRONT SENSOR ROTOR : Removal and Installation INFOID:0000000001115510
C
REMOVAL
Sensor rotor cannot be disassembled. Remove the sensor rotor together with hub bearing assembly. Refer to
FAX-9, "Removal and Installation" (2WD models), FAX-42, "Removal and Installation" (4WD models). D
INSTALLATION
Sensor rotor cannot be disassembled. Installation the sensor rotor together with hub bearing assembly. Refer E
to FAX-9, "Removal and Installation" (2WD models), FAX-42, "Removal and Installation" (4WD models).
REAR SENSOR ROTOR
REAR SENSOR ROTOR : Exploded View INFOID:0000000001115511
BRC
Refer to RAX-4, "Exploded View" (2WD models), RAX-13, "Exploded View" (4WD models).
G
REAR SENSOR ROTOR : Removal and Installation INFOID:0000000001115512
2WD MODELS
H
Removal
RAX-4, "Removal and Installation". I
Installation
Sensor rotor cannot be disassembled. Installation the sensor rotor together with hub bearing assembly. Refer
to RAX-4, "Removal and Installation". J
4WD MODELS
For removal and installation of sensor rotor, refer to RAX-14, "Disassembly and Assembly".
K
BRC-69
LHD models
JSFIA0083GB
1. ABS actuator and electric unit (control 2. Connector 3. Bracket

unit)
A. To front LH brake caliper B. To rear RH brake caliper C. To Rear LH brake caliper

D. To front RH brake caliper E. From master cylinder primary side F. From master cylinder secondary side
: Vehicle front
BRC-70
RHD models
A
BRC
H
JSFIA0084GB

unit) I
J
: Vehicle front

K
REMOVAL
CAUTION: L
• Before servicing, disconnect the battery cable from negative terminal.
• To remove brake tube, use a flare nut wrench to prevent flare nuts and brake tube from being dam-
aged. To install, use flare nut crowfoot and torque wrench. M
• Do not apply excessive impact to ABS actuator and electric unit (control unit), such as dropping it.
• Do not remove and install actuator by holding harness.
• After work is completed, bleed air from brake tube. Refer to BR-12, "Bleeding Brake System" (LHD
models), BR-62, "Bleeding Brake System" (RHD models). N
1. Remove cowl top. Refer to EXT-19, "Exploded View".
O
3. Loosen brake tube flare nuts, then remove brake tubes from ABS actuator and electric unit (control unit).
4. Remove tire (front LH side).
5. Remove fender protector (rear): (front LH side). Refer to EXT-21, "Exploded View". P
6. Remove ABS actuator and electric unit (control unit) bracket mounting nut.
7. Remove ABS actuator and electric unit (control unit) from vehicle.
INSTALLATION
CAUTION:
BRC-71
aged. To install, use flare nut crowfoot and torque wrench.
models), BR-62, "Bleeding Brake System" (RHD models).
• After installing harness connector in the ABS actuator and electric unit (control unit), make sure
connector is securely locked.
BRC-72
G SENSOR
G SENSOR
A
JSFIA0085GB
E
1. G sensor 2. Bracket
: Vehicle front BRC


G
REMOVAL
CAUTION:
H
• Do not drop or strike G sensor, because it has little endurance to impact.
• Do not use power tool etc., because G sensor is sensitive for the impact.
1. Remove center console assembly. Refer to IP-21, "Exploded View".
I
2. Disconnect G sensor harness connector.
3. Remove mounting nuts. Remove G sensor.
INSTALLATION J
CAUTION:
• Do not drop or strike G sensor, because it has little endurance to impact. K
• Do not use power tool etc., because G sensor is sensitive for the impact.
BRC-73
< BASIC INSPECTION > [ESP/TCS/ABS]
BASIC INSPECTION
PRECAUTIONS FOR DIAGNOSIS

If steering angle sensor, steering system parts, suspension system parts, ABS actuator and electric unit (con-
trol unit) or tires have been replaced, or if wheel alignment has been adjusted, be sure to adjust neutral posi-
tion of steering angle sensor before driving. Refer to BRC-78, "ADJUSTMENT OF STEERING ANGLE
SENSOR NEUTRAL POSITION : Description".
BRC-74
OVERALL SEQUENCE
A
BRC
JSFIA0010GB
P
DETAIED FLOW
1.COLLECT THE INFORMATION FROM THE CUSTOMER
the incident/malfunction occurred) using the diagnosis worksheet. Refer to BRC-77, "Diagnostic Work Sheet".
>> GO TO 2.
BRC-75

Check the DTC display with the self-diagnosis function. Refer to BRC-104, "CONSULT-III Function (ABS)".
Is there any DTC displayed?
YES >> GO TO 3.
NO >> GO TO 4.
3.PERFORM THE SYSTEM DIAGNOSIS
Perform the diagnosis applicable to the displayed DTC. Refer to BRC-186, "DTC No. Index".
>> GO TO 7.
4.CHECK THE SYMPTOM THAT IS NOT CONSIDERED A SYSTEM MALFUNCTION
Check that the symptom is a normal operation that is not considered a system malfunction. Refer to BRC-194,
"Description".
Is the symptom is a normal operation?
NO >> GO TO 5.
5.CHECK THE WARNING LAMP AND INDICATOR LAMP FOR ILLUMINATION
Check that the warning lamp and indicator lamp illuminate.
• ABS warning lamp: Refer to BRC-169, "Description".
• Brake warning lamp: Refer to BRC-170, "Description".
• ESP OFF indicator lamp: Refer to BRC-171, "Description".
• SLIP indicator lamp: Refer to BRC-172, "Description".
• HDC indicator lamp: Refer to BRC-173, "Description".
Is ON/OFF timing normal?
YES >> GO TO 6.
NO >> GO TO 2.
6.PERFORM THE DIAGNOSIS BY SYMPTOM
Perform the diagnosis applicable to the symptom.
>> GO TO 7.
>> GO TO 8.
8.FINAL CHECK
Perform the self-diagnosis again, and check that the malfunction is repaired completely. After checking, erase
the self-diagnosis memory. Refer to BRC-104, "CONSULT-III Function (ABS)".
Is no other DTC present and the repair completed?
YES >> INSPACTION END
NO >> GO TO 3.
BRC-76
Diagnostic Work Sheet INFOID:0000000001115518
BRC
H
SFIA3265E
BRC-77
ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION
ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Description
INFOID:0000000001115521
In case of doing work that applies to the list below, make sure to adjust neutral position of steering angle sen-
sor before running vehicle.
×: Required –: Not required
Situation Adjustment of steering angle sensor neutral position

Removing/Installing steering angle sensor ×
Replacing steering angle sensor ×
Removing/Installing steering wheel ×
Replacing steering wheel ×
Removing/Installing steering components ×
Replacing steering components ×
Removing/Installing suspension components ×
Replacing suspension components ×
Change tires to new ones —
Tire rotation —
Adjusting wheel alignment ×
ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Special Re-

pair Requirement INFOID:0000000001115522
ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION

CAUTION:
To adjust neutral position of steering angle sensor, make sure to use CONSULT-III
(Adjustment cannot be done without CONSULT-III)
1.ALIGN THE VEHICLE STATUS
Stop vehicle with front wheels in straight-ahead position.
>> GO TO 2.
2.PERFORM THE NEUTRAL POSITION ADJUSTMENT FOR THE STEERING ANGLE SENSOR
1. On the CONSULT-III screen, touch "WORK SUPPORT" and "ST ANG SEN ADJUSTMENT" in order.
2. Touch “START”.
CAUTION:
Do not touch steering wheel while adjusting steering angle sensor.
3. After approximately 10 seconds, touch “END”.
NOTE:
After approximately 60 seconds, it ends automatically.
4. Turn ignition switch OFF, then turn it ON again.
CAUTION:
Be sure to perform above operation.
>> GO TO 3.
1. Run vehicle with front wheels in straight-ahead position, then stop.
2. Select “DATA MONITOR”. Then make sure “STR ANGLE SIG” is within 0±2.5°.
Is the steering angle within the specified range?
YES >> GO TO 4.
BRC-78
NO >> Perform the neutral position adjustment for the steering angle sensor again, GO TO 1.
4.ERASE THE SELF-DIAGNOSIS MEMORY A
Erase the self-diagnosis memories of the ABS actuator and electric unit (control unit) and ECM.
• ABS actuator and electric unit (control unit): Refer to BRC-104, "CONSULT-III Function (ABS)".
B
• ECM
- MR20DE: Refer to ECM-87, "CONSULT-III Function".
- QR25DE: Refer to ECQ-89, "CONSULT-III Function".
- M9R: Refer to ECR-97, "Diagnosis Description". C
Are the memories erased?
NO >> Check the items indicated by the self-diagnosis. D
BRC
BRC-79
ESP
< FUNCTION DIAGNOSIS > [ESP/TCS/ABS]
FUNCTION DIAGNOSIS
ESP
JSFIA0069GB
• Electronic Stability Program system detects driver′s steering operation amount and brake pedal travel from
steering angle sensor and pressure sensor. Using information from yaw rate sensor, G sensor and wheel
sensor, ESP judges driving condition (conditions of under steer and over steer) to improve vehicle driving
stability by controlling brake application to 4 wheels and engine output.
• During ESP operation, it informs driver of system operation by flashing SLIP indicator lamp.
BRC-80
ESP
A
LHD models
BRC
P
JSFIA0071ZZ
1. Steering angle sensor 2. ABS warning lamp 3. Brake warning lamp

4. ESP OFF indicator lamp 5. SLIP indicator lamp 6. HDC indicator lamp
7. HDC switch 8. ABS actuator and electric unit (con- 9. Pressure sensor
trol unit)
BRC-81
ESP
10. Front wheel sensor 11. Yaw rate/side/decel G sensor 12. ESP OFF switch
13. Rear wheel sensor (2WD models) 14. Rear wheel sensor (4WD models)
A. Back of spiral cable assembly B. Combination meter C. Console finisher assembly

D. Engine room (right side) E. Engine room (right side) F. Steering knuckle
G. Center console H. Instrument driver lower panel I. Rear axle
RHD models
JSFIA0072ZZ
BRC-82
ESP
1. ABS actuator and electric unit (con- 2. HDC switch 3. Steering angle sensor A
trol unit)
4. ABS warning lamp 5. Brake warning lamp 6. ESP OFF indicator lamp
7. SLIP indicator lamp 8. HDC indicator lamp 9. ESP OFF switch
B
10. Front wheel sensor 11. Yaw rate/side/decel G sensor 12. Rear wheel sensor (2WD models)
A. Engine room (left side) B. Console finisher assembly C. Back of spiral cable assembly C
D. Combination meter E. Instrument driver lower panel F. Steering knuckle
G. Center console H. Rear axle
D
E
Pump
Motor BRC
ABS actuator and electric unit (control unit) Solenoid valve BRC-129, "Description"
G
Pressure sensor BRC-138, "Description"
ESP switch-over valve (CV1, CV2) BRC-155, "Description"
ESP switch-over valve (SV1, SV2) BRC-157, "Description" H
Yaw rate sensor BRC-143, "Description"
G sensor BRC-146, "Description" I
Steering angle sensor BRC-141, "Description"
ESP OFF switch BRC-165, "Description"
J
HDC switch BRC-167, "Description"
Brake warning lamp BRC-170, "Description" K
ESP OFF indicator lamp BRC-171, "Description"
SLIP indicator lamp BRC-172, "Description"
L
HDC indicator lamp BRC-173, "Description"
BRC-83
TCS
TCS
JSFIA0069GB
• Traction Control System is a function that electronically controls engine torque, brake fluid pressure and A/T
gear position to ensure the optimum slippage ratio at drive wheels by computing wheel speed signals from 4
wheel sensors. When ABS actuator and electric unit (control unit) detects a spin at drive wheels (rear
wheels), it compares wheel speed signals from all 4 wheels. At this time, LH and RH rear brake fluid pres-
sure are controlled, while fuel being cut to engine and throttle valve being closed to reduce engine torque by
the control unit. Further more, throttle position is continuously controlled to ensure the optimum engine
torque at all times.
• During TCS operation, it informs driver of system operation by flashing SLIP indicator lamp.
BRC-84
TCS
A
LHD models
BRC
P
JSFIA0071ZZ

trol unit)
BRC-85
TCS

RHD models
JSFIA0072ZZ
BRC-86
TCS
trol unit)
B
D
E
Pump
Motor BRC
G
J
L
BRC-87
ABS
ABS
JSFIA0069GB
• Anti-Lock Braking System is a function that detects wheel revolution while braking, electronically controls
braking force, and prevents wheel locking during sudden braking. It improves handling stability and maneu-
verability for avoiding obstacles.
BRC-88
ABS
A
LHD models
BRC
P
JSFIA0071ZZ

trol unit)
BRC-89
ABS

RHD models
JSFIA0072ZZ
BRC-90
ABS
trol unit)
B
D
E
Pump
Motor BRC
G
J
L
BRC-91
EBD
EBD
JSFIA0069GB
• Electric Brake force Distribution is a following function. ABS actuator and electric unit (control unit) detects
subtle slippages between the front and rear wheels during braking. Then is electronically controls the rear
braking force (brake fluid pressure) to reducing and reduces rear wheel slippage. Accordingly it improves
vehicle stability.
BRC-92
EBD
A
LHD models
BRC
P
JSFIA0071ZZ

trol unit)
BRC-93
EBD

RHD models
JSFIA0072ZZ
BRC-94
EBD
trol unit)
B
D
E
Pump
Motor BRC
G
J
L
BRC-95
HDC
HDC
JSFIA0069GB
• The Hill Descent Control system will help maintain vehicle speed when driving under 25 km/h (15 MPH) on
steeper downhill grades. HDC will provide braking allowing the driver to concentrate on steering while reduc-
ing the burden of brake and accelerator operation.
• To operate the system, set the 4WD switch to LOCK and push the HDC switch. The HDC indicator in the
combination meter will turn ON. While HDC is operating, the stop lamp will illuminate.
• If the accelerator or brake pedal is depressed while the HDC system is ON, the system will stop operating.
• During HDC operation, a mechanical noise may be heard. This is normal.
BRC-96
HDC
A
LHD models
BRC
P
JSFIA0071ZZ

trol unit)
BRC-97
HDC

RHD models
JSFIA0072ZZ
BRC-98
HDC
trol unit)
B
D
E
Pump
Motor BRC
G
J
L
BRC-99
HSA
HSA
JSFIA0069GB
• The HSA system will assist the driver by applying the brake automatically and preventing the vehicle from
rolling backward when starting on an uphill.
• The maximum holding time is 2 seconds. After 2 seconds, the vehicle will being to roll back gradually and
then HSA will stop operating completely.
BRC-100
HSA
A
LHD models
BRC
P
JSFIA0071ZZ

trol unit)
BRC-101
HSA

RHD models
JSFIA0072ZZ
BRC-102
HSA
trol unit)
B
D
E
Pump
Motor BRC
G
J
L
BRC-103
UNIT)]
UNIT)]
CONSULT-III Function (ABS) INFOID:0000000001115539
FUNCTION
Diagnostic test mode Function

This mode enables a technician to adjust some devices faster and more accurately by following
Work support
the indications on CONSULT-III.
Self-diagnostic results Self-diagnostic results can be read and erased quickly.
Data monitor Input/Output data in the ABS actuator and electric unit (control unit) can be read.
Diagnostic test mode is which CONSULT-III drives some actuators apart from the ABS actuator
Active test
and electric unit (control unit) and also shifts some parameters in a specified range.
ECU part number ABS actuator and electric unit (control unit) part number can be read.
CAN diagnostic support monitor The results of transmit/receive diagnosis of CAN communication can be read.
SELF-DIAG RESULTS MODE

Operation Procedure
1. Before performing the self-diagnosis, start engine and drive vehicle at 30 km/h (19 MPH) or more for
approximately 1 minute.
How to Erase Self-diagnosis Results
1. After erasing DTC memory, start engine and drive vehicle at 30 km/h (19 MPH) or more for approximately
1 minute as the final inspection, and make sure that the ABS warning lamp, ESP OFF indicator lamp,
SLIP indicator lamp and brake warning lamp turn OFF.
CAUTION:
If memory cannot be erased, perform applicably diagnosis.
NOTE:
• When the wheel sensor malfunctions, after inspecting the wheel sensor system, the ABS warning lamp,
ESP OFF indicator lamp, SLIP indicator lamp and brake warning lamp will not turn OFF even when the
system is normal unless the vehicle is driving at approximately 30 km/h (19 MPH) or more for approxi-
mately 1 minute.
• Brake warning lamp will turn ON in case of parking brake operation (when switch is ON) or of brake fluid
level switch operation (when brake fluid is insufficient).
• ESP OFF switch should not stay “ON” position.
Display Item List
Refer to BRC-186, "DTC No. Index".
DATA MONITOR MODE
Display Item List
×: Applicable : Optional item
SELECT MONITOR ITEM

MAIN SIGNLAS
NALS
FR LH SENSOR
× ×
[km/h (MPH)]
FR RH SENSOR
× ×
[km/h (MPH)]
Wheel speed
RR LH SENSOR
× ×
[km/h (MPH)]
RR RH SENSOR
× ×
[km/h (MPH)]
BRC-104
UNIT)]
SELECT MONITOR ITEM
Monitor item (Unit) Remarks A
ECU INPUT SIG-
MAIN SIGNLAS
NALS
STOP LAMP SW
× × Stop lamp switch signal status B
(On/Off)
BATTERY VOLT Battery voltage supplied to the ABS actuator and electric
× ×
(V) unit (control unit)
GEAR × × Gear position determined by TCM C
OFF SW
× × ESP OFF switch
(On/Off)
D
YAW RATE SEN
× × Yaw rate detected by yaw rate/side/decel G sensor
(°/s)
DECEL G-SEN
× × Decel G detected by yaw rate/side/decel G sensor E
(G)
ACCEL POS SIG Throttle actuator opening/closing is displayed (Linked with
×
(%) accelerator pedal)
SIDE G-SENSOR
BRC
× Transverse G detected by yaw rate/side/decel G sensor
(m/s2)
STR ANGLE SIG
× Steering angle detected by steering angle sensor G
(°)
PRESS SENSOR
× Brake fluid pressure detected by pressure sensor
(bar)
H
ENGINE RPM
× Engine speed
[tr/min (rpm)]
FLUID LEV SW
× Brake fluid level switch signal status I
(On/Off)
FR RH IN SOL
×
(On/Off)
FR RH OUT SOL J
×
(On/Off)
FR LH IN SOL
×
(On/Off) K
FR LH OUT SOL
×
(On/Off)
Operation status of each solenoid valve
RR RH IN SOL L
×
(On/Off)
RR RH OUT SOL
×
(On/Off) M
RR LH IN SOL
×
(On/Off)
RR LH OUT SOL N
×
(On/Off)
MOTOR RELAY
× Motor and motor relay operation
(On/Off) O
ACTUATOR RLY
× Actuator relay operation
(On/Off)
ABS WARN LAMP P
× ABS warning lamp
(On/Off)
OFF LAMP
× ESP OFF indicator lamp
(On/Off)
SLIP LAMP
× SLIP indicator lamp
(On/Off)
1ST GEAR SIG
1st gear status
(On/Off)
BRC-105
UNIT)]
SELECT MONITOR ITEM
MAIN SIGNLAS
NALS
N POSI SIG
N range status
(On/Off)
P POSI SIG
P range status
(On/Off)
R POSI SIG
R range status
(On/Off)
CRAKING SIG
CAN mask request for cranking
(On/Off)
CV1
Cut valve 1 monitor
(On/Off)
CV2
Cut valve 2 monitor
(On/Off)
SV1
Suction valve 1 monitor
(On/Off)
SV2
Suction valve 2 monitor
(On/Off)
STOP LAMP SW2
ASCD brake switch signal status
(On/Off)
STP ON RLY
Stop lamp on relay operation
(On/Off)
EBD WARN LAMP
Brake warning lamp
(On/Off)
HDC SW
HDC switch
(On/Off)
EBD SIGNAL
EBD operation
(On/Off)
ABS SIGNAL
ABS operation
(On/Off)
TCS SIGNAL
TCS operation
(On/Off)
VDC SIGNAL
ESP operation
(On/Off)
HSA SIGNAL
HSA operation
(On/Off)
HDC SIGNAL
HDC operation
(On/Off)
EBD FAIL SIG
EBD fail-safe status
(On/Off)
ABS FAIL SIG
ABS fail-safe status
(On/Off)
TCS FAIL SIG
TCS fail-safe status
(On/Off)
VDC FAIL SIG
ESP fail-safe status
(On/Off)
4WD MODE MONI
4WD mode monitor
(On/Off)
ACTIVE TEST MODE

CAUTION:
• Do not perform active test while driving vehicle.
• Make sure to completely bleed air from brake system.
BRC-106
UNIT)]
• The active test cannot be performed with the ABS warning lamp, ESP OFF indicator lamp, SLIP indi-
cator lamp and brake warning lamp are on. A
• ABS warning lamp, ESP OFF indicator lamp, SLIP indicator lamp and brake warning lamp are on dur-
ing active test.
• Erase memory of ICC system after implementing active test.
B
NOTE:
• When active test is performed while depressing the pedal, the pedal depression amount will change. This is
normal. (Only solenoid valve and ABS motor.)
• “TEST IS STOPPED” is displayed 10 seconds after operation start. C
• After “TEST IS STOPPED” is displayed, to perform test again, touch BACK and repeat step 3.
Test Item
D
ABS SOLENOID VALVE
• For ABS solenoid valve, touch “UP”, “KEEP” and “DOWN”. Then use screen monitor to check that solenoid
valve operates as shown in the table below.
E
Display
UP KEEP DOWN
BRC
FR RH SOL
CV1 OFF OFF OFF G
SV1 OFF OFF OFF
H
FR LH SOL
CV2 OFF OFF OFF
SV2 OFF OFF OFF I
RR RH SOL J
CV2 OFF OFF OFF
SV2 OFF OFF OFF
K
RR LH SOL
CV1 OFF OFF OFF
SV1 OFF OFF OFF L
ABS SOLENOID VALVE (ACT) M

• For ABS solenoid valve, touch “UP”, “ACT UP” and “ACT KEEP”. Then use screen monitor to check that
solenoid valve operates as shown in the table below.
N
Display
UP ACT UP ACT KEEP
FR RH IN SOL OFF OFF OFF O
FR RH OUT SOL OFF OFF OFF
FR RH SOL
CV1 OFF ON ON
SV1 OFF ON* OFF P
FR LH IN SOL OFF OFF OFF
FR LH OUT SOL OFF OFF OFF
FR LH SOL
CV2 OFF ON ON
SV2 OFF ON* OFF
BRC-107
UNIT)]
Display
UP ACT UP ACT KEEP
RR RH IN SOL OFF OFF OFF
RR RH OUT SOL OFF OFF OFF
RR RH SOL
CV2 OFF ON ON
SV2 OFF ON* OFF
RR LH IN SOL OFF OFF OFF
RR LH OUT SOL OFF OFF OFF
RR LH SOL
CV1 OFF ON ON
SV1 OFF ON* OFF
ABS MOTOR
• Touch “ON” and “OFF” on screen. Make sure motor relay and actuator relay operates as shown in table
below.
Display
ON OFF
MOTOR RELAY ON OFF
ABS MOTOR
ACTUATOR RLY ON ON
STOP LAMP ON RELAY

• Touch “ON” and “OFF” on screen. Make sure stop lamp on relay operates as shown in table below.
Display
ON OFF
STP ON RLY STP ON RLY ON OFF
BRC-108
< COMPONENT DIAGNOSIS > [ESP/TCS/ABS]
B
C
DTC DETECTION LOGIC D

Circuit of rear RH wheel sensor is open or short circuit. E
Circuit of rear LH wheel sensor is open or short circuit. • Harness or connector
Current signal from sensor is outside limits. • Wheel sensor BRC
Circuit of front RH wheel sensor is open or short circuit. • ABS actuator and electric unit
C1103 FR RH SENSOR-1 (control unit)
Circuit of front LH wheel sensor is open or short circuit. G

1.CHECK SELF-DIAGNOSIS RESULTS H

I
RR RH SENSOR-1
RR LH SENSOR-1 J
FR RH SENSOR-1
FR LH SENSOR-1
K
NO >> INSPECTION END L
CAUTION: M
N
• Check that there is no deformation the wheel sensor mounting surface. O
YES >> GO TO 2.
NO >> Repair wheel sensor mount or replace sensor rotor. Then perform the self-diagnosis. P
2.CHECK CONNECTOR
condition is found.
BRC-109
YES >> GO TO 3.

Continuity
12 E39 (Front RH) 4
27 E22 (Front LH) 2
E36 Existed
15 B41 (Rear RH) 8
30 B44 (Rear LH) 6

Continuity
21 E39 (Front RH) 3
23 E22 (Front LH) 1
E36 Existed
11 B41 (Rear RH) 7
26 B44 (Rear LH) 5

Continuity
12, 21
27, 23
15, 11
30, 26
YES >> GO TO 4.
Wheel sensor
— Voltage
Connector Terminal
E39 (Front RH) 3
E22 (Front LH) 1
B41 (Rear RH) 7
B44 (Rear LH) 5
BRC-110
NO >> Replace ABS actuator and electric unit (control unit). A
1.CHECK DATA MONITOR B
C

FR LH SENSOR D
RR RH SENSOR E

YES >> INSPECTION END BRC
BRC-111
ABS unit continually monitors wheel speed sensors to detect abnormal signals.
DTC DETECTION LOGIC

Signal from rear RH wheel sensor does not match other • Sensor not installed currently
3 wheel speed signal. • Sensor rotor or encoder dam-
Signal from rear LH wheel sensor does not match other aged
C1106 RR LH SENSOR-2 • Sensor rotor loose on axle
3 wheel speed signal.
Signal from front RH wheel sensor does not match other • Wheel not turning - e.g. vehi-
3 wheel speed signal. cle driven on 2WD dyno
Signal from front LH wheel sensor does not match other • Sensor damaged
C1108 FR LH SENSOR-2 • ABS unit damaged
3 wheel speed signal.

RR RH SENSOR-2
RR LH SENSOR-2
FR RH SENSOR-2
FR LH SENSOR-2
CAUTION:
YES >> GO TO 2.
2.CHECK CONNECTOR
condition is found.
YES >> GO TO 3.
BRC-112
3.CHECK WHEEL SENSOR HARNESS A

B
C
Continuity
Connector Terminal Connector Terminal D
12 E39 (Front RH) 4
27 E22 (Front LH) 2
E36 Existed E
15 B41 (Rear RH) 8
30 B44 (Rear LH) 6
BRC
Continuity
Connector Terminal Connector Terminal G
21 E39 (Front RH) 3
23 E22 (Front LH) 1
E36 Existed H
11 B41 (Rear RH) 7
26 B44 (Rear LH) 5
I
Continuity
Connector Terminal Connector Terminal J
12, 21
27, 23
E36 E36 3, 4 Not existed K
15, 11
30, 26
5. Reconnect ABS actuator and electric unit (control unit) connector. L
YES >> GO TO 4.
NO >> Repair or replace malfunctioning components. M
2. Check voltage between wheel sensor harness connector power supply terminal and ground. N
Wheel sensor
— Voltage O
Connector Terminal
E39 (Front RH) 3
E22 (Front LH) 1 P
B41 (Rear RH) 7
B44 (Rear LH) 5
BRC-113


FR LH SENSOR
RR RH SENSOR
BRC-114
A
Supplies electric power to the ABS actuator and electric unit (control unit). B

• Harness or connector D
When the ABS actuator and electric unit (control unit) • ABS unit
BATTERY VOLTAGE
C1109 power supply is lower than normal. Power supply is • Fuse
[ABNORMAL]
greater than normal limits. • Vehicle electrical power sys-
E
tem

1.CHECK SELF-DIAGNOSIS RESULTS BRC

G
BATTERY VOLTAGE [ABNORMAL]
Is above displayed on the self-diagnosis display? H
I
1.CHECK CONNECTOR J
K
replace terminal.
L
YES >> GO TO 2.
2.CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) POWER SUPPLY CIRCUIT AND M
GROUND CIRCUIT
2. Disconnect ABS actuator and electric unit (control unit) connector. N
3. Turn ignition switch ON or OFF and check voltage between ABS actuator and electric unit (control unit)
harness connector terminal and ground.
ABS actuator and electric unit (control unit) O

Connector Terminal
E36 16 Ground P
YES >> GO TO 3.
BRC-115

1. Use 12 V lamp (normal rating 10 to 20 W) connected between E36 terminals 16 and 4. With ignition
switch ON check bulb illuminates correctly.
2. Check ABS motor supply under loaded condition (connector E36 terminals 2 and 3).
YES >> GO TO 4.
ground.

— Continuity
Connector Terminal
YES >> Check battery for terminal looseness, low voltage, etc. it any malfunction is found, repair malfunc-
tioning parts.
NO >> Repair or replace malfunctioning components. (Check ABS earth bolt for tightness and corrosion.)
BRC-116
A
ABS unit is continuously monitoring ECU hardware and software for correct operation. B

Internal failure of control unit D
components. ABS solenoid
C1110 CONTROLLER FAILURE Possible internal failure of control unit components.
valve or motor power supply /
ground abnormal.
E
1. Check both ABS solenoid valve and motor supply and ground circuits using a suitable electrical load.
2. Check wheel speed sensor inputs.
3. Check the self-diagnosis results.
G
CONTROLLER FAILURE H
NO >> INSPECTION END I
J
1.REPLACE ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)
CAUTION:
Replace ABS actuator and electric unit (control unit) when self-diagnostic result shows items other K
than those applicable.
>> Replace ABS actuator and electric unit (control unit). L
BRC-117
PUMP
The pump returns the brake fluid stored in the reservoir to the master cylinder by reducing the pressure.
MOTOR
The motor drives the pump according to the signals transmitted by the ABS actuator and electric unit (control
unit).
DTC DETECTION LOGIC

During the actuator motor operating with ON, when the
actuator motor turns OFF, or when the control line for ac-
tuator motor relay is open. • Harness or connector
C1111 PUMP MOTOR • ABS actuator and electric unit
During the actuator motor operating with OFF, when the (control unit)
actuator motor turns ON, or when the control line for relay
is shorted to ground.

PUMP MOTOR
1.CHECK CONNECTOR
3. Check terminal for deformation, disconnect, looseness, and so on. If any malfunction is found, repair or
replace terminal.
YES >> GO TO 2.
2.CHECK ABS MOTOR AND MOTOR RELAY POWER SUPPLY CIRCUIT
3. Check voltage between the ABS actuator and electric unit (control unit) harness connector terminal and
ground.

— Voltage
Connector Terminal
BRC-118
YES >> GO TO 3. A
3.ABS POWER SUPPLY CHECK (UNDER LOAD CONDITION)
B
C
YES >> GO TO 4.
4.CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) GROUND CIRCUIT D
3. Check continuity between ABS actuator and electric unit (control unit) harness connector terminals and E
ground.
ABS actuator and electric unit (control unit) BRC

— Continuity
Connector Terminal
G
NO >> Repair or replace malfunctioning components. (Check ABS each bolt for tightness and corrosion.)
H
1.CHECK ACTIVE TEST I

2. Touch ON and OFF on screen. Make sure motor relay and actuator relay operates as shown in table
below. J
Display
ON OFF K
MOTOR RELAY ON OFF
ABS MOTOR
ACTUATOR RLY ON ON
L
NO >> Go to diagnosis procedure. Refer to BRC-118, "Diagnosis Procedure". M
BRC-119
C1113 G SENSOR
C1113 G SENSOR
Yaw rate/side/decel G sensor detects G affecting the vehicle, and transmits the data to the ABS actuator and
electric unit (control unit) as an analog voltage signal.
DTC DETECTION LOGIC

(control unit)
Yaw rate/side/decel G sensor is malfunctioning, or signal
C1113 G SENSOR • Yaw rate/side/decel G sensor
line of yaw rate/side/decel G sensor is open or shorted.
• Vehicle driven on 4WD rolling
road

G SENSOR
1.CHECK CONNECTOR
3. Disconnect yaw rate/side/decel G sensor connector.
replace terminal.
YES >> GO TO 2.
2.CHECK YAW RATE/SIDE/DECEL G SENSOR HARNESS
4. Check continuity between yaw rate/side/decel G sensor harness connector terminals and ABS actuator
and electric unit (control unit) harness connector terminals.
ABS actuator and electric unit (control unit) Yaw rate/side/decel G sensor
Continuity
13 4
14 5
E36 B38 Existed
28 2
29 6
BRC-120
C1113 G SENSOR
YES >> GO TO 3. A
3.CHECK YAW RATE/SIDE/DECEL G SENSOR HARNESS CONNECTOR
B
Check continuity between G sensor harness connector terminal and ground.
Yaw rate/side/decel G sensor C

Continuity
Connector Terminal
2–4
2–5 D
2–6
B38 Not existed
4–5
E
4–6
5–6
Is the inspection result normal? BRC
YES >> GO TO 4.
4.CHECK YAW RATE/SIDE/DECEL G SENSOR 1 G
1. Connect yaw rate/side/decel G sensor connector.

2. Connect ABS actuator and electric unit (control unit) connector. H
4. Move yaw rate/side/decel G sensor as shown in the figure to
check the output of before and after moving the sensor with the
CONSULT-III data monitor. I
Condition DATA MONITAOR

J
Horizontal Approx. 0 G
Vertical Approx. +1 G
YES >> Replace yaw rate/side/decel G sensor.
JSFIA0098ZZ
NO >> GO TO 5.
5.CHECK YAW RATE/SIDE/DECEL G SENSOR 2 L
2. Connect following terminals between yaw rate/side/decel G sensor and connector.
M
Yaw rate/side/decel G Harness connector

sensor Connector Terminal
N
2 2
4 4
B38
5 5 O
6 6
4. Check voltage between yaw rate/side/decel G sensor harness connector terminals. P
Yaw rate/side/decel G sensor

Voltage
connector Terminal
5–2 2.5 – 4.5 V
B38
6–2 0.5 – 2.5 V
BRC-121
C1113 G SENSOR
YES >> Replace ABS actuator end electric unit (control unit). Perform self-diagnosis again.
NO >> Replace yaw rate/side/decel G sensor. Perform self-diagnosis again.

Select “YAW RATE SENSOR”, “SIDE G-SENSOR” and “DECEL G-SEN”, in “DATA MONITOR” and check
yaw rate/side/decel G sensor signal.
YAW RATE SENSOR
Vehicle condition DATA MONITOR

Vehicle stop Approx. 0 d/s
Vehicle turning −100 to 100 d/s
SIDE G SENSOR

Vehicle stopped Approx. 0 m/s2
Vehicle turning right Negative value
Vehicle turning left Positive value
DECEL G SENSOR

Vehicle stopped −0.11 to +0.11 G
During acceleration Negative value
During deceleration Positive value
BRC-122
C1115 WHEEL SENSOR
C1115 WHEEL SENSOR
A
When the sensor rotor rotates, the magnetic field changes. It converts the magnetic field changes to current B
C
DTC DETECTION LOGIC

Harness or connector not a pos-
ABS SENSOR sible cause. Other possible
C1115 Miss-match between the 4 wheel speed sensor signals.
[ABNORMAL SIGNAL] causes tire radius (due to wrong E
size or pressure) interference.


G
ABS SENSOR [ABNORMAL SIGNAL]
I
CAUTION:
Do not check between wheel sensor terminals. J
1.CHECK TIRES
Check air pressure, wear and size. K
Are air pressure, wear and size within standard?
YES >> GO TO 2.
NO >> Adjust air pressure, or replace tire. L
M
• Check that there is no deformation, misalignment, float, and backlash on the wheel sensor and wheel sensor
mounting surface.
• Check that the wheel sensor in installed with no misalignment and backlash.
Are the sensor and sensor rotor normal? N
YES >> GO TO 3.
NO >> Repair wheel sensor mount or replace sensor rotor.
3.CHECK WHEEL SENSOR HARNESS O

BRC-123
C1115 WHEEL SENSOR
Continuity
12 E39 (Front RH) 4
27 E22 (Front LH) 2
E36 Existed
15 B41 (Rear RH) 8
30 B44 (Rear LH) 6

Continuity
21 E39 (Front RH) 3
23 E22 (Front LH) 1
E36 Existed
11 B41 (Rear RH) 7
26 B44 (Rear LH) 5

Continuity
12, 21
27, 23
15, 11
30, 26
YES >> GO TO 4.
Wheel sensor
— Voltage
Connector Terminal
E39 (Front RH) 3
E22 (Front LH) 1
B41 (Rear RH) 7
B44 (Rear LH) 5

BRC-124
C1115 WHEEL SENSOR
Wheel sensor Vehicle speed (DATA MONITOR) A

FR LH SENSOR
FR RH SENSOR Nearly matches the speedometer dis- B
RR RH SENSOR
Is the inspection result normal? C
D
BRC
BRC-125
C1116 STOP LAMP SWITCH
The stop lamp switch transmits the stop lamp switch signal (ON/OFF) to the ABS actuator and electric unit
(control unit).
DTC DETECTION LOGIC

• Stop lamp switch
C1116 STOP LAMP SW When stop lamp switch circuit is open.
(control unit)

STOP LAMP SW
1.CHECK STOP LAMP ILLUMINATE

Check stop lamps illuminate when brake pedal is pressed.
YES >> GO TO 2.
NO >> Check stop lamp circuit.
2.CHECK CONNECTOR
3. Disconnect stop lamp switch connector.
replace terminal.
5. Reconnect connectors securely.
6. Start engine.
7. Repeat pumping brake pedal carefully several times, and perform self-diagnosis.
Is any item indicated in the self-diagnosis display?
YES >> GO TO 3.
3.CHECK STOP LAMP SWITCH CIRCUIT
ground.
BRC-126
ABS actuator and electric A

unit (control unit) — Condition Voltage
Connector Terminal
Brake pedal is B
Battery voltage
depressed
E36 8 Ground
Brake pedal is
Approx. 0 V
released C
NO >> Repair or replace malfunctioning components. D
E
1.CHECK STOP LAMP SWITCH
2. Disconnect stop lamp switch connector. BRC
3. Check continuity between stop lamp switch connector terminals.
Stop lamp switch G

Terminal
Release stop lamp switch
Existed
(When brake pedal is depressed.) H
1−2
Push stop lamp switch
Not existed
(When brake pedal is released.)
Is the inspection result normal? I
NO >> Replace stop lamp switch.
J
BRC-127
C1118 4WD SYSTEM
C1118 4WD SYSTEM
It transmits the value calculated by 4WD control unit to ABS actuator and electric unit (control unit) with 4WD
communication line (line for 4WD system only). ABS actuator and electric unit (control unit) controls 4WD
solenoid valve according to the received command value.
DTC DETECTION LOGIC

• 4WD communication line
An error is detected on 4WD control unit side.
C1118 4WD SYSTEM • 4WD control unit
(4WD control unit fail-safe mode)
(control unit)

4WD SYSTEM
1.CHECK 4WD CONTROL UNIT

Perform 4WD control unit self-diagnosis. Refer to DLN-13, "CONSULT-III Function (ALL MODE AWD/4WD)".
Is DTC “C1211” or “C1212” detected?
YES-1 >> When C1211 is display: Refer to DLN-26, "Diagnosis Procedure".
YES-2 >> When C1212 is display: Refer to DLN-28, "Diagnosis Procedure".
BRC-128
C1120, C1122, C1124, C1126 IN ABS SOL
C1120, C1122, C1124, C1126 IN ABS SOL
A
C
DTC DETECTION LOGIC

C1120 FR LH IN ABS SOL
LH inlet solenoid circuit.
C1122 FR RH IN ABS SOL
RH inlet solenoid circuit. ABS actuator and electric unit
C1124 RR LH IN ABS SOL
inlet solenoid circuit. BRC
C1126 RR RH IN ABS SOL
RH inlet solenoid circuit.

FR LH IN ABS SOL I
FR RH IN ABS SOL
RR LH IN ABS SOL
J
RR RH IN ABS SOL
L
N
YES >> GO TO 2.
O
2.CHECK CONNECTOR
replace terminal.
YES >> GO TO 3.
BRC-129
C1120, C1122, C1124, C1126 IN ABS SOL
3.CHECK SOLENOID, ESP SWITCH-OVER VALVE AND ACTUATOR RELAY POWER SUPPLY CIRCUIT
ground.

— Voltage
Connector Terminal
YES >> GO TO 4.
4.CHECK SOLENOID, ESP SWITCH-OVER VALVE AND ACUATOR RELAY GROUND CIRCUIT
ground.

— Continuity
Connector Terminal
1.CHECK ACTIVE TEST

table below.
Display
UP KEEP DOWN
FR RH SOL
CV1 OFF OFF OFF
SV1 OFF OFF OFF
FR LH SOL
CV2 OFF OFF OFF
SV2 OFF OFF OFF
RR RH SOL
CV2 OFF OFF OFF
SV2 OFF OFF OFF
RR LH SOL
CV1 OFF OFF OFF
SV1 OFF OFF OFF
BRC-130
C1120, C1122, C1124, C1126 IN ABS SOL
YES >> INSPECTION END A
BRC
BRC-131
C1121, C1123, C1125, C1127 OUT ABS SOL
C1121, C1123, C1125, C1127 OUT ABS SOL
The solenoid valve increases, holds or decreases the fluid pressure of each brake caliper according to the sig-
DTC DETECTION LOGIC

C1121 FR LH OUT ABS SOL
LH outlet solenoid circuit.
C1123 FR RH OUT ABS SOL
RH outlet solenoid circuit. ABS actuator and electric unit
C1125 RR LH OUT ABS SOL
outlet solenoid circuit.
C1127 RR RH OUT ABS SOL
RH outlet solenoid circuit.

FR LH OUT ABS SOL
FR RH OUT ABS SOL
RR LH OUT ABS SOL
RR RH OUT ABS SOL

YES >> GO TO 2.
2.CHECK CONNECTOR
replace terminal.
YES >> GO TO 3.
BRC-132
C1121, C1123, C1125, C1127 OUT ABS SOL
3.CHECK SOLENOID, ESP SWITCH-OVER VALVE AND ACTUATOR RELAY POWER SUPPLY CIRCUIT A
B
ground.

— Voltage C
Connector Terminal
YES >> GO TO 4.
4.CHECK SOLENOID, ESP SWITCH-OVER VALVE AND ACUATOR RELAY GROUND CIRCUIT E
ground.
BRC

— Continuity
Connector Terminal G
H
I
1.CHECK ACTIVE TEST

1. Select each test menu item on ”ACTIVE TEST“. J
table below.
K
Display
UP KEEP DOWN
FR RH IN SOL OFF ON ON L
FR RH SOL
CV1 OFF OFF OFF
SV1 OFF OFF OFF
M
FR LH OUT SOL OFF OFF ON* N
FR LH SOL
CV2 OFF OFF OFF
SV2 OFF OFF OFF
RR RH IN SOL OFF ON ON O
RR RH SOL
CV2 OFF OFF OFF
P
SV2 OFF OFF OFF
RR LH SOL
CV1 OFF OFF OFF
SV1 OFF OFF OFF
BRC-133
C1121, C1123, C1125, C1127 OUT ABS SOL
BRC-134
C1130 ENGINE SIGNAL
C1130 ENGINE SIGNAL
A
ABS actuator and electric unit (control unit) and ECM exchange the engine signal with CAN communication B
line.
C
DTC DETECTION LOGIC

ECM signals are invalid or ECM self diagnosis indicates
C1130 ENGINE SIGNAL 1 (control unit) E
a fault that prevents correct TCS operation.
• ECM
• CAN communication line
DTC CONFIRMATION PROCEDURE BRC

G
ENGINE SIGNAL 1 H
1.CHECK ENGINE SYSTEM J
1. Perform ECM self-diagnosis. Repair or replace items indicated, then perform ECM self-diagnosis again.
- MR20DE: ECM-87, "CONSULT-III Function".
K
- QR25DE: ECQ-89, "CONSULT-III Function".
- M9R: ECR-97, "Diagnosis Description".
Is any item indicated on the self-diagnosis display? L
YES >> Repair or replace the affected part.
M
BRC-135
Activates or deactivates each solenoid valve according to the signals transmitted by the ABS actuator and
DTC DETECTION LOGIC

During the actuator relay operating with OFF, when the
relay is shorted to the ground. • Harness or connector
C1140 ACTUATOR RLY • ABS actuator and electric unit
During the actuator relay operating with ON, when the (control unit)
relay is open.

ACTUATOR RLY
1.CHECK CONNECTOR
replace terminal.
YES >> GO TO 2.
ground.

— Voltage
Connector Terminal
YES >> GO TO 3.
BRC-136
3.ABS POWER SUPPLY CHECK (UNDER LOAD CONDITION) A

Is the inspection result normal? B
YES >> GO TO 4.
4.CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) GROUND CIRCUIT C
3. Check continuity between ABS actuator and electric unit (control unit) harness connector terminals and D
ground.
ABS actuator and electric unit (control unit) E

— Continuity
Connector Terminal
BRC
NO >> Repair or replace malfunctioning components. (Check ABS each bolt for tightness and corrosion.)
G
1.CHECK ACTIVE TEST H

2. Touch ON and OFF on screen. Make sure motor relay and actuator relay operates as shown in table
below. I
Display
Test item Display item J
ON OFF
MOTOR RELAY ON OFF
ABS MOTOR
ACTUATOR RLY ON ON
K
NO >> Go to diagnosis procedure. Refer to BRC-136, "Diagnosis Procedure". L
BRC-137
C1142 PRESS SENSOR
C1142 PRESS SENSOR
The pressure sensor converts the brake fluid pressure to an electric signal and transmits it to the ABS actuator
and electric unit (control unit).
DTC DETECTION LOGIC

• Stop lamp switch
Pressure sensor signal line is open or shorted, or Pres-
C1142 PRESS SEN CIRCUIT • Pressure sensor
sure sensor is malfunctioning.
(control unit)

PRESS SEN CIRCUIT
1.CHECK CONNECTOR
3. Disconnect pressure sensor connector.
replace terminal.
5. Reconnect connectors securely.
YES >> GO TO 2.
2.CHECK HARNESS
3. Disconnect pressure sensor connector.
4. Check continuity between pressure sensor harness connector terminals and ABS actuator and electric
unit (control unit) harness connector terminals.
BRC-138
C1142 PRESS SENSOR
ABS actuator and electric unit A

Pressure sensor
(control unit) Continuity
10 1 Not existed B
10 2 Not existed
10 3 Existed
C
7 1 Not existed
E36 7 E31 2 Existed
7 3 Not existed D
32 1 Existed
32 2 Not existed
E
32 3 Not existed
YES >> GO TO 3. BRC
NO >> Repair or replace malfunctioning components. Perform self-diagnosis again.
3.CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)
G
1. Connect ABS actuator and electric unit (control unit) connector.
NOTE:
With pressure sensor harness connector disconnected.
2. Turn ignition switch ON. H
3. Check voltage between pressure sensor harness connector terminals.
Pressure sensor I
Voltage
Connector Terminal
E31 1–2 Approx. 5 V
J
YES >> GO TO 4.
NO >> Replace ABS actuator and electric unit (control unit). K
4.CHECK PRESSURE SENSOR
2. Connect following terminals between pressure sensor and connector. L
Connector
Pressure sensor M
Connector Terminal
1 1
2 E31 2 N
3 3
4. In 1 second or more after ignition switch ON, check pressure sensor voltage under the following condi- O
tions: (1) with brake pedal depressed, (2) with brake pedal not depressed.
Pressure sensor P
Condition Voltage
connector Terminal
When brake pedal is not depressed. Approx. 0.5 V
E31 1–2
When brake pedal is depressed. 0.5 – 4.5 V (Note)
NOTE:
Voltage changes according to the degree of the application of the brake pedal.
BRC-139
C1142 PRESS SENSOR
NO >> Replace pressure sensor.

On “DATA MONITOR”, select “PRESS SENSOR” and check the brake fluid pressure.
PRESS SENSOR
Condition
(DATA MONITOR)
With ignition switch turned ON and brake pedal released. Approx. 0 bar
With ignition switch turned ON and brake pedal depressed. 0 to 200 bar
BRC-140
C1143, C1144 STEERING ANGLE SENSOR
A
The steering angle sensor detects the rotation amount, angular velocity and direction of the steering wheel, B
and transmits the data to the ABS actuator and electric unit (control unit) via CAN communication.
C
DTC DETECTION LOGIC

Neutral position of steering angle sensor is dislocated, or • Harness or connector
C1143 ST ANG SEN CIRCUIT
the steering angle sensor is malfunctioning. • Steering angle sensor
• ABS actuator and electric unit E
C1144 ST ANG SEN SIGNAL Neutral position of steering angle sensor is not finished. (control unit)


G
ST ANG SEN CIRCUIT
ST ANG SEN SIGNAL H
J
1.CHECK VEHICLE STATE
Check vehicle for any suspension/steering misalignment or damage.
YES >> GO TO 2.
NO >> Correct any damage found.
2.CHECK CONNECTOR L

2. Disconnect ABS actuator and electric unit (control unit) connector. M
3. Disconnect steering angle sensor connector.
replace terminal.
5. Reconnect connectors and then perform the self-diagnosis. N
YES >> GO TO 3.
NO >> Poor connection of connector terminal. Replace or repair connector. O
3.CHECK STEERING ANGLE SENSOR HARNESS
1. Turn ignition switch OFF. P
2. Disconnect steering angle sensor connector.
3. Check continuity between steering angle sensor harness connector terminal and ground.
Steering angle sensor

— Continuity
Connector Terminal
M30 3 Ground Existed
BRC-141
5. Check voltage between steering angle sensor harness connector terminal and ground.
Steering angle sensor

— Voltage
Connector Terminal
M30 1 Ground Battery voltage
YES >> GO TO 4.
1. Connect the steering angle sensor connector and ABS actuator and electric unit (control unit) connector.
2. Select “STR ANGLE SIG” in “DATA MONITOR” and check steering angle sensor signal.
Steering condition STR ANGLE SIG (DATA MONITOR)

Driving straight ±2.5 °
Turn 90 ° to right Approx. +90 °
Turn 90 ° to left Approx. −90 °
YES >> GO TO 5.
NO >> Adjust neutral position of steering angle sensor.
5.CHECK FOR BACKLASH
1. Check for backlash [turn wheel to left then straight then right then straight (approx. 90°)].
2. Check straight position is always similar value.
Is there noticeable backlash?
YES >> Check sensor is correctly fitted to combination switch.
NO >> Check sensor output is correct from lock to lock.

Select “STR ANGLE SIG” in “DATA MONITOR” and check steering angle sensor signal.
Steering condition STR ANGLE SIG (DATA MONITOR)

Driving straight ±2.5 °
Turn 90 ° to right Approx. +90 °
Turn 90 ° to left Approx. −90 °
Special Repair Requirement INFOID:0000000001116911
1.ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION

Always perform the neutral position adjustment for the steering angle sensor, when replacing the steering
angle sensor. Refer to BRC-78, "ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION :
Description".
>> END
BRC-142
C1145 YAW RATE SENSOR
A
The yaw rate/side/decel G sensor detects the yaw rate affecting the vehicle, and transmits the data to the ABS B
actuator and electric unit (control unit) as an analog voltage signal.
C
DTC DETECTION LOGIC

Yaw rate/side/decel G sensor is malfunctioning, or the
C1145 YAW RATE SENSOR yaw rate/side/decel G sensor signal line is open or short-
(control unit) E
ed.
• Yaw rate/side/decel G sensor


G
YAW RATE SENSOR
I
1.CHECK CONNECTOR J
3. Disconnect yaw rate/side/decel G sensor connector. K
replace terminal.
L
YES >> GO TO 2.
M
2. Disconnect ABS actuator and electric unit (control unit) connector. N
O
Continuity
P
13 4
14 5
E36 B38 Existed
28 2
29 6
YES >> GO TO 3.
BRC-143
3.CHECK YAW RATE/SIDE/DECEL G SENSOR HARNESS CONNECTOR

Continuity
Connector Terminal
2–4
2–5
2–6
B38 Not existed
4–5
4–6
5–6
YES >> GO TO 4.
4.CHECK YAW RATE/SIDE/DECEL G SENSOR 1
1. Connect yaw rate/side/decel G sensor connector.
check the output of before and after moving the sensor with the
CONSULT-III data monitor.
Condition DATA MONITAOR

JSFIA0098ZZ
NO >> GO TO 5.
2. Connect following terminals between yaw rate/side/decel G sensor and connector.

2 2
4 4
B38
5 5
6 6
4. Check voltage between yaw rate/side/decel G sensor harness connector terminals.

Voltage
connector Terminal
5–2 2.5 – 4.5 V
B38
6–2 0.5 – 2.5 V
BRC-144
A
1.CHECK DATA MONITOR B

Select “YAW RATE SEN” in “DATA MONITOR” and check yaw rate/side/decel G sensor signal.
Vehicle condition YAW RATE SEN (DATA MONITOR) C

Vehicle stopped Approx. 0 d/s
D
E
BRC
BRC-145
C1146 SIDE G SENSOR
C1146 SIDE G SENSOR
Yaw rate/side/decel G sensor detects G affecting the vehicle, and transmits the data to the ABS actuator and
electric unit (control unit) as an analog voltage signal.
DTC DETECTION LOGIC

Yaw rate/side/decel G sensor is malfunctioning, or circuit • ABS actuator and electric unit
C1146 SIDE G-SEN CIRCUIT
of yaw rate/side/decel G sensor is open or shorted. (control unit)
• Yaw rate/side/decel G sensor

SIDE G-SEN CIRCUIT
1.CHECK CONNECTOR
replace terminal.
YES >> GO TO 2.
Continuity
13 4
14 5
E36 B38 Existed
28 2
29 6
YES >> GO TO 3.
BRC-146
C1146 SIDE G SENSOR
3.CHECK YAW RATE/SIDE/DECEL G SENSOR HARNESS CONNECTOR A

B
Continuity
Connector Terminal
2–4 C
2–5
2–6
B38 Not existed D
4–5
4–6
5–6 E
YES >> GO TO 4.
NO >> Repair or replace malfunctioning components. BRC
1. Connect yaw rate/side/decel G sensor connector. G
check the output of before and after moving the sensor with the H
CONSULT-III data monitor.
Condition DATA MONITAOR I

J
JSFIA0098ZZ
NO >> GO TO 5. K
2. Connect following terminals between yaw rate/side/decel G sensor and connector. L

M
2 2
4 4 N
B38
5 5
6 6
O
4. Check voltage between yaw rate/side/decel G sensor harness connector terminals.
P
Voltage
connector Terminal
5–2 2.5 – 4.5 V
B38
6–2 0.5 – 2.5 V
BRC-147
C1146 SIDE G SENSOR

Select “SIDE G-SENSOR” in “DATA MONITOR” and check yaw rate/side/decel G sensor signal.
Vehicle condition SIDE G-SENSOR (DATA MONITOR)

Vehicle turning right Negative value
BRC-148
C1154 PNP SWITCH
C1154 PNP SWITCH
A
1ST GEAR POSITION SWITCH B

1st gear position switch detects 1st gear to transmit its data as an analog signal to the ABS actuator and elec-
tric unit (control unit).
BACK-UP LAMP SWITCH C
Back-up lamp switch detects R range to transmit its data as an analog signal to the ABS actuator and electric
unit (control unit).
D
PARK/NEUTRAL POSITION SWITCH
Park/neutral position switch detects N range to transmit its data as an analog signal to the ABS actuator and
E
DTC DETECTION LOGIC BRC

• Harness or connector G
• 1st gear position switch
When 1st gear position switch, park/neutral position • Back-up lamp switch
C1154 PNP POSI SIG
switch and back-up lamp switch circuit is open. • Park/neutral position switch
• ABS actuator and electric unit H
(control unit)

I
J
PNP POSI SIG
K
L
CAUTION: M
• Regarding vehicles with M/T, “PNP POSI SIG” may be detected when holding the gear for a long time
in the center between the 1st position and N/R position. This is not an error if the system returns to
normal after restarting the engine.
• “PNP POSI SIG” may be detected when going up a slope, being toed with ignition switch ON and the N
gear in a shift position other than R position. This is not a shift position error. The system returns to
normal when parking on level ground after stopping the traction and restarting the engine.
1.CEHCK CONNECTOR O
3. Disconnect 1st gear position switch connector. P
4. Disconnect back-up lamp switch connector.
5. Disconnect park/neutral position switch connector.
replace terminal.
YES >> GO TO 2.
BRC-149
C1154 PNP SWITCH
2.CHECK EACH SWITCH
Select “1ST GEAR SIG”, “N POSI SIG” and “R POSI SIG” in “DATA MONITOR” and check 1st gear position
switch, park/neutral position switch and back-up lamp switch signal.
DATA MONITOR
Gear position
1ST GEAR SIG N POSI SIG R POSI SIG
R Off Off On
N Off On Off
1 On Off Off
YES >> GO TO 3.
3.CHECK HARNESS 1
3. Disconnect 1st gear position switch connector.
4. Check continuity between ABS actuator and electric unit (control unit) harness connector terminal and 1st
gear position switch harness connector terminal.
ABS actuator and electric unit

1st gear position switch
E36 31 F58 1 Existed
YES >> GO TO 4.
NO >> Replace or repair malfunctioning components.
4.CHECK HARNESS 2
1. Disconnect back-up lamp switch connector.
2. Check continuity between ABS actuator and electric unit (control unit) harness connector terminal and
back-up lamp switch harness connector terminal.

Back-up lamp switch
YES >> GO TO 5.
NO >> Replace or repair malfunctioning components.
5.CHECK HARNESS 3
1. Disconnect park/neutral position switch connector.
2. Check continuity between ABS actuator and electric unit (control unit) harness connector terminal and
park/neutral position switch harness connector terminal.

Park/neutral position switch
BRC-150
C1154 PNP SWITCH
NO >> Replace or repair malfunctioning components. A
1.CHECK EACH SWITCH B
Select “1ST GEAR SIG”, “N POSI SIG” and “R POSI SIG” in “DATA MONITOR” and check 1st gear position
switch, park/neutral position switch and back-up lamp switch signal.
C
DATA MONITOR
Gear position
1ST GEAR SIG N POSI SIG R POSI SIG D
R Off Off On
N Off On Off
1 On Off Off E

BRC-151
C1155 BRAKE FLUID LEVEL SWITCH
Brake fluid level switch contacts close when brake fluid level is low. This is detected by the combination meter
which sends the status of fluid level to the ESP unit via the CAN bus.
DTC DETECTION LOGIC

• Brake fluid level low
• Brake fluid level switch failure
Ignition switch ON and brake fluid signal low or not avail- • Wiring to brake fluid level
C1155 BR FLUID LEVEL LOW
able for 10 seconds. switch short circuit
• CAN bus failure
• Combination meter failure

BR FLUID LEVEL LOW
1.CHECK BRAKE FLUID LEVEL

Check the brake fluid level.
YES >> GO TO 2.
NO >> Investigate and fix.
2.CHECK BRAKE WARNING LAMP 1
Check that the brake warning lamp illuminates after the ignition switch is turned ON.
YES >> GO TO 3.
NO >> Check wiring to brake fluid level sensor and brake fluid level sensor.
3.CHECK BRAKE WARNING LAMP 2
ing brake.
YES >> GO TO 4.
NO >> Check parking brake switch.
4.CHECK CONNECTOR
2. Disconnect brake fluid level switch connector and combination meter connector.
replace terminal.
BRC-152
YES >> GO TO 5. A
B
C
Connector Terminal
D
When brake fluid is full in the reservoir
Not existed
tank.
E37 1–2
When brake fluid is empty in the reservoir E
Existed
tank.
YES >> GO TO 6. BRC
NO >> Brake fluid level switch is malfunction. Replace reservoir tank.
6.CHECK BRAKE FLUID LEVEL SWITCH CIRCUIT
1. Disconnect combination meter connector. G
2. Check continuity between brake fluid level switch harness connector terminals and combination meter
harness connector terminal and/or ground.
H
Combination meter Brake fluid level switch
Continuity
I
M34 27 E37 1 Existed
Combination meter J
— Continuity
Connector Terminal
M34 27 Ground Not existed
K

— Continuity
Connector Terminal L
E37 2 Ground Existed
M
N

1. Turn ignition switch OFF. O
P
Connector Terminal
When brake fluid is full in the reservoir
Not existed
tank.
E37 1–2
When brake fluid is empty in the reservoir
Existed
tank.
BRC-153
BRC-154
C1164, C1165 CV SYSTEM
A
The cut valve shuts off the normal brake fluid path from the master cylinder, when ESP/TCS is activated. B

ESP switch-over solenoid valve (CV1) on the primary D
C1164 CV1 side is open circuit or shorted, or the control line is open
or shorted to the power supply or the ground. • Harness or connector
ESP switch-over solenoid valve (CV2) on the primary (control unit) E
C1165 CV2 side is open circuit or shorted, or the control line is open
or shorted to the power supply or the ground.

Check the self-diagnosis results. G
CV1 H
CV2
I
1.CHECK CONNECTOR
replace terminal. L
YES >> GO TO 2. M
ground. O

— Voltage
YES >> GO TO 3.
BRC-155
ground.

— Continuity
Connector Terminal
1.CHECK ACTIVE TEST

2. On the display, touch “UP”, “ACT UP”, and “ACT KEEP”, and check that the system operates as shown in
the table below.
Display
UP ACT UP ACT KEEP
FR RH IN SOL OFF OFF OFF
FR RH SOL
CV1 OFF ON ON
SV1 OFF ON* OFF
FR LH SOL
CV2 OFF ON ON
SV2 OFF ON* OFF
RR RH SOL
CV2 OFF ON ON
SV2 OFF ON* OFF
RR LH SOL
CV1 OFF ON ON
SV1 OFF ON* OFF
BRC-156
C1166, C1167 SV SYSTEM
A
The suction valve supplies the brake fluid from the master cylinder to the pump, when ESP/TCS is activated. B

ESP switch-over solenoid valve (SV1) on the primary D
C1166 SV1 side is open circuit or shorted, or the control line is open
or shorted to the power supply or the ground. • Harness or connector
ESP switch-over solenoid valve (SV2) on the primary (control unit) E
C1167 SV2 side is open circuit or shorted, or the control line is open
or shorted to the power supply or the ground.

Check the self-diagnosis results. G
SV1 H
SV2
I
1.CHECK CONNECTOR
replace terminal. L
YES >> GO TO 2. M
ground. O

— Voltage
YES >> GO TO 3.
BRC-157
ground.

— Continuity
Connector Terminal
1.CHECK ACTIVE TEST

2. On the display, touch “UP”, “ACT UP”, and “ACT KEEP”, and check that the system operates as shown in
the table below.
Display
UP ACT UP ACT KEEP
FR RH IN SOL OFF OFF OFF
FR RH SOL
CV1 OFF ON ON
SV1 OFF ON* OFF
FR LH SOL
CV2 OFF ON ON
SV2 OFF ON* OFF
RR RH SOL
CV2 OFF ON ON
SV2 OFF ON* OFF
RR LH SOL
CV1 OFF ON ON
SV1 OFF ON* OFF
BRC-158
C1176 STOP LAMP SW2
C1176 STOP LAMP SW2
A
When the brake pedal is depressed, ASCD brake switch is turned OFF and stop lamp switch is turned ON. B

• Harness or connector D
• ASCD brake switch
C1176 STOP LAMP SW2 When ASCD brake switch circuit is open.
(control unit)
E
Self-diagnosis results G
STOP LAMP SW2
H
I
1.CHECK CONNECTOR
replace terminal. K
YES >> GO TO 2. L
2.CHECK ASCD BRAKE SWITCH
1. Turn ignition switch OFF. M
2. Disconnect ASCD brake switch connector.
3. Check continuity between ASCD brake switch connector terminals.
N
ASCD brake switch
Terminal
Brake pedal is fully released. Existed
O
1−2
Brake pedal is slightly depressed. Not existed
Is the inspection result normal? P
YES >> GO TO 3.
NO >> Replace ASCD brake switch.
3.CHECK ASCD BRAKE SWITCH POWER SUPPLY CIRCUIT
BRC-159
C1176 STOP LAMP SW2
4. Check voltage between ASCD brake switch harness connector and ground.
ASCD brake switch

— Voltage
Connector Terminal
YES >> GO TO 4.
4.CHECK ASCD BRAKE SWITCH INPUT SIGNAL CIRCUIT
3. Check continuity between ASCD brake switch harness connector and ABS actuator and electric unit (con-
trol unit) harness connector.

ASCD brake switch
E112 2 E36 6 Existed
1.CHECK ASCD BRAKE SWITCH

3. Check continuity between ASCD brake switch connector terminals.
ASCD brake switch

Terminal
Brake pedal is fully released. Existed
1−2
Brake pedal is slightly depressed. Not existed
NO >> Replace ASCD brake switch.
BRC-160
A
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul- B
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. C
D
DTC DETECTION LOGIC

E
When ABS actuator and electric unit (control unit) is not • CAN communication line
U1000 CAN COMM CIRCUIT transmitting or receiving CAN communication signal for 2 • ABS actuator and electric unit
seconds or more. (control unit) BRC
G
1.CHECK CONNECTOR
2. Disconnect ABS actuator and electric unit (control unit) connector. H
replace terminal.
4. Reconnect connector and perform self-diagnosis.
I
CAN COMM CIRCUIT J
YES >> Go to LAN-21, "CAN System Specification Chart".
BRC-161
DTC DETECTION LOGIC
DTC Items Diagnostic item is detected when... Possible cause

When detecting error during the initial diagnosis of CAN
ABS actuator and electric
U1010 CONTROL UNIT (CAN) controller of ABS actuator and electric unit (control
unit (control unit) error
unit).

1.RECHECK DTC
1. Turn the ignition switch OFF to ON.
Is DTC “U1010” detected?
1.ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)

Check that there is no malfunction in ABS actuator and electric unit (control unit) harness connector or discon-
nection.
YES >> Replace ABS actuator and electric unit (control unit). Refer to BRC-201, "Exploded View".
NO >> Repair or replace the harnesses and connectors.
BRC-162
A
The parking brake switch converts the status of the parking brake pedal to an electric signal and transmits it to B
the ABS actuator and electric unit (control unit).
C
1.CHECK PARKING BRAKE SWITCH OPERATION
Operate the parking brake pedal. Then check that the brake warning lamp in the combination meter turns on/
off correctly. D
Condition Brake warning lamp illumination status

E
When the parking brake switch is opera-
ON
tion
When the parking brake switch is not oper-
OFF BRC
ation.
G
H
2. Disconnect parking brake switch connector. I
Parking brake switch J

— Condition Continuity
Connector Terminal
When the parking brake switch
Existed K
is operated.
M103 1 Ground
Not existed
is not operated.
L
YES >> GO TO 2.
M
tion". N
NO >> Check ABS actuator and electric unit (control unit). Refer to BRC-104, "CONSULT-III Function O
(ABS)".
P
2. Disconnect parking brake switch connector.
BRC-163
Parking brake switch

— Condition Continuity
Connector Terminal
Existed
is operated.
M103 1 Ground
Not existed
is not operated.
BRC-164
ESP OFF SWITCH
ESP OFF SWITCH
A
ESP OFF switch can deactivate (turn OFF) the ESP/TCS function by pressing the ESP OFF switch. B
1.CHECK ESP OFF SWITCH OPERATION C

Turn ON/OFF the ESP OFF switch and check that the ESP OFF indicator lamp in the combination meter turns
ON/OFF correctly.
D
Condition ESP OFF indicator lamp illumination status
ESP OFF switch: ON ON
E
ESP OFF switch: OFF OFF
G
1.CHECK ESP OFF SWITCH
1. Turn ignition switch OFF. H
2. Disconnect ESP OFF switch connector.
3. Check continuity between ESP OFF switch connector terminals.
I
ESP OFF switch
Terminal
When ESP OFF switch is hold pressed. Existed J
1–2
When releasing ESP OFF switch. Not existed
K
YES >> GO TO 2.
NO >> ESP OFF switch is malfunctioning. Replace ESP OFF switch.
2.CHECK ESP OFF SWITCH HARNESS L
2. Check continuity between ESP OFF switch connector terminals and ABS actuator and electric unit (con-
trol unit) connector terminal and/or ground. M

ESP OFF switch
(control unit) Continuity N
E36 5 M5 1 Existed
O
— Continuity
Connector Terminal
P
E36 5 Ground Not existed
ESP OFF switch

— Continuity
Connector Terminal
M5 2 Ground Existed
BRC-165
ESP OFF SWITCH
YES >> GO TO 3.
NO >> If the open or short in harness, repair or replace harness.
tion".

2. Disconnect ESP OFF switch connector.
3. Check continuity between ESP OFF switch connector terminals.
ESP OFF switch

Condition Condition
Terminal
When ESP OFF switch is hold pressed. Existed
1–2
When releasing ESP OFF switch. Not existed
NO >> Replace ESP OFF switch.
BRC-166
HDC SWITCH
HDC SWITCH
A
HDC switch can activate the HDC function by pressing the HDC switch. B
1.CHECK HDC SWITCH OPERATION C

Turn ON/OFF the HDC switch and check that the HDC indicator lamp in the combination meter turns ON/OFF
correctly.
D
Condition HDC indicator lamp illumination status
HDC switch: ON ON
E
HDC switch: OFF OFF
G
1.CHECK HDC SWITCH
2. Disconnect HDC switch connector.
3. Check continuity between HDC switch connector terminals.
I
HDC switch
Terminal
HDC switch: ON Existed J
1−2
HDC switch: OFF Not existed
K
YES >> GO TO 2.
NO >> HDC switch is malfunctioning. Replace HDC switch.
2.CHECK HDC SWITCH HARNESS L
2. Check continuity between HDC switch connector terminals and ABS actuator and electric unit (control
unit) connector terminal and/or ground. M

HDC switch
(control unit) Continuity N
E36 18 M39 1 Existed
O
— Continuity
Connector Terminal
P
HDC switch
— Continuity
Connector Terminal
M39 2 Ground Existed
BRC-167
HDC SWITCH
YES >> GO TO 3.
NO >> If the open or short in harness, repair or replace harness.
tion".
1.CHECK HDC SWITCH

2. Disconnect HDC switch connector.
3. Check continuity between HDC switch connector terminals.
HDC switch
Terminal
HDC switch: ON Existed
1−2
HDC switch: OFF Not existed
NO >> Replace HDC switch.
BRC-168
ABS WARNING LAMP
ABS WARNING LAMP
A
×: ON –: OFF B
Condition ABS warning lamp
D

E
1.CHECK ABS WARNING LAMP OPERATION
Check that the lamp illuminates for approximately 1 second after the ignition switch is turned ON. BRC
NO >> Go to diagnosis procedure. Refer to BRC-169, "Diagnosis Procedure". G
1.CHECK SELF-DIAGNOSIS H
I
YES >> GO TO 2.
2.CHECK COMBINATION METER J
tion".
L
BRC-169
BRAKE WARNING LAMP
BRAKE WARNING LAMP
×: ON –: OFF
Condition Brake warning lamp (Note 1)

For 1 second after turning ON ignition switch × (Note 2)
1 second later after turning ON ignition switch × (Note 2)
NOTE:
• 1: Brake warning lamp will turn on in case of parking brake operation (when switch is ON) or of brake fluid level switch operation
(when brake fluid is insufficient).
• 2: After starting engine, brake warning lamp is turned off.

YES >> GO TO 2.
ing brake pedal.

ing brake pedal.
YES >> GO TO 2.
YES >> GO TO 3.
tion".
BRC-170
ESP OFF INDICATOR LAMP
ESP OFF INDICATOR LAMP
A
×: ON –: OFF B
Condition ESP OFF indicator lamp
ESP OFF switch turned ON. (ESP function is OFF.) ×
D
ESP/TCS function is malfunctioning. ×
EBD function is malfunctioning. × E
HDC function is malfunctioning. ×
Component Function Check INFOID:0000000001116951 BRC
1.ESP OFF INDICATOR LAMP OPERATION CHECK 1

Check that the lamp illuminates for approximately 1 second after the ignition switch is turned ON. G
YES >> GO TO 2.
NO >> Go to diagnosis procedure. Refer to BRC-171, "Diagnosis Procedure". H
2.ESP OFF INDICATOR LAMP OPERATION CHECK 2
Check that the ESP OFF indicator lamp in the combination meter turns ON/OFF correctly when operating the I
ESP OFF switch.
YES >> INSPECTION END J
NO >> Check ESP OFF switch. Refer to BRC-165, "Diagnosis Procedure".
K
Check that the ESP OFF indicator lamp in the combination meter turns ON/OFF correctly when operating the
ESP OFF switch. L
YES >> GO TO 2.
NO >> Check ESP OFF switch. Refer to BRC-165, "Diagnosis Procedure". M
Perform ABS actuator and electric unit (control unit) self-diagnosis. N
YES >> GO TO 3.
NO >> Check items displayed by self-diagnosis. O
P
tion".
BRC-171
SLIP INDICATOR LAMP
SLIP INDICATOR LAMP
×: ON –: OFF
Condition SLIP indicator lamp

For 1 second after turning ON ignition switch ×
VDC/TCS function is malfunctioning. ×
HDC function is malfunctioning. ×
1.CHECK SLIP INDICATOR LAMP OPERATION

YES >> GO TO 2.
tion".
BRC-172
HDC INDICATOR LAMP
HDC INDICATOR LAMP
A
×: ON –: OFF B
Condition HDC indicator lamp
VDC/TCS function is malfunctioning. ×
D
HDC function is malfunctioning. –
HDC switch is pressed (HDC function ON) × (Note)
NOTE: E
• When all HDC control conditions are satisfied: ON
• When HDC control conditions are not satisfied: BLINK
BRC
1.CHECK HDC INDICATOR LAMP OPERATION G

YES >> INSPECTION END H
I
Perform ABS actuator and electric unit (control unit) self-diagnosis. J
YES >> GO TO 2.
NO >> Check items displayed by self-diagnosis. K
tion". L
NO >> Repair or replace combination meter. M
BRC-173
< ECU DIAGNOSIS > [ESP/TCS/ABS]
ECU DIAGNOSIS

CAUTION:
The display shows the control unit calculation data, so a normal value might be displayed even in the
event the output circuit (harness) is open or short-circuited.
Data monitor
Condition
normal operation
FR LH SENSOR Wheel speed Nearly matches the

Vehicle running (Note 1) speed meter display
(± 10% or less)
FR RH SENSOR Wheel speed Nearly matches the

(± 10% or less)
RR LH SENSOR Wheel speed Nearly matches the

(± 10% or less)
RR RH SENSOR Wheel speed Nearly matches the

(± 10% or less)
When brake pedal is depressed On
STOP LAMP SW Stop lamp switch signal status
Battery voltage supplied to the ABS actuator
BATTERY VOLT Ignition switch ON 10 – 16 V
and electric unit (control unit)
1st gear 1
2nd gear 2
3rd gear 3
GEAR Gear position determined by TCM
4th gear 4
5th gear 5
6th gear 6
ESP OFF switch ON
On
(When ESP OFF indicator lamp is ON)
OFF SW ESP OFF switch ON/OFF
ESP OFF switch OFF
Off
(When ESP OFF indicator lamp is OFF)
Vehicle stop Approx. 0 d/s
YAW RATE SEN Yaw rate detected by yaw rate sensor
Accelerator pedal not depressed (igni-
0%
Throttle actuator opening/closing is displayed tion switch is ON)
ACCEL POS SIG
(linked with accelerator pedal) Depress accelerator pedal (ignition
0 - 100 %
switch is ON)
SIDE G-SENSOR Transverse G detected by side G sensor Vehicle turning right Negative value
BRC-174
Data monitor
Reference value in
Condition
normal operation
Steering angle detected by steering angle During straight Approx. 0°

STR ANGLE SIG
sensor
B
Steering wheel turned –720 to 720°
With ignition switch turned ON and
Approx. 0 bar
Brake fluid pressure detected by pressure brake pedal released
PRESS SENSOR C
sensor With ignition switch turned ON and
0 to 200 bar
brake pedal depressed
With engine stopped 0 rpm
D
ENGINE RPM With engine running Almost in accor-
Engine running dance with tachome-
ter display
E
When brake fluid level switch ON On
FLUID LEV SW Brake fluid level switch signal status
When brake fluid level switch OFF Off
Actuator (solenoid valve) is active (“AC- BRC
FR RH IN SOL Operation status of each solenoid valve
G
TIVE TEST” with CONSULT-III) or actu- On H
FR RH OUT SOL Operation status of each solenoid valve
not active and actuator relay is active Off I
TIVE TEST” with CONSULT-III) or actu- On J
FR LH IN SOL Operation status of each solenoid valve
(ignition switch ON) K
ator relay is inactive (in fail-safe mode) L
FR LH OUT SOL Operation status of each solenoid valve
(ignition switch ON) M
RR RH IN SOL Operation status of each solenoid valve N
O
RR RH OUT SOL Operation status of each solenoid valve
When the actuator (solenoid valve) is P
BRC-175
Data monitor
Condition
normal operation
RR LH IN SOL Operation status of each solenoid valve
RR LH OUT SOL Operation status of each solenoid valve
When the motor relay and motor are op-
On
erating
MOTOR RELAY Motor and motor relay operation
When the motor relay and motor are not
Off
operating
When the actuator relay is operating On
ACTUATOR RLY Actuator relay operation
When the actuator relay is not operating Off
ABS warning lamp When ABS warning lamp is ON On

ABS WARN LAMP
(Note 2) When ABS warning lamp is OFF Off
ESP OFF indicator lamp When ESP OFF indicator lamp is ON On

OFF LAMP
(Note 2) When ESP OFF indicator lamp is OFF Off
SLIP indicator lamp When SLIP indicator lamp is ON On

SLIP LAMP
(Note 2) When SLIP indicator lamp is OFF Off
Vehicle stopped −0.11 – +0.11 G
DECEL G-SEN Decel G detected by decel G sensor During acceleration Negative value
During deceleration Positive value
EBD is active On
EBD SIGNAL EBD operation
EBD is inactive Off
ABS is active On
ABS SIGNAL ABS operation
ABS is inactive Off
TCS is active On
TCS SIGNAL TCS operation
TCS is inactive Off
ESP is active On
VDC SIGNAL ESP operation
ESP is inactive Off
HSA is active On
HSA SIGNAL HSA operation
HSA is inactive Off
HDC is active On
HDC SIGNAL HDC operation
HDC is inactive Off
In EBD fail-safe On
EBD FAIL SIG EBD fail-safe signal
EBD is normal Off
In ABS fail-safe On
ABS FAIL SIG ABS fail-safe signal
ABS is normal Off
In TCS fail-safe On
TCS FAIL SIG TCS fail-safe signal
TCS is normal Off
BRC-176
Data monitor
Reference value in
Condition
normal operation
In ESP fail-safe On
VDC FAIL SIG ESP fail-safe signal B
ESP is normal Off
Crank is active On
CRANKING SIG Crank operation
Crank is inactive Off C
With 1st gear On
1ST GEAR SIG 1st gear operation
Without 1st gear Off
D
For N range On
N POSI SIG N position signal
Except for N range Off
For P range On E
P POSI SIG P position signal
Except for P range Off
For R range On
R POSI SIG R position signal
Except for R range Off BRC
AUTO is active AUTO
4WD MODE MONI Axle condition LOCK is active LOCK
G
2WD is active 2WD
TIVE TEST” with CONSULT-III) or actu- On H
CV1 Operation status of each solenoid valve
(ignition switch ON) I
ator relay is inactive (in fail-safe mode) J
CV2 Operation status of each solenoid valve
(ignition switch ON) K
SV1 Operation status of each solenoid valve L
M
SV2 Operation status of each solenoid valve
When the actuator (solenoid valve) is N
When brake pedal is depressed On O
STOP LAMP SW2 Stop lamp switch signal status
Stop lamp on relay is active On
STOP ON RLY Stop lamp on relay operation P
Stop lamp on relay is inactive Off
HDC switch ON
On
(HDC indicator lamp is ON)
HDC SW HDC switch ON/OFF status
HDC switch OFF
Off
(HDC indicator lamp is OFF)
BRC-177
Data monitor
Condition
normal operation
Brake warning lamp When brake warning lamp is ON On

EBD WARN LAMP
(Note 2), (Note 3) When brake warning lamp is OFF Off
NOTE:
• 1: Confirm tire pressure is normal.
• 2: On and off timing for warning lamp and indicator lamp.
- ABS warning lamp: Refer to BRC-169, "Description".
- Brake warning lamp: Refer to BRC-170, "Description".
- ESP OFF indicator lamp: Refer to BRC-171, "Description".
- SLIP indicator lamp: Refer to BRC-172, "Description".
- HDC indicator lamp: Refer to BRC-173, "Description".
• 3: Serves as EBD warning lamp.
BRC-178
Wiring Diagram -BRAKE CONTROL SYSTEM- INFOID:0000000001115647
BRC
P
JCFWA0035GB
BRC-179
JCFWA0036GB
BRC-180
BRC
JCFWA0037GB
BRC-181
JCFWA0038GB
BRC-182
BRC
JCFWA0039GB
BRC-183
JCFWA0040GB
BRC-184
BRC
JCFWA0041GB
P
Fail-Safe INFOID:0000000001115648
ABS, EBD SYSTEM

In case of electrical malfunctions with the ABS, ABS warning lamp, ESP OFF indicator lamp, SLIP indicator
lamp will turn on. In case of electrical malfunctions with the EBD, brake warning lamp, ABS warning lamp,
ESP OFF indicator lamp and SLIP indicator lamp will turn on. Simultaneously, the ESP/TCS/ABS become one
of the following conditions of the fail-safe function.
BRC-185
• For malfunction of ABS, only the EBD is activated and the condition of vehicle is the same condition of vehi-
cles without TCS/ABS system.
NOTE:
ABS self-diagnosis sound may be heard. That is a normal condition because a self-diagnosis for “Ignition
switch ON” and “The first starting” are being performed.
• For malfunction of EBD, EBD and ABS become inoperative, and the condition of vehicle is the same as the
condition of vehicles without TCS/ABS, EBD system.
ESP/TCS
In case of malfunction in the ESP/TCS/ABS system, ESP OFF indicator lamp, SLIP indicator lamp are turned
on, and the condition of vehicle is the same as the condition of vehicles without ESP/TCS control.
CAUTION:
If the Fail-Safe function is activated, then perform self-diagnosis for ESP/TCS/ABS control system.
HDC/HSA
• In case of HDC system malfunction, the HDC indicator lamp will remain off even though the HDC switch is
operated and the condition of the vehicle is the same as the condition of vehicles without HDC system.
• In case of HSA system malfunction, the VDC OFF and SLIP indicator lamps are turned ON and the condition
of the vehicle is the same as the condition of vehicles without HSA system.
DTC No. Index INFOID:0000000001115649
DTC Items (CONSULT screen terms) Reference

C1109 BATTERY VOLTAGE [ABNORMAL] BRC-115, "Description"
C1110 CONTROLLER FAILURE BRC-117, "Description"
C1111 PUMP MOTOR BRC-118, "Description"
C1113 G SENSOR BRC-120, "Description"
C1115 ABS SENSOR [ABNORMAL SIGNAL] BRC-123, "Description"
C1116 STOP LAMP SW BRC-126, "Description"
C1118 4WD SYSTEM BRC-128, "Description"
C1120 FR LH IN ABS SOL BRC-129, "Description"
C1121 FR LH OUT ABS SOL BRC-132, "Description"
C1122 FR RH IN ABS SOL BRC-129, "Description"
C1123 FR RH OUT ABS SOL BRC-132, "Description"
C1124 RR LH IN ABS SOL BRC-129, "Description"
C1125 RR LH OUT ABS SOL BRC-132, "Description"
C1126 RR RH IN ABS SOL BRC-129, "Description"
C1127 RR RH OUT ABS SOL BRC-132, "Description"
C1130 ENGINE SIGNAL 1 BRC-135, "Description"
C1140 ACTUATOR RLY BRC-136, "Description"
C1142 PRESS SEN CIRCUIT BRC-138, "Description"
C1143 ST ANG SEN CIRCUIT
C1144 ST ANG SEN SIGNAL
BRC-186
DTC Items (CONSULT screen terms) Reference
A
C1145 YAW RATE SENSOR BRC-143, "Description"
C1146 SIDE G-SEN CIRCUIT BRC-146, "Description"
C1154 PNP POSI SIG BRC-149, "Description" B
C1155 BR FLUID LEVEL LOW BRC-152, "Description"
C1164 CV 1
C1165 CV 2 C
C1166 SV 1
C1167 SV 2
D
C1176 STOP LAMP SW2 BRC-159, "Description"
U1000 CAN COMM CIRCUIT BRC-161, "Description"
U1010 CONTROL UNIT(CAN) BRC-162, "Description" E
BRC
BRC-187
< SYMPTOM DIAGNOSIS > [ESP/TCS/ABS]
SYMPTOM DIAGNOSIS
1.CHECK START
Check front and rear brake force distribution using a brake tester.
• LHD models: Refer to BR-52, "General Specifications".
• RHD models: Refer to BR-99, "General Specifications".
YES >> GO TO 2.
2.CHECK FRONT AND REAR AXLE
Make sure that there is no excessive play in the front and rear axles.
• Front
• Rear
YES >> GO TO 3.
3.CHECK WHEEL SENSOR AND SENSOR ROTOR
Check the following.
• Wheel sensor installation for damage.
• Sensor rotor installation for damage.
• Wheel sensor connector connection.
• Wheel sensor harness inspection.
YES >> GO TO 4.
NO >> • Replace wheel sensor or sensor rotor.
• Repair harness.
Make sure that the ABS warning lamp is turned off after the ignition switch is turned ON or when driving.
Is the ABS warning lamp illuminated?
YES >> Perform self-diagnosis.
NO >> Normal
BRC-188
A
1.CHECK BRAKE PEDAL STROKE B

Check brake pedal stroke.
• RHD models: Refer to BR-58, "Inspection and Adjustment". C
Is the stroke too large?
YES >> • Bleed air from brake tube and hose.
- LHD models: Refer to BR-12, "Bleeding Brake System". D
- RHD models: Refer to BR-62, "Bleeding Brake System".
• Check brake pedal, brake booster, and master cylinder for mount play, looseness, brake system
fluid leakage, etc. E
- Brake pedal
- Master cylinder BRC
• RHD models Refer to BR-63, "Inspection".
- Brake booster G
• RHD models: Refer to BR-64, "Inspection".
NO >> GO TO 2.
H
2. CHECK FUNCTION
Disconnect ABS actuator and electric unit (control unit) connector to deactivate ABS. Check if braking force is
normal in this condition. Connect connector after inspection. I
YES >> Normal
NO >> Check brake system. J
BRC-189
CAUTION:
The stopping distance on slippery road surfaces might be longer with the ABS operating than when
the ABS is not operating.
1.CHECK FUNCTION
Turn ignition switch OFF and disconnect ABS actuator and electric unit (control unit) connector to deactivate
ABS. In this condition, check stopping distance. After inspection, connect connector.
YES >> Normal
BRC-190
A
CAUTION: B
ABS does not operate when speed is 10 km/h (6 MPH) or lower.
Make sure that the ABS warning lamp turns OFF after ignition switch is turned ON or when driving. C
YES >> Normal
NO >> Perform self-diagnosis. D
BRC
BRC-191
CAUTION:
Under the following conditions, ABS is activated and vibration is felt when brake pedal is lightly
depressed (just place a foot on it).However, this is normal.
• When shifting gears
• When driving on slippery road
• During cornering at high speed
• When passing over bumps or grooves [at approximately 50 mm (1.97 in) or more]
• When pulling away just after starting engine [at approximately 10 km/h (6 MPH) or higher]
1.SYMPTOM CHECK 1
Check that there are pedal vibrations when the engine is started.
Do vibrations occur?
YES >> GO TO 2.
NO >> Inspect the brake pedal.
2.SYMPTOM CHECK 2
Check that there are ABS operation noises when the engine is started.
Do the operation noises occur?
YES >> GO TO 3.
NO >> Perform self -diagnosis.
3.SYMPTOM CHECK 3
Check symptoms when electrical component (headlamps, etc.) switches are operated.
Do symptoms occur?
YES >> Check if there is a radio, antenna, antenna lead wire, or wiring close to the control unit. If there is,
move it farther away.
NO >> Normal
BRC-192
VEHICLE JERKS DURING ESP/TCS/ABS CONTROL
VEHICLE JERKS DURING ESP/TCS/ABS CONTROL
A
1.SYMPTOM CHECK B
Check if the vehicle jerks during ESP/TCS/ABS control.
C
YES >> Normal.
NO >> GO TO 2.
2.CHECK SELF-DIAGNOSIS RESULTS D
Perform self-diagnostic of ABS actuator and electric unit (control unit).
Are self-diagnosis results indicated?
YES >> Check corresponding items, make repairs, and perform ABS actuator and electric unit (control E
unit) self-diagnosis.
NO >> GO TO 3.
3.CHECK CONNECTOR BRC
• Turn ignition switch OFF and disconnect ABS actuator and electric unit (control unit) connector and check
terminal for deformation, disconnection, looseness, etc.
• Securely connect connectors and perform ABS actuator and electric unit (control unit) self-diagnosis. G
YES >> If poor contact, damage, open or short circuit of connector terminal is found, repair or replace.
NO >> GO TO 4. H
4.CHECK ECM AND TCM SELF-DIAGNOSIS RESULTS
Perform ECM and TCM self-diagnosis. I
YES >> Check the corresponding items.
• ECM J
- MR20DE: Refer to ECM-87, "CONSULT-III Function".
- QR25DE: Refer to ECQ-89, "CONSULT-III Function".
- M9R: Refer to ECR-97, "Diagnosis Description".
• TCM K
- AT: Refer to TM-218, "CONSULT-III Function (TRANSMISSION)".
- CVT: Refer to TM-394, "CONSULT-III Function (TRANSMISSION)".
NO >> Replace ABS actuator and electric unit (control unit). L
BRC-193
Symptom Result
Slight vibrations are felt on the brake pedal and the operation noises occur, when ESP, TCS or ABS is acti-
vated.
This is a normal condi-
Stopping distance is longer than that of vehicles without ABS when the vehicle drives on rough, gravel, or
tion due to the ESP,
snow-covered (fresh, deep snow) roads.
TCS or ABS activation.
The brake pedal moves and generates noises, when TCS or ESP is activated due to rapid acceleration or
sharp turn.
This is a normal, and it is
The brake pedal vibrates and motor operation noises occur from the engine room, after the engine starts and
caused by the ABS op-
just after the vehicle starts.
eration check.
Depending on the road conditions, the driver may experience a sluggish feel. This is normal, because
TCS places the highest
TCS may activate momentarily if wheel speed changes when driving over location where friction coefficient priority on the optimum
varies, when downshifting, or when fully depressing accelerator pedal. traction (stability).
The ABS warning lamp, ESP OFF indicator lamp and SLIP indicator lamp may turn ON when the vehicle is
In this case, restart the
subject to strong shaking or large vibration, such as when the vehicle is rotating on a turntable or located on
engine on a normal
a ship while the engine is running.
road. If the normal con-
ESP may not operate normally or the ABS warning lamp, ESP OFF indicator lamp, and SLIP indicator lamp dition is restored, there
may illuminate, when running on a special road that is extremely slanted (e.g. bank in a circuit course). is no malfunction. At
that time, erase the self-
A malfunction may occur in the yaw rate/side G sensor system, when the vehicle turns sharply, such as dur-
diagnosis memory.
ing a spin turn, axle turn, or drift driving, while the ESP function is off (ESP OFF indicator lamp illuminated).
Normal (Deactivate the
ESP/TCS function be-
The vehicle speed will not increase even though the accelerator pedal is depressed, when inspecting the
fore performing an in-
speedometer on a 2-wheel chassis dynamometer.
spection on a chassis
dynamometer.)
BRC-194
PRECAUTIONS
< PRECAUTION > [ESP/TCS/ABS]
PRECAUTION A
PRECAUTIONS
WARNING: D
BRC
ness connectors.
G
WARNING: H
Clean brake pads and shoes with a waste cloth, then wipe with a dust collector.
• Only use DOT 4 brake fluid. Refer to MA-22, "Fluids and Lubricants".
• Never to reuse drained brake fluid.
• Never to spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it off I
immediately and wash with water if it gets on a painted surface.
• Never to use mineral oils such as gasoline or light oil. They may damage rubber parts and cause improper
operation. J
• Tighten the brake tube flare nut to the specified torque with a flare
nut torque wrench.
• Always conform the specified tightening torque when installing the K
brake pipes.
• Brake system is an important safety part. If a brake fluid leak is
detected, always disassemble the affected part. If a malfunction is L
detected, replace part with a new one.
• Turn the ignition switch OFF and disconnect the ABS actuator and
electric unit (control unit) connector or the battery negative terminal
before performing the work. M
SBR820BA
Precaution for Brake Control INFOID:0000000001115660 N
• Just after starting vehicle after ignition switch ON, brake pedal may vibrate or motor operating noise may be
heard from engine compartment. This is normal condition.
• When an error is indicated by ABS or another warning lamp, collect all necessary information from customer O
(what symptoms are present under what conditions) and check for simple causes before starting diagnostic
servicing. Besides electrical system inspection, check brake booster operation, brake fluid level, and oil
leaks. P
• If tire size and type are used in an improper combination, or brake pads are not Genuine NISSAN parts,
stopping distance or steering stability may deteriorate.
• ABS might be out of order or malfunctions by putting a radio (wiring inclusive), an antenna and a lead-in wire
near the control unit.
• If aftermarket parts (car stereo, CD player, etc.) have been installed, check for incidents such as harness
pinches, open circuits, and improper wiring.
• ESP system may not operate normally or a ESP OFF indicator lamp or SLIP indicator lamp may light.
BRC-195
PRECAUTIONS
< PRECAUTION > [ESP/TCS/ABS]
- When replacing the following parts with parts other than genuine parts or making modifications: Suspension-
related parts (shock absorber, spring, bushing, etc.), tires, wheels (other than specified sizes), brake-related
parts (pad, rotor, caliper, etc.), engine-related parts (muffler, ECM, etc.) and body reinforcement-related parts
(roll bar, tower bar, etc.).
- When driving with worn or deteriorated suspension, tires and brake-related parts.
BRC-196
PREPARATION
< PREPARATION > [ESP/TCS/ABS]
PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000001117077
B
Tool number
Description C
Tool name
D
GG94310000
Flare nut torque wrench Installing each brake piping
a: 10 mm (0.39 in)/ 12 mm (0.47 in)
E
S-NT406
BRC
BRC-197
WHEEL SENSOR
< ON-VEHICLE REPAIR > [ESP/TCS/ABS]
ON-VEHICLE REPAIR
WHEEL SENSOR
FRONT WHEEL SENSOR
FRONT WHEEL SENSOR : Exploded View INFOID:0000000001117067
JSFIA0039GB
1. Front LH wheel sensor
A. White line (slant line)

NOTE:
FRONT WHEEL SENSOR : Removal and Installation INFOID:0000000001117068
REMOVAL
CAUTION:
on sensor harness.
• When you see the harness of the wheel sensor from the front side of the vehicle ensure that the
white lines (A) are not twisted.
INSTALLATION
• When installing wheel sensor, be sure to press rubber grommets in until they lock at locations shown above
REAR WHEEL SENSOR
BRC-198
WHEEL SENSOR
REAR WHEEL SENSOR : Exploded View INFOID:0000000001117069
BRC
JSFIA0040GB
G
1. Rear LH wheel sensor
A. 2WD models B. 4WD models

Refer to GI-4, "Components" for symbol in the figure. H
NOTE:
I
REAR WHEEL SENSOR : Removal and Installation INFOID:0000000001117070
REMOVAL J
CAUTION:
on sensor harness. K
L
INSTALLATION
• When installing, make sure there is no foreign material such as iron chips on and in the mounting hole of the M
• When installing wheel sensor, be sure to press rubber grommets in until they lock at locations shown above N
BRC-199
SENSOR ROTOR
SENSOR ROTOR
FRONT SENSOR ROTOR
FRONT SENSOR ROTOR : Exploded View INFOID:0000000001117071
Refer to FAX-9, "Exploded View" (2WD models), FAX-42, "Exploded View" (4WD models).
FRONT SENSOR ROTOR : Removal and Installation INFOID:0000000001117072
REMOVAL
FAX-9, "Removal and Installation" (2WD models), FAX-42, "Removal and Installation" (4WD models).
INSTALLATION
to FAX-9, "Removal and Installation" (2WD models), FAX-42, "Removal and Installation" (4WD models).
REAR SENSOR ROTOR
REAR SENSOR ROTOR : Exploded View INFOID:0000000001117073
Refer to RAX-4, "Exploded View" (2WD models), RAX-13, "Exploded View" (4WD models).
REAR SENSOR ROTOR : Removal and Installation INFOID:0000000001117074
2WD MODELS
Removal
RAX-4, "Removal and Installation".
Installation
to RAX-4, "Removal and Installation".
4WD MODELS
For removal and installation of sensor rotor, refer to RAX-14, "Disassembly and Assembly".
BRC-200
A
LHD models B
BRC
I
JSFIA0083GB
1. ABS actuator and electric unit (control 2. Connector 3. Bracket J

unit)

K
: Vehicle front
L
BRC-201
RHD models
JSFIA0084GB

unit)

: Vehicle front
REMOVAL
CAUTION:
aged. To install, use flare nut crowfoot and torque wrench.
1. Remove cowl top. Refer to EXT-19, "Exploded View".
3. Loosen brake tube flare nuts, then remove brake tubes from ABS actuator and electric unit (control unit).
4. Remove tire (front LH side).
5. Remove fender protector (rear): (front LH side). Refer to EXT-21, "Exploded View".
6. Remove ABS actuator and electric unit (control unit) bracket mounting nut.
7. Remove ABS actuator and electric unit (control unit) from vehicle.
INSTALLATION
CAUTION:
BRC-202
aged. To install, use flare nut crowfoot and torque wrench. A
B
• After installing harness connector in the ABS actuator and electric unit (control unit), make sure
connector is securely locked.
C
BRC
BRC-203
G SENSOR
G SENSOR
JSFIA0086GB
1. yaw rate/side/decel G sensor 2. Bracket
: Vehicle front
REMOVAL
CAUTION:
• Do not drop or strike yaw rate/side/decel G sensor, because it has little endurance to impact.
• Do not use power tool etc., because yaw rate/side/decel G sensor is sensitive for the impact.
1. Remove center console assembly. Refer to IP-21, "Exploded View".
2. Disconnect yaw rate/side/decel G sensor harness connector.
3. Remove mounting bolts. Remove yaw rate/side/decel G sensor.
INSTALLATION
CAUTION:
• Do not drop or strike yaw rate/side/decel G sensor, because it has little endurance to impact.
• Do not use power tool etc., because yaw rate/side/decel G sensor is sensitive for the impact.
BRC-204
A
JSFIA0099ZZ
E
1. Steering angle sensor
: Vehicle front BRC


G
REMOVAL
1. Remove spiral cable assembly. Refer to SR-7, "Exploded View". H
2. Remove steering angle sensor from spiral cable assembly.
INSTALLATION
Note the following, and install in the reverse order of removal. I
CAUTION:
After work, make sure to adjust neutral position of steering angle sensor. Refer to BRC-78, "ADJUST-
MENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Description". J
BRC-205
ELECTRICAL & POWER CONTROL
SECTION CHG
CHARGING SYSTEM
B
E
CONTENTS
BASIC INSPECTION .................................... 3 PRECAUTIONS ................................................. 20 F
DIAGNOSIS AND REPAIR WORKFLOW .......... 3 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
Work Flow ................................................................. 3 SIONER" .................................................................20 G
FUNCTION DIAGNOSIS ............................... 6 PREPARATION ........................................... 21
CHARGING SYSTEM .......................................... 6 PREPARATION ................................................. 21 H
System Diagram ........................................................ 6 Special Service Tools ..............................................21
Component Parts Location ........................................ 6 ON-VEHICLE MAINTENANCE .................... 22 I
Component Description ............................................ 7
CHARGING SYSTEM PRELIMINARY IN-
COMPONENT DIAGNOSIS .......................... 8 SPECTION ........................................................ 22
Inspection Procedure ...............................................22 J
B TERMINAL CIRCUIT ....................................... 8
Description ................................................................ 8 ON-VEHICLE REPAIR ................................. 23
Diagnosis Procedure ................................................. 8 K
ALTERNATOR .................................................. 23
L TERMINAL CIRCUIT (OPEN) .......................... 9
Description ................................................................ 9 M9R MODELS ............................................................23
Diagnosis Procedure ................................................. 9 M9R MODELS : Exploded View ..............................23 L
M9R MODELS : Removal and Installation ..............24
L TERMINAL CIRCUIT (SHORT) .......................11 M9R MODELS : Disassembly and Assembly ..........25
Description .............................................................. 11 M9R MODELS : Inspection .....................................26
CHG
MR20DE MODELS .....................................................26
S TERMINAL CIRCUIT ......................................12 MR20DE MODELS : Exploded View .......................27
Description .............................................................. 12 MR20DE MODELS : Removal and Installation .......28 N
Diagnosis Procedure ............................................... 12 MR20DE MODELS : Disassembly and Assembly....28
MR20DE MODELS : Inspection ..............................29
CHARGING SYSTEM .........................................13
Wiring Diagram - CHARGING SYSTEM (GASO- QR25DE MODELS .....................................................30 O
LINE ENGINE MODELS) - ...................................... 13 QR25DE MODELS : Exploded View .......................30
Wiring Diagram - CHARGING SYSTEM (DIESEL QR25DE MODELS : Removal and Installation ........32
ENGINE MODELS) - ............................................... 16 QR25DE MODELS : Disassembly and Assembly....32 P
QR25DE MODELS : Inspection ...............................33
SYMPTOM DIAGNOSIS .............................. 19
CHARGING SYSTEM .........................................19 (SDS) ............................................................ 35
Symptom Table ....................................................... 19
PRECAUTION .............................................. 20 (SDS) ................................................................. 35
CHG-1
Alternator ................................................................ 35
CHG-2
BASIC INSPECTION A
B
OVERALL SEQUENCE
C
CHG
P
JPMIA0425GB
DETAILED FLOW
1.PRELIMINARY INSPECTION
Perform the preliminary inspection. Refer to CHG-22, "Inspection Procedure" .
CHG-3
>> GO TO 2.
2.INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS ON)
Turn the ignition switch ON.
Does the charge warning lamp illuminate?
YES >> GO TO 3.
NO >> GO TO 10.
3.INSPECTION WITH CHARGE WARNING LAMP (IDLING)
Start the engine and run it at idle.
Does the charge warning lamp turn OFF?
YES >> GO TO 4.
NO >> GO TO 5.
4.INSPECTION WITH CHARGE WARNING LAMP (ENGINE AT 2,500 RPM)
Increase and maintain the engine speed at 2,500 rpm.
Does the charge warning lamp illuminate?
YES >> GO TO 7.
5.“L” TERMINAL CIRCUIT (SHORT) INSPECTION
Check “L” terminal circuit (short). Refer to CHG-11, "Diagnosis Procedure".
YES >> GO TO 6.
NO >> Repair as needed.
6.“S” TERMINAL CIRCUIT INSPECTION
Check “S” terminal circuit. Refer to CHG-12, "Diagnosis Procedure".
YES >> GO TO 7.
7.MEASURE “B” TERMINAL VOLTAGE
Start engine. When keeping engine running at 2,500 rpm, measure “B” terminal voltage.
What voltage does the measurement result show?
Less than 13.0 V>>GO TO 8.
More than 16.0 V>>Replace IC voltage regulator.
8.“B” TERMINAL CIRCUIT INSPECTION
Check “B” terminal circuit. Refer to CHG-8, "Diagnosis Procedure" .
YES >> GO TO 9.
9.DISASSEMBLE AND CHECK ALTERNATOR
Check the following conditions.
• Rotor coil
• Rotor slip ring
• Brush
• Stator coil
Refer to the following.
• CHG-26, "M9R MODELS : Inspection" (M9R models)
• CHG-29, "MR20DE MODELS : Inspection" (MR20DE models)
• CHG-33, "QR25DE MODELS : Inspection" (QR25DE models)
Are these normal?
YES >> Replace IC voltage regulator and/or diode assembly.
CHG-4
10.INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS ON) A
1. Disconnect alternator connector and ground “L” harness side.
2. Turn the ignition switch ON.
Does the charge warning lamp illuminate? B
YES >> GO TO 11.
NO >> GO TO 12.
11.DISASSEMBLE AND CHECK ALTERNATOR C
Check the following conditions.
• Rotor coil
• Rotor slip ring D
• Brush
Refer to the following.
• CHG-26, "M9R MODELS : Inspection" (M9R models) E
• CHG-29, "MR20DE MODELS : Inspection" (MR20DE models)
• CHG-33, "QR25DE MODELS : Inspection" (QR25DE models)
Are these normal?
F
YES >> Replace IC voltage regulator.
12.CHECK “L” TERMINAL CIRCUIT (OPEN) G
Check “L” terminal circuit (open). Refer to CHG-9, "Diagnosis Procedure".
>> Repair as needed. H
CHG
CHG-5
CHARGING SYSTEM
FUNCTION DIAGNOSIS
CHARGING SYSTEM
JPMIA0426GB
The alternator provides DC voltage to operate the vehicle's electrical system and to keep the battery charged.
The voltage output is controlled by the IC voltage regulator.
JPMIA0274ZZ
1. Battery 2. Alternator 3. Charge warning lamp

A. Engine room (left side) B. Engine C. Combination meter
CHG-6
CHARGING SYSTEM
Component part Description

“B” terminal Refer to CHG-8, "Description". B
Alternator “S” terminal Refer to CHG-12, "Description".
“L” terminal Refer to CHG-9, "Description".
C
The IC voltage regulator warning function activates to illuminate
the charge warning lamp, if any of the following symptoms occur
Combination meter (Charge warning lamp) while alternator is operating:
• Excessive voltage is produced. D
• No voltage is produced.
CHG
CHG-7
B TERMINAL CIRCUIT
COMPONENT DIAGNOSIS
B TERMINAL CIRCUIT
“B” terminal circuit supplies power to charge the battery and to operate the vehicle’s electrical system.
1.CHECK “B” TERMINAL CONNECTION

2. Check if “B” terminal is clean and tight.
YES >> GO TO 2.
NO >> Repair “B” terminal connection.
2.CHECK “B” TERMINAL CIRCUIT
Check voltage between alternator “B” terminal and ground.
Terminals
(+) Voltage (Approx.)
(–)
Alternator “B” terminal Terminal
F59 (QR25DE)
1 Ground Battery voltage
F14 (M9R/MR20DE)
YES >> GO TO 3.
NO >> Check harness for open between alternator and fusible link.
3.CHECK “B” TERMINAL CONNECTION (VOLTAGE DROP TEST)
1. Start engine, then engine running at idle and warm.
2. Check voltage between battery positive terminal and alternator “B” terminal.
Terminals
(–) Voltage (Approx.)
(+)
Alternator “B” terminal Terminal
F59 (QR25DE)
Battery positive terminal 1 Less than 0.2 V
F14 (M9R/MR20DE)
YES >> “B” terminal circuit is normal. Refer to CHG-3, "Work Flow".
NO >> Check harness between battery and alternator for poor continuity.
CHG-8
L TERMINAL CIRCUIT (OPEN)
A
The “L” terminal circuit controls the charge warning lamp. The charge warning lamp illuminates when the igni- B
tion switch is set to ON or START. When the alternator is providing sufficient voltage with the engine running,
the charge warning lamp will go off. If the charge warning lamp illuminates with the engine running, a malfunc-
tion is indicated.
C
1.CHECK “L” TERMINAL CONNECTION D

2. Check if “L” terminal is clean and tight.
Is the inspection result normal? E
YES >> GO TO 2.
NO >> Repair “L” terminal connection.
2.CHECK “L” TERMINAL CIRCUIT (OPEN) F
1. Disconnect alternator connector.
2. Apply ground to alternator harness connector terminal.
3. Check condition of the charge warning lamp with the ignition switch in the ON position. G
Condition
Alternator harness connector Terminal H
Ignition switch position Charge warning lamp
Ground
F60 (QR25DE)
3 ON Illuminate
F15 (M9R/MR20DE)
I
Does it illuminate?
YES >> “L” terminal circuit is normal. Refer to CHG-3, "Work Flow".
NO >> GO TO 3. J
3.CHECK HARNESS CONTINUITY (OPEN CIRCUIT)
2. Disconnect the combination meter connector. K
3. Check continuity between alternator harness connector and combination meter harness connector.
Alternator harness connector Combination meter harness connector L

Continuity
Connector No. Terminal No. Connector No. Terminal No.
F60 (QR25DE)
3 M34 25 Existed
F15 (M9R/MR20DE) CHG
YES >> GO TO 4.
NO >> Repair the harness or connector. N
4.CHECK HARNESS CONTINUITY (OPEN CIRCUIT)

Check continuity between combination meter harness connector M34 terminal 2 and 10A fuse [No.3, located O
in the fuse block(J/B)].
YES >> GO TO 5. P
NO >> Repair the harness.
1. Connect the battery cable to the negative terminal.
2. Check voltage between combination meter harness connector and ground.
CHG-9
Terminals
(+)
Condition Voltage (Approx.)
Combination meter (–)
Terminal
harness connector
When the ignition switch is in
ON position
YES >> Replace combination meter.
NO >> Inspect the power supply circuit. Refer to PG-52, "Wiring Diagram - IGNITION POWER SUPPLY -
".
CHG-10
L TERMINAL CIRCUIT (SHORT)
L TERMINAL CIRCUIT (SHORT)
A
The “L” terminal circuit controls the charge warning lamp. The charge warning lamp illuminates when the igni- B
tion switch is set to ON or START. When the alternator is providing sufficient voltage with the engine running,
the charge warning lamp will go off. If the charge warning lamp illuminates with the engine running, a malfunc-
tion is indicated.
C
1.CHECK “L” TERMINAL CIRCUIT (SHORT) D

2. Disconnect alternator harness connector.
3. Turn ignition switch ON. E
Does charge warning lamp illuminate?
YES >> GO TO 2.
NO >> Refer to CHG-3, "Work Flow". F
2.CHECK HARNESS CONTINUITY (SHORT CIRCUIT)
1. Turn the ignition switch OFF.
2. Disconnect the battery cable from the negative terminal. G
3. Disconnect combination meter connector.
4. Check continuity between combination meter harness connector and ground.
H
Combination meter harness connector
Continuity
Connector No. Terminal No. Ground
M34 25 Not existed I
YES >> Replace combination meter.
J
NO >> Repair the harness.
CHG
CHG-11
S TERMINAL CIRCUIT
S TERMINAL CIRCUIT
The output voltage of the alternator is controlled by the IC voltage regulator at the “S” terminal detecting the
input voltage.
The “S” terminal circuit detects the battery voltage to adjust the alternator output voltage with the IC voltage
regulator.
1.CHECK “S” TERMINAL CONNECTION

2. Check if “S” terminal is clean and tight.
YES >> GO TO 2.
NO >> Repair “S” terminal connection.
2.CHECK “S” TERMINAL CIRCUIT
Check voltage between alternator harness connector and ground.
Terminals
(+) Voltage (Approx.)
(–)
Alternator harness connector Terminal
F60 (QR25DE)
4 Ground Battery voltage
F15 (M9R/MR20DE)
YES >> Refer to CHG-3, "Work Flow" .
NO >> Check harness for open between alternator and fuse.
CHG-12
CHARGING SYSTEM
CHARGING SYSTEM
A
Wiring Diagram - CHARGING SYSTEM (GASOLINE ENGINE MODELS) - INFOID:0000000001208707
CHG
P
JCMWA0519GB
CHG-13
CHARGING SYSTEM
JCMWA0520GB
CHG-14
CHARGING SYSTEM
CHG
JCMWA0521GB
CHG-15
CHARGING SYSTEM
Wiring Diagram - CHARGING SYSTEM (DIESEL ENGINE MODELS) - INFOID:0000000001208708
JCMWA0522GB
CHG-16
CHARGING SYSTEM
CHG
JCMWA0523GB
CHG-17
CHARGING SYSTEM
JCMWA0524GB
CHG-18
CHARGING SYSTEM
SYMPTOM DIAGNOSIS A
CHARGING SYSTEM
B
Symptom Reference
C
Discharged battery
The charge warning lamp does not illuminate when the ignition
switch is set to ON.
D
The charge warning lamp does not turn OFF after the engine Refer to CHG-3, "Work Flow".
starts.
The charge warning lamp turns ON when increasing the engine E
speed.
CHG
CHG-19
PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
WARNING:
ness connectors.
CHG-20
PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
B
Tool number
Description C
Tool name
KV10118200 (included in the adapter Removing and installing alternator pulley
kit: Mot. 1732)
Alternator pulley adapter D
E
PKIA1241E
CHG
CHG-21
CHARGING SYSTEM PRELIMINARY INSPECTION
< ON-VEHICLE MAINTENANCE >
CHARGING SYSTEM PRELIMINARY INSPECTION
Inspection Procedure INFOID:0000000001208712
1.CHECK BATTERY TERMINALS CONNECTION

Check if battery terminals are clean and tight.
YES >> GO TO 2.
NO >> Repair battery terminals connection.
2.CHECK FUSE
Check for blown fuse.
Unit Power source (Power supply terminals) Fuse No.

Alternator Battery (“S” terminal) 34
Combination meter Ignition switch ON (“L” terminal) 3
YES >> GO TO 3.
NO >> Be sure to eliminate the cause of malfunction before installing new fuse.
3.CHECK “E” TERMINAL CONNECTION
Check if “E” terminal (alternator ground harness) is clean and tight.
YES >> GO TO 4.
NO >> Repair “E” terminal connection.
4.CHECK DRIVE BELT TENSION
Check drive belt tension. Refer to the following.
• EM-257, "Checking" (M9R)
• EM-15, "Checking" (MR20DE)
• EM-138, "Checking" (QR25DE)
CHG-22
ALTERNATOR
ON-VEHICLE REPAIR A
ALTERNATOR
M9R MODELS
B
M9R MODELS : Exploded View INFOID:0000000001208713
REMOVAL C
JPMIA0307GB
I
1. Alternator connector 2. Alternator mounting bolt 3. Alternator
4. “B” terminal harness 5. “B” terminal nut
J
DISASSEMBLY
Type: A3TJ2481
K
CHG
CHG-23
ALTERNATOR
JPMIA0264GB
1. Rear bearing 2. Rotor assembly 3. Retainer

4. Front bearing 5. Front bracket assembly 6. Washer
7. Pulley 8. Stator assembly 9. IC voltage regulator assembly
10. Diode assembly 11. Rear bracket assembly 12. Terminal set
M9R MODELS : Removal and Installation INFOID:0000000001208714
REMOVAL
3. Remove RH fender protector partially.
5. Remove air inlet tube (1). Refer to EM-266, "Exploded View".
6. Get air inlet hose (2) out of alternator removal area.
7. Remove reservoir tank hose bracket mounting bolts (A) and res-
ervoir tank hose bracket.
8. Disconnect alternator connector (B).
9. Remove “B” terminal nut (C) and “B” terminal harness.
10. Remove upper alternator mounting bolt (D).
11. Completely loosen lower alternator mounting bolt (E), and pull it
out until the bolt head is in contact with the side member. And
then, remove the alternator by pulling it forward. JPMIA0351ZZ
NOTE:
The alternator can be removed together with the bolts by pulling it forward and using the alternator bracket
bolt hole cutout.
12. Remove alternator upward from the vehicle.
INSTALLATION
CHG-24
ALTERNATOR
CAUTION:
Be sure to tighten “B” terminal nut carefully. A
• Temporarily tighten the alternator bolts in order from the lower to the upper, and then tighten them in order
from the upper to the lower.
CAUTION:
B
For the alternator, the front side (pulley side) surface is the reference surface. Fit the reference sur-
face to the alternator mounting part, and then tighten the bolts.
• Install alternator, and check tension of belt. Refer to EM-257, "Checking".
C
M9R MODELS : Disassembly and Assembly INFOID:0000000001208922
DISASSEMBLY D
Rear Cover
NOTE:
Rear cover may be hard to remove because a ring is used to lock E
outer race of rear bearing. To facilitate removal of rear cover, heat
only the bearing box section until the temperature increases to
approximately 30°C (86°F) with a soldering iron (200W capacity).
CAUTION: F
Never use a heat gun, as if can damage diode assembly.
SEL032Z H
ASSEMBLY
Rear Bearing
I
CAUTION:
• Never reuse rear bearing. Replace with a new one.
• Never lubricate rear bearing outer race.
J
Rear Cover Installation
1. Fit brush assembly, diode assembly, regulator assembly and
stator assembly. K
CHG
SKIB4529E
N
2. Push brushed up with fingers and install them to rotor.
NOTE:
Take care not damage slip ring sliding surface. O
SKIB4530E
CHG-25
ALTERNATOR
M9R MODELS : Inspection INFOID:0000000001208923

Rotor Check
1. Resistance test
Resistance Refer to SDS CHG-35, "Al-

ternator".
• Replace the rotor if the measurement value is outside of the
specified range.
2. Insulator test
• Replace the rotor if continuity exists.
3. Check slip ring for wear.
SKIB4525E
Slip ring minimum outer : Refer to SDS CHG-35,

diameter "Alternator".
• Replace the rotor if the measurement value is outside of the specified range.
Brush Check
1. Check smooth movement of brush.
• Check brush holder and clean if it is not smooth.
2. Check brush for wear.
• Replace brush if it is worn down to the limit line.
SKIB4526E
Stator Check
1. Continuity test
• Replace the stator if continuity does not exist.
SKIB4527E
2. Ground test
• Replace the stator if continuity exists.
SKIB4528E
MR20DE MODELS
CHG-26
ALTERNATOR
MR20DE MODELS : Exploded View INFOID:0000000001208715
A
REMOVAL
PKID0787E G
1. Alternator connector 2. Alternator mounting bolt 3. Alternator

4. “B” terminal harness 5. “B” terminal nut H
DISASSEMBLY
I
Type: LR1140-802C
CHG
JPMIA0343GB
1. Stator assembly 2. Rotor assembly 3. Rotor spacer

4. Retainer 5. Front bearing 6. Front bracket assembly
CHG-27
ALTERNATOR
7. Pulley 8. Pulley cap 9. Rear bracket assembly
10. Diode assembly 11. Double labyrinth seal 12. IC voltage regulator assembly
13. Rear cover 14. Bush 15. “B” terminal nut
MR20DE MODELS : Removal and Installation INFOID:0000000001208716
REMOVAL
4. Disconnect alternator connector (A).
5. Remove “B” terminal nut (B) and “B” terminal harness.
6. Remove upper alternator mounting bolt (C).
7. Completely loosen lower alternator mounting bolt (D), and pull it
out until the bolt head is in contact with the side member. And
then, remove the alternator by pulling it forward.
NOTE:
The alternator can be removed together with the bolts by pulling
it forward and using the alternator bracket bolt hole cutout.
8. Remove alternator upward from the vehicle. JPMIA0352ZZ
INSTALLATION
CAUTION:
Be sure to tighten “B” terminal nut carefully.
• Temporarily tighten the alternator bolts in order from the lower to the upper, and then tighten them in order
from the upper to the lower.
CAUTION:
For the alternator, the front side (pulley side) surface is the reference surface. Fit the reference sur-
face to the alternator mounting part, and then tighten the bolts.
MR20DE MODELS : Disassembly and Assembly INFOID:0000000001208717
DISASSEMBLY
Rear Bracket Assembly
1. Remove rear cover.
2. Remove IC voltage regulator assembly.
3. Separate front bracket assembly, stator assembly and rear bracket assembly.
NOTE:
• Raise the temperature of the center of the rear bracket assem-
bly approximately between 30°C (86°F) and 50°C (122°F).
• Insert the tip of the suitable tool into the clearance between
front cover and stator core, and then separate front side (front
bracket assembly, rotor assembly) and rear side (rear bracket
assembly, stator assembly, diode assembly).
CAUTION:
Be careful not to damage stator assembly.
PKIC1176E
Front Cover
CHG-28
ALTERNATOR
1. Set rotor to the vise.
CAUTION: A
• Be careful not to damage the rotor.
• Use copper plate or thick cloth for rotor in the vise.
2. Remove pulley cap, using suitable tool. B
SKIB0531E
D
3. Remove alternator pulley, using alternator pulley adaptor [SST].
G
SKIB0731E
ASSEMBLY H
Rear Bearing
CAUTION:
• Never reuse rear bearing. Replace with a new one. I
Rear Cover Installation
1. Fit brush assembly, diode assembly, regulator assembly and J
stator assembly.
SKIB4529E
CHG
2. Push brushed up with fingers and install them to rotor.

NOTE: N
Take care not damage slip ring sliding surface.
SKIB4530E
MR20DE MODELS : Inspection INFOID:0000000001208718
CHG-29
ALTERNATOR
Rotor Check
1. Resistance test

ternator".
specified range.
2. Insulator test
SKIB4525E

Brush Check
SKIB4526E
Stator Check
1. Continuity test
SKIB4527E
2. Ground test
SKIB4528E
QR25DE MODELS
QR25DE MODELS : Exploded View INFOID:0000000001208719
REMOVAL
CHG-30
ALTERNATOR
JPMIA0318GB F
1. Alternator bracket 2. Upper alternator mounting bolt 3. Lower alternator mounting bolt
4. Alternator 5. “B” terminal harness 6. “B” terminal nut
G
7. Alternator connector
DISASSEMBLY H
Type: LR1110-713C
I
CHG
P
JPMIA0344GB
1. Stator 2. Rear bearing 3. Rotor

4. Retainer 5. Front bearing 6. Front cover
7. Pulley 8. Fan guide 9. Labyrinth seal
10. IC voltage regulator assembly 11. Diode assembly 12. Rear cover
CHG-31
ALTERNATOR
13. Terminal assembly 14. “B” terminal nut
QR25DE MODELS : Removal and Installation INFOID:0000000001208720
REMOVAL
3. Disconnect alternator connector (A).
4. Remove “B” terminal nut (B) and “B” terminal harness.
5. Remove harness clip (C) from the harness bracket.
6. Remove upper alternator mounting bolt (D).
7. Remove lower alternator mounting bolt (E).
JPMIA0353ZZ
8. Remove alternator upward from the vehicle.

INSTALLATION
CAUTION:
Be sure to tighten “B” terminal nut carefully.
QR25DE MODELS : Disassembly and Assembly INFOID:0000000001208721
DISASSEMBLY
Rear Cover
NOTE:
Rear cover may be hard to remove because a ring is used to lock
outer race of rear bearing. To facilitate removal of rear cover, heat
only the bearing box section until the temperature increases to
approximately 30°C (86°F) with a soldering iron (200W capacity).
CAUTION:
Never use a heat gun, as if can damage diode assembly.
SEL032Z
Front Cover
1. Set rotor to the vise.
CAUTION:
• Be careful not to damage the rotor.
• Use copper plate or thick cloth for rotor in the vise.
2. Remove pulley cap, using suitable tool.
SKIB0531E
CHG-32
ALTERNATOR
3. Remove alternator pulley, using alternator pulley adaptor [SST].
A
SKIB0731E
D
ASSEMBLY
Rear Bearing
CAUTION: E
• Never reuse rear bearing. Replace with a new one.
Rear Cover Installation F
1. Fit brush assembly, diode assembly, regulator assembly and
stator.
G
I
SKIB4529E
2. Push brushed up with fingers and install them to rotor. J

NOTE:
Take care not damage slip ring sliding surface.
K
SKIB4530E
CHG
QR25DE MODELS : Inspection INFOID:0000000001208722
N
Rotor Check
1. Resistance test O

ternator". P
specified range.
2. Insulator test
SKIB4525E
CHG-33
ALTERNATOR

Brush Check
SKIB4526E
Stator Check
1. Continuity test
SKIB4527E
2. Ground test
SKIB4528E
CHG-34
< SERVICE DATA AND SPECIFICATIONS (SDS)
Alternator INFOID:0000000001208723
B
Applied model M9R MR20DE QR25DE

C
A3TJ2481 LR1140-802C LR1110-713C
Type
MITSUBISHI make HITACHI make
Nominal rating [V - A] 12 - 150 12 - 140 12 - 110 D
Ground polarity Negative
Minimum revolution under no-
[rpm] Less than 1,300 Less than 1,200 Less than 1,100 E
load (When 13.5 V is applied)
More than 31/1,300 More than 56/1,500 More than 70/1,800
Hot output current (When 13.5
[A/rpm] More than 122/2,500 More than 114/2,500 More than 91/2,500
V is applied)
More than 144/5,000 More than 139/5,000 More than 110/5,000 F
Regulated output voltage [V] 14.1 - 14.7
Minimum length of brush [mm (in)] More than 5.00 (0.197) More than 6.00 (0.236)
4.1 - 5.3 (418 - 541, 14.7 - 1.1 - 3.7 (112 - 377, 4.00 - 1.00 - 3.43 (102 - 350, 3.60 G
Brush spring pressure [N (g, oz)]
19.1) 13.3) - 12.34)
Slip ring minimum outer diam-
[mm (in)] More than 22.1 (0.870) More than 14.7 (0.579) More than 26.0 (1.024) H
eter
Rotor (Field coil) resistance [Ω] 1.7 - 2.0 1.61 - 1.91 2.16 - 2.46
CHG
CHG-35
TRANSMISSION & DRIVELINE
SECTION CL CLUTCH
B
CL
E
CONTENTS
SYMPTOM DIAGNOSIS ............................... 2 Removal and Installation .........................................11 F
NOISE, VIBRATION AND HARSHNESS CLUTCH PIPING ............................................... 14

(NVH) TROUBLESHOOTING ............................. 2 Exploded View .........................................................14
G
NVH Troubleshooting Chart ...................................... 2 Hydraulic Layout ......................................................15
PRECAUTION ............................................... 3
REMOVAL AND INSTALLATION ............... 16 H
PRECAUTIONS ................................................... 3
Precaution for Procedure without Cowl Top Cover...... 3 CSC (CONCENTRIC SLAVE CYLINDER) ....... 16
Service Notice or Precautions for Clutch .................. 3 Exploded View .........................................................16
I
PREPARATION ............................................ 4
CLUTCH DISC AND CLUTCH COVER ............ 18
PREPARATION ................................................... 4 J
MR20DE, QR25DE .....................................................18
Special Service Tools ................................................ 4
MR20DE, QR25DE : Exploded View .......................18
Commercial Service Tools ........................................ 4
MR20DE, QR25DE : Removal and Installation .......18
MR20DE, QR25DE : Inspection ..............................19 K
ON-VEHICLE MAINTENANCE ..................... 5
CLUTCH PEDAL ................................................. 5 M9R ............................................................................20
Inspection and Adjustment ........................................ 5 M9R : Exploded View ..............................................20 L
M9R : Removal and Installation ...............................20
CLUTCH FLUID ................................................... 6 M9R : Inspection ......................................................21
Inspection .................................................................. 6
SERVICE DATA AND SPECIFICATIONS M
Air Bleeding Procedure ............................................. 6
(SDS) ............................................................ 22
ON-VEHICLE REPAIR .................................. 8
SERVICE DATA AND SPECIFICATIONS N
CLUTCH PEDAL ................................................. 8 (SDS) ................................................................. 22
Exploded View .......................................................... 8 Clutch Control System .............................................22
Removal and Installation ........................................... 9 Clutch Pedal ............................................................22
Inspection .................................................................. 9 O
Clutch Disc ..............................................................22
Clutch Cover ............................................................22
CLUTCH MASTER CYLINDER ..........................11
Exploded View ........................................................ 11 P
CL-1
Symptom
Reference
Clutch slips
Clutch noisy
Clutch pedal spongy

SUSPECTED PARTS (Possible cause)
Clutch grabs/chatters
Clutch does not disengage

CLUTCH PEDAL (Inspection and adjustment) CL-5
1
1
SYMPTOM DIAGNOSIS
tion. If necessary, repair or replace these parts.
CLUTCH LINE (Air in line) CL-6
2
1
ENGINE MOUNTING (Loose) EM-75 (MR20DE), EM-182 (QR25DE), EM-312 (M9R)
1
CSC (Concentric Slave Cylinder) (Worn, dirty or damaged) CL-16
3
1
2
CL-2
CLUTCH DISC (Out of true)
3
CLUTCH DISC (Runout is excessive)
3
2
CLUTCH DISC (Lining broken)
3
CLUTCH DISC (Dirty or burned)
3
CLUTCH DISC (Oily)
3
2
2
CLUTCH DISC (Worn out) CL-18
2
2
CLUTCH DISC (Hardened)
2
CLUTCH DISC (Lack of spline grease)
3
DIAPHRAGM SPRING (Damaged)
4
3
DIAPHRAGM SPRING (Out of tip alignment)
4
2
PRESSURE PLATE (Distortion)
5
4
FLYWHEEL (Distortion) EM-102 (MR20DE), EM-218 (QR25DE)
5
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
INFOID:0000000001180750
PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
B
C
CL
PIIB3706J
Service Notice or Precautions for Clutch INFOID:0000000001180751 F
CAUTION:
• Recommended clutch fluid is brake fluid “DOT 3”. Refer to MA-22, "Fluids and Lubricants".
G
• Never reuse drained clutch fluid.
• Never splash clutch fluid on painted areas.
• Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic sys-
tem. H
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding
parts may damage seal of CSC and may cause clutch fluid leakage. I
• Never disassemble master cylinder and CSC.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Never use compressed air.
J
CL-3
PREPARATION
< PREPARATION >
PREPARATION
PREPARATION
Tool number
Description
Tool name
ST20050240 Adjusting unevenness of diaphragm spring of
Diaphragm adjusting wrench clutch cover
ZZA0508D

Clutch aligner Installing clutch disc
1: Center shaft
2: Attachment
3: Guide
PCIB0017E
CL-4
CLUTCH PEDAL
CLUTCH PEDAL
B
INSPECTION
1. Check to see if the master cylinder rod end moves freely. It C
should not be bound by the clutch pedal.
• If the rod end does not move freely, remove the rod end and
check for deformation or damage on the rod end. Leave the
CL
rod end removed for step 2.
2. Check the clutch pedal stroke for free range of movement.
a. With the master cylinder rod end removed, manually move the E
clutch pedal up and down to determine if it moves freely.
b. If any sticking is noted, replace the clutch pedal assembly.
Reverify that the master cylinder rod end moves freely.
PCIB1491E F
3. Inspect the ASCD clutch switch position. (With ASCD)
a. If the rod end does not move freely, check that the ASCD clutch switch is not applying pressure to the
clutch pedal causing the rod end to bind. To adjust, disconnect the ASCD clutch switch electrical connec-
tor and turn the ASCD clutch switch. G
b. Connect the ASCD clutch switch electrical connector.
4. Check the clutch hydraulic system components (master cylinder assembly, CSC) for sticking or binding.
H
a. If any sticking or binding is noted, repair or replace the related parts as necessary.
b. If any hydraulic system repair was necessary, bleed the clutch hydraulic system. Refer to CL-6, "Air
Bleeding Procedure".
I
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all of the air from the system.
J
ADJUSTMENT
ASCD CLUTCH SWITCH
Adjust ASCD clutch switch (1) position so that clearance between K
clutch pedal (2) and thread end of ASCD clutch switch, with clutch
pedal fully released, is within specification “A”. (With ASCD)
L
Clearance “A” : Refer to CL-22, "Clutch Pedal".
JPDIB0046ZZ N
CLUTCH SWITCH
Adjust clutch switch (1) position so that clearance between clutch
pedal (2) and thread end of clutch switch, with clutch pedal fully O
depressed, is within specification “C”. (If equipped)
Clearance “C” : Refer to CL-22, "Clutch Pedal". P
JPDIB0047ZZ
CL-5
CLUTCH FLUID
CLUTCH FLUID
CLUTCH FLUID LEVEL

• Visually check for any clutch fluid leakage around the reservoir
tank.
• Check the clutch system for any leakage if the fluid level is
JPFIA0007ZZ
Air Bleeding Procedure INFOID:0000000001180756
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all the air from the system.
CAUTION:
• Monitor clutch fluid level in reservoir tank to make sure it does not empty.
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
• Bleed the air of bleeding connector (1).
1. Fill reservoir tank with new clutch fluid.
2. Connect a transparent vinyl hose to air bleeder of bleeding con-
nector.
3. “Depress” and “release” the clutch pedal slowly and fully 15
times at an interval of 2 to 3 seconds and release the clutch
pedal.
PCIB1494E
4. Push the lock pin (1) of the bleeding connector (2), and maintain
the position.
CAUTION:
Hold it to prevent releasing clutch tube from bleeding con-
nector when fluid pressure is applied in the tube.
JPDIB0041ZZ
CL-6
CLUTCH FLUID
5. Slide clutch tube (1) in the direction of the arrow as shown in the
figure. A
2 : Clutch housing
B
Dimension “A” : 10 mm (0.39 in)
6. Depress the clutch pedal soon and hold it, and then bleed the air
from the piping. C
CAUTION:
Hold it to prevent releasing clutch tube from bleeding con- JPDIB0042ZZ
nector when fluid pressure is applied in the tube. CL
7. Return clutch tube and lock pin to their original positions.
8. Release clutch pedal and wait for 5 seconds.
9. Repeat steps 3 to 8 until no bubbles are observed in the clutch fluid. E
CL-7
CLUTCH PEDAL
ON-VEHICLE REPAIR
CLUTCH PEDAL
LHD
JPDIB0052GB
1. Clutch pedal assembly 2. Clutch switch (if equipped) 3. Clip

4. ASCD clutch switch (with ASCD) 5. Pedal pad 6. Stopper rubber
Refer to GI-4, "Components" for the symbols in the figure.
CL-8
CLUTCH PEDAL
RHD
A
CL
H
JPDIB0053GB
1. Clutch pedal assembly 2. Clutch switch (if equipped) 3. Clip

4. ASCD clutch switch (with ASCD) 5. Pedal pad 6. Stopper rubber I
Removal and Installation INFOID:0000000001180758 J
REMOVAL
1. Remove front kicking plate inner and dash side finisher. Refer to INT-16, "Removal and Installation". K
2. Remove lower instrument panel, driver side. Refer to IP-12, "Removal and Installation".
3. Disconnect ASCD clutch switch harness connector and then disconnect clip of harness from clutch pedal
assembly. (With ASCD) L
4. Disconnect clutch switch harness connector. (If equipped)
5. Remove master cylinder rod end from clutch pedal assembly.
M
6. Remove clutch pedal assembly.
PCIB1491E
P
INSTALLATION
CL-9
CLUTCH PEDAL
Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found, replace
clutch pedal assembly.
CL-10
CLUTCH MASTER CYLINDER
A
CL
G
JPDIB0035ZZ
1. Reservoir tank assembly 2. Hose 3. Master cylinder assembly

H
REMOVAL I
CAUTION:
and wash the affected area with water. J
• Never disassemble master cylinder.
1. Remove the air cleaner case and air duct (inlet) or air ducts. Refer to EM-25, "Removal and Installation"
(MR20DE), EM-150, "Removal and Installation" (QR25DE), or EM-263, "Removal and Installation" (M9R).
(For LHD) K
2. Remove cowl top assembly. Refer to EXT-19, "Removal and Installation". (For RHD with QR25DE and
RHD with M9R)
L
3. Remove engine room insulator. (For RHD)
4. Drain clutch fluid in reservoir tank assembly and then remove hose.
5. Remove master cylinder rod end from clutch pedal assembly. M
PCIB1491E
P
CL-11
6. Remove lock pin (1) from connector of master cylinder (2) and
separate clutch tube (3).
7. Rotate master cylinder assembly clockwise by 45° and then
remove master cylinder assembly from the vehicle.
PCIB1497E
INSTALLATION
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
1. Tilt master cylinder assembly clockwise by 45° and insert it to
the mounting hole. Rotate counterclockwise and secure it. At
this time, nipple is upward of the vehicle.
2. Install master cylinder rod end to clutch pedal assembly.
3. Install hose to reservoir tank assembly and master cylinder
assembly.
CAUTION:
Set hose with painted mark facing upward.
SCIA1286E
4. Install clutch tube (1) into connector of master cylinder assembly

(2) until it stops.
5. Install lock pin (3) into connector of master cylinder assembly
until it stops.
6. Fill new clutch fluid according to the following.
a. Fill reservoir tank assembly with new clutch fluid.
b. Connect a transparent vinyl hose to air bleeder of bleeding con-
nector.
PCIB1500E
c. Push the lock pin (1) of the bleeding connector (2).
JPDIB0041ZZ
CL-12
d. Slide clutch tube (1) in the direction of the arrow as shown in the
figure. A
2 : Clutch housing
B
Dimension “A” : 10 mm (0.39 in)
e. Depress clutch pedal slowly to full stroke and then release it.
Repeat this until new clutch fluid comes out. C
CAUTION:
• Hold it to prevent releasing clutch tube from bleeding JPDIB0042ZZ
connector when fluid pressure is applied in the tube. CL
• Monitor clutch fluid level in reservoir tank to make sure it does not empty.
f. Place clutch tube and lock pin back into position with clutch pedal depressed.
g. Bleed the air from the clutch hydraulic system. Refer to CL-6, "Air Bleeding Procedure". E
7. After completing this procedure, inspect for clutch pedal. Refer to CL-5, "Inspection and Adjustment".
8. Install engine room insulator. (For RHD)
9. Install cowl top assembly. Refer to EXT-19, "Removal and Installation". (For RHD with QR25DE and RHD F
with M9R)
10. Install the air cleaner case and air duct (inlet) or air ducts. Refer to EM-25, "Removal and Installation"
(MR20DE), EM-150, "Removal and Installation" (QR25DE), or EM-263, "Removal and Installation" (M9R). G
(For LHD)
CL-13
CLUTCH PIPING
CLUTCH PIPING
RS6F94R
JPDIB0050ZZ
1. CSC (Concentric Slave Cylinder) 2. Clutch tube 3. Bracket

4. Clutch damper 5. Master cylinder assembly
RS6F52A
JPDIB0051GB
1. CSC (Concentric Slave Cylinder) 2. Clutch tube 3. Bracket

4. Clutch damper 5. Master cylinder assembly
A. QR25DE B. MR20DE and M9R
CL-14
CLUTCH PIPING
Hydraulic Layout INFOID:0000000001180763
CL
PCIB1499E
1. Clutch tube 2. Lock pin 3. CSC (Concentric Slave Cylinder)

E
4. Clutch damper 5. Master cylinder assembly 6. Clutch pedal assembly
F
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water. G
REMOVAL
Refer to the figure for removal procedure.
H
INSTALLATION
Refer to the figure for installation procedure.
• When installing clutch tube to connector of CSC, connector of clutch damper and connector of master cylin-
der, push it as far as it goes. I
• When installing lock pin to connector of CSC, connector of clutch damper and connector of master cylinder,
push it as far as it goes.
• After installation, bleed the air from the clutch hydraulic system. Refer to CL-6, "Air Bleeding Procedure". J
CAUTION:
Never scratch or damage clutch hose.
K
CL-15
CSC (CONCENTRIC SLAVE CYLINDER)
< REMOVAL AND INSTALLATION >
MR20DE and QR25DE
JPDIB0040GB
1. Transaxle assembly 2. CSC (Concentric Slave Cylinder)

M9R
JPDIB0048GB
1. Transaxle assembly 2. CSC (Concentric Slave Cylinder) 3. Sealing bolt

CAUTION:
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding
parts may damage seal of CSC and may cause clutch fluid leakage.
• Never disassemble CSC.
CL-16
REMOVAL
1. Remove transaxle assembly from the vehicle. Refer to TM-26, "Removal and Installation" (RS6F94R) or A
TM-86, "Removal and Installation" (RS6F52A).
2. Remove mounting bolts and then remove CSC from clutch housing.
B
INSTALLATION
1. Install CSC to clutch housing and then tighten bolts to the specified torque.
CAUTION: C
• Never reuse CSC.
• Never reuse sealing bolt. (For M9R)
• Never insert and operate CSC because piston and stopper of CSC components may fall off.
CL
2. Install transaxle assembly. Refer to TM-26, "Removal and Installation" (RS6F94R) or TM-86, "Removal
and Installation" (RS6F52A).
3. Bleed the air from the clutch hydraulic system. Refer to CL-6, "Air Bleeding Procedure".
E
CL-17
CLUTCH DISC AND CLUTCH COVER
MR20DE, QR25DE
MR20DE, QR25DE : Exploded View INFOID:0000000001180767
JPDIB0049GB
1. Flywheel 2. Clutch disc 3. Clutch cover

4. Input shaft
A. First step B. Final step
: Apply lithium-based grease including molybdenum disulphide.
CAUTION:
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder). Return CSC insert to
original position to remove transaxle assembly. Dust on clutch disc sliding parts may damage seal of CSC and may cause
clutch fluid leakage.
• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• When installing, be careful that grease applied to input shaft does not adhere to clutch disc.
• Never clean in solvent on clutch disc.
MR20DE, QR25DE : Removal and Installation INFOID:0000000001180768
CAUTION:
If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts
may damage seal of CSC and may cause clutch fluid leakage.
REMOVAL
1. Remove transaxle assembly from the vehicle. Refer to TM-26, "Removal and Installation" (RS6F94R) or
TM-86, "Removal and Installation" (RS6F52A).
2. Loosen clutch cover mounting bolts.
3. Remove clutch cover and clutch disc.
CAUTION:
Never drop clutch disc.
INSTALLATION
1. Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.
2. Apply recommended grease to clutch disc and input shaft splines.
CAUTION:
CL-18
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. And if it adheres to seal of A
CSC, it cause clutch fluid leakage. Wipe off excess grease. Wipe off any grease oozing from the
parts.
3. Install clutch disc using a suitable clutch aligner. B
4. Install clutch cover. Pre-tighten clutch cover mounting bolts.
5. Tighten clutch cover mounting bolts evenly to the specified
torque in two steps in the order shown in the figure. C
6. Install transaxle assembly to the vehicle. Refer to TM-26,
"Removal and Installation" (RS6F94R) or TM-86, "Removal and
Installation" (RS6F52A). CL
PCIB1772E E
MR20DE, QR25DE : Inspection INFOID:0000000001180769
INSPECTION AFTER REMOVAL F
CLUTCH DISC
• Measure circumferential runout relative to clutch disc center spline.
G
If it is outside the specification, replace clutch disc.
Runout limit/diameter of the : Refer to CL-22,

area to be measured "Clutch Disc". H
• Measure backlash to clutch disc spline and main drive gear spline
at the circumference of clutch disc. If outside the specification,
replace clutch disc. I
Maximum allowable spline : Refer to CL-22,

backlash (at outer edge of disc) "Clutch Disc".
SCL221
J
• Measure the depth “A” to clutch disc facing rivet heads using cali-
pers. If it exceeds the allowable facing wear limit, replace clutch
disc. K
Facing wear limit (depth to the : Refer to CL-22,

rivet head) "Clutch Disc". L
JPDIB0026ZZ
CLUTCH COVER N
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using the diaphragm adjusting wrench [SST: ST20050240].
O
Tolerance for diaphragm : Refer to CL-22,
spring lever unevenness "Clutch Cover".
P
• Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover.
NOTE:
• Worn thrust ring will generate a beating noise when tapped at the
rivet with a hammer. PCIB0276E
• Broken thrust ring will make a clinking sound when cover is

shaken up and down.
CL-19
• If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace clutch cover.
M9R
JPDIB0055GB
1. Flywheel 2. Clutch disc 3. Clutch cover

4. Input shaft
: Apply lithium-based grease including molybdenum disulphide.
CAUTION:
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder). Return CSC insert to
original position to remove transaxle assembly. Dust on clutch disc sliding parts may damage seal of CSC and may cause
clutch fluid leakage.
• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• When installing, be careful that grease applied to input shaft does not adhere to clutch disc.
• Never clean in solvent on clutch disc.
CAUTION:
If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts
may damage seal of CSC and may cause clutch fluid leakage.
REMOVAL
1. Remove transaxle assembly from the vehicle. Refer to TM-86, "Removal and Installation".
2. Loosen clutch cover mounting bolts.
3. Remove clutch cover and clutch disc.
CAUTION:
Never drop clutch disc.
INSTALLATION
1. Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.
2. Apply recommended grease to clutch disc and input shaft splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. And if it adheres to seal of
CL-20
CSC, it cause clutch fluid leakage. Wipe off excess grease. Wipe off any grease oozing from the
parts. A
3. Install clutch disc using a suitable clutch aligner (A).
4. Install clutch cover. Pre-tighten clutch cover mounting bolts.
5. Tighten clutch cover mounting bolts evenly to the specified B
torque in the order shown in the figure.
6. Install transaxle assembly to the vehicle. Refer to TM-86,
"Removal and Installation". C
CL
PCIB1503E

E

CLUTCH DISC F
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc.
G
Runout limit/diameter of the : Refer to CL-22,
area to be measured "Clutch Disc".
• Measure backlash to clutch disc spline and main drive gear spline H
at the circumference of clutch disc. If outside the specification,
replace clutch disc.
I
Maximum allowable spline : Refer to CL-22,
SCL221
backlash (at outer edge of disc) "Clutch Disc".
• Measure the depth “A” to clutch disc facing rivet heads using cali- J
pers. If it exceeds the allowable facing wear limit, replace clutch
disc.
Facing wear limit (depth to the : Refer to CL-22, K

rivet head) "Clutch Disc".
JPDIB0026ZZ M
CLUTCH COVER
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height N
using the diaphragm adjusting wrench [SST: ST20050240].
Tolerance for diaphragm : Refer to CL-22, O

spring lever unevenness "Clutch Cover".
• Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover. P
NOTE:
• Worn thrust ring will generate a beating noise when tapped at the
rivet with a hammer. PCIB0276E
• Broken thrust ring will make a clinking sound when cover is

shaken up and down.
• If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace clutch cover.
CL-21
< SERVICE DATA AND SPECIFICATIONS (SDS)
Clutch Control System INFOID:0000000001180773
Type of clutch control Hydraulic
Clutch Pedal INFOID:0000000001180774
Unit: mm (in)
Clearance “A” between clutch pedal and ASCD clutch switch

0.74 - 1.96 (0.0291 - 0.0772)
threaded end while clutch pedal is fully released.
Clearance “C” between clutch pedal and clutch switch threaded
0.74 - 1.96 (0.0291 - 0.0772)
end while clutch pedal is fully depressed.
Clutch Disc INFOID:0000000001180775
Unit: mm (in)
Engine type MR20DE QR25DE M9R

Model 225 240 250
Facing size (Outer dia. × Inner dia. × 225 × 160 × 3.2 (8.86 × 6.30 240 × 160 × 3.2 (9.45 × 6.30 250 × 165 × 3.75 (9.84 × 6.50
Thickness) × 0.126) × 0.126) × 0.1476)
Runout limit/diameter of the area to be
1.0 (0.039) /215 (8.46) dia. 0.7 (0.028) /230 (9.06) dia. 1.0 (0.039) /240 (9.45) dia.
measured
Maximum allowable spline backlash
0.9 (0.035) 1.0 (0.039) 1.28 (0.0504)
(at outer edge of disc)
Facing wear limit (depth to the rivet
0.3 (0.012)
head)
Clutch Cover INFOID:0000000001180776
Engine type MR20DE QR25DE M9R

Engine model code number* — — JG70B JG71B
Transaxle type RS6F94R RS6F52A
6,370 N (649.7 kg, 8,500 N (867.0 kg, 9,500 N (969.0 kg,
Set-load 5,390 N (549.8 kg, 1,211.7 lb)
1,432.0 lb) 1910.8 lb) 2135.6 lb)
Tolerance for diaphragm
0.7 mm (0.028 in) or less 0.8 mm (0.031 in) or less
spring lever unevenness
Diaphragm spring lever 21 - 23 mm (0.83 - 31.8 - 33.8 mm 28.6 - 30.6 mm
26.6 - 29.0 mm (1.047 - 1.142 in)
height 0.91 in) (1.252 - 1.331 in) (1.126 - 1.205 in)
*: Engine model code number means the last five numbers of a part number (10001 #####).
CL-22
DRIVER CONTROLS
SECTION DEF DEFOGGER

B
E
CONTENTS
BASIC INSPECTION .................................... 3 Component Inspection .............................................17 F
DIAGNOSIS AND REPAIR WORKFLOW .......... 3 DOOR MIRROR DEFOGGER ........................... 18

Work Flow ................................................................. 3 G
DRIVER SIDE .............................................................18
FUNCTION DIAGNOSIS ............................... 4 DRIVER SIDE : Description .....................................18
DRIVER SIDE : Component Function Check ..........18
REAR WINDOW DEFOGGER SYSTEM ............. 4 DRIVER SIDE : Diagnosis Procedure .....................18 H
System Diagram ........................................................ 4 DRIVER SIDE : Component Inspection ...................19
PASSENGER SIDE ....................................................19
Component Parts Location ........................................ 5 I
PASSENGER SIDE : Description ............................19
Component Description ............................................. 5
PASSENGER SIDE : Component Function Check
DIAGNOSIS SYSTEM (BCM) ............................. 6 ....19
PASSENGER SIDE : Diagnosis Procedure ............20 J
COMMON ITEM ........................................................... 6 PASSENGER SIDE : Component Inspection ..........21
COMMON ITEM : CONSULT-III Function (BCM -
COMMON ITEM) ....................................................... 6 REAR WINDOW DEFOGGER ON SIGNAL ..... 22
Description ...............................................................22 K
REAR WINDOW DEFOGGER ..................................... 6 Component Function Check ....................................22
REAR WINDOW DEFOGGER : CONSULT-III Diagnosis Procedure ...............................................22
Function (BCM - REAR DEFOGGER) ...................... 6 DEF
ECU DIAGNOSIS ......................................... 23
DIAGNOSIS SYSTEM (IPDM E/R) ...................... 8
Diagnosis Description ............................................... 8 BCM (BODY CONTROL MODULE) ................. 23
CONSULT-III Function (IPDM E/R) ......................... 10 Reference Value ......................................................23 M
Wiring Diagram - DEFOGGER CONTROL SYS-
COMPONENT DIAGNOSIS ......................... 13 TEM (LHD MODELS) - ............................................40
Wiring Diagram - DEFOGGER CONTROL SYS- N
REAR WINDOW DEFOGGER SWITCH ............13
TEM (RHD MODELS) - ...........................................45
Description .............................................................. 13
Fail Safe ..................................................................49
Component Function Check .................................... 13
DTC Inspection Priority Chart ...............................50 O
DTC Index ...............................................................51
REAR WINDOW DEFOGGER RELAY ..............15
IPDM E/R (INTELLIGENT POWER DISTRI-
Description .............................................................. 15 P
Component Function Check .................................... 15
BUTION MODULE ENGINE ROOM) ................ 52
Reference Value ......................................................52
Wiring Diagram - DEFOGGER CONTROL SYS-
REAR WINDOW DEFOGGER ...........................16 TEM (LHD MODELS) - ............................................57
Description .............................................................. 16 Wiring Diagram - DEFOGGER CONTROL SYS-
Component Function Check .................................... 16 TEM (RHD MODELS) - ...........................................62
Diagnosis Procedure ............................................... 16 Fail Safe ..................................................................66
DEF-1
DTC Index .............................................................. 68 PASSENGER SIDE ................................................... 71
PASSENGER SIDE : Diagnosis Procedure ............ 71
SYMPTOM DIAGNOSIS ............................. 69
REAR WINDOW DEFOGGER SWITCH DOES
REAR WINDOW DEFOGGER AND DOOR NOT LIGHT, BUT REAR WINDOW DEFOG-
MIRROR DEFOGGER DO NOT OPERATE. ..... 69 GER OPERATES ............................................... 72
Diagnosis Procedure .............................................. 69 Diagnosis Procedure ............................................... 72
REAR WINDOW DEFOGGER DOES NOT PRECAUTION ............................................ 73
OPERATE BUT BOTH OF DOOR MIRROR
DEFOGGER OPERATE. ................................... 70 PRECAUTIONS ................................................. 73
Diagnosis Procedure .............................................. 70 Precaution for Supplemental Restraint System
DOOR MIRROR DEFOGGER DOES NOT OP- SIONER" ................................................................. 73
ERATE ............................................................... 71
BOTH SIDE ............................................................... 71
BOTH SIDE : Diagnosis Procedure ........................ 71 FILAMENT ......................................................... 74
Inspection and Repair ............................................. 74
DRIVER SIDE ............................................................ 71
DRIVER SIDE : Diagnosis Procedure .................... 71
DEF-2
BASIC INSPECTION A
B
DETAILED FLOW
1.OBTAIN INFORMATION ABOUT SYMPTOM C
Interview the customer to obtain the malfunction information (conditions and environment when the malfunc-
tion occurred) as much as possible when the customer brings the vehicle in.
D
>> GO TO 2.
2.CHECK DTC E
Perform self diagnosis with CONSULT-III
YES >> Refer to BCS-65, "DTC Index". F
NO >> GO TO 3.
3.REPRODUCE THE MALFUNCTION INFORMATION G
Check the malfunction on the vehicle that the customer describes.
Inspect the relation of the symptoms and the condition when the symptoms occur.
H
>> GO TO 4.
4.IDENTIFY THE MALFUNCTIONING SYSTEM WITH “SYMPTOM DIAGNOSIS”
I
Use “Symptom diagnosis” from the symptom inspection result in step 3. Then identify where to start perform-
ing the diagnosis based on possible causes and symptoms.
J
>> GO TO 5.
5.IDENTIFY MALFUNCTIONING PARTS WITH “COMPONENT DIAGNOSIS”
Perform the diagnosis with “Component diagnosis” of the applicable system. K
>> GO TO 6.
DEF
M
>> GO TO 7.
7.FINAL CHECK
N
Check that malfunctions are not reproduced when obtaining the malfunction information from the customer,
referring to the symptom inspection result in step 3.
IAre all malfunctions corrected?
O
YES >> INSPECTION END.
NO >> GO TO4.
P
DEF-3
REAR WINDOW DEFOGGER SYSTEM
FUNCTION DIAGNOSIS
JMLIA0049GB
OPERATION DESCRIPTION
• BCM detects that the rear window defogger switch is turned ON when the ignition switch is ON, and then
transmits the rear window defogger switch signal to IPDM E/R via CAN communication for approximately 15
minutes.
• IPDM E/R turns rear window defogger relay ON when it receives the rear window defogger switch signal.
Then, it transmits the rear window defogger ON signal to ECM via CAN communication.
• The power is supplied to the rear window defogger and door mirror defogger (with mirror defogger) when the
rear window defogger relay is turned ON.
TIMER FUNCTION
• BCM transmits the rear window defogger switch signal to IPDM E/R for approximately 15 minutes when the
rear window defogger switch is turned ON with the ignition switch ON. Then, IPDM E/R operates the rear
window defogger and door mirror defogger (with mirror defogger).
• The timer is cancelled if the rear window defogger switch is pressed again during timer operation. BCM
stops the output of rear window defogger switch signal. The same reaction also occurs during timer opera-
tion if the ignition switch is turned OFF.
INPUT/OUTPUT SIGNAL CHART
Switch Input signal to BCM BCM function Acutuator

Rear window defogger switch Defogger switch signal Rear window defogger & Door mir- Rear window defogger
Ignition switch Ignition switch ON signal ror defogger control Door mirror defogger
DEF-4
JMLIA0048ZZ
I
Rear window defogger switch (built
in AUTO AMP.)
1. BCM M65,M66,M67 2. IPDM E/R E11, E13 3.
Gasoline engine models: M50, M51
Diesel engine models: M53 J
4. Rear window defogger D184 5. Rear window defogger D185
A. Behind glove box B. Engine room dash panel (LH) C. Behind back door trim finisher
K
DEF
• Rear window defogger switch operation is transmitted to IPDM E/R via CAN commu-
BCM nication.
• Performs the timer control of rear window defogger.
M
Rear window defogger relay • Operates the rear window defogger and the door mirror defogger with the control sig-
nal from IPDM E/R.
• BCM controls rear window defogger relay via CAN communication, and then oper-
IPDM E/R N
ates rear window defogger or door mirror defogger.
Auto amp. • The rear window defogger switch is installed.
(Rear window defogger switch) • Turns the indicator lamp ON when detecting the operation of rear window defogger.
• Heats the heating wire with the power supply from the rear window defogger relay to O
Rear window defogger
prevent the rear window from fogging up.
• Heats the heating wire with the power supply from the rear window defogger relay to
Door mirror defogger
prevent the door mirror from fogging up. P
DEF-5
COMMON ITEM
APPLICATION ITEM

Self-Diagnostic Results Displays the diagnosis results judged by BCM. Refer to BCS-65, "DTC Index".
Active Test The signals used to activate each device are forcibly supplied from BCM.
Configuration
• Write the vehicle specification when replacing BCM.
SYSTEM APPLICATION
NOTE:
×: Applicable item

System
— BCM ×
Rear window defogger REAR DEFOGGER × × ×
Wiper and washer WIPER × × ×
Immobilizer IMMU × ×
— PTC HEATER*
REAR WINDOW DEFOGGER : CONSULT-III Function (BCM - REAR DEFOGGER)
INFOID:0000000001279550
Data monitor
DEF-6
Monitor Item Description A

REAR DEF SW Displays “Press (ON)/other (OFF)” status determined with the rear window defogger switch.
B
ACTIVE TEST
C
Test Item Description
REAR DEFOGGER Give a drive signal to the rear window defogger relay to activate it.
D
DEF
DEF-7
DIAGNOSIS SYSTEM (IPDM E/R)
Diagnosis Description INFOID:0000000001366483
Auto active test

Description
In auto active test mode, the IPDM E/R sends a drive signal to the following systems to check their operation.
• Oil pressure warning lamp
• Rear window defogger
• Front wiper (LO, HI)
• Parking lamps
• License plate lamps
• Tail lamps
• Front fog lamps
• Headlamps (LO, HI)
• A/C compressor (magnet clutch)
• Cooling fan (LO, MID, HI)
Operation procedure
1. Close the hood and lift the wiper arms from the windshield. (Prevent windshield damage due to wiper
operation)
NOTE:
When auto active test is performed with hood opened, sprinkle water on windshield beforehand.
3. Turn the ignition switch ON, and within 20 seconds, press the driver door switch 20 times. Then turn the
ignition switch OFF.
CAUTION:
Close passenger door.
4. Turn the ignition switch ON within 10 seconds. Then the horn sounds once and the auto active test starts.
NOTE:
Only a vehicle with the vehicle security system, the horn sounds.
5. The oil pressure warning lamp starts blinking when the auto active test starts.
6. After a series of the following operations is repeated 3 times, auto active test is completed.
NOTE:
When auto active test mode has to be cancelled halfway through test, turn ignition switch OFF.
CAUTION:
• If auto active test mode cannot be actuated, check door switch system.
• Never start the engine.
Inspection in auto active test mode
When auto active test mode is actuated, the following 6 steps are repeated 3 times.
JPMIA0313ZZ
DEF-8
Operation A
Inspection location Operation
sequence
A Oil pressure warning lamp Blinks continuously during operation of auto active test.
1 Rear window defogger 10 seconds B
2 Front wiper LO for 5 seconds → HI for 5 seconds
• Parking lamps
• License plate lamps C
3 10 seconds
• Tail lamps
• Front fog lamps
4 Headlamps LO ⇔ HI 5 times D
5 A/C compressor (magnet clutch) ON ⇔ OFF 5 times
6 Cooling fan LO for 5 seconds → MID for 3 seconds → HI for 2 seconds
E
Concept of auto active test
JPMIA0310GB
• IPDM E/R starts the auto active test with the door switch signals transmitted by BCM via CAN communica-
tion. Therefore, the CAN communication line between IPDM E/R and BCM is considered normal if the auto K
active test starts successfully.
• The auto active test facilitates troubleshooting if any systems controlled by IPDM E/R cannot be operated.
Diagnosis chart in auto active test mode DEF
Symptom Inspection contents Possible cause

M
YES BCM signal input circuit
Perform auto active test. • Rear window defogger

Rear window defogger does not operate Does the rear window defog- • Rear window defogger ground circuit
ger operate? NO • Harness or connector between IPDM N
E/R and rear window defogger
• IPDM E/R
Any of the following components do not operate YES BCM signal input circuit O
• Parking lamps
• License plate lamps Perform auto active test. • Lamp or motor
• Tail lamps Does the applicable system • Lamp or motor ground circuit
• Front fog lamps operate? NO • Harness or connector between IPDM P
• Headlamps (HI, LO) E/R and applicable system
• Front wiper (HI, LO) • IPDM E/R
DEF-9
Symptom Inspection contents Possible cause
• Communication signal between BCM
and auto amp.
• BCM
YES • CAN communication signal between
Perform auto active test. BCM and ECM
A/C compressor does not operate Does the magnet clutch oper- • CAN communication signal between
ate? ECM and IPDM E/R
• Magnet clutch
• Harness or connector between IPDM
NO
E/R and magnet clutch
• IPDM E/R
E/R and oil pressure switch
YES
Perform auto active test. • IPDM E/R
Oil pressure warning lamp does not operate Does the oil pressure warning • CAN communication signal between
lamp blink? IPDM E/R and BCM
NO • CAN communication signal between
BCM and combination meter
• Combination meter
• ECM signal input circuit
YES • CAN communication signal between
ECM and IPDM E/R
• Cooling fan motor-2 power supply cir-
cuit
• Cooling fan motor-1 ground circuit
• Cooling fan relay-4 or cooling fan re-
lay-5 power supply circuit
• Cooling fan relay-5 ground circuit
Perform auto active test. • Harness or connector between IPDM
Cooling fan does not operate E/R and cooling fan motor
Does the cooling fan operate?
NO
E/R, and cooling fan relay-4 or cooling
fan relay-5
• Harness or connector between cooling
fan motor-2, and cooling fan relay-4 or
cooling fan relay-5
• Cooling fan relay-4 or cooling fan re-
lay-5
• Cooling fan motor
• IPDM E/R
CONSULT-III Function (IPDM E/R) INFOID:0000000001366484
APPLICATION ITEM
CONSULT-III performs the following functions via CAN communication with IPDM E/R.
Diagnosis mode Description

Self Diagnostic Result Displays the diagnosis results judged by IPDM E/R.
Data Monitor Displays the real-time input/output data from IPDM E/R input/output data.
Active Test IPDM E/R can provide a drive signal to electronic components to check their operations.
CAN Diag Support MNTR The results of transmit/receive diagnosis of CAN communication can be read.
SELF DIAGNOSTIC
Refer to PCS-26, "DTC Index".
DATA MONITOR
Monitor item
DEF-10
Monitor Item MAIN A

Description
[Unit] SIGNALS
MOTOR FAN REQ Displays the value of the cooling fan speed signal received from ECM via CAN commu-
×
[1 - 4] nication.
B
AC COMP REQ Displays the status of the A/C compressor request signal received from ECM via CAN
×
[Off/On] communication.
TAIL&CLR REQ Displays the status of the position light request signal received from BCM via CAN com- C
×
[Off/On] munication.
HL LO REQ Displays the status of the low beam request signal received from BCM via CAN commu-
×
[Off/On] nication.
D
HL HI REQ Displays the status of the high beam request signal received from BCM via CAN com-
×
Displays the status of the front fog light request signal received from BCM via CAN com-
E
FR FOG REQ munication.
×
[Off/On] NOTE:
This item is monitored only the vehicle with front fog lamp system.
Displays the status of the headlamp washer request signal received from BCM via CAN F
HL WASHER REQ communication.
[Off/On] NOTE:
This item is monitored only the vehicle with headlamp washer system.
G
FR WIP REQ Displays the status of the front wiper request signal received from BCM via CAN com-
×
[Stop/1LOW/Low/Hi] munication.
WIP AUTO STOP H
× Displays the status of the front wiper auto stop signal judged by IPDM E/R.
[STOP P/ACT P]
WIP PROT
× Displays the status of the front wiper fail-safe operation judged by IPDM E/R.
[Off/BLOCK]
I
ST RLY REQ Displays the status of the ignition and starter request signal received from BCM via CAN
[Off/On] communication.
IGN RLY
× Displays the status of the ignition relay judged by IPDM E/R. J
[Off/On]
RR DEF REQ Displays the status of the rear defogger request signal received from BCM via CAN com-
×
K
OIL P SW
Displays the status of the oil pressure switch judged by IPDM E/R.
[Open/Close]
REV SW NOTE:
[Off/On] This item is indicated, but not monitored. DEF
Displays the status of the daytime running light request signal received from BCM via
DTRL REQ CAN communication.
[Off/On] NOTE: M
This item is monitored only the vehicle with daytime running light system.
Displays the status of the hood switch judged by IPDM E/R.
HOOD SW
NOTE: N
[Off/On]
This item is monitored only the vehicle with the vehicle security system.
Displays the status of the theft warning horn request signal received from BCM via CAN
THFT HRN REQ communication.
[Off/On] NOTE: O
This item is monitored only the vehicle with the vehicle security system.
HORN CHIRP NOTE:
[Off/On] This item is indicated, but not monitored. P
ACTIVE TEST
Test item
DEF-11

Off OFF
REAR DEFOGGER
On Operates the rear window defogger relay.
Off OFF
FRONT WIPER Lo Operates the front wiper relay.
Hi Operates the front wiper relay and front wiper high relay.
1 OFF
2 Operates the cooling fan relay (LO operation).
MOTOR FAN
3 Operates the cooling fan relay (MID operation).
4 Operates the cooling fan relay (HI operation).
HEAD LAMP WASHER On Operates the headlamp washer relay for 1 second.
Off OFF
Operates the tail lamp relay and the daytime running light relay.
TAIL NOTE:
Daytime running light relay is with daytime running light system only.
Lo Operates the headlamp low relay.
EXTERNAL LAMPS
Operates the headlamp low relay and ON/OFF the headlamp high relay at 4 sec-
Hi
onds intervals.
Operates the front fog lamp relay.
Fog NOTE:
This item can test only the vehicle with front fog lamp system.
Operates horn relay for 20 ms.
HORN On NOTE:
This item can test only the vehicle with vehicle security system.
DEF-12
REAR WINDOW DEFOGGER SWITCH
B
The rear window defogger is operated by turning the rear window defogger switch ON.
Component Function Check INFOID:0000000001279554 C
1.CHECK REAR WINDOW DEFOGGER SWITCH OPERATION

Check (“REAR DEF SW”, “IGN ON SW”) in DATA MONITOR mode with CONSULT-III. Refer to DEF-6, "REAR D
WINDOW DEFOGGER : CONSULT-III Function (BCM - REAR DEFOGGER)".
When rear defogger switch is turned to ON E

REAR DEF SW :ON
OK or NG
F
OK >> Rear window defogger switch is OK.
NG >> Refer to DEF-13, "Diagnosis Procedure".
G
1.CHECK REAR WINDOW DEFOGGER SWITCH OPERATION

1. Turn ignition switch ON. H
BCM Voltage (V)

Ground Condition I
Connector Terminal (Approx.)
Rear window defogger switch is pressing. 0

J
M65 20 Ground Rear window defogger switch is not K

pressed.
JPMIA0154GB
DEF
YES >> GO TO 6.
M
NO >> GO TO 2.
2.CHECK REAR WINDOW DEFOGGER SWITCH CIRCUIT
2. Disconnect BCM connector and auto amp. connector.
3. Check continuity between BCM harness connector and auto amp. harness connector.
O
BCM Auto amp.
Continuity
Gasoline engine models M51 22 P
M65 20 Yes
Diesel engine models M53 25
4. Check continuity between BCM harness connector and ground.
BCM
Ground Continuity
Connector Terminal
M65 20 Ground No
DEF-13
YES >> GO TO 3.
NO >> Repair or replace harness between BCM and auto amp.
3.CHECK REAR WINDOW DEFOGGER SWITCH GROUND CIRCUIT
Check continuity between auto amp. harness connector and ground.
Auto amp.
Ground Continuity
Connector Terminal
Gasoline engine models M51 22
Ground Existed
Diesel engine models M53 25
YES >> GO TO 4.
NO >> Repair or replace harness between auto amp. and ground.
4.CHECK BCM OUTPUT SIGNAL
BCM Voltage (V)

Ground
M65 20 Ground
JPMIA0154GB

YES >> GO TO 5.
NO >> GO TO 6.
5.CHECK IINTERMITTENT INCDENT
Refer to GI-39, "Intermittent Incident"
YES >> Replace auto amp. Refer to VTL-18, "Removal and Installation"
NO >> Repair or replace the malfunctioning parts.
>> INSPECTION END
DEF-14
REAR WINDOW DEFOGGER RELAY
REAR WINDOW DEFOGGER RELAY
A
The rear window defogger is operated by turning the rear window defogger switch ON. B
1.CHECK REAR WINDOW DEFOGGER SWITCH OPERATION C

Check (“REAR DEF SW”, “IGN ON SW”) in DATA MONITOR mode with CONSULT-III. Refer to DEF-6, "REAR
WINDOW DEFOGGER : CONSULT-III Function (BCM - REAR DEFOGGER)".
D
When rear window defogger switch is turned to ON
REAR DEF SW :ON
E
OK or NG
OK >> Rear window defogger switch is OK.
F
1.CHECK FUSE G
2. Check the following.
- 15A fuse (No. 55, located in IPDM E/R) H
- 15A fuse (No. 56, located in IPDM E/R)
YES >> GO TO 2. I
NO >> Replace the blown fuse after repairing the affected circuit if a fuse is blown.
2.CHECK IPDM E/R OUTPUT SIGNAL
J
2. Check voltage between IPDM E/R harness connector and ground.
IPDM E/R K
Voltage (V)
Ground Condition of rear window defogger switch
ON Battery voltage
E11 12 Ground DEF
OFF 0
YES >> GO TO 3. M
NO >> Replace IPDM E/R. Refer to PCS-28, "Removal and Installation".
3.CHECK INTERMITTENT INCIDENT
N
Refer toGI-39, "Intermittent Incident"
>> INSPECTION END O
DEF-15
Heats the heating wire with the power supply from the rear window defogger relay to prevent the rear window
from fogging up.
1.CHECK REAR WINDOW DEFOGGER

Check that the heating wire of rear window defogger is heated when turning the rear window defogger switch
ON.
YES >> Rear window defogger is OK.
NO >> Refer to DEF-16, "Diagnosis Procedure".
1.CHECK REAR WINDOW DEFOGGER POWER SUPPLY CIRCUIT

2. Check voltage between rear window defogger harness connector and ground.
Rear window defogger Condition of rear window Voltage (V)

Ground
Connector Terminal defogger switch (Approx.)
ON Battery voltage
D184 1 Ground
OFF 0
YES >> GO TO 2.
NO >> GO TO 4.
2.CHECK REAR WINDOW DEFOGGER GROUND CIRCUIT
2. Disconnect rear window defogger connector.
3. Check continuity between rear window defogger harness connector and ground.

Ground Continuity
Connector Terminal
D185 3 Ground Existed
YES >> GO TO 3.
NO >> Repair or replace harness between rear window defogger and ground.
3.CHECK FILAMENT
Check filament.
Refer to DEF-17, "Component Inspection".
YES >> GO TO 5.
NO >> Repair filament.
4.CHECK REAR WINDOW DEFOGGER POWER SUPPLY CIRCUIT
2. Disconnect IPDM E/R and rear window defogger connectors.
3. Check continuity between IPDM E/R and rear window defogger harness connector.
DEF-16
IPDM E/R Rear window defogger A

Continuity
E11 12 D184 1 Existed
B
4. Check continuity between IPDM E/R connector and ground.
IPDM E/R
Ground Continuity C
Connector Terminal
YES >> GO TO 5.
NO >> Repair or replace harness between IPDM E/R and rear window defogger.
5.CHECK INTERMITTENT INCIDENT E
F
>> INSPECTION END
G
1.CHECK FILAMENT
Check the filament for damage or blown.
Refer to DEF-74, "Inspection and Repair". H
NO >> Repair filament. I
DEF
DEF-17
DOOR MIRROR DEFOGGER
DRIVER SIDE
DRIVER SIDE : Description INFOID:0000000001279564
Heats the heating wire with the power supply from the rear window defogger relay to prevent the door mirror
from fogging up.
DRIVER SIDE : Component Function Check INFOID:0000000001279565
1.CHECK DRIVER SIDE DOOR MIRROR DEFOGGER

Check that heating wire of driver side door mirror defogger is heated when turning the rear window defogger
switch ON.
YES >> Driver side door mirror defogger is OK.
NO >> Refer to DEF-18, "DRIVER SIDE : Diagnosis Procedure".
DRIVER SIDE : Diagnosis Procedure INFOID:0000000001279566
1.CHECK FUSE
2. Check 10A fuse (No. 6, located in fuse and fusible link box).
YES >> Replace the blown fuse after repairing the affected circuit if fuse is blown.
NO >> GO TO 2.
2.CHECK DOOR MIRROR DEFOGGER POWER SUPPLY CIRCUIT
2. Check voltage between door mirror (driver side) harness connector and ground.
Door mirror (driver side) Condition of rear win- Voltage (V)

Ground
Connector Terminal dow defogger switch (Approx.)
LHD D3 2 ON Battery voltage

Ground
RHD D23 1 OFF 0
YES >> GO TO 3.
NO >> GO TO 5.
3.CHECK DOOR MIRROR DEFOGGER GROUND CIRCUIT
2. Disconnect door mirror (driver side) connector.
3. Check continuity between door mirror (driver side) harness connector and ground.
Door mirror (driver side)

Ground Continuity
Connector Terminal
LHD D3 10
Ground Existed
RHD D23 5
YES >> GO TO 4.
NO >> Repair or replace harness between door mirror (driver side) and ground.
Check driver side door mirror defogger.
Refer to DEF-19, "DRIVER SIDE : Component Inspection".
DEF-18
YES >> GO TO 6.
NO >> Replace door mirror glass (driver side). Refer to MIR-25, "DOOR MIRROR ASSEMBLY : Removal A
and Installation".
5.CHECK DOOR MIRROR CIRCUIT
B
2. Disconnect IPDM E/R connector and door mirror (driver side) connector.
3. Check continuity between door mirror (driver side) harness connector and IPDM E/R harness connector.
C
Door mirror (driver side) IPDM E/R
Continuity
LHD D3 2 D
E11 12 Existed
RHD D23 1
4. Check continuity between door mirror (driver side) harness connector and ground. E
Door mirror (driver side)

Ground Continuity
Connector Terminal F
LHD D3 2
Ground Not existed
RHD D23 1
Is the inspection result normal? G
YES >> GO TO 6.
NO >> Repair or replace harness between door mirror (driver side) and IPDM E/R.
H
6.CHECK INTERMITTENT
I
>> INSPECTION END
DRIVER SIDE : Component Inspection INFOID:0000000001279567
J
2. Disconnect door mirror (driver side) connector.
3. Check continuity between door mirror terminals.
Door mirror (diver side)

DEF
Continuity
Connector Terminal
LHD D3 2 10 M
Existed
RHD D23 1 5
YES >> INSPECTION END. N
NO >> Replace door mirror glass (driver side). Refer to MIR-25, "DOOR MIRROR ASSEMBLY : Removal
and Installation".
PASSENGER SIDE O
PASSENGER SIDE : Description INFOID:0000000001316059
Heats the heating wire with the power supply from the rear window defogger relay to prevent the door mirror P
from fogging up.
PASSENGER SIDE : Component Function Check INFOID:0000000001316060
1.CHECK PASSENGER SIDE DOOR MIRROR DEFOGGER
DEF-19
Check that heating wire of passenger side door mirror defogger is heated when turning the rear window defog-
ger switch ON.
YES >> Passenger side door mirror defogger is OK.
NO >> Refer to DEF-20, "PASSENGER SIDE : Diagnosis Procedure".
PASSENGER SIDE : Diagnosis Procedure INFOID:0000000001316260
1.CHECK FUSE
2. Check 10A fuse (No. 6, located in fuse and fusible link box).
YES >> Replace the blown fuse after repairing the affected circuit if fuse is blown.
NO >> GO TO 2.
2.CHECK DOOR MIRROR DEFOGGER POWER SUPPLY CIRCUIT
2. Check voltage between door mirror (passenger side) harness connector and ground.
Door mirror (passenger side) Condition of rear win- Voltage (V)

Ground
LHD D43 1 ON Battery voltage

Ground
RHD D63 2 OFF 0
YES >> GO TO 3.
NO >> GO TO 5.
3.CHECK DOOR MIRROR DEFOGGER GROUND CIRCUIT
2. Disconnect door mirror (passenger side) connector.
3. Check continuity between door mirror (passenger side) harness connector and ground.
Door mirror (passenger side)

Ground Continuity
Connector Terminal
LHD D43 5
Ground Existed
RHD D63 10
YES >> GO TO 4.
NO >> Repair or replace harness between door mirror (passenger side) and ground.
4.CHECK PASSENGER SIDE DOOR MIRROR DEFOGGER
Check passenger side door mirror defogger.
Refer to DEF-21, "PASSENGER SIDE : Component Inspection".
YES >> GO TO 6.
NO >> Replace door mirror glass (passenger side). Refer to MIR-25, "DOOR MIRROR ASSEMBLY :
Removal and Installation".
5.CHECK DOOR MIRROR CIRCUIT
2. Disconnect IPDM E/R connector and door mirror (passenger side) connector.
3. Check continuity between door mirror (passenger side) harness connector and IPDM E/R harness con-
nector.
DEF-20
Door mirror (passenger side) IPDM E/R A

Continuity
LHD D43 1
E11 12 Existed B
RHD D63 2
4. Check continuity between door mirror (passenger side) harness connector and ground.
C
Ground Continuity
Connector Terminal
LHD D43 1 D
Ground Not existed
RHD D63 2
YES >> GO TO 6. E
NO >> Repair or replace harness between door mirror (passenger side) and IPDM E/R.
6.CHECK INTERMITTENT F
>> INSPECTION END G

PASSENGER SIDE : Component Inspection INFOID:0000000001316062
1.CHECK PASSENGER SIDE DOOR MIRROR DEFOGGER H

2. Disconnect door mirror (passenger side) connector.
I
3. Check continuity between door mirror terminals connector.

Continuity J
Connector Terminal
LHD D43 1 5
Existed
RHD D63 2 10 K
NO >> Replace door mirror glass (passenger side). Refer to MIR-25, "DOOR MIRROR ASSEMBLY : DEF
DEF-21
REAR WINDOW DEFOGGER ON SIGNAL
REAR WINDOW DEFOGGER ON SIGNAL
Turns the indicator lamp in the rear window defogger switch ON when operating the rear window defogger.
1.CHECK REAR WINDOW DEFOGGER ON SIGNAL

Check that the indicator lamps of rear window defogger switch are illuminated when turning the rear window
defogger switch ON.
OK >> Rear window defogger ON signal is OK.
1.CHECK REAR WINDOW DEFOGGER INDICATOR LAMPS ON SIGNAL

2. Check voltage between auto amp. connector ground.
Auto amp. Condition of rear win- Voltage (V)

Ground
Gasoline engine models M51 23 ON Battery voltage

Ground
Diesel engine models M53 24 OFF 0
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK REAR WINDOW DEFOGGER INDICATOR LAMPS CIRCUIT
2. Disconnect IPDM E/R and auto amp. connector.
3. Check continuity between IPDM E/R connector and auto amp. connector.
IPDM E/R Auto amp.

Continuity
M51 (Gasoline engine models) 23
E11 12 Existed
M53 (Diesel engine models) 24
4. Check continuity between IPDM E/R connector and ground.
IPDM E/R
Ground Continuity
Connector Terminal
YES >> GO TO 3.
NO >> Repair or replace harness between IPDM E/R and auto amp.
Refer to GI-39, "Intermittent Incident".
>> INSOECTION END
DEF-22
< ECU DIAGNOSIS >
ECU DIAGNOSIS A
B

C
Ignition switch OFF or ACC Off D
IGN ON SW
KEY ON SW E
CDL LOCK SW
Press door lock/unlock switch to the lock side On F
CDL UNLOCK SW
G
DOOR SW-DR
Passenger door closed Off H
DOOR SW-AS
DOOR SW-RR
Rear RH door opened On I
DOOR SW-RL
J
BACK DOOR SW
Back door opened On
“LOCK” button of Intelligent Key or door request switch are not K
Off
I-KEY LOCK pressed
“UNLOCK” button of Intelligent Key or door request switch are not DEF
Off
pressed
I-KEY UNLOCK
On
pressed M
PUSH SW
N
KEYLESS LOCK
“UNLOCK” button of key fob is not pressed Off O
KEYLESS UNLOCK
After the reception of air bag deployment signal from air bag diag- P
Off
On
nosis sensor unit
UNLOCK SHOCK
DEF-23
< ECU DIAGNOSIS >
NOTE: On
UNLOCK WITH DR
Vehicle speed sensing auto door lock function does not operate Off
LOCK WITH SPEED
ACC ON SW
Ignition switch ACC or ON On
REAR DEF SW
TAIL LAMP SW
TURN SIGNAL R
TURN SIGNAL L
HI BEAM SW
Lighting switch HI On
HEAD LAMP SW 1
HEAD LAMP SW 2
Other than lighting switch PASS Off
PASSING SW
AUTO LIGHT SW
FR FOG SW
RR FOG SW
Engine stopped Off
ENGINE RUN
Engine running On
LIT-SEN FAIL
AUT LIGHT SYS
Outside of the room is bright Off
support
IGN SW CAN
FR WIPER HI
FR WIPER LOW
FR WIPER INT
DEF-24
< ECU DIAGNOSIS >
A
FR WASHER SW
INT VOLUME Wiper intermittent dial is in a dial position 1 - 7 1-7 B
FR WIPER STOP
Rear wiper switch OFF Off C
RR WIPER ON
RR WIPER INT D
RR WIPER STOP
Other than rear wiper stop position On E
RR WASHER SW
F
NOTE: Off
REVERSE SW CAN
When headlamp washer switch is not pressed Off G
H/L WASH SW
FAN ON SIG H
Off
AIR COND SW I
On
HAZARD SW J
Hazard switch ON On
BRAKE SW
Brake pedal is depressed On K
TRNK OPNR SW
DEF
Close the hood
NOTE: Off
Open the hood On
M

AUTO RELOCK
Auto lock function is operating On N
GLS BREAK SEN
• Ignition switch OFF or ACC O
Off
P
DEF-25
< ECU DIAGNOSIS >
TERMINAL LAYOUT
JSMIA0031GB
PHYSICAL VALUES
CAUTION:
• Turn wiper intermittent dial position to 4 except when checking waveform or voltage of wiper inter-
Description".
DEF-26
< ECU DIAGNOSIS >
Terminal No. Description A

(Wire color) Value
Input/ Condition
+ − Output
Just after Insert mechanical key B
(W) Output der
Just after Insert mechanical key C
(G) Output der

Ground Input D

(SB) Ignition switch ON or ACC Battery voltage E
5 Battery voltage
der
*1
Remove mechanical key from ignition key F
(R)*2 0V
cylinder
DEF
DEF-27
< ECU DIAGNOSIS >
(Wire color) Value
Input/ Condition
+ − Output
All switch OFF

JPMIA0165GB
1.4 V
Lighting switch HI
JPMIA0166GB
1.3 V

Ground Input
JPMIA0167GB
1.3 V
JPMIA0169GB
1.3 V

with all switch OFF
JPMIA0196GB
1.3 V
DEF-28
< ECU DIAGNOSIS >
Input/ Condition
+ − Output
All switch OFF

JPMIA0165GB
1.4 V D
E
Lighting switch 1ST
F
JPMIA0166GB
1.3 V
G

H
Ground Input
JPMIA0168GB
I
1.3 V
J
with all switch OFF
• Wiper intermittent dial 1 K
JPMIA0169GB
1.3 V DEF
M
Rear wiper INT
N
JPMIA0196GB
1.3 V
O
DEF-29
< ECU DIAGNOSIS >
(Wire color) Value
Input/ Condition
+ − Output
All switch OFF
JPMIA0165GB
1.4 V
JPMIA0166GB
1.3 V
Combination
tent dial 4)
JPMIA0167GB
1.3 V
JPMIA0168GB
1.3 V
JPMIA0196GB
1.3 V
DEF-30
< ECU DIAGNOSIS >
Input/ Condition
+ − Output
All switch OFF C
JPMIA0165GB
1.4 V D
Lighting switch 2ND
F
JPMIA0166GB
1.3 V
G
9 Combination
H
(B)*4 tent dial 4)
JPMIA0167GB
I
1.3 V

K
JPMIA0168GB
1.3 V DEF
N
JPMIA0196GB
1.3 V
O
DEF-31
< ECU DIAGNOSIS >
(Wire color) Value
Input/ Condition
+ − Output
All switch OFF

JPMIA0165GB
1.3 V

JPMIA0167GB
1.3 V

Ground Input
JPMIA0168GB
1.3 V

JPMIA0169GB
1.3 V

with all switch OFF
JPMIA0196GB
1.3 V
11 Input/
(B) Output
DEF-32
< ECU DIAGNOSIS >
Input/ Condition
+ − Output
OFF
(When rear door RH C
(LG) switch RH
PKID0924E
11.2 V D
ON
opened) E
F
OFF
(V) switch G
PKID0924E
11.2 V
ON H
0V
OFF
14 J
(P)*3 Ground Input
switch switch
(BR)*4 PKID0924E
11.2 V K
ON
opened)
DEF
M
OFF
Driver door
*4
switch N
(P) PKID0924E
11.2 V
ON
O
opened)
DEF-33
< ECU DIAGNOSIS >
(Wire color) Value
Input/ Condition
+ − Output
OFF
(When rear door LH
(GR) switch LH
PKID0924E
11.2 V
ON
opened)

Ground Output

Ground Input
JPMIA0154GB
1.1 V
While pressing 0V
21 Input/
— CAN-L — —
(P) Output
22 Input/
— CAN-H — —
(L) Output
ON 0V
23 Security indica-
(V) tor
JPMIA0014GB
10.3 V
OFF 12 V
Ignition switch OFF or ACC 12 V

Ground
JPMIA0156GB
8.7 V
25
(G)
DEF-34
< ECU DIAGNOSIS >
Input/ Condition
+ − Output
26
Blower fan motor Blower fan mo- OFF C
(GR)*5 Ground Input
switch tor switch
(LG)*6
PKID0924E
11.2 V D
E
(A/C indicator OFF, blow- F
27
*6
ON PKID0924E
(Y) 11.2 V G
(A/C indicator ON and 0V H
ON).
Ignition switch OFF or ACC 0V I
28 J
Ignition switch ON
(R)*8
K
JPMIA0155GB
6.0 V
DEF
29
Not pressed
M
Back door opener Back door
(LG)*3 Ground Input
(O)*4
JPMIA0154GB N
1.2 V
Pressed 0V
O
P
Ground
JPMIA0154GB
1.2 V
Pressed to the unlock side 0V
DEF-35
< ECU DIAGNOSIS >
(Wire color) Value
Input/ Condition
+ − Output
33
OFF
(Y)*10
JPMIA0154GB
1.3 V
ON 0V
34
Door lock/unlock Door lock/un- Not pressed
(SB)*3 Ground
(P)*4
JPMIA0154GB
1.2 V
35 Headlamp washer Headlamp Not pressed

Ground
JPMIA0154GB
1.2 V
All switch OFF 0V
Lighting switch 2ND
Combination
36 Combination switch switch Lighting switch HI
Ground Output
tent dial 4)
Lighting switch 1ST
JPMIA0164GB
9.1 V
All switch OFF
0V
Ground Output
(R) OUTPUT 2 switch Any of the condition below
with all switch OFF
9.1 V
DEF-36
< ECU DIAGNOSIS >
Input/ Condition
+ − Output
All switch OFF 0V
B
Combination
38 Combination switch switch Front wiper switch INT C
Ground Output
tent dial 4)
Rear fog lamp switch ON D

JPMIA0162GB
9.3 V
All switch OFF 0V
E
Combination
39 Combination switch switch Lighting switch 2ND F
Ground Output
tent dial 4)
Front fog lamp switch ON G
JPMIA0163GB
9.3 V
All switch OFF
0V H
I
(P) OUTPUT 1 switch
• Wiper intermittent dial 2 J
9.1 V
K
Rear wiper switch INT
Ground Input Ignition switch OFF Battery voltage DEF
(LG) ply

Ground Output
M
N
O
44 Ignition switch
(B) ON
JPMIA0197GB P

0V
DEF-37
< ECU DIAGNOSIS >
(Wire color) Value
Input/ Condition
+ − Output

Ground Output
(V) ator opener switch
SKIA9232E
Not pressed 0V
47 Ignition switch
(BR) ON Turn signal switch LH
PKID0926E
6.5 V
48 Ignition switch
Ground Turn signal RH Output
PKID0926E
6.5 V
49 OFF 0V
(Y) ON 12 V
50 Unlock 5V
(G) lock 0V

52 Room lamp timer Interior room OFF 12 V

Ground Output

Ground Output Ignition switch
(L) er supply (IGN) ON 12 V

54 Door lock/un-
(O) lock switch
er's door)
SKIA9232E
Not pressed 0V
55
(B)
DEF-38
< ECU DIAGNOSIS >
Input/ Condition
+ − Output
Not pressed 0V
B

(V)
Ground
fuel lid lock
Output
lock switch
C
Pressed to the lock side
D
SKIA9232E

(Y) ply
E
(P) er supply (BAT)
0V F
59 is not pressed
12 V
is pressed
G
H
Ground Output
I
SKIA9232E
Not pressed 0V
*1: With Intelligent Key J
*3: RHD models
*4: LHD models K
*7: RHD models with side air bag DEF
*10: Except with xenon headlamp and daytime light system M
DEF-39
< ECU DIAGNOSIS >
Wiring Diagram - DEFOGGER CONTROL SYSTEM (LHD MODELS) - INFOID:0000000001279896
JCLWA0524GB
DEF-40
< ECU DIAGNOSIS >
DEF
JCLWA0525GB
DEF-41
< ECU DIAGNOSIS >
JCLWA0526GB
DEF-42
< ECU DIAGNOSIS >
DEF
JCLWA0527GB
DEF-43
< ECU DIAGNOSIS >
JCLWA0528GB
DEF-44
< ECU DIAGNOSIS >
Wiring Diagram - DEFOGGER CONTROL SYSTEM (RHD MODELS) - INFOID:0000000001279897
DEF
JCLWA0529GB
P
DEF-45
< ECU DIAGNOSIS >
JCLWA0530GB
DEF-46
< ECU DIAGNOSIS >
DEF
JCLWA0531GB
DEF-47
< ECU DIAGNOSIS >
JCLWA0532GB
DEF-48
< ECU DIAGNOSIS >
DEF
JCLWA0533GB
Fail Safe INFOID:0000000001551375 P

DEF-49
< ECU DIAGNOSIS >

• Fuel cut (ECM)
• Fuel cut (ECM)
• Fuel cut (ECM)
• Fuel cut (ECM)
• Fuel cut (ECM)

lamp operating.
NOTE:
Fail-safe Control
Priority DTC
1
DEF-50
< ECU DIAGNOSIS >
A
NOTE:
D
254 F
256
G
251
H
253
264 J
265 K
DEF
DEF-51
IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
< ECU DIAGNOSIS >
IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE
ROOM)

Changes depending on engine
coolant temperature, air condition-
MOTOR FAN REQ Engine idle speed 1-4
er operation status, vehicle speed,
etc.
A/C switch OFF Off
AC COMP REQ Engine running A/C switch ON
On
(Compressor is operating)
TAIL&CLR REQ
Lighting switch 1ST, 2ND or AUTO (Light is illuminated) On
HL LO REQ
Lighting switch 2ND or AUTO (Light is illuminated) On
HL HI REQ
Lighting switch HI (Light is illuminated) On
Lighting switch 2ND or Front fog lamp switch OFF Off

FR FOG REQ
AUTO (Light is illuminated) Front fog lamp switch ON On
HL WASHER REQ Front washer switch OFF Off

NOTE: Ignition switch ON, and low Front washer switch ON
This item is monitored only on the vehicle beam headlamp is ON (When headlamp washer is operat- On
with headlamp washer. ing)
Front wiper switch OFF Stop
Front wiper switch INT 1LOW
FR WIP REQ Ignition switch ON
Front wiper switch LO Low
Front wiper switch HI Hi
Front wiper stop position STOP P
WIP AUTO STOP Ignition switch ON Any position other than front wiper
ACT P
stop position
Front wiper operates normally Off
WIP PROT Ignition switch ON Front wiper stops at fail-safe oper-
BLOCK
ation
ST RLY REQ When Intelligent Key is outside the vehicle, and the push switch
Off
NOTE: is pushed
Vehicle without Intelligent Key system indi- When Intelligent Key is inside the vehicle, and the push switch is
cates only “ON”, and it does not change. On
pushed
IGN RLY
RR DEF REQ Ignition switch ON Rear window defogger switch ON

(Rear window defogger is operat- On
ing)
Ignition switch OFF, ACC or engine running Open
OIL P SW
Ignition switch ON Close
DEF-52
< ECU DIAGNOSIS >
A
NOTE:
REV SW Off
This item is indicated, but not monitored.
Daytime running light system is not operated with lighting switch
DTRL REQ Off B
OFF.
NOTE:
This item is monitored only on the vehicle Any of the condition below
with the daytime running light system. • Daytime running light system is operated. On
• Lighting switch 1ST, 2ND or AUTO (Light is illuminated) C
HOOD SW Close the hood Off
NOTE:
This item is monitored only on the vehicle Open the hood On D
with the vehicle security system.
THFT HRN REQ Not operation Off
NOTE:
This item is monitored only on the vehicle E
Horn is activated with vehicle security system. On
with the vehicle security system.
NOTE:
HORN CHIRP Off
This item is indicated, but not monitored. F
TERMINAL LAYOUT
G
DEF
JPMIA0311ZZ
PHYSICAL VALUES
DEF-53
< ECU DIAGNOSIS >

(Wire color) Value
Input/ Condition
+ − Output
1
Ground Battery power supply Input Ignition switch OFF Battery voltage
(G)
2
Ground Battery power supply Input Ignition switch OFF Battery voltage
(R)
3 When engine is clanking Battery voltage
(O)*1 Ground Starter relay power supply Output
When engine is not clanking 0V
(BR)*2
4 Cooling fan relay-1 power Cooling fan opera- OFF 0V

Ground Output
(W) supply tion MID or HI Battery voltage
5 Ignition switch OFF, ACC or ON 0V

Ground Ignition switch START Input
(R) Ignition switch START Battery voltage
6 Battery power supply
(BR) (Cooling fan relay)
7 Cooling fan motor-2 (HI) Cooling fan opera- OFF Battery voltage
Ground —
(P) ground tion HI 0V
8 Cooling fan relay-2 power Cooling fan opera- OFF 0V

Ground Output
(G) supply tion HI Battery voltage
11
(B)
12 0V
Rear window defogger re- switch OFF
3
(O)* Ground Output Ignition switch ON
lay power supply Rear window defogger
(G)*4 Battery voltage
switch ON
• Parking lamp Turn off Battery voltage
15*5 Ground
Daytime running light relay
Output
• License plate
(SB) control lamp Turn on 0V
• Tail lamp
16*6 Front fog lamp switch OFF 0V

Ground Front fog lamp (LH) Output Lighting switch 1ST
(Y) Front fog lamp switch ON Battery voltage
17*6 Front fog lamp switch OFF 0V

Ground Front fog lamp (RH) Output Lighting switch 1ST
(W) Front fog lamp switch ON Battery voltage
18 Lighting switch OFF 0V

Ground Headlamp LO (LH) Output
(L) Lighting switch 2ND Battery voltage
19*7 Headlamp aiming motor Lighting switch OFF 0V

Ground Output
(R) power supply Lighting switch 2ND Battery voltage
20 Lighting switch OFF 0V

Ground Headlamp LO (RH) Output
(SB) Lighting switch 2ND Battery voltage
Lighting switch OFF 0V
21
Ground Headlamp HI (LH) Output • Lighting switch 2ND and HI
(G) Battery voltage
• lighting switch PASS
Lighting switch OFF 0V
22
Ground Headlamp HI (RH) Output • Lighting switch 2ND and HI
(LG) Battery voltage
• lighting switch PASS
23 Engine stopped 0V
Ground Oil pressure switch Input Ignition switch ON
(W) Engine running Battery voltage
DEF-54
< ECU DIAGNOSIS >
Input/ Condition
+ − Output
Front wiper stop position 0V
24
Ground Front wiper auto stop Input Ignition switch ON
B
(Y) Any position other than
Battery voltage
front wiper stop position
25
Ground Ground — Ignition switch ON 0V C
(B)
26 Input/
— CAN-L — —
(P) Output
D
27 Input/
— CAN-H — —
(L) Output
31 Cooling fan opera- OFF Battery voltage

Ground Cooling fan relay-4 control Output E
(V) tion LO 0V
After passing approximately 2 seconds or more
Battery voltage
after turning the ignition switch from ON to OFF
32* 1 F
Ground ETC relay control Input • Ignition switch ON
(LG)
• For approximately 2 seconds after turning igni- 0V
tion switch from ON to OFF
G
Ignition switch OFF 0V
33*1 Ground Fuel pump relay control Input Engine stopped Battery voltage
(GR) Ignition switch ON
Engine running 0.8 V H
34* 8 Close the hood Battery voltage
Ground Hood switch Input
(Y) Open the hood 0V
When headlamp washer is I
Battery voltage
35*9 Headlamp washer relay not operating
Ground Output Ignition switch ON
(W) control When headlamp washer is
0V J
operating
37 Tail, license plate lamps Lighting switch OFF 0V

Ground Output
(R) and illuminations Lighting switch 1ST Battery voltage
K
38*10 Lighting switch OFF 0V
(O)*1 Ground Parking lamp (LH) Output
2 Lighting switch 1ST Battery voltage
(GR)* DEF
39*10 Lighting switch OFF 0V
Ground Parking lamp (RH) Output
(GR) Lighting switch 1ST Battery voltage
Ignition switch OFF or ACC 0V M
40
Ground Ignition relay power supply Output
(V) Ignition switch ON Battery voltage
41 Ignition switch OFF or ACC 0V
N
(O)*1 Ground Ignition relay power supply Output
2 Ignition switch ON Battery voltage
(L)*
42 Front wiper switch OFF 0V

Ground Front wiper HI Output Ignition switch ON O
(L) Front wiper switch HI Battery voltage
43 Front wiper switch OFF 0V

Ground Front wiper LO Output Ignition switch ON
(G) Front wiper switch LO Battery voltage P
Ignition switch ON Selector lever “P” or “N” Battery voltage
45 (Except M/T mod- Selector lever in any posi-
Ground Starter relay power supply Input els) 0V
(Y) tion other than “P” or “N”
Ignition switch ON (M/T models) Battery voltage
DEF-55
< ECU DIAGNOSIS >
(Wire color) Value
Input/ Condition
+ − Output
• After passing approximately 1 second or more 0V
46*1 Fuel pump relay power after turning the ignition switch ON
Ground Output
(W) supply • For approximately 1 second after turning the
ignition switch ON Battery voltage
• Engine running
0V
47 after turning the ignition switch from ON to OFF
(BR)*1 Ground ECM relay power supply Output • Ignition switch ON
(G)*2 • For approximately 20 seconds after turning ig- Battery voltage
nition switch from ON to OFF
0V
48 after turning the ignition switch from ON to OFF
1
(R)* Ground ECM relay power supply Output • Ignition switch ON
(V)*2 • For approximately 20 seconds after turning ig- Battery voltage
50 Cooling fan opera- OFF Battery voltage

Ground Cooling fan relay-5 control Output
(G) tion MID or HI 0V
Battery voltage
51
Ground ECM relay control Output • Ignition switch ON
(W)
• For approximately 20 seconds after turning ig- 0V
0V
52*1 Ground ETC relay power supply Output
(P) • Ignition switch ON
• For approximately 2 seconds after turning igni- Battery voltage
tion switch from ON to OFF
Engine stopped 0V
A/C switch OFF 0V
55
Ground A/C relay power supply Output
(O) Engine running A/C switch ON
(A/C compressor is oper- Battery voltage
ating)

Ground Ignition switch ON Input
(L) Ignition switch ON Battery voltage
57*8 The horn is not activated Battery voltage

Ground Horn relay control Output
(V) The horn is activated 0V

(Y) Ignition switch ON Battery voltage

(GR) Ignition switch ON Battery voltage

(SB) Ignition switch ON Battery voltage
61
Ground ECM power supply Output Ignition switch OFF Battery voltage
(O)
*1: MR engine and QR engine models

*2: M9R engine models
*3: MR engine models
*4: QR engine and M9R engine models
DEF-56
< ECU DIAGNOSIS >
*5: With daytime running light system
*6: With front fog lamp system A
*7: Halogen type headlamp
8
* : With vehicle security system
B
*9: With headlamp washer system
*10: Without daytime running light system
C
Wiring Diagram - DEFOGGER CONTROL SYSTEM (LHD MODELS) - INFOID:0000000001279902
DEF
JCLWA0524GB
DEF-57
< ECU DIAGNOSIS >
JCLWA0525GB
DEF-58
< ECU DIAGNOSIS >
DEF
JCLWA0526GB
DEF-59
< ECU DIAGNOSIS >
JCLWA0527GB
DEF-60
< ECU DIAGNOSIS >
DEF
JCLWA0528GB
DEF-61
< ECU DIAGNOSIS >
Wiring Diagram - DEFOGGER CONTROL SYSTEM (RHD MODELS) - INFOID:0000000001279903
JCLWA0529GB
DEF-62
< ECU DIAGNOSIS >
DEF
JCLWA0530GB
DEF-63
< ECU DIAGNOSIS >
JCLWA0531GB
DEF-64
< ECU DIAGNOSIS >
DEF
JCLWA0532GB
DEF-65
< ECU DIAGNOSIS >
JCLWA0533GB
CAN communication control

When CAN communication with ECM and BCM is impossible, IPDM E/R performs fail-safe control. After CAN
communication recovers normally, it also returns to normal control.
If no CAN communication is available with ECM
DEF-66
< ECU DIAGNOSIS >
Control part Fail-safe in operation A

• The cooling fan relay-1, the cooling fan relay-2, the cooling fan relay-3 and the cooling
fan relay-5 turn ON when the ignition switch is turned ON
Cooling fan • The cooling fan relay-1, the cooling fan relay-2, the cooling fan relay-3 and the cooling
B
fan relay-5 turn OFF when the ignition switch is turned OFF
• Cooling fan relay-4 OFF
A/C compressor A/C relay OFF
C
If no CAN communication is available with BCM
Control part Fail-safe in operation D

• The headlamp low relay turns ON when the ignition switch is turned ON
Headlamp • The headlamp low relay turns OFF when the ignition switch is turned OFF
• Headlamp high relay OFF
E
• Parking lamps • The tail lamp relay and the daytime running light relay*1 turn ON when the ignition
• License plate lamps switch is turned ON
• Tail lamps • The tail lamp relay and the daytime running light relay*1 turn OFF when the ignition
• Illuminations F
switch is turned OFF
• The status just before activation of fail-safe control is maintained until the ignition
switch is turned OFF while the front wiper is operating at LO or HI speed.
Front wiper • The front wiper is operated at LO speed until the ignition switch is turned OFF if the G
fail-safe control is activated while the front wiper is set in the INT mode and the front
wiper motor is operating.
Front fog lamps Front fog lamp relay OFF H
Starter motor Starter relay OFF
Rear window defogger Rear window defogger relay OFF
2
I
Headlamp washer* Headlamp washer relay OFF
Horn*3 Horn relay OFF

NOTE: J
• *1: With daytime running light system
• *2: With headlamp washer system
• *3: With vehicle security system K
Ignition relay malfunction detection function

• IPDM E/R monitors status of ignition relay by the voltage at ignition relay contact circuit inside it.
• IPDM E/R judges that the ignition relay is error, if status of the ignition relay and ignition switch ON signal DEF
(CAN) *.
• If the ignition relay cannot turn OFF due to contact seizure, it activates the tail lamp relay and daytime run-
ning light relay* for 10 minutes to alert the user to the ignition relay malfunction when the ignition switch is M
turned OFF.
Tail lamp relay and daytime

DTC Ignition switch Ignition relay N
running light relay*
— ON ON —
— OFF OFF — O
— OFF ON ON (10 minutes)
B2099: IGN RLY OFF ON OFF —
NOTE: P
• The tail lamp relay and the daytime running light relay* are turned OFF when the ignition switch is turned ON.
• *: With daytime running light system
Front wiper control

IPDM E/R detects the front wiper stop position with the front wiper auto stop signal.
When the front wiper auto stop signal is in the conditions listed below, IPDM E/R repeats a front wiper 10 sec-
onds operation and 20 seconds stop five times.
DEF-67
< ECU DIAGNOSIS >
Ignition switch Front wiper switch Front wiper auto stop signal
The front wiper auto stop signal (stop posi-
OFF
tion) cannot be input for 10 seconds.
ON
The front wiper auto stop signal does not
ON
change for 10 seconds.
NOTE:
This operation status can be confirmed on the IPDM E/R “Data Monitor” that displays “BLOCK” for the item
“WIP PROT” while the wiper is stopped.
CONSULT display Fail-safe TimingNOTE Reference page

No DTC is detected.
further testing — — — —
may be required.
U1000: CAN COMM CIRCUIT × CRNT PAST PCS-13
B2099: IGN RELAY OFF — CRNT PAST PCS-14
NOTE:
The details of time display are as follows.
• CRNT: The malfunctions that are detected now.
• PAST: The number is indicated when it is normal at present and a malfunction was detected in the past.
DEF-68
REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER DO NOT OPER-
ATE.
SYMPTOM DIAGNOSIS A
REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER DO NOT
OPERATE.
B
1.IPDM E/R AUTO ACTIVE TEST C

Check IPDM E/R active test.
Refer to DEF-8, "Diagnosis Description".
YES >> GO TO 2.
E
2.CHECK REAR WINDOW DEFOGGER SWITCH
Check rear window defogger switch.
Refer to DEF-13, "Component Function Check". F
YES >> GO TO 3.
NO >> Repair or replace the malfunctioning parts. G
3.CHECK REAR WINDOW DEFOGGER RELAY
Check rear window defogger relay.
Refer to DEF-15, "Component Function Check" H
YES >> GO TO 4.
NO >> Repair or replace the malfunctioning parts. I

Check rear window defogger. J
Refer to DEF-16, "Component Function Check"
YES >> GO TO 5. K
5.CONFIRM THE OPERATION
DEF
Confirm the operation again.
Is the result normal?
YES >> Check intermittent incident. Refer to GI-39, "Intermittent Incident" M
NO >> GO TO 1.
DEF-69
REAR WINDOW DEFOGGER DOES NOT OPERATE BUT BOTH OF DOOR MIR-
ROR DEFOGGER OPERATE.
REAR WINDOW DEFOGGER DOES NOT OPERATE BUT BOTH OF DOOR
MIRROR DEFOGGER OPERATE.

Check rear window defogger.
Refer to DEF-16, "Component Function Check".
YES >> GO TO 2.
YES >> Check intermittent incident. Refer to GI-39, "Intermittent Incident"
NO >> GO TO 1.
DEF-70
DOOR MIRROR DEFOGGER DOES NOT OPERATE
DOOR MIRROR DEFOGGER DOES NOT OPERATE
A
BOTH SIDE
BOTH SIDE : Diagnosis Procedure INFOID:0000000001505786
B
1.CHECK DOOR MIRROR DEFOGGER CIRCUIT
Check door mirror defogger circuit.
Refer to DEF-18, "DRIVER SIDE : Component Function Check" C
YES >> GO TO 2.
D
Confirm the operation again. E
NO >> GO TO 1. F
DRIVER SIDE
DRIVER SIDE : Diagnosis Procedure INFOID:0000000001279909 G

Check driver side door mirror defogger. H
Refer to DEF-19, "DRIVER SIDE : Component Inspection".
YES >> GO TO 2. I
J
YES >> Check intermittent incident. Refer to GI-39, "Intermittent Incident" K
NO >> GO TO 1.
PASSENGER SIDE
DEF
1.CHECK PASSENGER SIDE DOOR MIRROR DEFOGGER.

M
Check passenger side door mirror defogger.
Refer to DEF-21, "PASSENGER SIDE : Component Inspection"
N
YES >> GO TO 2.
2.CONFIRM THE OPERATION O
YES >> Check intermittent incident. Refer to GI-39, "Intermittent Incident" P
NO >> GO TO 1.
DEF-71
REAR WINDOW DEFOGGER SWITCH DOES NOT LIGHT, BUT REAR WINDOW
DEFOGGER OPERATES
REAR WINDOW DEFOGGER SWITCH DOES NOT LIGHT, BUT REAR WIN-
DOW DEFOGGER OPERATES
1.CHECK REAR WINDOW DEFOGGER INDICATOR

Check rear window defogger ON signal.
Refer to DEF-22, "Component Function Check".
YES >> GO TO 2.
NO >> GO TO 1.
DEF-72
PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
WARNING: D
F
ness connectors.
G
DEF
DEF-73
FILAMENT
ON-VEHICLE REPAIR
FILAMENT
Inspection and Repair INFOID:0000000001279914
INSPECTION
1. When measuring voltage, wrap tin foil around the top of the neg-
ative probe. Then press the foil against the wire with your finger.
SEL122R
2. Attach probe circuit tester (in Volt range) to middle portion of

each filament.
SEL263
3. If a filament is burned out, circuit tester registers 0 or battery

voltage.
4. To locate burned out point, move probe to left and right along fil-
ament. Test needle will swing abruptly when probe passes the
point.
SEL265
REPAIR
REPAIR EQUIPMENT
• Conductive silver composition (Dupont No. 4817 or equivalent)
DEF-74
FILAMENT
• Ruler 30 cm (11.8 in) long
• Drawing pen A
• Heat gun
• Alcohol
• Cloth
B
REPAIRING PROCEDURE
1. Wipe broken heat wire and its surrounding area clean with a
cloth dampened in alcohol. C
2. Apply a small amount of conductive silver composition to tip of
drawing pen.
Shake silver composition container before use. D
3. Place ruler on glass along broken line. Deposit conductive silver
composition on break with drawing pen. Slightly overlap existing
heat wire on both sides [preferably 5 mm (0.20 in)] of the break.
E
PIIA0215E
F
4. After repair has been completed, check repaired wire for conti-
nuity. This check should be conducted 10 minutes after silver
composition is deposited. G
Do not touch repaired area while test is being conducted.
I
SEL012D
5. Apply a constant stream of hot air directly to the repaired area J

for approximately 20 minutes with a heat gun. A minimum dis-
tance of 3 cm (1.2 in) should be kept between repaired area and
hot air outlet. K
If a heat gun is not available, let the repaired area dry for 24
hours.
DEF
M
SEL013D
DEF-75
BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY
SECTION DLKDOOR & LOCK

B
E
CONTENTS
WITH I-KEY, WITHOUT SUPER LOCK KEY REMINDER ........................................................37 F
KEY REMINDER : System Diagram ........................37
BASIC INSPECTION ................................... 22 KEY REMINDER : System Description ...................37
KEY REMINDER : Component Parts Location ......38 G
DIAGNOSIS AND REPAIR WORKFLOW .........22 KEY REMINDER : Component Description ............40
Work Flow ............................................................... 22
AUTO DOOR LOCK ..................................................40
INSPECTION AND ADJUSTMENT ....................25 AUTO DOOR LOCK : System Diagram ..................40 H
AUTO DOOR LOCK : System Description ..............40
AUTO DOOR LOCK :
CONTROL UNIT ........................................................ 25
Component Parts Location ....................................41 I
AUTO DOOR LOCK : Component Description .......43
CONTROL UNIT : Description ................................ 25
ADDITIONAL SERVICE WHEN REPLACING VEHICLE SPEED SENSING AUTO DOOR LOCK....43
CONTROL UNIT : Special Repair Requirement .... 25 VEHICLE SPEED SENSING AUTO DOOR LOCK J
: System Diagram ....................................................43
FUNCTION DIAGNOSIS .............................. 26 VEHICLE SPEED SENSING AUTO DOOR LOCK
DOOR LOCK FUNCTION ..................................26 : System Description ................................................43 DLK
VEHICLE SPEED SENSING AUTO DOOR LOCK
DOOR LOCK AND UNLOCK SWITCH ..................... 26 : Component Parts Location ..................................44
DOOR LOCK AND UNLOCK SWITCH : System VEHICLE SPEED SENSING AUTO DOOR LOCK L
Diagram ................................................................... 26 : Component Description ........................................46
DOOR LOCK AND UNLOCK SWITCH : System
AIR BAG INTERLOCK UNLOCK ..............................46
Description .............................................................. 26
AIR BAG INTERLOCK UNLOCK : System Dia- M
DOOR LOCK AND UNLOCK SWITCH :
gram ........................................................................46
Component Parts Location .................................... 28
AIR BAG INTERLOCK UNLOCK : System De-
DOOR LOCK AND UNLOCK SWITCH :
scription ...................................................................46 N
Component Description .......................................... 30
AIR BAG INTERLOCK UNLOCK :
INTELLIGENT KEY ................................................... 30 Component Parts Location ....................................47
INTELLIGENT KEY : System Diagram ................... 30 AIR BAG INTERLOCK UNLOCK :
INTELLIGENT KEY : System Description ............... 30 Component Description ..........................................49 O
INTELLIGENT KEY : Component Parts Location.... 31
INTELLIGENT KEY : Component Description ....... 33 BACK DOOR OPENER FUNCTION ................. 50
BACK DOOR OPENER SWITCH ..............................50 P
DOOR REQUEST SWITCH ....................................... 33
DOOR REQUEST SWITCH : System Diagram ...... 33 BACK DOOR OPENER SWITCH : System Dia-
DOOR REQUEST SWITCH : System Description.... 33 gram ........................................................................50
DOOR REQUEST SWITCH : BACK DOOR OPENER SWITCH : System De-
Component Parts Location .................................... 35 scription ...................................................................50
DOOR REQUEST SWITCH : BACK DOOR OPENER SWITCH :
Component Description .......................................... 37 Component Parts Location ....................................51
DLK-1
BACK DOOR OPENER SWITCH : DOOR REQUEST SWITCH ............................... 77
Component Description ......................................... 53
DRIVER SIDE ............................................................ 77
WARNING FUNCTION ...................................... 54 DRIVER SIDE : Description .................................... 77
System Diagram ..................................................... 54 DRIVER SIDE : Component Function Check ........ 77
System Description ................................................. 54 DRIVER SIDE : Diagnosis Procedure ..................... 77
Component Parts Location ................................... 57 DRIVER SIDE : Component Inspection .................. 78
PASSENGER SIDE ................................................... 78
HAZARD AND BUZZER REMINDER FUNC- PASSENGER SIDE : Description ........................... 78
TION ................................................................... 60 PASSENGER SIDE :
System Diagram ..................................................... 60 Component Function Check .................................. 79
System Description ................................................. 60 PASSENGER SIDE : Diagnosis Procedure ............ 79
Component Parts Location ................................... 61 PASSENGER SIDE : Component Inspection ......... 80
BACK DOOR ............................................................. 80
DIAGNOSIS SYSTEM (BCM) ............................ 64 BACK DOOR : Description ..................................... 80
BACK DOOR : Component Function Check ......... 81
COMMON ITEM ........................................................ 64 BACK DOOR : Diagnosis Procedure ...................... 81
COMMON ITEM : CONSULT-III Function (BCM - BACK DOOR : Component Inspection ................... 82
COMMON ITEM) .................................................... 64
DOOR SWITCH ................................................. 83
DOOR LOCK ............................................................. 64
DOOR LOCK : CONSULT-III Function (BCM - DRIVER SIDE ............................................................ 83
DOOR LOCK) ......................................................... 64 DRIVER SIDE : Description .................................... 83
DRIVER SIDE : Component Function Check ........ 83
INTELLIGENT KEY ................................................... 66 DRIVER SIDE : Diagnosis Procedure ..................... 83
INTELLIGENT KEY : CONSULT-III Function DRIVER SIDE : Component Inspection .................. 84
(BCM - INTELLIGENT KEY) ................................... 66
PASSENGER SIDE ................................................... 84
TRUNK ...................................................................... 66 PASSENGER SIDE : Description ........................... 84
TRUNK : CONSULT-III Function (BCM - TRUNK)... 66 PASSENGER SIDE :
Component Function Check .................................. 84
DIAGNOSIS SYSTEM (INTELLIGENT KEY PASSENGER SIDE : Diagnosis Procedure ............ 84
UNIT) .................................................................. 67 PASSENGER SIDE : Component Inspection ......... 85
CONSULT-III Function (INTELLIGENT KEY) ......... 67
REAR LH ................................................................... 86
COMPONENT DIAGNOSIS ........................ 70 REAR LH : Description ........................................... 86
REAR LH : Component Function Check ............... 86
U1000 CAN COMM CIRCUIT ............................ 70 REAR LH : Diagnosis Procedure ............................ 86
Description .............................................................. 70
REAR LH : Component Inspection ......................... 87
DTC Logic ............................................................... 70
Diagnosis Procedure .............................................. 70 REAR RH ................................................................... 87
REAR RH : Description ........................................... 87
U1010 CONTROL UNIT (CAN) ......................... 71 REAR RH : Component Function Check ............... 87
Description .............................................................. 71 REAR RH : Diagnosis Procedure ........................... 88
DTC Logic ............................................................... 71 REAR RH : Component Inspection ......................... 88
Special Repair Requirement ................................... 71 BACK DOOR ............................................................. 89
BACK DOOR : Description ..................................... 89
POWER SUPPLY AND GROUND CIRCUIT ..... 72 BACK DOOR : Component Function Check ......... 89
BACK DOOR : Diagnosis Procedure ...................... 89
INTELLIGENT KEY UNIT ......................................... 72
BACK DOOR : Component Inspection ................... 90
INTELLIGENT KEY UNIT : Diagnosis Procedure... 72
BCM ........................................................................... 72 KEY SWITCH ..................................................... 91

BCM : Diagnosis Procedure ................................... 72 Description .............................................................. 91
Component Function Check ................................... 91
DOOR LOCK AND UNLOCK SWITCH ............. 74 Diagnosis Procedure ............................................... 91
Description .............................................................. 74 Component Inspection ............................................ 92
Diagnosis Procedure .............................................. 74 IGNITION KNOB SWITCH ................................ 94
Component Inspection ............................................ 75 Description .............................................................. 94
DLK-2
Component Function Check .................................... 94 INSTRUMENT CENTER .......................................... 119
Diagnosis Procedure ............................................... 94 INSTRUMENT CENTER : Description .................. 119 A
Component Inspection ............................................ 95 INSTRUMENT CENTER :
Component Function Check ................................ 119
DOOR LOCK ACTUATOR .................................96 INSTRUMENT CENTER : Diagnosis Procedure .. 119 B
DRIVER SIDE ............................................................ 96 CONSOLE ................................................................ 122
DRIVER SIDE : Description .................................... 96 CONSOLE : Description ........................................ 122
DRIVER SIDE : Component Function Check ........ 96 CONSOLE : Component Function Check ............ 122 C
DRIVER SIDE : Diagnosis Procedure ..................... 96 CONSOLE : Diagnosis Procedure ......................... 122
PASSENGER SIDE ................................................... 97 REAR SEAT ............................................................. 125
PASSENGER SIDE : Description ........................... 97 REAR SEAT : Description ..................................... 125 D
PASSENGER SIDE : REAR SEAT : Component Function Check ......... 125
Component Function Check .................................. 98 REAR SEAT : Diagnosis Procedure ...................... 125
PASSENGER SIDE : Diagnosis Procedure ............ 98 E
ANTI-HIJACK RELAY ..................................... 129
REAR LH ................................................................... 99
REAR LH : Description ............................................ 99 PASSENGER SIDE .................................................. 129
REAR LH : Component Function Check ............... 99 PASSENGER SIDE : Description .......................... 129 F
REAR LH : Diagnosis Procedure ............................ 99 PASSENGER SIDE :
REAR RH ................................................................. 100 PASSENGER SIDE : Diagnosis Procedure .......... 129 G
REAR RH : Description ......................................... 100 PASSENGER SIDE : Component Inspection ........ 130
REAR RH : Component Function Check ............. 100
REAR RH : Diagnosis Procedure .......................... 101 INTELLIGENT KEY WARNING BUZZER ....... 131
Description ............................................................. 131 H
BACK DOOR OPENER ACTUATOR .............. 103 Component Function Check ................................ 131
Description ............................................................ 103 Diagnosis Procedure ............................................. 131
Component Function Check ................................ 103 Component Inspection ........................................... 132 I
BUZZER (COMBINATION METER) ............... 133
FUEL LID OPENER ACTUATOR .................... 105 Description ............................................................. 133
Description ............................................................ 105 J
Component Function Check ................................ 105 Diagnosis Procedure ............................................. 133
KEY WARNING LAMP .................................... 134 DLK
BACK DOOR OPENER SWITCH .................... 107 Description ............................................................. 134
Description ............................................................ 107 Component Function Check ................................ 134
Diagnosis Procedure ............................................. 107 L
Component Inspection .......................................... 108 LOCK WARNING LAMP ................................. 135
Description ............................................................. 135
OUTSIDE KEY ANTENNA ............................... 109 Component Function Check ................................ 135 M
DRIVER SIDE .......................................................... 109 Diagnosis Procedure ............................................. 135
DRIVER SIDE : Description .................................. 109 HAZARD WARNING LAMPS ......................... 136
DRIVER SIDE : Component Function Check ...... 109 N
Description ............................................................. 136
DRIVER SIDE : Diagnosis Procedure ................... 109
PASSENGER SIDE ................................................. 112 Diagnosis Procedure ............................................. 136
PASSENGER SIDE : Description ......................... 112 O
VEHICLE SPEED SIGNAL CIRCUIT .............. 137
PASSENGER SIDE :
Description ............................................................. 137
PASSENGER SIDE : Diagnosis Procedure .......... 112 P
BACK DOOR ........................................................... 115
BACK DOOR : Description .................................... 115
INTELLIGENT KEY BATTERY ....................... 138
Description ............................................................. 138
BACK DOOR : Component Function Check ....... 115
BACK DOOR : Diagnosis Procedure .................... 115
INSIDE KEY ANTENNA ................................... 119
ECU DIAGNOSIS ....................................... 139
DLK-3
INTELLIGENT KEY UNIT ................................ 139 DOOR DOES NOT LOCK/UNLOCK WITH
Reference Value ....................................................139 DOOR REQUEST SWITCH .............................. 219
Wiring Diagram - POWER DOOR LOCK CON-
TROL SYSTEM - ...................................................146 DRIVER SIDE .......................................................... 219
Wiring Diagram - INTELLIGENT KEY CONTROL DRIVER SIDE : Description .................................. 219
SYSTEM - ..............................................................154 DRIVER SIDE : Diagnosis Procedure ................... 219
Wiring Diagram - BACK DOOR OPENER CON-
PASSENGER SIDE ................................................. 219
TROL SYSTEM - ...................................................166
PASSENGER SIDE : Description ......................... 219
Fail Safe ................................................................169
PASSENGER SIDE : Diagnosis Procedure .......... 220
DTC Inspection Priority Chart .............................169
DTC Index .............................................................169 BACK DOOR ........................................................... 220
BACK DOOR : Description ................................... 220
BCM (BODY CONTROL MODULE) ................ 170 BACK DOOR : Diagnosis Procedure .................... 220
Reference Value ....................................................170
Wiring Diagram - POWER DOOR LOCK CON- ANTI-HIJACK FUNCTION DOES NOT OPER-
TROL SYSTEM - ...................................................187 ATE WITH DOOR REQUEST SWITCH ........... 222
Wiring Diagram - INTELLIGENT KEY CONTROL
SYSTEM - ..............................................................195 DRIVER SIDE .......................................................... 222
Wiring Diagram - BACK DOOR OPENER CON- DRIVER SIDE : Description .................................. 222
TROL SYSTEM - ...................................................207 DRIVER SIDE : Diagnosis Procedure ................... 222
Fail Safe ................................................................209
PASSENGER SIDE ................................................. 222
DTC Inspection Priority Chart .............................210
DTC Index .............................................................211
SYMPTOM DIAGNOSIS ............................ 212 KEY REMINDER FUNCTION DOES NOT OP-
DOOR LOCK ................................................... 212 ERATE .............................................................. 224
Symptom Table .....................................................212 Description ............................................................ 224
DOOR DOES NOT LOCK/UNLOCK WITH
DOOR LOCK AND UNLOCK SWITCH ........... 214 AUTO DOOR LOCK OPERATION DOES NOT
OPERATE ......................................................... 225
ALL DOOR ...............................................................214 Description ............................................................ 225
ALL DOOR : Description .......................................214 Diagnosis Procedure ............................................. 225
ALL DOOR : Diagnosis Procedure ........................214
VEHICLE SPEED SENSING AUTO LOCK
DRIVER SIDE ...........................................................214 OPERATION DOES NOT OPERATE ............... 226
DRIVER SIDE : Description ...................................215 Description ............................................................ 226
DRIVER SIDE : Diagnosis Procedure ...................215 Diagnosis Procedure ............................................. 226
PASSENGER SIDE ..................................................215 BACK DOOR DOES NOT OPENED ................ 227
PASSENGER SIDE : Description ..........................215 Description ............................................................ 227
PASSENGER SIDE : Diagnosis Procedure ..........215 Diagnosis Procedure ............................................. 227
REAR LH ..................................................................215 IGNITION KNOB RETURN FORGOTTEN
REAR LH : Description ..........................................216
WARNING DOES NOT OPERATE .................. 228
REAR LH : Diagnosis Procedure ...........................216
Description ............................................................ 228
REAR RH .................................................................216 Diagnosis Procedure ............................................. 228
REAR RH : Description .........................................216
REAR RH : Diagnosis Procedure ..........................216
IGNITION KEY WARNING DOES NOT OPER-
ATE ................................................................... 229
DOOR DOES NOT LOCK/UNLOCK WITH IN- Description ............................................................ 229
TELLIGENT KEY ............................................. 217 Diagnosis Procedure ............................................. 229
Description .............................................................217
OFF POSITION WARNING DOES NOT OP-
ERATE .............................................................. 230
ANTI-HIJACK FUNCTION DOES NOT OPER-
WARNING LAMP .................................................... 230
ATE WITH INTELLIGENT KEY ....................... 218
WARNING LAMP : Description ............................. 230
Description .............................................................218
WARNING LAMP : Diagnosis Procedure ............. 230
DLK-4
BUZZER (COMBINATION METER) ........................ 230 BUZZER REMINDER OPERATION DOES
BUZZER (COMBINATION METER) : Description.. 230 NOT OPERATE ............................................... 238 A
BUZZER (COMBINATION METER) : Diagnosis Description ............................................................. 238
Procedure .............................................................. 230 Diagnosis Procedure ............................................. 238
TAKE AWAY WARNING DOES NOT OPER- B
HAZARD REMINDER OPERATION DOES
ATE (DOOR IS OPENED) ................................ 231 NOT OPERATE ............................................... 239
Description ............................................................. 239
WARNING LAMP .................................................... 231 C
WARNING LAMP : Diagnosis Procedure .............. 231 SQUEAK AND RATTLE TROUBLE DIAG-
TAKE AWAY WARNING DOES NOT OPER- NOSES ............................................................ 240 D
Work Flow .............................................................. 240
ATE (ANY DOOR OPEN TO ALL DOORS
Inspection Procedure ............................................. 242
CLOSE) ............................................................ 232 Diagnostic Worksheet ............................................ 244
E
WARNING LAMP .................................................... 232
PRECAUTION ............................................ 246
WARNING LAMP : Diagnosis Procedure .............. 232 PRECAUTIONS ............................................... 246 F
INTELLIGENT KEY WARNING BUZZER ............... 232 Precaution for Supplemental Restraint System
INTELLIGENT KEY WARNING BUZZER : De- (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
scription ................................................................. 232 SIONER" ............................................................... 246
G
INTELLIGENT KEY WARNING BUZZER : Diag- Precaution Necessary for Steering Wheel Rota-
nosis Procedure .................................................... 232 tion After Battery Disconnect ................................. 246
Precaution for Procedure without Cowl Top Cover.. 247
TAKE AWAY WARNING DOES NOT OPER- Work ...................................................................... 247 H
ATE (TAKE AWAY THROUGH WINDOW) ...... 233
PREPARATION ......................................... 248
WARNING LAMP .................................................... 233 I
WARNING LAMP : Description ............................. 233 PREPARATION ............................................... 248
WARNING LAMP : Diagnosis Procedure .............. 233 Commercial Service Tools ..................................... 248
BUZZER (COMBINATION METER) ........................ 233 ON-VEHICLE REPAIR ............................... 249 J

BUZZER (COMBINATION METER) : Description.. 233
BUZZER (COMBINATION METER) : Diagnosis HOOD .............................................................. 249
Procedure .............................................................. 233 HOOD ASSEMBLY .................................................. 249 DLK
INTELLIGENT KEY LOW BATTERY WARN- HOOD ASSEMBLY : Exploded View ..................... 249
HOOD ASSEMBLY : Removal and Installation ..... 250
ING DOES NOT OPERATE ............................. 234
HOOD ASSEMBLY : Adjustment .......................... 251 L
Description ............................................................ 234
Diagnosis Procedure ............................................. 234 HOOD HINGE .......................................................... 252
HOOD HINGE : Exploded View ............................. 252
DOOR LOCK OPERATION WARNING HOOD HINGE : Removal and Installation ............. 252 M
CHIME DOES NOT OPERATE WITH DOOR
REQUEST SWITCH ......................................... 235 HOOD SUPPORT ROD ........................................... 253
Description ............................................................ 235 HOOD SUPPORT ROD : Exploded View .............. 253
N
Diagnosis Procedure ............................................. 235 HOOD SUPPORT ROD : Removal and Installa-
tion ......................................................................... 253
DOOR LOCK OPERATION WARNING
CHIME DOES NOT OPERATE WITH INTEL- HOOD LOCK CONTROL ......................................... 254 O
LIGENT KEY .................................................... 236 HOOD LOCK CONTROL : Exploded View ............ 254
Description ............................................................ 236 HOOD LOCK CONTROL : Removal and Installa-
Diagnosis Procedure ............................................. 236 tion ......................................................................... 254
P
HOOD LOCK CONTROL : Inspection ................... 255
BACK DOOR OPEN WARNING DOES NOT
OPERATE ......................................................... 237 RADIATOR CORE SUPPORT ........................ 256
Exploded View ....................................................... 256
Description ............................................................ 237
FRONT FENDER ............................................. 258
Exploded View ....................................................... 258
DLK-5
Removal and Installation .......................................258 BACK DOOR WEATHER-STRIP : Removal and
Installation ............................................................. 277
FRONT DOOR ................................................. 259
FRONT DOOR LOCK ....................................... 278
DOOR ASSEMBLY ..................................................259
DOOR ASSEMBLY : Exploded View .....................259 DOOR LOCK ........................................................... 278
DOOR ASSEMBLY : Removal and Installation .....260 DOOR LOCK : Exploded View .............................. 278
DOOR ASSEMBLY : Adjustment ..........................261 DOOR LOCK : Removal and Installation .............. 278
DOOR STRIKER ......................................................261 INSIDE HANDLE ..................................................... 280

DOOR STRIKER : Exploded View ........................262 INSIDE HANDLE : Exploded View ........................ 281
DOOR STRIKER : Removal and Installation .........262 INSIDE HANDLE : Removal and Installation ........ 281
DOOR HINGE ...........................................................262 OUTSIDE HANDLE ................................................. 281

DOOR HINGE : Exploded View .............................263 OUTSIDE HANDLE : Exploded View .................... 282
DOOR HINGE : Removal and Installation .............263 OUTSIDE HANDLE : Removal and Installation .... 282
DOOR CHECK LINK ................................................263 REAR DOOR LOCK ......................................... 285

DOOR CHECK LINK : Exploded View ..................264
DOOR CHECK LINK : Removal and Installation ..264 DOOR LOCK ........................................................... 285
DOOR LOCK : Exploded View .............................. 285
REAR DOOR ................................................... 265 DOOR LOCK : Removal and Installation .............. 285
DOOR ASSEMBLY ..................................................265 INSIDE HANDLE ..................................................... 287

DOOR ASSEMBLY : Exploded View .....................265 INSIDE HANDLE : Exploded View ........................ 287
DOOR ASSEMBLY : Removal and Installation .....266 INSIDE HANDLE : Removal and Installation ........ 287
DOOR ASSEMBLY : Adjustment ..........................267
OUTSIDE HANDLE ................................................. 287
DOOR STRIKER ......................................................267 OUTSIDE HANDLE : Exploded View .................... 288
DOOR STRIKER : Exploded View ........................268 OUTSIDE HANDLE : Removal and Installation .... 288
DOOR STRIKER : Removal and Installation .........268
BACK DOOR LOCK ......................................... 290
DOOR HINGE ...........................................................268
DOOR HINGE : Exploded View .............................269 DOOR LOCK ........................................................... 290
DOOR HINGE : Removal and Installation .............269 DOOR LOCK : Exploded View .............................. 290
DOOR LOCK : Removal and Installation .............. 290
DOOR CHECK LINK ................................................269
DOOR CHECK LINK : Exploded View ..................270 FUEL FILLER LID OPENER ............................ 291
DOOR CHECK LINK : Removal and Installation ..270
FUEL FILLER LID ................................................... 291
BACK DOOR ................................................... 271 FUEL FILLER LID : Exploded View ...................... 291
FUEL FILLER LID : Removal and Installation ....... 291
BACK DOOR ASSEMBLY .......................................271
BACK DOOR ASSEMBLY : Exploded View ..........271 DOOR SWITCH ................................................ 292
BACK DOOR ASSEMBLY : Removal and Installa- Exploded View ...................................................... 292
tion .........................................................................272 Removal and Installation ....................................... 292
BACK DOOR ASSEMBLY : Adjustment ................273
INSIDE KEY ANTENNA ................................... 293
BACK DOOR STRIKER ...........................................274
INSTRUMENT CENTER .......................................... 293
BACK DOOR STRIKER : Exploded View ..............274
INSTRUMENT CENTER : Exploded View ............ 293
BACK DOOR STRIKER : Removal and Installa-
tion .........................................................................274 INSTRUMENT CENTER : Removal and Installa-
tion ........................................................................ 293
BACK DOOR HINGE ...............................................274
CONSOLE ............................................................... 293
BACK DOOR HINGE : Exploded View ..................275
CONSOLE : Exploded View .................................. 294
BACK DOOR HINGE : Removal and Installation ..275
CONSOLE : Removal and Installation .................. 294
BACK DOOR STAY .................................................276
REAR ....................................................................... 294
BACK DOOR STAY : Exploded View ....................276
REAR : Exploded View ......................................... 294
BACK DOOR STAY : Removal and Installation ....276
REAR : Removal and Installation .......................... 295
BACK DOOR WEATHER-STRIP .............................276
BACK DOOR WEATHER-STRIP : Exploded View..276 OUTSIDE KEY ANTENNA ............................... 296
DLK-6
DRIVER SIDE .......................................................... 296 INTELLIGENT KEY : System Description ............. 311
DRIVER SIDE : Exploded View ............................ 296 INTELLIGENT KEY : Component Parts Location.. 312 A
DRIVER SIDE : Removal and Installation ............. 296 INTELLIGENT KEY : Component Description ...... 314
PASSENGER SIDE ................................................. 296 DOOR REQUEST SWITCH ..................................... 314

PASSENGER SIDE : Exploded View .................... 296 DOOR REQUEST SWITCH : System Diagram ..... 315 B
PASSENGER SIDE : Removal and Installation .... 296 DOOR REQUEST SWITCH : System Description.. 315
DOOR REQUEST SWITCH :
BACK DOOR ........................................................... 296 Component Parts Location .................................. 317 C
BACK DOOR : Exploded View .............................. 296 DOOR REQUEST SWITCH :
BACK DOOR : Removal and Installation .............. 296 Component Description ........................................ 319
INTELLIGENT KEY WARNING BUZZER ........ 298 KEY REMINDER ...................................................... 319 D
Exploded View ...................................................... 298 KEY REMINDER : System Diagram ...................... 319
Removal and Installation ....................................... 298 KEY REMINDER : System Description ................. 319
KEY REMINDER : Component Parts Location .... 320 E
BACK DOOR REQUEST SWITCH .................. 299
KEY REMINDER : Component Description .......... 322
Exploded View ...................................................... 299
Removal and Installation ....................................... 299 AUTO DOOR LOCK ................................................ 322
AUTO DOOR LOCK : System Diagram ................ 322 F
BACK DOOR OPENER SWITCH .................... 300 AUTO DOOR LOCK : System Description ............ 322
Exploded View ...................................................... 300 AUTO DOOR LOCK :
Removal and Installation ....................................... 300 Component Parts Location .................................. 323 G
INTELLIGENT KEY BATTERY ........................ 301 AUTO DOOR LOCK : Component Description ..... 325
Exploded View ...................................................... 301 VEHICLE SPEED SENSING AUTO DOOR LOCK.. 325
Removal and Installation ....................................... 301 H
INTELLIGENT KEY UNIT ................................. 302 : System Diagram .................................................. 325
Exploded View ...................................................... 302
: System Description .............................................. 325 I
WITH I-KEY & SUPER LOCK : Component Parts Location ................................ 326
BASIC INSPECTION ................................. 303 VEHICLE SPEED SENSING AUTO DOOR LOCK J
: Component Description ...................................... 328
DIAGNOSIS AND REPAIR WORKFLOW ....... 303
AIR BAG INTERLOCK UNLOCK ............................ 328
Work Flow ............................................................. 303 DLK
AIR BAG INTERLOCK UNLOCK : System Dia-
INSPECTION AND ADJUSTMENT .................. 306 gram ...................................................................... 328
ADDITIONAL SERVICE WHEN REPLACING scription ................................................................. 328 L
CONTROL UNIT ...................................................... 306 AIR BAG INTERLOCK UNLOCK :
ADDITIONAL SERVICE WHEN REPLACING Component Parts Location .................................. 329
CONTROL UNIT : Description .............................. 306 AIR BAG INTERLOCK UNLOCK :
M
ADDITIONAL SERVICE WHEN REPLACING Component Description ........................................ 331
CONTROL UNIT : Special Repair Requirement .. 306
BACK DOOR OPENER FUNCTION ............... 332
FUNCTION DIAGNOSIS ............................ 307 N
BACK DOOR OPENER SWITCH ............................ 332
DOOR LOCK FUNCTION ................................ 307 BACK DOOR OPENER SWITCH : System Dia-
gram ...................................................................... 332
DOOR LOCK AND UNLOCK SWITCH ................... 307 BACK DOOR OPENER SWITCH : System De- O
DOOR LOCK AND UNLOCK SWITCH : System scription ................................................................. 332
Diagram ................................................................. 307 BACK DOOR OPENER SWITCH :
DOOR LOCK AND UNLOCK SWITCH : System Component Parts Location .................................. 333 P
Description ............................................................ 307 BACK DOOR OPENER SWITCH :
DOOR LOCK AND UNLOCK SWITCH : Component Description ........................................ 335
Component Parts Location .................................. 309
DOOR LOCK AND UNLOCK SWITCH : WARNING FUNCTION .................................... 336
Component Description ........................................ 311 System Diagram .................................................... 336
System Description ................................................ 336
INTELLIGENT KEY ................................................. 311 Component Parts Location .................................. 339
INTELLIGENT KEY : System Diagram ................. 311
DLK-7
Component Description ........................................341 DOOR REQUEST SWITCH .............................. 361
HAZARD AND BUZZER REMINDER FUNC- DRIVER SIDE .......................................................... 361
TION ................................................................. 342 DRIVER SIDE : Description .................................. 361
System Diagram ....................................................342 DRIVER SIDE : Component Function Check ...... 361
System Description ................................................342 DRIVER SIDE : Diagnosis Procedure ................... 361
Component Parts Location ..................................343 DRIVER SIDE : Component Inspection ................ 362
Component Description ........................................345
PASSENGER SIDE ................................................. 362
DIAGNOSIS SYSTEM (BCM) .......................... 346 PASSENGER SIDE : Description ......................... 362
PASSENGER SIDE :
COMMON ITEM .......................................................346 Component Function Check ................................ 363
COMMON ITEM : CONSULT-III Function (BCM - PASSENGER SIDE : Diagnosis Procedure .......... 363
COMMON ITEM) ...................................................346 PASSENGER SIDE : Component Inspection ....... 364
DOOR LOCK ............................................................346 BACK DOOR ........................................................... 364
DOOR LOCK : CONSULT-III Function (BCM - BACK DOOR : Description ................................... 364
DOOR LOCK) ........................................................346 BACK DOOR : Component Function Check ....... 365
INTELLIGENT KEY ..................................................348
BACK DOOR : Component Inspection ................. 366
INTELLIGENT KEY : CONSULT-III Function
(BCM - INTELLIGENT KEY) ..................................348 DOOR SWITCH ................................................ 367
TRUNK .....................................................................348 DRIVER SIDE .......................................................... 367
TRUNK : CONSULT-III Function (BCM - TRUNK)..348 DRIVER SIDE : Description .................................. 367
DRIVER SIDE : Component Function Check ...... 367
DIAGNOSIS SYSTEM (INTELLIGENT KEY
UNIT) ................................................................ 349 DRIVER SIDE : Component Inspection ................ 368
CONSULT-III Function (INTELLIGENT KEY) ........349
PASSENGER SIDE ................................................. 368
COMPONENT DIAGNOSIS ....................... 352 PASSENGER SIDE : Description ......................... 368
PASSENGER SIDE :
U1000 CAN COMM CIRCUIT .......................... 352
Description .............................................................352
DTC Logic ..............................................................352
PASSENGER SIDE : Component Inspection ....... 369
REAR LH ................................................................. 370
U1010 CONTROL UNIT (CAN) ....................... 353 REAR LH : Description ......................................... 370
Description .............................................................353
REAR LH : Component Function Check ............. 370
DTC Logic ..............................................................353
REAR LH : Diagnosis Procedure .......................... 370
REAR LH : Component Inspection ....................... 371
Special Repair Requirement ..................................353
REAR RH ................................................................. 371
POWER SUPPLY AND GROUND CIRCUIT ... 354 REAR RH : Description ......................................... 371
INTELLIGENT KEY UNIT ........................................354 REAR RH : Component Function Check ............. 371
INTELLIGENT KEY UNIT : Diagnosis Procedure..354 REAR RH : Diagnosis Procedure ......................... 372
REAR RH : Component Inspection ....................... 372
BCM ..........................................................................354
BCM : Diagnosis Procedure ..................................354 BACK DOOR ........................................................... 373
DOOR LOCK AND UNLOCK SWITCH ........... 356 BACK DOOR : Component Function Check ....... 373
Description .............................................................356 BACK DOOR : Diagnosis Procedure .................... 373
Component Function Check ................................356 BACK DOOR : Component Inspection ................. 374
Component Inspection ...........................................357 KEY SWITCH .................................................... 375
Description ............................................................ 375
DOOR LOCK AND UNLOCK SWITCH INDI- Component Function Check ................................. 375
CATOR ............................................................. 359 Diagnosis Procedure ............................................. 375
Component Function Check ................................359
IGNITION KNOB SWITCH ............................... 378
Description ............................................................ 378
DLK-8
Component Function Check .................................. 378 Diagnosis Procedure ............................................. 396
Diagnosis Procedure ............................................. 378 Component Inspection ........................................... 397 A
OUTSIDE KEY ANTENNA .............................. 398
DOOR LOCK ACTUATOR ............................... 380
DRIVER SIDE ........................................................... 398 B
DRIVER SIDE .......................................................... 380 DRIVER SIDE : Description ................................... 398
DRIVER SIDE : Description .................................. 380 DRIVER SIDE : Component Function Check ...... 398
DRIVER SIDE : Component Function Check ...... 380 DRIVER SIDE : Diagnosis Procedure ................... 398 C
PASSENGER SIDE .................................................. 401
PASSENGER SIDE ................................................. 381 PASSENGER SIDE : Description .......................... 401
PASSENGER SIDE : Description ......................... 381 PASSENGER SIDE : D
PASSENGER SIDE : Component Function Check ................................ 401
Component Function Check ................................ 382 PASSENGER SIDE : Diagnosis Procedure .......... 401
PASSENGER SIDE : Diagnosis Procedure .......... 382 E
BACK DOOR ........................................................... 404
REAR LH ................................................................. 383 BACK DOOR : Description .................................... 404
REAR LH : Description .......................................... 383 BACK DOOR : Component Function Check ........ 404
REAR LH : Component Function Check ............. 383 BACK DOOR : Diagnosis Procedure ..................... 404 F
INSIDE KEY ANTENNA .................................. 408
REAR RH ................................................................. 384
INSTRUMENT CENTER .......................................... 408 G
REAR RH : Description ......................................... 384
REAR RH : Component Function Check ............. 384 INSTRUMENT CENTER : Description .................. 408
REAR RH : Diagnosis Procedure .......................... 385 INSTRUMENT CENTER :
Component Function Check ................................ 408 H
SUPER LOCK ACTUATOR ............................. 387 INSTRUMENT CENTER : Diagnosis Procedure .. 408
DRIVER SIDE .......................................................... 387 CONSOLE ................................................................ 411

DRIVER SIDE : Description .................................. 387 CONSOLE : Description ........................................ 411 I
DRIVER SIDE : Component Function Check ...... 387 CONSOLE : Component Function Check ............ 411
DRIVER SIDE : Diagnosis Procedure ................... 387 CONSOLE : Diagnosis Procedure ......................... 411
J
PASSENGER SIDE ................................................. 388 REAR SEAT ............................................................. 414
PASSENGER SIDE : Description ......................... 388 REAR SEAT : Description ..................................... 414
PASSENGER SIDE : REAR SEAT : Component Function Check ......... 414
Component Function Check ................................ 388 REAR SEAT : Diagnosis Procedure ...................... 414 DLK
ANTI-HIJACK RELAY ..................................... 418
REAR LH ................................................................. 389 L
REAR LH : Description .......................................... 389 PASSENGER SIDE .................................................. 418
REAR LH : Component Function Check ............. 389 PASSENGER SIDE : Description .......................... 418
REAR LH : Diagnosis Procedure .......................... 389 PASSENGER SIDE :
Component Function Check ................................ 418 M
REAR RH ................................................................. 390 PASSENGER SIDE : Diagnosis Procedure .......... 418
REAR RH : Description ......................................... 390 PASSENGER SIDE : Component Inspection ........ 419
REAR RH : Component Function Check ............. 390 N
REAR RH : Diagnosis Procedure .......................... 390 INTELLIGENT KEY WARNING BUZZER ....... 420
Description ............................................................. 420
BACK DOOR OPENER ACTUATOR .............. 392 Component Function Check ................................ 420
Description ............................................................ 392 Diagnosis Procedure ............................................. 420 O
Component Function Check ................................ 392 Component Inspection ........................................... 421
BUZZER (COMBINATION METER) ............... 422 P
FUEL LID OPENER ACTUATOR .................... 394 Description ............................................................. 422
KEY WARNING LAMP .................................... 423
BACK DOOR OPENER SWITCH .................... 396 Description ............................................................. 423
DLK-9
LOCK WARNING LAMP ................................. 424 PASSENGER SIDE ................................................. 504
Description .............................................................424 PASSENGER SIDE : Description ......................... 504
Component Function Check ................................424 PASSENGER SIDE : Diagnosis Procedure .......... 504
REAR LH ................................................................. 504
HAZARD WARNING LAMPS .......................... 425 REAR LH : Description ......................................... 504
Description .............................................................425 REAR LH : Diagnosis Procedure .......................... 505
REAR RH ................................................................. 505
VEHICLE SPEED SIGNAL CIRCUIT .............. 426 REAR RH : Diagnosis Procedure ......................... 505
Description .............................................................426
DOOR DOES NOT OPEN FROM INSIDE THE
VEHICLE ........................................................... 506
DRIVER SIDE .......................................................... 506
INTELLIGENT KEY BATTERY ....................... 427
DRIVER SIDE : Description .................................. 506
Description .............................................................427
Diagnosis Procedure .............................................427 PASSENGER SIDE ................................................. 506
ECU DIAGNOSIS ....................................... 428 PASSENGER SIDE : Diagnosis Procedure .......... 506
INTELLIGENT KEY UNIT ................................ 428 REAR LH ................................................................. 506
Reference Value ....................................................428 REAR LH : Description ......................................... 506
Wiring Diagram - SUPER LOCK CONTROL SYS- REAR LH : Diagnosis Procedure .......................... 507
TEM - .....................................................................435
Wiring Diagram - INTELLIGENT KEY CONTROL REAR RH ................................................................. 507
SYSTEM - ..............................................................443 REAR RH : Description ......................................... 507
Wiring Diagram - BACK DOOR OPENER CON- REAR RH : Diagnosis Procedure ......................... 507
TROL SYSTEM - ...................................................455
Fail Safe ................................................................458 DOOR LOCK AND UNLOCK SWITCH INDI-
DTC Inspection Priority Chart .............................458 CATOR DOES NOT ILLUMINATE ................... 508
DTC Index .............................................................458 Description ............................................................ 508
BCM (BODY CONTROL MODULE) ................ 459
Reference Value ....................................................459 DOOR DOES NOT LOCK/UNLOCK WITH IN-
Wiring Diagram - SUPER LOCK CONTROL SYS- TELLIGENT KEY .............................................. 509
TEM - .....................................................................476 Description ............................................................ 509
Wiring Diagram - INTELLIGENT KEY CONTROL Diagnosis Procedure ............................................. 509
SYSTEM - ..............................................................484
Wiring Diagram - BACK DOOR OPENER CON-
TROL SYSTEM - ...................................................496 ATE WITH INTELLIGENT KEY ........................ 510
Fail Safe ................................................................498 Description ............................................................ 510
DTC Inspection Priority Chart .............................499 Diagnosis Procedure ............................................. 510
DTC Index .............................................................500 DOOR DOES NOT LOCK/UNLOCK WITH
SYMPTOM DIAGNOSIS ............................ 501 DOOR REQUEST SWITCH .............................. 511
DOOR LOCK ................................................... 501 DRIVER SIDE .......................................................... 511

Symptom Table .....................................................501
DOOR DOES NOT LOCK/UNLOCK WITH
PASSENGER SIDE ................................................. 511
DOOR LOCK AND UNLOCK SWITCH ........... 503 PASSENGER SIDE : Description ......................... 511
ALL DOOR ...............................................................503 PASSENGER SIDE : Diagnosis Procedure .......... 512
ALL DOOR : Description .......................................503
BACK DOOR ........................................................... 512
ALL DOOR : Diagnosis Procedure ........................503
DRIVER SIDE ...........................................................503 BACK DOOR : Diagnosis Procedure .................... 512
DRIVER SIDE : Description ...................................503
DRIVER SIDE : Diagnosis Procedure ...................504
ATE WITH DOOR REQUEST SWITCH ........... 514
DLK-10
DRIVER SIDE .......................................................... 514 WARNING LAMP : Diagnosis Procedure .............. 524
DRIVER SIDE : Description .................................. 514 A
DRIVER SIDE : Diagnosis Procedure ................... 514 INTELLIGENT KEY WARNING BUZZER ............... 524
INTELLIGENT KEY WARNING BUZZER : De-
PASSENGER SIDE ................................................. 514 scription ................................................................. 524
PASSENGER SIDE : Description ......................... 514 INTELLIGENT KEY WARNING BUZZER : Diag- B
PASSENGER SIDE : Diagnosis Procedure .......... 514 nosis Procedure ..................................................... 524
KEY REMINDER FUNCTION DOES NOT OP- TAKE AWAY WARNING DOES NOT OPER- C
ERATE .............................................................. 516 ATE (TAKE AWAY THROUGH WINDOW) .... 525
Description ............................................................ 516
Diagnosis Procedure ............................................. 516 WARNING LAMP ..................................................... 525
WARNING LAMP : Description ............................. 525 D
AUTO DOOR LOCK OPERATION DOES NOT WARNING LAMP : Diagnosis Procedure .............. 525
OPERATE ......................................................... 517
BUZZER (COMBINATION METER) ........................ 525
Description ............................................................ 517 E
BUZZER (COMBINATION METER) : Diagnosis
VEHICLE SPEED SENSING AUTO LOCK Procedure .............................................................. 525
F
OPERATION DOES NOT OPERATE .............. 518 INTELLIGENT KEY LOW BATTERY WARN-
Description ............................................................ 518
ING DOES NOT OPERATE ............................ 527
Description ............................................................. 527 G
BACK DOOR DOES NOT OPENED ................ 519 Diagnosis Procedure ............................................. 527
Description ............................................................ 519
Diagnosis Procedure ............................................. 519 H
CHIME DOES NOT OPERATE WITH DOOR
IGNITION KNOB RETURN FORGOTTEN REQUEST SWITCH ........................................ 528
WARNING DOES NOT OPERATE .................. 520 Description ............................................................. 528
Description ............................................................ 520 Diagnosis Procedure ............................................. 528 I
IGNITION KEY WARNING DOES NOT OPER- CHIME DOES NOT OPERATE WITH INTEL- J
ATE ................................................................... 521 LIGENT KEY ................................................... 529
Description ............................................................ 521 Description ............................................................. 529
Diagnosis Procedure ............................................. 521 Diagnosis Procedure ............................................. 529
DLK
OFF POSITION WARNING DOES NOT OP- BACK DOOR OPEN WARNING DOES NOT
ERATE .............................................................. 522 OPERATE ....................................................... 530
Description ............................................................. 530 L
WARNING LAMP .................................................... 522 Diagnosis Procedure ............................................. 530
WARNING LAMP : Diagnosis Procedure .............. 522 BUZZER REMINDER OPERATION DOES
NOT OPERATE ............................................... 531 M
BUZZER (COMBINATION METER) ........................ 522
Description ............................................................. 531
BUZZER (COMBINATION METER) : Diagnosis N
Procedure .............................................................. 522 HAZARD REMINDER OPERATION DOES
NOT OPERATE ............................................... 532
TAKE AWAY WARNING DOES NOT OPER-
Description ............................................................. 532 O
ATE (DOOR IS OPENED) ................................ 523 Diagnosis Procedure ............................................. 532
WARNING LAMP .................................................... 523
SQUEAK AND RATTLE TROUBLE DIAG-
NOSES ............................................................ 533 P
WARNING LAMP : Diagnosis Procedure .............. 523
Work Flow .............................................................. 533
TAKE AWAY WARNING DOES NOT OPER- Inspection Procedure ............................................. 535
ATE (ANY DOOR OPEN TO ALL DOORS Diagnostic Worksheet ............................................ 537
CLOSE) ............................................................ 524
PRECAUTION ............................................ 539
WARNING LAMP .................................................... 524
PRECAUTIONS ............................................... 539
DLK-11
Precaution for Supplemental Restraint System REAR DOOR .................................................... 558
SIONER" ................................................................539 DOOR ASSEMBLY ................................................. 558
Precaution Necessary for Steering Wheel Rota- DOOR ASSEMBLY : Exploded View .................... 558
tion After Battery Disconnect .................................539 DOOR ASSEMBLY : Removal and Installation .... 559
Precaution for Procedure without Cowl Top Cover..540 DOOR ASSEMBLY : Adjustment .......................... 560
Work ......................................................................540
DOOR STRIKER ..................................................... 560
PREPARATION .......................................... 541 DOOR STRIKER : Exploded View ........................ 561
DOOR STRIKER : Removal and Installation ........ 561
PREPARATION ............................................... 541
DOOR HINGE .......................................................... 561
DOOR HINGE : Exploded View ............................ 562
ON-VEHICLE REPAIR ............................... 542 DOOR HINGE : Removal and Installation ............ 562
HOOD ............................................................... 542 DOOR CHECK LINK ............................................... 562

DOOR CHECK LINK : Exploded View .................. 563
HOOD ASSEMBLY ..................................................542 DOOR CHECK LINK : Removal and Installation . 563
HOOD ASSEMBLY : Exploded View .....................542
HOOD ASSEMBLY : Removal and Installation .....543 BACK DOOR .................................................... 271
HOOD ASSEMBLY : Adjustment ..........................544 BACK DOOR ASSEMBLY ...................................... 564
HOOD HINGE ...........................................................545 BACK DOOR ASSEMBLY : Exploded View ......... 564
HOOD HINGE : Exploded View .............................545 BACK DOOR ASSEMBLY : Removal and Installa-
HOOD HINGE : Removal and Installation .............545 tion ........................................................................ 565
BACK DOOR ASSEMBLY : Adjustment ............... 566
HOOD SUPPORT ROD ............................................546
HOOD SUPPORT ROD : Exploded View ..............546 BACK DOOR STRIKER .......................................... 567
HOOD SUPPORT ROD : Removal and Installa- BACK DOOR STRIKER : Exploded View ............. 567
tion .........................................................................546 BACK DOOR STRIKER : Removal and Installa-
tion ........................................................................ 567
HOOD LOCK CONTROL .........................................547
HOOD LOCK CONTROL : Exploded View ............547 BACK DOOR HINGE .............................................. 567
HOOD LOCK CONTROL : Removal and Installa- BACK DOOR HINGE : Exploded View ................. 568
tion .........................................................................547 BACK DOOR HINGE : Removal and Installation . 568
HOOD LOCK CONTROL : Inspection ...................548 BACK DOOR STAY ................................................ 569
RADIATOR CORE SUPPORT ......................... 549 BACK DOOR STAY : Exploded View ................... 569
BACK DOOR STAY : Removal and Installation .... 569
Exploded View .......................................................549
Removal and Installation .......................................549 BACK DOOR WEATHER-STRIP ............................ 569
BACK DOOR WEATHER-STRIP : Exploded View. 569
FRONT FENDER ............................................. 551
BACK DOOR WEATHER-STRIP : Removal and
Exploded View .......................................................551
Installation ............................................................. 570
FRONT DOOR LOCK ....................................... 571
FRONT DOOR ................................................. 552
DOOR LOCK ........................................................... 571
DOOR ASSEMBLY ..................................................552
DOOR ASSEMBLY : Exploded View .....................552
DOOR ASSEMBLY : Removal and Installation .....553
DOOR ASSEMBLY : Adjustment ..........................554 INSIDE HANDLE ..................................................... 573
INSIDE HANDLE : Exploded View ........................ 574
DOOR STRIKER ......................................................554
INSIDE HANDLE : Removal and Installation ........ 574
DOOR STRIKER : Exploded View ........................555
DOOR STRIKER : Removal and Installation .........555 OUTSIDE HANDLE ................................................. 574
OUTSIDE HANDLE : Exploded View .................... 575
DOOR HINGE ...........................................................555
OUTSIDE HANDLE : Removal and Installation .... 575
DOOR HINGE : Exploded View .............................556
DOOR HINGE : Removal and Installation .............556 REAR DOOR LOCK ......................................... 578
DOOR CHECK LINK ................................................556 DOOR LOCK ........................................................... 578
DOOR CHECK LINK : Exploded View ..................557 DOOR LOCK : Exploded View .............................. 578
DOOR CHECK LINK : Removal and Installation ..557 DOOR LOCK : Removal and Installation .............. 578
DLK-12
INSIDE HANDLE ..................................................... 580 INTELLIGENT KEY BATTERY ....................... 594
INSIDE HANDLE : Exploded View ........................ 580 Exploded View ....................................................... 594 A
INSIDE HANDLE : Removal and Installation ........ 580 Removal and Installation ....................................... 594
OUTSIDE HANDLE ................................................. 580 INTELLIGENT KEY UNIT ............................... 595
OUTSIDE HANDLE : Exploded View .................... 581 B
Exploded View ....................................................... 595
OUTSIDE HANDLE : Removal and Installation .... 581 Removal and Installation ....................................... 595
BACK DOOR LOCK ......................................... 583 DOOR LOCK AND UNLOCK SWITCH .......... 596 C
Exploded View ....................................................... 596
DOOR LOCK ........................................................... 583
DOOR LOCK : Removal and Installation .............. 583 WITHOUT I-KEY & SUPER LOCK D
FUEL FILLER LID OPENER ............................ 291 BASIC INSPECTION ................................. 597
FUEL FILLER LID ................................................... 584 DIAGNOSIS AND REPAIR WORKFLOW ...... 597 E
FUEL FILLER LID : Exploded View ...................... 584 Work Flow .............................................................. 597
FUEL FILLER LID : Removal and Installation ....... 584
INSPECTION AND ADJUSTMENT ................ 600
F
DOOR SWITCH ................................................ 585
Exploded View ...................................................... 585
CONTROL UNIT ...................................................... 600
ADDITIONAL SERVICE WHEN REPLACING G
INSIDE KEY ANTENNA ................................... 586 CONTROL UNIT : Description ............................... 600
INSTRUMENT CENTER .......................................... 586 CONTROL UNIT : Special Repair Requirement .... 600
H
INSTRUMENT CENTER : Exploded View ............ 586
INSTRUMENT CENTER : Removal and Installa- FUNCTION DIAGNOSIS ............................ 601
tion ........................................................................ 586
DOOR LOCK FUNCTION ............................... 601 I
CONSOLE ............................................................... 586
CONSOLE : Exploded View .................................. 587 DOOR LOCK AND UNLOCK SWITCH ................... 601
CONSOLE : Removal and Installation .................. 587 DOOR LOCK AND UNLOCK SWITCH : System
Diagram ................................................................. 601 J
REAR ....................................................................... 587 DOOR LOCK AND UNLOCK SWITCH : System
REAR : Exploded View ......................................... 587 Description ............................................................. 601
REAR : Removal and Installation .......................... 588 DOOR LOCK AND UNLOCK SWITCH : DLK
OUTSIDE KEY ANTENNA ............................... 589 DOOR LOCK AND UNLOCK SWITCH :
Component Description ........................................ 603
DRIVER SIDE .......................................................... 589 L
DRIVER SIDE : Exploded View ............................ 589 KEYFOB ................................................................... 603
DRIVER SIDE : Removal and Installation ............. 589 KEYFOB : System Diagram .................................. 604
KEYFOB : System Description .............................. 604 M
PASSENGER SIDE ................................................. 589
KEYFOB : Component Parts Location ................. 605
PASSENGER SIDE : Exploded View .................... 589
KEYFOB : Component Description ....................... 606
PASSENGER SIDE : Removal and Installation .... 589
AUTO DOOR LOCK ................................................ 606 N
BACK DOOR ........................................................... 589
AUTO DOOR LOCK : System Diagram ................ 607
BACK DOOR : Exploded View .............................. 589
AUTO DOOR LOCK : System Description ............ 607
BACK DOOR : Removal and Installation .............. 589
AUTO DOOR LOCK : O
INTELLIGENT KEY WARNING BUZZER ........ 591 Component Parts Location .................................. 608
Exploded View ...................................................... 591 AUTO DOOR LOCK : Component Description ..... 609
Removal and Installation ....................................... 591 P
VEHICLE SPEED SENSING AUTO DOOR LOCK.. 609
BACK DOOR REQUEST SWITCH .................. 592 VEHICLE SPEED SENSING AUTO DOOR LOCK
Exploded View ...................................................... 592 : System Diagram .................................................. 610
Removal and Installation ....................................... 592 VEHICLE SPEED SENSING AUTO DOOR LOCK
: System Description .............................................. 610
BACK DOOR OPENER SWITCH .................... 593 VEHICLE SPEED SENSING AUTO DOOR LOCK
Exploded View ...................................................... 593 : Component Parts Location ................................ 610
DLK-13
VEHICLE SPEED SENSING AUTO DOOR LOCK Description ............................................................ 628
: Component Description ......................................611 DTC Logic ............................................................. 628
AIR BAG INTERLOCK UNLOCK ............................612 Special Repair Requirement ................................. 628
AIR BAG INTERLOCK UNLOCK : System Dia-
gram ......................................................................612 POWER SUPPLY AND GROUND CIRCUIT .... 629
scription .................................................................612 BCM ......................................................................... 629
AIR BAG INTERLOCK UNLOCK : BCM : Diagnosis Procedure .................................. 629
Component Parts Location ..................................612
DOOR LOCK AND UNLOCK SWITCH ............ 630
Description ............................................................ 630
BACK DOOR OPENER FUNCTION ............... 614 Diagnosis Procedure ............................................. 630
BACK DOOR OPENER SWITCH ............................614
BACK DOOR OPENER SWITCH : System Dia- DOOR SWITCH ................................................ 633
gram ......................................................................614
DRIVER SIDE .......................................................... 633
BACK DOOR OPENER SWITCH : System De-
scription .................................................................614
BACK DOOR OPENER SWITCH :
Component Parts Location ..................................615
DRIVER SIDE : Component Inspection ................ 634
BACK DOOR OPENER SWITCH :
Component Description ........................................616 PASSENGER SIDE ................................................. 634
WARNING FUNCTION .................................... 617 PASSENGER SIDE :
System Diagram ....................................................617 Component Function Check ................................ 634
System Description ................................................617 PASSENGER SIDE : Diagnosis Procedure .......... 634
Component Parts Location ..................................618 PASSENGER SIDE : Component Inspection ....... 635
REAR LH ................................................................. 636
HAZARD REMINDER FUNCTION .................. 620 REAR LH : Description ......................................... 636
System Diagram ....................................................620 REAR LH : Component Function Check ............. 636
System Description ................................................620 REAR LH : Diagnosis Procedure .......................... 636
Component Parts Location ..................................621 REAR LH : Component Inspection ....................... 637
REAR RH ................................................................. 637
DIAGNOSIS SYSTEM (BCM) .......................... 623 REAR RH : Description ......................................... 637
COMMON ITEM .......................................................623
REAR RH : Diagnosis Procedure ......................... 638
COMMON ITEM : CONSULT-III Function (BCM -
COMMON ITEM) ...................................................623 REAR RH : Component Inspection ....................... 638
BACK DOOR ........................................................... 639

DOOR LOCK ............................................................623
DOOR LOCK : CONSULT-III Function (BCM -
DOOR LOCK) ........................................................623 BACK DOOR : Component Function Check ....... 639
MULTIREMOTE ENT ...............................................625 BACK DOOR : Component Inspection ................. 640
MULTIREMOTE ENT : CONSULT-III Function
(BCM - MULTIREMOTE ENT) ...............................625 KEY SWITCH .................................................... 641
Description ............................................................ 641
TRUNK .....................................................................626 Component Function Check ................................. 641
TRUNK : CONSULT-III Function (BCM - TRUNK)..626 Diagnosis Procedure ............................................. 641
COMPONENT DIAGNOSIS ....................... 627
DOOR LOCK ACTUATOR ............................... 643
U1000 CAN COMM CIRCUIT .......................... 627
Description .............................................................627 DRIVER SIDE .......................................................... 643
DTC Logic ..............................................................627 DRIVER SIDE : Description .................................. 643
Diagnosis Procedure .............................................627 DRIVER SIDE : Component Function Check ...... 643
U1010 CONTROL UNIT (CAN) ....................... 628
PASSENGER SIDE ................................................. 644
DLK-14
PASSENGER SIDE : Description ......................... 644 DTC Inspection Priority Chart ............................. 690
PASSENGER SIDE : DTC Index ............................................................. 691 A
PASSENGER SIDE : Diagnosis Procedure .......... 644 SYMPTOM DIAGNOSIS ............................ 692
REAR LH ................................................................. 645 DOOR LOCK ................................................... 692 B
REAR LH : Description .......................................... 645 Symptom Table ..................................................... 692
REAR LH : Diagnosis Procedure .......................... 645 DOOR DOES NOT LOCK/UNLOCK WITH C
DOOR LOCK AND UNLOCK SWITCH .......... 693
REAR RH ................................................................. 646
REAR RH : Description ......................................... 646 ALL DOOR ............................................................... 693
REAR RH : Component Function Check ............. 646 ALL DOOR : Description ....................................... 693 D
REAR RH : Diagnosis Procedure .......................... 646 ALL DOOR : Diagnosis Procedure ........................ 693
BACK DOOR OPENER ACTUATOR .............. 648 DRIVER SIDE ........................................................... 693
E
Description ............................................................ 648 DRIVER SIDE : Description ................................... 693
Component Function Check ................................ 648 DRIVER SIDE : Diagnosis Procedure ................... 694
Diagnosis Procedure ............................................. 648 PASSENGER SIDE .................................................. 694 F
FUEL LID OPENER ACTUATOR .................... 650 PASSENGER SIDE : Description .......................... 694
Description ............................................................ 650
Component Function Check ................................ 650 REAR LH .................................................................. 694 G
Diagnosis Procedure ............................................. 650 REAR LH : Description .......................................... 694
REAR LH : Diagnosis Procedure ........................... 695
BACK DOOR OPENER SWITCH .................... 652
Description ............................................................ 652 H
REAR RH ................................................................. 695
Component Function Check ................................ 652 REAR RH : Description ......................................... 695
Diagnosis Procedure ............................................. 652 REAR RH : Diagnosis Procedure .......................... 695
Component Inspection .......................................... 653 I
KEY REMINDER FUNCTION DOES NOT OP-
BUZZER (COMBINATION METER) ................. 654 ERATE ............................................................. 696
Description ............................................................ 654 Description ............................................................. 696 J
AUTO DOOR LOCK OPERATION DOES NOT
HAZARD WARNING LAMPS ........................... 655 OPERATE ....................................................... 697 DLK
Description ............................................................ 655 Description ............................................................. 697
Diagnosis Procedure ............................................. 655 L
VEHICLE SPEED SIGNAL CIRCUIT ............... 656 OPERATION DOES NOT OPERATE ............. 698
Description ............................................................ 656
Description ............................................................. 698
Component Function Check ................................ 656 M
BACK DOOR DOES NOT OPENED ............... 699
KEYFOB BATTERY ......................................... 657 Description ............................................................. 699 N
Description ............................................................ 657
Diagnosis Procedure ............................................. 657 BACK DOOR OPEN WARNING DOES NOT
OPERATE ....................................................... 700 O
ECU DIAGNOSIS ....................................... 658 Description ............................................................. 700
BCM (BODY CONTROL MODULE) ................. 658 Diagnosis Procedure ............................................. 700
P
Reference Value ................................................... 658 HAZARD REMINDER OPERATION DOES
Wiring Diagram - POWER DOOR LOCK CON-
NOT OPERATE ............................................... 701
TROL SYSTEM - ................................................... 675
Description ............................................................. 701
Wiring Diagram - REMOTE KEYLESS ENTRY
CONTROL SYSTEM - ........................................... 683
Wiring Diagram - BACK DOOR OPENER CON- SQUEAK AND RATTLE TROUBLE DIAG-
TROL SYSTEM - ................................................... 687 NOSES ............................................................ 702
Fail Safe ............................................................... 689
DLK-15
Work Flow ..............................................................702 DOOR HINGE : Removal and Installation ............ 724
Inspection Procedure .............................................704
Diagnostic Worksheet ............................................706 DOOR CHECK LINK ............................................... 724
PRECAUTION ............................................ 708 DOOR CHECK LINK : Removal and Installation . 725
PRECAUTIONS ............................................... 708 REAR DOOR .................................................... 726

DOOR ASSEMBLY ................................................. 726
DOOR ASSEMBLY : Exploded View .................... 726
SIONER" ................................................................708
DOOR ASSEMBLY : Removal and Installation .... 727
Precaution for Procedure without Cowl Top Cover..708
DOOR ASSEMBLY : Adjustment .......................... 728
Work ......................................................................708
DOOR STRIKER ..................................................... 728
PREPARATION .......................................... 709 DOOR STRIKER : Exploded View ........................ 729
PREPARATION ............................................... 709 DOOR STRIKER : Removal and Installation ........ 729
Commercial Service Tools .....................................709 DOOR HINGE .......................................................... 729
DOOR HINGE : Exploded View ............................ 730
ON-VEHICLE REPAIR ............................... 710 DOOR HINGE : Removal and Installation ............ 730
HOOD ............................................................... 710 DOOR CHECK LINK ............................................... 730
HOOD ASSEMBLY ..................................................710 DOOR CHECK LINK : Exploded View .................. 731
HOOD ASSEMBLY : Exploded View .....................710 DOOR CHECK LINK : Removal and Installation . 731
HOOD ASSEMBLY : Removal and Installation .....711 BACK DOOR .................................................... 271
HOOD ASSEMBLY : Adjustment ..........................712
BACK DOOR ASSEMBLY ...................................... 732
HOOD HINGE ...........................................................713 BACK DOOR ASSEMBLY : Exploded View ......... 732
HOOD HINGE : Exploded View .............................713 BACK DOOR ASSEMBLY : Removal and Installa-
HOOD HINGE : Removal and Installation .............713 tion ........................................................................ 733
HOOD SUPPORT ROD ............................................714 BACK DOOR ASSEMBLY : Adjustment ............... 734
HOOD SUPPORT ROD : Exploded View ..............714
BACK DOOR STRIKER .......................................... 735
HOOD SUPPORT ROD : Removal and Installa-
BACK DOOR STRIKER : Exploded View ............. 735
tion .........................................................................714
HOOD LOCK CONTROL .........................................715 tion ........................................................................ 735
HOOD LOCK CONTROL : Exploded View ............715
BACK DOOR HINGE .............................................. 735
HOOD LOCK CONTROL : Removal and Installa-
BACK DOOR HINGE : Exploded View ................. 736
tion .........................................................................715
BACK DOOR HINGE : Removal and Installation . 736
HOOD LOCK CONTROL : Inspection ...................716
BACK DOOR STAY ................................................ 737
RADIATOR CORE SUPPORT ......................... 717 BACK DOOR STAY : Exploded View ................... 737
Exploded View .......................................................717 BACK DOOR STAY : Removal and Installation .... 737
BACK DOOR WEATHER-STRIP ............................ 737
FRONT FENDER ............................................. 719 BACK DOOR WEATHER-STRIP : Exploded View. 737
Exploded View .......................................................719 BACK DOOR WEATHER-STRIP : Removal and
Removal and Installation .......................................719 Installation ............................................................. 738
FRONT DOOR ................................................. 720 FRONT DOOR LOCK ....................................... 739
DOOR ASSEMBLY ..................................................720 DOOR LOCK ........................................................... 739
DOOR ASSEMBLY : Exploded View .....................720 DOOR LOCK : Exploded View .............................. 739
DOOR ASSEMBLY : Removal and Installation .....721 DOOR LOCK : Removal and Installation .............. 739
DOOR ASSEMBLY : Adjustment ..........................722
INSIDE HANDLE ..................................................... 741
DOOR STRIKER ......................................................722 INSIDE HANDLE : Exploded View ........................ 742
DOOR STRIKER : Exploded View ........................723 INSIDE HANDLE : Removal and Installation ........ 742
DOOR STRIKER : Removal and Installation .........723
OUTSIDE HANDLE ................................................. 742
DOOR HINGE ...........................................................723 OUTSIDE HANDLE : Exploded View .................... 743
DOOR HINGE : Exploded View .............................724 OUTSIDE HANDLE : Removal and Installation .... 743
DLK-16
REAR DOOR LOCK ......................................... 746 DOOR LOCK AND UNLOCK SWITCH :
Component Parts Location .................................. 761 A
DOOR LOCK ........................................................... 746 DOOR LOCK AND UNLOCK SWITCH :
DOOR LOCK : Exploded View .............................. 746 Component Description ........................................ 762
KEYFOB ................................................................... 763 B
INSIDE HANDLE ..................................................... 748 KEYFOB : System Diagram .................................. 763
INSIDE HANDLE : Exploded View ........................ 748 KEYFOB : System Description .............................. 763
INSIDE HANDLE : Removal and Installation ........ 748 KEYFOB : Component Parts Location ................. 764 C
KEYFOB : Component Description ....................... 765
OUTSIDE HANDLE ................................................. 748
OUTSIDE HANDLE : Exploded View .................... 749 AUTO DOOR LOCK ................................................ 765
OUTSIDE HANDLE : Removal and Installation .... 749 AUTO DOOR LOCK : System Diagram ................ 766 D
AUTO DOOR LOCK : System Description ............ 766
BACK DOOR LOCK ......................................... 751
AUTO DOOR LOCK :
DOOR LOCK ........................................................... 751 Component Parts Location .................................. 767 E
DOOR LOCK : Exploded View .............................. 751 AUTO DOOR LOCK : Component Description ..... 768
VEHICLE SPEED SENSING AUTO DOOR LOCK.. 768
VEHICLE SPEED SENSING AUTO DOOR LOCK F
FUEL FILLER LID OPENER ............................ 291
: System Diagram .................................................. 769
FUEL FILLER LID ................................................... 752 VEHICLE SPEED SENSING AUTO DOOR LOCK
FUEL FILLER LID : Exploded View ...................... 752 : System Description .............................................. 769 G
FUEL FILLER LID : Removal and Installation ....... 752 VEHICLE SPEED SENSING AUTO DOOR LOCK
: Component Parts Location ................................ 769
DOOR SWITCH ................................................ 753 VEHICLE SPEED SENSING AUTO DOOR LOCK H
Exploded View ...................................................... 753 : Component Description ...................................... 770
AIR BAG INTERLOCK UNLOCK ............................ 771
BACK DOOR OPENER SWITCH .................... 754 AIR BAG INTERLOCK UNLOCK : System Dia- I
Exploded View ...................................................... 754 gram ...................................................................... 771
Removal and Installation ....................................... 754 AIR BAG INTERLOCK UNLOCK : System De-
scription ................................................................. 771 J
KEYFOB BATTERY ......................................... 755
Exploded View ...................................................... 755
WITHOUT I-KEY, WITH SUPER LOCK DLK
BASIC INSPECTION ................................. 756 BACK DOOR OPENER FUNCTION ............... 773
L
DIAGNOSIS AND REPAIR WORKFLOW ....... 756 BACK DOOR OPENER SWITCH ............................ 773
Work Flow ............................................................. 756 BACK DOOR OPENER SWITCH : System Dia-
gram ...................................................................... 773
INSPECTION AND ADJUSTMENT .................. 759 BACK DOOR OPENER SWITCH : System De- M
ADDITIONAL SERVICE WHEN REPLACING scription ................................................................. 773
CONTROL UNIT ...................................................... 759 BACK DOOR OPENER SWITCH :
ADDITIONAL SERVICE WHEN REPLACING Component Parts Location .................................. 774 N
CONTROL UNIT : Description .............................. 759 BACK DOOR OPENER SWITCH :
ADDITIONAL SERVICE WHEN REPLACING Component Description ........................................ 775
CONTROL UNIT : Special Repair Requirement .. 759 O
WARNING FUNCTION .................................... 776
FUNCTION DIAGNOSIS ............................ 760 System Diagram .................................................... 776
System Description ................................................ 776
DOOR LOCK FUNCTION ................................ 760 Component Parts Location .................................. 777 P
DOOR LOCK AND UNLOCK SWITCH ................... 760
DOOR LOCK AND UNLOCK SWITCH : System HAZARD REMINDER FUNCTION .................. 779
Diagram ................................................................. 760 System Diagram .................................................... 779
DOOR LOCK AND UNLOCK SWITCH : System System Description ................................................ 779
Description ............................................................ 760 Component Parts Location .................................. 780
DLK-17
DIAGNOSIS SYSTEM (BCM) .......................... 782 REAR LH : Description ......................................... 797
COMMON ITEM .......................................................782 REAR LH : Diagnosis Procedure .......................... 797
COMMON ITEM : CONSULT-III Function (BCM - REAR LH : Component Inspection ....................... 798
COMMON ITEM) ...................................................782
REAR RH ................................................................. 798
DOOR LOCK ............................................................782 REAR RH : Description ......................................... 798
DOOR LOCK : CONSULT-III Function (BCM - REAR RH : Component Function Check ............. 798
DOOR LOCK) ........................................................782 REAR RH : Diagnosis Procedure ......................... 799
REAR RH : Component Inspection ....................... 799
MULTIREMOTE ENT ...............................................784
MULTIREMOTE ENT : CONSULT-III Function BACK DOOR ........................................................... 800
(BCM - MULTIREMOTE ENT) ...............................784 BACK DOOR : Description ................................... 800
BACK DOOR : Component Function Check ....... 800
TRUNK .....................................................................785
TRUNK : CONSULT-III Function (BCM - TRUNK)..785
BACK DOOR : Component Inspection ................. 801
COMPONENT DIAGNOSIS ....................... 786
KEY SWITCH .................................................... 802
U1000 CAN COMM CIRCUIT .......................... 786 Description ............................................................ 802
Description .............................................................786 Component Function Check ................................. 802
Diagnosis Procedure .............................................786 Component Inspection .......................................... 803
U1010 CONTROL UNIT (CAN) ....................... 787 DOOR LOCK ACTUATOR ............................... 804
Description .............................................................787 DRIVER SIDE .......................................................... 804
DTC Logic ..............................................................787 DRIVER SIDE : Description .................................. 804
Diagnosis Procedure .............................................787 DRIVER SIDE : Component Function Check ...... 804
Special Repair Requirement ..................................787 DRIVER SIDE : Diagnosis Procedure ................... 804
POWER SUPPLY AND GROUND CIRCUIT ... 788 PASSENGER SIDE ................................................. 805
BCM ..........................................................................788 PASSENGER SIDE : Description ......................... 805
BCM : Diagnosis Procedure ..................................788 PASSENGER SIDE :
DOOR LOCK AND UNLOCK SWITCH ........... 789 PASSENGER SIDE : Diagnosis Procedure .......... 805
Description .............................................................789
Component Function Check ................................789 REAR LH ................................................................. 806
Diagnosis Procedure .............................................789 REAR LH : Description ......................................... 806
DOOR LOCK AND UNLOCK SWITCH INDI-
REAR RH ................................................................. 807
CATOR ............................................................. 792 REAR RH : Description ......................................... 807
Description .............................................................792
REAR RH : Diagnosis Procedure ......................... 807
SUPER LOCK ACTUATOR ............................. 809
DOOR SWITCH ............................................... 794
DRIVER SIDE .......................................................... 809
DRIVER SIDE ...........................................................794
DRIVER SIDE : Description ...................................794
DRIVER SIDE : Component Function Check .......794
DRIVER SIDE : Diagnosis Procedure ...................794
DRIVER SIDE : Component Inspection .................795 PASSENGER SIDE ................................................. 810
PASSENGER SIDE ..................................................795
PASSENGER SIDE :
PASSENGER SIDE : Description ..........................795
PASSENGER SIDE : PASSENGER SIDE : Diagnosis Procedure .......... 810
PASSENGER SIDE : Diagnosis Procedure ..........795 REAR LH ................................................................. 811
PASSENGER SIDE : Component Inspection ........796 REAR LH : Description ......................................... 811
REAR LH ..................................................................797
DLK-18
REAR LH : Diagnosis Procedure .......................... 811 DOOR DOES NOT LOCK/UNLOCK WITH
DOOR LOCK AND UNLOCK SWITCH .......... 859 A
REAR RH ................................................................. 812
REAR RH : Description ......................................... 812 ALL DOOR ............................................................... 859
REAR RH : Component Function Check ............. 812 ALL DOOR : Description ....................................... 859
REAR RH : Diagnosis Procedure .......................... 812 B
ALL DOOR : Diagnosis Procedure ........................ 859
BACK DOOR OPENER ACTUATOR .............. 814 DRIVER SIDE ........................................................... 859
Description ............................................................ 814 DRIVER SIDE : Description ................................... 859 C
Component Function Check ................................ 814 DRIVER SIDE : Diagnosis Procedure ................... 860
PASSENGER SIDE .................................................. 860
FUEL LID OPENER ACTUATOR .................... 816 PASSENGER SIDE : Description .......................... 860 D
Description ............................................................ 816 PASSENGER SIDE : Diagnosis Procedure .......... 860
Diagnosis Procedure ............................................. 816 REAR LH .................................................................. 860
E
REAR LH : Description .......................................... 860
BACK DOOR OPENER SWITCH .................... 818 REAR LH : Diagnosis Procedure ........................... 861
Description ............................................................ 818
REAR RH ................................................................. 861 F
REAR RH : Diagnosis Procedure .......................... 861
DOOR DOES NOT OPEN FROM INSIDE THE G
BUZZER (COMBINATION METER) ................. 820
Description ............................................................ 820 VEHICLE ......................................................... 862
Component Function Check ................................ 820 DRIVER SIDE ........................................................... 862 H
Diagnosis Procedure ............................................. 820 DRIVER SIDE : Description ................................... 862
HAZARD WARNING LAMPS ........................... 821 DRIVER SIDE : Diagnosis Procedure ................... 862
Description ............................................................ 821 PASSENGER SIDE .................................................. 862 I
Component Function Check ................................ 821 PASSENGER SIDE : Description .......................... 862
Diagnosis Procedure ............................................. 821 PASSENGER SIDE : Diagnosis Procedure .......... 862
VEHICLE SPEED SIGNAL CIRCUIT ............... 822 J
REAR LH .................................................................. 862
Description ............................................................ 822 REAR LH : Description .......................................... 862
Component Function Check ................................ 822 REAR LH : Diagnosis Procedure ........................... 863
Diagnosis Procedure ............................................. 822 DLK
REAR RH ................................................................. 863
KEYFOB BATTERY ......................................... 823 REAR RH : Description ......................................... 863
Description ............................................................ 823 REAR RH : Diagnosis Procedure .......................... 863
L
Diagnosis Procedure ............................................. 823 DOOR LOCK AND UNLOCK SWITCH INDI-
CATOR DOES NOT ILLUMINATE ................. 864
ECU DIAGNOSIS ....................................... 824 Description ............................................................. 864 M
BCM (BODY CONTROL MODULE) ................. 824
Reference Value ................................................... 824 KEY REMINDER FUNCTION DOES NOT OP-
N
Wiring Diagram - SUPER LOCK CONTROL SYS- ERATE ............................................................. 865
TEM - .................................................................... 841 Description ............................................................. 865
Wiring Diagram - REMOTE KEYLESS ENTRY Diagnosis Procedure ............................................. 865
CONTROL SYSTEM - ........................................... 849 O
Wiring Diagram - BACK DOOR OPENER CON- AUTO DOOR LOCK OPERATION DOES NOT
TROL SYSTEM - ................................................... 853 OPERATE ....................................................... 866
Fail Safe ............................................................... 855 Description ............................................................. 866 P
DTC Inspection Priority Chart ............................. 856 Diagnosis Procedure ............................................. 866
DTC Index ............................................................ 857
SYMPTOM DIAGNOSIS ............................ 858 OPERATION DOES NOT OPERATE ............. 867
Description ............................................................. 867
DOOR LOCK .................................................... 858 Diagnosis Procedure ............................................. 867
Symptom Table ..................................................... 858
BACK DOOR DOES NOT OPENED ............... 868
DLK-19
Description .............................................................868 Exploded View ...................................................... 888
Diagnosis Procedure .............................................868 Removal and Installation ....................................... 888
BACK DOOR OPEN WARNING DOES NOT FRONT DOOR .................................................. 889
OPERATE ........................................................ 869
Description .............................................................869 DOOR ASSEMBLY ................................................. 889
Diagnosis Procedure .............................................869 DOOR ASSEMBLY : Exploded View .................... 889
DOOR ASSEMBLY : Removal and Installation .... 890
HAZARD REMINDER OPERATION DOES DOOR ASSEMBLY : Adjustment .......................... 891
NOT OPERATE ............................................... 870 DOOR STRIKER ..................................................... 891
Description .............................................................870
DOOR STRIKER : Exploded View ........................ 892
DOOR STRIKER : Removal and Installation ........ 892
SQUEAK AND RATTLE TROUBLE DIAG- DOOR HINGE .......................................................... 892
NOSES ............................................................. 871 DOOR HINGE : Exploded View ............................ 893
Work Flow ..............................................................871 DOOR HINGE : Removal and Installation ............ 893
Inspection Procedure .............................................873
Diagnostic Worksheet ............................................875 DOOR CHECK LINK ............................................... 893
PRECAUTION ............................................ 877 DOOR CHECK LINK : Removal and Installation . 894
PRECAUTIONS ............................................... 877 REAR DOOR .................................................... 895
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- DOOR ASSEMBLY ................................................. 895
SIONER" ................................................................877 DOOR ASSEMBLY : Exploded View .................... 895
Precaution for Procedure without Cowl Top Cover..877 DOOR ASSEMBLY : Removal and Installation .... 896
Work ......................................................................877 DOOR ASSEMBLY : Adjustment .......................... 897
PREPARATION .......................................... 878 DOOR STRIKER ..................................................... 897

DOOR STRIKER : Exploded View ........................ 898
PREPARATION ............................................... 878 DOOR STRIKER : Removal and Installation ........ 898
DOOR HINGE .......................................................... 898
ON-VEHICLE REPAIR ............................... 879 DOOR HINGE : Exploded View ............................ 899
DOOR HINGE : Removal and Installation ............ 899
HOOD ............................................................... 879
DOOR CHECK LINK ............................................... 899
HOOD ASSEMBLY ..................................................879 DOOR CHECK LINK : Exploded View .................. 900
HOOD ASSEMBLY : Exploded View .....................879 DOOR CHECK LINK : Removal and Installation . 900
HOOD ASSEMBLY : Removal and Installation .....880
HOOD ASSEMBLY : Adjustment ..........................881 BACK DOOR .................................................... 271
HOOD HINGE ...........................................................882 BACK DOOR ASSEMBLY ...................................... 901

HOOD HINGE : Exploded View .............................882 BACK DOOR ASSEMBLY : Exploded View ......... 901
HOOD HINGE : Removal and Installation .............882 BACK DOOR ASSEMBLY : Removal and Installa-
tion ........................................................................ 902
HOOD SUPPORT ROD ............................................883 BACK DOOR ASSEMBLY : Adjustment ............... 903
HOOD SUPPORT ROD : Exploded View ..............883
HOOD SUPPORT ROD : Removal and Installa- BACK DOOR STRIKER .......................................... 904
tion .........................................................................883 BACK DOOR STRIKER : Exploded View ............. 904
HOOD LOCK CONTROL .........................................884 tion ........................................................................ 904
HOOD LOCK CONTROL : Exploded View ............884
HOOD LOCK CONTROL : Removal and Installa- BACK DOOR HINGE .............................................. 904
tion .........................................................................884 BACK DOOR HINGE : Exploded View ................. 905
HOOD LOCK CONTROL : Inspection ...................885 BACK DOOR HINGE : Removal and Installation . 905
RADIATOR CORE SUPPORT ......................... 886 BACK DOOR STAY ................................................ 906
BACK DOOR STAY : Exploded View ................... 906
Exploded View .......................................................886
BACK DOOR STAY : Removal and Installation .... 906
BACK DOOR WEATHER-STRIP ............................ 906
FRONT FENDER ............................................. 888
BACK DOOR WEATHER-STRIP : Exploded View. 906
DLK-20
BACK DOOR WEATHER-STRIP : Removal and BACK DOOR LOCK ....................................... 920
Installation ............................................................. 907 A
DOOR LOCK ............................................................ 920
FRONT DOOR LOCK ....................................... 908 DOOR LOCK : Exploded View .............................. 920
DOOR LOCK : Removal and Installation ............... 920
DOOR LOCK ........................................................... 908 B
DOOR LOCK : Exploded View .............................. 908 FUEL FILLER LID OPENER ........................... 291
FUEL FILLER LID .................................................... 921
INSIDE HANDLE ..................................................... 910 C
FUEL FILLER LID : Exploded View ....................... 921
INSIDE HANDLE : Exploded View ........................ 911 FUEL FILLER LID : Removal and Installation ....... 921
INSIDE HANDLE : Removal and Installation ........ 911
DOOR SWITCH ............................................... 922 D
OUTSIDE HANDLE ................................................. 911 Exploded View ....................................................... 922
OUTSIDE HANDLE : Exploded View .................... 912 Removal and Installation ....................................... 922
BACK DOOR OPENER SWITCH ................... 923 E
REAR DOOR LOCK ......................................... 915 Exploded View ....................................................... 923
DOOR LOCK ........................................................... 915
F
DOOR LOCK : Exploded View .............................. 915 KEYFOB BATTERY ........................................ 924
DOOR LOCK : Removal and Installation .............. 915 Exploded View ....................................................... 924
INSIDE HANDLE ..................................................... 917 G
INSIDE HANDLE : Exploded View ........................ 917 DOOR LOCK AND UNLOCK SWITCH .......... 925
INSIDE HANDLE : Removal and Installation ........ 917 Exploded View ....................................................... 925
OUTSIDE HANDLE ................................................. 917 Removal and Installation ....................................... 925 H
OUTSIDE HANDLE : Exploded View .................... 918
I
DLK
DLK-21
< BASIC INSPECTION > [WITH I-KEY, WITHOUT SUPER LOCK]
BASIC INSPECTION
OVERALL SEQUENCE
JMKIA0676GB
DETAILED FLOW
DLK-22
1.GET INFORMATION FOR SYMPTOM A

the incident/malfunction occurred).
B
>> GO TO 2.
2.CHECK DTC
C
1. Check DTC for Intelligent Key unit and BCM.
2. Perform the following procedure if DTC is displayed.
- Erase DTC.
- Study the relationship between the cause detected by DTC and the symptom described by the customer. D
3. Check related service bulletins for information.
Is any symptom described and any DTC detected?
Symptom is described, DTC is displayed>>GO TO 3. E
Symptom is described, DTC is not displayed>>GO TO 4.
Symptom is not described, DTC is displayed>>GO TO 5.
3.CONFIRM THE SYMPTOM F
Confirm the symptom described by the customer.
Connect CONSULT-III to the vehicle in “DATA MONITOR” mode and check real-time diagnosis results.
Verify relation between the symptom and the condition when the symptom is detected. G
>> GO TO 5.
H
4.CONFIRM THE SYMPTOM
Connect CONSULT-III to the vehicle in “DATA MONITOR ” mode and check real-time diagnosis results. I
Verify relation between the symptom and the condition when the symptom is detected.
>> GO TO 6. J
5.PERFORM DTC CONFIRMATION PROCEDURE
Perform DTC Confirmation Procedure for the displayed DTC, and then check that DTC is detected again.
If two or more DTCs are detected, refer to DLK-169, "DTC Inspection Priority Chart" (Intelligent Key unit), DLK
DLK-210, "DTC Inspection Priority Chart" (BCM) and determine trouble diagnosis order.
Is DTC detected?
L
YES >> GO TO 7.
6.DETECT MALFUNCTIONING SYSTEM BY SYMPTOM TABLE M
Detect malfunctioning system according to Symptom Table based on the confirmed symptom in step 4.
>> GO TO 7. N
7.DETECT MALFUNCTIONING PART BY DIAGNOSTIC PROCEDURE
Inspect according to Diagnostic Procedure of the system. O
NOTE:
The Diagnostic Procedure is described based on open circuit inspection. A short circuit inspection is also
required for the circuit check in the Diagnostic Procedure.
P
>> GO TO 8.
8.REPAIR OR REPLACE THE MALFUNCTIONING PART
1. Repair or replace the malfunctioning part.
2. Reconnect parts or connectors disconnected during Diagnostic Procedure again after repair and replace-
ment.
3. Check DTC. If DTC is displayed, erase it.
DLK-23
>> GO TO 9.
9.FINAL CHECK
When DTC was detected in step 9, perform DTC Confirmation Procedure or Component Function Check
again, and then check that the malfunctions have been fully repaired.
When symptom was described by the customer, refer to the confirmed symptom in step 3 or 4, and check that
the symptom is not detected.
Are all malfunctions corrected?
NO (DTC is detected)>>GO TO 7.
NO (Symptom remains)>>GO TO 6.
DLK-24
A
INFOID:0000000001280388 B
Perform the system initialization when replacing Intelligent Key unit, replacing Intelligent Key or registering an
additional Intelligent Key.
C
D
Refer to the CONSULT-III Operation Manual-NATS.
DLK
DLK-25
DOOR LOCK FUNCTION
< FUNCTION DIAGNOSIS > [WITH I-KEY, WITHOUT SUPER LOCK]
FUNCTION DIAGNOSIS
DOOR LOCK FUNCTION
DOOR LOCK AND UNLOCK SWITCH
DOOR LOCK AND UNLOCK SWITCH : System Diagram INFOID:0000000001280390
DOOR LOCK AND UNLOCK SWITCH OPERATION
JMKIA0563GB
DOOR LOCK AND UNLOCK SWITCH INDICATOR OPERATION
JMKIA0408GB
DOOR LOCK AND UNLOCK SWITCH : System Description INFOID:0000000001280391

Functions are available by operating the door lock and unlock switch on driver door. Interlocked with the lock/
unlock operation of door lock and unlock switch, door lock actuators of all doors are locked/unlocked.
Operation Condition
If the following conditions are not satisfied, door lock/unlock operation is not performed even if the door lock
and unlock switch is operated.
DLK-26
DOOR LOCK FUNCTION
Door lock and unlock switch Operation condition A

All of the following conditions are satisfied.
Lock operation • Except driver side doors are closed.
• Doors are not locked with Intelligent Key or door request switch.
B
All of the following conditions are satisfied.
Unlock operation
NOTE: C
When the door lock is locked with Intelligent Key or door request switch, door lock and unlock switch operation
will be invalid until either of the following conditions is satisfied.
• Turn ignition switch ON.
• Unlock with Intelligent Key or door request switch. D

Door lock and unlock switch indicator indicates door lock status. The indicator turns ON while ignition switch is E
ON and each door lock is locked. If any door is opened, the indicator will turn OFF.
1 Minute Timer
A timer to turn OFF the indicator will run for 1 minute after locking with Intelligent Key, door request switch or F
auto door lock.
30 Minutes Timer
A timer to turn OFF the indicator will run for 30 minutes after locking with door lock and unlock switch. G
NOTE:
1minute timer condition is satisfied while the 30 minutes timer is active, however the 30 minutes timer does not
change to 1 minute timer condition.
H
DLK
DLK-27
DOOR LOCK FUNCTION
DOOR LOCK AND UNLOCK SWITCH : Component Parts Location INFOID:0000000001394648
JMKIA0647ZZ
1. BCM 2. IPDM E/R 3. Intelligent Key unit

M65, M66, M67 E11, E13 M40
4. Passenger side anti-hijack relay 5. Power window main switch (door lock and 6. Inside key antenna (instrument
M90 unlock switch) center)
D5, D6 M56
7. Inside key antenna (console) 8. Inside key antenna (rear seat) 9. Intelligent Key warning buzzer
M252 B45 E25
10. Air bag diagnosis sensor unit
M59
A. Over the glove box B. Over the instrument lower panel (driver C. View with front bumper removed
side)
D. View with lower instrument cover re- E. View with center console rear finisher re- F. View with luggage floor spacer (LH)
moved moved removed
G. View with rear bumper fascia removed H. View with fuse box lid removed
DLK-28
DOOR LOCK FUNCTION
DLK
L
JMKIA0648ZZ
1. Combination meter 2. Lock warning lamp 3. Key warning lamp M

M34 M34 M34
4. Ignition knob switch, key switch and 5. Ignition knob switch, key switch and key 6. Front door switch (driver side)
key lock solenoid (key switch) lock solenoid (key lock solenoid) B34
N
M25 M25
7. Front door lock actuator (driver side) 8. Rear door lock actuator LH 9. Out side key antenna and front door
D9 D85 request switch (driver side)
D10 O
10. Out side key antenna and front door re- 11. Back door opener switch assembly (re- 12. Back door opener switch assembly
quest switch (driver side) quest switch) (opener switch)
D10 D187 D187
P
13. Back door lock assembly 14. Fuel lid opener actuator 15. Out side key antenna (back door)
D190 B58 D191
I. Inside the combination meter J. Inside the combination meter K. View with steering column cover re-
moved
L. View with luggage side lower finisher
(RH) removed.
DLK-29
DOOR LOCK FUNCTION
DOOR LOCK AND UNLOCK SWITCH : Component Description INFOID:0000000001280393
Item Function
BCM Controls the door lock function.
Door switch Detects door state (open or close).
Transmits door lock/unlock signal to BCM. Door lock/unlock switch indicator is built-in door
Door lock and unlock switch
lock and unlock switch.
Door lock actuator Receives door lock/unlock signal from BCM and locks/unlocks each door.
INTELLIGENT KEY
INTELLIGENT KEY : System Diagram INFOID:0000000001280394
INTELLIGENT KEY OPERATION
JMKIA0564GB
INTELLIGENT KEY : System Description INFOID:0000000001280395

The Intelligent Key has the same functions as the multi remote control system. Therefore, it can be used in the
same manner as the keyfob by operating the door lock/unlock button.
This function can be set to OFF with CONSULT-III. For the setting information, refer to DLK-67, "CONSULT-III
Function (INTELLIGENT KEY)".
OPERATION CONDITION
Remote controller operation Operation condition

• All doors are closed
Lock • Key switch is OFF (key is removed from ignition key cylinder)
• Ignition knob switch is OFF (Ignition switch is not pressed)
• Key switch is OFF (key is removed from ignition key cylinder)
Unlock
OPERATION AREA
To ensure that the Intelligent Key works effectively, use within a 100 cm range of each door, however the oper-
able range may differ according to surroundings.
DOOR LOCK AND UNLOCK CONTROL
When door lock and unlock button of the Intelligent Key are pressed, lock signal or unlock signal is transmitted
from Intelligent Key to Intelligent Key unit.
When Intelligent Key unit receives the door lock and unlock signal, it operates door lock actuator.
DLK-30
DOOR LOCK FUNCTION
ANTI-HIJACK MODE
When door lock is unlocked, pressing LOCK button on Intelligent Key once will lock all doors. When door lock A
is locked, pressing UNLOCK button on Intelligent Key door will unlock driver side door. Pressing UNLOCK but-
ton on Intelligent Key a second time within 5 seconds from the first time will unlock all doors and back door can
be opened with back door opener switch. B
NOTE:
Anti-hijack mode can be set to ON or OFF with CONSULT-III. For the setting information, refer to DLK-67,
"CONSULT-III Function (INTELLIGENT KEY)".
C
INTELLIGENT KEY : Component Parts Location INFOID:0000000001394651
DLK
JMKIA0647ZZ
P
M65, M66, M67 E11, E13 M40
D5, D6 M56
M252 B45 E25
DLK-31
DOOR LOCK FUNCTION
M59
side)
moved moved removed
JMKIA0648ZZ
1. Combination meter 2. Lock warning lamp 3. Key warning lamp

M34 M34 M34
M25 M25
D10
D10 D187 D187
DLK-32
DOOR LOCK FUNCTION
D190 B58 D191 A
moved
L. View with luggage side lower finisher B
(RH) removed.
INTELLIGENT KEY : Component Description INFOID:0000000001280397

C
Item Function
Intelligent Key unit Controls the door lock/unlock operation with BCM. D
BCM Controls the door lock/unlock operation with Intelligent Key unit.
Door switch Detects door state (open or closed).
E
Key switch Detects that mechanical key is inserted into ignition key cylinder.
Ignition knob switch Detects ignition knob state (push or release).
Outside key antenna Detects that Intelligent Key is in detection area of outside key antenna. F
Intelligent Key Transmits key ID to Intelligent Key unit when lock/unlock button is pressed.
Passenger side anti-hijack relay Controls the circuit of door lock actuator (passenger side, rear LH/RH).
G
Door lock actuator Receives lock/unlock signal from BCM and locks and unlocks each door.
DOOR REQUEST SWITCH

H
DOOR REQUEST SWITCH : System Diagram INFOID:0000000001280398
DOOR REQUEST SWITCH OPERATION

I
DLK
P
JMKIA0565GB
DOOR REQUEST SWITCH : System Description INFOID:0000000001280399

Only when pressing the request switch, it is possible to lock and unlock the door by carrying the Intelligent
Key. The Intelligent Key system is a system that makes it possible to lock and unlock the door by carrying the
DLK-33
DOOR LOCK FUNCTION
Intelligent Key, which operates based on the results of electronic ID verification using two-way communica-
tions between the Intelligent Key and the vehicle (Intelligent Key unit).
This function can be set to OFF with CONSULT-III. For the setting information, refer to DLK-67, "CONSULT-III
CAUTION:
The driver should always carry the Intelligent Key
OPERATION CONDITION
If the following conditions are not satisfied, door lock and unlock operation is not performed even if the request
switch is operated.
Each request switch operation Operation condition

• Key switch is OFF (Key is removed from ignition key cylinder.)
Lock operation • Ignition knob is OFF or LOCK position
• Any Intelligent Key is not inside the vehicle
• Intelligent Key is within outside key antenna detection area
• Key switch is OFF (Key is removed from ignition key cylinder.)
• Ignition knob is OFF or LOCK position
Unlock Operation
• Intelligent Key is not inside the vehicle*
*: Even with a registered Intelligent Key remaining inside the vehicle, door locks can be unlocked from outside of the vehicle with a spare
Intelligent Key as long as key IDs are different.
OUTSIDE KEY ANTENNA DETECTION AREA

The outside key antenna detection area of door lock and unlock
function is in the range of approximately 80 cm (31.50 in) surround-
ing the driver and passenger door handles (1) and the back door
request switch (2). However, this operating range depends on the
ambient conditions.
JMKIA0666ZZ

When the Intelligent Key detects that door request switch is pressed, it starts corresponding with outside key
antenna (door of request switch pressed side). Then, the Intelligent Key is checked to be near the door.
If the Intelligent Key is within the outside key antenna detection area, it receives the request signal and trans-
mits the key ID signal to the Intelligent Key unit. Intelligent Key unit receives the key ID signal and compares it
with the registered key ID. Intelligent Key unit sends the door lock and unlock signal to BCM via CAN commu-
nication.
ANTI-HIJACK MODE
• When door is unlocked, pressing door request switch (driver or passenger) once will lock all doors. When
door is locked, pressing door request switch (driver or passenger) once will unlock operated door. Pressing
the door request switch door a second time within 5 seconds from the first time will unlock all doors and back
door can be opened with back door opener switch.
• When door is unlocked, pressing door request switch (back door) will lock all doors. When door lock is
locked, pressing door request switch (back door) will unlock back door only and back door can be opened
with back door opener switch. Pressing back door opener switch a second time within 5 seconds will unlock
all doors.
NOTE:
Anti-hijack mode can be set to OFF with CONSULT-III and Intelligent Key. For the setting information, refer to
DLK-67, "CONSULT-III Function (INTELLIGENT KEY)".
DLK-34
DOOR LOCK FUNCTION
DOOR REQUEST SWITCH : Component Parts Location INFOID:0000000001394652
DLK
JMKIA0647ZZ
M

M65, M66, M67 E11, E13 M40 N
D5, D6 M56
O
M252 B45 E25
M59 P
side)
moved moved removed
DLK-35
DOOR LOCK FUNCTION
JMKIA0648ZZ

M34 M34 M34
M25 M25
D10
D10 D187 D187
D190 B58 D191
moved
(RH) removed.
DLK-36
DOOR LOCK FUNCTION
DOOR REQUEST SWITCH : Component Description INFOID:0000000001280401
Item Function
Intelligent Key unit Controls the door lock function with BCM. B
BCM Controls the door lock/unlock function with Intelligent Key unit.
Door request switch Transmits opertion signal (lock and unlock) to Intelligent Key unit.
C
Ignition knob switch Detects ignition knob state (push or release). D
Outside key antenna Detects that Intelligent Key is in detection area of outside key antenna.
Inside key antenna Detects that Intelligent Key is in detection area of inside key antenna.
E
Transmits key ID to Intelligent Key unit when request signal is received from out-
Intelligent Key
side key antenna.
F
Door lock actuator Receives lock/unlock signal from BCM and locks/unlocks each door.
KEY REMINDER
G
KEY REMINDER : System Diagram INFOID:0000000001280402
KEY REMINDER OPERATION H
DLK
M
JMKIA0566GB
KEY REMINDER : System Description INFOID:0000000001280403
N
KEY REMINDER OPERATION
Key reminder have the following 2 functions.
O
Operation Operation condition Operation
Right after driver side door is closed under the following con-
ditions.
P
Driver door close • Door lock operation. All doors unlock
• Driver side door is opened.
• Driver side door is in unlock state.
Right after all doors are closed under the following condi-
tions. • All doors unlock
Any door open to all doors close • Intelligent Key is inside the vehicle. • Active Intelligent Key warning
• Any door is opened. buzzer
• All doors are locked by door lock and unlock switch.
DLK-37
DOOR LOCK FUNCTION
CAUTION:
The above function operates when the Intelligent Key is inside the vehicle. However, there may be
times when the Intelligent Key cannot be detected, and this function will not operate when the Intelli-
gent Key is on the instrument panel, rear parcel shelf or in the glove box. Also, this system some-
times does not operate if the Intelligent Key is in the door pocket of an open door.
KEY REMINDER : Component Parts Location INFOID:0000000001394653
JMKIA0647ZZ

M65, M66, M67 E11, E13 M40
D5, D6 M56
M252 B45 E25
M59
side)
DLK-38
DOOR LOCK FUNCTION
moved moved removed A
DLK
JMKIA0648ZZ
N
M34 M34 M34
key lock solenoid (key switch) lock solenoid (key lock solenoid) B34 O
M25 M25
P
D10
D10 D187 D187
D190 B58 D191
DLK-39
DOOR LOCK FUNCTION
moved
(RH) removed.
KEY REMINDER : Component Description INFOID:0000000001280405
Item Function
Intelligent Key unit Controls the door lock function with BCM.
BCM Controls the door lock and unlock operation with Intelligent Key unit.
Inside key antenna Detects that Intelligent Key is in detection area of inside key antenna.
Intelligent Key Transmits key ID to Intelligent Key unit when Intelligent Key is searching.
Door lock actuator Receives lock and unlock signal from BCM and locks/unlocks each door.
AUTO DOOR LOCK

AUTO DOOR LOCK : System Diagram INFOID:0000000001280406
AUTO DOOR LOCK OPERATION
JMKIA0567GB
AUTO DOOR LOCK : System Description INFOID:0000000001280407

When all doors are locked and then doors are unlocked with Intelligent Key or door request switch, BCM does
not receive the following signals within 2 minutes*1, and all doors are automatically locked.
• Any door is opened.
• Ignition knob is pressed.
• Ignition key is inserted into ignition key cylinder.
• Door is locked with Intelligent Key.
• Door is locked/unlocked with door lock and unlock switch.
*1
: Auto door lock operation mode can be changed with CONSULT-III. Refer to DLK-67, "CONSULT-III Func-
tion (INTELLIGENT KEY)".
DLK-40
DOOR LOCK FUNCTION
AUTO DOOR LOCK : Component Parts Location INFOID:0000000001394654
DLK
JMKIA0647ZZ
M

M65, M66, M67 E11, E13 M40 N
D5, D6 M56
O
M252 B45 E25
M59 P
side)
moved moved removed
DLK-41
DOOR LOCK FUNCTION
JMKIA0648ZZ

M34 M34 M34
M25 M25
D10
D10 D187 D187
D190 B58 D191
moved
(RH) removed.
DLK-42
DOOR LOCK FUNCTION
AUTO DOOR LOCK : Component Description INFOID:0000000001280409
Item Function
BCM Controls the door lock function with Intelligent Key unit.
C
Ignition knob switch Detects ignition knob state (push or release).
Door lock and unlock switch Transmits door lock and unlock signal to BCM. D
Door lock actuator Receives lock and unlock signal from BCM and locks and unlocks each door.
VEHICLE SPEED SENSING AUTO DOOR LOCK E

VEHICLE SPEED SENSING AUTO DOOR LOCK : System Diagram INFOID:0000000001280410
VEHICLE SPEED SENSING AUTO DOOR LOCK OPERATION F
JMKIA0568GB
DLK
VEHICLE SPEED SENSING AUTO DOOR LOCK : System Description INFOID:0000000001280411
VEHICLE SPEED SENSING AUTO DOOR LOCK OPERATION L

When the vehicle speed exceeds 25 km/h (16 MPH), all doors are automatically locked. BCM receives vehicle
speed signal from combination meter via CAN communication.
DLK-43
DOOR LOCK FUNCTION
VEHICLE SPEED SENSING AUTO DOOR LOCK : Component Parts Location
INFOID:0000000001394655
JMKIA0647ZZ

M65, M66, M67 E11, E13 M40
D5, D6 M56
M252 B45 E25
M59
side)
moved moved removed
DLK-44
DOOR LOCK FUNCTION
DLK
L
JMKIA0648ZZ

M34 M34 M34
N
M25 M25
D10 O
D10 D187 D187
P
D190 B58 D191
moved
(RH) removed.
DLK-45
DOOR LOCK FUNCTION
VEHICLE SPEED SENSING AUTO DOOR LOCK : Component Description
INFOID:0000000001280413
Item Function
BCM Controls the door lock/unlock function.
Combination meter Transmits vehicle speed signal to BCM via CAN communication.
Door lock actuator Receives door lock and unlock signal from BCM and locks and unlocks each door.
AIR BAG INTERLOCK UNLOCK

AIR BAG INTERLOCK UNLOCK : System Diagram INFOID:0000000001280414
AIR BAG INTERLOCK UNLOCK OPERATION
JMKIA0569GB
AIR BAG INTERLOCK UNLOCK : System Description INFOID:0000000001280415

When ignition switch is ON and BCM receives air bag deployment signal, it operates automatically to unlock
all doors. Air bag diagnosis sensor unit sends the air bag deployment signal to BCM.
DLK-46
DOOR LOCK FUNCTION
AIR BAG INTERLOCK UNLOCK : Component Parts Location INFOID:0000000001394656
DLK
JMKIA0647ZZ
M

M65, M66, M67 E11, E13 M40 N
D5, D6 M56
O
M252 B45 E25
M59 P
side)
moved moved removed
DLK-47
DOOR LOCK FUNCTION
JMKIA0648ZZ

M34 M34 M34
M25 M25
D10
D10 D187 D187
D190 B58 D191
moved
(RH) removed.
DLK-48
DOOR LOCK FUNCTION
AIR BAG INTERLOCK UNLOCK : Component Description INFOID:0000000001280417
Item Function
BCM Controls the door lock function. B
Air bag diagnosis sensor unit Transmits air bag deployment signal to BCM for shock sensing auto unlock.
Door lock actuator Receives unlock signal from BCM and unlocks each door.
C
DLK
DLK-49
BACK DOOR OPENER FUNCTION
BACK DOOR OPENER SWITCH
BACK DOOR OPENER SWITCH : System Diagram INFOID:0000000001280418
BACK DOOR OPENER OPERATION
JMKIA0402GB
BACK DOOR OPENER SWITCH : System Description INFOID:0000000001280419

When back door opener switch is pressed, BCM opens back door opener actuator.
NOTE:
Back door opener actuator is not for locking the back door. The function is only to open the back door.
OPERATION CONDITION
If the following conditions are not satisfied, back door opener operation is not performed.
Back door opener switch operation Operation condition

• Vehicle speed is less than 5 km/h (3 MPH).
Back door open
• All doors are unlocked.
DLK-50
BACK DOOR OPENER SWITCH : Component Parts Location INFOID:0000000001394657
DLK
JMKIA0647ZZ
M

M65, M66, M67 E11, E13 M40 N
D5, D6 M56
O
M252 B45 E25
M59 P
side)
moved moved removed
DLK-51
JMKIA0648ZZ

M34 M34 M34
M25 M25
D10
D10 D187 D187
D190 B58 D191
moved
(RH) removed.
DLK-52
BACK DOOR OPENER SWITCH : Component Description INFOID:0000000001280421
Item Function
BCM Controls the back door opener function. B
Back door opener switch Transmits back door opener switch operation signal to BCM.
Back door opener actuator Opens the back door with the back door open signal from BCM.
C
DLK
DLK-53
WARNING FUNCTION
WARNING FUNCTION
INTELLIGENT KEY WARNING OPERATION
JMKIA0409GB
BACK DOOR OPEN WARNING OPERATION
JMKIA0410GB
DESCRIPTION
The warning functions are as follows and are given to the user as warning information and warnings using
combinations of Intelligent Key warning buzzer, key warning lamps and buzzer (built in combination meter).
Once one of the following conditions below is established, alert or warning will be executed.
DLK-54
WARNING FUNCTION
Warning chime A
Warning/Information functions Operation conditions Warning lamp Intelligent Key
Combination
warning buzz-
meter buzzer
er
B
When all the conditions below are met.
Active
• Ignition knob: OFF or LOCK (knob is
Ignition knob return forgotten for 5 seconds
pressed). — —
warning (pipipipi, C
• Door switch (driver side): ON (Door is
pipipipi···)
open).
Active
• Ignition switch: OFF position. D
Ignition key warning for 5 seconds
• Key switch: ON (inserted) — —
(when mechanical key is used) (pipipipi,
pipipipi···)
open).
E
• Ignition switch is between ACC and
OFF position or ignition knob is Active
“LOCK”
OFF position warning pressed in while ignition switch is in for 1 second — F
(RED blinking)
LOCK position. (pipi, pipi···)
• 3 seconds in the above state have
pressed.
G
• Ignition switch: Except LOCK position.
Any door
• Door switch: ON to OFF (Door is open “KEY” Active
open to all —
to closed). (RED blinking) (pi, pi, pi) H
doors closed
• Intelligent Key cannot be detected in-
side the vehicle.
• Door switch: ON (Door is open) I
“KEY”
Door is open • Key ID verification every 5 seconds — —
(RED blinking)
when registered Intelligent Key can
Take away not be detected inside the vehicle. J
warning
• Key ID verification: OK
• Every 30 seconds when registered In-
telligent Key cannot be detected in- DLK
Take away side the vehicle or result of vehicle Active for 3 sec-
“KEY”
through win- speed verification is NG. (The regis- onds —
(RED blinking)
dow tered Intelligent Key cannot be detect- (pipipi···
L
ed inside the vehicle when ignition
switch is ON.)
• Key switch: OFF (Key is removed
from ignition key cylinder.) M
DLK-55
WARNING FUNCTION
Warning chime

Combination
warning buzz-
meter buzzer
er
When request switch is pushed (lock op-
eration) under the following conditions.
• Door switch: ON (Any door is open).
Request Active for 2
• Ignition switch is in ACC or OFF posi-
switch opera- — — seconds
tion or ignition knob is pressed in
tion (pipipi···)
LOCK position or mechanical key is
inserted into ignition key cylinder.
Door lock op- • Intelligent Key is inside vehicle.
eration warn-
ing When Intelligent Key button is pushed
(lock operation) under the following con-
ditions.
Intelligent Key Active for 2
button opera- — — seconds
tion (pipipi···)
“KEY”
When Intelligent Key battery voltage is
Intelligent Key low battery (GREEN blink-
low, Intelligent Key unit is detected after — —
warning ing for 30 sec-
ignition switch is turned ON.
onds)
KEY WARNING LAMP & LOCK WARNING LAMP

The key indicator and lock indicator indicates Intelligent Key system status.
Operation Condition
Behavior of lamps Operation condition

All the following conditions are satisfied.
• Ignition knob is pushed in LOCK position. (Ignition knob switch is ON)
Lighting • Ignition key is removed from ignition key cylinder. (Key switch is OFF)
GREEN • Intelligent Key is detected inside of the vehicle.
• KEY RED lighting/blinking conditions are not satisfied.
Blinking while Intelligent Key low battery warning is operating.
KEY All the following conditions are satisfied.
• Ignition knob is pushed. (Ignition knob switch is ON)
Lighting
• Ignition key is removed from ignition key cylinder. (Key switch is OFF)
RED • Intelligent Key is not detected inside of the vehicle.
Blinking • Take away warning is operating.
• KEY RED lighting condition is not satisfied.
LOCK Blinking While OFF position warning is operating.
KEY(RED) and LOCK lighting • Ignition switch is ON.
• Steering lock ID is NG.

When back door opener switch is operated, when door lock is locked with door lock and unlock switch, speed
sensing lock or only driver side is unlocked with anti-hijack function, the buzzer (built in combination meter) will
sound.
• The buzzer (combination meter) will sound and the doors will not lock if the door lock and unlock switch is
pressed while the driver door is open and mechanical key is inserted ignition key cylinder.
pressed while any door other than the driver door is open.
DLK-56
WARNING FUNCTION
DLK
JMKIA0647ZZ
M

M65, M66, M67 E11, E13 M40 N
D5, D6 M56
O
M252 B45 E25
M59 P
side)
moved moved removed
DLK-57
WARNING FUNCTION
JMKIA0648ZZ

M34 M34 M34
M25 M25
D10
D10 D187 D187
D190 B58 D191
moved
(RH) removed.
DLK-58
WARNING FUNCTION
Item Function
BCM Controls the warning function with Intelligent Key unit. B
Intelligent Key unit Controls the warning function with BCM.
C
Door lock and unlock switch Transmits door lock and unlock signal to BCM.
Requests to turn ON hazard warning lamp to BCM and turn signal indicator to D
Intelligent Key unit
combination meter.
Turns ON the LOCK indicator, KEY indicator, turn signal indicator and buzzer
Combination meter (built in combination meter) by the request from Intelligent Key unit via CAN com-
E
munication.
Intelligent Key warning buzzer Sounds by the request from Intelligent Key unit.
Back door opener switch Transmits back door open signal to BCM F
DLK
DLK-59
HAZARD AND BUZZER REMINDER FUNCTION
HAZARD & BUZZER REMINDER FUNCTION
JMKIA0506GB

When door is locked or unlocked by Intelligent Key or door request switch, Intelligent Key unit sounds buzzer
and sends hazard request signal to BCM via CAN communication. Then BCM flashes hazard warning lamps
as a reminder.
NOTE:
Hazard and buzzer reminder function mode can be changed with CONSULT-III. Refer to DLK-67, "CONSULT-
III Function (INTELLIGENT KEY)".
Hazard Operation
Hazard reminder setting Door lock operation
Hazard warning lamp flash
(With CONSULT-III) (with Intelligent Key or door request switch)
OFF Any —
Lock Once
LOCK ONLY Unlock —
Unlock (Anti-hijack) —
Lock —
HAZARD ANSWER BACK
UNLK ONLY Unlock Twice
Unlock (Anti-hijack) Twice (quick)
Lock Once
LOCK/UNLK Unlock Twice
Buzzer Operation
Buzzer reminder setting Door lock operation
Buzzer warning sounds
Lock Once
ANSWER BACK WITH BUZZER Unlock Depends on other setting
I-KEY
LOCK Unlock (Anti-hijack) Depends on other setting
OFF Any —
DLK-60
(With CONSULT-III) (with Intelligent Key or door request switch) A
Lock Depends on other setting
ANSWER BACK WITH BUZZER Unlock Twice
I-KEY B
UNLOCK Unlock (Anti-hijack) Twice
OFF Any —
Lock Once C
ANSWER BACK FUNC- ON Unlock Twice
TION Unlock (Anti-hijack) Twice
D
OFF Any —
DLK
JMKIA0647ZZ
DLK-61

M65, M66, M67 E11, E13 M40
D5, D6 M56
M252 B45 E25
M59
side)
moved moved removed
JMKIA0648ZZ
DLK-62
1. Combination meter 2. Lock warning lamp 3. Key warning lamp A

M34 M34 M34
M25 M25 B
D10 C
D10 D187 D187
D
D190 B58 D191
moved E
(RH) removed.
F
Item Function G
BCM Controls the hazard and buzzer reminder function with Intelligent Key unit.
Intelligent Key unit Controls the hazard and buzzer reminder function with BCM.
H
munication.
I
Intelligent Key warning buzzer Sounds by the request signal from Intelligent Key unit.
DLK
DLK-63
COMMON ITEM
APPLICATION ITEM

Self-Diagnostic Results Displays the diagnosis results judged by BCM. Refer to DLK-211, "DTC Index".
Configuration
SYSTEM APPLICATION
NOTE:
×: Applicable item

System
— BCM ×
— PTC HEATER*
DOOR LOCK

DLK-64
Diagnosis mode Function Description A

B
DATA MONITOR
C
ACC ON SW Indicates [ON/OFF] condition of ignition switch in ACC position. D

KEY ON SW Indicates [ON/OFF] condition of key switch. E
DOOR SW-DR Indicates [ON/OFF] condition of front door switch (driver side). F
G
KEYLESS LOCK*2 Indicates [ON/OFF] condition of lock signal from key fob. H
I-KEY LOCK*1 Indicates [ON/OFF] condition of lock signal from Intelligent Key. I
J
DLK
sor unit.
SHOCK SENSOR agnosis sensor unit.) L
unit.
M
VEHICLE SPEED
[km/h].
*1
*2:
N
For the multi remote control system equipped vehicle.
ACTIVE TEST
O
P
DOOR LOCK IND
DOOR LOCK
OTHER UNLOCK].
WORK SUPPORT
DLK-65

INTELLIGENT KEY


DATA MONITOR

TRUNK
APPLICATION ITEM

DATA MONITOR


VEHICLE SPEED
[km/h].
*1
*2
: For the remote keyless entry system equipped vehicle.
ACTIVE TEST

DLK-66
DIAGNOSIS SYSTEM (INTELLIGENT KEY UNIT)
A
CONSULT-III Function (INTELLIGENT KEY) INFOID:0000000001557124
APPLICATION ITEM B
CONSULT-III performs the following functions via CAN communication with Intelligent Key unit.
Diagnosis mode Function Description C

SELF-DIAG RESULTS Displays the diagnosis results judged by Intelligent Key unit.
CAN DIAG SUPPORT MNTR Monitors the reception status of CAN communication viewed from Intelligent Key unit. D
DATA MONITOR The Intelligent Key unit input/output signals are displayed.
E
ECU IDENTIFICATION The Intelligent Key unit part number is displayed.
WORK SUPPORT
F
Support item Description Selection item Condition
It can check whether Intelligent Key ID code
CONFIRM KEY FOB ID — — G
is registered or not.
Take away warning chime (from window) ON Active

TAKE OUT FROM WINDOW WARN
mode can be changed. OFF Inactive H
Intelligent Key low battery warning mode can ON Active
LOW BATT OF KEY FOB WARN
be changed. OFF Inactive
Door lock function with Intelligent Key can be ON Active I

KEYLESS FUNCTION
changed. OFF Inactive
ON Active
ANSWER BACK FUNCTION Buzzer reminder operation can be changed. J
OFF Inactive
ON Active
SELECTIVE UNLOCK FUNCTION Anti-hijack mode can be changed.
OFF Inactive DLK
Hazard reminder operation mode can be
HAZARD ANSWER BACK Refer to DLK-60.
changed.
Buzzer reminder operation (lock operation) BUZZER Active L
ANSWER BACK WITH I-KEY LOCK mode by each door request switch can be
Buzzer reminder operation (unlock operation) BUZZER Active M

ANSWER BACK WITH I-KEY UNLOCK mode by each door request switch can be
Auto door lock operation mode can be OFF Inactive

AUTO RELOCK TIMER N
changed. 2 min. Active
Engine start function (by Intelligent Key) ON Active

ENGINE START BY I-KEY
mode can be changed. OFF Inactive O
Door lock function by door request switch can ON Active

LOCK/UNLOCK BY I-KEY
P
SELF-DIAG RESULT
Refer to DLK-169, "DTC Index".
DATA MONITOR
DLK-67

PUSH SW Indicates [ON (pressed)/OFF (released)] condition of ignition knob switch.
KEY SW Indicates [ON (inserted)/OFF (removed)] condition of key switch.
DR REQ SW Indicates [ON (pressed)/OFF (released)] condition of door request switch (driver side).
Indicates [ON (pressed)/OFF (released)] condition of door request switch (passenger
AS REQ SW
side).
BD/TR REQ SW Indicates [ON (pressed)/OFF (released)] condition of door request switch (back door).
Indicates [ON (ON or START position)/OFF (other than ON and START position)] con-
IGN SW
dition of ignition switch ON position.
ACC SW Indicates [ON/OFF] condition of ignition switch ACC position.
STOP LAMP SW Indicates [ON/OFF] condition of stop lamp switch.
DOOR LOCK SIG Indicates [ON/OFF] condition of LOCK signal from Intelligent Key.
DOOR UNLOCK SIG Indicates [ON/OFF] condition of UNLOCK signal from Intelligent Key.
Indicates [OPEN/CLOSE] condition of front door switch (driver side) from BCM via CAN
DOOR SW DR
communication.
Indicates [OPEN/CLOSE] condition of front door switch (passenger side) from BCM via
DOOR SW AS
CAN communication.
Indicates [OPEN/CLOSE] condition of rear door switch (RH) from BCM via CAN com-
DOOR SW RR
munication.
Indicates [OPEN/CLOSE] condition of rear door switch (LH) from BCM via CAN com-
DOOR SW RL
munication.
Indicates [OPEN/CLOSE] condition of back door switch from BCM via CAN communi-
DOOR BK SW
cation.
VEHICLE SPEED
[km/h].
ACTIVE TEST

This test is able to check door lock/unlock operation.
• ALL UNLK: All door lock actuators are unlocked.
• DR UNLK: Door lock actuator (driver side) is unlocked.
DOOR LOCK/UNLOCK
• AS UNLK: Door lock actuator (passenger side) is unlocked.
• BK UNLK: This item is indicated, but inactive.
• LOCK: All door lock actuator is locked.
This test is able to check Intelligent Key antenna operation.
When the following condition are met, LED (on Intelligent Key) blinks.
• ROOM ANT1: Inside key antenna (console) transmissions can be detected by Intel-
ligent Key, when “ROOM ANT1” is selected.
• ROOM ANT2: Inside key antenna (instrument center/rear seat) transmissions can be
detected by Intelligent Key, when “ROOM ANT2”is selected.
ANTENNA
• DRIVER ANT: Outside key antenna (driver side) transmissions can be detected by
Intelligent Key, when “DRIVER ANT” is selected.
• ASSIST ANT: Outside key antenna (passenger side) transmissions can be detected
by Intelligent Key, when “ASSIST ANT” is selected.
• BK DOOR ANT: Outside key antenna (rear bumper) transmissions can be detected
by Intelligent Key, when “BK DOOR ANT” is selected.
This test is able to check Intelligent Key warning buzzer operation.
OUTSIDE BUZZER • ON
• OFF
This test is able to check warning chime in combination meter operation.
• TAKE OUT: Take away warning chime sounds.
INSIDE BUZZER • KNOB: Ignition knob switch warning chime sounds.
• KEY: Key warning chime sounds.
• OFF
DLK-68
A
This test is able to check warning lamp operation.
• BLUE ON: Key warning lamp (green) illuminates.
• RED ON: Key warning lamp (red) illuminates.
• KNOB ON: Lock warning lamp illuminates. B
INDICATOR
• BLUE IND: Key warning lamp (green) flashes.
• RED IND: Key warning lamp (red) flashes.
• KNOB IND: Lock warning lamp flashes.
• OFF C
This test is able to check key interlock operation.
KEY LOCK SOLENOID*1 • LOCK: Key interlock is active.
• UNLOCK: Key interlock is inactive. D
*1: The item is only for MT model.
DLK
DLK-69
< COMPONENT DIAGNOSIS > [WITH I-KEY, WITHOUT SUPER LOCK]
COMPONENT DIAGNOSIS
vehicle is equipped with many electronic control unit, and each control unit shares information and links with
wiring. Each control unit transmits/receives data but selectively reads required data only.
DTC DETECTION LOGIC
CONSULT-III display
description
In CAN communication system, any item (or items)
of the following listed below is malfunctioning.
• Transmission
When Intelligent Key unit cannot communi-
• Receiving (BCM)
U1000 CAN COMM CIRCUIT cate CAN communication signal continuous-
ly for 2 seconds or more.
• Receiving (ECM)
• Receiving (METER/M&A)
• Receiving (MULTI AV)

2. Check “Self Diagnostic Result” of Intelligent Key unit.
DLK-70
A
CAN (Controller Area Network) is a serial communication line for real time applications. It is an on-vehicle mul- B
with 2 communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less C
CAN Communication Signal Chart, refer to LAN-25, "CAN Communication Signal Chart".
D
DTC DETECTION LOGIC

E
CONSULT-III display de-
scription
When detecting error during the initial diagnosis of CAN control- F
U1010 CONTROL UNIT (CAN) Intelligent Key unit
ler of Intelligent Key unit.

G
1.REPLACE INTELLIGENT KEY UNIT
When DTC [U1010] is detected, replace Intelligent Key unit. H
>> Replace Intelligent Key unit.

I
1.REQUIRED WORK WHEN REPLACING INTELLIGENT KEY UNIT J

Initialize control unit. Refer to CONSULT-III operation manual NATS-IVIS/NVIS.
>> Work end. DLK
DLK-71
INTELLIGENT KEY UNIT
INTELLIGENT KEY UNIT : Diagnosis Procedure INFOID:0000000001280447
1.CHECK FUSE AND FUSIBLE LINK

Check that the following fuse is not blown.
Terminal No. Signal name Fuse No.

11 Battery power supply 14 (10A)
6 Ignition power supply 1 (10A)
Is the fuse blown?
YES >> Replace the blown fuse after repairing the affected circuit if a fuse is blown.
NO >> GO TO 2.
1. Disconnect Intelligent Key unit connector.
3. Check voltage between Intelligent Key unit harness connector and ground.
Terminal
(+) (−) Voltage (V)
Intelligent Key unit (Approx.)
Connector Terminal
Ground
11
M40 Battery voltage
6
YES >> GO TO 3.
Check continuity between Intelligent Key unit harness connector and ground.

Continuity
M40 12 Exists
YES >> Intelligent Key unit power supply and ground circuit are OK.
BCM
BCM : Diagnosis Procedure INFOID:0000000001280448

Check that the following fuse and fusible link are not blown.
Terminal No. Signal name Fuse and fusible link No.

41 10 (10A)
57 J (50A)
4 ACC power supply 20 (10A)
DLK-72
Is the fuse fusing?
YES >> Replace the blown fuse or fusible link after repairing the affected circuit if a fuse or fusible link is A
blown.
NO >> GO TO 2.
2.CHECK POWER SUPPLY CIRCUIT B
3. Check voltage between BCM harness connector and ground. C
Terminals
(+) D
Voltage
Condition
BCM (−) (Approx.)
Connector Terminal
E
M66 41
Turn ignition switch OFF
M67 57
Ground Battery voltage
3 Turn ignition switch ON F
M65
4 Turn ignition switch ACC
G
YES >> GO TO 3.
3.CHECK GROUND CIRCUIT H
BCM I
Continuity
M67 55 Exists
J
YES >> BCM power supply and ground circuit are OK.
DLK
DLK-73
Transmits door lock/unlock operation to BCM.

1.CHECK FUNCTION
With CONSULT-III
Check “CDL LOCK SW ”and “CDL UNLOCK SW” in “Data Monitor” mode with CONSULT-III.
Monitor item Condition

LOCK : ON
CDL LOCK SW
UNLOCK : OFF
LOCK : OFF
CDL UNLOCK SW
UNLOCK : ON
YES >> Door lock and unlock switch is OK.
NO >> Refer to DLK-74, "Diagnosis Procedure".
1.CHECK DOOR LOCK AND UNLOCK SWITCH INPUT SIGNAL

2. Disconnect power window main switch (door lock and unlock switch) connector.
3. Check voltage between power window main switch (door lock and unlock switch) and ground.
Terminal
(+)
Signal
Power window main switch (–) (Reference value)
(door lock and unlock switch) Terminal
connector
D5 6
Ground
D6 18
JPMIA0154GB

YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK DOOR LOCK AND UNLOCK SWITCH CIRCUIT
2. Disconnect BCM connector.
3. Check continuity between BCM connector and power window main switch (door lock and unlock switch)
connector.
Power window main switch (door lock

BCM connector Terminal Terminal Continuity
and unlock switch) connector
32 D5 6
M65 Exists
34 D6 18
DLK-74
4. Check continuity between BCM connector and ground.
A
BCM connector Terminal Continuity
32 Ground
M65 Does not exist
34 B
YES >> GO TO 4.
C
NO >> Repair or replace harness.
3.CHECK DOOR LOCK AND UNLOCK SWITCH GROUND
Check continuity between power window main switch (door lock and unlock switch) connector and ground. D
Power window main switch

Terminal Continuity
(door lock and unlock switch) connector Ground E
D6 17 Exists
YES >> GO TO 5. F
G
2. Check voltage between BCM connector and ground.
H
Terminal
Signal
(+)
(–) (Reference value)
BCM connector Terminal I
32
J
M65 Ground
34
DLK
JPMIA0154GB

YES >> GO TO 5. L
NO >> GO TO 6.
5.CHECK DOOR LOCK AND UNLOCK SWITCH M
Check power window main switch (door lock and unlock switch).
Refer to DLK-75, "Component Inspection".
Is the inspection result normal? N
YES >> GO TO 6.
NO >> Replace power window main switch (door lock and unlock switch). Refer to PWC-83, "Removal
and Installation".
O
P
>> INSPECTION END
1.CHECK DOOR LOCK AND UNLOCK SWITCH

Check door lock and unlock switch.
DLK-75
Power window main switch Terminal Condition Continuity

D5 6 LOCK
17 Exists
D6 18 UNLOCK
NO >> Replace power windou main switch. Refer to PWC-83, "Removal and Installation".
DLK-76
DOOR REQUEST SWITCH
DOOR REQUEST SWITCH
A
DRIVER SIDE
B
Transmits lock/unlock operation to Intelligent Key unit.
C
1.CHECK FUNCTION
With CONSULT-III D
Check door request switch “DR REQ SW” in “Data Monitor” mode with CONSULT-III.

E
Door request switch is pressed :ON
DR REQ SW
Door request switch is released :OFF
Is the inspection result normal? F
YES >> Door request switch is OK.
NO >> Refer to DLK-77, "DRIVER SIDE : Diagnosis Procedure".
G
1.CHECK INTELLIGENT KEY UNIT INPUT SIGNAL H

I
Terminal
(+) Door request Voltage (V)
(–) switch condition (Approx.)
Intelligent Key unit J
Terminal
connector
Pressed 0
M40 5 Ground
Released 5 DLK
YES >> GO TO 6.
NO >> GO TO 2. L
2.CHECK FRONT DOOR REQUEST SWITCH CIRCUIT
1. Disconnect Intelligent Key unit connector. M
2. Check continuity between Intelligent Key unit harness connector and outside key antenna and front door
request switch (driver side) harness connector.
Intelligent Key unit Outside key antenna and front door N

Terminal Terminal Continuity
connector request switch (driver side)
M40 5 D30 3 Exists
O
3. Check continuity between Intelligent Key unit harness connector and ground.

Terminal Continuity P
connector Ground
M40 5 Does not exist
YES >> GO TO 3.
NO >> Repair or replace harness between Intelligent Key unit and outside key antenna and front door
request switch (driver side).
DLK-77
DOOR REQUEST SWITCH
3.CHECK DOOR REQUEST SWITCH GROUND CIRCUIT

Check continuity between outside key antenna and front door request switch (driver side) harness connector
and ground.
Outside key antenna and front door request

Terminal Continuity
switch (driver side) connector Ground
D30 4 Exists
YES >> GO TO 4.
NO >> Repair or replace outside key antenna and front door request switch (driver side) ground circuit.
4.CHECK INTELLIGENT KEY UNIT OUTPUT SIGNAL
1. Connect Intelligent Key unit connector.
Intelligent Key unit Voltage (V)

Terminal
connector Ground (Approx.)
M40 5 5
YES >> GO TO 5.
NO >> GO TO 6.
5.CHECK DOOR REQUEST SWITCH
Check outside key antenna and front door request switch (driver side).
Refer to DLK-78, "DRIVER SIDE : Component Inspection".
YES >> GO TO 6.
NO >> Replace front outside handle (driver side). Refer to DLK-282, "OUTSIDE HANDLE : Removal and
Installation".
>> INSPECTION END


Terminal
Outside key antenna and front door request switch Door request switch condition Continuity
(driver side)
Pressed Exists
3 4
Released Does not exist
Installation".
PASSENGER SIDE
DLK-78
DOOR REQUEST SWITCH
A
1.CHECK FUNCTION
With CONSULT-III
B
Check door request switch “AS REQ SW” in “Data Monitor” mode with CONSULT-III.

C
AS REQ SW
NO >> Refer to DLK-81, "BACK DOOR : Diagnosis Procedure".
E
1.CHECK INTELLIGENT KEY UNIT INPUT SIGNAL

F
Terminal G
connector
Terminal H
Pressed 0
M40 25 Ground
Released 5
I
YES >> GO TO 6.
NO >> GO TO 2. J
2.CHECK DOOR REQUEST SWITCH CIRCUIT
2. Check continuity between Intelligent Key unit harness connector and outside key antenna and front door DLK
request switch (passenger side) harness connector.
Outside key antenna and front door L

Terminal request switch (passenger side) Terminal Continuity
connector
connector
M40 25 D69 3 Exists M
Intelligent Key unit N

Terminal Continuity
connector Ground
Is the inspection result normal? O
YES >> GO TO 3.
request switch (passenger side). P
Check continuity between outside key antenna and front door request switch (passenger side) harness con-
nector and ground.
DLK-79
DOOR REQUEST SWITCH
Outside key antenna and front door re-

quest switch (passenger side) Terminal Continuity
connector Ground
D69 4 Exists
YES >> GO TO 4.
NO >> Repair or replace outside key antenna and front door request switch (passenger side) ground cir-
cuit.

Terminal
M40 25 5
YES >> GO TO 5.
NO >> GO TO 6.
Check outside key antenna and front door request switch (passenger side).
Refer to DLK-82, "BACK DOOR : Component Inspection".
YES >> GO TO 6.
NO >> Replace front outside handle (passenger side). Refer to DLK-282, "OUTSIDE HANDLE : Removal
and Installation".
>> INSPECTION END


Terminal
(passenger side)
Pressed Exists
3 4
and Installation".
BACK DOOR
BACK DOOR : Description INFOID:0000000001280465
DLK-80
DOOR REQUEST SWITCH
BACK DOOR : Component Function Check INFOID:0000000001280466
A
1.CHECK FUNCTION
With CONSULT-III
B
Check door request switch “BD/TR REQ SW” in “Data Monitor” mode with CONSULT-III.

C
BD/TR REQ SW
BACK DOOR : Diagnosis Procedure INFOID:0000000001280467
E

F
Terminal G
connector
Terminal H
Pressed 0
M40 29 Ground
Released 5
I
YES >> GO TO 6.
NO >> GO TO 2. J
2. Check continuity between Intelligent Key unit harness connector and back door opener switch assembly DLK
(request switch) harness connector.
Intelligent Key unit Back door opener switch L

connector (request switch) connector
M40 29 D186 3 Exists
3. Check continuity between Intelligent Key unit harness connector and ground. M

Terminal Continuity
connector Ground N
O
YES >> GO TO 3.
NO >> Repair or replace harness between Intelligent Key unit and back door opener switch assembly
(request switch).
3.CHECK DOOR REQUEST SWITCH GROUND CIRCUIT P
Check continuity between back door opener switch assembly request switch harness connector and ground.
Back door opener switch assembly

(request switch) Terminal Continuity
connector Ground
D186 4 Exists
DLK-81
DOOR REQUEST SWITCH
YES >> GO TO 4.
NO >> Repair or replace back door opener switch assembly (request switch) ground circuit.

Terminal
M40 29 5
YES >> GO TO 5.
NO >> GO TO 6.
Check back door opener switch assembly (request switch).
YES >> GO TO 6.
NO >> Replace back door opener switch assembly (request switch). Refer to DLK-299, "Removal and
Installation".
>> INSPECTION END

BACK DOOR : Component Inspection INFOID:0000000001280468

Terminal
Door request switch condition Continuity
Back door opener switch assembly (request switch)
Pressed Exists
3 4
YES >> Back door request switch is OK.
Installation".
DLK-82
DOOR SWITCH
DOOR SWITCH
A
DRIVER SIDE
B
Detects door open/closed condition.
C
1.CHECK FUNCTION
With CONSULT-III D
Check door switches “DOOR SW-DR” in “Data Monitor” mode with CONSULT-III.
Monitor item Condition E

OPEN :ON
DOOR SW-DR
CLOSE :OFF
YES >> Front door switch (driver side) is OK.
G
1.CHECK DOOR SWITCH INPUT SIGNAL H

2. Check signal between BCM harness connector and ground with oscilloscope.
I
Terminals
(+) Voltage (V)
Door condition
(–) (Approx.)
BCM J
Terminal
connector
OPEN 0
DLK
M65 15 Ground
CLOSE L
JPMIA0011GB M
YES >> GO TO 4.
NO >> GO TO 2. N
2.CHECK DOOR SWITCH CIRCUIT

1. Disconnect BCM connector and front door switch (driver side) connector. O
2. Check continuity between BCM harness connector and front door switch (driver side) harness connector.
Front door switch

P
BCM connector Terminal (driver side) Terminal Continuity
connector
M65 15 B34 2 Exists
DLK-83
DOOR SWITCH

Ground
YES >> GO TO 3.
NO >> Repair or replace harness between BCM and door switch.
3.CHECK DOOR SWITCH
Check front door switch (driver side).
YES >> GO TO 4.
NO >> Replace front door switch (driver side). Refer to DLK-292, "Removal and Installation".
>> INSPECTION END

1.CHECK DOOR SWITCH

Terminal
Door switch condition Continuity
front door switch (driver side)
Pressed Exists
2 Ground part of door switch
PASSENGER SIDE

1.CHECK FUNCTION
With CONSULT-III
Check door switches “DOOR SW-AS” in “Data Monitor” mode with CONSULT-III.

OPEN : ON
DOOR SW-AS
CLOSE : OFF
YES >> Front door switch (passenger side) is OK.
NO >> Refer to DLK-84, "PASSENGER SIDE : Diagnosis Procedure".
1.CHECK DOOR SWITCH INPUT SIGNAL

DLK-84
DOOR SWITCH
A
Terminals
(+) Voltage (V)
Door condition
(–) (Approx.) B
BCM
Terminal
connector
OPEN 0
C
M65 14 Ground D
CLOSE
JPMIA0011GB
E

YES >> GO TO 4. F
NO >> GO TO 2.
1. Disconnect BCM connector and front door switch (passenger side) connector. G
2. Check continuity between BCM harness connector and front door switch (passenger side) harness con-
nector.
H
Front door switch
BCM connector Terminal (passenger side) Terminal Continuity
connector
I
M65 14 B27 2 Exists
J
Ground
Is the inspection result normal? DLK
YES >> GO TO 3.
3.CHECK DOOR SWITCH L
Check front door switch (passenger side).

Refer to DLK-85, "PASSENGER SIDE : Component Inspection".
M
YES >> GO TO 4.
NO >> Replace front door switch (passenger side). Refer to DLK-292, "Removal and Installation".
N
O
>> INSPECTION END
P
1.CHECK DOOR SWITCH

DLK-85
DOOR SWITCH
Terminal
Front door switch (passenger side)
Pressed Exists
REAR LH
REAR LH : Description INFOID:0000000001280477

REAR LH : Component Function Check INFOID:0000000001280478
1.CHECK FUNCTION
With CONSULT-III
Check door switches “DOOR SW-RL” in “Data Monitor” mode with CONSULT-III.

OPEN :ON
DOOR SW-RL
CLOSE :OFF
YES >> Rear door switch LH is OK.
NO >> Refer to DLK-86, "REAR LH : Diagnosis Procedure".
REAR LH : Diagnosis Procedure INFOID:0000000001280479

Terminals
(+) Voltage (V)
Door condition
(–) (Approx.)
BCM
Terminal
connector
OPEN 0
M65 16 Ground
CLOSE
JPMIA0011GB

YES >> GO TO 4.
NO >> GO TO 2.
1. Disconnect BCM connector and rear door switch LH connector.
2. Check continuity between BCM harness connector and rear door switch LH harness connector.
DLK-86
DOOR SWITCH
Rear door switch LH A

connector
M65 16 B71 2 Exists
3. Check continuity between BCM harness connector and ground. B

Ground
M65 16 Does not exist C
YES >> GO TO 3.
NO >> Repair or replace harness between BCM and rear door switch LH. D
3.CHECK DOOR SWITCH

Check rear door switch LH. E
Refer to DLK-87, "REAR LH : Component Inspection".
YES >> GO TO 4. F
NO >> Replace rear door switch LH. Refer to DLK-292, "Removal and Installation".
G
>> INSPECTION END H

REAR LH : Component Inspection INFOID:0000000001280480
1.CHECK DOOR SWITCH I

Check rear door switch LH.
Terminal J
Rear door switch LH
Pressed Exists
2 Ground part of door switch DLK
YES >> Rear door switch LH is OK. L
REAR RH
M
REAR RH : Description INFOID:0000000001280481
Detects door open/close condition.

N
REAR RH : Component Function Check INFOID:0000000001280482
1.CHECK FUNCTION O
With CONSULT-III
Check door switches “DOOR SW-RR” in “Data Monitor” mode with CONSULT-III.
P
OPEN :ON
DOOR SW-RR
CLOSE :OFF
YES >> Rear door switch RH is OK.
NO >> Refer to DLK-88, "REAR RH : Diagnosis Procedure".
DLK-87
DOOR SWITCH
REAR RH : Diagnosis Procedure INFOID:0000000001280483

2. Check signal between BCM connector and ground with oscilloscope.
Terminals
(+) Voltage (V)
Door condition
(–) (Approx.)
BCM
Terminal
connector
OPEN 0
M65 12 Ground
CLOSE
JPMIA0011GB

YES >> GO TO 4.
NO >> GO TO 2.
1. Disconnect BCM connector and rear door switch RH connector.
2. Check continuity between BCM harness connector and rear door switch RH harness connector.
Rear door switch RH

connector
M65 12 B53 2 Exists

Ground
YES >> GO TO 3.
3.CHECK DOOR SWITCH
Check rear door switch RH.
Refer to DLK-88, "REAR RH : Component Inspection".
YES >> GO TO 4.
NO >> Replace rear door switch RH. Refer to DLK-290, "DOOR LOCK : Removal and Installation".
>> INSPECTION END

REAR RH : Component Inspection INFOID:0000000001280484
1.CHECK DOOR SWITCH

DLK-88
DOOR SWITCH
Terminal A
Rear door switch RH
Pressed Exists
2 Ground part of door switch B
YES >> Rear door switch RH is OK. C
NO >> Replace rear door switch RH. Refer to DLK-290, "DOOR LOCK : Removal and Installation".
BACK DOOR
D
Detects back door open condition.

E
1.CHECK FUNCTION F
With CONSULT-III
Check “BACK DOOR SW” in “Data Monitor” mode with CONSULT-III.
G
OPEN : ON
BACK DOOR SW
CLOSE : OFF H
YES >> Back door lock assembly (door switch) is OK.
NO >> Refer to DLK-89, "BACK DOOR : Diagnosis Procedure". I
J
1.CHECK BACK DOOR LOCK ASSEMBLY (DOOR SWITCH) INPUT SIGNAL
2. Check voltage between BCM harness connector and ground. DLK
Terminals
Back door Voltage (V)
(+)
condition (Approx.) L
(–)
BCM connector Terminal
OPEN 0
M65 13 Ground M
CLOSE Battery voltage
YES >> GO TO 6. N
NO >> GO TO 2.
2.CHECK BACK DOOR LOCK ASSEMBLY (DOOR SWITCH) CIRCUIT
1. Disconnect BCM connector back door lock assembly connector. O
2. Check continuity between BCM harness connector and back door lock assembly (door switch) harness
connector.
P
Back door lock assembly
(door switch) connector
DLK-89
DOOR SWITCH

Ground
YES >> GO TO 3.
NO >> Repair or replace harness between BCM and back door lock assembly (door switch).
3.CHECK BACK DOOR LOCK ASSEMBLY GROUND CIRCUIT
Check continuity between back door lock assembly harness connector and ground.

Terminal Continuity
(door switch) connector Ground
D190 3 Exists
YES >> GO TO 4.
NO >> Repair or replace back door lock assembly ground circuit.
Terminals
Voltage (V)
(+)
(–) (Approx.)
YES >> GO TO 5.
NO >> GO TO 6.
5.CHECK BACK DOOR LOCK ASSEMBLY (DOOR SWITCH)
Check back door lock assembly (door switch).
YES >> GO TO 6.
NO >> Replace back door lock assembly (door switch). Refer to DLK-290, "DOOR LOCK : Removal and
Installation".
>> INSPECTION END


Terminal
Back door condition Continuity
Back door lock assembly (door switch)
OPEN Exists
2 1
CLOSE Does not exist
NO >> Replace back door lock assembly. Refer to DLK-290, "DOOR LOCK : Removal and Installation".
DLK-90
KEY SWITCH
KEY SWITCH
A
Key switch detects that mechanical key is inserted into the key cylinder, and then transmits the signal to BCM B
and Intelligent Key unit.
1.CHECK KEY SWITCH INPUT SIGNAL

Check key switch (“KEY SW”) in “Data Monitor” mode with CONSULT-III. D

Insert mechanical key into key cylinder : ON
E
KEY SW
Remove mechanical key from key cylinder : OFF
YES >> Key switch is OK.
G

H
2. Disconnect Intelligent Key unit connector and BCM connector.
I
Terminals
(+) Voltage (V)
Condition
Intelligent Key unit con- (–) (Approx.) J
Terminal
nector
Insert mechanical key into key
Battery voltage DLK
cylinder
M40 7 Ground
Remove mechanical key from
0
key cylinder
4. Check voltage between BCM harness connector and ground. L
Terminals
(+) Condition
Voltage (V) M
(–) (Approx.)
Battery voltage N
cylinder
M65 5 Ground
0
key cylinder
O
YES >> GO TO 5.
NO >> GO TO 2. P
2.CHECK KEY SWITCH POWER SUPPLY CIRCUIT
1. Remove mechanical key from key cylinder.
2. Disconnect ignition knob switch, key switch and key lock solenoid connector.
3. Check voltage between ignition knob switch, key switch and key lock solenoid harness connector and
ground.
DLK-91
KEY SWITCH
Terminals
(+) Voltage (V)
(–) (Approx.)
Ignition knob switch, key switch and key
Terminal
lock solenoid connector
YES >> GO TO 3.
3.CHECK KEY SWITCH SIGNAL CIRCUIT
1. Check continuity between Intelligent Key unit harness connector and ignition knob switch, key switch and
key lock solenoid harness connector.
Ignition knob switch, key

Intelligent Key unit connector Terminal switch and key lock solenoid Terminal Continuity
connector
M40 7 M25 1 Exists
2. Check continuity between BCM harness connector and ignition knob switch, key switch and key lock sole-
noid harness connector.
Ignition knob switch, key switch

and key lock solenoid connector
M65 5 M25 1 Exists
3. Check continuity between ignition knob switch, key switch and key lock solenoid harness connector and
ground.
Ignition knob switch, key switch and

Terminal Ground Continuity
key lock solenoid connector
M25 1 Ground Does not exist
YES >> GO TO 4.
4.CHECK KEY SWITCH
Check key switch.
yes >> GO TO 5.
NO >> Replace key cylinder assembly.
>> INSPECTION END

COMPONENT INSPECTION
1.CHECK KEY SWITCH
Check continuity between ignition knob switch, key switch and key lock solenoid terminals.
Terminal
Ignition knob switch, key switch and key lock solenoid
DLK-92
KEY SWITCH
Insert mechanical key into key cylinder Exists
1 2 A
Remove mechanical key from key cylinder Does not exist
YES >> Key switch is OK. B
DLK
DLK-93
IGNITION KNOB SWITCH
Ignition knob switch detects that ignition knob is pressed, and then transmits the signal to Intelligent Key unit.
1.CHECK IGNITION KNOB SWITCH INPUT SIGNAL

Check ignition knob switch (“PUSH SW”) in “Data Monitor” mode with CONSULT-III.

Ignition knob switch is pressed : ON
PUSH SW
Ignition knob switch is released : OFF
YES >> Ignition knob switch is OK.

Terminals
(+) Voltage (V)
Condition
(–) (Approx.)
Intelligent Key unit con-
Terminal
nector
Ignition knob switch is pressed Battery voltage
M40 27 Ground
Ignition knob switch is released 0
YES >> GO TO 5.
NO >> GO TO 2.
2.CHECK IGNITION KNOB SWITCH POWER SUPPLY CIRCUIT
ground.
Terminals
(+) Voltage (V)
(–) (Approx.)
Terminal
YES >> GO TO 3.
3.CHECK IGNITION KNOB SWITCH SIGNAL CIRCUIT
DLK-94
Ignition knob switch, key A

connector
M40 27 M25 3 Exists
B
2. Check continuity between ignition knob switch, key switch and key lock solenoid connector and ground.
Ignition knob switch, key C

switch and key lock solenoid Terminal Continuity
connector Ground

D
YES >> GO TO 4.
NO >> Repair or replace harness. E
4.CHECK IGNITION KNOB SWITCH
Check ignition knob switch.
Refer to DLK-95, "Component Inspection". F
YES >> GO TO 5.
NO >> Replace ignition knob switch, key switch and key lock solenoid. G
Refer to GI-39, "Intermittent Incident". H
>> INSPECTION END

I
1.CHECK IGNITION KNOB SWITCH J

Check continuity between ignition knob switch, key switch and key lock solenoid terminals under the following
conditions.
DLK
Ignition knob switch, key switch and key lock so-
lenoid Condition Continuity
Terminal
L
Ignition knob switch is pressed Exists
3 4
Ignition knob switch is released Does not exist
YES >> Ignition knob switch, key switch and key lock solenoid is OK.
NO >> Replace ignition knob switch, key switch and key lock solenoid.
N
DLK-95
DOOR LOCK ACTUATOR
DOOR LOCK ACTUATOR
DRIVER SIDE
Locks/unlocks the door with the signal from BCM.

1.CHECK FUNCTION
With CONSULT-III
Check “DOOR LOCK/UNLOCK” in “Active Test” mode with CONSULT-III.
Test item Condition

:ALL UNLK The all door lock actuators are unlocked
DOOR LOCK/UNLOCK :DR UNLK The door lock actuator (driver side) is unlocked
:LOCK The all door lock actuators are locked
YES >> Front door lock actuator (driver side) is OK.

Terminals
Condition of door lock Voltage (V)
(+)
(–) and unlock switch (Approx.)
56 Lock 0 → Battery voltage → 0
M67 Ground
60 Unlock 0 → Battery voltage → 0
YES >> GO TO 6.
NO >> GO TO 2.
2.CHECK DOOR LOCK ACTUATOR CIRCUIT 1
1. Disconnect BCM connector and front door lock actuator (driver side) connector.
2. Check continuity between BCM harness connector and front door lock actuator (driver side) harness con-
nector.
Front door lock actuator (driv-

BCM connector Terminal er side) Terminal Continuity
connector
56 1
M67 D29 Exists
60 2

56 Ground
M67 Does not exist
60
YES >> GO TO 6.
DLK-96
DOOR LOCK ACTUATOR
NO >> GO TO 3.
3.CHECK DOOR LOCK ACTUATOR CIRCUIT 2 A
1. Disconnect passenger side anti-hijack relay connector.

2. Check continuity between BCM harness connector and passenger side anti-hijack relay harness connec-
B
tor.
Passenger side anti-hijack re-

BCM connector Terminal lay Terminal Continuity C
connector
M67 56 M90 3 Exists
3. Check continuity between BCM harness connector and ground. D

Ground
M67 56 Does not exist E

YES >> GO TO 4.
F
Check passenger side anti-hijack relay. G
Passenger side relay connector Terminal Continuity

M90 3 4 Exists H
YES >> GO TO 5.
NO >> Repair or replace harness. I

1. Check continuity between passenger side anti-hijack relay harness connector and front door lock actuator J
(driver side) harness connector.
Passenger side anti-hijack Front door lock actuator

Terminal Terminal Continuity DLK
relay connector (driver side) connector
M90 4 D29 1 Exists
2. Check continuity between passenger side anti-hijack relay harness connector and ground. L
Passenger side anti-hijack relay connector Terminal Continuity

Ground
M90 4 Does not exist M
YES >> GO TO 6.
NO >> Repair or replace harness. N
Refer to GI-39, "Intermittent Incident". O
>> INSPECTION END

PASSENGER SIDE P
DLK-97
DOOR LOCK ACTUATOR
1.CHECK FUNCTION
With CONSULT-III
Test item Condition

DOOR LOCK/UNLOCK :AS UNLK The door lock actuator (passenger side) is locked
YES >> Front door lock actuator (passenger side) is OK.

Terminals
(+)
M67 Ground
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK DOOR LOCK ACTUATOR CIRCUIT
1. Disconnect BCM connector and front door lock actuator (passenger side) connector.
2. Check continuity between BCM harness connector and front door lock actuator (passenger side) harness
connector.
Front door lock actuator

(passenger side) connector
56 2
M67 D68 Exists
54 1

56 Ground
M67 Does not exist
54

YES >> GO TO 3.
>> INSPECTION END
DLK-98
DOOR LOCK ACTUATOR
REAR LH
A
Locks/unlocks the door with the signal from BCM. B

1.CHECK FUNCTION C
With CONSULT-III
D
Test item Condition
DOOR LOCK/UNLOCK E
YES >> Rear door lock actuator LH is OK. F
G
2. Check voltage between BCM harness connector and ground. H
Terminals
Condition of door lock Voltage (V) I
(+)
M67 Ground J
YES >> GO TO 6. DLK
NO >> GO TO 2.
L
1. Disconnect BCM connector and rear door lock actuator LH connector.
2. Check continuity between BCM harness connector and rear door lock actuator LH harness connector.
Rear door lock actuator LH M

connector
56 1
M67 D115 Exists N
54 2
O
56 Ground
M67 Does not exist
54 P
YES >> GO TO 6.
NO >> GO TO 3.
DLK-99
DOOR LOCK ACTUATOR
tor.

BCM connector Terminal lay Terminal Continuity
connector
M67 56 M90 3 Exists

Ground
YES >> GO TO 4.
Check passenger side anti-hijack relay.

M90 3 4 Exists
YES >> GO TO 5.
1. Check continuity between passenger side anti-hijack relay harness connector and rear door lock actuator
LH harness connector.
Passenger side anti-hijack

Rear door lock actuator LH
relay Terminal Terminal Continuity
connector
connector
M90 4 D115 1 Exists
2. Check continuity between passenger side anti-hijack relay harness connector and ground.
Passenger side anti-hijack relay

Terminal Continuity
connector Ground
YES >> GO TO 6.
>> INSPECTION END

REAR RH

1.CHECK FUNCTION
With CONSULT-III
DLK-100
DOOR LOCK ACTUATOR
A
Test item Condition
DOOR LOCK/UNLOCK
:LOCK The all door lock actuators are locked B
YES >> Door lock actuator is OK.
C
D
2. Check voltage between BCM harness connector and ground. E
Terminals
(+)
and unlock switch (Approx.)
F
(–)
M67 Ground G
YES >> GO TO 6. H
NO >> GO TO 2.
1. Turn ignition switch OFF. I
2. Disconnect BCM connector and rear door lock actuator RH connector.
3. Check continuity between BCM harness connector and rear door lock actuator RH harness connector.
J
Rear door lock actuator RH
connector
56 2 DLK
M67 D95 Exists
54 1
L
56 Ground
M67 Does not exist M
54
YES >> GO TO 6. N
NO >> GO TO 3.
1. Disconnect passenger side anti-hijack relay. O
tor.
P
Anti-hijack relay
connector
M67 56 M90 3 Exists
DLK-101
DOOR LOCK ACTUATOR

Ground
YES >> GO TO 4.
Anti-hijack relay
Terminal Continuity
connector
M90 4 3 Exists
YES >> GO TO 5.
RH harness connector.
Passenger side anti-hijack relay Rear door lock actuator RH

connector connector
M90 3 D95 3 Exists

Terminal Continuity
connector Ground
YES >> GO TO 6.
>> INSPECTION END
DLK-102
BACK DOOR OPENER ACTUATOR
A
Opens the back door with the signal from BCM. B

1.CHECK FUNCTION C
With CONSULT-III
Check “TRUNK/GLASS HATCH” in “Active Test” mode with CONSULT-III.
D
Test item Condition
TRUNK/GLASS HATCH :OPEN Back door opener actuator operation
E
YES >> Back door opener actuator is OK.
F
1.CHECK BCM OUTPUT SIGNAL G

Check voltage between BCM harness connector and ground.
Terminals H
Condition of back door Voltage (V)
(+)
(–) opener switch (Approx.)
I
M66 45 Ground Pressed 0 → Battery voltage → 0
YES >> GO TO 4. J
NO >> GO TO 2.
2.CHECK BACK DOOR LOCK ASSEMBLY CIRCUIT
DLK
2. Disconnect BCM connector and back door lock assembly connector.
3. Check continuity between BCM harness connector and back door lock assembly harness connector.
L
connector
BCM connector Terminal Continuity N

Ground
O
YES >> GO TO 3.
3.CHECK BACK DOOR LOCK ASSEMBLY GROUND CIRCUIT P

Terminal Continuity
connector Ground
D190 3 Exists
DLK-103
YES >> GO TO 4.
>> INSPECTION END
DLK-104
FUEL LID OPENER ACTUATOR
A
Locks/unlocks the fuel lid with the signal from BCM. B

1.CHECK FUNCTION C
With CONSULT-III
D
Test item Condition
:ALL UNLK The fuel lid opener actuator are unlocked
E
DOOR LOCK/UNLOCK :DR UNLK The fuel lid opener actuator is unlocked
:LOCK The fuel lid opener actuator are locked
YES >> Fuel lid opener actuator is OK.
G
1.CHECK BCM OUTPUT SIGNAL H

Terminals
I
(+)
BCM connector Terminal J
M67 Ground
YES >> GO TO 6.
NO >> GO TO 2.
L
2.CHECK FUEL LID OPENER ACTUATOR CIRCUIT 1
1. Disconnect BCM connector and fuel lid opener actuator connector.
2. Check continuity between BCM harness connector and fuel lid opener actuator harness connector. M
Fuel lid opener actuator

connector
N
56 2
M67 B58 Exists
60 1
3. Check continuity between BCM harness connector and ground. O

56 Ground P
M67 Does not exist
60
YES >> GO TO 6.
NO >> GO TO 3.
DLK-105
2. Check continuity between BCM harness connector and passenger side anti-hijack relay connector.

connector
M67 56 M90 3 Exists

Ground
YES >> GO TO 4.
Check passenger side of anti-hijack relay.

Terminal Continuity
lay connector
M90 3 4 Exists
YES >> GO TO 5.
1. Check continuity between passenger side anti-hijack relay harness connector and fuel lid opener actuator
harness connector.

connector
connector
M90 4 B58 2 Exists

lay Terminal Continuity
connector Ground

YES >> GO TO 6.
>> INSPECTION END
DLK-106
A
Sends the back door opening signal to BCM. B

1.CHECK FUNCTION C
With CONSULT-III
Check “TRNK OPNR SW” in “Data Monitor” mode with CONSULT-III.
D
Back door opener switch is pressed :ON
TRNK OPNR SW E
Back door opener switch is released :OFF
YES >> Back door opener switch is OK. F
G
1.CHECK BCM INPUT SIGNAL
H
Terminals
(+)
(–) opener switch (Approx.) I
Pressed 0
M65 29 Ground
Released Battery voltage J
YES >> GO TO 5.
NO >> GO TO 2. DLK
2.CHECK BACK DOOR OPENER SWITCH CIRCUIT
1. Turn ignition switch OFF. L
2. Disconnect BCM connector and back door opener switch assembly (opener switch) connector.
3. Check continuity between BCM harness connector and back door opener switch assembly (opener
switch) harness connector.
M
Back door opener switch
assembly
(opener switch) N
connector
4. Check continuity between BCM harness connector and ground. O

Ground
M65 29 Does not exist P
YES >> GO TO 3.
DLK-107
Terminals
Voltage (V)
(+)
(–) (Approx.)
YES >> GO TO 4.
NO >> GO TO 6.
4.CHECK BACK DOOR OPENER SWITCH GROUND CIRCUIT
Check continuity between back door opener switch assembly (opener switch) connector and ground.

Terminal Continuity
(opener switch) connector Ground
D186 2 Exists
YES >> GO TO 5.
5.CHECK BACK DOOR OPENER SWITCH
Check back door opener switch assembly (opener switch).
YES >> GO TO 6.
NO >> Replace back door opener switch assembly. Refer to DLK-300, "Removal and Installation".
>> INSPECTION END



Terminal Back door opener switch condition Continuity
(opener switch)
Pressed Exists
D186 1 2
YES >> Back door opener switch assembly (opener switch) is OK.
DLK-108
OUTSIDE KEY ANTENNA
OUTSIDE KEY ANTENNA
A
DRIVER SIDE
B
Detects whether Intelligent Key is outside the vehicle.
Integrated in front outside handle (driver side).
C
1.CHECK OUTSIDE KEY ANTENNA INPUT SIGNAL D
With CONSULT-III
1. Check “ANTENNA” in “Active Test” mode with CONSULT-III.
2. Touch “DRIVER ANT”. E
3. When Intelligent Key is in outside key antenna (driver side) detection area, LED (on Intelligent Key) blinks.
Test Item Outside Antenna F

ANTENNA :DRIVER ANT Outside key antenna (driver side)
G
YES >> Outside key antenna (driver side) is OK.
DRIVER SIDE : Diagnosis Procedure INFOID:0000000001280524 H
1.CHECK OUTSIDE KEY ANTENNA INPUT SIGNAL 1

2. Check signal between Intelligent Key unit harness connector and ground with oscilloscope.
DLK
DLK-109
OUTSIDE KEY ANTENNA
Terminals
(+) Signal
Condition
Terminal
connector
When Intelligent Key

is in the antenna de-
tection area.
JMKIA0397ZZ
Driver side
19
(+)

is not in the antenna
detection area.
JMKIA0514ZZ
Request switch
M40 Ground
is pressed

tection area.
JMKIA0395ZZ
Driver side
20
(-)

detection area.
JMKIA0515ZZ

YES >> GO TO 4.
NO >> GO TO 2.
2.CHECK OUTSIDE KEY ANTENNA CIRCUIT
1. Disconnect Intelligent Key unit connector and outside key antenna and front door request switch (driver
side) connector.
Outside key antenna and front

Terminal door request switch (driver side) Terminal Continuity
connector
connector
19 1
M40 D30 Exists
20 2
3. Check continuity between Intelligent Key unit connector and ground.
DLK-110
OUTSIDE KEY ANTENNA
Intelligent Key unit A

Terminal Continuity
connector
Ground
19
M40 Does not exist
20 B
YES >> GO TO 3.
NO >> Repair or replace harness between Intelligent Key unit and outside key antenna (driver side). C
1. Replace outside key antenna. (New antenna or other antenna) D
2. Connect Intelligent Key unit connector and outside key antenna connector.
E
Terminals
(+) Signal
Condition
Intelligent Key unit F
Terminal
connector
G
tection area. H
JMKIA0397ZZ
Driver side Door request switch

19 I
(+) is pressed
When Intelligent Key J

detection area.
DLK
JMKIA0514ZZ
M40 Ground
L

is in the antenna de- M
tection area.
JMKIA0395ZZ
N
20
(-) is pressed
O
detection area. P
JMKIA0515ZZ

YES >> Replace outside key antenna and front door request switch (driver side). Refer to DLK-296,
"DRIVER SIDE : Removal and Installation".
NO >> GO TO 4.
DLK-111
OUTSIDE KEY ANTENNA

>> INSPECTION END

PASSENGER SIDE

Integrated in front outside handle (passenger side).
1.CHECK OUTSIDE KEY ANTENNA INPUT SIGNAL

With CONSULT-III
2. Touch “ASSIST ANT”.
3. When Intelligent Key is in outside key antenna (passenger side) detection area, LED (on Intelligent Key)
blinks.
Test Item Outside Antenna

ANTENNA :ASSIST ANT Outside key antenna (passenger side)
YES >> Outside key antenna (passenger side) is OK.

DLK-112
OUTSIDE KEY ANTENNA
Terminals A
(+) Signal
Condition
Terminal
connector B
C
tection area.
D
JMKIA0397ZZ
Passenger side
37
(+) E
When Intelligent Key F

detection area.
JMKIA0514ZZ G
Request switch
M40 Ground
is pressed
H

tection area. I
JMKIA0395ZZ
Passenger side J
38
(-)
DLK
detection area.
L
JMKIA0515ZZ

YES >> GO TO 4.
NO >> GO TO 2.
2.CHECK OUTSIDE KEY ANTENNA CIRCUIT N
1. Disconnect Intelligent Key unit connector and outside key antenna and front door request switch (passen-
ger side) connector.
2. Check continuity between Intelligent Key unit harness connector and outside key antenna and front door O
Outside key antenna and front P

Terminal door request switch (passenger Terminal Continuity
connector
side) connector
37 1
M40 D69 Exists
38 2
DLK-113
OUTSIDE KEY ANTENNA

Terminal Continuity
connector
Ground
37
M40 Does not exist
38
YES >> GO TO 3.
request switch (passenger side).
1. Replace outside key antenna. (New antenna or other antenna)
Terminal
(+) Signal
Condition
Terminal
connector
When Intelligent
Key is in the anten-
na detection area.
JMKIA0514ZZ
Passenger side 37
(+)
When Intelligent
Key is not in the
antenna detection
area.
JMKIA0514ZZ
Door request switch

M40 Ground
is pressed
When Intelligent
na detection area.
JMKIA0395ZZ
Passenger side 38
(-)
When Intelligent
Key is not in the
antenna detection
area.
JMKIA0515ZZ

YES >> Replace outside key antenna and front door request switch (passenger side). Refer to DLK-296,
"PASSENGER SIDE : Removal and Installation".
DLK-114
OUTSIDE KEY ANTENNA
NO >> GO TO 4.
4.CHECK INTERMITTENT INCIDENT A

B
>> INSPECTION END
BACK DOOR
C

Installed in rear bumper. D

E
With CONSULT-III F
2. Touch “BK DOOR ANT”.
3. When Intelligent Key is in outside key antenna (rear bumper) detection area, LED (on Intelligent Key)
blinks. G

ANTENNA :BK DOOR ANT Outside key antenna (rear bumper)
H

YES >> Outside key antenna (back door) is OK. I
J
2. Check signal between Intelligent Key unit harness connector and ground with oscilloscope. DLK
DLK-115
OUTSIDE KEY ANTENNA
Terminal
(+) Signal
Condition
Terminal
connector

tection area.
JMKIA0397ZZ
Rear bumper
17
(+)

detection area.
JMKIA0514ZZ
Request switch
M40 Ground
is pressed

tection area.
JMKIA0395ZZ
Rear bumper
18
(-)

detection area.
JMKIA0515ZZ

YES >> GO TO 4.
NO >> GO TO 2.
1. Disconnect Intelligent Key unit connector and outside key antenna (back door) connector.
2. Check continuity between Intelligent Key unit harness connector and outside key antenna (back door)
harness connector.
Intelligent Key unit Outside key antenna (back door)

connector connector
17 1
M40 D191 Exists
18 2
DLK-116
OUTSIDE KEY ANTENNA

Terminal Continuity
connector
Ground
17
M40 Does not exist
18 B
YES >> GO TO 3.
NO >> Repair or replace harness between Intelligent Key unit and outside key antenna (back door). C
1. Replace outside key antenna. (New antenna or other antenna) D
2. Connect Intelligent Key unit connector and outside key antenna (back door) connector.
E
Terminal
(+) Signal
Condition
Terminal
connector
G
When Intelligent
Key is in the an-
tenna detection
area. H
JMKIA0514ZZ
Rear bumper
17 I
(+)
When Intelligent J
Key is not in the
antenna detection
area.
DLK
JMKIA0514ZZ
Door request switch

M40 Ground
is pressed
L
When Intelligent
Key is in the an-
M
tenna detection
area.
JMKIA0395ZZ
N
Rear bumper
18
(-)
O
When Intelligent
Key is not in the
antenna detection
area. P
JMKIA0515ZZ

YES >> Replace outside key antenna (back door). Refer to DLK-296, "BACK DOOR : Removal and Instal-
lation".
NO >> GO TO 4.
DLK-117
OUTSIDE KEY ANTENNA

>> INSPECTION END
DLK-118
INSIDE KEY ANTENNA
INSIDE KEY ANTENNA
A
INSTRUMENT CENTER
INSTRUMENT CENTER : Description INFOID:0000000001280531
B
Detects whether Intelligent Key is inside the vehicle.
INSTRUMENT CENTER : Component Function Check INFOID:0000000001280532

C
1.CHECK INSIDE KEY ANTENNA INPUT SIGNAL

D
With CONSULT-III
2. Touch “ROOM ANT 2”.
3. When Intelligent Key is in inside key antenna (instrument center) detection area, LED (on Intelligent Key) E
blinks.
Test Item Inside Antenna F

ANTENNA :ROOM ANT 2 Inside key antenna (instrument center)
G
YES >> Inside key antenna (instrument center) is OK.
NO >> Refer to DLK-119, "INSTRUMENT CENTER : Diagnosis Procedure".
INSTRUMENT CENTER : Diagnosis Procedure INFOID:0000000001280533 H
1.CHECK INSIDE KEY ANTENNA INPUT SIGNAL 1

DLK
DLK-119
INSIDE KEY ANTENNA
Terminals
(+) Signal
Condition
Terminal
connector

tection area.
JMKIA0393ZZ
Instrument
center 33
(+)

detection area.
JMKIA0391ZZ
• All doors are
closed
M40 Ground
• Ignition knob
switch is pressed

tection area.
JMKIA0392ZZ
Instrument
center 34
(-)

detection area.
JMKIA0390ZZ

YES >> GO TO 4.
NO >> GO TO 2.
2.CHECK INSIDE KEY ANTENNA CIRCUIT
1. Disconnect Intelligent Key unit connector and inside key antenna (instrument center) connector.
2. Check continuity between Intelligent Key unit harness connector and inside key antenna (instrument cen-
ter) harness connector.
Intelligent Key unit Inside key antenna

connector (instrument center) connector
33 1
M40 M56 Exists
34 2
DLK-120
INSIDE KEY ANTENNA

Terminal Continuity
connector
Ground
33
M40 Does not exist
34 B
YES >> GO TO 3.
NO >> Repair or replace harness between Intelligent Key unit and inside key antenna (instrument cen- C
ter).
3.CHECK INSIDE KEY ANTENNA INPUT SIGNAL 2 D
1. Replace inside key antenna. (New antenna or other antenna)
2. Connect Intelligent Key unit connector and inside key antenna (instrument center) connector.
E
Terminals
(+) Signal
Condition F
Terminal
connector
When Intelligent Key is

in the antenna detec- H
tion area.
JMKIA0393ZZ
Instrument I
center 33
(+)
J
not in the antenna de-
tection area. DLK
• All doors are JMKIA0391ZZ
closed
M40 Ground
• Ignition knob
L
switch is pressed
When Intelligent Key is M

in the antenna detec-
tion area.
N
JMKIA0392ZZ
Instrument
center 34
(-)
O

not in the antenna de- P
tection area.
JMKIA0390ZZ

YES >> Replace inside key antenna (instrument center). Refer to DLK-293, "INSTRUMENT CENTER :
DLK-121
INSIDE KEY ANTENNA
NO >> GO TO 4.
>> INSPECTION END

CONSOLE
CONSOLE : Description INFOID:0000000001280534

CONSOLE : Component Function Check INFOID:0000000001280535

With CONSULT-III
3. When Intelligent Key is in inside key antenna (console) detection area, LED (on Intelligent Key) blinks.
Test Item Inside Antenna

ANTENNA :ROOM ANT 1 Inside key antenna (console)
YES >> Inside key antenna (console) is OK.
NO >> Refer to DLK-122, "CONSOLE : Diagnosis Procedure".
CONSOLE : Diagnosis Procedure INFOID:0000000001280536

DLK-122
INSIDE KEY ANTENNA
Terminal A
(+) Signal
Condition
Terminal
connector B
C
tection area.
D
JMKIA0393ZZ
Console
15
(+) E

detection area.
• All doors are JMKIA0391ZZ G

closed
M40 Ground
• Ignition knob
switch is pressed H

tection area. I
JMKIA0392ZZ
Console J
16
(-)
DLK
detection area.
L
JMKIA0390ZZ

YES >> GO TO 4.
NO >> GO TO 2.
2.CHECK INSIDE KEY ANTENNA CIRCUIT N
1. Disconnect Intelligent Key unit connector and inside key antenna (console) connector.
2. Check continuity between Intelligent Key unit harness connector and inside key antenna (console) har-
ness connector. O
Intelligent Key unit Inside key antenna (console)

connector connector P
15 1
M40 M252 Exists
16 2
DLK-123
INSIDE KEY ANTENNA
Intelligent Key unit connector Terminal Continuity

15 Ground
M40 Does not exist
16
YES >> GO TO 3.
NO >> Repair or replace harness between Intelligent Key unit and inside key antenna (console).
2. Connect Intelligent Key unit connector and inside key antenna (console) connector.
Terminal
(+) Signal
Condition
Terminal
connector

tion area.
JMKIA0393ZZ
Console
15
(+)

tection area.
JMKIA0391ZZ
• All doors are
closed
M40 Ground
• Ignition knob
switch is pressed

tion area.
JMKIA0392ZZ
Console
16
(-)

tection area.
JMKIA0390ZZ

YES >> Replace inside key antenna (console). Refer to DLK-294, "CONSOLE : Removal and Installation".
NO >> GO TO 4.
DLK-124
INSIDE KEY ANTENNA
A
>> INSPECTION END
REAR SEAT
B
REAR SEAT : Description INFOID:0000000001280537
Detects whether Intelligent Key is inside the vehicle. C

REAR SEAT : Component Function Check INFOID:0000000001280538
1.CHECK INSIDE KEY ANTENNA INPUT SIGNAL D

With CONSULT-III
2. Touch “ROOM ANT 2”. E
3. When Intelligent Key is in inside key antenna (rear seat) detection area, LED (on Intelligent Key) blinks.
Test Item Inside Antenna F

ANTENNA :ROOM ANT 2 Inside key antenna (rear seat)
G
YES >> Inside key antenna (rear seat) is OK.
NO >> Refer to DLK-125, "REAR SEAT : Diagnosis Procedure".
REAR SEAT : Diagnosis Procedure INFOID:0000000001280539 H

DLK
DLK-125
INSIDE KEY ANTENNA
Terminal
(+) Signal
Condition
Terminal
connector

tection area.
JMKIA0393ZZ
Rear seat
(+) 13

detection area.
JMKIA0391ZZ
• All doors are
closed
M40 Ground
• Ignition knob
switch is pressed

tection area.
JMKIA0392ZZ
Rear seat
(-) 14

detection area.
JMKIA0390ZZ

YES >> GO TO 4.
NO >> GO TO 2.
1. Disconnect Intelligent Key unit connector and inside key antenna (rear seat) connector.
2. Check continuity between Intelligent Key unit harness connector and inside key antenna (rear seat) har-
ness connector.
Intelligent Key unit Inside key antenna (rear seat)

connector connector
13 1
M40 B45 Exists
14 2
DLK-126
INSIDE KEY ANTENNA

Terminal Continuity
connector
Ground
13
M40 Does not exist
14 B
YES >> GO TO 3.
NO >> Repair or replace harness between Intelligent Key unit and inside key antenna (rear seat). C
1. Replace inside key antenna. (New antenna or other antenna) D
2. Connect Intelligent Key unit connector and inside key antenna (rear seat) connector.
E
Terminal
(+) Signal
Condition
Terminal
connector
G
tion area. H
JMKIA0393ZZ
Rear seat
13 I
(+)
When Intelligent Key is J

tection area.
DLK
JMKIA0391ZZ
• All doors are
closed
M40 Ground
• Ignition knob
switch is pressed L

in the antenna detec- M
tion area.
JMKIA0392ZZ
N
Rear seat
14
(-)
O
tection area. P
JMKIA0390ZZ

YES >> Replace inside key antenna (rear seat). Refer to DLK-295, "REAR : Removal and Installation".
NO >> GO TO 4.
DLK-127
INSIDE KEY ANTENNA

>> INSPECTION END
DLK-128
ANTI-HIJACK RELAY
ANTI-HIJACK RELAY
A
PASSENGER SIDE
B
Receives anti-hijack signal from Intelligent Key unit.
C
1.CHECK FUNCTION
1. All doors are locked using Intelligent Key or door request switch. D
2. Press door request switch (passenger side), only passenger side door is UNLOCK.
YES >> Anti-hijack relay is OK. E
F
1.CHECK INTELLIGENT KEY UNIT INPUT SIGNAL 1
Check voltage between Intelligent Key unit harness connector and ground.
G
Terminal
(+) Voltage (V)
Condition H
(–) (Approx.)
Terminal
connector
M40 11 Ground Ignition switch OFF Battery voltage
I
YES >> GO TO 2.
NO >> GO TO 6. J
DLK
Terminal
(+) Voltage (V)
Condition L
(–) (Approx.)
Terminal
connector
Press front door Battery voltage → 0 → Battery

Anti-hijack operation M
M40 40 Ground request switch voltage
(passenger side) Other than above Battery voltage
Is the inspection result normal? N
YES >> GO TO 3.
NO >> GO TO 4.
3.CHECK INTELLIGENT KEY UNIT GROUND CIRCUIT O

Terminal Continuity
P
connector Ground
M40 12 Exists
YES >> GO TO 5.
DLK-129
ANTI-HIJACK RELAY
4.CHECK PASSENGER SIDE ANTI-HIJACK RELAY GROUND CIRCUIT

2. Disconnect passenger side anti-hijack relay connector and Intelligent Key unit connector.
3. Check voltage between passenger side anti-hijack relay harness connector and ground.
Terminal
(+) Voltage (V)
Condition
(–) (Approx.)
Terminal
connector
4. Check continuity between passenger side anti-hijack relay harness connector and Intelligent Key unit con-
nector.
Passenger side anti-hijack relay Intelligent Key unit

connector connector
M90 1 M40 40 Exists

Ground
YES >> GO TO 5.
NO >> GO TO 6.
5.CHECK PASSENGER SIDE ANTI-HIJACK RELAY
YES >> GO TO 6.
NO >> Replace passenger side anti-hijack relay. Refer to DLK-28, "DOOR LOCK AND UNLOCK
SWITCH : Component Parts Location".
>> INSPECTION END

1.CHECK ANTI-HIJACK RELAY

Check continuity passenger side anti-hijack relay terminals.

Terminal Condition Continuity
relay connector
Battery voltage direct current
Does not exist
M90 4 3 supply between terminals 1 and 2
Other than above Exists
YES >> Passenger side anti-hijack relay is OK.
DLK-130
INTELLIGENT KEY WARNING BUZZER
A
Answers back and warns about an inappropriate operation. B

1.CHECK FUNCTION C
With CONSULT-III
Check Intelligent Key warning buzzer “OUTSIDE BUZZER” in “Active Test” mode with CONSULT-III.
D
YES >> Intelligent Key warning buzzer is OK.
E
1.CHECK INTELLIGENT KEY UNIT INPUT SIGNAL 1 F

Terminal G
(+) Warning buzzer Voltage (V)
(–) operation condition (Approx.)
Terminal H
connector
Sounding 0
M40 4 Ground
Not sounding Battery voltage
I
YES >> GO TO 5.
NO >> GO TO 2. J
2.CHECK INTELLIGENT KEY WARNING BUZZER POWER SUPPLY CIRCUIT
2. Disconnect Intelligent Key warning buzzer connector. DLK
3. Check voltage between Intelligent Key warning buzzer harness connector and ground.
Terminal L
(+) Voltage (V)
(–) (Approx.)
Intelligent Key warning buzzer
Terminal
connector M
N
YES >> GO TO 3.
NO >> Repair or replace Intelligent Key warning buzzer power supply circuit.
3.CHECK HARNESS CONTINUITY O
2. Check continuity between Intelligent Key warning buzzer harness connector and Intelligent Key unit har-
ness connector. P
Intelligent Key warning buzzer Intelligent Key unit
connector connector
E25 3 M40 4 Exists
3. Check continuity between Intelligent Key warning buzzer harness connector and ground.
DLK-131

Terminal Continuity
connector Ground
E25 3 Does not exist
YES >> GO TO 4.
NO >> Repair or replace harness between Intelligent Key warning buzzer and Intelligent Key unit.
4.CHECK INTELLIGENT KEY WARNING BUZZER
Check Intelligent Key warning buzzer.
YES >> GO TO 5.
NO >> Replace Intelligent Key warning buzzer. Refer to DLK-298, "Removal and Installation".
>> INSPECTION END


Connect battery power supply to Intelligent Key warning buzzer terminals 1 and 3, and check the operation.
Intelligent Key warning buzzer Terminal Operation

connector (+) (-)
Buzzer sounds
E25 1 3
DLK-132
BUZZER (COMBINATION METER)
A
Performs operation method guide and warning with buzzer. B

1.CHECK FUNCTION C
With CONSULT-III
Check the operation with “INSIDE BUZZER” in “Active Test” with CONSULT-III.
D
Test item Condition
:TAKE OUT Take away warning chime sounds
E
INSIDE BUZZER :KNOB Ignition knob switch warning chime sounds
:KEY Key warning chime sounds
Yes >> Warning buzzer in combination meter is OK.
No >> Refer to DLK-133, "Diagnosis Procedure".
G
1.CHECK BUZZER (COMBINATION METER) CIRCUIT H

Refer to DLK-133, "Component Function Check".
Yes >> GO TO 2. I
No >> Repair or replace buzzer (combination meter) circuit.
Refer to GI-39, "Intermittent Incident". J
>> INSPECTION END

DLK
DLK-133
KEY WARNING LAMP
KEY WARNING LAMP
Performs operation method guide and warning together with buzzer.

1.CHECK FUNCTION
With CONSULT-III
Check the operation with “INDICATOR” in “Active Test” mode with CONSULT-III.
Test item Condition

:BLUE ON Key warning lamp (green) illuminates
:RED ON Key warning lamp (red) illuminates
INDICATOR
:BLUE IND Key warning lamp (green) flashes
:RED IND Key warning lamp (red) flashes
Yes >> Key warning lamp in combination meter is OK.
1.CHECK KEY WARNING LAMP CIRCUIT

Refer toDLK-134, "Component Function Check" .
Yes >> GO TO 2.
No >> Repair or replace key warning lamp circuit.
>> INSPECTION END
DLK-134
LOCK WARNING LAMP
LOCK WARNING LAMP
A
Performs operation method guide and warning together with buzzer. B

1.CHECK FUNCTION C
With CONSULT-III
D
Test item Condition
:KNOB ON Lock warning lamp illuminates
INDICATOR E
:KNOB IND Lock warning lamp flashes
Yes >> Lock warning lamp in combination meter is OK. F
G
1.CHECK LOCK WARNING LAMP CIRCUIT
H
Yes >> GO TO 2.
No >> Repair or replace lock warning lamp circuit.
I
J
>> INSPECTION END
DLK
DLK-135
HAZARD WARNING LAMPS
Performs answer-back for each operation with the number of blinks.

1.CHECK FUNCTION
With CONSULT-III
Check hazard warning lamp “FLASHER” in “Active Test” mode with CONSULT-III.
YES >> Hazard warning lamp circuit is OK.
1.CHECK HAZARD SWITCH CIRCUIT

Check hazard switch circuit.
YES >> GO TO 2.
NO >> Repair or replace hazard warning switch circuit.
>> INSPECTION END
DLK-136
VEHICLE SPEED SIGNAL CIRCUIT
A
Displays the vehicle speed signal received from combination meter as a numerical value (km/h). B
1.CHECK FUNCTION C
Check that all doors are automatically locked at the vehicle speed of more than 25 km/h (16 MPH).
D
YES >> Vehicle speed signal circuit is OK.
Diagnosis Procedure INFOID:0000000001280562 E
1.CHECK VEHICLE SPEED SIGNAL CIRCUIT

Check vehicle speed signal “VEHICLE SPEED” in “Data Monitor” mode with CONSULT-III. F
YES >> GO TO 2.
NO >> Repair or replace vehicle speed signal circuit. G
>> INSPECTION END

I
DLK
DLK-137
INTELLIGENT KEY BATTERY
The following functions are available when having and carrying electronic ID.
• Door lock and unlock
• Engine start
Remote control entry function and panic alarm function are available when operating the button.
1.CHECK INTELLIGENT KEY FUNCTION

Does door lock and unlock operate when operating Intelligent Key switch?
YES >> Intelligent Key is OK.
1.CHECK INTELLIGENT KEY BATTERY

Check by connecting a resistance (approximately 300Ω) so that the
current value becomes about 10 mA.
Standard : Approx. 2.5 - 3.0V

Is the measurement value within the specification?
YES >> Replace Intelligent Key.
NO >> Replace Intelligent Key battery. Refer to DLK-138,
"Component Function Check".
OCC0607D
DLK-138
< ECU DIAGNOSIS > [WITH I-KEY, WITHOUT SUPER LOCK]
ECU DIAGNOSIS A
B

CONSULT-III MONITOR ITEM C
Release OFF
PUSH SW Ignition knob D
Press ON
Removed OFF
KEY ON SW Mechanical key
Inserted ON
E
Door request switch Release OFF
DR REQ SW
(driver) Press ON
Door request switch Release OFF F

AS REQ SW
(passenger) Press ON

BD/TR REQ SW G
(back door) Press ON
Other than ON position OFF
IGN SW Ignition switch
ON position ON H
Other than ACC or ON position OFF
ACC SW Ignition switch
ACC or ON position ON
I
Press OFF
STOP LAMP SW Brake pedal
Release ON
Lock button of Release OFF J

DOOR LOCK SIG
Intelligent Key Press ON
Unlock button of Release OFF

DOOR UNLOCK SIG DLK
Close OFF
DOOR SW DR Door (driver side)
Open ON L
Close OFF
DOOR SW AS Door (passenger side)
Open ON
Close OFF M
DOOR SW RR Door (rear RH)
Open ON
Close OFF
DOOR SW RL Door (rear LH) N
Open ON
Close OFF
DOOR BK SW Back door
Open ON O
DLK-139
TERMINAL LAYOUT
JMKIA0415ZZ
PHYSICAL VALUES

Wire Value [V]
Input/ Condition
+ – color Signal name (Approx.)
Output
Steering lock unit
1 Ground LG Output — 5
power supply
Input/
2 Ground L CAN - H — —
Output
Input/
3 Ground P CAN - L — —
Output
Intelligent Sounding 0
Intelligent Key warn-
4 Ground LG Output Key warning
ing buzzer Not sounding Battery voltage
buzzer
Front door ON (Pressed) 0
Front door request
request
5 Ground P switch Input
switch OFF (Released) 5
(driver side)
(driver side)
Ignition switch pow- Ignition OFF or ACC 0

6 Ground W Input
er supply switch ON or START Battery voltage
When ignition key is inserted into ig-
Battery voltage
nition key cylinder
7 Ground V Key switch Input
When ignition key is not inserted into
0
ignition key cylinder
Battery power sup-
11 Ground V Input Ignition switch OFF Battery voltage
ply
12 Ground B Ground — Ignition switch ON 0

tection area
JMKIA0393ZZ
Inside key antenna Ignition knob

13 Ground Y Output
(+) (rear seat) is pressed.

detection area
JMKIA0391ZZ
DLK-140
Wire Value [V] A
Input/ Condition
Output

is in the antenna de- C
tection area
JMKIA0392ZZ

D
14 Ground W Output
(-) (rear seat) is pressed.
E
detection area
F
JMKIA0390ZZ
When Intelligent Key H

tection area
JMKIA0393ZZ
I
15 Ground SB Output
(+) (console) is pressed.
J

DLK
detection area
JMKIA0391ZZ
L
M
tection area
N
JMKIA0392ZZ

16 Ground BR Output
(-) (console) is pressed. O
When Intelligent Key P

detection area
JMKIA0390ZZ
DLK-141
Wire Value [V]
Input/ Condition
Output

tection area
When the JMKIA0397ZZ

back door re-
Outside key antenna
17 Ground SB Output quest switch
(+) (rear bumper)
is operated
with ignition
switch OFF
detection area
JMKIA0514ZZ

tection area

back door re-
Outside key antenna
18 Ground V Output quest switch
(-) (rear bumper)
is operated
with ignition
switch OFF
detection area
JMKIA0515ZZ

tection area
When the
front door re- JMKIA0397ZZ
quest switch
Outside key antenna
19 Ground L Output (driver side)
(+) (driver side)
is operated
with ignition
switch OFF
detection area
JMKIA0514ZZ
DLK-142
Wire Value [V] A
Input/ Condition
Output

tection area
When the
Outside key antenna

quest switch D
20 Ground BR Output (driver side)
(-) (driver side)
is operated
with ignition
switch OFF E
detection area
F
JMKIA0515ZZ
G
Key lock so- LOCK*2 Battery voltage
*1 Ground W Key lock solenoid Output
22 lenoid
UNLOCK*2 0
Front door ON (Pressed) 0 H
Front door request request
25 Ground BR switch Input switch
(passenger side) (passenger OFF (Released) 5
side) I
Depress the brake pedal Battery voltage
26 Ground R Stop lamp switch Input
Release the brake pedal 0
J
When ignition knob
Battery voltage
Ignition switch is pressed
27 Ground L Ignition knob switch Input
switch OFF When ignition knob
0 DLK
switch is released
Lock (ON) 5
28 Ground O Unlock sensor Input
Unlock (OFF) 0 L
Back door request Back door re- ON (Pressed) 0
29 Ground GR Input
switch quest switch OFF (Released) 5
Steering lock unit M
31 Ground GR — — — 0
ground
LOCK status 5
N
Steering lock unit Input/ O

32 Ground P Steering lock
communication Output LOCK or UNLOCK
JMKIA0433ZZ
P
DLK-143
Wire Value [V]
Input/ Condition
Output

tection area
JMKIA0393ZZ
Inside key antenna
Ignition knob
33 Ground O (+) Output
is pressed.
(instrument center)

detection area
JMKIA0391ZZ

tection area
JMKIA0392ZZ
Inside key antenna
Ignition knob
34 Ground G (-) Output
is pressed.
(instrument center)

detection area
JMKIA0390ZZ

tection area
When the
front door re-
JMKIA0397ZZ
quest switch
Outside key antenna (passenger
37 Ground L Output
(+) (passenger side) side) is oper-
ated with ig-
nition switch
OFF
tection area
JMKIA0514ZZ
DLK-144
Wire Value [V] A
Input/ Condition
Output

tection area
When the
front door re-
quest switch JMKIA0395ZZ

D
38 Ground O Output
(-) (passenger side) side) is oper-
ated with ig-
nition switch E
OFF
detection area
F
JMKIA0515ZZ
Press front Battery voltage → 0 → Battery G

Anti-hijack operation
Passenger side anti- door request voltage
40 Ground Y Input
hijack relay switch (pas-
senger side) Other than above Battery voltage
H
*1: Only for MT model.
*2
: Key interlock operation is only for M/T model for operation condition, refer to SEC-16, "System Description".
I
DLK
DLK-145
Wiring Diagram - POWER DOOR LOCK CONTROL SYSTEM - INFOID:0000000001280577
JCKWA0345GB
DLK-146
DLK
JCKWA0346GB
DLK-147
JCKWA0347GB
DLK-148
DLK
JCKWA0348GB
DLK-149
JCKWA0349GB
DLK-150
DLK
JCKWA0350GB
DLK-151
JCKWA0351GB
DLK-152
DLK
JCKWA0352GB
DLK-153
Wiring Diagram - INTELLIGENT KEY CONTROL SYSTEM - INFOID:0000000001280578
JCKWA0377GB
DLK-154
DLK
JCKWA0378GB
DLK-155
JCKWA0379GB
DLK-156
DLK
JCKWA0380GB
DLK-157
JCKWA0381GB
DLK-158
DLK
JCKWA0382GB
DLK-159
JCKWA0383GB
DLK-160
DLK
JCKWA0384GB
DLK-161
JCKWA0385GB
DLK-162
DLK
JCKWA0386GB
DLK-163
JCKWA0387GB
DLK-164
DLK
JCKWA0388GB
DLK-165
Wiring Diagram - BACK DOOR OPENER CONTROL SYSTEM - INFOID:0000000001280579
JCKWA0409GB
DLK-166
DLK
JCKWA0410GB
DLK-167
JCKWA0411GB
DLK-168
Display contents of CONSULT-III Fail-safe Cancellation

B2013: STRG COMM 1 • Inhibits steering look unlocking Erase DTC B
• Inhibits steering look unlocking
B2552: INTELLIGENT KEY (BCM) Erase DTC C
• Fuel cut
(ECM)
D
B2590: NATS MALFUNCTION (BCM) Erase DTC
• Fuel cut
(ECM) E
If some DTCs are displayed at the same time, perform inspections one by one based on the following priority F
chart.
Priority DTC G
1 • U1010: CONTROL UNIT (CAN)
• B2552: INTELIGENT KEY
H
• B2013: STRG COMM 1
2
• B2590: NATS MALFUNCTION

I
NOTE:
Details of time display J
• CRNT: Displays when there is a malfunction now or after returning to the normal condition until turning igni-
DLK
→ 2 → 3...38 → 39 after returning to the normal condition whenever ignition switch OFF → ON. The counter
L
CONSULT display Detection condition Fail-safe Diagnosis
No DTC is detected.
further testing — — — M
may be required.
Check CAN communica-
Intelligent Key unit cannot receive CAN communi-
U1000: CAN COMM CIRCUIT — tion system.
cation signal continuously for 2 seconds or more. N
Refer to DLK-70
Intelligent Key unit detects internal CAN communi- Replace Intelligent Key
U1010: CONTROL UNIT (CAN) —
cation circuit malfunction. unit.
O
The ID verification result between Intelligent key unit Perform steering lock
B2013: STRG COMM 1 and steering lock unit are NG. Or Intelligent Key unit × unit ID registration with
cannot communicate with steering lock unit. CONSULT-III
Replace Intelligent Key P
B2552: INTELLIGENT KEY Intelligent Key unit internal malfunction. ×
unit.
The ID verification result between Intelligent key unit
Check NATS
B2590: ID DISCORD BCM-I-KEY and BCM are NG. Or Intelligent Key unit cannot ×
Refer to SEC-57
communicate with BCM.
DLK-169

IGN ON SW
KEY ON SW
CDL LOCK SW
CDL UNLOCK SW
DOOR SW-DR
DOOR SW-AS
DOOR SW-RR
DOOR SW-RL
BACK DOOR SW
Back door opened On
Off
I-KEY LOCK pressed
Off
pressed
I-KEY UNLOCK
On
pressed
PUSH SW
KEYLESS LOCK
KEYLESS UNLOCK
Off
On
nosis sensor unit
UNLOCK SHOCK
NOTE: On
UNLOCK WITH DR
DLK-170
A
LOCK WITH SPEED
Ignition switch OFF Off B
ACC ON SW
REAR DEF SW
Rear window defogger switch ON On C
TAIL LAMP SW
D
TURN SIGNAL R
Turn signal switch OFF Off E
TURN SIGNAL L
HI BEAM SW F
HEAD LAMP SW 1
Lighting switch 2ND On G
HEAD LAMP SW 2
H
PASSING SW
Lighting switch OFF Off I
AUTO LIGHT SW
FR FOG SW J
RR FOG SW
Rear fog lamp switch ON On DLK
Engine stopped Off
ENGINE RUN
Engine running On
Light & rain sensor is in normal condition OK L
LIT-SEN FAIL
AUT LIGHT SYS M
N
support
IGN SW CAN
Ignition switch ON On O
FR WIPER HI
Front wiper switch OFF Off P
FR WIPER LOW
FR WIPER INT
FR WASHER SW
DLK-171
FR WIPER STOP
RR WIPER ON
RR WIPER INT
RR WIPER STOP
RR WASHER SW
NOTE: Off
REVERSE SW CAN
H/L WASH SW
FAN ON SIG
Off
AIR COND SW
On
HAZARD SW
Hazard switch ON On
BRAKE SW
TRNK OPNR SW
Close the hood
NOTE: Off
Open the hood On
AUTO RELOCK
GLS BREAK SEN
Off
DLK-172
TERMINAL LAYOUT
A
DLK
N
JSMIA0031GB
PHYSICAL VALUES O
CAUTION:
• Turn wiper intermittent dial position to 4 except when checking waveform or voltage of wiper inter- P
Description".
DLK-173

(Wire color) Value
Input/ Condition
+ − Output
(W) Output der
(G) Output der

Ground Input

(SB) Ignition switch ON or ACC Battery voltage
5 Battery voltage
der
*1
Remove mechanical key from ignition key
(R)*2 0V
cylinder
DLK-174
Input/ Condition
+ − Output
All switch OFF

JPMIA0165GB
1.4 V D
E
Lighting switch HI
F
JPMIA0166GB
1.3 V
G

H
Ground Input
JPMIA0167GB
I
1.3 V

DLK
JPMIA0169GB
1.3 V L
Any of the condition below M

with all switch OFF
JPMIA0196GB
1.3 V
O
DLK-175
(Wire color) Value
Input/ Condition
+ − Output
All switch OFF

JPMIA0165GB
1.4 V
Lighting switch 1ST

JPMIA0166GB
1.3 V

Ground Input
JPMIA0168GB
1.3 V

with all switch OFF
JPMIA0169GB
1.3 V
Rear wiper INT

JPMIA0196GB
1.3 V
DLK-176
Input/ Condition
+ − Output
All switch OFF C
JPMIA0165GB
1.4 V D
F
JPMIA0166GB
1.3 V
G
Combination
H
tent dial 4)
JPMIA0167GB
I
1.3 V

DLK
JPMIA0168GB
1.3 V L
N
JPMIA0196GB
1.3 V
O
DLK-177
(Wire color) Value
Input/ Condition
+ − Output
All switch OFF
JPMIA0165GB
1.4 V
Lighting switch 2ND
JPMIA0166GB
1.3 V
9 Combination
(B)*4 tent dial 4)
JPMIA0167GB
1.3 V
JPMIA0168GB
1.3 V
JPMIA0196GB
1.3 V
DLK-178
Input/ Condition
+ − Output
All switch OFF

JPMIA0165GB
1.3 V D
E
F
JPMIA0167GB
1.3 V
G

H
Ground Input
JPMIA0168GB
I
1.3 V

(Wiper intermittent dial 4) DLK
JPMIA0169GB
1.3 V L

M
with all switch OFF
JPMIA0196GB
1.3 V
11 Input/ O
(B) Output
DLK-179
(Wire color) Value
Input/ Condition
+ − Output
OFF
(When rear door RH
(LG) switch RH
PKID0924E
11.2 V
ON
opened)
OFF
(V) switch
PKID0924E
11.2 V
ON
0V
OFF
14
(P)*3 Ground Input
switch switch
(BR)*4 PKID0924E
11.2 V
ON
opened)
OFF
Driver door
*4
switch
(P) PKID0924E
11.2 V
ON
opened)
DLK-180
Input/ Condition
+ − Output
OFF
(When rear door LH C
(GR) switch LH
PKID0924E
11.2 V D
ON
opened) E
Ground Output
F
G
Ground Input
H
JPMIA0154GB
1.1 V
While pressing 0V
I
21 Input/
— CAN-L — —
(P) Output
22 Input/
(L)
— CAN-H
Output
— — J
ON 0V
DLK
23 Security indica- L
(V) tor
JPMIA0014GB
M
10.3 V
OFF 12 V
Ignition switch OFF or ACC 12 V N

O
Ground
P
JPMIA0156GB
8.7 V
25
(G)
DLK-181
(Wire color) Value
Input/ Condition
+ − Output
26
Blower fan motor Blower fan mo- OFF
(GR)*5 Ground Input
switch tor switch
(LG)*6
PKID0924E
11.2 V

(A/C indicator OFF, blow-
27
*6
ON PKID0924E
(Y) 11.2 V
(A/C indicator ON and 0V
ON).
Ignition switch OFF or ACC 0V
28
Ignition switch ON
(R)*8
JPMIA0155GB
6.0 V
29
Back door opener Back door Not pressed
(LG)*3 Ground Input
(O)*4
JPMIA0154GB
1.2 V
Pressed 0V

Ground
JPMIA0154GB
1.2 V
Pressed to the unlock side 0 V
DLK-182
Input/ Condition
+ − Output
33
OFF C
(Y)*10
JPMIA0154GB
1.3 V D
ON 0V
34
Door lock/unlock Door lock/un- Not pressed F
(SB)*3 Ground
(P)*4
JPMIA0154GB
1.2 V G
35 Headlamp washer Headlamp Not pressed I

Ground
JPMIA0154GB
J
1.2 V
All switch OFF 0V DLK
Lighting switch 2ND
Combination
Lighting switch HI
L
Ground Output
tent dial 4)
Lighting switch 1ST M
JPMIA0164GB
9.1 V
All switch OFF N
0V
O
Ground Output
(R) OUTPUT 2 switch Any of the condition below P
with all switch OFF
9.1 V
DLK-183
(Wire color) Value
Input/ Condition
+ − Output
All switch OFF 0V
Combination
38 Combination switch switch Front wiper switch INT
Ground Output
tent dial 4)
Rear fog lamp switch ON JPMIA0162GB
9.3 V
All switch OFF 0V
Combination
39 Combination switch switch Lighting switch 2ND
Ground Output
tent dial 4)
JPMIA0163GB
9.3 V
All switch OFF
0V
(P) OUTPUT 1 switch
Rear wiper switch INT 9.1 V

(LG) ply

Ground Output


44 Ignition switch
(B) ON
JPMIA0197GB

0V
DLK-184
Input/ Condition
+ − Output

(V)
Ground
ator
Output
opener switch
C
SKIA9232E
D
Not pressed 0V
E
47 Ignition switch
(BR) ON Turn signal switch LH F
PKID0926E G
6.5 V
H
48 Ignition switch
Ground Turn signal RH Output I
PKID0926E J
6.5 V
49 OFF 0V
(Y) ON 12 V DLK
50 Unlock 5V
(G) lock 0V
L
52 Room lamp timer Interior room OFF 12 V M

Ground Output

Ground Output Ignition switch N
O
54 Door lock/un-
(O) lock switch
er's door) P
SKIA9232E
Not pressed 0V
55
(B)
DLK-185
(Wire color) Value
Input/ Condition
+ − Output
Not pressed 0V

Ground Output
(V) fuel lid lock lock switch Pressed to the lock side
SKIA9232E

(Y) ply
(P) er supply (BAT)
0V
59 is not pressed
12 V
is pressed

Ground Output
SKIA9232E
Not pressed 0V
*1: With Intelligent Key
*3: RHD models
*4: LHD models
*7: RHD models with side air bag
*10: Except with xenon headlamp and daytime light system
DLK-186
Wiring Diagram - POWER DOOR LOCK CONTROL SYSTEM - INFOID:0000000001557467
DLK
JCKWA0345GB
P
DLK-187
JCKWA0346GB
DLK-188
DLK
JCKWA0347GB
DLK-189
JCKWA0348GB
DLK-190
DLK
JCKWA0349GB
DLK-191
JCKWA0350GB
DLK-192
DLK
JCKWA0351GB
DLK-193
JCKWA0352GB
DLK-194
DLK
JCKWA0377GB
P
DLK-195
JCKWA0378GB
DLK-196
DLK
JCKWA0379GB
DLK-197
JCKWA0380GB
DLK-198
DLK
JCKWA0381GB
DLK-199
JCKWA0382GB
DLK-200
DLK
JCKWA0383GB
DLK-201
JCKWA0384GB
DLK-202
DLK
JCKWA0385GB
DLK-203
JCKWA0386GB
DLK-204
DLK
JCKWA0387GB
DLK-205
JCKWA0388GB
DLK-206
DLK
P
JCKWA0409GB
DLK-207
JCKWA0410GB
DLK-208
DLK
JCKWA0411GB
P

DLK-209

• Fuel cut (ECM)
• Fuel cut (ECM)
• Fuel cut (ECM)
• Fuel cut (ECM)
• Fuel cut (ECM)

lamp operating.
NOTE:
Fail-safe Control
Priority DTC
1
DLK-210
A
NOTE:
D
254 F
256
G
251
H
253
264 J
265 DLK
DLK-211
DOOR LOCK
< SYMPTOM DIAGNOSIS > [WITH I-KEY, WITHOUT SUPER LOCK]
SYMPTOM DIAGNOSIS
DOOR LOCK
The diagnostics item numbers show the sequence for inspection. Inspection in order from item 1.
Reference
NO. Function Operation condition Symptom Diagnostic Item
page
All doors DLK-214
Driver side DLK-215
Door lock and
1 unlock switch Press door lock and unlock switch. Door does not lock/unlock Passenger side DLK-215
function
Rear LH DLK-216
Rear RH DLK-216
Door does not lock/unlock — DLK-217
Intelligent Key
2 Press Intelligent Key button. Anti-hijack function does not
function — DLK-218
operate
Press driver side door request switch. — DLK-219
Press passenger side door request switch. Door does not lock/unlock — DLK-219
Press back door request switch. — DLK-220
Door request
3
switch function Press driver side door request switch, when
Driver side door DLK-222
all doors are locked. Anti-hijack function does not
Press passenger side door request switch, operate Passenger side
DLK-222
when all doors are locked. door
Lock all doors with door lock and unlock
Key reminder Key reminder function does
4 switch, when Intelligent Key is inside of the — DLK-224
function not operate
vehicle.
Auto door lock Unlock all doors and wait more than 2 min- Auto door lock operation
5 — DLK-225
function utes. does not operate
Vehicle speed
Vehicle speed sensing auto
sensing auto
6 Vehicle speed is more than 25km/h. door lock operation does not — DLK-226
door lock func-
operate
tion
Back door open-
7 Press back door opener switch. Back door does not open — DLK-227
er function
DLK-212
DOOR LOCK
Reference
NO. Function Operation condition Symptom Diagnostic Item
page A
Door is opened under the following condition. Ignition knob return forgotten
— DLK-228
• Ignition knob is OFF or LOCK position. warning does not operate
Driver side door is opened under the follow- B
ing conditions.
Ignition key warning does
• Ignition switch is OFF position. — DLK-229
not operate
• Mechanical key is inserts into ignition key
cylinder.
C
Door is opened under the following condition. Warning lamp DLK-230

• Ignition knob is between ACC and OFF po- OFF position warning does Buzzer
sition or ignition knob is pressed in while not operate D
(Combination DLK-230
ignition switch is in LOCK position. meter)
Door is opened under the following condi-
tions and wait more than 5 seconds. E
Warning lamp DLK-231
• Engine is running.
• Take Intelligent Key out of the vehicle.
Any door open to all door close under the fol- Intelligent Key
DLK-232
F
lowing conditions. Take away warning does not warning buzzer
• Engine is running. operate
• Take Intelligent Key out of the vehicle. Warning lamp DLK-232
G
Take away through window Intelligent Key Buzzer
under the following condition and wait more (Combination DLK-233
than 30 seconds. meter)
8 Warning function • Engine is running. Warning lamp DLK-233 H
Turn ignition switch ON position, when Intel- Intelligent Key low battery
Warning lamp DLK-234
ligent Key battery is low voltage. warning does not operate
I
Press door request switch under the follow-
ing conditions.
• Door is opened.
• Ignition switch is in ACC or OFF position or J
— DLK-235
ignition knob is pressed in LOCK position
or mechanical key is inserts into ignition
key cylinder.
• Intelligent Key is inside vehicle. Door lock operation warning DLK
chime does not operate
Press Intelligent Key button under the follow-
ing conditions.
• Door is opened. L
• Ignition switch is in ACC or OFF position or — DLK-236
ignition knob is pressed in LOCK position
or mechanical key is inserts into ignition
key cylinder. M
Press back door opener switch under the fol-
lowing conditions.
• Door is locked with door lock and unlock Back door open warning
— DLK-237 N
switch. does not operate
• Speed sensing lock or only driver side is
unlocked with anti-hijack function.
Press door request switch or Intelligent Key Buzzer reminder operation O
Hazard and — DLK-238
button. does not operate
9 buzzer reminder
function Press door request switch or Intelligent Key Hazard reminder operation
— DLK-239
button. does not operate P
DLK-213
DOOR DOES NOT LOCK/UNLOCK WITH DOOR LOCK AND UNLOCK SWITCH
DOOR DOES NOT LOCK/UNLOCK WITH DOOR LOCK AND UNLOCK
SWITCH
ALL DOOR
ALL DOOR : Description INFOID:0000000001515568
NOTE:
• Before performing the diagnosis in the following table, check “Work Flow”. Refer to DLK-22, "Work Flow".
• Check that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis, and
check each symptom.
Conditions of Vehicle (Operating Conditions)
• Except driver side, doors are closed.
• Super lock is not in set state.
• Passenger side door is not in anti-hijack state.
• Doors are not locked by Intelligent Key or door request switch.
ALL DOOR : Diagnosis Procedure INFOID:0000000001515569
1.CHECK POWER SUPPLY AND GROUND CIRCUIT

Check power supply and ground circuit.
Refer to DLK-72, "BCM : Diagnosis Procedure" (BCM).
YES >> GO TO 2.
Check Intelligent Key battery.
YES >> GO TO 3.
3.CHECK DOOR SWITCH
Check door switch.
Refer to DLK-84, "PASSENGER SIDE : Component Function Check" (passenger side).
Refer to DLK-86, "REAR LH : Component Function Check" (rear LH).
Refer to DLK-87, "REAR RH : Component Function Check" (rear RH).
Refer to DLK-89, "BACK DOOR : Component Function Check" (back door).
YES >> GO TO 4.
YES >> GO TO 5.
YES >> Check intermittent incident. Refer to GI-39, "Intermittent Incident".
NO >> GO TO 1.
DRIVER SIDE
DLK-214
A
NOTE:
• Check that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis, and B
check each symptom.
• Super lock is not in set state. C
D
1.CHECK DOOR LOCK ACTUATOR

E
Check door lock actuator (driver side).
Refer to DLK-96, "DRIVER SIDE : Component Function Check".
F
YES >> GO TO 2.
2.CONFIRM THE OPERATION G
YES >> Check intermittent incident. Refer to GI-39, "Intermittent Incident". H
NO >> GO TO 1.
PASSENGER SIDE
I
NOTE:
J
check each symptom.
Conditions of Vehicle (Operating Conditions) DLK
• Passenger side door is not in anti-hijack state. L
M
Check door lock actuator (passenger side).
Refer to DLK-98, "PASSENGER SIDE : Component Function Check". N
YES >> GO TO 2.
NO >> Repair or replace the malfunctioning parts. O
Confirm the operation again. P
NO >> GO TO 1.
REAR LH
DLK-215
NOTE:
check each symptom.

Check door lock actuator LH.
Refer to DLK-99, "REAR LH : Component Function Check".
YES >> GO TO 2.
NO >> Repair or replace the malfunctioning parts
NO >> GO TO 1.
REAR RH
NOTE:
check each symptom.

Check door lock actuator RH.
Refer to DLK-100, "REAR RH : Component Function Check".
YES >> GO TO 2.
NO >> GO TO 1.
DLK-216
DOOR DOES NOT LOCK/UNLOCK WITH INTELLIGENT KEY
DOOR DOES NOT LOCK/UNLOCK WITH INTELLIGENT KEY
A
NOTE: B
check each symptom.
Conditions of Vehicle (Operating Conditions) C
• Door lock and unlock switch operations are normal.
• Emergency key is removed from ignition key cylinder.
• All doors are closed. D
• Ignition knob is not pressed.
• No Intelligent keys are inside the vehicle.
Diagnosis Procedure INFOID:0000000001515579 E
1.CHECK POWER SUPPLY AND GROUND CIRCUIT

Check power supply and ground circuit. F
Refer to DLK-72, "INTELLIGENT KEY UNIT : Diagnosis Procedure" (Intelligent Key unit).
YES >> GO TO 2. G
2.CHECK DRIVER SIDE DOOR SWITCH H
Check drive side door switch.
YES >> GO TO 3.
3.CHECK KEY SWITCH J
Check key switch.
YES >> GO TO 4.
L
Refer to DLK-94, "Component Function Check". M
YES >> GO TO 5.
NO >> Repair or replace the malfunctioning parts. N
Refer to DLK-138, "Component Function Check". O
YES >> GO TO 6.
NO >> Repair or replace the malfunctioning parts. P
NO >> GO TO 1.
DLK-217
ANTI-HIJACK FUNCTION DOES NOT OPERATE WITH INTELLIGENT KEY
ANTI-HIJACK FUNCTION DOES NOT OPERATE WITH INTELLIGENT KEY
NOTE:
check each symptom.
• Door lock and unlock switch operations are normal.
• All doors are closed.
• Ignition knob is not pressed.
• No Intelligent Keys are inside the vehicle.
1.CHECK “SELECTIVE UNLOCK FUNCTION” SETTING IN “WORK SUPPORT”

Check “SELECTIVE UNLOCK FUNCTION” setting in “Work Support”.
Refer to DLK-67, "CONSULT-III Function (INTELLIGENT KEY)".
YES >> GO TO 2.
NO >> Set “SELECTIVE UNLOCK FUNCTION” of “Work Support”. Refer to DLK-67, "CONSULT-III
NO >> GO TO 1.
DLK-218
DOOR DOES NOT LOCK/UNLOCK WITH DOOR REQUEST SWITCH
A
DRIVER SIDE
B
NOTE:
• Check that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis, and C
check each symptom.
• Intelligent Key operation is normal.
• “LOCK/UNLOCK BY I-KEY” is ON when setting on CONSULT-III. D
• Ignition switch is in OFF position.
• No Intelligent Keys are inside the vehicle. E
1.CHECK “LOCK/UNLOCK BY I-KEY” SETTING IN “WORK SUPPORT” F

Check “LOCK/UNLOCK BY I-KEY”setting in “Work Support”.
G
YES >> GO TO 2.
NO >> Set “LOCK/UNLOCK BY I-KEY” of “Work Support”. Refer to DLK-67, "CONSULT-III Function
(INTELLIGENT KEY)". H

Check door request switch. I
YES >> GO TO 3. J
3.CHECK OUTSIDE KEY ANTENNA
DLK
Check outside key antenna.
L
YES >> GO TO 4.
4.CONFIRM THE OPERATION M
YES >> Check Intermittent Incident. Refer to GI-39, "Intermittent Incident". N
NO >> GO TO 1.
PASSENGER SIDE
O
NOTE:
• Before performing the diagnosis in the following table, check “Work Flow”. Refer to DLK-22, "Work Flow". P
check each symptom.
• “LOCK/UNLOCK BY I-KEY” is ON when setting on CONSULT-III.
DLK-219

Check door request switch.
Refer to DLK-79, "PASSENGER SIDE : Component Function Check".
YES >> GO TO 2.
YES >> GO TO 3.
YES >> Check Intermittent Incident. Refer to GI-39, "Intermittent Incident".
NO >> GO TO 1.
BACK DOOR
NOTE:
check each symptom.

Check back door request switch.
Refer to DLK-81, "BACK DOOR : Component Function Check".
YES >> GO TO 2.
Refer to DLK-115, "BACK DOOR : Component Function Check".
YES >> GO TO 3.
DLK-220
YES >> Check Intermittent Incident. Refer to GI-39, "Intermittent Incident".
NO >> GO TO 1. A
DLK
DLK-221
ANTI-HIJACK FUNCTION DOES NOT OPERATE WITH DOOR REQUEST
SWITCH
SWITCH
DRIVER SIDE
NOTE:
check each symptom.
1.CHECK “SELECTIVE UNLOCK FUNCTION” SETTING IN “WORK SUPPORT”

Check “SELECTIVE UNLOCK FUNCTION” setting in “Work Support”.
YES >> GO TO 2.
NO >> Set “SELECTIVE UNLOCK FUNCTION” of “Work Support”. Refer to DLK-67, "CONSULT-III
NO >> GO TO 1.
PASSENGER SIDE
NOTE:
check each symptom.

YES >> GO TO 2.
DLK-222
SWITCH
YES >> Check intermittent incident. Refer to GI-39, "Intermittent Incident". A
NO >> GO TO 1.
DLK
DLK-223
KEY REMINDER FUNCTION DOES NOT OPERATE
KEY REMINDER FUNCTION DOES NOT OPERATE
NOTE:
• Understand the operation when does it work, refer to DLK-37, "KEY REMINDER : System Description".
check each symptom.
• Request switch operation and door lock and unlock switch operation are normal.
1.CHECK DOOR SWITCH

Check door switch.
Refer to DLK-83, "DRIVER SIDE : Component Function Check". (Driver side)
Refer to DLK-84, "PASSENGER SIDE : Component Function Check". (Passenger side)
Refer to DLK-86, "REAR LH : Component Function Check". (Rear LH)
Refer to DLK-87, "REAR RH : Component Function Check". (Rear RH)
Refer to DLK-89, "BACK DOOR : Component Function Check". (Back door)
YES >> GO TO 2.
2.CHECK INSIDE KEY ANTENNA
Check inside key antenna.
Refer to DLK-119, "INSTRUMENT CENTER : Component Function Check". (Instrument center)
Refer to DLK-122, "CONSOLE : Component Function Check". (Console)
Refer to DLK-125, "REAR SEAT : Component Function Check". (Rear seat)
YES >> GO TO 3.
NO >> GO TO 1.
DLK-224
AUTO DOOR LOCK OPERATION DOES NOT OPERATE
AUTO DOOR LOCK OPERATION DOES NOT OPERATE
A
NOTE: B
• “AUTO RELOCK TIMER” is not OFF when setting on CONSULT-III.
check each symptom. C
• Understand the operation when does it work, refer to DLK-40, "AUTO DOOR LOCK : System Description".
• Request switch operation and door lock and unlock switch operation are normal. D
1.CHECK “AUTO RELOCK TIMER” SETTING IN “WORK SUPPORT” E
Check “AUTO RELOCK TIMER” setting in “Work Support”.

F
YES >> GO TO 2.
G
Is the result normal? H
NO >> GO TO 1.
I
DLK
DLK-225
VEHICLE SPEED SENSING AUTO LOCK OPERATION DOES NOT OPERATE
VEHICLE SPEED SENSING AUTO LOCK OPERATION DOES NOT OPER-
ATE
NOTE:
• Understand the operation when does it work, refer to DLK-43, "VEHICLE SPEED SENSING AUTO DOOR
LOCK : System Description".
check each symptom.
• Request switch operation and door lock and unlock switch operation are normal.
1.CHECK VEHICLE SPEED SIGNAL

Check vehicle speed signal.
YES >> GO TO 2.
NO >> GO TO 1.
DLK-226
BACK DOOR DOES NOT OPENED
BACK DOOR DOES NOT OPENED
A
NOTE: B
check each symptom.
• Door lock function is normal.
• Vehicle speed is less than 5 km/h (3MPH).
• All doors are unlocked. D
1.CHECK BACK DOOR OPENER SWITCH E
Check back door opener switch.

F
YES >> GO TO 2.
G
2.CHECK BACK DOOR OPENER ACTUATOR
Check back door opener actuator.
Refer to DLK-103, "Component Function Check". H
YES >> GO TO 3.
NO >> Repair or replace the malfunctioning parts. I
J
NO >> GO TO 1. DLK
DLK-227
IGNITION KNOB RETURN FORGOTTEN WARNING DOES NOT OPERATE
IGNITION KNOB RETURN FORGOTTEN WARNING DOES NOT OPERATE
NOTE:
check each symptom.
• Warning chime functions operating condition is extremely complicated, during operating confirmations,
reconfirm the list above twice in order to ensure proper operation. Refer to DLK-54, "System Description".
1.CHECK BUZZER (COMBINATION METER)

Check buzzer (combination meter).
YES >> GO TO 2.
NO >> GO TO 1.
DLK-228
IGNITION KEY WARNING DOES NOT OPERATE
IGNITION KEY WARNING DOES NOT OPERATE
A
NOTE: B
check each symptom.
• Door lock function is normal. D
1.CHECK BUZZER (COMBINATION METER) E

F
YES >> GO TO 2.
G
NO >> GO TO 1.
I
DLK
DLK-229
OFF POSITION WARNING DOES NOT OPERATE
OFF POSITION WARNING DOES NOT OPERATE
WARNING LAMP
WARNING LAMP : Description INFOID:0000000001515604
NOTE:
check each symptom.
WARNING LAMP : Diagnosis Procedure INFOID:0000000001515605

YES >> GO TO 2.
NO >> GO TO 1.
BUZZER (COMBINATION METER) : Description INFOID:0000000001515606
NOTE:
check each symptom.
BUZZER (COMBINATION METER) : Diagnosis Procedure INFOID:0000000001515607

YES >> GO TO 2.
NO >> GO TO 1.
DLK-230
TAKE AWAY WARNING DOES NOT OPERATE (DOOR IS OPENED)
TAKE AWAY WARNING DOES NOT OPERATE (DOOR IS OPENED)
A
WARNING LAMP
B
NOTE:
check each symptom.
reconfirm the list above twice in order to ensure proper operation. Refer to DLK-54, "System Description". D
E
1.CHECK KEY WARNING LAMP
Check KEY warning lamp. F
YES >> GO TO 2. G
Confirm the operation again. H
NO >> GO TO 1. I
DLK
DLK-231
TAKE AWAY WARNING DOES NOT OPERATE (ANY DOOR OPEN TO ALL
DOORS CLOSE)
TAKE AWAY WARNING DOES NOT OPERATE (ANY DOOR OPEN TO ALL
DOORS CLOSE)
WARNING LAMP
NOTE:
check each symptom.

Check KEY warning lamp.
YES >> GO TO 2.
NO >> GO TO 1.
INTELLIGENT KEY WARNING BUZZER : Description INFOID:0000000001515614
NOTE:
check each symptom.
INTELLIGENT KEY WARNING BUZZER : Diagnosis Procedure INFOID:0000000001515615

YES >> GO TO 2.
NO >> GO TO 1.
DLK-232
TAKE AWAY WARNING DOES NOT OPERATE (TAKE AWAY THROUGH WIN-
DOW)
TAKE AWAY WARNING DOES NOT OPERATE (TAKE AWAY THROUGH
A
WINDOW)
WARNING LAMP
B
NOTE:
• Before performing the diagnosis in the following table, check “Work Flow”. Refer to DLK-22, "Work Flow". C
check each symptom.
Conditions of Vehicle (Operating Conditions) D
E
1.CHECK KEY WARNING LAMP F

YES >> GO TO 2.
2.CONFIRM THE OPERATION H

Is the result normal? I
NO >> GO TO 1.
BUZZER (COMBINATION METER) J
BUZZER (COMBINATION METER) : Description INFOID:0000000001515620
NOTE: DLK
check each symptom. L
• Door lock function is normal. M
BUZZER (COMBINATION METER) : Diagnosis Procedure INFOID:0000000001515621
N
Refer to DLK-133, "Component Function Check". O
YES >> GO TO 2.
NO >> Repair or replace the malfunctioning parts. P
NO >> GO TO 1.
DLK-233
INTELLIGENT KEY LOW BATTERY WARNING DOES NOT OPERATE
INTELLIGENT KEY LOW BATTERY WARNING DOES NOT OPERATE
NOTE:
check each symptom.
1.CHECK “LOW BATT OF KEY FOB WARN” SETTING IN “WORK SUPPORT”

Check “LOW BATT OF KEY FOB WARN” setting in “Work Support”.
YES >> GO TO 2.
NO >> Set “LOW BATT OF KEY FOB WARN” setting in “Work Support”. Refer to DLK-67, "CONSULT-III
YES >> GO TO 3.
YES >> GO TO 4.
NO >> GO TO 1.
DLK-234
DOOR LOCK OPERATION WARNING CHIME DOES NOT OPERATE WITH
DOOR REQUEST SWITCH
A
DOOR REQUEST SWITCH
B
NOTE:
check each symptom.
reconfirm the list above twice in order to ensure proper operation. Refer to DLK-54, "System Description". D
E

Check Intelligent Key warning buzzer. F
YES >> GO TO 2. G
H
I
NO >> GO TO 1.
DLK
DLK-235
DOOR LOCK OPERATION WARNING CHIME DOES NOT OPERATE WITH IN-
TELLIGENT KEY
INTELLIGENT KEY
NOTE:
check each symptom.

YES >> GO TO 2.
NO >> GO TO 1.
DLK-236
BACK DOOR OPEN WARNING DOES NOT OPERATE
BACK DOOR OPEN WARNING DOES NOT OPERATE
A
NOTE: B
check each symptom.
• Door lock function and back door opener function is normal.
D
Check buzzer (combination meter). E
YES >> GO TO 2. F
Confirm the operation again. G
NO >> GO TO 1. H
DLK
DLK-237
BUZZER REMINDER OPERATION DOES NOT OPERATE
BUZZER REMINDER OPERATION DOES NOT OPERATE
NOTE:
check each symptom.
• “ANSWER BACK WITH I-KEY LOCK”, “ANSWER BACK WITH I-KEY UNLOCK” and “ANSWER BACK
FUNCTION” are ON when setting on CONSULT-III.
1.CHECK SETTING OF BUZZER REMINDER WITH CONSULT-III

Check “ANSWER BACK WITH I-KEY LOCK” and “ANSWER BACK WITH I-KEY UNLOCK” setting in “Work
Support”.
YES >> GO TO 2.
NO >> Set “ANSWER BACK WITH I-KEY LOCK” and “ANSWER BACK WITH I-KEY UNLOCK” setting in
“WORK SUPPORT”. Refer to DLK-67, "CONSULT-III Function (INTELLIGENT KEY)".
NO >> GO TO 1.
DLK-238
HAZARD REMINDER OPERATION DOES NOT OPERATE
HAZARD REMINDER OPERATION DOES NOT OPERATE
A
NOTE: B
check each symptom.
• “HAZARD ANSWER BACK” is ON when setting on CONSULT-III.
D
1.CHECK SETTING OF BUZZER REMINDER WITH CONSULT-III

E
Check “HAZARD ANSWER BACK” setting in “Work Support”.
F
YES >> GO TO 2.
NO >> Set “HAZARD ANSWER BACK” setting in “Work Support”. Refer to DLK-67, "CONSULT-III Func-
G
NO >> GO TO 1.
I
DLK
DLK-239
SQUEAK AND RATTLE TROUBLE DIAGNOSES
SBT842
CUSTOMER INTERVIEW
Interview the customer if possible, to determine the conditions that exist when the noise occurs. Use the Diag-
nostic Worksheet during the interview to document the facts and conditions when the noise occurs and any of
the customer's comments; refer to DLK-244, "Diagnostic Worksheet". This information is necessary to dupli-
cate the conditions that exist when the noise occurs.
• The customer may not be able to provide a detailed description or the location of the noise. Attempt to obtain
all the facts and conditions that exist when the noise occurs (or does not occur).
• If there is more than one noise in the vehicle, be sure to diagnose and repair the noise that the customer is
concerned about. This can be accomplished by a test drive with the customer.
• After identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics
are provided so the customer, service adviser and technician are all speaking the same language when
defining the noise.
• Squeak – (Like tennis shoes on a clean floor)
Squeak characteristics include the light contact/fast movement/brought on by road conditions/hard surfaces
= higher pitch noise/softer surfaces = lower pitch noises/edge to surface = chirping
• Creak – (Like walking on an old wooden floor)
Creak characteristics include firm contact/slow movement/twisting with a rotational movement/pitch depen-
dent on materials/often brought on by activity.
• Rattle – (Like shaking a baby rattle)
Rattle characteristics include the fast repeated contact/vibration or similar movement/loose parts/missing
clip or fastener/incorrect clearance.
• Knock – (Like a knock on a door)
Knock characteristics include hollow sounding/sometimes repeating/often brought on by driver action.
• Tick – (Like a clock second hand)
Tick characteristics include gentle contacting of light materials/loose components/can be caused by driver
action or road conditions.
• Thump – (Heavy, muffled knock noise)
Thump characteristics include softer knock/dead sound often brought on by activity.
• Buzz – (Like a bumble bee)
Buzz characteristics include high frequency rattle/firm contact.
• Often the degree of acceptable noise level will vary depending upon the person. A noise that you may judge
as acceptable may be very irritating to the customer.
• Weather conditions, especially humidity and temperature, may have a great effect on noise level.
DUPLICATE THE NOISE AND TEST DRIVE
If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on
the Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used to
duplicate the same conditions when you confirm the repair.
DLK-240
If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to dupli-
cate the noise with the vehicle stopped by doing one or all of the following: A
1) Close a door.
2) Tap or push/pull around the area where the noise appears to be coming from.
3) Rev the engine.
B
4) Use a floor jack to recreate vehicle “twist”.
5) At idle, apply engine load (electrical load, half-clutch on M/T model, drive position on A/T model).
6) Raise the vehicle on a hoist and hit a tire with a rubber hammer.
• Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs. C
• If it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the
vehicle body.
LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE D
1. Narrow down the noise to a general area. To help pinpoint the source of the noise, use a listening tool
(Engine Ear or mechanics stethoscope).
2. Narrow down the noise to a more specific area and identify the cause of the noise by: E
• removing the components in the area that you suspect the noise is coming from.
Do not use too much force when removing clips and fasteners, otherwise clips and fastener can be broken
or lost during the repair, resulting in the creation of new noise. F
• tapping or pushing/pulling the component that you suspect is causing the noise.
Do not tap or push/pull the component with excessive force, otherwise the noise will be eliminated only tem-
porarily. G
• feeling for a vibration with your hand by touching the component(s) that you suspect is (are) causing the
noise.
• placing a piece of paper between components that you suspect are causing the noise.
• looking for loose components and contact marks. H
Refer to DLK-242, "Inspection Procedure".
REPAIR THE CAUSE
I
• If the cause is a loose component, tighten the component securely.
• If the cause is insufficient clearance between components:
- separate components by repositioning or loosening and retightening the component, if possible.
- insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or urethane J
tape are available through your authorized Nissan Parts Department.
CAUTION:
Do not use excessive force as many components are constructed of plastic and may be damaged. DLK
NOTE:
• URETHANE PADS
Insulates connectors, harness, etc.
• INSULATOR (Foam blocks) L
Insulates components from contact. Can be used to fill space behind a panel.
• INSULATOR (Light foam block)
• FELT CLOTHTAPE M
Used to insulate where movement does not occur. Ideal for instrument panel applications.
The following materials, not available through NISSAN Parts Department, can also be used to repair
squeaks and rattles.
• UHMW(TEFLON) TAPE N
Insulates where slight movement is present. Ideal for instrument panel applications.
• SILICONE GREASE
Used in place of UHMW tape that will be visible or not fit. O
Note: Will only last a few months.
• SILICONE SPRAY
Use when grease cannot be applied.
• DUCT TAPE P
Use to eliminate movement.
CONFIRM THE REPAIR
Confirm that the cause of a noise is repaired by test driving the vehicle. Operate the vehicle under the same
conditions as when the noise originally occurred. Refer to the notes on the Diagnostic Worksheet.
DLK-241
Inspection Procedure INFOID:0000000001537519
Refer to Table of Contents for specific component removal and installation information.
INSTRUMENT PANEL
Most incidents are caused by contact and movement between:
1. Cluster lid A and instrument panel
2. Acrylic lens and combination meter housing
3. Instrument panel to front pillar garnish
4. Instrument panel to windshield
5. Instrument panel mounting pins
6. Wiring harnesses behind the combination meter
7. A/C defroster duct and duct joint
These incidents can usually be located by tapping or moving the components to duplicate the noise or by
pressing on the components while driving to stop the noise. Most of these incidents can be repaired by apply-
ing felt cloth tape or silicon spray (in hard to reach areas). Urethane pads can be used to insulate wiring har-
ness.
CAUTION:
Do not use silicone spray to isolate a squeak or rattle. If you saturate the area with silicone, you will
not be able to recheck the repair.
CENTER CONSOLE
Components to pay attention to include:
1. Shifter assembly cover to finisher
2. A/C control unit and cluster lid C
3. Wiring harnesses behind audio and A/C control unit
The instrument panel repair and isolation procedures also apply to the center console.
DOORS
Pay attention to the:
1. Finisher and inner panel making a slapping noise
2. Inside handle escutcheon to door finisher
3. Wiring harnesses tapping
4. Door striker out of alignment causing a popping noise on starts and stops
Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate
many of these incidents. You can usually insulate the areas with felt cloth tape or insulator foam blocks to
repair the noise.
TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid dumpers out of adjustment
2. Trunk lid striker out of adjustment
3. Trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sunvisor shaft shaking in the holder
3. Front or rear windshield touching headlining and squeaking
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these
incidents. Repairs usually consist of insulating with felt cloth tape.
DLK-242
SEATS
When isolating seat noise it is important to note the position the seat is in and the load placed on the seat A
when the noise is present. These conditions should be duplicated when verifying and isolating the cause of
the noise.
Cause of seat noise include: B
1. Headrest rods and holder
2. A squeak between the seat pad cushion and frame
3. Rear seatback lock and bracket C
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
or applying urethane tape to the contact area. D
UNDERHOOD
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment. E
Causes of transmitted underhood noise include:
1. Any component mounted to the engine wall
2. Components that pass through the engine wall F
3. Engine wall mounts and connectors
4. Loose radiator mounting pins
5. Hood bumpers out of adjustment G
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
H
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.
I
DLK
DLK-243
Diagnostic Worksheet INFOID:0000000001537520
PIIB8740E
DLK-244
DLK
PIIB8742E
DLK-245
PRECAUTIONS
< PRECAUTION > [WITH I-KEY, WITHOUT SUPER LOCK]
PRECAUTION
PRECAUTIONS
WARNING:
ness connectors.
INFOID:0000000001524328
NOTE:
TEM).
OPERATION PROCEDURE
NOTE:
rotated.
DLK-246
PRECAUTIONS
< PRECAUTION > [WITH I-KEY, WITHOUT SUPER LOCK]
A
B
D
PIIB3706J
Work INFOID:0000000001280619
E
• After removing and installing the opening/closing parts, be sure to carry out fitting adjustments to check their
operational.
• Check the lubrication level, damage, and wear of each part. If necessary, grease or replace it. F
DLK
DLK-247
PREPARATION
< PREPARATION > [WITH I-KEY, WITHOUT SUPER LOCK]
PREPARATION
PREPARATION
Engine ear Locating the noise
SIIA0995E
Remover tool Remove the clips, pawls, and metal clips
PIIB7923J
Power tool
PIIB1407E
DLK-248
HOOD
< ON-VEHICLE REPAIR > [WITH I-KEY, WITHOUT SUPER LOCK]
ON-VEHICLE REPAIR A
HOOD
HOOD ASSEMBLY
B
HOOD ASSEMBLY : Exploded View INFOID:0000000001280622
REMOVAL C
JMKIA0541ZZ
DLK
1. Hood assembly 2. Hood hinge 3. Hood insulator
4. Clamp 5. Hood support rod 6. Grommet
7. Radiator core seal 8. Hood bumper rubber center 9. Hood bumper rubber side L
ADJUSTMENT M
DLK-249
HOOD
JMKIA0542GB
1. Hood assembly 2. Hood bumper rubber side 3. Hood hinge

4. Hood lock assembly 5. Front grille 6. Front bumper
7. Front combination lamp 8. Front fender
HOOD ASSEMBLY : Removal and Installation INFOID:0000000001280623
REMOVAL
1. Support the hood lock assembly with the proper material to prevent it from falling.
WARNING:
DLK-250
HOOD
Bodily injury may occur if no supporting rod is holding the hood open when removing the hood
stay. A
2. Remove the hood hinge mounting nuts on the hood to remove the hood assembly.
CAUTION:
Perform work with 2 workers, because of its heavy weight. B
3. Remove the following parts after removing the hood assembly.
• Hood insulator
• Clamp
C
• Hood support rod
• Grommet
• Radiator core seal
• Hood bumper rubber center D
• Hood bumper rubber side
INSTALLATION
Install in the reverse order of removal. E
CAUTION:
• Perform work with 2 workers, because of its heavy weight.
• Before installing the hood hinge, apply anticorrosive agent onto the mounting surface of the vehicle F
body.
• After installing, perform hood fitting adjustment. Refer to DLK-251, "HOOD ASSEMBLY : Adjust-
ment".
G
HOOD ASSEMBLY : Adjustment INFOID:0000000001280624
mm(in) H
Portion Standard
E Clearance 4.0 – 8.0 (0.157 – 0.315)
Hood – Front grill A–A I
F Surface height - 0.4 – 4.0 (- 0.016 – 0.157)
G Clearance 4.0 – 8.0 (0.157 – 0.315)
Hood – Front bumper B–B
H Surface height - 0.4 – 4.0 (- 0.016 – 0.157) J
I Clearance 1.8 – 6.2 (0.071 – 0.244)
Hood – Front combination lamp C–C
J Surface height - 1.3 – 2.7 (- 0.051 – 0.106) DLK
K Clearance 2.6 – 4.6 (0.102 – 0.181)
Hood – Front fender D–D
L Surface height - 1.0 – 1.0 (- 0.039 – 0.039)
L
1. Check the clearance and the surface height between the hood and each part by visually and touching.
(Fitting standard dimension in the table below should be satisfied.)
M
2. Remove the front grille. Refer to EXT-18, "Removal and Installation".
3. In case any parts are out of specification, adjust them according to the procedures shown below.
4. Remove the hood lock and adjust the height by rotating the hood bumper rubber side until the hood
N
becomes 1 to1.5 mm (0.04 to 0.059 in) lower than the fender.
5. Temporarily tighten the hood lock, and position by engaging it with the hood striker. Check the lock and
striker for looseness and adjust the clearance and evenness with the striker to satisfy the specification.
O
6. Adjust A and B shown in the figure to the following value with hood's own weight by dropping it from
approximately. 200 mm (7.87 in) height or by pressing the hood lightly [approximately. 29 N (3 kg)].
DLK-251
HOOD
PIIB5794E
1. Hood striker 2. Primary latch 3. Secondary striker

4. Secondary latch
A : 20.0 mm (0.787 in)

B : 6.8 mm (0.268 in)
7. After adjustment tighten lock bolts to the specified torque.

HOOD HINGE
HOOD HINGE : Exploded View INFOID:0000000001280625
JMKIA0541ZZ

4. Clamp 5. Hood support rod 6. Gromet
7. Radiator core seal 8. Hood bumper rubber center 9. Hood bumper rubber side
HOOD HINGE : Removal and Installation INFOID:0000000001280626
REMOVAL
DLK-252
HOOD
1. Remove the hood assembly. Refer to DLK-250, "HOOD ASSEMBLY : Removal and Installation".
2. Remove the front fender. Refer to DLK-258, "Removal and Installation". A
3. Remove the hood hinge mounting bolts, and then remove the hood hinge.
INSTALLATION B
CAUTION:
• Before installation of hood hinge, apply anticorrosive agent onto the mounting surface of the vehicle
body. C
• After installation, apply touch-up paint (the body color) onto the head of the hinge mounting bolts
and nuts.
• After installation, perform hood fitting adjustment. Refer to DLK-251, "HOOD ASSEMBLY : Adjust- D
ment".
HOOD SUPPORT ROD
E
HOOD SUPPORT ROD : Exploded View INFOID:0000000001298150
DLK
M
JMKIA0541ZZ

4. Clamp 5. Hood support rod 6. Gromet N
7. Radiator core seal 8. Hood bumper rubber center 9. Hood bumper rubber side
O
HOOD SUPPORT ROD : Removal and Installation INFOID:0000000001280628
REMOVAL P
1. Support the hood lock assembly with the proper material to prevent it from falling.
WARNING:
Bodily injury may occur if no supporting rod is holding the hood open when removing the hood
stay.
2. Remove the hood support rod from the grommet.
INSTALLATION
DLK-253
HOOD
HOOD LOCK CONTROL
HOOD LOCK CONTROL : Exploded View INFOID:0000000001280629
JMKIA0543ZZ
1. Hood lock assembly 2. Hood lock control cable 3. Hood lock opener
:Clip
HOOD LOCK CONTROL : Removal and Installation INFOID:0000000001280630
REMOVAL
1. Remove the hood lock opener mounting bolts, and then remove the hood lock opener.
3. Remove the fender protector. Refer to EXT-21, "Removal and Installation".
4. Remove the hood lock mounting bolts, and then remove the hood lock.
5. Disconnect the hood lock cable from hood lock, and clip it from the hoodledge.
6. Remove the grommet on the dash lower panel, and pull the hood lock control cable toward the passenger
compartment.
CAUTION:
While pulling, do not to damage (peeling) the outside of the hood lock control cable.
INSTALLATION
CAUTION:
• Do not to bend the cable too much, keeping the radius 100 mm (3.94 in) or more.
DLK-254
HOOD
• Check that the cable is not offset from the positioning grom-
met, and apply the sealant to the grommet (at *mark) properly. A
PIIB5801E
D
• Check that the hood lock control cable is properly engaged with the hood lock.
• After installation, perform hood fitting adjustment. Refer to DLK-251, "HOOD ASSEMBLY : Adjust-
ment". E
• After installation, perform the hood lock control inspection. Refer to DLK-255, "HOOD LOCK CON-
TROL : Inspection".
HOOD LOCK CONTROL : Inspection INFOID:0000000001280631 F
NOTE:
If the hood lock cable is bent or deformed, replace it. G
1. Check that the secondary latch is properly engaged with the secondary striker [6.8 mm (0.268 in) shown
in the figure] by hood weight.
2. While operating the hood opener, carefully check that the front end of the hood is raised by approximately H
20.0 mm (0.787 in). Also check that the hood opener returns to the original position.
3. Check that the hood opener operating is condition 49 N (5.0 kg) or below.
4. Install so that static closing face of hood is 94 – 490 N·m (9.6 – 50.0 kg-m). I
NOTE:
• Exert vertical force on right side and left side of hood lock.
• Do not press simultaneously both sides.
J
5. Check the hood lock lubrication condition. If necessary, apply body grease to the hood lock.
DLK
DLK-255
RADIATOR CORE SUPPORT
JMKIA0544ZZ
1. Radiator core support upper center 2. Radiator core support upper RH 3. Radiator core support upper LH
4. Radiator core support lower 5. Radiator core support side RH 6. Radiator core support side LH
7. Hood lock support stay assembly 8. Front bumper fascia center bracket 9. Sensor bracket
10. Air guide RH 11. Air guide LH 12. Air guide upper RH (M9R model)
13. Air guide lower RH (M9R model) 14. Air guide upper LH (M9R model) 15. Air guide lower LH (M9R model)
REMOVAL
1. Remove the front bumper fascia and the energy absorber. Refer to EXT-13, "Removal and Installation".
2. Remove the bumper reinforcement. Refer to EXT-13, "Removal and Installation".
3. Disconnect the liquid tank connector. Refer to HA-66, "Exploded View".
4. Remove the front combination lamp. Refer to EXL-213, "Removal and Installation" (XENON TYPE), EXL-
409, "Removal and Installation" (HALOGEN TYPE).
5. Remove the washer tank. Refer to WW-104, "Removal and Installation".
6. Remove the air inlet hose (LH) and air inlet tube (LH). Refer to EM-266, "Exploded View" (M9R model).
7. Remove the charge air cooler. Refer to EM-266, "Removal and Installation" (M9R model).
8. Disconnect the hood lock control cable clamp, and then remove the hood lock assembly. Refer to DLK-
254, "HOOD LOCK CONTROL : Removal and Installation".
9. Remove the air guide mounting clips, and remove the air guide (LH/RH).
10. Remove the horn. Refer to HRN-6, "Removal and Installation".
DLK-256
11. Remove the Intelligent Key warning buzzer (with Intelligent Key systems). Refer to DLK-298, "Removal
and Installation". A
12. Disconnect the harness clips from the hood lock stay.
13. Remove the hood lock stay mounting bolts, and then remove the hood lock stay.
14. Remove the crush zone sensor. Refer to SR-15, "Removal and Installation". B
15. Place securely the hood support rod inside the engine mounting bracket hole.
CAUTION:
Check that the hood is securely fix. C
16. Remove the radiator core support upper side (RH,LH) mounting bolts, and remove the radiator core sup-
port side (RH,LH).
17. Remove the radiator core support upper center mounting bolts, and remove the radiator core support D
upper center.
18. Disconnect the harness clamp from radiator core support side (LH).
19. Remove the radiator core support lower assembly mounting bolts. E
20. Remove the radiator core support lower assembly while other worker is holding the radiator and con-
denser assembly to prevent the radiator and condenser from falling.
CAUTION: F
Operate with two workers, because of its heavy weight.
21. Put some wooden blocks (B) under the radiator and condenser,
and use a rope (A) to suspend it to prevent it from falling. G
CAUTION:
Operate with two workers, because of its heavy weight.
H
JMKIA0698ZZ
J
22. Remove the radiator core support side (RH,LH) mounting nuts, and remove the radiator core support side
(RH,LH) from radiator core support lower.
INSTALLATION DLK
DLK-257
FRONT FENDER
FRONT FENDER
JMKIA0545ZZ
1. Front fender 2. Front fender finisher
REMOVAL
1. Remove the fillet molding. Refer to EXT-24, "Removal and Installation".
3. Remove the front bumper fascia. Refer to EXT-13, "Removal and Installation".
4. Remove the front combination lamp. Refer to EXL-213, "Removal and Installation" (XENON TYPE),EXL-
409, "Removal and Installation" (HALOGEN TYPE).
5. Remove the inner fender protector. Refer to EXT-21, "Removal and Installation".
6. Remove the front fender finisher.
7. Remove the side turn signal lamp. Refer to EXL-222, "Removal and Installation".
8. Remove the mounting bolts and remove the front fender.
CAUTION:
Use a shop cloth to protect the body from being damaged during removal.
INSTALLATION
CAUTION:
• After installation, check the front fender adjustment. Refer to DLK-251, "HOOD ASSEMBLY : Adjust-
ment" and DLK-261, "DOOR ASSEMBLY : Adjustment".
• After installation, apply the touch-up paint (the body color) onto the head of the front fender mount-
ing bolts.
DLK-258
FRONT DOOR
FRONT DOOR
A
DOOR ASSEMBLY
DOOR ASSEMBLY : Exploded View INFOID:0000000001280636
B
REMOVAL
C
J
JMKIA0546ZZ
1. Front door panel 2. Door hinge (upper) 3. Door hinge (lower)

DLK
4. Door check link 5. Seal 6. Door bumper rubber
7. Grommet 8. Door striker 9. TORX bolt
L
ADJUSTMENT
DLK-259
FRONT DOOR
JMKIA0547GB
1. Front fender 2. Front door 3. Rear door

4. Body side outer 5. Front door hinge 6. Rear door hinge (upper)
7. Rear door hinge (lower) 8. Door striker 9. TORX bolt
DOOR ASSEMBLY : Removal and Installation INFOID:0000000001280637
CAUTION:
• Perform work with 2 workers, because of its heavy weight.
• When removing and installing the front door assembly, support the door with a jack and cloth to pro-
tect the door and body.
DLK-260
FRONT DOOR
REMOVAL
1. Remove the mounting bolts of the door check link on the vehicle. A
2. Remove the front door harness grommet, and then pull out the harness from the vehicle.
3. Disconnect the front door harness connector.
B
4. Remove the door hinge mounting nuts (door side), and then remove the door assembly.
INSTALLATION
Install in the reverse order of removal. C
CAUTION:
• Check the front door open/close operation after installation.
• Check the door hinge rotating part for poor lubrication. If necessary, apply body grease.
D
• When removing and installing the front door assembly, perform the fitting adjustment. Refer to DLK-
261, "DOOR ASSEMBLY : Adjustment".
• After installation, apply touch-up paint (the body color) onto the head of the door hinge mounting
nuts. E
DOOR ASSEMBLY : Adjustment INFOID:0000000001280638
F
CLEARANCE, SURFACE HEIGHT AND SURFACE MISMATCH ADJUSTMENT
mm(in)
Portion Clearance Surface height
G
Front fender – Front door A–A 3.4 – 5.4 (0.134 – 0.213) - 1.0 – 1.0 (- 0.039 – 0.039)
Front door – Rear door B–B 3.5 – 5.5 (0.138 – 0.217) - 1.0 – 1.0 (- 0.039 – 0.039)
H
Front door – Rear door G–G 3.0 – 6.0 (0.118 – 0.236) - 1.0 – 1.0 (- 0.039 – 0.039)
1. Check the clearance and surface height and surface mismatch between the front door and each part
I
visually and by touching. (Fitting standard dimension in the table below shall be satisfied.)
3. Remove the front fender. Refer to refer to DLK-258, "Removal and Installation". J
4. Loosen the door hinge mounting nuts on door side.
5. Adjust the surface height and surface mismatch of the front door according to the fitting standard dimen-
sion. DLK
6. Temporarily tighten the hinge mounting nuts on door side.
7. Loosen the door hinge mounting bolts on body side.
8. Raise the front door at rear end to adjust clearance of the front door according to the fitting standard L
dimension.
9. After adjustment tighten bolts and nuts to the specified torque.
10. Install the front fender. Refer to refer to DLK-258, "Removal and Installation". M
CAUTION:
After installation, check the front fender adjustment. Refer to DLK-261, "DOOR ASSEMBLY :
Adjustment". N
DOOR STRIKER ADJUSTMENT

Adjust the door striker so that it becomes parallel with the lock insertion direction. O
DOOR STRIKER
DLK-261
FRONT DOOR
DOOR STRIKER : Exploded View INFOID:0000000001280639
JMKIA0546ZZ

DOOR STRIKER : Removal and Installation INFOID:0000000001280640
REMOVAL
Remove the TORX bolts, and then remove the door striker.
INSTALLATION
CAUTION:
• When removing and installing the door striker, be sure to perform the fitting adjustment. Refer to
DLK-261, "DOOR ASSEMBLY : Adjustment".
DOOR HINGE
DLK-262
FRONT DOOR
DOOR HINGE : Exploded View INFOID:0000000001298151
JMKIA0546ZZ
I
7. Grommet 8. Door striker 9. TORX bolt J
DOOR HINGE : Removal and Installation INFOID:0000000001280642

DLK
REMOVAL
1. Remove the front door assembly. Refer to DLK-260, "DOOR ASSEMBLY : Removal and Installation". L
2. Remove the door hinge mounting bolts, and then remove the front door hinge.
INSTALLATION
M
CAUTION:
• Check the door hinge rotating part for poor lubrication. If necessary, apply body grease. N
• When removing and installing the front door assembly, perform the fitting adjustment. Refer to DLK-
261, "DOOR ASSEMBLY : Adjustment".
• After installation, apply touch-up paint (the body color) onto the head of the door hinge mounting
O
nuts.
DOOR CHECK LINK
P
DLK-263
FRONT DOOR
DOOR CHECK LINK : Exploded View INFOID:0000000001298152
JMKIA0546ZZ

DOOR CHECK LINK : Removal and Installation INFOID:0000000001280644
REMOVAL
1. Fully close the front door window.
2. Remove the front door finisher. Refer to INT-10, "FRONT DOOR FINISHER : Removal and Installation".
3. Remove the front door speaker. Refer to AV-38, "Removal and Installation".
4. Remove the mounting bolts of the door check link on the vehicle.
5. Remove the mounting bolts of the door check link on the door panel.
6. Take the door check link out from the hole of the door panel.
INSTALLATION
CAUTION:
Check the front door open/close operation after installation.
DLK-264
REAR DOOR
REAR DOOR
A
DOOR ASSEMBLY
DOOR ASSEMBLY : Exploded View INFOID:0000000001280645
B
REMOVAL
C
J
JMKIA0548ZZ
1. Rear door panel 2. Door hinge (upper) 3. Door hinge (lower)

DLK
4. Door check link 5. Seal 6. Hole cover
7. Door bumper rubber 8. Door striker 9. TORX bolt
L
ADJUSTMENT
DLK-265
REAR DOOR
JMKIA0547GB
1. Front fender 2. Front door 3. Rear door

4. Body side outer 5. Front door hinge 6. Rear door hinge (upper)
7. Rear door hinge (lower) 8. Door striker 9. TORX bolt
DOOR ASSEMBLY : Removal and Installation INFOID:0000000001280646
CAUTION:
• Perform work with 2 workers, because of it’s heavy weight.
• When removing and installing the front door assembly, support the door with a jack and cloth to pro-
tect the door and body.
DLK-266
REAR DOOR
REMOVAL
1. Remove the mounting bolts of the door check link on the vehicle. A
2. Remove the rear door harness grommet, and then pull out the door harness from the vehicle.
3. Disconnect the rear door harness connector.
B
4. Remove the door hinge mounting nuts (door side), and then remove the rear door assembly.
INSTALLATION
Install in the reverse order of removal. C
CAUTION:
• Check the rear door lock/unlock operation after installation.
• Check the rear door open/close operation after installation.
D
• After installation, perform the fitting adjustment. Refer to DLK-267, "DOOR ASSEMBLY : Adjust-
ment".
• After installation, apply touch-up paint (the body color) onto the head of the door hinge mounting E
nuts.
DOOR ASSEMBLY : Adjustment INFOID:0000000001280647
F
CLEARANCE, SURFACE HEIGHT AND SURFACE MISMATCH ADJUSTMENT
mm(in)
G
Portion Clearance Surface height
Front door – Rear door B–B 3.5 – 5.5 (0.138 – 0.217) -1.0 – 1.0 (-0.039 – 0.039)
Rear door – Body side outer C–C 3.5 – 5.5 (0.138 – 0.217) -1.0 – 1.0 (-0.039 – 0.039) H
Front door – Rear door G–G 3.0 – 6.0 (0.118 – 0.236) -1.5 – 1.5 (-0.059 – 0.059)
I
1. Check the clearance and surface height and surface mismatch between the rear door and each part visu-
ally and by touching. (Fitting standard dimension in the table below shall be satisfied.)
J
3. Remove the center pillar lower garnish. Refer to INT-16, "Removal and Installation".
4. Loosen the door hinge mounting nuts on door side.
5. Adjust the surface height and surface mismatch of the rear door according to the fitting standard dimen- DLK
sion.
6. Temporarily tighten the hinge mounting nuts on door side.
7. Loosen the door hinge mounting nuts and bolts on body side. L
8. Raise the rear door at rear end to adjust clearance of the rear door according to the fitting standard dimen-
sion.
9. After adjustment tighten bolts and nuts to the specified torque. M
10. Install the center pillar lower garnish. Refer to INT-16, "Removal and Installation".
DOOR STRIKER ADJUSTMENT
Adjust the door striker so that it becomes parallel with the lock insertion direction. N
DOOR STRIKER
O
DLK-267
REAR DOOR
DOOR STRIKER : Exploded View INFOID:0000000001280648
JMKIA0548ZZ

DOOR STRIKER : Removal and Installation INFOID:0000000001280649
REMOVAL
Remove the TORX bolts, and then remove the door striker.
INSTALLATION
CAUTION:
• Check the rear door open/close operation after installation.
• When removing and installing the door striker, be sure to perform the fitting adjustment. Refer to
DLK-267, "DOOR ASSEMBLY : Adjustment".
DOOR HINGE
DLK-268
REAR DOOR
DOOR HINGE : Exploded View INFOID:0000000001298153
JMKIA0548ZZ
I
7. Door bumper rubber 8. Door striker 9. TORX bolt J
DOOR HINGE : Removal and Installation INFOID:0000000001280651

DLK
REMOVAL
1. Remove the center pillar lower garnish. Refer to INT-16, "Removal and Installation". L
2. Remove the rear door assembly. Refer to DLK-266, "DOOR ASSEMBLY : Removal and Installation".
3. Remove the rear door hinge mounting bolts and nuts (body side), and then remove the door hinge.
M
INSTALLATION
CAUTION:
• Check the rear door open/close operation after installation. N
• When removing and installing the rear door assembly, perform the fitting adjustment. Refer to DLK-
267, "DOOR ASSEMBLY : Adjustment". O
• After installing, apply the touch-up paint (the body color) onto the head of the hinge mounting nuts.
DOOR CHECK LINK
P
DLK-269
REAR DOOR
DOOR CHECK LINK : Exploded View INFOID:0000000001298154
JMKIA0548ZZ

DOOR CHECK LINK : Removal and Installation INFOID:0000000001280653
REMOVAL
1. Remove the rear door finisher. Refer to INT-13, "REAR DOOR FINISHER : Removal and Installation".
2. Remove the rear door speaker.
3. Remove the mounting bolts of the check link on the vehicle.
4. Remove the door check link mounting bolts on the door panel.
5. Remove the door check link.
INSTALLATION
CAUTION:
Check front door open/close operation after installation.
DLK-270
BACK DOOR
BACK DOOR
A
BACK DOOR ASSEMBLY
BACK DOOR ASSEMBLY : Exploded View INFOID:0000000001280654
B
REMOVAL
C
J
JMKIA0549GB
1. Back door assembly 2. Back door hinge 3. Back door stay

DLK
4. Back door striker 5. Back door stay stud ball 6. Bumper rubber
7. Bumper rubber bracket 8. Back door lock assembly 9. Emergency lever
10. Back door lock cover (RH handle) 11. TORX bolt
L
ADJUSTMENT
M
DLK-271
BACK DOOR
JMKIA0550GB
1. Back door 2. Roof 3. Rear combination lamp

4. Body side outer 5. Back door hinge 6. Bumper rubber
7. Back door striker 8. TORX bolt
BACK DOOR ASSEMBLY : Removal and Installation INFOID:0000000001280655
REMOVAL
1. Remove the back door finisher inner (upper, lower, side LH). Refer to INT-31, "Removal and Installation".
2. Disconnect the connectors in the back door, and then remove the grommet, and pull out the harness.
DLK-272
BACK DOOR
3. Remove the grommet, and then disconnect the connectors (1), and pull out the washer tube (2) at (A).
A
JMKIA0557ZZ
4. Pull the harness out of the back door. D

5. Support the back door lock with the proper material to prevent it
from falling.
E
A : Jack
B : Shop cloth
F
G
JMKIA0555ZZ
6. Remove the back door stay bracket mounting bolts on the back door. H
7. Remove the back door hinge mounting nuts on the back door and remove the back door assembly.
CAUTION:
Perform work with 2 workers, because of its heavy weight. I
INSTALLATION
Install in the reverse order of removal. J
CAUTION:
• Check the back door open/close operation after installation.
• Check the back door lock/unlock operation after installation.
• After installation, perform fitting adjustment. Refer to DLK-273, "BACK DOOR ASSEMBLY : Adjust- DLK
ment".
BACK DOOR ASSEMBLY : Adjustment INFOID:0000000001280656
L
mm(in)
Portion Standard
M
E Clearance 5.0 – 7.0 (0.197 – 0.276)
Back door panel – Roof panel A–A
F Surface height -0.3 – 1.7 (-0.012 – 0.067)
N
Back door panel – Rear combination lamp B–B G Clearance 4.0 – 8.0 (0.157 – 0.315)
Back door panel – Rear combination lamp C–C H Clearance 4.0 – 8.0 (0.157 – 0.315)
I Clearance 5.0 – 7.0 (0.197 – 0.276) O
Back door panel – Body side outer D–D
J Surface height -1.0 – 1.1 (0.039 – 0.043)
FITTING ADJUSTMENT P
1. Check the clearance and the evenness between the back door and each part visually and by touching.
(Fitting standard dimension in the table below shall be satisfied.)
3. Loosen the bumper rubber.
4. Loosen the back door striker mounting bolts.
DLK-273
BACK DOOR
5. Lift up the back door approximately 100 – 150 mm (3.937 – 5.906 in) height then close it lightly and check
that it is engaged firmly with the back door closed.
6. Check the clearance and evenness.
7. Finally tighten the back door striker.
BACK DOOR STRIKER
BACK DOOR STRIKER : Exploded View INFOID:0000000001280657
JMKIA0549GB

BACK DOOR STRIKER : Removal and Installation INFOID:0000000001280658
REMOVAL
Remove the TORX bolts, and then remove the back door striker.
INSTALLATION
CAUTION:
• When removing and installing the back door striker, be sure to perform the fitting adjustment. Refer
to DLK-273, "BACK DOOR ASSEMBLY : Adjustment".
BACK DOOR HINGE
DLK-274
BACK DOOR
BACK DOOR HINGE : Exploded View INFOID:0000000001298155
JMKIA0549GB
I
7. Bumper rubber bracket 8. Back door lock assembly 9. Emergency lever J
DLK
BACK DOOR HINGE : Removal and Installation INFOID:0000000001280660
REMOVAL L
1. Remove the back door assembly. Refer to DLK-272, "BACK DOOR ASSEMBLY : Removal and Installa-
tion".
2. Remove the back door weather-strip. Refer to DLK-277, "BACK DOOR WEATHER-STRIP : Removal and M
Installation".
3. Remove the luggage side lower finisher. Refer to INT-28, "Removal and Installation".
4. Remove the luggage side upper finisher. Refer to INT-28, "Removal and Installation". N
5. Using remover tool, remove the headlining clip at the rear side of the headlining. Refer to INT-22, "NOR-
MAL ROOF : Exploded View" (NORMAL ROOF), INT-25, "SUNROOF : Exploded View" (SUNROOF).
6. Remove the rear side of the headlining. O
7. Remove the back door hinge mounting nuts (body side), and then remove the back door hinge.
INSTALLATION
P
CAUTION:
• Check the hinge rotating part for poor lubrication. If necessary, apply body grease.
• When removing and installing the back door assembly, perform the fitting adjustment. Refer to DLK-
273, "BACK DOOR ASSEMBLY : Adjustment".
• After installation, apply touch-up paint (the body color) onto the head of the hinge mounting nuts.
DLK-275
BACK DOOR
BACK DOOR STAY
BACK DOOR STAY : Exploded View INFOID:0000000001298156
JMKIA0549GB

BACK DOOR STAY : Removal and Installation INFOID:0000000001280662
REMOVAL
1. Remove the mounting bolts (body side), and then remove the back door stay bracket.
2. Remove the stud ball (back door side), and then remove the back door stay.
INSTALLATION
CAUTION:
Check the back door open/close operation after installation.
BACK DOOR WEATHER-STRIP
BACK DOOR WEATHER-STRIP : Exploded View INFOID:0000000001280663
REMOVAL
DLK-276
BACK DOOR
JMKIA0556ZZ F
1. Back door weather-strip

A. Mark (upper)
G
B. Mark (lower)
BACK DOOR WEATHER-STRIP : Removal and Installation INFOID:0000000001280664

H
REMOVAL
Pull up and remove engagement with body from the weather-strip joint.
CAUTION: I
After removal, do not pull strongly on the weather-strip.
INSTALLATION
J
1. Working from the upper section, align the weather-strip mark with vehicle center position mark and install
the weather-strip onto the vehicle.
2. For the lower section, align the weather-strip seam with center of the back door striker.
DLK
3. After installation, pull the weather-strip gently to ensure that there is no loose section.
NOTE:
Make sure that the weather-strip is fit tightly at each corner and the luggage rear plate.
L
DLK-277
FRONT DOOR LOCK
FRONT DOOR LOCK
DOOR LOCK
DOOR LOCK : Exploded View INFOID:0000000001280665
JMKIA0551GB
1. Outside handle assembly 2. Door key cylinder assembly (driver 3. Front gasket
side)
Outside handle escutcheon (passen-
ger side)
4. Rear gasket 5. TORX bolt 6. Outside handle bracket
7. Key rod 8. Door lock assembly 9. Inside handle
10. TORX bolt
:Vehicle front
DOOR LOCK : Removal and Installation INFOID:0000000001280666
REMOVAL
2. Disconnect the inside handle knob cable and the lock knob cable.
3. Remove the front door glass. Refer to GW-17, "Removal and Installation".
4. Remove the front door module assembly. Refer to GW-17, "Exploded View".
5. Disconnect the door antenna and the door request switch connector and remove the harness clamp
(models with Intelligent Key system).
DLK-278
FRONT DOOR LOCK
6. Remove the door side grommet, and loosen the TORX bolt.
CAUTION: A
Do not forcibly remove the TORX bolt.
JMKIA0020ZZ
D
7. Reach in to separate the door key cylinder rod connection (on
the handle) (driver side).
E
1. Door key cylinder assembly
2. Key rod
F
G
JMKIA0553ZZ
8. While pulling the outside handle, remove door key cylinder H

assembly.
JMKIA0560ZZ
DLK
9. Disconnect front door request switch harness connector (models with Intelligent Key system).
L
10. While pulling outside handle (1), slide toward rear of vehicle to
remove outside handle.
O
JMKIA0524ZZ
DLK-279
FRONT DOOR LOCK
11. Remove the front gasket (1) and the rear gasket (2).
JMKIA0667ZZ
12. While pulling the outside handle bracket, slide toward rear of
vehicle to remove the outside handle bracket.
PIIB5814E
13. Reach in to separate the outside handle cable connection.

14. Remove the door lock assembly TORX bolts.
15. Disconnect the door lock actuator connector, and then remove the door lock assembly.
16. Remove the key rod from door lock assembly.
INSTALLATION
CAUTION:
• To install each rod, rotate the rod holder until a click is felt.
• Check the door lock/unlock operation after installation.
• Check the door open/close operation after installation.
INSIDE HANDLE
DLK-280
FRONT DOOR LOCK
INSIDE HANDLE : Exploded View INFOID:0000000001298157
JMKIA0551GB
I
side)
J
ger side)
DLK
10. TORX bolt
:Vehicle front
Refer to GI-4, "Components" for symbols in the figure. L
INSIDE HANDLE : Removal and Installation INFOID:0000000001280668
M
REMOVAL
2. Remove the inside handle mounting bolts. N
3. Disconnect the inside handle knob cable and the lock knob cable, and then remove the inside handle.
INSTALLATION
Install in the reverse order of removal. O
CAUTION:
• Check the door open/close operation after installation. P
OUTSIDE HANDLE
DLK-281
FRONT DOOR LOCK
OUTSIDE HANDLE : Exploded View INFOID:0000000001298158
JMKIA0551GB
side)
ger side)
10. TORX bolt
:Vehicle front
OUTSIDE HANDLE : Removal and Installation INFOID:0000000001280670
REMOVAL
2. Disconnect the inside handle knob cable and the lock knob cable.
3. Remove the front door glass. Refer to GW-17, "Removal and Installation".
4. Remove the front door module assembly. Refer to GW-17, "Exploded View".
5. Disconnect the connector and remove the harness clamp (models with Intelligent Key system).
DLK-282
FRONT DOOR LOCK
6. Remove the door side grommet, and loosen the TORX bolt.
CAUTION: A
Do not forcibly remove the TORX bolt.
JMKIA0020ZZ
D
7. Reach in to separate the door key cylinder rod connection (on the handle) (driver side).
1. Door key cylinder assembly E

2. Key rod
JMKIA0553ZZ
H
8. Disconnect the door key cylinder switch harness connector.
9. While pulling the outside handle, remove the door key cylinder
assembly (driver side) or outside handle escutcheon (passenger I
side).
DLK
JMKIA0560ZZ
L
10. Disconnect the front door request switch harness connector (models with Intelligent Key system).
11. While pulling the outside handle, slide toward rear of vehicle to
remove the outside handle (1). M
JMKIA0524ZZ
P
DLK-283
FRONT DOOR LOCK
12. Remove the front gasket (1) and rear gasket (2).
JMKIA0667ZZ
PIIB5814E

INSTALLATION
CAUTION:
DLK-284
REAR DOOR LOCK
REAR DOOR LOCK
A
DOOR LOCK
B
JMKIA0552GB
J
1. Outside handle assembly 2. Outside handle escutcheon 3. Front gasket
4. Rear gasket 5. Outside handle bracket 6. TORX bolt
7. Door lock assembly 8. Inside handle 9. TORX bolt DLK
DOOR LOCK : Removal and Installation INFOID:0000000001280672 L
REMOVAL
1. Remove the rear door finisher. Refer to INT-13, "REAR DOOR FINISHER : Removal and Installation". M
2. Disconnect the inside handle knob cable.
3. Remove the door sealing screen. Refer to GW-23, "Removal and Installation".
4. Remove the lower partition sash. Refer to GW-17, "Removal and Installation". N
5. Remove the corner piece assembly. Refer to GW-17, "Removal and Installation".
O
7. Disconnect the door lock actuator connector.
DLK-285
REAR DOOR LOCK
8. Slide the door lock assembly from the inside the door panel until
the outside handle escutcheon TORX bolt can be seen.
JMKIA0554ZZ
9. While pulling the outside handle, remove the outside handle

escutcheon.
JMKIA0560ZZ
10. While pulling the outside handle(1), slide toward rear of vehicle
to remove the outside handle.
JMKIA0524ZZ
JMKIA0667ZZ
PIIB5814E
DLK-286
REAR DOOR LOCK
A
14. Remove the door lock assembly.
INSTALLATION
Install in the reverse order of removal. B
CAUTION:
• Check the door open/close operation after installation. C
INSIDE HANDLE
INSIDE HANDLE : Exploded View INFOID:0000000001298159 D
DLK
JMKIA0552GB L

4. Rear gasket 5. Outside handle bracket 6. TORX bolt M
7. Door lock assembly 8. Inside handle 9. TORX bolt
N
INSIDE HANDLE : Removal and Installation INFOID:0000000001280674
REMOVAL
O
2. Remove the inside handle mounting screws.
3. Disconnect the inside handle knob cable, and then remove the inside handle. P
INSTALLATION
CAUTION:
OUTSIDE HANDLE
DLK-287
REAR DOOR LOCK
OUTSIDE HANDLE : Exploded View INFOID:0000000001298160
JMKIA0552GB

4. Rear gasket 5. Outside handle bracket 6. TORX bolt
7. Door lock assembly 8. Inside handle 9. TORX bolt
OUTSIDE HANDLE : Removal and Installation INFOID:0000000001280676
REMOVAL
2. Disconnect the inside handle knob cable.
3. Remove the door sealing screen. Refer to GW-23, "Removal and Installation".
4. Remove the lower partition sash. Refer to GW-17, "Removal and Installation".
5. Remove the corner piece assembly. Refer to GW-17, "Removal and Installation".
7. Disconnect the door lock actuator connector.
8. Slide the door lock assembly from the inside the door panel until
the outside handle escutcheon TORX bolt can be seen.
JMKIA0554ZZ
DLK-288
REAR DOOR LOCK
9. While pulling the outside handle, remove the outside handle
escutcheon. A
JMKIA0560ZZ
D
10. While pulling the outside handle(1), slide toward rear of vehicle
to remove the outside handle.
E
G
JMKIA0524ZZ
H
JMKIA0667ZZ
DLK
L
N
PIIB5814E
13. Reach in to separate the outside handle cable connection. O

INSTALLATION
CAUTION: P
DLK-289
BACK DOOR LOCK
BACK DOOR LOCK
DOOR LOCK
JMKIA0549GB

DOOR LOCK : Removal and Installation INFOID:0000000001280678
REMOVAL
1. Remove the back door trim finisher lower. Refer to INT-31, "Removal and Installation".
2. Disconnect the back door lock assembly and back door opener switch connectors.
3. Remove the back door lock mounting bolts, and then remove the back door lock and actuator.
INSTALLTION
CAUTION:
Check the back door lock/unlock operation after installation.
DLK-290
FUEL FILLER LID OPENER
FUEL FILLER LID OPENER
A
FUEL FILLER LID
FUEL FILLER LID : Exploded View INFOID:0000000001280679
B
JMKIA0559ZZ
J
1. Fuel filler cap holder 2. Bumper rubber 3. Fuel filler lid lock actuator
4. Fuel filler lid lock seal 5. Fuel filler lid assembly 6. TORX bolt
7. Spring DLK
FUEL FILLER LID : Removal and Installation INFOID:0000000001280680
L
REMOVAL
1. Fully open the fuel filler lid.
2. Remove the filler cap. M
3. Remove the TORX bolts, and then remove the fuel filler lid assembly.
4. Remove the following parts after removing the fuel filler lid assembly.
• Fuel filler cap holder N
• Bumper rubber
• Spring
INSTALLATION O
CAUTION:
• Check the fuel filler lid open/close operation after installation. P
• After installation, apply the touch-up paint (the body color) onto the head of the mounting screws.
NOTE:
After installation, perform fitting adjustment.
mm(in)
Clearance Evenness
Fuel filler lid— – Body side outer 2.0 – 4.0 (0.079 – 0.157) −1.0 – 1.0 (−0.039 – 0.039)
DLK-291
DOOR SWITCH
DOOR SWITCH
JMKIA0451ZZ
1. Door switch (driver side)
REMOVAL
1. Remove the door switch mounting bolt (A), and then remove
door switch (1).
NOTE:
The same procedure is also performed for door switch (passen-
ger side, rear LH and rear RH).
JMKIA0452ZZ
INSTALLATION
DLK-292
INSIDE KEY ANTENNA
INSIDE KEY ANTENNA
A
INSTRUMENT CENTER
INSTRUMENT CENTER : Exploded View INFOID:0000000001495977
B
F
JMKIA0677ZZ
1. Inside key antenna (instrument center) G
INSTRUMENT CENTER : Removal and Installation INFOID:0000000001495978
H
REMOVAL
1. Instrument lower cover RH. Refer to IP-12, "Removal and Installation".
2. Remove the inside key antenna (instrument center) mounting I
screw (A), and then remove inside key antenna (instrument cen-
ter) (1).
J
DLK
JMKIA0637ZZ L
INSTALLATION
CONSOLE M
DLK-293
INSIDE KEY ANTENNA
CONSOLE : Exploded View INFOID:0000000001495979
JMKIA0678ZZ
1. Inside key antenna (console)
CONSOLE : Removal and Installation INFOID:0000000001495980
REMOVAL
1. Remove the center console. Refer to IP-21, "Removal and Installation".
2. Remove the inside key antenna mounting screw (A), and then
remove inside key antenna (console) (1).
JMKIA0632ZZ
INSTALLATION
REAR
JMKIA0679ZZ
1. Inside key antenna (rear seat)
DLK-294
INSIDE KEY ANTENNA
REAR : Removal and Installation INFOID:0000000001495982
A
REMOVAL
1. Remove the luggage floor spacer. Refer to INT-28, "Removal and Installation".
B
2. Remove the inside key antenna (rear seat) mounting clips (A),
and then remove inside key antenna (rear seat) (1).
E
JMKIA0635ZZ
INSTALLATION
Install in the reverse order of removal. F
DLK
DLK-295
OUTSIDE KEY ANTENNA
OUTSIDE KEY ANTENNA
DRIVER SIDE
DRIVER SIDE : Exploded View INFOID:0000000001495983
Refer to DLK-282, "OUTSIDE HANDLE : Removal and Installation".

DRIVER SIDE : Removal and Installation INFOID:0000000001495984
REMOVAL
Remove the front outside handle LH. Refer to DLK-575, "OUTSIDE HANDLE : Removal and Installation".
INSTALLATION
PASSENGER SIDE
PASSENGER SIDE : Exploded View INFOID:0000000001495985
Refer to DLK-282, "OUTSIDE HANDLE : Exploded View".

PASSENGER SIDE : Removal and Installation INFOID:0000000001495986
REMOVAL
Remove the front outside handle RH. Refer to DLK-282, "OUTSIDE HANDLE : Removal and Installation".
INSTALLATION
BACK DOOR
BACK DOOR : Exploded View INFOID:0000000001495987
JMKIA0680ZZ
1. Outside key antenna (back door) 2. Back door lower finisher
BACK DOOR : Removal and Installation INFOID:0000000001495988
REMOVAL
1. Remove the back door lower finisher. Refer to EXT-36, "Removal and Installation".
DLK-296
OUTSIDE KEY ANTENNA
2. Remove the outside key antenna (back door) (1) from back door
finisher (2). A
JMKIA0652ZZ
D
INSTALLATION
E
DLK
DLK-297
JMKIA0685ZZ
1. Intelligent Key warning buzzer
REMOVAL
2. Remove the Intelligent Key warning buzzer using flat-bladed
screw driver (A) etc.
JMKIA0634ZZ
INSTALLATION
DLK-298
BACK DOOR REQUEST SWITCH
BACK DOOR REQUEST SWITCH
A
D
JMKIA0651ZZ
1. Back door opener switch assembly 2. Back door finisher

E
REMOVAL F
1. Remove the back door finisher. Refer to EXT-34, "Removal and Installation".
2. Remove the back door opener switch assembly mounting bolt (A).
G
3. Remove the back door opener switch assembly (2) from back
door finisher (1).
H
J
JMKIA0638ZZ
INSTALLATION DLK
DLK-299
Refer to DLK-592, "Exploded View".

REMOVAL
Refer to DLK-592, "Removal and Installation".
INSTALLATION
DLK-300
A
Refer to DLK-138, "Diagnosis Procedure". B

REMOVAL C
1. Remove Intelligent Key cover.
2. Insert a flat-bladed screwdriver (A) wrapped with tape as shown
in the illustration and then separate lower and upper cases by D
twisting screwdriver.
CAUTION:
• Do not touch the circuit board or battery terminal.
E
• The Intelligent Key is water-resistant. However, if it does
get wet, immediately wipe it dry.
MIIB0661E
G
3. Remove the circuit board assembly from the upper case (1).
[Substrate assembly: circuit board (3) + rubber (2)]
4. Gently press the rubber (2) and remove the circuit board (3). H
CAUTION:
Do not touch the printed circuits directly.
5. Remove the battery (4) from the lower case (5) and replace it.
I
Battery replacement : Coin-type lithium battery
(CR2032)
J
CAUTION:
When replacing battery, keep dirt, grease, and other foreign
materials off the electrode contact area.
6. After replacement, assemble the upper and lower cases by DLK
engaging the hooks on their circumference while being careful
not to pinch the rubber, etc.
CAUTION: L
After replacing the battery, check that all Intelligent Key
functions work normally.
M
MIIB0662E
N
INSTALLATION
Install in the reverse order of removal. O
DLK-301
JMKIA0684ZZ
1. Intelligent Key unit M40
REMOVAL
1. Remove lower instrument panel (driver side). Refer to IP-12, "Removal and Installation".
2. Remove the Intelligent Key unit mounting screw (A), and then
remove Intelligent Key unit (1).
NOTE:
Perform the system initialization when replacing Intelligent Key
unit. Refer to DLK-25, "ADDITIONAL SERVICE WHEN
REPLACING CONTROL UNIT : Special Repair Requirement".
JMKIA0686ZZ
INSTALLATION
DLK-302
< BASIC INSPECTION > [WITH I-KEY & SUPER LOCK]
BASIC INSPECTION A
B
OVERALL SEQUENCE
C
DLK
JMKIA0676GB
DETAILED FLOW
DLK-303
1.GET INFORMATION FOR SYMPTOM

the incident/malfunction occurred).
>> GO TO 2.
2.CHECK DTC
1. Check DTC for Intelligent Key unit and BCM.
2. Perform the following procedure if DTC is displayed.
- Erase DTC.
- Study the relationship between the cause detected by DTC and the symptom described by the customer.
3. Check related service bulletins for information.
Is any symptom described and any DTC detected?
Symptom is described, DTC is displayed>>GO TO 3.
Symptom is described, DTC is not displayed>>GO TO 4.
Symptom is not described, DTC is displayed>>GO TO 5.
Connect CONSULT-III to the vehicle in “DATA MONITOR” mode and check real-time diagnosis results.
>> GO TO 5.
Connect CONSULT-III to the vehicle in “DATA MONITOR ” mode and check real-time diagnosis results.
>> GO TO 6.
5.PERFORM DTC CONFIRMATION PROCEDURE
Perform DTC Confirmation Procedure for the displayed DTC, and then check that DTC is detected again.
If two or more DTCs are detected, refer to DLK-458, "DTC Inspection Priority Chart" (Intelligent Key unit),
DLK-499, "DTC Inspection Priority Chart" (BCM) and determine trouble diagnosis order.
Is DTC detected?
YES >> GO TO 7.
6.DETECT MALFUNCTIONING SYSTEM BY SYMPTOM TABLE
Detect malfunctioning system according to Symptom Table based on the confirmed symptom in step 4.
>> GO TO 7.
7.DETECT MALFUNCTIONING PART BY DIAGNOSTIC PROCEDURE
Inspect according to Diagnostic Procedure of the system.
NOTE:
The Diagnostic Procedure is described based on open circuit inspection. A short circuit inspection is also
required for the circuit check in the Diagnostic Procedure.
>> GO TO 8.
8.REPAIR OR REPLACE THE MALFUNCTIONING PART
1. Repair or replace the malfunctioning part.
2. Reconnect parts or connectors disconnected during Diagnostic Procedure again after repair and replace-
ment.
3. Check DTC. If DTC is displayed, erase it.
DLK-304
>> GO TO 9. A
9.FINAL CHECK
When DTC was detected in step 9, perform DTC Confirmation Procedure or Component Function Check B
again, and then check that the malfunctions have been fully repaired.
When symptom was described by the customer, refer to the confirmed symptom in step 3 or 4, and check that
the symptom is not detected.
C
Are all malfunctions corrected?
NO (DTC is detected)>>GO TO 7.
NO (Symptom remains)>>GO TO 6.
YES >> INSPECTION END D
DLK
DLK-305
INFOID:0000000001280712
Perform the system initialization when replacing Intelligent Key unit, replacing Intelligent Key or registering an
additional Intelligent Key.
Refer to the CONSULT-III Operation Manual-NATS.
DLK-306
DOOR LOCK FUNCTION
< FUNCTION DIAGNOSIS > [WITH I-KEY & SUPER LOCK]
DOOR LOCK FUNCTION
B
DOOR LOCK AND UNLOCK SWITCH : System Diagram INFOID:0000000001280714
DOOR LOCK AND UNLOCK SWITCH OPERATION C
JMKIA0563GB
DOOR LOCK AND UNLOCK SWITCH INDICATOR OPERATION H
DLK
M
JMKIA0408GB
DOOR LOCK AND UNLOCK SWITCH : System Description INFOID:0000000001280715

N

Functions available by operating the door lock and unlock switch on center console. Interlocked with the lock/
unlock operation of door lock and unlock switch, door lock actuators of all doors are locked/unlocked. O
Operation Condition
If the following conditions are not satisfied, door lock/unlock operation is not performed even if the door lock
P
and unlock switch is operated.
DLK-307
DOOR LOCK FUNCTION
Door lock and unlock switch Operation condition

Following all conditions are satisfied.
Lock operation • Except driver side doors are closed.
Following all conditions are satisfied.
Unlock operation
NOTE:
When the door lock is locked with Intelligent Key or door request switch (in super lock set state), door lock and
unlock switch operation will be invalid until either following condition is satisfied.
• Turn ignition switch ON.
• Unlock with Intelligent key or door request switch.
Door lock and unlock switch indicator indicates door lock status. The indicator turn ON while ignition switch is
ON and door lock is locked or super lock is set. If any door is opened, the indicator will be turn OFF.
Door lock and unlock switch indicator have the following 2 functions.
1 Minute Timer
A timer must be running to turn OFF the indicator. The timer will running for 1 minute after super lock set or
lock with Intelligent Key, door request switch or auto door lock.
30 Minutes Timer
A timer must be running to turn OFF the indicator. The timer will running for 30 minutes after locking with door
lock and unlock switch.
NOTE:
1minuite timer condition is satisfied during 30 minutes timer is active, 30 minutes timer is not change to 1 min-
utes.
DLK-308
DOOR LOCK FUNCTION
DOOR LOCK AND UNLOCK SWITCH : Component Parts Location INFOID:0000000001280716
DLK
JMKIA0649ZZ
M

M65, M66, M67 E11, E13 M40 N
4. Passenger side anti-hijack relay 5. Door lock and unlock switch 6. Inside key antenna (instrument
M90 M89 center)
M56
O
M252 B45 E25
M59 P
A. Over the glove box B. Engine room LH C. Over the instrument lower panel
(driver side)
D. View with lower instrument cover re- E. View with center console removed F. View with luggage floor spacer re-
moved moved
G. View with front bumper fascia removed H. View with center console removed
DLK-309
DOOR LOCK FUNCTION
JMKIA0648ZZ

M34 M34 M34
4. Ignition knob switch, key switch and 5. Ignition knob switch, key switch and key 6. Front door switch (passenger side)
M25 M25
7. Front door lock actuator (passenger 8. Rear door lock actuator LH 9. Out side key antenna and front door
side) D85 request switch (driver side)
D9 D10
D10 D187 D187
D190 B58 D191
moved
L. Luggage side lower finisher (RH) re-
moved.
DLK-310
DOOR LOCK FUNCTION
DOOR LOCK AND UNLOCK SWITCH : Component Description INFOID:0000000001280717
Item Function
Transmits door lock and unlock signal to BCM. Door lock/unlock switch indicator is built-in
Door lock and unlock switch C
door lock/unlock switch.
Door lock actuator Receives door lock/unlock signal from BCM and locks/unlock each door.
INTELLIGENT KEY D
INTELLIGENT KEY : System Diagram INFOID:0000000001280718
E
J
JMKIA0564GB
INTELLIGENT KEY : System Description INFOID:0000000001280719

DLK

The Intelligent Key has the same functions as the multi remote control system. Therefore, it can be used in the L
same manner as the keyfob by operating the door lock/unlock button.
This function can be set to OFF with CONSULT-III. For the setting information, refer to DLK-349, "CONSULT-
M
OPERATION CONDITION
Remote controller operation Operation condition

N
Lock
• No Intelligent Keys are inside the vehicle. O
Unlock
P
OPERATION AREA
To ensure that the Intelligent Key works effectively, use within 100 cm range of each door, however the opera-
ble range may differ according to surroundings.
LOCK AND UNLOCK CONTROL
When door lock and unlock button of the Intelligent Key is pressed, lock signal or unlock signal is transmitted
from Intelligent Key to Intelligent Key unit.
When Intelligent Key unit receives the door lock and unlock signal, it operates door lock actuator.
DLK-311
DOOR LOCK FUNCTION
SUPER LOCK OPERATION
Super lock provides a higher anti-theft performance than a conventional power door lock system. The super
lock system is controlled by BCM.
When super lock is set, all doors can not be opened from the inside.
ANTI-HIJACK MODE
When door lock is unlocked, pressing LOCK button on keyfob once will lock all doors. When door lock is
locked, pressing UNLOCK button on keyfob will unlock driver side door. Pressing UNLOCK button on keyfob
second time within 5 seconds from the first time will unlock all doors and back door can be opened with back
door opener switch.
NOTE:
"MULTIREMOTE ENT : CONSULT-III Function (BCM - MULTIREMOTE ENT)".
INTELLIGENT KEY : Component Parts Location INFOID:0000000001393925
JMKIA0649ZZ
DLK-312
DOOR LOCK FUNCTION
1. BCM 2. IPDM E/R 3. Intelligent Key unit A

M65, M66, M67 E11, E13 M40
M90 M89 center)
M56 B
M252 B45 E25
10. Air bag diagnosis sensor unit C
M59
(driver side)
D
moved moved
E
DLK
JMKIA0648ZZ
DLK-313
DOOR LOCK FUNCTION

M34 M34 M34
M25 M25
D9 D10
D10 D187 D187
D190 B58 D191
moved
moved.
INTELLIGENT KEY : Component Description INFOID:0000000001280721
Item Function
Intelligent Key unit Controls the door lock/unlock operation with BCM.
BCM Controls the door lock/unlock operation with Intelligent Key unit.
Key switch Detects mechanical key is inserted into ignition key cylinder.
Outside key antenna Detects Intelligent Key is in detection area of outside key antenna.
Inside key antenna Detects Intelligent Key is in detection area of inside key antenna.
Intelligent Key Transmits key ID to Intelligent Key unit when lock/unlock button is pressed.
Door lock actuator Receives lock/unlock signal from BCM and lock and unlock each door.
Receives super lock set/release signal from BCM and set/release super lock sys-
Super lock actuator
tem.
DOOR REQUEST SWITCH
DLK-314
DOOR LOCK FUNCTION
DOOR REQUEST SWITCH : System Diagram INFOID:0000000001280722
A
JMKIA0565GB
I
DOOR REQUEST SWITCH : System Description INFOID:0000000001280723
DOOR REQUEST SWITCH OPERATION J

Only when pressing the request switch, it is possible to lock and unlock the door by carrying the Intelligent
Key. The Intelligent Key system is a system that makes it possible to lock and unlock the door by carrying the
Intelligent Key, which operates based on the results of electronic ID verification using two-way communica- DLK
tions between the Intelligent Key and the vehicle (Intelligent Key unit).
This function can be set to OFF with CONSULT-III. For the setting information, refer to DLK-349, "CONSULT-
CAUTION: L
The driver should always carry the Intelligent Key
OPERATION CONDITION
M
If the following conditions are not satisfied, door lock and unlock operation is not performed even if the request
switch is operated.
Each request switch operation Operation condition N

• Key switch is OFF (Key is removed from ignition key cylinder)
Lock operation • Ignition knob is OFF or LOCK position O
• No Intelligent Keys are inside the vehicle
• Key switch is OFF (Key is removed from ignition key cylinder)
• Ignition knob is OFF or lock position (Ignition switch is not pressed)
P
Unlock Operation
• Intelligent Key is not inside the vehicle*
*: Even with a registered Intelligent Key remaining inside the vehicle, door locks can be unlocked from outside of the vehicle with a spare
Intelligent Key as long as key IDs are different.
OUTSIDE KEY ANTENNA DETECTION AREA
DLK-315
DOOR LOCK FUNCTION
The outside key antenna detection area of door lock/unlock function
is in the range of approximately 80 cm (31.50 in) surrounding the
driver and passenger door handles (1) and the back door request
switch (2). However, this operating range depends on the ambient
conditions.
JMKIA0666ZZ

When the Intelligent Key detects that door request switch is pressed, it starts corresponding with outside key
antenna (request switch pressed door). Then, the Intelligent Key is checked to be near the door.
If the Intelligent Key is within the outside key antenna detection area, it receives the request signal and trans-
mits the key ID signal to the Intelligent Key unit. Intelligent Key unit receives the key ID signal and compares it
with the registered key ID. Intelligent Key unit sends door lock and unlock signal to BCM via CAN communica-
tion.
SUPER LOCK OPERATION
Super lock provides a higher anti-theft performance than a conventional power door lock system. The super
lock system is controlled by BCM and Intelligent Key unit.
When super lock is set, all doors cannot be opened from inside.
ANTI-HIJACK MODE
When door lock is unlocked, pressing LOCK button on keyfob once will lock all doors. When door lock is
locked, pressing UNLOCK button on keyfob will unlock driver side door. Pressing UNLOCK button on keyfob
second time within 5 seconds from the first time will unlock back door only and back door can be opened with
back door opener switch. Pressing back door opener switch a second time within 5 seconds will unlock all
doors.
NOTE:
"CONSULT-III Function (INTELLIGENT KEY)".
DLK-316
DOOR LOCK FUNCTION
DOOR REQUEST SWITCH : Component Parts Location INFOID:0000000001393926
DLK
JMKIA0649ZZ
M

M65, M66, M67 E11, E13 M40 N
M90 M89 center)
M56
O
M252 B45 E25
M59 P
(driver side)
moved moved
DLK-317
DOOR LOCK FUNCTION
JMKIA0648ZZ

M34 M34 M34
M25 M25
D9 D10
D10 D187 D187
D190 B58 D191
moved
moved.
DLK-318
DOOR LOCK FUNCTION
DOOR REQUEST SWITCH : Component Description INFOID:0000000001280725
Item Function
Door request switch Transmits operation signal (lock and unlock) to Intelligent Key unit.
C
Ignition knob switch Detects ignition knob state (push or release). D
Outside key antenna Detects Intelligent Key is in detection area of outside key antenna.
E
Transmits key ID to Intelligent Key unit when request signal is received from out-
Intelligent Key
side key antenna.
F
Door lock actuator Receives lock/unlock signal from BCM and locks/unlocks each door.
Receives super lock set/release signal from BCM and sets/releases super lock
Super lock actuator
system.
G
KEY REMINDER
KEY REMINDER : System Diagram INFOID:0000000001280726
H

I
DLK
JMKIA0566GB
N
KEY REMINDER : System Description INFOID:0000000001280727
KEY REMINDER OPERATION O

Key reminder have the following 2 functions.
DLK-319
DOOR LOCK FUNCTION
Operation Operation condition Operation

Right after driver side door is closed under the following con-
ditions
Driver door close • Door lock operation All doors unlock
• Driver side door is opened
• Driver side door is in unlock state.
Right after all doors are closed under the following condi-
tions • All doors unlock
Any door open to all door close • Intelligent Key is inside the vehicle • Honk Intelligent Key warning
• Any door is opened buzzer
• All doors are locked by door lock and unlock switch.
CAUTION:
The above function operates when the Intelligent Key is inside the vehicle. However, there may be
times when the Intelligent Key can not be detected, and this function will not operate when the Intelli-
gent Key is on the instrument panel, rear parcel shelf or in the glove box. Also, this system some times
does not operate if the Intelligent Key is in the door pocket for the open door.
KEY REMINDER : Component Parts Location INFOID:0000000001393927
JMKIA0649ZZ
DLK-320
DOOR LOCK FUNCTION
1. BCM 2. IPDM E/R 3. Intelligent Key unit A

M65, M66, M67 E11, E13 M40
M90 M89 center)
M56 B
M252 B45 E25
10. Air bag diagnosis sensor unit C
M59
(driver side)
D
moved moved
E
DLK
JMKIA0648ZZ
DLK-321
DOOR LOCK FUNCTION

M34 M34 M34
M25 M25
D9 D10
D10 D187 D187
D190 B58 D191
moved
moved.
KEY REMINDER : Component Description INFOID:0000000001280729
Item Function
BCM Controls the door lock and unlock operation with Intelligent Key unit.
Intelligent Key Transmits key ID to Intelligent Key unit when Intelligent Key searching.
Door lock actuator Receives lock and unlock signal from BCM and locks/unlocks each door.
AUTO DOOR LOCK

AUTO DOOR LOCK : System Diagram INFOID:0000000001280730
JMKIA0567GB
AUTO DOOR LOCK : System Description INFOID:0000000001280731
AUTO RELOCK OPERATION

When all door is locked then doors are unlocked with Intelligent Key, door request switch or BCM does not
receive the following signal within 2 minutes*1, all doors are automatically locked.
DLK-322
DOOR LOCK FUNCTION
• Any door is opened.
• Ignition knob is pressed. A
• Ignition key is inserted into ignition key cylinder.
• Door is locked with Intelligent Key.
• Door is locked/unlocked with door lock and unlock switch.
*1 B
: Auto door lock operation mode can be changed with CONSULT-III. Refer to DLK-349, "CONSULT-III Func-
AUTO DOOR LOCK : Component Parts Location INFOID:0000000001393928 C
DLK
O
JMKIA0649ZZ

P
M65, M66, M67 E11, E13 M40
M90 M89 center)
M56
M252 B45 E25
M59
DLK-323
DOOR LOCK FUNCTION
(driver side)
moved moved
JMKIA0648ZZ

M34 M34 M34
M25 M25
D9 D10
D10 D187 D187
D190 B58 D191
DLK-324
DOOR LOCK FUNCTION
moved A
moved.
B
AUTO DOOR LOCK : Component Description INFOID:0000000001280733
Item Function C
D
Ignition knob switch Detects ignition knob state (push or release). E
Door lock actuator Receives lock and unlock signal from BCM and lock and unlock each door.
F
VEHICLE SPEED SENSING AUTO DOOR LOCK : System Diagram INFOID:0000000001280734
G
VEHICLE SPEED SENSING AUTO DOOR LOCK OPERATION
H
DLK
L
JMKIA0568GB
VEHICLE SPEED SENSING AUTO DOOR LOCK : System Description INFOID:0000000001280735
M
VEHICLE SPEED SENSING AUTO DOOR LOCK OPERATION
When the vehicle speed exceeds more than 25km/h (16 MPH), all doors are automatically locked. BCM
receive the vehicle speed signal from combination meter via CAN communication. N
DLK-325
DOOR LOCK FUNCTION
VEHICLE SPEED SENSING AUTO DOOR LOCK : Component Parts Location
INFOID:0000000001393929
JMKIA0649ZZ

M65, M66, M67 E11, E13 M40
M90 M89 center)
M56
M252 B45 E25
M59
(driver side)
moved moved
DLK-326
DOOR LOCK FUNCTION
DLK
L
JMKIA0648ZZ

M34 M34 M34
N
M25 M25
D9 D10 O
D10 D187 D187
P
D190 B58 D191
moved
moved.
DLK-327
DOOR LOCK FUNCTION
VEHICLE SPEED SENSING AUTO DOOR LOCK : Component Description
INFOID:0000000001280737
Item Function
BCM Controls the door lock function.
Door lock actuator Receives door lock and unlock signal from BCM and lock and unlock each door.
AIR BAG INTERLOCK UNLOCK

AIR BAG INTERLOCK UNLOCK : System Diagram INFOID:0000000001280738
JMKIA0569GB
AIR BAG INTERLOCK UNLOCK : System Description INFOID:0000000001280739

When ignition switch is ON and BCM receive air bag deployment signal, it operates automatically to unlock all
doors. Air bag diagnosis sensor unit sends the air bag deployment signal to BCM.
DLK-328
DOOR LOCK FUNCTION
AIR BAG INTERLOCK UNLOCK : Component Parts Location INFOID:0000000001393930
DLK
JMKIA0649ZZ
M

M65, M66, M67 E11, E13 M40 N
M90 M89 center)
M56
O
M252 B45 E25
M59 P
(driver side)
moved moved
DLK-329
DOOR LOCK FUNCTION
JMKIA0648ZZ

M34 M34 M34
M25 M25
D9 D10
D10 D187 D187
D190 B58 D191
moved
moved.
DLK-330
DOOR LOCK FUNCTION
AIR BAG INTERLOCK UNLOCK : Component Description INFOID:0000000001280741
Item Function
Air bag diagnosis sensor unit Transmits air bag deployment signal to BCM.
Door lock actuator Receives door lock/unlock signal from BCM and lock and unlock each door.
C
DLK
DLK-331
BACK DOOR OPENER SWITCH : System Diagram INFOID:0000000001280742
JMKIA0402GB
BACK DOOR OPENER SWITCH : System Description INFOID:0000000001280743

When back door opener switch is pressed, BCM opens back door opener actuator.
NOTE:
Back door opener actuator is not for locking the back door. The function is only to open the back door.
OPERATION CONDITION
If the following conditions are not satisfied, back door opener operation is not performed.
Back door opener switch operation Operation condition

• Vehicle speed is less than 5 km/h (3 MPH).
Back door open
• All doors are unlocked.
DLK-332
BACK DOOR OPENER SWITCH : Component Parts Location INFOID:0000000001393931
DLK
JMKIA0649ZZ
M

M65, M66, M67 E11, E13 M40 N
M90 M89 center)
M56
O
M252 B45 E25
M59 P
(driver side)
moved moved
DLK-333
JMKIA0648ZZ

M34 M34 M34
M25 M25
D9 D10
D10 D187 D187
D190 B58 D191
moved
moved.
DLK-334
BACK DOOR OPENER SWITCH : Component Description INFOID:0000000001280745
Item Function
BCM Controls the back door opener function. B
Back door opener switch Transmits back door opener switch operation signal to BCM.
Back door opener actuator Opens the back door with the back door open signal from BCM.
C
DLK
DLK-335
WARNING FUNCTION
WARNING FUNCTION
JMKIA0409GB
JMKIA0410GB
DESCRIPTION
The warning functions are as follows and are given to the user as warning information and warnings using
combinations of Intelligent Key warning buzzer, key warning lamps and buzzer (built in combination meter).
Once one of the following conditions below is established, alert or warning will be executed.
DLK-336
WARNING FUNCTION
Warning chime A
Combination
warning buzz-
meter buzzer
er
B
Active
• Ignition knob: OFF or LOCK (knob is
Ignition knob return forgotten for 5 seconds
pressed). — —
warning (pipipipi, C
pipipipi···)
open).
Active
• Ignition switch: OFF position. D
Ignition key warning for 5 seconds
• Key switch: ON (inserted) — —
(when mechanical key is used) (pipipipi,
pipipipi···)
open).
E
• Ignition switch is between ACC and
OFF position or ignition knob is Active
“LOCK”
OFF position warning pressed in while ignition switch is in for 1 second — F
(RED blinking)
LOCK position. (pipi, pipi···)
• 3 seconds in the above state have
pressed.
G
• Ignition switch: Except LOCK position.
Any door
• Door switch: ON to OFF (Door is open “KEY” Active
open to all —
to closed). (RED blinking) (pi, pi, pi) H
doors closed
• Intelligent Key cannot be detected in-
side the vehicle.
• Door switch: ON (Door is open) I
“KEY”
Door is open • Key ID verification every 5 seconds — —
(RED blinking)
when registered Intelligent Key can
Take away not be detected inside the vehicle. J
warning
• Key ID verification: OK
• Every 30 seconds when registered In-
telligent Key cannot be detected in- DLK
Take away side the vehicle or result of vehicle Active for 3 sec-
“KEY”
through win- speed verification is NG. (The regis- onds —
(RED blinking)
dow tered Intelligent Key cannot be detect- (pipipi···
L
ed inside the vehicle when ignition
switch is ON.)
• Key switch: OFF (Key is removed
from ignition key cylinder.) M
DLK-337
WARNING FUNCTION
Warning chime

Combination
warning buzz-
meter buzzer
er
When request switch is pushed (lock op-
eration) under the following conditions.
Request Active for 2
switch opera- — — seconds
tion (pipipi···)
Door lock op- • Intelligent Key is inside vehicle.
eration warn-
ing When Intelligent Key button is pushed
(lock operation) under the following con-
ditions.
Intelligent Key Active for 2
button opera- — — seconds
tion (pipipi···)
“KEY”
When Intelligent Key battery voltage is
Intelligent Key low battery (GREEN blink-
low, Intelligent Key unit is detected after — —
warning ing for 30 sec-
ignition switch is turned ON.
onds)
KEY WARNING LAMP & LOCK WARNING LAMP

The key indicator and lock indicator indicates Intelligent Key system status.
Operation Condition
Behavior of lamps Operation condition

• Ignition knob is pushed in LOCK position. (Ignition knob switch is ON)
Lighting • Ignition key is removed from ignition key cylinder. (Key switch is OFF)
GREEN • Intelligent Key is detected inside of the vehicle.
• KEY RED lighting/blinking conditions are not satisfied.
Blinking while Intelligent Key low battery warning is operating.
KEY All the following conditions are satisfied.
• Ignition knob is pushed. (Ignition knob switch is ON)
Lighting
• Ignition key is removed from ignition key cylinder. (Key switch is OFF)
RED • Intelligent Key is not detected inside of the vehicle.
Blinking • Take away warning is operating.
• KEY RED lighting condition is not satisfied.
LOCK Blinking While OFF position warning is operating.
KEY(RED) and LOCK lighting • Ignition switch is ON.
• Steering lock ID is NG.

When back door opener switch is operated, when door lock is locked with door lock and unlock switch, speed
sensing lock or only driver side is unlocked with anti-hijack function, the buzzer (built in combination meter) will
sound.
pressed while the driver door is open and mechanical key is inserted ignition key cylinder.
pressed while any door other than the driver door is open.
DLK-338
WARNING FUNCTION
DLK
JMKIA0649ZZ
M

M65, M66, M67 E11, E13 M40 N
M90 M89 center)
M56
O
M252 B45 E25
M59 P
(driver side)
moved moved
DLK-339
WARNING FUNCTION
JMKIA0648ZZ

M34 M34 M34
M25 M25
D9 D10
D10 D187 D187
D190 B58 D191
moved
moved.
DLK-340
WARNING FUNCTION
Item Function
BCM Controls the warning function with Intelligent Key unit. B
Intelligent Key unit Controls the warning function with BCM.
C
Requests to turn ON hazard warning lamp to BCM and turn signal indicator to D
combination meter.
E
munication.
Intelligent Key warning buzzer Sounds by the request from Intelligent Key unit.
Back door opener switch Transmits back door open signal to BCM F
DLK
DLK-341
HAZARD & BUZZER REMINDER FUNCTION
JMKIA0506GB

When door is locked or unlocked by Intelligent Key or door request switch, Intelligent Key unit sounds buzzer
and sends hazard request signal to BCM via CAN communication. Then BCM flashes hazard warning lamps
as a reminder.
NOTE:
Hazard and buzzer reminder function mode can be changed with CONSULT-III. Refer to DLK-349, "CON-
SULT-III Function (INTELLIGENT KEY)".
Hazard Operation
Hazard reminder setting Door lock operation
Hazard warning lamp flash
OFF Any —
Lock Once
LOCK ONLY Unlock —
Unlock (Anti-hijack) —
Lock —
HAZARD ANSWER BACK
UNLK ONLY Unlock Twice
Lock Once
LOCK/UNLK Unlock Twice
Buzzer Operation
Lock Once
ANSWER BACK WITH BUZZER Unlock Depends on other setting
I-KEY
LOCK Unlock (Anti-hijack) Depends on other setting
OFF Any —
DLK-342
(With CONSULT-III) (with Intelligent Key or door request switch) A
Lock Depends on other setting
ANSWER BACK WITH BUZZER Unlock Twice
I-KEY B
UNLOCK Unlock (Anti-hijack) Twice
OFF Any —
Lock Once C
ANSWER BACK FUNC- ON Unlock Twice
TION Unlock (Anti-hijack) Twice
D
OFF Any —
DLK
JMKIA0649ZZ
DLK-343

M65, M66, M67 E11, E13 M40
M90 M89 center)
M56
M252 B45 E25
M59
(driver side)
moved moved
JMKIA0648ZZ
DLK-344
1. Combination meter 2. Lock warning lamp 3. Key warning lamp A

M34 M34 M34
M25 M25 B
D9 D10 C
D10 D187 D187
D
D190 B58 D191
moved E
moved.
F
Item Function G
BCM Controls the hazard and buzzer reminder function with Intelligent Key unit.
Intelligent Key unit Controls the hazard and buzzer reminder function with BCM.
H
munication.
I
Intelligent Key warning buzzer Sounds by the request signal from Intelligent Key unit.
DLK
DLK-345
COMMON ITEM
APPLICATION ITEM

Self-Diagnostic Results Displays the diagnosis results judged by BCM. Refer to DLK-500, "DTC Index".
Configuration
SYSTEM APPLICATION
NOTE:
×: Applicable item

System
— BCM ×
— PTC HEATER*
DOOR LOCK

DLK-346
Diagnosis mode Function Description A

B
DATA MONITOR
C
ACC ON SW Indicates [ON/OFF] condition of ignition switch in ACC position. D

KEY ON SW Indicates [ON/OFF] condition of key switch. E
DOOR SW-DR Indicates [ON/OFF] condition of front door switch (driver side). F
G
KEYLESS LOCK*2 Indicates [ON/OFF] condition of lock signal from key fob. H
I-KEY LOCK*1 Indicates [ON/OFF] condition of lock signal from Intelligent Key. I
J
DLK
sor unit.
SHOCK SENSOR agnosis sensor unit.) L
unit.
M
VEHICLE SPEED
[km/h].
*1
*2:
N
For the multi remote control system equipped vehicle.
ACTIVE TEST
O
P
DOOR LOCK IND
DOOR LOCK
OTHER UNLOCK].
WORK SUPPORT
DLK-347

INTELLIGENT KEY


DATA MONITOR

TRUNK
APPLICATION ITEM

DATA MONITOR


VEHICLE SPEED
[km/h].
*1
*2
: For the remote keyless entry system equipped vehicle.
ACTIVE TEST

DLK-348
A
CONSULT-III Function (INTELLIGENT KEY) INFOID:0000000001280758
APPLICATION ITEM B
CONSULT-III performs the following functions via CAN communication with Intelligent Key unit.
Diagnosis mode Function Description C

SELF-DIAG RESULTS Displays the diagnosis results judged by Intelligent Key unit.
CAN DIAG SUPPORT MNTR Monitors the reception status of CAN communication viewed from Intelligent Key unit. D
DATA MONITOR The Intelligent Key unit input/output signals are displayed.
E
ECU IDENTIFICATION The Intelligent Key unit part number is displayed.
WORK SUPPORT
F
Support item Description Selection item Condition
It can check whether Intelligent Key ID code
CONFIRM KEY FOB ID — — G
is registered or not.
Take away warning chime (from window) ON Active

TAKE OUT FROM WINDOW WARN
mode can be changed. OFF Inactive H
Intelligent Key low battery warning mode can ON Active
LOW BATT OF KEY FOB WARN
Door lock function with Intelligent Key can be ON Active I

KEYLESS FUNCTION
ON Active
ANSWER BACK FUNCTION Buzzer reminder operation can be changed. J
OFF Inactive
ON Active
SELECTIVE UNLOCK FUNCTION Anti-hijack mode can be changed.
OFF Inactive DLK
Hazard reminder operation mode can be
HAZARD ANSWER BACK Refer to DLK-342.
changed.
Buzzer reminder operation (lock operation) BUZZER Active L
ANSWER BACK WITH I-KEY LOCK mode by each door request switch can be
Buzzer reminder operation (unlock operation) BUZZER Active M

ANSWER BACK WITH I-KEY UNLOCK mode by each door request switch can be
Auto door lock operation mode can be OFF Inactive

AUTO RELOCK TIMER N
changed. 2 min. Active
Engine start function (by Intelligent Key) ON Active

ENGINE START BY I-KEY
mode can be changed. OFF Inactive O
Door lock function by door request switch can ON Active

LOCK/UNLOCK BY I-KEY
P
SELF-DIAG RESULT
Refer to DLK-458, "DTC Index".
DATA MONITOR
DLK-349

PUSH SW Indicates [ON (pressed)/OFF (released)] condition of ignition knob switch.
KEY SW Indicates [ON (inserted)/OFF (removed)] condition of key switch.
DR REQ SW Indicates [ON (pressed)/OFF (released)] condition of door request switch (driver side).
Indicates [ON (pressed)/OFF (released)] condition of door request switch (passenger
AS REQ SW
side).
BD/TR REQ SW Indicates [ON (pressed)/OFF (released)] condition of door request switch (back door).
Indicates [ON (ON or START position)/OFF (other than ON and START position)] con-
IGN SW
dition of ignition switch ON position.
ACC SW Indicates [ON/OFF] condition of ignition switch ACC position.
STOP LAMP SW Indicates [ON/OFF] condition of stop lamp switch.
DOOR LOCK SIG Indicates [ON/OFF] condition of LOCK signal from Intelligent Key.
DOOR UNLOCK SIG Indicates [ON/OFF] condition of UNLOCK signal from Intelligent Key.
Indicates [OPEN/CLOSE] condition of front door switch (driver side) from BCM via CAN
DOOR SW DR
communication.
Indicates [OPEN/CLOSE] condition of front door switch (passenger side) from BCM via
DOOR SW AS
CAN communication.
Indicates [OPEN/CLOSE] condition of rear door switch (RH) from BCM via CAN com-
DOOR SW RR
munication.
Indicates [OPEN/CLOSE] condition of rear door switch (LH) from BCM via CAN com-
DOOR SW RL
munication.
Indicates [OPEN/CLOSE] condition of back door switch from BCM via CAN communi-
DOOR BK SW
cation.
VEHICLE SPEED
[km/h].
ACTIVE TEST

This test is able to check door lock/unlock operation.
• ALL UNLK: All door lock actuators are unlocked.
• DR UNLK: Door lock actuator (driver side) is unlocked.
DOOR LOCK/UNLOCK
• AS UNLK: Door lock actuator (passenger side) is unlocked.
• BK UNLK: This item is indicated, but inactive.
• LOCK: All door lock actuator is locked.
This test is able to check Intelligent Key antenna operation.
When the following condition are met, LED (on Intelligent Key) blinks.
• ROOM ANT1: Inside key antenna (console) transmissions can be detected by Intel-
ligent Key, when “ROOM ANT1” is selected.
• ROOM ANT2: Inside key antenna (instrument center/rear seat) transmissions can be
detected by Intelligent Key, when “ROOM ANT2”is selected.
ANTENNA
• DRIVER ANT: Outside key antenna (driver side) transmissions can be detected by
Intelligent Key, when “DRIVER ANT” is selected.
• ASSIST ANT: Outside key antenna (passenger side) transmissions can be detected
by Intelligent Key, when “ASSIST ANT” is selected.
• BK DOOR ANT: Outside key antenna (rear bumper) transmissions can be detected
by Intelligent Key, when “BK DOOR ANT” is selected.
This test is able to check Intelligent Key warning buzzer operation.
OUTSIDE BUZZER • ON
• OFF
This test is able to check warning chime in combination meter operation.
• TAKE OUT: Take away warning chime sounds.
INSIDE BUZZER • KNOB: Ignition knob switch warning chime sounds.
• KEY: Key warning chime sounds.
• OFF
DLK-350
A
This test is able to check warning lamp operation.
• BLUE ON: Key warning lamp (green) illuminates.
• RED ON: Key warning lamp (red) illuminates.
• KNOB ON: Lock warning lamp illuminates. B
INDICATOR
• BLUE IND: Key warning lamp (green) flashes.
• RED IND: Key warning lamp (red) flashes.
• KNOB IND: Lock warning lamp flashes.
• OFF C
This test is able to check key interlock operation.
KEY LOCK SOLENOID*1 • LOCK: Key interlock is active.
• UNLOCK: Key interlock is inactive. D
*1: The item is only for MT model.
DLK
DLK-351
< COMPONENT DIAGNOSIS > [WITH I-KEY & SUPER LOCK]
COMPONENT DIAGNOSIS
DTC DETECTION LOGIC
CONSULT-III display
description
In CAN communication system, any item (or items)
of the following listed below is malfunctioning.
• Transmission
When Intelligent Key unit cannot communi-
• Receiving (BCM)
U1000 CAN COMM CIRCUIT cate CAN communication signal continuous-
ly for 2 seconds or more.
• Receiving (ECM)
• Receiving (METER/M&A)
• Receiving (MULTI AV)

2. Check “Self Diagnostic Result” of BCM.
DLK-352
A
CAN (Controller Area Network) is a serial communication line for real time applications. It is an on-vehicle mul- B
with 2 communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less C
CAN Communication Signal Chart, refer to LAN-25, "CAN Communication Signal Chart".
D
DTC DETECTION LOGIC

E
CONSULT-III display de-
scription
When detecting error during the initial diagnosis of CAN control- F
U1010 CONTROL UNIT (CAN) Intelligent Key unit
ler of Intelligent Key unit.

G
1.REPLACE INTELLIGENT KEY UNIT
When DTC [U1010] is detected, replace Intelligent Key unit. H
>> Replace Intelligent Key unit.

I
1.REQUIRED WORK WHEN REPLACING INTELLIGENT KEY UNIT J

Initialize control unit. Refer to CONSULT-III operation manual NATS-IVIS/NVIS.
>> Work end. DLK
DLK-353
INTELLIGENT KEY UNIT : Diagnosis Procedure INFOID:0000000001298174

Check that the following fuse is not blown.
Terminal No. Signal name Fuse No.

11 Battery power supply 14 (10A)
Is the fuse blown?
YES >> Replace the blown fuse after repairing the affected circuit if a fuse is blown.
NO >> GO TO 2.
Terminal
(+) (−) Voltage (V)
Intelligent Key unit (Approx.)
Connector Terminal
Ground
11
M40 Battery voltage
6
YES >> GO TO 3.

Continuity
M40 12 Exists
YES >> Intelligent Key unit power supply and ground circuit are OK.
BCM
BCM : Diagnosis Procedure INFOID:0000000001298175

Check that the following fuse and fusible link are not blown.
Terminal No. Signal name Fuse and fusible link No.

41 10 (10A)
57 J (50A)
4 ACC power supply 20 (10A)
DLK-354
Is the fuse fusing?
YES >> Replace the blown fuse or fusible link after repairing the affected circuit if a fuse or fusible link is A
blown.
NO >> GO TO 2.
2.CHECK POWER SUPPLY CIRCUIT B
3. Check voltage between BCM harness connector and ground. C
Terminals
(+) D
Voltage
Condition
BCM (−) (Approx.)
Connector Terminal
E
M66 41
Turn ignition switch OFF
M67 57
Ground Battery voltage
3 Turn ignition switch ON F
M65
4 Turn ignition switch ACC
G
YES >> GO TO 3.
3.CHECK GROUND CIRCUIT H
BCM I
Continuity
M67 55 Exists
J
YES >> BCM power supply and ground circuit are OK.
DLK
DLK-355
Transmits door lock/unlock operation to BCM.

1.CHECK FUNCTION
With CONSULT-III
Check “CDL LOCK SW ”and “CDL UNLOCK SW” in “Data Monitor” mode with CONSULT-III.

LOCK : ON
CDL LOCK SW
UNLOCK : OFF
LOCK : OFF
CDL UNLOCK SW
UNLOCK : ON
1.CHECK DOOR LOCK AND UNLOCK INPUT SIGNAL

2. Disconnect door lock and unlock switch connector.
3. Check voltage between door lock and unlock switch harness connector and ground.
Terminal
(+) Signal
Door lock and unlock switch
Terminal
connector
1
M89 Ground
2
JPMIA0154GB

YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK DOOR LOCK AND UNLOCK SWITCH CIRCUIT
2. Disconnect BCM connector.
3. Check continuity between BCM harness connector and door lock and unlock switch harness connector.
Door lock and unlock

switch connector
32 2
M65 M89 Exists
34 1
DLK-356
BCM connector Terminal Continuity A

32 Ground
M65 Does not exist
34
B
YES >> GO TO 4.
C
Check continuity between door lock and unlock switch harness connector and ground.
D
Door lock and unlock switch connector Terminal Continuity
Ground
M89 3 Exists
Is the inspection result normal? E
YES >> GO TO 5.
F
2. Check voltage between BCM harness connector and ground. G
Terminal
Signal
(+) H
32
I
M65 Ground
34
J
JPMIA0154GB

YES >> GO TO 5.
NO >> GO TO 6.
L
Check door lock and unlock switch
Refer to DLK-357, "Component Inspection". M
YES >> GO TO 6.
NO >> Replace door lock and unlock switch. Refer to DLK-596, "Removal and Installation". N
O
>> INSPECTION END

Component Inspection INFOID:0000000001298179 P

Check door lock and unlock switch.
DLK-357
Door lock and unlock switch Terminal Condition Continuity

1 LOCK
M89 3 Exists
2 UNLOCK
NO >> Replace door lock and unlock switch. Refer to DLK-596, "Removal and Installation".
DLK-358
DOOR LOCK AND UNLOCK SWITCH INDICATOR
A
The door lock and unlock switch indicates door lock status. The indicator will illuminate when a lock operation B
is accomplished, and during this status, if any door is opened, the indicator will turn OFF.
C
1.CHECK FUNCTION
With CONSULT-III
Check “DOOR LOCK IND” in “Active Test” mode with CONSULT-III. D
Test item Condition

:ON Illuminated E
DOOR LOCK IND
:OFF Not illuminated
Diagnosis Procedure INFOID:0000000001280778 G
1.CHECK DOOR LOCK AND UNLOCK SWITCH INDICATOR INPUT SIGNAL

2. Check voltage between door lock and unlock switch harness connector and ground.
Terminal I
(+) Voltage
Condition
(–) (Approx.)
Terminal J
switch connector
Door lock operation is accom-
Battery voltage
M89 6 Ground plished
Any door is OPEN 0 DLK

L
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK DOOR LOCK AND UNLOCK SWITCH CIRCUIT M
1. Disconnect BCM connector and door lock and unlock switch connector.
2. Check continuity between BCM harness connector and door lock and unlock switch harness connector.
N
switch connector
M65 17 M89 6 Exists
O

Ground P
YES >> GO TO 3.
Check continuity between door lock and unlock switch harness connector and ground.
DLK-359
Door lock and unlock switch connector Terminal Continuity

Ground
M89 4 Exists
YES >> GO TO 4.
>> INSPECTION END
DLK-360
DOOR REQUEST SWITCH
DOOR REQUEST SWITCH
A
DRIVER SIDE
B
C
1.CHECK FUNCTION
With CONSULT-III D
Check door request switch “DR REQ SW” in “Data Monitor” mode with CONSULT-III.

E
DR REQ SW
G
1.CHECK INTELLIGENT KEY UNIT INPUT SIGNAL H

I
Terminal
Intelligent Key unit J
Terminal
connector
Pressed 0
M40 5 Ground
Released 5 DLK
YES >> GO TO 6.
NO >> GO TO 2. L
2.CHECK FRONT DOOR REQUEST SWITCH CIRCUIT
1. Disconnect Intelligent Key unit connector. M
Intelligent Key unit Outside key antenna and front door N

connector request switch (driver side)
M40 5 D30 3 Exists
O

Terminal Continuity P
connector Ground
YES >> GO TO 3.
request switch (driver side).
DLK-361
DOOR REQUEST SWITCH

Check continuity between outside key antenna and front door request switch (driver side) harness connector
and ground.
Outside key antenna and front door request

Terminal Continuity
switch (driver side) connector Ground
D30 4 Exists
YES >> GO TO 4.
NO >> Repair or replace outside key antenna and front door request switch (driver side) ground circuit.

Terminal
M40 5 5
YES >> GO TO 5.
NO >> GO TO 6.
YES >> GO TO 6.
Installation".
>> INSPECTION END


Terminal
(driver side)
Pressed Exists
3 4
Installation".
PASSENGER SIDE
DLK-362
DOOR REQUEST SWITCH
A
1.CHECK FUNCTION
With CONSULT-III
B
Check door request switch “AS REQ SW” in “Data Monitor” mode with CONSULT-III.

C
AS REQ SW
E

F
Terminal G
connector
Terminal H
Pressed 0
M40 25 Ground
Released 5
I
YES >> GO TO 6.
NO >> GO TO 2. J
2. Check continuity between Intelligent Key unit harness connector and outside key antenna and front door DLK
Outside key antenna and front door L

Terminal request switch (passenger side) Terminal Continuity
connector
connector
Intelligent Key unit N

Terminal Continuity
connector Ground
Is the inspection result normal? O
YES >> GO TO 3.
request switch (passenger side). P
Check continuity between outside key antenna and front door request switch (passenger side) harness con-
nector and ground.
DLK-363
DOOR REQUEST SWITCH
Outside key antenna and front door re-

quest switch (passenger side) Terminal Continuity
connector Ground
D69 4 Exists
YES >> GO TO 4.
NO >> Repair or replace outside key antenna and front door request switch (passenger side) ground cir-
cuit.

Terminal
M40 25 5
YES >> GO TO 5.
NO >> GO TO 6.
YES >> GO TO 6.
and Installation".
>> INSPECTION END


Terminal
(passenger side)
Pressed Exists
3 4
and Installation".
BACK DOOR
DLK-364
DOOR REQUEST SWITCH
A
1.CHECK FUNCTION
With CONSULT-III
B
Check door request switch “BD/TR REQ SW” in “Data Monitor” mode with CONSULT-III.

C
BD/TR REQ SW
E

F
Terminal G
connector
Terminal H
Pressed 0
M40 29 Ground
Released 5
I
YES >> GO TO 6.
NO >> GO TO 2. J
2. Check continuity between Intelligent Key unit harness connector and back door opener switch assembly DLK
(request switch) harness connector.
Intelligent Key unit Back door opener switch L

connector (request switch) connector
3. Check continuity between Intelligent Key unit harness connector and ground. M

Terminal Continuity
connector Ground N
O
YES >> GO TO 3.
NO >> Repair or replace harness between Intelligent Key unit and back door opener switch assembly
(request switch).
3.CHECK DOOR REQUEST SWITCH GROUND CIRCUIT P
Check continuity between back door opener switch assembly request switch harness connector and ground.

(request switch) Terminal Continuity
connector Ground
D186 4 Exists
DLK-365
DOOR REQUEST SWITCH
YES >> GO TO 4.
NO >> Repair or replace back door opener switch assembly (request switch) ground circuit.

Terminal
M40 29 5
YES >> GO TO 5.
NO >> GO TO 6.
YES >> GO TO 6.
Installation".
>> INSPECTION END


Terminal
Door request switch condition Continuity
Back door opener switch assembly (request switch)
Pressed Exists
3 4
YES >> Back door request switch is OK.
Installation".
DLK-366
DOOR SWITCH
DOOR SWITCH
A
DRIVER SIDE
B
C
1.CHECK FUNCTION
With CONSULT-III D
Check door switches “DOOR SW-DR” in “Data Monitor” mode with CONSULT-III.
Monitor item Condition E

OPEN :ON
DOOR SW-DR
CLOSE :OFF
G
1.CHECK DOOR SWITCH INPUT SIGNAL H

I
Terminals
(+) Voltage (V)
Door condition
(–) (Approx.)
BCM J
Terminal
connector
OPEN 0
DLK
M65 15 Ground
CLOSE L
JPMIA0011GB M
YES >> GO TO 4.
NO >> GO TO 2. N

1. Disconnect BCM connector and front door switch (driver side) connector. O
2. Check continuity between BCM harness connector and front door switch (driver side) harness connector.
Front door switch

P
BCM connector Terminal (driver side) Terminal Continuity
connector
M65 15 B34 2 Exists
DLK-367
DOOR SWITCH

Ground
YES >> GO TO 3.
3.CHECK DOOR SWITCH
YES >> GO TO 4.
>> INSPECTION END

1.CHECK DOOR SWITCH

Terminal
front door switch (driver side)
Pressed Exists
PASSENGER SIDE

1.CHECK FUNCTION
With CONSULT-III
Check door switches “DOOR SW-AS” in “Data Monitor” mode with CONSULT-III.

OPEN : ON
DOOR SW-AS
CLOSE : OFF

DLK-368
DOOR SWITCH
A
Terminals
(+) Voltage (V)
Door condition
(–) (Approx.) B
BCM
Terminal
connector
OPEN 0
C
M65 14 Ground D
CLOSE
JPMIA0011GB
E

YES >> GO TO 4. F
NO >> GO TO 2.
1. Disconnect BCM connector and front door switch (passenger side) connector. G
2. Check continuity between BCM harness connector and front door switch (passenger side) harness con-
nector.
H
Front door switch
BCM connector Terminal (passenger side) Terminal Continuity
connector
I
M65 14 B27 2 Exists
J
Ground
YES >> GO TO 3.
3.CHECK DOOR SWITCH L

M
YES >> GO TO 4.
N
O
>> INSPECTION END
P
1.CHECK DOOR SWITCH

DLK-369
DOOR SWITCH
Terminal
Front door switch (passenger side)
Pressed Exists
REAR LH

1.CHECK FUNCTION
With CONSULT-III
Check door switches “DOOR SW-RL” in “Data Monitor” mode with CONSULT-III.

OPEN :ON
DOOR SW-RL
CLOSE :OFF
YES >> Rear door switch LH is OK.

Terminals
(+) Voltage (V)
Door condition
(–) (Approx.)
BCM
Terminal
connector
OPEN 0
M65 16 Ground
CLOSE
JPMIA0011GB

YES >> GO TO 4.
NO >> GO TO 2.
1. Disconnect BCM connector and rear door switch LH connector.
2. Check continuity between BCM harness connector and rear door switch LH harness connector.
DLK-370
DOOR SWITCH
Rear door switch LH A

connector
M65 16 B71 2 Exists
3. Check continuity between BCM harness connector and ground. B

Ground
M65 16 Does not exist C
YES >> GO TO 3.
NO >> Repair or replace harness between BCM and rear door switch LH. D
3.CHECK DOOR SWITCH

Check rear door switch LH. E
Refer to DLK-371, "REAR LH : Component Inspection".
YES >> GO TO 4. F
G
>> INSPECTION END H

REAR LH : Component Inspection INFOID:0000000001298203
1.CHECK DOOR SWITCH I

Check rear door switch LH.
Terminal J
Rear door switch LH
Pressed Exists
2 Ground part of door switch DLK
YES >> Rear door switch LH is OK. L
REAR RH
M
Detects door open/close condition.

N
1.CHECK FUNCTION O
With CONSULT-III
Check door switches “DOOR SW-RR” in “Data Monitor” mode with CONSULT-III.
P
OPEN :ON
DOOR SW-RR
CLOSE :OFF
YES >> Rear door switch RH is OK.
DLK-371
DOOR SWITCH

2. Check signal between BCM connector and ground with oscilloscope.
Terminals
(+) Voltage (V)
Door condition
(–) (Approx.)
BCM
Terminal
connector
OPEN 0
M65 12 Ground
CLOSE
JPMIA0011GB

YES >> GO TO 4.
NO >> GO TO 2.
1. Disconnect BCM connector and rear door switch RH connector.
2. Check continuity between BCM harness connector and rear door switch RH harness connector.
Rear door switch RH

connector
M65 12 B53 2 Exists

Ground
YES >> GO TO 3.
3.CHECK DOOR SWITCH
Refer to DLK-372, "REAR RH : Component Inspection".
YES >> GO TO 4.
NO >> Replace rear door switch RH. Refer to DLK-585, "Removal and Installation".
>> INSPECTION END

REAR RH : Component Inspection INFOID:0000000001298207
1.CHECK DOOR SWITCH

DLK-372
DOOR SWITCH
Terminal A
Rear door switch RH
Pressed Exists
2 Ground part of door switch B
YES >> Rear door switch RH is OK. C
NO >> Replace rear door switch RH. Refer to DLK-585, "Removal and Installation".
BACK DOOR
D
Detects back door open condition.

E
1.CHECK FUNCTION F
With CONSULT-III
Check “BACK DOOR SW” in “Data Monitor” mode with CONSULT-III.
G
OPEN : ON
BACK DOOR SW
CLOSE : OFF H
NO >> Refer to DLK-373, "BACK DOOR : Diagnosis Procedure". I
J
1.CHECK BACK DOOR LOCK ASSEMBLY (DOOR SWITCH) INPUT SIGNAL
2. Check voltage between BCM harness connector and ground. DLK
Terminals
Back door Voltage (V)
(+)
condition (Approx.) L
(–)
OPEN 0
M65 13 Ground M
CLOSE Battery voltage
YES >> GO TO 6. N
NO >> GO TO 2.
2.CHECK BACK DOOR LOCK ASSEMBLY (DOOR SWITCH) CIRCUIT
1. Disconnect BCM connector back door lock assembly connector. O
2. Check continuity between BCM harness connector and back door lock assembly (door switch) harness
connector.
P
(door switch) connector
DLK-373
DOOR SWITCH

Ground
YES >> GO TO 3.
NO >> Repair or replace harness between BCM and back door lock assembly (door switch).

Terminal Continuity
(door switch) connector Ground
D190 3 Exists
YES >> GO TO 4.
NO >> Repair or replace back door lock assembly ground circuit.
Terminals
Voltage (V)
(+)
(–) (Approx.)
YES >> GO TO 5.
NO >> GO TO 6.
YES >> GO TO 6.
NO >> Replace back door lock assembly (door switch). Refer to DLK-583, "DOOR LOCK : Removal and
Installation".
>> INSPECTION END


Terminal
Back door condition Continuity
Back door lock assembly (door switch)
OPEN Exists
2 1
CLOSE Does not exist
NO >> Replace back door lock assembly. Refer to DLK-583, "DOOR LOCK : Removal and Installation".
DLK-374
KEY SWITCH
KEY SWITCH
A
Key switch detects that mechanical key is inserted into the key cylinder, and then transmits the signal to BCM B
and Intelligent Key unit.

Check key switch (“KEY SW”) in “Data Monitor” mode with CONSULT-III. D

Insert mechanical key into key cylinder : ON
E
KEY SW
Remove mechanical key from key cylinder : OFF
YES >> Key switch is OK.
G

H
2. Disconnect Intelligent Key unit connector and BCM connector.
I
Terminals
(+) Voltage (V)
Condition
Intelligent Key unit con- (–) (Approx.) J
Terminal
nector
Battery voltage DLK
cylinder
M40 7 Ground
0
key cylinder
4. Check voltage between BCM harness connector and ground. L
Terminals
(+) Condition
Voltage (V) M
(–) (Approx.)
Battery voltage N
cylinder
M65 5 Ground
0
key cylinder
O
YES >> GO TO 5.
NO >> GO TO 2. P
2.CHECK KEY SWITCH POWER SUPPLY CIRCUIT
1. Remove mechanical key from key cylinder.
ground.
DLK-375
KEY SWITCH
Terminals
(+) Voltage (V)
(–) (Approx.)
Ignition knob switch, key switch and key
Terminal
lock solenoid connector
YES >> GO TO 3.
3.CHECK KEY SWITCH SIGNAL CIRCUIT
Ignition knob switch, key

connector
M40 7 M25 1 Exists
2. Check continuity between BCM harness connector and ignition knob switch, key switch and key lock sole-
noid harness connector.

M65 5 M25 1 Exists
3. Check continuity between ignition knob switch, key switch and key lock solenoid harness connector and
ground.
Ignition knob switch, key switch and

Terminal Ground Continuity
key lock solenoid connector
M25 1 Ground Does not exist
YES >> GO TO 4.
4.CHECK KEY SWITCH
Check key switch.
yes >> GO TO 5.
>> INSPECTION END

COMPONENT INSPECTION
1.CHECK KEY SWITCH
Check continuity between ignition knob switch, key switch and key lock solenoid terminals.
Terminal
Ignition knob switch, key switch and key lock solenoid
DLK-376
KEY SWITCH
Insert mechanical key into key cylinder Exists
1 2 A
Remove mechanical key from key cylinder Does not exist
YES >> Key switch is OK. B
DLK
DLK-377
Ignition knob switch detects that ignition knob is pressed, and then transmits the signal to Intelligent Key unit.

Check ignition knob switch (“PUSH SW”) in “Data Monitor” mode with CONSULT-III.

Ignition knob switch is pressed : ON
PUSH SW
Ignition knob switch is released : OFF
YES >> Ignition knob switch is OK.

Terminals
(+) Voltage (V)
Condition
(–) (Approx.)
Intelligent Key unit con-
Terminal
nector
Ignition knob switch is pressed Battery voltage
M40 27 Ground
Ignition knob switch is released 0
YES >> GO TO 5.
NO >> GO TO 2.
2.CHECK IGNITION KNOB SWITCH POWER SUPPLY CIRCUIT
ground.
Terminals
(+) Voltage (V)
(–) (Approx.)
Terminal
YES >> GO TO 3.
3.CHECK IGNITION KNOB SWITCH SIGNAL CIRCUIT
DLK-378
Ignition knob switch, key A

connector
M40 27 M25 3 Exists
B
2. Check continuity between ignition knob switch, key switch and key lock solenoid connector and ground.
Ignition knob switch, key C

switch and key lock solenoid Terminal Continuity
connector Ground

D
YES >> GO TO 4.
Refer to DLK-379, "Component Inspection". F
YES >> GO TO 5.
NO >> Replace ignition knob switch, key switch and key lock solenoid. G
>> INSPECTION END

I
1.CHECK IGNITION KNOB SWITCH J

Check continuity between ignition knob switch, key switch and key lock solenoid terminals under the following
conditions.
DLK
Ignition knob switch, key switch and key lock so-
lenoid Condition Continuity
Terminal
L
Ignition knob switch is pressed Exists
3 4
Ignition knob switch is released Does not exist
YES >> Ignition knob switch, key switch and key lock solenoid is OK.
NO >> Replace ignition knob switch, key switch and key lock solenoid.
N
DLK-379
DOOR LOCK ACTUATOR
DOOR LOCK ACTUATOR
DRIVER SIDE

1.CHECK FUNCTION
With CONSULT-III
Test item Condition

DOOR LOCK/UNLOCK :DR UNLK The door lock actuator (driver side) is unlocked
YES >> Front door lock actuator (driver side) is OK.

Terminals
(+)
M67 Ground
YES >> GO TO 6.
NO >> GO TO 2.
1. Disconnect BCM connector and front door lock actuator (driver side) connector.
2. Check continuity between BCM harness connector and front door lock actuator (driver side) harness con-
nector.
Front door lock actuator (driv-

BCM connector Terminal er side) Terminal Continuity
connector
56 1
M67 D29 Exists
60 2

56 Ground
M67 Does not exist
60
YES >> GO TO 6.
DLK-380
DOOR LOCK ACTUATOR
NO >> GO TO 3.
3.CHECK DOOR LOCK ACTUATOR CIRCUIT 2 A

B
tor.

BCM connector Terminal lay Terminal Continuity C
connector
M67 56 M90 3 Exists
3. Check continuity between BCM harness connector and ground. D

Ground
M67 56 Does not exist E

YES >> GO TO 4.
F
Check passenger side anti-hijack relay. G
Passenger side relay connector Terminal Continuity

M90 3 4 Exists H
YES >> GO TO 5.
NO >> Repair or replace harness. I

1. Check continuity between passenger side anti-hijack relay harness connector and front door lock actuator J
(driver side) harness connector.
Passenger side anti-hijack Front door lock actuator

Terminal Terminal Continuity DLK
relay connector (driver side) connector
M90 4 D29 1 Exists
2. Check continuity between passenger side anti-hijack relay harness connector and ground. L

Ground
M90 4 Does not exist M
YES >> GO TO 6.
Refer to GI-39, "Intermittent Incident". O
>> INSPECTION END

PASSENGER SIDE P
DLK-381
DOOR LOCK ACTUATOR
1.CHECK FUNCTION
With CONSULT-III
Test item Condition

DOOR LOCK/UNLOCK :AS UNLK The door lock actuator (passenger side) is locked
YES >> Front door lock actuator (passenger side) is OK.

Terminals
(+)
M67 Ground
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK DOOR LOCK ACTUATOR CIRCUIT
1. Disconnect BCM connector and front door lock actuator (passenger side) connector.
2. Check continuity between BCM harness connector and front door lock actuator (passenger side) harness
connector.

56 2
M67 D68 Exists
54 1

56 Ground
M67 Does not exist
54

YES >> GO TO 3.
>> INSPECTION END
DLK-382
DOOR LOCK ACTUATOR
REAR LH
A
Locks/unlocks the door with the signal from BCM. B

1.CHECK FUNCTION C
With CONSULT-III
D
Test item Condition
DOOR LOCK/UNLOCK E
YES >> Rear door lock actuator LH is OK. F
G
2. Check voltage between BCM harness connector and ground. H
Terminals
Condition of door lock Voltage (V) I
(+)
M67 Ground J
YES >> GO TO 6. DLK
NO >> GO TO 2.
L
1. Disconnect BCM connector and rear door lock actuator LH connector.
2. Check continuity between BCM harness connector and rear door lock actuator LH harness connector.
Rear door lock actuator LH M

connector
56 1
M67 D115 Exists N
54 2
O
56 Ground
M67 Does not exist
54 P
YES >> GO TO 6.
NO >> GO TO 3.
DLK-383
DOOR LOCK ACTUATOR
tor.

connector
M67 56 M90 3 Exists

Ground
YES >> GO TO 4.

M90 3 4 Exists
YES >> GO TO 5.
LH harness connector.

Rear door lock actuator LH
connector
connector
M90 4 D115 1 Exists

Terminal Continuity
connector Ground
YES >> GO TO 6.
>> INSPECTION END

REAR RH

1.CHECK FUNCTION
With CONSULT-III
DLK-384
DOOR LOCK ACTUATOR
A
Test item Condition
DOOR LOCK/UNLOCK
:LOCK The all door lock actuators are locked B
YES >> Door lock actuator is OK.
C
D
2. Check voltage between BCM harness connector and ground. E
Terminals
(+)
and unlock switch (Approx.)
F
(–)
M67 Ground G
YES >> GO TO 6. H
NO >> GO TO 2.
2. Disconnect BCM connector and rear door lock actuator RH connector.
3. Check continuity between BCM harness connector and rear door lock actuator RH harness connector.
J
connector
56 2 DLK
M67 D95 Exists
54 1
L
56 Ground
M67 Does not exist M
54
YES >> GO TO 6. N
NO >> GO TO 3.
1. Disconnect passenger side anti-hijack relay. O
tor.
P
Anti-hijack relay
connector
M67 56 M90 3 Exists
DLK-385
DOOR LOCK ACTUATOR

Ground
YES >> GO TO 4.
Anti-hijack relay
Terminal Continuity
connector
M90 4 3 Exists
YES >> GO TO 5.
RH harness connector.
Passenger side anti-hijack relay Rear door lock actuator RH

connector connector
M90 3 D95 3 Exists

Terminal Continuity
connector Ground
YES >> GO TO 6.
>> INSPECTION END
DLK-386
SUPER LOCK ACTUATOR
SUPER LOCK ACTUATOR
A
DRIVER SIDE
B
The super lock system is controlled by BCM.
C
1.CHECK FUNCTION
With CONSULT-III D
Check “SUPER LOCK” in “Active Test” mode with CONSULT-III.
Test item Condition

E
:LOCK (SET) The super lock actuator is locked (SET)
SUPER LOCK
:UNLOCK (RELEASE) The super lock actuator is unlocked (RELEASE)
YES >> Front super lock actuator (driver side) is OK.
G
1.CHECK OUTPUT SIGNAL H

Check voltage between BCM connector and ground.
Terminals
Voltage (V)
I
(+) Condition
(–) (Approx.)
60 UNLOCK (RELEASE) J
M67 Ground 0 → Battery voltage → 0
59 LOCK (SET)
DLK
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK SUPER LOCK ACTUATOR CIRCUIT L
2. Disconnect BCM and front door lock actuator (driver side) connector.
3. Check continuity between BCM connector and front door lock actuator (driver side) connector. M
Door lock actuator

connector
N
59 1
M67 D29 Exists
60 2
4. Check continuity between BCM connector and ground. O

59 Ground P
M67 Does not exist
60

YES >> GO TO 3.
DLK-387
SUPER LOCK ACTUATOR

>> INSPECTION END.

PASSENGER SIDE

1.CHECK FUNCTION
With CONSULT-III
Test item Condition

SUPER LOCK
YES >> Front super lock actuator (passenger side) is OK.
1.CHECK OUTPUT SIGNAL

Terminals
Voltage (V)
(+) Condition
(–) (Approx.)
54 UNLOCK (RELEASE)
59 LOCK (SET)
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK SUPER LOCK ACTUATOR CIRCUIT
2. Disconnect BCM and front door lock actuator (passenger side) connector.
3. Check continuity between BCM connector and front door lock actuator (passenger side) connector.

59 1
M67 D68 Exists
54 2

59 Ground
M67 Does not exist
54

DLK-388
SUPER LOCK ACTUATOR
YES >> GO TO 3.
NO >> Repair or replace harness. A
B
>> INSPECTION END.

REAR LH C
The super lock system is controlled by BCM. D
E
1.CHECK FUNCTION
With CONSULT-III
Check “SUPER LOCK” in “Active Test” mode with CONSULT-III. F
Test item Condition

:LOCK (SET) The super lock actuator is locked (SET) G
SUPER LOCK
H
YES >> Rear super lock actuator LH is OK.
I

Check voltage between BCM connector and ground. J
Terminals
Voltage (V)
(+) Condition
(Approx.)
DLK
(–)
54 UNLOCK (RELEASE)
M67 Ground 0 → Battery voltage → 0 L
59 LOCK (SET)
YES >> GO TO 3. M
NO >> GO TO 2.
2. Disconnect BCM and rear door lock actuator LH connector.
3. Check continuity between BCM connector and rear door lock actuator LH connector.
O
Rear door lock actuator (pas-
senger side) connector
59 1 P
M67 D115 Exists
54 2

59 Ground
M67 Does not exist
54
DLK-389
SUPER LOCK ACTUATOR

YES >> GO TO 3.
>> INSPECTION END.

REAR RH

1.CHECK FUNCTION
With CONSULT-III
Test item Condition

SUPER LOCK
YES >> Rear super lock actuator RH is OK.

Terminals
Voltage (V)
(+) Condition
(–) (Approx.)
54 UNLOCK (RELEASE)
59 LOCK (SET)
YES >> GO TO 3.
NO >> GO TO 2.
2. Disconnect BCM and rear door lock actuator RH connector.
3. Check continuity between BCM connector and rear door lock actuator RH connector.

connector
59 1
M67 D95 Exists
54 2
DLK-390
SUPER LOCK ACTUATOR
BCM connector Terminal Continuity A

59 Ground
M67 Does not exist
54
B
YES >> GO TO 3.
NO >> Repair or replace harness. C
Refer to GI-39, "Intermittent Incident". D
>> INSPECTION END.

E
DLK
DLK-391
Opens the back door with the signal from BCM.

1.CHECK FUNCTION
With CONSULT-III
Check “TRUNK/GLASS HATCH” in “Active Test” mode with CONSULT-III.
Test item Condition

TRUNK/GLASS HATCH :OPEN Back door opener actuator operation
YES >> Back door opener actuator is OK.

Terminals
(+)
M66 45 Ground Pressed 0 → Battery voltage → 0
YES >> GO TO 4.
NO >> GO TO 2.
2.CHECK BACK DOOR LOCK ASSEMBLY CIRCUIT
2. Disconnect BCM connector and back door lock assembly connector.
3. Check continuity between BCM harness connector and back door lock assembly harness connector.

connector

Ground
YES >> GO TO 3.

Terminal Continuity
connector Ground
D190 3 Exists
DLK-392
YES >> GO TO 4.
NO >> Repair or replace harness. A
B
>> INSPECTION END

C
DLK
DLK-393
Locks/unlocks the fuel lid with the signal from BCM.

1.CHECK FUNCTION
With CONSULT-III
Test item Condition

:ALL UNLK The fuel lid opener actuator are unlocked
DOOR LOCK/UNLOCK :DR UNLK The fuel lid opener actuator is unlocked
:LOCK The fuel lid opener actuator are locked
YES >> Fuel lid opener actuator is OK.

Terminals
(+)
M67 Ground
YES >> GO TO 6.
NO >> GO TO 2.
1. Disconnect BCM connector and fuel lid opener actuator connector.
2. Check continuity between BCM harness connector and fuel lid opener actuator harness connector.

connector
56 2
M67 B58 Exists
60 1

56 Ground
M67 Does not exist
60
YES >> GO TO 6.
NO >> GO TO 3.
DLK-394
2. Check continuity between BCM harness connector and passenger side anti-hijack relay connector. A

connector
B
M67 56 M90 3 Exists

3. Check continuity between BCM harness connector and ground. C

Ground
M67 56 Does not exist D
YES >> GO TO 4.
Check passenger side of anti-hijack relay.
F
Terminal Continuity
lay connector
M90 3 4 Exists
G

YES >> GO TO 5. H
1. Check continuity between passenger side anti-hijack relay harness connector and fuel lid opener actuator I
harness connector.

J
connector
connector
M90 4 B58 2 Exists DLK
Passenger side anti-hijack re- L

lay Terminal Continuity
connector Ground

M
YES >> GO TO 6.
O
>> INSPECTION END

P
DLK-395
Sends the back door opening signal to BCM.

1.CHECK FUNCTION
With CONSULT-III
Check “TRNK OPNR SW” in “Data Monitor” mode with CONSULT-III.

Back door opener switch is pressed :ON
TRNK OPNR SW
Back door opener switch is released :OFF
YES >> Back door opener switch is OK.
1.CHECK BCM INPUT SIGNAL

Terminals
(+)
Pressed 0
M65 29 Ground
Released Battery voltage
YES >> GO TO 5.
NO >> GO TO 2.
2.CHECK BACK DOOR OPENER SWITCH CIRCUIT
2. Disconnect BCM connector and back door opener switch assembly (opener switch) connector.
3. Check continuity between BCM harness connector and back door opener switch assembly (opener
switch) harness connector.
Back door opener switch

assembly
(opener switch)
connector

Ground
YES >> GO TO 3.
DLK-396
Terminals A
Voltage (V)
(+)
(–) (Approx.)
B

YES >> GO TO 4. C
NO >> GO TO 6.
4.CHECK BACK DOOR OPENER SWITCH GROUND CIRCUIT
Check continuity between back door opener switch assembly (opener switch) connector and ground. D

Terminal Continuity
(opener switch) connector Ground E
D186 2 Exists
YES >> GO TO 5. F
5.CHECK BACK DOOR OPENER SWITCH G
Is the inspection result normal? H
YES >> GO TO 6.
6.CHECK INTERMITTENT INCIDENT I
J
>> INSPECTION END
DLK
L
Terminal Back door opener switch condition Continuity
(opener switch)
Pressed Exists M
D186 1 2
N
YES >> Back door opener switch assembly (opener switch) is OK.
DLK-397
OUTSIDE KEY ANTENNA
OUTSIDE KEY ANTENNA
DRIVER SIDE

Integrated in front outside handle (driver side).

With CONSULT-III
2. Touch “DRIVER ANT”.
3. When Intelligent Key is in outside key antenna (driver side) detection area, LED (on Intelligent Key) blinks.

ANTENNA :DRIVER ANT Outside key antenna (driver side)
YES >> Outside key antenna (driver side) is OK.

DLK-398
OUTSIDE KEY ANTENNA
Terminals A
(+) Signal
Condition
Terminal
connector B
C
tection area.
D
JMKIA0397ZZ
Driver side
19
(+) E

detection area.
JMKIA0514ZZ G
Request switch
M40 Ground
is pressed
H

tection area. I
JMKIA0395ZZ
Driver side J
20
(-)
DLK
detection area.
L
JMKIA0515ZZ

YES >> GO TO 4.
NO >> GO TO 2.
1. Disconnect Intelligent Key unit connector and outside key antenna and front door request switch (driver
side) connector.
2. Check continuity between Intelligent Key unit harness connector and outside key antenna and front door O
Outside key antenna and front P

Terminal door request switch (driver side) Terminal Continuity
connector
connector
19 1
M40 D30 Exists
20 2
3. Check continuity between Intelligent Key unit connector and ground.
DLK-399
OUTSIDE KEY ANTENNA

Terminal Continuity
connector
Ground
19
M40 Does not exist
20
YES >> GO TO 3.
NO >> Repair or replace harness between Intelligent Key unit and outside key antenna (driver side).
Terminals
(+) Signal
Condition
Terminal
connector

tection area.
JMKIA0397ZZ

19
(+) is pressed

detection area.
JMKIA0514ZZ
M40 Ground

tection area.
JMKIA0395ZZ

20
(-) is pressed

detection area.
JMKIA0515ZZ

YES >> Replace outside key antenna and front door request switch (driver side). Refer to DLK-575, "OUT-
SIDE HANDLE : Removal and Installation".
NO >> GO TO 4.
DLK-400
OUTSIDE KEY ANTENNA

>> INSPECTION END B

PASSENGER SIDE
C
Integrated in front outside handle (passenger side).
D
E
With CONSULT-III
1. Check “ANTENNA” in “Active Test” mode with CONSULT-III. F
2. Touch “ASSIST ANT”.
3. When Intelligent Key is in outside key antenna (passenger side) detection area, LED (on Intelligent Key)
blinks.
G
ANTENNA :ASSIST ANT Outside key antenna (passenger side)
H
YES >> Outside key antenna (passenger side) is OK.
NO >> Refer to DLK-401, "PASSENGER SIDE : Diagnosis Procedure". I
1.CHECK OUTSIDE KEY ANTENNA INPUT SIGNAL 1 J

DLK
DLK-401
OUTSIDE KEY ANTENNA
Terminals
(+) Signal
Condition
Terminal
connector

tection area.
JMKIA0397ZZ
Passenger side
37
(+)

detection area.
JMKIA0514ZZ
Request switch
M40 Ground
is pressed

tection area.
JMKIA0395ZZ
Passenger side
38
(-)

detection area.
JMKIA0515ZZ

YES >> GO TO 4.
NO >> GO TO 2.
1. Disconnect Intelligent Key unit connector and outside key antenna and front door request switch (passen-
ger side) connector.
Outside key antenna and front

Terminal door request switch (passenger Terminal Continuity
connector
side) connector
37 1
M40 D69 Exists
38 2
DLK-402
OUTSIDE KEY ANTENNA

Terminal Continuity
connector
Ground
37
M40 Does not exist
38 B
YES >> GO TO 3.
NO >> Repair or replace harness between Intelligent Key unit and outside key antenna and front door C
request switch (passenger side).
3.CHECK OUTSIDE KEY ANTENNA INPUT SIGNAL 2 D
E
Terminal
(+) Signal
Condition F
Terminal
connector
When Intelligent
Key is in the anten- H
na detection area.
JMKIA0514ZZ
I
Passenger side 37
(+)
J
When Intelligent
Key is not in the
antenna detection
area. DLK
JMKIA0514ZZ
Door request switch

M40 Ground
is pressed
L
When Intelligent M
na detection area.
N
JMKIA0395ZZ
Passenger side 38
(-)
O
When Intelligent
Key is not in the
antenna detection P
area.
JMKIA0515ZZ

YES >> Replace outside key antenna and front door request switch (passenger side). Refer to DLK-575,
"OUTSIDE HANDLE : Removal and Installation".
DLK-403
OUTSIDE KEY ANTENNA
NO >> GO TO 4.
>> INSPECTION END

BACK DOOR

Installed in rear bumper.

With CONSULT-III
2. Touch “BK DOOR ANT”.
3. When Intelligent Key is in outside key antenna (rear bumper) detection area, LED (on Intelligent Key)
blinks.

ANTENNA :BK DOOR ANT Outside key antenna (rear bumper)
YES >> Outside key antenna (back door) is OK.

DLK-404
OUTSIDE KEY ANTENNA
Terminal A
(+) Signal
Condition
Terminal
connector B
C
tection area.
D
JMKIA0397ZZ
Rear bumper
17
(+) E

detection area.
JMKIA0514ZZ G
Request switch
M40 Ground
is pressed
H

tection area. I
JMKIA0395ZZ
Rear bumper J
18
(-)
DLK
detection area.
L
JMKIA0515ZZ

YES >> GO TO 4.
NO >> GO TO 2.
1. Disconnect Intelligent Key unit connector and outside key antenna (back door) connector.
2. Check continuity between Intelligent Key unit harness connector and outside key antenna (back door)
harness connector. O
Intelligent Key unit Outside key antenna (back door)

17 1
M40 D191 Exists
18 2
DLK-405
OUTSIDE KEY ANTENNA

Terminal Continuity
connector
Ground
17
M40 Does not exist
18
YES >> GO TO 3.
NO >> Repair or replace harness between Intelligent Key unit and outside key antenna (back door).
2. Connect Intelligent Key unit connector and outside key antenna (back door) connector.
Terminal
(+) Signal
Condition
Terminal
connector
When Intelligent
Key is in the an-
tenna detection
area.
JMKIA0514ZZ
Rear bumper
17
(+)
When Intelligent
Key is not in the
antenna detection
area.
JMKIA0514ZZ
Door request switch

M40 Ground
is pressed
When Intelligent
Key is in the an-
tenna detection
area.
JMKIA0395ZZ
Rear bumper
18
(-)
When Intelligent
Key is not in the
antenna detection
area.
JMKIA0515ZZ

YES >> Replace outside key antenna (back door). Refer to EXT-36, "Removal and Installation".
NO >> GO TO 4.
DLK-406
OUTSIDE KEY ANTENNA

>> INSPECTION END B
DLK
DLK-407
INSIDE KEY ANTENNA
INSIDE KEY ANTENNA
INSTRUMENT CENTER
INSTRUMENT CENTER : Description INFOID:0000000001298257
INSTRUMENT CENTER : Component Function Check INFOID:0000000001298258

With CONSULT-III
3. When Intelligent Key is in inside key antenna (instrument center) detection area, LED (on Intelligent Key)
blinks.

ANTENNA :ROOM ANT 2 Inside key antenna (instrument center)
YES >> Inside key antenna (instrument center) is OK.
NO >> Refer to DLK-408, "INSTRUMENT CENTER : Diagnosis Procedure".
INSTRUMENT CENTER : Diagnosis Procedure INFOID:0000000001298259

DLK-408
INSIDE KEY ANTENNA
Terminals A
(+) Signal
Condition
Terminal
connector B
C
tection area.
D
JMKIA0393ZZ
Instrument
center 33
(+)
E

detection area.

closed
M40 Ground
• Ignition knob
switch is pressed H

tection area. I
JMKIA0392ZZ
Instrument
J
center 34
(-)
DLK
detection area.
L
JMKIA0390ZZ

YES >> GO TO 4.
NO >> GO TO 2.
1. Disconnect Intelligent Key unit connector and inside key antenna (instrument center) connector.
2. Check continuity between Intelligent Key unit harness connector and inside key antenna (instrument cen-
ter) harness connector. O
Intelligent Key unit Inside key antenna

connector (instrument center) connector P
33 1
M40 M56 Exists
34 2
DLK-409
INSIDE KEY ANTENNA

Terminal Continuity
connector
Ground
33
M40 Does not exist
34
YES >> GO TO 3.
NO >> Repair or replace harness between Intelligent Key unit and inside key antenna (instrument cen-
ter).
2. Connect Intelligent Key unit connector and inside key antenna (instrument center) connector.
Terminals
(+) Signal
Condition
Terminal
connector

tion area.
JMKIA0393ZZ
Instrument
center 33
(+)

tection area.
• All doors are JMKIA0391ZZ
closed
M40 Ground
• Ignition knob
switch is pressed

tion area.
JMKIA0392ZZ
Instrument
center 34
(-)

tection area.
JMKIA0390ZZ

YES >> Replace inside key antenna (instrument center). Refer to DLK-586, "INSTRUMENT CENTER :
DLK-410
INSIDE KEY ANTENNA
NO >> GO TO 4.

B
>> INSPECTION END
CONSOLE
C
CONSOLE : Description INFOID:0000000001298260

D
CONSOLE : Component Function Check INFOID:0000000001298261
1.CHECK INSIDE KEY ANTENNA INPUT SIGNAL E

With CONSULT-III
2. Touch “ROOM ANT 1”. F
3. When Intelligent Key is in inside key antenna (console) detection area, LED (on Intelligent Key) blinks.

G
ANTENNA :ROOM ANT 1 Inside key antenna (console)
YES >> Inside key antenna (console) is OK. H
NO >> Refer to DLK-411, "CONSOLE : Diagnosis Procedure".
CONSOLE : Diagnosis Procedure INFOID:0000000001298262
I
DLK
DLK-411
INSIDE KEY ANTENNA
Terminal
(+) Signal
Condition
Terminal
connector

tection area.
JMKIA0393ZZ
Console
15
(+)

detection area.
JMKIA0391ZZ
• All doors are
closed
M40 Ground
• Ignition knob
switch is pressed

tection area.
JMKIA0392ZZ
Console
16
(-)

detection area.
JMKIA0390ZZ

YES >> GO TO 4.
NO >> GO TO 2.
1. Disconnect Intelligent Key unit connector and inside key antenna (console) connector.
2. Check continuity between Intelligent Key unit harness connector and inside key antenna (console) har-
ness connector.
Intelligent Key unit Inside key antenna (console)

connector connector
15 1
M40 M252 Exists
16 2
DLK-412
INSIDE KEY ANTENNA
Intelligent Key unit connector Terminal Continuity A

15 Ground
M40 Does not exist
16
B
YES >> GO TO 3.
NO >> Repair or replace harness between Intelligent Key unit and inside key antenna (console).
C
2. Connect Intelligent Key unit connector and inside key antenna (console) connector. D
Terminal
E
(+) Signal
Condition
Terminal
connector F
G
tion area.
H
JMKIA0393ZZ
Console
15
(+)
I

not in the antenna de- J
tection area.
• All doors are JMKIA0391ZZ DLK

closed
M40 Ground
• Ignition knob
switch is pressed
L
tion area. M
JMKIA0392ZZ
Console N
16
(-)

O
tection area.
P
JMKIA0390ZZ

YES >> Replace inside key antenna (console). Refer to DLK-587, "CONSOLE : Removal and Installation".
NO >> GO TO 4.
DLK-413
INSIDE KEY ANTENNA
>> INSPECTION END

REAR SEAT
REAR SEAT : Description INFOID:0000000001298263

REAR SEAT : Component Function Check INFOID:0000000001298264

With CONSULT-III
3. When Intelligent Key is in inside key antenna (rear seat) detection area, LED (on Intelligent Key) blinks.

ANTENNA :ROOM ANT 2 Inside key antenna (rear seat)
YES >> Inside key antenna (rear seat) is OK.
NO >> Refer to DLK-414, "REAR SEAT : Diagnosis Procedure".
REAR SEAT : Diagnosis Procedure INFOID:0000000001298265

DLK-414
INSIDE KEY ANTENNA
Terminal A
(+) Signal
Condition
Terminal
connector B
C
tection area.
D
JMKIA0393ZZ
Rear seat
(+) 13 E

detection area.

closed
M40 Ground
• Ignition knob
switch is pressed H

tection area. I
JMKIA0392ZZ
Rear seat J
(-) 14
DLK
detection area.
L
JMKIA0390ZZ

YES >> GO TO 4.
NO >> GO TO 2.
1. Disconnect Intelligent Key unit connector and inside key antenna (rear seat) connector.
2. Check continuity between Intelligent Key unit harness connector and inside key antenna (rear seat) har-
ness connector. O
Intelligent Key unit Inside key antenna (rear seat)

13 1
M40 B45 Exists
14 2
DLK-415
INSIDE KEY ANTENNA

Terminal Continuity
connector
Ground
13
M40 Does not exist
14
YES >> GO TO 3.
NO >> Repair or replace harness between Intelligent Key unit and inside key antenna (rear seat).
2. Connect Intelligent Key unit connector and inside key antenna (rear seat) connector.
Terminal
(+) Signal
Condition
Terminal
connector

tion area.
JMKIA0393ZZ
Rear seat
13
(+)

tection area.
JMKIA0391ZZ
• All doors are
closed
M40 Ground
• Ignition knob
switch is pressed

tion area.
JMKIA0392ZZ
Rear seat
14
(-)

tection area.
JMKIA0390ZZ

YES >> Replace inside key antenna (rear seat). Refer to DLK-588, "REAR : Removal and Installation".
NO >> GO TO 4.
DLK-416
INSIDE KEY ANTENNA

>> INSPECTION END B
DLK
DLK-417
ANTI-HIJACK RELAY
ANTI-HIJACK RELAY
PASSENGER SIDE
Receives anti-hijack signal from Intelligent Key unit.

1.CHECK FUNCTION
1. All doors are locked using Intelligent Key or door request switch.
2. Press door request switch (passenger side), only passenger side door is UNLOCK.
YES >> Anti-hijack relay is OK.

Terminal
(+) Voltage (V)
Condition
(–) (Approx.)
Terminal
connector
YES >> GO TO 2.
NO >> GO TO 6.
Terminal
(+) Voltage (V)
Condition
(–) (Approx.)
Terminal
connector
Press front door Battery voltage → 0 → Battery

M40 40 Ground request switch voltage
(passenger side) Other than above Battery voltage
YES >> GO TO 3.
NO >> GO TO 4.
3.CHECK INTELLIGENT KEY UNIT GROUND CIRCUIT

Terminal Continuity
connector Ground
M40 12 Exists
YES >> GO TO 5.
DLK-418
ANTI-HIJACK RELAY
4.CHECK PASSENGER SIDE ANTI-HIJACK RELAY GROUND CIRCUIT A

2. Disconnect passenger side anti-hijack relay connector and Intelligent Key unit connector.
3. Check voltage between passenger side anti-hijack relay harness connector and ground.
B
Terminal
(+) Voltage (V)
Condition C
(–) (Approx.)
Terminal
connector
D
4. Check continuity between passenger side anti-hijack relay harness connector and Intelligent Key unit con-
nector.
E
Passenger side anti-hijack relay Intelligent Key unit
connector connector
M90 1 M40 40 Exists
F

Ground G
YES >> GO TO 5. H
NO >> GO TO 6.
I
Is the inspection result normal? J
YES >> GO TO 6.
DLK
L
>> INSPECTION END
M
1.CHECK ANTI-HIJACK RELAY

Check continuity passenger side anti-hijack relay terminals. N

Terminal Condition Continuity
relay connector
O
Battery voltage direct current
Does not exist
M90 4 3 supply between terminals 1 and 2
Other than above Exists
P
YES >> Passenger side anti-hijack relay is OK.
DLK-419
Answers back and warns about an inappropriate operation.

1.CHECK FUNCTION
With CONSULT-III
Check Intelligent Key warning buzzer “OUTSIDE BUZZER” in “Active Test” mode with CONSULT-III.

Terminal
(+) Warning buzzer Voltage (V)
(–) operation condition (Approx.)
Terminal
connector
Sounding 0
M40 4 Ground
Not sounding Battery voltage
YES >> GO TO 5.
NO >> GO TO 2.
2.CHECK INTELLIGENT KEY WARNING BUZZER POWER SUPPLY CIRCUIT
2. Disconnect Intelligent Key warning buzzer connector.
3. Check voltage between Intelligent Key warning buzzer harness connector and ground.
Terminal
(+) Voltage (V)
(–) (Approx.)
Terminal
connector
YES >> GO TO 3.
NO >> Repair or replace Intelligent Key warning buzzer power supply circuit.
3.CHECK HARNESS CONTINUITY
2. Check continuity between Intelligent Key warning buzzer harness connector and Intelligent Key unit har-
ness connector.
Intelligent Key warning buzzer Intelligent Key unit

connector connector
E25 3 M40 4 Exists
3. Check continuity between Intelligent Key warning buzzer harness connector and ground.
DLK-420
Intelligent Key warning buzzer A

Terminal Continuity
connector Ground
E25 3 Does not exist
Is the inspection result normal? B
YES >> GO TO 4.
NO >> Repair or replace harness between Intelligent Key warning buzzer and Intelligent Key unit.
4.CHECK INTELLIGENT KEY WARNING BUZZER C

D
YES >> GO TO 5.
E
F
>> INSPECTION END
G

Connect battery power supply to Intelligent Key warning buzzer terminals 1 and 3, and check the operation. H
Intelligent Key warning buzzer Terminal Operation

connector (+) (-) I
Buzzer sounds
E25 1 3
J
DLK
DLK-421
Performs operation method guide and warning with buzzer.

1.CHECK FUNCTION
With CONSULT-III
Check the operation with “INSIDE BUZZER” in “Active Test” with CONSULT-III.
Test item Condition

:TAKE OUT Take away warning chime sounds
INSIDE BUZZER :KNOB Ignition knob switch warning chime sounds
:KEY Key warning chime sounds
Yes >> Warning buzzer in combination meter is OK.
1.CHECK BUZZER (COMBINATION METER) CIRCUIT

Refer to WCS-16, "Component Function Check".
Yes >> GO TO 2.
No >> Repair or replace buzzer (combination meter) circuit.
>> INSPECTION END
DLK-422
KEY WARNING LAMP
KEY WARNING LAMP
A
Performs operation method guide and warning together with buzzer. B

1.CHECK FUNCTION C
With CONSULT-III
D
Test item Condition
:BLUE ON Key warning lamp (green) illuminates
E
:RED ON Key warning lamp (red) illuminates
INDICATOR
:BLUE IND Key warning lamp (green) flashes
:RED IND Key warning lamp (red) flashes F
Yes >> Key warning lamp in combination meter is OK.
No >> Refer to DLK-423, "Diagnosis Procedure". G
H
1.CHECK KEY WARNING LAMP CIRCUIT
Refer toMWI-24, "Diagnosis Description" .
Yes >> GO TO 2.
No >> Repair or replace key warning lamp circuit.
2.CHECK INTERMITTENT INCIDENT J
DLK
>> INSPECTION END
DLK-423
LOCK WARNING LAMP
LOCK WARNING LAMP
Performs operation method guide and warning together with buzzer.

1.CHECK FUNCTION
With CONSULT-III
Test item Condition

:KNOB ON Lock warning lamp illuminates
INDICATOR
:KNOB IND Lock warning lamp flashes
Yes >> Lock warning lamp in combination meter is OK.
1.CHECK LOCK WARNING LAMP CIRCUIT

Refer to MWI-24, "Diagnosis Description".
Yes >> GO TO 2.
No >> Repair or replace lock warning lamp circuit.
>> INSPECTION END
DLK-424
A
Performs answer-back for each operation with the number of blinks. B

1.CHECK FUNCTION C
With CONSULT-III
Check hazard warning lamp “FLASHER” in “Active Test” mode with CONSULT-III.
D
YES >> Hazard warning lamp circuit is OK.
E
1.CHECK HAZARD SWITCH CIRCUIT F

Check hazard switch circuit.
Refer to EXL-84, "Component Function Check".
YES >> GO TO 2.
NO >> Repair or replace hazard warning switch circuit.
2.CHECK INTERMITTENT INCIDENT H

I
>> INSPECTION END
DLK
DLK-425
Displays the vehicle speed signal received from combination meter as a numerical value (km/h).
1.CHECK FUNCTION
Check that all doors are automatically locked at the vehicle speed of more than 25 km/h (16 MPH).
YES >> Vehicle speed signal circuit is OK.
1.CHECK VEHICLE SPEED SIGNAL CIRCUIT

Check vehicle speed signal “VEHICLE SPEED” in “Data Monitor” mode with CONSULT-III.
YES >> GO TO 2.
NO >> Repair or replace vehicle speed signal circuit.
>> INSPECTION END
DLK-426
A
The following functions are available when having and carrying electronic ID. B
• Door lock and unlock
• Engine start
Remote control entry function and panic alarm function are available when operating the button.
C
1.CHECK INTELLIGENT KEY FUNCTION D

Does door lock and unlock operate when operating Intelligent Key switch?
YES >> Intelligent Key is OK. E
F
G
Check by connecting a resistance (approximately 300Ω) so that the
current value becomes about 10 mA.
Standard : Approx. 2.5 - 3.0V H
Is the measurement value within the specification?

YES >> Replace Intelligent Key. I
NO >> Replace Intelligent Key battery. Refer to DLK-594,
"Removal and Installation".
J
OCC0607D
DLK
DLK-427
< ECU DIAGNOSIS > [WITH I-KEY & SUPER LOCK]
ECU DIAGNOSIS

CONSULT-III MONITOR ITEM
Release OFF
PUSH SW Ignition knob
Press ON
Removed OFF
KEY ON SW Mechanical key
Inserted ON

DR REQ SW
(driver) Press ON

AS REQ SW
(passenger) Press ON

BD/TR REQ SW
(back door) Press ON
Other than ON position OFF
IGN SW Ignition switch
ON position ON
Other than ACC or ON position OFF
ACC SW Ignition switch
ACC or ON position ON
Press OFF
STOP LAMP SW Brake pedal
Release ON
Lock button of Release OFF

DOOR LOCK SIG
Unlock button of Release OFF

DOOR UNLOCK SIG
Close OFF
DOOR SW DR Door (driver side)
Open ON
Close OFF
DOOR SW AS Door (passenger side)
Open ON
Close OFF
DOOR SW RR Door (rear RH)
Open ON
Close OFF
DOOR SW RL Door (rear LH)
Open ON
Close OFF
DOOR BK SW Back door
Open ON
DLK-428
TERMINAL LAYOUT
A
JMKIA0415ZZ
D
PHYSICAL VALUES

Wire
Condition
Value [V] E
color Input/ (Approx.)
+ – Signal name
Output
Steering lock unit
1 Ground LG Output — 5 F
power supply
Input/
2 Ground L CAN - H — —
Output
G
Input/
3 Ground P CAN - L — —
Output
Intelligent Sounding 0
Intelligent Key warn- H
4 Ground LG Output Key warning
ing buzzer Not sounding Battery voltage
buzzer
Front door request
request I
5 Ground P switch Input
switch OFF (Released) 5
(driver side)
(driver side)
Ignition switch pow- Ignition OFF or ACC 0 J

6 Ground W Input
er supply switch ON or START Battery voltage
When ignition key is inserted into ig-
Battery voltage
nition key cylinder DLK
7 Ground V Key switch Input
When ignition key is not inserted into
0
ignition key cylinder
Battery power sup- L
11 Ground V Input Ignition switch OFF Battery voltage
ply
12 Ground B Ground — Ignition switch ON 0
M

N
tection area
JMKIA0393ZZ O
13 Ground Y Output
(+) (rear seat) is pressed.
P

detection area
JMKIA0391ZZ
DLK-429
Wire Value [V]
Input/ Condition
Output

tection area
JMKIA0392ZZ

14 Ground W Output
(-) (rear seat) is pressed.

detection area
JMKIA0390ZZ

tection area
JMKIA0393ZZ

15 Ground SB Output
(+) (console) is pressed.

detection area
JMKIA0391ZZ

tection area
JMKIA0392ZZ

16 Ground BR Output
(-) (console) is pressed.

detection area
JMKIA0390ZZ
DLK-430
Wire Value [V] A
Input/ Condition
Output

tection area
Outside key antenna

back door re- D
17 Ground SB Output quest switch
(+) (rear bumper)
is operated
with ignition
switch OFF E
detection area
F
JMKIA0514ZZ

tection area

I
back door re-
Outside key antenna
18 Ground V Output quest switch
(-) (rear bumper)
is operated
with ignition J
switch OFF
DLK
detection area
JMKIA0515ZZ
L
M
tection area
When the N
quest switch
Outside key antenna
19 Ground L Output (driver side)
(+) (driver side)
is operated
O
with ignition
switch OFF
detection area
JMKIA0514ZZ
DLK-431
Wire Value [V]
Input/ Condition
Output

tection area
When the
quest switch
Outside key antenna
20 Ground BR Output (driver side)
(-) (driver side)
is operated
with ignition
switch OFF
detection area
JMKIA0515ZZ
Key lock so- LOCK*2 Battery voltage

22*1 Ground W Key lock solenoid Output
lenoid
UNLOCK*2 0
Front door request request
25 Ground BR switch Input switch
(passenger side) (passenger OFF (Released) 5
side)
Depress the brake pedal Battery voltage
26 Ground R Stop lamp switch Input
Release the brake pedal 0
When ignition knob
Battery voltage
Ignition switch is pressed
27 Ground L Ignition knob switch Input
switch OFF When ignition knob
0
switch is released
Lock (ON) 5
28 Ground O Unlock sensor Input
Unlock (OFF) 0
Back door request Back door re- ON (Pressed) 0

29 Ground GR Input
switch quest switch OFF (Released) 5
Steering lock unit
31 Ground GR — — — 0
ground
LOCK status 5
Steering lock unit Input/

32 Ground P Steering lock
communication Output LOCK or UNLOCK
JMKIA0433ZZ
DLK-432
Wire Value [V] A
Input/ Condition
Output

tection area
JMKIA0393ZZ
Inside key antenna
Ignition knob
D
33 Ground O (+) Output
is pressed.
(instrument center)
E
detection area
F
JMKIA0391ZZ

tection area
JMKIA0392ZZ
I
Inside key antenna
Ignition knob
34 Ground G (-) Output
is pressed.
(instrument center)
J

DLK
detection area
JMKIA0390ZZ
L
M
tection area
When the N
front door re-
JMKIA0397ZZ
quest switch
37 Ground L Output
(+) (passenger side) side) is oper- O
ated with ig-
nition switch
OFF
tection area
JMKIA0514ZZ
DLK-433
Wire Value [V]
Input/ Condition
Output

tection area
When the
front door re-
quest switch JMKIA0395ZZ

38 Ground O Output
(-) (passenger side) side) is oper-
ated with ig-
nition switch
OFF
detection area
JMKIA0515ZZ
Press front Battery voltage → 0 → Battery

Passenger side anti- door request voltage
40 Ground Y Input
hijack relay switch (pas-
senger side) Other than above Battery voltage
*1: Only for MT model.

*2
: Key interlock operation is only for M/T model for operation condition, refer to SEC-16, "System Description".
DLK-434
Wiring Diagram - SUPER LOCK CONTROL SYSTEM - INFOID:0000000001558752
DLK
P
JCKWA0361GB
DLK-435
JCKWA0362GB
DLK-436
DLK
JCKWA0363GB
DLK-437
JCKWA0364GB
DLK-438
DLK
JCKWA0365GB
DLK-439
JCKWA0366GB
DLK-440
DLK
JCKWA0367GB
DLK-441
JCKWA0368GB
DLK-442
DLK
P
JCKWA0389GB
DLK-443
JCKWA0390GB
DLK-444
DLK
JCKWA0391GB
DLK-445
JCKWA0392GB
DLK-446
DLK
JCKWA0393GB
DLK-447
JCKWA0394GB
DLK-448
DLK
JCKWA0395GB
DLK-449
JCKWA0396GB
DLK-450
DLK
JCKWA0397GB
DLK-451
JCKWA0398GB
DLK-452
DLK
JCKWA0399GB
DLK-453
JCKWA0400GB
DLK-454
DLK
P
JCKWA0409GB
DLK-455
JCKWA0410GB
DLK-456
DLK
JCKWA0411GB
DLK-457
Display contents of CONSULT-III Fail-safe Cancellation

B2013: STRG COMM 1 • Inhibits steering look unlocking Erase DTC
B2552: INTELLIGENT KEY (BCM) Erase DTC
• Fuel cut
(ECM)
B2590: NATS MALFUNCTION (BCM) Erase DTC
• Fuel cut
(ECM)
If some DTCs are displayed at the same time, perform inspections one by one based on the following priority
chart.
Priority DTC
1 • U1010: CONTROL UNIT (CAN)
• B2552: INTELIGENT KEY
• B2013: STRG COMM 1
2
• B2590: NATS MALFUNCTION
NOTE:
• CRNT: Displays when there is a malfunction now or after returning to the normal condition until turning igni-
→ 2 → 3...38 → 39 after returning to the normal condition whenever ignition switch OFF → ON. The counter
CONSULT display Detection condition Fail-safe Diagnosis

No DTC is detected.
further testing — — —
may be required.
Check CAN communica-
Intelligent Key unit cannot receive CAN communi-
U1000: CAN COMM CIRCUIT — tion system.
cation signal continuously for 2 seconds or more.
Refer to DLK-352
Intelligent Key unit detects internal CAN communi- Replace Intelligent Key
U1010: CONTROL UNIT (CAN) —
cation circuit malfunction. unit.
The ID verification result between Intelligent key unit Perform steering lock
B2013: STRG COMM 1 and steering lock unit are NG. Or Intelligent Key unit × unit ID registration with
cannot communicate with steering lock unit. CONSULT-III
Replace Intelligent Key
B2552: INTELLIGENT KEY Intelligent Key unit internal malfunction. ×
unit.
The ID verification result between Intelligent key unit
Check NATS
B2590: ID DISCORD BCM-I-KEY and BCM are NG. Or Intelligent Key unit cannot ×
Refer to SEC-57
communicate with BCM.
DLK-458
A
VALUES ON THE DIAGNOSIS TOOL B

VEHICLE SPEED While driving Equivalent to speedometer reading C
IGN ON SW
D
KEY ON SW
Door lock/unlock switch does not operate Off E
CDL LOCK SW
CDL UNLOCK SW F
DOOR SW-DR
Driver's door opened On G
DOOR SW-AS
H
DOOR SW-RR
DOOR SW-RL I
BACK DOOR SW
Back door opened On J
Off
I-KEY LOCK pressed
“LOCK” button of Intelligent Key or door request switch are pressed On DLK
Off
pressed
I-KEY UNLOCK L
On
pressed
PUSH SW M
KEYLESS LOCK
“LOCK” button of key fob is pressed On N
KEYLESS UNLOCK
O
Off
P
On
nosis sensor unit
UNLOCK SHOCK
NOTE: On
UNLOCK WITH DR
DLK-459
LOCK WITH SPEED
ACC ON SW
REAR DEF SW
TAIL LAMP SW
TURN SIGNAL R
TURN SIGNAL L
HI BEAM SW
HEAD LAMP SW 1
HEAD LAMP SW 2
PASSING SW
AUTO LIGHT SW
FR FOG SW
RR FOG SW
Engine stopped Off
ENGINE RUN
Engine running On
LIT-SEN FAIL
AUT LIGHT SYS
support
IGN SW CAN
FR WIPER HI
FR WIPER LOW
FR WIPER INT
FR WASHER SW
DLK-460
A
FR WIPER STOP
Front wiper stop position On B
RR WIPER ON
Rear wiper switch OFF Off C
RR WIPER INT
RR WIPER STOP D
RR WASHER SW
Rear washer switch ON On E
NOTE: Off
REVERSE SW CAN
F
H/L WASH SW
Blower fan motor switch OFF Off G
FAN ON SIG
Off H
AIR COND SW
On
Hazard switch OFF Off I
HAZARD SW
Hazard switch ON On
BRAKE SW J
TRNK OPNR SW
When back door opener switch is pressed On DLK
Close the hood
NOTE: Off
HOOD SW Vehicles without theft warning system are OFF-fixed L
Open the hood On
AUTO RELOCK M
GLS BREAK SEN
The vehicle with glass break sensor On N
Off
Ignition switch ON On O
DLK-461
TERMINAL LAYOUT
JSMIA0031GB
PHYSICAL VALUES
CAUTION:
• Turn wiper intermittent dial position to 4 except when checking waveform or voltage of wiper inter-
Description".
DLK-462
Terminal No. Description A

(Wire color) Value
Input/ Condition
+ − Output
Just after Insert mechanical key B
(W) Output der
Just after Insert mechanical key C
(G) Output der

Ground Input D

(SB) Ignition switch ON or ACC Battery voltage E
5 Battery voltage
der
*1
Remove mechanical key from ignition key F
(R)*2 0V
cylinder
DLK
DLK-463
(Wire color) Value
Input/ Condition
+ − Output
All switch OFF

JPMIA0165GB
1.4 V
Lighting switch HI
JPMIA0166GB
1.3 V

Ground Input
JPMIA0167GB
1.3 V
JPMIA0169GB
1.3 V

with all switch OFF
JPMIA0196GB
1.3 V
DLK-464
Input/ Condition
+ − Output
All switch OFF

JPMIA0165GB
1.4 V D
E
Lighting switch 1ST
F
JPMIA0166GB
1.3 V
G

H
Ground Input
JPMIA0168GB
I
1.3 V
J
with all switch OFF
• Wiper intermittent dial 1 DLK
JPMIA0169GB
1.3 V L
M
Rear wiper INT
N
JPMIA0196GB
1.3 V
O
DLK-465
(Wire color) Value
Input/ Condition
+ − Output
All switch OFF
JPMIA0165GB
1.4 V
JPMIA0166GB
1.3 V
Combination
tent dial 4)
JPMIA0167GB
1.3 V
JPMIA0168GB
1.3 V
JPMIA0196GB
1.3 V
DLK-466
Input/ Condition
+ − Output
All switch OFF C
JPMIA0165GB
1.4 V D
Lighting switch 2ND
F
JPMIA0166GB
1.3 V
G
9 Combination
H
(B)*4 tent dial 4)
JPMIA0167GB
I
1.3 V

DLK
JPMIA0168GB
1.3 V L
N
JPMIA0196GB
1.3 V
O
DLK-467
(Wire color) Value
Input/ Condition
+ − Output
All switch OFF

JPMIA0165GB
1.3 V

JPMIA0167GB
1.3 V

Ground Input
JPMIA0168GB
1.3 V

JPMIA0169GB
1.3 V

with all switch OFF
JPMIA0196GB
1.3 V
11 Input/
(B) Output
DLK-468
Input/ Condition
+ − Output
OFF
(When rear door RH C
(LG) switch RH
PKID0924E
11.2 V D
ON
opened) E
F
OFF
(V) switch G
PKID0924E
11.2 V
ON H
0V
OFF
14 J
(P)*3 Ground Input
switch switch
(BR)*4 PKID0924E
11.2 V DLK
ON
opened)
L
M
OFF
Driver door
*4
switch N
(P) PKID0924E
11.2 V
ON
O
opened)
DLK-469
(Wire color) Value
Input/ Condition
+ − Output
OFF
(When rear door LH
(GR) switch LH
PKID0924E
11.2 V
ON
opened)

Ground Output

Ground Input
JPMIA0154GB
1.1 V
While pressing 0V
21 Input/
— CAN-L — —
(P) Output
22 Input/
— CAN-H — —
(L) Output
ON 0V
23 Security indica-
(V) tor
JPMIA0014GB
10.3 V
OFF 12 V
Ignition switch OFF or ACC 12 V

Ground
JPMIA0156GB
8.7 V
25
(G)
DLK-470
Input/ Condition
+ − Output
26
Blower fan motor Blower fan mo- OFF C
(GR)*5 Ground Input
switch tor switch
(LG)*6
PKID0924E
11.2 V D
E
(A/C indicator OFF, blow- F
27
*6
ON PKID0924E
(Y) 11.2 V G
(A/C indicator ON and 0V H
ON).
Ignition switch OFF or ACC 0V I
28 J
Ignition switch ON
(R)*8
DLK
JPMIA0155GB
6.0 V
L
29
Not pressed
M
Back door opener Back door
(LG)*3 Ground Input
(O)*4
JPMIA0154GB N
1.2 V
Pressed 0V
O
P
Ground
JPMIA0154GB
1.2 V
Pressed to the unlock side 0V
DLK-471
(Wire color) Value
Input/ Condition
+ − Output
33
OFF
(Y)*10
JPMIA0154GB
1.3 V
ON 0V
34
Door lock/unlock Door lock/un- Not pressed
(SB)*3 Ground
(P)*4
JPMIA0154GB
1.2 V
35 Headlamp washer Headlamp Not pressed

Ground
JPMIA0154GB
1.2 V
All switch OFF 0V
Lighting switch 2ND
Combination
36 Combination switch switch Lighting switch HI
Ground Output
tent dial 4)
Lighting switch 1ST
JPMIA0164GB
9.1 V
All switch OFF
0V
Ground Output
(R) OUTPUT 2 switch Any of the condition below
with all switch OFF
9.1 V
DLK-472
Input/ Condition
+ − Output
All switch OFF 0V
B
Combination
38 Combination switch switch Front wiper switch INT C
Ground Output
tent dial 4)
Rear fog lamp switch ON D

JPMIA0162GB
9.3 V
All switch OFF 0V
E
Combination
39 Combination switch switch Lighting switch 2ND F
Ground Output
tent dial 4)
Front fog lamp switch ON G
JPMIA0163GB
9.3 V
All switch OFF
0V H
I
(P) OUTPUT 1 switch
• Wiper intermittent dial 2 J
9.1 V
DLK
Rear wiper switch INT
Ground Input Ignition switch OFF Battery voltage L
(LG) ply

Ground Output
M
N
O
44 Ignition switch
(B) ON
JPMIA0197GB P

0V
DLK-473
(Wire color) Value
Input/ Condition
+ − Output

Ground Output
(V) ator opener switch
SKIA9232E
Not pressed 0V
47 Ignition switch
(BR) ON Turn signal switch LH
PKID0926E
6.5 V
48 Ignition switch
Ground Turn signal RH Output
PKID0926E
6.5 V
49 OFF 0V
(Y) ON 12 V
50 Unlock 5V
(G) lock 0V

52 Room lamp timer Interior room OFF 12 V

Ground Output

Ground Output Ignition switch

54 Door lock/un-
(O) lock switch
er's door)
SKIA9232E
Not pressed 0V
55
(B)
DLK-474
Input/ Condition
Signal name

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QUICK REFERENCE INDEX

© 2007 NISSAN EUROPE S.A.S.

IMPORTANT SAFETY NOTICE

NISSAN EUROPE S.A.S.

FEATURES OF NEW MODEL ..................... 21 SERVICE INFORMATION FOR ELECTRICAL

Drive Shaft Installation Bolt : 44.3 N·m (4.5 kg-m, 33 ft-lb)

1. Union bolt 2. Copper washer 3. Brake hose

1. Test group number and test group title

• For detail, refer to following GI-11, "Description".

Number Item Description

8 Splice • The shaded circle “ ” means the splice.

• This means the connector information.

The following ABBREVIATIONS are used: B

Hexagonal Tightening torque (Without lubricant)

Hexagonal Tightening torque

Comfort TDRARAY-EEA TDRALAY-EGA

Information About Identification or Model Code INFOID:0000000001316110

Vehicle identification number (Chas- Vehicle identification number plate

VEHICLE Identification Number ARRANGEMENT

Type approval number (Models

ENGINE SERIAL NUMBER

AUTOMATIC TRANSAXLE NUMBER

Overall length 4,630 (182.3)

Precautions For Xenon Headlamp Service INFOID:0000000001316115

General Precautions INFOID:0000000001316118

• Do not operate the engine for an extended period of time without

• Before jacking up the vehicle, apply wheel chocks or other tire

• Before servicing the vehicle: N

• Before connecting or disconnecting any harness connector for the

Turbocharger (If Equipped) INFOID:0000000001316121

The turbocharger turbine revolves at extremely high speeds and

HOSE REMOVAL AND INSTALLATION

Engine Oils INFOID:0000000001316123

Diesel fuel of at least 50 cetane.

Safety stand attachment F

recovery hooks or main structural members of the vehicle.

Control Units and Electrical Parts INFOID:0000000001316133

Connector & Harness

COLD OR HOT START UP L

Continuity Check Method

Resistance Check Method D

VOLTAGE DROP TESTS

Measuring Voltage Drop — Steb-by-Step

INPUT-OUTPUT VOLTAGE CHART

INPUT-OUTPUT VOLTAGE CHART

Body Switch ON 0V Battery voltage (Inoperative lamp)

Body Switch ON 0V Higher than 0 Approx. 4 (Example)

• When CONSULT-III/GST is connected with a data link connector B

HEAD LAMP LEVELIZER

This mode enables a technician to adjust I

CAN diagnosis The condition of CAN communication line can

HEAD LAMP LEVELIZER

This mode can show results of self-diagnosis

CONSULT-III/GST Data Link Connector (DLC) Circuit INFOID:0000000001316138

Symptom Check item

DRIVE BELTS ....................................................15 Removal and Installation .........................................34

REMOVAL AND INSTALLATION ............... 75 PRECAUTION ........................................... 131